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techtalk:ref:elec30 [2020/02/09 00:31] hippysmack [Ironhead Wiring Mishaps and Meltdowns] |
techtalk:ref:elec30 [2024/01/13 22:20] hippysmack |
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| See also illustrated [[techtalk:ref:elec07|1959-1985 Sportster Main Wiring Diagrams (created with reference to the OEM manual)]] in the REF section of the Sportsterpedia. \\ | See also illustrated [[techtalk:ref:elec07|1959-1985 Sportster Main Wiring Diagrams (created with reference to the OEM manual)]] in the REF section of the Sportsterpedia. \\ | ||
| - | It's important to have some sort of fail safe mechanism whether a fuse wire, fuse or circuit breaker inline between the battery and the voltage regulator. ((The Doctor71 of the XLFORUM http://xlforum.net/forums/showthread.php?p=5805036#post5805036)) \\ | + | It's important to have some sort of fail safe mechanism whether a fuse wire, fuse or circuit breaker inline between the battery and the voltage regulator. ((The Doctor71 of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/198978-ignition-wire-meltdown-74-xlh-and-hd-service-bulletin-659#post4376553)) \\ |
| Else you can unsuspectingly experience a dead short, melted wiring or even watching your bike go up in flames (literally). \\ | Else you can unsuspectingly experience a dead short, melted wiring or even watching your bike go up in flames (literally). \\ | ||
| It appears that HD's quick fix in 1974 to the meltdown was Service Bulletin #659 adding a fusable wire inline from the battery. \\ | It appears that HD's quick fix in 1974 to the meltdown was Service Bulletin #659 adding a fusable wire inline from the battery. \\ | ||
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| * Installing an inline fuse. | * Installing an inline fuse. | ||
| * Or all of the above. | * Or all of the above. | ||
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| ====== Broken Horn Bracket ====== | ====== Broken Horn Bracket ====== | ||
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| The horn bracket that is mounted along with the key switch between the cylinders has been known to cause meltdowns. \\ | The horn bracket that is mounted along with the key switch between the cylinders has been known to cause meltdowns. \\ | ||
| The fact of the bracket breaking (due to being loose, vibration, age etc,) isn't the problem (electrically speaking). \\ | The fact of the bracket breaking (due to being loose, vibration, age etc,) isn't the problem (electrically speaking). \\ | ||
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| The subsequent dead short heats up the wires, melting them and triggers the carnage shown below. \\ | The subsequent dead short heats up the wires, melting them and triggers the carnage shown below. \\ | ||
| At this point, the motor is dead, no lights, no nothing. You're stranded on the side of the road, wondering just what happened. \\ | At this point, the motor is dead, no lights, no nothing. You're stranded on the side of the road, wondering just what happened. \\ | ||
| - | ===== The Doctor71'S 1974 xlh ===== | ||
| + | ===== The Doctor71's 1974 xlh ===== | ||
| This happened to my 74 XLH and all initially started by a broken horn bracket: \\ | This happened to my 74 XLH and all initially started by a broken horn bracket: \\ | ||
| This particular bike did not come with a fuse wire installed from the factory. So the main circuit was unprotected. \\ | This particular bike did not come with a fuse wire installed from the factory. So the main circuit was unprotected. \\ | ||
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| For the fix, I added a reinforcement to the horn bracket & TIG welded it up, replaced all those wires, & added my own fuse wire. \\ | For the fix, I added a reinforcement to the horn bracket & TIG welded it up, replaced all those wires, & added my own fuse wire. \\ | ||
| - | Before pic. Note the relative pristine condition of the horn mounting bracket, p/n 69129-72. ((photo by The Doctor71 of the XLFORUM http://xlforum.net/forums/showthread.php?p=5805036#post5805036)) \\ | + | Before pic. Note the relative pristine condition of the horn mounting bracket, p/n 69129-72. ((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-1957-1985/198978-ignition-wire-meltdown-74-xlh-and-hd-service-bulletin-659#post4376553)) \\ |
| {{:techtalk:ref:elec:74_xlh_wiring_meltdown_1_by_the_doctor71.jpg?direct&300|}} \\ | {{:techtalk:ref:elec:74_xlh_wiring_meltdown_1_by_the_doctor71.jpg?direct&300|}} \\ | ||
