Fuel Sender Unit Mystery

For the past few years my fuel gauge has read empty on my '08 Sportsman 800. I just thought the float was detached. and never got around to fixing. Well today I pulled the gas tank (need to change spark plugs.) and took off the fuel sender unit.

Sender unit looks good, float is undamaged and attached. I cleaned up the resistor pad with some scotch bright pad - but still it don't work. If I plug in the sender unit outside of the tank and manually move the float value it works. Yet when I install in the tank and fill with gas, I'm only get an empty reading.

A new sender unit is $450 so that's not an option.

I'm stuck on why this fuel float sender is not working properly

Any suggestions?

Fuel Sender Unit Mystery

For the past few years my fuel gauge has read empty on my '08 Sportsman 800. I just thought the float was detached. and never got around to fixing. Well today I pulled the gas tank (need to change spark plugs.) and took off the fuel sender unit.

Sender unit looks good, float is undamaged and attached. I cleaned up the resistor pad with some scotch bright pad - but still it don't work. If I plug in the sender unit outside of the tank and manually move the float value it works. Yet when I install in the tank and fill with gas, I'm only get an empty reading.

A new sender unit is $450 so that's not an option.

I'm stuck on why this fuel float sender is not working properly

Any suggestions?