Ironhead 77 xlh re wiring from scratch.... connectors!

[goirish64]

anyone out there have any clue as to where i could find the stock replacement connectors for the connections in the headlight housing? or something that will work? according to the schematic its 2 12 terminal and one 6 terminal. any kind of connectors work for anyone else?

[76 sporty]

you can get a decent from radio shack that is what i have on my bike and they work great

[hcrashster]

Do what I do, Junkyard. Cheap and.................cheap.

[bustert]

why use junk unless you are doing an antique. use weatherpacks available from auto parts or electronic parts stores. there are electronic outlets on the web like digikey and ecm and all electronics. weatherpacks are standard issue on all cars nowdays and offer sealed protection. most have a release system where you can remove and install individual wires if need be.

[goirish64]

thanks for the good info. im gonna check out radio shack tommorow. the internet hasnt been too kind to me, ive been searching. jp cycle didnt really give me much. thanks this wiring is confusing the hell out of me

[waza]

What ever you do, Don't use stake ons.
If you want original type, there are kits on ebay that have the correct motorcycle type brass connectors, male & female also with 2 & 3 one piece female, all with clear boots(+ instructions). They also come with proper wire strippers and the correct crimping pliers as used at the factory. These kits run between $60-100 but are well worth it. You can get proper shrink tubing in any length from a good electrical supply house. Radio shack only has short pieces of shrink tubing.
I don't have the links right now but if no one else adds them in, I'll post tomorrow. Do it right, you can make a better loom than the factory did if you are patient.
Good luck

[mikethebike61]

The H-D dealer should have them. They are 80cents each plus you need the presser. A Molex hand crimper (performance-pcs.com) is what you need to properly crimp them. I also solder the wire before crimpimg then hit that with a gun just to make sure.
I also ordered some from a fastener supply but we will not know if they are the correct ones until they get here. If they are they will be a GM part. Hold tight for about a week and I'll let you know.

[mikethebike61]

Originally Posted by waza

What ever you do, Don't use stake ons.
They also come with proper wire strippers and the correct crimping pliers as used at the factory.Good luck

The FACTORY tool is closer to $400.00, aftermarket range from $25 to $180.

[Bob F]

Welcome to the XLForum.

[stoney77]

Waza has a good remedy,but I'm not sure why he says not to use sta-cons. If you are refering to those large black block connectors that take up so much room in the shell,you can go to an electronic supply house where you can find something suitable at a reasonable cost.Everything from srink tube,connecting blocks,wire,soldering tools,ect. Or, do something I've allways wanted to do. Take each individual conductor,use small quick-connect connectors(ones that you can connect and reconnect a number of times).AS far as the other connectors go like on the flasher unit,either Radioshack has them or electronic supply.Just remember when purchaseing those conn. get the right wire size gauge.Hope this helps stoney