Low fuel light

[cushman eagle]

My low fuel light does not seem to be working this year
It does come on when I start the bike,but no longer comes on with a low fuel situation.
When it used to come on, it would hold about 4.9 gallons,but I have put in 5.3-5.5 this year,and it has not come on.
What tests can I make to find the problem?

[Mr Jensee]

Cushman I looked it up in the service manual and it says if the float does not go down on it's own in the fuel tank it is time to replace the sensor. You might check the wiring going to the sensor for pinching and fraying but if the wiring is fine the ohm meter shows a good connection it is probably time to replace.

[cushman eagle]

Mr.Jensee,I am glad you are still active on the forum.The gauge still works fine,it is the low fuel light that does not work.
Looking through the schematic in my service manual,I think the gauge uses 2 of the three wires,and the light 1 of them.
It looks like the light uses a sensor separate from the float.

[Highway Rider]

The float and the low fuel light sensor are 2 separate things on the same assemble. So yes you can have the fuel gauge work but the low fuel light won't work. Mine was doing the same thing and I replaced the float assembly in the tank and that cured the issue. Easy fix. The assembly cost around $80 when I did mine and that was from a Kawasaki dealer. I installed it myself

[cushman eagle]

The float and the low fuel light sensor are 2 separate things on the same assemble. So yes you can have the fuel gauge work but the low fuel light won't work. Mine was doing the same thing and I replaced the float assembly in the tank and that cured the issue. Easy fix. The assembly cost around $80 when I did mine and that was from a Kawasaki dealer. I installed it myself

Thank you Jim,I was thinking the same thing

[Highway Rider]

You're welcome

[cushman eagle]

Checked it out
I disconnected the plug at the sender,energized the low fuel light wire with a 9 volt battery and the low fuel light lit ,so I know the circuit is good.
So I ordered the sender.

[Mr Jensee]

Glad we could help.

[cushman eagle]

I got my new fuel sender in, and today had a chance to run the bike low on fuel,as the gauge was dropping just below E,the low fuel light started to glow. I was only a mile from a gas station,and by the time I got there,it was glowing as normal.
I filled it up.taking 4.88 gallons,at 260 miles.
Back to normal!

[Highway Rider]