The Sportster and Buell Motorcycle Forum - The XLFORUM®
 

Go Back   The Sportster and Buell Motorcycle Forum - The XLFORUM® > SPORTSTER MOTORCYCLE FORUM > Sportster Motorcycle Era Specific and Model Specific > Ironhead Sportster Motorcycle Talk (1957-1985)
XLF Blogs XLF Arcade XLF Disclaimer/Privacy Statement/Terms Of Use

Ironhead Sportster Motorcycle Talk (1957-1985) For all those that wanna talk about Ironhead Sportster Motorcycles

Active Threads
0 su carb question
Last Post: Serious Blac
Posted On: 16 Minutes Ago
Replies: 34
Views: 879
0 In tank fuel filter on 2004 xlc
Last Post: Folkie
Posted On: 18 Minutes Ago
Replies: 3
Views: 50
0 Bike not started for 5 years
Last Post: connorneil13
Posted On: 53 Minutes Ago
Replies: 2
Views: 37
0 Another clutch Question
Last Post: Folkie
Posted On: 56 Minutes Ago
Replies: 8
Views: 133
0 tire changer
Last Post: Eric Von Zipper
Posted On: 1 Hour Ago
Replies: 4
Views: 362
0 never mind
Last Post: Eric Von Zipper
Posted On: 1 Hour Ago
Replies: 142
Views: 11,342
0 The Dealer Is So Out of Touch - Shitty Experience
Last Post: Eric Von Zipper
Posted On: 1 Hour Ago
Replies: 27
Views: 1,719
2 Your daily tunes...
Last Post: Eric Von Zipper
Posted On: 1 Hour Ago
Replies: 13
Views: 564
0 Knowing weather you can ride
Last Post: Eric Von Zipper
Posted On: 1 Hour Ago
Replies: 20
Views: 647
0 Too HOT to ride?
Last Post: Eric Von Zipper
Posted On: 1 Hour Ago
Replies: 338
Views: 26,672
0 Noise from Primary. Bike with extremely low miles
Last Post: Tomcatt
Posted On: 5 Hours Ago
Replies: 11
Views: 362
0 Grenade plate fix with XR1200 parts...
Last Post: PetesPonies
Posted On: 5 Hours Ago
Replies: 49
Views: 6,217
0 Show your favorite pic of your bike. just one
Last Post: glbsportster
Posted On: 6 Hours Ago
Replies: 4,762
Views: 1,833,161
0 Rear Master Cylinder Rebuild or New?
Last Post: PetesPonies
Posted On: 6 Hours Ago
Replies: 14
Views: 2,213
0 Hottie of the day, no nudity.
Last Post: trainman
Posted On: 6 Hours Ago
Replies: 16,847
Views: 1,670,261
0 Frame bracket
Last Post: Bwf347
Posted On: 7 Hours Ago
Replies: 13
Views: 560
0 im sure its been done to death trans fluid
Last Post: John Harper
Posted On: 7 Hours Ago
Replies: 11
Views: 284
0 Happy Birthday Mrs. Folkie.
Last Post: Ireeman
Posted On: 7 Hours Ago
Replies: 14
Views: 263
0 Changed gas cap and experienced problems
Last Post: TUCCI
Posted On: 7 Hours Ago
Replies: 5
Views: 103
1 Three Harley-Davidson Sportsters That Don’t Care What You Think
Last Post: Ireeman
Posted On: 7 Hours Ago
Replies: 5
Views: 296
0 Spoke hub bearing assembly
Last Post: Jonv
Posted On: 7 Hours Ago
Replies: 7
Views: 223
0 Official XL Forum Random Image Thread (NO NUDITY!)
Last Post: Ireeman
Posted On: 8 Hours Ago
Replies: 46,378
Views: 7,373,194
0 my recent ebay purchase
Last Post: Moon Wolf
Posted On: 8 Hours Ago
Replies: 29
Views: 1,756
0 Stock wires for coil relocation
Last Post: Bikeaholic
Posted On: 8 Hours Ago
Replies: 1
Views: 89
0 Best Tuner options?
Last Post: Bikeaholic
Posted On: 8 Hours Ago
Replies: 8
Views: 212
0 top end noise
Last Post: Toejam503
Posted On: 9 Hours Ago
Replies: 7
Views: 236
0 LED headlight caused problems
Last Post: Bluto
Posted On: 10 Hours Ago
Replies: 1
Views: 59
0 Broke my drive belt (Stay With The Belt Or Do A Chain Conversion?)
Last Post: jkinkade
Posted On: 10 Hours Ago
Replies: 89
Views: 23,759
0 Barnet clutch spring plate
Last Post: dayypete
Posted On: 10 Hours Ago
Replies: 5
Views: 97
0 Hi from Barcelona!
Last Post: shanneba
Posted On: 12 Hours Ago
Replies: 7
Views: 88
More...
Members Birthdays
Sponsored Links
Reply
 
Share Thread Tools Display Modes
  #11  
Old 10th January 2020
IXL2Relax's Avatar
IXL2Relax IXL2Relax is offline
XL FORUM TEAM MEMBER
 
Join Date: Feb 2013
Location: Let Freedom Ring in PA
Posts: 7,155
Sportster/Buell Model: Sportster 883►1200
Sportster/Buell Year: 1994
IXL2Relax has disabled reputation
Default

Monumental Effort - Kudos to you!!!


