Harley Davidson Sportster Models 2009. Service Repair Manual — page 51
DTCs P0501 and P0502 (Part 1 of 2)
1
YES
NO
2
2
3
NO
NO
NO
YES
NO
YES
YES
Clear DTCs using odometer self-diagnostics. See
4.6 ODOMETER SELF-DIAGNOSTICS. Confirm
proper operation with no check engine lamp.
Inspect connector [65].
Is connector mated properly?
Remove and inspect VSS. Inspect for debris and clean if
necessary. Place odometer into diagnostic mode and clear
DTCs. Connect all circuits and ride motorcycle for
approximately 1.0 mile (1.6 km). Check for speedometer
function.
Is speedometer functioning properly?
Mate connector [65].
System OK.
Check for continuity between terminal
A of connector [65B] (BK/R) wire and
ground.
Is continuity present?
Check for continuity between terminal A
of connector [65B] (BK/R) wire and
terminal 14 of Breakout Box.
Is continuity present?
Check for continuity between terminal C
of connector [65B] (BK) wire and ground.
Is continuity present?
Locate and repair open on
(R/W) and (BK/R) wires
between [78B] and [65B].
Repair open on (BK) wire between
connector [65B] and ground.
Repair short to ground.
YES
fc01988_en
Go to DTCs
P0501 and P0502
(Part 2 of 2).
4-98 2009 Sportster Diagnostics: Engine Management
DTCs P0501 and P0502 (Part 2 of 2)
Clear DTCs using odometer self-diagnostics. See
4.6 ODOMETER SELF-DIAGNOSTICS. Confirm
proper operation with no check engine lamp.
3
YES
NO
2
YES
YES
NO
NO
NO
NO
Continued from DTCs P0501 and P0502 (Part 1 of 2).
Check for continuity between terminal B of connector [65B] (BK/BE) wire and
terminal 33 of Breakout Box.
Is continuity present?
Check for voltage at terminal 33 on breakout
box. DVOM should read 4-6 volts when gear tooth
absent and 0-1 volts when gear tooth is present.
Does voltage fall within specifications?
Locate and repair open on
(BK/BE) wire between [78B]
and [65B].
No voltage fluctuation from
high (4-6 volts) to low (0-1
volts).
Battery voltage is
present.
Voltage fluctuates from high
(4.6 volts) to low (0-1 volts).
Replace ECM. Reprogram
and learn password.
Locate and repair short to
voltage on (BK/BE) wire
between [78B] and [65B].
Measure resistance between
ground and terminal 33 on
breakout box.
Is resistance less than 100
ohms?
Replace VSS.
Locate and repair short to
ground on (BK/BE) wire
between [78B] and [65B].
Replace ECM. Reprogram
and learn password.
No voltage
present.
fc01989_en
2009 Sportster Diagnostics: Engine Management 4-99
4.23
DTC P0562, P0563
GENERAL
Battery Voltage
. Battery voltage is monitored by the Electronic
Control Module (ECM) (terminal "13"). If the battery voltage
fails to meet normal operating parameters, a code is set.
NOTE
When either Diagnostic Trouble Code (DTC) P0562 or P0563
is set, the battery icon in the speedometer on XL, tachometer
on XR, will illuminate.
•
DTC P0562 is displayed when battery voltage is less than
12.2 volts at idle and voltage does not increase when
engine speed is greater than 2000 RPM.
•
DTC P0563 is displayed when battery positive voltage is
greater than 15.0 volts for more than 4 seconds.
NOTES
•
Warm idle speed will be automatically increased if battery
voltage is low at idle.
•
TSM/TSSM/HFSM problems may also set DTC P0562 or
P0563.
Table 4-36. Code Description
DESCRIPTION
DTC
Battery voltage low
P0562
Battery voltage high
P0563
ed02845
Figure 4-47. System Relay
DIAGNOSTICS
TOOL NAME
PART NUMBER
BREAKOUT BOX
HD-43876
Diagnostic Tips
•
Low voltage generally indicates a loose wire, corroded
connections, battery and/or a charging system problem.
•
A high voltage condition may be caused by a faulty voltage
regulator.
Diagnostic Notes
Each reference number below correlates to a circled number
on the flowchart(s).
1.
