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Discussion Starter #1
I'm told I have a fuel sensor malfunction, causing my MFD to have a constant blinking fuel pump icon and MFD showing LO FUEL, even when I have plenty of fuel. How do I change a fuel sensor or is this a service I should leave to a Vic service department? I am very mechanically inclined.
 

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I'm told I have a fuel sensor malfunction, causing my MFD to have a constant blinking fuel pump icon and MFD showing LO FUEL, even when I have plenty of fuel. How do I change a fuel sensor or is this a service I should leave to a Vic service department? I am very mechanically inclined.
Its not THAT bad.....I just did one on my 99 V92 the other day (although its slightly different). Ive also been apart of changing the fuel pump/sender on a 2003 TC....which would be the same.

Do you have a service manual? If you dont already get one - there is a list of downloadable PDF files here on the forum that will have the one you need. If you cant located it I have one, IM me your email address and I can get it to you.

Remove tank

Then when you flip it over there is a spring clip that holds a large plug in place - pull it out.

Then you need to pull that plug.....sometimes they come easy....sometimes they come hard. It pulls straight out - only held in with 2 orings.

The pump and sending unit come out of that hole.

I bought a used one on eBay for $25.

If you dont want to hassle with it but want to get rid of the blinking idiot light......if you unplug the sending unit wiring harness (under the tank, unbolt and lift up to see it) it will default to FULL all the time and the light will stay out.

This video will cover it for you.

 

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Aaron - thank you so very much. the video is a big help. Sure makes it plainer and I'm sure I can do this removal\replace myself. I do have a couple of questions:
(1. you said you were part of changing the fuel pump/sender....was that change-out just the "sender" apparatus or the whole fuel pump and sender unit?
(2. you said the fuel pump and sender unit come out of the same hole (and the video shows that)...and that you bought "one" on eBay for $25. The "one" you bought...was that just the sender or the fuel pump and sender unit?
My local Vic dealer quotes me $192.9 just for the sender unit. The fuel pump assembly costs $546.29 which includes several other parts that go with it. I just don't want to buy more than what I need.
I'm thinking I only need the sender unit since I have to fuel pressure or acceleration issues. If you would rather email me...its [email protected]. I don'e have a service manual, but I'll see if I can download one from the forum. Thanks again.
 

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Aaron - thank you so very much. the video is a big help. Sure makes it plainer and I'm sure I can do this removal\replace myself. I do have a couple of questions:
(1. you said you were part of changing the fuel pump/sender....was that change-out just the "sender" apparatus or the whole fuel pump and sender unit?
(2. you said the fuel pump and sender unit come out of the same hole (and the video shows that)...and that you bought "one" on eBay for $25. The "one" you bought...was that just the sender or the fuel pump and sender unit?
My local Vic dealer quotes me $192.9 just for the sender unit. The fuel pump assembly costs $546.29 which includes several other parts that go with it. I just don't want to buy more than what I need.
I'm thinking I only need the sender unit since I have to fuel pressure or acceleration issues. If you would rather email me...its [email protected]. I don'e have a service manual, but I'll see if I can download one from the forum. Thanks again.
1

On my V92 (1999 model) they used an external fuel pump. My gauge was stuck on full.....so I swapped out the sending unit only. The pump is under the seat, behind the shock.....the tank is entirely different and doesnt have the same plug setup yours has (like in the video). So you have two separate items....pump external, sending unit internal.

On my uncles V92 (2003 V92TC) his IS like the tank in the video and just like yours. His sending unit was fine but his fuel pump was bad (it would start and run for a second and die.....VERY low fuel pressure when measured at the rail). He pulled the plug....yanked the sending unit out (its actually part of the plug, mounted on the back of it.....the reason you dont see it in the video is because thats the tank off a vegas or kingpin....and they dont have fuel gauges so there is no sending unit) and then the pump. He had Rylan Voss at The Vic Shop rebuild the pump and then he put it back together (old sending unit, old pump but newly rebuilt). They are two separate units that work completely independent of each other. So in closing we changed only the pump (well....had it rebuilt).

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I bought just the sender. They are two separate pieces entirely and thats the same throughout the model years, rather its an early V92 with external pump or newer V92 with internal pump. They set in different places in the tank, have different wiring harnesses.....two different parts entirely.

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I would think you just need the sender.....and I wouldnt be afraid of a used one of eBay if you want to save some money. After 2002 when they went to internal fuel pumps all the sending units are the same - I just looked it up.....same part number from 2002 thru 2005. The sending unit is actually mounted on the back side of that large "plug".

Now remember....when you take that plug out there are 2 large orings......your going to want to replace those. If you buy a used sending unit on eBay.....make sure you source those orings from somewhere.....dealer, online etc. They shouldnt be hard to find.....its the same oring that they still use on the Cross Country and newer bikes.....they have used them on near everything.
 
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