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Unread 07-26-2014, 01:23 AM   #1
Not Yet Wild
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Default 1/0 wire too big for batt connections?

Hello all,

I believe this to be my first post although I joined up a few years ago when I bought an old Yamaha gas rig. It and the blue smoke are gone.

Just purchased a 2011 Precedent and am enjoying it daily. I read several posts about upsizing battery connection wire to 4 or 2 ga. I had a 60" length of 1/0 fine stranded laying around (I think it's a piece of welding lead) and several single hole terminals, so I made up new battery to battery connections. As I was installing these today, I started thinking about fault current and other horrendous things, so thought I would ask; am I oversized on the wire? Is the original battery connection wire (looks like #6) designed to burn open before a battery fire?

Not anticipating a disaster, but just concerned I may have just circumvented a fuse link by replacing the original straps; or is the biggest / least resistance connections all good? I realize 1/0 is overkill, but I was out no money on the material. It was shop scrap I had hanging on a nail.

Also had a surging issue I solved with a key-off exercise of the "go" pedal. An MCOR(?) problem? I found the solution here on BGW forum, but am I going to be buying parts soon or is the pedal exercise solution good for a while?
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Unread 07-26-2014, 09:14 AM   #2
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Default Re: 1/0 wire too big for batt connections?

The factory high current is not designed as a protection fuseable link. Although 1/0 is a bit large there is nothing wrong with using it. Most people upgrade to 4 AWG or 2 AWG so 0 AWG isn't too large, just a bit harder to work with and fit.

If you only replaced the battery jumpers you are not done yet, all the high current cable should be upgraded for most improvement.
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Unread 07-26-2014, 10:19 AM   #3
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Default Re: 1/0 wire too big for batt connections?

In case you don't know. 1/0 wire won't fit through the hole in the OBC. There is a work around by using a bolt.
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Unread 07-26-2014, 10:35 AM   #4
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Default Re: 1/0 wire too big for batt connections?

You're going to have to deal with space issues at the solenoid and controller, unless your building a race cart I wouldn't go larger than 1g just being practical. Is it bad to go larger, no.
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Unread 07-26-2014, 10:54 AM   #5
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Default Re: 1/0 wire too big for batt connections?

I thought the last jump from batteries to motor controls would be in order to gain full benefit. I'm out of 1/0 now, so will buy a couple lengths of 2 ga. for the final connection.

Any noticeable performance difference, or just optimum charge / discharge / low heat loss?

Last edited by Remus Redbone; 07-26-2014 at 10:56 AM.. Reason: Spelling
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Unread 07-26-2014, 11:08 AM   #6
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Default Re: 1/0 wire too big for batt connections?

Going from 6g to 2g you will get better torque under load. If you use 2g to motor and 1/0 across batts. Then you can consider that 2g is your smallest restriction, your cables have to go through the solenoid and controller also otherwise no true benefit.
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Unread 07-26-2014, 05:42 PM   #7
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Default Re: 1/0 wire too big for batt connections?

Besides battery cables, what other cables should be replaced on a 1995 48volt.
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Unread 07-26-2014, 10:17 PM   #8
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Default Re: 1/0 wire too big for batt connections?

Quote:
Originally Posted by Grizz3500 View Post
Besides battery cables, what other cables should be replaced on a 1995 48volt.
All of them. The ones going to the forward/reverse switch,the ones to the solenoid, and the ones going to controller and motor. Anything that is 6ga.
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