Was battery allowed to discharge or be drawn down by a
starting problem?
a.
Yes. Charge battery.
b.
No. See
1.7 CHARGING SYSTEM, Troubleshooting
2.
Connect BREAKOUT BOX (Part No. HD-43876) between
wire harness and ECM. See
3.
Use DVOM with RPM Pick-up to check RPM on vehicles
without tachometers.
4.
This checks for voltage drops in the ECM circuit.
a.
Place (+) probe to battery positive terminal.
b.
Place (-) probe to (W/BK) terminal on Breakout Box.
5.
Problem is most likely the ground connection at the frame.
4-100 2009 Sportster Diagnostics: Engine Management
BK
GY
GY
GY
BK
BK
R
R
R
R
R
BE/GY
BE/GY
BE/GY
GN/O
GN/O
Y/GN
W/BK
W/BK
W/BK
W/BK
R/BK
R/BK
2
31
13
10
28
2
31
13
10
28
System Relay
ECM
Battery
4
3
4
3
Switch Power
30 Amp
MAXIFUSE
Battery
Ignition
Switch
To Fuel Pump Fuse
I - IGN
B - BATT
A - ACC
15 Amp
IGN Fuse
15 Amp
ECM fuse
Ground
Ground
Engine Case
Ground Point
GND 1
System
Relay
Fuse Block
[119A]
[119B]
86
85
30
87A
87
1
2
3
4
5
U
S
E
T
K
[22B]
[22A]
[78B]
[78A]
Engine Stop
Switch
em00266
Figure 4-48. Ignition Power Circuit
Table 4-37. Wire Harness Connectors
LOCATION
TYPE
DESCRIPTION
NO.
Under fuel tank
6-place Molex
Right handlebar controls
[22]
Under seat
36-place Packard
ECM
[78]
Under left side cover
5-place Amp
System relay
[119]
2009 Sportster Diagnostics: Engine Management 4-101
DTCs P0562 and P0563 (Part 1 of 2)
Clear DTCs using odometer self-diagnostics. See 4.6
ODOMETER SELF-DIAGNOSTICS. Confirm proper
operation with no check engine lamp.
2
YES
NO
3
4
5
1
YES
YES
YES
YES
YES
NO
NO
NO
NO
NO
Perform charging system tests.
Is charging system OK?
With ignition ON, measure voltage drop
between battery positive (+) terminal
and Breakout Box terminal “13” (-).
Is voltage drop greater than 0.5 volt?
Repair charging system.
See 1.7 CHARGING
SYSTEM.
Connect Breakout Box. Measure voltage on
Breakout Box between terminal 13 (+) and
terminal 10 (-) and again between terminal 13
and terminal 28 (-) with engine running at
2000 RPM or higher for 10 seconds or longer.
Is voltage above 11.0 volts?
System
OK.
1
Repair open on (W/BK)
wire between [22B]
and [78B] or terminals.
Locate and
repair
bad
connection.
Problem is intermittent.
Perform 4.8 WIGGLE TEST.
Locate and
repair bad connection.
With ignition ON, measure resistance
between ignition fuse and connector
[22B] terminal 3.
Is resistance greater than 1 ohm?
Check for voltage drop between battery
negative (-) terminal and terminal 10 (+)
on Breakout Box connector and between
battery negative (-) terminal and terminal
28 on Breakout Box.
Is voltage drop greater than 0.5 volt?
With ignition OFF, measure resistance
between Breakout Box terminal 13
and connector [22B] terminal 4.
Is resistance greater than 1 ohm?
Inspect [22] for
corrosion or loose
wires.
If above conditions are
not present, replace
engine stop switch.
fc01990_en
Go to DTCs P0562
and P0563 (Part 2
of 2).
