Harley Davidson Sportster Models 2009. Service Repair Manual — page 45
2.4
SPEEDOMETER/TACHOMETER
GENERAL
. The speedometer on XL and tachometer on
XR consists of a warning display and four status lamps. The
lamps include: check engine, low fuel, battery, and security.
Trip Odometer Reset Switch
. Pressing the trip odometer reset switch provides
the following capabilities:
•
Change the odometer display between mileage, trip A and
trip B values (press and immediately release).
•
Reset an individual trip odometer (press and hold 2-3
seconds).
•
Gain access to the diagnostic mode and clear DTCs. See
•
Display odometer while ignition switch is OFF. Press and
hold trip odometer reset switch while ignition switch is OFF
and odometer mileage will be displayed.
•
On models with dual scale speedometers, toggle between
miles/kilometers on odometer and trip odometer display.
To toggle display, turn ignition switch ON. Press and hold
trip odometer reset switch while odometer is displayed.
Release switch when change is noted. (If trip odometer
reset switch is held while trip odometer is displayed, trip
odometer will reset).
1
2
3
4
5
ed01721
1.
Sixth gear indicator (not used)
2.
Check engine lamp
3.
Low fuel lamp
4.
Battery lamp
5.
Security lamp (key icon)
Figure 2-6. Indicator Lamps (Typical)
ed02816
Figure 2-7. Trip Odometer Reset Switch (Typical)
SPEEDOMETER THEORY OF OPERATION
The speedometer circuit consists of a Vehicle Speed Sensor
(VSS), the ECM, the trip odometer reset switch and the
speedometer. The VSS is mounted on the rear of the engine
crankcase behind the starter motor assembly. The sensor cir-
cuitry is that of a Hall-effect sensor triggered by the gear teeth
of 5th gear on the transmission mainshaft.
The output from the sensor is a series of pulses that are inter-
preted by the ECM circuitry, converted into serial data then
sent to the speedometer. The vehicle speed serial data is also
transmitted to the TSM/TSSM/HFSM for turn signal cancella-
tion.
ODOMETER THEORY OF OPERATION
The odometer mileage is permanently stored and will not be
lost when electrical power is turned off or disconnected. The
trip odometer reset switch allows switching between the odo-
meter, trip odometer A and trip odometer B displays.
To zero the trip odometer, have the desired trip odometer dis-
play visible and press and hold the trip odometer reset switch.
The trip odometer mileage will be displayed for 2-3 seconds
and then the trip mileage will return to zero miles.
The odometer can display six numbers to indicate a maximum
of 999999 miles/kilometers. The trip odometers can display six
numbers with a tenth of a mile accuracy for a maximum of
99999.9 miles/kilometers.
TACHOMETER THEORY OF OPERATION
See
. The tachometer receives serial data from the
ECM. The tachometer interprets the serial data and converts
it into tachometer needle movement.
NOTE
Indicator lamps in the tachometer face may illuminate during
a "WOW" test, even though they do not function during normal
vehicle operation.
2009 Sportster Diagnostics: Instruments 2-15
ed02817
Figure 2-8. Tachometer (Typical)
DIAGNOSTICS
TOOL NAME
PART NUMBER
HARNESS CONNECTOR TEST KIT
HD-41404-B
BREAKOUT BOX
HD-42682
INSTRUMENT HARNESS ADAPTERS
HD-46601
Diagnostic Notes
Each reference number below correlates to a circled number
on the flowchart(s).
1.
If problems are intermittent, wiggle harness while per-
forming tests.
2.
Connect BREAKOUT BOX (Part No. HD-42682) (black)
between tachometer connector [108A] (at the back of the
tachometer) and wire harness connector [108B] using
INSTRUMENT HARNESS ADAPTERS (Part No. HD-
46601). See
.
3.
Use HARNESS CONNECTOR TEST KIT (Part No. HD-
41404-B), black pin probe and patch cord.
1
5
3
2
4
ed01765
1.
Engine temperature lamp
2.
Check engine lamp
3.
Low fuel lamp
4.
Battery lamp
5.
