Harley Davidson Sportster Models 2009. Service Repair Manual

6.37

HORN

TROUBLESHOOTING

If the horn does not sound or sounds weak, check for the fol-
lowing:

•

Discharged battery. To charge battery, see

1.17 BATTERY

MAINTENANCE

•

Loose, frayed or damaged wiring to horn terminal.

If battery is charged and wiring appears to be in good condition,
perform a VOLTAGE TEST for the following:

•

Inoperative horn switch.

•

Open circuit to horn.

•

Open ground to frame.

•

Inoperative horn.

VOLTAGE TEST

Remove terminal clips from horn spade connectors.

Connect voltmeter leads, positive (+) to wire terminal and
negative (-) to ground.

Turn ignition switch ON and press horn switch.

If battery voltage is not present, check for the following:

Horn switch is inoperative. Replace switch. See

6.41 LEFT HANDLEBAR SWITCHES

Wiring to horn is open. Repair wiring.

If battery voltage is present, check for the following:

Ground is open between mounting hardware or
ground wire. Repair wiring.

Horn is inoperative. Replace horn. See

6.37 HORN,

Replacement: Models with Front Mounted Horn

6.37 HORN, Replacement: Models with Side Mounted
Horn

REPLACEMENT: MODELS WITH FRONT
MOUNTED HORN

See

Figure 6-135

. Remove terminal clips from horn spade

connectors (1, 3).

Remove screws (4) and lock washers (6) from horn bracket
(2) and remove horn assembly (5).

Install horn assembly with screws and washers into horn
bracket. Tighten screws to 72-108 in-lbs (8.1-12.2 Nm).

Install the yellow wire with black tracer to the left spade
connector (3) and the black wire to the right spade con-
nector (1).

sm01373

Right spade connector

Horn bracket

Left spade connector

Screw (3)

Horn assembly

Lock washer (3)

Screw (2)

Washer (2)

Figure 6-135. Horn Components (Models with Front

Mounted Horn)

REPLACEMENT: MODELS WITH SIDE
MOUNTED HORN

See

Figure 6-136

. Remove terminal clips from horn spade

connections on back of horn (12).

Remove acorn nut (3) and lock washer (4) to free horn
assembly from rubber mount (6) stud.

Remove wire conduit from clamp (9) at back of support
bracket (5).

Remove nut (10) from circular recess at back of chrome
cover and bracket (2) and remove horn (12) from cover
and bracket.

Slide horn (12) into chrome cover and bracket (2) pushing
stud at back of horn assembly through hole in horn support
bracket (5). Apply two drops of LOCTITE THREAD-
LOCKER 271 (red) to threads of nut (10). Install nut (10)
on horn stud and tighten to 80-100 in-lbs (9.0-11.3 Nm).

Attach the yellow wire with black tracer to front terminal
and the black wire to rear terminal. Push wire conduit into
clamp (9) at back of horn bracket (5).

Install support bracket (5) on rubber mount (6) stud with
lock washer (4) and acorn nut (3). Tighten acorn nut (3)
to 60-180 in-lbs (6.8-20.4 Nm).

HOME

6-98 2009 Sportster Service: Electrical

sm01670

Screw (2)

Clip nut (2)

Cover and bracket

Clamp

10.

Nut

Acorn nut

11.

Lock washer

Washer (2)

12.

Horn

Support bracket

13.

Rubber mount

Screw (2)

14.

Mounting bracket

Lock nut

Figure 6-136. Horn Components (Models with Side Mounted Horn)

HOME

2009 Sportster Service: Electrical 6-99

6.38

MAIN FUSE

GENERAL

Fuses prevent the electrical overload of a circuit. A fuse closes
a circuit as long as current (amperage) flowing through the
fuse does not exceed the ampere rating of the fuse. If the circuit
current exceeds the fuse ampere rating, the fuse opens and
the current flow is interrupted.

See

Figure 6-137

. The main fuse is located in a holder [5] (1)

mounted on the battery strap (2) under the left side cover. The
main fuse is rated at 30 Amperes.

