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techtalk:ih:elec02m [2023/02/15 20:25] hippysmack [Attachments] |
techtalk:ih:elec02m [2023/03/09 15:20] hippysmack [1979-1981 Sportster Battery Tray / Parts] |
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| ====== 1967-1978 XLH Battery Tray / Parts ====== | ====== 1967-1978 XLH Battery Tray / Parts ====== | ||
| - | ===== Auxiliaries and Mounting ===== | + | ===== Mounting the tray ===== |
| - | Click on a pic to enlarge: \\ | + | **To the Oil Tank**: \\ |
| + | The battery tray is mounted straight to the oil tank by the 3 holes on the back of the tray with (3) 5/16"-24 x 9/16 hex head screws. \\ | ||
| + | Be careful to use the right length bolts so you don't punch thru the inside of the tank or crack the bracket welds on the tank. \\ | ||
| + | From there, every mounting point (2 for the battery tray and 3 for the oil tank) to the frame/motor has rubber mount isolater studs (62563-65), 5 total. ((DirtyCory of the XLFORUM http://xlforum.net/forums/showthread.php?p=4080202#post4080202)) \\ | ||
| - | There were a total of 6 part number changes for these year battery trays but they all bolt up the same. \\ | + | **Battery Carrier Support**: \\ |
| - | Tray dimensions (where battery sits) are app. 8" long x 5 1/8" wide. Maximum battery height is app. 6 1/2". ((The Doctor71 of the XLFORUM)) \\ | + | The carrier/tray is lifted off the motor resting on a battery carrier support (66480-67). \\ |
| - | 67-78 battery trays have (3) mounting holes in the rear wall, welded mount (L) for a rubber mount and a hole in right plate for a rubber mount. \\ | + | The support bracket is mounted to the engine on the 2 holes in front of the rear motor mount with (2) 3/18"x16x3/4" hex head bolts (4713W) and lockwashers (7038). \\ |
| - | The main visual differences are in the welded right side regulator mounting plate and the front right inside corner of the tray itself. \\ | + | The bracket hole in the middle for a grommet (11422) for cable / hose protection. \\ |
| - | See the battery tray pics below for more information on specific trays. \\ | + | The battery cable, solenoid to the starter motor, and the 3/8" ID return oil hose to the tank line runs through the hole. ((IronMick of the XLFORUM http://xlforum.net/forums/showthread.php?t=1400314)) \\ |
| - | The battery tray also doubles as a voltage regulator and starter relay mounting base. \\ | + | **Carrier Front Mount**: \\ |
| - | Later versions also incorporate different mounting points for the starter relay. \\ | + | The bracket on the left side of the tray gets a rubber mounting isolator stud (62563-65) mounted behind it with 1/4" lockwasher and 1/4"x20 nut. \\ |
| - | The same 3 hole mount voltage regulator (74510-64) was used from 1967-1977. \\ | + | The other end of the isolater attaches to the support bracket with 1/4" lockwasher and 1/4"x20 nut. \\ |
| - | In 1978, the MoCo installed a 2 hole mount solid state regulator (74504-78). \\ | + | |
| - | 1967-E1968 XLH models did not have a factory mounted starter relay but had a kit with a mounting bracket to retrofit one. \\ | + | **Carrier Rear Mount**: \\ |
| - | L1968-E1971 XLH models did not use a starter relay. \\ | + | There is a terminal block channel welded to the left frame downtube. \\ |
| - | L1971-1974 models mounted the relay (71455-67) on two lower holes on the side panel below the voltage regulator. \\ | + | On the bottom of the terminal is a threaded 1/4"x20 hole that gets a rubber mounting isolator stud (62563-65) screwed into it. \\ |
| - | In 1975, a new style starter relay (71463-73A) was mounted under the front right corner of the battery tray. \\ | + | The 1/4" hole in the tray's side panel sets onto the other end of the isolator stud with a 1/4" lockwasher and 1/4"x20 nut fastening it to the panel. \\ |
