Remote electrical harness plug repair?

SeaHorse

Petty Officer 1st Class
Joined
Oct 2, 2001
Messages
205
My 3 cyl Merc has a 7 pin harness that connects the remote to the motor. The molded plug where it plugs into the motor has 7 pins that stick into the female near the left front of the motor. One of the wires, the gray electric choke wire has failed at (or near) the plug. I know I can fix this by tapping into the harness just before the plug and wiring that with a connector to the choke solenoid but I'm looking for a better fix. I'm thinking it's possible to open the harness sheathing, cut the gray wire about 6" from the plug, then pull out the pin from the head, then resolder a piece of marine wire to the pin, feed the wire back through the head and reseat the pin down into the head then resolder the wire together and tape up the sheath. <br /><br />Has anybody done this? Is there a better solution?
 

Ben Konopacky

Petty Officer 1st Class
Joined
Apr 5, 2004
Messages
296
Re: Remote electrical harness plug repair?

Seahorse, If you are not useing a tach.you could disconnect the brown wire that goes between tach.and switch box(some times there is a jumper across the G 7 E on the motor side)changes color to salmon. check your manual.
 

SeaHorse

Petty Officer 1st Class
Joined
Oct 2, 2001
Messages
205
Re: Remote electrical harness plug repair?

Ben,<br />Thanks. I do use the tach but I see that there's a white from the ignition switch to the plug but it's not shown as used on the female(motor) side. I'll try for that one.
 

Chris1956

Supreme Mariner
Joined
Mar 25, 2004
Messages
28,105
Re: Remote electrical harness plug repair?

Seahorse, I repaired the female plug once by drilling a hole though the back of the plug directly to the failed wire. I inserted a good wire, solderer it to the brass female connector and siliconed it to seal it form the elements. It is a bit unsightly, but has worked for 20+ years.
 
Top