I was looking to rebuild the wiring harness in my 1988 Harley Davison Sportster XLH 883 because it’s old and worn so it needs changing because I’m having electrical issues all through the bike and I was wondering because Drag Specialties puts out 16 gauge primary wire in a 35 foot roll in all the colors my stock harness has, could I use 16 gauge primary wire for the main wiring harness for my bike?

 

Know there is at least one red wire that is larger then the rest, what size are the majority of wires? Sure would not go smaller but going too big although electrical would be fine but it would make it difficult to work with.

I see factory finished available for $150. Have no idea of quality but the one by Lindsay sure looks good. No way would I be able to come up with all those crimped connectors.

 

probably cheaper to buy a harness. hd does use 16ga wire but make sure you use the right type as the insulation is the determining factor for the environment. however, not a hard job, made one for my 1974ch many moons ago.

 

Two years ago I went through the wiring harnesses on my 1989 FLSTC, just because of it`s age.

The wiring was in great shape, no chafes, rubs etc, but the plastic connectors were starting to look questionable.

I de-pinned the connectors, cleaned all the pins and sockets, and installed new connectors.

It is unlikely you need a new harness, unless it has been hacked into.

 

looks can be deceiving. copper changes over time and the insulation gets brittle but the salvation is hd does not stress to the limits. all of my exposed wiring def had issues but the wiring inside the frame rail looked brand new.
it was a bird in the hand type of thing since the frame was going through restoration and modification and engine out, that too got a boost in power.

 

How much does an element change?

 

Wow! Did the op say all of that in one breath?

Anyhow…I’d buy a new harness, if the existing one really has deteriorated.