Harley Davidson Sportster Models 2009. Service Repair Manual — page 71
A.16
PACKARD MICRO-64 CONNECTORS
PACKARD MICRO-64 CONNECTOR REPAIR
TOOL NAME
PART NUMBER
PACKARD MICRO-64 TERMINAL
REMOVER
HD-45928
PACKARD MICRO-64 TERMINAL
CRIMPER
HD-45929
General
Packard Micro-64 connectors are frequently found on
speedometers, tachometers and the ECM of Touring Models.
For pin 73 of these ECMs, see
.
Separating Pin and Socket Housings
Bend back the external latches slightly and separate the pin
and socket housings.
Mating Pin and Socket Housings
Orient the wire lead colors and push the pin and socket hous-
ings of the connector together until the latches click.
Removing Terminal
1.
See
. Locate the head of the secondary lock
(1) on one side of the connector housing.
2.
Insert the blade of a small screwdriver between the center
ear of the lock and the connector housing and gently pry
out lock. When partially removed, pull lock from connector
housing.
3.
Locate pin hole (2) between terminals on mating end of
connector.
4.
. Obtain the PACKARD MICRO-64 TER-
MINAL REMOVER (Part No. HD-45928).
5.
. Push the adjacent terminals all the way
into the connector housing and then insert tool into hole
until it bottoms.
6.
Leaving the tool installed, gently tug on wires to pull either
one or both terminals from wire end of connector. Remove
tool.
sm00046
Figure A-47. Packard Micro 64 Terminal Remover
(HD-45928)
sm00048
Figure A-48. Packard Micro 64 Connector: Insert Tool and
Remove Terminal
2009 Sportster Service: Appendix A Connector Repair A-31
Installing Terminal
1.
Insert terminal into its respective numbered chamber on
wire end of connector. No special orientation of the ter-
minal is necessary.
NOTE
. For wire location purposes, the corners of
the socket housing are stamped (3) with the numbers 1, 6, 7
and 12, representing terminals 1-6 on one side, and 7-12 on
the other.
2.
Bottom the terminal in the chamber and then gently tug
on the wire to verify that it is locked in place.
NOTE
Once the terminal is removed it may not lock in place when
first reinstalled. Until the lock engages, move the terminal back
and forth slightly while wiggling the lead.
3.
Since the terminal remover tool releases two terminals
simultaneously, repeat step 2 on the adjacent terminal
even if it was not pulled from the connector housing.
4.
With the center ear on the head of the secondary lockpin
facing the mating end of the connector, push secondary
lock in until head is flush with the connector housing.
Preparing Wire Leads for Crimping
Strip lead removing 1/8 in. (3.0 mm) of insulation.
Crimping Terminals
1.
Inspect new socket terminal for bent or deformed contact
and crimp tails. Replace as necessary.
2.
. Squeeze the handles of the PACKARD
MICRO-64 TERMINAL CRIMPER (Part No. HD-45929)
to cycle the tool to the fully open position (1).
3.
Raise locking bar and barrel holder by pushing up on
bottom tab with index finger (2).
4.
With the crimp tails facing upward, insert terminal through
locking bar into front hole in barrel holder (20-22 gauge
wire) (3).
5.
Release locking bar to lock position of contact. When
correctly positioned, the locking bar fits snugly in the space
at the front of the core crimp tails and the closed side of
the terminal rests on the outer nest of the crimp tool.
6.
Insert wires between crimp tails until ends make contact
with locking bar. Verify that wire is positioned so that wide
pair of crimp tails squeeze bare wire strands, while the
narrow pair folds over the insulation material.
7.
Squeeze handle of crimp tool until tightly closed (4). Tool
automatically opens when the crimping sequence is com-
plete.
8.
Raise locking bar and barrel holder to remove contact.
Inspecting Crimps
Inspect the quality of the core and insulation crimps. Distortion
should be minimal.
1
2
3
4
5
6
7
8
9 10
11 12
1
6
7
12
1
2
3
sm00047
1.
Secondary lock
2.
Pin hole
3.
Stamped number
Figure A-49. Packard Micro 64 Connector: Housing
sm00045
Figure A-50. Packard Micro 64 Terminal Crimper (HD-45929)
A-32 2009 Sportster Service: Appendix A Connector Repair
3
1
2
4
sm00049
1.
Open position
2.
Raising locking bar
3.
Insert terminal
4.
