Harley Davidson 2008 Sportster Models. Electrical Diagnostics Manual — page 11
Table 4-15. Wire Harness Connectors
NO.
DESCRIPTION
TYPE
LOCATION
[119]
System relay
5-place Amp
Under left side cover
[141]
Fuel pump and low fuel switch
4-place Molex, black
Forward of relay/fuse blocks
[145]
Engine harness
16-place Molex
Under seat
2008 Sportster Diagnostics: Engine Management 4-45
System Relay: DTC P1001, P1003
Check for battery voltage at terminal “87” of
system relay (with relay installed) during first 2-
3 seconds after key ON. Battery voltage (10-13
volts) present for 2-3 seconds after key ON?
YES
NO
System relay OK. Measure resistance
No voltage or voltage always
(with relay removed) between
present.
1
terminal “87” of the system relay and
coil connector [83B] at terminal “A”.
Is resistance less than 0.5 ohm?
Check for 10-13 volts at
terminal “30” of the system relay.
Voltage present?
YES
NO
Recheck connections.
Find and repair
YES
NO
Wiggle harness while
connection or
repeating test. Repair
open wire (Y/GN).
With ignition ON, check for
Check for continuity to
intermittent.
10-13 volts at terminal “86” of
ground on (BE/GY) wire.
the system relay.
Continuity present?
Voltage present?
YES
NO
YES
NO
Measure resistance
Repair short
Find and repair
between terminal “85” of
Is ignition
to ground and replace
open between fuse
System Relay and terminal “2”
fuse good?
2
ECM fuse.
and relay.
on Breakout Box.
Is resistance less than
0.5 ohm?
YES
NO
YES
NO
Check for continuity to ground
Locate and
on terminal “2” on Breakout Box.
repair open on
Find and repair
Continuity present?
(GN/O) wire.
Repair short
open on (W/BK) wire
to ground and replace
between connector [22]
ignition fuse.
and relay.
YES
NO
Repair short
Replace System Relay. Does
to ground.
fuel pump run for the first 2
seconds after key ON?
YES
NO
System
Replace ECM. Reprogram
OK.
and learn password.
Clear DTCs using speedometer self diagnostics. See 4.6
fc01209_en
SPEEDOMETER SELF DIAGNOSTICS. Confirm proper operation
with no check engine lamp.
4-46 2008 Sportster Diagnostics: Engine Management
System Relay: DTC P1002
Remove system relay. Check for
voltage on terminal “2” of Breakout Box.
Voltage present?
YES
NO
Replace
Remove Breakout Box
System Relay.
connector from ECM.
Is voltage still present on terminal “2”?
YES
NO
Replace ECM.
Repair short
Reprogram and learn
to voltage on
password.
(GN/O) wire.
Clear DTCs using speedometer self diagnostics.
See 4.6 SPEEDOMETER SELF DIAGNOSTICS.
Confirm proper operation with no check engine
lamp.
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2008 Sportster Diagnostics: Engine Management 4-47
System Relay: DTC P1004
Check for poor connections, damaged terminals,
poor ground or wires reversed at fuel pump.
Do any of these conditions exist?
YES
NO
Condition: Fuel pump continues to run
Repair.
with key OFF.
Remove system relay.
Does pump continue to run?
Clear DTCs using speedometer self diagnostics.
See 4.6 SPEEDOMETER SELF DIAGNOSTICS.
Confirm proper operation with no check engine
lamp.
YES
NO
Replace short to
Replace
voltage on (Y/GN) wire.
System Relay.
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4-48 2008 Sportster Diagnostics: Engine Management
FUEL PRESSURETEST
4.15
2. Purge fuel supply line of high pressure fuel.
GENERAL
a. See Figure 4-26. Unplug fuel pump fuse from relay/
The fuel pump delivers fuel to the fuel line, to a cavity in the
fuse block.
induction module that supplies the fuel injectors and to the
pressure regulator, where the system pressure is controlled.
b. Start engine and allow vehicle to run.
