Harley Davidson 2013 Sportster Models. Service Manual — page 30
6.32
HORN
TROUBLESHOOTING
If the horn does not sound or sounds weak, check for the fol-
lowing:
•
Discharged battery. To charge battery, see
•
Loose, frayed or damaged wiring to horn terminal.
If battery is charged and wiring appears to be in good condition,
perform a VOLTAGE TEST for the following:
•
Inoperative horn switch.
•
Open circuit to horn.
•
Open ground to frame.
•
Inoperative horn.
VOLTAGE TEST
1.
Remove terminal clips from horn spade connectors.
2.
Connect voltmeter leads, positive (+) to wire terminal and
negative (-) to ground.
3.
Turn ignition switch ON and press horn switch.
4.
If battery voltage is not present, check for the following:
a.
Horn switch is inoperative. Replace switch. See
b.
Wiring to horn is open. Repair wiring.
5.
If battery voltage is present, check for the following:
a.
Ground is open between mounting hardware or
ground wire. Repair wiring.
b.
Horn is inoperative. Replace horn. See
.
REPLACEMENT: FRONT MOUNT
TORQUE VALUE
FASTENER
4.1-5.4 Nm
36-48
in-lbs
Horn mounting screw
1.
See
. Remove terminal clips from horn spade
connectors (1, 3).
2.
Remove screws (4) and lockwashers (6) from horn bracket
(2). Remove horn assembly (5).
3.
Install horn assembly with screws and washers into horn
bracket. Tighten to 36-48
in-lbs
(4.1-5.4 Nm).
4.
Install the yellow wire with black tracer to the left spade
connector (3) and the black wire to the right spade con-
nector (1).
4
7
5
3
6
1
8
2
sm01373
1. Right spade connector
2. Horn bracket
3. Left spade connector
4. Screw (3)
5. Horn assembly
6. Lockwasher (3)
7. Screw (2)
8. Washer (2)
Figure 6-133. Horn Components
REPLACEMENT: SIDE MOUNT
TORQUE VALUE
FASTENER
9.0-11.3 Nm
80-100
in-lbs
Horn, side mounted, stud nut
6.8-20.4 Nm
60-180
in-lbs
Horn, side mounted, acorn nut
1.
See
. Remove terminal clips from horn spade
connections on back of horn (12).
2.
Remove acorn nut (3) and lockwasher (4) to free horn
assembly from rubber mount (6) stud.
3.
Remove wire conduit from clamp (9) at back of support
bracket (5).
4.
Remove nut (10) from circular recess at back of chrome
cover and bracket (2) and remove horn (12) from cover
and bracket.
5.
Install horn (12) with chrome cover and bracket (2) through
hole in horn support bracket (5). Apply two drops of LOC-
TITE 262 HIGH STRENGTH THREADLOCKER AND
SEALANT (red) to threads of nut (10) and install. Tighten
to 80-100
in-lbs
(9.0-11.3 Nm).
6.
Attach the yellow wire with black tracer to front terminal
and the black wire to rear terminal. Push wire conduit into
clamp (9) at back of horn bracket (5).
2013 Sportster Service: Electrical 6-87
7.
Install support bracket (5) on rubber mount (6) stud with
lockwasher (4) and acorn nut (3). Tighten to 60-180
in-lbs
(6.8-20.4 Nm).
14
9
6
5
13
7
12
3
11
4
2
8
10
11
1
sm01670b
1. Clip nut (2)
2. Cover and bracket
3. Acorn nut
4. Lockwasher
5. Support bracket
6. Rubber mount
7. Locknut
8. Screw (2)
9. Clamp
10. Nut
11. Washer (2)
12. Horn
13. Screw (2)
14. Mounting bracket
Figure 6-134. Side Mount Horn Components
6-88 2013 Sportster Service: Electrical
6.33
HANDLEBAR SWITCH ASSEMBLIES
REPAIR PROCEDURES
TOOL NAME
PART NUMBER
ROBINAIR HEAT GUN
HD-25070
ULTRA TORCH UT-100
HD-39969
HEAT SHIELD ATTACHMENT
HD-41183
1.
