Low fuel light flashing - Kawasaki Versys Forum
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post #1 of 3 (permalink) Old 05-16-2015, 07:59 AM Thread Starter
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Low fuel light flashing

My low fuel warning light has started flashing all the time. My mechanic friend said he tested the float in the tank and it is working properly. Any ideas on how to reset/repair this issue other than replacing the entire speedo/tach assembly?
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post #2 of 3 (permalink) Old 05-16-2015, 08:51 AM
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How was the float tested? You may want to check the fuel level sending unit's contact.

2007 Versys Repair Manual- 16-80 ELECTRICAL SYSTEM Switches and Sensors

Fuel Level Sensor Inspection

•Remove the fuel tank (see Fuel Tank Removal in the Fuel System (DFI) chapter).
Bolts [A]
Fuel Level Sensor [B]
•Check that the float moves up and down smoothly without binding. It should go down under its own weight. If the float does not move smoothly, replace the sensor.
Float in Full Position [A]
Float in Empty Position [B]
Float Arm Stoppers [C]
•Using the hand tester [A], measure the resistance across the terminals in the fuel level sensor lead connector [B].
Special Tools - Hand Tester: 57001-1394
If the tester readings are not as specified, or do not change smoothly according as the float moves up and down, replace the sensor.

Fuel Level Sensor Resistance
Standard: Full position [C]: 4 ∼ 10 Ω
Empty position: 90 ∼ 100 Ω

•Install a new gasket [A] on the fuel level sensor as shown.
Hollows [B]
Front [C]
•Apply a non-permanent locking agent to the threads of the level sensor bolts and tighten it.
Torque - Fuel Level Sensor Bolts: 6.9 Nm (0.70 kgfm, 61 inlb)

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post #3 of 3 (permalink) Old 05-16-2015, 10:30 AM Thread Starter
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THX, great video, as soon as I run out of gas Ill pull the sending unit and check for good numbers, maybe bend the arm some like the guy in the video.
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