Harley Davidson 2006 Sportster XLH MODELS. Service Manual — page 24

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BULB REQUIREMENTS

7.3

BULB CHART

Table 7-6. Bulb Chart (All Models)

LAMP DESCRIPTION

NUMBER OF

CURRENT DRAW

HARLEY-DAVIDSON

(ALL LAMPS 12 V)

BULBS REQUIRED

(AMPERES)

PART NUMBER

HEADLAMP

High beam/low beam

4.58/5.00

67329-03

High beam/low beam (HDI)

4.58/5.00

67697-81

Position lamp (HDI)

0.32

53438-92

DIRECTIONAL/RUNNING LAMPS

Front running

0.59/2.25

68168-89

Rear directional

2.25

68572-64B

Front (HDI)

1.75

68163-84

Rear (HDI)

1.75

68163-84

TAIL AND STOP LAMP

Tail lamp

0.59

68167-88

Stop lamp

2.10

68167-88

Tail lamp (HDI)

0.59

68167-88

Stop lamp (HDI)

2.10

68167-88

INSTRUMENT PANEL INDICATOR LAMPS

High beam

0.15

68024-94

Oil pressure

0.15

68024-94

Neutral

0.15

68024-94

Directional

0.15

68024-94

GAUGE LAMPS

Speedometer*

N/A

Odometer*

N/A

Tachometer*

N/A

*Illuminated with LEDs

2006 Sportster: Electrical

7-3

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BATTERY TRAY

7.4

GENERAL

11764

See Figure 7-1. The battery tray is located behind the vehi-

cle’s left side cover. The battery tray is a light-weight, sturdy

plastic assembly which supports the battery, TSM/TSSM, and

rear brake lamp switch assembly.

REMOVAL

Remove left side cover. See REMOVING LEFT SIDE

COVER under 1.6 LEFT SIDE COVER.

1WARNING

Prevent accidental vehicle start-up, which could cause

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

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

tery. (00280a)

Disconnect battery cables, negative cable first, and

Rear brake hose clamp

remove battery. See BATTERY DISCONNECTION AND

Battery tray

REMOVAL under 1.7 BATTERY MAINTENANCE.

TORX screw

Rear brake lamp switch assembly

Reach under battery tray and push TSM/TSSM up from

H-bracket

cavity in bottom of tray. Unplug and remove TSM/TSSM.

TSM/TSSM connector [30B]

See REMOVAL under 7.32 TURN SIGNAL/SECURITY

MODULE (TSM/TSSM).

Figure 7-1. Battery Tray Assembly

Remove rear brake master cylinder reservoir cover.

Unbolt reservoir and secure out of the way with an elastic

tiedown cord, mechanic’s wire or cable strap. See 2.13

REAR BRAKE MASTER CYLINDER RESERVOIR.

See Figure 7-1. Remove screw securing rear brake hose

clamp (1) to battery tray (2).

Remove TORX screw (3) securing rear brake lamp

switch assembly (4) to battery tray. Gently pull brake

lamp switch assembly back out of the way. Do not bend

or stress metal brake lines.

See Figure 7-2. Remove three screws (4) securing bat-

tery tray to mounting tabs (5) on frame.

x0667x7x

Frame

Battery tray

Battery strap support

Screw (3)

Tray mounting tabs on frame (3)

Figure 7-2. Battery Tray Mounting Screws

7-4

2006 Sportster: Electrical

HOME

See Figure 7-3. Slide H-bracket (1) up frame tube as far

INSTALLATION

as possible and disengage battery tray upright support

(3) from tabs (2) on H-bracket.

See Figure 7-1. Make sure TSM/TSSM connector [30B]

(6) and rear brake lamp switch assembly (4) are out of

CAUTION

the way.

Slide battery tray (2) into place behind H-bracket (5).

Do not exert excessive force on H-bracket or battery tray.

Make sure battery tray mounting tabs are positioned

Doing so may damage H-bracket or tray upright support.

behind (to the right of) frame mounts.

Lift up battery tray slightly so that mounting tabs will clear

See Figure 7-3. Push H-bracket (1) up as far as possible

mounts on frame. See Figure 7-2. As you lift up on tray,

and engage battery tray upright support (3) into tabs (2)

pull down gently on end of battery strap support (3) to

on H-bracket.

clear frame and wiring harnesses above battery tray.

See Figure 7-2. Install three screws (4) to secure battery

10. Slide battery tray out and remove from left side of vehi-

tray to frame. Do not tighten screws until all three have

cle.

been started. Then tighten screws to

96-156 in-lbs

(10.9-17.6 Nm).

See Figure 7-1. Install rear brake lamp switch (4). Secure

11765

with TORX screw (3). Tighten to 72-120 in-lbs (8.1-13.6

Nm).

