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techtalk:evo:elec03 [2019/08/02 04:43]
ixl2relax [Single-fire Ignition To Dual-fire Tachometer Adapter]
techtalk:evo:elec03 [2019/12/02 21:20] (current)
ixl2relax [Speedometer Connectors]
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 | Do not remove or install the master cylinder assembly and do not remove the switch housing assembly without first placing a 5/32in (4mm) thick cardboard insert between the brake lever and lever bracket. Removing the assembly without the insert in place may result in damage to the rubber boot and plunger of the front stoplight switch. | | Do not remove or install the master cylinder assembly and do not remove the switch housing assembly without first placing a 5/32in (4mm) thick cardboard insert between the brake lever and lever bracket. Removing the assembly without the insert in place may result in damage to the rubber boot and plunger of the front stoplight switch. |
  
-{{:​techtalk:​evo:​elec:​brakelight-taillight-wiring-1.jpg?​800|}}+{{:​techtalk:​evo:​elec:​brakelight-taillight-wiring-1.jpg?​800|}} ​((Illustration created by IXL2Relax at the XLForum))
  
 The Rear Brake Switch is installed in the rear brake hydraulic line from the master cylinder to the caliper, typically on the left side ahead of the caliper. It is a hydraulically activated switch, meaning that at a certain level of hydraulic pressure in the brake line, the switch closes to conduct power thru it to the rear brake light. (1986-2019 used the same rear brake switch, P/N 72023-51E. It's possible to also use a NAPA P/N ECH SL147.)((http://​xlforum.net/​forums/​showthread.php?​t=49330)) The Rear Brake Switch is installed in the rear brake hydraulic line from the master cylinder to the caliper, typically on the left side ahead of the caliper. It is a hydraulically activated switch, meaning that at a certain level of hydraulic pressure in the brake line, the switch closes to conduct power thru it to the rear brake light. (1986-2019 used the same rear brake switch, P/N 72023-51E. It's possible to also use a NAPA P/N ECH SL147.)((http://​xlforum.net/​forums/​showthread.php?​t=49330))
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 |  14 | | | 1998 Only - Not-S Not Used ^ 1998 ONLY - BK/Y - For Ck Eng Lt | |  14 | | | 1998 Only - Not-S Not Used ^ 1998 ONLY - BK/Y - For Ck Eng Lt |
 | Dev= Speedo/​Tach/​Indicator |||| | | Dev= Speedo/​Tach/​Indicator |||| |
 +
 +^  Connector 20A/B & Pins (on Main Harness) All Models |||
 +^ Years ^ Shell P/N ^ Pin P/N |
 +|  1994-1996 ​  ​| ​ 72119-94BK ​ |  72191-94 ​ |
 +|  1997        |  73162-96BK ​ |  73191-96 ​ |
 +|  1998 (14p)  |  73164-96BK ​ |  73191-96 ​ |
 +|  1999-2003 ​  ​| ​ 74119-98BK ​ |  74193-98 ​ |
 \\ \\
 +
  
 ---- ----
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 ===== Indicator Lights - Idiot Lights ===== ===== Indicator Lights - Idiot Lights =====
  
-**1992-1994** models used Indicator Units without replaceable individual bulbs - The entire unit needs to be replaced:\\+**1992-1994** models used Indicator Units without replaceable individual bulbs - The entire unit (incandescent bulb in individual cylindrical housing with pig tail wires) ​needs to be replaced:\\
   * 68020-92A - INDICATOR LAMP, OIL PRESSURE (RED)\\   * 68020-92A - INDICATOR LAMP, OIL PRESSURE (RED)\\
   * 68021-92A - INDICATOR LAMP, TURN SIGNAL (GREEN) (2 needed)\\   * 68021-92A - INDICATOR LAMP, TURN SIGNAL (GREEN) (2 needed)\\
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 Here is info regarding the repair of faulty indicator lights (2014-later) that use Speedometer activation thru the CANbus. Here is info regarding the repair of faulty indicator lights (2014-later) that use Speedometer activation thru the CANbus.
-  * [[techtalk:​evo:​elec03b|Subdoc - Tech Info From '​jbee'​ of the XLForum]]+  * [[techtalk:​evo:​elec03b|Subdoc - Indicator / Warning Lights Not Working - Repair]]
  
