Engine rewire ???

[Dartboy]

My Mercury 80 wiring covering looks to be perishing possibly giving me bad starting problems. What type of cable would you use, Copper or tinned, Auto type cable or which else do you recommend, to rewire the ignition/ stator/ trigger circuits. <br /><br />Summer is on the arisen, good boating to all

 

[wileecoyote985]

Re: Engine rewire ???

dartboy<br /><br />I used automotive type wiring for my '69 Merc 500. I also used waterproof connecters that have the built in heat shrink wrap. Make sure to pay atention to wire guage sizes and use at least as heavy a wire as used by the factory.<br /><br /> Just work on one wire at a time, when possible, to minimize any confusion. Also helps to have the wiring diagram in front of you that's included in the shop manual.

 

[Ben Konopacky]

Re: Engine rewire ???

dartboy, my recomendation would be to re wire with marine grade(finer wire ,more strands of smaller guage.tinned)little more $ but well worth it ,don't crimp,solder on connector term. with rosin flux (no acid) I boats might have it.i know west marine carries all sizes and colors.

 

[New2merc]

Re: Engine rewire ???

Hey sounds like we are doing the same to the motors, I just rewired all I could on mine, I used 12 gauge wires all different colors to make the install easier. I noticed The other message said not to crimp, I went ahead and did that, I guess time will tell If I have any long term problems.

 

[Paul Moir]

Re: Engine rewire ???

I now follow JB's method for terminal connectors. It's pretty darn good.<br />Have a look here.<br />The problem with soldering on the terminal is it bonds together the wires, making them likely to fatigue and break at the ends. The problem with <br />crimping is that you don't have a brain dead great electrical connnection. <br />JB's method is definitly 'belt and suspenders', but that sort of practice works so well in marine environments.

 

[Chris1956]

Re: Engine rewire ???

Dartboy, You could also buy an aftermarket harness. The price for a harness that fits a lot of Merc's is $80-90 at Surplus unlimited and other vendors. If you do a google search on the part number, you might find several sources.<br /><br />I would also check the battery cables in the boat harness. I had a case where the positive battery cable rotted out near where it joins the main harness. It was under the insulation, and hard to see.