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techtalk:ih:elec02m [2023/02/15 20:44]
hippysmack [1978 (66205-78)]
techtalk:ih:elec02m [2023/12/30 02:28] (current)
hippysmack [1972-1974 (66205-67B)]
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 The 52-55 carriers leave the battery in a bit more forward position than the 56-60 carrier. \\ The 52-55 carriers leave the battery in a bit more forward position than the 56-60 carrier. \\
  
-{{:​techtalk:​ih:​elec:​1952-1954_k-model_battery_tray_by_animalhouse2010.jpg?​direct&​300|}} ((photo courtesy of Ebay seller, animalhouse2010,​ [[https://​www.ebay.com/​str/​animalhouse2010?​_trksid=p2047675.l2563|Link to Ebay store:]] )) {{:​techtalk:​ih:​elec:​1955_battery_tray_66224-52a_by_animalhouse2010.jpg?​direct&​300|}} ((photo courtesy of Ebay seller, animalhouse2010,​ [[https://​www.ebay.com/​str/​animalhouse2010?​_trksid=p2047675.l2563|Link to Ebay store:]] )) {{:​techtalk:​ih:​elec:​1956-1960_battery_tray_66224-52b_by_dr_dick.jpg?​direct&​300|}} ((photo by Dr Dick of the XLFORUM, labeled by Hippysmack) ​http://​xlforum.net/​forums/showthread.php?​t=1062720&​page=20)) \\+{{:​techtalk:​ih:​elec:​1952-1954_k-model_battery_tray_by_animalhouse2010.jpg?​direct&​300|}} ((photo courtesy of Ebay seller, animalhouse2010,​ [[https://​www.ebay.com/​str/​animalhouse2010?​_trksid=p2047675.l2563|Link to Ebay store:]] )) {{:​techtalk:​ih:​elec:​1955_battery_tray_66224-52a_by_animalhouse2010.jpg?​direct&​300|}} ((photo courtesy of Ebay seller, animalhouse2010,​ [[https://​www.ebay.com/​str/​animalhouse2010?​_trksid=p2047675.l2563|Link to Ebay store:]] )) {{:​techtalk:​ih:​elec:​1956-1960_battery_tray_66224-52b_by_dr_dick.jpg?​direct&​300|}} ((photo by Dr Dick of the XLFORUM, labeled by Hippysmack) ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-era-specific-and-model-specific/​ironhead-sportster-motorcycle-talk-1957-1985/​112326-a-photo-catalog-of-ironhead-parts/​page20?​t=1062720&​page=20)) \\
  
 ===== 1961-1964 66224-52C ===== ===== 1961-1964 66224-52C =====
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 ((photo courtesy of Ebay seller, flathead1461,​ [[https://​www.ebay.com/​sch/​flathead1461/​m.html?​item=284170342423&​nordt=true&​nma=true&​orig_cvip=true&​rt=nc&​si=erCzdk8rpr1SOK4bAqOvxy6IHKI%253D&​_trksid=p2047675.l2562|Link to site:]] ))  ((photo courtesy of Ebay seller, flathead1461,​ [[https://​www.ebay.com/​sch/​flathead1461/​m.html?​item=284170342423&​nordt=true&​nma=true&​orig_cvip=true&​rt=nc&​si=erCzdk8rpr1SOK4bAqOvxy6IHKI%253D&​_trksid=p2047675.l2562|Link to site:]] )) 
 {{:​techtalk:​ih:​elec:​1961-1964_xlh_battery_tray_pic2_by_flathead1461.jpg?​direct&​300|}} {{:​techtalk:​ih:​elec:​1961-1964_xlh_battery_tray_pic2_by_flathead1461.jpg?​direct&​300|}}
-((photo courtesy of Ebay seller, flathead1461,​ [[https://​www.ebay.com/​sch/​flathead1461/​m.html?​item=284170342423&​nordt=true&​nma=true&​orig_cvip=true&​rt=nc&​si=erCzdk8rpr1SOK4bAqOvxy6IHKI%253D&​_trksid=p2047675.l2562|Link to site:]] )) {{:​techtalk:​ih:​elec:​1964_xlh_battery_tray_by_magneto_sportster.jpg?​direct&​300|}} ((photo by Magneto Sportster of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?​t=2075542&​page=4)) \\+((photo courtesy of Ebay seller, flathead1461,​ [[https://​www.ebay.com/​sch/​flathead1461/​m.html?​item=284170342423&​nordt=true&​nma=true&​orig_cvip=true&​rt=nc&​si=erCzdk8rpr1SOK4bAqOvxy6IHKI%253D&​_trksid=p2047675.l2562|Link to site:]] )) {{:​techtalk:​ih:​elec:​1964_xlh_battery_tray_by_magneto_sportster.jpg?​direct&​300|}} ((photo by Magneto Sportster of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-era-specific-and-model-specific/​ironhead-sportster-motorcycle-talk-1957-1985/​198705-magneto-sportster-s-1964-xlh-restoration-project/​page4?​t=2075542&​page=4)) \\
  
