There are two approaches to extending the battery cables of the outboard motor: splice in a new extension and re-use the old cables, or discard the old cables and get a new, one-piece, splice-free cable. We explore each solution.
SPLICED BATTERY CABLES
If you wish to extend the battery cables by splicing in a new conductor, the new conductor will need to have very low voltage drop. The existing battery cables were probably sized to be about the smallest conductors which would provide proper voltage drop for their length, so the extension cables need to be very large size conductors in order that they have almost no voltage drop. Because a spliced cable will have extra connections, these connections are also potential sources of additional voltage drop, and one must be very careful that the splice and its connections are very well made so as not to introduce any additional voltage drop into the circuit. The location of the splice must also be considered. If it is below deck and in an area where water can pool and stand, the splice must be absolutely waterproof.
NON-SPLICED BATTERY CABLES
Discarding the original battery cables and replacing them with new cables of the proper conductor size for the total length of the circuit eliminates all of the splice and connector problems. If the conductor is run in a tunnel there will not be any spliced connections which may be in standing water. Generally this results in a smaller size conductor being used than if you splice an extension onto the original cable. Although you will have to purchase more cable, the cost will be about the same because the price of the smaller cable will be less per foot. The smaller cable will be more flexible, which is a benefit for use with an outboard motor.
FUSING
If the extended conductor runs through a tunnel or conduit, consideration ought to be given to using a fuse to protect it. In most cases engine starting circuits are not fused because the peak current is very high and fuses which can tolerate such a current are very expensive, bulky, and difficult to find. Inserting a fuse also adds more connections to the circuit, and these are also sources of potential voltage drop. Most installation do not use a fuse. Locating a primary battery disconnect switch near the battery is a reasonable alternative. This means you will also have to relocate the primary battery distribution switch to be closer to the battery.