Kawasaki Zephyr ZR750C1 - Fuel Gauge Sender Unit Repair

In this video, we take a look at the fuel gauge sender unit, as the fuel gauge is not working. We've already tested the gauge itself, by shorting the two wires that lead to it, so we know it's the sender unit that is the problem.
It's no surprise, because the bike has been standing for over a decade. Stale fuel messes things up over time and, don't forget, that there's a certain amount of water in fuel.
Anyway, for us, it turned out that it was not simply a case of cleaning things up (although they certainly did need cleaning). The terminal that attaches to the coil had broken away.
We cleaned up the sender unit and soldered the terminal back on. Sorry, we took this off site for further investigation and did not film this part of the repair. I have included a photograph in the video where you can see the broken terminal sitting on top of the coil. It needed folding down in to its correct place and re-soldering. This worked a treat, as you can see.
Hopefully, for you, your sender unit just needs a good clean.
Even if you don't have this model of bike, or even a Kawasaki, you should find this a useful video for diagnosing and fixing this type of issue.

[@petardjurakovic4460]

Hi, I was wondering if I could use ZR750 gauge on my Zephyr 550? Do you think they are the same?

[@MotorcycleFettlers]

Sorry, I don't know, you'd need to check if the part numbers are the same, I think.

[@petardjurakovic4460]

just checked, they are, thanks! @@MotorcycleFettlers

[@MotorcycleFettlers]

Excellent.

[@therealslimshady4555]

Good man when I got my petrol tank painted on my kawasaki gpz900r it was away for nearly a year. Painter took ill. Anyway i coudnt remember the way the float was located. Pointing towards the seat or the front of the bike. Your one was towards the front end so mine is going the same direction ❤

[@MotorcycleFettlers]

Glad it helped.

[@jantinusulijn9797]

Hi, Mine is showing that my tank is full, when it's not. I got everything out, cleaned it, nothing seemed to be broken but no difference. anything else i could do?

[@MotorcycleFettlers]

Hi. I'd try a few things. I'd do a continutity test of the gauge by shorting the two wires. I'm assuming that is OK as I'm guessing yours goes from zero to full when you switch it on. You should, at least, be able to isolate if it's a gauge or sender unit issue. I'd also do a continuity test of the sender unit if you have a multimeter and you can, of course, operate the sender unit out of the tank. I don't think there's so much that can go wrong with the sender unit. Mine was a dry solder joint so it did not work. Yours seems the oposite and maybe you have a short some where. Does it show full when the sender unit is not connected? You should be able to isolate if it's the sender unit or gauge and work from there.

[@jantinusulijn9797]

@@MotorcycleFettlers hi, thanks for the reply. The only thing i know is that the meter goes to full when i switch it on. And goes to zero when i disconnect it under the tank. The floater in the tank goes up and down easily aswell... So kind of stuck here... Thanks

[@MotorcycleFettlers]

Yep. Your guess is as good as mine. Perhaps there's a fault with the gauge in that it only registers on or off or, I think, more likely there's a short on the sender unit side. I'd definitely check the wires that lead to the sender unit to see if the insulation has worn and there's a short as a short does seem the most likely issue. A multi meter is definitely your friend, for checking that ther is no wiring issue.