| - | After pics. Back in the garage, with pics of the horn mounting bracket, et al, after removal. ((photo by The Doctor71 of the XLFORUM http://xlforum.net/forums/showthread.php?p=5805036#post5805036)) \\ | + | After pics. Back in the garage, with pics of the horn mounting bracket, et al, after removal. ((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-1957-1985/198978-ignition-wire-meltdown-74-xlh-and-hd-service-bulletin-659#post4376553)) \\ |
| {{:techtalk:ref:elec:74_xlh_wiring_meltdown_2_by_the_doctor71.jpg?direct&230|}} {{:techtalk:ref:elec:74_xlh_wiring_meltdown_3_by_the_doctor71.jpg?direct&230|}} {{:techtalk:ref:elec:74_xlh_wiring_meltdown_4_by_the_doctor71.jpg?direct&230|}} | {{:techtalk:ref:elec:74_xlh_wiring_meltdown_2_by_the_doctor71.jpg?direct&230|}} {{:techtalk:ref:elec:74_xlh_wiring_meltdown_3_by_the_doctor71.jpg?direct&230|}} {{:techtalk:ref:elec:74_xlh_wiring_meltdown_4_by_the_doctor71.jpg?direct&230|}} | ||
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| {{:techtalk:ref:elec:74_xlh_wiring_meltdown_7_by_the_doctor71.jpg?direct&300|}} \\ | {{:techtalk:ref:elec:74_xlh_wiring_meltdown_7_by_the_doctor71.jpg?direct&300|}} \\ | ||
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| ===== Hopper's 1977 XLCH ===== | ===== Hopper's 1977 XLCH ===== | ||
| - | + | Or: Most carb problems are electrical. ((Hopper of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/55696-my-bike-caught-fire?t=277021)) \\ | |
| - | Or: Most carb problems are electrical. ((Hopper of the XLFORUM http://xlforum.net/forums/showthread.php?t=277021)) \\ | + | |
| Hopper had been fine tuning the Keihin carburetor to get a nice reliable idle without carb farts, stalling, or unwanted high-idling. \\ | Hopper had been fine tuning the Keihin carburetor to get a nice reliable idle without carb farts, stalling, or unwanted high-idling. \\ | ||
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| In the third pic below is what fractured and fell down on top of those bare hot terminals. \\ | In the third pic below is what fractured and fell down on top of those bare hot terminals. \\ | ||
| - | {{:techtalk:ref:elec:74_xlh_wiring_meltdown_1_by_hopper.jpg?direct&300|}} ((photo by Hopper of the XLFORUM http://xlforum.net/forums/showthread.php?t=277021&page=4)) {{:techtalk:ref:elec:74_xlh_wiring_meltdown_2_by_hopper.jpg?direct&300|}} ((photo by Hopper of the XLFORUM http://xlforum.net/forums/showthread.php?t=277021&page=4)) {{:techtalk:ref:elec:74_xlh_wiring_meltdown_3_by_hopper.jpg?direct&300|}} ((photo by Hopper of the XLFORUM http://xlforum.net/forums/showthread.php?t=277021&page=4)) \\ | + | {{:techtalk:ref:elec:74_xlh_wiring_meltdown_1_by_hopper.jpg?direct&300|}} ((photo by Hopper of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/55696-my-bike-caught-fire/page4?t=277021&page=4)) {{:techtalk:ref:elec:74_xlh_wiring_meltdown_2_by_hopper.jpg?direct&300|}} ((photo by Hopper of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/55696-my-bike-caught-fire/page4?t=277021&page=4)) {{:techtalk:ref:elec:74_xlh_wiring_meltdown_3_by_hopper.jpg?direct&300|}} ((photo by Hopper of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/55696-my-bike-caught-fire/page4?t=277021&page=4)) \\ |
| This is all that was left of the main power wire from the battery to the ignition switch. \\ | This is all that was left of the main power wire from the battery to the ignition switch. \\ | ||
| A good foot of copper simply vaporized and disappeared. \\ | A good foot of copper simply vaporized and disappeared. \\ | ||
| - | {{:techtalk:ref:elec:74_xlh_wiring_meltdown_4_by_hopper.jpg?direct&300|}} ((photo by Hopper of the XLFORUM http://xlforum.net/forums/showthread.php?t=277021&page=4)) \\ | + | {{:techtalk:ref:elec:74_xlh_wiring_meltdown_4_by_hopper.jpg?direct&300|}} ((photo by Hopper of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/55696-my-bike-caught-fire/page4?t=277021&page=4)) \\ |
| Nearby wires were well fried too, the ones going to the breakers after they leave the switch in the first pic below. \\ | Nearby wires were well fried too, the ones going to the breakers after they leave the switch in the first pic below. \\ | ||
| The others are the other end of the main loom going under the seat post area. \\ | The others are the other end of the main loom going under the seat post area. \\ | ||
