Harley Davidson 2008 Electrical Diagnostics Harley Davidson 2008 Electrical Diagnostics Manual

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2008 Sportster Models
Electrical Diagnostics Manual
©2007 H-D.
ALL RIGHTS RESERVED
99495-08
Printed in the U.S.A.
VISIT THE HARLEY-DAVIDSON WEB SITE
http://www.harley-davidson.com
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GENERAL
This electrical diagnostic service manual has been prepared with two purposes in mind. First, it will acquaint the user with the construction of the Harley-Davidson product and assist in the performance of repair. Secondly, it will introduce to the professional Harley-Davidson Technician the latest field-tested and factory-approved diagnostic methods.We sincerely believe that this manual will make your association with Harley-Dav­idson products more pleasant and profitable.
HOW TO USE YOUR SERVICE MANUAL
Refer to the table below for the content layout of this manual.
CHAPTERNO.
Starting / Charging1 Instruments2 TSM/HFSM3 Engine Management4 Appendix A Connector RepairA Appendix B WiringB Appendix C ConversionsC Appendix D GlossaryD Appendix E TSM/TSSM (Japan/Korea)E
Use the TABLE OF CONTENTS (which follows this FORE­WORD) and the INDEX (at the back of this manual) to quickly locate subjects. Sections and topics in this manual are sequentially numbered for easy navigation.
For example, a cross-reference shown as 2.1 SPECIFICA- TIONS refers to chapter 2 CHASSIS, heading 2.1 SPECIFIC­ATIONS.
For quick and easy reference, all pages contain a section number followed by a page number. For example, page 3-5 refers to page 5 in section 3.
A number of acronyms and abbreviations are used in this document. See the D.1 GLOSSARY for a list of acronyms, abbreviations and definitions.
PREPARATION FOR SERVICE
NOTES
To avoid unnecessary disassembly, carefully read all rel­ative service information before repair work is started.
In figure legends, the number which follows the name of a part indicates the quantity necessary for one complete assembly.
When servicing a vehicle equipped with the Harley-Dav­idson Smart Security System (H-DSSS), you must first disarm the security system. Either keep the fob in close proximity to the vehicle, or use Digital Technician to disable the security system while the vehicle is being serviced and re-enable the system after service is completed.
SERVICE BULLETINS
In addition to the information presented in this Service Manual, Harley-Davidson Motor Company will periodically issue Service Bulletins to Harley-Davidson dealers. Service Bulletins cover interim engineering changes and supplementary information. Consult the Service Bulletins to keep your product knowledge current and complete.
USE GENUINE REPLACEMENT PARTS
Do not use aftermarket parts and custom made front forks which can adversely affect performance and handling. Removing or altering factory installed parts can adversely affect performance and could result in death or serious injury. (00001a)
To ensure satisfactory and lasting repairs, carefully follow the Service Manual instructions and use only genuine Harley­Davidson replacement parts. Behind the emblem bearing the words GENUINE HARLEY-DAVIDSON stand more than 100 years of design, research, manufacturing, testing and inspecting experience.This is your assurance that the parts you are using will fit right, operate properly and last longer.
WARNINGS AND CAUTIONS
Statements in this service manual preceded by the following words are of special significance.

FOREWORD

Stop the engine when refueling or servicing the fuel system. Do not smoke or allow open flame or sparks near gasoline. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00002a)
Good preparation is very important for efficient service work. A clean work area at the start of each job will allow you to perform the repair as easily and quickly as possible, and will reduce the incidence of misplaced tools and parts. A motorcycle that is excessively dirty should be cleaned before work starts. Cleaning will occasionally uncover sources of trouble. Tools, instruments and any parts needed for the job should be gathered before work is started. Interrupting a job to locate tools or parts is a distraction and causes needless delay.
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. (00119a)
CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. (00139a)
CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage. (00140a)
I
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NOTE
Refers to important information, and is placed in italic type. It is recommended that you take special notice of these items.
Proper service and repair is important for the safe, reliable operation of all mechanical products.The service procedures recommended and described in this service manual are effective methods for performing service operations.
information or product returns, warranty or otherwise, visit www.spx.com.
Loctite Sealing and Threadlocking Pr oducts
Some procedures in this manual call for the use of Loctite products. If you have any questions regarding Loctite product usage or retailer/wholesaler locations, please contact Loctite Corp. at www.loctite.com.
PRODUCT REGISTERED MARKS
Always wear proper ey e protection when using hammer s, arbor or hydraulic presses, gear pullers, spring com­pressors, slide hammers and similar tools. Flying parts could result in death or serious injury. (00496b)
Some of these service operations require the use of tools specially designed for the purpose.These special tools should be used when and as recommended. It is important to note that some warnings against the use of specific service methods, which could damage the motorcycle or render it unsafe, are stated in this service manual. Howe v er, please remember that these warnings are not all-inclusive. Inadequate safety precau­tions could result in death or serious injury.
Since Harley-Davidson could not possibly know, evaluate or advise the service trade of all possible ways in which service might be performed, or of the possible hazardous con­sequences of each method, we have not undertaken any such broad evaluation. Accordingly, anyone who uses a service procedure or tool which is not recommended by Harley-Dav­idson must first thoroughly satisfy himself that neither his nor the operator's safety will be jeopardized as a result. Failure to do so could result in death or serious injury.
PRODUCT REFERENCES
Allen, Amp Multilock, Bluetooth, Brembo, Delphi, Deutsch, Dunlop, Dynojet, Fluke, G.E. Versilube, Gunk, Hydroseal, Hylomar, Kevlar, Lexan, Loctite, Lubriplate, Keps, K&N, Mag­naflux, Marson Thread-Setter Tool Kit, MAXI fuse, Molex, MPZ, Mulitilock, Novus, Packard, Pirelli, Permatex, Philips, PJ1, Pozidriv , Robinair , S100, Sems, Snap-on, Teflon, Threadlocker , Torca, Torco, TORX, Tufoil, Tyco, Ultratorch, Velcro, X-Acto, and XM Satellite Radio are among the trademarks of their respective owners.
H-D MICHIGAN, INC.TRADEMARK INFORMATION
Harley, Harley-Davidson, H-D, Bar & Shield, Digital Tech, Digital Technician, Destroyer, Deuce, Dyna, Electra Glide, Evolution, F at Boy, Glaze, Gloss, H-D, H-Dnet.com, HD , Harley, Heritage Softail, Heritage Springer, Low Rider, Night Rod, Night Train, Profile, Revolution, Road Glide, Road King, Rocker, Softail, Sportster, Sun Ray, Sunwash, Tech Link, Twin Cam 88, Twin Cam 88B, Twin Cam 96, Twin Cam 96B, Twin Cam 103, Twin Cam 103B, Twin Cam 110, Twin Cam 110B, Tour­Pak, Screamin' Eagle, Softail, Super Guide, Super Premium, SYN3, Ultra Glide, V-Rod, VRSC, V-Rod, VRSC, Wide Glide, and Harley-Davidson Genuine Motor P arts and Genuine Motor Accessories are among the trademarks of H-D Michigan, Inc.
CONTENTS
Read and follow warnings and directions on all products. Failure to follow warnings and directions can result in death or serious injury. (00470b)
When reference is made in this manual to a specific brand name product, tool or instrument, an equivalent product, tool or instrument may be substituted.
Kent-Moore Products
All tools mentioned in this manual with an "HD", "J" or "B" preface must be ordered through SPX K ent-Moore. For ordering
All photographs, illustrations and procedures may not neces­sarily depict the most current model or component, but are based on the latest production information available at the time of publication.
Since product improvement is our continual goal, Harley-Da v­idson reserves the right to change specifications, equipment or designs at any time without notice and without incurring obligation.
II FOREWORD
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STARTING / CHARGING
1.1 STARTER TROUBLESHOOTING
General...............................................................................1-1
Starter Troubleshooting......................................................1-1
1.2 STARTING SYSTEM DIAGNOSIS
Diagnostics.........................................................................1-3
Diagnostic Notes.........................................................1-3
Job/Time Code Values................................................1-3
1.3 STARTER ACTIVATION CIRCUITS
Starter Activation Circuits.................................................1-12
1.4 DIAGNOSTICS/TROUBLESHOOTING
Voltage Drop.....................................................................1-13
2.2 INITIAL DIAGNOSTIC CHECK:
SPEEDOMETER
General...............................................................................2-4
Diagnostic Notes.........................................................2-4
Circuit Diagram/Wire Harness Connector Table..........2-4
Job/Time Code Values................................................2-4
Reprogramming ECM..................................................2-4
Initial Diagnostics...............................................................2-4
Diagnostic Tips............................................................2-4
Diagnostic Notes.........................................................2-5
Other Diagnostic Trouble Codes..................................2-5
2.3 SPEEDOMETER SELF DIAGNOSTICS
General.............................................................................2-10
Diagnostics.......................................................................2-10
Diagnostic Tips..........................................................2-10
Diagnostic Notes.......................................................2-10
1.5 TESTING STARTER ON MOTORCYCLE
Start Relay Test................................................................1-14
Starter Current Draw Test.................................................1-14
1.6 TESTING STARTER ON BENCH
Free Running Current Draw Test......................................1-16
Starter Solenoid................................................................1-16
Solenoid Pull-In Test.........................................................1-16
Solenoid Hold-In Test........................................................1-17
Solenoid Return Test........................................................1-17
1.7 CHARGING SYSTEM
General.............................................................................1-18
Alternator...................................................................1-18
Voltage Regulator......................................................1-18
Troubleshooting................................................................1-18
Battery.......................................................................1-18
Wiring........................................................................1-18
Testing..............................................................................1-22
Milliampere Draw Test...............................................1-22
Total Current Draw Test.............................................1-22
Current and Voltage Output Test: Using HD-48053....1-23
Current and Voltage Output Test: Using Load
Tester.........................................................................1-23
Stator Check..............................................................1-24
AC Output Check......................................................1-25
1.8 BATTERY TESTING
General.............................................................................1-26
Voltmeter Test...................................................................1-26
Conductance Test.............................................................1-26
Load Test..........................................................................1-26
INSTRUMENTS
2.1 CHECKING FOR DIAGNOSTIC TROUBLE CODES
Check Engine Lamp...........................................................2-1
Security Lamp....................................................................2-2
Turn Signal Module (TSM)..........................................2-2
Turn Signal Security Module (TSSM) or Hands-Free
Security Module (HFSM).............................................2-2
Code Types.........................................................................2-3
Current........................................................................2-3
Historic........................................................................2-3
Retrieving Diagnostic Trouble Codes..................................2-3
Multiple Diagnostic Trouble Codes.....................................2-3
2.4 SPEEDOMETER/TACHOMETER
General.............................................................................2-12
Trip Odometer Reset Switch.....................................2-12
Speedometer Theory of Operation...................................2-12
Odometer Theory of Operation.........................................2-12
Tachometer Theory of Operation......................................2-12
Diagnostics.......................................................................2-13
Diagnostic Notes.......................................................2-13
2.5 BREAKOUT BOX: SPEEDOMETER/TACHOMETER
General.............................................................................2-16
Speedometer....................................................................2-16
Installation.................................................................2-16
Removal....................................................................2-16
Tachometer.......................................................................2-16
Installation.................................................................2-16
Removal....................................................................2-16
2.6 INDICATOR LAMPS
General.............................................................................2-17
Job/Time Code Values..............................................2-17
Diagnostics.......................................................................2-17
Diagnostic Notes.......................................................2-17
2.7 DTC B1004, B1005
General.............................................................................2-21
Diagnostics.......................................................................2-21
Diagnostic Tips..........................................................2-21
Diagnostic Notes.......................................................2-21
2.8 DTC B1006, B1007
General.............................................................................2-25
Accessory or Ignition Line Overvoltage.....................2-25
2.9 DTC B1008
General.............................................................................2-27
Trip Odometer Reset Switch Closed.........................2-27
Diagnostics.......................................................................2-27
Diagnostic Notes.......................................................2-27
2.10 DTC U1016, U1255
General.............................................................................2-30
Loss of ECM Serial Data...........................................2-30
Diagnostics.......................................................................2-30
Diagnostic Notes.......................................................2-30

