DIY-Changing the fuel sensor (Kawasaki ninja 300)

DIY-Fuel level error

If Kawasaki Ninja 300 is showing fuel level error, then a sensor inside the fuel pump (Part No- 49040) might be the problem. I had the same problem and this is how I resolved it.

Sensor Functioning

It has this spindle which has one hollow cylinder at the end. The cylinder floats on the fuel level and accordingly one jockey slides over the electric resistance meter. The meter registers the level and its reflected on the dashboard.

Problem identification

My motorcycle was showing wrong fuel level because of this faulty part. This is a subpart of the fuel pump.

I took it to Kawasaki service centre and as most of the time, without digging deep into the problem their solution was to replace the whole fuel pump.

I was pretty sure that the fuel pump is ok and the problem can be solved without replacing it.

And I got another excuse to dissemble the motorcycle and learn something new :P

So I decided to do it by myself.

The process to remove the fuel pump-

I’ll keep it short, as each step can be searched on YouTube or Kawasaki Ninja 300 manual for details

*Important-Empty the fuel tank completely before starting

1. Open both sides of the upper side fairing(refer Kawasaki ninja 300 manual)

Open side fairing

*Its better you remove the large side fairing also but if you are careful, tank can be removed just after removing the side upper fairing only.

2.Remove small under saddle fairings

3.Remove the seat

4.Remove the battery ( very important as there is lots of petrol fume and sparks can be dangerous) apart from that fuel pump should not be removed without disconnecting the battery.

5.Remove the tank.

After removing the tank from motorcycle

Removed the Fuel Pump from the Tank

The fuel pump is under the tank and fixed with 5 screws

6.Remove the fuel pump from the tank.

Fuel Pump and fuel sensor

Carbon on the faulty sensor

This is the part which I found was faulty, hopefully its clear that there is carbon on the thin metal circuit. That's why the connection breaks when the jockey is in that area.

Now as the problem narrowed is down to this circuit only.

Firstly I tried to clean it and check, but no luck. It needed to be replaced.

Old and new sensor

I bought a new one from eBay and installed it at the place of the faulty sensor

Testing the fuel pump after with new sensor

Checked it before installing the whole setup and it worked.

Final testing after reassembling the motorcycle

I installed the fuel pump,tank,battery, seat, fairing back and refueled the tank.

It is working perfectly now.