Harley Davidson Sportster Models 2009. Service Repair Manual — page 12

ON

ON

ON

OFF

OFF

OFF

Key On

Key On

Key On

Lamp OFF: No Current or Historic DTCs

Lamp OFF

Lamp ON 8 Seconds:

Only Historic DTCs Exist

Lamp Remains ON: Current DTC*

* Historic DTCs May Also Exist

4 Sec.

4 Sec.

4 Sec.

4 Sec.

8 Sec.

4 Sec.

em01046

Figure 4-5. Check Engine Lamp Operation

CODE TYPES

TOOL NAME

PART NUMBER

DIGITAL TECHNICIAN II

HD-48650

There are two types of DTCs: current and historic. If a DTC is
stored, it can be read using either a computer-based diagnostic
package called DIGITAL TECHNICIAN II (Part No. HD-48650)
or odometer self-diagnostics. See

4.6 ODOMETER SELF-

DIAGNOSTICS

.

NOTES

•

To differentiate between current and historic DTCs, a
computer-based diagnostic package called DIGITAL
TECHNICIAN II (Part No. HD-48650) must be employed.

•

All DTCs reside in the memory of the ECM, TSM/TSSM/
HFSM, speedometer or tachometer until the DTC is
cleared by use of the odometer self-diagnostics. See

4.6 ODOMETER SELF-DIAGNOSTICS

.

•

A historic DTC is also cleared after a total of 50 trips has
elapsed. A trip consists of a start and run cycle. After the
50 trip retention period, the DTC is automatically erased
from memory providing that no subsequent faults of the
same type are detected in that period.

Current

Current DTCs are those which are present during the current
ignition cycle. See the appropriate flowcharts for solutions.

Historic

If a particular problem happens to resolve itself, the active
status problem is dropped and it becomes a historic DTC rather
than a current DTC.

Historic DTCs can only be retrieved using a computer-based
diagnostic package called DIGITAL TECHNICIAN II (Part
No. HD-48650).

Historic DTCs are stored for 50 ignition cycles after any DTC
was last set as current to assist in the diagnosis of intermittent
faults. On the 50th cycle, the DTC will clear itself. The check
engine lamp will not indicate the existence of only historic
DTCs.

It is important to note that historic DTCs will exist whenever
the system indicates the existence of a current fault. See

4.4 CHECKING FOR DIAGNOSTIC TROUBLE CODES: EFI,
Multiple Diagnostic Trouble Codes

if multiple DTCs are found.

Diagnostic charts are designed for use with current DTCs and
as a result they frequently suggest part replacement. When
diagnosing a historic DTC the charts can be helpful but should
not lead to part replacement without verification the part is
faulty.

RETRIEVING DIAGNOSTIC TROUBLE
CODES

TOOL NAME

PART NUMBER

DIGITAL TECHNICIAN II

HD-48650

The engine management system provides two levels of dia-
gnostics.

•

The most sophisticated mode employs a computer-based
diagnostic package called DIGITAL TECHNICIAN II (Part
No. HD-48650).

•

The second mode requires using the odometer self dia-
gnostics. Speedometer, tachometer (if equipped),
TSM/TSSM/HFSM and ECM DTCs can be accessed and
cleared. See

4.6 ODOMETER SELF-DIAGNOSTICS

.

HOME

2009 Sportster Diagnostics: Engine Management 4-7

2

1

om01271

1.

Rear drive belt

2.

Deflection graduations 1/8 in. (3.2 mm) apart

Figure 1-54. Belt Deflection: XR 1200 Model

3

4

2

1

om00847

1.

Transmission sprocket

2.

Rear wheel sprocket

3.

Force of 10 lbs (4.5 kg)

4.

Deflection (refer to table)

Figure 1-55. Gauging Belt Deflection: Sportster XL Models

1

5

2

3

4

om01272

1.

Transmission sprocket

2.

Rear wheel sprocket

3.

Force of 10 lbs (4.5 kg)

4.

Deflection (refer to table)

5.

Idler wheel

Figure 1-56. Gauging Belt Deflection: XR 1200 Model

BELT DEFLECTION ADJUSTMENT

See

Figure 1-55

. Determine belt deflection in manner specified

in

1.16 REAR BELT DEFLECTION, Rear Drive Belt: Sportster

Models

. If belt deflection is not correct, adjust per the following

procedure.

