Differences

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--- techtalk:ih:elec03 [2019/10/08 14:17]
hippysmack [Horn]
+++ techtalk:ih:elec03 [2021/06/21 02:17]
hippysmack [1973]
@@ Line 4: / Line 4: @@
 ====== SWITCHES ======
-\\
-====== INSTRUMENTS ======
+===== Keyswitch =====
-\\
+The Keyswitch is fed from the main Circuit Breaker. Typically, this feed wire is RED. The Keyswitch has two positions (besides OFF).
+There is a RUN position & a LIGHTS position. This allows the lights to be off for starting (especially kick starting) but then can be turned on by moving the keyswitch to the second on position. But sometime in the late 70's, the MoCo began putting a shorting wire across both output connections of the Keyswitch. This meant that all the circuits are powered whenever the Keyswitch is ON, so that the lights are guaranteed to be on (basically making the keyswitch simply an ON/OFF switch). The Keyswitch labels were likely to be B - IG - L for Battery, Ignition & Lights.
-===== Speedometers =====
 \\
+===== Brake Switch =====
+^{{techtalk:miscres:instruction_sheet_header_4.png?nolink&900|}}||||||||
+|  Front and Rear Brake Switches  ||||||||
+|**Year Model**|Position|Switch Part#|Additional|**Year Model**|Position|Switch Part#|Additional|
+|1959-1966|Rear|72004-52|Complete|1973-1981|Front|72001-69B|Switch only|
+|1967-1972|Rear|72004-67|Kit with wires|1977-1978|Rear|:::|:::|
+|L1969-1972|Front|71900-70|Includes terminal|1979-1985|Rear|72023-51A|Switch only|
+|1973-1974|Rear|72004-70|Switch only|1982-1985|Front|71574-82|Includes terminal and wiring|
+|1975-1976|Rear|72004-75|Switch only|
+The stock 77 rear brake light switch is a cheesy little thing that attaches to the pressed metal inner sprocket cover/brake cable mounting plate under the aluminum sprocket cover. ((Hopper of the XLFORUM http://xlforum.net/forums/showthread.php?t=496897)) They are tiny and often get clogged up with chain gunk in there. The little flat plate sticking out from the end of the cable operates it. It mounts on a right angle metal bracket going to the quarter nut and stud above, allowing adjusment. \\
+Rear Brake Switch (72001-69B) on 1977 XLCH. \\
+{{:techtalk:ih:elec:1977_xlch_rear_brake_switch_by_hopper.jpg?direct&300|}} ((photo by Hopper of the XLFORUM http://xlforum.net/forums/showthread.php?t=496897)) \\
+====== INSTRUMENTS ======
+===== Sub Documents =====
+  * [[techtalk:ih:elec03f|Pics and Info of Speedometers and Tachometers Per Year Model]]
+===== Speedometers =====
+All Ironhead Sportster speedos, whether tranny driven or front wheel driven, are 2:1 ratio. \\
 -72 - Transmission Driven - 2:1 Ratio Speedometers\\
 -83 - 19" Wheel Driven Right Side - 2:1 Ratio Speedometers ((http://xlforum.net/forums/showthread.php?threadid=1545261))\\
@@ Line 20: / Line 46: @@
 \\
+^{{techtalk:miscres:instruction_sheet_header_4.png?nolink&900|}}|||||||
-^  Speedometers for Sportsters / K Models\\ with gradients in MPH  |||  ^  Speedometers for Sportsters and K Models\\ with gradients in KPH  |||
+|  Speedometers for Sportsters / K Models\\ with gradients in MPH  |||  |  Speedometers for Sportsters and K Models\\ with gradients in KPH  |||
 |All K Models|1952-1954|67007-52^ |KH / XL / XLH|1954-1958|67008-52|
 |:::|:::|67007-54 \\ Replaced 67007-52^ |XLH & XLCH|1959-1967|67008-59 |
@@ Line 40: / Line 66: @@
 |XLX|1983-1984|67016-83^ |
 |:::|1985|67016-85^ |
 ===== Tachometers =====
