Content      ..     23      24      25      26     ..

Harley Davidson 2006 Sportster XLH MODELS. Service Manual - page 25

HOME

NOTE

6. Disconnect the red battery charger lead to the positive

If the battery is still in the vehicle, connect the negative lead

(+) terminal of the battery.

to the chassis ground. Be sure that the ignition and all electri-

cal accessories are turned off.

7. Mark the charging date on the battery.

4.

Step away from the battery and turn on the charger.

8. Perform either a conductance test or load test to deter-

Refer to the charging instructions in Table 7-10.

mine the condition of the battery. See CONDUCTANCE

TEST or LOAD TEST under 7.14 BATTERY.

1WARNING

9. If charging battery because voltmeter test reading was

Unplug or turn OFF battery charger before disconnecting

below 12.6 V, perform voltmeter test. See VOLTMETER

charger cables from battery. Disconnecting clamps with

TEST under 7.14 BATTERY.

charger ON can cause a spark and battery explosion,

10. Install the battery in the motorcycle. See BATTERY

which could result in death or serious injury. (00067a)

INSTALLATION AND CONNECTION under 1.7 BAT-

5.

After the battery is fully charged, disconnect the black

TERY MAINTENANCE.

battery charger lead to the negative (-) terminal of the

battery.

Table 7-10. Battery Charging Rates/Times (Approximate)

STATE OF CHARGE

BATTERY

3 AMP

6 AMP

10 AMP

20 AMP

AMP HOUR

% OF

CHARGER

CHARGER

CHARGER

CHARGER

VOLTAGE

CHARGE

12.7

100%

-

-

-

-

1 hour,

12.6

75%

34 minutes

20 minutes

10 minutes

10 minutes

2 hours,

1 hour,

12.3

50%

40 minutes

20 minutes

12

20 minutes

10 minutes

3 hours,

1 hour,

12.0

25%

1 hour

30 minutes

20 minutes

40 minutes

4 hours,

2 hours,

1 hour,

11.8

0%

40 minutes

30 minutes

14 minutes

20 minutes

NOTE

NOTE

The figures listed above assume that the battery is charging

The use of constant current chargers to charge sealed main-

at room temperature. If warmer than room temperature, use a

tenance-free batteries is not recommended. Any overcharge

slightly shorter charging time. If colder, use a slightly longer

will cause dry-out and premature battery failure. If a constant

charging time.

current charger is the only type available, do not exceed the

charge times listed above and do not continue charging the

battery if it gets hot. When charging, never exceed 15 volts.

7-24

2006 Sportster: Electrical

HOME

BATTERY CABLES

7.15

REMOVAL

11311

2

3

1.

Open left side cover. Remove Maxi-Fuse. See

7.25

MAXI-FUSE.

2.

See Figure 7-23. Remove maxi-fuse cover (4) from bat-

tery strap (3) by grasping cover and sliding it toward the

rear of the motorcycle.

3.

Remove battery strap screw and flat washer (5). Unhook

battery strap (3) from battery tray mount on top of battery

and remove strap.

4

1WARNING

Prevent accidental vehicle start-up, which could cause

1

5

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

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

tery. (00280a)

1.

Maxi-fuse holder [5]

2.

Positive (+) battery terminal (under rubber boot)

4.

Disconnect negative (-) battery cable from crankcase.

3.

Battery strap

Disconnect positive (+) battery cables from battery. See

4.

Maxi-fuse cover

BATTERY DISCONNECTION AND REMOVAL under 1.7

5.

Screw and flat washer

BATTERY MAINTENANCE.

a. Negative cable - See Figure 7-24. Remove nut (2)

Figure 7-23. Maxi-Fuse and Battery Location

that secures negative (-) battery cable (1) to ground

stud on crankcase boss behind starter motor

assembly (3). Remove cable connector from stud.

x0609x1x

Pull on end of negative (-) cable gently to free it

from cable clip (4).

b. positive (+) cable - See Figure 7-23. Lift up protec-

tive rubber boot covering battery positive (+) termi-

nal. Unthread screw from battery positive

(+)

1

terminal and remove positive (+) battery cable from

4

post. Remove positive (+) battery cable from holders

on battery tray.

c. Remove maxi-fuse wiring harness from battery posi-

tive (+) terminal post. Inspect maxi-fuse wiring har-

3

ness and holder. See REPLACEMENT under 7.27

MAXI-FUSE HOLDER.

