Harness wire gauge size?

Wow!
Thanks and thanks again!

That should be more than enough sources to chase down the things I need. I wasn't to fussed over having the perfect vintage connectors, and non of the multi wire plastic harnesses on my bike are broken, or looking too bad yet, so perhaps I can recycle them. We will see where the adventure in wiring goes.

I will be sure to get myself a pair of proper crimpers, or perhaps borrow a set locally if I can.
Unless I am greatly mistake, none of the wires on my bike currently need to pass through any handlebars or narrow passages, but there are come tight spaces where bundles need to pass, and the headlight holder is a nightmare of wiring. Perhaps 18ga will suffice overall.

I'll have a good look into all of this as time goes by. Thanks!

Jonny

For brighter headlihts, try to use at least 16 gauge or even 14 gauge. 18 gauge, in my opinion, will restrict the current flow.

Good Advice. I haven't the funds at present to refit a modern halogen headlight, so I will be sure an use a bigger gauge wire for that. As well as the primary circuit (the BROWN wire as OMR says, tho I think it is a different color on my bike....) I was suggesting that the turn signals etc... won't get an increase wire gauge as there is likely no real benefit.

Cheers!

Jon

Wire Termination Insulation & Sizes

Terminal Insulation Color Wire Sizes
RED

---

22-18 gauge wire
BLUE

---

16-14 gauge wire
YELLOW

---

12-10 gauge wire
RED

---

8 Gauge
BLUE

---

6 Gauge
YELLOW

---

4 Gauge

The ring terminal holes comes in many sizes, from #4 up to 1/2" in most cases, it's a matter of finding the tightest fitting hole to fit the fastener for the termination.

American Wire Gauge(AWG) is backwards to what many people think; that is 22 gauge is many times smaller than 10 gauge even though the number is bigger.

Sherco Auto parts
NiAc ™ Heat Shrink Butt Connectors
Adhesive Lined—Moisture Proof Low Temp. Cross-Linked Ionic Polymer.
10 Pack 100 Pack 1000 Pack
HSNRBS 22-18 Gauge Red NiAc™ $3.50 $24.95 $174.95
HSNBBS 16-14 Gauge Blue NiAc™ $3.50 $24.95 $174.95
HSNYBS 12-10 Gauge Yellow NiAc™ $4.25 $ 39.95 $269.95

NiAc Assortment SBA-HSN
30 Red, 40 Blue, 30 Yellow
$29.95



(Heatshrink Terminal Installation)


(Heatshrink Terminals And Connectors, AAA Protection)


(Heatshrinkable Crimpable Terminals)

As an electrician by trade, I'm held to a standard refered to as the National Electric Code and it is written by the National Fire Protection Association. The previously mentioned "THEY" allow # 12 wire to carry 20 amps, # 14 is good for 15 amps etc. It's all available in article 310-16 of the NEC book. Paul