Harley Davidson 2013 Sportster Models. Service Manual — page 43
TRIP ODOMETER RESET SWITCH
REPLACEMENT
TOOL NAME
PART NUMBER
CRIMPING TOOL
HD-45929
TORQUE VALUE
FASTENER
1.4-2.0 Nm
12-18
in-lbs
Speedometer and tachometer
mounting screw: XR 1200X
To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before pro-
ceeding. (00251b)
1.
Remove main fuse.
2.
See
. Remove reset switch boot (11) from back
cover (5).
3.
Remove screws (6) and back cover (5).
4.
Remove tachometer connector [108B] (12).
5.
Follow instructions to push the trip reset socket terminals
out the front of the tachometer connector [108B]. See
A.10 DELPHI MICRO 64 SEALED CONNECTOR
6.
Cut off the socket terminals. Pull the faulty switch out of
the connector.
7.
Push the wires of a replacement switch through the
tachometer connector [108B] (sockets 8, 11) and crimp
new
socket terminals using CRIMPING TOOL (Part
No. HD-45929), on replacement switch wiring.
8.
Draw the terminals back into the connector until the ter-
minal seats.
9.
Install tachometer connector [108B] (12).
10. Position reset switch in squared boss on back cover (5).
Secure with a
new
reset switch boot (11).
11. Place back cover over speedometer and tachometer while
positioning harness to avoid damage. Align mounting
holes. Install screws (6). Tighten to 12-18
in-lbs
(1.4-2.0
Nm).
12. Install main fuse.
TACHOMETER REMOVAL
NOTE
The speedometer and tachometer have backlight LEDs that
cannot be replaced. If an LED fails, replace the entire unit.
To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before pro-
ceeding. (00251b)
1.
Remove main fuse.
2.
See
. Remove reset switch boot (11) from back
cover (5).
3.
Remove screws (6) and back cover (5).
4.
Open latches on each side of tachometer connector [108B]
(12) and separate connector halves.
5.
Push out the tachometer with gasket (13).
6.
Inspect gasket, tachometer connector, trip odometer reset
switch, reset switch boot and wiring. Repair or replace as
required.
TACHOMETER INSTALLATION
TORQUE VALUE
FASTENER
1.4-2.0 Nm
12-18
in-lbs
Speedometer and tachometer
mounting screw: XR 1200X
1.
If replacing the trip odometer reset switch, see
6.5 SPEEDOMETER AND TACHOMETER: XR 1200X,
Trip Odometer Reset Switch Replacement
2.
See
. Install gasket (13) on tachometer (1).
3.
Orient face upright and press tachometer (1) into instru-
ment housing/bracket (4).
4.
Attach tachometer connector [108B] (12) to tachometer.
5.
Attach trip odometer reset switch (10) into squared boss
on back cover (5) and secure with reset switch boot (11).
6.
Place back cover over speedometer and tachometer while
positioning harness to avoid damage. Align mounting
holes. Install screws (6). Tighten to 12-18
in-lbs
(1.4-2.0
Nm).
7.
Install main fuse.
2013 Sportster Service: Electrical 6-11
6.6
ELECTRONIC CONTROL MODULE (ECM)
GENERAL
See
. The ECM receives data from sensors such as
the CKP sensor and the TMAP sensor. The ECM uses this
data to time the ignition spark as well as providing other engine
management functions.
NOTE
This part cannot be repaired. Replace upon failure.
XL Models:
The ECM is mounted in front of the battery in a
caddy.
XR 1200X:
The ECM is mounted in a bracket on the rear fender
under the seat.
4
1
2
3
5
sm06665
1. ECM cover fastener
2. Fuel pump wiring
3. Rear O2 sensor wiring
4. ECM cover
5. Rear O2 sensor wiring clip
Figure 6-8. ECM Cover: XL Models
1
2
3
sm06666
1. ECM
2. ECM connector
3. ECM connector latch
Figure 6-9. ECM: XL Models
1
1
2
sm05525
1. Fastener (2)
2. Electronic Control Module
Figure 6-10. Electronic Control Module (ECM): XR 1200X
REMOVAL
XL Models
To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before pro-
ceeding. (00251b)
1.
