Harley Davidson Sportster Models 2009. Service Repair Manual - page 68

ADAPTER (Part No. HD-46282-1A) into top footrest bracket
hole in frame. Place handle of tool on top of adapter.

Shift transmission into neutral. Apply a few drops of
LOCTITE THREADLOCKER 262 (red) to the left-hand
threads of transmission sprocket nut (3). Apply a thin film
of clean Harley-Davidson 20W-50 engine oil to the back
face of the sprocket nut. Turn the nut counterclockwise
to install it onto main drive gear shaft.

See

Figure 5-111

. Use TRANSMISSION SPROCKET

HOLDING TOOL (Part No. HD-46282) (1), MAIN-
SHAFT LOCK NUT WRENCH (Part No. HD-46288)
(2), and a torque wrench (3). Place handle of sprocket
holding tool on top of footrest bracket. Tighten nut to
50 ft-lbs (68 Nm) initial torque, ONLY.

See

Figure 5-112

. Scribe a line on the transmission

sprocket nut and continue the line on the transmission
sprocket as shown.

Tighten the transmission sprocket nut an additional
30° - 40°.

NOTE

The lockplate has four screw holes and can be turned to
either side, so you should be able to find a position without
having to additionally tighten the nut. If you cannot align
the screw holes properly, the nut may be additionally
TIGHTENED until the screw holes line up, but do not
exceed 45° as specified above. Never LOOSEN nut to
align the screw holes.

See

Figure 5-108

. Install lockplate (4) over nut (3) so

that two of lockplate's four drilled holes (diagonally
opposite) align with sprocket's (2) two tapped holes.

sm01327

Transmission sprocket holding tool

Mainshaft lock nut wrench

Torque wrench

Figure 5-111. Tightening Transmission Lock nut: All

Models (XL Model with Passenger Footrests Shown)

sm01470

Transmission sprocket

Sprocket nut

Line scribed on nut and sprocket

Figure 5-112. Transmission Sprocket Nut Final Tightening

Procedure

NOTE

To maximize the lockplate's security, you must install BOTH
screws to secure the lockplate.

Install socket head screws through two of the four holes
in lockplate, then into two corresponding tapped holes in
sprocket.

Tighten socket head screws (5) to 90-110 in-lbs (10.2-
12.4 Nm).

XR models and XL models without passenger
footrests: remove SPROCKET HOLDING TOOL
ADAPTER (Part No. HD-46282-1A).

XL Models

See

Figure 5-108

. Install screw and washer (6) to secure

muffler interconnect bracket to engine crankcase. Tighten
to 30-33 ft-lbs (40.7-44.8 Nm).

Install rear drive belt onto transmission sprocket. See

5.7 DRIVE BELT

Adjust rear belt deflection and rear wheel alignment. See

1.16 REAR BELT DEFLECTION

Install belt guard. See

2.24 BELT GUARD AND DEBRIS

DEFLECTOR

See

Figure 5-107

. Install sprocket cover (1). Secure with

two screws (2, 3). Note that long screw goes in top hole,
short screw in bottom hole. Do not tighten screws at this
time.

Install exhaust pipe clamp bracket (4), washer (5) and
screw (6). Tighten to 30-33 ft-lbs (40.7-44.8 Nm) . Now
tighten screws (2, 3) to 80-120 in-lbs (9.0-13.6 Nm).

HOME

2009 Sportster Service: Drive/Transmission 5-69

Install rear exhaust pipe and rear muffler. See

4.15 EXHAUST SYSTEM: XL MODELS

XR Models

Install rear drive belt onto transmission sprocket. See

5.7 DRIVE BELT

Adjust rear belt deflection and rear wheel alignment. See

1.16 REAR BELT DEFLECTION

Attach rear brake master cylinder, rider footrest and
mounting bracket assembly to frame with two screws.
Tighten to 45-50 ft-lbs (61-68 Nm).

Install belt guard. See

2.24 BELT GUARD AND DEBRIS

DEFLECTOR

Install sprocket cover. Secure with three screws. Note that
of the two smaller diameter screws securing cover, longer
screw goes in top hole, shorter screw in bottom hole.
Larger diameter screw goes in rear hole. Tighten rear
(larger) screw to 30-33 ft-lbs (40.7-44.8 Nm).Tighten for-
ward and lower (smaller) screws to 80-120 in-lbs (9.0-
13.6 Nm).

