Join Date: Apr 2005
Location: Guilford, CT, USA
Not much in the way of substantive help, I'm afraid, just thinking out loud. You know that the electrical contacts work by turning the gauge upside down, so you have ruled that out as a problem. The Manual indicates that "The immersion-tube sensor has to be calibrated if it or the fuel tank has been replaced. Calibration allows the reserve fuel capacity of the fuel tank to be adjusted to suit customer preferences." (p. 16.8) You didn't replace your sender tube, but removing it may produce the same result. This requires a trip to the dealer and hookup to the Moditec. I do not know if this is a "must do" procedure, or if it only needs to be done if you want to calibrate in the "reserve" amount of fuel.
Sender tubes get bent in one of two ways that I've read about (there may be many more that I haven't read): vacuum in the fuel tank causing the sides to collapse inward, bending the tube, or pushing a gas nozzle too far down and to the center of the bike, hitting the tube. Have you noticed a sucking sound as you unscrewed the gas cap? If so, you likely have a vacuum condition, and it may have bent the tube again. Do you still have the charcoal cannister? I'm not sure if it is possible to "overfill" the bike and have gas sucked back to the cannister (or be blocking the line from the cannister to the tank), but if you have a vacuum in the tank it is likely from a blocked line to the cannister, a sludge filled cannister, or a blocked open air line from the cannister to the rear of the bike. You'll have to find it and fix it or the tube will continue to get bent.
If your sender tube is straight I'm out of ideas. Good luck and let us know what you find.
'99 Canyon Red K1200 LT - Buddah Bike