• Required reading for all forum users!!!

    Welcome!
    Register to access the full functionality of the GSResources forum. Until you register and activate your account you will not have full forum access, nor will you be able to post or reply to messages.

    A note to new registrants...
    All new forum registrations must be activated via email before you have full access to the forum.

    A Special Note about Email accounts!
    DO NOT SIGN UP USING hotmail, outlook, gmx, sbcglobal, att, bellsouth or email.com. They delete our forum signup emails.

    A note to old forum members...
    I receive numerous requests from people who can no longer log in because their accounts were deleted. As mentioned in the forum FAQ, user accounts are deleted if you haven't logged in for the past 6 months. If you can't log in, then create a new forum account. If you don't get an error message, then check your email account for an activation message. If you get a message stating that the email address is already in use, then your account still exists so follow the instructions in the forum FAQ for resetting your password.

    Have you forgotten your password or have a new email address? Then read the forum FAQ for details on how to reset it.

    Any email requests for "can't log in anymore" problems or "lost my password" problems will be deleted. Read the forum FAQ and follow the instructions there - that's what we have one for...

  • Returning Visitors

    If you are a returning visitor who never received your confirmation email, then odds are your email provider is blockinig emails from our server. The only thing that can be done to get around this is you will have to try creating another forum account using an email address from another domain.

    If you are a returning visitor to the forum and can't log in using your old forum name and password but used to be able to then chances are your account is deleted. Purges of the databases are done regularly. You will have to create a new forum account and you should be all set.

Gauge wire for harness

  • Thread starter Thread starter oohsam
  • Start date Start date
O

oohsam

Guest
Hey guys,
I'm about to rewire the GS1100G....with a simplified wiring loom.
Cant find anything in the search....

Just wanting to know what Gauge wire is most commonly used here for you guys. The general understanding I have is

for all 10Amp fuses = 18 Gauge wire
for all 20Amp fuses (for the rectifier) 20amps
and an 18 Gauge wire for the earth to chasis.

And 18Gauge for battery wires.

Am i way off?
 
Yes. :D

I looked a some "official" charts that showed current carrying capacity and was surprised to see numbers quite a bit larger than I expected.

However, I like to err on the side of caution, so have used larger wires than necessary for some applications.

First of all, your stock 1100G probably never had a 20 amp fuse. The stock main fuse is 15 amps. All the others were 10 amp fuses.
Starting at the end of the fuse block away from the AUX terminals, the fuses are LIGHTS, SIGNALS, IGNITION, MAIN and AUX.
The LIGHTS fuse obviously powers the head and tail lights, as well as the instrument lights.
The SIGNALS fuse powers the turn signals, brake light, horns and the oil pressure warning light.
The IGNITION fuse powers the coils and ignitor.
The MAIN fuse powers the entire bike until the engine is running and the stator is producing power. Then, current goes the other way through the MAIN fuse to charge the battery.
The AUX fuse only powers whatever you connect to the AUX terminals.

Looking at loads, the headlight will draw about 5 amps, the tail light less than 1 amp. Add in all the other lights for about another 2 amps, total of about 8 amps.
The brake light draws about 2.5 amps, the turn signals draw about 5 amps while they are ON, the horns draw a few amps, too.
The coils draw about 8 amps, the ignitor maybe 1 more.

You say you have a "simplified wiring loom". Depending on what you have eliminated, you can adjust your loads accordingly.

For 10 amp loads, 20ga is supposed to work, I would use 18ga.
For 15 amp loads, 18ga is supposed to work, I would use 16ga.
For higher loads or charging current from the regulator to the battery (and the ground from the regulator to the battery), I would suggest 14ga or 12ga wire.
What I think you might be calling "battery wires" would be the ones going to the starter? Definitely 8ga or even 6ga for those.

.
 
Your assumptions were correct and I thank you for your input!

Time to buy some wire!
 
You realize, of course:

worthless.gif





Yeah, we like "project" pictures, too. :D

.
 
heheheh Yes I know!
Here is what I'm working on. Its a bloody mess. But it runs!

attachment.php


attachment.php
 
Back
Top