Harley Davidson 2006 Sportster XLH MODELS. Service Manual

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Initial Diagnostic Check (Part 2 of 3)

Continued from Initial Diagnostic Check (Part 1 of 3).

Turn ignition switch ON, is odometer backlight present?

YES

Perform “wow” test.

Replace Speedometer.

See 4.5 SPEEDOMETER SELF DIAGNOSTICS.

The following features should be functional

1) backlight should illuminate

2) needle should sweep its full range of motion

3) LEDs should illuminate:

• check engine

• battery

• security (all models)

Are all features functional?

YES

Turn key to ACC.

Turn key to IGN. Check for

Is backlight present?

battery voltage at Breakout

Box cavity 1 (black).

Is battery voltage present?

YES

Check for battery voltage at

Breakout Box cavity 6 (black).

Replace Speedometer.

Is instrument

fuse blown?

Is battery voltage present?

YES

Locate and repair

Locate and repair open

source of fault.

between terminal 1 of

Replace fuse.

connector [39] and

Replace Speedometer.

Is accessory

instrument fuse.

fuse blown?

YES

STOP

Locate and repair

Locate and repair open on O/W

Go to Initial Diagnostic

source of fault.

wire between terminal 6 of con-

Check (Part 3 of 3).

Replace fuse.

nector [39] and accessory fuse.

2006 Sportster: Engine Management

4-11

HOME

Initial Diagnostic Check (Part 3 of 3)

Continued from Initial Diagnostic Check (Part 2 of 3).

Is problem intermittent?

NO.

YES

Speedometer Inoperative

Tachometer Inoperative

(no vehicle speed).

(no engine speed).

Repeat Diagnostic

Check while wiggling

Remove and inspect

harnesses.

vehicle speed sensor.

See Test 2.4 (Part 1 of 2).

Was intermittent found?

Is debris present?

YES

Locate and repair

No trouble found.

Remove debris. Reinstall

Check for damaged wiring/

intermittent.

vehicle speed sensor.

loose connection between

vehicle speed sensor and ICM.

Is wiring damage/loose

connection present?

YES

Locate and repair

Replace Speedometer.

source of fault.

4-12

2006 Sportster: Engine Management

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SPEEDOMETER SELF DIAGNOSTICS

4.5

GENERAL

11526

The speedometer is capable of displaying and clearing

speedometer, tachometer, TSM/TSSM, and ICM diagnostic

trouble codes (DTCs) (diagnostic mode).

DIAGNOSTICS

Diagnostic Tips

● For a quick check of speedometer function, a “wow” test

can be performed. Press and hold odometer reset switch

(Figure 4-8.) then turn ignition switch (Figure 4-9.) ON.

Release reset switch. See Figure 4-10. Background light-

ing should illuminate, gauge needles should sweep their

full range of motion, and check engine (1), battery (2)

and security (3) indicator lamps should illuminate. The

1. Ignition OFF

security lamp may illuminate even if the vehicle is not

2. ACC ON

equipped with a security system.

3. Ignition ON

● If instrument module fails “wow” test, check for battery,

Figure 4-9. Ignition Switch

ground, ignition and accessory wiring to speedometer. If

any feature in the instrument module is non-functional,

see 2.2 INITIAL DIAGNOSTIC CHECK: SPEEDOME-

TER.

x0523x3x

Diagnostic Notes

Use of speedometer self diagnostics assumes that DIGITAL

TECHNICIAN (Part No. HD-44750) is NOT available.

The reference numbers below correlate with the circled num-

bers in Speedometer Self Diagnostics (flow chart) on the next

page.

1. To exit diagnostic mode, turn ignition switch OFF.

2. To clear DTCs for the selected module, press the speed-

ometer reset switch for more than 5 seconds when a

DTC is displayed. This procedure will clear all DTCs for

the selected module.

