Harley Davidson Sportster Models 2009. Service Repair Manual — page 35
1
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9
10
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13
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15
sm03715
10.
1.
Wave washer
Solenoid
2.
11.
Hex screw
O-ring
12.
3.
Round bushing
Solenoid cover
4.
13.
Rubber gasket
Square bushing
14.
5.
Contact plate
Plunger
6.
15.
Return spring
Post bolt
16.
7.
Paper insulator washer
Rubber boot
8.
17.
Hex nut
Hold-in terminal
9.
Jam nut
Figure 6-37. Solenoid Assembly
Assembly
1.
Assemble short post (field coil):
a.
From inside solenoid housing, insert sleeve on square
bushing into hole in solenoid housing.
b.
With the foot inboard against solenoid winding, align
hole in contact plate with hole in square bushing.
c.
Slide short post bolt through holes in hold-in terminal,
contact plate, square bushing and solenoid housing.
d.
At outside of solenoid housing, install round bushing,
O-ring and wave washer onto end of post. Install jam
nut, but do not tighten.
2.
Assemble long post (battery):
a.
On inside of solenoid housing, align hole in paper
insulator washer with hole in solenoid housing. Insert
sleeve on square bushing into holes.
b.
With the foot inboard against solenoid winding, align
hole in contact plate with hole in square bushing.
c.
Slide long post bolt through holes in contact plate,
square bushing, paper insulator washer and solenoid
housing.
d.
At outside of solenoid housing, install round bushing,
o-ring and wave washer onto end of post. Verify that
index pin on round bushing engages blind hole in
solenoid housing. Install jam nut, but do not tighten.
3.
Apply a light film of LUBRIPLATE 110 to plunger shaft and
install return spring. Install plunger in solenoid.
6-34 2009 Sportster Service: Electrical
4.
While depressing plunger, alternately tighten jam nuts to
65-80 in-lbs (7.3-9.0 Nm). Verify that contact plates have
not rotated out of alignment with plunger.
5.
Install new rubber gasket on solenoid cover flange.
6.
Install three hex screws to secure solenoid cover. Altern-
ately tighten hex screws until snug.
2009 Sportster Service: Electrical 6-35
6.15
IGNITION SYSTEM
TROUBLESHOOTING
See the ELECTRICAL DIAGNOSTIC MANUAL for complete
troubleshooting information.
6-36 2009 Sportster Service: Electrical
6.16
IGNITION AND LIGHT SWITCH
GENERAL
See
. A combination ignition and light switch is
located on the right side of the frame in front of the fuel tank.
The motorcycle key unlocks the ignition/light switch. The rider
rotates the key to select one of three positions. Refer to
.
NOTE
The ignition/light switch cannot be repaired. Replace the unit
if it fails.
To lock the switch, the key is removed in either OFF or ACC.
To leave the 4-way flashers and the tail lamp on and lock the
switch, the rider can remove the key in ACC. In ACC, the
instrument (icon) lamps, 4-way flashers (front and rear direc-
tional), horn and brake lamp are on or can be activated. On
HDI motorcycles the position lamp and taillight are on.
The automatic-on headlamp feature provides increased
visibility of the rider to other motorists. Be sure headlamp
is on at all times. Poor visibility of rider to other motorists
can result in death or serious injury. (00030b)
OFF
ACC.
IGNITION
2
1
3
sm01345
1.
Ignition OFF
2.
Accessory (ACC) ON
3.
Ignition ON
Figure 6-38. Ignition/Light Switch
Table 6-10. Ignition/Headlamp Switch Positions: Sportster Models
FUNCTION
SWITCH POSITION
LOCATION AND OPERATION
Ignition and lamps are off. Key may be removed.
OFF
Switch is on right side of steering neck.
Push in and turn key to operate.
Instrument lamps are on. Brake lamp and horn can
be activated. Key may be removed except for
international models.
ACC*
Ignition and lamps are on.
IGNITION*
*International models have an additional function - position lamp and tail lamp are also on.
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.
Unplug main fuse. See
.
3.
See
. Remove ignition switch face nut (5).
4.
Remove seat.
5.
Remove fuel tank. See
or
6.
Remove mounting screw (7). Remove switch cover (3).
Remove switch (2) from switch cover (3).
7.
Remove harness covering and cut switch wires 3.0 in.
(76.2 mm) from switch.
