Harley Davidson Sportster Models 2009. Service Repair Manual — page 83
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 4-60. Serial Data Circuit (XL)
2009 Sportster Diagnostics: Engine Management 4-125
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 4-61. Serial Circuit Data (XR)
Table 4-48. Wire Harness Connectors
LOCATION
TYPE
DESCRIPTION
NO.
Under fuel tank
12-place Molex
Instruments
[20]
Under battery
12-place Deutsch
TSM/TSSM/HFSM
[30]
Back of speedometer
12-place Packard
Speedometer (XL)
[39]
Back of speedometer
5-place Packard
Display (XR)
[39]
Under seat
36-place Packard
ECM
[78]
4-126 2009 Sportster Diagnostics: Engine Management
Table 4-48. Wire Harness Connectors
LOCATION
TYPE
DESCRIPTION
NO.
Behind 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 4-127
DTCs U1064 and U1255
Can you read TSM/TSSM/HFSM hardware part number?
See 4.6 ODOMETER SELF-DIAGNOSTICS.
Install Breakout Box on speedometer.
While wiggling harness, check for continuity
between terminal 3 (gray) and terminal 2
(black) of Breakout Box.
Is continuity present?
Install Breakout Box on speedometer on XL,
tachometer on XR.
Check for continuity between terminal 3 (gray)
and terminal 2 (black) of Breakout Box
Is continuity present?
Replace TSM/TSSM/HFSM.
Learn password.
Repair open on
(LGN/V) wire.
Repair intermittent
on (LGN/V) wire.
Clear DTCs. Test ride.
Does DTC U1064 return?
No trouble found.
Replace TSM/TSSM/HFSM.
Learn password.
1
YES
NO
Clear DTCs using odometer self-diagnostics. See
4.6 ODOMETER SELF-DIAGNOSTICS. Confirm
proper operation with no check engine lamp.
NO
NO
YES
YES
YES
NO or “No Rsp”
1
fc01863_en
4-128 2009 Sportster Diagnostics: Engine Management
4.30
DTC U1097, U1255
GENERAL
Loss of Speedometer Serial Data
The serial data connector provides a means for the speedo-
meter on XL, and tachometer on XR, Electronic Control Module
(ECM) and TSM/TSSM/HFSM to communicate their current
status. When all operating parameters on the serial data link
are within specifications, a state of health message is sent
between the components. A Diagnostic Trouble Code (DTC)
U1097 indicates that the speedometer on XL, and tachometer
on XR, is not capable of sending this state of health message.
A DTC U1255 indicates that no messages were present during
power up of the current key cycle. A DTC U1097 indicates that
there was communication on the data bus since power up, but
communication was lost or interrupted during that key cycle.
Table 4-49. Code Description
DESCRIPTION
DTC
Loss of all speedometer serial data (state
of health)
U1097
Missing message at speedometer
U1255
DIAGNOSTICS
TOOL NAME
PART NUMBER
BREAKOUT BOX
HD-42682
BREAKOUT BOX
HD-43876
INSTRUMENT HARNESS ADAPTER
HD-46601
NOTE
If DTC is historic and not current, wiggle wire harness while
performing voltage and continuity tests to identify intermittents.
Diagnostic Notes
Each reference number below correlates to a circled number
on the flowchart(s).
1.
Connect BREAKOUT BOX (Part No. HD-43876) to wire
harness connector [78B]. Leave ECM [78A] disconnected.
See
2.
Connect BREAKOUT BOX (Part No. HD-42682) (black)
to wire harness connector [39B] on XL, and connector
[108B] on XR, using INSTRUMENT (Part No. HD-46601).
Leave speedometer [39A] on XL, and connector [108A]
on XR, disconnected. See
ed02819
Figure 4-62. Speedometer Connector [39] on XL, and
tachometer connector [108A] on XR (Typical)
2009 Sportster Diagnostics: Engine Management 4-129
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 4-63. Serial Data Circuit (XL)
4-130 2009 Sportster Diagnostics: Engine Management
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 4-64. Serial Data Circuit (XR)
Table 4-50. Wire Harness Connectors
LOCATION
TYPE
DESCRIPTION
NO.
Under fuel tank
12-place Molex
Instruments
[20]
Under battery
12-place Deutsch
TSM/TSSM/HFSM
[30]
Back of speedometer
12-place Packard
Speedometer (XL)
[39]
Back of speedometer
5-place Packard
Display (XR)
[39]
Under seat
36-place Packard
ECM
[78]
2009 Sportster Diagnostics: Engine Management 4-131
Table 4-50. Wire Harness Connectors
LOCATION
TYPE
DESCRIPTION
NO.
Behind left side cover
4-place Deutsch
Data link connector
[91]
Back of tachometer
12-place Packard
Tachometer (if equipped)
[108]
4-132 2009 Sportster Diagnostics: Engine Management
DTCs U1097 and U1255
1
YES
NO
Clear DTCs using odometer self -diagnostics. See 4.6
ODOMETER SELF -DIAGNOSTICS. Confirm proper
operation with no check engine lamp.
