(General) Diameter of electrical cables

[Phred]

Try Z1 Enterprises for wiring, connectors and the tools for the connectors. They have a wide assortment. I changed many of the old bullet connectors to weatherproof spade connectors.

[bwringer]

Try Z1 Enterprises for wiring, connectors and the tools for the connectors. They have a wide assortment. I changed many of the old bullet connectors to weatherproof spade connectors.

Nice! I didn't know they had this stuff.

https://www.z1enterprises.com/store/category/suzuki/electrical/connectors

https://www.z1enterprises.com/product/RI11-001

https://www.z1enterprises.com/product/KL35-9266

They don't tell you what gauge the wire is or what the insulation is made of, so you just have to make a few assumptions...

With wiring, it's easy to go down a bit of an expensive rabbit hole and go overboard making everything NASA grade. You have to find a good middle ground between the often crappy stock connectors and something suitable for an interstellar oceanic mission.

[Grimly]

One simple point to bear in mind, with bike (or any vehicle wiring) is the vibration resistance of the wiring. I don't know how many vehicle wiring harnesses I've seen repaired with the wrong type of cable - ie, too few strands in it. Finely-stranded cables are more flexible and tend to resist cracking for far longer, even if installed incorrectly. Of course, making sure the harness isn't allowed to flap about is important, too.

[posplayr]

One simple point to bear in mind, with bike (or any vehicle wiring) is the vibration resistance of the wiring. I don't know how many vehicle wiring harnesses I've seen repaired with the wrong type of cable - ie, too few strands in it. Finely-stranded cables are more flexible and tend to resist cracking for far longer, even if installed incorrectly. Of course, making sure the harness isn't allowed to flap about is important, too.

Agreed:

If you look at power cables on LiPo batteries for Drones they have very fine stranded cables. I don't know what the count typically is but Automotive grade wires is usually adequate for a motorcycle but it is very important to keep the wires wrapped so that individual strands have not only the support of the individual cable, but also the wrapped cable group. Securing the wrapped cable group then provides a very good support that can be used to minimize any "flapping around".

Of course you have to make sure you don't have soldered joints with solder wicked way up a wires that is subject to flapping. It will break off in short order.

Wire to wire soldered butt joints need to be stabilized inside of the harness wrap as an absolute necessity.

This is one area at least that house wiring twist caps are an improvement if you can't actually do a proper job .

[Zagg]

Nice! I didn't know they had this stuff.

https://www.z1enterprises.com/store/category/suzuki/electrical/connectors

https://www.z1enterprises.com/product/RI11-001

https://www.z1enterprises.com/product/KL35-9266

They don't tell you what gauge the wire is or what the insulation is made of, so you just have to make a few assumptions...

Perfectly timed thread. I had the same question regarding gauge of wire from Z1 Enterprises so I emailed them.... The response was 18 gauge. Hope this helps! Thanks so much for all the insight!

For reference, I asked about the wire in general but referenced part#KS001-1015 so the rep from Z1 had something specific to go on.

[nastyjones]

I posted this in another thread but it's relevant here too for those who want to simplify their wiring, eliminating the many wires that go nowhere on our bikes.
Probably the simplest wiring diagram ever.

http://www.bikeexif.com/motorcycle-wiring