Gas gauge fix

pantera · May 21st, 2009, 04:02 PM

On my Kawasaki vn 900 custom there is a fix for the inaccurate gas gauge by putting certain resistors in the wire harness.Wonder if this would work on the Ninja?

HKr1 · May 21st, 2009, 05:42 PM

On the 250r:
Full is 4-10 Ohms
Empty is 90-100 Ohms

Looking at that pic, kinda looks like a 620 ohms & 2200 ohms in series for 2820 ohms. Also looking at that pic, its in parallel with the fuel sender. So lets say the 250r is:
Full @ 5 ohms
Empty @ 95 ohms
With these resistors added:
Full would be 4.9 Ohms
Empty would be 91.9 ohms

So it would come off empty a little bit more than normal.

pantera · May 21st, 2009, 06:01 PM

260 is the ohms they are trying to achieve on that thread.I just ended up bending the float arm on my vn 900 and fixed the problem.I am no where near electronically inclined enough to experiment with resistors.I wish when I filled the tank on the Ninja though it would actually read full.

HKr1 · May 21st, 2009, 07:23 PM

I finally got to click on the pic and make it bigger, before I was getting invalid link.
Anyway looks like Red/Red/Brown for 220 ohms & Yellow/Violet/Black for 470. That added together would be 690 ohms. If they were trying for 260, one Red/Blue/Black would have been nice.

But still, 470 wouldnt change the full resistance much. Empty with 470 & 95 would be 79 ohms. That would be a big diff, dont think it would show empty.
If you were to use 260 ohms, that would make it 69.

Your 900 is probably a different empty resistance than the 250r. I think the ZRX1200 is close to 500.

Whats wrong with the gauge anyway, not showing full or empty??

krazygluon · May 21st, 2009, 08:28 PM

Meh, my problem with the guage isn't the full/empty markers...its the complete nonlinearity of the needle as it moves from full to empty.

But seeing as that's a tank geometry problem, not an electronics problem, I can deal.

pantera · May 22nd, 2009, 01:36 AM

Gauge does not show full when the tank is filled and reads empty after just 150 miles.At 150 miles on the trip and the gauge reading empty it took 3 gallons to fill the tank back up.

kkim · May 22nd, 2009, 01:44 AM

I take it the bike is not under warranty?

pantera · May 22nd, 2009, 01:57 AM

No ,the bike is no longer under warranty.How many miles can you travel on a full tank before the gauge reads empty?

kkim · May 22nd, 2009, 02:10 AM

roughly 160-180.

HKr1 · May 22nd, 2009, 07:34 AM

Quote:

Originally Posted by pantera

Gauge does not show full when the tank is filled and reads empty after just 150 miles.

Think check the float resistance @ full, and go from there

Quote:

Originally Posted by pantera

260 is the ohms they are trying to achieve on that thread.

That might be the total they were looking for over all. That 470 & a 500 sender would be kinda close @ 242.

pantera · May 31st, 2009, 11:21 AM

Someone on another site just told me Kawasaki has a new updated gas gauge for these bikes.Any one else know anything about this?

GiGs · March 24th, 2012, 08:37 PM

I realize this thread is a little (3 years) old...

BUT I *may* have discovered a fix to all those who have the problem with the fuel gauge indicating the wrong status.

I want to make it clear that I do NOT have this problem.

IF YOU CANNOT SOLDER DO NOT ATTEMPT THIS !!!!

This is a picture of the back of my fuel gauge:

Notice the burnt plastic / hot glue ? That means those resistors are getting quite hot, hot enough (eventually) to possibly fail completely or go bad and give an inaccurate reading (which would give you a false reading on your fuel gauge !).

The ohm's should read as follows:

NOTE : You will need to cut 1 leg of the 47 ohm resistor to get a proper reading, otherwise it will give you a reading of the coil inside (which is 22 ohms with the resistor connected). IF YOU CANNOT SOLDER DO NOT ATTEMPT THIS !!!!

With that said, if your readings are not correct...the resistors will need to be replaced. From some super quick calculations, they are 3 watt's each, have an accuracy rating of +/- 5% (see the gold band at the end of the resistors..) and are metal film resistors.

You must buy the exact same ohm resistor if you want to have an accurate reading. The type i.e metal film is not "especially" important, the wattage can be higher (which will give off less heat) but CANNOT be any lower otherwise you risk burning it to a crisp.

For those measuring or replacing who are wondering, resistors DO NOT have a polarity i.e a positive + or a negative -. They can be installed OR measured either way, just make sure to set your multimeter to Ω or 200 Ω before you start measuring

Bear in mind that this is only going out on a guess as I have no other proof minus the bunt glue/plastic mix on the resistor....

If your willing to try this, great...please let me know the results.

Be warned, it's a big job (my bike is completely apart so it was very easy for me but that's a whole other story). I am not and will not be held responsible for anything you screw up.

That was just a quick post, if more detail is needed let me know i'll try to check back here.

CZroe · March 25th, 2012, 02:19 AM

Mine reads empty before it is sometimes and not empty when it is empty others, so I doubt my inaccuracy is caused by this.

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May 21st, 2009, 05:42 PM	#2
HKr1 IC2(SW) Name: Kerry Location: Pensacola Join Date: Nov 2008 Motorcycle(s): . Posts: A lot.	On the 250r: Full is 4-10 Ohms Empty is 90-100 Ohms Looking at that pic, kinda looks like a 620 ohms & 2200 ohms in series for 2820 ohms. Also looking at that pic, its in parallel with the fuel sender. So lets say the 250r is: Full @ 5 ohms Empty @ 95 ohms With these resistors added: Full would be 4.9 Ohms Empty would be 91.9 ohms So it would come off empty a little bit more than normal.

