Differences

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--- techtalk:ih:elec02m [2023/02/15 20:41]
hippysmack [1978 (66205-78)]
+++ techtalk:ih:elec02m [2023/03/09 15:20]
hippysmack [1979-1981 Sportster Battery Tray / Parts]
@@ Line 94: / Line 94: @@
 ====== 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). \\
--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). \\
--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 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 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. \\
+-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)) \\
@@ 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)) \\
+===== 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). \\
+-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) =====
@@ Line 323: / Line 336: @@
 -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). \\
+===== 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) =====
@@ Line 389: / Line 405: @@
 The regulator mounts to the panel with (2) 1/4"-20 x 5/16" locknuts. \\
+== Starter Relay ==
+-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 ======
@@ Line 438: / 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. \\
-{{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)) \\

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