Harley Davidson Sportster Models 2009. Service Repair Manual — page 68
ADAPTER (Part No. HD-46282-1A) into top footrest bracket
hole in frame. Place handle of tool on top of adapter.
2.
Shift transmission into neutral. Apply a few drops of
LOCTITE THREADLOCKER 262 (red) to the left-hand
threads of transmission sprocket nut (3). Apply a thin film
of clean Harley-Davidson 20W-50 engine oil to the back
face of the sprocket nut. Turn the nut counterclockwise
to install it onto main drive gear shaft.
a.
. Use TRANSMISSION SPROCKET
HOLDING TOOL (Part No. HD-46282) (1), MAIN-
SHAFT LOCK NUT WRENCH (Part No. HD-46288)
(2), and a torque wrench (3). Place handle of sprocket
holding tool on top of footrest bracket. Tighten nut to
50 ft-lbs (68 Nm) initial torque, ONLY.
b.
See
. Scribe a line on the transmission
sprocket nut and continue the line on the transmission
sprocket as shown.
c.
Tighten the transmission sprocket nut an additional
30° - 40°.
NOTE
The lockplate has four screw holes and can be turned to
either side, so you should be able to find a position without
having to additionally tighten the nut. If you cannot align
the screw holes properly, the nut may be additionally
TIGHTENED until the screw holes line up, but do not
exceed 45° as specified above. Never LOOSEN nut to
align the screw holes.
d.
See
. Install lockplate (4) over nut (3) so
that two of lockplate's four drilled holes (diagonally
opposite) align with sprocket's (2) two tapped holes.
1
2
3
sm01327
1.
Transmission sprocket holding tool
2.
Mainshaft lock nut wrench
3.
Torque wrench
Figure 5-111. Tightening Transmission Lock nut: All
Models (XL Model with Passenger Footrests Shown)
45
30
2
1
3
sm01470
1.
Transmission sprocket
2.
Sprocket nut
3.
Line scribed on nut and sprocket
Figure 5-112. Transmission Sprocket Nut Final Tightening
Procedure
NOTE
To maximize the lockplate's security, you must install BOTH
screws to secure the lockplate.
3.
Install socket head screws through two of the four holes
in lockplate, then into two corresponding tapped holes in
sprocket.
4.
Tighten socket head screws (5) to 90-110 in-lbs (10.2-
12.4 Nm).
5.
XR models and XL models without passenger
footrests: remove SPROCKET HOLDING TOOL
ADAPTER (Part No. HD-46282-1A).
XL Models
1.
See
. Install screw and washer (6) to secure
muffler interconnect bracket to engine crankcase. Tighten
to 30-33 ft-lbs (40.7-44.8 Nm).
2.
Install rear drive belt onto transmission sprocket. See
3.
Adjust rear belt deflection and rear wheel alignment. See
4.
Install belt guard. See
.
5.
See
. Install sprocket cover (1). Secure with
two screws (2, 3). Note that long screw goes in top hole,
short screw in bottom hole. Do not tighten screws at this
time.
6.
Install exhaust pipe clamp bracket (4), washer (5) and
screw (6). Tighten to 30-33 ft-lbs (40.7-44.8 Nm) . Now
tighten screws (2, 3) to 80-120 in-lbs (9.0-13.6 Nm).
2009 Sportster Service: Drive/Transmission 5-69
7.
Install rear exhaust pipe and rear muffler. See
4.15 EXHAUST SYSTEM: XL MODELS
XR Models
1.
Install rear drive belt onto transmission sprocket. See
.
2.
Adjust rear belt deflection and rear wheel alignment. See
.
3.
Attach rear brake master cylinder, rider footrest and
mounting bracket assembly to frame with two screws.
Tighten to 45-50 ft-lbs (61-68 Nm).
4.
Install belt guard. See
5.
Install sprocket cover. Secure with three screws. Note that
of the two smaller diameter screws securing cover, longer
screw goes in top hole, shorter screw in bottom hole.
Larger diameter screw goes in rear hole. Tighten rear
(larger) screw to 30-33 ft-lbs (40.7-44.8 Nm).Tighten for-
ward and lower (smaller) screws to 80-120 in-lbs (9.0-
13.6 Nm).
6.
Install exhaust system. See
.
All Models
Install main fuse. See
.
5-70 2009 Sportster Service: Drive/Transmission
SUBJECT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE NO.
