Content .. 69 70 71 72 ..

Harley Davidson Sportster Models 2009. Service Repair Manual - page 71

A.16

PACKARD MICRO-64 CONNECTORS

PACKARD MICRO-64 CONNECTOR REPAIR

TOOL NAME

PART NUMBER

PACKARD MICRO-64 TERMINAL
REMOVER

HD-45928

PACKARD MICRO-64 TERMINAL
CRIMPER

HD-45929

General

Packard Micro-64 connectors are frequently found on
speedometers, tachometers and the ECM of Touring Models.
For pin 73 of these ECMs, see

A.10 PACKARD 150 METRI-

PACK CONNECTORS

Separating Pin and Socket Housings

Bend back the external latches slightly and separate the pin
and socket housings.

Mating Pin and Socket Housings

Orient the wire lead colors and push the pin and socket hous-
ings of the connector together until the latches click.

Removing Terminal

See

Figure A-49

. Locate the head of the secondary lock

(1) on one side of the connector housing.

Insert the blade of a small screwdriver between the center
ear of the lock and the connector housing and gently pry
out lock. When partially removed, pull lock from connector
housing.

Locate pin hole (2) between terminals on mating end of
connector.

See

Figure A-50

. Obtain the PACKARD MICRO-64 TER-

MINAL REMOVER (Part No. HD-45928).

See

Figure A-48

. Push the adjacent terminals all the way

into the connector housing and then insert tool into hole
until it bottoms.

Leaving the tool installed, gently tug on wires to pull either
one or both terminals from wire end of connector. Remove
tool.

sm00046

Figure A-47. Packard Micro 64 Terminal Remover

(HD-45928)

sm00048

Figure A-48. Packard Micro 64 Connector: Insert Tool and

Remove Terminal

HOME

2009 Sportster Service: Appendix A Connector Repair A-31

Installing Terminal

Insert terminal into its respective numbered chamber on
wire end of connector. No special orientation of the ter-
minal is necessary.

NOTE

See

Figure A-49

. For wire location purposes, the corners of

the socket housing are stamped (3) with the numbers 1, 6, 7
and 12, representing terminals 1-6 on one side, and 7-12 on
the other.

Bottom the terminal in the chamber and then gently tug
on the wire to verify that it is locked in place.

NOTE

Once the terminal is removed it may not lock in place when
first reinstalled. Until the lock engages, move the terminal back
and forth slightly while wiggling the lead.

Since the terminal remover tool releases two terminals
simultaneously, repeat step 2 on the adjacent terminal
even if it was not pulled from the connector housing.

With the center ear on the head of the secondary lockpin
facing the mating end of the connector, push secondary
lock in until head is flush with the connector housing.

Preparing Wire Leads for Crimping

Strip lead removing 1/8 in. (3.0 mm) of insulation.

Crimping Terminals

Inspect new socket terminal for bent or deformed contact
and crimp tails. Replace as necessary.

See

Figure A-51

. Squeeze the handles of the PACKARD

MICRO-64 TERMINAL CRIMPER (Part No. HD-45929)
to cycle the tool to the fully open position (1).

Raise locking bar and barrel holder by pushing up on
bottom tab with index finger (2).

With the crimp tails facing upward, insert terminal through
locking bar into front hole in barrel holder (20-22 gauge
wire) (3).

Release locking bar to lock position of contact. When
correctly positioned, the locking bar fits snugly in the space
at the front of the core crimp tails and the closed side of
the terminal rests on the outer nest of the crimp tool.

Insert wires between crimp tails until ends make contact
with locking bar. Verify that wire is positioned so that wide
pair of crimp tails squeeze bare wire strands, while the
narrow pair folds over the insulation material.

Squeeze handle of crimp tool until tightly closed (4). Tool
automatically opens when the crimping sequence is com-
plete.

Raise locking bar and barrel holder to remove contact.

Inspecting Crimps

Inspect the quality of the core and insulation crimps. Distortion
should be minimal.