REMOVAL

Open left side cover. See

2.20 LEFT SIDE COVER

See

Figure 6-137

. Squeeze cover release latches (4)

together and pull fuse holder [5] (1) from protective cover
(3).

See

Figure 6-138

. Grasp fuse holder (2) and pull main

fuse (1) straight out.

If you are performing other procedures before re-installing
the main fuse, close the left side cover.

INSTALLATION

Open left side cover. See

2.20 LEFT SIDE COVER

See

Figure 6-138

. Install main fuse (1) by lining up spade

terminals on fuse with sockets in fuse holder [5] (2). Press
fuse firmly into holder.

See

Figure 6-137

. While holding protective cover (3) in

place, push fuse holder [5] (1) into cover until cover release
latches (4) snap into place.

Close left side cover.

Be sure that all lights and switches operate properly before
operating motorcycle. Low visibility of rider can result in
death or serious injury. (00316a)

Turn ignition switch ON and verify proper operation of
electrical system.

sm01262

Main fuse holder [5]

Battery strap

Protective cover

Cover release catches

Relay and fuse blocks

Figure 6-137. 30 Amp Main Fuse Location: All Models (XL

Model Shown)

sm01264

Main fuse

Fuse holder [5]

Figure 6-138. Removing/Installing Main Fuse: All Models

(XL Model Shown)

HOME

6-100 2009 Sportster Service: Electrical

6.39

HANDLEBAR SWITCH ASSEMBLIES

GENERAL

The switches are of rugged construction and feature a superior
seal to protect electrical contacts and components from dirt
and moisture in harsh environments.

The left handlebar switches include the headlamp HI - LO
switch, horn and left turn signal switch. The right handlebar
switches include the engine start and RUN - OFF switch and
right turn signal switch. The individual switches are non-
repairable and must be replaced if they malfunction.

NOTES

•

On certain models, the turn signal wiring is routed through
the lower switch housings and handlebars.

•

To replace or repair individual switches in either the right
or left handlebar switch assemblies, see

6.40 RIGHT

HANDLEBAR SWITCHES

6.41 LEFT HANDLEBAR

SWITCHES

REPAIR PROCEDURES

TOOL NAME

PART NUMBER

ROBINAIR HEAT GUN

HD-25070

ULTRA TORCH UT-100

HD-39969

HEAT SHIELD ATTACHMENT

HD-41183

See

6.40 RIGHT HANDLEBAR SWITCHES

and

6.41 LEFT

HANDLEBAR SWITCHES

. The removal and installation steps

listed apply when replacing the entire switch assembly, switch
housing or handlebars.

The information below is useful when repairing handlebar
switch assemblies.

To better access wires and avoid damaging conduit with
radiant heating device, push conduit back and secure with
extra 7.0 in. (177.8 mm) cable strap in kit.

Strip 0.5 in (12.7 mm) of insulation off switch wires. Twist
stripped ends of switch wires until all strands are tightly
coiled.

Cut dual wall heat-shrink tubing, supplied in repair kit into
1.0 in. (25.4 mm) segments. Slide tubing over each wire
of new switch assembly.

Splice existing and new switch wires, matching wire colors.
Solder the spliced connections. For best results, do one
wire at a time.

Center the heat-shrink tubing over the soldered splices.

Be sure to follow manufacturer's instructions when using
the UltraTorch UT-100 or any other radiant heating device.
Failure to follow manufacturer's instructions can cause a
fire, which could result in death or serious injury. (00335a)

•

Avoid directing heat toward any fuel system component.
Extreme heat can cause fuel ignition/explosion resulting
in death or serious injury.

•

Avoid directing heat toward any electrical system com-
ponent other than the connectors on which heat shrink
work is being performed.

•

Always keep hands away from tool tip area and heat shrink
attachment.

