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techtalk:ref:elec30 [2020/02/08 23:11] hippysmack [Hopper's 1977 XLCH] |
techtalk:ref:elec30 [2020/02/09 00:31] hippysmack [Ironhead Wiring Mishaps and Meltdowns] |
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====== Ironhead Wiring Mishaps and Meltdowns ====== | ====== Ironhead Wiring Mishaps and Meltdowns ====== | ||
\\ | \\ | ||
+ | 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. \\ | + | 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)) \\ |
- | Else you can unsuspectingly experience a 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. \\ | ||
[[techtalk:ih:elec02#fuse_wire|Clich here to see more on the fuse wire]] in the Sportsterpedia. \\ | [[techtalk:ih:elec02#fuse_wire|Clich here to see more on the fuse wire]] in the Sportsterpedia. \\ | ||
- | |||
It's important to have some sort of protection on the main circuit. \\ | It's important to have some sort of protection on the main circuit. \\ | ||
If it applies to your ride, you can ward off a potential meltdown in multiple ways. Do whatever works for you: | If it applies to your ride, you can ward off a potential meltdown in multiple ways. Do whatever works for you: | ||
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====== Broken Horn Bracket ====== | ====== Broken Horn Bracket ====== | ||
- | \\ | ||
- | ===== The Doctor71'S 1974 xlh ===== | ||
- | Horn brackets that are 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. \\ | + | The fact of the bracket breaking (due to being loose, vibration, age etc,) isn't the problem (electrically speaking). \\ |
The key switch terminals are bare ended (no insulation). \\ | The key switch terminals are bare ended (no insulation). \\ | ||
Should the horn bracket break, the horn will (most likely) swing down & rest on the back of the ignition switch for awhile, shorting the terminals. \\ | Should the horn bracket break, the horn will (most likely) swing down & rest on the back of the ignition switch for awhile, shorting the terminals. \\ | ||
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 ===== | ||
- | This happened to a 74 XLH 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. \\ |
See the 'before' pic of the horn / switch brackets below (taken ≈ 8 months prior to my catastrophic event). \\ | See the 'before' pic of the horn / switch brackets below (taken ≈ 8 months prior to my catastrophic event). \\ | ||
The ends of the ignition switch wires were heat-shrink'd immediately after this pic was taken. \\ | The ends of the ignition switch wires were heat-shrink'd immediately after this pic was taken. \\ | ||
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{{: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 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)) \\ | ||
- | The first pic below 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. \\ | ||
- | |||
- | Nearby wires were well fried too, the ones going to the breakers after they leave the switch. \\ | ||
- | Notice the other end of the main loom going under the seat post area. \\ | ||
{{: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 http://xlforum.net/forums/showthread.php?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. \\ | ||
+ | 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 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)) \\ | ||
+ | |||
+ | Took some fixing. \\ | ||
+ | I opened the melted outer cover, replaced the fully toasted wires, patched some singed ones with fusion tape and Nitto tape, heat shrink and whatever it took. \\ | ||
+ | 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)) \\ | ||
+ | |||
+ | The rat's nest under the seat survived unscathed except the wires to the ignition breaker and lights breaker. \\ | ||
+ | I added another fourth breaker, a 30amp job, right next to the battery so this cant happen again. \\ | ||
+ | The closeness of wires and terminals and steel frame and fender parts is absolutely terrifying. \\ | ||
+ | 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)) \\ | ||
+ | |||
+ | 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. \\ | ||
+ | Also the patched and spliced main loom with a couple of layers of Nitto tape wound around it in opposite directions. \\ | ||
+ | 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)) \\ | ||
\\ | \\ |