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Old 4 Weeks Ago
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Default L84-85 Dangerous Stock Wiring?

Below is what I wrote in the Sportsterpedia regarding the regulator output wiring for the Late84 & 1985 models.

Perhaps those owners with these models can check to verify whether the bikes themselves ARE wired from the factory as the FSM wiring diagrams indicate.

Please post up what you find...


===================================

http://sportsterpedia.com/doku.php/t...t_be_dangerous

L1984-1985 Wiring Issue - Might Be Dangerous

Note: The L84-85 Wiring Diagrams show an improper connection from the Regulator to the Battery.

The wiring diagram shows an unsafe connection but we have not been able to determine if the actual bikes are wired wrongly that matches the diagrams. So the following information needs to be verified against the actual bike wiring.

The Main Circuit Breaker is supposed to protect the wiring from a shorted battery. If the regulator is connected directly to the battery (as shown on the diagrams), not utilizing the main circuit breaker for protection, there is a potentially dangerous situation. If the regulator internally or externally shorts that wire, connected to the battery, to ground, the battery will supply upto 200 amps of current, causing the wire to overheat and possibly creating a fire. This is what the Main Circuit breaker is to prevent.

So, the proper way to connect the output of the voltage regulator to the system is at the output side of the Main Circuit Breaker (typically, on the Silver Stud). The battery would be connected to the Main Circuit Breaker on the Brass Stud.

This is the way earlier & later model wiring diagrams show the connection of the voltage regulator to the circuit breakers. The L84-85 diagrams are the only ones showing this improper, potentially dangerous, wiring.

If you find that your bike is improperly wired, matching the diagrams, PLEASE, rewire your bike to make it safe. Be sure the output wire of the voltage regulator is connected to the output side of the Main Circuit Breaker (typically, on the Silver Stud).


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I've worked on a bunch of the old Harleys and I've seen that many times.
I wonder if they were using fusible links instead?
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Thanks Decman for your thoughts...

The wiring diagrams for at least the 79-E84 show a Main Circuit Breaker and ONLY THE BATTERY is on the incoming side of that breaker, which is the proper wiring. They also show the Regulator connected on the output side of the Main Circuit Breaker.

The Fuse Wire Bulletin (SB#659 - http://sportsterpedia.com/lib/exe/fe...in:tsb0659.pdf) shows even the Fusible Link in the right place between the Battery & the Regulator connection.

The wiring diagrams for EVOs, 86-up, show the Regulator connected on the output side of the Main Circuit Breaker (and, later, MaxiFuse).

It is only these Late84-85 wiring diagrams that show the improper wiring. I can't believe the FACTORY would go back to using a Fusible Link at the battery when the Main Circuit Breaker is also there & it's only a matter of connecting to it properly.

I'm guessing that the diagram is wrong as this was the first year of the alternator and required the diagram to be modified because of that. I think the factory wired it correctly but the updated diagram showed the connection at the wrong place. That's what I'm trying to confirm.

Because so many bikes (especially the Ironheads) have had the wiring modified (either deliberately or simply by accident while making repairs or modifications) it is hard to find this answer unless you have a truly UNMOLESTED model of those years. For those who don't understand this issue (and its dangers), I can image that putting the wiring back improperly (maybe for convenience) was easy to do.

Decman (or anyone else) - Have you seen this improper wiring on an UNMOLESTED Ironhead of those specific years?


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I would appreciate someone with a 1985 that still has the stock wiring letting us know which way the MoCo wired the Regulator...

TIA

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