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Harley Davidson Sportster Models 2009. Service Repair Manual - page 37

See

Figure 6-81

. Insert license plate lamp harness (6) into

fender harness clip (1) on left side of fender.

Feed harness through feed-through hole (5) on left side
of rear fender.

See

Figure 6-80

. Plug in license plate lamp connector [40].

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.

Install rear wheel. See

2.4 WHEELS

. Make certain rear

wheel is properly aligned and rear drive belt is properly
tensioned. See

1.16 REAR BELT DEFLECTION

Plug in main fuse. See

6.38 MAIN FUSE

Remove vehicle from lift.

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)

10. Turn ignition switch ON. Verify that license plate lamp

module is operating properly. Turn ignition switch OFF.

REMOVAL (HDI ONLY)

See

Figure 6-83

. The XL 1200N built for international markets

incorporates a center-mounted license plate holder and lamp
assembly.

sm03732

Figure 6-83. License Plate Holder and Lamp Assembly: XL

1200N (HDI)

Position vehicle upright on a suitable lift. Unplug main
fuse. See

6.38 MAIN FUSE

Remove seat. See

2.38 SEAT: XL MODELS

Remove rear wheel. See

2.4 WHEELS

See

Figure 6-84

. Unplug license plate lamp harness con-

nector [40] (2).

See

Figure 6-85

. Remove license plate lamp harness (3)

from harness bracket (1) and three harness clips (2). Feed
harness and connector in through hole in rear fender.

See

Figure 6-86

. Remove two fender support screws with

washers (4). Remove screw with washer (5) securing rear
fender to fender brace (2). Remove fender brace and
license plate holder assembly (1) from vehicle.

sm03733

Interconnect harness

License plate lamp harness connector [40]

Right turn signal/brake/tail lamp harness con-
nector [19]

Left turn signal/brake/tail lamp harness con-
nector [18]

Figure 6-84. Rear Lighting Interconnect Harness: XL 1200N

(HDI)

sm03734

Harness bracket

Harness clip (3)

License plate lamp harness

License plate holder

Feedthrough hole

Figure 6-85. License Plate Holder and Lamp Harness

Mounting: XL 1200N (HDI)

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6-66 2009 Sportster Service: Electrical

sm03735

License plate holder

Rear fender brace

Tab

Fender support screw with washer (2)

Screw with washer

Figure 6-86. License Plate Holder: XL 1200N (HDI)

See

Figure 6-87

. Remove two screws with washers (2)

securing license plate lamp housing to license plate holder
(1). See

Figure 6-88

. Separate lamp housing (3) and

gasket (2) from license plate holder (1).

sm03736

License plate holder

Screw with washer (2)

Figure 6-87. License Plate Holder and Lamp Mounting

Screws: XL 1200N (HDI)

sm03737

License plate holder

Gasket

Lamp housing

Figure 6-88. Lamp Housing Separated from License Plate

Holder: XL 1200N (HDI)

See

Figure 6-89

. Insert the tip of a small flat bladed

screwdriver (3) into each slot (2) in lamp housing. Gently
tilt screwdriver handle outward (away from lamp housing)
just enough to disengage housing from cover. Separate
housing from cover and slide housing away from tabs (4)
in cover.

See

Figure 6-90

. If replacing a light bulb (2), gently pull

bulb straight out of socket assembly (3). Push new light
bulb into socket.

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2009 Sportster Service: Electrical 6-67

sm03738

Lamp housing

Slot (2)

Screwdriver

Tab (2)

Feedthru slots for harness wires

Figure 6-89. Removing License Plate Lamp Housing Cover:

XL 1200N (HDI)

sm03739

Lamp housing

Light bulb (2)

Socket assembly

Housing cover

Tab (2)

Slot (2)

Figure 6-90. Replacing License Plate Light Bulbs: XL 1200N

(HDI)

INSTALLATION (HDI ONLY)

If reusing license plate lamp housing, see

Figure 6-90

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 6-88

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

See

Figure 6-87

. 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 6-86

. 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 6-91

. 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 6-85

. 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 6-84

. Plug license plate lamp harness con-

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

Install rear wheel. See

2.4 WHEELS

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. See

2.38 SEAT: XL MODELS

11. Plug in main fuse. See

6.38 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)

12. Turn ignition switch to IGNITION and check license plate

lamp to make sure both bulbs are lit. Turn ignition switch
OFF.

