Hi all, I’ve been having some strange issues with my fuel gauge recently and wondered if anyone else had experienced them or could help diagnose the fault.

About a month or so ago not long after swapping out the fuel filter the fuel gauge died, stuck at empty.

Tried bleeding any air out of the system, no good.
Tried disconnecting the battery, no good.
Tried disconnecting the wiring that connects to the top of the fuel tank access cover, no good.
Tried disconnecting the battery and the outer wiring connector, still no good.

Originally I thought I had a bad pump and sender and they just happened to go pop right after changing the filter so I ordered one and syched myself up to be elbow deep in diesel.

Before I disconnected everything I wanted to make sure the new one worked okay so positioned the floats high up, connected the pump wires to the under side of the existing fuel tank cover, turned the ignition on and it read okay. Decided to plug the existing pump back in and try it, on the off chance it would work and surprisingly it did.

So I didn’t install the new pump just reconnected everything put it back and away I went. The fix lasted about 4 days and then the issue came back. This time I just repeated everything I did before, disconnected the battery, disconnected the hoses and wiring connectors from the top, lifted the cover out the way so I could get to the wiring that plugs in from the pump. Unplugged the connector, plugged it back in and once again the issue was fixed.

Problem I’ve got is it’s always temporary, I’ve done this 3 or 4 times now and can get it working for a few days but it always dies again. At this point I’m not sure if the sender on the pump is bad, or if it’s the cover that everything plugs into.

I work a lot with computers but am quite new to doing my own spannering, just can’t understand why if the sender was the problem unplugging the pump connector that sits inside the tank fixes it, but unplugging the top connector that requires a lot less disassembly makes no difference.

Any insight or help would be much appreciated.

Thanks,
Dan

There's a mod you can do to the wiring on the sender unit. From memory you cut out a connector and solder the wires back together. Easy once you get to the sender/pump.
There's a write up on here somewhere, try a search for sender unit.
Did mine 4 years ago and no problems since
Good luck. 2007 3.6 TDV8
1979 Mini Special
1988 Yamaha FJ1200
!952 BSA Gold Flash

Try this one
https://www.fullfatrr.com/forum/topic41061...p;start=15 2007 3.6 TDV8
1979 Mini Special
1988 Yamaha FJ1200
!952 BSA Gold Flash