Harley Davidson 2008 Sportster Models. Electrical Diagnostics Manual - page 9
CHECKING FOR DIAGNOSTIC TROUBLE
CODES: EFI
4.4
CHECK ENGINE LAMP
2. See
4.4 CHECKING FOR DIAGNOSTIC TROUBLE
CODES: EFI, Code Types for a complete description of
To diagnose system problems, start by observing the behavior
DTC formats.
of the check engine lamp.
NOTE
NOTES
Some DTCs can only be fully diagnosed during actuation. For
•
See Figure 4-4. "Key ON" means that the Ignition Switch
example, a problem with the ignition coil will be considered a
is turned to IGNITION and the Engine Stop Switch is set
current fault even after the problem is corrected, since the ECM
to RUN (although the engine is not running).
will not know of its resolution until after the coil is exercised by
•
When the Ignition Switch is turned ON, the check engine
vehicle start sequence. In this manner, there may sometimes
lamp will illuminate for approximately four seconds and
be a false indication of the current trouble code.
then turn off.
•
If the check engine lamp is not illuminated at Key ON or
ed02814
if it fails to turn OFF after the initial four-second period,
2
then see 4.6 SPEEDOMETER SELF DIAGNOSTICS.
3
•
If the check engine lamp comes on late (after 20 seconds),
1
ACC.
the problem is likely a serial data bus failure. Test for
Diagnostic Trouble Codes (DTCs) using speedometer self
diagnostics. See
4.6 SPEEDOMETER SELF DIA-
GNOSTICS.
1.
See Figure 4-5. After lamp turns off after being illuminated
for the first four-second period, one of three situations may
occur.
a.
The lamp remains off. This indicates there are no
current fault conditions or stored DTCs currently
detected by the Electronic Control Module (ECM).
1. Ignition OFF
b.
The lamp stays off for only four seconds and then
2. Accessory (ACC) ON
comes back on for an eight-second period. This
3. Ignition ON
indicates a code is stored, but no current DTC exists.
Figure 4-4. Ignition Switch
c.
The lamp remains on beyond the eight-second period.
This indicates a current DTC exists.
em01046
ON
4 Sec.
Lamp OFF: No Current or Historic DTCs
OFF
Key On
Lamp ON 8 Seconds:
Only Historic DTCs Exist
ON
4 Sec.
8 Sec.
Lamp OFF
OFF
4 Sec.
Key On
Lamp Remains ON: Current DTC*
ON
4 Sec.
OFF
4 Sec.
Key On
* Historic DTCs May Also Exist
Figure 4-5. Check Engine Lamp Operation
2008 Sportster Diagnostics: Engine Management 4-5
engine lamp will not indicate the existence of only historic
CODE TYPES
DTCs.
PART NUMBER
TOOL NAME
It is important to note that historic DTCs will exist whenever
HD-44750
DIGITAL TECHNICIAN
the system indicates the existence of a current fault. See
4.4 CHECKING FOR DIAGNOSTIC TROUBLE CODES: EFI,
There are two types of Diagnostic Trouble Codes (DTCs):
Multiple Diagnostic Trouble Codes if multiple DTCs are found.
current and historic. If a DTC is stored, it can be read using
either a computer-based diagnostic package called DIGITAL
Diagnostic charts are designed for use with current DTCs and
TECHNICIAN (Part No. HD-44750) or speedometer self dia-
as a result they frequently suggest part replacement. When
gnostics. See 4.6 SPEEDOMETER SELF DIAGNOSTICS.
diagnosing a historic DTC the charts can be helpful but should
not lead to part replacement without verification the part is
NOTES
faulty.
•
To differentiate between current and historic DTCs, a
computer-based diagnostic package called DIGITAL
RETRIEVING DIAGNOSTIC TROUBLE
TECHNICIAN (Part No. HD-44750) must be employed.
CODES
•
All DTCs reside in the memory of the ECM, TSM/TSSM/
PART NUMBER
TOOL NAME
HFSM, speedometer or tachometer until the DTC is
HD-44750
DIGITAL TECHNICIAN
cleared by use of the speedometer self diagnostics. See
4.6 SPEEDOMETER SELF DIAGNOSTICS.
The engine management system provides two levels of dia-
•
A historic DTC is also cleared after a total of 50 trips has
gnostics.
elapsed. A trip consists of a start and run cycle. After the
•
The most sophisticated mode employs a computer-based
50 trip retention period, the DTC is automatically erased
diagnostic package called DIGITAL TECHNICIAN (Part
from memory providing that no subsequent faults of the
No. HD-44750).
same type are detected in that period.
•
The second mode requires using the speedometer self
Current
diagnostics. Speedometer, tachometer
(if equipped),
TSM/TSSM/HFSM and ECM DTCs can be accessed and
Current DTCs are those which are present during the current
cleared. See 4.6 SPEEDOMETER SELF DIAGNOSTICS.
ignition cycle. See the appropriate flow charts for solutions.
MULTIPLE DIAGNOSTIC TROUBLE CODES
Historic
If a particular problem happens to resolve itself, the active
While it is possible for more than one fault to occur and set
status problem is dropped and it becomes a historic DTC rather
more than one DTC, there are several conditions which may
than a current DTC.
result in one fault setting multiple DTCs:
Historic DTCs can only be retrieved using a computer-based
Serial data DTCs (U1016, U1064, U1097, U1255, U1300 and
diagnostic package called DIGITAL TECHNICIAN (Part No. HD-
U1301) may be accompanied by other DTCs. Always correct
44750).
the serial data DTCs before resolving the other DTCs.