Secure brake hose clamp (1) to battery tray with screw.

Tighten to 30-40 in-lbs (3.4-4.5 Nm).

Install rear brake master cylinder reservoir. Secure using

screw with captive washer. Tighten to 20-25 in-lbs (2.3-

2.8 Nm). Install reservoir cover. See 2.13 REAR BRAKE

MASTER CYLINDER RESERVOIR.

Plug TSM/TSSM connector [30B] into TSM/TSSM. Install

TSM/TSSM into cavity in bottom of battery tray. See

INSTALLATION under 7.32 TURN SIGNAL/SECURITY

MODULE (TSM/TSSM).

1WARNING

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

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

nected, the resulting sparks can cause a battery explo-

sion, which could result in death or serious injury.

(00068a)

9. Install battery. Connect battery cables, positive (+) cable

H-bracket

first. See BATTERY INSTALLATION AND CONNEC-

Tabs

TION under 1.7 BATTERY MAINTENANCE.

Upright support

Battery tray

10. Install left side cover. See INSTALLING LEFT SIDE

COVER under 1.6 LEFT SIDE COVER.

Figure 7-3. Battery Tray H-Bracket Support

2006 Sportster: Electrical

7-5

HOME

IGNITION SYSTEM

7.5

The CKP sensor is located in the front left side of the crank-

GENERAL

case. Readings are taken off the 30 teeth on the left side fly-

wheel (two teeth are missing to establish a reference point).

The ignition system consists of five component assemblies:

The CKP generates an AC signal which is sent to the ICM

● the ignition control module (ICM),

where it is used to reference engine position (TDC) and

speed.

● the crank position (CKP) sensor,

● the manifold absolute pressure (MAP) sensor,

The MAP sensor is located on top of the intake manifold. The

MAP sensor monitors the intake manifold pressure (vacuum)

● the bank angle sensor (BAS), incorporated into the TSM/

and sends the information to the ICM which adjusts the timing

TSSM.

advance curve for optimum performance.

● the ignition coil, spark plugs and spark plug wires.

The BAS is located inside the Turn Signal Module (TSM) or

The ICM is mounted under the seat. The ICM contains all of

optional Turn Signal Security Module (TSSM) located in the

the solid state components used in the ignition system.

bottom of the battery tray.

The ICM computes the spark advance for ignition timing

The BAS will shut the ignition off, if the vehicle lean angle

based on sensor input from the CKP sensor and MAP sensor.

exceeds 45° for more than one second. Once the sensor is

The ICM also regulates the low-voltage circuits between bat-

tripped, the motorcycle must be uprighted, turned off and

tery and ignition coil.

then on again before the engine can be restarted. The BAS

signal is delivered to the ICM via the Serial Data Link circuit

The dwell time for the ignition coil is also calculated in the

from the TSM/TSSM.

microprocessor of the ICM and is dependent upon battery

voltage. The programmed dwell is an added feature to keep

The ignition coil is divided into front and rear coils that fire the

battery drain to a minimum and yet give adequate spark dura-

spark plugs independently, one cylinder at a time.

tion at all speeds.

The ignition system provides a spark near top dead center for

A computer based diagnostic tool, DIGITAL TECHNICIAN

starting. At RPM and loads above this, the system gives a

(Part No. HD-44750), can access the information received by

spark advance that varies between 0° and 58°.

and stored in the ICM.

The ICM has added protection against transient voltages,

TROUBLESHOOTING

continuous reverse voltage protection, and protection against

damage due to jump starts. The ICM is fully enclosed in a

See the SPORTSTER MODELS ELECTRICAL DIAGNOS-

polyurethane material to protect it from vibration, dust, water

TIC MANUAL for complete troubleshooting information.

or oil.

NOTE

The ICM cannot be repaired. Replace the unit if it fails.

7-6

2006 Sportster: Electrical

HOME

x0607a7x

HAND CONTROLS,

RIGHT

[162 ]

BATTERY

RIGHT TURN SWITCH

ENGINE STOP/RUN SWITCH

START SWITCH

STARTER

W/BK

STOPLIGHT SWITCH

IGNITION SWITCH LEGEND

SWITCH

RED/BLACK

RED

RED/GRAY

POSITION

OFF

[22B]

ACC.