Crimp terminal
Figure A-51. Packard Micro 64 Connector: Terminal in
Crimper
2009 Sportster Service: Appendix A Connector Repair A-33
A.17
SEALED SPLICE CONNECTORS
SEALED SPLICE CONNECTOR REPAIR
TOOL NAME
PART NUMBER
ROBINAIR HEAT GUN
HD-25070
PACKARD CRIMPING TOOL
HD-38125-8
ULTRA TORCH UT-100
HD-39969
HEAT SHIELD ATTACHMENT
HD-41183
General
Splice connectors and several OE ring terminal connectors
use heat shrink covering to seal the connection.
Preparing Wire Leads
NOTE
If adjacent wires are to be spliced, stagger the splices so that
the sealed splice connectors will not touch each other but are
located at different positions along the length of the wires.
1.
Using a shop gauge, identify the gauge of the wire.
2.
Match the wire gauge to a sealed splice connector by color
and part number. Refer to
3.
Using a wire stripper, cut and strip a length of insulation
off the wire ends. Refer to
for the strip length.
Table A-5. Sealed Splice Connectors
STRIP LENGTH
PART NO.
COLOR
WIRE GAUGE
3/8 in. (9.5 mm)
70585-93
Red
18-20
(0.5-0.8 mm)
3/8 in. (9.5 mm)
70586-93
Blue
14-16
(1.0-2.0 mm)
3/8 in. (9.5 mm)
70587-93
Yellow
10-12
(3.0-5.0 mm)
NOTE
If any copper wire strands are cut off of the wire core, trim the
end and strip the wire again in a larger gauge stripper.
Splicing Wire Leads
NOTE
. The connector is crimped twice - one side
and then the other.
1.
See
. Open the PACKARD CRIMPING
TOOL (Part No. HD-38125-8) ratchet by squeezing the
handles closed.
2.
Match the connector color to the wire gauge crimp die in
the jaws and insert one end of the sealed connector.
3.
Gently squeeze the handles until the connector is held in
the jaws.
4.
. Feed the stripped end of a wire into the
connector until the wire stops inside the metal insert (1).
5.
Squeeze the handles tightly closed to crimp the lead in
the insert (2). The tool automatically opens when the
crimping is complete.
6.
Slide the connector to the other half of the metal insert.
Insert the stripped wire lead (1) until it stops, and crimp
the lead in the insert (2).
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.
7.
Use an ULTRA TORCH UT-100 (Part No. HD-39969), or
a ROBINAIR HEAT GUN (Part No. HD-25070) with a
HEAT SHIELD ATTACHMENT (Part No. HD-41183), to
heat the connector from the center of the crimp (3) out to
each end.
NOTE
It is acceptable for the splice to rest against the heat shrink
tool attachment.
Inspecting Seals
. Allow the splice to cool and inspect the seal.
The insulation should appear smooth and cylindrical. Melted
sealant will have extruded out the ends (4) of the insulation.
A-34 2009 Sportster Service: Appendix A Connector Repair
1
2
3
sm00050
1.
Red connector die
2.
Blue connector die
3.
Yellow connector die
Figure A-52. Packard Crimping Tool (HD-38125-8)
1
1
4
2
2
4
3
sm00051
1.
Wire lead in metal insert
2.
Crimp metal insert
3.
Center of crimp
4.
Melted sealant
Figure A-53. Sealed Splice Connector
2009 Sportster Service: Appendix A Connector Repair A-35
B.1
CONNECTORS
CONNECTOR LOCATIONS
Function/Location
Refer to
. On the motorcycle, a connector can be
identified by its function and location.
Place and Color
The place (number of wire cavities of a connector housing)
and color of the connector can also aid identification.
Connector Number
On wiring diagrams and in service/repair instructions, con-
nectors are identified by a number in brackets.
Repair Instructions
Refer to
. The repair instructions in Appendix A are
by connector type.
Table B-1. 2009 Sportster Connector Locations
LOCATION
TYPE
DESCRIPTION
NO.
