Harley Davidson 2006 Sportster XLH MODELS. Service Manual — page 27
HOME
SPEEDOMETER AND TACHOMETER: XL 1200R
7.30
TRIP ODOMETER RESET SWITCH
9437
REPLACEMENT
2
CAUTION
To prevent accidental vehicle start-up, which could
cause death or serious injury, remove maxi-fuse before
1
proceeding. (00251a)
1.
Open left side cover and remove Maxi-Fuse. Close left
side cover. See 7.25 MAXI-FUSE.
2.
Unthread trip odometer reset boot from back plate.
3.
Remove screws holding speedometer housing back-
plate.
4.
See Figure 7-76. Open latches on each side of speed-
ometer connector
[39]
(1) and separate connector
halves.
5.
Follow instructions to push the trip reset socket terminals
4
out the front of the speedometer socket connector half
3
[39B]. See B.4 PACKARD ELECTRICAL CONNEC-
TORS.
6.
Cut off the socket terminals and pull the faulty switch out
1.
Speedometer connector socket half [39B]
of the connector.
2.
Back gasket
7.
Push the wires of a replacement switch through the
3.
Locating key
speedometer connector (sockets 8, 11) and crimp new
4.
Trip odometer reset switch
socket terminals using crimping tool
(Part No. HD-
45929), on replacement switch wiring.
Figure 7-76. Speedometer (XL 1200R)
8.
Draw the terminal back into the connector until the termi-
nal seats.
9.
Position reset switch in squared boss on back of speed-
ometer housing.
10.
Align back plate with vent hole on bottom. Install back plate
screws and tighten.
11.
Replace trip odometer reset switch boot.
12.
Open left side cover and install Maxi-Fuse. Close left side
cover.
2006 Sportster: Electrical
7-63
HOME
SPEEDOMETER REMOVAL
9438
NOTE
The speedometer and tachometer have backlight bulbs that
cannot be replaced. If the bulb fails, replace the entire unit.
CAUTION
To prevent accidental vehicle start-up, which could
1
cause death or serious injury, remove maxi-fuse before
proceeding. (00251a)
1.
Open left side cover and remove Maxi-Fuse. Close left
3
side cover. See 7.25 MAXI-FUSE.
2
2.
Unthread trip odometer reset boot from housing back
plate.
3.
Remove screws holding speedometer housing back
plate.
4.
Open latches on each side of speedometer connector
[39] and separate connector halves.
5.
Push out the speedometer and front gasket.
6.
Inspect front and back gaskets, speedometer connector
1.
Tachometer connector [108]
[39] and wiring, trip reset switch and wiring, and trip reset
2.
Wire harness
boot. Repair or replace as required.
3.
Locating key
Figure 7-77. Tachometer (XL 1200R)
TACHOMETER REMOVAL
CAUTION
To prevent accidental vehicle start-up, which could
cause death or serious injury, remove maxi-fuse before
proceeding. (00251a)
1.
Open left side cover and remove Maxi-Fuse. Close left
side cover. See 7.25 MAXI-FUSE.
2.
Remove screws holding tachometer housing back plate.
3.
Open latches on each side of tachometer connector
[108] and separate connector halves.
4.
Push out the tachometer and front gasket.
5.
Inspect front and back gaskets, tachometer connector
[108] and wiring. Repair or replace as required.
7-64
2006 Sportster: Electrical
HOME
1.
Speedometer
x0620x7x
2.
Trip odometer reset switch
3.
Reset switch boot
4.
Front gasket
5.
Instrument housing
6.
Speedometer back plate
6
7.
Tachometer back plate
7
8.
Screw (4)
5
9.
Back gasket
10. Tachometer
3
11. Main harness pin connector [20A]
4
12. Vent hole
13. Indicator lamp socket (5)
8
2
12
9
1
11
13
10
Figure 7-78. Speedometer and Tachometer (XL 1200R)
SPEEDOMETER INSTALLATION
TACHOMETER INSTALLATION
1.
If replacing the trip odometer reset switch, see TRIP
1. See Figure 7-78. Install front gasket (4) on tachometer
ODOMETER RESET SWITCH REPLACEMENT
(10).
