Harley Davidson 1986-2003 XL/XLH Sportster. Service Manual — page 25

d. Check headlight adjustment as described in this sec-

tion.

1991-2003 models

These model are equipped with a quartz halogen bulb.

Refer to Figure 109 and Figure 111.

WARNING

If the headlight has just burned out or has just
been turned off, it will be hot. Don’t touch the
bulb until it cools.

NOTE

A single screw secures the trim ring on 883C
and 1200C models.

1. Remove the trim ring retaining screws (Figure 112),
then remove the trim ring.
2. Remove the headlight lens assembly (Figure 113) from
the housing.
3. Depress the locking tabs on both sides of the electrical
connector (Figure 114). Then hold the locking tabs down
and pull the connector off the headlight terminals. Remove
the headlight lens assembly.
4. Remove the socket cover (A, Figure 115) from the back
of the headlight lens assembly.
5. Depress the ends of the bulb retaining clip (A, Figure
116) and unhook the clip from the headlight assembly slots.
Pivot the retaining clip away from the bulb.

CAUTION

When handling a quartz halogen bulb (

Fig-

ure 117

), do not touch the bulb glass. Any

traces of oil on the bulb will drastically re-
duce the life of the bulb. Clean any traces of
oil from the bulb glass with a cloth moistened
in alcohol or lacquer thinner.

6. Lift the bulb (B, Figure 116) out of the headlight lens as-
sembly.
7. Replace the retaining clip (A, Figure 116) if damaged.
8. Install by reversing the preceding steps while noting the
following:

a. On models 883C and 1200C, reinstall the rubber fin-

ger gasket (Figure 118), if removed, so the small
notch properly fits around the bulb holder base.

b. Install the bulb and make sure the tabs on the bulb fit

into the slots in the lens bulb holder; see B, Figure
116.

c. Position the socket cover with the TOP mark (B, Fig-

ure 114). This ensures that the vent holes in the
socket cover are positioned at the bottom. Push it on
until it is completely seated.

d. Make sure the electrical connector is free of corro-

sion and that the wiring in the headlight housing will
not be pinched when the headlight lens is installed.

e. Make sure the electrical connector is pushed on

tightly.

f. Check headlight operation before riding the motorcy-

cle.

g. Check headlight adjustment as described in this

section.

Headlight Adjustment

Adjust the headlight horizontally and vertically accord-

ing to the appropriate Department of Motor Vehicle
regulations.

Refer to Figure 119.

ELECTRICAL SYSTEM

427

12

106

107

108

428

CHAPTER TWELVE

109

HEADLIGHT

(ALL MODELS EXCEPT 883C AND 1200C)

1. Screw
2. Outer molding ring
3. Headlight (1986-1990 models)/

Headlight lens
(1991-2003 models)

4. Bulb
5. Rubber mount
6. Retaining ring
7. Screw
8. Inner molding ring
9. Socket cover

10. Headlight housing

11. Grommet
12. Cable guide
13. Grommet

(1994-2003 models)

14. Plug
15. Nut
16. Lockwasher
17. Grommet
18. Headlight bracket
19. Bolt
20. Washer

ELECTRICAL SYSTEM

429

12

110

111

HEADLIGHT (883C

AND 1200C MODELS)

1. Positioning lamp

bulb (HDI models)

2. Bulb socket

(HDI models)

3. Grommet

(HDI models)

4. Screw
5. Trim ring
6. Headlight lens
7. Bulb

8. Retaining clip
9. Socket cover

10. Adapter ring
11. Gasket
12. Nut
13. Washer
14. Bolt
15. Headlight mount
16. Headlight housing

112

113

114

115

116

1. Park the motorcycle on a level surface approximately 25
ft. (7.6 m) from the wall.

2. Make sure the tires are inflated to the correct pressure
when performing this adjustment. Refer to Chapter Three.

3. Have an assistant of the same approximate weight as the
primary rider sit on the seat.

4. Draw a horizontal line on a wall that is 35 in. (889 mm)
above the floor.

5. Aim the headlight at the wall and turn on the headlight.
Switch the headlight to high beam.

6. Check the headlight beam alignment. The broad, flat
pattern of light (main beam of light) should be centered on
the horizontal line (equal area of light above and below
line).

