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| techtalk:evo:elec03c [2021/01/05 07:47] – [EVO: Electrical System - Sub-03C] ixl2relax | techtalk:evo:elec03c [2024/01/03 02:06] (current) – hippysmack | ||
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| **Wiring of the Headlight Housing Connector** | **Wiring of the Headlight Housing Connector** | ||
| - | The original wiring diagrams do not have Pin# identificaitons. So in this description we will identify pin numbers for the internal connector (mounted to the headlight housing) starting with the Orange wires and looking at the connector from the backside, where the wires are inserted. | + | The original wiring diagrams do not have Pin# identificaitons. So in this description we will identify pin numbers for the internal connector (mounted to the headlight housing) starting with the Orange wires and looking at the connector from the backside, where the wires are inserted. |
| - | Of course, when looking at the backside of the external connector, where the wires are inserted, the pin location | + | Of course, when looking at the backside of the external |
| - | (Note - This is NOT the way the Amp/Tyco Mate-N-Lok connector pins are numbered from the manufacturer.) | + | (Note - This is NOT the way the Amp/Tyco Mate-N-Lok connector pins are numbered from the manufacturer |
| - | {{: | + | | |
| + | |||
| + | **1986-1990 Wiring of the Headlight Housing Connector** | ||
| ^ 1986-1990 Wiring of the Headlight Housing Connector || | ^ 1986-1990 Wiring of the Headlight Housing Connector || | ||
| - | | **Mounted (inside) Connector** \\ 1 - ORANGE - Power from Accessory Fuse \\ 2 - Also ORANGE Jumpered | + | | **Mounted (inside) Connector** \\ 1 - ORANGE - Power from Accessory Fuse \\ 2 - No Wire but jumpered on face from Pin#1 \\ 3 - No wire but jumpered on face from Pin#1 \\ 4 - ORANGE |
| (These are the orignal OEM wire colors - Since many bikes have been rewired over the years, your colors may vary and even the pin function locations may have been reorganized if your bike wiring has been butchered (errr - customized).) | (These are the orignal OEM wire colors - Since many bikes have been rewired over the years, your colors may vary and even the pin function locations may have been reorganized if your bike wiring has been butchered (errr - customized).) | ||
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| **Right Turn Signal use Pin#6 & Pin#12**\\ | **Right Turn Signal use Pin#6 & Pin#12**\\ | ||
| - | Pin#6 - sends power to the Right Running Light in the TS housing (BLUE wire inside - BLACK outside). The TS housing is grounded thru the handlebar ground.\\ | + | Pin#6 - sends power to the Right Running Light in the TS housing (Jumpered to Pin#5 (No Wire) inside - BLACK outside). The TS housing is grounded thru the handlebar ground.\\ |
| Pin#12 - blinking signal to the Right TS - This is a BLACK wire with a BROWN Tape Band. This same pin has a wire to one side of the TS Indicator.\\ | Pin#12 - blinking signal to the Right TS - This is a BLACK wire with a BROWN Tape Band. This same pin has a wire to one side of the TS Indicator.\\ | ||
| ....... With other wires, this same signal (from the Handlebar Right TS Switch) is used to drive the Right Rear Turn Signal) | ....... With other wires, this same signal (from the Handlebar Right TS Switch) is used to drive the Right Rear Turn Signal) | ||
| **Oil Indicator Light (OL) uses Pin#2 & Pin#10**\\ | **Oil Indicator Light (OL) uses Pin#2 & Pin#10**\\ | ||
| - | Pin#2 - sends power to the OL (ORANGE wire inside - BLACK outside)\\ | + | Pin#2 - sends power to the OL (Jumpered to Pin#1 (No Wire) inside - BLACK outside)\\ |
| Pin#10 - active signal from Oil Pressure Sensor (GREEN wire inside - BLACK outside) (Gnd=LoOilPressure) | Pin#10 - active signal from Oil Pressure Sensor (GREEN wire inside - BLACK outside) (Gnd=LoOilPressure) | ||
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| **Speedometer Light uses Pin#3**\\ | **Speedometer Light uses Pin#3**\\ | ||
| - | Pin#3 - sends power to the Speedometer Light (ORANGE wire inside - ORANGE wire outside). The other side of the light is grounded thru the speedometer itself, thru the handlebar ground. | + | Pin#3 - sends power to the Speedometer Light (Jumpered to Pin#1 (No Wire) inside - ORANGE wire outside). The other side of the light is grounded thru the speedometer itself, thru the handlebar ground. |
| **Tachometer Light & Signal uses Pin#4 & Pin#7**\\ | **Tachometer Light & Signal uses Pin#4 & Pin#7**\\ | ||
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| - | **1993 | + | **1993 |
| - | For 1993 (and presumably for 1991-1992) the functional wire locations on this connector (therefore, the wire colors) were arranged a little differently but all the same functions were implemented. | + | For 1993 (and presumably for 1991-1992) the functional wire locations on this connector (therefore, the wire colors) were arranged a little differently |
