SBT Jetski Engines, Parts & Accessories

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  1. #1
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    Default 97 GP1200 - Fuel Indicator Not Accurate

    Hi all,

    I have a 97 GP 1200 and the fuel indicator always reads "Low Fuel" and on every start up, beeps continuosly until I press "Mode".

    I am relatively mechanically inclined, and I figure there must be a float or something in the tank that is gummed up and stuck.

    I know that there is always a full tank when I first go out on the water each day, so do you guys have any suggestions?

    Could it be electrical?

    A friend of mine just had his entire instrument cluster replaced on his 97 GP1200 and it still does the same thing.

    We both have the same problem.

    Please help.

  2. #2
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    Default Re: 97 GP1200 - Fuel Indicator Not Accurate

    It's rare on that model, but yes it's the float. You need to remove the handlebars and front cowl to access the baffle assembly.

    Otherwise you can short the two sending wires going into the tank to show a full tank on the gauge.
    SBT Tech Support is here to help with your problems.
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  3. #3
    Joined
    Jul 2004
    From
    Michigan
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    Default Re: 97 GP1200 - Fuel Indicator Not Accurate

    Thanks.

    Are there any special tools required to remove the handlebar? There's a little play in the handlebars already, and I was hoping to tighten them up anyway.

    How many hours do you approximate it would all take?

    (Reason I ask is that I want to be able to ride it tomorrow, but if I can get it done today, I would start it today)

    Thanks again,

  4. #4
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    Default Re: 97 GP1200 - Fuel Indicator Not Accurate

    It's about a 2 hour job. Nothing required except a phillips screwdriver and some sockets.
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    We try to answer each question quickly and accurately.
    Please do not use Private Messaging for Tech Support, use the forums.

  5. #5
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    Michigan
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    Default Re: 97 GP1200 - Fuel Indicator Not Accurate

    Great, Thanks again.


    I just dug out my Owners and Service Manual and am reading through it.

    I will be sure to let you know the results.

    Thanks again,

  6. #6
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    Default Re: 97 GP1200 - Fuel Indicator Not Accurate

    I'm reading through the service manual and is the "Pipe Joint Assembly" where the float would be?

  7. #7
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    Default Re: 97 GP1200 - Fuel Indicator Not Accurate

    No, it's on the baffle assembly going down into the tank - where all the lines attatch.
    SBT Tech Support is here to help with your problems.
    We try to answer each question quickly and accurately.
    Please do not use Private Messaging for Tech Support, use the forums.

  8. #8
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    Michigan
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    Default Re: 97 GP1200 - Fuel Indicator Not Accurate

    Once I get the float out of the tank, are there any precautions you recommend?

    Also, what is okay to clean it with?

  9. #9
    Joined
    Aug 2003
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    Thumbs up Re: 97 GP1200 - Fuel Indicator Not Accurate

    I replaced the fuel pickup/sending unit (or I guess its also called the "baffle") earlier this spring on my '98 GP1200 for the same reason you describe (surprisingly the pickup worked fine when I hooked up an digital ohm meter and tested the resistance while moving the float by hand out of the tank but could never get it to work in the tank, so I replaced it and the new one works fine).

    But in anycase, I did not have to remove the handlebars to replace it.

    1) Start with as little gas in the tank as possible. Siphon it out if necessary (you can hook up a siphon hose to the reserve pickup line on the top of the tank).
    2) disconnect all the fuel and vent lines connected to the fuel pickup/sender (make sure they are labeled before disconnecting... if not, label them).
    3) loosen/disconnect the hold-down straps on the gas tank.
    4) drain and set aside the oil tank (mine is always empty as I premix).
    5) disconnect the fuel filler hose on the front of the tank.
    6) loosen the pipe clamp holding the fuel pickup onto the tank and carefully using a screwdriver pry it out of the tank.
    7) tip/tilt the top of the fuel tank back towards the motor while sliding the bottom of the tank towards the front of the ski...
    8) there should be just enough room to pull the fuel pickup out of the tank on the engine side. It's a tight fit, but it will slide out.
    9) use the reverse steps to install the new fuel pickup.

  10. #10
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    Default Re: 97 GP1200 - Fuel Indicator Not Accurate

    thanks for the tip...

    earlier today i removed the top cover, and manuevered around not having to completely remove the handlebar.

    i removed the baffle, and cleaned the float a little. i made sure it was able to slide up and down the baffle.

    have yet to test to see if it works, but if it doesn't, i'll just replace the whole thing.

    thanks again.

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