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Product

JASO D 611 Japanese Automotive Harness Wires60 V DC JASO D 611AV / AVS / AVSS (0.3 mm)-40 to +80 °C (Class A)

AV / AVS / AVSS AV/AVS/AVSS Automotive Wire60 V DC JASO D 611 standard (AV), thin (AVS) & extra-thin (AVSS) PVC automotive wire

AV, AVS and AVSS are Japanese automotive low-voltage primary harness wires governed by JASO D 611 (and JIS C 3406), rated -40 °C to +80 °C (ISO Class A). They progress from standard-wall AV (0.6–0.8 mm wall) to thin-wall AVS (0.5 mm wall) and extra-thin-wall A

JASO D 611 Oil & Fuel
Horizontal Self-Extinguishing
JASO D 611 / JIS C 3406
Order designation
AVSS 0.85
Max. OD
1.80 mm
Copper mass
7.7 kg/km
Total mass ≈
9.8 kg/km
Min. bend R
7.2 mm
All sizes (14)
Request a quoteDatasheetWhatsApp
Engineering reply in 2 business hoursCut-to-length export drumsEN 10204 3.1 certificate per drum
Rated voltage
60 V DC / 25 V A
JASO D 611 automotive primary
Thermal class
-40 to +80 °C
Class A continuous operation
Wall tiers
AV / AVS / AVSS
0.6 mm (AV) · 0.5 (AVS) · 0.3 (AVSS)
Size range
0.3f to 15 mm²
AVSS 0.3f–2.0 · AVS 0.5–5.0 · AV 0.5–15
Conductor
Cu + 'f' flex
Symmetrical 7/19 or 19×0.16 mm ('f')
Min. bend radius
4 × wire OD
High-density Japanese OEM looms

Typical values for this cable type, based on JASO D 611 / JIS C 3406 — confirmed in the datasheet and quotation for your order.

Application fit

Is AV / AVS / AVSS right for your machine?

Standard primary wire series for Japanese and Asian OEM passenger vehicles, motorcycles, forklifts, agricultural tractors and excavators using 025, 040, 060 and 090 series multi-pin connector systems.

Fixed installation

Suitable

Engineered for cabin, instrument panel, door and body wiring looms in Japanese vehicles.

Switchgear & control cabinet wiring

Suitable

AVSS 0.3 mm wall fits miniature 0.64 mm (025) and 1.5 mm (060) Japanese multi-pin connectors.

Free-hanging vertical run

With conditions

AVSS 'f' (0.3f / 0.5f / 0.75f / 1.25f) flexible stranding suits door hinges and steering columns.

Furnace, kiln & high-temp zone

Not suitable

PVC is limited to +80 °C; use cross-linked AEX / FLR2X for +125 °C engine bays.

FLR2X +125 °C XLPE wire
Typical machinesJapanese OEM passenger carsMotorcycles & powersportsExcavators & construction plantForklifts & material handlingMarine & outboard harnesses

Construction

Layer by layer

Annealed bare copper conductor (7/19 concentric or 19-strand flexible 'f') + lead-free JASO D 611 PVC insulation in AV (standard), AVS (thin) or AVSS (0.30 mm extra-thin) wall + colour/stripe skin.

123
Schematic, not to scale — generated from the layer data
#LayerMaterial & reference
1Annealed bare copper conductorConcentric stranded copper (7 or 19 wires) or fine-stranded flexible 'f' copper (e.g. 7/0.26 or 19/0.16 mm) per JASO D 611JASO D 611
2JASO D 611 lead-free PVCPlasticized lead-free PVC insulation: AV (0.6–1.1 mm wall), AVS (0.5–0.9 mm wall), or AVSS (0.30–0.40 mm extra-thin wall)JASO D 611
3Colour-coded / tracer outer skinSmooth extruded PVC surface with Japanese colour code and longitudinal tracer stripeJASO D 611

AV (JIS C 3406 / JASO D 611 Standard Wall)

0.60 mm to 1.10 mm wall thickness (0.5 to 15 mm²) for general chassis, motorcycle and heavy equipment looms.

AVS (JASO D 611 Thin Wall)

0.50 mm to 0.80 mm reduced wall thickness (0.3 to 5.0 mm²) for lighter cabin and body harnesses.

