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Everyone knows what a nightmare the FX/XL headlight bucket wiring is, but it had to come out to paint the bucket and replace the handlebar switches.
I took bunches of pictures along the way, so I have a chance to put it together right. The metal sockets are held into the plastic connector by a little tab on their side. Careful fiddling with a tiny screwdriver releases it.
Repeat a dozen more times and the main harness is free of the bucket:
The metal pins can sometimes be released from the plastic with the proper tool, a hollow metal tube, but I found the tiny screwdriver worked better.
These little metal strips are used as jumpers and come out easily. I left one side in place so they don't get lost.
One of the reasons there are so many wires and connectors is Harley uses this mess to connect the orange Aux power wires together:
I was able to buy NOS replacement switches fairly inexpensively. The only problem is the wire sleeve is black, so I have to change it to the original grey.
Now I just have to figure out how to remove this mess. I guess if you don't have the right part, glue in whatever you have? I just ordered a rectangular flasher for under $10...
[edit: I'm soaking it in gasoline overnight. I'll let you know how that works out]
The gasoline soak worked like a charm. The big blobs pulled right off, and the rest scraped down to clean metal very easily. Another tip in the jar!
Very quick blast with the sandblaster and it looks pretty good. I'll get some rust converter tomorrow when the stores reopen to get where I didn't blast.
Front turn signal wiring done. The original housings were shot, but the wire was in good shape. Replacement housings looked great, but wires were cut by seller. First thought was cut and splice, or change out the whole socket assemblies with wires. Then it occurred to me I could use the nice clean replacement sockets with the original wires by popping out the contact and spring:
Like new:
The Neutral and Oil Pressure lights were in OK shape, and I was going to re-use them, but today I decided to go with new. Why not at this point? So this is as far as I got with rewiring today:
I have to fix the main harness, someone cut off the plug that goes to the rear fender, and repaired the sheath going to the motor. The rest of it is in very good shape.
7 Surprising Harley-Davidson Products that Are Not Motorcycles
Slideshow: The bar-and-shield logo shows up on far more than motorcycles, some of the company's most unexpected products have nothing to do with riding.
Slideshow: From the troubled AMF years to modern misfires, these bikes earned reputations for reliability issues, questionable engineering, or disappointing performance.
Crazy Bunderbike Build Looks Amazing, But Is It Impossible to Ride?
Slideshow: The Swiss custom shop has taken a Harley Softail and stretched it into something so long and low that it looks closer to a rolling sculpture than a conventional motorcycle.
Engraved Rebellion: Inside Bundnerbike's Glam Rock II
Slideshow: A standard cruiser becomes an intricate metal canvas in the hands of a Swiss custom house known for pushing Harley-Davidson platforms far beyond their factory brief.
Slideshow: Harley-Davidson's challenges aren't abstract; they show up in dropping shipments, shrinking dealer traffic, and strategic decisions that aren't yet translating into growth.
