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2006 Buell Lightning: Appendix B B-1

Latch

AMP MULTILOCK ELECTRICAL CONNECTORS B.1

REMOVING SOCKET/PIN TERMINALS

inadvertently released. Repeat the step without releasing the tang.

1. Remove connector from the retaining device, either attachment or rosebud clip.

2. Depress the button on the socket terminal side of the connector (plug) and pull apart the pin and socket halves.

3. Bend back the latch slightly and free one side of secondary lock, then repeat the step to release the other side. Rotate the secondary lock outward on hinge to access terminals in chambers of connector housing.

4. Looking in the terminal side of the connector (opposite the secondary lock), take note of the cavity next to each terminal.

5. See Figure B-1. With the flat edge against the terminal, insert the pick tool (Snap-On TT600-3) into the cavity until it stops. Pivot the end of the pick away from the terminal (locktab is inside housing) and gently tug on wire to pull terminal from chamber. Do not tug on the wire until the tang is released or the terminal will be difficult to remove. A “click” is heard if the tang is engaged but then

NOTE● If pick tool is not available, a push pin/safety pin may

be used instead.

● An ELECTRICAL TERMINAL CRIMP TOOL (Part No.HD-41609) is used to install Amp Multi lock pin and socket terminals on wires. If new terminals must be installed, see Crimping Instructions on the next page.

INSTALLING SOCKET/PIN TERMINALS

NOTEFor wire location purposes, numbers are stamped into the secondary locks of both the socket and pin housings. See Figure B-2.

1. From the secondary lock side of the connector, insert the terminal into its respective numbered chamber until it snaps in place. For proper fit, the slot in the terminal must face the tang in the chamber.

d0242x3x

Pin terminalSecondary lock open

Pin housing

Latch Socket housing

Secondary lock open

Button

Latch

Secondary lock open

Socket terminal

Figure B-1. 10-Place Amp Multilock Connector

d0243x8x

Socket terminal

Secondary lock open4

Socket housing

2 Pick tool

1

Pin terminal 3

Secondary lock open4

Pin housing

1

2 Pick tool

1. Open secondary lock. 32. 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.

NOTES

Figure B-2. Release Tang and Back Out Terminals

● See Figure B-3. The tang in the chamber engages the slot to lock the terminal in position.

● On the pin side of the connector, tangs are positioned at the bottom of each chamber, so the slot in the pin terminal (on the side opposite the crimp tails) must face 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.

2. Gently tug on wire end to verify that the terminal is locked in place and will not back out of chamber. d0244x8x

Pin housing

Tang

Tang

Socket housing

Button

3. Rotate the hinged secondary lock inward until tabs fully 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.

Figure B-3. Multilock Connector Cutaway View

Secondary locks open (socket housings shown)

Stamped numbers on secondary locks indicate wire color locations

– AMP

1 2 3– AMP

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 terminal

d0245x2x

Figure B-4. 3-Place and 6-Place Amp Multilock Connectors


CRIMPING INSTRUCTIONS

1. Squeeze the handles to cycle the crimp tool (Part No.HD-41609) to the fully open position.

2. Raise locking bar by pushing up on bottom flange. With the crimp tails facing upward, insert contact (socket/pin) through locking bar, so that the closed side of the contact rests on the front nest (concave split level area of the crimp tool). See Figure B-3.

3. Release locking bar to lock position of contact. When correctly positioned, the locking bar fits snugly in the space at the front of the core crimp tails.

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 short pair of crimp tails squeeze bare wire strands, while long pair folds over insulation material.

5. Squeeze handle of crimp tool until tightly closed. Tool automatically opens when the crimping sequence is complete. Raise up locking bar and remove contact.

6. Inspect the quality of the core and insulation crimps. Dis- tortion should be minimal.

1. Insulating crimp tail 12. Core crimp tail

23. Locking bar groove4. Tang slot 3

3 2 1

4

4

1. Raise locking bar and seat contact on front nest of crimp tool. Release locking bar

2. Insert stripped lead until it contacts locking bar.

GAUGE WIRE

CRIMPTOOL NEST

20 Front

16 Middle

18 Rear

d0246x8x3. Close and squeeze crimp tool. 4. Raise locking bar and remove contact.

Figure B-5. Amp Multilock Crimping Procedure

DEUTSCH ELECTRICAL CONNECTORS B.2

GENERAL

Deutsch Connectors feature a superior seal to protect electrical 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 various parts of the Deutsch connector. The following instructions may be followed for all 2-pin through 12-pin Deutsch connectors.

Socket housing: alignment tabs and/or external latch, secondary locking wedge, internal seal, wire seal, seal pin.

NOTE

Seal pins or plugs are installed in the wire seals of unused pin and socket locations. If removed, seal pins must be replaced to maintain the integrity of the environmental seal.