TABLE OF CONTENTS

III
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TABLE OF CONTENTS
2.11 DTC U1064, U1255
General.............................................................................2-33
Loss of TSM/TSSM/HFSM Serial Data.....................2-33
Diagnostics.......................................................................2-33
Diagnostic Notes.......................................................2-33
2.12 DTC U1300, U1301 OR BUS ER
General.............................................................................2-37
Serial Data Low or Serial Data Open/High................2-37
Diagnostics.......................................................................2-37
Diagnostic Tips..........................................................2-37
Diagnostic Notes.......................................................2-37
TSM/HFSM
3.1 TURN SIGNAL OVERVIEW
General...............................................................................3-1
Security System: Japan/Korea...........................................3-1
Turn Signal Functions.........................................................3-1
Manual Cancellation...........................................................3-1
Automatic Cancellation.......................................................3-1
Bank Angle Functions........................................................3-1
Bank Angle Restart............................................................3-1
Clutch/Neutral Interlock......................................................3-1
Security System H-DSSS...................................................3-1
3.2 HARLEY-DAVIDSON SMART SECURITY SYSTEM
Components.......................................................................3-2
Security Immobilization......................................................3-2
HFSM Features..................................................................3-3
3.3 H-DSSS ACTUATION
General...............................................................................3-5
Sidecar Configuration.........................................................3-5
Actuation............................................................................3-5
Fob Assignment..................................................................3-5
Power Disruption and Configuring......................................3-5
3.4 PERSONAL IDENTIFICATION NUMBER (PIN)
General...............................................................................3-6
Initial Pin Entry...................................................................3-6
Changing the Pin................................................................3-6
Modifying an Existing Pin............................................3-6
3.5 ARMING/DISARMING SECURITY SYSTEM
Hands-Free Fob..................................................................3-8
Security Lamp (Key Icon)...................................................3-8
Arming................................................................................3-8
Disarming...........................................................................3-9
Automatic Disarming...................................................3-9
Disarming with a Personal Identification Number
(PIN)............................................................................3-9
3.6 WARNINGS AND ALARMS
Warnings..........................................................................3-10
Alarm................................................................................3-10
Activation...................................................................3-10
Deactivation...............................................................3-10
Siren Chirp Mode (Confirmation)......................................3-10
Chirpless Mode.........................................................3-10
Chirp Mode................................................................3-10
Switching Modes.......................................................3-10
3.7 SERVICE/EMERGENCY FUNCTIONS
Transport Mode................................................................3-11
To Enter Transpor t Mode...........................................3-11
To Exit Transport Mode..............................................3-11
Service Mode...................................................................3-11
Four-Way Flashing...........................................................3-11
To Arm the HFSM with the Hazard Warning Flashers
ON.............................................................................3-11
To Disarm the HFSM and Turn the Hazard Warning
Flashers OFF............................................................3-11
3.8 TROUBLESHOOTING
Turn Signals (TSM/HFSM)...............................................3-12
Security System (HFSM)..................................................3-12
Diagnostics Mode.............................................................3-12
Troubleshooting................................................................3-12
3.9 CHECKING FOR DIAGNOSTIC TROUBLE CODES
General.............................................................................3-13
Security/Lamp Diagnostics...............................................3-13
Code Types.......................................................................3-14
Current......................................................................3-14
Historic......................................................................3-14
Retrieving DTCs...............................................................3-14
Multiple DTCs/Priority Order............................................3-15
3.10 INITIAL DIAGNOSTIC CHECK: TSM/HFSM
General.............................................................................3-16
Diagnostic Notes.......................................................3-16
Circuit Diagram/Wire Harness Connector Table........3-16
Job/Time Codes........................................................3-16
Reprogramming ECM................................................3-16
Initial Diagnostics.............................................................3-16
Diagnostic Tips..........................................................3-16
Diagnostic Notes.......................................................3-16
Other Diagnostic Trouble Codes (DTCs)...................3-17
3.11 SPEEDOMETER SELF DIAGNOSTICS
General.............................................................................3-22
Diagnostics.......................................................................3-22
Diagnostic Tips..........................................................3-22
Diagnostic Notes.......................................................3-22
3.12 BREAKOUT BOX:TSM/HFSM
General.............................................................................3-24
Installation........................................................................3-24
Removal...........................................................................3-24
3.13 FAILS TO DISARM (HFSM ONLY)
General.............................................................................3-26
Job/Time Codes...............................................................3-26
Diagnostics.......................................................................3-26
IV TABLE OF CONTENTS
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TABLE OF CONTENTS
Diagnostic Tips..........................................................3-26
Diagnostic Notes.......................................................3-26
3.14 DTC B0563
General.............................................................................3-29
Diagnostics.......................................................................3-29
Diagnostic Tips..........................................................3-29
Diagnostic Notes.......................................................3-29
3.15 TSM/HFSM:TURN SIGNAL ERRORS AND DTCS
General.............................................................................3-30
Diagnostics.......................................................................3-30
Job/Time Codes........................................................3-30
Diagnostic Tips..........................................................3-30
Diagnostic Notes.......................................................3-32
3.16 DTC B1131, B1132 (HFSM ONLY)
General.............................................................................3-46
Diagnostics.......................................................................3-46
Diagnostic Tips..........................................................3-46
Diagnostic Notes.......................................................3-46
3.17 DTC B1134
General.............................................................................3-49
Diagnostics.......................................................................3-49
Diagnostic Notes.......................................................3-49
3.18 DTC B1135
Diagnostics.......................................................................3-52
DTC B1135 Accelerometer Fault..............................3-52
3.19 DTC B1136, B1142 (HFSM ONLY)
Diagnostics.......................................................................3-53
DTC B1136 Accelerometer Tip-Over Self-Test
Fault..........................................................................3-53
DTC B1142 Internal Fault..........................................3-53
3.20 DTC B1141 (HFSM ONLY)
Diagnostics.......................................................................3-54
Diagnostic Tips..........................................................3-54
Diagnostic Notes.......................................................3-54
3.21 DTC B1143, B1144, B1145 (HFSM ONLY)
General.............................................................................3-57
Diagnostics.......................................................................3-57
Diagnostic Notes.......................................................3-57
3.22 DTC B1154, B1155
Diagnostics.......................................................................3-62
Diagnostic Tips..........................................................3-62
Diagnostic Notes.......................................................3-62
3.23 DTC U1016, U1255
General.............................................................................3-66
Diagnostics.......................................................................3-66
Diagnostic Notes.......................................................3-66
3.24 DTC U1300, U1301 OR BUS ER
Diagnostics.......................................................................3-69
Diagnostic Tips..........................................................3-69
Diagnostic Notes.......................................................3-69
3.25 TSM/HFSM: PASSWORD LEARN
General.............................................................................3-70
Password Learning...........................................................3-70
3.26 HFSM MAINTENANCE
General.............................................................................3-71
Hands-Free Fob................................................................3-71
Schedule...................................................................3-71
Battery Replacement.................................................3-71
Smart Siren (If Installed)...................................................3-71
Schedule...................................................................3-71
Battery Replacement: Early Style Siren....................3-71
Battery Replacement: Late Style Siren.....................3-71
ENGINE MANAGEMENT
4.1 SPECIFICATIONS
Specifications.....................................................................4-1
4.2 EFI SYSTEM
General...............................................................................4-2
Troubleshooting..................................................................4-2
4.3 EFI DIAGNOSTIC INTRODUCTION
System Problems...............................................................4-4
No Start.......................................................................4-4
Poor Performance.......................................................4-4
Check Engine Lamp....................................................4-4
Resolving Problems............................................................4-4
4.4 CHECKING FOR DIAGNOSTIC TROUBLE CODES: EFI
Check Engine Lamp...........................................................4-5
Code Types.........................................................................4-6
Current........................................................................4-6
Historic........................................................................4-6
Retrieving Diagnostic Trouble Codes..................................4-6
Multiple Diagnostic Trouble Codes.....................................4-6
4.5 INITIAL DIAGNOSTIC CHECK: EFI
General...............................................................................4-7
Diagnostic Notes.........................................................4-7
Circuit Diagram/Wire Harness Connector Table..........4-7
Reprogramming ECM..................................................4-7
Initial Diagnostics...............................................................4-7
General Information.....................................................4-7
Diagnostic Tips............................................................4-7
Diagnostic Notes.........................................................4-7
Other Diagnostic Trouble Codes (DTCs).....................4-7
4.6 SPEEDOMETER SELF DIAGNOSTICS
General.............................................................................4-15
Diagnostics.......................................................................4-15
Diagnostic Tips..........................................................4-15
Diagnostic Notes.......................................................4-15
TABLE OF CONTENTS V
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TABLE OF CONTENTS
4.7 BREAKOUT BOX: EFI
General.............................................................................4-17
Installation........................................................................4-17
Removal...........................................................................4-17
4.8 WIGGLE TEST
General.............................................................................4-18
Procedure.........................................................................4-18
4.9 INTAKE LEAK TEST
General.............................................................................4-19
Leak Tester.......................................................................4-19
Parts List...................................................................4-19
Tester Assembly........................................................4-19
Tester Adjustment......................................................4-19
Procedure.........................................................................4-19
4.10 ENGINE CRANKS, BUT WILL NOT START
General.............................................................................4-21
