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  #1  
Old 25th May 2018
Ironface Ironface is offline
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Unhappy 77 bobber wiring HELP....

Hello I am trying to put my 77 xlh Sportster back on the road. I acquired the bike a year or so ago but recently have been working on it daily trying to bring her back to life.....The guy I got the bike from said he lost intrest in the middle of turning it ino a bobber style bike. The point I am at now is the wiring. It is stripped down to the bare minimum so no switches on the bars no turn signals just your basic Chopper wiring. However when I got the bike all the wires were ran and basically just hanging there not connected to any of the relays or ign. switch. I have found many basic ironhead/chopper diagrams and also have a owners manual but have been unable to find exactly what I'm looking for. I think I'm just over reading it or over-thinking it getting myself confused with the relays.(3, 15amp) 2 of them bridged together. I want to use the original key switch (B,G,ST) a push button start, with a kill switch also. I am new to the xlh form but feel i have finally found the right place for some answers. Any chance anybody could Point me in the right direction for a simple detailed diagram using the original key switch most of the ones I come across have the key switch marked (ign,acc,bat) thx in advance. Any input is greatly appreciated.
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  #2  
Old 25th May 2018
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Hi Ironface, welcome to the Forum!

There's no need for several identical duplicate threads in different sections, so I've merged them.
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  #3  
Old 25th May 2018
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These are just some thoughts that may help you.

There's nothing more complicated than reworking old questionably "modified" old wiring.

#1 Get your camara out and take pictures of everything before you start. this will help with the routing/ colors /previous repairs etc. Use a factory diagram to map what you removed or replaced/bypassed etc.

#2 The relays you speak of, are they not circuit breakers?

#3 The original key switch goes OFF _ IGNITION _ IGNITION w/Lights.(simplified)

#4 Wait till you see whats inside that headlamp assembly! (always a surprise)

#5 If you post a picture of something here on this forum, you'll find an answer, other members will always be helpfull.

#6 There WAS a kill switch up on the bars.... it goes through the headlamp assembly to power your ignition.


Matt

It's not clear from your post if you are stripping down original wiring.
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  #4  
Old 25th May 2018
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Go to napa or autozone or oreillys. Start buying some breakers. I just got everything working on my 1980 custom build all the way to turn signals. I cannot tell you details on how I did it. I'd have to stand next to you.

Napa had my starter relay. But no body had my buss 144 flasher relay. So I jury rigged a generic round universal flasher relay.

Buy a bag of tie wraps. This project starts out at one wire at a time. That is how you eat a elephant. One bite at a time.

Edit:

Quote:
I just got everything working on my 1980 custom build all the way to turn signals.
Scratch that. I fibbed. My front Disc Brake master cylinder brake switch is no good. I cut the wires inside the master cylinder. They are still in there. I just want no shorts. I will solder new wires on a new switch when I find a new switch. Right now. Rear master cylinder brake light switch controls the brake light on rear fender.

2nd Edit: I got a pack of 10 of these coming to finish off my switches. They are missing like they are missing on yours. I emailed the seller twice to make sure 10 came to pack. A loit of ebay sellers try to rip you off and sell you just 1 button cover for the same price.

Quote:
GiGi-DuRu, May 24, 2:08 PM PDT

Yes, will comes 10 pieces.
Thx
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  #5  
Old 28th May 2018
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all the resources are there. just take it slow. one wire at a time like Roky said. heres a good read for basic wiring.
you should have at least a test light in your tool box or upgrade to a multimeter

https://www.streetchopperweb.com/wir...d-vintage-tech
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Old 28th May 2018
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Welcome to the XLForum.

Quote:
I think I'm just over reading it or over-thinking it getting myself confused with the relays.(3, 15amp) 2 of them bridged together.
It's one wire at a time. Get a large piece of cardboard and draw it out.

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Old 28th May 2018
Nate.evans Nate.evans is offline
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^ I used something similar to that to get mine wired. it was a lot easier to just rip everything out and rewire than it was to trouble shoot....
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