Has anyone attempted to re-wire the external and internal wiring harness?
I have recently purchased a '72 Mercury 800 (80 HP), that has been sitting for about 3 years and all the wires are deteriorated. I have found that the aftermarket harnesses are pretty expensive, I want to re-wire myself but want to make sure it is worth the effort. The plug that mounts to the side of the motor (external) is also deteriorated, would it be worth it to hard wire right to the internal and eliminate the plug?
Any suggestions for this project would be greatly appreciated.
If both sides of the quick disconnect plug are in reasonable shape, I would retain it. Use butt splices to attach the new wires to the old harness. Crimp, solder and shink tube the butt splices to make it last. Use different color wires or at least different color tape to ID the wires.