Pin housing: alignment grooves and/or external latch cover, attachment clip, secondary locking wedge, wire seal, seal pin.

4566

Figure B-6. Remove Secondary Locking Wedge

REMOVING/DISASSEMBLING

Attachment clips are attached to the pin housings of most connectors. The clips are then attached to T-studs on the motorcycle frame. T-studs give positive location to electrical connectors and wire harness. Consistent location reduces electrical 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.

NOTE

With few exceptions, the socket housing can always be found on the accessory side, while the pin side of the connector is connected to the wiring harness.

REMOVING/INSTALLING SOCKETS

1. See Figure B-7. Remove the secondary locking wedge.Insert the blade of a small screwdriver between the socket housing and locking wedge inline with the groove (inline with the pin holes if the groove is absent). Turn the screwdriver 90 degrees to pop the wedge up.

2. See Figure B-8. Gently depress terminal latches inside socket housing and back out sockets through holes in rear wire seal.

s0545x8x

Figure B-7. Depress Terminal Latches/Back Out Pins

NOTEAn ELECTRICAL TERMINAL CRIMP TOOL (Part No. HD-39965) is used to install Deutsch pin and socket terminals on wires. If new terminals must be installed, follow the instructions included with the crimping tool or see Crimping Instruc- tions in this section.

Fit rear wire seal into back of socket housing, if removed. Grasp socket approximately 1.0 in. (25.4 mm) behind the contact barrel. Gently push sockets through holes in wire seal into their respective chambers. Feed socket into chamber until it “clicks” in place. Verify that socket will not back out of chamber; a slight tug on the wire will confirm that

it is properly locked in place.

B-6 2006 Buell Lightning: Appendix B

d0248x8x

Wire seal

Pin terminal

Pin housing

Locking wedge

Locking wedge

Latch cover

Alignment grooves

Internal seal

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.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.

d0249x3x

Pin

NOTES● 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.

● 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.

housing

Arrow points to external latch

REMOVING/INSTALLING PINS

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.

2. Gently depress terminal latches inside pin housing and back out pins through holes in wire seal.

Socket housing

Figure B-9. Depress Terminal Latches/Back Out Pins

NOTEAn ELECTRICAL TERMINAL CRIMP TOOL (Part No. HD-39965) is used to install Deutsch pin and socket terminals on wires. If new terminals must be installed, see Crimping Instructions 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 barrel. Gently push pins through holes in wire seal into their 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

h41475

Figure B-10. Deutsch Connector Pick Tool(Part No. HD-41475-100)

housing and press down until it snaps in place. The 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 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 terminals are not properly installed by not entering its fully installed position.

ASSEMBLING/INSTALLING

1. 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 connector. 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.

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 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 other connectors, including those associated with right side accessories, are black.

5893

5892

5891

Lock tab

Lock bar

Pin housing

Attachment clip

Attachment clip installed

If it should become necessary to replace a plug or receptacle, please note that the 8-pin and 12-pin gray and black connectors are not interchangeable. Since location of the alignment tabs differ between the black and gray connectors, plugs or receptacles must be replaced by those of the same color. If replacing both the socket and pin halves, then the black may be substituted for the gray, and vice versa. The socket and pin halves of all other connectors are interchangeable, that is, the black may be mated with the gray, since the alignment tabs are absent and the orientation

of the external latch is the same.

Figure B-11. Attachment Clip Installation

2. See Figure B-11. Fit the attachment clip to the pin housing, if removed. Place large end of slot on attachment clip over T-stud on frame. Push assembly forward to engage small end of slot.


d0250x8x

Locking bar

1. Insert contact through middle hole in locking bar.

2. Insert stripped lead until it 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 Procedure


1. See Figure B-12. Squeeze the handles to cycle the crimp tool to the fully open position.

2. Raise locking bar by pushing up on bottom flange. With the crimp tails facing upward and the rounded side of the contact barrel resting on the concave split level area of the crimp tool, insert contact (socket/pin) through middle hole of locking bar.

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.

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 short pair of crimp tails squeeze bare wire strands, while long pair folds over insulation material.

5. Squeeze handle of crimp tool until tightly closed. Tool automatically opens when the crimping sequence is complete. Raise up locking bar and remove contact.

6. Inspect the quality of the core and insulation crimps. Dis- tortion should be minimal.

d0251x3x11

10

98

7

6 2-pin connector

5

4

2

111 3

10

98

7

65 3-pin connector

4

2

111 3

10

9

8

7

6

5 4-pin connector

4

2SOCKET SIDE PIN SIDE

1. Socket terminal2. Wire seal3. Socket housing4. External latch5. Internal seal6. Locking wedge

7. Locking wedge8. Latch cover 19. Pin housing10. Wire seal

3

11. Pin terminal

Figure B-13. 2-Pin, 3-pin and 4-pin Deutsch Connectors


PACKARD ELECTRICAL CONNECTORS B.3

GENERAL Unlike most connectors, where the terminals are pulled out the wire end of the connector, to remove the terminals from

From a servicing standpoint, there are two basic types of Packard electrical connectors, those with pull-to-seat terminals and those with push-to-seat terminals.

