Harley Davidson 2006 Sportster XLH MODELS. Service Manual — page 38

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1. Pin terminal

2. Socket terminal

3. Pin housing

4. Socket housing

5. Wire seal

6. Locking wedge

7. Latch cover

8. Alignment grooves

9. Alignment tabs

10. Internal seal

11. External latch

12. Wire seal

13. Seal pin

Figure 5-8. 12-pin Deutsch Connector (Exploded View)

3. Install internal seal on lip of socket housing, if removed.

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Insert tapered end of secondary locking wedge into

socket housing and press down until it snaps in place.

The wedge fits into the center groove within the socket

housing and holds the terminal latches tightly closed.

Pin

housing

NOTES

● While rectangular wedges do not require a special orien-

tation, the conical secondary locking wedge of the 3-pin

connector must be installed with the arrow pointing

Arrow points to

toward the external latch. See Figure 5-9.

external latch

● If the secondary locking wedge does not slide into the

installed position easily, verify that all terminals are fully

installed in the socket housing. The lock indicates when

terminals are not properly installed by not entering its

fully installed position.

REMOVING/INSTALLING PINS

Socket

housing

1. Remove the secondary locking wedge. Use the hooked

end of a stiff piece of mechanics wire a needle nose pli-

ers, or a suitable pick tool (Part No. HD-41475-100). See

Figure 5-10.

Figure 5-9. Depress Terminal Latches/Back Out Pins

2. Gently depress terminal latches inside pin housing and

back out pins through holes in wire seal.

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NOTE

h41475-100

An ELECTRICAL TERMINAL CRIMP TOOL (Part No. HD-

39965) is used to install Deutsch pin and socket terminals on

wires. If new terminals must be installed, see Crimping

Instructions in this section.

3. Fit wire seal into back of pin housing. Grasp crimped pin

approximately 1.0 in. (25.4 mm) behind the contact bar-

rel. Gently push pins through holes in wire seal into their

Figure 5-10. Deutsch Connector Pick Tool

respective numbered locations. Feed pin into chamber

(Part No. HD-41475-100)

until it “clicks” in place. Verify that pin will not back out of

chamber; a slight tug on the wire will confirm that it is

properly locked in place.

4. Insert tapered end of secondary locking wedge into pin

housing and press down until it snaps in place. The

5893

Lock tab

wedge fits in the center groove within the pin housing

and holds the terminal latches tightly closed.

NOTES

● While rectangular wedges do not require a special orien-

tation, the conical secondary locking wedge of the 3-pin

Lock bar

connector must be installed with the arrow pointing

toward the external latch. See Figure 5-9.

● If the secondary locking wedge does not slide into the

installed position easily, verify that all terminals are fully

installed in the pin housing. The lock indicates when ter-

minals are not properly installed by not entering its fully

5892

installed position.

Pin housing

ASSEMBLING/INSTALLING

1. Insert socket housing into pin housing until it snaps in

place. Two-, three-, four- and six-pin Deutsch connectors

have one external latch on the socket half of the connec-

tor. To fit the halves of the connector together, the latch

on the socket side must be aligned with the latch cover

Attachment clip

on the pin side.

For those connectors with two external latches (8-pin

and

12-pin), a different system is used to prevent

5891

improper assembly. Align the tabs on the socket housing

with the grooves on the pin housing. Push the connector

halves together until the latches “click.” If latches do not

click (latch), press on one side of the connector until that

latch engages, then press on the opposite side to

engage the other latch.

NOTE

Deutsch connectors are color coded for location purposes.

Those connectors associated with left side accessories, such

Attachment clip installed

as the front and rear left turn signals, are gray. All other con-

nectors, including those associated with right side accesso-

ries, are black.

Figure 5-11. Attachment Clip Installation

If it should become necessary to replace a plug or receptacle,

please note that the 8-pin and 12-pin gray and black connec-

tors are not interchangeable. Since location of the alignment

See Figure 5-11. Fit the attachment clip to the pin hous-

tabs differ between the black and gray connectors, plugs or

ing, if removed. Place large end of slot on attachment

receptacles must be replaced by those of the same color. If

clip over T-stud on frame. Push assembly forward to

replacing both the socket and pin halves, then the black may

engage small end of slot.

be substituted for the gray, and vice versa. The socket and pin

halves of all other connectors are interchangeable, that is, the

black may be mated with the gray, since the alignment tabs

are absent and the orientation of the external latch is the

same.

