EVO: Electrical System - Sub-02M

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====== EVO: Electrical System - Sub-02M ======
====== Pics and Information on stock EVO Battery Trays and Parts ======

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|Year|Model|Battery Tray|Notes|
|1983-1993|All|66191-83|  |
|1994-1996|All|66194-94|  |
|1997|All|66194-94A|  |
|1998-2003|All (except 883R)|66194-98|  |
|2002-2003|883R|62951-02 (black)|  |
|2004-2006|All|66194-04 \\ 66194-04B (2006)|  |
|2007-2009|All|66194-04C|  |
|2010-2013|All|66194-04D|  |
|2014-2016|All|66000031|  |


===== 1983-1993 Battery Tray / Parts =====
Battery tray part# (66191-83). \\
This style battery tray looks identical to the 82 tray. However, the MoCo added a flange on the front side extending below the bottom and welded a 1/2" steel nipple to it as an oil tank drain plug. \\
The 82 and prior oil tanks have a removeable threaded drain plug to drain the tank. \\
83-up oil tanks have an extra (1/2") hose nipple on them to drain the tank instead that gets plugged off by the nipple under the battery tray. \\
The hose runs across the bike from the tank under the battery tray, bends and terminates on the welded plug. \\

The tray mounts to the frame from the bracket underneath with (1) rubber mount stud (62563-65). \\
83-90 battery trays mount to the oil tank with (2) 5/16" x 24 x 5/8" hex head bolts with 1/16" thick washers. \\
91-93 battery trays mount to the oil tank with (2) 5/16" x 24 x 3/4" hex head bolts with 1/16" thick washers. \\
The chrome battery strap (66476-73A) hooks to bottom left side of the tray, loops over the cover and bolts to the right side of the tray using a 1/4" x 20 nut and washer. \\

1982-1985 XL, XLS had a chrome battery cover (66367-73). \\
1983-1985 XLX had a black battery cover (66359-80). \\
1986-1993 XL883 had a black battery cover (66359-80). \\
1986-1987 XL1100 had a chrome battery cover (66367-73). \\
1988-1993 XL1200 had a chrome battery cover (66367-73). \\
There are (2) pads (66352-65) under the cover to protect the terminals. \\ 

{{:techtalk:evo:elec:1983-1993_sportster_battery_tray_pic1_by_c3cycle.com.jpg?direct&300|}} ((photo courtesy of c3cycle.com, Link to site:https://www.c3cycle.com/)) {{:techtalk:evo:elec:1983-1993_sportster_battery_tray_pic2_by_c3cycle.com.jpg?direct&300|}} ((photo courtesy of c3cycle.com, Link to site:https://www.c3cycle.com/)) \\

{{:techtalk:evo:elec:1983-1993_sportster_battery_tray_pic3_by_c3cycle.com.jpg?direct&300|}} ((photo courtesy of c3cycle.com, Link to site:https://www.c3cycle.com/)){{:techtalk:evo:elec:1983-1993_sportster_battery_tray_pic4_by_c3cycle.com.jpg?direct&300|}} ((photo courtesy of c3cycle.com, Link to site:https://www.c3cycle.com/)){{:techtalk:evo:elec:1983-1993_sportster_battery_tray_pic5_by_c3cycle.com.jpg?direct&300|}} ((photo courtesy of c3cycle.com, Link to site:https://www.c3cycle.com/)) \\
===== 1994-1996 Battery Tray / Parts =====
Battery tray part# (66194-94). \\
The pad (66103-74A) that sits under the battery is available as James Gasket# (JGI-66103-74-A).  \\

