Hey there,

I was talking with my father about me wanting to work on the wiring harness and how I was kinda worried about choosing the right different wire sections, then he told me that it did not really matter, I could redo the entire thing using, say, 1.5mm² electrical wire, and they do it on the bikes only to save costs.
Is that so ?

My gut feeling was that different sections would offer different electrical behaviour (resistance, thus amperage).

Thanks

Often wire size (gauge) is determined for mechanical reasons not electrical load. Skinny wires are easily broken by vibration or handling.
Gary

Using a larger wire is like having a wider hallway or a larger pipe.....there is less resistance to movement and the current can flow through easier.

I would try and copy the size of the wires in the bike as closely as possible.

One of the things that makes me crazy when wiring a bike is the super thin wires used on a lot of aftermarket LED lights. Putting crimp connectors on them is a pain, and certain to fail soon.
One of the reason (besides the increased resistance of thinner wires) that I use thicker wires is the safety/strength of using the thicker wires in connectors.
Many moons ago I did some voltage drop tests on OEM skinny battery leads vs the more full figured aftermarket ones on a 900 Ducati. The chubby wires showed almost no voltage drop, while the OEM ones were around 1/2 volt drop per lead.
Bike started a lot quicker.