Table Of Contents

Page

General 5-1

Wiring 5-2

Switches 5-9

Lamps 5-13

Charging System 5-15

Ignition System ■ 1979 and Earlier 5-19

Ignition System • 1980 and Later 5-24

Ignition Coil 5-25

Spark Plugs 5-27

Battery 5-29

Horn 5-31

Starter Motor 5-31

Tools 5-35

GENERAL

SPECIFICATIONS

Spark timing 35° BTC fully advanced

3° BTC fully retarded

Ignition timer air gap

1979 and earlier 0.004 to 0.006 in.

1980 and later not applicable

Spark plugs

Size 14 mm

Type

1979 and earlier Harley-Davidson No. 5A6A (Standard)

Harley-Davidson No. 5R6A (Resistor type)

1980 and later Harley-Davidson No. 5R6A

Note: Harley-Davidson No. 5A6 plug may be used in place of a No. 5A6A plug and a 5R6 plug can be used in place of a 5R6A plug if regapped to 0.038 to 0.043 in.

Battery

FL/FLH 12 volt, 32amp.hr.

Starter

FUFLH/FXE/FXEF/FXS ... Electric, 12 volt Bendix drive

FX Manual

Rectifier-regulator Voltage control with ambient compensation

Alternator Integral permanent magnet design —

225 watts

Horn Electric vibrating

Lights

Headlight (sealed beam)

FL 50W lower, 60W upper

FX 35W lower, 45W upper

Stoplight 32 C.P.

Tail light 4 C.P.

WIRING

19781/i-79 FL/FLH — WIRING DIAGRAM KEY

1. Front terminal board (terminals 1 to 11)

2. Switch (terminals 1 to 6)

3. Regulator-rectifier module

4. Alternator to module connector plug

5. Alternator stator

6. Tail and stoplight

7. Battery positive terminal

8. Battery negative terminal

9. Oil pressure signal switch

10. Headlamp beam switch

11. Horn switch

12. Ignition timer

13. Stoplight switch — rear

14. Starter solenoid

15. Starter motor

16. Ignition coil

17. Rear wiring harness connector

18. Speedometer light

19. Headlamp

20. Neutral indicator light

21. Neutral switch

22. Starter button

23. Oil signal light

24. Horn

25. High beam indicator lamp

26. Engine stop switch

27. Starter relay

28. Right turn signal switch

29. Turn signal flasher

30. Left front turn signal lamp

31. Right front turn signal lamp

32. Left rear turn signal lamp

33. Right rear turn signal lamp

34. Left turn signal pilot lamp

35. Right turn signal pilot lamp

36. Stoplight switch - front

37. Connector (11)

38. Terminal board mounting sc

39. Transmission stud

40. Frame lug bolt

41. Right handlebar harness

42. Left handlebar harness

43. Left turn signal switch

44. Lighting circuit breaker

45. Ignition circuit breaker

46. Accessories circuit breaker

47. Main circuit breaker

48. Emergency flasher

49. Emergency flasher switch

50. Handlebar clamp bolt

Wiring Motorbike Colour Codes Diagram

accessory 14

ignition. light &

accessory switch connections ignition. 2-3-45-6

light &

accessory__

switch connections accessory 14

ignition. light &

accessory ignition. 2-3-45-6

light &

accessory__

KEY TO COLOR CODE (bk) black

(bn) brown green

(y) yellow

(v) violet

(o) orange

Figure 5-1. 1978'/i-79 FUFLH Wiring Diagram

1978V2-79 FX/FXE - WIRING DIAGRAM KEY

1.

Headlamp housing

27.

2.

Socket-plug combination

28.

3.

Socket-plug combination

29.

4.

Socket-plug combination

30.

5.

Wiring harness

31.

6.

Headlamp beam switch

32.

7.

Horn switch

33.

8.

Ignition timer

34.

9.

Wire connector

35.

10.

Battery positive terminal

36.

11.

Battery negative terminal

39.

12.

Frame lug bolt

40.

13.

Stoplight switch - rear

41.

14.

