Harley Davidson 1986-2003 sportster troubleshooting manuale cycletech

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d. If the voltage is incorrect, check the ignition system

wiring as described in Ignition Circuit Wiring Check

section in this section.

Perform the following:

Voltmeter

a. Disconnect the pink wire from the ignition coil termi-

nal (Figure 48).

b. Turn the ignition switch on.

c. Connect the negative voltmeter lead to ground. Con-

nect the postive voltmeter lead to the white/black and

pink ignition coil terminals separately. The voltmeter

should read 12 volts at both terminals.

d. If the voltage is correct, proceed to Step 5.

White/black

e. If the voltage is incorrect, replace the ignition coil.

Perform the following:

a. Disconnect the pink wire from the ignition coil termi-

Pink

Ignition coil

White/black

nal (Figure 49).

b. Remove one of the spark plugs. Connect the spark

plug wire and connector to the spark plug and ground

the spark plug base to the engine cylinder head (Fig-

ure 50). Position the spark plug so the electrodes are

visible.

White/black

c. Turn the ignition switch on.

Pink

d. Connect the jumper wire without the capacitor be-

tween a good engine ground and the ignition coil

Ignition coil

pink wire terminal, as shown in Figure 49. Momen-

White/black

tarily touch the jumper wire with the capacitor to the

ignition coil pink wire terminal (Figure 49) while ob-

serving the spark plug firing tip. The spark plug

should fire. Turn the ignition switch off and remove

the jumper wire assembly.

e. If there is spark, proceed to Step 6.

Jumper wire

f. If there is no spark, replace the ignition coil.

g. Reinstall the spark plug.

Perform the following:

a. Reconnect the ignition coil pink wire to its terminal

on the ignition coil.

At the harness end of the connector, connect the posi-

b. Turn the ignition switch on.

tive voltmeter lead to socket No. 5 (pink wire) and the

c. Disconnect the 6-terminal ignition connector (Figure

black voltmeter lead to socket No. 6 (black wire). The

45).

voltmeter should read 11-13 volts. Disconnect the

d. At the harness end of the connector, connect the

voltmeter and turn the ignition switch off.

positve voltmeter lead to the ignition module socket

If the voltage is correct, proceed to Step 8.

No. 1 (white/black wire) and the negative voltmeter

If the voltage is incorrect, check the continuity be-

lead to the ignition module socket No. 6 (black wire).

tween socket No. 5 (pink wire) and the pink-wire ter-

The voltmeter should read 11-13 volts. Disconnect

minal at the ignition coil. If there is continuity, repair

the voltmeter and turn the ignition switch off.

the short to ground on the pink wire. If there is no

e. If the voltage is correct, proceed to Step 7.

continuity repair the open circuit in the pink wire.

f. If the voltage is incorrect, check the continuity be-

Perform the following:

tween socket No. 1 (white/black wire) on the ignition

a. Install the test harness between the halves of the igni-

module connector and the white/black wire at the igni-

tion coil connector (Figure 45), and check the volt-

tion coil. If there is continuity, repair the open between

age between the green/gray wire and the black wire.

socket No. 6 (black wire) and ground. If there is no

b. Turn the ignition switch on.

continuity, repair the open in the white/black wire.

c. Connect the red voltmeter lead to terminal No. 4 on

Perform the following:

the test harness, and connect the negative voltmeter

a. Disconnect the 6-terminal ignition module connector

lead to terminal No. 6 on the test harness. The volt-

(Figure 45).

meter should read 0.6-1.1 volts. Disconnect the volt-

b. Turn the ignition switch on.

meter and turn the ignition switch off.

-------------------------------------------------------------------------------------------------------------------------------------------------------------

good ground. The voltmeter should read battery volt-

age. Disconnect the voltmeter and turn the ignition

switch off.

c. If the voltage is correct, perform Step 3.

d. If the voltage is incorrect, check for an open circuit

between the battery, 30-amp circuit breaker, ignition

switch, and fuse block. Make the necessary repairs.

Check for voltage at the right control switch connector.

a. Disconnect the right control connector from the switch

(Chapter Twelve).

b. Turn the ignition switch on.

c. On the harness side of the connector, attach the

positve voltmeter lead to pin No. 3 (gray wire) and

connect the negative voltmeter lead to a good ground.

The voltmeter should read battery voltage. Discon-

nect the voltmeter and turn the ignition switch off.

d. If voltage is correct, perform step 4.

e. If voltage is incorrect, repair the open in the gray wire

between the connector and fuse block.

4. Perform the following:

a. Connect the right control switch connector to its mate.

b. Turn the ignition switch on.

c. Turn the engine stop switch to the run position.

d. Connect the positive voltmeter lead to pin No. 5

(white/black wire) on the harness side of the connec-

tor, and connect the negative voltmeter lead to a good

ground. The voltmeter should read battery voltage.

