Fuel sending removal on a 96 SPX

[68ragtop]

Fuel sending removal on a 96 GSX

Hi Guys, I am hoping the fuel tank doesn't need to be removed to pull the sending unit, but it is starting to look that way.
I removed the unit from my 92XP a while back, & that one had a plastic sleeve that the unit & fuel pickups slid down into. Very easy to take out. However, on this 96, It appears there is no separate sleeve & its all in one making it very long. If this is the case, I need about 4 more inches of clearance to pull it out of the top of the tank. Not sure this part of the rebuild is going to be worthwhile.

Thoughts?

 

[ocod]

Have you tried un strapping gas tank and moving it forward to get clearance through storage bin?

 

[LouDoo]

Yep, Oscar is correct, you need to unhook everything including the two rubber straps and the oil tank, move the tank forward and you should be able to remove the fuel baffle without removing the fuel tank.

Lou

 

[68ragtop]

Yes, in fact that's what it says to do in the service manual too, However the hull gets too narrow to pull it further ahead than a foot or so. Also tried tipping the tank on an angle. There is just not enough clearance under there & its a very deep tank. My guess is the tank has to come completely out, however I am not so sure I want to pull the engine to do it.

 

[68ragtop]

The service manual shows the pickup/sender along side the fill inlet. If that was the case, it would work. However, this one has the sender way back, almost directly under the fuel shut off switch.

I'll see if I can post a picture, But I am not feeling too optimistic at the moment.

 

[68ragtop]

I Got it!
I removed the ECU & that gave me a few more inches. Then tipped it forward. I just squeaked out. Thank for the positive thoughts on moving it further forward.

Thanks ocod & Lou Nice to have you guys in my back pocket

 

[LouDoo]

Hmmm...., I wonder if someone replaced the gas tank with one from an early GTI or GTX... How much fuel does the tank hold? If that's the case you could have a problem.

Lou

 

[LouDoo]

Great, I guess you can ignore my last post.

Lou

 

[kicker]

would it be the same procedure for a 96 GSX, or do you need to go through the steering assembly hole. Gonna do mine next week.

 

[68ragtop]

Thanks Lou, I guess its one of those deals. Hadn't done one in this model before, So I got caught being negative when it didn't go like I expected.

Funny thing is, I pulled the float & the magnets are intact & it works the gauge fine now. Go figure. I never checked the continuity before pulling it, so I am not sure if the problem was in the sender, or on the ski side of the wiring. I was in the middle of ripping out all the tempo lines & figured I would pull it seeing I have it that far apart. At least I got to blow out the pickup tubes & the screen. So I'll just pretend thats why I went through the trouble....

Who knows? Maybe the thing was working. It had the fuel light on, but it had between 1/4 - 1/3 tank of fuel that I could see visually.
I guess I'll find out when I get it back together.

 

[68ragtop]

would it be the same procedure for a 96 GSX, or do you need to go through the steering assembly hole. Gonna do mine next week.

Funny you say that, I was looking at removing the steering assembly, but that looked like a PITA too. Sliding it forward just barely worked, but I had to get the MPEM box out of the way, & tip it up as high as I could from the engine side.

 

[LouDoo]

I've never done a GSX, I did my 96GTI and a 96XP and they both slid forward far enough to clear the fuel baffle. Actually there's a little more room in the GSX so it's probably the same procedure.

Actually the 96GTI I was able to do without moving the gas tank, so you might get lucky with the 96GSX also.

Lou

 

[68ragtop]

I am not sure why I said SPX in my title, I keep calling it that....... The ski I have been working about is a 96 GSX

Sorry for the misleading info.... Anyway, Tank is back together, & just for the record, It does read empty with the tank 1/4 full, but appears to be working fine. So, I didn't need to pull it apart after all.

 

[LouDoo]

1/4 tank reading empty sounds about right. To avoid confusion in the future why not list your ski(s) in your profile?

