Harley Davidson Sportster Models 2009. Service Repair Manual — page 37

3.

See

Figure 6-81

. Insert license plate lamp harness (6) into

fender harness clip (1) on left side of fender.

4.

Feed harness through feed-through hole (5) on left side
of rear fender.

5.

See

Figure 6-80

. Plug in license plate lamp connector [40].

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.

7.

Install rear wheel. See

2.4 WHEELS

. Make certain rear

wheel is properly aligned and rear drive belt is properly
tensioned. See

1.16 REAR BELT DEFLECTION

.

8.

Plug in main fuse. See

6.38 MAIN FUSE

.

9.

Remove vehicle from lift.

Be sure headlamp, tail and stop lamp and turn signals are
operating properly before riding. Poor visibility of rider to
other motorists can result in death or serious injury.
(00478b)

10. Turn ignition switch ON. Verify that license plate lamp

module is operating properly. Turn ignition switch OFF.

REMOVAL (HDI ONLY)

See

Figure 6-83

. The XL 1200N built for international markets

incorporates a center-mounted license plate holder and lamp
assembly.

sm03732

Figure 6-83. License Plate Holder and Lamp Assembly: XL

1200N (HDI)

1.

Position vehicle upright on a suitable lift. Unplug main
fuse. See

6.38 MAIN FUSE

2.

Remove seat. See

2.38 SEAT: XL MODELS

.

3.

Remove rear wheel. See

2.4 WHEELS

.

4.

See

Figure 6-84

. Unplug license plate lamp harness con-

nector [40] (2).

5.

See

Figure 6-85

. Remove license plate lamp harness (3)

from harness bracket (1) and three harness clips (2). Feed
harness and connector in through hole in rear fender.

6.

See

Figure 6-86

. Remove two fender support screws with

washers (4). Remove screw with washer (5) securing rear
fender to fender brace (2). Remove fender brace and
license plate holder assembly (1) from vehicle.

1

2

4

3

sm03733

1.

Interconnect harness

2.

License plate lamp harness connector [40]

3.

Right turn signal/brake/tail lamp harness con-
nector [19]

4.

Left turn signal/brake/tail lamp harness con-
nector [18]

Figure 6-84. Rear Lighting Interconnect Harness: XL 1200N

(HDI)

4

3

2

1

5

sm03734

1.

Harness bracket

2.

Harness clip (3)

3.

License plate lamp harness

4.

License plate holder

5.

Feedthrough hole

Figure 6-85. License Plate Holder and Lamp Harness

Mounting: XL 1200N (HDI)

HOME

6-66 2009 Sportster Service: Electrical

1

2

3

4

5

sm03735

1.

License plate holder

2.

Rear fender brace

3.

Tab

4.

Fender support screw with washer (2)

5.

Screw with washer

Figure 6-86. License Plate Holder: XL 1200N (HDI)

7.

See

Figure 6-87

. Remove two screws with washers (2)

securing license plate lamp housing to license plate holder
(1). See

Figure 6-88

. Separate lamp housing (3) and

gasket (2) from license plate holder (1).

1

2

sm03736

1.

License plate holder

2.

Screw with washer (2)

Figure 6-87. License Plate Holder and Lamp Mounting

Screws: XL 1200N (HDI)

1

2

3

sm03737

1.

License plate holder

2.

Gasket

3.

Lamp housing

Figure 6-88. Lamp Housing Separated from License Plate

Holder: XL 1200N (HDI)

8.

See

Figure 6-89

. Insert the tip of a small flat bladed

screwdriver (3) into each slot (2) in lamp housing. Gently
tilt screwdriver handle outward (away from lamp housing)
just enough to disengage housing from cover. Separate
housing from cover and slide housing away from tabs (4)
in cover.

9.

See

Figure 6-90

. If replacing a light bulb (2), gently pull

bulb straight out of socket assembly (3). Push new light
bulb into socket.

HOME

2009 Sportster Service: Electrical 6-67

1

4

3

2

2

5

sm03738

1.

Lamp housing

2.

Slot (2)

3.

Screwdriver

4.

Tab (2)

5.

Feedthru slots for harness wires

Figure 6-89. Removing License Plate Lamp Housing Cover:

XL 1200N (HDI)

1

2

4

3

5

6

sm03739

1.

Lamp housing

2.

Light bulb (2)

3.