7. Check the headlight beam lateral alignment. With the
headlight beam pointed straight ahead (centered), there
should be an equal area of light to the left and right of cen-
ter.

8A. On all models except 883C and 1200C models, if the
beam is not aligned as described in Steps 6 and/or 7, adjust
it by performing the following.

a. Remove the plug on top of the headlight bracket (Fig-

ure 120).

b. Loosen the headlight mounting nut (Figure 121).
c. Tilt or rotate the headlight assembly to adjust the

beam position.

d. Tighten the headlight mounting nut 120-240 in.-lb.

(14-27 N•m).

e. Install the plug (Figure 120).

8B. On 883C and 1200C models, if the beam is not aligned
as described in Steps 6 and/or 7, adjust it by performing the
following.

a. Loosen the upper headlight mounting nut (12, Figure

111).

b. Tilt the headlight assembly up or down to adjust the

beam vertically.

c. When the beam is properly adjusted, tighten the up-

per headlight mounting bolt securely.

d. Loosen the horizontal adjustment bolt (14, Figure 111).
e. Move the headlight left or right to adjust the beam

horizontally.

f. When the beam is properly adjusted, tighten the

lower headlight mounting bolt securely.

430

CHAPTER TWELVE

117

118

Gasket

Bulb

Clip

119

HEADLIGHT ADJUSTMENT

25 ft.
(7.6 m)

35 in.
(0.9 m)

Taillight/Brake Light Replacement

1986-1998 models

WARNING

Make sure the taillight and brake light oper-
ate correctly before operating the motorcycle.

1. Remove the two mounting screws and remove the lens
assembly (Figure 122) from the taillight base.
2. Push in the bulb (Figure 123), turn the bulb one-quarter
turn counterclockwise and remove the bulb from the socket.
3. Replace the lens gasket if torn or damaged.
4. Install the bulb and lens.

1999-2003 models

Refer to Figure 124.

1. Remove the two mounting screws and remove the lens
assembly from the taillight base.
2. Pull the bulb socket (Figure 125) from the lens.

ELECTRICAL SYSTEM

431

12

122

123

124

TAILLIGHT

(1999-2003 MODELS)

1. Screw
2. Lens
3. Bulb
4. Bulb/socket

assembly

5. Circuit board
6. Nut
7. Base assembly
8. Rear lighting

harness

125

120

121

3. Remove the bulb from the socket.
4. Apply a coat of dielectric grease to the new bulb and in-
sert the bulb into the socket.
5. Install the bulb socket into the lens assembly.
6. Install the lens.

Taillight Base Replacement
(1999-2003 Models)

WARNING

Make sure the taillight and brake light oper-
ate correctly before operating the motorcycle.

Refer to Figure 126.

1. Remove the two mounting screws and remove the lens
assembly from the taillight base.
2. Depress the locking tab, and remove the 4-terminal tail-
light connector (1, Figure 126) from the circuit board in the
base.
3. Use a terminal pick (part No. HD-39621-28 or equival-
ent) to depress the locking tab on the top of each remaining
connector and remove the left- and right- turn signal con-
nectors and the power connector from the circuit board in
the base.
4. Remove the pin housing/circuit board mounting screw
from the base.
5. Lift the pin housing (A, Figure 127) from the circuit
board (B), and then remove the circuit board from the base.
6. Remove the two nuts and bolts, and then remove the
base from the fender.
7. Installation is the reverse of removal. Note the following:

a. Tighten the base mounting screws to 45-48 in.-lb.

(5-5.5 N•m).

b. Make sure the circuit board snaps into place in the

base.

