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  #1  
Old 4 Weeks Ago
Attaxic Attaxic is offline
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Sportster/Buell Model: Sportster XLH 1000
Sportster/Buell Year: 1983
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Cool 1983 Ironhead- Final wiring

Hello.. I am Actually trying to finish my bike this week and be riding by the weekend. I posted a year ago when I was tearing her down. She all back together now, I just got busy and had to set her aside for a few months. 1983 Ironhead XLS 1000. I need to wire her up and make sure she runs right. I have new coil, plugs, top end rebuilt, battery, compufire timing points and blue rotor for the dual fire. I cannot time the bike until it can run. This is my first time doing ANY of this. I'm taking my time..I'm not one to make a "post per problem" so I will post a few things that have halted me... Also I am using this 77' sportster diagram for reference. I have a few minor differences. Other than that, I can manage the rest. I just wanted to be sure about the wiring. I also need a start button, I might have mentioned that somewhere in here. I was planning on a custom fab handlebar button, or a hidden one. Suggestions?

Pictures: https://imgur.com/a/5IZNgc9

Headlamp
Off amazon it was some LED Bluetooth Lamp that I wanted to be cool with but lost the key controller to adjust color and I have no clue what this plug is. I am not electrically savvy.

Starter Relay..? (black cube)
I believe this is my starter relay. It has 4 cables coming out of it. +,-, and what are the others? What do the symbols on the relay mean? I know the power needs to hit a 30 amp fuse and then to my start button. (I still need one lol)

Compufire Dual Fire
I waited a month for this stupid blue rotor. ordered the first from ebay and got a black one with a blue dot Ordered the correct one from Dennis Kirk instead. 2 days later I had it. Awesome. In the pictures, my bike is in 4th gear, TDC and the advance unit is in. I was following the PDF file I found online for instructions, but the only two ways my rotor fits doesn't seem the way in the instructions. Am I on the right track?

Starter
So I had a total of 3 plugs on my starter.. The positive is on, I am sure its correct. Its on the left next to the hose. There is an identical on on top. Where should it lead?
The gold fin under..Is that a VOES Switch or something? I had a plug in there before when the bike ran, no clue what it ran to. It was a green wire. Only other on I saw that it could potentially lead to, is the starter relay. 3rd pic.

Edit: I came to the garage to tinker and realized my Cycle Electric Generator needs to be wired as well. The instructions say only connect positive terminal of you do not have a generator light. Although it needs to power after the ignition switch. I’m not sure how to do this. I understand it, but I lack the experience. Suggested a 20amp fuse sit between that and the battery. How many things should I be connecting to my batt?

I genuinely appreciate all the help I can get, in advance. Please yell at me and make sure I did everything right. I did mention it's my first time doing a motorcycle rebuild. Although I made sure to take pictures, videos, etc. I could've missed SOMETHING. I had the Clymers manual in my pocket the whole time. I referred to it so much. Cheers guys, thank you.

Last edited by Attaxic; 4 Weeks Ago at 15:56.. Reason: No pics
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  #2  
Old 4 Weeks Ago
IXL2Relax's Avatar
IXL2Relax IXL2Relax is offline
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First up - I see no pictures...


Here's the Sportsterpedia section about your Starter/Solenoid:
http://sportsterpedia.com/doku.php/t...k:evo:engctl02
(It's in the EVO section, but your '83 IH uses the same)

Battery connects to one side of the High Current posts & the actual Starter Motor connects to the output side of the High Current posts. The small blade connection IS from the output side of the Starter Relay (and is typically a GREEN wire).





The Starter Relay has 4 functional connections. Two are for the primary side which is a coil to activate the relay. The other two are the contacts which will flow power to the Starter Solenoid.

So, on the primary (coil) side, you need one connection to ground (85). The other side of the primary (coil) side of the relay (86) is a wire from your Start Button to bring power (when pressed) to activate the coil in the Starter Relay.

On the Contacts side of the relay (87), you have one wire coming from the Accessory Fuse. The other Contact (30) is the output power to the Starter Solenoid (typically a GREEN wire).


Post up your pictures for additional help.

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Last edited by IXL2Relax; 4 Weeks Ago at 08:51..
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  #3  
Old 4 Weeks Ago
Attaxic Attaxic is offline
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Quote:
Originally Posted by IXL2Relax View Post
First up - I see no pictures...


Here's the Sportsterpedia section about your Starter/Solenoid:
http://sportsterpedia.com/doku.php/t...k:evo:engctl02
(It's in the EVO section, but your '83 IH uses the same)

Battery connects to one side of the High Current posts & the actual Starter Motor connects to the output side of the High Current posts. The small blade connection IS from the output side of the Starter Relay (and is typically a GREEN wire).





The Starter Relay has 4 functional connections. Two are for the primary side which is a coil to activate the relay. The other two are the contacts which will flow power to the Starter Solenoid.

So, on the primary (coil) side, you need one connection to ground (85). The other side of the primary (coil) side of the relay (86) is a wire from your Start Button to bring power (when pressed) to activate the coil in the Starter Relay.

On the Contacts side of the relay (87), you have one wire coming from the Accessory Fuse. The other Contact (30) is the output power to the Starter Solenoid (typically a GREEN wire).


Post up your pictures for additional help.

