Harley Davidson Sportster Models 2009. Service Repair Manual

12. Remove TSM/TSSM/HFSM. See

6.10 TURN SIGNAL

AND SECURITY MODULE (TSM/TSSM/HFSM)

Reach under battery tray and push TSM/TSSM/HFSM
up from cavity in bottom of tray.

Unplug harness connector [30B].

H-DSSS equipped models: unplug antenna con-
nector [208B].

13. Remove wiring harness from two frame clips on front left

frame downtube.

14. Remove vapor valve from clip on H-bracket. See

4.21 EVAPORATIVE EMISSIONS CONTROL (CA
MODELS)

15. Remove battery tray. See

6.12 BATTERY TRAY

16. Pull H-bracket away from rear frame downtube.

17. Remove main wiring harness from left side of vehicle,

carefully sliding wire harness caddies between rear cyl-
inder and frame as harness is removed.

INSTALLATION

See

Figure 6-108

. The main wiring harness can be divided up

into four "bundles", originating at the H-bracket (1). These
bundles are:

Lower left bundle (2) including:

•

Rear stop lamp switch wires [121B],

•

Crankcase ground [GND1],

•

Fuel pump connector [141A],

•

Siren connector [142B],

•

TSM/TSSM/HFSM connector [30B],

•

Main fuse holder [5],

•

Data link connector [91A],

•

Rear oxygen (O2) sensor connector [137B].

Lower right bundle (3) including:

•

Vehicle speed sensor (VSS) connector [65B],

•

Green starter motor wire [128B].

•

Engine Temperature (ET) sensor connector [90B],

Upper left bundle (4) including:

•

ECM connector [78B],

•

Engine sub-harness connector [145A],

•

P&A battery connector [160B],

•

Rear lighting sub-harness connector [7A],

•

Fuel sender resistor assembly/connector [200].

Upper right bundle (5) including:

•

Hand control connectors [22B], [24B],

•

Headlamp connector [38A],

•

Front turn signal connector [31A],

•

Instruments connector [20B],

•

Horn wires [122B],

•

Ignition/light switch [33],

•

Coil connector [83B],

•

Neutral switch connector [136B],

•

Oil pressure switch connector [120B],

•

Crank position (CKP) sensor connector [79B],

•

Front oxygen (O2) sensor connector [138B],

•

Voltage regulator DC output connector [77B].

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6-82 2009 Sportster Service: Electrical

sm03797

Upper right bundle

H-bracket

Lower left bundle

Front view

Rear view

Lower right bundle

Upper left bundle

Figure 6-108. Main Wiring Harness H-bracket

See

Figure 6-108

. Loosely position new main wiring har-

ness on vehicle. From left side of vehicle, slide H-bracket
(1) into position on rear frame downtube, guiding each
wire bundle toward its respective area on the vehicle. Make
sure lower right bundle (3) and upper right bundle (5) with
wire harness caddies feed out toward right side of vehicle.
Press H-bracket onto rear frame downtube until it snaps
in place.

Feed upper left bundle (4) up over top of oil tank. Make
sure engine sub-harness also feeds up into that area.

Feed upper right bundle along frame backbone toward
front of vehicle.

Feed TSM/TSSM/HFSM harness connector into position
under battery tray location.

NOTE

The TSM/TSSM/HFSM harness connector MUST be in position
before the battery tray is installed. Make sure the harness feeds
over the top of the oil tank return hose.

Install battery tray. See

6.12 BATTERY TRAY

. Make sure

battery tray interlocks with H-bracket on left side. Make
sure to re-attach rear brake hose fasteners and rear brake
master cylinder reservoir.

Plug connector [30B] into TSM/TSSM/HFSM. H-DSSS
equipped models: plug in antenna connector [208B].

Lower TSM/TSSM/HFSM into place in bottom of battery
tray.

Snap vapor valve into clip on left side of H-bracket. See

4.21 EVAPORATIVE EMISSIONS CONTROL (CA
MODELS)

Slide P&A battery harness and connector [160B] and fuel
sender resistor assembly/connector [200] into recess in
top left rear corner of oil tank, under frame.

10. Plug rear lighting connector [7B] into main harness con-

nector [7A].

11. Plug engine sub-harness connector [145B] into main har-

ness connector [145A].