Look into the mating end of the connector. If it appears that the terminal can be extracted from this side, then it is proba- bly the pull-to-seat type.

At least one Packard pull-to-seat terminal can be easily rec- ognized by the presence of a locking ear. The ear engages a slot in the connector housing and prevents the terminal from being removed from the wire end side of the connector. The ear also acts as a strain relief in the event that the wires are pulled and further inhibits movement of the terminal inside the chamber. For an example of this type of connector, note the MAP sensor connector [80].

the pull-to-seat connectors, the terminal is pushed out the mating end of the connector. Once a new terminal is crimped onto the end of the wire, the wire is pulled to draw the terminal back inside the chamber of the connector housing.

Two types of Packard pull-to-seat electrical connectors are used. One type has an external latch to lock the pin and socket halves together, while the other makes use of a wire- form. See Figure B-14. The manner in which the terminals are picked differs between these two types of connectors, as further described below.

d0258x8x

A

Locate tang on latch side of chamber.

C

Push on wire end of lead to remove terminal.

B

Pivot end of pin to depress tang.

D

Raise tang and re-install terminal.

Figure B-14. Packard Connectors

PULL-TO-SEAT TERMINALS

Removing External Latch Type

To remove a pull-to-seat terminal from connectors with external latches, proceed as follows:

1. Remove the connector from the retaining device, if present.

2. Bend back the external latch(es) slightly and separate the pin and socket halves of the connector.

3. To free a pull-to-seat terminal from the connector housing, first look into the mating end of the connector to find the locking tang. See A in Figure B-14. The tangs are always positioned in the middle of the chamber and are on the same side as the external latch. On those connectors 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 procedure 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 connector. 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 are available to install Packard pin and socket terminals on wires. If new terminals must be installed, see Crimping Instructions.

Installing External Latch Type

NOTEFor wire location purposes, alpha characters are stamped into the socket housings.

1. To install a terminal back into the chamber of the connector housing, use a thin flat blade, like that on an X-Acto knife, and carefully bend the tang outward away from the terminal body. See D in Figure B-14.

2. Gently pull on the lead at the wire end of the connector to draw the terminal back into the chamber. A click is heard when the terminal is properly seated.

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

4. Push the pin and socket halves of the connector together until the latches “click.”


PUSH-TO-SEAT TERMINALS

The Packard push-to-seat terminal connectors found on Soft- ail model vehicles are listed below.

● Ignition Switch [33]

● Fuse Terminals

● MAP Sensor [80]

Removing Push-to-Seat Terminals

Like most connectors, Packard push-to-seat terminals are pulled out the wire end of the connector. To remove a push- to-seat terminal, proceed as follows:

1. Remove the connector from the retaining device, if present.

2. Bend back the external latch(es) slightly and separate the pin and socket halves of the connector.

NOTEBoth the Ignition Light/Key Switch and the Main Power connectors are provided with secondary locks. The secondary lock, which may be molded onto the connector or exist as a separate piece, aids in terminal retention. Secondary locks must be opened (or removed) before the terminals can be extracted 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 secondary 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 connector (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.

Installing Push-to-Seat Terminals

NOTEFor wire location purposes, alpha characters are stamped onto the secondary locks or onto the wire end of the connector housing.

1. To install a terminal back into the chamber of the connector housing, use a thin flat blade, like that on an X-Acto knife, and carefully bend the tang outward away from the terminal body.

2. Push the lead into the chamber at the wire end of the connector. A click is heard when the terminal is properly seated.

3. Gently tug on the wire end to verify that the terminal is locked in place and will not back out of the chamber.

4. Close or install the secondary lock. Rotate the hinged secondary lock inward until tabs fully engage latches on both sides of connector.

5. Push the pin and socket halves of the connector together until the latches “click.”

6. Install connector on retaining device, if present.

NOTEA series of Packard Electrical Terminal Crimp Tools are available to install Packard pin and socket terminals on wires. If new terminals must be installed, see Crimping Instructions.


1. Strip wire lead removing 5/32 in. (4 mm) of insulation.

2. Compress handles until ratchet automatically opens.

NOTE

Always perform core crimp before insulation/seal crimp.

3. See Table B-1. Determine the correct dye or nest for the core crimp.

d0259x8xTool tip

NOTE

When the word “TIP” appears in the Crimp Table, use the tip 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 nest. Be sure the core crimp tails are pointing towards the forming jaws.

5. Gently apply pressure to handles of tool until crimpers 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 bare wire strands, while long pair folds over insulation or seal material.

