Harley Davidson 2013 Sportster Models. Service Manual - page 45

2013 Sportster Service: Electrical 6-43

INSTALLATION: HDI

TORQUE VALUE

FASTENER

1.2-1.3 Nm

14-16

in-lbs

License plate lamp housing
screw: XL 883N

14.9-24.4 Nm

132-216

in-lbs

Fender support, rear, screw:
XL 883N

2.3-2.8 Nm

20-25

in-lbs

Fender brace, rear, screw

61-68 Nm

45-50 ft-lbs

Shock absorber mounting bolt

If reusing license plate lamp housing, see

Figure 6-62

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.

See

Figure 6-60

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

See

Figure 6-59

. 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).

See

Figure 6-58

. 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.

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

See

Figure 6-63

. 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).

Now tighten screw securing fender to center of fender
brace to 20-25

in-lbs

(2.3-2.8 Nm).

See

Figure 6-57

. 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).

See

Figure 6-56

. Plug license plate lamp harness con-

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

10. Install lower shock absorber screw and nut on each side

of vehicle. Tighten to 45-50 ft-lbs (61-68 Nm). 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)

11. Install seat.

12. 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)

13. Verify operation of lighting system.

sm03742

1. License plate holder
2. Rear fender brace
3. Threaded insert
4. Hole

Figure 6-63. License Plate Holder and Rear Fender Brace:

XL 883N, XL 1200X (HDI)

6-44 2013 Sportster Service: Electrical

6.18

FRONT TURN SIGNALS

BULB REPLACEMENT

Insert coin in notch of front or rear turn signal lens cap.
Carefully twist coin until lens cap pops out of turn signal
housing.

Replace bulb.

Push bulb and turn counterclockwise.

Pull bulb from socket when tab on bulb clears opening
on socket.

Coat base of

new

bulb with ELECTRICAL CONTACT

LUBRICANT.

Push

new

bulb in and turn clockwise to lock in place.

Snap lens cap back into housing.

ALL EXCEPT XL 1200X

TORQUE VALUE

FASTENER

10.8-16.3 Nm

96-144

in-lbs

Turn signal, front, ball head
studs

10.8-13.6 Nm

96-120

in-lbs

Turn signal clamp, front, screw

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

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 fuel tank. See

4.5 FUEL TANK: XR 1200X

Separate left and right wire harness caddies. See

See

Figure 6-64

. Locate turn signal connector [31] (4)

mounted on right wire harness caddy (2). Press latch (5)
and separate connector halves.

Remove the corresponding socket terminals from con-
nector [31B].

See

Figure 6-65

. Loosen the hex screw holding turn signal

housing ball end stud to front of hand lever bracket.

Pull the wire conduit through the coil bracket, the fork
clamp and handlebar clips.

Installation

See

Figure 6-66

. Inspect the ball head stud (1) and replace

as required. Tighten

new

ball head studs to 96-144

in-lbs

(10.8-16.3 Nm).

Lay old turn signal housing and wires next to

new

and cut

new

wires to length.

Trim sheath back approximately 2.5 in (63.5 mm) and
crimp

new

socket terminals onto wires.

Route wires through handlebar clips, between fork clamp
and head lamp bracket and then through coil bracket.

Install housing ball end stud into the lever bracket and aim
to front. Tighten to 96-120

in-lbs

(10.8-13.6 Nm).

Insert socket terminals into turn signal connector.

Join the connector [31] halves. Reassemble left and right
wire harness caddies. See

Install fuel tank. See

4.5 FUEL TANK: XR 1200X

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)

10. Test the turn signals.

sm01170a

1. Frame backbone
2. Right wire harness caddy
3. Left wire harness caddy
4. Turn signal connector [31]
5. Connector latch

Figure 6-64. Turn Signal Connector [31]

2013 Sportster Service: Electrical 6-45

sm01294

Figure 6-65. Turn Signal Ball Stud Screw

sm01366

1. Ball end stud
2. Turn signal assembly
3. Bulb
4. Lens

Figure 6-66. Front Turn Signal Components: All Except XL

1200X

XL 1200X

TORQUE VALUE

FASTENER

16.3-21.7 Nm

12-16 ft-lbs

Turn signal housing to bracket:
XL 1200X

40.7-47.5 Nm

30-35 ft-lbs

Fork bracket pinch screw

Removal

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

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

Remove main fuse.

