1997 GTX fuel low

[johngtx]

Hi all
I am have an issue with my ski and looking for suggestions.
I have only taken the ski out three times and 2 of those times I had a seemingly random fuel low warning.first time I rushed back to the shore to check fuel level.it was still half. So I thought maybe the float got stuck so went back out hit my own wake a couple time to loosen it.seems to have helped something as it then works as normal. Same story the next time except I didn't bother to visually check fuel level and just carried on riding and a couple minutes later it comes back to life. Any ideas as to the cause? Electrical or mechanical?

 

[Dr Honda]

Chances are... the float is starting to die. The old floats will eventually sink.

 

[johngtx]

Its a white plastic float if that helps. Would it sink and then float back up to normal?it fell out the baffle when I was cleaning everything out.and the one magnet popped out.found the magnet against the freezer.lol.I then just popped it back in it's slot.... also in my manual it says something about aligning the arrow on the baffle with the tank.I had no arrow but put it back the same way I found it...what's that all about?perhaps that was for a different model?

 

[kicker]

Normally the white floats dont sink. If you had a loose magnet there is a good chance that might be your problem and not giving you a correct reading.
I would inspect the the wires and connections first to see if there is any obvious issues there. It might be the gauge, test it by pulling the connection apart that feeds the baffle and short out the connection, your gauge should read full.

If its not the wires or the gauge, then proceed with pulling the baffle and inspecting the float. With the baffle out you can test it with a meter to check resistance. If your getting proper resistance throughout the baffle its more then likely a wire somewhere.

When you pull the baffle put a mark on the tank and one on the baffle so when you put it back in the fuel lines and wiring will line up properly.

 

[Minnetonka4me]

Is the level dropping on the gauge, or is it just blinking low fuel?

I have always glued the magnet back in flush with the foam. Maybe you pushed in in...?

 

[johngtx]

thanks for the suggestions guys.
it will go from a seemingly correct reading to low and i get the low fuel warning.so it reads empty and warns low fuel.
a few minutes later it returns to normal.the float is a white plastic with two magnets in separate recesses.the magnet that fell out just clipped back in.one thing i did notice is the circuit board with the little glass tubes could move towards and away from the float rails if that makes sense.is this normal or maybe its moving to far from the magnet to activate the glass switches? the second time i went out it was fine on the water but once i put it on the trailer and started it on the ramp to blow out the water it showed low,i shut it down drove home and when i flushed it was back to normal....so is the instruction to mark the baffle and place it back the same way purely for reconnecting the lines in the same place or is there design implications?

 

[kicker]

To me it sounds like a bad wire or connection, this is what I would do.


1) disconnect the wire from the baffle, take the end that goes to the mpem and with a piece of wire short out the 2 wires. Hit the start button without the key in. If working properly you should get a "full" reading on the gauge. Because there might be a bad connection, move the wires around to see if the reading on the gauge changes. If you have a broken reading or no reading on the gauge the problem is in the wires to the gauges or a faulty gauge. make sure your connections are solid and clean, no rust or gunk in them.

2)If 1 does not come to a conclusion, pull the baffle out and check the magnets, make sure they are secure in the right place.

3) if magnets were in the correct position put meter on baffle wires and check resistance while sliding the float up and down the baffle, the range should be from about 30 to 80, if memory serves me correct. If the readings are not changing or your not getting a reading the problem will be within the baffle.

How the baffle goes back in will not affect on how the gauge works.

The circuit board does jiggle around a little inside the baffle, it is not a tight fit. The magnets do not have to be that close in order to get a reading.

Try that and let us know what it does.

 

[johngtx]

thanks man will do.

 

[Minnetonka4me]

Good point kicker....it screams bad LCD to me. I had a GSI blinking low oil all the time and the sensor and wiring were fine. I hooked up a different gauge and it didnt have the issue.

Bridging the wires will tell you whats up.

Did you shake the float? You can usually hear it. If Im not positive I will put gas in a cup and toss it in. Kinda sounds like a float that barely floats.

 

[kicker]

Minnetonka, I have not heard of the new style white floats sinking, but there is always a first time i guess, you come across a lot more skis then I do, you would know better. I ruled out the internal baffle fuse cause it works intermittently.

Johngtx, does both the "low fuel" light come on and the digital gauge read empty or is it just one of the 2?

 

[Minnetonka4me]

Oh Ive def seen those with gas in them...too many as a matter of fact.

One more question....does it do it no matter where the fuel level is or only if its say half full?

If thats the case there prob a bad spot in the sensor.

 

[johngtx]

Yes the gauge shows low and warning blinks low fuel.the float was definitely dry when I had it out but I did drop it... I think I must pull the baffle and see if all the levels work.

 

[kicker]

Dont pull the baffle until you check the wires from the baffle to the mpem and gauge, its just easier to rule that out first. I know its probably not that hard on the GTX to pull the baffle out but no sense doing until you know there are no bad wire or connections.

I know on my GSX, I will avoid pulling the baffle like a plague, its a real PITA.

 

[johngtx]

OK will do.its really easy on this model.remove fuel lines and it comes right out threw the glove box.I suppose easiest way to check if its a faulty wire is turn it on and wiggle the wires around?

 

[kicker]

do you have an ohm meter/tester that you can use to test the resistance?

 

[johngtx]

Nope not anymore I have owned two but the seem to get legs and disappear.but I will go buy one tomorrow.I just tried now the wiggling technique and nothing happened still reading half.it was showing low fuel when I parked it last but yesterday I was trying to figure out how I was going to access the underside of the hull to repair the worn down Gelcoat and in the process of pulling it off the trailer and then putting it back it fixed itself again...

 

[kicker]

See if you can borrow one, you will need it to test the baffle as well. For starters you can pull the connection apart coming from the baffle. Then take the end that goes to the gauges and short it out with a small piece of wire. Hit the start stop button check the gauge, you should get a "full" reading on the gauge.

 

[johngtx]

So I am assuming that I need to wait for it to stop working again to do this test?

 

[Minnetonka4me]

No...you are bypassing the sensor. Basically you will be testing your wiring and gauge with that test.

 

[johngtx]

OK so I shorted it get full gauge reading.if just disconnected I get zero gauge and no low fuel warning.is the low fuel warning a seperate sensor from the level reading?when I reconnect is goes back to half reading.the tank visually looks half so I think it is reading true when it is working...when tank was full it read full...but I am still not following the point in testing the gauge when it is working.surely the test would be more conclusive when its giving me the low fuel?or am I missing something.lol
Thanks for the help guys!

 

[kicker]

I agree Johngtx, the whole process is easier to trouble shoot when it is not working. You can do the same test again when it is not working properly and that will tell you if it is the wiring going to the gauge.

The next thing I would do is pull the baffle and inspect and test the float again.
Take the float out and put it in a cup of fuel, and see if it floats properly in fuel, don't use water, it wont give you the same results. Also make sure the magnets are in place properly and secure. Run an ohm test as in Post 7 item #3.

If the above all checks out OK I would conclude its in your wiring somewhere.