On battery strap, behind left side
cover
2-place Metri-Pack, black
MAXIFUSE
[5]
Under seat
6-place Multilock, black
Tail lamp harness to main harness
[7]
Inside tail lamp lens
2-place Multilock, white
Left rear turn signal
[18]
Inside tail lamp lens
2-place Multilock, black
Right rear turn signal
[19]
Under fuel tank
12-place Molex, black
Instruments
[20]
Under fuel tank
6-place Molex, black
Right hand controls
[22]
Under fuel tank
8-place Molex, gray
Left hand controls and horn
[24]
Under battery
12-place Deutsch, gray
TSM/TSSM/HFSM
[30]
Under fuel tank
6-place Molex, black
Front turn signals
[31]
Right side of frame behind neck
-
Ignition switch
[33]
Under fuel tank
4-place Multilock, black
Headlamp
[38]
Back of speedometer
12-place Packard Micro-64, black
Speedometer (XL)
[39]
Back of speedometer
5-place Packard
Tachometer (XR)
[39]
In front of engine crankcase
2-place Lyall, black
Voltage regulator to stator
[46]
Behind left side cover
Spade terminals
Fuse block
[61]
Right rear top of crankcase
3-place Packard, black
Vehicle Speed Sensor (VSS)
[65]
In front of engine crankcase
2-place Lyall, black
Voltage regulator (DC output)
[77]
Under seat
36-place Packard, gray
Electronic Control Module (ECM)
[78]
Front of left crankcase
2-place Deutsch, black
Crankshaft Position (CKP) sensor
[79]
Top of intake manifold
4-place Packard, black
Temperature Manifold Absolute
Pressure (TMAP) sensor
[80]
Back of coil, under fuel tank
4-place Delphi, black
Ignition coil
[83]
Top of intake manifold
2-place Delphi, black
Front injector
[84]
Top of intake manifold
2-place Delphi, black
Rear injector
[85]
Top of induction module
4-place Delphi, black
Idle Air Control (IAC)
[87]
Behind air cleaner backing plate
3-place Delphi, black
Throttle Position (TP) sensor
[88]
Above induction module, right side
2-place Delphi, black
Engine Temperature (ET) sensor
[90]
On battery strap, behind left side
cover
4-place Deutsch, gray
Data link connector
[91]
Inside tail lamp lens
4-place Multilock, black
Tail lamp
[93]
Inside tail lamp lens
6-place Multilock, black
Tail lamp power in
[94]
Back of tachometer
12-place Packard Micro-64, gray
Tachometer
[108]
Fuse/relay block, behind left side
cover
5-place Amp, spade terminals
Relay/fuse block
[119]
2009 Sportster Service: Appendix B Wiring B-1
Table B-1. 2009 Sportster Connector Locations
LOCATION
TYPE
DESCRIPTION
NO.
Oil pressure switch, under oil filter
mount
90° post terminal, black
Oil pressure switch
[120]
Stop lamp switch, under battery tray
Spade terminals, black
Rear stoplight switch
[121]
Between cylinders, left side
90° spade terminals, black
Horn
[122]
Starter solenoid
Locking spade terminal, white
Starter solenoid
[128]
Left side along frame toward front
of engine
3-place, black
Jiffy Stand Sensor (HDI)
[133]
Right side frame, beneath gearcase
cover
1-place molded jumper, black
Neutral switch
[136]
On H-bracket
2-place Amp, black
Rear oxygen sensor
[137]
Electrical caddie behind voltage
regulator
2-place Amp, black
Front oxygen sensor
[138]
Forward of relay/fuse blocks
4-place Molex, black
Fuel pump and low fuel switch
[141]
Under frame
3-place Packard, black
Security siren
[142]
Under seat
16-place Molex, black
Engine harness
[145]
Under seat
1-place Packard, gray
B+ connector
[160]
Right side behind air box
2-place
Active intake solenoid
[178]
Under seat
3-place Molex, black
Fuel sender resistor assembly
[200]
Under battery
4-place Deutsch, gray
HFSM antenna connector
[208]
Under seat
2-place Molex, black
Security antenna
[209]
Crankcase housing, top rear
Ring terminal
Powertrain ground
[GND1]
B-2 2009 Sportster Service: Appendix B Wiring
B.2
WIRING DIAGRAMS
WIRING DIAGRAM INFORMATION
Wire Color Codes
Wire traces on wiring diagrams are labeled with alpha codes.
Refer to
For Solid Color Wires: See
. The alpha code
identifies wire color (3).
For Striped Wires: The code is written with a slash (/) between
the solid color code and the stripe code (4). For example, a
trace labeled GN / Y is a green wire with a yellow stripe.
Wiring Diagram Symbols
. On wiring diagrams and in service/repair
instructions, connectors are identified by a number in brackets
(1). The letter (2) inside the brackets identifies whether the
housing is a socket or pin housing.
