Reply
 
Thread Tools Search this Thread Display Modes
 
Old 05-15-2018, 11:28 PM   #1
Lt. JG
 
Join Date: Apr 2018
Posts: 18
Default Fuel Gauge Stuck at Full

I have a 2003 Maxum 2100 SR and the fuel gauge is stuck showing full regardless of the tank level. I opened up the fuel tank area to look at the fuel sender as I thought this would be my problem. I pulled it out and it looked actually fairly new.

I started inspecting the wires; looks like there is a pink wire and a black. I'm assuming the pink wire goes to the fuel gauge. Not sure what the black one is (assuming power?); it turns into a green and yellow. I'm pretty sure the green one is ground (see pictures). The problem with the green one is that it's not hooked up to anything, so I think that is most likely the problem with the fuel gauge showing full all the time, but wanted to verify that is most likely the problem.

Assuming the ground wire not actually being grounded is my problem, where is a good location to ground it. The wire is really short; I'm sure I'll have to splice a longer section to reach where it should go. Maybe this is why it was never hooked up in the first place. Probably the previous owner said screw it and never did it when they replaced it?
Attached Thumbnails
IMG_1455.jpg   IMG_1456.jpg   IMG_1457.jpg   IMG_1458.jpg  
__________________

bdericks is offline   Reply With Quote
Old 05-16-2018, 01:34 AM   #2
Admiral
 
mmwjr's Avatar
 
Join Date: Feb 2012
Location: Essex, Maryland
Posts: 10,176
Default

The green wire is a bonding wire used to tie all metal objects together so they are at the same potential, ground. Since you have a plastic tank no metal to bond. The black wire is the negative for the fuel sendor and the pink is the fuel sendor sense wire. Yes that looks like a new sendor but I cannot tell if it’s wired correctly.

Try disconnecting the pink wire and see if the gauge moves then ground it and see what it reads.
__________________

__________________
1997 Silverton 362, 7.4 Crusaders
1997 2400 SCR, 5.7 Vortec / Bravo 2

Mike
mmwjr is offline   Reply With Quote
Old 05-16-2018, 03:16 AM   #3
Lt. JG
 
Join Date: Apr 2018
Posts: 18
Default

Thanks Mike for the reply. I'll test it tomorrow and let you know.
bdericks is offline   Reply With Quote
Old 05-16-2018, 04:32 AM   #4
member
 
Join Date: Apr 2018
Posts: 346
Default

When you remove the pink wire, your Gage should go to MT position.
Gugi47 is offline   Reply With Quote
Old 05-16-2018, 02:06 PM   #5
Moderator

 
shrew's Avatar
 
Join Date: Apr 2008
Posts: 5,588
Default

That doesn't look like a solid green bonding wire. That is a Green/Yellow. In Picture #3, those are Home Depot/Lowe's residential-style quick connects. Those are not tinned and are not appropriate for marine use.

Disconnect and reconnect them several times. This may scrape any corrosion that might be impeding conduction. Accor makes marine disconnects.
shrew is offline   Reply With Quote
Old 05-17-2018, 12:36 AM   #6
Lt. JG
 
Join Date: Apr 2018
Posts: 18
Default Update`

Ok so I did what you suggested Mike. When I turn the boat to the "On" position and fuel gauge shows "Full" (always stuck there).

1st and 2nd picture is me disconnecting the pink wire to see if the gauge moves, which is does; moves from "Full" to "Empty".

3rd, 4th, and 5th picture shows me using a lead from my multi meter to connect the pink wire to ground. The gauge stayed at "Empty".
Attached Thumbnails
IMG_1477.jpg   IMG_1479.jpg   IMG_1480.jpg   IMG_1482.jpg   IMG_1484.jpg  

bdericks is offline   Reply With Quote
Old 05-17-2018, 12:40 AM   #7
Lt. JG
 
Join Date: Apr 2018
Posts: 18
Default

@Shrew,

These? https://www.westmarine.com/buy/ancor...09_275_004_010
bdericks is offline   Reply With Quote
Old 05-17-2018, 12:45 AM   #8
Captain
 
donald's Avatar
 
Join Date: Jun 2016
Location: Mn.
Posts: 663
Default

Question? How much fuel do you have in your tank?
Don
__________________
1995 Maxum 2400 SCR 5.7 A1 G2 LUNA DE MIEL SOLD
1988 Bayliner 2455 5.0 IO (sold)
1987 Seaswerl 18ft C. Cabin 4.3 IO(lost in fire)
2012 South Bay Pontoon
donald is offline   Reply With Quote
Old 05-17-2018, 01:23 AM   #9
Lt. JG
 
