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techtalk:ref:elec06 [2018/11/19 23:25]
techtalk:ref:elec06 [2019/12/18 16:09] (current)
hippysmack [Sub Documents]
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 +[[:​techtalk:​menu|{{ ​ :​techtalk:​gototechnicalmenu.jpg|}}]]
 ====== REF: Electrical System ====== ====== REF: Electrical System ======
-====== ​Instruments - Speedo - Tach ======+====== ​Turn Signals ​======
-\\+Here's a chart of alternative incandescent bulbs that can be used in place of 1157 Run/Turn or Run/Brake bulbs:\\ 
-====== ​Speedometers ​====== +====== ​LED Lighting ​======
-===== HD Combination Speedo/Tach ===== 
-{{  :​techtalk:​ref:​elec:​hd-70900274-speedotachcombo.jpg?300|}}((pic from kingchops - XLForum.net t=2031561)) +LEDs are not only highly shock resistant but they have a very long lifetime and can be made quite bright (and in many different colors). ((Scooter_Trash of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=205077)) \\
-==== HD 70900274 ==== +
-This 4" Combination Digital Speedometer and Analog Sweep Tachometer is offered as an upgrade item and allows you to monitor engine speed, fuel level and gear position, without adding additional handlebar-mounted gauges. See Fitment Info below.+
-  * 4" Spun Aluminum Dial, MPH/km/h, Worldwide Models +===== Converting ​to LED Turn Signals =====
-  * Unit mounts in the stock dash opening and is a direct plug-in installation +
-  * Backlit gauge includes a large LCD (liquid crystal display) information screen that displays odometer/​tripmeter data, miles-to-empty readings, an easy-to-read segmented fuel display, a gear position indicator and clock +
-  * Features push-button adjustable backlighting with over 600 color tone options allowing the rider to adjust pointer, LCD and backlighting colors to match any paint scheme or viewing preference +
-  * Digital speed reading can be easily toggled between MPH and kph to simplify cross-border travel +
-  * Mileage reinstatement resides in the vehicle ECM so initial mileage will be uploaded at the time of installation +
-  * 07+ Sportsters require additional Fuel Sensor Kit (HD 61200008) to utilize Fuel Gauge and Range function+
-Fitment: Fits '​04-'​13 XL (except XR, XL50 and '​04-'​08 XL1200R)\\ +Selecting ​and mounting the LED turn signals can be fairly easy with many aftermarket options. ​\\ 
-Note: As a result of different vehicle capabilities, the following exceptions apply: Gear position not available on ’04-’07 models, Range function not available on ’04-’06 XL models and ’04-’08 Dyna® models, Fuel level function not available on ’04-06 XL models.+Howeverthey may not simply be straight wired in as the OEM bulbs are. \\ 
 +The recommendation is to use a ‘load balancer’. \\
-\\+If all you do first is replace the bulbs with LED lights, all is normal except the lights don’t blink when you push the turn signal switch. \\ 
 +The root cause is that standard bulbs (app around 20-30 watts and 12-14 volts) draw a couple of amps. \\ 
 +Normal electromechanical flashers need an amp or two to flash on and off. \\ 
 +But LEDs draw only a few milliamps, which is not enough to activate the flashers. Hence the edict to use ‘load balancers’. \\ 
 +A load balancer is nothing but a dummy load (or more simply called a resistor). \\ 
 +By installing a resistor in parallel with your light, the resistor acts as a dummy load drawing the amps you need in order to make the flasher work. \\
-==== HD 70900475 ==== +**Choosing a resister**: \\ 
-This 4" Combination Digital Speedometer and Analog Sweep Tachometer allows ​you to monitor engine speed, fuel level and gear positionwithout adding additional handlebar-mounted gaugesSee Fitment Info below.+It's important to understand that each incandescent bulb runs 24w when it flashes. ((IXL2Relax of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​p=5396701#​post5396701)) \\ 
 +You need a 6-ohm resistor to simulate that equiv load. \\ 
 +Using a resistor rated at 10-watts is definitely going to heat up when you run 24-watts of power through it. \\ 
 +You need a 50-watt resistor because components should be spec'd for twice the rating that they will regularly encounter ​to provide reliability ​and safety. \\ 
 +You might get away with cutting cornerssometimes, but it's not a good idea as a policy\\ 
 +You need one 6-ohm, 50-watt resistor to replace each turn signal bulb (that you either eliminate or replace with LED version or mini-bulbs)\\
-Features are as listed above for pre-2014 models.+Between 1991 and 2007, the total load that each side of the Turn Signal Module is expecting is 2 x 24w = 48w. \\ 
 +That's what it is designed to function with when blinking the TS lights. \\ 