Turn Signal Bulb Replacement

WARNING

Make sure the turn signals operate correctly
before operating the motorcycle.

1. Remove the turn signal lens (Figure 128).
2. Push in the bulb (Figure 129), rotate it and remove it.
3. Install a new bulb.
4. Install the lens.

Speedometer/Tachometer Bulb Replacement

1986-1994 models

1. Detach the speedometer or tachometer cable (A, Figure
130).
2. Remove the rear cover (B, Figure 130).
3. Replace a damaged bulb by pulling the bulb socket out
of the speedometer or tachometer housing. Remove the
bulb from the socket.

432

CHAPTER TWELVE

126

TAILLIGHT BASE

(1999-2003 MODELS)

1. 4-pin taillight

connector

2. 2-pin left turn signal

connector

3. Screw
4. 2-pin right turn signal

5. 6-pin power connector
6. Base

127

128

connector

4. Install the new bulb and insert the bulb socket into the
instrument housing.
5. Install the rear cover and the speedometer or tachometer
cover.

1995-1998 models

1. Remove the rear cover on the speedometer or tachometer.
2. Turn the lamp socket (Figure 131) and detach the socket
from the speedometer or tachometer.
3. Pull out the lamp from the socket.
4. Insert a new lamp into the socket.
5. Install the lamp socket into the speedometer or tachometer.
6. Install the speedometer or tachometer rear cover.

1999-2003 models

The illumination bulbs for a 1999-2003 model speedometer

or tachometer are LED type lamps. The lamps are not avail-
able individually but only as part of the instrument panel.

Indicator Light Replacement

1986-1990 models

A panel of indicator lights adjacent to the speedometer

provides information concerning the turn signals, high
beam, neutral position and oil pressure.
1. Disconnect the cable (A, Figure 130) from the instru-
ment(s).
2. Remove the instrument panel screws (Figure 132) and
lift the instrument(s) away from the handlebar.
3. Replace damaged bulbs by pulling the bulb socket out of
the gauge housing. Remove the bulb from the socket.
4. Reverse the preceding steps for installation.

1991-1993 models

Indicator lights on a panel below the speedometer (Fig-

ure 133) monitor the headlight high beam, oil pressure,
neutral position and turn signal lamps. The individual

ELECTRICAL SYSTEM

433

12

129

130

131

132

133

lamps do not have replaceable bulbs. If one of the lamps be-
comes faulty, the individual indicator lamp harness (Figure
134) must be replaced as an assembly.
1. On 1991 models, remove the speedometer or tachometer
if equipped.
2. Remove the headlight lens assembly as described in the

Headlight Replacement

in this section.

3. Remove the headlight adjust nut (Figure 121),
lockwasher and washer securing the headlight housing to
the headlight bracket. Then slide the headlight housing out
of the headlight bracket. See Figure 109.
4. Disconnect the indicator lamp connector in the head-
light housing. Figure 135 shows the individual lamp
positions.
5. Remove the indicator lamp leads from the connector us-
ing a terminal tool (part No. HD-97364-71 [Figure 136] or
equivalent).

NOTE

When replacing the left- or right turn indica-
tor or high beam indicator lamp harness, dis-
connect its ground wire from the upper fork
bracket.

6. Using a sharp, pointed tool, pry the trim cover (Figure
135) from the indicator lamp housing on the instrument
bracket.
7. Working at the indicator lamp on the instrument bracket,
push the indicator light harness through the indicator lamp
housing and remove it. See Figure 137.
8. Install a new indicator light harness by reversing the
preceding steps. Check and adjust the headlight beam as
described in this section.

1994 models

Indicator lights on a panel below the speedometer (Fig-

ure 133) monitor the headlight high beam, oil pressure,
neutral position and turn signal lamps. The individual
lamps do not have replaceable bulbs. If one of the lamps be-
comes faulty, the lamp assembly must be removed from the
indicator light panel.