Push conduit back to better access wires and avoid dam-
aging conduit with radiant heating device. Secure conduit
with extra 7.0 in (177.8 mm) cable strap in kit.
2.
Strip 0.5 in (12.7 mm) of insulation off switch wires. Twist
stripped ends of switch wires until all strands are tightly
coiled.
3.
Cut dual wall heat shrink tubing, supplied in repair kit into
1.0 in (25.4 mm) segments. Slide tubing over each wire
of
new
switch assembly.
4.
Splice existing and
new
switch wires, matching wire colors.
Solder the spliced connections. For best results, splice
one wire at a time.
5.
Center the heat shrink tubing over the soldered splices.
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)
•
Avoid directing heat toward any fuel system component.
Extreme heat can cause fuel ignition/explosion resulting
in death or serious injury.
•
Avoid directing heat toward any electrical system com-
ponent other than the connectors on which heat shrink
work is being performed.
•
Always keep hands away from tool tip area and heat shrink
attachment.
6.
See
. Use ULTRA TORCH UT-100 (Part
No. HD-39969) or ROBINAIR HEAT GUN (Part No. HD-
25070) with HEAT SHIELD ATTACHMENT (Part No. HD-
41183) or equivalent. Uniformly heat the heat shrink tubing
to insulate and seal the soldered connections. Apply heat
just until the meltable sealant exudes out both ends of
tubing and assumes a smooth cylindrical appearance.
7.
Inspect solder connection.
a.
Inspect the melted sealant for solder beads.
b.
Excess solder or heat may force some solder out with
the melted sealant.
c.
Remove any solder found.
d.
Briefly heat the connection to reseal the tubing if
solder beads were removed.
e.
Use less solder or reduce heating time or intensity
when doing subsequent splices.
Be sure that all lights and switches operate properly before
operating motorcycle. Low visibility of rider can result in
death or serious injury. (00316a)
3
2
1
sm00082
1. Ultra Torch UT-100
2. Robinair Heat Gun
3. Heat Shield Attachment
Figure 6-135. Radiant Heating Devices
CONNECTORS
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 fuel tank. See
or
.
4.
Separate left and right wire harness caddies. See
5.
See
or
. Locate right handlebar
connector [22] (4, 5) mounted on left wire harness caddy
(2). Press latch (3) and separate connector halves.
2013 Sportster Service: Electrical 6-89
6.
In the same manner, locate left handlebar connector [24]
(6), press latch and separate connector halves.
7.
See
A.19 MOLEX MX 150 SEALED CONNECTOR
to
service connectors [22] and [24].
8.
Mate right handlebar connector [22] halves. Mate left
handlebar connector [24] halves.
9.
Reassemble left and right wire harness caddies. See
.
10. Replace fuel tank. See
or
.
11. 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)
12. Verify operation of electrical system.
3
6
2
5
6
1
sm03386
1. Frame backbone
2. Left wire harness caddy
3. Connector latch
4. Right handlebar pin connector [22A]
5. Right handlebar socket connector [22B]
6. Left handlebar control connector [24]
Figure 6-136. Handlebar Connectors: XL Models
1
2
3
5
4
6
sm05561
1. Frame backbone
2. Left wire harness caddy
3. Connector latch
4. Right handlebar pin connector [22A]
5. Right handlebar socket connector [22B]
6. Left handlebar control connector [24]
Figure 6-137. Handlebar Connectors: XR 1200X
6-90 2013 Sportster Service: Electrical
6.34
RIGHT HANDLEBAR SWITCHES
REMOVAL
To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before pro-
ceeding. (00251b)
1.
Remove main fuse.
Do not remove or install the master cylinder assembly
without first positioning a 5/32-inch (4 mm) thick insert
between the brake lever and lever bracket. Removing or
installing the master cylinder assembly without the insert
in place may result in damage to the rubber boot and
plunger on the front stoplight switch. (00324a)
NOTE
Place a 5/32 in (4 mm) thick cardboard insert between the
brake lever and lever bracket. Without the insert, the rubber
boot and plunger of the front stop lamp switch can be damaged.
2.
See
. Place the cardboard insert between the
brake lever and lever bracket.
