1995 Osprey 200
Gauge stuck on E (Yes there's fuel in it )
The green wire isn't connected to anything and looks like it never was
Any suggestions on how to to trouble shoot/diagnose/repair would be appreciated
Gerard
The green wire is there simply to bond the tank and fuel fill if you have an aluminum tank. If you don't, tie it back, it's not necessary. The pink wire off the sender goes to the "S" terminal on the gauge. The black wire off the sender is your ground, that can be terminated to any known "good" ground. The black off the tach goes to the "G" terminal on the back of your fuel gauge. The purple off the tach goes to the "I" terminal on your fuel gauge.
Now, the gauge works on resistance, not voltage. Now the sender has a resistance in the 33-240 Ohm range, 240 when full, 33 when empty. If you pull the sender and move the arm all the way up (like it's full), the reading across the pink and black wires will read 240 Ohms or so. With the arm all the way down, it will read around 33.
And that's how you TS a sender gauge. As long as the wiring is good, if the resistance readings are right, the gauge is no good. If the resistance readings aren't there (and that's what I'm betting...), you need a new sender...
BTW, if you have a bad ground, the gauge will peg on "Full", not "Empty"...