Remove main fuse.
2.
See
. Remove fuel pump wiring (2) from ECM
cover (4). Disconnect fuel pump connector [141].
6-12 2013 Sportster Service: Electrical
3.
Remove rear oxygen sensor (O2) wiring (3) from rear O2
sensor wiring clip (5) and ECM cover. Disconnect rear O2
connector [85].
4.
Remove ECM cover fastener (1).
5.
Slide ECM cover out from left side of vehicle.
6.
Press the clip holding the ECM to the caddy and remove
the ECM.
7.
See
. Press the connector latch (3) and unplug
ECM wiring harness connector (2) [78B] from ECM (1).
XR 1200X
To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before pro-
ceeding. (00251b)
1.
Remove main fuse.
2.
Remove rear fender. See
3.
See
. Remove fasteners (1) and ECM (2).
INSTALLATION
TORQUE VALUE
FASTENER
3.4-6.8 Nm
30-60
in-lbs
ECM cover fastener: XL
Models
2.0-2.5 Nm
18-22
in-lbs
ECM fasteners: XR 1200X
XL Models
1.
See
. Plug ECM wiring harness connector [78B]
(2) into ECM. Gently press connector until latch (3) clicks
in place.
2.
Install ECM into caddy. Press ECM into caddy until it is
held by clip.
3.
See
. Slide ECM cover (4) into position from left
side of motorcycle.
4.
Install ECM cover fastener (1). Tighten to 30-60
in-lbs
(3.4-6.8 Nm).
5.
Connect rear O2 connector [85]. Install O2 sensor wiring
(3) into ECM cover and clip (5)
6.
Connect fuel pump connector [141]. Install fuel pump
wiring (2) into ECM cover (4).
7.
Install main fuse.
8.
Perform password learn procedure. See
.
XR 1200X
1.
See
. Install ECM (2) and fasteners (1).
2.
Tighten fasteners to 18-22
in-lbs
(2.0-2.5 Nm).
3.
Install rear fender. See
4.
Install main fuse.
5.
Perform password learn procedure. See
.
After installing seat, pull upward on seat to be sure it is
locked in position. While riding, a loose seat can shift
causing loss of control, which could result in death or
serious injury. (00070b)
6.
Install seat.
2013 Sportster Service: Electrical 6-13
6.7
TURN SIGNAL AND SECURITY MODULE
(TSM/TSSM/HFSM)
GENERAL
See
. The TSM has two functions:
•
Control turn signals.
•
Serve as the BAS.
The optional factory-installed security system provides the
same functionality as the TSM, but also includes security and
immobilization functions.
Two security system modules are available: The TSSM for
Japan/Korea markets and the HFSM for all other markets.
See the electrical diagnostic manual for complete details of
the TSM/TSSM/HFSM features and functions.
NOTE
This part cannot be repaired. Replace upon failure.
sm01275
Figure 6-11. TSM/TSSM/HFSM (TSM Shown)
REMOVAL
NOTE
See
. The TSM/TSSM/HFSM (3) is located in a
cavity in the bottom of the battery tray (1).
1.
Remove battery. See
2.
Unplug wiring harness connectors: 4-pin connector [208]
(HFSM only) has one latch. Unplug this connector first.
Then unplug 12-pin connector [30B].
3.
See
. Reach under the battery tray (1) and
push upward on TSM/TSSM/HFSM (3) to lift it out of its
cavity (2).
4.
Remove TSM/TSSM/HFSM from vehicle.
1
2
3
sm06664
1. Battery tray
2. Cavity
3. TSM/TSSM/HFSM
Figure 6-12. TSM/TSSM/HFSM Connectors: All Models
INSTALLATION
1.
See
. Pull wiring harness connector [208]
(HFSM only) and connector [30B] up through cavity (2) in
bottom of battery tray (1).
2.
Position TSM/TSSM/HFSM (3) over cavity with con-
nector(s) facing oil tank.
3.
Lower TSM/TSSM/HFSM into cavity. See
Make sure top of TSM/TSSM/HFSM is flush with bottom
of battery tray.
