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So as the title says, I'm wondering what gauge to use? I'm planning to completely rewire my cb160 as the PO had rigged up some funny business for at least one wire on the outside of the harness, which leads me to believe there is obviously at least one bad wire within... So I figured since this bike was sitting in a junk yard for I don't know how long, it can't hurt to give her some new wires...
I thought I read somewhere that the stock wires are 18 gauge, but does that include all the wries (minus the battery cables of course)? Or is there some 16 gauge wires in there somewhere? And would it hurt to use 16 gauge throughout?
Most of the stock wires are probably 16 gauge. I use 18 gauge for most of the wiring runs in the harnesses I make, but 14 gauge for the big circuits like the headlight and ignition coils.
Awesome... Thanks Sonreir... I actually purchased your R/R from ebay a couple weeks ago for my cb160 project... So if I buy 16 Gauge for most of the new harness with 14 for the headlight and coils, it shouldn't make a difference when I start connecting all those wires together right?
Keep in mind that the circuit is only as wide as its smallest part. The headlight circuit includes 16ga leads that go through your dimmer switch, so even if you run 14ga up to this point, the resistance will increase at the switch anyway. If that's a concern, the common solution is to route the high current circuits through a relay that is switched by your headlight switch, which in your bike is a position on your key.
Honda produced these in great numbers and I've never seen an issue with wiring. If you're using new bullets and clean contact points, why wouldn't Honda's design suffice?
Use the original 3.9mm bullets that your Honda comes with. The insulated ones are as good as it gets and I don't use anything else, except a different size as needed.
CycleTerminal.com has everything your bike could need for wiring, even the proper crimping tools, which is also very necessary. If you crimp these right you could hang from the damn things.
Then again, Sonrier has been known to make a custom harness or two by order
I forgot to mention that more fuses isolate circuits better. So if your headlight shorts to the bucket it's not going to keep you from making it home. I like one for headlights, ignition, brake/tail and one main before the ignition switch but bypassing the charging wire from rectifier. Calculate fuse amperage carefully.
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