Remove fuel tank. See

Separate left and right wire harness caddies. See

Locate the turn signal connector [31] mounted on right
wire harness caddy. Press latch and separate connector
halves.

Remove the corresponding socket terminals from con-
nector [31B].

Remove the turn signal bracket fastener (front fork bracket
pinch screw) and washer and the bracket.

Remove the turn signal nut and lockwasher to remove the
turn signal.

Installation

See

Figure 6-67

. Thread the turn signal leads through the

bracket (1).

Install the turn signal (2) with the lockwasher (3) and nut
(4) and tighten to 12-16 ft-lbs (16.3-21.7 Nm).

Fit the bracket to the upper fork clamp.

Install and tighten the turn signal bracket fastener (6) and
washer (5) (front fork bracket pinch screw) to 30-35 ft-lbs
(40.7-47.5 Nm).

Insert socket terminals into turn signal connector.

Join the connector [31] halves. Reassemble left and right
wire harness caddies. See

Install the cable straps.

Install the fuel tank. See

Install main fuse.

6.18 FRONT TURN SIGNALS, Bulb Replacement

6-46 2013 Sportster Service: Electrical

6.19

REAR TURN SIGNALS

GENERAL

Bulb Replacement

See

Tail and Stop Lamps

XL 883N, XL 1200X/V:

The rear turn signals are the tail and

stop lamps. This feature may not be available in all markets.
The rear turn signal/stop lamp functions are provided by an
electronic converter module. See

6.20 REAR LIGHTING

CONVERTER MODULE: XL 883N, XL 1200X/V (DOM)

NOTE

XL 883N and XL 1200X/V models in certain markets are
equipped with LED rear turn signal/stop lamp/tail lamp
assemblies. These models do not require an electronic con-
verter module. The LED assemblies are sealed units and
cannot be disassembled. The entire rear turn signal housing
assembly must be replaced.

XL 883R/L

TORQUE VALUE

FASTENER

10.9-17.6 Nm

96-156

in-lbs

Turn signal housing to mount,
rear, fastener

14.9-24.4 Nm

132-216

in-lbs

Turn signal stalk nut

14.9-24.4 Nm

132-216

in-lbs

Strut cover screw

Removal

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.

See

Figure 6-68

. Remove two screws (2) and tail lamp

lens (3) from tail lamp base (4).

See

Figure 6-69

. Remove left and right turn signal con-

nectors (1, 2). Pull turn signal wiring harnesses through
harness access holes (3) in tail lamp base.

Remove lower shock absorber mounting screws and nuts.
See

See

Figure 6-70

. Disengage turn signal wiring harnesses

from wire retention brackets (1).

See

Figure 6-71

. Remove screws (3, 4), washers (5), nuts

(7) and nut plate (8).

Remove rear fender strut covers (1) with attached turn
signal assemblies (2) from rear fender struts. Carefully
slide wiring through holes.

Remove socket terminals from left and right turn signal
connectors [18B], [19B].

10. Unscrew and remove turn signal stalk (6) and fender strut

cover (1) from each turn signal assembly (2). Mount will
separate from turn signal housing.

sm01668

1. Rear fender
2. Screw (2)
3. Tail lamp lens
4. Tail lamp base

Figure 6-68. Tail Lamp Lens: All Models Except XL 883N,

XL 1200X/V and XL 1200C/C ANV/CP/CA/CB

sm06775

1. Left turn signal connector [19]
2. Right turn signal connector [18]
3. Wiring harness access hole (2)

Figure 6-69. Turn Signal Connectors: All Models Except

XL 883N, XL 1200X/V/C/CP/CA/CB

6-48 2013 Sportster Service: Electrical

sm01296

1. Wire retention bracket (2)
2. Turn signal wiring harness (2)
3. Rear turn signal stalk nut (2)
4. Nut plate (2)
5. Nut (2)

Figure 6-70. Turn Signal Wire Routing: XL 883R/L

sm01669

1. Rear fender strut cover (2)
2. Rear turn signal assembly (2)
3. Screw (2)
4. Screw (2)
5. Washer (4)
6. Turn signal stalk (2)
7. Nut (4)
8. Nut plate (2)
9. Rear fender
10. Frame

Figure 6-71. Rear Fender Mounting Components (typical)

Installation

Lay old turn signal housing and wires next to

new

and cut

new

wires to length. Trim sheath back approximately 2.5

in (63.5 mm).

