Electrical equipment and instruments of motorcycle Harley Sportster XL1200 (2012-2023)

Fastener torque values
The table below lists torque values for all fasteners presented in this chapter. FASTENER TORQUE VALUE Notes Alternator rotor to sprocket screw 120-140 in·lbs 13.6-15.8 Nm 6.24 ALTERNATOR , Assembly and Installation Alternator stator mounting screw...

Specifications of electrical components
Table 6-1. Electrical: XL models COMPONENT SPECIFICATION Ignition timing Not adjustable Battery 12 V, 225 CCA, 12 Ah, sealed and maintenance free Charging system Single-phase, 30 A system (357 W@ 13.5 V, 2000 rpm, 405 W max power @ 13.5 V) Spark...

Fuses and relays
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 6-3. The electrical system relay/fuse block is located in front...

Speedometer: XL models — removal and installation
Removal Note. The speedometer has backlight LEDs that cannot be replaced. If an LED fails, replace the entire unit. Warning! To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. 1....

Speedometer and tachometer: XR 1200X
Speedometer removal Warning! To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. Note. This part cannot be repaired. Replace upon failure. 1. Remove main fuse. 2. See Figure 6-7....

Electronic control module (ECM) — removal and installation
See Figure 6-9. The ECM receives data from sensors such as the CKP sensor and the TMAP sensor. The ECM uses this data to time the ignition spark as well as providing other engine management functions. Figure 6-9. ECM: XL models: 1. ECM; 2. ECM...

Turn signal and security module (TSM/TSSM/HFSM)
See Figure 6-11. The TSM has two functions: Control turn signals. Serve as the BAS. Figure 6-11. TSM/TSSM/HFSM (TSM shown) The optional factory-installed security system provides the same functionality as the TSM, but also includes security and...

Crank position sensor (CKP) — removal and installation
The CKP sensor is a variable reluctance (VR) sensor. It generates an AC signal by sensing the passing of 30 teeth cast into the left side flywheel. Two consecutive teeth are missing in the flywheel to establish a reference point. The CKP sensor...

Vehicle speed sensor (VSS) — removal and installation
The VSS is powered and monitored by the ECM. The ECM processes the vehicle speed signal and transmits this signal to the TSM/TSSM and speedometer through serial data. Note. This part cannot be repaired. Replace upon failure. Removal Warning! To...

Neutral indicator switch
See Figure 6-103. The neutral indicator switch (1) is threaded into the right crankcase half (3) immediately forward of the main drive gear (4). A short jumper wire assembly (2) connects the switch to the harness connector [136] under the engine...

Main wiring harness — removal and installation
Wire harness connectors Figure 6-104. Main wiring harness: XL models: 1. ECM caddy; 2. Lower left bundle; 3. Lower right bundle; 4. Upper rear bundle; 5. Upper front bundle; 6. Front view; 7. Rear view See Figure 6-104, Figure 6-105 or Figure 6-106....

Electrical caddies — removal and installation
Wire harness caddy: XL models FASTENER TORQUE VALUE Ignition switch bracket screw 35-45 in·lbs 4.0-5.1 Nm Figure 6-110. Wire harness caddy: locking tabs See Figure 6-112. The left and right wire harness caddies are locked together with three tabs...

Jiffy stand sensor (JSS): international models
Removal 1. Position motorcycle upright on a suitable lift. 2. See Figure 6-120. Unplug JSS harness connector [133] (1). Figure 6-120. JSS connector: 1. JSS connector [133]; 2. J-clip 3. Cut cable strap securing JSS harness to frame. 4. See Figure...

Security system/optional siren
Fob battery Battery replacement schedule Replace the fob battery every year. Battery replacement 1. Open the fob case. a. See Figure 6-125. Place a thin blade in the thumbnail slot (1) between the two halves of the case. b. Slowly twist the blade....

Oil pressure switch — removal and installation
The oil pressure signal lamp switch is a pressure-actuated diaphragm-type switch. When oil pressure is low, spring tension holds the switch contacts closed. This completes the signal lamp circuit causing the indicator lamp to illuminate. See Figure...

Horn — removal and installation
Troubleshooting If the horn does not sound or sounds weak, check for the following: Discharged battery. To charge battery, see 1.22 BATTERY MAINTENANCE . Loose, frayed or damaged wiring to horn terminal. If battery is charged and wiring appears to...

