Harley Davidson 2008 Sportster Models. Electrical Diagnostics Manual — page 13

    em01210
    [78A]
    [78B]
    Y/GN
    K
    5
    87
    ECM
    T
    4
    87A
    System
    BE/GY
    E
    3
    30
    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
    Front injector
    21
    21
    W/Y
    13
    13
    W/Y
    W/Y
    B
    B
    Y/GN
    O/GY
    1
    1
    O/GY
    Pump
    [84B] [84A]
    BK
    4
    4
    BK
    Rear Injector
    Y/GN
    A
    A
    Rear injector
    19
    19
    GN/GY
    8
    8
    GN/GY
    GN/GY
    B
    B
    [141A] [141B]
    GND 1
    7
    7
    Y/GN
    [85B]
    [85A]
    Ignition Coil
    [145A] [145B]
    Y/GN
    A
    A
    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
    GY
    R/BK
    Battery
    Engine Case
    Ground Point
    I
    B
    A
    [33B]
    Ignition Switch
    4
    3
    2
    [22B]
    [30B]
    4
    3
    [22A]
    2
    Ground
    10
    10
    BK
    [30A]
    Ground
    28
    28
    BK
    GND 1
    Engine Stop
    TSM/HFSM
    Switch
    Figure 4-45. Fuel Injector Circuit
    Table 4-31. Wire Harness Connectors
    NO.
    DESCRIPTION
    TYPE
    LOCATION
    [22]
    Right hand controls
    6-place Molex, black
    Under fuel tank
    [30]
    TSM/TSSM/HFSM
    12-place Deutsch, gray
    Under battery
    [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, black
    Back of coil, under fuel tank
    [84]
    Front injector
    2-place Delphi
    Beneath fuel tank
    [85]
    Rear injector
    2-place Delphi
    Beneath fuel tank
    2008 Sportster Diagnostics: Engine Management 4-85
    Table 4-31. Wire Harness Connectors
    NO.
    DESCRIPTION
    TYPE
    LOCATION
    [119]
    Relay/fuse block
    5-place Amp, spade ter-
    Fuse/relay block, behind left side cover
    minals
    [141]
    Fuel pump and low fuel switch
    4-place Molex, black
    Forward of relay/fuse blocks
    [145]
    Engine harness
    16-place Molex
    Under seat
    4-86 2008 Sportster Diagnostics: Engine Management
    Fuel Injectors (Part 1 of 3): DTC P0261, P0262, P0263, P0264
    1
    Is wire bail on connector securely
    attached to the fuel injector?
    YES
    NO
    See Figure 4-44. Using Fuel
    Reconnect.
    Injector Test Lamp, crank
    engine. Does lamp flash?
    YES
    NO
    Check Terminal A (Y/GN)
    Recheck connections.
    wire on injector connector to
    Perform 4.8 WIGGLE TEST
    2
    ground. Voltage equivalent
    to check for intermittents.
    to battery voltage for 2
    Intermittents present?
    seconds after key ON?
    YES
    NO
    YES
    NO
    Repair
    Measure resistance of suspect
    intermittent.
    2
    injector across injector terminals.
    Resistance 10.0-25.0 ohms?
    STOP
    Check for 12 volts at
    terminal “87” of System
    Relay during first 2 seconds
    Go to Fuel Injectors:
    YES
    NO
    after key ON. Correct
    (Part 2 of 3) DTC
    voltage present?
    P0261, P0262, P0263,
    P0264.
    Check for loose
    Replace
    1
    or corroded terminals
    injector.
    in harness.
    NO
    NO
    System relay OK. Measure
    resistance between terminal
    “87” of System Relay and
    STOP
    terminal “A” (Y/GN) wire at
    injector connector. Resistance
    less than 0.5 ohm?
    Go to Fuel Injectors:
    (Part 3 of 3) DTC
    P0261, P0262, P0263,
    YES
    NO
    P0264.
    Perform 4.8 WIGGLE
    Find and repair
    TEST to check for
    bad connection
    intermittents. Repair
    or open wire.
    as necessary.
