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Harley Davidson 2006 Sportster XLH MODELS. Service Manual - page 2

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See Figure B-2. With the flat side against the terminal,

NOTE

insert the pick tool (Snap-On TT600-3) into the cavity

An Electrical Terminal Crimp Tool (Part No. HD-41609) is

until it stops.

used to install Amp Multi-lock pin and socket terminals on

wires. If new terminals must be installed, see

Crimping

Pivot the end of the pick away from the terminal and gen-

tly tug on wire to pull terminal from chamber. Do not tug

Instructions on the next page.

on the wire until the tang is released or the terminal will

be difficult to remove. A “click” is heard if the tang is

engaged but then inadvertently released. Repeat the

step without releasing the tang.

x0325x7x

Step 4

Step 2

Step 1

Step 3

Step 4

Step 2

Step 1

Step 3

Pick tool

Socket housing

Secondary lock open

Socket terminal

Pin housing

Pin terminal

Figure B-2. Amp Multi-lock Connector

B-2

2006 Sportster: Appendix B

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

INSTALLING

locked in place and will not back out of chamber.

SOCKET/PIN TERMINALS

3. Rotate the hinged secondary lock inward until tabs fully

engage latches on both sides of connector.

NOTE

4. Insert the socket housing (plug) into the pin housing

See Figure B-3. For wire location purposes, numbers are

(receptacle) until it snaps in place.

stamped into the secondary locks of both the socket and pin

5. Install connector on retaining device, either attachment

housings.

or rosebud clip.

From the secondary lock side of the connector, insert the

terminal into its respective numbered chamber until it

snaps in place. For proper fit, the slot in the terminal

must face the tang in the chamber.

NOTE

The tang in the chamber engages the slot to lock the terminal

in position. On the pin side of the connector, tangs are posi-

tioned at the bottom of each chamber, so the slot in the pin

terminal

(on the side opposite the crimp tails) must face

downward. On the socket side, tangs are at the top of each

chamber, so the socket terminal slot (on the same side as the

crimp tails) must face upward. Up and down can be deter-

mined by the position of the release button (used to separate

the pin and socket halves), the button always being the top of

the connector.

2006 Sportster: Appendix B

B-3

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x0326x7x

Secondary Locks Open

3-place

6-place

10-place

connector

– AMP

- AMP

Numbers Stamped on Secondary Locks for Wire Color Locations (Socket Housings Shown)

x0327x7x

x0328x7x

Socket terminal

Latch

Button

Pin housing

Secondary lock open

Socket housing

Pin terminal

Figure B-3. 3-Place and 6-Place Amp Multi-lock Connectors

B-4

2006 Sportster: Appendix B

HOME

4. Strip lead removing 5/32 inch (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

See Figure B-4. Squeeze the handles to cycle the crimp

pair of crimp tails squeeze bare wire strands, while long

tool (Part No. HD-41609) to the fully open position.

pair folds over insulation material.

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, insert contact (socket/pin)

automatically opens when the crimping sequence is

through locking bar, so that the closed side of the contact

complete. Raise up locking bar and remove contact.

rests on the front nest (concave split level area of the

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

crimp tool).

tortion should be minimal.

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.

Insulating crimp tail

Core crimp tail

Locking bar groove

Tang slot

Raise locking bar and seat contact

Insert stripped lead until it

on front nest of crimp tool. Release

contacts locking bar.

locking bar

GAUGE

CRIMPTOOL

WIRE

NEST

Front

Middle

Rear

Close and squeeze crimp tool.

Raise locking bar and remove contact.

d0246x8x

Figure B-4. Amp Multilock Crimping Procedure

2006 Sportster: Appendix B

B-5

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DEUTSCH ELECTRICAL CONNECTORS

B.2

GENERAL

REMOVING/INSTALLING SOCKETS

The XL models utilize Deutsch DT and DTM Series Electrical

1. See Figure B-6. Remove the secondary locking wedge.

Connectors. The Deutsch Connector features a superior seal

Insert the blade of a small screwdriver between the

to protect electrical contacts from dirt and moisture in harsh

socket housing and locking wedge in line with the groove

environments. The connector also provides better pin reten-

(in line with the pin holes if the groove is absent). Turn

tion than previous connectors.

the screwdriver 90 degrees to pop the wedge up.

