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  1. #1
    SplishSplash's Avatar
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    Ultra 150 Fuel Gauge issue

    Well my fuel gauge is acting up, it reads either 2 bars or less regardless of how full the tank is.
    I checked the resistance of the sender and it was correct for reading 2 bars (~4K ohms) but it would not read the full tank.

    So, is it the float in the sending unit or the sending unit?
    Can it be removed without moving the tank?

    Thanks


  2. #2
    SplishSplash's Avatar
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    Quote Originally Posted by SplishSplash View Post
    Well my fuel gauge is acting up, it reads either 2 bars or less regardless of how full the tank is.
    I checked the resistance of the sender and it was correct for reading 2 bars (~4K ohms) but it would not read the full tank.

    So, is it the float in the sending unit or the sending unit?
    Can it be removed without moving the tank?

    Thanks
    Ah geeze , $300+ for the tank sending unit!! oh great!

  3. #3
    Had the same issue, my fuel gauge always read full. Here is what you have to do... First empty all fuel from the fuel tank, Mark all the lines that go into the sending unit with masking tape and label them so you know what goes where when you reassemble. Next remove the lines and disconnect the plug for the sending unit, now you can remove the 2 hose clamps that go around the rubber sleeve at the top of the sending unit. Next your going to need to unstrap the tie downs that hold the fuel and oil tank in place. It makes it easier if you also unhook the filler neck tubes for the fuel and oil tanks. Next you need to lift the front of the fuel tank up as far as possible, this will tilt the rear of the tank just enough to be able to slide the sending unit out behind the bracket that sits above the sending unit. 2 screws removes the cover to he sending unit and the float will be sitting in there somewhere. Clean the float and float pathway if it is gummed up, if not gummed up you may need to replace the sending unit as I did I think I paid $60 for a used one off eBay a few weeks ago. I hope this helps let me know how you make out. Good luck!!!

  4. #4
    It mighy be easier to remove the steering support then unstrap the tank and pull forward.. just fyi

    Just keep in mind the sending units are different. Earlier models have the vent in on them new models dont. If your buying a used one make sure you get the one for your year

  5. #5
    SplishSplash's Avatar
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    Good news, fixed it. It was just stuck in the slide, cleaned it up and working like a charm.

    Removal was not hard at all.

    1. Remove hull cross brace
    2. Disconnect fuel sending unit plug
    3. Label , then remove the 4 fuel lines
    4. Undo lower hose clamp on fuel unit
    5. Lift up entire sending unit/ fuel pickup and move it slightly rearward and it came up and right out of the tank.

    Reinstall is the reverse.

  6. #6
    steve45's Avatar
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    I need to pull mine... I bought a new sender for about $250 (1999 model). I'll try to fix the old one, but I'll use the new one if I have to.

  7. #7
    SplishSplash's Avatar
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    Quote Originally Posted by steve45 View Post
    I need to pull mine... I bought a new sender for about $250 (1999 model). I'll try to fix the old one, but I'll use the new one if I have to.
    I woud just put the new one in, then no worries if it going to do it again.

  8. #8
    steve45's Avatar
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    Of course I'll test it before putting it all back together!

  9. #9
    SplishSplash's Avatar
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    Rats, it lasted 2 days and quit again. Looks like I'll have to replace it. I think the float is so old it's absorbing gas and it sinks after it been in fuel for a while.

  10. #10
    steve45's Avatar
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    Ethanol tears shit up. Write your congressman and complain that they mandated the use of that crap.

    I wonder if you can dry and coat the float with something to prevent it from sinking again (assuming that's the cause).

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