Harley Davidson Sportster Models 2009. Service Repair Manual — page 48
4.13
SYSTEM RELAY CHECK
GENERAL
System Relay
. With the ignition switch ON and the engine
stop switch at RUN, the ECM will energize the system relay to
complete the circuit to the in-tank fuel pump, ignition coil, and
fuel injectors. They will remain powered as long as the engine
is cranking or running, and the ECM is receiving ignition refer-
ence pulses from the CKP sensor. If there are no reference
pulses, the ECM will de-energize the system relay within 2
seconds after ignition is ON or engine has stalled, or immedi-
ately after the ignition is shut OFF.
Table 4-14. Code Description
DESCRIPTION
DTC
System relay coil open/low
P1001
System relay coil high/shorted
P1002
System relay contacts open
P1003
System relay contacts closed
P1004
ed02845
Figure 4-24. System Relay
DIAGNOSTICS
TOOL NAME
PART NUMBER
HARNESS CONNECTOR TEST KIT
HD-41404-B
BREAKOUT BOX
HD-43876
Diagnostic Notes
Each reference number below correlates to a circled number
on the flowchart(s).
1.
Use HARNESS CONNECTOR TEST KIT (Part No. HD-
41404-B), gray pin probe and patch cord.
2.
Connect BREAKOUT BOX (Part No. HD-43876) to ECM.
See
Table 4-15. Wire Harness Connectors
LOCATION
TYPE
DESCRIPTION
NO.
Under fuel tank
6-place Molex
Right handlebar controls
[22]
Under battery
12-place Deutsch, gray
TSM/TSSM/HFSM
[30]
Under seat
36-place Packard
ECM
[78]
Back of coil
4-place Delphi
Ignition coil
[83]
Top of intake manifold
2-place Delphi, black
Front injector
[84]
Top of intake manifold
2-place Delphi, black
Rear injector
[85]
Under left side cover
5-place Amp
System relay
[119]
Forward of relay/fuse blocks
4-place Molex, black
Fuel pump and low fuel switch
[141]
Under seat
16-place Molex
Engine harness
[145]
4-50 2009 Sportster Diagnostics: Engine Management
System
Relay
Front Injector
Rear Injector
15 Amp
ECM Fuse
15 Amp
Fuel Pump
Fuse
30 Amp
MAXIFUSE
15 Amp
IGN Fuse
Engine Stop
Switch
Ignition
TSM/TSSM/HFSM
Fuel
Pump
Ignition
Coil
Battery
System Relay
Front Injector
Rear Injector
Rear Coil
Front Coil
Battery
Switch Power
Ground
Ground
BK
BK
GY
BK
GY
BK
BK
GY
GY
W/Y
W/Y
W/Y
R
R
R
R
R
GN/GY
GN/GY
GN/GY
BE/GY
BE/GY
BE/GY
GN/O
Y/GN
Y/BE
BE/O
Y/BE
BE/O
R/BK
R/BK
W/BK
GN/O
Y/GN
O/GY
O/GY
Y/GN
Y/GN
Y/GN
W/BK
W/BK
Y/GN
Y/GN
Y/GN
W/BK
10
19
21
2
31
13
28
A
B
A
B
A
B
A
B
1
4
1
4
13
7
8
13
7
8
[145A] [145B]
2
2
11
29
10
19
21
2
31
13
28
11
29
A
B
C
D
ECM
A
B
C
D
4
3
4
3
Fuse Block
GND 1
GND 1
Engine Case
Ground Point
[22B]
[22A]
[30B]
[30A]
[83A]
[83B]
[119A]
[119B]
[85A]
[85B]
[84A]
[84B]
[141B]
[141A]
[78B]
[78A]
86
85
30
87A
87
1
2
3
4
5
U
S
E
T
K
B
A
I
Ignition
Switch
em00263
Figure 4-25. System Relay Circuit
2009 Sportster Diagnostics: Engine Management 4-51
DTCs P1001 and P1003
Check for battery voltage at terminal 87 of system relay (with relay
installed) during first 2-3 seconds after key ON.