5.

Note routing of negative (-) battery cable around frame

downtube and remove battery with negative (-) battery

cable attached.

2

1.

Negative battery cable

2.

Nut

3.

Starter motor assembly

4.

Cable clip

Figure 7-24. Negative Battery Cable Routing to Ground

2006 Sportster: Electrical

7-25

HOME

6.

Inspect positive (+) and negative (-) cables for cuts, fray-

INSTALLATION

ing or other damage. See BATTERY INSPECTION under

1.7 BATTERY MAINTENANCE.

1. Route fastener through negative (-) battery cable ring

7.

As required, remove negative (-) battery cable from bat-

and into negative (-) battery terminal of a fully charged

tery.

battery. Position negative

(-) battery cable so that it

8.

See Figure 7-25. As required, pull back rubber cap (3)

hangs straight down from negative (-) battery terminal.

and using a 12 mm wrench, remove nut with captive lock

Tighten to 40-50 in-lbs (4.5-5.7 Nm).

washer (5) and positive (+) battery cable (2) from starter

2. Apply a light coat of petroleum jelly or corrosion retardant

post (4).

material to the negative (-) battery terminal.

3. See Figure 7-24. Slide battery in battery tray. Route neg-

ative (-) battery cable (1) around frame downtube.

10634

1

1WARNING

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

2

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)

3

4.

See Figure 7-23. With negative (-) battery cable discon-

nected from ground on crankcase, thread fastener

through positive (+) battery cable and maxi-fuse wiring

harness into positive (+) battery terminal (2). Tighten to

40-50 in-lbs (4.5-5.7 Nm).

4

5.

Apply a light coat of petroleum jelly or corrosion retardant

material to the positive (+) battery terminal. Place protec-

tive rubber boot over terminal.

5

6.

Hook top of battery strap (3) to battery tray mount on top

of battery. Install flat washer and strap screw (5). Tighten

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

7.

Snap positive (+) battery cable into holders on electrical

bracket.

8.

Hook maxi-fuse cover to pin on battery strap and slide

forward until it snaps into place.

1.

Starter assembly

9.

See Figure 7-25. Install positive (+) battery cable (2) and

2.

Positive (+) battery cable

nut with captive lock washer (5) on starter post (4). Using

3.

Rubber cap

a 12 mm wrench, tighten lock nut to 60-85 in-lbs (6.8-9.6

4.

Starter post

Nm).

5.

Nut with captive lock washer

10.

Push rubber cap (3) over starter post.

Figure 7-25. Positive (+) Cable Starter Post Connection

11.

See Figure 7-24. Press negative battery cable (1) into

(Right Side View - Rubber Cap Pulled Back)

cable clip (4).

12.

Place negative battery cable connector onto stud on

crankcase boss behind starter motor assembly

(3).

Thread nut

(2) onto crankcase ground stud behind

starter motor.

7-26

2006 Sportster: Electrical

HOME

13. See Figure 7-26. Press negative battery cable connector

11302

against cable stop on crankcase and tighten nut to 55-75

in-lbs (6.2-8.5 Nm).

14. Install Maxi-Fuse. Close left side cover. See 7.25 MAXI-

FUSE.

1WARNING

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

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

shift causing loss of control, which could result in death

or serious injury. (00070a)

15. Install seat. See INSTALLATION under 2.32 SEAT.

Figure 7-26. Negative Battery Cable Stop on Crankcase

2006 Sportster: Electrical

7-27

HOME

HEADLAMP

7.16

REPLACEMENT-XL 883, XL 883L,

16

x0611x7x

XL 883R, XL 1200R

15

14

NOTE

13

The headlamp is a replaceable bulb (element) type. Replace

with the specified H4 halogen bulb, only.

