Content .. 2 3 4

Harley Davidson 1986-2003 sportster troubleshooting manuale cycletech - page 4

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the set-adjust knob until the meter needle reads zero. When

the leads are uncrossed, the needle should move to the other

end of the scale, indicating infinite resistance.

Male

Female

During a continuity test, a reading of infinite resistance

indicates an open in the circuit or component. A reading of

zero indicates continuity, that is, there is no measurable re-

sistance in the circuit or component. A measured reading

indicates the actual resistance to current flow that is present

Female

in that circuit. Even though resistance is present, the circuit

(test here)

has continuity.

Continuity test

Perform a continuity test to determine the integrity of a

circuit, wire or component. A circuit has continuity if it

forms a complete circuit; that is if there are no opens in ei-

ther the electrical wires or components within the circuit. A

circuit with an open, on the other hand, has no continuity.

This type of test can be performed with a self-powered test

light or an ohmmeter. An ohmmeter gives the best results.

1. Disconnect the negative battery cable or disconnect the

test circuit/component from its power source.

2. Attach one test lead (test light or ohmmeter) to one end of

the part of the circuit to be tested.

3. Attach the other test lead to the other end of the part or the

circuit to be tested.

4. The self-powered test light comes on if there is continu-

ity. An ohmmeter reads 0 or low resistance if there is conti-

works properly with a jumper wire installed, an open exists

nuity. A reading of infinite resistance indicates no

between the two jumped points in the circuit.

continuity; the circuit is open.

To troubleshoot with a jumper wire, first use the wire to

5. If testing a component, note the resistance and compare

determine if the problem is on the ground side or the load

this to the specification if available.

side of a device. Test the ground by connecting the wire be-

tween the lamp and a good ground. If the lamp comes on,

Short test

the problem is the connection between the lamp and

ground. If the lamp does not come on with the wire in-

An analog ohmmeter or one with an audible continuity

stalled, the lamp’s connection to ground is good, so the

indicator works best for short testing. A self-powered test

problem is between the lamp and the power source.

light may also be used.

To isolate the problem, connect the wire between the bat-

1. Disconnect the negative battery cable (Chapter Twelve).

tery and the lamp. If it comes on, the problem is between

2. If necessary, remove the blown fuse from the fuse panel

these two points. Next, connect the wire between the bat-

(Chapter Twelve).

tery and the fuse side of the switch. If the lamp comes on,

3. Connect one test lead of the ohmmeter to the load side

the switch is good. By successively moving the wire from

(battery side) of the fuse terminal in the fuse panel.

one point to another, the problem can be isolated to a partic-

4. Connect the other test lead to a confirmed ground loca-

ular place in the circuit.

tion. Make sure the ground is not insulated. If possible, use

the battery ground connection.

Note the following when using a jumper wire:

5. Wiggle the wiring harness relating to the suspect circuit

1. Make sure the wire gauge (thickness) is the same as that

at approximately 6 in. (15 cm) intervals. Watch the ohmme-

used in the circuit being tested. Smaller gauge wire rapidly

ter while progressing along the harness.

overheats and could melt.

6. If the ohmmeter needle moves or the ohmmeter beeps,

2. Make sure the jumper wire has insulated alligator clips.

there is a short-to-ground at that point in the harness.

This prevents accidental grounding (sparks) or possible

shock. Install an inline fuse/fuse holder in the jumper wire.

Jumper Wire

3. A jumper wire is a temporary test measure. Do not leave a

Use a jumper wire to bypass a potential problem and iso-

jumper wire installed as a permanent solution. This creates

late it to a particular point in a circuit. If a faulty circuit

a fire hazard.

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SPEEDOMETER DIAGNOSTIC CODES

Diagnostic code

Fault

Troubleshooting chart

d01

Speed sensor power

¹Figure 94 or Figure 96

output shorted low

d02

Speed sensor power

¹Figure 94 or Figure 96

output shorted high or open

d03

Not used

d04

Not used

d05

Speed sensor return shorted high

¹Figure 94 or Figure 97

d06

Speed sensor return shorted low

¹Figure 94 or Figure 97

d07

Not used

d08

Speedometer power overvoltage

¹Figure 94 or Figure 97

d09

Speed sensor output shorted high

²Figure 100 or Figure 101

d10

Speed sensor output

²Figure 100 or Figure 101

shorted low or open

CAL 14

Speedometer application calibration

number for domestic (U.S. models)

CAL 15

Speedometer application

calibration number for HDI models

5-digit number³

Speedometer pulses per unit after

all does are displayed

1. Refer to Figure 94 for 1997-1998 models except late-model 1998 883 models. Refer to Figure 96 or Figure 97

for late model 1998 883 models and 1999 models.

