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techtalk:evo:elec01 [2019/02/26 04:09] ixl2relax [Battery Cables - The Place to Start] |
techtalk:evo:elec01 [2019/06/17 18:35] ixl2relax [Grounding is Critical] |
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| The large Negative Battery Cable on the early models went to rear motor mount. Later, it was moved to the backside of the Primary cavity on the crankcase near the Starter Motor. | The large Negative Battery Cable on the early models went to rear motor mount. Later, it was moved to the backside of the Primary cavity on the crankcase near the Starter Motor. | ||
| - | "I was checking the voltage at the battery against the voltage at the starter, at first it was the same. I moved the bike to get to the other side and double checked the voltage and it dropped significantly. I nudge the battery once and watched the voltage go to zero! I removed the positive lead and it appeared fine on the outside. One good pull on both ends and the end to the starter and about 2" of copper strands slid out from the insulating jacketing."((TimC - http://xlforum.net/forums/showthread.php?t=1513037)) | + | "I was checking the voltage at the battery against the voltage at the starter, at first it was the same. I moved the bike to get to the other side and double checked the voltage and it dropped significantly. I nudge the battery once and watched the voltage go to zero! I removed the positive lead and it appeared fine on the outside. One good pull on both ends and the end to the starter and about 2" of copper strands slid out from the insulating jacketing", said TimC of the XLForum.((http://xlforum.net/forums/showthread.php?t=1513037)) |
| **To check the battery cables** - PULL HARD on both ends of both the positive and the negative cables where they mount to the battery and to the engine. There should be no looseness to the cable at the connector junction. Corrosion in the connectors and the wire itself can be hidden from your casual examination yet will still cause severe loss in current capability. Therefore, PULL HARD to be sure they are solid. | **To check the battery cables** - PULL HARD on both ends of both the positive and the negative cables where they mount to the battery and to the engine. There should be no looseness to the cable at the connector junction. Corrosion in the connectors and the wire itself can be hidden from your casual examination yet will still cause severe loss in current capability. Therefore, PULL HARD to be sure they are solid. | ||
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| Ground connections on the bike are like a spider web - they should all be interconnected through the various ground bolts, harness connectors and individual components. There should only be a very slight difference in resistance between any two ground points in the entire system. If there is excess resistance between any ground point and the negative battery terminal, there is something loose, frayed, corroded or disconnected. | Ground connections on the bike are like a spider web - they should all be interconnected through the various ground bolts, harness connectors and individual components. There should only be a very slight difference in resistance between any two ground points in the entire system. If there is excess resistance between any ground point and the negative battery terminal, there is something loose, frayed, corroded or disconnected. | ||
| - | Over the years, HD has grounded the Sportster electrical systems in a number of ways. In the early models (typically, 1993-earlier), **components were grounded to the frame** at a nearby point while power was distributed throughout the system on a minimal number of wires in the wiring harness. There could be as many as a dozen points on the frame used for grounding. The front lights & instruments were grounded thru a connecting strap between the forks & the frame. | + | Over the years, HD has grounded the Sportster electrical systems in a number of ways. |
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| + | In the early models (typically, 1993-earlier), **components were grounded to the frame** at a nearby point while power was distributed throughout the system on a minimal number of wires in the wiring harness. There could be as many as a dozen points on the frame used for grounding. The front lights & instruments were grounded thru a connecting strap between the fork risers & the handlebars. | ||
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| + | {{:techtalk:evo:elec:86-93-handlebarground.jpg?500|}}{{:techtalk:evo:elec:86-93-devicegrounds.jpg?250|}} | ||
| **Beginning in 1994**, the wiring harness itself began to carry ground wires to various components. The wiring harness by then consisted of many separate power wires to multiple locations, with a number of circuit breakers protecting the various circuits from overload. | **Beginning in 1994**, the wiring harness itself began to carry ground wires to various components. The wiring harness by then consisted of many separate power wires to multiple locations, with a number of circuit breakers protecting the various circuits from overload. | ||
