Any time you upgrade your alternator, you should also strongly consider upgrading the gauge (size) of the wire that charges the battery as well as the fusible link in case of a short.
The chart below charts the gauge wire required based on alternator amperage output and length of wire.
| Alternator Output (Amps) | Up to 4 ft | 4 – 7 ft | 7 – 10 ft | 10 – 13 ft | 13 – 16 ft |
|---|---|---|---|---|---|
| 20 or less | 14 | 12 | 12 | 10 | 10 |
| 20-35 | 12 | 10 | 8 | 8 | 6 |
| 35-50 | 10 | 8 | 8 | 6 | 6 |
| 50-65 | 8 | 8 | 6 | 4 | 4 |
| 65-85 | 6 | 6 | 4 | 4 | 2 |
| 85-105 | 6 | 6 | 4 | 2 | 2 |
| 105-125 | 4 | 4 | 4 | 2 | 2 |
| 125-150 | 2 | 2 | 2 | 2 | 0 |
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