Trigger Wiring Rotted. Repair? Replace Harness?

[dctucker]

1981 80hp, 4 cyl. Just noticed that some of the wiring to the switchbox is pretty rotten and extremely likely to fail soon. The worst is from the trigger to the switchbox, and also from the stator (?) to something just aft of the switchbox (rectifier??). All the wiring from the switchbox to the coils looks to be in good shape.<br /><br />If if can cut back to solid wire and insulation, is it okay to solder and heatshrink new marine grade wire, or do I need to replace the harnesses? I don't currently have a flywheel holder or puller, so I'm hoping it's okay to just replace the rotten stuff... Just began self employment and don't want to spend any cash if I can get away for less!

 

[Laddies]

Re: Trigger Wiring Rotted. Repair? Replace Harness?

Most of those wires are stainless or something that don't like to solder well although I have never tryed to silver solder on them, but have been able to recoat them with liquid vinal or liquid tape.--Bob

 

[dctucker]

Re: Trigger Wiring Rotted. Repair? Replace Harness?

Not that I don't beleive you, but I don't beleive you With the greenish corrosion, they sure look like regular old tinned copper strand to me... Guess I'll try cutting back and soldering in new. Don't have much to loose.

 

[Laddies]

Re: Trigger Wiring Rotted. Repair? Replace Harness?

DC with a little luck I hope your right the two I tryed did not show corrosion and I think the same a you do if it's corroded it's copper wire

 

[andrewkafp]

Re: Trigger Wiring Rotted. Repair? Replace Harness?

DcT<br />I fixed mine (Same age) by peeling back the insulation as far back to the trigger as<br />possible and using a crimped wire joiner to add new wire of similar ampege.(Auto wire)<br />You can buy a rubberweld tape that stretches to re-form the loom insulation.<br />Also, I think Clams has posted a technique for even fixing them when they go right back to the trigger.<br />BTW Try to keep the colour the same for identifying any problems with the trigger.

 

[rodbolt]

Re: Trigger Wiring Rotted. Repair? Replace Harness?

if I were you I would liquid tape them. if they are the stainless stranded it wont solder and if they are copper they are rotten and most likely wont solder. liquid tape them with 4 or 5 thin coats until you can save some coins for replacements.<br /> this a a problem I have a lot of experience with .

 

[prolinews]

Re: Trigger Wiring Rotted. Repair? Replace Harness?

I have a 81 50hp that has some fixed wires two years and counting I'm still crossing my fingers ,don't want to spend the money until it tears up.

 

[agrazela]

Re: Trigger Wiring Rotted. Repair? Replace Harness?

dctucker,<br /><br />On my 78 70hp, I have replaced much of the internal wiring with marine-grade wire and butt joints, with heat-shrink over the joints. This has worked well for me.<br /><br />Of course, I wouldn't venture out of the bays with this jerry-rigged electrical system...

 

[dctucker]

Re: Trigger Wiring Rotted. Repair? Replace Harness?

Laddiesservice,<br /><br />I eat my words! I stripped back the cover and found more rotting insulation on 3 wires. All white (?). I cut out the rottenest parts, put heat shrink over the rest, and tried to solder on some new ends. It was quite a challenge and I'm not really sure that I got good solder connections. <br /><br />Hopefully it will hold up. If I have trouble with any ignition related issues, I'll know where to look, and may eventually just buy a new stator and trigger just to get fresh wiring.<br /><br />I searched, but couldn't find the link to Clam's instructions for rewiring this stuff. Can anyone point me in the right direction?

 

[dctucker]

Re: Trigger Wiring Rotted. Repair? Replace Harness?

It was fairly warm in the Boston area yesterday, so I rolled the trailer out of the garage, hooked up the muffs and fired it up. Ran fine, though it took quite a while to catch at first. After it finally got running subsequent restarts were nearly instantaneous. Nice! Guess I'll give it some on the water testing soon enough, as the days are getting better First weekend in April maybe...<br /><br />BTW, clearing some dried mud from the pee hole outlet allowed water to flow from there. Still need to drop the LU and replace the impeller, but that was a reassurring sign.

 

[andrewkafp]

Re: Trigger Wiring Rotted. Repair? Replace Harness?

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