Harley Davidson 2006 Sportster XLH MODELS. Service Manual — page 26

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CONNECTORS

10498

See Figure 7-47. Under the fuel tank, locate the right

handlebar switch connector [22] (grey) (4) and the left

handlebar switch connector [24] (black) (5) in the right

hand backbone clip hung from the frame tube.

To separate the connectors, use a screw driver to press

down the locking tang on top of the connector and pull

the socket half from the pin half.

To remove socket half for routing or to service the 6-pin

Deutsch electrical connectors, see B.1 APPENDIX B-

WIRING AMP MULTILOCK ELECTRICAL CONNEC-

TORS.

To mate the connectors, press the socket half into the pin

half until it clicks in place.

Main frame tube

Left hand backbone clip

Left handlebar switch connector pin half [24A]

(grey color)

Left handlebar switch connector socket half

[24B] (grey color)

Right handlebar switch connector [22]

(black color) in right hand backbone clip

Figure 7-47. Backbone Clip

2006 Sportster: Electrical

7-43

HOME

RIGHT HANDLEBAR SWITCH

7.22

REMOVAL

10433

NOTE

The removal and installation steps listed apply when replac-

ing the entire switch assembly, switch housing or handlebars.

CAUTION

To prevent accidental vehicle start-up, which could

cause death or serious injury, remove maxi-fuse before

proceeding. (00251a)

Open left side cover and remove Maxi-Fuse. Close left

side cover. See 7.25 MAXI-FUSE.

CAUTION

Do not remove the switch housing assembly without first

placing a 5/32 in. (3.96 mm) cardboard insert between the

brake lever and lever bracket. Removing the assembly

without the insert in place may result in damage to the

rubber boot and plunger of the front stoplight switch.

See Figure 7-48. Place 5/32 in. (3.96 mm) cardboard

Figure 7-48. Install Cardboard Insert

insert between brake lever and lever bracket.

Using a T-27 TORX drive head, remove the two screws

with flat washers securing the handlebar clamp to the

master cylinder housing. Remove the brake lever/master

cylinder assembly and clamp from the handlebar.

Using a T-25 TORX drive head, remove the upper and

lower switch housing screws.

Remove the friction shoe from the end of the throttle ten-

sion adjuster screw.

NOTE

The friction screw is a loose fit and may fall out or become

dislodged if the lower switch housing is turned upside down

or shaken.

Remove the brass ferrules from the notches on the

inboard side of the throttle control grip. Remove the fer-

rules from the cable end fittings.

Remove the throttle control grip from the end of the han-

dlebar.

Pull the crimped inserts at the end of the throttle and idle

control cable housings from the lower switch housing.

For best results, use a rocking motion while pulling.

Place a drop of light oil on the retaining rings, if neces-

sary. Remove the cables from the switch housing.

7-44

2006 Sportster: Electrical

HOME

INSTALLATION

Table 7-14. Throttle/Idle Cable

Identification

With the concave side facing upward, install the friction

shoe so that the pin hole is over the point of the adjuster

CABLE

INSERT SIZE

INSERT COLOR

screw.

Idle

1/4 in. (6.3 mm)

gold

NOTE

The friction screw is a loose fit and may fall out or become

Throttle

5/16 in. (7.9 mm)

silver

dislodged if the lower switch housing is turned upside down

or shaken.

See Figure 7-49. Push the throttle and idle control cables

into the lower switch housing until they snap in place.

5256

Refer to Table 7-14. Note the different diameter inserts

crimped into the end of the throttle and idle cable hous-

ings. Proceed as follows:

a. Push throttle cable housing insert (2) into the larger

hole in front of the tension adjuster screw (3).

b. Push idle cable housing insert (1) into the smaller

hole at the rear of the tension adjuster screw.

5255

End fitting

Upper switch housing cable

Figure 7-50. Route Cable to Upper Switch Housing

NOTE

To aid assembly, place a drop of light oil on the retaining rings

of the crimped inserts. Always replace the retaining rings if

damaged or distorted.

Idle cable insert

3. See Figure 7-50. Route the cable (2) to the upper switch

Throttle cable insert

housing as shown

Tension adjuster screw

4. Slide the throttle control grip over the end of the right

handlebar until it bottoms against the closed end. Rotate

Figure 7-49. Install Throttle/Idle Control Cables

the grip so that the ferrule notches are at the top. To pre-

in Lower Switch Housing

vent binding, pull the grip back about 1/8 inch (3.2 mm).

2006 Sportster: Electrical

7-45

HOME

See Figure

7-51. Position the lower switch housing

10433

beneath the throttle control grip. Install the brass ferrules

(4) onto the cable so that the end fittings seat in the fer-

rule recess. Seat the ferrules in their respective notches

(3) on the throttle control grip. Verify that the cables are

captured in the grooves (2) molded into the grip.

Position the upper switch housing over the handlebar

and lower switch housing.

