Choke Wire

[Frankimuni]

Hi Folks,
If this is posted in the wrong area, I apologize in advance.

Just bought a used bought. It sat all winter and mice got into the engine and ate the choke wire. The nest was around it.
Problem is, I can't find the rest of the wire to fix it.

The engine is a 1979 Mercury 80hp 800 thunderbolt ignition 4cyl. 2 stroke.

Any help is appreciated.

 

[Scott Danforth]

first, welcome aboard

the downside to most 70's and 80's mercury outboards are the wiring harnesses falling apart. the insulation lasts only about 15 years. the Mice didnt help

the two common choices are buy a new harness or build a new harness.

 

[Chris1956]

The choke wire is grey in color. The balance of the wire should be hanging out of the quick disconnect male plug on the inside of the lower cowl.

As Scott advises, if the insulation is falling of the harness in general, it is best to replace it. The web will have several sources, with different prices. Make sure to order one with the exact year if you can, as they changed the wire colors, in 1980. You also should have a 4 coil ignition (no distributor). That is ADI ignition. Make sure you order that style.

Newer harnesses will fit your motor, however, the change in wire colors is confusing.

 

[Frankimuni]

Thanks for the quick replies.
The harness looks like it was cleaned up a bit over the year, still in relatively good shape. I will look for a new one though.
As far as the rest of the wire, it's MIA. I am trying not to take it apart, but it looks like that's the only option at this point. Better safe than sorry.
Any recommendations on what company to get the harness or should I just go to mercury?

 

[Chris1956]

You should be able to see the rear of the quick disconnect plug. The wire should be there. There is a couple of bolts and a clamp, and the wiring harness slips out.
I would use the OEM part number and do a search on the web. All the aftermarket harnesses are likely made by Sierra or GLM.

 

[Frankimuni]

Sounds good. I'll be back at it tomorrow if the weather holds up and keep you posted.

 

[Frankimuni]

Hey Guys,
Just wanted to thank for your help. I found the gray wire tucked up under the flywheel alongside the harness. Cut it all the way back to the plug and ran a new wire to the choke. Works good. I will eventually have to rewire the whole engine, I did fix a couple of other wires that needed attention. Thanks again for all your help.
I did find a blog with wiring diagrams. Not sure I can post the link here. If it's okay, I will.

 

[Chris1956]

the maxrules web site has the wiring diagrams