Wiring question for Westerbeke W27

[josrulz]

Hi all, I'm changing how the alternator on our Westerbeke W27 is wired to the batteries on our Sabre 34 Mk I. In the original configuration, the wire on the alternator's output positive post enters a wiring harness on the W27 that wraps around the engine, and reappears at the starter positive connection. The charging current is then carried via the starter cable to the Perko battery switch "ALL" post. Of course everything in the harness is painted with Westerbeke's red paint, so it's difficult to tell what's what.

Not only are we upping the wire size, but we're rewiring to run from the alternator directly to the house bank (properly fused of course). So I don't need that wire in the harness.

So here are my questions:

1. Does that alternator wire in the harness make any "stops" on its way from the alternator to the starter? Or is it a single continuous wire? When we disconnect, I want to make sure I'm not causing some other problem.
   
   
2. How should I permanently disconnect this wire? I'm concerned that trying to dig it out of the harness could do more harm than good. Can I just disconnect both ends and somehow cap them off? Suggestions on best way to do this?

Thanks for your help!
-J

[Maine Sail]

Unless your wiring is different, has been modified etc., which it could have been, the B+ from the alt normally goes directly to the starter post. You MAY have an ammeter circuit which the B+/output also runs through, these are BAD, and are usually orange & red wires out to the ammeter and back to the starter post..

The best and safest method is to open the loom and see what you have inside. A mechanic or PO MAY have tapped into that circuit for something else so disconnecting it may cause something to not work.. If it is just a straight run, no one tapped into it, remove the B+ to starter jumper, re-tape the harness and place new loom over it..

Opening the harness is never a bad idea. You'd be HORRIFIED at what I have often found hiding inside them....

[josrulz]

Originally Posted by Maine Sail

Unless your wiring is different, has been modified etc., which it could have been, the B+ from the alt normally goes directly to the starter post. You MAY have an ammeter circuit which the B+/output also runs through, these are BAD, and are usually orange & red wires out to the ammeter and back to the starter post..

The best and safest method is to open the loom and see what you have inside. A mechanic or PO MAY have tapped into that circuit for something else so disconnecting it may cause something to not work.. If it is just a straight run, no one tapped into it, remove the B+ to starter jumper, re-tape the harness and place new loom over it..

Opening the harness is never a bad idea. You'd be HORRIFIED at what I have often found hiding inside them....

OK thanks Maine Sail. I'll just open it up then. We don't have an ammeter, just the standard original voltmeter (being replaced by a Victron BMV-602 battery monitor). And there are not a lot of mods to our boat. However, I'll proceed carefully just in case.

I have to say, I know I'm really a boat nerd when the idea of upsizing to 4 AWG alternator wire has me giddy.
-J