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17th November 2009
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Chief Know It All
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Join Date: Dec 2008
Posts: 448 Sportster/Buell Model: XLCH Sportster/Buell Year: 1975
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another minimalistic wiring diagram
well one of the things i'm planning to do to my bike this year is re-wire it...........
theres a couple burned spots in my harness and some P.O repairs that aren't real pretty....
plus i want to clean up that rats nest inside the headlight
so i drew up this little diagram that someone else may also find useful........
i plan to print it out and keep it inside a ziplock baggie in my tool kit "just in case"

Last edited by scottericsonon; 18th November 2009 at 12:40..
Reason: updated drawing
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17th November 2009
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Biker
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Join Date: Jun 2008
Posts: 22 Sportster/Buell Model: sportster Sportster/Buell Year: 1981
Reputation: 10

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thanks, nice, simple,easy to folllow.
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18th November 2009
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Senior Custom Bike Builder
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Join Date: Jan 2008
Location: Brisbane, Australia
Posts: 2,638 Sportster/Buell Model: 1000cc Ironhead Sportster Sportster/Buell Year: 1977 Other Motorcycle Model: 96 KDX200 Dirt Bike
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you will need a diode in your gen light circuit
__________________
24 beers in a carton. ...24 hours in a day . .. coincidence??
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18th November 2009
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Chief Know It All
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Join Date: Dec 2008
Posts: 448 Sportster/Buell Model: XLCH Sportster/Buell Year: 1975
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where at russ? i hadnt seen one in my manual........
all i saw was one side going to 12V and the other going to the genny
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18th November 2009
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Senior Custom Bike Builder
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Join Date: Jan 2008
Location: Brisbane, Australia
Posts: 2,638 Sportster/Buell Model: 1000cc Ironhead Sportster Sportster/Buell Year: 1977 Other Motorcycle Model: 96 KDX200 Dirt Bike
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I think they are in the headlight nest in a stock harness, they are just inline, see post #22 here and pick that part out, you need to make sure the diode is around the right way. What your aiming to do is allow power to flow one way but not back from the battery the other way, the light will glow when it picks up a difference in voltage on both sides of the diode
http://xlforum.net/vbportal/forums/s...=411626&page=3
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18th November 2009
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Biker
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Join Date: Feb 2009
Posts: 58 Sportster/Buell Model: XLS Roadster Sportster/Buell Year: 1982
Reputation: 10

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The diode should be in the headlight bucket, placed in series with the gen indicator light, or in a wire going from a 12 pin to 6 pin plug, possibly an orange wire. Part #74563-65. Make sure it's taped up good or use a heat shrink.
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18th November 2009
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Chief Know It All
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Join Date: Dec 2008
Posts: 448 Sportster/Buell Model: XLCH Sportster/Buell Year: 1975
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fixed with the diode...........
should just be a standard 1n-4004
thanx for the heads up
diode isn't shown in my service manual OR my parts book
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18th November 2009
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Rider Of The Iron Steed
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Join Date: Dec 2003
Location: London, ON Canada
Posts: 23,730 Sportster/Buell Model: XLH Sportster/Buell Year: 1978
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54 to 78 book, page 192, 193
79 to 85 book, page 126, 127
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18th November 2009
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Chief Know It All
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Join Date: Dec 2008
Posts: 448 Sportster/Buell Model: XLCH Sportster/Buell Year: 1975
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i must need new glasses because im STILL not seeing it,,,,,,,,,
ive hilighted all the relevant wires here

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18th November 2009
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Rider Of The Iron Steed
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Join Date: Dec 2003
Location: London, ON Canada
Posts: 23,730 Sportster/Buell Model: XLH Sportster/Buell Year: 1978
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In my 70 to 78 FM it does not show up in the diagrams until 1978. Then it is number 49, left side of diagram, inside the headlite housing dashed line.
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