See

Figure 6-139

. Using the ULTRA TORCH UT-100 (Part

No. HD-39969) or ROBINAIR HEAT GUN (Part No. HD-
25070) with HEAT SHIELD ATTACHMENT (Part No. HD-
41183) or other suitable radiant heating device, uniformly
heat the heat-shrink tubing to insulate and seal the
soldered connections. Apply heat just until the meltable
sealant exudes out both ends of tubing and it assumes a
smooth cylindrical appearance.

Inspect the melted sealant for solder beads. Excess solder
or heat may force some solder out with the melted sealant.
Use a small needle nose pliers to remove any solder
found. Briefly heat the connection to reseal the tubing if
solder beads were removed. Use less solder or reduce
heating time or intensity when doing subsequent splices.

Be sure that all lights and switches operate properly before
operating motorcycle. Low visibility of rider can result in
death or serious injury. (00316a)

sm00082

Ultra Torch UT-100

Robinair Heat Gun

Heat Shield Attachment

Figure 6-139. Radiant Heating Devices

HOME

2009 Sportster Service: Electrical 6-101

CONNECTORS

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

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 fuel tank. See

4.6 FUEL TANK: XL MODELS

4.7 FUEL TANK: XR MODELS

Separate left and right wire harness caddies. See

6.33 ELECTRICAL CADDIES

On XL 883C/XL 1200C models, remove riser cover from
the back of the handlebar riser. See

2.32 HANDLEBARS

See

Figure 6-140

Figure 6-141

. Locate right handlebar

connector [22] (4, 5) mounted on left wire harness caddy
(2). Press latch (3) and separate connector halves.

In the same manner, locate left handlebar connector [24]
(6), press latch and separate connector halves.

To remove socket or pin halves for routing or to service
Molex electrical connectors, see

A.9 MOLEX CON-

NECTORS

Mate right handlebar connector [22] halves. Mate left
handlebar connector [24] halves.

10. Reassemble left and right wire harness caddies. See

6.33 ELECTRICAL CADDIES

11. Replace fuel tank. See

4.6 FUEL TANK: XL MODELS

4.7 FUEL TANK: XR MODELS

12. On XL 883C/XL 1200C models, replace riser cover. Make

certain that handlebar control harnesses are not pinched
between handlebar riser and riser cover. Tighten screws
to 8-12 in-lbs (0.9-1.4 Nm).

13. 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)

14. Turn ignition switch ON and verify correct operation of

handlebar switches.

sm03386

Frame backbone

Left wire harness caddy

Connector latch

Right handlebar pin connector [22A]

Right handlebar socket connector [22B]

Left handlebar control connector [24]

Figure 6-140. Handlebar Connectors (XL Models Only)

sm05561

Frame backbone

Left wire harness caddy

Connector latch

Right handlebar pin connector [22A]

Right handlebar socket connector [22B]

Left handlebar control connector [24]

Figure 6-141. Handlebar Connectors (XR 1200 Models Only)

HOME

6-102 2009 Sportster Service: Electrical

6.40

RIGHT HANDLEBAR SWITCHES

REMOVAL

NOTE

The removal and installation steps listed apply when replacing
the entire switch assembly, switch housing or handlebars.

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

Remove main fuse. See

6.38 MAIN FUSE

NOTE

Do not remove the switch housing assembly without first placing
a 5/32 in. (4 mm) thick cardboard insert between the brake
lever and lever bracket. Removing the assembly without the
insert in place may result in damage to the rubber boot and
plunger of the front stoplight switch.

See

Figure 6-142

. Place the cardboard insert between the

brake lever and lever bracket.

Using a T27 TORX drive head, remove the two screws
with flat washers securing the handlebar clamp to the
master cylinder housing. Remove the brake lever/master
cylinder assembly and clamp from the handlebar.

Using a T25 TORX drive head, remove the upper and
lower switch housing screws.

Remove the friction shoe from the end of the tension
adjuster screw.

NOTE

The friction screw is a loose fit and may fall out or become
dislodged if the lower switch housing is turned upside down or
shaken.