    Clear DTCs using speedometer self diagnostics. See 4.6
    SPEEDOMETER SELF DIAGNOSTICS. Confirm proper operation with no
    check engine lamp.
    fc01229_en
    2008 Sportster Diagnostics: Engine Management 4-87
    Fuel Injectors (Part 2 of 3): DTC P0261, P0262, P0263, P0264
    Continued from Fuel Injectors (Part 1 of 3): DTC
    Continued from Fuel Injectors (Part 1 of 3): DTC
    P0261, P0262, P0263, P0264.
    P0261, P0262, P0263, P0264.
    2
    2
    FRONT INJECTOR: DTC P0261 or P0262.
    REAR INJECTOR: DTC P0263 or P0264.
    3
    Measure resistance between Breakout Box terminal
    Measure resistance between Breakout Box terminal
    3
    “21” (W/Y) wire and terminal “B” of front injector
    “19” (GN/GY) wire and terminal “B” of rear injector
    connector [84B].
    connector [85B].
    Resistance
    less than 0.5 ohm?
    YES
    NO
    Check for continuity between
    Repair open or
    terminal “10” and ground.
    poor connection.
    Front injector codes: Check
    NO
    continuity between terminal “21”
    and terminal “10”. or
    Rear injector codes: Check
    continuity between terminal “19”
    Repair open
    and terminal “10”.
    Continuity present?
    YES
    NO
    Repair short
    Check for voltage with key on.
    to ground.
    Front injector codes: Check
    Breakout Box terminal “21”.
    Rear injector codes: Check
    Breakout Box terminal “19”.
    Voltage present after 2 seconds?
    YES
    NO
    Replace ECM.
    Repair short
    Reprogram
    to voltage.
    and learn password.
    Clear DTCs using speedometer self diagnostics. See 4.6
    SPEEDOMETER SELF DIAGNOSTICS. Confirm proper operation with
    no check engine lamp.
    fc01230_en
    4-88 2008 Sportster Diagnostics: Engine Management
    Fuel Injectors (Part 3 of 3): DTC P0261, P0262, P0263, P0264
    Continued from Fuel Injectors (Part 2 of 3): DTC P0261,
    P0262, P0263, P0264.
    Check for 12 volts at terminal “30” of the system relay.
    Correct voltage present?
    YES
    NO
    Check for 12 volts at terminal “86”
    Find and repair open on
    3
    of the System Relay.
    (BE/GY) wire between
    Correct voltage present?
    fuse and relay.
    NO
    YES
    Measure resistance between
    See 4.11 NO ECM
    terminal “86” of the System
    POWER.
    Relay and ECM terminal “13” on
    Breakout Box.
    Resistance less than 0.5 ohm?
    YES
    NO
    Measure resistance between
    Find and repair
    terminal “85” of the System
    open on (W/BK)
    Relay and ECM terminal “2” on
    wire.
    Breakout Box.
    Resistance less than 0.5 ohm?
    NO
    YES
    Install known good relay.
    Find and repair
    Does fuel pump run for first
    open on (GN/O)
    2 seconds after key ON?
    wire.
    NO
    YES
    Reinstall original
    Replace
    relay. Replace ECM.
    relay.
    Reprogram and
    learn password.
    Clear DTCs using speedometer self diagnostics. See 4.6
    SPEEDOMETER SELF DIAGNOSTICS. Confirm proper operation
    with no check engine lamp.
    fc01231_en
    2008 Sportster Diagnostics: Engine Management 4-89
    DTC P0373,
    P0374
    4.23
    GENERAL
    Table 4-32. Code Description
    CKP Sensor
    DTC
    DESCRIPTION
    See Figure 4-46. The Crankshaft Position (CKP) sensor (1) is
    P0373
    CKP sensor intermittent
    located on the front of the left engine crankcase. The sensor
    harness connector [79] (3) is located under a protective boot
    P0374
    CKP sensor synch error
    (2) behind the front left frame downtube.