Historic DTCs are stored for 50 ignition cycles after any DTC
Refer to Table 4-7. This table gives most ECM DTCs a priority
was last set as current to assist in the diagnosis of intermittent
ranking.
faults. On the 50th cycle, the DTC will clear itself. The check
4-6 2008 Sportster Diagnostics: Engine Management
INITIAL DIAGNOSTIC CHECK:
EFI
4.5
GENERAL
Diagnostic Tips
•
If odometer reads "BUS Er" with the Ignition Switch turned
PART NUMBER
TOOL NAME
ON (Engine Stop Switch at RUN with the engine off), check
HD-44750
DIGITAL TECHNICIAN
data bus for an open or short to ground. between data link
connector [91A] terminal "3" and ECM connector [78B]
To locate faulty circuits or other system problems, follow the
terminal "5", TSM/TSSM/HFSM connector [30B] terminal
diagnostic flow charts in this section. For a systematic
"3", speedometer connector [39B] terminal "2" or tacho-
approach, always begin with
4.5 INITIAL DIAGNOSTIC
meter (if equipped) connector [108B] terminal "2".
CHECK: EFI, Initial Diagnostics. Read the general information
and then work your way through the flow chart box by box.
•
Check for an open data test terminal between data link
connector [91A] terminal "3" and TSM/TSSM/HFSM con-
Diagnostic Notes
nector [30B] terminal "3". With ignition key turned ON,
If a numbered circle appears adjacent to a flow chart box, then
serial data bus voltage should be typically 0.6-0.8 volts.
more information is offered in the diagnostic notes. Many dia-
The range of acceptable voltage is 0-7.0 volts.
gnostic notes contain supplemental information, descriptions
•
To identify intermittents, wiggle instrument and/or vehicle
of various diagnostic tools or references to other parts of the
harness while performing steps in the Diagnostic Check
manual where information on the location and removal of
charts.
components may be obtained.
Diagnostic Notes
Circuit Diagram/Wire Harness Connector
Each reference number below correlates to a circled number
Table
on the flow chart(s).
When working through a flow chart, refer to the illustrations,
1. Compare engine behavior to symptoms tables.
the associated circuit diagram and the wire harness connector
table as necessary. The wire harness connector table for each
a. Starts hard. Refer to Table 4-4.
circuit diagram identifies the connector number, description,
b. Hesitates, stumbles, surges, misfires and/or sluggish
type and general location.
performance. Refer to Table 4-5.
In order to perform most diagnostic routines, a Breakout Box
c. Engine exhaust emits black smoke or fouls plugs.
and a digital volt/ohmmeter
(DVOM) are required. See
Refer to Table 4-6.
4.7 BREAKOUT BOX: EFI.
To perform the circuit checks with any degree of efficiency, a
2. Connect BREAKOUT BOX (Part No. HD-42682) and
familiarity with the various wire connectors is also necessary.
INSTRUMENT HARNESS ADAPTERS (Part No. HD-
46601) between wire harness and speedometer. See
Reprogramming ECM
2.5 BREAKOUT BOX: SPEEDOMETER/TACHOMETER
Diagnostic charts frequently suggest ECM replacement. In the
All EFI diagnostic codes are listed in Table 4-7.
event an ECM needs to be replaced, it must be reprogrammed
using a computer-based diagnostic package called DIGITAL
Other Diagnostic Trouble Codes (DTCs)
TECHNICIAN (Part No. HD-44750). See your dealer. Password
See 3.10 INITIAL DIAGNOSTIC CHECK: TSM/HFSM for any
learn procedure must also be performed. See 3.25 TSM/HFSM:
codes related to the Turn Signal Module (TSM), Turn Signal
PASSWORD LEARN.
Security Module (TSSM) or Hands-Free Security Module
INITIAL DIAGNOSTICS
(HFSM).
See 2.2 INITIAL DIAGNOSTIC CHECK: SPEEDOMETER for
PART NUMBER
TOOL NAME
any codes related to the speedometer or tachometer.
HD-42682
BREAKOUT BOX
HD-46601
INSTRUMENT HARNESS ADAPTERS
General Information
The diagnostic check is an organized approach to identifying
a problem caused by an electronic control system malfunction.
2008 Sportster Diagnostics: Engine Management 4-7
Table 4-3. Typical Scan Values for Engine Data
ITEM
MIN.
MAX.
HOT
VALUE
VALUE
IDLE
TMAP
MAP sensor
10 kPa
104 kPa
10.3-13.3 in. Hg (35-45 kPa)
sensor
0
Volt
5.1 Volts
IA
T Sensor
3° F (-16° C)
248° F (120° C)
104-140° F (40-60° C)
0.0
Volts
5.0
Volts
2.0-3.5 Volts
TP sensor
0
100
0%
0.2
Volt
4.5
Volts
0.2-1.0 Volt
IAC pintle
0
155
20-50 steps
RPM
800
5600
1000
ET sensor
3° F (-16° C)
464° F (240° C)
230-300° F (110-150° C)
0.0
Volt
5.0
Volts
0.5-1.5 Volts
INJ PW front
0
50 ms
2-4 ms
INJ PW rear
0
50 ms
2-4 ms
Advance front
0
50°
10-15°
Advance rear
0
50°
10-15°
VSS
0
120
0 MPH (km/h)
Battery voltage
10
15
13.4 Volts
ENG RUN
Off
Run
Run
Idle RPM
800
1250
1000
imately
260° F (127° C). Idle settings may be changed with
NOTE
the idle set procedure. See the Service Manual.
