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Wiring Guide in Classic Motorcycles Mechanics Magazine

Classic Motorcycle Mechanics Downloads

Ralph Ferrand wrote a series of articles about motorcycles electrics which was published in Classic Motorcycle Mechanics Magazine between September 2016 and February 2017. We have now persuaded CMM to put them together in a downloadable format for a bargin price.

If you're new to wiring and want to learn some professional tips and tricks go to CMM downloads or click the banner above.

Heat Shrink Gun

Heat Shrink Gun

We took one of these new tools from Laser Tools to test for Classic Motorcycle Mechanics magazine. Ralph was so impressed with this excellent tool that he instantly put in an order for stock for Biker's Toolbox.

This tool is lightweight and easy to use with a blow temperature set perfectly for electrical heat shrink tube. It only uses 300watts of power making it far more frugal than the big heat guns, which is a big bonus given the price of lecky these days! Big heat guns tend to have big nozzles that get very hot and can burn the hand that feeds them and often take a while to cool down to a safe temperature.

For us this little tool is a revelation for wiring and we expect to sell bucket loads of them to canny bike fettlers

Price: £17.64 (Excluding VAT at 20%)

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Click for larger image


People who bought this item also bought:
1. 1mm² Thin Wall Cable
2. PVC Sleeving
3. Mini Blade Fuses

Compact Cable Cutter

Compact Cable Cutter

This compact cable cutter is specified to cut copper cable up to 25mm². It has cushioned handles, return spring and locking latch for toolbox storage. It is no substitute for side cutters for general bike wiring, but is perfect for cutting motorcycle battery and earth cables. Tool length 167mm

Price: £6.49 (Excluding VAT at 20%)

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Laser Heavy Cable Cutters

Laser Heavy Cable Cutters

These robust heavy (by motorcycle standards) cutters will neatly slice through any electrical cable you are likely to come across on a motorcycle.

This professional quality tool is manufactured from chrome vanadium and will cut through all aluminium and copper wire like a knife through butter.

Jaw capacity 19mm, which is far larger than any cable that should be on your motorcycle.

Price: £15.26 (Excluding VAT at 20%)

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Electricians Scissors

Electricians Scissors

To say we were impressed with this tool is an understatement. We cut through 16mm² battery cable with this tool like a knife through butter leaving a neater cut than many wire cutters. It claims to be able to cut through 70mm² cable, but as we don't use anything thicker than 16mm² on bikes we didn't try it on anything heavier. The scissor part of the cutter slices though every type of sleeving we use and stock effortlessly.

The tool claims to be able to crimp, and we were surprised to discover that, with a bit of care, it will crimp 1mm² and 2mm² tube type butt connectors.

The cable cutter part can also be used to carefully cut through the insulation on a battery cable.

Price: £18.16 (Excluding VAT at 20%)

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Laser 150mm VDE Side Cutters

Laser 150mm VDE Side Cutters

Professional 150mm diagonal side cutters with ergonomic grip with 1000volt protection, which won't need on a bike ... hopefully. The reason we chose these is that they are highly visible and comfortable to use. As with all Laser tools they are excellent quality without breaking the bank.

Price: £13.87 (Excluding VAT at 20%)

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Laser Automatic Wire Stripper

Laser Automatic Wire Stripper

Excellent quality self adjusting wire stripper, perfect for motorcycle work. This professional tool is easy to use and is the type we have used in our own workshop for many years where it has delivered sterling service.

There is an inbuilt wire cutter which is handy if you haven't got a pair of side cutters to hand. There are some crimp tools in the handle, but they're no replacement for a proper crimp tool; we just see it as a really great wire stripper, end of !

Price: £22.11 (Excluding VAT at 20%)

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People who bought this item also bought:
1. 2mm² Thin Wall Cable
2. 1mm² Thin Wall Cable
3. 3.9mm Male Bullet Connectors

Automatic Wire Stripper

Automatic Wire Stripper

This is a very easy to use wire stripper suitable for wire from 0.5mm² - 6.00mm². It has a handy wire cutter which is useful when a pair of side cutters aren't to hand.

It is a decent quality tool at a very good price. Although it has some inbuilt crimp tools we would not regard them as especially good.