A=Pin: The letter A after a connector number and the pin
symbol (6) identifies a pin housing.
B=Socket: The letter B after a connector number and the
socket symbol (5) identifies a socket housing.
Other symbols found on the wiring diagrams include the symbol
for a diode (7), a symbol for a wire-to-wire connection (8), a
symbol verifying that no connection (9) between two wire traces
exists, symbols for actual (10) and virtual (11) splices, and a
symbol identifying two wires that are twisted together (12).
Actual splices (10) are splices where two wires are connected
together at a specific location along a wire. Virtual splices (11)
are splices shown connected anywhere along a wire, usually
used in a wiring or schematic diagram for clarity.
9
12
1
2
1
2
8
11
10
7
6
5
3
4
TN
TN
W
W
GN/Y
GN/Y
1
2
4
1
2
4
[21A]
[21B]
ed01711
1.
Connector number
2.
Terminal code (A=pin, B=socket)
3.
Solid wire color
4.
Striped wire color
5.
Socket symbol
6.
Pin symbol
7.
Diode
8.
Connection
9.
No connection
10. Physical splice
11. Virtual splice
12. Twisted pair
Figure B-1. Connector/Wiring Diagram Symbols (typical)
Table B-2. Wire Color Codes
WIRE COLOR
ALPHA CODE
Blue
BE
Black
BK
Brown
BN
Green
GN
Gray
GY
Light Green
LGN
Orange
O
Pink
PK
Red
R
Tan
TN
Violet
V
White
W
Yellow
Y
2009 Sportster Service: Appendix B Wiring B-3
2009 SPORTSTER WIRING DIAGRAMS
Refer to the table below for wiring diagram information.
Wiring Diagram List
LOCATION
DIAGRAM
Figure B-2
Main Harness (XL): 2009 Sportster DOM. and INT. Models
Figure B-3
Indicator Lamps and Controls (XL): 2009 Sportster DOM. and INT. Models
Figure B-4
Starting and Charging: 2009 Sportster DOM. and INT. Models
Figure B-5
Engine Management (1 of 2) (XL): 2009 Sportster DOM. and INT. Models
Figure B-6
Engine Management (2 of 2) (XL): 2009 Sportster DOM. and INT. Models
Figure B-7
Lights (1 of 2) (XL): 2009 Sportster DOM. and INT. Models
Figure B-8
Lights (2 of 2) (XL): 2009 Sportster DOM. and INT. Models
Figure B-9
Horn and Instruments (XL): 2009 Sportster DOM. and INT. Models
Figure B-10
Security (1 of 2) (XL): 2009 Sportster DOM. and INT. Models
Figure B-11
Security (2 of 2) (XL): 2009 Sportster DOM. and INT. Models
Figure B-12
Main Harness (XR): 2009 Sportster DOM. and INT. Models
Figure B-13
Indicator Lamps and Controls (XR): 2009 Sportster DOM. and INT. Models
Figure B-14
Engine Management (1 of 2) (XR): 2009 Sportster DOM. and INT. Models
Figure B-15
Engine Management (2 of 2) (XR): 2009 Sportster DOM. and INT. Models
Figure B-16
Lights (1 of 2) (XR): 2009 Sportster DOM. and INT. Models
Figure B-17
Lights (2 of 2) (XR): 2009 Sportster DOM. and INT. Models
Figure B-18
Horn and Instruments (XR): 2009 Sportster DOM. and INT. Models
Figure B-19