Excess fuel pressure is bypassed to the fuel tank through the
c. When engine stalls, operate starter for three seconds
pressure regulator.
to remove any remaining fuel from fuel line.
See Figure 4-26. The fuel pump fuse is located on the relay/
fuse block behind the left side cover. The fuel pump can be
turned on by applying battery voltage to the fuel pump fuse.
Improper fuel system pressure may contribute to one of the
Gasoline can drain from quick-connect fitting when
following conditions:
removing fuel line. Gasoline is extremely flammable and
highly explosive, which could result in death or serious
•
Cranks, but won't run.
injury. Wipe up spilled fuel immediately and dispose of
•
Cuts out (may feel like ignition problem).
rags in a suitable manner. (00267a)
•
Hesitation, loss of power or poor fuel economy.
3. Pull up on chrome sleeve of quick-connect fitting (fitting
on left side of fuel tank) and pull down on fuel supply line
to disconnect.
ed02846
Do not twist fuel line fitting, as fuel line can crack causing
a fuel leak. Gasoline is extremely flammable and highly
explosive, which could result in death or serious injury.
(00274a)
4. Attach gauge assembly to vehicle's fuel tank and fuel line.
a. See Figure 4-28. Pull up on chrome sleeve of fuel
tank quick-connect fitting (2) and insert neck of FUEL
PRESSURE GAUGE ADAPTER (Part No. HD-44061)
into fuel supply line.
b. While pushing up on bottom of adapter, pull down on
chrome sleeve until it "clicks" into the locked position.
Tug on adapter to be sure that it will not come free.
Figure 4-26. Fuel Pump Fuse
c. See Figure 4-28. In the same manner, install fuel
supply line fitting into adapter quick-connect fitting
TESTING
(4). Tug on fuel supply line to be sure that it will not
come free.
PART NUMBER
TOOL NAME
HD-41182
FUEL PRESSURE GAUGE
HD-44061
FUEL PRESSURE GAUGE ADAPTER
To prevent spray of fuel, be sure quick-connect fittings
The fuel pressure gauge allows for fuel injector and fuel system
are properly mated. Gasoline is extremely flammable and
pressure diagnosis. A special adapter allows the gauge to be
highly explosive, which could result in death or serious
attached to the external fuel supply line.
injury. (00268a)
1. Remove left side cover.
5. See Figure 4-28. Verify that fuel valve (6) and air bleed
petcock on FUEL PRESSURE GAUGE (Part No. HD-
41182) are closed.
To prevent spray of fuel, purge system of high-pressure
6. See Figure 4-27. Remove protective cap (3) from free end
fuel before supply line is disconnected. Gasoline is
of fuel pressure gauge adapter. See Figure 4-28. Connect
extremely flammable and highly explosive, which could
fuel pressure gauge to Schroeder valve. Tighten fitting (5)
result in death or serious injury. (00275a)
securely.
7. See Figure 4-26. Install fuel pump fuse.
8. Start and idle engine to pressurize fuel system. Open fuel
valve to allow fuel to flow down hose of pressure gauge.
9. Position clear air bleed tube in a suitable container. Open
and close air bleed petcock to purge gauge and hose of
2008 Sportster Diagnostics: Engine Management 4-49
air. Repeat this step several times until only solid fuel
ed02847
(without bubbles) flows from air bleed tube. Close petcock.
1
2
10. Open and close throttle to change engine speed. Note
pressure gauge reading. Fuel pressure should remain
steady at 55-62 psi (380-425 kPa).
11. Turn engine off. Position air bleed tube in a suitable con-
tainer. Open air bleed petcock to relieve fuel system
4
pressure and purge pressure gauge of gasoline.
3
Gasoline can drain from the adapter when gauge is
removed. Gasoline is extremely flammable and highly
6
5
explosive, which could result in death or serious injury.