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Locking bar

1. Insert contact through middle

Insert stripped lead until it

hole in locking bar.

contacts locking bar.

3. Close and squeeze crimp tool

Raise locking bar and remove

contact.

Insulation crimp

Core crimp

Figure 5-12. Deutsch Crimping Procedure

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. See Figure 5-12. Squeeze the handles to cycle the crimp

pair of crimp tails squeeze bare wire strands, while long

tool to the fully open position.

pair folds over insulation material.

2. Raise locking bar by pushing up on bottom flange. With

5. Squeeze handle of crimp tool until tightly closed. Tool

the crimp tails facing upward and the rounded side of the

automatically opens when the crimping sequence is

contact barrel resting on the concave split level area of

complete. Raise up locking bar and remove contact.

the crimp tool, insert contact (socket/pin) through middle

6. Inspect the quality of the core and insulation crimps. Dis-

hole of locking bar.

tortion should be minimal.

3. Release locking bar to lock position of contact. If the

crimp tails are slightly out of vertical alignment, the crimp

tool automatically rotates the contact so that the tails

face straight upward. When correctly positioned, the

locking bar fits snugly in the space between the contact

band and the core crimp tails.

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x0564x5x

2-pin connector

3-pin connector

4-pin connector

SOCKET SIDE

PIN SIDE

Socket terminal

Locking wedge

Wire seal

Latch cover

Socket housing

Pin housing

External latch

10.

Wire seal

Internal seal

11.

Pin terminal

Locking wedge

Figure 5-13. 2-Pin, 3-pin and 4-pin Deutsch Connectors

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MINI-DEUTSCH ELECTRICAL CONNECTORS

5.4

GENERAL

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For Size 20, 16 and 12 Contacts

Wire Range 26-12 AWG

Mini-Deutsch connectors make use of a solid barrel contact

without crimp tails. As a result, a special TERMINAL CRIMP

TOOL (Part No. HD-42879) is needed to install pin and

socket terminals on wires.

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Figure 5-15. Selector Knob

1. Indentor cover

2. Contact

3. Indentor points

1. Adjusting screw

2. Locknut

3. Locking pin

4. Selector knob

Figure 5-14. Deutsch Solid Barrel Contact Crimp Tool

(Part No. HD-42879)

CRIMPING INSTRUCTIONS

1. Squeeze the handles to cycle the crimp tool to the fully

open position.

2. See Figure 5-14. Remove locking pin (3) from selector

knob (4).

3. See Figure 5-15. Raise selector knob and rotate until

selected wire size stamped on wheel is aligned with

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“SEL. NO.” arrow.

Figure 5-16. Indentor Points

4. Loosen knurled locknut and turn adjusting screw clock-

wise (in) until it stops.

5. Turn tool over and drop contact into indenter cover hole

with the wire end out.

6. Turn adjusting screw counterclockwise (out) until contact

is flush with bottom of depression in indenter cover.

Tighten knurled locknut.

7. See Figure 5-16. Slowly squeeze handles of crimp tool

until contact (2) is centered between indenter points (3).

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Strip wire lead removing 1/4 in. (6.3 mm) of insulation.

See Figure 5-17. Insert bare wire strands into contact

barrel.

10. Squeeze handle of crimp tool until tightly closed. Tool

automatically opens when the crimping sequence is

complete.

11. Remove crimped contact from indenter.

12. Inspect the quality of the crimp. Verify that all wire

strands are in crimp barrel.

NOTE

Tool must be readjusted when changing contact size/type.

13. Install pin to lock position of selector knob.

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Figure 5-17. Contact Barrel

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SEALED BUTT SPLICE CONNECTORS

5.5

INSTALLATION

Red

Butt splicing may be a necessary procedure for the replace-

Blue

ment of some components.

1. Strip 3/8 in. (9.5 mm) of insulation off the ends of the

wires.

2. Compress the handles of the Packard Crimp Tool (HD-

Yellow

38125-8) until the ratchet automatically opens.

3. Refer to Table 5-2. Since the size of the connectors var-

ies with the gauge of the wire, always used the correct

components when creating sealed splices.