ELECTRICAL
6.1
FASTENER TORQUE VALUES
FASTENER TORQUE VALUES IN THIS
CHAPTER
The table below lists torque values for all fasteners presented
in this chapter.
NOTES
TORQUE VALUE
FASTENER
6.29 ALTERNATOR, Assembly and Installation
13.6-15.8 Nm
120-140 in-lbs
Alternator rotor-to-sprocket screw
6.29 ALTERNATOR, Assembly and Installation
3.4-4.5 Nm
30-40 in-lbs
Alternator stator mounting screw
6.24 TURN SIGNALS, Front Housing Replacement
10.8-17.6 Nm
96-156 in-lbs
Ball head studs (front turn signals)
6.11 BATTERY CABLES, Installation
6.2-8.5 Nm
55-75 in-lbs
Battery negative cable-to-crankcase nut
6.11 BATTERY CABLES, Installation
6.8-7.9 Nm
60-70 in-lbs
Battery negative terminal screw
6.11 BATTERY CABLES, Installation
6.8-7.9 Nm
60-70 in-lbs
Battery positive terminal screw
6.11 BATTERY CABLES, Installation
4.1-6.8 Nm
36-60 in-lbs
Battery strap screw
6.12 BATTERY TRAY, Installation
10.9-17.6 Nm
96-156 in-lbs
Battery tray mounting screw
6.12 BATTERY TRAY, Installation
8.1-13.6 Nm
72-120 in-lbs
Brake (rear) lamp switch screw
6.12 BATTERY TRAY, Installation
3.4-4.5 Nm
30-40 in-lbs
Brake hose clamp-to-battery tray screw
6.12 BATTERY TRAY, Installation
2.3-2.8 Nm
20-25 in-lbs
Brake rear master cylinder reservoir
mounting screw
6.27 REAR STOP LAMP SWITCH, Replacement
2.3-2.8 Nm
20-25 in-lbs
Brake rear master cylinder reservoir
mounting screw
6.19 IGNITION COIL, Installation
4.0-5.1 Nm
35-45 in-lbs
Coil mounting bracket screw
6.19 IGNITION COIL, Installation
2.7-8.1 Nm
24-72 in-lbs
Coil mounting screw
6.19 IGNITION COIL, Installation
2.7-8.1 Nm
24-72 in-lbs
Coil mounting screw
6.28 CRANK POSITION SENSOR (CKP), Installa-
tion
9.0-11.3 Nm
80-100 in-lbs
Crank position sensor (CKP) screw
6.17 ELECTRONIC CONTROL MODULE
(ECM), Installation
2.0-2.5 Nm
18-22 in-lbs
ECM fasteners: XR models
6.25 LICENSE PLATE LAMP MODULE: XL
1200N, Installation (HDI Only)
14.9-24.4 Nm
132-216 in-lbs
Fender support screw with washer
6.22 INDICATOR LAMP MODULE, Replacement:
XL 1200L and XL 1200N/XL 1200L/XL 1200N
16.3-24.4 Nm
12-18 ft-lbs
Handlebar clamp screw
6.22 INDICATOR LAMP MODULE, Replacement:
XL 1200L and XL 1200N/XL 1200L/XL 1200N
16.3-24.4 Nm
12-18 ft-lbs
Handlebar clamp screw
6.40 RIGHT HANDLEBAR SWITCHES, Installation
12.2-14.9 Nm
108-132 in-lbs
Handlebar clamp screws
6.41 LEFT HANDLEBAR SWITCHES, Installation
12.2-14.9 Nm
108-132 in-lbs
Handlebar clamp screws
6.22 INDICATOR LAMP MODULE, Replacement:
XL 883C and XL 1200C/XL 883C/XL1200C
16.3 -24.4 Nm
12-18 ft-lbs
Handlebar riser clamp screw
6.22 INDICATOR LAMP MODULE, Replacement:
XL 883C and XL 1200C/XL 883C/XL1200C
16.3 -24.4 Nm
12-18 ft-lbs
Handlebar riser clamp screw
6.22 INDICATOR LAMP MODULE, Replacement:
XL 883C and XL 1200C/XL 883C/XL1200C
0.9-1.4 Nm
8-12 in-lbs
Handlebar riser cover screw
6.40 RIGHT HANDLEBAR SWITCHES, Installation