Security (1 of 2) (XR): 2009 Sportster DOM. and INT. Models
Figure B-20
Security (2 of 2) (XR): 2009 Sportster DOM. and INT. Models
B-4 2009 Sportster Service: Appendix B Wiring
E
K
T
S
U
I
C
Q
P
R
M
O
G
H
A
B
P
R
I
J
C
D
M
O
G
H
A
B
K
L
S
U
F
E
IGN 15A
Fuel Pump
15A
Ignition
Switch
[33]
Battery 15A
ECM 15A
[5]
30 Amp
MAXIFUSE
B
A
GND1
Powertrain
Ground
Point
Engine
Case
Ground
Point
IGN − I
BATT – B
ACC – A
ECM
TSM/TSSM/HFSM
Fuseblocks
Top View
Top View
[119]
ACCESSORIES
LIGHTS
IGNITION
FUEL PUMP
START RELAY SYSTEM RELAY
ECM
BATTERY
SPARE
P&A IGN
INSTRUMENTS
SPARE
System
Relay
SPARE
OPEN
Idle Air Control (A) Hi
Idle Air Control (B) Low
Injector Rear
Injector Front
Battery
Idle Air Control (B) Hi
Idle Air Control (A) Low
To instruments and
indicator lamps
[61]
To Right Hand
Controls
Start
Relay
Starter
Red
band
Access 15A
P&A IGNV
15A
To Left Hand
Controls
P&A
Battery
1 2 3 4 5 6 7 8 9 10
12
1
1
2
2
1
2
1 2
Data Link
Connector
Jiffy Stand
Sensor
Ignition
Coil
1 2 3 4
P
o
w
er
Coil
Rear
Coil
F
ront
P
o
w
er
D C B A
D C B A
To
Engine
Harness
C
B
A
To Vehicle
Speed Sensor
Front
O2
Sensor
Engine
Temperature
Sensor
Rear
O2
Sensor
HDI
Only
INSTR 15A
To Fuel Pump
And Sender
ASSY
1 2 3
1 2 3
1 2 3
4
1 2 3 4
1 2 3 4
5 6
1 2 3 4 5 6
Spare 15A
To Front
Turn Signals
To
Headlamp
Lights 15A
Spare 15A
Spare 15A
1 2 3 4 5 6
1 2 3 4 5 6
7 8
A
B
C
A
B
C
Power
Signal
Ground
2
1
2
1 Antenna ’A’
Antenna ’B’
Hands Free Antenna
To Rear
Lighting
Fuel Sender
Resistor Assy
240
240
Oil
Pressure
Sending
Unit
Neutral
Switch
B A
1
Battery
Battery
Ignition
Serial Data
Neutral Switch
Left Turn Feed
Right Turn Feed
Right Turn Switch Input
Left Turn Switch Input
Start Relay Control
Clutch Switch
Alarm Signal
Ground
Receive Antenna
XMIT Antenna A
XMIT Antenna B
System Relay
Serial Data
Engine Temperature
Intake Air Temperature
Oxygen Sensor (A)
Jiffy Stand Sensor (HDI)
Ground
Coil Rear
Crank POS Sensor (–)
Switched Power
5V Sensor Power
Oxygen Sensor (B)
Throttle POS Sensor Input
Map Sensor Input
5V Sensor Ground
Ground
Coil Front
Crank POS Sensor (+)
Vehicle Speed Sensor Input
1
2
3
4
5
6
7
8
9
10
11
12
1
2
3
4
5
6
7
8
9
10
11
12
1
2
3
1
2
3
2
5
6
7
8
9
10
11
12
13
14
17
18
19
21
23
24
25
26
28
29
30
31
33
35
36
2
5
6
7
8
9
10
11
12
13
14
17
18
19
21
23
24
25
26
28
29
30
31
33
35
36
1
2
3
4
5
7
8
9
11
12
13
14
Crank
Position
Sensor
(Ckp)
2 1
2 1
Rear
Stop Lamp
Switch
A
B
BK
BK
BK
BK
BK
BK
BK
BK
BK
BK
BK
GY
BE
BK
BK
BK
GN
GN
TN
TN
R
W
1 2 3
1 2 3
BK
BE
BE
R/W
GN/BN
GN/BN
GN/GY
GN/GY
PK/GN
PK/GN
BE/GY
BE/GY
BE/GY
BN/GY
GY/BE
GY/BE
BE/GN
BE/GN
BK/BE
BK/BE
[38B]
[31B]
[22A]
[20A]
Security
Siren
(Optional)
HFSM Only
SOCKET CONNECTOR
(B SIDE)
PIN CONNECTOR
(A SIDE)
To
Horn
[122A]
SWITCH
POSITION
RED/
BLACK
RED
RED/
GRAY
OFF
ACC.
