IH: Electrical System

SWITCHES


INSTRUMENTS


Speedometers


1957-72 - Transmission Driven - 2:1 Ratio Speedometers
1973-83 - 19“ Wheel Driven Right Side - 2:1 Ratio Speedometers 1)
1984-85 - 19” Wheel Driven Left Side - 2:1 Ratio Speedometers
. Driven Unit = 67127-84A for use with 2:1 Speedometers - (CableRPM-2000=60mphOnSpeedo)


Speedometers for Sportsters / K Models
with gradients in MPH
Speedometers for Sportsters and K Models
with gradients in KPH
All K Models1952-195467007-52 KH / XL / XLH1954-195867008-52
67007-54
Replaced 67007-52
XLH & XLCH1959-196767008-59
KH models
Sportsters (except C & CH)
1955-1958
1957-1958
67007-54A 67008-59A1968
Replacement part for 1959-1967
XLH & XLCH
XLH & XLCH1959-196467007-59 1969
Replacement part for 1959-1968
67008-59B
1965-E196767007-59A 1970-197267021-70
L1967-196867007-59B 197367021-73A
196967007-59C 1974-197667043-74A
1970-197367020-70 1977-1979
Replacement for 1974-1976
67043-74B
197367020-73B XL
XLS
1980-1983
1981-1982
67043-75C
1974-197667020-74A
1977
Replacement for 1974-1976
67020-74B
1978
Replacement for 1974-1978
67020-75D
XL & XLCH197967020-74B
XL
XLS
1980-1983
1981-1982
67020-75D
XLS1983-198467100-83
198567100-85
XLX1983-198467016-83
198567016-85

Tachometers

XLCHL1962-196492051-62 (Smith)
XLCH
Late XLH
196592051-65

2)

Speedometer and Tach Pics Per Year Model

Sportster gauges from 1957-1969 3)Here is the speedometer (67007-54A) used on
1955-1956 KH and 1957 and 1958 Sportsters
(except C and H models). The “flippers” hide key
switches for the ignition and lights. 4)
This A-C speedometer (67007-59), manufactured by
United Motors 5), was used from 1959 to 1964 on
both the XLH and XLCH models. The bracket shown
here is for the XLH; it fits under the locomotive
nacelle and the trip odometer cable and knob comes
through the nacelle back panel. The XLCH models
had a different bracket with the odometer reset cable
knob mounting next to the speedo face. 6)
The so-called Smiths gauges were introduced with
the 1965 models. Although the tach was, in fact,
built by Smiths, the speedo was still made by AC
and is identical to the earlier Speedometer except
for the fact. The 120 MPH version (lower right) was
used from 1965 to 1967. The 150 MPH version
was introduced in 1968 in celebration of a factory
tuned Sportster going 150 mph on the Bonneville
salt flats. 7)
Here are all of them until at least 1978. 8)Sportster 1957-1958 (67007-54A) used on
1955-1956 KH and 1957 and 1958 Sportsters
(except C and H models)9) 10)
1959-1964 (67007-59) XLH & XLCH 1959-1964 Speedo w/ XLCH bracket 11) 1965-1967 (67007-59A) XLH & XLCH
Replacement speedometer for 1959-1964 12) 13)
Sportster 1970-1973 14)Sportster 1974 + 15)1971 XLCH 16)

Speedometer Drive Gear

'68 XLCH speedometer drive gear location in the case 17) Inside view of a 69 XLH speedo drive gear as mounted 18)

Staring down a problem with the speedometer not working can be catastrophic when visualizing the possible causes and particularly the effects thereof.