Install exhaust system. See

4.16 EXHAUST SYSTEM:

XR MODELS

All Models

Install main fuse. See

6.38 MAIN FUSE

HOME

5-70 2009 Sportster Service: Drive/Transmission

TABLE OF CONTENTS

SUBJECT

............................................................................................................................

PAGE NO.

ELECTRICAL

6.1

FASTENER TORQUE VALUES

FASTENER TORQUE VALUES IN THIS
CHAPTER

The table below lists torque values for all fasteners presented
in this chapter.

NOTES

TORQUE VALUE

FASTENER

6.29 ALTERNATOR, Assembly and Installation

13.6-15.8 Nm

120-140 in-lbs

Alternator rotor-to-sprocket screw

6.29 ALTERNATOR, Assembly and Installation

3.4-4.5 Nm

30-40 in-lbs

Alternator stator mounting screw

6.24 TURN SIGNALS, Front Housing Replacement

10.8-17.6 Nm

96-156 in-lbs

Ball head studs (front turn signals)

6.11 BATTERY CABLES, Installation

6.2-8.5 Nm

55-75 in-lbs

Battery negative cable-to-crankcase nut

6.11 BATTERY CABLES, Installation

6.8-7.9 Nm

60-70 in-lbs

Battery negative terminal screw

6.11 BATTERY CABLES, Installation

6.8-7.9 Nm

60-70 in-lbs

Battery positive terminal screw

6.11 BATTERY CABLES, Installation

4.1-6.8 Nm

36-60 in-lbs

Battery strap screw

6.12 BATTERY TRAY, Installation

10.9-17.6 Nm

96-156 in-lbs

Battery tray mounting screw

6.12 BATTERY TRAY, Installation

8.1-13.6 Nm

72-120 in-lbs

Brake (rear) lamp switch screw

6.12 BATTERY TRAY, Installation

3.4-4.5 Nm

30-40 in-lbs

Brake hose clamp-to-battery tray screw

6.12 BATTERY TRAY, Installation

2.3-2.8 Nm

20-25 in-lbs

Brake rear master cylinder reservoir
mounting screw

6.27 REAR STOP LAMP SWITCH, Replacement

2.3-2.8 Nm

20-25 in-lbs

Brake rear master cylinder reservoir
mounting screw

6.19 IGNITION COIL, Installation

4.0-5.1 Nm

35-45 in-lbs

Coil mounting bracket screw

6.19 IGNITION COIL, Installation

2.7-8.1 Nm

24-72 in-lbs

Coil mounting screw

6.19 IGNITION COIL, Installation

2.7-8.1 Nm

24-72 in-lbs

Coil mounting screw

6.28 CRANK POSITION SENSOR (CKP), Installa-
tion

9.0-11.3 Nm

80-100 in-lbs

Crank position sensor (CKP) screw

6.17 ELECTRONIC CONTROL MODULE
(ECM), Installation

2.0-2.5 Nm

18-22 in-lbs

ECM fasteners: XR models

6.25 LICENSE PLATE LAMP MODULE: XL
1200N, Installation (HDI Only)

14.9-24.4 Nm

132-216 in-lbs

Fender support screw with washer

6.22 INDICATOR LAMP MODULE, Replacement:
XL 1200L and XL 1200N/XL 1200L/XL 1200N

16.3-24.4 Nm

12-18 ft-lbs

Handlebar clamp screw

6.22 INDICATOR LAMP MODULE, Replacement:
XL 1200L and XL 1200N/XL 1200L/XL 1200N

16.3-24.4 Nm

12-18 ft-lbs

Handlebar clamp screw

6.40 RIGHT HANDLEBAR SWITCHES, Installation

12.2-14.9 Nm

108-132 in-lbs

Handlebar clamp screws

6.41 LEFT HANDLEBAR SWITCHES, Installation

12.2-14.9 Nm

108-132 in-lbs

Handlebar clamp screws

6.22 INDICATOR LAMP MODULE, Replacement:
XL 883C and XL 1200C/XL 883C/XL1200C

16.3 -24.4 Nm

12-18 ft-lbs

Handlebar riser clamp screw

6.22 INDICATOR LAMP MODULE, Replacement:
XL 883C and XL 1200C/XL 883C/XL1200C

16.3 -24.4 Nm

12-18 ft-lbs