Remove the brass ferrules from the notches on the inboard
side of the throttle control grip. Remove the ferrules from
the cable end fittings.

Remove the throttle control grip from the end of the
handlebar.

Pull the crimped inserts at the end of the throttle and idle
control cable housings from the lower switch housing. For
best results, use a rocking motion while pulling. Place a
drop of light oil on the retaining rings, if necessary.
Remove the cables from the switch housing.

sm03387

Figure 6-142. Install Cardboard Insert

DISASSEMBLY

Do not remove or install the master cylinder assembly
without first positioning a 5/32-inch (4 mm) thick insert
between the brake lever and lever bracket. Removing or
installing the master cylinder assembly without the insert
in place may result in damage to the rubber boot and
plunger on the front stoplight switch. (00324a)

Place the cardboard insert between the brake lever and
lever bracket.

Using a T25 TORX drive head, remove the upper and
lower switch housing screws.

If replacing lower housing switches, perform steps 4
through 7 before continuing to repair section. If replacing
upper housing switches, proceed directly to repair section.

See

Figure 6-151

. Using a T27 TORX drive head, loosen

the upper screw (1) securing the handlebar switch clamp
to the master cylinder housing. Remove the lower clamp
screw with flat washer (2).

Remove the brass ferrules from the notches on the inboard
side of the throttle control grip. Remove the ferrules from
the cable end fittings.

Remove the friction shoe from the end of the tension
adjuster screw.

NOTE

The friction shoe is a loose fit and may fall out or become dis-
lodged if the lower switch housing is turned upside down or
shaken.

HOME

2009 Sportster Service: Electrical 6-103

Remove the throttle control grip from the end of the
handlebar.

SWITCH REPAIR/REPLACEMENT

Upper Housing Repair

NOTE

Replace the engine stop and engine start switches as a single
assembly even if only one switch is determined to be faulty.

See

Figure 6-143

. From inside the switch housing, remove

the screw with lockwasher (4) to release the bracket (5).
Remove the bracket and switch assembly from the
housing.

Move cable conduit (3) from beneath wing of bracket. Cut
wires 0.25 in. (6.4 mm) from old switches (1, 2). Discard
old switch and bracket assembly.

Slide conduit forward over cut ends of switch wires and
cut off 0.5 in. (12.7 mm) of conduit (3) material. Push
conduit back to access switch wires.

See

Figure 6-144

. Separate new engine stop switch (2)

and engine start switch (1) wires into two bundles.

NOTE

Replacement stop switch and start switch wires are cut to
length, 2.5 in. (63.5 mm) and 2.0 in. (50.8 mm) respectively,
and partially stripped.

See

6.39 HANDLEBAR SWITCH ASSEMBLIES

for

information on splicing and general repair practices.

Loop switch wires so that spliced lengths are positioned
as shown in

Figure 6-144

. Route wires downstream of

splices beneath wing on engine stop switch side of bracket
as shown in

Figure 6-143

See

Figure 6-144

. Install a new7.0 in. (177.8 mm) cable

strap (5) beneath wing on engine start switch side (1) of
bracket and capture wire splices (4).

Place switch assembly into upper housing aligning hole
in bracket with threaded hole in boss. Be sure that bracket
is fully seated. The step at the edge of the boss captures
the bottom edge of the bracket, while tabs on each side
of the bracket fit in slots cast into the housing.

See

Figure 6-143

. Install screw and lockwasher (4) to

secure bracket (5) inside housing. Verify that wing on
engine stop switch (2) side of bracket captures edge of
conduit (3) as shown.

10. Securely tighten cable strap to draw splices to bracket.

Remove any excess cable strap material.

11. Continue with

6.40 RIGHT HANDLEBAR SWITCHES,

Assembly

sm01087

Start switch

Stop switch

Conduit

Screw with lockwasher

Bracket

Figure 6-143. Upper Housing Without Splices

sm01088

Start switch

Stop switch

Conduit

Splices

Cable strap

Figure 6-144. Upper Housing With Splices

HOME

6-104 2009 Sportster Service: Electrical

Lower Housing Repair

From inside the switch housing, carefully cut cable strap
to free conduit from the turn signal switch bracket.