Currently awaiting new stock

Price: £13.49 (Excluding VAT at 20%)

Automatic Wire Stripper 1.0 - 3.2mm²

Automatic Wire Stripper 1.0 - 3.2mm²

This automatic wire stripper has dies for 5 different wire sizes:- 1.0mm², 1.6mm², 2.0mm², 2.6mm² & 3.2mm²

It is a fascinating action that you can play with for hours. It is a decent, effective and quick to use tool, but at this price point is not one for the professional

Price: £15.99 (Excluding VAT at 20%)

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Basic Non-Insulated Terminal Crimping Tool

Basic Non-Insulated Terminal Crimping Tool

These are a good quality set of crimping pliers that will perform well at a budget price. The ratcheting version are much nicer to use, but this set will do the job if you don't do enough wiring to justify the extra expense of the better set. In our opinion the ratcheting versions are well worth the small extra expense.

This tool will work with spade or lucar connectors, Japanese or British bullets, some ring connectors as well as the vast majority of multi-block connectors found on British, Japanese, American and European Bikes.

Price: £12.45 (Excluding VAT at 20%)

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Laser Professional Ratchet Crimping Tool

Laser Professional Ratchet Crimping Tool

Without a shadow of doubt, this is the best way we have found of crimping bike connectors and terminals and though it's not the cheapest solution, you will have long forgotten the cost years later when you are enjoying this premium quality professional tool.

It crimps the terminals with just the correct amount of pre-set pressure, which is adjustable, though we have never found the need to alter the factory setting on ours. It will crimp rings, bullets, spades as well as the vast majority of multi-block connectors found on motorcycles from Japan, Europe, America and the UK

Price: £32.99 (Excluding VAT at 20%)

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Tube Type Terminal Pro Ratchet Crimping Tool

Tube Type Terminal Pro Ratchet Crimping Tool

Professional crimping tool for tube tytpe terminals. This tool is great for crimping 10mm battery cable terminals and also for inline splices when adding length to cables or repairing breaks in a loom. This is suitable for cables from 1.5 - 10mm

Price: £35.03 (Excluding VAT at 20%)

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Professional Superseal / Econoseal Ratchet Crimping Tool

Professional Superseal / Econoseal Ratchet Crimping Tool

Superseal / Econoseal ratchet crimping tool with comfortable ergonomically designed handles for ease of use. The ratchet ensures that the correct crimping pressure is applied before release; the pressure can also be adjusted. Crimp range: 0.5 - 2.0mm²

This crimp tool is suitable for standard superseal and AMP econoseal terminals on the outer jaw and superseal 2.8mm on the inner jaw.

Price: £29.55 (Excluding VAT at 20%)

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British Brass Bullet Crimp and Fitting Tools

British Brass Bullet Crimp and Fitting Tools

British bike electrics were legendary for their lack of reliabilty causing that well know phrase - Lighting by Lucas - the prince of darkness

Part of the problem was that many of the brass bullets were soldered on. One should not solder anything on a bike if not essential because the molten solder is drawn into the multi-strand flexible wire by capillary action makeing the wire a single conductor wire and vulnerable to suffering stress fractures caused by the not inconsiderable vibration found in classic British singles and twins. Another issue is the brass corroding which can be minimised by covering the bullets and sockets in a dielectric grease of corrosion block grease.

These tools can put an end to the delights of soldering bullets. The crimp tool will fit the bullets nicely and the fitting tool squeezes the bullets into sockets which isn't a fun job without this tool

Price: £26.74 (Excluding VAT at 20%)

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Electrical Heat Shrink Kit

Electrical Heat Shrink Kit

Complete kit for fitting heat shrink insulation to electrical wiring. This comprehensive kit contains different coloured heat shrink in a variety of different sizes together with a neat little gas torch which is fueled from readily available cigarette lighter gas (Gas not included). The totch has piezo electric self ignitor, so no messing about with matches. If is fabulously portable.

We have always used an electric heat gun in our workshop, and so were sceptical of the value of such kit, but still took one on to try. We were very surpised at how usable the kit is, which is why we are now comfortable offering it for sale. Whilst we would still use the heat gun for building whole looms we have now taken to using this little torch as weapon of choice for smaller jobs. We're hoping that the manufacturers rep has forgotten we have the demonstrator - if not we'll have to buy one!