 ====== 1965-1966 XLH Battery Tray / Parts ====== ====== 1965-1966 XLH Battery Tray / Parts ======
- 
 1965 marked the first use of a 12v charging system for Sportsters (XLH only). XLCH didn't have a battery until 1970. \\ 1965 marked the first use of a 12v charging system for Sportsters (XLH only). XLCH didn't have a battery until 1970. \\
-The 65-66 battery tray (66223-65) was designed to hold two 6 volt dry charged batteries wired together to create 12v. ((Magneto Sportster of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?​p=5903020#post5903020)) \\+The 65-66 battery tray (66223-65) was designed to hold two 6 volt dry charged batteries wired together to create 12v. ((Magneto Sportster of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-era-specific-and-model-specific/​ironhead-sportster-motorcycle-talk-1957-1985/​201845-any-1965-1966-xlh-battery-tray-pics#post4511992)) \\
 The rear of the tray sits on the 4 bolt rear motor mount and mounts with (2) 3/​8"​x18x1-3/​16"​ bolts (front 2 bolt holes in top of the mount). \\ The rear of the tray sits on the 4 bolt rear motor mount and mounts with (2) 3/​8"​x18x1-3/​16"​ bolts (front 2 bolt holes in top of the mount). \\
 There are two sides and a rear wall making up the tray. \\ There are two sides and a rear wall making up the tray. \\
 The batteries are heavily padded, pad (66418-65) on each side wall, (66101-65) on the rear wall, (66100-65) under both batteries and (66102-65) between the batteries. \\ The batteries are heavily padded, pad (66418-65) on each side wall, (66101-65) on the rear wall, (66100-65) under both batteries and (66102-65) between the batteries. \\
  
-{{:​techtalk:​ih:​elec:​battery_tray_xlh_1965-1966_pic1_by_magneto_sportster.jpg?​direct&​300|}} ((photo by Magneto Sportster of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?​p=5903020#post5903020)) {{:​techtalk:​ih:​elec:​battery_tray_xlh_1965-1966_pic2_by_magneto_sportster.jpg?​direct&​300|}} ((photo by Magneto Sportster of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?​p=5903020#post5903020)) \\+{{:​techtalk:​ih:​elec:​battery_tray_xlh_1965-1966_pic1_by_magneto_sportster.jpg?​direct&​300|}} ((photo by Magneto Sportster of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-era-specific-and-model-specific/​ironhead-sportster-motorcycle-talk-1957-1985/​201845-any-1965-1966-xlh-battery-tray-pics#post4511992)) {{:​techtalk:​ih:​elec:​battery_tray_xlh_1965-1966_pic2_by_magneto_sportster.jpg?​direct&​300|}} ((photo by Magneto Sportster of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-era-specific-and-model-specific/​ironhead-sportster-motorcycle-talk-1957-1985/​201845-any-1965-1966-xlh-battery-tray-pics#post4511992)) \\
  
-{{:​techtalk:​ih:​elec:​battery_tray_xlh_1965-1966_pic3_by_magneto_sportster.jpg?​direct&​300|}} ((photo by Magneto Sportster of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?​p=5903020#post5903020)) {{:​techtalk:​ih:​elec:​battery_tray_xlh_1965-1966_pic4_by_magneto_sportster.jpg?​direct&​300|}} ((photo by Magneto Sportster of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?​p=5903020#post5903020)) {{:​techtalk:​ih:​elec:​battery_tray_xlh_1965-1966_pic5_by_magneto_sportster.jpg?​direct&​300|}} ((photo by Magneto Sportster of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?​p=5903020#post5903020))  \\+{{:​techtalk:​ih:​elec:​battery_tray_xlh_1965-1966_pic3_by_magneto_sportster.jpg?​direct&​300|}} ((photo by Magneto Sportster of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-era-specific-and-model-specific/​ironhead-sportster-motorcycle-talk-1957-1985/​201845-any-1965-1966-xlh-battery-tray-pics#post4511992)) {{:​techtalk:​ih:​elec:​battery_tray_xlh_1965-1966_pic4_by_magneto_sportster.jpg?​direct&​300|}} ((photo by Magneto Sportster of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-era-specific-and-model-specific/​ironhead-sportster-motorcycle-talk-1957-1985/​201845-any-1965-1966-xlh-battery-tray-pics#post4511992)) {{:​techtalk:​ih:​elec:​battery_tray_xlh_1965-1966_pic5_by_magneto_sportster.jpg?​direct&​300|}} ((photo by Magneto Sportster of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-era-specific-and-model-specific/​ironhead-sportster-motorcycle-talk-1957-1985/​201845-any-1965-1966-xlh-battery-tray-pics#post4511992))  \\
  