6 5 4 3

IGNITION

DOT INDICATES CONTINUITY WITH RED

6 5 4 3

WIRE IN SWITCH POSITION INDICATED

IGNITION

30 AMP

[22A]

MAXI-FUSE

SWITCH

[5B]

W/BK

B A

[64B]

TURN SIGNAL/SECURITY MODULE

IGN: 15A

R/BK

BATTERY

IGNITION

VSS / SERIAL DATA LINK

LGN/V

SECURITY INDICATOR

POWERTRAIN

LEFT TURN FEED

GROUND

RIGHT TURN FEED

RIGHT TURN SWITCH INPUT

POINT

LEFT TURN SWITCH INPUT

START RELAY CONTROL

IGNITION ENABLE SIGNAL

ALARM SIGNAL

GROUND

TS/TSSM

[GND1]

[30A]

[30B]

[20A]

START

RELAY

[62A]

LGN/V

U S E T K

BK/R

[62B]

TN/GN

INSTRUMENTS

DATA

LGN/V

LINK

BLK

R/BK

[91A]

IGNITION

COIL

Y/BE

W/BK

BE/O

[83A]

[83B]

CRANK POSITION

[BLK]

SENSOR

[10A]

[10B]

RUN/STOP SIGNAL

W/BK

[79B]

BATTERY

+5V SENSOR PWR

R/W

1 2

SENSOR GROUND

BK/W

MODULE GROUND

BK/W

COIL FRONT

BE/O

COIL REAR

Y/BE

MAP

[79A]

CRANK SENSOR (+)

[80B]

SENSOR

CRANK SENSOR (-)

[80A]

VEHICLE SPD SIG

MAP SIGNAL

V/W

DATALINK

LGN/V

Figure 7-4. Ignition Circuit (All Models)

HOME

MANIFOLD ABSOLUTE PRESSURE SENSOR (MAP)

7.6

REMOVAL

10080

1WARNING

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.

XL 883C/XL 1200C:

a. Remove seat. See REMOVAL under 2.32 SEAT.

b. Remove fuel tank. See 4.8 FUEL TANK REMOVAL.

See Figure 7-5. Remove wiring harness connector [80B]

from MAP sensor connector [80A] (6). Remove screw (1)

and clip (2).

With a slight twisting motion, pull MAP sensor (3) straight

out of intake manifold body.

NOTE

x0555a7x

The MAP sensor cannot be repaired. Replace the unit if it

fails.

INSTALLATION

See Figure 7-5. Install new MAP sensor (3) with mount-

ing seal (4) into hole in top of intake manifold (5). Gently

press down on sensor body until it is fully seated onto

manifold.

Install clip (2) and secure with screw (1). Tighten to 25-35

in-lbs (2.8-3.9 Nm).

Plug wiring harness connector [80B] into MAP sensor

connector [80A] (6).

XL 883C/XL 1200C:

a. Install

fuel

tank. See

4.8

FUEL TANK

INSTALLATION.

Screw

Clip

MAP sensor

1WARNING

MAP sensor mounting seal

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

Intake manifold

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

MAP sensor connector [80A]

shift causing loss of control, which could result in death

or serious injury. (00070a)

Figure 7-5. MAP Sensor

b. Install seat. See INSTALLATION under 2.32 SEAT.

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

side cover.

7-8

2006 Sportster: Electrical

HOME

IGNITION/LIGHT SWITCH

7.7

GENERAL

10445

See Figure 7-6. A combination ignition and light switch is

located on the right side of the frame in front of the fuel tank.

The motorcycle key unlocks the ignition/light switch. The rider

rotates the key to select one of three positions. Refer to

Table 7-7.

NOTE

The ignition/light switch cannot be repaired. Replace the unit

if it fails.

Table 7-7. Ignition/Light Switch Positions

POSITION

FUNCTION

OFF

Ignition locked, lights off; key removable

Ignition locked, instrument lights on;

ACC(essory)

key removable

(HDI: position lamp and tail lamp on)

OFF

Ignition unlocked, lights on;

IGNITION

ACC

key not removable

IGNITION

Switch cover

To lock the switch, the key is removed in either OFF or ACC.

Face nut

To leave the 4-way flashers and the tail lamp on and lock the

Mounting fastener

switch, the rider can remove the key in ACC. In ACC, the

instrument (icon) lamps, 4-way flashers (front and rear direc-

Figure 7-6. Ignition/Light Switch

tional) and tail/brake lamp are on or can be activated. On HDI

(XL 1200C shown)

motorcycles the position lamp and taillight are on.

CAUTION

Turn the ignition switch to the OFF position and remove

the key before locking the motorcycle. Leaving the key in

the ACC position will keep the instrument lights on and

result in a discharged battery. (00155a)

1WARNING

The automatic-on headlamp feature provides increased

visibility of the rider to other motorists. Be sure head-

lamp is on at all times. Poor visibility of rider to other

motorists can result in death or serious injury. (00030b)

2006 Sportster: Electrical

7-9

HOME

5. Install and tighten mounting screw (7) to 35-45 in-lbs

REMOVAL

(4.0-5.1 Nm).