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6-68 2009 Sportster Service: Electrical

sm03742

License plate holder

Rear fender brace

Threaded insert

Hole

Figure 6-91. License Plate Holder and Rear Fender Brace:

XL 1200N (HDI)

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2009 Sportster Service: Electrical 6-69

6.26

REAR LIGHTING CONVERTER MODULE: XL
1200N (DOMESTIC ONLY)

GENERAL

NOTE

HDI XL 1200N models are equipped with a sealed LED tail
lamp, brake lamp and turn signal assembly in each rear turn
signal housing. Instead of a rear lighting converter module, this
model is equipped with an interconnect harness between main
harness rear lighting connector [7B] and the turn signal [18]
and [19] and license plate lamp [40] harness connectors.

The domestic XL 1200N rear turn signal lamps also serve as
tail lamps and brake lamps. Dual filament bulbs provide these
features; one filament provides the tail lamp function while the
other filament provides the dual function of turn signal and
brake lamp.

In order for a single filament to function both as turn signal and
brake lamp, a converter module is required. See

Figure 6-92

The converter module (1) is incorporated into an interconnect
harness that connects the main wiring harness to the rear
lighting harnesses.

See

Figure 6-93

. The converter module (3) is located in front

of the battery, under the frame "Y" section.

sm01248

Converter module

Rubber mounting tab

Main harness connector [7]

License plate lamp connector [40]

Right turn signal connector [18]

Left turn signal connector [19]

Figure 6-92. Converter and Interconnect Harness

REMOVAL

Remove seat.

Open left side cover. See

2.20 LEFT SIDE COVER

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

1.17 BATTERY MAINTENANCE

See

Figure 6-94

. Unplug the following harness connectors:

Left rear lighting harness [19] (1)

Right rear lighting harness [18] (2)

License plate lamp harness [40] (3)

Main wiring harness [7] (4)

See

Figure 6-95

. Push in on converter module rubber

mounting tab to release it from hole in frame.

See

Figure 6-96

. Reach up under frame "Y" section and

pull converter module down. Carefully remove module and
interconnect harness assembly from vehicle.

sm01249

Oil tank

Relay/fuse blocks

Converter module

Figure 6-93. Converter Module Location

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6-70 2009 Sportster Service: Electrical

sm01250

Left rear lighting harness connector [19]

Right rear lighting harness connector [18]

License plate lamp harness [40]

Main wiring harness connector [7]

Figure 6-94. Rear Lighting Harness Connectors: XL 1200N

INSTALLATION

See

Figure 6-96

. Feed converter module/interconnect

harness connectors up through battery compartment, for-
ward of battery strap bracket.

Position converter module up inside frame, under "Y"
section. See

Figure 6-95

. Pull rubber mounting tab through

hole in frame to secure module.

See

Figure 6-94

. Plug in the following harness connectors:

Left rear lighting harness [19] (1)

Right rear lighting harness [18] (2)

License plate lamp harness [40] (3)

Main wiring harness [7] (4)

Install battery and connect battery cables. See

1.17 BAT-

TERY 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)

Close left side cover. See

2.20 LEFT SIDE COVER

Turn ignition switch ON and test rear lighting functions.
Make sure tail lamps, brake lamps and turn signals operate
properly. Make sure license plate lamp is illuminated. Turn
ignition switch OFF.

