Found this when I pulled the sender out. Insulation seems to be melting/ crumbling off the wire.

Anything I can re-coat the wire with that would stand up to ethanol? Or just get a new sender unit?

 

Being cheap and not liking to throw away repairable parts , If this unit functions fine otherwise than the crumbling insulation my attempt at repair would be as follows ;

Go to the nearest small engine repair shop and buy a foot and a half of "Tygon" fuel tubing, or whichever tubing they sell that they claim is compatible with ethanol . Carefully remove the fitting from one end of your wire by using tiny screwdrivers to pry slightly open the crimps holding the wire to the fitting and then slip the fuel proof tubing over the wire and then carefully recrimp the fitting back onto the wire , and then soldering it for good measure if practical for you . If you can't solder at least make sure you get it crimped back together good , but soldering really is recommended here if at all possible .

I did this to a fuel gauge sender for a 53 Buick that was absolutely unobtainium some years back which is why I know it'll work , especially if you solder the fitting back onto the wire like I did .......

 

Or maybe email racetronix and see if they would sell you some wire just for that?

 

This seems like a good idea. Thinking I'll try to find the smallest fuel line I can.