7. Squeeze handle of crimp tool until tightly closed. Tool automatically opens when the crimping sequence is complete.

8. Table B-1. Determine the correct dye or nest for the insulation/seal crimp.

9. 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.

Packard 115 Packard 271

Figure B-15. Packard Terminal Crimp Tools

Table B-1. Packard Terminal Crimp Tools

SPECIFICATION PACKARD 115 PACKARD 271

Part No. HD-38125-8 HD-38125-7

Type of CrimpNon-sealed terminals,

butt splices

Non-sealed terminals

Dye/nests F-G A-E

d0260x8x

10. Squeeze handle of crimp tool until tightly closed. Toolautomatically opens when the crimping sequence is 1 2complete.

311. See Figure B-16. Inspect the quality of the core (3) and

insulation/seal (2) crimps. Distortion should be minimal.

1. Insulation2. Insulation crimp3. Core crimp

Figure B-16. Inspect Core and Insulation/Seal Crimps


ELECTRICAL CONNECTORS B.4

GENERAL

The following table provides a brief description of the connectors found on the Buell Lightning.

Connector numbers are listed in [brackets] in this manual.

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

[83] ignition coil 3-place Packardbeneath air cleaner assembly baseplate base

[84] front fuel injector 2-place Packardbeneath air cleaner assembly baseplate base

[85] rear fuel injector 2-place Packardbeneath air cleaner assembly baseplate 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

[90] engine temperature sensor 1-place bulletbeneath air cleaner assembly baseplate base

[91A] data link 4-place Deutsch under seat, right side of vehicle

[93] tail light

2-place spade

1-place spade(ground)

back of tail light, under seat

Table B-2. Electrical Connector and Location Table

CONNECTOR 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

[121] front brake switch 2-place Multilockunderside of front master cylinder 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

[161] Interactive exhaust to solenoidunder air cleaner assembly baseplate cover

[178] Active intake system to solenoidunder air cleaner assembly baseplate cove

[179] Active intake system to ECM under seat

HOME

INDEX TO WIRING DIAGRAMS

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-29

7

1 2

1 2 3 4

1 2 3 4 5 B

ATT

ER

Y

NE

UT

RA

L LE

FT

TU

RN

R

IGH

T T

UR

N

HIG

H B

EA

MC

HE

CK

EN

GIN

E

OIL

PR

ES

SU

RE

R TN/Y

V BN

W

BK

/Y

GN

/Y

IGN

ITIO

N

GR

OU

ND

TA

CH

IN

LFW

VS

S IN

O/W

BK

PK

Y

/R

WV

/BN

O

/W BK

KE

Y S

WS

TAR

TIG

NIT

ION

BK

/R

W/B

K

W/B

K

GY

/O

LOC

KR

R/G

Y

R/B

K R

GY

W/Y

TN

/LT.

GN

BK

Y BE

W Y/B

K

V/B

N

V BN

O

GY

GN

/GY

R/Y

2006 Buell Lightning: Electrical B-17

HOME

bd0016aL

[88B] [88A] [83B] [83A]

THROTTLE 1 1 BK/WY/BE 1 1IGNITION SWITCH WIRING DIAGRAM 1 O 1 BN POSITION 2 2 V/Y

GY 2 2 IGN.KEY POSITION 1 3 4 2 [121B]

2 R/Y[31B] 2 BK SENSOR 3 3 R/W

BE/O 3 3 COIL ENGINE TEMP SENSORPARK 0 0 PK/Y 1 1

LOCK

OFF

ON 0 0 0 0

[90B] [90A]

[137B] [137A]

OXYGEN SENSOR

WIRE COLOR

WIRE SECT mm

R R/BK R

1 1 1

R/GY

1 Y/BN

V/GY 1 1 GY

1 1 YBK/O 2 2 BK

+ +

BATTERY USER + BATTERY USER +

FLASHER

RH CONTROLS

1 2 3 4

[22A]

SW

1 2 3 4

[33B]

FRONT INJECTOR

[84B]

REAR INJECTOR

1 2

[85B]

LT.GN/Y

IAT

1

[97B]

BK

[97A]

BK

STARTER SOLENOID

[128A]

BK/W 2 [89B] [GRD2]1 GN

ECM[30B]

5V SENSOR POWER 1 R/W

GROUND[128B]

(GY)

[11B]

THROTTLE POS SENSOR CAMSHAFT POS SENSOR

OXYGEN SENSOR KEEP ALIVE

FAN CONTROLSENSOR GROUND

VEHICLE SPEED SENSOR ENGINE TEMP INPUT

2 V/Y3 GN/W4 V/GY5 Y6 BK/O7 BK/W8 W9 PK/Y

O W

TN/V

O/W 1

ACTIVE MUFFLER1 CONTROL SUB-2 HARNESS3 [165A]