Diagnostics.......................................................................4-21
Diagnostic Notes.......................................................4-21
Diagnostic Tips..........................................................4-21
4.11 NO ECM POWER
General.............................................................................4-28
No Spark/No Check Engine Lamp at Key On............4-28
Diagnostics.......................................................................4-28
Diagnostic Notes.......................................................4-28
4.12 STARTS,THEN STALLS
General.............................................................................4-32
Diagnostic Trouble Codes U1300, U1301, or BUS
ER.............................................................................4-32
Diagnostics.......................................................................4-32
Diagnostic Tips..........................................................4-32
Diagnostic Notes.......................................................4-32
4.13 FUEL SYSTEM ELECTRICAL TEST
General.............................................................................4-36
Diagnostics.......................................................................4-36
Diagnostic Notes.......................................................4-36
4.14 SYSTEM RELAY CHECK
General.............................................................................4-43
System Relay............................................................4-43
Diagnostics.......................................................................4-43
Diagnostic Notes.......................................................4-43
4.15 FUEL PRESSURE TEST
General.............................................................................4-49
Testing..............................................................................4-49
Diagnostics.......................................................................4-50
Diagnostic Notes.......................................................4-50
4.16 IDLE AIR CONTROL
General.............................................................................4-53
IAC Operation............................................................4-53
Diagnostic Trouble Code P0505: Loss of Idle Speed
Control.......................................................................4-53
Diagnostics.......................................................................4-53
Diagnostic Tips..........................................................4-53
Diagnostic Notes.......................................................4-53
4.17 MISFIRE AT IDLE OR UNDER LOAD
General.............................................................................4-58
Misfire at Idle or Under Load.....................................4-58
Diagnostics.......................................................................4-58
Diagnostic Notes.......................................................4-58
4.18 DTC P0107, P0108, P0112, P0113
General.............................................................................4-64
MAP Signal...............................................................4-64
IAT Signal..................................................................4-64
Diagnostics.......................................................................4-64
Diagnostic Tips: MAP Sensor....................................4-64
Diagnostic Notes: MAP Sensor.................................4-64
Diagnostic Tips: IAT Sensor.......................................4-65
Diagnostic Notes: IAT Sensor....................................4-65
4.19 DTC P0117, P0118
General.............................................................................4-71
ET Sensor.................................................................4-71
Diagnostics.......................................................................4-71
Diagnostic Tips..........................................................4-71
Diagnostic Notes.......................................................4-71
4.20 DTC P0122, P0123
General.............................................................................4-75
Throttle Position (TP) Sensor....................................4-75
Diagnostics.......................................................................4-75
Diagnostic Tips..........................................................4-75
Diagnostic Notes.......................................................4-75
4.21 DTC P0131, P0132, P0134, P0151, P0152, P0154
General.............................................................................4-79
Oxygen Sensor.........................................................4-79
Diagnostics.......................................................................4-79
Diagnostic Tips..........................................................4-79
Diagnostic Notes.......................................................4-79
4.22 DTC P0261, P0262, P0263, P0264
General.............................................................................4-84
Fuel Injectors.............................................................4-84
Diagnostics.......................................................................4-84
Diagnostic Notes.......................................................4-84
4.23 DTC P0373, P0374
General.............................................................................4-90
CKP Sensor..............................................................4-90
Diagnostics.......................................................................4-90
Diagnostic Tips..........................................................4-90
Diagnostic Notes.......................................................4-90
4.24 DTC P0501, P0502
General.............................................................................4-93
Vehicle Speed Sensor (VSS)....................................4-93
Diagnostics.......................................................................4-93
Diagnostic Notes.......................................................4-93
VI TABLE OF CONTENTS
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TABLE OF CONTENTS
4.25 DTC P0562, P0563
General.............................................................................4-97
Battery Voltage..........................................................4-97
Diagnostics.......................................................................4-97
Diagnostic Tips..........................................................4-97
Diagnostic Notes.......................................................4-97
4.26 DTC P0603, P0605
General...........................................................................4-101
ECM Failure............................................................4-101
Diagnostics.....................................................................4-101
DTC P0603.............................................................4-101
DTC P0605.............................................................4-101
4.27 DTC P1009, P1010
General...........................................................................4-102
Password Problem..................................................4-102
Diagnostics.....................................................................4-102
Diagnostic Notes.....................................................4-102
4.28 DTC P1351, P1352, P1354, P1355
General...........................................................................4-105
Ignition Coil.............................................................4-105
Diagnostics.....................................................................4-105
Diagnostic Notes.....................................................4-105
4.29 DTC P1501, P1502
General...........................................................................4-110
Jiffy Stand Sensor (HDI)..........................................4-110
Diagnostics.....................................................................4-110
Diagnostic Notes.....................................................4-110
4.30 DTC U1064, U1255
General...........................................................................4-115
Loss of TSM/TSSM/HFSM Serial Data...................4-115
Diagnostics.....................................................................4-115
Diagnostic Notes.....................................................4-115
4.31 DTC U1097, U1255
General...........................................................................4-118
Loss of Speedometer Serial Data...........................4-118
Diagnostics.....................................................................4-118
Diagnostic Notes.....................................................4-118
APPENDIX A CONNECTOR REPAIR
A.1 AMP 1-PLACE CONNECTORS
AMP 1-Place Connector Repair.........................................A-1
General.......................................................................A-1
Separating Pin and Socket Housings.........................A-1
Mating Pin and Socket Housings................................A-1
Removing Socket Ter minals........................................A-1
Installing Socket Ter minal...........................................A-1
Removing Pin Terminal...............................................A-1
Installing Pin Terminal.................................................A-2
A.2 AMP MULTILOCK CONNECTORS
AMP Multilock Connector Repair.......................................A-3
General.......................................................................A-3
Separating Pin and Socket Housings.........................A-3
Mating Pin and Socket Housings................................A-3
Removing Terminals from Housing.............................A-3
Inserting Terminals into Housing.................................A-4
Preparing Wire Leads for Crimping.............................A-4
Crimping Terminals to Leads......................................A-6
Inspecting Crimped Terminals.....................................A-6
A.3 DELPHI CONNECTORS
Delphi Connector Repair....................................................A-8
General.......................................................................A-8
Separating Pin and Socket Housings.........................A-8
Mating Pin and Socket Housings................................A-8
Removing Socket Ter minals........................................A-8
Installing Socket Terminals..........................................A-8
A.4 DEUTSCH 1-PLACE ELECTRICAL CONNECTORS
Deutsch 1-Place Connector Repair..................................A-10
Separating Pin and Socket Housings.......................A-10
Mating Pin and Socket Housings..............................A-10
Removing Socket Ter minals......................................A-10
Installing Socket Terminals........................................A-10
A.5 DEUSCH ELECTRICAL CONNECTORS
Deutsch Connector Repair...............................................A-11
General.....................................................................A-11
Separating Pin and Socket Housings.......................A-11
Mating Pin and Socket Housings..............................A-11
Removing Socket Ter minals......................................A-11
Installing Socket Terminals........................................A-11
Removing Pin Terminals...........................................A-13
Installing Pin Terminals.............................................A-13
Crimping Terminals...................................................A-14
A.6 DEUTSCH STANDARD TERMINALS
Deutsch Standard Terminal Crimps.................................A-15
Preparing Wire Leads for Crimping...........................A-15
Crimping Terminal to Lead........................................A-15
Inspecting Crimps.....................................................A-15
A.7 DEUTSCH MINI-TERMINAL CRIMPS
Deutsch Mini Terminal Crimps.........................................A-16
Preparing Wire Leads for Crimping...........................A-16
Crimping a Mini Terminal to Wire Lead.....................A-16
Inspecting Crimps.....................................................A-16
A.8 DEUTSCH SOLID BARREL TERMINALS
Deutsch Solid Barrel Terminal Crimps.............................A-17
Preparing Wire Leads For Crimping.........................A-17
Adjusting Crimper Tool..............................................A-17
Crimping a Barrel Contact To Wire Lead...................A-17
Inspecting Crimps.....................................................A-17
A.9 RELAY AND FUSE BLOCKS
Fuse Block Repair............................................................A-19
Removing Socket Ter minals......................................A-19
Installing Socket Terminals........................................A-19
Crimping Terminals...................................................A-19
A.10 150 METRI-PACK CONNECTORS
150 Metri-Pack Connector Repair....................................A-20
TABLE OF CONTENTS VII
Page 9
TABLE OF CONTENTS
General.....................................................................A-20
Separating Pin and Socket Housings.......................A-20
Mating Pin and Socket Housings..............................A-20
Removing Socket Ter minal.......................................A-20
Inserting Socket Terminal..........................................A-20
A.11 280 METRI-PACK CONNECTORS
280 Metri-Pack Connector Repair....................................A-22
General.....................................................................A-22
Separating Pin and Socket Housings.......................A-22
Mating Pin and Socket Housings..............................A-22
Removing Socket Ter minals......................................A-22
Installing Socket Terminals........................................A-22
Crimping Terminals...................................................A-22
A.12 480 METRI-PACK CONNECTORS
480 Metri-Pack Connector Repair....................................A-24
General.....................................................................A-24
Separating Pin and Socket Housings.......................A-24
Mating Pin and Socket Housings..............................A-24
Removing Socket Ter minals......................................A-24
Installing Socket Terminals........................................A-24
A.13 630 METRI-PACK CONNECTORS
630 Metri-Pack Connector Repair....................................A-25
General.....................................................................A-25
Separating Pin and Socket Housings.......................A-25
Mating Pin and Socket Housings..............................A-25
Removing Socket Ter minal.......................................A-25
Installing Socket Ter minal.........................................A-25
A.14 800 METRI-PACK CONNECTORS
Delphi Maxi-Fuse Housing Repair...................................A-26
General.....................................................................A-26
Removing Maxi-Fuse................................................A-26
Installing Maxi-Fuse..................................................A-26
Removing Socket Ter minals......................................A-26
