2012 Fuel Gauge Install on an 07 Ninja

[burnrich]

Can anybody indicate if it's even possible to install the fuel float on a pregen. My guess so far would be to drill a hole in the tank for the install. I've ordered a digital gauge similar to the koso off ebay and now need to solve the guage float install problem.

[Klondike1020]

If I were to try that mod I would probably cut out a flat piece of steel traced out to be the same size as the fuel gauges foot print 3/8 thick or thicker and weld it to the bottom of the pre gen tank. I would only be using it to provide some meat to drill and thread bolt holes into tha would hold the sending unit in place.

You can't really drill a hole and fasten the sending unit without threaded holes to bolt it to.

There may be some kind of inserts that would work of that application though.


or get a smashed ninja tank and cut the opening out of the tank and weld it into the GPX tank?

[CZroe]

I've heard nothing but bad things about welding on a gas tank.

Those gauges typically expect you to simply leave the function disconnected if you don't have a fuel sender. The generic gauges are usually designed such that the info is not shown, not prominent/called out, or labeled on the display because a lot of bikes don't have fuel gauges.

[crazymadbastard]

Originally Posted by burnrich

Can anybody indicate if it's even possible to install the fuel float on a pregen. My guess so far would be to drill a hole in the tank for the install. I've ordered a digital gauge similar to the koso off ebay and now need to solve the guage float install problem.

Which gauge?

keep us updated please.

[CZroe]

Here's a fuel sender for $20 if you want to risk it anyway:
http://oemninjaparts.com/shop/fuel-level-sender-unit/

[Hero Danny]

I know this is what you don't want to hear, because 2 months ago this is what I didn't want to hear. I owned a pregen (03) and I really wanted a fuel gauge. Well, turns out after doing extensive research I found out it was not only risky and difficult to do, 99% of the time it is completely inaccurate.

Sorry bud I know the feeling of wanting a fuel gauge, but it just isn't going to happen unless you buy another bike..


You can try by all means though, if you are able to some how get it working, then hell, more power to you!

Good luck!

[b.miller123]

The pregens do have a fuel gauge. It's called the tripodometer. Reset it everytime you fill up and after getting down to the reserve one time you'll know about how much gas you have left.

[burnrich]

Originally Posted by crazymadbastard

Which gauge?

keep us updated please.

The gauge is here: http://pages.ebay.com/link/?nav=item...839078&alt=web

Should come in a few weeks so watch this space. The Chinese are good at copies but not so good at engineering so 70 aud = nothing ventured nothing gained..

I was planning on getting a fabrication place to do the fuel tank float mod as I'm **** with a tig welder anyway.

Watch this space

[CZroe]

That might be a little problem: from what I hear here, most places will refuse to weld on a fuel tank.

"5. If necessary, we can change the LED light for you, add or delete certain icon"

Why not just have the fuel meter removed?

[choneofakind]

whole tank holds 4.75 gallons. Reserve tank is 0.75 gallons. You get about 60 mpg. We'll call it 55 to be safe.

55 x 4 = 220 miles. So go about 210-220 miles until you even worry about filling up, or just go until you have to switch to reserve. You have (very conservatively) 20 miles of reserve gas when you get down to the reserve tank. You can get more by leaning the bike over at a standstill and getting gas across the gas tank hump, but that's not necessary.


I learned to drive on a car with a gas gauge that was always pegged at F. The gas gauge has always been unnecessary to me, especially on a motorcycle, where you can open the tank and see how much fuel you have left. Also, read around the newgen forums a bit. The gas gauges are terribly inaccurate. The only purpose they consistently serve accurately is adding weight to the bike. The temp gauge on your pregen dash is much more useful. I'll take a temp gauge over a fuel gauge any day.

[Klondike1020]

I agree a temp gauge is more useful !

Welding on a gas tank is no biggie- empty it, wash it with soap and water, let it dry.

NEVER weld on a tank that has not been washed !!!! fuel fumes go BOOM.

