Harley Davidson Sportster Models 2009. Service Repair Manual — page 41
2009 Harley-Davidson Sportster Models
Electrical Diagnostic Manual
99495-09
Harley-Davidson motorcycles conform to all applicable U.S.A. Federal Motor Vehicle Safety Standards
and U.S.A. Environmental Protection Agency regulations effective on the date of manufacture.
To maintain the safety, dependability, and emission and noise control performance, it is essential that
the procedures, specifications and service instructions in this manual are followed.
Any substitution, alteration or adjustment of emission system and noise control components outside of
factory specifications may be prohibited by law.
IMPORTANT NOTICE
Harley-Davidson Motor Company
2009 Harley-Davidson
Sportster Models Electrical
Diagnostic Manual
ALL RIGHTS RESERVED
99495-09
Printed in the U.S.A.
VISIT THE HARLEY-DAVIDSON WEB SITE
http://www.harley-davidson.com
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2009 Harley-Davidson Sportster Models Electrical Diagnostic Manual (99495-09)
NOTES
ABOUT THIS MANUAL
GENERAL
This electrical diagnostic service manual has been prepared
with two purposes in mind. First, it will acquaint the user with
the construction of the Harley-Davidson product and assist in
the performance of repair. Secondly, it will introduce to the
professional Harley-Davidson Technician the latest field-tested
and factory-approved diagnostic methods. We sincerely believe
that this manual will make your association with Harley-Dav-
idson products more pleasant and profitable.
HOW TO USE YOUR SERVICE MANUAL
Refer to the table below for the content layout of this manual.
CHAPTER
NO.
Starting / Charging
1
Instruments
2
TSM/HFSM
3
Engine Management
4
Appendix A Connector Repair
A
Appendix B Wiring
B
Appendix C Conversions
C
Appendix D Glossary
D
Appendix E TSM/TSSM (Japan/Korea)
E
Use the TABLE OF CONTENTS (which follows this FORE-
WORD) and the INDEX (at the back of this manual) to quickly
locate subjects. Sections and topics in this manual are
sequentially numbered for easy navigation.
For example, a cross-reference shown as 2.1 SPECIFICA-
TIONS refers to chapter 2 CHASSIS, heading 2.1 SPECIFIC-
ATIONS.
For quick and easy reference, all pages contain a section
number followed by a page number. For example, page 3-5
refers to page 5 in section 3.
A number of acronyms and abbreviations are used in this
document. See the
for a list of acronyms,
abbreviations and definitions.
PREPARATION FOR SERVICE
Stop the engine when refueling or servicing the fuel
system. Do not smoke or allow open flame or sparks near
gasoline. Gasoline is extremely flammable and highly
explosive, which could result in death or serious injury.
(00002a)
Good preparation is very important for efficient service work.
A clean work area at the start of each job will allow you to
perform the repair as easily and quickly as possible, and will
reduce the incidence of misplaced tools and parts. A motorcycle
that is excessively dirty should be cleaned before work starts.
Cleaning will occasionally uncover sources of trouble. Tools,
instruments and any parts needed for the job should be
gathered before work is started. Interrupting a job to locate
tools or parts is a distraction and causes needless delay.
NOTES
•
To avoid unnecessary disassembly, carefully read all rel-
ative service information before repair work is started.
•
In figure legends, the number which follows the name of
a part indicates the quantity necessary for one complete
assembly.
•
When servicing a vehicle equipped with the Harley-Dav-
idson Smart Security System (H-DSSS), you must first
disarm the security system. Either keep the fob in close
proximity to the vehicle, or use Digital Technician II to
disable the security system while the vehicle is being ser-
viced and re-enable the system after service is completed.
SERVICE BULLETINS
In addition to the information presented in this Service Manual,
Harley-Davidson Motor Company will periodically issue Service
Bulletins to Harley-Davidson dealers. Service Bulletins cover
interim engineering changes and supplementary information.
Consult the Service Bulletins to keep your product knowledge
current and complete.
USE GENUINE REPLACEMENT PARTS
Do not use aftermarket parts and custom made front forks
which can adversely affect performance and handling.
