KTM 1190/1290 Adventure Fuel Gauge Fix

KTM 1190 and 1290 Adventure bike have fuel gauge issues. I have found a fix that worked for me and I feel it will work for many others too.
Remember to sand a "little bit extra" off as well to compensate for the float expanding in warm weather.

[@richardshapero1403]

Thanks for your video. I repaired my fuel float as you demonstrated and it works like it is supposed to work. Total time was about 45 minutes. Thanks again!

[@mivarsson]

Awesome! Mine was replaced a few months ago and the replacement has been stuck for a couple of refuels now. Time to get to work! Thanks for the video!

[@sbartholomew-nb2zw]

dammit! i wish i would have seen this two weeks ago. my 1190 fuel sensor has made me walk twice by lying to me (40-70 mi range displayed while running out). the second time, i called the dealership and ordered a new sensor while walking. $250 i could have saved by doing what you showed here.

[@richardshapero1403]

Thanks for the excellent video. My gauge works perfectly now and has for the last 3 fill-ups.

[@FirstLast-su7tb]

Thanks for the fuel gage fix. I almost took it into the shop

[@Loudpedal10]

Great info. I'll be doing my 2015 1290 SA this week. Thanks!

[@eubikedude]

Good job - now KTM need to look at this and make sure the floats are finished properly/better from the factory. ;) Ducati could do with taking a look too. :)

[@SURFINASPHALT]

Well Done Inmate!😎👍🏼

[@julesviolin]

The float material is probably affected by fuel and expands with age. The 790 has been issued with a modified sender so it's obvious KTM knew there was a problem. My 2000 790 covered just 700 miles before the fuel guage got stuck on empty !!

[@erkipalusoo]

Mine gauge shows always empty tank. So I took it apart. And the problem is that the white float doesn't float anymore on the gasoline, it sinks. I dried it on the hot room but when I put it back on the gasoline bubbles come out and gasoline goes in, so it sinks again. Supid issue...

[@TheLeftwing71]

I have same issue, thanks for the video.

[@chrisnix5775]

Excellent video thank you!

[@lgcabrera]

This method can be applied to the 799 Adventure fuel sending unit? Mi e apparently is getting stucked on empty no matter I completely fill the tank!

[@sandbiker]

Thanks, very well done helpful video. My 1090 R has 2500 miles on it. Sometimes the gauge works, sometimes it doesn't. I plan to make this mod to my float as well. For what it's worth, I think this may be temperature related. My gauge starting working again last week when temps here WI dropped to a high of 60 degrees. It is getting hot again, now in the mid 80s and the gauge is not functioning. Just a thought.

[@myhobbyvideos]

sandbiker I don’t know if I said it in the video but I thought I did. Higher temps cause the foam float to expand causing it to stick.

[@sandbiker]

Yes, I did catch your comment on this being "temperature" related. In WI, we had temps jump into the 90s for a few days, gauge stopped working. Then temps fell back into the mid 40s to low 60s and the gauge starts functioning again. You called it, thanks.

[@kinnanton]

I have a 2016 1290 Super Duke R and my fuel gauge always shows empty. I removed the pipe but the floating unit wasn't stuck. I was surprised. It moved easily. So I reassembled the bike and the problem still exist. I have no idea what else could be the problem. Any idea?

[@Captndarty]

Mine used to get stuck. “full“. The dealer did this trick now mine gets stuck on empty.

[@tomdyll2728]

This worked for me too. Thank you!

[@erikwhitley413]

Thank you! I have a thousand miles or so on my 1190, and either I get incredible gas mileage or mine is stuck. Looks like I have a project. Did you have to drain the tank before removing?

[@myhobbyvideos]

Erik Whitley , you do not need to drain the tank.

[@Speeds1486]

The dealership told me the float swells because of ethanol, in US gas.

[@Dazza-u4c]

Mine is a 2014 model and has never stuck.

[@jonmbakermd]

Yep mine sticks too. How long has your repair lasted?

[@myhobbyvideos]

It is still working

[@Kaegis]

My 2019 1290R is stuck on empty? lol

[@grishfish]

I asked my Ktm dealer about the 'fix' and they do the exact same as you. Mine stuck once, but became unstuck when I filled up the tank. How difficult was removing the metal cylinder?

[@myhobbyvideos]

Removing the metal tube is easy. Easier than the "fix" itself.

[@cmlago]

Muy buen video!! Muy útil!!!

[@mt-015]

Such bullshit! I want one of these bikes but ktm better get their shit together

[@julesviolin]

⚠️Edit. Just took my sensor out. 790 2020 model. My float doesn't float at all so it wasn't stuck or swelled. Just doesn't float when immersed in fuel. Crazy design ⚠️ Part number 63507080100 has been 63507080200 £100