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techtalk:ih:elec02m [2023/02/15 20:42] hippysmack [1978 (66205-78)] |
techtalk:ih:elec02m [2023/12/30 02:27] hippysmack [1972-1974 (66205-67B)] |
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The 52-55 carriers leave the battery in a bit more forward position than the 56-60 carrier. \\ | The 52-55 carriers leave the battery in a bit more forward position than the 56-60 carrier. \\ | ||
- | {{:techtalk:ih:elec:1952-1954_k-model_battery_tray_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:1955_battery_tray_66224-52a_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:1956-1960_battery_tray_66224-52b_by_dr_dick.jpg?direct&300|}} ((photo by Dr Dick of the XLFORUM, labeled by Hippysmack) http://xlforum.net/forums/showthread.php?t=1062720&page=20)) \\ | + | {{:techtalk:ih:elec:1952-1954_k-model_battery_tray_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:1955_battery_tray_66224-52a_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:1956-1960_battery_tray_66224-52b_by_dr_dick.jpg?direct&300|}} ((photo by Dr Dick of the XLFORUM, labeled by Hippysmack) https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/112326-a-photo-catalog-of-ironhead-parts/page20?t=1062720&page=20)) \\ |
===== 1961-1964 66224-52C ===== | ===== 1961-1964 66224-52C ===== | ||
Line 79: | Line 79: | ||
((photo courtesy of Ebay seller, flathead1461, [[https://www.ebay.com/sch/flathead1461/m.html?item=284170342423&nordt=true&nma=true&orig_cvip=true&rt=nc&si=erCzdk8rpr1SOK4bAqOvxy6IHKI%253D&_trksid=p2047675.l2562|Link to site:]] )) | ((photo courtesy of Ebay seller, flathead1461, [[https://www.ebay.com/sch/flathead1461/m.html?item=284170342423&nordt=true&nma=true&orig_cvip=true&rt=nc&si=erCzdk8rpr1SOK4bAqOvxy6IHKI%253D&_trksid=p2047675.l2562|Link to site:]] )) | ||
{{:techtalk:ih:elec:1961-1964_xlh_battery_tray_pic2_by_flathead1461.jpg?direct&300|}} | {{:techtalk:ih:elec:1961-1964_xlh_battery_tray_pic2_by_flathead1461.jpg?direct&300|}} | ||
- | ((photo courtesy of Ebay seller, flathead1461, [[https://www.ebay.com/sch/flathead1461/m.html?item=284170342423&nordt=true&nma=true&orig_cvip=true&rt=nc&si=erCzdk8rpr1SOK4bAqOvxy6IHKI%253D&_trksid=p2047675.l2562|Link to site:]] )) {{:techtalk:ih:elec:1964_xlh_battery_tray_by_magneto_sportster.jpg?direct&300|}} ((photo by Magneto Sportster of the XLFORUM http://xlforum.net/forums/showthread.php?t=2075542&page=4)) \\ | + | ((photo courtesy of Ebay seller, flathead1461, [[https://www.ebay.com/sch/flathead1461/m.html?item=284170342423&nordt=true&nma=true&orig_cvip=true&rt=nc&si=erCzdk8rpr1SOK4bAqOvxy6IHKI%253D&_trksid=p2047675.l2562|Link to site:]] )) {{:techtalk:ih:elec:1964_xlh_battery_tray_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-1957-1985/198705-magneto-sportster-s-1964-xlh-restoration-project/page4?t=2075542&page=4)) \\ |
====== 1965-1966 XLH Battery Tray / Parts ====== | ====== 1965-1966 XLH Battery Tray / Parts ====== | ||
- | |||
1965 marked the first use of a 12v charging system for Sportsters (XLH only). XLCH didn't have a battery until 1970. \\ | 1965 marked the first use of a 12v charging system for Sportsters (XLH only). XLCH didn't have a battery until 1970. \\ | ||
- | The 65-66 battery tray (66223-65) was designed to hold two 6 volt dry charged batteries wired together to create 12v. ((Magneto Sportster of the XLFORUM http://xlforum.net/forums/showthread.php?p=5903020#post5903020)) \\ | + | The 65-66 battery tray (66223-65) was designed to hold two 6 volt dry charged batteries wired together to create 12v. ((Magneto Sportster of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/201845-any-1965-1966-xlh-battery-tray-pics#post4511992)) \\ |
The rear of the tray sits on the 4 bolt rear motor mount and mounts with (2) 3/8"x18x1-3/16" bolts (front 2 bolt holes in top of the mount). \\ | The rear of the tray sits on the 4 bolt rear motor mount and mounts with (2) 3/8"x18x1-3/16" bolts (front 2 bolt holes in top of the mount). \\ | ||
There are two sides and a rear wall making up the tray. \\ | There are two sides and a rear wall making up the tray. \\ | ||