-|XLCH|L1962-1964|92051-62 (Smith)|
+|XLCH|L1962-1964|92051-62|
 |XLCH \\ Late XLH|1965|92051-65|
-{{:techtalk:ih:elec:tach_cable_fitting_on_77_model_by_talkstotoads.jpg?direct&200|}} ((photo by TalksToToads of the XLFORUM http://xlforum.net/forums/showthread.php?t=2073848&highlight=breather))
+==== Tach Drive Gear (1971-1980) ====
-===== Speedometer and Tach Pics Per Year Model  =====
+{{:techtalk:ih:elec:tach_cable_fitting_on_77_model_by_talkstotoads.jpg?direct&150|}} ((photo by TalksToToads of the XLFORUM http://xlforum.net/forums/showthread.php?t=2073848&highlight=breather)) \\
-|{{:techtalk:ih:elec:1957-1969_sportster_speedo_gauges_by_moon_wolf.jpg?direct&300|}}|{{:techtalk:ih:elec:1957-1958_sportster_speedo_gauge_w_bracket_by_moon_wolf.jpg?direct&300|}}|{{:techtalk:ih:elec:1959-1964_sportster_speedo_gauge_by_moon_wolf.jpg?direct&300|}}|
+{{:techtalk:ih:elec:tachometer_drive_gear_92097-71_pic1_by_boneyard_cycles.jpg?direct&300|}} ((photo courtesy of Boneyard Cycles in Melbourne, FL, [[https://www.ebay.com/str/barce49|Link to Ebay Store]] )) {{:techtalk:ih:elec:tachometer_drive_gear_92097-71_pic2_by_boneyard_cycles.jpg?direct&300|}} ((photo courtesy of Boneyard Cycles in Melbourne, FL, [[https://www.ebay.com/str/barce49|Link to Ebay Store]] )) {{:techtalk:ih:elec:tach_drive_gear_on_74_xlh_by_sly.jpg?direct&300|}} ((photo by Sly of the XLFORUM http://xlforum.net/forums/showthread.php?t=819534)) \\
-|Sportster gauges from 1957-1969 ((Photo by Moon Wolf of the XLFORUM http://xlforum.net/forums/showthread.php?t=1745575&page=2))|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. ((Photo by Moon Wolf of the XLFORUM http://xlforum.net/forums/showthread.php?t=1745575&page=2))|This A-C speedometer (67007-59), manufactured by \\ United Motors  ((HD Service Bulletin #419 dated April 22, 1960 pg OA-7)), 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. ((Photo by Moon Wolf of the XLFORUM http://xlforum.net/forums/showthread.php?t=1745575&page=2))|
-|{{:techtalk:ih:elec:1965-1968_sportster_speedo_gauges_by_moon_wolf.jpg?direct&300|}}|{{:techtalk:ih:elec:001_ih_sportster_gauges_by_moon_wolf.jpg?direct&300|}}|{{:techtalk:ih:elec:1957-1958_sportster_gauges_by_moon_wolf.jpg?direct&300|}}|
+If you are not using the tach, you can remove the drive unit from the cam cover and plug it using something like this Colony plug. \\
-|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. ((Photo by Moon Wolf of the XLFORUM http://xlforum.net/forums/showthread.php?t=1745575&page=2))|Here are all of them until at least 1978. ((Photo by Moon Wolf of the XLFORUM http://xlforum.net/forums/showthread.php?t=1745575&page=2))|Sportster 1957-1958 (67007-54A) used on \\ 1955-1956 KH and 1957 and 1958 Sportsters \\ (except C and H models)((Photo by Moon Wolf of the XLFORUM http://xlforum.net/forums/showthread.php?t=1745575&page=2)) ((1952-1959 Sportster and K model Parts Catalog pg 67))|
-|{{:techtalk:ih:elec:1959-1964_sportster_gauges_by_moon_wolf.jpg?direct&300|}}|{{:techtalk:ih:elec:1959-1964_speedometer_by_scoobydo.jpg?direct&300|}}|{{:techtalk:ih:elec:1965-1967_sportster_gauges_by_moon_wolf.jpg?direct&300|}}|
+{{:techtalk:ih:elec:tach_drive_plug_-_71-e84_cam_cover_pic1_by_billeuze.jpg?direct&300|}} ((photo by billeuze of the XLFORUM http://xlforum.net/forums/showthread.php?p=5889748&highlight=plug#post5889748)) {{:techtalk:ih:elec:tach_drive_plug_-_71-e84_cam_cover_pic2_by_billeuze.jpg?direct&300|}} ((photo by billeuze of the XLFORUM http://xlforum.net/forums/showthread.php?p=5889748&highlight=plug#post5889748)) \\
