Re: Generator Terminals and Wire Gauges

Posted by Fish'n Jim On 2024/2/19 12:51:03

The shop manual should also have the complete wiring diagram and that will have the wire GA and insulation color. I know I got it, not sure in where.
Rules of thumb,
The connecting stud is usually sized for the proper terminal connector. If hole is too big or too small to fit, it's the wrong wire GA. Terminals come with a 2 size range typically, like 14-16, 18-20, etc. By good quality and stay away from the cheapo offshore stuff. International EC permits stuff that's "iffy".
6 VDC is typically larger GA due to increased amperage due to lower voltage. V=IR, R constant. Diam determines ampacity so non-linear, R^2 law.

Make sure you got a good crimper with the proper dies. Terminals can be obtained from the usual auto electric supplies or carriers. Del City, etc. Even though its nor OEM, I like to shrink wrap each connector. Gives a finished touch and prevents corrosion and puking apart. SAE doesn't permit soldering, but I don't see an issue if you want a better connection, however, residual acid solder flux should be removed. I only do it, if it's a single crimp w/o the insulation crimp. Plus the insulation may discolor and why it helps to shrink wrap.