The batteries are heavily padded, pad (66418-65) on each side wall, (66101-65) on the rear wall, (66100-65) under both batteries and (66102-65) between the batteries. \\ | The batteries are heavily padded, pad (66418-65) on each side wall, (66101-65) on the rear wall, (66100-65) under both batteries and (66102-65) between the batteries. \\ | ||
- | {{:techtalk:ih:elec:battery_tray_xlh_1965-1966_pic1_by_magneto_sportster.jpg?direct&300|}} ((photo by Magneto Sportster of the XLFORUM http://xlforum.net/forums/showthread.php?p=5903020#post5903020)) {{:techtalk:ih:elec:battery_tray_xlh_1965-1966_pic2_by_magneto_sportster.jpg?direct&300|}} ((photo by Magneto Sportster of the XLFORUM http://xlforum.net/forums/showthread.php?p=5903020#post5903020)) \\ | + | {{:techtalk:ih:elec:battery_tray_xlh_1965-1966_pic1_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-1957-1985/201845-any-1965-1966-xlh-battery-tray-pics#post4511992)) {{:techtalk:ih:elec:battery_tray_xlh_1965-1966_pic2_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-1957-1985/201845-any-1965-1966-xlh-battery-tray-pics#post4511992)) \\ |
- | {{:techtalk:ih:elec:battery_tray_xlh_1965-1966_pic3_by_magneto_sportster.jpg?direct&300|}} ((photo by Magneto Sportster of the XLFORUM http://xlforum.net/forums/showthread.php?p=5903020#post5903020)) {{:techtalk:ih:elec:battery_tray_xlh_1965-1966_pic4_by_magneto_sportster.jpg?direct&300|}} ((photo by Magneto Sportster of the XLFORUM http://xlforum.net/forums/showthread.php?p=5903020#post5903020)) {{:techtalk:ih:elec:battery_tray_xlh_1965-1966_pic5_by_magneto_sportster.jpg?direct&300|}} ((photo by Magneto Sportster of the XLFORUM http://xlforum.net/forums/showthread.php?p=5903020#post5903020)) \\ | + | {{:techtalk:ih:elec:battery_tray_xlh_1965-1966_pic3_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-1957-1985/201845-any-1965-1966-xlh-battery-tray-pics#post4511992)) {{:techtalk:ih:elec:battery_tray_xlh_1965-1966_pic4_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-1957-1985/201845-any-1965-1966-xlh-battery-tray-pics#post4511992)) {{:techtalk:ih:elec:battery_tray_xlh_1965-1966_pic5_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-1957-1985/201845-any-1965-1966-xlh-battery-tray-pics#post4511992)) \\ |
====== 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 https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/139872-side-mount-xlh-oil-tank-help-please#post2980739)) \\ | ||
- | 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 https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/131846-oil-line-routing?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. \\ | + | |
- | L1968-E1971 XLH models did not use a starter relay. \\ | + | |
- | L1971-1974 models mounted the relay (71455-67) on two lower 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 battery tray. \\ | + | |
- | 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. \\ | + | **Carrier Rear Mount**: \\ |
- | 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)) \\ | + | There is a terminal block channel welded to the left frame downtube. \\ |
- | The battery tray is fastened with a rubber mounting stud (62563-65) to the support bracket. \\ | + | 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. \\ |
- | 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 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. \\ |
- | 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 https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/189608-oil-leak-near-solenoid-weird-bolt-underneath-it?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 https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/132498-grounding-voltage-regulator/page2?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. \\ | ||
These ground the regulator to the carrier thru the steel center sleeves. \\ | These ground the regulator to the carrier thru the steel center sleeves. \\ | ||
Line 138: | Line 135: | ||
The ground can also be bolted to the regulator / relay mounting studs / bolts. See pics below. \\ | The ground can also be bolted to the regulator / relay mounting studs / bolts. See pics below. \\ | ||
The ground strap was either (70165-58) on 67-69 XLH, (70169-70) on 70-78 XLCH, 70-77 XLH or (70183-78) on 1978 XLs. \\ | The ground strap was either (70165-58) on 67-69 XLH, (70169-70) on 70-78 XLCH, 70-77 XLH or (70183-78) on 1978 XLs. \\ | ||