3.
Using a T27 TORX drive head, remove the two screws
with flat washers securing the handlebar clamp to the
master cylinder housing. Remove the brake lever/master
cylinder assembly and clamp from the handlebar.
4.
Using a T25 TORX drive head, remove the upper and
lower switch housing screws.
5.
Remove the friction shoe from the end of the tension
adjuster screw.
NOTE
The friction screw is a loose fit. It may fall out or become dis-
lodged if the lower switch housing is turned upside down or
shaken.
6.
Remove the brass ferrules from the notches on the inboard
side of the throttle control grip. Remove the ferrules from
the cable end fittings.
7.
Remove the throttle control grip from the end of the
handlebar.
8.
Pull the crimped inserts at the end of the throttle and idle
control cable housings from the lower switch housing. For
best results, use a rocking motion while pulling. Place a
drop of light oil on the retaining rings, if necessary.
Remove the cables from the switch housing.
sm03387
Figure 6-138. Install Cardboard Insert
DISASSEMBLY
Do not remove or install the master cylinder assembly
without first positioning a 5/32-inch (4 mm) thick insert
between the brake lever and lever bracket. Removing or
installing the master cylinder assembly without the insert
in place may result in damage to the rubber boot and
plunger on the front stoplight switch. (00324a)
1.
Place the cardboard insert between the brake lever and
lever bracket.
2.
Remove the upper and lower switch housing screws.
3.
If replacing lower housing switches, perform steps 4
through 7 before continuing to repair section. If replacing
upper housing switches, proceed directly to repair section.
4.
See
. Loosen the upper screw (1) securing
the handlebar switch clamp to the master cylinder housing.
Remove the lower clamp screw with flat washer (2).
5.
Remove the brass ferrules from the notches on the inboard
side of the throttle control grip. Remove the ferrules from
the cable end fittings.
6.
Remove the friction shoe from the end of the tension
adjuster screw.
NOTE
The friction shoe is a loose fit. It may fall out or become dis-
lodged if the lower switch housing is turned upside down or
shaken.
7.
Remove the throttle control grip from the end of the
handlebar.
2013 Sportster Service: Electrical 6-91
SWITCH REPAIR/REPLACEMENT
Switch and Lead Replacement
After cutting off the connector terminals, pull the leads of faulty
switches through the conduit. Route replacement switch leads
through the conduit. Terminate the leads at the connector. If
necessary, replace the switches.
Switch Only Replacement: Upper Housing
NOTE
If only one switch is faulty, replace the horn switch and high/low
beam switch as a single assembly.
1.
See
. From inside the switch housing, remove
the screw with lockwasher (4) to release the bracket (5).
Remove the bracket and switch assembly from the
housing.
2.
Move cable conduit (3) from beneath wing of bracket. Cut
wires 0.25 in (6.4 mm) from old switches (1, 2). Discard
old switch and bracket assembly.
3.
Slide conduit forward over cut ends of switch wires and
cut off 0.5 in (12.7 mm) of conduit (3) material. Push con-
duit back to access switch wires.
4.
See
. Separate
new
engine stop switch (2)
and engine start switch (1) wires into two bundles.
5.
See
6.33 HANDLEBAR SWITCH ASSEMBLIES
for
information on splicing and general repair practices.
6.
See
. Loop switch wires and bundle splices.
7.
See
. Route wires downstream of splices
beneath wing on engine stop switch side of bracket.
8.
See
. Install a
new
7.0 in (177.8 mm) cable
strap (5) beneath wing on engine start switch side (1) of
bracket and capture wire splices (4).
9.
Place switch assembly into upper housing aligning hole
in bracket with threaded hole in boss. Seat the bracket.
The step at the edge of the boss captures the bottom edge
of the bracket. Tabs on each side of the bracket fit in slots
cast into the housing.
10. See
. Install screw and lockwasher (4) to
secure bracket (5) inside housing. Verify that wing on
engine stop switch (2) side of bracket captures edge of
conduit (3) as shown.
11. Securely tighten cable strap to draw splices to bracket.
Trim cable straps.