Is battery voltage (10-13 volts) present for 2-3 seconds after key ON?
YES
System relay OK. Measure resistance
(with relay removed) between terminal
87 of the system relay and coil
connector [83B] at terminal A.
Is resistance less than 0.5 ohm?
YES
NO
Recheck connections.
Wiggle harness while
repeating test. Repair
intermittent.
Find and repair
connection or
open wire (Y/GN).
YES
NO
With ignition ON, check for
10-13 volts at terminal 86 of
the system relay.
Is voltage present?
Check for continuity to
ground on (BE/GY) wire.
Is continuity present?
Check for 10-13 volts at
terminal 30 of the system relay.
Is voltage present?
2
1
No voltage or voltage always
present.
YES
NO
Measure resistance
between terminal 85 of
system relay and
terminal 2 on Breakout
Box.
Is resistance less than
0.5 ohm?
Is ignition
fuse good?
YES
NO
Find and repair
open between fuse
and relay.
Repair short
to ground and
replace
ECM fuse.
YES
NO
Check for continuity to
ground
on terminal 2 on Breakout
Box.
Is continuity present?
Locate and
repair open on
(GN/O) wire.
YES
NO
Repair short
to ground and replace
ignition fuse.
Find and repair
open on (W/BK) wire
between connector [22]
and relay.
YES
NO
Repair short
to ground.
Replace system relay. Does
fuel pump run for the first 2
seconds after key ON?
YES
System
OK.
Replace ECM. Reprogram
and learn password.
NO
Clear DTCs using odometer self-diagnostics. See
4.6 ODOMETER SELF-DIAGNOSTICS. Confirm
proper operation with no check engine lamp.
fc01828_en
NO
4-52 2009 Sportster Diagnostics: Engine Management
DTC P1002
Remove system relay. Check
for voltage on terminal 2 of
Breakout Box.
Is voltage present?
YES
NO
Remove Breakout Box
connector from ECM.
Is voltage still present on
terminal 2?
YES
NO
Repair short to voltage on
(GN/O) wire.
Replace ECM.
Reprogram and learn password.
Replace
system relay.
Clear DTCs using odometer self-diagnostics. See
4.6 ODOMETER SELF-DIAGNOSTICS. Confirm
proper operation with no check engine lamp.
fc01829_en
2
2009 Sportster Diagnostics: Engine Management 4-53
DTC P1004
Check for poor connections, damaged terminals, poor
ground or wires reversed at fuel pump.
Do any of these conditions exist?
YES
NO
Repair.
Condition: Fuel pump continues
to run with key OFF. Remove
system relay.
Does pump continue to run?
Clear DTCs using odometer self-diagnostics. See 4.6
ODOMETER SELF-DIAGNOSTICS. Confirm proper
operation with no check engine lamp.
YES
NO
Replace short to
voltage on (Y/GN) wire.
Replace
System Relay.
fc01830_en
4-54 2009 Sportster Diagnostics: Engine Management
4.14
IDLE AIR CONTROL
GENERAL
TOOL NAME
PART NUMBER
DIGITAL TECHNICIAN II
HD-48650
IAC Operation
The ECM controls engine idle speed by moving the Idle Air
Control (IAC) to open or close a passage around the throttle
plate. It does this by sending voltage pulses to the proper motor
winding of the IAC. This causes the pintle to move in or out of
the IAC a given distance for each pulse received.
•
To increase idle speed, the ECM retracts the pintle,
allowing more air to flow through the throttle body.
•
To decrease idle speed, the ECM extends the pintle,
allowing less air to flow through the throttle body.
The IAC position is measured in steps. This can be done only
by using the DIGITAL TECHNICIAN II (Part No. HD-48650).
•
A high number of steps represents a retracted pintle and
open passage around throttle plate. This correlates with
an increase in the amount of air flowing through the throttle
body.
•
Zero steps represents a fully extended pintle. A zero
reading indicates an abnormal condition in which the pintle
has been fully extended and has consequently closed the
passage around throttle plate.
Each time the ignition is turned off, the ECM resets the IAC by
sending enough pulses to extend the pintle and effectively
close the throttle body. The fully extended value is the ECM
reference point. A given number of steps are then calculated
by the ECM for use in setting the proper idle speed and IAC
position.
