Thunderbolt 800 Wiring Harness

[hartleck]

All the wiring in my old harness has cracked and brittle insulation so I went to order a new wiring harness from here on iboats and found this:

80 800 4 1970 3051041-3059820 414-2770
80 800 4 1971 3144219-3192962 414-2770

In an earlier thread I was told that my Serial#, 3052262, was a 1971. This shows it as a 1970. I really don't care which it is but I do want to get the right harness. Is the 1970 the one I should order?

 

[carholme]

Re: Thunderbolt 800 Wiring Harness

In the first place that is a CDI harness:

http://support.crowleymarine.com/attachments/token/96rqwddc9bgdqph/?name=414-2770.pdf

which fits both years, however Iboats own s/n listing refutes this and says that your is a 1971.

80 4 2986444 1971
80 4 3186263 1972

As the 1972 starting s/n is 3186263 which is higher than your 3052262, yours is a 1971.

The p/n for your original harness is 59741 for the 1971 800E and you will see from the CDI sheet that 414-2770, is a replacement harness for your engine.

Hope this makes sense.

Gerry

 

[hartleck]

Re: Thunderbolt 800 Wiring Harness

As I look at the picture I can't tell if the wires are long enough to travel back to the control box. Is that harness a different part or part of this harness? Thanks by the way for the help. Sorry I'm having to bother you with this, but I really appreciate your help.

 

[carholme]

Re: Thunderbolt 800 Wiring Harness

hartleck;

The harness which we have been discussing all along is the engine internal harness, ie; it goes from the various engine components to the male pug on the engine cowling, seen here as item 37:

http://www.crowleymarine.com/mercury-outboard/parts/445_70.cfm

Your external harness from the engine to the control box will be a different part number depending on what control box you have but I am assuming that it is a standard 7 wire harness.

Gerry

 

[hartleck]

Re: Thunderbolt 800 Wiring Harness

hartleck;

...Your external harness from the engine to the control box will be a different part number depending on what control box you have but I am assuming that it is a standard 7 wire harness.

Gerry

Here is a picture of my control.

 

[carholme]

Re: Thunderbolt 800 Wiring Harness

Here is a link to the control box parts. I have this box on my 68 Merc 500.

Do you want to replace the harness from the box back to the engine? If so is yours one piece from the box to the engine plug or is it split for passage through the splash pan?

Gerry

 

[hartleck]

Re: Thunderbolt 800 Wiring Harness

Here is a link to the control box parts. I have this box on my 68 Merc 500.

Do you want to replace the harness from the box back to the engine? If so is yours one piece from the box to the engine plug or is it split for passage through the splash pan?

Gerry

Yes, from the box back to the engine. It appears to be one piece going directly into the plug. There was no link.

 

[carholme]

Re: Thunderbolt 800 Wiring Harness

Getting too old and stupid.

http://www.crowleymarine.com/mercury-outboard/parts/640_28.cfm

Gerrry

 

[hartleck]

Re: Thunderbolt 800 Wiring Harness

Getting too old and stupid.

http://www.crowleymarine.com/mercury-outboard/parts/640_28.cfm

Gerrry

Not so I feel I am the stupid one. I checked the link and followed it farther and found the harness is obsolete. Further options at Crowley took me back to the internal harness again, http://www.crowleymarine.com/parts/206467.cfm , if I understand this right.

 

[Gomer50]

Re: Thunderbolt 800 Wiring Harness

If your looking for a internal wire harness take a look here.http://www.outboardparts.com/mercury/mall/merchrnss.htm
If your looking for an external wiring harness take a look here.
http://cgi.ebay.com/ebaymotors/OLDE...8185076QQptZBoatQ5fPartsQ5fAccessoriesQ5fGear

 

[carholme]

Re: Thunderbolt 800 Wiring Harness

hartleck;

I just wanted you to see the box assy and all it's parts. CDI has new harnesses as you saw re the internal harness. I would be careful about buying old ones off ebay as they are probably in the same condition as yours. Aside from brittleness of the wires, corrosion in the plug which attaches to the engine is often a problem as well as damaged or missing portions of the pin connectors.

CDI Harnesses:

http://www.cdielectronics.com/Products.aspx?Criteria=4

Gerry

 

[hartleck]

Re: Thunderbolt 800 Wiring Harness

I just finished the external harness install today. The de-soldering was a bear but all came out well. The moment of truth when I turned the key after connecting the battery. Wow!!! the sweet sound of her turning over. My wife jumped out of her chair and hollered with joy. Now I'm working on the replacement of the control cables. The only problem is remembering where part 51 and 50 goes and how. If anyone has pictures I'd be very appreciative.