Harley Davidson 2013 Sportster Models. Service Manual - page 43

2013 Sportster Service: Electrical 6-11

6.6

ELECTRONIC CONTROL MODULE (ECM)

GENERAL

See

Figure 6-9

. The ECM receives data from sensors such as

the CKP sensor and the TMAP sensor. The ECM uses this
data to time the ignition spark as well as providing other engine
management functions.

NOTE

This part cannot be repaired. Replace upon failure.

XL Models:

The ECM is mounted in front of the battery in a

caddy.

XR 1200X:

The ECM is mounted in a bracket on the rear fender

under the seat.

sm06665

1. ECM cover fastener
2. Fuel pump wiring
3. Rear O2 sensor wiring
4. ECM cover
5. Rear O2 sensor wiring clip

Figure 6-8. ECM Cover: XL Models

sm06666

1. ECM
2. ECM connector
3. ECM connector latch

Figure 6-9. ECM: XL Models

sm05525

1. Fastener (2)
2. Electronic Control Module

Figure 6-10. Electronic Control Module (ECM): XR 1200X

REMOVAL

XL Models

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

Remove main fuse.

See

Figure 6-8

. Remove fuel pump wiring (2) from ECM

cover (4). Disconnect fuel pump connector [141].

6-12 2013 Sportster Service: Electrical

Remove rear oxygen sensor (O2) wiring (3) from rear O2
sensor wiring clip (5) and ECM cover. Disconnect rear O2
connector [85].

Remove ECM cover fastener (1).

Slide ECM cover out from left side of vehicle.

Press the clip holding the ECM to the caddy and remove
the ECM.

See

Figure 6-9

. Press the connector latch (3) and unplug

ECM wiring harness connector (2) [78B] from ECM (1).

XR 1200X

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

Remove main fuse.

Remove rear fender. See

2.35 REAR FENDER: XR

2.35 REAR FENDER: XR 1200X

See

Figure 6-10

. Remove fasteners (1) and ECM (2).

INSTALLATION

TORQUE VALUE

FASTENER

3.4-6.8 Nm

30-60

in-lbs

ECM cover fastener: XL
Models

2.0-2.5 Nm

18-22

in-lbs

ECM fasteners: XR 1200X

XL Models

See

Figure 6-9

. Plug ECM wiring harness connector [78B]

(2) into ECM. Gently press connector until latch (3) clicks
in place.

Install ECM into caddy. Press ECM into caddy until it is
held by clip.

See

Figure 6-8

. Slide ECM cover (4) into position from left

side of motorcycle.

Install ECM cover fastener (1). Tighten to 30-60

in-lbs

(3.4-6.8 Nm).

Connect rear O2 connector [85]. Install O2 sensor wiring
(3) into ECM cover and clip (5)

Connect fuel pump connector [141]. Install fuel pump
wiring (2) into ECM cover (4).

Install main fuse.

Perform password learn procedure. See

6.38 TSM/HFSM:

PASSWORD LEARN

XR 1200X

See

Figure 6-10

. Install ECM (2) and fasteners (1).

Tighten fasteners to 18-22

in-lbs

(2.0-2.5 Nm).

Install rear fender. See

Install main fuse.

Perform password learn procedure. See

6.38 TSM/HFSM:

PASSWORD LEARN

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)

Install seat.

2013 Sportster Service: Electrical 6-13

6.7

TURN SIGNAL AND SECURITY MODULE
(TSM/TSSM/HFSM)

GENERAL

See

Figure 6-11

. The TSM has two functions:

•

Control turn signals.

•

Serve as the BAS.

The optional factory-installed security system provides the
same functionality as the TSM, but also includes security and
immobilization functions.

Two security system modules are available: The TSSM for
Japan/Korea markets and the HFSM for all other markets.

See the electrical diagnostic manual for complete details of
the TSM/TSSM/HFSM features and functions.

NOTE

This part cannot be repaired. Replace upon failure.

sm01275

Figure 6-11. TSM/TSSM/HFSM (TSM Shown)

REMOVAL

NOTE

See

Figure 6-12

. The TSM/TSSM/HFSM (3) is located in a

cavity in the bottom of the battery tray (1).

Remove battery. See

Unplug wiring harness connectors: 4-pin connector [208]
(HFSM only) has one latch. Unplug this connector first.
Then unplug 12-pin connector [30B].

