Disconnection and Removal
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 injury. (00049a)
  1. See Figure 1. Unthread nut and remove battery negative cable (black) from crankcase stud behind starter motor assembly.
  2. Remove left side cover.
  3. Remove Maxi-Fuse and holder from battery strap by grasping holder and sliding it toward the rear of the motorcycle. Then remove Maxi-Fuse holder from its mounting pin on battery strap.
  4. Remove data link connector from battery strap.
  5. Remove battery strap screw and flat washer. Unhook battery strap from battery tray mount on top of battery and remove strap.
  6. Unthread bolt and remove battery positive cables (red) from battery positive (+) terminal.
  7. Remove battery and attached negative cable as an assembly from the battery tray.
Installation and Connection
NOTICE
Connect the cables to the correct battery terminals. Failure to do so could result in damage to the motorcycle electrical system. (00215a)
WARNING
Connect positive (+) 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 injury. (00068a)
WARNING
Do not allow positive (+) battery cable to contact ground with negative (-) cable connected. Resulting sparks can cause a battery explosion, which could result in death or serious injury. (00069a)
1. Apply a light coat of petroleum jelly or corrosion retardant material to negative (-) battery terminal before installation.
2. Place the fully charged battery with the negative cable attached into the battery tray.
3. See Figure 1. Route negative cable around frame downtube.
NOTICE
Do not over-tighten bolts on battery terminals. Use recommended torque values. Over-tightening battery terminal bolts could result in damage to battery terminals. (00216a)
4. With negative (-) cable disconnected from grounding point on crankcase, insert bolt through Maxi-Fuse cable first then through main battery positive cable (+) (red) and into threaded hole of battery positive (+) terminal.
5. Tighten bolt to 4.5–5.7 N·m (45–50 in-lbs).
6. Apply a light coat of petroleum jelly or corrosion retardant material to positive (+) battery terminal. Place protective rubber boot over terminal.
NOTICE
Keep battery clean and lightly coat terminals with petroleum jelly to prevent corrosion. Failure to do so could result in damage to battery terminals. (00217a)
7. Hook top of battery strap to battery tray mount on top of battery. Install flat washer and strap screw.
8. Tighten the strap screw to 4.07–6.78 N·m (36–60 in-lbs).
9. Route main positive battery cable through holders on electrical bracket.
10. Hook Maxi-Fuse holder to pin on battery strap and slide forward until it snaps into place.
11. Place data link connector on battery strap.
12. Place negative battery cable end onto stud on crankcase boss behind starter motor assembly. Thread nut onto stud.
13. Tighten nut to 6.2–8.5 N·m (55–75 in-lbs).
14. Install left side cover.
Figure 1. Negative Battery Cable and Crankcase Stud: Sportster Models