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Harley Davidson 2006 Sportster XLH MODELS. Service Manual - page 29

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AC Output Check

10070

1. See Figure 1-21. Test AC output.

1

a. Disconnect voltage regulator connector from alter-

nator stator wiring.

b. Connect an AC voltmeter across both stator connec-

tor sockets.

c. Run the engine at 2000 RPM. The AC output should

be 38-52 volts AC (approximately 19-26 per 1000

RPM).

2. Compare test results to specifications.

a. If the output is below specifications, charging prob-

lem could be a faulty rotor or stator.

3

b. If output is good, charging problem might be faulty

voltage regulator. Replace as required.

3. Check the output again as previously described under

CURRENT AND VOLTAGE OUTPUT TEST.

2

1.

Alternator stator connector [46B]

2.

DVOM set to AC volts scale

3.

Meter leads to stator connector sockets

Figure 1-21. Check Stator AC Voltage Output

2006 Sportster: Starting & Charging

1-21

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IGNITION COIL

1.8

TROUBLESHOOTING

x0649a1x

Follow the troubleshooting procedures listed under 4.4 INI-

TIAL DIAGNOSTIC CHECK: ICM if the engine will not start,

is difficult to start or runs roughly. Also check condition of

4

3

spark plug cables. Insulation on cables may be cracked or

damaged allowing high tension current to short to metal

R

F

2

2

parts. This problem is most noticeable when cables are wet.

If poor starting/running condition persists, check resistance of

ignition coil primary and secondary windings using an ohm-

meter.

1

1

NOTE

Terminal 1

Terminal 2

Terminal 3

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

rear coil

+12 V

front coil

Primary Circuit Test

1. Primary resistance should be 0.5-0.7 ohms.

1.

Remove ignition coil.

2. Secondary resistance should be 5.5-7.5K ohms.

2.

Set ohmmeter scale to RX1.

3. Front spark plug

4. Rear spark plug

3. See Figure 1-22. Using HARNESS CONNECTOR TEST

KIT (Part No. HD-41404) gray socket probes, place multi-

Figure 1-22. Ignition Coil Circuit

meter wires on primary coil windings from terminal 1 to

2, and from terminal 2 to 3.

Test Results

4. Refer to Table 1-5. Check primary coil winding resis-

tance.

1. A low resistance value indicates a short in the coil wind-

ing. Replace coil.

a. Normal resistance range is 0.5-0.7 ohms.

2. A high resistance value might indicate that there is some

b. See TEST RESULTS which follows if resistance is

corrosion/oxidation of the coil terminals. Clean the termi-

not within normal operating range.

nals and repeat resistance test. If resistance is still high

after cleaning terminals, replace coil.

Secondary Circuit Test

3. An infinite ohms (∞ or OL) resistance value indicates an

1.

Remove ignition coil.

open circuit (a break in the coil winding). Replace coil.

2.

Set ohmmeter scale to RX1K.

3.

See Figure 1-22. Place multimeter wires on secondary

Ignition Coil Substitution

coil windings from terminal 2 to R, and from terminal 2 to

If a coil tester is not available, use the following test.

F.

NOTE

4.

Refer to Table 1-5. Check secondary coil winding resis-

Coil will function without being attached to frame.

tance.

a. Normal resistance range is 5.5-7.5K ohms.

1. Substitute a new ignition coil by attaching it to any con-

venient point near the old coil. Transfer connector [83] to

b. See TEST RESULTS which follows if resistance is

new coil.

not within normal operating range.

2. Attach new spark plug cables to coil and spark plugs.

3. Test system. If ignition trouble is eliminated by the tem-

porary installation of a new coil, carefully inspect old coil

Table 1-5. Ignition Coil Winding Resistance

and cables for damage. The insulation on the cables may

be cracked or otherwise damaged allowing high tension

NORMAL

OHMMETER

current to short to metal parts. This is most noticeable in

WINDING

RESISTANCE RANGE

SCALE

wet weather or after the motorcycle has been washed.

(IN OHMS)

Primary

R x 1

0.5-0.7

Secondary

R x 1K

5.5K-7.5K

1-22

2006 Sportster: Starting & Charging

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BATTERY TESTING

1.9

GENERAL

CONDUCTANCE TEST

Three different procedures may be performed to provide a

Test the battery using the MCR-101 HD ADVANCED BAT-

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

TERY CONDUCTANCE AND ELECTRICAL SYSTEM ANA-

tance test, or a load test.

