Harley Davidson 2006 Sportster XLH MODELS. Service Manual - page 37
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DTC P0602, P0603, P0604, P0605, P0607
4.17
GENERAL
DIAGNOSTICS
ICM Failure
DTC P0607 Test
All of the following diagnostic trouble codes (DTCs) indicate
1. Power down the vehicle.
an internal failure which requires replacement of the ignition
2. Clear DTCs using speedometer self-diagnostics.
control module. See the Sportster Service Manual for
3. Replace ICM if DTCs reappear.
replacement procedures.
● DTC P0602 - Calibration memory error
● DTC P0603 - EEPROM failure
DTC P0602, P0603, P0604, P0605 Test
● DTC P0604 - RAM failure
1.
Power down the vehicle.
● DTC P0605 - Program memory error
2.
Clear DTCs.
● DTC P0607 - A to D converter error
3.
Using Digital Technician, reprogram ICM using the cor-
rect calibration. See your dealer.
NOTE
4.
Restart vehicle. If DTC reappears, replace ICM. Repro-
Dealership technicians filing warranty claims should use job/
gram and perform password learn.
time code 7913 for all DTC P0602, P0603, P0604, P0605 and
P0607 ICM replacements.
2006 Sportster: Engine Management
4-51
HOME
DTC P1009, P1010
4.18
GENERAL
7844
Password Problem
The ICM and TSM/TSSM exchange passwords during opera-
tion. An incorrect password or missing password will set a
DTC, and vehicle starts, then stalls.
NOTE
See Figure 4-32. If the TSM/TSSM is not connected to the
wiring harness, the vehicle will not start.
Table 4-23. Code Description
DTC
DESCRIPTION
P1009
Incorrect password
P1010
Missing password
Figure 4-32. TSM/TSSM Module
DIAGNOSTICS
10073
Diagnostic Notes
1
The reference numbers below correlate with the circled num-
bers on the Test 4.18 flow charts.
4
5
1.
DTC P1009 may be set if a recent ICM or TSM/TSSM
replacement did not follow the correct password assign-
ment procedure. See
3.23 PASSWORD LEARN for
details.
2.
Use HARNESS CONNECTOR TEST KIT (Part No. HD-
3
41404), black socket probes and patch cord.
3.
Connect BREAKOUT BOX (Part No. HD-42682) (black)
2
between ICM connector [10A] and wire harness connec-
tor [10B]. See 4.6 BREAKOUT BOX: ICM.
4.
See TURN SIGNAL/SECURITY MODULE, REMOVAL/
1.
Terminal 1: no connection
INSTALLATION, in the Sportster Service Manual. If nec-
2.
Terminal 2: ground (BK)
essary, be sure to reference the Electrical Diagnostic
3.
Terminal 3: serial data (LtGN/V)
Manual for the password learn routine.
4.
Terminal 4: power (GY)
5.
Protective cap
11313
Figure 3-33. Diagnostic Link Connector [91A] Terminals
Figure 4-31. Diagnostic Link Connector [91A]
(Left Side Cover Removed)
4-52
2006 Sportster: Engine Management
HOME
x0541x4x
15 Amp
Ignition Fuse
LtGN/V
GY
BN/GY
15 Amp
Battery Fuse
[30B]
1
2
3
4 5 6 7 8 9 10 11 12
[30A]
1
2
3
4 5 6 7 8 9 10 11 12
TSM/TSSM
1
BK
2
Diagnostic Link
LtGN/V
3
Connector
GY
4
[91A]
[10B]
1
2
3
4 5 6 7 8 9 10 11 12
12V
[10A]
1
2
3
4 5 6 7 8 9 10 11 12
ICM
Figure 4-34. ICM and TSM/TSSM Circuit
Table 4-24. Wire Harness Connectors in Figure 4-34.
NO.
