2000 4.3 190 hp carb. Blue main engine electrical connector problem.

[moondrifter]

While looking for a wierd solution as to why the voltage at the console is so much lower that at the back, I moved the large blue connector that is mounted on the back of the engine. The engine sputtered once. We were on the water and wanted to look into it after done for the day. There must be something dirty in there to cause that to happen with just a little wiggling.
How would you service this multi-pin connector and what would you use. I don't want to booger it up doing it my way, which it usually wrong.
Thanks
Moondrifter

 

[guyjg]

...why the voltage at the console is so much lower...

Wires connected to the voltmeter may be corroded. Clean the connections. You may need to replace the wire terminal ends if there is blue/green corrosion. The wire ends need to be shiney copper and then tinned w/solder to prevent future corrosion. If the copper wire is blackend it should be replaced because it will have increased in resistance thereby reducing voltage. I apply a coating of liquid rubber AFTER the connection is tightened.

The main plug, called a barrel plug, should be disconnected during off season storage to prevent corrosion. Use a clamp to keep the plug from vibrating loose. It should be clamped just snug when connected. I used a large zip tie.

To clean any corrosion I use 1000 grit sandpaper to gently remove it from the male pins. Then I spray w/alchohol and compressed air. Use a ring shank finish nail or wire to gently clean corroded female pins. DON'T use a nail or wire so big that it spreads the female pins. Insert the a wire or pointed end of a nail that just barely fits the opening. A pipe cleaner also works on large pins. A "little" WD-40 can be used inside the male plug but make sure to blow it dry w/compressed air.