YES
YES
YES
NO
NO
1
2
2
IMPORTANT:
Always start from
4.5 INITIAL DIAGNOSTIC CHECK: EFI.
Can you read ECM hardware part number?
See 4.6 ODOMETER SELF-DIAGNOSTICS.
While wiggling harness, check for continuity between ECM
Breakout Box terminal 5 and speedometer Breakout Box
terminal 2 (black).
Is continuity present?
Check for continuity between
ECM Breakout Box terminal 5
and speedometer Breakout
Box terminal 2 (black).
Is continuity present?
Replace
speedometer on XL,
tachometer on XR.
Repair open
on
(LGN/V) wire.
Clear DTCs. Test Ride.
Did DTC U1097 return?
Repair intermittent on
(LGN/V) wire.
No trouble found.
Replace speedometer.
NO or “No rsp”
fc01864_en
2009 Sportster Diagnostics: Engine Management 4-133
4.31
FUEL PRESSURE TEST
GENERAL
The fuel pump delivers fuel through the fuel line, to a cavity in
the induction module. This cavity directs the fuel to the fuel
injectors and pressure regulator. The pressure regulator con-
trols the fuel pressure by passing excess fuel back to the fuel
tank. Improper fuel pressure may contribute to one of the fol-
lowing symptoms:
•
cranks, but won't run
•
cut out (may feel like ignition problem)
•
hesitation, loss of power, or poor fuel economy
If incorrect fuel pressure is suspected, perform a fuel pressure
test. See the service manual for the required tools and pro-
cedure for performing a fuel pressure test.
DIAGNOSTICS
Perform a fuel pressure test. See the service manual. The fuel
pressure should remain steady between 55-62 PSI (380-425
KPa). If pressure does not hold steady, follow either the low
fuel pressure or high fuel pressure procedure, depending on
the symptom.
Low Fuel Pressure
1.
Check the fuel filter or pump inlet screen for restrictions.
If the concern is found, clean the pump inlet screen or
replace the fuel filter.
2.
If the concern was not corrected, inspect for a:
•
restricted pressure line or flex hose between the fuel tank
and the test gauge.
•
faulty fuel pump.
•
restricted check valve fitting assembly.
•
leak inside the tank caused by faulty coupling hose or
connection, such as a hose at the filter or pump. This
condition can be identified, if the fuel level in the tank is
low, by a ringing sound inside the tank during the first 2
seconds after key on. This is caused by the high pressure
fuel spraying against the inside of the tank.
•
faulty fuel pressure regulator.
Once the concern is located, repair as needed.
High Fuel Pressure
1.
Inspect the check valve fitting assembly and the fuel tank.
If the concern is found correct as needed.
2.
If the concern was not corrected, replace the fuel regulator.
4-134 2009 Sportster Diagnostics: Engine Management
SUBJECT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE NO.
APPENDIX A CONNECT
OR REP
AIR
NOTES
A.1
AMP MULTILOCK CONNECTORS
AMP MULTILOCK CONNECTOR REPAIR
TOOL NAME
PART NUMBER
AMP MULTILOCK CRIMPER
HD-41609
General
AMP Multilock connectors are found between wire harnesses
and component wiring and may be either floating or anchored
to the frame with attachment clips.
See
. Attachment clips (1) on the pin housings are
fitted to T-studs on the motorcycle frame. The T-studs identify
OE connector locations. To maintain serviceability, always
return connectors to OE locations after service.
Obtain the necessary tools to repair the connector and ter-
minals.
NOTE
For terminal crimping use the AMP MULTILOCK
CRIMPER (Part No. HD-41609).
Separating Pin and Socket Housings
1.
If necessary, slide connector attachment clip T-stud to the
large end of the opening.
2.
. Depress the release button (2) on the
socket terminal side of the connector and pull the socket
housing (3) out of the pin housing (4).
Mating Pin and Socket Housings
1.
Hold the housings to match wire color to wire color.
2.
Insert the socket housing into the pin housing until it snaps
in place.
3.
If OE location is a T-stud, fit large opening end of attach-
ment clip over T-stud and slide connector to engage T-
stud to small end of opening.
2
3
1
4
sm00002
1.
Attachment clip
2.
Release button
3.
Socket housing
4.
Pin housing
Figure A-1. AMP Multilock Connector
Removing Terminals from Housing
1.
. Bend back the latch (1) to free one end
of secondary lock (2) then repeat on the opposite end.
Hinge the secondary lock outward.
2.
Look in the terminal side of the connector (opposite the
secondary lock) and note the cavity next to each terminal.
3.
Insert a pick or pin into the terminal cavity until it stops.
NOTE
If socket/pin terminal tool is not available, a push pin/safety pin
or a Snap-on pick (Part No. TT600-3) may be used.
4.
Press the tang in the housing to release the terminal.
a.
