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techtalk:ih:elec02 [2020/03/22 18:11]
hippysmack [Voltage Regulator]
techtalk:ih:elec02 [2021/06/15 01:49] (current)
hippysmack [Generator Drive Gears]
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 ====== FUSES, RELAYS, CHARGING SYSTEM ====== ====== FUSES, RELAYS, CHARGING SYSTEM ======
 \\ \\
-See also illustrated ​[[techtalk:ref:elec07|1959-1985 Sportster Main Wiring Diagrams (created with reference to the OEM manual)]] ​in the REF section ​of the Sportsterpedia\\+See also in the Sportsterpedia:​ \\ 
 + ​* ​[[techtalk:ih:elec08|1959-1985 Sportster ​Illustrated ​Main Wiring Diagrams (created with reference to the OEM manual)]] ​\\ 
 + * [[techtalk:​ref:​elec07|The REFerence Section has simplified wiring diagrams for custom rewiring.]] \\ 
 + * [[techtalk:​ih:​elec08#​l1984-1985_wiring_issue_-_might_be_dangerous|For L84-85 models, be sure to check the warning ​of a potential danger issue with the main wiring.]]
 ===== Circuit Breakers ===== ===== Circuit Breakers =====
- +Be sure to review the basic [[techtalk:​ref:​elec01|Electrical Concepts]] in the Reference Section, especially wire gauging. ​\\
-Be sure to review the basic [[techtalk:​ref:​elec01|Electrical Concepts]] in the Reference Section, especially wire gauging.+
  
 The Circuit Breakers (CB) used on Sportsters are of the self-resetting type. Once they break contact, they will automatically reset after a period of time. These breakers function based on a bi-metallic strip that is heated by current flowing through the strip. More current will cause more heat. The Circuit Breakers (CB) used on Sportsters are of the self-resetting type. Once they break contact, they will automatically reset after a period of time. These breakers function based on a bi-metallic strip that is heated by current flowing through the strip. More current will cause more heat.
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 The following quotation makes the point that fuses are often slow to react to overcurrent situations. It is critical to replace rated fuses with the same rating in order to properly protect the circuits.\\ The following quotation makes the point that fuses are often slow to react to overcurrent situations. It is critical to replace rated fuses with the same rating in order to properly protect the circuits.\\
 <​blockquote>​First,​ fuse ratings can be a bit misleading. A 10A ATO (automotive) fuse will conduct 11 amps for 100 hours minimum. At 13.5 Amps a 10A ATO fuse can take as long as 10 minutes to blow. It is not like once you draw 10 amps "​poof"​ the fuse is gone. (From FUSE SIZING PRIMER located at http://​www.powerlet.com/​learningCenter/​fuseSizing)</​blockquote>​ <​blockquote>​First,​ fuse ratings can be a bit misleading. A 10A ATO (automotive) fuse will conduct 11 amps for 100 hours minimum. At 13.5 Amps a 10A ATO fuse can take as long as 10 minutes to blow. It is not like once you draw 10 amps "​poof"​ the fuse is gone. (From FUSE SIZING PRIMER located at http://​www.powerlet.com/​learningCenter/​fuseSizing)</​blockquote>​
 +
 +{{:​techtalk:​ih:​elec:​circuit_breaker_-_main_xlh_74589-71_pic1_by_jrsvintageharley1990.jpg?​direct&​300|}} ((photo courtesy of Ebay seller, jrsvintageharley1990. [[https://​www.ebay.com/​str/​jrsvintageharleyparts?​_trksid=p2047675.l2563|Link to Ebay Store]] : )) {{:​techtalk:​ih:​elec:​circuit_breaker_-_main_xlh_74589-71_pic2_by_jrsvintageharley1990.jpg?​direct&​300|}} ((photo courtesy of Ebay seller, jrsvintageharley1990. [[https://​www.ebay.com/​str/​jrsvintageharleyparts?​_trksid=p2047675.l2563|Link to Ebay Store]] : )) {{:​techtalk:​ih:​elec:​circuit_breaker_-_xlch_main_74589-72_pic1_by_tomscybershop.jpg?​direct&​300|}} ((photo courtesy of Ebay seller, jrsvintageharley1990. [[https://​www.ebay.com/​str/​jrsvintageharleyparts?​_trksid=p2047675.l2563|Link to Ebay Store]] : )) \\
 +
 +{{:​techtalk:​ih:​elec:​1970-1972_main_circuit_breaker_location_by_the_doctor71.jpg?​direct&​300|}} ((photo by The Doctor71 of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=2078550)) {{:​techtalk:​ih:​elec:​circuit_breaker_clips_-_1973-1978_sportster_by_hcrashster.jpg?​direct&​300|}} ((photo by hcrashster of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=1297584&​page=3)) {{:​techtalk:​ih:​elec:​circuit_breaker_cluster_1977_xlch_by_hopper.jpg?​direct&​300|}} ((photo by Hopper of the XLFORUM, annotated by Hippysmack http://​xlforum.net/​forums/​showthread.php?​t=957851)) \\
 +
 +{{:​techtalk:​ih:​elec:​circuit_breakers_1979-1981_compilation_from_cleanmotorcycleframes_and_motorhedmike.jpg?​direct&​300|}} ((photo combo by Hippysmack from pics from motorhedmike of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=2072078&​highlight=oil+filter+bracket and Ebay seller, cleanmotorcycleframes,​ [[https://​www.ebay.com/​str/​cleanmotorcycleframes|Link to Ebay Store]] ))  {{:​techtalk:​ih:​elec:​circuit_breakers_1982-1985_sportster_by_flthd31.jpg?​direct&​300|}} ((photo by flthd31 of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​p=5895447#​post5895447)) \\
  
