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techtalk:ih:elec02 [2023/04/07 01:01] hippysmack [Sub Documents] |
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| * [[techtalk:ref:elec07|The REFerence Section has simplified wiring diagrams for custom rewiring.]] \\ | * [[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.]] | * [[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.]] | ||
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| ===== 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. \\ | ||
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| | 1967-1969 Circuit Breaker Location ((photo courtesy of Ebay seller, kerrmudgeon. [[https://www.ebay.com/sch/i.html?item=165642081196&rt=nc&_trksid=p2047675.m3561.l2562&_ssn=kerrmudgeon|Link to Items For Sale page]] )) | | | 1967-1969 Circuit Breaker Location ((photo courtesy of Ebay seller, kerrmudgeon. [[https://www.ebay.com/sch/i.html?item=165642081196&rt=nc&_trksid=p2047675.m3561.l2562&_ssn=kerrmudgeon|Link to Items For Sale page]] )) | | ||
| |{{:techtalk:ih:elec:1967-1969_circuit_breaker_location_by_kerrmudgeon.jpg?direct&300|}}| | |{{:techtalk:ih:elec:1967-1969_circuit_breaker_location_by_kerrmudgeon.jpg?direct&300|}}| | ||
| + | |||
| + | | 1969-E1971 XLH Circuit Breaker with Wires (74589-67A) ((photos courtesy of TomsCyberShop.com www.TomsCyberShop.com)) || | ||
| + | |{{:techtalk:ih:elec:1969-e1971_circuit_breaker_74589-67a_pic1_by_toms_cyber_shop.jpg?direct&300|}}|{{:techtalk:ih:elec:1969-e1971_circuit_breaker_74589-67a_pic2_by_toms_cyber_shop.jpg?direct&300|}}| | ||
| | 1970-1971 XLCH Circuit Breaker with Wires (74589-70) ((photos courtesy of Stripped Down Cycles [[https://www.ebay.com/str/strippeddowncycles?_trksid=p2047675.m3561.l2563|Link to Ebay Store:]] )) || | | 1970-1971 XLCH Circuit Breaker with Wires (74589-70) ((photos courtesy of Stripped Down Cycles [[https://www.ebay.com/str/strippeddowncycles?_trksid=p2047675.m3561.l2563|Link to Ebay Store:]] )) || | ||
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| |{{:techtalk:ih:elec:circuit_breaker_-_main_xlh_74589-71_pic1_by_jrsvintageharley1990.jpg?direct&300|}}|{{:techtalk:ih:elec:circuit_breaker_-_main_xlh_74589-71_pic2_by_jrsvintageharley1990.jpg?direct&300|}}| | |{{:techtalk:ih:elec:circuit_breaker_-_main_xlh_74589-71_pic1_by_jrsvintageharley1990.jpg?direct&300|}}|{{:techtalk:ih:elec:circuit_breaker_-_main_xlh_74589-71_pic2_by_jrsvintageharley1990.jpg?direct&300|}}| | ||
| - | | 1972 XLCH Circuit Breaker with Wires (74589-72) ((photo courtesy of Ebay seller, jrsvintageharley1990. [[https://www.ebay.com/str/jrsvintageharleyparts?_trksid=p2047675.l2563|Link to Ebay Store]] : )) | 1970-1972 XLCH Circuit Breaker Location ((photo by The Doctor71 of the XLFORUM http://xlforum.net/forums/showthread.php?t=2078550)) | | + | | 1972 XLCH Circuit Breaker with Wires (74589-72) ((photo courtesy of Ebay seller, jrsvintageharley1990. [[https://www.ebay.com/str/jrsvintageharleyparts?_trksid=p2047675.l2563|Link to Ebay Store]] : )) | 1970-1972 XLCH Circuit Breaker Location ((photo by The Doctor71 of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/201479-1970-sportster-overload?t=2078550)) | |
| |{{:techtalk:ih:elec:circuit_breaker_-_xlch_main_74589-72_pic1_by_tomscybershop.jpg?direct&300|}}|{{:techtalk:ih:elec:1970-1972_main_circuit_breaker_location_by_the_doctor71.jpg?direct&300|}}| | |{{:techtalk:ih:elec:circuit_breaker_-_xlch_main_74589-72_pic1_by_tomscybershop.jpg?direct&300|}}|{{:techtalk:ih:elec:1970-1972_main_circuit_breaker_location_by_the_doctor71.jpg?direct&300|}}| | ||
| ==== Pics of 1973-1985 Circuit Breakers ==== | ==== Pics of 1973-1985 Circuit Breakers ==== | ||
| - | | 1977-1978 Sportster Circuit Breaker Locations ((Left photo by hcrashster of the XLFORUM http://xlforum.net/forums/showthread.php?t=1297584&page=3)), ((Right photo by Hopper of the XLFORUM, annotated by Hippysmack http://xlforum.net/forums/showthread.php?t=957851)) || | + | | 1977-1978 Sportster Circuit Breaker Locations ((Left photo by hcrashster of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/127032-getting-this-78-back-to-the-way-it-should-be/page3?t=1297584&page=3)), ((Right photo by Hopper of the XLFORUM, annotated by Hippysmack https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/106469-where-is-a-good-spot-to-mount-circut-breakers-on-a-1975-frame?t=957851)) || |
| |{{:techtalk:ih:elec:circuit_breaker_clips_-_1973-1978_sportster_by_hcrashster.jpg?direct&300|}}|{{:techtalk:ih:elec:circuit_breaker_cluster_1977_xlch_by_hopper.jpg?direct&300|}}| | |{{:techtalk:ih:elec:circuit_breaker_clips_-_1973-1978_sportster_by_hcrashster.jpg?direct&300|}}|{{:techtalk:ih:elec:circuit_breaker_cluster_1977_xlch_by_hopper.jpg?direct&300|}}| | ||
