Harley Davidson 2006 Sportster XLH MODELS. Service Manual

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x0522a3x

LtGN/V

O/W

BN/GY

Odometer

reset switch

BN/GY

4 5 6 7 8 9 10 11 12

[39B]

[30B]

4 5 6 7 8 9 10 11 12

[39A]

[30A]

Speedometer

TSM/TSSM

[108B]

4 5 6 7 8 9 10 11

[108A]

Tachometer

[20B]

(if equipped)

5 67 8 9

11 12

[20A]

5 67 8 9

11 12

15A

ACC

Data link

connector

BN/GY

15A

BATT

LtGN/V

15A

INST

15A

[91A]

[91B]

IGN

Fuse

block

LtGN/V

[10B]

[10A]

Ignition Control Module (ICM)

Figure 3-10. Serial Data Circuit

Table 3-11. Wire Harness Connectors in Figure 3-10.

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

2006 Sportster: TSM & TSSM

3-23

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Initial Diagnostic Check (Part 1 of 3)

Does engine

start?

YES.

NO.

Starts and runs.

Starts, then stalls.

Cranks, but will not start.

Engine will not crank.

Check for diagnostic trouble codes

See 4.10 STARTS

See 4.9 ENGINE CRANKS

See 1.2 STARTING

(DTCs). See 3.10 SPEEDOME-

THEN STALLS.

BUT WILL NOT START.

SYSTEM DIAGNOSIS.

TER SELF DIAGNOSTICS

DTCs found?

YES

Unable to enter

No DTCs

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 3-9.

Does odometer display appear with

trouble codes, refer to

display backlighting?

Table 3-10.

YES

Check for continuity to ground at breakout box

cavity 7 (black). Wiggle harness during continuity

check. Continuity present?

STOP

Go to Initial Diagnostic

Check (Part 2 of 3).

YES

Check for battery voltage at

breakout box cavity 5

Locate and repair open

(black) of speedometer while

between cavity 7

wiggling harness. Battery volt-

and ground.

age continuously present?

YES

With ignition switch OFF and speedometer

Locate and repair open

connector [39] disconnected, check continuity

between cavity 5 and

between Breakout Box cavities 8 and 11

battery fuse.

Is continuity present when speedometer reset

switch is depressed and infinity when released?

YES

Replace Speedometer.

Replace speedometer

reset switch.

3-24

2006 Sportster: TSM & TSSM

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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

Perform “wow” test.

Replace Speedometer.

See 3.10 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

With ignition switch turned to

Turn key to ACC.

IGN, check for battery voltage

Is backlight present?

at cavity 1 of Breakout Box.

Battery voltage present?

YES

Check for battery voltage at

Breakout Box cavity 6.

Replace Speedometer.

Is instrument

fuse blown?

Is battery voltage present?

YES

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

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.

2006 Sportster: TSM & TSSM

3-25

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Initial Diagnostic Check (Part 3 of 3)

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

Is problem intermittent?

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?

under 2.4 SPEEDOMETER/

TACHOMETER

YES

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

Locate and repair

Replace Speedometer.

source of fault.

3-26

2006 Sportster: TSM & TSSM

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SPEEDOMETER SELF DIAGNOSTICS

3.10

GENERAL

10067

The speedometer is capable of displaying and clearing

speedometer, TSM/TSSM, and ICM diagnostic trouble codes

(DTCs) (diagnostic mode).

DIAGNOSTICS

Diagnostic Tips

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

can be performed. See Figure 3-11. Figure 3-12. and

Figure 3-13. Press and hold odometer reset switch then

turn ignition switch to IGNITION. Release reset switch.

Background lighting should illuminate, gauge needles

should sweep their full range of motion, and indicator

lamps (battery, security and check engine) should illumi-

nate.

Figure 3-12. Odometer Reset Switch

● If speedometer fails “wow” test, check for battery, ground,

ignition, odometer reset switch and accessory wiring to

speedometer. If any feature in the speedometer is non-

functional, see

2.2 INITIAL DIAGNOSTIC CHECK:

11526

SPEEDOMETER.

Diagnostic Notes

Use of speedometer self diagnostics assumes that DIGITAL

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

The reference numbers below correlate with the circled num-

bers in Speedometer Self Diagnostics (chart).

