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techtalk:evo:elec02 [2023/11/26 01:54]
ixl2relax [Circuit Breakers & Fuses]
techtalk:evo:elec02 [2024/01/02 23:52] (current)
hippysmack
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 If the rated amperage for the CB is exceeded, the strip will be overheated, causing it to bend away from the internal contact, thereby opening the circuit and removing the current flow. Once the bi-metallic strip has cooled sufficiently,​ it will return from its heated position and once again make contact. This will allow the current to begin flowing again. If the circuit is still drawing excessive current, the CB will repeat the open & close cycling until the current level is reduced below the current rating and no longer causing the bi-metallic strip to overheat. If the rated amperage for the CB is exceeded, the strip will be overheated, causing it to bend away from the internal contact, thereby opening the circuit and removing the current flow. Once the bi-metallic strip has cooled sufficiently,​ it will return from its heated position and once again make contact. This will allow the current to begin flowing again. If the circuit is still drawing excessive current, the CB will repeat the open & close cycling until the current level is reduced below the current rating and no longer causing the bi-metallic strip to overheat.
  
-The circuit breakers have copper (incoming power) and silver (outgoing power) colored terminals. The copper terminal of the Main Circuit Breaker is the input side for the battery. ((Ironmick of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?​t=1378363&​page=3)) The keyswitch is attached to the output side, the silver terminal. Also, the wire from the Voltage Regulator (VR) attaches on the (silver) output terminal, then passes current thru the circuit breaker in reverse direction to charge the battery. CAUTION: You should NOT run the output wire from the Voltage Regulator on the copper terminal of the circuit breaker, nor directly to the battery positive terminal, even if the original wiring was connected that way. Connecting in that way would allow a failing VR to short the battery to ground, pulling hundreds of amps of current from the battery and potentially causing a fire.+The circuit breakers have copper (incoming power) and silver (outgoing power) colored terminals. The copper terminal of the Main Circuit Breaker is the input side for the battery. ((Ironmick of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-era-specific-and-model-specific/​ironhead-sportster-motorcycle-talk-1957-1985/​130580-the-dreadful-electrical/​page3?​t=1378363&​page=3)) The keyswitch is attached to the output side, the silver terminal. Also, the wire from the Voltage Regulator (VR) attaches on the (silver) output terminal, then passes current thru the circuit breaker in reverse direction to charge the battery. CAUTION: You should NOT run the output wire from the Voltage Regulator on the copper terminal of the circuit breaker, nor directly to the battery positive terminal, even if the original wiring was connected that way. Connecting in that way would allow a failing VR to short the battery to ground, pulling hundreds of amps of current from the battery and potentially causing a fire.
  
 Although very reliable, over time & usage, the CB may no longer function at the rated current, requiring replacement of the Circuit Breaker. Although very reliable, over time & usage, the CB may no longer function at the rated current, requiring replacement of the Circuit Breaker.
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 {{ :​common:​space100x5px.jpg?​200|}}{{ :​techtalk:​evo:​elec:​86-circuitbreakers-juzyhd.jpg?​400|}} {{ :​common:​space100x5px.jpg?​200|}}{{ :​techtalk:​evo:​elec:​86-circuitbreakers-juzyhd.jpg?​400|}}
  
-**(1991-1993)** ((Pic from juzyHD at http://​xlforum.net/​forums/showthread.php?​t=2072379))+**(1991-1993)** ((Pic from juzyHD at https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-styles/​sportster-motorcycle-project/​195941-made-some-changes-to-my-bike?​t=2072379))
   * All 1991 to 1993 models have 4 circuit breakers mounted on the front side of the rear fender under the seat. ((Clymer 1986-2003 HD Xl/XLH Sportster Service Manual pg 457))   * All 1991 to 1993 models have 4 circuit breakers mounted on the front side of the rear fender under the seat. ((Clymer 1986-2003 HD Xl/XLH Sportster Service Manual pg 457))
   * Circuit Breakers (CB) - Under Seat - Automatically Resettable - Ring Lugs for wiring   * Circuit Breakers (CB) - Under Seat - Automatically Resettable - Ring Lugs for wiring
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 {{ :​common:​space100x5px.jpg?​200|}}{{ :​techtalk:​evo:​elec:​98-03-fuseblock-triangle.jpg?​200|}}{{ :​techtalk:​evo:​elec:​98-03-fuseblock.jpg?​200|}} {{ :​common:​space100x5px.jpg?​200|}}{{ :​techtalk:​evo:​elec:​98-03-fuseblock-triangle.jpg?​200|}}{{ :​techtalk:​evo:​elec:​98-03-fuseblock.jpg?​200|}}
-**(1998-2003)** ((Pics by Shu of the XLForum - http://​xlforum.net/​forums/showthread.php?t=805221 - annotated by IXL2Relax))+**(1998-2003)** ((Pics by Shu of the XLForum - https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-electrical/​sportster-motorcycle-electrical-and-ignition/​96048-bike-not-starting?t=805221 - annotated by IXL2Relax))
  