LYZER. Perform a battery test as follows:

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

1. Connect the MCR-101 HD analyzer leads to the vehicle’s

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

battery.

the battery must be fully charged.

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

ual to perform a battery test.

VOLTMETER TEST

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

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

The voltmeter test provides a general indicator of battery con-

See Figure 1-23. The analyzer’s printer will provide you with a

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

printout including one of five possible test results:

100% fully charged condition. Refer to Table 1-6.

●

GOOD BATTERY-return the battery to service.

If the open circuit (disconnected) voltage reading is below

12.6V, charge the battery and then recheck the voltage after

● GOOD-RECHARGE-fully charge the battery and return

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

to service.

is 12.7V or above, perform the LOAD TEST described in this

● CHARGE & RETEST-Fully charge the battery and

section.

retest.

● REPLACE BATTERY-replace the battery and retest.

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

Table 1-6. Voltmeter Test

NOTE

Voltage (OCV)

State of Charge

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

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

12.7

100%

connecting the battery cables from the battery, retest the

12.6

75%

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

12.3

50%

12.0

25%

x0661x3x

11.8

0%

MCR-101 HD V1.0

(C) MIDTRONICS

MON 02/21/05

3:45 PM

LAST 6 OF VIN

012345

DATE CODE

B5

BATTERY TEST

RATING:

295 CCA

65958-94

12.32V

95CCA

REPLACE BATTERY

WARRANTY CODE

9J9G9N-0132N8

Figure 1-23. Battery Test Results-Printout

2006 Sportster: Starting & Charging

1-23

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LOAD TEST

d0428x8x

VOLTS

To load test the battery, proceed as follows:

AMPS

1. Remove battery from motorcycle.

1

CAUTION

Load testing a discharged battery can result in perma-

nent battery damage.

2. Always fully charge the battery before testing or test

readings will be incorrect. Load testing a discharged bat-

tery can also result in permanent battery damage.

3. After charging, allow battery to stand for at least one

2

hour before testing.

1WARNING

3

Turn battery load tester OFF before connecting tester

cables to battery terminals. Connecting tester cables

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

sion, which could result in death or serious injury.

(00252a)

1.

Load tester

4. See Figure 1-24. Connect tester leads to battery posts

2.

Induction pickup

and place induction pickup over negative (black) cable.

3.

Battery

Figure 1-24. Load Test Battery

CAUTION

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

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

Table 1-7. Voltmeter Test For Battery

onds.

Charge Conditions

5. Refer to Table 1-8. Load battery at 50% of CCA rating

using the load tester. Voltage reading after 15 seconds

VOLTAGE (OCV)

STATE OF CHARGE

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

12.7

100%

1WARNING

12.6

75%

12.3

50%

Turn battery load tester OFF before disconnecting tester

cables to battery terminals. Disconnecting tester cables

12.0

25%

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

11.8

0%

sion, which could result in death or serious injury.

(00253a)

6. Install the battery in the motorcycle.

Table 1-8. Battery Load Test

COLD CRANKING

100%

50%

AMPERAGE (CCA)

Sportster models

200

100

1-24

2006 Sportster: Starting & Charging

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CHECKING FOR DIAGNOSTIC TROUBLE CODES

2.1

CHECK ENGINE LAMP

x0523x3x

2

See Figure 2-1. To diagnose Ignition Control Module (ICM)

system problems, begin by observing the behavior of the

1

check engine lamp (1).

3

NOTES

●

See Figure 2-2. “Key ON” means that the ignition key is

turned to IGNITION (3) and the engine stop switch is set

to RUN (although the engine is not running).

●

When the ignition switch is turned ON, the check engine

lamp will illuminate for approximately four seconds and

then turn off.

●

If the check engine lamp is not illuminated at Key ON the

problem is likely to be an instrument failure. See 2.2 INI-

TIAL DIAGNOSTIC CHECK: SPEEDOMETER.

●

If the check engine lamp illuminates late (after 20 sec-

onds), the problem is most likely a serial data bus failure.

Test for diagnostic trouble codes (DTCs) using speedom-

eter self diagnostics. See

2.2 INITIAL DIAGNOSTIC

CHECK: SPEEDOMETER.

1.

Check engine lamp

●

If the check engine lamp fails to turn OFF after the initial

2.