Remove the screw with lockwasher to release the turn
signal switch bracket. Remove the bracket and switch
assembly from the housing.

Continue with TURN-RIGHT SIGNAL SWITCH or FRONT
STOPLIGHT SWITCH procedures which follow.

Turn-Right Signal Switch

Perform steps in LOWER HOUSING REPAIR.

Cut wire 1.5 in. (38.1 mm) from old switch. Discard old
switch assembly.

NOTE

Replacement turn-right signal switch wires are cut to length of
1.5 in. (38.1 mm) and partially stripped.

See

6.39 HANDLEBAR SWITCH ASSEMBLIES

for

information on splicing and general repair practices.

Continue with

6.40 RIGHT HANDLEBAR SWITCHES,

Assembly

Front Stoplight Switch

Perform steps in LOWER HOUSING REPAIR.

Carefully remove the wedge between the switch and switch
housing, if present. To remove the switch from the housing,
depress the plunger and slowly rotate switch upward while
rocking slightly.

Cut wires 1.0 in. (25.4 mm) from old switch. Discard old
switch.

NOTE

Replacement stoplight switch wires are cut to length of 2.5 in.
(63.5 mm) and partially stripped.

See

6.39 HANDLEBAR SWITCH ASSEMBLIES

for

information on splicing and general repair practices.

Carefully depress plunger against inside wall of switch
housing. With thumb over plunger bore, move switch into
the installed position in the switch housing cavity. When
plunger is positioned against thumb, slowly rotate switch
downward while rocking slightly. Release the plunger only
after switch is properly positioned in the cavity.

Verify that the plunger is square in the bore and that the
boot is not compressed, collapsed or torn. If necessary,
gently work the plunger in and out until boot is fully
extended.

See

Figure 6-145

. Push down on switch (1) so that it bot-

toms against housing and wires (3) run in groove at base
of cavity. With the concave side facing outward, insert
wedge (2) between switch and outboard side of switch
housing.

Push wedge down until it also bottoms against housing.
Verify that the plunger is still square in the bore and then
place a drop of RTV Silicone Sealant on upper corner of
wedge.

Continue with

6.40 RIGHT HANDLEBAR SWITCHES,

Assembly

sm01089

Stoplight switch

Wedge

Switch wires

Lower switch housing

Figure 6-145. Install Stoplight Switch

ASSEMBLY

See

Figure 6-146

. Insert tapered end of new 7.0 in. (177.8

mm) cable strap (1) into round hole in turn signal switch
bracket (2) and then feed back through using the adjacent
hole. Reserve the oblong hole for the bracket screw.

NOTE

Be sure that all splices are positioned above the turn signal
switch bracket.

Place the turn signal switch assembly into the housing,
aligning the oblong hole in the bracket with the threaded
hole in the boss. Be sure that the bracket is fully seated.
Tabs on each side of bracket are captured in slots cast
into switch housing.

Start screw with lockwasher to secure bracket inside
housing.

If routed incorrectly, wires can be pinched by casting or
handlebar resulting in switch failure. (00542b)

Loop switch wires so that spliced lengths are positioned
across bracket.

Capturing conduit about 0.25 in. (6.4 mm) from end,
securely tighten cable strap to draw conduit to bracket.
Remove any excess cable strap material.

Install second 7.0 in. (177.8 mm) cable strap capturing
conduit and wire splices. Securely tighten cable strap to

HOME

2009 Sportster Service: Electrical 6-105

draw splices to conduit. Remove any excess cable strap
material.

Tighten screw to secure bracket inside housing.

Route wire bundle to upper switch housing by gently
pressing conduit into channel next to angular arm of
bracket. Secure bundle to arm using third cable strap. Cut
any excess cable strap material. If necessary, bend
angular arm of bracket downward to firmly secure front
stoplight switch in position.

