Harley Davidson 2013 Sportster Models. Service Manual — page 45
3
2
1
sm03737
1. License plate holder
2. Gasket
3. Lamp housing
Figure 6-60. Lamp Housing Separated from License Plate
Holder: XL 883N, XL 1200X (HDI)
10. See
. Insert the tip of a small flat bladed
screwdriver (3) into each slot (2) in lamp housing. Gently
tilt screwdriver handle outward (away from lamp housing)
just enough to disengage housing from cover. Separate
housing from cover and slide housing away from tabs (4)
in cover.
11. See
. If replacing a light bulb (2), gently pull
bulb straight out of socket assembly (3). Push
new
light
bulb into socket.
1
4
3
2
2
5
sm03738
1. Lamp housing
2. Slot (2)
3. Screwdriver
4. Tab (2)
5. Feedthru slots for harness wires
Figure 6-61. Removing License Plate Lamp Housing Cover:
XL 883N, XL 1200X (HDI)
1
2
4
3
5
6
sm03739
1. Lamp housing
2. Light bulb (2)
3. Socket assembly
4. Housing cover
5. Tab (2)
6. Slot (2)
Figure 6-62. Replacing License Plate Light Bulbs: XL 883N,
XL 1200X (HDI)
2013 Sportster Service: Electrical 6-43
INSTALLATION: HDI
TORQUE VALUE
FASTENER
1.2-1.3 Nm
14-16
in-lbs
License plate lamp housing
screw: XL 883N
14.9-24.4 Nm
132-216
in-lbs
Fender support, rear, screw:
XL 883N
2.3-2.8 Nm
20-25
in-lbs
Fender brace, rear, screw
61-68 Nm
45-50 ft-lbs
Shock absorber mounting bolt
1.
If reusing license plate lamp housing, see
.
Carefully fit housing cover (4) onto lamp housing (1),
sliding tabs on cover (5) into slots (6) in housing. Make
sure harness wires fit into feedthrough slots in housing.
Gently snap cover onto housing, being careful not to pinch
wires.
2.
See
. Fit gasket (2) onto lamp housing (3).
3.
See
. Install lamp housing onto license plate
holder (1) with lamp housing cover facing upward. Secure
with two screws (2). Tighten to 14-16
in-lbs
(1.2-1.3 Nm).
4.
See
. Fit tab (3) on license plate holder (1) into
slot in rear fender brace (2). Install assembly onto vehicle.
Install screw with washer (5) through fender and into
fender brace. Tighten only finger-tight at this time.
5.
Install two screws with washers (4) through fender struts,
fender, fender brace and into threaded inserts in license
plate holder.
6.
See
. Make sure license plate holder threaded
inserts (3) fit into holes (4) in fender brace (2). Tighten to
132-216
in-lbs
(14.9-24.4 Nm).
7.
Now tighten screw securing fender to center of fender
brace to 20-25
in-lbs
(2.3-2.8 Nm).
8.
See
. Install license plate lamp harness (3)
into three clips (2) in fender bracket. Feed harness and
connector through feedthrough hole (5) in fender. Press
harness into harness bracket (1).
9.
See
. Plug license plate lamp harness con-
nector [40B] into interconnect harness connector [40B]
(2).
10. Install lower shock absorber screw and nut on each side
of vehicle. Tighten to 45-50 ft-lbs (61-68 Nm). 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)
11. Install seat.
12. 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)
13. Verify operation of lighting system.
2
4
3
1
sm03742
1. License plate holder
2. Rear fender brace
3. Threaded insert
4. Hole
Figure 6-63. License Plate Holder and Rear Fender Brace:
XL 883N, XL 1200X (HDI)
6-44 2013 Sportster Service: Electrical
6.18
FRONT TURN SIGNALS
BULB REPLACEMENT
1.
Insert coin in notch of front or rear turn signal lens cap.
Carefully twist coin until lens cap pops out of turn signal
housing.
2.
Replace bulb.
a.
Push bulb and turn counterclockwise.
b.
Pull bulb from socket when tab on bulb clears opening
on socket.
c.
Coat base of
new
bulb with ELECTRICAL CONTACT
LUBRICANT.
d.
Push
new
bulb in and turn clockwise to lock in place.
3.
Snap lens cap back into housing.
