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

Never remove warning label attached to top of battery.
Failure to read and understand all precautions contained
in warning, could result in death or serious injury. (00064a)

Batteries, battery posts, terminals and related accessories
contain lead and lead compounds, and other chemicals
known to the State of California to cause cancer, and birth
defects or other reproductive harm. Wash hands after
handling. (00019e)

All AGM batteries are permanently sealed, maintenance-free,
valve-regulated, lead/calcium and sulfuric acid batteries. The
batteries are shipped pre-charged and ready to be put into
service. Do not attempt to open these batteries for any reason.

NOTE

For charging information, see

1.17 BATTERY MAINTENANCE,

Charging Battery

. For testing information, see ELECTRICAL

DIAGNOSTIC MANUAL.

sm03272

Warning label

Positive (+) terminal

Negative (-) terminal

Warranty/date code label

Figure 1-63. Battery

om00618

Keep flames away

Contents are corrosive

Wear safety glasses

Read instructions

Keep away from children

Contents are explosive

Figure 1-64. Battery Warning Label

HOME

1-52 2009 Sportster Service: Maintenance

Table 1-14. Antidotes for Battery Acid

TREATMENT

CONTACT

Flush with water.

External

Drink large quantities of milk or water, followed
by milk of magnesia, vegetable oil or beaten
eggs. Get immediate medical attention.

Internal

Flush with water. Get immediate medical
attention.

Eyes

BATTERY DISCONNECTION AND REMOVAL

Disconnect negative (-) battery cable first. If positive (+)
cable should contact ground with negative (-) cable con-
nected, the resulting sparks can cause a battery explosion,
which could result in death or serious injury. (00049a)

Open left side cover.

NOTE

If vehicle is equipped with optional security siren, verify that
fob is present and turn ignition key to IGNITION before
removing main fuse or disconnecting battery.

See

Figure 1-65

. Press main fuse holder (1) toward the

rear of the motorcycle until it pops off its mounting pin on
battery strap (3). Remove main fuse holder from battery
strap.

Press data link connector (5) toward the rear of the
motorcycle until it pops off its mounting pin on battery
strap. Remove the connector from battery strap.

Remove battery strap screw and flat washer (4). Unhook
battery strap from battery tray mount on top of battery and
remove strap.

See

Figure 1-66

. Remove nut (2) that secures the negative

(-) battery cable (1) connector to ground stud (5) on
crankcase boss behind starter motor assembly (3).
Remove cable connector from stud.

Pull end of negative (-) cable forward gently to free it from
cable clip (4).

See

Figure 1-65

. Lift up protective rubber boot covering

battery positive (+) terminal (2). Remove screw from bat-
tery positive (+) terminal and remove positive (+) battery
cables.

See

Figure 1-67

. Disconnect positive (+) battery cable (2)

from cable holders (1).

Remove battery from battery tray. See

Figure 1-66

. Note

routing of negative (-) battery cable around frame down-
tube.

10. If battery is to be left out of vehicle (i.e. winter storage),

close left side cover.

sm03273

Main fuse and holder

Positive (+) battery terminal (under protective
rubber boot)

Battery strap

Screw and flat washer

Data link connector

Figure 1-65. Main Fuse and Battery Location: All Models

sm03275

Negative (-) battery cable

Nut

Starter motor assembly

Cable clip

Ground stud

Figure 1-66. Negative (-) Battery Connection

HOME

2009 Sportster Service: Maintenance 1-53

sm03276

Cable holders

Positive battery cable

Figure 1-67. Positive (+) Battery Cable Holders

CLEANING AND INSPECTION

Battery top must be clean and dry. Dirt and electrolyte on
top of the battery can cause battery to self-discharge.
Clean battery top with a solution of baking soda (sodium
bicarbonate) and water (5 teaspoons baking soda per
quart or liter of water). When the solution stops bubbling,
rinse off the battery with clean water.

Clean cable connectors and battery terminals using a wire
brush or sandpaper. Remove any oxidation.

Inspect the battery screws, clamps and cables for
breakage, loose connections and corrosion. Clean clamps.

Check the battery posts for melting or damage caused by
overtightening.

Inspect the battery for discoloration, raised top or a warped
or distorted case, which might indicate that the battery has
been frozen, overheated or overcharged.

Inspect the battery case for cracks or leaks.

CHARGING BATTERY

Safety Precautions

Never charge a battery without first reviewing the instructions
for the charger being used. In addition to the manufacturer's
instructions, follow these general safety precautions:

•

Always wear eye, face and hand protection.

•

Always charge batteries in a well-ventilated area.

•

Turn the charger off before connecting the leads to the
battery to avoid dangerous sparks.

•

Never try to charge a visibly damaged or frozen battery.

•

Connect the charger leads to the battery; red positive (+)
lead to the positive (+) terminal and black negative (-) lead
to the negative (-) terminal. If the battery is still in the
vehicle, connect the negative lead to the chassis ground.
Be sure that the ignition and all electrical accessories are
turned off.

•

Make sure that the charger leads to the battery are not
separated, frayed or loose.

•

If the battery gets hotter than 110° F (43° C) during char-
ging, discontinue charger and allow the battery to cool.

•

Always turn the charger off before removing charger leads
from the battery to avoid dangerous sparks.

Using a Battery Charger

Charge the battery if any of the following conditions exist:

•

Vehicle lights appear dim.