Removing or altering factory installed parts can adversely
affect performance and could result in death or serious
injury. (00001a)
To ensure satisfactory and lasting repairs, carefully follow the
Service Manual instructions and use only genuine Harley-
Davidson replacement parts. Behind the emblem bearing the
words GENUINE HARLEY-DAVIDSON stand more than 100
years of design, research, manufacturing, testing and inspecting
experience. This is your assurance that the parts you are using
will fit right, operate properly and last longer.
WARNINGS AND CAUTIONS
Statements in this service manual preceded by the following
words are of special significance.
WARNING indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury. (00119a)
CAUTION indicates a potentially hazardous situation
which, if not avoided, may result in minor or moderate
injury. (00139a)
CAUTION used without the safety alert symbol indicates
a potentially hazardous situation which, if not avoided,
may result in property damage. (00140a)
I
FOREW
ORD
NOTE
Refers to important information, and is placed in italic type. It
is recommended that you take special notice of these items.
Proper service and repair is important for the safe, reliable
operation of all mechanical products. The service procedures
recommended and described in this service manual are
effective methods for performing service operations.
Always wear proper eye protection when using hammers,
arbor or hydraulic presses, gear pullers, spring com-
pressors, slide hammers and similar tools. Flying parts
could result in death or serious injury. (00496b)
Some of these service operations require the use of tools
specially designed for the purpose. These special tools should
be used when and as recommended. It is important to note
that some warnings against the use of specific service methods,
which could damage the motorcycle or render it unsafe, are
stated in this service manual. However, please remember that
these warnings are not all-inclusive. Inadequate safety precau-
tions could result in death or serious injury.
Since Harley-Davidson could not possibly know, evaluate or
advise the service trade of all possible ways in which service
might be performed, or of the possible hazardous con-
sequences of each method, we have not undertaken any such
broad evaluation. Accordingly, anyone who uses a service
procedure or tool which is not recommended by Harley-Dav-
idson must first thoroughly satisfy himself that neither his nor
the operator's safety will be jeopardized as a result. Failure to
do so could result in death or serious injury.
PRODUCT REFERENCES
Read and follow warnings and directions on all products.
Failure to follow warnings and directions can result in
death or serious injury. (00470b)
When reference is made in this manual to a specific brand
name product, tool or instrument, an equivalent product, tool
or instrument may be substituted.
Kent-Moore Products
All tools mentioned in this manual with an "HD", "J" or "B"
preface must be ordered through SPX Kent-Moore. For ordering
information or product returns, warranty or otherwise, visit
www.spx.com.
Loctite Sealing and Threadlocking Products
Some procedures in this manual call for the use of Loctite
products. If you have any questions regarding Loctite product
usage or retailer/wholesaler locations, please contact Loctite
Corp. at www.loctite.com.
PRODUCT REGISTERED MARKS
Allen, Amp Multilock, Bluetooth, Brembo, Delphi, Deutsch,
Dunlop, Dynojet, Fluke, G.E. Versilube, Gunk, Hydroseal,
Hylomar, Kevlar, Lexan, Loctite, Lubriplate, Keps, K&N, Mag-
naflux, Marson Thread-Setter Tool Kit, MAXI fuse, Molex, MPZ,
Mulitilock, Novus, Packard, Pirelli, Permatex, Philips, PJ1,
Pozidriv, Robinair, S100, Sems, Snap-on, Teflon, Threadlocker,
Torca, Torco, TORX, Tufoil, Tyco, Ultratorch, Velcro, X-Acto,
and XM Satellite Radio are among the trademarks of their
respective owners.