4.0-5.1 Nm
35-45 in-lbs
Handlebar switch housing screws
6.41 LEFT HANDLEBAR SWITCHES, Installation
4.0-5.1 Nm
35-45 in-lbs
Handlebar switch housing screws
6.22 INDICATOR LAMP MODULE, Replacement:
All Other Models/all except XL 883C/XL 1200C/XL
1200L/XL 1200N
16.3-24.4 Nm
12-18 in-lbs
Handlebar upper clamp screw
6.37 HORN, Replacement: Models with Front
Mounted Horn
8.1-12.2 Nm
72-108 in-lbs
Horn, front mounted, mounting screw
2009 Sportster Service: Electrical 6-1
NOTES
TORQUE VALUE
FASTENER
6.37 HORN, Replacement: Models with Side
Mounted Horn
6.8-20.4 Nm
60-180 in-lbs
Horn, side mounted, acorn nut
6.37 HORN, Replacement: Models with Side
Mounted Horn
9.0-11.3 Nm
80-100 in-lbs
Horn, side mounted, stud nut
6.16 IGNITION AND LIGHT SWITCH, Installation
4.0-5.1 Nm
35-45 in-lbs
Ignition/light switch mounting screw
6.34 JIFFY STAND SWITCH: INTERNATIONAL
MODELS, Installation
10.9-13.6 Nm
96-120 in-lbs
Jiffy stand switch screw
6.25 LICENSE PLATE LAMP MODULE: XL
1200N, Installation (HDI Only)
1.2-1.3 Nm
14-16 in-lbs
License plate lamp housing screw
6.33 ELECTRICAL CADDIES, Wire Harness
Caddy: XL Models
4.0-5.1 Nm
35-45 in-lbs
Light switch bracket screw
6.33 ELECTRICAL CADDIES, Wire Harness
Caddy: XR Models
4.0-5.1 Nm
35-45 in-lbs
Light switch bracket screw
6.14 STARTER SOLENOID, Solenoid Contacts
7.3-9.0 Nm
65-80 in-lbs
Long post jam nut
6.31 NEUTRAL INDICATOR SWITCH, Replace-
ment
13.6-20.3 Nm
120-180 in-lbs
Neutral indicator switch
6.36 OIL PRESSURE SWITCH, Installation
12.2-17.9 Nm
108-158 in-lbs
Oil pressure switch adapter: XR 1200
only
6.11 BATTERY CABLES, Installation
6.8-9.6 Nm
60-85 in-lbs
Positive battery cable-to-starter post lock
nut
6.25 LICENSE PLATE LAMP MODULE: XL
1200N, Installation (HDI Only)
2.3-2.8 Nm
20-25 in-lbs
Rear fender brace screw
6.24 TURN SIGNALS, Rear Housing Replacement
3.4-4.5 Nm
30-40 in-lbs
Rear turn signal housing screws: XR
models
6.24 TURN SIGNALS, Rear Housing Replacement
10.9-17.6 Nm
96-156 in-lbs
Rear turn signal housing-to-stalk
6.8 SPEEDOMETER: XL 883C/XL 1200C, Install-
ation/XL 883C/XL 1200C only
0.9-1.4 Nm
8-12 in-lbs
Riser cover screw
6.24 TURN SIGNALS, Front Housing Replacement
0.9-1.4 Nm
8-12 in-lbs
Riser cover screw
6.39 HANDLEBAR SWITCH ASSEMBLIES, Con-
nectors/XL 883C/XL 1200C only
0.9-1.4 Nm
8-12 in-lbs
Riser cover screw
6.13 STARTER, Field Coil Assembly
7.9-10.2 Nm
70-90 in-lbs
Solenoid ring terminal nut
6.13 STARTER, Field Coil Assembly
10.2-12.4 Nm
90-110 in-lbs
Starter end cover screw
6.13 STARTER, Installation
17.6-27.1 Nm
13-20 ft-lbs
Starter mounting bolt
6.13 STARTER, Installation
6.8-9.6 Nm
60-85 in-lbs
Starter positive terminal nut
6.13 STARTER, Field Coil Assembly
4.4-7.3 Nm
39-65 in-lbs
Starter thru bolts
6.29 ALTERNATOR, Assembly and Installa-
tion/Screw must be flush with plate. Do not exceed
torque specification.