2. Refer to Figure 100 for 1997-1998 models except late-model 1998 883 models. Refer to Figure 101 for late

model 1998 883 models and 1999 models.

2002-2003 models. Number will vary depending on part number.

4. Never use a jumper wire across any load (a component

and its 12-terminal connector on the back of the speedome-

that is connected and turned on). This would cause a direct

ter (A, Figure 91).

short and blow the fuse(s).

When in the diagnostic mode, the speedometer runs a se-

ries of tests and then displays the results of these tests as di-

agnostic codes.

ELECTRONIC SPEEDOMETER/TACHOMETER

To enter the diagnostic mode, perform the following:

Refer to the following procedures to troubleshoot prob-

1. Press and hold the reset switch.

lems related to the electronic speedometer/tachometer.

2. Turn the ignition on.

3. When you enter the diagnostic mode, the first code, d0l,

will appear in the odometer display followed by a status in-

Tools

dicator, either SEt or CLr. For example: d01SEt indicates

that code d01 has been set. The code d01CLr indicates d01

A speedometer test harness is required to troubleshoot

is clear.

the speed sensor. Fabricate the harness from one 3-pin

Deutsch male connector, two 3-socket Deutsch female con-

NOTE

nectors, and 6-inch lengths of 18-gauge wire. Use three

When in the diagnostic mode never press the

wires to connect the male connector to one of the female

reset switch for more than five seconds. This

connectors and splice the second female connector to the

erases all stored diagnostic codes.

wires. See Figure 90.

During testing, connect the harness between the two

4. Briefly press the reset switch to display the next code and

sides of the speed sensor connector when instructed to in-

its status. Codes are displayed sequentially by code number.

stall the test harness. Probe the second female connector at

5. Toggle through the codes one by one and note which

the indicated test points.

codes have been set. When all codes have been displayed,

the speedometer will display the calibration number (CAL

14 or CAL 15).

Speedometer Diagnostics

6. When a diagnostic code has been set, refer to the chart in

(1998 883 and All 1999-2003 Models)

Figure 92 to identify the fault and appropriate trouble-

The speedometer in 1999-2003 models and in some

shooting chart (Figures 93-97).

late-model 1998 883 models has a self-diagnostic function.

7. Diagnostic codes are cleared whenever the reset switch

This speedometer can be identified by its amber back light

is pressed and held for five seconds while the speedometer

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ODOMETER, TRIP ODOMETER

AND RESET SWITCH (1997-2003 MODELS)

Symptom: Odometer is inoperable and

trip odometer is inoperable.

Turn the ignition on.

Does odometer display correct numbers?

*Replace speedometer.

Yes

Press the trip reset switch. Does the

Verify that the trip display consists

LCD display on the speedometer tog-

Yes

of the correct numbers. Are the cor-

gle between trip and odometer modes?

rect numbers displayed?

Yes

Turn the reset switch boot clockwise to

Perform the di-

*Replace the

tighten. Toggle the switch again and

agnostic proce-

speedometer.

verify operation. Does LCD display tog-

dure in Figure

gle between trip and odometer modes?

94 or Figure 95.

Yes

Unit function-

Remove the boot

On 1997-1998 models, cut leads 1 in.

ing properly.

over the trip reset

from reset switch. Place a jump wire

switch. Toggle the

across the leads to the speedometer.

trip reset switch

without the boot.

Does the LCD dis-

On 1999-2003 models, momentarily

play toggle be-

place a jumper wire across the switch

tween the trip

terminals located on the connector on

odometer and

the back of the speedometer.

odometer modes?

Does the LCD display toggle be-

tween trip and odometer modes?

Yes

Replace the boot.

Yes

Replace the

*Replace the

*Before replacing the speedometer,

reset switch.

speedometer.

confirm that it is defective by taking the

motorcycle to a dealership. Further

testing requires the use of a Scanalyzer.

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INOPERATIVE, INACCURATE OR

ERRATIC SPEEDOMETER

(1995-1998 MODELS EXCEPT LATE MODEL 1998 883 MODELS)

Symptom: speedometer is inoperative,

*Note: Before replacing the speedometer or speed

reads high or low, needle sticks or is in-

sensor, confirm that it is defective by taking the

termittent and erratic.

motorcycle to a dealership. Further testing

requires the use of a Scanalyzer.

Turn the ignition on.

Is the speedometer backlighting on?

Check the speedometer and odometer

bulbs. Have the bulbs failed?

