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Author Topic:   Battery wiring harness
Braunbehrens posted 02-12-2001 11:34 PM ET (US)   Profile for Braunbehrens   Send Email to Braunbehrens  
I just purchased a Montauk with a '79 90HP Mercury on it. The cables to the battery are badly corroded, and the battery is aft, in the corner. I'd like to put the battery in the console, and I've read the excellent thread about that, but I have a different problem. My harness connects to the Mercury with a plug that carries all the various control wires as well as the main connection to the battery. The plug is not openable. If I buy a new harness I have to rewire everything, and I'd like to avoid that, but I can't get in the plug to attach the new battery cables. As far as I can see there are 3 options, a new harness (lot's of work), cut the cables and attach the new cables to the old ones (bad idea probably), and bypass the plug and attach the cables directly to the inside of the outboard (this is probably the best option, but how do I get in and out of the outboard?)

Any suggestions are welcome.

Zack posted 02-13-2001 11:25 AM ET (US)     Profile for Zack  Send Email to Zack     
I have had the same problem with two old Mercury's that I have. I cut the battery wires back to where the wire was good and connected new wire with "butt connectors"(I used a nicro press tool to make connection). I used liquid tape to seal the ends, then taped them good. I have been using one for over a year now with no problem. Mercury was noted for the bad wires in the older motors. Hope this helps. Zacks
Braunbehrens posted 02-13-2001 11:56 AM ET (US)     Profile for Braunbehrens  Send Email to Braunbehrens     
Thanks Zack, I'll give it a shot. I just hope the cable isn't corroded all the way to the plug.


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