    DIAGNOSTICS
    If the CKP sensor signal is weak or absent, DTC P0373 or
    P0374 will be set.
    PART NUMBER
    TOOL NAME
    NOTE
    HD-41404-B
    HARNESS CONNECTOR TEST KIT
    If signal is not detected or cannot synchronize (DTC P0374),
    Diagnostic Tips
    engine will not start.
    •
    Engine must be cranked for more than five seconds
    without CKP signal to set code.
    ed02855
    1
    2
    Diagnostic Notes
    Each reference number below correlates to a circled number
    on the flow chart(s).
    1. Connect BREAKOUT BOX (Part No. HD-43876) to ECM
    wire harness only
    (leave ECM disconnected). See
    4.7 BREAKOUT BOX: EFI.
    2. One megohm is very high resistance.
    3. Use HARNESS CONNECTOR TEST KIT (Part No. HD-
    41404-B), brown socket probes and patch cords.
    4. For testing purposes, install sensor without running wiring
    3
    along normal path. Disconnect and route wiring properly
    if system is now OK.
    1. CKP sensor
    2. Protective boot
    3. Connector [79] (under boot)
    Figure 4-46. CKP Sensor Location
    4-90 2008 Sportster Diagnostics: Engine Management
    em01211
    CKP
    Sensor
    1
    2
    [79A]
    [79B]
    1
    2
    [78A]
    10
    12
    28
    30
    [78B]
    10
    12
    28
    30
    [GND1]
    ECM
    Figure 4-47. CKP Sensor Circuit
    Table 4-33. Wire Harness Connectors
    NO.
    DESCRIPTION
    TYPE
    LOCATION
    [78]
    Electronic Control Module (ECM)
    36-place Packard
    Under seat
    [79]
    Crankshaft Position (CKP) sensor
    2-place Mini-Deutsch
    Front of left crankcase
    2008 Sportster Diagnostics: Engine Management 4-91
    CKP Sensor: DTC P0373, P0374
    Connect Breakout Box to harness only,
    1
    leaving ECM disconnected.
    Measure resistance between terminals 30 and 28
    2
    and between terminals “12” and “28” on Breakout Box.
    Resistance more than 1 megohm?
    YES
    NO
    Check for intermittent connection, pinched or
    Disconnect connector [79]. Leaving
    damaged wires, and loose CKP sensor fasteners.
    ECM disconnected, measure resistance
    Conditions found?
    between terminals “12” and “28” and
    terminals “30” and “28” on Breakout Box.
    Continuity to ground
    YES
    NO
    (less than 1 megohm resistance)?
    Connect DVOM to terminals “12” and “30”
    Repair as
    on Breakout Box. Set DVOM to AC volts and crank
    necessary.
    YES
    NO
    engine.
    Does DVOM read 1 VAC minimum during cranking?
    Repair short to
    Replace
    ground on “R” or
    CKP sensor.
    YES
    NO
    BK wire between
    See Service
    connectors [78B]
    Manual.
    and [79B].
    With DVOM still connected,
    Connect DVOM at Terminals “1” and “2” of
    check for intermittents using
    connector [79A].
    3
    4.8 WIGGLE TEST.
    Does DVOM read 1 VACminimum while
    Intermittents present?
    cranking?
    YES
    NO
    YES
    NO
    Check for continuity
    Repair as
    Install known good
    between terminal
    necessary.
    CKP sensor. Clear
    Replace CKP
    “1” of connector [79B]
    4
    codes and retest.
    sensor. See
    and terminal “30” on
    DTC P0373 or
    Service Manual.
    Breakout Box.
    P0374 set?
    Continuity present?
    YES
    NO
    YES
    NO
    Reinstall original
    CKP sensor.
    Replace CKP
    Repair open on (BK)
    Repair open on (R)
    Replace ECM.
    sensor
    wire between terminal
    wire between terminal
    Reprogram and
    “2” of connector [79B]
    “1” of connector [79B]
    learn password.
    and terminal “12” of
    and terminal “30” of
    connector [78B].
    connector [78B].
