Taking my FXR tank apart to send to a PDR guy to take out a ding. He’ll need to get to the ding through the hole the level float mounts on. Got everything else apart but the float sensor cap won’t budge. All 5 torx bolts are out, but it’s pretty stuck. I expect the gasket doesn’t want to let go. Problem is there’s nothing to grab onto that I wouldn’t be afraid of snapping off. And these aren’t a quick trip to the dealer to replace! Any suggestions? I’m wary of spraying it with PB blaster, think that would be safe?

 

Looks like the nut in the center has to come off. Then you remove the top plate, then the sending unit.

https://partsfinder.onlinemicrofiche...20FUEL%20GAUGE

 

For sure, definitely don't want to mess up that sender.

Try a paint can opener or an old screwdriver with a short "L" bent on the tip. Gently pry against the side of the well and edge sender flange. As in, try to pry the flange sideways. Do that in several places around.

If it's still stuck tight, fashion a cap or plug for the sender wire tube and pour denatured alcohol in the well till it is up even with the flange and let that soak a while. It will soften the gasket and dissolve whatever gasket sealant was used. then go back with the opener and try again. (it won't hurt anything to get alcohol in the tank)

 

Thanks, but I’m not sure that’s correct. The sender is one piece, with a gasket between the top plate (shown in my photo, and part 17 in that diagram) and held to the tank and compressing the gasket with 5,torx screws.. That center bolt and the one next to it were connectors for the wiring going to the gauge and down that little hole to the underside of the tank and then the bike harness. That nut was what held the O-Ring connector. I replaced the nuts when I disconnected the wires so I wouldn’t lose them.

Great idea on the alcohol. I’ll see if I have a cheap screwdriver I can sacrifice as well. Maybe grind down the tip so it’ll get under there easily.

 

IIRC You would be correct on this

 

Got it out. Took @t150vej ’s advice and sacrificed an old flathead and bent it over. Popped off the sender in a second. Nice. Now got to get a response from Moto PDR if he wants to do the job. Supposed to be excellent.

 

It’s all wrapped up and ready to go to a PDR guy to get this dent out. Once that’s fixed I’ll deal with the touch up spots.

 

Don’t know who your PDR guy is but I used a guy in Sarasota who was a magician on a car I had. He was trained in Germany working for Mercedes and the guy made dents disappear like magic.
Joe Demarco , Pro Dent 941-315-4329

 

I was going to use “motopdr” who gets really good reviews. However he just came back with a $370 quote. Seems expensive to me, I paid $150 for a car dent a couple months ago. I’ll call your guy, I’m in North Port so Sarasota is a quick trip. Thanks!

 

I really would like to know how this works out .
Please let us know

WP