KZR's Bikes of the Month for 2024

ZN1100 Frankenbike fuel level sender replacement

More
30 Oct 2020 17:57 - 30 Oct 2020 17:59 #838010 by jljim
I have been working through the last ( I Hope ) details on the ZN1100 Frakenbike project. The fuel level sender that was inside my hopelessly rusted and leaking fuel tank had both of the leads and the float arm cut off. I derusted it and managed to get it to function a little electrically but the resistance windings were separated in enough places to make the output fairly erratic. Thought about soldering a wire on the cut off float arm and attaching a float, but a used one showed up on EBay. Ultimately it was only usable as a representation of what a complete sender should be. I went searching for Kaw fuel sending unit pictures and found a very clean, and cheap, sender from a '08-'12 Ninja 250 that looked close enough to try. Only needed to shorten and rebend the float arm, separate the float from the cut off piece and reattach it. The pig tail is a little longer but the connector is a perfect match to ZN wiring. The winding resistance is a near perfect match for the ZN gage. The 4 hole mounting flange bolts right in. I attached a couple pics of the original sending unit, I didn't take a pic of the modified Ninja 250 sender. If someone here is more talented than me, please post a pic of the 250 sender for comparison. Tested the gage by filling the tank a gallon at a time. About 3.5 gals it reads full, shows empty wth 3 gals drained out.

Attachment image.jpeg not found

Attachment image.jpeg not found

Attachment image.jpeg not found


1981 KZ650 CSR
1985 ZN 1100 LTD
1982 GS1100GL
1979 Puch Maxi ( sold to buy the 650 )
1987 GL1200 Interstate
1986 GL1200 Aspencade (parts donor)
Attachments:
Last edit: 30 Oct 2020 17:59 by jljim.

Please Log in or Create an account to join the conversation.

More
01 Nov 2020 10:42 #838090 by jljim
Here is a Ninja 250 sender pic along with the original ZN.

Attachment 4AEEB72B-A9E7-4E26-9964-E4171F048057.jpeg not found

Attachment 27A91A01-F73F-4906-9725-48054E8F2621.jpeg not found

Attachment 63843724-B490-48BC-918D-23C05F0B2701.jpeg not found


1981 KZ650 CSR
1985 ZN 1100 LTD
1982 GS1100GL
1979 Puch Maxi ( sold to buy the 650 )
1987 GL1200 Interstate
1986 GL1200 Aspencade (parts donor)
Attachments:

Please Log in or Create an account to join the conversation.

More
02 Nov 2020 07:28 - 02 Nov 2020 07:29 #838137 by martin_csr
Replied by martin_csr on topic ZN1100 Frankenbike fuel level sender replacement
Thanks. Great pics. You may already know this, but the ZN1100 has the same fuel gauge gasket as a number of other models, including the ZG1000 Concours. So somebody else might be able to go with a fuel gauge form one of those models. But I would try to go with the newest unit possible, such as from the Ninja 250.
Last edit: 02 Nov 2020 07:29 by martin_csr.

Please Log in or Create an account to join the conversation.

Powered by Kunena Forum

If you like KZR Please consider making a donation. Thank you.

KZRider is free, but not without cost.

Please consider chipping in a few bucks to help cover the cost of running the KZR servers.