4.
Plug 4-pin [208] (HFSM only) and 12-pin [30B] wiring
harness connectors into TSM/TSSM/HFSM.
5.
Install battery. Do not install left side cover at this time.
See
.
6.
Perform TSM/TSSM/HFSM password learn and set-up
procedure. See
for procedure.
7.
Install left side cover. See
.
6-14 2013 Sportster Service: Electrical
6.8
BATTERY CABLES
REMOVAL
1.
Remove left side cover. See
.
2.
See
. Slide main fuse and holder (1) toward
rear of motorcycle to detach from battery strap (4).
3.
Remove battery. See
4.
Disconnect negative (-) battery cable from crankcase.
5.
Inspect main fuse wiring harness and holder
6.
Note routing of negative (-) battery cable around frame
downtube.
3
4
1
5
6
2
sm06657
1. Main fuse and holder
2. Positive (+) battery cable holder
3. Positive (+) battery terminal (under protective
rubber boot)
4. Battery strap
5. Screw
6. Data link connector
Figure 6-13. Main Fuse and Battery Location: All Models
7.
Inspect positive (+) and negative (-) cables for cuts, fraying
or other damage. See
8.
See
. As required, pull back rubber cap (3) and
using a 12 mm wrench, remove nut with captive lock-
washer (5) and positive (+) battery cable (2) from starter
post (4).
1
3
5
2
4
sm06687
1. Starter assembly
2. Positive (+) battery cable
3. Rubber cap
4. Starter post
5. Nut with captive lockwasher
Figure 6-14. Positive (+) Cable Starter Post Connection:
All Models
INSTALLATION
TORQUE VALUE
FASTENER
6.8-7.9 Nm
60-70
in-lbs
Battery negative terminal
screw
6.8-7.9 Nm
60-70
in-lbs
Battery positive terminal screw
4.1-6.8 Nm
36-60
in-lbs
Battery strap screw
6.8-9.6 Nm
60-85
in-lbs
Battery positive cable to
starter post locknut
6.2-8.5 Nm
55-75
in-lbs
Battery negative cable to
crankcase nut
1.
Apply a light coat of petroleum jelly or corrosion retardant
material to the negative battery terminal.
2.
Slide battery in battery tray. Connect negative (-) battery
cable to battery. Tighten to 60-70
in-lbs
(6.8-7.9 Nm).
Connect positive (+) battery cable first. If positive (+) cable
should contact ground with negative (-) cable connected,
the resulting sparks can cause a battery explosion, which
could result in death or serious injury. (00068a)
3.
See
. With negative (-) battery cable discon-
nected from ground on crankcase, install the fuse cable
and the positive (+) battery cable.
a.
Thread fastener through main fuse cable.
b.
Thread fastener through the positive (+) battery cable.
c.
Thread fastener into the positive battery terminal (3).
d.
Tighten to 60-70
in-lbs
(6.8-7.9 Nm).
2013 Sportster Service: Electrical 6-15
4.
Apply a light coat of petroleum jelly or corrosion retardant
material to the positive battery terminal. Place protective
rubber boot over terminal.
5.
Hook top of battery strap (4) to battery tray mount on top
of battery. Install screw (5). Tighten to 36-60
in-lbs
(4.1-
6.8 Nm).
6.
Place positive battery cable into holder on ECM caddy.
7.
Hook main fuse and holder (1) to pin on battery strap and
slide forward until it snaps into place.
8.
Hook data link connector [91A] (6) to pin on battery strap
and slide forward until it snaps into place.
9.
See
. Install positive (+) battery cable (2) and
nut with captive lockwasher (5) on starter post (4). Using
a 12 mm wrench, tighten to 60-85
in-lbs
(6.8-9.6 Nm).
10. Push rubber cap (3) over starter post.
11. Place negative battery cable connector onto stud on
crankcase boss behind starter motor assembly. Thread
nut onto crankcase ground stud behind starter motor.
12. See
. Press negative battery cable connector
against cable stop on crankcase. Using a swivel socket,
tighten to 55-75
in-lbs
(6.2-8.5 Nm).
