Johnson outboard wire harness help

[Joshua Stansbury]

Hey guys I have a 1997 25hp johnson outboard j25EEUB that I'm trying to find a new harness for the motor and that goes from ignition to motor. Any ideas for a part number?

 

[MDCrappie]

Not sure what part you would be referring to, maybe the "Motor Cable Assembly"? If you take highlight this part of your post - 1997 25hp johnson outboard j25EEUB and then right click and select "search......" you will get a bunch of sites. Scroll down to the crowley marine one and click it. You will get diagrams for all parts of that motor. Look at the pictures and select the part you need. When you do find it please let us know what it was you were looking for.

https://www.crowleymarine.com/johnson/oem-parts/outboard/1997/j25eeub

https://www.crowleymarine.com/evinrude/products/5000016-motor-cable-kit-assembly

 

[Joshua Stansbury]

Not sure what part you would be referring to, maybe the "Motor Cable Assembly"? If you take highlight this part of your post - 1997 25hp johnson outboard j25EEUB and then right click and select "search......" you will get a bunch of sites. Scroll down to the crowley marine one and click it. You will get diagrams for all parts of that motor. Look at the pictures and select the part you need. When you do find it please let us know what it was you were looking for.

https://www.crowleymarine.com/johnson/oem-parts/outboard/1997/j25eeub

https://www.crowleymarine.com/evinrude/products/5000016-motor-cable-kit-assembly

Yep, I did that and they don't have what I'm looking for that's why I came here.

 

[Joshua Stansbury]

I'll get pictures tomorrow

 

[MrGiggles]

Remote or tiller? The harnesses are vastly different between the two.

 

[MDCrappie]

Yep, I did that and they don't have what I'm looking for that's why I came here.

If you described what you are looking for like you did here then they probably didn't understand what want. It sounds like you are maybe looking for the harness that goes from the motor to the ignition(key) switch on the remote control? If so then that is probably part of the control itself and you would need to likely replace the individual wires, or the entire remote itself.

 

[Joshua Stansbury]

If you described what you are looking for like you did here then they probably didn't understand what want. It sounds like you are maybe looking for the harness that goes from the motor to the ignition(key) switch on the remote control? If so then that is probably part of the control itself and you would need to likely replace the individual wires, or the entire remote itself.

Yep, that's why I literally wrote in my first post "from ignition to motor" but I guess if we're gonna split hairs here I could have also put (key) in the description.

 

[Joshua Stansbury]

Remote or tiller? The harnesses are vastly different between the two.

That I didn't think of that, it's remote console

 

[MDCrappie]

Yep, that's why I literally wrote in my first post "from ignition to motor" but I guess if we're gonna split hairs here I could have also put (key) in the description.

Not splitting hairs, lots of parts to the "Ignition", and likely the reason why Crowley did not know what you wanted.
The key switch on that motor actually works the choke, starter and ignition.......

 

[Pappy]

Yep, that's why I literally wrote in my first post "from ignition to motor" but I guess if we're gonna split hairs here I could have also put (key) in the description.

BUT.....that is still a general statement as harnesses can be from a dash mounted ignition switch and gauges or from a side mounted control or a console mounted control/key switch.
What he is asking for is simply more and more specific information. Simple.
Secondly, what issue are you having with the current harness you have?

 

[Joshua Stansbury]

BUT.....that is still a general statement as harnesses can be from a dash mounted ignition switch and gauges or from a side mounted control or a console mounted control/key switch.
What he is asking for is simply more and more specific information. Simple.
Secondly, what issue are you having with the current harness

The harness on the motor is melted. And the harness that runs from the throttle/key is also melted where it connects to the engine harness

 

[oilsmoke]

What caused it to melt? Fire? Electrical short? Failed component?

Assuming you have a control box and not just a bare throttle and dash ignition key, it sounds like what your after is a controller harness and an engine harness.

Since OMC is no longer in business and those older motors have all but been abandoned by BRP now the only options are aftermarket and your own ingenuity.

The motor harness is available from CDI 413-0016. the conroller harness is the same from 1996 to 2016. Your best bet is to buy a used controller as it'll be far cheaper than buying anything new to fix your wiring.
A full 1997 Parts list is here: 1997 OMC

If you need to build your own harness, most of the connector ends are available but they're not cheap. Your almost always better off finding a parts motor or used harness off fleabay, even if its just for the connectors.

What I've found over the years most motors are not worth the cost of a new harness and depending on the motor it can cascade into a rather pricey repair if the damage includes several components as well.

Take and post some pics so people here can get a better idea of what your looking for and what sort of damage your trying to fix. Most of us know the parts only by proper marine terminology and just saying ign. to motor can mean several things in several different types of set ups.

If you didn't buy the boat or motor new, there's also the chance that what your dealing with is not OEM so without seeing it, we all can only guess.

 

[Joshua Stansbury]

Here's what I'm looking at trying to replace

 

[Joshua Stansbury]

What caused it to melt? Fire? Electrical short? Failed component?