INSTALLATION
TOOL NAME
PART NUMBER
ULTRA TORCH UT-100
HD-39969
1.
Slide replacement conduit on harness wires.
2009 Sportster Service: Electrical 6-37
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)
2.
Observing color codes, install butt connectors to harness
wires. Complete butt splice to new ignition switch. Seal
butt splice connectors using ULTRA TORCH UT-100 (Part
No. HD-39969) or other radiant heating device. See
for more detailed
information.
3.
Slide conduit over butt splice connectors.
4.
See
. Insert ignition switch into hole of switch
cover. The word "TOP" stamped on the switch body should
face upward toward the lettering on the switch position
decal. Loosely install face nut (5).
5.
Install and tighten mounting screw (7) to 35-45 in-lbs (4.0-
5.1 Nm).
6.
Tighten face nut (5) to secure switch (2) within cover (3).
7.
Using two new cable straps (6), secure main harness to
frame backbone.
8.
Install fuel tank. See
or
.
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)
9.
Install seat.
10. Plug in 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)
11. Check ignition/light switch for proper operation.
O
F
F
AC C
IG
N
IT
IO
N
5
1
6
3
4
7
2
sm01346
1.
Butt connector
2.
Ignition/light switch
3.
Switch cover
4.
Decal
5.
Face nut
6.
Cable strap (2)
7.
Mounting screw
Figure 6-39. Ignition/Light Switch Assembly
6-38 2009 Sportster Service: Electrical
6.17
ELECTRONIC CONTROL MODULE (ECM)
GENERAL
See
. The Electronic Control Module (ECM) (1) is
mounted in a bracket on the rear fender under the seat. The
ECM receives data from sensors such as the crank position
(CKP) sensor and the temperature manifold absolute pressure
(TMAP) sensor. The ECM uses this data to time the firing of
the spark from the ignition coil as well as providing other engine
management functions.
NOTE
The ECM cannot be repaired. Replace the unit if it fails.
1
1
4
5
2
3
sm00916
1.
Electronic Control Module (ECM)
2.
ECM wiring harness connector [78B]
3.
Connector latch
4.
ECM latch (2)
5.
Antenna (H-DSSS system only)
Figure 6-40. Electronic Control Module (ECM): XL Models
1
1
2
sm05525
1.
Fastener (2)
2.
Electronic Control Module
Figure 6-41. Electronic Control Module (ECM): XR Models
REMOVAL
XL Models
1.
Remove seat.
To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before pro-
ceeding. (00251b)
2.
Unplug main fuse. See
3.
. Depress connector latch (3) and unplug
ECM wiring harness connector [78B] (2) from ECM (1).
4.
Gently bend back latches (4) and pull ECM straight up
from mounting posts.
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
2.
Remove rear fender. See
3.
See
. Remove fasteners (1) and ECM (2).
INSTALLATION
XL Models
1.
See
. Install ECM (1) on mounting posts. Press
down gently on ECM until latches (4) click, locking ECM
in place.
2.
Plug ECM wiring harness connector [78B] (2) into ECM.
Gently press connector until latch (3) clicks in place.
3.
Plug in main fuse.
4.
Perform reprogramming and password learn procedure.
See the electrical diagnostic manual for instructions.
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)
5.
Install seat.
XR Models
1.
See
. Install ECM (2) and fasteners (1).
2.
Tighten fasteners to 18-22 in-lbs (2.0-2.5 Nm).
3.
Install rear fender. See
2009 Sportster Service: Electrical 6-39
4.
Plug in main fuse.
5.
Perform reprogramming and password learn procedure.
See the electrical diagnostic manual for instructions.
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)
6.
Install seat.
6-40 2009 Sportster Service: Electrical
6.18
SPARK PLUG CABLES
GENERAL
Resistor-type high-tension spark plug cables have a carbon-
impregnated fabric core (instead of solid wire) for radio noise
suppression and improved reliability of electronic components.
Use the exact replacement cable for best results.
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.
Unplug main fuse. See
.
3.
Remove seat. See
.
4.
Remove fuel tank. See
.
5.
XL models only: See
. Remove screw (1)
securing left wire harness caddy (2) to right wire harness
caddy. See
. Carefully disen-
gage left wire harness caddy and pull away from frame
backbone.