IXL _______ >>>> My Motorcycle Chronicles Are Here <<<<
For FREE Sportster Tech Info from the XLForum:
Explore The Sportsterpedia - The Best Kept Secret on the XLForum!
__________________
### The ride is more enjoyable to nowhere in particular! ###
Reply With Quote
  #12  
Old 12th January 2020
Hippysmack's Avatar
Hippysmack Hippysmack is offline
XL FORUM TEAM MEMBER
 
Join Date: Jul 2014
Posts: 5,504
Sportster/Buell Model: Xl1250S
Sportster/Buell Year: 98
Other Motorcycle Model: Kawasaki Vulcan 500
Other Motorcycle Year: 95
Reputation: 5057098
Hippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond repute
Default

Thanks.
It's good to bounce ideas off each other sometimes.
Your opinions were helpful and saved lots of time.

1979 Sportster XLH/XLS:


1979 Sportster XLCH:


1980 Sportster XLH/XLS:


1981 Sportster XLH/XLS:


1982 Sportster XLH/XLS:
__________________
Reference the XLFORUM'S Sportsterpedia for additional technical information & advice

In Search of Fuel, Sunshine and a Steady Idle.

Last edited by Hippysmack; 14th January 2020 at 08:09..
Reply With Quote
  #13  
Old 13th January 2020
jsandidge's Avatar
jsandidge jsandidge is offline
XL FORUM TEAM MEMBER
 
Join Date: Oct 2019
Posts: 99
Sportster/Buell Model: xlh
Sportster/Buell Year: 1981
Other Motorcycle Model: Suzuki GS850GL
Other Motorcycle Year: 1982
Reputation: 11741
jsandidge is a glorious beacon of lightjsandidge is a glorious beacon of lightjsandidge is a glorious beacon of lightjsandidge is a glorious beacon of lightjsandidge is a glorious beacon of lightjsandidge is a glorious beacon of lightjsandidge is a glorious beacon of lightjsandidge is a glorious beacon of lightjsandidge is a glorious beacon of lightjsandidge is a glorious beacon of lightjsandidge is a glorious beacon of light
Default

I love it. Thanks so much.
Reply With Quote
  #14  
Old 13th January 2020
60Gunner's Avatar
60Gunner 60Gunner is offline
Chief of Security
 
Join Date: Sep 2017
Location: United States
Posts: 2,771
Sportster/Buell Model: 1200/1250C
Sportster/Buell Year: 05
Reputation: 2836782
60Gunner has a reputation beyond repute60Gunner has a reputation beyond repute60Gunner has a reputation beyond repute60Gunner has a reputation beyond repute60Gunner has a reputation beyond repute60Gunner has a reputation beyond repute60Gunner has a reputation beyond repute60Gunner has a reputation beyond repute60Gunner has a reputation beyond repute60Gunner has a reputation beyond repute60Gunner has a reputation beyond repute
Default

Nice job! Easier to read than the factory ones.
__________________
05 1200/1250C/Hammer 570 Cams/E1 clutch kit +15% spring
TC88A Gunner's V00D00 map/DCPR7E/Taylor Pro 8mm
S&S Premium Lifters/KhromeWerks HP Plus 3" slip ons
HSR42 25 pilot 2 turns Y8 needle jet 97 needle 2nd groove 170 main
Dragtron II AC K&N filter/VR1 20W50/Spectro 85wt Primary Oil
Max torque 87.7@4400rpm/max hp 86.8@5600rpm




Need help with your Sportster? Check out the Sportsterpedia!
Reply With Quote
  #15  
Old 13th January 2020
Hippysmack's Avatar
Hippysmack Hippysmack is offline
XL FORUM TEAM MEMBER
 
Join Date: Jul 2014
Posts: 5,504
Sportster/Buell Model: Xl1250S
Sportster/Buell Year: 98
Other Motorcycle Model: Kawasaki Vulcan 500
Other Motorcycle Year: 95
Reputation: 5057098
Hippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond repute
Default

Thanks, I hope someone gets some use from them.
The Moco color coded some of the lines to make the ignition, charging and starter circuits stand out from the rest of the tiny lines and lettering on 79-85 drawings.
Had to squint a lot.....
Reply With Quote
  #16  
Old 13th January 2020
Iron John Iron John is offline
XL FORUM TEAM MEMBER
 