12

1

CAUTION

2

To prevent accidental vehicle start-up, which could

3

cause death or serious injury, remove maxi-fuse before

4

proceeding. (00251a)

1.

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

5

side cover. See 7.25 MAXI-FUSE.

2.

See Figure 7-27. Remove screw (8) and chrome outer

6

molding ring (6).

11

3.

Hold headlamp reflector/lens (5) and compress release

tabs on sides of bulb connector (10) to pull connector

from spade terminals.

10

4.

Pull rubber boot (3) from back of reflector/lens.

9

1.

Headlamp shell

5.

Press ends of retaining clip (4) to unhook from notched

2.

Adapter ring

retaining tabs and pivot retaining clip back.

8

3.

Rubber boot

6.

Remove bulb (9).

4.

Retaining clip

7

5.

Reflector/lens

6.

Moulding ring

CAUTION

7.

Moulding ring nut

Do not touch glass bulb portion of headlamp bulb with

8.

Moulding ring screw

bare hands. Oil from your skin deposited on the bulb will

9.

Bulb

create temperature variances in the glass during normal

10.

Bulb connector

lamp operation; this can cause the bulb to fracture. When

11.

Headlamp connector [38]

removing or installing any halogen bulb, touch only the

12.

Headlamp bracket

terminal side or metal base of the bulb. Keep glass bulb

13.

Headlamp mounting washer

clean and free of any foreign material.

14.

Lockwasher

15.

Nut

7.

Fit replacement bulb (9).

16.

Headlamp bracket plug

NOTE

The tab opposite the center spade connector of bulb fits the

Figure 7-27. Headlamp Components

top notch in the reflector which points to the top of the reflec-

tor/lens.

8.

Pivot the retaining clip (4) over the bulb (9) and press the

ends into the retaining post.

9.

Install rubber boot (3) with word TOP over top notch.

Press center ring down flush with base of bulb.

2006 Sportster: Electrical

7-29

HOME

10. See Figure 7-28. If replacing the small position lamp (3)

REPLACEMENT-XL 883C, XL 1200C

in the side of the reflector/lens on HDI XL 883, XL 883L,

XL 883R and XL 1200R models:

NOTE

a. Pull the spade connectors from the bulb holder.

The headlamp is a replaceable bulb (element) type. Replace

b. Pull the bulb holder from the reflector/lens.

with the specified H4 halogen bulb, only.

c. Quarter turn the bulb to remove and replace.

d. Replace the bulb holder and mate connectors.

CAUTION

11. Mate the bulb connector to the bulb.

To prevent accidental vehicle start-up, which could

12. Fit the adapter ring and the reflector/lens to the head-

cause death or serious injury, remove maxi-fuse before

lamp shell.

proceeding. (00251a)

13. Install the moulding ring screw and nut.

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

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

side cover. See 7.25 MAXI-FUSE.

cover. See 7.25 MAXI-FUSE.

2. Remove screw and chrome molding ring.

15. After final assembly, align headlamp as described in

3. See Figure 7-29. Hold headlamp reflector/lens (3) and

ADJUSTMENT under 1.28 HEADLAMP ALIGNMENT.

compress release tabs (6) on sides of headlamp connec-

tor [38] (2). Pull connector from spade terminals.

4. Remove headlamp reflector/lens and metal adapter ring

9433

(1).

2

5. Pull rubber boot (5) from rubber finger gasket (4) on back

of reflector/lens.

6. See Figure 7-30. Press ends of retaining clip (3) to

1

unhook from notched retaining post (4).

7. Pivot retaining clip back and remove bulb (5).

CAUTION

Do not touch glass bulb portion of headlamp bulb with

bare hands. Oil from your skin deposited on the bulb will

create temperature variances in the glass during normal

lamp operation; this can cause the bulb to fracture. When

removing or installing any halogen bulb, touch only the

terminal side or metal base of the bulb. Keep glass bulb

clean and free of any foreign material.

