Fuel sender question...

Is it possible to install a fuel sender in an '82 XJ650R Seca tank? I've put an '83 gauge pack on the bike and wiring the voltage gauge is easy but the fuel gauge obviously not.

It would be a nice luxury to have but I don't want to change out tanks if I don't have to.

What should I be looking for to find out if I can do this? Should I even be thinking about doing this?

 

This would be tough. The fuel sended in the 750 tanks are glued around the edge of the inside of the tank. Getting those in position would be hard. Keeping them there is another matter. It definately would be easier to switch the tanks but I don't know if the 750 will fit the 650. Someone here should know.

 

I'll probably check the gallery to see what 750 tanks I think would look good on my Seca.

Not having the gas sender is not a stopper obviously but it would be nice to have since I have the gauge already.

 

Glued? My Seca 750 has a gasket (81). Sounds fishy when you say glued Max, I think something isn't right.

 

See, that's what I thought too because I heard other people talk about having to remove the fuel sender before doing the "BB rust removal trick".

 

I have serious doubts about the possibility of adding a Fuel Sender to any tank not originally equiped to accomodate one.

The fasteners for the sending unit are attached to captive nuts welded on the inside of the tank; and the platform for attachment of the unit to the tank is reinforced.

With that said ... It would be possible to do a Custom mod to make it happen.

You'd need the mounting section for a sending cut from a tank so equipped.
Then, you'd have to do some cutting and welding to mount the section to your tank.

This mod is going to have to be welded-up by an experienced and highly-talented MIG welding profesional. The bead of the weld needs to be "Puddled" -- with no slag -- completely around the piece being fitted-on.

Complicating the issue, is the very light-gauge of the sheet metal used to make fuel tanks. The thin metal is highly prone to burn-through. Therefore, the welding needs to be done in short-lengthed sections to prevent the burn-through and warping of the donor section. Leaving the door open to a possible leak. So ...

It can be done.
But, it needs the hand of a First Rate MIG or TIG welder.

 

As I suspected. Only worth it if you have a lot of spare cash and a spare tanks just in case.

Thanks!

 

Well maybe I shoud have been quiet. I am repating something I heard when I had my Seca back in the 80's. Service shop managers will tell you anything to keep you from working on your bike and sending it to them. My Maxim doesn't have a fuel gauge so I can't go out and look.

 

If using a stock fuel gasket, a riv-nut may be the answer for installation of the sender while avoiding the dreaded welder. DON'T settle for the cheap ones, they WILL strip out all to easily and you don't want that in that location. We use a very nice grade of capture nut in the aviation industry, shouldn't be hard to find some for your modification.

 

There's a thought - I work for an aerospace manufacturing firm so I wonder what that might be able to get me. We press studs into thin copper bars and other materials all the time so maybe we have a solution that's acceptable.

I wonder if it would be worthwhile to create a custom tank. I bet I could have the guys fab something up for me from stainless. This bears some thinking.

I had the odd idea the other day of taking the bare Seca Turbo tank and installing that and making it look like a manta ray but I think that was some of the factory workers on break letting stuff into the air ducts. ^_^