This..Yields that….This particular incident luckily didn't hurt any engine parts
Broken teeth on bent speedo drive unit 19)Metal pieces in case behind trap door 20)Busted teeth on tranny 21)


LIGHTS


Headlight

In Late 1977, Shorter Headlight Bracket Mounting Bolts Used

  • In late 1977, shorter bolts were used to mount the headlight bracket to allow it to be installed or removed with the handlebars clamped in place. The shorter bolt also allows for the mounting of the headlight bracket after mounting the speedometer / tachometer bracket underneath the handlebar upper clamp which provides easy access to the wiring connections at the headlight terminal block.
  • The shorter bolts 5/16“x18 1-1/8” (43868-72) replaced the longer 5/16“x18 1-1/4” bolts (2871W). The longer bolts can also be shortened for this application. 22)

Brake Light Switch


Front Brake Switch

  • All motorcycles shipped after Jan 1, 1969 are equipped with a stoplight switch on the front brake control lever to conform with Federal Motor Vehicle Safety standards. 23)
71900-70 with terminal 24)Late 1969-1972 XLH / XLCHThe handlever bracket has a threaded hole for the plunger type switch which closes the brake light circuit when the lever is moved with one wire leaving connected at the ignition 'hot' and the other at the rear brake light terminal. 25)
72024-71P 26)1973 XLH/XLCH
72001-69 27)1974-1978 XLH / XLCH
replacement for
1973 XLH/XLCH
72001-69B 28)1979-1981 XLH / XLCH / XLS / XLX
replaced 72001-69 for
1973-1978 XLH / XLCH
71574-82 29)1982-1985 XL / XLS / XLX

Rear Brake Switch

  • The MoCo issued a Service Bulletin on November, 28 1969 stating that the 1970 type Sportster rear brake light switch was now being supplied with mounting hardware as a kit, with wiring, (72004-67) for replacement of earlier switches used back to 1967.
    • The new switch was mounted on the (rear fork) right side and activated by an adjustable bracket on the brake operating rod.
    • The switch is also recommended for replacement on Late 1969 models (mounted at the rear chain guard). In some cases, the L69 switches strike the saddlebag when the rear fork bottoms out. The new switch solves that problem. 30)
72004-52 complete 31) 32)1952-1958 K/KH Models
1957-1958 XL
1959-1966 XLH/XLCH
72005-67 kit with wiring 33)1967 XLH/XLCH
72004-67 kit with wiring 34)Replacement for 1967-1969 XLH/XLCH
72005-67A kit with wiring 35) 36) 37)1968-1971 XLH/XLCH
retro-fit replacement for
1967-1972 XLH/XLCH 38)
72004-70 switch only 39) 40)1973-1974 XLH/XLCH
72004-75 switch only 41)1975-1976 XLH/XLCH
72001-69B 42)1977-1978 XLH / XLCH
72023-51A 43)1979-1985 XL/XLCH/XLS/XLX

Handlebar Braking Switch

Brake Pedal Braking Switch


Taillight - License Light


Turn Signals

(1973-85 Simple Turn Signal Function)
These model years HD implemented a basic turn signal circuit using a bi-metallic, current/heat-controlled, Turn Signal Flasher Unit similar to those in automobiles. The 12v power wire feeds thru the Flasher and then goes to the handlebar switches. The Left or Right handlebar turn signal switch could be pressed to feed the power to the bulbs on that side of the bike. When connected to the bulbs, thus completing the circuit, the Flasher unit would supply power until the current flowing through it would heat the bi-metallic elements sufficiently to cause a break (like a circuit breaker) in the circuit. Once the flasher cooled down, the bi-metallic elements would again conduct power to the turn signal bulbs, thus causing an on-off cycle that repeated until the handlebar switch was released.

From 1973-1981, the handlebar TS switches were small pushbuttons. They were momentary contact. The turn signal only stayed flashing while the button was depressed.
From 1982-1985, the handlebar TS housings were changed, creating a larger TS button. The switches were still momentary contact, working only while the button was depressed.

  • (Converting to LEDs) - Because of the way these bikes were wired, you can replace the single current/heat-activated flasher with a new electronic flasher that is capable of properly flashing LEDs or Incandescent bulbs. However, the indicator light may need to be modified by grounding one side and feeding power from the right and left circuits thru diodes to the power side of the indicator.