6. Tighten face nut (5) to secure switch (2) within cover (3).

1WARNING

7. Using two new cable straps (6), secure main harness to

frame backbone.

To prevent accidental vehicle start-up, which could

8. Install fuel tank. See INSTALLATION under 4.8 FUEL

cause death or serious injury, remove maxi-fuse before

TANK .

proceeding. (00251a)

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

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

side cover.

side cover. See 7.25 MAXI-FUSE.

10. Check ignition/light switch for proper operation.

See Figure 7-7. Remove ignition switch face nut (5).

Remove fuel tank. See REMOVAL under 4.8 FUEL

TANK.

x0064a7x

Remove mounting screw (7). Remove switch cover (3).

Remove switch (2) from switch cover (3).

Remove harness covering and cut switch wires 3 in.

(76.2 mm) from switch.

INSTALLATION

Slide replacement conduit on harness wires.

1WARNING

Be sure to follow manufacturer's instructions when

using the UltraTorch UT-100 or any other radiant heating

device. Failure to follow manufacturer's instructions can

cause a fire, which could result in death or serious injury.

(00335a)

Observing color codes, install butt connectors to harness

wires. Complete butt splice to new ignition switch. Seal

Butt connector

butt splice connectors using UltraTorch UT-100 (Part No.

Ignition/light switch

HD-39969) or other radiant heating device. See B.5

Switch cover

SEALED BUTT SPLICE CONNECTORS for more

Decal

detailed information.

Face nut

Slide conduit over butt splice connectors.

Cable strap (2)

Fastener

See Figure 7-7. Insert ignition switch into hole of switch

cover. The word “TOP” stamped on the switch body

should face upward toward the lettering on the switch

Figure 7-7. Ignition/Light Switch Assembly

position decal. Loosely install face nut (5).

7-10

2006 Sportster: Electrical

HOME

IGNITION CONTROL MODULE (ICM)

7.8

GENERAL

REMOVAL

See Figure 7-8. The ignition control module (ICM) is located

1. Remove seat. See REMOVAL under 2.32 SEAT.

under the seat. The ICM receives data from the crank position

(CKP) sensor and the manifold absolute pressure (MAP) sen-

1WARNING

sor. The ICM uses this data to time the firing of the spark from

the ignition coil.

To prevent accidental vehicle start-up, which could

cause death or serious injury, remove maxi-fuse before

NOTE

proceeding. (00251a)

The ignition control module cannot be repaired. Replace the

unit if it fails.

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

side cover. See 7.25 MAXI-FUSE.

3. See Figure 7-8. Disconnect ICM wiring harness connec-

10057

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

4. Remove two lock nuts (3) securing ICM to motorcycle.

Remove ICM.

INSTALLATION

1. See Figure 7-8. Install ICM (1) on mounting studs.

2. Install lock nuts (3) on studs. Tighten to 12-15 in-lbs

(1.4-1.7 Nm).

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

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

side cover.

5. Perform reprogramming and password learn procedure.

See the SPORTSTER MODELS ELECTRICAL DIAG-

NOSTIC MANUAL for instructions.

Ignition Control Module (ICM)

1WARNING

ICM wiring harness connector [10]

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

Lock nut (2)

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

Rear fender

shift causing loss of control, which could result in death

or serious injury. (00070a)

Figure 7-8. ICM

6. Install seat. See INSTALLATION under 2.32 SEAT.

2006 Sportster: Electrical

7-11

HOME

SPARK PLUG CABLES

7.9

GENERAL

10746

Resistor-type high-tension spark plug cables have a carbon-

impregnated fabric core (instead of solid wire) for radio noise

suppression and improved reliability of electronic compo-

nents. Use the exact replacement cable for best results.

REMOVAL

1WARNING

To prevent accidental vehicle start-up, which could

Front spark plug cable

cause death or serious injury, remove maxi-fuse before

Rear spark plug cable

proceeding. (00251a)

Figure 7-9. Routing Spark Plug Cables from Ignition Coil

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

side cover. See 7.25 MAXI-FUSE.

1WARNING

11472

Never disconnect a spark plug cable with the engine run-

ning. If you disconnect a spark plug cable with the

engine running, you may receive a shock from the igni-

tion system which could result in death or serious injury.

CAUTION

When disconnecting each spark plug cable from its

spark plug terminal, always grasp and pull on the rubber

boot at the end of the cable assembly (as close as possi-

11307

ble to the spark plug terminal). Do not pull on the cable

portion itself. Pulling on the cable will damage the

cable’s carbon core.

See Figure 7-9. Pull front spark plug boot and cable (1)

from left side ignition coil tower.

Pull rear spark plug boot and cable (2) from right side

ignition coil tower.