-|1959-1964 (67007-59) XLH & XLCH|  1959-1964 Speedo w/ XLCH bracket ((photo by scoobydo of the XLFORUM http://xlforum.net/forums/showthread.php?t=1023743&highlight=fuel+strainer+xlch))  |1965-1967 (67007-59A) XLH & XLCH \\ Replacement speedometer for 1959-1964 ((1957-1967 HD Sportster Parts Catalog pg 82)) ((Photo by Moon Wolf of the XLFORUM http://xlforum.net/forums/showthread.php?t=1745575&page=2))|
-|{{:techtalk:ih:elec:1970-1973_sportster_gauges_by_moon_wolf.jpg?direct&300|}}|{{:techtalk:ih:elec:1974_sportster_gauge_by_moon_wolf.jpg?direct&300|}}|{{:techtalk:ih:elec:1971_sportster_speedo_gauge_by_laddabbo.jpg?direct&300|}}|
+{{:techtalk:ih:elec:tach_drive_plug_-_71-e84_cam_cover_pic3_by_billeuze.jpg?direct&400|}} ((photo by billeuze of the XLFORUM http://xlforum.net/forums/showthread.php?p=5889748&highlight=plug#post5889748)) {{:techtalk:ih:elec:tach_drive_plug_-_71-e84_cam_cover_pic4_by_billeuze.jpg?direct&400|}} ((photo by billeuze of the XLFORUM http://xlforum.net/forums/showthread.php?p=5889748&highlight=plug#post5889748)) \\
-|Sportster 1970-1973 ((Photo by Moon Wolf of the XLFORUM http://xlforum.net/forums/showthread.php?t=1745575&page=2))|Sportster 1974 + ((Photo by Moon Wolf of the XLFORUM http://xlforum.net/forums/showthread.php?t=1745575&page=2))|1971 XLCH ((Photo by Len PA of the XLFORUM http://xlforum.net/forums/showthread.php?t=1745575&page=4))|
 ===== Speedometer Drive Gear =====
-|{{:techtalk:ih:general:speedometer_drive_gear_location_1_by_a0gambo.jpg?direct&300|}}|{{:techtalk:ih:general:speedometer_drive_gear_location_2_by_a0gambo.jpg?direct&300|}}|{{:techtalk:ih:general:speedometer_drive_gear_inside_case_by_austinshovel.jpg?direct&300|}}|
+==== 1952-1972 ====
-|  '68 XLCH speedometer drive gear location in the case  ((photos by a0gambo of the XLFORUM http://xlforum.net/forums/showthread.php?t=1682985))  ||  Inside view of a 69 XLH speedo drive gear as mounted ((photo by austinshovel of the XLFORUM http://xlforum.net/forums/showthread.php?t=1940385))  |
+The mechanical speedometer on K Models / XLH from 1952-1972 and XLCH from 1959-1972 is run by a (11T) gear unit attached to the transmission. \\
+This was not used on 1958 XLC or XLCH. \\
+{{:techtalk:ih:elec:speedometer_drive_unit_pic1_by_americanvintagecycles.jpg?direct&300|}} ((photo courtesy of Ebay seller, American Vintage Cycles. [[https://www.ebay.com/str/jeannenrawlsk0?_trksid=p2047675.l2563|Link to Ebay Store]] )) {{:techtalk:ih:elec:speedometer_drive_unit_pic2_by_americanvintagecycles.jpg?direct&300|}} ((photo courtesy of Ebay seller, American Vintage Cycles. [[https://www.ebay.com/str/jeannenrawlsk0?_trksid=p2047675.l2563|Link to Ebay Store]] )) \\
+The speedometer drive unit goes into the hole in the lower right side of the transmission beside the oil pump. \\ The pic on the right shows the drive unit as installed from the inside. \\
+{{:techtalk:ih:elec:speedometer_drive_gear_location_1_by_a0gambo.jpg?direct&300|}} ((68 XLCH speedometer drive gear location,  photo by a0gambo of the XLFORUM http://xlforum.net/forums/showthread.php?t=1682985)) {{:techtalk:ih:elec:speedometer_drive_gear_location_2_by_a0gambo.jpg?direct&300|}} ((68 XLCH speedometer drive gear location,  photo by a0gambo of the XLFORUM http://xlforum.net/forums/showthread.php?t=1682985)) {{:techtalk:ih:elec:speedometer_drive_gear_location_3_by_austinshovel.jpg?direct&300|}} ((Inside view of a 69 XLH speedo drive gear, photo by austinshovel of the XLFORUM http://xlforum.net/forums/showthread.php?t=1940385)) \\