Handlebar riser clamp screw

6.22 INDICATOR LAMP MODULE, Replacement:
XL 883C and XL 1200C/XL 883C/XL1200C

0.9-1.4 Nm

8-12 in-lbs

Handlebar riser cover screw

6.40 RIGHT HANDLEBAR SWITCHES, Installation

4.0-5.1 Nm

35-45 in-lbs

Handlebar switch housing screws

6.41 LEFT HANDLEBAR SWITCHES, Installation

4.0-5.1 Nm

35-45 in-lbs

Handlebar switch housing screws

6.22 INDICATOR LAMP MODULE, Replacement:
All Other Models/all except XL 883C/XL 1200C/XL
1200L/XL 1200N

16.3-24.4 Nm

12-18 in-lbs

Handlebar upper clamp screw

6.37 HORN, Replacement: Models with Front
Mounted Horn

8.1-12.2 Nm

72-108 in-lbs

Horn, front mounted, mounting screw

HOME

2009 Sportster Service: Electrical 6-1

NOTES

TORQUE VALUE

FASTENER

6.37 HORN, Replacement: Models with Side
Mounted Horn

6.8-20.4 Nm

60-180 in-lbs

Horn, side mounted, acorn nut

6.37 HORN, Replacement: Models with Side
Mounted Horn

9.0-11.3 Nm

80-100 in-lbs

Horn, side mounted, stud nut

6.16 IGNITION AND LIGHT SWITCH, Installation

4.0-5.1 Nm

35-45 in-lbs

Ignition/light switch mounting screw

6.34 JIFFY STAND SWITCH: INTERNATIONAL
MODELS, Installation

10.9-13.6 Nm

96-120 in-lbs

Jiffy stand switch screw

6.25 LICENSE PLATE LAMP MODULE: XL
1200N, Installation (HDI Only)

1.2-1.3 Nm

14-16 in-lbs

License plate lamp housing screw

6.33 ELECTRICAL CADDIES, Wire Harness
Caddy: XL Models

4.0-5.1 Nm

35-45 in-lbs

Light switch bracket screw

6.33 ELECTRICAL CADDIES, Wire Harness
Caddy: XR Models

4.0-5.1 Nm

35-45 in-lbs

Light switch bracket screw

6.14 STARTER SOLENOID, Solenoid Contacts

7.3-9.0 Nm

65-80 in-lbs

Long post jam nut

6.31 NEUTRAL INDICATOR SWITCH, Replace-
ment

13.6-20.3 Nm

120-180 in-lbs

Neutral indicator switch

6.36 OIL PRESSURE SWITCH, Installation

12.2-17.9 Nm

108-158 in-lbs

Oil pressure switch adapter: XR 1200
only

6.11 BATTERY CABLES, Installation

6.8-9.6 Nm

60-85 in-lbs

Positive battery cable-to-starter post lock
nut

6.25 LICENSE PLATE LAMP MODULE: XL
1200N, Installation (HDI Only)

2.3-2.8 Nm

20-25 in-lbs

Rear fender brace screw

6.24 TURN SIGNALS, Rear Housing Replacement

3.4-4.5 Nm

30-40 in-lbs

Rear turn signal housing screws: XR
models

6.24 TURN SIGNALS, Rear Housing Replacement

10.9-17.6 Nm

96-156 in-lbs

Rear turn signal housing-to-stalk

6.8 SPEEDOMETER: XL 883C/XL 1200C, Install-
ation/XL 883C/XL 1200C only

0.9-1.4 Nm

8-12 in-lbs

Riser cover screw

6.24 TURN SIGNALS, Front Housing Replacement

0.9-1.4 Nm

8-12 in-lbs

Riser cover screw

6.39 HANDLEBAR SWITCH ASSEMBLIES, Con-
nectors/XL 883C/XL 1200C only

0.9-1.4 Nm

8-12 in-lbs

Riser cover screw

6.13 STARTER, Field Coil Assembly

7.9-10.2 Nm

70-90 in-lbs

Solenoid ring terminal nut

6.13 STARTER, Field Coil Assembly

10.2-12.4 Nm

90-110 in-lbs

Starter end cover screw

6.13 STARTER, Installation

17.6-27.1 Nm

13-20 ft-lbs

Starter mounting bolt

6.13 STARTER, Installation

6.8-9.6 Nm

60-85 in-lbs

Starter positive terminal nut

6.13 STARTER, Field Coil Assembly

4.4-7.3 Nm

39-65 in-lbs

Starter thru bolts

6.29 ALTERNATOR, Assembly and Installa-