LIC. PLATE LAMPAIR TEMP INPUT

SERIAL DATA RECEIVE SERIAL DATA TRANSMIT

10 LT.GN/Y11 LT.GN/R12 V/R

BK 1[45B]

Y/BE FUSE/RELAY ASSEMBLY [61B] FOOT BRAKE SWACTIVE MUFFLER CONTROL 1 W DYNO

BATTERY 30 AMP. R/Y 1 1 R/Y[164B]

SWITCHED IGNITION 1 GY

LOOPR/Y

TN/Y41 35 R

DIODEO 2 2 O

(BK) SYSTEM GROUND A 2 BK BK [GRD3] TN/Y 40 34 TN/LT.GN

[121A] [121B]

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 LIGHTINJECTOR FRONT OUTPUT 5 W/Y O COOLING FAN 10 AMP.

O/W 1 [93B]FRONT COIL PRIMARY

REAR COIL PRIMARY6 Y/BE7 BE/O

[GRD1] R 30IGNITION

24 Y/BN15AMP. R/Y 1

INJECTOR REAR OUTPUT 8 GN/GY GY/O 27 21 R/BK BN 1 RH TURN SIGNALACTIVE MUFFLER FEEDBACK 9 TN/V ACCESSORY 10AMP.

BK 2 [18B]BANK ANGLE SENSOR

SYSTEM GROUND B10 LT.GN/GY11 BK

R/GY 28SPARE

22 O/W15 AMP. LH TURN SIGNAL

TACHOMETER OUTPUT 12 PK BK 31

SPARE

25 BK

10 AMP.

V 1 [19B]

1 1 BK BK 32 26 BK BK 2

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 BKKEY SWITCH 15AMP. BN/Y C C BN/Y LOW

R 44 38 R

[86A]

GY D D GY

[86B]

NEUTRAL SW

SENSOR

[131B]

TN/Y 1

VSS

1

[131A]

R/W A A R W B B W

BK/W C C BK

[39B] 12

[65B] [65A]

ASSEMBLY

86 1W/BK W/BK

LT.GN/GY 5BK/W 6 1 2 3 4 5 6 7 8

[24A] O/W 1W 2

R/W A GN/W B BK/W C

A R/WB GN/W C BK/W

85 9 BK BANK ANGLE SENSOR Y 3LH CONTROLS

30 5 GY/O [134B]BK 4 [14B] [14A]

87A 3 GY/O [38B]

SPEEDOMETER 86 10 BK/RLT.GN/R 1

BK 1

[39A] 85 2 TN/LT.GNBK 2 [91A] R 2

[77B]30 6 R/BK V 1 LH TURN SIGNAL [95B] V/R 3 1 1 GN/Y

87 7 GN R/BK

BK 2[31B]

1 2

CLUTCH SWGY 4 OIL PRESSURE SW

[120B]

86 11 R/BKGN/Y

85 19 BK30 15 R

87A 13[120A] A= MALE

87 14 R/BK B= FEMALE


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INDEX TO WIRING DIAGRAMS

B.5 2006 Lightning Models Main Harness

HOME


2006 Lightning Models Main Harness 2006 Lightning Models Main Harness

1 2

1 2 3 4

1234

BAT

TER

Y

NE

UTR

AL

LEF

T TU

RN

R

IGH

T TU

RN

H

IGH

BE

AM

CH

EC

K E

NG

INE

O

IL P

RE

SS

UR

E

R TN/Y BK

/Y

IGN

ITIO

N

GR

OU

ND

TA

CH

IN

LFW

VS

S IN

BK W

KE

Y S

WIG

NIT

ION

W/B

K

W/B

K

GY

/O

LOC

KR

R/B

K R

GY

W/Y

TN/L

T.G

N

BK

GY

GN

/GY

R/Y

CO

NT

RO

L E

LEC

TR

ON

ICS HA

LL S

EN

SO

R

CO

NTR

OL

SIG

NA

L

3

B-18 2006 Buell Lightning: Electrical

HOME

bs0017aL

[88B] [88A] [83B] [83A]

THROTTLE 1 1 BK/WY/BE 1 1

POSITION 2 2 V/YGY 2 2 IGN. ENGINE TEMP SENSOR

IGNITION SWITCH WIRING DIAGRAM

SENSOR 3 3 R/WBE/O 3 3 COIL

[90B]

PK/Y 1

[90A]

1

KEY POSITION 1 3 4 2

PARK 0 0

LOCK

[137B] [137A]

OXYGEN SENSOR

OFF

ON 0 0 0 0 Y/BN

V/GY 1 1 GY

1 1 Y

WIRE COLOR R

WIRE SECT mm 1R/BK

1

R R/GY

1 1 RH CONTROLS SW [33A]

FRONT INJECTOR REAR INJECTOR

BK/O 2 2 BK

+ + CONNECTING

1 2 [97B] [97A]

