Harley Davidson Sportster Models 2009. Service Repair Manual — page 14

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)

Do not allow positive (+) battery cable to contact ground
with negative (-) cable connected. Resulting sparks can
cause a battery explosion, which could result in death or
serious injury. (00069a)

5.

See

Figure 1-65

. With negative (-) battery cable discon-

nected from grounding point on crankcase, insert screw
through positive (+) battery cables: through main fuse
cable first, then through main positive (+) battery cable,
and into positive (+) battery terminal (2). Thread screw
into terminal. Tighten to 60-70 in-lbs (6.8-7.9 Nm).

6.

Apply a light coat of petroleum jelly or corrosion retardant
material to the positive (+) battery terminal. Place pro-
tective rubber boot over terminal.

7.

Hook top of battery strap (3) to battery tray mount on top
of battery. Install flat washer and strap screw (4). Tighten
to 36-60 in-lbs (4.1-6.8 Nm).

8.

Route main positive (+) battery cable through holders on
electrical bracket.

9.

Hook main fuse holder (1) to top pin on battery strap and
slide forward until it snaps into place.

10. Hook data link connector (5) to bottom pin on battery strap

and slide forward until it snaps into place.

11. See

Figure 1-66

. Press negative (-) battery cable (1) into

cable clip (4).

12. Place negative (-) battery cable connector onto ground

stud (5) on crankcase boss behind starter motor assembly
(3). Thread nut (2) onto stud.

13. See

Figure 1-68

or

Figure 1-69

. Press negative (-) battery

cable connector (1) against cable stop (2) on crankcase
and tighten nut (3) to 55-75 in-lbs (6.2-8.5 Nm).

14. Close left side cover.

2

3

1

sm03277

1.

Negative battery cable connector

2.

Cable stop

3.

Nut

Figure 1-68. Attaching Negative (-) Battery Cable to Ground

Stud Crankcase: XL Models

1

2

3

sm05267

1.

Negative battery cable connector

2.

Cable stop

3.

Nut

Figure 1-69. Attaching Negative (-) Battery Cable to Ground

Stud Crankcase: XR Models

STORAGE

TOOL NAME

PART NUMBER

GLOBAL BATTERY CHARGER

99863-01A

Batteries contain sulfuric acid, which could cause severe
burns to eyes and skin. Wear a protective face shield,
rubberized gloves and protective clothing when working
with batteries. KEEP BATTERIES AWAY FROM CHILDREN.
(00063a)

HOME

1-56 2009 Sportster Service: Maintenance

Do not allow battery to completely discharge. The electro-
lyte in a discharged battery will freeze. The more dis-
charged a battery is, the more easily it can freeze and crack
the battery case. (00218a)

If the motorcycle is to be stored with the security system armed,
connect a GLOBAL BATTERY CHARGER (Part No. 99863-
01A) to maintain battery charge.

If the motorcycle is to be stored with the battery installed, a
GLOBAL BATTERY CHARGER unavailable, and with the
security system not armed, unplug the main fuse.

If the motorcycle will not be operated for several months, such
as during the winter season, remove the battery from the
motorcycle and fully charge.

See

Figure 1-70

. Self-discharge is a normal condition and

occurs continuously at a rate that depends on the ambient
temperature and the battery's state of charge. Batteries dis-
charge at a faster rate at higher ambient temperatures. To
reduce the self-discharge rate, store battery in a cool (not
freezing), dry place.

Charge the battery every month if stored at temperatures below
60° F (16° C). Charge the battery more frequently if stored in
a warm area above 60° F (16° C).

NOTES

•

The GLOBAL BATTERY CHARGER (Part No. 99863-01A)
may be used to maintain battery charge for extended
periods of time without risk of overcharging or boiling.

•

When returning a battery to service after storage, see
ELECTRICAL DIAGNOSTIC MANUAL.

3

6

9

12

15

50 %

75 %

100 %

0

2

4

3

1

om00036

1.

Capacity

2.

Months of non-use

3.

Measured at 105° F (40° C)

4.

Measured at 77° F (25° C)

Figure 1-70. Effective Rate of Temperature on Battery

Self-discharging Rate

HOME

2009 Sportster Service: Maintenance 1-57

1.18

SPARK PLUGS

GENERAL

Harley-Davidson 6R12 and 10R12X spark plugs have a resistor
element to reduce the radio interference which originates in
the motorcycle ignition system. Use only the resistor-type spark
plugs specified.