Hot idle specifications are with stock exhaust, the engine
operating at 1000 RPM and an engine temperature of approx-
Table 4-4. Engine Starts Hard
CAUSE
SOLUTION
Battery discharged
1.7 CHARGING SYSTEM, Troubleshooting.
Spark plugs
4.17 MISFIRE AT IDLE OR UNDER LOAD.
Spark plug wires
4.17 MISFIRE AT IDLE OR UNDER LOAD.
Ignition coil
4.17 MISFIRE AT IDLE OR UNDER LOAD.
Valve sticking
See Section 3 in the Service Manual.
Water or dirt in fuel system
Drain and refill with fresh fuel.
Loss of battery power to ECM terminal 31*
4.11 NO ECM POWER.
* Codes will not clear (although they appear to).
Table 4-5. Engine Performance Problems
CAUSE
SOLUTION
Manifold leak
4.9 INTAKE LEAK TEST.
NOTE: When manifold leak is large enough, IAC will close to 0
A low IAC count may also indicate an air leak.
and code P0505 will set.
TMAP sensor plugged or not operating properly
4.18 DTC P0107, P0108, P0112, P0113.
Water or dirt in fuel system
Drain and refill with fresh fuel.
4-8 2008 Sportster Diagnostics: Engine Management
Table 4-5. Engine Performance Problems
CAUSE
SOLUTION
Spark plugs
4.17 MISFIRE AT IDLE OR UNDER LOAD.
Throttle plate not opening fully
See Throttle Cable Adjustment in the Service Manual.
Low fuel pressure
4.15 FUEL PRESSURE TEST.
Table 4-6. Engine Exhaust Emits Black Smoke or Fouls Plugs
CAUSE
SOLUTION
Clogged air filter
See Air Cleaner Filter in the Service Manual.
TMAP sensor plugged or not operating properly
4.18 DTC P0107, P0108, P0112, P0113.
Table 4-7. EFI Diagnostic Trouble Codes (DTC) and Fault Conditions
RANKING
DTC
FAULT CONDITION
SOLUTION
1
P0605
ECM flash error
4.26 DTC P0603, P0605
2
P0603
ECM EEPROM error
4.26 DTC P0603, P0605
3
"BUS Er"
Serial data bus shorted low/open/high
4.12 STARTS, THEN STALLS
4
U1300
ECM serial data low
4.12 STARTS, THEN STALLS
5
U1301
ECM serial data open/high
4.12 STARTS, THEN STALLS
6
U1300
TSM/TSSM/HFSM serial data low
4.12 STARTS, THEN STALLS
7
U1301
TSM/TSSM/HFSM serial data open/high
4.12 STARTS, THEN STALLS
8
U1300
speedometer/tachometer serial data low
4.12 STARTS, THEN STALLS
9
U1301
speedometer/tachometer
serial data open/high
4.12 STARTS, THEN STALLS
10
U1064
Loss
of TSM/TSSM/HFSM serial data at ECM
4.30 DTC U1064, U1255
11
U1064
Loss of TSM/TSSM/HFSM serial data at
4.30 DTC U1064, U1255
speedometer
12
U1016
Loss
of all ECM serial data (state of health) at
3.23 DTC U1016, U1255
TSM/TSSM/HFSM
Loss
of all ECM serial data (state of health) at
3.23 DTC U1016, U1255
speedometer
Loss of vehicle speed
3.23 DTC U1016, U1255
Loss of vehicle inhibit motion
3.23 DTC U1016, U1255
Loss of powertrain security status
3.23 DTC U1016, U1255
13
U1097
Loss of speedometer serial data at
4.31 DTC U1097, U1255
TSM/TSSM/HFSM
14
U1255
Missing response at
TSM/TSSM/HFSM
3.23 DTC U1016, U1255
15
U1255
Missing response at speedometer
4.31 DTC U1097, U1255
16
P1003
System relay contacts open
4.14 SYSTEM RELAY CHECK
17
P1002
System relay coil high/shorted
4.14 SYSTEM RELAY CHECK
18
P1001
System relay coil open/low
4.14 SYSTEM RELAY CHECK
19
P1004
System relay contacts closed
4.14 SYSTEM RELAY CHECK
20
P1009
Incorrect password
4.27 DTC P1009, P1010
21
P1010
Missing password (starts then stalls)
4.27 DTC P1009, P1010
22
P0373
CKP sensor intermittent
4.23 DTC P0373, P0374
2008 Sportster Diagnostics: Engine Management 4-9
Table 4-7. EFI Diagnostic Trouble Codes (DTC) and Fault Conditions
RANKING
DTC
FAULT CONDITION
SOLUTION
23
P0374
CKP sensor synch error
4.23 DTC P0373, P0374
24
P0122
TP sensor open/low
4.20 DTC P0122, P0123
25
P0123
TP sensor high
4.20 DTC P0122, P0123
26
P1501
Jiffy stand sensor low
4.29 DTC P1501, P1502
27
P1502
Jiffy stand sensor high
4.29 DTC P1501, P1502
28
P0107
MAP sensor open/low
4.18 DTC P0107, P0108, P0112, P0113
29
P0108
MAP sensor high
4.18 DTC P0107, P0108, P0112, P0113
30
P0117
ET sensor voltage low
4.19 DTC P0117, P0118
31
P0118
ET sensor open/high