 ====== 1967-1978 XLH Battery Tray / Parts ====== ====== 1967-1978 XLH Battery Tray / Parts ======
-===== Auxiliaries and Mounting ===== +===== Mounting ​the tray ===== 
-Click on a pic to enlarge: \\+**To the Oil Tank**: \\ 
 +The battery tray is mounted straight to the oil tank by the 3 holes on the back of the tray with (3) 5/​16"​-24 x 9/16 hex head screws. \\ 
 +Be careful ​to use the right length bolts so you don't punch thru the inside of the tank or crack the bracket welds on the tank. \\ 
 +From there, every mounting point (2 for the battery tray and 3 for the oil tank) to the frame/motor has rubber mount isolater studs (62563-65), 5 total. ((DirtyCory of the XLFORUM https://​www.xlforum.net/​forum/​sportster-motorcycle-forum/​sportster-motorcycle-era-specific-and-model-specific/​ironhead-sportster-motorcycle-talk-1957-1985/​139872-side-mount-xlh-oil-tank-help-please#​post2980739)) ​\\ 
  
-There were total of 6 part number changes for these year battery ​trays but they all bolt up the same. \\ +**Battery Carrier Support**: \\ 
-Tray dimensions ​(where battery sitsare app. 8" long x 5 1/8" ​wide. Maximum battery height is app. 6 1/2"((The Doctor71 of the XLFORUM)) \\ +The carrier/​tray is lifted off the motor resting on a battery ​carrier support (66480-67). \\ 
-67-78 battery trays have (3) mounting holes in the rear wall, welded mount (L) for a rubber mount and a hole in right plate for a rubber mount. \\ +The support bracket is mounted to the engine on the 2 holes in front of the rear motor mount with (23/18"x16x3/4" ​hex head bolts (4713W) and lockwashers ​(7038)\\ 
-The main visual differences are in the welded right side regulator mounting plate and the front right inside corner of the tray itself\\ +The bracket hole in the middle for a grommet ​(11422) for cable / hose protection. \\ 
-See the battery tray pics below for more information on specific trays. \\+The battery cable, solenoid to the starter motor, ​and the 3/8" ID return oil hose to the tank line runs through the hole((IronMick of the XLFORUM https://www.xlforum.net/​forum/​sportster-motorcycle-forum/​sportster-motorcycle-era-specific-and-model-specific/​ironhead-sportster-motorcycle-talk-1957-1985/​131846-oil-line-routing?​t=1400314)) ​\\
  
-The battery tray also doubles as a voltage regulator and starter relay mounting base. \\ +**Carrier Front Mount**: ​\\ 
-Later versions also incorporate different mounting points for the starter relay. ​\\ +The bracket on the left side of the tray gets rubber mounting isolator stud (62563-65) mounted ​behind it with 1/4" lockwasher and 1/​4"​x20 nut. \\ 
-The same 3 hole mount voltage regulator (74510-64) was used from 1967-1977. \\ +The other end of the isolater attaches to the support bracket with 1/4" lockwasher and 1/4"x20 nut. \\
-In 1978, the MoCo installed a 2 hole mount solid state regulator (74504-78). \\ +
- +
-1967-E1968 XLH models did not have a factory mounted starter relay but had a kit with a mounting ​bracket ​to retrofit one. \\ +
-L1968-E1971 XLH models did not use a starter relay. \\ +
-L1971-1974 models mounted the relay (71455-67) on two lower holes on the side panel below the voltage regulator. \\ +
-In 1975, new style starter relay (71463-73Awas mounted ​under the front right corner of the battery tray. \\ +
-There is a squared area added to the inside corner of the tray with 2 mounting studs pointing down for the relay. \\ +
- +
-{{:​techtalk:​ih:​elec:​1967-1977_xlh_style_voltage_regulator_by_badruchez.jpg?​direct&​300|}} ((photo by Badruchez of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=1227876)) {{:​techtalk:​ih:​elec:​l1967-e68_--_l1971-1974_xlh_starter_relay_location_by_the_doctor71.jpg?​direct&​300|}} ((photo by The Doctor71 ​of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​p=5830422&​highlight=starter+relay#​post5830422)) {{:​techtalk:​ih:​elec:​1975-1978_style_starter_relay_by_badruchez.jpg?​direct&​300|}} ((photo by Badruchez of the XLFORUM http://xlforum.net/​forums/​showthread.php?​t=1227876)) \\ +
- +
-\\+
  