NOTE

Rear brake line is clamped tightly to rear fork to avoid chafing
of brake line in clamp. A small amount of slack must be main-
tained in rear brake line between clamp and rear caliper when
rear wheel is adjusted.

1.

XL Models: See

Figure 1-57

. Remove screw (4) from

clamp (3) on rear brake line (2).

2.

See

Figure 1-58

. Remove e-clip (1) and loosen rear axle

nut (4). Turn axle adjuster nuts (2) on each side of rear
fork clockwise to decrease belt deflection (increase ten-
sion), or counterclockwise to increase belt deflection
(decrease tension). Turn both adjuster nuts the same
number of turns in order to maintain approximate alignment
of rear wheel.

3.

Check rear wheel alignment. Wheel must be centered in
rear fork. See

1.16 REAR BELT DEFLECTION, Wheel

Alignment

.

Do not exceed specified torque when tightening axle nut.
Exceeding torque can cause wheel bearings to seize during
vehicle operation, which could result in death or serious
injury. (00408e)

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1-48 2009 Sportster Service: Maintenance

4.

After belt deflection and wheel alignment are properly
adjusted,

a.

Tighten axle nut (4) to 95-105 ft-lbs (129-142 Nm).
Install e-clip (1).

b.

XL Models: See

Figure 1-57

. Reposition clamp (3)

on rear brake line (2) and secure clamp to rear fork
(1) with screw (4). Tighten to 30-40 in-lbs (3.4-4.5
Nm).

3

3

2

4

1

5

sm01443

1.

Rear fork

2.

Rear brake line

3.

Clamp

4.

Screw

5.

Rear brake caliper

Figure 1-57. Rear Brake Line: XL Models

1

2

3

4

5

6

sm03591

1.

E-clip

2.

Axle adjuster nut (2)

3.

Axle adjuster (2)

4.

Axle nut

5.

Washer

6.

Protective cap (2)

Figure 1-58. Secondary Drive Belt Adjustment (typical; XL

model shown)

WHEEL ALIGNMENT

TOOL NAME

PART NUMBER

AXLE ALIGNMENT PLUG SET

HD-48856

Checking Wheel Alignment

Check vehicle alignment according to following proced-
ures. Incorrect alignment can adversely affect stability and
handling, which could result in death or serious injury.
(00287a)

1.

Obtain AXLE ALIGNMENT PLUG SET (Part No. HD-
48856). See

Figure 1-59

. Insert axle alignment plugs (1,

2) into left and right ends of rear axle.

2.

For XL Models: See

Figure 1-60

. Fabricate an alignment

tool using a piece of 1/8-in. (3.175 mm) diameter aluminum
welding rod 21.5 in. (546 mm) long. Grind one end down
to a blunt point. Use pliers to bend rod at a 90 degree
angle, 2.25 in. (57 mm) from the blunt point, as shown.
Place a snug-fitting rubber grommet (2) on rod to act as
a slide measurement indicator.

3.

For XR Models: See

Figure 1-61

. Fabricate an alignment

tool using a piece of 1/8-in. (3.175 mm) diameter aluminum
welding rod 22.375 in. (568 mm) long. Grind one end down
to a blunt point. Use pliers to bend rod as shown. Place a
snug-fitting rubber grommet (2) on rod to act as a slide
measurement indicator.

4.

Figure 1-62

. Insert blunt point of alignment tool in rear fork

pivot bolt dimple (2) on right side of rear fork (3). Slide
rubber grommet along tool shaft until it aligns with hole in
center of alignment plug (5). Measure distance from
pointed end of alignment tool to grommet. Repeat meas-
urement for left side of rear fork.

HOME

2009 Sportster Service: Maintenance 1-49

5.

If left and right side measurements are not equal, adjust
rear wheel alignment.

1

2

3

4

2

3

sm03606

1.

Axle alignment plug (smaller)

2.

Axle alignment plug (larger)

3.

Alignment hole

4.

Rear axle (right side)

Figure 1-59. Axle Alignment Plugs

1

2

3

4

sm05426

1.

Blunt point

2.

Rubber grommet

3.

2.25 in. (57 mm)

4.

19.25 in. (489 mm)

Figure 1-60. Wheel Alignment Tool: XL Models

1

6

2

5

3

4

sm05427

1.

Blunt point

2.

