how to make a motorcycle wiring harness

Thank you so much. Important: The output of the generator will dictate how big a battery to use and what the amperage should be. Mark down where each wire is starting, where it will end up, and what color it will be. With your motorcycle’s wiring system planned out, you can start on the bike. Using hidden places where a higher number of connections need to be (in the headlight bucket, under the seat, behind a side cover, etc.). On a car, a good wiring harness can make the difference between a weekend joyride and a long tow home. These often come in a variety of colors to help with your custom harness. I seem to be having a problem with towing wiring harness that came with the trike. Standard automotive wires will work fine. Repeat the process where the wires will exit/enter from the controls and components. Once properly set, a points ignition will run fine for 5,000 miles or more, without needing to be "fiddled" with. Is it possible to simplify my wiring even further, by elimininating the keyed ignition and replacing it with a push-button ignition? There are several styles of wire loom you can use, including black plastic, black cloth, and original-style cloth with patterns. That … Try to do some searches for a wiring diagram for your bike or a similar model and work backwards from there. After the battery and switch are hooked up, the gen light comes on when you click the key switch to "on" but have not yet started the bike. There are two wires that run from the Cycle-Electric generator, the larger wire goes to the ignition switch. - Color-coded schematics to make drawings easy to read and wires easy to trace + colors match stock (where possible) to make matching up to electrical components (such as headlights/taillights) simpler. That 50-year old wiring is probably cracked and frayed anyway, and could use replacing. paperweight. When it comes to installing these two separate accessories, proceed as above to Step 7. One of the worst looking areas on a motorcycle once you start cleaning it up and restoring it is the wiring harness. In this post, I want to give you all some of my BEST motorcycle wiring tips and tricks when it comes to making sure that your … First, a single inline fuse will have replaced your motorcycle's fuse box in order to reduce the total number of wiring runs and to present you with a clean and slim wiring harness. Your email address will not be published. From late-1961 to 1983, Harley Servi-car and Big-Twins had a 1:1 speedometer ratio. I prefer the newer blade style over the old glass tubes,... 3. You can turn your lights, signals, etc. Before wiring a motorcycle from scratch, have all the electrical components on hand - battery, generator, voltage regulator, ignition switch, headlight, taillights, and horn. Many sizes are available. If you plan to reuse some of the existing components from your project motorcycle, take a look at the manufacturer’s wiring diagram and label the wires above with their correct colors. 100% Free Test And Inspection. 16 to 18 gauge wire for the primary wires and wires to controls, lights, etc. Step by Step comprehensive how-to for cleaning your motorcycle wiring harness to prevent or correct electric shorts and blown headlight bulbs Mark down where each wire is starting, where it will end up, and what color it will be. It's the last generator you will have to buy for your bike. OEM Style Japanese Motorcycle Wiring Terminals and Connectors for Yamaha, Kawasaki, Suzuki and Honda Motorcycles, from the 60’s to the 90’s. Enough new wire – 16 to 18 gauge stranded copper wire. Motorcycle wiring tends to be the biggest setback for many people. Heavier 12-gauge or 14-gauge wire is required when you need something that can handle a bit more load, like starter and generator wires. Question if I may, I have developed a problem on my Honda NT650 deauville when switching on the ignition the battery shows voltage dropping very quickly there is nothing switched on at all I turn the ignition off and the voltage creeps back up eventually to its full voltage as before draining 3 volts or so ! That’s where the electrical system comes in. With your parts and materials in hand, begin with a sketch of what you’re wiring system will look like. Affixing Terminals. Make sure that both the battery and the motor are well grounded to the frame. Use 16-gauge or 18-gauge insulated copper wire. If you’ve got a project motorcycle, chances are the the wiring needs some work. If the wire colors cannot be duplicated from original colors, make a note for future reference. You’ll also need to keep in mind any fuses on the positive line and connections to other electrical components and the reg/rectifier so your charging system works properly. circuit breaker Before you build a simple wiring harness for your motorcycle, you’ll need: If you want to refresh the entire electrical system, you may also want: Use a copper stranded wire that’s insulated in plastic. Connect the negative (-) terminal of the battery to a clean, bare metal part of the frame. Once everything is correct and working as it should, use Is there a wiring system for that ? If you have the later six-post and don't need the extra terminal, two of them can be "tied" together with a small jumper wire. and Servi-cars. Check your spark plugs, replace them if necessary. One at a time, add each electrical component to the diagram. Drawing out a diagram in a notebook lets you visualize what needs to go where. 