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techtalk:ih:elec02m [2023/02/15 20:11]
hippysmack [Attachments]
techtalk:ih:elec02m [2023/12/30 02:28] (current)
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 =====
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 ((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 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 sitsare 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 (23/18"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 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, new style starter relay (71463-73Awas 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 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 isolatedfrom 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 kit71449-67) 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 343:
 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). \\
-  ​ + 
-== Tail/Brake Lights and Turn Signals ​== +===== 1967-1974 Upgrade (66205-67C) ===== 
-No provisions ​for wiring. \\ +This battery tray was sold for parts order starting in 1975 for use on 67-74 XLH models replacing all previous versions. \\
-In 1973, the MoCo changed to connectors ​on the rear turns/tail instead of using frame or battery carrier mounted terminal blocks. \\+
  
 ===== 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 374:
  
 == Starter Relay == == Starter Relay ==
-1975-1978 models ​used 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 -75 battery tray on the (2) 1/4" studs hanging down from the cornered bracket in the rear frame rail. \\ It mounts underneath the -75 battery tray on the (2) 1/4" studs hanging down from the cornered bracket in the rear frame rail. \\
- 
-== Wiring Terminal Block  == 
-The -75 battery tray did not come with the terminal block feature on the side panel edge. \\ 
-Nor does 75-up XLH models have a need for the temrinals on the battery tray. \\ 
  
 ==== 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 wallwelded 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 ======
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 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 410: Line 440:
 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 437: Line 467:
 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 ======