DESCRIPTION
TYPE
LOCATION
[10]
Ignition control module
12-place Deutsch
under seat
[30]
TSM/TSSM
12-place Deutsch
under battery
[91]
Diagnostic link connector
4-place Deutsch
behind left side cover
2006 Sportster: Engine Management
4-53
HOME
Test 4.18
PASSWORD PROBLEM: DTC P1009, P1010
Which DTC was set?
1
DTC P1009. Bad password.
DTC P1010. No password.
Reprogram password. See
Are there any U-codes set?
4
3.23 PASSWORD LEARN.
Does DTC P1009 still exist?
YES
NO
YES
NO
2
4
Troubleshoot
Remove Connector [10].
Replace TSM/TSSM
System
lowest U-code.
Check for continuity to ground at
and relearn password.
OK.
terminal 3 of Connector [91A].
Is system OK?
Is continuity present?
YES
NO
YES
NO
4
Locate and repair
Check for battery voltage
System
Reinstall original TSM/
short to ground.
on terminal 3 of Connector [91A].
OK.
TSSM and replace ICM.
Is battery voltage present?
Reprogram and
relearn password.
YES
NO
2
Locate and repair
Check for continuity between
short to voltage.
3
terminal 3 of Connector [91A]
and Breakout Box cavity 12.
Is continuity present?
YES
NO
4
2
Replace TSM/TSSM and
Inspect terminals
relearn password.
for damage or repair
Is system OK?
opens as necessary.
YES
NO
4
System
Reinstall original TSM/
OK.
TSSM and replace ICM.
Reprogram and
relearn password.
Clear DTCs using speedometer self diagnostics. See
4.5 SPEEDOMETER SELF DIAGNOSTICS. Confirm
proper operation with no security lamp.
4-54
2006 Sportster: Engine Management
HOME
DTC P1351, P1352, P1354, P1355
4.19
GENERAL
10561
Ignition Coil
Ignition coil DTCs will set if the ignition coil primary voltage is
out of range. This could occur if there is an open coil or loss of
power to the coil. If front and rear DTCs are set simulta-
neously, it is likely a coil power failure or a coil failure has
occurred.
The coil receives power from the engine run/stop switch. The
ignition control module is responsible for turning on the coils
by providing the ground to activate the coils, which in turn
powers the coils.
Table 4-25. Code Description
DTC
DESCRIPTION
P1351
Front ignition coil open/low
P1352
Front ignition coil high/shorted
P1354
Rear ignition coil open/low
P1355
Rear ignition coil high/shorted
Figure 4-35. Ignition Coil Circuit Test
DIAGNOSTICS
x0560x4x
Coil tower
Diagnostic Notes
3
The reference numbers below correlate with the circled num-
bers on the Test 4.19 flow charts.
1. Use HARNESS CONNECTOR TEST KIT (Part No. HD-
41404), gray pin probes and patch cord.
2
CAUTION
Gently connect test lamp to connector [83B]. Forcefully
inserting test lamp will result in ignition connector termi-
1
nal damage.
2. See Figure 4-35. Plug IGNITION COIL CIRCUIT TEST
ADAPTER (Part No. HD-44687) and FUEL INJECTOR
Figure 4-36. Ignition Coil Connector Terminals
TEST LAMP (Part No. HD-34730-2C) into Breakout Box.
Note that cranking the engine with test lamp in place of
the ignition coil can sometimes cause a DTC P1351,
P1352, P1354 or P 1355. This condition is normal and
does not by itself indicate a malfunction. DTCs must be
cleared if this condition occurs.
Table 4-26. Coil Terminal Description
3. Connect BREAKOUT BOX (Part No. HD-42682) (black)
between ICM connector [10A] and wire harness connec-
TERMINAL
DESCRIPTION
WIRE COLOR
tor [10B]. See 4.6 BREAKOUT BOX: ICM.
4. Use HARNESS CONNECTOR TEST KIT (Part No. HD-
1
Rear coil
Y/BE
41404), gray socket probes and patch cord.