Wipe up spilled fuel immediately and dispose of rags in a
1. Fuel supply line
suitable manner. (00254a)
2. Fuel tank quick-connect fitting
12. Remove fuel pressure gauge from the adapter. Install
3. Fuel pressure gauge adapter
protective cap over Schroeder valve.
4. Adapter quick-connect fitting
5. Pressure adapter/Schroeder valve fitting
6. Fuel valve (closed position)
Figure 4-28. Fuel Line
Gasoline can drain from the fuel line and adapter when
removed. Gasoline is extremely flammable and highly
explosive, which could result in death or serious injury.
Wipe up spilled fuel immediately and dispose of rags in a
suitable manner. (00255a)
ed02848
13. Pull up on sleeve of quick-connect fitting and remove fuel
supply line from fuel pressure gauge adapter. Release
adapter from fuel tank in the same manner.
14. Pull up on chrome sleeve of fuel tank quick-connect fitting
and insert neck of fuel supply line fitting. While pushing
up on bottom of fuel supply line fitting, pull down on
chrome sleeve until it "clicks" into the locked position. Tug
on fuel supply line to be sure that it will not come free.
15. Install left side cover.
ed02849
1
3
2
Figure 4-29. Fuel Pressure Gauge Installed
DIAGNOSTICS
Diagnostic Notes
1. Adapter
2. Quick-connect fitting
Each reference number below correlates to a circled number
3. Protective cap
on the flow chart(s).
Figure 4-27. Fuel Pressure Gauge Adapter
1. If the regulator is faulty, see Service Manual.
4-50 2008 Sportster Diagnostics: Engine Management
2. If fuel system has pressure, but it is less than specification,
surge and lose power as pressure begins to drop
check for the following conditions.
rapidly.
a. The amount of fuel to the injectors is within limits, but
3. This condition may be identified when the fuel level is low
pressure is too low. Also, hard starting cold and
and the fuel pump turned on for the first two seconds after
overall poor performance condition may exist.
key ON. A metallic ringing sound can be heard as the high
b. Restricted fuel flow causing pressure drop. However,
pressure fuel is sprayed against the inside wall of the fuel
if pressure drop occurs only when driving, engine may
tank.
2008 Sportster Diagnostics: Engine Management 4-51
Fuel Pressure Test
Install fuel pressure gauge. See TESTING
under 4.15 FUEL PRESSURE TEST.
Start and idle engine.
Open and close throttle to change engine
speed. Does fuel pressure remain steady
at 55-62 PSI (380-425 kPa)?
YES
NO
NO
Steady pressure.
Low pressure.
High pressure.
Inspect check valve fitting
No trouble found.
Check for restricted fuel filter
assembly and fuel tank. If OK,
Review symptoms.
2
or pump inlet screen. Are filter
1
replace faulty fuel pressure
and screen OK?
regulator.
YES
NO
Replace filter or clean pump
Check for restricted pressure line or flex hose between
inlet screen. Retest.
tank and test gauge. If lines are OK, check for:
Faulty fuel pump.
3
Clear DTCs using speedometer self diagnostics.
Restricted check valve fitting assembly.
See 4.6 SPEEDOMETER SELF DIAGNOSTICS.
Leak inside tank caused by faulty coupling hose
Confirm proper operation with no check engine
1
or connection, such as hose at filter or pump.
lamp.
Faulty fuel pressure regulator.
fc01212_en
4-52 2008 Sportster Diagnostics: Engine Management
IDLE AIR CONTROL
4.16
a multiple code situation. Resolve the other codes first to cor-
GENERAL
rect.
PART NUMBER
TOOL NAME
HD-44750
DIGITAL TECHNICIAN
Table 4-16. Code Description
DTC
DESCRIPTION
IAC Operation
P0505
Loss of idle speed control
The ECM controls engine idle speed by moving the Idle Air
Control (IAC) to open or close a passage around the throttle
DIAGNOSTICS
plate. It does this by sending voltage pulses to the proper motor
winding of the IAC. This causes the pintle to move in or out of
PART NUMBER
TOOL NAME
the IAC a given distance for each pulse received.
