96 spx fuel gauge/ baffle sender problems

[nathan porter]

Hi guys big thanks from Syd Australia. Firstly have to say thanks to the previous guys who I have taken so much advice from regarding the fuel sender /gauge problem. It does seem a common defect.

One time when I was out riding the fuel gauge seemed to be going down like it had a whole in the tank. Do a few jumps and it came good. Next time the same thing but eventually there was no fuel bars showing on the gauge and the fuel light stayed on all the time.

As stated in the fuel/baffle sender repair thread.

I removed the fuel sender/ baffle and checked the float in the fuel, that was all good. I have checked the magnets in the float and they are all good. I did the resistance check of the fuel sender and the Resistance changes as the float moves, that was all good.

I have shorted the pink black/pink wires going to the fuel gauge and hit the start and all I get is a flash of all the 4 warning lights and all the fuel bars light up with this flash for a second and then the fuel light just stays on with no fuel bars. This is the same if I have the lanyard on or off.

I did here if I shorted the wires going to the gauge this would at least stop the red light from coming on but this doesnt seem to work at the moment.

If I go under the nose hatch and follow the fuel gauge wires back to there first plug connection. Its a multi pin connection and I can do a resistance check of the wires going to the fuel gauge. I get about 30 ohms resistance and it just keeps climing. I am no expert with the multimeter but when I select it to the buzzer function when checking for continuity I get the OL which means open circuit. What should the resistance be going to the gauge.
I have checked all the fuses in the waterproof box. And now I have hit a wall.
Any help would be greatly appreciated.
Thanks Nathan

 

[Chester]

What color is the fuel float?

Chester

 

[ski-d00]

your float may be sinking giving you what seems to be an empty tank, older ones tend to do that, but if you short the pink and pink/black wires going to the gauge, it should read as a full tank, are you sure the light is for low fuel and not something else?

 

[nathan porter]

Thanks guys. The Float is black. It way be old but it still floats. I did do some thorough checking og it after all the posts about sinking floats.

I have checked the resistance with this float when it is in the sender and is shows mid range and the fuel tank is about half full so to my understanding that part of it works fine.

When I short the wires going to the gauge and hit the start button I dont get a full tank showing I get a flash of all 4 warning lights a quick flash of all the fuel bars, they go out and then the fuel light just stays on. Its the Bottom left Warning light with the fuel bowser picture.

I am thinking its a gauge problem now.?

 

[nathan porter]

warning lights

:ack:

Ok guys here are the gauge pics. Can someone tell me what they mean.

I hit the start button and all 4 warning lights flash along with all the fuel bars. Then all the fuel bars go out and the fuel warning light stays on.

Is my gauge buggered.

Have checked the resistance from the sender all the way to the gauge and its good.

When I short the pink/ pink black wires going to the gauge the fuel warning light stays on and no fuel bars indicate.

If I read correctly from other threads when I short the wires going to the fuel gauge it should read full.

Please help. Cheers

 

[Chester]

Thanks guys. The Float is black. It way be old but it still floats. I did do some thorough checking og it after all the posts about sinking floats.

I have checked the resistance with this float when it is in the sender and is shows mid range and the fuel tank is about half full so to my understanding that part of it works fine.

When I short the wires going to the gauge and hit the start button I dont get a full tank showing I get a flash of all 4 warning lights a quick flash of all the fuel bars, they go out and then the fuel light just stays on. Its the Bottom left Warning light with the fuel bowser picture.

I am thinking its a gauge problem now.?

The black floats are the bad ones that end up sinking. Did you test it in water or gas? A bad float that sinks in fuel will float in water.

Chester

 

[ski-d00]

It does sound like you have a bad gauge but those gauges are pretty reliable unless they get moisture in them. Check your connections all the way to the gauge including the ground side of the gauge.

 

[nathan porter]

warning lights

Thanks guys will check my connections to the gauge. If I take the gauge out is there a way I can check it. Even if I have to take it to the dealer. Do they have some way of checking it.

And yes I checked the fuel float in water and in fuel and it was all good. If the float wasnt working I Wouldnt be getting any resistance. The fuel tank is half full and the resistance is about 45ohms when measured right up at the gauge so that tells me the float is sitting approx half way because 85 ohms is a full tank.

Thanks guys.

 

[nathan porter]

Wiring Diagrams

Where is the best place to get wiring diagrams for the 96 spx.

Are they in the premium members area and do you have to pay to be a part of it.

 

[Moto-Madness]

Any luck on this issue? I have the same problem on my 95 XP.