Harley Davidson 2006 Sportster XLH MODELS. Service Manual

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BREAKOUT BOX: SPEEDOMETER/TACHOMETER

2.5

GENERAL

10077

The BREAKOUT BOX (Part No. HD-42682) and INSTRU-

MENT HARNESS ADAPTERS (Part No. HD-46601) connect

to the speedometer connector [39] or tachometer connector

[108]. Used in conjunction with a DVOM, the breakout box

allows circuit diagnosis of wiring harness and connections

without having to probe with sharp objects

NOTE

See wiring diagrams for speedometer and tachometer termi-

nal functions.

SPEEDOMETER

Installation

Figure 2-14. Speedometer Connector [39]

1. See Figure 2-14. Depress latch on connector [39B].

(Tachometer Connector [108] Similar)

Connect instrument harness adapters to connectors

[39A] and [39B].

TACHOMETER

Attach black connectors from Breakout Box to instrument

harness adapters.

Installation

Removal

See Figure 2-14. Depress latch on connector [108B].

1. Disconnect Breakout Box from instrument harness

Connect instrument harness adapters to connectors

adapters.

[108A] and [108B].

2. See Figure 2-14. Detach instrument harness adapters

Attach black connectors from Breakout Box to instrument

from connectors [39A] and [39B].

harness adapters.

3. Plug wire harness connector [39B] into speedometer

connector [39A].

Removal

1. Disconnect Breakout Box from instrument harness

adapters.

2. See Figure 2-14. Detach instrument harness adapters

from connectors [108A] and [108B].

3. Plug wire harness connector [108B] into tachometer con-

nector [108A].

2006 Sportster: Instruments

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INDICATOR LAMPS

2.6

GENERAL

10078

See Figure 2-15. Sportsters are equipped with incandescent

indicator lamps which may be replaced individually. See the

Sportster Service Manual for lamp replacement procedure.

See DIAGNOSTICS which follows for troubleshooting proce-

dures.

Table 2-5. Indicator Lamp

Connector [20] Terminals

TERMINAL

WIRE

FUNCTION

ON [20]

COLOR

Brown

right turn

White

high beam

Violet

left turn

Orange

neutral/oil pressure power

Tan

neutral lamp to switch

Lamp assembly

Green/yellow

oil pressure lamp to switch

Release latch (4)

Black

turn signal/high beam ground

Lamp bezel

Figure 2-15. Indicator Lamp Assembly (typical)

Table 2-6. Indicator Lamp Wiring

Diagnostic Notes

INDICATOR LAMP

CONNECTION

The reference number below correlates with the circled num-

Oil pressure

ground through switch

ber on the Diagnostics flow charts which follow.

Neutral

ground through switch

Connect BREAKOUT BOX (Part No. HD-42682) (black)

High beam

12 VDC when active

between wire harness connector [20A] and instruments

connector [20B].

Right/left turn

12 VDC when active

Job/Time Code Values

Dealership technicians filing warranty claims should use the

job/time code values printed in bold text underneath the

appropriate repair.

2-18

2006 Sportster: Instruments

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x0548x2x

GN/Y

[20B]

4 5 6 7 8 9 10 11 12

[20A]

4 5 6 7 8 9 10 11 12

[39B]

Main harness connector

4 5 6 7 8 9 10 11 12

[39A]

Speedometer

4 5 6 7 8 9 10 11 12

[108B]

4 5 6 7 8 9 10 11 12

[108A]

Tachometer

(if equipped)

Figure 2-16. Indicator Lamp Circuitry

Table 2-7. Wire Harness Connectors in Figure 2-16.

NO.

DESCRIPTION

TYPE

LOCATION

[20]

Instruments

12-place Deutsch

under fuel tank

[39]

Speedometer

12-place Packard

back of speedometer

[108]

Tachometer (if equipped)

12-place Packard

back of tachometer

2006 Sportster: Instruments

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DIAGNOSTICS

Oil Pressure or Neutral Indicator Will Not Function

Turn on ignition switch. Check for

12 VDC at Breakout Box cavity 6.

Turn off ignition switch.

Was 12 VDC present?