Pull spark plug boot and cable assemblies from front and

rear spark plugs

See Figure 7-10. Use needle nose pliers (2) to pinch legs

of rear cable clip

(1) under cylinder head bracket.

Remove clip from bracket. Spread clip open and remove

spark plug cable.

Repeat above step for front spark plug cable clip.

Spark plug cable clip

Carefully pull spark plug cables from between cylinders

Needlenose pliers

under fuel tank.

Figure 7-10. Removing Spark Plug Cable Clip

7-12

2006 Sportster: Electrical

HOME

INSPECTION

11306

Check cables for cracks or loose terminals.

Use ohmmeter to measure resistance. Resistance must

be 5,030-13,733 ohms for 20-in. (508 mm) cable.

Replace cables that are worn/damaged or that do not

meet resistance specifications.

Check cable boots for cracks or tears; also check for

loose fit on ignition coil and spark plugs. Replace boots if

you find any of the detrimental conditions mentioned

above.

INSTALLATION

See Figure 7-9. Plug rear spark plug cable (2) into right

side ignition coil tower. Route cable and protective con-

duit around throttle cables, crossing over top of engine

between the cylinder heads.

See Figure 7-11. Slip cable clip (4) over rear spark plug

cable. Press legs of cable clip down into rear hole in cyl-

inder head bracket until clip locks in place.

Press cable and boot onto rear spark plug until it clicks.

See Figure 7-9. Plug front spark plug cable (1) into left

side ignition coil tower. Route cable and protective con-

duit to the right, around throttle cables, crossing over top

of engine between the cylinder heads.

See Figure 7-11. Slip cable clip (3) over front spark plug

cable. Press legs of cable clip down into front hole in cyl-

Front spark plug cable

inder head bracket until clip locks in place.

Rear spark plug cable

Front cable clip

Press cable and boot onto front spark plug until it clicks.

Rear cable clip

CAUTION

Figure 7-11. Spark Plug Cable Routing

(Fuel Tank Removed For Clarity)

See Figure 7-11. Make sure spark plug cables are routed

properly and cannot chafe against frame, fuel tank or fuel

valve assembly.

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

side cover. See 7.25 MAXI-FUSE.

2006 Sportster: Electrical

7-13

HOME

IGNITION COIL

7.10

GENERAL

10580

The ignition coil is attached to a mounting bracket secured by

the front fuel tank mounting bolt.

The ignition coil is divided into separate front and rear coils

that fire the spark plugs one cylinder at a time.

NOTE

The ignition coil cannot be repaired. Replace the unit if it fails.

TROUBLESHOOTING

See the SPORTSTER MODELS ELECTRICAL DIAGNOS-

TIC MANUAL for complete troubleshooting information.

REMOVAL

1WARNING

Ignition coil

To prevent accidental vehicle start-up, which could

Ignition coil mounting bracket

cause death or serious injury, remove maxi-fuse before

Mounting fastener

proceeding. (00251a)

Rear cylinder spark plug cable boot

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

Front cylinder spark plug cable boot

side cover. See 7.25 MAXI-FUSE.

Figure 7-12. Ignition Coil Mounting

See Figure 7-12. On right side, pull rear cylinder spark

(Fuel Tank Removed for Clarity)

plug boot (4) and cable from ignition coil tower.

On left side, pull front cylinder spark plug boot (5) and

cable from ignition coil tower.

Remove right side mounting fastener.

10532

Remove left side mounting fastener (3) and lower ignition

coil from mounting bracket (2).

See Figure 7-13. Lift tab and separate ignition coil con-

nector [83] to remove ignition coil.

INSTALLATION

See Figure 7-13. Hold ignition coil in place and mate

ignition coil connector [83] halves.

See Figure 7-12. Position nut plate inside ignition coil

mounting bracket. and fasten ignition coil (1) to nut plate

through mounting bracket (2).

Move to right side and fasten ignition coil to nut plate

through mounting bracket.

Tighten right and left mounting fasteners (3) to 24-72 in-

lbs (2.7-8.1 Nm).

Push front spark plug boot (5) and cable on to ignition

Figure 7-13. Ignition Coil Connector [83]

coil tower until it clicks into place.

Push rear cylinder spark plug boot (4) and cable into the

coil tower until it clicks in place.

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

side cover.

7-14

2006 Sportster: Electrical

HOME

CHARGING SYSTEM

7.11

GENERAL

VOLTAGE REGULATOR

The regulator is a series regulator with shunt control. The cir-

See Figure 7-14. The charging system consists of the alter-

cuit combines the functions of rectifying and regulating.

nator and voltage regulator. See schematic diagram of the

charging system circuit below.