| - | | 1979-1981 Sportster Circuit Breaker Locations ((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]] )) | 1982-1985 Sportster Circuit Breaker Locations ((photo by flthd31 of the XLFORUM http://xlforum.net/forums/showthread.php?p=5895447#post5895447)) | | + | | 1979-1981 Sportster Circuit Breaker Locations ((photo combo by Hippysmack from pics from motorhedmike of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/195685-1981-basket-restomod-questions?t=2072078&highlight=oil+filter+bracket and Ebay seller, cleanmotorcycleframes, [[https://www.ebay.com/str/cleanmotorcycleframes|Link to Ebay Store]] )) | 1982-1985 Sportster Circuit Breaker Locations ((photo by flthd31 of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/202232-electronic-module-area-wiring-mount#post4499825)) | |
| |{{:techtalk:ih:elec:circuit_breakers_1979-1981_compilation_from_cleanmotorcycleframes_and_motorhedmike.jpg?direct&300|}}|{{:techtalk:ih:elec:circuit_breakers_1982-1985_sportster_by_flthd31.jpg?direct&300|}}| | |{{:techtalk:ih:elec:circuit_breakers_1979-1981_compilation_from_cleanmotorcycleframes_and_motorhedmike.jpg?direct&300|}}|{{:techtalk:ih:elec:circuit_breakers_1982-1985_sportster_by_flthd31.jpg?direct&300|}}| | ||
| - | |||
| ===== Fuse Wire ===== | ===== Fuse Wire ===== | ||
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| 1971 parts catalog shows it's use thru 71 but the L69 wiring diagrams only show the use of the capacitor thru E1969. \\ | 1971 parts catalog shows it's use thru 71 but the L69 wiring diagrams only show the use of the capacitor thru E1969. \\ | ||
| - | {{: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)) \\ | + | {{:techtalk:ih:elec:capacitor_on_1966-1969_xlch_by_magneto_sportster.jpg?direct&300|}} ((photo by Magneto Sportster of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/156767-voltage-regulator-mounting-and-fasteners/page2?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 https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/156767-voltage-regulator-mounting-and-fasteners/page2?t=1677718&page=2)) \\ |
| ====== Battery ====== | ====== Battery ====== | ||
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| |**Voltage**|12v - (2) 6v \\ batteries in series| (1) 12v | (1) 12v | (1) 12v | (1) 12v | | |**Voltage**|12v - (2) 6v \\ batteries in series| (1) 12v | (1) 12v | (1) 12v | (1) 12v | | ||
| |**Yuasa \\ Battery#** ((1996 MMI Docs unless otherwise specified))| | | 12N7-4A \\ (7 AH) (74 CCA) | YB16-B \\ (19AH) (240 CCA) | AGM \\ (19AH) (270 CCA) | | |**Yuasa \\ Battery#** ((1996 MMI Docs unless otherwise specified))| | | 12N7-4A \\ (7 AH) (74 CCA) | YB16-B \\ (19AH) (240 CCA) | AGM \\ (19AH) (270 CCA) | | ||
| - | |**Motobatt \\ Battery#**| | MB9U ((The Doctor71 of the XLFORUM http://xlforum.net/forums/showthread.php?p=5990104#post5990104)) \\ (11AH) (140 CCA) | | + | |**Motobatt \\ Battery#** ((https://www.motobatt.us/MB9U-Motobatt-12V-Battery))| | | MB9U ((The Doctor71 of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/205073-battery-availability-for-late-60-s-through-mid-70-s-xlch-s#post4629677)) AGM \\ (11AH) (140 CCA) | |
| ====== Generator ====== | ====== Generator ====== | ||
| Removal: \\ | 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)) \\ | + | 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 https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/34037-cam-cover-vent-leaking-oil-when-running#post724845)) \\ |
| ===== Sub Documents ===== | ===== Sub Documents ===== | ||
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| Polarization is a simple process used to restore the field pole residual magnetism and ensure the magnetic direction is correct. | 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)) | + | ((Decman - https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/110750-polarizing-generator-what-s-this-all-about?t=1040003+Post#6)) |
| \\ | \\ | ||
| ===== Diode For Generator Light ===== | ===== Diode For Generator Light ===== | ||
| - | A diode is a one way electronic check valve that only allows current to flow in one direction.((Chief - XLFORUM http://xlforum.net/forums/showthread.php?t=1205686)) On some Sportsters, a diode is installed in the "Gen" light circuit to help determine if the generator/regulator is working correctly. If all is working the way it should be, with the bike running and everything working correctly, the generator/regulator will be producing a higher voltage than the battery (i.e. it's charging the battery). The voltages at each end of the diode will be such that the diode allows no electricity to flow through the circuit, and the "Gen" light stays off.((Yellowstone Kelly of the XLFORUM http://xlforum.net/forums/showthread.php?t=1378363)) | + | A diode is a one way electronic check valve that only allows current to flow in one direction.((Chief - XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/122434-gen-light-diode-explanation?t=1205686)) On some Sportsters, a diode is installed in the "Gen" light circuit to help determine if the generator/regulator is working correctly. If all is working the way it should be, with the bike running and everything working correctly, the generator/regulator will be producing a higher voltage than the battery (i.e. it's charging the battery). The voltages at each end of the diode will be such that the diode allows no electricity to flow through the circuit, and the "Gen" light stays off.((Yellowstone Kelly of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/130580-the-dreadful-electrical?t=1378363)) |