2.
See Figure 7-78. Install front gasket (4) on speedometer
2. Threading wiring through back gasket (9) and install gas-
(1).
ket matching tabs to locating keys in tachometer housing
(5).
3.
Threading wiring through back gasket (9), install match-
ing tabs of gasket (9) to locating keys in speedometer
NOTE
housing (5).
If necessary, lubricate rubber gaskets with alcohol or glass
cleaner.
NOTE
If necessary, lubricate rubber gaskets with alcohol or glass
3. Slide tachometer (10) into housing (5) and press firmly
cleaner.
until fully seated.
4.
Orient face upright and press speedometer (1) into hous-
4. See Figure 7-77. Loop wiring to fit in available space and
ing (5). Wiring must past between locating keys and back
mate connector [108] halves.
gasket and through cutout in speedometer back.
5. See Figure 7-78. Align back plate with vent hole (12) at
5.
Mate speedometer connector halves [39]
bottom. Install back plate screws (8) and tighten.
6.
Push trip reset switch (2) through housing back plate (6)
6.
Open left side cover and install Maxi-Fuse. Close left side
and thread on the trip reset boot (3).
cover. See 7.25 MAXI-FUSE.
7.
Align back plate (6) with vent hole (12) at bottom \with
reset switch (2) in rectangular boss in back of speedome-
ter (1) and thread in and tighten screws (8).
8.
Open left side cover and install Maxi-Fuse. Close left side
cover. See 7.25 MAXI-FUSE.
2006 Sportster: Electrical
7-65
HOME
SPEEDOMETER: XL 883C, XL 1200C
7.31
REMOVAL
9436
NOTE
The speedometer has a backlight bulb that cannot be
replaced. If the bulb fails, replace the entire unit.
2
CAUTION
1
1
To prevent accidental vehicle start-up, which could
cause death or serious injury, remove maxi-fuse before
proceeding. (00251a)
1.
Open left side cover and remove Maxi-Fuse. Close left
side cover. See 7.25 MAXI-FUSE.
2.
Protect the fuel tank and remove riser cover from the
back of the handlebar riser. See 2.25 HANDLEBARS.
NOTE
3
The tripmeter reset boot does not have to be unthreaded from
the back of the speedometer to remove the speedometer.
4
3.
See Figure 7-80. Use a 3/32 in. ball-end Allen wrench to
remove two screws (5) holding speedometer (1) to han-
dlebar bracket/clamp (3).
1.
Speedometer mounting hole
2.
Speedometer connector [39]
4.
Using small diameter rod or Allen wrench, gently press
3.
Trip odometer reset switch in square boss
through bottom condensation/vent hole in handlebar
4.
Condensation/vent hole
bracket/clamp to push speedometer from bracket.
5.
Holding speedometer to prevent damage, depress tabs
Figure 7-79. Handlebar Bracket/Clamp (XL 883C/1200C)
to separate connector [39] and remove speedometer.
6.
Inspect gasket, speedometer connector [39] and wiring,
trip reset switch and wiring, and trip reset boot. Repair or
replace as required.
x0619x7x
2
3
5
1
6
4
1.
Speedometer
2.
Gasket
3.
Bracket/handlebar clamp
4.
Handlebar riser
5.
Screw (2)
6.
Screw (4)
Figure 7-80. Speedometer Components (XL 883C/1200C)
7-66
2006 Sportster: Electrical
HOME
3.
If removed, push trip reset switch through handlebar
INSTALLATION
bracket/clamp and into tab square in base of handlebar/
clamp bracket and thread on the trip reset boot.
1.
If replacing the trip odometer switch:
4.
Hold speedometer (1) in place and mate speedometer
a. Push the trip reset socket terminals out the front of
connector [39] halves.
the speedometer socket connector half [39B]. See
B.4 PACKARD ELECTRICAL CONNECTORS.
NOTE
b. Cut off the socket terminals and pull the faulty switch
If necessary, lubricate gasket with alcohol or glass cleaner.
out of the connector.
5.