tion/Screw must be flush with plate. Do not exceed
torque specification.

6.3 Nm

56 in-lbs

Stator harness retainer screw

6.27 REAR STOP LAMP SWITCH, Replacement

9.5-13.6 Nm

84-120 in-lbs

Stoplight switch to tee nut

6.24 TURN SIGNALS, Rear Housing Replacement

14.9-24.4 Nm

132-216 in-lbs

Strut cover screw

6.23 TAIL LAMP: ALL MODELS EXCEPT XL
1200N, Base Replacement

5.1-5.4 Nm

45-48 in-lbs

Tail lamp base mounting screw: XL
models only

6.23 TAIL LAMP: ALL MODELS EXCEPT XL
1200N, Base Replacement

4.1-6.8 Nm

36-60 in-lbs

Tail lamp base mounting screw: XR
models only

6.23 TAIL LAMP: ALL MODELS EXCEPT XL
1200N, Bulb Replacement

2.3-2.7 Nm

20-24 in-lbs

Tail lamp lens screw

6.23 TAIL LAMP: ALL MODELS EXCEPT XL
1200N, Base Replacement

2.3-2.7 Nm

20-24 in-lbs

Tail lamp lens screw

6.24 TURN SIGNALS, Front Housing Replacement

10.9-13.6 Nm

96-120 in-lbs

Turn signal (front) clamp screw

6.24 TURN SIGNALS, Rear Housing Replacement

14.9-24.4 Nm

132-216 in-lbs

Turn signal stalk nut

HOME

6-2 2009 Sportster Service: Electrical

NOTES

TORQUE VALUE

FASTENER

6.30 VEHICLE SPEED SENSOR (VSS), Installation

9.0-11.3 Nm

80-100 in-lbs

Vehicle speed sensor (VSS) screw

6.3 VOLTAGE REGULATOR, Installation: XL
Models

4.1-6.8 Nm

36-60 in-lbs

Voltage regulator mounting screw

6.3 VOLTAGE REGULATOR, Installation: XR
Models

4.1-6.8 Nm

36-60 in-lbs

Voltage regulator mounting screw

HOME

2009 Sportster Service: Electrical 6-3

6.2

SPECIFICATIONS: ELECTRICAL

SPECIFICATIONS: 2009 SPORTSTER
MODELS

Table 6-1. Ignition System: 2009 Sportster XL Models

SPECIFICATION

COMPONENT

not adjustable

Ignition timing

12 volt, 12 amp/hr,

sealed and maintenance free

Battery

HD-6R12

Spark plug type

12 mm

Spark plug size

0.97-1.09 mm

0.038-0.043 in.

Spark plug gap

16.3-24.4 Nm

12-18 ft-lbs

Spark plug torque

Table 6-2. Ignition System: 2009 Sportster XR 1200 Model

SPECIFICATION

COMPONENT

not adjustable

Ignition timing

12 volt, 12 amp/hr,

sealed and maintenance free

Battery

10R12X

Spark plug type

12 mm

Spark plug size

0.81-0.97 mm

0.032-0.038 in.

Spark plug gap

16.3-24.4 Nm

12-18 ft-lbs

Spark plug torque

Table 6-3. Ignition Coil Resistance

SECONDARY

PRIMARY

RESISTANCE

1500-2400 Ohms

0.3-0.7 Ohms

All Models

Table 6-4. Alternator

SPECIFICATION

ITEM

20-28 VAC per 1000 engine
RPM

AC voltage output

0.1-0.3 Ohms

Stator coil resistance

Table 6-5. Voltage Regulator

SPECIFICATION

ITEM

14.3-14.7 VDC

Voltage output @ 75 F

32 Amps

Current @ 3600 RPM

Table 6-6. Battery

SPECIFICATION

MODEL

12 volt, 12 Ampere hours

All

Table 6-7. Fuses

AMP RATING

ITEM

Main fuse

Battery

Ignition

Lights

Accessories

Instruments

Fuel Pump

Electronic Control Module
(ECM)

P&A Ign

Engine control (XR1200
models only)

Table 6-8. Starter Specifications

STARTER DATA

3000 RPM (min.) @ 11.5 V

Free speed

90 amp (max.) @ 11.5 V

Free current

200 amp (max.) @ 68°F

Cranking current

8.0 ft-lbs (10.8 Nm) @ 2.4 V

Stall torque

Table 6-9. Starter Service Wear Limits

MM.

