Harley Davidson Sportster Models 2009. Service Repair Manual — page 81
3.22
DTC U1300, U1301 OR BUS ER
DIAGNOSTICS
The typical serial data voltage range is 0 volts (inactive) to 7
volts (active). Due to the short pulse, voltages will be much
lower on a DVOM. In analog mode, a DVOM reading serial
data will show continuous voltage when active, typically 0.6-
0.8 volts. The range for acceptable operations is 0-7.0 volts.
Diagnostic Tips
•
If serial data is shorted, these Diagnostic Trouble Codes
(DTCs) will automatically cause the check engine lamp to
illuminate. The odometer will read "BUS Er" in this condi-
tion.
•
DTCs P1009 and P1010 may accompany DTCs U1300
and U1301.
Diagnostic Notes
If a U1300, U1301 or "BUS Er" is present, perform diagnostic
procedures listed in
.
ed01340
Figure 3-34. Data Link Connector [91A]
Table 3-25. Code Description
START WITH FLOWCHART
DESCRIPTION
DTC
Serial data low
U1300
Serial data open/high
U1301
3-70 2009 Sportster Diagnostics: TSM/HFSM
3.23
TSM/HFSM: PASSWORD LEARN
GENERAL
If the ECM or TSM/HFSM is faulty, follow the instructions in
the service manual for ECM or TSM/HFSM replacement. Then,
to determine if password learn is necessary, refer to
Table 3-26. Password Learn
IS PASSWORD LEARN
NECESSARY?
DEVICE REPLACED
Yes
ECM
No *
TSM
Yes
TSM/HFSM
* If a TSM has been replaced by a HFSM, or a HFSM has
been replaced by a TSM, password learn is necessary.
PASSWORD LEARNING
TOOL NAME
PART NUMBER
DIGITAL TECHNICIAN II
HD-48650
To perform password learning procedure, refer to
When finished, continue with all instructions under
.
Always perform all appropriate instructions under
after TSM/HFSM replacement or removal.
NOTE
Fob assignment must be performed at an authorized Harley-
Davidson dealer using DIGITAL TECHNICIAN II (Part No. HD-
48650).
Table 3-27. Setting TSM/HFSM and ECM Password
NOTES
CONFIRMATION
ACTION
NO.
With Ignition Switch turned off,
Check Engine Lamp and
Security Lamp will be off.
Ignition must be turned off for at least 15 seconds.
Install new TSM/HFSM or ECM. Perform all steps under
.
1
Set Engine Stop Switch to RUN.
2
TSM/HFSM enables start
relay.
Verify Check Engine Lamp
and Security Lamp illuminate
and then turn off.
Turn Ignition Switch ON.
3
Password has not been
learned. ECM sets DTC
P1009.
Engine starts and stalls.
Check Engine Lamp illumin-
ates and stays on.
Attempt normal start one time.
4
ECM enters Password
Learning mode for ten
minutes. Do not cycle Ignition
Switch or interrupt vehicle
power or Password Learn will
be unsuccessful.
Security Lamp illuminates.
Wait ten seconds. Security Lamp will illuminate and stay
on.
5
This takes ten minutes.
Wait until Security Lamp turns off.
6
ECM must not be allowed to
shutdown.
Quickly (within two seconds) turn Ignition Switch
OFF-ON.
7
This takes ten minutes.
Wait until Security Lamp turns off.
8
ECM must not be allowed to
shutdown.
Quickly (within two seconds) turn Ignition Switch
OFF-ON.
9
This takes ten minutes.
Wait until Security Lamp turns off.
10
ECM must not be allowed to
shutdown.
Quickly (within two seconds) turn Ignition Switch
OFF-ON.
11
Turn Ignition Switch OFF. Wait 15 seconds before
turning Ignition Switch on. Turn Ignition Switch ON and
start engine to confirm successful Password Learn
procedure. Clear DTCs.