BATTERY USER + BATTERY USER +[22A] 1 2 3 4

[33B]

[84B] [85B]

LT.GN/Y

IAT BK

1BK/W 2 [89B]

[GRD2]

ECM

5V SENSOR POWER 1 R/W(GY) THROTTLE POS SENSOR

CAMSHAFT POS SENSOR2 V/Y3 GN/W ACTIVE MUFFLER SUB HARNESS

[11B]KEEP ALIVE

FAN CONTROL SENSOR GROUND

VEHICLE SPEED SENSOR ENGINE TEMP INPUT

5 Y6 BK/O7 BK/W8 W9 PK/Y

O 1W 2

TN/V 3

[165A]

1 O2 W3 TN/V

[165B]

AIR TEMP INPUTSERIAL DATA RECEIVE

SERIAL DATA TRANSMIT

10 LT.GN/Y11 LT.GN/R12 V/R

DYNOY/BE FUSE/RELAY ASSEMBLY [61B]

30 AMP

MUFFLER VALVE ACTUATOR

Vbat[164B]

(BK)

ACTIVE MUFFLER CONTROL

SWITCHED IGNITION SYSTEM GROUND A

1 W

1 GY2 BK

LOOP

BK [GRD3]

R/Y TN/Y TN/Y

BATTERY

41 35DIODE

40 34

R

TN/LT.GN

MOTOR

DC

1 O2 BK3 W

FUEL PUMP OUTPUT 3 BN/Y BK BRAKE/HORN/MUFFLER 10 AMP 4 TN/V

[10B] CHECK ENGINE LAMP INJECTOR FRONT OUTPUT

4 BK/Y5 W/Y

29 23O COOLING FAN

R/BK10 AMP

GROUND

FRONT COIL PRIMARYREAR COIL PRIMARY

6 Y/BE7 BE/O

[GRD1] R 30IGNITION

24 Y/BN15 AMP [161A] [161B]

INJECTOR REAR OUTPUTACTIVE MUFFLER FEEDBACK

8 GN/GY9 TN/V

GY/O 27 21 R/BK

BANK ANGLE SENSOR SYSTEM GROUND B

TACHOMETER OUTPUT

10 LT.GN/GY11 BK12

POSITION SENSOR

1200 models only willcontain the circuitry forthe active muffler system.

R 42ECM 10 AMP

36 Y FUEL PUMP MTRA

BK BAB BK

KEY SWITCH 10 AMP BN/Y C C BN/Y LOWR 44 38 R GY D

[86A]

D GY

[86B]

NEUTRAL SW

FUEL SENSOR

TN/Y 1

[131B]

VSS

1

[131A]

R/W A A RW B

BK/W CB W C BK

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

[39B] 1

[62B] 2

[65B] [65A]

FUSE/RELAY LT.GN/GY 5 R/W A A R/WASSEMBLY

86 1W/BK W/BK

BK/W 6 12 GN/W B

BK/W CB GN/W C BK/W

85 930 5

BK GY/O

BANK ANGLE SENSOR BK 4 [14B] [14A]

87A 3 GY/O [38B]

SPEEDOMETER

[39A]

87 4 GY

[95B]LT.GN/R

BK V/R

123 [91A]

86 1185 1930 15

R/BK R/BK BKR

CLUTCH SW 1 2 GY 4

87A 1387 14 R/BK


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2006 Lightning Models Engine Management Circuit


2006 Lightning Models Engine Management Circuit 2006 Lightning Models Engine Management Circuit

1 2 3 4 5

RB

ATTE

RY

NE

UTR

AL

LEFT

TU

RN

R

IGH

T TU

RN

H

IGH

BE

AM

CH

EC

K E

NG

INE

O

IL P

RE

SS

UR

E

V BN

W

IGN

ITIO

N

GR

OU

ND

TA

CH

IN

LFW

VS

S IN

O/W

BK

V/BN

O

/W BK

KE

Y S

WST

ART

LOC

KR

R/G

Y R

Y BE

W V/BN

V BN

O

R/Y


bs0018aL

IGNITION SWITCH WIRING DIAGRAM BRAKE SW [121B] RH TURN SIGNAL

KEY POSITION 1 3 4 2

PARK 0 0

LOCK

OFF

1 O2 R/Y

[31B]

1 BN

2 BK

ON 0 0 0 0

WIRE COLOR

WIRE SECT mmR R/BK R

1 1 1

+ +

R/GY

1 IGN SW

IGN

CONNECTINGBATTERY USER + BATTERY USER +

[33A]

1 2 3 4

FLASHER

[30B]

1 2 3 4

[33B]

BK

[GRD2]

O/W 1LIC. PLATE LAMP

BATTERY 30 AMP [61B]

BK 1

R/Y 1 1

[45B]

R/YR/Y 41 35 R O 2 2 O

BK BRAKE/HORN/MUFFLER 10 AMP[121A] [121B]