HD-41404-B
HARNESS CONNECTOR TEST KIT
•
To increase idle speed, the ECM retracts the pintle,
HD-43876
BREAKOUT BOX
allowing more air to flow through the throttle body.
•
To decrease idle speed, the ECM extends the pintle,
Diagnostic Tips
allowing less air to flow through the throttle body.
Engine idle speed can be adversely affected by the following:
The IAC position is measured in steps. This can be done only
•
A loss of idle speed control does not necessarily imply the
by using the DIGITAL TECHNICIAN (Part No. HD-44750).
IAC actuator or wiring has failed. It can be caused by a
•
A high number of steps represents a retracted pintle and
number of conditions such as an intake air leak, improperly
open passage around throttle plate. This correlates with
adjusted throttle stop (factory set) or a misfiring cylinder.
an increase in the amount of air flowing through the throttle
•
Leaking injectors will cause fuel imbalance and poor idle
body.
quality due to different air/fuel ratios in each cylinder. To
•
Zero steps represents a fully extended pintle. A zero
check for leaky injectors, first remove the air cleaner. See
reading indicates an abnormal condition in which the pintle
Air Cleaner in the Service Manual. Then, with the throttle
has been fully extended and has consequently closed the
wide open, turn key ON for 2 seconds and then OFF for
passage around throttle plate.
2 seconds five consecutive times. Replace the fuel injector
if there is any evidence of raw fuel in the bores. See Fuel
Each time the ignition is turned off, the ECM resets the IAC by
Injectors in the Service Manual.
sending enough pulses to extend the pintle and effectively
close the throttle body. The fully extended value is the ECM
•
Vacuum leaks. To check for vacuum, see 4.9 INTAKE
reference point. A given number of steps are then calculated
LEAK TEST.
by the ECM for use in setting the proper idle speed and IAC
•
Contaminated fuel.
position.
•
Excessive oil in the crankcase (oil sumping).
NOTE
•
TP sensor reading of greater than 1% (possible throttle
Warm idle speed is controlled by the ECM and can be adjusted
cable misadjustment) or battery voltage reading of less
only by using the DIGITAL TECHNICIAN (Part No. HD-44750).
than 9 volts or a vehicle speed sensor (VSS) greater than
Diagnostic Trouble Code P0505: Loss of
0 will disable idle speed control.
Idle Speed Control
•
If there is a loss of battery power at ECM terminal "31",
vehicle will start but IAC pintle will not reset at key OFF.
Loss of idle speed control will result if the idle RPM is 200 from
Eventually pintle will be out of position causing perform-
preset idle speed and IAC motor is at zero or maximum for
ance problems.
greater than 5 seconds. This code may occur with others for
Diagnostic Notes
Each reference number below correlates to a circled number
on the flow chart(s).
1. When the engine is stopped, the IAC pintle extends and
then retracts to a fixed "Park" position for increased air-
flow and idle speed during the next engine start sequence.
This key OFF reset procedure takes 10 seconds to per-
form.
2008 Sportster Diagnostics: Engine Management 4-53
2. Test lamp behavior may follow two patterns. The color of
ed02850
the lights is not relevant to IAC operation.
a. Normal behavior: At key ON, test lights will altern-
ately flash and then remain steady on to confirm ECM
signals. At key OFF lights alternately flash and go out
after 10 second reset procedure.
b. Problem indicated: One or more lights fail to illu-
minate during key ON/key OFF cycle.
NOTE
There is a remote possibility that one of the circuits is shorted
to voltage which would have been indicated by a steady light.
Disconnect ECM and turn the ignition ON. Probe terminals to
check for this condition.