YES

Check for continuity to

Check for blown fuses

ground at Breakout Box

or locate open.

cavity 8 (neutral) and

5048

cavity 9 (oil pressure).

Is continuity present?

YES

Check each terminal for continuity

Replace indicator lamp.

to ground through switch.

5191

Is continuity present?

YES

Repair open in GN/Y

Replace oil

Replace neutral

wire (oil pressure) or

pressure switch.

switch.

TN wire (neutral).

5161

5157

5048

High Beam or R/L Turn Signal Indicator Will Not Function

Check for ground at

Breakout Box cavity 12.

Is ground present?

YES

Check for 12 VDC when circuit is active:

Locate and repair

Breakout Box cavity 5 (left turn), cavity 3

open in circuit.

(right turn) or cavity 4 (high beam).

5048

Is voltage present?

YES

Replace indicator lamp.

Locate and repair

open in circuit.

5191

5048

2-20

2006 Sportster: Instruments

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DTC B1006, B1007

2.7

GENERAL

Accessory Or Ignition Line Overvoltage

Ignition and accessory voltage is constantly monitored by the

Speedometer (terminal 1-ignition and terminal 6-accessory).

If the battery voltage fails to meet normal operating parame-

ters, a code is set.

● Code B1006 is displayed when accessory line voltage is

greater than 16.0 volts for longer than 5 seconds.

● Code B1007 is displayed when ignition line voltage is

greater than 16.0 volts for longer than 5 seconds.

NOTE

ICM or TSM/TSSM may also set a battery voltage diagnostic

trouble code (DTC).

Table 2-8. Code Description

DTC

DESCRIPTION

B1006

Accessory line overvoltage

B1007

Ignition line overvoltage

2006 Sportster: Instruments

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Test 2.7

ACCESSORY OR IGNITION LINE OVERVOLTAGE: DTC B1006, B1007

Is battery charger connected?

YES.

Disconnect battery charger. Clear codes.

Diagnose charging system.

See 1.7 CHARGING SYSTEM.

NOTE

Battery charger may cause overvoltage

condition which will set codes.

Start vehicle. Run at 3000

RPM for 5 seconds.

Does code reset?

YES

Diagnose charging system.

System normal.

See 1.7 CHARGING SYSTEM.

Clear DTCs using speedometer self diagnostics. See

2.3 SPEEDOMETER SELF DIAGNOSTICS. Confirm

proper operation with no check engine lamp.

2-22

2006 Sportster: Instruments

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DTC B1008

2.8

GENERAL

10067

Reset Switch Closed

Code B1008 will be set if odometer reset switch terminals are

in a constant shorted state.

Table 2-9. Code Description

DTC

DESCRIPTION

B1008

Reset switch closed

Diagnostic Notes

The reference number below correlates with the circled num-

ber on the Test 2.8 flow chart.

Figure 2-17. Odometer Reset Switch

1. Disconnect speedometer connector [39] (at the back of

the speedometer). See 2.5 BREAKOUT BOX: SPEED-

OMETER/TACHOMETER.

2. Connect BREAKOUT BOX (Part No. HD-42682) (black)

to wire harness connector [39B] using INSTRUMENT

HARNESS ADAPTERS (Part No. HD-46601), leaving

speedometer disconnected.

x0543a2x

[39A]

[39B]

IGNITION

DATABUS

Reset

BATTERY

ACCESSORY

Switch

GROUND

TRIP SW

FUEL LEVEL

TRIP SW

Speedometer

Figure 2-18. Odometer Reset Switch Circuit

Table 2-10. Wire Harness Connector in Figure 2-18.

NO.

DESCRIPTION

TYPE

LOCATION

[39]

Speedometer

12-place Packard

back of speedometer

2006 Sportster: Instruments

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Test 2.8

RESET SWITCH CLOSED: DTC B1008

Remove reset switch rubber boot.

Clear codes. See 2.3 SPEEDOMETER

SELF DIAGNOSTICS.

Are codes still present?

YES

With speedometer connector [39]

Replace boot.

disconnected, measure resistance

between Breakout Box cavities 8 and 11

(black). Resistance should be less than

1 ohm with switch depressed and infinity

ohms when released.

Is it?

YES

Replace Speedometer.