Crimp

new

terminals onto wires.

See

Figure 6-72

. Install each turn signal housing (3) and

mount (4) to rear fender strut cover with turn signal stalk
(5). Tighten to 96-156

in-lbs

(10.9-17.6 Nm).

Press wiring harness terminal sockets into left and right
connector housings [19B], [18B].

Install rear fender strut covers over fender struts. Push
turn signal wiring harness through the hole in the strut and
fender.

Thread nut onto turn signal stalk from inside fender. Finger
tighten.

Secure fender to each fender strut with screw, washer and
nut in forward mounting hole. Install screw, washer and
nut plate in aft mounting hole. Finger tighten.

Tighten fasteners:

Tighten turn signal stalk nuts to 132-216

in-lbs

(14.9-

24.4 Nm).

Tighten strut cover screws to 132-216

in-lbs

(14.9-

24.4 Nm).

Engage turn signal wiring harness in wire retention bracket
on each side of rear fender.

10. Push left and right turn signal wiring harnesses through

corresponding harness access holes in tail lamp base.

11. Attach left [18] and right [19] turn signal connectors.

12. Attach tail lamp lens to tail lamp base.

13. Install lower shock absorber mounting screws and nuts.

See

14. Install main fuse.

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)

15. Install seat.

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)

16. Verify operation of lighting system.

2013 Sportster Service: Electrical 6-49

sm01367a

1. Lens
2. Bulb (element)
3. Rear turn signal housing
4. Mount
5. Turn signal stalk

Figure 6-72. Rear Turn Signal Components: XL 883R/L

XL 883N AND XL 1200X/V

TORQUE VALUE

FASTENER

10.9-17.6 Nm

96-156

in-lbs

Turn signal housing to mount,
rear, fastener

14.9-24.4 Nm

132-216

in-lbs

Turn signal stalk nut

14.9-24.4 Nm

132-216

in-lbs

Strut cover screw

Removal

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.

Raise the rear wheel.

Remove lower shock absorber mounting screws and nuts.
See

Raise motorcycle to access the underside of the rear
fender.

See

Figure 6-73

. Unplug rear lighting harness connectors

[18], [19] (1, 2).

See

Figure 6-74

. Remove left rear lighting harness (3)

from RH and LH harness bracket (1).

Remove lighting harness from RH and LH lower bracket
harness clips (2).

See

Figure 6-75

. Pull both rear lighting harnesses (2, 3)

through feed-through holes (4, 5) in rear fender.

10. See

Figure 6-76

. Remove screws (3, 4), washers (5), nuts

(7) and nut plate (8). Remove rear fender strut covers (1)
with attached turn signal assemblies (2) from rear fender

struts. Carefully feed turn signal harnesses through holes
in fender and fender struts.

11. Remove socket terminals from left and right turn signal

connectors [18B], [19B].

12. Remove turn signal stalk (6) (1) and fender strut cover

from each turn signal assembly (2). Mount will separate
from turn signal housing.

sm01171

1. Left rear lighting harness connector [19]
2. Right rear lighting harness connector [18]
3. Brown band

Figure 6-73. Rear Lighting Harness Connectors: XL 883N,

XL 1200X/V

sm01173

1. Harness bracket
2. Lower bracket harness clip (3)
3. Left rear lighting harness

Figure 6-74. Rear Lighting Harness Removal/Installation:

XL 883N, XL 1200X/V

6-50 2013 Sportster Service: Electrical

sm01172a

1. Harness bracket (2)
2. Right rear lighting harness
3. Left rear lighting harness
4. Right feed-through hole
5. Left feed-through hole
6. License plate lamp harness

Figure 6-75. Lighting Harnesses and Harness Brackets:

XL 883N, XL 1200X/V

sm01669

1. Rear fender strut cover (2)
2. Rear turn signal assembly (2)
3. Screw (2)
4. Screw (2)
5. Washer (4)
6. Turn signal stalk (2)
7. Nut (4)
8. Nut plate (2)
9. Rear fender
10. Frame

Figure 6-76. Rear Fender Mounting Components (typical)

Installation

Lay old turn signal housing and wires next to

new

and cut

new

wires to length. Trim sheath back approximately 2.5

in (63.5 mm).