NOTE
Warm idle speed is controlled by the ECM and can be adjusted
only by using the DIGITAL TECHNICIAN II (Part No. HD-
48650).
Diagnostic Trouble Code P0505: Loss of
Idle Speed Control
Loss of idle speed control will result if the idle RPM is 200 from
preset idle speed and IAC motor is at zero or maximum for
greater than 5 seconds. This code may occur with others for
a multiple code situation. Resolve the other codes first to cor-
rect.
Table 4-16. Code Description
DESCRIPTION
DTC
Loss of idle speed control
P0505
DIAGNOSTICS
TOOL NAME
PART NUMBER
HARNESS CONNECTOR TEST KIT
HD-41404-B
BREAKOUT BOX
HD-43876
Diagnostic Tips
Engine idle speed can be adversely affected by the following:
•
A loss of idle speed control does not necessarily imply the
IAC actuator or wiring has failed. It can be caused by a
number of conditions such as an intake air leak, improperly
adjusted throttle stop (factory set) or a misfiring cylinder.
•
Leaking injectors will cause fuel imbalance and poor idle
quality due to different air/fuel ratios in each cylinder. To
check for leaky injectors, first remove the air cleaner. See
Air Cleaner in the service manual. Then, with the throttle
wide open, turn key ON for 2 seconds and then OFF for
2 seconds five consecutive times. Replace the fuel injector
if there is any evidence of raw fuel in the bores. See Fuel
Injectors in the service manual.
•
Vacuum leaks. To check for vacuum, see Intake Leak Test
in the service manual.
•
Contaminated fuel.
•
Excessive oil in the crankcase (oil sumping).
•
TP sensor reading of greater than 1% (possible throttle
cable misadjustment) or battery voltage reading of less
than 9 volts or a VSS greater than 0 will disable idle speed
control.
•
If there is a loss of battery power at ECM terminal 31,
vehicle will start but IAC pintle will not reset at key OFF.
Eventually pintle will be out of position causing perform-
ance problems.
Diagnostic Notes
Each reference number below correlates to a circled number
on the flowchart(s).
1.
When the engine is stopped, the IAC pintle extends and
then retracts to a fixed "Park" position for increased air-
flow and idle speed during the next engine start sequence.
This key OFF reset procedure takes 10 seconds to per-
form.
2009 Sportster Diagnostics: Engine Management 4-55
2.
Test lamp behavior may follow two patterns. The color of
the lights is not relevant to IAC operation.
a.
Normal behavior: At key ON, test lights will altern-
ately flash and then remain steady on to confirm ECM
signals. At key OFF lights alternately flash and go out
after 10 second reset procedure.
b.
Problem indicated: One or more lights fail to illu-
minate during key ON/key OFF cycle.
NOTE
There is a remote possibility that one of the circuits is shorted
to voltage which would have been indicated by a steady light.
Disconnect ECM and turn the ignition ON. Probe terminals to
check for this condition.
3.
Connect BREAKOUT BOX (Part No. HD-43876) to EFI
wire harness only, leaving ECM disconnected. See
4.
Use HARNESS CONNECTOR TEST KIT (Part No. HD-
41404-B), gray pin probe and patch cord.
5.
Repair faulty ECM connection or replace ECM. If ECM
requires replacement, see ECM in the service manual.
ed02020
Figure 4-26. IAC Test Lamp (Part No. HD-41199-3)
ed02850
Figure 4-27. IAC Connector (typical)
ed02851
Figure 4-28. IAC Pintle (typical)
4-56 2009 Sportster Diagnostics: Engine Management
A
17
18
35
36
17
18
35
36
B
C
D
A
B
C
D
2
1
9
4
2
1
9
4
[87A]
[87B]
[145A]
ECM
[145B]
[78A]
[78B]
IAC
Motor
IA
C
(A)
HI
IA
C
(B)
HI
IA
C
(B)
LO
W
IA
C
(A)
LO
W
BE/GN
BE/GN
BN/R
BN/R
BK/PK
BK/PK
BK/O
BK/O
em01204
Figure 4-29. IAC Circuit
Table 4-17. Wire Harness Connectors
LOCATION
TYPE
DESCRIPTION
NO.