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

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

ter reset switch for more than five seconds when DTC is

displayed. This procedure will clear all DTCs for the

selected module.

x0523x3x

Ignition OFF

ACC ON

Ignition ON

Figure 3-13. Ignition Switch

Figure 3-11. Speedometer

2006 Sportster: TSM & TSSM

3-27

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Speedometer Self Diagnostics (chart)

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

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.

choose Speedometer,

Device

press and release reset

response?

switch.

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.

To choose Tachometer,

If “no rsp” displayed on

“none”

DTC

press and release reset

odometer on tachometer

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

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.

3-28

2006 Sportster: TSM & TSSM

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BREAKOUT BOX: TSM/TSSM

3.11

GENERAL

s0474x9x

The BREAKOUT BOX (Part No. HD-42682) splices into the

main harness. Used in conjunction with a digital volt/ohmme-

ter (DVOM), it allows circuit diagnosis of wiring harness and

connections without having to probe with sharp objects.

INSTALLATION

1. Gain access to TSM/TSSM. See the Sportster Service

Manual.

Terminal 1

2. See Figure 3-14. Depress latches on connector [30B].

Terminal 12

3. See Figure 3-15. Attach Breakout Box to connector.

Figure 3-14. TSM/TSSM Connector Terminals

a. Mate gray socket housing on Breakout Box with

TSM/TSSM connector [30A].

b. Mate gray pin housing on Breakout Box with wire

11532

harness connector [30B].

4. Reinstall battery and reconnect battery cables.

REMOVAL

1. See Figure 3-14. Depress latches on connector [30B].

2. Detach gray Breakout Box connector from TSM/TSSM

connector [30A].

3. Detach gray Breakout Box connector from wire harness

connector [30B].

4. Disconnect battery cables and remove battery.

5. Reinstall TSM/TSSM. See the Sportster Service Manual.

6. Install parts removed for access.

NOTE

Vehicle will not start with TSM/TSSM disconnected or incor-

rectly mounted.

TSM/TSSM

TSM/TSSM connector [30A]

Wire harness connector [30B]

Breakout Box (Part no. HD-42682)

Figure 3-15. Breakout Box: TSM/TSSM

Table 3-12. TSM/TSSM Connector [30B]

TERMINAL

FUNCTION

TERMINAL

FUNCTION

Battery

Right turn switch input

Ignition

Left turn switch input

serial data

Start relay control

Security lamp

Ignition enable signal (not used)

Left turn feed

Alarm signal

Right turn feed

Ground

2006 Sportster: TSM & TSSM

3-29

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NO SECURITY LAMP AT KEY ON

3.12

GENERAL

x0523x3x

No TSSM Power (Security Equipped

Vehicles Only)

See Figure 3-16. When the Ignition/Light Key Switch is turned

to IGNITION, the security lamp should illuminate for 4 sec-

onds. Following the initial period of illumination, the lamp

should go off for 4 seconds. It may then come back on for an

8 second period, indicating a historic diagnostic trouble code

(DTC) or remain on, indicating a current DTC.

Power and ground are supplied to the Security lamp from the

speedometer circuitry. The TSSM activates an LED driver cir-

cuit in the speedometer to illuminate the security lamp. A lack

of power to the TSSM will cause the security lamp to be inop-

erative and will also create a no start situation.

Job/Time Code Values

Dealership technicians filing warranty claims should use the

Figure 3-16. Security Lamp

job/time code values printed in bold text underneath the

appropriate repair.

10071

DIAGNOSTICS

Diagnostic Tips

● Check for open in BN/V wire.

● Check for blown battery fuse. See Figure 3-17.

Diagnostic Notes

The reference numbers below correlate with the circled num-

bers on the Test 3.12 flow charts.

Connect BREAKOUT BOX (Part No. HD-42682) (gray)

as follows:

Starter relay

a. Mate gray socket housing on Breakout Box with

Accessories fuse

TSM/TSSM connector [30A].

Battery fuse

b. Mate gray pin housing on Breakout Box with wire

Lights fuse

harness connector [30B].