Installing Socket Terminals........................................A-26
A.15 METRI-PACK TERMINALS
Metri-Pack Ter minal Crimps.............................................A-28
Matching Terminal To Crimper..................................A-28
Preparing Wire Lead.................................................A-28
Crimping Wire Core..................................................A-28
Crimping Insulation/Seal...........................................A-28
Inspecting Crimps.....................................................A-29
A.16 MOLEX CONNECTORS
Molex Connector Repair..................................................A-30
Separating Pin and Socket Housings.......................A-30
Mating Pin and Socket Housings..............................A-30
Removing Terminals.................................................A-30
Installing Terminals...................................................A-30
A.17 PACKARD ECM CONNECTOR
Packard 100W Connector Repair.....................................A-32
General.....................................................................A-32
Separating Socket Housing From ECM....................A-32
Mating Socket Housing To ECM...............................A-32
Removing Socket Ter minal.......................................A-32
Installing Socket Ter minal.........................................A-32
Crimping Terminals...................................................A-32
A.18 PACKARD MICRO-64 CONNECTORS
Packard Micro-64 Connector Repair................................A-34
General.....................................................................A-34
Separating Pin and Socket Housings.......................A-34
Mating Pin and Socket Housings..............................A-34
Removing Terminal...................................................A-34
Installing Terminal.....................................................A-34
Preparing Wire Leads for Crimping...........................A-35
Crimping Terminals...................................................A-35
Inspecting Crimps.....................................................A-35
A.19 SEALED SPLICE CONNECTORS
Sealed Splice Connector Repair......................................A-37
General.....................................................................A-37
Preparing Wire Leads...............................................A-37
Splicing Wire Leads..................................................A-37
Inspecting Seals.......................................................A-37
APPENDIX B WIRING
B.1 CONNECTORS
Connector Locations..........................................................B-1
Function/Location.......................................................B-1
Place and Color..........................................................B-1
Connector Number......................................................B-1
Repair Instructions......................................................B-1
B.2 WIRING DIAGRAMS
Wiring Diagram Information...............................................B-3
Wire Color Codes........................................................B-3
Wiring Diagram Symbols............................................B-3
2008 Sportster Wiring Diagrams........................................B-4
APPENDIX C CONVERSIONS
C.1 METRIC CONVERSION
Conversion Table................................................................C-1
C.2 FLUID CONVERSIONS
United States System........................................................C-2
Metric System....................................................................C-2
British Imperial System......................................................C-2
C.3 TORQUE CONVERSIONS
United States System........................................................C-3
Metric System....................................................................C-3
APPENDIX D GLOSSARY
D.1 GLOSSARY
Acronyms and Abbreviations.............................................D-1
VIII TABLE OF CONTENTS
Page 10
TABLE OF CONTENTS
APPENDIX E TSM/TSSM (JAPAN/KOREA)
E.1 TSM/TSSM (JAPAN/KOREA) O VERVIEW
General..............................................................................E-1
TSM............................................................................E-1
TSSM..........................................................................E-1
Troubleshooting..................................................................E-1
E.2 TSM/TSSM FEATURES
General..............................................................................E-3
Turn Signal Functions........................................................E-3
TSSM/TSSM Features................................................E-3
Bank Angle Function..........................................................E-3
Clutch/Neutral Interlock Functions.....................................E-3
TSM/TSSM Features..................................................E-3
Security Alarm and Immobilization Functions....................E-3
TSSM Feature.............................................................E-3
E.3 VEHICLE DELIVERY
General..............................................................................E-5
Configuring A TSSM..........................................................E-5
Sidecar Configuration.........................................................E-5
Power Disruption and Configuring.....................................E-5
Key Fob Assignment:TSSM...............................................E-5
Pin Entry: TSSM.................................................................E-6
Changing the Pin:TSSM....................................................E-8
General.....................................................................E-14
Disarming the System...............................................E-14
E.8 DIAGNOSTIC TROUBLE CODES (DTC)
TSM/TSSM......................................................................E-16
Code Types......................................................................E-17
Current......................................................................E-17
Historic......................................................................E-17
Retrieving Diagnostic Trouble Codes...............................E-17
Multiple Diagnostic Trouble Codes...................................E-17
E.9 INITIAL DIAGNOSTIC CHECK: TSM/TSSM
General............................................................................E-19
Diagnostic Notes.......................................................E-19
Circuit Diagram/Wire Harness Connector Table.......E-19
Job/Time Code Values..............................................E-19
Reprogramming ECM...............................................E-19
Initial Diagnostics.............................................................E-19
Diagnostic Tips.........................................................E-19
Diagnostic Notes.......................................................E-19
Other Diagnostic Trouble Codes (DTCs)...................E-19
E.10 SPEEDOMETER SELF DIAGNOSTICS
General............................................................................E-24
Diagnostics......................................................................E-24
Diagnostic Tips.........................................................E-24
Diagnostic Notes.......................................................E-24
E.4 TURN SIGNAL FUNCTIONS
General..............................................................................E-9
Automatic Cancellation......................................................E-9
Manual Cancellation...........................................................E-9
Four-Way Flashing.............................................................E-9
Diagnostics Mode..............................................................E-9
E.5 BANK ANGLE FUNCTION
General............................................................................E-10
Operation.........................................................................E-10
E.6 SECURITY SYSTEM FUNCTIONS (TSSM ONLY)
General............................................................................E-11
Security System Operation.......................................E-11
Security System Options: TSSM...............................E-11
Alarm Sensitivity: TSSM...................................................E-11
Sensitivity..................................................................E-11
Transport Mode.........................................................E-12
Auto-Arming Function:TSSM...........................................E-12
Storage Mode: TSSM.......................................................E-13
E.7 ARMING/DISARMING (TSSM ONLY)
General............................................................................E-14
Security Lamp..................................................................E-14
Using Key FOB:TSSM.....................................................E-14
General.....................................................................E-14
Arming the System...................................................E-14
Disarming the System...............................................E-14
Troubleshooting.........................................................E-14
Using the Pin....................................................................E-14
E.11 BREAKOUT BOX:TSM/TSSM
General............................................................................E-26
Installation........................................................................E-26
Removal...........................................................................E-26
E.12 FAILS TO DISARM (TSSM ONLY)
General............................................................................E-28
Security Equipped Vehicles Only..............................E-28
Job/Time Code Values..............................................E-28
Diagnostics......................................................................E-28
Diagnostic Tips.........................................................E-28
Diagnostic Notes.......................................................E-28
E.13 TURN SIGNAL ERRORS: B1121, B1122, B1141
General............................................................................E-31
Job/Time Code Values..............................................E-31
Diagnostics......................................................................E-31
Diagnostic Tips: All....................................................E-31
Diagnostic Notes: All Tur n Signal Flow Charts..........E-33
E.14 DTC B0563
General............................................................................E-43
Battery Voltage High.................................................E-43
Diagnostics......................................................................E-43
Diagnostic Tips.........................................................E-43
Diagnostic Notes.......................................................E-43
E.15 DTC B1131, B1132
General............................................................................E-44
TABLE OF CONTENTS IX
Page 11
TABLE OF CONTENTS
Alarm Output Low (DTC B1131) or Alarm Output High
(DTC B1132).............................................................E-44
Diagnostics......................................................................E-44
Diagnostic Tips.........................................................E-44
Diagnostic Notes.......................................................E-44
E.16 DTC B1134
General............................................................................E-47
Starter Output High...................................................E-47
Diagnostics......................................................................E-47
Diagnostic Notes.......................................................E-47
E.17 DTC B1135
General............................................................................E-50
Accelerometer Fault: B1135......................................E-50
E.18 DTC B1154, B1155
General............................................................................E-51
Diagnostic Notes..............................................................E-51
E.19 DTC U1016, U1255
General............................................................................E-55
Loss of ECM Serial Data..........................................E-55
Diagnostics......................................................................E-55
Diagnostic Notes.......................................................E-55
E.20 DTC U1300, U1301 OR BUS ER
General............................................................................E-58
Serial Data Low or Serial Data Open/High...............E-58
Diagnostics......................................................................E-58
Diagnostic Tips.........................................................E-58
Diagnostic Notes.......................................................E-58
E.21 TSM/TSSM: PASSWORD LEARN
General............................................................................E-59
Password Learning..........................................................E-59
E.22 TSSM MAINTENANCE
General............................................................................E-60
Key FOB...........................................................................E-60
Schedule...................................................................E-60
Battery Replacement................................................E-60
Siren (If Installed).............................................................E-60
Schedule...................................................................E-60
Battery Replacement: Early Style Siren....................E-60
Battery Replacement: Late Style Siren.....................E-61
REFERENCE MATERIAL
TOOLS...........................................................I
TORQUE VALUES........................................V
INDEX.........................................................VII
X TABLE OF CONTENTS
Page 12
SUBJECT............................................................................................................................PAGE NO.
1.1 STARTER TROUBLESHOOTING..............................................................................................1-1
1.2 STARTING SYSTEM DIAGNOSIS............................................................................................1-3
1.3 STARTER ACTIVATION CIRCUITS.........................................................................................1-12
1.4 DIAGNOSTICS/TROUBLESHOOTING...................................................................................1-13
1.5 TESTING STARTER ON MOTORCYCLE...............................................................................1-14
1.6 TESTING STARTER ON BENCH............................................................................................1-16
1.7 CHARGING SYSTEM.............................................................................................................1-18
1.8 BATTERY TESTING................................................................................................................1-26