See

Figure 6-12

. Reach under the battery tray (1) and

push upward on TSM/TSSM/HFSM (3) to lift it out of its
cavity (2).

Remove TSM/TSSM/HFSM from vehicle.

sm06664

1. Battery tray
2. Cavity
3. TSM/TSSM/HFSM

Figure 6-12. TSM/TSSM/HFSM Connectors: All Models

INSTALLATION

See

Figure 6-12

. Pull wiring harness connector [208]

(HFSM only) and connector [30B] up through cavity (2) in
bottom of battery tray (1).

Position TSM/TSSM/HFSM (3) over cavity with con-
nector(s) facing oil tank.

Lower TSM/TSSM/HFSM into cavity. See

Figure 6-12

Make sure top of TSM/TSSM/HFSM is flush with bottom
of battery tray.

Plug 4-pin [208] (HFSM only) and 12-pin [30B] wiring
harness connectors into TSM/TSSM/HFSM.

Install battery. Do not install left side cover at this time.
See

6.38 TSM/HFSM: PASSWORD LEARN

Perform TSM/TSSM/HFSM password learn and set-up
procedure. See

for procedure.

Install left side cover. See

2.18 LEFT SIDE COVER

6-14 2013 Sportster Service: Electrical

6.8

BATTERY CABLES

REMOVAL

Remove left side cover. See

2.18 LEFT SIDE COVER

See

Figure 6-13

. Slide main fuse and holder (1) toward

rear of motorcycle to detach from battery strap (4).

Remove battery. See

Disconnect negative (-) battery cable from crankcase.

Inspect main fuse wiring harness and holder

Note routing of negative (-) battery cable around frame
downtube.

sm06657

1. Main fuse and holder
2. Positive (+) battery cable holder
3. Positive (+) battery terminal (under protective

rubber boot)

4. Battery strap
5. Screw
6. Data link connector

Figure 6-13. Main Fuse and Battery Location: All Models

Inspect positive (+) and negative (-) cables for cuts, fraying
or other damage. See

See

Figure 6-14

. As required, pull back rubber cap (3) and

using a 12 mm wrench, remove nut with captive lock-
washer (5) and positive (+) battery cable (2) from starter
post (4).

sm06687

1. Starter assembly
2. Positive (+) battery cable
3. Rubber cap
4. Starter post
5. Nut with captive lockwasher

Figure 6-14. Positive (+) Cable Starter Post Connection:

All Models

INSTALLATION

TORQUE VALUE

FASTENER

6.8-7.9 Nm

60-70

in-lbs

Battery negative terminal
screw

6.8-7.9 Nm

60-70

in-lbs

Battery positive terminal screw

4.1-6.8 Nm

36-60

in-lbs

Battery strap screw

6.8-9.6 Nm

60-85

in-lbs

Battery positive cable to
starter post locknut

6.2-8.5 Nm

55-75

in-lbs

Battery negative cable to
crankcase nut

Apply a light coat of petroleum jelly or corrosion retardant
material to the negative battery terminal.

Slide battery in battery tray. Connect negative (-) battery
cable to battery. Tighten to 60-70

in-lbs

(6.8-7.9 Nm).

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)

See

Figure 6-13

. With negative (-) battery cable discon-

nected from ground on crankcase, install the fuse cable
and the positive (+) battery cable.

Thread fastener through main fuse cable.

Thread fastener through the positive (+) battery cable.

Thread fastener into the positive battery terminal (3).

Tighten to 60-70

in-lbs

(6.8-7.9 Nm).

2013 Sportster Service: Electrical 6-15

Apply a light coat of petroleum jelly or corrosion retardant
material to the positive battery terminal. Place protective
rubber boot over terminal.

Hook top of battery strap (4) to battery tray mount on top
of battery. Install screw (5). Tighten to 36-60

in-lbs

(4.1-

6.8 Nm).

Place positive battery cable into holder on ECM caddy.

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

Hook data link connector [91A] (6) to pin on battery strap
and slide forward until it snaps into place.

See

Figure 6-14

. Install positive (+) battery cable (2) and

nut with captive lockwasher (5) on starter post (4). Using
a 12 mm wrench, tighten to 60-85

in-lbs

(6.8-9.6 Nm).

10. Push rubber cap (3) over starter post.

11. Place negative battery cable connector onto stud on

crankcase boss behind starter motor assembly. Thread
nut onto crankcase ground stud behind starter motor.

