Custom Motorcycle Wire Harness Manufacturer

Yihetai is a professional custom Motorcycle wire harness manufacturer in China. We provide customized motorcycle wiring harness, motorcycle cable assembly and OEM wire harness solutions for different power, signal, lighting, ignition, battery, sensor and control system applications. As an experienced wire harness manufacturer, custom cable assembly supplier and direct wiring harness factory, Yihetai manufactures motorcycle wire harnesses according to customer drawings, samples, BOM lists, pinout diagrams or application requirements.

A motorcycle wire harness is the main electrical connection system used inside motorcycles, scooters, electric motorcycles, off-road bikes, ATVs and other two-wheel or small vehicle platforms. It connects the battery, ignition switch, ECU, lights, dashboard, sensors, motor controller, charging system, switches and other electronic components. Based on your design, we can customize wire gauge, cable length, connector type, terminal type, branch layout, protection sleeve, insulation material, waterproof structure, color coding, label and testing requirements.

Our custom Motorcycle wire harness solutions are widely used in motorcycle manufacturing, electric scooters, e-bikes, off-road motorcycles, mobility vehicles, powersports equipment, repair parts, aftermarket upgrades and OEM vehicle electronics. Whether you need a simple motorcycle lighting harness, a battery connection harness, an ECU wiring harness or a complete main wiring harness, Yihetai can provide a stable, cost-effective and production-ready custom wiring solution.

Send us your drawing, sample or technical requirements, and our engineering team will help you evaluate the design and provide a fast quotation

What Is a Motorcycle Wire Harness?

A Motorcycle wire harness is a customized electrical cable and wire assembly used to connect different electrical and electronic systems inside a motorcycle or electric motorcycle. It transmits power, signals and control commands between the battery, controller, engine system, ignition system, sensors, lights, switches, dashboard, charging system and other components.

Compared with a standard cable, a custom motorcycle wire harness is designed to fit the actual motorcycle layout, installation space, wire routing, vibration environment, waterproof requirements and electrical performance needs. It may include multiple branches, different connectors, terminals, protective sleeves, cable ties, labels, heat-shrink tubes, corrugated tubes, waterproof seals and molded parts.

For motorcycle OEMs, aftermarket brands and electronic device suppliers, a properly designed custom motorcycle cable assembly can improve assembly efficiency, reduce wiring errors, protect the circuit from vibration and moisture, and make the final product easier to install and maintain.

Common Custom Motorcycle Wire Harness Types We Manufacture

Common Custom Motorcycle Wire Harness Types We Manufacture
Yihetai manufactures different types of custom Motorcycle wire harness and motorcycle cable assembly products according to customer design requirements.

Common types include:

Complete motorcycle main wiring harness
Motorcycle engine wiring harness
Motorcycle headlight wiring harness
Motorcycle tail light wiring harness
Motorcycle turn signal wire harness
Motorcycle handlebar switch cable assembly
Motorcycle ignition switch harness
Motorcycle battery cable assembly
Motorcycle controller wiring harness
Electric scooter wiring harness

Motorcycle sensor cable assembly
Motorcycle sensor cable assembly
Motorcycle charging port cable assembly
Motorcycle charging port cable assembly
Motorcycle GPS tracker cable assembly
ATV and UTV wiring harness
Off-road motorcycle lighting harness
Motorcycle OBD diagnostic cable assembly
Motorcycle OBD diagnostic cable assembly
Electric motorcycle BMS wire harness

We can also manufacture according to your existing sample, damaged harness, connector part number, pinout definition or installation requirements.