The problem with using a ninja 300 sending unit is that the tanks are shaped differently so the movement of the unit may not accurately report your fuel level. You may be able to modify it and calibrate the gauge on the cluster though, but I wouldn't know about that. Probably just bend the wire the float is on a bit and get it close

I would consider putting a tube across the low sides of the tanks to equalize the fuel level from either side of the hump while you are working on it. its easily done but unnecessary and complicates tank removal unless you but a one way check valve on the non sending unit side and a valve on the other or something. used to have this issue with my old CBs but really its probably not worth the trouble.

LOW TECH IS BEST TECH - possibility

[Road Dawg1]

New to Ninjas and motorcycles in general, but you might be better off with a calibrated stick to poke into the tank and check fuel levels.

[capt_bugaloo]

Why bother? The fuel gauge on my 2011 is horribly inaccurate and not to be trusted.

Simply get into the habit of resetting your tripmeter at every fuel stop, and then you'll know exactly how far you've travelled since that tank up.

[verboten1]

That is exactly what I was going to say. I hate mine and wish I had a temp gauge

[nickjpass]

The fuel gauge sucks anyway

Not worth it imo

[crazymadbastard]

Originally Posted by CZroe

That might be a little problem: from what I hear here, most places will refuse to weld on a fuel tank.

Radiator shop will do it.

[burnrich]

Gauge arrived today. Now the fun begins figuring out if its compatible. At least they sent me a wiring diagram. The real challenge will be the fuel gauge. It came with magnetic speed sensor and conversion plugs for the old wiring harness. I think I'll get a metal fabrication place to do the tank float customisation. This while exercise is to satisfy my own amusement really to see if its actually possible to get it working on a pregen.

[fishnbarrel]

If you do weld on the tank, put dry ice in it before you weld. A fire need fuel, oxygen and an ignition source. Dry ice melts, displacing the fuel and oxygen so you cant get a fire.

[crazymadbastard]

Originally Posted by burnrich

Gauge arrived today. Now the fun begins figuring out if its compatible. At least they sent me a wiring diagram. The real challenge will be the fuel gauge. It came with magnetic speed sensor and conversion plugs for the old wiring harness. I think I'll get a metal fabrication place to do the tank float customisation. This while exercise is to satisfy my own amusement really to see if its actually possible to get it working on a pregen.

ok its been 8 hours + this thing installed yet?

[burnrich]

Originally Posted by crazymadbastard

ok its been 8 hours + this thing installed yet?

I know right? I looked at the wiring diagram over pizza last night and decided to go the cautious route and not screw it up. Please stop back on 2020 and I should have it finished

[crazymadbastard]

Originally Posted by burnrich

I know right? I looked at the wiring diagram over pizza last night and decided to go the cautious route and not screw it up. Please stop back on 2020 and I should have it finished

Not screw it up by not installing it? A harbor is the safest place for a ship, but that is not what ships are made for, Mate.

[burnrich]

Installed the gauge temporarily and got most of the features working and she looks pretty damb good. Fuel gauge will install down the track as tank mod will be a little more tricky. I'll post a fuel installation tutorial including photos for anybody interested in installing one o. Their pregen.

[crazymadbastard]

Originally Posted by burnrich

Installed the gauge temporarily and got most of the features working and she looks pretty damb good. Fuel gauge will install down the track as tank mod will be a little more tricky. I'll post a fuel installation tutorial including photos for anybody interested in installing one o. Their pregen.

Sweet! how hard was the wiring.

[burnrich]

The wiring was easy. You can figure out what goes where with a simple test light to figure out some of the wiring or just check the back of your instrument cluster for correct wire color coding. The jury is out on whether or not these gauges are accurate or not. I have a feeling the real Koso gauge is worth paying for but for now the Chinese knockoff will do the job. Don't expect any tech support from the sellers of these gauges as they are useless. Also the gear indicator doesn't seem to work with a sensor I purchased off eBay and tried to install with the gauge. More troubleshooting required on that one.