Colours included: Red, Green, Blue, Yellow, White and Clear
Sizes:
Black only - 1off 15mm x 500mm
All colours - 60off 1.5mm x 35mm, 60off 2.5mm x 100mm, 25off 3.0 mm x 100mm, 20off 5.00mm x 100mm, 10off 6.0mm x 100mm & 10off 10.0mm x 100mm,

Price: £35.52 (Excluding VAT at 20%)

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Motorcycle Relay Tester

Motorcycle Relay Tester

Quickly and accurately tests 4 styles of electro-mechanical relays on most modern bikes, and other vehicles. Simply attach the crock clips to a battery, plug in the suspect relay and press the test button. The tester will repeatedly test the relay automatically. A green LED light tells you the relay is fully functioning and e red tells you that it needs replacing. A switch lets you selct between 4pin and 5 pin relays

• Coil test voltage 9 volts.
• Suitable for various applications including relay coil resistance/relay contacts and cyclic testing. (Not suitable for later Ford 4-pin relay).
• Relay coil resistance 20-50 ohms.
Relay contact resistance threshold 200 milliohms. CE, UKCA & RoHS compliant.

Price: £35.70 (Excluding VAT at 20%)

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People who bought this item also bought:
1. Heat Shrink Gun
2. Spark Plug Gapping Tool
3. Testing Jump Leads

4amp Intelligent Battery Charger

4amp Intelligent Battery Charger

A mains powered 4A intelligent battery charger for use on 6V and 12V automotive batteries. Fully automatic, it features a 10-stage charging cycle which monitors the state of the battery and adjusts the charging output to suit. Automatically drops to a trickle charge of <1 amp when the battery is fully charged (a separate maintenance mode is also available) to avoid overcharging.

Suitable for use on motorcycles, cars, vans and boats etc.

• Charges & maintains 6v/12v lead acid, LiFePO4 (Lithium Iron phosphate) AGM & GEL batteries.

• Winter mode for specialised battery charging in cold weather conditions. Automatically drops to a trickle charge of <1 amp when the battery is fully charged (a separate maintenance mode is also available).

• 10-stage fully automatic charging cycle with microprocessor control, adjusts current to match battery type & condition. LCD screen indicates charge level.

• Protection: Overcharging, overheating, short circuits, reverse polarity, low voltage. Insulation Class IP65.

• Supplied with BS plug, crocodile clips with 1.5m (connected) cable & O-ring terminals with quick connector. CE, GS & RoHS compliant.

Price: £41.61 (Excluding VAT at 20%)

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Battery Charger Lead

Battery Charger Lead

This lead can be permanently attached to your bike battery ready to be connected to an Intelligent Battery Charger to manage your battery and keep it ready for a sunny day.

Perfect for the Laser 4A Intelligent charger above.

Price: £4.49 (Excluding VAT at 20%)

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Budget Digital Multimeter

Budget Digital Multimeter

This is not an all signing, all dancing, top of the range multimeter as graces a professional workshop. What it is, is a basic low cost meter that will do most tasks a DIY person will want tracing an electrical fault on their bike. It will also be great around the home.

It measures DC Voltage with 5 ranges, AC voltage with 2 ranges (useful for measuring alternator outputs or main voltage around the home/workshop), DC Current up to 10amps with 5 ranges, resistance with 5 ranges, a diode testing range, which you're most likely to use for connectivity and also there's a transistor tester which you're very unlikely to use. If you knew how to use this function you'd probably buy a more expensive meter.

It's a perfect meter to stick in your luggage when touring.

Price: £4.99 (Excluding VAT at 20%)

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Pocket Multimeter

Pocket Multimeter

• Handy compact unit, small enough to fit in your pocket, making it ideal for basic circuit testing whilst on the move.
• Features flip lid for added screen protection and storage of leads.
• Conforms to EN 61010-1 CAT II safety requirements.
• Supplied with test leads.
• Measures: - AC and DC Voltage - DC Current - Resistance - Audible Continuity

Price: £16.07 (Excluding VAT at 20%)

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Laser Multimeter

Laser Multimeter

This is a basic workshop multimeter offering all the tanges you're are likely to need in a bike workshop. It also has a temperature probe which can be useful eg testing the temperature of the coolant. It's not super high quality professional instrument, but offers excellent value for money with the a build quality that will be fine in a home workshop or light professional work.

• Digital Multi Meter for measuring DC and AC voltage, DC current, resistance and testing diodes.
• Full range overload protection and automatic polarity indication.
• Supplied with temperature probe.
• Low battery indicator • Supplied with 9v Battery
• CE & RoHS compliant. CATIII 300v.