Replace reset switch.

Clear DTCs using speedometer self diagnostics. See

2.3 SPEEDOMETER SELF DIAGNOSTICS. Confirm

proper operation with no check engine lamp.

2-24

2006 Sportster: Instruments

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DTC U1016, U1255

2.9

GENERAL

10077

Loss of ICM Serial Data

The serial data line provides a means for the ignition control

module (ICM), TSM/TSSM and speedometer to communicate

their current status. When all operating parameters on the

serial data line are within specifications, a state of health

message is sent between the components. A diagnostic trou-

ble code (DTC) U1016 indicates that the ICM is not capable

of sending this state of health message. A DTC U1255 indi-

cates that no messages were present during power up of the

current key cycle. A DTC U1016 indicates that there was

communication on the data bus since power up, but commu-

nication was lost or interrupted during that key cycle.

Table 2-11. Code Description

Figure 2-19. Speedometer Connector [39]

DTC

DESCRIPTION

U1016

Loss of all ICM serial data

10073

U1255

Serial data error/missing message

DIAGNOSTICS

Diagnostic Notes

The reference number below correlates with the circled num-

ber on the Test 2.9 flow chart.

1. Connect BREAKOUT BOX (Part No. HD-42682) (black)

between speedometer connector [39A] (at the back of

the speedometer) and wire harness connector [39B]

using INSTRUMENT HARNESS ADAPTERS (Part No.

HD-46601). See 2.5 BREAKOUT BOX: SPEEDOME-

Terminal 1: no connection

TER/TACHOMETER.

Terminal 2: ground (BK)

Terminal 3: serial data (LtGN/V)

2. Use HARNESS CONNECTOR ADAPTER KIT (Part No.

Terminal 4: power (GY)

HD-41404), black pin probe and patch cord.

Protective cap

Figure 2-20. Data Link Connector [91A] Terminals

2006 Sportster: Instruments

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x0522a3x

LtGN/V

O/W

BN/GY

Odometer

reset switch

BN/GY

4 5 6 7 8 9 10 11 12

[39B]

[30B]

4 5 6 7 8 9 10

4 5 6 7 8 9 10 11 12

4 5 6 7 8 9 10

[39A]

[30A]

Speedometer

TSM/TSSM

[108B]

4 5 6 7 8 9 10

[108A]

Tachometer

[20B]

(if equipped)

5 67 8

11 12

[20A]

5 67 8

11 12

15A

ACC

Data link

connector

BN/GY

15A

BATT

LtGN/V

15A

INST

[91A]

[91B]

15A

IGN

Fuse

block

LtGN/V

[10B]

[10A]

Ignition Control Module (ICM)

Figure 2-21. Serial Data Circuit

Table 2-12. Wire Harness Connectors in Figure 2-21.

NO.

DESCRIPTION

TYPE

LOCATION

[10]

Ignition control module

12-place Deutsch

under seat

[20]

Instruments

12-place Deutsch

under fuel tank

[30]

TSM/TSSM

12-place Deutsch

under battery

[39]

Speedometer

12-place Packard

back of speedometer

[91A]

Data link connector

4-place Deutsch

behind left side cover

[108]

Tachometer (if equipped)

12-place Packard

back of tachometer

2-26

2006 Sportster: Instruments

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Test 2.9

LOSS OF ICM SERIAL DATA: DTC U1016, U1255

Can you read ICM hardware Part No.?

(see 2.3 SPEEDOMETER SELF DIAGNOSTICS)

YES

NO or “No Rsp”

While wiggling harness, check

Check continuity between Break-

continuity between Breakout Box

out Box cavity 2 (black) and ter-

cavity 2 (black) and terminal 12 of

minal 12 of connector [10B].

connector [10B].

Is continuity present?

YES

Clear codes. Test ride.

Repair intermittent

Replace ICM.

Repair open on

Does DTC U1016

on Lt Gn/V wire.

Reprogram and learn

Lt Gn/V wire.

return?

password.

YES

Replace ICM.

No trouble found.

Reprogram and learn

password.

Clear DTCs using speedometer self diagnostics. See

2.3 SPEEDOMETER SELF DIAGNOSTICS. Confirm

proper operation with no check engine lamp.