3

8. Fit replacement bulb (5).

1.

Headlamp connector [38]

NOTE

2.

Rubber boot

The tab opposite the center spade connector of bulb (5) fits

3.

HDI position lamp

the top notch (2) in the reflector which points to the top of the

reflector/lens (6).

Figure 7-28. HDI Headlamp (XL 1200R)

9. Pivot the retaining clip (3) over the bulb and press the

ends into the retaining post (4).

10. If necessary, remove and fit a replacement rubber finger

gasket (1).

NOTE

The smaller single notch of the rubber finger gasket (1) will fit

over the top notch (2) of the reflector/lens (6).

7-30

2006 Sportster: Electrical

HOME

11. If replacing the small position lamp in the side of the

9430

reflector/lens on HDI XL 883C/1200C models:

3

a. Pull the spade connectors from the bulb holder.

2

b. Pull the bulb holder from the reflector/lens.

c. Quarter turn the bulb to remove and replace.

d. Replace the bulb holder and mate connectors.

12. See Figure 7-31. Install rubber boot with word TOP (1)

1

over top notch.

13. Press center ring (2) down flush with base of bulb (3) and

press air out of boot to seal bore of boot to bulb and boot

4

flange to rubber finger gasket.

6

NOTE

Air will re-enter the rubber boot and raise the center ring

5

above bottom of bulb.

9432

1

1.

Adapter ring

2.

Headlamp connector [38]

3.

Reflector/lens

4.

Rubber finger gasket

5.

Rubber boot

6.

Connector release tab

Figure 7-29. Remove Headlamp

2

3

9431

1

2

3

1.

TOP mark

4

2.

Center ring

3.

Bulb (element)

3

Figure 7-31. Headlamp Boot (TOP Mark)

5

6

1.

Rubber finger gasket

2.

Top notch

3.

Retaining clip

4.

Retaining post

5.

Bulb

6.

Reflector/lens

Figure 7-30. Headlamp Assembly

2006 Sportster: Electrical

7-31

HOME

14. See Figure 7-32. Fit the molding ring (2) to the reflector/

16.

Press the reflector/lens assembly into the headlamp

lens (7) and fit the adapter ring to the headlamp shell (1).

shell matching the two notches on the moulding ring to

the bulges on the headlamp shell.

NOTES

● The two notches on the circumference of the adapter

17.

Rotate the moulding clockwise to lock the moulding ring

ring will fit the two bulges on rim of headlamp shell.

down on the reflector/lens. Install the moulding ring

screw (9) and tighten.

● A single tab on the circumference of the reflector will fit

the notch on the inside of the adapter ring.

18.

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

cover. See 7.25 MAXI-FUSE.

● The four fingers of the rubber finger gasket are installed

between the adapter ring and the reflector/lens.

19.

After final assembly, align headlamp as described

in

ADJUSTMENT under 1.28 HEADLAMP ALIGNMENT.

15. Mate the headlamp connector (3) to the spade connector

on the bulb (10).

x0610x7x

15

1

2

4

3

14

13

6

5

7

12

8

1.

Headlamp shell

11

2.

Adapter ring

3.

Connector [38]

10

4.

Rubber finger gasket

5.

Rubber boot

6.

Retaining clip

7.

Reflector/lens

8.

Moulding ring

9.

Moulding ring screw

10.

Bulb

11.

Bolt and washer

9

12.

Headlamp mounting

13.

Bolt and washer

14.

Headlamp socket connector [38B]

15.

Washer and nut

Figure 7-32. Headlamp Components XL 883C/1200C

7-32

2006 Sportster: Electrical

HOME

INDICATOR LAMPS

7.17

REPLACEMENT-XL 883, XL 883L,

REPLACEMENT-XL 1200R

XL 883R

CAUTION

CAUTION

To prevent accidental vehicle start-up, which could

cause death or serious injury, remove maxi-fuse before

To prevent accidental vehicle start-up, which could

proceeding. (00251a)

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.