2
Power
W/BK
3
Front coil
BE/O
2006 Sportster: Engine Management
4-55
HOME
x0540x4x
Engine
Stop Switch
To TSM/TSSM connector [30] terminal 2 and
diagnostic link connector [91A] terminal 4
GY
1
2
3
4
5
6
[22B]
15 Amp
[22A]
Ignition Fuse
R/BK To Ignition Switch
GY
W/BK
Ignition
Coil
1
2
3
[83A]
[83B]
W/BK
Y/BE
W/BK
BE/O
BK
[10B]
[10A]
Ignition Control Module (ICM)
Figure 4-37. Ignition Coil Circuit Diagram
Table 4-27. Wire Harness Connectors in Figure 4-37.
NO.
DESCRIPTION
TYPE
LOCATION
[10]
Ignition control module
12-place Deutsch
under seat
[22]
Right handlebar control
6-place Deutsch
under fuel tank
[83]
Ignition coil
3-place Packard
on coil, under fuel tank
4-56
2006 Sportster: Engine Management
HOME
Test 4.19 (Part 1 of 2)
IGNITION COIL: DTC P1351, P1352, P1354, P1355
1
Disconnect coil connector [83]. Turn
ignition switch ON. Measure voltage on
terminal 2 of wire harness connector.
Is voltage equal to battery voltage
during first two seconds after key ON?
YES
NO
2
Front coil codes: Check between Breakout
Repair open wire or
3
Box cavity 6 and cavity 1.
connection on W/BK wire.
Rear coil codes: Check between Breakout
Box cavity 7 and cavity 1.
Does test lamp flash when engine is cranked?
YES
NO
4
Measure coil resistance.
Replace ICM.
Front coil codes: Check between coil
Reprogram and
Terminal 2 and Terminal 3.
perform password learn.
Rear coil codes: Check between coil
Terminal 2 and Terminal 1.
Is resistance 0.5-0.7 ohms?
YES
NO
Replace coil.
See Sportster Service
STOP
Manual
Go to Test 4.19
(Part 2 of 2).
Clear DTCs using speedometer self diagnostics. See
4.5 SPEEDOMETER SELF DIAGNOSTICS. Confirm
proper operation with no security lamp.
2006 Sportster: Engine Management
4-57
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Test 4.19 (Part 2 of 2)
IGNITION COIL: DTC P1351, P1352, P1354, P1355
Continued from Test 4.19 (Part 1 of 2).
Using Breakout Box, measure resistance between ICM and coil
1
terminals as follows.
COIL
BREAKOUT
3
DTC
TERMINAL
BOX CAVITY
P1351/
3
6
P1352
(BE/O wire)
P1354/
1
7
P1355
(Y/BE wire)
Is resistance less than 0.5 ohms?
YES
NO
Perform 4.7 WIGGLE TEST
Repair open wire
to check for intermittents.
or connection.
Are intermittents present?
YES
NO
Repair
Check for continuity to ground.
intermittent.
Front coil codes: Check Breakout Box cavity 6.
Rear coil codes: Check Breakout Box cavity 7.
Is continuity present?
YES
NO
Repair short
Check for voltage.
to ground.
Front coil codes: Check Breakout Box cavity 6.
Rear coil codes: Check Breakout Box cavity 7.
Is voltage present?
YES
NO
Repair short
Replace ICM.
to voltage.
Reprogram and
learn password.
Clear DTCs using speedometer self diagnostics. See
4.5 SPEEDOMETER SELF DIAGNOSTICS. Confirm
proper operation with no security lamp.
4-58
2006 Sportster: Engine Management
HOME
DTC U1064
4.20
GENERAL
7844
Loss of TSM/TSSM Serial Data
The serial data line provides a means for the ICM and TSM/
TSSM to communicate their current status. When all operat-
ing parameters are within specifications, a state of health
message is sent between the components. A DTC U1064
indicates that the TSM/TSSM is not capable of sending this
state of health message.
