'72 merc 800.......magic electric smoke

KT64TM

Petty Officer 3rd Class
Joined
Jul 13, 2003
Messages
83
No..... Not the ignition box, the external harness ground to battery wire melted insulator. Can't afford the nearly $300 aftermarket replacement. Any suggestions on re building/wiring the harness?
 

Fuzzytbay

Chief Petty Officer
Joined
Jun 6, 2008
Messages
557
Re: '72 merc 800.......magic electric smoke

Is the plug still ok, and how long before the plug is the harness ok?
Post a pic if you can, that would be good. You can always rebuild a harness, its just a question of cost, and time.
 

Chris1956

Supreme Mariner
Joined
Mar 25, 2004
Messages
28,123
Re: '72 merc 800.......magic electric smoke

See what surplusunlimited.com has for a price on that harness. I found them to be cheaper.
 

Moody Blue

Captain
Joined
May 24, 2004
Messages
3,136
Re: '72 merc 800.......magic electric smoke

Making your own harness is not that difficult. Question is can you salvage the plug that connects into the motor. If so, strip back the outer jacket to expose the individual wires. Cut off the damaged wire(s) back to good material. Buy quality waterproof crimp-on butt-splice connectors and using the same gauge wire replace any damaged wires. Make sure you don't cross connect any of the wires. There are several different materials you can use to jacket the new harness. Make sure all the connection points are waterproof.

Which ever way you decide to go, be sure you find out what caused the problem in the first place. Most likely it was a bad connection either in the motor connector, or at the battery or where the gnd connects to the motor.
 

KT64TM

Petty Officer 3rd Class
Joined
Jul 13, 2003
Messages
83
Re: '72 merc 800.......magic electric smoke

'preciate your responses.

The cause of the problem is old wiring and repeated attempts to start this old girl.

The link led me to a replacement harness for $124.
 
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