1.

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

2. Protect headlamp bracket. See Figure

7-34. Holding

side cover. See 7.25 MAXI-FUSE.

speedometer/tachometer bracket (3), remove two bolts

2.

Protect headlamp bracket. See Figure

7-33. Holding

with lock washers from speedometer/tachometer

speedometer bracket (3), remove two bolts with lock

bracket.

washers from speedometer bracket.

3. Pull faulty wire lead and bulb socket (6) from indicator

3.

Pull faulty wire lead and bulb socket (6) from indicator

bulb housing (4).

bulb housing (4).

4. Replace bulb (5).

4.

Replace bulb (5).

5. Lubricate rubber bulb socket with alcohol or glass

5.

Lubricate rubber bulb socket with alcohol or glass

cleaner and push socket into indicator bulb housing.

cleaner and push socket into indicator bulb housing.

6. Install speedometer/tachometer bracket. Tighten screws

6.

Install speedometer bracket. Tighten screws to 12-18 ft-

to 12-18 ft-lbs (16.3-24.4 Nm).

lbs (16.3-24.4 Nm).

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

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

cover.

cover.

x0613a7x

x0613a7x

6

6

3

4

5

4

5

3

2

2

7

7

1

1

1.

Trim plate

1. Trim plate

2.

Lens

2. Lens

3.

Speedometer bracket

3. Speedometer/tachometer bracket

4.

Indicator bulb housing

4. Indicator bulb housing

5.

Bulb

5. Bulb

6.

Bulb socket

6. Bulb socket

7.

Screw

7. Screw

Figure 7-34. Indicator Lights (XL 1200R)

Figure 7-33. Indicator Lights (XL 883, XL 883L, XL 883R)

2006 Sportster: Electrical

7-33

HOME

REPLACEMENT-XL 883C, XL 1200C

x0612x7x

6

CAUTION

5

To prevent accidental vehicle start-up, which could

cause death or serious injury, remove maxi-fuse before

proceeding. (00251a)

1

2

1.

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

side cover. See 7.25 MAXI-FUSE.

3

2.

Remove fuel tank. See 4.4 FUEL TANK.

3.

Remove the decorative cover behind the handlebar riser.

4

4.

See Figure 7-35. Pull faulty wire lead and bulb socket (3)

from indicator lamp housing (2).

5.

Replace bulb (4).

6.

Lubricate bulb socket (3) with alcohol or glass cleaner

and push socket (3) into indicator lamp housing (2).

7.

Install decorative cover behind handlebar riser. Tighten

screws to 8-12 in-lbs (0.9-1.4 Nm).

8.

Install fuel tank.

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

1.

Speedometer housing/handlebar clamp

cover.

2.

Indicator lamp housing

3.

Bulb socket (5)

4.

Bulb (5)

5.

Lens

6.

Indicator lamp bezel

Figure 7-35. Indicator Lights (XL 883C, 1200C)

7-34

2006 Sportster: Electrical

HOME

TAIL LAMP

7.18

BULB REPLACEMENT

BASE REPLACEMENT

Use of the HD-39621-28 Terminal tool is recommended for

NOTE

this procedure. See B.1 APPENDIX B-WIRING AMP MUL-

Sportsters are equipped with a tail lamp incorporating a rear

TILOCK ELECTRICAL CONNECTORS

lighting harness and circuit board to simplify replacement.

1.

Make certain ignition switch is turned OFF.

CAUTION

2.

See Figure 7-36. Remove two screws and lens (4) from

base (3).

To prevent accidental vehicle start-up, which could

cause death or serious injury, remove maxi-fuse before

3.

Depress locking tab and remove 4-Pin multilock connec-

proceeding. (00251a)

tor from circuit board.

4.

Turn socket assembly (1) one-quarter turn counterclock-

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

wise to release assembly from lens. Remove

(pull)

side cover. See 7.25 MAXI-FUSE.

assembly from lens. Remove bulb from socket.