12
Perform all steps under
13
2009 Sportster Diagnostics: TSM/HFSM 3-71
3.24
HFSM MAINTENANCE
GENERAL
The HFSM uses a battery in the fob and siren. These are the
only parts requiring periodic maintenance.
HANDS-FREE FOB
Schedule
Replace the fob battery every year.
Battery Replacement
1.
. Open the fob case.
a.
Place a thin blade in the thumbnail slot (1) between
the 2 halves of the case.
b.
Slowly twist the blade.
2.
Replace battery (2).
a.
Remove the original battery.
b.
Install a new battery with the positive (+) side down.
Use a Panasonic® 2032 or equivalent.
3.
With O-ring (3) in place, align case halves and snap case
halves together.
1
2
3
1
ed02055
1.
Thumbnail slot
2.
Battery (Panasonic 2032)
3.
O-ring
Figure 3-35. Open Fob: HFSM
SMART SIREN (IF INSTALLED)
Schedule
The siren's internal 9 volt battery is rechargeable and does not
need to be replaced on a regular basis. Battery life under
normal conditions is approximately three to six years.
NOTES
•
. Early style siren will
work with both TSSM and HFSM. Late style siren will only
work with HFSM.
•
The internal siren battery may not charge if the vehicle's
battery is less than 12.5 volts.
Battery Replacement: Early Style Siren
1.
Disarm system and remove siren.
2.
See
. Remove battery cover.
a.
Place the siren module on a flat and sturdy table with
the potted section (area with epoxy covering circuit
board) facing up and towards you.
b.
Position a knife blade at a 45 degree angle to the long
side of the siren case. Insert the knife blade between
the siren case and battery cover at one of the two
accessible corners of the battery cover. Keep the
blade slightly higher towards the battery cover as this
helps keep the blade away from the battery seal.
c.
Slowly twist the blade towards the battery cover and
the cover will pop off.
NOTES
•
For protection against corrosion, battery terminals and
battery clip are covered with a special grease. Do not wipe
away this substance. Apply all available existing grease
to terminals on new battery.
•
Only a 9 volt nickel metal hydride battery should be used
in the siren.
3.
Replace battery by removing old battery from polarized
battery clip. Install a new 9 volt nickel metal hydride bat-
tery.
4.
Reinstall battery cover.
a.
Carefully replace the rubber seal.
b.
Align battery cover with case placing round corners
on cover away from connector [142A]. Snap cover
into place.
5.
Install siren and check operation. If siren is working prop-
erly, it will respond with two chirps after receiving the arm
command.
Battery Replacement: Late Style Siren
1.
Disarm system and remove siren.
2.
See
. With a small screwdriver or pick, push
the catches (1) in through the two slots (2) in the end of
the siren to release the battery cover (3).
3-72 2009 Sportster Diagnostics: TSM/HFSM
NOTES
•
For protection against corrosion, battery terminals and
battery clip are covered with a special grease. Do not wipe
away this substance. Apply all available existing grease
to terminals on new battery.
•
Only a 9 volt nickel metal hydride battery should be used
in the siren.
3.
Replace battery (4) by removing old battery from polarized
battery clip.
4.
Recharge and re-install or install a new 9 volt nickel metal
hydride battery.
5.
Reinstall battery cover (3).
a.
Carefully replace the rubber seal (5) on the cover.
b.
Align battery cover with case placing round corners
on cover away from connector [142A] (6).
c.
Snap cover into place.
6.
Install siren and check operation. If siren is working prop-
erly, it will respond with two chirps after receiving the arm
command.
1
2
3
ed03016
1.
Cover
2.
Battery
3.
Connector [142A]
Figure 3-36. Battery Compartment (Early Style Siren)
4
5
6
3
1
2
ed02958
1.
Catch
2.
Slot
3.
Cover
4.
9 Volt battery
5.
Rubber seal
6.
Connector [142A]
Figure 3-37. Siren Battery Compartment (Late Style Siren)
2009 Sportster Diagnostics: TSM/HFSM 3-73
3-74 2009 Sportster Diagnostics: TSM/HFSM
NOTES
SUBJECT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE NO.