    Clear DTCs using speedometer self diagnostics. See 4.6
    SPEEDOMETER SELF DIAGNOSTICS. Confirm proper operation with
    fc01232_en
    no check engine lamp.
    4-92 2008 Sportster Diagnostics: Engine Management
    DTC P0501,
    P0502
    4.24
    GENERAL
    NOTE
    Vehicle Speed Sensor (VSS)
    The MAP, TP, Jiffy Stand, and VSS sensors are connected to
    the same reference line (+5V Vref). If the reference line goes
    See Figure 4-48. The VSS is powered and monitored by the
    to ground or open, multiple codes will be set (DTC P0107,
    ECM. The ECM processes the vehicle speed signal and
    P0108, P0122, P0123, P0501, P0502, P01501, P01502). Start
    transmits this signal to the TSM/TSSM/ HFSM and speedo-
    with the trouble code having the lowest ranking value.
    meter through serial data.
    DIAGNOSTICS
    Table 4-34. Code Description
    PART NUMBER
    TOOL NAME
    DTC
    DESCRIPTION
    HD-41404-B
    HARNESS CONNECTOR TEST KIT
    P0501
    VSS low
    HD-43876
    BREAKOUT BOX
    P0502
    VSS high/open
    Diagnostic Notes
    Each reference number below correlates to a circled number
    ed02857
    on the flow chart(s).
    1. The speedometer has a built-in diagnostic mode. See
    2.3 SPEEDOMETER SELF DIAGNOSTICS.
    2. Use HARNESS CONNECTOR TEST KIT (Part No. HD-
    41404-B), black pin probe and patch cord.
    3. Connect BREAKOUT BOX (Part No. HD-43876) between
    wire harness and ECM. See 4.7 BREAKOUT BOX: EFI.
    Figure 4-48. Vehicle Speed Sensor and Connector
    2008 Sportster Diagnostics: Engine Management 4-93
    em01212
    A
    A
    BK/R
    Vehicle
    Speed
    B
    B
    BK/BE
    Sensor
    C
    C
    BK
    [65A]
    [65B]
    GND 1
    Speedometer
    To TP and
    R/W
    jiffy stand sensor
    [39A]
    2
    [39B]
    2
    [20A]
    7
    7
    [20B]
    [78A]
    5
    10
    14
    33
    To
    [78B]
    5
    10
    14
    33
    TSM/TSSM/HFSM
    ECM
    Figure 4-49. Vehicle Speed Sensor
    Table 4-35. Wire Harness Connectors
    NO.
    DESCRIPTION
    TYPE
    LOCATION
    [20]
    Instruments
    12-place Molex
    Under fuel tank
    [39]
    Speedometer
    12-place Packard
    Back of speedometer
    [65]
    Vehicle Speed Sensor (VSS)
    3-place Delphi
    Rear of transmission case
    [78]
    Electronic Control Module (ECM)
    36-place Packard
    Under seat
    4-94 2008 Sportster Diagnostics: Engine Management
    Vehicle Speed Sensor (Part 1 of 2): DTC P0501, P0502
    Inspect connector [65].
    Is connector mated properly?
    YES
    NO
    Remove and inspect vehicle speed sensor. Inspect
    Mate connector [65].
    for debris and clean if necessary. Place speedometer
    into diagnostic mode and clear diagnostic trouble codes.
    1
    Connect all circuits and ride motorcycle for approximately
    1.0 mile (1.6 km). Check for speedometer function.
    Speedometer functioning properly?
    YES
    NO
    Check for continuity between terminal
    System OK.
    “A” of connector [65B] (BK/R) wire and
    2
    ground.
    Continuity present?
    NO
    NO
    Repair short to ground.
    Check for continuity between terminal “A”
    2
    of connector [65B] (BK/R) wire and
    terminal “14” of Breakout Box.
    3
    Continuity present?
    YES
    NO
    Clear DTCs using speedometer self diagnostics.