Table 4-28. Code Description
DTC
DESCRIPTION
U1064
Loss of TSM/TSSM serial data
Figure 4-38. TSM/TSSM
DIAGNOSTICS
10073
Diagnostic Notes
1
The reference number below correlates with the circled num-
4
5
ber on the Test 4.20 flow chart.
1. Connect BREAKOUT BOX (Part No. HD-42682) as fol-
lows:
a. Mate black socket housing on Breakout Box with
3
speedometer connector [39A] (at the back of the
speedometer) using INSTRUMENT HARNESS
ADAPTERS (Part No.HD-46601).
2
b. Mate black pin housing on Breakout Box with wire
harness connector [39B] using INSTRUMENT HAR-
NESS ADAPTERS (Part No.HD-46601).
1.
Terminal 1: no connection
c. Mate gray socket housing on Breakout Box with
2.
Terminal 2: ground (BK)
TSM/TSSM connector [30A].
3.
Terminal 3: serial data (LtGN/V)
4.
Terminal 4: power (GY)
d. Mate gray pin housing on Breakout Box with wire
5.
Protective cap
harness connector [30B].
Figure 4-39. Diagnostic Link Connector
2006 Sportster: Engine Management
4-59
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x0522a3x
BK
LtGN/V
O
LtGN/V
O/W
BN/GY
GY
BK
Odometer
reset switch
BN/GY
1
2
3
4 5 6 7 8 9 10 11 12
[39B]
[30B]
1
2
3
4 5 6 7 8 9 10
11
12
1
2
3
4 5 6 7 8 9 10 11 12
1
2
3
4 5 6 7 8 9 10
11
12
[39A]
[30A]
Speedometer
TSM/TSSM
[108B]
1
2
3
4 5 6 7 8 9 10
11
12
1
2
3
4 5 6 7 8 9 10
11
12
[108A]
Tachometer
[20B]
(if equipped)
1
2
3
4
5 67 8
9
10
11 12
[20A]
1
2
3
4
5 67 8
9
10
11 12
BK
15A
ACC
Diagnostic link
connector
BN/GY
15A
1
1
BATT
BK
2
2
LtGN/V
3
3
15A
INST
4
4
GY
15A
[91A]
[91B]
IGN
Fuse
block
LtGN/V
[10B]
1
2
3
4
5
6
7
8
9
10
11
12
[10A]
Ignition Control Module (ICM)
Figure 4-40. Serial Data Circuit
Table 4-29. Wire Harness Connectors in Figure 4-40.
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]
Diagnostic link connector
4-place Deutsch
behind left side cover
[108]
Tachometer (if equipped)
12-place Packard
back of tachometer
4-60
2006 Sportster: Engine Management
HOME
Test 4.20
LOSS OF TSM/TSSM SERIAL DATA: DTC U1064
Can you read TSM/TSSM hardware Part No.?
See 4.5 SPEEDOMETER SELF DIAGNOSTICS.
YES
NO or “No rsp”
1
1
While wiggling harness, check for
Check for continuity between
continuity between Breakout Box cavity
Breakout Box cavity 3 (gray)
3 (gray) and cavity 2 (black).
and cavity 2 (black).
Is continuity present?
Is continuity present?
YES
NO
YES
NO
Clear DTCs. Test Ride.
Repair intermittent on
Replace TSM/TSSM.
Repair open on
Did DTC U1064 return?
Lt GN/V wire.
Perform password learn.
Lt GN/V wire.
YES
NO
Replace TSM/TSSM.
No trouble found.
Perform password learn.
Clear DTCs using speedometer self diagnostics. See
4.5 SPEEDOMETER SELF DIAGNOSTICS. Confirm
proper operation with no security lamp.