| - | There is a squared area added to the inside corner of the tray with 2 mounting studs pointing down for the relay. \\ | + | |
| - | + | ||
| - | {{:techtalk:ih:elec:1967-1977_xlh_style_voltage_regulator_by_badruchez.jpg?direct&300|}} ((photo by Badruchez of the XLFORUM http://xlforum.net/forums/showthread.php?t=1227876)) {{:techtalk:ih:elec:l1967-e68_--_l1971-1974_xlh_starter_relay_location_by_the_doctor71.jpg?direct&300|}} ((photo by The Doctor71 of the XLFORUM http://xlforum.net/forums/showthread.php?p=5830422&highlight=starter+relay#post5830422)) {{:techtalk:ih:elec:1975-1978_style_starter_relay_by_badruchez.jpg?direct&300|}} ((photo by Badruchez of the XLFORUM http://xlforum.net/forums/showthread.php?t=1227876)) \\ | + | |
| - | + | ||
| - | \\ | + | |
| - | + | ||
| - | The tray is lifted off the motor resting on a battery carrier support (66480-67) with a hole thru the middle. The hole has a grommet (11422) for cable / hose protection. \\ | + | |
| - | The battery cable, solenoid to the starter motor, and the 3/8" ID return oil hose to the tank line runs through the hole. ((IronMick of the XLFORUM http://xlforum.net/forums/showthread.php?t=1400314)) \\ | + | |
| - | The battery tray is fastened with a rubber mounting stud (62563-65) to the support bracket. \\ | + | |
| - | Another rubber mounting stud is installed behind the regulator and bolted to the oil tank with (3) 5/16"x24x9/16" hex head bolts. \\ | + | |
| - | The support bracket is mounted to the engine on the 2 holes in front of the rear motor mount with (2) 3/18"x16x3/4" hex head bolts (4713W) and lockwashers. \\ | + | |
| - | Battery strap (66470-67). Side cover (66379-67). There were 2 top covers with pads underneath to protect it from the terminals (66368-67) black and (66369-67) chrome. \\ | + | |
| + | Battery Carrier Support. Click on a pic to enlarge: \\ | ||
| + | {{:techtalk:ih:elec:1967-1978_xlh_battery_tray_support_w_rubbermounts_by_tomscybershop.jpg?direct&300|}} ((photo courtesy of TomsCyberShop.com www.TomsCyberShop.com)) {{:techtalk:ih:elec:1967-1978_xlh_battery_tray_support_mount_location_by_on_.....jpg?direct&300|}} ((photo by on½.... of the XLFORUM http://xlforum.net/forums/showthread.php?t=2022017)) \\ | ||
| - | {{:techtalk:ih:elec:1967-1978_xlh_battery_tray_support_pic1_by_tomscybershop.jpg?direct&300|}} ((photo courtesy of TomsCyberShop.com www.TomsCyberShop.com)) {{:techtalk:ih:elec:1967-1978_xlh_battery_tray_support_by_flthd31.jpg?direct&300|}} ((photo by flthd31 of the XLFORUM)) {{:techtalk:ih:elec:1967-1978_xlh_battery_tray_support_mount_location_by_on_.....jpg?direct&300|}} ((photo by on½.... of the XLFORUM http://xlforum.net/forums/showthread.php?t=2022017)) \\ | + | ===== Grounding the tray ===== |
| + | The battery tray and oil tank are (shock isolated) from the motor and frame by the rubber mount studs. \\ | ||
| + | And most of those rubber mounts retain electrical continuity to/thru both their mounting studs. \\ | ||
| + | If using rubber mounts with the spring inside, the battery carrier is grounded to the frame due to the spring feature in the mounts. \\ | ||
| + | On the inside of the rubber part are two metal plates with the threaded stud attached to each one and then some the plates are connected inside with a spring. \\ | ||
| + | These type rubber mounts ensure electrical continuity from end to end of the studs. \\ | ||
| + | On others, the plates are either glued onto or sunk into the rubber, where the rubber is solid and has no electrical continuity between the studs. \\ | ||
