Darn Sensors !

[chanley28]

So I have three sensor problems I would like to figure out on my 82 xj1100 maxim. The oil sensor, fuel sensor, and the battery sensor. I will start with the battery, I removed the seat, and side covers to realize that my battery has no sensor. It looks like someone has replaced the battery, chopped the sensor wires, and now the damn warning light comes on every time I start the bike. The OIL sensor has to either be bad, or needs to be cleaned, and it looks like a pain in the rear to get it out of there, and finally the fuel gauge constantly reads empty, when the tank is full. I don't really enjoy messing with fuel lines, and tank bolts and such. I am seriously considering just taking the entire gauge cluster off, and trying to install an aftermarket gauge. I am not quite sure what kind of impact this will have on the bike, but with some help I may figure something cool out. Has anyone else put an aftermarket speedo/gauges on their bike?

[crazy steve]

...I am seriously considering just taking the entire gauge cluster off, and trying to install an aftermarket gauge. I am not quite sure what kind of impact this will have on the bike, but with some help I may figure something cool out. Has anyone else put an aftermarket speedo/gauges on their bike?

This has been discussed several times... this thread will show you the issues with aftermarket gauges
http://www.xs11.com/forum/showthread.php?t=29788

I'm no XJ expert, but if you do a search, I'm pretty sure the solution is out there in the archives (look at the 'search' in the toolbar) if a XJ owner doesn't chime in. IIRC, there's a bit of rewiring involved for some, and some repair for the other. HTH

[CatatonicBug]

The battery sensor can be fixed in one of two ways. Either you re-wire it, and put the sensor back on (you'd need to get the right kind of battery too), or you can use the tech tip to eliminate the sensor altogether.

The oil sensor is mounted to the oil pan. IIRC, you have to remove the oil pan to get the sensor out. To get the oil pan out, you have to remove the exhaust. Really, you can do the whole thing, start to finish in about 2 hours. Use RTV for a replacement oil pan gasket.

The Fuel sender is mounted in the tank, and has a couple of wires that plug into the wiring harness in front of the seat. Double check the connector there, and make sure the leads are making a circuit. Then, it may mean taking the fuel sender out of the tank, which takes a bit more work. I tend to lean toward the problem of an electical connection issue though.

[Cobia]

If all else fails.....

Your probably looking at bad/dirty electrical connections. Go through each one, clean them and lubricate them with diaelectric grease.
And for the time being.... on the lower left of your instrument console there's a reset button, press it twice and it turns the idiot lights off!!! DAHIK

[chanley28]

Yeah I have been resetting the warning light every time I start the bike. Thats why I would either like to fix the lights that come on for the respective sensor, or just eliminate the whole damn thing and put on aftermarket gauges. lol I guess I just don't know which one will me more costly/time consuming lol. Not really bothered by the troubleshooting or the time, but what I don't want to do is start creating more problems than what is present now you know.

P.S. - Some people can be a real smart-ass when it come to these questions on here lol luckily common sense is not required to post on this forum lol

[cruiser]

You will be time and money ahead to fix the problems IMHO

Here is the battery sensor bypass link.
http://www.xs11.com/forum/showthread.php?t=668

The fuel gauge trouble involves a few different things to check but not hard to do.
First make sure it's plugged in, the connection is under the front part of the seat.
I've had trouble with my fuel gauge and this is what I've done from a previous post.

My XJ starts reading bad about once a year. I run the fuel low or drain the tank, disconnect the sensor wire connection and take the tank off, turn it upside down and remove 4 screws that fasten the unit to gas tank. The gasket is rubber so you can re-use it. Pull out the float assembly and you can carefully remove the metal cover over the resistance components and clean the resistance wire and contact arm with electrical contact cleaner and toothbrush GENTLY.
I seem to always have a buildup of fine almost powdery substance built up on the resistance wire. Always wondered if it has something to do with the ethanol fuel in Minnesota?

The other problem on XJ fuel gauge is the float has a tendency to slide down the arm because the fastener that holds it in place is not gripping the float arm.

You can test the sensor after cleaning to these specs.
Full should read 20 ohms

Half should read 160-180 ohms

Empty should read 300-330 ohms

[COOL TOM]

Oil sensor

The oil sensor will come out of the oil pan without removeing the oil pan . Just take the two screws out then get a pair of channelock pliers give it a small twist and pull and it should come out. Clean with carb or brake cleaner, use rtv and put it back in.