12. See

Figure 6-14

. Press negative battery cable connector

against cable stop on crankcase. Using a swivel socket,
tighten to 55-75

in-lbs

(6.2-8.5 Nm).

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)

13. Install seat.

sm01169

Figure 6-15. Negative Battery Cable Stop on Crankcase

(typical)

6-16 2013 Sportster Service: Electrical

6.9

BATTERY TRAY

GENERAL

See

. The battery tray is located behind the left side

cover. The battery tray supports the battery, TSM/TSSM/HFSM
and rear stop lamp switch (XL models only).

REMOVAL

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)

Remove battery. See

SIGNAL AND SECURITY MODULE (TSM/TSSM/HFSM)

Unplug and remove TSM/TSSM/HFSM. See

6.7 TURN

XL Models:

see

BRAKE MASTER CYLINDER RESERVOIR

. Position rear stop lamp

switch as follows:

Remove rear brake master cylinder reservoir cover.

Secure the reservoir out of the way. See

2.13 REAR

Remove brake line clamp fastener (5) from battery
tray (4).

Remove TORX fastener (3) securing rear stop lamp
switch assembly (2) to battery tray. Gently pull stop
lamp switch assembly back out of the way. Do not
bend or stress metal brake lines.

Remove ECM caddy fastener (1).

sm06674

1. ECM caddy fastener
2. Rear stop lamp switch assembly
3. TORX fastener
4. Battery tray
5. Brake line clamp fastener
6. Battery tray fastener

Figure 6-16. Battery Tray Assembly

See

Figure 6-17

. Remove three fasteners (3) securing

battery tray to mounting tabs on frame.

Lift up battery tray slightly so that mounting tabs will clear
mounts on frame. As you lift up on tray, pull down gently
on end of battery strap support (2) to clear frame and
wiring harnesses above battery tray.

Remove negative battery cable and vent line from battery
tray retaining clips.

Slide battery tray out and remove from left side.

2013 Sportster Service: Electrical 6-17

sm01344a

1. Battery tray
2. Battery strap support
3. Screw (3)
4. Oil tank vent clip
5. Battery cable clip

Figure 6-17. Battery Tray

INSTALLATION

TORQUE VALUE

FASTENER

10.9-17.6 Nm

96-156

in-lbs

Battery tray mounting
fasteners

8.1-13.6 Nm

72-120

in-lbs

Stop lamp switch bracket
screw

3.4-4.5 Nm

30-40

in-lbs

Brake hose clamp to battery
tray screw

8.1-10.8 Nm

72-96

in-lbs

ECM caddy fastener

See

. Make sure the TSM/TSSM/HFSM con-

nector [30B], the antenna connector [208B] (HFSM only)

and the rear stop lamp switch assembly (2) are out of the
way.

See

Figure 6-17

. Slide battery tray (1) into place. Make

sure battery tray mounting tabs are positioned behind (to
the right of) frame mounts.

Secure the negative battery cable and the oil tank vent
line to the battery tray retaining clips (4, 5).

Install three screws (3) to secure battery tray to frame. Do
not tighten screws until all three have been started. Tighten
to 96-156

in-lbs

(10.9-17.6 Nm).

XL models only:

see

2.13 REAR BRAKE MASTER CYLINDER RESER-
VOIR

. Position rear stop lamp

switch as follows:

Install rear stop lamp switch (2). Secure with TORX
screw (3). Tighten to 72-120

in-lbs

(8.1-13.6 Nm).

Secure brake hose clamp (5) to battery tray with
screw. Tighten to 30-40

in-lbs

(3.4-4.5 Nm).

Install ECM caddy fastener (1). Tighten to 72-96

in-lbs

(8.1-10.8 Nm).

Install rear brake master cylinder reservoir. See

Install reservoir cover.

Install TSM/TSSM/HFSM into cavity in bottom of battery
tray. See

6.7 TURN SIGNAL AND SECURITY MODULE

(TSM/TSSM/HFSM)

Install battery. See

Install left side cover. See

2.18 LEFT SIDE COVER

6-18 2013 Sportster Service: Electrical

6.10

STARTER

REMOVAL

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)

Disconnect battery. See

4.13 EXHAUST SYSTEM: XL MODELS

Drain transmission lubricant and remove primary cover.
See

5.3 PRIMARY COVER

Remove

rear

muffler

and

exhaust

pipe.

See

4.14 EXHAUST

SYSTEM: XR 1200X

Remove the starter solenoid connector [128].