Rubber grommet

3.

5/8 in. (16 mm)

4.

15-1/4 in. (387 mm)

5.

6-1/2 in. (165 mm)

6.

3-7/8 in. (98 mm)

Figure 1-61. Wheel Alignment Tool: XR Models

Adjusting Wheel Alignment

1.

See

Figure 1-58

. Remove and discard e-clip (1).

2.

Loosen rear axle nut (4).

3.

On side of rear fork that has longer distance from pivot
bolt to axle center, turn nut (2) on axle adjuster (3) coun-
terclockwise to shorten distance. Adjust axle until left and
right side alignment measurements are equal.

NOTES

•

Keep axle adjuster mechanisms firmly seated (under ten-
sion) on each side of rear fork during wheel alignment
procedures above. Do so by applying moderate upward
force on lower span of rear belt. This tensions rear belt,
which holds rear axle forward against both adjuster
mechanisms.

•

Do not tighten rear axle nut or install new e-clip until after
checking rear drive belt tension.

2

1

3

4

5

sm01615

1.

Wheel alignment tool

2.

Rear fork pivot bolt dimple

3.

Rear fork

4.

Rubber grommet

5.

Axle alignment plug

Figure 1-62. Checking Wheel Alignment Using Wheel

Alignment Tool (XL Models Shown)

HOME

1-50 2009 Sportster Service: Maintenance

4.

Verify rear drive belt deflection after aligning rear wheel;
adjust if required. See

1.16 REAR BELT DEFLECTION,

Belt Deflection Adjustment

.

NOTE

Rear brake line is clamped tightly to rear fork to avoid chafing
of brake line in clamp. If rear axle has been moved forward or
back, make sure there is a small amount of slack in rear brake
line between clamp and rear caliper. If necessary, loosen clamp
screw, reposition brake line, then tighten screw. See

1.16 REAR BELT DEFLECTION, Belt Deflection Adjustment

.

Do not exceed specified torque when tightening axle nut.
Exceeding torque can cause wheel bearings to seize during
vehicle operation, which could result in death or serious
injury. (00408e)

5.

If not yet done, tighten axle nut to 95-105 ft-lbs (129-142
Nm) and install new e-clip.

HOME

2009 Sportster Service: Maintenance 1-51

4.5

INITIAL DIAGNOSTIC CHECK: EFI

GENERAL

TOOL NAME

PART NUMBER

DIGITAL TECHNICIAN II

HD-48650

To locate faulty circuits or other system problems, follow the
diagnostic flowcharts in this section. For a systematic approach,
always begin with

4.5 INITIAL DIAGNOSTIC CHECK: EFI,

General

. Read the general information and then work your way

through the flowchart box by box.

Diagnostic Notes

If a numbered circle appears adjacent to a flowchart box, then
more information is offered in the diagnostic notes. Many dia-
gnostic notes contain supplemental information, descriptions
of various diagnostic tools or references to other parts of the
manual where information on the location and removal of
components may be obtained.

Circuit Diagram/Wire Harness Connector
Table

When working through a flowchart, refer to the illustrations,
the associated circuit diagram and the wire harness connector
table as necessary. The wire harness connector table for each
circuit diagram identifies the connector number, description,
type and general location.

In order to perform most diagnostic routines, a Breakout Box
and a digital volt/ohmmeter (DVOM) are required. See

4.7 BREAKOUT BOX: EFI

.

To perform the circuit checks with any degree of efficiency, a
familiarity with the various wire connectors is also necessary.

Reprogramming ECM

Diagnostic charts frequently suggest ECM replacement. In the
event an ECM needs to be replaced, it must be reprogrammed
using a computer-based diagnostic package called DIGITAL
TECHNICIAN II (Part No. HD-48650). See your dealer. Pass-
word learn procedure must also be performed. See

3.23 TSM/HFSM: PASSWORD LEARN

.

INITIAL DIAGNOSTICS

TOOL NAME

PART NUMBER

BREAKOUT BOX

HD-42682

INSTRUMENT HARNESS ADAPTERS

HD-46601

General Information

The diagnostic check is an organized approach to identifying
a problem caused by an electronic control system malfunction.