Yes

Disconnect the speed sensor connec-

tor [65]. With the ignition turned on,

Replace the bulbs

If speedometer backlighting

measure the voltage at the red wire on

as necessary.

is not on, check for 9-12

the speedometer side of the connector

volts on the orange/white

[65B]. On 1995-96 models, voltage

wire and continuity to

should be 8-12 volts. On 1997-1998

ground on the black wire at

models, voltage should be 6-12 volts. Is

terminals on back of the

voltage within specification?

speedometer. Repair as nec-

essary.

Check for open wires or

Yes

Check for continuity to

replace the speedome-

ground at the black wire on

ter* if the wires are in

the speedometer side of the

good condition.

speed-sensor connector

[65B]. Is continuity found?

Yes

Wiggle the harness while checking the volt-

age between the orange/white wire and the

black wire at the back of the speedometer

Check the speedometer

at the meter harness connector [20] on

test harness in-line be-

1995-1996 models. Does voltage fluctuate?

tween the speedometer

and sensor side of the

speed-sensor connector.

With the ignition turned

Yes

on, rotate the rear wheel

and check for voltage on

the white wire. Voltage

Repair wiring as

Make sure the spark

should fluctuate between

necessary.

plug wire terminals

0-1 volts and 6-12 volts. Is

are properly seated

voltage present?

onto spark plugs and

secondary coil termi-

Yes

nals/standoffs. Also

check for wear points

on the spark plug

Repair as neces-

wires where insulation

6-12 volts is

6-12 volts present,

sary.

may be damaged. Is

not present.

but no fluctuation

there damage?

to 0-1 volt.

* Replace the

*Replace the speed sen-

* Replace the speedometer.

speedometer.

sor with a known good

unit and recheck. If prob-

lem persists, take the

motorcycle to a dealer-

ship for further testing.

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INOPERATIVE, INACCURATE OR ERRATIC SPEEDOMETER

(LATE-MODEL 1998 883 AND 1999-2003 MODELS)

*Note: Before replacing the

Symptom: speedometer is inoperative, reads high

speedometer, confirm it is defective

or low, needle sticks or is intermittent and erratic.

by taking the motorcycle to a

dealership. Further testing requires

the use of a Scanalyzer.

Turn ignition switch on. Is the speedometer

backlighting on?

Yes

Disconnect the 12-terminal speedometer

connector [39] from the back of the

speedometer. Turn the ignition on. Mea-

Enable the diagnostic

sure the voltage at the orange/white ter-

mode and check for

minal in the speedometer connector. Is

codes. Are any codes

the voltage 12 volts?

present?

Return the speedome-

ter to normal operating

Yes

state. Turn the ignition

Yes

switch on. Rotate the

Check continuity

Locate and re-

back tire. Turn the igni-

to ground on the

pair the open in

Perform the di-

tion off. Enable the di-

black wire at con-

the orange/white

agnostic proce-

agnostic mode. Are

nector [39B]. Con-

wire.

dure indicated

any codes present?

tinuity present?

in Figure 92.

Yes

Locate and re-

* Replace

pair the open in

Further testing required.*

speedometer.

the black wire.

Repair the har-

ness or connec-

tors.

Odometer reset

switch

5th gear

mainshaft

Connector [65]

Speed

sensor

Sensor leads:

R-Red: +12 VDC

White/green wire

W-White: Output signal (square wave)

to turn signal

canceler

B-Black: Ground

Speedometer

12 VDC input

Connector [39]

(on back of speedometer)

Connector [20]

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SPEEDOMETER DIAGNOSTIC CODES d01 AND d02

(LATE MODEL 1998 883 AND 1999-2003 MODELS)

*Note: Before replacing the speedometer, confirm

that it is defective by taking the motorcycle to a

dealership. Further testing requires the use of a

Scanalyzer.

Disconnect the speed-sensor connec-

tor [65]. Turn the ignition on. Measure

the voltage at the red terminal on the

Yes

connector. Is voltage present?

Check for continuity to ground on the black

wire in connector [65B]. Is continuity present?

Check for open or grounded wires.

Yes

Are any present?

Perform the diag-

Check for open

Yes

nostic procedure

wires. Are any

in Figure 97.

present?

Repair the

* Replace the

wires.

speedometer.

Yes

Repair the wires.

* Replace the

speedometer.

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SPEEDOMETER: DIAGNOSTIC CODES d05, d06 AND d08

(LATE MODELS 1998 883 AND 1999-2003 MODELS)

Turn the ignition on. Slowly rotate the rear

6-12 volts is

* Replace

wheel, and check for voltage on the white ter-

not present.

speedometer.

minal of the speed-sensor connector [65]

while the connector is still connected to the

6-12 volt is

speedometer. The voltage should fluctuate be-

*Replace the speed

present, but

tween 0-1 volt and 6-12 volts as the teeth on

no fluctuation

sensor with a

5th gear approach and pass the speed sensor.

to 0-1 volt.

known good unit

and recheck. If the

Is voltage present?

problem persists,

take the motorcycle

Yes

to a dealership for

further testing.

