REPLACING STARTER BUTTON AND WIRING ADVISE

Hi all. Have a 1981 Yamaha Midnight Maxim XJ650......starter button broke off got a new one......someone decided to cut the old solder off at the top of where the wires were attached to the old button. Now not enough room in that area. What kind of splice can be done? gauge wire and such should be used to fix this. Thanks in advance for any help.

 

The starter wire actuates the solenoid which puts the real amperage to the start motor... so I would use something around 12 or 10 gauge just be certain. I do a 4 part split, mesh and wind, solder then heat shrink for strength.
Probably done nearly every other wire at the headset on my harness.
Good luck!

 

no not 12 ga. trina is talking about the starter button on the control light gauge wire if you measure the diameter of the insulation and count the strands

XJ PARTS CATALOG, SECTION D: ELECTRICAL SYSTEM

So how to you determine what size wire is in your hand? Well, this is kind of confusing, but here goes:

- for stranded-core wire (which is what is used on most vehicular applications, including these bikes), you should do the following:

* Make a small cut about 1/2" long and remove the insulation from the wire.
* Then you will need to count the individual strands of copper....how many individual strands are there?
* Next, use a micrometer and measure the thickness of any one single strand.
* Then, look at the following information to determine the gauge of your automotive wire:

# of strands / diameter of each wire strand

7 x .028" = 20-gauge wire
(this example means that a 20-gauge wire has 7 individual wire strands, each strand measuring .028" in diameter)

16 x .030" =18-gauge wire
19 x .029" =16-gauge wire
19 x .027" =14-gauge wire
19 x .025" =12-gauge wire
19 x .023" =10-gauge wire
19 x .021" = 08-gauge wire
37 x .021" = 06-gauge wire

Wow, that's a lot of work, isn't it?

Here's the shortcut method that applies to your harness wires.........you measure the outside diameter of the wire in your hand (meaning, the O.D. of the insulation) and that measurement tells you what the AWG of the wire core is. NOTE: make sure that you measure the wire on a straight portion of the wire, and it's useful to take 2 or 3 different measurements to make sure you are not measuring a distorted, "egg-shaped" area of the insulation:

If the wire OD is 2.03mm - 2.19mm (.0799 to .0862"), then it's 20-gauge (20g) AWG or 0.40mm squared (metric size).
NOTE: 20g wire is rated for a maximum load of 11 amps of current at 12VDC.

If the wire OD is 2.26mm - 2.42mm (.0890 to .0953"), then it's 18-gauge (18g) AWG or 0.75mm squared (metric size).
NOTE: 18g wire is rated for a maximum load of 16 amps of current at 12VDC.

If the wire OD is 2.48mm - 2.64mm (.0976 to .1039"), then it's 16-gauge (16g) AWG or 1.25mm squared (metric size).
NOTE: 16g wire is rated for a maximum load of 22 amps of current at 12VDC.

If the wire OD is 2.89mm - 3.05mm (.1138 to .1201"), then it's 14-gauge (14g) AWG or 2.00mm squared (metric size).
NOTE: 14g wire is rated for a maximum load of 32 amps of current at 12VDC.
NOTE: 14g wire is the largest size wire normally found in the wiring harnesses on these bikes. Battery cables and the solenoid-to-starter motor cable are larger, of course, but of all the main harness and accessory wiring, 14-gauge is the largest that you'll find.

If the wire OD is 3.49mm - 3.65mm (.1374 to .1437"), then it's 12-gauge (12g) AWG or 3.00mm squared (metric size).
NOTE: 12g wire is rated for a maximum load of 41 amps of current at 12VDC.

If the wire OD is 4.32mm - 4.48mm (.1701 to .1764"), then it's 10-gauge (10g) AWG or 5.00mm squared (metric size).
NOTE: 10g wire is rated for a maximum load of 55 amps of current at 12VDC.

 

if wires were cut from switch
you should be able to solder the wires back on to the switch are the wires still connected to the connector in the wiring harness?

you could get the connector pins from chacal and run new wire from connector to switch. other wise it is called a linemans splice

 

Wow... now that is specific. nice info to be sure, with a picture to boot!

 

try to leave no questions unanswered .
not my work Chacals he has all the answers you just have to look