ALL EXCEPT XL 1200X
TORQUE VALUE
FASTENER
10.8-16.3 Nm
96-144
in-lbs
Turn signal, front, ball head
studs
10.8-13.6 Nm
96-120
in-lbs
Turn signal clamp, front, screw
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 fuel tank. See
or
.
4.
Separate left and right wire harness caddies. See
.
5.
See
. Locate turn signal connector [31] (4)
mounted on right wire harness caddy (2). Press latch (5)
and separate connector halves.
6.
Remove the corresponding socket terminals from con-
nector [31B].
7.
See
. Loosen the hex screw holding turn signal
housing ball end stud to front of hand lever bracket.
8.
Pull the wire conduit through the coil bracket, the fork
clamp and handlebar clips.
Installation
1.
See
. Inspect the ball head stud (1) and replace
as required. Tighten
new
ball head studs to 96-144
in-lbs
(10.8-16.3 Nm).
2.
Lay old turn signal housing and wires next to
new
and cut
new
wires to length.
3.
Trim sheath back approximately 2.5 in (63.5 mm) and
crimp
new
socket terminals onto wires.
4.
Route wires through handlebar clips, between fork clamp
and head lamp bracket and then through coil bracket.
5.
Install housing ball end stud into the lever bracket and aim
to front. Tighten to 96-120
in-lbs
(10.8-13.6 Nm).
6.
Insert socket terminals into turn signal connector.
7.
Join the connector [31] halves. Reassemble left and right
wire harness caddies. See
8.
Install fuel tank. See
or
.
9.
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)
10. Test the turn signals.
3
5
1
2
4
sm01170a
1. Frame backbone
2. Right wire harness caddy
3. Left wire harness caddy
4. Turn signal connector [31]
5. Connector latch
Figure 6-64. Turn Signal Connector [31]
2013 Sportster Service: Electrical 6-45
sm01294
Figure 6-65. Turn Signal Ball Stud Screw
3
1
4
2
sm01366
1. Ball end stud
2. Turn signal assembly
3. Bulb
4. Lens
Figure 6-66. Front Turn Signal Components: All Except XL
1200X
XL 1200X
TORQUE VALUE
FASTENER
16.3-21.7 Nm
12-16 ft-lbs
Turn signal housing to bracket:
XL 1200X
40.7-47.5 Nm
30-35 ft-lbs
Fork bracket pinch screw
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
.
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
.
4.
Separate left and right wire harness caddies. See
.
5.
Locate the turn signal connector [31] mounted on right
wire harness caddy. Press latch and separate connector
halves.
6.
Remove the corresponding socket terminals from con-
nector [31B].
7.
Remove the turn signal bracket fastener (front fork bracket
pinch screw) and washer and the bracket.
8.
Remove the turn signal nut and lockwasher to remove the
turn signal.
Installation
1.
See
. Thread the turn signal leads through the
bracket (1).
2.
Install the turn signal (2) with the lockwasher (3) and nut
(4) and tighten to 12-16 ft-lbs (16.3-21.7 Nm).
3.
Fit the bracket to the upper fork clamp.
4.
Install and tighten the turn signal bracket fastener (6) and
washer (5) (front fork bracket pinch screw) to 30-35 ft-lbs
(40.7-47.5 Nm).
5.
Insert socket terminals into turn signal connector.
6.
Join the connector [31] halves. Reassemble left and right
wire harness caddies. See
7.
Install the cable straps.
8.
Install the fuel tank. See
9.
Install main fuse.
6-46 2013 Sportster Service: Electrical
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. Verify operation of lighting system.
5
6
2
1
4
3
sm06847
1. Turn signal bracket
2. Turn signal assembly
3. Lockwasher
4. Nut
5. Washer
6. Fork pinch screw
Figure 6-67. Front Turn Signal Components: XL 1200X
2013 Sportster Service: Electrical 6-47
6.19
REAR TURN SIGNALS
GENERAL
Bulb Replacement
See
6.18 FRONT TURN SIGNALS, Bulb Replacement
Tail and Stop Lamps
XL 883N, XL 1200X/V:
The rear turn signals are the tail and
stop lamps. This feature may not be available in all markets.
The rear turn signal/stop lamp functions are provided by an
electronic converter module. See
CONVERTER MODULE: XL 883N, XL 1200X/V (DOM)
.