- | 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 https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/186413-earth-ground-wire-for-battery-tray?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 https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/171411-battery-tray-and-oil-tank-mount-its-not-plug-n-play?t=1838788)) \\ |
- | {{:techtalk:ih:elec:1967-e1968_xlh_extra_battery_tray_ground_by_randy3934.jpg?direct&300|}} ((photo by randy3934 of the XLFORUM http://xlforum.net/forums/showthread.php?t=1838788)) \\ | + | {{:techtalk:ih:elec:1967-e1968_xlh_extra_battery_tray_ground_by_randy3934.jpg?direct&300|}} ((photo by randy3934 of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/171411-battery-tray-and-oil-tank-mount-its-not-plug-n-play?t=1838788)) \\ |
Alternative grounding point for the tray. \\ | Alternative grounding point for the tray. \\ | ||
{{: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 https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/123719-1976-sportster-starter-electrical-questions?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 https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/199924-momentary-starter-switch-installation-question/page2?highlight=starter+relay#post4410585)) {{:techtalk:ih:elec:1975-1978_style_starter_relay_by_badruchez.jpg?direct&300|}} ((photo by Badruchez of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/123719-1976-sportster-starter-electrical-questions?t=1227876)) \\ | ||
\\ | \\ | ||
+ | |||
===== 1967-1969 (66205-67) ===== | ===== 1967-1969 (66205-67) ===== | ||
Line 191: | Line 203: | ||
Stock tail light assemblies were wired to a 2 point insulating terminal block (71561-67) on the frame. \\ | Stock tail light assemblies were wired to a 2 point insulating terminal block (71561-67) on the frame. \\ | ||
The terminal block mounts to the left downtube by two attachment points below the regulator mounts. \\ | The terminal block mounts to the left downtube by two attachment points below the regulator mounts. \\ | ||
- | It serves as the junction point so that the rear fender can be removed. ((Magneto Sportster of the XLFORUM http://xlforum.net/forums/showthread.php?t=2082309)) \\ | + | It serves as the junction point so that the rear fender can be removed. ((Magneto Sportster of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/204874-wiring-terminal-block-71561-67?t=2082309)) \\ |
No wiring terminal provisions are on the -67 battery tray to mount tail/brake or turn lights. \\ | No wiring terminal provisions are on the -67 battery tray to mount tail/brake or turn lights. \\ | ||
The wiring was a basic twist and shield operation in the rear with wires run up to the terminal board at the forks. \\ | The wiring was a basic twist and shield operation in the rear with wires run up to the terminal board at the forks. \\ | ||
Line 308: | Line 320: | ||
{{:techtalk:ih:elec:1972-1974_xlh_battery_tray_66205-67b_pic1_by_the_doctor71.jpg?direct&300|}} ((photo by The Doctor71 of the XLFORUM)) {{:techtalk:ih:elec:1972-1974_xlh_battery_tray_66205-67b_pic2_by_the_doctor71.jpg?direct&300|}} ((photo by The Doctor71 of the XLFORUM)) {{:techtalk:ih:elec:1972-1974_xlh_battery_tray_66205-67b_pic5_by_the_doctor71.jpg?direct&300|}} ((photo by The Doctor71 of the XLFORUM)) \\ | {{:techtalk:ih:elec:1972-1974_xlh_battery_tray_66205-67b_pic1_by_the_doctor71.jpg?direct&300|}} ((photo by The Doctor71 of the XLFORUM)) {{:techtalk:ih:elec:1972-1974_xlh_battery_tray_66205-67b_pic2_by_the_doctor71.jpg?direct&300|}} ((photo by The Doctor71 of the XLFORUM)) {{:techtalk:ih:elec:1972-1974_xlh_battery_tray_66205-67b_pic5_by_the_doctor71.jpg?direct&300|}} ((photo by The Doctor71 of the XLFORUM)) \\ | ||
+ | |||
+ | ---- | ||
+ | |||
+ | The pic below is a -67A battery tray with the terminal block on the edge panel cut out to fit 1973-up frames with the added strut supports. \\ | ||
+ | The terminal edge is bent backwards which puts that portion into the left strut support. \\ | ||