6.3 Nm
56 in-lbs
Stator harness retainer screw
6.27 REAR STOP LAMP SWITCH, Replacement
9.5-13.6 Nm
84-120 in-lbs
Stoplight switch to tee nut
6.24 TURN SIGNALS, Rear Housing Replacement
14.9-24.4 Nm
132-216 in-lbs
Strut cover screw
6.23 TAIL LAMP: ALL MODELS EXCEPT XL
1200N, Base Replacement
5.1-5.4 Nm
45-48 in-lbs
Tail lamp base mounting screw: XL
models only
6.23 TAIL LAMP: ALL MODELS EXCEPT XL
1200N, Base Replacement
4.1-6.8 Nm
36-60 in-lbs
Tail lamp base mounting screw: XR
models only
6.23 TAIL LAMP: ALL MODELS EXCEPT XL
1200N, Bulb Replacement
2.3-2.7 Nm
20-24 in-lbs
Tail lamp lens screw
6.23 TAIL LAMP: ALL MODELS EXCEPT XL
1200N, Base Replacement
2.3-2.7 Nm
20-24 in-lbs
Tail lamp lens screw
6.24 TURN SIGNALS, Front Housing Replacement
10.9-13.6 Nm
96-120 in-lbs
Turn signal (front) clamp screw
6.24 TURN SIGNALS, Rear Housing Replacement
14.9-24.4 Nm
132-216 in-lbs
Turn signal stalk nut
6-2 2009 Sportster Service: Electrical
NOTES
TORQUE VALUE
FASTENER
6.30 VEHICLE SPEED SENSOR (VSS), Installation
9.0-11.3 Nm
80-100 in-lbs
Vehicle speed sensor (VSS) screw
6.3 VOLTAGE REGULATOR, Installation: XL
Models
4.1-6.8 Nm
36-60 in-lbs
Voltage regulator mounting screw
6.3 VOLTAGE REGULATOR, Installation: XR
Models
4.1-6.8 Nm
36-60 in-lbs
Voltage regulator mounting screw
2009 Sportster Service: Electrical 6-3
6.2
SPECIFICATIONS: ELECTRICAL
SPECIFICATIONS: 2009 SPORTSTER
MODELS
Table 6-1. Ignition System: 2009 Sportster XL Models
SPECIFICATION
COMPONENT
not adjustable
Ignition timing
12 volt, 12 amp/hr,
sealed and maintenance free
Battery
HD-6R12
Spark plug type
12 mm
Spark plug size
0.97-1.09 mm
0.038-0.043 in.
Spark plug gap
16.3-24.4 Nm
12-18 ft-lbs
Spark plug torque
Table 6-2. Ignition System: 2009 Sportster XR 1200 Model
SPECIFICATION
COMPONENT
not adjustable
Ignition timing
12 volt, 12 amp/hr,
sealed and maintenance free
Battery
10R12X
Spark plug type
12 mm
Spark plug size
0.81-0.97 mm
0.032-0.038 in.
Spark plug gap
16.3-24.4 Nm
12-18 ft-lbs
Spark plug torque
Table 6-3. Ignition Coil Resistance
SECONDARY
PRIMARY
RESISTANCE
1500-2400 Ohms
0.3-0.7 Ohms
All Models
Table 6-4. Alternator
SPECIFICATION
ITEM
20-28 VAC per 1000 engine
RPM
AC voltage output
0.1-0.3 Ohms
Stator coil resistance
Table 6-5. Voltage Regulator
SPECIFICATION
ITEM
14.3-14.7 VDC
Voltage output @ 75 F
32 Amps
Current @ 3600 RPM
Table 6-6. Battery
SPECIFICATION
MODEL
12 volt, 12 Ampere hours
All
Table 6-7. Fuses
AMP RATING
ITEM
30
Main fuse
15
Battery
15
Ignition
15
Lights
15
Accessories
15
Instruments
15
Fuel Pump
15
Electronic Control Module
(ECM)
15
P&A Ign
15
Engine control (XR1200
models only)
Table 6-8. Starter Specifications
STARTER DATA
3000 RPM (min.) @ 11.5 V
Free speed
90 amp (max.) @ 11.5 V
Free current
200 amp (max.) @ 68°F
Cranking current
8.0 ft-lbs (10.8 Nm) @ 2.4 V
Stall torque
Table 6-9. Starter Service Wear Limits
MM.
IN.
ITEM
11.0
0.443
Brush length (minimum)
0.41
0.016
Commutator runout
28.98
1.141
Commutator diameter (minimum)
0.203
0.008
Commutator mica depth (minimum)
6-4 2009 Sportster Service: Electrical
6.3
VOLTAGE REGULATOR
GENERAL
See
. The voltage regulator is located between the
frame downtubes at the front of the motorcycle. When installing
connectors (3, 4) after service, make sure to engage external
latches (5) to prevent connectors from separating during vehicle
operation.