2006 Sportster: Engine Management
4-61
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DTC U1097
4.21
GENERAL
10057
Loss of Speedometer Serial Data
The serial data line provides a means for the speedometer,
ICM and TSM/TSSM to communicate their current status.
When all operating parameters are within specifications, a
state of health message is sent between the components. A
diagnostic trouble code
(DTC) U1097 indicates that the
speedometer is not capable of sending this state of health
message.
Table 4-30. Code Description
DTC
DESCRIPTION
Loss of all speedometer serial data
U1097
Figure 4-41. ICM Connector [10]
(state of health)
10073
DIAGNOSTICS
1
Diagnostic Notes
4
5
The reference numbers below correlate with the circled num-
bers on the Test 4.21 flow chart.
1. Connect BREAKOUT BOX (Part No. HD-42682) (black)
to wire harness connector [39B] using INSTRUMENT
3
HARNESS ADAPTERS (Part No. HD-46601). Leave
speedometer [39A] disconnected. See 2.5 BREAKOUT
2
BOX: SPEEDOMETER/TACHOMETER.
2. Use HARNESS CONNECTOR ADAPTER KIT (Part No.
HD-41404), black pin probe and patch cord.
1.
Terminal 1: no connection
2.
Terminal 2: ground (BK)
3.
Terminal 3: serial data (LtGN/V)
4.
Terminal 4: power (GY)
5.
Protective cap
Figure 4-42. Diagnostic Link Connector
4-62
2006 Sportster: Engine Management
HOME
x0522a3x
BK
LtGN/V
O
LtGN/V
O/W
BN/GY
GY
BK
Odometer
reset switch
BN/GY
1
2
3
4 5 6 7 8 9 10 11 12
[39B]
[30B]
1
2
3
4 5 6 7 8 9 10 11 12
1
2
3
4 5 6 7 8 9 10 11 12
1
2
3
4 5 6 7 8 9 10 11 12
[39A]
[30A]
Speedometer
TSM/TSSM
[108B]
1
2
3
4 5 6 7 8 9 10 11
12
1
2
3
4 5 6 7 8 9 10 11
12
[108A]
Tachometer
[20B]
(if equipped)
1
2
3
4
5 67 8 9
10
11 12
[20A]
1
2
3
4
5 67 8 9
10
11 12
BK
15A
ACC
Diagnostic link
connector
BN/GY
15A
1
1
BATT
BK
2
2
LtGN/V
3
3
15A
INST
4
4
GY
15A
[91A]
[91B]
IGN
Fuse
block
LtGN/V
[10B]
1
2
3
4
5
6
7
8
9
10
11
12
[10A]
Ignition Control Module (ICM)
Figure 4-43. Serial Data Circuit
Table 4-31. Wire Harness Connectors in Figure 4-43.
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]
Diagnostic link connector
4-place Deutsch
behind left side cover
[108]
Tachometer (if equipped)
12-place Packard
back of tachometer
2006 Sportster: Engine Management
4-63
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Test 4.21
LOSS OF SPEEDOMETER SERIAL DATA: DTC U1097
IMPORTANT!
Always perform Initial Diagnostic Check first.
See 4.4 INITIAL DIAGNOSTIC CHECK: ICM.
Can you read ICM hardware Part No.?
See 4.5 SPEEDOMETER SELF DIAGNOSTICS.
YES
NO or “No rsp”
1
1
While wiggling harness, check for continuity
Check continuity between Breakout
between Breakout Box cavity 2 (black) and
Box cavity 2 (black) and terminal 12
2
2
terminal 12 of connector [10B].
of connector [10B].
Is continuity present?
Is continuity present?
YES
NO
YES
NO
Replace speedometer.
Repair open on
Lt GN/V wire.
Clear DTCs. Test ride.
Repair intermittent on
Did U1097 return?
Lt GN/V wire.
YES
NO
Replace speedometer
No trouble found.
