I have a 1993 Evinrude VE150. It has a powerpack that has 6 wires that end in mini-spark plug boots that go onto small pins on coils that mount onto the back of the power pack. There are 3 coils with 2 little pins per coil for the powerpack wire boots, and 2 larger pins per coil for the regular spark plug boots. The 6 power pack boots and the 6 spark plug boots wind up being crammed tightly together as the 3 coils are mounted one above another on the back of the power pack.
Late one afternoon, while my motor was running on the muffs, I noticed a spark jumping between one the the little rubber boots and the adjacent larger boot. I found a hole in the smaller boot and a pinhole burned into the larger, spark plug boot.
I ordered new spark plug wires and a new boot for the wire from the power pack and a new PIN receptacle to go on the end of the wire from the power pack.
I cut off the small boot with the hole in it, and could not figure how to get the new boot over the steel receptacle (smaller version of the steel receptacle that is inside a spark plug boot). I had ordered a new receptacle, so I cut the old receptacle off the end of the power pack wire (possibly a mistake), ran the new boot up the wire, crimped on a new receptacle, and proceeded to sin profusely while trying to get the little boot over the little receptacle! I pulled several of the little steel receptacles off the power pack wire while trying to stuff them into the boot.
Has anyone done this successfully? I’m sure there is a simple way that can save my soul!