9 10

11 12

sm00047

Secondary lock

Pin hole

Stamped number

Figure A-49. Packard Micro 64 Connector: Housing

sm00045

Figure A-50. Packard Micro 64 Terminal Crimper (HD-45929)

HOME

A-32 2009 Sportster Service: Appendix A Connector Repair

sm00049

Open position

Raising locking bar

Insert terminal

Crimp terminal

Figure A-51. Packard Micro 64 Connector: Terminal in

Crimper

HOME

2009 Sportster Service: Appendix A Connector Repair A-33

A.17

SEALED SPLICE CONNECTORS

SEALED SPLICE CONNECTOR REPAIR

TOOL NAME

PART NUMBER

ROBINAIR HEAT GUN

HD-25070

PACKARD CRIMPING TOOL

HD-38125-8

ULTRA TORCH UT-100

HD-39969

HEAT SHIELD ATTACHMENT

HD-41183

General

Splice connectors and several OE ring terminal connectors
use heat shrink covering to seal the connection.

Preparing Wire Leads

NOTE

If adjacent wires are to be spliced, stagger the splices so that
the sealed splice connectors will not touch each other but are
located at different positions along the length of the wires.

Using a shop gauge, identify the gauge of the wire.

Match the wire gauge to a sealed splice connector by color
and part number. Refer to

Table A-5

Using a wire stripper, cut and strip a length of insulation
off the wire ends. Refer to

Table A-5

for the strip length.

Table A-5. Sealed Splice Connectors

STRIP LENGTH

PART NO.

COLOR

WIRE GAUGE

3/8 in. (9.5 mm)

70585-93

Red

18-20

(0.5-0.8 mm)

3/8 in. (9.5 mm)

70586-93

Blue

14-16

(1.0-2.0 mm)

3/8 in. (9.5 mm)

70587-93

Yellow

10-12

(3.0-5.0 mm)

NOTE

If any copper wire strands are cut off of the wire core, trim the
end and strip the wire again in a larger gauge stripper.

Splicing Wire Leads

NOTE

See

Figure A-53

. The connector is crimped twice - one side

and then the other.

See

Figure A-52

. Open the PACKARD CRIMPING

TOOL (Part No. HD-38125-8) ratchet by squeezing the
handles closed.

Match the connector color to the wire gauge crimp die in
the jaws and insert one end of the sealed connector.

Gently squeeze the handles until the connector is held in
the jaws.

See

Figure A-53

. Feed the stripped end of a wire into the

connector until the wire stops inside the metal insert (1).

Squeeze the handles tightly closed to crimp the lead in
the insert (2). The tool automatically opens when the
crimping is complete.

Slide the connector to the other half of the metal insert.
Insert the stripped wire lead (1) until it stops, and crimp
the lead in the insert (2).

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.

Use an ULTRA TORCH UT-100 (Part No. HD-39969), or
a ROBINAIR HEAT GUN (Part No. HD-25070) with a
HEAT SHIELD ATTACHMENT (Part No. HD-41183), to
heat the connector from the center of the crimp (3) out to
each end.

NOTE

It is acceptable for the splice to rest against the heat shrink
tool attachment.

Inspecting Seals

See

Figure A-53

. Allow the splice to cool and inspect the seal.

The insulation should appear smooth and cylindrical. Melted
sealant will have extruded out the ends (4) of the insulation.

HOME

A-34 2009 Sportster Service: Appendix A Connector Repair

sm00050

Red connector die

Blue connector die

Yellow connector die

Figure A-52. Packard Crimping Tool (HD-38125-8)

sm00051

Wire lead in metal insert

Crimp metal insert

Center of crimp

Melted sealant

Figure A-53. Sealed Splice Connector

HOME

2009 Sportster Service: Appendix A Connector Repair A-35

B.1

CONNECTORS

CONNECTOR LOCATIONS

Function/Location

Refer to

Table B-1

. On the motorcycle, a connector can be

identified by its function and location.

Place and Color

The place (number of wire cavities of a connector housing)
and color of the connector can also aid identification.

Connector Number

On wiring diagrams and in service/repair instructions, con-
nectors are identified by a number in brackets.

Repair Instructions

Refer to

Table B-1

. The repair instructions in Appendix A are

by connector type.

Table B-1. 2009 Sportster Connector Locations

LOCATION

TYPE

DESCRIPTION

NO.

