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Ironhead Sportster Motorcycle Talk (1957-1985) For all those that wanna talk about Ironhead Sportster Motorcycles

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  #41  
Old 30th July 2018
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Make sure you have a good ground point for the case - The big terminals get the battery voltage & goes to the Starter Solenoid...



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  #42  
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Quote:
Originally Posted by IXL2Relax View Post
Make sure you have a good ground point for the case - The big terminals get the battery voltage & goes to the Starter Solenoid...



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Shouldn't the verbosity on the right read "The fat terminals carry power to the starter solenoid and are interchangeable?
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Quote:
Originally Posted by Smerch View Post
Shouldn't the verbosity on the right read "The fat terminals carry power to the starter solenoid and are interchangeable?
Quote:
Originally Posted by IXL2Relax View Post
The big terminals get the battery voltage & goes to the Starter Solenoid...
That's what I said - To clarify the image text - which I didn't create...

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  #44  
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What gauge do you recommend ?
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  #45  
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Quote:
Originally Posted by phooster View Post
What gauge do you recommend ?
14-16awg for the “control” wiring, and 4 or 6 awg for the “high voltage” wires.
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  #46  
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Of course, Doodah Man is right...

Here are a handful of simplified diagrams in the REFERENCE section of the Sportsterpedia:
http://sportsterpedia.com/doku.php/techtalk:ref:elec07

and here are some wire gauge specs for carrying current:
http://sportsterpedia.com/doku.php/techtalk:ref:elec01

and what gauge wire was used for various circuits on a 1996 EVO XL model:
http://sportsterpedia.com/doku.php/techtalk:evo:elec01

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  #47  
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1972 used a GM horn relay, a bit smaller than the one shown. or one from a marine store called a slave relay
and if you want smaller a cube relay
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Bruce brought it to my attention that terms “control voltage” and “high voltage” might be confusing/misleading since both sides of the relay are still only 12v, and I agree. That’s the HVAC technician in me. So to clarify, the smaller gauge wire wire is low current and the heavier gauge wire is high current. The larger wires connected between battery and relay and relay to starter have to be large enough to carry the high current load and not melt and cause a fire that burns your bike to the ground. So, if there was any confusion, be certain and ask questions before proceeding.
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Or a fog light relay.

If you are willing or interested in moving beyond OEM there are many other options.
horn relays, starter relays from lawn equipment, etc.
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