Disconnect the voltmeter and turn the ignition switch

off.

e. If voltage is correct, repair the open in the

white/black wire between the ignition coil and

right-hand switch connector (No. 22).

f. If voltage is incorrect, check the engine stop switch

If the voltage is correct, proceed to Step

and its wiring. Repair or replace the faulty compo-

If the voltage is incorrect, check the bank angle sen-

nent as necessary.

sor as described in this section.

Perform the following:

a. Remove the timing cover.

Bank Angle Sensor Check

b. Crank the engine and observe the rotor LED. If it is

1. Inspect the bank angle sensor (A, Figure 51). Note the

flashing, replace the ignition module. If it is not flash-

following:

ing, proceed to substep c.

a. Make sure the sensor connection is secure.

c. Crank the engine and observe the rotor cup. If the ro-

b. Make sure the sensor is mounted correctly. It must be

tor is rotating, replace the ignition module. If it does

secure against the battery case and sit upright on the

not rotate, remove the gearcase cover (Chapter Five)

case.

and check for an engine mechanical failure.

c. Make sure there is no ferrous metal within 1/4 inch of

10. Install and reconnect all parts removed for this proce-

the side, face or top of the sensor.

dure.

CAUTION

To avoid damaging the terminals in Step 2, re-

Ignition Circuit Wiring Check

move the bank angle sensor before discon-

necting the connector.

1. Check the ignition circuit fuse. If the fuse is burned out,

find the source of the problem.

2. Remove the bank angle sensor (A, Figure 51) and dis-

2. Check the voltage at the gray wire at the fuse block.

connect the sensor connector (B).

a. Turn the ignition switch on.

3. Turn the ignition on.

b. Connect the positve voltmeter lead to the gray-wire

4. Measure the voltage between socket A (green/gray wire)

terminal and connect the negative voltmeter lead to a

on the sensor connector and socket B (black wire) of the

-------------------------------------------------------------------------------------------------------------------------------------------------------------

connector. Disconnect the voltmeter and turn the ignition

switch off. Note the following:

a. If the voltage was zero volts, perform Step 5.

b. If the voltage was 3.0-3.5 volts, perform Step 6.

c. If the voltage measured 11-13 volts, repair the short

in the green/gray wire.

Perform the following:

a. Disconnect the bank angle sensor connector.

b. Disconnect the 6-terminal ignition module connector

(Figure 45).

c. Check the continuity between socket A (green/gray

wire) on the sensor connector and socket No. 4 (light

green/gray wire) on the harness end of the ignition

module connector. If there is continuity, perform

substep d. If there is no continuity, repair the open

circuit in the green/gray wire.

d. Check the continuity between socket B (black wire)

on the sensor connector and ground. If there is conti-

Check engine light

nuity, perform substep e. If there is no continuity, re-

pair the open circuit in the black wire.

e. Check the continuity between socket A (green/gray

wire) on the sensor connector and ground. If continu-

ity is present, repair the short to ground in the

green/gray wire. If continuity is not present, perform

substep f.

f. Inspect the harness for damage; repair as necessary. If

the harness is not damaged, replace the ignition module.

Perform the following:

a. Turn the ignition on.

b. Measure the voltage between socket B (black wire)

(12-pin) and two female Deutsch connectors (12-socket).

on the sensor connector and socket C (gray wire) on

Wire the No. 1 pin on the male connector to the No. 1 socket

the connector. If the voltmeter reads 11-13 volts, per-

on each female connector, No. 2 pin to No. 2 socket, etc.

form Step c. If the voltage is not 11-13 volts, repair

the open circuit in the gray wire between the sensor

When the test harness is required, test points are identi-

connector and the ignition fuse.

fied as terminals on the black- or gray-colored harness, (ter-

c. Make sure that the sensor connection and/or its

minal No. 2 on the black test harness, for example).

mounting location/position were not the source of the

Consequently, take care to identify one harness as black and

malfunction. See Step 1.

the other as gray. Use black connector housings on one har-

d. Replace the sensor, if it failes any of these steps.

ness and gray housings on the other or wrap the wires of

one test harness with black electrical tape and wrap the

wires of the second harness with gray tape.

IGNITION SYSTEM

(1998-2003 1200S MODELS)

To connect the test harnesses, disconnect the black (con-

nector No. 10) and gray (connector No. 11) ignition-mod-

Review Precautions and Troubleshooting Preparation in

ule connectors from the ignition module. Connect the gray

Ignition System (1986-1997 Models) in this chapter.

test harness in-line between the ignition module and gray

Refer to the wiring diagrams at the end of this manual.

ignition-module connector (A, Figure 52). Connect the

black test harness in-line between the ignition-module and

black ignition-module connector (B, Figure 52). Probe the

Tools

second female connector on each respective test harness at

the indicated test point.

