LouSiana
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SuzukiSavage.com Rocks!
Posts: 73
Hannover, Germany
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I would say the original is about AWG 6. A stronger one might be desireable, but I think it is not required.
What you should bear in mind is a multiple insulation at the cable! Don't ever use a simple PVC-insulated cable. Choose one with at least heavy silicone insulation and maybe additionally a cotton cloth insulation.
Temperature of the engine would melt down PVC easily. AFAIK the stock wire is triple insulated with PVC, cotton and an ugly rippled hose (did I say that correct?).
And if you go with the wire to the starter, you did ony the half job done. The other part is the ground wire and the "hot" wire fom battery + to the starter relay.
As mentioned otherwhere here, the initial current is about 200 Ampere, the average current with compression strokes is about 50-60 Ampere, depending on how much the battery voltage drops. Therefore: The lower the losses in the high current wiring, the more the battery may drop in voltage. We got a critical point at about 9.5 Volts, then the plug would not fire anymore. So the limits in current through thinner stock harness may have still an advantage. If you only think it's ugly, right. But remember, you then might need at last a heavy duty battery. Some aftermarket batteries have only borderline values... Especially if you try to start her in winter. Oil gets thicker, voltage drops more by higher consumption and restricted battery chemistry.
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