H-D MICHIGAN, INC. TRADEMARK
INFORMATION
Harley, Harley-Davidson, H-D, Bar & Shield, Cross Bones,
Digital Tech, Digital Technician, Digital Technician II, Dyna,
Electra Glide, Evolution, Fat Bob, Fat Boy, Glaze, Gloss, H-D,
H-Dnet.com, HD, Harley, Harley-Davidson, Heritage Softail,
Low Rider, Night Rod, Nightster, Night Train, Profile, Revolu-
tion, Road Glide, Road King, Road Tech, Rocker, Softail,
Sportster, Street Glide, Street Rod, Sun Ray, Sunwash, Tech
Link, Twin Cam 88, Twin Cam 88B, Twin Cam 96, Twin Cam
96B, Twin Cam 103, Twin Cam 103B, Twin Cam 110, Twin
Cam 110B, Tour-Pak, Screamin' Eagle, Softail, Super Glide,
SYN3, Ultra Classic, V-Rod, VRSC and Harley-Davidson
Genuine Motor Parts and Genuine Motor Accessories are
among the trademarks of H-D Michigan, Inc.
CONTENTS
All photographs, illustrations and procedures may not neces-
sarily depict the most current model or component, but are
based on the latest production information available at the time
of publication.
Since product improvement is our continual goal, Harley-Dav-
idson reserves the right to change specifications, equipment
or designs at any time without notice and without incurring
obligation.
II FOREWORD
Diagnostics. . . . . . . . . . . . . . . . . . .1-3
Diagnostic Notes. . . . . . . . . . . . . . .1-3
Job/Time Code Values. . . . . . . . . . . . 1-3
1.3 DIAGNOSTICS/TROUBLESHOOTING
Voltage Drop. . . . . . . . . . . . . . . . . .1-11
1.4 STARTER ACTIVATION CIRCUITS
Starter Activation Circuits. . . . . . . . . . . . .1-12
1.5 TESTING STARTER ON MOTORCYCLE
Armature. . . . . . . . . . . . . . . . ...1-16
Brushes and Brush Holder. . . . . . . . . . 1-18
General. . . . . . . . . . . . . . . . . . . .1-20
Alternator. . . . . . . . . . . . . . . . ...1-20
Voltage Regulator. . . . . . . . . . . . . ..1-20
Troubleshooting. . . . . . . . . . . . . . . . 1-20
Battery. . . . . . . . . . . . . . . . . ...1-20
Wiring. . . . . . . . . . . . . . . . . . 1-20
Testing. . . . . . . . . . . . . . . . . . . ..1-24
2.1 CHECKING FOR DIAGNOSTIC TROUBLE
CODES
Code Types. . . . . . . . . . . . . . . . . . .2-3
Current. . . . . . . . . . . . . . . . . . 2-3
Historic. . . . . . . . . . . . . . . . . . 2-3
2.2 INITIAL DIAGNOSTIC CHECK:
ODOMETER
General. . . . . . . . . . . . . . . . . . . ...2-4
Initial Diagnostics. . . . . . . . . . . . . . . ...2-5
Diagnostic Tips. . . . . . . . . . . . . . ..2-13
Diagnostic Notes. . . . . . . . . . . . . ...2-13
General. . . . . . . . . . . . . . . . . . . .2-15
Trip Odometer Reset Switch. . . . . . . . . .2-15
Diagnostic Notes. . . . . . . . . . . . . ...2-16
2.5 BREAKOUT BOX:
SPEEDOMETER/TACHOMETER
Installation. . . . . . . . . . . . . . . . .2-20
Removal. . . . . . . . . . . . . . . . . 2-20
Tachometer. . . . . . . . . . . . . . . . . ...2-20
Installation. . . . . . . . . . . . . . . . .2-20
Removal. . . . . . . . . . . . . . . . . 2-20
General. . . . . . . . . . . . . . . . . . . .2-21
Job/Time Code Values. . . . . . . . . . . ..2-21
