Honda 3 wire vs GY-6 Fuel Sender

[mousewheels]

txaero121 posted some pics of a Honda Aero 50 3 wire gauge he's working on. He noted the GY-6 sender looks very similar and might be used for parts.

I tore down a GY6 sender a few years back and it might even work as a replacement - if the float/float arm are swapped.

-- Let's dive into some photos

Elite 50 Left/GY6 Right
Main difference is the float/float arms differ. The GY6 sender mounted up fine in my SA50 tank.

Elite50_vs_GY6_Fuel_Sensor.jpg (174.2 KiB) Viewed 1856 times

Edit: Add - Honda Metropolitan sender parts also look promising. Photo taken from an online seller of OEM parts.

Honda_Metropolitan_Fuel_Sender_a.jpg (30.58 KiB) Viewed 1804 times

Fuel sender hold down. Elite 50 is a better looking part but IRC the GY6 fit on the SA50 tank.

Elite50_vs_GY6_Fuel_Sensor_holddown.jpg (135.2 KiB) Viewed 1856 times

[mousewheels]

GY6 Parts Breakdown
It did appear that the GY-6 float arm could be swapped out with any Honda arm I've seen.

GY6_Fuel_Sender_Teardown_sm.jpg (70.99 KiB) Viewed 1854 times

GY6 Wiper

GY6_Fuel_Sensor_Wiper_sm.jpg (71.16 KiB) Viewed 1854 times

GY6 Circuit Board

GY6_Fuel_Sender_Board_sm.jpg (236.12 KiB) Viewed 1854 times

[mousewheels]

GY-6 Sender PCB (Left)/ txaero121's Aero 50 PCB (Right) -- Thanks txaero!

We should add some width measurements here. IRC between the Elite SA50 and GY6
the parts looked very close to the same...

The GY-6 has only 8 steps of resolution vs 12 on the Honda. We'll compare overall resistances later.

GY6_vs_Honda_NB50_Fuel_Sender_Board_sm.jpg (115.24 KiB) Viewed 1854 times

[mousewheels]

GY-6 Fuel Sensor Resistance
Instead of using a meter, we'll trace the circuit.

-- Determine value of each resistor --
The first 2 digits printed on each resistor is the base value, the last digit (0) is a multiplier of 10x.
In this circuit board, all multipliers are (0), so there is no x10 multiplier factor.

Green (Wiper) to Blue/White when FULL = 33 ohms
Green (Wiper) to Yellow/White when EMPTY = 33 ohms

Green (Wiper) to Blue/White when EMPTY = (7 * 68 ohms) + 56 ohms + 33 ohms = 565 ohms
Green (Wiper) to Yellow/White when FULL = (7 * 68 ohms) + 56 ohms + 33 ohms = 565 ohms

Resistance between (Blue/White), (Yellow/White) wires = (7 * 68 ohms) + 56 ohms + 33 ohms = 598 ohms

GY6_Fuel_Sender_Board_ann.jpg (168.85 KiB) Viewed 1840 times

[mousewheels]

Comparison of GY-6 Fuel Sender Resistance to Various Honda Scooters

The GY-6 is a virtual clone (in terms of resistance) for the Honda Aero 50/ Elite SE50/ Elite SA50 for years listed below
All other models showing resistance ranges have the GY-6 within the valid value

The Spree is the only scooter showing a slight difference on the Green to Yellow White (FULL) condition of 506 for Spree vs 566 for GY-6
Given the range of resistance tolerance for other models, a reasonable option for someone to try?

Multi_Model_Fuel_Sender_Resistance.jpg (124.3 KiB) Viewed 1840 times

Edit: Add - Honda Metropolitan sender resistance is also within range. So 'Met sender may be the high quality option - its around $50.

Honda_CHF50_Metropolitan_Fuel_Sender_s.jpg (24.98 KiB) Viewed 1803 times

[Txaero121]

You the man !!. Perfect break down I knew i was on to somthing just could not find someone to break down the gy6 sender ! This is exactly what i was hoping to hear will be ordering a gy6 3 plug off Amazon 11$ on prime looks like all it needs at least on my 86 aero 50 would be for me to swap the wire connections to bullet style .! You just saved ALOT of us a good amount of $ and headache on finding a replacement honda part. I think I'll try to just run the gy6 off the bat if it gives me any trouble I'll swap over to the honda. Another thing most people are asking 100$ + on a used sender on ebay that who knows if they work or how long it will work !!

[mousewheels]

Another thing most people are asking 100$ + on a used sender on ebay that who knows if they work or how long it will work !!

That's crazy high. At that price we can get a new part - I added the Honda Metropolitan sender into this thread, it's 1/2 that price. It looks that it would work with a float arm assembly swap.

[Txaero121]

funny thing is even before i could post the listing from ebay it sold yesterday for 100$! i feel bad for whoever bought that knowning the above information now !!!.