INSPECTION

Disconnecting spark plug cable with engine running can
result in electric shock and death or serious injury.
(00464b)

1.

After the engine has cooled to room temperature, discon-
nect cables from both spark plugs.

2.

Remove spark plugs. If a plug has eroded electrodes,
heavy deposits or a cracked insulator, discard it.

3.

See

Figure 1-71

. Compare your observations of the plug

deposits with the descriptions provided below.

a.

A wet, black and shiny deposit on plug base, elec-
trodes and ceramic insulator tip indicates an oil fouled
plug. The condition may be caused by one or more
of the following: worn pistons, worn piston rings, worn
valves, worn valve guides, worn valve seals, a weak
battery or a faulty ignition system.

b.

A dry, fluffy or sooty black deposit indicates an air-
fuel mixture that is too rich.

c.

A light brown, glassy deposit indicates an overheated
plug. This condition may be accompanied by cracks
in the insulator or by erosion of the electrodes and is
caused by an air-fuel mixture that is too lean, a hot-
running engine, valves not seating or improper ignition
timing. The glassy deposit on the spark plug is a
conductor when hot and may cause high-speed mis-
firing. A plug with eroded electrodes, heavy deposits
or a cracked insulator must be replaced.

d.

A plug with a white, yellow, tan or rusty brown
powdery deposit indicates balanced combustion.
Clean off spark plug deposits at regular intervals.

Compressed air can pierce the skin and flying debris from
compressed air could cause serious eye injury. Wear
safety glasses when working with compressed air. Never
use your hand to check for air leaks or to determine air
flow rates. (00061a)

4.

If the plugs require cleaning between tune-ups, proceed
as follows:

a.

Degrease firing end of spark plug using ELECTRICAL
CONTACT CLEANER. Dry plug with compressed air.

b.

Use a thin file to flatten spark plug electrodes. A spark
plug with sharp edges on its electrodes requires 25-
40% less firing voltage than one with rounded edges.

c.

If the plugs cannot be cleaned, replace with new
spark plugs.

5.

Check electrode gap with a wire-type feeler gauge. Bend
the outside of the electrode so only a slight drag on the
gauge is felt when passing it between electrodes. Proper
gap measurement is listed in

Table 1-16

.

6.

Check condition of threads on cylinder head and plug. If
necessary to remove deposits, apply penetrating oil and
clean out with a thread chaser.

7.

Apply LOCTITE ANTI-SEIZE to the spark plug threads.
Install and tighten to 12-18 ft-lbs (16.3-24.4 Nm).

8.

Connect spark plug cables. Rear cylinder plug cable
attaches to top coil terminal. Verify that cables are securely
connected to coil and spark plugs.

Table 1-16. Spark Plug Gap

GAP (MM)

GAP (IN.)

TYPE

MODEL

0.96-1.09

0.038-0.043

6R12

All XL

0.81-0.97

0.032-0.038

10R12X

XR

sm01640

Figure 1-71. Typical Spark Plug Deposits

HOME

1-58 2009 Sportster Service: Maintenance

SPARK PLUG CABLE INSPECTION

1.

Inspect spark plug cables. Replace cables that are worn
or damaged.

a.

Check for cracks or loose terminals.

b.

Check for loose fit on ignition coil and spark plugs.

2.

Check cable boots/caps for cracks or tears. Replace
boots/caps that are worn or damaged.

3.

See

Figure 1-72

. Check spark plug cable resistance with

an ohmmeter. Compare values from test with

Table 1-17

.

Replace cables not meeting resistance specifications.

Table 1-17. Spark Plug Cable Resistance

RESISTANCE (OHMS)

CABLE

1,750-4,836

Front

4,968-13,427

Rear

1

3

2

4

sm02659

1.

Ohmmeter positive lead

2.

Ohmmeter negative lead

3.

Spark plug cable

4.