Lou

 

[ocod]

1/4 tank reading empty sounds about right. To avoid confusion in the future why not list your ski(s) in your profile?

Lou

I am not sure why I said SPX in my title, I keep calling it that....... The ski I have been working about is a 96 GSX

Sorry for the misleading info.... Anyway, Tank is back together, & just for the record, It does read empty with the tank 1/4 full, but appears to be working fine. So, I didn't need to pull it apart after all.

We still need a picture to be sure.



Lou may even help you get a sponsor girl to spice up the photo.

 

[kicker]

Ok, you did confuse me, I said I would start next week but decided to get right at it. I've got the tank pulled up towards the front of the ski as far as possible. Moved the MPEM out of the way, disconnected the oil tank and all electrical.
It was stated that the ECU was removed, Im not sure what that is. If it is the fuel selector valve that makes sense because I keep pulling the up and hitting the bottom of that valve.

At this point I cant tell how much more clearance I need to get it out, if pulling the fuel selector valve out will be enough that's great.

The other thing that confuses me a bit is that you said that you had to tip it up as high as I could from the engine side. Is that not reversed? I have been trying to lift it up as high as i can from the front of the ski.

 

[68ragtop]

Kicker, what I did was detached the electrical box on the front port side & left it loose, but out of the way, then slid the tank as far to the front of the ski as possible, it will go past where the electrical box was clipped in place. It will take a good push. Once its up as far as it will go, I then lifted the rear of the tank so it was tipped until I could pull the sending unit out from the storage box opening at an angle. It was a very tight fit. My fuel selector was already out becasue I was replacing all the fuel lines, but I don't that would have been in the way, but its possible.

Glad we could share the same misery on the same day....

 

[kicker]

Understood, I didnt realize/catch that you were bringing it through the storage hole. I have been trying to tilt the tank in such a way that I could take it out on an angle under the console area. Thats not working, I keep coming up short a few inches. I will do it your way.

 

[WhiskeyD]

On the 96 SPX/XP the baffle and even the entire tank are pretty easy to remove since the tank is so small. I believe a GSX has a larger tank so thats probably why you ran into problems.

 

[68ragtop]

Understood, I didnt realize/catch that you were bringing it through the storage hole. I have been trying to tilt the tank in such a way that I could take it out on an angle under the console area. Thats not working, I keep coming up short a few inches. I will do it your way.

Thats exactly where I was at. Needed another 4 inches under there. Lou & ocod got me thinking in the right direction. It will go out the front, but you will have no extra room whatsoever.

I would like to get mine back together tonight, but I am waiting on my order of Oetiker clamps. Hopefully tomorrow night.

 

[ocod]

...........................

Browser hadn't refreshed to see replies to kickers q.

My info was too late

 

[kicker]

Nicely done guys, thanks for the help. Out the front storage compartment it came, but wow it was tight. Checked it with an ohm meter and I'm getting readings through out the length of the baffle from 90 to 7. Problem is the float sinks like a stone, had to fish it out of the tank with one of those magnetic bendy stick things.
Correct me if I'm wrong but If I'm getting an ohm reading throughout, then the fuse is not blown.

 

[ocod]

Nicely done guys, thanks for the help. Out the front storage compartment it came, but wow it was tight. Checked it with an ohm meter and I'm getting readings through out the length of the baffle from 90 to 7. Problem is the float sinks like a stone, had to fish it out of the tank with one of those magnetic bendy stick things.
Correct me if I'm wrong but If I'm getting an ohm reading throughout, then the fuse is not blown.

Hip Hip Hooray

:grouphug:

 

[LouDoo]

Chances are you only need a new float, which is the problem at least 90% of the time, personally I have not had one where it wasn't the float. Replace it with the newer molded type.

Lou

 

[68ragtop]

I didn't realize the floats had problems "floating" Maybe this one is still bad. Never checked to see if it floated, I just checked the magnets & resistance. Not sure what style mine has, its dark in color, nearly black, & had what appeared to be 4 magnets embedded in it. Should have taken a picture......