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post #1 of 6 (permalink) Old 07-28-2019, 08:10 AM Thread Starter
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Fuel Gauge Blinking - Workshop manual tests passed

My Rincon 650 2005 model, its fuel gauge, all the bars keep blinking. It works sometimes, mainly when the tank is nearly full to full, but even then not always.

I have the workshop manual and followed the test procedures with a multimeter. All the tests passed, Ie: it blinks when I jump the 2 connector pins of the dash (combination meter) together and when I turn the ignition on with the connector disconnected.

I also, removed the fuel level sensor/float assembly from the fuel tank and checked the resistance, all checked out ok, when I move the float by hand the resistance values change and match the figures given in the manual. full 5-7 ohms and empty 204-210 ohms. Also, the "RES" flashed on my dash when I manually put the float to empty. However, I never see "Res" when the fuel sensor is in the tank so I'm thinking the float is somehow getting stuck or impeded within the tank somehow but would that cause the gauge to blink or just cause the level to read wrong but at constant point of like 4 bars for example??

So it seems to be intermittent, but more often than not the fuel gauge bars are just blinking at me. The connector seems clean and in good condition. Could the sensor itself be dying and working intermittently or what;s the most likely cause here?

Appreciate some pointers on my next troubleshooting steps to take.
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post #2 of 6 (permalink) Old 07-28-2019, 08:55 AM
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If you look close at the sliders (attached to the float base) 4 little fingers move up and down on those blocks on the PCB) in the back ground, you will probably find a bent slider or one missing like in my photo (from wear) and possible a small crack in the base or where they attach to the base of the float. The float portion is most likely worn out. You can also go back to the connector and make sure it is dry and clean too.

https://www.hondapartshouse.com/oemp.../fuel-unit-set
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Last edited by Oilcan; 07-28-2019 at 08:59 AM.
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post #3 of 6 (permalink) Old 08-03-2019, 05:07 PM Thread Starter
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Hey OilCan, cheers for the suggestion, I just removed it again and checked them little fingers, they are all present and I bent them out a little bit but I think they were fine, I can see them contacting the solder strips on the Pcb when back together. The solder strips all look good on the Pcb itself too, I checked them with my multimeter for continuity and the strips all work ok.

I checked the fuel sender again when I had it out, with the sender out of the tank but connected to the loom when I move the float by hand the dash display doesn't respond immediately, takes about a minute delay for it to move and then it only moves 1 bar at a time. For example, say the gauge reads full and I move the float to empty, the dash display moves 1 bar at a time at about 1 minute timings until it finally gets to display reserve on the dash. Theres 6 bars in total on the display, so it take 5 mins for my display to go from full to reserve when I do this. Is this normal, I'm guessing this delay is normal so the gauge doesn't flash a different reading every 5 secs if your going over bumps or hills where the fuel float might move position momentarily.

Also, if I turn the ignition off during the time when the gauge is making its way from full to reserve, and say its at bar no.3 in the middle before I turn it off, when I turn it back on it correctly reads the reserve position instantly. I assume this is all normal.

The only other thing I noticed which might indicate a problem is when moving the float by hand it seems to go from 202 full to 126 with little movement, it's hard to get a reading of like 180 / 160 / 140 by hand,,, it seems very keen to do a big jump from 202 to 126, perhaps the pcb / fingers are worn a little causing a sort of skipping effect?

I think I'll just chance fitting a new sender assembly, does the float / pcb / sender / loom piece all come as a complete assembly?
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post #4 of 6 (permalink) Old 08-03-2019, 08:58 PM Thread Starter
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Actually, when I look at the pic I took of the Pcb when I had it apart, some of the contact strips looks a more faded colour to other parts of it, maybe it can't read the faded parts as good, it still had continuity though on them parts,,, I think i'll just replace it anyway and go from there.
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post #5 of 6 (permalink) Old 08-04-2019, 08:04 AM
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The slow reaction from the sender is as you guessed. The fuel float ass'y was as a complete unit. 30FUEL UNIT SET
PN: 37080-HN8-000 $37.08

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post #6 of 6 (permalink) Old Yesterday, 04:26 PM Thread Starter
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A new fuel assembly fixed it, cheers for the help OIlcan. Can't believe I lived with it for so long, ha.
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