-The tray is lifted off the motor resting on battery carrier support (66480-67) with a hole thru the middle. The hole has a grommet (11422) for cable / hose protection. \\ +**Carrier Rear Mount**: \\ 
-The battery cable, solenoid to the starter motor, and the 3/8" ​ID return oil hose to the tank line runs through the hole. ((IronMick of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=1400314)) \\ +There is a terminal block channel welded to the left frame downtube. \\ 
-The battery tray is fastened with a rubber mounting stud (62563-65) ​to the support bracket. \\ +On the bottom of the terminal is a threaded 1/4"x20 hole that gets a rubber mounting ​isolator ​stud (62563-65) ​screwed into it. \\ 
-Another rubber mounting stud is installed behind the regulator and bolted to the oil tank with (3) 5/16"x24x9/​16"​ hex head bolts. \\ +The 1/4" ​hole in the tray's side panel sets onto the other end of the isolator stud with a 1/4" ​lockwasher and 1/4"x20 nut fastening it to the panel. \\
-The support bracket is mounted to the engine on the 2 holes in front of the rear motor mount with (2) 3/18"x16x3/​4" ​hex head bolts (4713W) and lockwashers. \\ +
-Battery strap (66470-67). Side cover (66379-67). There were 2 top covers with pads underneath ​to protect it from the terminals (66368-67) black and (66369-67) chrome. \\+
  
 +Battery Carrier Support. Click on a pic to enlarge: \\
 +{{:​techtalk:​ih:​elec:​1967-1978_xlh_battery_tray_support_w_rubbermounts_by_tomscybershop.jpg?​direct&​300|}} ((photo courtesy of TomsCyberShop.com www.TomsCyberShop.com)) {{:​techtalk:​ih:​elec:​1967-1978_xlh_battery_tray_support_mount_location_by_on_.....jpg?​direct&​300|}} ((photo by on½.... of the XLFORUM https://​www.xlforum.net/​forum/​sportster-motorcycle-forum/​sportster-motorcycle-era-specific-and-model-specific/​ironhead-sportster-motorcycle-talk-1957-1985/​189608-oil-leak-near-solenoid-weird-bolt-underneath-it?​t=2022017)) \\
  
-{{:​techtalk:​ih:​elec:​1967-1978_xlh_battery_tray_support_pic1_by_tomscybershop.jpg?​direct&​300|}} ​((photo courtesy of TomsCyberShop.com www.TomsCyberShop.com)) {{:​techtalk:​ih:​elec:​1967-1978_xlh_battery_tray_support_by_flthd31.jpg?​direct&​300|}} ((photo ​by flthd31 of the XLFORUM)) {{:​techtalk:​ih:​elec:​1967-1978_xlh_battery_tray_support_mount_location_by_on_.....jpg?​direct&​300|}} ((photo by on½.... of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=2022017)) ​\\+===== Grounding the tray ===== 
 +The battery tray and oil tank are (shock isolatedfrom the motor and frame by the rubber mount studs\\ 
 +And most of those rubber mounts retain electrical continuity to/thru both their mounting studs\\ 
 +If using rubber mounts with the spring inside, the battery carrier is grounded to the frame due to the spring feature in the mounts\\ 
 +On the inside of the rubber part are two metal plates with the threaded stud attached to each one and then some the plates are connected inside with a spring\\ 
 +These type rubber mounts ensure electrical continuity from end to end of the studs\\ 
 +On others, the plates are either glued onto or sunk into the rubber, where the rubber is solid and has no electrical continuity between the studs. \\ 
 +If you're not sure, check for continuity between the two threaded ends with a multimeter before proceeding. \\
  
