connector repair

[tblshur]

i have a 83 johnson 140 the stator connectors and power pack conn looks kinda dark maybe small pits in them how do you clean them or where can you get new ones and how would you replace them

 

[Bosunsmate]

Re: connector repair

you can get those connectors from a dealer. They will show you how to do it.
Iboats might sell them, you normally just pull them out

 

[tblshur]

Re: connector repair

thank you Bosunsmate for your quick reply and info 3 hrs to nearest dealer ,may get some next wk striper fishing in tenn.thanks again and stay warm.

 

[Bosunsmate]

Re: connector repair

no worries, its hot here in the southern hemisphere, summer starts in 3days, i dont need to heat up the water tank when i get home.
Look up your motor on marineengine dotcom. you can get the parts sent to you in the mail. It would save a 6hour round trip, id only enjoy that if it was by sea

 

[Bosunsmate]

Re: connector repair

Just pull each wire out carefully and make sure you put it back in the correct hole in the new plug. Have a look at the current plug and where the connectors a sitting. Get them sitting like that in the new plug as if any a too short they wont connect. Pushing them in can be un-easy. I use a small screwdriver and work them in.
I just watched a video of some people striper fishing, the rod had some bend in it. Nice looking fish for eating too.

 

[tblshur]

Re: connector repair

thanks Bosunsmate i never thought me would have conn, i thought you would have to buy a new complete connector and splice it in the wire didnt like that idea. my striper fishing is actually hybred i guess, fishing inland lake in tenn,but lots of fun. thanks again and have a good day.:joyous:

 

[James R]

Re: connector repair

If you have that much damage you will need connectors and pins. If that is the case draw a picture of the wiring colors and pin layout and cut the old connector off, getting back to good wire. Make sure you have sufficient wire length. You will need to carefully crimp the new pins to the wires. There are crimp tools made for this but they are very expensive. Use a little WD40 to lube the pin holes then the pins will slide in easily.

 

[bonzoscott]

Re: connector repair

I would use Dielectric grease. I also fabricated a make shift tool for this (it's not much). Some auto wiper blades used to have a thin strip of stainless steel in them. Cut off two inches of that and clamp it in some vise grips. De-burr the end. It needs to be warm (Tennessee), use a hair dryer. Slop it up in Dielectric grease. Push female pins out through the center hole. The male pins have a shoulder you can get the tool on and work 'em out. Get new pins and / or wire if needed, crimp them on with the "V" in pliers or vise grips. Each pin must be inserted close to the proper depth in the rubber connector housing. It's alot of crap but necessary in many cases. Some applications have to be cut to remove or replace. Mice like to eat wire insulation too. If it's still running, wrap it up in tape until it's time to rework. If you have to spice new wire here and there, solder it and use heat shrink. Those crimp connectors always fail sooner or later.