HOMEAMP MULTILOCK ELECTRICAL CONNECTORS                                                                                   ...
d0243x8x                                                             Socket terminal                                      ...
Secondary locks open (socket housings shown)             Stamped numbers on secondary locks indicate wire color locations ...
Figure B-4. 3-Place and 6-Place Amp Multilock Connectors
CRIMPING INSTRUCTIONS                                                  4.    Strip lead removing 5/32 in. (4 mm) of insula...
3.          Close and squeeze crimp tool.              4.   Raise locking bar and remove contact.                         ...
DEUTSCH ELECTRICAL CONNECTORS                                                                                           B....
it is properly locked in place.
d0248x8x                                   Wire seal                                                 Pin housing          ...
Socket  housingFigure B-9. Depress Terminal Latches/Back Out Pins B-6    2006 Buell Lightning: Appendix B
NOTEAn ELECTRICAL TERMINAL CRIMP TOOL (Part No.                           h41475HD-39965) is used to install Deutsch pin a...
Figure B-11. Attachment Clip Installation2.   See Figure B-11. Fit the attachment clip to the pin hous-     ing, if remove...
d0250x8x                                  Locking bar                            1.   Insert contact through middle       ...
d0251x3x                            11                                   10                                             9 ...
Figure B-13. 2-Pin, 3-pin and 4-pin Deutsch Connectors
PACKARD ELECTRICAL CONNECTORS                                                                                             ...
PULL-TO-SEAT                                                        Installing External Latch TypeTERMINALS               ...
PUSH-TO-SEAT                                                      Installing                    Push-to-SeatTERMINALS     ...
CRIMPING INSTRUCTIONS                                               d0259x8x                                              ...
ELECTRICAL CONNECTORS                                                                                                     ...
Table B-2. Electrical Connector and Location TableCONNECTOR             COMPONENT(S)                   DESCRIPTION        ...
HOMEINDEX TO WIRING                                                           B.5                                      Tab...
HOMEbd0016aL                                                                                                              ...
HOME                                                                                                                      ...
HOME       2006 Lightning Models Main Harness   2006 Lightning Models Main Harness                                        ...
Sm appb1
Sm appb1
Sm appb1
Sm appb1
Sm appb1
Sm appb1
Sm appb1
Sm appb1
Sm appb1
Sm appb1
Sm appb1
Sm appb1
Sm appb1
Sm appb1
Sm appb1
Sm appb1
Sm appb1
Sm appb1
Upcoming SlideShare
Loading in …5
×

Sm appb1

408 views
345 views

Published on

Published in: Business, Technology
0 Comments
0 Likes
Statistics
Notes
  • Be the first to comment

  • Be the first to like this

No Downloads
Views
Total views
408
On SlideShare
0
From Embeds
0
Number of Embeds
3
Actions
Shares
0
Downloads
1
Comments
0
Likes
0
Embeds 0
No embeds

No notes for slide

Sm appb1

  1. 1. HOMEAMP MULTILOCK ELECTRICAL CONNECTORS B.1REMOVING SOCKET/PIN inadvertently released. Repeat the step without releasing the tang.TERMINALS NOTE1. Remove connector from the retaining device, either ● If pick tool is not available, a push pin/safety pin may be used instead. attachment or rosebud clip.2. Depress the button on the socket terminal side of the ● An ELECTRICAL TERMINAL CRIMP TOOL (Part No. connector (plug) and pull apart the pin and socket HD-41609) is used to install Amp Multi lock pin and halves. socket terminals on wires. If new terminals must be installed, see Crimping Instructions on the next page.3. Bend back the latch slightly and free one side of second- ary lock, then repeat the step to release the other side. Rotate the secondary lock outward on hinge to access INSTALLING SOCKET/PIN terminals in chambers of connector housing.4. Looking in the terminal side of the connector (opposite TERMINALS the secondary