4-102 2009 Sportster Diagnostics: Engine Management
Left Turn Switch
Left Hand
Controls
IGN
15A
ACCY
15A
Ignition
Switch
[7A]
[33]
Battery 15A
ECM 15A
Security
Siren
(Optional)
A
J
D
A
B
I
C
B
Start
Relay
A
B
C
A
B
C
Power
Signal
Ground
BK
30 Amp
MAXIFUSE
B
A
GND1
Powertrain
Ground
Point
IGN − I
BATT – B
ACC – A
I
Q
C
P
R
87
87A
30
85
86
5
4
3
2
1
ECM
TSM/TSSM/HFSM
[61B]
Right Turn Switch
Engine Stop Switch
Start Switch
Right Hand
Controls
Fuseblocks
Top View
Top View
[119]
Accessories
Lights
Ignition
Fuel Pump
Start Relay
System Relay
ECM
Battery
Spare
P&A IGN
Instruments
Spare
System
Relay
Engine Control
Open
[119B]
[128]
6 5 4 3
1
6 5 4 3
1
6 5
2 1
6 5
2
To Front
Turn Signals
To Rear Lighting
To Instruments And
Indicator Lamps
[61]
1
5
1
5
3
5
7
12
K
T
E
S
U
87
87A
30
85
86
5
4
3
2
1
Starter
Battery
Red
Band
2
2
1
1
Antenna ‘A’
Antenna ‘B’
Hands Free Antenna
Battery
1
2
3
Battery
Ignition
Serial Data
Left Turn Feed
Right Turn Feed
Right Turn Switch Input
Left Turn Switch Input
Start Relay Control
Alarm Signal
Ground
Receive Antenna
XMIT Antenna A
XMIT Antenna B
System Relay
Serial Data
Ground
Switched Power
Ground
1
2
3
5
6
7
8
9
11
12
1
2
3
1
2
3
5
6
7
8
9
11
12
2
5
10
13
28
31
2
5
10
13
28
31
Socket Connector
Pin Connector
(A Side)
(B Side)
E
K
T
S
U
I
C
Q
P
R
M
O
G
H
A
B
15A
15A
15A
P
R
I
J
C
D
15A
15A
15A
M
O
G
H
A
B
15A
15A
15A
K
L
S
U
F
15A
15A
E
SWITCH
POSITION
RED/BLACK
RED
RED/GRAY
OFF
ACC.
IGNITION
Ignition Switch Legend
Dot indicates continuity with red
Wire in switch position indicated
HFSM Only
[162]
[5]
[163]
[20A]
Page 2
[31B]
Page 2
[7B]
Page 2
BN
BK
BK
GY
W/V
V
BN/GY
LGN/BN
LGN/BN
BN/GY
TN/GN
LGN/V
W/BN
BK
BK
GN
GY
BK
BK
BK
O/W
W/V
O/W
W/V
O/W
O/Y
BK
O/Y
R
R
R
R
R
R
BK
BK
BK
BN
V
BN/GY
LGN/V
BE/GY
Y/BK
W/BK
R/GY
R/BK
R/BK
R/GY
GN/O
GN
TN/GN
BE/GY
BE/GY
BK/R
W/BK
GN/O
R/BK
BK
BK
BN
GY
O/W
V
W/BN
W/BK
BK/R
GY
O/W
W/BN
W/BK
BK/R
BK
BN
V
LGN/V
Engine Case
Ground Point
[24B]
[24A]
[78B]
[78A]
[208B]
[208A]
[209A]
[209B]
[30B]
[30A]
[22A]
[22B]
[20B]
[31A]
[142B]
[142A]
et00126
Figure B-19. Security (1 of 2) (XR): 2009 Sportster DOM. and INT. Models
Figure B-19.
Figure B-19.
Security (1 of 2) (XR): 2009 Sportster DOM. and INT. Models
Security (1 of 2) (XR): 2009 Sportster DOM. and INT. Models
BK
V
BK
BN
1
2
5
6
2
3
5
7
12
Configuration For XR
Front Turn Signals
Serial Data
Battery
Ground
Serial Data
Battery
Ground
C
B
D
2
5
7
C
B
D
2
5
7
From Main
Harness
LGN/V
BN/GY
BK
BN/GY
LGN/V
BK
BN
V
BK
BK
Speedometer
Tachometer
BN/GY
LGN/V
BK
BN
V
To Main
Harness
Left
Turn
Right
Turn
SOCKET CONNECTOR
PIN CONNECTOR
(A SIDE)
(B SIDE)
[20B]
Page 1
[31A]
Page 1
BK
BK
BK
BN
BK
BN
V
V
[39B]
[39A]
[108B]
[108A]
[31B]
[20A]
et00127
Figure B-20. Security (2 of 2) (XR): 2009 Sportster DOM. and INT. Models
Figure B-20.
