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techtalk:evo:elec03c [2021/01/05 07:34] ixl2relax |
techtalk:evo:elec03c [2024/01/03 02:06] (current) hippysmack |
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| **Wiring of the Headlight Housing Connector** | **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. | + | 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. The two Orange wires are Pin#1 & Pin#4 followed by the Blue wire as Pin#5, 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. | + | Of course, when looking at the backside of the external mating connector (from the wire side), the pin locations will be reversed, as they are counted from right to left. Just to be clear, the Pin#1 on the mating external connector is Top Right. |
| - | (Note - This is NOT the way the Amp/Tyco Mate-N-Lok connector pins are numbered from the manufacturer.) | + | (Note - This is NOT the way the Amp/Tyco Mate-N-Lok connector pins are numbered from the manufacturer if you happen to find that information.) |
| - | {{:techtalk:evo:elec:88-headlighthousing-conn.jpg?400|}}((pic from Mission1 in this XLF thread: http://xlforum.net/forums/showthread.php?t=2078276\\ Annotated by IXL2Relax)) {{:techtalk:evo:elec:86-93-headlighthousingconn.jpg?250|}}((Diagram by IXL2Relax)) | + | | {{:techtalk:evo:elec:88-headlighthousing-conn.jpg?400|}}((pic from Mission1 in this XLF thread: https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-electrical/sportster-motorcycle-lighting/201229-oem-headlight-bucket?t=2078276\\ Annotated by IXL2Relax)) | {{:techtalk:evo:elec:86-93-headlighthousingconn.jpg?250|}}((Diagram by IXL2Relax))\\ \\ External View of Connector (Reverse Pin#)\\ {{:techtalk:evo:elec:88-headlighthousing-conn-extface.jpg?230|}}((pic from Mission1 in this XLF thread: https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-electrical/sportster-motorcycle-lighting/201229-oem-headlight-bucket?t=2078276\\ Annotated by IXL2Relax)) | |
| + | |||
| + | **1986-1990 Wiring of the Headlight Housing Connector** | ||
| ^ 1986-1990 Wiring of the Headlight Housing Connector || | ^ 1986-1990 Wiring of the Headlight Housing Connector || | ||
| - | | **Mounted (inside) Connector** \\ 1 - ORANGE - Power from Accessory Fuse \\ 2 - Also ORANGE Jumpered from #1 \\ 3 - Also ORANGE Jumpered from #2 \\ 4 - Also ORANGE Jumpered from #3 \\ 5 - BLUE - Power from Lights Fuse \\ 6 - BLUE Jumpered from #5 \\ \\ 7 - PINK - From Coil for Tachometer Trigger \\ 8 - VIOLET - From Lt TS Switch from flasher \\ 9 - TAN - From Neutral Switch \\ 10- GREEN - From Oil Pressure Switch \\ 11- WHITE - From HiBeam wire at Headlight bulb \\ 12- BROWN - From Rt TS Switch from flasher | **External (outside) Connector** \\ 1 - BLACK to Neutral Light (power) \\ 2 - BLACK to Oil Light (power) \\ 3 - ORANGE to Speedometer Light (power) \\ 4 - ORANGE to Tachometer Light (power) \\ 5 - BLACK to Front Left Running Light (power) \\ 6 - BLACK to Front Right Running Light (power) \\ \\ 7 - PINK - To Tachometer Trigger \\ 8 - BLACK w/VIOLET Tape to Left Front TS (+ another wire) \\ 9 - BLACK - To Neutral Light (Gnd=InNeutral) \\ 10- BLACK - To Oil Light (Gnd=LowOilPressure) \\ 11- BLACK - To HiBeam Indicator Light \\ 12- BLACK w/BROWN Tape to Right Front TS (+ another wire) \\ \\ (+) One BLACK wire from Pin#8 and one BLACK wire from Pin#12\\ also goes to either side of the TS Indicator Light | | + | | **Mounted (inside) Connector** \\ 1 - ORANGE - Power from Accessory Fuse \\ 2 - No Wire but jumpered on face from Pin#1 \\ 3 - No wire but jumpered on face from Pin#1 \\ 4 - ORANGE - Jumper Wire from #1 \\ 5 - BLUE - Power from Lights Fuse \\ 6 - No Wire but jumpered on face from Pin#5 \\ \\ 7 - PINK - From Coil for Tachometer Trigger \\ 8 - VIOLET - From Lt TS