lock), take note of the cavity next to each terminal. NOTE5. See Figure B-1. With the flat edge against the terminal, For wire location purposes, numbers are stamped into the insert the pick tool (Snap-On TT600-3) into the cavity secondary locks of both the socket and pin housings. See until it stops. Pivot the end of the pick away from the ter- Figure B-2. minal (locktab is inside housing) and gently tug on wire 1. From the secondary lock side of the connector, insert to pull terminal from chamber. Do not tug on the wire the terminal into its respective numbered chamber until it until the tang is released or the terminal will be difficult to snaps in place. For proper fit, the slot in the terminal remove. A “click” is heard if the tang is engaged but then must face the tang in the chamber. d0242x3x Pin terminal Secondary lock open Pin housing L Latch Socket housing Secondary lock open Button Latch Secondary lock open Socket terminal Figure B-1. 10-Place Amp Multilock Connector 2006 Buell Lightning: Appendix B B-1
  2. 2. d0243x8x Socket terminal Secondary lock open 4 Socket housing 2 Pick tool 1 Pin terminal 3 Secondary lock open 4 Pin housing 1 Pick tool 2 1. Open secondary lock. 3 2. Insert pick into cavity on inboard side of connector. 3. Pivot end of pick to release tang. 4. Gently tug on wire to remove terminal from housing. Figure B-2. Release Tang and Back Out Terminals NOTES● See Figure B-3. The tang in the chamber engages the slot to lock the terminal in position. Pin housing Socket housing● On the pin side of the connector, tangs are positioned at Button the bottom of each chamber, so the slot in the pin termi- nal (on the side opposite the crimp tails) must face Tang down- ward.● 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 determined by the position of the release button (used to separate the pin and socket halves). Consider the button to always be on top of the connector. Tang2. Gently tug on wire end to verify that the terminal is locked in place and will not back out of chamber. d0244x8x3. Rotate the hinged secondary lock inward until tabs fully Figure B-3. Multilock Connector Cutaway View engage latches on both sides of connector.4. Insert the socket housing (plug) into the pin housing (receptacle) until it snaps in place.5. Install connector on retaining device, either attachment or rosebud clip.
  3. 3. Secondary locks open (socket housings shown) Stamped numbers on secondary locks indicate wire color locations – AMP – AMP 1 2 3 1 2 3 4 5 6 5 6 7 8 9 10 3-place 6-place 12-place Secondary lock Pin terminal Socket housing Button Pin housing Secondary lock Pin terminal Secondary lock Socket terminal Latch Button Pin housing Latch Socket housing Secondary lock Socket terminald0245x2x
  4. 4. Figure B-4. 3-Place and 6-Place Amp Multilock Connectors
  5. 5. CRIMPING INSTRUCTIONS 4. Strip lead removing 5/32 in. (4 mm) of insulation. Insert wires between crimp tails until ends make contact with locking bar. Verify that wire is positioned so that short1. Squeeze the handles to cycle the crimp tool (Part No. pair of crimp tails squeeze bare wire strands, while long HD-41609) to the fully open position. pair folds over insulation material.2. Raise locking bar by pushing up on bottom flange. With the crimp tails facing upward, insert contact (socket/pin) 5. Squeeze handle of crimp tool until tightly closed. through locking bar, so that the closed side of the Tool automatically opens when the crimping sequence is contact rests on the front nest (concave split level area complete. Raise up locking bar and remove contact. of the crimp tool). See Figure B-3. 6. Inspect the quality of the core and insulation crimps. Dis-3. Release locking bar to lock position of contact. When tortion should be minimal. correctly positioned, the locking bar fits snugly in the space at the front of the core crimp tails. 1. Insulating crimp tail 2. Core crimp tail 1 1 3. Locking bar groove 2 3 2 4. Tang slot 3 4 4 1. Raise locking bar and seat contact 2. Insert stripped lead until it on front nest of crimp tool. contacts locking bar. Release locking bar GAUGE CRIMPTOOL WIRE NEST 20 Front 16 Middle 18 Rear d0246x8x 2006 Buell Lightning: Appendix B B B-5
  6. 6. 3. Close and squeeze crimp tool. 4. Raise locking bar and remove contact. Figure B-5. Amp Multilock Crimping Procedure B-4 2006 Buell Lightning: Appendix B
