Wire harness caddy: XL models
FASTENER | TORQUE VALUE | |
Ignition switch bracket screw | 35-45 in·lbs | 4.0-5.1 Nm |
![](https://motoinstruction.ru/img/harley/12/118348.jpg)
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 and secured with a screw.
![](https://motoinstruction.ru/img/harley/12/118350.jpg)
Figure 6-112. Right wire harness caddy latch clip: 1. Right wire harness caddy; 2. Caddy latch clip; 3. Main harness; 4. Engine sub-harness; 5. Frame backbone
See Figure 6-111. The wire harness caddy assembly (1, 2) is secured to the ignition switch bracket (3) with two push-in fasteners (6, 7), and to the frame with mounting tabs hooked onto a bracket under the frame backbone tube.
![](https://motoinstruction.ru/img/harley/12/118349.jpg)
Figure 6-111. Wire harness caddy assembly: 1. Right wire harness caddy; 2. Left wire harness caddy; 3. Ignition switch bracket; 4. Coil bracket; 5. Screw w/lockwasher (lockwasher between bracket and switch housing); 6. Push-in fastener, large; 7. Push-in fastener, small; 8. Screw; 9. Throttle cable (2); 10. Cable strap (2); 11. Tab (3) (engage left and right caddies); 12. Screw
Removal
Warning! 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.
1. Purge the fuel supply hose of high pressure gasoline. Disconnect fuel supply hose from fuel pump module. See 4.4 FUEL TANK: XL MODELS.
Warning! To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding.
2. Remove main fuse.
3. Remove seat.
4. Remove fuel tank. See 4.4 FUEL TANK: XL MODELS.
5. Separate ignition coil connector [83B].
6. See Figure 6-111. Remove screw (8) and disengage coil bracket (4) from mounting boss on frame.
7. See Figure 6-112. Unhook caddy latch clip (2) from right wire harness caddy (1).
Note. It is not necessary to remove rear spark plug cable from wire harness caddy latch clip, unless latch clip is being replaced.
8. If necessary, cut cable strap securing rear spark plug cable to caddy latch clip.
9. Remove engine sub-harness from loop in caddy latch clip.
10. See Figure 6-111. Remove screw (12) and carefully disengage left wire harness caddy (2) from right wire harness caddy (1).
11. Cut two cable straps (10) securing throttle cables (9) to right wire harness caddy.
12. Disengage rear spark plug cable from trough in right wire harness caddy. Cut barbed cable strap securing engine sub-harness to right wire harness caddy.
13. CA Models: Cut barbed cable strap securing EVAP canister purge hose to rear of right wire harness caddy and cut the barbed cable strap through the bridge caddy.
14. See Figure 6-111. Remove and discard push-in fasteners (6, 7). Unhook right wire harness caddy from frame backbone bracket. Lower ignition switch bracket (3) from mounting bosses on frame to free right wire harness caddy.
15. See Figure 6-113. Unplug the following connectors:
- a. Headlamp connector [38B] (4),
- b. Left hand control connector (gray) [24B] (3),
- c. Right hand control connector (black) [22B] (5),
- d. Front turn signal connector [31B] (6),
- e. Instruments connector [20A] (7).
![](https://motoinstruction.ru/img/harley/12/118351.jpg)
Figure 6-113. Wire harness caddies: 1. Left wire harness caddy; 2. Right wire harness caddy; 3. Left handlebar control connector [24A]; 4. Headlamp connector [38A]; 5. Right handlebar control connector [22A]; 6. Front turn signals connector [31A]; 7. Instruments connector [20B]; 8. Two cable straps securing throttle cables; 9. Portion of main wiring harness
16. Make a note of the location of all cable straps securing harnesses and harness connectors to left and right wire harness caddies. Cut cable straps and remove harnesses and connectors from caddies. Remove wire harness caddies from vehicle.