2. See Figure 7-36. Remove two screws and lens (4) from

5.

Coat base of new bulb with electrical contact grease

base (3).

(Part No. 99861-90). Install (push) new bulb into socket.

3. Depress locking tab and remove 4-Pin multilock connec-

6.

Install

(push) bulb assembly into lens. Turn assembly

tor from circuit board.

one-quarter turn clockwise to lock in place.

4. See Figure 7-37. Using a terminal pick, depress locking

7.

Connect 4-Pin multilock connector to circuit board.

tabs and remove two 2-Pin turn signal connectors and 6-

8.

Install lens to base with two screws. Tighten screws to

Pin Power In connector from circuit board.

20-24 in-lbs (2.3-2.7 Nm).

5. Remove screw, pin housing and circuit board from base.

9.

Turn ignition on and test for proper tail lamp operation.

6. Remove base from rear fender.

7. Install new base to rear fender. Tighten screws to 45-48

x0305a7x

in-lbs (5.1-5.4 Nm).

1

8. See Figure 7-38. Install circuit board/pin housing to base

2

with screw.

x0306a7x

1

4

3

1.

Bulb/socket assembly

2.

4-pin multilock connector

3.

Base

4.

Lens

2

Figure 7-36. Tail Lamp

1.

Terminal pick

2.

2-pin connector

Figure 7-37. Removing 2-Pin Connectors

2006 Sportster: Electrical

7-35

HOME

NOTE

x0307x7x

Cavity numbers are on the back side of secondary locks on

connector housings.

1

x0308a7x

2

3

4

1

2

H-D

USA

68830-98

1.

Pin housing

2.

Circuit board

Figure 7-38. Pin Housing and Circuit Board

NOTE

Circuit board snaps in on bottom.

9.

See Figure 7-39. Install connectors to circuit board.

1.

Tail lamp [93]

10. Install lens to base with two screws. Tighten screws to

2.

Left turn signal [18]

20-24 in-lbs (2.3-2.7 Nm).

3.

Right turn signal [19]

4.

Power in [94]

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

cover. See 7.25 MAXI-FUSE.

Figure 7-39. Tail Lamp Base Connectors

12. Turn ignition on and test for proper tail lamp and turn sig-

nal operation.

Table 7-11. Connector Specifications

FUNCTION

TYPE

NUMBER

WIRE COLOR

CAVITY

V

1

Right turn signal

2-pin Multilock

19

BK

2

V

1

Left turn signal

2-pin Multilock

18

BK

2

BE

1

O/W*

2

Tail lamp

4-pin Multilock

93

R/Y

3

BK

4

O/W

1

BN

2

BE

3

Power

6-pin Multilock

94

R/Y

4

V

5

BK

6

* HDI only. OPEN on DOM.

7-36

2006 Sportster: Electrical

HOME

TURN SIGNALS

7.19

BULB REPLACEMENT

9434

1.

Insert coin in notch of front or rear turn signal lens cap.

Carefully twist coin until lens cap pops out of turn signal

housing.

2

2.

Replace bulb.

3

a. Push bulb and turn counterclockwise.

1

b. Pull bulb from socket when tab on bulb clears open-

ing on socket.

c. Push new bulb in and turn clockwise to lock in

place.

3.

Snap lens cap back into housing.

4

FRONT HOUSING REPLACEMENT

CAUTION

1.

Turn signal connector socket half [31B]

To prevent accidental vehicle start-up, which could

2.

Backbone clip

cause death or serious injury, remove maxi-fuse before

3.

Turn signal connector pin half [31A]

proceeding. (00251a)

4.

Rail clips

1.

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

side cover. See 7.25 MAXI-FUSE.

Figure 7-40. Turn Signal Connector [31]

2.

Remove fuel tank. See REMOVAL under 4.8 FUEL

TANK.

3.

On XL 883C/1200C models, remove riser cover from the

9435

back of the handlebar riser. See 2.25 HANDLEBARS.