IN.

ITEM

11.0

0.443

Brush length (minimum)

0.41

0.016

Commutator runout

28.98

1.141

Commutator diameter (minimum)

0.203

0.008

Commutator mica depth (minimum)

HOME

6-4 2009 Sportster Service: Electrical

6.3

VOLTAGE REGULATOR

GENERAL

See

Figure 6-1

. The voltage regulator is located between the

frame downtubes at the front of the motorcycle. When installing
connectors (3, 4) after service, make sure to engage external
latches (5) to prevent connectors from separating during vehicle
operation.

NOTE

The voltage regulator cannot be repaired. Replace the unit if
it fails.

sm01350a

Voltage regulator

Screw (2)

Stator pin connector [46A]

DC output pin connector [77A]

External latch

Figure 6-1. Voltage Regulator

sm01166

Pin connector [46A] (voltage regulator side)

Socket connector [46B] (stator side)

External latch

Open latch

Separate socket connector from pin connector

Figure 6-2. Separating Connector Halves (Stator Connector

Shown)

REMOVAL: 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

NOTE

When unplugging the voltage regulator connectors, pull apart
each connector by firmly grasping both connector halves. Do
not pull on leads or damage to the wires and/or terminals may
result.

See

Figure 6-2

. Unplug stator connector [46]. Lift external

latch (3) on pin housing and separate connector halves
(5).

See

Figure 6-4

. Gently pry apart clips (2) and remove DC

output connector [77] (1) from voltage regulator caddy (3).
Lift external latch on pin housing and separate connector
halves.

HOME

2009 Sportster Service: Electrical 6-5

See

Figure 6-5

. Remove screws (2) from locations at top

and bottom of voltage regulator. Remove regulator from
vehicle, carefully threading harnesses through opening in
regulator mounting bracket.

sm01165

Stator connector [46]

Locking latch

Figure 6-3. Stator Connector [46] Location

sm01133

DC output connector [77]

Clip (2)

Voltage regulator caddy

Figure 6-4. DC Output Connector [77] Location

sm01129a

Voltage regulator

Mounting screw (2)

Figure 6-5. Voltage Regulator Location

INSTALLATION: XL MODELS

See

Figure 6-6

. Position voltage regulator close to

mounting bracket (1). Orient regulator so cooling fins face
forward and wiring harnesses exit regulator body toward
right side of vehicle.

Thread DC output wiring harness into opening (3) between
mounting bracket and frame downtube on right side of
vehicle. Route DC output harness connector [77A] toward
left side of vehicle.

See

Figure 6-7

. Route stator harness (3) down along

between right frame downtube and body of voltage regu-
lator (2), and under voltage regulator caddy (1). Route
stator harness connector [46A] toward right side of vehicle.

See

Figure 6-6

. Mount voltage regulator on mounting

bracket (1) between frame downtubes and secure with
mounting screws at two locations (2). Tighten to 36-60 in-
lbs (4.1-6.8 Nm).

See

Figure 6-3

. Plug stator connector [46A] (1) into socket

connector [46B]. Fold external locking latch (2) over and
lock in place.

In the same fashion, plug voltage regulator DC output
connector [77A] into socket [77B]. Fold external latch over
and lock in place.

See

Figure 6-8

. Snap DC output harness connector

assembly (3) into tabs (4) in the voltage regulator caddy
(2). Insert DC output cables into cable clip (7) on caddy.

Plug in main fuse. See

6.38 MAIN FUSE

Test charging system. See the ELECTRICAL DIA-
GNOSTIC MANUAL.