NOTE

Prior to replacing one or more of. the indica-
tor light panel lamp assemblies, review the
information listed in

Electrical Connectors

in this section.

1. Remove the headlight bracket bolts (A, Figure 138) and
lockwashers and remove the headlight bracket (B).
2. Disconnect the black 12-pin Deutsch connector located
between the headlight lens assembly and the headlight
bracket. See Figure 139 (speedometer only) or Figure 140
(speedometer and tachometer) for a schematic diagram of
the 12-pin connector. Also, refer to the wiring diagrams at
the end of this manual.

434

CHAPTER TWELVE

134

INDICATOR LAMP

HARNESS CONNECTORS

(1986-1993 MODELS)

1. Trim cover
2. Bezel
3. Indicator lamps

135

INDICATOR LAMP

ASSEMBLY

Left turn

Neutral

Right turn

Instrument
bracket

Trim
cover

High beam

Oil pressure

Indicator lamp housing

136

Terminal tool

3. Depress the two latches on the connector and disconnect
the pin and socket halves.

4. Insert a wide-blade screwdriver between the socket
housing and locking wedge at the point shown in Figure
141. Then turn the screwdriver 90

°

and pop the secondary

locking wedge off the socket housing.

5. Depress the terminal latches mounted inside the socket
housing and pull all of the sockets out through the rear wire
seal.

6. Locate the cable strap on the wiring harness leading to
the Deutsch connector. Cut the cable strap and remove the
conduit.

7. Using a sharp, pointed tool, pry the trim cover (Figure
135) from the indicator lamp housing on the instrument
bracket.

8. Using wire cutters, cut the wire from the bulb assembly
approximately 1 1/2 in. (38.1 mm) above the wire splices.
By cutting the wire at this distance, the splice and other
bulb connections are left intact

NOTE

The oil and neutral lamps lead to the
three-wire splice. The high beam and turn
signal lamps lead to the four-wire splice.

9. Push the bulb assembly through the front of the indica-
tor lamp housing and discard.

10. Trim the wires on the replacement bulb assembly to the
same length as that on the discarded assembly.

11. Install a new Deutsch socket terminal to the head of the
replacement bulb assembly. Match the lead with the col-
ored tape on the wire.

12. Insert the replacement bulb–socket end first through
the front of the indicator lamp housing.

13. Align the trim cover (Figure 135) with the indicator
lamp housing and snap it in place.

14. Install the butt connector to the remaining black,
untaped wire on the replacement bulb assembly. Complete
the butt splice as described in the

Electrical Connectors

in

this chapter.

15. Slide the conduit over the butt splices and wire crimps
and install a new cable strap to secure the conduit to the wir-
ing harness.

16. Align and then install the rear wire seal into the the
back of the socket housing.

17. Hold the wire socket approximately 1 in. (25.4 mm)
behind the contact barrel and push the socket through the
holes in the wire seal and into the correct chamber until it
clicks in place; see Figure 139 or Figure 140 for the indi-
vidual wire positions. Lightly tug on the wire to verify that
it is locked in place.

18. Install the internal seal onto the socket housing lip.
Align and insert the tapered end of the secondary locking
wedge into the center groove within the socket housing.
Then press the wedge down until it locks in place.

19. Align the socket housing tabs with the pin housing
grooves and push the connector halves together until they
click in place.

20. Place the Deutsch connector underneath the bracket at
the backside of the headlight assembly.

21. Align the headlight bracket holes with the mating holes
in the upper steering stem bracket. Install the headlight
bracket bolts and lockwashers and tighten to 120-192
in.-lb. (14-22 N•m).

1995-2003 models

A panel of indicator lights adjacent to the speedometer

provides information concerning the turn signals, high
beam, neutral position and oil pressure.