Assuming you have a control box and not just a bare throttle and dash ignition key, it sounds like what your after is a controller harness and an engine harness.

Since OMC is no longer in business and those older motors have all but been abandoned by BRP now the only options are aftermarket and your own ingenuity.

The motor harness is available from CDI 413-0016. the conroller harness is the same from 1996 to 2016. Your best bet is to buy a used controller as it'll be far cheaper than buying anything new to fix your wiring.
A full 1997 Parts list is here: 1997 OMC

If you need to build your own harness, most of the connector ends are available but they're not cheap. Your almost always better off finding a parts motor or used harness off fleabay, even if its just for the connectors.

What I've found over the years most motors are not worth the cost of a new harness and depending on the motor it can cascade into a rather pricey repair if the damage includes several components as well.

Take and post some pics so people here can get a better idea of what your looking for and what sort of damage your trying to fix. Most of us know the parts only by proper marine terminology and just saying ign. to motor can mean several things in several different types of set ups.

If you didn't buy the boat or motor new, there's also the chance that what your dealing with is not OEM so without seeing it, we all can only guess.

The wires melted because they got hot. I posted pictures of what I'm looking to find. Thanks

 

[oilsmoke]

That wire leading into the cylinder head cover is a temp switch for the overheat buzzer in the control box. Its held in place by a rubber plug and seal beneath the water cover, for which you will also need a gasket for.

You won't find an exact harness match, just the DI harness which is sort of a universal fit where you reuse or buy new connectors where needed.
The easier route if your not comfortable do basically making your own harness is to just buy a used one off fleabay.

More importantly you need to know why those wires got hot, did the motor overheat that bad? If it did, you likely have far worse issues to deal with. If they got hot because of a short somewhere that needs to be fixed first. The melted sensor won't be the source, its the result. The sensor simply grounds the negative lead to the buzzer when it sees a set temp.

I can almost guarantee the cost of fixing all that will exceed the value of that motor unless you find used parts. If it were me I'd buy a roll of marine grade 16ga wire and start soldering and heat shrinking all the connections. Go wire by wire and make sure every connection is secure and it'll be fine. Your only other hope is to find a dealer that has one still in stock that they ordered and didn't sell but that's a long shot.

 

[MDCrappie]

The wires melted because they got hot. I posted pictures of what I'm looking to find. Thanks

Ironic - the part you have circled with the tan stiped wire is the temperature sensor.
https://www.crowleymarine.com/evinrude/products/5000015-temperature-switch-assembly

The other part you have circled are part of the motor cable assembly, which in linked and you quoted saying Crowley didn't have what you need. (Post #3)

I don't think you can buy the part of the harness going into the side remote by itself.

Your best best is to try and find a junk motor and utilize those parts. Buying what you need new would well surpass the value of the motor.

 

[Joshua Stansbury]

That wire leading into the cylinder head cover is a temp switch for the overheat buzzer in the control box. Its held in place by a rubber plug and seal beneath the water cover, for which you will also need a gasket for.

You won't find an exact harness match, just the DI harness which is sort of a universal fit where you reuse or buy new connectors where needed.
The easier route if your not comfortable do basically making your own harness is to just buy a used one off fleabay.

More importantly you need to know why those wires got hot, did the motor overheat that bad? If it did, you likely have far worse issues to deal with. If they got hot because of a short somewhere that needs to be fixed first. The melted sensor won't be the source, its the result. The sensor simply grounds the negative lead to the buzzer when it sees a set temp.

I can almost guarantee the cost of fixing all that will exceed the value of that motor unless you find used parts. If it were me I'd buy a roll of marine grade 16ga wire and start soldering and heat shrinking all the connections. Go wire by wire and make sure every connection is secure and it'll be fine. Your only other hope is to find a dealer that has one still in stock that they ordered and didn't sell but that's a long shot.

The motor over heated It still runs and I did a compression check it has 70psi in one cylinder and 77psi in another.

 

[Joshua Stansbury]

Ironic - the part you have circled with the tan stiped wire is the temperature sensor.
https://www.crowleymarine.com/evinrude/products/5000015-temperature-switch-assembly

The other part you have circled are part of the motor cable assembly, which in linked and you quoted saying Crowley didn't have what you need. (Post #3)

I don't think you can buy the part of the harness going into the side remote by itself.

Your best best is to try and find a junk motor and utilize those parts. Buying what you need new would well surpass the value of the motor.

Yes crowley doesn't have what I was looking for, just because I circled something doesn't mean thats what I was talking about. It would be great if you would stop trying to help please.

 

[MDCrappie]

Yes crowley doesn't have what I was looking for, just because I circled something doesn't mean thats what I was talking about. It would be great if you would stop trying to help please.

DONE

 

[Pappy]

The harness on the motor is melted. And the harness that runs from the throttle/key is also melted where it connects to the engine harness

Okay ....so you need two separate harnesses then