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.

sm01251

Figure 6-95. Converter Module Rubber Mounting Tab

sm01252

Figure 6-96. Removing/Installing Converter Module

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2009 Sportster Service: Electrical 6-71

6.27

REAR STOP LAMP SWITCH

GENERAL

XL models only: See

Figure 6-97

. 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 models only: The rear stop lamp switch is located under-
neath the motorcycle near the rear brake master cylinder
reservoir. The rear stop lamp switch is threaded 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 is tripped and the rear
stop lamp illuminates.

NOTE

The rear stop lamp switch cannot be repaired. Replace the
unit if it fails.

REPLACEMENT

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

Remove left side cover. See

2.20 LEFT SIDE COVER

Remove main fuse. See

6.38 MAIN FUSE

XL models only: move rear brake master cylinder reser-
voir out of the way:

Remove the rear brake master cylinder reservoir
cover; grasp cover and pull straight away from reser-
voir.

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

2.15 REAR BRAKE

MASTER CYLINDER RESERVOIR

See

Figure 6-97

Figure 6-98

. Pull terminal sockets from

spade connections (4) on stop lamp switch.

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

Thread new stoplight switch (3) to tee nut (2) on brake
line. Tighten switch to 84-120 in-lbs (9.5-13.6 Nm).

Install terminal sockets on switch spade connections (4).

XL models only: Install rear brake master cylinder
reservoir:

Replace the reservoir mounting screw. Tighten to
20-25 in-lbs (2.3-2.8 Nm).

Replace the plastic guard around the reservoir.

Install main fuse. Install left side cover.

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)

Refill master cylinder and bleed brakes. See

1.8 BLEEDING HYDRAULIC BRAKE SYSTEM

. Test

operation of rear brake.

10. Test operation of brake lamp with the rear brake applied

and the ignition/light switch turned ON.

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Rear brake line

Tee nut

Rear stop lamp switch

Spade connector terminal socket (2) [121]

Figure 6-97. Rear Stop Lamp Switch: XL Models Only

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6-72 2009 Sportster Service: Electrical

sm05579

Rear brake line

Tee nut

Rear stop lamp switch

Spade connector terminal socket (2) [121]

Figure 6-98. Rear Stop Lamp Switch: XR Models Only

HOME

2009 Sportster Service: Electrical 6-73

6.28

CRANK POSITION SENSOR (CKP)

GENERAL

The crank position (CKP) sensor is a variable reluctance (VR)
sensor that generates an AC signal by sensing the passing of
the 30 teeth cast into the engine's left side flywheel. Two con-
secutive teeth are missing in the flywheel to establish a refer-
ence point. The CKP sensor sends a signal to the Electronic
Control Module (ECM). This signal is used to reference engine
position (TDC) and engine speed. The CKP sensor is located
near the lower front left corner of the engine crankcase.

NOTE

The crank position sensor cannot be repaired. Replace the
unit if it fails.

REMOVAL

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

Unplug main fuse. See

6.38 MAIN FUSE

See

Figure 6-99

. Disconnect CKP sensor harness con-

nector [79A] from wiring harness connector [79B] (4), loc-
ated along left frame downtube.

Remove CKP wire harness from j-clip (3).

Remove screw (2). Carefully remove CKP sensor (1) and
o-ring from engine crankcase.

sm01279

Crank position (CKP) sensor

Screw

Wire harness j-clip

CKP sensor harness connector [79] (under pro-
tective rubber boot)

Figure 6-99. Crank Position (CKP) Sensor (Typical, XL

Model Shown)

INSTALLATION

NOTE

The CKP sensor o-ring has a blue teflon coating that provides
lubrication during installation. It is not necessary to coat the o-
ring with engine oil or other lubricant to install it.

See

Figure 6-99

. Carefully install CKP sensor (1) and o-

ring into engine crankcase with screw (2). Tighten to 80-
100 in-lbs (9.0-11.3 Nm).