Join Date: Apr 2017
Location: Birmingham, AL
Posts: 84
Sportster/Buell Model: XLH1000
Sportster/Buell Year: 1973
Reputation: 75684
Iron John has much to be proud ofIron John has much to be proud ofIron John has much to be proud ofIron John has much to be proud ofIron John has much to be proud ofIron John has much to be proud ofIron John has much to be proud ofIron John has much to be proud ofIron John has much to be proud ofIron John has much to be proud ofIron John has much to be proud of
Default

Thanks so much for these. I'm preparing to rewire my 73 XLH and this will come in handy.
__________________
'73 XLH
Reply With Quote
  #17  
Old 14th January 2020
Hippysmack's Avatar
Hippysmack Hippysmack is offline
XL FORUM TEAM MEMBER
 
Join Date: Jul 2014
Posts: 5,504
Sportster/Buell Model: Xl1250S
Sportster/Buell Year: 98
Other Motorcycle Model: Kawasaki Vulcan 500
Other Motorcycle Year: 95
Reputation: 5057098
Hippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond repute
Default

You can probably print these big enough to sit down and redraw or highlight your proposed wiring editions.
It helps to plan things out sometimes.
Just be sure to reference your manual also.

1983-E1984 Sportster XLH:


1983-E1984 Sportster XLS:


1983-E1984 Sportster XLX:


1983-1984 Sportster XR-1000:

Last edited by Hippysmack; 15th January 2020 at 20:24..
Reply With Quote
  #18  
Old 16th January 2020
Hippysmack's Avatar
Hippysmack Hippysmack is offline
XL FORUM TEAM MEMBER
 
Join Date: Jul 2014
Posts: 5,504
Sportster/Buell Model: Xl1250S
Sportster/Buell Year: 98
Other Motorcycle Model: Kawasaki Vulcan 500
Other Motorcycle Year: 95
Reputation: 5057098
Hippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond repute
Default

L1984-1985 Sportster XLH:


L1984-1985 Sportster XLS:


L1984-1985 Sportster XLX:
Reply With Quote
Sponsored Links
  #19  
Old 2 Weeks Ago
Hippysmack's Avatar
Hippysmack Hippysmack is offline
XL FORUM TEAM MEMBER
 
Join Date: Jul 2014
Posts: 5,504
Sportster/Buell Model: Xl1250S
Sportster/Buell Year: 98
Other Motorcycle Model: Kawasaki Vulcan 500
Other Motorcycle Year: 95
Reputation: 5057098
Hippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond repute
Default Discrepencies in the factory wiring diagrams.

I've noticed some irregularities in some of the factory drawings and I'll list them here in this post.


73-74 wiring diagrams:

I've been trying to track down the "Fuse Wire" that shows up in the -78 FSM diagram on the XLCH drawing.
It is noted on the XLCH drawing but is not noted on the XL drawing.
However, the connector for it is present on both drawings in their installed positions.

The Doctor71 brought my attention to Service Bulletin #659. I added more info to that in the service bulletin page in the Sportsterpedia:
http://www.sportsterpedia.com/doku.p...artsplus-01bL:
A 2“ long 20 gauge wire (70105-73) was added in the wiring circuit on FL,FLH, FX, FXE, XL and XLCH models to act as a fuse wire.
The fuse wire protects wiring between the battery and the lighting, ignition and accessory circuit breakers.
Because the motorcycle wiring is heavier gauge, this fuse will burn out first in case of a short or overload and open the circuit.
Caution: Do not use heavier gauge wire for a fuse wire. In place of this HD part, any 20 gauge braided wire will work also.
Before replacing the fuse wire, check for short circuits in the wiring and ignition switch to determine the cause of burnout.

When troubleshooting the electrical system for loss of power, check this wire for burnout at the following locations;
FL/FLH: The fuse wire is connected to the starter relay terminal (#1) and to the connector in the conduit leading to the battery positive terminal.
FXE: The fuse wire is connected to the starter solenoid (long) terminal and to the connector in the conduit leading to the starter relay tan wire terminal.
FX: The fuse wire is connected to the battery positive terminal and to the tan wire connector in the conduit. The tan wire terminates at the "B" terminal on the ignition switch.
XL: The fuse wire is connected to the regulator "BAT" terminal and to the red wire connector in the conduit leading to the starter solenoid (long) terminal.
XLCH: The fuse wire is connected to the battery positive terminal and to the red wire connector in conduit leading to the regulator "B+" terminal.


Attached below is the service bulletin #659 (3 pages).

