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914_fuel_sender_023.jpg
1011 viewsRemove the 10mm bolt from the rear, right side of the expansion tank. Note that in this picture the drain hose has been disconnected.
914_fuel_sender_024.jpg
899 viewsRemove the other 10mm bolt from the left side of the expansion tank.
914_fuel_sender_019.jpg
910 viewsRemove the gas expansion tank.
914_fuel_sender_018.jpg
920 viewsThe fuel sender exposed.
914_fuel_sender_016.jpg
906 viewsThe plug removed from the sending unit.
914_fuel_sender_014.jpg
865 viewsSender assembly easily comes out of the tank.
914_fuel_sender_013~0.jpg
998 views(This is a copy of the last picture but the disassembly is the opposite of the assembly :-) ) Unbend the tabs surrounding the retaining nut and remove the nut. Grab the top of the sender assembly and pull the tube away from the top. This will expose the float and wires.
914_fuel_sender_001.jpg
1018 viewsThe black float is at the top of the sender assembly.
914_fuel_sender_002.jpg
898 viewsThe float is at the bottom of the sender assembly.
914_fuel_sender_003.jpg
914 viewsThe bottom of the sender assembly.
914_fuel_sender_007.jpg
974 viewsBottom view of the float.
914_fuel_sender_008.jpg
860 viewsThe underside of the top of the sender assembly. The corrosion here wasn't as bad as the photo depicts.
914_fuel_sender_009.jpg
845 viewsClose-up of the float and how it holds on to the sending wire.
914_fuel_sender_010.jpg
950 viewsMake sure the notches line up when putting it back together.
914_fuel_sender_011.jpg
831 viewsThe tab fits into the hole at the bottom of the assembly tube.
914_fuel_sender_013.jpg
845 viewsSnug the nut down but don't over-tighten! Carefully bend the tabs back over the nut to keep it secure and from rotating. If that nut falls into the tank consider it gone and your outer tube will drop to the bottom of the tank and clunk around, possibly damaging the sender's wires!
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