    Check for continuity between terminal “C”
    See 4.6 SPEEDOMETER SELF DIAGNOSTICS.
    of connector [65B] (BK) wire and ground.
    Locate and repair open on
    Confirm proper operation with no check engine
    Continuity present?
    (R/W) and (BK/R) wires
    between [78B] and [65B].
    lamp.
    YES
    NO
    Repair open on (BK) wire between
    STOP
    connector [65B] and ground.
    Go to. Vehicle Speed
    Sensor: (Part 2 of 2) DTC
    fc01233_en
    P0501, P0502
    2008 Sportster Diagnostics: Engine Management 4-95
    Vehicle Speed Sensor (Part 2 of 2): DTC P0501, P0502
    Continued from Vehicle Speed Sensor: (Part 1 of
    2
    2) DTC P0501, P0502.
    Check for continuity between terminal “B” of
    connector [65B] (BK/BE) wire and terminal “33” of
    3
    Breakout Box.
    Continuity present?
    YES
    NO
    Check for voltage at terminal “33” on breakout
    box. Meter should read 4-6 volts when gear tooth
    Locate and repair open on
    absent and 0-1 volts when gear tooth is present.
    (BK/BE) wire between [78B]
    Does voltage fall within specifications?
    and [65B].
    YES
    NO
    NO
    NO
    Voltage fluctuates from high
    No voltage fluctuation from
    (4.6 volts) to low (0-1 volts).
    Battery voltage
    No voltage present.
    high (4-6 volts) to low (0-1
    present.
    volts).
    Measure continuity to
    Replace ECM. Reprogram
    Locate and repair short to
    ground from terminal “33” on
    Replace vehicle speed
    and learn password.
    voltage on (BK/BE) wire
    breakout box. Is resistance
    sensor.
    between [78B] and [65B].
    less than 100 ohms?
    YES
    NO
    Locate and repair short to
    Replace ECM. Reprogram
    ground on (BK/BE) wire
    and learn password.
    between [78B] and [65B].
    Clear DTCs using speedometer self diagnostics.
    See 4.6 SPEEDOMETER SELF DIAGNOSTICS.
    Confirm proper operation with no check engine
    lamp.
    fc01234_en
    4-96 2008 Sportster Diagnostics: Engine Management
    DTC P0562,
    P0563
    4.25
    GENERAL
    DIAGNOSTICS
    Battery Voltage
    PART NUMBER
    TOOL NAME
    See Figure 4-50. Battery voltage is monitored by the Electronic
    HD-43876
    BREAKOUT BOX
    Control Module (ECM) (terminal "13"). If the battery voltage
    fails to meet normal operating parameters, a code is set.
    Diagnostic Tips
    •
    Low voltage generally indicates a loose wire, corroded
    NOTE
    connections, battery and/or a charging system problem.
    When either Diagnostic Trouble Code (DTC) P0562 or P0563
    is set, the battery icon in the speedometer will illuminate.
    •
    A high voltage condition may be caused by a faulty voltage
    regulator.
    •
    DTC P0562 is displayed when battery voltage is less than
    12.2 volts at idle and voltage does not increase when
    Diagnostic Notes
    engine speed is greater than 2000 RPM.
    Each reference number below correlates to a circled number
    •
    DTC P0563 is displayed when battery positive voltage is
    on the flow chart(s).
    greater than 15.0 volts for more than 4 seconds.
    1. Was battery allowed to discharge? Was battery drawn
    down by a starting problem?
    NOTES
    a. Yes. Charge battery.
    •
    Warm idle speed will be automatically increased if battery
    voltage is low at idle.
    b. No. See 1.7 CHARGING SYSTEM, Troubleshooting.
    •
    TSM/TSSM/HFSM problems may also set DTC P0562 or
    2. Connect BREAKOUT BOX (Part No. HD-43876) between
    P0563.
    wire harness and ECM. See 4.7 BREAKOUT BOX: EFI.
    3. Use DVOM with RPM Pick-up to check RPM on vehicles
    Table 4-36. Code Description
    without tachometers.