Press speedometer into bracket and secure with screws
c. Push the wires of a replacement switch through the
(5).
speedometer connector (sockets 8, 11) and crimp
6.
Install riser cover. Tighten screws to 8-12 in-lbs (0.9-1.4
new socket terminals using crimping tool (Part No.
Nm).
HD-45929), on replacement switch wiring.
7.
Open left side cover and install Maxi-Fuse. Close left side
d. Draw the terminal back into the connector until the
cover. See 7.25 MAXI-FUSE.
terminal seats.
2.
See Figure 7-80. If removed, install gasket (2) in handle-
bar bracket/clamp (3).
2006 Sportster: Electrical
7-67
HOME
TURN SIGNAL/SECURITY MODULE (TSM/TSSM)
7.32
GENERAL
11332
1
See Figure 7-81. The turn signal module (TSM) has two
major functions:
● Control turn signals.
● Serve as bank angle sensor.
The optional factory-installed security system
(turn signal
security module or TSSM) provides the same functionality as
the TSM, but also includes security and immobilization func-
tions.
3
2
See the SPORTSTER MODELS ELECTRICAL DIAGNOS-
TIC MANUAL for complete details of the TSM/TSSM features
and functions.
1. Battery tray
2. Oil tank
NOTE
3. TSM/TSSM
The TSM/TSSM cannot be repaired. Replace the unit if it
fails.
Figure 7-82. TSM/TSSM Location
TESTING
11333
For diagnostic information, see the SPORTSTER MODELS
5
ELECTRICAL DIAGNOSTIC MANUAL.
4
REMOVAL
NOTE
3
See Figure 7-82. The TSM/TSSM (3) is located in a cavity in
2
the bottom of the battery tray (1).
1.
Remove left side cover. See 1.6 LEFT SIDE COVER.
2.
Remove battery. See BATTERY DISCONNECTION
AND REMOVAL under 1.7 BATTERY MAINTENANCE.
1
3.
See Figure 7-83. Reach under the battery tray (1) and
push upward on TSM/TSSM (3) to lift it out of its cavity
1.
Battery tray
(2).
2.
Cavity
4.
Grasp top of TSM/TSSM, disconnect wiring harness con-
3.
TSM/TSSM
nector [30B] (4) and remove TSM/TSSM from vehicle.
4.
Harness connector [30B]
5.
TSM/TSSM connector [30A]
Figure 7-83. TSM/TSSM Connector [30]
7844
Figure 7-81. TSM/TSSM
7-68
2006 Sportster: Electrical
HOME
INSTALLATION
1.
See Figure 7-83. Pull wiring harness connector [30B] (4)
up through cavity (2) in bottom of battery tray (1).
2.
Position TSM/TSSM (3) over cavity with connector [30A]
(5) facing oil tank.
3.
Plug wiring harness connector [30B] into TSM/TSSM.
4.
Lower TSM/TSSM into cavity. See Figure 7-82. Make
sure top of TSM/TSSM is flush with bottom of battery
tray.
5.
Install battery. Do not install left side cover at this time.
See BATTERY INSTALLATION AND CONNECTION
under 1.7 BATTERY MAINTENANCE.
6.
Perform TSM/TSSM password learn and setup proce-
dure. See the SPORTSTER MODELS ELECTRICAL
DIAGNOSTIC MANUAL for procedure.
7.
Install left side cover. See 1.6 LEFT SIDE COVER.
2006 Sportster: Electrical
7-69
HOME
OIL PRESSURE SWITCH
7.33
GENERAL
REMOVAL
CAUTION
PART NO.
SPECIALTY TOOL
To prevent accidental vehicle start-up, which could
HD-41675
Oil pressure sending unit wrench
cause death or serious injury, remove maxi-fuse before
proceeding. (00251a)
The oil pressure signal lamp switch is a pressure-actuated
1. Open left side cover and remove Maxi-Fuse. Close left
diaphragm-type switch. When oil is not circulating through the
side cover. See 7.25 MAXI-FUSE.
system or when oil pressure is abnormally low, spring tension
holds the switch contacts closed, thereby completing the sig-
2. Place a container under vehicle to catch any oil that may
nal lamp circuit and causing the indicator lamp to illuminate.
leak out when oil pressure switch is removed.
