I temporarily wired up my bow and stern lights to test things out. Everything worked!
Lights, horn, etc. were controlled as planned. I disconnected the positive lead on the the starter motor, because I wasn't ready to turn it over. However, this let me test the choke solenoid and starter relay, which also worked as planned. The only problem I had was that the choke solenoid blew a 5A fuse. So, I installed a 10A and things worked fine.
I also labelled all the wires and updated my wiring diagram. I find that if you don't keep accurate records of what you did, you come back a few days later and don't remember what goes where.
The last challenge was at the motor. Everything I read suggested using #4 wire for the starter circuit. I ordered #4 cable and had the wire ready to go for the motor. However, the Mercury outboard I bought has a channel for the battery cables that did not take #4 wire. I had to reorder all new lengths of #6 cable, new terminals and rebuild.
Here you can see the starter cables in their channel. The black goes in first followed by red. There is a cover plate that holds these cables plus the control circuit cable all in place.
After all the circuits were in place, I removed the plugs and sprayed some fog oil into the cylinders. I reconnected the starter motor wire and tried the starter. So far, so good. I'm going to try starting the motor this weekend.
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