Installation
1. See Figure 6-113. Fit portion of main wiring harness (9) and ignition switch harness along top of right wire harness caddy (2) and secure with cable straps, as shown in the figure.
2. Mount front turn signals connector [31A] (6) onto mounting tab on right wire harness caddy.
3. See Figure 6-111. Place throttle cables (9) in groove in right wire harness caddy (1).
4. See Figure 6-113. Place instruments connector [20B] (7) into right wire harness caddy (2). Secure connector and throttle cables with a cable strap (8). Secure throttle cables and harnesses (as shown in the figure) with a second cable strap.
5. Mount handlebar control connectors [22A], [24A] (5, 3) to left wire harness caddy (1) with cable straps. Mount headlamp connector [38A] (4) onto tab on left wire harness caddy.
6. See Figure 6-111. Hook right wire harness caddy (1) into bracket on frame backbone. Secure front of caddy onto ignition switch bracket mounting boss on right side of frame. Raise ignition switch bracket (3) up into position and mount it onto boss on frame.
Note. Make sure ignition switch bracket upright is outboard of right wire harness caddy and throttle cables on right side of frame.
7. Secure right wire harness caddy to ignition switch bracket with new push-in fasteners (6, 7).
8. See Figure 6-112. Install caddy latch clip (2) onto right wire harness caddy (1). Make sure engine sub-harness (4) is routed in loop in caddy latch clip.
9. See Figure 6-114. Raise coil bracket (5) up into position and mount it on boss on left side of frame. Secure coil bracket to ignition switch bracket with screw (6). Tighten to 35-45 in·lbs (4.0-5.1 Nm).
![](https://motoinstruction.ru/img/harley/12/118352.jpg)
Figure 6-114. Rear spark plug cable routing: 1. Ignition coil; 2. Rear spark plug cable boot; 3. Rear spark plug cable; 4. Notch in right wire harness caddy; 5. Coil bracket; 6. Screw
10. Plug in ignition coil connector [83B].
Note. Make sure coil bracket upright is outboard of all wire harnesses leading to front of vehicle on left side of frame.
11. Route rear spark plug cable (3) from ignition coil (1) tower down through notch (4) in right wire harness caddy.
12. Route rear spark plug cable in right wire harness caddy trough.
13. Route engine sub-harness around trough in right wire harness caddy. Secure sub-harness to caddy trough with a cable strap. Run strap through hole in boss that originally secured engine sub-harness.
14. California Models: Secure EVAP canister purge hose to rear of right wire harness caddy with two barbed cable straps.
15. Plug in the following connectors:
- a. Instruments connector [20A] (7),
- b. Front turn signal connector [31B] (6),
- c. Right hand control connector (black) [22B] (5),
- d. Left hand control connector (gray) [24B] (3),
- e. Headlamp connector [38B] (4).
16. See Figure 6-111. Mate left wire harness caddy (2) to right wire harness caddy (1). Secure with screw (12) and tighten.
17. See Figure 6-115. If barbed cable strap (3) securing rear spark plug cable (1) to caddy latch clip was cut, install new barbed cable strap 7.0-7.25 in (178-184 mm) from tip of spark plug cable boot (2).
![](https://motoinstruction.ru/img/harley/12/118353.jpg)
Figure 6-115. Rear spark plug cable and cable strap: XL models: 1. Rear spark plug cable; 2. Spark plug boot (spark plug end); 3. Barbed cable strap; 4. 7.0-7.25 in (178-184 mm)
18. Orient cable strap so that spark plug cable is above mounting boss on caddy latch clip when barbed prong on cable strap is inserted in hole in boss. Press cable strap barbed prong firmly into hole in caddy latch clip mounting boss.
19. Make sure rear spark plug cable is plugged onto rear spark plug.
20. Install fuel tank. See 4.4 FUEL TANK: XL MODELS.
Warning! After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury.