Turn the ignition on. Wiggle the harness and

measure the voltage on the orange/white ter-

Repair the

minal and black terminal of the speedometer

Yes

connector as necessary.

connector [39] while it is still connected to

the speedometer. Does the voltage fluctuate?

Make sure the spark plug wire terminals are

properly seated onto spark plugs and sec-

Repair the

ondary coil terminals/standoffs. Also check

Yes

insulation as necessary.

for wear points on the spark plug wires

where insulation may be damaged. Is the in-

sulation damaged?

Check the speedometer speed sensor. Clean

System is operational.

or replace the sensor as required. Is the

Yes

problem repaired?

* Replace the speedometer.

*Note: Before replacing the speedometer or

speed sensor, confirm it is defective by taking

the motorcycle to a dealership. Further testing

requires the Scanalyzer.

**Begin troubleshooting diagnostic code d08

here.

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TURN SIGNAL MODULE CONNECTORS

(1991-1993 MODELS)

Speedometer

Left turn

signal switch

signal light

Module

Right turn

signal switch

signal light

Power

Orange

Black

Brown

White/

green

Violet

White/

brown

White/

violet

Module pin

connector

Socket connector

is in the diagnostic mode. All codes will be cleared whether

TURN SIGNAL MODULE

they have been displayed or not.

(1991-1996 MODELS)

8. To exit the diagnostic mode, turn the ignition switch

Performance Test

from on to off and then to on again. Do not press the reset

(1991-1993 Models)

switch while doing so. Diagnostic codes are also cleared

If the turn signals are not working properly, perform the

when the vehicle speed reaches 5 mph.

following performance test. A jumper wire, ohmmeter and

voltmeter will be required.

1. Remove the turn signal module as described in Chapter

Speedometer/Tachometer Troubleshooting

Twelve.

(1995-1998 Models, Except 1998 883 Models)

2. After removing the module, identify the socket connec-

tor and module pin connectors using the diagram in Figure

98.

Find the symptom that best describes the condition in

3. With ignition switch off, check for ground at pin No. 1.

Figure 93 or Figure 94 and perform the indicated test pro-

4. Turn the ignition switch on.

cedures. Some test procedures, however, require the use of

5. Check for voltage at pin No. 2. Voltmeter should read 12

the speedometer tester (part No. HD-41354). Take the mo-

volts.

torcycle to a dealership when indicated to do so in the trou-

6. Connect a jumper wire between pins No. 2 and No. 4.

bleshooting chart.

The right front and rear turn signal lights should illuminate.

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TURN SIGNAL MODULE CONNECTORS (1994-1996 MODELS)

Socket housing alignment tabs

Pin housing alignment tabs

Speedometer

Left turn

signal switch

signal light

Module

Right turn

signal switch

signal light

Power

Wire

number

color

Description/function

Black

Module ground to motorcycle

Orange/white

12vdc input from accessory circuit breaker

White/green

Speedometer reed switch input

Brown

Pulsed 12 vdc for flashing right turn signal lights

Violet

Pulsed 12 vdc for flashing left turn signal lights

White/brown

12 vdc from right turn signal switch (when pressed)

White/violet

12 vdc from left turn signal switch (when pressed)

Not used

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7. Connect a jumper wire between pins No. 2 and No. 6.

Troubleshooting

The left front and rear turn signal lights should illuminate.

The following troubleshooting procedures help isolate

8. Connect a jumper wire between pins No. 4 and No. 8

specific problems to the module. If it is necessary to access

and depress the right turn signal switch button. The right

the turn signal module, remove it as described in Chapter

front and rear turn signal lights should illuminate.

Twelve.

9. Connect a jumper wire betweens pins No. 6 and No. 10

Refer to Figure 98 or Figure 99 for socket and module

and depress the left turn signal switch button. The left front

pin connector identification.

and rear turn signal lights should illuminate.

10. Remove the jumper wire and turn the ignition switch

off.

One or both turn signals do not flash. Light on front or

rear side is lit, but does not flash

11. If the module passed all six tests, the module is service-

able. If the module failed one or more tests, refer to Trou-

1. Remove the lens and check for a burned out bulb. Re-

bleshooting in this section.

place bulb if necessary.