Crimp

new

terminals onto wires.

See

Figure 6-77

. Install each turn signal housing (3) and

mount (4) to rear fender strut cover with turn signal stalk.
Tighten to 96-156

in-lbs

(10.9-17.6 Nm).

Press wiring harness terminal sockets into left and right
connector housings [19B], [18B].

Install rear fender strut covers over fender struts. Push
turn signal wiring harness through hole in strut and fender.

Finger tighten nut onto turn signal stalk from inside fender.

Secure fender to each fender strut with screw, washer and
nut in forward mounting hole. Install screw, washer and
nut plate in aft mounting hole. Finger tighten.

NOTE

See

Figure 6-78

. Make certain that tab (3) on nut plate (2) fits

into slot (4) in fender brace (1) when securing nut plate with
rearmost fender mounting screw (5).

Tighten mounting screws in the following sequence:

Tighten turn signal stalk nuts to 132-216

in-lbs

(14.9-

24.4 Nm).

Tighten strut cover screws to 132-216

in-lbs

(14.9-

24.4 Nm).

Install lower shock absorber mounting screws and nuts.
See

10. Install main fuse.

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)

11. Install seat.

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)

12. Verify operation of lighting system.

2013 Sportster Service: Electrical 6-51

sm01367

1. Lens
2. Bulb (element)
3. Rear turn signal housing
4. Mount
5. Turn signal stalk
6. Rear turn signal housing (sealed unit: XL 883N,

XL 1200X, XL 1200V)

Figure 6-77. Rear Turn Signal Components

sm01174

1. Rear fender brace
2. Nut plate (2)
3. Tab
4. Slot
5. Mounting screw (2)

Figure 6-78. Rear Fender Nut Plate: XL 883N, XL 1200X/V

XL 1200C/C ANV/CP/CA/CB

TORQUE VALUE

FASTENER

10.9-17.6 Nm

96-156

in-lbs

Turn signal housing to mount,
rear, fastener

14.9-24.4 Nm

132-216

in-lbs

Turn signal stalk nut

14.9-24.4 Nm

132-216

in-lbs

Turn signal stalk nut

Removal

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.

Raise the rear wheel.

Remove the lower shock absorber mounting screws and
nuts. See

Raise the motorcycle to access the underside of the rear
fender.

See

Figure 6-79

. Separate the RH [18] (3) and LH [19] (4)

turn signal connector housings.

Remove the turn signal wire harness from the RH and LH
wire retention brackets.

Pull the harness connectors through the feed holes in the
fender.

Remove screws, washers, nuts and nut plate.

10. Remove rear fender strut covers with attached turn signals.

11. Thread the wire harness through the holes in the fender

and fender struts.

12. Unscrew and remove turn signal stalk and fender strut

cover from each turn signal assembly.

13. Remove socket terminals from RH [18B] and LH [19B]

turn signal connectors.

6-52 2013 Sportster Service: Electrical

sm07136

1. Main harness connector [7]
2. Tail lamp connector [40]
3. RH turn signal connector [18]
4. LH turn signal connector [19]

Figure 6-79. Turn Signal Wire Harness: XL 1200C/C

ANV/CP/CA/CB

Installation

Lay turn signal housing wires next to

new

and cut

new

length. Trim sheath back 2.5 in (63.5).

Crimp

new

terminals onto leads.

Assemble the turn signal housing to the mount and install
the fastener. Tighten to 96-156

in-lbs

(10.9-17.6 Nm).

Install wire harness terminals into RH and LH connector
housings [18B], [19B].

Thread turn sign wire harness through hole in strut and
fender and install strut covers over fender struts.

Thread nut onto turn signal stalk from inside the strut.
Finger tighten.

Secure fender to strut with screws, washers and nuts.
Finger tighten.

