Harley Davidson 1986-2003 XL/XLH Sportster. Service Manual

could result in damage to the boot and
plunger on the brake light switch.

1. Insert a piece of 5/32-inch thick cardboard (A, Figure
155) between the brake lever and the brake lever bracket
2. Remove the clamp bolts from the master cylinder and
remove the master cylinder/brake lever assembly from the
handlebar.
3. Remove the screws securing the switch housing to the
handlebar. Separate the halves of the switch housing (Fig-
ure 154). Account for the friction shoe from the end of the
friction screw in the lower switch housing.
4. If necessary, remove the throttle and idle control cables
from the lower switch housing by performing the following:

a. Unhook the cables from the throttle grip and remove

the ferrule from the end of each cable.

b. Rock the end of the throttle cable back and forth. At

the same time, pull the cable insert and the throttle ca-
ble from the switch housing. Repeat this procedure to
remove the idle control cable from the switch hous-
ing.

5. Installation is the reverse of removal. Note the following:

a. Make sure the friction shoe and the friction screw are

in place in the lower switch housing.

b. The switch harness must be properly routed in the

grooves in the switch housing.

c. Make sure the switch wires are not pinched between

the housing halves and loosely install the switch
screws.

d. Install the master cylinder/brake lever assembly in-

board of the switch assembly. Make sure the tab on
the lower switch housing engages the slot (B, Figure
155) in the top of the brake lever bracket.

e. Tighten the master cylinder clamp screws to 70-80

in.-lb. (8-9 N•m).

f. Tighten the switch housing screws to 35-45 in.-lb.

(4-5 N•m).

Start switch/engine stop switch replacement

NOTE

The start switch (A,

Figure 156

) and the en-

gine stop switch (B) are available only as an
assembly.

Refer to Figure 154.

1. Remove the right handlebar switch as described in this
section.
2. Remove the screw (C, Figure 156) securing the switch
assembly and remove the start/engine stop switch assembly
from the upper switch housing.
3. Pull back the conduit on the harness (D, Figure 156),
and cut each wire 1/4 inch from the switch.
4. Splice the new switches to the harness.
5. Fit the switch assembly into the upper switch housing.
Make sure the end of the switch assembly bracket secures
the harness in the switch housing as shown in Figure 156.

6. Loosely install the switch assembly mounting screw
into the upper switch housing. Do not tighten the screw at
this time.

7. Gather the splices together, and fit them into the switch
housing as shown in A, Figure 157.

8. Fit a new 7-inch cable tie (B, Figure 157) around the
splices. Make sure the cable tie loops around the left end of
the switch assembly bracket.

9. Tighten the switch assembly mounting screw (C, Figure
156).

10. Tighten the cable tie to draw the splices into the upper
switch housing and hold them against the switch assembly
bracket. Cut off the excess cable tie. See B, Figure 157.

444

CHAPTER TWELVE

155

156

157

11. Reassemble the right handlebar switch as described in
this section.

Right turn signal switch

Refer to Figure 154.

1. Remove the right handlebar switch as described in this
section.

2. Cut the cable tie that secures the harness to the turn sig-
nal switch.

3. Remove the mounting screw and remove the turn signal
switch assembly (A, Figure 158) from the lower switch
housing.
4. Cut the turn signal wires approximately 1-1/2 inches
from the end of the switch and discard the switch.
5. Splice the wires of a new turn signal switch to the har-
ness .
6. Fit a 7-inch cable tie through the switch bracket as
shown in Figure 158.
7. Place the turn signal switch assembly into the lower
switch housing and loosely install the mounting screw. Do
not tighten the screw at this time.
8. Wrap the cable tie (B, Figure 158) around the switch
harness and tighten the cable tie so the harness is secured
against the turn signal switch bracket. Cut off the excess ca-
ble tie.
9. Loop a second cable tie around the switch harness.
Gather the splices, wrap them in the cable tie, and tighten
the cable tie so the splices are secured against the switch
harness. Cut the excess cable tie.
10. Tighten the turn signal switch mounting screw se-
curely.
11. Reassemble the handlebar switch as described in this
section.

Left handlebar switch removal/installation

Refer to Figure 159.