 \\ \\
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 {{:​techtalk:​ref:​elec:​1978_sportster_xl_fuse_wire_by_hippysmack.png?​direct&​500|}} ((drawing by Hippysmack)) \\ {{:​techtalk:​ref:​elec:​1978_sportster_xl_fuse_wire_by_hippysmack.png?​direct&​500|}} ((drawing by Hippysmack)) \\
  
 +===== Capacitor =====
 +XLCH used a capacitor (32727-63) to improve power to the horn on mid 1963-1969 year models (starting above engine number 63XL 3015) ((1957-1967 HD Sportster Parts Catalog, pg 27)) \\
 +From 1966-1969, it is mounted on top of the seat casting on the left side bolted with a #10-32 x 5/8" screw, (3) exterior teeth lockwashers and a nut. \\
 +1971 parts catalog shows it's use thru 71 but the L69 wiring diagrams only show the use of the capacitor thru E1969. \\  ​
  
-====== ​Generator ​ ​======+{{:​techtalk:​ih:​elec:​capacitor_on_1966-1969_xlch_by_magneto_sportster.jpg?​direct&​300|}} ((photo by Magneto Sportster of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=1677718&​page=2)) {{:​techtalk:​ih:​elec:​regulator_on_1966-1969_xlch_by_magneto_sportster.jpg?​direct&​300|}} ((photo by Magneto Sportster of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=1677718&​page=2)) \\ 
 + 
 +====== Battery ====== 
 +===== Sub Documents ===== 
 +  * [[techtalk:​ih:​elec02m|Pics and Information on stock IH Battery Trays and Parts]] 
 + 
 + 
 +====== Generator ====== 
 +Removal: \\ 
 +There is a trick to removing the generator: Lift up on the inner end and hold down on the outer end then remove it. ((IronMick of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​p=754976)) \\
  
 ===== Sub Documents ===== ===== Sub Documents =====
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 The purpose of polarizing is to tell the generator whether to output positive or negative ground. \\ The purpose of polarizing is to tell the generator whether to output positive or negative ground. \\
  
 +**A little bit about polarizing.**\\
 +Why do generators need to be polarized? Generators need some magnetism to get started. This "​residual"​ magnetism remains in the field pole pieces even after the engine has stopped. The next time the generator starts up, the residual magnetism creates a small voltage in the Armature windings. Not enough to charge the battery, but enough to allow the field windings to draw current. As the field current increases, the pole pieces create even more magnetism. That makes even more voltage in the armature, and the cycle continues until the generator is capable of producing maximum output.
  
 +Anytime a generator is disconnected from the system, there is a possibility the residual magnetism may have decreased to the point where it can no longer get the generator started producing voltage. In the case of a new generator or one which has been mis-treated,​ the residual may even be of the wrong direction (north and south poles reversed).
 +
 +Polarization is a simple process used to restore the field pole residual magnetism and ensure the magnetic direction is correct.
 +((Decman - http://​xlforum.net/​forums/​showthread.php?​t=1040003 Post#6))
 \\ \\
  
 +===== Generator Drive Gears =====
 +There were several generator drive gears used for K Models and Sportsters and even more used on other HD models. \\
 +
 +  * **1952-1962 K/​KH/​Sportsters** used a drive gear with an integral oil slinger (daisy wheel) on the end and pinned to the generator shaft. \\ It looks like a gear with a tinker toy connector glued on the end. It's a lathe machined affair combined with a spring loaded sleeve in the cover. \\ These are great gears but no one repops them and they are expensive and hard to find.
 +    * **K and KH Models** used gear (31071-52). \\
 +    * **1957 (only) XL Sportster** used gear (31071-52A) with no nut or washer.
 +    * **1958-1962 Sportsters** also used a daisy wheel gear (31071-58) but now bolted to the generator shaft.
 +  * **L1962-1978 Sportsters** used a more standard looking 14T gear (31073-63) used with a 1-5/8" washer style slinger (31067-63). \\ Not as good but a lot cheaper to make.
 +  * **1979-1981 Sportsters** used 14T gear (31073-63A) with the 1-5/8" slinger washer (31067-63).
 +  * **1982-E1984 Sportsters** used the same 14T gear (31073-63A) with a 1-3/4" slinger washer (31066-82) to accommodate the larger crankcase breather valve.
  