NOTE
When disconnecting each spark plug cable from its spark plug
terminal, always grasp and pull on the rubber boot at the end
of the cable assembly (as close as possible to the spark plug
terminal). Do not pull on the cable portion itself. Pulling on the
cable will damage the cable's carbon core.
6.
See
. Pull front spark plug boot
and cable (2) from left side ignition coil (1) tower.
1
2
3
sm03784
1.
Screw
2.
Left wire harness caddy
3.
Ignition coil
Figure 6-42. Ignition Coil and Left Wire Harness Caddy (XL
Models Only)
7.
Pull rear spark plug boot (3) and cable from right side
ignition coil tower.
8.
Unplug spark plug boot and cable assemblies from front
and rear spark plugs.
9.
XL models only: Disengage rear spark plug cable from
notch in right wire harness caddy (5) and remove cable
from vehicle.
10. XR models only: See
. Disengage rear spark
plug cable from wire harness caddy (5) and remove cable
from vehicle.
1
2
3
4
5
sm03785
1.
Ignition coil
2.
Front spark plug cable boot
3.
Rear spark plug cable boot
4.
Rear spark plug cable
5.
Notch in right wire harness caddy
Figure 6-43. Spark Plug Cable Routing (XL Models Only)
2009 Sportster Service: Electrical 6-41
1
2
4
5
3
sm05528
1.
Ignition coil
2.
Front spark plug cable boot
3.
Rear spark plug cable boot
4.
Rear spark plug cable
5.
Harness caddy
Figure 6-44. Spark Plug Cable Routing (XR Models Shown)
11. XL models only: See
. Remove rear spark
plug cable (2) from curved trough on wire harness caddy
(1). Cut cable strap (4). Feed spark plug cable out from
between frame and engine and remove cable from vehicle.
Remove cable strap from mounting boss on caddy latch
clip (5). Discard cable strap.
1
2
3
2
4
5
sm03786
1.
Right wire harness caddy
2.
Rear spark plug cable
3.
Engine sub-harness
4.
Cable strap
5.
Caddy latch clip
Figure 6-45. Rear Spark Plug Cable Routing (XL Models
Only)
INSTALLATION
1.
See
or
. Plug rear spark plug cable
boot (3) into right side ignition coil (1) tower.
2.
XL models only: Route cable between wire harness
caddies, and down through notch (5) in right caddy, toward
right side of engine.
3.
XR models only: Route rear spark plug cable through
harness caddy (5) as shown.
4.
XL models only: See
. Route rear spark plug
cable (2) in trough in right wire harness caddy (1), over
top of engine sub-harness (3) and back toward left side
of engine.
5.
XL models only: See
. Install new barbed
cable strap (3) onto spark plug cable (1), 7.0-7.25 in. (178-
184 mm) from tip of spark plug cable boot (2), orienting
cable strap so that spark plug cable is above mounting
boss on caddy latch clip when barbed prong on cable strap
is inserted in hole in boss. Press cable strap barbed prong
firmly into hole in caddy latch clip mounting boss.
6-42 2009 Sportster Service: Electrical
6.
Plug rear spark plug cable and boot onto rear spark plug
until it clicks.
7.
or
. Plug front spark plug cable
and boot (2) into left side ignition coil (1) tower. Plug other
end of cable onto front spark plug until it clicks.
NOTE
Make sure rear spark plug cable is routed properly and cannot
chafe against frame, fuel tank or rear cylinder head.
8.
XL models only: See
. Mate left wire harness
caddy (2) to right wire harness caddy. Secure with screw
(1) and tighten. See
.
9.
Install fuel tank. See
or
.
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)
10. Install seat. See
or
.
11. Plug in main fuse. See
.
12. Start vehicle and verify proper ignition function.
1
2
3
4
sm03787
1.
Rear spark plug cable
2.
Spark plug boot (spark plug end)
3.
Barbed cable strap
4.
7.0-7.25 in. (178-184 mm)
Figure 6-46. Rear Spark Plug Cable and Cable Strap (XL
Models Only)
2009 Sportster Service: Electrical 6-43
6.19
IGNITION COIL
GENERAL
The ignition coil is attached to a mounting bracket secured by
the front fuel tank mounting bolt. The unit is divided into sep-
arate front and rear coils that fire the spark plugs one cylinder
at a time.
The ignition coil is mounted on the left half of a two-piece
bracket assembly. The right half of the bracket assembly
secures the ignition switch and right wire harness caddy to the
vehicle. The two bracket halves are secured together with a
screw.
