OMC Engine Harness: Replacement for Main Connector

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Author Topic:   OMC Engine Harness: Replacement for Main Connector

cleaver97 posted 05-12-2008 09:30 AM ET (US)
Looking for some input for the repair of a damaged wire harness on my 15' Dauntless with a 50hp Johnson. Had a problem starting and traced it back to the 8 prong (I think 8 prong) round wire harness plug in the engine. When pulled apart the whole thing disintegrated in my hands. I would like to get two end whips (female and male) and solder and heat shrink new ends on both sides. Cannot seem to find a manufacturer who sells just whip ends. On the few occasions that I found someone that only sells the the whip they sell the male or female end only. Like to wrap this up. It is the only thing keeping me from setting the boat in the water for the season.
Any help would be greatly appreciated.
HAPPYJIM posted 05-12-2008 02:37 PM ET (US)
I had to splice mine and used crimp connectors. I have a high priced crimp tool that makes perfect crimps. I staggered the splices so there wouldn't be a large bulge from the splices. I wrapped every thing with 3-M rubber electrical tape and then applied 2 coats of Scotch electrical coating. The entire splice length is about a foot long.
jimh posted 05-12-2008 09:16 PM ET (US)
What is a whip end? I do not recall hearing that term used in electrical circuits.
cleaver97 posted 05-12-2008 09:43 PM ET (US)
You are right, it is not a technical term but I guess slang used for construction wiring. I mean to say a round plug connector without the complete wire harness, just about a foot of wire bundle with the 8 prong end which can than be spliced into the appropriate wire connectors.
Bella con23 posted 05-12-2008 10:51 PM ET (US)
Jim,
My crew is in the process of relocating a department in one of the facilities and part of that move is the pre-wired work station cubicles that are powered by a "whip end" or "power whip" wired through a wall plate and plugged into each run of work stations.
As a healthcare electrician I have heard the term more than once dealing primarily with installation of pre-wired assemblies.
I don't agree with the term, but it is used in the industry.
Joe
jimh posted 05-12-2008 11:20 PM ET (US)
"Whip end" must be an electrician's trade term. I don't recall hearing anyone use it before. I have been working in electronics (not electrical trades) for about 50 years. Thanks for the clarification.
The OMC motors use a rather large rubber-booted connector. I think it was made by Amphenol. I would check on the Bombardier part website to see if it is available as a replacement part.
http://shop.evinrude.com/
The Bombardier part website provides excellent parts breakdown diagrams with call outs and part numbers. If the connector is available as a part, you could source if from the OEM.
If you don't want to go with an OEM replacement, you could just make your own connector using off-the-shelf parts. You can make a decent connector using MOLEX connector housings, pins, and sockets.
You can also look for a surplus wiring harness. These will be common for the boat side of the connector. For the engine side you might have to look for a basket case engine from a repair shop.
jimh posted 05-13-2008 12:55 AM ET (US)
To satisfy my own curiosity, I checked on Bombardier's outstanding parts website
shop.evinrude.com
and I was easily able to locate the parts you desired. Their cost is quite moderate. You can order them directly from the website.
Replacing the OEM connector would make a better repair. It is much simpler than making numerous splices and butt connections.
cleaver97 posted 05-14-2008 08:45 AM ET (US)
Thanks Jim, great advise as always. I was trying to avoid a hard wire (crimp and shrink tape) on the wire harness in the event I wanted to change the OB engine and would have to cut all the wires as opposed to the stock plug. Will look into your suggestions.

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Author	Topic: OMC Engine Harness: Replacement for Main Connector
cleaver97	posted 05-12-2008 09:30 AM ET (US) Looking for some input for the repair of a damaged wire harness on my 15' Dauntless with a 50hp Johnson. Had a problem starting and traced it back to the 8 prong (I think 8 prong) round wire harness plug in the engine. When pulled apart the whole thing disintegrated in my hands. I would like to get two end whips (female and male) and solder and heat shrink new ends on both sides. Cannot seem to find a manufacturer who sells just whip ends. On the few occasions that I found someone that only sells the the whip they sell the male or female end only. Like to wrap this up. It is the only thing keeping me from setting the boat in the water for the season. Any help would be greatly appreciated.
HAPPYJIM	posted 05-12-2008 02:37 PM ET (US) I had to splice mine and used crimp connectors. I have a high priced crimp tool that makes perfect crimps. I staggered the splices so there wouldn't be a large bulge from the splices. I wrapped every thing with 3-M rubber electrical tape and then applied 2 coats of Scotch electrical coating. The entire splice length is about a foot long.
jimh	posted 05-12-2008 09:16 PM ET (US) What is a whip end? I do not recall hearing that term used in electrical circuits.
cleaver97	posted 05-12-2008 09:43 PM ET (US) You are right, it is not a technical term but I guess slang used for construction wiring. I mean to say a round plug connector without the complete wire harness, just about a foot of wire bundle with the 8 prong end which can than be spliced into the appropriate wire connectors.
Bella con23	posted 05-12-2008 10:51 PM ET (US) Jim, My crew is in the process of relocating a department in one of the facilities and part of that move is the pre-wired work station cubicles that are powered by a "whip end" or "power whip" wired through a wall plate and plugged into each run of work stations. As a healthcare electrician I have heard the term more than once dealing primarily with installation of pre-wired assemblies. I don't agree with the term, but it is used in the industry. Joe
jimh	posted 05-12-2008 11:20 PM ET (US) "Whip end" must be an electrician's trade term. I don't recall hearing anyone use it before. I have been working in electronics (not electrical trades) for about 50 years. Thanks for the clarification. The OMC motors use a rather large rubber-booted connector. I think it was made by Amphenol. I would check on the Bombardier part website to see if it is available as a replacement part. http://shop.evinrude.com/ The Bombardier part website provides excellent parts breakdown diagrams with call outs and part numbers. If the connector is available as a part, you could source if from the OEM. If you don't want to go with an OEM replacement, you could just make your own connector using off-the-shelf parts. You can make a decent connector using MOLEX connector housings, pins, and sockets. You can also look for a surplus wiring harness. These will be common for the boat side of the connector. For the engine side you might have to look for a basket case engine from a repair shop.
jimh	posted 05-13-2008 12:55 AM ET (US) To satisfy my own curiosity, I checked on Bombardier's outstanding parts website shop.evinrude.com and I was easily able to locate the parts you desired. Their cost is quite moderate. You can order them directly from the website. Replacing the OEM connector would make a better repair. It is much simpler than making numerous splices and butt connections.
cleaver97	posted 05-14-2008 08:45 AM ET (US) Thanks Jim, great advise as always. I was trying to avoid a hard wire (crimp and shrink tape) on the wire harness in the event I wanted to change the OB engine and would have to cut all the wires as opposed to the stock plug. Will look into your suggestions.