Price: £26.39 (Excluding VAT at 20%)

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Laser Automotive Multimeter

Laser Automotive Multimeter

This Automotive Multi Meter is a compact 3 3/4 digit instrument for measuring DC and AC voltage

• Also measures DC and AC current, resistance, diode and continuity
• Data hold function and frequency measurement. Low battery indication, overload protection and audible continuity
• Meter capabilities 250V AC/DC (voltage), 32.6 M Ohms (resistance), 10Amp (current), Screen size 63 x 32mm. 1 x PP3 9v battery (included)
• Tests Tacho (RPM), dwell angle, temperature and duty cycle
• Conforms to IEC/EN61010-2010, CE and ROHS,CATII

Price: £66.40 (Excluding VAT at 20%)

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Electrical Test Leads

Electrical Test Leads

For use with most multimeters.

• Length 48"/122cm, OD 3.8mm; rating 1000V/10 amps.
• For use with most other accessories with 4mm banana sockets.
• Manufactured from silicone material. Test leads are CATIII 1000V.
• Colour: red & black.

Price: £11.47 (Excluding VAT at 20%)

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Test Lead Crocodile Clips

Test Lead Crocodile Clips

Fully insulated crocodile clips with 4mm female banana plug connector

• Red and black.
• 1000V/10 amp.
• For use with any lead with a 4mm banana plug.
• Wide opening jaws.

Price: £8.37 (Excluding VAT at 20%)

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20 Amp Automotive Current Tester - Standard Blade Fuse

20 Amp Automotive Current Tester - Standard Blade Fuse

We think that these little testers are the best thing since sliced bread ! You can test the current drain on any circuit, simply by removing a fuse and inserting the plug. In the case of a bike with a fuse in the charging circuit, you can even test the current the alternator is putting back into the battery. It will measure up to 20amps which is just what you want on a bike. Most multi-meters only test up to 10amps DC, which often isn't enough on a charging circuit.

If your bike doesn't have a fused charging output from the regulator/rectifier it is worth fitting an in-line fuse holder, not only for safety, but also as a port to easily test the charging current. We've been trying to think of a way to overcome the difficulty of testing bike charging for years, and we think that this unique solution is sheer genius.

Price: £19.10 (Excluding VAT at 20%)

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20 Amp Automotive Current Tester - Mini Blade Fuse

20 Amp Automotive Current Tester - Mini Blade Fuse

We think that these little testers are the best thing since sliced bread ! You can test the current drain on any circuit, simply by removing a fuse and inserting the plug. In the case of a bike with a fuse in the charging circuit, you can even test the current the alternator is putting back into the battery. It will measure up to 20amps which is just what you want on a bike. Most multi-meters only test up to 10amps DC, which often isn't enough on a charging circuit.

If your bike doesn't have a fused charging output from the regulator/rectifier it is worth fitting an in-line fuse holder, not only for safety, but also as a port to easily test the charging current. We've been trying to think of a way to overcome the difficulty of testing bike charging for years, and we think that this unique solution is sheer genius.

Price: £16.77 (Excluding VAT at 20%)

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80 Amp Automotive Current Tester

80 Amp Automotive Current Tester

This is the big brother of the 20 Amp tester. It can be used with Maxi, Standard and Mini blade fuse holders and can measure up to 80amps. It has a hold function as well as a peak current mode. As even the best multimeters only read up to 10amps and most mid to larger bikes will charge at quite a bit more than 10amps this is the perfect tool.

If your bike doesn't have a fused charging output from the regulator/rectifier it is worth fitting an in-line fuse holder, not only for safety, but also as a port to easily test the charging current. We've been trying to think of a way to overcome the difficulty of testing bike charging for years, and we think that this unique solution is sheer genius.

Price: £59.72 (Excluding VAT at 20%)

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Testing Jump Leads

Testing Jump Leads

Pairs of test jump leads in five different colours with insulated crocodile clips on both ends. 500mm long.

We have always found these invaluable when chasing down electrical faults. They can be used as extensions to meter leads. We often plug spare terminals into multi-block connectors and then attached them with the jump leads to the multimeter.