12. Slide left wire harness caddy between front cylinder head

and frame, from right side of vehicle toward left side.

13. Make sure harness (part of upper right bundle) containing

neutral switch connector [136B], CKP sensor connector
[79B], oil pressure switch connector [120B], front O2
sensor connector [138B] and voltage regulator DC output
connector [77B] runs down front left frame downtube.

14. Vehicles with front mounted horn: Install horn wire

harness in clip attached to rear of right front frame down-
tube.

15. Install wire harness caddy. See

6.33 ELECTRICAL CAD-

DIES

HOME

2009 Sportster Service: Electrical 6-83

16. Plug in the following harness connectors:

Oil pressure switch [120B],

Voltage regulator DC output [77B],

Crank Position (CKP) sensor [79B],

Front oxygen (O2) sensor [138B],

Rear oxygen (O2) sensor [137B],

Neutral switch jumper [136B],

Engine temperature (ET) sensor [90B],

Horn [122B],

ECM [78B],

Harness ground wire at engine crankcase [GND1],

Rear stop lamp switch [121B],

Vehicle speed sensor (VSS) [65B],

m. Green starter motor wire [128B].

Vehicles with optional security siren: Plug in
security siren connector [142B].

17. XL models only: Secure clutch cable and wiring harness

running down left frame downtube with two frame clips.
Make sure lower frame clip also captures front O2 sensor
harness and frame clip is positioned as close to bottom
of upper voltage regulator bracket as possible.

18. XR models only: Secure wiring harness running down

left frame downtube onto both oil cooler bracket clips.

19. See

Figure 6-107

. Secure ET sensor harness to H-bracket

(1) with a barbed cable strap (2). Make sure there is a loop
in the harness between the ET sensor and the H-bracket
to avoid damaging harness during vehicle operation.

20. Install fuel tank. See

Figure 6-109

. Make sure fuel pump

harness rests in harness clip (5) on wire harness caddy
latch clip (2). See

4.6 FUEL TANK: XL MODELS

4.7 FUEL TANK: XR MODELS

NOTE

Make sure there is a loop in fuel pump harness between caddy
latch clip and fuel pump module to avoid pinching harness
between fuel tank and frame backbone. See

4.6 FUEL TANK:

XL MODELS

4.7 FUEL TANK: XR MODELS

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)

21. Install battery and connect battery cables, positive (+)

cable first. See

1.17 BATTERY MAINTENANCE

22. Install left side cover. See

2.20 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)

23. Install seat. See

2.38 SEAT: XL MODELS

2.39 SEAT:

XR MODELS

24. Start vehicle and test operation of all electrical functions:

headlamp, tail lamp(s), turn signals, brake lamp(s), indic-
ator lamps, instruments, horn and handlebar controls.

sm03800

Right wire harness caddy

Wire harness caddy latch clip

Main harness

Engine sub-harness

Fuel pump harness clip

Figure 6-109. Right Wire Harness Caddy Latch Clip

(Typical, XL Models Shown)

HOME

6-84 2009 Sportster Service: Electrical

6.33

ELECTRICAL CADDIES

GENERAL

Two electrical caddies are used on all Sportster models. They
are:

•

Voltage regulator caddy: located between the front frame
downtubes below the voltage regulator. This caddy sup-
ports the voltage regulator DC output connector [77] and
the neutral switch wiring harness.

•

Wire harness caddy: a matched pair of caddies located
under the fuel tank. This assembly supports handlebar
control harness connectors [22] and [24], instruments
connector [20], headlamp connector [38] and front turn
signals connector [31]. This caddy assembly also supports
the rear spark plug cable, main harness, engine sub-har-
ness and throttle cables.

VOLTAGE REGULATOR CADDY: XL
MODELS ONLY

See

Figure 6-110

. The voltage regulator caddy (1) is attached

to the lower end of the voltage regulator mounting bracket by
four tabs (2) located on the caddy.

Removal

See

Figure 6-111

. Remove DC output connector [77] (3)

from mounting tabs (4) on caddy (2). Remove DC output
cables from cable clip (7).

Remove neutral switch harness (5) from mounting tabs
(6) on voltage regulator caddy.

Grasp caddy and gently pull straight away from frame
downtubes. It may be necessary to bend four tabs (item
2,

Figure 6-110

) back slightly to disengage caddy from

voltage regulator bracket on frame.