3. Connect BREAKOUT BOX (Part No. HD-43876) to EFI
wire harness only, leaving ECM disconnected. See
Figure 4-31. IAC Connector
4.7 BREAKOUT BOX: EFI.
4. Use HARNESS CONNECTOR TEST KIT (Part No. HD-
41404-B), gray pin probe and patch cord.
ed02851
5. Repair faulty ECM connection or replace ECM. If ECM
requires replacement, see ECM in the Service Manual.
ed02020
Figure 4-30. IAC Test Lamp (Part No. HD-41199-3)
Figure 4-32. IAC Pintle
4-54 2008 Sportster Diagnostics: Engine Management
em01204
IAC
Motor
[87A]
A
B C D
[87B]
A B C D
2
1
9
4
[145B]
[145A]
2
1
9
4
17
18
35
36
[78B]
[78A]
17
18
35
36
ECM
Figure 4-33. IAC Circuit
Table 4-17. Wire Harness Connectors
NO.
DESCRIPTION
TYPE
LOCATION
[78]
Electronic Control Module (ECM)
36-place Packard
Under seat
[87]
Idle Air Control (IAC)
4-place Delphi
Beneath fuel tank
[145]
Engine harness
16-place Molex
Under seat
2008 Sportster Diagnostics: Engine Management 4-55
Idle Air Control (Part 1 of 2): DTC P0505
Remove air cleaner cover and element. Is
throttle valve completely closed?
YES
NO
Monitor IAC pintle for 10 seconds after turning
Lubricate and
ignition OFF. Does pintle extend and then
adjust throttle
1
retract during 10 second key OFF
cables.
reset procedure?
YES
NO
Check intake manifold for leaks,
Disconnect IAC and connect test lamp.
see 4.9 INTAKE LEAK TEST.
See Figure 4-31.
Leaks found?
Turn ignition key ON for 2 seconds,
2
then turn ignition key OFF for 10
seconds.
Check test lamp during key ON/OFF
cycle.
YES
NO
Repair intake
Check fuel pressure.
Problem
Normal
leak.
See 4.15 FUEL
indicated.
behavior.
PRESSURE
TEST.
Remove test lamp.
Connect Breakout Box to connector
Repair faulty IAC
[78B] leaving ECM disconnected.
connection or IAC assembly.
Check terminal “31” for battery voltage.
Battery voltage present?
YES
NO
Go to 4.11 NO ECM POWER.
Using DVOM, measure resistance
between IAC connector [87B]
and Breakout Box.
3
IAC
WIRE COLOR
ECM
A
BE/GN
to 35
4
B
BN/R
to 36
C
BK/PK
to 18
D
BK/O
to 17
Does each wire measure 0.5 ohms or less?
YES
NO
Turn ignition ON. With ECM still
Repair poor connection
disconnected, check voltage on all
at connectors [87B] or
4
four terminals at connector [87B].
[78B] or repair open wire
Is voltage present?
in harness.
YES
NO
Clear DTCs using speedometer self diagnostics.
See 4.6 SPEEDOMETER SELF DIAGNOSTICS.
Repair short
Go to Idle Air
Confirm proper operation with no check engine
to voltage.
STOP
Control: (Part 2 of
lamp.
2) DTC P0505.
fc01213_en
4-56 2008 Sportster Diagnostics: Engine Management
Idle Air Control (Part 2 of 2): DTC P0505
Continued from Idle Air Control: (Part 1 of 2)
DTC P0505 .
Turn ignition OFF. Measure resistance between
4
each terminal on connector [87B] and ground.
Is resistance greater than
1 megohm for all terminals?
YES
NO
Inspect ECM
Repair short
connections.
to ground.
Connections OK?
YES
NO
Replace ECM.
Repair ECM
5
Reprogram and learn
connections.
password.
Clear DTCs using speedometer self diagnostics.
See 4.6 SPEEDOMETER SELF DIAGNOSTICS.
Confirm proper operation with no check engine
lamp.
fc01214_en
2008 Sportster Diagnostics: Engine Management 4-57
MISFIRE AT IDLE OR UNDER LOAD
4.17
GENERAL
Table 4-18. Spark Plug Cables
Misfire at Idle or Under Load
SPECIFICATION
FRONT
REAR
•
Battery condition and connections may also cause misfires.