Ignition fuse

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

Instruments fuse

Spare fuse

as follows:

a. Mate black socket housing on Breakout Box with

Figure 3-17. Relay/Fuse Panel

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

speedometer) using INSTRUMENT HARNESS

ADAPTERS (Part No.HD-46601).

b. Mate black pin housing on Breakout Box with wire

harness connector [39B] using INSTRUMENT HAR-

NESS ADAPTERS (Part No.HD-46601).

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

41404), purple pin probe and patch cord between break-

out Breakout Box and ground. Align blade with slot in

cavity of Breakout Box.

4. Security lamp failure requires speedometer replacement.

See the Sportster Service Manual.

3-30

2006 Sportster: TSM & TSSM

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x0539x3x

Ground

Battery

BN/GY

Security LED

BN/V

Ignition

Security lamp

(inside speedometer)

[39A]

[39B]

[20B]

4 5 6

9 10

4 5 6

9 10

[20A]

15 Amp

30 Amp

Battery

Main Fuse

Fuse

Battery

BN/GY

+12V

15 Amp

Ignition Fuse

+12V

15 Amp

BN/V

Instrument Fuse

[30B]

4 5 67

10 11 12

[30A]

4 5 67

10 11 12

TSM/TSSM

Figure 3-18. Security Lamp Circuit

Table 3-13. Wire Harness Connectors in Figure 3-18.

NO.

DESCRIPTION

TYPE

LOCATION

[20]

Instruments

12-Place Deutsch

under fuel tank

[30]

TSM/TSSM

12-place Deutsch

under battery

[39]

Speedometer

12-place Packard

back of speedometer

2006 Sportster: TSM & TSSM

3-31

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Test 3.12 (Part 1 of 3)

NO SECURITY LAMP AT KEY ON

Security equipped vehicles only.

Turn Ignition/Light Key Switch to IGNITION.

Set engine stop switch to RUN. Press starter

button. Turn ignition switch to OFF.

Did engine crank when starter button was pressed?

YES

Check for continuity between

Breakout Box cavity 4 (black) and

STOP

cavity 4 (gray).

Is continuity present?

Go to Test 3.12

(Part 2 of 3).

YES

Check for continuity to

Repair open on BN/V wire

ground on Breakout

between connectors [30B]

Box cavity 4 (black).

and [39B].

Is continuity present?

6735

YES

Locate and repair short to

Reconnect connector [39]. Place

ground on BN/V wire.

jumper between Breakout Box cavity 4

(gray) and battery positive terminal.

6736

Does security lamp illuminate?

YES

Replace TSM/TSSM. Learn

Replace

password and perform setup.

speedometer.

6737

6738

Clear DTCs using speedometer self diagnostics. See

3.10 SPEEDOMETER SELF DIAGNOSTICS. Confirm

proper operation with no security lamp.

3-32

2006 Sportster: TSM & TSSM

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Test 3.12 (Part 2 of 3)

NO SECURITY LAMP AT KEY ON

Continued from Test 3.12 (Part 1 of 3).

Is connector [30] fully mated?

YES

Place red meter lead at Breakout

Mate

Box cavity 1 (gray) and black meter

connector.

lead at Breakout Box

6739

cavity 12 (gray).

Is battery voltage present?

YES

Move red meter lead to

Breakout Box cavity 2 (gray).

Is battery voltage present?

STOP

Go to Test 3.12

YES

(Part 3 of 3).

Replace TSSM.

Remove left side cover.

Learn password and

Check for voltage at ignition

perform setup.

fuse. See Figure 3-17.

Is battery voltage present

6740

on both terminals?

YES

Locate and repair open on

gray wire between ignition

STOP

fuse and TSSM.

6741

Go to 4.11 NO

SPARK/NO ICM

POWER.

Clear DTCs using speedometer self diagnostics. See

3.10 SPEEDOMETER SELF DIAGNOSTICS. Confirm

proper operation with no security lamp.

2006 Sportster: TSM & TSSM

3-33

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Test 3.12 (Part 3 of 3)

NO SECURITY LAMP AT KEY ON

Continued from

Test 3.12 (Part 2 of 3).

Check resistance to ground at

Breakout Box cavity12 (gray).

Is resistance less than 1 ohm?

YES

Check for 12 volts at both terminals of

15 amp battery fuse. See Figure 3-17.

Locate and

Is proper voltage present at

repair poor

both terminals?

ground.

