Fuel sender replacement

Fuel sender replacement:

Disconnect the battery.

Pop off the cap in the middle of the tank.

Remove the sending wire or cable, depending on the year.

Set 2 clean shop towels on the tank. The first is to set the screws on, and other is used to wipe off the opening as much as possible before going any further. If you have access to compressed air, blow the dirt away from the sender area.

Remove the screws, being careful to note the placement of any insulating washers. Set the hardware on the towel and set aside. Be sure not to drop anything into the tank.

While noting the direction the lever is facing, pull out the sender and set it aside.

Now is a good time to check out the condition of inside of the tank.  Check the condition of the filter screen/sock, and perform a good inspection for rust and debris.  A small/bright flashlight will detect any of the above.

Wipe off the top of the tank again, and clean off any old gasket material. You want it CLEAN!

Set the new gasket in place (make sure to order one), and install the new sender (clocked the way the old one came out).

Wipe off the hardware, and reinstall the screws, hook up the wire/cable and install the cap.

Have you read our diagnostic tech article yet? http://www.airheadparts.com/page.asp?recid=67

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