NOTE
The voltage regulator cannot be repaired. Replace the unit if
it fails.
1
4
3
2
5
sm01350a
1.
Voltage regulator
2.
Screw (2)
3.
Stator pin connector [46A]
4.
DC output pin connector [77A]
5.
External latch
Figure 6-1. Voltage Regulator
4
3
2
1
5
sm01166
1.
Pin connector [46A] (voltage regulator side)
2.
Socket connector [46B] (stator side)
3.
External latch
4.
Open latch
5.
Separate socket connector from pin connector
Figure 6-2. Separating Connector Halves (Stator Connector
Shown)
REMOVAL: XL MODELS
To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before pro-
ceeding. (00251b)
1.
Unplug main fuse. See
NOTE
When unplugging the voltage regulator connectors, pull apart
each connector by firmly grasping both connector halves. Do
not pull on leads or damage to the wires and/or terminals may
result.
2.
. Unplug stator connector [46]. Lift external
latch (3) on pin housing and separate connector halves
(5).
3.
. Gently pry apart clips (2) and remove DC
output connector [77] (1) from voltage regulator caddy (3).
Lift external latch on pin housing and separate connector
halves.
2009 Sportster Service: Electrical 6-5
4.
. Remove screws (2) from locations at top
and bottom of voltage regulator. Remove regulator from
vehicle, carefully threading harnesses through opening in
regulator mounting bracket.
2
1
sm01165
1.
Stator connector [46]
2.
Locking latch
Figure 6-3. Stator Connector [46] Location
1
2
3
sm01133
1.
DC output connector [77]
2.
Clip (2)
3.
Voltage regulator caddy
Figure 6-4. DC Output Connector [77] Location
2
1
sm01129a
1.
Voltage regulator
2.
Mounting screw (2)
Figure 6-5. Voltage Regulator Location
INSTALLATION: XL MODELS
1.
. Position voltage regulator close to
mounting bracket (1). Orient regulator so cooling fins face
forward and wiring harnesses exit regulator body toward
right side of vehicle.
2.
Thread DC output wiring harness into opening (3) between
mounting bracket and frame downtube on right side of
vehicle. Route DC output harness connector [77A] toward
left side of vehicle.
3.
. Route stator harness (3) down along
between right frame downtube and body of voltage regu-
lator (2), and under voltage regulator caddy (1). Route
stator harness connector [46A] toward right side of vehicle.
4.
See
. Mount voltage regulator on mounting
bracket (1) between frame downtubes and secure with
mounting screws at two locations (2). Tighten to 36-60 in-
lbs (4.1-6.8 Nm).
5.
See
. Plug stator connector [46A] (1) into socket
connector [46B]. Fold external locking latch (2) over and
lock in place.
6.
In the same fashion, plug voltage regulator DC output
connector [77A] into socket [77B]. Fold external latch over
and lock in place.
7.
See
. Snap DC output harness connector
assembly (3) into tabs (4) in the voltage regulator caddy
(2). Insert DC output cables into cable clip (7) on caddy.
8.
Plug in main fuse. See
.
9.
Test charging system. See the ELECTRICAL DIA-
GNOSTIC MANUAL.
6-6 2009 Sportster Service: Electrical
3
2
1
4
sm01139
1.
Voltage regulator mounting bracket
2.
Regulator fastener locations
3.
Opening for wiring harness routing
4.
Voltage regulator caddy
Figure 6-6. Voltage Regulator Mounting Bracket (All
Models)
1
3
2
sm03918
1.
Voltage regulator caddy
2.
Voltage regulator
3.
Stator harness
Figure 6-7. Stator Harness Routing
1
2
3
4
4
5
6
7
sm03803
1.
Voltage regulator
2.
Voltage regulator caddy
3.
Voltage regulator DC output connector [77]
4.
DC output connector mounting tabs (4)
5.
Neutral switch wiring harness
6.
Neutral switch harness mounting tabs (2)
7.
DC output cable clip
Figure 6-8. Voltage Regulator Caddy: Rear View
REMOVAL: XR MODELS
To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before pro-
ceeding. (00251b)
1.
