TOPIC:

Hi, folks. I'm in the process of going through my entire wire harness off the bike. I've also replaced the fuse block with a new spade-type. I want to make a new sub-harness off the block - keeping the old one intact in case anyone has use for it.

My problem is the factory manual does not indicate wire gauges, and I want to do it right. Now, the majority of the wires feel like 18 gauge, but the white primary and the black ground are heavier gauge. I've compared them with 12 gauge new wire, but the factory wires definitely don't seem to be 12 gauge.

Have any of you had occasion to re-wire or recreate? My best guess is the other colored wires are 18 gauge, and the white and black wires are 14 or 16 gauge. Can anyone confirm? I appreciate any guidance!

as long as you are using a larger wire size I dont think you will have a issue, s,aller will make the wires get hot , not good thing, one size bigger should not present an issue

Thanks, BSKZ650. I've decided to go with 14 gauge on primary white (power) and black (ground). The rest are 16 gauge - just to be on the safe side.

I've also laid the entire harness out on a board, and slowly going through every wire - replacing where appropriate or needed, and replacing all connectors and bullet connectors (ordering a Pro Kit from Vintage Connections).

If you are committed to upgrading the wiring can I suggest that you add the WG Coil Re-powering mod. while you're at it. Its the most bang for the buck. I implemented it with a separate 5 Amp fuse for easy troubleshooting. If you need a diagram check the archives or let me know.

Best of success.

Double post.

Post edited by: bill_wilcox100, at: 2007/11/14 00:46

Thanks, Bill, and yes, I'm committed - I better be as my bike is now down to bare frame and engine mounted on engine stand:P

I have done the WG mod and routed every thing within the harness itself. Now I'm hunting down harness sleeves in different sizes to organize and clean everything up.