Battery lamp

four second period, see

2.2 INITIAL DIAGNOSTIC

3.

Security lamp

CHECK: SPEEDOMETER.

1.

See Figure 2-3. After the check engine lamp turns off fol-

Figure 2-1. Speedometer

lowing the first four second illumination period, one of

three events may occur:

a. The lamp remains off. This indicates there are no

11526

current fault conditions or stored DTCs currently

detected by the ICM.

2

3

b. The lamp remains off for only four seconds and then

illuminates for an eight-second period. This indi-

cates a DTC is stored, but no current DTC exists.

c. If the lamp remains on beyond the eight-second

1

period, a current DTC exists.

2.

See CODE TYPES which follows for a complete descrip-

tion of DTC formats.

NOTE

Some DTCs can only be fully diagnosed during actuation. For

example, a problem with the ignition coil will be considered a

current fault even after the problem is corrected, since the

ICM will not know of its resolution until after the coil is exer-

cised by the vehicle start sequence. In this manner, there

may sometimes be a false indication of the current DTC.

1. Ignition OFF

2. ACC ON

3. Ignition ON

Figure 2-2. Ignition Switch

2006 Sportster: Instruments

2-1

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1.

See Figure 2-3. After the security lamp turns off following

SECURITY LAMP

the first four second illumination period, one of three

events may occur:

a. The lamp remains off. This indicates there are no

Turn Signal Module (TSM)

current fault conditions or stored DTCs currently

If the turn signals flash six four-way flashes shortly after key

detected by the TSM/TSSM.

ON, it indicates a diagnostic trouble code (DTC) has been

b. The lamp stays off for only four seconds and then

logged sometime in the last three ignition cycles.

comes back on for an eight-second period. This indi-

cates a DTC is stored, but no current DTC exists.

Turn Signal Security Module (TSSM)

c. If the lamp remains on beyond the eight-second

period, a current DTC exists.

See Figure 2-1. To diagnose turn signal security module

(TSSM) system problems, begin by observing the behavior of

2.

See CODE TYPES which follows for a complete descrip-

the security lamp (3).

tion of DTC formats.

NOTE

NOTES

Some DTCs can only be fully diagnosed during actuation. For

● To provide an indication of TSSM DTCs, the security

example, a problem with the turn signals will be considered a

lamp is enabled on TSSM models.

current fault even after the problem is corrected, since the

● See Figure 2-2. “Key ON” means that the ignition key is

TSM/TSSM will not know of its resolution until after the turn

signals are activated. In this manner, there may sometimes

turned to IGNITION and the engine stop switch is set to

RUN (although the engine is not running).

be a false indication of the current DTC.

● When the ignition switch is turned ON, the security lamp

will illuminate for approximately four seconds and then

turn off.

● If the security lamp is not illuminated at Key ON, the

problem is likely to be an instrument failure. See 2.3

SPEEDOMETER SELF DIAGNOSTICS.

● If the security lamp illuminates late (after 20 seconds),

the problem is most likely a serial data bus failure. Test

for DTCs using speedometer self diagnostics. See 2.3

SPEEDOMETER SELF DIAGNOSTICS.

● If the security lamp fails to turn OFF after the initial four

second period, a problem exists in the instrumentation.

See 2.3 SPEEDOMETER SELF DIAGNOSTICS.

ON

4 Sec.

A

Lamp OFF: No Current or Historic DTCs

OFF

Key ON

Lamp ON 8 Seconds:

Only Historic DTCs Exist

ON

4 Sec.

8 Sec.

B

Lamp OFF

OFF

4 Sec.

Key ON

Lamp Remains ON: Current DTC *

ON

4 Sec.

C

OFF

4 Sec.

Key ON

* Historic DTCs May Also Exist

Figure 2-3. Check Engine and Security Lamp Operation

2-2

2006 Sportster: Instruments

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INITIAL DIAGNOSTIC CHECK: SPEEDOMETER

2.2

GENERAL

10062

● Constant power is supplied to the speedometer through

terminal 5 of connector [39]. The speedometer turns on

1

when power is applied to terminal 1. The speedometer

proceeds through an initialization sequence every time

power is removed and re-applied to terminal 6. The visi-

ble part of this sequence is the check engine lamp, secu-

rity lamp, backlighting and odometer display. Upon key

ON (Run/Off switch set to RUN), the check engine lamp

2

and security lamp will illuminate for four seconds and

then (if parameters are normal) will turn off.

