Motorcycle Wiring Guide Ralph Ferrand wrote a series of articles about motorcycles electrics which was published in Classic Motorcycle Mechanics Magazine between September 2016 and February 2017. We have now persuaded CMM to put them together in a downloadable format for a bargin price. If you're new to wiring and want to learn some professional tips and tricks click the banner above.
2mm² Thin Wall Cable 25amp PVC insulated thin wall wire. This cable has 28 strands of 0.3mm premium copper conductor . The thinner than standard insulation making it perfect for motorcyle wiring. It allows groups of cable to be more flexible and take up less space. When looms are thinner they are less likely to get trapped and damaged. This is used for heavier current applications such as feeds from the regulator/rectifier. We supply cable by the metre so you only need buy what you need. When you have cables with a second, thinner colour, this is known as a tracer. For example if you require a black cable with a yellow tracer (Kawasaki ground) then you order black/yellow ie the tracer is the second colour.
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Colour Black £0.50 Blue £0.50 Brown £0.50 Green £0.50 Grey £0.50 Orange £0.50 Pink £0.50 Purple £0.50 Red £0.50 White £0.50 Yellow £0.50 Black/Grey £0.50 Black/White £0.50 Black/Yellow £0.50 Blue/Green £0.50 Blue/Red £0.50 Blue/White £0.50 Blue/Yellow £0.50 Brown/Black £0.50 Brown/Blue £0.50 Brown/Green £0.50 Brown/Purple £0.50 Brown/Red £0.50 Brwon/White £0.50 Green/Black £0.50 Green/Red £0.50 Green/White £0.50 Green/Yellow £0.50 Orange/Black £0.50 Purple/Orange £0.50 Red/Black £0.50 Red/Green £0.50 Red/White £0.50 Red/Yellow £0.50 White/Black £0.50 White/Blue £0.50 White/Green £0.50 White/Grey £0.50 White/Orange £0.50 White/Purple £0.50 White/Red £0.50 White/Yellow £0.50 Yellow/White £0.50
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10mm² Thin Wall Cable PVC insulated thin wall wire. This cable has 80 strands of 0.4mm premium copper conductor. We use this cable for battery and starter applications. We supply cable by the metre so you only need buy what you need.
Total Price: £3.05 (Excluding VAT at 20%)
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Colour Red (£3.05 Excluding VAT) Black (£3.05 Excluding VAT)
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16mm² Thin Wall Cable PVC insulated thin wall wire. This cable has 126 strands of 0.4mm premium copper conductor. We use this cable for battery and starter applications on big twins that require extra starting current. We supply cable by the metre so you only need buy what you need.
Price: £4.17 (Excluding VAT at 20%)
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Colour Red (£4.17 Excluding VAT) Black (£4.17 Excluding VAT)
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Battery Lead Terminals with 6mm Hole for 10mm² Cable 2 ring terminals for 10mm cable with 6mm hole. These are great to make up battery leads and leads from the starter motor to the solenoid on motorcycles. To attach this properly you will need a tube type crimp tool such as This For a really professional and safe finish the joint should be sleeved in heat shrink as shown in the photo. 2off Terminals in each packet
Price: £0.99 (Excluding VAT at 20%)
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Battery Lead Terminals with 5mm Hole for 10mm² Cable 2 ring terminals for 10mm cable with 6mm hole. These are great to make up battery leads and leads from the starter motor to the solenoid on motorcycles. To attach this properly you will need a tube type crimp tool such as This For a really professional and safe finish the joint should be sleeved in heat shrink as shown in the photo. 2off Terminals in each packet
Price: £0.99 (Excluding VAT at 20%)
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Battery Lead Terminals with 8mm Hole for 16mm² Cable 2 ring terminals for 16mm cable with 8mm hole. These are great to make up battery leads and leads from the starter motor to the solenoid on motorcycles. For a really professional and safe finish the joint should be sleeved in heat shrink as shown in the photo. 2off Terminals in each packet
Price: £1.34 (Excluding VAT at 20%)
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Battery Lead Terminals with 6mm Hole for 16mm² Cable 2 ring terminals for 16mm² cable with 6mm hole. These are great to make up battery leads and leads from the starter motor to the solenoid on motorcycles. For a really professional and safe finish the joint should be sleeved in heat shrink as shown in the photo. 2off Terminals in each packet
Price: £1.34 (Excluding VAT at 20%)
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10mm Ready Made Custom Battery / Starter Leads For those who need a battery lead but are not wanting to make enough to justify the cost of a suitable crimp tool we are now making custom 10mm² battery, earth and starter wires. Just let us know the length and colour. Measure from eye to eye (ie the hole in the ring) and we will do the rest
Price: £4.99 (Excluding VAT at 20%)
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Nylon Cable Ties Premium quality nylon cable ties in all the sizes we use in our workshops.