Switch "ST" lights terminal

42.

15.

Switch "G" ignition terminal

43.

16.

Switch "B" battery terminal

44.

17.

Regulator - rectifier module

45.

18.

Alternator to module connector plug

46.

19.

Alternator stator

47.

20.

Horn

48.

21.

Headlamp socket

49.

22.

Engine stop switch

50.

23.

Stoplight switch — front

51.

24.

Ignition coil

52.

25.

Main circuit breaker

53.

26.

Rear turn signal connector

54.

Tail lamp connector

Long stud on starter solenoid

Speedometer light

Oil pressure signal switch

Neutral switch

Neutral indicator light

Oil signal lamp

High beam indicator lamp

Tail and stoplight

Tachometer

Lighting circuit breaker

Ignition circuit breaker

Accessories circuit breaker

Starter switch

Right turn signal switch

Left turn signal switch

Turn signal flasher

Left front turn signal lamp

Right front turn signal lamp

Left rear turn signal lamp

Right rear turn signal lamp

Starter relay (FXE only)

Starter solenoid (FXE only)

Starter motor (FXE only)

Violet tag

Brown tag

Utv Key Wiring

19781/j-79 FXS/FXEF WIRING DIAGRAM KEY

1. Headlamp housing

2. Socket-plug combination

3. Socket-plug combination

4. Socket-plug combination

5. Socket-plug combination

6. Socket-plug combination

7. Socket-plug combination

8. Wiring harness

9. Headlamp beam switch

10. Horn switch

11. Ignition timer

12. Wire connector

13. Battery positive terminal

14. Battery negative terminal

15. Frame lug bolt

16. Stoplight switch - rear

17. Switch "ST" lights terminal

18. Switch "G" ignition terminal

19. Switch "B" battery terminal

20. Regulator-rectifier module

21. Alternator to module connector plug

22. Alternator stator

23. Horn

24. Headlamp socket

25. Engine stop switch

26. Stoplight switch - front

27. Ignition coil

28. Speedometer light

29. Oil pressure switch

30. Neutral switch

31. Neutral indicator lamp

32. Oil signal lamp

33. High beam indicator lamp

34. Tail and stoplight

35. Tachometer

36. Lighting circuit breaker

37. Ignition circuit breaker

38. Accessories circuit breaker

39. Main circuit breaker

40. Starter switch

41. Right turn signal switch

42. Left turn signal switch

43. Turn signal flasher

44. Left front turn signal lamp

45. Right front turn signal lamp

46. Left rear turn signal lamp

47. Right rear turn signal lamp

48. Starter relay

49. Starter solenoid

50. Starter motor

51. Violet tag

52. Brown tag

53. Handlebar bolt

KEY TO COLOR CODE

©

BLUE

®

BLACK

®

BROWN

©

GREEN

©

GRAY

©

ORANGE

®

PINK

(5)