Socket: Lift the socket tang (8) up.
b.
Pin: Press the pin tang (7) down.
NOTE
A "click" is heard if the tang is released.
5.
Gently tug on wire to pull wire and terminal from cavity.
2009 Sportster Diagnostics: Appendix A Connector Repair A-1
5
2
7
1
3
6
1
2
4
8
sm00013
1.
Latch
2.
Secondary lock open
3.
Pin housing
4.
Socket housing
5.
Pin terminal
6.
Socket terminal
7.
Tang (pin)
8.
Tang (socket)
Figure A-2. AMP Multilock Connector: Socket and Pin
Housings
Inserting Terminals into Housing
NOTE
. Cavity numbers are stamped into the sec-
ondary locks of both the socket and pin housings. Match the
wire color to the cavity number found on the wiring diagram.
1.
Hold the terminal so the catch faces the tang in the
chamber. Insert the terminal into its numbered cavity until
it snaps in place.
NOTES
•
Up and down can be determined by the position of the
release button, the button is the top of the connector.
•
On the pin side of the connector, tangs are positioned at
the bottom of each cavity, so the slot in the pin terminal
(on the side opposite the crimp tails) must face downward.
•
On the socket side, tangs are at the top of each cavity, so
the socket terminal slot (on the same side as the crimp
tails) must face upward.
2.
Gently tug on wire end to verify that the terminal is locked
in place.
3.
Rotate the hinged secondary lock inward until tabs fully
engage latches on both sides of connector.
– AMP
1
2
3
– AMP
1
2
3
4
5
6
5
6
7
8
9
10
4
3
2
1
1
2
3
sm00005
1.
3-place housing
2.
6-place housing
3.
10-place housing
Figure A-3. AMP Multilock Connector: Cavity Numbers on
Secondary Locks (Socket Housings Shown)
Preparing Wire Leads for Crimping
1.
Strip 5/32 in. (4.0 mm) of insulation from the wire lead.
A-2 2009 Sportster Diagnostics: Appendix A Connector Repair
2.
and
. Select the pin/socket ter-
minals from the parts catalog and identify the insulation
crimp tails (1) and the wire crimp tails (2) and the groove
for the crimp tool locking bar (3).
3.
Identify the wire lead gauge and the corresponding crimper
tool and nesting die. Refer to
.
Table A-1. AMP Multilock Connector: Crimp Tool Wire
Gauge/Nest
NEST
WIRE GAUGE
Front
20
Middle
16
Rear
18
5
2
7
1
3
6
1
2
4
8
sm00013
1.
Latch
2.
Secondary lock open
3.
Pin housing
4.
Socket housing
5.
Pin terminal
6.
Socket terminal
7.
Tang (pin)
8.
Tang (socket)
Figure A-4. AMP Multilock Connector: Socket and Pin
Housings
2009 Sportster Diagnostics: Appendix A Connector Repair A-3
2
3
1
sm00001
1.
Insulation crimp tail
2.
Wire crimp tail
3.
Locking bar groove
Figure A-5. AMP Multilock Connector: Socket Terminal
Crimping Terminals to Leads
NOTE
Crimping with an Amp Multilock tool is a one step operation.
One squeeze crimps both the wire core and the insulation tails.
1.
. Squeeze the handles to cycle the AMP
MULTILOCK CRIMPER (Part No. HD-41609) to the fully
open position (1).
2.
Raise locking bar by pushing up on bottom flange (2).
NOTE
. Hold the terminal with the
insulation crimp tail (1) facing up. The tool will hold the terminal
by the locking bar groove (3) and crimp the wire crimp tail (2)
around the bare wire of the stripped lead and the insulation
crimp tail around the insulation.
3.
. With the insulation crimp tail facing
upward, insert terminal (pin or socket) (3) through the
locking bar, so that the closed side of the terminal rests
on the nest of the crimp tool.
4.
Release locking bar to lock position of contact (4). When
correctly positioned, the locking bar fits snugly in the space
at the front of the core crimp tails.
5.
Insert stripped end of lead (5) until ends make contact with
locking bar.
6.
Verify that wire is positioned so that wire crimp tails
squeeze bare wire strands, while insulation crimp tails fold
over the wire lead insulation.
7.
Squeeze handle of crimp tool until tightly closed. Tool
automatically opens when the crimping sequence is com-
plete.
8.
Raise up locking bar (7) and remove crimped terminal.
4
6
7
3
1
2
5
8
sm00007
1.
Open position
2.
Locking bar flange
3.
Insert contact
4.
Release locking bar
5.
Insert lead
6.
Squeeze
7.
Raise locking bar
8.
Remove crimped terminal
Figure A-6. AMP Multilock Connector: Terminal Crimping
Procedure
Inspecting Crimped Terminals
. Inspect the wire core crimp (2) and insulation
crimp (1). Distortion should be minimal.
A-4 2009 Sportster Diagnostics: Appendix A Connector Repair
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