| + | If you're not sure, check for continuity between the two threaded ends with a multimeter before proceeding. \\ | ||
| - | **Grounding the tray**: The tray and oil tank are isolated from the motor and frame by the rubber mount studs. \\ | ||
| The 3 terminal, 3 coil XLH regulator is mounted over 3 studs on the battery carrier. ((Dr Dick of the XLFORUM http://xlforum.net/forums/showthread.php?s=8bf2b3750d89be7e977e058968ab36e0&t=1417973&page=2)) \\ | The 3 terminal, 3 coil XLH regulator is mounted over 3 studs on the battery carrier. ((Dr Dick of the XLFORUM http://xlforum.net/forums/showthread.php?s=8bf2b3750d89be7e977e058968ab36e0&t=1417973&page=2)) \\ | ||
| The regulator rubber bushes have steel sleeves. The lower 2 regulator bushings have a ground plate that covers the top of the bushes/sleeves. \\ | The regulator rubber bushes have steel sleeves. The lower 2 regulator bushings have a ground plate that covers the top of the bushes/sleeves. \\ | ||
| Line 140: | Line 138: | ||
| The routing and connection points of this wire changed between 74 and 75 models. ((Dr Dick of the XLFORUM http://xlforum.net/forums/showthread.php?t=1993253)) \\ | The routing and connection points of this wire changed between 74 and 75 models. ((Dr Dick of the XLFORUM http://xlforum.net/forums/showthread.php?t=1993253)) \\ | ||
| - | The 67-E68 XLH with the factory relay kit (71449-67) got a 2nd ground where the support bracket mounts to the front of the battery tray. \\ | + | 1967-E1968 XLH (with the factory relay kit, 71449-67) got a 2nd ground where the support bracket mounts to the front of the battery tray. \\ |
| There should be a short ground wire making the jump between both ends of the isolator (67-E68). ((randy3934 of the XLFORUM http://xlforum.net/forums/showthread.php?t=1838788)) \\ | There should be a short ground wire making the jump between both ends of the isolator (67-E68). ((randy3934 of the XLFORUM http://xlforum.net/forums/showthread.php?t=1838788)) \\ | ||
| Line 148: | Line 146: | ||
| {{:techtalk:ih:elec:1972-1974_xlh_battery_tray_66205-67b_pic7_by_the_doctor71.jpg?direct&300|}} ((photo by The Doctor71 of the XLFORUM, labeled by Hippysmack)) {{:techtalk:ih:elec:1972-1974_xlh_battery_tray_66205-67b_pic6_by_the_doctor71.jpg?direct&300|}} ((photo by The Doctor71 of the XLFORUM, labeled by Hippysmack)) {{:techtalk:ih:elec:1972-1974_xlh_battery_tray_66205-67b_pic8_by_the_doctor71.jpg?direct&300|}} ((photo by The Doctor71 of the XLFORUM, labeled by Hippysmack)) \\ | {{:techtalk:ih:elec:1972-1974_xlh_battery_tray_66205-67b_pic7_by_the_doctor71.jpg?direct&300|}} ((photo by The Doctor71 of the XLFORUM, labeled by Hippysmack)) {{:techtalk:ih:elec:1972-1974_xlh_battery_tray_66205-67b_pic6_by_the_doctor71.jpg?direct&300|}} ((photo by The Doctor71 of the XLFORUM, labeled by Hippysmack)) {{:techtalk:ih:elec:1972-1974_xlh_battery_tray_66205-67b_pic8_by_the_doctor71.jpg?direct&300|}} ((photo by The Doctor71 of the XLFORUM, labeled by Hippysmack)) \\ | ||
| + | |||
| + | ===== Electricals mounted to tray ===== | ||
| + | The battery tray also serves as a mounting point for the voltage regulator, starter relay and main circuit breaker (depending on year model). \\ | ||
| + | Early to late carrier versions incorporate different mounting points for the starter relay and circuit breaker. \\ | ||
| + | The same 3 hole mount voltage regulator (74510-64) was used from 1967-1977. \\ | ||
| + | In 1978, the MoCo installed a 2 hole mount solid state regulator (74504-78). \\ | ||
| + | |||
| + | 1967-E1968 XLH models did not have a factory mounted starter relay but had a kit with a mounting bracket to retrofit one. \\ | ||
| + | L1968-E1971 XLH models did not use a starter relay. \\ | ||