See Figure B-7. A 12-pin connector is illustrated to show the

2. Gently depress terminal latches inside socket housing

various parts of the Deutsch connector. The following instruc-

and back out sockets through holes in rear wire seal.

tions may be followed for all 2-pin through 12-pin Deutsch

NOTE

connectors.

An Electrical Terminal Crimp Tool (Part No. HD-39965) is

Socket housing: alignment tabs and/or external latch, sec-

used to install Deutsch pin and socket terminals on wires. If

ondary locking wedge, internal seal, wire seal, seal pin.

new terminals must be installed, follow the instructions

NOTE

included with the crimping tool or see Crimping Instructions in

Seal pins or plugs are installed in the wire seals of unused pin

this section.

and socket locations. If removed, seal pins must be replaced

Fit rear wire seal into back of socket housing, if removed.

to maintain the integrity of the environmental seal.

Grasp socket approximately 1 inch (25.4 mm) behind the

Pin housing: alignment grooves and/or external latch cover,

contact barrel. Gently push sockets through holes in wire

attachment clip, secondary locking wedge, wire seal, seal pin.

seal into their respective chambers. Feed socket into

chamber until it “clicks” in place. Verify that socket will not

back out of chamber; a slight tug on the wire will confirm

REMOVING/DISASSEMBLING

that it is properly locked in place.

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

Attachment clips are attached to the pin housings of most

Insert tapered end of secondary locking wedge into

connectors. The clips are then attached to T-studs on the

socket housing and press down until it snaps in place.

motorcycle frame. T-studs give positive location to electrical

The wedge fits into the center groove within the socket

connectors and wire harness. Consistent location reduces

housing and holds the terminal latches tightly closed.

electrical problems and improves serviceability.

Push the connector toward the rear to disengage small

NOTES

end of slot on attachment clip from T-stud. Lift connector

●

See Figure B-5. While rectangular wedges do not require

off T-stud.

a special orientation, the conical secondary locking

Depress the external latch(es) on the socket housing

wedge of the 3-pin connector must be installed with the

side and use a rocking motion to separate the pin and

arrow pointing toward the external latch.

socket halves. Two-, three-, four- and six-pin Deutsch

●

If the secondary locking wedge does not slide into the

connectors have one external latch, while eight- and

installed position easily, verify that all terminals are fully

twelve-pin connectors have two, both of which must be

installed in the socket housing. The lock indicates when

pressed simultaneously to separate the connector

terminals are not properly installed by not entering its

halves.

fully installed position.

NOTE

With few exceptions, the socket housing can always be found

on the accessory side, while the pin side of the connector is

plumbed to the wiring harness.

B-6

2006 Sportster: Appendix B

HOME

x0014a7x

4566

Pin Housing

Arrow points to

external latch

Socket

Housing

Figure B-5. 3-pin Locking Wedge Orientation

Figure B-6. Remove Secondary Locking Wedge

X0047X7X

Socket Side

Socket terminal

Seal pin

Wire seal

Socket housing

External latch

Alignment tabs

Internal seal

Locking wedge

Pin Side

Locking wedge

10. Alignment grooves

11. Latch cover

12. Pin housing

13. Wire seal

14. Pin terminal

Figure B-7. 12-pin Deutsch Connector (Exploded View)

2006 Sportster: Appendix B

B-7

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NOTES

REMOVING/INSTALLING PINS

● Deutsch connectors are color coded for location pur-

poses. Those connectors associated with left side acces-

Remove the secondary locking wedge. Use the hooked

sories, such as the front and rear left turn signals, are

end of a stiff piece of mechanics wire or a needle nose

gray. All other connectors, including those associated

pliers, whichever is most suitable.

with right side accessories, are black.

