Question about Harley Davidson XL 1200 C Sportster Custom Motorcycles
To replace the right hand turn signal button, you have to take the right hand switch housing apart which includes the throttle. Start by loosening both throttle cables at their adjustments. Loosen them all the way. Take mirrors and other stuff off the handlbar that might be in the way. Remove the two bolts that hold the switch housing halves together and carefully lift the top. Disconnect the throttle and idle cable from the throttle sleeve. Remove the throttle sleeve leaving both halves of the switch housing free.
Now, there is a screw that holds the switches in the housing. I think those swiches come as a pair. You may have to replace the right turn signal switch and the start switch. Here's the tricky part. I haven't done a model as late as yours but the ones I have done required that I unsolder the old wires and resolder them to the new switches in order to make the repair look like new. The new switches may or may not come with new wires but I never figured out how to get the new wires in the wire sleeve and into the headlight. It was just simplier and easier to solder the original wires to the new switches. Once the wires are securely connected, install the switches and the screw that holds them in.
Now, apply a good coating of white lithium grease to the handlebar, the inside of the throttle sleeve, and the nylon ring that the throttle cables connect into. Slide the sleeve on the handlebar and put the lower half of the switch housing in place. Connect the throttle and idle cables into the throttle sleeve. Make sure you have the little barrels on the cable ends. Carefully put the top half back on and get the bolts started. When you do this, make sure that you are not going to pinch a wire inside the housing when you tighten it up. Now, slide the housing and the throttle sleeve towards the center of the handlebar until it stops and then back it back off about 1/4 inch or so. Tighten the bolts that hold the switch housing together. Readjust the throttle cable and the idle cable. You want just a bit of slack in each cable.
Once finished. With the engine OFF, turn the throttle wide open and let go of the throttle grip. It should snap shut. If not, you may have the cables adjusted too tightly or the throttle sleeve is up against the end of the handlebar on the inside of the sleeve. The throttle must snap shut in order for the vehicle to be safe. Make sure your throttle works correctly. Failure to do so my result in serios injury or death.
Posted on Aug 19, 2010
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Posted on Jan 02, 2017
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