After installing seat, pull upward on seat to be sure it is
locked in position. While riding, a loose seat can shift
causing loss of control, which could result in death or
serious injury. (00070b)
13. Install seat.
sm01169
Figure 6-15. Negative Battery Cable Stop on Crankcase
(typical)
6-16 2013 Sportster Service: Electrical
6.9
BATTERY TRAY
GENERAL
See
. The battery tray is located behind the left side
cover. The battery tray supports the battery, TSM/TSSM/HFSM
and rear stop lamp switch (XL models only).
REMOVAL
Prevent accidental vehicle start-up, which could cause
death or serious injury. First disconnect negative (-) battery
cable at engine and then positive (+) cable from battery.
(00280b)
1.
Remove battery. See
2.
Unplug and remove TSM/TSSM/HFSM. See
SIGNAL AND SECURITY MODULE (TSM/TSSM/HFSM)
3.
XL Models:
see
. Position rear stop lamp
switch as follows:
a.
Remove rear brake master cylinder reservoir cover.
b.
Secure the reservoir out of the way. See
BRAKE MASTER CYLINDER RESERVOIR
.
c.
Remove brake line clamp fastener (5) from battery
tray (4).
d.
Remove TORX fastener (3) securing rear stop lamp
switch assembly (2) to battery tray. Gently pull stop
lamp switch assembly back out of the way. Do not
bend or stress metal brake lines.
e.
Remove ECM caddy fastener (1).
4
5
3
6
1
2
sm06674
1. ECM caddy fastener
2. Rear stop lamp switch assembly
3. TORX fastener
4. Battery tray
5. Brake line clamp fastener
6. Battery tray fastener
Figure 6-16. Battery Tray Assembly
4.
See
. Remove three fasteners (3) securing
battery tray to mounting tabs on frame.
5.
Lift up battery tray slightly so that mounting tabs will clear
mounts on frame. As you lift up on tray, pull down gently
on end of battery strap support (2) to clear frame and
wiring harnesses above battery tray.
6.
Remove negative battery cable and vent line from battery
tray retaining clips.
7.
Slide battery tray out and remove from left side.
2013 Sportster Service: Electrical 6-17
3
2
4
1
5
sm01344a
1. Battery tray
2. Battery strap support
3. Screw (3)
4. Oil tank vent clip
5. Battery cable clip
Figure 6-17. Battery Tray
INSTALLATION
TORQUE VALUE
FASTENER
10.9-17.6 Nm
96-156
in-lbs
Battery tray mounting
fasteners
8.1-13.6 Nm
72-120
in-lbs
Stop lamp switch bracket
screw
3.4-4.5 Nm
30-40
in-lbs
Brake hose clamp to battery
tray screw
8.1-10.8 Nm
72-96
in-lbs
ECM caddy fastener
1.
See
. Make sure the TSM/TSSM/HFSM con-
nector [30B], the antenna connector [208B] (HFSM only)
and the rear stop lamp switch assembly (2) are out of the
way.
2.
See
. Slide battery tray (1) into place. Make
sure battery tray mounting tabs are positioned behind (to
the right of) frame mounts.
3.
Secure the negative battery cable and the oil tank vent
line to the battery tray retaining clips (4, 5).
4.
Install three screws (3) to secure battery tray to frame. Do
not tighten screws until all three have been started. Tighten
to 96-156
in-lbs
(10.9-17.6 Nm).
5.
XL models only:
see
. Position rear stop lamp
switch as follows:
a.
Install rear stop lamp switch (2). Secure with TORX
screw (3). Tighten to 72-120
in-lbs
(8.1-13.6 Nm).
b.
Secure brake hose clamp (5) to battery tray with
screw. Tighten to 30-40
in-lbs
(3.4-4.5 Nm).
c.
Install ECM caddy fastener (1). Tighten to 72-96
in-lbs
(8.1-10.8 Nm).
d.
Install rear brake master cylinder reservoir. See
2.13 REAR BRAKE MASTER CYLINDER RESER-
VOIR
e.
Install reservoir cover.