6742

YES

Locate and repair open in

BN/GY wire between battery

One Terminal.

Neither terminal.

fuse and TSM/TSSM.

6743

Replace

Locate and repair

battery fuse.

open between main

fuse and fuse block.

6744

6745

Clear DTCs using speedometer self diagnostics. See

3.10 SPEEDOMETER SELF DIAGNOSTICS. Confirm

proper operation with no security lamp.

3-34

2006 Sportster: TSM & TSSM

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SECURITY LAMP ON CONTINUOUSLY

3.13

GENERAL

x0523x3x

See Figure 3-19. When the Ignition/Light Key Switch is turned

to IGNITION, the security lamp should illuminate for 4 sec-

onds. Following the initial period of illumination, the lamp

should go off for 4 seconds. It may then come back on for an

8 second period, indicating a historic diagnostic trouble code

(DTC) or remain on, indicating a current DTC.

Job/Time Code Values

Dealership technicians filing warranty claims should use the

job/time code values printed in bold text underneath the

appropriate repair.

DIAGNOSTICS

Diagnostic Notes

Figure 3-19. Security Lamp

The reference number below correlates with the circled num-

ber on the Test 3.13 flow chart.

1. Connector [39B] is on the back of the speedometer. Use

HARNESS CONNECTOR TEST KIT (Part No. HD-

41404), black pin probe and patch cord.

2006 Sportster: TSM & TSSM

3-35

HOME

x0539x3x

Ground

Battery

BN/GY

Security LED

Ignition

Security lamp

(inside speedometer)

[39A]

[39B]

[20B]

4 5 6 7 8 9 10 11 12

[20A]

15 Amp

30 Amp

Battery

Main Fuse

Fuse

Battery

BN/GY

+12V

15 Amp

Ignition Fuse

+12V

BN/V

15 Amp

Instrument Fuse

[30B]

4 5 6 7 8 9 10 11 12

[30A]

4 5 6 7 8 9 10 11 12

TSM/TSSM

Figure 3-20. Security Lamp Circuit

Table 3-14. Wire Harness Connectors in Figure 3-20.

NO.

DESCRIPTION

TYPE

LOCATION

[20]

Instruments

12-Place Deutsch

under fuel tank

[30]

TSM/TSSM

12-place Deutsch

under battery

[39]

Speedometer

12-place Packard

back of speedometer

3-36

2006 Sportster: TSM & TSSM

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Test 3.13

SECURITY LAMP ON CONTINUOUSLY

Turn Ignition/Light Key Switch to IGNITION.

Does security lamp turn ON for 4 seconds

and then turn OFF for 4 seconds?

YES

Security lamp function OK. Check for

Turn Ignition/Light Key Switch to OFF.

diagnostic trouble codes. See Section

Disconnect TSM/TSSM connector [30].

3.8 CHECKING FOR DIAGNOSTIC

Turn switch to IGNITION.

TROUBLE CODES.

Does security lamp illuminate?

YES

Disconnect connector [39].

Replace TSM/TSSM.

Check for voltage on terminal 4

Learn password and

(BN/V wire) of connector [30].

perform setup.

Is voltage present?

6750

YES

Repair short to battery

Replace

on BN/V wire between

speedometer.

connectors [30A] and [39B].

6752

6751

Clear DTCs using speedometer self diagnostics. See

3.10 SPEEDOMETER SELF DIAGNOSTICS. Confirm

proper operation with no security lamp.

2006 Sportster: TSM & TSSM

3-37

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KEY FOB SIGNAL TO TSSM WEAK OR FAILS

3.14

GENERAL

o0235xox

Security Equipped Vehicles Only

This section applies only to those vehicles equipped with the

optional security system.

NOTE

Disarming function may require practice. The key fob button

must be pressed twice within 1.5 seconds to send the disarm

command. The action is very similar to double-clicking a com-

puter mouse. Light quick taps work best; very hard or very

slow taps are less likely to work.

See Figure 3-21. The key fob sends a RF signal to activate all

remote TSSM functions. The left front turn signal switch wire

Figure 3-21. Key Fob Battery

serves as the vehicle’s antenna. If the TSSM does not

respond (no confirmation at arming/disarming system) or

Diagnostic Notes

responds weakly (limited range, won’t consistently arm/dis-

The reference number below correlates with the circled num-

arm or synchronize), follow the Test 3.14 flow chart.

ber on the Test 3.14 flow chart.

