12 replies to this topic

[Kevin Leclair]

So my fuel gauge quit reading this Memorial Day weekend, any ideas of what could be causing the problem other than a bad fuel baffle? From what I have heard there is a fuse in the fuel baffle that is near to impossible to replace so you are better off replacing the whole fuel baffle...

Any ideas before I spend the $150 to buy a new fuel baffle? I tried running some Mercury QuikClean throuht the fuel system too see if that would help anything but unfortunately no luck. It was working when I was putting gas in at the pump but as soon as I got home to flush it out to get it ready to put on the water it quit reading.

[gofast]

Kevin , Im not familiier with your specific boat ,but, i am a retired master mechanic . Most all fuel gauges work by sending a low voltage to the sending unit . It then travels thru a arm and wiper setup to a ground , which in a boat means another wire going to batt neg.if you can sccess the wires to the unit and unplug them , one shoulld have 7-9 vdc the other should ohm to batt neg . I have found nearly all the time loose connections / corrosion to be the problem. hope I have been of some help.

[Kevin Leclair]

Thanks for the heads up, I will take a look at this too.

[tiggerman]

So my fuel gauge quit reading this Memorial Day weekend, any ideas of what could be causing the problem other than a bad fuel baffle? From what I have heard there is a fuse in the fuel baffle that is near to impossible to replace so you are better off replacing the whole fuel baffle...

Any ideas before I spend the $150 to buy a new fuel baffle? I tried running some Mercury QuikClean throuht the fuel system too see if that would help anything but unfortunately no luck. It was working when I was putting gas in at the pump but as soon as I got home to flush it out to get it ready to put on the water it quit reading.

Other than checking all the other fuses, it is most likely the sender-
I just bought a new one from ParkerYamaha that was really cheaper than the 150 bucks that most places want. I think it was like 116.00 or so.

[jonw9]

There could really be 2 reasons (I have them both).

1) There is a little fuse (F1) on the board inside the baffle that blows. You need to cut apart the baffle and replace the fuse, then somehow re-close the hole you cut.

Here is a pretty good walk-through:
http://greenhulk.net...ead.php?t=26017

2) The float quits working. Causes of this include floats that no longer float, magnets that come off the float, or in my case, the bottom comes off the baffle and the float floats away.

The cheapest I found was here, but shipping puts it around $135:
http://www.powersedg.../5/default.aspx

Everyplace Local was $141.

The new part number is 204560223 which replaces the older part of 204560059, which was what my '99 had. I would be sad to see if you have the newer part, because I am hoping they fixed the problem.

I guess a third way could be the wiring/gauge. You can check this by unplugging the baffle and jumpering the (in my case) pink and pink/black wires, and the gauge should read full.

[Kevin Leclair]

Thanks for the detailed post Jon. My guess is it is the fuse inside the fuel baffle and that doesn't look too easy to replace, plus I am not sure how safe it is after you have cut it open to replace it.

I think I am going to end up just ordering the newer fuel baffle part (204560223). Is this a direct replacement for the older part, meaning will it still fit our boats if we have the older part in there now? Did you replace yours yourself, if so how difficult was it to replace?

[jonw9]

Thanks for the detailed post Jon. My guess is it is the fuse inside the fuel baffle and that doesn't look too easy to replace, plus I am not sure how safe it is after you have cut it open to replace it.

I think I am going to end up just ordering the newer fuel baffle part (204560223). Is this a direct replacement for the older part, meaning will it still fit our boats if we have the older part in there now? Did you replace yours yourself, if so how difficult was it to replace?

I had mine out to try and repair, and that is when I found I was missing the float as well, so I put it back together. A couple of the "spring" clamps fell off into the engine bay, but I luckily had some screw type clamps to replace them.

It wasn't terribly hard to take out. On my Speedster SK the ski-pylon is directly in the way and was a bit of a pain.

I have not ordered mine as of yet. I had some engine problems this weekend, so I am waiting to see how that goes first. The 223 is the direct replacement, as told by several dealers (I called all over for one locally)

[Kevin Leclair]

So is the float a completely different part that I would have to order too if this was missing? Is the float not a part of the new fuel baffle?

[jonw9]

So is the float a completely different part that I would have to order too if this was missing?  Is the float not a part of the new fuel baffle? 

No, the float will be included in the new baffle. The problem is however the bottom is held on is not the most secure method, and the bottom can fall off, releasing the float (as it did in my case).

I think this can be checked by measuring the resistance between the pk and pk/blk wires on the baffle. I think there should still be a resistance. Of it comes out open (OL) then it is more than likely the fuse.

[Kevin Leclair]

Just ordered mine, so we see if this fixes the problem when it comes in....

1 of 204560223 - BAFFLE-PICK UP @ $119.59ea.

Subtotal: $119.59
Shipping: $13.60 via UPS Ground
Sales Tax: $0.00
Total Amt: $133.19

Powers Edge
11995 N. Maple Island Dr.
Fremont, MI 49412
231-924-2694
orders@powersedge.net

[Kevin Leclair]

Well it took about a week but I finally got an answer from Powersedge.net on why they weren't receiving the part I ordered. Seems like they can't get jet boat parts, they only can get parts for the jet skis from BRP. They credited my money back and then directly me to another dealer, http://shawmuthills.com/. I have ordered the part from them so we will see how long it takes to get here.

[Kevin Leclair]

I received my fuel baffle yesterday, very happy with the part and delivery. I will let you guys know if it works out once I get it installed. It might take me sometime to get it installed though because I am right in the middle of a move so I have the doo in storage for now.

[gbsambo]

I just tried fixing mine using Jonw9's method - cutting apart the baffle and removing the F1 fuse - and it worked great!! I've had my boat for 4 years and the fuel gauge has never worked - until now.


If you just take it slow, it's really easy to do.

All it cost me was a little over an hour of my time.

Thanks for the tip!

I'd advise anybody else who has the same problem with their fuel gauge to try this first before spending your $150.00 for a new part.