I've got a '92 FXSTC that I am switching the controls to the 96-06 style. My question is in the wiring. The old setup uses 7 wires, each switch seems to have it's own circuit. The new style uses 6 wires, with 2 switches combining power circuits. I have a wiring diagram for my bike, but the wiring diagram that came with the switches is very basic. Any insight that anybody may have would be appreciated.

Another question. The 96+ master is 9/16. The 95 and before master is 5/8. They both use the same caliper and brake lines. Is the design of that 96+ that much different that they went down in size on it with no brake feel changes?

 

I got it figured out. If anyone is interested, there are redundant power wires on the pre-96 controls. Just eliminate one of the circuits, I eliminated the green wires for the original turn signals. Power is shared in the 96+ switches.

 

Well done, you answered one question while we were thinking about it!

As for the master cylinder, Harley make two, although externally the look the same. The 5/8" is for single disc, the 9/16" is for twin disc. The extra volume is used for moving two sets of caliper pistons.

 

The 9/16" is for single caliper and 11/16" is dual caliper....on the 96-up m/c's

hemdog, are they flashing?? do you have a flasher unit module or the mechanical flasher?? I did this mod to my '90 Heritage(Wagner mechanical flasher) and couldn't get the signals to flash until I cut the shared power line and ran a line for the signals to make it a 7 wire harness again...

 

I have the module under the speedo. The flash fine, so does the emergency flasher. The green wire was just piggy-backed/splices on the body side of the connector, so I left that one free. I'll see if the cancel function still works when I get it back together, but I don't see any reason why it wont.

From everything I've researched, the only thing different between a 95 FXSTC and a 96 as far as the front brake is concerned is the master cylinder. Just seems weird to me that went down in size. Must be different piston design to compensate for the 1/16" difference.