Socket assembly

4.

Housing cover

5.

Tab (2)

6.

Slot (2)

Figure 6-90. Replacing License Plate Light Bulbs: XL 1200N

(HDI)

INSTALLATION (HDI ONLY)

1.

If reusing license plate lamp housing, see

Figure 6-90

.

Carefully fit housing cover (4) onto lamp housing (1),
sliding tabs on cover (5) into slots (6) in housing. Make
sure harness wires fit into feedthrough slots in housing.
Gently snap cover onto housing, being careful not to pinch
wires.

2.

See

Figure 6-88

. Fit gasket (2) onto lamp housing (3).

3.

See

Figure 6-87

. Install lamp housing onto license plate

holder (1) with lamp housing cover facing upward. Secure
with two screws (2). Tighten to 14-16 in-lbs (1.2-1.3 Nm).

4.

See

Figure 6-86

. Fit tab (3) on license plate holder (1) into

slot in rear fender brace (2). Install assembly onto vehicle.
Install screw with washer (5) through fender and into
fender brace. Tighten only finger-tight at this time.

5.

Install two screws with washers (4) through fender struts,
fender, fender brace and into threaded inserts in license
plate holder. See

Figure 6-91

. Make sure license plate

holder threaded inserts (3) fit into holes (4) in fender brace
(2). Tighten to 132-216 in-lbs (14.9-24.4 Nm).

6.

Now tighten screw securing fender to center of fender
brace to 20-25 in-lbs (2.3-2.8 Nm).

7.

See

Figure 6-85

. Install license plate lamp harness (3)

into three clips (2) in fender bracket. Feed harness and
connector through feedthrough hole (5) in fender. Press
harness into harness bracket (1).

8.

See

Figure 6-84

. Plug license plate lamp harness con-

nector [40B] into interconnect harness connector [40B]
(2).

9.

Install rear wheel. See

2.4 WHEELS

.

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

2.38 SEAT: XL MODELS

.

11. Plug in main fuse. See

6.38 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)

12. Turn ignition switch to IGNITION and check license plate

lamp to make sure both bulbs are lit. Turn ignition switch
OFF.

HOME

6-68 2009 Sportster Service: Electrical

2

1

3

4

sm03742

1.

License plate holder

2.

Rear fender brace

3.

Threaded insert

4.

Hole

Figure 6-91. License Plate Holder and Rear Fender Brace:

XL 1200N (HDI)

HOME

2009 Sportster Service: Electrical 6-69

6.26

REAR LIGHTING CONVERTER MODULE: XL
1200N (DOMESTIC ONLY)

GENERAL

NOTE

HDI XL 1200N models are equipped with a sealed LED tail
lamp, brake lamp and turn signal assembly in each rear turn
signal housing. Instead of a rear lighting converter module, this
model is equipped with an interconnect harness between main
harness rear lighting connector [7B] and the turn signal [18]
and [19] and license plate lamp [40] harness connectors.

The domestic XL 1200N rear turn signal lamps also serve as
tail lamps and brake lamps. Dual filament bulbs provide these
features; one filament provides the tail lamp function while the
other filament provides the dual function of turn signal and
brake lamp.

In order for a single filament to function both as turn signal and
brake lamp, a converter module is required. See

Figure 6-92

.

The converter module (1) is incorporated into an interconnect
harness that connects the main wiring harness to the rear
lighting harnesses.

See

Figure 6-93

. The converter module (3) is located in front

of the battery, under the frame "Y" section.

2

6

3

4

5

1

sm01248

1.

Converter module

2.

Rubber mounting tab

3.

Main harness connector [7]

4.

License plate lamp connector [40]

5.

Right turn signal connector [18]

6.

Left turn signal connector [19]

Figure 6-92. Converter and Interconnect Harness

REMOVAL

1.

Remove seat.

2.

Open left side cover. See

2.20 LEFT SIDE COVER

.

Prevent accidental vehicle start-up, which could cause
death or serious injury. First disconnect negative (-) battery
cable at engine and then positive (+) cable from battery.
(00280b)

3.

Remove battery. See

1.17 BATTERY MAINTENANCE

.

4.

See

Figure 6-94

. Unplug the following harness connectors:

a.

Left rear lighting harness [19] (1)

b.

Right rear lighting harness [18] (2)

c.