Verify that the wire harness conduit runs in the depres-

sion at the bottom of the handlebar. Be sure that the

upper switch housing harness will not be pinched under

the handlebar when the switch housing screws are tight-

ened.

Start the upper and lower switch housing screws, but do

not tighten.

5257

1. Groove

5/32 in. (3.96 mm) cardboard insert

Figure 7-52. Cardboard Insert in Place

5258

Throttle cable

Groove in throttle grip

Notch

Ferrule

Idle cable

Figure 7-51. Install Throttle/Idle Control Cables

on Throttle Control Grip

CAUTION

See Figure 7-52. Do not remove the 5/32 inch (3.96 mm)

cardboard insert wedged between the brake lever and

lever bracket. Removal will result in damage to the rub-

Switch housing assembly

ber boot and plunger of the front stoplight switch during

Tab

installation of the master cylinder assembly.

Groove

Brake lever Bracket

See Figure 7-53. Position the brake lever/master cylinder

assembly inboard of the switch housing assembly,

Figure 7-53. Fit Brake Lever/Master Cylinder to

engaging the tab (2) on the lower switch housing in the

Right Handlebar Switch Housings

groove (3) at the top of the brake lever bracket

7-46

2006 Sportster: Electrical

HOME

10. Align the holes in the handlebar clamp with those in the

DISASSEMBLY

master cylinder housing and start the two screws (with

flat washers). Position for rider comfort. Beginning with

the top screw, tighten the screws to

108-132 in-lbs

CAUTION

(12.2-14.9 Nm) using a T27 TORX drive head.

11. Using a T25 TORX drive head, tighten the lower and

See Figure 7-48. Do not remove the switch housing

upper switch housing screws to 35-45 in-lbs (4.0-5.1

assembly without first placing a 5/32 inch cardboard

Nm).

insert between the brake lever and lever bracket. Remov-

ing the assembly without the insert in place may result in

12. If necessary, wrap four new wiring harness retainers

damage to the rubber boot and plunger of the front stop-

around handlebar wiring harnesses and push retainers

light switch.

into holes in handlebar. See INSTALLATION under 2.25

HANDLEBARS.

1. Place the cardboard insert between the brake lever and

lever bracket.

NOTE

Always tighten the lower switch housing screw first so that

2. Using a T25 TORX drive head, remove the upper and

any gap between the upper and lower housings is at the front

lower switch housing screws.

of the switch.

3. If replacing lower housing switches, perform steps

13. Remove the cardboard insert between the brake lever

through 7 before continuing to repair section. If replacing

and lever bracket.

upper housing switches, proceed directly to repair sec-

tion.

14. Open left side cover and install Maxi-Fuse. Close left

side cover. See 7.25 MAXI-FUSE.

4. Using a T27 TORX drive head, loosen the upper screw

securing the handlebar clamp to the master cylinder

1WARNING

housing. Remove the lower clamp screw with flat washer.

5. Remove the brass ferrules from the notches on the

Be sure that all lights and switches operate properly

inboard side of the throttle control grip. Remove the fer-

before operating motorcycle. Low visibility of rider can

rules from the cable end fittings.

result in death or serious injury. (00316a)

6. Remove the friction shoe from the end of the tension

15. Test the switches for proper operation.

adjuster screw.

NOTE

The friction shoe is a loose fit and may fall out or become dis-

lodged if the lower switch housing is turned upside down or

shaken.

7. Remove the throttle control grip from the end of the han-

dlebar.

2006 Sportster: Electrical

7-47

HOME

SWITCH REPAIR/REPLACEMENT

x0310x7x

Upper Switch Housing Repair

NOTE

Replace the engine stop and engine start switches as a sin-

gle assembly even if only one switch is determined to be

faulty.

See Figure 7-54. From inside the switch housing, remove

the screw with lock washer (4) to release the bracket (5).

Remove the bracket and switch assembly from the hous-

ing.

Move cable conduit (3) from beneath wing of bracket. Cut

wires 0.25 in. (6.4 mm) from old switches (1, 2). Discard

old switch and bracket assembly.

Slide conduit forward over cut ends of switch wires and

cut off 0.5 in. (12.7 mm) of conduit material. Push con-

duit back to access switch wires.

Separate new engine stop switch (2) and engine start

switch (1) wires into two bundles.

NOTE

Start switch

Replacement stop switch and start switch wires are cut to

Stop switch

length; 2.5 in. (63.5 mm) and 2 in. (50.8 mm), respectively,

Conduit

and partially stripped.

Screw with lock washer

See 7.21 HANDLEBAR SWITCHES for information on

Bracket

splicing and general repair practices.

Figure 7-54. Upper Right Handlebar Switch Housing

Loop switch wires so that spliced lengths are positioned

(Without Splices)

as shown in Figure 7-55. Route wires downstream of

splices beneath wing on engine stop switch side of

bracket as shown in Figure 7-54.