STARTING / CHARGING

Page 13
NOTES
Page 14

1.1STARTER TROUBLESHOOTING

GENERAL

The troubleshooting tables contain detailed procedures to solve and correct problems. Follow 1.2 STARTING SYSTEM DIA-
GNOSIS to diagnose starting system problems.The 1.4 DIA-
Table 1-1. Starter Does Not Run or Runs at Very Low Speeds
PROBLEM
Wiring
negative cable, at either end.
or start relay, especially relay ground wire (grounds through TSM/TSSM/HFSM).
stop switch, clutch switch or neutral switch
Brushes worn below specification.Starting motor
windings.
Incorrect oil for low temperature.Temperature
GNOSTICS/TROUBLESHOOTING, Voltage Drop procedure
will help you to locate poor connections or components with excessive voltage drops.

STARTER TROUBLESHOOTING

SOLUTIONPROBABLE CAUSESOURCE OF
Charge battery.Voltage drop due to discharged battery.Battery Replace battery.Short-circuited or open between electrodes. Clean and retighten.Poor contact condition of battery terminal(s). Repair or replace cable(s).Poor or no connection at either battery positive or
Clean, tighten or replace cable(s) as needed.Cracked or corroded battery cable ends. Tighten connections or repair or replace wire(s).Open wire(s) or poor connection at handlebar switch
Replace switch.Poor switch contacts or open switch.Start switch, engine
Replace relay.Open coil winding.Start relay Replace relay.Poor or no continuity at relay points. Disarm security system.TSM/TSSM/HFSM has disabled start relay. Polish contact surf ace or replace solenoid assemblyPoor contact condition caused by burnt contact.Solenoid Repair or replace solenoid assembly.Pull-in winding open or short-circuited. Repair or replace solenoid assembly.Hold-in winding open or short-circuited. Check brush spring tension. Replace field frame
and holder. Re-face or replace.Commutator burnt. Correct by undercutting.Commutator high mica. Replace starter.Field winding grounded. Replace starter.Armature winding grounded or short-circuited. Replace starter.Free running current draw out of range. Replace starter.Reduction gears damaged. Replace starter.Insufficient brush spring tension. Repair or replace lead wire.Disconnected lead wire between solenoid and field
Replace bearing.Ball bearing sticks. Use recommended viscosity oil for temperature
range. Consult Owner's Manual.
2008 Sportster Diagnostics: Starting / Charging 1-1
Page 15
Table 1-2. Pinion Does Not Engage With Ring Gear While Starter is Cranked or Engine Cannot Be Cranked
SOLUTIONPROBABLE CAUSESOURCE OF PROBLEM
Charge battery.Voltage drop due to discharged battery.Battery Replace battery.Short-circuited or open between electrodes. Clean and retighten.Poor contact condition of battery terminal(s).
Overrunning clutch
compression spring).
Poor sliding condition of spline teeth.
Table 1-3. Starter Does Not Stop Running
Replace overrunning clutch.Overrunning clutch malfunction (rollers or
Replace pinion.Pinion teeth worn out. Replace overrunning clutch.Pinion does not run in overrunning direction. Remove foreign materials, dirt or replace
overrunning clutch or pinion shaft. Replace overrunning clutch and idler gear.Reduction gears damaged. Replace clutch shell.Excessively worn teeth.Gear teeth on clutch shell
SOLUTIONPROBABLE CAUSESOURCE OF PROBLEM
Replace start switch or start relay.Unopened contacts.Start switch or start relay Replace start switch or start relay.Poor return caused by sticky switch or relay contacts. Replace clutch shell.Excessively worn teeth.Gear teeth on clutch shell Replace spring.Return spring worn.Solenoid Replace solenoid.Coil layer shorted. Replace solenoid.Contact plate melted and stuck.
1-2 2008 Sportster Diagnostics: Starting / Charging
Page 16