1. Remove the headlight bracket bolts (A, Figure 138) and
lockwashers and remove the headlight bracket (B).

2. On 883C and 1200C models, remove the covers on the
handlebar riser (Chapter Fourteen).

3. Pull out the wire lead of the indicator light requiring re-
placement (Figure 142 or Figure 143) from the back of the
indicator light panel.

4. Pull out the indicator bulb, then install the new bulb.

5. Reverse the removal steps for installation. Lubricate the
socket with alcohol or glass cleaner before inserting it into
the indicator panel.

ELECTRICAL SYSTEM

435

12

137

138

436

CHAPTER TWELVE

139

SINGLE INSTRUMENT PLUG SPEEDOMETER (ALL 883 MODELS)

12-PIN BLACK

Vertical
alignment

Hi
B

N

Oil

Speedometer

Black

Splice

Black

Black

Black

Splice

1. Orange w/ white tape
2. White/ green
3. Black w/ brown tape
4. Black w/ white tape
5. Black w/ violet tape
6. Seal pin

7. Seal pin
8. Black w/ yellow tape
9. Black w/ green tape

10. Orange
11. Black (16 gauge)
12. Black (18 gauge)

140

DUAL INSTRUMENT SPEEDOMETER AND TACHOMETER PLUG

(ALL 1200 MODELS) 12-PIN BLACK

Speedometer

Hi

B

Speedometer

N

Oil

Tachometer

Vertical alignment tabs (left side)

Splice

Splice

Splice

Black

Black

Black

Black

1. Orange w/ white tape
2. White/ green
3. Black w/ brown tape
4. Black w/ white tape
5. Black w/ violet tape
6. Pale orange

7. Pink
8. Black w/ yellow tape
9. Black w/ green tape

10. Bright orange
11. Black (16 gauge)
12. Black (18 gauge)

ELECTRONIC

SPEEDOMETER/TACHOMETER

All 1995-2003 models are equipped with an electronic

speedometer. Some models are also equipped with an elec-
tronic tachometer. Refer to Figure 142 or Figure 143.

Troubleshooting

Refer to Chapter Two for troubleshooting procedures.

Removal/Installation

All 1995-1998 models, except 1998 883 models

1. Disconnect the negative battery cable as described in
this chapter.
2. To remove the speedometer, perform the following:

a. Remove the seat (Chapter Seventeen) and the fuel

tank (Chapter Eleven).

b. Slide the speedo-sensor connector off the T-stud on

the frame, and disconnect the connector (1995-1997
models: Figure 144, 1998 models: Figure 145).

c. Cut the cable ties that secure the speedometer harness

to the motorcycle. Note how the cable is routed
through the frame; it must be rerouted along the same
path during installation.

d. Remove the headlight assembly so the speedometer

harness can be removed. On 883C and 1200C
models, remove the fork bracket and riser covers
(Chapter Fourteen).

e. Remove the odometer boot from the back of the

speedometer.

f. Remove the cover from the back of the speedometer.

g. Remove the nuts from the speedometer studs (A, B

and C, Figure 146). Remove each wire and the ring
connector from the terminal stud. On models where
the wires do not have removable connectors, cut each
indicated wire approximately one inch from the
speedometer, and install ring terminals on the wires
to install the speedometer.

3. To remove the tachometer, perform the following:

a. Remove the cover from the back of the tachometer.

b. Remove the nuts from the tachometer studs, and re-

move wires (D, E, and F, Figure 146) from the ta-
chometer.

4. Loosen the rear cushion. Push the instrument toward the
rear of the motorcycle and out of the housing.

5. Remove the front cushion from the instrument.

6. Installation is the reverse of removal while noting the
following:

a. Route the wiring through the back of the bracket.

b. Make sure the front and rear gaskets are properly

seated on the bracket.

c. When installing a speedometer, install a new reset

switch boot, and route the speed-sensor cable along
the same path noted during removal.