{{:techtalk:evo:elec:1994-1996_sportster_battery_tray_pic1_by_americanbikestrippers.jpg?direct&300|}} ((photo by Ebay seller, americanbikestrippers, [[https://www.ebay.com/str/AmericanBikestrippers?_trksid=p2047675.l2563|Ebay store link]] and [[https://www.ebay.com/itm/Harley-Sportster-Sport-XL1200s1996-Battery-Tray/254775512597?hash=item3b51cdce15:g:dPwAAOSwDTdfrDQy|Auction link on date of posting]] )) {{:techtalk:evo:elec:1994-1996_sportster_battery_tray_pic2_by_americanbikestrippers.jpg?direct&300|}} ((photo by Ebay seller, americanbikestrippers, [[https://www.ebay.com/str/AmericanBikestrippers?_trksid=p2047675.l2563|Ebay store link]] and [[https://www.ebay.com/itm/Harley-Sportster-Sport-XL1200s1996-Battery-Tray/254775512597?hash=item3b51cdce15:g:dPwAAOSwDTdfrDQy|Auction link on date of posting]] )) {{:techtalk:evo:elec:1994-1996_sportster_battery_tray_pic3_by_americanbikestrippers.jpg?direct&300|}} ((photo by Ebay seller, americanbikestrippers, [[https://www.ebay.com/str/AmericanBikestrippers?_trksid=p2047675.l2563|Ebay store link]] and [[https://www.ebay.com/itm/Harley-Sportster-Sport-XL1200s1996-Battery-Tray/254775512597?hash=item3b51cdce15:g:dPwAAOSwDTdfrDQy|Auction link on date of posting]] )) \\

{{:techtalk:evo:elec:1994-1996_sportster_battery_tray_pic4_by_americanbikestrippers.jpg?direct&300|}} ((photo by Ebay seller, americanbikestrippers, [[https://www.ebay.com/str/AmericanBikestrippers?_trksid=p2047675.l2563|Ebay store link]] and [[https://www.ebay.com/itm/Harley-Sportster-Sport-XL1200s1996-Battery-Tray/254775512597?hash=item3b51cdce15:g:dPwAAOSwDTdfrDQy|Auction link on date of posting]] )) {{:techtalk:evo:elec:1994-1996_sportster_battery_tray_pic6_by_americanbikestrippers.jpg?direct&300|}} ((photo by Ebay seller, americanbikestrippers, [[https://www.ebay.com/str/AmericanBikestrippers?_trksid=p2047675.l2563|Ebay store link]] and [[https://www.ebay.com/itm/Harley-Sportster-Sport-XL1200s1996-Battery-Tray/254775512597?hash=item3b51cdce15:g:dPwAAOSwDTdfrDQy|Auction link on date of posting]] )) {{:techtalk:evo:elec:1994-1996_sportster_battery_tray_pic8_by_americanbikestrippers.jpg?direct&300|}} ((photo by Ebay seller, americanbikestrippers, [[https://www.ebay.com/str/AmericanBikestrippers?_trksid=p2047675.l2563|Ebay store link]] and [[https://www.ebay.com/itm/Harley-Sportster-Sport-XL1200s1996-Battery-Tray/254775512597?hash=item3b51cdce15:g:dPwAAOSwDTdfrDQy|Auction link on date of posting]] )) 

\\
===== 1997 Battery Tray / Parts =====
Battery tray part# (66194-94A). \\
In 97, the MoCo added 2 rubber bumpers (60429) to the back of the tray along with a beefier rubber pad (66214-97) for the battery to sit on. \\
The pad slips into the corner holes to protect the battery wires from getting cut by the tray. \\

