Harness wire gauge size?

I am going to build a new wiring harness on my 82' GPZ 550 over the winter and wanted to double check on the size of the stock wiring. I want to go up a gauge size since the factory wiring was pushing its limits. Looking at the size, it mostly seems to be 18g, I just wanted to see if anyone knows for sure what size was originally used. It will be nice to have a harness with sealed and unburned connectors.

I recently made a harness for mine. Go to riwire.com for wire and vintageconnections.com for the connectors. They have everything you need.

It's mostly 18, which is what I mainly used. I put in 16 where I felt it would be necessary. Soldered all my crimps and splices, generous use to heat shrink. Its now better than stock IMO.

I'll list what I remember for wire sizes and what they are used in:

18 gauge: Turn signal wiring,instrument wiring, and stop/running light wiring.

16 gauge: Igniton wiring,fuse holder wiring for higher draw(amps)circuits like the headlight.

12 gauge: Even higher current circuits, like for the 20 and 30 amp main fuse.

8 guage: The size supplied for the battery cables(I upgraded my cables to 6 AWG(American Wire Gauge) welding cables, for increased current capability.

Thank you Mike and T_dub, that was the information I was looking for. Unfortunately I might end up getting the new harness finished before I figure the darn ignition relay problem I have now.

Dredging up and older conversation, I know, but as I am close to the point of ordering in the wire and fitting to make up a new wiring hareness as well, I figured it would be a decent time to chime in here and get some of the specifics.

Following Mfolks advice on where to use the heavier gauge wires, and upgrading the main battery and starter cable to 6ga instead of 8ga is how I am going to start.

A few other questions tho:

Tdub - you said you were going to use 16ga in a few other places as appropriate. Could you elaborate? Also, did you find a good Canadian source for large amounts of shrink wrap? Ive been stuck buying it a CT, and it is waaay to expensive if I plan on doing the whole bike that way...

Mfolks - Is there a good reason not to just use 16ga pretty much everywhere except for the places that really have super fine wiring? (Ie: instrument cluster lights...) I mean, there would be a slight decrease in resistance through the wires vs. a stock wire at 18ga correct? Or is it simply a matter of wasted money and weight, as there would be no real advantage in going to higher guage wire for low amperage circuits.

Thanks all. Hope I haven't bitten off more than I can chew with this one.

Cheers!

Oh, and an unfortunate side note. Vintage connections will no longer ship to Canada. I didn't write to ask why, but I suspect it doesn''t really mattter since they just don't do it any longer.

So, I guess I need to figure out how to get a post office box on the US side of the border or some such. Unless there is anyone living near the Niagara/Buffalo area in the States who would be willing to act as a mailing address who I could then pick up the package from?

If there a KZ'er in that area, I'd be mighty grateful if that could be arranged.

Cheers!

16 gauge wire, if bundled together, will have a slightly larger diameter than 18 gauge will, especially if you're going to run wires inside a handlebar, or other confined spaces.

There are thinner insulation wires available,so read this:

www.awcwire.com/FAQ-Automotive-Wire.aspx

Jonny- if you can't get your shipping issue worked out give Eastern Beaver a try. www.easternbeaver.com/Main/main.html

BTW eastern beaver was the only place I could readily find 2.5 mm bullet connectors.

I live in Toronto,Canada and ordered all my electrical needs from CYCLE-RE-CYCLE PART II and can be reached at www.crc2onlinecatalog.com . Good Luck.

Jonny wrote:
Also, did you find a good Canadian source for large amounts of shrink wrap? Ive been stuck buying it a CT, and it is waaay to expensive if I plan on doing the whole bike that way.

B !

For heat shrink I go to Princess Auto. Much better deal than CT. they have a location at the east end of Hamilton.
Last time I looked they seemed to have a good selection of wire

Johnny, if your still having problems finding elec. connectors try any marine place where you live, many of them carry the identical type of connectors we use for our bikes. Don't forget to use a proper double crimp type of crimper, this will save you headaches later on.

www.pbase.com/mainecruising/wire_termination (The Good, Bad, & Ugly of Crimpers).