● To locate faulty circuits or other system problems, follow

the diagnostic flow charts and tests in this section. For a

systematic approach, always begin with INITIAL DIAG-

NOSTICS which follows. Read the general information

1.

Oil tank

and then work your way through the flow chart box by

2.

Relay/fuse block

box.

● Loss of power on any of the four power inputs will

Figure 2-4. Relay/Fuse Block Location

change speedometer behavior. Refer to Table 2-1.

Diagnostic Notes

10071

If a numbered circle appears adjacent to a flow chart box,

2

more information is offered in the diagnostic notes. Many

5

diagnostic notes contain supplemental information, descrip-

1

tions of various diagnostic tools or references to other parts

of the manual where information on the location and removal

of components may be obtained.

Circuit Diagram/Wire Harness

Connector Table

When working through a flow chart, refer to the illustrations,

6

3

the associated circuit diagram and the wire harness connec-

tor table as necessary. The wire harness connector table for

4

7

each circuit diagram identifies the connector number, descrip-

1.

Starter relay

tion, type and general location.

2.

Accessories fuse

In order to perform most diagnostic routines, a Breakout Box

3.

Battery fuse

and a DVOM are required. See

2.5 BREAKOUT BOX:

4.

Lights fuse

SPEEDOMETER/TACHOMETER.

5.

Ignition fuse

6.

Instruments fuse

To perform the circuit checks with any degree of efficiency, a

7.

Spare fuse

familiarity with the various wire connectors is also necessary.

Job/Time Code Values

Figure 2-5. Starter Relay and Fuses

Dealership technicians filing warranty claims should use the

job/time code values printed in bold text underneath the

appropriate repair.

Reprogramming ICM

Diagnostic charts frequently suggest ICM replacement. In the

event an ignition control module (ICM) needs to be replaced,

it must be reprogrammed using a computer based diagnostic

package called DIGITAL TECHNICIAN (Part No. HD-44750).

See your dealer. Password learn procedure must also be per-

formed. See 3.23 PASSWORD LEARN.

2-4

2006 Sportster: Instruments

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INITIAL DIAGNOSTICS

Diagnostic Notes

The reference number below correlates with the circled num-

ber on the initial diagnostic check flow charts. See page 2-7.

Diagnostic Tips

1. Connect BREAKOUT BOX (Part No. HD-42682) (black)

●

If Speedometer reads “BUS Er” while ignition key is

between speedometer connector [39A] (at the back of

turned ON (engine stop switch at RUN with the engine

the speedometer) and wire harness connector [39B]

off), check diagnostic link for an open or short to ground

using INSTRUMENT HARNESS ADAPTERS (Part No.

between data link connector [91A] terminal 3 and ICM

HD-46601). See 2.5 BREAKOUT BOX: SPEEDOME-

connector [10] terminal 12, TSM/TSSM connector [30]

TER/TACHOMETER.

terminal 3, speedometer connector [39] terminal 2 or

All Speedometer diagnostic trouble codes are listed in Table

tachometer (if equipped) connector [108] terminal 2.

2-2.

●

Check for an open diagnostic test terminal between data

link connector [91A] terminal 3 and TSM/TSSM connec-

Other Diagnostic Trouble Codes

tor [30] terminal 3. With ignition key turned ON, transmit

See 3.9 INITIAL DIAGNOSTIC CHECK: TSM/TSSM for any

data should be typically

0.6-0.8 volts. The range of

diagnostic trouble codes related to the turn signal module

acceptable operation is greater than 0.0 volts and less

(TSM) or turn signal security module (TSSM).

than 7.0 volts.

See 4.4 INITIAL DIAGNOSTIC CHECK: ICM for any diagnos-

●

To identify intermittents, wiggle instrument and/or vehicle

tic trouble codes related to the ignition control module (ICM).

harness while performing steps in the Initial Diagnostic

Check charts.