Switch (flashing ON) \\ 9 - TAN - From Neutral Switch \\ 10- GREEN - From Oil Pressure Switch \\ 11- WHITE - From HiBeam wire at Headlight bulb \\ 12- BROWN - From Rt TS Switch (flashing ON) | **External (outside) Connector** \\ 1 - BLACK to Neutral Light (power) \\ 2 - BLACK to Oil Light (power) \\ 3 - ORANGE to Speedometer Light (power) \\ 4 - ORANGE to Tachometer Light (power) \\ 5 - BLACK to Left Front Running Light (power) \\ 6 - BLACK to Right Front Running Light (power) \\ \\ 7 - PINK - To Tachometer Trigger \\ 8 - BLACK w/VIOLET Tape to Left Front TS (+ another wire) \\ 9 - BLACK - To Neutral Light (Gnd=InNeutral) \\ 10- BLACK - To Oil Light (Gnd=LowOilPressure) \\ 11- BLACK - To HiBeam Indicator Light \\ 12- BLACK w/BROWN Tape to Right Front TS (+ another wire) \\ \\ (+) One BLACK wire from Pin#8 and one BLACK wire from Pin#12\\ also goes to either side of the TS Indicator Light | |
| (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).) | (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).) | ||
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| **Right Turn Signal use Pin#6 & Pin#12**\\ | **Right Turn Signal use Pin#6 & Pin#12**\\ | ||
| - | Pin#6 - sends power to the Right Running Light in the TS housing (BLUE wire inside - BLACK outside). The TS housing is grounded thru the handlebar ground.\\ | + | Pin#6 - sends power to the Right Running Light in the TS housing (Jumpered to Pin#5 (No Wire) inside - BLACK outside). The TS housing is grounded thru the handlebar ground.\\ |
| 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.\\ | 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) | ....... 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**\\ | **Oil Indicator Light (OL) uses Pin#2 & Pin#10**\\ | ||
| - | Pin#2 - sends power to the OL (ORANGE wire inside - BLACK outside)\\ | + | Pin#2 - sends power to the OL (Jumpered to Pin#1 (No Wire) inside - BLACK outside)\\ |
| Pin#10 - active signal from Oil Pressure Sensor (GREEN wire inside - BLACK outside) (Gnd=LoOilPressure) | Pin#10 - active signal from Oil Pressure Sensor (GREEN wire inside - BLACK outside) (Gnd=LoOilPressure) | ||
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| **Speedometer Light uses Pin#3**\\ | **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. | + | Pin#3 - sends power to the Speedometer Light (Jumpered to Pin#1 (No 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**\\ | **Tachometer Light & Signal uses Pin#4 & Pin#7**\\ | ||
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| \\ | \\ | ||
| - | **1993 wiring of the Headlight Housing Connector:**\\ | + | **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. | + | For 1993 (and presumably for 1991-1992) the functional wire locations on this connector (therefore, the wire colors) were arranged a little differently (from 1986-90) 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. | + | 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 sent ON/OFF power to the Turn Signal bulb in order to flash the Turn Signal. This new TSM also allowed the use of 4-way flashers. |
| ^ 1993 Wiring of the Headlight Housing Connector (presumed for 1991-1992 also) || | ^ 1993 Wiring of the Headlight Housing Connector (presumed for 1991-1992 also) || | ||