NOTE
The ignition coil cannot be repaired. Replace the unit if it fails.
TROUBLESHOOTING
See the ELECTRICAL DIAGNOSTIC MANUAL for complete
troubleshooting information.
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 on
bottom left side of fuel tank. See
To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before pro-
ceeding. (00251b)
2.
Unplug main fuse. See
.
3.
Remove seat.
.
4.
Remove fuel tank. See
.
5.
XL Models Only: See
. Remove screw (1)
securing left wire harness caddy (2) to right wire harness
caddy. See
. Carefully disen-
gage left wire harness caddy and pull away from frame
backbone.
NOTE
When disconnecting each spark plug cable from its spark plug
terminal, always grasp and pull on the rubber boot at the end
of the cable assembly (as close as possible to the spark plug
terminal). Do not pull on the cable portion itself. Pulling on the
cable will damage the cable?s carbon core.
1
2
3
sm03784
1.
Screw
2.
Left wire harness caddy
3.
Ignition coil
Figure 6-47. Ignition Coil and Left Wire Harness Caddy (XL
Models Only)
6.
. Unplug coil harness con-
nector [83B] (2) from ignition coil (1).
7.
Pull front spark plug boot and cable (3) from left ignition
coil tower.
8.
Pull rear spark plug boot and cable (4) from right ignition
coil tower.
9.
Remove screw (5) securing coil bracket (6). Remove coil
and bracket from vehicle.
10. See
. Remove two screws (4)
to separate ignition coil (1) from mounting bracket (2) and
plate (3).
6-44 2009 Sportster Service: Electrical
1
2
3
4
5
6
sm03788
1.
Ignition coil
2.
Coil harness connector [83B]
3.
Front spark plug boot and cable
4.
Rear spark plug boot and cable
5.
Screw
6.
Mounting bracket
Figure 6-48. Ignition Coil Mounting and Connections: XL
Models Only
6
2
1
3
4
5
sm05538
1.
Ignition coil
2.
Coil harness connector [83B]
3.
Front spark plug boot and cable
4.
Rear spark plug boot and cable
5.
Screw
6.
Mounting bracket
Figure 6-49. Ignition Coil Mounting and Connections: XR
Models Only
1
2
3
4
5
sm03789
1.
Ignition coil
2.
Mounting bracket
3.
Plate
4.
Screw (2)
5.
Spark plug cables (2)
Figure 6-50. Ignition Coil Mounting: XL Models Only
5
2
3
4
1
sm05540
1.
Ignition coil
2.
Mounting bracket
3.
Plate
4.
Screw (2)
5.
Spark plug cables (2)
Figure 6-51. Ignition coil Mounting: XR Models Only
INSTALLATION
1.
XL Models Only: see
. Position new ignition
coil (1) on underside of mounting bracket (2). Fasten coil
to mounting bracket with two screws (4) and nut plate (3).
Tighten screws to 24-72 in-lbs (2.7-8.1 Nm).
2.
XR Models Only: see
. Position plate (3) over
new ignition coil (1). Place screws (4) through coil and
plate and secure to mounting bracket (2). Tighten screws
to 24-72 in-lbs (2.7-8.1 Nm).
3.
or
. Slide coil (1) with mounting
bracket (6) into position. Make sure all wiring harnesses
from front end of vehicle are positioned between coil
bracket upright and vehicle frame. Secure bracket with
screw (5) and tighten to 35-45 in-lbs (4.0-5.1 Nm).
2009 Sportster Service: Electrical 6-45
4.
Plug spark plug cables into ignition coil towers; front spark
plug cable (3) to left side of coil, rear spark plug cable (4)
to right side of coil.
5.
XL Models Only: see
. Mate left wire harness
caddy (2) to right wire harness caddy. Secure with screw
(1) and tighten. See
.
6.
Install fuel tank. See
or
.
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. See
or
.
8.
Plug in main fuse. See
.
6-46 2009 Sportster Service: Electrical
6.20
CHARGING SYSTEM
GENERAL
. The charging system consists of the alternator
and voltage regulator. See schematic diagram of the charging
B.2 WIRING DIAGRAMS, 2009 Sportster
.