HOME

6-6 2009 Sportster Service: Electrical

sm01139

Voltage regulator mounting bracket

Regulator fastener locations

Opening for wiring harness routing

Voltage regulator caddy

Figure 6-6. Voltage Regulator Mounting Bracket (All

Models)

sm03918

Voltage regulator caddy

Voltage regulator

Stator harness

Figure 6-7. Stator Harness Routing

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 6-8. Voltage Regulator Caddy: Rear View

REMOVAL: 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

NOTE

When unplugging the voltage regulator connectors, pull apart
each connector by firmly grasping both connector halves. Do
not pull on leads or damage to the wires and/or terminals may
result.

See

Figure 6-9

. Unplug stator connector (4). Carefully pull

barbed cable strap (3) from frame.

See

Figure 6-10

. Cut cable strap (1). Lift external latch on

connector and separate connector halves.

See

Figure 6-11

. Remove screws (1) from locations at top

and bottom of voltage regulator (2). Remove regulator
from vehicle, carefully threading harnesses through
opening in regulator mounting bracket.

HOME

2009 Sportster Service: Electrical 6-7

sm05563

Oil pressure switch

J-clip

Barbed cable strap

Stator connector

Figure 6-9. Oil Pressure Switch (Right Side View XR 1200)

sm05585

Cable strap

DC output conector

Oil pressure switch, neutral switch harness

Oil filter

Figure 6-10. DC Output Connector: XR Models

sm05586

Screw (2)

Voltage regulator

Stator wiring

Cable strap

Figure 6-11. Stator Wire Routing: XR Models

INSTALLATION: XR MODELS

See

Figure 6-12

. Position voltage regulator close to

mounting bracket (1). Orient regulator so cooling fins face
forward and wiring harnesses exit regulator body toward
right side of vehicle.

Thread DC output wires below mounting bracket . Route
DC output connector (2) toward left side of vehicle.

Route stator wires (4) down along between right frame
downtube and body of voltage regulator. Route stator
harness connector [46A] toward right side of vehicle.

NOTE

When installing voltage regulator, make sure wires do not get
pinched between bracket and regulator.

Mount voltage regulator on mounting bracket and secure
with mounting screws. Tighten to 36-60 in-lbs (4.1-6.8
Nm).

See

Figure 6-13

. Connect stator connector (1) and fold

external latch over and lock in place. Secure stator con-
nector to bracket with barbed cable strap (3).

Secure stator wires to right frame down tube with cable
strap (2).

See

Figure 6-14

. Connect voltage regulator DC output

connector. Fold external latch over and lock in place.

Secure DC output connector (2) along with oil pressure
switch, neutral switch harness (3) to voltage regulator
bracket with cable strap (1).

Plug in main fuse. See

6.38 MAIN FUSE

HOME

6-8 2009 Sportster Service: Electrical

10. Test charging system. See the electrical diagnostic

manual.

sm05588

Voltage regulator mounting bracket

DC output connector

DC output wires

Stator wires

Figure 6-12. Voltage Regulator Wire Routing: XR Models

sm05589

Stator connector

Cable strap

Barbed cable strap

Figure 6-13. Stator Connector: XR Models

sm05585

Cable strap

DC output conector

Oil pressure switch, neutral switch harness

Oil filter

Figure 6-14. DC Output Connector: XR Models

HOME

2009 Sportster Service: Electrical 6-9

6.4

FUSES AND RELAYS

GENERAL

The starter relay allows a relatively small amount of current
flowing through the starter button to control the large current
flow required to activate the starter solenoid.

See

Figure 6-15

. The electrical system relay/fuse block is loc-

ated in front of the battery under the left side cover. The relays
and fuses are mounted in the relay/fuse block. All fuses except
the P&A fuse are rated at 15 amperes.

REPLACING FUSES

Open left side cover. See

2.20 LEFT SIDE COVER

See

Figure 6-15

. Pull suspect fuse (1-9) from slots in

relay/fuse block and inspect for blown condition or other
damage.

Replace as necessary:

Insert new fuse in appropriate location by lining up
spade terminals on fuse with sockets in relay/fuse
block.

Press fuse firmly into sockets.

Close left side cover.

Turn ignition switch ON and verify proper operation of cir-
cuit protected by replacement fuse.