Ohmmeter

Figure 1-72. Testing Resistance

HOME

2009 Sportster Service: Maintenance 1-59

A

B

IGN 15A

ACCY 15A

Ignition

Switch

[33]

Battery 15A

J

D

A

I

C

B

30 Amp

MAXIFUSE

B

A

[GND1]

Powertrain

Ground

Point

IGN − I

BATT – B

ACC – A

ECM

TSM/TSSM/HFSM

[61B]

Headlamp Hi/lo Switch
Left Turn Switch

Left Hand
Controls

Right Turn Switch

Front Stop Lamp Switch

Right Hand
Controls

Fuseblocks

Top View

Top View

[119]

Accessories

Lights

Ignition

Fuel Pump

Start Relay System Relay

ECM

Battery

Spare

P&A IGN

Instruments

Spare

Engine Control

Open

2

5

1

2

5

1

6 5 4 3 2 1

To Front

Turn Signals

To Rear Lighting

To Instruments And

Indicator Lamps

[61]

Rear

Stop Lamp

Switch

1 2 3 4 5 6

1 2 3 4 5

1 2 3 4 5

1 2 3 4 5

7

12

1 2 3 4

To Headlamp

Lights 15A

R

P

Battery

1
2
3

5
6
7
8

12

1
2
3

5
6
7
8

12

5

10

28

5

10

28

HFSM only

SOCKET CONNECTOR

PIN CONNECTOR

(A SIDE)

(B 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

Serial Data

Ground

Ground

Battery
Ignition

Serial Data

Left Turn Feed

Right Turn Feed

Right Turn Switch Input

Left Turn Switch Input

Ground

1
2
3
4

1
2
3
4

Receive Antenna

XMIT Antenna A
XMIT Antenna B

[162]

[5]

[163]

Page 2

[31B]

[20A]

Page 2

[38B]

Page 2

[7B]

Page 2

GY

BK

BN

BN

W/V

O/W

V

W

V

LGN/V

LGN/V

BN/GY

BN/GY

W/BN

BK

O/W

R/Y

O/W

R/Y

W/BN

W/BN

BE

BE

BN

BK

BK

R

R

R

R

R

V

R/GY

R/BK

R/BK

R/BK

R/GY

GY

BK

BK

BE

BK

O/W

BN/GY

BE

BN

BK

O/W

O/W

O/W

R/Y

O/W

R/Y

V

BE

BE

BK

O/W

W/V

W/V

Y

Y

Y

W

W

W

BK

BK

LGN/V

Engine Case

Ground Point

[121B]

[121A]

[24B]

[24A]

[78B]

[78A]

[208B]

[208A]

[38A]

[7A]

[30B]

[30A]

[20B]

[22A]

[22B]

[31A]

et00125

Figure B-16. Lights (1 of 2) (XR): 2009 Sportster DOM. and INT. Models

Figure B-16.

Figure B-16.

Lights (1 of 2) (XR): 2009 Sportster DOM. and INT. Models

Lights (1 of 2) (XR): 2009 Sportster DOM. and INT. Models

[38B]

[31B]

[108B]

[108A]

[39B]

[39A]

[20A]

Speedometer

Tachometer

Configuration For XR

Front Lighting

To Main
Harness

To Main
Harness

To Main

Harness

Serial Data

Battery

Accessory

Ground

RPM x 100

Serial Data

Battery

Accessory

Ground

C

B
A
D

C

B
A
D

2

1
2
3
4
5

7

12

5
6
7

2

5
6
7

Left

Turn

Right

Turn

Position Lamp

(HDI ONLY)

1
2

5
6

1
2
3
4

Headlamp

High

Beam

Low

Beam

[31A]
Page 1

[38A]
Page 1

[20B]

Page 1

BK

BK

BK

BN

O/W

O/W

O/W

V

W

BN

BK

BK

BK

W

V

LGN/V

LGN/V

LGN/V

BN/GY

BN/GY

BN/GY

BK

BK

BK

BK

BK

BK

BK

BE

BE

BE

BN

BN
BE

O/W

O/W

V

V

Y

Y

W

W

Running lamps

(DOM only)

Rear Lighting

BE
BE

Right

Turn

Left

Turn

1
2

1
2

To Main
Harness

2

1

1
2
3

1

2

3

4

5

6

2

1

1

2

3

4

5

6

4
3
2
1

1

2

3

4

1

2

3

4

5

6

Tail
(DOM Only)

Tail
(HDI Only)

[7A]
page 1

BK

BK

BK

BK

BK

BN

BE

BN

BE

BK

O/W

O/W

R/Y

R/Y

R/Y

R/Y

V

V

V

BE
BE

[94B]

[94A]

[7B]

[19B]

[18B]

[19A]

[18A]

[93B]

[93A]

V

et00142

Figure B-17. Lights (2 of 2) (XR): 2009 Sportster DOM. and INT. Models