10067

Check engine lamp

Battery lamp

Security lamp

Figure 4-10. Speedometer

Figure 4-8. Odometer Reset Switch

2006 Sportster: Engine Management

4-13

HOME

Speedometer Self Diagnostics (flow chart)

While holding odometer reset switch in,

turn ignition switch to IGN.

Release reset switch.

See 2.2 INITIAL DIAGNOSTIC

Does “diag” appear?

CHECK: SPEEDOMETER

YES

Press and release

reset switch.

“PSSPT” appears.

To display DTCs for

the ICM, press and

”P” flashing.

hold reset switch for

more than 5 seconds.

To choose TSM/

TSSM, press and

release reset switch.

To display DTCs for

TSM/TSSM, press and

”S” flashing.

hold reset switch for

more than 5 seconds.

Device

choose Speedometer,

press and release reset

response?

switch.

“no rsp” displayed.

To display DTCs for

YES

See applicable code from

”SP” flashing.

speedometer, press and

other modules. Models

hold reset switch for more

not equipped with a

than 5 seconds.

tachometer will display

“no rsp” normally.

If “no rsp” displayed on

To choose Tachometer,

“none” displayed.

odometer on tachometer

press and release reset

DTC displayed.

equipped vehicle,

switch.

see 2.4 SPEEDOMETER/

TACHOMETER.

To display DTCs for

tachometer, press and

Press and release

”T” flashing.

hold reset switch for more

reset switch. Part num-

reset switch. More

than 5 seconds.

ber of module will be

DTCs displayed?

displayed.

To choose ICM, press and

release reset switch.

YES

“end” displayed. To clear all

DTCs for selected module hold

reset switch for more than 5

seconds. If DTCs are not to be

cleared, Press and release reset

switch. Part number of module

will be displayed.

Press and release reset

switch again to continue to

next module.

4-14

2006 Sportster: Engine Management

HOME

BREAKOUT BOX: ICM

4.6

GENERAL

10057

The BREAKOUT BOX (Part No. HD-42682) splices into the

main harness. Used in conjunction with a DVOM, it allows cir-

cuit diagnosis of wiring harness and connections without hav-

ing to probe with sharp objects.

INSTALLATION

Remove seat. See the Sportster Service Manual for

details.

See Figure 4-11. Depress latches on connector [10] to

separate pin and socket halves.

See Figure 4-12. Attach Breakout Box as follows:

a. Mate black socket housing on Breakout Box with

ICM connector [10A].

b. Mate black pin housing on Breakout Box with har-

ness connector [10B].

Figure 4-11. ICM Connector [10]

REMOVAL

1. See Figure 4-12. Remove Breakout Box as follows:

a. Remove black socket housing on Breakout Box from

ICM connector [10A].

b. Remove black pin housing on Breakout Box from

harness connector [10B].

2. See Figure 4-11. Mate pin and socket halves of ICM con-

nector [10].

3. Install seat.

f2001x8x

Connect Black Side

Only for Tests

f1998x9x

Figure 4-12. Breakout Box (Part No. HD-42682)

2006 Sportster: Engine Management

4-15

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WIGGLE TEST

4.7

GENERAL

hd39978

The wiggle test indicates the presence of intermittents in a

wiring harness.

PROCEDURE

Using DVOM (Part No. HD-39978)

1. See Figure

4-13. Connect DVOM to wiring harness

between the suspect connections. When diagnosing igni-

tion control module connections, a BREAKOUT BOX

Figure 4-13. Fluke 78 Multimeter (DVOM)

(Part No. HD-42682) may be used to simplify the proce-

(Part No. HD-39978)

dure. See 4.6 BREAKOUT BOX: ICM.

2. Set DVOM to read voltage changes.

3. Start motorcycle engine and run at idle.

4. Shake or wiggle harness to detect intermittents. If inter-

mittents are present, radical voltage changes will register

on the DVOM.

4-16

2006 Sportster: Engine Management

HOME

INTAKE LEAK TEST

4.8

GENERAL

11479

1DANGER

Propane is an extremely flammable liquid and vapor.

