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How to fix low-fuel light? (FE570)

Joined Jul 2010
239 Posts | 1+
London, England
First time out on a brand new bike and I run out of fuel because the warning light didn't come on.

There doesn' seem to be much to it - sensor in the back of the tank; connector about 6 inches away; loom; warning lamp.

The bulb is OK and I oiked the tank out last night to look at the sensor. Electrically, what is it supposed to do? Is it just a switch?

Any ideas for fault-finding?

Greg
 
According to the wiring diagram it's a variable resistor. I don't know for sure on the 'Bergs but on many bikes it's a thermistor, i.e. a resistor whose resistance varies according to temperature and it works because the fuel keeps it cooler until the level gets too low and the thermistor is uncovered, at which point it warms up slightly, and the resulting change in resistance is enough to trigger the light.

Having said that, there is a specific symbol for a thermistor and that's not what's shown on the wiring diagram, it just shows a simple variable resistor which would require movement to make it change it's value so maybe this one works on some kind of float or by measuring resistance through the fuel. Actually, given the reports of boiling fuel you'd wonder whether a thermistor wouldn't end up bringing the light on even when there *is* plenty of fuel left!

Either way, its resistance should drop when the fuel falls below the sensor but I have no idea what the values should be before or after. Maybe someone has had this problem before and taken measurements?

First check the indicator bulb's ok, and that it hasn't pulled back out of the mounting tube and is lit but hanging down behind the speedo unit out of sight! Then you could check that you have 12V on pin 1 of the sensor plug (brown-orange) and 0v on pin 2 (brown). Pin 1 comes through the indicator light so it might be dropping a little voltage if some current is drawn through the bulb which would mean it could be less than 12V, but if the bulb's not lit it shouldn't be dropping much. Pin 2 goes to earth so it should definitely be 0V. You'd want to check these with the plug connected to the sensor if you can. If you can only check with it disconnected it won't tell you as much but I'd then expect the full 12V on pin 1 as there should be no voltage drop across the bulb, and you could do a resistance check from pin 2 to the chassis which should be essentially 0 Ohms.

If you can't see any problems with the wiring and the indicator bulb looks ok, maybe your dealer can get you another sensor so you can try swapping it over?
 
Thanks Pete - very helpful.

(Note to myself: buy w/shop manual CD and wiring diagram!)

Greg
 
Dude same $hit happened to me first ride, it was pi$$ing down rain and cold as a grave diggers was roosting alon g (blaaaaaaaaaaaaart rorrrrrrrrrrrrrrrrrrrrt blaaaaaaaaaaaaaaaaat ) and then it conked out. There are two ways the sensor can be installed to give higher and lower low fuel readings. I think petem cold be onto something with the thermistor I'd imagine it would be freaking cold where you ride, the day mine ran out we had just started up after smoko.
 
berglsmerg said:
Dude same $hit happened to me first ride, it was pi$$ing down rain and cold as a grave diggers was roosting alon g (blaaaaaaaaaaaaart rorrrrrrrrrrrrrrrrrrrrt blaaaaaaaaaaaaaaaaat ) and then it conked out. There are two ways the sensor can be installed to give higher and lower low fuel readings. I think petem cold be onto something with the thermistor I'd imagine it would be freaking cold where you ride, the day mine ran out we had just started up after smoko.
Luckily, my mate had plenty in his 450EXC - so I just swigged the dregs of my Coke bottle; rinsed it out with a bit of petrol and then poured 500ml into my 'Berg. The nearest gas station was only about a mile away.

Greg
 
petem said:
First check the indicator bulb's ok, and that it hasn't pulled back out of the mounting tube and is lit but hanging down behind the speedo unit out of sight! Then you could check that you have 12V on pin 1 of the sensor plug (brown-orange) and 0v on pin 2 (brown). Pin 1 comes through the indicator light so it might be dropping a little voltage if some current is drawn through the bulb which would mean it could be less than 12V, but if the bulb's not lit it shouldn't be dropping much. Pin 2 goes to earth so it should definitely be 0V. You'd want to check these with the plug connected to the sensor if you can. If you can only check with it disconnected it won't tell you as much but I'd then expect the full 12V on pin 1 as there should be no voltage drop across the bulb, and you could do a resistance check from pin 2 to the chassis which should be essentially 0 Ohms.
The bulb is good and I have 12v on the bulb socket. I'll try getting to the connector behind the tank without taking the bike apart as the engine has to be running to make the checks!