1. Loosen the clamp bolts securing the clutch-lever assem-
bly to the handlebar, then remove the clutch lever assembly.
2. Remove the screws securing the switch housing to the
handlebar. Separate the halves of the switch housing (Fig-
ure 151).
3. Installation is the reverse of removal. Note the following:

a. The switch harness must be properly routed in the

grooves in the switch housing.

b. Make sure that no wire is pinched between the switch

housing halves.

c. Install the clutch lever assembly on the inboard side

of the switch housing.

d. Make sure the tab on the lower switch housing en-

gages the slot in the bottom of the clutch lever
bracket.

e. Tighten the clutch lever clamp bolts to 60-80 in.-lb.

(7-9 N•m).

f. Tighten the switch housing securing screws to 35-45

in.-lb. (4-5 N•m).

Horn switch/dimmer switch removal/installation

Refer to Figure 159.

NOTE

The horn switch (A,

Figure 160

) and the dim-

mer switch (B) are available only as an as-
sembly.

ELECTRICAL SYSTEM

445

159

LEFT HANDLEBAR SWITCH

ASSEMBLY (1996-2003 MODELS)

1. Upper

housing

2. Horn switch/

dimmer switch
assembly

3. Left turn signal switch
4. Lower housing
5. Screw
6. Harness
7. Connector

158

1. Remove the left handlebar switch assembly as described
in this section.
2. Remove the screw (C, Figure 160) securing the switch
assembly and remove the horn/dimmer switch assembly
from the upper switch housing.
3. Pull back the conduit on the harness (D, Figure 160),
and cut each wire 1/4-inch from the switch.
4. Splice the new switches to the harness.
5. Fit the switch assembly into the upper switch housing.
Make sure the end of the switch assembly bracket secures
the harness in place in the switch housing as shown in Fig-
ure 160.
6. Loosely install the switch assembly mounting screw
into the upper switch housing. Do not tighten the screw at
this time.
7. Gather the splices together and fit them into the switch
housing as shown in A, Figure 161.
8. Fit a new 7-inch cable tie around the splices. Make sure
the cable tie loops around the left end of the switch-assem-
bly bracket.
9. Securely tighten the switch assembly mounting screw.
10. Tighten the cable tie to draw the splices into the upper
switch housing and hold them against the switch-assembly
bracket. Cut off the excess cable tie. See B, Figure 161.
11. Reassemble the left handlebar switch as described in
this section.

Left turn signal switch

Refer to Figure 159.

1. Remove the left handlebar switch as described in this
chapter.
2. Cut the cable tie that secures the harness to the turn sig-
nal switch.
3. Remove the mounting screw and remove the turn signal
switch assembly (A, Figure 162) from the lower switch
housing.
4. Cut the turn signal wires approximately 1-1/2 inches
from the end of the switch and discard the switch.
5. Splice the wires of a new turn signal switch to the har-
ness.

6. Fit a 7-inch cable tie through the switch bracket as
shown in Figure 162.

7. Place the turn signal switch assembly into the lower
switch housing, and loosely install the mounting screw. Do
not tighten the screw at this time.

8. Wrap the cable tie (B, Figure 162) around the switch har-
ness and tighten the cable tie so the harness is secured against
the turn signal switch bracket. Cut the excess cable tie.

9. Loop a second cable tie around the switch harness.
Gather the splices, wrap them in the cable tie, and tighten
the cable tie so the splices are secured against the switch
harness. Cut the excess cable tie.

10. Tighten the turn-signal switch mounting screw se-
curely.

11. Reassemble the handlebar switch as described in this
section.

Front Brake Light Switch Replacement
(1996-2003 Models)

NOTE

Refer to

Handlebar Switches

in this section

when replacing the front brake light switch on
1986-1995 models.

The front brake light switch (Figure 154) is mounted in

the right handlebar switch lower housing.

446

CHAPTER TWELVE

161

162

160

1. Separate the right handlbar switch housing as described
in

Handlebar Switch Replacement

in this section.

2. If the wedge between the switch and the switch housing
is still in place, remove it.

3. Cut the switch wires 1 in. from the defective switch.

4. While depressing the switch plunger, rotate the switch
upward, rocking it slightly, and remove it from the switch
housing.

5. Check that the plunger is square in the bore and that the
boot is not compressed, collapsed or torn. Work the plunger
in and out until the boot is fully extended.

6. Slip a piece of heat shrink tubing over each wire cut in
Step 3.
7. Solder the wire ends to the new switch. Then shrink the
tubing over the wires.
8. Install the switch by reversing the removal steps. Note
the following:

a. When clamping the switch housing onto the handle-

bar, check the wiring harness routing position to
make sure it is not pinched between the housing and
handlebar.