Vapor may cause flash fire. Keep away from heat, sparks

and flame. Keep container closed. Use only with ade-

quate ventilation. Failure to follow this alert can result in

death or serious injury.

1WARNING

Read all directions and warnings on propane bottle. Fail-

ure to follow all directions and warnings on bottle could

result in death or serious injury.

NOTES

● To prevent false readings, keep air cleaner cover

installed when performing test.

● Do not direct propane into air cleaner, false readings will

result.

LEAK TESTER

Parts List

● Standard 14 oz. propane cylinder.

● Propane Enrichment Kit (Part No. HD-41417).

Tester Assembly

1. See Figure 4-14. Make sure valve knob (6) is closed

(fully clockwise).

Screw valve assembly (5) onto propane bottle (1).

Propane bottle

Nozzle

Tester Adjustment

Copper tube

1. See Figure 4-14. Press and hold trigger button (8).

Hose

2. Slowly open valve knob (6) until pellet in flow gauge (7)

Valve assembly

Valve knob

rises to between 5 and 10 SCFH on gauge.

Flow gauge

3. Release trigger button.

Trigger button

Hanger

Figure 4-14. Leak Tester

2006 Sportster: Engine Management

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PROCEDURE

11482

1. Start engine.

2. Warm up engine to operating temperature.

1DANGER

Propane is an extremely flammable liquid and vapor.

Vapor may cause flash fire. Keep away from heat, sparks

and flame. Keep container closed. Use only with ade-

quate ventilation. Failure to follow this alert can result in

death or serious injury.

NOTE

Do not direct propane stream toward air cleaner. If propane

enters air cleaner, a false reading will be obtained.

3. See Figure 4-15. Aim nozzle (3) toward possible sources

of leak such as intake manifold mating surfaces.

4. Push trigger button

(2) to release propane. Tone of

engine will change when propane enters source of leak.

5. When test is finished, release trigger button and close

valve knob (turn knob fully clockwise).

Propane bottle

Trigger button

Nozzle

Figure 4-15. Checking for Leaks

4-18

2006 Sportster: Engine Management

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ENGINE CRANKS BUT WILL NOT START

4.9

GENERAL

d0273x8x

If starter will not crank engine, the problem is not ignition

related. See SECTION 1 - STARTING & CHARGING 1.

Engine can be started with diagnostic test wire installed or if

the receive data line is grounded. Ignition key switch must be

turned OFF after test wire is removed or check engine lamp

will continue to flash stored diagnostic trouble codes (DTCs).

DIAGNOSTICS

Diagnostic Notes

The reference numbers below correlate with the circled num-

Figure 4-16. Spark Tester

bers on the Test 4.9 flow charts.

1. Check for DTCs. See RETRIEVING DIAGNOSTIC

TROUBLE CODES under 4.3 CHECKING FOR DIAG-

NOSTIC TROUBLE CODES.

10561

2. Check the condition of the battery. Perform a voltage test

and recharge if below 12.60V. Check battery connections

and perform either a conductance test (using MCR-101

HD Electrical System Analyzer) or load test. Replace the

battery if necessary.

3. Remove spark plug cable from spark plug.

a. Visually check condition of plug.

b. See Figure 4-16. Attach cable to SPARK TESTER

(Part No. HD-26792). Clip tester to cylinder head

bolt.

c. While cranking engine, look for spark. Repeat pro-

cedure on other spark plug cables.

NOTE

Engine will not spark with both spark plugs removed. When

checking for spark, use SPARK TESTER (Part No. HD-

26792) with both plugs installed.

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

41404) gray pin probes and patch cords.

5. See Figure 4-17. Plug IGNITION COIL CIRCUIT TEST

ADAPTER (Part No. HD-44687) and FUEL INJECTOR

TEST LAMP (Part No. HD-34730-2C) into Breakout Box

cavities 1 and 6.