Troubleshooting the ignition system requires a breakout

box (part No. HD-42682). The breakout box connects

Troubleshooting the ignition system also requires a har-

inline between the ignition module and the wiring harness.

ness test kit (part No. HD-41404). Different-sized termi-

It provides test points for checking a live circuit.

nals are used in the connectors on a Sportster. This kit is

If a breakout box is not available, fabricate two test har-

equipped with different sized probes for checking the volt-

nesses as shown in Figure 44. Make each test harness from

age and resistance of the various-sized terminals without

24 lengths of 18-gauge wire, a male Deutsch connector

damaging the wire insulation.

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CODE DESCRIPTION TROUBLESHOOTING CHART

Code

Component/circuit

Action

MAP sensor

Figure 68

Battery voltage

Figure 69

Front coil

Figure 70

Rear coil

Figure 70

Tachometer

1998 models

Figure 71

1999-2003 models

Figure 72

Cam position sensor

Figure 73

Bank angle sensor

Figure 74

1998 models: RAM/ROM failure

Replace ignition module*

1999-2003 models: RAM failure

Replace ignition module*

1999-2003 models: ROM failure

Replace ignition module*

EE PROM failure

Replace ignition module*

*Before replacing the ignition module confirm it is defective by taking it to a dealership. Further testing

requires the scanalyzer.

2 in.

Diagnostic Trouble Codes

and two Deutsch sockets (part No. 72191-94), as shown in

Figure 55, is required.

The 1200S models have an on-board diagnostic system

To retrieve the diagnostic trouble codes without the

to help troubleshoot the ignition system. During operation,

Scanalyzer, perform the following:

the system identifies faults and stores this information as a

1. Remove the left side cover from the motorcycle.

two-digit diagnostic trouble code.

If a trouble code has been set, the check engine light (Fig-

2. Remove the data link connector (Figure 56) from its

ure 53) will come on. During normal operation, the check

holder on the back of the side cover.

engine light illuminates for approximately four seconds

3. Remove the protective cover (A, Figure 57) from the

when the ignition is turned to on. The check-engine light

data link connector (B), and connect the jumper to pins No.

then turns off and remains off. If a diagnostic trouble code

1 and No. 2 on the data link connector.

has been set, the check-engine light turns on for four sec-

4. Turn the ignition switch to ignition. After approximately

onds, turns off, and then turns back on for eight seconds or

eight seconds, the system enters the diagnostic mode.

it remains on beyond the eight-second period.

a. The diagnostic mode begins with a ready signal,

Trouble codes can be retrieved with the Scanalyzer (Part

which is a series of rapid flashes of approximately

No. HD-41325) or by counting the number of times the

three per second. The ready signal indicates that the

check-engine light flashes. If using the Scanalyzer for code

system is ready to flash a diagnostic trouble code.

retrieval, follow the manufacturer’s instructions. Code(s)

can also be retrieved by performing the procedure de-

b. This is followed by a two-second pause.

scribed in this section. Use the chart in Figure 54 to identify

c. The system then flashes the first digit of the stored di-

the defective system and to determine a course of action.

agnostic trouble code. The check-engine light will il-

luminate for one second and then turn off for one

second. Count the number of flashes, and record this

Retrieving codes

number.

Diagnostic trouble codes are displayed as a series of

d. The system will pause for two seconds, and then flash

flashes at the check-engine light. To retrieve any stored di-

the second digit of the diagnostic trouble code. Count

agnostic trouble codes, a jumper made of 18-gauge wire

the number of flashes, and record this number.

-------------------------------------------------------------------------------------------------------------------------------------------------------------

e. The system will pause for two seconds, and then flash

the ready signal, which indicates it is ready to flash

the next code.

f. The system will pause for two seconds, and then flash

the first digit of the next diagnostic trouble code.

5. The system displays codes, sequentially, one-at-a-time,

until each diagnostic trouble code has been displayed. The

system then repeats. The check-engine light will continue

to flash stored codes until the jumper wire is disconnected.

When the codes repeat, this indicates that all the stored

codes have been displayed.

6. Find the diagnostic trouble code in Figure 54, and per-

form the procedure indicated in the chart. If multiple codes

have been set, troubleshoot the lowest numbered code first.

The source of subsequent codes may be the same malfunc-

tion that has caused the first.

7. Reinstall the protective cover onto the data link connec-

tor, and fit the connector into its holder in the back of the

left side cover.

8. Align the side cover pins with the grommets in the

frame, and push the side cover into place.

