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Thread: 90s Johnson 25HP Battery Cable Assembly...options

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    Default 90s Johnson 25HP Battery Cable Assembly...options

    Hello,

    I have a great running 25hp Johnson that when I hit the starter button the starter engages but the motor doesn't turn quickly like it should. It is like the starter is struggling to turn the motor over. It will turn once or twice and this repeats. The battery cables are in bad shape; my guess is they are original. There is a lot of corrosion inside the insulation. I've cut the wires back multiple times and reattached connectors but I'm fairly certain my issue is these cables. First question, how can I safely bypass the cables and hook jumper cables directly to the starter or solenoid to test my theory? I don't want to mess anything up doing this, but I think I should be able to disconnect the battery cables and use my jumper cables to eliminate the battery cables in hopes of identifying that as the issue.

    2nd ?, assuming I am right and my cables are the culprit, what are my options? I am not opposed to buying OEM from my dealer, but that is going to be pretty expensive. Is there really anything special about the OEM cables that would prevent me from just making my own with cable from NAPA? If that is fine, what gauge should I buy? The battery is right by the motor in back of boat.

    Thanks!
    no matter what I'm doing, I've got hunting or fishing on my mind...

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    Barnacle Bill's Avatar
    Barnacle Bill is offline Super Mod and 2014 Crappie.com Man of the Year * Crappie.com Supporter
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    Stop wasting your time and replace those wires. From what you are describing there is corrosion through out those wires and will continue to cause problems. I've always used 4 or 6 gauge and never had a problem. Be sure you get a good tight crimp when you put the new lugs on. If you just want to satisfy your curiosity do a voltage drop test on them to verify they are the problem. All you need is a multimeter and a couple minutes of time.
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    Replace them with 6 guage cables....you can get them at any auto parts store. Just measure them and get some the same length.

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    Thank you gents! I'll head to NAPA in the morning after I get the old ones out to measure.
    no matter what I'm doing, I've got hunting or fishing on my mind...

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    Quote Originally Posted by G";3697991]Replace them with 6 guage cables....you can get them at any auto parts store. Just measure them and get some the same length.

    Sent from my SAMSUNG-SM-G891A using [URL="http://r.tapatalk.com/byo?rid=87936
    Crappie.com Fishing mobile app[/URL]
    Would 4 ga. be ok too? There is a video online of a guy with a 25 Johnson and he used 4 ga. An electrician friend this week told me to just go to the auto parts store and get a jumper cable. In fact I am headed there this morning, as the hurricane has made fishing iffy where I live, but this project has been on my mind for awhile.

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    Yep 4 guage is even better
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    Battery booster cables that are copper plated aluminum, as opposed to copper only, both OK?

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    Here is what you really need to get. Marine grade fine wire pre made.
    https://www.homedepot.com/p/Power-Br...FRGCaQodMrYNeA



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    Quote Originally Posted by USMA65 View Post
    Battery booster cables that are copper plated aluminum, as opposed to copper only, both OK?
    You don't want aluminum....all copper. Get ready made cables the length you need with the ends you need.
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    Genuinedealz.com can make any size and lenth you need. They will use marine terminals and heat shrink where the terminals are crimped on. If you can't find what you need locally check them out.
    Thanks USMA65 thanked you for this post

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