 +The TSM is designed to expect a certain range of amps being drawn by the lights. ((Cosmo Kramer of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=205077&​page=8)) \\ 
 +When a bulb burns out, that changes the amp draw and the TSM blinks fast (instead of not blinking at all as in older models) to notify the rider that there is an issue. \\ 
 +Prior to '91, the turn signal flasher was an automotive type with no intelligence. \\ 
 +From 2007 on, most of the TSMs are smart enough to sense and function with whatever the standard load requires. \\ 
 +(whether incandescent,​ LED or mini-bulb, without adding load resistors) \\ 
 +If you eliminate or replace (with LEDs) both front & back turn signals on the same side, you can parallel two resistors to obtain a 3-ohm load (equiv to two bulbs). \\ 
 +THAT ONLY REQUIRES ONE CONNECTION TO THE TURN SIGNAL LINE for that side of the bike (no terrorizing of the harness is necessary). \\ 
 +Just make one connection, anywhere along the entire TS wiring, for the resistors to replace the bulbs, on that side of the bike. \\ 
 +(VIOLET wire on LEFT side and/or BROWN wire on the RIGHT side with resistors often placed somewhere under the seat) \\ 
 +So fundamentally use the right parts, install in a nice clean, protected method of connection (solder, shrink-wrap, etc)\\
-Fitment: Fits '​14-later XL US modelsXL models require separate purchase ​of Fuel Sensor Kit P/N 61200008A to make use of the fuel level and range function.\\+|  Simplified OEM turns((drawing by Scooter_Trash ​of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=205077,​ redrawn by Hippysmack)) ​ |  Resister / load balancer inline. ((drawings by Scooter_Trash ​of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=205077,​ redrawn by Hippysmack)) ​ || 
 \\ \\
-{{  :​techtalk:​ref:​elec:​fuelsensorkit-61200008a.jpg?​300|}} 
-==== HD 61200008A XL Fuel Level Sensor Kit ==== 
-This kit has a graduated, in-tank sensor unit which is based on capacitive sensing technology to accurately monitor the fuel level. Included is a jumper plug to replace the stock resistor pack and a new fuel pump gasket. Specified to be compatible with 70900100C, 70900274 and 70900475, it has been discovered that it is also able to activate the fuel level gauge on the 2016-later 1200CX Roadster speedometer,​ P/N 70900549. ((XLForum Thread - http://​xlforum.net/​forums/​showthread.php?​t=2031561)) 
-The in-tank sensor provides ​the fuel level information ​to the Speedo/Tach LCD display for at-a-glance viewing.+The 3-wire flashers have their own ground wire and they should require no load of any sort to function. \\ 
 +The addition of two diodes for the indicator bulb in the configuration shown below should guarantee there is no bleed from one circuit ​to the other. ((IXL2Relax of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​p=5396701#​post5396701)) \\
-The sensor produced multiple levels ​of resistance based on the fuel level, thus elimnating the previous two-level (ok/loresistor pack functionThe jumper plug shorts socket1 to socket2 ​of connector 200B, thus grounding ​the new in-tank sensorSocket3 of connector 200B is not used and simply plugged.+|  3 wire flasher. ((photo by hawk69 ​of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=205077&​page=7))  |  Example 86-90 model LED turn signal conversion with 3-wire LED flasher((drawings by IXL2Relax ​of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​p=5396701#​post5396701)) ​ || 
-**Note:** There have been many reports that it is difficult to make the jumper plug contact pins protrude enough to make contact with the sockets in the 200B connector. Be sure you assemble the jumper correctly and insert the pins sufficiently.+====== Front Turns ====== 
 +===== The vwclogan Front Turn Signal Mod =====
 +|  2007 XL1200N ((photo by vwclogan of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=916453&​page=2)) ​ |
-Additional info at this XLForum Thread:\\ +|Tools include a hacksaw, file and a drill. ((photo by vwclogan of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=916453))|1/​4"​ steel tubing, black 1/4" PVC tubing or a \\ bunch of washers can used for spacers. ((photo by vwclogan of the XLFORUM ​http://​xlforum.net/​forums/​showthread.php?​t=916453)) ((http://​xlforum.net/​forums/​showthread.php?​t=916453&​page=5))| 
 +|Template for the bracket. \\ Entire drawing should print out 2" x 2". \\ (notched to get around a small edge in the tree) ((photo by vwclogan of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=916453&​page=2))|Holes drilled in 3/4" wide bracket. \\ Left hole (tree) - 3/8". Right hole (turn) 5/16". ((photo by vwclogan of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=916453))|