2. If the bulb is good, check for the following:

Performance Test

a. Check the bulb socket contacts for corrosion. Clean

(1994-1996 Models)

contacts and recheck. If corrosion consistently builds

on the contacts, wipe the contacts with a dielectric

If the turn signals are not working properly, perform the

grease before installing the bulb.

following performance test. A jumper wire, ohmmeter and

b. Check for a broken bulb wire. Repair the wire or con-

voltmeter will be required.

nector.

c. Check for a loose bulb socket where it is staked to the

1. Remove the turn signal module as described in Chapter

housing. If the bulb socket is loose, replace the light

Twelve.

assembly.

2. After removing the module, identify the socket connec-

d. Check for a poor ground connection. If the ground is

tor and module pin connectors using the diagram in Figure

poor, scrape the ground mounting area or replace

99.

damaged ground wire(s), as required.

3. With ignition switch off, check for ground at pin No. 1.

4. Turn the ignition switch on.

Turn signals do not operate on one side

5. Check for voltage at pin No. 2. Voltmeter should read 12

volts.

1. Perform the checks listed under One or both turns sig-

6. Connect a jumper wire between pins No. 2 and No. 4.

nals do not flash. Light on front or rear side is lit, but does

The right front and rear turn signal lights should illuminate.

not flash in this section. If these checks do not locate the

7. Connect a jumper wire between pins No. 2 and No. 5.

problem, proceed to Step 2.

The left front and rear turn signal lights should illuminate.

2. Inoperative handlebar directional switch. Perform the

following:

CAUTION

a. Turn the ignition switch on.

Do not use a jumper on 1996 models in Steps

b. Disconnect the turn signal module electrical connec-

8 or 9. The turn signal switch will be dam-

tor.

aged.

c. Locate pin No. 8 or No. 10 (1991-1993 models) or

pin No. 6 or No. 7 (1994-1996 models ) on the socket

8A. On 1994-1995 models, connect a jumper wire between

connector.

pins No. 4 and No. 6 and depress the right turn signal switch

d. With a voltmeter set on the DC scale, connect the

button. The right turn signal lights should illuminate.

negative lead to a good ground and the positive lead

8B. On 1996 models, depress the right turn signal button

to one of the pin numbers specified in substep c and

and check for 12 volts at pin No. 6.

press the turn signal switch. The voltmeter should

9A. On 1994-1995 models, connect a jumper wire between

read 12 volts when the switch is pressed in.

pins No. 5 and No. 7 and depress the left turn signal switch

e. If there is a 12 volt reading, proceed to Step 3.

button. The Left turn signal lights should illuminate.

f. If there is no voltage reading, proceed to Step 4.

9B. On 1996 models, depress the left turn signal button and

3. If 12 volts were recorded in Step 2, and the lights and

check for 12 VDC at pin No. 7.

connecting wires are in good condition, the module may be

10. Remove the jumper wire and turn the ignition switch

damaged. Replace the module and retest.

off.

4. If no voltage was recorded in Step 2, check the handle-

11. If the module passed all six tests, the module is service-

bar switch and related wiring for damage. Further tests can

able. If the module failed one or more tests, refer to Trou-

be made by performing continuity and voltage checks.

bleshooting in this section.

5. Reconnect the turn signal module electrical connector.

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Turn signals/hazard lights do not operate on both sides

TURN SIGNAL MODULE

(1997-2003 MODELS)

1. If none of the turn signals or hazard flashers operate,

Use the following troubleshooting charts

(Figures

check the turn signal module for proper ground with an

100-103) to help isolate specific turn signal problems. Find

ohmmeter. Using the wiring diagram at the end of this man-

the particular symptom and follow the procedures until the

ual, trace the ground connection from the module to the

problem is corrected. If it is necessary to access the turn sig-

frame tab. If a ground is not present, remove the ground

nal module, remove it as described in Chapter Twelve.

wire at the frame and scrape the frame and clean the con-

The troubleshooting charts refer to various connectors by

nector. Check the ground wire for breaks. Repair as re-

code numbers. The connectors are identified in the wiring

quired. If a ground is present, perform Step 2.

diagrams located at the end of this manual.

Refer to Figure 104 to identify the socket and pin con-

CAUTION

nectors in the turn signal module connector.

Do not operate the module without pin No. 1

grounded. Otherwise, the module will burn

out.

EXCESSIVE VIBRATION

2. Refer to the appropriate wiring diagram and locate the

Excessive vibration is usually caused by loose engine

accessory circuit breaker. Turn the ignition switch on and

mounting hardware. High speed vibration may be due to a

check for voltage on the hot or load side of the circuit

bent axle shaft or loose or faulty suspension components.

breaker with a voltmeter. If there is no voltage, refer to

Vibration can also be caused by the following conditions:

Chapter Twelve and check the following components:

1. Improperly balanced wheel(s).

2. Defective or damaged tire(s).

a. Accessory circuit breaker.