  7. 7. DEUTSCH ELECTRICAL CONNECTORS B.2GENERAL 4566Deutsch Connectors feature a superior seal to protect electri-cal contacts from dirt and moisture in harsh environments.The connector also provides superior pin retention.See Figure B-8. This 12-pin connector illustrates the variousparts of the Deutsch connector. The following instructionsmay be followed for all 2-pin through 12-pin Deutsch connec-tors.Socket housing: alignment tabs and/or external latch, sec-ondary locking wedge, internal seal, wire seal, seal pin. NOTESeal pins or plugs are installed in the wire seals of unusedpin and socket locations. If removed, seal pins must bereplaced to maintain the integrity of the environmental seal.Pin housing: alignment grooves and/or external latch Figure B-6. Remove Secondary Locking Wedgecover, attachment clip, secondary locking wedge, wire seal,seal pin.REMOVING/DISASSEMBLING s0545x8xAttachment clips are attached to the pin housings of mostconnectors. The clips are then attached to T-studs on themotorcycle frame. T-studs give positive location to electricalconnectors and wire harness. Consistent location reduceselectrical problems and improves serviceability.1. Push the connector to disengage small end of slot on attachment clip from T-stud. Lift connector off T-stud.2. Depress the external latch(es) on the socket housing side and use a rocking motion to separate the pin and socket halves. Two-, three-, four- and six-pin Deutsch connectors have one external latch, while eight- and twelve-pin connectors have two, both of which must be pressed simultaneously to separate the connector halves. NOTEWith few exceptions, the socket housing can always befound on the accessory side, while the pin side of the Figure B-7. Depress Terminal Latches/Back Out Pinsconnector is connected to the wiring harness. NOTEREMOVING/INSTALLING SOCKETS An ELECTRICAL TERMINAL CRIMP TOOL (Part No. HD- 39965) is used to install Deutsch pin and socket terminals on1. See Figure B-7. Remove the secondary locking wedge. wires. If new terminals must be installed, follow the instruc- Insert the blade of a small screwdriver between the tions included with the crimping tool or see Crimping Instruc- socket housing and locking wedge inline with the groove tions in this section. (inline with the pin holes if the groove is absent). Turn the screwdriver 90 degrees to pop the wedge up. Fit rear wire seal into back of socket housing, if removed. Grasp socket approximately 1.0 in. (25.4 mm) behind the2. See Figure B-8. Gently depress terminal latches inside contact barrel. Gently push sockets through holes in wire socket housing and back out sockets through holes in seal into their respective chambers. Feed socket into rear wire seal. chamber until it “clicks” in place. Verify that socket will not back out of chamber; a slight tug on the wire will confirm that
  8. 8. it is properly locked in place.
  9. 9. d0248x8x Wire seal Pin housing Pin terminal Locking wedge Locking wedge Internal seal Latch cover Alignment grooves Socket housing Wire seal Alignment tabs Seal pin External latch Socket terminal Figure B-8. 12-pin Deutsch Connector (Exploded View)3. Install internal seal on lip of socket housing, if removed. d0249x3x Insert tapered end of secondary locking wedge into socket housing and press down until it snaps in place. The wedge fits into the center groove within the socket housing and holds the terminal latches tightly closed. Pin NOTES housing● While rectangular wedges do not require a special orien- tation, the conical secondary locking wedge of the 3-pin connector must be installed with the arrow pointing toward the external latch. See Figure B-9. Arrow points to external latch● If the secondary locking wedge does not slide into the installed position easily, verify that all terminals are fully installed in the socket housing. The lock indicates when terminals are not properly installed by not entering its fully installed position. 2. Gently depress terminal latches inside pinREMOVING/INSTALLING PINS housing and back out pins through holes in wire seal.1. Remove the secondary locking wedge. Use the hooked end of a stiff piece of mechanics wire a needle nose pli- ers, or a suitable pick tool (Part No. HD-41475-100). See Figure B-10. 2006 Buell Lightning: Appendix B B B-7
  10. 10. Socket housingFigure B-9. Depress Terminal Latches/Back Out Pins B-6 2006 Buell Lightning: Appendix B