2006 Sportster: Instruments

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DTC U1064, U1255

2.10

GENERAL

11332

Loss of TSM/TSSM Serial Data

The serial data line provides a means for the ignition control

module (ICM), TSM/TSSM and speedometer to communicate

their current status. When all operating parameters on the

serial data line are within specifications, a state of health

message is sent between the components. A diagnostic trou-

ble code (DTC) U1064 indicates that the TSM/TSSM is not

receiving this state of health message. A DTC U1255 indi-

cates that no messages were present during power up of the

current key cycle. A DTC U1064 indicates that there was

communication on the data bus since power up, but commu-

Figure 2-22. TSM/TSSM (under Battery)

nication was lost or interrupted during that key cycle.

Table 2-13. Code Description

10073

DTC

DESCRIPTION

U1064

Loss of TSM/TSSM serial data

U1255

Serial data error/missing message

DIAGNOSTICS

Diagnostic Notes

The reference numbers below correlate with the circled num-

bers on the Test 2.10 flow chart.

Connect BREAKOUT BOX (Part No. HD-42682) as fol-

Terminal 1: no connection

lows:

Terminal 2: ground (BK)

Terminal 3: serial data (LtGN/V)

a. Mate black socket housing on Breakout Box with

Terminal 4: power (GY)

speedometer connector [39A] (at the back of the

Protective cap

speedometer) using INSTRUMENT HARNESS

ADAPTERS (Part No.HD-46601).

Figure 2-23. Data Link Connector [91A] Terminals

b. Mate black pin housing on Breakout Box with wire

harness connector [39B] using INSTRUMENT HAR-

NESS ADAPTERS (Part No.HD-46601).

c. Mate gray socket housing on Breakout Box with

TSM/TSSM connector [30A].

d. Mate gray pin housing on Breakout Box with wire

harness connector [30B].

2-28

2006 Sportster: Instruments

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x0522a3x

LtGN/V

O/W

BN/GY

Odometer

reset switch

BN/GY

4 5 6 7 8 9 10 11 12

[39B]

[30B]

4 5 6 7 8 9 10 11 12

[39A]

[30A]

Speedometer

TSM/TSSM

[108B]

4 5 6 7 8 9 10 11

[108A]

Tachometer

[20B]

(if equipped)

5 67 8 9

11 12

[20A]

5 67 8 9

11 12

15A

ACC

Data link

connector

BN/GY

15A

BATT

LtGN/V

15A

INST

[91A]

[91B]

15A

IGN

Fuse

block

LtGN/V

[10B]

[10A]

Ignition Control Module (ICM)

Figure 2-24. Serial Data Circuit

Table 2-14. Wire Harness Connectors in Figure 2-24.

NO.

DESCRIPTION

TYPE

LOCATION

[10]

Ignition control module

12-place Deutsch

under seat

[20]

Instruments

12-place Deutsch

under fuel tank

[30]

TSM/TSSM

12-place Deutsch

under battery

[39]

Speedometer

12-place Packard

back of speedometer

[91A]

Data link connector

4-place Deutsch

behind left side cover

[108]

Tachometer (if equipped)

12-place Packard

back of tachometer

2006 Sportster: Instruments

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Test 2.10

LOSS OF TSM/TSSM SERIAL DATA: DTC U1064, U1255

Can you read TSM/TSSM hardware Part No.?

See 2.3 SPEEDOMETER SELF DIAGNOSTICS.

YES

NO or “No Rsp”

While wiggling harness, check for continuity

Check for continuity between

between Breakout Box cavity 3 (grey) and

Breakout Box cavity 3 (grey) and

Breakout Box cavity 2 (black).

Is continuity present?

YES

Clear codes. Test ride.

Repair intermittent

Replace TSM/TSSM.

Repair open on

Does DTC U1064

on Lt GN/V wire.

Perform password learn.

Lt Gn/V wire.

return?

YES

Replace ICM.

No trouble found.

Reprogram and learn

password.

Clear DTCs using speedometer self diagnostics. See

2.3 SPEEDOMETER SELF DIAGNOSTICS. Confirm

proper operation with no check engine lamp.