See Figure 7-84. The oil pressure switch is located under the
3. See Figure
7-84. Remove wiring harness connector
oil filter mount at the front of the engine crankcase.
[120] (4) by pulling elbow connector straight down from
stud on oil pressure switch (3).
NOTE
4. Using OIL PRESSURE SENDING UNIT WRENCH,
The oil pressure switch cannot be repaired. Replace the unit
remove oil pressure switch.
if it fails.
INSTALLATION
11353
NOTE
Perform step 1 below only if original oil pressure switch is
being re-installed. New switches have a sealant contact patch
on the mounting threads. If new switch is being installed,
2
begin with step 2.
1. Coat threads of oil pressure switch with LOCTITE 565
HIGH PERFORMANCE PIPE SEALANT with TEFLON.
2. See Figure 7-84. Install oil pressure switch (3). Using
1
OIL PRESSURE SENDING UNIT WRENCH, tighten
switch snugly. DO NOT OVERTIGHTEN.
3
3. Attach wiring harness connector [120] (4) to oil pressure
switch (3).
4
4. Open left side cover and install Maxi-Fuse. Close left
side cover. See 7.25 MAXI-FUSE.
1.
Oil filter mount
NOTE
2.
Oil filter
If an appreciable amount of oil leaked out when oil pressure
3.
Oil pressure switch
switch was removed, it will have to be replaced with fresh oil.
4.
Oil pressure switch connector [120]
5. Check oil level in oil tank. See 1.5 ENGINE OIL AND FIL-
Figure 7-84. Oil Pressure Indicator Lamp Switch
TER. Top off oil level if necessary.
(Left Side View XL 1200C)
6. Start engine and test oil pressure switch for proper oper-
ation. Check oil pressure switch for leaks.
7-70
2006 Sportster: Electrical
HOME
CRANK POSITION SENSOR (CKP)
7.34
GENERAL
11339
The crank position (CKP) sensor is a variable reluctance (VR)
sensor that generates an AC signal by sensing the passing of
the 30 teeth cast into the engine’s left side flywheel. Two teeth
are missing in the flywheel to establish a reference point. The
1
CKP sensor sends a signal to the Ignition Control Module
(ICM). This signal is used to reference engine position (TDC)
2
and engine speed. The CKP sensor is located near the lower
front left corner of the engine crankcase.
NOTE
The crank position sensor cannot be repaired. Replace the
4
unit if it fails.
3
REMOVAL
CAUTION
To prevent accidental vehicle start-up, which could
cause death or serious injury, remove maxi-fuse before
proceeding. (00251a)
1.
Crank position (CKP) sensor
1.
Open left side cover and remove Maxi-Fuse. Close left
2.
Screw
side cover. See 7.25 MAXI-FUSE.
3.
Wire harness j-clip
2.
See Figure 7-85. Disconnect CKP sensor harness con-
4.
CKP sensor harness connector [79]
nector [79A] from wiring harness connector [79B] (4),
located along left frame downtube.
Figure 7-85. Crank Position (CKP) Sensor.
3.
Remove CKP wire harness from j-clip (3).
4.
Remove screw (2). Carefully remove CKP sensor (1) and
O-ring from engine crankcase.
INSTALLATION
NOTE
The CKP sensor O-ring has a blue teflon coating that pro-
vides lubrication during installation. It is not necessary to coat
the O-ring with engine oil or other lubricant to install it.
1.
See Figure 7-85. Carefully install CKP sensor (1) and O-
ring into engine crankcase with screw (2). Tighten to 80-
100 in-lbs (9.0-11.3 Nm).
2.
Route CKP sensor wiring harness through j-clip (3).
3.
Attach CKP sensor harness connector [79A] to wiring
harness connector [79B] (4).
4.
Open left side cover and install Maxi-Fuse. Close left
side cover. See 7.25 MAXI-FUSE.
5.
Start engine and verify operation.