  11. 11. NOTEAn ELECTRICAL TERMINAL CRIMP TOOL (Part No. h41475HD-39965) is used to install Deutsch pin and socket terminals onwires. If new terminals must be installed, see CrimpingInstructions in this section.3. Fit wire seal into back of pin housing. Grasp crimped pin approximately 1.0 in. (25.4 mm) behind the contact bar- Figure B-10. Deutsch Connector Pick Tool rel. Gently push pins through holes in wire seal into their (Part No. HD-41475-100) respective numbered locations. Feed pin into chamber until it “clicks” in place. Verify that pin will not back out of chamber; a slight tug on the wire will confirm that it is properly locked in place.4. Insert tapered end of secondary locking wedge into pin housing and press down until it snaps in place. The 5893 Lock tab wedge fits in the center groove within the pin housing and holds the terminal latches tightly closed. NOTES● While rectangular wedges do not require a special orien- tation, the conical secondary locking wedge of the 3-pin Lock bar connector must be installed with the arrow pointing toward the external latch. See Figure B-9.● If the secondary locking wedge does not slide into the installed position easily, verify that all terminals are fully installed in the pin housing. The lock indicates when ter- minals are not properly installed by not entering its fully installed position. 5892 Pin housingASSEMBLING/INSTALLING1. Insert socket housing into pin housing until it snaps in place. Two-, three-, four- and six-pin Deutsch connectors have one external latch on the socket half of the connec- tor. To fit the halves of the connector together, the latch on the socket side must be aligned with the latch cover on the pin side. Attachment clip For those connectors with two external latches (8-pin and 12-pin), a different system is used to prevent improper assembly. Align the tabs on the socket 5891 housing 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. NOTEDeutsch connectors are color coded for location purposes.Those connectors associated with left side accessories,such as the front and rear left turn signals, are gray. All Attachment clip installedother con- nectors, including those associated with right sideaccesso- ries, are black. of the external latch is the same.If it should become necessary to replace a plug orreceptacle, please note that the 8-pin and 12-pin gray andblack connec- tors are not interchangeable. Since location ofthe alignment tabs differ between the black and grayconnectors, plugs or receptacles must be replaced by thoseof the same color. If replacing both the socket and pinhalves, then the black may be substituted for the gray, andvice versa. The socket and pin halves of all other connectorsare interchangeable, that is, the black may be mated with thegray, since the alignment tabs are absent and the orientation
  12. 12. Figure B-11. Attachment Clip Installation2. See Figure B-11. Fit the attachment clip to the pin hous- ing, if removed. Place large end of slot on attachment clip over T-stud on frame. Push assembly forward to engage small end of slot.
  13. 13. d0250x8x Locking bar 1. Insert contact through middle 2. Insert stripped lead until it hole in locking bar. contacts locking bar. 3. Close and squeeze crimp tool 4. Raise locking bar and remove contact. Insulation crimp Core crimp Figure B-12. Deutsch Crimping ProcedureCRIMPING INSTRUCTIONS 4. Strip lead removing 5/32 in. (4 mm) of insulation. Insert wires between crimp tails until ends make contact with locking bar. Verify that wire is positioned so that short1. See Figure B-12. Squeeze the handles to cycle the pair of crimp tails squeeze bare wire strands, while long crimp tool to the fully open position. pair folds over insulation material.2. Raise locking bar by pushing up on bottom flange. With 5. Squeeze handle of crimp tool until tightly closed. the crimp tails facing upward and the rounded side of the Tool automatically opens when the crimping sequence is contact barrel resting on the concave split level area of complete. Raise up locking bar and remove contact. the crimp tool, insert contact (socket/pin) through middle 6. Inspect the quality of the core and insulation crimps. Dis- hole of locking bar. tortion should be minimal.3. Release locking bar to lock position of contact. If the crimp tails are slightly out of vertical alignment, the crimp 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 band and the core crimp tails. 2006 Buell Lightning: Appendix B B B-9
