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Old 02-07-2010, 11:33 PM   #1 (permalink)
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From: charlotte

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Gas light stays on with a full tank

Hello everyone! Im glad to join this forum. I have a 2006 636 and a few weeks ago my gas light would not go off after I filled the tank. It has been like that for a while now. I looked on the bike bandit parts diagram and did not see any low fuel sensor or anything. Does anyone know what I need to look for or what the problem could be? Thanks
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Old 02-08-2010, 08:35 PM   #2 (permalink)
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I'm just guessing here, but if it's anything like my 87 zx750, there is a levels sender mounted into the bottom of the tank that has a float inside the tank that obviously senses the fuel level. Coming out of the sender unit there are three wires(one plug). One of the wires is for the ground (-) to the unit, one wire is from the variable resistor that the float controls to tell the gage the tank level, and the third wire comes off of a switch that is actuated when the float is at the bottom of it's travel which puts 12V to the low fuel level light. Since I don't even know if your model even has a fuel level gage, I can't really say if yours is the same or not. However either way even if yours doesn't have a gage then it will still have a sensor only it will be 2 wires instead of 3. and the check will be the same.look at the back of your gage panel and determine the colors of the two wires going to the fuel light. then examine the plug going to the tank and see which one of those two colors it has in common. that common wire is what turns your light on and off. Seperate the plug. does your light go off? Yes, the problem is either the switch in the tank or the wiring betwenn the plug and the switch. no, the problem is that you have most likely got a place on the wire between the light and the plug that has chafed through it's insulation due to vibration that is now grounded to the frame someplace. Like I said I'm just guessing here but this is a pretty standard way of setting up this sort of thing.
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Last edited by nauticalmike : 02-08-2010 at 08:37 PM. Reason: punctuation
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Old 02-08-2010, 08:39 PM   #3 (permalink)
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Old 02-08-2010, 10:23 PM   #4 (permalink)
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From: charlotte

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Thanks for the good info. Im gonna check that out. I dont have a fuel gauge on my bike just the light so I will look for the 2 wire sensor in the tank. Hopefully its something like a wire grounded because I would hate to buy a complete fuel pump. I will pull the tank in the morning and check it out.
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