Gently depress terminal latches inside pin housing and

● If it should become necessary to replace a plug or recep-

back out pins through holes in wire seal.

tacle, please note that the 8-pin and 12-pin gray and

NOTE

black connectors are not interchangeable. Since location

An Electrical Terminal Crimp Tool (Part No. HD-39965) is

of the alignment tabs differ between the black and gray

used to install Deutsch pin and socket terminals on wires. If

connectors, plugs or receptacles must be replaced by

new terminals must be installed, see Crimping Instructions in

those of the same color. If replacing both the socket and

this section.

pin halves, then the black may be substituted for the gray,

and vice versa. The socket and pin halves of all other

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

connectors are interchangeable, that is, the black may be

approximately 1 inch (25.4 mm) behind the contact bar-

mated with the gray, since the alignment tabs are absent

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

and the orientation of the external latch is the same.

respective numbered locations. Feed pin into chamber

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

3. Fit the attachment clip to the pin housing, if removed.

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

Place large end of slot on attachment clip over T-stud on

properly locked in place.

frame; push assembly forward to engage small end of

slot.

Insert tapered end of secondary locking wedge into pin

housing and press down until it snaps in place. The

wedge fits in the center groove within the pin housing

CRIMPING INSTRUCTIONS

and holds the terminal latches tightly closed.

NOTES

1. See Figure B-8. Squeeze the handles to cycle the crimp

● See Figure B-5. While rectangular wedges do not require

tool to the fully open position.

a special orientation, the conical secondary locking

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

wedge of the 3-pin connector must be installed with the

the crimp tails facing upward and the rounded side of the

arrow pointing toward the external latch.

contact barrel resting on the concave split level area of

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

● If the secondary locking wedge does not slide into the

hole of locking bar.

installed position easily, verify that all terminals are fully

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

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

minals are not properly installed by not entering its fully

crimp tails are slightly out of vertical alignment, the crimp

installed position.

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

ASSEMBLING/INSTALLING

band and the core crimp tails.

4. Strip lead removing 5/32 inch (3.96 mm) of insulation.

Insert socket housing into pin housing until it snaps in

Insert wires between crimp tails until ends make contact

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

with locking bar. Verify that wire is positioned so that

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

short pair of crimp tails squeeze bare wire strands, while

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

long pair folds over insulation material.

on the socket side must be aligned with the latch cover

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

on the pin side.

automatically opens when the crimping sequence is

For those connectors with two external latches (8-pin

complete. Raise up locking bar and remove contact.

and

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

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

improper assembly. Align the tabs on the socket housing

tion should be minimal.

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.

B-8

2006 Sportster: Appendix B

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d0250x8x

Locking bar

Insert contact through middle

Insert stripped lead until it

hole in locking bar.

contacts locking bar.

Close and squeeze crimp tool

Raise locking bar and remove

contact.

Insulation crimp

Core crimp

Figure B-8. Deutsch Crimping Procedure

2006 Sportster: Appendix B

B-9

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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 B-9. 2-Pin, 3-Pin and 4-Pin Deutsch Connectors

B-10

2006 Sportster: Appendix B

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MINI-DEUTSCH CONNECTORS

B.3

GENERAL

d0253x8x

For Size 20, 16 and 12 Contacts

Wire Range 26-12 AWG

NOTE

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. See Crimping Instructions below

for details.

d0252x8x

Figure B-11. Selector Knob

1. Indentor cover

2. Contact

3. Indentor points

Adjusting screw

Locknut

Locking pin

Selector knob

Figure B-10. Deutsch Solid Barrel Contact Crimp Tool

(Part No. HD-42879)

CRIMPING INSTRUCTIONS

Squeeze the handles to cycle the crimp tool to the fully

open position.

See Figure B-10. Remove locking pin (3) from selector

knob (4).

d0254x8x

See Figure B-11. Raise selector knob and rotate until

selected wire size stamped on wheel is aligned with

Figure B-12. Indentor Points

“SEL. NO.” arrow.

Loosen knurled locknut and turn adjusting screw clock-

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

wise (in) until it stops.

with the wire end out.