1
3
5
2
4
sm01087
1. Start switch
2. Stop switch
3. Conduit
4. Screw with lockwasher
5. Bracket
Figure 6-139. Upper Housing Without Splices
1
3
5
2
4
sm01088
1. Start switch
2. Stop switch
3. Conduit
4. Splices
5. Cable strap
Figure 6-140. Upper Housing With Splices
Switch Only Replacement: Lower Housing
1.
From inside the switch housing, carefully cut cable strap
to free conduit from the turn signal switch bracket.
6-92 2013 Sportster Service: Electrical
2.
Remove the screw with lockwasher to release the turn
signal switch bracket. Remove the bracket and switch
assembly from the housing.
Turn-Right Signal Switch Only
1.
Cut wire 1.5 in (38.1 mm) from old switch. Discard old
switch assembly.
2.
See
6.33 HANDLEBAR SWITCH ASSEMBLIES
for
information on splicing and general repair practices.
Front Stop Lamp Switch Only
1.
Carefully remove the wedge between the switch and switch
housing, if present. To remove the switch from the housing,
press the plunger and slowly rotate switch upward while
rocking slightly.
2.
Cut wires 1.0 in (25.4 mm) from old switch. Discard old
switch.
3.
See
6.33 HANDLEBAR SWITCH ASSEMBLIES
for
information on splicing and general repair practices.
4.
Carefully press plunger against inside wall of switch
housing. With thumb over plunger bore, move switch into
the installed position in the switch housing cavity. When
plunger is positioned against thumb, slowly rotate switch
downward while rocking slightly. Release the plunger only
after switch is properly positioned in the cavity.
5.
Verify that the plunger is square in the bore and that the
boot is not compressed, collapsed or torn. If necessary,
gently work the plunger in and out until boot is fully
extended.
6.
See
. Push down on switch (1) so that it bot-
toms against housing and wires (3) run in groove at base
of cavity. With the concave side facing outward, insert
wedge (2) between switch and outboard side of switch
housing.
7.
Push wedge down until it also bottoms against housing.
Verify that the plunger is still square in the bore. Place a
drop of RTV SILICONE SEALANT on upper corner of
wedge.
1
4
2
3
sm01089
1. Stop lamp switch
2. Wedge
3. Switch wires
4. Lower switch housing
Figure 6-141. Install Stop Lamp Switch
ASSEMBLY
1.
See
. Insert tapered end of
new
7.0 in (177.8
mm) cable strap (1) into round hole in turn signal switch
bracket (2) and then feed back through using the adjacent
hole. Reserve the oblong hole for the bracket screw.
NOTE
Be sure that all splices are positioned above the turn signal
switch bracket.
2.
Place the turn signal switch assembly into the housing,
aligning the oblong hole in the bracket with the threaded
hole in the boss. Be sure that the bracket is fully seated.
Tabs on each side of bracket are captured in slots cast
into switch housing.
3.
Start screw with lockwasher to secure bracket inside
housing.
If routed incorrectly, wires can be pinched by casting or
handlebar resulting in switch failure. (00542b)
4.
Loop switch wires so that spliced lengths are positioned
across bracket.
5.
Capturing conduit about 0.25 in (6.4 mm) from end,
securely tighten cable strap to draw conduit to bracket.
Trim cable straps.
6.
Install second 7.0 in (177.8 mm) cable strap capturing
conduit and wire splices. Securely tighten cable strap to
draw splices to conduit. Trim cable straps.
2013 Sportster Service: Electrical 6-93
7.
Tighten screw to secure bracket inside housing.
8.
Route wire bundle to upper switch housing by gently
pressing conduit into channel next to angular arm of
bracket.
9.
Secure bundle to arm using third cable strap. Trim cable
straps.
10. If necessary, bend angular arm of bracket downward to
firmly secure front stop lamp switch in position.
3
2
1
sm01090
1. Cable strap
2. Bracket
3. Right turn signal switch
Figure 6-142. Insert Cable Strap in Switch Bracket
INSTALLATION
TORQUE VALUE
FASTENER
12.2-14.9 Nm
108-132
in-lbs
Handlebar control lever clamp
screw
4.0-5.1 Nm
35-45
in-lbs
Switch housing screw
1.