Clearing codes

The system will retain the trouble codes until they are

cleared with the Scanalyzer or until the motorcycle has

been run through 50 start-run cycles. After a fault has been

corrected, the memory is erased automatically after 50

start-run cycles if the fault does not reoccur. A start-run cy-

cle occurs when the engine is started and run for at least 30

seconds before being turned off.

Ignition Control Module Replacement

Before replacing the ignition module, confirm that the ig-

nition module is defective by having a dealership test it.

There are several ignition-module tests that can only be

performed with a Scanalyzer (part no. HD-41325).

Troubleshooting Tests

1. Review Precautions and Troubleshooting Preparations

in Ignition System (1986-1997 Models) in this chapter. Re-

fer to the wiring diagrams at the end of this manual.

2. Peform the spark test as described in Starting The En-

gine in this chapter.

a. If there is spark, the problem is not in the ignition sys-

tem. Check the fuel system.

Wiggle Test

b. If there is no spark or only a weak one, recheck the ig-

Several troubleshooting procedures advise performing a

nition with new spark plugs. If the condition remains

wiggle test. Perform the following when so advised:

the same with new spark plugs and if all external wir-

ing connections are good, the problem is most likely

1. Connect the meter as instructed in the flow chart.

in the ignition system; perform the procedure in Fig-

2. Wiggle the wiring harness and observe the meter.

ure 58. Follow the procedure in the chart until the

3. Large resistance fluctuations indicate the presence of an

problem is resolved.

intermittent short in the harness. Check the wiring harness.

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RETRIEVING DIAGNOSTIC CODES (1998-2003 1200S MODELS)

Turn the ignition switch on,

No light.

Do not start the engine.

Note Check Engine light

Perform the diagnostic procedure in Figure 62

(1998 models) or Figure 63 (1999 models).

Does light go off after 4 seconds?

Perform the diagnostic procedure in Figure 64.

Yes

Does the engine start?

Perform the diagnostic procedure in Figure 66.

Yes

Does the check engine

light display ignition

module data?

Disconnect the black (10B) and

gray (11B) connectors from the

ignitin module. Check for continu-

Yes

ity to ground at the indicated termi-

Is continuity present between pins

nals of the data link connector

on data link connector and igni-

[91A].

tion module?

Are any trouble codes

displayed?

1998 models: Pins 1, 3 and 4.

1999-2003 models: Pins 1 and 3.

Data

Ignition

Continuity to ground?

Link

Module

terminal

Yes

1 (Green/red) to

11 [11B]

Yes

2 (Black)

11 [10B]

Refer to

Perform a wiggle

3 (Violet/red)

12 [11B]

applicable

test and attempt to

4 (White/black) to

1 [10B]

Repair

trouble

reproduce the

short to

code (Fig-

symptoms. Repair

ground.

ure 54);

the harness as

start with

required. If the

lowest

problem cannot be

Yes

numbered

reproduced, refer

code.

to Figure 61.

Inspect the

*Replace

terminals for

the igni-

*Note: Before replacing the ignition module, confirm

tion

damage or

that it is defective by taking the motorcycle to a

module.

repair opens

Harley Davidson dealership or other qualified service

as neces-

shop. Further testing requires the use of a

sary.

Harley Davidson Scanalyzer.

-------------------------------------------------------------------------------------------------------------------------------------------------------------

Spark Plug Cable Resistance Test

1. Disconnect the spark plug cable from the spark plug and

from the ignition coil.

2. Connect the probes of an ohmmeter to the cable termi-

nals.

3. Replace the spark plug cable if the resistance is not

within the specification in Table 2.

4. Repeat this procedure for the remaining cables.

Ignition Coil Test (1998-2003 1200S Models)

1. Disconnect the spark plug wires (A, Figure 59) from the

coil towers on the coil.

2. Disconnect the ignition coil connector (B, Figure 59)

from the ignition-coil primary terminals.

3. Measure the resistance in the primary windings.

a. Measure the resistance between primary terminals A

and B on the ignition coil.

b. Measure the resistance between primary terminals B

and C on the coil.

c. Compare the readings to the specification in Table 2.

4. Measure the resistance of the secondary windings.

a. Measure the resistance between both secondary ter-

minals (No. 1 and 4) on the front coil (Figure 60).

b. Measure the resistance between both secondary ter-

minals (No. 2 and 3) on the rear coil (Figure 60).

c. Compare the readings to the specification in Table 2.

5. Replace the ignition coil if any reading is not within

specification.

An extreme rich condition

causes

choked,

dull

Troubleshooting Symptoms

sound from the exhaust and an inability to clear the exhaust

with the throttle held wide open.

Refer to Figures 61-74 for various symptoms and testing

procedures.

