Gregory Bender

Fuel level sensor repair

Moto Guzzi V7 Sport, 750 S, 750 S3, 850 T, 850 T3, 850 T3 California, V1000 I-Convert, V1000 G5, 1000 SP, Le Mans, Le Mans II, Le Mans CX 100, Le Mans 1000, 1000 SP III, 1000 S, California II, California III, California 1100, California Jackal, California EV, California EV Touring, California Aluminium, California Titanium, California Special, California Special Sport, California Stone-Metal, California Stone-Touring, California Classic, California Touring, and California Vintage models

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Faced with a leaky float inside the gas gauge/fuel level sensor (MG# 18103050) on my Moto Guzzi I-Convert, I decided to attempt a repair. Had I had some extra fuel tank liner (such as POR-15) on hand, I would have attempted to paint the exterior of the float. Instead, I purchased some closed cell nylon foam (McMaster-Carr part number 3623K61) and then modified the float to accept the foam. This foam is supposed to be fuel and oil resistant, so hopefully it will hold up to gasoline inside the gas tank. Time will tell...

The fuel level sensor float (MG# 18103050) and foam (McMaster-Carr part number 3623K61).
The fuel level sensor float (MG# 18103050) and foam (McMaster-Carr part number 3623K61).

Photo courtesy of Gregory Bender.

I made a hole in the float using a drill and my Dremel tool. I left a lip all around the OD for strength and so that the foam would be physically held in place.
I made a hole in the float using a drill and my Dremel tool. I left a lip all around the OD for strength and so that the foam would be physically held in place.

Photo courtesy of Gregory Bender.

To insert the foam, I rolled it very tightly at a severe angle. Doing so kept the OD small enough that I could insert it within the hole I made. With the OD of the roll inside, I used a tweezer to push the rest inside.
To insert the foam, I rolled it very tightly at a severe angle. Doing so kept the OD small enough that I could insert it within the hole I made. With the OD of the roll inside, I used a tweezer to push the rest inside.

Photo courtesy of Gregory Bender.

I drilled a couple of holes in the bottom of the float to prevent gasoline from filling the float.
I drilled a couple of holes in the bottom of the float to prevent gasoline from filling the float.

Photo courtesy of Gregory Bender.