•

Electric starter sounds weak.

•

Battery has not been used for an extended period of time.

Explosive hydrogen gas, which escapes during charging,
could cause death or serious injury. Charge battery in a
well-ventilated area. Keep open flames, electrical sparks
and smoking materials away from battery at all times.
KEEP BATTERIES AWAY FROM CHILDREN. (00065a)

If battery releases an excessive amount of gas during
charging, decrease the charging rate. Overheating can
result in plate distortion, internal shorting, drying out or
damage. (00413b)

Perform a voltmeter test to determine the state of charge.
See the ELECTRICAL DIAGNOSTIC MANUAL. If battery
needs to be charged, proceed to the next step.

NOTE

The figures listed in the table assume that the battery is char-
ging at room temperature. If warmer than room temperature,
use a slightly shorter charging time. If colder, use a slightly
longer charging time.

HOME

1-54 2009 Sportster Service: Maintenance

Table 1-15. 12 Amp-Hour Battery Charging Rates and Times

20 AMP

CHARGER

10 AMP

CHARGER

6 AMP

CHARGER

3 AMP

CHARGER

PERCENT

CHARGE

READING

(VOLTS)

N/A

100

12.7

10 minutes

20 minutes

34 minutes

1 hour 10 minutes

12.6

20 minutes

40 minutes

1 hour 10 minutes

2 hours 20 minutes

12.3

30 minutes

1 hour

1 hour 40 minutes

3 hours 20 minutes

12.0

40 minutes

1 hour 20 minutes

2 hours 14 minutes

4 hours 30 minutes

11.8

•

The figures listed above assume the battery is charging at room temperature. If warmer than room temperature, use a
slightly shorter charging time. If colder, use a slightly longer charging time.

•

The use of constant current chargers to charge sealed maintenance-free batteries is not recommended. Any overcharge
will cause dry-out and premature battery failure. If a constant current charger is the only type available, do not exceed the
charge times listed above and do not continue charging the battery if it gets hot. When charging, never exceed 15 volts
for more than 30 minutes.

NOTE

The use of constant current chargers to charge sealed main-
tenance-free batteries is not recommended. Any overcharge
will cause dry-out and premature battery failure. If a constant
current charger is the only type available, do not exceed the
charge times listed above and do not continue charging the
battery if it gets hot. When charging, never exceed 15 volts for
more than 30 minutes.

Unplug or turn OFF battery charger before connecting
charger cables to battery. Connecting cables with charger
ON can cause a spark and battery explosion, which could
result in death or serious injury. (00066a)

Do not reverse the charger connections described in the
following steps or the charging system of the motorcycle
could be damaged. (00214a)

Connect red battery charger lead to the positive (+) ter-
minal of the battery.

Connect black battery charger lead to the negative (-)
terminal of the battery.

NOTE

If the battery is still in the vehicle, connect the negative lead
to the chassis ground. Be sure that the ignition and all electrical
accessories are turned off.

Step away from the battery and turn on the charger. See
the charging instructions in

Table 1-15

Unplug or turn OFF battery charger before disconnecting
charger cables from battery. Disconnecting clamps with
charger ON can cause a spark and battery explosion, which
could result in death or serious injury. (00067a)

After the battery is fully charged, disconnect the black
battery charger lead to the negative (-) terminal of the
battery.

Disconnect the red battery charger lead to the positive (+)
terminal of the battery.

Mark the charging date on the battery.

Perform either a conductance test or load test to determine
the condition of the battery. See the ELECTRICAL DIA-
GNOSTIC MANUAL.

If charging battery because voltmeter test reading was
below 12.6 V, perform voltmeter test. See the ELEC-
TRICAL DIAGNOSTIC MANUAL.

BATTERY INSTALLATION AND
CONNECTION

Connect the cables to the correct battery terminals. Failure
to do so could result in damage to the motorcycle electrical
system. (00215a)

If negative (-) battery cable was removed from battery,
insert screw through negative (-) battery cable and into
negative (-) battery terminal. Thread screw into terminal.
Position negative (-) battery cable so that it hangs straight
down from negative (-) battery terminal. Tighten screw to
60-70 in-lbs (6.8-7.9 Nm).

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

Open left side cover.

Slide fully charged battery into battery tray, routing neg-
ative (-) battery cable around frame downtube.

HOME

2009 Sportster Service: Maintenance 1-55

Figure B-14.

Engine Management (1 of 2) (XR): 2009 Sportster DOM. and

INT. Models

Engine Management (1 of 2) (XR): 2009 Sportster DOM. and

INT. Models

Engine Stop Switch

Tachometer

Right Hand
Controls

Configuration For XR

To Main

Harness

To Main
Harness

6
7

Fuel Pump And Low Fuel Switch

(In Fuel Tank)

[86]

1 2 3 4

To main harness

Speedometer

Ignition

Serial Data

Battery

Ground

RPM x 100

Serial Data

Battery

Ground

1
2

Accessory

[141A]

[162]

[20B]

Page 1

[22B]

Page 1

LGN/V

BN/GY

Y/R

Y/W

W/BK

O/W

[20A]

[141B]

[22A]

[108B]

[108A]

[39B]

[39A]

et00121

Figure B-15. Engine Management (2 of 2) (XR): 2009 Sportster DOM. and INT. Models

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