Lean

FUEL SYSTEM

1. Blistered or very white spark plug electrodes.

Begin fuel system troubleshooting with the fuel tank and

2. Engine overheats.

work through the system, reserving the carburetor as the fi-

3. Slow acceleration and engine power is reduced.

nal point. Do not assume the carburetor is the problem. Un-

necessary carburetor adjustment can compound the problem.

4. Flat spots on acceleration that are similar in feel to when

the engine starts to run out of gas.

5. Engine speed fluctuates at full throttle.

Identifying Carburetor Conditions

Refer to the following conditions to identify whether the

Troubleshooting

engine is running lean or rich.

Isolate fuel system problems to the fuel tank, fuel shutoff

Rich

valve and filter, fuel hoses, external fuel filter (if used) or

carburetor. In the following procedures, it is assumed that

1. Fouled spark plugs.

the ignition system is working properly.

2. Engine misfires and runs rough under load.

Refer to Figure 75 or Figure 76 and the following sec-

3. Excessive exhaust smoke as the throttle is increased.

tions for possible causes of fuel system problems.

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SYMPTOMS

Symptom

Possible cause

Action

Hard to Start

Battery discharged

Troubleshoot the charging system

as described in this chapter

Spark plugs

Perform the procedure in Figure 67

Ignition coil

Perform the procedure in Figure 67

Plug wires

Perform the procedure in Figure 67

Valve sticking

Refer to the Chapter Four

Water or dirt in

Drain the fuel system and refill

the fuel system

with fresh fuel

Engine hesitates,

Manifold leak

Spray water around the intake

stumbles, surges,

manifold seals while the engine

misfires or is sluggish

idles. If idle speed changes,

replace the seals.

MAP sensor is not

Check the vacuum hose connection and

operating properly

perform the procedure in Figure 68

Water or dirt in the fuel system

Drain the fuel system and

refill with fresh fuel

Spark plug

Perform the procedure in Figure 68

EVAP hose disconnected from

Reconnect

carburetor (California models)

Throttle plates not opening fully

Adjust the throttle cable as

described in Chapter Three

Engine exhaust emits

Clogged air filter

Replace the air filter (Chapter Three)

black smoke or spark

MAP sensor is not

Check the vacuum hose connection and

plugs are fouled

operating properly

perform the procedure in Figure 68

Fuel level system

the overflow tube, whatever was holding the fuel valve off

of its seat has been dislodged. If fuel continues to flow from

The fuel level system is shown in Figure 77 or Figure

the overflow tube, remove and service the carburetor. See

78. Proper carburetor operation depends on a constant and

Chapter Ten or Chapter Eleven.

correct carburetor fuel level. As fuel is drawn from the float

bowl during engine operation, the float level in the bowl

NOTE

drops. As the float drops, the fuel valve moves from its seat

Fuel will not flow from the vacuum-operated

and allows fuel to flow through the seat into the float bowl.

fuel shutoff valve on 1995-2003 models until

the engine is running.

Fuel entering the float bowl causes the float to rise and push

against the fuel valve. When the fuel level reaches a prede-

termined level, the fuel valve is pushed against the seat to

Starting enrichment (choke) system

prevent the float bowl from overfilling.

If the fuel valve fails to close, the engine will run rich or

A cold engine requires a rich mixture to start and run

flood with fuel. Symptoms of this problem are rough run-

properly. On all models, a cable-actuated starter enrichment

ning, excessive black smoke and poor acceleration. This

valve is used for cold starting.

condition will sometimes clear up when the engine is run at

If the engine is difficult to start when cold, check the

wide-open throttle and the fuel is being drawn into the en-

starting enrichment (choke) cable adjustment described in

gine before the float bowl can overfill. However, as the en-

Chapter Three.

gine speed is reduced, the rich running condition returns.

Several things can cause fuel overflow. In most in-

stances, a small piece of dirt is trapped between the fuel

Accelerator pump system

valve and seat, or the float level is incorrect. If fuel is flow-

ing out of the overflow tube connected to the bottom of the

During sudden acceleration, the diaphragm type acceler-

float bowl, the fuel valve inside the carburetor is being held

ator pump system (Figure 80 or Figure 81) provides addi-

open. First check the position of the fuel shutoff valve lever

tional fuel to the engine. Without this system, the carburetor

(A, Figure 79). Turn the fuel shutoff valve lever off. Then

would not be able to provide a sufficient amount of fuel.

lightly tap on the carburetor float bowl and turn the fuel

The system consists of a spring-loaded neoprene dia-

shutoff valve lever on. If the fuel flow stops running out of

phragm that is compressed by the pump lever during sudden

-------------------------------------------------------------------------------------------------------------------------------------------------------------

NO CHECK ENGINE LAMP WITH KEY ON (1998 MODELS)

Turn the ignition switch on. Turn

the engine stop switch to run.