Signal-STAT Flashers

From a bulletin in 1961:
Different flasher modules have different characteristics. It is important to use the appropriate one when replacing them. For instance:

  • Flasher (68543-61) was originally used for directional signals with 21 candlepower to the front and rear lamps (6872-50) and 1 candlepower pilot lamps (71090-47). If any of the signal bulbs burn out, the pilot lamp in the same circuit will remain on.44) Flasher (68543-61A) was the replacement for directional signals. 45)
  • Flasher (68542-61) is used for pursuit lamps or other flashing lamps which use either one or two 32 candlepower lamps (68715-49).46)
Year modelPart #Used ForMarkingsApplication
Voltage
Notes
1957-E196368543-61Directional signalsN 221-6V63-prongs: X (hot), L (switched), P (not used)
1957-196568543-61ADirectional signals143-12V6Replaced 68543-61 in L1963. Disregard the 12V markings per HD. 2 prongs: X (hot), L (switched)
68542-61Pursuit lampsF 421-6V6

Horn

This is a rebuild of the stock Delco Remy horn from a 68 XLCH.
There are horn rebuild kits available, but they are pretty simple in design and a good cleaning may be all that is needed.
The repop one from J&P Cycles is on the right (3rd pic below). It has 2 wire connections as opposed to the single wire connection on the original horn.

47) 48) 49)

A bench grinder was used to grind the rivet faces off flat. You can also use a drill bit that is larger than the hole in the rivets to drill off the face.
Then you can use a center punch to knock the rivets out or pull them out of the other side with pliers.
Then separate the halves and clean up all surfaces with sand paper or a wire wheel.

50) 51) 52)

You can check the continuity of the coil but be careful not to break the wire.
Use some 400 grit sand paper to lightly resurface the contact points (you may have to push the lower contact down to get the sandpaper in and out).
After everything is cleaned up, reassemble the horn and test.
There is a small screw on the back of the horn, you can make slight turns on it to adjust the horn for the best sound.
Keep in mind that too far one way or the other and the horn will not work at all. Use pop rivets to put the horn back together after a thin coat of RTV.
Ensure that you don't get any sealant on the vibrating plate or it will not work.

53) 54) 55)


3) , 4) , 6) , 7) , 8) , 9) , 13) , 14) , 15)
5)
HD Service Bulletin #419 dated April 22, 1960 pg OA-7
10)
1952-1959 Sportster and K model Parts Catalog pg 67
12)
1957-1967 HD Sportster Parts Catalog pg 82
18)
photo by austinshovel of the XLFORUM http://xlforum.net/forums/showthread.php?t=1940385
22)
HD Service Latter ML-38 dated March 4, 1977
23) , 25)
HD Service Bulletin #588A dated October 9, 1969 pg 315
24) , 27) , 38) , 40) , 41) , 42)
1954-1978 HD Sportster Parts Catalog pg 199
26)
1962-1973 Sportster Parts Catalog Supplement
28) , 43)
1979-1985 HD Sportster Parts Catalog pg 130
29)
1979-1985 HD Sportster Parts Catalog pg 132
30) , 34)
HD Service Bulletin #606 dated November 28, 1969 pg OC-351
31)
1954-1957 HD Spare Parts Catalog for All Sportster and K Models pg 60
32) , 33)
1957-1967 HD Sportster / KH Model Parts Catalog pg 101
35)
1967-1968 HD Sportster / KH Model Parts Catalog Supplement
36)
1959-1969 HD Sportster / K Model Parts Catalog Supplement
37)
1961-1971 HD Sportster Parts Catalog pg 116
39)
1962-1973 HD Sportster Parts Catalog Supplement
44) , 46)
HD Service Bulletin #438 dated March 28, 1961 pg OC-59
45)
HD Service Bulletin #473 dated February 28, 1963 pg OC-97
48) , 50) , 51) , 52) , 53) , 54) , 55)
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