The Sportster and Buell Motorcycle Forum Motor Stage  

Go Back   The Sportster and Buell Motorcycle Forum > SPORTSTER MOTORCYCLE ZONE > Sportster Motorcycle Era Specific and Model Specific > Ironhead Sportster Motorcycle Talk (1957-1985)
XLF Gallery XLF Classifieds XLF Blogs XLF Shout XLF Arcade XLF Disclaimer/Privacy Statement/Terms Of Use

Ironhead Sportster Motorcycle Talk (1957-1985) For all those that wanna talk about Ironhead Sportster Motorcycles

Members Birthdays
seajay, Hugh Betcha (68), jimhd89 (65), JayFL459 (65), Big Al (58), dakota_dj (57), 10walt (55), kiltbill (55), timsvalk (54), horsewriter (49), Benetampa (37)
CV Performance
Licks Holiday
Energy One Clutches
Fix My Hog

Lickscycles
Reply
 
Share Thread Tools Display Modes
  #1  
Old 14th June 2012
dsk1000 dsk1000 is offline
Biker
 
Join Date: Aug 2009
Posts: 39
Sportster/Buell Model: XLCH
Sportster/Buell Year: 1975
Reputation: 109
dsk1000 is on a distinguished roaddsk1000 is on a distinguished road
Default THE Wiring Harness Routing Thread

Hey guys,

Wire routing has been a nebulous topic here. I've read all the threads about wiring harnesses I could find. In a number of them, some folks talk about running their main wiring harness through the backbone of the frame using the stock holes, entering at the front right side of the frame and through the rear near the circuit breakers.

I'd love to hear from someone who's actually done this or seen it done. Specifically, I'd like to know how they run the key and horn drops if the harness is inside the frame, with no holes mid-frame where they need to be.

Also, it's not clear to me which method was stock. I would lean toward assuming running outside the frame was stock. Anyone know or have documentation of this? My year is 1975 but I'm sure info relevant to all years would be helpful to the group.

The pragmatist in me says running the wiring through the frame could make it that much harded to fix any problems that arise and subject it to chafing from vibration. Maybe that's overly cautious. I'd love your thoughts on that too.

It could make a valuable sticky if we could sort the wire routing info out once and for all and would be willing to work up some diagrams/graphics if we can reach a credible consensus.

Thanks, Doug
Reply With Quote
  #2  
Old 14th June 2012
piniongear's Avatar
piniongear piniongear is offline
Master Custom Bike Builder
 
Join Date: Dec 2009
Posts: 3,046
Sportster/Buell Model: XLCH
Sportster/Buell Year: 1971
Other Motorcycle Model: FXDL
Other Motorcycle Year: 2003
Reputation: 25604
piniongear is a name known to allpiniongear is a name known to allpiniongear is a name known to allpiniongear is a name known to allpiniongear is a name known to allpiniongear is a name known to allpiniongear is a name known to allpiniongear is a name known to allpiniongear is a name known to allpiniongear is a name known to allpiniongear is a name known to all
Default

You can expect to receive several different answers to your question, and all may be correct.
What I am saying is that it depends on what year model you have.
1972 and earlier have the hole in the front right side of the frame member and an open tube at the other end of the member.

The 1973 and later frame was changed and the casting under the seat was replaced by a welded steel strap.
What this strap did was seal off the end of the top tube and seal off both of the vertical frame tubes where the supports for the old solo seat were located.
If you have the later model frame you may find the hole still in the right side of the frame top tube but the other end should not have an open tube showing.
In this case you will have to run your wiring outside the frame unless you want to drill/cut a 1 inch hole in the end of the top tube (under the seat).

Here is a pic of my wiring going into the top right hole on my 1971 XLCH..................................



You can see the shrink wiring bundle entering the hole on the right side of the pic.
The wiring is run inside the top tube and exits at the rear under the seat.

After exit of the frame tube, these wires connect to a small panel board (4 or 5 connections) and from the panel board the wires are run to the horn and other places that are required on an XLCH and XLH.

These models are different, with the largest difference being the CH is kick start only while the XLH is electric (or electric and kick).
1972 and earlier came from the factory with this wire routing.
pg
__________________
Rolling down the highway on two wheels since 1957...
Owner Red/White 1971 XLCH & 2003 FXDL-Silver over Black
Reply With Quote
  #3  
Old 14th June 2012
dsk1000 dsk1000 is offline
Biker
 
Join Date: Aug 2009
Posts: 39
Sportster/Buell Model: XLCH
Sportster/Buell Year: 1975
Reputation: 109
dsk1000 is on a distinguished roaddsk1000 is on a distinguished road
Default

Thank you. My 75 does have a hole in the rear of the backbone. I ran a wire just to see if I could do it. There does seem to be a "hump" somewhere inside the backbone, but I got over it by running a fish wire from the rear.