   * These models have a Main Circuit Breaker, 4 Fuses, the Starter Relay and the Data Link Connector (1200S Only) located under left-side triangle cover to rear of battery.   * These models have a Main Circuit Breaker, 4 Fuses, the Starter Relay and the Data Link Connector (1200S Only) located under left-side triangle cover to rear of battery.
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 **Take Note:** The charging system is designed to keep the battery charged and supply power to run the bike. However, even if you disconnect the regulator from the system (and/or the stator from the regulator), the bike will run just fine on the battery alone. Without being recharged, the battery will slowly discharge (over time, depending on the actual current being drawn) to the point where the voltage will be too low to operate the igntion system and the bike will fail to run. **Take Note:** The charging system is designed to keep the battery charged and supply power to run the bike. However, even if you disconnect the regulator from the system (and/or the stator from the regulator), the bike will run just fine on the battery alone. Without being recharged, the battery will slowly discharge (over time, depending on the actual current being drawn) to the point where the voltage will be too low to operate the igntion system and the bike will fail to run.
  
-The run-time on the battery alone is surprising. If your stator or regulator fails while on a long-distance ride, you can recharge the battery (wherever possible) and then run the bike on it alone. To do so, you should minimize the current draw from unnecessary components by removing the fuses to those component circuits (such as lights) or disconnecting the devices, temporarily. Of course, running in daylight with other riders would be a safe decision in this emergency.((Sportsterpaul rode 500 miles on the battery alone - http://​xlforum.net/​forums/showthread.php?p=5759538&​postcount=437))+The run-time on the battery alone is surprising. If your stator or regulator fails while on a long-distance ride, you can recharge the battery (wherever possible) and then run the bike on it alone. To do so, you should minimize the current draw from unnecessary components by removing the fuses to those component circuits (such as lights) or disconnecting the devices, temporarily. Of course, running in daylight with other riders would be a safe decision in this emergency.((Sportsterpaul rode 500 miles on the battery alone - https://www.xlforum.net/​forum/general-area/​organize-a-ride-out-or-find-a-riding-buddy/​195543-2019-east-coast-meet-and-greet/​page30?​postcount=437#​post4315866))
  
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 It is possible for the voltage regulator output wire and the ignition sensor wires to contact the transmission cover screws and transmission case if the wires are not routed properly. Powertrain movement can cause the insulation to be rubbed through resulting in intermittent ignition, charging problems or generating of a fault code on EFI models. ((HD Tech Tip #43 dated September 1995)) It is possible for the voltage regulator output wire and the ignition sensor wires to contact the transmission cover screws and transmission case if the wires are not routed properly. Powertrain movement can cause the insulation to be rubbed through resulting in intermittent ignition, charging problems or generating of a fault code on EFI models. ((HD Tech Tip #43 dated September 1995))
  
-**CAUTION: As shown in the Charging System diagram, BE SURE the output of the voltage regulator is connected to the Keyswitch-Side of the Main Circuit Breaker or Fuse! This is a SAFETY ISSUE. Some models from the factory were wired incorrectly on the battery-side of the main circuit breaker.** ((see http://​xlforum.net/​forums/showthread.php?t=2080336 - Post#24 & #32))+**CAUTION: As shown in the Charging System diagram, BE SURE the output of the voltage regulator is connected to the Keyswitch-Side of the Main Circuit Breaker or Fuse! This is a SAFETY ISSUE. Some models from the factory were wired incorrectly on the battery-side of the main circuit breaker.** ((see https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-electrical/​sportster-motorcycle-electrical-and-ignition/​203144-is-this-battery-failure?t=2080336 - Post#24 & #32))
  
  
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 **Additional XLForum Links related to the charging system:**\\ **Additional XLForum Links related to the charging system:**\\
-Testing Charging System - http://​xlforum.net/​forums/showpost.php?​p=2239332\\ +Testing Charging System - https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-electrical/​sportster-motorcycle-electrical-and-ignition/​84152-no-charging-what-next#​post1736398\\ 
-Discussion of aftermarket regulator - http://​xlforum.net/​forums/archive/index.php/t-1648679.html\\+Discussion of aftermarket regulator - https://www.xlforum.net/​forum/sportster-motorcycle-forum/sportster-motorcycle-electrical/sportster-motorcycle-electrical-and-ignition/​153118-shunt-vs-series-voltage-regulators\\