License plate lamp harness [40] (3)

d.

Main wiring harness [7] (4)

5.

See

Figure 6-95

. Push in on converter module rubber

mounting tab to release it from hole in frame.

6.

See

Figure 6-96

. Reach up under frame "Y" section and

pull converter module down. Carefully remove module and
interconnect harness assembly from vehicle.

1

3

2

sm01249

1.

Oil tank

2.

Relay/fuse blocks

3.

Converter module

Figure 6-93. Converter Module Location

HOME

6-70 2009 Sportster Service: Electrical

4

2

1

3

sm01250

1.

Left rear lighting harness connector [19]

2.

Right rear lighting harness connector [18]

3.

License plate lamp harness [40]

4.

Main wiring harness connector [7]

Figure 6-94. Rear Lighting Harness Connectors: XL 1200N

INSTALLATION

1.

See

Figure 6-96

. Feed converter module/interconnect

harness connectors up through battery compartment, for-
ward of battery strap bracket.

2.

Position converter module up inside frame, under "Y"
section. See

Figure 6-95

. Pull rubber mounting tab through

hole in frame to secure module.

3.

See

Figure 6-94

. Plug in the following harness connectors:

a.

Left rear lighting harness [19] (1)

b.

Right rear lighting harness [18] (2)

c.

License plate lamp harness [40] (3)

d.

Main wiring harness [7] (4)

4.

Install battery and connect battery cables. See

1.17 BAT-

TERY MAINTENANCE

.

Be sure headlamp, tail and stop lamp and turn signals are
operating properly before riding. Poor visibility of rider to
other motorists can result in death or serious injury.
(00478b)

5.

Close left side cover. See

2.20 LEFT SIDE COVER

.

6.

Turn ignition switch ON and test rear lighting functions.
Make sure tail lamps, brake lamps and turn signals operate
properly. Make sure license plate lamp is illuminated. Turn
ignition switch OFF.

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.

sm01251

Figure 6-95. Converter Module Rubber Mounting Tab

sm01252

Figure 6-96. Removing/Installing Converter Module

HOME

2009 Sportster Service: Electrical 6-71

6.27

REAR STOP LAMP SWITCH

GENERAL

XL models only: See

Figure 6-97

. The rear stop lamp switch

(3) is located behind the rear brake master cylinder reservoir
under the left side cover. The rear stop lamp switch is threaded
into a tee nut in the rear brake line.

XR models only: The rear stop lamp switch is located under-
neath the motorcycle near the rear brake master cylinder
reservoir. The rear stop lamp switch is threaded into a tee nut
in the rear brake line.

The stop lamp switch is an open type switch which closes with
hydraulic pressure. When the pressure in the line reaches a
preset level, the rear stop lamp switch is tripped and the rear
stop lamp illuminates.

NOTE

The rear stop lamp switch cannot be repaired. Replace the
unit if it fails.

REPLACEMENT

To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before pro-
ceeding. (00251b)

1.

Remove left side cover. See

2.20 LEFT SIDE COVER

.

Remove main fuse. See

6.38 MAIN FUSE

.

2.

XL models only: move rear brake master cylinder reser-
voir out of the way:

a.

Remove the rear brake master cylinder reservoir
cover; grasp cover and pull straight away from reser-
voir.

b.

Remove reservoir mounting screw and secure reser-
voir upright out of the way. See

2.15 REAR BRAKE

MASTER CYLINDER RESERVOIR

.

3.

See

Figure 6-97

or

Figure 6-98

. Pull terminal sockets from

spade connections (4) on stop lamp switch.

4.

Remove stop lamp switch (3) from tee nut (2).

5.

Thread new stoplight switch (3) to tee nut (2) on brake
line. Tighten switch to 84-120 in-lbs (9.5-13.6 Nm).

6.

Install terminal sockets on switch spade connections (4).

7.

XL models only: Install rear brake master cylinder
reservoir:

a.

Replace the reservoir mounting screw. Tighten to
20-25 in-lbs (2.3-2.8 Nm).

b.

Replace the plastic guard around the reservoir.

8.

Install main fuse. Install left side cover.

After repairing the brake system, test brakes at low speed.
If brakes are not operating properly, testing at high speeds
can cause loss of control, which could result in death or
serious injury. (00289a)

9.