Table 2-1. Speedometer Function Chart-Loss Of Input

Terminal 5

Terminal 8 and 11

Terminal 1 (IGN)

Terminal 6 (ACC)

Terminal 7 (GRD)

(Constant)

(Reset Switch)

● Security lamp

● Will not “wow”

● Speedometer

● Speedometer com-

● No reset switch

glows dimly dur-

will be non-func-

pletely non-func-

function

● Turn signals still functional

ing 4-second

tional in acces-

tional

● Will not “wow”

bulb check

● Speedometer will indicate

sory and ignition

● Diagnostics absent

vehicle speed (zero)

modes

● Tachometer unaffected

● Security lamp

● Security lamp still func-

still performs 4-

tions

second bulb

check in ignition

● Check engine lamp and

mode

battery lamp non-func-

tional

● Diagnostics absent

Table 2-2. Speedometer Diagnostic Trouble Code (DTC) Priority Chart

DTC

RANKING

FAULT CONDITION

SOLUTION

B1006

7

Accessory line overvoltage

2.7 DTC B1006, B1007

B1007

6

Ignition line overvoltage

2.7 DTC B1006, B1007

B1008

8

Reset switch closed

2.8 DTC B1008

U1016

3

Loss of ICM serial data

2.9 DTC U1016, U1255

U1064

4

Loss of TSM/TSSM serial data

2.10 DTC U1064, U1255

Missing response from other module

U1255

5

2.10 DTC U1064, U1255

(TSM/TSSM and/or ICM) at startup

U1300

1

Serial data bus shorted low

2.11 DTC U1300, U1301 OR BUS ER

U1301

2

Serial data bus shorted high

2.11 DTC U1300, U1301 OR BUS ER

2006 Sportster: Instruments

2-5

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x0522a3x

BK

LtGN/V

O

LtGN/V

O/W

BN/GY

GY

BK

Odometer

reset switch

BN/GY

1

2

3

4 5 6 7 8 9 10 11 12

[39B]

[30B]

1

2

3

4 5 6 7 8 9 10

11

12

1

2

3

4 5 6 7 8 9 10 11 12

1

2

3

4 5 6 7 8 9 10

11

12

[39A]

[30A]

Speedometer

TSM/TSSM

[108B]

1

2

3

4 5 6 7 8 9 10

11

12

1

2

3

4 5 6 7 8 9 10

11

12

[108A]

Tachometer

[20B]

(if equipped)

1

2

3

4

5 67 8

9

10

11 12

[20A]

1

2

3

4

5 67 8

9

10

11 12

BK

15A

ACC

Data link

connector

BN/GY

15A

1

1

BATT

BK

2

2

LtGN/V

3

3

15A

INST

4

4

GY

[91A]

[91B]

15A

IGN

Fuse

block

LtGN/V

[10B]

1

2

3

4

5

6

7

8

9

10

11

12

[10A]

Ignition Control Module (ICM)

Figure 2-6. Serial Data Circuit

Table 2-3. Wire Harness Connectors in Figure 2-6.

NO.

DESCRIPTION

TYPE

LOCATION

[10]

Ignition control module

12-place Deutsch

under seat

[20]

Instruments

12-place Deutsch

under fuel tank

[30]

TSM/TSSM

12-place Deutsch

under battery

[39]

Speedometer

12-place Packard

back of speedometer

[91A]

Data link connector

4-place Deutsch

behind left side cover

[108]

Tachometer (if equipped)

12-place Packard

back of tachometer

2-6

2006 Sportster: Instruments

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Initial Diagnostic Check (Part 1 of 3)

Does engine

start?

YES.

YES.

NO.

NO.

Starts and runs.

Starts, then stalls.

Cranks, but will not start.

Engine will not crank.

Check for DTCs. See

See 4.10 STARTS

See 4.9 ENGINE CRANKS

See 1.2 STARTING

2.3 SPEEDOMETER

THEN STALLS.

BUT WILL NOT START.

SYSTEM DIAGNOSIS.

SELF DIAGNOSTICS

Were DTCs found?

NO

NO

YES

Unable to enter

No codes

diagnostic mode.

displayed.

Refer to applicable DTC priority

With ignition switch OFF, press and

For a list of symptoms that

chart. All DTCs are listed by

release odometer reset switch.

may not set diagnostic

priority in Table 2-2.

Does odometer display appear with

trouble codes, refer to

display backlighting?

Table 3-10.

YES

NO

1

Check for continuity to ground at

Breakout Box cavity 7 (black). Wiggle

STOP

harness during continuity check.

Is continuity present?

Go to Initial Diagnostic

Check (Part 2 of 3).

YES

NO

Check for battery voltage at Breakout Box

Locate and

cavity 5 (black) while wiggling harness.

repair open.

Is battery voltage continuously present?

