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 or 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 4.4 FUEL TANK: XL MODELS or 4.5 FUEL TANK: XR 1200X.
5. XL Models: See Figure 6-25. Remove screw (1) securing left wire harness caddy (2) to right wire harness caddy. See 6.28 ELECTRICAL CADDIES. Carefully disengage left wire harness caddy and pull away from frame backbone.
Figure 6-25. Ignition coil and left wire harness caddy: XL models: 1. Screw; 2. Left wire harness caddy; 3. Ignition coil
Note. Always grasp rubber boot as close as possible to the spark plug terminal when removing spark plug cables. Do not pull on the cable portion itself. Pulling on the cable will damage the cable's carbon core.
6. See Figure 6-26 or Figure 6-27. Pull front spark plug boot and cable (2) from left side ignition coil (1) tower.
Figure 6-26. Spark plug cable routing: XL models: 1. Ignition coil; 2. Front spark plug cable boot; 3. Rear spark plug cable boot; 4. Rear spark plug cable; 5. Notch in right wire harness caddy
7. Pull rear spark plug boot (3) and cable from right side ignition coil tower.
8. Unplug spark plug boot and cable assemblies from front and rear spark plugs.
9. XL Models: Disengage rear spark plug cable from notch in right wire harness caddy (5). Remove the cable.
10. XR 1200X: See Figure 6-27. Disengage rear spark plug cable from wire harness caddy (5). Remove the cable.
Figure 6-27. Spark plug cable routing: XR 1200X: 1. Ignition coil; 2. Front spark plug cable boot; 3. Rear spark plug cable boot; 4. Rear spark plug cable; 5. Harness caddy
11. XL Models: See Figure 6-28. Remove rear spark plug cable (2) from curved trough on wire harness caddy (1).
- a. Cut cable strap (4).
- b. Feed spark plug cable out from between frame and engine. Remove the cable.
- c. Remove cable strap from mounting boss on caddy latch clip (5). Discard cable strap.
Figure 6-28. Rear spark plug cable routing: XL models: 1. Right wire harness caddy; 2. Rear spark plug cable; 3. Engine sub-harness; 4. Cable strap; 5. Caddy latch clip
Installation
1. See Figure 6-26 or Figure 6-27. Plug rear spark plug cable boot (3) into right side ignition coil (1) tower.
2. XL Models: Route cable between wire harness caddies, and down through notch (5) in right caddy, toward right side of engine.
3. XR 1200X: Route rear spark plug cable through harness caddy (5) as shown.
4. XL Models: See Figure 6-28. Route rear spark plug cable (2) in trough in right wire harness caddy (1), over top of engine sub-harness (3) and back toward left side of engine.
5. XL Models: See Figure 6-29. Install new barbed cable strap (3) onto spark plug cable (1), 7.0-7.25 in (178-184 mm) from tip of spark plug cable boot (2).
Figure 6-29. 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)
- a. Orient the cable strap so that the spark plug cable is above the mounting boss on the caddy latch clip.
- b. Press the cable strap barbed prong firmly into the hole in the caddy latch clip mounting boss.
6. Plug rear spark plug cable and boot onto rear spark plug until it clicks.
7. See Figure 6-26 or Figure 6-27. Plug front spark plug cable and boot (2) into left side ignition coil (1) tower. Plug other end of cable onto front spark plug until it clicks.
Note. Make sure rear spark plug cable is routed properly and cannot chafe against frame, fuel tank or rear cylinder head.
8. XL Models: See Figure 6-25. Mate left wire harness caddy (2) to right wire harness caddy. Secure with screw (1) and tighten. See 6.28 ELECTRICAL CADDIES.
9. Install fuel tank. See 4.4 FUEL TANK: XL MODELS or 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.
10. Install seat.
11. Install main fuse.
12. Start the engine. Verify ignition function.