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Pictures posted... Iím not sure if what I have matches correctly. I donít understand why I have two terminals on my starter solenoid. Staring at it for the past 20 minutes hasnít helped. Previously I had a BADLANDS ignition module or ignition unit, itís called. Idk if I need one at this point. Iím getting close to just taking it to a shop because I donít want the head ache. Itís just pissing me off that this is one thing I canít understand.
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Old 4 Weeks Ago
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Well - I did describe that - The Solenoid has TWO LARGE TERMINAL which are the posts for the High Current Contacts. One is wired directly to the battery, the other is wired directly to the Starter Motor. When the Solenoid is activated by the smaller GREEN wire, the internal High Current Contact will flow power from the battery to the Starter Motor.

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You need to post the pictures here in a message. Upload first to any photo hosting site [except PhotoBucket!] then copy the IMG code from there to your post here.

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The solenoid on the starter has a bolt terminal for the jumbo wire straight to Battery + and a blade terminal for the green wire from the start relay. The start relay has two control wires and two switched wires. Your wiring diagram will tell you how those wires need to be connected, but the operation is pretty simple: handlebar switch -> start relay -> starter solenoid -> starter motor. That arrangement isolates your tiny handlebar switches from the huge currents necessary to operate the starter solenoid and motor.
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Quote:
Originally Posted by Attaxic View Post
Pictures posted... Iím not sure if what I have matches correctly. I donít understand why I have two terminals on my starter solenoid. Staring at it for the past 20 minutes hasnít helped. Previously I had a BADLANDS ignition module or ignition unit, itís called. Idk if I need one at this point. Iím getting close to just taking it to a shop because I donít want the head ache. Itís just pissing me off that this is one thing I canít understand.
Iíve made notation on your starter pic to help clarify.

The switch and relay wiring is already explained well by IXL2Relax and BigMek.

Are you sure that 'Badlands" thing wasn't a brake/turn module ?

Also, you should really need get your images here in your message as already mentioned.

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Your starter relay actually has a diagram on the top showing how it should be wired. Pins 85 and 86 are for the two control wires - one goes to your Start button and the other to ground. It doesn't matter which goes where.

Pins 87, 87a, and 30 are the switched wires. Notice that the diagram shows 30 and 87a connected with a diagonal line - this means they are connected when the relay is off. Don't wire your starter to 87a or it'll run whenever the key is on! Instead, the starter should be connected across 30 and 87. Green wire to the starter solenoid should go to 30, the other wire (your big yellow one I think) goes to the ACC breaker or another positive fused connection. Note, don't do this one backwards or 87a will be energized all the time. Not a good idea to have an unconnected positive terminal hanging in the breeze - potential short circuits and such.

Your headlamp is a standard H4 plug. One terminal goes to Ground, one is for low beam, and one for high beam. You can get the matching female socket at auto parts places, though regular female blade terminals will work in a pinch.

As far as battery connections, only three wires should connect directly to your battery: the big ground cable, the big positive cable to the starter, and the wire going to your main fuse or circuit breaker. All other fuses or breakers should branch off the main. By this, I mean if you look at your Main fuse/breaker, one end should go to the battery and the other to your other stuff (probably the key switch is your first stop). Only the battery should be connected to one side of the breaker/fuse, otherwise you've bypassed it.

On the wiring diagram for my 82, the Main breaker has one end connected to the battery and the other connected to the generator and key switch. I'd suggest the same connection when wiring your generator.

The secondary fuses/breakers should also be rated for less than the main - the idea is if your headlight shorts, you want your lights to go out but the engine to keep running. Easier to diagnose where the problem is and less likely to leave you stranded.

Edit: You have multiple terminals on your starter solenoid because it's also a relay, just a heck of a lot bigger. The green wire going in is one of the control wires; the other control wire is the body of the starter connected to ground. The switched wires are the big one from the battery and the stubby one going to the starter motor.
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Pictures: https://imgur.com/a/5IZNgc9

I hoped that worked. Someone found them. I’m sorry guys My day turned real shitty, real quick I haven’t been online. I appreciate the help. In the garage currently...

I’m taking the rest of the night to read through this. I don’t know how to properly tag someone, but Mr IXL2Relax and BigMek thank you for explaining it to me like I’m 5 (no sarcasm) I’m understanding it. I’m just way overthinking it. This bike haunts me with nothing but electrical and charging issues. So I’m just a nut about it sorry. I'm the kind of learner, that if I don't know everything about everything and why it works/how, I'll blow up. Also, I'd be lying if I wasn't excited.

What was throwing me off is that I didn’t know what plug style to use, fltdh31 in his picture shows it as the starter relay connection and I couldn’t figure it out. I don’t want to just wrap a cable there and throw tape on it right? Also what gage should most of this be?? I have a brand new spool of 14 gauge 10 color. I was told to use 14 or 16 on lights, coils etc. Battery 8 or 10.. I'm reusing cables.

Last edited by Attaxic; 4 Weeks Ago at 06:02.. Reason: Words
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Attaxic Attaxic is offline
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Quote:
Originally Posted by flthd31 View Post
I’ve made notation on your starter pic to help clarify.

The switch and relay wiring is already explained well by IXL2Relax and BigMek.

Are you sure that 'Badlands" thing wasn't a brake/turn module ?

Also, you should really need get your images here in your message as already mentioned.

Thank you for your explanation sir. You are right badlands was my brake and turn module. I do not have turn signals, but a single brake light and headlamp. I will eventually add them. Pics should work on my other comment. But it looks like you guys can see them already?
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