04 Cali EV fuel level thermistor

[JoeMay]

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.

[Wayne Orwig]

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.

[antmanbee]

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.

[MGrego]

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 

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.

[JoeMay]

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.

[joyinthecenter]

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

[Wayne Orwig]

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.