1. HOME
AMP MULTILOCK ELECTRICAL CONNECTORS B.1
REMOVING SOCKET/PIN inadvertently released. Repeat the step without
releasing the tang.
TERMINALS
NOTE
1. 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. NOTE
5. 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. 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. Tang
2. Gently tug on wire end to verify that the terminal is
locked in place and will not back out of chamber. d0244x8x
3. 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. 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 terminal
d0245x2x

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

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 short
1. 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. 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. DEUTSCH ELECTRICAL CONNECTORS B.2
GENERAL 4566
Deutsch 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 various
parts of the Deutsch connector. The following instructions
may 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.
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 Figure B-6. Remove Secondary Locking Wedge
cover, attachment clip, secondary locking wedge, wire seal,
seal pin.
REMOVING/DISASSEMBLING s0545x8x
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 Figure B-7. Depress Terminal Latches/Back Out Pins
connector is connected to the wiring harness.
NOTE
REMOVING/INSTALLING SOCKETS An ELECTRICAL TERMINAL CRIMP TOOL (Part No.
HD-
39965) is used to install Deutsch pin and socket terminals on
1. 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 the
2. 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. it is properly locked in place.

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 pin
REMOVING/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. Socket
housing
Figure B-9. Depress Terminal Latches/Back Out Pins
B-6 2006 Buell Lightning: Appendix B

11. NOTE
An ELECTRICAL TERMINAL CRIMP TOOL (Part No. h41475
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 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 housing
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 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.
NOTE
Deutsch 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 installed
other con- nectors, including those associated with right side
accesso- ries, are black.
of the external latch is the same.
If it should become necessary to replace a plug or
receptacle, please note that the 8-pin and 12-pin gray and
black connec- tors 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

12. Figure B-11. Attachment Clip Installation
2. 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. 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 Procedure
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 short
1. 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. 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 SIDE
1. Socket terminal 7. Locking wedge
2. Wire seal 8. Latch cover 1
3. Socket housing 9. Pin housing
4. External latch 3
10. Wire seal
5. Internal seal 11. Pin terminal
6. Locking wedge

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

16. 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 the pull-to-seat connectors, the terminal is pushed out the
Packard electrical connectors, those with pull-to-seat termi- mating end of the connector. Once a new terminal is crimped
nals 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 that
the terminal can be extracted from this side, then it is proba- Two types of Packard pull-to-seat electrical connectors are
bly 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 terminals
ognized by the presence of a locking ear. The ear engages are picked differs between these two types of connectors, as
a slot in the connector housing and prevents the terminal further described below.
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].
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 Connectors
B-10 2
2006 Buell Lightning: Appendix B

17. PULL-TO-SEAT Installing External Latch Type
TERMINALS 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 the
Type connec- tor housing, use a thin flat blade, like that on an
To remove a pull-to-seat terminal from connectors with exter- X-Acto knife, and carefully bend the tang outward away
nal 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.
NOTE
A series of Packard Electrical Terminal Crimp Tools are
avail- able to install Packard pin and socket terminals on
wires. If new terminals must be installed, see Crimping
Instructions.

18. PUSH-TO-SEAT Installing Push-to-Seat
TERMINALS Terminals
NOTE
The Packard push-to-seat terminal connectors found on Soft- For wire location purposes, alpha characters are stamped
ail 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 away
Removing 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 properly
Like 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 is
push- 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 on
2. 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 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 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.
NOTE
A series of Packard Electrical Terminal Crimp Tools are
avail- able to install Packard pin and socket terminals on
wires. If new terminals must be installed, see Crimping
Instructions.
B-12 2006 Buell Lightning: Appendix B

19. CRIMPING INSTRUCTIONS d0259x8x
Tool tip
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.
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 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.
Tools
7. 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-sealed
8. 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-E
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.
d0260x8x
10. Squeeze handle of crimp tool until tightly closed. Tool
automatically opens when the crimping sequence is 1 2
complete.
3
11. 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. ELECTRICAL CONNECTORS B.4
GENERAL 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. 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
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. HOME
INDEX 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-29
B-16 2006 Buell Lightning: Appendix B

23. HOME
bd0016aL
[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. 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 Harness
7
7
B-16 2006 Buell Lightning: Appendix B

25. HOME
2006 Lightning Models Main Harness 2006 Lightning Models Main Harness
2006 Buell Lightning: Electrical B-19