REPLACING RELAYS

Open left side cover. See

2.20 LEFT SIDE COVER

See

Figure 6-15

. To unplug old relay (10 or 11), grasp

body of relay and with a gentle rocking motion, pull straight
out from relay/fuse block.

To install new relay, line up spade terminals of relay with
sockets in relay/fuse block and push relay firmly into
sockets.

Close left side cover.

Turn ignition switch ON and start vehicle to verify proper
operation of relay circuits.

sm01267a

ECM fuse

Fuel pump fuse

Ignition fuse

Instruments fuse

Accessories fuse

Battery fuse

Lights fuse

P&A Ign fuse

Spare fuse

10. Starter relay
11. System relay
12. Spare fuse
13. Engine control (XR models) or spare fuse (XL

models)

14. Open

Figure 6-15. Relay/Fuse Blocks (Typical)

HOME

6-10 2009 Sportster Service: Electrical

6.5

MAIN FUSE HOLDER

GENERAL

The main fuse holder is attached to the battery strap behind
the left side cover.

REPLACEMENT

To prevent accidental vehicle start-up, which could cause
death or serious injury, disconnect negative (-) battery
cable before proceeding. (00048a)

Remove negative battery cable from engine crankcase.
See

1.17 BATTERY MAINTENANCE

Unplug main fuse. See

6.38 MAIN FUSE

Disassemble main fuse holder and remove cable terminals.
Replace components as necessary and reassemble. See

A.4 DELPHI MAIN FUSE HOUSING

for disas-

sembly/assembly instructions.

Install negative battery cable on engine crankcase. See

1.17 BATTERY MAINTENANCE

Plug in main fuse.

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

sm01270

Main fuse cover

Main fuse holder

Figure 6-16. Main Fuse and Holder

HOME

2009 Sportster Service: Electrical 6-11

6.6

SPEEDOMETER: XL SINGLE GAUGE MODELS
EXCEPT XL 883C/XL 1200C

REMOVAL

NOTE

The speedometer has a backlight bulb that cannot be replaced.
If the bulb fails, replace the entire unit.

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

Unplug main fuse. See

6.38 MAIN FUSE

See

Figure 6-17

. Remove reset switch boot (9) from trip

odometer reset switch (8) on speedometer housing back
plate (5).

Remove two screws (7) and back plate.

Unplug speedometer socket connector [39B] (10) from
back of speedometer.

Gently push out speedometer (1) and front gasket (2).

Inspect front (2) and back (4) gaskets, speedometer con-
nector [39] and wiring, trip odometer reset switch and
wiring and reset switch boot. Repair or replace as required.

INSTALLATION

TOOL NAME

PART NUMBER

CRIMPING TOOL

HD-45929

If replacing trip odometer switch:

Push trip reset socket terminals out the front of the
speedometer socket connector half [39B]. See

A.16 PACKARD MICRO-64 CONNECTORS

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

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

Draw terminal back into connector until terminal seats.

See

Figure 6-17

. Install front gasket (2) on speedometer

(1).

Threading speedometer harness and connector [39B]
through back gasket (4), install matching tabs of gasket
to locating keys in instrument housing/bracket (3).

NOTE

If necessary, lubricate rubber gaskets with alcohol or glass
cleaner.

Orient face upright and press speedometer into instrument
housing/bracket. Wiring must past between locating keys
and gasket and through cutout in speedometer back.

Plug speedometer socket connector [39] (10) into back of
speedometer.

Push trip odometer reset switch (8) through back plate (5)
and thread on reset switch boot (9).

Hold back plate in place with reset switch in rectangular
boss in back of speedometer (1) and vent hole (6) at
bottom. Secure with screws and tighten.

Plug in main fuse.

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6-12 2009 Sportster Service: Electrical

sm01374

Reset switch boot

Speedometer

10.

Front gasket

Speedometer harness connector [39B]

11.

Indicator lamp module

Instrument housing/bracket

12.

Back gasket

Instrument harness connector [20A]

13.

Speedometer housing/handlebar clamp

Back plate

14.

Vent hole

XL 1200L/XL 1200N

15.

All other single gauge XL models except XL
883C/XL 1200C

Screw (2)

Trip odometer reset switch

Figure 6-17. Speedometer Components: XL Single Gauge Models Except XL 883C/XL 1200C

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2009 Sportster Service: Electrical 6-13

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