Hello Johnr.
Well I have replaced about four of thoes things and have the old ones just in case I can figure something out. Well to half ass answer your question the sender is a circuit board of some type. And I would venture to guess that there is a capacitor of some type or something that increases the current at different positions of the float. In other words it would be hard to repair the sender to work w/that gage. It probably uses micro mili amps to operate the gauge. You would have to know what voltages the gage could take. It looks like it would take more than just regular wiring to get it to work. It also has that function that tells how many miles you can go etc. And I bet it all works within that circuit board.These boards seldom work on large current or voltages. There could be current limiting devices and it may be designed to work on less than 1.65v. I think its pretty complicated w/o some type of diagram that tells us exactly what is doing what. If not u can risk damaging that high dollar gauge. But I am w/u on trying to figure something out. I think the gauge and the sender act as a complete circuit.They compliment each other mated some how. I have not truly proven this theory, but my last sender failed because it came apart. But I think when filling the bike, do not top it off. Just fill it up and stop. I use to cram the fuel as much as I could. This may not be good for this type of sensor. Just a thought, because I seem to have got longer life from the sender that came apart. Last about 2yrs or 15000 miles of daily riding. I am still watching this new one replaced.
Well I have replaced about four of thoes things and have the old ones just in case I can figure something out. Well to half ass answer your question the sender is a circuit board of some type. And I would venture to guess that there is a capacitor of some type or something that increases the current at different positions of the float. In other words it would be hard to repair the sender to work w/that gage. It probably uses micro mili amps to operate the gauge. You would have to know what voltages the gage could take. It looks like it would take more than just regular wiring to get it to work. It also has that function that tells how many miles you can go etc. And I bet it all works within that circuit board.These boards seldom work on large current or voltages. There could be current limiting devices and it may be designed to work on less than 1.65v. I think its pretty complicated w/o some type of diagram that tells us exactly what is doing what. If not u can risk damaging that high dollar gauge. But I am w/u on trying to figure something out. I think the gauge and the sender act as a complete circuit.They compliment each other mated some how. I have not truly proven this theory, but my last sender failed because it came apart. But I think when filling the bike, do not top it off. Just fill it up and stop. I use to cram the fuel as much as I could. This may not be good for this type of sensor. Just a thought, because I seem to have got longer life from the sender that came apart. Last about 2yrs or 15000 miles of daily riding. I am still watching this new one replaced.