suzuki control box questions (not the ECM)

[keakar]

I have been very lucky and never had to open a control box to replace the cables so I have no idea what the inside looks like or how the cables attach or the wiring is done inside of it and that really is my question.

does anyone know where I can find pictures of the insides so I can judge if I want to shorten my wiring harness?

I have a flatboat so everything is out in the open with no place to hide extra wires and I have a 8ft steering cable and a 8ft control cables but I have a 12ft wiring harness that is looped up and tied off in the middle like a birds nest. I would like to shorten the wiring harness to 8ft to match everything else so it has a uniform neat finished clean look instead of looking like bubba didn't have the right wires and just made it work.

my main question is if the wires have a plug end inside the control box or do they just fan out with individual connectors going where they need to go?

I will NOT be splicing the harness anywhere between the motor plug and the control box so it will all stay waterproof and sealed.

[bgizzle]

On mine. The elec wires go from Trim button down the throttle then where the handle pivots it coils around it on inside then goes down through console and separately have quick connects. The assembly is fairly easy to take apart. 3 or 4 screws. The last one on mine was hidden you have to put throttle in forward and look in toward the pivot. There's also a screw on inside


"Go ahead, share your opinion! I won't cry"

[bgizzle]

Take the slack out at the pivot of throttle. I wouldn't do anything else but that or pin it up with tie wrap. It's longer from factory for a reason.


"Go ahead, share your opinion! I won't cry"

[keakar]

Originally Posted by bgizzle

Take the slack out at the pivot of throttle. I wouldn't do anything else but that or pin it up with tie wrap. It's longer from factory for a reason.


"Go ahead, share your opinion! I won't cry"

I think you misunderstood what im asking to do, im not saying its 4 inches too long im saying the big thick heavy wiring harness cable is 4 feet too long after I make a 2ft loop with it by the motor and it cant be easily bent and folded so its like a 4"x8" figure 8 I have strapped together hanging there that looks like cr ap.

I will make sure to leave ample slack inside the box from things that move but this main cable is heavy and stiff and does not move at all so there is no reason it needs to be that long unless the ends are formed into special plugs like the one inside the motor cover. I have enough extra cable to be able to wrap it around the motor cover twice before I run it along side of the control cables which have a big 2ft loop in them at the motor for flexibility and slack.

I want to trim the wiring harness to the same size and length as the control cables and im going to make sure its still got all the slack it needs.

with the info you gave me I felt ok taking the control box apart so I drilled out the stuck screws andits all individual quick connects in there so I can trim it to the correct size and replace the connectors.

im disappointed to find out its not thnn wire in the harness though, I figured a factory OEM wire harness should be all thnn wire but its just plain copper wire

thanks for your help

[bgizzle]

The only thnn wires you should have should be on your motor. Can't say I blame the manufacturer bc there's no heat issues to combat anywhere but the motor so they ain't gonna spend the extra $ to go heavy duty if they don't HAVE to. Just my opinion.


"Go ahead, share your opinion! I won't cry"

[keakar]

Originally Posted by bgizzle

The only thnn wires you should have should be on your motor. Can't say I blame the manufacturer bc there's no heat issues to combat anywhere but the motor so they ain't gonna spend the extra $ to go heavy duty if they don't HAVE to. Just my opinion.


"Go ahead, share your opinion! I won't cry"

well its not about the heat its about the corrosion protection, thnn wires wont instantly start to corrode on contact with salt water like bare copper wires do.

I finished it up around 2 pm and it was a little tricky getting all those wires and connectors in that tiny little 1 1/2" x 1" pocket they have to fit in lol.

I did some cussing and took a few tries to get everything just right to lay flat and in order so it compressed just right. if they didn't make the horn the size of a skoal can, there would be plenty of room for the wires to fit with ease.

im glad I got in there to regrease everything that moved and clean up and smear grease on a lot of corrosion in there where water collects at the bottom. not sure why there are lots of little openings for rain water to be able to get in but not much thought given to a way to help it get out like maybe slant it towards the drain opening so the water drains better.

ended up shortening the cable by 50" and now all cables can be bundled together in one neat grouping