Figure B-20.
Security (2 of 2) (XR): 2009 Sportster DOM. and INT. Models
Security (2 of 2) (XR): 2009 Sportster DOM. and INT. Models
C.1
METRIC CONVERSION
CONVERSION TABLE
Table C-1. Metric Conversions
INCHES to MILLIMETERS
(IN x 25.40 = MM)
MILLIMETERS to INCHES
(MM x 0.03937 = IN)
mm
in
mm
in
mm
in
mm
in
in
mm
in
mm
in
mm
in
mm
84.14
3-5/16
49.21
1-15/16
15.240
.6
.025
.001
3.582
91
2.283
58
.9842
25
.0039
.1
85.72
3-3/8
50.80
2
15.875
5/8
.051
.002
3.622
92
2.323
59
1.024
26
.0078
.2
86.36
3.4
52.39
2-1/16
17.462
11/16
.076
.003
3.661
93
2.362
60
1.063
27
.0118
.3
87.31
3-7/16
53.34
2.1
17.780
.7
.102
.004
3.701
94
2.401
61
1.102
28
.0157
.4
88.90
3-1/2
53.97
2-1/8
19.050
3/4
.127
.005
3.740
95
2.441
62
1.142
29
.0197
.5
90.49
3-9/16
55.56
2-3/16
20.320
.8
.152
.006
3.779
96
2.480
63
1.181
30
.0236
.6
91.44
3.6
55.88
2.2
20.638
13/16
.178
.007
3.819
97
2.519
64
1.220
31
.0275
.7
92.07
3-5/8
57.15
2-1/4
22.225
7/8
.203
.008
3.858
98
2.559
65
1.260
32
.0315
.8
93.66
3-11/16
58.42
2.3
22.860
.9
.229
.009
3.897
99
2.598
66
1.299
33
.0354
.9
93.98
3.7
58.74
2-5/16
23.812
15/16
.254
.010
3.937
100
2.638
67
1.338
34
.0394
1
95.25
3-3/4
60.32
2-3/8
25.40
1
.397
1/64
3.976
101
2.677
68
1.378
35
.0787
2
96.52
3.8
60.96
2.4
26.99
1-1/16
.508
.020
4.016
102
2.716
69
1.417
36
.1181
3
96.84
3-13/16
61.91
2-7/16
27.94
1.1
.762
.030
4.055
103
2.756
70
1.456
37
.1575
4
98.42
3-7/8
63.50
2-1/2
28.57
1-1/8
.794
1/32
4.094
104
2.795
71
1.496
38
.1968
5
99.06
3.9
65.09
2-9/16
30.16
1-3/16
1.016
.040
4.134
105
2.834
72
1.535
39
.2362
6
100.01
3-15/16
66.04
2.6
30.48
1.2
1.270
.050
4.173
106
2.874
73
1.575
40
.2756
7
101.6
4
66.67
2-5/8
31.75
1-1/4
1.524
.060
4.212
107
2.913
74
1.614
41
.3149
8
102.19
4-1/16
68.26
2-11/16
33.02
1.3
1.588
1/16
4.252
108
2.953
75
1.653
42
.3543
9
104.14
4.1
68.58
2.7
33.34
1-5/16
1.778
.070
4.291
109
2.992
76
1.693
43
.3937
10
104.77
4-1/8
69.85
2-3/4
34.92
1-3/8
2.032
.080
4.331
110
3.031
77
1.732
44
.4331
11
106.36
4-3/16
71.12
2.8
35.56
1.4
2.286
.090
4.370
111
3.071
78
1.772
45
.4724
12
106.68
4.2
71.44
2-13/16
36.51
1-7/16
2.540
.1
4.409
112
3.110
79
1.811
46
.5118
13
107.95
4-1/4
73.02
2-7/8
38.10
1-1/2
3.175
1/8
4.449
113
3.149
80
1.850
47
.5512
14
109.22
4.3
73.66
2.9
39.69
1-9/16
4.762
3/16
4.488
114
3.189
81
1.890
48
.5905
15
109.54
4-5/16
74.61
2-15/16
40.64
1.6
5.080
.2
4.527
115
3.228
82
1.929
49
.6299
16
111.12
4-3/8
76.20
3
41.27
1-5/8
6.350
1/4
4.567
116
3.268
83
1.968
50
.6693
17
111.76
4.4
77.79
3-1/16
42.86
1-11/16
7.620
.3
4.606
117
3.307
84
2.008
51
.7086
18
112.71
4-7/16
78.74
3.1
43.18
1.7
7.938
5/16
4.645
118
3.346
85
2.047
52
.7480
19
114.30
4-1/2
79.37
3-1/8
44.45
1-3/4
9.525
3/8
4.685
119
3.386
86
2.086
53
.7874
20
115.89
4-9/16
80.96
3-3/16