-**Grounding the tray**: The tray and oil tank are isolated from the motor and frame by the rubber mount studs. \\ +The 3 terminal, 3 coil XLH regulator is mounted over 3 studs on the battery carrier. ((Dr Dick of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-era-specific-and-model-specific/​ironhead-sportster-motorcycle-talk-1957-1985/​132498-grounding-voltage-regulator/​page2?​s=8bf2b3750d89be7e977e058968ab36e0&​t=1417973&​page=2)) \\
-The 3 terminal, 3 coil XLH regulator is mounted over 3 studs on the battery carrier. ((Dr Dick of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?​s=8bf2b3750d89be7e977e058968ab36e0&​t=1417973&​page=2)) \\+
 The regulator rubber bushes have steel sleeves. The lower 2 regulator bushings have a ground plate that covers the top of the bushes/​sleeves. \\ The regulator rubber bushes have steel sleeves. The lower 2 regulator bushings have a ground plate that covers the top of the bushes/​sleeves. \\
 These ground the regulator to the carrier thru the steel center sleeves. \\ These ground the regulator to the carrier thru the steel center sleeves. \\
Line 138: Line 135:
 The ground can also be bolted to the regulator / relay mounting studs / bolts. See pics below. \\ The ground can also be bolted to the regulator / relay mounting studs / bolts. See pics below. \\
 The ground strap was either (70165-58) on 67-69 XLH, (70169-70) on 70-78 XLCH, 70-77 XLH or (70183-78) on 1978 XLs. \\ The ground strap was either (70165-58) on 67-69 XLH, (70169-70) on 70-78 XLCH, 70-77 XLH or (70183-78) on 1978 XLs. \\
-The routing and connection points of this wire changed between 74 and 75 models. ((Dr Dick of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?​t=1993253)) \\+The routing and connection points of this wire changed between 74 and 75 models. ((Dr Dick of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-era-specific-and-model-specific/​ironhead-sportster-motorcycle-talk-1957-1985/​186413-earth-ground-wire-for-battery-tray?​t=1993253)) \\
  
-The 67-E68 XLH with the factory relay kit (71449-67) got a 2nd ground where the support bracket mounts to the front of the battery tray. \\ +1967-E1968 XLH (with the factory relay kit71449-67) got a 2nd ground where the support bracket mounts to the front of the battery tray. \\ 
-There should be a short ground wire making the jump between both ends of the isolator (67-E68). ((randy3934 of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?​t=1838788)) \\+There should be a short ground wire making the jump between both ends of the isolator (67-E68). ((randy3934 of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-era-specific-and-model-specific/​ironhead-sportster-motorcycle-talk-1957-1985/​171411-battery-tray-and-oil-tank-mount-its-not-plug-n-play?​t=1838788)) \\
  
-{{:​techtalk:​ih:​elec:​1967-e1968_xlh_extra_battery_tray_ground_by_randy3934.jpg?​direct&​300|}} ((photo by randy3934 of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?​t=1838788)) \\+{{:​techtalk:​ih:​elec:​1967-e1968_xlh_extra_battery_tray_ground_by_randy3934.jpg?​direct&​300|}} ((photo by randy3934 of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-era-specific-and-model-specific/​ironhead-sportster-motorcycle-talk-1957-1985/​171411-battery-tray-and-oil-tank-mount-its-not-plug-n-play?​t=1838788)) \\
  
 Alternative grounding point for the tray. \\ Alternative grounding point for the tray. \\
  