See Figure 7-55. Install a new 7.0 in. (178 mm) cable

x0311x7x

strap (5) beneath wing on engine start switch (1) side of

bracket and capture wire splices (4).

Place switch assembly into upper housing aligning hole

in bracket with threaded hole in boss. Be sure that

bracket is fully seated. The step at the edge of the boss

captures the bottom edge of the bracket, while tabs on

each side of the bracket fit in slots cast into the housing.

See Figure 7-54. Install Phillips screw and lock washer

(4) to secure bracket (5) inside housing. Verify that wing

on engine stop switch (2) side of bracket (5) captures

edge of conduit (3) as shown.

10.

Securely tighten cable strap to draw splices to bracket.

Remove any excess cable strap material.

11.

Continue with ASSEMBLY on page page 7-50.

Start switch

Stop switch

Conduit

Splices

Cable strap

Figure 7-55. Upper Right Handlebar Switch Housing

(With Splices)

7-48

2006 Sportster: Electrical

HOME

Lower Switch Housing Repair

x0312x7x

From inside the switch housing, carefully cut cable strap

to free conduit from the turn signal switch bracket.

Remove the screw with lock washer to release the turn

signal switch bracket. Remove the bracket and switch

assembly from the housing.

RIGHT TURN SIGNAL SWITCH

Cut wire 1.5 in. (38.1 mm) from old switch. Discard old

switch assembly.

NOTE

Replacement turn-right signal switch wires are cut to length;

1.5 in. (38.1 mm), and partially stripped.

See 7.21 HANDLEBAR SWITCHES for information on

splicing and general repair practices.

Continue with ASSEMBLY on page page 7-50.

FRONT STOPLIGHT SWITCH

Carefully remove the wedge between the switch and

switch housing, if present. To remove the switch from the

housing, depress the plunger and slowly rotate switch

Stoplight switch

upward while rocking slightly.

Wedge

Cut wires 1.0 in. (25.4 mm) from old switch. Discard old

Switch wires

switch.

Lower switch housing

NOTE

Figure 7-56. Install Stoplight Switch

Replacement stoplight switch wires are cut to length; 2.5 in.

(63.5 mm), and partially stripped.

6. See Figure 7-56. Push down on switch (1) so that it bot-

See 7.21 HANDLEBAR SWITCHES for information on

toms against housing and wires (3) run in groove at base

splicing and general repair practices.

of cavity. With the concave side facing outward, insert

Carefully depress plunger against inside wall of switch

wedge (2) between switch and outboard side of switch

housing. With thumb over plunger bore, move switch into

housing.

the installed position in the switch housing cavity. When

7. Push wedge down until it also bottoms against housing.

plunger is positioned against thumb, slowly rotate switch

Verify that the plunger is still square in the bore and then

downward while rocking slightly. Release the plunger

place a drop of RTV Silicone Sealant on upper corner of

only after switch is properly positioned in the cavity.

wedge.

Verify that the plunger is square in the bore and that the

8. Continue with ASSEMBLY on page page 7-50.

boot is not compressed, collapsed, or torn. If necessary,

gently work the plunger in and out until boot is fully

extended.

2006 Sportster: Electrical

7-49

HOME

ASSEMBLY

x0313x7x

See Figure 7-57. Insert tapered end of new 7.0 in. (178

mm) cable strap (1) into round hole in turn signal switch

bracket (2) and then feed back through using the adja-

cent hole. Reserve the oblong hole for the bracket screw.

NOTE

Be sure that all splices are positioned above the turn signal

switch bracket.

Place the turn signal switch assembly into the housing,

aligning the oblong hole in the bracket with the threaded

hole in the boss. Be sure that the bracket is fully seated.

Tabs on each side of bracket are captured in slots cast

into switch housing.

Start screw with lock washer to secure bracket inside

housing.

CAUTION

If routed incorrectly, wires may be pinched by casting or

handlebar resulting in switch failure.

Loop switch wires so that spliced lengths are positioned

1. Cable strap

across bracket.

2. Bracket

3. Right turn signal switch

Capturing conduit about 0.25 in. (6.4 mm) from end,

securely tighten cable strap to draw conduit to bracket.

Figure 7-57. Insert Cable Strap in Switch Bracket

Remove any excess cable strap material.

Install second 7.0 in. (178 mm) cable strap capturing

conduit and wire splices. Securely tighten cable strap to

draw splices to conduit. Remove any excess cable strap

material.

Tighten screw to secure bracket inside housing.

Route wire bundle to upper switch housing by gently

pressing conduit into channel next to angular arm of

bracket. Secure bundle to arm using third cable strap.

Cut any excess cable strap material. If necessary, bend

angular arm of bracket downward to firmly secure front

stoplight switch in position.

See INSTALLATION on page 7-45.