Refill master cylinder and bleed brakes. See

1.8 BLEEDING HYDRAULIC BRAKE SYSTEM

. Test

operation of rear brake.

After repairing the brake system, test brakes at low speed.
If brakes are not operating properly, testing at high speeds
can cause loss of control, which could result in death or
serious injury. (00289a)

10. Test operation of brake lamp with the rear brake applied

and the ignition/light switch turned ON.

4

1

3

2

sm01253

1.

Rear brake line

2.

Tee nut

3.

Rear stop lamp switch

4.

Spade connector terminal socket (2) [121]

Figure 6-97. Rear Stop Lamp Switch: XL Models Only

HOME

6-72 2009 Sportster Service: Electrical

1

2

4

3

sm05579

1.

Rear brake line

2.

Tee nut

3.

Rear stop lamp switch

4.

Spade connector terminal socket (2) [121]

Figure 6-98. Rear Stop Lamp Switch: XR Models Only

HOME

2009 Sportster Service: Electrical 6-73

6.28

CRANK POSITION SENSOR (CKP)

GENERAL

The crank position (CKP) sensor is a variable reluctance (VR)
sensor that generates an AC signal by sensing the passing of
the 30 teeth cast into the engine's left side flywheel. Two con-
secutive teeth are missing in the flywheel to establish a refer-
ence point. The CKP sensor sends a signal to the Electronic
Control Module (ECM). This signal is used to reference engine
position (TDC) and engine speed. The CKP sensor is located
near the lower front left corner of the engine crankcase.

NOTE

The crank position sensor cannot be repaired. Replace the
unit if it fails.

REMOVAL

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

6.38 MAIN FUSE

.

2.

See

Figure 6-99

. Disconnect CKP sensor harness con-

nector [79A] from wiring harness connector [79B] (4), loc-
ated along left frame downtube.

3.

Remove CKP wire harness from j-clip (3).

4.

Remove screw (2). Carefully remove CKP sensor (1) and
o-ring from engine crankcase.

4

2

1

3

sm01279

1.

Crank position (CKP) sensor

2.

Screw

3.

Wire harness j-clip

4.

CKP sensor harness connector [79] (under pro-
tective rubber boot)

Figure 6-99. Crank Position (CKP) Sensor (Typical, XL

Model Shown)

INSTALLATION

NOTE

The CKP sensor o-ring has a blue teflon coating that provides
lubrication during installation. It is not necessary to coat the o-
ring with engine oil or other lubricant to install it.

1.

See

Figure 6-99

. Carefully install CKP sensor (1) and o-

ring into engine crankcase with screw (2). Tighten to 80-
100 in-lbs (9.0-11.3 Nm).

2.

Route CKP sensor wiring harness through j-clip (3).

3.

Attach CKP sensor harness connector [79A] to wiring
harness connector [79B] (4).

4.

Plug in main fuse. See

6.38 MAIN FUSE

.

5.

Start engine and verify operation.

HOME

6-74 2009 Sportster Service: Electrical

6.29

ALTERNATOR

REMOVAL AND DISASSEMBLY

1.

Open left side cover. See

2.20 LEFT SIDE COVER

.

Prevent accidental vehicle start-up, which could cause
death or serious injury. First disconnect negative (-) battery
cable at engine and then positive (+) cable from battery.
(00280b)

2.

Disconnect negative battery cable from crankcase. Discon-
nect positive (+) battery cables from battery. See

1.17 BATTERY MAINTENANCE

. Close left side cover.

3.

Remove primary cover. See

5.3 PRIMARY CHAIN

ADJUSTER

.

4.

Remove clutch assembly, primary chain and engine
sprocket/rotor assembly as a unit. See

5.5 PRIMARY

DRIVE AND CLUTCH: XL MODELS

or

5.6 PRIMARY

DRIVE AND CLUTCH: XR MODELS

.

5.

Remove/disassemble rotor and/or stator, as required.
Refer to the following procedures.

Rotor

1.

Remove bolts securing alternator rotor to engine sprocket.

2.

See

Figure 6-100

. Position blocking (2) under rotor (1).

Press sprocket (3) free of rotor.

NOTE

Resistance to sprocket/rotor disassembly is due in part to the
magnetic force of the permanent rotor magnets.

Stator

1.