On battery strap, behind left side
cover

2-place Metri-Pack, black

MAXIFUSE

[5]

Under seat

6-place Multilock, black

Tail lamp harness to main harness

[7]

Inside tail lamp lens

2-place Multilock, white

Left rear turn signal

[18]

Inside tail lamp lens

2-place Multilock, black

Right rear turn signal

[19]

Under fuel tank

12-place Molex, black

Instruments

[20]

Under fuel tank

6-place Molex, black

Right hand controls

[22]

Under fuel tank

8-place Molex, gray

Left hand controls and horn

[24]

Under battery

12-place Deutsch, gray

TSM/TSSM/HFSM

[30]

Under fuel tank

6-place Molex, black

Front turn signals

[31]

Right side of frame behind neck

Ignition switch

[33]

Under fuel tank

4-place Multilock, black

Headlamp

[38]

Back of speedometer

12-place Packard Micro-64, black

Speedometer (XL)

[39]

Back of speedometer

5-place Packard

Tachometer (XR)

[39]

In front of engine crankcase

2-place Lyall, black

Voltage regulator to stator

[46]

Behind left side cover

Spade terminals

Fuse block

[61]

Right rear top of crankcase

3-place Packard, black

Vehicle Speed Sensor (VSS)

[65]

In front of engine crankcase

2-place Lyall, black

Voltage regulator (DC output)

[77]

Under seat

36-place Packard, gray

Electronic Control Module (ECM)

[78]

Front of left crankcase

2-place Deutsch, black

Crankshaft Position (CKP) sensor

[79]

Top of intake manifold

4-place Packard, black

Temperature Manifold Absolute
Pressure (TMAP) sensor

[80]

Back of coil, under fuel tank

4-place Delphi, black

Ignition coil

[83]

Top of intake manifold

2-place Delphi, black

Front injector

[84]

Top of intake manifold

2-place Delphi, black

Rear injector

[85]

Top of induction module

4-place Delphi, black

Idle Air Control (IAC)

[87]

Behind air cleaner backing plate

3-place Delphi, black

Throttle Position (TP) sensor

[88]

Above induction module, right side

2-place Delphi, black

Engine Temperature (ET) sensor

[90]

On battery strap, behind left side
cover

4-place Deutsch, gray

Data link connector

[91]

Inside tail lamp lens

4-place Multilock, black

Tail lamp

[93]

Inside tail lamp lens

6-place Multilock, black

Tail lamp power in

[94]

Back of tachometer

12-place Packard Micro-64, gray

Tachometer

[108]

Fuse/relay block, behind left side
cover

5-place Amp, spade terminals

Relay/fuse block

[119]

HOME

2009 Sportster Service: Appendix B Wiring B-1

Table B-1. 2009 Sportster Connector Locations

LOCATION

TYPE

DESCRIPTION

NO.

Oil pressure switch, under oil filter
mount

90° post terminal, black

Oil pressure switch

[120]

Stop lamp switch, under battery tray

Spade terminals, black

Rear stoplight switch

[121]

Between cylinders, left side

90° spade terminals, black

Horn

[122]

Starter solenoid

Locking spade terminal, white

Starter solenoid

[128]

Left side along frame toward front
of engine

3-place, black

Jiffy Stand Sensor (HDI)

[133]

Right side frame, beneath gearcase
cover

1-place molded jumper, black

Neutral switch

[136]

On H-bracket

2-place Amp, black

Rear oxygen sensor

[137]

Electrical caddie behind voltage
regulator

2-place Amp, black

Front oxygen sensor

[138]

Forward of relay/fuse blocks

4-place Molex, black

Fuel pump and low fuel switch

[141]

Under frame

3-place Packard, black

Security siren

[142]

Under seat

16-place Molex, black

Engine harness

[145]

Under seat

1-place Packard, gray

B+ connector

[160]

Right side behind air box

2-place

Active intake solenoid

[178]

Under seat

3-place Molex, black

Fuel sender resistor assembly

[200]

Under battery

4-place Deutsch, gray

HFSM antenna connector

[208]

Under seat

2-place Molex, black

Security antenna

[209]

Crankcase housing, top rear

Ring terminal

Powertrain ground

[GND1]

HOME

B-2 2009 Sportster Service: Appendix B Wiring

B.2

WIRING DIAGRAMS

WIRING DIAGRAM INFORMATION

Wire Color Codes

Wire traces on wiring diagrams are labeled with alpha codes.
Refer to

Table B-2

For Solid Color Wires: See

Figure B-1

. The alpha code

identifies wire color (3).