7-50

2006 Sportster: Electrical

HOME

LEFT HANDLEBAR SWITCH

7.23

REMOVAL

5261

NOTE

The removal and installation steps listed apply when replac-

ing the entire switch assembly, switch housing or handlebars.

CAUTION

To prevent accidental vehicle start-up, which could

cause death or serious injury, remove maxi-fuse before

proceeding. (00251a)

Open left side cover and remove Maxi-Fuse. Close left

side cover. See 7.25 MAXI-FUSE.

Using a T-27 TORX drive head, remove the two screws

with flat washers securing the handlebar clamp to the

clutch lever bracket. Remove the clutch hand lever

assembly and clamp from the handlebar.

Using a T-25 TORX drive head, remove the upper and

lower switch housing screws.

Remove the grip sleeve from the end of the handlebar if

damaged.

Grip sleeve

INSTALLATION

Ribs

Grooves

If the grip sleeve was removed, thoroughly clean handle-

bar to remove all adhesive residue.

Figure 7-58. Install Left Handlebar Switch Housings

a. Using a piece of emery cloth, rough grip end of left

3. Verify that the wire harness conduit runs in the groove at

side of handlebar.

the bottom of the handlebar. Be sure that the upper

NOTE

switch housing harness will not be pinched under the

Before applying adhesive in the next step, clean the left side

handlebar when the switch housing screws are tight-

of handlebar with acetone.

ened.

b. Apply LOCTITE PRISM PRIMER (770) to inside of

4. Start the upper and lower switch housing screws, but do

handgrip. Remove any excess PRISM PRIMER.

not tighten.

Wait two minutes for PRISM PRIMER to set before

beginning the next step.

c. Apply LOCTITE PRISM SUPERBONDER (411) to

inside of handgrip. Place new handgrip on left buck-

horn handlebar.

NOTE

SUPERBONDER will set in four minutes and be fully cured in

24 hours.

d. Roll grip to evenly distribute adhesive on inside sur-

faces. Install grip on handlebar with a twisting

motion.

See Figure 7-58. Install upper and lower switch housings

on handlebar. Be sure that ribs (2) on outboard side of

switch housings fit in grooves (3) molded into grip.

2006 Sportster: Electrical

7-51

HOME

See Figure 7-59. Position the clutch hand lever assembly

8. If necessary, wrap four new wiring harness retainers

inboard of the switch housing assembly, engaging the

around handlebar wiring harnesses and push retainers

tab (3) on the lower switch housing in the groove (2) at

into holes in handlebar. See INSTALLATION under 2.25

the bottom of the clutch lever bracket.

HANDLEBARS.

9. Open left side cover and install Maxi-Fuse. Close left side

cover. See 7.25 MAXI-FUSE.

5263

1WARNING

Be sure that all lights and switches operate properly

before operating motorcycle. Low visibility of rider can

result in death or serious injury. (00316a)

10. Test the switches for proper operation.

DISASSEMBLY

1. Using a T25 TORX drive head, remove the upper and

lower switch housing screws.

2. If replacing lower housing switches, perform step

before continuing to repair section. If replacing upper

housing switches, proceed directly to repair section.

Clutch lever bracket

Groove

3. Using a T27 TORX drive head, loosen the upper screw

Tab

securing the handlebar clamp to the clutch lever bracket.

Switch housing assembly

Remove the lower clamp screw with flat washer.

Figure 7-59. Fit Clutch Lever Bracket to

Left Handlebar Switch Housings

Align the holes in the handlebar clamp with those in the

clutch lever bracket and start the two screws (with flat

washers). Position for rider comfort. Beginning with the

top screw, tighten the screws to 108-132 in-lbs (12.2-

14.9 Nm) using a T27 TORX drive head.

Using a T25 TORX drive head, tighten the lower and

upper switch housing screws to 35-45 in-lbs (4.0-5.1

Nm).

NOTE

Always tighten the lower switch housing screw first so that

any gap between the upper and lower housings is at the front

of the switch.

7-52

2006 Sportster: Electrical

HOME

NOTE

SWITCH REPAIR/REPLACEMENT

Replacement high/low beam switch wires and horn switch

wires are cut to length; 2.5 in. (63.5 mm) and 2.0 in. (50.8

mm), respectively, and partially stripped.

Upper Switch Housing Repair

5. See 7.21 HANDLEBAR SWITCHES for information on

NOTE

splicing and general repair practices.

Replace the horn switch and high/low beam switch as a sin-

gle assembly even if only one switch is determined to be

6. See Figure

7-61. Loop switch wires so that spliced

faulty.

lengths are positioned as shown. Route wires down-

stream of splices beneath wing on high/low beam switch

See Figure 7-60. From inside the switch housing, remove

side of bracket as shown in Figure 7-60.

the screw with lock washer (4) to release the bracket (5).