4.19 DTC P0117, P0118
32
P0112
IA
T sensor voltage low
4.20 DTC P0122, P0123
33
P0113
IA
T sensor open/high
4.20 DTC P0122, P0123
34
P1351
Front ignition coil open/low
4.28 DTC P1351, P1352, P1354, P1355
35
P1354
Rear ignition coil open/low
4.28 DTC P1351, P1352, P1354, P1355
36
P1352
Front ignition coil high/shorted
4.28 DTC P1351, P1352, P1354, P1355
37
P1355
Rear ignition coil high/shorted
4.28 DTC P1351, P1352, P1354, P1355
38
P0261
Front injector open/low
4.22 DTC P0261, P0262, P0263, P0264
39
P0263
Rear injector open/low
4.22 DTC P0261, P0262, P0263, P0264
40
P0262
Front injector high
4.22 DTC P0261, P0262, P0263, P0264
41
P0264
Rear injector high
4.22 DTC P0261, P0262, P0263, P0264
42
P0562
Battery voltage low
4.25 DTC P0562, P0563
43
P0563
Battery voltage high
4.25 DTC P0562, P0563
44
P0501
VSS sensor low
4.24 DTC P0501, P0502
45
P0502
VSS sensor high
4.24 DTC P0501, P0502
46
P0505
Loss of idle speed control
4.21 DTC P0131, P0132, P0134, P0151,
P0152, P0154
47
P0131
Front O2
sensor low (lean)
4.21 DTC P0131, P0132, P0134, P0151,
P0152, P0154
48
P0151
Rear O2
sensor low (lean)
4.21 DTC P0131, P0132, P0134, P0151,
P0152, P0154
49
P0132
Front O2
sensor high (rich)
4.21 DTC P0131, P0132, P0134, P0151,
P0152, P0154
50
P0152
Rear O2
sensor high (rich)
4.21 DTC P0131, P0132, P0134, P0151,
P0152, P0154
51
P0134
Front O2
sensor open/not responding
4.21 DTC P0131, P0132, P0134, P0151,
P0152, P0154
52
P0154
Rear O2
sensor open/not responding
4.21 DTC P0131, P0132, P0134, P0151,
P0152, P0154
4-10 2008 Sportster Diagnostics: Engine Management
Speedometer
em01120
Tachometer (Optional)
TSM/TSSM/HFSM
1
2
5
6
7
[39A]
1
2
5
6 7
[108A]
1
2
5
6
7
[39B]
1
2
5
6 7
[108B]
[30A]
1
2
3
12
[30B]
1
2
3
12
[GND1]
1
2
6
7
12
[20A]
1
2
6
7
12
[20B]
To ACCY fuse
R/GY
O/W
To BATT fuse
12V ACCY
Fuse
[GND1]
R
BN/GY
BN/GY
12V BATT
GY
Fuse
To INSTR fuse
LGN/V
R/BK
O
12V INSTR
1
Fuse
To IGN fuse
BK
2
Data Link
Connector
LGN/V
3
R/BK
GY
GY
4
12V IGN
Fuse
[91A]
[GND1]
[78B]
5
[78A]
5
ECM
Figure 4-6. Diagnostic Check
Table 4-8. Wire Harness Connectors
NO.
DESCRIPTION
TYPE
LOCATION
[20]
Instruments
12-place Molex
Under fuel tank
[30]
TSM/TSSM/HFSM
12-place Deutsch
Under battery tray
[39]
Speedometer
12-place Packard
Back of speedometer
[78]
Electronic Control Module (ECM)
36-place Packard
Under seat
[91]
Data link connector
4-place Deutsch
Under left side cover
[108]
T
achometer (if equipped)
12-place Packard
Back of tachometer
2008 Sportster Diagnostics: Engine Management 4-11
Initial Diagnostic Check (Part 1 of 3)
Does engine
start?
YES.
YES.
NO.
NO.
Starts and
Starts, then
Cranks, but
Engine will not
runs.
stalls.
will not start.
crank.
Check for diagnostic trouble
codes (DTCs). See 4.6
See 4.12 STARTS, THEN
See 4.10 ENGINE CRANKS,
See 1.2 STARTING SYSTEM
SPEEDOMETER SELF
STALLS.
BUT WILL NOT START.
DIAGNOSIS.
DIAGNOSTICS
DTCs found?
NO
YES
NO
Unable to enter
diagnostic mode.
No DTCs
displayed.
Refer to applicable DTC priority chart.
With ignition switch OFF, press and
All DTCs are listed in
No codes displayed. For
release trip odometer reset switch.
Table 4-7. DTCs are listed by priority.
symptoms that may not set
Does odometer display appear with
1
diagnostic trouble codes,
display backlighting?
refer to Table 4-4, Table 4-5
and Table 4-6.
YES
NO
STOP
Check for continuity to ground on terminal “7” of
2
speedometer. Wiggle harness during continuity check.
Continuity present?
Go to Initial Diagnostic
Check (Part 2 of 3).
YES
NO
Check for battery voltage at Breakout
Locate and repair open
Box terminal “5” (black) of
between terminal “7”
speedometer while wiggling harness.
and ground.
Battery voltage continuously present?
YES
NO
With ignition switch OFF and speedometer
Locate and repair open
connector [39] disconnected, check continuity
between terminal “5” and
between Breakout Box terminals “8” and “11”
battery fuse.