See
. Push the throttle and idle control cables
into the lower switch housing until they snap in place. Note
the different diameter inserts crimped into the end of the
throttle and idle cable housings.
a.
Push the silver insert (2) of throttle cable housing into
the hole in front of tension adjuster screw (3).
b.
Push the gold insert (1) of idle cable housing into the
hole at the rear of tension adjuster screw (3).
NOTE
To aid assembly, place a drop of light oil on the retaining rings
of the crimped inserts. Always replace the retaining rings if
damaged or distorted.
2.
See
. Route the cable (2) to the upper switch
housing as shown.
3.
Slide the throttle control grip over the end of the right
handlebar until it bottoms against the closed end. Rotate
the grip so that the ferrule notches are at the top. To pre-
vent binding, pull the grip back about 1/8 in (3.2 mm).
4.
With the concave side facing upward, install the friction
shoe so that the pin hole is over the point of the adjuster
screw.
NOTE
The friction shoe is a loose fit and may fall out or become dis-
lodged if the lower switch housing is turned upside down or
shaken.
5.
See
. Position lower switch housing beneath
the throttle control grip. Install the brass ferrules (4) onto
the cable so that the end fittings seat in the ferrule recess.
Seat the ferrules in their respective notches (3) on the
throttle control grip. Verify that the cables are captured in
the grooves (2) molded into the grip.
6.
Position the upper switch housing over the handlebar and
lower switch housing.
7.
Verify that the wire harness conduit runs in the depression
at the bottom of the handlebar. Be sure that the upper
switch housing harness will not be pinched under the
handlebar when the switch housing screws are tightened.
8.
Start the upper and lower switch housing screws, but do
not tighten.
Do not remove or install the master cylinder assembly
without first positioning a 5/32-inch (4 mm) thick insert
between the brake lever and lever bracket. Removing or
installing the master cylinder assembly without the insert
in place may result in damage to the rubber boot and
plunger on the front stoplight switch. (00324a)
1
3
2
sm02636a
1. Idle cable insert (gold insert, rear hole)
2. Throttle cable insert (silver insert, front hole)
3. Tension adjuster screw
Figure 6-143. Right Lower Module Housing
6-94 2013 Sportster Service: Electrical
1
1
2
sm02634
1. End fittings
2. Upper switch housing cable
Figure 6-144. Route Cable to Upper Switch Housing
5
4
3
2
1
sm01084a
1. Throttle cable (silver insert, front hole)
2. Groove in throttle grip
3. Notch
4. Brass ferrule
5. Idle cable (gold insert, rear hole)
Figure 6-145. Throttle Cable Attachment
9.
See
. Position the brake lever/master cylinder
assembly inboard of the switch housing assembly, enga-
ging the tab (2) on the lower switch housing in the groove
(3) at the top of the brake lever bracket.
10. Align the holes in the handlebar switch clamp with the
master cylinder housing. Start the two screws (with flat
washers). Position for rider comfort. Beginning with the
top screw, tighten to specification using a T27 TORX drive
head. Refer to
.
11. Using a T25 TORX drive head, tighten lower and upper
switch housing screws to specification. Refer to
NOTE
Always tighten the lower switch housing screw first so that any
gap between the upper and lower housings is at the front of
the switch.
Table 6-9. Handlebar Switch Assembly Fasteners
TORQUE
FASTENER
108-132
in-lbs
(12.2-14.9 Nm)
Handlebar clamp screw
35-45
in-lbs
(4.0-5.1 Nm)
Switch housing screws
12. Remove the cardboard insert between the brake lever and
lever bracket.
13. Adjust throttle cables. See
14. 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)
15. Test the switches for proper operation.
16. Secure wire harness to handlebar as necessary.
4
3
2
1
sm01086
1. Switch housing assembly
2. Tab
3. Groove
4. Brake lever bracket
Figure 6-146. Switch Housing Alignment (typical)
2013 Sportster Service: Electrical 6-95
1
2
sm02633
1. Upper screw
2. Lower screw and flat washer
Figure 6-147. Handlebar Switch Clamp Screws
6-96 2013 Sportster Service: Electrical
6.35
LEFT HANDLEBAR SWITCHES
REMOVAL
NOTE
The removal and installation steps listed apply when replacing
the entire switch assembly, a switch housing or the handlebar.