For Striped Wires: The code is written with a slash (/) between
the solid color code and the stripe code (4). For example, a
trace labeled GN / Y is a green wire with a yellow stripe.

Wiring Diagram Symbols

See

Figure B-1

. On wiring diagrams and in service/repair

instructions, connectors are identified by a number in brackets
(1). The letter (2) inside the brackets identifies whether the
housing is a socket or pin housing.

A=Pin: The letter A after a connector number and the pin
symbol (6) identifies a pin housing.

B=Socket: The letter B after a connector number and the
socket symbol (5) identifies a socket housing.

Other symbols found on the wiring diagrams include the symbol
for a diode (7), a symbol for a wire-to-wire connection (8), a
symbol verifying that no connection (9) between two wire traces
exists, symbols for actual (10) and virtual (11) splices, and a
symbol identifying two wires that are twisted together (12).

Actual splices (10) are splices where two wires are connected
together at a specific location along a wire. Virtual splices (11)
are splices shown connected anywhere along a wire, usually
used in a wiring or schematic diagram for clarity.

GN/Y

[21A]

[21B]

ed01711

Connector number

Terminal code (A=pin, B=socket)

Solid wire color

Striped wire color

Socket symbol

Pin symbol

Diode

Connection

No connection

10. Physical splice
11. Virtual splice
12. Twisted pair

Figure B-1. Connector/Wiring Diagram Symbols (typical)

Table B-2. Wire Color Codes

WIRE COLOR

ALPHA CODE

Blue

Black

Brown

Green

Gray

Light Green

LGN

Orange

Pink

Red

Tan

Violet

White

Yellow

HOME

2009 Sportster Service: Appendix B Wiring B-3

2009 SPORTSTER WIRING DIAGRAMS

Refer to the table below for wiring diagram information.

Wiring Diagram List

LOCATION

DIAGRAM

Figure B-2

Main Harness (XL): 2009 Sportster DOM. and INT. Models

Figure B-3

Indicator Lamps and Controls (XL): 2009 Sportster DOM. and INT. Models

Figure B-4

Starting and Charging: 2009 Sportster DOM. and INT. Models

Figure B-5

Engine Management (1 of 2) (XL): 2009 Sportster DOM. and INT. Models

Figure B-6

Engine Management (2 of 2) (XL): 2009 Sportster DOM. and INT. Models

Figure B-7

Lights (1 of 2) (XL): 2009 Sportster DOM. and INT. Models

Figure B-8

Lights (2 of 2) (XL): 2009 Sportster DOM. and INT. Models

Figure B-9

Horn and Instruments (XL): 2009 Sportster DOM. and INT. Models

Figure B-10

Security (1 of 2) (XL): 2009 Sportster DOM. and INT. Models

Figure B-11

Security (2 of 2) (XL): 2009 Sportster DOM. and INT. Models

Figure B-12

Main Harness (XR): 2009 Sportster DOM. and INT. Models

Figure B-13

Indicator Lamps and Controls (XR): 2009 Sportster DOM. and INT. Models

Figure B-14

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

Figure B-15

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

Figure B-16

Lights (1 of 2) (XR): 2009 Sportster DOM. and INT. Models

Figure B-17

Lights (2 of 2) (XR): 2009 Sportster DOM. and INT. Models

Figure B-18

Horn and Instruments (XR): 2009 Sportster DOM. and INT. Models

Figure B-19

Security (1 of 2) (XR): 2009 Sportster DOM. and INT. Models

Figure B-20

Security (2 of 2) (XR): 2009 Sportster DOM. and INT. Models

HOME

B-4 2009 Sportster Service: Appendix B Wiring

IGN 15A

Fuel Pump

15A

Ignition

Switch

[33]

Battery 15A

ECM 15A

[5]

30 Amp

MAXIFUSE

GND1

Powertrain

Ground

Point

Engine

Case

Ground

Point

IGN − I

BATT – B

ACC – A

ECM

TSM/TSSM/HFSM

Fuseblocks

Top View

[119]