4.

See Figure 7-40. Push the turn signal connector [31] for-

ward off of the mating rails in the backbone clip (2) and

separate the connector [31] halves (1, 3).

5.

Remove the corresponding socket terminals from con-

nector [31B]. See B.1 APPENDIX B-WIRING AMP MUL-

TILOCK ELECTRICAL CONNECTORS.

6.

See Figure 7-41. Using a 4 mm Allen wrench, loosen the

Allen screw in the front of the hand lever bracket to

release the turn signal housing ball end stud.

7.

Pull the wire conduit through the fuel tank bracket, the

fork clamp and handlebar clips.

8.

See Figure 7-42. Inspect the ball head stud (1) and

replace as required. Tighten new ball head studs to 96-

156 in-lbs (10.8-17.6 Nm).

9.

Lay old turn signal housing and wires next to new and

cut new wires to length.

10.

Trim sheath back approximately 2.5 in. (63.5 mm) and

crimp new socket terminals onto wires.

Figure 7-41. Turn Signal Ball Stud Allen Screw

2006 Sportster: Electrical

7-37

HOME

11. On XL 883C/XL 1200C, route wires through handlebar

REAR HOUSING REPLACEMENT

clips, between fork clamp and decorative cover and then

through fuel tank bracket.

12. On XL 883, XL 883L, XL 883R and XL 1200R, route

CAUTION

wires through handlebar clips, between fork clamp and

head lamp bracket and then through fuel tank bracket.

To prevent accidental vehicle start-up, which could

cause death or serious injury, remove maxi-fuse before

13. See Figure 7-42. Install housing ball end stud (1) into the

proceeding. (00251a)

lever bracket and aim to front. Using a 4 mm Allen

wrench, tighten Allen screw to 96-120 in-lbs (10.8-13.5

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

Nm).

side cover. See 7.25 MAXI-FUSE.

14. Insert socket terminals into turn signal connector. Refer

2. Remove seat. See REMOVAL under 2.32 SEAT.

to Table 7-12.

3. Remove tail lamp lens from tail lamp base.

15. Mate connector [31] halves and push front to rear to

4. See Figure 7-43. Depress latches on left turn signal con-

engage rails inside backbone clip.

nector [18] (white) (1) and right connector [19] (black)

(2). Unplug connectors from rear lighting circuit board.

16. Replace fuel tank.

5. Remove the corresponding socket terminals from left

17. On XL 883C/1200C, replace riser cover. Tighten screws

connector [19B] and the right connector [18B]. See B.1

to 8-12 in-lbs (0.9-1.4 Nm).

APPENDIX B-WIRING AMP MULTILOCK ELECTRICAL

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

CONNECTORS.

cover. See 7.25 MAXI-FUSE.

10056

x0614x7x

2

1

1

2

3

4

1.

Left turn signal connector [18] (white)

2.

Right turn signal connector [19] (black)

1.

Ball end stud

2.

Turn signal assembly

Figure 7-43. Turn Signal Connectors [18] [19]

3.

Bulb

4.

Lens

Figure 7-42. Front Turn Signal Components

Table 7-12. Front Turn Signal

Connector [31] Wire Colors

HAND

WIRE COLOR

CAVITY

BK

1

Right turn signal

BN

2

BE (DOM only)

3

BE (DOM only)

4

Left turn signal

V

5

BK

6

7-38

2006 Sportster: Electrical

HOME

6.

See Figure 7-44. Remove rear turn signal stalk nuts (3)

12. Route wires through holes and tail lamp base and rear

from inside rear fender on both sides.

fender. Engage turn signal wiring in wire retention brack-

ets.

13. Install rear fender strut covers over fender struts. Push

10507

turn signal wiring harness through appropriate hole in

strut and fender. Thread nut onto turn signal stud from

inside fender.

14. Install right side rear fender strut cover with attached turn

signal assembly to fender strut. Secure fender to strut

with screw, washer and nut in forward mounting hole.

