EVO: Electrical System - Sub-03C

Wiring of the Headlight Housing Connector

The original wiring diagrams do not have Pin# identificaitons. So in this description we will identify pin numbers for the internal connector (mounted to the headlight housing) starting with the Orange wires and looking at the connector from the backside, where the wires are inserted. We will call these four Orange wires Pin#1-4 follwed by the two Blue wires as Pin#5-6, naming them from left to right. The row of wires below that will be numbered Pin#7-12. To be clear, the Pin#1 is Top Left.

Of course, when looking at the backside of the external connector, where the wires are inserted, the pin location will be reversed, as they are counted from right to left. Just to be clear, the Pin#1 from the outside is Top Right.

(Note - This is NOT the way the Amp/Tyco Mate-N-Lok connector pins are numbered from the manufacturer.)

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(These are the orignal OEM wire colors - Since many bikes have been rewired over the years, your colors may vary and even the pin function locations may have been reorganized if your bike wiring has been butchered (errr - customized).)

Another way of presenting the above data (related to the 1986-1990 wiring) is to summarize the functional connections on this Headlight Housing Connector:

Left Turn Signal uses Pin#5 & Pin#8
Pin#5 - sends power to the Left Turn Signal (BLUE wire on inside connector - BLACK wire outside) - This is not the blinking signal to the TS it is the power.
Pin#8 - blinking signal to the Left TS - This is a BLACK wire with a VIOLET Tape Band. This same pin has a wire to one side of the TS Indicator.
……. With other wires, this same signal (from the Handlebar Left TS Switch) is used to drive the Left Rear Turn Signal)

Right Turn Signal use Pin#6 & Pin#12
Pin#6 - sends power to the Right Turn Signal (BLUE wire inside - BLACK outside) - This is not the blinking signal to the TS it is the power.
Pin#12 - blinking signal to the Right TS - This is a BLACK wire with a BROWN Tape Band. This same pin has a wire to one side of the TS Indicator.
……. With other wires, this same signal (from the Handlebar Right TS Switch) is used to drive the Right Rear Turn Signal)

Oil Indicator Light (OL) uses Pin#2 & Pin#10
Pin#2 - sends power to the OL (ORANGE wire inside - BLACK outside)
Pin#10 - active signal from Oil Pressure Sensor (GREEN wire inside - BLACK outside) (Gnd=LoOilPressure)

Neutral Indicator Light (NL) uses Pin#1 & Pin#9
Pin#1 - sends power to the NL (ORANGE wire inside - BLACK outside)
Pin#9 - active signal from Neutral Switch (TAN wire inside - BLACK outside) (Gnd=InNeutral)

HiBeam Indicator Light (HL) uses ONLY Pin#11
Pin#11 - WHITE wire on the inside connector comes to it from the headlight bulb socket. It has power when the HiBeam is ON. The outside connection to Pin#11 is a BLACK wire that goes to the HiBeam Indicator Bulb (HL). The other side of the HL is grounded to the Upper Fork Bracket.
(NOTE: the Hi or Lo Beam power for the bulb comes from the Left Handlebar Hi/Lo Switch directly to the headlight bulb socket and IS NOT wired thru this 12-pin connector.)

Speedometer Light uses Pin#3
Pin#3 - sends power to the Speedometer Light (ORANGE wire inside - ORANGE wire outside). The other side of the light is grounded thru the speedometer itself, thru the handlebar ground.

Tachometer Light & Signal uses Pin#4 & Pin#7
Pin#4 - sends power to the Tachometer Light (ORANGE wire inside - ORANGE wire outside). The other side of the light is grounded thru the tachometer itself, thru the handlebar ground.
Pin#7 - sends the RPM Signal Pulses from the Ignition Control Module to the Tachometer (PINK wire inside - PINK outside).

1993 wiring of the Headlight Housing Connector:
For 1993 (and presumably for 1991-1992) the functional wire locations on this connector (therefore, the wire colors) were arranged a little differently but all the same functions were implemented.

In 1991, a Turn Signal Canceller Module (TSM) was introduced on the Sportster. This allowed pulses from the Speeodmeter to cancel the flashing turn signals (not wired thru this 12-pin connector). This TSM now took over the function of the simple automobile-type flasher that was used previously. The new TSM did not route the active TS power signals thru the Turn Signal Switches (as previously) but rather, it simply obtained a low-current pulse from the momentary TS handlebar switches to start or stop the flashing function within the TSM. When flashing was needed, the TSM grounded one wire of the Turn Signal bulb in order to flash the Turn Signal. This new TSM also allowed the use of 4-way flashers.

(These are the orignal 1993 OEM wire colors - Since many bikes have been rewired over the years, your colors may vary and even the pin function locations may have been reorganized if your bike wiring has been butchered (errr - customized).)

Headlight Housing & Connector Part Numbers

For 1986-1993, the Headlight Housing now uses this P/N 67743-75.
This housing, although it has an earlier -75 suffix, superceded the original version which was P/N 67743-84. The -84 version used a Speedometer Cable Retainer, P/N 56073-83. It is believed that the -75 version (used before & later superceding the -84 version) does not use this retainer. The -84 version was stock from 1984 thru 1993 and sometime later the 67743-75 version superceded it for replacement parts. Likely, they didn't want to make one version with the retainer & one without it.

Headlight Housing Connector Parts:

The Mounted Connector on Headlight Housing:
72276-74 - Connector Shell using male pins
72039-71A - Male pin for Connector shell (x12)

The External Connector:
72278-74A - Connector Shell using female pins
72038-71A - Female pin for Connector Shell (x12)
67839-74 - Weatherproofing boot for External Connector

An XLForm discussion related to this subject occured in this thread:
http://xlforum.net/forums/showthread.php?t=2078276