ENGINE MANA
GEMENT
NOTES
4.1
SPECIFICATIONS
SPECIFICATIONS
Table 4-1. General Specifications
DATA
IGNITION
1000 ± 50 RPM
Idle speed
12 mm
Spark plug size
0.038-0.043 in (0.97-1.09 mm)
Spark plug gap
0.032-0.038 in (0.81-0.97 mm)
Spark plug gap (XR)
Harley-Davidson
No. 6R12 (no substitute)
Spark plug type
Harley-Davidson
No. 10R12X
Spark plug type (XR)
0.3-0.7 ohms
Ignition coil primary res-
istance at room temper-
ature
1500-2400 ohms
Ignition coil secondary
resistance at room tem-
perature
Table 4-2. Fuse Ratings
RATING (AMPERES)
ITEM
15
ECM fuse
15
Fuel pump fuse
15
Ignition fuse
15
Instruments fuse
15
Accessory fuse
15
Battery fuse
15
Lights fuse
15
P&A ignition fuse
30
Main fuse
15
Engine Control
2009 Sportster Diagnostics: Engine Management 4-1
13
6
7
5
4
3
1
2
3
8
11
10
9
12
14
ed02838
8.
1.
Accessories fuse
ECM fuse
2.
9.
Fuel pump fuse
Battery fuse
10.
3.
Lights fuse
Spare
4.
11.
Start relay
P&A ignition fuse
12.
5.
Open
System relay
6.
13.
Ignition fuse
MAXIFUSE
14.
7.
Spare fuse (XL) - Engine Control (XR)
Instruments fuse
Figure 4-1. Fuses and Relays
4-2 2009 Sportster Diagnostics: Engine Management
4.2
EFI SYSTEM
GENERAL
The engine management system consists of the following
components:
•
Electronic Control Module (ECM).
•
Crankshaft Position (CKP) Sensor.
•
Combination Intake Air Temperature (IAT)/Manifold
Absolute Pressure (MAP) Sensor (TMAP).
•
Idle Air Control (IAC).
•
Throttle Position (TP) Sensor.
•
Vehicle Speed Sensor (VSS).
•
Turn Signal Module (TSM) or optional, factory-installed
Turn Signal Security Module (TSSM) (Japan/Korea) or
Hands-Free Security Module (HFSM). This includes an
integrated Bank Angle Sensor (BAS).
•
Ignition Coil.
•
Jiffy Stand Sensor (HDI).
•
Oxygen Sensors.
•
Active Intake Solenoid (HDI).
The ECM is mounted under the seat. It computes the spark
advance for proper ignition timing based on sensor inputs from
CKP, TMAP and TP sensors, and regulates the low-voltage
circuits between battery and ignition coil.
The ECM contains all of the solid state components used in
the ignition system. The dwell time for the ignition coil is also
calculated in the microprocessor and is dependent upon battery
voltage. The programmed dwell is an added feature to give
adequate spark at all speeds. (The ECM has added protection
against transient voltages, continuous reverse voltage protec-
tion, and damage due to jump starts.) The ECM is fully
enclosed to protect it from vibration, dust, water or oil. This unit
is a non-repairable item. If it fails, it must be replaced.
The CKP sensor is located in the front left side of the crank-
case. The CKP sensor generates an AC signal which is sent
to the ECM where it is used to reference engine position (TDC)
and speed. It functions by taking readings off the 30 teeth on
the left side flywheel (two teeth are missing to establish a ref-
erence point).
The TMAP sensor is located on top of the intake manifold. The
TMAP sensor monitors the intake manifold pressure (vacuum)
and intake air temperature and sends the information to the
ECM where the module adjusts the spark timing and fuel curve
for optimum performance.
The BAS is within the TSM/TSSM/HFSM. If the vehicle tips
over, the engine will be shut off. Once the sensor is tripped,
the motorcycle must be uprighted, turned off and then on again
before the engine can be restarted. This is communicated
across the data bus.