  
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 ===== Headlight ===== ===== Headlight =====
  
-Early model Sportsters (1990-older) used a sealed-beam,​ 5-3/4" headlamp. In 1991, they were supplied with a headlamp ​lense (bulb housing) which uses a replaceable bulb known as an H4 version. The supplied bulbs were rated at 55w for low beam and 60w for high beam. Modern bulb model 9003 is also physically equivalent. Various brands and types of H4 bulbs are available including new LED versions. ​Not all LED units are sized the same so some testing of the physical depth (both inside the lense and behind the lense) is necessary to proper fitting.+Early model Sportsters (1990-older) used a sealed-beam,​ 5-3/4" headlamp. In 1991, they were supplied with a headlamp ​lens (bulb housing) which uses a replaceable bulb known as an H4 version. The supplied bulbs were rated at 55w for low beam and 60w for high beam. Modern bulb model 9003 is also physically equivalent ​and may have the H4 designation as well. Various brands and types of bulbs are available ​in the H4/9003 base fitting ​including new LED versions. ​However, not all LED units are sized & positioned correctly for the H4/9003 lens, so some testing of the physical depth (both inside the lens and behind the lens) is necessary to proper fitting. It is important to obtain LED bulbs that are compatible with the headlight housing lens design - It is important in order to produce an appropriate light beam pattern similar to the original motorcycle style projection.
  
-The low beam usually throws a narrow light, a relatively ​short distance. The high beam is a broader beam and is redirected (by the reflector) to throw light farther down the roadway.+The low beam usually throws a more narrow light, a relatively ​shorter ​distance. The front-most element in the bulb has a small reflector built into the bulb to throw the produced light upwards against the lens reflector in order that the light will be projected downward onto the road surface. The high beam (produced by a second element closer to the connector that throws light in a 360° pattern) produces ​a broader beam and is redirected (by the entire ​reflector) to throw light farther ​and wider down the roadway.
  
-Typical (recent) wiring practice is to supply the low-beam power on a Yellow Wire and the high-beam power on a White Wire. These wires come from the Left Handlebar, Hi/Lo Headlight Switch. With the introduction of the BCM in 2014, the handlebar switches are digital and communicate their status to the BCM over the CANbus. The BCM uses BLUE/Yellow & BLUE/White Wires to supply power to the Lo & Hi headlight filaments.+Typical (recent) ​HD wiring practice is to supply the low-beam power on a Yellow Wire and the high-beam power on a White Wire. These wires come from the Left Handlebar, Hi/Lo Headlight Switch. With the introduction of the BCM in 2014, the handlebar switches are digital and communicate their status to the BCM over the CANbus. The BCM uses BLUE/Yellow & BLUE/White Wires to supply power to the Lo & Hi headlight filaments
 + 
 +See this [[http://​candlepowerinc.com/​pdfs/​H4_9003.pdf|PDF file at the Candlepower brand website]] for some additional information about H4 & 9003(HB2) specifications. Also an interesting read that shows reflection diagrams is [[https://​ratwell.com/​technical/​BoschH4.html|THIS WEB PAGE LINK]] regarding H4 vs 9003 bulbs.
  
 {{techtalk:​evo:​elec:​h4-bulb-conn.jpg}}((Illustration created by IXL2Relax at the XLForum)) {{techtalk:​evo:​elec:​h4-bulb-conn.jpg}}((Illustration created by IXL2Relax at the XLForum))
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 \\ \\
  
-{{:​techtalk:​evo:​elec:​3157-bulbsocket.jpg?​400|}}+{{:​techtalk:​evo:​elec:​3157-bulbsocket.jpg?​400|}} ​((Illustration created by IXL2Relax at the XLForum))
  
 \\ \\
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 The front TS units have dual-element bulbs (P/N 68168-89A - #1157) that provide Running & Turn Signal functions. The rear TS units have single-element bulbs (P/N  68572-64B - #1156) that provide Turn Signal functions only. The front TS units have dual-element bulbs (P/N 68168-89A - #1157) that provide Running & Turn Signal functions. The rear TS units have single-element bulbs (P/N  68572-64B - #1156) that provide Turn Signal functions only.
  
