re wire
Cruiser
Joined: May 2007
Posts: 207
Likes: 1
heheh, depends on how you are at wiring. no it's not real difficult, but if you are not mechanical it could be a mess. unless you are doing a restoration, I would recommend simplifying the wiring (simple is much more reliable) When I am doing a custom job, I always solder and heat shrink all the connections, never use any blade connectors if possible, there are a few company's that sell wiring harness to fit, but I feel they are very over priced. (what isn't for a harley anymore)
Road Master
Joined: Jun 2008
Posts: 1,078
Likes: 39
From: NW Florida
Crampfan is correct it is not difficult. If you are not doing a restoration I would definitely simplify the wiring. The 66 to 69 wiring diagram is much simpler than the later FLH wiring diagrams. The early bikes had a circuit board in the headlight that you can connect the wires with bolts and nuts. The later circuit board required pin connectors and has about 50 wires going to it. Even the early diagram is much more complicated than needed. Your service manual should have the stock wiring diagrams. Soldered connections are mush better than just crimping them. If you are not buying a ready made harness, make sure you acquire enough different colored wires to match your wiring diagram. Nothing is worse than trying to trace an electrical problem when the previous owner wired it all in black. Also use the proper gauge wire for each circuit.
Road Captain
Joined: Oct 2007
Posts: 742
Likes: 23
Crampfan is correct it is not difficult. If you are not doing a restoration I would definitely simplify the wiring. The 66 to 69 wiring diagram is much simpler than the later FLH wiring diagrams. The early bikes had a circuit board in the headlight that you can connect the wires with bolts and nuts. The later circuit board required pin connectors and has about 50 wires going to it. Even the early diagram is much more complicated than needed. Your service manual should have the stock wiring diagrams. Soldered connections are mush better than just crimping them. If you are not buying a ready made harness, make sure you acquire enough different colored wires to match your wiring diagram. Nothing is worse than trying to trace an electrical problem when the previous owner wired it all in black. Also use the proper gauge wire for each circuit.
I will (sometime this year) rewire my bike, simplifying everything.
Cone shovel, kick only, no turn signals
What's the right wire gauge to do it? Is there one wire gauge I can use for the whole bike?
thank
Club Member
Joined: Mar 2009
Posts: 66,102
Likes: 51,359
From: Niles Canyon Ca.
I use 12ga for the big power wires from the battery to the breakers , main tab on the switch and to the feed side of the lights & starter relays everything else can be 16ga . If you use the handlebar switches and relays those can go down to 18ga for easy handling . Without turn signals wiring a bike is pretty simple and I do recommend you use at least a main circuit breaker off the battery and relay for the lights if you run the big 7" or high output bulbs .
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Road Captain
Joined: Oct 2007
Posts: 742
Likes: 23
circuit brakers are planned and 1 switch on the handlebar for lights
Headlight is an old spotlight with a 30/30W sealed beam.
4 or 6 bullet lights as rear/stop lights
thanks
Headlight is an old spotlight with a 30/30W sealed beam.
4 or 6 bullet lights as rear/stop lights
thanks
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Seasoned HDF Member
Joined: Nov 2006
Posts: 12,878
Likes: 5,448
From: la la land jerzey
think about it this way -- if you have ever used a map to find a street than you can use a wire diagram to fine a bulb --
its not rocket $hit its wires to bulbs and on off switches and they are all different colors - jz
its not rocket $hit its wires to bulbs and on off switches and they are all different colors - jz