1.2STARTING SYSTEM DIAGNOSIS

1
3
2
ed02787

DIAGNOSTICS

TOOL NAMEPART NUMBER
HARNESS CONNECTOR TEST KITHD-41404-B BREAKOUT BOXHD-42682
Diagnostic Notes
Each reference number below correlates to a circled number on the flow chart(s).
1. See 1.4 DIAGNOSTICS/TROUBLESHOOTING, Voltage
Drop.
2. Remove starter motor. Connect jumper wires as described
in 1.6 TESTING STARTER ON BENCH, Free Running
Current Draw Test.
3. Connect BREAKOUT BOX (Part No. HD-42682) to TSM/
TSSM/HFSM as follows:
a. On models with a TSM/HFSM, see 3.12 BREAK OUT
BOX:TSM/HFSM.
b. On models with a TSSM (Japan/Korea), see
E.11 BREAKOUT BOX:TSM/TSSM.
4. Use HARNESS CONNECTOR TEST KIT (Part No. HD-
41404-B) gray terminal socket probe and patch cord.
5. See 1.5 TESTING STARTER ON MOT ORCYCLE, Starter
Current Draw Test.
6. If the neutral switch or ground is open, a reading of se veral hundred ohms is normal due to the neutral indicator lamp (LED).
7. Closely inspect handlebar controls for pinched wiring.
Job/Time Code Values
Dealership technicians filing warranty claims should use the job/time code values printed in bold text underneath the appropriate repair.
1. Motor terminal
2. Battery terminal
3. Relay terminal Figure 1-1. Starter Terminals
2008 Sportster Diagnostics: Starting / Charging 1-3
Page 17
GY
GY
GY
GN
GN
BK
BK
BK
BK
BK
TN
TN
R
R
R
R
R
BN/GY BN/GY
TN/GN TN/GN
BK/R
BK/R
BK
BK/R
BK/R
BK
BK/R
BK/R
GY
BK/R
W/BK
W/BK
W/BK
W/BK
W/BK
W/BK
R/BK
R/BK
R/BK
Wire Color Code Key
BK- Black BN - Brown
R - Red O - Orange
Y - Yellow
GN - Green BE - Blue
V - Violet
GY - Gray
W - White
LGN - Light Green
PK - Pink TN - Tan
Wire color-XX/XX-Stripe color
GND 1
Battery Ignition
Neutral switch
Start relay control
Ground
Engine Stop Switch Start Switch
Front Stop Lamp Switch
Right Turn Switch
[22B]
[22A]
1
1
2
9
12
TSM/TSSM/HFSM
Neutral Switch
[30A]
Right Hand Controls
3
787
8
6
3446
4
Clutch switch 10
1 2
9
12
4
10
[30B]
[24A][24B]
[136A] [136B]
[78A]
To system relay
ECM
[78B]
1 2 3
HFSM ONLY
[208A]
Starter
Ignition - 15A
Battery - 15A
30 Amp
MAXIFUSE
[5B]
IGN
Switch
[33]
[61B]
B A
J
BA
I
Powertrain
Ground
Point
Battery
B
I
[119B]
SWITCH POSITION
RED/BLACK RED RED/GRAY
OFF ACC IGNITION
Ignition Switch Legend
Dot indicates continuity with red wire in switch position indicated
Socket Connector
Pin Connector
(A side)
(B side)
E
K
T
S
U
STARTRELAY SYSTEMRELAY
I
C
Q
P
R
M
O
G
H
A
B
FUEL PUMP
SPARE
ECM
15A
15A
15A
P
R
I
J
C
D
BATTERY
LIGHTS
ACCESSORIES
15A
15A
15A
M
O
G
H
A
B
INSTRUMENTS
SPARE
IGNITION
15A
15A
15A
K
L
F
SPARE
OPEN
P&A IGN
15A
15A
Top View
E
[119]
[61]
1
Start Relay
Receive antenna Transmit antenna A Transmit antenna B
87
87A
30 85
86
I C
P R
5 3
2 1
Switch power 13 13
Left Hand Controls
Clutch Switch
em01118
1-4 2008 Sportster Diagnostics: Starting / Charging
Figure 1-2. Starting Circuit Schematic
Page 18
Starter Testing 1
Check battery using visual inspection, voltage test, and either conductance test or load test.
Check connections at battery and starter
components. Is system operational?
YES
Starter
runs on.
YES YES
NO
Starter spins, but
does not
engage.
Starter stalls
or spins too
slowly.
Check for audible
clicking noise
Disconnect solenoid relay
terminal from solenoid.
Is 12V present on (GN) wire
with starter button not
pressed?
See Starter
Testing 5: Starter
Spins But Does
Not Engage.
See Starter
Testing 6: Starter
Stalls or Spins Too
Slowly.
Solenoid clicks.
See Starter
Testing 2:
Solenoid Clicks.
YES NO
Is 12V present on start relay terminal 86(1) with starter
button not pressed?
Replace solenoid.
YES NO
Replace
start relay.
OR
Relay clicks. See Starter Testing 3:
Relay Clicks
OR
Nothing clicks. See Starter
Testing 4: Nothing Clicks
(Part 1 of 2).
5818 5832
5845
5822
fc01000_en
Replace
starter button
2008 Sportster Diagnostics: Starting / Charging 1-5
Page 19
Starter Testing 2: Solenoid Clicks
Perform voltage drop tests between battery
and relay terminal on solenoid. Is voltage
drop less than 1.0 volt?
YES NO
Backtrack to pinpoint poor
connections or relay contact
problems using voltagedrop tests.
Perform voltage drop tests from
battery positive to starter motor
terminal. Crank engine.
Is voltage drop greater than 1.0 volt?
YES
Perform voltage drop tests from battery positive to starter battery
terminal. Crank engine.
Is voltage drop greater than 1.0 volt?
YES
Repair connection
between battery and
starter.
NO
Perform voltage drop tests
between battery negative and
starter ground studs or bolts.
Is voltage drop greater than 1.0 volt?
NO
Repair or replace
solenoid (contacts).
YES
Clean ground
connections.
STOP
NO
5824
5845 5824
5823
1
1 1
1
Go to Starter Testing 3: Relay Clicks. Begin with box marked with bold asterisk.
fc01001_en
1
1-6 2008 Sportster Diagnostics: Starting / Charging
Page 20
Starter Testing 3: Relay Clicks
Test for voltage at solenoid
relay terminal (GN) on starter.
Is 12V present when starter
button is pressed?
YES NO
Does starter motor
turn if jumped?
YES
Replace
solenoid.
NO
Replace or repair
starter motor.
Test for voltage to relay.
Is 12V present on relay terminal
30(3)?
YES NO
Test for voltage to relay.
Is 12V present on relay
terminal 87(5)?
Repair open on (R/BK)
wire feeding terminal
30(3) on start relay.
YES
Repair open on (GN) wire between relay and solenoid.
NO
Replace
start relay.
5827
5832
5827
5860
5817
2
fc01002_en
2008 Sportster Diagnostics: Starting / Charging 1-7
Page 21
Starter Testing 4: Nothing Clicks (Part 1 of 2)
Do turn signals work properly?
YES
With the Engine Stop Switch in
the RUN position. Turn the Ignition Switch on. With the
starter buttondepressed, check
for battery voltage from starter
button to relayterminal 86.
Battery voltage present?
NO
Is connector [30] fully mated?
YES NO
Continuity to ground on TSM/
TSSM/HFSM terminal 12?
Mate connector [30].
YES
Continuity on terminal 1to
battery fuse?
Repair open.
NO
YES
Continuity on terminal 2to
ignition fuse?
NO
Repair open.
YES
Continuity on terminal 2to
ignition fuse?
NO
Repair open.
6792
6805
6806
6793
6791
3
YES
Check for ground at relay
terminal 85. Ground present?
YES
Substitute good
relay or test relay.
NO
Check for continuity from relay terminal 85
to terminal 9on TSM/TSSM/HFSM
connector [30]. Continuity present?
NO
Repair open.
YES
STOP
Go to Starter Testing 4: Nothing Clicks (Part 2 of 2).
5828
NO
Disconnect connector [22]. Check for continuity between
terminal 4(W/BK) and terminal 6(BK/R)
of connector [22A].
Continuity present with starter button pressed?
4
NO
Check for battery voltage to
starter button,at connector [22B]
terminal 3(GY).
Battery voltage present?
YES
NOYES
Locate and repair open in (GY) wire
connector [22B].
Locate and repair
open in (BK/R) wire
from connector
[22B] to relay.
5831
5831
Replace
starter button.
5818
7
fc01003_en
1-8 2008 Sportster Diagnostics: Starting / Charging
Page 22
Starter Testing 4: Nothing Clicks (Part 2 of 2)
Continued from
Starter Testing 4: Nothing Clicks (Part 1 of 2).
Vehiclein neutral. Install breakout box
HD-42682. Measure continuity to ground
on terminal 4(Gray) (neutral switch).
Is continuity (less than 10 ohms) present?
YES
Clutch Disengaged (pulled in). Measure continuity to
ground on terminal 10(Gray)(clutch switch) with clutch disengaged. Is continuity present?
NO
Measure continuity to ground at black female terminal at neutral
switch. Is continuity present?
YES
Replace neutral switch.
NO
Locate and repair open on black wire between neutral
switch and ground.
YES
Check for voltage on TSM/
TSSM/HSFM terminal 9(Gray)
with key ON. Voltagepresent?
YES
Locate and repair
short to voltage.
NO
Replace TSM/TSSM/
HFSM. See Service
Manual.
NO
Measure continuity to ground on
terminal 8on connector [24B].
Is continuity present?
YES
Replace clutch switch.
NO
Locate and repair open
on black wire between
clutch switch and
ground.
5157
5862
5830
5838
5168
5861
6
fc01004_en
2008 Sportster Diagnostics: Starting / Charging 1-9
Page 23
Starter Testing 5: Starter Spins But Does Not Engage
Remove starter. Disassemble drive
housing assembly. Inspect for damage
to armature gear or idler gear.
Is damage present?
YES
Replace damaged idler
gear and armature.
NO
Starter clutch failure.
Replace starter clutch.
5825
5837
fc01005_en
1-10 2008 Sportster Diagnostics: Starting / Charging
Page 24
Starter Testing 6: Starter Stalls or Spins Too Slowly
Perform voltage drop tests from battery
positive to starter motor terminal. Crank engine.
Is voltage drop greater than 1.0 volt?
YES NO
Perform voltage drop tests between battery
positive to starter battery terminal. Crank engine.
Is voltage drop greater than 1.0 volt?
Perform voltage drop tests between battery
negative and starter studs or bolts.
Is voltage drop greater than 1.0 volt?
1 1
YES
Repair connection
between battery
and starter.
NO
Repair or replace
solenoid
(contacts).
5824
5845
NOYES
Clean ground
connections.
Perform starter motor current
draw test (on vehicle).
Perform starter motor free
running current draw bench test.
Are test results within range?
5
2
YES NO
Remove spark plugs. While in
5th gear, rotate rear wheel.
Check for engine, primary
and/or crankshaft bind.
Replace or repair
starter motor.
5817
5835
1
Use appropriate code
fc01006_en
2008 Sportster Diagnostics: Starting / Charging 1-11
Page 25

