XDiavel Fuel Sensor Fail

xDiavel03 said:

Took my 2016 in for recall related to key programming and rear brake line replacement.

They gave me the bike back with fuel sensor issues. And the service rep wanted me to pay for the fix.

What part do I need to order to replace the fuel sensor. I looked into the diagram and could not find what exact part I need to order and replace.

https://issuu.com/du...222863/37053161

Can you point me in the right direction ?

Click to expand...

Of course they wanted you to pay for it, the fuel sensor has nothing to do with the work they performed, the fuel sensor craps out on these bikes all the time but easily changed.
The partnumber is 59210241B.

Go to Drawing 32, Fuel tank and the POS nr 11 there you have it on the link you attached.

Remove the seat and the big bolt holding the tank, lift it upwards on that end where you removed the bolt. Remove all the silicon hoses, grounding from underneath it. After everything remove just pull the tank towards you it it will slide out.
If i remember correctly the sensor itself is just held with 4 allen keys.

Might be an idea to check if it has even been plugged back in first before you buy a new one

If you get stuck let me know, it’s a pretty simple job. Stop going to the stealership, bunch of knuckle draggers.

Thanks For all the info. I opened the tank to check any loose connect and half way the fuel gauge start woking.

I feel like this conversation has happened many times. I have a 2016 X Diavel and my fuel sensor has also quit working. No error messages - just shows Empty all the time. While I can use the trip meter to avoid a disaster, it is really annoying to look down at my costly bike and see that low fuel warning. It is like having a blinking appliance with a clock you can never set. I am surprised at how this troubles me - almost as bad as the cost of keeping this beast fed in rear tires.

My question is are there any video's of X Diavel owners replacing this part? I would be stoked if someone could share this with me the mechanically challenged and save me the 2 hours of dealer labor at $207/hour.

Thank you

SantaCruzXD said:

My question is are there any video's of X Diavel owners replacing this part? I would be stoked if someone could share this with me the mechanically challenged and save me the 2 hours of dealer labor at $207/hour.

Click to expand...

+1. I have the same problem, and would love to know too.

I’m going to be changing mine today. Has anyone done it before. Tank have to be empty. Half full?

Removing the tank is very easy. I can do it in about 1 minute.

That it is. Getting the gas out can be a pain

Go out for a ride before you remove it then you don’t need to worry about that.

Stand the half full tank on end and then you can remove the sensor. No need to empty it

Add me to the list. I have a 2018 XD with about 3k miles on it and today I stopped to put in gas since the dash was yelling (blinking) that it was empty. I thought I had put gas in recently and when I opened the tank to fill it up, I found it was about 90% full. Oh, crap! I new the sensor was probably bad (after having read this forum for the past few years).

I guess I'll order the $200 part and install it after I ride the fuel out of the tank. I already have a few other bikes torn down and I really didn't want another, but oh well.

The new part number appears to be 59210242C, but I need to confirm.

-S1930

My sensor failed at 2,100 miles on the odometer. Dealer replaced it no problem.

Mine failed at 123 miles. The second one goes in and out all the time. I just use my trip mileage.

Tonyt said:

Mine failed at 123 miles. The second one goes in and out all the time.

Click to expand...

Isn't the second one under some sort of warranty?

Not after a couple years

Mine failed again - thankfully purchased the ever red warranty.

thiz11 said:

My fuel sensor just went out completely. It had started being flaky a few months ago. I had half a tank and it went empty. Filled it up and still empty. All the other times, it would reset with tank empty to a new fill up. Same thing happened on my Diavel at 9500mi. I have 16000mi on the X. Will contact dealer tomorrow.

Click to expand...

Did it stop the bike from running?

2019 xdiavel s started flashing red tank and nil remaining range. Read the forums. Bloody fuel sensor. Then read about a guy that bought the bypass but the problem fixed before install. Lifted my full tank, unplaged the two wires. Cleaned them with WD40. No problems now. Just poor connection.
Go figure.