Job/Time Code Values

1. After a battery disconnect, the TSSM will not enter the

configuration mode on the first attempt. All attempts to

Dealership technicians filing warranty claims should use the

assign a fob or enter the configuration mode will require

job/time code values printed in bold text underneath the

at least two attempts.

appropriate repair.

DIAGNOSTICS

Diagnostic Tips

● Verify key fob battery voltage is at least 2.9 volts. See

3.24 TSSM MAINTENANCE.

● Interference from physical surroundings may affect RF

transmission. Place fob next to left handgrip and disarm

with two clicks or move motorcycle to a new location and

retest.

● Check for damage to antenna wire. Does left turn signal

work?

NOTE

See

3.7 ARMING/DISARMING SECURITY SYSTEM

(TSSM). Use only the proper key fob for your market and

TSSM package.

2006 Sportster: TSM & TSSM

3-39

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x0534a3x

W/V

Left turn signal

[24B]

[24A]

switch

Key Fob

Antenna

30 Amp

main fuse

–

15 Amp

security

fuse

Battery

BN/GY

W/V

[30B]

4 5 6 7 8 9 10 11 12

[30A]

TSSM

Figure 3-22. Antenna Circuit

Table 3-15. Wire Harness Connectors in Figure 3-22.

NO.

DESCRIPTION

TYPE

LOCATION

[24]

Left handlebar switch

6-place Deutsch

under fuel tank

[30]

TSSM

12-place Deutsch

under battery

3-40

2006 Sportster: TSM & TSSM

HOME

Test 3.14

KEY FOB SIGNAL TO TSSM WEAK OR FAILS

Correct key fob for vehicle?

YES

Does left turn

Obtain correct fob or replace

signal function?

fob. Verify fob is synchronized

to vehicle’s TSSM.

YES

Replace fob battery and

See 3.15 TURN SIGNAL

retest. See 3.24 TSSM

ERRORS: DTC B1121,

MAINTENANCE.

Does fob work?

YES

System

Attempt to assign new fob

OK.

to TSSM and retest.

Does fob work?

6755

YES

System

Replace TSSM.

OK.

Perform password

learn and setup.

6756

6757

2006 Sportster: TSM & TSSM

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TURN SIGNAL ERRORS: DTC B1121, B1122, B1141

3.15

GENERAL

7844

The turn signals will automatically cancel either based on the

speed/acceleration of the vehicle or based upon turn comple-

tion. See 3.4 TSM/TSSM TURN SIGNAL FUNCTIONS.

For turn signal diagnostics, refer to Table 3-16.

Job/Time Code Values

Dealership technicians filing warranty claims should use the

job/time code values printed in bold text underneath the

appropriate repair.

DIAGNOSTICS

Diagnostic Tips

Figure 3-23. TSM/TSSM

● Diagnostic trouble code (DTC) B1121 and B1122 will illu-

minate the security lamp.

● DTC B1141 will not illuminate the security lamp.

● When the TSM/TSSM is in four-way flasher mode, a fault

on either the left or right turn lamp output will not cause

either DTC B1121 and DTC B1122 to be set. If fault

occurs on both left and right outputs, then both DTC

B1121 and DTC B1122 will be set.

● When the TSM/TSSM detects an over current (or short to

ground) condition, it will turn off the turn lamp outputs.

The outputs will be automatically reactivated once the

fault is removed.

Table 3-16. Turn Signal Errors

SYMPTOM

START WITH FLOW CHART

DTC(S)

Turn signals will not cancel upon turn completion

Turn Signal Error 1A (Part 1 of 2)

N/A

Turn signals cancel erratically

Turn Signal Error 1A (Part 2 of 2)

N/A

Turn signals will not flash, 4-way flashers inoperable

Turn Signal Error 2A

B1121, B1122, B1141

Left or right turn signals flash at double the normal rate

Turn Signal Error 3A

N/A

while all bulbs are working

3-42

2006 Sportster: TSM & TSSM

Harley Davidson 2006 Sportster XLH MODELS. Service Manual - page 32