Harley Davidson 2008 Sportster Models. Electrical Diagnostics Manual — page 1
ABOUT THIS MANUAL
GENERAL
NOTES
•
To avoid unnecessary disassembly, carefully read all rel-
This electrical diagnostic service manual has been prepared
ative service information before repair work is started.
with two purposes in mind. First, it will acquaint the user with
the construction of the Harley-Davidson product and assist in
•
In figure legends, the number which follows the name of
the performance of repair. Secondly, it will introduce to the
a part indicates the quantity necessary for one complete
professional Harley-Davidson Technician the latest field-tested
assembly.
and factory-approved diagnostic methods. We sincerely believe
•
When servicing a vehicle equipped with the Harley-Dav-
that this manual will make your association with Harley-Dav-
idson Smart Security System (H-DSSS), you must first
idson products more pleasant and profitable.
disarm the security system. Either keep the fob in close
HOW TO USE YOUR SERVICE MANUAL
proximity to the vehicle, or use Digital Technician to disable
the security system while the vehicle is being serviced and
Refer to the table below for the content layout of this manual.
re-enable the system after service is completed.
NO.
CHAPTER
SERVICE BULLETINS
1
Starting / Charging
In addition to the information presented in this Service Manual,
2
Instruments
Harley-Davidson Motor Company will periodically issue Service
Bulletins to Harley-Davidson dealers. Service Bulletins cover
3
TSM/HFSM
interim engineering changes and supplementary information.
4
Engine Management
Consult the Service Bulletins to keep your product knowledge
current and complete.
A
Appendix A Connector Repair
B
Appendix B Wiring
USE GENUINE REPLACEMENT PARTS
C
Appendix C Conversions
D
Appendix D Glossary
E
Appendix E TSM/TSSM (Japan/Korea)
Do not use aftermarket parts and custom made front forks
which can adversely affect performance and handling.
Use the TABLE OF CONTENTS (which follows this FORE-
Removing or altering factory installed parts can adversely
WORD) and the INDEX (at the back of this manual) to quickly
affect performance and could result in death or serious
locate subjects. Sections and topics in this manual are
injury. (00001a)
sequentially numbered for easy navigation.
To ensure satisfactory and lasting repairs, carefully follow the
For example, a cross-reference shown as 2.1 SPECIFICA-
Service Manual instructions and use only genuine Harley-
TIONS refers to chapter 2 CHASSIS, heading 2.1 SPECIFIC-
Davidson replacement parts. Behind the emblem bearing the
ATIONS.
words GENUINE HARLEY-DAVIDSON stand more than 100
years of design, research, manufacturing, testing and inspecting
For quick and easy reference, all pages contain a section
experience. This is your assurance that the parts you are using
number followed by a page number. For example, page 3-5
will fit right, operate properly and last longer.
refers to page 5 in section 3.
A number of acronyms and abbreviations are used in this
WARNINGS AND CAUTIONS
document. See the D.1 GLOSSARY for a list of acronyms,
Statements in this service manual preceded by the following
abbreviations and definitions.
words are of special significance.
PREPARATION FOR SERVICE
WARNING indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
Stop the engine when refueling or servicing the fuel
injury. (00119a)
system. Do not smoke or allow open flame or sparks near
gasoline. Gasoline is extremely flammable and highly
explosive, which could result in death or serious injury.
(00002a)
CAUTION indicates a potentially hazardous situation
Good preparation is very important for efficient service work.
which, if not avoided, may result in minor or moderate
A clean work area at the start of each job will allow you to
injury. (00139a)
perform the repair as easily and quickly as possible, and will
reduce the incidence of misplaced tools and parts. A motorcycle
that is excessively dirty should be cleaned before work starts.
Cleaning will occasionally uncover sources of trouble. Tools,
CAUTION used without the safety alert symbol indicates
instruments and any parts needed for the job should be
a potentially hazardous situation which, if not avoided,
gathered before work is started. Interrupting a job to locate
may result in property damage. (00140a)
tools or parts is a distraction and causes needless delay.
I
NOTE
information or product returns, warranty or otherwise, visit
Refers to important information, and is placed in italic type. It
is recommended that you take special notice of these items.
Loctite Sealing and Threadlocking Products
Proper service and repair is important for the safe, reliable
Some procedures in this manual call for the use of Loctite
operation of all mechanical products. The service procedures
products. If you have any questions regarding Loctite product
recommended and described in this service manual are
usage or retailer/wholesaler locations, please contact Loctite
effective methods for performing service operations.
Corp. at www.loctite.com.
PRODUCT REGISTERED MARKS
Allen, Amp Multilock, Bluetooth, Brembo, Delphi, Deutsch,
Always wear proper eye protection when using hammers,
Dunlop, Dynojet, Fluke, G.E. Versilube, Gunk, Hydroseal,
arbor or hydraulic presses, gear pullers, spring com-
Hylomar, Kevlar, Lexan, Loctite, Lubriplate, Keps, K&N, Mag-
pressors, slide hammers and similar tools. Flying parts
naflux, Marson Thread-Setter Tool Kit, MAXI fuse, Molex, MPZ,
could result in death or serious injury. (00496b)
Mulitilock, Novus, Packard, Pirelli, Permatex, Philips, PJ1,
Some of these service operations require the use of tools
Pozidriv, Robinair, S100, Sems, Snap-on, Teflon, Threadlocker,
specially designed for the purpose. These special tools should
Torca, Torco, TORX, Tufoil, Tyco, Ultratorch, Velcro, X-Acto,
be used when and as recommended. It is important to note
and XM Satellite Radio are among the trademarks of their
that some warnings against the use of specific service methods,
respective owners.
which could damage the motorcycle or render it unsafe, are
stated in this service manual. However, please remember that
H-D MICHIGAN, INC. TRADEMARK
these warnings are not all-inclusive. Inadequate safety precau-
INFORMATION
tions could result in death or serious injury.
