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Kupe's Zodiac 650B
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Date:  7-18-2015
Number of Hours:  1.00
Manual Reference:  
Brief Description:  Battery/Starter Cables Installed

Installed the battery and starter cables today. It was one hot and humid day and even though this was a reasonably simple task, I must have sweated off 10 pounds out in the garage!

Both cables are made out of AWG4 wire. For you non-electricians, that's a wire a little bigger than the thickness of a pencil. I measured out where the two wires would run (battery to solenoid, solenoid to starter) and then used my braided cable cutters to cut through that wire. Once cut, I stripped off the last 1/2" of insulation Then I added ring terminals to the ends of the wire. These ring terminals required the use of my swaging crimp, which is the size of a large set of bolt cutters, to crush the ring terminal tightly around the bare wire. Once the terminals were in place, I added silicon rubber boots to cover the terminals and keep the weather out once they're attached.

Attaching was straightforward. The solenoid was clearly marked for battery (+) and starter, and the ring terminals were attached to the solenoids via large copper bolts with nuts. For the starter, I ran the cable along the lower right side engine mount, behind the oil fill tube and up to the the starter attaching the ring terminal to another large copper bolt with a nut and lock washer. I temporarily tied off the starter cable with zip ties but will eventually switch to adel clamps.

For now I'm leaving the battery cable disconnected from the battery end.
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Solenoid with battery (upper) and starter (lower) cables attached and covered.

Solenoid with battery (upper) and starter (lower) cables attached and covered.

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Looking aft: Starter in foreground with cable attached and solenoid and battery in the background.

Looking aft: Starter in foreground with cable attached and solenoid and battery in the background.

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Alternator wires attached to the rectifier-regulator via butt splices.

Alternator wires attached to the rectifier-regulator via butt splices.

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