NOTE
XL 883N and XL 1200X/V models in certain markets are
equipped with LED rear turn signal/stop lamp/tail lamp
assemblies. These models do not require an electronic con-
verter module. The LED assemblies are sealed units and
cannot be disassembled. The entire rear turn signal housing
assembly must be replaced.
XL 883R/L
TORQUE VALUE
FASTENER
10.9-17.6 Nm
96-156
in-lbs
Turn signal housing to mount,
rear, fastener
14.9-24.4 Nm
132-216
in-lbs
Turn signal stalk nut
14.9-24.4 Nm
132-216
in-lbs
Strut cover screw
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.
2.
Remove seat.
3.
See
. Remove two screws (2) and tail lamp
lens (3) from tail lamp base (4).
4.
See
. Remove left and right turn signal con-
nectors (1, 2). Pull turn signal wiring harnesses through
harness access holes (3) in tail lamp base.
5.
Remove lower shock absorber mounting screws and nuts.
See
6.
See
. Disengage turn signal wiring harnesses
from wire retention brackets (1).
7.
See
. Remove screws (3, 4), washers (5), nuts
(7) and nut plate (8).
8.
Remove rear fender strut covers (1) with attached turn
signal assemblies (2) from rear fender struts. Carefully
slide wiring through holes.
9.
Remove socket terminals from left and right turn signal
connectors [18B], [19B].
10. Unscrew and remove turn signal stalk (6) and fender strut
cover (1) from each turn signal assembly (2). Mount will
separate from turn signal housing.
3
2
1
4
sm01668
1. Rear fender
2. Screw (2)
3. Tail lamp lens
4. Tail lamp base
Figure 6-68. Tail Lamp Lens: All Models Except XL 883N,
XL 1200X/V and XL 1200C/C ANV/CP/CA/CB
1
3
3
2
sm06775
1. Left turn signal connector [19]
2. Right turn signal connector [18]
3. Wiring harness access hole (2)
Figure 6-69. Turn Signal Connectors: All Models Except
XL 883N, XL 1200X/V/C/CP/CA/CB
6-48 2013 Sportster Service: Electrical
5
1
3
2
4
sm01296
1. Wire retention bracket (2)
2. Turn signal wiring harness (2)
3. Rear turn signal stalk nut (2)
4. Nut plate (2)
5. Nut (2)
Figure 6-70. Turn Signal Wire Routing: XL 883R/L
5
8
10
2
1
9
4
3
5
6
7
sm01669
1. Rear fender strut cover (2)
2. Rear turn signal assembly (2)
3. Screw (2)
4. Screw (2)
5. Washer (4)
6. Turn signal stalk (2)
7. Nut (4)
8. Nut plate (2)
9. Rear fender
10. Frame
Figure 6-71. Rear Fender Mounting Components (typical)
Installation
1.
Lay old turn signal housing and wires next to
new
and cut
new
wires to length. Trim sheath back approximately 2.5
in (63.5 mm).
2.
Crimp
new
terminals onto wires.
3.
See
. Install each turn signal housing (3) and
mount (4) to rear fender strut cover with turn signal stalk
(5). Tighten to 96-156
in-lbs
(10.9-17.6 Nm).
4.
Press wiring harness terminal sockets into left and right
connector housings [19B], [18B].
5.
Install rear fender strut covers over fender struts. Push
turn signal wiring harness through the hole in the strut and
fender.
6.
Thread nut onto turn signal stalk from inside fender. Finger
tighten.
7.
Secure fender to each fender strut with screw, washer and
nut in forward mounting hole. Install screw, washer and
nut plate in aft mounting hole. Finger tighten.
8.
Tighten fasteners:
a.
Tighten turn signal stalk nuts to 132-216
in-lbs
(14.9-
24.4 Nm).
b.
Tighten strut cover screws to 132-216
in-lbs
(14.9-
24.4 Nm).
9.
Engage turn signal wiring harness in wire retention bracket
on each side of rear fender.
10. Push left and right turn signal wiring harnesses through
corresponding harness access holes in tail lamp base.
11. Attach left [18] and right [19] turn signal connectors.
12. Attach tail lamp lens to tail lamp base.
13. Install lower shock absorber mounting screws and nuts.
See
.
14. Install main fuse.
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)
15. Install seat.
Be sure headlamp, tail and stop lamp and turn signals are
operating properly before riding. Poor visibility of rider to
other motorists can result in death or serious injury.