Remove positive (+) battery lead and solenoid wire from
starter.

NOTE

A ball hex driver may be required to gain access to the starter
mounting bolts.

See

Figure 6-18

. Remove the two starter mounting bolts

and washers.

XL Models:

Remove fastener securing oil line retaining

clamp to starter.

Remove starter and gasket from right side of motorcycle.

sm01600a

Figure 6-18. Starter Mounting Bolts

TOUCH-UP PAINT

Touch up damaged paint before installation. Follow the direc-
tions provided with the touch-up paint. Paint flaking does not
require starter replacement.

INSTALLATION

TORQUE VALUE

FASTENER

17.6-27.1 Nm

13-20 ft-lbs

Starter mounting bolt

1.8-2.4 Nm

16-21

in-lbs

Starter motor oil line clamp
fastener

6.8-9.6 Nm

60-85

in-lbs

Starter positive terminal nut

Install starter and starter gasket from right side of motor-
cycle.

See

Figure 6-18

. Install two starter mounting bolts and

washers. Tighten to 13-20 ft-lbs (17.6-27.1 Nm).

XL Models:

Install oil line clamp to starter motor. Tighten

to 16-21

in-lbs

(1.8-2.4 Nm).

Connect the starter solenoid connector [128].

Install positive (+) battery cable and solenoid wire to
solenoid stud. Tighten to 60-85

in-lbs

(6.8-9.6 Nm). Place

rubber boot securely over terminal.

Install primary cover. See

5.3 PRIMARY COVER

Fill primary chaincase / transmission with proper lubricant.
See

1.10 TRANSMISSION LUBRICANT

Install rear exhaust pipe and muffler. See

4.13 EXHAUST

SYSTEM: XL MODELS

4.14 EXHAUST SYSTEM: XR

Connect battery. See

2013 Sportster Service: Electrical 6-19

SOLENOID

TORQUE VALUE

FASTENER

7.3-9.0 Nm

65-80

in-lbs

Solenoid contact post jamnut

6.8-9.0 Nm

60-80

in-lbs

Starter ring terminal hex nut

Cover and Plunger Removal

See

Figure 6-19

. Remove fasteners (1), cover (2) and

gasket (3).

Remove the plunger (4) with spring (5).

sm06876

1. Fasteners
2. Cover
3. Gasket
4. Plunger
5. Spring

Figure 6-19. Soleniod Plunger

Short Post Contact: Starter

Disassemble the short post contact:

Remove the hex nut and the ring terminal from the
post.

See

Figure 6-20

. Remove jamnut (8), wave washer

(7), O-ring (6) and round bushing (5):

Remove the post bolt (1).

Remove the hold-in terminal (2) from the post bolt.

Remove the contact plate (3) and the square bushing
(4).

Assemble the short post contact:

Insert the square bushing into the housing.

Install the contact plate with the 90 degree part of the
contact plate against the solenoid winding.

Install the post bolt through the hold-in terminal, the
contact plate and the square bushing.

Install the round bushing, O-ring, wave washer and
jamnut.

sm06877

1. Post bolt
2. Hold-in terminal
3. Contact plate
4. Square bushing
5. Round bushing
6. O-ring
7. Wave washer
8. Jamnut

Figure 6-20. Short Post Contact (starter)

Long Post Contact: Battery Positive

See

Figure 6-21

. Remove the long post contact:

Remove hex nut (9).

Remove jamnut (8), wave washer (7), O-ring (6) and
the round bushing (5).

Remove post bolt (4), contact plate (3), square
bushing (2) and paper insulator (1).

Install the long post contact:

Insert the square bushing through the paper insulator
into the housing.

Install the contact plate with the foot against the
solenoid winding.

Install the post bolt.

NOTE

Check that the index pin on the round bushing fits the blind
hole in the housing.

Install the round bushing, O-ring, wave washer and
jamnut.

6-20 2013 Sportster Service: Electrical

sm06878a

1. Paper insulator
2. Square bushing
3. Contact plate
4. Post bolt
5. Round bushing
6. O-ring
7. Wave washer
8. Jamnut
9. Hex nut

Figure 6-21. Long Post Contact (battery)

Plunger and Cover Installation

Apply LUBRIPLATE 110 to the plunger shaft. Install the
spring.

Install the plunger and spring in the housing.

While compressing the plunger, alternately tighten the
contact post jamnuts to 65-80

in-lbs

(7.3-9.0 Nm).