Does the engine start?

Did the no check engine light and

Yes

no start conditions occur simulta-

neously?

Turn the ignition switch off. Con-

If the engine will not

Yes

nect both test harnesses (Figure

start, see Figure 66.

44) between the ignition module

Then return to this chart

and the module connectors [10].

No ignition module

to resolve the no check

Place a jumper between Pin 4 on

power. Perform the

engine lamp condition.

the black test harness (B) and

diagnostic proce-

ground. Is the check engine light

dure in Figure 65.

on?

Disconnect the 14-pin me-

Yes

ter-harness connector [20]. Re-

move the black/yellow wire from

connector [20B] and ground it. Re-

*Replace faulty

connect connector [20B]. Is the

ignition module.

check engine light on?

Is there an open in the or-

Yes

ange/white wire that

feeds the bulb or an open

in the wire from the bulb

Repair open or short

to the connector [20B]?

to voltage on the

*Replace the speedome-

black/yellow wire be-

ter if the LED has failed.

tween connector [20A]

and connector [10B].

Yes

Repair.

Replace

faulty ta-

chometer

(lamp not re-

*Before replacing the ignition module or

placeable).

speedometer, confirm that it is defective by taking

the motorcycle to a dealership. Further testing

requires the use of a Scanalyzer.

-------------------------------------------------------------------------------------------------------------------------------------------------------------

NO CHECK ENGINE LIGHT WITH KEY ON (1999-2003 MODELS)

Turn the ignition switch on. Turn

the engine stop switch to RUN.

Does the engine start?

Did no check engine light and no start

Yes

conditions occur simultaneously?

Turn the ignition switch off. Con-

Yes

nect both test harnesses (Figure

44) between the ignition module

and the module connectors [10].

No ignition module

If the engine will not

Place a jumper between Pin 4 on

start, see Figure 65. Then

power. Perform the

the black test harness (B) and

return to this chart to re-

diagnostic proce-

solve the no check en-

ground. Is the check engine light

dure in Figure 66.

gine lamp condition.

on?

Disconnect the 12-pin meter har-

Yes

ness connector [20]. Check the

continuity on the black/yellow

wire between the speedometer

Place a jumper wire between Pin

connector [39] and connector

4 on the test harness (B) and

[20B]. Is the check engine light

ground. Is the check engine light

on?

Yes

Repair the open on the

black/yellow wire be-

*Replace the

*Replace

tween connector [20A]

tween harness connec-

defective igni-

the speed-

and connector [10B].

tor [20B] and

tion module.

ometer.

speedometer connector

[39].

*Replace the speedom-

eter if the LED has

failed.

*Before replacing the ignition module or

speedometer, confirm that it is defective by taking

the motorcycle to a dealership. Further testing

requires the Scanalyzer.

-------------------------------------------------------------------------------------------------------------------------------------------------------------

CHECK ENGINE LIGHT CONTINUOUSLY ON

Turn the ignition switch off. Dis-

With ignition switch on, verify

connect the ignition module black

that there is not a 4-second lamp

connector [10]. Turn the ignition

off period. Does the lamp go off?

switch on. Is the check engine

lamp off?

Yes

Check engine light functioning

*Replace

properly. Check for trouble

ignition

codes.

module.

1998

1999-2003

models

Disconnect the 14-pin meter-harness

Disconnect the 12-pin speedometer

connector [20]. Remove the black/yel-

connector [39]. Check for continuity

low wire from connector [20B]. Recon-

to ground on the 4-pin black/yellow

nect [20B] the connector

wire in the igntion module connector

Is the check engine light on?

[10]. Is continuity present?

Yes

Disconnect the

12-pin me-

Repair the

*Replace the

Repair the short

ter-harness con-

short to

speedometer.

to ground on the

nector [20].

ground on the

black/yellow wire

Remove the

black/yellow

between the

black/yellow

wire between

12-pin connector

wire, from the

the connector

[20A] and the

connector. Re-

[20B] and the

ignition module

connect the me-

lamp in the

connector [10].

ter connector

speedometer.

[20]. Is the check

engine light on?

*Before replacing the ignition

module or the speedometer,

confirm it is defective by

taking the motorcycle to a

Yes

dealership. Further testing

requires the use of a

Repair the short to

Repair the short to ground on

Scanalyzer.

ground on the black/yel-

the black/yellow wire between

low wire between the me-

the meter connector [20A] and

ter connector [20B] and

ignition module connector [10B].

the speedometer con-

nector [39B].

-------------------------------------------------------------------------------------------------------------------------------------------------------------

NO SPARK, NO CHECK ENGINE LIGHT WITH KEY ON

Check the ignition fuse.