3. Defective or damaged wheel(s).

b. Main circuit breaker.

4. Tight primary chain links.

c. Starter relay.

5. Severely worn primary chain.

d. Ignition switch.

6. Loose or damaged engine mounting bracket.

7. Internal engine wear or damage.

e. Circuit wiring.

8. Broken frame.

Turn signals do not cancel

FRONT SUSPENSION AND STEERING

Poor handling may be caused by improper tire pressure, a

1. Support the motorcycle so that the front wheel clears the

damaged or bent frame or front steering components, worn

ground.

wheel bearings or dragging brakes.

2A. On 1994 models, connect an ohmmeter to the speed-

ometer white/green wire and ground. Spin the front wheel

and watch the ohmmeter scale. The ohmmeter should alter-

Irregular or Wobbly Steering

nate between 0 ohms and infinity.

1. Loose wheel axle nut(s).

a. If ohmmeter reading is correct, disconnect the mod-

2. Loose or worn steering head bearings.

ule pin connector. With a voltmeter set on the DC

3. Excessive wheel hub bearing play.

scale, connect the negative lead to a good ground and

4. Damaged cast wheel.

the positive lead to the No. 3 pin (white/green) socket

5. Spoke wheel out of alignment.

connector. The voltmeter should read 12 volts. If ohm

6. Unbalanced wheel assembly.

and volt readings are correct, the module is damaged.

7. Worn hub bearings.

b. If ohmmeter reading is incorrect, check for damaged

8. Incorrect wheel alignment.

wiring from the speedometer white/green wire to the

9. Bent or damaged steering stem or frame (at steering

module. If wiring is okay, the reed switch in the

neck).

speedometer may be damaged.

10. Tire incorrectly seated on rim.

11. Excessive front end loading from non-standard

2B. On 1995-1996 models, set a voltmeter to the DC scale.

equipment.

Connect the positive meter lead to pin 3 and connect the

negative meter lead to a good ground. Turn the ignition on

and spin the rear wheel. The voltmeter readings should al-

Stiff Steering

ternate between 0-1 volts and 8-12 volts. If the voltage is

within specification, replace the turn signal module. If the

1. Low front tire air pressure.

readings are not within specification, check the speedome-

2. Bent or damaged steering stem or frame at the steering

ter wiring and the speedometer.

neck.

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100

TURN SIGNALS WILL NOT CANCEL

(1997-1998 MODELS, EXCEPT LATE-MODEL 1998 833 MODELS)*

Turn the ignition on. Check for voltage on the white/green terminal on the harness side of the turn

signal module connector [30] while it is still connected to the turn signal module. The voltage should

fluctuate between 0-1 volts and 6-12 volts while the rear wheel is being turned. Does it?

Yes

No voltage

No fluctuation

Replace the turn

Disconnect the turn signal module

Check for continuity between

signal module.

connector [30] and remove the

the white/green speedometer

white/green speedometer harness

harness wire on the back of

wire from the back of thespeedom-

the speedometer and

eter. Check for continuity to

white/green wire in the turn

ground on the white/green wire. Is

signal module connector [30].

there continuity present?

Is there continuity present?

Yes

Repair

Replace the

Is battery

Repair open

short to

turn signal

voltage pres-

in white/green

ground on

module.

ent on

wire.

white/green

wire.

wire with the

connector

[30] still dis-

connected?

Yes

Repair the short

Refer to speedome-

to voltage.

ter troubleshooting.

*Late model 1998 883 models are equipped with a speedometer

featuring self-diagnostic capabilities.

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101

TURN SIGNALS WILL NOT CANCEL

(LATE MODEL 1998 883CC AND 1999-2003 MODELS)

Use this chart for speedometer trouble

codes 9 (speed output shorted high) and 10

(speed output shorted low or open).

Turn the ignition on. Check for voltage on the white/green terminal on the harness

side of the turn signal module connector [30] while it is still connected to the turn sig-

nal module. The meter should read 3-6 volts when the wheel is turned faster than 3

mph, and it should read 9-11 volts when the wheel is stationary. Does it?

Yes

No voltage

No fluctuation

Disconnect connector [30] and re-

move the speedometer harness con-

Replace the turn

Disconnect connector [30] and

nector at the back of the

signal module.

remove the speedometer har-

speedometer. Check for continuity be-

ness connector at the back of

tween the white/green speedometer

the speedometer. Check for con-

harness connector at the back of the

tinuity to ground on the

speedometer and white/green wire in

white/green wire. Is there conti-

the turn signal module connector [30].

nuity?