See

6.40 RIGHT HANDLEBAR SWITCHES, Installation

If lower housing switches were replaced, perform the
entire procedure.

If upper housing switches were replaced, begin with
step 11.

sm01090

Cable strap

Bracket

Right turn signal switch

Figure 6-146. Insert Cable Strap in Switch Bracket

INSTALLATION

See

Figure 6-147

. Push the throttle and idle control cables

into the lower switch housing until they snap in place. Note
the different diameter inserts crimped into the end of the
throttle and idle cable housings.

Push the silver insert (2) of throttle cable housing into
the hole in front of tension adjuster screw (3).

Push the gold insert (1) of idle cable housing into the
hole at the rear of tension adjuster screw (3).

NOTE

To aid assembly, place a drop of light oil on the retaining rings
of the crimped inserts. Always replace the retaining rings if
damaged or distorted.

See

Figure 6-148

. Route the cable (2) to the upper switch

housing as shown.

Slide the throttle control grip over the end of the right
handlebar until it bottoms against the closed end. Rotate
the grip so that the ferrule notches are at the top. To pre-
vent binding, pull the grip back about 1/8 in. (3.2 mm).

With the concave side facing upward, install the friction
shoe so that the pin hole is over the point of the adjuster
screw.

NOTE

The friction shoe is a loose fit and may fall out or become dis-
lodged if the lower switch housing is turned upside down or
shaken.

See

Figure 6-149

. Position lower switch housing beneath

the throttle control grip. Install the brass ferrules (4) onto
the cable so that the end fittings seat in the ferrule recess.
Seat the ferrules in their respective notches (3) on the
throttle control grip. Verify that the cables are captured in
the grooves (2) molded into the grip.

Position the upper switch housing over the handlebar and
lower switch housing.

Verify that the wire harness conduit runs in the depression
at the bottom of the handlebar. Be sure that the upper
switch housing harness will not be pinched under the
handlebar when the switch housing screws are tightened.

Start the upper and lower switch housing screws, but do
not tighten.

HOME

6-106 2009 Sportster Service: Electrical

sm02636

Idle cable insert (gold insert, rear hole)

Throttle cable insert (silver insert, front hole)

Tension adjuster screw

Figure 6-147. Right Lower Switch Housing

sm02634

End fittings

Upper switch housing cable

Figure 6-148. Route Cable to Upper Switch Housing

sm01084

Throttle cable (silver insert, front hole)

Groove in throttle grip

Notch

Brass ferrule

Idle cable (gold insert, rear hole)

Figure 6-149. Throttle Cable Attachment

See

Figure 6-150

. Position the brake lever/master cylinder

assembly inboard of the switch housing assembly, enga-
ging the tab (2) on the lower switch housing in the groove
(3) at the top of the brake lever bracket.

10. Align the holes in the handlebar switch clamp with those

in the master cylinder housing and start the two screws
(with flat washers). Position for rider comfort. Beginning
with the top screw, tighten to specification using a T27
TORX drive head. Refer to

Table 6-16

11. Using a T25 TORX drive head, tighten lower and upper

switch housing screws to specification. Refer to

Table 6-16

NOTE

Always tighten the lower switch housing screw first so that any
gap between the upper and lower housings is at the front of
the switch.

Table 6-16. Handlebar Switch Assembly Fasteners

TORQUE

FASTENER

108-132 in-lbs (12.2-14.9 Nm)

Handlebar clamp screws

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

Switch housing screws

12. Remove the cardboard insert between the brake lever and

lever bracket.

13. Adjust throttle cables. See

2.30 THROTTLE CABLES:

ALL MODELS

14. Install 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)

15. Test the switches for proper operation.

HOME

2009 Sportster Service: Electrical 6-107

6.41

LEFT HANDLEBAR SWITCHES

REMOVAL

NOTE

The removal and installation steps listed apply when replacing
the entire switch assembly, switch housing or handlebars.

