DIY Engine Cable Assy Tips - 1989 Evinrude 175 Crossflow

[guitman32]

Im am going to re-do the engine cable assembly (motor-back wiring harness) due to shorting cables and corroding connections, including diodes and 5-wire power pack connector. Engine is VRO delete.

Wanted to know if anyone has any tips or tricks...so far have the follow list of questions and items:

1)Solder, heat shrink all connections where possible, liberal use of liquid tape, etc

2)Do I use solder or crimp connectors for the connections between the engine cable-to-console cable (Im deleting the Big Reg Harness)?

3)Any recommendations on type (eg butt/spade/bullet?)

4)Looking for a specific over the counter diode model to replace the over priced BRP #583898 Diode Kit. Thinking something in the 600V/30-40A range. Dont know if Reverse Current rating is material??

5)Any ideas where I can get Evinrude color matched wire?

Your input is welcome.

 

[daselbee]

Re: DIY Engine Cable Assy Tips - 1989 Evinrude 175 Crossflow

I have found this place to have very good prices on adhesive lined heat shrink crimp connectors.

www.delcity.com

 

[tashasdaddy]

Re: DIY Engine Cable Assy Tips - 1989 Evinrude 175 Crossflow

get the OEM service manual.

 

[guitman32]

Re: DIY Engine Cable Assy Tips - 1989 Evinrude 175 Crossflow

I have found this place to have very good prices on adhesive lined heat shrink crimp connectors.

www.delcity.net

Thanks, good link.

get the OEM service manual.

Have the manual, thanks.





Re: the blocking diode, I opened up the harness and the diode used is as follows: 1N5397

Specs:
PIV: 600V
RMS Reverse Voltage: 420
Operating Temp Range: -65 to +125 C
Average Output current: 1.5A
Peak Forward Surge Current: 50A

 

[guitman32]

Re: DIY Engine Cable Assy Tips - 1989 Evinrude 175 Crossflow

Does anyone know a convenient source of typical colored harness wire?

Black/Yellow (kill)
Yellow/Red (starter)
Purple/White (choke)
Grey (tach)
Purple (accy)
Tan (alarm)

 

[guitman32]

Re: DIY Engine Cable Assy Tips - 1989 Evinrude 175 Crossflow

Got the harness made. Overall wasn't very difficult. Trickiest part was getting the amphenol connectors right and the joints between multiple wires and the diode on the tan side. Used dielectric grease on all critical connections and adhesive line shrink tubing. In the picture it is just loosely tie wrapped in place for final fitting.

I Wish I had found wire colors that correspond to original, but I got the close enough with solid colors. Either way gauges exceed the original wire size on the hot connections and grounds, and the diode is upsided on the amperage and voltage. I feel confident that my harness quality at least meets the CDI equivalent.

Old (hacked up) harness on the bottom, new (almost there) on top:

Again if you need the diode part, the one that was in my harness was a 1N5397 (600v peak, 420v rms, 1.5a).