Is continuity present when trip odometer reset
switch is depressed and infinity when released?
YES
NO
Replace trip odometer
Replace speedometer.
reset switch.
fc01194_en
4-12 2008 Sportster Diagnostics: Engine Management
Initial Diagnostic Check (Part 2 of 3)
Continued from Initial Diagnostic Check
(Part 1 of 3).
Turn ignition switch ON.
Is odometer backlight present?
YES
NO
Perform “WOW” test. See 4.6
SPEEDOMETER
SELF DIAGNOSTICS.
The following features should be functional
Replace Speedometer.
1) backlight should illuminate
2) needle should sweep its full range of
motion
3) LED’s that should illuminate:
• check engine
• battery
• security (all models)
• low fuel
• sixth gear
4) LED’s that may illuminate:
• pursuit
• cruise (although not cruise equipped)
Are all features functional?
YES
NO
With ignition switch turned to
Turn key to ACC.
2
IGN, check for battery voltage
Is backlight present?
at terminal “1” of Breakout Box.
Battery voltage present?
YES
NO
YES
NO
Check for battery voltage at
Is problem intermittent?
2
Breakout Box terminal “6”.
Replace speedometer.
Is instrument
Battery voltage present?
fuse good?
YES
NO
YES
NO
Locate and repair
Locate and repair
Replace speedometer.
Is accessory fuse
open between terminal
source of fault.
good?
“1” of connector [39]
Replace fuse.
and instrument fuse.
YES
YES
NO
fc01195_en
Locate and repair open on (O/W)
Locate and repair
STOP
wire between terminal “6” of con-
source of fault.
nector [39] and accessory fuse.
Replace fuse.
Go to Initial Diagnostic
Check (Part 3 of 3).
2008 Sportster Diagnostics: Engine Management 4-13
Initial Diagnostic Check (Part 3 of 3)
Continued from Initial Diagnostic
Check (Part 2 of 3).
Is problem intermittent?
NO
NO
YES
Speedometer inoperative
Tachometer Inoperative
(no vehicle speed).
(no engine speed).
Repeat Diagnostic
Remove and inspect vehicle
Check while wiggling
See 2.4 SPEEDOMETER/
speed sensor. Debris
harnesses.
TACHOMETER.
present?
Was intermittent found?
YES
NO
YES
NO
Locate and repair
No trouble found.
Check for damaged wiring/loose
intermittent.
Remove debris. Reinstall
connection between vehicle speed
vehicle speed sensor.
sensor and ECM. Is wiring damage/
loose connection present?
YES
NO
Locate and repair
Replace Speedometer.
source of fault.
fc01196_en
4-14 2008 Sportster Diagnostics: Engine Management
SPEEDOMETER SELF DIAGNOSTICS
4.6
GENERAL
ed02830
The speedometer is capable of displaying and clearing
speedometer, tachometer, TSM/TSSM/HFSM, and ECM trouble
codes (DTCs) (diagnostic mode).
DIAGNOSTICS
Diagnostic Tips
•
For a quick check of speedometer function, a "WOW" test
can be performed. See Figure 4-8. Press and hold trip
odometer reset switch then turn Ignition Switch ON.
Release trip odometer reset switch. See Figure 4-7.
Background lighting should illuminate, speedometer needle
should sweep its full range of motion, and indicator lamps
(sixth gear, check engine, low fuel, battery and security)
should illuminate.
•
If speedometer fails "WOW" test, check for battery, ground,
ignition, trip odometer reset switch and accessory to
speedometer. If any feature in the speedometer is non-
1
5
functional, see
2.2 INITIAL DIAGNOSTIC CHECK:
2
4
SPEEDOMETER.
3
Diagnostic Notes
1.
Sixth gear indicator (not used)
Each reference number below correlates to a circled number
2.
Check engine lamp
on the flow chart(s).
3.
Low fuel lamp
1. To exit diagnostic mode, turn Ignition Switch OFF.
4.
Battery lamp
5.
Security lamp (key icon)
2. To clear DTCs for the selected module, press the trip
odometer reset switch for more than 5 seconds when a
Figure 4-7. Speedometer
DTC is displayed. This procedure will clear all DTCs for
the selected module.
ed02814
2
3
1
ACC.
1. Ignition OFF
2. Accessory (ACC) ON
3. Ignition ON
Figure 4-8. Ignition Switch
2008 Sportster Diagnostics: Engine Management 4-15
Speedometer Self Diagnostics (chart)
While holding trip odometer reset
switch in, turn ignition switch to
1
IGNITION.
Make sure Engine Stop Switch is in
RUN position.
Release trip odometer reset switch.
Does “diag” appear?
YES
NO
Press and release trip odometer reset switch.
“PSSPtb” appears.
To display DTCs for the
ECM, press and hold trip
See 2.2 INITIAL
”P” flashing.
odometer reset switch for more
DIAGNOSTIC
than 5 seconds.
CHECK: SPEEDOMETER.
To choose TSM/
TSSM/HFSM, press
and release trip odometer
reset switch.
To display DTCs for
TSM/TSSM, press and hold trip
Device
”S” flashing.
odometer reset switch for more
response?
than 5 seconds.
NO
To choose Speedometer,
press and release trip
“no rsp” displayed. See applicable code from
odometer reset switch.
other modules. Models not equipped with a
tachometer or ABS will display “no rsp” normally.