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

Remove main fuse. See

6.38 MAIN FUSE

Using a T25 TORX drive head, loosen but do not remove
the upper and lower switch housing screws.

Using a T27 TORX drive head, remove the two screws
with flat washers securing the handlebar clamp to the
clutch lever bracket. Remove the clutch hand lever
assembly and clamp from the handlebar.

Remove the upper and lower switch housing screws.

Remove the grip sleeve from the end of the handlebar if
damaged.

DISASSEMBLY

Using a T25 TORX drive head, remove the upper and
lower switch housing screws.

If replacing lower housing switches, perform next step
before continuing to repair section. If replacing upper
housing switches, proceed directly to repair section.

Using a T27 TORX drive head, loosen the upper screw
securing the handlebar clamp to the clutch lever bracket.
Remove the lower clamp screw with flat washer.

SWITCH REPAIR/REPLACEMENT

Upper Housing Repair

NOTE

Replace the horn switch and high/low beam switch as a single
assembly even if only one switch is determined to be faulty.

See

Figure 6-152

. From inside the switch housing, remove

the screw with lockwasher (4) to release the bracket (5).
Remove bracket and switch assembly from the housing.

Move cable conduit (3) from beneath wing of bracket. Cut
wires 0.25 in. (6.4 mm) from old switches (1, 2). Discard
old switch and bracket assembly.

Slide conduit forward over cut ends of switch wires and
cut off 0.5 in. (12.7 mm) of conduit (3) material. Push
conduit back to access switch wires.

Separate the new horn switch (1) and high/low beam
switch (2) wires into two bundles.

NOTE

Replacement high/low beam switch and horn switch wires are
cut to length of 2.5 in. (63.5 mm) and 2.0 in. (50.8 mm)
respectively, and partially stripped.

See

6.39 HANDLEBAR SWITCH ASSEMBLIES

for

information on splicing and general repair practices.

Loop switch wires so that spliced lengths are positioned
as shown in

Figure 6-153

. Route wires downstream of

splices beneath wing on high/low beam switch side of
bracket as shown in

Figure 6-152

See

Figure 6-153

. Install a new 7.0 in. (177.8 mm) cable

strap (5) beneath wing on horn switch side (1) of bracket
and capture wire splices (4).

See

Figure 6-152

. Install screw and lockwasher (4) to

secure bracket (5) inside housing. Verify that wing on
high/low switch (2) side of bracket captures edge of conduit
(3) as shown.

10. Securely tighten cable strap to draw splices to bracket.

Remove any excess cable strap material.

11. Continue with

6.41 LEFT HANDLEBAR SWITCHES,

Assembly

sm01091

Horn switch

High/low beam switch

Conduit

Screw with lockwasher

Bracket

Figure 6-152. Upper Housing Without Splices

HOME

2009 Sportster Service: Electrical 6-109

sm01092

Horn switch

High/low beam switch

Conduit

Splices

Cable strap

Figure 6-153. Upper Housing With Splices

Lower Housing Repair

From inside the switch housing, carefully cut cable strap
to free conduit from the turn signal switch bracket.

Remove screw with lockwasher to release the turn signal
switch bracket. Remove the bracket and switch assembly
from the housing.

Continue with TURN-LEFT SIGNAL SWITCH or CLUTCH
INTERLOCK SWITCH procedures.

Turn-Left Signal Switch

Perform steps in LOWER HOUSING REPAIR.

Cut wires 1.5 in. (38.1 mm) from old switch (Turn-L(eft)
Signal Switch). Discard switch assembly.

NOTE

Replacement turn-right signal switch wires are cut to length of
1.5 in. (38.1 mm) and partially stripped.

See

6.39 HANDLEBAR SWITCH ASSEMBLIES

for

information on splicing and general repair practices.

Continue with

6.41 LEFT HANDLEBAR SWITCHES,

Assembly

Clutch Interlock Switch

Perform steps in LOWER HOUSING REPAIR.