Harley, Harley-Davidson, H-D, Bar & Shield, Digital Tech,
Since Harley-Davidson could not possibly know, evaluate or
Digital Technician, Destroyer, Deuce, Dyna, Electra Glide,
advise the service trade of all possible ways in which service
Evolution, Fat Boy, Glaze, Gloss, H-D, H-Dnet.com, HD, Harley,
might be performed, or of the possible hazardous con-
Heritage Softail, Heritage Springer, Low Rider, Night Rod, Night
sequences of each method, we have not undertaken any such
Train, Profile, Revolution, Road Glide, Road King, Rocker,
broad evaluation. Accordingly, anyone who uses a service
Softail, Sportster, Sun Ray, Sunwash, Tech Link, Twin Cam
procedure or tool which is not recommended by Harley-Dav-
88, Twin Cam 88B, Twin Cam 96, Twin Cam 96B, Twin Cam
idson must first thoroughly satisfy himself that neither his nor
103, Twin Cam 103B, Twin Cam 110, Twin Cam 110B, Tour-
the operator's safety will be jeopardized as a result. Failure to
Pak, Screamin' Eagle, Softail, Super Guide, Super Premium,
do so could result in death or serious injury.
SYN3, Ultra Glide, V-Rod, VRSC, V-Rod, VRSC, Wide Glide,
and Harley-Davidson Genuine Motor Parts and Genuine Motor
PRODUCT REFERENCES
Accessories are among the trademarks of H-D Michigan, Inc.
CONTENTS
All photographs, illustrations and procedures may not neces-
Read and follow warnings and directions on all products.
sarily depict the most current model or component, but are
Failure to follow warnings and directions can result in
based on the latest production information available at the time
death or serious injury. (00470b)
of publication.
When reference is made in this manual to a specific brand
Since product improvement is our continual goal, Harley-Dav-
name product, tool or instrument, an equivalent product, tool
idson reserves the right to change specifications, equipment
or instrument may be substituted.
or designs at any time without notice and without incurring
Kent-Moore Products
obligation.
All tools mentioned in this manual with an "HD", "J" or "B"
preface must be ordered through SPX Kent-Moore. For ordering
II FOREWORD
STARTING / CHARGING
2.2 INITIAL DIAGNOSTIC CHECK:
SPEEDOMETER
1.1 STARTER TROUBLESHOOTING
General
2-4
Diagnostic Notes
2-4
General
1-1
Circuit Diagram/Wire Harness Connector Table
2-4
Starter Troubleshooting
1-1
Job/Time Code Values
2-4
1.2 STARTING SYSTEM DIAGNOSIS
Reprogramming ECM
2-4
Initial Diagnostics
2-4
Diagnostics
1-3
Diagnostic Tips
2-4
Diagnostic Notes
1-3
Diagnostic Notes
2-5
Job/Time Code Values
1-3
Other Diagnostic Trouble Codes
2-5
1.3 STARTER ACTIVATION CIRCUITS
2.3 SPEEDOMETER SELF DIAGNOSTICS
Starter Activation Circuits
1-12
General
2-10
Diagnostics
2-10
1.4 DIAGNOSTICS/TROUBLESHOOTING
Diagnostic Tips
2-10
Voltage Drop
1-13
Diagnostic Notes
2-10
1.5 TESTING STARTER ON MOTORCYCLE
2.4 SPEEDOMETER/TACHOMETER
Start Relay Test
1-14
General
2-12
Starter Current Draw Test
1-14
Trip Odometer Reset Switch
2-12
Speedometer Theory of Operation
2-12
1.6 TESTING STARTER ON BENCH
Odometer Theory of Operation
2-12
Free Running Current Draw Test
1-16
Tachometer Theory of Operation
2-12
Starter Solenoid
1-16
Diagnostics
2-13
Solenoid Pull-In Test
1-16
Diagnostic Notes
2-13
Solenoid Hold-In Test
1-17
Solenoid Return Test
1-17
2.5 BREAKOUT BOX:
SPEEDOMETER/TACHOMETER
1.7 CHARGING SYSTEM
General
2-16
General
1-18
Speedometer
2-16
Alternator
1-18
Installation
2-16
Voltage Regulator
1-18
Removal
2-16
Troubleshooting
1-18
Tachometer
2-16
Battery
1-18
Installation
2-16
Wiring
1-18
Removal
2-16
Testing
1-22
Milliampere Draw Test
1-22
2.6 INDICATOR LAMPS
Total Current Draw Test
1-22
General
2-17
Current and Voltage Output Test: Using HD-48053
1-23
Job/Time Code Values
2-17
Current and Voltage Output Test: Using Load
Diagnostics
2-17
Tester
1-23
Diagnostic Notes
2-17
Stator Check
1-24
AC Output Check
1-25
2.7 DTC B1004, B1005
1.8 BATTERY TESTING
General
2-21
Diagnostics
2-21
General
1-26
Diagnostic Tips
2-21
Voltmeter Test
1-26
Diagnostic Notes
2-21
Conductance Test
1-26
Load Test
1-26
2.8 DTC B1006, B1007
INSTRUMENTS
General
2-25
Accessory or Ignition Line Overvoltage
2-25
2.1 CHECKING FOR DIAGNOSTIC TROUBLE
2.9 DTC B1008
CODES
General
2-27
Check Engine Lamp
2-1
Trip Odometer Reset Switch Closed