WARNING

Do not ride the motorcycle until the throttle ca-
bles are properly adjusted (Chapter Three).

b. To install the right handlbar switch housing, refer to

the

Throttle and Idle Cables

section in Chapter Ten or

Chapter Eleven.

Ignition/Lighting Switch

The ignition/light switch is not servicable. If the switch is

faulty, it must be replaced.

Removal/installation (1986-1991 models)

1. Disconnect the negative battery cable as described in
this chapter.
2. Remove the ignition key.
3. Remove the outer chrome nut securing the ignition
switch to the mounting plate (Figure 163).
4. Push the ignition switch through the cover (toward the
inside) and remove it from the mounting plate (Figure
163).
5. Label and disconnect the electrical connectors from
the switch; refer to the wiring diagrams at the end this
manual.
6. Installation is the reverse of the preceding steps.
7. Check the ignition/light switch for proper operation.

Removal/installation (1992-1993 models)

1. Disconnect the negative battery cable as described in
this chapter.
2. Remove the ignition key.
3. Remove the outer chrome nut (A, Figure 164) securing
the ignition switch to the mounting plate.
4. Loosen the enrichener cable nut on the backside of the
cable bracket (B, Figure 164). Remove the enrichener ca-
ble out of the cable slot in bracket.
5. Remove the top center engine mount bracket Torx screw
(C, Figure 164) and remove the enrichener cable bracket.
On 1200 models remove the horn and bracket.
6. Remove the ignition switch locknut (Figure 165). Re-
move the switch, switch cover and trim plate off of the top
center engine mount bracket.

ELECTRICAL SYSTEM

447

163

Nut

Locknut

Switch

164

165

7. Label and disconnect the electrical connectors from the
switch; refer to the wiring diagrams at the end this manual.
8. Remove the ignition switch.
9. Installation is the reverse of the preceding steps while
noting the following.

a. Tighten the ignition switch locknut to 72 in.-lb. (8

N•m).

b. Tighten the top center engine mount bracket Torx

screw to 60-120 in.-lb. (7-14 N•m).

c. Check the ignition/light switch for proper operation.

Removal/installation (1994 models)

1. Disconnect the negative battery cable as described in
this chapter.
2. Remove the ignition key.
3. Remove the fuel tank as described in Chapter Seven.
4. Cut the two main wiring harness cable straps. Discard
the cable straps.
5. The enrichener cable hex nut uses left-hand threads.
Turn the nut clockwise to remove it. Loosen the enrichener
cable nut on the backside of the cable bracket. Then remove
the enrichener cable from the cable slot in bracket.
6. Remove the top center engine mount bracket Torx screw
and remove the enrichener cable bracket. On 1200 models
remove the horn and bracket.
7. Remove the outer chrome nut (Figure 166) securing the
ignition switch to the mounting plate.
8. Remove the ignition switch locknut and the ignition
switch cover.
9. Remove the ignition switch from the switch cover.
10. If replacing the ignition switch, remove the ignition
switch harness cover and cut the switch wires 3 in. (80 mm)
from the switch.
11. Install by reversing the removal steps while noting the
following:

a. To reconnect the new ignition switch, slide the re-

placement conduit onto the wiring harness. Match the
ignition switch and wiring harness color codes, in-
stall new butt connectors to the wiring harness and ig-
nition switch wires. Seal the butt splice connectors as
described in the

Sealed Butt Connectors

Electrical

Connectors

in this chapter.

b. Install the ignition switch into the hole in the switch

cover so the TOP mark stamped on the switch body
faces upward toward the switch position decal.

c. Tighten the ignition switch locknut to 72 in.-lb. (8.1

N•m).

d. Tighten the top center engine mount bracket Torx

screw to 60-120 in.-lb. 7-14 N•m).

e. Check the ignition/light switch for proper operation.

Removal/installation (1995-2003 models)

1. Disconnect the negative battery cable as described in
this chapter.

2. Remove the fuel tank as described in Chapter Eleven.

3. Remove the ring nut (A, Figure 167).

4. Remove the decal (B, Figure 167).

5. Remove the retaining screw (C, Figure 167).

6. Remove the switch cover (3, Figure 168).

7. Cut the switch wires approximately 3 in. (80 mm) from
the switch.

8. Splice the new ignition switch (1, Figure 168) to the
harness. Splice similar color wires to each other and follow
the procedure in

Sealed Butt Connectors

Electrcal Con-

nectors

in this chapter.