Length in.
7.0-7.25
22.9-23.1
See Battery in the Service Manual for more information.
Length mm
177.8-184.2
580.9-587.5
•
Fuel system problems may also cause misfires. Consult
Resistance-ohms
21K-58K
68.6K-185K
4.15 FUEL PRESSURE TEST and then see symptom
tables under 4.5 INITIAL DIAGNOSTIC CHECK: EFI.
3. Perform spark plug cable resistance test.
•
Mechanical problems with the engine may cause misfires.
a. Remove spark plug cable from spark plug and ignition
See Service Manual for more information.
coil. For best results, use a needle nose pliers for
removal/installation on coil. Gently grasp cable as
•
Vehicle modifications including intake and exhaust may
close to terminals as possible.
cause misfires.
b. Using an ohmmeter, touch probes to terminals on
DIAGNOSTICS
each end plug cable.
PART NUMBER
TOOL NAME
c. Compare resistance values to Table 4-18. Replace
HD-26792
SPARK TESTER
cables not meeting specifications. Reinstall and repeat
procedure on other spark plug cable.
HD-41404-B
HARNESS CONNECTOR TEST KIT
HD-43876
BREAKOUT BOX
4. If carbon tracking is evident on outside of coil towers,
replace ignition coil and inspect spark plug cables. Cables
Diagnostic Notes
must be clean and tight. Excessive cable resistance or
faulty connections can cause coil damage.
Each reference number below correlates to a circled number
on the flow chart(s).
5. This test can also be performed by substituting a known
good coil for one causing the no spark condition. The coil
does not require full installation to be functional. Verify
faulty coil by performing resistance test. See Ignition Coil
Wipe up spilled fuel and dispose of rags in a suitable
in the Service Manual.
manner. An open spark around gasoline could cause a
6. Use HARNESS CONNECTOR TEST KIT (Part No. HD-
fire or explosion, resulting in death or serious injury.
41404-B) , red pin probe and patch cord to relay and gray
(00518b)
pin probe and patch cord to the coil connector [83B].
1. Connect BREAKOUT BOX (Part No. HD-43876) between
wire harness and ECM. See 4.7 BREAKOUT BOX: EFI.
ed02012
NOTE
Engine will not spark with both spark plugs removed. When
checking for spark, use SPARK TESTER (Part No. HD-26792)
with both plugs installed.
2. See Figure 4-34. A SPARK TESTER (Part No. HD-26792)
must be used to verify adequate secondary voltage
(25,000 volts) at the spark plug.
a. Turn Ignition Switch OFF.
b. Remove spark plug cable from spark plug. Visually
check plug condition.
c. Attach cable to SPARK TESTER. Clip tester to cyl-
inder head bolt.
d. While cranking engine, watch for spark to jump tester
Figure 4-34. Spark Tester
gap on leads.
e. Reinstall and repeat procedure on other spark plug
cable.
4-58 2008 Sportster Diagnostics: Engine Management
em01205
[78A]
[78B]
Y/GN
K
5
87
ECM
T
4
87A
BE/GY
E
3
30
System
Relay
System relay
2
2
GN/O
GN/O
S
2
85
W/BK
U
1
86
[119B]
Fuse Block
15 Amp
Fuel Pump
Front Injector
Fuse
Y/GN
A
A
Fuel
Y/GN
O/GY
1
1
O/GY
Front injector
21
21
W/Y
13
13
W/Y
W/Y
B
B
Pump
[84B]
[84A]
BK
4
4
BK
Rear Injector
Y/GN
A
A
[141A] [141B]
Rear injector
19
19
GN/GY
8
8
GN/GY
B
B
[85B]
[85A]
Ignition
Coil
7
7
Y/GN
Y/GN
A
A
[145A]
[145B]
Y/GN
B
B
Spark Plugs
Rear coil
11
11
Y/BE
Y/BE
C
C
Front coil
29
29
BE/O
BE/O
D
D
[83B] [83A]
15 Amp
30 Amp
ECM Fuse
MAXIFUSE
Battery
31
31
BE/GY
BE/GY
R
R
R
Switch power
13
13
W/BK
15 Amp
IGN Fuse
R/BK
I
B
A
[33B]
Ignition
Switch
BK
+
-
4
3
[22B]
4
3
[22A]
Battery
Ground
10
10
BK
Ground
28
28
BK
[128A] [128B]
Starter
Engine Stop
Motor
Switch
Figure 4-35. Ignition Coil Circuit Diagram
Table 4-19. Wire Harness Connectors
NO.
