Powersports

Wiring Adventures — From Snow to Street

Snowmobiles, Side by Sides, and Motorcycles are just a few fun-loving applications where you will find our harnesses and assemblies. Kato Cable’s engineering team can be counted on to deliver a few “tricks of the trade” in this exciting market segment.

Powersports Wire Harness - How it Works

What it is:

A powersports wire harness is a collection of wires, cables, and connectors designed to efficiently distribute electrical power in powersports equipment, such as ATVs, motorcycles, or snowmobiles.

Function:

These harnesses connect key components like the engine, battery, and lighting systems, ensuring reliable performance and safety. Built to endure rough conditions, vibration, and exposure to the elements, the wire harness helps streamline installation, minimize electrical issues, and maintain the overall functionality of power sports vehicles.

Benefits

Enhanced Durability:

Powersports vehicles such as motorcycles, ATVs, snowmobiles, and jet skis operate in extreme conditions, requiring wire harnesses to be built to handle moisture, dirt, high speeds, and temperature extremes.

Easy Maintenance and Upgrades:

With a well-organized wire harness, diagnosing electrical issues and performing upgrades becomes easier, reducing downtime during racing or recreational use.

Vibration Resistance:

Like agricultural machinery, powersports vehicles experience constant vibrations. Powersports wire harnesses are designed to stay intact despite these harsh conditions.

Compact and Lightweight:

Powersports vehicles need to maintain a light and compact design. Wire harnesses are designed to save space and reduce weight, which is crucial for performance.

Reliability and Safety:

Powersports vehicles require reliable electrical systems for safe operation, especially in high-speed or off-road conditions. Wire harnesses ensure that electrical connections remain secure and functional during intense use.

Protection Against Environmental Factors:

These wire harnesses are made from materials that resist water, dust, and chemical exposure, ensuring the vehicle operates in a variety of weather and terrain conditions.

Examples of Applications

Motorcycles:

Wire harnesses in motorcycles manage the electrical connections between the engine, lights, ignition systems, and controls.

ATVs (All-Terrain Vehicles):

ATVs use wire harnesses to connect various systems such as engine control, fuel injection, lighting, and safety features like kill switches and sensors.

Go-Karts:

In racing or recreational go-karts, wire harnesses connect components like the engine, ignition systems, safety features (e.g., kill switch), and lighting.

Snowmobiles:

Snowmobiles require wire harnesses to connect electrical systems for ignition, headlights, heated grips, and temperature control in cold conditions.

Jet Skis and Watercraft:

Jet skis use wire harnesses to manage power for the engine, GPS systems, lights, and other electronic systems while withstanding exposure to water and salt.

Electric and Hybrid Power Sports Vehicles:

Electric motorcycles, e-bikes, and hybrid power sports vehicles rely on wire harnesses to manage the electric motor, battery, charging system, and control units.

Process Control & Engineering Control Services

Process Control

Precision and consistency are at the heart of every custom cable solution. Our Process Control strategies ensure each assembly meets exact specifications, from initial concept to final production. Through rigorous quality checks, standardized procedures, and real-time monitoring, we optimize efficiency while maintaining the highest level of reliability.

Engineering Control

From concept to completion, Engineering Control ensures every design is optimized for functionality, manufacturability, and long-term performance. Our expert team evaluates form, fit, and function, applies industry best practices and testing protocols, and leverages innovative solutions to deliver high-quality and cost-effective cable and harness assemblies.

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Our Products are Proudly Made in the USA

The Kato Cable Advantage

The Kato Cable Advantage is a holistic approach to looking at the value that you bring to your customers, employees and community. Our customers relate directly to our responsiveness and engineering value, to the investments that we have made into efficiencies and automation, and to the key metrics of industry leading Quality and On Time Delivery. Our employees relate to a sense of inclusion, an appreciation and value to feedback, and the philosophy of making improvements every day. Our community relates to our growth and volunteerism and leadership that we strive for in our region. Together these attributes and values truly deliver the Kato Cable Advantage!

Quality & Reliability

Delivering precision-engineered wire harnesses, cable assemblies, and electro-mechanical assemblies that meet the highest industry standards.

Innovation

Continuously improving processes and technologies to provide cutting-edge solutions for diverse industries.

Customer Commitment

Building strong partnerships through collaboration, responsiveness, and tailored solutions.

Your Industry, Our Vision

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