Technical Info Page

Doc explains adjusting the FJ fuel gauge

One of the problems Ive notice over the many
years is the fuel gauge on the Fudge is not accurate. It seems to be consistent but you are never
sure exactly how much fuel is left.
What should happen is the reserve light should
come on when 4 litres is left. If you fill up at this
point the FJ1200 should take 18 litres and the
FJ1100 20ltrs. In the real world this is not the case,
in fact my FJ1100 light would come on after using
only 15 litres. This means that there is another 9
litres left but the question is how long are you prepared to risk driving with the red light on?. So to
take the worry out I have adjusted the gauge so
that the needle points to the E mark with 4 litres
left.

Sender unit hidden under reflective sheeting

To complete this task you will need to drain the fuel

from the tank, please let it drain naturally as there
will always be some left in the tank. The FJ1100
has a Prime switch on the tap to allow it to be
drained. The 1TX tap is vacuum operated so you
will need to suck on the small pipe so the tap thinks
the engine is running (right pain). The 3CV and
3XW model have a tap which is always on, so simply disconnect the fuel pipe to the fuel pump (located behind the right hand side panel).
Once your happy that the tank is empty, using a
measuring jug, fill up with 4 litres. Reconnect the
tank and turn the ignition on (but put kill switch to
protect the coils from over heating). Let the gauge
settle for a few minutes. Your goal is to get the needle to sit on the E mark so if it needs adjusting you
will need to remove the fuel sender unit, this is very
easy.
Remove tank from bike. Tip up the tank so you can
gain access to the unit that sits underneath the

tank under the reflective

covering (this will need to
be pulled back to access
the unit), the fuel will sit
at the bottom of the tank so no need to empty again.
Remove the unit via four 8mm headed bolts. It is a
little tricky getting the sender unit out through the
small hole but it will come with a bit of manoeuvring.
Once removed, the long wire arm that has the float
on it, will need to be bent, so adjust the height of the
float for the given amount of fuel, in our case 4ltrs.
As a rule, bend arm up to allow the gauge needle to
drop.
Refit unit, note that there is a rubber gasket so it will
reseal without the aid of any sealant etc.. Refit tank
and turn ignition on to check gauge. Repeat adjustment until needle reads E.
Out
of
interest
after
I
completed
this task I
checked
the
total
amount of
fuel
that
can be fitted into the
FJ1100
tank.
I
noticed
Becareful not to damage unit when removing that
I
c o u l d
only get 23ltrs until it reached the top of the filler
tube (FJ1100 officially holds 24.5 litre and FJ1200
22ltrs). I then managed to squeeze in another litre
but it took me several minutes to achieve this which
would be unacceptable at a forecourt.

Metal arm needs to be bent to adjust float height