(00478b)
16. Verify operation of lighting system.
2013 Sportster Service: Electrical 6-49
1
2
4
5
3
sm01367a
1. Lens
2. Bulb (element)
3. Rear turn signal housing
4. Mount
5. Turn signal stalk
Figure 6-72. Rear Turn Signal Components: XL 883R/L
XL 883N AND XL 1200X/V
TORQUE VALUE
FASTENER
10.9-17.6 Nm
96-156
in-lbs
Turn signal housing to mount,
rear, fastener
14.9-24.4 Nm
132-216
in-lbs
Turn signal stalk nut
14.9-24.4 Nm
132-216
in-lbs
Strut cover screw
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.
2.
Remove seat.
3.
Raise the rear wheel.
4.
Remove lower shock absorber mounting screws and nuts.
See
5.
Raise motorcycle to access the underside of the rear
fender.
6.
See
. Unplug rear lighting harness connectors
[18], [19] (1, 2).
7.
See
. Remove left rear lighting harness (3)
from RH and LH harness bracket (1).
8.
Remove lighting harness from RH and LH lower bracket
harness clips (2).
9.
See
. Pull both rear lighting harnesses (2, 3)
through feed-through holes (4, 5) in rear fender.
10. See
. Remove screws (3, 4), washers (5), nuts
(7) and nut plate (8). Remove rear fender strut covers (1)
with attached turn signal assemblies (2) from rear fender
struts. Carefully feed turn signal harnesses through holes
in fender and fender struts.
11. Remove socket terminals from left and right turn signal
connectors [18B], [19B].
12. Remove turn signal stalk (6) (1) and fender strut cover
from each turn signal assembly (2). Mount will separate
from turn signal housing.
1
2
3
sm01171
1. Left rear lighting harness connector [19]
2. Right rear lighting harness connector [18]
3. Brown band
Figure 6-73. Rear Lighting Harness Connectors: XL 883N,
XL 1200X/V
3
1
2
sm01173
1. Harness bracket
2. Lower bracket harness clip (3)
3. Left rear lighting harness
Figure 6-74. Rear Lighting Harness Removal/Installation:
XL 883N, XL 1200X/V
6-50 2013 Sportster Service: Electrical
2
1
4
6
3
1
5
sm01172a
1. Harness bracket (2)
2. Right rear lighting harness
3. Left rear lighting harness
4. Right feed-through hole
5. Left feed-through hole
6. License plate lamp harness
Figure 6-75. Lighting Harnesses and Harness Brackets:
XL 883N, XL 1200X/V
5
8
10
2
1
9
4
3
5
6
7
sm01669
1. Rear fender strut cover (2)
2. Rear turn signal assembly (2)
3. Screw (2)
4. Screw (2)
5. Washer (4)
6. Turn signal stalk (2)
7. Nut (4)
8. Nut plate (2)
9. Rear fender
10. Frame
Figure 6-76. Rear Fender Mounting Components (typical)
Installation
1.
Lay old turn signal housing and wires next to
new
and cut
new
wires to length. Trim sheath back approximately 2.5
in (63.5 mm).
2.
Crimp
new
terminals onto wires.
3.
See
. Install each turn signal housing (3) and
mount (4) to rear fender strut cover with turn signal stalk.
Tighten to 96-156
in-lbs
(10.9-17.6 Nm).
4.
Press wiring harness terminal sockets into left and right
connector housings [19B], [18B].
5.
Install rear fender strut covers over fender struts. Push
turn signal wiring harness through hole in strut and fender.
6.
Finger tighten nut onto turn signal stalk from inside fender.
7.
Secure fender to each fender strut with screw, washer and
nut in forward mounting hole. Install screw, washer and
nut plate in aft mounting hole. Finger tighten.
NOTE
See
. Make certain that tab (3) on nut plate (2) fits
into slot (4) in fender brace (1) when securing nut plate with
rearmost fender mounting screw (5).
8.
Tighten mounting screws in the following sequence:
a.
Tighten turn signal stalk nuts to 132-216
in-lbs
(14.9-
24.4 Nm).
b.
Tighten strut cover screws to 132-216
in-lbs
(14.9-
24.4 Nm).
9.
Install lower shock absorber mounting screws and nuts.
See
.
10. Install main fuse.
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)
11. Install seat.
Be sure headlamp, tail and stop lamp and turn signals are
operating properly before riding. Poor visibility of rider to
other motorists can result in death or serious injury.