Is there continuity?

Yes

Is battery

Repair

Replace the

voltage pres-

Repair open in

short to

turn signal

ent on

white/green

ground on

module.

white/green

wire.

white/green

wire with the

wire.

connector

[30] still dis-

connected?

Yes

Repair the short

Refer to speedome-

to voltage.

ter troubleshooting.

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102

TURN SIGNALS WILL NOT FLASH RIGHT, WILL NOT FLASH LEFT

(1997-2003 MODELS, EXCEPT LATE-MODEL 1998 883 MODELS)

Does the turn signal indicator illumi-

Perform the diagnostic proce-

nate on the side that will not flash?

dure in Figure 103.

Yes

Inspect the bulbs on the side that will

Replace the bulbs as necessary.

not flash. Have the bulbs failed?

Yes

Disconnect the turn signal module

connector [30] from the turn signal

With the bulbs removed, check

module. Place a jumper wire across

for continuity between the termi-

terminals 2 and 3 in the connector,

nal in the bulb socket and

and turn the ignition on. Both right

terminal 3. Is there continuity?

side turn signal lamps should be on.

Are they?

Yes

Disconnect the turn signal module

connector [30] from the turn signal

Repair the

module. Place a jumper wire across

open ground

open in the

terminals 2 and 4 in the connector,

circuit.

wire.

and turn the ignition on. Both left

side turn signal lamps should be on.

Are they?

Yes

Replace

With the bulbs re-

Repair the

the turn

moved, check for

open in the

signal

continuity between

wire.

module.

terminal in the bulb

socket and terminal

Repair the

4. Is there continuity?

Yes

open

ground

circuit.

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103

TURN SIGNALS WILL NOT FLASH, 4-WAY FLASHES INOPERABLE

Inspect the bulbs on a side that will

Replace the bulbs as necessary.

not flash. Has a bulb failed?

Yes

Disconnect the turn signal module

Keep the ignition on. Measure the volt-

connector [30] Turn the ignition on.

age between terminals 1 and 7 of the

Measure the voltage between termi-

turn signal module connector when the

Yes

nals 1 and 2 on the connector. Does

right turn signal switch is pressed.

the meter read 12 volts?

Does the meter read 12 volts?

Yes

Check the resistance to ground at terminal 1

of the turn signal module connector. Is the

Depress the right turn signal switch,

resistance less than 1 ohm?

and check the voltage at the

white/brown terminal in the harness

side of the right handlebar connector

Yes

[22] while it is connected to the con-

trols. Does the meter read 12 volts?

Check for 12 volts at

Repair poor ground

both terminals of the

connection.

Yes

15 amp accessory

circuit breaker. Is 12

volts present at both

Yes

Repair the open

Check for conti-

terminals?

between the han-

nuity at the or-

Repair the open in the

ange/white wire

dlebar connector

orange/white wire be-

to ground. Is

[22] and the turn

tween the accessory

there continuity?

signal module.

circuit breaker terminal

and turn the signal

One

Neither

module.

Yes

terminal

Repair the short

Is 12 volts present

Replace

Repair the

to ground.

at orange/white

the circuit

open be-

wire in connector

breaker.

tween the

[22]?

ignition

Repair the open

switch and

between the

the circuit

Yes

connector [22]

breaker

and the circuit

block.

breaker block.

Replace the turn

signal switch.

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

Depress the left turn signal switch

Keep the ignition on. Measure the voltage be-

and check the voltage at the

tween terminals 1 and 8 of the turn signal mod-

white/violet terminal in the harness

ule connector when the left turn signal switch

side of the left handlebar connector

is pressed. Does the meter read 12 volts?

[24] while it is connected to the con-

trols. Does the meter read 12 volts?

Yes

Place a jumper across terminals 2 and 3 in the turn

signal module connector, and turn the ignition on.

Repair open between

Check continuity at the

Both right turn signal lamps should turn on. Do they?

connector [24] and

white/violet wire to ground.

turn signal module.

Is continuity present?

Yes

Check for continuity

Place a jumper

Repair the short

Is 12 volts present at the

between terminal 3

across terminals 2

to ground.

orange/white wire in

and the lamps. Is

and 4 in the turn

connector [24]?

continuity present?

signal module con-

nector, and turn the

ignition ON. Both

left turn signal

Yes

lamps should turn

on. Do they?

Repair the

Repair

Replace the turn

Repair the open

open be-

open

signal switch.

between the

tween the

ground

connector [24]

lamps and

circuit.

Yes

and the circuit

turn signal

breaker block.

module con-

nector [30].