6.
Install TSM/TSSM/HFSM into cavity in bottom of battery
tray. See
6.7 TURN SIGNAL AND SECURITY MODULE
.
Connect positive (+) battery cable first. If positive (+) cable
should contact ground with negative (-) cable connected,
the resulting sparks can cause a battery explosion, which
could result in death or serious injury. (00068a)
7.
Install battery. See
.
8.
Install left side cover. See
.
6-18 2013 Sportster Service: Electrical
6.10
STARTER
REMOVAL
Prevent accidental vehicle start-up, which could cause
death or serious injury. First disconnect negative (-) battery
cable at engine and then positive (+) cable from battery.
(00280b)
1.
Disconnect battery. See
.
2.
Drain transmission lubricant and remove primary cover.
See
3.
Remove
rear
muffler
and
exhaust
pipe.
See
4.13 EXHAUST SYSTEM: XL MODELS
or
4.
Remove the starter solenoid connector [128].
5.
Remove positive (+) battery lead and solenoid wire from
starter.
NOTE
A ball hex driver may be required to gain access to the starter
mounting bolts.
6.
See
. Remove the two starter mounting bolts
and washers.
7.
XL Models:
Remove fastener securing oil line retaining
clamp to starter.
8.
Remove starter and gasket from right side of motorcycle.
sm01600a
Figure 6-18. Starter Mounting Bolts
TOUCH-UP PAINT
Touch up damaged paint before installation. Follow the direc-
tions provided with the touch-up paint. Paint flaking does not
require starter replacement.
INSTALLATION
TORQUE VALUE
FASTENER
17.6-27.1 Nm
13-20 ft-lbs
Starter mounting bolt
1.8-2.4 Nm
16-21
in-lbs
Starter motor oil line clamp
fastener
6.8-9.6 Nm
60-85
in-lbs
Starter positive terminal nut
1.
Install starter and starter gasket from right side of motor-
cycle.
2.
See
. Install two starter mounting bolts and
washers. Tighten to 13-20 ft-lbs (17.6-27.1 Nm).
3.
XL Models:
Install oil line clamp to starter motor. Tighten
to 16-21
in-lbs
(1.8-2.4 Nm).
4.
Connect the starter solenoid connector [128].
5.
Install positive (+) battery cable and solenoid wire to
solenoid stud. Tighten to 60-85
in-lbs
(6.8-9.6 Nm). Place
rubber boot securely over terminal.
6.
Install primary cover. See
.
7.
Fill primary chaincase / transmission with proper lubricant.
See
.
8.
Install rear exhaust pipe and muffler. See
or
Connect positive (+) battery cable first. If positive (+) cable
should contact ground with negative (-) cable connected,
the resulting sparks can cause a battery explosion, which
could result in death or serious injury. (00068a)
9.
Connect battery. See
.
2013 Sportster Service: Electrical 6-19
SOLENOID
TORQUE VALUE
FASTENER
7.3-9.0 Nm
65-80
in-lbs
Solenoid contact post jamnut
6.8-9.0 Nm
60-80
in-lbs
Starter ring terminal hex nut
Cover and Plunger Removal
1.
See
. Remove fasteners (1), cover (2) and
gasket (3).
2.
Remove the plunger (4) with spring (5).
4
3
5
1
2
sm06876
1. Fasteners
2. Cover
3. Gasket
4. Plunger
5. Spring
Figure 6-19. Soleniod Plunger
Short Post Contact: Starter
1.
Disassemble the short post contact:
a.
Remove the hex nut and the ring terminal from the
post.
b.
See
. Remove jamnut (8), wave washer
(7), O-ring (6) and round bushing (5):
c.
Remove the post bolt (1).
d.
Remove the hold-in terminal (2) from the post bolt.
e.
Remove the contact plate (3) and the square bushing
(4).
2.
Assemble the short post contact:
a.
Insert the square bushing into the housing.
b.
Install the contact plate with the 90 degree part of the
contact plate against the solenoid winding.
c.
Install the post bolt through the hold-in terminal, the
contact plate and the square bushing.
d.