 {{:​techtalk:​ih:​elec:​1972-1974_xlh_battery_tray_66205-67b_pic7_by_the_doctor71.jpg?​direct&​300|}} ((photo by The Doctor71 of the XLFORUM, labeled by Hippysmack)) {{:​techtalk:​ih:​elec:​1972-1974_xlh_battery_tray_66205-67b_pic6_by_the_doctor71.jpg?​direct&​300|}} ((photo by The Doctor71 of the XLFORUM, labeled by Hippysmack)) {{:​techtalk:​ih:​elec:​1972-1974_xlh_battery_tray_66205-67b_pic8_by_the_doctor71.jpg?​direct&​300|}} ((photo by The Doctor71 of the XLFORUM, labeled by Hippysmack)) \\ {{:​techtalk:​ih:​elec:​1972-1974_xlh_battery_tray_66205-67b_pic7_by_the_doctor71.jpg?​direct&​300|}} ((photo by The Doctor71 of the XLFORUM, labeled by Hippysmack)) {{:​techtalk:​ih:​elec:​1972-1974_xlh_battery_tray_66205-67b_pic6_by_the_doctor71.jpg?​direct&​300|}} ((photo by The Doctor71 of the XLFORUM, labeled by Hippysmack)) {{:​techtalk:​ih:​elec:​1972-1974_xlh_battery_tray_66205-67b_pic8_by_the_doctor71.jpg?​direct&​300|}} ((photo by The Doctor71 of the XLFORUM, labeled by Hippysmack)) \\
 +
 +===== Electricals mounted to tray =====
 +The battery tray also serves as a mounting point for the voltage regulator, starter relay and main circuit breaker (depending on year model). \\
 +Early to late carrier versions incorporate different mounting points for the starter relay and circuit breaker. \\
 +The same 3 hole mount voltage regulator (74510-64) was used from 1967-1977. \\
 +In 1978, the MoCo installed a 2 hole mount solid state regulator (74504-78). \\
 +
 +1967-E1968 XLH models did not have a factory mounted starter relay but had a kit with a mounting bracket to retrofit one. \\
 +L1968-E1971 XLH models did not use a starter relay. \\
 +L1971-1974 models mounted the relay (71455-67) on two lower 1/4" holes on the side panel below the voltage regulator. \\
 +In 1975, a new style starter relay (71463-73A) was mounted under the front right corner of the rear battery tray frame rail. \\
 +There is a squared area added to the inside corner of the tray with 2 1/4" mounting studs pointing down for the relay. \\
 +
 +{{:​techtalk:​ih:​elec:​1967-1977_xlh_style_voltage_regulator_by_badruchez.jpg?​direct&​300|}} ((photo by Badruchez of the XLFORUM https://​www.xlforum.net/​forum/​sportster-motorcycle-forum/​sportster-motorcycle-era-specific-and-model-specific/​ironhead-sportster-motorcycle-talk-1957-1985/​123719-1976-sportster-starter-electrical-questions?​t=1227876)) {{:​techtalk:​ih:​elec:​l1967-e68_--_l1971-1974_xlh_starter_relay_location_by_the_doctor71.jpg?​direct&​300|}} ((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/​199924-momentary-starter-switch-installation-question/​page2?​highlight=starter+relay#​post4410585)) {{:​techtalk:​ih:​elec:​1975-1978_style_starter_relay_by_badruchez.jpg?​direct&​300|}} ((photo by Badruchez of the XLFORUM https://​www.xlforum.net/​forum/​sportster-motorcycle-forum/​sportster-motorcycle-era-specific-and-model-specific/​ironhead-sportster-motorcycle-talk-1957-1985/​123719-1976-sportster-starter-electrical-questions?​t=1227876)) \\
  
 \\ \\
 +
 ===== 1967-1969 (66205-67) ===== ===== 1967-1969 (66205-67) =====
  
Line 191: Line 203:
 Stock tail light assemblies were wired to a 2 point insulating terminal block (71561-67) on the frame. \\ Stock tail light assemblies were wired to a 2 point insulating terminal block (71561-67) on the frame. \\
 The terminal block mounts to the left downtube by two attachment points below the regulator mounts. \\ The terminal block mounts to the left downtube by two attachment points below the regulator mounts. \\
-It serves as the junction point so that the rear fender can be removed. ((Magneto Sportster of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?​t=2082309)) \\+It serves as the junction point so that the rear fender can be removed. ((Magneto Sportster of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-era-specific-and-model-specific/​ironhead-sportster-motorcycle-talk-1957-1985/​204874-wiring-terminal-block-71561-67?​t=2082309)) \\
 No wiring terminal provisions are on the -67 battery tray to mount tail/brake or turn lights. \\ No wiring terminal provisions are on the -67 battery tray to mount tail/brake or turn lights. \\
 The wiring was a basic twist and shield operation in the rear with wires run up to the terminal board at the forks. \\  The wiring was a basic twist and shield operation in the rear with wires run up to the terminal board at the forks. \\ 
Line 308: Line 320:
  