(00478b)
12. Verify operation of lighting system.
2013 Sportster Service: Electrical 6-51
1
2
4
5
3
6
sm01367
1. Lens
2. Bulb (element)
3. Rear turn signal housing
4. Mount
5. Turn signal stalk
6. Rear turn signal housing (sealed unit: XL 883N,
XL 1200X, XL 1200V)
Figure 6-77. Rear Turn Signal Components
3
5
2
1
4
sm01174
1. Rear fender brace
2. Nut plate (2)
3. Tab
4. Slot
5. Mounting screw (2)
Figure 6-78. Rear Fender Nut Plate: XL 883N, XL 1200X/V
XL 1200C/C ANV/CP/CA/CB
TORQUE VALUE
FASTENER
10.9-17.6 Nm
96-156
in-lbs
Turn signal housing to mount,
rear, fastener
14.9-24.4 Nm
132-216
in-lbs
Turn signal stalk nut
14.9-24.4 Nm
132-216
in-lbs
Turn signal stalk nut
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.
2.
Remove seat.
3.
Raise the rear wheel.
4.
Remove the lower shock absorber mounting screws and
nuts. See
.
5.
Raise the motorcycle to access the underside of the rear
fender.
6.
See
. Separate the RH [18] (3) and LH [19] (4)
turn signal connector housings.
7.
Remove the turn signal wire harness from the RH and LH
wire retention brackets.
8.
Pull the harness connectors through the feed holes in the
fender.
9.
Remove screws, washers, nuts and nut plate.
10. Remove rear fender strut covers with attached turn signals.
11. Thread the wire harness through the holes in the fender
and fender struts.
12. Unscrew and remove turn signal stalk and fender strut
cover from each turn signal assembly.
13. Remove socket terminals from RH [18B] and LH [19B]
turn signal connectors.
6-52 2013 Sportster Service: Electrical
1
3
4
2
sm07136
1. Main harness connector [7]
2. Tail lamp connector [40]
3. RH turn signal connector [18]
4. LH turn signal connector [19]
Figure 6-79. Turn Signal Wire Harness: XL 1200C/C
ANV/CP/CA/CB
Installation
1.
Lay turn signal housing wires next to
new
and cut
new
to
length. Trim sheath back 2.5 in (63.5).
2.
Crimp
new
terminals onto leads.
3.
Assemble the turn signal housing to the mount and install
the fastener. Tighten to 96-156
in-lbs
(10.9-17.6 Nm).
4.
Install wire harness terminals into RH and LH connector
housings [18B], [19B].
5.
Thread turn sign wire harness through hole in strut and
fender and install strut covers over fender struts.
6.
Thread nut onto turn signal stalk from inside the strut.
Finger tighten.
7.
Secure fender to strut with screws, washers and nuts.
Finger tighten.
8.
Tighten fasteners:
a.
Turn signal stalks to strut cover to 132-216
in-lbs
(14.9-24.4 Nm).
b.
Fender strut cover to strut to 132-216
in-lbs
(14.9-
24.4 Nm).
9.
Thread turn signal wires through fender and behind the
wire retention bracket.
10. Thread the turn signal wires through the fender openings
and connect the housings [18] and [19].
11. Install shock absorber mounting screws and nuts and
lower the motorcycle. See
.
12. Install main fuse.
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.
Be sure headlamp, tail and stop lamp and turn signals are
operating properly before riding. Poor visibility of rider to
other motorists can result in death or serious injury.
(00478b)
14. Verify operation of lighting system.
XR 1200X
TORQUE VALUE
FASTENER
3.4-4.5 Nm
30-40
in-lbs
Turn signal housing, rear,
screws: XR 1200X
Removal
1.
Remove seat.
2.
Remove main fuse.
3.
Remove two screws and tail lamp lens from tail lamp base.
4.
See
. Remove left and right turn signal con-
nectors (1, 2). Pull turn signal wiring harnesses through
harness access holes in tail lamp base (3).
5.
Remove socket terminals from left and right turn signal
connectors.
6.
See
. Remove screws (6), plate (4), reflector
(3) and turn signal housing (2).
7.
Lay old turn signal housing and wires next to
new
and cut
new
wires to length. Trim sheath back approximately 2.5
in (63.5 mm).
8.
Crimp
new
terminals onto wires.
