Fuel sending unit help

[oldyam80sg]

I have the tank off my SG as I'm determined to get the fuel light to work.The tab on the fuel sending unit that has a plastic piece behind it has broken off.Could i take a soldering gun and solder a o-ring connector to the metal rivet?Once i remove the sending unit from the tank-would that be safe enough?Whoever made this design at Yamaha-i don't know what they were thinking.Does anyone got a spare sending unit?

[The Lorax]

Yes, I believe you could solder a lug or something to it, if it's the no ground side, just be careful not to short to ground and don't get it too hot as not to melt the insulation on the between the wire connection and ground. I think a while back, one of my terminals btoke off and I soldered it I just cant remember which side it was. in any case, just be careful and you should be righteous. have a nice day and ride safe

[oldyam80sg]

Ok i know this is going to sound totally stupid but without removing the unit from the bike could i do it with a soldering gun?

[DiverRay]

Ok i know this is going to sound totally stupid but without removing the unit from the bike could i do it with a soldering gun?

Yes, you COULD do it that way. Just do it outside, and make sure all you other bikes are signed over to me First!!
In reality, DO NOT try it on the bike!!! Remove the tank, and then remove the sending unit from the tank. That is the ONLY safe way to apply heat to a vessel that has had gasoline in it for almost 30 years. The fuel does go into the metal, and the flash point is low.
Wire brush whats left of the lug clean, use some good flux, and solder the wire back on. I would then put in some type of strain relief, as the wire WILL try to break at the solder joint from vibration. That is why the lugs are crimped, and not soldered from the factory.

[oldyam80sg]

No Good-I removed the unit from the tank and tried to solder it on.Worked until i moved the tank and then it broke off.There is not alot of metal to really heat up and connect anything-any suggestions?

[wingnut]

How about a small sheet metal screw and gas tank sealer? Not very elegant but it should work. I've used that 2 part tank sealer on a couple of fuel tanks with good results. You could fabricate a 90 degree bracket, secure it to the sending unit with a #6 sheet metal screw applying some of the sealer to the screw and around the bracket.

[oldyam80sg]

I just looked up epoxy where i get supplies-Couldn't i use epoxy and use a ring terminal and bond the piece onto the rivet?

[XSPastor]

buy another one?

You can buy these on ebay now and then...

fuel sensor

[DiverRay]

Do you have a pop rivet tool? if not, you should be able to pick one up for about $10.00. Drill the old rivet out with a 1/8" drill, buy a "sealed" pop rivet, and install the wire crimped on to a new lug.
You ARE talking about the ground lug, correct????

[oldyam80sg]

The piece that attaches to plastic behind it is the piece I'm talking about-The other tab is still there.I thought that the green attaches to the broken tab and the black attaches to the the other tab-is that correct?I was looking at conductive epoxy at a company where i get supplies.This should work correct?It says that you can use it on electrical circuit boards and other stuff.

[DiverRay]

Conductive epoxy "should" work. You DO have to worry about the resistance it has, though. The fuel sending unit is just a big, LOW Ohm, variable resistor.
If you have room for a "larger diameter" lug to fit around the head of the rivet, that may be worth a try. Crimp the lug on the end of the wire, and then try to solder it on too whats left on the gauge. If it didn't work, you then use the epoxy. You should have a lot more contact area, and less resistance. JAT

[oldyam80sg]

Thank You for all the replies.The e-bay link that XSPastor gave -I'm currently bidding on that item.You would not believe the prices that people want for this unit.One company wanted $150.00 for it.I don't think Bike Bandit wanted that much!

[XSPastor]

Good luck - hope ya get it!

[XSPastor]

Another one if you don't get the first one...

fuel sensor

A little pricey though...

[oldyam80sg]

Looks like a new part and i could not resist.Thanks Again XSPastor!