DESCRIPTION
TYPE
LOCATION
[22]
Right handlebar controls
6-place Molex
Under fuel tank
[33]
Ignition switch
-
Right side of frame behind neck
[78]
Electronic Control Module (ECM)
36-place Packard
Under seat
[83]
Ignition coil
4-place Delphi
Back of coil
[84]
Front injector
2-place Delphi, black
Top of intake manifold
[85]
Rear injector
2-place Delphi, black
Top of intake manifold
[119]
System relay
5-place Amp
Under left side cover
2008 Sportster Diagnostics: Engine Management 4-59
Table 4-19. Wire Harness Connectors
NO.
DESCRIPTION
TYPE
LOCATION
[128]
Starter solenoid
Locking spade terminal,
Starter solenoid
white
[141]
Fuel pump
4-place Molex
Left side, in front of fuse/relay blocks
[145]
Engine harness
16-place Molex
Under seat
4-60 2008 Sportster Diagnostics: Engine Management
Misfire at Idle or Under Load (Part 1 of 3)
Is fuel contaminated?
YES
NO
Drain and flush
Connect Breakout Box. Check for
tank. Refill with
continuity between terminal “10 “of ECM
fresh fuel.
1
and battery negative and terminal “28” of
ECM and battery negative. Resistance
should be less than 1 ohm. Is it?
YES
NO
Use spark tester to check
Locate and repair poor
2
cables. Did spark jump
ground connection.
tester gap?
YES
NO
Check resistance of each spark plug
cable that did not fire the spark tester.
Check for:
• Faulty, worn or cracked spark plug(s).
Also, check for faulty plug wire
• Plug fouling due to engine
3
connections
mechanical fault.
• Faulty or poor connection at plug or coil.
and wires for carbon tracking.
Are spark plug cables OK?
YES
NO
Coils should be free
Replace
4
of carbon tracking.
faulty spark plug cables.
Are they?
YES
NO
Switch coil with unit
Replace
2
known to be good.
ignition coil.
Re-perform spark test.
5
Did spark jump gap
during engine cranking?
NO
STOP
YES
Go to Misfire At
Idle Or Under Load
(Part 2 of 3).
Original ignition coil
is faulty. Replace
fc01215_en
2008 Sportster Diagnostics: Engine Management 4-61
Misfire at Idle or Under Load (Part 2 of 3)
Continued from Misfire at Idle or Under
Load (Part 1 of 3).
6
Measure resistance between relay
terminal “87” and coil connector [83B]
terminal “A” (Y/GN) wire. Wiggle harness.
Is resistance continuously less than 0.5 ohms?
YES
NO
Reassemble coil and fuel tank. Measure
Find source of
voltage drop between battery (positive
intermittent and
lead) and terminal “87” (negative lead) on
repair.
System Relay with engine running.
Is voltage drop less than 1.0 volt?
YES
NO
Problem fuel related. Refer to Table
Repeat voltage drop test after moving
4-5. Engine Performance Problems
negative lead to terminal “30”.
under 4.5 INITIAL DIAGNOSTIC
With engine running, is voltage drop less
CHECK: EFI.
than 1.0 volt?
YES
NO
Repeat voltage drop test after
Replace system
moving negative lead to 15 amp ECM
relay.
fuse (BE/GY) wire.
