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General Category => General Discussion => Topic started by: JoeMay on June 10, 2024, 07:16:50 PM

Title: 04 Cali EV fuel level thermistor
Post by: JoeMay on June 10, 2024, 07:16:50 PM

Has anyone be able to find and successfully use a non-OEM one?  I'm having no luck locating an OEM one that doesn't take 4 to 6 weeks to get here from Italy and that isn't over 125 bucks.  The part number is 01 10 30 90.  Thank you.

Title: Re: 04 Cali EV fuel level thermistor
Post by: Wayne Orwig on June 11, 2024, 08:43:03 AM

Since the connector can't be swapped like the older models, how do you know the thermistor is bad?

I have one where the filter broke the metal stem on the thermistor. I slipped some brass tube around it and soldered it.

Title: Re: 04 Cali EV fuel level thermistor
Post by: antmanbee on June 11, 2024, 10:19:19 AM

With the internal pump assembly the fix for the thermistor is inexpensive.
Look at this thread, especially post #38.
https://wildguzzi.com/forum/index.php?topic=105885.0
Also read post #24 for the info I used to fix it.

Title: Re: 04 Cali EV fuel level thermistor
Post by: MGrego on June 11, 2024, 12:30:02 PM

I replaced the thermistor in my '04 EV several years ago.  I kind of struggled getting the pump and filter back in the tank, apparently I bent the thermistor so the fuel warning light was coming on at 1/2 tank  :violent1:

Just a friendly anecdote to remind you when you replace it, the bend on the thermistor may have to be adjusted to get the light to come when you want it to.

Title: Re: 04 Cali EV fuel level thermistor
Post by: JoeMay on June 11, 2024, 07:56:00 PM

I much appreciate this great input and advice.  I was fully intending to pull the pump assembly to diagnose the issue.  However, for the heck of it, I did some early checking on a replacement thermistor.  It's encouraging to learn that I may not have to go down that hole.  The light began acting up a long time ago after the dealer replaced a disintegrated fuel pick-up line with one that could withstand constant immersion in fuel.  I have a Garmin Zumo 550 so I just used it's fuel-use monitoring feature and disconnected the lead to the light.  That work around was fine for many years, but now I'm preparing to sell the bike and I want the fuel alert system to be working for the buyer.

Title: Re: 04 Cali EV fuel level thermistor
Post by: joyinthecenter on June 16, 2026, 01:43:59 AM

Finally getting back to fixing this. Anyone have recommendations or viable part substitutions? I'm doubtful that a quick solder will hold.


(https://i.ibb.co/MkyhYytM/IMG-1757.jpg) (https://ibb.co/MkyhYytM)

Title: Re: 04 Cali EV fuel level thermistor
Post by: Wayne Orwig on June 16, 2026, 07:51:54 AM

The right diameter brass tube from a hobby store will slip over that and solder to.
Maybe two pieces of say 12 awg wire, one soldered along each side of it.