7. See Figure 7-61. Install a new 7.0 in. (178 mm) cable

Remove bracket and switch assembly from the housing.

strap (5) beneath wing on horn switch (1) side of bracket

Move cable conduit (3) from beneath wing of bracket. Cut

and capture wire splices (4).

wires 0.25 in. (6.4 mm) from old switches (1, 2). Discard

8. Place switch assembly into upper housing aligning hole

old switch and bracket assembly.

in bracket with threaded hole in boss. Be sure that

Slide conduit forward over cut ends of switch wires and

bracket is fully seated. The step at the edge of the boss

cut off 0.5 in. (12.7 mm) of conduit (3) material. Push

captures the bottom edge of the bracket, while tabs on

conduit back to access switch wires.

each side of the bracket fit in slots cast into the housing.

Separate new horn switch (1) and high/low beam switch

(2) wires into two bundles.

x0315x7x

x0314x7x

Horn switch

High/low beam switch

Conduit

Splices

Screw with lock washer

Cable strap

Bracket

Figure 7-61. Upper Left Handlebar Switch Housing

Figure 7-60. Upper Left Handlebar Switch Housing

(With Splices)

(Without Splices)

2006 Sportster: Electrical

7-53

HOME

See Figure 7-60. Install screw with lock washer (4) to

3. Start screw with lock washer to secure bracket inside

secure bracket (5) inside housing. Verify that wing on

housing.

high/low beam switch (2) side of bracket captures edge

4. See Figure

7-61. Loop switch wires so that spliced

of conduit (3) as shown.

lengths are positioned as shown.

10. Securely tighten cable strap to draw splices to bracket.

5. Capturing conduit about 0.25 in. (6.4 mm) from end,

Remove any excess cable strap material.

securely tighten cable strap to draw conduit to bracket.

11. Continue with ASSEMBLY on next page.

Remove any excess cable strap material.

6. Tighten screw to secure bracket inside housing.

Lower Switch Housing Repair

7. Route wire bundle to upper switch housing below and

From inside the switch housing, carefully cut cable strap

then forward of the main wire harness, positioning con-

to free conduit from the turn signal switch bracket.

duit in channel next to angular arm of bracket. Secure

bundle to arm using new cable strap. Cut any excess

Remove screw with lock washer to release the turn sig-

cable strap material.

nal switch bracket. Remove the bracket and switch

assembly from the housing.

8. See INSTALLATION on page 7-51.

Cut wires 1.5 in. (38.1 mm) from old switch (Turn-L(eft)

Signal Switch). Discard switch assembly.

x0316x7x

See 7.21 HANDLEBAR SWITCHES for information on

splicing and general repair practices.

Continue with ASSEMBLY on next page.

ASSEMBLY

See Figure 7-62. Insert tapered end of new 7.0 in. (178

mm) cable strap (1) into round hole in turn signal switch

bracket (2) and then feed back through using the adja-

cent hole. Reserve the oblong hole for the bracket screw.

NOTE

Be sure that all splices are positioned above the turn signal

switch bracket.

Place the turn signal switch assembly (3) into the hous-

ing, aligning the oblong hole in the bracket with the

threaded hole in the boss. Be sure that the bracket is

fully seated. Tabs on each side of bracket are captured in

slots cast into switch housing.

Cable strap

Bracket

Left turn signal switch

Figure 7-62. Insert Cable Strap in Switch Bracket

7-54

2006 Sportster: Electrical

HOME

HORN

7.24

TROUBLESHOOTING

REPLACEMENT: ALL MODELS

EXCEPT XL 1200C

If the horn does not sound or sounds weak, check for the fol-

lowing:

1. See Figure 7-63. Remove terminal clips from horn spade

● Discharged battery. To charge battery, see CHARGING

connectors (1, 3).

under 7.14 BATTERY.

2. Remove screws (4) and lock washers (6) from horn

● Loose, frayed or damaged wiring to horn terminal.

bracket (2) and remove horn assembly (5).

If battery is charged and wiring appears to be in good condi-

3. Install horn assembly with screws and washers into horn

tion, perform a VOLTAGE TEST for the following:

bracket. Tighten screws to 35-45 in-lbs (4.0-5.1 Nm).

4. Install the yellow wire with black tracer to the left spade

● Inoperative horn switch.

connector (3) and the black wire to the right spade con-

● Open circuit to horn.

nector (1).

● Open ground to frame.

● Inoperative horn.

x0616a7x

VOLTAGE TEST

Remove terminal clips from horn spade connectors.

Connect voltmeter leads, positive (+) to wire terminal and

negative (-) to ground.

Turn ignition switch ON and press horn switch.

If battery voltage is not present, check for the following:

● Horn switch is inoperative. Replace switch. See 7.23

LEFT HANDLEBAR SWITCH.

● Wiring to horn is open. Repair wiring.

If battery voltage is present, check for the following:

● Ground is open between mounting hardware or

ground wire. Repair wiring.

