some folks say cleaning the green plug with some electrical contact cleaner can help. Others say disconnecting the battery overnight can fix the problem. You should try these tricks before spending the money on a new fuel sender.

If you need to replace the sender, simple steps.

1. Drain fuel
2. Remove tank
3. Flip tank over.
4. There's a green plug with wire leading to the unit with some bolts (8mm head (if I recall)) and a rectangular shaped plate. That's it. Remove the bolts (reuse the washers), remove the sender, very weird part.
5. Replace with new part the opposite way you took off.
6. Replace tank, reconnect plugs, reconnect fuel lines, gas up. That should do it.

Make sure you save and reuse the little rubber washers on the 4 bolts(they may be on the gasket when you take it off) and I would hold on to that gasket from the old sender too. Tighten, but don't over tighten (as you can damage the gasket (you can't buy the gasket alone, it comes with the fuel sender)).

The fuel sender unit is about $35-$40 (if I recall). I've done it twice. 1st time I failed to see the 4 washers on the screws. And I think I may have over tightened it. It worked fine for about 2 months, then I went on a long trip and when returning from temps in the high 50s at about 7500' elevation down to 110F at 1100' within an hour screwed it up. Leaked something terrible after about 15 minutes sitting in my garage and the gasket looked warped when I took it off. Bike was out of commission for about 1.5 weeks waiting on a new fuel sender (and those 4 washers I didn't notice). Don't know if it was the 50+ temperature change, pressure change from altitude, the missing washers, the overtightening or what. It didn't leak for that entire trip, till I got home (thank goodness for that). Sold the 1st replacement unit to Mark7 here on the RSC, just told him he'd have to use his original gasket. I did it right the second time.