Install the round bushing, O-ring, wave washer and
jamnut.
1
8
4
2
5
6
7
3
sm06877
1. Post bolt
2. Hold-in terminal
3. Contact plate
4. Square bushing
5. Round bushing
6. O-ring
7. Wave washer
8. Jamnut
Figure 6-20. Short Post Contact (starter)
Long Post Contact: Battery Positive
1.
See
. Remove the long post contact:
a.
Remove hex nut (9).
b.
Remove jamnut (8), wave washer (7), O-ring (6) and
the round bushing (5).
c.
Remove post bolt (4), contact plate (3), square
bushing (2) and paper insulator (1).
2.
Install the long post contact:
a.
Insert the square bushing through the paper insulator
into the housing.
b.
Install the contact plate with the foot against the
solenoid winding.
c.
Install the post bolt.
NOTE
Check that the index pin on the round bushing fits the blind
hole in the housing.
d.
Install the round bushing, O-ring, wave washer and
jamnut.
6-20 2013 Sportster Service: Electrical
7
9
1
5
8
6
2
3
4
sm06878a
1. Paper insulator
2. Square bushing
3. Contact plate
4. Post bolt
5. Round bushing
6. O-ring
7. Wave washer
8. Jamnut
9. Hex nut
Figure 6-21. Long Post Contact (battery)
Plunger and Cover Installation
1.
Apply LUBRIPLATE 110 to the plunger shaft. Install the
spring.
2.
Install the plunger and spring in the housing.
3.
While compressing the plunger, alternately tighten the
contact post jamnuts to 65-80
in-lbs
(7.3-9.0 Nm).
4.
Check that the contact plates are aligned to the solenoid
winding.
5.
Install the cover:
a.
Install a
new
gasket on the cover.
b.
Install the cover.
c.
Install the fasteners until snug.
6.
Install the starter ring terminal.
7.
Install the hex nut. Tighten to 60-80
in-lbs
(6.8-9.0 Nm).
CLUTCH SHAFT ASSEMBLY
Removal
1.
See
. Loosen the two long starter support bolts
(1).
2.
Remove the two fasteners (2) and separate the clutch
assembly housing (4) from the starter/solenoid housing
(3).
3.
Save the spring (5) from the solenoid plunger shaft.
NOTE
Remove the old assembly lube to release the steel ball (8).
4.
Remove and save the steel ball from the bearing end of
the clutch shaft assembly (6) bore.
5.
Tap on the end of the shaft to remove the clutch shaft
assembly from the housing.
6.
Remove the idler gear (7) from the bearing cage.
7.
Remove bearing cage and the five steel cylinders.
6
5
7
2
3
1
4
8
sm06872a
1. Starter support bolts
2. Fasteners
3. Starter/solenoid housing
4. Clutch assembly housing
5. Spring
6. Clutch shaft assembly
7. Idler gear
8. Steel ball
Figure 6-22. Starter Drive Housing and Clutch Shaft
Inspection
1.
Inspect the O-rings in the clutch assembly housing bore.
2.
Inspect the spring for kinks or elongation.
3.
Inspect the steel ball.
4.
Inspect the idler gear and the cage.
5.
Inspect the clutch shaft assembly pinion gear for missing
or damaged teeth.
6.
Check that the roller bearings and the clutch gear on the
clutch shaft rotate freely.
Installation
1.
Lubricate components with LUBRIPLATE 110.
2.
See
. Install the bearing cage (1) with the five
steel cylinders (2).
3.
Install the idler gear (3) over the bearing cage.
4.
Match the gear teeth to the idler gear and install the clutch
assembly (4) in the housing. Seat the bearing in the
counterbore.
5.
Install the steel ball (5) in the bore of the shaft.
6.
Apply a light film of LUBRIPLATE 110 to solenoid plunger
shaft. Install return spring (6) on solenoid plunger shaft.
2013 Sportster Service: Electrical 6-21
7.
Apply a thin layer of HARLEY-DAVIDSON HIGH PER-
FORMANCE SEALANT - GRAY to the face of the clutch
assembly housing.
8.
