DIY Network

Electrical Restoration From "Classic Rides" episode DCLR-107

Figure A

In this final segment host Kevin Tetz and Harley-Davidson master mechanic Bill "Dunk" Dunkelberger complete the electrical wiring for the '65 Electra Glide project bike.

Since turn signals are being added to the bike and there's no harness for the rear turn signals, Kevin and Dunk had to make one and tie it into the existing terminals for the front (figure A). The rear turn signal wires are connected to the front turn signal connections at the electrical panel.

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	Figure B
	Figure C
	Figure D
	Figure E
	Figure F

Finishing the Electrical System

• Run the harness out the back, and be sure to leave enough slack. Just mirror the existing harness and run along the frame and make a nice, neat path for it, which can be hidden by using some zip ties.

• Continue down the frame to the back of the bike where you'll connect the wiring to the rear fender. Be sure to stagger the connection in order not to have a big pile of connectors. Make a cut (figure B) to create some room to where you'll have a nice, smooth harness that you can put in a shielding later on.

  Note: The taillights won't be hooked up until the re-install of the newly painted fender.

• Now that the wires are run, it's time to install the battery and voltage regulator.

  Tip: Be sure to use a battery mat to isolate against vibration and to catch anything that falls. It helps with corrosion as well.

• During the disassembly the lead wires were labeled, which makes for a smoother assembly now. Attach the wiring harness lead to the corresponding terminals on the voltage regulator (figure C), which is secured to the mounting plate.

• For the project bike a new chrome voltage regulator cover (figure D) goes on and is secured into place.

  Tips: Connect the positive battery terminal first in case you make a mistake and touch the ground wire into something else other than the battery, you won't arc off and short circuit the system.

  Temporarily hook up the negative battery cable using a pair of locking pliers to hold it in place. That way you can disconnect it quickly if there is a problem with the circuit.

• Use a voltage meter to test the circuit, and be sure to test the terminals at the front electrical panel by clamping the ground to the panel screw and the lead to the individual terminals (figure E).

• Next, check the points on the distributor. With the spark plugs removed to prevent actual start-up, turn the rear tire with the bike in gear. This will turn the camshaft to the open position on the points.

• Use a feeler gauge to check the gap of the breaker points (figure F). For the project bike it was a little tight, so Dunk uses a screwdriver to loosen the locking screw, and then he turns the adjusting screw to open the contact points just a little -- and then he tests the gap again.

• Tighten the first screw to lock the points in place, and replace the distributor cap.

• The last thing to do is to clean up the wiring harness. Split corrugated tubing is simply pressed over the wires to bundle them neatly. The covers come in several sizes. Use plastic cable ties to hold them neatly to the bike's frame.

In the next episode the new exhaust system is installed and the body panels are color sanded and buffed and installed.

RESOURCES :

The Eastwood Company

The Eastwood Company is a supplier of automotive-restoration parts, tools and supplies.

The Easthill Group, Inc.
The Eastwood Company
Website: www.eastwoodco.com

Restoration Parts (Custom Chrome)
Custom Chrome
Website: www.customchrome.com

Motorcycle Restoration Parts (In the Wind Motorcycle Parts)
In Wind Motorcycle Parts
508 Lovell Rd.
Knoxville, TN 37932
Phone: 865-560-5650 or 865-777-0884
Fax: 865-777-0886

Norton Abrasives

Sandpapers, cleaners, abrasives and bodywork supplies.
Website: www.nortonautomotive.com

Auto Body Color and Supply
Phone: 615-726-0361 (Nashville Store)

Motostorm Chrome Paint
Website: www.motostorm.com

Also available through Innate Technologies (see contact information, below, under the Guest entry for Nate Chase).

Keller Wallace Street Rods
6340 Clinton Highway
Knoxville, TN 37912
Phone: 865-680-3623

GUESTS :

William "Dunk" Dunkelberger
Restoration Coordinator / Mechanic
Harrly Hoggs & Piggletts
1409 Piney Rd.
Maryville, TN 37803
Phone: 865-681-7699
E-mail: hoggsandpiggletts@yahoo.com

Nate Chase
Automotive Painter and Designer
Innate Technologies
PO Box 540691
Omaha, NE 68154
Phone: 702-651-6551
E-mail: E-mail: sales@innate.com
Website: www.innate.com