4. See Figure 5-18. Determine the correct die or nest for

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the crimping operation. Match the color or gauge wire

marked on the butt splice connector with the correspond-

Figure 5-18. Packard Crimp Tool (Part No. HD-38125-8)

ing crimp cavity on the crimp tool.

5. Gently apply pressure to the handles until the crimper

lightly secures one side of the metal insert inside the butt

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splice connector. The connector must be crimped in two

stages; one side then the other.

6. See Figure 5-19. Feed the wire into the butt splice con-

nector until the stripped end contacts the wire stop inside

Metal insert

the metal insert.

7. Squeeze the handles of the crimp tool until tightly closed.

The tool automatically opens when the crimping

Crimp wire ends

sequence is complete.

8. Repeat steps 5, 6, and 7 on the other side of the butt

splice connector.

NOTE

If adjacent wires are being spliced, stagger the splices so that

the butt splice connectors are spaced at different positions

Melted sealant after heating/cooling

along the length of the wires.

1WARNING

Use caution when operating the UltraTorch UT-100 or any

other radiant heating device. Read the manufacturers

Figure 5-19. Installing Sealed Butt Splice Connectors

instructions carefully before use. Always keep hands

away from tool tip area and heat shrink attachment.

Avoid directing the heat toward any fuel system compo-

Table 5-2. Common Sealed Splices

nent. Extreme heat can cause fuel ignition or explosion.

Avoid directing heat toward any electrical system com-

CONNECTOR

ponent other than the connectors on which heat shrink

GAUGE WIRE

PART NO.

COLOR

work is being performed. Be sure to turn the “ON/OFF”

switch to the “OFF” position after use. Improper handling

18-20

Red

70585-93

could result in death or serious injury.

14-16

Blue

70586-93

Using the UltraTorch UT-100 (Part No. HD-39969), Robi-

10-12

Yellow

70587-93

nair Heat Gun (Part No. HD-25070) with heat shrink

attachment (Part No. HD-41183) or other suitable radiant

NOTE

heating device, heat the crimped splice to encapsulate

It is acceptable for the splice to rest against the heat shrink

the butt splice connection. Apply heat from the center of

tool attachment.

the crimp out to each end until the meltable sealant

10. Heat the center of the splice until the crimp indentations

exudes out both ends of the connector.

disappear and the tubing assumes a smooth cylindrical

appearance.

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PACKARD ELECTRICAL CONNECTORS

5.6

Unlike most connectors, where the terminals are pulled out

GENERAL

the wire end of the connector, to remove the terminals from

From a servicing standpoint, there are two basic types of

the pull-to-seat connectors, the terminal is pushed out the

Packard electrical connectors, those with pull-to-seat termi-

mating end of the connector. Once a new terminal is crimped

nals and those with push-to-seat terminals.

onto the end of the wire, the wire is pulled to draw the termi-

nal back inside the chamber of the connector housing.

Look into the mating end of the connector. If it appears that

the terminal can be extracted from this side, then it is proba-

bly the pull-to-seat type.

Two types of Packard pull-to-seat electrical connectors are

used. One type has an external latch to lock the pin and

At least one Packard pull-to-seat terminal can be easily rec-

socket halves together, while the other makes use of a wire-

ognized by the presence of a locking ear. The ear engages a

form. See Figure 5-20. The manner in which the terminals are

slot in the connector housing and prevents the terminal from

picked differs between these two types of connectors, as fur-

being removed from the wire end side of the connector. The

ther described below.

ear also acts as a strain relief in the event that the wires are

pulled and further inhibits movement of the terminal inside

the chamber.

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Locate tang on latch side of chamber.

Push on wire end of lead to

remove terminal.

Pivot end of pin to depress tang.

Raise tang and re-install terminal.

Figure 5-20. Packard Connectors

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PULL-TO-SEAT TERMINALS

Installing External Latch Type

NOTE

For wire location purposes, alpha characters are stamped

Removing External Latch Type

into the socket housings.

To remove a pull-to-seat terminal from connectors with exter-

To install a terminal back into the chamber of the connec-

nal latches, proceed as follows:

tor housing, use a thin flat blade, like that on an X-Acto

Remove the connector from the retaining device, if

knife, and carefully bend the tang outward away from the

present.

terminal body. See D in Figure 5-20.