1998 883 and 1999-2003 models

1. Disconnect the negative battery cable as described in
this chapter.

2. When removing the speedometer, perform the following:

a. Remove the odometer reset boot from the back of the

speedometer.

b. Remove the cover from the back of the speedometer

and remove the reset switch.

c. Depress the lock tab and remove the speedometer

connector (A, Figure 147) from the back of the
speedometer.

3. When removing the tachometer, perform the following:

a. Remove the cover from the back of the tachometer.

b. Remove the tachometer connector (B, Figure 147)

from the tachometer.

4. Loosen the rear cushion. Push the instrument toward the
rear of the motorcycle and out of the housing.

5. Remove the front cushion from the instrument.

6. Installation is the reverse of removal while noting the
following:

a. Route the wiring through the back of the bracket.

b. Make sure the front and rear gaskets are properly

seated on the bracket.

c. When installing a speedometer, install a new reset

switch boot.

ELECTRICAL SYSTEM

437

12

141

Secondary
locking wedge

438

CHAPTER TWELVE

142

SPEEDOMETER

(ALL 1995-2003 MODELS, EXCEPT 883C AND 1200C MODELS)

1. Speed-sensor connector
2. Reset switch
3. Boot
4. Front cushion
5. Bracket (All 1200 models,

except 1200C models)

6. Rear cushion
7. Cover
8. Socket
9. Bulb (speedometer,

odometer, tachometer)

10. Screw
11. Bracket (All 883 models,

except 883C models)

12. Bolt
13. Speed sensor
14. O-ring
15. Indicator lamp

socket

16. Indicator lamp bulb
17. Indicator lamp

housing

18. Indicator lamp lens
19. Trim plate
20. Tachometer
21. Speedometer
22. Speedometer harness
23. Main-harness connector

ELECTRICAL SYSTEM

439

12

143

SPEEDOMETER

(883C AND 1200C MODELS)

1. Washer
2. Bolt
3. Indicator lamp bezel
4. Indicator lamp lens
5. Indicator lamp jewel
6. Indicator lamp housing
7. Indicator lamp bulb
8. Indicator lamp socket
9. Speedometer harness

10. Main-harness connector
11. Socket
12. Bulb

13. Speed-sensor connector
14. Screw
15. Boot
16. Cover
17. Reset switch
18. Grommet
19. Rear cushion
20. Bracket
21. Front cushion
22. Speedometer
23. Speed sensor
24. O-ring

Speed-Sensor
Removal/Installation

1. Disconnect the negative battery cable as described in
this chapter.
2. Remove the seat (Chapter Seventeen).
3. Slide the speed-sensor connector off the T-stud on the
frame, and unplug the connector. Refer to Figure 144
(1995-1997 models) and Figure 145 (1998-2003 models).
4. The speed-sensor is mounted on the right side of the
transmission cases, just below the starter. Remove the sen-
sor mounting screw, lift the sensor from the crankcase,
then remove the sensor from the left side of the motorcy-
cle. Note how the sensor cable is routed through the mo-
torcycle. The replacement cable must be rerouted along
the same path.
5. Installation is the reverse of removal. Tighten the
speed-sensor mounting screw to 80-100 in.-lb. (9-11 N•m).

Reset Switch
Removal/Installation

1. Remove the boot from the tripmeter reset knob on the
back of the housing.
2. Remove the cover from the back of the speedometer
housing.
3. Cut the reset switch wires and splice in a new switch. Fol-
low the procedure in

Sealed Butt Connectors

in this chapter.

4. Installation is the reverse of removal.

SWITCHES

Testing

Test switches for continuity by using an ohmmeter or a

self-powered test light at the switch connector plug and oper-
ating the switch in each of its operating positions. Compare
the results with the switch operating diagrams included in the
wiring diagrams located at the end of this manual.

For example, Figure 148 shows the continuity diagram

for a typical ignition switch. It shows which terminals
should show continuity when the switch is in a given posi-
tion. When the ignition switch is in the ignition position,
there should be continuity between the red/black, red and
red/gray terminals. Note the line on the continuity diagram.
An ohmmeter connected between these three terminals
should indicate little or no resistance, or a test light should
light. When the starter switch is off, there should be no con-
tinuity between the same terminals. Replace the switch or
button if it does not perform properly.