Greg
 
I agree with Petem, the little sensor in the Fuel tank looks like a variable resistor. You can check it by doing this:
Engine switched off.
Unplug the low fuel light bulb.
With your multimeter set to Resistance, connect the black lead to the frame or anything metal like the fork bolt.
The Red lead of your multimeter connect to the Black/Red wire in the light bulb socket.

My tank had quite a bit of fuel in it and I measured 1,312 Ohms. When I siphoned as much petrol out of the tank as I could the resistance dropped to 1,256 Ohms. I could not get all the petrol out of the back part of the tank to make the resistance fall even further.

I measured the resistance of the light bulb too while I had it out. 6.2 Ohms.

Double check you have not put the bulb in 90 degrees out. The little wires on the globe need to contact with the plug connectors.

As you tested there should be +12V on the Blue/Yellow wire in the globe plug but only when you hit the started or the engine is running.

The Black/Red Wire is marked Black/Red in the repair manual but appears to be Brown/Red on my bike.

Low+Fuel+Light.jpg
 
It's all taken a turn for the worse!

The wiring loom has gone up in smoke! It's now at the dealers and I'm claiming on my 30-day warranty!

I'll bet my bottom dollar that the fuel light problem was symptomatic of a loom fault.

:(

Greg

PS the bike is supposed to go to Spain next Sunday for a week of trail riding! What chance now?
 
The dealer reports that they have found the loom to be chafing the frame under the tank causing a short circuit. A new loom is now on its way from Austria.

Hats off to The KTM Centre in Hemel who assure me that my bike will be fixed in time for shipping to Spain this weekend!

Greg
 
A big 'up' to The KTM Centre in Hemel Hempstead who have now got my bike fixed in record time!

:cheers: :cheers: :cheers:

Greg
 
I had that problem on my 450FX. It kept blowing fuses. I found the wiring loom was rubbing on the engine case on a bolt boss under the tank area. I pulled the loom over to the frame with some wire ties to prevent any further chaffing.
 
GregUK said:
A big 'up' to The KTM Centre in Hemel Hempstead who have now got my bike fixed in record time!

:cheers: :cheers: :cheers:

Greg


Nice one Greg, have a great trip :cheers:
 
EddieFE said:
Nice one Greg, have a great trip :cheers:
I was so desperate at the beginning of the week, I almost had to go and buy my old bike back!!

8)
 
GregUK said:
EddieFE said:
Nice one Greg, have a great trip :cheers:
I was so desperate at the beginning of the week, I almost had to go and buy my old bike back!!

8)



Yes, I wonder where the old DRZ is now :lol:

Glad you got it sorted.
PS.
The 450 starts and goes like a good un. :wink:
 
EddieFE said:
Glad you got it sorted.

The FE570 is now back in pristine condition and is tucked up in my garage. What's more the fuel light now works too!

I saw the old wiring loom this morning - what a mess!

Greg
 
Any chance of some pic's of where the loom was damaged?
I'm just about to buy one and I'd like to check it before I ride it.
 
I wasn't able to get pictures of my burnt out loom as the repair was done by the dealer. I understand, however, that the rubbing was somewhere under the tank.

The dealer commented that before fitting the new loom they checked the routing of the loom against other bike(s) on the in the showroom and that mine had been different. The issue may, therefore, be limited to just a few bikes incorrectly assembled in the factory.

Greg
 
Mine didn't work today...in fact, it was my first ride with my brand new FE570S. It (low fuel light) didn't came on and strange thing...my bike ran out of gas with almost 3 liters still in the tank. Wonder what's the problem???
 

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