NOTE

For charging system troubleshooting and diagnostic proce-

dures, see the SPORTSTER MODELS ELECTRICAL DIAG-

ALTERNATOR

NOSTIC MANUAL.

The alternator consists of two main components: the rotor

which is mounted on the engine sprocket shaft, and the sta-

tor, which is bolted to the engine crankcase.

x0034f7x

STATOR

BATTERY

VOLTAGE

[46B]

REGULATOR

[46A]

30 AMP

MAXIFUSE

[5B]

B A

[77B]

[77A]

GND 2

Wire Color Code Key

BK - Black

GN - Green

LT.GN - Light Green

PIN CONNECTOR

(A side)

BN - Brown

BE - Blue

PK - Pink

R - Red

V - Violet

TN - Tan

SOCKET CONNECTOR

O - Orange

GY - Gray

(B side)

Y - Yellow

W - White

Figure 7-14. Charging System Circuit (All Models)

2006 Sportster: Electrical

7-15

HOME

ALTERNATOR

7.12

REMOVAL AND DISASSEMBLY

Stator

1. Disconnect stator wiring from voltage regulator wiring at

Open left side cover. See 1.6 LEFT SIDE COVER.

connector [46].

2. Remove cable straps.

1WARNING

3. Withdraw stator wiring from opening between right

crankcase half and gear case cover.

Prevent accidental vehicle start-up, which could cause

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

4. Using a T-27 TORX driver, remove and discard screws

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

which secure stator to left crankcase half.

tery. (00280a)

CAUTION

Disconnect negative battery cable from crankcase. Dis-

connect positive (+) battery cables from battery. See

Stator TORX screws contain a thread locking compound.

BATTERY DISCONNECTION AND REMOVAL under 1.7

Do not reuse existing screws. Always use new screws

BATTERY MAINTENANCE. Close left side cover.

with the proper thread locking compound. Loss of torque

Remove primary cover. See Primary Cover REMOVAL

on TORX fasteners could result in alternator damage.

under 6.3 PRIMARY CHAIN ADJUSTER.

5. Remove stator wiring grommet from left crankcase half.

Remove clutch assembly, primary chain and engine

6. Withdraw stator wiring from grommet hole in left crank-

sprocket/rotor assembly as a unit. Refer to 6.5 PRIMARY

case half. Remove stator.

DRIVE/CLUTCH REMOVAL.

Remove/disassemble rotor and/or stator, as required.

CLEANING, INSPECTION AND

Refer to the following procedures.

REPAIR

Rotor

Remove bolts which secure alternator rotor to engine

CAUTION

sprocket.

Do not strike or drop alternator rotor or damage to mag-

See Figure 7-15. Position blocking (2) under rotor (1).

net adhesive may occur. Magnet adhesive damage can

Press sprocket (3) free of rotor.

result in rotor failure.

NOTE

1. Clean rotor with a petroleum-base solvent. Remove all

Resistance to sprocket/rotor disassembly is due in part to the

foreign material from rotor magnets. Replace rotor if

magnetic force of the permanent rotor magnets.

rotor magnets are cracked or loose.

2. Clean stator by wiping with a clean cloth.

3. Examine stator leads for cracked or damaged insulation.

8610

NOTE

The rotor and stator can be replaced individually if either is

damaged.

Rotor

Blocking

Sprocket

Figure 7-15. Removing Rotor From Sprocket

7-16

2006 Sportster: Electrical

HOME

ASSEMBLY AND INSTALLATION

CAUTION

Depending on whether the rotor, the stator, or both the rotor

Make sure stator wiring is routed about 1-1/2 in. (38 mm)

and stator were removed/disassembled, perform the applica-

forward of gear case cover rear edge. If routed too far to

ble procedures which follow:

the rear of this position, wiring could contact the moving

secondary drive belt and/or sprocket, resulting in dam-

Stator

age to stator wiring and charging system.

See Figure 7-16. Feed stator wiring (5) with attached

4. Route stator wiring (5) across top of crankcase halves to

grommet into open grommet hole in left crankcase half.

right side of engine. Route stator wiring downward

Apply a light coating of clean engine oil or chaincase

through opening between right crankcase half and gear-

lubricant to grommet. Install grommet into hole in left

case cover.

crankcase half.

5. Route stator wiring forward and then upward along

inboard side of right frame downtube. Connect stator wir-

CAUTION

ing to voltage regulator wiring at connector [46] (6).

Stator TORX screws contain a thread locking compound.

6. Secure stator wiring, along with any other wires and

Do not reuse existing screws. Always use new screws

hoses routed in the same location, to right frame down-

with the proper thread locking compound. Loss of torque

tube using cable straps.

on TORX fasteners can result in alternator damage.