Clear DTCs using speedometer self diagnostics. See
4.5 SPEEDOMETER SELF DIAGNOSTICS. Confirm
proper operation with no security lamp.
4-64
2006 Sportster: Engine Management
HOME
CONNECTOR LOCATIONS
5.1
Table 5-1. Sportster Connector Locations
CONNECTOR
DESCRIPTION
TYPE
LOCATION
NO.
[5]
Maxi-Fuse
spade terminals
on battery strap, behind left side cover
[7]
tail lamp harness to main harness
6-place Multilock, black
under seat
[10]
ignition control module (ICM)
12-place Deutsch, black
under seat
[18]
left rear turn signal
2-place Multilock, white
inside tail lamp lens
[19]
right rear turn signal
2-place Multilock, black
inside tail lamp lens
[20]
instruments
12-place Deutsch, black
under fuel tank
[22]
right hand controls
6-place Deutsch, black
under fuel tank
[24]
left hand controls and horn
6-place Deutsch, gray
under fuel tank
[30]
TSM/TSSM
12-place Deutsch, gray
under battery
[31]
front turn signals
6-place Multilock, black
under fuel tank
[33]
ignition key switch
-
right side of frame behind neck
[38]
headlamp
4-place Multilock, black
under fuel tank
[39]
speedometer
12-place Packard Micro-64, black
back of speedometer
[46]
voltage regulator to stator
2-place round molded, black
in front of engine crankcase
[61]
relay/fuse block
spade terminals
behind left side cover
[62]
starter relay
5-place Amp
fuse/relay block, behind left side cover
[65]
vehicle speed sensor (VSS)
3-place Packard, black
right rear top of crankcase
[77]
voltage regulator (D.C. output)
2-place Packard, black
in front of engine crankcase
[79]
crank position sensor (CKP)
2-place Deutsch, black
left side, frame, beneath primary cover
manifold absolute pressure
[80]
3-place Packard, black
top of intake manifold
(MAP) sensor
on coil, under fuel tank
[83]
ignition coil
3-place Packard, black
[91]
data link connector
4-place Deutsch, gray
behind left side cover
[93]
tail lamp
4-place Multilock, black
inside tail lamp lens
[94]
tail lamp power in
6-place Multilock, black
inside tail lamp lens
[108]
tachometer
12-place Packard Micro-64, gray
back of tachometer
[120]
oil pressure switch
90o post terminal, black
oil pressure switch, under oil filter mount
stop lamp switch, under electrical
[121]
rear stoplight switch
spade terminals, black
bracket
[122]
horn
90o spade terminals, black
between cylinders, left side
[128]
starter solenoid
locking spade terminal, white
starter solenoid
[136]
neutral switch
1-place molded jumper, black
right side frame, beneath gearcase cover
[142]
security siren
3-place Packard, black
under H-bracket
[160]
B+ connector
1-place Packard, gray
under seat
[GND1], [GND2]
harness grounds (2)
ring terminals
crankcase housing, top rear
2006 Sportster: Wiring
5-1
HOME
AMP MULTILOCK ELECTRICAL CONNECTORS
5.2
NOTE
REMOVING SOCKET/PIN
● If pick tool is not available, a a push pin/safety pin may be
TERMINALS
used instead.
● An ELECTRICAL TERMINAL CRIMP TOOL (Part No.
1. Remove connector from the retaining device, either
HD-41609) is used to install Amp Multi lock pin and
attachment or rosebud clip.
socket terminals on wires. If new terminals must be
2. Depress the button on the socket terminal side of the
installed, see Crimping Instructions on the next page.
connector
(plug) and pull apart the pin and socket
halves.
3. Bend back the latch slightly and free one side of second-
INSTALLING SOCKET/PIN
ary lock, then repeat the step to release the other side.
TERMINALS
Rotate the secondary lock outward on hinge to access
terminals in chambers of connector housing.