21. Install seat.
22. Install main fuse.
Warning! Be sure headlamp, tail and stop lamp and turn signals are operating properly before riding. Poor visibility of rider to other motorists can result in death or serious injury.
23. Verify the operation of the electrical system.
Wire harness caddy: XR 1200X
FASTENER | TORQUE VALUE | |
Ignition switch mounting screw | 35-45 in·lbs | 4.0-5.1 Nm |
Removal
Warning! 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.
1. Purge the fuel supply hose of high pressure gasoline. Disconnect fuel supply hose from fuel pump module. See 4.5 FUEL TANK: XR 1200X.
Warning! To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding.
2. Remove main fuse.
3. Remove seat.
4. Remove fuel tank. See 4.5 FUEL TANK: XR 1200X.
5. Remove air box. See 4.3 AIR CLEANER ASSEMBLY, XR 1200X.
6. See Figure 6-116. Remove screw (3), connector (1) and disengage coil bracket (2) from mounting boss on frame.
![](https://motoinstruction.ru/img/harley/12/118354.jpg)
Figure 6-116. XR caddy removal: 1. Coil connector; 2. Coil bracket; 3. Screw; 4. Rear spark plug wire; 5. Push-in fastener; 6. Cover
7. Remove rear spark plug wire (4) from caddy. Support coil away from engine and caddy.
8. Separate push-in fastener (5) from caddy.
9. See Figure 6-117. Unhook caddy latch clip (1) from right side of frame.
![](https://motoinstruction.ru/img/harley/12/118355.jpg)
Figure 6-117. Caddy latch clip: 1. Latch clip; 2. Ignition switch bracket
10. See Figure 6-118. Detach connector (2) from right side of caddy.
![](https://motoinstruction.ru/img/harley/12/118356.jpg)
Figure 6-118. Right side connectors: 1. Cable strap (2); 2. Connector
11. Cut two cable straps (1) from right side of caddy.
12. See Figure 6-116. Remove cover (6) from caddy.
13. See Figure 6-119. Cut remaining five cable straps from left side of caddy.
![](https://motoinstruction.ru/img/harley/12/118357.jpg)
Figure 6-119. Cable strap locations
14. Pull caddy away from frame and move ignition switch away from caddy. Support ignition switch away from engine.
15. Pull connectors from left side of caddy and remove caddy from motorcycle.
Installation
1. See Figure 6-119. Place caddy in position next to motorcycle frame, Attach ignition switch bracket into position on caddy and place caddy on motorcycle frame.
2. Install connectors on left side of caddy.
3. Install five cable straps to secure connector wires in position on left side of caddy.
4. See Figure 6-118. Attach connector (2) to right side of caddy.
5. Install two cable straps (1) as shown on right side of caddy. Make sure wires on left side of caddy are also secured with the rearward cable strap.
6. See Figure 6-117. Make sure harness and purge hose (California models) are attached to caddy latch clip (1). Install latch clip on right side of frame.
7. See Figure 6-116. Install cover (6) on caddy.
8. Install push-in fastener (5).
9. See Figure 6-116. Slip lower end of coil bracket (2) into caddy slot. make sure coil bracket is flush with end of ignition switch bracket and attach top end of coil bracket to mounting boss on frame.
10. Install connector (1) and then screw (3). Tighten screw (3) to 35-45 in·lbs (4.0-5.1 Nm).
11. Install rear spark plug wire (4) on caddy.
12. Install air box. See 4.3 AIR CLEANER ASSEMBLY, XR 1200X.
13. Install fuel tank. See 4.5 FUEL TANK: XR 1200X.
Warning! After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury.
14. Install seat.
15. Install main fuse.
Warning! Be sure that all lights and switches operate properly before operating motorcycle. Low visibility of rider can result in death or serious injury.
Warning! Be sure headlamp, tail and stop lamp and turn signals are operating properly before riding. Poor visibility of rider to other motorists can result in death or serious injury.
16. Verify the operation of the electrical system.