RED

©

VIOLET

®

WHITE

S

YELLOW

®

r

1978 200 Wiring Diagram
Figure 5-3. 1978'/2-79 FXS/FXEF Wiring Diagram

1980 FL/FLH — WIRING DIAGRAM KEY

1. Front terminal board (terminals 1 to 11)

2. Switch (terminals 1 to 6)

3. Regulator-rectifier module

4. Alternator to module connector plug

5. Alternator stator

6. Tail and stop lamp

7. Battery positive terminal

8. Battery negative terminal

9. Oil pressure signal switch

10. Headlamp beam switch

11. Horn switch

12. Ignition module

14. Starter solenoid

15. Starter motor

16. Ignition coil

17. Rear wiring harness connector

18. Speedometer light

19. Headlamp

20. Neutral indicator light

21. Neutral switch

22. Starter button

23. Oil signal light

24. Horn

25. High beam indicator lamp

26. Engine stop switch

27. Starter relay

28. Right turn signal switch

29. Turn signal flasher

30. Left front turn signal lamp

31. Right front turn signal lamp

32. Left rear turn signal lamp

33. Right rear turn signal lamp

34. Left turn signal pilot lamp

35. Right turn signal pilot lamp

36. Stop lamp switch — front

37. Connector (11)

38. Terminal board mounting screw

39. Starter motor mounting bolt

40. Frame lug bolt

41. Right handlebar harness

42. Left handlebar harness

43. Left turn signal switch

44. Lighting circuit breaker (15A)

45. Ignition circuit breaker (15A)

46. Accessories circuit breaker (15A]

47. Main circuit breaker (30A)

48. Emergency flasher

49. Emergency flasher switch

50. Handlebar clamp bolt

51. Ignition sensor

switch connections

position

contacts

accessory

1-4

off

ignition. light & accessory

24 56

ignition. light &

accessory

2 34 66

key to color code

(bk)

black

O

brown

green

0

red

0

white

G

yellow

(be)

8lue

©

violet

©

orange

H

gray

©

tan

Figure 5-3A. 1980 FL/FLH Wiring Diagram

5-8A

1980 FXE WIRING DIAGRAM KEY

1. Headlamp housing

2. Socket-plug combination

3. Socket-plug combination

4. Socket-plug combination

5. Wiring harness

6. Headlamp beam switch

7. Horn switch

8. Ignition timer

9. Wire connector

10. Battery positive terminal

11. Battery negative terminal

12. Frame lug bolt

13. Stoplight switch — rear

14. Switch "ST" lights terminal

15. Switch "G" ignition terminal

16. Switch "B" battery terminal

17. Regulator — rectifier module

18. Alternator to module connector plug

19. Alternator stator

20. Horn

21. Headlamp socket

22. Engine stop switch

23. Stoplight switch — front

24. Ignition coil

25. Main circuit breaker (30A)

26. Rear turn signal connector

27. Tail lamp connector

28. Long stud on starter solenoid

29. Speedometer light

30. Oil pressure signal switch

31. Neutral switch

32. Neutral indicator light

33. Oil signal lamp

34. High beam indicator lamp

35. Tail and stoplight

36. Tachometer

39. Lighting circuit breaker (15A)

40. Ignition circuit breaker (15A)

41. Accessories circuit breaker (15A)

42. Starter switch

43. Right turn signal switch

44. Left turn signal switch

45. Turn signal flasher

46. Left front turn signal lamp

47. Right front turn signal lamp

48. Left rear turn signal lamp

49. Right rear turn signal lamp

50. Starter relay (FXE only)

51. Starter solenoid (FXE only)

52. Starter motor (FXE only)

53. Violet tag

54. Brown tag

55. Ignition sensor

56. Starter motor ground

54 49

54 49

53 48

key to color code

©

black

H

brown

^n)

green

red

®

white

yellow

(BE)

SLUE

©

violet

®

orange

(gv)

gray

©

tan

(pk)