● Horn is inoperative. Replace horn. See REPLACE-

MENT: ALL MODELS EXCEPT XL

1200C or

REPLACEMENT: XL 1200C.

Right spade connector

Horn bracket

Left spade connector

Screw (3)

Horn assembly

Lock washer (3)

Screw (2)

Washer (2)

Figure 7-63. Horn Components

(All Models Except XL 1200C)

2006 Sportster: Electrical

7-55

HOME

Slide horn (12) into chrome cover and bracket (2) push-

REPLACEMENT: XL 1200C

ing stud at back of horn assembly through hole in horn

support bracket

(5). Apply two drops of LOCTITE

See Figure 7-64. Remove terminal clips from horn spade

THREADLOCKER 271 (red) to threads of nut (10).

connections on back of horn (12).

Install nut (10) on horn stud and tighten to 80-100 in-lbs

(9.0-11.3 Nm).

Remove acorn nut (3) and lock washer (4) to free horn

Attach the yellow wire with black tracer to front terminal

assembly from rubber mount (6) stud.

and the black wire to rear terminal. Push wire conduit

Remove wire conduit from clamp (9) at back of support

into clamp (9) at back of horn bracket (5).

bracket (5).

Install support bracket (5) on rubber mount (6) stud with

lock washer (4) and acorn nut (3). Tighten acorn nut (3)

Remove nut (10) from circular recess at back of chrome

to 60-180 in-lbs (6.8-20.4 Nm).

cover and bracket (2) and remove horn (12) from cover

and bracket.

x0617a7x

Clip nut (2)

Screw (2)

Cover and bracket

Clamp

Acorn nut

10. Nut

Lock washer

11. Washer (2)

Support bracket

12. Horn

Rubber mount

13. Screw (2)

Lock nut

14. Horn and choke bracket

Figure 7-64. Horn Components (XL 1200C)

7-56

2006 Sportster: Electrical

HOME

MAXI-FUSE

7.25

GENERAL

11312

Fuses prevent the electrical overload of a circuit. A fuse

closes a circuit as long as current (amperage) flowing through

the fuse does not exceed the Ampere rating of the fuse. If the

circuit current exceeds the fuse Ampere rating, the fuse

opens and the current flow is interrupted.

See Figure 7-65. The main fuse is a Maxi-Fuse located in a

holder [5] (1) mounted on the battery strap, under the left side

cover. The Maxi-Fuse is rated at 30 Amperes.

REMOVING

Open left side cover. See 1.6 LEFT SIDE COVER.

See Figure 7-66. Squeeze cover release latches (3)

together and pull fuse holder [5] (1) from protective cover

(2).

See Figure 7-67. Grasp fuse holder (2) and pull Maxi-

Fuse (1) straight out.

If you are performing other procedures before re-install-

Fuse holder [5]

ing the Maxi-Fuse, close the left side cover.

Protective cover

Cover release latches

INSTALLING

Figure 7-66. 30-Amp Maxi-Fuse

Open left side cover. See 1.6 LEFT SIDE COVER.

See Figure 7-67. Install Maxi-Fuse (1) by lining up spade

11481

terminals on fuse with sockets in fuse holder [5] (2).

Press Maxi-Fuse firmly into holder.

See Figure 7-66. Push fuse holder [5] (1) into protective

cover (2) until cover release latches (3) snap into place.

Close left side cover.

Turn ignition switch ON and verify proper operation of

electrical system.

11458

Maxi-Fuse

Fuse holder [5]

Figure 7-67. Removing/Installing Maxi-Fuse

Maxi-Fuse holder [5]

Battery strap

Relay/fuse block

Figure 7-65. Fuses

2006 Sportster: Electrical

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HOME

SYSTEM FUSES AND STARTER RELAY

7.26

GENERAL

10071

The starter relay allows a relatively small amount of current

flowing through the starter button to control the large current

flow required to activate the starter solenoid.

The electrical system relay/fuse block (3) is located in the

upper left rear corner of the oil tank. The starter relay and five

fuses are mounted in the relay/fuse block. The fuses are rated

at 15 Amperes.

REPLACING 15-AMP FUSES

Open left side cover. See 1.6 LEFT SIDE COVER.

See Figure 7-68. Pull suspect fuse (2-6) from slots in

Starter relay

relay/fuse block and inspect for blown condition or other

Accessories fuse

damage. Replace as necessary:

Battery fuse

Lights fuse

a. Insert new fuse in appropriate location by lining up

Ignition fuse

spade terminals on fuse with sockets in relay/fuse

Instruments fuse

block.

Spare fuse

b. Press fuse firmly into sockets.

Close left side cover.

Figure 7-68. Relay/Fuse Block

Turn ignition switch ON and verify proper operation of cir-

cuit protected by replacement fuse.

REPLACING STARTER RELAY

Open left side cover. See 1.6 LEFT SIDE COVER.