    DTC
    DESCRIPTION
    4. This checks for voltage drops in the ECM circuit.
    P0562
    Battery voltage low
    a. Place (+) probe to battery positive terminal.
    P0563
    Battery voltage high
    b. Place (-) probe to (W/BK) terminal on Breakout Box.
    5. Problem is most likely the ground connection at the frame.
    ed02845
    Figure 4-50. System Relay
    2008 Sportster Diagnostics: Engine Management 4-97
    em01213
    To fuse pump fuse
    [78A]
    [78B]
    ECM
    Y/GN
    K
    5
    87
    T
    4
    87A
    BE/GY
    E
    3
    30
    System
    System relay
    2
    2
    GN/O
    GN/O
    S
    2
    85
    Relay
    W/BK
    U
    1
    86
    30 Amp
    [119B]
    Fuse Block
    MAXIFUSE
    R
    R
    +
    -
    15 Amp
    Battery
    ECM fuse
    Battery
    31
    31
    BE/GY
    BE/GY
    R
    Engine Case
    Ground Point
    15 Amp
    IGN Fuse
    Switch power
    13
    13
    W/BK
    GY
    R/BK
    R/BK
    C
    I - IGN
    Ignition
    R
    B
    B - BATT
    Switch
    A
    A - ACC
    [33B] [33A]
    4
    3
    [22B]
    4
    3
    [22A]
    Engine Stop
    Switch
    Ground
    10
    10
    BK
    Ground
    28
    28
    BK
    GND 1
    Figure 4-51. Ignition Coil Circuit
    Table 4-37. 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
    [119]
    System relay
    5-place Amp
    Under left side cover
    4-98 2008 Sportster Diagnostics: Engine Management
    Battery Voltage (Part 1 of 2): DTC P0562, P0563
    Perform charging system tests.
    1
    Charging system OK?
    YES
    NO
    Connect Breakout Box. Measure voltage on
    2
    Breakout Box between terminal “13” (+) and
    Repair charging system.
    terminal “10” (-) and again between terminal “13”
    See Section 1.7
    and terminal “28” (-) with engine running at
    CHARGING SYSTEM.
    3
    2000 RPM or higher for 10 seconds or longer.
    Is voltage above 11.0 volts?
    YES
    NO
    System
    With ignition ON, measure voltage drop
    1
    OK.
    between battery positive (+) terminal
    4
    and Breakout Box terminal “13” (-).
    Is voltage drop greater than 0.5 volt?
    NO
    YES
    Check for voltage drop between battery
    With ignition OFF, measure resistance
    negative (-) terminal and terminal “10” (+)
    between Breakout Box terminal “13”
    on Breakout Box connector and between
    and connector [22B] terminal “4”.
    battery negative (-) terminal and terminal
    Is resistance greater than 1 ohm?
    “28” on Breakout Box.
    Is voltage drop greater than 0.5 volt?
    NO
    YES
    YES
    With ignition ON, measure resistance
    NO
    between ignition fuse and connector
    Repair open on (W/BK)
    [22B] terminal 3.
    wire between [22B]
    and [78B] or terminals.
    Problem is intermittent.
    Is resistance greater than 1 ohm?
    Locate and repair
    Perform 4.8 WIGGLE
    5
    bad connection.
    TEST. Locate and
    repair bad connection.
    YES
    NO
    Inspect [22] for corrosion or
    loose wires. If above conditions
    STOP
    are not present, replace engine
    Clear DTCs using speedometer self diagnostics.
    stop switch.
    See 4.6 SPEEDOMETER SELF DIAGNOSTICS.
    Confirm proper operation with no check engine
    Go to Battery Voltage: (Part
    lamp.
    2 of 2) DTC P0562, P0563.
    fc01235_en
    2008 Sportster Diagnostics: Engine Management 4-99
    Battery Voltage (Part 2 of 2): DTC P0562, P0563
    Continued from Battery Voltage: (Part 1 of 2) DTC
    P0562, P0563.
    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?