Security lamp
Figure 2-9. Instruments (XR)
BK
BK
BK
BK
BK
O/W
O/W
O/W
O
O
O
LGN/V
LGN/V
LGN/V
BN/GY
BN/GY
BN/GY
BN/V
BN/V
Ignition
Serial data
Battery
Accessory
Ground
1
2
5
6
7
1
2
5
6
7
RPM x 100
Ignition
Serial data
Battery
Accessory
Ground
Trip SW
Trip SW
1
2
6
7
11
12
1
2
4
5
6
7
8
11
1
2
4
5
6
7
8
11
[39A] [39B]
[108A] [108B]
Tachometer
(if equipped)
Speedometer
Odometer
Reset Switch
[20A]
Security LP
em01124
Figure 2-10. Speedometer/Tachometer Circuit (XL)
2-16 2009 Sportster Diagnostics: Instruments
BK
BK
BK
GY
GY
O/W
O/W
O/W
O
O
LGN/V
LGN/V
LGN/V
BN/GY
BN/GY
BN/GY
BN/V
BN/V
Serial Data
Battery
Accessory
Ground
C
B
A
D
C
B
A
D
RPM x 100
Ignition
Serial Data
Battery
Accessory
Ground
Trip/Reset
Trip/Reset
1
2
6
7
11
12
1
2
4
5
6
7
8
11
1
2
4
5
6
7
8
11
[108A] [108B]
[39A] [39B]
Tachometer
Speedometer
Trip/Reset
Switch
[20A]
[154]
Security LP
em01305
Figure 2-11. Speedometer/Tachometer Circuit (XR)
Table 2-5. Wire Harness Connectors
LOCATION
TYPE
DESCRIPTION
NO.
Under fuel tank
12-place Molex
Instruments
[20]
Back of speedometer
12-place Packard
Speedometer (XL)
[39]
Back of speedometer
5-place Packard
Speedometer (XR)
[39]
Back of tachometer
12-place Packard
Tachometer (if equipped)
[108]
2009 Sportster Diagnostics: Instruments 2-17
Tachometer Inoperative (Part 1 of 2)
Perform “WOW” test. See 2.3 ODOMETER
SELF-DIAGNOSTICS.
The following features should be functional
1) backlight should illuminate
2) needle should sweep its full range of motion
3) LED’s may illuminate (XL only):
• cruise (although not cruise equipped)
• pursuit (although not a police vehicle)
Are all features functional?
YES
Is problem intermittent?
YES
NO
Repeat “WOW” test
while wiggling
harnesses.
No trouble
found.
NO
Check for battery voltage at
Breakout Box terminal 1.
Is battery voltage present?
YES
NO
Is instrument
fuse good?
YES
NO
Locate and
repair
source of
fault.
Replace
fuse.
Locate and repair
open in (O) wire
between terminal
1 of connector
[108] and
instrument fuse.
Check for continuity
between Breakout Box
terminal 2 and terminal 7
of connector [20].
Is continuity present?
YES
NO
Locate and
repair open
on (LGN/V)
wire.
3
2
fc01966_en
1
Go to
Tachometer
Inoperative
(Part 2 of 2).
2-18 2009 Sportster Diagnostics: Instruments
Tachometer Inoperative (Part 2 of 2)
Continued from Tachometer Inoperative (Part 1 of 2).
Check for continuity to ground on Breakout Box terminal 7. Wiggle
harness during continuity check.
Is continuity present?
YES
NO
Check for battery voltage at Breakout Box
terminal 5 while wiggling harness.
Is battery voltage continuously present?
Locate and repair open on (BK) wire
between terminal 7 of connector [108]
and ground.
YES
NO
Check for battery voltage at Breakout
Box terminal 6.
Is battery voltage present?
Locate and repair open on (BN/GY)
wire between terminal 5 of connector
[108] and battery fuse.
YES
NO
Replace tachometer.
Locate and repair open
on (O/W) wire between
terminal 6 of connector
[108] and accessory
fuse.
fc01067_en
2009 Sportster Diagnostics: Instruments 2-19
2.5
BREAKOUT BOX:
SPEEDOMETER/TACHOMETER
GENERAL
TOOL NAME
PART NUMBER
BREAKOUT BOX
HD-42682
INSTRUMENT HARNESS ADAPTERS
HD-46601
The BREAKOUT BOX (Part No. HD-42682) and INSTRUMENT
HARNESS ADAPTERS (Part No. HD-46601) connect to the
speedometer connector [39] (XL only) or tachometer connector
[108]. Used in conjunction with a DVOM, the breakout box
allows circuit diagnosis of wiring harness and connections
without having to probe with sharp objects
NOTE
See wiring diagrams for speedometer and tachometer terminal
functions.
