Stator Wire Gauge?

[Mr.humbucker]

I will be installing a SH775 regulator/rectifier on a GS650G project and will be making a harness with the proper connectors. What gauge of wire should I be using to this cobble together?

Thanks to all!

[Nessism]

14g is plenty for the power and ground output. For input, 16g is more than enough.

[Gorminrider]

I'd use what Suzuki uses +1 or 2 only if you can suit the crimp connectors and easily bend the wire. If I recall, the wire windings on the stator are 18 in solid wire so that'd be a minimum on Power bearing wires...go bigger on stranded wire. ...but going to what the starter uses( the size on the solenoid nuts is massive overkill and inconvenient.

[bwringer]

Suzuki actually used metric wire, which is very nearly impossible to get here in the US of A. Not sure if it's easier to find in Canada.

As noted above, AWG wire is plenty close enough; go with Nessism's recommendations.

[Gorminrider]

The original stator windings are indeed very slightly smaller than 18 but I rewind with 18. It's fairly hefty for the demands on these bikes.

I dare say making a new harness with 16 gauge wouldn't fit under the tank That said, the red wire going to ignition is larger than the most of the harness. I'd use similar on your R/R rewire since that's the wire you're tapping the R/R into. otherwise, there's no win attaching a thicker gauge to a thinner but I can see some attaching thinner to thicker aka 'a bus". The suzuki B/W trunk in the harness would be one I don't like as is and the orange back from key to fusebox is another.