Diagnostics. . . . . . . . . . . . . . . . . ...2-21
Diagnostic Notes. . . . . . . . . . . . . ...2-21
Diagnostic Tips. . . . . . . . . . . . . . ..2-26
Diagnostic Notes. . . . . . . . . . . . . ...2-26
General. . . . . . . . . . . . . . . . . . . .2-30
Accessory or Ignition Line Overvoltage. . . . . .2-30
General. . . . . . . . . . . . . . . . . . . .2-32
Trip Odometer Reset Switch Closed. . . . . . .2-32
Diagnostics. . . . . . . . . . . . . . . . . ...2-32
Diagnostic Notes. . . . . . . . . . . . . ...2-32
General. . . . . . . . . . . . . . . . . . . .2-34
III
T
ABLE OF CONTENTS
Loss of ECM Serial Data. . . . . . . . . . ...2-34
Diagnostics. . . . . . . . . . . . . . . . . ...2-34
Diagnostic Notes. . . . . . . . . . . . . ...2-34
General. . . . . . . . . . . . . . . . . . . .2-39
Loss of TSM/TSSM/HFSM Serial Data. . . . . .2-39
Diagnostics. . . . . . . . . . . . . . . . . ...2-39
Diagnostic Notes. . . . . . . . . . . . . ...2-39
2.12 DTC U1300, U1301 OR BUS ER
General. . . . . . . . . . . . . . . . . . . .2-44
Serial Data Low or Serial Data Open/High. . . . 2-44
Diagnostics. . . . . . . . . . . . . . . . . ...2-44
Diagnostic Tips. . . . . . . . . . . . . . ..2-44
Diagnostic Notes. . . . . . . . . . . . . ...2-44
3.2 HARLEY-DAVIDSON SMART SECURITY
SYSTEM
3.4 PERSONAL IDENTIFICATION NUMBER
(PIN)
Modifying an Existing Pin. . . . . . . . . . . 3-6
3.5 ARMING/DISARMING SECURITY
SYSTEM
Warnings. . . . . . . . . . . . . . . . . . ..3-10
Alarm. . . . . . . . . . . . . . . . . . . . 3-10
Activation. . . . . . . . . . . . . . . . ...3-10
Deactivation. . . . . . . . . . . . . . . ...3-10
Siren Chirp Mode (Confirmation). . . . . . . . . ..3-10
3.7 SERVICE/EMERGENCY FUNCTIONS
Transport Mode. . . . . . . . . . . . . . . . 3-11
3.9 CHECKING FOR DIAGNOSTIC TROUBLE
CODES
Current. . . . . . . . . . . . . . . . . ..3-14
Historic. . . . . . . . . . . . . . . . . ..3-14
3.10 INITIAL DIAGNOSTIC CHECK:
TSM/HFSM
General. . . . . . . . . . . . . . . . . . . .3-16
Initial Diagnostics. . . . . . . . . . . . . . . .3-16
3.11 ODOMETER SELF-DIAGNOSTICS
Diagnostic Tips. . . . . . . . . . . . . . ..3-24
Diagnostic Notes. . . . . . . . . . . . . ...3-24
IV TABLE OF CONTENTS
TABLE OF CONTENTS
3.13 FAILS TO DISARM (HFSM ONLY)
Diagnostic Tips. . . . . . . . . . . . . . ..3-28
Diagnostic Notes. . . . . . . . . . . . . ...3-28
Diagnostic Tips. . . . . . . . . . . . . . ..3-31
Diagnostic Notes. . . . . . . . . . . . . ...3-31
3.15 TSM/HFSM: TURN SIGNAL ERRORS
AND DTCS
3.16 DTC B1131, B1132 (HFSM ONLY)
Diagnostic Tips. . . . . . . . . . . . . . ..3-48
Diagnostic Notes. . . . . . . . . . . . . ...3-48
Diagnostic Notes. . . . . . . . . . . . . ...3-51
3.18 DTCS B1135, B1136, B1141, AND B1142
Diagnostics. . . . . . . . . . . . . . . . . ...3-54
DTC B1135 Accelerometer Fault. . . . . . . ..3-54
Diagnostic Notes. . . . . . . . . . . . . ...3-54
3.19 DTC B1143, B1144, B1145 (HFSM
ONLY)
General. . . . . . . . . . . . . . . . . . . .3-58
Diagnostics. . . . . . . . . . . . . . . . . ...3-58