9. Install the switch by reversing the removal procedure.
Tighten the retaining screw (C, Figure 167) to 35-45 in.-lb.
(4-5 N•m).

448

CHAPTER TWELVE

166

IGNITION SWITCH

(1994 MODELS)

1. Switch cover
2. Switch
3. Nut
4. Mounting bracket

167

Oil Pressure Switch

Operation

The oil pressure switch is located under the oil filter

mounting boss on the crankcase (Figure 169). A pres-
sure-actuated diaphragm-type oil pressure switch is used.
When the oil pressure is low or when oil is not circulating
through a running engine, spring tension inside the switch,

holds the switch contacts closed. This completes the signal
light circuit and causes the low oil pressure indicator lamp
to light.

The oil pressure signal light should turn on when any of

the following occurs:
1. The ignition switch is turned on prior to starting the en-
gine.
2. The engine speed idle is below 1000 rpm.
3. The engine is operating with low oil pressure.
4. Oil is not circulating through the running engine.

NOTE

The oil pressure indicator light may not come
on when the ignition switch is turned off then
back on immediately. This is due to the oil
pressure retained in the oil filter housing. Test
the electrical part of the oil pressure switch in
the following steps. If the oil pressure switch,
indicator lamp and related wiring are in good
condition, inspect the lubrication system as
described in Chapter Two.

Testing/replacement

1. Disconnect the electrical connector from the switch
(Figure 169).
2. Turn the ignition switch on.
3. Ground the switch wire to the engine.
4. The low oil pressure indicator lamp on the instrument
panel should light.
5. If the indicator lamp does not light, check for a defective
indicator lamp, and inspect all wiring between the switch
and the indicator lamp.
6A. If the oil pressure warning light operates properly, at-
tach the electrical connector to the pressure switch. Make
sure the connection is tight and free of oil.
6B. If the warning light remains on when the engine is run-
ning, shut the engine off. Check the engine lubrication sys-
tem as described in Chapter Two.
7. To replace the switch, perform the following:

a. Unscrew the switch (Figure 169) from the engine.
b. Unless the new switch has pre-applied sealant, apply

pipe sealant to the switch threads prior to installation.

c. Install the switch and tighten it to 60-84 in.-lb. (7-9

N•m).

d. Test the new switch as described in Steps 1-4.

Neutral Indicator Switch
Testing/Replacement

The neutral indicator switch is located on the right side of

the crankcase in front of the drive sprocket (Figure 170).
The neutral indicator light on the instrument panel should
light when the ignition is turned on and the transmission is
in neutral.
1. Remove the drive sprocket cover as described in Chap-
ter Thirteen.

ELECTRICAL SYSTEM

449

168

169

170

IGNITION SWITCH

(1995-2003 MODELS

1. Ignition switch
2. Screw
3. Cover

4. Decal
5. Nut

2. Disconnect the electrical connector from the neutral in-
dicator switch (Figure 170).
3. Turn the ignition switch on.
4. Ground the end of the neutral indicator switch wire.
5A. If the neutral indicator lamp lights, the neutral switch
or attached wire lead is faulty. Verify the condition of the
switch wire lead is good, and if so, replace the neutral indi-
cator switch and retest.
5B. If the neutral indicator lamp does not light, check for a
burned out indicator lamp, faulty wiring or a loose or cor-
roded connection. If necessary, replace the lamp as de-
scribed in this chapter.
6A. If the problem was solved in Steps 3-5, reconnect the
electrical connector to the neutral switch. Make sure the
connection is tight and free from oil.
6B. If the problem was not solved in Steps 3-5, replace the
neutral indicator switch as described in the following steps.
7. Remove the drive sprocket as described in Chapter Thir-
teen.
8. Disconnect the wire lead from the switch (Figure 170).
9. Unscrew the switch from the right crankcase.
10. Install the switch and tighten to 36-60 in.-lb. (4.1-6.8
N•m).
11. Reconnect the switch wire lead to the switch.
12. Install the drive sprocket as described in Chapter Thirteen.