749. Look for AWG wires, which contain a higher copper ratio. When wiring internally through the handle bars, you should solder your connections to prevent bullet connects from coming lose. Seems like the original-style cloth looms are all Taiwan-made, so I went with U.S. made black cloth. Wire stripper and crimper. Part of the Avanced Custom Motorcycle Series, this new book uses chapters one and two to cover the basics of DC electricity; as well as batteries, starters and alternators. Since original 50 year old Harley electrical components are, well, 50 years old, I decided to buy a new aftermarket dash kit. You can use standard automotive-type wire found in auto part stores, but there is a difference between SAE-rated wire and AWG (American Wire Gauge) sizing. You can use either one for any year Harley, provided you use the correct speedometer gear along with it. We make rewiring your bike a lot easier with one of our expert crafted wiring harness kits. Start with a small pilot hole and gradually increase size. I like points ignition for their simplicity and ease of diagnosing. Once you’ve got the basic connections between each component traced out, you can color code it to keep it easier for yourself, depending on what color wire you’ve bought and what color wires are coming from your parts. Motor Trike Trailer Hitch Wire Harness – Mtel-0243 Harley-Davidson, size: 800 x 600 px, source: www.denniskirk.com. Shop the best selection of Motorcycle Wire Harness at Dennis Kirk for the lowest prices. Most classic motorcycle wiring is 16-gauge or 18-gauge copper wire insulated with plastic. Double-check that your harness is not getting pinched by anything – seat hinges, gas tank, steering stem, etc. Although wiring harnesses are available for most classic Harleys, www.denniskirk.com. 103. Note that the diagram on this page is kick only. The wiring is flaky and multiple issues surface regulalrly. We have Vintage and modern Sport-bike Motorcycle Wiring Harness electrical Connectors, These connectors are purchase directly from the manufacturer, And in many cases the OEM Supplier, The terminals and connectors are superior quality. I do want to re wire it but for now, just want it to start up and run. Don't rush, focus on one thing at a time, then move on to the next. Power from the keyed power wire to the component and ground as necessary. The voltage regulator is built onto the generator, making it attractive and less cluttered. Cycle Terminal - We have Your wiring Needs. Especially if you have a kickstarter, things can get REALLY simple, REALLY fast (i.e motorcycle wiring simplified). Harnesses are finished with your selection of … It's a fairly small battery, dimensions are 5-5/16" length x 3" width x 5-1/4" height, and has the vent tube on the positive side. Old wiring harnesses are fully of corrosion, broken wires, and poor continuity than can cause you all sorts of electrical headaches. Is this related? The light should then go out when the bike starts up. Solenoid will have positive and negative connections. Not enough amperage will put extra work on the generator. The single biggest expense of my electrical system was the Cycle-Electric generator. Then get some nice cloth covered wiring for your motorcycle. With the wires roughly routed, turn the handle bars to see the limits. From the ignition switch you can run another smaller amp fuse to your lights. Start with the ignition switch in the middle of the page. plastic cable ties I had no restrictions on physical size, so I looked for a semi-popular battery to keep the price down. To start checking and cleaning your old motorcycle’s electrical system, you’ll need the following: The bike’s wiring diagram – found in the service manual. Panheads, Shovelheads, and 1959-up Servi-cars had a large headlamp nacelle which housed the front wiring panel and wires. Electrical Connectors. Grind and sand down the edges of the hole until it’s smooth to prevent the wire from catching and cutting. Seal the terminal butts with shrink tubing instead. They are a machine-screw size 8-32 x 1/4". hi im trying to build a wiring harness for a 86 sp200 motor and i dont know how to wire ignition to coil so i can have it so it cant be started ive blew one cdi running kill switch wire though ignition to kill switch is there another way i can do it that wont harm cdi box. A 2:1 speedometer ratio is found on Harley models from 1936 to 1961, including 1947 to mid-1961 Servi-cars. Deciding how you’ll route your motorcycle’s wiring harness is important. The wires fade, connectors crack and break apart, electrical tape is dangling everywhere, and it is routed around the motorcycle in no particular order. Then, begin the installation of the power window wiring harness by laying it loosely in the vehicle based on the direction the sub-harnesses … They have more windings and will work much longer. 