pink

Figure 5-3B. 1980 FXE Wiring Diagram

1980 FXS/FXEF WIRING DIAGRAM KEY

27. Ignition coil

28. Speedometer light

29. Oil pressure signal switch

30. Neutral switch

31. Neutral indicator lamp

32. Oil signal lamp

33. High Beam indicator lamp

34. Tail and stop lamp

35. Tachometer

36. Lighting circuit breaker

37. Ignition circuit breaker

38. Accessories circuit breaker

39. Main circuit breaker

40. Starter switch

41. Right turn signal switch

42. Left turn signal switch

43. Turn signal flasher

44. Left front turn signal lamp

45. Right front turn signal lamp

46. Left rear turn signal lamp

47. Right rear turn signal lamp

48. Starter relay

49. Starter solenoid

50. Starter motor

51. Violet tag

52. Brown tag

53. Handlebar bolt

54. Ignition sensor

55. Starter motor ground

KEY TO COLOR CODE

BE

BLUE

BK

BLACK

BN

BROWN

GN

GREEN

GY

GRAY

O

ORANGE

PK

PINK

R

RED

V

VIOLET

W

WHITE

Y

YELLOW

TN

1. Headlamp housing

2. Socket-plug combination

3. Socket-plug combination

4. Socket-plug combination

5. Socket-plug combination

6. Socket-plug combination

7. Socket-plug combination

8. Wiring harness ^^Headlamp beam switch nO^Horn switch

TT Ignition timer

12. Wire connector

13. Battery positive terminal

14. Battery negative terminal

15. Frame lug bolt

17. Switch "ST" lights terminal

18. Switch "G" ignition terminal

19. Switch "B" battery terminal

20. Regulator-rectifier module

21. Alternator to module connector plug

22. Alternator Stator

23. Horn

24. Headlamp socket

25. Engine stop switch

26. Stop lamp switch — front

SWITCHES

IGNITION-LIGHT SWITCH

GENERAL FL

The ignition-light switch is located on the instrument panel. Lift lock cover and use the key to lock or unlock. It is not necessary to keep the key inserted in the lock to operate this switch after it has been unlocked. The center position of the switch is the "OFF" position for both lights and ignition. The left (counterclockwise) of center position is for accessories only. There are two positions to the right (clockwise) of center position. For U.S.A. operation, both positions operate ignition and lights, with standard wiring. The switch can be locked only in the "OFF" and "ACCESSORIES" positions. The FL ignition switch may be disassembled for repair.

FX/FX E

The ignition-light switch is located below the gas tank on left side of motorcycle. From the "OFF" vertical position there are two positions to the right for ignition and lights. For U.S.A. operation, both positions operate ignition and lights, with standard wiring. Key can only be removed in the "OFF," locked position. The FX ignition switch is not repairable. It must be replaced if it is defective.

FXS/FXEF

The ignition switch is located at the rear of the oil tank, under the seat on the left side of the motorcycle. Operation is identical to the FX models.

DISASSEMBLING IGNITION-LIGHT SWITCH - FL

Remove instrument panel cover by prying out side-cover clip located at trip mileage set knob and turning out mount ing base center screw located in the center of instrument panel below speedometer.

Disconnect all wires connected to switch terminals and remove four switch mounting screws.

See figure 5-4. All directions for disassembly apply with switch in an inverted position. Switch must be in "off" position and unlocked.

Grasp end of roller contact retainer with pliers and simultaneously move it upward and away from roller contact (1). Lift off roller contact and switch mounting plate assembly (2). Notice that this plate is positioned with the three-terminal side away from lock cover hinge.

Reinforcing plate (3) with contact bar holder (4) and roller contact retainer (5) can be removed from switch cover by slipping part assembly sideways until one set of tabs clears slot in switch cover, then lifting and sliding assembly the opposite direction to clear other tab.

Switch base (7) and lock plate (6) can be removed from switch cover. Note that narrow end of elongated hole in lock, and lug on switch lock (8) which fits into hole in lock plate, are toward lock cover hinge.

Lock assembly (8) can now he lifted out of switch cover (9). CLEANING, INSPECTION AND REPAIR

Wash all parts in cleaning solvent and dry with compressed air.

Inspect all parts, particularly roller contact and plate assembly for excessive wear of contacting brass buttons and roller surfaces. Extreme wear of these parts may allow head m

1. Roller contact

2. Switch mounting plate assembly

3. Reinforcing plate

Contact bar holder Roller contact retainer Switch lock plate

7. Switch base

8. Ignition switch cylinder

9. Switch cover

Figure 5-4. Ignition Light Switch — FL

ot roller contact retainer to short against switch lock plate. Loosened terminals on switch mounting plates may also cause a short or an inconsistent positive contact. Replace all worn or rusted parts.

ASSEMBLING IGNITION-LIGHT SWITCH

Apply a light coat of grease to head of roller contact retainer, lock plate, roller contact and contact buttons on switch mounting plate.

Assemble parts in reverse order of disassembly. If lock cylinder had to be removed from case for repair or replacement, it must be replaced in correct position or switch cannot be locked. To reassemble correctly, insert lock cylinder into housing with tumblers in any one of the four registers. While pressing cylinder into housing with fingertip, insert key and turn clockwise as far as possible. Remove key and complete assembly.

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