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  #1  
Old 2nd September 2009
BLIGHT BLIGHT is offline
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Default My COLOR Wiring Diagram '77 XLCR

Hey dudes... I'm well along on my 'gentle' restoration of the '77 XLCR. It seems like I've been working on this a lot bike a lot longer than I have, but I only got my hands on it August 18th! It won't be a 'concours' bike, 'cause I just want it to look good enough so I can actually ride it and be proud of the way it looks!

Anyway... I'll post some update pics in a day or two. I've been doing a lot of sanding, cleaning, painting, wiring, sweating... etc.

Wiring? Yeah, the bike had been monkeyed with. Some of the wires were replaced with wires of different colors (thanks!) and the starter relay was shot... I replaced all the incorrect stuff, and just to make it a little clearer (for me) I decided to draw a color wiring diagram on AutoCad.

It just helps me a lot to see things in COLOR. I traced two different wiring diagrams and added my own touches to simplify and clarify things. This is NOT H-D's artwork, so don't fret about copyright infringements... this is MY original artwork, and I'm contributing it here for the XL Forum users to use. I used this actual diagram to check out and rewire my bike, and everything works! No guarantees though! If you see any errors please let me know! Use at your own risk, bla bla bla.




Cheers!
BLIGHT
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  #2  
Old 2nd September 2009
BLIGHT BLIGHT is offline
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Oh, by the way... PM me if any of you XLCR owners want a PDF image of the diagrams. They are much clearer than the JPG's I posted here in case you want to save them in your computer for future reference.

Cheers,
BLIGHT
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  #3  
Old 2nd September 2009
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FourCams FourCams is offline
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Very nice!
Is the jumper on the ignition switch stock? or did you put it there to combine the lights and ignition?
(I'm wondering if that was hd's solution to mandatory daytime running lights)
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  #4  
Old 2nd September 2009
BLIGHT BLIGHT is offline
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Quote:
Originally Posted by FourCams View Post
Very nice!
Is the jumper on the ignition switch stock? or did you put it there to combine the lights and ignition?
(I'm wondering if that was hd's solution to manditory daytime running lights)
Hey 4Cams... that jumper is right off the '77 XLCR H-D shop manual wiring diagram. I think the full-time 'headlight law' came into effect around '77. (Actually, I left this jumper off my bike) I like to have the choice on whether the headlight is on or not. I actually like the fact that H-D put a 3 position ignition switch on these bikes to permit separate headlight/ignition control.

Cheers,
BLIGHT
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  #5  
Old 2nd September 2009
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FourCams FourCams is offline
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Quote:
Originally Posted by BLIGHT View Post
Hey 4Cams... that jumper is right off the '77 XLCR H-D shop manual wiring diagram. I think the full-time 'headlight law' came into effect around '77. (Actually, I left this jumper off my bike) I like to have the choice on whether the headlight is on or not. I actually like the fact that H-D put a 3 position ignition switch on these bikes to permit separate headlight/ignition control.

Cheers,
BLIGHT
Thanks man. I wish the stock diagrams were color coded.
You put a lot of work into that. Once again; nice job.
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Old 2nd September 2009
BLIGHT BLIGHT is offline
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Quote:
Originally Posted by FourCams View Post
Thanks man. I wish the stock diagrams were color coded. You put a lot of work into that. Once again; nice job.
Thanks, I might be persuaded to do another popular diagram in COLOR if there is a big demand. I just got a Clymer manual that covers XL Sportsters from 1959 to 1985... that's only 26 years, but there are 37 separate wiring diagrams in the back!!!

The diagrams are all somewhat similar in function, BUT there are many, many variations on the wiring routing, switches, and wire-loom color designations.

Cheers,
BLIGHT
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Old 2nd September 2009
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Quote:
Originally Posted by BLIGHT View Post
Oh, by the way... PM me if any of you XLCR owners want a PDF image of the diagrams...
Another way is to open a SkyDrive account, upload the files there, and post a link in your message. Same idea as using PhotoBucket for pics and YouTube for vids.
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Interesting as I am re-wiring my bike at the moment. I have a question for you electrical types. On the turn signal circuit (orange wire) there is a diode illustrated but I cannot find a part number for this, any idea where I get one? Thanks.
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Old 2nd September 2009
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Harley has them (at least the one near me) that's where I bought mine.
It was missing when I bought it. Part# 74563-65 is for the diode it's self. That should be enough to get a dealership to find one. They sell it as a unit with wires and connectors soldered onto it already and it even had the old wire protectant sleeve on each side! The diode's are hard to read but I think that they say 100h on them.
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Old 2nd September 2009
BLIGHT BLIGHT is offline
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Hey guys, here's the SkyDrive (thanks Mick!) links to the PDF files I already had a Windows Live account, but didn't know they give you 25gb of online storage....that's pretty nice! (You don't need an account to access them, since I set them up as 'Public' files)

https://cid-cc712b00a0b9df64.skydriv...0Sheet%201.pdf
https://cid-cc712b00a0b9df64.skydriv...0Sheet%202.pdf

Click the "Download" button and download each PDF. For some reason, the server has decided to add an underscore at the beginning and end of the file name. After you download the files, just right click them in Windows Explorer and select Rename.... you can delete these pesky underscores and launch the pdf's directly!

Oh, and I believe the diode referred to above is indeed in the wiring harness (inline like a fuse) If all else fails, you should be able to get one at Radio Shack, just make sure it can handle the amps, prolly around 5A or so, and be sure to solder it in the right direction or it will cause problems.

Cheers!
BLIGHT
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