See Figure 7-68. Grasp body of starter relay (1) and with

a gentle rocking motion, pull relay straight out from relay/

fuse block.

Install new starter relay by lining up spade terminals of

relay with sockets in relay/fuse block. Push relay firmly

into sockets.

Close left side cover.

Turn ignition switch ON and start vehicle to verify proper

operation of starter circuit.

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2006 Sportster: Electrical

HOME

MAXI-FUSE HOLDER

7.27

REPLACEMENT

11982

1WARNING

To prevent accidental vehicle start-up, which could

cause death or serious injury, disconnect negative (-)

battery cable before proceeding. (00048a)

Remove negative battery cable from engine crankcase.

See BATTERY DISCONNECTION AND REMOVAL

under 1.7 BATTERY MAINTENANCE.

Open left side cover and remove Maxi-Fuse. See 7.25

MAXI-FUSE.

See Figure 7-69. With a small flat blade screwdriver,

gently pry up tabs (one on each side) of secondary lock

(1) and remove secondary lock from body of fuse holder

Figure 7-70. Release Wire Terminal

(2).

From Fuse Holder Body

See Figure 7-70. Insert screwdriver blade into slot in fuse

holder body above wire terminal.

See Figure 7-71. Push screwdriver into slot to unlock

release latch (3). Pull wire terminal (2) from fuse holder

11983

body (1). Repeat procedure for other wire.

Insert wire terminals in body of new fuse holder. Push

wire terminals in until release latch clicks into place.

NOTE

See Figure 7-69. Insert wire from battery terminal (3) into slot

A in fuse holder, wire from wiring harness (4) into slot B.

See Figure 7-69. Install secondary lock (1) onto body of

fuse holder (2).

See Figure 7-67. Install Maxi-Fuse (1) by lining up spade

terminals on fuse with sockets in fuse holder (2). Press

Maxi-Fuse firmly into holder.

11981

Fuse holder body

Wire terminal

Release latch

Moisture seal

Figure 7-71. Wire Terminal

See Figure 7-66. Push fuse holder (1) into protective

cover (2) until cover release latches (3) snap into place.

10.

Install negative battery cable on engine crankcase. See

BATTERY INSTALLATION AND CONNECTION under

1.7 BATTERY MAINTENANCE.

11.

Close left side cover. See 1.6 LEFT SIDE COVER.

Secondary lock

12.

Turn ignition switch ON and verify proper operation of

Fuse holder

vehicle’s electrical system.

To battery positive (+) terminal

To wiring harness

Figure 7-69. Removing Fuse Holder Secondary Lock

2006 Sportster: Electrical

7-59

HOME

RELAY/FUSE BLOCK

7.28

7. Loosen and remove mounting studs. This allows oil tank

GENERAL

to be lowered far enough to remove relay/fuse block.

See Figure 7-72. The electrical system relay/fuse block is

8. See Figure 7-74. Gently pry back release latch (1), lift

located in the upper left rear corner of the oil tank. The starter

relay/fuse block up slightly. Pull relay/fuse block out as far

relay and five fuses are mounted in the relay/fuse block.

as wiring harness will allow. Press down on oil tank to

gain sufficient clearance.

11458

10057

Figure 7-72. Relay/Fuse Block

Ignition Control Module (ICM)

REMOVAL

ICM wiring harness connector [10]

Lock nut (2)

Remove seat. See REMOVAL under 2.32 SEAT.

Rear fender

Oil tank/ICM mounting stud (2)

Open left side cover. See 1.6 LEFT SIDE COVER.

Figure 7-73. ICM

1WARNING

Prevent accidental vehicle start-up, which could cause

death or serious injury. First disconnect negative (-) bat-

10117

tery cable at engine and then positive (+) cable from bat-

tery. (00280a)

Disconnect negative battery cable from crankcase. Dis-

connect positive (+) battery cables from battery. See

BATTERY DISCONNECTION AND REMOVAL under 1.7

BATTERY MAINTENANCE.

See Figure 7-72. Remove relay and all fuses from relay/

fuse block. See 7.26 SYSTEM FUSES AND STARTER

RELAY.

See Figure 7-73. Disconnect ICM harness connector

[10] (2) from ICM (1).

Remove lock nuts (3) and lift ICM off oil tank/ICM mount-

Release latch

ing studs (5).

Terminal socket

Pick tool cavity

Figure 7-74. Relay/Fuse Block

7-60

2006 Sportster: Electrical

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Two release tangs anchor each terminal (2) in relay/fuse

5. See Figure 7-73. Install oil tank/ICM mounting studs (5).

block. Note cavity (3) on each side of terminal socket.

Tighten to 36-60 in-lbs (4.1-6.8 Nm).

