Service Bulletin Bulletin No.

2006-23R1

Circulate to: Sales Manager Accounting Service Manager Technician Parts Manager

Engine Wiring Harness Chafing – 200/225/250/275 Verado

Models Affected
Models Covered Serial Number
200/225/250/275 Verado 1B390142 and Below
EU 200/225/250/275 Verado 0P468636 and Below

Situation
Mercury Marine has identified a potential engine wiring harness chafing issue located on
the starboard side of the engine near the lower forward corner of the electrical box. As the
ground wire ring terminals are secured with the grounding stud locknut, the terminals can
fan out toward the engine wiring harness conduit. Wires protruding out of the conduit slit
at this location can become chafed by the wire crimped portion of the ground wire ring
terminal and be shorted to ground. Depending on the wires shorted, an engine system
failure and/or an engine guardian fault may occur. Mercury Marine has changed the
orientation of the described ground wire ring terminals and corrected this issue.

25711
a - Ground stud
b - Crimped end of ring terminal
c - Chafed wire

THE INFORMATION IN THIS DOCUMENT IS CONFIDENTIAL AND PROTECTED BY COPYRIGHT AND IS THE PROPERTY OF MERCURY MARINE.

This document is provided for the sole and exclusive use of the original recipient as prescribed by Mercury Marine and may not be distributed or copied, digitally or
otherwise, without the prior written consent of Mercury Marine.

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Engine Wiring Harness Chafing – 200/225/250/275 Verado

Troubleshooting/Inspection
IMPORTANT: Prior to performing in‑depth troubleshooting procedures on these affected
outboards, examine the engine wiring harness condition around the ground stud location.
Repair any damaged wires or replace the engine wiring harness as required.
Correction
1. Remove the locknut securing the three ground lead ring terminals to the ground stud.

25712
a - Ground stud/locknut
b - Ground lead ring terminals
c - Ring terminal crimp too close to wiring harness

2. Clean the neoprene protective coating from the ring terminals, ground stud, locknut,
and the contact surface of the cylinder block mounting boss.
3. Reposition the ring terminals:
• Heavy terminal should be installed first with the crimp toward the engine.
• Two remaining terminals should be installed with the crimps facing away from the
engine.
4. Stack and position the ring terminals to provide clearance from the engine wiring
harness. Hold the ground wire terminals in this position and secure the connections
with the locknut.

THE INFORMATION IN THIS DOCUMENT IS CONFIDENTIAL AND PROTECTED BY COPYRIGHT AND IS THE PROPERTY OF MERCURY MARINE.

This document is provided for the sole and exclusive use of the original recipient as prescribed by Mercury Marine and may not be distributed or copied, digitally or
otherwise, without the prior written consent of Mercury Marine.

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 Engine Wiring Harness Chafing – 200/225/250/275 Verado

Description Nm lb. in. lb. ft.

Locknut (M8) 17 150

25713
a - Heavy terminal ‑ Crimp toward engine (positioned behind outer terminals)
b - Two remaining terminals ‑ Crimp away from engine
c - Clearance between crimps and harness

5. Coat the ground wire connection with Liquid Neoprene.

Tube Ref No. Description Where Used Part No.

25 Liquid Neoprene Ground wire connection 92-25711-3

Parts Required – Engine Wiring Harness Replacement Only

Qty. Description Part Number
1 Engine wiring harness
84‑880616T04
-or- (USA S/N 0T980000 through 1B226999)
Engine wiring harness
1
(USA S/N 1B227000 through 1B381711) 84‑880616T05
-or-
(Belgium S/N 0P409357 through 0P464487)
Engine wiring harness
1
(USA S/N 1B381712 through 1B390142) 84‑880616T06
-or-
(Belgium S/N 0P464488 through 0P468636)

Dealer Outboard Inventory

Affected outboards in dealer inventory should have the orientation of the ground wire ring
terminals inspected and/or corrected prior to customer delivery. Outboards brought in for
other service work may also be inspected and/or corrected as required.
Warranty
Mercury Marine will credit the dealer for the cost of parts and labor. Complete a warranty
claim listing:
• Outboard serial number
FOR INSPECTION, CORRECTION, AND/OR WIRE REPAIR
• 0.5 hour labor

THE INFORMATION IN THIS DOCUMENT IS CONFIDENTIAL AND PROTECTED BY COPYRIGHT AND IS THE PROPERTY OF MERCURY MARINE.

This document is provided for the sole and exclusive use of the original recipient as prescribed by Mercury Marine and may not be distributed or copied, digitally or
otherwise, without the prior written consent of Mercury Marine.

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Engine Wiring Harness Chafing – 200/225/250/275 Verado

• Warranty Flat Rate Code: SB05

• Part Code: 331
• Failure Code: 00
FOR INSPECTION, CORRECTION, AND WIRING HARNESS REPLACEMENT
• 2.0 hours labor
• Warranty Flat Rate Code: SB20
• Part Code: 331
• Failure Code: 00
US and Canada
Complete/process the claim via MercNET or return a warranty claim form.
International
Follow instructions issued by Marine Power International office or by an authorized Marine
Power Distributor.

THE INFORMATION IN THIS DOCUMENT IS CONFIDENTIAL AND PROTECTED BY COPYRIGHT AND IS THE PROPERTY OF MERCURY MARINE.

This document is provided for the sole and exclusive use of the original recipient as prescribed by Mercury Marine and may not be distributed or copied, digitally or
otherwise, without the prior written consent of Mercury Marine.

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