SPEEDOMETER: XL ONLY
TOOL NAME
PART NUMBER
BREAKOUT BOX
HD-42682
INSTRUMENT HARNESS ADAPTERS
HD-46601
Installation
1.
. Press latch on connector [39B].
2.
Connect INSTRUMENT HARNESS ADAPTERS (Part
No. HD-46601) to connectors [39A] and [39B].
3.
Attach black connectors from BREAKOUT BOX (Part
No. HD-42682) to INSTRUMENT HARNESS
ADAPTERS (Part No. HD-46601).
Removal
1.
Disconnect BREAKOUT BOX (Part No. HD-42682)from
INSTRUMENT HARNESS ADAPTERS (Part No. HD-
46601).
2.
Detach INSTRUMENT HARNESS ADAPTERS (Part
No. HD-46601) from connectors [39A] and [39B].
3.
See
. Plug wire harness connector [39B] into
speedometer connector [39A].
ed02819
Figure 2-12. Speedomter Connector [39] on XL or
Tachometer Connector [108] on XR (Typical)
TACHOMETER
TOOL NAME
PART NUMBER
BREAKOUT BOX
HD-42682
INSTRUMENT HARNESS ADAPTERS
HD-46601
Installation
1.
Press latch on connector [108B].
2.
Connect INSTRUMENT HARNESS ADAPTERS (Part
No. HD-46601) to connectors [108A] and [108B].
3.
Attach black connectors from BREAKOUT BOX (Part
No. HD-42682) to INSTRUMENT HARNESS
ADAPTERS (Part No. HD-46601).
Removal
1.
Disconnect BREAKOUT BOX (Part No. HD-42682) from
INSTRUMENT HARNESS ADAPTERS (Part No. HD-
46601).
2.
Detach INSTRUMENT HARNESS ADAPTERS (Part
No. HD-46601)from connectors [108A] and [108B].
3.
Plug wire harness connector [108B] into tachometer con-
nector [108A].
2-20 2009 Sportster Diagnostics: Instruments
2.6
INDICATOR LAMPS
GENERAL
See
. All models are equipped with Light Emitting
Diode (LED) indicator lamps, which must be replaced as a
complete assembly with harness.
Job/Time Code Values
Dealership technicians filing warranty claims should use the
job/time code values printed in bold text underneath the
appropriate repair.
2
3
1
ed02820
1.
LED assembly
2.
Release latch (4)
3.
Lamp bezel
Figure 2-13. Indicator Lamp Assembly (Typical)
DIAGNOSTICS
TOOL NAME
PART NUMBER
HARNESS CONNECTOR TEST KIT
HD-41404-B
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.
2009 Sportster Diagnostics: Instruments 2-21
TN
TN
BK
BK
BK
BK
BK
BK
BK
BK
BK
BN
BN
O
O
O
O
O
O
W
W
V
V
GN/Y
GN/Y
3
6
5
4
9
8
12
Main Harness Connector
[20A]
[39A]
[39B]
Speedometer
[108A]
Tachometer
(if equipped)
[108B]
1
7
1
7
1
7
Ignition
Ground
Ground
Ignition
1
7
em01121
Figure 2-14. Indicator Lamp Circuit (XL)
2-22 2009 Sportster Diagnostics: Instruments
TN
TN
BK
BK
BK
BK
BK
BK
BK
BK
BK
BK
BN
BN
O
O
O
O
O
W
W
V
V
GN/Y
GN/Y
3
6
5
4
9
8
12
Main Harness Connector
[20A]
[108A]
[108B]
Speedometer
[39A]
Tachometer
[39B]
1
7
1
7
D
Ground
Ground
Ignition
D
em01306
Figure 2-15. Indicator Lamp Circuit (XR)
Table 2-6. Wire Harness Connectors
LOCATION
TYPE
DESCRIPTION
NO.
