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Well I'm not exactly sure what I was doing but like you all have been saying, you definitely don't need to put power to that orange wire to make the starter run. I plan on making a new wiring harness and just ditching the old one. I've got a new ignition switch on the way so hopefully it will...

Thank you all so much for the advice and help. My set up is the second choice there. Here's what is happening. My key switch no longer works and I've had to cut my external harness almost completely off to get rid of the bad wiring inside. So I've removed the key switch and wiring problems...

I have a 73' 20hp Merc200 with a set of controls. They are branded Mercontrol and usually have a single lever that controls shifting and the throttle and then there is a second lever that controls the throttle for use when starting. There is also a wiring harness that connects to the keyswitch...

See thats the weird part. You can't engage the starter solenoid without putting 12v to the orange wire. I've tried just putting power to the starter through the solenoid and the solenoid will not work without power to orange wire first. This is quite the confusing little system.

When you switch the key "ON" there is 12V to the orange wire. When you start the motor and it is running, there is 36V on the orange wire. I was just wondering if that wire was how the stator was sending voltage back to the battery to charge it. Most keyed ignitions have a separate circuit...

I would just look over the wiring and make sure nothing is cracked or corroded. I have a 73' Merc 20HP that Ive had some wiring problems with but nothing terrible. As long as he will run it for you and the cylinders have good compression then you should be ok. These Mercs were built to run...

Well you were absolutely correct. I disconnected the keyswitch completely and just plugged the external harness in and guess what? Still no spark. So I examined the harness and about 2 feet from the plug at the engine the external insulation was broken and all the wires inside were cracked...

Well I tried what you said Mike and still no spark. So I took the key switch off the remote and hard wired it right to the internal wiring harness plug on the motor. When the key switch is in the on position there is no spark, when you turn it like you are going to start it then I get spark. So...

Thank you JMichael! I will try that when I get home from work today.

Here is the wiring diagram.

So I have a strange problem. I have a 73' Merc200 20 HP and when I have it connected to my remote controls it will turn over but will not fire. I have no spark in either plug. But when i take it off remote and pull start it, it fires right up and runs awesome. I've checked continuity in my...

Well its been a while since I last posted and we've gotten a lot done. The sandblasting worked out really well. Whatever coating was on this boat before I got it would not come off by any other means so sandblasting was the way to go. It didn't seem to hard the aluminum at all, definitely...

Dropped the boat off at a local shop to get sand blasted. The paint that was on the boat seemed to be some sort of bed liner. Nothing would take it off and I tried about everything. Zip strip, sanding, wire wheel, and even a small sand blaster from Harbor Freight that my father-in-law had...

Thank you! Comments and suggestions are always appreciated!

Now back to my boat. This weekend we prepped the aluminum for welding and cut out all the pieces. We got everything tacked together and then welded the console completely. We then cut out the front door and will be added hinges and a locking latch as well as shelves to keep valuables and...

So over the weekend I went to my inlaws and my Father-in-law and I got started on the aluminum version of the console. Before I get into that I wanted to show you all his Alumacraft. I don't know the exact model or year and I don't have any before pictures but I just wanted to show off his...

So it't been a while, but I've finally had some time to work on the boat. Since my first few posts I added a little more power to the boat and purchased a 20hp Mercury Merc 200. I got a screamin deal on it that I couldn't pass up. It came with a steering cable and wheel, as well as the...

So I have been running my 14' Lone Star Commander with a 10hp tiller and I recently bought a 73 Merc 200 20hp which came with all the good stuff, steering, cables, mercontrol, etc and I have been debating on whether to make a side console or a center console. My boat is 54 inches wide at the...

Thanks fellas! I really appreciate the insight. I got her running the other day on the first turn of the key! The water pump wasn't working though so I had to turn it off quick. That will need replaced and then I'll start the fun and lengthy process of building a side console for my...

That's exactly what I was hoping to hear. Thanks again!! Just out of curiosity, how has your motor been? Have any reliability issues or major problems to look out for?