O 29 23 R/BK BK 1 TAIL LIGHT

[GRD1] O/W 1[93B]

ACCESSORY 10AMP

R/Y 1BN 1 RH TURN SIGNAL

R/GY 28 22 O/WBK 2 [18B]

LH TURN SIGNALV 1

BK 2 [19B]

LIGHTS 15 AMPR/BK 43

RR 44

37 BE

38 R

KEY SWITCH 15 AMP

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

[39B]

HEADLAMP

O/W 1ASSEMBLY

[62B]1 2 3 4 5 6 7 8

LH CONTROLS

W 2Y 3

BK 4

[38B]

SPEEDOMETER[39A]

86 10

30 687A 8

LH TURN SIGNALV 1

87 7

86 1185 1930 1587A 1387 14

R/BK

R/BK

BK 2 [31B]


2006 Lightning Lighting Circuit


2006 Lightning Lighting Circuit 2006 Lightning Lighting Circuit

1 2 3 4B

ATTE

RY

N

EU

TRA

L LE

FT T

UR

N

RIG

HT

TUR

N

HIG

H B

EA

MC

HE

CK

EN

GIN

E

OIL

PR

ES

SU

RE

R TN/Y G

N/Y

IGN

ITIO

N

GR

OU

ND

TA

CH

IN

LFW

VS

S IN

O/W

BK

PK

Y/

R

W

KE

Y S

WS

TAR

T

LOC

KR

R/G

Y R

Y/B

K

O

R/Y


bs0019aL

IGN IGNITION SWITCH WIRING DIAGRAMSW

IGN

[33A]

KEY POSITION

PARK

LOCK

OFF

1 3 4 2

0 0

1 2 3 4ON 0 0 0 0

[33B]WIRE COLOR

WIRE SECT mm

CONNECTING

R R/BK

1 1

+

R R/GY

1 1

+

BK

[GRD2]

BATTERY USER + BATTERY USER +

ECM

(GY)

[11B]

5V SENSOR POWER THROTTLE POS SENSOR CAMSHAFT POS SENSOR

OXYGEN SENSORKEEP ALIVE

FAN CONTROL

1 R/W23456

SENSOR GROUND VEHICLE SPEED SENSOR

ENGINE TEMP INPUTAIR TEMP INPUT

SERIAL DATA RECEIVE SERIAL DATA TRANSMIT

7 BK/W8 W9

101112 FUSE/RELAY ASSEMBLY

(BK)

[10B]

SWITCHED IGNITION SYSTEM GROUND A

FUEL PUMP OUTPUT CHECK ENGINE LAMP

1 GY2 BK34

BKBK [GRD3]

R/Y TN/Y TN/Y

O

BATTERY 30 AMP41 35

DIODE40 34

29 23

[61B]

R

TN/LT.GN

R/BKINJECTOR FRONT OUTPUT 5

FRONT COIL PRIMARY 6REAR COIL PRIMARY 7

INJECTOR REAR OUTPUT 8ACTIVE MUFFLER FEEDBACK 9

[GRD1] BRAKE/HORN/MUFFLER10 AMP

ACCESSORY 10AMPBANK ANGLE SENSOR

SYSTEM GROUND B TACHOMETER OUTPUT

1011 BK12 PK

R/GY 28 22 O/W

HORN

1 1 BK2 2 Y/BK FUEL PUMP MTR

[122A] [122B]KEY SWITCH 15 AMP

Y/R A BK B

C

A Y/R B BKC LOW

R 44 38 R GY D

[86A]

D GY

[86B]

NEUTRAL SW

FUEL SENSOR

TN/Y 1 1

[131B]

VSS[131A]

R/W A W B

BK/W C

A R B W C BK

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

[39B]

[65B] [65A]

[24A]

FUSE/RELAY ASSEMBLY [62B]

1 2 3 4 5 6 7 8

LH CONTROLS

SPEEDOMETER[39A]

86 1085 230 687A 887 7

TN/LT.GN

1 1 GN/Y

[120B] OIL PRESSURE SW

86 1185 1930 1587A 1387 14

R/BK GN/Y

[120A]


2006 Lightning Models Horn & Instruments Circuit


2006 Lightning Models Horn & Instruments Circuit 2006 Lightning Models Horn & Instruments Circuit

1 2 3 4

1 2 3 4

KE

Y S

WS

TAR

T

IG

NIT

ION

BK

/R

W/B

K

W/B

K

GY

/O

LOC

KR

R/B

K R

TN

/LT.