2006 Sportster: Electrical
7-71
HOME
VEHICLE SPEED SENSOR (VSS)
7.35
GENERAL
10622
The vehicle speed sensor (VSS) is powered and monitored
by the ignition control module (ICM). The ICM processes the
vehicle speed signal and transmits this signal to the turn sig-
1
nal module/turn signal security module
(TSM/TSSM) and
3
speedometer through serial data.
NOTE
The vehicle speed sensor cannot be repaired. Replace the
unit if it fails.
2
REMOVAL
CAUTION
To prevent accidental vehicle start-up, which could
cause death or serious injury, remove maxi-fuse before
1.
VSS connector [65]
proceeding. (00251a)
2.
Screw
3.
Vehicle speed sensor (VSS)
1.
Open left side cover and remove Maxi-Fuse. Close left
side cover. See 7.25 MAXI-FUSE.
Figure 7-86. Vehicle Speed Sensor
2.
See Figure 7-86. Disconnect VSS harness connector
[65A] (1) from VSS (3) mounted on rear of engine case
below starter motor assembly.
3.
Remove screw (2). Carefully remove VSS and O-ring
from engine crankcase.
INSTALLATION
NOTE
The new VSS O-ring has a teflon coating that provides lubri-
cation during installation. It is not necessary to coat the O-
ring with engine oil or other lubricant to install it.
1.
See Figure 7-86. Carefully install VSS (3) and O-ring into
engine crankcase with screw (2). Tighten to 80-100 in-
lbs (9.0-11.3 Nm).
2.
Attach VSS harness connector [65A] (1) to VSS.
3.
Open left side cover and install Maxi-Fuse. Close left
side cover. See 7.25 MAXI-FUSE.
4.
Start engine and test ride motorcycle to verify proper
operation.
7-72
2006 Sportster: Electrical
HOME
NEUTRAL INDICATOR SWITCH
7.36
GENERAL
TEST
See Figure 7-87. The neutral indicator switch (1) is threaded
into the right crankcase half (3) immediately forward of the
main drive gear (4). A short jumper wire assembly (2) con-
PART NO.
SPECIALTY TOOL
nects the switch to the harness connector [136] under the
HD-41404
Harness connector test kit
engine crankcase.
A pin on the shifter drum contacts the neutral indicator switch
1. Turn the ignition/light switch to OFF.
plunger, completing the neutral indicator circuit.
2. Shift transmission to neutral. Verify by rocking motorcy-
A motorcycle whose neutral indicator lamp does not light can
cle.
be tested to determine if the problem can be found:
3. See Figure 7-88. Locate and unplug neutral indicator
harness connector [136] (1) between engine crankcase
● in a burned out indicator lamp, the wire harness to the
and lower right frame rail, directly under oil pump.
instruments or in the main wire harness.
● in the neutral indicator switch and its jumper wire.
If switch requires replacement, the rear muffler and rear
11469
exhaust pipe must be removed to remove the transmission
sprocket cover. The drive belt and transmission sprocket must
also be removed; there is not enough clearance to allow the
removal of the switch without first removing the transmission
sprocket.
1
NOTE
The neutral indicator switch cannot be repaired. Replace the
switch if it fails.
11473
2
2
1
1.
Neutral indicator harness connector [136]
2.
Neutral switch jumper wire (to neutral indicator
switch [131])
Figure 7-88. Neutral Indicator Switch Connector [136]
4
3
1.
Neutral indicator switch
2.
Jumper wire connector [131]
3.
Right crankcase half
4.
Main drive gear
Figure 7-87. Neutral Indicator Switch
2006 Sportster: Electrical
7-73
HOME
NOTE
11470
See Figure 7-89. Pin connector half [136A] connects to neu-
tral indicator switch via jumper cable. Socket connector half
connects through harness to Instruments connector [20] and
from there to neutral indicator lamp.
4.
See Figure 7-90. Select a suitable test jumper cable
assembly (2) and probe (3) from the HARNESS CON-
NECTOR TEST KIT. Connect one end of the test jumper
cable to the harness socket connector [136B] (1). Plug
3
the test probe into the other end of the test jumper cable.
2
5.
With ignition switch ON, touch the probe to a suitable
ground.
a. If neutral indicator lamp lights, problem is in neutral
1
indicator switch or neutral switch jumper wire.