10. With the flat edge against inside of relay/fuse block,

6. See Figure 7-72. Install relay and all fuses in relay/fuse

insert pick tool (Snap-On Part no. TT600-3) into one of

block. See

7.26 SYSTEM FUSES AND STARTER

the cavities until it stops. Pivot end of pick toward termi-

RELAY.

nal to depress release tang. Remove tool and repeat

7. Install ICM (1) on mounting studs, secure with lock nuts

procedure on opposite side of socket. Tug on wire to pull

(3). Tighten to 12-15 in-lbs (1.4-1.7 Nm).

terminal from wire end of chamber.

8. Plug ICM wiring harness connector [10] (2) into ICM.

NOTE

For best results, obtain Snap-On GA500A to depress both

1WARNING

release tangs simultaneously. Insert smallest pair of pins on

GA500A until body of tool almost contacts face of relay/fuse

Connect positive (+) battery cable first. If positive (+)

block. Leaving tool in place, pull on wire to remove. To over-

cable should contact ground with negative (-) cable con-

come any resistance, use a moderate amount of force to pull

nected, the resulting sparks can cause a battery explo-

wire from terminal socket.

sion, which could result in death or serious injury.

(00068a)

11. Repeat above steps to remove remaining terminals from

relay/fuse block.

9. Connect battery cables, positive (+) cable first. See BAT-

TERY INSTALLATION AND CONNECTION under 1.7

BATTERY MAINTENANCE.

INSTALLATION

10. Close left side cover. See 1.6 LEFT SIDE COVER.

NOTE

1WARNING

See Appendix B wiring diagrams for wire locations.

After installing seat, pull upward on front of seat to be

Using a thin, flat blade, like that on an X-Acto knife, care-

sure it is in locked position. While riding, a loose seat can

fully bend release tangs outward away from terminal

shift causing loss of control, which could result in death

body.

or serious injury. (00070a)

Push wire terminal into chamber at rear of new relay/

11. Install seat. See INSTALLATION under 2.32 SEAT.

fuse block until release tangs click in place. Gently tug on

wire to verify that terminal is locked in place and will not

12. Turn ignition switch ON and verify proper operation of

back out of relay/fuse block chamber.

vehicle’s electrical system.

Repeat steps 1-2 above until all wires are seated in

relay/fuse block.

Push relay/fuse block back in recess in oil tank until

release latch snaps in place. It may be necessary to

press down on oil tank to gain sufficient clearance.

2006 Sportster: Electrical

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SPEEDOMETER: XL 883, XL 883L, XL 883R

7.29

NOTE

REMOVAL

If necessary, lubricate rubber gaskets with alcohol or glass

cleaner.

NOTE

4. Orient face upright and press speedometer into (1) hous-

The speedometer has a backlight bulb that cannot be

ing/bracket (3). Wiring must past between locating keys

replaced. If the bulb fails, replace the entire unit.

and gasket and through cutout in speedometer back.

5. Mate speedometer connector halves [39]

CAUTION

6. Push trip reset switch through housing back plate and

To prevent accidental vehicle start-up, which could

thread on the trip reset boot (6).

cause death or serious injury, remove maxi-fuse before

7. Hold back plate (5) in place with reset switch in rectangu-

proceeding. (00251a)

lar boss in back of speedometer (1) and vent hole (8) at

bottom. Tighten screws.

Open left side cover and remove Maxi-Fuse. Close left

side cover. See 7.25 MAXI-FUSE.

Open left side cover and install Maxi-Fuse. Close left side

cover.

See Figure 7-75. Unthread trip odometer reset boot (6)

from back of housing/bracket (3).

Remove screws (7) holding speedometer housing back

x0618x7x

plate (5).

Open latches on each side of speedometer connector

[39] and separate connector halves.

Push out the speedometer (1) and front gasket (2).

Inspect front (2) and back (4) gaskets, speedometer con-

nector [39] and wiring, trip reset switch and wiring, and

trip reset boot (6). Repair or replace as required.

INSTALLATION

If replacing the trip odometer switch:

a. Push the trip reset socket terminals out the front of

the speedometer socket connector half [39B]. See

B.4 PACKARD ELECTRICAL CONNECTORS.

b. Cut off the socket terminals and pull the faulty switch

out of the connector.

Speedometer

c. Push the wires of a replacement switch through the

Front gasket

speedometer connector (sockets 8, 11) and crimp

Speedometer housing/bracket

new socket terminals using crimping tool (Part No.

Back gasket

HD-45929), on replacement switch wiring.

Back plate

Trip odometer reset boot

d. Draw the terminal back into the connector until the

Screw

terminal seats.

Back plate vent hole

See Figure 7-75. Install front gasket (2) on speedometer

(1).

Figure 7-75. Speedometer Components

Threading wiring through back gasket (4), install match-

(XL 883/XL 883L/XL 883R)

ing tabs of gasket to locating keys in speedometer hous-

ing/bracket (3).

7-62

2006 Sportster: Electrical

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Harley Davidson 2006 Sportster XLH MODELS. Service Manual — page 26

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