Route CKP sensor wiring harness through j-clip (3).

Attach CKP sensor harness connector [79A] to wiring
harness connector [79B] (4).

Plug in main fuse. See

6.38 MAIN FUSE

Start engine and verify operation.

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6-74 2009 Sportster Service: Electrical

6.29

ALTERNATOR

REMOVAL AND DISASSEMBLY

Open left side cover. See

2.20 LEFT SIDE COVER

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 negative battery cable from crankcase. Discon-
nect positive (+) battery cables from battery. See

1.17 BATTERY MAINTENANCE

. Close left side cover.

Remove primary cover. See

5.3 PRIMARY CHAIN

ADJUSTER

Remove clutch assembly, primary chain and engine
sprocket/rotor assembly as a unit. See

5.5 PRIMARY

DRIVE AND CLUTCH: XL MODELS

5.6 PRIMARY

DRIVE AND CLUTCH: XR MODELS

Remove/disassemble rotor and/or stator, as required.
Refer to the following procedures.

Rotor

Remove bolts securing alternator rotor to engine sprocket.

See

Figure 6-100

. Position blocking (2) under rotor (1).

Press sprocket (3) free of rotor.

NOTE

Resistance to sprocket/rotor disassembly is due in part to the
magnetic force of the permanent rotor magnets.

Stator

See

Figure 6-101

. Open external latch (4) and unplug

stator harness (2) connector [46B] from voltage regulator
harness (3) connector [46A] (1). See

6.3 VOLTAGE

REGULATOR

for procedure.

Make note of cable strap positions and remove cable
straps from stator harness.

Withdraw stator harness from opening between right
crankcase half and gear case cover.

See

Figure 6-102

. Using a T-27 TORX driver, remove and

discard screws (3) securing stator to left crankcase half.

Remove two screws (9) and harness retainer (8).

Remove stator harness grommet (10) from left crankcase
half.

Withdraw stator harness from grommet hole in left crank-
case half. Remove stator.

sm01163

Rotor

Blocking

Sprocket

Figure 6-100. Removing Rotor from Sprocket

sm01124

Stator connector [46]

Stator harness

Voltage regulator harness

External latch

Figure 6-101. Stator Connector Location (Typical, XL

Models Shown)

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2009 Sportster Service: Electrical 6-75

sm01666

Motor sprocket

Rotor

Screw (4)

Stator

Stator wiring harness

Connector [46B]

Bolt (8)

Stator harness retainer

Screw (2)

10. Stator harness grommet

Figure 6-102. Alternator Components

CLEANING AND INSPECTION

Clean rotor with a petroleum-base solvent. Remove all
foreign material from rotor magnets. Replace rotor if rotor
magnets are cracked or loose.

Clean stator by wiping with a clean cloth.

Examine stator leads for cracked or damaged insulation.

NOTE

The rotor and stator can be replaced individually if either is
damaged.

ASSEMBLY AND INSTALLATION

Depending on whether the rotor, the stator, or both the rotor
and stator were removed, perform the applicable procedures
which follow:

Stator

See

Figure 6-102

. Feed stator wiring harness (5) with

attached grommet (10) into open grommet hole in left
crankcase half.

Apply a light coating of clean engine oil or chaincase lub-
ricant to grommet. Press grommet into hole in left crank-
case half.

Position stator (4) on left crankcase half. Secure stator
using new TORX screws. Use TORX driver to tighten
screws to 30-40 in-lbs (3.4-4.5 Nm).

Position stator harness retainer (8) over harness and onto
engine crankcase with mounting holes facing aft. Secure
with two screws (9). Make sure harness is not pinched.
Tighten screws to 56 in-lbs (6.3 Nm) (maximum). Do not
exceed torque specification.

Route stator wiring harness across top of crankcase halves
to right side of engine. Route stator harness downward

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6-76 2009 Sportster Service: Electrical

through opening between right crankcase half and gear-
case cover.