Replace neutral indicator switch and neutral switch
jumper wire. See REPLACEMENT which follows.
1.
Harness socket connector [136B]
b. If neutral indicator lamp does not light, problem is
2.
Test jumper (from harness connector test kit)
elsewhere in circuit (i.e. indicator lamp burned out,
3.
Probe (from harness connector test kit)
loose connection, or faulty wiring). See SPORTS-
TER MODELS ELECTRICAL DIAGNOSTIC MAN-
Figure 7-90. Testing Neutral Indicator Harness
UAL.
REPLACEMENT
x0658x7x
INSTRUMENTS
[20A]
CAUTION
1
1
To prevent accidental vehicle start-up, which could
2
2
3
3
INSTRUMENTS
cause death or serious injury, remove maxi-fuse before
4
4
FUSE
5
5
15A
proceeding. (00251a)
O
6
6
O
7
7
1. Open left side cover and remove Maxi-Fuse. Close left
TN
8
8
TN
TN
9
9
side cover. See 7.25 MAXI-FUSE.
NEUTRAL
10
10
[136B]
[136A]
INDICATOR
11
11
2. Remove rear muffler and exhaust pipe. See
2.27
LAMP
12
12
EXHAUST SYSTEM.
NEUTRAL SWITCH
3. Remove sprocket cover and rear drive belt from trans-
[131]
mission sprocket. See 6.6 SECONDARY DRIVE BELT.
Figure 7-89. Neutral Indicator Circuit
4. Remove transmission sprocket. See
6.6 TRANSMIS-
SION SPROCKET.
7-74
2006 Sportster: Electrical
HOME
5.
See Figure 7-91. Unplug jumper wire connector (2) from
11474
neutral indicator switch (1). Unscrew switch with washer
from right crankcase half (3).
1
6.
Note routing of neutral switch jumper wire down between
crankcase and rear of gearcase cover.
7.
Install new neutral indicator switch with washer and
tighten to 36-60 in-lbs (4.0-6.8 Nm).
8.
Plug new neutral switch jumper wire into neutral indica-
tor switch [131]. Route jumper wire in same way that old
2
jumper was routed.
9.
See Figure 7-88. Plug jumper wire pin connector [136A]
into harness socket connector [136B].
10.
Install transmission sprocket. See 6.6 TRANSMISSION
3
SPROCKET.
11.
Install secondary drive belt and sprocket cover. See 6.6
SECONDARY DRIVE BELT.
12.
Adjust drive belt tension and rear wheel alignment. See
BELT DEFLECTION ADJUSTMENT and WHEEL
ALIGNMENT under 1.15 REAR BELT DEFLECTION.
1.
Neutral indicator switch
13.
Install rear muffler and exhaust pipe. See
2.27
2.
Jumper wire connector [131]
EXHAUST SYSTEM.
3.
Right crankcase half
14.
Open left side cover and install Maxi-Fuse. Close left
side cover. See 7.25 MAXI-FUSE.
Figure 7-91. Neutral Indicator Switch
15.
Turn ignition switch on and check the operation of the
neutral indicator lamp.
2006 Sportster: Electrical
7-75
HOME
OPTIONAL SECURITY SIREN
7.37
GENERAL
11528
See Figure 7-92. The security siren (1) is a self-contained unit
with its own replaceable power supply (9-V battery). The unit
1
is mounted on a bracket attached to the rear brake master
cylinder (3) mounting bracket under the rear fork pivot point.
The siren’s internal 9-volt battery is rechargeable and does
not need to be replaced on a regular basis. Battery life under
normal conditions is approximately three to six years.
NOTE
2
The internal siren battery may not charge if the vehicle’s bat-
tery is less than 12.5 volts.
REMOVAL
3
1.
See Figure 7-92. Unplug siren harness connector [142B]
1.
Security siren housing
(2) from siren assembly (1).
2.
Tab (2)
2.
See Figure 7-93. Gently pry up on two tabs (2) while pull-
3.
