IH: Electrical System - Sportsterpedia

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====== IH: Electrical System ======

====== SWITCHES ======

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====== INSTRUMENTS ======

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===== Speedometers =====

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1957-72 - Transmission Driven - 2:1 Ratio Speedometers - (CableRPM-2000=60mphOnSpeedo)\\
1973-83 - 19" Wheel Driven Right Side - 2:1 Ratio Speedometers - CableRPM-2000=60mphOnSpeedo) ((http://xlforum.net/forums/showthread.php?threadid=1545261))\\
1984-85 - 19" Wheel Driven Left Side - 2:1 Ratio Speedometers - (CableRPM-2000=60mphOnSpeedo)\\
. Driven Unit = 67127-84A for use with 2:1 Speedometers\\

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^  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 |
|KH models \\ Sportsters (except C & CH)|1955-1958 \\ 1957-1958|67007-54A^ |67008-59A|1968 \\ Replacement part for 1959-1967|XLH & XLCH|
|XLH & XLCH|1959-1964|67007-59^ |:::|1969 \\ Replacement part for 1959-1968|67008-59B|
|:::|1965-E1967|67007-59A^ |:::|1970-1972|67021-70|
|:::|L1967-1968|67007-59B^ |:::|1973|67021-73A|
|:::|1969|67007-59C^ |:::|1974-1976|67043-74A|
|:::|1970-1973|67020-70^ |:::|1977-1979 \\ Replacement for 1974-1976|67043-74B|
|:::|1973|67020-73B^ |XL \\ XLS|1980-1983 \\ 1981-1982|67043-75C|
|:::|1974-1976|67020-74A^ |
|:::|1977 \\ Replacement for 1974-1976|67020-74B^ |
|:::|1978 \\ Replacement for 1974-1978|67020-75D^ |
|XL & XLCH|1979|67020-74B^ |
|XL \\ XLS|1980-1983 \\ 1981-1982|67020-75D^ |
|XLS|1983-1984|67100-83^ |
|:::|1985|67100-85^ |
|XLX|1983-1984|67016-83^ |
|:::|1985|67016-85^ |



===== Tachometers =====
|XLCH|L1962-1964|92051-62 (Smith)|
|XLCH \\ Late XLH|1965|92051-65|




===== Speedometer and Tach Pics Per Year Model  =====

|{{: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|}}|
|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|}}|
|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|}}|
|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|}}|
|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|}}|
|  '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))  |

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))|



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====== LIGHTS ======


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==== 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. ((HD Service Latter ML-38 dated March 4, 1977)) 


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==== Brake Light Switch ====

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=== 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|


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=== 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|

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==== Handlebar Braking Switch ====





==== Brake Pedal Braking Switch ====






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==== Taillight - License Light ====

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===== 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.((HD Service Bulletin #438 dated March 28, 1961 pg OC-59)) Flasher (68543-61A) was the replacement for directional signals. ((HD Service Bulletin #473 dated February 28, 1963 pg OC-97))
  * Flasher (68542-61) is used for pursuit lamps or other flashing lamps which use either one or two 32 candlepower lamps (68715-49).((HD Service Bulletin #438 dated March 28, 1961 pg OC-59))

|Year model|Part #|Used For|Markings|Application \\ Voltage|Notes|
|1957-E1963|68543-61|Directional signals|N 221-6V|6|3-prongs: X (hot), L (switched), P (not used)|
|1957-1965|68543-61A|Directional signals|143-12V|6|Replaced 68543-61 in L1963. Disregard the 12V markings per HD. 2 prongs: X (hot), L (switched)|  
| |68542-61|Pursuit lamps|F 421-6V|6|


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