STARTER ACTIVATION CIRCUITS

200A
20A
20A
0.1A
200A
0.1A
200A
20A
20A
0.1A
200A
0.1A
200A
20A
20A
0.1A
200A
0.1A
200A
20A 20A
0.1A
200A
0.1A
ITEM A
ITEM C
OPEN CIRCUIT
ITEM D
GROUND CIRCUIT
ITEM B
IDEAL CLOSED CIRCUIT
VDC
OV
VDC
VDC
VOV21
4
3
5
6
7
8
1
2
1
2
3
4
8
7
6
5
1
3
4
2
3
4
5
6
7
2
1
8
7
6
5
ed02788

1.3STARTER ACTIVATION CIRCUITS

1. Start switch
2. Relay
3. Solenoid
4. Starter
5. Battery
6. MAXIFUSE
7. Ignition switch
8. Ignition fuse Figure 1-3.Typical Circuitry. Refer to wiring diagrams for more information.
1-12 2008 Sportster Diagnostics: Starting / Charging
Page 26

1.4DIAGNOSTICS/TROUBLESHOOTING

VOLTAGE DROP

Check the integrity of all wiring, switches, fuses and connectors between the source and destination.
The voltage drop test measures the difference in potential or the actual voltage dropped between the source and destination.
1. See ITEM A in Figure 1-3. Attach your red meter lead to the most positive part of the circuit, which in this case would be the positive post of the battery (5).
2. See ITEM B in Figure 1-3. Attach the black meter lead to the final destination or component in the circuit (solenoid terminal from relay).
3. Activate the starter and observe the meter reading. The meter will read the voltage dropped or the difference in potential between the source and destination. An ideal circuit's voltage drop would be 0 volt or no voltage dropped, meaning no difference in potential.
4. See ITEM C in Figure 1-3. An open circuit should read 12 volts, displaying all the voltage dropped, and the entire difference in potential displayed on the meter.
NOTE
Open circuits on the ground side will read zero.
5. Typically, a good circuit will drop less than 1.0 volt. If the voltage drop is greater , back track through the connections
until the source of the potential difference is found.The benefits of doing it this way are speed and accuracy.
a. Readings are not as sensitive to real battery voltage. b. Readings show the actual voltage dropped, not just
the presence of voltage.
c. This tests the system as it is actually being used. It
is more accurate and will display hard to find poor connections.
d. This approach can be used on lighting circuits, ignition
circuits, etc. Start from most positive and go to most negative (the destination or component).
6. See ITEM D in Figure 1-3.The negative or ground circuit can be checked as well.
a. Place the negative lead on the most negative part of
the circuit (or the negative battery post). Remember, there is nothing more negative than the negative post of the battery.
b. Place the positive lead to the ground you wish to
check.
c. Activate the circuit. This will allow you to read the
potential difference or voltage dropped on the neg­ative or ground circuit.This technique is very effective for identifying poor grounds due to powdered paint. Even the slightest connection may cause an ohm­meter to give a good reading. However, when suffi­cient current is passed through, the resistance caused by the powdered paint will cause a voltage drop or potential difference in the ground circuit.
2008 Sportster Diagnostics: Starting / Charging 1-13
Page 27

START RELAY TEST

1
3
4
2
ed02790
1
4
2 5 3
3
1
2
ed02791
1. Open left side cover.
2. See Figure 1-4. Locate start relay (1) in relay/fuse block (2) forward of battery (3) on motorcycle's left side.
3. If replacing old start relay: a. To unplug old relay, grasp body of relay and with a
gentle rocking motion, pull straight out from relay/ fuse block.
b. To plug in new rela y, line up spade terminals of relay
with sockets in relay/fuse block and push relay firmly into sockets.
4. The start relay can be tested using the motorcycle's 12 volt battery and a multimeter.
a. See Figure 1-4. Unplug start relay (1) from rela y/ fuse
block (2).
b. See Figure 1-5. To energize the relay, connect the
negative battery terminal to the relay terminal "85" or "2" and relay terminal "86" or "1" to the positive battery terminal.
c. Check for continuity between relay terminals "3" and
"5". A good relay shows continuity (continuity tester lamp "on" or a zero ohm reading on the ohmmeter). A malfunctioning relay will not show continuity and must be replaced.
5. If start relay is functioning properly , plug it into relay/ fuse block and proceed to 1.5 TESTING STARTER ON
MOTORCYCLE, Starter Current Draw Test.

1.5TESTING STARTER ON MOTORCYCLE

1. Ohmmeter
2. Battery
3. Start relay Figure 1-5. Start Relay Test

STARTER CURRENT DRAW TEST

NOTES
Engine temperature should be stable and at room temper­ature.
Battery should be fully charged.
See Figure 1-6. Check starter current draw with an induction ammeter before disconnecting battery. Proceed as follows:
1. Verify that transmission is in neutral. Disconnect spark plug wires from spark plug terminals.
2. Clamp induction ammeter over positive battery cable ne xt to starter.
3. With Ignition Switch ON, turn engine over by pressing starter switch while reading the ammeter. Disregard initial high current reading which is normal when engine is first turned over.
a. Typical starter current draw will range from 160 to
200 amperes.
b. If starter current draw exceeds 250 amperes, the
problem may be in the starter or starter drive. Remov e starter for further tests. See the Service Manual.
1. Start relay
2. Relay/fuse blocks
3. Battery
4. MAXIFUSE Figure 1-4. Start Relay
1-14 2008 Sportster Diagnostics: Starting / Charging
NOTE
A DC current probe may be used if an induction ammeter is not available.
Page 28
1
2
ed02792
1. Induction ammeter
2. Battery Figure 1-6. Starter Current Draw Test
2008 Sportster Diagnostics: Starting / Charging 1-15
Page 29

FREE RUNNING CURRENT DRAW TEST

1
3
4
2
ed02793
2
3
4
5
1
ed02794
1. Place starter in vise, using a clean shop towel to prevent scratches or other damage.
2. See Figure 1-8. Attach one heavy jumper cable (6 gauge minimum).
a. Connect one end to the starter mounting flange (1). b. Connect the other end to the negative (-) terminal of
a fully charged battery (2).
3. Connect a second heavy jumper cable (6 gauge minimum). a. Connect one end to the positive (+) terminal of the
battery (2).
b. Connect the other end to the battery terminal (4) on
the starter solenoid. Place an induction ammeter (3) over cable.
4. Connect a smaller jumper cable (14 gauge minimum). a. Connect one end to the positive (+) terminal of the
battery (2).
b. Connect the other end to the solenoid relay terminal
(5).