To display DTCs for
speedometer, press and
YES
If “no rsp” displayed on odometer on tachometer
”SP” flashing.
hold trip odometer reset
equipped vehicle, See Section 2.4
switch for more than 5
SPEEDOMETER/TACHOMETER.
seconds.
To choose Tachometer,
press and release trip odometer
DTC
2
reset switch.
“none” displayed.
displayed.
To display DTCs for tachometer,
press and hold trip odometer
”T” flashing.
reset switch for more than 5
Press and release trip
seconds.
odometer reset switch.
Press and release
Are more DTCs displayed?
trip odometer reset
To choose ABS, press
switch. Part number
and release trip odometer
of module will be
reset switch.
displayed.
YES
To display DTCs for
ABS, press and
NO
”b” flashing.
hold trip odometer reset
switch for more
than 5 seconds.
“end” displayed. To clear all DTCs for selected
To choose ECM, press
module hold trip odometer reset switch for more than
and release trip odometer
5 seconds. If DTCs are not to be cleared, Press and
reset switch.
release trip odometer reset switch. Part number of
module will be displayed.
Press and release trip
odometer reset switch again to
continue to next module.
fc01065_en
4-16 2008 Sportster Diagnostics: Engine Management
BREAKOUT BOX:
EFI
4.7
GENERAL
ed02841
PART NUMBER
TOOL NAME
2
HD-43876
BREAKOUT BOX
6
The BREAKOUT BOX (Part No. HD-43876) splices into the
3
main harness. Used in conjunction with a digital volt/ohmmeter
DVOM, it allows circuit diagnosis of wiring harness and connec-
tions without having to probe with sharp objects.
NOTE
See wiring diagrams for ECM terminal functions.
INSTALLATION
5
1. Remove seat to gain access to Electronic Control Module
(ECM).
2. See Figure 4-9. Depress latch (1) on ECM connector (2)
to separate pin and socket halves [78].
3. See Figure 4-10. Attach Breakout Box (1) between ECM
(2) and ECM wiring harness.
4
a. Attach Breakout Box pin connector (3) to ECM har-
ness socket connector [78B] (4).
1
b. Attach Breakout Box socket connector (5) to ECM pin
1. Breakout Box
connector [78A] (6).
2. ECM
3. Breakout Box pin connector
4. ECM harness socket connector [78B]
ed02840
5. Breakout Box socket connector
1
6. ECM pin connector [78A]
2
Figure 4-10. Installed Breakout Box
REMOVAL
1. See Figure 4-10. Depress latch on Breakout Box socket
connector (5). Detach connector from ECM pin connector
[78A] (6).
2. Detach Breakout Box pin connector (3) from ECM harness
socket connector [78B] (4).
3. Reattach ECM harness connector to ECM.
1. Latch
4. Install seat.
2. ECM connector [78B]
Figure 4-9. ECM Location
2008 Sportster Diagnostics: Engine Management 4-17
WIGGLETEST
4.8
3. Shake or wiggle harness to detect intermittents. If intermit-
GENERAL
tents are present, radical voltage changes will register on
The wiggle test indicates the presence of intermittents in a
the DVOM.
wiring harness.
PROCEDURE
sm00202
PART NUMBER
TOOL NAME
HD-43876
BREAKOUT BOX
NOTE
When diagnosing Electronic Control Module (ECM) connec-
tions, use a BREAKOUT BOX (Part No. HD-43876) to simplify
the procedure. See 4.7 BREAKOUT BOX: EFI.
1. See Figure 4-11. Connect digital volt/ohmmeter (DVOM)
to wiring harness between the suspect connections. Set
DVOM to read voltage changes.
2. Start motorcycle engine and run at idle.
Figure 4-11. Fluke 78 Multimeter (DVOM)
4-18 2008 Sportster Diagnostics: Engine Management
INTAKE LEAK TEST
4.9
GENERAL
ed02843
8
9
Do not allow open flame or sparks near propane. Propane
is extremely flammable, which could cause death or ser-
ious injury. (00521b)
To prevent false readings, keep airbox cover installed when
7
performing test.
Do not direct propane into air cleaner, false readings will result.
LEAK TESTER
PART NUMBER
TOOL NAME
HD-41417
PROPANE ENRICHMENT KIT
6
Parts List
•
Standard 14 oz. propane cylinder.
•
PROPANE ENRICHMENT KIT (Part No. HD-41417).
5
Tester Assembly
1. See Figure 4-12. Make sure valve knob (6) is closed (fully
clockwise).
2. Screw valve assembly (5) onto propane bottle (1).
4
Tester Adjustment
1
1.
See Figure 4-12. Press and hold trigger button (8).
2.
Slowly open valve knob (6) until pellet in flow gauge (7)
rises to between 5 and 10 SCFH on gauge.
2
3.
Release trigger button.
3
1. Propane bottle
2. Nozzle
3. Copper tube
4. Hose
5. Valve assembly
6. Valve knob
7. Flow gauge
8. Trigger button
9. Hanger
Figure 4-12. Leak Tester
PROCEDURE
1. Start engine.
2. Warm engine to operating temperature.
NOTE
Do not direct propane stream toward front of engine. If propane
enters air cleaner, a false reading will be obtained.
3. See Figure 4-13. Aim nozzle (3) toward possible sources
of leak such as intake manifold mating surfaces.
2008 Sportster Diagnostics: Engine Management 4-19
4. Push trigger button (2) to release propane. Tone of engine
ed02844
will change when propane enters source of leak.
5. When test is finished, release trigger button and close
valve knob (turn knob fully clockwise).