Rear Brake Light Switch Testing/Replacement

A hydraulic, normally-open rear brake light switch is

used on all models. The rear brake light is located behind
the left side cover inline with the rear brake caliper brake
hose assembly (Figure 171). When the rear brake pedal is
applied, hydraulic pressure closes the switch contacts, pro-
viding a ground path so the rear brake lamp comes on. If the
rear brake lamp does not come on, perform the following:
1. Turn the ignition switch off.
2. Disconnect the electrical connectors from the switch.
3. Connect an ohmmeter between the switch terminals.
Check the following:

a. Apply the rear brake pedal. There should be continuity.
b. Release the rear brake pedal. There should be no con-

tinuity.

c. If the switch fails either of these tests, replace the

switch.

4. If necessary, replace the brake light switch as described
in the following steps.
5. Remove the rubber boot from the switch.
6. Place a drip pan under the switch, as some brake fluid
will drain out when the switch is removed.
7. Unscrew the switch from the T-fitting on the rear brake
line. Make sure to hold the T-fitting with a wrench when
performing Step 8.
8. Thread the new switch into the fitting and tighten it to
84-120 in.-lb.(9-14 N•m).
9. Reconnect the switch electrical connectors.
10. Bleed the rear brake as described in Chapter Sixteen.

11. Check the rear brake light with the ignition switch
turned on and the rear brake applied.

HORN

Testing

1. Label, then disconnect the electrical connectors from
the horn.

2. Connect a positive voltmeter test lead to the yellow or
yellow/black electrical connector and the negative test lead
to ground.

3. Turn the ignition switch to the on position.

4. Press the horn button. If battery voltage is present, the horn
is faulty or is not grounded properly. If there is no battery volt-
age, either the horn switch or the horn wiring is faulty.

5. Replace the horn or horn switch as necessary.

450

CHAPTER TWELVE

171

172

HORN

(1986-1990 883 MODELS)

1. Fuel tank bolt
2. Lockwasher
3. Horn

4. Ground strap
5. Spacer

Removal/Installation

1986-1995 883 models

Refer to Figure 172 or Figure 173.

1. Label and then disconnect the horn electrical connec-
tor(s) at the horn spade terminals.
2. Remove the rubber cap from the front fuel tank mount-
ing bolt.
3A. On 1986-1990 models, remove the front fuel tank
mounting bolt.
3B. On 1991-1995 models, hold the front fuel tank mount-
ing bolt and remove the horn locknut.
4. Remove the horn, bracket and spacer.
5. Install by reversing the preceding removal steps while
noting the following:

a. Make sure the electrical connectors and horn spade

terminals are free of corrosion.

b. Tighten the front fuel tank mounting bolt to the tight-

ening torque specified in Table 4.

c. Check that the horn operates correctly.

1986-1990 1100 and 1200 models

Refer to Figure 174.

1. Label and then disconnect the horn electrical connectors
at the horn spade terminals.
2. Disconnect the ground strap from the support bracket.
3. Remove the bolt (4, Figure 174), then remove the horn
assembly.
4. Remove the nut (10, Figure 174) and separate the horn
and cover.
5. Install by reversing the removal steps. Note the following:

a. Make sure the electrical connectors and horn spade

terminals are free of corrosion.

b. Check that the horn operates correctly.

All 1991-2003 1200 models except 1200C models

Refer to Figure 175.

1. Label and then disconnect the horn electrical connectors
at the horn spade terminals.
2. Remove the Acorn nut and lockwasher securing the
horn assembly to the rubber mount stud.
3. Remove the horn assembly and remove the wire clip
from the backside of the horn bracket.
4. Remove the locknut from the recess in the horn bracket.
Then remove the horn and tooth lockwasher.
5. Install by reversing the preceding removal steps while
noting the following:

a. Make sure the electrical connectors and horn spade

terminals are free of corrosion.

b. Check that the horn operates correctly.

ELECTRICAL SYSTEM

451

173

HORN

(1991-1995 883 MODELS)

1. Rubber cap
2. Horn
3. Locknut
4. Bracket
5. Spacer
6. Fuel tank bolt

174

HORN (1986-1990

1100 AND 1200 MODELS)

1. Nut
2. Lockwasher
3. Washer
4. Bolt
5. Screw
6. Lockwasher

7. Ground strap
8. Support bracket
9. Wellnut

10. Nut
11. Cover
12. Horn

All 1996-2003 and 1998-2003 XL1200S models

Refer to Figure 176.