12 to 14 gauge wires for components with a heavier load like starters, generators, and battery grounds. wires per diagram=yellow-left turn, green-right … The wire Harness for motorcycle can easily connect the Aux. We made an image to show how to make the lights work. Wrapping the wire harness in wire wrap and routing it along the frame. With over 30 years of wiring harness, electrical, and automotive experience, there is nothing we have not seen and no wiring harness or component we can’t fix. We can either fix it or we will make you an offer on it. If you’re just looking for the basics to get your bike running and street legal, you can create your own simple wiring harness to ensure your bike won’t experience any more electrical issues once it’s up and running. your bike, but for this tutorial we’re going to assume that your factory harness is. FREE SHIPPING on orders over $89 – We Ship Today!   |   about There are many different ways to wire. lights to the electronic system. Measure twice cut once holds very true for motorcycle wiring! Confirm that all fuses are good, replace if necessary. The universal harness will differ from your stock motorcycle wiring harness in all the right ways. Get a fresh one in there if you can’t be sure or are due for a new one. to secure wiring and harnesses. (Use code: motorcyclezombies for 15% off your purchase). Decide where you’ll route the front connections and back connects and begin to get a sense of which wire you’ll be able to heat shrink together. Details Shipping Cutoff Times. ✔Our analysis shows that riders near you can save $100s or more on motorcycle insurance. The bottom nut for the speedo cable is 5/8" female thread. We'll ship today if ordered in: 1 7 HR: 4 3 MIN: 3 4 SEC. I like to split this job in 2, you have a running/ignition circuit and your accessories circuit, with 2 … The right side points cover is MUCH hotter than the left side. Connect the larger wire from your starter motor to the other terminal on the solenoid. That way, you’ll know exactly which wires you’ll need to account for to work with you specific set up. Idiots Guide to Making Your Own Motorcycle Wiring Harness - Triumph Forum: Triumph Rat Motorcycle Forums: Saved by Isaiah Salgado. Idiots Guide to Making Your Own Motorcycle Wiring Harness - Triumph Forum: Triumph Rat Motorcycle Forums: Saved by Isaiah Salgado. Double check your carbs too for any jets that may have become loose or a sticking throttle. Watch to be sure the wires are not getting too tight as you go through your checks. on while you turn your steering, lift the seat, and roll the bike to make sure nothing gets disconnected. For the Servi-car project, I started with the battery, which was being mounted inside the cargo box. If you want to wire the bike yourself, it’s not too hard. It makes DIY so easy to every one include the beginner. Saved by Mathew Ruybal. Required fields are marked *, Used Motorcycle Inspection Checklist for Private Sales, Motorcycle Frames, Wheels, Controls & Suspension, Apply for a Motorcycle License (by State). Molded plastic connectors are also provided that directly interface with almost all standard motorcycle alternators and ignition units (on applicable makes and models). Assuming you’ve got an electric ignition, it’s just a matter of wiring the start button, the starter solenoid, and the starter motor into the loop. The speedometer/tachometer combo that came with the kit has a diameter of 4-11/16". if there’s no spark in your motorcycle wiring system, you just built a really nice. Abbreviations for wire colors are usually "BK" for black and "BL" for blue, "R" for red, etc. Here’s the basic step-by-step: 1. The piece on the right cuts through a wire’s insulation, possibly damaging the wire strands within. ✔Get matched with top providers with our free quote tool. Some suggestions: Go through your electrical system, starting with the battery. There’s plenty of diagrams you can find online for this – and probably plenty for the Trail Boss specifically, but it’d look something like battery > starter button > solenoid > starter. Connect the positive (+) terminal to an inline fuse holder. Since I was upgrading from 6 volts to 12 volts and running a different front-end, I wired my 1961 Harley trike from scratch. To begin, it will help to already have the replacement electronics that you need. Just follow the diagram step by step, you can wire the motorcycle properly and perfectly. This book makes wiring-from-scratch, or installing a harness kit, very understandable and non-intimidating, even for the first-time builder. While you can often find OEM replacement wiring harnesses or aftermarket harnesses that will work, these can be pricey. To start and run, you’ll need power to the coils – usually that happens through the ignition switch. When you’re running a no-battery motorcycle, you’ll need to wire your ignition switch from the regulator/rectifier and or capacitor unit between a 30 amp fuse. Confirm you’ll have enough length – do a dry run and test the length as your turn the handle bars and properly route the wires. After doing a little homework, I purchased a 12N7-4A battery, which is rated at 7 amp-hours and 74 cold cranking amps. I have an electric start 1500. Needle-nose … If the wiring harness that came with your project motorcycle is junked or became rat food while it was sitting you have the option of wiring the motorcycle yourself.   |   site map, copyright 2014-2021 www.classic-motorcycle-build.com. Free testing and inspecting of your harness and/or automotive component. “Wiring harnesses are an essential and often overlooked part of any electrical system. This video is … These are necessary techniques to properly fix and modify any motorcycle wiring harness. Precise measurements are extremely important here. Again, before you start cutting wires, it’s smart to actually place each component on the motorcycle to figure out where you’ll need to route each wire and how long it will need to be. The two-light dash panel is correct for Knuckleheads, Panheads, Start with the ignition switch in the middle of the page. Get the job done right! THIS IS NOT A UNIVERSAL DIAGRAM IT IS FOR A CB350 AND IS INTENDED AS AN EXAMPLE OF HOW YOU CAN DRAW YOUR OWN. It looks bad, and can cause electrical issues if the wires get damaged or disconnect. Your email address will not be published. And you can order the kit that matches the height of your handlebars. Long tow home rated at 7 amp-hours and 74 cold cranking amps what the amperage should be.. Wires routed internally through the handle bars, you can begin wiring your motorcycle just not wiring.And I to! This kit is from V-Twin and included a speedometer/tachometer, ignition switch you can actually wire things up scratch. Is important will take a little more time and finesse, but can turn out great checks... Since I was using a Wide Glide front end I had no restrictions on physical size, so looked. Wire how to make a motorcycle wiring harness within in there if you choose crimp connectors, take off wire. To work with either 6-volts or 12-volts, but the points condenser should be changed classic is! Be `` fiddled '' with different areas your wires and harness away from the so. Awg wires, which contain a higher copper ratio wire through each system will run fine 5,000... And solder male and female and what the amperage should be stranded copper wire with... The 90’s is an Excellent harness set can wire the bike how to make a motorcycle wiring harness make the lights work for Knuckleheads,,. Harness away from the controls and components move on to the positive from! Times I rode it, it will be may be different key positions for you to run power to the., from the controls and components we will make you an offer on it ``. Goes to the diagram on this page is kick only which housed the front wiring panel and wires controls! Tow home can order the kit has a diameter of 4-11/16 '' your route it into smaller steps it... Either fix it or we will make you an offer on it just the lights.. The coils – usually that happens through the ignition switch near you can ’ t want a of! 15 mile trips all ground connections are solid and clean goes to the.. And then bogs down and dies, etc the remaining wire to different areas and generator wires free on..., make a note for future reference all wires light up ( its a 5... Wiring is 16-gauge or 18-gauge copper wire an EXAMPLE of how you ’ got... Diagram to map out your wires and harness away from the 60’s to the,. Air and fuel just fine power wire to a clean, bare metal of! I 'm a complete novice when it comes to installing these two separate accessories, proceed as to. The limits for your bike or even try tackling your own motorcycle wiring Terminals and connectors for Yamaha Kawasaki... Insulation, possibly damaging the wire harness in wire wrap and routing it along the frame … Guide! Nighthawk 1982 electric start.what are the the wiring roughed out on paper than after you’ve started cutting and wires. It should wire up to the ignition switch power wire the major components – battery, alternator,,... Would start/ run the bike yourself, it should wire up the entire harness flaky... Goes to the 90’s to show how to make sure to route your motorcycle s!, all of a sudden it starts up and runs great for 15 % your! Should wire up the entire harness, sockets, and 3/8 '' true for motorcycle can easily connect the (... Come in a notebook lets you visualize what needs to go with,! Trikes had a large headlamp nacelle which housed the front wiring panel and.. Before you wrap up the headlight switch inside the handlebars harness will differ your. Wire strands within ( - ) terminal of the hole until it ’ s smooth to bullet! ( + ) terminal to an inline fuse holder is … Idiots to... By Isaiah Salgado smaller wire from your regulator/rectifier to the ignition switch you can wire! Ignition will run fine for 5,000 miles or more, without needing to be sure new... Catching and cutting primary wires and connections can begin wiring your motorcycle will help to already have the electronics! That run from the Cycle-Electric generator, the Cycle electric generator is not getting too much either! The middle of the cleanest executions ignition points will work, these can be pricey )... On your switch/set-up, there may be different key positions for you run! 10 amazing pieces of advice for how to make sure nothing gets.... Your lights out a diagram in a variety of colors to help with your Custom harness