2-27
Security Lamp
2-2
Diagnostics
2-27
Turn Signal Module (TSM)
2-2
Diagnostic Notes
2-27
Turn Signal Security Module (TSSM) or Hands-Free
Security Module (HFSM)
2-2
2.10 DTC U1016, U1255
Code Types
2-3
General
2-30
Current
2-3
Loss of ECM Serial Data
2-30
Historic
2-3
Diagnostics
2-30
Retrieving Diagnostic Trouble Codes
2-3
Diagnostic Notes
2-30
Multiple Diagnostic Trouble Codes
2-3
III
TABLE OF CONTENTS
Activation
3-10
2.11 DTC U1064, U1255
Deactivation
3-10
General
2-33
Siren Chirp Mode (Confirmation)
3-10
Loss of TSM/TSSM/HFSM Serial Data
2-33
Chirpless Mode
3-10
Diagnostics
2-33
Chirp Mode
3-10
Diagnostic Notes
2-33
Switching Modes
3-10
2.12 DTC U1300, U1301 OR BUS ER
3.7 SERVICE/EMERGENCY FUNCTIONS
General
2-37
Transport Mode
3-11
Serial Data Low or Serial Data Open/High
2-37
To Enter Transport Mode
3-11
Diagnostics
2-37
To Exit Transport Mode
3-11
Diagnostic Tips
2-37
Service Mode
3-11
Diagnostic Notes
2-37
Four-Way Flashing
3-11
To Arm the HFSM with the Hazard Warning Flashers
TSM/HFSM
ON
3-11
To Disarm the HFSM and Turn the Hazard Warning
3.1 TURN SIGNAL OVERVIEW
Flashers OFF
3-11
General
3-1
3.8 TROUBLESHOOTING
Security System: Japan/Korea
3-1
Turn Signal Functions
3-1
Turn Signals (TSM/HFSM)
3-12
Manual Cancellation
3-1
Security System (HFSM)
3-12
Automatic Cancellation
3-1
Diagnostics Mode
3-12
Bank Angle Functions
3-1
Troubleshooting
3-12
Bank Angle Restart
3-1
3.9 CHECKING FOR DIAGNOSTIC TROUBLE
Clutch/Neutral Interlock
3-1
Security System H-DSSS
3-1
CODES
General
3-13
3.2 HARLEY-DAVIDSON SMART SECURITY
Security/Lamp Diagnostics
3-13
SYSTEM
Code Types
3-14
Components
3-2
Current
3-14
Security Immobilization
3-2
Historic
3-14
HFSM Features
3-3
Retrieving DTCs
3-14
Multiple DTCs/Priority Order
3-15
3.3 H-DSSS ACTUATION
3.10 INITIAL DIAGNOSTIC CHECK:
General
3-5
Sidecar Configuration
3-5
TSM/HFSM
Actuation
3-5
General
3-16
Fob Assignment
3-5
Diagnostic Notes
3-16
Power Disruption and Configuring
3-5
Circuit Diagram/Wire Harness Connector Table
3-16
Job/Time Codes
3-16
3.4 PERSONAL IDENTIFICATION NUMBER
Reprogramming ECM
3-16
(PIN)
Initial Diagnostics
3-16
Diagnostic Tips
3-16
General
3-6
Diagnostic Notes
3-16
Initial Pin Entry
3-6
Other Diagnostic Trouble Codes (DTCs)
3-17
Changing the Pin
3-6
Modifying an Existing Pin
3-6
3.11 SPEEDOMETER SELF DIAGNOSTICS
3.5 ARMING/DISARMING SECURITY
General
3-22
SYSTEM
Diagnostics
3-22
Diagnostic Tips
3-22
Hands-Free Fob
3-8
Diagnostic Notes
3-22
Security Lamp (Key Icon)
3-8
Arming
3-8
3.12 BREAKOUT BOX: TSM/HFSM
Disarming
3-9
General
3-24
Automatic Disarming
3-9
Installation
3-24
Disarming with a Personal Identification Number
Removal
3-24
(PIN)
3-9
3.13 FAILS TO DISARM (HFSM ONLY)
3.6 WARNINGS AND ALARMS
General
3-26
Warnings
3-10
Job/Time Codes
3-26
Alarm
3-10
Diagnostics
3-26
IV TABLE OF CONTENTS
TABLE OF CONTENTS
Diagnostic Tips
3-26
3.24 DTC U1300, U1301 OR BUS ER
Diagnostic Notes
3-26
Diagnostics
3-69
Diagnostic Tips
3-69
3.14 DTC B0563
Diagnostic Notes
3-69
General
3-29
Diagnostics
3-29
3.25 TSM/HFSM: PASSWORD LEARN
Diagnostic Tips
3-29
General
3-70
Diagnostic Notes
3-29
Password Learning
3-70
3.15 TSM/HFSM: TURN SIGNAL ERRORS
3.26 HFSM MAINTENANCE
AND DTCS
General
3-71
General
3-30
Hands-Free Fob
3-71
Diagnostics
3-30
Schedule
3-71
Job/Time Codes
3-30
Battery Replacement
3-71
Diagnostic Tips
3-30
Smart Siren (If Installed)
3-71
Diagnostic Notes
3-32
Schedule
3-71
Battery Replacement: Early Style Siren
3-71
3.16 DTC B1131, B1132 (HFSM ONLY)
Battery Replacement: Late Style Siren
3-71
General
3-46
Diagnostics
3-46
ENGINE MANAGEMENT
Diagnostic Tips
3-46
Diagnostic Notes
3-46
4.1 SPECIFICATIONS
3.17 DTC B1134
Specifications
4-1
General
3-49
4.2 EFI SYSTEM
Diagnostics
3-49
General
4-2
Diagnostic Notes
3-49
Troubleshooting
4-2
3.18 DTC B1135
4.3 EFI DIAGNOSTIC INTRODUCTION
Diagnostics
3-52
System Problems
4-4
DTC B1135 Accelerometer Fault
3-52
No Start
4-4
3.19 DTC B1136, B1142 (HFSM ONLY)
Poor Performance
4-4
Check Engine Lamp
4-4
Diagnostics
3-53
Resolving Problems
4-4
DTC B1136 Accelerometer Tip-Over Self-Test
Fault
3-53
4.4 CHECKING FOR DIAGNOSTIC TROUBLE
DTC B1142 Internal Fault
3-53
CODES: EFI
3.20 DTC B1141 (HFSM ONLY)
Check Engine Lamp
4-5
Diagnostics
3-54
Code Types
4-6