1. Turn the handlebar to the right to access the fork.
2. Label and then disconnect the horn electrical connectors
at the horn spade terminals.
3. Remove the bolts that secure the horn to the horn
bracket, then remove the horn.
4. Install by reversing the removal steps. Note the following:

a. Make sure the electrical connectors and horn spade

terminals are free of corrosion.

b. Tighten the horn mounting bolts to 6-9 in.-lb. (0.5-1

N•m).

c. Check that the horn operates correctly.

ELECTRICAL BRACKET

Removal/Installation

1994-1997 models

The electrical bracket contains the turn signal module,

circuit breakers or fuses, starter relay and main circuit
breaker. Refer to Figure 177 and Figure 178.
1. Disconnect the negative battery cable as described in
this chapter.
2. Remove the seat (Chapter Seventeen).

452

CHAPTER TWELVE

175

HORN (1991-2003 1200

AND 1200C MODELS)

1. Horn
2. Cover
3. Washer
4. Bracket
5. Locknut
6. Clamp
7. Screw
8. Acorn nut
9. Lockwasher

10. Mount stud
11. Bracket

176

HORN (1996-2003 883 AND

1998-2003 1200C MODELS)

1. Bolt
2. Horn
3. Bolt
4. Washer
5. Wellnut
6. Damper
7. Horn bracket
8. Nut plate
9. Clip

177

ELECTRICAL BRACKET

(1994-1996 MODELS)

1. Electrical bracket
2. Ignition circuit breaker (15 amp)
3. Instuments circuit breaker (10 amp)
4. Lights circuit breaker (10 amp)
5. Accessories circuit breaker (15 amp)
6. Starter relay
7. Speed-sensor connector
8. Turn-signal module
9. Main circuit breaker (50 amp)

3. Remove the two electrical bracket bolts and lift the elec-
trical bracket from the frame.
4. Remove the wellnuts from the frame.
5. Inspect the rubber wellnuts for cracks, tears or other
signs of deterioration. Replace them as necessary.
6. Installation is the reverse of removal. Tighten the elec-
trical bracket mounting bolts to 6-9 in.-lb. (0.5-1 N•m).

1998-2003 models

The electrical bracket contains the main circuit breaker,

fuse block, and starter relay. On 1200S models, the data
link connector is also on the electrical bracket, which is be-
hind the left side cover. See Figure 179.
1. Remove the negative battery cable as described in this
chapter.
2. Gently pull the side cover from the motorcycle until the
mounts are released from the grommets in the frame.
3. Install by aligning the mounts with the frame grommets.
Gently press the side cover until the mounts are secured in
the grommets.

TURN SIGNAL FLASHER

(1986-1990 MODELS)

Replacement

The turn signal flasher is located in the headlight housing

behind the sealed beam.
1. Remove the sealed beam as described in

Lighting Sys-

tem

in this chapter.

NOTE

Early 1986 models are equipped with a rect-
angular shaped flasher. Late 1986-1990
models are equipped with a round flasher
with a blue stripe. Refer to

Figure 180

. Do

not use original equipment round flashers not
marked with a blue stripe. These are four-way
flashers that will cause incorrect turn signal
operation. Early 1986 models can use the
later style blue-striped flasher

ELECTRICAL SYSTEM

453

178

ELECTRICAL BRACKET

(1997 MODELS)

1. Electrical bracket
2. Ignition circuit breaker (15 amp)
3. Instruments circuit breaker (10 amp)
4. Lights circuit breaker (10 amp)
5. Accessories circuit breaker (15 amp)
6. Starter relay
7. Speed-sensor connector
8. Turn-signal module
9. Main circuit breaker (30 amp)

179

ELECTRICAL BRACKET

(1998-2003 MODELS)

1. Main circuit breaker (30 amp)
2. Data link connector (1200S models only)
3. Fuse block
4. Mount
5. Starter relay

180

New style part No. 68543-64B

Blue stripe

Old style part No. 68543-64A

2. Remove the flasher and insert a new unit. Check the turn
signal operation.
3. Make sure the flasher is positioned in the headlight
housing so the electrical terminals face toward the rear of
the motorcycle.

CAUTION

Installing the flasher with the terminals
pointing forward may damage the terminals if
they contact the headlight sealed beam.

TURN SIGNAL MODULE

(1991-2003 MODELS)

All 1991-2003 models are equipped with a turn signal

module, an electronic microprocessor that controls the turn
signals and the four-way hazard flasher. The turn signal
module receives its information from the speedometer and
turn signal switches.