See

Figure 6-101

. Open external latch (4) and unplug

stator harness (2) connector [46B] from voltage regulator
harness (3) connector [46A] (1). See

6.3 VOLTAGE

REGULATOR

for procedure.

2.

Make note of cable strap positions and remove cable
straps from stator harness.

3.

Withdraw stator harness from opening between right
crankcase half and gear case cover.

4.

See

Figure 6-102

. Using a T-27 TORX driver, remove and

discard screws (3) securing stator to left crankcase half.

5.

Remove two screws (9) and harness retainer (8).

6.

Remove stator harness grommet (10) from left crankcase
half.

7.

Withdraw stator harness from grommet hole in left crank-
case half. Remove stator.

1

3

2

2

sm01163

1.

Rotor

2.

Blocking

3.

Sprocket

Figure 6-100. Removing Rotor from Sprocket

2

3

1

4

sm01124

1.

Stator connector [46]

2.

Stator harness

3.

Voltage regulator harness

4.

External latch

Figure 6-101. Stator Connector Location (Typical, XL

Models Shown)

HOME

2009 Sportster Service: Electrical 6-75

4

6

8

3

1

9

10

5

2

7

sm01666

1.

Motor sprocket

2.

Rotor

3.

Screw (4)

4.

Stator

5.

Stator wiring harness

6.

Connector [46B]

7.

Bolt (8)

8.

Stator harness retainer

9.

Screw (2)

10. Stator harness grommet

Figure 6-102. Alternator Components

CLEANING AND INSPECTION

1.

Clean rotor with a petroleum-base solvent. Remove all
foreign material from rotor magnets. Replace rotor if rotor
magnets are cracked or loose.

2.

Clean stator by wiping with a clean cloth.

3.

Examine stator leads for cracked or damaged insulation.

NOTE

The rotor and stator can be replaced individually if either is
damaged.

ASSEMBLY AND INSTALLATION

Depending on whether the rotor, the stator, or both the rotor
and stator were removed, perform the applicable procedures
which follow:

Stator

1.

See

Figure 6-102

. Feed stator wiring harness (5) with

attached grommet (10) into open grommet hole in left
crankcase half.

2.

Apply a light coating of clean engine oil or chaincase lub-
ricant to grommet. Press grommet into hole in left crank-
case half.

3.

Position stator (4) on left crankcase half. Secure stator
using new TORX screws. Use TORX driver to tighten
screws to 30-40 in-lbs (3.4-4.5 Nm).

4.

Position stator harness retainer (8) over harness and onto
engine crankcase with mounting holes facing aft. Secure
with two screws (9). Make sure harness is not pinched.
Tighten screws to 56 in-lbs (6.3 Nm) (maximum). Do not
exceed torque specification.

5.

Route stator wiring harness across top of crankcase halves
to right side of engine. Route stator harness downward

HOME

6-76 2009 Sportster Service: Electrical

through opening between right crankcase half and gear-
case cover.

6.

Route stator harness forward and then upward along
inboard side of right frame downtube.

7.

See

Figure 6-101

. Connect stator harness (2) to voltage

regulator harness (3) at connector [46] (1) and lock
external latch (4) in place. See

6.3 VOLTAGE REGU-

LATOR

for procedure.

8.

Secure stator harness and neutral switch with cable straps
as noted from stator removal.

Rotor

1.

See

Figure 6-103

. Position rotor (1) on sprocket (2). Align

holes in sprocket with holes in rotor. Apply a drop of
LOCTITE THREADLOCKER 243 (blue) to threads of each
mounting bolt. Insert mounting bolts through rotor and
start bolts into tapped holes in sprocket.

2.

Position a section of pipe (3) with an inside diameter larger
than the sprocket mounting hub over center of rotor.

3.

Press rotor onto sprocket. Tighten screws to 120-140 in-
lbs
(13.6-15.8 Nm).

Final Assembly

1.

Install clutch assembly, primary chain and engine
sprocket/rotor assembly as a unit. See

5.5 PRIMARY

DRIVE AND CLUTCH: XL MODELS

or

5.6 PRIMARY

DRIVE AND CLUTCH: XR MODELS

.

2.

Install primary cover, left footrest assembly and gear shift
lever. See

5.3 PRIMARY CHAIN ADJUSTER

.

3.

Open left side cover. See

2.20 LEFT SIDE COVER

.