 +{{:​techtalk:​ih:​elec:​generator_drive_gear_k-kh_or_xl_pic1_by_j-dvintage.jpg?​direct&​300|}} ((photo courtesy of Ebay seller, JDVintagellc. [[https://​www.ebay.com/​str/​jdvintagellc?​_trksid=p2047675.l2563|Link to Ebay Store]] )) {{:​techtalk:​ih:​elec:​generator_drive_gear_k-kh_or_xl_pic2_by_j-dvintage.jpg?​direct&​300|}} ((photo courtesy of Ebay seller, JDVintagellc. [[https://​www.ebay.com/​str/​jdvintagellc?​_trksid=p2047675.l2563|Link to Ebay Store]] )) \\
 + 
 +{{:​techtalk:​ih:​elec:​generator_drive_gear_k-kh_or_xl_pic3_by_j-dvintage.jpg?​direct&​300|}} ((photo courtesy of Ebay seller, JDVintagellc. [[https://​www.ebay.com/​str/​jdvintagellc?​_trksid=p2047675.l2563|Link to Ebay Store]] )) 
 +{{:​techtalk:​ih:​elec:​generator_drive_gear_k-kh_or_xl_pic4_by_j-dvintage.jpg?​direct&​300|}} ((photo courtesy of Ebay seller, JDVintagellc. [[https://​www.ebay.com/​str/​jdvintagellc?​_trksid=p2047675.l2563|Link to Ebay Store]] )) \\
 ====== Starter Relay ====== ====== Starter Relay ======
 ===== 1974-1979 Starter Relay ===== ===== 1974-1979 Starter Relay =====
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 \\ \\
  
 +{{:​techtalk:​ih:​elec:​voltage_regulator_1958_xlh_1959-1964_xlh-xlch_by_murph1068.jpg?​direct&​300|}} ((photo by murph1068 of the XLFORUM)) \\
 +
 +{{:​techtalk:​ih:​elec:​regulator_on_1965_xlch_by_moon_wolf.jpg?​direct&​300|}} ((photo by Moon Wolf of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=649699&​page=5)) {{:​techtalk:​ih:​elec:​regulator_on_1966-1969_xlch_by_animalhouse2010.jpg?​direct&​300|}} ((photo courtesy of Ebay seller, animalhouse2010,​ [[https://​www.ebay.com/​str/​animalhouse2010?​_trksid=p2047675.l2563|Link to Ebay store:]] ))  \\
 +
 +{{:​techtalk:​ih:​elec:​1970-1977_xlch_voltage_regulator_bracket_74525-70_by_tomscybershop.jpg?​direct&​300|}} ((photo courtesy of TomsCyberShop.com www.TomsCyberShop.com)) {{:​techtalk:​ih:​elec:​1970-1977_xlch_voltage_regulator_and_bracket_by_simeli.jpg?​direct&​300|}} ((photo by simeli of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=1677718)) \\
 +
 +{{:​techtalk:​ih:​elec:​voltage_regulator_74505-78_pic1_by_jrsvintageharley1990.jpg?​direct&​300|}} ((photo courtesy of Ebay seller, Jrs Vintage Harley 1990, [[https://​www.ebay.com/​str/​jrsvintageharleyparts?​_trksid=p2047675.l2563|Link to Ebay Store]] )) {{:​techtalk:​ih:​elec:​voltage_regulator_74505-78_pic2_by_jrsvintageharley1990.jpg?​direct&​300|}} ((photo courtesy of Ebay seller, Jrs Vintage Harley 1990, [[https://​www.ebay.com/​str/​jrsvintageharleyparts?​_trksid=p2047675.l2563|Link to Ebay Store]] )) \\
 +
 +{{:​techtalk:​ih:​elec:​voltage_regulator_74523-84_pic1_by_jrsvintageharley1990.jpg?​direct&​300|}} ((photo courtesy of Ebay seller, Jrs Vintage Harley 1990, [[https://​www.ebay.com/​str/​jrsvintageharleyparts?​_trksid=p2047675.l2563|Link to Ebay Store]] )) {{:​techtalk:​ih:​elec:​voltage_regulator_74523-84_pic2_by_jrsvintageharley1990.jpg?​direct&​300|}} ((photo courtesy of Ebay seller, Jrs Vintage Harley 1990, [[https://​www.ebay.com/​str/​jrsvintageharleyparts?​_trksid=p2047675.l2563|Link to Ebay Store]] )) \\
  
 \\ \\
  
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