4. Looking in the terminal side of the connector (opposite
NOTE
the secondary lock), take note of the cavity next to each
For wire location purposes, numbers are stamped into the
terminal.
secondary locks of both the socket and pin housings. See
Figure 5-2.
5. See Figure 5-1. With the flat edge against the terminal,
insert the pick tool (Snap-On TT600-3) into the cavity
1.
From the secondary lock side of the connector, insert the
until it stops. Pivot the end of the pick away from the ter-
terminal into its respective numbered chamber until it
minal (locktab is inside housing) and gently tug on wire to
snaps in place. For proper fit, the slot in the terminal
pull terminal from chamber. Do not tug on the wire until
must face the tang in the chamber.
the tang is released or the terminal will be difficult to
remove. A “click” is heard if the tang is engaged but then
inadvertently released. Repeat the step without releasing
the tang.
d0242x3x
1
3
4
5
2
3
6
1.
Pin terminal
2.
Latch
2
3.
Secondary lock (open)
4.
Pin housing
5.
Socket housing
6.
Button
3
7.
Socket terminal
7
Figure 5-1. 10-Place Amp Multilock Connector
NOTES
● On the pin side of the connector, tangs are positioned at
the bottom of each chamber, so the slot in the pin termi-
● See Figure 5-3. The tang in the chamber engages the
nal (on the side opposite the crimp tails) must face down-
slot to lock the terminal in position.
ward.
5-2
2006 Sportster: Wiring
HOME
d0243x8x
Socket terminal
Secondary lock open
4
Socket housing
2
Pick tool
1
Pin terminal
3
Secondary lock open
4
Pin housing
1
Pick tool
2
1. Open secondary lock.
3
2. Insert pick into cavity on inboard side
of connector.
3. Pivot end of pick to release tang.
4. Gently tug on wire to remove terminal
from housing.
Figure 5-2. Release Tang and Back Out Terminals
●
On the socket side, tangs are at the top of each chamber,
d0244x8x
so the socket terminal slot (on the same side as the
crimp tails) must face upward.
1
●
Up and down can be determined by the position of the
3
4
release button (used to separate the pin and socket
halves). Consider the button to always be on top of the
connector.
2.
Gently tug on wire end to verify that the terminal is
locked in place and will not back out of chamber.
3.
Rotate the hinged secondary lock inward until tabs fully
engage latches on both sides of connector.
4.
Insert the socket housing (plug) into the pin housing
4
2
(receptacle) until it snaps in place.
1. Pin housing
5.
Install connector on retaining device, either attachment
2. Socket housing
or rosebud clip.
3. Button
4. Tang
Figure 5-3. Multilock Connector Cutaway View
2006 Sportster: Wiring
5-3
HOME
d0245x8x
Secondary locks open (socket housings shown)
Stamped numbers on secondary locks indicate wire color locations
- AMP
- AMP
1
2
3
1
2
3
4
5
6
5
6
7
8
9
10
3-place
6-place
12-place
4
6
1
7
5
4
1
4
2
7
3
3
5
1. Pin terminal
2. Socket terminal
3. Latch
6
4
4. Secondary lock (open)
5. Pin housing
2
6. Socket housing
7. Button
Figure 5-4. 3-Place and 6-Place Amp Multilock Connectors
5-4
2006 Sportster: Wiring
HOME
4.
Strip lead removing 5/32 in. (4 mm) of insulation. Insert
CRIMPING INSTRUCTIONS
wires between crimp tails until ends make contact with
locking bar. Verify that wire is positioned so that short
1. Squeeze the handles to cycle the crimp tool (Part No.
pair of crimp tails squeeze bare wire strands, while long
pair folds over insulation material.
HD-41609) to the fully open position.
5.
Squeeze handle of crimp tool until tightly closed. Tool
2. Raise locking bar by pushing up on bottom flange. With
automatically opens when the crimping sequence is
the crimp tails facing upward, insert contact (socket/pin)
complete. Raise up locking bar and remove contact.
through locking bar, so that the closed side of the contact
rests on the front nest (concave split level area of the
6.