+ | {{:techtalk:ih:elec:1973_xlh_with_modified_battery_tray_at_rear_strut_by_ztatzau.jpg?direct&400|}} ((photo by ZTatZAU of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/204909-battery-trays#post4940824)) \\ | ||
+ | |||
==== Attachments ==== | ==== Attachments ==== | ||
Line 323: | Line 342: | ||
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) ===== | ||
Line 392: | Line 414: | ||
1975-1978 models use the round starter relay (71463-73) which was later updated to (71463-73A). \\ | 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. \\ | 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 397: | Line 422: | ||
1970 marked the first use of a battery on the XLCH using battery tray (66208-70). There was a main circuit breaker between the battery and the ignition/light switch mounted under the battery tray. \\ | 1970 marked the first use of a battery on the XLCH using battery tray (66208-70). There was a main circuit breaker between the battery and the ignition/light switch mounted under the battery tray. \\ | ||
- | Made for battery (Yuasa model# 12n7-4A) 5.31x3x5.25. ((timberjack of the XLFORUM http://xlforum.net/forums/showthread.php?t=1513044)) \\ | + | Made for battery (Yuasa model# 12n7-4A) 5.31x3x5.25. ((timberjack of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/139455-battery-size?t=1513044)) \\ |
On E1973 models, the MoCo deleted the circuit breaker and in L1973 they added a 20 gauge fuse wire for the main circuit. [[techtalk:ih:elec02#fuse_wire|Click Here]] to read more about the fuse wire in the Sportsterpedia. \\ | On E1973 models, the MoCo deleted the circuit breaker and in L1973 they added a 20 gauge fuse wire for the main circuit. [[techtalk:ih:elec02#fuse_wire|Click Here]] to read more about the fuse wire in the Sportsterpedia. \\ | ||
Also [[techtalk:miscres:miscres05|Click Here]] to go to the Service Bulletin page of the Sportsterpedia to download TSB# 659. \\ | Also [[techtalk:miscres:miscres05|Click Here]] to go to the Service Bulletin page of the Sportsterpedia to download TSB# 659. \\ | ||
Line 414: | Line 439: | ||
1970-1972 tray (66208-70) has a welded bracket on bottom of tray to mount the main circuit breaker. 1973-1978 (66236-73) does not have that bracket. \\ | 1970-1972 tray (66208-70) has a welded bracket on bottom of tray to mount the main circuit breaker. 1973-1978 (66236-73) does not have that bracket. \\ | ||
- | {{:techtalk:ih:elec:1970-1972_xlch_circuit_breaker_location_pic2_by_tomscybershop.jpg?direct&300|}} ((photo courtesy of TomsCyberShop.com www.TomsCyberShop.com)) {{: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:1973-1978_xlch_battery_tray_by_cincinnatikid.jpg?direct&300|}} ((photo by CincinnatiKid of the XLFORUM http://xlforum.net/forums/showthread.php?t=1821477&page=5)) \\ | + | {{:techtalk:ih:elec:1970-1972_xlch_circuit_breaker_location_pic2_by_tomscybershop.jpg?direct&300|}} ((photo courtesy of TomsCyberShop.com www.TomsCyberShop.com)) {{:techtalk:ih:elec:1970-1972_main_circuit_breaker_location_by_the_doctor71.jpg?direct&300|}} ((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:1973-1978_xlch_battery_tray_by_cincinnatikid.jpg?direct&300|}} ((photo by CincinnatiKid of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/169764-74-xlch-a-revival/page5?t=1821477&page=5)) \\ |
====== 1979-1981 Sportster Battery Tray / Parts ====== | ====== 1979-1981 Sportster Battery Tray / Parts ====== | ||
Line 441: | Line 466: | ||
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 https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/142113-battery-bouncing-around-in-tray?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 https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/104459-1981-battery-box?t=924613)) {{techtalk:ih:elec:1980-1981_battery_hold_down_bracket_pic2_by_boilermaker.jpg?direct&300|}} ((photo by boilermaker of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/104459-1981-battery-box?t=924613)) {{techtalk:ih:elec:1980-1981_battery_hold_down_bracket_pic3_by_boilermaker.jpg?direct&300|}} ((photo by boilermaker of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/104459-1981-battery-box?t=924613)) \\ |
====== 1982-1993 Sportster Battery Trays / Parts ====== | ====== 1982-1993 Sportster Battery Trays / Parts ====== |