Route stator harness forward and then upward along
inboard side of right frame downtube.

See

Figure 6-101

. Connect stator harness (2) to voltage

regulator harness (3) at connector [46] (1) and lock
external latch (4) in place. See

6.3 VOLTAGE REGU-

LATOR

for procedure.

Secure stator harness and neutral switch with cable straps
as noted from stator removal.

Rotor

See

Figure 6-103

. Position rotor (1) on sprocket (2). Align

holes in sprocket with holes in rotor. Apply a drop of
LOCTITE THREADLOCKER 243 (blue) to threads of each
mounting bolt. Insert mounting bolts through rotor and
start bolts into tapped holes in sprocket.

Position a section of pipe (3) with an inside diameter larger
than the sprocket mounting hub over center of rotor.

Press rotor onto sprocket. Tighten screws to 120-140 in-
lbs (13.6-15.8 Nm).

Final Assembly

Install clutch assembly, primary chain and engine
sprocket/rotor assembly as a unit. See

5.5 PRIMARY

DRIVE AND CLUTCH: XL MODELS

5.6 PRIMARY

DRIVE AND CLUTCH: XR MODELS

Install primary cover, left footrest assembly and gear shift
lever. See

5.3 PRIMARY CHAIN ADJUSTER

Open left side cover. See

2.20 LEFT SIDE COVER

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)

Connect battery cables, positive (+) cable first. See

1.17 BATTERY MAINTENANCE

. Close left side cover.

Test charging system. See ELECTRICAL DIAGNOSTIC
MANUAL.

sm01164

Rotor

Sprocket

Pipe section

Figure 6-103. Pressing Rotor onto Sprocket

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2009 Sportster Service: Electrical 6-77

6.30

VEHICLE SPEED SENSOR (VSS)

GENERAL

The vehicle speed sensor (VSS) is powered and monitored by
the Electronic Control Module (ECM). The ECM processes the
vehicle speed signal and transmits this signal to the turn signal
module/turn signal security module (TSM/TSSM) and
speedometer through serial data.

NOTE

The vehicle speed sensor cannot be repaired. Replace the unit
if it fails.

REMOVAL

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

Unplug main fuse. See

6.38 MAIN FUSE

See

Figure 6-104

. Disconnect VSS harness connector

[65A] (1) from VSS (3) mounted on rear of engine case
below starter motor assembly.

Remove screw (2). Carefully remove VSS and o-ring from
engine crankcase.

sm01280

VSS connector [65]

Screw

Vehicle speed sensor (VSS)

Figure 6-104.Vehicle Speed Sensor: All Models (XL Shown)

INSTALLATION

NOTE

The new VSS o-ring has a teflon coating that provides lubrica-
tion during installation. It is not necessary to coat the o-ring
with engine oil or other lubricant to install it.

See

Figure 6-104

. Carefully install VSS (3) and o-ring into

engine crankcase with screw (2). Tighten to 80-100 in-lbs
(9.0-11.3 Nm).

Attach VSS harness connector [65A] (1) to VSS.

Plug in main fuse. See

6.38 MAIN FUSE

Start engine and test ride motorcycle to verify proper
operation.

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6-78 2009 Sportster Service: Electrical

6.31

NEUTRAL INDICATOR SWITCH

GENERAL

See

Figure 6-105

. The neutral indicator switch (1) is threaded

into the right crankcase half (3) immediately forward of the
main drive gear (4). A short jumper wire assembly (2) connects
the switch to the harness connector [136] under the engine
crankcase.

A pin on the shifter drum contacts the neutral indicator switch
plunger, completing the neutral indicator circuit.

A motorcycle whose neutral indicator lamp does not light can
be tested to determine if the problem can be found:

•

In a burned out indicator lamp, the wire harness to the
instruments or in the main wire harness.

•

In the neutral indicator switch and its jumper wire.