Diagnostic Tips
3-54
Current
4-6
Diagnostic Notes
3-54
Historic
4-6
Retrieving Diagnostic Trouble Codes
4-6
3.21 DTC B1143, B1144, B1145 (HFSM
Multiple Diagnostic Trouble Codes
4-6
ONLY)
4.5 INITIAL DIAGNOSTIC CHECK: EFI
General
3-57
General
4-7
Diagnostics
3-57
Diagnostic Notes
4-7
Diagnostic Notes
3-57
Circuit Diagram/Wire Harness Connector Table
4-7
Reprogramming ECM
4-7
3.22 DTC B1154, B1155
Initial Diagnostics
4-7
Diagnostics
3-62
General Information
4-7
Diagnostic Tips
3-62
Diagnostic Tips
4-7
Diagnostic Notes
3-62
Diagnostic Notes
4-7
Other Diagnostic Trouble Codes (DTCs)
4-7
3.23 DTC U1016, U1255
General
3-66
4.6 SPEEDOMETER SELF DIAGNOSTICS
Diagnostics
3-66
General
4-15
Diagnostic Notes
3-66
Diagnostics
4-15
Diagnostic Tips
4-15
Diagnostic Notes
4-15
TABLE OF CONTENTS V
TABLE OF CONTENTS
Diagnostics
4-53
4.7 BREAKOUT BOX: EFI
Diagnostic Tips
4-53
General
4-17
Diagnostic Notes
4-53
Installation
4-17
Removal
4-17
4.17 MISFIRE AT IDLE OR UNDER LOAD
4.8 WIGGLE TEST
General
4-58
Misfire at Idle or Under Load
4-58
General
4-18
Diagnostics
4-58
Procedure
4-18
Diagnostic Notes
4-58
4.9 INTAKE LEAK TEST
4.18 DTC P0107, P0108, P0112, P0113
General
4-19
General
4-64
Leak Tester
4-19
MAP Signal
4-64
Parts List
4-19
IAT Signal
4-64
Tester Assembly
4-19
Diagnostics
4-64
Tester Adjustment
4-19
Diagnostic Tips: MAP Sensor
4-64
Procedure
4-19
Diagnostic Notes: MAP Sensor
4-64
Diagnostic Tips: IAT Sensor
4-65
4.10 ENGINE CRANKS, BUT WILL NOT
Diagnostic Notes: IAT Sensor
4-65
START
4.19 DTC P0117, P0118
General
4-21
Diagnostics
4-21
General
4-71
Diagnostic Notes
4-21
ET Sensor
4-71
Diagnostic Tips
4-21
Diagnostics
4-71
Diagnostic Tips
4-71
4.11 NO ECM POWER
Diagnostic Notes
4-71
General
4-28
4.20 DTC P0122, P0123
No Spark/No Check Engine Lamp at Key On
4-28
Diagnostics
4-28
General
4-75
Diagnostic Notes
4-28
Throttle Position (TP) Sensor
4-75
Diagnostics
4-75
4.12 STARTS, THEN STALLS
Diagnostic Tips
4-75
General
4-32
Diagnostic Notes
4-75
Diagnostic Trouble Codes U1300, U1301, or BUS
4.21 DTC P0131, P0132, P0134, P0151,
ER
4-32
Diagnostics
4-32
P0152, P0154
Diagnostic Tips
4-32
General
4-79
Diagnostic Notes
4-32
Oxygen Sensor
4-79
Diagnostics
4-79
4.13 FUEL SYSTEM ELECTRICAL TEST
Diagnostic Tips
4-79
General
4-36
Diagnostic Notes
4-79
Diagnostics
4-36
Diagnostic Notes
4-36
4.22 DTC P0261, P0262, P0263, P0264
General
4-84
4.14 SYSTEM RELAY CHECK
Fuel Injectors
4-84
General
4-43
Diagnostics
4-84
System Relay
4-43
Diagnostic Notes
4-84
Diagnostics
4-43
Diagnostic Notes
4-43
4.23 DTC P0373, P0374
General
4-90
4.15 FUEL PRESSURE TEST
CKP Sensor
4-90
General
4-49
Diagnostics
4-90
Testing
4-49
Diagnostic Tips
4-90
Diagnostics
4-50
Diagnostic Notes
4-90
Diagnostic Notes
4-50
4.24 DTC P0501, P0502
4.16 IDLE AIR CONTROL
General
4-93
General
4-53
Vehicle Speed Sensor (VSS)
4-93
IAC Operation
4-53
Diagnostics
4-93
Diagnostic Trouble Code P0505: Loss of Idle Speed
Diagnostic Notes
4-93
Control
4-53
VI TABLE OF CONTENTS
TABLE OF CONTENTS
Mating Pin and Socket Housings
A-3
4.25 DTC P0562, P0563
Removing Terminals from Housing
A-3
General
4-97
Inserting Terminals into Housing
A-4
Battery Voltage
4-97
Preparing Wire Leads for Crimping
A-4
Diagnostics
4-97
Crimping Terminals to Leads
A-6
Diagnostic Tips
4-97
Inspecting Crimped Terminals
A-6
Diagnostic Notes
4-97
A.3 DELPHI CONNECTORS
4.26 DTC P0603, P0605
Delphi Connector Repair
A-8
General
4-101
General
A-8
ECM Failure
4-101
Separating Pin and Socket Housings
A-8
Diagnostics
4-101
Mating Pin and Socket Housings
A-8
DTC P0603
4-101
Removing Socket Terminals
A-8
DTC P0605
4-101
Installing Socket Terminals
A-8
4.27 DTC P1009, P1010
A.4 DEUTSCH 1-PLACE ELECTRICAL
General
4-102
CONNECTORS
Password Problem
4-102
Deutsch 1-Place Connector Repair
A-10
Diagnostics
4-102
Separating Pin and Socket Housings
A-10
Diagnostic Notes
4-102
Mating Pin and Socket Housings
A-10
4.28 DTC P1351, P1352, P1354, P1355
Removing Socket Terminals
A-10
Installing Socket Terminals
A-10
General
4-105
Ignition Coil
4-105
A.5 DEUSCH ELECTRICAL CONNECTORS
Diagnostics
4-105
Deutsch Connector Repair
A-11
Diagnostic Notes
4-105
General
A-11
4.29 DTC P1501, P1502
Separating Pin and Socket Housings
A-11
Mating Pin and Socket Housings
A-11
General
4-110