2013 Sportster Service: Electrical 6-53
1
3
3
2
sm06775
1. Left turn signal connector [19]
2. Right turn signal connector [18]
3. Wiring harness access hole (2)
Figure 6-80. Turn Signal Connectors: All Models Except
XL 883N, XL 1200X/V/C/CP/CA/CB
1
2
3
5
4
6
sm05569
1. Tail light base
2. Left turn signal
3. Reflector
4. Plate
5. Connector
6. Screw (2)
Figure 6-81. Turn Signal Housing Removal: XR 1200X
Installation
1.
See
. Install turn signal housing (2), reflector
(3), and plate (4) with screws (6). Tighten screws to 30-40
in-lbs
(3.4-4.5 Nm).
2.
Press wiring harness terminal sockets into left [19B] and
right [18B] connector housings.
3.
Push left and right turn signal wiring harnesses through
corresponding harness access holes in tail lamp base.
4.
Plug left turn signal connector [18] and right connector
[19] into left and right sockets located on rear lighting cir-
cuit board in tail lamp base.
5.
Attach tail lamp lens to tail lamp base.
6.
Install main fuse.
Be sure headlamp, tail and stop lamp and turn signals are
operating properly before riding. Poor visibility of rider to
other motorists can result in death or serious injury.
(00478b)
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)
7.
Install seat.
8.
Verify operation of lighting system.
6-54 2013 Sportster Service: Electrical
6.20
REAR LIGHTING CONVERTER MODULE: XL
883N, XL 1200X/V (DOM)
GENERAL
NOTE
HDI XL 883N and XL 1200X/V models have a sealed LED tail
lamp, stop lamp and turn signal assembly in each rear turn
signal housing.
The domestic XL 883N and XL 1200X/V rear turn signal lamps
also serve as tail lamps and stop lamps. One filament provides
the tail lamp function while the other filament provides the turn
signal and stop lamp.
See
. In order for a single filament to function both
as turn signal and stop lamp, a converter module is required.
The converter module is located in front of the battery, under
the frame "Y" section.
5
3
1
2
4
sm07123
1. Converter module
2. Main harness connector [7]
3. License plate lamp connector [40]
4. Right turn signal connector [18]
5. Left turn signal connector [19]
Figure 6-82. Converter and Interconnect Harness
REMOVAL
1.
Remove seat.
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)
2.
Remove battery. See
3.
See
. Unplug the following harness connectors:
a.
Antenna [209] (1) (H-DSSS equipped motorcycles
only)
b.
Right rear lighting harness [18] (2)
c.
Left rear lighting harness [19] (3)
d.
License plate lamp harness [40] (4)
e.
Main wiring harness [7] (5)
f.
Engine harness connector [145] (6)
4.
See
. Remove ECM caddy fastener.
5.
Remove right side cover.
6.
Remove fastener securing bracket to oil tank.
7.
Remove barbed cable strap securing temperature sensor
harness to bracket.
8.
See
. Remove bracket fasteners (2).
9.
Remove bracket (3) with converter module (7).
10. Remove cable strap securing temperature sensor wire to
oil tank mounting bracket.
11. Remove rubber mounting tab (5) from mounting tab hole
(4) to release module from bracket.
2
3
4
5
6
1
8
7
9
sm06682
1. Antenna [209] (H-DSSS equipped vehicles only)
2. Right rear lighting harness connector [18]
3. Left rear lighting harness connector [19]
4. License plate lamp harness [40]
5. Main wiring harness connector [7]
6. Engine harness connector [145]
7. Flat washer
8. Seat post
9. Frame crossmember tab
Figure 6-83. Rear Lighting Harness Connectors: XL 883N,
XL 1200X/V
2013 Sportster Service: Electrical 6-55
sm06684
Figure 6-84. ECM Caddy Fastener
6
7
2
1
3
4
5
sm06679
1. Frame
2. Bracket fastener (3)
3. Bracket
4. Mounting tab hole
5. Rubber mounting tab
6. Module holder
7. Module
Figure 6-85. Converter Module
INSTALLATION
TORQUE VALUE
FASTENER
8.1-10.8 Nm
72-96
in-lbs
ECM caddy fastener
4.1-6.8 Nm
36-60
in-lbs
Converter module bracket
fasteners, rear lighting
1.
Feed converter module/interconnect harness connectors
up through battery compartment, forward of battery strap
bracket.