Diagnostic Tips

•

If odometer reads "BUS Er" with the ignition switch turned
ON (engine stop switch at RUN with the engine off), check
data bus for an open or short to ground. between data link
connector [91A] terminal 3 and ECM connector [78B] ter-
minal 5, TSM/TSSM/HFSM connector [30B] terminal 3,
speedometer connector [39B] terminal 2 (XL), terminal C
(XR) or tachometer (if equipped) connector [108B] terminal
2.

•

Check for an open data test terminal between data link
connector [91A] terminal 3 and TSM/TSSM/HFSM con-
nector [30B] terminal 3. With ignition key turned ON, serial
data bus voltage should be typically 0.6-0.8 volts. The
range of acceptable voltage is 0-7.0 volts.

•

To identify intermittents, wiggle instrument and/or vehicle
harness while performing steps in the Diagnostic Check
charts.

Diagnostic Notes

Each reference number below correlates to a circled number
on the flowchart(s).

1.

Compare engine behavior to symptoms tables.

a.

Starts hard. Refer to

Table 4-4

.

b.

Hesitates, stumbles, surges, misfires and/or sluggish
performance. Refer to

Table 4-5

.

c.

Engine exhaust emits black smoke or fouls plugs.
Refer to

Table 4-6

.

2.

Connect BREAKOUT BOX (Part No. HD-42682) and
INSTRUMENT HARNESS ADAPTERS (Part No. HD-
46601) between wire harness and speedometer on XL,
and tachometer on XR . See

2.5 BREAKOUT BOX:

SPEEDOMETER/TACHOMETER

All EFI diagnostic codes are listed in

Table 4-7

.

Other DTCs

See

3.10 INITIAL DIAGNOSTIC CHECK: TSM/HFSM

for any

codes related to the TSM, TSSM or HFSM.

See

2.2 INITIAL DIAGNOSTIC CHECK: ODOMETER

for any

codes related to the speedometer or tachometer.

HOME

2009 Sportster Diagnostics: Engine Management 4-9

Table 4-3. Typical Scan Values for Engine Data

HOT

IDLE

MAX.

VALUE

MIN.

VALUE

ITEM

10.3-13.3 in. Hg (35-45 kPa)

104 kPa

10 kPa

MAP sensor

TMAP
sensor

5.1 Volts

0 Volt

104-140° F (40-60° C)

248° F (120° C)

3° F (-16° C)

IAT Sensor

2.0-3.5 Volts

5.0 Volts

0.0 Volts

0%

100

0

TP sensor

0.2-1.0 Volt

4.5 Volts

0.2 Volt

20-50 steps

155

0

IAC pintle

1000

5600

800

RPM

230-300° F (110-150° C)

464° F (240° C)

3° F (-16° C)

ET sensor

0.5-1.5 Volts

5.0 Volts

0.0 Volt

2-4 ms

50 ms

0

INJ PW front

2-4 ms

50 ms

0

INJ PW rear

10-15°

50°

0

Advance front

10-15°

50°

0

Advance rear

0 MPH (km/h)

120

0

VSS

13.4 Volts

15

10

Battery voltage

Run

Run

Off

ENG RUN

1000

1250

800

Idle RPM

NOTE

Hot idle specifications are with stock exhaust, the engine
operating at 1000 RPM and an engine temperature of approx-

imately 260 °F (127 °C). Idle settings may be changed with the
idle set procedure. See the service manual.

Table 4-4. Engine Starts Hard

SOLUTION

CAUSE

1.7 CHARGING SYSTEM, Troubleshooting

.

Battery discharged

4.15 MISFIRE AT IDLE OR UNDER LOAD

.

Spark plugs

4.15 MISFIRE AT IDLE OR UNDER LOAD

.

Spark plug wires

4.15 MISFIRE AT IDLE OR UNDER LOAD

.

Ignition coil

See Section 3 in the Service Manual.

Valve sticking

Drain and refill with fresh fuel.

Water or dirt in fuel system

4.10 NO ECM POWER

.

Loss of battery power to ECM terminal 31*

* Codes will not clear (although they appear to).

Table 4-5. Engine Performance Problems

SOLUTION

CAUSE

A low IAC count may also indicate an air leak.

Manifold leak
NOTE: When manifold leak is large enough, IAC will close to 0
and code P0505 will set.

4.16 DTC P0107, P0108, P0112, P0113

.

TMAP sensor plugged or not operating properly

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4-10 2009 Sportster Diagnostics: Engine Management