Removing Socket Terminals
A-11
Jiffy Stand Sensor (HDI)
4-110
Installing Socket Terminals
A-11
Diagnostics
4-110
Removing Pin Terminals
A-13
Diagnostic Notes
4-110
Installing Pin Terminals
A-13
Crimping Terminals
A-14
4.30 DTC U1064, U1255
General
4-115
A.6 DEUTSCH STANDARD TERMINALS
Loss of TSM/TSSM/HFSM Serial Data
4-115
Deutsch Standard Terminal Crimps
A-15
Diagnostics
4-115
Preparing Wire Leads for Crimping
A-15
Diagnostic Notes
4-115
Crimping Terminal to Lead
A-15
Inspecting Crimps
A-15
4.31 DTC U1097, U1255
General
4-118
A.7 DEUTSCH MINI-TERMINAL CRIMPS
Loss of Speedometer Serial Data
4-118
Deutsch Mini Terminal Crimps
A-16
Diagnostics
4-118
Preparing Wire Leads for Crimping
A-16
Diagnostic Notes
4-118
Crimping a Mini Terminal to Wire Lead
A-16
Inspecting Crimps
A-16
APPENDIX A CONNECTOR REPAIR
A.8 DEUTSCH SOLID BARREL TERMINALS
A.1 AMP 1-PLACE CONNECTORS
Deutsch Solid Barrel Terminal Crimps
A-17
AMP 1-Place Connector Repair
A-1
Preparing Wire Leads For Crimping
A-17
General
A-1
Adjusting Crimper Tool
A-17
Separating Pin and Socket Housings
A-1
Crimping a Barrel Contact To Wire Lead
A-17
Mating Pin and Socket Housings
A-1
Inspecting Crimps
A-17
Removing Socket Terminals
A-1
Installing Socket Terminal
A-1
A.9 RELAY AND FUSE BLOCKS
Removing Pin Terminal
A-1
Fuse Block Repair
A-19
Installing Pin Terminal
A-2
Removing Socket Terminals
A-19
Installing Socket Terminals
A-19
A.2 AMP MULTILOCK CONNECTORS
Crimping Terminals
A-19
AMP Multilock Connector Repair
A-3
General
A-3
A.10 150 METRI-PACK CONNECTORS
Separating Pin and Socket Housings
A-3
150 Metri-Pack Connector Repair
A-20
TABLE OF CONTENTS VII
TABLE OF CONTENTS
General
A-20
Crimping Terminals
A-32
Separating Pin and Socket Housings
A-20
Mating Pin and Socket Housings
A-20
A.18 PACKARD MICRO-64 CONNECTORS
Removing Socket Terminal
A-20
Packard Micro-64 Connector Repair
A-34
Inserting Socket Terminal
A-20
General
A-34
Separating Pin and Socket Housings
A-34
A.11 280 METRI-PACK CONNECTORS
Mating Pin and Socket Housings
A-34
280 Metri-Pack Connector Repair
A-22
Removing Terminal
A-34
General
A-22
Installing Terminal
A-34
Separating Pin and Socket Housings
A-22
Preparing Wire Leads for Crimping
A-35
Mating Pin and Socket Housings
A-22
Crimping Terminals
A-35
Removing Socket Terminals
A-22
Inspecting Crimps
A-35
Installing Socket Terminals
A-22
Crimping Terminals
A-22
A.19 SEALED SPLICE CONNECTORS
Sealed Splice Connector Repair
A-37
A.12 480 METRI-PACK CONNECTORS
General
A-37
480 Metri-Pack Connector Repair
A-24
Preparing Wire Leads
A-37
General
A-24
Splicing Wire Leads
A-37
Separating Pin and Socket Housings
A-24
Inspecting Seals
A-37
Mating Pin and Socket Housings
A-24
Removing Socket Terminals
A-24
APPENDIX B WIRING
Installing Socket Terminals
A-24
B.1 CONNECTORS
A.13 630 METRI-PACK CONNECTORS
Connector Locations
B-1
630 Metri-Pack Connector Repair
A-25
Function/Location
B-1
General
A-25
Place and Color
B-1
Separating Pin and Socket Housings
A-25
Connector Number
B-1
Mating Pin and Socket Housings
A-25
Repair Instructions
B-1
Removing Socket Terminal
A-25
Installing Socket Terminal
A-25
B.2 WIRING DIAGRAMS
A.14 800 METRI-PACK CONNECTORS
Wiring Diagram Information
B-3
Wire Color Codes
B-3
Delphi Maxi-Fuse Housing Repair
A-26
Wiring Diagram Symbols
B-3
General
A-26
2008 Sportster Wiring Diagrams
B-4
Removing Maxi-Fuse
A-26
Installing Maxi-Fuse
A-26
APPENDIX C CONVERSIONS
Removing Socket Terminals
A-26
Installing Socket Terminals
A-26
C.1 METRIC CONVERSION
A.15 METRI-PACK TERMINALS
Conversion Table
C-1
Metri-Pack Terminal Crimps
A-28
Matching Terminal To Crimper
A-28
C.2 FLUID CONVERSIONS
Preparing Wire Lead
A-28
United States System
C-2
Crimping Wire Core
A-28
Metric System
C-2
Crimping Insulation/Seal
A-28
British Imperial System
C-2
Inspecting Crimps
A-29
C.3 TORQUE CONVERSIONS
A.16 MOLEX CONNECTORS
United States System
C-3
Molex Connector Repair
A-30
Metric System
C-3
Separating Pin and Socket Housings
A-30
Mating Pin and Socket Housings
A-30
APPENDIX D GLOSSARY
Removing Terminals
A-30
Installing Terminals
A-30
D.1 GLOSSARY
A.17 PACKARD ECM CONNECTOR
Acronyms and Abbreviations
D-1
Packard 100W Connector Repair
A-32
General
A-32
Separating Socket Housing From ECM
A-32
Mating Socket Housing To ECM
A-32
