So, I figured I could clean up the wiring on my 02 nighttrain while the tank was off and the mess of wires that where between the trans n splash guard. Thought everything was labeled before I hacked off the main bundle going to ignition switch, speedo and dummy lights. Apparently I did not and have caused a huge freaking headache in the process.

I chopped the bundle because I am planning on putting a black line dash on, moving the coil in between the jugs, moved the horn to the splash guard and a mini speedo off the side of the rear jug, pipe side. The bundle of wires located at the splash guard was horrible but looks great now. Been soldering/shrink wrapping everything like a champ, actually my wife has; it's going to be her bike when done and she wants to work on it. Love that lady, she ain't afraid to take on challenges, hell she works on b-52s.

Any way it started off after we thought everything was good, had to rerun some rear signal and tailght wires, the led module that was running them took up a lot of space; bearly could stuff it into where the battery was and locating back by splash guard wasn't going to work. Running a huge headwinds headlight, I decided to use that empty space up there and put the module there and run the wires back, works great! All signals work, tail light function properly.

So it was then we discovered the horn and headlight wasn't working, broke the test light and started tracing all the wires. Found that the horn wire had broken inside of handle bars, so we pulled the cables out again, resolver, re shrinked. Now the horn worked. Excellent but still no headlight, traced out more wires, looking at the colors again, found a blue wire that runs to the hi/low switch back by the battery that had been cut, two wires sticking up, twisted them together and we had light, well after we tested them, one had power the other nothing.

I had been just taking the three wires from the ignition switch and twisting them together and connecting/disconnecting the ground from battery.

Well today, figured I would work on it a bit more; after placing all the cables nicely back. Found out I still have a few more issues. Darn it!!!!!!!

When testing which wire is the accessory wire and which could be the ignition wire discovered that, one wire the headlight will turn on but not the tail light which means it's the ignition wire. If I switch to the other wire, head goes off but tail light turns on, which would be the running light as the led bulb is 3 wire; hi lo ground. Come to think about it, I think I only tested for a constant power source for running light not to see if it was from the accessory or ignition wire. Of course this is when all three wires from the ignition switch were bundled together. Hmmm, typing this out is helping me trouble shoot.

So hopefully fixing that will fix the last issue, my last issue which frustrates but makes me laugh is, if I honk the horn, brights blink; if I switch to bright the horn comes on and stays on.

If anyone has a wiring diagram for 02 softail, please share. I guess I will just give it a day or two and then back at it

 

Don't you have the shop manual for your bike? Should be in there. If you didn't have that before you chopped the wires then, shame on you! Better go down to your Harley dealer and order one, because that is copyrighted information and cannot be shared here (against forum rules) if it's the wiring diagram out of the manual. I SUCK at electrical, but can figure almost anything out with those diagrams...

 

+1 on the manual. The wiring diagrams in the back are pretty detailed and laid out nicely. I'm not great with wiring, but with the help of those diagrams and a little patience was able to install a GripAce, and accomplish the exact project you are doing. Here's the link to thread on the build

https://www.hdforums.com/forum/softa...ress-pics.html

Is your bike carb or injected?

 

SGT I will send you a wiring diagram when I get home tonight.I believe it's frowned upon posting HD manual stuff on here. G.

 

Your right, it is, because Harley closely watches sites like this for copyright violations.
They have lawyers just sitting around waiting for the chance to nail anyone they think is using ANY of their logos or paperwork without their written permission.
That's why you never see anyone selling or talking about electronic or CD versions of the manuals here.
We routinely remove any threads or posts that refer to them or advertize them because Harley doesn't publish them on anything but paper.
Therefore anyone trying to sell or make CD or electronic versions is violating their copyright.
And we want NO part of the grief Harley will dish out if they think we're aiding and abetting anyone violating their copyright.

 

Really old post but history repeated its self on my 1978. FLH. it's the anniversary model. And I bought it Five years ago. Wiring mess, just joined our group.last month. Glad I did. For five years I felt I was a victim. But reading several post. I now believe our Harleys had alot of bad wrenching done on them over the years. Been working on my 78 last few months. Bought a maintenance widdow maker. And got into several issues after riding for five years. AJ

 

Unfortunately, too many bad hands get into these bikes. I just corrected a bunch of wiring on an 08 street glide and an 06 Hyabusa. Both had been to multiple shops that made a mess of things. Both are back to their owners and correct.

 

Great post, probably most shops are not to blame. But the owners trying to fix items by using a band aide. My 78 FLH had 34 if those blue splice clips installed all over my bike. When I got the bike delivered the Battery was Dead. I mean totally dead. After a three day trip from Florida. The guy that delivered it was enroute to Sturgis South Dakota. Claimed the bike started and the seller rode it to his trailer. I tried to do a one Amp charge. But realized two cells were totally dead. I went to NAPA and bought a new higher Amp battery. My 78 FLH had lots of lights. After doing some checking my battery system was drawing 2.5 amps. But I noticed my power switch was installed backwards. Clip was to the rear not to the front. Caused a constant draw thru the battery. I had to buy a new switch so I removed the headlite. And that when I found 30 blue splice ties. Crazy stuff. AJ