GL1200 low fuel level sensor repair


Information and questions on GL1200 Goldwings (1984-1987)
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SilverDave
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GL1200 low fuel level sensor repair

Post by SilverDave » Fri Oct 16, 2015 10:40 am



About a month ago, I obtained some NTC thermistors, dremmeled open the "slosh can" on the low fuel sensor, soldered in a new NTC thermistor, re-sealed the can, tested it and re-installed the unit in the gas tank ..

It "worked " perfectly at first ...... Now it stays "off" for about 20 minutes of riding , and then slowly starts the red light glowing , even with a full tank of gas...

Clearly the thermistor is overheating after some time .. Its actually more annoying, when driving , than when it was defunct for the last decade .

Its not available as a part anymore from Honda, and neither are the electrically equivalent "37810-MN5-08" part from the 1500 or from the Honda Magna V65.

I have been given three suggestions from other 1200 owners so far :

A) Try soldering in another NTC thermistor ( I have 4 others ).

B) Drill a few more tiny holes in the slosh can to let in more cooling gas .

C) Just cut the right wire and go back to the way it was ( Which wire would that be ?? I want to leave the level sensor working .)


Any other suggestions ??/


SilverDave



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WingAdmin
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Re: GL1200 low fuel level sensor repair

Post by WingAdmin » Fri Oct 16, 2015 12:39 pm

Yup! You can abandon the rather crappy system Honda used for a low-fuel sensor and instead do what Virgilmobile and I both did: replace the whole thing with a float switch:

viewtopic.php?f=14&t=11167

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SilverDave
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Re: GL1200 low fuel level sensor repair

Post by SilverDave » Sat Oct 17, 2015 11:16 am

Wow ! Finding a "555" circuit board, several resistors and caps, a float switch, and fabricating some sort of holder for the new float ? ?

I have none of the circuit materials around here, and Radio Shack , in Canada went out of business.
( Its successor " The Source" now sells few breadboarding parts )

Hmmmm
Theres got to be an easier way ...

LOL

SilverDave

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Re: GL1200 low fuel level sensor repair

Post by virgilmobile » Sat Oct 17, 2015 12:26 pm

The electronics is not necessary.It just makes the light blink

thompsoj22
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Re: GL1200 low fuel level sensor repair

Post by thompsoj22 » Sun Oct 18, 2015 8:33 am

hey im new to the forum, I also like all the Bells and whistles to work as designed. My opinion is to start looking for fuel at 150 miles no matter what the light says, and drill more cooling holes for your mod and see what happens.

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Re: GL1200 low fuel level sensor repair

Post by SilverDave » Sun Oct 18, 2015 11:47 am

Well the glowing red light, even when its full is quite annoying ...
and the gas level gauge works very well

So... I took the cowardly way out... until I can find a working " slosh can "

I snipped and shrink wrapped the blue/white wire ...

so no red light ( 'cept at startup) and a working gas level meter .

SilverDave

<<< Thompso22 : So you think that drilling more holes might help ?? >>>

thompsoj22
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Re: GL1200 low fuel level sensor repair

Post by thompsoj22 » Mon Oct 19, 2015 6:55 am

total immersion, it was designed to work as purchased so im not sure why you'd have to change it's design to get it to work. unless it has something to do with mounting angle/position. don't rule out a new "bad" component, also verify the ground circuit is solid and the low fuel "check relay" isn't the culprit. possible differences in resistance between stock/new thermistor and the relay allowing the light to illuminate.

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SilverDave
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Re: GL1200 low fuel level sensor repair

Post by SilverDave » Tue Oct 20, 2015 9:48 pm

yes... I saw the " check relay" on my wiring diagram , in my Clymers manual .

so... where EXACTLY , in an Aspy is that relay physically located ?

behind the dash ? under the false tank ?

( and what does it look like ? )

And how might I go about testing it for faulty operation ??

SilverDave

Alloy Artist
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Re: GL1200 low fuel level sensor repair

Post by Alloy Artist » Tue Mar 21, 2017 8:29 pm

New to the forum, plenty familiar with motorcycles and repairs, although this one's not what I'm used to.

Just bought an '86 1200 SEi. It has a few issues, but I'm working through most of them. The one that's got me stuck is the FUEL (not fuel system) light on the dash. After searching this forum and others, I'm pretty much convinced it's the thermistor in the sending unit causing the problem. The fuel level display is reading accurately. The fuel pump works as it should. When I first turn the bike on, the ECU flashes during it's check sequence, and then the lights go off and stay off, so no code detected. I pulled the sending unit out of the tank, cleaned it, and reinstalled - same result, fuel light stays on. If I pull the connector off the unit while the bike is running, the fuel level display drops on the dash, and when I plug it back in, the reading goes back to half a tank, which is about what's in there. All fuses are good. All contacts are clean. I don't see any exposed wires to short out.

Is there anything else I'm not thinking of?

I am not really keen on rebuilding the sensor, and I don't want to convert to a different type of setup. All I really want is for the light to stay off. I see a reference to a blue/white wire and cutting it, and that is more appealing to me as a fix for now. I'm assuming the wire being referred to is the white wire with blue stripe that is part of the bundle going into the connector attached to the top of the sending unit. If I understand correctly, I can cut that wire, and the display will still function. I just won't have an operable warning light. Is this correct?

Thanks for the help.

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Re: GL1200 low fuel level sensor repair

Post by sportsfreaked » Tue Mar 21, 2017 8:52 pm

Dave this is how I did mine and it's been working. It worked all of last year after the repair. viewtopic.php?f=12&t=35157&p=209590#p209590
Thanks to all who answer and help. It is greatly appreciated!
Ed

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Re: GL1200 low fuel level sensor repair

Post by Alloy Artist » Fri Mar 24, 2017 10:09 pm

OK, now I'm really confused. I swapped the sending unit for one that was tested good - light still stays on.

Clipped the white wire with blue stripe - light still stays on.

What am I missing?

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Re: GL1200 low fuel level sensor repair

Post by WingAdmin » Wed Mar 29, 2017 2:04 pm

Alloy Artist wrote:OK, now I'm really confused. I swapped the sending unit for one that was tested good - light still stays on.

Clipped the white wire with blue stripe - light still stays on.

What am I missing?
The white wire with blue stripe is definitely the correct wire. If you clipped it and the light is still on, that means that wire is being shorted to ground at some point. Try following it up as far as you can to see if you can find a point at which it is getting shorted to ground.



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