YES

NO

With ignition switch OFF and speedometer

Locate and

connector [39] disconnected, check continuity

repair open.

between Breakout Box cavities 8 and 11 (black).

Is continuity present when speedometer reset

switch is depressed and infinity when released?

YES

NO

Replace Speedometer.

Replace speedometer

reset switch.

2006 Sportster: Instruments

2-7

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Initial Diagnostic Check (Part 2 of 3)

Continued from Initial Diagnostic Check (Part 1 of 3).

Turn ignition switch ON, is odometer backlight present?

YES

NO

Perform “wow” test.

Replace Speedometer.

See 2.3 SPEEDOMETER SELF DIAGNOSTICS.

The following features should be functional

1) backlight should illuminate

2) needle should sweep its full range of motion

3) LEDs should illuminate:

• check engine

• battery

• security (all models)

Are all features functional?

YES

NO

1

Turn key to ACC.

Turn key to IGN. Check for

Is backlight present?

battery voltage at Breakout

Box cavity 1 (black).

Is battery voltage present?

YES

NO

YES

NO

1

Check for battery voltage at

Replace Speedometer.

Is instrument

Breakout Box cavity 6 (black).

Is battery voltage present?

fuse blown?

YES

NO

YES

NO

Locate and repair

Locate and repair open

source of fault.

between terminal 1 of

Replace fuse.

connector [39] and

Replace Speedometer.

Is accessory

instrument fuse.

fuse blown?

YES

NO

STOP

Locate and repair

Locate and repair open on O/W

Go to Initial Diagnostic

source of fault.

wire between terminal 6 of con-

Check (Part 3 of 3).

Replace fuse.

nector [39] and accessory fuse.

2-8

2006 Sportster: Instruments

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Initial Diagnostic Check (Part 3 of 3)

Continued from Initial Diagnostic Check (Part 2 of 3).

Is problem intermittent?

NO.

NO.

YES

Speedometer Inoperative

Tachometer Inoperative

(no vehicle speed).

(no engine speed).

Repeat Diagnostic

Check while wiggling

Remove and inspect

harnesses.

vehicle speed sensor.

See Test 2.4 (Part 1 of 2).

Was intermittent found?

Is debris present?

YES

NO

YES

NO

Locate and repair

No trouble found.

Remove debris. Reinstall

Check for damaged wiring/

intermittent.

Vehicle speed sensor.

loose connection between

vehicle speed sensor and ICM.

Is wiring damage/loose

connection present?

YES

NO

Locate and repair

Replace Speedometer.

source of fault.

2006 Sportster: Instruments

2-9

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SPEEDOMETER SELF DIAGNOSTICS

2.3

GENERAL

11526

The speedometer is capable of displaying and clearing

2

3

speedometer, tachometer, TSM/TSSM, and ICM diagnostic

trouble codes (DTCs) (diagnostic mode).

DIAGNOSTICS

1

Diagnostic Tips

● For a quick check of speedometer function, a “wow” test

can be performed. Press and hold odometer reset switch

(Figure 2-7.) then turn ignition switch (Figure 2-8.) ON.

Release reset switch. See Figure 2-9. Background light-

ing should illuminate, gauge needle should sweep its full

range of motion, and check engine (1), battery (2) and

security (3) indicator lamps should illuminate. The secu-

1.

Ignition OFF

rity lamp may illuminate even if the vehicle is not

2.

ACC ON

equipped with a security system.

3.

Ignition ON

● If instrument module fails “wow” test, check for battery,

Figure 2-8. Ignition Switch

ground, ignition, odometer reset switch and accessory

wiring to speedometer. If any feature in the instrument

module is non-functional, see 2.2 INITIAL DIAGNOSTIC

CHECK: SPEEDOMETER.

x0523x3x

2

Diagnostic Notes

Use of speedometer self diagnostics assumes that DIGITAL

1

TECHNICIAN (Part No. HD-44750) is not available.

3

The reference numbers below correlate with the circled num-

bers in Speedometer Self Diagnostics (flow chart) which fol-

lows.

1. To exit diagnostic mode, turn ignition switch OFF.

2. To clear DTCs for the selected module, press the speed-

ometer reset switch for more than 5 seconds when a

code is displayed. This procedure will clear all DTCs for

the selected module.