| - | {{:techtalk:ref:elec:74_xlh_wiring_meltdown_5_by_hopper.jpg?direct&300|}} ((photo by Hopper of the XLFORUM http://xlforum.net/forums/showthread.php?t=277021&page=4)) {{:techtalk:ref:elec:74_xlh_wiring_meltdown_6_by_hopper.jpg?direct&300|}} ((photo by Hopper of the XLFORUM http://xlforum.net/forums/showthread.php?t=277021&page=4)) {{:techtalk:ref:elec:74_xlh_wiring_meltdown_7_by_hopper.jpg?direct&300|}} ((photo by Hopper of the XLFORUM http://xlforum.net/forums/showthread.php?t=277021&page=4)) \\ | + | {{:techtalk:ref:elec:74_xlh_wiring_meltdown_5_by_hopper.jpg?direct&300|}} ((photo by Hopper of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/55696-my-bike-caught-fire/page4?t=277021&page=4)) {{:techtalk:ref:elec:74_xlh_wiring_meltdown_6_by_hopper.jpg?direct&300|}} ((photo by Hopper of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/55696-my-bike-caught-fire/page4?t=277021&page=4)) {{:techtalk:ref:elec:74_xlh_wiring_meltdown_7_by_hopper.jpg?direct&300|}} ((photo by Hopper of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/55696-my-bike-caught-fire/page4?t=277021&page=4)) \\ |
| Took some fixing. \\ | Took some fixing. \\ | ||
| Line 153: | Line 145: | ||
| Had to solder some new sections in some. \\ | Had to solder some new sections in some. \\ | ||
| - | {{:techtalk:ref:elec:74_xlh_wiring_meltdown_8_by_hopper.jpg?direct&300|}} ((photo by Hopper of the XLFORUM http://xlforum.net/forums/showthread.php?t=277021&page=4)) {{:techtalk:ref:elec:74_xlh_wiring_meltdown_9_by_hopper.jpg?direct&300|}} ((photo by Hopper of the XLFORUM http://xlforum.net/forums/showthread.php?t=277021&page=4)) \\ | + | {{:techtalk:ref:elec:74_xlh_wiring_meltdown_8_by_hopper.jpg?direct&300|}} ((photo by Hopper of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/55696-my-bike-caught-fire/page4?t=277021&page=4)) {{:techtalk:ref:elec:74_xlh_wiring_meltdown_9_by_hopper.jpg?direct&300|}} ((photo by Hopper of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/55696-my-bike-caught-fire/page4?t=277021&page=4)) \\ |
| The rat's nest under the seat survived unscathed except the wires to the ignition breaker and lights breaker. \\ | The rat's nest under the seat survived unscathed except the wires to the ignition breaker and lights breaker. \\ | ||
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| But I figure the master breaker right at the battery will prevent any meltdown if a bottle cap or something should blow in there off the road and arc those terminals. \\ | But I figure the master breaker right at the battery will prevent any meltdown if a bottle cap or something should blow in there off the road and arc those terminals. \\ | ||
| - | {{:techtalk:ref:elec:74_xlh_wiring_meltdown_10_by_hopper.jpg?direct&300|}} ((photo by Hopper of the XLFORUM http://xlforum.net/forums/showthread.php?t=277021&page=4)) {{:techtalk:ref:elec:74_xlh_wiring_meltdown_11_by_hopper.jpg?direct&300|}} ((photo by Hopper of the XLFORUM http://xlforum.net/forums/showthread.php?t=277021&page=4)) \\ | + | {{:techtalk:ref:elec:74_xlh_wiring_meltdown_10_by_hopper.jpg?direct&300|}} ((photo by Hopper of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/55696-my-bike-caught-fire/page4?t=277021&page=4)) {{:techtalk:ref:elec:74_xlh_wiring_meltdown_11_by_hopper.jpg?direct&300|}} ((photo by Hopper of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/55696-my-bike-caught-fire/page4?t=277021&page=4)) \\ |
| And the ignition switch now has a cocoon of fusion tape and Nitto tape to insulate those terminals plus some super heavy duty heat shrink to go over top off all that. \\ | And the ignition switch now has a cocoon of fusion tape and Nitto tape to insulate those terminals plus some super heavy duty heat shrink to go over top off all that. \\ | ||
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| And the TIG welded horn bracket with a strengthened patch so hopefully it won`t break again. \\ | And the TIG welded horn bracket with a strengthened patch so hopefully it won`t break again. \\ | ||
| - | {{:techtalk:ref:elec:74_xlh_wiring_meltdown_12_by_hopper.jpg?direct&300|}} ((photo by Hopper of the XLFORUM http://xlforum.net/forums/showthread.php?t=277021&page=4)) {{:techtalk:ref:elec:74_xlh_wiring_meltdown_13_by_hopper.jpg?direct&300|}} ((photo by Hopper of the XLFORUM http://xlforum.net/forums/showthread.php?t=277021&page=4)) \\ | + | {{:techtalk:ref:elec:74_xlh_wiring_meltdown_12_by_hopper.jpg?direct&300|}} ((photo by Hopper of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/55696-my-bike-caught-fire/page4?t=277021&page=4)) {{:techtalk:ref:elec:74_xlh_wiring_meltdown_13_by_hopper.jpg?direct&300|}} ((photo by Hopper of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/55696-my-bike-caught-fire/page4?t=277021&page=4)) \\ |
| \\ | \\ | ||
