See Figure 6-131. The oil pressure switch is located under the oil filter mount at the front of the engine crankcase.
Figure 6-131. Oil pressure indicator lamp switch: XL models: 1. Oilfilter; 2. Oil pressure switch; 3. Oil pressure switch connector [120]
Note. This part cannot be repaired. Replace upon failure.
Removal
PART NUMBER | TOOL NAME |
HD-41675 | OIL PRESSURE SENDING UNIT WRENCH |
Warning! To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding.
1. Remove main fuse.
2. See Figure 6-131. Remove wiring harness connector [120] (3) by pulling elbow connector straight down from stud on oil pressure switch (2).
3. XR1200X: See Figure 6-132. Disconnect voltage regulator stator connector (4). Reposition neutral switch wire and voltage regulator stator wire as needed.
Figure 6-132. Oil pressure switch: XR 1200X: 1. Oil pressure switch; 2. J-clip; 3. Barbed cable strap; 4. Stator connector [47]
4. Place a container under the motorcycle to catch any oil that may leak out when oil pressure switch is removed.
Note. XR 1200X: Hold oil pressure switch adapter with a wrench to prevent the adapter from being removed while removing the oil pressure switch.
5. Using OIL PRESSURE SENDING UNIT WRENCH (Part No. HD-41675), remove oil pressure switch.
Installation
PART NUMBER | TOOL NAME |
HD-41675 | OIL PRESSURE SENDING UNIT WRENCH |
FASTENER | TORQUE VALUE | |
Oil pressure switch adapter: XR 1200X | 13-17 ft·lbs | 17.6-23.0 Nm |
Oil pressure switch | 50-70 in·lbs | 5.6-7.9 Nm |
1. XR 1200X: if the oil pressure switch adapter came out with the oil pressure switch, install the adapter:
- a. Separate oil pressure switch from adapter.
- b. Remove and discard old O-ring. Install new O-ring.
- c. Install adapter and tighten to 13-17 ft·lbs (17.6-23.0 Nm).
Note. Perform following step only if original oil pressure switch is being re-installed. New switches have a sealant contact patch on the mounting threads.
2. Coat threads of oil pressure switch with LOCTITE 565 HIGH PERFORMANCE PIPE SEALANT with TEFLON.
3. See Figure 6-131. Install oil pressure switch (2). Using OIL PRESSURE SENDING UNIT WRENCH (Part No. HD-41675), tighten switch to 50-70 in·lbs (5.6-7.9 Nm).
4. XR 1200X: See Figure 6-132.
- a. Reposition neutral switch wire and stator wire.
- b. Secure stator connector (4) to bracket with barbed cable strap (3) and make sure neutral switch wire and oil pressure switch wires are secured in J-clip (2).
- c. Join halves of stator connector [47] and secure with lock.
Note. Oil pressure switch connector [120] must always face away from vehicle.
5. Attach wiring harness connector [120] to oil pressure switch. Make sure connector points away from motorcycle.
6. Install main fuse.
Note. Replace oil if significant loss.
7. Check oil level in oil tank. See 1.6 ENGINE OIL AND FILTER. Top off oil level if necessary.
8. Start engine and test oil pressure switch for proper operation. Check oil pressure switch for leaks.