-    * (Converting to LEDs) - Because of the way these bikes were wired, you can replace the single current/​heat-activated flasher with a new electronic flasher that is capable of properly flashing LEDs or Incandescent bulbs. However, the indicator light may need to be modified by grounding one side and feeding power from the right and left circuits thru diodes to the power side of the indicator.+    * (Converting to LEDs) - Because of the way these bikes were wired, you can replace the single current/​heat-activated flasher with a new electronic flasher that is capable of properly flashing LEDs or Incandescent bulbs. However, the indicator light may need to be modified by grounding one side and feeding power from the right and left circuits thru diodes to the power side of the indicator.\\ (See the schematic mods in the REF section: [[techtalk:​ref:​elec20#​led_turn_signal_schematic|HERE]])
 \\ \\
  
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       * Now, start the bike and check the turn signal functions       * Now, start the bike and check the turn signal functions
       * (Note: a variation is to use the 4-way flashers for 15 flashes after the individual turn signals)       * (Note: a variation is to use the 4-way flashers for 15 flashes after the individual turn signals)
-    * (If your particular module for these years does not respond correctly after doing the above procedure, you may need to install load equalizer resistors as detailed for earlier models.)+    * (If your particular module for these years does not respond correctly after doing the above procedure, you may need to install load equalizer resistors as detailed for earlier models. BUT, you may also want to wait for a week, putting up with the hyperflash to see if your TSM is just a 'slow learner'​ and whether it will '​eventually'​ learn to deal with the LEDs.)((xElvis at xlforum.net/​forums/​showthread.php?​t=2074413))
     * Service Bulletin M-1115 relates to earlier version TSM/TSSM for BT models (using a similar procedure with 5-blinks required), but might apply to later XL versions.     * Service Bulletin M-1115 relates to earlier version TSM/TSSM for BT models (using a similar procedure with 5-blinks required), but might apply to later XL versions.
 \\ \\
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 The above models have no center Tail Light. The BCM creates Run/​Stop/​Turn functions with the Rear Right & Left Turn Signal units. The rear turn signal bulbs are dual-element bulbs (P/N 68168-89A - #1157). The Dim Element is used as the Running Tail Light while the Bright Element is used for both the Turn Signal & Stop Light Function. ​ The above models have no center Tail Light. The BCM creates Run/​Stop/​Turn functions with the Rear Right & Left Turn Signal units. The rear turn signal bulbs are dual-element bulbs (P/N 68168-89A - #1157). The Dim Element is used as the Running Tail Light while the Bright Element is used for both the Turn Signal & Stop Light Function. ​
  
-    * (Converting to LEDs) - The BCM has a definite procedure for learning the lighting loads that are normal (whether incandescent,​ LED or otherwise). The instructions state:+    * (Converting to LEDs) - The BCM has a definite procedure ​(using the 4-way Hazard Flashing) ​for learning the lighting loads that are normal (whether incandescent,​ LED or otherwise). The instructions state:
       * The BCM can self-learn when the Hazard flashers are active after the LED installation       * The BCM can self-learn when the Hazard flashers are active after the LED installation
       * The BCM ignores the first two cycles of the Hazard flashes       * The BCM ignores the first two cycles of the Hazard flashes
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 **Simplified Schematics of Turn Signal Circuits**\\ **Simplified Schematics of Turn Signal Circuits**\\
  
-{{techtalk:​evo:​elec:​86-90-stockturnsignaldesign.jpg|}}((Illustration created by IXL2Relax at the XLForum)) +{{techtalk:​evo:​elec:​86-90-stockturnsignaldesign.jpg?600|}}((Illustration created by IXL2Relax at the XLForum))\\ 
 +(For 86-90 LED mods see the schematic in the REF section: [[techtalk:​ref:​elec20#​led_turn_signal_schematic|HERE]])
 \\ \\
 {{techtalk:​evo:​elec:​91-13-stockturnsignaldesign.jpg?​600|}}((Illustration created by IXL2Relax at the XLForum)) {{techtalk:​evo:​elec:​91-13-stockturnsignaldesign.jpg?​600|}}((Illustration created by IXL2Relax at the XLForum))