    YES
    NO
    With ignition ON, measure voltage drop
    Replace GY wire
    between battery positive (+) terminal and
    or terminals.
    (R/BK) terminal at 15 amp ignition fuse.
    Is voltage drop greater than 0.5 volt?
    YES
    NO
    With ignition ON, measure voltage drop
    Replace fuse or
    between battery positive (+) and both fuse
    fuse terminals.
    terminals (-).
    Is voltage drop greater than 0.5 volt?
    YES
    NO
    With ignition ON, measure voltage drop
    Replace ignition
    between battery positive (+) terminal and
    switch or terminals.
    one fuse terminal (-).
    Is voltage drop greater than 0.5 volt?
    YES
    NO
    High resistance between
    Replace main fuse.
    main fuse and battery.
    Replace wire or terminals.
    Clear DTCs using speedometer self diagnostics.
    See 4.6 SPEEDOMETER SELF DIAGNOSTICS.
    Confirm proper operation with no check engine
    fc01236_en
    lamp.
    4-100 2008 Sportster Diagnostics: Engine Management
    DTC P0603,
    P0605
    4.26
    GENERAL
    DIAGNOSTICS
    PART NUMBER
    TOOL NAME
    These codes are set under two conditions.
    HD-44750
    DIGITAL TECHNICIAN
    •
    If DTC P0603 or P0605 occur during normal operation,
    replace ECM. Reprogram and learn password.
    ECM Failure
    •
    If DTC P0603 or P0605 occur during or after reprogram-
    Refer to Table 4-38. The DTCs listed indicate a failure which
    ming, perform the following:
    requires replacement of the ECM. See the Service Manual for
    DTC P0603
    replacement information.
    1. Clear DTCs.
    NOTE
    After replacing ECM, reprogram, perform password learning
    2. Power down the vehicle. Wait 10 seconds.
    procedure and clear codes. ECM must be reprogrammed using
    3. Turn ignition ON.
    the DIGITAL TECHNICIAN (Part No. HD-44750). See your
    dealer. Password learn procedure must also be performed.
    4. Replace ECM if codes reappear.
    See 3.25 TSM/HFSM: PASSWORD LEARN.
    DTC P0605
    Table 4-38. Code Description
    1. Clear DTCs.
    DTC
    DESCRIPTION
    2. Power down the vehicle.
    P0603
    ECM EEPROM error
    3. Attempt to reprogram ECM using correct calibration.
    P0605
    ECM flash error
    4. Restart vehicle. If code reappears, replace ECM.
    2008 Sportster Diagnostics: Engine Management 4-101
    DTC P1009,
    P1010
    4.27
    GENERAL
    ed01340
    Password Problem
    The ECM, TSM/TSSM/HFSM and speedometer exchange
    passwords during operation. An incorrect password or missing
    password will set a diagnostic code.
    NOTE
    If the TSM/TSSM/HFSM is not connected to the wiring harness,
    the vehicle will not start.
    Table 4-39. Code Description
    DTC
    DESCRIPTION
    P1009
    Incorrect password
    P1010
    Missing password
    Figure 4-52. Data Link Connector [91A]
    DIAGNOSTICS
    PART NUMBER
    TOOL NAME
    HD-41404-B
    HARNESS CONNECTOR TEST KIT
    sm01275
    HD-43876
    BREAKOUT BOX
    Diagnostic Notes
    Each reference number below correlates to a circled number
    on the flow chart(s).
    1. DTC P1009 may be set if a recent ECM or TSM/TSSM/
    HFSM replacement did not follow the correct password
    assignment procedure. See
    3.25 TSM/HFSM: PASS-
    WORD LEARN for details.
    2. Use HARNESS CONNECTOR TEST KIT (Part No. HD-
    41404-B), black socket probes and patch cord.
    3. Connect BREAKOUT BOX (Part No. HD-43876) between
    wire harness and ECM. See 4.7 BREAKOUT BOX: EFI.
    4. Historic codes DTC U1300 or DTC U1301 would also have
    been set. Clear codes.