Removing Socket Terminal
A-32
Installing Socket Terminal
A-32
VIII TABLE OF CONTENTS
TABLE OF CONTENTS
General
E-14
APPENDIX E TSM/TSSM
Disarming the System
E-14
(JAPAN/KOREA)
E.8 DIAGNOSTIC TROUBLE CODES (DTC)
E.1 TSM/TSSM (JAPAN/KOREA) OVERVIEW
TSM/TSSM
E-16
Code Types
E-17
General
E-1
Current
E-17
TSM
E-1
Historic
E-17
TSSM
E-1
Retrieving Diagnostic Trouble Codes
E-17
Troubleshooting
E-1
Multiple Diagnostic Trouble Codes
E-17
E.2 TSM/TSSM FEATURES
E.9 INITIAL DIAGNOSTIC CHECK:
General
E-3
TSM/TSSM
Turn Signal Functions
E-3
TSSM/TSSM Features
E-3
General
E-19
Bank Angle Function
E-3
Diagnostic Notes
E-19
Clutch/Neutral Interlock Functions
E-3
Circuit Diagram/Wire Harness Connector Table
E-19
TSM/TSSM Features
E-3
Job/Time Code Values
E-19
Security Alarm and Immobilization Functions
E-3
Reprogramming ECM
E-19
TSSM Feature
E-3
Initial Diagnostics
E-19
Diagnostic Tips
E-19
E.3 VEHICLE DELIVERY
Diagnostic Notes
E-19
Other Diagnostic Trouble Codes (DTCs)
E-19
General
E-5
Configuring A TSSM
E-5
E.10 SPEEDOMETER SELF DIAGNOSTICS
Sidecar Configuration
E-5
Power Disruption and Configuring
E-5
General
E-24
Key Fob Assignment: TSSM
E-5
Diagnostics
E-24
Pin Entry: TSSM
E-6
Diagnostic Tips
E-24
Changing the Pin: TSSM
E-8
Diagnostic Notes
E-24
E.4 TURN SIGNAL FUNCTIONS
E.11 BREAKOUT BOX: TSM/TSSM
General
E-9
General
E-26
Automatic Cancellation
E-9
Installation
E-26
Manual Cancellation
E-9
Removal
E-26
Four-Way Flashing
E-9
E.12 FAILS TO DISARM (TSSM ONLY)
Diagnostics Mode
E-9
General
E-28
E.5 BANK ANGLE FUNCTION
Security Equipped Vehicles Only
E-28
General
E-10
Job/Time Code Values
E-28
Operation
E-10
Diagnostics
E-28
Diagnostic Tips
E-28
E.6 SECURITY SYSTEM FUNCTIONS (TSSM
Diagnostic Notes
E-28
ONLY)
E.13 TURN SIGNAL ERRORS: B1121, B1122,
General
E-11
B1141
Security System Operation
E-11
Security System Options: TSSM
E-11
General
E-31
Alarm Sensitivity: TSSM
E-11
Job/Time Code Values
E-31
Sensitivity
E-11
Diagnostics
E-31
Transport Mode
E-12
Diagnostic Tips: All
E-31
Auto-Arming Function: TSSM
E-12
Diagnostic Notes: All Turn Signal Flow Charts
E-33
Storage Mode: TSSM
E-13
E.14 DTC B0563
E.7 ARMING/DISARMING (TSSM ONLY)
General
E-43
General
E-14
Battery Voltage High
E-43
Security Lamp
E-14
Diagnostics
E-43
Using Key FOB: TSSM
E-14
Diagnostic Tips
E-43
General
E-14
Diagnostic Notes
E-43
Arming the System
E-14
E.15 DTC B1131, B1132
Disarming the System
E-14
Troubleshooting
E-14
General
E-44
Using the Pin
E-14
TABLE OF CONTENTS IX
TABLE OF CONTENTS
Alarm Output Low (DTC B1131) or Alarm Output High
Serial Data Low or Serial Data Open/High
E-58
(DTC B1132)
E-44
Diagnostics
E-58
Diagnostics
E-44
Diagnostic Tips
E-58
Diagnostic Tips
E-44
Diagnostic Notes
E-58
Diagnostic Notes
E-44
E.21 TSM/TSSM: PASSWORD LEARN
E.16 DTC B1134
General
E-59
General
E-47
Password Learning
E-59
Starter Output High
E-47
Diagnostics
E-47
E.22 TSSM MAINTENANCE
Diagnostic Notes
E-47
General
E-60
Key FOB
E-60
E.17 DTC B1135
Schedule
E-60
General
E-50
Battery Replacement
E-60
Accelerometer Fault: B1135
E-50
Siren (If Installed)
E-60
Schedule
E-60
E.18 DTC B1154, B1155
Battery Replacement: Early Style Siren
E-60
General
E-51
Battery Replacement: Late Style Siren
E-61
Diagnostic Notes
E-51
REFERENCE MATERIAL
E.19 DTC U1016, U1255
TOOLS
I
General
E-55
Loss of ECM Serial Data
E-55
Diagnostics
E-55
TORQUE VALUES
V
Diagnostic Notes
E-55
INDEX
VII
E.20 DTC U1300, U1301 OR BUS ER
General
E-58
X TABLE OF CONTENTS
SUBJECT
PAGE NO.
1.1 STARTER TROUBLESHOOTING
1-1
1.2 STARTING SYSTEM DIAGNOSIS
1-3
1.3 STARTER ACTIVATION CIRCUITS
1-12
1.4 DIAGNOSTICS/TROUBLESHOOTING
1-13
1.5 TESTING STARTER ON MOTORCYCLE
1-14
1.6 TESTING STARTER ON BENCH
1-16
1.7 CHARGING SYSTEM
1-18
1.8 BATTERY TESTING
1-26
STARTER TROUBLESHOOTING
1.1
GNOSTICS/TROUBLESHOOTING, Voltage Drop procedure
GENERAL
will help you to locate poor connections or components with
The troubleshooting tables contain detailed procedures to solve
excessive voltage drops.
and correct problems. Follow 1.2 STARTING SYSTEM DIA-
GNOSIS to diagnose starting system problems. The 1.4 DIA-
STARTER TROUBLESHOOTING
Table 1-1. Starter Does Not Run or Runs at Very Low Speeds
SOURCE OF
PROBABLE CAUSE
SOLUTION
PROBLEM
Battery
Voltage drop due to discharged battery.
