Which amperage wires to use?

[coldsummer]

I bought a new custom wiring loom for my z650 from a guy in the States who made it up from pictures I sent of my old loom and various references he already had. Surprisingly it turned out pretty good with only a few mismatched colours and connectors. Some of the wires are a little bit short and I need to put some extensions on them, in particular the ones from the contact breakers and a few odd ones here and there.

I'm not sure which size wire to use, I have 5 and 8 amps both of which look slightly thicker than the ones used in the new loom. Does it matter if I use a thicker wire, ie slightly higher amp rating? Does anybody know the correct spec? Any general pointers I should consider? Any help greatly appreciated as always. Thanks chaps.

[PAULJAC47]

Hi Simon, if the cross sectional area of your cable is greater and its the same metal and amount of strands will be fine.When extending cables i tend to use the same method as when they were built,use heat shrink insulation and wrap the wires together solder the joint.only use this technique on your low amperage wiring though. dont be tempted to use some of the nasty connectors available out there...Cheers Paul J

[coldsummer]

Thanks Paul. I've got the nice (expensive) jap style coonectors which seem to do a good connection. I'll take a closer look at the wires, the insulation may be a bit fatter on the reels I have.

[Ginger Bear]

Hi Simon,

I'm working away from home again......

I'll do my best to catch up with you soon.

[snotie1965]

Thanks Paul. I've got the nice (expensive) jap style coonectors which seem to do a good connection. I'll take a closer look at the wires, the insulation may be a bit fatter on the reels I have.

Have you got a link for expensive jap style connectors ?

[LondonZ1]

For a short length of wire for a low current application the gauge is not critical. I used 0.5mm2 for control lines, 1.0mm2 for horn and lights and 10mm2 for starter and main earth on my Zed special.

I would recommend using solder sleeves to splice in a wire extension, pics here:

http://www.z1ownersclub.co.uk/forum/viewtopic.php?t=17160&postdays=0&postorder=asc&start=195

You can buy them from RS Components. You need a suitable heat gun but they give you a high quality solder joint, strain relief and sealing in one easy low-skill operation.

[coldsummer]

Thanks Paul. I've got the nice (expensive) jap style coonectors which seem to do a good connection. I'll take a closer look at the wires, the insulation may be a bit fatter on the reels I have.

Have you got a link for expensive jap style connectors ?

Not that expensive really but you'll need the proper crimping tool http://www.vehicle-wiring-products.eu/V ... ullets.php

[coldsummer]

For a short length of wire for a low current application the gauge is not critical. I used 0.5mm2 for control lines, 1.0mm2 for horn and lights and 10mm2 for starter and main earth on my Zed special.

I would recommend using solder sleeves to splice in a wire extension, pics here:

http://www.z1ownersclub.co.uk/forum/viewtopic.php?t=17160&postdays=0&postorder=asc&start=195

You can buy them from RS Components. You need a suitable heat gun but they give you a high quality solder joint, strain relief and sealing in one easy low-skill operation.

Thanks! You've heard about my skill level then? :-)

[coldsummer]

Hi Simon,

I'm working away from home again......

I'll do my best to catch up with you soon.

Look forward to it Steve. I've tried not to call upon you so far but I must admit I've been considering stocking up on incentives (ie crates of Stella!).

Be good to catch up regardless, glad to see you are busy!

[KeithZ1R]

Simon VWP's site is quite informative if you look carefully

http://www.vehicle-wiring-products.eu/V ... dcable.php

and as a rule of thumb (within reason) apply " what will do a lot, will do a little, but what will do a little will not do a lot!" sack soldering use proper Japanese bullets, soldered joints can bend and subsequently crack and break

[ZedHead]

Using the formula I=V/R 12/3 = 4 amps for 3 ohm coils. Your 5 amp wire will suffice

[ZedHead]

Using the formula I=V/R 12/3 = 4 amps for 3 ohm coils. Your 5 amp wire will suffice

Better still z650 uses 4 ohm coils so only draw 3 amps

[coldsummer]

Thanks chaps

[ZedHead]

Nice little guide and calculator here

http://www.12voltplanet.co.uk/cable-siz ... ction.html

[coldsummer]

Nice little guide and calculator here

http://www.12voltplanet.co.uk/cable-siz ... ction.html

Great link, thanks.