Retrofitting Smart Technology into Classic Motorcycles: A Guide for Mechanics

John Melendez
Jun 27
7 min read

Mechanic Installing smart phone into classic motorcycle

Getting Smart with a Vintage Bike

Classic motorcycles embody a timeless appeal, blending mechanical simplicity with raw riding experience. However, modern riders increasingly seek the convenience and safety of smart technology, such as GPS navigation, real-time diagnostics, and smartphone connectivity. Retrofitting these features into older bikes allows mechanics to preserve the charm of vintage motorcycles while enhancing functionality. This comprehensive guide explores the process of integrating smart tech into classic motorcycles, offering practical steps, tools, and considerations for mechanics aiming to meet this growing demand.

Why Retrofitting Smart Tech Matters

The rise of connected vehicles has transformed the automotive industry, and motorcycles are no exception. Riders of classic bikes, from 1960s Triumphs to 1980s Harleys, want to maintain their machine’s retro aesthetic while enjoying modern conveniences. Smart technology addresses key needs: navigation for exploring new routes, diagnostics for monitoring bike health, and smartphone integration for hands-free communication. By retrofitting these features, mechanics can cater to a niche market of enthusiasts who value both heritage and innovation. The global connected motorcycle market, valued at $98.2 million in 2023, is projected to reach $326.9 million by 2032, reflecting strong demand for such upgrades.

Understanding the Core Technologies

Before starting a retrofit, mechanics must familiarize themselves with the key technologies involved. These include:

GPS Navigation: Modern GPS systems provide turn-by-turn directions, live traffic updates, and route planning. Compact GPS modules can be discreetly installed on classic bikes without compromising their look.
Diagnostics Systems: Onboard diagnostic (OBD) tools monitor engine performance, tire pressure, and other metrics, alerting riders to potential issues via smartphone apps or dedicated displays.
Smartphone Connectivity: Bluetooth-enabled systems allow riders to sync their phones with the bike for calls, music, and app integration. This often requires a control unit and handlebar-mounted interfaces.
Internet of Things (IoT): IoT devices enable real-time data sharing between the bike, rider, and cloud-based platforms, supporting features like predictive maintenance and theft tracking.

These technologies, once exclusive to new motorcycles, are now available as aftermarket kits, making them accessible for retrofitting.

Planning the Retrofit Process

Retrofitting smart tech requires careful planning to ensure compatibility with a classic bike’s mechanical and electrical systems. Mechanics should follow these steps:

Assess the Motorcycle: Evaluate the bike’s electrical system, wiring, and available space for new components. Older bikes often have 6-volt systems, which may need upgrading to 12-volt to support modern electronics.
Define Rider Needs: Consult with the owner to determine desired features, such as GPS, diagnostics, or full smartphone integration. This helps prioritize components and budget.
Select Compatible Components: Choose aftermarket kits designed for motorcycles, ensuring they are compact and durable for open-road conditions. Brands like Sena, Beeline, and Bosch offer retrofit-friendly solutions.
Plan Wiring and Mounting: Map out where to install modules, displays, and wiring to maintain the bike’s aesthetics. Use weather-resistant connectors to protect against vibration and moisture.
Test Electrical Load: Verify that the bike’s alternator and battery can handle additional power demands. Upgrading to a modern regulator or high-capacity battery may be necessary.

By addressing these factors upfront, mechanics can avoid complications during installation.

Installing GPS Navigation Systems

GPS navigation is a popular retrofit feature, offering riders reliable route guidance without relying on bulky maps or phone mounts. Here’s how to integrate GPS into a classic motorcycle:

Choose a GPS Unit: Compact devices like the Beeline Moto or TomTom Rider are ideal for retrofitting. These units are waterproof, vibration-resistant, and designed for motorcycle use.
Mounting the Device: Install the GPS on the handlebars or near the instrument cluster using a secure, quick-release mount. Ensure the display is visible without obstructing the rider’s view.
Power Supply: Connect the GPS to the bike’s electrical system via a switched power source, such as the ignition circuit, to prevent battery drain. Use a fuse for safety.
Wiring Integration: Route wires neatly along the frame, securing them with zip ties or conduit to avoid exposure. Conceal connections under the tank or side panels for a clean look.
Testing and Calibration: Power on the GPS, pair it with the rider’s smartphone (if applicable), and test navigation functions. Calibrate the unit to ensure accurate route tracking.