Diagnostic Notes. . . . . . . . . . . . . ...3-58
Diagnostics. . . . . . . . . . . . . . . . . ...3-61
Diagnostic Tips. . . . . . . . . . . . . . ..3-61
Diagnostic Notes. . . . . . . . . . . . . ...3-61
Diagnostic Notes. . . . . . . . . . . . . ...3-65
3.22 DTC U1300, U1301 OR BUS ER
Diagnostics. . . . . . . . . . . . . . . . . ...3-70
Diagnostic Tips. . . . . . . . . . . . . . ..3-70
Diagnostic Notes. . . . . . . . . . . . . ...3-70
Schedule. . . . . . . . . . . . . . . . ...3-72
Battery Replacement. . . . . . . . . . . . .3-72
Smart Siren (If Installed). . . . . . . . . . . . ...3-72
Specifications. . . . . . . . . . . . . . . . . .4-1
4.3 EFI DIAGNOSTIC INTRODUCTION
System Problems. . . . . . . . . . . . . . . ...4-5
Resolving Problems. . . . . . . . . . . . . . . 4-5
4.4 CHECKING FOR DIAGNOSTIC TROUBLE
CODES: EFI
Current. . . . . . . . . . . . . . . . . . 4-7
Historic. . . . . . . . . . . . . . . . . . 4-7
4.5 INITIAL DIAGNOSTIC CHECK: EFI
General. . . . . . . . . . . . . . . . . . . ...4-9
Initial Diagnostics. . . . . . . . . . . . . . . ...4-9
Diagnostic Tips. . . . . . . . . . . . . . ..4-20
Diagnostic Notes. . . . . . . . . . . . . ...4-20
TABLE OF CONTENTS V
TABLE OF CONTENTS
4.9 ENGINE CRANKS, BUT WILL NOT
START
Diagnostic Notes. . . . . . . . . . . . . ...4-24
Diagnostic Tips. . . . . . . . . . . . . . ..4-24
General. . . . . . . . . . . . . . . . . . . .4-31
No Spark/No Check Engine Lamp at Key On. . . 4-31
Diagnostics. . . . . . . . . . . . . . . . . ...4-31
Diagnostic Notes. . . . . . . . . . . . . ...4-31
General. . . . . . . . . . . . . . . . . . . .4-36
Diagnostic Trouble Codes U1300, U1301, or BUS
ER. . . . . . . . . . . . . . . . . . . .4-36
Diagnostics. . . . . . . . . . . . . . . . . ...4-36
Diagnostic Tips. . . . . . . . . . . . . . ..4-36
Diagnostic Notes. . . . . . . . . . . . . ...4-36
4.12 FUEL SYSTEM ELECTRICAL TEST
Diagnostic Notes. . . . . . . . . . . . . ...4-42
General. . . . . . . . . . . . . . . . . . . .4-50
System Relay. . . . . . . . . . . . . . . 4-50
Diagnostics. . . . . . . . . . . . . . . . . ...4-50
Diagnostic Notes. . . . . . . . . . . . . ...4-50
General. . . . . . . . . . . . . . . . . . . .4-55
Diagnostics. . . . . . . . . . . . . . . . . ...4-55
Diagnostic Tips. . . . . . . . . . . . . . ..4-55
Diagnostic Notes. . . . . . . . . . . . . ...4-55
4.15 MISFIRE AT IDLE OR UNDER LOAD
General. . . . . . . . . . . . . . . . . . . .4-60
Misfire at Idle or Under Load. . . . . . . . . .4-60
Diagnostics. . . . . . . . . . . . . . . . . ...4-60
Diagnostic Notes. . . . . . . . . . . . . ...4-60
4.16 DTC P0107, P0108, P0112, P0113
General. . . . . . . . . . . . . . . . . . . .4-66
MAP Signal. . . . . . . . . . . . . . . ...4-66
IAT Signal. . . . . . . . . . . . . . . . ..4-66
Diagnostics. . . . . . . . . . . . . . . . . ...4-66
General. . . . . . . . . . . . . . . . . . . .4-73
ET Sensor. . . . . . . . . . . . . . . . .4-73
Diagnostics. . . . . . . . . . . . . . . . . ...4-73
Diagnostic Tips. . . . . . . . . . . . . . ..4-73
