Knucklehead Motorcycle Build Part 10: Wiring, Oil Lines, Seat, Start

The reassembly of our Knucklehead motorcycle is nearing completion. Kevin is ready to rewire this bike. Being that the Knucklehead motorcycle has a magneto and a generator, wiring is basic and minimal. The motorcycle does not need a battery or battery cables because of the existence of the magneto. Because the bike is designed for kick start only, there is no wiring needed for a starter, a starter relay, or start switches. The Cycle Electric generator is the best assembly available. The unit that Kevin installed has a regulator rectifier built into the assembly.

Existing wiring was labeled when Kevin stripped the Knucklehead motorcycle. Although Kevin does not need the aid of labels, it is still a good working habit. Even if you have a strong grasp of the motorcycle’s electrical system, the labeling can be an aid for a quicker reassembly.

Kevin stresses the importance of soldiering all electrical connections. Solder should also be used on all crimped connections. It is of utmost importance that a quality heat shrink is installed over all connections. Wiring needs to be routed safely so that it can not be cut or pinched. It should not be able to be pulled taunt or loosely rub on another component. Wiring also needs to be routed so that it can not be in contact with exhaust pipes or any other source of extreme heat.

Kevin completes all wiring for the headlight, rear brake switch, taillight, generator, and for the magnito. He then mounts the fuel tank. It is secured with appropriate hardware at its front and rear mounting points. The fuel delivery hose is attached to the carburetor. The petcock is tested for proper function and the fuel system is inspected for leaks. Lastly, he mounts the solo seat and fills the oil tank with 60 weight oil.

The Knucklehead is ready to be rolled off the lift where it can be kickstarted. Watch as he brings this classic Knucklehead Motorcycle to life! Once started, Kevin can adjust the carburetor, set final oil level and make any other necessary adjustments.

Watch the 10-Part Knucklehead Build Again