4 Custom Chopper Wiring Tips

iframe width="315" height="177" src="https://www.youtube.com/embed/zxnbmfHKu5o?rel=0" frameborder="0" allowfullscreen>

These custom chopper wiring tips may help ensure your motorcycle build project, whether stock, custom, or chopper, will operate properly every time you start it up.

Without proper wiring, in fact, the bike won't start at all.

Many safety features, including head lamp, tail lamp, turn signals, horn, and alarm system (if you have one) as well as creature-comfort features such as your electric start, will not operate without proper wiring.

The tips are below. But here's a videos you might enjoy (I put part 2 at the bottom):

The builder in this chopper wiring video has a Masters rating from Harley Davidson University and is a Harley Davidson Lead Mechanic. We highly recommend his custom biking building DVD. He makes everything easy to understand, and you'll watch it over and over. It's quantum leaps better than any American Chopper episode. I know, that was a little tongue in cheek, but it really is good, and if you don't like it, send it back.

Now for more Chopper Wiring Tips:

Wiring Tip #1 Follow the Wiring Diagram: If you are building a kit bike, a wiring diagram should be included. If you are rewiring a stock bike, the wiring diagram can be obtained from the manufacturer, dealer, and often can be found online. Use this diagram as a Bible, and do not decide to waver from it. Choosing another way to route wires can be useful sometimes, but the color coding and pin assignment will be completely useless if you suddenly decide you can wing it.

Wiring Tip #2 Fuses: Always add a fuse into each and every circuit you build, whether you are changing your existing wiring harness to add an accessory or replace a bad wire, or wiring a motorcycle from scratch. 

Do not simply tap into a circuit that exists which is fused. It is very easy to overload the circuit. It is wise to mount the fuse in close proximity to the ignition switch or battery so that a failed circuit or dead short will not cause your electrical harness to burn up before shutting down. Generally, it is a good idea to use fuse sizes that is close to 10% more than the load limit of the circuit being wires. If, for example, you are adding an accessory which requires a maximum of 20 amps, incorporate a fuse into the circuit that will shut down as near 22 amps as possible. So, in this example, you would select a 25 amp fuse since that is the nearest fuse size to the 22 amp 10% overload rule.

Wiring Tip #3 Relays: A relay is simply a switch which allows a connection between two or more terminals in the relay to exist. Relays are frequently black plastic boxes about 1 inch square which often have a mounting tab. Bosch relays are probably the most commonly used and are certainly affordable. But, there are lots of other relay manufacturers. The pin diagram of the relay will tell you how to wire the switch to create the circuit you want to complete. Relays serve several purposes:


A. A relay can send full power to an electrical device yet allow the switch for the device to use smaller wiring. This is necessary when running wiring through narrow handlebars or tubing which must operate high powered devices such as head lamps. 

B. Relays can divert power from one device to another using the same wire. An example of this application would be a head lamp wiring set up where the same wires but different positions on the switch causes the head light to be dim or bright.

Custom Chopper Wiring Tip #4. Check Wiring Regularly: Periodically, as you care checking fluid levels and chain snugness on your motorcycle, remember that a great wiring tip is to run your hands over each wire, feeling for cracks or other indications that a wire may need replacing. It is far, far better to go ahead and replace a worn wire than to end up having to do the job while stuck on the road somewhere.

iframe width="315" height="177" src="https://www.youtube.com/embed/Hxk-X9U9uC4?rel=0" frameborder="0" allowfullscreen>

Have An Opinion About This Wiring Video or Article?

Do you have an opinion or story about this motorcycle wiring article and videos? Share it!

[ ? ]

Author Information (optional)

To receive credit as the author, enter your information below.

(first or full name)

(e.g., City, State, Country)

Submit Your Contribution

  •  submission guidelines.

(You can preview and edit on the next page)

What Other Visitors Have Said

Click below to see contributions from other visitors to this page...

Factory or Pre-Made Harness! 
Great video if you are using a factory or pre-made harness, but what about us few who refuse to sub-out any of the build, including making our own wiring …

Perfect Connections and Protection 
Heat shrink! Think ahead of time heat shrink whatever you can. Heat shrink were parts of harness enter or exit tubing (frame or bars etc.) adding that …

Wiring Controls, Sensors, Gauges, Starting System and Lights? 
Does this video cover all of the wiring from the controls to the engine sensors to gauges and idiot lights, starting system and charging system? All …

That Was Great! 
Wow that was great he did what I have to do next!

Good handlebar swap video Not rated yet
As always this guys video work is very informative. But I think it's a stretch to call this a wiring video. I really wish that he would put out a sportster …

Motorcycle Building and Maintenance Videos Not rated yet
Fantastic, carefully thought out instructional videos. My son has just been offered an apprenticeship in Harley's and now I will be ordering dvd's to assist …

Wish I Had Seen The Wiring Videos Before I Started! Not rated yet
Love the wiring videos, thank you! Wish I had seen them before I started my project, would have made things much simpler. Always good to see how others …

Top End Interest Not rated yet
Awesome keep them coming. There is serious interest in a top end rebuild tape on xl forum. A lot of guys want to put in stage 2 heads and 1250 cylinders, …

Outstanding Motorcycle Wiring Video... Not rated yet
Outstanding. The visual imagery was clear and the audio was solid, no extra noise. The information imparted was easy to understand, and the visual was …

Sharp Assembler Not rated yet
The assembler is sharp, with good commentary, the audio is surprisingly good, the lighting and back drop work well. The camera angles and close ups …

Nice custom motorcycle wiring video Not rated yet
Very nice custom motorcycle wiring video. I have done it twice on my bike (mockup and final build) and it is really as simple as on the video. But if …

Click here to write your own.