Ironhead 1980 IRONHEAD Wanting to rewire

[JonJuan76]

Hey there,

I'm looking for any advice on rewiring my 1980 Ironhead. I have a new headlamp and mounting bracket to mount on the lower tree. I opened up the original headlamp and it looks like a rats nest :/ I have new controls to mount on bars and wanted to do away with all of the switches and add my own toggles and buttons. Can I just do away with the wiring harness and reroute my own wiring? Can I do any permanent damage to the bike if I go in as a newbie and start snipping away? Any advice would rule. Thanks!

-Jon

[joey81iron85]

Run your own 14 gauge wire fuses or breakers

[hogmania]

if you do it right and get all the wires where they are suppose to be it will do no harm to the bike, but just don't go in and start snipping away, make sure you know where all the wire are suppose to end up at and make good connections.

[ultra...good]

No offense, but this is one of those things that if you have to ask, you probably should not try it. Maybe over the winter when the bike would be sitting anyway and it won't piss you off. But if you do not know enough about electrical that you have to ask, it will probably take a while.
That being said, it is something that can definetely be done. Time, patience, a few feet of wire and the right tools, and it can be better then a factory harness.

[IronMick]

One option is to buy a complete new wire harness with all original correct wire colors etc. J&P Cycles is one source. I have not installed one myself but others here have reported easy install.

Before you begin take lots of time to study the wire diagrams and understand each circuit. Here is some info from the Stickys; pay attention especially to thye word description in the first post; understand it completely before you start snipping ...

IronHead Wire Diagrams Etc
http://xlforum.net/forums/s...d.php?t=441447

[FearlessFrisbee]

And take photos of the connections before disconnecting/cutting, just in case you get called away for a while and have to come back a week or two later.

[ryder rick]

Originally Posted by JonJuan76

Hey there,

if I go in as a newbie and start snipping away? Any advice would rule. Thanks!

-Jon

Stop right there! This will be the beginning of your troubles.

Don't cut on your OEM harness, save it and the headlight.

Make or buy a new harness if your gonna.

[JonJuan76]

Gentlemen, thank you for your input I really do appreciate it. I was using the idea of snipping away loosely :P I'm familiar with wiring when it comes to a boat, but motorcycles are a whole new beast. I've got the fever and I've already begun tearing it down to build it back up to what I want. I will remove the harness without snipping and headlight as well. Thanks again for the advice!

-Jon

[waiteitei]

easy riders book tips and tricks vol 1 has nice simple wiring diagrams

make up your own simple loom its not rocket science

[antsap]

Hey JonJuan76,

Here are some suggestions/tips I can offer up. I've stripped down and wired two bikes now from the ground up, and have been very happy with the results. One was my ironhead which was a custom mess from the PO (no harness, just a bad rats nest home wire job), the other was my brothers shovel which was built from parts with no previous wiring on it.

1) If you can make good connections, then you can do this. I'm a fan of the solder/shrink tube method, though many people also use crimping successfully. Whatever method you will use, make sure you have good tools for the job, and practice ahead of time on junk wire/connections off the bike unless you are already comfy and good to go in that area.

2) What I think is the most important part ... I definitely advise planning, planning, planning. Study your bike in its current form. If its the stock harness right now, then the FSM and its circuit schematics will be a great aid to you. Understand all of the wiring and connections in their current form, and I agree with what was said above ... lots of before pictures can only help.

3) Once you fully understand what's there and how it works, decide what you want to do different. Draw out your plans (those easy rider pictorials are great aids). Have all of your supplies and parts in house and ready to go. When you step up to your bike to wire it, it should almost be mindlessly following your plans on paper and just implementing it on the bike ... all the thinking/testing/planning should be done ahead of time.

Test your circuits on a bench/breadboard if you are unsure about anything. This can be done by using mock up wires/alligator clips, using switches, and replacing components with simple lamps. Plan how you will run your wires, what kind of sheathing you'll use, and where you'll ziptie or attach them.

If you do this, you can end up with a beautiful custom job with only the wires you need routed neatly around your bike. You'll always know exactly what every wire on your bike is there for in the future. Keep your drawings and plans for reference! They will now replace what's in your FSM for your bike.

Good luck with the project if you jump in! I think you'll find it very rewarding in the end.