-==== VSS Modification for 1995-2003 12v Sensor ====+|Parts: (2) 5/​16"​x24x1-1/2" bolt, lockwashers and spacers. ((photos by vwclogan of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=916453))|| 
-There have been a lot of issues and malfunctions of speedometers in these yearsThe below modification is intended to raise the voltage under load for the sensor as a possible fix for intermittent malfunctions. ( See [[http://​xlforum.net/​forums/​showthread.php?​t=800778|this XLForum Thread]] which is related.)+|Remove the lower tree bolt on the right side. ((photo by vwclogan ​of the XLFORUM, resized/​cropped by Hippysmack http://​xlforum.net/​forums/​showthread.php?​t=916453&​page=2))|Remove ​the rounded bolt from the signal with an \\ Allen wrench. ((photo by vwclogan of the XLFORUM ​http://​xlforum.net/​forums/​showthread.php?​t=916453&​page=2))| 
-{{:​techtalk:​ref:​elec:​vss-12v-wiring-mod-reliability.jpg?400|}}+|Mount the new bracket to the tree. Torque the existing bolt (#45 Torx socket head) to 30-35 ft lbs. ((photos by vwclogan of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=916453&​page=2)) ((http://​xlforum.net/​forums/​showthread.php?​t=916453&​page=6))||Add a spacer on a bolt to extend the turn housing. ((photo by vwclogan of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=916453&​page=2))| 
-\\+|Tighten the turn and zip tie the wires nice and neat. ((photos by vwclogan of the XLFORUM, resized/​cropped by Hippysmack http://​xlforum.net/​forums/​showthread.php?​t=916453&​page=2))||Reposition as needed and start on the other side. ((photo by vwclogan of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=916453&​page=2))| 
 +|  After / Before \\ Stock front turns on a 2007 XL1200N ((photo by vwclogan of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=916453&​page=2)) ​ |
-===== VSS/​Speedometer Pulse Rate Converter ​=====+==== Alternate Bracket Material ​==== 
 +|  Bracket made from aluminum flat bar ((photos by Matt.loup.t of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=916453&​page=11))  || 
-The Vehicle Speed Sensor produces ​different number of pulses-per-mph between the 883 and 1200 modelsThe electronic speedometers on 1995-2003 model Sportsters were different between the 883 models ​and the 1200 modelsBeginning ​in 2004, the VSS signal was sent to the ECM so that the ECM could be programmed to account for the differences between the models ​and send the right speed information to the speedometer.+|These rectangular strips were bought from hardware storeThey are size 3 (CHGO NO 3) and the holes are 1" apart (center to center)\\ You can also find stainless spacers ​in the correct size. Cut and shape the brackets, over drill one hole on each, paint them. ((photos by DedPyro of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=916453&​page=11))||| 
-Dakota Digital makes product (SIM-1) to receive ​the pulses from the VSS and convert them to the appropriate pulse rate that is expected by the present speedometerThis conversion can help compensate for larger/​smaller tires and different final drive ratios ​(changes in sprockets).\\ +|Use the original signal mounts, some flat metal stock and bolt with the same thread as mirrors. Cut the stock to size and drill the 3/8" holes for the tree mount. ((photos by dieselbikin of the XLFORUM ​http://xlforum.net/forums/showthread.php?​t=916453&​page=10))||| 
-[[http://www.dakotadigital.com/index.cfm/page/ptype=product/​product_id=1011/​category_id=519/​mode=prod/​prd1011.htm|SIM-1 Product Description]] - [[http://www.dakotadigital.com/​pdf/​SIM-1.pdf|Install Instructions]]+|{{:​techtalk:​ref:​elec:​turn_signal_relocation_1_by_dieselbikin.jpg?​direct&​300|}}|{{:techtalk:​ref:​elec:​turn_signal_relocation_2_by_dieselbikin.jpg?​direct&​300|}}|{{:​techtalk:​ref:​elec:​turn_signal_relocation_3_by_dieselbikin.jpg?​direct&​300|}}|
-Apparently, S&S also had a conversion product (55-1007) that is no longer available.\\ +|**Modification for 48'​s**. The only difference ​is that you need to drill two 3/8" holes in both brackets and angle the brackets from the tree \\ slightly to allow the nut to clear. The 48 turn signal has the wires running through the mounting stud rather than having them come out the back of the housing. \\ The mounting stud is the perfect length to fit the new 1" spacer and there is ample room to bolt the original nut and lock washer to the new bracket. ((photos by ccain of the XLFORUM ​http://​xlforum.net/​forums/​showthread.php?​t=916453&​page=11))||| 
-[[http://​xlforum.net/​forums/​showthread.php?​t=23665|XLForum Thread]] - [[https://www.sscycle.com/​docs/​default-source/​instruction-sheets/​51-1056_speedometecalibrator55-1007_20060427.pdf?sfvrsn=4|Product Install]]+|{{:techtalk:​ref:​elec:​turn_signal_relocation_1_by_ccain.jpg?​direct&​300|}}|{{:​techtalk:​ref:​elec:​turn_signal_relocation_2_by_ccain.jpg?​direct&​300|}}|{{:​techtalk:​ref:​elec:​turn_signal_relocation_3_by_ccain.jpg?direct&​300|}}|