{{:techtalk:evo:elec:1997_battery_tray_by_rileysusedmotorcycleparts_pic1.jpg?direct&300|}} ((photo by Ebay seller, rileysusedmotorcycleparts, store: [[https://www.ebay.com/str/RileysMotorcycleParts?_trksid=p2047675.l2563|Ebay store link:]] and [[https://www.ebay.com/itm/Harley-davidson-1997-Sportster-1200-91-97-883-Battery-Tray-Box-Holder-66194-49a/264940976302?_trkparms=aid%3D1110018%26algo%3DHOMESPLICE.COMPLISTINGS%26ao%3D1%26asc%3D20200423103927%26meid%3Db8fdda058ccc4c9480e3dcff06da1ac6%26pid%3D100013%26rk%3D3%26rkt%3D12%26sd%3D154139205243%26itm%3D264940976302%26pmt%3D1%26noa%3D0%26pg%3D2047675%26algv%3Ddefault%26brand%3DHarley-Davidson&_trksid=p2047675.c100013.m1986|Auction link on date of posting]] )) {{:techtalk:evo:elec:1997_battery_tray_by_rileysusedmotorcycleparts_pic2.jpg?direct&300|}} ((photo by Ebay seller, rileysusedmotorcycleparts, store: [[https://www.ebay.com/str/RileysMotorcycleParts?_trksid=p2047675.l2563|Ebay store link:]] and [[https://www.ebay.com/itm/Harley-davidson-1997-Sportster-1200-91-97-883-Battery-Tray-Box-Holder-66194-49a/264940976302?_trkparms=aid%3D1110018%26algo%3DHOMESPLICE.COMPLISTINGS%26ao%3D1%26asc%3D20200423103927%26meid%3Db8fdda058ccc4c9480e3dcff06da1ac6%26pid%3D100013%26rk%3D3%26rkt%3D12%26sd%3D154139205243%26itm%3D264940976302%26pmt%3D1%26noa%3D0%26pg%3D2047675%26algv%3Ddefault%26brand%3DHarley-Davidson&_trksid=p2047675.c100013.m1986|Auction link on date of posting]] )) {{:techtalk:evo:elec:1997_battery_tray_by_rileysusedmotorcycleparts_pic3.jpg?direct&300|}} ((photo by Ebay seller, rileysusedmotorcycleparts, store: [[https://www.ebay.com/str/RileysMotorcycleParts?_trksid=p2047675.l2563|Ebay store link:]] and [[https://www.ebay.com/itm/Harley-davidson-1997-Sportster-1200-91-97-883-Battery-Tray-Box-Holder-66194-49a/264940976302?_trkparms=aid%3D1110018%26algo%3DHOMESPLICE.COMPLISTINGS%26ao%3D1%26asc%3D20200423103927%26meid%3Db8fdda058ccc4c9480e3dcff06da1ac6%26pid%3D100013%26rk%3D3%26rkt%3D12%26sd%3D154139205243%26itm%3D264940976302%26pmt%3D1%26noa%3D0%26pg%3D2047675%26algv%3Ddefault%26brand%3DHarley-Davidson&_trksid=p2047675.c100013.m1986|Auction link on date of posting]] )) \\

{{:techtalk:evo:elec:1997_battery_tray_by_rileysusedmotorcycleparts_pic6.jpg?direct&300|}} ((photo by Ebay seller, rileysusedmotorcycleparts, store: [[https://www.ebay.com/str/RileysMotorcycleParts?_trksid=p2047675.l2563|Ebay store link:]] and [[https://www.ebay.com/itm/Harley-davidson-1997-Sportster-1200-91-97-883-Battery-Tray-Box-Holder-66194-49a/264940976302?_trkparms=aid%3D1110018%26algo%3DHOMESPLICE.COMPLISTINGS%26ao%3D1%26asc%3D20200423103927%26meid%3Db8fdda058ccc4c9480e3dcff06da1ac6%26pid%3D100013%26rk%3D3%26rkt%3D12%26sd%3D154139205243%26itm%3D264940976302%26pmt%3D1%26noa%3D0%26pg%3D2047675%26algv%3Ddefault%26brand%3DHarley-Davidson&_trksid=p2047675.c100013.m1986|Auction link on date of posting]] )) {{:techtalk:evo:elec:1997_battery_tray_by_rileysusedmotorcycleparts_pic5.jpg?direct&300|}} ((photo by Ebay seller, rileysusedmotorcycleparts, store: [[https://www.ebay.com/str/RileysMotorcycleParts?_trksid=p2047675.l2563|Ebay store link:]] and [[https://www.ebay.com/itm/Harley-davidson-1997-Sportster-1200-91-97-883-Battery-Tray-Box-Holder-66194-49a/264940976302?_trkparms=aid%3D1110018%26algo%3DHOMESPLICE.COMPLISTINGS%26ao%3D1%26asc%3D20200423103927%26meid%3Db8fdda058ccc4c9480e3dcff06da1ac6%26pid%3D100013%26rk%3D3%26rkt%3D12%26sd%3D154139205243%26itm%3D264940976302%26pmt%3D1%26noa%3D0%26pg%3D2047675%26algv%3Ddefault%26brand%3DHarley-Davidson&_trksid=p2047675.c100013.m1986|Auction link on date of posting]] ))  {{:techtalk:evo:elec:1997_battery_tray_by_rileysusedmotorcycleparts_pic4.jpg?direct&300|}} ((photo by Ebay seller, rileysusedmotorcycleparts, store: [[https://www.ebay.com/str/RileysMotorcycleParts?_trksid=p2047675.l2563|Ebay store link:]] and [[https://www.ebay.com/itm/Harley-davidson-1997-Sportster-1200-91-97-883-Battery-Tray-Box-Holder-66194-49a/264940976302?_trkparms=aid%3D1110018%26algo%3DHOMESPLICE.COMPLISTINGS%26ao%3D1%26asc%3D20200423103927%26meid%3Db8fdda058ccc4c9480e3dcff06da1ac6%26pid%3D100013%26rk%3D3%26rkt%3D12%26sd%3D154139205243%26itm%3D264940976302%26pmt%3D1%26noa%3D0%26pg%3D2047675%26algv%3Ddefault%26brand%3DHarley-Davidson&_trksid=p2047675.c100013.m1986|Auction link on date of posting]] )) \\