Check that the contact plates are aligned to the solenoid
winding.

Install the cover:

Install a

new

gasket on the cover.

Install the cover.

Install the fasteners until snug.

Install the starter ring terminal.

Install the hex nut. Tighten to 60-80

in-lbs

(6.8-9.0 Nm).

CLUTCH SHAFT ASSEMBLY

Removal

See

Figure 6-22

. Loosen the two long starter support bolts

(1).

Remove the two fasteners (2) and separate the clutch
assembly housing (4) from the starter/solenoid housing
(3).

Save the spring (5) from the solenoid plunger shaft.

NOTE

Remove the old assembly lube to release the steel ball (8).

Remove and save the steel ball from the bearing end of
the clutch shaft assembly (6) bore.

Tap on the end of the shaft to remove the clutch shaft
assembly from the housing.

Remove the idler gear (7) from the bearing cage.

Remove bearing cage and the five steel cylinders.

sm06872a

1. Starter support bolts
2. Fasteners
3. Starter/solenoid housing
4. Clutch assembly housing
5. Spring
6. Clutch shaft assembly
7. Idler gear
8. Steel ball

Figure 6-22. Starter Drive Housing and Clutch Shaft

Inspection

Inspect the O-rings in the clutch assembly housing bore.

Inspect the spring for kinks or elongation.

Inspect the steel ball.

Inspect the idler gear and the cage.

Inspect the clutch shaft assembly pinion gear for missing
or damaged teeth.

Check that the roller bearings and the clutch gear on the
clutch shaft rotate freely.

Installation

Lubricate components with LUBRIPLATE 110.

See

Figure 6-23

. Install the bearing cage (1) with the five

steel cylinders (2).

Install the idler gear (3) over the bearing cage.

Match the gear teeth to the idler gear and install the clutch
assembly (4) in the housing. Seat the bearing in the
counterbore.

Install the steel ball (5) in the bore of the shaft.

Apply a light film of LUBRIPLATE 110 to solenoid plunger
shaft. Install return spring (6) on solenoid plunger shaft.

2013 Sportster Service: Electrical 6-21

6.11

IGNITION SWITCH

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)

Purge the fuel supply hose of high pressure gasoline.
Disconnect fuel supply hose from fuel pump module. See

4.5 FUEL TANK: XR

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

Remove main fuse.

Remove seat.

Remove fuel tank. See

A.23 SEALED SPLICE CONNECTOR

See

Figure 6-24

. Remove ignition switch face nut (5).

Remove mounting screw (7). Remove switch cover (3).
Remove switch (2) from switch cover (3).

Remove cable strap securing switch harness to wire har-
ness caddy.

Cut switch wires 3.0 in (76.2 mm) from switch.

Remove harness covering.

INSTALLATION

TOOL NAME

PART NUMBER

ULTRA TORCH UT-100

HD-39969

TORQUE VALUE

FASTENER

4.0-5.1 Nm

35-45

in-lbs

Ignition switch mounting screw

Slide replacement conduit on harness wires.

Be sure to follow manufacturer's instructions when using
the UltraTorch UT-100 or any other radiant heating device.
Failure to follow manufacturer's instructions can cause a
fire, which could result in death or serious injury. (00335a)

Observing color codes, install seal splice connectors to
harness wires. Complete sealed splice to

new

ignition

switch. Seal splice connectors with ULTRA TORCH UT-
100 (Part No. HD-39969) or other radiant heating device.
See

Slide conduit over sealed splice connectors.

See

Figure 6-24

. Insert ignition switch into hole of switch

cover. The word "TOP" stamped on the switch body should
face upward toward the lettering on the switch position
decal. Loosely install face nut (5).

Install mounting screw (7). Tighten to 35-45

in-lbs

(4.0-

5.1 Nm).

Tighten face nut (5) to secure switch (2) within cover (3).

Using

new

cable strap (6), secure ignition switch harness

to wire harness caddy.

Install fuel tank. 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)

Install seat.

10. Install main fuse.

Be sure that all lights and switches operate properly before
operating motorcycle. Low visibility of rider can result in
death or serious injury. (00316a)

11. Check ignition switch.

AC C

sm01346

1. Sealed splice connector
2. Ignition switch
3. Switch cover
4. Decal
5. Face nut
6. Cable strap
7. Mounting screw

Figure 6-24. Ignition Switch

2013 Sportster Service: Electrical 6-23

6.12

SPARK PLUG CABLES

GENERAL

Resistor-type high-tension spark plug cables have a carbon-
impregnated fabric core (instead of solid wire) for radio noise
suppression and improved reliability of electronic components.
Use the exact replacement cable for best results.