When testing the switches, note the following:

1. Check the battery as described in this chapter. Charge or
replace the battery if necessary.
2. Disconnect the negative battery cable as described in
this chapter before checking the continuity of any switch.

440

CHAPTER TWELVE

144

145

146

147

3. Detach all connectors located between the switch and
the electrical circuit.

CAUTION

Do not attempt to start the engine with the
battery disconnected.

4. When separating two connectors, pull on the connector
housings and not the wires.
5. After locating a defective circuit, check the connectors
to make sure they are clean and properly connected. Check
all wires going into a connector housing to make sure each
wire is positioned properly and the wire end is not loose.
6. To reconnect connectors properly, push them together
until they click or snap into place.

Handlebar Switches
(1986-1995 Models)

Left handlebar switch description

The left side handlebar switch housing (Figure 149) is

equipped with the following switches:
1. Headlight dimmer.
2. Horn.
3. Left side turn signal.

Right handlebar switch description

The right side handlebar switch housing (Figure 150) is

equipped with the following switches:
1. Engine stop/run.
2. Start.
3. Right side turn signal.
4. Front brake light.

Handlebar switch replacement

1. Remove the screws securing the left handlebar switch
housing. Separate the switch housing (Figure 151) to ac-
cess the switches (Figure 152).

ELECTRICAL SYSTEM

441

12

148

IGNITION SWITCH (TYPICAL)

Red/black

Red

Red/gray

Off

!

Accessory

!

!

Ignition

!

!

!

Position

Switch

149

150

151

2. Remove the screws securing the right handlebar switch
housing. Separate the switch housing (Figure 150) to ac-
cess the switches (Figure 153).

NOTE

The switch assembly may be replaced either
by separating the terminal ends from the con-
nector, if the necessary tools are available, or
by cutting and splicing the switch wires.

3A. On models without splices, remove the screw and bracket.
3B. On models with splices, remove the cable strap.
4. Pull the switch(es) out of the housing.
5. Cut the switch wire(s) from the switch(es) being
replaced.
6. Slip a piece of heat shrink tubing over each wire cut in
Step 5.
7. Solder the wire end(s) to the new switch. Shrink the tub-
ing over the wire(s).
8. Install the switch by reversing the removal steps. Note
the following:

a. When clamping the switch housing onto the handle-

bar, check the wiring harness routing position to
make sure it is not pinched between the housing and
handlebar.

WARNING

Do not ride the motorcycle until the throttle
cables

are

properly

adjusted

(Chapter

Three).

b. To install the right side switch housing, refer to

Throttle

and Idle Cables

in Chapter Ten or Chapter Eleven.

c. Tighten the housing screws securely.

Handlebar Switches
(1996-2003 Models)

Right handlebar switch description

The right side handlebar switch housing is equipped with

the following switches:
1. Engine stop/run.
2. Start.
3. Right side turn signal.
4. Front brake light.

NOTE

To service the front brake light switch, refer to
the

Front brake light switch replacement

in

this section..

Right handlebar switch removal/installation

Refer to Figure 154.

CAUTION

Failure to insert a piece of cardboard be-
tween the brake lever and the lever bracket

442

CHAPTER TWELVE

152

LEFT HANDLEBAR SWITCH

(1986-1995 MODELS)

1. Lower housing
2. Screw
3. Machine screw
4. Left turn signal switch
5. Upper housing
6. Dimmer switch (HI-LO)
7. Horn switch

153

RIGHT HANDLEBAR

SWITCH (1986-1995 MODELS)

1. Lower housing
2. Screw
3. Machine screw
4. Right turn signal switch
5. Brake light switch
6. Upper housing
7. Engine stop/run switch
8. Start switch