Yes

Is the fuse okay?

Connect both test harnesses (Figure

44) between the ignition module and

the module connectors. With the igni-

tion on, connect the positive voltmeter

Replace and find the

lead to pin 1 on the black test harness.

source of the fault.

Connect the negative voltmeter lead to

pin 2 on the black test harness. Does

the voltage equal 12 ± 1 volt?

Yes

Check continuity between Pin 2

* Replace the ig-

on the black test harness and

nition module.

ground. Is continuity present?

*Note: Before replacing the

ignition module, confirm it is

defective by taking the

Yes

motorcycle to a dealership.

Further testing requires the

Scanalyzer.

Is continuity present between pin

Repair the

1 on the black test harness and

open in the

Pin 4 (white/black) of the right

white/black

handlebar connector [22B].

wire.

Repair the

Yes

open in the

white/black

wire.

Ignition module

Check for continuity be-

tween pin 3 in the grey ig-

nition module connector

[11] and pin 4

(white/black) on the han-

Engine stop switch

dlebar connector [22B]. Is

continuity present?

White/

Replace the

Grey

black

engine stop

switch.

Yes

Repair the open in the

gray wire between the

Grey

handlebar connector

[22A] and the fuse block.

15 Amp

ignition fuse

To ignition switch

-------------------------------------------------------------------------------------------------------------------------------------------------------------

ENGINE CRANKS BUT WILL NOT START

Check for trouble

Find the code in Figure 54 and

Yes

codes. Codes found?

turn to the indicated trouble-

shooting chart.

Check battery connec-

Recharge

tions. Check voltage. Is

the battery

voltage above 12.80?

and retest.

Yes

Does the battery pass the

Replace the

load test (Chapter Twelve)?

battery and

retest.

Yes

Check spark plug condi-

Turn the ignition on and the engine

tion. Replace, if fouled.

stop switch to run. Does the check

Perform a spark test as

engine light illuminate for 4 sec-

described in Starting The

onds?

Engine in this chapter. Is

spark present?

Yes

Check for battery voltage at ter-

Perform the diag-

minal B of coil connector [83B]

nostic procedure

Perform an engine com-

as described in this section. Is

in Figure 65.

pression test (Chapter

battery voltage present?

Three). If compression is

good, check the fuel sys-

Yes

tem as described in this

chapter.

Disconnect the ignition coil connector [83B].

Open in the white/black

Connect a test lamp to terminal A (rear cylinder) of

wire to coil. Repair the

the connector and crank the engine. Repeat for ter-

open circuit.

minal C (front cylinder). Does the test light turn on

Yes

while cranking?

Are the coil connec-

Repair.

tions in good condi-

tion?

Yes

Are the plug

Replace the coil.

Yes

wires in the

Yes

Test the resistance of

correct coil

the spark plug wires.

towers?

Correct the routing.

Is the resistance

within the specifica-

tion in Table 2?

Replace the spark plug wires.

-------------------------------------------------------------------------------------------------------------------------------------------------------------

Connect both test harnesses (Figure 44) be-

Poor connection at the ignition mod-

tween the ignition module and the module

ule connector [10B] or an open in the

connectors. Check the continuity between

harness between the coil and ignition

Terminal A in the ignition coil connector

module. Repair open.

[83B] and Pin 7 on the black test harness.

Measure the resistance between Terminal C

in the ignition coil connector and Pin 6 in the

Turn the ignition off. Measure the resis-

black test harness. Is the resistance less

tance between Terminal A in the cam

than 1.0 ohm?

position sensor connector [14B] and

Pin 1 in the gray test harness. Measure

Yes

the resistance between Terminal C in

the cam position sensor connector and

Pin 8 on the gray test harness. Is the re-

Disconnect the cam position sensor connec-

sistance greater than 1.0 ohm?

tor [14]. With the ignition on, measure volt-

age between terminal A and terminal C of

connector [14B]. Is 5VDC present?

Yes

Repair

Check continuity between

open.

terminal A in the cam po-

Reconnect the cam position sensor [14] con-

sition sensor connector

nector. Turn the ignition on, and measure the

[14B] and ground. Is con-

voltage between Pins 3 and 8 on the gray

Yes

tinuity present?

test harness while cranking the engine. Is

the voltage 0-5 volts?

Repair short to

ground the on

red/white wire.

*Replace igni-

Yes

tion module.

Remove the test harnesses. Reconnect both

Disconnect the cam position sensor

ignition module connectors to the ignition

connector [14]. Measure the resistance

module and reconnect the cam position sen-

between terminal B on the connector

sor connector to the sensor. Try to start the

and Pin 3 in the gray test harness. Is the

engine. Does it start?

resistance greater than 1.0 ohm?