2.
See
. Install module (7) and module holder (6)
into bracket (3) by pulling rubber mounting tab (5) into
mounting tab hole (4).
3.
Position bracket up inside frame, under "Y" section.
4.
Install but do not tighten bracket fasteners (2).
5.
See
. Install ECM caddy fastener. Tighten to
72-96
in-lbs
(8.1-10.8 Nm).
6.
Tighten bracket fasteners to 36-60
in-lbs
(4.1-6.8 Nm).
7.
Secure temperature sensor wire to oil tank mounting
bracket with a cable strap.
8.
Install right side cover.
9.
See
. Plug in the following harness connectors:
a.
Antenna [209] (1)
b.
Right rear lighting harness [18] (2)
c.
Left rear lighting harness [19] (3)
d.
License plate lamp harness [40] (4)
e.
Main wiring harness [7] (5)
f.
Engine harness connector [145] (6)
10. Install battery. See
.
Be sure headlamp, tail and stop lamp and turn signals are
operating properly before riding. Poor visibility of rider to
other motorists can result in death or serious injury.
(00478b)
11. Close left side cover. 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)
12. Install seat.
13. Verify operation of lighting system.
6-56 2013 Sportster Service: Electrical
6.21
REAR STOP LAMP SWITCH
GENERAL
XL Models:
See
. The rear stop lamp switch (3) is
located behind the rear brake master cylinder reservoir under
the left side cover. The rear stop lamp switch is threaded into
a tee nut in the rear brake line.
XR 1200X:
The rear stop lamp switch is located underneath
the motorcycle near the rear brake master cylinder reservoir.
The rear stop lamp switch threads into a tee nut in the rear
brake line.
The stop lamp switch is an open type switch which closes with
hydraulic pressure. When the pressure in the line reaches a
preset level, the rear stop lamp switch closes and the rear stop
lamp illuminates.
NOTE
This part cannot be repaired. Replace upon failure.
REPLACEMENT
TORQUE VALUE
FASTENER
14.9-18.9 Nm
132-168
in-lbs
Stop lamp switch to tee nut
2.3-2.8 Nm
20-25
in-lbs
Brake master cylinder reser-
voir, rear, mounting screw
1.
Remove main fuse.
2.
XL Models:
move rear brake master cylinder reservoir
out of the way:
a.
Remove the rear brake master cylinder reservoir
cover. Grasp cover and pull straight away from
reservoir.
b.
Remove reservoir mounting screw and secure reser-
voir upright out of the way. See
3.
See
or
. Pull terminal sockets from
spade connections (4) on stop lamp switch.
4.
Remove stop lamp switch (3) from tee nut (2).
5.
Thread
new
stop lamp switch (3) to tee nut (2) on brake
line. Tighten switch to 132-168
in-lbs
(14.9-18.9 Nm).
NOTE
XR 1200X: Make sure that the brake switch wires do not con-
tact the ground strap cable.
6.
Install terminal sockets on switch spade connections (4).
7.
XL Models:
Install rear brake master cylinder reservoir:
a.
Replace the reservoir mounting screw. Tighten to
20-25
in-lbs
(2.3-2.8 Nm).
b.
Replace the brake master cylinder reservoir cover.
8.
Install main fuse.
9.
Install left side cover.
10. Refill
master
cylinder
and
bleed
brakes.
See
.
After repairing the brake system, test brakes at low speed.
If brakes are not operating properly, testing at high speeds
can cause loss of control, which could result in death or
serious injury. (00289a)
11. Test operation of rear brake.
Be sure headlamp, tail and stop lamp and turn signals are
operating properly before riding. Poor visibility of rider to
other motorists can result in death or serious injury.
(00478b)
12. Test operation of stop lamp with the rear brake applied
and the ignition/light switch turned ON.
4
1
3
2
sm01253
1. Rear brake line
2. Tee nut
3. Rear stop lamp switch
4. Spade connector terminal socket (2) [121]
Figure 6-86. Rear Stop Lamp Switch: XL Models Only
2013 Sportster Service: Electrical 6-57
1
2
4
3
sm05579
1. Rear brake line
2. Tee nut
3. Rear stop lamp switch
4. Spade connector terminal socket (2) [121]
Figure 6-87. Rear Stop Lamp Switch: XR 1200X
6-58 2013 Sportster Service: Electrical
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