May 21st, 2009, 06:01 PM	#3
pantera ninjette.org member Name: Brion Location: Rochester, NY Join Date: May 2009 Motorcycle(s): 2016 Kawasaki Vulcan 900 Custom / 2017 Kawasaki Ninja 300 Posts: 133	260 is the ohms they are trying to achieve on that thread.I just ended up bending the float arm on my vn 900 and fixed the problem.I am no where near electronically inclined enough to experiment with resistors.I wish when I filled the tank on the Ninja though it would actually read full.

May 21st, 2009, 07:23 PM	#4
HKr1 IC2(SW) Name: Kerry Location: Pensacola Join Date: Nov 2008 Motorcycle(s): . Posts: A lot.	I finally got to click on the pic and make it bigger, before I was getting invalid link. Anyway looks like Red/Red/Brown for 220 ohms & Yellow/Violet/Black for 470. That added together would be 690 ohms. If they were trying for 260, one Red/Blue/Black would have been nice. But still, 470 wouldnt change the full resistance much. Empty with 470 & 95 would be 79 ohms. That would be a big diff, dont think it would show empty. If you were to use 260 ohms, that would make it 69. Your 900 is probably a different empty resistance than the 250r. I think the ZRX1200 is close to 500. Whats wrong with the gauge anyway, not showing full or empty??

May 21st, 2009, 08:28 PM	#5
krazygluon Parking Lot Qualified Name: Fielding Location: Michigan Join Date: May 2009 Motorcycle(s): '09 Ninja 250 Posts: 30	Meh, my problem with the guage isn't the full/empty markers...its the complete nonlinearity of the needle as it moves from full to empty. But seeing as that's a tank geometry problem, not an electronics problem, I can deal.

May 22nd, 2009, 01:36 AM	#6
pantera ninjette.org member Name: Brion Location: Rochester, NY Join Date: May 2009 Motorcycle(s): 2016 Kawasaki Vulcan 900 Custom / 2017 Kawasaki Ninja 300 Posts: 133	Gauge does not show full when the tank is filled and reads empty after just 150 miles.At 150 miles on the trip and the gauge reading empty it took 3 gallons to fill the tank back up.

May 22nd, 2009, 01:44 AM	#7
kkim Join Date: Nov 2008 Posts: Too much.	I take it the bike is not under warranty?

May 22nd, 2009, 01:57 AM	#8
pantera ninjette.org member Name: Brion Location: Rochester, NY Join Date: May 2009 Motorcycle(s): 2016 Kawasaki Vulcan 900 Custom / 2017 Kawasaki Ninja 300 Posts: 133	No ,the bike is no longer under warranty.How many miles can you travel on a full tank before the gauge reads empty?

May 22nd, 2009, 02:10 AM	#9
kkim Join Date: Nov 2008 Posts: Too much.	roughly 160-180.

May 31st, 2009, 11:21 AM	#11
pantera ninjette.org member Name: Brion Location: Rochester, NY Join Date: May 2009 Motorcycle(s): 2016 Kawasaki Vulcan 900 Custom / 2017 Kawasaki Ninja 300 Posts: 133	Someone on another site just told me Kawasaki has a new updated gas gauge for these bikes.Any one else know anything about this?

March 24th, 2012, 08:37 PM	#12
GiGs ninjette.org member Name: Michael Location: Melbourne Join Date: Sep 2010 Motorcycle(s): 2008 Kawasaki Ninja 250r Posts: 139	I realize this thread is a little (3 years) old... BUT I may have discovered a fix to all those who have the problem with the fuel gauge indicating the wrong status. I want to make it clear that I do NOT have this problem. IF YOU CANNOT SOLDER DO NOT ATTEMPT THIS !!!! This is a picture of the back of my fuel gauge: Notice the burnt plastic / hot glue ? That means those resistors are getting quite hot, hot enough (eventually) to possibly fail completely or go bad and give an inaccurate reading (which would give you a false reading on your fuel gauge !). The ohm's should read as follows: NOTE : You will need to cut 1 leg of the 47 ohm resistor to get a proper reading, otherwise it will give you a reading of the coil inside (which is 22 ohms with the resistor connected). IF YOU CANNOT SOLDER DO NOT ATTEMPT THIS !!!! With that said, if your readings are not correct...the resistors will need to be replaced. From some super quick calculations, they are 3 watt's each, have an accuracy rating of +/- 5% (see the gold band at the end of the resistors..) and are metal film resistors. You must buy the exact same ohm resistor if you want to have an accurate reading. The type i.e metal film is not "especially" important, the wattage can be higher (which will give off less heat) but CANNOT be any lower otherwise you risk burning it to a crisp. For those measuring or replacing who are wondering, resistors DO NOT have a polarity i.e a positive + or a negative -. They can be installed OR measured either way, just make sure to set your multimeter to Ω or 200 Ω before you start measuring Bear in mind that this is only going out on a guess as I have no other proof minus the bunt glue/plastic mix on the resistor.... If your willing to try this, great...please let me know the results. Be warned, it's a big job (my bike is completely apart so it was very easy for me but that's a whole other story). I am not and will not be held responsible for anything you screw up. That was just a quick post, if more detail is needed let me know i'll try to check back here.

March 25th, 2012, 02:19 AM	#13
CZroe CPT Falcon Name: J.Emmett Turner Location: Newnan, GA Join Date: Apr 2009 Motorcycle(s): '08 CP Blue EX250J, '97 unpainted EX250F, 2nd '97 unpainted EX250F (no engine), '07 black EX250F Posts: A lot.	Mine reads empty before it is sometimes and not empty when it is empty others, so I doubt my inaccuracy is caused by this.