Removal/Installation

1991-1993 models

On 1991-1993 models, the turn signal module (Figure

181) is mounted on the inboard side of the ignition control
module bracket (Figure 182).
1. Remove the seat.
2. Disconnect the negative battery cable as described in
this chapter.
3. Remove the turn signal module mounting bolt.
4. Disconnect the module electrical connector.
5. Reverse the steps for installation.

1994-1996 models

On 1994-1996 models, the module (Figure 183) is

mounted on the front right side of the electrical bracket un-
der the seat.
1. Remove the seat (Chapter Seventeen).
2. Disconnect the negative battery cable as described in
this chapter.
3. Remove the bolts securing the electrical bracket (Figure
184) to the frame. Lift the electrical bracket out of the frame.
4. Locate the 8-pin Deutsch connector on the left side of
the electrical bracket. Push the connector up and disconnect
its clip from the T-stud.
5. Disconnect the turn signal module plug from its electri-
cal connector.
6. Cut the cable straps securing the module to the electrical
bracket. Note the position of the cable straps as they are
routed through the electrical bracket for reassembly. Re-
move the module and discard the cable straps.
7. Position the new cable straps through the holes in the
front of the electrical bracket.

454

CHAPTER TWELVE

181

TURN SIGNAL MODULE

(1991-1993 MODELS)

1. Mounting pad
2. Direction canceler module
3. Rubber washer
4. Screw

182

183

TURN SIGNAL MODULE

(1994-1996 MODELS)

1. Directional canceler module
2. Socket plug

8. Position the new turn signal module against the front of
the electrical bracket so that the flat side faces out and the
plug end faces down.

9. Wrap the cables around the two grooves in the side of
the module, then connect and tighten the cables. Cut off ca-
ble excess.

10. Reconnect the turn signal module plug to the electrical
connector.

11. Position the large end of the attachment clip end slot
over the T-stud on the electrical bracket. Push the connector
assembly down and engage small end of slot.

12. Install electrical bracket mounting bolts and tighten se-
curely.

13. Check that the turn signal and flasher systems work
properly.

1997 models

On 1997 models, the turn signal module (Figure 185) is

mounted on the electrical bracket under the seat.
1. Remove the seat (Chapter Seventeen).
2. Disconnect the negative battery cable as described in
this chapter.
3. Remove the bolts securing the electrical bracket (1, Fig-
ure 178) to the frame.
4. Depress the external latches on the 8-terminal Deutsch
onnector and remove the connector from the turn-signal
module (8, Figure 178).
5. Remove the mounting screw securing the module to the
bracket and remove the turn signal module.
6. Position the new turn signal module against the bracket,
and install the mounting screw. Tighten the turn signal
module mounting screw to 36-60 in.-lb. (4-7 N•m).
7. Reconnect the 8-terminal harness connector to the turn
signal module plug.
8. Install the electrical bracket. Tighten the electrical
bracket mounting bolt to 6-9 in.-lb. (0.5-1 N•m).
9

Check that the turn signal and flasher systems work

properly.

1998-2003 models

On 1998-2003 models, the module (Figure 185) is

mounted on the rear fender.
1. Remove the seat (Chapter Seventeen).
2. Disconnect the negative battery cable as described in
this chapter.
3. On 1200S models, remove the bolts securing the electri-
cal bracket to the frame. Lift the bracket from the frame
crossmembers under the seat.
4. Depress the external latches on the 8-terminal Deutsch
connector (A, Figure 186) and remove the connector from
the turn signal module (B).
5. Remove the mounting screw securing the module to the
rear fender and remove the turn signal module.
6. Position the new turn signal module against the rear
fender, and install the mounting screw. Be sure the rubber
damper (C, Figure 186) is in place behind the module.

ELECTRICAL SYSTEM

455

184

ELECTRICAL BRACKET

(1994-1996 MODELS)

Main circuit breaker

Electrical bracket

Starter relay

185

Socket

plug

Module

186

Tighten the turn signal module mounting screw to 36-60
in.-lb. (4-7 N

•

m).

7. Reconnect the 8-terminal harness connector to the
tum-signal-module plug.
8. On 1200S models, secure the electrical bracket to the
frame. Torque the electrical bracket mounting bolts to 6-9
in.-lb. (0.5-1 N•m).
9. Check that the turn signal and flasher systems work
properly.

Turn Signal Module Troubleshooting

Refer to Chapter Two.

