Harley Davidson Sportster Models 2009. Service Repair Manual — page 37
3.
. 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.
. 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
. Make certain rear
wheel is properly aligned and rear drive belt is properly
tensioned. See
.
8.
Plug in main fuse. See
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)
. 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
2.
Remove seat. See
3.
Remove rear wheel. See
.
4.
See
. Unplug license plate lamp harness con-
nector [40] (2).
5.
See
. 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.
. 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)
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
. Remove two screws with washers (2)
securing license plate lamp housing to license plate holder
(1). See
. 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
. 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
. If replacing a light bulb (2), gently pull
bulb straight out of socket assembly (3). Push new light
bulb into socket.
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
.
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.
. Fit gasket (2) onto lamp housing (3).
3.
. 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
. 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
. 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.
. 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.
. Plug license plate lamp harness con-
nector [40B] into interconnect harness connector [40B]
(2).
9.
Install rear wheel. See
.
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
.
11. Plug in main fuse. See
.
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.
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)
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
.
The converter module (1) is incorporated into an interconnect
harness that connects the main wiring harness to the rear
lighting harnesses.
See
. 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
.
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
.
4.
. 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.
. Push in on converter module rubber
mounting tab to release it from hole in frame.
6.
. 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
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
. 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
. Pull rubber mounting tab through
hole in frame to secure module.
3.
. 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
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
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
2009 Sportster Service: Electrical 6-71
6.27
REAR STOP LAMP SWITCH
GENERAL
XL models only: See
. 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
.
Remove main fuse. See
.
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
3.
or
. 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
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
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
.
2.
See
. 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.
. 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
.
5.
Start engine and verify operation.
6-74 2009 Sportster Service: Electrical
6.29
ALTERNATOR
REMOVAL AND DISASSEMBLY
1.
Open left side cover. See
.
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
. Close left side cover.
3.
Remove primary cover. See
4.
Remove clutch assembly, primary chain and engine
sprocket/rotor assembly as a unit. See
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
. 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
. Open external latch (4) and unplug
stator harness (2) connector [46B] from voltage regulator
harness (3) connector [46A] (1). See
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
. 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)
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
. 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
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
. Connect stator harness (2) to voltage
regulator harness (3) at connector [46] (1) and lock
external latch (4) in place. See
for procedure.
8.
Secure stator harness and neutral switch with cable straps
as noted from stator removal.
Rotor
1.
. 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
2.
Install primary cover, left footrest assembly and gear shift
lever. See
3.
Open left side cover. See
.
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
. 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
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
.
2.
See
. 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
. 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
.
4.
Start engine and test ride motorcycle to verify proper
operation.
6-78 2009 Sportster Service: Electrical
6.31
NEUTRAL INDICATOR SWITCH
GENERAL
. 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
2.
XL models: remove rear muffler and exhaust pipe. See
4.15 EXHAUST SYSTEM: XL MODELS
. XR models:
remove exhaust system. See
.
3.
Remove sprocket cover and rear drive belt from transmis-
sion sprocket. See
.
4.
Remove transmission sprocket. See
5.
. 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
12. Install secondary drive belt and sprocket cover. See
13. Adjust drive belt tension and rear wheel alignment. See
14. XL models: install rear muffler and exhaust pipe. See
4.15 EXHAUST SYSTEM: XL MODELS
. XR models:
install exhaust system. See
15. Plug in main fuse. See
.
16. Turn ignition switch on and check the operation of the
neutral indicator lamp.
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)
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
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
2.
Remove seat.
.
3.
Remove left side cover. See
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
.
5.
Remove fuel tank. See
.
6.
Remove wire harness caddy. See
7.
See
. 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.
2009 Sportster Service: Electrical 6-81
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