IGNITION
Ignition Switch Legend
Dot Indicates Continuity With Red
Wire In Switch Position Indicated
To Charging
System. See
Starting And
Charging
Sheet
2 1
2 1
[7B]
[24A]
[65A]
[145B]
TN
TN
BN
BK
BK
GY
GY
BK
BK
BK
BK
BE
BE
BN
GY
BK
BK
BK
BK
BK
BK
BE
BE
BN
BK
BK
Y/W
R/W
R/W
W/Y
W/Y
V/W
V/W
W/V
O/Y
O/W
Y/R
Y/W
BK
Y/R
Y/W
O/W
O/W
O/W
O/W
O/W
O/W
R/Y
R/Y
R/Y
W/V
O
R
BK
R
Y
Y
V
W
W
V
V
BN
V
R
R
O
R
R
R
R
R
R
W
LGN/V
LGN/V
LGN/V
LGN/Y
LGN/Y
LGN/V
TN/GN
TN/GN
LGN/BN
LGN/BN
BN/GY
BN/GY
BN/GY
GN/Y
GN/Y
Y/GN
Y/GN
Y/GN
Y/GN
O/GY
Y/GN
Y/BK
Y/BK
BK/R
Y/BK
Y/BE
Y/BE
W/BN
W/BN
O/GN
O/GN
PK/Y
PK/Y
W/BK
W/BK
W/BK
BK/O
BK/O
BE/O
BE/O
BN/R
BN/R
BK/R
BK/R
BK/R
BK/R
BK/R
BK/R
BK/R
BK/R
BK/R
R/GY
R/GY
BK/R
O/GY
GY/V
GY/V
BK/V
BK/V
BK/W
BK/W
BK/W
BK/W
BK/W
PK/O
PK/O
[38A]
[31A]
[141A]
[24B]
[136B]
[136A]
[120B]
[120A]
[122B]
[121B]
[121A]
[20B]
[83A]
[83B]
[79A]
[79B]
[22B]
[200A]
[200B]
[209A]
[209B]
[160B]
[208B]
[208A]
[78B]
[78A]
[65B]
[30B]
[30A]
[142B]
[142A]
[133B]
[133A]
[137B]
[137A]
[138B]
[138A]
[90B]
[90A]
[7A]
[91A]
[128]
[145A]
15A
15A
15A
15A
15A
15A
15A
15A
15A
15A
15A
[61B]
[119B]
86
85
30
87A
87
1
2
3
4
5
R
P
C
Q
I
86
85
30
87A
87
1
2
3
4
5
U
S
E
T
K
M
O
G
H
M
O
K
L
G
H
F
E
A
B
A
B
D
C
J
I
R
P
et01153
Figure B-2. Main Harness (XL): 2009 Sportster DOM. and INT. Models
Figure B-2.
Figure B-2.
Main Harness (XL): 2009 Sportster DOM. and INT. Models
Main Harness (XL): 2009 Sportster DOM. and INT. Models
Hand Controls,
Left
Horn Switch
Headlamp Hi/Lo Switch
Left Turn Switch
Clutch Switch
Hand Controls,
Right
O/W
R/Y
GY
W/BK
W/BN
BK/R
O/W
Y
BE
W
W/V
Y/BK
1
2
3
4
5
6
1 2 3 4 5 6 7 8
BK/R
BK
[22A]
[24A]
Speedometer
Tachometer
BN/GY
O/W
BN
W
V
O
LGN/V
TN
GN/Y
BK
BK
BK
O
O
BK
Configuration for XL1200R
Ignition
Serial data
Battery
Accessory
Ground
Trip odometer reset switch
Trip odometer reset switch
Fuel level
RPM x 100
Ignition
Serial data
Battery
Accessory
Ground
[39A]
[39B]
[108A]
[108B]
Speedometer
BN/GY
O/W
LGN/V
BK
BK
O
O
BK
BK
BN
W
V
TN
GN/Y
BN/GY
O/W
LGN/V
Trip Odometer
Reset Switch
Trip Odometer
Reset Switch
Y/W
Y/W
[20A]
To main
harness
To main
harness
To main
harness
[20A]
To main
harness
BN/GY
O/W
LGN/V
O
BK
BN
W
V
TN
GN/Y
Y/W
[39A]
[39B]
1
2
5
6
7
8
9
11
1
2
5
6
7
1
2
4
5
6
7
8
9
11
1
2
5
6
7
8
9
11
1
2
5
6
7
1
2
4
5
6
7
8
9
11
BK
BK
O
BK
BN/GY
O/W
LGN/V
Y/W
1
2
3
4
5
6
7
8
9
10
12
1
2
3
4
5
6
7
8
9
10
12
BN
W
V
TN
GN/Y
BK
BK
BK
O
O
Ignition
Serial Data
Security LP
Battery
Accessory
Ground
Trip odometer reset switch
Trip odometer reset switch
Fuel level
Right Turn Switch
Engine Stop Switch
Start Switch
Front Stop Lamp Switch
Configuration for all except XL1200R
Socket Connector
Pin Connector
(A side)
(B side)
[24B]
[162]
[22B]
[20B]
[163]
[20B]
et01154
Figure B-3. Indicator Lamps and Controls (XL): 2009 Sportster DOM. and INT. Models
Figure B-3.
