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Equipment & Gear => Power Equipment & RV => Topic started by: Stein on March 09, 2021, 09:49:16 AM

Title: Marine plug wire repair
Post by: Stein on March 09, 2021, 09:49:16 AM: So, I replaced spark plugs and one of the terminals on the spark plug side pulled out. Mercury is backordered for who knows how long and nobody has them in stock. I haven't been able to cross reference any aftermarket (Sierra, etc) set either.

I have the wire and the boot and it looks like if I buy the stainless terminal, clean up the end of the wire, crimp it back on and stuff it into the boot I should be good to go? I've never built a plug wire and the marine stuff is supposed to be different but from my research it seems that if I use the original wire and boot and get a stainless crimp end I should be good to go?

Any advice on that route?
Title: Re: Marine plug wire repair
Post by: KFhunter on March 09, 2021, 10:05:15 AM: Outboard kicker?

Ya, I've built plug wires plenty of times. Use a little sparkplug boot grease next time for easier removal.

If you can, soilder on the new terminal before you slide the boot over it. If your wire itself is corroded replace the whole thing.

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Title: Re: Marine plug wire repair
Post by: Stein on March 09, 2021, 10:15:19 AM: This was the wire for my main motor. I always use dielectric grease and am as careful as possible but this one just let go. I replace every year and it's only 3 years old so who knows.

I would hate to miss out on early season koke fishing, I think I'll do the repair then order a new set when they get in stock but that might be a while.
Title: Re: Marine plug wire repair
Post by: MountainWalk on March 09, 2021, 11:30:45 AM: Silver solder, lead free. Good heat from the solder iron from below. Use good quality flux.
Title: Re: Marine plug wire repair
Post by: MountainWalk on March 09, 2021, 11:34:18 AM: As KFhunter mentioned, a little dialetic grease makes everything nicer. Who doesn't like a little lube?
Title: Re: Marine plug wire repair
Post by: Stein on March 09, 2021, 12:00:09 PM: Quote from: MountainWalk on March 09, 2021, 11:30:45 AM
Silver solder, lead free. Good heat from the solder iron from below. Use good quality flux.

Will that work on stainless?
Title: Re: Marine plug wire repair
Post by: MountainWalk on March 09, 2021, 12:03:17 PM: Ahhh.. I missed that part... Sir, I do not know. I originally thought that the wire itself was stranded, or torn. My mistake.
Title: Marine plug wire repair
Post by: Stein on March 09, 2021, 12:09:32 PM: I can't tell what the wire is made of, but the terminal will be stainless for sure.

Weird, I just tried to strip the wire and there is no wire, looks like a carbon core (if my Google is working)? Sounds like I can terminate the same as a solid core.

(https://uploads.tapatalk-cdn.com/20210309/c8e08fbeff1316b27c2c1ae4fb207953.jpg)
Title: Re: Marine plug wire repair
Post by: jay.sharkbait on March 09, 2021, 12:15:42 PM: Carbon filament.

I just fold the filament back over the wire insulation and crimp the new terminal over both and pull the terminal back into the boot.
Title: Re: Marine plug wire repair
Post by: KFhunter on March 09, 2021, 12:34:54 PM: Quote from: jay.sharkbait on March 09, 2021, 12:15:42 PM
Carbon filament.

I just fold the filament back over the wire insulation and crimp the new terminal over both and pull the terminal back into the boot.
This

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Title: Re: Marine plug wire repair
Post by: Stein on March 09, 2021, 01:13:24 PM: Thanks guys.