+\\
+Staring down a problem with the speedometer not working can be catastrophic when visualizing the possible causes and particularly the effects thereof. \\
+Also, if you're not going to use the OEM speedo drive, then remove it and plug the hole. That freewheeling drive has been known to destroy the trans and engine case. ((72 Ironhead XLH of the XLFORUM http://xlforum.net/forums/showthread.php?t=2000442)) \\
+Just unscrew it and screw in a plug. Colony makes a Speedometer Drive Block-Off Plug (2057-2) for K Models and XLs. \\
-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||
 |{{:techtalk:ih:general:speedometer_drive_unit_by_dr_dick.jpg?direct&300|}}|{{:techtalk:ih:general:speedometer_drive_damage_1_by_dr_dick.jpg?direct&300|}}|{{:techtalk:ih:general:speedometer_drive_damage_2_by_dr_dick.jpg?direct&300|}}|
 |Broken teeth on bent speedo drive unit ((photo by Dr Dick of the XLFORUM http://xlforum.net/forums/showthread.php?t=1567534))|Metal pieces in case behind trap door ((photo by Dr Dick of the XLFORUM http://xlforum.net/forums/showthread.php?t=1567534))|Busted teeth on tranny ((photo by Dr Dick of the XLFORUM http://xlforum.net/forums/showthread.php?t=1567534))|
+==== 1973 ====
+{{:techtalk:ih:elec:speedometer_drive_unit_1973_pic1_by_evilgeniushd1936.jpg?direct&300|}} ((photo courtesy of Ebay seller, Evil Genius M/C Parts. [[https://www.ebay.com/str/evilgeniusmcparts?_trksid=p2047675.l2563|Link to Ebay Store]] )) {{:techtalk:ih:elec:speedometer_drive_unit_1973_pic2_by_evilgeniushd1936.jpg?direct&300|}} ((photo courtesy of Ebay seller, Evil Genius M/C Parts. [[https://www.ebay.com/str/evilgeniusmcparts?_trksid=p2047675.l2563|Link to Ebay Store]] )) {{:techtalk:ih:elec:speedometer_drive_unit_1973_pic3_by_evilgeniushd1936.jpg?direct&300|}} ((photo courtesy of Ebay seller, Evil Genius M/C Parts. [[https://www.ebay.com/str/evilgeniusmcparts?_trksid=p2047675.l2563|Link to Ebay Store]] )) \\
  \\
 ====== LIGHTS ======
 \\
-==== Headlight ====
+===== Headlight =====
 === In Late 1977, Shorter Headlight Bracket Mounting Bolts Used ===
@@ Line 91: / Line 122: @@
   * 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. ((HD Service Latter ML-38 dated March 4, 1977))
-----
-==== 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. (( HD Service Bulletin #588A dated October 9, 1969 pg 315))
-|71900-70 with terminal ((1954-1978 HD Sportster Parts Catalog pg 199))|Late 1969-1972 XLH / XLCH|The 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. (( HD Service Bulletin #588A dated October 9, 1969 pg 315))|
-|72024-71P ((1962-1973 Sportster Parts Catalog Supplement))|1973 XLH/XLCH|
-|72001-69  ((1954-1978 HD Sportster Parts Catalog pg 199))|1974-1978 XLH / XLCH \\ replacement for \\ 1973 XLH/XLCH|:::|
-|72001-69B ((1979-1985 HD Sportster Parts Catalog pg 130))|1979-1981 XLH / XLCH / XLS / XLX \\ replaced 72001-69 for \\ 1973-1978 XLH / XLCH|
-|71574-82 ((1979-1985 HD Sportster Parts Catalog pg 132))|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. ((HD Service Bulletin #606 dated November 28, 1969 pg OC-351))
