Wiring Questions
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Intermediate
Joined: Mar 2012
Posts: 44
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From: Newberg, Oregon
Wiring Questions
Hi Guys... I last posted when I bought a new '77 XLT it was sooo ugly that a friend is painting the sheet metal for me. In the meantime I am learning and fixing... the generator was shot so I ordered a new one online should be here by tuesday...the wiring is old and repaired, even the wire to the points was wrapped poorly with elec tape, I am probably going to replace only what I have too now because I want to ride it. Has any one tried to purchase a new aftermarket harness and install it? What was the experience like? Be safe
Tourer
Joined: Jan 2011
Posts: 350
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From: Reidsville, NC
I replaced the harness on a 78 with points and generator. It ain't too bad. Grab a manual with a schematic though. The hardest part for me was the regulator plug ran through a slot in the frame smaller than the plug. I had to end up cutting, soldering and heat shrinking it. A stock frame shouldn't be a problem, his was custom rigid.
I have not installed a new complete wire harness myself but i have heard from a few guys on these forums who have. Each has reported that it was a relatively easy job. It is what i would do.
I missed your last post as it is another part of HDForums. The original tach and speedo come up on eBay quite often, and IMO are much nicer than new modern ones. Good used ones or NOS. You can also get after market new ones - from J&P Cycles and other regular suppliers; these are the same except they do not say Harley Davidson on the face. You should be able to get a pair for about $100.
The new, made overseas generators have a reputation for early failure. Often they are sold without the drive gear - which you can get but it is an additional expense. Let us know if there are any problems with it.
I do not do restorations on my IronHeads. I like the idea of a refurbish. I use as many original or period parts as i can. eBay is a good source as are these ...
These are the ones to try for OEM NOS parts that i know of ...
http://www.tomsnosparts.com/
www.OldDude.com
www.SportySpecialties.com
rdns@genesco.net <- decals & transfers
www.NOSParts.nl <- does not ship to North America
www.JWBoon.com <- does not ship to North America
You must have original HD part numbers to order from any of these or to search/buy on eBay. For this you need the factory parts catalog 99451-78B. I assume it is the factory service manual 99484-78 that you have ordered; you must have both of these.
I missed your last post as it is another part of HDForums. The original tach and speedo come up on eBay quite often, and IMO are much nicer than new modern ones. Good used ones or NOS. You can also get after market new ones - from J&P Cycles and other regular suppliers; these are the same except they do not say Harley Davidson on the face. You should be able to get a pair for about $100.
The new, made overseas generators have a reputation for early failure. Often they are sold without the drive gear - which you can get but it is an additional expense. Let us know if there are any problems with it.
I do not do restorations on my IronHeads. I like the idea of a refurbish. I use as many original or period parts as i can. eBay is a good source as are these ...
These are the ones to try for OEM NOS parts that i know of ...
http://www.tomsnosparts.com/
www.OldDude.com
www.SportySpecialties.com
rdns@genesco.net <- decals & transfers
www.NOSParts.nl <- does not ship to North America
www.JWBoon.com <- does not ship to North America
You must have original HD part numbers to order from any of these or to search/buy on eBay. For this you need the factory parts catalog 99451-78B. I assume it is the factory service manual 99484-78 that you have ordered; you must have both of these.
Last edited by IronMick; Apr 29, 2012 at 07:45 AM.
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Joined: Apr 2012
Posts: 72
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From: Paris, KY
I think I got my harness from J&P. It was real easy to install but I did find that some of the terminals had bad crimps that caused some issues with poor current flow. I had an electrician buddy of mine replace all of the terminals and heat shrink then and it has been great! It may have been a fluke. I would give them a visual check before installing.
Before that, I had made my own harness using the schematic in the FM and that worked great for about 10 years. The only reason I replaced it was I was having power issues and was unsure if the wiring was a contributor.
Dave
Before that, I had made my own harness using the schematic in the FM and that worked great for about 10 years. The only reason I replaced it was I was having power issues and was unsure if the wiring was a contributor.
Dave
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Intermediate
Joined: Mar 2012
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From: Newberg, Oregon
The generator that I got was a poorly rebuilt one from India, I sent it back and bought a "new" one also from India. I got a starter from Taiwan. The Harley dealership sells boots and helmets from China.... Going to repair the existing wiring for now. Yes I have a shop manual and a parts manual. Should have it running tomorrow, but the paint is not done yet. Just so I am clear what is the diff between restore and refurbish?
Restore is to make it as close to possible to the way it came from the factory; exactly the same if possible. The guys who do restorations are fanatics. They have the bikes judged at shows. They get points out of 100. A 100 point restoration is rare and envied. You get really p1ssed if you get 96 points and a guy beats you with 97.
I began to use refurbish to distinguish what i do from that. I build my bikes to ride. I do not care much if they get dents and scratches. I do not avoid gravel roads. My bike looks "original" to the general public but is far from it. Lots of cool 1960s and 70s parts; i use a 1980 XLS Roadster tank for longer trips.
http://www.youtube.com/watch?v=dwgzY...ure=plpp_video
I began to use refurbish to distinguish what i do from that. I build my bikes to ride. I do not care much if they get dents and scratches. I do not avoid gravel roads. My bike looks "original" to the general public but is far from it. Lots of cool 1960s and 70s parts; i use a 1980 XLS Roadster tank for longer trips.
http://www.youtube.com/watch?v=dwgzY...ure=plpp_video
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