Siren housing mounting boss (2)
ing siren housing (1) toward the left side of the motorcy-
cle. This will disengage siren mounting bosses (3) from
Figure 7-93. Security Siren Mount
mounting bracket. Allow siren assembly to drop down
(Guard Removed for Clarity)
and remove from vehicle.
DISASSEMBLY
11527
1. See Figure 7-94. Remove three screws (4) and bottom
1
cover (1) from top cover (2) of security siren assembly.
4
11529
3
1
3
2
1.
Security siren assembly
2.
Siren harness connector [142B]
3.
Rear brake master cylinder
4.
Guard
Figure 7-92. Security Siren
4
2
1.
Bottom cover
2.
Top cover
3.
Mounting boss (2)
4.
Screw (3)
Figure 7-94. Security Siren Housing
7-76
2006 Sportster: Electrical
HOME
2.
See Figure 7-95. Remove security siren (1) from top
7867
cover (3).
11531
1
4
4
1
2
3
1.
Battery compartment cover
2.
Battery
3.
Connector [142A]
4.
Potted section
3
Figure 7-96. Siren Battery Compartment
NOTE
x0663x7x
For protection against corrosion, battery terminals and bat-
1
tery clip are covered with a special grease. Do not wipe away
3
5
this substance. Apply all available existing grease to termi-
nals on new battery. If more grease is needed, use ELECTRI-
CAL CONTACT LUBRICANT.
2. See Figure 7-97. Replace battery by removing old bat-
tery from polarized battery clip. Install a new 9 volt nickel
metal hydride battery. See the Sportster Models Parts
2
Catalog for the correct part number.
1.
Security siren module
2.
Bottom cover
7866
3.
Top cover
4.
Battery compartment cover
5.
Screw (3)
Figure 7-95. Security Siren Assembly
BATTERY REPLACEMENT
1.
See Figure 7-96. Remove battery compartment cover
(1):
a. Place the siren module on a flat and sturdy table
with the potted section (area with epoxy covering cir-
cuit board) (4) facing up and towards you.
b. Position a knife blade at a 45 degree angle to the
long side of the siren case. Insert the knife blade
between the siren case and battery compartment
cover (1) at one of the two accessible corners of the
cover. Keep the blade slightly higher towards the
battery compartment cover as this helps keep the
Figure 7-97. Siren Battery
blade away from the battery seal.
c. Slowly twist the blade towards the battery compart-
ment cover and the cover will pop off.
2006 Sportster: Electrical
7-77
HOME
NOTE
INSTALLATION
Only a nickel metal hydride nine-volt battery should be used
in the siren.
1. See Figure 7-93. Position siren (1) in mounting bracket
3.
See Figure 7-96. Reinstall battery compartment cover
so that mounting bosses (3) align with mounting clips in
(1):
bracket and connector socket [142A] faces rear master
cylinder.
a. Carefully replace rubber seal.
2. Slide siren housing toward the right side of the vehicle
b. Align battery compartment cover (1) with case plac-
until tabs (2) lock siren in place.
ing round corners on cover away from connector
[142A] (3). Snap cover into place.
3. See Figure 7-92. Plug harness connector [142B] (2) into
siren connector socket [142A].
4. Check siren operation. If siren is working properly, it will
ASSEMBLY
respond with two chirps after receiving the arm com-
mand.
1.
See Figure 7-95. Place security siren module (1) inside
top cover (3) with siren connector [142A] positioned in
cutout in cover and siren battery compartment cover (4)
visible.
2.
See Figure 7-94. Place bottom cover (1) on top cover (2)
and secure with three screws (4).
7-78
2006 Sportster: Electrical
HOME
BANK ANGLE SENSOR (BAS)
7.38
GENERAL
11332
See Figure 7-98. The bank angle sensor (BAS) is located
inside either the turn signal module (TSM) or turn signal
security module (TSSM). The bank angle sensor performs
two functions.
● Emergency engine shutdown: Monitors vehicle lean
and will provide engine shutdown when lean exceeds 45
degrees from vertical for more than one second.
● Emergency outputs disable: Monitors vehicle lean and
will disable turn signal lamps and starter motor when
lean exceeds 45 degrees from vertical for more than one
second.