Bend back the external latch(es) slightly and separate

Gently pull on the lead at the wire end of the connector to

the pin and socket halves of the connector.

draw the terminal back into the chamber. A click is heard

when the terminal is properly seated.

To free a pull-to-seat terminal from the connector hous-

ing, first look into the mating end of the connector to find

Push on the lead to verify that the terminal is locked in

the locking tang. See A in Figure 5-20. The tangs are

place.

always positioned in the middle of the chamber and are

4. Push the pin and socket halves of the connector together

on the same side as the external latch. On those connec-

until the latches “click.”

tors with locking ears, the tang is on the side opposite

the ear.

PUSH-TO-SEAT TERMINALS

At a slight angle, gently insert the point of a one inch

safety pin down the middle of the chamber (about 1/8

inch) and pivot the end of the pin toward the terminal

Removing Push-to-Seat Terminals

body. When a click is heard, remove the pin and repeat

the procedure. See B in Figure 5-20. The click is the

Like most connectors, Packard push-to-seat terminals are

sound of the tang returning to the locked position as it

pulled out the wire end of the connector. To remove a push-

slips from the point of the pin. Pick at the tang in this

to-seat terminal, proceed as follows:

manner until the clicking stops and the pin seems to slide

Remove the connector from the retaining device, if

in at a slightly greater depth than it had previously. This is

present.

an indication that the tang has been depressed.

Bend back the external latch(es) slightly and separate

NOTES

the pin and socket halves of the connector.

●

On those terminals that have been extracted on a previ-

ous occasion, no clicking sound may be heard when the

NOTE

pin is pivoted to depress the tang, but proceed as if the

Both the Ignition/Light Switch and the Main Power connectors

clicking is audible and then push on the wire end of the

are provided with secondary locks. The secondary lock,

lead to check if the terminal is free.

which may be molded onto the connector or exist as a sepa-

rate piece, aids in terminal retention. Secondary locks must

●

When picking multiple terminals, the end of the pin may

be opened

(or removed) before the terminals can be

become malleable. For best results, continue the proce-

extracted from the connector housing.

dure with a new safety pin.

Remove the pin and push on the wire end of the lead to

extract the terminal from the mating end of the connec-

tor. See C in Figure 5-20. If necessary, pull back the con-

duit and remove the wire seal at the back of the

connector to introduce some slack in the wires.

NOTE

A series of Packard Electrical Terminal Crimp Tools are avail-

able to install Packard pin and socket terminals on wires. If

new terminals must be installed, see Crimping Instructions.

2006 Sportster: Wiring

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Open or remove the secondary lock. Ignition Switch:

CRIMPING INSTRUCTIONS

Bend back the latch slightly and free one side of the sec-

ondary lock, then repeat the step to release the other

1. Strip wire lead removing 5/32 in. (4 mm) of insulation.

side. Rotate the secondary lock outward on hinge to

2. Compress handles until ratchet automatically opens.

access the terminals in the chambers of the connector

housing.

NOTE

Looking in the mating end or terminal side of the connec-

Always perform core crimp before insulation/seal crimp.

tor (opposite the secondary lock), take note of the larger

3. Determine the correct die or nest for the core crimp by

cavity next to each terminal.

checking with the appropriate crimp table.

Insert the pick (Snap-On TT600-3) into the cavity until it

NOTE

stops. Pivot the end of the pick toward the terminal to

When the word “TIP” appears in the Crimp Table, use the tip

depress the locking tang. Remove the pick and gently

of the tool specified to perform the core crimp procedure. See

tug on the wire to pull the terminal from the wire end of

Figure 5-21.

the connector. Repeat the step if the terminal is still

locked in place.

NOTE

d0259x8x

A series of Packard Electrical Terminal Crimp Tools are avail-

Tool tip

able to install Packard pin and socket terminals on wires. If

new terminals must be installed, see Crimping Instructions.

Installing Push-to-Seat Terminals

NOTE

For wire location purposes, alpha characters are stamped

onto the secondary locks or onto the wire end of the connec-

tor housing.

1. To install a terminal back into the chamber of the connec-

tor housing, use a thin flat blade, like that on an X-Acto

knife, and carefully bend the tang outward away from the

terminal body.

