DIY Network

'48 Indian Motorcycle: Circuit Breaker, Voltage Regulator and Final Wiring From "Classic Rides" episode DCLR-309

Chris and Craig test the new battery for the '48 Indian.

Electricity is on tap during this phase of the restoration of our 1948 Indian Chief motorcycle. Host Craig Reynolds and antique motorcycle expert Chris Matthews add a few safety features to ensure proper function and reliability for the wiring.

They also install the shift linkage with a period correct shift knob, and then install the new seat. After a few final checks, this monster is ready to start for the first time.

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New battery and materials for wiring and testing

Materials and tools:

complete set of SAE or metric wrenches
wire cutters
wire stripper
various barrel connectors
soldering iron and solder
shrink wrap
lighter

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.

Note: This is a summary of steps included in the automotive 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.

	Installing the circuit breaker
	Tucking in the circuit-breaker wires.

Circuit Breaker

An important step in any restoration or rebuild is to make sure that all the work you do isn't in vain. It would be a shame if our Indian burst into flames because of a short circuit, so to prevent that possibility, we'll install a circuit breaker. We'll also be installing a voltage regulator, which will keep our electrical system working within the correct parameters.

• The first step is to install a circuit breaker in the negative cable going to the battery. So we'll have to remove the battery from the bike.

• Back off the hold-down plate a few turns and the battery can be slid out. Once it's removed, the lid can be taken off.

• With the lid removed we can access the negative cable. Pull the wire out and using the wire cutters, clip it right in the middle.

• The using the stripper, remove about 1/2 inch of insulation from each end of the wire. Then remove about 1/2 inch from the ends of the circuit breaker wires.

• Insert one exposed end of the negative wire and one end of the circuit breaker wire into the barrel connector and using the wire cutters, crimp the ends of the connector so the wires are held tight.

• Repeat this process for the other end of the negative wire and once the circuit breaker is on and crimped tight, the entire assembly can be tucked back down into the battery cover. But for the sake of safety, do not reconnect the battery to the wire harness.

Chris installs the voltage regulator.

Voltage Regulator

With the circuit breaker taken care of, we move on to the voltage regulator. The regulator mounts on the generator itself and controls how much voltage is allowed to be output.

• There are three wires coming out of the generator: field, armature and battery. All three of these will plug into the regulator, but first we need to mount the bracket on the generator.

• Pass the three wires through the regulator bracket and tighten the pinch bolt on the bracket.

• Now it's time to mount the regulator on the bracket, so first plug the three wires into their respective terminals on the regulator, they are labeled, and then set it in place on the generator.

• The regulator is held to the mount with four set screws. Insert them into the holes on the mount and tighten with a screwdriver to complete the installation.

	Magneto cap
	Installing the magneto cap
	Chris works on the magneto.
	Chris installs the sparkplug wires.

Final Wiring

Now that we have some safety measure set up on our wire harness, we can go ahead and start connecting everything. For this part of the wiring, we solder a connection and also using a barrel connector to plug in the headlight wires.

• The first step is to prep all the wires. This means removing any old connections that may be on them and stripping the ends of insulation.

• Use the clippers to cut off any old connections and then using the wire stripper, take off about 1/2 inch of insulation from all the wires.

• We're going to solder the main line from the rear brakes to the harness. Since we've already preps the wires, this should be a breeze. The first step is to slide a piece of shrink wrap on one side of the wire.

• Splice the two ends together and then apply heat with the soldering iron.

• Melt a small amount of solder onto the splice.

• Allow it to cool and then slide the shrink wrap over the connection.

• Then heat the shrink wrap with the lighter until it compresses over the connection.

• The final step is to install a brake light switch in the brake line. The switch will mount to the chain guard with two screws.

• The two wires of the brake light wire are attached to the posts and secured with small nuts.

• Then the switch can be set in place on the chain guard and the two screws can be tightened.

• The final step is to attach the return spring. This will link the switch to the brake linkage and cause the light to come on when the brake pedal is pushed.

• Hook one end of the spring to the brake light switch and the other end on the brake linkage.

In the project that follows, Chris and Craig connect the ignition switch, add a period-correct shift lever and attach the seat on the '48 Indian.

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