CIRCUIT BREAKERS

(1986-1997 MODELS)

All 1986-1997 models use circuit breakers to protect the

electrical system. Circuit breaker ratings for the various cir-
cuits are listed in Table 1.

Whenever a failure occurs in any part of the electrical

system, each circuit breaker is self-resetting and will auto-

matically return power to the circuit when the electrical
fault is corrected.

CAUTION

If an electrical fault on circuit-breaker
equipped models is not found and cor-
rected, the breakers will cycle on and off
continuously. This will cause the motorcy-
cle to run erratically and eventually dis-
charge the battery.

456

CHAPTER TWELVE

187

188

CIRCUIT BREAKERS

(1986-1991 MODELS)

Grey

White

Orange

Red

Red Blue

Green

Black

IGNITION

ACCY

MAIN

LIGHTS

189

CIRCUIT BREAKERS

(1992-1993 MODELS)

To voltage
regulator

To main
wiring harness

Black

Blue

Green

LIGHTS

White

Grey

IGNITION

Red

MAIN

Orange

Red

To battery positive
terminal

ACCY

190

CIRCUIT BREAKERS

(1994-1996 MODELS)

Ignition 15 amp

Instruments

10 amp

Lights 15 amp

Accessories

10 amp

Red/Black

Red/black

Grey

Orange

Blue

Orange/
white

FRONT

(1994-1995 models)

FRONT

(1996 models)

Most faults can be traced to a short circuit in the wiring.

This may be caused by worn-through insulation or by a
wire that has worked loose and shorted to ground. Occa-
sionally, the electrical overload that causes the circuit
breaker to trip may occur in a switch or motor. Use the wir-
ing diagrams at the end of the manual to determine which
circuits are protected by each circuit breaker.

All 1986-1993 models have four circuit breakers

mounted on the front side of the rear fender underneath the
seat (Figure 187). Refer to Figure 188 or Figure 189. Dis-
connect the negative battery cable prior to servicing the cir-
cuit breakers.

All 1994-1997 models have five circuit breakers. The ig-

nition, instruments, lights and accessories circuit breakers
are mounted in the circuit breaker block installed in the elec-
trical bracket mounted underneath the seat (Figure 190 or
Figure 191). The main circuit breaker is mounted in the elec-
trical bracket on the right side of the circuit breaker block

(Figure 184). Disconnect the negative battery cable as de-
scribed in this chapter prior to servicing the circuit breakers.

FUSES

(1998-2003 MODELS)

All 1998-2003 models use fuses (Figure 192) to protect elec-

trical circuits. Fuse ratings for each circuit are listed in Table 1.

Usually a blown fuse can be traced to a short circuit in the

wiring. This may be caused by worn-through insulation or
by a wire that has worked loose and shorted to ground. Oc-
casionally, the electrical overload that causes the fuse to
blow may occur in a switch or motor. Use the wiring dia-
grams at the end of this manual to determine which circuits
are protected by each fuse.

The ignition, instruments, lights and accessories circuit

fuses are mounted in the fuse block (3, Figure 193), which
is behind the starter relay (5) in the electrical bracket. Pull
up on the latch to release the fuse box. The main circuit
breaker is behind the cover on the electrical bracket.

Whenever a fuse blows, correct the electrical fault before

replacing the fuse.

ELECTRICAL CONNECTOR SERVICE

Deutsch Electrical Connectors Socket

Terminal removal/installation

This procedure is shown on a 12-pin Duetsch connector

and is the same for 2-, 3-, 4- and 6-pin Duetsch connectors.

Refer to Figure 194 and Figure 195.

ELECTRICAL SYSTEM

457

191

CIRCUIT BREAKERS

(1997 MODELS)

Ignition 15 amp

Instruments

10 amp

Lights 10 amp

Accessories

15 amp

Green

Orange

Blue

Orange/

white

Red/black

Red/green

FRONT

192

CIRCUIT BREAKERS

(1998-2003 MODELS)

Ignition 15 amp

Instruments

15 amp

Lights 15 amp

Accessories

15 amp

Green

Orange

Blue

Orange/

white

Red/black

Red/green

193

ELECTRICAL BRACKET

(1998-2003 MODELS)

1. Main circuit breaker (30 amp)
2. Data link connector (1200S models only)
3. Fuse block
4. Mount
5. Starter relay

Orange/

white

Red/black

Orange/

white

Harley Davidson 1986-2003 XL/XLH Sportster. Service Manual - page 26