Front and rear coils fire each spark plug independently (one
cylinder at a time - no wasted spark). The coil also has an extra
terminal to monitor current on the coil secondary circuit. This
is used for knock detection and combustion diagnostics.
The ignition system gives a spark near top dead center for
starting. At RPM and loads above this, the system gives a
spark advance that varies between 0 and 50.
The IAT, ET, TP and oxygen sensors are used to provide
information to the ECM to fine tune spark and fuel delivery.
The VSS is used as an input for idle speed control.
The oxygen sensors monitor the exhaust gas for oxygen con-
tent. The fuel/air mixture is then adjusted to maintain an optimal
air/fuel ratio.
TROUBLESHOOTING
See the diagnostic charts for troubleshooting information.
2009 Sportster Diagnostics: Engine Management 4-3
DTCs P0562 and P0563 (Part 2 of 2)
Clear DTCs using odometer self-diagnostics. See
4.6 ODOMETER SELF-DIAGNOSTICS. Confirm
proper operation with no check engine lamp.
YES
NO
YES
YES
YES
NO
NO
NO
Continued from DTCs P0562 and P0563 (Part 2 of 2).
With ignition ON, measure voltage drop between battery positive (+) terminal and
(GY) terminal on 15 amp ignition fuse (-).
Is voltage drop greater than 0.5 volt?
With ignition ON, measure voltage drop
between battery positive (+) terminal and
(R/BK) terminal at 15 amp ignition fuse.
Is voltage drop greater than 0.5 volt?
With ignition ON, measure voltage drop
between battery positive (+) and both fuse
terminals (-).
Is voltage drop greater than 0.5 volt?
With ignition ON, measure voltage drop
between battery positive (+) terminal and
one fuse terminal (-).
Is voltage drop greater than 0.5 volt?
High resistance between
main fuse and battery.
Replace wire or terminals.
Replace GY wire
or terminals.
Replace fuse or
fuse terminals.
Replace ignition
switch or terminals.
Replace main fuse.
fc01991_en
2009 Sportster Diagnostics: Engine Management 4-103
4.24
DTC P0603, P0605
GENERAL
TOOL NAME
PART NUMBER
DIGITAL TECHNICIAN II
HD-48650
ECM Failure
Refer to
. The DTCs listed indicate a failure which
requires replacement of the ECM. See the Service Manual for
replacement information.
NOTE
After replacing ECM, reprogram, perform password learning
procedure and clear codes. ECM must be reprogrammed using
the DIGITAL TECHNICIAN II (Part No. HD-48650). See your
dealer. Password learn procedure must also be performed.
See
Table 4-38. Code Description
DESCRIPTION
DTC
ECM EEPROM error
P0603
ECM flash error
P0605
DIAGNOSTICS
These codes are set under two conditions.
•
If DTC P0603 or P0605 occur during normal operation,
replace ECM. Reprogram and learn password.
•
If DTC P0603 or P0605 occur during or after reprogram-
ming, perform the following:
DTC P0603
1.
Clear DTCs.
2.
Power down the vehicle. Wait 10 seconds.
3.
Turn ignition ON.
4.
Replace ECM if codes reappear.
DTC P0605
1.
Clear DTCs.
2.
Power down the vehicle.
3.
Attempt to reprogram ECM using correct calibration.
4.
Restart vehicle. If code reappears, replace ECM.
4-104 2009 Sportster Diagnostics: Engine Management
4.25
DTC P0661, P0662
GENERAL
Active Intake Solenoid (HDI XR Models Only)
The active intake solenoid regulates the amount of air that
enters the air cleaner. The active intake solenoid opens when
vehicle speed exceeds 45 MPH (70 km/h) with 50% or greater
throttle opening. Once open, active intake will close when
vehicle speed falls below 40 MPH (65 km/h). The power for
the active intake solenoid comes from the engine control fuse.
The ECM provides the path to ground to trigger the active
intake solenoid.