2-30

2006 Sportster: Instruments

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DTC U1300, U1301 OR BUS ER

2.11

GENERAL

11313

Serial Data Low or Serial Data Open/High

See Figure 2-25. The typical serial data voltage range is 0

volts (inactive) to 7 volts (active). Due to the short pulse, volt-

ages will be much lower on a DVOM. In analog mode, a

DVOM reading serial data will show continuous voltage when

active, typically 0.6-0.8 volts. The range for acceptable opera-

tions is 0-7.0 volts.

Table 2-15. Code Description

DTC

DESCRIPTION

U1300

Serial data low

U1301

Serial data open/high

Figure 2-25. Data Link Connector [91A]

DIAGNOSTICS

(Behind Left Side Cover)

Diagnostic Tips

● If serial data is shorted, these diagnostic trouble codes

(DTCs) will automatically cause the check engine lamp

to illuminate. The odometer will read “Bus Er” in this con-

dition.

● DTCs P1009 and P1010 may accompany DTCs U1300

and U1301.

Diagnostic Notes

The reference numbers below correlate with the circled num-

bers on the Test 2.11 flow charts.

1. Check for DTCs. See RETRIEVING DIAGNOSTIC

TROUBLE CODES under 4.3 CHECKING FOR DIAG-

NOSTIC TROUBLE CODES.

2. Disconnect ICM at connector [10] (under seat). Discon-

nect TSM/TSSM at connector [30] (under battery). Dis-

connect speedometer at connector

[39]

(on back of

speedometer). If vehicle is equipped with a tachometer,

disconnect tachometer at connector [108] (on back of

tachometer).

3. Use HARNESS CONNECTOR TEST KIT (Part No. HD-

41404), black socket probe and patch cord.

4. Remove fuses one by one until voltage drops to locate

suspect shorted circuit.

2006 Sportster: Instruments

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x0522a3x

LtGN/V

O/W

BN/GY

Odometer

reset switch

BN/GY

4 5 6 7 8 9 10 11 12

[39B]

[30B]

4 5 6 7 8 9 10

4 5 6 7 8 9 10 11 12

4 5 6 7 8 9 10

[39A]

[30A]

Speedometer

TSM/TSSM

[108B]

4 5 6 7 8 9 10

[108A]

Tachometer

[20B]

(if equipped)

5 67 8

11 12

[20A]

5 67 8

11 12

15A

ACC

Data link

connector

BN/GY

15A

BATT

LtGN/V

15A

INST

[91A]

[91B]

15A

IGN

Fuse

block

LtGN/V

[10B]

[10A]

Ignition Control Module (ICM)

Figure 2-26. Serial Data Circuit

Table 2-16. Wire Harness Connectors in Figure 2-26.

NO.

DESCRIPTION

TYPE

LOCATION

[10]

Ignition control module

12-place Deutsch

under seat

[20]

Instruments

12-place Deutsch

under fuel tank

[30]

TSM/TSSM

12-place Deutsch

under battery

[39]

Speedometer

12-place Packard

back of speedometer

[91A]

Data link connector

4-place Deutsch

behind left side cover

[108]

Tachometer (if equipped)

12-place Packard

back of tachometer

2-32

2006 Sportster: Instruments

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Test 2.11 (Part 1 of 2)

SERIAL DATA LOW OR SERIAL DATA OPEN/HIGH: DTC U1300, U1301 OR BUS ER

Is there fresh

fuel in tank?

YES

Check for DTCs using 3.10 SPEED-

Add fuel.

OMETER SELF DIAGNOSTICS.

Any DTCs found?

YES.

NO.

DTC P1009,

DTC U1300 or

BUS Er present.

No codes found.

P1010 found. See

U1301 are found.

Speedometer will not

4.18 DTC P1009,

communicate with other

P1010.

modules.

Inspect intake manifold for

leaks using intake leak test

(propane enrichment).

Are leaks present?

YES

STOP

Replace intake

Replace ICM.

Go to Test 2.11

manifold seals.

Reprogram and learn

(Part 2 of 2).

password.

Clear DTCs using speedometer self diagnostics. See

2.3 SPEEDOMETER SELF DIAGNOSTICS. Confirm

proper operation with no check engine lamp.