Charge battery.
Short-circuited or open between electrodes.
Replace battery.
Poor contact condition of battery terminal(s).
Clean and retighten.
Wiring
Poor or no connection at either battery positive or
Repair or replace cable(s).
negative cable, at either end.
Cracked or corroded battery cable ends.
Clean, tighten or replace cable(s) as needed.
Open wire(s) or poor connection at handlebar switch
Tighten connections or repair or replace wire(s).
or start relay, especially relay ground wire (grounds
through TSM/TSSM/HFSM).
Start
switch, engine
Poor switch contacts or open switch.
Replace switch.
stop switch, clutch
switch or neutral
switch
Start relay
Open coil winding.
Replace relay.
Poor or no continuity at relay points.
Replace relay.
TSM/TSSM/HFSM has disabled start relay
Disarm security system.
Solenoid
Poor contact condition caused by burnt contact.
Polish contact surface or replace solenoid assembly
Pull-in winding open or short-circuited.
Repair or replace solenoid assembly.
Hold-in winding open or short-circuited.
Repair or replace solenoid assembly.
Starting motor
Brushes worn below specification.
Check brush spring tension. Replace field frame
and holder.
Commutator burnt.
Re-face or replace.
Commutator high mica.
Correct by undercutting.
Field winding grounded.
Replace starter.
Armature winding grounded or short-circuited.
Replace starter.
Free running current draw out of range.
Replace starter.
Reduction gears damaged.
Replace starter.
Insufficient brush spring tension.
Replace starter.
Disconnected lead wire between solenoid and field
Repair or replace lead wire.
windings.
Ball bearing sticks.
Replace bearing.
T
emperature
Incorrect oil for low temperature.
Use recommended viscosity oil for temperature
range. Consult Owner's Manual.
2008 Sportster Diagnostics: Starting / Charging 1-1
Table 1-2. Pinion Does Not Engage With Ring Gear While Starter is Cranked or Engine Cannot Be Cranked
SOURCE OF PROBLEM
PROBABLE CAUSE
SOLUTION
Battery
Voltage drop due to discharged battery.
Charge battery.
Short-circuited or open between electrodes.
Replace battery.
Poor contact condition of battery terminal(s).
Clean and retighten.
Overrunning clutch
Overrunning clutch malfunction
(rollers or
Replace overrunning clutch.
compression spring).
Pinion teeth worn out.
Replace pinion.
Pinion does not run in overrunning direction.
Replace overrunning clutch.
Poor sliding condition of spline teeth.
Remove foreign materials, dirt or replace
overrunning clutch or pinion shaft.
Reduction gears damaged.
Replace overrunning clutch and idler gear.
Gear teeth on clutch shell
Excessively worn teeth.
Replace clutch shell.
Table 1-3. Starter Does Not Stop Running
SOURCE OF PROBLEM
PROBABLE CAUSE
SOLUTION
Start switch or start relay
Unopened contacts.
Replace start switch or start relay.
Poor return caused by sticky switch or relay contacts.
Replace start switch or start relay.
Gear teeth on clutch shell
Excessively worn teeth.
Replace clutch shell.
Solenoid
Return spring worn.
Replace spring.
Coil layer shorted.
Replace solenoid.
Contact plate melted and stuck.
Replace solenoid.
1-2 2008 Sportster Diagnostics: Starting / Charging
STARTING SYSTEM DIAGNOSIS
1.2
6. If the neutral switch or ground is open, a reading of several
DIAGNOSTICS
hundred ohms is normal due to the neutral indicator lamp
PART NUMBER
TOOL NAME
(LED).
HD-41404-B
HARNESS CONNECTOR TEST KIT
7. Closely inspect handlebar controls for pinched wiring.
HD-42682
BREAKOUT BOX
Job/Time Code Values
Diagnostic Notes
Dealership technicians filing warranty claims should use the
job/time code values printed in bold text underneath the
Each reference number below correlates to a circled number
appropriate repair.
on the flow chart(s).
1. See 1.4 DIAGNOSTICS/TROUBLESHOOTING, Voltage
ed02787
Drop.
2. Remove starter motor. Connect jumper wires as described
in 1.6 TESTING STARTER ON BENCH, Free Running
Current Draw Test.
3
3. Connect BREAKOUT BOX (Part No. HD-42682) to TSM/
TSSM/HFSM as follows:
a. On models with a TSM/HFSM, see 3.12 BREAKOUT
1
BOX: TSM/HFSM.
b. On models with a TSSM
(Japan/Korea), see
E.11 BREAKOUT BOX: TSM/TSSM.
2
4. Use HARNESS CONNECTOR TEST KIT (Part No. HD-
41404-B) gray terminal socket probe and patch cord.
1. Motor terminal
5. See 1.5 TESTING STARTER ON MOTORCYCLE, Starter
2. Battery terminal
Current Draw Test.