| In 1991, a Turn Signal Canceller Module (TSM) was introduced on the Sportster. This allowed pulses from the Speeodmeter to cancel the flashing turn signals (not wired thru this 12-pin connector). This TSM now took over the function of the simple automobile-type flasher that was used previously. The new TSM did not route the active TS power signals thru the Turn Signal Switches (as previously) but rather, it simply obtained a low-current pulse from the momentary TS handlebar switches to start or stop the flashing function within the TSM. When flashing was needed, the TSM sent ON/OFF power to the Turn Signal bulb in order to flash the Turn Signal. This new TSM also allowed the use of 4-way flashers. | In 1991, a Turn Signal Canceller Module (TSM) was introduced on the Sportster. This allowed pulses from the Speeodmeter to cancel the flashing turn signals (not wired thru this 12-pin connector). This TSM now took over the function of the simple automobile-type flasher that was used previously. The new TSM did not route the active TS power signals thru the Turn Signal Switches (as previously) but rather, it simply obtained a low-current pulse from the momentary TS handlebar switches to start or stop the flashing function within the TSM. When flashing was needed, the TSM sent ON/OFF power to the Turn Signal bulb in order to flash the Turn Signal. This new TSM also allowed the use of 4-way flashers. | ||
| ^ 1993 Wiring of the Headlight Housing Connector (presumed for 1991-1992 also) || | ^ 1993 Wiring of the Headlight Housing Connector (presumed for 1991-1992 also) || | ||
| - | | **Mounted (inside) Connector (3A)** \\ 1 - ORANGE - Power from Accessory Fuse \\ 2 - Also ORANGE Jumpered | + | | **Mounted (inside) Connector (3A)** \\ 1 - ORANGE - Power from Accessory Fuse \\ 2 - No Wire but jumpered on face from Pin#1 \\ 3 - No wire but jumpered on face from Pin#1 \\ 4 - ORANGE |
| (These are the orignal 1993 OEM wire colors - Since many bikes have been rewired over the years, your colors may vary and even the pin function locations may have been reorganized if your bike wiring has been butchered (errr - customized).) | (These are the orignal 1993 OEM wire colors - Since many bikes have been rewired over the years, your colors may vary and even the pin function locations may have been reorganized if your bike wiring has been butchered (errr - customized).) | ||
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| **For 1986-1993, the Headlight Housing now uses this P/N 67743-75.**\\ | **For 1986-1993, the Headlight Housing now uses this P/N 67743-75.**\\ | ||
| This housing, although it has an earlier -75 suffix, superceded the original version which was P/N 67743-84. The -84 version used a Speedometer Cable Retainer, P/N 56073-83. It is believed that the -75 version (used before & later superceding the -84 version) does not use this retainer. The -84 version was stock from 1984 thru 1993 and sometime later the 67743-75 version superceded it for replacement parts. Likely, they didn't want to make one version with the retainer & one without it. | This housing, although it has an earlier -75 suffix, superceded the original version which was P/N 67743-84. The -84 version used a Speedometer Cable Retainer, P/N 56073-83. It is believed that the -75 version (used before & later superceding the -84 version) does not use this retainer. The -84 version was stock from 1984 thru 1993 and sometime later the 67743-75 version superceded it for replacement parts. Likely, they didn't want to make one version with the retainer & one without it. | ||
| + | |||
| + | In the parts catalog, on the Wiring & Misc Electrical page, the connectors & pins are listed: | ||
| **Headlight Housing Connector Parts:** | **Headlight Housing Connector Parts:** | ||
| - | The Mounted Connector | + | For the connector mounted |
| 72276-74 - Connector Shell using male pins\\ | 72276-74 - Connector Shell using male pins\\ | ||
| - | 72039-71A - Male pin for Connector shell (x12) | + | 72039-71A - Male pin for Connector shell (x12)\\ |
| + | 72275-74 - Jumper Connector Plate - For Two Terminals\\ | ||
| + | 72277-74 - Jumper Connector Plate - For Three Terminals | ||
| - | The External Connector:\\ | + | For the external mating connector:\\ |
| 72278-74A - Connector Shell using female pins\\ | 72278-74A - Connector Shell using female pins\\ | ||
| 72038-71A - Female pin for Connector Shell (x12)\\ | 72038-71A - Female pin for Connector Shell (x12)\\ | ||
| - | 67839-74 - Weatherproofing boot for External Connector | + | 67839-74 - Weatherproofing boot on External |
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| An XLForm discussion related to this subject occured in this thread:\\ | An XLForm discussion related to this subject occured in this thread:\\ | ||
| - | http:// | + | https://www.xlforum.net/ |
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