Fuel warning light sender unit repair. Curvy.
 

Just out of interest, I had to strip the fuel tank on my SV650SY to line it as it was a bit rusty. I wondered what the rattle in the tank was, and thought it might have been rust deposits (not a missing diamond earring, as the girl I bought it off suggested..ahem!). When I took the sender unit out, after much jiggling and fiddling, I found that one of the electronic components had come adrift from the bracket. Easy fix, it's just soldered on to the bracket. I've posted a pic as there isnt a photo in the Haynes manual.

By the way, you can't get the O ring seal separately from Suzuki, it comes with a new sender unit, so you'll need to pick one up elsewhere if you do this job. I made one using an O ring kit we just happened to have in work.

Hope this helps someone. :)

Re: Fuel warning light sender unit
 

I also did that but then very shortly after took my bike off the road and haven't been able to test it yet. The second stage fuel light was not working on my bike. Do you now have a second stage on you fuel light? That didnt work before?

Re: Fuel warning light sender unit
 

Looks to me like it it's the first stage sensor that has been re-attached.

Re: Fuel warning light sender unit
 

Unfortunately, I've done the same thing, have started stripping the bike to do some mods to turn it into a track day bike, so I don't know whether it has worked yet. The component that had come loose on mine was the lower one, is the one deeper inside the tank. I did use to get a flashing warning light when I was low on fuel. I took the tank off at this point to do the lining, so don't know what happened next. I'll post on here when I get it running again.

Re: Fuel warning light sender unit repair. Curvy.
 

Ah good to know, I have a rattly tank and have never found the cause, also my second stage fuel light does not work!

Will have to have a look me thinks

Re: Fuel warning light sender unit repair. Curvy.
 

Sounds like we all three had the same issue although i never noticed the rattle until i had the tank off. I looked into it because it would be nice to get the second warning. I've run out three times i think really pushing it looking for petrol.

Re: Fuel warning light sender unit repair. Curvy.
 

Mine ratlles when put on n off the side stand. Only run out of fuel once, couple of years back now but was only a few hundred yards from home.

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Re: Fuel warning light sender unit repair. Curvy.
 

first time I was waiting for it to come on when I just had the bike, nice 2 mile push uphill. second was finding out sustained high speed reduces tank range to 20 miles less than normal spirited riding. third was just being a cheap student. I really hope I have fixed the sensor!