NOTE

Figure 4-17. Ignition Coil Circuit Test

Cranking the engine with test lamp in place of the ignition coil

can sometimes cause a DTC P1351 or P1352 to be set. This

condition is normal and does not by itself indicate a malfunc-

tion. Clear DTCs afterward.

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

between ICM connector [10A] and wire harness connec-

tor [10B]. See 4.6 BREAKOUT BOX: ICM.

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

41404), brown socket probe and patch cord.

2006 Sportster: Engine Management

4-19

HOME

x0538b4x

Engine

Stop Switch

To TSM/TSSM connector [30] terminal 2 and

diagnostic link connector [91A] terminal 4

[22B]

[22A]

15 Amp

Ignition Fuse

R/BK To Ignition Switch

W/BK

Crank

Position

Sensor

Ignition

(CKP)

Coil

[83A]

[83B]

[79A]

[79B]

W/BK

Y/BE

BE/O

W/BK

[10B]

[10A]

Ignition Control Module (ICM)

Figure 4-18. Ignition Circuit Diagram

Table 4-9. Wire Harness Connectors in Figure 4-18.

NO.

DESCRIPTION

TYPE

LOCATION

[10]

Ignition control module

12-Place Deutsch

under seat

[22]

Right handlebar switch controls

6-Place Deutsch

under fuel tank

[79]

CKP sensor

2-place mini-Deutsch

under engine, left side

[83]

Ignition coil

3-place Packard

on coil, under fuel tank

4-20

2006 Sportster: Engine Management

HOME

Test 4.9 (Part 1 of 3)

ENGINE CRANKS, BUT WILL NOT START

Is there fresh fuel in tank?

Are spark plug wires firmly

connected to coil terminals?

Add fuel and/

or connect

spark plugs.

YES

Check battery

Check for DTCs.

connections and voltage.

Any DTCs found?

Is voltage above 12.60?

YES

Does battery pass conductance

Recharge battery.

Refer to priority listing

test or load test?

in Table 4-7.

YES

Check spark plug condition,

Replace battery.

replace if fouled. Check spark at

both plugs while cranking.

Is spark present?

YES

Check compression. See the Sportster

Turn ignition ON and engine

Service Manual. If compression is good,

stop switch to RUN.

check fuel system.

Does check engine lamp

illuminate for 4 seconds

immediately after Key ON?

YES

Check battery voltage at W/BK wire

See

connector [83B] using DVOM.

4.11 NO SPARK/NO ICM

Is battery voltage present?

POWER.

YES

Locate and repair open on

Go to Test 4.9

STOP

W/BK wire to coil.

(Part 2 of 3).

2006 Sportster: Engine Management

4-21

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Test 4.9 (Part 2 of 3)

ENGINE CRANKS, BUT WILL NOT START

Continued from Test 4.9 (Part 1 of 3).

Front coil code: check between Breakout

Box cavities 1 (black) and 6 (black).

Does test lamp flash when engine is cranked?

YES

Check coil connections.

Check continuity between BE/O wire

Are connections OK?

terminal of connector [83B] and

Breakout Box cavity 6 (black).

Is resistance less than 1.0 ohm?

YES

Test spark plug cable resis-

Repair.

tance. See 4.12 MISFIRE.

Is resistance OK?

YES

Connect DVOM to Breakout

Poor connection at

Box cavities 8 (black) and 9 (black).

connector [10B] or open

YES

Set DVOM for AC volts.

in harness between coil

Crank engine.

and ICM. Repair open.

Are plug wires in

Replace spark

Does DVOM read 1 VAC minimum?

correct coil towers?

plug cables.

YES

Disconnect CKP sensor connector

Replace

Route

[79]. Check connector for moisture and

coil.

correctly.

STOP

corrosion. Check wires for chafing.

Connect DVOM to terminals 1 and 2 of

connector [79A]. Crank engine.

Go to Test 4.9

(Part 3 of 3).

Does DVOM read 1 VAC minimum?