6. Turn adjusting screw counterclockwise (out) until contact

is flush with bottom of depression in indentor cover.

Tighten knurled locknut.

7. See Figure B-12. Slowly squeeze handles of crimp tool

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

2006 Sportster: Appendix B B-11

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

See Figure B-13. 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 indentor.

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.

d0255x8x

Figure B-13. Contact Barrel

B-12

2006 Sportster: Appendix B

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PACKARD ELECTRICAL CONNECTORS

B.4

GENERAL

REMOVING PULL-TO-SEAT TERMI-

NALS/EXTERNAL LATCH TYPE

See Figure B-14. From a servicing standpoint, there are two

basic types of Packard electrical connectors, those with pull-

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

to-seat terminals and those with push-to-seat terminals.

nal latches, proceed as follows:

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

Remove the connector from the retaining device, if

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

present.

bly the pull-to-seat type.

Bend back the external latch(es) slightly and separate

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

the pin and socket halves of the connector.

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

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

slot in the connector housing and prevents the terminal from

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

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

the locking tang. See A in Figure B-15. The tangs are

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

always positioned in the middle of the chamber and are

pulled and further inhibits movement of the terminal inside

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

the chamber.

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

Unlike most connectors, where the terminals are pulled out

the ear.

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

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

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

(25.4 mm) safety pin about 1/8 inch (3.2 mm) down the

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

middle of the chamber and pivot the end of the pin

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

toward the terminal body. When a click is heard, remove

nal back inside the chamber of the connector housing.

the pin and repeat the procedure. See B in Figure B-15.

Packard pull-to-seat electrical connectors have an external

The click is the sound of the tang returning to the locked

latch to lock the pin and socket halves together.

position as it slips from the point of the pin. Pick at the

tang in this manner until the clicking stops and the pin

seems to slide in at a slightly greater depth than it had

previously. This is an indication that the tang has been

depressed.

NOTES

●

On those terminals that have been extracted on a previ-

ous occasion, no clicking sound may be heard when the

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

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

lead to check if the terminal is free.

●

When picking multiple terminals, the end of the pin may

become malleable. For best results, continue the proce-

dure with a new safety pin.

x031x7x

3-Place - Typical

Figure B-14. Packard Pull-to-Seat Terminal Connectors

(Socket Sides)

2006 Sportster: Appendix B B-13

HOME

See Figure B-15. Remove the pin and push on the wire

INSTALLING PULL-TO-SEAT

end of the lead to extract the terminal from the mating

end of the connector. See item C. If necessary, pull back

TERMINALS/EXTERNAL LATCH

the conduit and remove the wire seal at the back of the

TYPE

connector to introduce some slack in the wires.

NOTE

A series of Packard Electrical Terminal Crimp Tools are avail-

For wire location purposes, alpha characters are stamped

able to install Packard pin and socket terminals on wires.

into the socket housings.

1. See Figure B-15. To install a terminal back into the

chamber of the connector housing, use a thin flat blade,

like that on an X-Acto knife, and carefully bend the tang

outward away from the terminal body. See item D.

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

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

when the terminal is properly seated.

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

place.

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

until the latches “click.”

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.

x0332x7x

Figure B-15. Depress Tang and Extract Terminal From Mating End of Connector

B-14

2006 Sportster: Appendix B

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SEALED BUTT SPLICE CONNECTORS

B.5

INSTALLATION

Table B-1. Wire Specifications

CONNECTOR

Butt splicing may be a necessary procedure for replacement

WIRE GAUGE

PART NO.

COLOR

of some components. Proceed as follows:

Strip 3/8 inch (9.5 mm) of insulation off the ends of the

18-20

Red

70585-93

wires.

14-16

Blue

70586-93

See Figure B-17. Insert wires into opposite ends of the

10-12

Yellow

70587-93

butt splice connector. Feed the wires into the connector

until the stripped ends are housed within the metal

insert. Since the size of the connectors vary with the

NOTE

gauge of the wire, reference the following table to ensure

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

properly sealed splices.

tool attachment.

