Fuel tank Sender problem

[MP]

I just installed an IS tank on my standard.  Put in a new sender unit.  Wires to rear, float to right, so that is correct.  Mounted the tank, and hooked up the wires.  Sender was tested before installation, and it worked the Motosen gauge correctly.
I put in about 1 gallon of gas, and no movement on the gauge.  I then shook the bike back and forth, and the gauge moved up to E.
Bike is on a lift, so is level.
I then put in another 2 or so gallons of gas, gauge moved nicely up to just under 1/2, just where it should be, and moved smoothly.
I quit adding fuel.  Buttoned a few things up, and dropped the bike to the floor, and onto the sidestand.
After starting, the gauge is below E.
I rode it about 40 miles, and did not move.  I shook the bike when I got home,no movement.  I took the wires apart, and hooked them together, and the gauge went to full, so it is getting power, and wiring from connections to gauge is good.
1. Is the float stuck somehow in the tank?
2. Did I cut a wire going to the tank, on the tank wiring harness?  Was OK after tank tightened down.
3. Any other ideas?
MP

[BonS]

Did you notice whether the tank float is a hollow type bulb? If so, it could have a leak and not be floating any longer. Just a question and a guess.

[3W-lonerider]

try putting more gas in it..when my gas bar on my i/s starts flashing that i'm almost empty and i pull into a gas station i normally have around 2 gallon left in the tank..

[rmrc51]

I'll be watching this post continually. I'm about to do the same. My IS tank should be ready this week and I'll be installing it this coming weekend.

I hope you find that it's just a wiring problem and you don't have to remove the sender again. 

[MP]

Yeah, I thought about the float having a factory leak too, thus floating to start with, but in a few minutes taking a dive.  I sure hop I do not have to take it all apart again for a factory flaw!!!!
I wish I could see the float in the tank, but the tunnel is so wide, you cannot.
I do not think more gas would help.  If it was just under 1/2, why after a few minutes would it be not only at zero, but pegged to the bottom, well below E?  I wish that were the case, but with a total of 3 gal in the tank, if it is still pegged below E, I might as well not use it anyway, if it acts that way all the time.
I am leaning toward the leaking float myself.  Any other ideas?
You might want to check your float before you install yours.  Stick it in a can of gas overnight, and see if it leaks any,rmrc51.
MP

[rmrc51]

You might want to check your float before you install yours.  Stick it in a can of gas overnight, and see if it leaks any,rmrc51.
MP

I'll "DEFINITELY",,,do that!

I'll post my results.

[Master Blaster]

had one with similar prob once, found the wiper board with the coil on it was broke.  Must have done it installing the sending unit.  That thing is a little flimsy, and dont take much to crack it.

[RTaz]

....check your ground wires ....

[rmrc51]

MP, did you find the problem? 

[MP]

I have not worked on it yet.  I am thinking either a bad float, or I broke something putting it in.  I ordered a new sender, and am waiting for it to arrive before I do anything.  I do not want to take the tank off, remove the sender, find it is bad, and have nothing to put back in.

[rmrc51]

I have not worked on it yet.  I am thinking either a bad float, or I broke something putting it in.  I ordered a new sender, and am waiting for it to arrive before I do anything.  I do not want to take the tank off, remove the sender, find it is bad, and have nothing to put back in.

Totally understandable regarding waiting for the new sender before removing the tank. Please post again when the new sender arrives and what you find!

[Scott in Ok]

The only thing I can add is I installed an I/S tank on a Std once, with the fuel sender.  I didn't test it as you did, I just put it in how I thought it should go.  It didn't work at all.  Come to find out I didn't have it in the right orientation.  Pulled it back out and installed it correctly and it worked just fine. 

Not saying that is your problem, just giving my experience.

-Scott

[rmrc51]

The only thing I can add is I installed an I/S tank on a Std once, with the fuel sender.  I didn't test it as you did, I just put it in how I thought it should go.  It didn't work at all.  Come to find out I didn't have it in the right orientation.  Pulled it back out and installed it correctly and it worked just fine. 

Not saying that is your problem, just giving my experience.

-Scott

Good point Scott

I believe MP did have it installed properly. Float arm towards the right side of the tank which would place the float itself towards the front on the tank on the right hand side.

[MP]

I made sure to install correctly, with the wire harness to the back.  It worked when I first put the gas in.  Went up as I filled the tank.  Spot on.   Then, after sitting about 1/2 hour while I got ready to ride, it was below E, and stayed there.  That is why I am leaning toward a leaky float. 
OK at first, then filled up and sank over the 1/2 hour.  Bike never moved during that time.
Ground is OK, because if I plug the lead from the gauge into the ground wire, it goes to full, so ground is working.
MP

[rmrc51]

I made sure to install correctly, with the wire harness to the back.  It worked when I first put the gas in.  Went up as I filled the tank.  Spot on.   Then, after sitting about 1/2 hour while I got ready to ride, it was below E, and stayed there.  That is why I am leaning toward a leaky float. 
OK at first, then filled up and sank over the 1/2 hour.  Bike never moved during that time.
Ground is OK, because if I plug the lead from the gauge into the ground wire, it goes to full, so ground is working.
MP

That really does sound like the float filled up with gas. I haven't tested mine yet as you suggested but I'll definitely test it over night with he float laying in water to make sure it doesn't have any cracks. My tank is still at the paint shop and should be ready by the end of the week so I'll either be installing everything this coming weekend or the following weekend.

Again, let us know what you find when you remove your tank again after the new sender arrives.

[MP]

I would test it in a can of gas.  Gas will go thru a hole water will not.  In fact, that just made me think, with the fine screen on the petcock, I wonder if that is water tight?  Now, I need to go test one and see!

[rmrc51]

I would test it in a can of gas.  Gas will go thru a hole water will not.  In fact, that just made me think, with the fine screen on the petcock, I wonder if that is water tight?  Now, I need to go test one and see!

Good point regarding testing with gas. I'll do that. 

[MP]

Forget the testing for a leak.  I talked to the local Honda service manager, and he said all the floats are a solid material, thus they cannot leak.  He figured something must have gone bad with the controls/wiring on the sender.  So, when the new one gets here, I will swap it out, and see what happens.  Will tst the first one though on the gauge, after I remove it, and can move the float.
MP