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Size 100mm x 2.5mm 100off (+£0.99) 150mm x 3.6mm 100off (+£1.35) 120mm x 4.8mm 100off (+£1.69) 160mm x 4.8mm 100off (+£1.89) 200mm x 4.8mm 100off (+£1.95) 300mm x 4.8mm 100off (+£2.99) 368mm x 7.6mm 50off (+£3.49)
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19mm Self Adhesive Cable Tie Fixing These cable tie fixings can either be using the self adheasive foam pad, but if you want extra strength a counter sunk machine screw or self tapper can be used. Can be used with any cable tie up to 3.6mm. Base 19mm x 19mm Supplied in packs of 5
Price: £0.70 (Excluding VAT at 20%)
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28mm Self Adhesive Cable Tie Fixings These cable tie fixings can either be using the self adheasive foam pad, but if you want extra strength a counter sunk machine screw or self tapper can be used. Can be used with any cable tie up to 4.8mm. Base 28mm x 28mm Supplied in packs of 5
Price: £0.80 (Excluding VAT at 20%)
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6mm Aluminium Self Adhesive Mounting Clips 6mm aluminium cable mounting clips with a self adhesive base. Suitable for fixing cables or conduit.
Price: £1.49 (Excluding VAT at 20%)
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10mm Aluminum Self Adhesive Mounting Clips 10mm aluminium cable mounting clips with a self adhesive base. Suitable for fixing cables or conduit.
Price: £1.84 (Excluding VAT at 20%)
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Cable Tie Eyelet Fixing These eyelet type fixing are great when you can use a screw but there isn't a flat enough surface to use the above fixings. Takes an M4 (3/16") pan head screw and is suitabe efor cable ties up to 5mm. The body is 10mm x 20mm. Supplied in packs of 5
Price: £0.75 (Excluding VAT at 20%)
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Cable Tie Cradle Mount This mount can be screwed to the frame, fairing panels & boxes using screws with a diameter of up to 5mm. It will take cable ties with a width of up to 9mm and secure harness sections. The base is 21.9mm x 15.9mm. Self tapping screws or machine screws can be used
Price: £0.80 (Excluding VAT at 20%)
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4 Pin 20 Amp Micro Relay Micro relays are perfect for motorcycles where there is always a space and weight issue. Very rarely will you ever need more than 20amps (240watts @ 12 volts). Very often horns use more current than is wise to draw through the handle bar switch, especially if you use a louder snail horn or similar to make your presense on the road apparent to the seemingly psychopathic car drivers out to get you. Relays are very simple to use. Below is a very simple diagram showing how a relay is used to switch a lamp.What you are doing is to draw a very low current through your handle bar switch to power an elctromagnet which operates a much heavier switch to power the load.
Price: £4.99 (Excluding VAT at 20%)
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5 Pin 20 Amp Micro Relay This relay is the same as the one above except that when the coil is energised by the handlebar or other switch, it can be used to turn off another load as well as switching on the first. They are not as commonly used on bikes, but they do have their uses, for instance if you fitted day running LED lights to your bike you might want to switch them off when you switched on the main head lamp.
Price: £4.99 (Excluding VAT at 20%)
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Micro Relay Plug Whilst you can use female spade terminals to collect to a relay, these relay bases or plugs make life a lot easier and neater. These bases can be screwed, bolted or riveted to the bike eg the battery box making it easier to replace a relay should it fail
Price: £1.49 (Excluding VAT at 20%)
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