Unplug main fuse. See
NOTE
When unplugging the voltage regulator connectors, pull apart
each connector by firmly grasping both connector halves. Do
not pull on leads or damage to the wires and/or terminals may
result.
2.
See
. Unplug stator connector (4). Carefully pull
barbed cable strap (3) from frame.
3.
. Cut cable strap (1). Lift external latch on
connector and separate connector halves.
4.
See
. Remove screws (1) from locations at top
and bottom of voltage regulator (2). Remove regulator
from vehicle, carefully threading harnesses through
opening in regulator mounting bracket.
2009 Sportster Service: Electrical 6-7
1
2
3
4
sm05563
1.
Oil pressure switch
2.
J-clip
3.
Barbed cable strap
4.
Stator connector
Figure 6-9. Oil Pressure Switch (Right Side View XR 1200)
1
2
3
4
sm05585
1.
Cable strap
2.
DC output conector
3.
Oil pressure switch, neutral switch harness
4.
Oil filter
Figure 6-10. DC Output Connector: XR Models
1
3
4
1
2
sm05586
1.
Screw (2)
2.
Voltage regulator
3.
Stator wiring
4.
Cable strap
Figure 6-11. Stator Wire Routing: XR Models
INSTALLATION: XR MODELS
1.
. Position voltage regulator close to
mounting bracket (1). Orient regulator so cooling fins face
forward and wiring harnesses exit regulator body toward
right side of vehicle.
2.
Thread DC output wires below mounting bracket . Route
DC output connector (2) toward left side of vehicle.
3.
Route stator wires (4) down along between right frame
downtube and body of voltage regulator. Route stator
harness connector [46A] toward right side of vehicle.
NOTE
When installing voltage regulator, make sure wires do not get
pinched between bracket and regulator.
4.
Mount voltage regulator on mounting bracket and secure
with mounting screws. Tighten to 36-60 in-lbs (4.1-6.8
Nm).
5.
. Connect stator connector (1) and fold
external latch over and lock in place. Secure stator con-
nector to bracket with barbed cable strap (3).
6.
Secure stator wires to right frame down tube with cable
strap (2).
7.
See
. Connect voltage regulator DC output
connector. Fold external latch over and lock in place.
8.
Secure DC output connector (2) along with oil pressure
switch, neutral switch harness (3) to voltage regulator
bracket with cable strap (1).
9.
Plug in main fuse. See
.
6-8 2009 Sportster Service: Electrical
10. Test charging system. See the electrical diagnostic
manual.
1
2
3
4
sm05588
1.
Voltage regulator mounting bracket
2.
DC output connector
3.
DC output wires
4.
Stator wires
Figure 6-12. Voltage Regulator Wire Routing: XR Models
1
3
2
sm05589
1.
Stator connector
2.
Cable strap
3.
Barbed cable strap
Figure 6-13. Stator Connector: XR Models
1
2
3
4
sm05585
1.
Cable strap
2.
DC output conector
3.
Oil pressure switch, neutral switch harness
4.
Oil filter
Figure 6-14. DC Output Connector: XR Models
2009 Sportster Service: Electrical 6-9
6.4
FUSES AND RELAYS
GENERAL
The starter relay allows a relatively small amount of current
flowing through the starter button to control the large current
flow required to activate the starter solenoid.
. The electrical system relay/fuse block is loc-
ated in front of the battery under the left side cover. The relays
and fuses are mounted in the relay/fuse block. All fuses except
the P&A fuse are rated at 15 amperes.
REPLACING FUSES
1.
Open left side cover. See
.
2.
See
. Pull suspect fuse (1-9) from slots in
relay/fuse block and inspect for blown condition or other
damage.
3.
Replace as necessary:
a.
Insert new fuse in appropriate location by lining up
spade terminals on fuse with sockets in relay/fuse
block.
b.
Press fuse firmly into sockets.
4.
Close left side cover.
5.
Turn ignition switch ON and verify proper operation of cir-
cuit protected by replacement fuse.
REPLACING RELAYS
1.
Open left side cover. See
.
2.
. To unplug old relay (10 or 11), grasp
body of relay and with a gentle rocking motion, pull straight
out from relay/fuse block.
3.
To install new relay, line up spade terminals of relay with
sockets in relay/fuse block and push relay firmly into
sockets.
4.
Close left side cover.
5.
Turn ignition switch ON and start vehicle to verify proper
operation of relay circuits.
2
13
4
6
1
12
10
11
3
5
8
14
9
7
sm01267a
1.