Key Features of Our Motorcycle Wire Harness

Custom motorcycle wire harness designs for gasoline motorcycles, electric motorcycles, scooters, ATVs and UTVs
Custom motorcycle harness designs for power, signal, lighting, ignition and control system connections
Compatible with JST, Molex, TE, Sumitomo, Yazaki, Deutsch and equivalent connector brands
Available in multiple wire gauges, colors, insulation materials and branch configurations
Optional waterproof connectors, heat shrink tubing, corrugated tube and braided sleeve protection
Stable power and signal transmission for motorcycle ECU, sensors, lights and control modules
High-quality cutting, stripping, crimping, soldering, bundling and assembly process control
Suitable for vibration, heat, moisture, dust and outdoor motorcycle working environments
100% electrical testing before shipment to verify continuity, pinout and wiring accuracy

Technical Specifications

Parameter	Available Options
Product Name	Custom Motorcycle Wire Harness / Motorcycle Cable Assembly
Wire Gauge	16AWG–22AWG, customized according to current and signal requirements
Cable Type	Single wire, multi-core cable, shielded cable, battery cable, flat cable, round cable
Connector Type	Waterproof connector, automotive connector, JST, Molex, TE, Deutsch-style connector, open-end wire，custom connector
Terminal Type	Crimp terminal, ring terminal, spade terminal, bullet terminal, quick disconnect terminal
Conductor	Bare copper, tinned copper or customer-specified conductor
Jacket Material	PVC, XLPE, TPE, TPU, silicone, high-temperature material
Protective Sleeve	Corrugated tube, braided sleeve, PVC tube, heat-shrink tube, tape wrapping
Waterproof Design	Rubber seal, waterproof connector, overmolding, heat-shrink sealing
Voltage Rating	12V, 24V, 48V, 60V, 72V or customized for electric motorcycle systems
Temperature Range	Commonly -20°C to +80°C; higher range available with special materials
Cable Length	Customized according to motorcycle frame layout and installation space
Process	Cutting, stripping, crimping, soldering, welding, bundling, overmolding, testing
Testing	Continuity, short/open circuit, wire sequence, pull force, insulation resistance, visual inspection
Production Type	Prototype, small batch, medium-volume and mass production

Applications

Our Motorcycle wire harness solutions are widely used in industrial, consumer and special vehicle applications.

Motorcycle OEM electrical systems
Electric motorcycle controller systems
Scooter and e-bike power systems
ATV and powersports wiring systems
Motorcycle production line assembly
Vehicle testing and diagnostic equipment
Battery pack and BMS connection systems
Motor controller and power distribution modules
Taillight and turn signal cable assemblies
Dashboard and LCD display harnesses

USB charger and accessory power cables
Heated grip and auxiliary light wiring
Custom motorcycle modification harnesses
Delivery motorcycles and fleet vehicles
Off-road motorcycles and dirt bikes
Racing motorcycle data acquisition systems
Outdoor waterproof motorcycle cable assemblies
High-vibration vehicle electrical systems
Custom OEM wire harness integration projects
GPS tracker and alarm system cables

Customization Options

At Yihetai, all Motorcycle wire harness products can be customized according to customer requirements.

Custom Item	Available Options	Notes
Wire Type	Single wire, multi-core cable, shielded cable, battery cable	Selected according to power, signal or control function
Conductor	Bare copper, tinned copper, stranded conductor	Customized for flexibility and conductivity
Wire Gauge	16AWG–22AWG or custom	Based on current load and installation space
Length	Fully customized	Designed according to motorcycle frame and routing path
Color	Black, red, yellow, green, blue, custom colors	Supports color coding for easy assembly
Connector	Waterproof connector, JST, Molex, TE, Deutsch-style, open-end，custom connector	Connector matching support available
Terminal	Ring, spade, bullet, blade, crimp terminal, solder terminal	Selected according to mating component
Jacket Material	PVC, TPE, TPU, silicone, XLPE	Flame retardant or high-temperature options available
Protective Material	Corrugated tube, braided sleeve, heat shrink, tape wrapping	Improves abrasion and vibration resistance
Waterproofing	Rubber seal, molded connector, heat shrink, sealed housing	Suitable for outdoor motorcycle applications
Process	Cutting, stripping, crimping, soldering, bundling, overmolding	OEM and ODM production supported
Labeling	Cable labels, wire markers, barcode, custom logo	Helps installation and traceability
Testing	Continuity, pinout, pull test, insulation resistance, visual inspection	100% electrical testing before shipment

We can manufacture based on customer drawings, samples, BOM lists, wire diagrams, connector specifications or application requirements.

