916 Electrical wire burnt

[RWG]

Hi Folk,
Pulled my 1994, 916 on bench tonight after a good day's ride. My aim was to carry out service & belts, drained oi. And removed filter pulled ancillaries of to gain access to belt covers and noticed how dirty it was between cylinders.
So I decided to give a deeper clean before cracking on, I removed the throtle bodies & plastic coolant catch tan, , berried between cylinders that is when I found the 2 wires from generator to rectifier where very hard and about to fray.

My question is can anyone please give me the wiring specification ie diameter for current capacity, hope I am making sense. My idea is I will cut out the hard existing wires and renew making slightly longer to allow better option of re routing away from engine case under catch tank ?

I should say the black plug on regulator is good, however the original white plug for yellow wires has been replaced with bullet connectors.

It is the early 2 yellow wire regulator, any advise would be appreciated.
Regards
Paul

 

[WAYNE]

Hi Folk,
Pulled my 1994, 916 on bench tonight after a good day's ride. My aim was to carry out service & belts, drained oi. And removed filter pulled ancillaries of to gain access to belt covers and noticed how dirty it was between cylinders.
So I decided to give a deeper clean before cracking on, I removed the throtle bodies & plastic coolant catch tan, , berried between cylinders that is when I found the 2 wires from generator to rectifier where very hard and about to fray.

My question is can anyone please give me the wiring specification ie diameter for current capacity, hope I am making sense. My idea is I will cut out the hard existing wires and renew making slightly longer to allow better option of re routing away from engine case under catch tank ?

I should say the black plug on regulator is good, however the original white plug for yellow wires has been replaced with bullet connectors.

It is the early 2 yellow wire regulator, any advise would be appreciated.
Regards
Paul

Any advice out there, i'm shit at electrics but do know enough to get me through.

 

[Markduc]

I’ll admit straight off I don’t know the size , but a 2.5mm tri rated cable should suffice
heat shrink each core and overall sleeve it with a loose heat resistant sleeve and be careful where you put the soldered
joints vibration and all that

 

[Nelly]

They were barely big enough when new tbh. With age, they’ll be border line at best. If you’re going to the trouble of repairing, I’d go a bit further and run a new 2 core cable directly back to the windings. Use an oil resistant cable with at least 2.5mm cores. It’ll mean removing the alternator cover, but if you’re into giving the bike a good going over, it’s not much more work and you can check the alternator nut at the same time

 

[Birdie]

I used this on my early 748, ( https://www.ebay.co.uk/itm/264413021057?hash=item3d903e8381:g:HfIAAOSw9jpklDB3&amdata=enc:AQAIAAAA4HLNYGfuRO1NTzt76IeuwhgBKRCz4HAocuJ/jD0ril78urY/FiJDtJRhkcUikLFtcCufYSgKIeqSlveP+e4pZYyQgv5m7H1efaAY9uEsOUj5umOE9UzIV6wpsdXURytQ/6n1+XqPZsfLOLbFPr7PP4xM/IO7CHWlcCDsPSTWr4Je5hax0ECN5O3s/YPufLyieRnE7Lf0B81r8nd7FF9MvtuWDNVcg69VtpZtLmELOz0TihPDscNK7vtB8M4dxTRSQijOx9FoMgYy0ITyqHRmhz0Tvl3IEe2KnXPj+jtP/soF|tkp:BFBMpLbtpcBi )

Search Ebay or go to a model shop there's plenty available. I used 12 AWG.
It is used by RC modelers for Lipo Batteries, very flexible and heat resistant, while I was at it I moved the reg/rec to the back of the number plate to keep it cooler.
It's been trouble free for around 10 years now.


.

 

[AirCon]

I used this on my early 748, ( https://www.ebay.co.uk/itm/264413021057?hash=item3d903e8381:g:HfIAAOSw9jpklDB3&amdata=enc:AQAIAAAA4HLNYGfuRO1NTzt76IeuwhgBKRCz4HAocuJ/jD0ril78urY/FiJDtJRhkcUikLFtcCufYSgKIeqSlveP+e4pZYyQgv5m7H1efaAY9uEsOUj5umOE9UzIV6wpsdXURytQ/6n1+XqPZsfLOLbFPr7PP4xM/IO7CHWlcCDsPSTWr4Je5hax0ECN5O3s/YPufLyieRnE7Lf0B81r8nd7FF9MvtuWDNVcg69VtpZtLmELOz0TihPDscNK7vtB8M4dxTRSQijOx9FoMgYy0ITyqHRmhz0Tvl3IEe2KnXPj+jtP/soF|tkp:BFBMpLbtpcBi )

Search Ebay or go to a model shop there's plenty available. I used 12 AWG.
It is used by RC modelers for Lipo Batteries, very flexible and heat resistant, while I was at it I moved the reg/rec to the back of the number plate to keep it cooler.
It's been trouble free for around 10 years now.


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This is excellent advice from @Birdie and the correct grade of wire (better than the OEM), if you intend lengthening the wire consider going to 10AWG then solder the wires directly to the coil and shellac / heat shrink the sleeve.