Diagnostic Notes. . . . . . . . . . . . . ...4-73
General. . . . . . . . . . . . . . . . . . . .4-77
TP Sensor. . . . . . . . . . . . . . . . .4-77
Diagnostics. . . . . . . . . . . . . . . . . ...4-77
Diagnostic Tips. . . . . . . . . . . . . . ..4-77
Diagnostic Notes. . . . . . . . . . . . . ...4-78
4.19 DTC P0131, P0132, P0134, P0151,
P0152, P0154
General. . . . . . . . . . . . . . . . . . . .4-82
Oxygen Sensor. . . . . . . . . . . . . . .4-82
Diagnostics. . . . . . . . . . . . . . . . . ...4-82
Diagnostic Tips. . . . . . . . . . . . . . ..4-82
Diagnostic Notes. . . . . . . . . . . . . ...4-82
4.20 DTC P0261, P0262, P0263, P0264
General. . . . . . . . . . . . . . . . . . . .4-87
Fuel Injectors. . . . . . . . . . . . . . . .4-87
Diagnostics. . . . . . . . . . . . . . . . . ...4-87
Diagnostic Notes. . . . . . . . . . . . . ...4-87
General. . . . . . . . . . . . . . . . . . . .4-93
CKP Sensor. . . . . . . . . . . . . . . ..4-93
Diagnostics. . . . . . . . . . . . . . . . . ...4-93
Diagnostic Tips. . . . . . . . . . . . . . ..4-93
Diagnostic Notes. . . . . . . . . . . . . ...4-93
General. . . . . . . . . . . . . . . . . . . .4-96
Vehicle Speed Sensor (VSS). . . . . . . . . 4-96
Diagnostics. . . . . . . . . . . . . . . . . ...4-96
Diagnostic Notes. . . . . . . . . . . . . ...4-96
General. . . . . . . . . . . . . . . . . . ...4-100
Battery Voltage. . . . . . . . . . . . . . 4-100
Diagnostics. . . . . . . . . . . . . . . . . .4-100
Diagnostic Tips. . . . . . . . . . . . . . 4-100
Diagnostic Notes. . . . . . . . . . . . . .4-100
General. . . . . . . . . . . . . . . . . . ...4-104
ECM Failure. . . . . . . . . . . . . . . 4-104
Diagnostics. . . . . . . . . . . . . . . . . .4-104
DTC P0603. . . . . . . . . . . . . . . .4-104
DTC P0605. . . . . . . . . . . . . . . .4-104
VI TABLE OF CONTENTS
TABLE OF CONTENTS
General. . . . . . . . . . . . . . . . . . ...4-105
Active Intake Solenoid (HDI XR Models Only). . 4-105
Diagnostics. . . . . . . . . . . . . . . . . .4-105
Diagnostic Notes. . . . . . . . . . . . . .4-105
General. . . . . . . . . . . . . . . . . . ...4-109
Password Problem. . . . . . . . . . . . ..4-109
Diagnostics. . . . . . . . . . . . . . . . . .4-109
Diagnostic Notes. . . . . . . . . . . . . .4-109
4.27 DTC P1351, P1352, P1354, P1355
General. . . . . . . . . . . . . . . . . . ...4-114
Ignition Coil. . . . . . . . . . . . . . . .4-114
Diagnostics. . . . . . . . . . . . . . . . . .4-114
Diagnostic Notes. . . . . . . . . . . . . .4-114
General. . . . . . . . . . . . . . . . . . ...4-119
Jiffy Stand Sensor (HDI). . . . . . . . . . ..4-119
Diagnostics. . . . . . . . . . . . . . . . . .4-119
Diagnostic Notes. . . . . . . . . . . . . .4-119
General. . . . . . . . . . . . . . . . . . ...4-124
Loss of TSM/TSSM/HFSM Serial Data. . . . ...4-124
Diagnostics. . . . . . . . . . . . . . . . . .4-124
Diagnostic Notes. . . . . . . . . . . . . .4-124
General. . . . . . . . . . . . . . . . . . ...4-129
Loss of Speedometer Serial Data. . . . . . ...4-129
