I take it that it is best to run the tank down before this task. I had run out of gas today on I75. It does help to know haw far you have, however the bike sputtered a bit and was able to get off to a station and get fuel without having to push Ha HA

 

You can have 3/4 full of gas during this task. As long as gas is below the acess panel and gas is not sloshing out.....it's fine. Like I said earlier, you never put your hands inside the tank.

 

First, you might want to check and make sure that you have 12 volts coming to the gauge and have a good ground as problems with either of these will cause gauge errors. It probably is the sending unit, but we always check this out first along with ensuring the gauge will go all the way to full.

 

I did this exact thing with my gas gauge that wasn't working when I bought the bike. I had taken the tank off for other reasons, and I went ahead and disassembled the entire tank, and I pulled the fuel sender unit out and moved the arm around, and it looked fine. After I reassembled everything and plugged all the the wires back in, the gas gauge magically started working... I have no idea why it wasn't working before, nor why it suddenly started working again, but I'm happy!

I reused the bolts (didn't know you weren't "supposed" to!) and haven't had a leak. Didn't replace the cork either - just carefully disassembled and reassembled everything. The unit bolts onto the top of the tank right behind the fuel door - so unless your tank is completely full, I don't see any way the gas would go up to leak out! Once you've burned less than 1/2 gallon, the fuel level is below where the unit is mounted anyway.

I have a carb - don't know if EFI makes any difference with this...

 

With the EFI there are fuel lines, fuel pump, big fuel stainer, pressure regulator in there along with the level sender. I had to drain the tank to remove the fuel lines so I could get the whole wretched mess out to replace the regulator.

 

Yet another reason why I love my simple CV carb setup! Less to worry about!.

 

And part of the reason I'm taking the EFI off my bike and putting a carb on it. I've got about 85% of the parts to do the job lined up. Just a few more odds and ends and I'll do the swap.