My warning buzzer had quit working and I finally found the problem. The wire harness was installed too tight from the motor to the boat. It was rubbing in the transom boot and finally wore thru the harness and one of the small wires inside. The warning buzzer is the only thing that seems to be affected. Two questions: 1) Can I splice the one broken wire, and if so, what can I use to place around the wires and cables (without disconnecting them) to allow them to move un-restricted in the transom boot after the splice? The splice will tend to bind when the motor is turned. 2) If I should replace the whole harness, what is the part number? The motor is a 2004 DF250.
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Motor to boat wire harness
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Check to make sure there is not excessive wiring tie wrapped up somewhere out of the way. Usually the harness are too long so the are wrapped up and put out of place. The following link should assist you.
2004 Suzuki Outboard PartsLast edited by boats.net; 09-27-2011, 04:50 PM.
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