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Tail light wiring

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Tail light wiring

Post  GrahamN on Mon Jan 30, 2017 10:22 am

Seeking advice about the wiring loom on my Falcon 70.
The outer covering on the wire to the tail light is badly perished and I first thought to use insulation tape to cover the cracks and absence of the cable's sleeve.
I wonder is it possible to replace this cable and if so what size of wire do I use?

GrahamN

Posts : 13
Join date : 2016-11-09
Age : 78
Location : Lancashire

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Re: Tail light wiring

Post  Druid on Tue Jan 31, 2017 1:13 pm

Hi Graham,

Assuming that you have the standard tail and stop light i.e. 6Volt 3/18Watt, you could use 0.75 sq. mm twin core oval/round flex (as used on household appliances and rated at 6A) Standard 6V tail/stop lamp takes 0.5 and 3 A respectively.
If you prefer to use single cables use 24-0.2mm (24 strands of 0.2mm dia wire, 6 Amp rating) flexible equipment wire which is available in many colours. Best to run singles in sleeving under mudguard.

Cables and sleeving available from Maplin stores or specialist suppliers like Vehicle Wiring Products, phone 0115 9305454.

Regards
Dave

Druid

Posts : 43
Join date : 2014-10-09

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Wiring loom

Post  GrahamN on Thu Feb 02, 2017 1:14 pm

Thanks Dave for your response to my plea.
In the absence of qualified advice I went ahead and cobbled together a replacement loom using different coloured cables. Friendly advice had told me it didn't matter too much, so long as the cables were about right. I've now checked those I've used, two of which are slightly bigger than the other three. The bigger cables are labelled 2.5mm2 600v. 14AWG and are about 40ply and I have used these to connect the rectifyer to the main switch and also the ammeter; the other cables are marked 0.75mm2 and are 7ply these I have used for the rear brake and stop light switch and ammeter to battery.
I've not yet fitted everything onto the bike nor yet fired her up, but will let you know how I get on.
Thanks again for your guidance, and I am sure other readers of this post will benefit from your expertise.
Regards
Graham

GrahamN

Posts : 13
Join date : 2016-11-09
Age : 78
Location : Lancashire

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Re: Tail light wiring

Post  Druid on Fri Feb 03, 2017 11:02 pm

Hi Graham,

The 2.5 sq. mm cables you have used have a current rating of approx. 30A (6Amp probably maximum current on these machines) but it is better to have cables that have a higher current rating than required, particularly on 6V systems where volt drops can be an issue. It would be better if you made the connections between ammeter - battery and battery - earth using the "2.5" also.
Whist the 0.75 cable is OK regarding its current rating for the tail/stop lamp, with only seven strands it is not really a "flexible" cable so try to avoid using it were it is subject to repeated flexing such as between head lamp and frame. In these locations it will be susceptible to fracture and particularly so at terminations i.e. crimp terminals. A "proper" mult-strand cable ie.24 x 0.2 cable, would be a far more reliable option.

Hope you find this information useful.

Regards
Dave

Druid

Posts : 43
Join date : 2014-10-09

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Cable size

Post  GrahamN on Sun Feb 05, 2017 1:07 pm

Thanks again Dave will follow your advice and make some changes.
Regards
Graham

GrahamN

Posts : 13
Join date : 2016-11-09
Age : 78
Location : Lancashire

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