ACCESSORIES

LIGHTS

IGNITION

FUEL PUMP

START RELAY SYSTEM RELAY

ECM

BATTERY

SPARE

P&A IGN

INSTRUMENTS

SPARE

System
Relay

SPARE

OPEN

Idle Air Control (A) Hi

Idle Air Control (B) Low

Injector Rear

Injector Front

Battery

Idle Air Control (B) Hi

Idle Air Control (A) Low

To instruments and

indicator lamps

[61]

To Right Hand

Controls

Start
Relay

Starter

Red
band

Access 15A

P&A IGNV

15A

To Left Hand

Controls

P&A

Battery

1 2 3 4 5 6 7 8 9 10

1 2

Data Link

Connector

Jiffy Stand

Sensor

Ignition
Coil

1 2 3 4

Coil

Rear

Coil

ront

D C B A

To
Engine
Harness

C
B
A

To Vehicle

Speed Sensor

Front

Sensor

Engine

Temperature

Sensor

Rear

Sensor

HDI

Only

INSTR 15A

To Fuel Pump

And Sender

ASSY

1 2 3

1 2 3 4

5 6

1 2 3 4 5 6

Spare 15A

To Front

Turn Signals

Headlamp

Lights 15A

Spare 15A

1 2 3 4 5 6

7 8

B
C

Power

Signal

Ground

1 Antenna ’A’

Antenna ’B’

Hands Free Antenna

To Rear

Lighting

Fuel Sender

Resistor Assy

240

Oil

Pressure

Sending

Unit

Neutral

Switch

B A

Battery

Ignition

Serial Data

Neutral Switch

Left Turn Feed

Right Turn Feed

Right Turn Switch Input

Left Turn Switch Input

Start Relay Control

Clutch Switch

Alarm Signal

Ground

Receive Antenna
XMIT Antenna A
XMIT Antenna B

System Relay

Serial Data

Engine Temperature

Intake Air Temperature

Oxygen Sensor (A)

Jiffy Stand Sensor (HDI)

Ground

Coil Rear

Crank POS Sensor (–)

Switched Power

5V Sensor Power

Oxygen Sensor (B)

Throttle POS Sensor Input

Map Sensor Input

5V Sensor Ground

Ground

Coil Front

Crank POS Sensor (+)

Vehicle Speed Sensor Input

1
2
3
4
5
6
7
8
9

10
11
12

1
2
3
4
5
6
7
8
9

10
11
12

1
2
3

5
6
7
8
9

10
11
12
13
14

17
18
19

23
24
25
26

28
29
30
31

35
36

5
6
7
8
9

10
11
12
13
14

17
18
19

23
24
25
26

28
29
30
31

35
36

1
2

3
4
5

7
8
9

11
12
13
14

Crank
Position
Sensor
(Ckp)

2 1

Rear

Stop Lamp

Switch

1 2 3

R/W

GN/BN

GN/GY

PK/GN

BE/GY

BN/GY

GY/BE

BE/GN

BK/BE

[38B]

[31B]

[22A]

[20A]

Security

Siren

(Optional)

HFSM Only

SOCKET CONNECTOR
(B SIDE)

PIN CONNECTOR

(A SIDE)

Horn

[122A]

SWITCH
POSITION

RED/

BLACK

RED

RED/

GRAY

OFF
ACC.
IGNITION

Ignition Switch Legend

Dot Indicates Continuity With Red

Wire In Switch Position Indicated

To Charging

System. See

Starting And

Charging

Sheet

2 1

[7B]

[24A]

[65A]

[145B]

Y/W

R/W

W/Y

V/W

W/V

O/Y

O/W

Y/R

Y/W

Y/R

Y/W

O/W

R/Y

W/V

LGN/V

LGN/Y

LGN/V

TN/GN

LGN/BN

BN/GY

GN/Y

Y/GN

O/GY

Y/GN

Y/BK

BK/R

Y/BK

Y/BE

W/BN

O/GN

PK/Y

W/BK

BK/O

BE/O

BN/R

BK/R

R/GY

BK/R

O/GY

GY/V

BK/V

BK/W

PK/O

[38A]

[31A]

[141A]

[24B]

[136B]

[136A]

[120B]

[120A]

[122B]

[121B]

[121A]

[20B]

[83A]

[83B]

[79A]

[79B]

[22B]

[200A]

[200B]

[209A]

[209B]

[160B]

[208B]

[208A]

[78B]

[78A]

[65B]

[30B]

[30A]

[142B]

[142A]

[133B]

[133A]

[137B]

[137A]

[138B]

[138A]

[90B]

[90A]

[7A]

[91A]

[128]

[145A]

15A

[61B]

[119B]

87A

et01153

Figure B-2. Main Harness (XL): 2009 Sportster DOM. and INT. Models

Figure B-2.