GN

BK


bd0023bLIGNITION SWITCH WIRING DIAGRAM

RH CONTROLS

IGN SW

IGN

[33A]

KEY POSITION

PARK

LOCK

OFF

1 3 4 2

0 0

ON 0 0 0 0 STARTER

[22A]1 2 3 4

[33B]

WIRE COLOR

WIRE SECT mm

CONNECTING

R R/BK

1 1

+

R R/GY

1 1

+

SOLENOIDBK

BK [128A]

BATTERY USER + BATTERY USER +[GRD2]

1 GN

FUSE & DIODE ASSY [61B]

GROUND [128B]

R/Y

BATTERY 30 AMP

41 35 R

TN/Y

GY/O

DIODE

40 34

IGNITION 15 AMP

27 21

TN/LT.GN

R/BK

R KEY SWITCH 15 AMP

44 38 R

NEUTRAL SW

TN/Y 1 1

[131B] [131A]

RELAY CENTER

[62B]

W/BK86 1

85 9

30 5

87A 387 4

W/BK BK GY/O GY/O

86 10

85 2

30 6

87A 8

87 7

86 11

85 19

30 15

87A 13

87 14

BK/R TN/LT.GN R/BK

GN R/BK

BK R

R/BK

CLUTCH SW

[95B]

1 2

A= MALE

B= FEMALE


2006 Lightning Models Starting Circuit

2006 Lightning Models Charging Circuit


2006 Lightning Models Starting Circuit 2006 Lightning Models Starting Circuit


bs0021xx

BATTERY CABLE

BK

STARTER SOLENOID

BATTERY[128A]

STARTER MOTOR

BK

[GRD2]

FUSE/RELAY ASSEMBLY

BATTERY, 30A [61B]

R/Y 41 35 R

TO VOLTAGE REGULATOR

BK

R

[77B]

1 1

2 2

[77A]

VOLTAGE REGULATOR

STATOR(HD 3-PHASE)

1 12 23 34 4

[46A] [46B]

2006 Lightning Models Component Circuits


2006 Lightning Models Charging Circuit 2006 Lightning Models Charging Circuit

1 1 1

V/B

N

O/W BK

GY

W/Y G

Y G

N/G

Y

LT.G

N/Y

B

K/W

O BK

WT

N/V


bs0020aL

BATTERY CABLEBK

STARTER SOLENOID

[128A]

FRONT TURN SIGNALS

LH TURN SIGNALS BRAKE SW.

BATTERY

VEHICLE SPEED SENSOR

BE 1BK 2

[31A]

1 V2 BK

[31B]

MAIN HARNESS

[121A]

1 2

BK

[GRD2]

STARTER MOTOR

[65A]

RH TURN SIGNALS RH CONTROLS

BE 1 1 BNW/BK W/BK

2 [22B]3 BATTERY, 30A R A

[31A] [31B] GY 4 R/Y 41 35 R W BHORN

[122A]

TO VOLTAGE REGULATOR

BK C

BK 1 1TO MAIN HARNESS LH CONTROLS 1 2R 2 2

1 O/W2 W

Y 1 1BE 2 2

BK

Y/BK

[77B] [77A]MUFFLER VALVE ACTUATOR

3 Y4 BK

W 3 3Y/BK 4 4BE/W 5 5

Y/BK POSITIONHEADLIGHTSUB-HARNESS(ES)

[38LA]

[95A]

CLUTCH SW. 1 2

V BN O

[24B]

6 67 78 8

[24A]

VOLTAGE REGULATOR

SENSOR MTR

CONTROL ELECTRONICS

1 2 3 4

[161A]

1 Y2 BK

HI AND LO

1 W

[38HA]

STATOR

MUFFLER ACTUATOR SUB-HARNESS

Y0206.1AA

2 2

[165B]

1 O

1 2 3 4

[161B]

[29A]

POSITION

[29B]

1 O/W

4 4

[46A] [46B]

3 TN/V

LAMPS(HDI ONLY)

2 BK

TAIL LAMP/REAR TURNING LIGHTS

LH TURN SIGNAL

[19A]

BE 1

BK 2

FLASHERFRONT INJECTOR REAR INJECTOR

TO MAIN HARNESS

TAIL LIGHT

LIC PLATE LAMPO/W 1

BK 1 TO MAIN HARNESS

[30A]

1 2 4

1 2 3 4 5

[30B]

[84A]

1 1

[84B]

[85A]

1 1

[85B]

GN/Y 1

[120B]

1 GN/Y

[120A]

[93A][45A]

RH TURN SIGNAL

[18A]

BE 1

BK 2

ENGINE TEMP SENSOR

MAIN HARNESS

PK/Y 1 1

[90B] [90A] FUEL PUMP

BANK ANGLE SENSOR

1 12 23 3 UP

R/W 4 4

[89A]A Y/R B BKC BN/Y1 2 INTAKE AIR TEMP D GY1 2

MTR

LOWLT.GN/GY 5 5

BK/W 6 6

[134B] [134A]

[89B]FUEL SENSOR


2006 Lightning Models Component Circuits 2006 Lightning Models Component Circuits

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