| + | L1971-1974 models mounted the relay (71455-67) on two lower 1/4" holes on the side panel below the voltage regulator. \\ | ||
| + | In 1975, a new style starter relay (71463-73A) was mounted under the front right corner of the rear battery tray frame rail. \\ | ||
| + | There is a squared area added to the inside corner of the tray with 2 1/4" mounting studs pointing down for the relay. \\ | ||
| + | |||
| + | {{:techtalk:ih:elec:1967-1977_xlh_style_voltage_regulator_by_badruchez.jpg?direct&300|}} ((photo by Badruchez of the XLFORUM http://xlforum.net/forums/showthread.php?t=1227876)) {{:techtalk:ih:elec:l1967-e68_--_l1971-1974_xlh_starter_relay_location_by_the_doctor71.jpg?direct&300|}} ((photo by The Doctor71 of the XLFORUM http://xlforum.net/forums/showthread.php?p=5830422&highlight=starter+relay#post5830422)) {{:techtalk:ih:elec:1975-1978_style_starter_relay_by_badruchez.jpg?direct&300|}} ((photo by Badruchez of the XLFORUM http://xlforum.net/forums/showthread.php?t=1227876)) \\ | ||
| \\ | \\ | ||
| + | |||
| ===== 1967-1969 (66205-67) ===== | ===== 1967-1969 (66205-67) ===== | ||
| Line 323: | Line 336: | ||
| 1972-1974 XLH uses starter relay (71455-67). \\ | 1972-1974 XLH uses starter relay (71455-67). \\ | ||
| It mounts on the 2 lower holes on the side panel under the voltage regulator with (2) 1/4"-20x5/8" round head screws (2765W) with nuts (7688). \\ | It mounts on the 2 lower holes on the side panel under the voltage regulator with (2) 1/4"-20x5/8" round head screws (2765W) with nuts (7688). \\ | ||
| + | |||
| + | ===== 1967-1974 Upgrade (66205-67C) ===== | ||
| + | This battery tray was sold for parts order starting in 1975 for use on 67-74 XLH models replacing all previous versions. \\ | ||
| ===== 1975-1977 (66205-75) ===== | ===== 1975-1977 (66205-75) ===== | ||
| This battery tray was originally sold for 1975-1977 XLH models only. \\ | This battery tray was originally sold for 1975-1977 XLH models only. \\ | ||
| - | In 1979, all previous 67-77 XLH battery trays were obsoleted and this tray was suggested for use as a replacement for 67-77 XLH models. \\ | ||
| == Features == | == Features == | ||
| Line 356: | Line 371: | ||
| ==== Updated Battery Trays for 75-77 XLH ==== | ==== Updated Battery Trays for 75-77 XLH ==== | ||
| - | There are no factory updated battery trays for 75-77 XLH models. \\ | + | There are no factory updated battery trays for 75-77 XLH models. \\ |
| + | The -75 tray was the last one made for 67-77 XLH models. \\ | ||
| + | It was sold through the -78A parts book for 1967-1977 XLH (replaced those year original trays). \\ | ||
| ===== 1978 (66205-78) ===== | ===== 1978 (66205-78) ===== | ||
| - | The 1978 XLH battery tray is basically the same as the 75-77 tray with exception of the side panel which is flat across the top where 75-77 is slanted to a round point on top. \\ | + | The 1978 XLH battery tray is basically the same as the 75-77 tray. \\ |
| + | However, the side panel is flat across the top and has only 2 mounting studs for the new regulator where 75-77 is slanted to a round point on top with 3 studs. \\ | ||
| == Features == | == Features == | ||
| - | The same base frame as 67-74 XLH battery trays with (3) mounting holes in the rear wall, welded mount on left for a rubber mount. \\ | + | * Same base frame as 67-77 XLH battery trays with (3) mounting holes in the rear wall and the welded mount on left for a rubber isolator mount. |
| - | Welded on side panel with only 2 studs in it for mounting the new solid state voltage regulator. \\ | + | * Welded on redesigned side panel with 2 welded studs in it for mounting the new solid state voltage regulator. |