Handlebar switch assemblies
Repair procedures PART NUMBER TOOL NAME HD-25070 ROBINAIR HEAT GUN HD-39969 ULTRA TORCH UT-100 HD-41183 HEAT SHIELD ATTACHMENT 1. Push conduit back to better access wires and avoid damaging conduit with radiant heating device. Secure conduit with...

Right handlebar switches — removal, installation, disassembly and assembly
Removal Warning! To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. 1. Remove main fuse. Notice: Do not remove or install the master cylinder assembly without first positioning a...

Left handlebar switches — removal, installation, disassembly and assembly
Removal Note. The removal and installation steps listed apply when replacing the entire switch assembly, a switch housing or the handlebar. Warning! To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse...

Personal identification number (PIN)
The PIN consists of five digits. Each digit can be any number from 1 through 9. There can be no zeros (0) in the PIN. Use the PIN to disarm the security system in case the fob becomes unavailable. Initial PIN entry To enter a PIN on a motorcycle...

H-DSSS actuation
Setting up a vehicle TSM/HFSM depends on whether the vehicle has a TSM or the optional HFSM security system installed. Sidecar configuration Warning! Only Touring Harley-Davidson Motorcycles are suitable for sidecar use. Consult a Harley-Davidson...

TSM/HFSM: password learn
If the ECM or TSM/HFSM is faulty, replace the unit. See 6.6 ELECTRONIC CONTROL MODULE (ECM) or 6.7 TURN SIGNAL AND SECURITY MODULE (TSM/TSSM/HFSM) . Then, to determine if password learn is necessary, refer to Table 6-13. Table 6-13. Password learn...

Autofuse unsealed electrical connector — disassembly and assembly
Autofuse unsealed connector repair PART NUMBER TOOL NAME GA500A SNAP-ON TERMINAL PICK Autofuse Unsealed connector terminals are found in ignition switches and some fuse blocks. Disassembly 1. See Figure A-1 or Figure A-2. Insert smallest pair of...

Bosch compact 1.1M connector
PART NUMBER TOOL NAME GA500A SNAP-ON TERMINAL PICK See Figure A-3. The Bosch Compact 1.1M connector is found on MAP and TMAP sensors on all models. Figure A-3. Bosch compact 1.1M connector Housings Separate: Snap back the secondary lock. Press on...

Delphi 100W micro-pack sealed connector
A Delphi 100W Micro-Pack Sealed connector connects the electronic control module (ECM) to the main harness. Separating socket housing from ECM See Figure A-6. While pressing the connector into the ECM, press the thumb lever (1) against the connector...

Delphi 150 metri-pack sealed connector repair
Delphi 150 Metri-Pack Sealed connectors are embossed with the initials (P.E.D.). There are two types of connectors in this series: Pull-to-Seat Push-to-Seat Separating pin and socket housings Bend back the external latch slightly and separate the...

Delphi 280 metri-pack unsealed connector
Fuse block repair Removing socket terminals 1. See Figure A-11. To remove secondary locks, insert end of small flat blade screwdriver (1) under lip of locking wedge (2) and gently pry up secondary lock. igure A-11. Fuse block: remove secondary...

Delphi 480 metri-pack unsealed connector
A 480 Metri-Pack connector is frequently used for the B+ (battery voltage) connector to power P&A accessories. See Figure A-13. An AFL housing (5) is used on many igni-tion/light switches. The secondary lock (4) must be opened before removing the...

Delphi 630 metri-pack unsealed connector
PART NUMBER TOOL NAME SNAP-ON TT600-3 SNAP-ON PICK Separating pin and socket housings Note. If necessary, remove connector from barbed anchor or other retaining device. Bend back the external latch slightly and separate pin and socket halves of the...

Delphi 800 metri-pack sealed main fuse housing
Removing socket terminals Warning! Disconnect negative (-) 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...

Delphi metri-pack terminal repair
Metri-pack terminal crimps PART NUMBER TOOL NAME HD-38125-6 PACKARD TERMINAL CRIMP TOOL HD-38125-7 PACKARD TERMINAL CRIMPER HD-38125-8 PACKARD CRIMPING TOOL Matching terminal to crimper Metri-Pack connectors embossed with the initials P.E.D. require...

Delphi micro 64 sealed connector
PART NUMBER TOOL NAME HD-45928 TERMINAL REMOVER HD-45929 TERMINAL CRIMPER Delphi Micro 64 Sealed connectors are frequently found on speedometers, tachometers and the ECM of Touring Models. Separating pin and socket housings Bend back the external...