Under seat
36-place Packard
ECM
[78]
Beneath fuel tank
4-place Delphi
IAC
[87]
Under seat
16-place Molex
Engine harness
[145]
2009 Sportster Diagnostics: Engine Management 4-57
DTC P0505 (Part 1 of 2)
YES
NO
NO
YES
Remove air cleaner cover and element.
Is throttle valve completely closed?
Monitor IAC pintle for 10 seconds after turning ignition OFF.
Does pintle extend and then retract during 10 second key OFF
reset procedure?
Lubricate and
adjust throttle
cables.
Check intake manifold for leaks,
see service manual.
Are leaks found?
Disconnect IAC and connect test lamp. See Figure 4-32. Turn
ignition key ON for 2 seconds, then turn ignition key OFF for 10
seconds.
Check test lamp during key ON/OFF cycle.
NO
YES
Check fuel
pressure.
See service
manual.
Repair intake
leak.
Normal
behavior.
Problem
indicated.
Remove test lamp.
Connect Breakout Box to connector
[78B] leaving ECM disconnected.
Check terminal 31 for battery voltage.
Is battery voltage present?
YES
NO
Using DVOM, measure resistance
between IAC connector [87B]
and Breakout Box.
Does each wire measure 0.5 ohms or less?
IAC
A
B
C
D
ECM
to 35
to 36
to 18
to 17
WIRE COLOR
BE/GN
BN/R
BK/PK
BK/O
YES
NO
YES
NO
Turn ignition ON. With ECM still disconnected, check voltage on all four
terminals at connector [87B].
Is voltage present?
Repair poor connection at
connectors [87B] or [78B] or repair
open wire in harness.
Repair short
to voltage.
Clear DTCs using odometer self-diagnostics. See 4.6
ODOMETER SELF-DIAGNOSTICS. Confirm proper
operation with no check engine lamp.
Repair faulty IAC
connection or IAC assembly.
Go to 4.10 NO ECM POWER.
3
4
4
2
1
fc01972_en
Go to DTC P0505
(Part 2 of 2).
3
4-58 2009 Sportster Diagnostics: Engine Management
DTC P0505 (Part 2 of 2)
YES
NO
NO
YES
Continued from DTC P0505 (Part 1 of 2).
Turn ignition OFF. Measure resistance between each terminal on connector [87B] and ground.
Is resistance greater than 1 megohm for all terminals?
Inspect ECM connections.
Are connections OK?
Repair short
to ground.
Replace ECM.
Reprogram and learn password.
Repair ECM
connections.
5
4
Clear DTCs using odometer self-diagnostics. See 4.6
ODOMETER SELF-DIAGNOSTICS. Confirm proper
operation with no check engine lamp.
fc01973_en
2009 Sportster Diagnostics: Engine Management 4-59
4.15
MISFIRE AT IDLE OR UNDER LOAD
GENERAL
Misfire at Idle or Under Load
•
Battery condition and connections may also cause misfires.
See Battery in the service manual for more information.
•
Fuel system problems may also cause misfires. See the
service manual and then see symptom tables under
4.5 INITIAL DIAGNOSTIC CHECK: EFI
•
Mechanical problems with the engine may cause misfires.
See service manual for more information.
•
Vehicle modifications including intake and exhaust may
cause misfires.
DIAGNOSTICS
TOOL NAME
PART NUMBER
SPARK TESTER
HD-26792
HARNESS CONNECTOR TEST KIT
HD-41404-B
BREAKOUT BOX
HD-43876
Diagnostic Notes
Each reference number below correlates to a circled number
on the flowchart(s).
Wipe up spilled fuel and dispose of rags in a suitable
manner. An open spark around gasoline could cause a
fire or explosion, resulting in death or serious injury.
(00518b)
1.
Connect BREAKOUT BOX (Part No. HD-43876) between
wire harness and ECM. See
.
