Questions about 2002-2003 wire harness...

I am preparing for the arrival of my 2002 90 hp Johnson V4 this coming weekend. You may recall from other posts that this is for a re-power of a 1985 Force, so there will be differences in wire harness and connections.

Downloaded and was reading the owners manual and looking at gauges. Figure a new set of gauges are in order, but not being familiar with the "newer" style Johnson/Evinrude wire harness and connectors, I figure I better ask the pros...

The diagram of the engine shows that the wire harness has three distinct connectors on it. I am only familiar with the old "red plug" and oil tank pin-plug type connectors. This is where I need help.

My issues are:

1) The manual says a "System Check Gauge" or a "System Check Tachometer" is needed. These gauges display the following Warning Lights: No Oil, Water temp, Check Engine, Low Oil. Is this mandatory, or will the warning horn also sound if no System Check style gauge is used?

2) Some gauges (like the Teleflex Sahara line) list either "Stud" or "Deutsch" style connectors (part numbers for each gauge are different depending on connector). I think the Deutsch is the type of connector that is used on the 2002+ model years? Yes/no? Can I use traditional Stud style gauges with the Deutsch connectors if adapters are used (or if the plug is removed)?

3) The remote oil tank is supplied with the outboard, so the connections should be fine. I am expecting the Deutsch connectors for the oil tank warning wire harness. Yes/No?

4) I asked for a Concealed Flush mount control to replace the same style already in the boat. Mike Jr. at 1outboard.com says that the Concealed control comes with a separate small plate with the ignition switch that the wire harness connects to. Sound right?

5) Are the three connectors from the outboard for 1) System Check, 2) Tilt/trim and 3) ignition and gauges?

Any light you can shed on the harness and connectors and how to hook up (either generic or Deutsch connector gauges) is greatly appreciated!

BTW, I did order the BRP Service Manual last week, its hasn't arrived yet.

Thanks,

Mark

Re: Questions about 2002-2003 wire harness...

Mark, Only the System Check tach has a different connector (8 pin DIP). The rest of the gauges are stud connectors. A std OMC wiring harness for that motor has both the 8 pin DIP and stud connectors, if you want to use a non-system check gauge.

It is likley you can use a seperate buzzer w/o the system check tach, however, the cost of the system check tach is just a small amount more than a standard tach, so I recommedn you use it.

See if the maxrules.com website has your wiring diaghram, as I don't remember the three harness plugs functions. The wiring diaghram is a bit complicated, so look it over real well, before you're sure you understand it.

Re: Questions about 2002-2003 wire harness...

Chris1956 said:

Mark, Only the System Check tach has a different connector (8 pin DIP). The rest of the gauges are stud connectors. A std OMC wiring harness for that motor has both the 8 pin DIP and stud connectors, if you want to use a non-system check gauge.

It is likley you can use a seperate buzzer w/o the system check tach, however, the cost of the system check tach is just a small amount more than a standard tach, so I recommedn you use it.

See if the maxrules.com website has your wiring diaghram, as I don't remember the three harness plugs functions. The wiring diaghram is a bit complicated, so look it over real well, before you're sure you understand it.

Click to expand...

Thanks for the info. I did some digging and found the following parts are needed to put a 1996 and later motor on a boat that was not setup for one:

- Concealed Side Mount Control (5006561) and ignition switch w/horn (176408) OR Surface Side Mount control w/ignition switch (177225).

- Wire Harness Wiring kit (12ft) (176339). Kits 176340, 176341, and 176342 are longer versions of same kit, up to 28 ft long.

- 33C type control cables for throttle and shift.

The motor is supposed to come with a concealed side mount control box, ignition switch, wire harness and oil tank as per my order. I have a feeling something will get messed up or not be as I specified. Will find out this coming weekend.