    Figure 4-53. TSM/TSSM/HFSM
    5. See the Service Manual for TSM/TSSM/HFSM replace-
    ment. See
    3.25 TSM/HFSM: PASSWORD LEARN,
    Password Learning for the password learning procedure.
    4-102 2008 Sportster Diagnostics: Engine Management
    Speedometer
    em01120
    Tachometer (Optional)
    TSM/TSSM/HFSM
    1
    2
    5
    6
    7
    [39A]
    1
    2
    5
    6 7
    [108A]
    1
    2
    5
    6
    7
    [39B]
    1
    2
    5
    6 7
    [108B]
    [30A]
    1
    2
    3
    12
    [30B]
    1
    2
    3
    12
    [GND1]
    1
    2
    6
    7
    12
    [20A]
    1
    2
    6
    7
    12
    [20B]
    To ACCY fuse
    R/GY
    O/W
    To BATT fuse
    12V ACCY
    Fuse
    [GND1]
    R
    BN/GY
    BN/GY
    12V BATT
    GY
    Fuse
    To INSTR fuse
    LGN/V
    R/BK
    O
    12V INSTR
    1
    Fuse
    To IGN fuse
    BK
    2
    Data Link
    Connector
    LGN/V
    3
    R/BK
    GY
    GY
    4
    12V IGN
    Fuse
    [91A]
    [GND1]
    [78B]
    5
    [78A]
    5
    ECM
    Figure 4-54. Serial Data Circuit
    Table 4-40. Wire Harness Connectors
    NO.
    DESCRIPTION
    TYPE
    LOCATION
    [20]
    Instruments
    12-place Molex
    Under fuel tank
    [30]
    TSM/TSSM/HFSM
    12-place Deutsch
    Under battery tray
    [39]
    Speedometer
    12-place Packard
    Back of speedometer
    [78]
    Electronic Control Module (ECM)
    36-place Packard
    Under seat
    [91]
    Data link connector
    4-place Deutsch
    Under left side cover
    [108]
    T
    achometer (if equipped)
    12-place Packard
    Back of tachometer
    2008 Sportster Diagnostics: Engine Management 4-103
    Password Problem: DTC P1009, P1010
    Which diagnostic trouble
    code was set?
    DTC P1009.
    Bad password.
    1
    DTC P1010.
    Perform password learn.
    No password.
    See 3.25 TSM/HFSM:
    Are there any
    PASSWORD LEARN.
    5
    U-codes set?
    DTC P1009 still exist?
    YES
    NO
    YES
    NO
    Replace TSM/TSSM/HFSM
    System
    Troubleshoot
    Remove ECM connector [78]. Check
    5
    and relearn password.
    OK.
    lowest U-code.
    for continuity to ground at data link
    2
    System OK?
    connector [91A] terminal “3”.
    Continuity present?
    YES
    NO
    YES
    NO
    Repair short
    Reinstall original
    4
    System
    to ground.
    Check for battery voltage on terminal “3”.
    TSM/TSSM/HFSM.
    OK.
    Battery voltage present?
    5
    Replace ECM.
    Reprogram and relearn
    password.
    YES
    NO
    Repair short
    2
    Test data link connector [91A]
    4
    to voltage.
    terminal “3” against Breakout Box
    terminal “5” for continuity.
    3
    Continuity present?
    NO
    YES
    Inspect terminals
    Replace TSM/TSSM/HFSM and
    2
    for damage or repair
    5
    relearn password.
    opens as necessary.
    System OK?
    YES
    NO
    System
    Reinstall original TSM/TSSM/HFSM.
    OK.
    5
    Replace ECM. Reprogram and
    relearn password.
    Clear DTCs using speedometer self diagnostics.
    See 4.6 SPEEDOMETER SELF DIAGNOSTICS.
    Confirm proper operation with no check engine
    fc01237_en
    lamp.
    4-104 2008 Sportster Diagnostics: Engine Management

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    Матвей Александрович10.06.2024 14:18
    Политика конфиденциальности