Under fuel tank
12-place Molex
Instruments
[20]
Back of speedometer
12-place Packard
Speedometer (XL)
[39]
Back of speedometer
5-place Packard
Speedometer (XR)
[39]
Back of tachometer
12-place Packard
Tachometer (if equipped)
[108]
2009 Sportster Diagnostics: Instruments 2-23
Oil Pressure or Neutral Indicator Will Not Function
Turn on ignition switch. Check for 12 VDC at connector [20B] terminal
6. Turn off ignition switch.
Was 12 VDC present?
1
YES
Check for continuity to ground at Breakout Box terminal 8 (Neutral)
and terminal 9 (oil pressure).
Is continuity present?
YES
Replace indicator
lamp.
NO
Check for open fuses
or locate open circuit.
NO
Check each terminal for continuity
to ground through switch.
Is continuity present?
YES
NO
NO
Repair open in (GN/Y)
wire (oil pressure) or
(TN) wire (neutral).
Replace oil
pressure switch.
Replace neutral
switch.
5048
5191
5048
5161
5157
fc01068_en
2-24 2009 Sportster Diagnostics: Instruments
High Beam or R/L Turn Signal Indicator Will Not Function
Check for ground at connector [20B] terminal 12.
Is ground present?
YES
NO
Check for 12 VDC when circuit is active:
Breakout Box terminal 5 (left turn), terminal 3
(right turn) or terminal 4 (high beam).
Is voltage present?
YES
Replace indicator lamp.
Locate and repair
open in circuit.
NO
Locate and repair
open in circuit.
1
5048
5191
5048
fc01069_en
2009 Sportster Diagnostics: Instruments 2-25
BK
BK
BK
GY
GY
GY
O/W
O/W
O/W
O/W
O
O
O
R
BN/GY
BN/GY
BN/GY
BN/GY
BN/GY
LGN/V
BK
BK
BK
O/W
O
O
BN/GY
LGN/V
LGN/V
LGN/V
LGN/V
LGN/V
LGN/V
R/BK
R/BK
R/GY
1 2
3
12
1 2
3
12
1 2
5
7
6
1 2
5
7
6
1 2
5 6 7
1 2
5 6 7
Ignition
Ser
ial
data
Batter
y
Accessor
y
Ground
Ignition
Ser
ial
Data
Batter
y
Batter
y
Ignition
Ser
ial
Data
Ground
Accessor
y
Ground
Speedometer
TSM/TSSM/HFSM
Tachometer (Optional)
To ACCY Fuse
To BATT Fuse
To INSTR Fuse
To IGN Fuse
12V ACCY
Fuse
12V BATT
Fuse
12V INSTR
Fuse
12V IGN
Fuse
3
1
2
4
Data Link
Connector
2
1
6
7
12
2
1
6
7
12
ECM
Ser
ial
Data
5
5
GND1
GND1
GND1
[78B]
[78A]
[30A]
[30B]
[20A]
[20B]
[108A]
[108B]
[39A]
[39B]
[91A]
Ground
Serial Data
Power
em01120
Figure 4-6. Diagnostic Check (XL)
2009 Sportster Diagnostics: Engine Management 4-13
BK
BK
BK
GY
GY
O/W
O/W
O/W
O/W
O
R
BN/GY
BN/GY
BN/GY
BN/GY
BN/GY
LGN/V
BK
BK
GY
BK
O/W
O
O
O
BN/GY
LGN/V
LGN/V
LGN/V
LGN/V
LGN/V
LGN/V
R/BK
R/BK
R/GY
1 2
3
12
1 2
3
12
1 2
5
7
6
1 2
5
7
6
C
B A D
C
B A D
Ser
ial
Data
Batter
y
Accessor
y
Ground
Ignition
Ser
ial
Data
Batter
y
Batter
y
Ignition
Ser
ial
Data
Ground
Accessor
y
Ground
Speedometer
TSM/TSSM/HFSM
Tachometer
To ACCY Fuse
To BATT Fuse
To INSTR Fuse
To IGN Fuse
12V ACCY
Fuse
12V BATT
Fuse
12V INSTR
Fuse
12V IGN
Fuse
3
1
2
4
Ground
Serial Data
Power
Data Link
Connector
2
1
6
7
12
2
1
6
7
12
ECM
Ser
ial
Data
5
5
GND1
GND1
GND1
[78B]
[78A]
[108A]
[108B]
[20A]
[20B]
[39A]
[39B]
[30A]
[30B]
[91A]
em01304
Figure 4-7. Serial Data Circuit (XR)
Table 4-8. Wire Harness Connectors
LOCATION
TYPE
DESCRIPTION
NO.