Carefully slide caddy out from between frame front down-
tubes and engine toward left side of motorcycle.

Installation

Slide new voltage regulator caddy from left side of
motorcycle, in between frame front downtubes and engine,
below voltage regulator.

See

Figure 6-110

. Line up four caddy mounting tabs (2)

with bottom of voltage regulator (3) mounting bracket and
press into place.

See

Figure 6-111

. Press neutral switch wiring harness (5)

into tabs (6) on caddy (2).

Install voltage regulator DC output cables into cable clip
(7) on caddy. Press voltage regulator DC output connector
[77] (3) into mounting tabs (4) on caddy.

sm03802

Voltage regulator caddy

Mounting tabs (4)

Voltage regulator

Figure 6-110. Voltage Regulator Caddy: Front View

sm03803

Voltage regulator

Voltage regulator caddy

Voltage regulator DC output connector [77]

DC output connector mounting tabs (4)

Neutral switch wiring harness

Neutral switch harness mounting tabs (2)

DC output cable clip

Figure 6-111. Voltage Regulator Caddy: Rear View

WIRE HARNESS CADDY: XL MODELS

See

Figure 6-112

. The wire harness caddy assembly (1, 2) is

secured to the ignition switch bracket (3) with two push-in
fasteners (6, 7), and to the frame with mounting tabs hooked
onto a bracket under the frame backbone tube. The left and
right wire harness caddies are locked together with three tabs
(see

Figure 6-113

) and secured with a screw (item 12,

Figure 6-112

HOME

2009 Sportster Service: Electrical 6-85

sm03804

Right wire harness caddy

Left wire harness caddy

Ignition switch bracket

Coil bracket

Screw w/lockwasher (lockwasher between
bracket and switch housing)

Push-in fastener, large

Push-in fastener, small

Screw

Throttle cable (2)

10. Cable strap (2)
11. Tab (3) (engage left and right caddies)
12. Screw

Figure 6-112. Wire Harness Caddy Assembly

sm03805

Figure 6-113. Wire Harness Caddy: Locking Tabs

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

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

Remove seat.

Remove fuel tank. See

4.6 FUEL TANK: XL MODELS

See

Figure 6-112

. Remove screw (8) and disengage coil

bracket (4) from mounting boss on frame.

See

Figure 6-114

. Unhook caddy latch clip (2) from right

wire harness caddy (1).

NOTE

It is not necessary to remove rear spark plug cable from wire
harness caddy latch clip, unless latch clip is being replaced.

If necessary, cut cable strap securing rear spark plug cable
to caddy latch clip.

Remove engine sub-harness from loop in caddy latch clip.

See

Figure 6-112

. Remove screw (12) and carefully disen-

gage left wire harness caddy (2) from right wire harness
caddy (1).

10. Cut two cable straps (10) securing throttle cables (9) to

right wire harness caddy.

11. See

Figure 6-115

. Disengage rear spark plug cable (2)

from trough in right wire harness caddy (1). Cut barbed

HOME

6-86 2009 Sportster Service: Electrical

cable strap securing engine sub-harness (3) to right wire
harness caddy.

12. California models: Cut barbed cable strap (5) securing

EVAP canister purge hose (4) to rear of right wire harness
caddy.

13. See

Figure 6-112

. Remove and discard push-in fasteners

(6, 7). Unhook right wire harness caddy from frame back-
bone bracket. Lower ignition switch bracket (3) from
mounting bosses on frame to free right wire harness
caddy.

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Right wire harness caddy

Caddy latch clip

Main harness

Engine sub-harness

Frame backbone

Figure 6-114. Right Wire Harness Caddy Latch Clip

sm03799

Right wire harness caddy

Rear spark plug cable

Engine sub-harness

EVAP canister purge hose (California models
only)

Barbed cable strap (California models only)

Figure 6-115. Rear Spark Plug Cable Routing

14. See

Figure 6-116

. Unplug the following connectors:

Headlamp connector [38B] (4).

Left hand control connector (gray) [24B] (3).

Right hand control connector (black) [22B] (5).

Front turn signal connector [31B] (6).

Instruments connector [20A] (7).