Diagnostics. . . . . . . . . . . . . . . . . .4-129
Diagnostic Notes. . . . . . . . . . . . . .4-129
Low Fuel Pressure. . . . . . . . . . . . ..4-134
High Fuel Pressure. . . . . . . . . . . . ..4-134
AMP Multilock Connector Repair. . . . . . . . . ...A-1
Delphi Connector Repair. . . . . . . . . . . . . A-6
A.3 DEUTSCH 1-PLACE ELECTRICAL
CONNECTORS
Deutsch 1-Place Connector Repair. . . . . . . . . A-8
A.4 DEUSCH ELECTRICAL CONNECTORS
Deutsch Connector Repair. . . . . . . . . . . . .A-9
A.5 DEUTSCH STANDARD TERMINALS
Deutsch Standard Terminal Crimps. . . . . . . . .A-13
A.6 DEUTSCH MINI-TERMINAL CRIMPS
Deutsch Mini Terminal Crimps. . . . . . . . . . .A-14
A.7 DEUTSCH SOLID BARREL TERMINALS
Deutsch Solid Barrel Terminal Crimps. . . . . . . .A-15
Fuse Block Repair. . . . . . . . . . . . . . . A-17
Metri-Pack Connector Repair. . . . . . . . . A-18
A.10 280 METRI-PACK CONNECTORS
Metri-Pack Connector Repair. . . . . . . . . A-20
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TABLE OF CONTENTS
A.11 480 METRI-PACK CONNECTORS
Metri-Pack Connector Repair. . . . . . . . . A-22
A.12 630 METRI-PACK CONNECTORS
Metri-Pack Connector Repair. . . . . . . . . A-23
A.13 800 METRI-PACK CONNECTORS
Delphi Main Fuse Housing Repair. . . . . . . . ...A-24
Metri-Pack Terminal Crimps. . . . . . . . . . . .A-26
Molex Connector Repair. . . . . . . . . . . . ..A-28
Packard 100W Connector Repair. . . . . . . . . .A-30
A.17 PACKARD MICRO-64 CONNECTORS
Packard Micro-64 Connector Repair. . . . . . . . A-32
Sealed Splice Connector Repair. . . . . . . . . ..A-35
Connector Locations. . . . . . . . . . . . . . ..B-1
Wiring Diagram Information. . . . . . . . . . . ...B-3
Wire Color Codes. . . . . . . . . . . . . . B-3
Wiring Diagram Symbols. . . . . . . . . . . B-3
Sportster Wiring Diagrams. . . . . . . . . . B-4
Conversion Table. . . . . . . . . . . . . . . . C-1
Acronyms and Abbreviations. . . . . . . . . . . .D-1
APPENDIX E TSM/TSSM
(JAPAN/KOREA)
E.1 TSM/TSSM (JAPAN/KOREA) OVERVIEW
General. . . . . . . . . . . . . . . . . . . ..E-1
TSM. . . . . . . . . . . . . . . . . . . E-1
TSSM. . . . . . . . . . . . . . . . . . ..E-1
Troubleshooting. . . . . . . . . . . . . . . . ..E-1
Turn Signal Functions. . . . . . . . . . . . . . E-2
TSM/TSSM Features. . . . . . . . . . . . ..E-2
TSM/TSSM Features. . . . . . . . . . . . ..E-2
Security Alarm and Immobilization Functions. . . . . E-2
TSSM Feature. . . . . . . . . . . . . . . .E-2
VIII TABLE OF CONTENTS
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E.6 SECURITY SYSTEM FUNCTIONS (TSSM
ONLY)
General. . . . . . . . . . . . . . . . . . . E-10
Alarm Sensitivity: TSSM. . . . . . . . . . . . ...E-10
Sensitivity. . . . . . . . . . . . . . . . ..E-10
Transport Mode. . . . . . . . . . . . . . .E-11
E.7 ARMING/DISARMING (TSSM ONLY)
Using the Pin. . . . . . . . . . . . . . . . . E-13
General. . . . . . . . . . . . . . . . . .E-13
Disarming the System. . . . . . . . . . . ...E-13
E.8 DIAGNOSTIC TROUBLE CODES (DTC)