ECM fuse
2.
Fuel pump fuse
3.
Ignition fuse
4.
Instruments fuse
5.
Accessories fuse
6.
Battery fuse
7.
Lights fuse
8.
P&A Ign fuse
9.
Spare fuse
10. Starter relay
11. System relay
12. Spare fuse
13. Engine control (XR models) or spare fuse (XL
models)
14. Open
Figure 6-15. Relay/Fuse Blocks (Typical)
6-10 2009 Sportster Service: Electrical
6.5
MAIN FUSE HOLDER
GENERAL
The main fuse holder is attached to the battery strap behind
the left side cover.
REPLACEMENT
To prevent accidental vehicle start-up, which could cause
death or serious injury, disconnect negative (-) battery
cable before proceeding. (00048a)
1.
Remove negative battery cable from engine crankcase.
See
.
2.
Unplug main fuse. See
.
3.
Disassemble main fuse holder and remove cable terminals.
Replace components as necessary and reassemble. See
for disas-
sembly/assembly instructions.
4.
Install negative battery cable on engine crankcase. See
5.
Plug in main fuse.
6.
Turn ignition switch ON and verify proper operation of
vehicle's electrical system.
2
1
sm01270
1.
Main fuse cover
2.
Main fuse holder
Figure 6-16. Main Fuse and Holder
2009 Sportster Service: Electrical 6-11
6.6
SPEEDOMETER: XL SINGLE GAUGE MODELS
EXCEPT XL 883C/XL 1200C
REMOVAL
NOTE
The speedometer has a backlight bulb that cannot be replaced.
If the bulb 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.
Unplug main fuse. See
.
2.
See
. Remove reset switch boot (9) from trip
odometer reset switch (8) on speedometer housing back
plate (5).
3.
Remove two screws (7) and back plate.
4.
Unplug speedometer socket connector [39B] (10) from
back of speedometer.
5.
Gently push out speedometer (1) and front gasket (2).
6.
Inspect front (2) and back (4) gaskets, speedometer con-
nector [39] and wiring, trip odometer reset switch and
wiring and reset switch boot. Repair or replace as required.
INSTALLATION
TOOL NAME
PART NUMBER
CRIMPING TOOL
HD-45929
1.
If replacing trip odometer switch:
a.
Push trip reset socket terminals out the front of the
speedometer socket connector half [39B]. See
A.16 PACKARD MICRO-64 CONNECTORS
b.
Cut off socket terminals and pull faulty switch wires
out of connector.
c.
Push wires of a replacement switch through speedo-
meter connector (sockets 8, 11) and crimp new socket
terminals using CRIMPING TOOL (Part No. HD-
45929), on replacement switch wiring.
d.
Draw terminal back into connector until terminal seats.
2.
See
. Install front gasket (2) on speedometer
(1).
3.
Threading speedometer harness and connector [39B]
through back gasket (4), install matching tabs of gasket
to locating keys in instrument housing/bracket (3).
NOTE
If necessary, lubricate rubber gaskets with alcohol or glass
cleaner.
4.
Orient face upright and press speedometer into instrument
housing/bracket. Wiring must past between locating keys
and gasket and through cutout in speedometer back.
5.
Plug speedometer socket connector [39] (10) into back of
speedometer.
6.
Push trip odometer reset switch (8) through back plate (5)
and thread on reset switch boot (9).
7.
Hold back plate in place with reset switch in rectangular
boss in back of speedometer (1) and vent hole (6) at
bottom. Secure with screws and tighten.
8.
Plug in main fuse.
6-12 2009 Sportster Service: Electrical
3
11
7
12
2
10
9
6
5
1
8
4
13
11
7
12
2
10
9
6
5
1
8
4
14
15
sm01374
9.
1.
Reset switch boot
Speedometer
2.
10.
Front gasket
Speedometer harness connector [39B]
11.
3.
Indicator lamp module
Instrument housing/bracket
4.
12.
Back gasket
Instrument harness connector [20A]
13.
5.
Speedometer housing/handlebar clamp
Back plate
6.
14.
Vent hole
XL 1200L/XL 1200N
15.
7.
All other single gauge XL models except XL
883C/XL 1200C
Screw (2)
8.
Trip odometer reset switch
Figure 6-17. Speedometer Components: XL Single Gauge Models Except XL 883C/XL 1200C
2009 Sportster Service: Electrical 6-13
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