AVSS / AVSSf (JASO D 611 Extra-Thin Wall)

0.30 mm ultra-compact wall (0.3f to 2.0 mm²) including 'f' flexible stranding for high-pin-count ECU connectors.

Technical data

Ratings & operating limits

Typical values: Typical values for this cable type, based on JASO D 611 / JIS C 3406. Values for your order are confirmed in the datasheet and quotation.

Electrical

Rated voltage
60 V DC / 25 V AC
AC dielectric withstand
1.0 kV rms for 1 min (AVSS/AVS) · 2.0 kV rms (AV)
Spark test voltage
3.0 kV (AVSS) · 5.0 kV (AVS / AV)

Thermal

Continuous operating range
-40 °C to +80 °C (JASO D 611 Class A)
Low-temperature winding
-40 °C cold winding test without cracking

Mechanical

Wall thickness @ 0.5 mm²
AV: 0.60 mm (2.2 mm OD) · AVS: 0.50 mm (2.0 mm OD) · AVSS: 0.30 mm (1.6 mm OD)
Scrape & tape abrasion
Meets JASO D 611 blade-scrape cycle requirements

Resistance

Flame propagation
Extinguishes within 15 s (AVSS/AVS) or 30 s (AV) in JASO horizontal flame test
Oil immersion
JIS K 2215 / IRM 902 oil immersion at +50 °C

Reference standards

Primary standards
JASO D 611 & JIS C 3406
International alignment
ISO 6722-1 Class A

Identification

Japanese size notation
0.3f, 0.5f, 0.5, 0.75f, 0.85, 1.25f, 1.25, 2.0, 3.0, 5.0, 8.0 mm²
Colour code
B, W, R, G, Y, L (Blue), Br, Lg, O, P, V, Gr + tracer stripes

Sizes

14 standard sizes (AV / AVS / AVSS)

Nominal dimensions, wall thickness, copper mass and electrical parameters for AV / AVS / AVSS per JASO D 611 / JIS C 3406.

Dimensions & masses
DesignationJASO Type & SizeStrands / Wall mmMax. OD
mm		Copper
kg/km		Total mass ≈
kg/km		Min. bend R
mm		Enquiry
AV / AVS / AVSS size range
AVSS 0.3fAVSS 0.3f mm²19/0.16 · 0.30 mm1.403.44.95.6
AVSS 0.5fAVSS 0.5f mm²19/0.19 · 0.30 mm1.604.86.66.4
AVSS 0.5AVSS 0.5 mm²7/0.32 · 0.30 mm1.605.06.86.4
AVSS 0.85AVSS 0.85 mm²19/0.24 · 0.30 mm1.807.79.87.2
AVSS 1.25fAVSS 1.25f mm²37/0.21 · 0.30 mm2.1011.414.08.4
AVSS 1.25AVSS 1.25 mm²19/0.29 · 0.30 mm2.1011.213.88.4
AVSS 2.0AVSS 2.0 mm²37/0.26 · 0.40 mm2.6017.521.810.4
AVS 0.5AVS 0.5 mm²7/0.32 · 0.50 mm2.005.08.28.0
AVS 0.85AVS 0.85 mm²11/0.32 · 0.50 mm2.207.911.58.8
AVS 1.25AVS 1.25 mm²16/0.32 · 0.50 mm2.5011.515.810.0
AVS 2.0AVS 2.0 mm²26/0.32 · 0.50 mm2.9018.724.011.6
AVS 3.0AVS 3.0 mm²41/0.32 · 0.60 mm3.6029.537.514.4
AVS 5.0AVS 5.0 mm²65/0.32 · 0.70 mm4.4046.858.017.6
AV 8.0AV 8.0 mm²50/0.45 · 0.90 mm5.5071.088.522.0
  • Typical values for this cable type; dimensions and weights for your order are confirmed in the quotation.
  • Dimensions and maximum overall diameters conform to JASO D 611 / JIS C 3406.

Quality & approvals

Testing & inspection

Routine tests on every production length, sample and type tests per batch — documented on an EN 10204 3.1 inspection certificate.

