Harley Davidson Sportster Models 2009. Service Repair Manual - page 8

A.16 PACKARD MICRO-64 CONNECTORS

Figure 6-23

. Remove reset switch boot (11) from back

cover (5).

Remove screws (6) and back cover (5).

Remove tachometer connector (12).

Follow instructions to push the trip reset socket terminals
out the front of the tachometer connector. See

Cut off the socket terminals and pull the faulty switch out
of the connector.

Push the wires of a replacement switch through the
tachometer connector (sockets 8, 11) and crimp new
socket terminals using CRIMPING TOOL (Part No. HD-
45929), on replacement switch wiring.

Draw the terminals back into the connector until the ter-
minal seats.

Install tachometer connector (12).

10. Position reset switch in squared boss on back cover (5)

and secure with new reset switch boot (11).

11. Place back cover over speedometer and tachometer while

positioning harness to avoid damage. Rotate speedometer
and tachometer as needed to align mounting holes and
install screws (6).

12. Plug in main fuse. See

TACHOMETER REMOVAL

NOTE

The speedometer and tachometer have backlight bulbs that
cannot be replaced. If the bulb fails, replace the entire unit.

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

Unplug main fuse. See

6.9 SPEEDOMETER AND TACHOMETER: XR MODELS,
Trip Odometer Reset Switch Replacement

See

Figure 6-23

. Remove reset switch boot (11) from back

cover (5).

Remove screws (6) and back cover (5).

Open latches on each side of tachometer connector (12)
and separate connector halves.

Push out the tachometer with seal (13).

Inspect seal, tachometer connector, trip odometer reset
switch, reset switch boot, and wiring. Repair or replace as
required.

TACHOMETER INSTALLATION

If replacing the trip odometer reset switch, see

See

Figure 6-23

. Install seal (13) on tachometer (1).

Orient face upright and press tachometer (1) into instru-
ment housing/bracket (4).

Attach tachometer connector (12) to tachometer.

Attach trip odometer reset switch (10) into squared boss
on back cover (5) and secure with reset switch boot (11).

Place back cover over speedometer and tachometer while
positioning harness to avoid damage. Rotate speedometer
and tachometer as needed to align mounting holes and
install screws (6).

Plug in main fuse. See

2009 Sportster Service: Electrical 6-21

6.10

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

GENERAL

Figure 6-24

. The Turn Signal Module (TSM) has two major

functions:

•

Control turn signals.

•

Serve as bank angle sensor.

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 Turn Signal
Security Module (TSSM) for Japan/Korea markets, and the
Hands Free Security Module (HFSM) for all other markets.

See the ELECTRICAL DIAGNOSTIC MANUAL for complete
details of the TSM/TSSM/HFSM features and functions.

NOTE

The TSM/TSSM/HFSM cannot be repaired. Replace the unit
if it fails.

sm01275

Figure 6-24. TSM/TSSM/HFSM (TSM Shown)

TESTING

For diagnostic information, see the ELECTRICAL DIAGNOSTIC
MANUAL.

sm01276

Battery tray

Oil tank

TSM/TSSM/HFSM

Figure 6-25. TSM/TSSM/HFSM Location: All Models (XL

Shown)

REMOVAL

NOTE

See

Figure 6-25

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

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

Remove left side cover. See

2.20 LEFT SIDE COVER

Remove battery. See

1.17 BATTERY MAINTENANCE

Figure 6-26

. Reach under the battery tray (1) and

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

Grasp top of TSM/TSSM/HFSM and unplug wiring harness
connectors: 4-pin connector [208] (5) (HFSM only) has
one latch. Unplug this connector first. Then unplug 12-pin
connector [30B] (4).

Remove TSM/TSSM/HFSM from vehicle.

6-22 2009 Sportster Service: Electrical

sm01277

Battery tray

Cavity

TSM/TSSM/HFSM

12-pin harness connector [30B]

4-pin antenna harness connector [208] (HFSM
only)

Figure 6-26.TSM/TSSM Connectors: All Models (XL Shown)

INSTALLATION

See

Figure 6-26

. Pull wiring harness connector [208] (5)

(HFSM only) and connector [30B] (4) up through cavity
(2) in bottom of battery tray (1).

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

Plug 4-pin [208] (5) (HFSM only) and 12-pin [30B] (4)
wiring harness connectors into TSM/TSSM/HFSM.

