Rebuilding fuse box...what gauge wire to use?

[njcafe84]

Im gonna finally fix the rats nest of inline fuses on my bike left to me by the previous owner.

Im switching to a small blade style fuse box so I have to cut and solder together all new wires and curious as to what gauge wire I should be using.

 

[xschris]

I would use the same gauge that it came with, I think it's 14.

 

[Keenzo]

What about using 16G? I'm rewiring my whole bike and I got new free 16G wire from my work that we use to wire the electronics in cab's on excavation equipment (radio, power seats, Ect). I striped all the 14G wire off my bike because it was such a rats nest but the wires from my Ignition coils are still 14G. If I solder a 16G wire to a 14G wire will I blow up my Ignition coil or melt the 14G wire to the ignition wire?

 

[xschris]

You may be ok but with lighter wire you risk over heating the 16ga compared the the 14.

 

[bcware]

There must be a way to calculate the true requirement. I know they all use the same 14 normally, but I bet only the line with the largest fuse really needs it. The 14 is probably overkill for a line with a 10 amp fuse for example. I'm no electrician though!

Edit:

I found this:

AWG 	 	 	 	Maximum amps for chassis wiring 	Maximum amps for power transmission 		
14 	 	 	 	32 	 	 	 	 	 	5.9
16 	 	 	 	22 	 	 	 	 	 	3.7

I believe this application would be considered "chassis wiring" and as such 16 gauge is right at its max on the 20 amp line. I would go with 14 just like Yamaha did. Any kind of surge on that 20 amp line in the fuse box and the fuse isn't just going to blow; it will definitely melt the wire. Prolonged use might melt it too since you're running at/near the max.

 

[drewpy]

do you have thinwall wire in the states? its thinner but can carry more amps due to superior sheathing