Connect positive (+) battery cable first. If positive (+) cable
should contact ground with negative (-) cable connected,
the resulting sparks can cause a battery explosion, which
could result in death or serious injury. (00068a)

4.

Connect battery cables, positive (+) cable first. See

1.17 BATTERY MAINTENANCE

. Close left side cover.

5.

Test charging system. See ELECTRICAL DIAGNOSTIC
MANUAL.

2

3

1

sm01164

1.

Rotor

2.

Sprocket

3.

Pipe section

Figure 6-103. Pressing Rotor onto Sprocket

HOME

2009 Sportster Service: Electrical 6-77

6.30

VEHICLE SPEED SENSOR (VSS)

GENERAL

The vehicle speed sensor (VSS) is powered and monitored by
the Electronic Control Module (ECM). The ECM processes the
vehicle speed signal and transmits this signal to the turn signal
module/turn signal security module (TSM/TSSM) and
speedometer through serial data.

NOTE

The vehicle speed sensor cannot be repaired. Replace the unit
if it fails.

REMOVAL

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

6.38 MAIN FUSE

.

2.

See

Figure 6-104

. Disconnect VSS harness connector

[65A] (1) from VSS (3) mounted on rear of engine case
below starter motor assembly.

3.

Remove screw (2). Carefully remove VSS and o-ring from
engine crankcase.

1

2

3

sm01280

1.

VSS connector [65]

2.

Screw

3.

Vehicle speed sensor (VSS)

Figure 6-104.Vehicle Speed Sensor: All Models (XL Shown)

INSTALLATION

NOTE

The new VSS o-ring has a teflon coating that provides lubrica-
tion during installation. It is not necessary to coat the o-ring
with engine oil or other lubricant to install it.

1.

See

Figure 6-104

. Carefully install VSS (3) and o-ring into

engine crankcase with screw (2). Tighten to 80-100 in-lbs
(9.0-11.3 Nm).

2.

Attach VSS harness connector [65A] (1) to VSS.

3.

Plug in main fuse. See

6.38 MAIN FUSE

.

4.

Start engine and test ride motorcycle to verify proper
operation.

HOME

6-78 2009 Sportster Service: Electrical

6.31

NEUTRAL INDICATOR SWITCH

GENERAL

See

Figure 6-105

. The neutral indicator switch (1) is threaded

into the right crankcase half (3) immediately forward of the
main drive gear (4). A short jumper wire assembly (2) connects
the switch to the harness connector [136] under the engine
crankcase.

A pin on the shifter drum contacts the neutral indicator switch
plunger, completing the neutral indicator circuit.

A motorcycle whose neutral indicator lamp does not light can
be tested to determine if the problem can be found:

In a burned out indicator lamp, the wire harness to the
instruments or in the main wire harness.

In the neutral indicator switch and its jumper wire.

If switch requires replacement, the rear muffler and rear
exhaust pipe must be removed to remove the transmission
sprocket cover. The drive belt and transmission sprocket must
also be removed; there is not enough clearance to allow the
removal of the switch without first removing the transmission
sprocket.

NOTE

The neutral indicator switch cannot be repaired. Replace the
switch if it fails.

4

1

3

2

sm01281

1.

Neutral indicator switch

2.

Jumper wire connector [136]

3.

Right crankcase half

4.

Main drive gear

Figure 6-105. Neutral Indicator Switch Location: All Models

(XL Shown)

REPLACEMENT

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

6.38 MAIN FUSE

.

2.

XL models: remove rear muffler and exhaust pipe. See

4.15 EXHAUST SYSTEM: XL MODELS

. XR models:

remove exhaust system. See

4.16 EXHAUST SYSTEM:

XR MODELS

.

3.

Remove sprocket cover and rear drive belt from transmis-
sion sprocket. See

5.7 DRIVE BELT

.

4.

Remove transmission sprocket. See

5.16 TRANSMISSION

SPROCKET

.

5.

See

Figure 6-106

. Unplug jumper wire connector (2) from

neutral indicator switch (1). Remove switch with washer
from right crankcase half (3).

6.

Note routing of neutral switch jumper wire down between
crankcase and rear of gearcase cover.

7.

If necessary in order to unplug neutral switch jumper wire
from neutral switch harness connector [136], cut cable
strap securing neutral switch harness and stator harness
to bottom right frame tube under oil pump.

8.

