IH: Electrical System

Ironhead - Stock Wiring Schematic Drawings (created with reference to the OEM manual)

1959-1985 Sportster Main Wiring Diagrams
The drawings below have been created using the factory schematic drawings from the FSMs as reference. They are available here but are not intended to replace the factory drawings. Some parts symbols are generic, may not represent the actual period parts and have been spread out for clarity from the originals. However, the parts are labeled. The drawings are not to scale and parts and wiring are positioned on the drawings for clarity.


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1959-1962 Sportster CH

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1959-1964 Sportster H

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1963-1964 Sportster CH

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1965 Sportster CH

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1965-1966 Sportster H

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1966 Sportster CH

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1967 Sportster H

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1967-E1969 Sportster CH

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1968-E1969 Sportster H

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L1969 Sportster H

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L1969 Sportster CH

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1970-1971 Sportster XLH

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1970-1971 Sportster XLCH

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1972 Sportster XLH - Standard Seat

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1972 Sportster XLH - Low Seat

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1972 Sportster XLCH - Standard Seat

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1972 Sportster XLCH - Low Seat

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1973-1974 Sportster XL

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1973-1974 Sportster XLCH

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1975-1976 Sportster XL

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1975-1976 Sportster XLCH

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1977 Sportster XL

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1977 Sportster XLCH

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1978 Sportster XL

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1978 Sportster XLCH

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1979 Sportster XLH/XLS

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1979 Sportster XLCH

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1980 Sportster XLH/XLS

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1981 Sportster XLH/XLS

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1982 Sportster XLH/XLS

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1983-E1984 Sportster XLH

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1983-E1984 Sportster XLS

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1983-E1984 Sportster XLX

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1983-1984 Sportster XR-1000

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L1984-1985 Sportster XLH

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L1984-1985 Sportster XLS

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L1984-1985 Sportster XLX

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L1984-1985 Wiring Issue - Might Be Dangerous

Note: The L84-85 Wiring Diagrams show an improper connection from the Regulator to the Battery.
The wiring diagram shows an unsafe connection but we have not been able to determine if the actual bikes are wired wrongly that matches the diagrams. So the following information needs to be verified against the actual bike wiring.

The Main Circuit Breaker is supposed to protect the wiring from a shorted battery. If the regulator is connected directly to the battery (as shown on the diagrams), not utilizing the main circuit breaker for protection, there is a potentially dangerous situation. If the regulator internally or externally shorts that wire, connected to the battery, to ground, the battery will supply upto 200 amps of current, causing the wire to overheat and possibly creating a fire. This is what the Main Circuit breaker is to prevent.

So, the proper way to connect the output of the voltage regulator to the system is at the output side of the Main Circuit Breaker (typically, on the Silver Stud). The battery would be connected to the Main Circuit Breaker on the Brass Stud.

This is the way earlier & later model wiring diagrams show the connection of the voltage regulator to the circuit breakers. The L84-85 diagrams are the only ones showing this improper, potentially dangerous, wiring.

If you find that your bike is improperly wired, matching the diagrams, PLEASE, rewire your bike to make it safe. Be sure the output wire of the voltage regulator is connected to the output side of the Main Circuit Breaker (typically, on the Silver Stud).

??I'm guessing (which is also dangerous) that the diagram is wrong as this was the first year of the alternator and required the diagram to be modified because of that. I think the factory wired it correctly but the updated diagram showed the connection at the wrong place.

Because so many bikes (especially the Ironheads) have had the wiring modified (either deliberately or simply by accident while making repairs or modifications) it is hard to find this answer unless you have a truly UNMOLESTED model of those years. For those who don't understand this issue (and its dangers), I can image that putting the wiring back improperly (maybe for convenience) was easy to do.??


1)
drawing by Hippysmack, the 1957-1969 HD Sportster XL/XLH/XLCH FSM pg 168 used as reference
2)
drawing by Hippysmack, the 1957-1969 HD Sportster XL/XLH/XLCH FSM pg 166 used as reference
3)
drawing by Hippysmack, the 1957-1969 HD Sportster XL/XLH/XLCH FSM pg 170 used as reference
4)
drawing by Hippysmack, the 1957-1969 HD Sportster XL/XLH/XLCH FSM pg 173 used as reference
5)
drawing by Hippysmack, the 1957-1969 HD Sportster XL/XLH/XLCH FSM pg 172 used as reference
6)
drawing by Hippysmack, the 1957-1969 HD Sportster XL/XLH/XLCH FSM pg 174 used as reference
7)
drawing by Hippysmack, the 1957-1969 HD Sportster XL/XLH/XLCH FSM pg 175 used as reference
8)
drawing by Hippysmack, the 1957-1969 HD Sportster XL/XLH/XLCH FSM pg 176 used as reference
9)
drawing by Hippysmack, the 1957-1969 HD Sportster XL/XLH/XLCH FSM pg 178 used as reference
10)
drawing by Hippysmack, the 1957-1969 HD Sportster XL/XLH/XLCH FSM pg 180 used as reference
11)
drawing by Hippysmack, the 1957-1969 HD Sportster XL/XLH/XLCH FSM pg 181 used as reference
12)
drawing by Hippysmack, the 1970-1978 HD Sportster XL/XLH/XLCH/XLT FSM pg 5-3 used as reference
13) , 14)
drawing by Hippysmack, the 1970-1978 HD Sportster XL/XLH/XLCH/XLT FSM pg 5-5 used as reference
15) , 17)
drawing by Hippysmack, the 1970-1978 HD Sportster XL/XLH/XLCH/XLT FSM pg 5-7 used as reference
16)
drawing by Hippysmack, the 1970-1978 HD Sportster XL/XLH/XLCH/XLT FSM pg 5-6 used as reference
18) , 19)
drawing by Hippysmack, the 1970-1978 HD Sportster XL/XLH/XLCH/XLT FSM pg 5-9 used as reference
20) , 21)
drawing by Hippysmack, the 1970-1978 HD Sportster XL/XLH/XLCH/XLT FSM pg 5-11 used as reference
22) , 23)
drawing by Hippysmack, the 1970-1978 HD Sportster XL/XLH/XLCH/XLT FSM pg 5-13 used as reference
24) , 25)
drawing by Hippysmack, the 1970-1978 HD Sportster XL/XLH/XLCH/XLT FSM pg 5-15 used as reference
26) , 27) , 28) , 29) , 30) , 31) , 32) , 33) , 34) , 35) , 36) , 37)
drawing by Hippysmack, the 1979-1985 HD Sportster XL/XLH/XLCH/XLT FSM used as reference
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