This is an old revision of the document!


REF: Electrical System

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

These drawings 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. Click on a drawing to enlarge:

XL / XLH Main Wiring Diagrams

1)

2)

1959-1964
Sportster H 3)
1965-1966
Sportster H 4)
1967
Sportster H 5)
1968-E1969
Sportster H 6)
L1969
Sportster H 7)
1970-1971
Sportster XLH 8)
1972
Sportster XLH
Standard Seat 9)
1972
Sportster XLH
Low Seat 10)
1973-1974
Sportster XL 11)
1975-1976
Sportster XL 12)
1977
Sportster XL 13)
1978
Sportster XL 14)

XLCH Main Wiring Diagrams

1959-1962 CH:
15)

1963-1964 CH:
16)

1959-1962
Sportster CH 17)
1963-1964
Sportster CH 18)
1965
Sportster CH 19)
1966
Sportster CH 20)
1967-E1969
Sportster CH 21)
L1969
Sportster CH 22)
1970-1971
Sportster XLCH 23)
1972
Sportster XLCH
Standard Seat 24)
1972
Sportster XLCH
Low Seat 25)
1973-1974
Sportster XLCH 26)
1975-1976
Sportster XLCH 27)
1977
Sportster XLCH 28)
1978
Sportster XLCH 29)

Ironhead - Simplified Wiring Schematics

This wiring diagram is a minimal config - No Starter - No Turn Signals - No Front Brake Switch - No Kill Switch.

The ignition module is an Ultima version and fits in the nosecone where previously only the cam sensor plate was mounted. In this diagram the Ultima Single-Fire Configuration is used, feeding separate trigger signals to the dual coils to fire the front & rear spark plugs separately (the Ultima BLUE wire fires the front coil & the Ultima PINK wire fires the rear coil).

If you choose to use a dual-fire configuration of the Ultima ignition, it will also work when you pair it to the appropriate dual-fire coil. In that case, you will only use the Ultima PINK wire to fire the selected dual-fire coil. (The Ultima BLUE wire will not be used at all with a dual-fire version.)

Using the VOES connection with either configuration (which helps with idle & cruising spark timing by providing more advance) is recommended by connecting the Ultima VIOLET wire to the VOES unit.

Implementing a tachometer is optional. If used, the Ultima GREEN wire will connect to the tachometer signal input wire. The tach will also need a ground connection on the bike and key-operated power for the tach light.

There are only six wire colors to minimize wire purchase: Black - White - Red - Blue - Yellow - Green. There are enough colors so that no connecting point should have the same color twice in order to make it easier to know which device is connected to/from another device.

This circuit uses the Frame/Engine for ground conduction. Be sure you have good ground points at the needed locations or run a separate black wire to those locations to assure a good ground.

Beware that the brake light shares the same fuse as the ignition circuit - So, if you have a short to ground in the brake circuit it will blow the fuse & kill the ignition. You could add a separate fuse for the brake light to avoid that potential problem.

The diagram shows an optional Gen Light, implemented with a diode and an incandescent bulb.

To implement the VOES, add it with a vacuum hose to the carb - then wire the single VOES wire into the Violet Wire of the Ultima ignition module.

To implement a tachometer, use a normal HD dual-fire tach and wire the input signal to the Green Wire of the Ultima module.


Some Other Simplfied Wiring Diagrams to represent basic wiring:

Wiring for Magneto Fired Sportsters 30)

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Wiring for an Electric Start Sportster 31)

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Generic HD Wiring Diagram 32)

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Ironhead CAD Wiring Diagram ('77) 33)

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1) , 3)
re-drawn by Hippysmack from the 1957-1969 HD Sportster XL/XLH/XLCH FSM pg 166
2) , 4)
re-drawn by Hippysmack from the 1957-1969 HD Sportster XL/XLH/XLCH FSM pg 172
5)
re-drawn by Hippysmack from the 1957-1969 HD Sportster XL/XLH/XLCH FSM pg 175
6)
re-drawn by Hippysmack from the 1957-1969 HD Sportster XL/XLH/XLCH FSM pg 178
7)
re-drawn by Hippysmack from the 1957-1969 HD Sportster XL/XLH/XLCH FSM pg 180
8)
re-drawn by Hippysmack from the 1970-1978 HD Sportster XL/XLH/XLCH/XLT FSM pg 5-3
9) , 23)
re-drawn by Hippysmack from the 1970-1978 HD Sportster XL/XLH/XLCH/XLT FSM pg 5-5
10) , 25)
re-drawn by Hippysmack from the 1970-1978 HD Sportster XL/XLH/XLCH/XLT FSM pg 5-7
11) , 26)
re-drawn by Hippysmack from the 1970-1978 HD Sportster XL/XLH/XLCH/XLT FSM pg 5-9
12) , 27)
re-drawn by Hippysmack from the 1970-1978 HD Sportster XL/XLH/XLCH/XLT FSM pg 5-11
13) , 28)
re-drawn by Hippysmack from the 1970-1978 HD Sportster XL/XLH/XLCH/XLT FSM pg 5-13
14) , 29)
re-drawn by Hippysmack from the 1970-1978 HD Sportster XL/XLH/XLCH/XLT FSM pg 5-15
15) , 17)
re-drawn by Hippysmack from the 1957-1969 HD Sportster XL/XLH/XLCH FSM pg 168
16) , 18)
re-drawn by Hippysmack from the 1957-1969 HD Sportster XL/XLH/XLCH FSM pg 170
19)
re-drawn by Hippysmack from the 1957-1969 HD Sportster XL/XLH/XLCH FSM pg 173
20)
re-drawn by Hippysmack from the 1957-1969 HD Sportster XL/XLH/XLCH FSM pg 174
21)
re-drawn by Hippysmack from the 1957-1969 HD Sportster XL/XLH/XLCH FSM pg 176
22)
re-drawn by Hippysmack from the 1957-1969 HD Sportster XL/XLH/XLCH FSM pg 181
24)
re-drawn by Hippysmack from the 1970-1978 HD Sportster XL/XLH/XLCH/XLT FSM pg 5-6
31)
drawing by OutlawTexan67
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