Join Date: Apr 2018
Posts: 18
Default

@Don,

It's almost full. Previous trip I topped it off before I headed out. Spent the whole day on the lake (a lot of wide open throttle just cruising), and throughout the day I thought it was odd that my fuel gauge never moved. On my way home at the end of the day, I topped it off again (used 28 gallons). My fuel gauge should have been around 1/2 by the end of the day since it's a 50 gallon tank, but as mentioned before, it showed full all day
bdericks is offline   Reply With Quote
Old 05-17-2018, 01:28 AM   #10
Lt. JG
 
Join Date: Apr 2018
Posts: 18
Default Update #2

So I believe the problem is now fixed. I just pulled the sender again and tested the float vs the fuel gauge. I am now seeing appropriate readings (see pics). I tested it at 1/2 (pic 1&2), 1/4 tank (pic 3&4), and empty (pic 5&6). The only reading that is a bit off is the 1/2. Float is at 1/4, but reading is closer to 3/4 than 1/2. Oh well, it at least I'm getting some readings now.

Thanks to everyone's replies and help. I think I will either change out those connectors or heat shrink them to prevent corrosion or becoming loose again in the future.
Attached Thumbnails
IMG_1487.jpg   IMG_1488.jpg   IMG_1489.jpg   IMG_1490.jpg   IMG_1491.jpg  

bdericks is offline   Reply With Quote
Old 05-17-2018, 01:29 AM   #11
Lt. JG
 
Join Date: Apr 2018
Posts: 18
Default

picture #6
Attached Thumbnails
IMG_1492.jpg  
bdericks is offline   Reply With Quote
Old 05-17-2018, 02:12 AM   #12
Admiral
 
mmwjr's Avatar
 
Join Date: Feb 2012
Location: Essex, Maryland
Posts: 10,176
Default

Yep that was what I would point you to do since the gauge tested fine.

Glad you resolved the issue.
__________________
1997 Silverton 362, 7.4 Crusaders
1997 2400 SCR, 5.7 Vortec / Bravo 2

Mike
mmwjr is offline   Reply With Quote
Old 05-17-2018, 04:11 AM   #13
member
 
Join Date: Apr 2018
Posts: 346
Default

Glad to see your problem solve.
Gugi47 is offline   Reply With Quote
Old 05-17-2018, 11:23 AM   #14
Admiral
 
mmwjr's Avatar
 
Join Date: Feb 2012
Location: Essex, Maryland
Posts: 10,176
Default

BTY the problem was not a loose connection as that would have made the gauge read empty just like the first test where you disconnected the wire. I suspect the float was hung up.
__________________
1997 Silverton 362, 7.4 Crusaders
1997 2400 SCR, 5.7 Vortec / Bravo 2

Mike
mmwjr is offline   Reply With Quote
Old 05-17-2018, 04:35 PM   #15
Captain
 
donald's Avatar
 
Join Date: Jun 2016
Location: Mn.
Posts: 663
Default

Glad you got it fixed.
Thanks for posting your findings as it helps others.
Don
__________________

__________________
1995 Maxum 2400 SCR 5.7 A1 G2 LUNA DE MIEL SOLD
1988 Bayliner 2455 5.0 IO (sold)
1987 Seaswerl 18ft C. Cabin 4.3 IO(lost in fire)
2012 South Bay Pontoon
donald is offline   Reply With Quote
Reply

Tags
2100 sr, fuel, fuel sender, maxum 2100, maxum 2100 sr

Thread Tools Search this Thread
Search this Thread:

Advanced Search
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are Off
Pingbacks are Off
Refbacks are Off


Powered by vBadvanced CMPS v3.2.3

All times are GMT. The time now is 08:55 PM.


Powered by vBulletin® Version 3.8.8 Beta 4
Copyright ©2000 - 2024, vBulletin Solutions, Inc.