| - | The welded side plate was moved a little farther to the left of the bike than 67-74 model trays. \\ | + | * The side panel was moved a little farther to the left of the bike than 67-74 model trays. \\ To compensate for the distance change the metal area for the rubber mount was pressed / molded rearwards the same distance of the plate shift. \\ There is a round bossed area in the back of the regulator plate reflecting this change. |
| - | To compensate for the distance change using the same rubber mount, the metal area for the rubber mount was pressed / molded rearwards the same distance of the plate shift. \\ | + | * Has a squared off area in the corner of the rear frame rail with two studs hanging down for the -73 starter relay mount. |
| - | There is a round bossed area in the back of the regulator plate reflecting this change. \\ | + | * Does not have the 2 small holes to mount the circuit breaker on rear of the panel. |
| - | Has no terminal plate on the side panel. \\ | + | * Does not have the terminal block feature on the side panel for turn signal wiring. |
| - | It does not have a countersunk hole in the rear frame rail for the early circuit breaker mount (under the battery). \\ | + | * Does not have a countersunk hole in the rear frame rail for the early circuit breaker mount under the battery. |
| - | **It Does NOT** have the two lower holes on the regulator plate for the early starter relay.\\ | + | * Does not have the two lower holes on the regulator plate for the early starter relay. |
| - | Has a squared off area in the corner of the rear frame rail with two studs hanging down for the -73A starter relay mount. \\ | + | |
| - | \\ | + | {{:techtalk:ih:elec:1978_xlh_battery_tray_66205-78_pic1_by_oldiron_10.jpg?direct&300|}} ((photo courtesy of Ebay seller, oldiron_10 [[https://www.ebay.com/sch/i.html?item=403952880197&rt=nc&_trksid=p2047675.m3561.l2562&_ssn=oldiron_10|Link to Items For Sale page]] )) {{:techtalk:ih:elec:1978_xlh_battery_tray_66205-78_pic2_by_oldiron_10.jpg?direct&300|}} ((photo courtesy of Ebay seller, oldiron_10 [[https://www.ebay.com/sch/i.html?item=403952880197&rt=nc&_trksid=p2047675.m3561.l2562&_ssn=oldiron_10|Link to Items For Sale page]] )) {{:techtalk:ih:elec:1978_xlh_battery_tray_66205-78_pic3_by_oldiron_10.jpg?direct&300|}} ((photo courtesy of Ebay seller, oldiron_10 [[https://www.ebay.com/sch/i.html?item=403952880197&rt=nc&_trksid=p2047675.m3561.l2562&_ssn=oldiron_10|Link to Items For Sale page]] )) \\ |
| == Attachments == | == Attachments == | ||
| + | == Circuit Breaker == | ||
| + | There are no factory provisions for mounting a circuit breaker on the -78 battery tray. \\ | ||
| + | L1973-E1978 XLH/XLCH got a fuse wire in the circuit instead of a main breaker in addition to the (3) 15A breakers behind the seat. \\ | ||
| + | The fuse wire was in different locations for either H or CH models. \\ | ||
| + | [[techtalk:ih:elec02#fuse_wire|Click Here]] for more detailed information on the fuse wire in the IH electrical section of the Sportsterpedia. \\ | ||
| + | L1978 models used the pop-in style "ice cube" main breaker attached as the other 3 breakers behind the seat. \\ | ||
| + | |||
| == Voltage Regulator == | == Voltage Regulator == | ||
| 1978 XLH was factory mounted with a new solid state voltage regulator (74504-78). \\ | 1978 XLH was factory mounted with a new solid state voltage regulator (74504-78). \\ | ||
| - | The unit is rectangle shaped and the mounts moved in which allowed for the new square top construction on the battery tray side panel. \\ | + | The unit is rectangular shaped and the mounts moved in which allowed for the new square top construction on the battery tray side panel. \\ |