Inspect the quality of the core and insulation crimps. Dis-
crimp tool). See Figure 5-5.
tortion should be minimal.
3. Release locking bar to lock position of contact. When
correctly positioned, the locking bar fits snugly in the
space at the front of the core crimp tails.
1.
Insulating crimp tail
1
2.
Core crimp tail
1
2
3
2
3.
Locking bar groove
3
4
4.
Tang slot
4
1. Raise locking bar and seat contact
2.
Insert stripped lead until it
on front nest of crimp tool. Release
contacts locking bar.
locking bar
GAUGE
CRIMPTOOL
WIRE
NEST
20
Front
16
Middle
18
Rear
3. Close and squeeze crimp tool.
4.
Raise locking bar and remove contact.
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Figure 5-5. Amp Multilock Crimping Procedure
2006 Sportster: Wiring
5-5
HOME
DEUTSCH ELECTRICAL CONNECTORS
5.3
GENERAL
4566
Deutsch Connectors feature a superior seal to protect electri-
cal contacts from dirt and moisture in harsh environments.
The connector also provides superior pin retention.
See Figure 5-8. This 12-pin connector illustrates the various
parts of the Deutsch connector. The following instructions
may be followed for all 2-pin through 12-pin Deutsch connec-
tors.
Socket housing: alignment tabs and/or external latch, sec-
ondary locking wedge, internal seal, wire seal, seal pin.
NOTE
Seal pins or plugs are installed in the wire seals of unused pin
and socket locations. If removed, seal pins must be replaced
to maintain the integrity of the environmental seal.
Figure 5-6. Remove Secondary Locking Wedge
Pin housing: alignment grooves and/or external latch cover,
attachment clip, secondary locking wedge, wire seal, seal pin.
s0545x8x
REMOVING/DISASSEMBLING
Attachment clips are attached to the pin housings of most
connectors. The clips are then attached to T-studs on the
motorcycle frame. T-studs give positive location to electrical
connectors and wire harness. Consistent location reduces
electrical problems and improves serviceability.
1. Push the connector to disengage small end of slot on
attachment clip from T-stud. Lift connector off T-stud.
2. Depress the external latch(es) on the socket housing
side and use a rocking motion to separate the pin and
socket halves. Two-, three-, four- and six-pin Deutsch
connectors have one external latch, while eight- and
twelve-pin connectors have two, both of which must be
pressed simultaneously to separate the connector
halves.
NOTE
Figure 5-7. Depress Terminal Latches/Back Out Pins
With few exceptions, the socket housing can always be found
on the accessory side, while the pin side of the connector is
connected to the wiring harness.
NOTE
An ELECTRICAL TERMINAL CRIMP TOOL (Part No. HD-
39965) is used to install Deutsch pin and socket terminals on
REMOVING/INSTALLING SOCKETS
wires. If new terminals must be installed, follow the instruc-
tions included with the crimping tool or see Crimping Instruc-
1. See Figure 5-6. Remove the secondary locking wedge.
tions in this section.
Insert the blade of a small screwdriver between the
socket housing and locking wedge inline with the groove
Fit rear wire seal into back of socket housing, if removed.
(inline with the pin holes if the groove is absent). Turn the
Grasp socket approximately 1.0 in. (25.4 mm) behind the
screwdriver 90 degrees to pop the wedge up.
contact barrel. Gently push sockets through holes in wire seal
into their respective chambers. Feed socket into chamber
2. See Figure 5-7. Gently depress terminal latches inside
until it “clicks” in place. Verify that socket will not back out of
socket housing and back out sockets through holes in
chamber; a slight tug on the wire will confirm that it is properly
rear wire seal.
locked in place.
5-6
2006 Sportster: Wiring