-|72004-52 complete ((1954-1957 HD Spare Parts Catalog for All Sportster and K Models pg 60)) ((1957-1967 HD Sportster / KH Model Parts Catalog pg 101))|1952-1958 K/KH Models \\ 1957-1958 XL \\ 1959-1966 XLH/XLCH|
-|72005-67 kit with wiring ((1957-1967 HD Sportster / KH Model Parts Catalog pg 101))|1967 XLH/XLCH|
-|72004-67 kit with wiring ((HD Service Bulletin #606 dated November 28, 1969 pg OC-351))|Replacement for 1967-1969 XLH/XLCH|
-|72005-67A kit with wiring ((1967-1968 HD Sportster / KH Model Parts Catalog Supplement)) ((1959-1969 HD Sportster / K Model Parts Catalog Supplement)) ((1961-1971 HD Sportster Parts Catalog pg 116))|1968-1971 XLH/XLCH \\ retro-fit replacement for \\ 1967-1972 XLH/XLCH ((1954-1978 HD Sportster Parts Catalog pg 199))|
-|72004-70 switch only ((1962-1973 HD Sportster Parts Catalog Supplement)) ((1954-1978 HD Sportster Parts Catalog pg 199))|1973-1974 XLH/XLCH|
-|72004-75 switch only ((1954-1978 HD Sportster Parts Catalog pg 199))|1975-1976 XLH/XLCH|
-|72001-69B ((1954-1978 HD Sportster Parts Catalog pg 199))|1977-1978 XLH / XLCH|
-|72023-51A ((1979-1985 HD Sportster Parts Catalog pg 130))|1979-1985 XL/XLCH/XLS/XLX|
-----
-==== Handlebar Braking Switch ====
-==== Brake Pedal Braking Switch ====
-\\
 ==== Taillight - License Light ====
@@ Line 174: / Line 151: @@
 ====== Horn ======
-This is a rebuild of the stock Delco Remy horn from a 68 XLCH. \\
+There was a truck load of changes in the horn mounts between late 1970 till 1975. ((Dr Dick of the XLFORUM http://xlforum.net/forums/archive/index.php/t-1492366.html)) \\
+The changes weren't really cataloged in the part books. \\
+Basically: \\
+-1970 all used the same geometry. \\
+and 1966 used different stuff than 67> but the end result was same. \\
+And this 1st gen stuff was used on some 1971's, maybe even some 72's also. \\
+This set up used the larger diameter, short, stiff, 5/16" stud rubber mount. \\
+It held the horn way more solid than the later smaller, longer, 1/4" stud rubber mount. \\
+Both 1st gen brackets had less inward offset than any of the later ones. \\
+The shananigans began in late 1970 with the intro of the 'low' seat kit. \\
+and maybe the 1972 bikes that came from the factory using the older standard seats supposedly came with the 1st gen 65-70 setup. \\
+In late 1971, the low seat was available factory installed for the 1st time. \\
+The low seat required the ignition switch to be moved from the right side under the high seat to the left side on top motor mount where it fouled the horn brackets. \\
+At first, the new brackets with deeper offsets that opened up room for switch were supplied that used the old 5/16" rubber. \\
+There were some issues with interference. The smaller rubber mount and another set of new brackets were furnished to solve that issue. \\
+But the 1/4" rubber mount let the horn flop around to much hitting fins and/or shaking the wire loose from the slip-on terminal. \\
+The bumper was the fix for this. This 3rd gen setup was used till 1974. \\
+In 1975, a bigger ignition switch was used. New brackets again, 4th gen. \\
+There are so many different brackets used that having mismatched stuff is common changing horn position to who knows where. \\
+Below is a rebuild of the stock Delco Remy horn from a 68 XLCH. ((68iron of the XLFORUM http://xlforum.net/forums/showthread.php?t=962963&highlight=diaphragm)) \\
 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. \\

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