Battery Cable Size?

Kper

.
Mar 12, 2014
148
Catalina 25 Iowa
Preparing to replace the original wiring from the batteries to the 9.9/two stroke outboard with electric start (hoping to change to 4 stroke eventually) but I'm having trouble determining wire size and the charts I'm finding online still leave me with some doubt.

The original duplex is not marked with a size and I am not a good judge of determining its size. Taking into consideration of where the wiring will be run I'm guessing about 17' will be required.

I'm thinking I need 8 gauge but not certain.
 
Sep 15, 2009
6,243
S2 9.2a Fairhope Al
Preparing to replace the original wiring from the batteries to the 9.9/two stroke outboard with electric start (hoping to change to 4 stroke eventually) but I'm having trouble determining wire size and the charts I'm finding online still leave me with some doubt.

The original duplex is not marked with a size and I am not a good judge of determining its size. Taking into consideration of where the wiring will be run I'm guessing about 17' will be required.

I'm thinking I need 8 gauge but not certain.
whats the amp draw of the starter ..and is that 17 feet round trip or one way there is a chart for working this out i think Genuinedealz as one on there site
 

Kper

.
Mar 12, 2014
148
Catalina 25 Iowa
whats the amp draw of the starter ..and is that 17 feet round trip or one way there is a chart for working this out i think Genuinedealz as one on there site
That's a one-way measurement.

Thanks for the link, Woody, I think I'll find everything I need there.
 
Nov 18, 2010
2,441
Catalina 310 Hingham, MA
I like this chart from Blue Sea Systems. Warning it is a large PDF but it has fuses, wires and fuse holders all in one place.

For sizing you need to know the current flow in amps. You said you were thinking about going 4-stroke, so I looked at this Honda at Defender. That has a 12 Amp alternator and on a quick look I didn't see what the current was for the starter but they have a 20 amp fuse in that line so it's less than 20 amp and we can use that for an example.

You said the one-way distance was 17 feet. You base wire size on round trip so you are dealing with 34 feet. Always round up so we are looking at the 40 foot line on the chart.

This would be a critical system and you would not want more than 3% voltage drop.

So you are looking at 6 American wire gauge (AWG) wire for this run.

Next you need to go down to select the fuse size. You fuse based on the wire, not the current. A 6 AWG wire is fused at 125 amps for a single wire with an MRBF terminal fuse (I would think that would be easiest but your overall setup would dictate what type of fuse) or 80 amps for a bundled wire. I would presume this would be a bundled wire but that depends on your setup again.

And the fuse should be located within 7 inches of the battery (at least that is the requirement on an inboard, I don't think it would be different on an outboard).

I know Genuinedealz was mentioned. I purchased some supplies from them and wasn't very happy with the quality. I would stick with some decent tinned wire. Check out the store here at SBO.

Hope this helped. And I am sure Maine Sail will correct me if I said anything wrong.

Good luck and fair winds,

Jesse
s/v Smitty
 

Kper

.
Mar 12, 2014
148
Catalina 25 Iowa
That's a chart I can understand, Jesse. Thanks for the additional link.