TSM/TSSM. . . . . . . . . . . . . . . . . ..E-15
Code Types. . . . . . . . . . . . . . . . . ..E-16
Current. . . . . . . . . . . . . . . . . ..E-16
Historic. . . . . . . . . . . . . . . . . ..E-16
E.9 INITIAL DIAGNOSTIC CHECK:
TSM/TSSM
General. . . . . . . . . . . . . . . . . . . E-18
Initial Diagnostics. . . . . . . . . . . . . . . .E-18
Diagnostic Tips. . . . . . . . . . . . . . .E-18
Diagnostic Notes. . . . . . . . . . . . . ...E-18
Other DTCs. . . . . . . . . . . . . . . ...E-18
E.10 ODOMETER SELF-DIAGNOSTICS
Diagnostic Tips. . . . . . . . . . . . . . .E-26
Diagnostic Notes. . . . . . . . . . . . . ...E-26
E.12 FAILS TO DISARM (TSSM ONLY)
General. . . . . . . . . . . . . . . . . . . E-30
Security Equipped Vehicles Only. . . . . . . ..E-30
Job/Time Code Values. . . . . . . . . . . ..E-30
Diagnostics. . . . . . . . . . . . . . . . . ..E-30
Diagnostic Tips. . . . . . . . . . . . . . .E-30
Diagnostic Notes. . . . . . . . . . . . . ...E-30
E.13 TURN SIGNAL ERRORS: B1121, B1122,
B1141
General. . . . . . . . . . . . . . . . . . . E-33
Job/Time Code Values. . . . . . . . . . . ..E-33
Diagnostics. . . . . . . . . . . . . . . . . ..E-33
General. . . . . . . . . . . . . . . . . . . E-46
Battery Voltage High. . . . . . . . . . . . .E-46
Diagnostics. . . . . . . . . . . . . . . . . ..E-46
Diagnostic Tips. . . . . . . . . . . . . . .E-46
Diagnostic Notes. . . . . . . . . . . . . ...E-46
General. . . . . . . . . . . . . . . . . . . E-47
Alarm Output Low (DTC B1131) or Alarm Output High
(DTC B1132). . . . . . . . . . . . . . . .E-47
Diagnostics. . . . . . . . . . . . . . . . . ..E-47
Diagnostic Tips. . . . . . . . . . . . . . .E-47
Diagnostic Notes. . . . . . . . . . . . . ...E-47
General. . . . . . . . . . . . . . . . . . . E-50
Starter Output High. . . . . . . . . . . . ...E-50
Diagnostics. . . . . . . . . . . . . . . . . ..E-50
Diagnostic Notes. . . . . . . . . . . . . ...E-50
General. . . . . . . . . . . . . . . . . . . E-53
Accelerometer Fault: B1135. . . . . . . . . ..E-53
TABLE OF CONTENTS IX
TABLE OF CONTENTS
General. . . . . . . . . . . . . . . . . . . E-58
Loss of ECM Serial Data. . . . . . . . . . ..E-58
Diagnostics. . . . . . . . . . . . . . . . . ..E-58
Diagnostic Notes. . . . . . . . . . . . . ...E-58
E.20 DTC U1300, U1301 OR BUS ER
General. . . . . . . . . . . . . . . . . . . E-63
Serial Data Low or Serial Data Open/High. . . ...E-63
Diagnostics. . . . . . . . . . . . . . . . . ..E-63
Diagnostic Tips. . . . . . . . . . . . . . .E-63
Diagnostic Notes. . . . . . . . . . . . . ...E-63
General. . . . . . . . . . . . . . . . . . . E-65
Key FOB. . . . . . . . . . . . . . . . . . ...E-65
Schedule. . . . . . . . . . . . . . . . ...E-65
Battery Replacement. . . . . . . . . . . . E-65
Siren (If Installed). . . . . . . . . . . . . . . .E-65
REFERENCE MATERIAL
TOOLS. . . . . . . . . . . . . . ...I
TORQUE VALUES. . . . . . . . . . V
INDEX. . . . . . . . . . . . . . .VII
X TABLE OF CONTENTS
TABLE OF CONTENTS
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