If switch requires replacement, the rear muffler and rear
exhaust pipe must be removed to remove the transmission
sprocket cover. The drive belt and transmission sprocket must
also be removed; there is not enough clearance to allow the
removal of the switch without first removing the transmission
sprocket.

NOTE

The neutral indicator switch cannot be repaired. Replace the
switch if it fails.

sm01281

Neutral indicator switch

Jumper wire connector [136]

Right crankcase half

Main drive gear

Figure 6-105. Neutral Indicator Switch Location: All Models

(XL Shown)

REPLACEMENT

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

Unplug main fuse. See

6.38 MAIN FUSE

XL models: remove rear muffler and exhaust pipe. See

4.15 EXHAUST SYSTEM: XL MODELS

. XR models:

remove exhaust system. See

4.16 EXHAUST SYSTEM:

XR MODELS

Remove sprocket cover and rear drive belt from transmis-
sion sprocket. See

5.7 DRIVE BELT

Remove transmission sprocket. See

. Unplug jumper wire connector (2) from

neutral indicator switch (1). Remove switch with washer
from right crankcase half (3).

Note routing of neutral switch jumper wire down between
crankcase and rear of gearcase cover.

If necessary in order to unplug neutral switch jumper wire
from neutral switch harness connector [136], cut cable
strap securing neutral switch harness and stator harness
to bottom right frame tube under oil pump.

Install new neutral indicator switch with washer and tighten
to 120-180 in-lbs (13.6-20.3 Nm).

Plug new neutral switch jumper wire into neutral indicator
switch [131]. Route jumper wire in same way that old
jumper was routed.

10. Plug jumper wire pin connector [136A] into harness socket

connector [136B]. Secure neutral switch harness and stator
harness with cable strap to bottom right frame tube under
oil pump.

11. Install transmission sprocket. See

5.16 TRANSMISSION

SPROCKET

12. Install secondary drive belt and sprocket cover. See

5.7 DRIVE BELT

13. Adjust drive belt tension and rear wheel alignment. See

1.16 REAR BELT DEFLECTION

14. XL models: install rear muffler and exhaust pipe. See

4.15 EXHAUST SYSTEM: XL MODELS

. XR models:

install exhaust system. See

4.16 EXHAUST SYSTEM: XR

MODELS

15. Plug in main fuse. See

6.38 MAIN FUSE

16. Turn ignition switch on and check the operation of the

neutral indicator lamp.

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2009 Sportster Service: Electrical 6-79

sm01284

Neutral indicator switch

Jumper wire connector [131]

Right crankcase half

Figure 6-106. Neutral Indicator Switch: All Models (XL

Shown)

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6-80 2009 Sportster Service: Electrical

6.32

MAIN WIRING HARNESS

GENERAL

The main wiring harness supplies power to all electrical sys-
tems on the vehicle. It is an electrical conduit, passing signals
from sensors and switches, as well transferring data between
the ECM, TSM/TSSM/HFSM and speedometer.

Various wiring sub-harnesses, such as the engine sub-harness,
handlebar control harnesses, instruments harness and rear
lighting harness are connected to the main wiring harness.
These sub-harnesses are discussed elsewhere in this manual.

See

B.2 WIRING DIAGRAMS

of this manual for wiring

schematics. See the ELECTRICAL DIAGNOSTIC MANUAL
for testing and troubleshooting information.

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

4.6 FUEL TANK: XL MODELS

Remove seat.

Remove left side cover. See

2.20 LEFT SIDE COVER

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 cables, negative cable first, and remove
battery. See

1.17 BATTERY MAINTENANCE

Remove fuel tank. See

4.6 FUEL TANK: XL MODELS

4.7 FUEL TANK: XR MODELS

Remove wire harness caddy. See

6.33 ELECTRICAL

CADDIES

See

Figure 6-107

. Cut cable strap (2) securing ET sensor

harness to H-bracket (1).