Send us your drawing, sample or specification for a fast quotation

Manufacturing Capability

Yihetai’s wiring harness factory in Xiamen excels in motorcycle wire harness production with automated crimpers, braid machines, and molding lines. We handle full assemblies from pigtails to complete harnesses, supporting high-volume OEM runs for global brands. Our CAD design integrates bike schematics for perfect fit.

From material selection to final assembly and testing, processes adhere to strict controls for performance and reliability. Typical lead time for prototypes is 5-7 days, mass production 3-4 weeks.

Quality Assurance & Control

Full-process quality control at Yihetai uses documented systems tracking every wire from reel to pack, minimizing defects in motorcycle wire harnesses. Engineers perform in-line audits for compliance. Certified to ISO 9001:2015, UL, and IATF 16949, we meet automotive powersports standards.

Specific inspection items include:

Incoming material inspection (wire/connector specs)
Incoming material inspection (wire/connector specs)
Visual and continuity check on 100% units
High-voltage test (1kV)
High-voltage test (1kV)
Salt spray and thermal cycling
Every harness is delivered with guaranteed electrical integrity and consistent quality across batches

Why Choose Yihetai

25+ years of custom wire harness experience serving automotive, industrial, medical, renewable energy, lighting, and consumer electronics industries

Strong engineering support for custom design, connector matching, and wire harness layout based on real application needs

Direct wire harness factory in China offering competitive pricing, stable production, and flexible support for custom projects

Support from prototype to mass production, including sample development, engineering verification, and volume manufacturing

Strict quality control with 100% electrical testing for continuity, wire sequence, short circuit, and custom electrical requirements

Custom wiring solutions for OEM and aftermarket projects, built according to your drawings or samples

Frequently Asked Questions

Can Yihetai manufacture motorcycle wire harnesses according to our sample?

Yes. Yihetai can manufacture custom motorcycle wire harnesses according to your existing sample, drawing, BOM list or application requirements. If you only have a physical sample, we can review the connector types, wire colors, wire gauges, branch lengths and terminal structures, then help create a production-ready solution for sampling and mass production.

What motorcycle wire harness types can you produce?

We can produce complete motorcycle main wiring harnesses, headlight harnesses, tail light harnesses, turn signal harnesses, ignition switch harnesses, battery cable assemblies, controller wiring harnesses, BMS harnesses, sensor cable assemblies, GPS tracker cables and waterproof connector harnesses. We also support electric motorcycle, scooter, ATV, UTV and off-road vehicle wiring applications.

Do you support prototype development before mass production?

Yes. Yihetai supports prototype development for motorcycle wire harness and motorcycle cable assembly projects. Prototype samples allow you to verify connector fit, cable routing, branch length, electrical function, installation convenience and product appearance before mass production. After sample approval, we can prepare mass production with documented process control and 100% electrical testing.

Can you customize motorcycle wire harnesses for electric bikes?

Yes, we specialize in EV motorcycle harnesses with high-voltage (up to 600V) insulation, CAN bus shielding, and BMS integration. Custom options include silicone wires for battery packs, quick-disconnect plugs, and IP67 sealing. Provide your schematic or sample, and our team prototypes in days, ensuring compliance with safety standards and optimal thermal management for extended range.

Can you make waterproof motorcycle cable assemblies?

Yes. We can manufacture waterproof motorcycle cable assemblies using sealed connectors, rubber seals, heat-shrink tubes, molded connector structures, corrugated tubes and protective sleeves. Waterproof design is especially important for motorcycles because the harness may be exposed to rain, vibration, dust, oil, mud and frequent temperature changes during real road use.