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    Harness issues

    The neutral safety switch must close for power to go to the starter solenoid. Make sure the control is in neutral, and make sure power is getting to the starter solenoid, when you turn the key. The positive battery cable should run to one of the large posts on the starter solenoid. This power...
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    WOT problem

    You might find something on e-Bay The 40 HP might be close enough. Try to stick with OEM manuals. https://www.ebay.com/sch/i.html?_from=R40&_trksid=p2047675.m570.l1313&_nkw=mercury+outboard+service+manual&_sacat=0
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    Boat Cover Ribs/Braces

    Gee, how about a 2X4 ridge pole? If you need it, you can tie some light rope from gunwale to gunwale across the ridge pole, to help support the cover..
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    WOT problem

    Your motor has a specific setting for spark advance, when throttle is closed, but ready to open. It also has a spec for max spark advance. These need to be set precisely to avoid engine damage and allow proper operation. I would therefore recommend you perform a link and synch. A OEM service...
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    Viking 190SI

    Controls are specific to engine brand. Some controls can be configured for Merc and Johnnyrude, Yammie etc. These are usually made by third parties. Steering systems are usually universal. Fuel systems are easily adapted. Wiring diagrams are hard to find for specific models. You can try...
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    2002 Rinker Captiva 192

    Could be several things or combinations. Steering cables bind. Steering rod on outboards get dirty or corroded. Sterndrive power steering rods get dirty or corroded. Power steering fluid gets low. You need to isolate the binding to the correct component. So disconnect the steering cable...
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    My winter cover solution

    I support my cover as Lou does, except I use light rope instead of fiberglass lath. However, there is usually a spot or two where the water pools. This year in addition to the light rope support, I took some web strap and installed snaps on the ends and a buckle in the center. The snaps...
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    Jack up the bow while boat is on the trailer ...

    Jack up the front of the trailer. The trailer should be plenty strong, as the bow is pretty light.
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    Harness issues

    You could probably do that, however, without knowing exactly what motor year you have, I do not know for sure if it will work. Hardwiring the wiring to the motor would make it difficult to remove the motor from the boat, without disconnecting the wires at the various parts of the motor. A...
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    Harness issues

    As I said in post #10, the new harness does not have integrated battery cables, like your original did. Of course, I have no idea what you have now, after your last post stated that the original system was gutted. If you somehow use the new boat wiring harness, it will power your gauges and...
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    Harness issues

    The factory harness provides sufficient power to gauges. Anything else should be directly connected to the battery and run to a fuse block. An inline fuse at the battery is a good idea as well. A master shut off switch is also a good idea. Keep in mind that those old Mercs only charged at...
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    Harness issues

    I do not have any experience with pre-switchbox (point/coil) ignitions. That would make your motor pre 1970s, I would think. Scott is correct. A water resistant plug with the correct number of wires, might be the easiest. Hopefully you have a wiring diagram. The maxrules web site has Merc...
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    Harness issues

    If your 850 has the quick disconnect plug on the starboard side of the cowl base, it is not plug and play. Mechanically it will work fine. The separate brown wire is overheat, which you likely do not have. If you have a 1976 or newer Merc 850, you will need to replace the engine harness...
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    Harness issues

    Your old 850 boat harness includes the battery cables. A newer harness will not. Hence you will need separate battery cables, plus the new harness. Of course you could buy new controls and harness and cut off the skinny plug and graft the old quick connect to the new wires. Usually, those...
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    Harness issues

    Is your motor ADI ignition with 4 coils? If so, you should be able to get an ADI ignition motor harness with the round skinny plug, for a more modern 4 cylinder ADI motor, say a '90s 115HP. This engine harness plug will match the newer controls wiring harness. You would need to route the...
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    Harness issues

    What exactly is the issue? Newer controls will work the shift and throttle properly. Your wiring can be adapted to the new wiring. You would need an interconnection diagram. Not too difficult
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    Rectifier/Regulator

    Earlier Mercs had a singular 40Amp VR. Later Mercs had twin 20A VR what do you have?
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    98 Johnson leaking hydraulic fluid.

    You can buy a new reservoir, cap, orings and screws for about $80. I just replaced my cap as it tended to cross thread. The new one ($20) works like new.
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    Lower unit oil

    Gee, I use a hand impact driver. They come with various widths of slotted screw driver bits. If you use the impact driver correctly, the plugs do not strip.
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    40hp mercury exhaust leak

    My '93 Merc V6 has a rubber hose from the block to the cowling for the idle exhaust relief. If this hose leaks, exhaust gets under the cowling. Do you have something similar?
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