Price: £3.99 (Excluding VAT at 20%)

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Hot Air Gun 1600W 2-Speed 375°C / 500°C

Hot Air Gun 1600W 2-Speed 375°C / 500°C

• Two step switch for temperature and airflow control.
• Gun can also be stood vertically.
• As well as being used for shrinking heatshrink sleeve and heating up bike parts to help free stuck fasteners is suitable for paint stripping, soft soldering, removing sticky labels and defrosting frozen pipes.
• Fitted with 3-pin plug

Price: £21.11 (Excluding VAT at 20%)

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Variable Temperature Hot Air Gun Kit 2000W 50-450°C / 90-600°C

Variable Temperature Hot Air Gun Kit 2000W 50-450°C / 90-600°C

• Two step airflow control switch, with variable temperature range on both levels.
• Gun is designed to stand vertically, allowing use as a safe Bunsen burner alternative.
• As well as being used for shrinking heatshrink sleeve and heating up bike parts to help free stuck fasteners is suitable for paint stripping, soft soldering, removing sticky labels and defrosting frozen pipes.
• Fitted 3-pin plug.
• Supplied with four nozzles and scraper, all in a storage case.

Price: £55.40 (Excluding VAT at 20%)

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25watt Soldering Iron

25watt Soldering Iron

There are very few places you should soldering on a motorcycle, but there are a few places that have to be soldered and handle bar switchs are one such place. This eminently affordable tool is absolutely perefct for the job, having a 4mm tip and just the right amount of heat. The non slip handle makes it nice to use.

Price: £10.21 (Excluding VAT at 20%)

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Soldering Iron Stand with Tip Cleaner

Soldering Iron Stand with Tip Cleaner

We tested this stand for a magazine article and were suitably impressed. We used it with the 25watt iron above to rewire some Kawasaki Z900 handle bar switches. It basically does what it says on the packaging. It should decrease the small of burning flesh when soldering bike switches and keep the tip clean.

Price: £13.29 (Excluding VAT at 20%)

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Magnetic Soldering Stand

Magnetic Soldering Stand

This excellent stand is like having an extra pair of hands that don't shake. We tested this for Classic Motorcycle Mechanics magazine and were so impressed we decided to add it on here and insisted on keeping the tester! Whilst it is clearly designed to be used on a steel bench we actually tested on an ordinarly worktop and found it great.

Price: £35.31 (Excluding VAT at 20%)

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12 Piece Terminal Release Set

12 Piece Terminal Release Set

This is a lovely set and would be our choice were we starting from scratch. It's a very reasonable price for a professional set in a robust case. This will be far more comfortable to use than the wheel keys which give you a sore palm, after a while, if you're stripping a whole loom ! This set should cover the vast majority of multi-block connectors you find on motorcycles from around the world.

We use this set in our workshop and feel it's a great improvement over the wheel type.

NOW BACK IN STOCK!.

Price: £25.20 (Excluding VAT at 20%)

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Terminal & Connector Release Tool Set 5pc

Terminal & Connector Release Tool Set 5pc

A 5 piece terminal and connector tool set designed for Supaseal/Deutsch DT.

Terminal and connector release tool with 4 interchangeable tools.
1 x Terminal locking plate release tool for male Supaseal, Deutsch male and female Ford connectors.
1 x Deutsch terminals locking plate on female connectors.
1 x Deutsch terminals release tool.
1 x Terminal release tool on Ford and Supaseal.

Price: £31.61 (Excluding VAT at 20%)

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Sealey 12 Piece Terminal Release Set

Sealey 12 Piece Terminal Release Set

This is a well made professional terminal release kit which will cover the vast majority terminals you will find in the average motorcycle wiring system.

Price: £45.47 (Excluding VAT at 20%)

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Superseal Connector Terminal Extraction Tool

Superseal Connector Terminal Extraction Tool

This tool is used to remove the terminals from a Superseal connector so that the body can be re-used with new terminals or a wire changed

Price: £13.12 (Excluding VAT at 20%)

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Spark Tester

Spark Tester

This non-contact spark indicator will test for the presence of power on spark plugs, coils and distributors. Simply place the grooved end over the spark plug wire with the engine running and the high intensity bulb will flash indicating spark. Pen type pocket clip for handy use. Saves loads of time trying to work out if you have a duff coil etc.
CE certificated and RoHS compliant.

Price: £9.37 (Excluding VAT at 20%)

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Spark Plug Gapping Tool

Spark Plug Gapping Tool


A very useful American tool that makes it dead easy to set the plug gap. Far easier than mucking about with feeler gauges.

Gauges and Gaps all Types of Spark Plugs from .020" to .100" (.50mm to 2.53mm).

Tapered edge for gauging spark plugs. Specially designed hole with flange adjusts side wire of plug without pressuring centre electrode.

Price: £3.25 (Excluding VAT at 20%)

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Show First 12 Product(s) Online Catalogue > Electrical Tools