Just recently, the top fuel bar (five bars in total) on the fuel meter of my 2004 DL650 seems to go out and then come back on, intermittently while riding in the first 120km (72 miles) of fuel. Seems ok on the lower bars (120km-450km).
Does anyone have any ideas or fixed such a problem?
Also, how does one fix/clean a fuel level sensor? Spray carby cleaner on it?
Is it possible to lower and raise the fuel float sensor while it is within the tank ....say with a peace of wire (maybe not a very safe thing to do)?
The story so far:
I refill my DL650 so the fuel was touching the bottom of the input neck. After about 60kms (36miles), I noticed that the top fuel bar had gone out. In the past, it goes out after around 120kms (~70miles). So I fill up the tank (about 2.5 litres) and the top bar still did not come on while riding 5 minutes to home. While riding more, the top (fifth) bar comes back on over ~10km of riding and then goes back out over 5km of riding. Noticed it has come on while riding over a few miles of rough road (makes me think either a loose wire or bad spots on the fuel level sensor's variable resistor). I have refilled the tank about 3 times, and each time it has had an inconsistent reading on the top fuel bar. One time, the fuel bar went off after about 30km (18 miles) from refilling.
After reaching about 120km (72 miles) on the tripmeter, the meter seems to be reading consistently (not up and down
With about 2 litres from a full tank but only showing 4 bars, measured the resistance on the fuel tank sensor/float as 4.7 ohms while bike was vertical and similar reading on the sidestand. On another week, did another reading when four bars were showing and with about 2 litres from a full tank. It showed 4.5ohms as expected. I put a ~5ohm resistor across the wires leading to the fuel meter and it showed 5 bars as expected. The Suzuki manual states the fuel level sensor reads 4ohms on a full tank and 6.5ohms when cutting out the top bar (after using about 4 litres).
I tested the fuel meter on the instrument panel by sticking five various resistors across it's two wires and it seems to show the right levels for each resistance valve (although the 7ohm resistor showed 5 bars rather than 4). So the fuel meter (instrument panel) sounds ok.
I stuck some fuel injector cleaner in the tank when I last refuelled, but still have an inconsistent top fuel bar.
Last night, I got home and the bike was showing 4 bars (after 50km), so I pulled off the fairing and disconnected the instrument panel. I checked all the wiring connectors from the fuel tank to the instrument panel were ok. Even reading 4.5 ohm at the wiring behind the instrument panel. Reconnected the instrument panel and it was reading 5 bars. I then put everything back together and put the bike upright and the it started reading only 4 bars. This morning, it read 4 bars when I rode to work (50km-80km on trip meter).
My last resort is to pull the fuel pump/level sensor out from the tank, clean it with carby cleaner (anyone got a better suggestion for cleaner?) and read the resistance valves while lifting the fuel float. I probably won't find any problems, put it back and find I still have the problem.
Just a couple of days before the fuel level problems started happening, I left the DL650 out in the rain to help clean all the dirt off it (we have water restrictions here). All the wire connectors look ok (no rusting).
The instrument panel was replaced under warrantee about 3,000kms ago due to a faulty speedo. This fixed the speedo problem, and the fuel meter seemed to be ok, until about 600kms ago. The bike has done about 17,000kms in total.
Normally I would put up with this problem, but I did this same with a sticking speedo needle, and it got progressively worse over time till it stopped working on occasions (same thing could happen with the fuel sensor or meter). Fix was to replace the instrument panel.
Dave M. (Australia)