Power and motor wire gauges and type and connectors!

[Thecaptain115]

I recently purchased a speed controller from JRH (Holmes Hobbies, EXCELLENT guy!) and the motor and battery leads do not seem very heavy duty. They have that kind of plastic insulation, the stuff that melts if its gets even remotely hot. Looks just like the insulation on the wires from inside a PC power supply. Are these types of wires considered normal for ebikes, or is this something people often swap out for silicon insulated wires? I'm trying to eliminate all possible failure points in this build right from the get go. I have not yet purchased a motor, but am looking really closely at the Crystalyte brand. Anyone have any comments about the quality of the motor wires on CL motors?

What about connectors? I'm thinking of running bullet connectors for the motor wires, and just heat shrinking over them. I havent decided on battery connectors yet, but was planning on running Dean's Ultra or Power Poles. I've personally tested both, and both can handle the job no problem.

[rojitor]

Don't worry about the wires of the controller, they will not melt that easily ( you do not plan to use 9000w do you?)
The wires of crystalyte motors are not really thick, they have a small hole to get out so they are usually 14-16 gauge, there's a few threads about upgrading to 12 or 10 gauge nevertheless they are enough for common configurations. The phase connectors are usualy andersons pp45 you will not have a problem if you change to bullets.

[mark5]

What about connectors? I'm thinking of running bullet connectors for the motor wires, and just heat shrinking over them. I havent decided on battery connectors yet, but was planning on running Dean's Ultra or Power Poles. I've personally tested both, and both can handle the job no problem.

Several past threads on connectors:

Connectors ! Andersons, Deans, etc..
http://endless-sphere.com/forums/viewtopic.php?f=16&t=2767
Common high current connectors - and my opinion on them
http://endless-sphere.com/forums/viewtopic.php?f=11&t=1090
What connector do you use for main power line? (survey)
http://www.endless-sphere.com/forums/viewtopic.php?f=5&t=5457

[Thecaptain115]

Well what brand motors have the biggest phase wires? (just for reference)

[dogman]

Few come with anything beyond 12 guage, that is, for a bicycle. Most have even smaller guage, but it's plenty for up to 1500w.