Figure B-3.
Indicator Lamps and Controls (XL): 2009 Sportster DOM.
and INT. Models
Indicator Lamps and Controls (XL): 2009 Sportster DOM.
and INT. Models
Engine Stop Switch
Start Switch
Right Hand
Controls
GND1
TSM/TSSM/HFSM
HFSM Only
6
4 3
6
1
2
4
9
10
12
1
2
4
9
10
12
3
Starter
Ignition 15A
Battery 15A
30 Amp
MAXIFUSE
Ignition
Switch
[61B]
B A
Powertrain
Ground
Point
Battery
[119B]
Charging
30 Amp
Main Fuse
Powertrain
Ground
Point
Switch
Position
RED/BLACK
RED
RED/GRAY
Off
ACC.
Ignition
Ignition Switch Legend
Dot Indicates Continuity With Red
Wire In Switch Position Indicated
E
K
T
S
U
Start Relay
System Relay
I
C
Q
P
R
M
O
G
H
A
B
Fuel pump
Spare
ECM
15A
15A
15A
P
R
I
J
C
D
Battery
Lights
Accessories
15A
15A
15A
M
O
G
H
A
B
Instruments
Spare
Ignition
15A
15A
15A
K
L
S
U
F
Spare
Open
P&A IGN
15A
15A
E
[119]
[61]
1 2
Stator
1 2
Voltage
Regulator
Battery
–
+
B
A
–
+
GND1
1
2
3
4
IGN − I
BATT – B
ACC – A
Start Relay
Red
Band
Fuse Blocks
Top view
Top view
[128]
W/BK
Neutral
Switch
TN
TN
Left Hand
Controls
Clutch Switch
7
8
7
8
BK
BK/R
BK
TN
BK
BK
BK
BK
BK
BK
BK
BK
BK
BK
BK
BK
BK
BK
BK
GY
GY
GN
GN
GY
GY
BK/R
BK/R
BK/R
R/BK
R/BK
R/BK
BK/R
BK/R
Battery
Ignition
Neutral Switch
Start Relay Control
Clutch Switch
Chassis Ground
Receive Antenna
XMIT Antenna A
XMIT Antenna B
[163]
[33]
[162]
[5]
[5]
Engine
Case
Ground
Point
BK
Engine
Case
Ground
Point
R
R
R
R
R
R
R
R
R
BN/GY
BN/GY
TN/GN
TN/GN
[136B]
[136A]
[46B]
[46A]
[24B]
[24A]
[22A]
[22B]
[77A]
[77B]
[30B]
[30A]
86
85
30
87A
87
1
2
3
4
5
R
P
C
Q
I
A
B
J
I
[208A]
et00141
Figure B-4. Starting and Charging: 2009 Sportster DOM. and INT. Models
Figure B-4.
Figure B-4.
Starting and Charging: 2009 Sportster DOM. and INT. Models
Starting and Charging: 2009 Sportster DOM. and INT. Models
Battery
Ignition
Serial data
Ground
Receive antenna
XMIT antenna A
XMIT antenna B
Idle air control (A) hi
Idle air control (B) low
Injector rear
Injector front
Battery
Idle air control (B) hi
Idle air control (A) low
System relay
Serial data
Engine temperature
Intake air temperature
Oxygen sensor (A)
Jiffy stand sensor (HDI)
Ground
Coil rear
Crank pos sensor (–)
Switched power
5V sensor power
Oxygen sensor (B)
Throttle pos sensor input
Map sensor input
5V sensor ground
Ground
Coil front
Crank pos sensor (+)
Vehicle speed sensor input
IGN 15A
Fuel
Pump 15A
Ignition
Switch
[33]
Battery 15A
ECM 15A
A
J
G
A
B
I
H
B
BK
30 Amp
MAXIFUSE
B
A
GND1
IGN − I
BATT – B
ACC – A
ECM
TSM/TSSM/HFSM
[61B]
Fuse Blocks
