Question 1

For a typical bike project, what does the harness do, where it runs on the bike, what it deals with, and which failures you design to prevent?

Accepted Answer

The harness serves power distribution and signal transmission. It is routed from the engine to the handlebars, typically routed beneath the seat. Motorcycle harnesses must withstand intense vibration and exposure to oil; designs employ robust, locking connectors for secure mating and durable jacketing materials to enhance resistance.

Question 2

Which rules or certifications do you follow for motorcycle wire harnesses, and how do you prove you meet them?

Accepted Answer

IATF 16949 certification can be provided by an accredited third-party certification body.

Question 3

What checks do you run before shipping to make sure that your wire harnesses satisfy client requirements?

Accepted Answer

Primary inspections include visual inspections and electrical testing, along with any additional customer-specified tests—such as high-potential (hipot) or waterproof testing. All inspections are conducted in accordance with IPC-620 standards, and detailed inspection reports are issued.

Question 4

How do you keep water, heat, sun, and chemicals from causing damage, and how do you confirm this holds up over time?

Accepted Answer

All these conformity and performance reports are issued by independent third‐party laboratories engaged by our suppliers. Environmental durability tests are tailored to each criterion—for example, IP67 waterproofing is verified in high‐pressure water chambers, while UV resistance is assessed in dedicated ultraviolet exposure chambers.

Question 5

What is the harness made of, how do you size it for the job, and what temperature levels can it handle safely?

Accepted Answer

Harnesses are composed of conductors, jacketing materials, and connectors. For power circuits, insulation jacketing is selected based on system voltage and conductor gauge is determined by current requirements. Signal wiring is specified according to signal type and frequency—for example, high-frequency signals use twisted pairs, and ultra-high-frequency lines incorporate additional shielding. Standard temperature ratings range from –40 °C to 105 °C.

Question 6

At the handlebars and headstock: what's the tightest bend you design for, how many steering cycles it's designed to survive, how you clamp and route wires to avoid rubbing/crushing, and how you test this?

Accepted Answer

The design specifications do not mandate a minimum bending cycle requirement at this location, so we typically do not perform dedicated bend testing. For harness retention, we wrap the wiring in tape to enhance abrasion resistance, install protective rubber grommets at pass-throughs, and secure free-hanging sections with cable ties featuring mounting clips anchored to designated support points. Compression loads are prohibited by OEM design, and any such testing is conducted by the OEM. If we perform these tests, we utilize a cable-bending apparatus or construct a custom test fixture according to customer requirements.

Question 7

What do you use at the ends (the "plugs"), how do you keep water and fuel out at connections, how do you keep joints from loosening, and how do you check that these stay sealed and tight?

Accepted Answer

Connector selection typically utilizes automotive-grade, locking-style connectors. Sealing components—such as molded rubber grommets—are installed at each wire entry cavity, and O‐rings or elastomeric seals are fitted between mating plug and receptacle interfaces to increase insertion resistance. If clients require additional verification of sealing integrity, specialized fixtures are employed to perform leak‐down (air‐tightness) testing.

Motorcycle Wiring HarnessManufacturing

Motorcycle Applications

Engine & Powertrain Systems

Instrument & Dashboard

Lighting & Electrical

Handlebar & Control Systems

Motorcycle-Grade Technical Capabilities

Why Choose Our Motorcycle Wire Harness Services

IATF 16949 Certified Manufacturing

Vibration & Environmental Testing

Oil & Chemical Resistance

Motorcycle OEM Experience

Certifications

Frequently Asked Questions About Motorcycle Wire Harnesses

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