See Figure B-16. Crimp the wires within the connector

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

using the Packard Crimp Tool (HD-38125-8). Be sure to

disappear and the tubing assumes a smooth cylindrical

match the color or gauge wire marked on the butt splice

appearance.

connector with the corresponding crimp cavity on the

crimp tool.

x0333x7x

NOTE

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

Red

the butt splice connectors are spaced at different positions

along the length of the wires.

Blue

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)

Yellow

See Figure B-17. Using the UltraTorch UT-100 (HD-

39969), Robinair Heat Gun (HD-25070) with heat shrink

attachment (HD-41183) or other suitable radiant heating

device, heat the crimped splice to encapsulate the butt

splice connection. Apply heat from the center of the

crimp out to each end until the meltable sealant exudes

Figure B-16.

Packard

Crimp Tool

(HD-38125-8)

out both ends of the connector.

Metal

Melted sealant

insert

Insert stripped wire

Crimp wire ends

Apply heat and allow

ends into connector

in connector

connector to cool

Figure B-17. Installing Sealed Butt Connectors

2006 Sportster: Appendix B B-15

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CONNECTOR LOCATIONS

B.6

Table B-2. Sportster Electrical Connector Locations

CONNECTOR

DESCRIPTION

TYPE

LOCATION

NO.

[5]

Maxi fuse

spade terminals

on battery strap, under left side cover

[7]

tail lamp harness to main harness

6-place Multilock, black

under seat

[10]

ignition control module (ICM)

12-place Deutsch, black

under seat

[18]

left rear turn signal

2-place Multilock, white

inside tail lamp lens

[19]

right rear turn signal

2-place Multilock, black

inside tail lamp lens

[20]

instruments

12-place Deutsch, black

under fuel tank

[22]

right hand controls

6-place Deutsch, black

under fuel tank

[24]

left hand controls and horn

6-place Deutsch, gray

under fuel tank

[30]

TSM/TSSM

12-place Deutsch, gray

under battery

[31]

front turn signals

6-place Multilock, black

under fuel tank

[33]

ignition key switch

right side of frame behind neck

[38]

headlamp

4-place Multilock, black

under fuel tank

[39]

speedometer

12-place Packard Micro-64, black

back of speedometer

[46]

voltage regulator to stator

2-place round molded, black

in front of engine crankcase

[61]

relay/fuse block

spade terminals

under left side cover

[62]

starter relay

5-place Amp

fuse/relay block, under left side cover

[65]

vehicle speed sensor (VSS)

3-place Packard, black

right rear top of crankcase

[77]

voltage regulator (D.C. output)

2-place Packard, black

in front of engine crankcase

[79]

crank position sensor (CKP)

2-place Deutsch, black

left side, frame, beneath primary cover

[80]

manifold air pressure sensor

3-place Packard, black

top of manifold

[83]

ignition coil

3-place Packard, black

back of coil

[91]

data link connector

4-place Deutsch, gray

electrical bracket, under left side cover

[93]

tail lamp

4-place Multilock, black

inside tail lamp lens

[94]

tail lamp power in

6-place Multilock, black

inside tail lamp lens

[108]

tachometer

12-place Packard Micro-64, gray

back of tachometer

[120]

oil pressure switch

90^o post terminal, black

oil pressure switch, under oil filter mount

stop lamp switch, under electrical

[121]

rear stoplight switch

spade terminals, black

bracket

[122]

horn

flag terminal (2), black

between cylinders, left side

[128]

starter solenoid

locking spade terminal, white

starter solenoid

[131]

neutral switch

1-place molded jumper, black

right side frame, beneath gearcase cover

[142]

security siren

3-place Deutsch, black

electrical bracket, under left side cover

[160]

B+ connector

1-place Packard, gray

under seat

harness grounds (2)

ring terminals

crankcase housing, top rear

B-16

2006 Sportster: Appendix B

HOME

INDEX TO WIRING DIAGRAMS

B.7

Table B-3. 2006 Sportster Wiring Diagrams

MODEL

DIAGRAM

PAGE