Wiring questions

[AJRanger]

Motor is a 69 Johnson 55hp

I was all proud of myself for replacing all of my fuel lines, just finishing that up when I noticed the wires running beside it looked like they were caked with something. I attempted to clean them and discovered it was actually the wire sheathing falling apart...

Long story short, If I were a rich man, I would by a new wiring harness (degraded wire throughout!) but since that isn't an option at $165, I am going to build my own. I have found most of the connectors I need, but I am having trouble finding the wire. I am tempted to throw in machine grade, fuel and heat resistant wire (because I can swipe it from work) but it isn't 'tinned' marine grade... is this going to be a huge issue? If so, anybody know where I can buy it by the foot on-line? I really don't need 100' of any one color.

Second, there are three connectors (all the same style) that I can't find anywhere. Would I be a complete idiot to just axe the connectors and wire direct? If so, what is the solution to replace an obsolete connector?

 

[Tim Frank]

Re: Wiring questions

Motor is a 69 Johnson 55hp

I was all proud of myself for replacing all of my fuel lines, just finishing that up when I noticed the wires running beside it looked like they were caked with something. I attempted to clean them and discovered it was actually the wire sheathing falling apart...

Long story short, If I were a rich man, I would by a new wiring harness (degraded wire throughout!) but since that isn't an option at $165, I am going to build my own. I have found most of the connectors I need, but I am having trouble finding the wire. I am tempted to throw in machine grade, fuel and heat resistant wire (because I can swipe it from work) but it isn't 'tinned' marine grade... is this going to be a huge issue? If so, anybody know where I can buy it by the foot on-line? I really don't need 100' of any one color.

Second, there are three connectors (all the same style) that I can't find anywhere. Would I be a complete idiot to just axe the connectors and wire direct? If so, what is the solution to replace an obsolete connector?

Been there, done it, have the tee-shirt.

Read this thread for a few tips:

http://forums.iboats.com/showthread.php?t=281464

 

[AJRanger]

Re: Wiring questions

Thanks! I was just looking at it and realized that I can run the wires a lot more efficiently than Johnson did.

I am going to kill the harness connector, and every other connector I can. It will be one less thing to go wrong in the future.
I talked to a local boat dealer and their mechanic said that they don't use the tinned wire, they use exactly what I have piles of laying around at work... it is possible that I might get out of this for almost nothing. That can't be right?!?

Are there any of the plastic connectors that I should replace with new ones? This would be a lot easier if my repair manual would get here, I ordered it a week ago!

 

[Tim Frank]

Re: Wiring questions

I resused the 2 small single wire connectors, i think one was a ground wire, the other was a temperature sender.
Other than that I made all connections on the terminal strip. Interior motor wiring I never touched again, the cable running in also connected on that strip....wiring colours matched because I used the excess wire in the main cable running to the big plug to do the rewire inside the cover.

I had a 15 foot boat and the excess cable was more than 6 feet. By the time i cut back 8"-12" from the plug (it was inside a heavy rubber jacket, the wire was priistine and I had 5'+ to work with of all the colour and gauge that I needed.

Keep in mind that I took the motor off every fall for the winter and stored it in my basement....if you are not going to do that, you can make more permanent connections.

 

[AJRanger]

Re: Wiring questions

Update-

Replaced every spec of wire in my engine. It started up the very first time! Just a note if anyone else decides to do this- keep in mind how you want to re-bundle and run the wires. I ended up having to re-wire a few connections because they were too long or short when all was said and done. Also, pay attention to the order of your wires so you don't end up with something that belongs on the motorside of the bundle on the outside.

My lesson learned: Start with the wires that need to tie in closest to your main line from the battery and work your way back. You end up with a much nicer bundle to wrap at the end. Use water tight butt splices AND heatshrink. Worth the expense to ensure a lasting and corrosion free connection.

 

[Tim Frank]

Re: Wiring questions

Well done....sounds like you are off and running.