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.
Using a T25 TORX drive head, loosen but do not remove
the upper and lower switch housing screws.
3.
Using a T27 TORX drive head, remove the two screws
with flat washers securing the handlebar clamp to the
clutch lever bracket. Remove the clutch hand lever
assembly and clamp from the handlebar.
4.
Remove the upper and lower switch housing screws.
5.
Remove the left hand grip from the end of the handlebar
if damaged. See
2.30 HANDLEBAR, Left Hand Grip
.
DISASSEMBLY
1.
Remove the upper and lower switch housing screws.
2.
If replacing lower housing switches, perform next step
before continuing to repair section. If replacing upper
housing switches, proceed directly to repair section.
3.
Loosen the upper screw securing the handlebar clamp to
the clutch lever bracket. Remove the lower clamp screw
with flat washer.
SWITCH REPAIR AND REPLACEMENT
Switch and Lead Replacement
After cutting off the connector terminals, pull the leads of faulty
switches through the conduit. Route replacement switch leads
through the conduit. Terminate the leads at the connector. If
necessary, replace only the switches.
Switch Only Replacement: Upper Housing
NOTE
If only one switch is faulty, replace the horn switch and high/low
beam switch as a single assembly.
1.
See
. From inside the switch housing, remove
the screw with lockwasher (4) to release the bracket (5).
Remove bracket and switch assembly from the housing.
2.
Move cable conduit (3) from beneath wing of bracket. Cut
wires 0.25 in (6.4 mm) from old switches (1, 2). Discard
old switch and bracket assembly.
3.
Slide conduit forward over cut ends of switch wires and
cut off 0.5 in (12.7 mm) of conduit (3) material. Push con-
duit back to access switch wires.
4.
Separate the
new
horn switch (1) and high/low beam
switch (2) wires into two bundles.
5.
See
6.33 HANDLEBAR SWITCH ASSEMBLIES
for
information on splicing and general repair practices.
6.
See
. Loop switch wires.
7.
See
. Route wires downstream of splices
beneath wing on high/low beam switch side of bracket.
8.
See
. Install a
new
7.0 in (177.8 mm) cable
strap (5) beneath wing on horn switch side (1) of bracket
and capture wire splices (4).
9.
Place switch assembly into upper housing aligning hole
in bracket with threaded hole in boss. Be sure that bracket
is fully seated. The step at the edge of the boss captures
the bottom edge of the bracket. Tabs on each side of the
bracket fit in slots cast into the housing.
10. See
. Install screw and lockwasher (4) to
secure bracket (5) inside housing. Verify that wing on
high/low switch (2) side of bracket captures edge of conduit
(3) as shown.
11. Securely tighten cable strap to draw splices to bracket.
Trim cable straps.
1
3
5
2
4
sm01091
1. Horn switch
2. High/low beam switch
3. Conduit
4. Screw with lockwasher
5. Bracket
Figure 6-148. Upper Housing Without Splices
2013 Sportster Service: Electrical 6-97
1
3
5
2
4
sm01092
1. Horn switch
2. High/low beam switch
3. Conduit
4. Splices
5. Cable strap
Figure 6-149. Upper Housing With Splices
Switch Only Replacement: Lower Housing
1.
From inside the switch housing, carefully cut cable strap
to free conduit from the turn signal switch bracket.
2.
Remove screw with lockwasher to release the turn signal
switch bracket. Remove the bracket and switch assembly
from the housing.
Turn-Left Signal Switch Only
1.
Cut wires 1.5 in (38.1 mm) from old turn signal switch.
Discard switch assembly.
2.
See
6.33 HANDLEBAR SWITCH ASSEMBLIES
for
information on splicing and general repair practices.
Clutch Interlock Switch Only
1.
See
. Cut wires 0.25 in (6.4 mm) from old
switch. Discard switch assembly.
2.