===== 1998-2003 Battery Tray / Parts =====
Battery tray part# (66194-98). \\
The bank angle sensor (32495-98) attaches to the right side of the tray with one #10-24 x 3/4" flange hex head self tapping screw. \\

{{:techtalk:evo:elec:1998-2003_sportster_battery_tray_pic1_by_rileysusedmotorcycleparts.jpg?direct&300|}} 
((photo by Ebay seller, rileysusedmotorcycleparts, store: [[https://www.ebay.com/str/RileysMotorcycleParts?_trksid=p2047675.l2563|Ebay store link:]] )) {{:techtalk:evo:elec:1998-2003_sportster_battery_tray_pic2_by_rileysusedmotorcycleparts.jpg?direct&300|}} ((photo by Ebay seller, rileysusedmotorcycleparts, store: [[https://www.ebay.com/str/RileysMotorcycleParts?_trksid=p2047675.l2563|Ebay store link:]] )) {{:techtalk:evo:elec:1998-2003_sportster_battery_tray_3_by_americanbikestrippers.jpg?direct&300|}} ((photo by Ebay seller, americanbikestrippers, [[https://www.ebay.com/str/AmericanBikestrippers?_trksid=p2047675.l2563|Ebay store link]] )) \\

{{:techtalk:evo:elec:1998-2003_sportster_battery_tray_pic2_by_rileysusedmotorcycleparts.jpg?direct&300|}} ((photo by Ebay seller, rileysusedmotorcycleparts, store: [[https://www.ebay.com/str/RileysMotorcycleParts?_trksid=p2047675.l2563|Ebay store link:]] ))
{{:techtalk:evo:elec:1998-2003_sportster_battery_tray_pic5_by_rileysusedmotorcycleparts.jpg?direct&300|}} ((photo by Ebay seller, rileysusedmotorcycleparts, store: [[https://www.ebay.com/str/RileysMotorcycleParts?_trksid=p2047675.l2563|Ebay store link:]] ))
{{:techtalk:evo:elec:1998-2003_sportster_battery_tray_pic6_by_rileysusedmotorcycleparts.jpg?direct&300|}} ((photo by Ebay seller, rileysusedmotorcycleparts, store: [[https://www.ebay.com/str/RileysMotorcycleParts?_trksid=p2047675.l2563|Ebay store link:]] )) \\


\\

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Trace: • REF: Service Procedures 9A • EVO: Electrical System - Sub-03B • REF: Suspension - Sub-04A • IH: Engine Control - Sub-01F • EVO: Electrical System - Sub-02M
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