DIY Network

'48 Indian Motorcycle Restoration: Handlebar Repair and Wiring From "Classic Rides" episode DCLR-307

Our American classic, the 1948 Indian Chief motorcycle is more than half way through its restoration process. Now it's time to get some parts back on.

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	The headlight as seen on the fully restored '48 Indian.
	For the horn button and headlight switch, both of which will be mounted on the handlebars, Chris solders the new wiring to the ends of the old wires.

Project Overview

In this phase of the restoration, several things happen: First, Classic Rides host Craig Reynolds and motorcycle restoration expert Chris Matthews rewire and install the handlebars. Next, Chris shows Craig how to test the Indian's generator and a new battery is bolted in. Finally, they attach all the brake and clutch linkages, and add a place to put their feet in the form of brand new running boards.

To get things started, Chris and Craig replace the grips and rewire the handlebars. The wires for the horn and headlight controls are routed inside the handle bars themselves. While this makes for a very clean look, it makes things a little difficult in terms of replacing the old and outdated wiring. Luckily, Chris has a technique that makes the process bearable, if not easy. While he's at it, he also replaces the 50 year old handlebar grips with something new.

Materials/Tools:

new horn and head light switches
soldering kit
new handlebar grips
knife
screwdriver
wire cutters
wire stripper

Note: This is a summary of steps included in the restoration procedures shown in this episode of Classic Rides. These are general guidelines for restoration procedures on this particular make and model of motorcycle, and for the level of restoration selected for this project. There may be variations in procedures depending model, condition of vehicle, level of restoration undertaken and the types of replacement parts or upgrade kits selected. Always follow proper safety precautions, and read and follow manufacturer's guidelines, diagrams and safety notices that come with any replacement parts or kit that you select.

Safety Alert: As a standard safety precaution, always disconnect the vehicle's negative battery cable before you begin work on any electrical or mechanical components.

	Figure A
	Figure B

Handlebar Grips Replacement

• We start by removing and replacing the grips. Removal is easy, using a knife, make a cut along the length of the grip (figure A), then peel off the old piece (figure B).

• With the old grips removed, the new ones can now can be slid on.

• Tip: If the grips appear to be overly tight and won't budge when you try to install them, a few squirts of hairspray on the inside of the grips will allow them to slide on easily.

Once the grips are finished, we can move on to the wiring on the horn button.

	Chris feeds the wiring through the handlebars.
	Soldering the wires for the horn button and lights.

• Using a screwdriver, remove the retaining screw on the horn button and let the cover drop into your hand.

• The button itself will be attached to the wires running through the handlebar. Pull the horn away from the bar until a couple of inches of wire is exposed.

• The old button can now be cut from the wires and tossed aside.
  
  
• Now comes the special technique: We solder the ends of the new wires to the old wires, right where the horn button was cut off.

• The important thing to keep in mind throughout this process is to make sure that you are soldering the correct end of the wires.

  Tip: Always solder the end that is towards the outside of the handlebars. Otherwise, when you pull the wire through, your new horn or headlight switch will be in the center clamping area of the handlebars.

• Using the wire stripper, strip about an inch of insulation of the old wires and the new.

• Splice the two wires together and hold the soldering gun to them, once they're hot, melt a small amount of solder into the splice.

• Once you've formed a good solder connection, allow the connection to cool.
  

  	Chris and Craig install the handlebars on the '48 Indian.

• The wires can now be pulled through. Grab a hold of the old wires that are coming out of the middle of the handle bars and pull. The other end of the old wires will pull through, taking with them the new wires.

• Once the new wires are all the way through the handle bars the horn button should be snug against its mounting point. The horn button cover can be installed, re-place its screw and tighten.

• The only thing left to do is cut the new wires just before the soldered joint, disconnecting them from the old.

RESOURCES :

Welders
Lincoln Electric
Website: www.lincolnelectric.com

Kiwi Indian
Website: www.kiwi-indian.com

V-Twin Mfg.
Rims, Spokes, Hubs, Tire Irons and Truing Stand
Website: www.vtwinmfg.com

Motorcycle Lift
Handy Lift
Website: www.handy-lift.com

Various Tools
Eastwood
Website: www.eastwoodco.com

Hepavac Asbestos Vacuum
Bullseye
Website: www.bullseyecorp.com

Parts Washer
Safety Kleen
Website: www.safety-kleen.com

Chrome Polish
G & H Metal Finishers
282 Dakota St.
Paterson, NJ 07503

Belt Grinder
Ellis Manufacturing
Website: www.ellissaw.com

Powder Coating Shop
Best Signs
Phone: 865-922-5247
E-mail: bestsigns@tds.net

Coker Classic White Wall Tires, Tubes and Spoke Covers
Coker Tires
Website: www.coker.com

Gaskets/Headers
James Gaskets
Website: www.jamesgaskets.com