1

1

Install screw, washer and nut plate in aft mounting hole.

Finger-tighten screws only at this time.

15. Now tighten mounting screws in the following sequence:

a. Tighten turn signal stud nuts to

132-216 in-lbs

(14.9-24.4 Nm).

2

3

b. Tighten strut cover screws to 132-216 in-lbs (14.9-

24.4 Nm).

1.

Wire retention bracket

2.

Left turn signal wiring conduit

x0615x7x

3.

Rear turn signal stalk nut

2

3

Figure 7-44. Turn Signal Wire Routing

4

7.

Pull turn signal wiring harnesses through holes in tail

lamp base and wire retention brackets under rear fender.

5

Disengage turn signal wiring harnesses from wire reten-

tion brackets (1).

1

8.

Remove rear fender strut covers with attached turn sig-

nal assemblies from rear fender struts.

9.

Remove housing and mount.

1. Lens

10. Lay old turn signal housing and wires next to new and

2. Bulb (element)

cut new wires to length. Trim sheath back approximately

3. Rear turn signal housing

2.5 in. (63.5 mm). Crimp new terminals onto wires.

4. Mount

5. Stud

11. Install turn signal housing and mounts to rear fender strut

covers.

Figure 7-45. Rear Turn Signal Components

2006 Sportster: Electrical

7-39

HOME

REAR STOP LAMP SWITCH

7.20

GENERAL

1

WARNING

See Figure 7-46. The rear stop lamp switch (3) is located

After repairing the brake system, test brakes at low

behind the rear brake master cylinder reservoir under the left

speed. If brakes are not operating properly, testing at

side cover. The rear stop lamp switch is threaded into a tee

high speeds can cause loss of control, which could

nut (2) in the rear brake line (1).

result in death or serious injury. (00289a)

The stop lamp switch is an open type switch which closes

11. Refill master cylinder and bleed brakes. See 1.9 BLEED-

with hydraulic pressure. When the pressure in the line

ING HYDRAULIC BRAKE SYSTEM. Test operation of

reaches a preset level, the rear stop lamp switch is tripped

rear brake.

and the rear stop lamp illuminates.

NOTE

1WARNING

The rear stop lamp switch cannot be repaired. Replace the

unit if it fails.

Check for proper tail lamp/stop lamp operation before

riding motorcycle. Visibility is a major concern for motor-

cyclists. Failure to have proper lamp operation could

REPLACEMENT

result in death or serious injury.

12. Test operation of brake lamp with the rear brake applied

and the ignition/light switch turned ON.

CAUTION

To prevent accidental vehicle start-up, which could

cause death or serious injury, remove maxi-fuse before

11334

proceeding. (00251a)

1.

Remove left side cover. See 1.6 LEFT SIDE COVER.

2

Remove Maxi-Fuse. See 7.25 MAXI-FUSE.

1

2.

Remove the rear brake master cylinder reservoir cover.

3.

Remove reservoir mounting screw and secure reservoir

upright out of the way. See 2.13 REAR BRAKE MASTER

CYLINDER RESERVOIR.

4.

See Figure 7-46. Pull terminal sockets from spade con-

nections (4) at bottom of stop lamp switch.

3

5.

Unscrew stop lamp switch (3) from tee nut (2).

6.

Thread new stoplight switch (3) to tee nut (2) on brake

4

line. Tighten switch to 84-120 in-lbs (9.5-13.6 Nm).

7.

Install terminal sockets on switch spade connections (4).

1.

Rear brake line

8.

Replace the reservoir mounting screw. Tighten to 20-25

2.

Tee nut

in-lbs (2.3-2.8 Nm).

3.

Rear stop lamp switch

4.

Spade connector terminal socket (2) [121]

9.

Replace the plastic guard around the reservoir.

10. Install Maxi-Fuse. Install left side cover.

Figure 7-46. Rear Stop Lamp Switch

2006 Sportster: Electrical

7-41

Content      ..     23      24      25      26     ..