2. Push the lead into the chamber at the wire end of the

connector. A click is heard when the terminal is properly

seated.

Packard 115

Packard 271

3. Gently tug on the wire end to verify that the terminal is

locked in place and will not back out of the chamber.

4. Close or install the secondary lock. Ignition Switch:

Figure 5-21. Packard Terminal Crimp Tools

Rotate the hinged secondary lock inward until tabs fully

engage latches on both sides of connector.

5. Push the pin and socket halves of the connector together

until the latches “click.”

Table 5-3. Packard Terminal Crimp Tools

6. Install connector on retaining device, if present.

SPECIFICATION

PACKARD 115

PACKARD 271

Part No.

HD-38125-8

HD-38125-7

Non-sealed

Type of Crimp

terminals,

terminals

butt splices

Die/nests

F-G

A-E

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4. Lay the back of the core crimp tails on the appropriate

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nest. Be sure the core crimp tails are pointing towards

the forming jaws.

5. Gently apply pressure to handles of tool until crimpers

slightly secure the core crimp tails.

6. Insert stripped wire between crimp tails. Verify that wire

is positioned so that short pair of crimp tails squeeze

bare wire strands, while long pair folds over insulation or

seal material.

7. Squeeze handle of crimp tool until tightly closed. Tool

automatically opens when the crimping sequence is

complete.

8. Determine the correct die or nest for the insulation/seal

crimp.

1. Insulation

9. Lay the back of the insulation/seal crimp tails on the

2. Insulation crimp

appropriate nest. Be sure the insulation/seal crimp tails

3. Core crimp

are pointing towards the forming jaws.

Figure 5-22. Inspect Core and Insulation/Seal Crimps

10. Squeeze handle of crimp tool until tightly closed. Tool

automatically opens when the crimping sequence is

complete.

11. See Figure 5-22. Inspect the quality of the core (3) and

insulation/seal (2) crimps. Distortion should be minimal.

2006 Sportster: Wiring

5-17

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MICRO 64 TERMINALS

HD45929

General

Use the following instructions to service the speedometer and

tachometer connectors.

Removal

Bend back the external latches slightly and separate the

pin and socket halves of the connector.

Figure 5-23. Packard Micro 64 Terminal Remover

(Part No. HD-45928).

NOTE

To differentiate between the speedometer and tachometer

connectors, note that the speedometer connector has a sec-

ond length of conduit leading to the odometer reset switch.

Small

f2202x8x

Locate the head of the secondary lockpin on one side of

Hole

the connector housing. See Figure 5-24.

Secondary

3. Insert the blade of a small screwdriver between the cen-

Lockpin

ter ear of the lockpin and the connector housing and

gently pry out lockpin. When partially removed, pull lock-

pin from connector housing.

4. Obtain the Packard Micro 64 Terminal Remover (HD-

45928). See Figure 5-23. Proceed as follows:

a. Locate small hole between terminals on mating end

of connector. See Figure 5-24.

b. Push the adjacent terminals all the way into the con-

nector housing and then insert tool into hole until it

Figure 5-24. Mating End of Connector

bottoms. See upper frame of Figure 5-25.

c. Leaving the tool installed, gently tug on wires to pull

either one or both terminals from wire end of con-

nector. See lower frame of Figure 5-25. Remove

tool.

5. If necessary, crimp new terminals on wires. See Crimp-

ing Instructions in this section.

Installation

NOTE

For wire location purposes, the corners of the socket housing

are stamped with the numbers 1, 6, 7 and 12, representing

terminals 1-6 on one side, and 7-12 on the other. See Figure

5-24.

f2196x8x

Insert terminal into its respective numbered chamber on

wire end of connector. No special orientation of the ter-

minal is necessary.

Bottom the terminal in the chamber and then gently tug

on the wire to verify that it is locked in place.

NOTE

Once the terminal is removed it may not lock in place when

first reinstalled. Until the lock engages, move the terminal

back and forth slightly while wiggling the lead.

f2197x8x

Figure 5-25. Insert Tool and Remove Terminal

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HD45928

Figure 5-26. Packard Micro 64 Terminal Crimper

(Part No. HD-45929)

f2198x8x

Figure 5-27. Raise Locking Bar and Barrel Holder

3. Since the terminal remover tool releases two terminals

simultaneously, repeat step 2 on the adjacent terminal

even if it was not pulled from the connector housing.

f2199x8x

4. With the center ear on the head of the secondary lockpin

facing the mating end of the connector, push lockpin in

until head is flush with the connector housing.

