Bimota Forum

[hindsight]

Something that has bugged me for a while on my DB2 - it had no fuel level sender, which I have to admit took me a bit surprise when I first figured that out, at the side of the road - waiting for rescue (Ralph, apologies if you warned me.. )

I looked about for the correct part, but drew a blank, so decided recently that it was time to get creative. I'm not clear how most DB2 are configured, but mine had an aluminium blanking plate covering the hole where the sender unit would be installed, and the loom connector tied to the frame, not used. Perhaps a past owner had a failed unit, couldn't find the right part, and blanked it off - not sure. I could see approximately a 34mm bolt pattern, and a 10mm hole in the middle.

After a lot of hunting around I figured that a Yam R6/R1 sender looked like it had a very similar bolt spacing as the DB2, which seemed to be the main critical fitting factor:



Unfortunately, given that the actual insertion hole in the tank is a circular 10mm diameter, it was clear I'd have to open it out a bit, and there wasn't much tolerance to error with the dimensions.

What I decided to do was to 3d-print a template that I could be sure would fit the sender unit. This could then be bolted into the tank to use as a template:






Some careful work with a rotary tool and a milling bit:


The insulation on the (second-hand) sender that I'd bought had started to go a bit hard and brittle, so replaced the wires, and the connector. If it ever gives me grief, I can just purchase a brand new sender from Yamaha, now that I know I can get it to fit.



The bolt distancing isn't perfect, and I had to slightly oval the holes on the sender unit to get it installed, but it's good enough. Initially I had a leak - I think the o-ring on the underside wasn't sealing correctly with the textured plastic tank surface, but a small bead of permatex seems to have done the job. Success - fuel warning light lit!



Mike

[Bud977]

Nice work. Just like a bought one. Hope the level works out.

[hindsight]

[Bud977]

Was thinking the same thing. You might also be able to cut off the bottom bit, then bend and drill a new fixing bracket. Regardless, it looks like you have the ability to figure it out. Well done.

[hindsight]

Just yesterday, I measured about 2.5l of fuel going into the tank before the light extinguished, which seems about right to me for the moment. I'll leave it like that, and see how I get on with it.