2004 EV California *low fuel light* repair?

[Peter949]

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Hello - The low fuel light on my 04 EV no longer works. It was never reliable when I first purchased the bike, and would sometimes turn on when there was still 2 or 3 gallons left in the tank. Now the light will never come on (the bulb is good) and I wanted  to ask if there is a repair that I can look into?  My local dealer was of no help ... they just said the sensor is in the fuel pump.   If anyone has any experience with repairing a  - low fuel level  - indicator please let me know. Thank you in advance for any help!     

[Kiwi_Roy]

Does this model have an in tank pump, if so the sensor may be a magnetic float switch, did the light snap on?

The earlier model had an expensive thermistor, the light would turn on slowly over several seconds, going off and on as the fuel sloshed around

The drawing calls for a switch but I have learned to take the schematics with a grain of salt.
http://www.thisoldtractor.com/guzzi007/schematics/2004_EV_Catalytic.gif

[StuCorpe]

I think that is the same as my 03. Mine started leaking fuel out of the sensor so I had to replace it. It unscrews from the bottom of the tank (just ahead of the fuel outlet). A simple job to replace. I got the new sensor from Harpers.

[Wayne Orwig]

The sensor IS in the fuel pump.
Sort of. It is attached to the fuel pump plate.
And no, you can't plug it in wrong. No it does not screw into the bottom of the tank.

It is a thermistor, almost  like the earlier models. I had the fuel filter come loose, and break off the sensor. That was under warranty then, so MG supplied a new sensor. You remove the fuel pump plate and screw the new sensor in. Replace the fuel filter since you are touching it. make sure it is all strapped down so it doesn't bang around in the tank.

BTW, a while back I took mine back out and bent calibrated it. It normally came on with about 1.5 gallons remaining. Now it comes on with closer to 1 gallon remaining, which I prefer.


Why does it look like the back rest is on the wrong side in the photo?

[Peter949]

Thank you for the replies to my broken low fuel light repair question!  The 'Thermister' sensor attached to a fuel pump plate must be the problem ... and thank you Wayne for the great suggestions which includes your sensor 'calibration' method. Also Wayne ... as for my odd looking backrest in the photo, I simply removed the foam pad with only the plastic plate screwed back on.

Again, thanks for this very interesting fuel sensor info ... but it is amazing that my Moto Guzzi dealer did not really understand how to correct/fix my low fuel light problem.

[twhitaker]

but it is amazing that my Moto Guzzi dealer did not really understand how to correct/fix my low fuel light problem.

Not that amazing. Some dealers will take on the brand but not send the mechanic to school (if there is still a school). 

[Wayne Orwig]

Not that amazing. Some dealers will take on the brand but not send the mechanic to school (if there is still a school). 

No 'school' in their right mind would instruct students on a 12 year old bike repair.
It takes ole phartz that have been with the brand. A new dealer would have a hard time hiring and keeping someone that had those skills.

[Kiwi_Roy]

The sensor IS in the fuel pump.
Sort of. It is attached to the fuel pump plate.
And no, you can't plug it in wrong. No it does not screw into the bottom of the tank.

It is a thermistor, almost  like the earlier models. I had the fuel filter come loose, and break off the sensor. That   

https://www.aliexpress.com/item/Automotive-fuel-level-sensor-fuel-pump-alarm-sensor-NTC-thermistor/32548087148.html?spm=2114.40010508.4.93.dqV8DV
Are they like this Wayne, I bought a couple a while back a direct fit for a Triumph Tiger

[Wayne Orwig]

https://www.aliexpress.com/item/Automotive-fuel-level-sensor-fuel-pump-alarm-sensor-NTC-thermistor/32548087148.html?spm=2114.40010508.4.93.dqV8DV
Are they like this Wayne, I bought a couple a while back a direct fit for a Triumph Tiger

Almost perfect. If you attached a rod to that with a screw hole stamped in it, that would be it. In other words, that part you found could easily be used to repair them. Or a bit is solder, a soft steal wire, and a couple of washers, and you could make one from scratch with those.

[ccoli]

I welded mine back together when it broke.
Have a 2003 blue/chrome tank with fuel pump etc included available for  $75 + shipping.

[Tom H]

PM sent on the tank.

Tom