NOTE
Engine will not spark with both spark plugs removed. When
checking for spark, use SPARK TESTER (Part No. HD-26792)
with both plugs installed.
2.
See
. A SPARK TESTER (Part No. HD-26792)
must be used to verify adequate secondary voltage
(25,000 volts) at the spark plug.
a.
Turn ignition switch OFF.
b.
Remove spark plug cable from spark plug. Visually
check plug condition.
c.
Attach cable to SPARK TESTER (Part No. HD-
26792). Clip tester to cylinder head bolt.
d.
While cranking engine, watch for spark to jump tester
gap on leads.
e.
Reinstall and repeat procedure on other spark plug
cable.
Table 4-18. Spark Plug Cables
REAR
FRONT
SPECIFICATION
19.37-19.63
6.25-6.6
Length in.
492-499
158-168
Length mm
4842-13087
2159-3086
Resistance-ohms
3.
Perform spark plug cable resistance test.
a.
Remove spark plug cable from spark plug and ignition
coil. For best results, use a needle nose pliers for
removal/installation on coil. Gently grasp cable as
close to terminals as possible.
b.
Using an ohmmeter, touch probes to terminals on
each end plug cable.
c.
Compare resistance values to
. Replace
cables not meeting specifications. Reinstall and repeat
procedure on other spark plug cable.
4.
If carbon tracking is evident on outside of coil towers,
replace ignition coil and inspect spark plug cables. Cables
must be clean and tight. Excessive cable resistance or
faulty connections can cause coil damage.
5.
This test can also be performed by substituting a known
good coil for one causing the no spark condition. The coil
does not require full installation to be functional. Verify
faulty coil by performing resistance test. See ignition coil
in the service manual.
6.
Use HARNESS CONNECTOR TEST KIT (Part No. HD-
41404-B) , red pin probe and patch cord to relay and gray
pin probe and patch cord to the coil connector [83B].
ed02012
Figure 4-30. Spark Tester
4-60 2009 Sportster Diagnostics: Engine Management
System
Relay
Front Injector
Rear Injector
15 Amp
ECM Fuse
15 Amp
Fuel Pump
Fuse
30 Amp
MAXIFUSE
15 Amp
IGN Fuse
Fuel
Pump
Ignition
Coil
Battery
System Relay
Front Injector
Rear Injector
Rear Coil
Front Coil
Battery
Switch Power
Ground
Ground
BK
BK
GY
BK
BK
GY
GY
W/Y
W/Y
W/Y
R
R
R
R
R
GN/GY
GN/GY
GN/GY
BE/GY
BE/GY
BE/GY
GN/O
Y/GN
Y/BE
BE/O
Y/BE
BE/O
R/BK
R/BK
W/BK
GN/O
Y/GN
O/GY
O/GY
Y/GN
Y/GN
Y/GN
W/BK
W/BK
Y/GN
Y/GN
Y/GN
W/BK
10
19
21
2
31
13
28
A
B
A
B
A
B
A
B
1
4
1
4
13
7
8
13
7
8
11
29
10
19
21
2
31
13
28
11
29
A
B
C
D
ECM
A
B
C
D
4
3
4
3
Fuse Block
GND 1
GND 1
[22B]
[22A]
[83A]
[83B]
[119A]
[119B]
[85A]
[85B]
[84A]
[84B]
[141B]
[141A]
[145B]
[145A]
[128B]
[128A]
[78B]
[78A]
86
85
30
87A
87
1
2
3
4
5
U
S
E
T
K
BK
BK
Starter
Motor
Engine Stop
Switch
B
A
I
Ignition
Switch
em00264
Figure 4-31. Ignition Coil Circuit Diagram
Table 4-19. Wire Harness Connectors
LOCATION
TYPE
DESCRIPTION
NO.
Under fuel tank
6-place Molex
Right handlebar controls
[22]
Under seat
36-place Packard
ECM
[78]
Back of coil
4-place Delphi
Ignition coil
[83]
Top of intake manifold
2-place Delphi, black
Front injector
[84]
Top of intake manifold
2-place Delphi, black
Rear injector
[85]
Under left side cover
5-place Amp
System relay
[119]
2009 Sportster Diagnostics: Engine Management 4-61
Table 4-19. Wire Harness Connectors
LOCATION
TYPE
DESCRIPTION
NO.