Tighten fasteners:

Turn signal stalks to strut cover to 132-216

in-lbs

(14.9-24.4 Nm).

Fender strut cover to strut to 132-216

in-lbs

(14.9-

24.4 Nm).

Thread turn signal wires through fender and behind the
wire retention bracket.

10. Thread the turn signal wires through the fender openings

and connect the housings [18] and [19].

11. Install shock absorber mounting screws and nuts and

lower the motorcycle. See

12. Install main fuse.

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.

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)

14. Verify operation of lighting system.

XR 1200X

TORQUE VALUE

FASTENER

3.4-4.5 Nm

30-40

in-lbs

Turn signal housing, rear,
screws: XR 1200X

Removal

Remove seat.

Remove main fuse.

Remove two screws and tail lamp lens from tail lamp base.

See

Figure 6-80

. Remove left and right turn signal con-

nectors (1, 2). Pull turn signal wiring harnesses through
harness access holes in tail lamp base (3).

Remove socket terminals from left and right turn signal
connectors.

See

Figure 6-81

. Remove screws (6), plate (4), reflector

(3) and turn signal housing (2).

Lay old turn signal housing and wires next to

new

and cut

new

wires to length. Trim sheath back approximately 2.5

in (63.5 mm).

Crimp

new

terminals onto wires.

2013 Sportster Service: Electrical 6-53

sm06775

1. Left turn signal connector [19]
2. Right turn signal connector [18]
3. Wiring harness access hole (2)

Figure 6-80. Turn Signal Connectors: All Models Except

XL 883N, XL 1200X/V/C/CP/CA/CB

sm05569

1. Tail light base
2. Left turn signal
3. Reflector
4. Plate
5. Connector
6. Screw (2)

Figure 6-81. Turn Signal Housing Removal: XR 1200X

Installation

See

Figure 6-81

. Install turn signal housing (2), reflector

(3), and plate (4) with screws (6). Tighten screws to 30-40

in-lbs

(3.4-4.5 Nm).

Press wiring harness terminal sockets into left [19B] and
right [18B] connector housings.

Push left and right turn signal wiring harnesses through
corresponding harness access holes in tail lamp base.

Plug left turn signal connector [18] and right connector
[19] into left and right sockets located on rear lighting cir-
cuit board in tail lamp base.

Attach tail lamp lens to tail lamp base.

Install main fuse.

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)

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.

Verify operation of lighting system.

6-54 2013 Sportster Service: Electrical

6.20

REAR LIGHTING CONVERTER MODULE: XL
883N, XL 1200X/V (DOM)

GENERAL

NOTE

HDI XL 883N and XL 1200X/V models have a sealed LED tail
lamp, stop lamp and turn signal assembly in each rear turn
signal housing.

The domestic XL 883N and XL 1200X/V rear turn signal lamps
also serve as tail lamps and stop lamps. One filament provides
the tail lamp function while the other filament provides the turn
signal and stop lamp.

See

Figure 6-82

. In order for a single filament to function both

as turn signal and stop lamp, a converter module is required.
The converter module is located in front of the battery, under
the frame "Y" section.

sm07123

1. Converter module
2. Main harness connector [7]
3. License plate lamp connector [40]
4. Right turn signal connector [18]
5. Left turn signal connector [19]

Figure 6-82. Converter and Interconnect Harness

REMOVAL

Remove seat.

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

1.22 BATTERY MAINTENANCE

See

Figure 6-83

. Unplug the following harness connectors:

Antenna [209] (1) (H-DSSS equipped motorcycles
only)

Right rear lighting harness [18] (2)

Left rear lighting harness [19] (3)

License plate lamp harness [40] (4)

Main wiring harness [7] (5)

Engine harness connector [145] (6)

See

Figure 6-84

. Remove ECM caddy fastener.

Remove right side cover.

Remove fastener securing bracket to oil tank.

Remove barbed cable strap securing temperature sensor
harness to bracket.

See

Figure 6-85

. Remove bracket fasteners (2).

Remove bracket (3) with converter module (7).

10. Remove cable strap securing temperature sensor wire to

oil tank mounting bracket.