5. Push the pin and socket halves of the connector together

until the latches “click.”

Crimping Instructions

Strip lead removing 1/8 inch (3.0 mm) of insulation.

Obtain the Packard Micro 64 Terminal Crimper (HD-

45929). See Figure 5-26.

Squeeze the handles to cycle the tool to the fully open

Locking

Barrel

position.

Bar

Holder

Obtain new contact (socket terminal). Verify that contact

Figure 5-28. Position Contact in Crimper

and crimp tails are not bent or deformed.

Raise locking bar and barrel holder by pushing up on

bottom tab with index finger. See Figure 5-27.

With the crimp tails facing upward, insert contact through

locking bar into front hole in barrel holder (20-22 gauge

wire).

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 and the closed

side of the terminal rests on the outer nest of the crimp

tool. See Figure 5-28.

Insert wires between crimp tails until ends make contact

with locking bar. Verify that wire is positioned so that wide

pair of crimp tails squeeze bare wire strands, while the

f2201x8x

narrow pair folds over the insulation material.

Squeeze handle of crimp tool until tightly closed. Tool

Figure 5-29. Crimp Terminal Onto Wire

automatically opens when the crimping sequence is

complete. See Figure 5-29.

10.

Raise locking bar and barrel holder to remove contact.

11.

Inspect the quality of the core and insulation crimps. Dis-

tortion should be minimal.

2006 Sportster: Wiring

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INDEX TO WIRING DIAGRAMS

5.7

Table 5-4. Wiring Diagrams

DIAGRAM

PAGE

2006 ALL SPORTSTER DOM. and INT. MODELS, MAIN HARNESS, PAGE 1 OF 2

5-21

2006 ALL SPORTSTER DOM. and INT. MODELS, MAIN HARNESS, PAGE 2 OF 2

5-23

2006 ALL SPORTSTER DOM. and INT. MODELS, IGNITION CIRCUIT, PAGE 1 OF 1

5-25

2006 ALL SPORTSTER DOM. and INT. MODELS, STARTING AND CHARGING, PAGE 1 OF 1

5-27

2006 ALL SPORTSTER DOM. and INT. MODELS, HORN AND INSTRUMENTS, PAGE 1 OF 1

5-29

2006 ALL SPORTSTER DOM. and INT. MODELS, LIGHTS, PAGE 1 OF 2

5-31

2006 ALL SPORTSTER DOM. and INT. MODELS, LIGHTS, PAGE 2 OF 2

5-33

2006 ALL SPORTSTER DOM. and INT. MODELS, SECURITY, PAGE 1 OF 2

5-35

2006 ALL SPORTSTER DOM. and INT. MODELS, SECURITY, PAGE 2 OF 2

5-37

Table 5-5. Wire Color Code Key

ABBREVIATION

COLOR

Black

Brown

Red

Orange

Yellow

Green

Blue

Violet

Gray

White

Pink

Tan

LGN

Light Green

Wire color-XX/XX-Stripe color

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2006 Sportster: Wiring

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xd0021xxx

Main Harness 1 of 2

HORN

REAR LAMPS

LEFT HAND

FRONT TURN

RIGHT HAND

VOLTAGE

SIGNALS

CONTROL (BK)

[7A]

CONTROL (GY)

REGULATOR

STARTER

Y-BK

[24A]

[31A]

[22A]

2 3

3 4 56

IGN

30 AMP

[46A]

SWITCH

MAXIFUSE

1 2

[33]

[5B]

REAR

1 2

STOPLIGHT

SWITCH

[46B]

[121]

HEADLAMP

[77A]

[38A]

O/W

B A

BATTERY

[77B]

O/W

BN/GY

INSTRUMENTS

LGN/V

[20A]

GN/Y

[61B]

STATOR

BN/V

IGNITION

POWERTRAIN

15A

GROUND

R/BK

POINT

GN/Y

LIGHTS

15A

[136A]

[136B]

R/BK

[142A]

[142B]

[GND1]

[GND2]