  14. 14. d0251x3x 11 10 9 8 7 6 2-pin connector 5 4 2 1 11 3 10 9 8 7 6 5 3-pin connector 4 2 1 11 3 10 9 8 7 6 5 4-pin connector 4 t 2 SOCKET SIDE PIN SIDE1. Socket terminal 7. Locking wedge2. Wire seal 8. Latch cover 13. Socket housing 9. Pin housing4. External latch 3 10. Wire seal5. Internal seal 11. Pin terminal6. Locking wedge
  15. 15. Figure B-13. 2-Pin, 3-pin and 4-pin Deutsch Connectors
  16. 16. PACKARD ELECTRICAL CONNECTORS B.3GENERAL Unlike most connectors, where the terminals are pulled out the wire end of the connector, to remove the terminals fromFrom a servicing standpoint, there are two basic types of the pull-to-seat connectors, the terminal is pushed out thePackard electrical connectors, those with pull-to-seat termi- mating end of the connector. Once a new terminal is crimpednals and those with push-to-seat terminals. onto the end of the wire, the wire is pulled to draw the termi- nal back inside the chamber of the connector housing.Look into the mating end of the connector. If it appears thatthe terminal can be extracted from this side, then it is proba- Two types of Packard pull-to-seat electrical connectors arebly the pull-to-seat type. used. One type has an external latch to lock the pin and socket halves together, while the other makes use of a wire-At least one Packard pull-to-seat terminal can be easily rec- form. See Figure B-14. The manner in which the terminalsognized by the presence of a locking ear. The ear engages are picked differs between these two types of connectors, asa slot in the connector housing and prevents the terminal further described below.from being removed from the wire end side of theconnector. The ear also acts as a strain relief in the eventthat the wires are pulled and further inhibits movement ofthe terminal inside the chamber. For an example of thistype of connector, note the MAP sensor connector [80]. d0258x8x A C Locate tang on latch side of chamber. Push on wire end of lead to remove terminal. B D Pivot end of pin to depress tang. Raise tang and re-install terminal. Figure B-14. Packard ConnectorsB-10 2 2006 Buell Lightning: Appendix B
  17. 17. PULL-TO-SEAT Installing External Latch TypeTERMINALS NOTE For wire location purposes, alpha characters are stamped into the socket housings.Removing External Latch 1. To install a terminal back into the chamber of theType connec- tor housing, use a thin flat blade, like that on anTo remove a pull-to-seat terminal from connectors with exter- X-Acto knife, and carefully bend the tang outward awaynal latches, proceed as follows: from the terminal body. See D in Figure B-14.1. Remove the connector from the retaining device, if 2. Gently pull on the lead at the wire end of the connector present. to draw the terminal back into the chamber. A click is heard when the terminal is properly seated.2. Bend back the external latch(es) slightly and separate the pin and socket halves of the connector. 3. Push on the lead to verify that the terminal is locked in place.3. To free a pull-to-seat terminal from the connector hous- ing, first look into the mating end of the connector to find 4. Push the pin and socket halves of the connector together the locking tang. See A in Figure B-14. The tangs are until the latches “click.” always positioned in the middle of the chamber and are on the same side as the external latch. On those connec- tors with locking ears, the tang is on the side opposite the ear.4. At a slight angle, gently insert the point of a one inch safety pin down the middle of the chamber (about 1/8 inch) and pivot the end of the pin toward the terminal body. When a click is heard, remove the pin and repeat the procedure. See B in Figure B-14. The click is the sound of the tang returning to the locked 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.5. Remove the pin and push on the wire end of the lead to extract the terminal from the mating end of the connec- tor. See C in Figure B-14. If necessary, pull back the con- duit and remove the wire seal at the back of the connector to introduce some slack in the wires. NOTEA series of Packard Electrical Terminal Crimp Tools areavail- able to install Packard pin and socket terminals onwires. If new terminals must be installed, see CrimpingInstructions.