11. Remove rubber mounting tab (5) from mounting tab hole

(4) to release module from bracket.

sm06682

1. Antenna [209] (H-DSSS equipped vehicles only)
2. Right rear lighting harness connector [18]
3. Left rear lighting harness connector [19]
4. License plate lamp harness [40]
5. Main wiring harness connector [7]
6. Engine harness connector [145]
7. Flat washer
8. Seat post
9. Frame crossmember tab

Figure 6-83. Rear Lighting Harness Connectors: XL 883N,

XL 1200X/V

2013 Sportster Service: Electrical 6-55

sm06684

Figure 6-84. ECM Caddy Fastener

sm06679

1. Frame
2. Bracket fastener (3)
3. Bracket
4. Mounting tab hole
5. Rubber mounting tab
6. Module holder
7. Module

Figure 6-85. Converter Module

INSTALLATION

TORQUE VALUE

FASTENER

8.1-10.8 Nm

72-96

in-lbs

ECM caddy fastener

4.1-6.8 Nm

36-60

in-lbs

Converter module bracket
fasteners, rear lighting

Feed converter module/interconnect harness connectors
up through battery compartment, forward of battery strap
bracket.

See

Figure 6-85

. Install module (7) and module holder (6)

into bracket (3) by pulling rubber mounting tab (5) into
mounting tab hole (4).

Position bracket up inside frame, under "Y" section.

Install but do not tighten bracket fasteners (2).

See

Figure 6-84

. Install ECM caddy fastener. Tighten to

72-96

in-lbs

(8.1-10.8 Nm).

Tighten bracket fasteners to 36-60

in-lbs

(4.1-6.8 Nm).

Secure temperature sensor wire to oil tank mounting
bracket with a cable strap.

Install right side cover.

See

Figure 6-83

. Plug in the following harness connectors:

Antenna [209] (1)

Right rear lighting harness [18] (2)

Left rear lighting harness [19] (3)

License plate lamp harness [40] (4)

Main wiring harness [7] (5)

Engine harness connector [145] (6)

10. Install battery. See

1.22 BATTERY MAINTENANCE

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

11. Close left side cover. See

2.18 LEFT SIDE COVER

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)

12. Install seat.

13. Verify operation of lighting system.

MASTER CYLINDER RESERVOIR

6-56 2013 Sportster Service: Electrical

6.21

REAR STOP LAMP SWITCH

GENERAL

XL Models:

See

Figure 6-86

. 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 1200X:

The rear stop lamp switch is located underneath

the motorcycle near the rear brake master cylinder reservoir.
The rear stop lamp switch threads 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 closes and the rear stop
lamp illuminates.

NOTE

This part cannot be repaired. Replace upon failure.

REPLACEMENT

TORQUE VALUE

FASTENER

14.9-18.9 Nm

132-168

in-lbs

Stop lamp switch to tee nut

2.3-2.8 Nm

20-25

in-lbs

Brake master cylinder reser-
voir, rear, mounting screw

Remove main fuse.

XL Models:

move rear brake master cylinder reservoir

out of the way:

Remove the rear brake master cylinder reservoir
cover. Grasp cover and pull straight away from
reservoir.

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

2.13 REAR BRAKE

See

Figure 6-86

Figure 6-87

. Pull terminal sockets from

spade connections (4) on stop lamp switch.

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

Thread

new

stop lamp switch (3) to tee nut (2) on brake

line. Tighten switch to 132-168

in-lbs

(14.9-18.9 Nm).

NOTE

XR 1200X: Make sure that the brake switch wires do not con-
tact the ground strap cable.

Install terminal sockets on switch spade connections (4).

XL Models:

Install rear brake master cylinder reservoir:

Replace the reservoir mounting screw. Tighten to
20-25

in-lbs

(2.3-2.8 Nm).

Replace the brake master cylinder reservoir cover.

Install main fuse.

Install left side cover.

10. Refill

master

cylinder

and

bleed

brakes.

See

2.17 BLEEDING BRAKES

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)

11. Test operation of rear brake.

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)

12. Test operation of stop lamp with the rear brake applied

and the ignition/light switch turned ON.

sm01253

1. Rear brake line
2. Tee nut
3. Rear stop lamp switch
4. Spade connector terminal socket (2) [121]

Figure 6-86. Rear Stop Lamp Switch: XL Models Only