15. Make a note of the location of all cable straps securing

harnesses and harness connectors to left and right wire
harness caddies. Cut cable straps and remove harnesses
and connectors from caddies. Remove wire harness cad-
dies from vehicle.

sm03807

Left wire harness caddy

Right wire harness caddy

Left handlebar control connector [24A]

Headlamp connector [38A]

Right handlebar control connector [22A]

Front turn signals connector [31A]

Instruments connector [20B]

Two cable straps securing throttle cables

Portion of main wiring harness

Figure 6-116. Wire Harness Caddies (Removed from

Vehicle for Clarity)

Installation

See

Figure 6-116

. Fit portion of main wiring harness (9)

and ignition switch harness along top of right wire harness
caddy (2) and secure with cable straps, as shown in the
figure.

Mount front turn signals connector [31A] (6) onto mounting
tab on right wire harness caddy.

See

Figure 6-112

. Place throttle cables (9) in groove in

right wire harness caddy (1).

HOME

2009 Sportster Service: Electrical 6-87

See

Figure 6-116

. Place instruments connector [20B] (7)

into right wire harness caddy (2). Secure connector and
throttle cables with a cable strap (8). Secure throttle cables
and harnesses (as shown in the figure) with a second
cable strap.

Mount handlebar control connectors [22A], [24A] (5, 3) to
left wire harness caddy (1) with cable straps. Mount
headlamp connector [38A] (4) onto tab on left wire harness
caddy.

See

Figure 6-112

. Hook right wire harness caddy (1) into

bracket on frame backbone. Secure front of caddy onto
ignition switch bracket mounting boss on right side of
frame. Raise ignition switch bracket (3) up into position
and mount it onto boss on frame.

NOTE

Make sure ignition switch bracket upright is outboard of right
wire harness caddy and throttle cables on right side of frame.

Secure right wire harness caddy to ignition switch bracket
with new push-in fasteners (6, 7).

See

Figure 6-114

. Install caddy latch clip (2) onto right

wire harness caddy (1). Make sure engine sub-harness
(4) is routed in loop in caddy latch clip.

See

Figure 6-117

. Raise coil bracket (5) up into position

and mount it on boss on left side of frame. Secure coil
bracket to ignition switch bracket with screw (6). Tighten
to 35-45 in-lbs (4.0-5.1 Nm).

NOTE

Make sure coil bracket upright is outboard of all wire harnesses
leading to front of vehicle on left side of frame.

sm03808

Ignition coil

Rear spark plug cable boot

Rear spark plug cable

Notch in right wire harness caddy

Coil bracket

Screw

Figure 6-117. Rear Spark Plug Cable Routing

10. Route rear spark plug cable (3) from ignition coil (1) tower

down through notch (4) in right wire harness caddy.

11. See

Figure 6-115

. Route rear spark plug cable (2) in right

wire harness caddy trough.

12. Route engine sub-harness (3) around trough in right wire

harness caddy. Secure sub-harness to caddy trough with
a cable strap. Run strap through hole in boss that originally
secured engine sub-harness.

13. California models: Secure EVAP canister purge hose

(4) to rear of right wire harness caddy with a barbed cable
strap (5).

14. Plug in the following connectors:

Instruments connector [20A] (7).

Front turn signal connector [31B (6)].

Right hand control connector (black) [22B] (5).

Left hand control connector (gray) [24B] (3).

Headlamp connector [38B] (4).

15. See

Figure 6-112

. Mate left wire harness caddy (2) to right

wire harness caddy (1). Secure with screw (12) and
tighten.

16. See

Figure 6-118

. If barbed cable strap (3) securing rear

spark plug cable (1) to caddy latch clip was cut, install
new barbed cable strap 7.0-7.25 in. (178-184 mm) from
tip of spark plug cable boot (2), orienting cable strap so
that spark plug cable is above mounting boss on caddy
latch clip when barbed prong on cable strap is inserted in
hole in boss. Press cable strap barbed prong firmly into
hole in caddy latch clip mounting boss.

sm03787

Rear spark plug cable

Spark plug boot (spark plug end)

Barbed cable strap

7.0-7.25 in. (178-184 mm)

Figure 6-118. Rear Spark Plug Cable and Cable Strap (XL

Models Only)

17. Make sure rear spark plug cable is plugged onto rear spark

plug.