Fit the clutch assembly housing to the starter/solenoid
housing to the clutch assembly housing.
9.
Install the fasteners and alternately tighten until snug.
3
1
4
6
2
5
sm06871b
1. Bearing cage
2. Steel cylinders
3. Idler gear
4. Clutch shaft assembly
5. Steel ball
6. Spring
Figure 6-23. Starter Clutch Assembly
6-22 2013 Sportster Service: Electrical
6.11
IGNITION SWITCH
REMOVAL
To prevent spray of fuel, purge system of high-pressure
fuel before supply line is disconnected. Gasoline is
extremely flammable and highly explosive, which could
result in death or serious injury. (00275a)
1.
Purge the fuel supply hose of high pressure gasoline.
Disconnect fuel supply hose from fuel pump module. See
or
To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before pro-
ceeding. (00251b)
2.
Remove main fuse.
3.
Remove seat.
4.
Remove fuel tank. See
or
.
5.
See
. Remove ignition switch face nut (5).
6.
Remove mounting screw (7). Remove switch cover (3).
Remove switch (2) from switch cover (3).
7.
Remove cable strap securing switch harness to wire har-
ness caddy.
8.
Cut switch wires 3.0 in (76.2 mm) from switch.
9.
Remove harness covering.
INSTALLATION
TOOL NAME
PART NUMBER
ULTRA TORCH UT-100
HD-39969
TORQUE VALUE
FASTENER
4.0-5.1 Nm
35-45
in-lbs
Ignition switch mounting screw
1.
Slide replacement conduit on harness wires.
Be sure to follow manufacturer's instructions when using
the UltraTorch UT-100 or any other radiant heating device.
Failure to follow manufacturer's instructions can cause a
fire, which could result in death or serious injury. (00335a)
2.
Observing color codes, install seal splice connectors to
harness wires. Complete sealed splice to
new
ignition
switch. Seal splice connectors with ULTRA TORCH UT-
100 (Part No. HD-39969) or other radiant heating device.
See
.
3.
Slide conduit over sealed splice connectors.
4.
See
. Insert ignition switch into hole of switch
cover. The word "TOP" stamped on the switch body should
face upward toward the lettering on the switch position
decal. Loosely install face nut (5).
5.
Install mounting screw (7). Tighten to 35-45
in-lbs
(4.0-
5.1 Nm).
6.
Tighten face nut (5) to secure switch (2) within cover (3).
7.
Using
new
cable strap (6), secure ignition switch harness
to wire harness caddy.
8.
Install fuel tank. See
or
.
After installing seat, pull upward on seat to be sure it is
locked in position. While riding, a loose seat can shift
causing loss of control, which could result in death or
serious injury. (00070b)
9.
Install seat.
10. Install main fuse.
Be sure that all lights and switches operate properly before
operating motorcycle. Low visibility of rider can result in
death or serious injury. (00316a)
11. Check ignition switch.
O
F
F
AC C
IG
N
IT
IO
N
5
1
6
3
4
7
2
sm01346
1. Sealed splice connector
2. Ignition switch
3. Switch cover
4. Decal
5. Face nut
6. Cable strap
7. Mounting screw
Figure 6-24. Ignition Switch
2013 Sportster Service: Electrical 6-23
6.12
SPARK PLUG CABLES
GENERAL
Resistor-type high-tension spark plug cables have a carbon-
impregnated fabric core (instead of solid wire) for radio noise
suppression and improved reliability of electronic components.
Use the exact replacement cable for best results.
REMOVAL
To prevent spray of fuel, purge system of high-pressure
fuel before supply line is disconnected. Gasoline is
extremely flammable and highly explosive, which could
result in death or serious injury. (00275a)
1.
Purge the fuel supply hose of high-pressure gasoline.
Disconnect fuel supply hose from fuel pump module. See
or
To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before pro-
ceeding. (00251b)
2.
Remove main fuse.
3.
Remove seat.
4.
Remove fuel tank. See
or
.
5.
XL Models:
See
. Remove screw (1) securing
left wire harness caddy (2) to right wire harness caddy.
See
. Carefully disengage
left wire harness caddy and pull away from frame back-
bone.
