Hawk Fuel Sending Unit Fix -

[Painlesstom]

I've been having a blast with my Hawk, all the typical mods and some custom stuff. Digital dash was a must! Accurate speedo and a nice tach were much needed. Was tired of the fuel gauge accuracy issues, constantly showing between full, then empty, then 3/4 full. All in the course of 1 mile of riding. Hated to think it was a fault with the new dash, and having seen the stock fuel gauge bounce all over as well as hearing others complain about the same... I dug in and pulled the tank. Got the sending unit out and popped the cover off to see the mechanism and potentiometer. Ohm meter showed 100 ohms when full, 9 ohms empty. But as I articulated the float through it's range and bounced it around to mimic sloshing, I saw the readings go to 100 in the middle of the travel and was all over. Was not linear at all. Very erratic, just like the gauge indicated. What I also saw was the hinge point in the unit had so much slop in it that the sensor arm was breaking contact with the resistor board. A simple zip tie to hold pressure so it couldn't wobble around stabilized things and made it rock solid. I calibrated the float position so the gauge shows one bar when the fuel level is just at the main on position. So when I see that single bar at the bottom I know it's time to get gas or be ready to hit reserve. (That's what the bottom picture is showing)

Oh, and before you fill the tank back up make sure you look in the tank with a flashlight and verify the float travels to it's end points without touching the sides of the tank. It should move freely.

[Red Hawk]

Brilliant, this should sticky.

[Painlesstom]

I love simple fixes, this one made me very happy. haha

[JerryHawk250]

Thanks for posting. I found the same issue on mine too. I was able to correct it without the zip tie and just tweaked it until it made contact throughout the entire path.

[Megadan]

Good tip on the fix. I am going to add this to my resource guide.

I never pay much attention to my fuel gauge and just judge my need for fuel based on my trip meter (always reset when fueling) or the sound of the slosh in the tank - which I check by rocking my bike when I get on. Old habits from riding old bikes that either had no fuel gauge, or broken ones lol.

[david3921]

Not to be a Debbie downer but is the zip tie going to last? Won't the gas eventually eat it up? I would suggest that you use wire to wrap around and twist tight. Great fix otherwise, though.

[Painlesstom]

Zip ties are impervious to fuel. Have been using them for many years on connections inside gas tanks without any problem. This is a permanent fix.

[Painlesstom]

I've heard the same. Longer arm would give more resolution for better accuracy between F and E probably. But from what I've seen they also have the same exact design in the mechanism, so would benefit from this fix as well.

[N7sithis]

Just tried this on my 2022 X-pro Hawk 250 and it looks like they started using a different sending unit, mine does not look like the one pictured, sadly, no easy fix for me.