-(As always, the links provided were functional at the time they were listedSearch the web for the product model if the links are inactive.)+|{{:​techtalk:​ref:​elec:​turn_signal_relocation_6_by_ccain.jpg?​direct&​300|}}|{{:​techtalk:​ref:​elec:​turn_signal_relocation_7_by_ccain.jpg?​direct&​300|}}|
 +|All thread coupling: In the first pic below, the top 2 fasteners were removed from each side and discarded; (L) 3/8" x 18 pinch bolt and (R) turn signal stud. \\ The 2-1/4" threaded rod and coupling nut replaces the pinch bolt and provides for more threads in the tree. 3/8" rods can be cut from all-thread or a 5" carriage bolt. \\ The coupling nuts are 1-3/4" long or can be cut shorter (these were cut to 7/8"). The signal stud is replaced with a 5/16" x 24 bolt with the head ground down just \\ enough to fit inside the coupling nut snugly. It is then cut so there is about 1/2" of threads to screw into the turn signal housing with a jam nut threaded on it. \\ The carriage end of the 5/16" bolt is then inserted into the coupling that has been side drilled and tapped for a #10x32 set screw to hold the signal bolt tight. ​ \\ The tree can be torqued back properly by use of a crows foot on a socket wrench applied to the coupling. ((photos by alank of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=438111&​page=2))|||
 +==== Bikes with this mod ====
 +**Mounted to lower trees**:
 +|  2012 883N ((photo by byumetalman of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=916453&​page=10)) ​ |  2009 XL1200N ((photo by privation of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=916453&​page=4)) ​ |  2007 883L ((photo by Gillespk of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=916453&​page=9)) ​ |
 +|  2012 XL1200X ​ ((photo by ccain of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=916453&​page=11)) ​ |  2012 XL1200C ((photo by Matt.loup.t of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=916453&​page=11)) ​ |  2007 XL1200R ((photo by DedPyro of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=916453&​page=11)) ​ |
 +**Mounted to upper trees**:
 +|  2000 XL1200 ((photo by dieselbikin of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=916453&​page=10)) ​ |
 +===== Front Turns on the Forks =====
 +|98 1200C \\ Turns mounted with electrical conduit clamps. ((photo by jacobbuelow of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=916453))|09 883L \\ Turns mounted with electrical conduit clamps. ((photo by rockmanbm of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=916453&​page=7))|
 \\ \\
 +====== Rear Turns ======
 \\ \\
-====== ​Tachometers ​======+===== Loose Rear Turn Signal - Fixes ===== 
 +Some times the double-ended stud that mounts the rear turn signal housing to the fender (thru a stand-off spacer) is not long enough to get a good bite on the threads in the housing. That eventually leads to the first few threads stripping out. Even though there are more threads in the housing, the stud will not reach deep enough. 
 +Note that on some of the stock studs, the housing threads on the double-ended stud have a different pitch than the fender mounting threads. 
 +SportyTrace suggested the following: ((http://​xlforum.net/​forums/​showthread.php?​t=2072073))\\ 
 +I ended up fabbing up a replacement longer threaded stud that could get deeper into the indicator body to use the good remaining threads. I used all-thread rod. The trick was getting a nut fixed into place on threaded rod and making the stalk the correct length. I ended up purposely messing up the threads at the fixing point and added loctite too. Worked a treat, but was a bit fiddly. Shown below: original stock one on top and home-made replacement beneath.\\ 
 +The threads may be repairable using JB Weld (lightly coating the inside of the hole), then rethreading the housing. If all the threads in the housing are stripped, using the above extended stud might reach far enough to use a nut (or speed nut) on the inside of the housing.  
 +====== 86-90 LED Turn Signal Schematic ====== 
 +The stock turn signal blinker is 'load activated',​ meaning it requires a certain current draw before it functions correctly. 
 +If you change the TS bulbs to LED type, the stock blinker will not work (unless you use load equalizers). But, for these years, it is a simple matter replace the OEM Flasher with an LED-compatible Flasher, then add some diodes and ground wires to make the change. The following electrical diagram illustrates the needed changes. 
 \\ \\