K11 Owners Group

joeangi · Posted: Fri Apr 09, 2010 9:42 am Post subject: Fuel sending unit repair

After being unable to get my fuel guage to work, it was detremined that the sending unit was at fault. I figured that I might as well see if it was something that could be repaired. There are four metal tabs to take the sending unit apart. I gently pryed them back with a pair of dykes. As soon as I got the case apart, it was evident what was wrong.

easier to see

I figured that I would attempt to solder a wire in the break. After a few attempts under a magnifier, I was able to put a patch in the wire. I had some very thin wire that I used, but you could use a single strand of some multi strand wire.

I have tested it with a ohm meter, and it works fine. I ran out of time to re-install and test. But, with the sender in the tank, I get variable resiatance, so I think I got it. Time will tell if it holds up.

Joe
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1994 K1100RS
1986 K100RS

Ted · Posted: Fri Apr 09, 2010 10:07 am Post subject:

Awesome bit of tech - looks like that topmost blue wire was the culprit judging from the indentation it has apparently made?
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Ted

KOG#1

RAL88 · Posted: Fri Apr 09, 2010 12:33 pm Post subject:

Great bit of work there. It looks like there is a slider that moves across the wires to change resistance. You might want to make sure the slider does not hit your repair or it may break the wire again.
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Rich

"If it ain't broke, take it apart and make it work better"
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'96' K1100LT-SE
'97' R850GS-R

joeangi · Posted: Fri Apr 09, 2010 1:00 pm Post subject:

Good catch, yes I pulled the repair away a little, and attempted to bend down the stop a hair so the wiper would not cross the repair. Thinking about it more, I should have bent the wires in a "U" shape so they would interlock and to add a bit if mechanical strength to the repair.
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1994 K1100RS
1986 K100RS

joeangi · Posted: Sun Apr 11, 2010 7:27 pm Post subject:

Update, just finished putting the bike together, and the gauge works fine. I checked it by moving the rod by hand and it functions perfectly.
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1994 K1100RS
1986 K100RS

SugarHillCTD · Posted: Sun Apr 11, 2010 7:41 pm Post subject:

Nice fix.

.......that is a truly primitive way of measuring fuel. Resistive windings and a sliding contact? Marconi would be proud.

B ut M any W onder
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John & Cathy

'92 K100RS4V Pearl White SOLD
'04 K1200GT
IBA Several-SS1k, BBG, 50CC NYC to S.F.

Mystic Red · Posted: Sun Apr 11, 2010 8:18 pm Post subject:

Sweet, I wouldn't have even thought about a repair. Would'a popped for a new one. Embarassed

Nice effort.
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Scott Hespelt, '94 K11LT
K11 OG #466