Attachment 20626

Attachment 20627

Attachment 20628

Here is the link to the fuse wire pic at NOSParts:
https://nosparts.nl/cgi-bin/dbsql/db...umber=70105-73



The fuse wire doesn't show up in the -74 FSM but does in the -78 FSM.
Neither the fuse wire nor the connector (#35 in the -78 FSM) for it show up in the parts catalogs or supplement catalogs thru -78B.
But the wire itself can be seen at NOSParts.com.
The pic shows the wire skimmed on each end for connectors though.
Looking closer at the wiring diagram, connector #35 also shows up as a splice tap on the green wire coming off the turn signal flasher.
So it appears they simply cut the red wire and used a splice tap on it inside the conduit to install the fuse wire inline at the factory.

As to 'connector #35', the FSM wiring diagrams do not distinguish between what type connector they refer to.
It seems they are not refering to a specific part or type but rather denoting a wire splice of sorts.
#35 is designated for the fuse wire, TS flasher, ignition and turn signal lamp wires (some years) etc.
But, going beyond the manual, it has to be small enough to fit inside the wire jacket or conduit without hindering the other wires beside it, especially with the vibration.
Since it doesn't seem to show up in the catalogs specifically for the fuse wire, it could be as simple as a small folded piece of steel.

The TS flasher connector appears to be an permanent 3 way tap as should be the fuse wire with a permanent 2 way.
By permanent, I mean a crimp connector instead of a 2 piece socket.

The connectors in the parts books look to range from crimp types to plastic housing punch connectors and simply listed as 'connector'.

If the fuse wire connector could fit in the jacket (like the 75 wire does) then it can't take up much space, as a socket connector would, I'd think .

Due to positioning, it would need to be a structural sound connection.


The TSB does not require dealers to retrofit this change to previous models.
And that splice tap is probably what they are referring to in the service bulletin.
I've added a reference to the service bulletin on the "L73 Fuse Wire" on the 73-74 drawings.
And also cropped out these drawings for added emphasis on the existance of the fuse wire.





edit:
The handlebar ground is listed in the -76A parts catalog being for L73-up XLH/XLCH.
It also is listed in the -74 supplement catalog for L73 models.
Yet the wiring diagrams in the -78 FSM show only show it starting in 1977.
So I'll add that to the drawings also.


75-76 wiring diagrams:
The splice tap for the fuse wire is present in both these drawings but the wording "Fuse Wire" has been omitted on both drawings.
So the fuse wire was also present on 75-76 models.
On the 75-76 XL drawing, the connector is on the wire between the starter solenoid and the starter relay and appears to connect to the relay.
(red wire is denoted at the solenoid)
I've also shown the fuse wire on the main wiring diagram and added a reference to the service bulletin.
And also cropped out these drawings for added emphasis on the existance of the fuse wire.






77 wiring diagrams:
The fuse wire was replaced with a main circuit breaker in 1977.
Connector #35 is still shown in the wiring key for the splice tap at the turn signal flasher.
Tthe 30 amp (main) breaker (74599-77) doesn't show up in the 77 supplement catalog although it is in the 78 FSM drawing as being installed on 77 models.
It doesn't show up for parts order until the 78 supplement (October 1977 ( 78 year model season)).
And even then it shows up for 78 to * - XLH, XLCH (not 77).
-78B shows it for 78 models.
So E77 models should have come with the fuse wire.
The only reference I have thus far to a main circuit breaker being installed on a 77 Sportster at all is the -78 FSM wiring diagram.





78 wiring diagrams:
The solid state regulator came out in 78 and the hookup for it changed to a plugged set of wiring.
Yet the 75 fuse wire was being sold for 78 models also.
So there may be some E78s that came with the fuse wire and older regulator.


Last edited by Hippysmack; 2 Weeks Ago at 05:17..
Reply With Quote
  #20  
Old 2 Weeks Ago
Serious Blac's Avatar
Serious Blac Serious Blac is online now
Chief Harley Engineer
 
Join Date: Aug 2017
Posts: 502
Sportster/Buell Model: xls roadster
Sportster/Buell Year: 1982
Other Motorcycle Model: Oh yeah!
Reputation: 108620
Serious Blac has much to be proud ofSerious Blac has much to be proud ofSerious Blac has much to be proud ofSerious Blac has much to be proud ofSerious Blac has much to be proud ofSerious Blac has much to be proud ofSerious Blac has much to be proud ofSerious Blac has much to be proud ofSerious Blac has much to be proud ofSerious Blac has much to be proud ofSerious Blac has much to be proud of
Default

Wonder how many people knew about the handlebar earth!
__________________
The Devil is in the detail.
Reply With Quote
Reply

Bookmarks


Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
 
Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off

Forum Jump



Sponsored Links
All times are GMT +1. The time now is 10:54.


Powered by vBulletin® Version 3.8.11
Copyright ©2000 - 2020, vBulletin Solutions Inc.
XL Forum® - Linson Media LLC