45.72
1.8
10.160
.4
4.724
120
3.425
87
2.126
54
.8268
21
116.84
4.6
81.28
3.2
46.04
1-13/16
11.112
7/16
4.764
121
3.464
88
2.165
55
.8661
22
117.47
4-5/8
82.55
3-1/4
47.62
1-7/8
12.700
1/2
4.803
122
3.504
89
2.205
56
.9055
23
119.06
4-11/16
83.82
3.3
48.26
1.9
14.288
9/16
4.842
123
3.543
90
2.244
57
.9449
24
2009 Sportster Diagnostics: Appendix C Conversions C-1
C.2
FLUID CONVERSIONS
UNITED STATES SYSTEM
Unless otherwise specified, all fluid volume measurements in
this Service Manual are expressed in United States (U.S.)
units-of-measure. See below:
•
1 pint (U.S.) = 16 fluid ounces (U.S.)
•
1 quart (U.S.) = 2 pints (U.S.) = 32 fl. oz. (U.S.)
•
1 gallon (U.S.) = 4 quarts (U.S.) = 128 fl. oz. (U.S.)
METRIC SYSTEM
Fluid volume measurements in this Service Manual include
the metric system equivalents. In the metric system, 1 liter (L)
= 1,000 milliliters (mL). Should you need to convert from U.S.
units-of-measure to metric units-of-measure (or vice versa),
refer to the following:
•
fluid ounces (U.S.) x 29.574 = milliliters
•
pints (U.S.) x 0.473 = liters
•
quarts (U.S.) x 0.946 = liters
•
gallons (U.S.) x 3.785 = liters
•
milliliters x 0.0338 = fluid ounces (U.S.)
•
liters x 2.114 = pints (U.S.)
•
liters x 1.057 = quarts (U.S.)
•
liters x 0.264 = gallons (U.S.)
BRITISH IMPERIAL SYSTEM
Fluid volume measurements in this Service Manual do not
include the British Imperial (Imp.) system equivalents. The fol-
lowing conversions exist in the British Imperial system:
•
1 pint (Imp.) = 20 fluid ounces (Imp.)
•
1 quart (Imp.) = 2 pints (Imp.)
•
1 gallon (Imp.) = 4 quarts (Imp.)
Although the same unit-of-measure terminology as the U.S.
system is used in the British Imperial (Imp.) system, the actual
volume of each British Imperial unit-of-measure differs from its
U.S. counterpart. The U.S. fluid ounce is larger than the British
Imperial fluid ounce. However, the U.S. pint, quart, and gallon
are smaller than the British Imperial pint, quart, and gallon,
respectively. Should you need to convert from U.S. units to
British Imperial units (or vice versa), refer to the following:
•
fluid ounces (U.S.) x 1.042 = fluid ounces (Imp.)
•
pints (U.S.) x 0.833 = pints (Imp.)
•
quarts (U.S.) x 0.833 = quarts (Imp.)
•
gallons (U.S.) x 0.833 = gallons (Imp.)
•
fluid ounces (Imp.) x 0.960 = fluid ounces (U.S.)
•
pints (Imp.) x 1.201 = pints (U.S.)
•
quarts (Imp.) x 1.201 = quarts (U.S.)
•
gallons (Imp.) x 1.201 = gallons (U.S.)
C-2 2009 Sportster Diagnostics: Appendix C Conversions
C.3
TORQUE CONVERSIONS
UNITED STATES SYSTEM
The U.S. units of torque, foot pounds and inch pounds, are
used in this service manual. To convert units, use the following
equations:
•
foot pounds (ft-lbs) X 12.00000 = inch pounds (in-lbs).