Top View
Top View
[119]
Accessories
Lights
Ignition
Fuel Pump
Start Relay
System Relay
ECM
Battery
Spare
P&A IGN
Instruments
Spare
System
Relay
Spare
Open
[119B]
To instruments and
indicator lamps
[61]
To right hand
controls
Engine
Harness
Powertrain
Ground
Point
4 3
2
2
3
1
2
3
1
12
2
3
1
2
3
1
2
5
6
7
8
9
10
11
12
13
14
17
18
19
21
23
24
25
26
28
29
30
31
35
36
2
5
6
7
8
9
10
11
12
13
14
17
18
19
21
23
24
25
26
28
29
30
31
35
33
33
36
2
1
3
4
12
2 1
2 1
6 7
10
12
1 2
1
1
1
2
2
2
Data
Link
Connector
Ignition
Coil
D C B A
D C B A
P
o
w
er
Coil
rear
Coil
front
P
o
w
er
K
T
E
S
U
87
87A
30
85
86
5
4
3
2
1
[133B]
[133A]
Front
O
2
Sensor
Rear
O
2
Sensor
HDI
only
INSTR 15A
G
H
To fuel pump
and sender
ASSY
1 2 3 4
Fuel Sender
Resistor ASSY
240
240
Battery
1
2
3
4
5
7
8
9
11
12
13
14
1
2
3
4
5
7
8
9
11
12
13
14
Idle Air
Control
D C B A
D C B A
Intake Air
Temperature/
Manifold Absolute
Pressure Sensor
Throttle
Position
Sensor
A B C D
A B C D
A
A
B
B
C
C
Engine
Temperature
Sensor
2 1
2 1
Rear
Injector
Front
Injector
A B
A B
A B
A B
R
BK
Crank
Position
Sensor
(CKP)
R
BK
1 2 3
1 2 3
SOCKET CONNECTOR
(B side)
PIN CONNECTOR
(A side)
E
K
T
S
U
I
C
Q
P
R
M
O
G
H
A
B
15A
15A
15A
P
R
I
J
C
D
15A
15A
15A
M
O
G
H
A
B
15A
15A
15A
K
L
S
U
F
15A
15A
E
Switch
Position
RED/BLACK
RED
RED/GRAY
OFF
ACC.
IGNITION
Ignition Switch Legend
Dot indicates continuity with red
wire in switch position indicated
HFSM only
Jiffy Stand
Sensor
BK
R
W
1 2 3
1 2 3
[5]
[20A]
Page 2
[22A]
Page 2
[141B]
Page 2
BN/GY
GY
GY
GY
GY
BK
BK
BK
BK
BK
BK
BK
BK
BK
BE
BEBE
BK
BK
BK
BK
BK
W/Y
V/W
V/W
Y/W
Y/W
Y/W
Y/R
Y/R
R/W
R/W
R/W
R/W
W/Y
O
O
R
R
R
R
R
R
R
R
R
BK
R
W
LGN/V
LGN/V
LGN/Y
LGN/V
LGN/Y
LGN/V
BN/GY
PK/GN
BN/GY
BE/GN
BE/GY
BE/GY
BE/GY
GN/BN
BK/PK
GN/GY
GN/BN
GN/GY
PK/GN
BK/PK
BE/GN
GY/BE
GY/BE
GY/BE
GN/O
Y/BE
Y/GN
Y/GN
PK/O
PK/Y
GY/V
O/GY
Y/GN
Y/GN
Y/GN
Y/GN
Y/BE
BN/R
BK/W
BK/W
BK/W
BK/O
BK/W
BK/W
BE/O
BK/W
BN/R
BE/O
GY/V
W/BK
BK/O
W/BK
W/BK
O/GY
R/BK
R/BK
R/BK
PK/Y
GN/O
PK/O
W/Y
W/Y
V/W
V/W
R/W
R/W
LGN/Y
LGN/Y
BK/PK
BK/PK
BE/GN
BE/GN
GN/GY
GN/GY
Y/GN
Y/GN
BK/O
BK/O
BN/R
BN/R
BK/W
BK/W
GY/V
GY/V
Engine
Case
Ground
Point
[141A]
[138B]
[138A]
[90B]
[90A]
[87B]
[87A]
[80B]
[80A]
[88B]
[88A]
[137B]
[137A]
[20B]
[83A]
[83B]
[79A]
[79B]
[85A]
[85B]
[22B]
[84A]
[84B]
[200A]
[200B]
[91A]
[145B]
[145A]
[78B]
[78A]
[208A]
[30B]
[30A]
et01156
Figure B-5. Engine Management (1 of 2) (XL): 2009 Sportster DOM. and INT. Models
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