Main Harness (XL): 2009 Sportster DOM. and INT. Models

Hand Controls,
Left

Horn Switch

Headlamp Hi/Lo Switch

Left Turn Switch

Clutch Switch

Hand Controls,
Right

O/W

R/Y

W/BK

W/BN

BK/R

O/W

W/V

Y/BK

1 2 3 4 5 6 7 8

BK/R

[22A]

[24A]

Speedometer

Tachometer

BN/GY

O/W

LGN/V

GN/Y

Configuration for XL1200R

Ignition

Serial data

Battery

Accessory

Ground

Trip odometer reset switch

Fuel level

RPM x 100

Ignition

Serial data

Battery

Accessory

Ground

[39A]

[39B]

[108A]

[108B]

Speedometer

BN/GY

O/W

LGN/V

GN/Y

BN/GY

O/W

LGN/V

Trip Odometer

Reset Switch

Trip Odometer

Reset Switch

Y/W

[20A]

To main
harness

[20A]

To main
harness

BN/GY

O/W

LGN/V

GN/Y

Y/W

[39A]

[39B]

1
2

5
6
7
8
9

1
2

5
6
7

1
2

4
5
6
7
8
9

1
2

5
6
7
8
9

1
2

5
6
7

1
2

4
5
6
7
8
9

BN/GY

O/W

LGN/V

Y/W

1
2
3
4
5
6
7
8
9

GN/Y

Ignition

Serial Data

Security LP

Battery

Accessory

Ground

Trip odometer reset switch

Fuel level

Right Turn Switch

Engine Stop Switch

Start Switch

Front Stop Lamp Switch

Configuration for all except XL1200R

Socket Connector

Pin Connector

(A side)

(B side)

[24B]

[162]

[22B]

[20B]

[163]

[20B]

et01154

Figure B-3. Indicator Lamps and Controls (XL): 2009 Sportster DOM. and INT. Models

Figure B-3.

Indicator Lamps and Controls (XL): 2009 Sportster DOM.

and INT. Models

Indicator Lamps and Controls (XL): 2009 Sportster DOM.

and INT. Models

Engine Stop Switch
Start Switch

Right Hand
Controls

GND1

TSM/TSSM/HFSM

HFSM Only

4 3

1
2

Starter

Ignition 15A

Battery 15A

30 Amp

MAXIFUSE

Ignition

Switch

[61B]

B A

Powertrain

Ground

Point

Battery

[119B]

Charging

30 Amp

Main Fuse

Powertrain

Ground

Point

Switch
Position

RED/BLACK

RED

RED/GRAY

Off

ACC.

Ignition

Ignition Switch Legend

Dot Indicates Continuity With Red
Wire In Switch Position Indicated

Start Relay

System Relay

Fuel pump

Spare

ECM

15A

Battery

Lights

Accessories

15A

Instruments

Spare

Ignition

15A

Spare

Open

P&A IGN

15A

[119]

[61]

1 2

Stator

1 2

Voltage

Regulator

Battery

–

GND1

1
2
3
4

IGN − I

BATT – B

ACC – A

Start Relay

Red
Band

Fuse Blocks

Top view

[128]

W/BK

Neutral

Switch

Left Hand
Controls

Clutch Switch

BK/R

R/BK

BK/R

Battery

Ignition

Neutral Switch

Start Relay Control

Clutch Switch

Chassis Ground

Receive Antenna
XMIT Antenna A
XMIT Antenna B

[163]

[33]

[162]

[5]

Engine

Case

Ground

Point

Engine

Case

Ground

Point

BN/GY

TN/GN

[136B]

[136A]

[46B]

[46A]

[24B]

[24A]

[22A]

[22B]

[77A]

[77B]

[30B]

[30A]

87A

[208A]

et00141

Figure B-4. Starting and Charging: 2009 Sportster DOM. and INT. Models

Figure B-4.