NOTE
Always grasp rubber boot as close as possible to the spark
plug terminal when removing spark plug cables. Do not pull on
the cable portion itself. Pulling on the cable will damage the
cable's carbon core.
6.
See
or
. Pull front spark plug boot
and cable (2) from left side ignition coil (1) tower.
1
2
3
sm03784
1. Screw
2. Left wire harness caddy
3. Ignition coil
Figure 6-25. Ignition Coil and Left Wire Harness Caddy:
XL Models
7.
Pull rear spark plug boot (3) and cable from right side
ignition coil tower.
8.
Unplug spark plug boot and cable assemblies from front
and rear spark plugs.
9.
XL Models:
Disengage rear spark plug cable from notch
in right wire harness caddy (5). Remove the cable.
10.
XR 1200X:
See
. Disengage rear spark plug
cable from wire harness caddy (5). Remove the cable.
11.
XL Models:
See
. Remove rear spark plug
cable (2) from curved trough on wire harness caddy (1).
a.
Cut cable strap (4).
b.
Feed spark plug cable out from between frame and
engine. Remove the cable.
c.
Remove cable strap from mounting boss on caddy
latch clip (5). Discard cable strap.
6-24 2013 Sportster Service: Electrical
1
2
3
4
5
sm03785
1. Ignition coil
2. Front spark plug cable boot
3. Rear spark plug cable boot
4. Rear spark plug cable
5. Notch in right wire harness caddy
Figure 6-26. Spark Plug Cable Routing: XL Models
1
2
4
5
3
sm05528
1. Ignition coil
2. Front spark plug cable boot
3. Rear spark plug cable boot
4. Rear spark plug cable
5. Harness caddy
Figure 6-27. Spark Plug Cable Routing: XR 1200X
1
2
3
2
4
5
sm03786
1. Right wire harness caddy
2. Rear spark plug cable
3. Engine sub-harness
4. Cable strap
5. Caddy latch clip
Figure 6-28. Rear Spark Plug Cable Routing: XL Models
INSTALLATION
1.
See
or
. Plug rear spark plug cable
boot (3) into right side ignition coil (1) tower.
2.
XL Models:
Route cable between wire harness caddies,
and down through notch (5) in right caddy, toward right
side of engine.
3.
XR 1200X:
Route rear spark plug cable through harness
caddy (5) as shown.
4.
XL Models:
See
. Route rear spark plug cable
(2) in trough in right wire harness caddy (1), over top of
engine sub-harness (3) and back toward left side of
engine.
5.
XL Models:
See
. Install
new
barbed cable
strap (3) onto spark plug cable (1), 7.0-7.25 in (178-184
mm) from tip of spark plug cable boot (2).
a.
Orient the cable strap so that the spark plug cable is
above the mounting boss on the caddy latch clip.
b.
Press the cable strap barbed prong firmly into the
hole in the caddy latch clip mounting boss.
6.
Plug rear spark plug cable and boot onto rear spark plug
until it clicks.
2013 Sportster Service: Electrical 6-25
7.
See
or
. Plug front spark plug cable
and boot (2) into left side ignition coil (1) tower. Plug other
end of cable onto front spark plug until it clicks.
NOTE
Make sure rear spark plug cable is routed properly and cannot
chafe against frame, fuel tank or rear cylinder head.
8.
XL Models:
See
. Mate left wire harness caddy
(2) to right wire harness caddy. Secure with screw (1) and
tighten. See
.
9.
Install fuel tank. See
or
.
After installing seat, pull upward on seat to be sure it is
locked in position. While riding, a loose seat can shift
causing loss of control, which could result in death or
serious injury. (00070b)
10. Install seat.
11. Install main fuse.
12. Start the engine. Verify ignition function.
1
2
3
4
sm03787
1. Rear spark plug cable
2. Spark plug boot (spark plug end)
3. Barbed cable strap
4. 7.0-7.25 in (178-184 mm)
Figure 6-29. Rear Spark Plug Cable and Cable Strap: XL
Models
6-26 2013 Sportster Service: Electrical
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