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Compass Marine How To | all galleries >> Welcome To MarineHowTo.com >> Universal Diesel Wiring Harness Upgrade > These Wires Had Been Fairly Oxidized
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These Wires Had Been Fairly Oxidized



These wires from the factory wiring harness had been fairly oxidized. Cleaning them with the Dremel #530 wheel makes them clean enough for re-termination and creates a good, clean, copper to copper connection. The #530 SS wheel is stiff enough to get into the inner stranding, not just the outer strands. Occasionally you need to manually open or fan the strands out but it takes just a few seconds per wire, that's it. Be sure to get all copper stranding as clean as possible or just replace the wires.


Once clean I use adhesive lined heat shrink crimp on ring terminals. This keeps moisture out and creates a sealed connection.


In a perfect world every one of these wire would be replaced with new but not all owners can afford that. Cleaning and re-terminating can be a reasonable alternative.


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Marion 19-May-2012 22:34
Thank you! I just bought a Bristol 35.5 with a Universal 5432 that developed electrical problems on the delivery trip home. (The engine switch burned up.) When I pulled the panel off I also noted that the wires going to the ammeter had overheated, so I knew I had major electrical problems. I downloaded the Universal manual and could not believe that the wiring diagram showed the alternator output routed directly to the ammeter. This post is wonderful and will save me hours of troubleshooting and repair time. Thanks again!