See
6.33 HANDLEBAR SWITCH ASSEMBLIES
for
information on splicing and general repair practices.
sm02644
Figure 6-150. Clutch Interlock Switch
ASSEMBLY
1.
See
. Insert tapered end of
new
7.0 in (177.8
mm) cable strap (1) into round hole in turn signal switch
bracket (2) and then feed back through using the adjacent
hole. Reserve the oblong hole for the bracket screw.
NOTE
Be sure that all splices are positioned above the turn signal
switch bracket.
2.
Aligning the oblong hole in the bracket with the threaded
hole in the boss. Place the turn signal switch assembly
(3) into the housing. Fully seat the bracket. Tabs on each
side of bracket are captured in slots cast into switch
housing.
3.
Start screw with lockwasher to secure bracket inside
housing.
If routed incorrectly, wires can be pinched by casting or
handlebar resulting in switch failure. (00542b)
4.
Loop switch wires so that spliced lengths are positioned
across bracket.
5.
Capturing conduit about 0.25 in (6.4 mm) from end,
securely tighten cable strap to draw conduit to bracket.
Trim cable straps.
6.
Tighten screw to secure bracket inside housing.
7.
Route wire bundle to upper switch housing below and then
forward of the main wire harness.
8.
Position conduit in channel next to angular arm of bracket.
Secure bundle to arm using
new
cable strap.
9.
Trim cable strap.
6-98 2013 Sportster Service: Electrical
3
2
1
sm01094
1. Cable strap
2. Bracket
3. Left turn signal switch
Figure 6-151. Insert Cable Strap in Switch Bracket
INSTALLATION
TORQUE VALUE
FASTENER
12.2-14.9 Nm
108-132
in-lbs
Handlebar control lever clamp
screw
4.0-5.1 Nm
35-45
in-lbs
Switch housing screw
1.
If the hand grip was removed, install a
new
hand grip. See
2.30 HANDLEBAR, Left Hand Grip
.
2.
See
. Install upper and lower switch housings
on handlebar. Be sure that ribs (2) on outboard side of
switch housings fit in grooves (3) molded into grip.
3.
Verify that the wire harness conduit runs in the groove at
the bottom of the handlebar. Do not pinch the upper switch
housing harness under the handlebar when the switch
housing screws are tightened.
4.
Start the upper and lower switch housing screws, but do
not tighten.
5.
See
. Position the clutch hand lever assembly
inboard of the switch housing assembly, engaging the tab
(3) on the lower switch housing in the groove (2) at the
bottom of the clutch lever bracket.
6.
Align the holes in the handlebar switch clamp with the
clutch lever bracket. Start the two screws with flat washers.
Position for rider comfort. Beginning with the top screw,
tighten screws to specification with a T27 TORX drive
head. Refer to
7.
Using a T25 TORX drive head, tighten lower and upper
switch
housing
screws
to
specification.
Refer
to
NOTE
Tighten the lower switch housing screw first. The gap between
the upper and lower housings is at the front of the switch.
Table 6-10. Handlebar Switch Assembly Fasteners
TORQUE
FASTENER
108-132
in-lbs
(12.2-14.9 Nm)
Handlebar clamp screw
35-45
in-lbs
(4.0-5.1 Nm)
Switch housing screws
8.
Install main fuse.
9.
Verify the operation of the clutch interlock switch. See the
electrical diagnostic manual.
Be sure that all lights and switches operate properly before
operating motorcycle. Low visibility of rider can result in
death or serious injury. (00316a)
10. Test the switches for proper operation.
11. Secure wire harness to handlebar as necessary.
1
2
3
sm02632
1. Grip sleeve
2. Ribs
3. Grooves
Figure 6-152. Left Handlebar Switch Housings
2013 Sportster Service: Electrical 6-99
4
2
3
1
sm02631
1. Clutch lever bracket
2. Groove
3. Tab
4. Switch housing assembly
Figure 6-153. Clutch Lever Bracket
6-100 2013 Sportster Service: Electrical
6.36
PERSONAL IDENTIFICATION NUMBER (PIN)
GENERAL
The PIN consists of five digits. Each digit can be any number
from 1 through 9. There can be no zeros (0) in the PIN. Use
the PIN to disarm the security system in case the fob becomes
unavailable.