Position stator (4) on left crankcase half. Secure stator

using new TORX screws. Use TORX driver to tighten

screws to 30-40 in-lbs (3.4-4.5 Nm).

x0608x7x

Triple sprocket

Rotor

Fastener (4)

Stator

Stator wiring

Connector [46]

Mounting bolt (8)

Figure 7-16. Alternator Components

2006 Sportster: Electrical

7-17

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Rotor

3560

See Figure 7-17. Position rotor (1) on sprocket (2). Align

holes in sprocket with holes in rotor. Apply a drop of

LOCTITE THREADLOCKER 243 (blue) to threads of

each mounting bolt. Insert mounting bolts through rotor

and start bolts into tapped holes in sprocket.

Position a section of pipe (3) with an inside diameter

larger than the sprocket mounting hub over center of

rotor.

Press rotor onto sprocket. Tighten screws to 120-140 in-

lbs (13.6-15.8 Nm).

Final Assembly

Install clutch assembly, primary chain and engine

sprocket/rotor assembly as a unit. See 6.5 PRIMARY

DRIVE/CLUTCH INSTALLATION.

Rotor

Install primary cover, left footrest assembly and gear shift

Sprocket

lever. See Primary Cover INSTALLATION under 6.3

Pipe section

PRIMARY CHAIN ADJUSTER.

Open left side cover. See 1.6 LEFT SIDE COVER.

Figure 7-17. Pressing Rotor onto Sprocket

1WARNING

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

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

nected, the resulting sparks can cause a battery explo-

sion, which could result in death or serious injury.

(00068a)

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

TERY INSTALLATION AND CONNECTION under 1.7

BATTERY MAINTENANCE. Close left side cover.

Test charging system. See the SPORTSTER MODELS

ELECTRICAL DIAGNOSTIC MANUAL.

7-18

2006 Sportster: Electrical

HOME

VOLTAGE REGULATOR

7.13

GENERAL

11986

See Figure 7-18. The voltage regulator (1) is located between

the frame downtubes at the front of the motorcycle.

NOTE

The voltage regulator cannot be repaired. Replace the unit if

it fails.

REMOVAL

1WARNING

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

Voltage regulator

When unplugging the alternator stator connector, pull

Stator connector [46A]

apart the connector by firmly grasping both connector

Barbed cable strap

halves. Do not pull on leads or damage to the wires and/

DC output connector [77A]

or terminals may result.

Expanding peg

Voltage regulator fastener locations (2)

See Figure 7-18. Unplug alternator stator connector [46]

(2). Cut barbed cable strap (3) and remove from stator

Figure 7-18. Voltage Regulator

harness and frame bracket. Discard barbed cable strap.

Unplug voltage regulator DC output connector [77] (4).

Lift the external latch on the socket housing side and

separate the halves.

Pinch legs of expanding peg (5) attached to connector

half [77A] and remove peg from frame bracket.

Remove fasteners from locations (6) at top and bottom of

voltage regulator and remove regulator from vehicle.

2006 Sportster: Electrical

7-19

HOME

INSTALLATION

x0629a7x

See Figure 7-19. Wrap barbed cable strap (5) around

stator harness next to connector (3) on new voltage reg-

ulator (1).

See Figure 7-20. Position voltage regulator close to

mounting bracket (1). Orient regulator so cooling fins

face forward and wiring harnesses exit regulator body

toward right side of vehicle.

Thread wiring harnesses into opening

(3) between

mounting bracket and frame downtube on right side of

vehicle and then behind mounting bracket toward left

side.

See Figure 7-18. Plug voltage regulator DC output con-

nector [77A] (4) into socket [77B].

Pinch legs of expanding peg (5) attached to connector

half [77A].

Plug voltage regulator stator connector [46A] (2) into

alternator stator connector [46B].

See Figure 7-20. Insert expanding peg attached to DC

output connector [77A] into left side hole (5) in voltage

Voltage regulator

regulator mounting bracket. Push on peg until it snaps in

Screw (2)

place.

Stator connector [46A]

DC output connector [77A]

Press barbed cable strap attached to stator connector

Barbed cable strap

[46A] into right side hole (4) in mounting bracket.

Mount voltage regulator on mounting bracket

(1)

Figure 7-19. Voltage Regulator Components

between frame downtubes and secure with fasteners at

two locations (2). Tighten to 30-60 in-lbs (3.4-6.8 Nm).

10.

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

side cover. See 7.25 MAXI-FUSE.

11987

11.

Test charging system. See the SPORTSTER MODELS

ELECTRICAL DIAGNOSTIC MANUAL.

