TROUBLESHOOTING AND ELECTRICAL SYSTEM: 800 AND 810 GAS
Test Procedures
Page 11-32
2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual
11
TEST PROCEDURE 25 – FUEL LEVEL SENDING UNIT
See General Warning on page 1-1.
ý
WARNING
• To avoid the possibility of fire or explosion, make sure the fuel tank cap is securely in place
while performing this test procedure.
1. Turn the key switch to OFF and remove the key. Place the Forward/Reverse handle in the NEUTRAL
position. Chock the wheels.
2. Disconnect the battery cables as instructed.
See WARNING “To avoid unintentionally starting...” in
General Warning on page 1-2.
3. Disconnect the orange wire from the center post of the fuel level sending unit.
4. With a multimeter set to 2k ohms, place the red (+) probe of the multimeter on the center post of the send-
ing unit. Place the black (–) probe on the ground connection of the sending unit
(Figure 11-34,
Page 11-33)
.
5. The following resistance readings (in ohms) should be obtained depending on the position of the float
inside the fuel tank. The resistance reading will vary according to the exact position of the float. The chart
below may be used as a guideline to determine if the fuel level sending unit is operating correctly. Make
sure the float is at the surface of the fuel in the tank.
6. If the readings are within the specifications listed above, the fuel level sending unit is working properly.
If the readings are incorrect, the fuel level sending unit has failed and the fuel tank must be replaced.
See
Fuel Tank Removal on page 16-22.
7. If the readings are correct and the fuel gauge does not function correctly, check the continuity of the
orange wire from the fuel level sending unit to the fuel gauge/hour meter. Leave the battery disconnected
while checking continuity. Also check the continuity of the yellow wire from the fuel gauge/hour meter to
the key switch, and the black ground wires at the fuel level sending unit and at the fuel gauge/hour meter.
See Fuel Gauge/Hour Meter Removal, Section 13, Page 13-22.
8. If the readings are correct according to the position of the float, but give an incorrect reading on the fuel
gauge/hour meter, test the fuel gauge/hour meter.
See Test Procedure 26 – Fuel Gauge on
page 11-33.
FLOAT POSITION
RESISTANCE READING
FUEL GAUGE READINGS
Lower position (tank empty)
240 ± 20 ohms
Empty
Center position (tank half full)
120 ± 20 ohms
Half full
Upper position (tank full)
60 ± 20 ohms
Full
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