Igniton Switch wires questions -16 gauge vs 18 gauge wires Splice together OK ??

[TexomaGuy]

My original ignition switch went bad so I ordered a replacement. I have a 2008 Bass Tracker 175 TXW with a Mercury Optimax 75 HP. The wires on the original one are clearly marked 16 gauge. The OEM number on the replacement is 87-88107A5 so I ordered a replacement marpac number 7-1155 that claims to be the same.  The color of the wires are EXACTLY the same however the wires are 18 gauge. Has anyone run across this before? Would there be problems splicing the 18 gauge ignition switch wire into 16-gauge wire?
Thank you in advance.

[Bud Kennedy]

I think you are OK to move ahead with the install.  The big deal will be the method you use to splice the wires.  The best way has to be with solder and shrink tube.  DO NOT USE A CRIMP ON BUTT CONNECTOR.

[TexomaGuy]

Thanks! Good advice. I'll solder instead of the connectors.

[TNDiver]

What size wire does the OEM recommend?  You can always got to a lower number, but you can't go to a higher number.  If it requires 18 AWG, then you can go 16 and lower numbers, but you can not go 20 or higher AWG.  The lower the number, the larger diameter the wire is and can better handle larger currents. 

Now you could get by with the 20 AWG, but if something goes wrong, the manufacturer will blame the wiring, even if it is not the problem.  That is why I usually go with a lower number than required, but I am putting in more safeguards. 

[TexomaGuy]

Thanks for your reply. The original ignition switch is 16 gauge and the new one I got is 18. So it would be installing 18 gauge to 16 gauge.

[Bud Kennedy]

I see the reference to the Marpac replacement that you purchased.  If you are concerned you should go buy a switch from the OEM (Mercury)  That way you want have any concerns

[TNDiver]

The ignition switch is 18 AWG running to a 16 AWG that goes to the battery correct?  If so you should be fine.

[TexomaGuy]

Yes correct

[TNDiver]

The ignition is telling you it needs 18 AWG, so running the 16 to the battery is good.  But you couldn't do a 20 or higher AWG to the battery.

[BassmanRudy]

I would recommend using these. Strip just enough wire to hit the target hole then crimp and use a heat gun(or lighter lol) to melt/seal the ends. A nice waterproof connection that will be compact as well. We use these a lot for aircraft maintenance.


For 18 Gauge you will need the Blue splice.

Sent from my SM-G970U using Tapatalk

[TexomaGuy]

Thanks!