INSTRUMENTS

15A

OPTIONAL

R/BK

SECURITY SIREN

ACCESSORIES

LGN/BN

OIL PRESSURE

BN/GY

15A

NEUTRAL SWITCH

SWITCH

[131]

0/W

R/GY

[120]

BATTERY

[30A]

15A

[30B]

BN/GY

BATTERY

BN/GY

IGNITION

VSS / SERIAL DATA LINK

LGN/V

SECURITY INDICATOR

BN/V

LEFT TURN FEED

RIGHT TURN FEED

[62A]

TURN SIGNAL/SECURITY MODULE

RIGHT TURN SWITCH INPUT

W/BN

LEFT TURN SWITCH INPUT

W/V

START RELAY CONTROL

TN/GN

T K USE

IGNITION ENABLE SIGNAL

ALARM SIGNAL

LGN/BN

[62B]

GROUND

BK/R

R/BK

TN/GN

DATA

LGN/V

[160B]

LINK

[91A]

B+ CONNECTOR

IGNITION

9 amp max.

COIL

Y/BE

W/BK

BE/O

[65A]

Twisted Pair

[65B]

[83A]

[83B]

BK/R

BK/BE

START RELAYACCESSORY

IGNITION

15A

[BLK]

BATTERY

INSTRUMENTS

[10A]

15A

[10B]

LIGHTS

VEHICLE SPEED SENSOR

SPARE

RUN/STOP SIGNAL

W/BK

U T S

15A

BATTERY

BN/GY

+5V SENSOR PWR

R/W

MAP

SENSOR GROUND

BK/W

SENSOR

[61] TOP VIEW

MODULE GROUND

[80A]

COIL FRONT

BE/O

BK/W

[79B]

IGNITION CONTROL MODULE

COIL REAR

Y/BE

CRANK SENSOR (+)

[80B]

CRANK SENSOR (-)

VEHICLE SPD SIG

W/GN

1 2

MAP SIGNAL

V/W

CRANK POSITION

DATALINK

LGN/V

SENSOR

PIN CONNECTOR

(A side)

[79A]

R BK

SOCKET CONNECTOR

(B side)

2006 ALL SPORTSTER DOM. and INT. MODELS, MAIN HARNESS, PAGE 1 OF 2

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2006 ALL SPORTSTER DOM. and INT. MODELS,

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xd0022xxx

Main Harness 2 of 2

[39A]

[39B]

TRIP RESET

POSITION LAMP

SWITCH

HDI ONLY

IGNITION

DATABUS

LGN/V

SECURITY LP

BN /V

BATTERY

BN/GY

ACCESSORY

O/W

SPEEDOMETER

GROUND

TRIP SW

FUEL LEVEL

TRIP SW

[38B]

O-W

RIGHT

BN/GY

TURN

O/W

[108A]

[108B]

HAND CONTROLS,

[

212]

RIGHT

IGNITION

MAIN

[162 ]

DATALINK

LGN/V

HARNESS

[20B]

PURSUIT

GN/Y

HEADLAMP

RPM x 100

BATTERY

BN/GY

ACCESSORY

O/W

RIGHT TURN SWITCH

TACHOMETER

[31B]

GROUND

ENGINE STOP/RUN SWITCH

START SWITCH

CRUISE ENGAGED

STOPLIGHT SWITCH

CRUISE ENABLE

[

182

]

DOM ONLY

[22B]

LEFT

TURN

[214]

CONFIGURATION FOR XL1200R

RIGHT

TURN

[190]

[24B]

[39A]

[39B]

IGNITION

R/Y

DATABUS

LGN/V

HORN SWITCH

SECURITY LP

BN /V

O/W

HEADLAMP HI/LO SWITCH

BATTERY

BN/GY

ACCESSORY

O/W

LEFT TURN SWITCH

SPEEDOMETER

GROUND

[94B]

[7B]

TAIL LAMP

TRIP SW

5 4

FUEL LEVEL

[198]

HAND CONTROLS,

5 4

LEFT

TRIP SW

[19B]

[163]

O/W

[94A]

BN/GY

[19A]

TRIP RESET

SWITCH

MAIN

BRAKE LIGHT

LGN/V

HARNESS

[18B]

[18A]

[20B]