YES

Check for continuity between

With meter still connected,

socket 1 of connector [79B]

check for resistance.

and Breakout Box cavity 8.

Is resistance 600-1200 ohms?

Is continuity present?

YES

Remove and inspect

Replace CKP

Locate and repair open on

CKP sensor. Remove

sensor.

BK wire between socket 2 of

R wire between socket 1 of con-

any debris on sensor.

connector [79B] and socket 9

nector [79B] and socket 8 of

Reinstall sensor.

of connector [10B].

connector [10B].

4-22

2006 Sportster: Engine Management

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STARTS THEN STALLS

4.10

GENERAL

11313

Serial Data Low or Serial Data Open/High

See Figure 4-19. 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 4-10. Code Description

DTC

DESCRIPTION

U1300

Serial data low

U1301

Serial data open/high

Figure 4-19. Diagnostic Link Connector [91A]

(Behind Left Side Cover)

DIAGNOSTICS

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

Diagnostic Tips

between ICM connector [10A] and wire harness connec-

● If serial data is shorted, these diagnostic trouble codes

tor

[10B]. See

4.6 BREAKOUT BOX: ICM. Connect

(DTCs) will automatically cause the check engine lamp

BREAKOUT BOX (Part No. HD-42682) (gray) between

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

TSM/TSSM connector [30A] and wire harness connector

dition.

[30B]. See 3.11 BREAKOUT BOX: TSM/TSSM.

● DTCs P1009 and P1010 may accompany DTCs U1300

Use HARNESS CONNECTOR TEST KIT (Part No. HD-

and U1301.

41404), black socket probes and patch cord.

Historic DTC U1300 would have been set. Clear historic

Diagnostic Notes

DTCs.

The reference numbers below correlate with the circled num-

bers on the Test 4.10 flow charts.

Check for DTCs. See RETRIEVING DIAGNOSTIC

TROUBLE CODES under 4.3 CHECKING FOR DIAG-

NOSTIC TROUBLE CODES.

4-24

2006 Sportster: Engine Management

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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

Diagnostic link

connector

BN/GY

15A

BATT

LtGN/V

15A

INST

15A

[91A]

[91B]

IGN

Fuse

block

LtGN/V

[10B]

[10A]

Ignition Control Module (ICM)

Figure 4-20. Serial Data Circuit

Table 4-11. Wire Harness Connectors in Figure 4-20.

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

cavity in bottom of battery tray

[39]

Speedometer

12-place Packard

back of speedometer

[91A]

Diagnostic link connector

4-place Deutsch

behind left side cover

[108]

Tachometer

12-place Packard

back of tachometer

2006 Sportster: Engine Management

4-25

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Test 4.10 (Part 1 of 2)

Starts Then Stalls: DTC U1300, U1301 OR BUS ER

Is there fresh

fuel in tank?

YES

Check for DTCs using 4.5 SPEEDOMETER

Add fuel.

SELF DIAGNOSTICS.

Any DTCs found?

YES.

NO.

DTC P1009,

DTC U1300 or

BUS Er present.

No DTCs 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 (runs longer

when propane is present)?

STOP

YES

Go to Test 4.10

(Part 2 of 2).

Replace intake

Replace ICM.

manifold seals.

Reprogram and learn

password.

Clear DTCs using speedometer self diagnostics. See

4.5 SPEEDOMETER SELF DIAGNOSTICS. Confirm

proper operation with no check engine lamp.

* See 4.8 INTAKE LEAK TEST for instructions.

4-26

2006 Sportster: Engine Management

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Test 4.10 (Part 2 of 2)

Starts, Then Stalls: DTC U1300, U1301 OR BUS ER

Continued from Test 4.10 (Part 1 of 2)

Test the three diagnostic link connector [91A] terminals for continuity.

DIAGNOSTIC LINK

BREAKOUT BOX

CONNECTOR [91A]

(BLACK)

Terminal

Wire Color

Cavity

N/A

Lt. GN/V

GY terminal on left

side of ignition fuse

Is continuity present in all three circumstances?