18. Install fuel tank. See

4.6 FUEL TANK: XL MODELS

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)

19. Install seat.

20. Plug in main fuse. See

6.38 MAIN FUSE

HOME

6-88 2009 Sportster Service: Electrical

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)

21. Start vehicle and test the operation of headlamp, turn

signals, brake lamp(s), indicator lamps, instruments and
handlebar controls.

WIRE HARNESS CADDY: XR MODELS

Removal

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

4.7 FUEL TANK: XR MODELS

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

Remove seat.

Remove fuel tank. See

4.7 FUEL TANK: XR MODELS

Remove airbox. See

4.5 AIRBOX: XR MODELS

See

Figure 6-119

. Remove screw (3), connector (1) and

disengage coil bracket (2) from mounting boss on frame.

Remove rear spark plug wire (4) from caddy. Support coil
away from engine and caddy.

Separate push-in fastener (5) from caddy.

See

Figure 6-120

. Unhook caddy latch clip (1) from right

side of frame.

10. See

Figure 6-121

. Detach connector (2) from right side of

caddy.

11. Cut two cable straps (1) from right side of caddy.

12. See

Figure 6-119

. Remove cover (6) from caddy.

13. See

Figure 6-122

. Cut remaining five cable straps from

left side of caddy.

14. Pull caddy away from frame and move ignition switch away

from caddy. Support ignition switch away from engine.

15. Pull connectors from left side of caddy and remove caddy

from motorcycle.

sm05535

Coil connector

Coil bracket

Screw

Rear spark plug wire

Push-in fastener

Cover

Figure 6-119. XR Caddy Removal

sm05532

Latch clip

Ignition switch bracket

Figure 6-120. Caddy Latch Clip

HOME

2009 Sportster Service: Electrical 6-89

sm05533

Cable strap (2)

Connector

Figure 6-121. Right Side Connectors

sm05534

Figure 6-122. Cable Strap Locations

Installation

See

Figure 6-122

. Place caddy in position next to motor-

cycle frame, Attach ignition switch bracket into position on
caddy and place caddy on motorcycle frame.

Install connectors on left side of caddy.

Install five cable straps to secure connector wires in posi-
tion on left side of caddy.

See

Figure 6-121

. Attach connector (2) to right side of

caddy.

Install two cable straps (1) as shown on right side of caddy.
Make sure wires on left side of caddy are also secured
with the rearward cable strap.

See

Figure 6-120

. Make sure harness and purge hose

(California models) are attached to caddy latch clip (1).
Install latch clip on right side of frame.

See

Figure 6-119

. Install cover (6) on caddy.

Install push-in fastener (5).

See

Figure 6-119

. Slip lower end of coil bracket (2) into

caddy slot. make sure coil bracket is flush with end of
ignition switch bracket and attach top end of coil bracket
to mounting boss on frame.

10. Install connector (1) and then screw (3). Tighten screw (3)

to 35-45 in-lbs (4.0-5.1 Nm).

11. Install rear spark plug wire (4) on caddy.

12. Install airbox. See

4.5 AIRBOX: XR MODELS

13. Install fuel tank. See

4.7 FUEL TANK: XR MODELS

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)

14. Install seat.

15. 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)

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. Start vehicle and test the operation of headlamp, turn

signals, brake lamp(s), indicator lamps, instruments and
handlebar controls.

HOME

6-90 2009 Sportster Service: Electrical

6.34

JIFFY STAND SWITCH: INTERNATIONAL
MODELS

GENERAL

See

Figure 6-123

. International models are equipped with a

jiffy stand interlock feature. If the rider attempts to start the
engine or pushes the starter button while the transmission is
in gear and the jiffy stand is down, the jiffy stand interlock
system will not permit the engine to run. The message "SidE
StAnd" will scroll across the odometer to indicate this to the
rider. Raising the jiffy stand (or putting the transmission in
neutral) will permit the engine to run and clear the message.

If the jiffy stand falls out of the fully retracted position while
riding at speeds greater than 10 mph (15 km/h), the jiffy stand
interlock system will maintain engine operation and alert the
rider about this by illuminating the indicators (flash twice) and
scroll the message "SidE StAnd" across the odometer. The
message will remain until the system detects the jiffy stand in
the fully retracted position again. The rider may continue to
operate the vehicle while in this mode. The rider may clear the
text messages at any time by pressing the trip switch once
while the vehicle is powered up.