•
inch pounds (in-lbs) X 0.08333 = foot pounds (ft-lbs).
METRIC SYSTEM
All metric torque specifications are written in Newton-meters
(Nm). To convert metric to United States units and United
States to metric, use the following equations:
•
Newton meters (Nm) X 0.737563 = foot pounds (ft-lbs).
•
Newton meters (Nm) X 8.85085 = inch pounds (in-lbs).
•
foot pounds (ft-lbs) X 1.35582 = Newton meters (Nm).
•
inch pounds (in-lbs) X 0.112985 = Newton meters (Nm).
2009 Sportster Diagnostics: Appendix C Conversions C-3
D.1
GLOSSARY
ACRONYMS AND ABBREVIATIONS
Table D-1. Acronyms and Abbreviations
DESCRIPTION
ACRONYM OR ABBREVIATION
Amperes
A
Alternating Current
AC
Accessory
ACC
Automatic Compression Release
ACR
Absorbed Glass Mat (battery)
AGM
Ampere
AMP
American Wire Gauge
AWG
Battery Voltage
B+
Bank Angle Sensor
BAS
Before Top Dead Center
BTDC
Celsius (Centigrade)
C
California
CA
Calibration
CAL
Cubic Centimeters
CC
Cold Cranking Amps
CCA
Crankshaft Position
CKP
Centimeter
cm
Direct Current
DC
Data Link Connector
DLC
Domestic
DOM
Diagnostic Trouble Code
DTC
Digital Volt Ohm Meter
DVOM
Electronic Control Module
ECM
Engine Coolant Temperature
ECT
Electrically Erasable Programmable Read Only Memory
EEPROM
Electronic Fuel Injection
EFI
Engine Temperature
ET
Evaporative Emissions Control System
EVAP
Fahrenheit
F
Foot-Pounds
ft-lbs
Fluid Ounce
fl oz.
Gram
g
Gallon
GAL
Gross Axle Weight Rating
GAWR
Ground (electrical)
GND
Gross Vehicle Weight Rating
GVWR
Harley-Davidson International
HDI
Harley-Davidson Smart Security System
H-DSSS
Hands Free Security Module
HFSM
Mercury
Hg
2009 Sportster Diagnostics: Appendix D Glossary D-1
Table D-1. Acronyms and Abbreviations
DESCRIPTION
ACRONYM OR ABBREVIATION
Idle Air Control
IAC
Intake Air Temperature
IAT
Instrument Cluster
IC
Inside Diameter
ID
Ignition Light/Key Switch
IGN
Inch
In.
Injector Pulse Width
INJ PW
Inch-Pounds
in-lbs
Kilogram
Kg
Kilometer
Km
Kilopascal
kPa
Kilometers Per Hour
km/hr
Liter
L
Liquid Crystal Display
LCD
Light Emitting Diode
LED
Milliampere
mA
Manifold Absolute Pressure
MAP
milliliter
ml
millimeter
mm
Miles Per Hour
MPH
millisecond
ms
Newton-Meter
Nm
Not Applicable
N/A
Number
no.
Oxygen
O2
Outside Diameter
OD
Original Equipment Manufacturer
OEM
Ounce
oz
Parts and Accessories
P&A
Part Number
PN
Pounds per Square Inch
PSI
Reserve
RES
Revolutions Per Minute
RPM
Cubic Feet per Hour at Standard Conditions
SCFH
Throttle Control Actuator
TCA
Top Dead Center
TDC
Twist Grip Sensor
TGS
Throttle Position
TP
Intake Air Temperature/Manifold Absolute Pressure
TMAP
Turn Signal Module
TSM
Turn Signal/Security Module
TSSM
Volt
V
Volts of Alternating Current
VAC
D-2 2009 Sportster Diagnostics: Appendix D Glossary
Table D-1. Acronyms and Abbreviations
DESCRIPTION
ACRONYM OR ABBREVIATION
Volts of Direct Current
VDC
Vehicle Identification Number
VIN
Vehicle Speed Sensor
VSS
2009 Sportster Diagnostics: Appendix D Glossary D-3
SUBJECT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE NO.
APPENDIX E
TSM/TSSM (J
AP
AN/K
OREA)
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