For a seamless aesthetic, mechanics can integrate the GPS display into the existing instrument cluster, though this requires custom fabrication skills.

Adding Real-Time Diagnostics

Diagnostics systems enhance a classic bike’s reliability by monitoring critical systems in real time. These tools can detect issues like low tire pressure, overheating, or engine faults, notifying riders via a smartphone app or dedicated display. To install diagnostics:

Select a Diagnostic Tool: Aftermarket OBD systems, such as those from Dynojet or HealTech, are compatible with older motorcycles. These kits include sensors and a control unit.
Install Sensors: Attach sensors to key components, such as the engine, tires, or fuel system. For example, tire pressure monitoring systems (TPMS) require valve-stem sensors.
Connect the Control Unit: Mount the control unit under the seat or in a weatherproof enclosure. Wire it to the bike’s electrical system and sensors, ensuring secure connections.
Integrate with Smartphone: Pair the control unit with a Bluetooth-enabled app, allowing riders to view diagnostics data. Some systems also support cloud-based alerts for mechanics.
Test Functionality: Run the bike through various conditions (idle, cruising, high RPM) to verify sensor accuracy. Check app notifications for real-time updates.

Diagnostics retrofits are particularly valuable for long-distance riders, as they reduce the risk of breakdowns and simplify troubleshooting.

Enabling Smartphone Connectivity

Smartphone connectivity transforms the riding experience by allowing hands-free communication, music streaming, and app access. Bluetooth systems are the backbone of this feature. Here’s how to implement it:

Choose a Bluetooth System: Sena and Cardo offer motorcycle-specific Bluetooth headsets and control units. These systems integrate with helmets and handlebar controls.
Install the Control Unit: Mount the Bluetooth module in a protected location, such as under the seat. Connect it to the bike’s power supply and pair it with the rider’s smartphone.
Add Handlebar Controls: Install a handlebar-mounted controller for volume, call answering, and music playback. Ensure it’s ergonomic and blends with the bike’s design.
Integrate with Helmet: Fit the rider’s helmet with Bluetooth speakers and a microphone, typically included in headset kits. Test audio quality at various speeds.
Verify Connectivity: Confirm that the system supports stable connections for calls, music, and navigation prompts. Test range and interference resistance.

For riders seeking advanced features, mechanics can integrate IoT-enabled systems that sync with apps for real-time tracking, geo-fencing, or remote engine kill, enhancing security.

Overcoming Common Challenges

Retrofitting smart tech into classic motorcycles presents unique challenges, particularly due to their age and mechanical simplicity. Mechanics should be prepared to address:

Electrical Compatibility: Older bikes may lack the power capacity for modern electronics. Upgrading to a 12-volt system or adding a secondary battery can resolve this.
Space Constraints: Classic bikes have limited room for new components. Use compact modules and creative mounting solutions, such as custom brackets or integrated panels.
Aesthetic Preservation: Riders value their bike’s original look. Conceal wires and components wherever possible, and choose devices with retro-inspired designs.
Durability: Motorcycles face vibration, weather, and dust. Select components rated for harsh conditions, and seal connections with dielectric grease.
Mechanic Expertise: Smart tech requires knowledge of electronics and software. Mechanics unfamiliar with these systems should invest in training or partner with specialists.

By anticipating these issues, mechanics can deliver high-quality retrofits that satisfy clients.