The jiffy stand locks when placed in the full forward (down)
position with vehicle weight on it. If the jiffy stand is not
in the full forward (down) position with vehicle weight on
it, the vehicle can fall over which could result in death or
serious injury. (00006a)

Always park motorcycle on a level, firm surface. An
unbalanced motorcycle can fall over, which could result
in death or serious injury. (00039a)

Be sure jiffy stand is fully retracted before riding. If jiffy
stand is not fully retracted, it can contact the road surface
causing a loss of vehicle control, which could result in
death or serious injury. (00007a)

sm03598

Jiffy stand switch

Screw

Jiffy stand switch harness

Jiffy stand

Figure 6-123. Jiffy Stand Switch

REMOVAL

Position vehicle upright on a suitable lift.

See

Figure 6-124

. Unplug jiffy stand switch harness con-

nector [133] (2), located next to left front frame downtube,
by front electrical caddy.

See

Figure 6-125

. Cut cable strap (2) securing jiffy stand

switch harness (1) to frame under left side of engine.

See

Figure 6-123

. Remove screw (2). Remove jiffy stand

switch (1) and harness from vehicle.

HOME

2009 Sportster Service: Electrical 6-91

sm03880

Jiffy stand switch harness

Jiffy stand switch harness connector [133]

J-clip

Figure 6-124. Jiffy Stand Switch Harness Connector

sm03881

Jiffy stand switch harness

Cable strap

Figure 6-125. Jiffy Stand Switch Harness Routing

INSTALLATION

See

Figure 6-123

. Install jiffy stand switch (1), attach with

screw (2), finger-tight.

NOTE

See

Figure 6-126

. Make sure jiffy stand switch (1) is correctly

aligned with switch mounting tab (2) on jiffy stand bracket (3).
If switch is not properly aligned with mounting tab when screw
is tightened, switch or mounting tab may be damaged.

See

Figure 6-126

. With switch (1) properly aligned with

switch mounting tab (2) on jiffy stand bracket (3), tighten
screw to 96-120 in-lbs (10.9-13.6 Nm).

See

Figure 6-125

. Route jiffy stand switch harness (1)

forward along frame under left side of engine. Secure
harness to frame with new cable strap (2), making sure
harness is routed on outboard side of frame as shown in
the figure.

See

Figure 6-124

. Plug jiffy stand switch harness con-

nector [133A] (2) into main harness connector [133B].

NOTE

See

Figure 6-124

. Do not route jiffy stand switch harness (1)

through j-clip (3). This puts undue stress on harness wires.
Harness could chafe against j-clip, possibly causing harness
to fail.

Test new jiffy stand switch:

Disengage clutch and place vehicle in gear.

Turn ignition switch ON. With jiffy stand down and
clutch disengaged, attempt to start vehicle. Engine
should not start. The message "SidE StAnd" should
scroll across the odometer display.

Retract jiffy stand. With clutch disengaged and
transmission in gear, attempt to start vehicle. Engine
should start and run. The "SidE StAnd" message
should clear from the odometer display.

Shift transmission into neutral. Turn ignition switch
OFF.

sm04379

Jiffy stand switch

Switch mounting tab

Jiffy stand bracket

Figure 6-126. Mounting Jiffy Stand Switch: Top View

(Assembly Removed from Vehicle for Clarity)

HOME

6-92 2009 Sportster Service: Electrical

6.35

OPTIONAL SECURITY SIREN

GENERAL

See

Figure 6-127

. The security siren (1) is a self-contained

unit with its own replaceable power supply (9-volt battery). The
unit is mounted on a bracket attached to the rear brake master
cylinder (3) mounting bracket under the rear fork pivot point.

The siren's internal 9-volt battery is rechargeable and does not
need to be replaced on a regular basis. Battery life under
normal conditions is approximately three to six years.

NOTE

The internal siren battery may not charge if the vehicle's battery
is less than 12.5 volts.

REMOVAL

See

Figure 6-127

. Disarm security system. While system

is disarmed, unplug siren harness connector [142B] (2)
from siren assembly (1).

