Mercury 2.5L 200 rigging questions

jasoncooperpcola · #1 06-12-2012, 05:43 PM

I am trying to get whats needed to rig my 94 Mercury 2.5L 200. So far i have decided on a Mercury Commander binnacle control, Teleflex Extreme cables, and Mercury Flagship gauges.

I keep seeing Gen II controls and everybody recommends them? Whats the difference and is the Commander a Gen II?

I found a wire harness locally today for $50, its 14' long and has the correct connector on it for the engine. I have figured out that the Red/Yellow wire is for Starting, the black/yellow stripe wire is for shutoff, and the Yellow/black stripe wire is for "enrichment" i assume that is the choke right? That leaves a purple, brown, grey , and red and black wire i dont know what they are for. I assume the red and black wires are for power/negative for the ignition, gauges,etc. I still need a key switch and a tilt/trim harness to go from the outboard to the remote.

phatdaddy · #2 06-12-2012, 10:54 PM

all i have is a 2.0 manual. but according to it , the purple wire is switched power for the gauges, the gray is the tach pulse, the tan wire is the temp signal, the only brown i see is a brown white that is the signal for the trim indicator. i would verify these with a grown up, but this might get you started. i talked to a guy today who thinks he has a 25' wiring harness, he is going ot check, but he said he would need to get $120. sounds pricey to me. if you want , i can scan and send you a pic or two.

jasoncooperpcola · #3 06-13-2012, 06:58 PM

Phat, i purchased a dowloadable manual for the 1990-2000 2.5-275 Mercury/Mariner outboards, it was $8. If anybody wants, i can email you a copy of the manual, (i think??)

Still trying to verify some of the wires. I know one of these wires has to be for a warning horn for overheating, low oil etc. I did purchase the wire harness yesterday. It makes it much easier starting and killing the engine. So far i have not had to use the choke, it turns over for a half second then fires up, even after sitting all night.

Also i ordered a new in box Mercury Commander Gen II binnacle control for $275. Now i need gauges, key switch, kill switch, warning horn, Teleflex Xtreme cables, and a hydraulic steering support shaft.

Should i worry about the kill switch? I have never worn one, when on the boat with other people. But i have a feeling i will be doing alot of fishing by myself.

On a side note, i can't find the trim sender on this motor. Is it a different design than the Johnson?

On a side note, i don't think i have a trim sender on my motor. I can find one anywhere.

phatdaddy · #4 06-13-2012, 08:54 PM

in the dia i have, the kill switch is the blk/yellow & black. this is in the side mount remote control units.
is the oil injection completely gone? no tank on motor or a blank plate where the pump goes. i might can come up with some pieces parts for that. i would still run premix since thats the way you got the motor.
the trim indicator is a brown/white wire

jasoncooperpcola · #5 06-13-2012, 09:02 PM

Phat i have figured out the black wire with yellow stripe is for shut off, the red wire with yellow stripe is for starting. Yellow wire with black stripe is for choke, the brown wire is for the overheat sensors but on the outboard side of the connector its a brown wire with blue stripe. Purple wire runs into the motor and stops at a terminal block. Previous owner had it hooked to a fuel pump. Gray wire goes behind the coils into a black box so i think thats the tach wire. I have 12v between the red and black wires so they supply power forward to the ignition switch.

All i have left of the oil injection is the warning box. There is a blank plate over the crankshaft hole.

I have no brown/white wire. Heck i dont even have a trim sender.

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Wiring diagram below, it would be nice if they labeled 1-8 on the connector with what they do.

phatdaddy · #6 06-13-2012, 10:33 PM

what i am looking at is the diagram for the control box, so that might be the difference in the color codes. i think merc used different colors for different motors,but they all went to the 8 pin harness. i only have the manual for the 2.0, so that might be the problem.
sorry, not much help.

Destroyer · #7 06-14-2012, 12:10 AM

Looking at your engine while sitting in your boat, the tilt/trim sender is on your right, (port side) just about level with the top of the swivel. it looks like a small round black button, maybe an inch in dia and 3/4 of an inch thick. 2 small machine screws (either 10 x24 or 12 x 24) hold it in place. It has two wires coming out of it. One wire loops to one of those machine screws and is ground. it's about 4" long. The other wire connects via a push in connector to your wire harness and goes back, thru your harness, to your tilt guage.

jasoncooperpcola · #8 06-14-2012, 09:13 AM

Phat you are a big help! The harness i got has diff wire colors. Will have to trace wires.

jasoncooperpcola · #9 06-14-2012, 05:14 PM

Found a cowling for the Mercury.

Going to get it Saturday and visit Family, that lives close.

Destroyer, i could not find anything on the bracket that has wires except for the tilt/trim motor.

Destroyer · #10 06-14-2012, 08:00 PM

Quote:

Originally Posted by jasoncooperpcola

Found a cowling for the Mercury.

Going to get it Saturday and visit Family, that lives close.

Destroyer, i could not find anything on the bracket that has wires except for the tilt/trim motor.

Look at the shaft end of the main hydraulic cylinder. It's like a cap on the outboard end of the pivot. I'll upload a few pics tomorrow.. Can't find my adaptor to insert the SD card into this comp, so will have to wait till I get to work tomorrow to upload it.