Starting and Charging: 2009 Sportster DOM. and INT. Models

Battery

Ignition

Serial data

Ground

Receive antenna

XMIT antenna A
XMIT antenna B

Idle air control (A) hi

Idle air control (B) low

Injector rear

Injector front

Battery

Idle air control (B) hi

Idle air control (A) low

System relay

Serial data

Engine temperature

Intake air temperature

Oxygen sensor (A)

Jiffy stand sensor (HDI)

Ground

Coil rear

Crank pos sensor (–)

Switched power

5V sensor power

Oxygen sensor (B)

Throttle pos sensor input

Map sensor input

5V sensor ground

Ground

Coil front

Crank pos sensor (+)

Vehicle speed sensor input

IGN 15A

Fuel

Pump 15A

Ignition

Switch

[33]

Battery 15A

ECM 15A

30 Amp

MAXIFUSE

GND1

IGN − I

BATT – B

ACC – A

ECM

TSM/TSSM/HFSM

[61B]

Fuse Blocks

Top View

[119]

Accessories

Lights

Ignition

Fuel Pump

Start Relay

System Relay

ECM

Battery

Spare

P&A IGN

Instruments

Spare

System
Relay

Spare

Open

[119B]

To instruments and

indicator lamps

[61]

To right hand

controls

Engine

Harness

Powertrain

Ground

Point

4 3

2
3

5
6
7
8
9

10
11
12
13
14

17
18
19

23
24
25
26

28
29
30
31

35
36

5
6
7
8
9

10
11
12
13
14

17
18
19

23
24
25
26

28
29
30
31

3
4

2 1

6 7

1 2

Data

Link

Connector

Ignition
Coil

D C B A

Coil

rear

Coil

front

K
T
E
S

87A

30
85
86

5
4
3
2
1

[133B]

[133A]

Front

Sensor

Rear

Sensor

HDI

only

INSTR 15A

To fuel pump

and sender

ASSY

1 2 3 4

Fuel Sender

Resistor ASSY

240

Battery

2
3
4
5

7
8

11
12
13
14

2
3
4
5

7
8

11
12
13
14

Idle Air

Control

D C B A

Intake Air

Temperature/

Manifold Absolute

Pressure Sensor

Throttle

Position

Sensor

A B C D

Engine

Temperature

Sensor

2 1

Rear

Injector

Front

Injector

A B

Crank
Position
Sensor
(CKP)

1 2 3

SOCKET CONNECTOR
(B side)

PIN CONNECTOR

(A side)

15A

Switch
Position

RED/BLACK

RED

RED/GRAY

OFF
ACC.
IGNITION

Ignition Switch Legend

Dot indicates continuity with red

wire in switch position indicated

HFSM only

Jiffy Stand

Sensor

1 2 3

[5]

[20A]

Page 2

[22A]

Page 2

[141B]

Page 2

BN/GY

BEBE

W/Y

V/W

Y/W

Y/R

R/W

W/Y

LGN/V

LGN/Y

LGN/V

LGN/Y

LGN/V

BN/GY

PK/GN

BN/GY

BE/GN

BE/GY

GN/BN

BK/PK

GN/GY

GN/BN

GN/GY

PK/GN

BK/PK

BE/GN

GY/BE

GN/O

Y/BE

Y/GN

PK/O

PK/Y

GY/V

O/GY

Y/GN

Y/BE

BN/R

BK/W

BK/O

BK/W

BE/O

BK/W

BN/R

BE/O

GY/V

W/BK

BK/O

W/BK

O/GY

R/BK

PK/Y

GN/O

PK/O

W/Y

V/W

R/W

LGN/Y

BK/PK

BE/GN

GN/GY

Y/GN

BK/O

BN/R

BK/W

GY/V

Engine

Case

Ground

Point

[141A]

[138B]

[138A]

[90B]

[90A]

[87B]

[87A]

[80B]

[80A]

[88B]

[88A]

[137B]

[137A]

[20B]

[83A]

[83B]

[79A]

[79B]

[85A]

[85B]

[22B]

[84A]

[84B]

[200A]

[200B]

[91A]

[145B]

[145A]

[78B]

[78A]

[208A]

[30B]

[30A]

et01156

Figure B-5. Engine Management (1 of 2) (XL): 2009 Sportster DOM. and INT. Models

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