I suppose then that running everything back to the terminal area would require me to rebuld the wiring harness, or at least the wires related to the horn and key, and then extend them back forward to where they need to be.
Reply With Quote
  #4  
Old 14th June 2012
piniongear's Avatar
piniongear piniongear is offline
Master Custom Bike Builder
 
Join Date: Dec 2009
Posts: 3,046
Sportster/Buell Model: XLCH
Sportster/Buell Year: 1971
Other Motorcycle Model: FXDL
Other Motorcycle Year: 2003
Reputation: 25604
piniongear is a name known to allpiniongear is a name known to allpiniongear is a name known to allpiniongear is a name known to allpiniongear is a name known to allpiniongear is a name known to allpiniongear is a name known to allpiniongear is a name known to allpiniongear is a name known to allpiniongear is a name known to allpiniongear is a name known to all
Default

Quote:
Originally Posted by dsk1000 View Post
Thank you. My 75 does have a hole in the rear of the backbone. I ran a wire just to see if I could do it. There does seem to be a "hump" somewhere inside the backbone, but I got over it by running a fish wire from the rear.

I suppose then that running everything back to the terminal area would require me to rebuld the wiring harness, or at least the wires related to the horn and key, and then extend them back forward to where they need to be.
Correct.
That is one of the problems using a purchased wiring harness rather than building your own harness. There are plus and minus issues to both ways.

As I see it, your horn and key wires terminate at the horn & switch location using this harness.
This works fine for routing the wire outside the frame tube.

If you want to route inside the frame tube you will have to connect on to the horn and switch wire(s) and extend them back to the control panel, then run them forward to the horn and switch.
If you choose to do this I suggest you solder the connections and then cover those connections with shrink tube. That way you will never have a grounding problem and can forget it.

But you may be better off to use the harness as it was designed for (outside the frame tube). Most of it will be hidden by the fuel tank anyway.
One of those things where you have to make your choice.
pg
Reply With Quote
  #5  
Old 14th June 2012
72 Ironhead XLH's Avatar
72 Ironhead XLH 72 Ironhead XLH is offline
Master Custom Bike Builder
 
Join Date: May 2005
Location: NJ
Posts: 3,168
Sportster/Buell Model: XLH
Sportster/Buell Year: 72
72 Ironhead XLH has disabled reputation
Default

http://stores.ebay.com/FURRYLETTERS
sleeving for wiring , different size and color
Reply With Quote
Know Thy Hog

  #6  
Old 14th June 2012
72 Ironhead XLH's Avatar
72 Ironhead XLH 72 Ironhead XLH is offline
Master Custom Bike Builder
 
Join Date: May 2005
Location: NJ
Posts: 3,168
Sportster/Buell Model: XLH
Sportster/Buell Year: 72
72 Ironhead XLH has disabled reputation
Default

http://www.ebay.com/itm/RED-LIGHT-pa...item53e580602f
http://www.ebay.com/itm/GREEN-LIGHT-...item35aefab830
http://www.ebay.com/itm/AMBER-LIGHT-...item53e58061b2
3/4 BRAIDED EXPANDABLE SLEEVING RATTLE SNAKE
Reply With Quote
  #7  
Old 15th June 2012
72 Ironhead XLH's Avatar
72 Ironhead XLH 72 Ironhead XLH is offline
Master Custom Bike Builder
 
Join Date: May 2005
Location: NJ
Posts: 3,168
Sportster/Buell Model: XLH
Sportster/Buell Year: 72
72 Ironhead XLH has disabled reputation
Default

just a bump
Reply With Quote
  #8  
Old 15th June 2012
dsk1000 dsk1000 is offline
Biker
 
Join Date: Aug 2009
Posts: 39
Sportster/Buell Model: XLCH
Sportster/Buell Year: 1975
Reputation: 109
dsk1000 is on a distinguished roaddsk1000 is on a distinguished road
Default

Thanks 72. Been looking for good supplies of that stuff.
Reply With Quote
  #9  
Old 15th June 2012
GA_Ironhead GA_Ironhead is offline
Senior Master Custom Bike Builder
 
Join Date: Mar 2006
Location: Athens, GA
Posts: 3,650
Sportster/Buell Model: XLCH
Sportster/Buell Year: 1962
Reputation: 10517
GA_Ironhead is a glorious beacon of lightGA_Ironhead is a glorious beacon of lightGA_Ironhead is a glorious beacon of lightGA_Ironhead is a glorious beacon of lightGA_Ironhead is a glorious beacon of lightGA_Ironhead is a glorious beacon of lightGA_Ironhead is a glorious beacon of lightGA_Ironhead is a glorious beacon of lightGA_Ironhead is a glorious beacon of lightGA_Ironhead is a glorious beacon of lightGA_Ironhead is a glorious beacon of light
Default

Support your local supporting vendor: http://www.lowbrowcustoms.com/index....duct_list&c=30
Reply With Quote
Reply

Bookmarks


Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
 
Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off

Forum Jump


Custom Search

All times are GMT +1. The time now is 07:37.


Powered by vBulletin® Version 3.8.5
Copyright ©2000 - 2014, Jelsoft Enterprises Ltd.
XL Forum - Linson Media LLC