Main components
1. Wires:
The wires in the motorcycle harness are used to transmit power and signals, and usually have multiple colors to distinguish different functions. The conductor material of the wire is usually copper, and the outside has a heat-resistant, wear-resistant, and corrosion-resistant insulation layer to cope with the high temperature and vibration when the motorcycle is running.
2. Connectors:
The connector is an important part of the wiring harness assembly, ensuring that the wires can be firmly connected to the various electronic components of the motorcycle. Commonly used connectors include multi-pin sockets, circular connectors, etc., which need to have good waterproof and dustproof properties.
3. Sheaths and sleeves:
In order to protect the wiring harness, the outside is often wrapped with a sheath or a corrugated tube to prevent the wires from being affected by motorcycle vibration, scratches or other external environments.
4. Terminals:
The terminal is used to fix the wire to the connector to ensure good contact between the wire and the electronic component or device. The terminal material is usually copper or copper alloy, and the surface is tinned or silver-plated to improve conductivity and corrosion resistance.
5. Fuse box and relay: The wiring harness assembly contains fuse boxes and relays to protect the electrical system from overcurrent and control the on and off of the circuit.
Main functions
1. Power transmission: The wiring harness assembly transmits power from the battery to various systems and components of the motorcycle through cables, such as the ignition system, lighting system, dashboard, starting system, etc.
2. Signal transmission: The wiring harness transmits information from sensors or switches to the control unit or dashboard to realize various functions of the motorcycle, such as fuel display, speed display, engine status monitoring, etc.
3. Protection function: The motorcycle wiring harness needs to work under harsh conditions such as high temperature, humidity, vibration and dust, so the sheath and sealing design of the wiring harness assembly ensure that the wires are protected from external influences and extend their service life.
Application areas
Ignition system: Provide power to the spark plug to start the engine.
Lighting system: Connect the headlights, taillights, turn signals, etc. to ensure the normal lighting and signal functions of the motorcycle.
Dashboard system: Transmit the operating data of the sensor and the motorcycle to the dashboard for display.
Starting system: The start button and the starter are connected through the wiring harness to start the motorcycle.
Design considerations
1. Durability and heat resistance:
The high temperature and vibration generated by the motorcycle during driving put high demands on the insulation layer and sheath of the wiring harness. Wear-resistant and high-temperature resistant materials need to be considered when designing the wiring harness to ensure long-term reliability.
2. Waterproofness:
Motorcycles are often used outdoors, and the wiring harness must have a waterproof function, especially in the connector part to prevent moisture from entering and causing short circuits or corrosion.
3. Simple layout:
The wiring harness needs to be reasonably laid out to avoid excessive wire interweaving and friction, and must be close to the frame to prevent loosening or wear during vibration.
4. Safety:
In the wiring harness assembly, fuses and relays are usually configured to prevent overcurrent or short circuits, protect the motorcycle's electrical system and driving safety.
Summary
The motorcycle wiring harness assembly is the core component of the motorcycle's electrical system, ensuring stable power and signal transmission from the battery to various electronic devices. High-quality wiring harness design can significantly improve the performance, durability and safety of the motorcycle. During production, customized design is required according to the specific model and requirements of the motorcycle to meet different functional needs and environmental conditions.