| - | | **Mounted (inside) Connector (3A)** \\ 1 - ORANGE - Power from Accessory Fuse \\ 2 - Also ORANGE Jumpered from #1 \\ 3 - Also ORANGE Jumpered from #2 \\ 4 - Also ORANGE Jumpered from #3 \\ 5 - BLUE - Lights Fuse Power to front lights \\ 6 - BLUE Jumpered from #5 \\ \\ 7 - VIOLET - From TS Module for Left Side Flash \\ 8 - PINK - From Coil for Tachometer Trigger \\ 9 - WHITE - From HiBeam wire at Headlight bulb \\ 10- TAN - From Neutral Switch \\ 11- GREEN - From Oil Pressure Switch \\ 12- BROWN - From TS Module for Right Side Flash | **External (outside) Connector (3B)** \\ 1 - BLACK to Neutral Light (power) \\ 2 - BLACK to Oil Light (power) \\ 3 - ORANGE to Speedometer Light (power) \\ 4 - ORANGE to Tachometer Light (power) \\ 5 - BLACK to Front Left TS Light (power) \\ 6 - BLACK to Front Right TS Light (power) \\ \\ 7 - VIOLET - Left Turn Signal (Flash-Gnd=ON) \\ 8 - PINK - To Tachometer RPM Trigger \\ 9 - BLACK - Power to HiBeam Indicator (when HiBeam ON) \\ 10- BLACK - active Neutral Indicator (Gnd=InNeutral) \\ 11- BLACK - active Oil Indicator (Gnd=LowOilPressure) \\ 12- BROWN - Right Turn Signal (Flash-Gnd=ON) \\ \\ ... TS Indicator Light wired separately. | | + | | **Mounted (inside) Connector (3A)** \\ 1 - ORANGE - Power from Accessory Fuse \\ 2 - No Wire but jumpered on face from Pin#1 \\ 3 - No wire but jumpered on face from Pin#1 \\ 4 - ORANGE - Jumper Wire from #1 \\ 5 - BLUE - Power from Lights Fuse \\ 6 - No Wire but jumpered on face from Pin#5 \\ \\ 7 - VIOLET - From TSM for Left Side (flashing ON) \\ 8 - PINK - From Coil for Tachometer Trigger \\ 9 - WHITE - From HiBeam wire at Headlight bulb \\ 10- TAN - From Neutral Switch \\ 11- GREEN - From Oil Pressure Switch \\ 12- BROWN - From TSM for Right Side (flashing ON) | **External (outside) Connector (3B)** \\ 1 - BLACK to Neutral Light (power) \\ 2 - BLACK to Oil Light (power) \\ 3 - ORANGE to Speedometer Light (power) \\ 4 - ORANGE to Tachometer Light (power) \\ 5 - BLACK to Right Front Running Light (power) \\ 6 - BLACK to Right Front Running Light (power) \\ \\ 7 - VIOLET - Left Turn Signal (FlashPower=ON) \\ 8 - PINK - To Tachometer RPM Trigger \\ 9 - BLACK - Power to HiBeam Indicator (when HiBeam ON) \\ 10- BLACK - active Neutral Indicator (Gnd=InNeutral) \\ 11- BLACK - active Oil Indicator (Gnd=LowOilPressure) \\ 12- BROWN - Right Turn Signal (FlashPower=ON) \\ \\ ... Turn Signal Indicator Light was wired separately. | |
| (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).) | (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).) | ||
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| **For 1986-1993, the Headlight Housing now uses this P/N 67743-75.**\\ | **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. | 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. | ||
| + | |||
| + | In the parts catalog, on the Wiring & Misc Electrical page, the connectors & pins are listed: | ||
| **Headlight Housing Connector Parts:** | **Headlight Housing Connector Parts:** | ||
| - | The Mounted Connector on Headlight Housing:\\ | + | For the connector mounted on the Headlight Housing:\\ |
| 72276-74 - Connector Shell using male pins\\ | 72276-74 - Connector Shell using male pins\\ | ||
| - | 72039-71A - Male pin for Connector shell (x12) | + | 72039-71A - Male pin for Connector shell (x12)\\ |
| + | 72275-74 - Jumper Connector Plate - For Two Terminals\\ | ||
| + | 72277-74 - Jumper Connector Plate - For Three Terminals | ||
| - | The External Connector:\\ | + | For the external mating connector:\\ |
| 72278-74A - Connector Shell using female pins\\ | 72278-74A - Connector Shell using female pins\\ | ||
| 72038-71A - Female pin for Connector Shell (x12)\\ | 72038-71A - Female pin for Connector Shell (x12)\\ | ||
| - | 67839-74 - Weatherproofing boot for External Connector | + | 67839-74 - Weatherproofing boot on External Mating Connector |
| \\ | \\ | ||
| An XLForm discussion related to this subject occured in this thread:\\ | An XLForm discussion related to this subject occured in this thread:\\ | ||
| - | http://xlforum.net/forums/showthread.php?t=2078276 | + | https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-electrical/sportster-motorcycle-lighting/201229-oem-headlight-bucket?t=2078276 |
| \\ | \\ | ||