Starter solenoid
Locking spade terminal,
white
Starter solenoid
[128]
Left side, in front of fuse/relay blocks
4-place Molex
Fuel pump
[141]
Under seat
16-place Molex
Engine harness
[145]
4-62 2009 Sportster Diagnostics: Engine Management
Misfire at Idle or Under Load (Part 1 of 3)
Is fuel contaminated?
YES
NO
Drain and flush
tank. Refill with
fresh fuel.
Connect Breakout Box. Measure resistance
between terminal 10 of ECM and battery
negative and terminal 28 of ECM and
battery negative. Resistance should be less
than 1 ohm.
Is it?
YES
NO
Use spark tester to check
cables.
Did spark jump tester gap?
Locate and repair poor
ground connection.
YES
NO
Check for:
• Faulty, worn or cracked spark plug(s).
• Plug fouling due to engine
mechanical fault.
• Faulty or poor connection at plug or coil.
Check resistance of each spark plug
cable that did not fire the spark tester.
Also, check for faulty plug wire
connections and wires for carbon
tracking.
Are spark plug cables OK?
YES
NO
Coils should be free
of carbon tracking.
Are they?
Replace
faulty spark plug cables.
YES
Switch coil with unit
known to be good.
Re-perform spark test.
Did spark jump gap
during engine cranking?
NO
Replace
ignition coil.
YES
Original ignition coil
is faulty.
Replace ignition coil.
NO
1
2
3
4
2
5
fc01215_en
Go to Misfire At Idle Or
Under Load
(Part 2 of 3).
2009 Sportster Diagnostics: Engine Management 4-63
Misfire at Idle or Under Load (Part 2 of 3)
Continued from Misfire at Idle or Under Load (Part 1 of 3).
Measure resistance between relay terminal 87 and coil connector [83B]
terminal A (Y/GN) wire. Wiggle harness.
Is resistance continuously less than 0.5 ohms?
YES
NO
Reassemble coil and fuel tank. Measure
voltage drop between battery (positive
lead) and terminal 87 (negative lead) on
System Relay with engine running.
Is voltage drop less than 1.0 volt?
Find source of
intermittent and
repair.
YES
Problem fuel related. Refer to Table
4-5. Engine Performance Problems
under 4.5 INITIAL DIAGNOSTIC
CHECK: EFI.
NO
Repeat voltage drop test after moving negative
lead to terminal 30.
With engine running, is voltage drop less
than 1.0 volt?
YES
Replace system
relay.
NO
Repeat voltage drop test after
moving negative lead to 15 amp ECM
fuse (BE/GY) wire.
With engine running, is voltage drop less than 1.0
volt?
YES
NO
Repair (BE/GY) wire.
Repeat voltage drop test after
moving negative lead to 15 amp ECM
fuse (R) wire.
With engine running, is voltage drop less
than 1.0 volt?
YES
Replace 15 amp
ECM fuse.
NO
6
fc01216_en
Go to Misfire at Idle or
Under Load (Part 3 of 3).
4-64 2009 Sportster Diagnostics: Engine Management
Misfire at Idle or Under Load (Part 3 of 3)
Continued from Misfire at Idle or Under Load (Part 2 of 3).
Repeat voltage drop test after moving negative lead to 30 amp
main fuse (left side).
With engine running, is voltage drop less than 1.0 volt?
YES
Check terminal
or repair wire.
NO
Repeat voltage drop test after
moving negative lead to 30 amp main
fuse (right side).
With engine running, is voltage drop less
than 1.0 volt?
YES
NO
Check terminal
or replace
main fuse.
Repeat voltage drop test after
moving negative lead to starter motor
battery terminal.
With engine running, is voltage drop less
than 1.0 volt?
YES
NO
Repair wire
between main
fuse and starter
motor.
Repair or replace
battery cable.
fc01217_en
2009 Sportster Diagnostics: Engine Management 4-65
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