Figure 7-98. TSM/TSSM Location (Under Battery)
The turn signals, starter motor, ignition control module (ICM)
and coil will be disabled in the event the vehicle tilts more
TESTING
than 45 degrees from vertical for longer than one second.
For diagnostic information, see the SPORTSTER MODELS
If TSM/TSSM is accidentally reconfigured for use with side-
ELECTRICAL DIAGNOSTIC MANUAL.
car, correct using the method in the SPORTSTER MODELS
ELECTRICAL DIAGNOSTIC MANUAL.
REPLACEMENT
OPERATION
Refer to removal/installation instructions under 7.32 TURN
SIGNAL/SECURITY MODULE (TSM/TSSM).
The engine will shut off automatically if the motorcycle tilts
more than 45 degrees from vertical for longer than one sec-
ond and the speedometer TIP indicator lamp will illuminate.
The engine will automatically shut off even if the tilt occurs at
a very slow speed.
To restart the motorcycle after shutdown has occurred:
1.
Return the motorcycle to an upright position.
2.
Cycle the ignition key OFF-ON before restarting.
2006 Sportster: Electrical
7-79
HOME
NOTES
7-80
2006 Sportster: Electrical
HOME
APPENDIX A-GLOSSARY
A.1
Acronyms and Abbreviations
ACRONYM OR ABBREVIATION
DESCRIPTION
A
Amperes
AC
Alternating Current
ACC
Accessory
ACR
Automatic Compression Release
AGM
Absorbed Glass Mat (battery)
AMP
Ampere
AWG
American Wire Guage
B+
Battery voltage
BAS
Bank Angle Sensor
BTDC
Before Top Dead Center
C
Celcius (Centigrade)
CA
California
CAL
Calibration
CC
Cubic Centimeters
CCA
Cold Cranking Amps
CKP
Crankshaft Position
cm
Centimeter
CV
Constant Velocity
DC
Direct Current
DLC
Data Link Connector
DOM
Domestic
DTC
Diagnostic Trouble Code
DVOM
Digital Volt Ohm Meter
ECM
Electronic Control Module
ECT
Engine Coolant Temperature
EEPROM
Electrically Erasable Programmable Read Only Memory
EFI
Electronic Fuel Injection
ET
Engine Temperature
EVAP
Evaporative Emissions Control System
F
Fahrenheit
ft-lbs
Foot-Pounds
fl oz.
Fluid Ounce
g
Gram
GAL
Gallon
GAWG
Gross Axle Weight Rating
GND
Ground (electrical)
GVWR
Gross Vehicle Weight Rating
HDI
Harley-Davidson International
Hg
Mercury
IAC
Idle Air Control
IAT
Intake Air Temperature
ICM
Ignition Control Module
ID
Inside Diameter
Glossary
A-I
HOME
Acronyms and Abbreviations
ACRONYM OR ABBREVIATION
DESCRIPTION
IGN
Ignition Light/Key Switch
IM
Instrument Module
In.
Inch
INJ PW
Injector Pulse Width
in-lbs
Inch-Pounds
Kg
Kilogram
Km
Kilometer
kPa
Kilopascal
km/hr
Kilometers Per Hour
L
Liter
LCD
Liquid Crystal Display
LED
Light Emitting Diode
mA
Milliampere
MAP
Manifold Absolute Pressure
ml
mililiter
mm
millimeter
MPH
Miles Per Hour
ms
millisecond
Nm
Newton-Meter
N/A
Not Applicable
no.
number
O2
oxygen
OD
Outside Diameter
OEM
Original Equipment Manufacturer
oz
Ounce
P&A
Parts and Accessories
PN
Part Number
PSI
Pounds Per Square Inch
RES
Reserve
RPM
Revolutions Per Minute
SCFH
Cubic Feet per Hour at Standard Conditions
TDC
Top Dead Center
TP
Throttle Position
TSM
Turn Signal Module
TSSM
Turn Signal/Security Module
V
Volt
VAC
Volts of Alternating Current
VDC
Volts of Direct Current
VIN
Vehicle Identification Number
VSS
Vehicle Speed Sensor
A-II
Glossary
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