See

Figure 6-128

. Gently pry up on two tabs (2) while

pulling siren housing (1) toward the left side of the motor-
cycle. This will disengage siren mounting bosses (3) from
mounting bracket. Allow siren assembly to drop down and
remove from vehicle.

sm01285

Security siren assembly

Siren harness connector [142B]

Rear brake master cylinder

Guard

Figure 6-127. Security Siren

sm01286

Security siren housing

Tab (2)

Siren housing mounting boss (2)

Figure 6-128. Security Siren Mount (Guard Removed for

Clarity)

DISASSEMBLY

See

Figure 6-129

. Remove three screws (4) and bottom

cover (1) from top cover (2) of security siren assembly.

See

Figure 6-130

. Remove security siren (1) from top

cover (3).

sm01287

Bottom cover

Top cover

Mounting boss (2)

Screw (3)

Figure 6-129. Security Siren Housing

HOME

2009 Sportster Service: Electrical 6-93

sm01379

Security siren module

Bottom cover

Top cover

Battery compartment cover

Screw (3)

Figure 6-130. Security Siren Assembly

BATTERY REPLACEMENT

Schedule

The siren's internal 9 volt battery is rechargeable and does not
need to be replaced on a regular basis. Battery life under
normal conditions is approximately three to six years.

NOTES

•

See

Figure 6-131

and

Figure 6-132

. Early style siren will

work with both TSSM and HFSM. Late style siren will only
work with HFSM.

•

The internal siren battery may not charge if the vehicle's
battery is less than 12.5 volts.

Battery Replacement: Early Style Siren

Disarm system and remove siren.

See

Figure 6-131

. Remove battery cover.

Place the siren module on a flat and sturdy table with
the potted section (area with epoxy covering circuit
board) facing up and towards you.

Position a knife blade at a 45 degree angle to the long
side of the siren case. Insert the knife blade between
the siren case and battery cover at one of the two
accessible corners of the battery cover. Keep the
blade slightly higher towards the battery cover as this
helps keep the blade away from the battery seal.

Slowly twist the blade towards the battery cover and
the cover will pop off.

NOTES

•

For protection against corrosion, battery terminals and
battery clip are covered with a special grease. Do not wipe
away this substance. Apply all available existing grease
to terminals on new battery.

•

Only a 9 volt nickel metal hydride battery should be used
in the siren.

Replace battery by removing old battery from polarized
battery clip. Install a new 9 volt nickel metal hydride bat-
tery.

Reinstall battery cover.

Carefully replace the rubber seal.

Align battery cover with case placing round corners
on cover away from connector [142A]. Snap cover
into place.

Install siren and check operation. If siren is working prop-
erly, it will respond with two chirps after receiving the arm
command.

Battery Replacement: Late Style Siren

Disarm system and remove siren.

See

Figure 6-132

. With a small screwdriver or pick, push

the catches (1) in through the two slots (2) in the end of
the siren to release the battery cover (3).

NOTES

•

Only a 9 volt nickel metal hydride battery should be used
in the siren.

Replace battery (4) by removing old battery from polarized
battery clip.

Recharge and re-install or install a new 9 volt nickel metal
hydride battery.

Reinstall battery cover (3).

Carefully replace the rubber seal (5) on the cover.

Align battery cover with case placing round corners
on cover away from connector [142A] (6).

Snap cover into place.

HOME

6-94 2009 Sportster Service: Electrical

Install siren and check operation. If siren is working prop-
erly, it will respond with two chirps after receiving the arm
command.

sm06144

Cover

Battery

Connector [142A]

Figure 6-131. Siren Battery Compartment (Early Style Siren)

sm06145

Catch

Slot

Cover

9 Volt battery

Rubber seal

Connector [142A]

Figure 6-132. Siren Battery Compartment (Late Style Siren)

ASSEMBLY

See

Figure 6-130

. Place security siren module (1) inside

top cover (3) with siren connector [142A] positioned in
cutout in cover and siren battery compartment cover (4)
visible.

See

Figure 6-129

. Place bottom cover (1) on top cover (2)

and secure with three screws (4).

INSTALLATION

See

Figure 6-128

. Position siren (1) in mounting bracket

so that mounting bosses (3) align with mounting clips in
bracket and connector socket [142A] faces rear master
cylinder.