Lower TSM/TSSM/HFSM into cavity. See

Figure 6-25

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

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

1.17 BATTERY MAINTENANCE

Perform TSM/TSSM/HFSM password learn and setup
procedure. See the ELECTRICAL DIAGNOSTIC MANUAL
for procedure.

Install left side cover. See

2.20 LEFT SIDE COVER

2009 Sportster Service: Electrical 6-23

Pry between the brake pads and brake disc to force all
caliper pistons back into their bores. Use care not to
scratch the rotor or cause warpage.

sm01421

Front brake master cylinder assembly

Diaphragm

Diaphragm plate

Reservoir cover

Captive screw (2)

Figure 1-33. Front Brake Master Cylinder Cover Assembly

(Typical)

Figure 1-34

. Remove pad pins (1).

Remove pad spring (2) and brake pads through opening
in caliper assembly.

NOTE

The pad pins are manufactured with a relief near the center of
their length, where the pad spring touches. Do not use this
area as a measurement point to determine pad pin wear.

Inspect pad pin for grooving and wear. Measure pad pin
diameter in an unworn area, and then in the area of any
grooving or wear. If wear is more than 0.011 in. (0.28 mm),
replace pin.

Inspect pad spring for wear or cracks. If worn or damaged,
replace.

sm05128

Pad pins

Pad spring

Figure 1-34. Front Caliper Assembly: XR Models

Installation

NOTE

See

Figure 1-35

. When replacing front brake pads, make sure

pad spring is installed with the arrow and word "UP" (2) pointing
up, and captured by both pad pins (3).

See

Figure 1-34

. Install new outer brake pad and pad

spring. Make sure friction material faces brake disc.

NOTES

If pad pin does not fit, check the following:

•

You are using the correct set of pads.

•

Pad spring orientation must match

Figure 1-35

•

Pads must be pushed tight up against pad spring before
pad pins are installed.

While holding new outer pad in place, insert pad pins
through holes in tabs of pad and into pad spring.

Install new inner brake pad, making sure friction material
faces brake disc.

Push pad pins through holes in tabs of inner pad and into
holes in caliper housing.

Tighten pad pins to 131-173 in-lbs (14.8-19.6 Nm).

1-32 2009 Sportster Service: Maintenance

sm05101

Banjo bolt hole

Arrow and word "UP"

Pad pins (2)

Figure 1-35. Front Caliper Pad Spring Orientation

After servicing brakes and before moving motorcycle,
pump brakes to build brake system pressure. Insufficient
pressure can adversely affect brake performance, which
could result in death or serious injury. (00279a)

Pump brake lever to move pistons out until they contact
outside brake pad. Verify piston location against pad.

Direct contact of D.O.T. 4 brake fluid with eyes can cause
irritation. Avoid eye contact. In case of eye contact flush
with large amounts of water and get medical attention.
Swallowing large amounts of D.O.T. 4 brake fluid can cause
digestive discomfort. If swallowed, obtain medical atten-
tion. Use in well ventilated area. KEEP OUT OF REACH OF
CHILDREN. (00240a)

D.O.T. 4 brake fluid will damage painted and body panel
surfaces it comes in contact with. Always use caution and
protect surfaces from spills whenever brake work is per-
formed. Failure to comply can result in cosmetic damage.
(00239b)

NOTE

If D.O.T. 4 brake fluid contacts painted surfaces, IMMEDI-
ATELY flush area with clear water.

Figure 1-36

. Check brake fluid level in master cylinder.

Add enough HARLEY-DAVIDSON D.O.T. 4 BRAKE FLUID
to reservoir to bring fluid level even with ridge (1) cast into
inside of reservoir, about 1/4 in. (6.35 mm) below top edge.

sm01422

Cast-in ridge

Sight glass

Figure 1-36. Filling Front Master Cylinder Reservoir

(Typical)

See

Figure 1-33

. Install diaphragm (2), diaphragm plate

(3), reservoir cover (4) and screws (5) on front brake
master cylinder reservoir. Tighten screws to 9-17 in-lbs
(1.0-2.0 Nm).

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)

Test brake system.

Turn ignition switch ON. Pump brake lever to verify
operation of the brake lamp.

Test ride the motorcycle. If the brakes feel spongy,
bleed the system. See

1.8 BLEEDING HYDRAULIC

BRAKE SYSTEM

NOTE

Avoid making hard stops for the first 100 miles (160 km). This
allows the new pads to become conditioned to the brake discs.