Tools and Equipment Needed

Successful retrofitting requires specialized tools and equipment. Mechanics should have:

Multimeter: For testing electrical circuits and diagnosing power issues.
Wire Crimping Tools: For creating secure, weatherproof connections.
Soldering Kit: For permanent wiring joints in high-vibration areas.
Diagnostic Scanner: For interfacing with OBD systems and verifying sensor data.
Mounting Hardware: Including brackets, zip ties, and adhesive pads for securing components.
Software Tools: Apps or PC software for configuring GPS, diagnostics, and Bluetooth systems.

Investing in quality tools ensures efficient installations and reliable results.

Cost Considerations for Mechanics and Riders

Retrofitting smart tech involves costs for parts, labor, and potential bike modifications. Typical expenses include:

GPS Systems: $100–$300 for compact units like Beeline Moto.
Diagnostics Kits: $150–$500, depending on sensor complexity.
Bluetooth Systems: $200–$400 for Sena or Cardo kits with helmet integration.
Electrical Upgrades: $50–$200 for regulators, batteries, or wiring harnesses.
Labor: $200–$1,000, based on retrofit complexity and mechanic rates.

Riders should weigh these costs against the benefits of enhanced safety, convenience, and resale value. Mechanics can offer tiered packages (e.g., basic GPS vs. full connectivity) to accommodate different budgets.

Maintaining Retrofits for Long-Term Performance

Once installed, smart tech requires regular maintenance to ensure reliability. Mechanics should advise riders to:

Check Connections: Inspect wiring and connectors for wear, especially after long rides or wet conditions.
Update Software: Install firmware updates for GPS, diagnostics, and Bluetooth systems to maintain compatibility and performance.
Test Sensors: Periodically verify that diagnostics sensors are accurate, using a scanner or app.
Protect Components: Clean and reseal modules to prevent water or dust ingress.
Monitor Battery Health: Ensure the bike’s battery can support added electrical loads, replacing it if necessary.

Offering maintenance packages can build long-term client relationships and ensure retrofit longevity.

The Future of Smart Retrofits

The demand for smart retrofits is poised to grow as connected motorcycle technology advances. Innovations like vehicle-to-vehicle (V2V) communication, radar-based safety systems, and AI-driven diagnostics are already appearing in new bikes and will likely become available as aftermarket solutions. Mechanics who master retrofitting now can position themselves as leaders in this evolving market. Additionally, collaborations between manufacturers, tech companies, and telecom providers are driving down costs and improving retrofit kit accessibility, making these upgrades more viable for classic bike owners.

Conclusion

Retrofitting smart technology into classic motorcycles blends the best of old and new, offering riders modern functionality without sacrificing vintage style. By integrating GPS, diagnostics, and smartphone connectivity, mechanics can enhance safety, convenience, and enjoyment for their clients. The process requires careful planning, technical expertise, and attention to aesthetics, but the results are well worth the effort. As the connected motorcycle market expands, mechanics who embrace this trend will find ample opportunities to serve a passionate and growing community of riders.

+++

Look Here for Updates from

Altus Scooter & Motorcycle Parts™

Since 1997, Altus Scooter & Motorcycle Parts™ has been the driving force behind cutting-edge fuel delivery systems for scooters, motorcycles, jet skis, and small boat outboard engines. Our products include a full line of high-quality replacement fuel pump assemblies, plain fuel pumps, ECUs and fuel filters.

Return regularly to Altus Scooter & Motorcycle Parts™ for more updates!

Go see Altus Scooter & Motorcycle Parts™ Now!

Altus offers international product shipping for all products.

Altus also offers full replacement service for scooter and motorcycle console display LCDs - available only at Altus’s Taiwan Taichung 豐原區 factory. LCD replacement service takes only about 15 minutes.

About Altus:

Since 1997, Altus Scooter & Motorcycle Parts™ has been the driving force behind cutting-edge fuel delivery systems for scooters, motorcycles, jet skis, and small boat outboard engines.Our products include a full line of high-quality replacement fuel pump assemblies, plain fuel pumps, ECUS and fuel filters.