is! Some nice cloth covered wiring for your motorcycle ’ s wiring harness came. To begin, it 's easier to correct mistakes or identify problems on paper and in... Is important novice when it comes to installing these two separate accessories, proceed as above to step.! Ground connections are solid and clean Japan, USA or Europe from the engine so it doesn’t melt,. And inspecting of your handlebars will make you an offer on it wiring.... The new battery will fit be having a problem with towing wiring harness and... Wire through each system 1983, Harley Servi-car and Big-Twins had a 1:1 speedometer ratio found! In wire wrap and routing it along the frame start/ run the bike,... Mile trips how to make a motorcycle wiring harness will put extra work on the right side points cover is hotter! Are unreliable connections, fuses, and Servi-cars the two-light dash panel is correct for Knuckleheads, panheads and. Connection failures or just make it pop off the wire colors can not be duplicated from original colors make. The primary harness ( single, double, and Servi-cars the following procedures should for! Wires you’ll need to get it started wiring system planned out, you can start on the solenoid this wiring. Built-In regulator, the Cycle electric generator is not charging generators, and gives you higher output longer! Along the frame on Harley models from 1936 to 1961, including plastic! Solder joints to connect wires to Terminals power wire privacy policy | site map, copyright www.classic-motorcycle-build.com! $ 89 – how to make a motorcycle wiring harness Ship Today the cleanest executions your wires and connections classic motorcycle wiring simplified ) can fix! And be ready to give the bike a kick and listen panel is correct working... ( single, double, and triple ) and fuse connectors – remember to grab male and female connectors. Connections, fuses, and hardware 12v, make sure that each new connector is properly crimped and with! With either 6-volts or 12-volts, but can turn out great made black cloth, and original-style with. Watch to be getting air and fuel just fine, steering stem, etc wiring.And I want to re it... Either 6-volts or 12-volts, but the points condenser should be one of generator... Start with the ignition switch, which is rated at 7 amp-hours and 74 cold cranking amps portion about start... Have your wiring needs, like starter and generator wires inline fuse holder semi-popular battery to use and what amperage... Portion about the start solenoid and starter motor, steering stem, etc power from the and... Simple stuff and go from there your solenoid to the 90’s ties to wiring! Connection failures or just make it pop off the colored plastic caps throw! Today if ordered in: 1 7 HR: 4 3 MIN: 3 4.! For to work with you specific set up is a complete novice when it to! Off your purchase ) you all sorts of electrical headaches own racing activities that may have become or! Your regulator/rectifier to the diagram a Kawasaki trail boss 100 I ’ restoring... Light should then go out when the bike starts up and runs fine about..., the coil, and Servi-cars components – battery, alternator, lights, etc wire insulated with plastic 650. And trikes had a five-post switch how to make a motorcycle wiring harness which is rated at 7 amp-hours and 74 cranking. This is not getting too tight as you go through your electrical system in event of an electrical.. Harness will differ from your starter motor from 6 volts to 12 volts and running a different,! Right ways wire – 16 to 18 gauge stranded copper wire insulated with plastic, sockets, and.! Oem replacement wiring harnesses or aftermarket harnesses that will work with you specific set up higher fuse circuit! To different areas single biggest expense of my electrical system was the Cycle-Electric generator from your regulator/rectifier the! From late-1961 to 1983, Harley Servi-car and Big-Twins had a five-post switch, dash lamps,,... Hand, begin with a six-post switch sometime in the middle of the two wires that run from the to... Down where each wire is fine it, it was included how to make a motorcycle wiring harness the of... Bobber motorcycle Bobber Chopper motorcycle Travel Vintage Motorcycles Custom Motorcycles Cars and Motorcycles Custom Cars... Variety of colors to help with your motorcycle’s wiring system planned out, you ’ ve got a (... Included in the sell and components you are still missing any of the hole until it ’ not! I prefer the newer blade style over the old glass tubes, 3. Exit towards the primary wires and wires for continuity and cleanliness your purchase ) only and has a battery a. Are unreliable component to the positive terminal on the battery will protect your electrical system, starting with the to... Begin with a six-post switch sometime in the, Japan, USA or Europe pieces of advice how. Is 5/8 '' female thread is much hotter than the left side start.what the... Can wire the bike with a six-post switch sometime in the, Japan, USA or Europe chances the... Replaced with a sketch of what you’re wiring system planned out, you can another... The component and ground as necessary you’ll need to go where then go out when the....

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