3
2
1
1. Propane bottle
2. Trigger button
3. Nozzle
Figure 4-13. Checking for Leaks
4-20 2008 Sportster Diagnostics: Engine Management
ENGINE CRANKS,
BUT WILL NOT START
4.10
terminals "13" and "11". Start engine. If lamp flashes, no
GENERAL
problem is found. Repeat for Breakout Box terminals "13"
If the starter will not crank the engine, the problem is not EFI
and "29".
related. Refer to CHAPTER 1 - STARTING / CHARGING,
8. Use HARNESS CONNECTOR TEST KIT (Part No. HD-
CHAPTER 3 - TSM/HFSM or Appendix E - TSM/TSSM
41404-B), brown socket probe and patch cord.
(Japan/Korea).
DIAGNOSTICS
Diagnostic Tips
Check TP sensor value with a digital volt/ohmmeter (DVOM).
PART NUMBER
TOOL NAME
If TP sensor is equal to or greater than 3.8 volts, system is in
HD-26792
SPARK TESTER
"clear flood" mode and engine will not start. While spark is
HD-34730-2C
FUEL INJECTOR TEST LAMP
present, fuel is shut off. Problem can be mechanical, such as
throttle cables stuck
HD-41404-B
HARNESS CONNECTOR TEST KIT
HD-41404-B
HARNESS CONNECTOR TEST KIT
ed02012
HD-43876
BREAKOUT BOX
HD-44687
IGNITION COIL CIRCUIT TEST
ADAPTER
MCR-101 HD
ELECTRICAL SYSTEM ANALYZER
Diagnostic Notes
Each reference number below correlates to a circled number
on the flow chart(s).
1. Check for Diagnostic Trouble Codes
(DTCs). See
4.4 CHECKING FOR DIAGNOSTIC TROUBLE CODES:
EFI, Retrieving Diagnostic Trouble Codes.
2. Check the condition of the battery. Perform a voltage test
and recharge if below 12.60V. Check battery connections
Figure 4-14. Spark Tester
and perform either a conductance test using ELECTRICAL
SYSTEM ANALYZER (Part No. MCR-101 HD) , or a load
test. Replace the battery if necessary. See Battery in the
Service Manual.
ed02013
3. Connect BREAKOUT BOX (Part No. HD-43876). See
4.7 BREAKOUT BOX: EFI.
4. Remove spark plug cable from spark plug.
a. Visually check condition of plug.
b. See Figure
4-14. Attach cable to SPARK
TESTER (Part No. HD-26792). Clip tester to cylinder
head bolt.
c. While cranking engine, look for spark. Repeat pro-
cedure on other spark plug cables.
NOTE
Engine will not spark with both spark plugs removed. When
checking for spark, use SPARK TESTER (Part No. HD-26792)
with both plugs installed.
5. Use HARNESS CONNECTOR TEST KIT (Part No. HD-
41404-B), gray pin probe and patch cord.
6. Typically, when IAC is not functioning, the engine will not
start unless throttle is opened and the engine will stall
when throttle is closed.
7. See Figure 4-15. Plug IGNITION COIL CIRCUIT TEST
Figure 4-15. Ignition Coil Circuit Test
ADAPTER (Part No. HD-44687) and FUEL INJECTOR
TEST LAMP (Part No. HD-34730-2C) into Breakout Box
2008 Sportster Diagnostics: Engine Management 4-21
Y/GN
K
5
87
em01200
CKP
System
[78A]
[78B]
T
4
87A
Relay
ECM
[79B]
[79A]
BE/GY
E
3
30
GN/O
S
2
85
CKP (+)
30
30
R
R
1
1
R
W/BK
U
1
86
CKP (-)
12
12
BK
BK
2
2
BK
System relay
2
2
GN/O
[119B]
Fuse Block
Ignition Coil
Y/GN
A
A
Y/GN
B
B
Spark Plugs
Rear coil
11
11
Y/BE
Y/BE
C
C
Front coil
29
29
BE/O
BE/O
D
D
15 Amp
[83B] [83A]
ECM Fuse
Battery
31
31
BE/GY
BE/GY
R
R
R
30 Amp
15 Amp
Ignition
MAXIFUSE
Ignition Fuse
R
B
Switch
GY
R/BK
R/BK
I
-
+
Y/GN
7
7
Y/GN
Y/GN
A
A
[33B]
Front injector
21
21
W/Y
W/Y
13
13
W/Y
W/Y
B
B
Front
Battery
[84B]
[84A]
Injector
Engine Case
Y/GN
A
A
Ground Point
Fuel Pump
Rear injector
19
19
GN/GY
GN/GY
8
8
GN/GY
B
B
Rear
[85B]
[85A]
Injector
Y/GN
O/GN
1
1
O
2
2
15 Amp
IAC (A) low
35
35
BE/GN
BE/GN
9
9
BE/GN
A
A
Fuel Pump
3
3
Idle
Fuse
BK
4
4
BK
IAC (B) high
36
36
BN/R
BN/R
4
4
BN/R
B
B
Air
IAC (B) low
18
18
BK/PK
BK/PK
1
1
BK/PK
Control
C
C
[141A]
[141B]
IAC (A) high
17
17
BK/O
BK/O
2
2
BK/O
D
D
GND 1
Front O2
Sensor
Switch power
13
13
W/BK
[87B]
[87A]
BK/W
A
A
Intake air temp
7
7
LGN/Y
LGN/Y
14
14
LGN/Y
LGN/Y
B
B
TMAP
Sensor
[138A]
R/W
C
C
1
2
MAP sensor input
25
25
V/W
V/W
11
11
V/W
V/W
D
D
1
2
[138B]
[80B]
[80A]
Rear O2
Sensor
BK/W
3
3
BK/W
BK/W
A
A
TP