See

Figure 6-154

. Cut wires 0.25 in. (6.4 mm) from old

switch. Discard switch assembly.

NOTE

Replacement turn-right signal switch wires are cut to length
and partially stripped.

See

6.39 HANDLEBAR SWITCH ASSEMBLIES

for

information on splicing and general repair practices.

Continue with

6.41 LEFT HANDLEBAR SWITCHES,

Assembly

sm02644

Figure 6-154. Clutch Interlock Switch

ASSEMBLY

See

Figure 6-155

. Insert tapered end of new 7.0 in. (177.8

mm) cable strap (1) into round hole in turn signal switch
bracket (2) and then feed back through using the adjacent
hole. Reserve the oblong hole for the bracket screw.

NOTE

Be sure that all splices are positioned above the turn signal
switch bracket.

Place the turn signal switch assembly (3) into the housing,
aligning the oblong hole in the bracket with the threaded
hole in the boss. Be sure that the bracket is fully seated.
Tabs on each side of bracket are captured in slots cast
into switch housing.

Start screw with lockwasher to secure bracket inside
housing.

If routed incorrectly, wires can be pinched by casting or
handlebar resulting in switch failure. (00542b)

Loop switch wires so that spliced lengths are positioned
across bracket.

Capturing conduit about 0.25 in. (6.4 mm) from end,
securely tighten cable strap to draw conduit to bracket.
Remove any excess cable strap material.

Tighten screw to secure bracket inside housing.

Route wire bundle to upper switch housing below and then
forward of the main wire harness, positioning conduit in
channel next to angular arm of bracket. Secure bundle to

HOME

6-110 2009 Sportster Service: Electrical

arm using new cable strap. Cut any excess cable strap
material.

See

6.41 LEFT HANDLEBAR SWITCHES, Installation

If lower housing switches were replaced, perform the
whole procedure.

If upper housing switches were replaced, begin with
step 7.

Verify the operation of the clutch interlock switch. See the
ELECTRICAL DIAGNOSTIC MANUAL.

sm01094

Cable strap

Bracket

Left turn signal switch

Figure 6-155. Insert Cable Strap in Switch Bracket

INSTALLATION

If the grip sleeve was removed, thoroughly clean handlebar
to remove all adhesive residue. Pour adhesive into new
grip. Roll grip to evenly distribute adhesive on inside sur-
faces. Install grip on handlebar with a twisting motion.

See

Figure 6-156

. Install upper and lower switch housings

on handlebar. Be sure that ribs (2) on outboard side of
switch housings fit in grooves (3) molded into grip.

Verify that the wire harness conduit runs in the groove at
the bottom of the handlebar. Be sure that the upper switch
housing harness will not be pinched under the handlebar
when the switch housing screws are tightened.

Start the upper and lower switch housing screws, but do
not tighten.

See

Figure 6-157

. Position the clutch hand lever assembly

inboard of the switch housing assembly, engaging the tab

(3) on the lower switch housing in the groove (2) at the
bottom of the clutch lever bracket.

Align the holes in the handlebar switch clamp with those
in the clutch lever bracket and start the two screws (with
flat washers). Position for rider comfort. Beginning with
the top screw, tighten screws to specification with a T27
TORX drive head. Refer to

Table 6-17

Using a T25 TORX drive head, tighten lower and upper
switch housing screws to specification. Refer to

Table 6-17

NOTE

Always tighten the lower switch housing screw first so that any
gap between the upper and lower housings is at the front of
the switch.

Table 6-17. Handlebar Switch Assembly Fasteners

TORQUE

FASTENER

108-132 in-lbs (12.2-14.9 Nm)

Handlebar clamp screws

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

Switch housing screws

Install 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)

Test the switches for proper operation.

10. Secure wire harness to handlebar as necessary.

sm02632

Grip sleeve

Ribs

Grooves

Figure 6-156. Left Handlebar Switch Housings

HOME

2009 Sportster Service: Electrical 6-111

Harley Davidson Sportster Models 2009. Service Repair Manual - page 39