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28th May 2013
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Biker
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Join Date: May 2013
Posts: 15 Sportster/Buell Model: XLH 1000 Sportster/Buell Year: 1985
Reputation: 10

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1985 XLH Completely rewire or don't fix if not broke?
Debating on whether to get brave and completely rewire my 85 or is it smarter thing to "don't fix if it's not broke"?
I can get away with the wiring as is but based on the age, dry rot in Arizona and upon inspecting I can see a lot of contact points that are getting loose, fraying, cracking, and that's just what I can see as I am sure there is more if I start getting in there. But I think once I start getting in there it will disturb the wiring enough I will probably have to address it (i.e. it will probably crack more and come undone by just digging in there).
It's a bear of a job and heard many a horror stories. But my thinking is just suck it up and take care of it all at once instead of playing this electrical whack a mole and constantly be messing with it. And sooner or later I am confident it will leave me on the side of the road stranded somewhere remote when the wrong wire rattles loose or breaks off.
What's worse is it looks like this thing has been wired over at least a couple times so there are random wires, some cut off, everywhere. The previous owner never addressed it and only rewired on a piece meal basis. This makes me want to fix it right but also compounds the problem once I get in there I may not be able to tell what goes well.
Which brings me to the next issue of getting a reliable diagram. I don't think I want to start down the road until I get one. My "no service manual" says its included but it doesn't have one. I talk to guys selling harnesses (by the way is ~$180 a good price for a harness?) and they don't have one but tell me its in the manual. The dealer points me to the manual but the same one I have that doesn't have it. I have googled images including had drawn diagrams that look right but I have no idea.
Another option would have the dealer do it, would be done right but estimating it would be about 1k that I would rather put elsewhere. Does 1k sound about right for dealer service?
Any one do this? About how many hours? How/where did you get a diagram? How did it work after rewiring and did you regret or would you do the same again? Anything else you can do that makes sense while your rewiring (otehr know problems to fix, etc.)?
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28th May 2013
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Chief Know It All
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Join Date: Jul 2012
Location: Peoples Republic of Ma.
Posts: 416 Sportster/Buell Model: xlh Sportster/Buell Year: 1985 Other Motorcycle Model: cb450 Other Motorcycle Year: 1974
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I also have an '85 and have a copy of the fsm. Mine has all the wiring diagrams in the back of the book.
Dan
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28th May 2013
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Senior Master Custom Bike Builder
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Join Date: Jun 2008
Location: Cornelius, OR
Posts: 9,510
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A complete rewire is using a nuke bomb to kill a rabbit.
Fix what is wrong with it. It's not hard to do and a complete rewire may not be necessary.
Remember don't work on the electrics for a carb problem or vice versey.
__________________
Ryder Rick "I know right from wrong, but sometimes, wrong feels right"
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28th May 2013
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Master Custom Bike Builder
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Join Date: Dec 2011
Location: under a roof
Posts: 3,009 Sportster/Buell Model: xlh 1000 69 79 xlch Sportster/Buell Year: 1977 Sportster/Buell Model #2: 80 FXE 82FLH 83FXR Other Motorcycle Model: 78FLH 79xlch 96xl 79xlh
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The 79 wiring harness I'm re doing released the mysterious smoke contained within the plastic shielding melting everything between the right handlebar control to the battery.
__________________
I'm not a complete idiot, some parts are missing. not enough room to list all my harleys.
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28th May 2013
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Senior Chief Know It All 1st Class
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Join Date: Jun 2010
Location: mason city
Posts: 1,126 Sportster/Buell Model: xlx61 Sportster/Buell Year: 85
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find a buddy with the fsm that has the wiring diagrams and get a legitimate copy. in your case i would recommend the re-wire. it can be a pain, but not sitting out in the middle of nowhere could be dangerous.
if you're having trouble getting a copy of your diagram, pm me.
note: this is not an offer for either of us to do anything illegal!
__________________
85 xlx61 (with a million miles and a million mods)
05 xl1200r (bought used)
00 vstar650 (for the wife)
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28th May 2013
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Senior Master Custom Bike Builder
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Join Date: Dec 2007
Location: Australia
Posts: 9,370 Sportster/Buell Model: XLCH 1000 Sportster/Buell Year: 1977 Sportster/Buell Model #2: 75 motor in Norton frame. Other Motorcycle Model: 42WLA 45, Harton, Narley Other Motorcycle Year: 1942
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If you have to make your own new wiring loom, there are a couple of simplified wiring diagrams in teh Tech Stickys Index.
__________________
In theory there is no difference between theory and practice. In practice there is.
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28th May 2013
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Master Custom Bike Builder
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Join Date: Jan 2008
Location: Brisbane, Australia
Posts: 3,072 Sportster/Buell Model: 1000cc Ironhead Sportster Sportster/Buell Year: 1977 Other Motorcycle Model: 96 KDX200 Dirt Bike
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__________________
24 beers in a carton. ...24 hours in a day . .. coincidence??
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31st May 2013
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Biker
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Join Date: May 2013
Posts: 15 Sportster/Buell Model: XLH 1000 Sportster/Buell Year: 1985
Reputation: 10

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Quote:
Originally Posted by russzx6
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Thanks bro!
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31st May 2013
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XL FORUM TEAM MEMBER
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Join Date: Apr 2012
Posts: 2,492 Sportster/Buell Model: XLS roadster Sportster/Buell Year: 1985
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I know your pain on the wiring the bike back up. if you're going to do it just bite the bullet and be done. I would start by getting newer slimmer water tight connectors for behind the headlight where it seems all the problems seem to be stored. The same for the connectors under the seat.
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IF IT NEVER BREAKS THEN YOU DON'T RIDE IT
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31st May 2013
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Senior Chief Master Mechanic 1st Class
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Join Date: Jun 2007
Posts: 1,275 Sportster/Buell Model: 1969 XLCH Sportster/Buell Year: 1969 Sportster/Buell Model #2: XLH 900 Sportster/Buell Year #2: 1965 Other Motorcycle Model: XLH 1000 75th Anniversary Other Motorcycle Year: 1978
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If you are going to re-wire, DO NOT replicate the factory harness. Its MUCH more complicated than it needs to be.
Get a copy of one of the simplified harnesses... they literally have half the wires and work just as well. Less wires = less mess and easier troubleshooting down the road.
__________________
Fear no Evo.
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