  18. 18. PUSH-TO-SEAT Installing Push-to-SeatTERMINALS Terminals NOTEThe Packard push-to-seat terminal connectors found on Soft- For wire location purposes, alpha characters are stampedail model vehicles are listed below. onto the secondary locks or onto the wire end of the connec-● Ignition Switch [33] tor housing.● Fuse Terminals 1. To install a terminal back into the chamber of the● MAP Sensor [80] connec- tor housing, use a thin flat blade, like that on an X-Acto knife, and carefully bend the tang outward awayRemoving Push-to-Seat from the terminal body.Terminals 2. Push the lead into the chamber at the wire end of the connector. A click is heard when the terminal is properlyLike most connectors, Packard push-to-seat terminals are seated.pulled out the wire end of the connector. To remove a 3. Gently tug on the wire end to verify that the terminal ispush- to-seat terminal, proceed as follows: locked in place and will not back out of the chamber.1. Remove the connector from the retaining device, if 4. Close or install the secondary lock. Rotate the hinged present. secondary lock inward until tabs fully engage latches on2. Bend back the external latch(es) slightly and separate both sides of connector. the pin and socket halves of the connector. 5. Push the pin and socket halves of the connector together NOTE until the latches “click.”Both the Ignition Light/Key Switch and the Main Power con- 6. Install connector on retaining device, if present.nectors are provided with secondary locks. The secondarylock, which may be molded onto the connector or exist as aseparate piece, aids in terminal retention. Secondary locksmust be opened (or removed) before the terminals can beextracted from the connector housing.3. Open or remove the secondary lock. Bend back the latch slightly and free one side of the secondary lock, then repeat the step to release the other side. Rotate the sec- ondary lock outward on hinge to access the terminals in the chambers of the connector housing.4. Looking in the mating end or terminal side of the connec- tor (opposite the secondary lock), take note of the larger cavity next to each terminal.5. Insert the pick (Snap-On TT600-3) into the cavity until it stops. Pivot the end of the pick toward the terminal to depress the locking tang. Remove the pick and gently tug on the wire to pull the terminal from the wire end of the connector. Repeat the step if the terminal is still locked in place. NOTEA series of Packard Electrical Terminal Crimp Tools areavail- able to install Packard pin and socket terminals onwires. If new terminals must be installed, see CrimpingInstructions.B-12 2006 Buell Lightning: Appendix B
  19. 19. CRIMPING INSTRUCTIONS d0259x8x Tool tip1. Strip wire lead removing 5/32 in. (4 mm) of insulation.2. Compress handles until ratchet automatically opens. NOTEAlways perform core crimp before insulation/seal crimp.3. See Table B-1. Determine the correct dye or nest for the core crimp. NOTEWhen the word “TIP” appears in the Crimp Table, use thetip of the tool specified to perform the core crimp procedure.See Figure B-15.4. Lay the back of the core crimp tails on the appropriate Packard 115 Packard 271 nest. Be sure the core crimp tails are pointing towards the forming jaws.5. Gently apply pressure to handles of tool until crimpers Figure B-15. Packard Terminal Crimp Tools slightly secure the core crimp tails.6. Insert stripped wire between crimp tails. Verify that wire is positioned so that short pair of crimp tails squeeze Table B-1. Packard Terminal Crimp bare wire strands, while long pair folds over insulation or seal material. Tools7. Squeeze