Pontoon boat OB wiring harnesses coiled up in motor pod

[guy48065]

I have an 18' pontoon with a 2000 Johnson 40HP (J40PLSSM). It's a pretty short run from the OB to the helm and there's several feet of harness just coiled up in the motor pod. Is this normal setup? Are these harnesses "one size fits all"?

Previous owner chopped the harness inside the console so I have no gauge feeds. I'm weighing whether to replace the entire harness with new (or good used), or just pull some of that extra into the console and install new connectors for what I need (planning to add some gauges). I do have the tools & skills to install the Deutsch connectors. The problem with the cheaper solution of pulling some of the unused harness is then I will have to do something with the extra length of the part of the harness that pops up thru the floor boot at the back corner and runs with the shift & throttle cables to the remote.
A 3rd option would be to just solder new wires to the chopped ones in the console.

I don't know squat about dealer setup and have never scrutinized other boats to compare.

 

[Scott Danforth]

Very common with boat builders

 

[guy48065]

Meaning...?

 

[Scott Danforth]

The coil of wire. Boat builder buys one control harness length to have less variation in stock.

A tailored harness length would add a lot of cost of boat when new that no one wants to pay

 

[mjf55]

Does the pod stay dry? Does the harness get wet? If it stays dry, I would not mess with it and leave ot alone.

To hook up the gauges, how much length do you need? I would not solder additional lengths to the harness. If you need just a few inches, pull that amount and then use the correct heat shrink adhesive lined crimp connector.
A photo or two of the engine pod and back of gauges would help assess the plan.

 

[guy48065]

Pod does not stay dry. And after watching a couple youtube clips showing what goes on under the deck at high speed I'm not wanting to make any cuts below the deck. AND there's already a taped-up section of that harness under there. All in all I think it's best to replace the entire harness.

Maybe I can find a shorter one to clean up the wiring even more.

 

[mjf55]

Sounds like a reasonable plan. If looking at a used harness, check connectors and wire for corrosion. If new, you should not have that.

If you have more time than money ( like me ) you can custimize your existing cable. Again, no soldering ( although that is a controversial subject here )

Still concerned about your control cables, would you find shorter versions or leave them be?

 

[guy48065]

The control cables are all point-to-point with no extra.