 {{:​techtalk:​ih:​elec:​1972-1974_xlh_battery_tray_66205-67b_pic1_by_the_doctor71.jpg?​direct&​300|}} ((photo by The Doctor71 of the XLFORUM)) {{:​techtalk:​ih:​elec:​1972-1974_xlh_battery_tray_66205-67b_pic2_by_the_doctor71.jpg?​direct&​300|}} ((photo by The Doctor71 of the XLFORUM)) {{:​techtalk:​ih:​elec:​1972-1974_xlh_battery_tray_66205-67b_pic5_by_the_doctor71.jpg?​direct&​300|}} ((photo by The Doctor71 of the XLFORUM)) \\ {{:​techtalk:​ih:​elec:​1972-1974_xlh_battery_tray_66205-67b_pic1_by_the_doctor71.jpg?​direct&​300|}} ((photo by The Doctor71 of the XLFORUM)) {{:​techtalk:​ih:​elec:​1972-1974_xlh_battery_tray_66205-67b_pic2_by_the_doctor71.jpg?​direct&​300|}} ((photo by The Doctor71 of the XLFORUM)) {{:​techtalk:​ih:​elec:​1972-1974_xlh_battery_tray_66205-67b_pic5_by_the_doctor71.jpg?​direct&​300|}} ((photo by The Doctor71 of the XLFORUM)) \\
 +
 +----
 +
 +The pic below is a -67A battery tray with the terminal block on the edge panel cut out to fit 1973-up frames with the added strut supports. \\
 +The terminal edge is bent backwards which puts that portion into the left strut support. \\
 +{{:​techtalk:​ih:​elec:​1973_xlh_with_modified_battery_tray_at_rear_strut_by_ztatzau.jpg?​direct&​400|}} ((photo by ZTatZAU of the XLFORUM https://​www.xlforum.net/​forum/​sportster-motorcycle-forum/​sportster-motorcycle-era-specific-and-model-specific/​ironhead-sportster-motorcycle-talk-1957-1985/​204909-battery-trays#​post4940824)) \\   
 +
 +----
  
 ==== Attachments ==== ==== Attachments ====
Line 323: Line 343:
 1972-1974 XLH uses starter relay (71455-67). \\ 1972-1974 XLH uses starter relay (71455-67). \\
 It mounts on the 2 lower holes on the side panel under the voltage regulator with (2) 1/​4"​-20x5/​8"​ round head screws (2765W) with nuts (7688). \\ It mounts on the 2 lower holes on the side panel under the voltage regulator with (2) 1/​4"​-20x5/​8"​ round head screws (2765W) with nuts (7688). \\
 +
 +===== 1967-1974 Upgrade (66205-67C) =====
 +This battery tray was sold for parts order starting in 1975 for use on 67-74 XLH models replacing all previous versions. \\
  
 ===== 1975-1977 (66205-75) ===== ===== 1975-1977 (66205-75) =====
Line 400: Line 423:
  
 1970 marked the first use of a battery on the XLCH using battery tray (66208-70). There was a main circuit breaker between the battery and the ignition/​light switch mounted under the battery tray. \\ 1970 marked the first use of a battery on the XLCH using battery tray (66208-70). There was a main circuit breaker between the battery and the ignition/​light switch mounted under the battery tray. \\
-Made for battery (Yuasa model# 12n7-4A) 5.31x3x5.25. ((timberjack of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?​t=1513044)) \\+Made for battery (Yuasa model# 12n7-4A) 5.31x3x5.25. ((timberjack of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-era-specific-and-model-specific/​ironhead-sportster-motorcycle-talk-1957-1985/​139455-battery-size?​t=1513044)) \\
 On E1973 models, the MoCo deleted the circuit breaker and in L1973 they added a 20 gauge fuse wire for the main circuit. [[techtalk:​ih:​elec02#​fuse_wire|Click Here]] to read more about the fuse wire in the Sportsterpedia. \\ On E1973 models, the MoCo deleted the circuit breaker and in L1973 they added a 20 gauge fuse wire for the main circuit. [[techtalk:​ih:​elec02#​fuse_wire|Click Here]] to read more about the fuse wire in the Sportsterpedia. \\
 Also [[techtalk:​miscres:​miscres05|Click Here]] to go to the Service Bulletin page of the Sportsterpedia to download TSB# 659. \\ Also [[techtalk:​miscres:​miscres05|Click Here]] to go to the Service Bulletin page of the Sportsterpedia to download TSB# 659. \\
Line 417: Line 440:
 1970-1972 tray (66208-70) has a welded bracket on bottom of tray to mount the main circuit breaker. 1973-1978 (66236-73) does not have that bracket. \\ 1970-1972 tray (66208-70) has a welded bracket on bottom of tray to mount the main circuit breaker. 1973-1978 (66236-73) does not have that bracket. \\
  