handle of crimp tool until tightly closed. SPECIFICATION PACKARD 115 PACKARD 271 Tool automatically opens when the crimping sequence is Part No. HD-38125-8 HD-38125-7 complete. Non-sealed Non-sealed8. Table B-1. Determine the correct dye or nest for the Type of Crimp terminals, terminals insu- lation/seal crimp. butt splices Dye/nests F-G A-E9. Lay the back of the insulation/seal crimp tails on the appropriate nest. Be sure the insulation/seal crimp tails are pointing towards the forming jaws. d0260x8x10. Squeeze handle of crimp tool until tightly closed. Tool automatically opens when the crimping sequence is 1 2 complete. 311. See Figure B-16. Inspect the quality of the core (3) and insulation/seal (2) crimps. Distortion should be minimal. 1. Insulation 2. Insulation crimp 3. Core crimp Figure B-16. Inspect Core and Insulation/Seal Crimps
  20. 20. ELECTRICAL CONNECTORS B.4GENERAL Connector numbers are listed in [brackets] in this manual.The following table provides a brief description of the connec-tors found on the Buell Lightning. Table B-2. Electrical Connector and Location Table CONNECTOR COMPONENT(S) DESCRIPTION LOCATION [10] ECM (black) 12-place Deutsch under seat [11] ECM (gray) 12-place Deutsch under seat [14] cam position sensor 3-place Deutsch under sprocket cover [18] right rear turn signal 2 1-place bullet under seat [19] left rear turn signal 2 1-place bullet under seat [22] right hand controls 4-place Multilock behind windscreen [24] left hand controls 4-place Multilock behind windscreen [30] flasher 5-place Amp behind windscreen [31] right front turn signal 2 1-place bullet behind windscreen [31] left front turn signal 2 1-place bullet behind windscreen [33] ignition switch 4-place Augat behind windscreen [38] headlamp connector 4-place Amp behind windscreen [39] instrument module 20-place Multilock in front modules behind windscreen [45] license plate lamp 2 1-place bullet under seat [46] stator 4-place Deutsch under sprocket cover [65] vehicle speed sensor 3-place Deutsch under sprocket cover [77] voltage regulator 2-place Packard under sprocket cover beneath air cleaner assembly base- [83] ignition coil 3-place Packard plate base beneath air cleaner assembly base- [84] front fuel injector 2-place Packard plate base beneath air cleaner assembly base- [85] rear fuel injector 2-place Packard plate base [86] fuel pump 4-place Multilock left side of rear shock absorber [88] throttle position sensor 3-place Packard right side of engine between cylinders [89] intake air temperature sensor 2-place Amp in air cleaner assembly baseplate base beneath air cleaner assembly base- [90] engine temperature sensor 1-place bullet plate base [91A] data link 4-place Deutsch under seat, right side of vehicle 2-place spade [93] tail light 1-place spade back of tail light, under seat (ground)B-14 2006 Buell Lightning: Appendix B
  21. 21. Table B-2. Electrical Connector and Location TableCONNECTOR COMPONENT(S) DESCRIPTION LOCATION [95] clutch switch 2-place Multilock underside of clutch lever assembly [97] cooling fan 2-place Multilock behind rear cylinder, under seat [120] oil pressure switch post terminal crankcase above oil filter underside of front master cylinder [121] front brake switch 2-place Multilock assembly [121] rear brake switch 2-place Multilock under seat [122] horn spade terminals behind windscreen [128] starter solenoid spade terminals top of starter [131] neutral switch 1-place bullet under sprocket cover [134] bank angle sensor 6-place Sumitomo under seat [137] oxygen sensor 1-place Packard behind rear cylinder head [164] Interactive exhaust circuit to ECM under seat under air cleaner assembly baseplate [161] Interactive exhaust to solenoid cover under air cleaner assembly baseplate [178] Active intake system to solenoid cove [179] Active intake system to ECM under seat