Delphi GT 150 sealed connector repair
Delphi connectors are embossed with the brand name, Delphi, on the housing latch or terminal block. Separating pin and socket housings See Figure A-23. Bend back the external latch(es) slightly and separate pin and socket halves of connector. Figure...

Delphi GT 280 sealed 73-terminal ECM connector
Note. Do not operate latch lever when connector is not mated to ECU. Damage will occur. Separating socket housing from ECM See Figure A-25. Remove strap (1). Press the latch (2). Rotate lock lever to the released position (3). Figure A-25. Unlatch...

Deutsch DT sealed connector repair
PART NUMBER TOOL NAME HD-41475 DEUTSCH TERMINAL REPAIR KIT HD-41475-100 FLAT BLADE L-HOOK Deutsch DT sealed connectors are colored coded for location purposes. DT connectors associated with left side accessories, such as the front and rear left turn...

Deutsch DT sealed terminal repair
PART NUMBER TOOL NAME HD-39965-A DEUTSCH TERMINAL CRIMP TOOL Preparing wire leads for crimping 1. Use a shop gauge to determine gauge of wire lead. 2. Strip 5/32 in (4.0 mm) of insulation from the wire lead. Crimping terminal to lead 1. See Figure...

Deutsch DTM sealed mini terminal repair
PART NUMBER TOOL NAME HD-38125-7 PACKARD TERMINAL CRIMPER Preparing wire leads for crimping Strip 5/32 in (4.0 mm) of insulation from the wire lead. Crimping a mini terminal to wire lead 1. See Figure A-36. Compress the handles of PACKARD TERMINAL...

Deutsch DTM sealed solid barrel mini terminal repair
PART NUMBER TOOL NAME HD-42879 ELECTRICAL CRIMPER TOOL Preparing wire leads for crimping For size 20, 16 and 12 contacts, wire ranges 26-12 AWG. Strip 1/4 in (6.4 mm) of insulation from the wire lead. Adjusting crimper tool 1. See Figure A-37....

JAE MX19 sealed connectors
PART NUMBER TOOL NAME B-50085 TERMINAL EXTRACTOR Connector housings Separate Housings: See Figure A-39. Press the two release buttons on each side of the housing to separate the connector. Figure A-39. Release buttons: JAE MX19 sealed connector...

Molex CMC sealed connectors
PART NUMBER TOOL NAME HD-50423 0.6 MM TERMINAL EXTRACTOR TOOL HD-50424 1.5 MM TERMINAL EXTRACTOR TOOL Separating the connector Release: See Figure A-41. Press the catch and rotate the lever arm down. Figure A-41. Release Connect: Press on the front...

Molex MX 150 sealed connector repair
PART NUMBER TOOL NAME HD-48114 TERMINAL REMOVER Separating pin and socket housings See Figure A-46. Press the latch while pulling the pin and socket housings apart. Figure A-46. Molex MX 150 Sealed Connector: Latch Mating pin and socket housings 1....

Tyco 070 multilock unsealed connector repair
PART NUMBER TOOL NAME HD-41609 AMP MULTI-LOCK CRIMPER SNAP-ON TT600-3 SNAP-ON PICK Tyco 070 Multilock Unsealed connectors are found between wire harnesses and component wiring and may be either floating or anchored to the frame with attachment...

Tyco GET 64 sealed connector
PART NUMBER TOOL NAME B-50085 TERMINAL EXTRACTOR See Figure A-65. The Tyco GET 64 Sealed connector is found on the ECM of Dyna and Softail Models. Figure A-65. Tyco GET 64 sealed connector latch Housings Separate: Press on the latch. Pull the socket...

Tyco MCP sealed connector
PART NUMBER TOOL NAME B-0085 TERMINAL EXTRACTOR GA500A SNAP-ON TERMINAL PICK The Tyco MCP sealed connector is used on certain ABS modules. Housing Separate: See Figure A-70. Press and hold the lock tab. Pulling on both ends of the lever, open the...

Sealed splice connector repair
PART NUMBER TOOL NAME HD-25070 HEAT GUN HD-38125-8 PACKARD CRIMPING TOOL HD-39969 ULTRA TORCH HD-41183 HEAT SHIELD ATTACHMENT Splice connectors and several OE ring terminal connectors use heat shrink covering to seal the connection. Preparing wire...