-{{:​techtalk:​ih:​elec:​1970-1972_xlch_circuit_breaker_location_pic2_by_tomscybershop.jpg?​direct&​300|}} ((photo courtesy of TomsCyberShop.com www.TomsCyberShop.com)) {{:​techtalk:​ih:​elec:​1970-1972_main_circuit_breaker_location_by_the_doctor71.jpg?​direct&​300|}} ((photo by The Doctor71 of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?​t=2078550)) {{:​techtalk:​ih:​elec:​1973-1978_xlch_battery_tray_by_cincinnatikid.jpg?​direct&​300|}} ((photo by CincinnatiKid of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?​t=1821477&​page=5)) \\+{{:​techtalk:​ih:​elec:​1970-1972_xlch_circuit_breaker_location_pic2_by_tomscybershop.jpg?​direct&​300|}} ((photo courtesy of TomsCyberShop.com www.TomsCyberShop.com)) {{:​techtalk:​ih:​elec:​1970-1972_main_circuit_breaker_location_by_the_doctor71.jpg?​direct&​300|}} ((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/​201479-1970-sportster-overload?​t=2078550)) {{:​techtalk:​ih:​elec:​1973-1978_xlch_battery_tray_by_cincinnatikid.jpg?​direct&​300|}} ((photo by CincinnatiKid of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-era-specific-and-model-specific/​ironhead-sportster-motorcycle-talk-1957-1985/​169764-74-xlch-a-revival/​page5?​t=1821477&​page=5)) \\
  
 ====== 1979-1981 Sportster Battery Tray / Parts ====== ====== 1979-1981 Sportster Battery Tray / Parts ======
Line 444: Line 467:
 You can try and cut some pieces of rubber or wood trim to shim it until you can purchase the bracket or make one. \\ You can try and cut some pieces of rubber or wood trim to shim it until you can purchase the bracket or make one. \\
  
-{{techtalk:​ih:elec:​1980_sportster_w_battery_bracket_missing_by_marine_hm.jpg?direct&​300|}} ((photo by marine hm of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?​t=1539788)) ​\\+|1980-1981 XL-XLS Oil Tank Bracket 66279-80 ((photo courtesy of Stripped Down Cycles [[https://www.ebay.com/​str/​strippeddowncycles?_trksid=p2047675.m3561.l2563|Link to Ebay Store:]] ))|Possible temp fix for missing bracket ​((photo by marine hm of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-era-specific-and-model-specific/​ironhead-sportster-motorcycle-talk-1957-1985/​142113-battery-bouncing-around-in-tray?​t=1539788))
 +|{{:​techtalk:​ih:​elec:​1980-1981_xl-xls_oil_tank_bracket_66279-80_by_stripped_down_cycles.jpg?​direct&​300|}}|{{techtalk:​ih:​elec:​1980_sportster_w_battery_bracket_missing_by_marine_hm.jpg?​direct&​300|}}|
  
-Original Bracket for 80-81 Sportsters: \\ +Original Bracket for 80-81 Sportsters ​installed: \\ 
-{{techtalk:​ih:​elec:​1980-1981_battery_hold_down_bracket_pic1_by_boilermaker.jpg?​direct&​300|}} ((photo by boilermaker of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?t=924613)) {{techtalk:​ih:​elec:​1980-1981_battery_hold_down_bracket_pic2_by_boilermaker.jpg?​direct&​300|}} ((photo by boilermaker of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?t=924613)) {{techtalk:​ih:​elec:​1980-1981_battery_hold_down_bracket_pic3_by_boilermaker.jpg?​direct&​300|}} ((photo by boilermaker of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?t=924613)) \\+{{techtalk:​ih:​elec:​1980-1981_battery_hold_down_bracket_pic1_by_boilermaker.jpg?​direct&​300|}} ((photo by boilermaker of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-era-specific-and-model-specific/​ironhead-sportster-motorcycle-talk-1957-1985/​104459-1981-battery-box?t=924613)) {{techtalk:​ih:​elec:​1980-1981_battery_hold_down_bracket_pic2_by_boilermaker.jpg?​direct&​300|}} ((photo by boilermaker of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-era-specific-and-model-specific/​ironhead-sportster-motorcycle-talk-1957-1985/​104459-1981-battery-box?t=924613)) {{techtalk:​ih:​elec:​1980-1981_battery_hold_down_bracket_pic3_by_boilermaker.jpg?​direct&​300|}} ((photo by boilermaker of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-era-specific-and-model-specific/​ironhead-sportster-motorcycle-talk-1957-1985/​104459-1981-battery-box?t=924613)) \\
  
 ====== 1982-1993 Sportster Battery Trays / Parts ====== ====== 1982-1993 Sportster Battery Trays / Parts ======