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Fuel Sending Unit Repair

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  • #31
    I used PermaTex Threadlocker Blue on mine after reading up on how it tolerates gasoline. It is still doing well.
    '96 ProStar 205 SD LT-1

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    • #32
      Tried this repair tonight. Got a good reading on the ohm meter after repair but the gauge is still showing empty... Any ideas what it could be? Thanks for the help.

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      • #33
        Gauge may have given up it's ghost... here's an inexpensive replacement http://www.cheaperthandirt.net/produ...FdFDMgodKhQAIQ
        sigpic...A bad day water skiing still beats a good day at work...1995 Pro Star 205....

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        • #34
          You can try connecting the sending unit to the wiring harness and turning it onto its side to move the float. If you are getting the proper readings when you bench test the sending unit you should see the guage move as you tilt it. If not, perhaps you don't have the wiring harness connected to the proper terminals? And of course the guage could be bad too.

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          • #35
            Originally posted by Tateau18 View Post
            Tried this repair tonight. Got a good reading on the ohm meter after repair but the gauge is still showing empty... Any ideas what it could be? Thanks for the help.
            Check for voltage at the pink wire to the sender. It's not high current, so there's no danger of sparks. Touch the pink wire to the black wire at the sender. If you see no movement, do the same at the gauge and see if it pegs the needle. If it pegs the needle at the gauge, you have a problem with the wires or a terminal.

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            • #36
              I just wanted to comment on this thread as a new(new to me, I just bought a 92 prostar 205) mastercraft owner. I read this randomly while surfing the net, and thought I would give it a shot. While it took me longer than 20 minutes, this seams to have fixed my sending unit. My fuel gauge is now working again. Mark me down as another person who this fix has worked for. Thanks for the thread!

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              • #37
                I am original owner of a 94 ProStar 205. It has been on dry land for about 2 years (Texas drought and we did a 13 month relocation). Got back to Austin and took 2 runs up Lake Austin and was amazed that the fuel guage kept showing full... incredible fuel consumption!! Or the gauge/sending unit was not working.
                Yep, sending unit was the culprit and everything to repair was in this thread! It was exactly what I needed. I used JB Weld "Water Weld" to attach the magnets.
                Probably good to go another 20 years.
                Thank you Team Talk!!

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                • #38
                  So my 95 205 gas gauge was pegged on full for the past month or so. Took the sender apart like the post showed and sure enough it's the magnets on the sending unit. Have it all apart like the pictures show ready to glue and reassemble.

                  One question though, how do I know I have the magnets polarity correct before I reinstall? Might be a dumb question but better safe than sorry before I JB Weld them in.
                  1995 Mastercraft Prostar 205

                  Former 1986 Mastercraft Skier

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                  • #39
                    This should help with your polarity question:

                    I repaired my '91 PS190 sending unit a couple months back as my magnets were both scattered about. My sending unit looked like the one in the pic at the start of this thread. The float has one long slot where two magnets are placed long wise at each end with a gap between them. I held the two magnets pointed towards each other (like they are oriented in the float slot) but held them tip to tip and found the orientation where the magnets pushed each other apart. Then I glued them in that position, but of course in the slot they are spaced a little apart (as the pic shows) but they don't push enough to fight the glue. I used regular JB weld. Check your soldering over well, mine was a tiny bit cracked near one of the terminal rivets up top but a little soldering fixed that. My gauge works great now for just $1 worth of glue and a little effort!

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                    • #40
                      Junk Fuel Sending Unit

                      Stock ones are JUNK ! Type WEMA FUEL SENDER, get a great quality stainless steel sender for ABOUT 43 bucks, stop fooling around with magnets and silicone and JB weld. That stuff is cutting into your water time

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                      • #41
                        Thanks for this thread

                        I just repaired my sender in the exact manner you outline. I opened it up and sure enough the two magnets where dislodged from the float. 5 minute epoxy which is impervious to water or chemicals and I'm all set. Repair cost $6.13.

                        One note for change: I could not pull my sender out of the tank...the sender dipstick is too long to pull it out. At first I tried to pull it out through the lower ski-rope eyeloop by removing those 4 bolts, but the angles still would not work.

                        So I ended up unscrewing all the screws that hold the sender and fuel out/return module. I was able to angle the sender unit starboard and pull it out through the starboard blower outlet. (black with 4 screws)

                        It obviously went back in the same way.

                        One other small thing that stumped me for 10 minutes: I couldn't figure out how to take apart the sender and circuit board. Remove the 3 8TI screws at the top, and remove the bronze washers on the base off the electrical pick-ups.

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                        • #42
                          Anyone done this repair on a 1986 craft?

                          From reading this thread this appears to be for newer models. Any stars and stripes out there that have done this repair?

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                          • #43
                            Not for a Stars ad Strips but its for a 2 wire sender. This should head you in the right direction.
                            http://www.mastercraft.com/teamtalk/...ht=fuel+sender
                            99 MariStar 230 Sport LTR 330

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                            • #44
                              Thank u

                              Thank u!

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                              • #45
                                Another Fuel Level Sender Repaired

                                Add one more repaired fuel level sender to all of the others mentioned in this thread. My '98 MariStar fuel gauge did not respond last time I filled the tank so I removed the sender last weekend. After reading the posts in this thread I removed the bottom cover and found one loose magnet no longer attached to the slot in the float. I guess some of these senders use two magnets in the float; mine only used one.

                                It's repaired, back together now and working. A lot more satisfying to fix what you have instead of just buying a replacement unit.

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