Table 4-39. Code Description
DESCRIPTION
DTC
Active intake solenoid open/low
P0661
Active intake high/shorted
P0662
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.
See the service manual for all service information.
2.
Connect a BREAKOUT BOX (Part No. HD-43876) between
EFI wire harness and ECM. See
3.
Use HARNESS CONNECTOR TEST KIT (Part No. HD-
41404-B), purple terminal probe and patch cord.
2009 Sportster Diagnostics: Engine Management 4-105
20
10
28
2
1
6
10
6
10
2
1
20
10
28
ECM
Active
Intake
Solenoid
Battery
30 Amp
MAXIFUSE
GND 1
Ignition Switch
15 Amp
Engine Control
Fuse
Active Intake Solenoid HDI
Ground
Ground
BK
BK
BK
R
R
R
LGN/R
LGN/R
GY/O
GY/O
R/BK
R
R/BK
[145B]
[145A]
[78B]
[78A]
A
CC
−
BA
TT
−
IGN
−
I B A
[178A]
[178B]
em01307
Figure 4-49. Active Intake Solenoid Circuit
Table 4-40. Wire Harness Connectors
LOCATION
TYPE
DESCRIPTION
NO.
Under seat
36-place Packard
ECM
[78]
Rear of air box
2-place Amp
Active Intake Solenoid (HDI)
[178]
4-106 2009 Sportster Diagnostics: Engine Management
DTCs P0661 and P0662 (Part 1 of 2)
Is connector securely attached to the
active intake solenoid?
YES
1
Reconnect.
Turn active intake solenoid on by
grounding terminal 20 on breakout box.
Solenoid should activate immediately
after ignition switch is turned to IGN.
Does it?
YES
NO
Recheck connections. Perform
4.8 WIGGLE TEST to check for
intermittents.
Are intermittents present?
Check terminal 1 (LGN/R) wire on
active intake solenoid connector
[178B] to ground.
Is voltage equivalent to battery voltage
after ignition switch is turned to IGN?
YES
NO
Measure resistance of
active intake solenoid
across solenoid terminals.
Is resistance 16-20 ohms?
Repair
intermittent.
NO
YES
NO
Check for loose
or corroded terminals
in harness.
Replace
active intake
solenoid.
YES
NO
Inspect engine
control fuse.
Is fuse OK?
Locate and repair
bad connection
or open on (LGN/R)
wire between engine
control fuse and
connector [178B].
3
YES
NO
Check for 12 volts at terminal L
of fuse block after ignition
switch is turned to IGN.
Is battery voltage present?
YES
NO
Replace
fuse.
Locate and repair
open on (R/BK) wire to
engine control fuse.
Clear DTCs using odometer self-diagnostics. See 4.6
ODOMETER SELF-DIAGNOSTICS. Confirm proper
operation with no check engine lamp.
2
fc01992_en
Go to DTCs
P0661 and
P0662
(Part 2 of 2).
2009 Sportster Diagnostics: Engine Management 4-107
DTCs P0661 and P0662 (Part 2 of 2)
Continued from DTCs P0661 and P0662 (Part 1 of 2).
Measure resistance between Breakout Box
terminal 20 (GY/O) wire and terminal 2 of active intake solenoid connector [178B].
Is resistance less than 0.5 ohm?
YES
NO
Measure resistance between ground
and Breakout Box terminal 20.
Is resistance less than 1000 ohms?
Repair open or
poor connection.
YES
NO
Repair short to ground on
(GY/O) wire.
Disconnect connectors [178] and [78]. Check
for voltage at Breakout Box terminal 20 with
ignition switch turned to IGN.
Is voltage present?
Locate and repair
short to voltage on
(GY/O) wire.
YES
NO
Replace ECM.
Reprogram
and learn password.
Clear DTCs using odometer self-diagnostics. See 4.6
ODOMETER SELF-DIAGNOSTICS. Confirm proper
operation with no check engine lamp.
2
3
fc01993_en
4-108 2009 Sportster Diagnostics: Engine Management
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