10067

1. Check engine lamp

2. Battery lamp

3. Security lamp

Figure 2-9. Speedometer

Figure 2-7. Odometer Reset Switch

2-10

2006 Sportster: Instruments

HOME

Speedometer Self Diagnostics (flow chart)

1

While holding odometer reset switch in,

turn ignition switch to IGN.

Make sure Run/Stop switch is in

RUN position.

Release reset switch.

Does “diag” appear?

YES

NO

See 2.2 INITIAL DIAGNOSTIC

Press and release

CHECK: SPEEDOMETER

reset switch.

“PSSPT” appears.

To display DTCs for

the ICM, press and

”P” flashing.

hold reset switch for

more than 5 seconds.

To choose TSM/

TSSM, press and

release reset switch.

To display DTCs for

TSM/TSSM, press and

”S” flashing.

hold reset switch for

more than 5 seconds.

To

choose Speedometer,

Device

press and release reset

response?

switch.

NO

To display DTCs for

“no rsp” displayed.

speedometer, press and

YES

”SP” flashing.

See applicable code from

hold reset switch for more

other modules. Models

than 5 seconds.

not equipped with a

tachometer will display

“no rsp” normally.

2

To choose Tachometer,

If “no rsp” displayed on

“none”

DTC

press and release reset

odometer on tachometer

displayed.

displayed.

switch.

equipped vehicle,

see 2.4 SPEEDOMETER/

TACHOMETER.

Press and release

To display DTCs for

Press and release

reset switch.

tachometer, press and

reset switch. Part

”T” flashing.

Are more DTCs

hold reset switch for more

number of module will

displayed?

than 5 seconds.

be displayed.

To choose ICM, press and

YES

NO

release reset switch.

“end” displayed. To clear all

DTCs for selected module, hold

reset switch for more than 5

seconds. If DTCs are not to be

cleared, press and release reset

switch. Part number of module

will be displayed.

Press and release reset

switch again to continue to

next module.

2006 Sportster: Instruments

2-11

HOME

SPEEDOMETER/TACHOMETER

2.4

GENERAL

x0523x3x

2

See Figure 2-10. The speedometer consists of a speedome-

ter display and three status lamps. The lamps include: check

1

engine (1), battery (2) and security (3).

3

NOTE

The security status lamp may illuminate during the “wow’ test

even if the vehicle is not equipped with a security system.

Reset Switch

See Figure 2-11. Pressing the odometer reset switch pro-

vides the following capabilities:

● Change the odometer display between mileage, trip A

and trip B values (press and immediately release).

● Reset an individual trip odometer (press and hold 2-3

seconds).

● Gain access to the diagnostic mode and clear diagnostic

trouble codes (DTCs). See 2.3 SPEEDOMETER SELF

DIAGNOSTICS.

● Display odometer while ignition key is OFF. Press and

1. Check engine lamp

hold reset switch while key is OFF and odometer mileage

2. Battery lamp

will be displayed.

3. Security lamp

● On models with dual scale speedometers, toggle

between miles/kilometers on odometer and trip odome-

Figure 2-10. Speedometer

ter display. To toggle display, turn key ON. Press and

hold reset switch while odometer is displayed. Release

switch when change is noted. (If reset switch is held

while trip odometer is displayed, trip odometer will reset).

10067

Figure 2-11. Odometer Reset Switch

2-12

2006 Sportster: Instruments

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SPEEDOMETER THEORY

TACHOMETER THEORY

OF OPERATION

OF OPERATION

The speedometer consists of a vehicle speed sensor, odome-

See Figure 2-12. The tachometer receives serial data from

ter reset switch and the speedometer. The vehicle speed sen-

the ICM. The tachometer interprets the serial data and con-

sor is mounted on the rear of the engine crankcase behind

verts it into tachometer needle movement.

the starter motor assembly. The sensor circuitry is that of a

Hall-Effect sensor triggered by the gear teeth of 5th gear on

the transmission mainshaft.

d0717x8x

The output from the sensor is a series of pulses that are inter-

preted by the ICM circuitry, converted into serial data then

sent to the speedometer to control the position of the speed-

ometer needle and the liquid crystal (LCD) odometer display.

The vehicle speed serial data is also transmitted to the TSM/

TSSM for turn signal cancellation.

The odometer mileage is permanently stored and will not be

lost when electrical power is turned off or disconnected. The

odometer reset switch allows switching between the odome-

ter, trip odometer A and trip odometer B displays.