  22. 22. HOMEINDEX TO WIRING B.5 Table B-3. Wiring Diagrams DIAGRAM PAGE Main harness B-17 Engine management circuit B-19 Lighting circuit B-21 Horn and instruments circuit B-23 Starting circuit B-25 Charging circuits B-27 Component circuits B-29B-16 2006 Buell Lightning: Appendix B
  23. 23. HOMEbd0016aL [88B] [88A] [83B] [83A] THROTTLE 1 1 BK/W Y/BE 1 1 IGNITION SWITCH WIRING DIAGRAM 1 O 1 BN POSITION 2 2 V/Y GY 2 2 IGN. KEY POSITION 4 2 R/Y SENSOR 3 3 R/W 1 3 2 [121B] [31B] 2 BK BE/O 3 3 COIL ENGINE TEMP SENSOR PARK 0 0 PK/Y 1 1 LOCK [90B] [90A] OFF [137B] [137A] ON 0 0 0 0 OXYGEN SENSOR V/GY 1 1 GY WIRE COLOR R R/BK R R/GY WIRE SECT mm 1 1 1 1 Y/BN 1 1 Y BK/O 2 2 BK + + BATTERY USER + BATTERY USER + LOCK SW FRONT INJECTOR REAR INJECTOR RH CONTROLS [97B] [97A] 1 2 1 2 STARTER 1 2 3 4 [84B] SOLENOID GN/GY GY GY W/Y 1 2 3 4 BK/R W/BK W/BK GY/O [85B] 1 2 3 4 BK [128A] [22A] [33B] IAT BK R/BK R/GY R R FLASHER 1 2 3 4 5 LT.GN/Y 1 BK BK/W 2 [89B] 1 GN [GRD2] V/BN O/W R/Y [30B] ECM GROUND [128B] 5V SENSOR POWER 1 R/W (GY) THROTTLE POS SENSOR 2 V/Y CAMSHAFT POS SENSOR 3 GN/W [11B] OXYGEN SENSOR 4 V/GY ACTIVE MUFFLER KEEP ALIVE 5 Y O 1 CONTROL SUB- FAN CONTROL 6 BK/O W TN/ 2 HARNESS SENSOR GROUND 7 BK/W V 3 [165A] VEHICLE SPEED SENSOR 8 W ENGINE TEMP INPUT 9 PK/Y LIC. PLATE LAMP O/W 1 AIR TEMP INPUT 10 LT.GN/Y [45B] SERIAL DATA RECEIVE 11 LT.GN/R BK 1 SERIAL DATA TRANSMIT 12 V/R Y/BE FUSE/RELAY ASSEMBLY [61B] FOOT BRAKE SW ACTIVE MUFFLER CONTROL 1 W DYNO BATTERY 30 AMP. R/Y 1 1 R/Y [164B] LOOP R/Y 41 35 R O 2 2 O SWITCHED IGNITION 1 GY TN/Y DIODE (BK) SYSTEM GROUND A 2 BK BK TN/Y 40 34 [121A] [121B] [GRD3] TN/LT.GN FUEL PUMP OUTPUT 3 BN/Y BK BRAKE/HORN/MUFFLER 10 AMP. [10B] CHECK ENGINE LAMP 4 BK/Y O 29 23 R/BK BK 1 TAIL LIGHT INJECTOR FRONT OUTPUT 5 W/Y O COOLING FAN 10 AMP. [93B] O/W 1 FRONT COIL PRIMARY 6 Y/BE [GRD1] R 30 24 Y/BN REAR COIL PRIMARY 7 BE/O IGNITION 15AMP. R/Y 1 INJECTOR REAR OUTPUT 8 GN/GY GY/O 27 21 R/BK BN 1 RH TURN SIGNAL ACTIVE MUFFLER FEEDBACK 9 TN/V ACCESSORY 10AMP. BK 2 [18B] BANK ANGLE SENSOR 10 LT.GN/GY R/GY 28 22 O/W SYSTEM GROUND B 11 BK SPARE 15 AMP. LH TURN SIGNAL TACHOMETER OUTPUT 12 PK BK 31 25 BK V 1 [19B] SPARE 10 AMP. BK 2 1 1 BK BK 32 26 BK R 42 36 Y FUEL PUMP MTR [122A] [122B] LIGHTS 15 AMP. Y/R A A Y/R R/BK 43 37 BE BK B B BK KEY SWITCH 15AMP. BN/Y C C BN/Y LOW R 44 38 R GY D D GY SENSOR [86A] [86B] NEUTRAL SW TN/Y 1 1 [131B] [131A] VSS 2006 Buell Lightning: Electrical B-17
  24. 24. HOME R/W A A R INDEX TO WIRING B.5 W B BK/W C B W C BK BK/Y GN/Y R TN/ BN W O/W Y/R [39B] [65B] [65A] YV BK PK 1 W 2 IGNITION GROUND TACH IN LFW VSS IN ASSEMBLY LT.GN/GY 5 R/W A A R/W [24A] O/W 1 V/BN Y/BK W/BK BK/W 6 GN/W B B GN/W BN BE 86 1 1 2 3 4 5 6 7 8 W 2 W O W/BK Y V BK/W C C BK/W IGNITION BANK ANGLE SENSOR Y 3 HIGH BEAM LEFT TURN RIGHT TURN BATTERY NEUTRAL CHECK ENGINE OIL PRESSURE 85 9 BK LH CONTROLS 30 5 BK 4 [14B] [14A] GY/O [134B] TN/LT.GN 87A 3 GY/O [38B] BK SPEEDOMETER 86 10 BK/R BK 1 LT.GN/R 1 START [39A] 85 2 TN/LT.GN R 2 BK 2 [91A] [77B] 30 6 R/BK V 1 LH TURN SIGNAL [95B] V/R 3 1 1 GN/Y 87 7 BK 2 1 2 GY 4 OIL PRESSURE SW GN [31B] CLUTCH SW [120B] R/BK GN/Y 86 11 R/BK KEY SW 85 19 BK 30 15 R [120A] 87A 13 A= MALE 87 14 R/BK B= FEMALE 2006 Lightning Models Main Harness77 B-16 2006 Buell Lightning: Appendix B
  25. 25. HOME 2006 Lightning Models Main Harness 2006 Lightning Models Main Harness 2006 Buell Lightning: Electrical B-19

×