With engine running, is voltage drop less
than 1.0
YES
NO
Repeat voltage drop test after
moving negative lead to 15 amp ECM
Repair (BE/GY) wire.
fuse (R) wire.
With engine running, is voltage drop less
than 1.0 volt?
YES
NO
Replace 15 amp
ECM fuse.
STOP
Go to Misfire at Idle or
Under Load (Part 3 of 3).
fc01216_en
4-62 2008 Sportster Diagnostics: Engine Management
Misfire at Idle or Under Load (Part 3 of 3)
Continued from Misfire at Idle or Under
Load (Part 2 of 3).
Repeat voltage drop test after
moving negative lead to 30 amp Main fuse (left
side). With engine running, is voltage drop less
than 1.0 volt?
YES
NO
Check terminal
Repeat voltage drop test after
or repair wire.
moving negative lead to 30 amp
Main fuse (right side). With engine
running, is voltage drop less than
1.0 volt?
YES
NO
Check terminal
Repeat voltage drop test after
or replace
moving negative lead to starter
Main fuse.
motor battery terminal. With engine
running, is voltage drop less than
1.0 volt?
YES
NO
Repair wire
Repair or replace
between main
battery cable.
fuse and starter
motor.
fc01217_en
2008 Sportster Diagnostics: Engine Management 4-63
DTC P0107,
P0108, P0112, P0113
4.18
GENERAL
ed02852
See Figure 4-36. The Temperature Manifold Absolute Pressure
(TMAP) sensor provides the functions of both an Intake Air
Temperature (IAT) sensor and a Manifold Absolute Pressure
(MAP) sensor in one unit.
The TMAP sensor is supplied 5 volts from ECM terminal "14"
and sends IAT and MAP signals back to ECM terminals "7"
and "25" respectively.
MAP Signal
The MAP signal varies in accordance with engine vacuum and
atmospheric barometric pressure. Changes in barometric
pressure are influenced by weather and altitude.
IAT Signal
The IAT portion of the TMAP sensor is a thermistor device,
meaning that at a specific temperature, it will have a specific
resistance across its terminals. As this resistance varies, so
does the voltage on terminal "7" of the ECM.
•
At high temperatures, the resistance of the IAT sensor is
very low, which effectively lowers the signal voltage on
terminal "7".
•
At low temperatures, the resistance is very high, allowing
Figure 4-36. TMAP Sensor
the voltage to rise close to 5 volts.
The ECM monitors this voltage to compensate for various
operating conditions.
DIAGNOSTICS
PART NUMBER
TOOL NAME
Table 4-20. Code Description
HD-23738
VACUUM PUMP
DTC
DESCRIPTION
HD-41404-B
HARNESS CONNECTOR TEST KIT
P0107
MAP sensor open/low
HD-41404-B
HARNESS CONNECTOR TEST KIT
P0108
MAP sensor high
HD-43876
BREAKOUT BOX
P0112
IAT sensor voltage low
HD-43876
BREAKOUT BOX
P0113
IAT sensor open/high
Diagnostic Tips: MAP Sensor
•
DTC P0107 or P0108 will set if the MAP sensor signal is
out of range. DTC P0108 can only be detected with the
engine running.
•
MAP sensor output check. Using the VACUUM
PUMP (Part No. HD-23738), apply a vacuum to the pres-
sure port of the TMAP sensor. The MAP signal voltage
should lower as the vacuum is applied.
•
The TMAP, Jiffy Stand, and TP sensors are connected to
the same reference line (+5V Vref). If the reference line
goes to ground or open, multiple codes will be set (DTC
P0107, P0108, P0122, P0123).
Diagnostic Notes: MAP Sensor
Each reference number below correlates to a circled number
on the flow chart(s).
1. Connect BREAKOUT BOX (Part No. HD-43876) between
wire harness and ECM. See 4.7 BREAKOUT BOX: EFI.
2. Use HARNESS CONNECTOR TEST KIT (Part No. HD-
41404-B), gray pin probes and patch cords.
4-64 2008 Sportster Diagnostics: Engine Management
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