Replace

Check for conti-

the turn

nuity between

signal

terminal 4 and

module.

the lamps. Is

there continuity?

Yes

Repair the open

Repair the open between

ground circuit.

the lamps and turn sig-

nal module connector

[30].

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104

TURN SIGNAL MODULE CONNECTORS

(1994-2003 MODELS)

Socket housing alignment tabs

Pin housing alignment tabs

Speedometer

Left turn

signal switch

signal light

Module

Right turn

signal switch

signal light

Power

Wire

number

color

Description/function

Black

Module ground to motorcycle

Orange/white

12vdc input from accessory circuit breaker

White/green

Speedometer reed switch input

Brown

Pulsed 12 vdc for flashing right turn signal lights

Violet

Pulsed 12 vdc for flashing left turn signal lights

Not used

White/brown

12 vdc from right turn signal switch (when pressed)

White/violet

12 vdc from left turn signal switch (when pressed)

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

3. Loose or worn steering head bearings.

Insufficient Braking Power

Worn brake pads or disc, air in the hydraulic system,

Stiff or Heavy Fork Operation

glazed or contaminated pads, low brake fluid level, or a

leaking brake line or hose can cause this problem. Visually

1. Incorrect fork oil viscosity.

check for leaks. Check for worn brake pads. Also check for

2. Excessive amount of fork oil.

a leaking or damaged primary cup seal in the master cylin-

3. Bent fork tubes.

der. Bleed and adjust the brakes. Rebuild a leaking master

4. Incorrect fork springs.

cylinder or brake caliper. Brake drag will result in excessive

heat and brake fade. See Brake Drag in this section.

Poor Fork Operation

Spongy Brake Feel

1. Low fork oil level

2. Contaminated fork oil.

This problem is generally caused by air in the hydraulic

3. Worn or damaged fork tubes.

system. Bleed and adjust the brakes as described in Chapter

4. Bent or damaged fork tubes.

Sixteen.

5. Incorrect fork springs.

6. Heavy front end loading from non-standard equipment.

Brake Drag

Poor Rear Shock Absorber Operation

Check brake adjustment. Check for insufficient brake

pedal and/or hand lever free play. Also check for worn,

1. Rear shocks adjusted incorrectly.

loose or missing parts in the brake calipers. Check the brake

2. Incorrect loading.

disc for warp or excessive runout.

3. Heavy rear end loading from non-standard equipment.

4. Weak or worn springs.

Brakes Squeal or Chatter

5. Damper unit leaking.

6. Shock shaft worn or bent.

Check brake pad thickness and disc condition. Make sure

7. Incorrect rear shock springs.

that the pads are not loose. Check that the anti-rattle springs

are properly installed and in good condition. Clean off any

dirt on the pads. Loose components can also cause this.

BRAKE PROBLEMS

Check for:

All models are equipped with front and rear disc brakes.

1. Warped brake disc.

Perform the maintenance specified in Chapter Three to

2. Loose brake disc.

minimize brake system problems. Brake system service is

3. Loose caliper mounting bolts.

covered in Chapter Sixteen. When refilling the front and

4. Loose front axle nut.

rear master cylinders, use only DOT 5 silicone-based brake

5. Worn wheel bearings.

fluid.

6. Damaged hub.

Table 1 and Table 2 are on the following page.

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Table 1 STARTER SPECIFICATIONS

Current draw

Normal

160-200 amps

Maximum

250 amps

Maximum no-load current @ 11.5 volts

90 amps

Minimum no-load speed @ 11.5 volts

3000 rpm

Table 2 ELECTRICAL SPECIFICATIONS

Alternator

Stator coil resistance

0.2-0.4 ohms

AC voltage output

19-26 Vac per 1000 rpm

Battery capacity

12 volt, 19 amp hr.

Ignition coil

Primary resistance

1200S models

0.4-0.6 ohms

All other models

2.5-3.1 ohms

Secondary resistance

1986-1992 models

11,250-13.750 ohms

1993-2003 models

1200S models

11,700-12,700 ohms

All other models

10,000-12,500 ohms

Spark plug cable resistance (1998-2003 1200S)

Front left cable (No. 1)

5039-11,758 ohms

Rear center cable (No.2)

4665-10,886 ohms

Rear left cable (No. 3)

5787-13,504 ohms

Front center cable (No. 4)

4882-11,392 ohms

Voltage regulator

Voltage output

1986-1993 models

13.8-15 VDC @ 75° F (24° C)

1994-2003 models

14.3-14.7 VDC @75° F (24° C)

Amps @ 3600 rpm

1986-1990 models

19 amps

1991-2003 models

22 amps

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