Mechanics opinion needed on a 90HP Merc Four Stroke

MDownes

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Jul 7, 2021
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I have a 2006 90hp Mercury EFI four stroke outboard. Serial number 1B272689.

A mouse chewed the spark plug wires and they need to be replaced. From the Mercury parts catalog, they are part number 804272A1. It seems that Mercury doesn't sell them any more and the Mercury dealers tell me they can't help me. I called the Mercury customer assistance help line at 920-929-5040 and they told me that's too bad but there's nothing they can do for me. Nobody will offer me an alternative or any kind of solution. It's quite unbelievable that a manufacturer like Mercury won't make any attempt to help their customer especially with something as simple and common as a spark plug wire. I told the guy on the phone that I understand that he doesn't know what to do about it but can he put me onto his manager or someone who could help me find the right person at the company who can help. He just kept telling me they don't make the part any more and there's nothing he can do. It was really frustrating and I may have got a little loud on the phone after a while. He hung up on me.

Anyway, that's my rant on Mercury customer support.

So I have a question to all you mechanics out there that may be reading this. I'm not a mechanic myself but I know something about motors and it seems to me that a spark plug wire for an outboard wouldn't much different than a spark plug wire for a car. If I took one of the wires off my outboard and brought it to an automotive parts store could I simply ask them to sell me a wires of a similar length and configuration? Am I being naive? It should be ok, right?

Thanks in advance
Martin
 

b1pig

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Jul 8, 2021
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Pull one of the plug wires off and take it to your local auto parts store. I'm pretty sure the terminal ends are the same as auto plug wires. A basic replacement kit should work for you....
 

Sea Rider

Supreme Mariner
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Sep 20, 2008
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12,345
Those must be inside wired, not carbon wired, if both end connectors are in good shape just replace with new car cable with same diam and lenght...

Happy Boating
 

MDownes

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Jul 7, 2021
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Thanks for your help everyone. It turns out that my local auto parts stores weren't very helpful either. They told me to find out what car and model year has a set of wires that matches my boat motor and they would sell them to me. They didn't want to put any effort into it.

In the end, I bought a wire kit and made them myself. I was a little worried about at first but in the end, it was really easy to do.

The boat runs great now.
 

Doh

Petty Officer 2nd Class
Joined
Aug 12, 2008
Messages
193
Car Plug Wires are Fiberglass/Carbon. You need Wire Core Plug Wire.

Go to your local Small Engine Shop, the type that sells Motor Cycles, 4 wheelers, Snowmobiles. They will have a roll of wire and caps/ends.

The hard [part will be at the Coil, I believe the Coil comes with the Wire attached.
 
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