Let’s jump into the task of Mercruiser Bayliner gauge repair! First we removed the gauges from the boat. During this step it is recommended to take pictures or label the wires. As we are talking about 20+ years wires their color could be faded and hard to distinguish from each other. The other approach can be to remove only one gauge at the time so we could be sure that the hanging wires will belong to the removed unit.
When we have the gauge in our hand clean it from the rust and dust. Spray some screw loosener on it. We are dealing with 20+ years old plastic elements we should be very careful as they brake very easily. We broke one of the gauge needle and it took a while to repair it.
After the loosened the screws but did not removed them we should carefully remove the glass and metal frame from the front. Only after this we should remove the nut from the back because those held the inner components in place!
After some tests it turned out that the plastic part was separated from the shaft, that caused the gauge not to show anything. Also as plastic part was blocking the metal piece to move freely..
We took a little candle wax and sticked them together and the gauge came back to life. After we calibrated the gauge with our lab power supply (that is why we need to use wax as its easy to remove) and the declared to be good we glued it with high heat resistance instant adhesive. We waited 24h removed the wax retested the gauge and put some glue where the wax before.
After everything was working we assembled the gauge and installed it to the boat. Everything worked perfectly. We saved the boat owner ruin the main gauge board look with using different color, style and type gauges.
This was the Mercruiser Bayliner gauge repair topic for today!
Have a good day!