3. Relay terminal
Figure 1-1. Starter Terminals
2008 Sportster Diagnostics: Starting / Charging 1-3
em01118
Right
Hand Controls
Right Turn Switch
W/BK
Battery
Engine Stop Switch
W/BK
Start Switch
BK
Front Stop Lamp Switch
Ignition Switch Legend
SWITCH
RED/BLACK
RED
RED/GRAY
POSITION
OFF
ACC
IGNITION
To system relay
W/BK
6
4
3
[22A]
Dot indicates continuity with red
wire in switch position indicated
6
4
3
[22B]
IGN
30 Amp
GN
Switch
MAXIFUSE
[33]
[5B]
[78A]
[78B]
Starter
Switch power
13
13
W/BK
B I
ECM
B A
[136A] [136B]
TN
1
1
Neutral
Switch
[61B]
Ignition - 15A
A
B
GY
R/BK
TSM/TSSM/HFSM
[30A]
[30B]
Battery - 15A
J
I
Battery
1
1
BN/GY
BN/GY
R
Ignition
2
2
GY
BK/R
Neutral switch
4
4
TN
87
GN
I
5
Clutch Switch
87A
BK
R/BK
C
3
30
Start relay control
9
9
TN/GN
TN/GN
P
2
85
BK/R
R
1
86
Clutch switch
10
10
BK/R
Ground
12
12
BK
Start Relay
BK/R
7
7
BK/R
[119B]
BK
8
8
BK
Left Hand
Receive antenna
1
Controls
Transmit antenna A
2
[24B] [24A]
Transmit antenna B
3
Powertrain
[208A]
Ground
BK
HFSM ONLY
Point
[119]
[61]
GND 1
SPARE
START RELAY SYSTEM RELAY
SPARE
LIGHTS
OPEN
M
O
M
O
P
R
15A
P
Q
R
S
T
U
15A
15A
FUEL PUMP
INSTRUMENTS
BATTERY
SPARE
G
H
I
K
G
H
I
J
K
L
15A
15A
15A
15A
Wire Color Code Key
C
E
ECM
IGNITION
ACCESSORIES
P&A IGN
A
B
A
B
C
D
E
F
15A
15A
15A
15A
BK- Black
GN - Green
LGN - Light Green
BN - Brown
BE - Blue
PK - Pink
Top View
R - Red
V - Violet
TN - Tan
O - Orange
GY - Gray
Wire color-XX/XX-Stripe color
Pin Connector
(A side)
Y - Yellow
W - White
Socket Connector
(B side)
Figure 1-2. Starting Circuit Schematic
1-4 2008 Sportster Diagnostics: Starting / Charging
Starter Testing 1
Check battery using visual inspection, voltage
test, and either conductance test or load test.
Check connections at battery and starter
components. Is system operational?
5822
YES
YES
YES
NO
Starter spins, but
Starter stalls
Starter
Check for audible
does not
or spins too
runs on.
clicking noise
engage.
slowly.
Disconnect solenoid relay
See Starter
See Starter
Solenoid clicks.
terminal from solenoid.
Testing 5: Starter
Testing 6: Starter
See Starter
Is 12V present on (GN) wire
Spins But Does
Stalls or Spins Too
Testing 2:
with starter button not
Not Engage.
Slowly.
Solenoid Clicks.
pressed?
YES
NO
OR
Is 12V present on start relay
Replace
Relay clicks. See
terminal “86” (1) with starter
solenoid.
Starter Testing 3:
button not pressed?
Relay Clicks
5845
YES
NO
OR
Replace
Replace
Nothing clicks. See Starter
starter button
start relay.
Testing 4: Nothing Clicks
(Part 1 of 2).
5818
5832
fc01000_en
2008 Sportster Diagnostics: Starting / Charging 1-5
Starter Testing 2: Solenoid Clicks
Perform voltage drop tests between battery
1
and relay terminal on solenoid. Is voltage
drop less than 1.0 volt?
YES
NO
Perform voltage drop tests from
Backtrack to pinpoint poor
battery positive to starter motor
1
connections or relay contact
1
terminal. Crank engine.
problems using voltage drop tests.
Is voltage drop greater than 1.0 volt?
5823
YES
NO
Perform voltage drop tests from
Perform voltage drop tests
battery positive to starter battery
between battery negative and
1
1
terminal. Crank engine.
starter ground studs or bolts.
Is voltage drop greater than 1.0 volt?
Is voltage drop greater than 1.0 volt?
NO
STOP
YES
NO
YES
Go to Starter Testing 3:
Relay Clicks. Begin with box
Repair connection
marked with bold asterisk.
Repair or replace
Clean ground
between battery and
solenoid (contacts).
connections.
starter.
5845
5824
5824
fc01001_en
1-6 2008 Sportster Diagnostics: Starting / Charging
Starter Testing 3: Relay Clicks
Test for voltage at solenoid
relay terminal (GN) on starter.
Is 12V present when starter
button is pressed?
YES
NO
Test for voltage to relay.
Is 12V present on relay terminal
Does starter motor
2
“30” (3)?
turn if jumped?
YES
NO
YES
NO
Test for voltage to relay.
Repair open on (R/BK)
Replace
Replace or repair
Is 12V present on relay
wire feeding terminal
solenoid.
starter motor.
terminal “87” (5)?
“30” (3) on start relay.
5860
5817
5827
YES
NO
Repair open on
Replace
(GN) wire between
start relay.
relay and solenoid.
5832
5827
fc01002_en
2008 Sportster Diagnostics: Starting / Charging 1-7
Starter Testing 4: Nothing Clicks (Part 1 of 2)
Do turn signals work properly?
YES
NO
With the Engine Stop Switch in
Is connector [30] fully mated?
the RUN position. Turn the
Ignition Switch on. With the
starter button depressed, check
YES
NO
for battery voltage from starter
button to relay terminal “86”.
Continuity to ground on TSM/
Battery voltage present?
3
Mate connector [30].
TSSM/HFSM terminal “12”?
6792
YES
NO
Continuity on terminal “1” to
Repair open.
battery fuse?
6805
YES
NO
Continuity on terminal “2” to
Repair open.
ignition fuse?
6806
YES
NO
Continuity on terminal “2” to
Repair open.
ignition fuse?
6791
6793
YES
NO
Disconnect connector [22]. Check for continuity between
Check for ground at relay
terminal “4” (W/BK) and terminal “6” (BK/R)
4
terminal “85”. Ground present?
of connector [22A].
Continuity present with starter button pressed?
YES
NO
YES
NO
Check for battery voltage to
Substitute good
Check for continuity from relay terminal “85”
starter button, at connector [22B]
relay or test relay.
Replace
to terminal “9” on TSM/TSSM/HFSM
terminal “3” (GY).
7
starter button.
connector [30]. Continuity present?
Battery voltage present?
5818
YES
NO
YES
NO
Locate and repair
Locate and repair
Repair open.
open in (BK/R) wire
open in (GY) wire
STOP
from connector
connector [22B].
5828
[22B] to relay.
5831
Go to Starter Testing 4:
5831
Nothing Clicks (Part 2 of 2).
fc01003_en
1-8 2008 Sportster Diagnostics: Starting / Charging
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