SOCKET CONNECTOR
PIN CONNECTOR
(A side)
(B side)
30 AMP
MAXIFUSE
[5]
POWERTRAIN
GROUND
POINT
BK
BK
BK
[77A]
[77B]
1 2
STATOR
1 2
VOLTAGE
REGULATOR
BATTERY
–
+
BK
[46B]
[46A]
R
R
B A
BK
BK
BK
BK
[GND1]
R
R
–
+
sm01665
Figure 6-52. Charging System Circuit (All Models)
ALTERNATOR
The alternator consists of two main components: the rotor
which is mounted on the engine sprocket shaft, and the stator,
which is bolted to the engine crankcase.
VOLTAGE REGULATOR
The regulator is a series regulator with shunt control. The circuit
combines the functions of rectifying and regulating.
NOTE
For charging system troubleshooting and diagnostic proced-
ures, see ELECTRICAL DIAGNOSTIC MANUAL.
2009 Sportster Service: Electrical 6-47
6.21
HEADLAMP
REPLACEMENT: XL 883C/XL 1200C
NOTE
The headlamp is a replaceable bulb (element) type. Replace
with the specified H4 halogen bulb, only.
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.
Remove screw and chrome molding ring.
3.
See
. Hold headlamp reflector/lens (3) and
compress release tabs (6) on sides of headlamp connector
[38] (2). Pull connector from spade terminals.
4.
Remove headlamp reflector/lens and metal adapter ring
(1).
5.
Pull rubber boot (5) from rubber finger gasket (4) on back
of reflector/lens.
6.
. Press ends of retaining clip (3) to unhook
from notched retaining post (4).
7.
Pivot retaining clip back and remove bulb (5).
To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before pro-
ceeding. (00251b)
8.
Fit replacement bulb (5).
NOTE
The tab opposite the center spade connector of bulb (5) fits
the top notch (2) in the reflector which points to the top of the
reflector/lens (6).
9.
Pivot the retaining clip (3) over the bulb and press the
ends into the retaining post (4).
10. If necessary, remove and fit a replacement rubber finger
gasket (1).
NOTE
The smaller single notch of the rubber finger gasket (1) will fit
over the top notch (2) of the reflector/lens (6).
11. If replacing the small position lamp in the side of the
reflector/lens on HDI XL 883C/XL 1200C models:
a.
Pull the spade connectors from the bulb holder.
b.
Pull the bulb holder from the reflector/lens.
c.
Quarter turn the bulb to remove and replace.
d.
Replace the bulb holder and mate connectors.
12. See
. Install rubber boot with word TOP (1)
over top notch.
13. Press center ring (2) down flush with base of bulb (3) and
press air out of boot to seal bore of boot to bulb and boot
flange to rubber finger gasket.
NOTE
Air will re-enter the rubber boot and raise the center ring above
bottom of bulb.
14. See
. Fit the adapter ring (2) to the
reflector/lens (7) and fit the adapter ring to the headlamp
shell (1).
NOTES
•
The two notches on the circumference of the adapter ring
will fit the two bulges on rim of headlamp shell.
•
A single tab on the circumference of the reflector will fit
the notch on the inside of the adapter ring.
•
The four fingers of the rubber finger gasket are installed
between the adapter ring and the reflector/lens.
15. Mate the headlamp connector (3) to the spade connector
on the bulb (10).
16. Press the reflector/lens assembly into the headlamp shell
matching the two notches on the moulding ring to the
bulges on the headlamp shell.
17. Rotate the moulding clockwise to lock the moulding ring
down on the reflector/lens. Install the moulding ring screw
(9) and tighten.
18. Plug in main fuse. See
.
19. After final assembly, align headlamp as described in
2
3
1
6
4
5
sm01290
1.
Adapter ring
2.
Headlamp connector [38]
3.
Reflector/lens
4.
Rubber finger gasket
5.
Rubber boot
6.
Connector release tab
Figure 6-53. Remove Headlamp
6-48 2009 Sportster Service: Electrical
3
3
2
1
6
5
4
sm01291
1.
Rubber finger gasket
2.
Top notch
3.
Retaining clip
4.
Retaining post
5.
Bulb
6.
Reflector/lens
Figure 6-54. Headlamp Assembly
3
2
1
sm01292
1.
TOP mark
2.
Center ring
3.
Bulb (element)
Figure 6-55. Headlamp Boot (TOP Mark)
2009 Sportster Service: Electrical 6-49
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