loose main harness 8 pin connection

[bateyl]

What is the best way to tighten the 8 pin connecton on my 40 hp mercury. The motor will start most of the time but sometimes it will not. I checked the starting system with my volt meter and when I touched the 8 pin connector with the key on the warning horn would go off and back on. I pulled the connector apart and it appears to be clean but after i put it back together I can make the horn go off and on by just moving the connector slightly. It appears to be loose and not staying connected all the time. Any suggestions?

Thanks

 

[zorak]

Re: loose main harness 8 pin connection

Most of the time the pins are split down the center.Take a really thin blade knife and push it down between both halves of each pin to spread the halves out . You can also clean them with some very fine sandpaper if they are dirty. On the female side of the connector you may be able to roll some sandpaper really tight and get into the holes.

 

[Mi duckdown]

Re: loose main harness 8 pin connection

What zorak said. plus put a small amount of di-electric grease on the probes.

 

[bateyl]

Re: loose main harness 8 pin connection

Well in the process of trying to tighten up the pin connectors I believe I have ruined them to the point the connector is no longer useable. What would I need to use to cut out the pin connector? Possibly crimp or soldier the wires together at that point? Do they make a water resistant crimp on connectors and if so where would I get them?

Thanks for the help.

 

[CDI Tech Support]

Re: loose main harness 8 pin connection

Well in the process of trying to tighten up the pin connectors I believe I have ruined them to the point the connector is no longer useable. What would I need to use to cut out the pin connector? Possibly crimp or soldier the wires together at that point? Do they make a water resistant crimp on connectors and if so where would I get them?

Thanks for the help.

If you're interested, we sell replacement harnesses. Check here for the correct part#:

Application Guide - Mercury

 

[bateyl]

Re: loose main harness 8 pin connection

I also need the male part of the connector. I looked up the harness on your site and it had only the engine harness and female part of the plug or connector.

 

[CDI Tech Support]

Re: loose main harness 8 pin connection

I also need the male part of the connector. I looked up the harness on your site and it had only the engine harness and female part of the plug or connector.

If you're referring to what the engine harness plugs in to, that would be the control harness (the harness that connects the control box to the engine harness). Control harnesses can be determined here (after determining the engine harness):

CDI Troubleshooting Guide

Choose either:

Mercury Engine to Control Harness Cross Reference (sorted by CDI Engine Harness Part Number)

Mercury Engine to Control Harness Cross Reference (sorted by OEM Engine Harness Part Number)

Since your engine harness has 8 pins, that likely means you have a cannon style plug. If this is the case, the correct control harness part# is 474-9560. List Price is $282.00.

 

[bateyl]

Re: loose main harness 8 pin connection

If I used snap connectors with heat shrink in place of the 8 pin connector that connects the engine harness to the control harness, do you think that would be a good connection? The wiring on both harnesses are in good shape, it is just the connector that is messed up.

Thanks

 

[CDI Tech Support]

Re: loose main harness 8 pin connection

If I used snap connectors with heat shrink in place of the 8 pin connector that connects the engine harness to the control harness, do you think that would be a good connection? The wiring on both harnesses are in good shape, it is just the connector that is messed up.

Thanks

I've never heard of anyone trying that, so I cannot give any advice on it.