Install new neutral indicator switch with washer and tighten
to 120-180 in-lbs (13.6-20.3 Nm).

9.

Plug new neutral switch jumper wire into neutral indicator
switch [131]. Route jumper wire in same way that old
jumper was routed.

10. Plug jumper wire pin connector [136A] into harness socket

connector [136B]. Secure neutral switch harness and stator
harness with cable strap to bottom right frame tube under
oil pump.

11. Install transmission sprocket. See

5.16 TRANSMISSION

SPROCKET

.

12. Install secondary drive belt and sprocket cover. See

5.7 DRIVE BELT

.

13. Adjust drive belt tension and rear wheel alignment. See

1.16 REAR BELT DEFLECTION

.

14. XL models: install rear muffler and exhaust pipe. See

4.15 EXHAUST SYSTEM: XL MODELS

. XR models:

install exhaust system. See

4.16 EXHAUST SYSTEM: XR

MODELS

.

15. Plug in main fuse. See

6.38 MAIN FUSE

.

16. Turn ignition switch on and check the operation of the

neutral indicator lamp.

HOME

2009 Sportster Service: Electrical 6-79

2

3

1

sm01284

1.

Neutral indicator switch

2.

Jumper wire connector [131]

3.

Right crankcase half

Figure 6-106. Neutral Indicator Switch: All Models (XL

Shown)

HOME

6-80 2009 Sportster Service: Electrical

6.32

MAIN WIRING HARNESS

GENERAL

The main wiring harness supplies power to all electrical sys-
tems on the vehicle. It is an electrical conduit, passing signals
from sensors and switches, as well transferring data between
the ECM, TSM/TSSM/HFSM and speedometer.

Various wiring sub-harnesses, such as the engine sub-harness,
handlebar control harnesses, instruments harness and rear
lighting harness are connected to the main wiring harness.
These sub-harnesses are discussed elsewhere in this manual.

See

B.2 WIRING DIAGRAMS

of this manual for wiring

schematics. See the ELECTRICAL DIAGNOSTIC MANUAL
for testing and 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. See

4.6 FUEL TANK: XL MODELS

or

4.7 FUEL TANK: XR

MODELS

.

2.

Remove seat.

2.38 SEAT: XL MODELS

or

2.39 SEAT:

XR MODELS

.

3.

Remove left side cover. See

2.20 LEFT SIDE COVER

.

Prevent accidental vehicle start-up, which could cause
death or serious injury. First disconnect negative (-) battery
cable at engine and then positive (+) cable from battery.
(00280b)

4.

Disconnect battery cables, negative cable first, and remove
battery. See

1.17 BATTERY MAINTENANCE

.

5.

Remove fuel tank. See

4.6 FUEL TANK: XL MODELS

or

4.7 FUEL TANK: XR MODELS

.

6.

Remove wire harness caddy. See

6.33 ELECTRICAL

CADDIES

.

7.

See

Figure 6-107

. Cut cable strap (2) securing ET sensor

harness to H-bracket (1).

1

2

sm03795

1.

H-bracket

2.

ET sensor harness cable strap

Figure 6-107. Remove/Install Cable Straps

8.

Unplug the following harness connectors from the main
harness:

a.

Oil pressure switch [120B],

b.

Voltage regulator DC output [77B],

c.

Crank Position (CKP) sensor [79B],

d.

Front oxygen (O2) sensor [138B],

e.

Rear oxygen (O2) sensor [137B],

f.

Neutral switch jumper [136B],

g.

Engine temperature (ET) sensor [90B],

h.

Horn [122B],

i.

ECM [78B],

j.

Harness ground wire at engine crankcase [GND1],

k.

Rear stop lamp switch [121B],

l.

Vehicle speed sensor (VSS) [65B],

m. Green starter motor wire [128B].

n.

Vehicles with optional security siren: Unplug
security siren connector [142B].

9.

Vehicles with front mounted horn: Remove horn wire
harness from clip attached to right front frame downtube.

10. Locate engine sub-harness connector [145A] and rear

lighting sub-harness connector [7A] on top of oil tank.
Unplug both sub-harnesses from main harness.

11. Pull P&A battery harness/connector [160B] and fuel sender

resistor assembly/connector [200] out from recess in top
left rear corner of oil tank, under frame.

HOME

2009 Sportster Service: Electrical 6-81

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Политика конфиденциальности