true, most crimping pliers can handle only up to 6mm² wires. There are some though that go up to 10mm². For everything larger than that you`ll need much bigger tools that will also cost 10x and more. Doesn`t make sense to buy that for most people unless they use them professionally or very often.
I didn`t mean to criticize btw if that is how my comments were understood.

G.

Just a good discussion as far as I can see

ditto,no worries G

Yup. Bigger wires are better.
I too did the Powerlet upgrade on my ST2, and later my ST4s. Good improvement.

Proper crimping is the key with any connector, and bigger connectors are more difficult/prone to problems. Putting some dielectric grease on those also helps that the connection doesn't degrade over time.

If you have a cable that is a bit sluggish, cut through the crimp and take a look at how ugly it can be inside. A little bit of water and time will kill it. If it wasn't crimped tight originally, water will creep in and degrade everything. Just putting on a new connector often helps, but you have to clean a new section of cable, and it may not be long enough anymore.

Cheers,

Will soldering the crimps be an advantage?

Which type of grease would be better to use,dielectric or conductive?

I usually solder the ends after crimping. That will fill the smallest gap and grant contact in the full section. Be aware though the brazing solder should not creep in the cable behind the connector as it will become stiff and with vibration that`s usually the point where it breaks.

Dielectic and conductive grease are two different things. Conductive is for contacts/contact surfaces to improve flow of electrical current, dielectic to protect contacts after they`ve been assembled. It seals from moisture. So clean all contact areas and use dielectic grease after you have connected everything. I personally never did but theoretically you can use both.
Mentioning sealing from moisture - it`s important to overlap connector and cable with heat shrinking tube.

Thanks G.
Legend as always.

This is a great discussion and very educational to boot!.

Mike, Thanks for posting (approved by me) the info on your wiring kit. The older Ducs have wiring issues and they are quite hard to resolve in a DIY manner without the specialized knowledge and tools. I have had conversations (written) with Mike and think he's an upstanding guy and trying to do the right thing for our older bikes.

This is definetely a topic I don`t think we ever had before.

Thanks for the considered reply. Makes sense.

So aside from connections the main variable is just the material (i.e copper alloying/impurities).

Well, and corrosion as you say....

Regarding handling of current a 4 (21mm²) is not required for the starter. (You could probably tow a car with it btw ). Even the original cable can handle that. The main issue is the voltage drop. The point where we have a different opinion is to use thicker cables just to compensate their degragation over time. It seems this is one of the remaining arguments. Every cable will degrade a bit over time specially the ones which are exposed to weather. Therefore it`s important to make the new cables neatly, clean all contact surfaces and then seal them. If this is done with the necessary care there won`t be any problems for a long time.
If you still want something thicker take a 6 or 5 (16mm²), that`s more than sufficiant and easier to install than a 4. Of course a thicker cable will get less warm.

G.