Yes

With the engine

The crankshaft and

running, wiggle

camshaft may be out

Repair the

Remove the cam

the cam position

of time. Check for

open in the

timing cover and

sensor and wires

proper cam timing,

connection.

crank the engine.

to identify any

pinion gear key fail-

Does the rotor cup

loose connections

ure, loose rotor cup

rotate?

(engine misfires or

or other mechanical

stalls). Were any

failure.

found?

Yes

Mechanical failure

Yes

Replace the

indicated. Inspect

cam posi-

for a loose rotator

Replace the cam po-

Repair.

tion sensor.

cup and sheared

sition sensor.

pinion gear key

(Chapter Five).

*Before replacing the ignition module, confirm it is defective by taking it to a dealership. Further testing

requires the Scanalyzer.

-------------------------------------------------------------------------------------------------------------------------------------------------------------

MISFIRE

Is the fuel contaminated?

Drain and flush the tank. (Chapter Eleven)

Yes

Refill with fresh fuel.

Check for:

• Faulty, worn or cracked spark plugs.

Perform a spark test as described in

• Plug fouling due to engine mechanical

Starting the Engine in this chapter. Is

Yes

• fault.

a good spark present?

• Faulty or poor connection at plugs.

Check the spark plug wire resistance

on any plug that did not fire. Is the re-

Replace the faulty wires.

sistance within the specification in

Table 2?

Yes

The coils should be free of carbon

Replace the ignition coil.

tracking. Are they?

Yes

Switch the coil a known-good unit. Is

The original ignition coil is defec-

a good spark present with the

Yes

tive.

known-good coil?

Disconnect the negative battery termi-

nal (Chapter Twelve). Measure the re-

sistance between the positive battery

terminal and Terminal B in the ignition

Find the short and repair.

coil connector [83B]. Also measure

the resistance while wiggling the har-

ness. Is the resistance less than 1.0

ohm?

Yes

*Replace the ignition module.

Yes

Replace the cam position sensor with

a known-good sensor. Static time the

engine and recheck the resistance.

Does the problem still exist?

The system is OK.

-------------------------------------------------------------------------------------------------------------------------------------------------------------

MAP SENSOR

Connect both test harnesses

With the key on and engine off, the

(Figure 44) between the ignition

voltage must be between 4.2 and

module and the module connec-

4.95 VDC. With the engine idling at

tors. With the ignition on, mea-

operating temperature, voltage must

sure the voltage between pin 2

be 1.5-3.0

VDC. Is it?

and pin 8 on the gray test har-

ness.

Yes

Perform a wiggle test. Large voltage

Check the reference voltage. With the ignition on,

changes or setting a trouble code while

measure the voltage between terminal 1 (Red/white)

wiggling the harness indicates the location

and terminal 3 (Black/whte) of the MAP-sensor con-

of an intermittent. Is an intermittent pres-

nector [80B]. Is the voltage approximately 5 VDC?

ent?

Yes

No;

Greater

Less

Yes

than 5V.

Remove the test

Locate short to

Find and repair the

Replace the MAP

harness and

12 Volts on the

short or bad connec-

sensor. Clear the

check for an

Red/white wire

tion.

codes and road test.

open. Check the

in wire har-

Did the check engine

resistance be-

ness. Repair

lamp come on and

tween Terminal 2

as necessary.

set Code 12?

on the MAP sen-

sor connector

[80B] and Pin 2

Connect both test harnesses

in the gray igni-

(Figure 44) between the ignition

tion-module con-

Yes

module and the module connec-

nector [11B]. Is

tors. Check the continuity be-

the resistance

tween terminal 1 and the MAP

Install the original MAP sensor.

System

less than 1 ohm?

sensor connector [80B] and Pin

*Replace the ignition module and

is now

1 in the gray test harness. Check

road test again to verify.

OK.

the continuity between terminal 3

in the MAP-sensor connector

and pin 8 in the gray test har-

Locate and re-

ness. Is there continuity?

Yes

pair grounded vi-

olet/white wire.

Check for short to ground.

Disconnect the ignition module.

Measure the resistance

Check the resistance between

between Terminal 1 in

the MAP connector [80B], termi-

Yes

MAP sensor connector

nal 1 and terminal 3. Is it greater

Repair the

[80B] and chassis ground.

than 1 megohm?

open wire.

Replace the

Is resistance greater than

MAP sensor.

1 megohm?

Yes

Locate and re-

*Replace the ig-

Locate and repair the

pair grounded

nition module.

short between the

violet/white

red/white and

wire.

black/white wires.

Harley Davidson 1986-2003 sportster troubleshooting manuale cycletech - page 2