To zero the trip odometer, have the desired trip odometer dis-

play visible and press and hold the reset switch. The trip

odometer mileage will be displayed for 2-3 seconds and then

the trip mileage will return to zero miles.

The odometer can display six numbers to indicate a maxi-

Figure 2-12. Tachometer

mum of 999999 miles/kilometers. The trip odometers can dis-

play six numbers with a tenth of a mile accuracy for a

maximum of 99999.9 miles/kilometers.

DIAGNOSTICS

Diagnostic Notes

The reference numbers below correlate with circled numbers

on the tachometer diagnostic flow chart which follows.

1. If problems are intermittent, wiggle harness while per-

forming tests.

2. Connect BREAKOUT BOX (Part No. HD-42682) (black)

between tachometer connector [108A] (at the back of the

tachometer) and wire harness connector [108B] using

INSTRUMENT HARNESS ADAPTERS (Part No. HD-

46601). See 2.5 BREAKOUT BOX: SPEEDOMETER/

TACHOMETER.

3. Use HARNESS CONNECTOR TEST KIT (Part No. HD-

41404), black pin probe and patch cord.

2006 Sportster: Instruments

2-13

HOME

x0549x2x

[39A]

[39B]

IGNITION

1

O

DATABUS

2

LtGN/V

Odometer

NC

3

reset switch

SECURITY LP

4

BN/V

BATTERY

5

BN/GY

ACCESSORY

6

O/W

GROUND

7

BK

TRIP SW

8

BK

FUEL LEVEL

9

NC

10

TRIP SW

11

BK

NC

12

Speedometer

[20B]

O/W

1

BN/GY

2

[108A]

[108B]

3

4

5

IGNITION

1

O

O

6

DATALINK

2

LtGN/V

LtGN/V

7

NC

3

8

PURSUIT

4

9

RPM x 100

BATTERY

5

BN/GY

10

ACCESSORY

6

O/W

BN/V

11

GROUND

7

BK

BK

12

NC

8

NC

9

CRUISE ENGAGED

10

NC

11

CRUISE ENABLE

12

Tachometer

(if equipped)

Figure 2-13. Speedometer/Tachometer Circuitry

Table 2-4. Wire Harness Connectors in Figure 2-13.

NO.

DESCRIPTION

TYPE

LOCATION

[20]

Instruments

12-place Deutsch

under fuel tank

[39]

Speedometer

12-place Packard

back of speedometer

[108]

Tachometer (if equipped)

12-place Packard

back of tachometer

2-14

2006 Sportster: Instruments

HOME

Test 2.4 (Part 1 of 2)

TACHOMETER INOPERATIVE

1

Perform “wow” test. See 2.3 SPEEDOMETER

SELF DIAGNOSTICS.

The following features should be functional

1) backlight should illuminate

2) needle should sweep its full range of motion

3) LED’s may illuminate:

• cruise (although not cruise equipped)

• pursuit (although not a police vehicle)

Are all features functional?

YES

NO

2

Is problem intermittent?

Check for battery voltage at

Breakout Box cavity 1.

Is battery voltage present?

YES

NO

YES

NO

Repeat tachometer

No trouble found.

Diagnostic Check while

wiggling harnesses.

Is instrument

fuse blown?

YES

NO

Locate and repair

Locate and repair

source of fault.

open in orange wire

Replace fuse.

between terminal 1 of

connector [108] and

instrument fuse.

3

Check for continuity between Breakout Box

cavity 2 and terminal 7 of connector [20].

Is continuity present?

YES

NO

Locate and repair open

on Lt Gn/V wire.

STOP

Go to Test 2.4

(Part 2 of 2).

2006 Sportster: Instruments

2-15

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Test 2.4 (Part 2 of 2)

Continued from Test 2.4 (Part 1 of 2).

Check for continuity to ground on

Breakout Box cavity 7. Wiggle

harness during continuity check.

Is continuity present?

YES

NO

Check for battery voltage

Locate and repair

at Breakout Box cavity 5

open on BK wire

while wiggling harness.

between terminal 7 of

Is battery voltage

connector [108] and

continuously present?

ground.

YES

NO

Check for battery voltage at

Locate and repair open

Breakout Box cavity 6.

on BN/GY wire between

Is battery voltage present?

terminal 5 of connector

[108] and battery fuse.

YES

NO

Replace tachometer.

Locate and repair open on

O/W wire between terminal 6

of connector [108] and

accessory fuse.

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