REMOVAL

Purge the fuel supply hose of high-pressure gasoline.
Disconnect fuel supply hose from fuel pump module. See

4.5 FUEL TANK: XR

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

Remove main fuse.

Remove seat.

Remove fuel tank. See

XL Models:

See

Figure 6-25

. Remove screw (1) securing

left wire harness caddy (2) to right wire harness caddy.
See

6.28 ELECTRICAL CADDIES

. Carefully disengage

left wire harness caddy and pull away from frame back-
bone.

NOTE

Always grasp rubber boot as close as possible to the spark
plug terminal when removing spark plug cables. Do not pull on
the cable portion itself. Pulling on the cable will damage the
cable's carbon core.

See

Figure 6-26

. Pull front spark plug boot

and cable (2) from left side ignition coil (1) tower.

sm03784

1. Screw
2. Left wire harness caddy
3. Ignition coil

Figure 6-25. Ignition Coil and Left Wire Harness Caddy:

XL Models

Pull rear spark plug boot (3) and cable from right side
ignition coil tower.

Unplug spark plug boot and cable assemblies from front
and rear spark plugs.

XL Models:

Disengage rear spark plug cable from notch

in right wire harness caddy (5). Remove the cable.

10.

XR 1200X:

See

. Disengage rear spark plug

cable from wire harness caddy (5). Remove the cable.

11.

XL Models:

See

Figure 6-28

. Remove rear spark plug

cable (2) from curved trough on wire harness caddy (1).

Cut cable strap (4).

Feed spark plug cable out from between frame and
engine. Remove the cable.

Remove cable strap from mounting boss on caddy
latch clip (5). Discard cable strap.

6-24 2013 Sportster Service: Electrical

sm03785

1. Ignition coil
2. Front spark plug cable boot
3. Rear spark plug cable boot
4. Rear spark plug cable
5. Notch in right wire harness caddy

Figure 6-26. Spark Plug Cable Routing: XL Models

sm05528

1. Ignition coil
2. Front spark plug cable boot
3. Rear spark plug cable boot
4. Rear spark plug cable
5. Harness caddy

Figure 6-27. Spark Plug Cable Routing: XR 1200X

sm03786

1. Right wire harness caddy
2. Rear spark plug cable
3. Engine sub-harness
4. Cable strap
5. Caddy latch clip

Figure 6-28. Rear Spark Plug Cable Routing: XL Models

INSTALLATION

See

Figure 6-26

. Plug rear spark plug cable

boot (3) into right side ignition coil (1) tower.

XL Models:

Route cable between wire harness caddies,

and down through notch (5) in right caddy, toward right
side of engine.

XR 1200X:

Route rear spark plug cable through harness

caddy (5) as shown.

XL Models:

See

Figure 6-28

. Route rear spark plug cable

(2) in trough in right wire harness caddy (1), over top of
engine sub-harness (3) and back toward left side of
engine.

XL Models:

See

Figure 6-29

. Install

new

barbed cable

strap (3) onto spark plug cable (1), 7.0-7.25 in (178-184
mm) from tip of spark plug cable boot (2).

Orient the cable strap so that the spark plug cable is
above the mounting boss on the caddy latch clip.

Press the cable strap barbed prong firmly into the
hole in the caddy latch clip mounting boss.

Plug rear spark plug cable and boot onto rear spark plug
until it clicks.

2013 Sportster Service: Electrical 6-25

See

Figure 6-26

. Plug front spark plug cable

and boot (2) into left side ignition coil (1) tower. Plug other
end of cable onto front spark plug until it clicks.

NOTE

Make sure rear spark plug cable is routed properly and cannot
chafe against frame, fuel tank or rear cylinder head.

XL Models:

See

Figure 6-25

. Mate left wire harness caddy

(2) to right wire harness caddy. Secure with screw (1) and
tighten. See

6.28 ELECTRICAL CADDIES

Install fuel tank. 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.

11. Install main fuse.

12. Start the engine. Verify ignition function.

sm03787

1. Rear spark plug cable
2. Spark plug boot (spark plug end)
3. Barbed cable strap
4. 7.0-7.25 in (178-184 mm)

Figure 6-29. Rear Spark Plug Cable and Cable Strap: XL

Models