GN/Y

BN /V

R/Y

O/W

RUNNING LIGHT (HDI)

RUNNING LIGHT (DOM)

[93A]

[93B]

PIN CONNECTOR

(A side)

LEFT

SOCKET CONNECTOR

CONFIGURATION FOR XL883, XL883L, XL883R, XL883C, XL1200C

TURN

(B side)

[ 194]

2006 ALL SPORTSTER DOM. and INT. MODELS, MAIN HARNESS, PAGE 2 OF 2

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2006 ALL SPORTSTER DOM. and INT. MODELS,

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xd0030xxx

Ignition 1 of 1

HAND CONTROLS,

RIGHT

[162]

[39A]

[39B]

RIGHT TURN SWITCH

ENGINE STOP/RUN SWITCH

IGNITION

DATABUS

LGN/V

START SWITCH

SECURITY LP

PIN CONNECTOR

STOPLIGHT SWITCH

BATTERY

(A side)

ACCESSORY

SPEEDOMETER

GROUND

SOCKET CONNECTOR

TRIP SW

(B side)

IGNITION SWITCH LEGEND

FUEL LEVEL

SWITCH

RED/BLACK

RED

RED/GRAY

POSITION

TRIP SW

[22B]

OFF

6 5 4 3

ACC.

IGNITION

STARTER

6 5 4

2 1

[108A]

[108B]

DOT INDICATES CONTINUITY WITH RED

[22A]

WIRE IN SWITCH POSITION INDICATED

IGNITION

MAIN

DATALINK

LGN/V

HARNESS

IGNITION

SWITCH

PURSUIT

[20B]

RPM x 100

BATTERY

ACCESSORY

B A

TACHOMETER

GROUND

[61B]

CRUISE ENGAGED

IGN: 15A

CRUISE ENABLE

[30A]

[30B]

R/BK

BATTERY

30 AMP

IGNITION

MAXI-FUSE

VSS / SERIAL DATA LINK

LGN/V

[5B]

SECURITY INDICATOR

LEFT TURN FEED

RIGHT TURN FEED

TURN SIGNAL/

RIGHT TURN SWITCH INPUT

SECURITY MODULE

LEFT TURN SWITCH INPUT

CONFIGURATION FOR XL1200R

START RELAY CONTROL

IGNITION ENABLE SIGNAL

ALARM SIGNAL

GROUND

TS/TSSM

START RELAY

ACCESSORY

IGNITION

15A

BATTERY

INSTRUMENTS

15A

LIGHTS

SPARE

U T S

15A

INSTRUMENTS

[61] TOP VIEW

[20A]

LGN/V

[39A]

[39B]

IGNITION

POWERTRAIN

DATABUS

LGN/V

GROUND

SECURITY LP

POINT

BATTERY

ACCESSORY

SPEEDOMETER

GROUND

DATA

LGN/V

TRIP SW

LINK

FUEL LEVEL

[91A]

IGNITION

[GND1]

TRIP SW

COIL

[65A]

Y/BE

Twisted Pair

[65B]

W/BK

BE/O

BK/R

VEHICLE

BK/BE

SPEED

MAIN

[83A]

[83B]

SENSOR

LGN/V

HARNESS

[20B]

[BLK]

[10A]

[10B]

RUN/STOP SIGNAL

W/BK

BATTERY

+5V SENSOR PWR

R/W

MAP

SENSOR GROUND

BK/W

SENSOR

MODULE GROUND

BK/W

[80A]

CRANK POSITION

COIL FRONT

BE/O

[79B]

SENSOR

IGNITION CONTROL MODULE

COIL REAR

Y/BE

CRANK SENSOR (+)

[80B]

CRANK SENSOR (-)

CONFIGURATION FOR XL883, XL883L, XL883R, XL883C, XL1200C

VEHICLE SPD SIG

BK/BE

1 2

MAP SIGNAL

V/W

DATALINK

LGN/V

[79A]

R BK

2006 ALL SPORTSTER DOM. and INT. MODELS, IGNITION CIRCUIT, PAGE 1 OF 1

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2006 ALL SPORTSTER DOM. and INT. MODELS,

IGNITION CIRCUIT, PAGE 1 OF 1

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Harley Davidson 2006 Sportster XLH MODELS. Service Manual — page 38

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