5V sensor power
14
14
R/W
R/W
5
5
R/W
R/W
B
B
Sensor
TPS input
24
24
GY/V
GY/V
12
12
GY/V
C
C
[137A]
1
2
[145A]
[145B]
[88B]
[88A]
1
2
[137B]
Engine temp
6
6
PK/Y
PK/Y
1
1
ET
BK/W
2
2
Sensor
[90B]
[90A]
Oxygen sensor A
8
8
PK/O
5V sensor ground
26
26
BK/W
Oxygen sensor B
23
23
PK/GN
To
Serial data link
5
5
LGN/V
LGN/V
7
7
LGN/V
speedometer
GY
3
3
GY
Engine
and
W/BK
4
4
W/BK
Stop
tachometer
Switch
[20B]
[20A]
BK/R
A
A
1
[22B]
[22A]
Data Link
VSS input
33
33
BK/BE
BK/BE
B
B
BK
2
Ground
10
10
C
C
Connector
BK
BK
LGN/V
3
Vehicle
GY
4
[65B]
[65A]
Speed
Sensor
[91A]
Ground
28
28
BK
GND 1
2
3
[30B]
2
3
[30A]
GND 1
TSM/TSSM/HFSM
Figure 4-16. EFI Circuit Diagram
4-22 2008 Sportster Diagnostics: Engine Management
Table 4-9. Wire Harness Connectors
NO.
DESCRIPTION
TYPE
LOCATION
[20]
Instruments
12-place Molex, black
Under fuel tank
[30]
TSM/TSSM/HFSM
12-place Deutsch, gray
Under battery
[22]
Right handlebar controls
6-place Molex
Under fuel tank
[33]
Ignition switch
-
Right side of frame behind neck
[65]
Vehicle Speed Sensor (VSS)
3-place Packard
Right rear top of crankcase
[78]
Electronic Control Module (ECM)
36-place Packard
Under seat
[79]
Crankshaft Position (CKP) sensor
2-place Mini-Deutsch
Front of left crankcase
[80]
T
emperature Manifold Absolute Pres-
4-place Packard, black
sure (TMAP) sensor
[83]
Ignition coil
4-place Delphi
Back of coil
[84]
Front injector
2-place Delphi, black
Top of intake manifold
[85]
Rear injector
2-place Delphi, black
Top of intake manifold
[87]
Idle Air Control (IAC)
4-place Delphi, black
Top of induction module
[88]
Throttle Position (TP) sensor
3-place Delphi, black
Behind air cleaner backing plate
[90]
Engine
Temperature (ET) sensor
2-place Delphi, black
Above induction module, right side
[91A]
Data link connector
4-place Deutsch, gray
On battery strap, behind left side cover
[119]
Relay/fuse block
5-place Amp, spade
ter-
Fuse/relay block, behind left side cover
minals
[137]
Rear oxygen sensor
2-place Amp, black
On H-bracket
[138]
Front oxygen sensor
2-place Amp, black
Electrical caddie behind voltage regu-
lator
[141]
Fuel pump and low fuel switch
4-place Molex, black
Forward of relay/fuse blocks
[145]
Engine harness
16-place Molex, black
Under seat
2008 Sportster Diagnostics: Engine Management 4-23
Engine Cranks, But Will Not Start (Part 1 of 4)
Fresh fuel in tank?
NOTE
Refer to IGNITION COIL in the
Service Manual for proper coil terminal
location.
Spark plug wires firmly
connected to proper coil terminals?
Add fuel /connect
NO
spark plugs.
YES
Check for diagnostic trouble
1
codes (DTCs).
DTCs found?
NO
Is TSM/TSSM/HFSM mounted
YES
in proper orientation?
Refer to Table 4-7.
YES
NO
Start with
the lowest ranking
DTC.
Check battery connections
Install TSM/TSSM/HFSM properly.
2
and voltage. Is voltage
above 12.6V?
YES
NO
At some point in the flow chart you
may be instructed to jump directly
Was battery allowed to discharge?
to a the box with the bold asterisk.
Does battery pass conductance
Was battery drawn
Disregard the asterisk (but not the
test or load test?
down by starting problem?
instruction box ) if your normal pro
-
Recharge battery.
gression through the chart brings
you to this location.
YES
NO
Turn ignition key ON and engine stop
Replace battery.
switch to RUN. Did fuel pump run for 2
seconds and check engine lamp illuminate
for 4 seconds?
YES
NO
NO
No pump,
Connect Breakout Box to ECM [78]. Measure
No light or pump
light OK.
voltage to Breakout Box with DVOM at terminal “13”
3
(+) and terminal “2” (-). Crank engine for greater
See
than 2 seconds to insure proper system operation.
4.13 FUEL SYSTEM
6-12 volts present continuously?
See 4.11 NO ECM POWER.
ELECTRICAL TEST.
YES
NO
Go to Engine
Go to bold asterisk in
cranks, but will
STOP
Engine Cranks, But Will Not Start
not start
fc01197_en
(Part 4 of 4).
(Part 2 of 4).
4-24 2008 Sportster Diagnostics: Engine Management