Ironhead 1980 IRONHEAD Wanting to rewire

[ironowner]

i'm fixin' to rewire my 1980 ironhead too. got a complete harness and hand controls from J&P.

[Gone]

I'm going to be re-wiring the handlebar harness on my 1980 as well. Saving up the $$ for the control assemblies w/ harness. I'd be interested in hearing how you both fare on yours. I would also add that a good multimeter or at least a continuity tester will be valuable in tracing wires from endpoint to endpoint.

[hdsince73]

I rewired most of my 80 sporty as i changed the headlight and housing ( same thing just one in better condition) because alot of the okd wires were in bad shape, now I've read alot about of the guys not liking the clymer manuals, and there is alot of just generic info in it, but it also has wiring diagrams in the back of most of the sporty models up to 85, and the diagram for my 80 was spot on and very easy to read.

[Gone]

I got a full color 11 X 17 laminated diagram for the 1980 from http://www.ebay.com/itm/Harley-Sport...item3350e9cdc3. All the colors are accurate to the factory manual. This diagram makes the manual easier to understand. To me it was worth the $16.00 plus shipping. I'll look at the Clymer as well. I never just go by one source if I have others to look at and compare.

[CaptCaveman]

I've got an 81 and the wiring harness is pretty easy as long as you haven't had a previous owner "fixing" problems.

[ironowner]

this dude bypassed the start relay so he wouldn't have to cough up $20. with big yellow and red wires and wire nuts!
i just rode it till the wiring went hinky, but now i'm getting ready to rewire.

[hcrashster]

For the least hassle, i would recommend the J&P wiring kits. [Handle bar kit is not included] What you get is a loom with cutouts for ignition, horn, etc.
All wiring is pre stripped on the ends and you crimp or solder the included pins. This is great as the harness is cut to length for a stock bike, and even better if your doing a custom wire job , because all you have to do is lengthen or cut where needed.
The wires also follow HD color coding for the appropriate year.

When I did my 78 hardtail, I used the 75 schematic. It's a little cleaner than the 78, and simple is good. Total time to completely wire was around 4 hours. 4 LAZY hours.

One hint. Schematics. Most office supply stores like Staples or Office Max won't blow you up an expanded copy. It's a copyright rule they adhere to. If you bring in a single page there is no problem. Believe me, you want that expanded schematic.

[ironowner]

already got the harness and hand controls sections from J&P. did you crimp or soldier?

[doodah man]

solder is the best way, but since i suck at it, i used crimp connectors when i rewired mine a few years ago. haven't had any problems out of it yet.

[hcrashster]

Solder and shrink tubing. I hate surprises.

Aside from the crimpers and cutters and case of Bud, you may want to pick up a pin removal tool J&P part # 381-087. I purchased one at Pep Boys and it is a big time saver when the right pin goes into the wrong holding block position.