YES

Disconnect ICM at

Inspect terminals

connector [10].

for damage or repair

Does speedometer display

opens as necessary.

TSM/TSSM data?

YES

Replace ICM. Reprogram

Disconnect TSM/TSSM at connector

and learn password.

[30]. Check for continuity to ground

at terminal 3 of connector [91A].

Is there continuity to ground?

YES

Locate and repair short

Check for voltage at terminal 3

to ground.

of connector [91A].

Is voltage present?

YES

Locate and repair short

Replace TSM/TSSM. Reprogram

to voltage.

and learn password.

Is system OK?

YES

System

Disconnect connector [39].

OK.

Is system OK?

YES

Replace

speedometer.

tachometer if

equipped.

2006 Sportster: Engine Management

4-27

HOME

NO SPARK/NO ICM POWER

4.11

GENERAL

DIAGNOSTICS

The ignition control module turns on when power is applied to

terminal 1 of connector [10]. The ignition control module goes

Diagnostic Notes

through an initialization sequence every time power is

removed and re-applied to terminal 1. The only visible part of

The reference numbers below correlate with the circled num-

this sequence is the check engine lamp. Upon starting, the

bers on the Test 4.11 flow chart.

check engine lamp will illuminate for 4 seconds and then (if

See FUSES in the Sportster Service Manual.

parameters are normal) turn off.

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

between ICM connector [10A] and wire harness connec-

tor [10B]. See 4.6 BREAKOUT BOX: ICM.

Use HARNESS CONNECTOR TEST KIT (Part No. HD-

4104), black pin probe and patch cord.

4-28

2006 Sportster: Engine Management

HOME

x0540a4x

Engine

Stop Switch

To TSM/TSSM connector [30] terminal 2 and

diagnostic link connector [91A] terminal 4

[22B]

15 Amp

[22A]

Ignition Fuse

R/BK To Ignition Switch

W/BK

Ignition

Coil

[83A]

[83B]

W/BK

Y/BE

W/BK

BE/O

[10B]

[10A]

Ignition Control Module (ICM)

Figure 4-21. Ignition Control Module Power Circuit Diagram

Table 4-12. Wire Harness Connectors in Figure 4-21.

NO.

DESCRIPTION

TYPE

LOCATION

[10]

Ignition control module

12-place Deutsch

under seat

[22]

Right handlebar switch controls

6-place Deutsch

under fuel tank

[83]

Ignition coil

3-place Packard

on coil, under fuel tank

2006 Sportster: Engine Management

4-29

HOME

Test 4.11

NO SPARK/NO ICM POWER

Check ignition

fuse.

Is fuse OK?

YES

With ignition ON, place multimeter red

Replace fuse

wire on Breakout Box cavity 1 (black)

and find source

and multimeter black wire on Breakout

of fault.

Box cavity 5 (black).

Is voltage 12V± 1.0V.?

YES

Replace ICM.

Check continuity between Breakout

Box cavity 5 (black) and ground.

Is continuity present?

YES

Check continuity between terminal

Repair open in BK

4 (W/BK) of connector [22A] and

wire (cavity 5) to

Breakout Box cavity 1 (black).

ground.

Is continuity present?

YES

Check continuity between

Locate and repair

sockets 4 (W/BK) and 3 (GY)

open in W/BK wire

of connector [22B] with engine

between connectors

stop switch ON.

[22] and [10].

Is continuity present?

YES

Locate and repair open

Replace

in GY wire between

engine stop

connector [22A] and

switch.

fuse block.

Clear DTCs using speedometer self diagnostics. See

4.5 SPEEDOMETER SELF DIAGNOSTICS. Confirm

proper operation with no check engine lamp.

4-30

2006 Sportster: Engine Management

Harley Davidson 2006 Sportster XLH MODELS. Service Manual - page 35