Slide siren housing toward the right side of the vehicle
until tabs (2) lock siren in place.

See

Figure 6-127

. Plug harness connector [142B] (2) into

siren connector socket [142A].

Check siren operation. If siren is working properly, it will
respond with two chirps after receiving the arm command.

HOME

2009 Sportster Service: Electrical 6-95

6.36

OIL PRESSURE SWITCH

GENERAL

The oil pressure signal lamp switch is a pressure-actuated
diaphragm-type switch. When oil is not circulating through the
system or when oil pressure is abnormally low, spring tension
holds the switch contacts closed, thereby completing the signal
lamp circuit and causing the indicator lamp to illuminate.

See

Figure 6-133

. The oil pressure switch is located under the

oil filter mount at the front of the engine crankcase.

NOTE

The oil pressure switch cannot be repaired. Replace the unit
if it fails.

sm01278

Oil filter

Oil pressure switch

Oil pressure switch connector [120]

Figure 6-133. Oil Pressure Indicator Lamp Switch (Left

Side View XL 1200C)

sm05563

Oil pressure switch

J-clip

Barbed cable strap

Stator connector

Figure 6-134. Oil Pressure Switch (Right Side View XR

1200)

REMOVAL

TOOL NAME

PART NUMBER

OIL PRESSURE SENDING UNIT
WRENCH

HD-41675

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 6-133

. Remove wiring harness connector [120]

(3) by pulling elbow connector straight down from stud on
oil pressure switch (2).

XL models only: remove voltage regulator DC output
connector and neutral switch wiring harness from voltage
regulator caddy. Remove caddy. See

6.33 ELECTRICAL

CADDIES

XR models only: see

Figure 6-134

. Disconnect voltage

regulator stator connector (4). Reposition neutral switch
wire and voltage regulator stator wire as needed.

Place a container under vehicle to catch any oil that may
leak out when oil pressure switch is removed.

NOTE

XR models only: hold oil pressure switch adapter with a
wrench to prevent the adapter from being removed while
removing the oil pressure switch.

Using OIL PRESSURE SENDING UNIT WRENCH (Part
No. HD-41675), remove oil pressure switch.

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6-96 2009 Sportster Service: Electrical

INSTALLATION

TOOL NAME

PART NUMBER

OIL PRESSURE SENDING UNIT
WRENCH

HD-41675

XR models only: if, during removal, oil pressure switch
adapter came out with oil pressure switch, install adapter
in the following way:

Separate oil pressure switch from adapter.

Remove old O-ring and install a new O-ring.

Install adapter and tighten to 108-158 in-lbs (12.2-
17.9 Nm).

NOTE

Perform following step only if original oil pressure switch is
being re-installed. New switches have a sealant contact patch
on the mounting threads. If new switch is being installed, begin
with step 2.

Coat threads of oil pressure switch with LOCTITE 565
HIGH PERFORMANCE PIPE SEALANT with TEFLON.

See

Figure 6-133

. Install oil pressure switch (2). Using

OIL PRESSURE SENDING UNIT WRENCH (Part No. HD-
41675), tighten switch snugly. DO NOT OVERTIGHTEN.

XL models only: install voltage regulator caddy and attach
DC output connector and neutral switch wiring harness to
caddy. See

6.33 ELECTRICAL CADDIES

XR models only: see

Figure 6-134

Reposition neutral switch wire and stator wire (4).

Secure stator connector to bracket with barbed cable
strap (3) and make sure neutral switch wire and oil
pressure switch wires are secured in J-clip (2).

Mate halves of stator connector and secure with lock.

NOTE

Oil pressure switch connector [120] must always face away
from vehicle.

Attach wiring harness connector [120] (3) to oil pressure
switch. Make sure connector points away from motorcycle.

Plug in main fuse. See

6.38 MAIN FUSE

NOTE

If an appreciable amount of oil leaked out when oil pressure
switch was removed, it will have to be replaced with fresh oil.

Check oil level in oil tank. See

1.6 ENGINE OIL AND

FILTER

. Top off oil level if necessary.

Start engine and test oil pressure switch for proper opera-
tion. Check oil pressure switch for leaks.

HOME

2009 Sportster Service: Electrical 6-97

Harley Davidson Sportster Models 2009. Service Repair Manual - page 38