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Gas level Sending Unit Float........Came off the arm!

Discussion in 'XJ Technical Chat' started by 4nik8r, Jan 3, 2017.

  1. 4nik8r

    4nik8r Member

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    Anyone had this problem happen to them? The float came off the arm and there seems to be some unusual wear inside the mounting hole.

    Pics to follow.
     
  2. XJ550H

    XJ550H Well-Known Member Premium Member

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    with all the sloshing around of gas in the tank i would think the float takes a beating
     
  3. 4nik8r

    4nik8r Member

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    Yes, agreed......this looks like a lot of wear and tear at the center. There is only one washer on the arm? Now I need some expert advice on how to do a good repair. Anyone have a picture of what an undamaged one looks like? IMG_5577.JPG
     
  4. XJ550H

    XJ550H Well-Known Member Premium Member

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    I just took the sender out of my tank to look at it. the hole seams large for the application but is not worn in a conical shape.
    there is about 2mm clearance from the rod to the float.
    you could use a large pop rivet and gas tank epoxy and glue the rivet into the float maybe a nylon rivet,
    or a threaded aluminum or nylon stand off drill out the center to fit the rod and glue it inside the float
    the hard part would be removing the washer from the arm
    float.jpg
     
  5. hogfiddles

    hogfiddles XJ-Wizard, Host-Central NY Carb Clinic Moderator Premium Member

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    Geez..... You'd think a little piece of foam would last longer than 30 yrs-------

    I would first consider slipping an appropriately sized pop-rivet onto the arm, collar end first. Then the float, then another pop-rivet tube end first to sandwich the float. Then one more rivet to crimp onto the arm to prevent the others from walking back off. I don't think that the weight will be much of an issue...the float will still float, and a couple rivets shouldn't be too heavy for the float to still easily lift.
     
    Last edited: Jan 6, 2017
  6. XJ550H

    XJ550H Well-Known Member Premium Member

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    HCP2738SET Aftermarket fuel sending unit BLOCK-OFF PLATE AND GASKET. Fits all XJ550 Seca, XJ650 Turbo, XJ750 Seca, 1982 XJ750 Maxim, XJ1100, and all XS1100 model tanks.
    $ 24.95

    could be that the sending unit from the bikes listed above will fit your tank if you decide to get a new unit
     
  7. XJ550H

    XJ550H Well-Known Member Premium Member

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    wtf only 30 years you would think Yamaha whould have known about xjbikes.com and we were going to keep their bikes running for decades after the stopped making them

    good idea on the multi rivet use
     
    Last edited: Jan 6, 2017
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  8. 4nik8r

    4nik8r Member

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    XJ550H - thanks for the pic that shows me what it should look like. And thanks to both of you for the pop rivet suggestion. I was thinking maybe an appropriate sized split-sleeve collar made from some kind of re-purposed plastic or light rubber, and the use of gas tank epoxy to hold it all together. Speaking of which - is good old JB Weld sufficient, or do I need something specifically gas-resistant? I have Seal All, would that suffice? Whichever route I go - collar or pop rivets - I'll need an adhesive.
     
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  9. hogfiddles

    hogfiddles XJ-Wizard, Host-Central NY Carb Clinic Moderator Premium Member

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    If any adhesive is used, it needs to be fuel-application -specific.

    Another thought....if you have a small tap/die set, thread the shaft and lock it on with a couple aluminum lock nuts, or similar
     
  10. 4nik8r

    4nik8r Member

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    The Seal-All is contact adhesive that is gasoline and oil resistant, but not necessarily gasoline specific. Worked well for me when used for minor line leaks, but here in Canada choices are limited. Dave, is there anything better you'd recommend?
     
  11. XJ550H

    XJ550H Well-Known Member Premium Member

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    jb weld makes a gastank repair epoxy but only call it gasoline resistant
     
  12. k-moe

    k-moe Pie, Bacon, Bourbon. Moderator Premium Member

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    Measure the float for size. Buy a replacement from an auto parts store. It does not need to be foam. It can be brass, or hollow plastic and it'll still float. Fix it in place with safety wire. You might need to tweak the float arm a bit to adjust the accuracy of the gauge (it probably needs it anyway).
     
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  13. k-moe

    k-moe Pie, Bacon, Bourbon. Moderator Premium Member

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    I am so dumb. Just safety wire the old float to the arm.
     
  14. XJ550H

    XJ550H Well-Known Member Premium Member

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  15. chacal

    chacal Moderator Moderator Supporting Vendor Premium Member

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    If anyone knows of a method to repair (or modernize) these sending units, let me know! We've got lots of used non-functioning sending units that could sure use a bolt-on upgrade to the resistance board..........
     
  16. Rice_Burnarr

    Rice_Burnarr Member

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    Got any pics of said sending units and resistance board? I've (thankfully) never needed to know what they look like.
     
  17. Maxim-X

    Maxim-X Well-Known Member

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