Voltage regulator mounting bracket

Regulator fastener locations

Opening for wiring harnesses

Hole for stator connector [46A] barbed cable strap

Hole for DC connector [77A] expanding peg

Figure 7-20. Voltage Regulator Mounting Bracket

(All Models)

7-20

2006 Sportster: Electrical

HOME

BATTERY

7.14

GENERAL

CONDUCTANCE TEST

Three different procedures may be performed to provide a

Test the battery using the ADVANCED BATTERY CONDUC-

good indicator of battery condition: a voltage test, a conduc-

TANCE AND ELECTRICAL SYSTEM ANALYZER (Part No.

tance test, or a load test.

HD-48053). Perform a battery test as follows:

A battery may be tested, whether fully charged or not, via

1. Connect the analyzer leads to the vehicle’s battery.

conductance test. In order to perform a load test, however,

2. Follow the instructions in the analyzer’s instruction man-

the battery must be fully charged.

ual to perform a battery test.

The test results will include a decision on the battery’s condi-

VOLTMETER TEST

tion, the measured state of charge and the measured CCA.

See Figure 7-21. The analyzer’s printer will provide you with a

The voltmeter test provides a general indicator of battery con-

printout including one of five possible test results:

dition. Check the voltage of the battery to verify that it is in a

● GOOD BATTERY-return the battery to service.

100% fully charged condition. Refer to Table 7-8.

● GOOD-RECHARGE-fully charge the battery and return

If the open circuit (disconnected) voltage reading is below

to service.

12.6V, charge the battery. See CHARGING. Then recheck

the voltage after the battery has set for one to two hours. If

● CHARGE & RETEST-Fully charge the battery and

the voltage reading is 12.7V or above, perform the LOAD

retest.

TEST described in this section.

● REPLACE BATTERY-replace the battery and retest.

● BAD CELL-REPLACE-replace the battery and retest.

Table 7-8. Voltmeter Test For Battery Charge

NOTE

A REPLACE BATTERY test result may also mean a poor con-

VOLTAGE (OCV)

STATE OF CHARGE

nection between the battery cables and the vehicle. After dis-

connecting the battery cables from the battery, retest the

12.7

100%

battery using the out-of-vehicle test before replacing.

12.6

75%

12.3

50%

12.0

25%

x0661x3x

MCR-101 HD V1.0

11.8

(C) MIDTRONICS

MON 02/21/05

3:45 PM

LAST 6 OF VIN

012345

DATE CODE

BATTERY TEST

RATING:

295 CCA

65958-94

12.32V

95CCA

REPLACE BATTERY

WARRANTY CODE

9J9G9N-0132N8

Figure 7-21. Battery Test Results-Printout

2006 Sportster: Electrical

7-21

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LOAD TEST

x0301a7x

VOLTS

The load test measures battery performance under full cur-

AMPS

rent load. To load test the battery, proceed as follows:

Remove battery from motorcycle. See BATTERY DIS-

CONNECTION AND REMOVAL under 1.7 BATTERY

MAINTENANCE.

CAUTION

Load testing a discharged battery can result in perma-

nent battery damage.

Always fully charge the battery before testing or test

readings will be incorrect. See CHARGING. Load testing

a discharged battery can also result in permanent bat-

tery damage.

After charging, allow battery to stand for at least one

hour before testing.

1WARNING

Turn battery load tester OFF before connecting tester

Load tester

cables to battery terminals. Connecting tester cables

Induction pickup

with load tester ON can cause a spark and battery explo-

Battery

sion, which could result in death or serious injury.

(00252a)

Figure 7-22. Load Test Battery

See Figure 7-22. Connect tester leads to battery posts

and place induction pickup over negative (black) cable.

Table 7-9. Load Test-Cold Cranking Amps

CAUTION

COLD CRANKING

To avoid load tester and/or battery damage, do not leave

100%

50%

AMPERAGE (CCA)

the load tester switch turned ON for more than 20 sec-

onds.

Sportster models

205

102.5

Refer to Table 7-9. Load battery at 50% of CCA rating

using the load tester. Voltage reading after 15 seconds

1WARNING

should be 9.6V or more at 70°F (21°C).

Turn battery load tester OFF before disconnecting tester

cables to battery terminals. Disconnecting tester cables

1WARNING

with load tester ON can cause a spark and battery explo-

Turn battery load tester OFF before disconnecting tester

sion, which could result in death or serious injury.

cables to battery terminals. Disconnecting tester cables

(00253a)

with load tester ON can cause a spark and battery explo-

7. Install the battery in the motorcycle. See BATTERY

sion, which could result in death or serious injury.

INSTALLATION AND CONNECTION under 1.7 BAT-

(00253a)

TERY MAINTENANCE.

Install the battery in the motorcycle. See BATTERY

INSTALLATION AND CONNECTION under 1.7 BAT-

TERY MAINTENANCE.

7-22

2006 Sportster: Electrical

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