2006 Sportster: Instruments

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Test 2.11 (Part 2 of 2)

SERIAL DATA LOW OR SERIAL DATA OPEN/HIGH: DTC U1300, U1301 OR BUS ER

Continued from Test 2.11 (Part 1 of 2)

Set run/stop switch to RUN. Turn ignition key ON.

Is BUS Er present?

YES

Turn ignition key OFF.

Turn ignition key OFF. While wiggling

Disconnect ICM at connector

harness, check for continuity to ground at

[10]. Turn ignition key ON.

terminal 3 of connector [91A].

Is BUS Er present?

Is continuity to ground present at any time?

YES

Turn ignition key OFF.

Replace ICM.

Disconnect TSM/TSSM at connector

Reprogram and perform

Locate and repair

Turn ignition switch ON.

[30]. Turn ignition key ON.

password learn.

intermittent short

While wiggling harness,

Is BUS Er present?

to ground.

check for voltage at terminal

3 of connector [91A].

Is voltage present at

any time?

YES

Is vehicle equipped

Replace TSM/TSSM. Per-

YES

with a tachometer?

form password learn.

Locate and repair

No problem

intermittent short

found.

YES

to voltage.

Turn ignition key OFF. Disconnect tachometer

at connector [108]. Turn ignition key ON.

Is BUS Er present?

YES

urn ignition key OFF. Disconnect

Replace tachometer.

speedometer at connector [39].

Check for continuity to ground at

terminal 3 of connector [91A].

Is continuity to ground present?

YES

Locate and repair short

Turn ignition switch ON.

to ground.

Check for voltage at terminal

3 of connector [91A].

Is voltage present?

YES

Clear DTCs using speedometer self diagnostics. See

Locate and repair short

Replace

2.3 SPEEDOMETER SELF DIAGNOSTICS. Confirm

to voltage.

speedometer.

proper operation with no check engine lamp.

2-34

2006 Sportster: Instruments

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TSM/TSSM OVERVIEW

3.1

GENERAL

7844

See Figure 3-1. The turn signal module (TSM) has two major

functions:

● Control turn signals.

● Serve as bank angle sensor.

The optional, factory-installed, security system (turn signal

security module or TSSM) provides the same functionality as

the TSM, but also includes security and immobilization func-

tions.

See 3.2 TSM/TSSM FEATURES for complete details.

TROUBLESHOOTING

Problems fall into at least one of four categories:

● Turn signal malfunction.

Figure 3-1. TSM/TSSM

● Bank angle (engine disable).

● Security lamp problem (TSSM only).

● Security system malfunction (TSSM only).

s0457xtm

To resolve TSM/TSSM problems, four basic steps are

involved. In order of occurrence, they are:

Retrieve diagnostic trouble codes (DTCs) using speed-

ometer self diagnostics. See

3.10 SPEEDOMETER

SELF DIAGNOSTICS.

Diagnose system problems. This involves using special

tools and the diagnostic flow charts in this section.

Correct problems through the replacement and/or repair

of the affected components.

After repairs are performed, the work must be validated.

This involves clearing the diagnostic trouble codes and

confirming proper vehicle operation as indicated by the

behavior of the turn signals.

Figure 3-2. Key Fob

2006 Sportster: TSM & TSSM

3-1

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x0524a3x

Battery

LtGN/BN

Battery

backed siren

(optional)

TSM/TSSM

30 Amp

Main

Fuse

fuse

block

BN/GY

Battery

fuse

ICM

W/BK

Start

switch

IGN fuse

IGN

R/BK

Run/stop

switch

BK/R

R/BK

IGN

R/BK

ACC fuse

Left

Ignition

turn

switch

BATT

TN/GN

Starter

O/W

relay

Starter

Right

turn

switch

Left turn lamps

LtGN/V

BN/V

ICM

LtGN/V

Speedometer

Right turn lamps

security lamp

GND

NOTE

TSM/TSSM Terminal 10 not connected.

Figure 3-3. Simplified TSM/TSSM Wiring

3-2

2006 Sportster: TSM & TSSM

Harley Davidson 2006 Sportster XLH MODELS. Service Manual - page 30