Chopper Cache

Fitment, source notes & wire connections

1991 Harley Evo Softail Minimal Rewire

1991 · Softail Evolution · Electric start / two-wire stator charging / electronic ignition

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Community reference trace · By Choppercache

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Diagram reference

An interactive 1991 Evo Softail wiring reference for an electric-start, two-wire stator, regulator/rectifier, electronic-ignition, headlight, tail-light, and brake-light configuration.

This diagram shows 15 components and 23 wire connections. The details below describe the saved diagram; they do not confirm compatibility with your machine.

Recorded fitment
1991 Softail Evolution
Configuration
Electric start / two-wire stator charging / electronic ignition
Circuits labeled in the diagram
Charging, Main, Grounds, Lighting, Ignition, Starting

Components shown

  • STAT · Single-Phase Stator

    Two AC stator outputs

  • REG/REC · Regulator / Rectifier

    2 AC in / DC out / ground

  • BAT · Battery

    Negative grounded to frame

  • GND · Ground

    Battery negative return

  • KEY · Key Switch

    Battery / accessory / ignition-on / spring start

  • DIMMER · Toggle Switch

    Two-position selector

  • HEAD · Headlight

    High / low beam

  • COIL · Ignition Coil

    Key-switched primary

  • EI · Electronic Ignition

    Power / pickup pair / coil negative

  • BRAKE SW · Brake Switch

    Normally-open brake-light switch

  • BRAKE · Brake Light

    Tail / brake lamp

  • GND · Ground

    Brake-light chassis return

  • SR-791783-1 · Starter Relay

    Battery / start trigger / motor

  • M-799428-2 · Starter Motor

    High-current motor / case ground

  • PICK · Magnetic Pickup

    Two-wire crank trigger

Source notes

Community reference trace · Choppercache Community minimal-wiring discussion for a 1991 Evo Softail. Confirm the installed starter, ignition-module, and regulator/rectifier terminal labels before wiring. Recorded reference URLs: https://forum.chopcult.com/forum/nbsp/american-bikes-build-threads/47209-easy-chopper-wiring-91-evo-softail

Community reference trace · Choppercache

Publication note: Community minimal-wiring discussion for a 1991 Evo Softail. Confirm the installed starter, ignition-module, and regulator/rectifier terminal labels before wiring.

Limitations and checks

Community minimal-wiring discussion for a 1991 Evo Softail. Confirm the installed starter, ignition-module, and regulator/rectifier terminal labels before wiring. These recorded references do not establish that this circuit has been tested on your motorcycle. Match the installed components, polarity, terminal pinouts, wire sizes, and circuit protection to the relevant service documentation before applying power.

Verify your hardware pinouts, polarity, wire sizes, and component ratings before applying power.

Wire connections (23)
Wire connections recorded in this diagram
FromToGaugeColor
BAT · B−GND · GND6 AWGBlack / frame ground
BAT · B+KEY · BATReference not shownDiagram red / source unlabeled
STAT · AC 1REG/REC · AC 1Reference not shownDiagram green / source unlabeled
REG/REC · DC +BAT · B+Reference not shownDiagram green / source unlabeled
KEY · ACCDIMMER · INReference not shownDiagram yellow / source unlabeled
DIMMER · HIGHHEAD · HIGHReference not shownDiagram yellow / source unlabeled
DIMMER · LOWHEAD · LOWReference not shownDiagram blue / source unlabeled
KEY · ONCOIL · KEYReference not shownDiagram brown / source unlabeled
COIL · POINTSEI · COIL −Reference not shownDiagram brown / source unlabeled
KEY · ACCBRAKE SW · INReference not shownReference not labeled
BRAKE SW · OUTBRAKE · BRAKEReference not shownDiagram red / source unlabeled
BRAKE · GNDGND · GNDReference not shownBlack / frame ground
KEY · ACCBRAKE · TAILReference not shownDiagram yellow / source unlabeled
SR-791783-1 · 30 BATBAT · B+6 AWGRed
SR-791783-1 · 87 MOTORM-799428-2 · MOTOR6 AWGRed
SR-791783-1 · 85 GNDGND · GND8 AWGBlack
KEY · STARTSR-791783-1 · 86 STARTReference not shownBlue
STAT · AC 2REG/REC · AC 2Reference not shownDiagram green / source unlabeled
REG/REC · GNDGND · GND6 AWGBlack / frame ground
KEY · ONEI · IGN +Reference not shownDiagram brown / source unlabeled
PICK · PICKUP +EI · PICKUP +Reference not shownDiagram brown / source unlabeled
PICK · PICKUP −EI · PICKUP −Reference not shownDiagram brown / source unlabeled
EI · GNDGND · GND6 AWGBlack / frame ground
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