  1. ConductorClass 5 stranding
  2. Spark test100 % in-line
  3. Lay-upCores, earth, fillers
  4. SheathingInner, braid / screen, outer
  5. Electrical testsAC voltage, resistance
  6. DimensionsOD, wall thickness
  7. Inspection documents & dispatchDrum & dispatch
Testing & inspectionTest value / referenceFrequency
Routine tests
3.0–5.0 kV spark test & conductor DC resistanceZero pinhole breakdown; DC resistance per JASO D 611 Table 2100 % of spools
Sample tests
JASO D 611 blade scrape abrasion & 1–2 kV AC dielectricMeets scrape cycle count and wet dielectric testEvery lot
Thermal ageing, oil immersion & -40 °C cold windingVerified per JASO D 611 Class A test scheduleType qualification

Inspection certificate

Issued with every drum, listing the routine test results for that length.

Product approvals

JASO D 611 (AV / AVS / AVSS)JIS C 3406ISO 6722-1 Class AELV & RoHS 3 Compliant

Company certificates

ISO 9001ISO 14001ISO 45001VDE marks approvalUL / cULCE · LVD / EMC

Marking & supply

Ordering & delivery

Sheath marking

TEBAOFLEX JASO D 611 AVSS 0.5f / AVS 1.25 60VDC LEAD-FREE PVC [lot/spool]
Delivery form
Non-returnable plastic spools, barrel packs or wooden drums
Standard spool lengths
500 m · 1000 m · 2000 m spools (or barrel packs)
MOQ
500 m (stock colours) · 2000 m (striped/custom)
Lead time
2–3 weeks ex-works
Incoterms
EXW, FOB, CIF, DAP

Technical documents

Downloads

PDFAV / AVS / AVSS AV/AVS/AVSS Automotive Wire – technical datasheet14 sizes · construction, technical data, approvalsXLSXAV / AVS / AVSS spec data (Excel)All 14 sizes with dimensions and data, for your BOM or quotation
Revision
2026-10-20
Updated
2026-10-20

FAQ

Questions engineers ask first

Not covered here? Send your drawing — an engineer replies within 2 business hours.

What is the exact difference between AV, AVS and AVSS in JASO D 611?
AV is the original JIS C 3406 standard-wall wire (0.60 mm wall on 0.5 mm², 2.2 mm OD). AVS reduces the PVC wall to 0.50 mm (2.0 mm OD on 0.5 mm²), while AVSS reduces the wall to an extra-thin 0.30 mm (1.6 mm OD on 0.5 mm²), cutting harness cross-sectional area by nearly 50 %.
What does the suffix 'f' mean in AVSS 0.3f, 0.5f and 1.25f?
The lowercase 'f' designates a flexible fine-stranded conductor (for example, 19 strands of 0.16 mm or 0.19 mm wire instead of 7 strands of 0.32 mm) used in flexing zones such as door grommets, tailgate harnesses and steering columns.
Why does JASO D 611 use 0.85 mm² and 1.25 mm² instead of European 0.75 mm² and 1.0/1.5 mm²?
Japanese automotive wire gauges evolved from building multiples of 0.32 mm copper strands (7×0.32 = 0.56 mm², 11×0.32 = 0.88 mm² called '0.85', 16×0.32 = 1.28 mm² called '1.25', and 26×0.32 = 2.09 mm² called '2.0').
When should CIVUS be selected instead of AVSS?
When ECU connector pitch drops to 0.50 mm or 0.64 mm micro-terminals and even AVSS 0.3f (1.40 mm OD) is too bulky, CIVUS uses a compressed copper conductor with a 0.20 mm ultra-thin wall to achieve a 0.95 mm outer diameter at 0.13 mm².

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01Selected sizes

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03Message for our engineers

AV / AVS / AVSS AV/AVS/AVSS Automotive Wire

Selected sizes:


Reel & motion:
- Reel type: 
- Drum core diameter (mm): 
- Cable length on drum (m): 
- Travel speed (m/min): 
- Max. acceleration: 
- Cycles per hour: 
- Length and quantity: 
- Ambient temperature: 
- Exposure (outdoor, water, oil, abrasion): 
- Destination country: 
- Equipment and operating conditions:
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