Under fuel tank
12-place Molex
Instruments
[20]
Under battery tray
12-place Deutsch
TSM/TSSM/HFSM
[30]
Back of speedometer
12-place Packard
Speedometer (XL)
[39]
Back of speedometer
5-place Packard
Speedometer (XR)
[39]
Under seat
36-place Packard
ECM
[78]
4-14 2009 Sportster Diagnostics: Engine Management
Table 4-8. Wire Harness Connectors
LOCATION
TYPE
DESCRIPTION
NO.
Under left side cover
4-place Deutsch
Data link connector
[91]
Back of tachometer
12-place Packard
Tachometer (if equipped)
[108]
2009 Sportster Diagnostics: Engine Management 4-15
Initial Diagnostic Check (Part 1 of 3)
Does engine
start?
YES.
Starts and runs.
YES.
Starts, then stalls.
NO.
Cranks, but will not start.
NO.
Engine will not crank.
Check for DTCs. See 4.6
ODOMETER
SELF-DIAGNOSTICS.
DTCs found?
See 4.11 STARTS,
THEN STALLS.
See 4.9 ENGINE CRANKS,
BUT WILL NOT START.
See 1.2 STARTING
SYSTEM DIAGNOSIS.
YES
Refer to applicable DTC priority
chart. All DTCs are listed in Table
4-7. DTCs are listed by priority.
NO
Unable to enter
diagnostic mode.
NO
No DTCs
displayed.
With ignition switch OFF, press and
release trip odometer reset switch.
Does odometer display appear with
backlighting?
For a list of symptoms that
may not set DTCs, refer to
Table 3-6.
YES
NO
Check for continuity to ground at
Breakout Box terminal 7 (Black). Wiggle
harness during continuity check.
Is continuity present?
YES
NO
Check for battery voltage at Breakout Box
terminal 5 (Black) while wiggling harness.
Is battery voltage continuously present?
Locate and repair open
between terminal 7 and
ground.
YES
NO
With ignition switch OFF and speedometer
connector [39] on XL or tachometer connector [108]
on XR disconnected, check continuity
between Breakout Box terminals 8 and 11 (Black).
Is continuity present when trip odometer reset
switch is depressed and infinity when released?
Locate and repair open
between terminal 5 and
battery fuse.
YES
NO
Replace
speedometer (XL),
tachometer (XR).
Replace trip odometer
reset switch.
1
2
fc01963_en
Go to Initial Diagnostic
Check (Part 2 of 3).
4-16 2009 Sportster Diagnostics: Engine Management
Initial Diagnostic Check (Part 2 of 3)
Continued from Initial Diagnostic Check (Part 1 of 3).
Turn ignition switch ON.
Is odometer backlight present?
YES
NO
Replace speedometer (XL),
tachometer (XR).
Perform “WOW” test.
See 4.6 ODOMETER SELF-DIAGNOSTICS.
The following features should be functional
1) backlight should illuminate
2) needle should sweep its full range of motion
3) LED’s should illuminate:
• check engine
• battery
• security (all models)
4) LED’s that may illuminate:
• low fuel
• cruise (although not cruise equipped)
Are all features functional?
YES
Turn ignition switch to ACC.
Is backlight present?
YES
NO
Check for battery voltage at
Breakout Box terminal 6 (Black).
Is battery voltage present?
YES
NO
Replace
speedometer (XL),
tachometer (XR).
Is accessory
fuse good?
YES
Locate and repair
source of fault.
Replace fuse.
Locate and repair open
on (O/W) wire between
terminal 6 of connector
[39] on XL, or connector
[108] on XR and
accessory fuse.
2
NO
With ignition switch turned to IGNITION, check for
battery voltage at terminal 1 of Breakout Box.
Is battery voltage present?
YES
NO
Replace speedometer (XL),
tachometer (XR).
Is instrument
fuse good?
YES
NO
Locate and
repair
source of fault.
Replace fuse.
Locate and repair open
between terminal 1 of
connector [39] on XL, or
connector [108] on XR
and
instrument fuse.
2
fc02006_en
NO
Go to Initial
Diagnostic
Check (Part 3 of
3).
2009 Sportster Diagnostics: Engine Management 4-17
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