Ironhead 1985 XLH Completely rewire or don't fix if not broke?

[Ironinthe520]

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.)?

[cxf]

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

[ryder rick]

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.

[randy3934]

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.

[mycle1000]

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!

[Hopper]

If you have to make your own new wiring loom, there are a couple of simplified wiring diagrams in teh Tech Stickys Index.

[russzx6]

http://xlforum.net/forums/s...d.php?t=411626

[Ironinthe520]

Originally Posted by russzx6

http://xlforum.net/forums/s...d.php?t=411626

Thanks bro!

[iNSaNeSHaNe]

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.

[81Fe]

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.