BRAKE PAD REPLACEMENT: REAR

Removal

NOTES

•

Do not remove rear caliper from mounting bracket unless
caliper mounting pins and boots require service. Removing
caliper from mounting bracket unnecessarily increases
the risk of contaminants falling into caliper boots and

2009 Sportster Service: Maintenance 1-33

bushings which could damage caliper during vehicle
operation.

•

See

Figure 1-38

. It is not required or recommended to

remove or loosen the caliper mounting fasteners (3).

•

It is not necessary or recommended to remove the rear
brake caliper from the caliper mounting bracket to replace
pads.

•

If D.O.T. 4 brake fluid contacts painted surfaces, IMMEDI-
ATELY flush area with clear water.

Place motorcycle in an upright, level position.

Remove rear master cylinder reservoir cover.

Place a suitable container under the rear master cylinder
to catch any fluid that may overflow.

NOTE

As the piston is pushed back into the caliper, fluid level may
rise higher than the upper fluid level in the reservoir. Remove
fluid as necessary to avoid fluid overflow.

Press against the outside of the brake caliper body to push
the caliper piston back into its bore, forcing fluid back to
the reservoir.

NOTE

See

Figure 1-37

. When replacing rear brake pads, make sure

pad spring does not become dislodged and fall out. If it does,
reinstall it before installing new pads.

sm05122

Pad spring

Caliper housing

Figure 1-37. Rear Caliper Pad Spring

NOTE

Left shock absorber is disconnected from rear fork for clarity
of photograph. Pad replacement does not require the shock
be disconnected.

Figure 1-38

. Remove pad pin plug (1).

Loosen, but do not remove, brake pad pin (2) (metric).

Pull pad pin part way out until inner pad drops free.
Remove pad and note the pad's original orientation for
replacement purposes.

Continue to remove pad pin until outer pad drops free.

Inspect pad pin for grooving and wear. Measure pad pin
diameter in an unworn area, and then in the area of any
grooving or wear. If wear is more than 0.011 in. (0.28 mm),
replace pin.

sm05129

Pad pin plug

Pad pin

Mounting fasteners

Figure 1-38. Rear Caliper Assembly

Installation

NOTE

The caliper and mounting bracket are shown removed for clarity
of photograph. Removal is not required to replace brake pads.

See

Figure 1-39

. Install new outside brake pad using the

same orientation as pad previously removed. Make sure
front mounting tab (3) is seated in slot (6) in caliper
mounting bracket and pad friction material faces brake
disc.

Install pad pin into caliper and through outer pad.

Position inner pad and continue to install pad pin while
pressing brake pads firmly up against pad spring. Tighten
pad pin to 131-173 in-lbs (14.8-19.6 Nm).

NOTE

If pad pin does not fit, check the following:

•

The correct pads are being installed.

•

Pad spring orientation is correct as shown in

Figure 1-37

•

See

Figure 1-39

. Pad front mounting tabs (3) must be fully

seated in mounting bracket slot (6).

•

Pads must be pushed tight up against pad spring before
pad pin is installed.

Figure 1-38

. Install pad pin plug (1). Tighten to 18-25

in-lbs (2.0-2.9 Nm).

1-34 2009 Sportster Service: Maintenance

sm01435

Outside brake pad

Inside brake pad

Front mounting tab

Pad pin hole

Rear caliper mounting bracket

Slot

Figure 1-39. Rear Brake Pads

Pump brake pedal to move piston out until it contacts
outside brake pad. Verify piston location against pad.

NOTE

Rear brake master cylinder reservoir must be in a level position
when filling and checking fluid level.

Remove rear brake master cylinder reservoir cover and
check brake fluid level in master cylinder reservoir. If
necessary, add HARLEY-DAVIDSON D.O.T. 4 BRAKE
FLUID to reservoir until fluid reaches upper fluid level.

Replace reservoir cover.

Test brake system.

Turn ignition switch ON. Pump brake pedal to verify
operation of the rear brake lamp.

Test ride motorcycle at low speed. If the brakes feel
spongy, bleed the system. See

1.8 BLEEDING

HYDRAULIC BRAKE SYSTEM

NOTE

Avoid making hard stops for the first 100 miles (160 km). This
allows the new pads to become conditioned to the brake discs.