| The regulator mounts to the panel with (2) 1/4"-20 x 5/16" locknuts. \\ | The regulator mounts to the panel with (2) 1/4"-20 x 5/16" locknuts. \\ | ||
| - | {{:techtalk:ih:elec:1978_xlh_battery_tray_66205-78_pic1_by_oldiron_10.jpg?direct&300|}} ((photo courtesy of Ebay seller, oldiron_10 [[https://www.ebay.com/sch/i.html?item=403952880197&rt=nc&_trksid=p2047675.m3561.l2562&_ssn=oldiron_10|Link to Items For Sale page]] )) {{:techtalk:ih:elec:1978_xlh_battery_tray_66205-78_pic2_by_oldiron_10.jpg?direct&300|}} ((photo courtesy of Ebay seller, oldiron_10 [[https://www.ebay.com/sch/i.html?item=403952880197&rt=nc&_trksid=p2047675.m3561.l2562&_ssn=oldiron_10|Link to Items For Sale page]] )) {{:techtalk:ih:elec:1978_xlh_battery_tray_66205-78_pic3_by_oldiron_10.jpg?direct&300|}} ((photo courtesy of Ebay seller, oldiron_10 [[https://www.ebay.com/sch/i.html?item=403952880197&rt=nc&_trksid=p2047675.m3561.l2562&_ssn=oldiron_10|Link to Items For Sale page]] )) \\ | + | == Starter Relay == |
| + | 1975-1978 models use the round starter relay (71463-73) which was later updated to (71463-73A). \\ | ||
| + | It mounts underneath the -78 battery tray on the (2) 1/4" studs hanging down from the cornered bracket in the rear frame rail. \\ | ||
| + | |||
| + | ==== Updated Battery Trays for 75-77 XLH ==== | ||
| + | There are no factory updated battery trays for 1978 XLH models. \\ | ||
| ====== 1970-1978 XLCH Battery Tray / Parts ====== | ====== 1970-1978 XLCH Battery Tray / Parts ====== | ||
| Line 429: | Line 460: | ||
| You can try and cut some pieces of rubber or wood trim to shim it until you can purchase the bracket or make one. \\ | You can try and cut some pieces of rubber or wood trim to shim it until you can purchase the bracket or make one. \\ | ||
| - | {{techtalk:ih:elec:1980_sportster_w_battery_bracket_missing_by_marine_hm.jpg?direct&300|}} ((photo by marine hm of the XLFORUM http://xlforum.net/forums/showthread.php?t=1539788)) \\ | + | |1980-1981 XL-XLS Oil Tank Bracket 66279-80 ((photo courtesy of Stripped Down Cycles [[https://www.ebay.com/str/strippeddowncycles?_trksid=p2047675.m3561.l2563|Link to Ebay Store:]] ))|Possible temp fix for missing bracket ((photo by marine hm of the XLFORUM http://xlforum.net/forums/showthread.php?t=1539788))| |
| + | |{{:techtalk:ih:elec:1980-1981_xl-xls_oil_tank_bracket_66279-80_by_stripped_down_cycles.jpg?direct&300|}}|{{techtalk:ih:elec:1980_sportster_w_battery_bracket_missing_by_marine_hm.jpg?direct&300|}}| | ||
| - | Original Bracket for 80-81 Sportsters: \\ | + | Original Bracket for 80-81 Sportsters installed: \\ |
| {{techtalk:ih:elec:1980-1981_battery_hold_down_bracket_pic1_by_boilermaker.jpg?direct&300|}} ((photo by boilermaker of the XLFORUM http://xlforum.net/forums/showthread.php?t=924613)) {{techtalk:ih:elec:1980-1981_battery_hold_down_bracket_pic2_by_boilermaker.jpg?direct&300|}} ((photo by boilermaker of the XLFORUM http://xlforum.net/forums/showthread.php?t=924613)) {{techtalk:ih:elec:1980-1981_battery_hold_down_bracket_pic3_by_boilermaker.jpg?direct&300|}} ((photo by boilermaker of the XLFORUM http://xlforum.net/forums/showthread.php?t=924613)) \\ | {{techtalk:ih:elec:1980-1981_battery_hold_down_bracket_pic1_by_boilermaker.jpg?direct&300|}} ((photo by boilermaker of the XLFORUM http://xlforum.net/forums/showthread.php?t=924613)) {{techtalk:ih:elec:1980-1981_battery_hold_down_bracket_pic2_by_boilermaker.jpg?direct&300|}} ((photo by boilermaker of the XLFORUM http://xlforum.net/forums/showthread.php?t=924613)) {{techtalk:ih:elec:1980-1981_battery_hold_down_bracket_pic3_by_boilermaker.jpg?direct&300|}} ((photo by boilermaker of the XLFORUM http://xlforum.net/forums/showthread.php?t=924613)) \\ | ||