INITIAL PIN ENTRY
To enter a PIN on a motorcycle with no PIN previously installed
during HFSM actuation, refer to
Table 6-11. Entering an Initial PIN: HFSM, TSSM
CONFIRMATION
ACTION
STEP
Select a five-digit (1 through 9) initial PIN and record in the owner's
manual and on the wallet card.
1
With an assigned fob present, set engine stop switch to
OFF.
2
Cycle ignition switch
IGNITION
-OFF-
IGNITION
-OFF-
IGNITION.
3
Turn signals flash three times.
Press
left
turn signal button twice.
4
Five dashes appear in the odometer
window. The first dash flashes.
Press
right
turn signal button once.
5
Enter first digit (a) of initial PIN by pressing
left
turn signal button until
desired digit is displayed in odometer.
6
The digit (a) replaces the dash in the
odometer. The second dash flashes.
Press
right
turn signal button once.
7
Enter second digit (b) of initial PIN by pressing
left
turn signal button
until desired digit is displayed in odometer.
8
The digit (b) replaces the dash in the
odometer. The third dash flashes.
Press
right
turn signal button once.
9
Enter third digit (c) of initial PIN by pressing
left
turn signal button until
desired digit is displayed in odometer.
10
The digit (c) replaces the dash in the
odometer. The fourth dash flashes.
Press
right
turn signal button once.
11
Enter fourth digit (d) of initial PIN by pressing
left
turn signal button
until desired digit is displayed in odometer.
12
The digit (d) replaces the dash in the
odometer. The fifth dash flashes.
Press
right
turn signal button once.
13
Enter fifth digit (e) of initial PIN by pressing
left
turn signal button until
desired digit is displayed in odometer.
14
The digit (e) replaces the dash in the
odometer. The first digit flashes.
Press
right
turn signal button once.
15
Turn the ignition switch to
OFF.
16
CHANGING THE PIN
The rider can change the PIN at any time. Refer to
.
Modifying an Existing PIN
If a PIN was previously entered, the odometer will display the
equivalent digit. Each additional press of the left turn switch
will increment the digit.
Examples:
•
To advance from 5 to 6, press and release the left turn
switch 1 time.
•
To advance from 8 to 2, press and release the left turn
switch 3 times (9-1-2).
2013 Sportster Service: Electrical 6-101
Table 6-12. Changing the PIN: HFSM
NOTES
CONFIRMATION
ACTION
STEP
Select a five-digit (1 through 9) PIN and
record in the owner's manual and on the
wallet card.
1
With fobs present, cycle ignition switch
IGNITION-OFF-IGNITION-OFF-IGNITION.
2
Turn signals flash 3 times.
Press
left
turn signal button twice.
3
Current PIN will appear in odometer. The
first digit will flash.
Press
right
turn signal button once.
4
Enter first digit (a) of new PIN by pressing
left
turn signal button until desired digit is
displayed in odometer.
5
The new digit replaces the current in the
odometer. The second digit flashes.
Press
right
turn signal button once.
6
Enter second digit (b) of new PIN by
pressing
left
turn signal button until
desired digit is displayed in odometer.
7
The new digit replaces the current in the
odometer. The third digit flashes.
Press
right
turn signal button once.
8
Enter third digit (c) of new PIN by pressing
left
turn signal button until desired digit is
displayed in odometer.
9
The new digit replaces the dash in the
odometer. The fourth digit flashes.
Press
right
turn signal button once.
10
Enter fourth digit (d) of new PIN by
pressing
left
turn signal button until
desired digit is displayed in odometer.
11
The new digit replaces the current in the
odometer. The fifth digit flashes.
Press
right
turn signal button once.
12
Enter fifth digit (e) of new PIN by pressing
left
turn signal button until desired digit is
displayed in odometer.
13
The new digit replaces the current in the
odometer. The first digit flashes.
Press
right
turn signal button once.
14
Turning ignition switch to OFF
stores PIN.
Turn the ignition switch to
OFF.
15
6-102 2013 Sportster Service: Electrical
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