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techtalk:evo:elec03c [2021/01/26 10:12] 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. The two Orange wires are Pin#1 & Pin#4 follwed 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. | + | 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 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. | 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. | ||
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| (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.) | (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-extface.jpg?230|}}((pic from Mission1 in this XLF thread: http://xlforum.net/forums/showthread.php?t=2078276\\ Annotated 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 - No Wire but jumpered on face from #1 \\ 3 - No wire but jumpered on face from #1 \\ 4 - ORANGE - Jumper Wire from #1 \\ 5 - BLUE - Power from Lights Fuse \\ 6 - No Wire but jumpered on face from #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 | | + | | **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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| \\ | \\ | ||
| - | **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 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. | 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 - No Wire but jumpered on face from #1 \\ 3 - No wire but jumpered on face from #1 \\ 4 - ORANGE - Jumper Wire from #1 \\ 5 - BLUE - Power from Lights Fuse \\ 6 - No Wire but jumpered on face from #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. | | + | | **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 the connector mounted on the 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 | + | 72275-74 - Jumper Connector Plate - For Two Terminals\\ |
| 72277-74 - Jumper Connector Plate - For Three Terminals | 72277-74 - Jumper Connector Plate - For Three Terminals | ||
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| 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 |
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