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Fueling issue on Starcraft EX23

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Starman2020 View Drop Down
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Joined: 05/03/2020
Location: Ringgold GA
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    Posted: 05/03/2020 at 1:54pm
Hi to all!.  I am looking for some opinions on a fueling issue on my 2017 Starcraft EX23.  We just purchased the boat and I am trying to figure out the nuances associated with it.  I thought I might have a bad sending unit on the boat because after filling and taking a maiden voyage, the needle stayed pegged on full.  We went out for a couple more weekends and finally it started to move.  The problem was, it seemed to fall from 3/4 tank to pegged at empty within 15 minutes of driving back to the dock.  I was sweating bullets.  When I fueled it took on almost 30 gallons.(the boat specs say 30 gallon tank and yet it has a 39 gallon tank installed)  Refilled and took out the last couple of days down the Tennessee River 34 miles roundtrip and the gauge never moved.  Got back and refueled to top off and it took 12 gallons.  Pulled the sending unit which is the reed type and ran it through it's travel and it read perfectly on the in dash gauge. I reinstalled and decided to investigate issue number two.  When trying to fuel it gets a lot of splash back when it gets to what I think is near the top.  It seems like you have to run it real slow.  I looked down the 45 degree filler neck and noticed something blocking it.  I pulled the filler neck and noticed it extends down into the tank approx six inches with a ping pong ball check valve at the end.  I read that the ball was for rollover but in theory as you fuel it floats up until it blocks the hole of the filler neck.  If you fill slowly you can get the fuel to god past the ball and farther up the six inches of the filler neck.  That's when the lightbulb went off.  Did the engineers design the tank to be considered full when the ball is seated against the bottom of the filler neck even though there is probably eight inches of headroom left in the tank?  Is the reason my sending unit stays pegged because I am overfilled and need to burn off a bunch of fuel before the float can start to fall?  Also when I considered replacing the sender the instructions said to measure from the top of tank to the bottom and subtract an inch.  Mine is 15 inches and yet the KUS float is a 10 inch model.  Was this intentional by the engineers due to the headroom?  I would think that the float would never read full with that much headroom in a tank.  See my confusion?  Any ideas?
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