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Author Topic:   External throttle/shift control connector pinouts
skred posted 12-21-2012 01:56 PM ET (US)   Profile for skred   Send Email to skred  
I have identified the wires in the round connector coming out of my Mercury Throttle/Shift control. The connector is extends out of the control assembly by about 8 inches of leads. I have posted the pinout colors here:
http://s216.beta.photobucket.com/user/skred/media/pinout_zps78a731e2. jpg.html?sort=3&o=0

Can anyone identify the white and black/white pins in the plug, and the separate brown lead? The motor is a 1998 Merc 40 hp.

jimh posted 12-21-2012 10:13 PM ET (US)     Profile for jimh  Send Email to jimh     
Could the BROWN lead actually be a TAN color?

Could the BLACK & WHITE lead actually be BLACK with YELLOW STRIPE?

skred posted 12-23-2012 10:32 AM ET (US)     Profile for skred  Send Email to skred     
Yes, the brown could be considered a shade of tan.... It comes out of the same wire bundle that connects to the 5-pin plug, but is separate, and has a small female receptacle to connect to additional cable to somewhere...
The black and white may well be black and faded yellow. If so, that would make the tan lead a temp warning horn lead, and the black/yellow stripe a shorting or stop circuit (however, I haven't a clue what that circuit is for)....
jimh posted 12-23-2012 12:28 PM ET (US)     Profile for jimh  Send Email to jimh     
The BLACK with YELLOW STRIPE circuit usually connects to a switch operated by a safety lanyard. When the lanyard is pulled from the switch, the circuit is made to ground. This shorts out the primary spark ignition coil voltage, suppressing all engine spark, and stopping the engine. This circuit can carry relatively high voltage, about 300-Volts, so it is usually well insulated.
L H G posted 12-23-2012 02:29 PM ET (US)     Profile for L H G    
The 5-pin round plug is called a "5 pin Tachometer Harness Connector". It for instrument connections from a side mount control. Mercury and Teleflex both make a Tach harness pigtail that plugs into this harness plug, about $40.

Purple and black are Ignition and Neg, respectively. Gray is the tachometer sender. There should be a brown/white stripe wire that is the optional trim indicator sender. Trim senders are not included on Mercs smaller than V-6, but there is an optional add-on kit. The 5th pin should be tan/blue stripe. This is from the engine's temp sender for all or nothing warning horn activation. The loose tan wire is an "accessory wire" and can be used for a temp gauge, if engine is equipped with optional temp sender kit.

To the best of my knowledge, Mercury has never used all white or black/white stripe wire in outboard wiring. Your colors must be faded, or the control must be very old using a different wire convention.

jimh posted 12-23-2012 05:08 PM ET (US)     Profile for jimh  Send Email to jimh     
A search with GOOGLE on the terms "1998 Mercury remote control wiring" produced this link:

http://motorka.org/doc/mercury/service_manual/mercury_2t/ mercury_225_225EFI_250EFI/2d.pdf

There is little doubt that VIOLET is the switched 12-volts via the ignition key switch, BLACK is the battery negative, and GRAY is the tachometer signal. This follows like the night the day and is universal in outboard engine remote control and instrumentation wiring.

The above linked diagram identifies the other two conductors of the five pin as TAN with BLUE STRIPE and BROWN with WHITE STRIPE conductors.

According to my research at http://continuouswave.com/whaler/reference/wireColorCode.html#Merc , those conductors would be identified by their color for the functions

TAN with BLUE STRIPE = Temperature Switch to Warning Horn

BROWN with WHITE STRIPE = Trim Sender to Trim Gauge

The above linked diagram also identifies the separate wire as a TAN conductor. This color is associated to function as

TAN = Temperature Switch to Warning Horn

--or--

TAN = Temperature Sender to Temperature Gauge

jimh posted 12-29-2012 09:21 AM ET (US)     Profile for jimh  Send Email to jimh     
Just to be clear, the document to which I have given a hyperlink above goes on for about 30-pages and shows every imaginable combination of Mercury control, harness, and gauge wiring. You should be able to find the exact configuration for your 1998 Mercury engine in that publication. I mention this because is some browsers the PDF file just opens to the first page, and it may not be clear that there are many more pages to follow.

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