| If your generator/regulator takes a big dump and stops producing the correct voltage, the battery voltage will be higher than the voltage being produced by the generator/regulator. The relationship of the voltages at each end of the diode will then be "reversed" from normal, and that will cause the diode to allow current flow. The "Gen" light will light up, telling you that something is wrong. That's why the "Gen" light lights up when you first turn the key on, as the battery voltage is higher than the voltage being produced by the generator/regulator, since it isn't producing any voltage with the engine not running. | If your generator/regulator takes a big dump and stops producing the correct voltage, the battery voltage will be higher than the voltage being produced by the generator/regulator. The relationship of the voltages at each end of the diode will then be "reversed" from normal, and that will cause the diode to allow current flow. The "Gen" light will light up, telling you that something is wrong. That's why the "Gen" light lights up when you first turn the key on, as the battery voltage is higher than the voltage being produced by the generator/regulator, since it isn't producing any voltage with the engine not running. | ||
| - | The diode was first shown on the schematics for 1978 models((IronMick Post#44 - http://xlforum.net/forums/showthread.php?t=1205686)) and thru Early 1984. Late 1984 & 1985 ironhead models use an alternator instead of a generator, therefore, they have no generator light. | + | The diode was first shown on the schematics for 1978 models((IronMick Post#44 - https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/122434-gen-light-diode-explanation?t=1205686)) and thru Early 1984. Late 1984 & 1985 ironhead models use an alternator instead of a generator, therefore, they have no generator light. |
| - | An extensive discussion of the function of the diode is locate in this [[http://xlforum.net/forums/showthread.php?t=1205686|XLForum Thread]]. | + | An extensive discussion of the function of the diode is locate in this [[https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/122434-gen-light-diode-explanation?t=1205686|XLForum Thread]]. |
| - | A simple explanation of the Gen Light is that it is comparing the voltage output from the Generator to the voltage in the system (ie., the Battery voltage). When there is enough difference between those voltages (typically more than 1.5v difference), then the Gen Light will begin to glow. The diode assures that the light will come on only when the Generator voltage is lower than the Battery voltage, meaning the Generator may have a problem.((Adding the diode (to models that did not originally have them) helps to redefine the condition WHEN the generator is considered to be actually malfunctioning - http://xlforum.net/forums/showthread.php?t=2080968)) | + | A simple explanation of the Gen Light is that it is comparing the voltage output from the Generator to the voltage in the system (ie., the Battery voltage). When there is enough difference between those voltages (typically more than 1.5v difference), then the Gen Light will begin to glow. The diode assures that the light will come on only when the Generator voltage is lower than the Battery voltage, meaning the Generator may have a problem.((Adding the diode (to models that did not originally have them) helps to redefine the condition WHEN the generator is considered to be actually malfunctioning - https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/203681-electrical-issue-question?t=2080968)) |
| \\ | \\ | ||
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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: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:regulator_on_1965_xlch_by_moon_wolf.jpg?direct&300|}} ((photo by Moon Wolf of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/85218-1965-xlch-only-model-specific-help/page5?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: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 https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/156767-voltage-regulator-mounting-and-fasteners?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_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]] )) \\ | ||
