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TECHNICAL MOTOBRICK WRENCHING In Remembrance of Inge K. => The Motobrick Workshop => Topic started by: RetroTexan on March 23, 2015, 05:17:13 PM

Title: 'Petrol Gauge' bypass
Post by: RetroTexan on March 23, 2015, 05:17:13 PM
Hey all,

The petrol gauge (part #62161459565) was completely corroded inside my fuel tank, along with the fuel pump and the filter. I've replaced the pump and filter but since I've decided to go the cafe route with this 1990 k100rt, I'm wondering if I can bypass having to buy a new petrol gauge?

I know the wires that are connected to the fuel pump run through the gauge, but I threw it out thinking I could buy a new one easily (sometimes I'm dumb). Anyway, do you guys have any suggestions for a way to wire up the fuel pump without having to buy a new petrol gauge?

Thanks, Steve
Title: Re: 'Petrol Gauge' bypass
Post by: Inge K. on March 23, 2015, 05:33:07 PM
Which of the wires to the pump is broken/problem, power or ground?
Title: Re: 'Petrol Gauge' bypass
Post by: RetroTexan on March 23, 2015, 05:35:58 PM
Both, there was a clip on the outside of the fuel tank that connected to the petrol gauge. I assume it housed the power and ground for the fuel pump as well as the signal wire from the petrol gauge. No wires exist currently.

I'd like to run power and ground just from the fuel pump out but I have no idea what kind of wire protection I need to look for so that the gasoline won't eat it away.
Title: Re: 'Petrol Gauge' bypass
Post by: Inge K. on March 23, 2015, 05:46:13 PM
You should use wires with polyurethane insulation inside the tank, if you have enough left of the old power
wire so you can solder them together.....the ground is connected directly to the mounting plate, on both sides.
Title: Re: 'Petrol Gauge' bypass
Post by: Scott_ on March 23, 2015, 06:09:47 PM
Inge, I think he's at the point that he needs to replace the sender assy as he states
Quote
but I threw it out thinking I could buy a new one easily

to be able to get the circuit out of the tank to the rest of the harness, and be able to seal the tank again.
Title: Re: 'Petrol Gauge' bypass
Post by: RetroTexan on April 14, 2015, 09:46:22 PM
Phew! Just went through my parts drawer and I'm smarter than I thought! I clipped the wires before I tossed the sensor so I still have the poly-wrapped wires that connect to the fuel pump. And I kept the connector that runs outside of the fuel tank!

Now all I have to figure out is how to reconnect the connector to the fuel tank and the poly-wrap wires to the connector.

I know the ground is soldered directly to the inside of the tank but there seems to be 2 wires from the connector, which one do I connect the voltage wire running to the fuel pump?

Also, as a side question: What would be the best way to attach the connector to the fuel tank? Would using a heat gun to melt the end be wise? Or maybe some sort of hot glue or JB Weld??? What is something that gas with ethanol wouldn't eat away at and cause a leak later down the road?