1.6TESTING STARTER ON BENCH

1. Mounting flange
2. Battery
3. Induction ammeter
4. Battery terminal
5. Relay terminal Figure 1-8. Free Running Current Draw Test
5. Check ammeter reading. a. Ammeter should show 90 amps maximum.
b. If reading is higher, disassemble starter for inspection.
See the Service Manual.
c. If starter current draw on vehicle was over 200 amps
and this test was within specification, there may be a problem with engine, primary drive or jackshaft.
1. Starter motor
2. Nut with washer (metric)
3. Positive battery cable ring terminal
4. Solenoid wire connector [128] Figure 1-7. Starter Wires

STARTER SOLENOID

Do not disassemble solenoid. Before testing, disconnect field wire from motor terminal as shown in Figure 1-9.
Each test should be performed for only 3-5 seconds to prev ent damage to solenoid.
The solenoid Pull-in, Hold-in, and Return tests must be per­formed together in one continuous operation. Conduct all three tests one after the other in the sequence given without interrup­tion.

SOLENOID PULL-IN TEST

1. See Figure 1-9. Using a 12 volt battery, connect three separate test leads as follows:
a. Solenoid housing to negative battery post. b. Solenoid motor terminal to negative battery post. c. Solenoid relay terminal to positive battery post.
2. Observe starter shaft. a. If starter shaft extends strongly, solenoid is working
properly.
b. If starter shaft does not extend strongly, replace the
solenoid.
1-16 2008 Sportster Diagnostics: Starting / Charging
Page 30
2
3
1
ed02795
1. Motor terminal
2
3
1
ed02796
2
1
3
ed02797
2. Relay terminal
3. Battery Figure 1-9. Pull-In Test
1. Motor terminal
2. Relay terminal
3. Battery Figure 1-10. Hold-In Test

SOLENOID HOLD-IN TEST

1. See Figure 1-10. With test leads still connected in the manner specified in the previous 1.6 TESTING STARTER
ON BENCH, Solenoid Pull-In Test, disconnect solenoid
motor terminal/battery negative test lead at negative bat­tery post only; reconnect loose end of this test lead to positive battery post instead.
2. Observe starter shaft. a. If starter shaft remains extended, solenoid is working
properly.
b. If starter shaft retracts, replace the solenoid.

SOLENOID RETURN TEST

1. See Figure 1-11. With test leads still connected in the manner specified at the end of the previous 1.6 TESTING
ST AR TER ON BENCH, Solenoid Hold-In Test, disconnect
solenoid relay terminal/positive battery post test lead at either end.
2. Observe starter pinion. a. If starter shaft retracts, solenoid is working properly.
b. If starter shaft does not retract, replace the solenoid.
1. Motor terminal
2. Relay terminal
3. Battery Figure 1-11. Return Test
2008 Sportster Diagnostics: Starting / Charging 1-17
Page 31

1.7CHARGING SYSTEM

1
2
ed02798
ed02799

GENERAL

The charging system consists of the alternator and regulator. The charging system circuit is shown in Figure 1-14.
Alternator
The alternator consists of two main components:
The rotor which mounts to the engine sprocket shaft.
The stator which bolts to the engine crankcase.
Voltage Regulator
See Figure 1-12.The voltage regulator (1) is a series regulator with shunt control.The circuit combines the functions of recti­fying and regulating.
Battery
Check for a weak or dead battery . See 1.8 BATTERY TESTING for battery testing procedures. Battery must be fully charged in order to perform a load test, or starting or charging tests. However, a partially discharged battery may be tested using the BATTERY TEST function of the ELECTRICAL SYSTEM TESTER (Part No. HD-48053).
Wiring
See Figure 1-13.The stator connector plug and socket connec­tion must be clean and tight.
Check for corroded or loose connections in the charging circuit. See Figure 1-14.
1. Voltage regulator
2. DC output connector [77] Figure 1-12.Voltage Regulator

TROUBLESHOOTING

TOOL NAMEPART NUMBER
ELECTRICAL SYSTEM TESTERHD-48053
When the charging system fails to charge or does not charge at a satisfactory rate, make the f ollowing recommended checks.
Figure 1-13. Stator Connector [46]
1-18 2008 Sportster Diagnostics: Starting / Charging
Page 32
BK
BK
BK
BK
BK
BK
BK
BK
BK
R
R
R
30 Amp
MAXIFUSE
Powertrain
Ground
Point
[77A]
[77B]
Stator
Voltage
Regulator
Battery
[46B] [46A]
[GND1]
+
+
1 2
1 2
B A
Socket Connector
Pin Connector
(A side)
(B side)
[5]
em01119
Figure 1-14. Charging System Circuit
2008 Sportster Diagnostics: Starting / Charging 1-19
Page 33
Charging System (Part 1 of 2)
Test battery.
Charge or replace as required.
Inspect regulator.
See REGULATORINSPECTION.
PASS FAIL
Perform MILLIAMP DRAW
TEST (If applicable).
Correct as
required.
5306
PASS
Perform TOTAL CURRENT
DRAW TEST.
Record measurement.
FAIL
Isolate damaged
component or wiring.
5308
PASS
FAIL
Isolate damaged wiring or
excessive accessories.
5310
STOP
Go to Charging
System (Part 2 of 2).
NOTE
Whenever a charging system component failsa test and is replaced, re-test the system to be sure the problem has been corrected.
fc01060_en
1-20 2008 Sportster Diagnostics: Starting / Charging
Page 34
Charging System (Part 2 of 2)
Continued From
Charging System (Part 1 of 2).
Perform CURRENT OUTPUT TEST. Record
measurement and compare with TOTAL
CURRENT
DRAW TEST before proceeding.
PASS FAIL
Perform
VOLTAGE
OUTPUT TEST.
Perform
STATOR CHECK.
PASS FAIL
Replace
voltage regulator.
System tests good up to this point.
Suspect:
Accessories on for long periods when vehicle is parked and not running.
Accessories on when vehicle is ridden very slowly for long periods.
Battery self-discharge and/or accessory draw because vehicle was not operated for a long period.
5316
PASS FAIL
Perform AC
OUTPUT TEST.
Replace
stator.
5312
PASS
Replace voltage
regulator.
Perform CURRENT
OUTPUT TEST.
Inspect rotor.
FAIL
FAILPASS
Damaged or
slipping rotor.
System
OK.
5315
NOTE Whenever a charging system component failsa test and is replaced, re-test the system to be sure the problem has been corrected.
5319
FAILPASS
Replace
stator.
Replace
rotor.
5314 5319
fc01061_en
2008 Sportster Diagnostics: Starting / Charging 1-21
Page 35
1
2
3
ed02801

TESTING

TOOL NAMEPART NUMBER
HD-48053
ADVANCED BATTERY CONDUCT­ANCE AND ELECTRICAL SYSTEM ANALYZER
Milliampere Draw Test
NOTES
Be sure accessories are not wired so they stay on at all times. This condition could drain battery completely if vehicle is parked for a long time. Check for this by con­necting ammeter between negative battery cable and ground.
TSM/TSSM/HFSM will continue to draw 16-25 mA for 30 seconds after ignition is turned off. Any disruption and reconnection of battery power, such as disconnecting the battery to place a meter in series, will cause TSM/TSSM/ HFSM to draw 16-25 mA for 30 seconds.
1. See Figure 1-15. Connect ammeter between negative battery cable and crankcase ground. With this arrange­ment, you will also pick up any regulator drain.
2. With ignition switch turned to OFF and all lights and accessories off, observe current reading.
a. Refer to Table 1-4. Add voltage regulator draw to
appropriate value for TSM/TSSM/HFSM. If sum is greater than reading observed on ammeter, draw is within limits.
b. A higher reading indicates excessive current draw.
Any accessories must be considered and checked for excessive drain.
NOTE
A battery with a surface discharge condition could suffer a static drain. Correct by cleaning battery case.
Table 1-4. Maximum Meter Reading (Averaged)
DRAW IN MILLIAMPERESITEM
1Voltage regulator 1Speedometer 1Tachometer (if equipped) 1TSM (non-security models) 3TSSM (disarmed) 3TSSM (armed) 1TSSM (storage mode) 1HFSM
20.0*Security siren
* Siren will draw for 2-24 hours from time motorcycle battery is connected and 0.05 milliamperes once siren battery is charged. F or best results , disconnect siren during milliampere draw test.
1. 12 VDC battery
2. Battery negative cable
3. Crankcase
Figure 1-15. Milliampere Draw Test (Ignition turned to OFF)
Total Current Draw Test
If battery runs down during use, the current draw of the motorcycle components and accessories may exceed output of the charging system.
NOTE
If a load tester is unavailable, an ammeter with current probe may be used.
Turn battery load tester OFF before connecting tester cables to battery terminals. Connecting tester cables with load tester ON can cause a spark and battery explosion, which could result in death or serious injury. (00252a)
1. See Figure 1-16. To check for this condition, place load tester induction pickup or current probe pickup ov er battery negative cable.
2. Disconnect stator plug from voltage regulator. Start the motorcycle and run the engine at 2000 RPM.
3. With ignition and all continuously running lights and accessories turned on (headlamp on high beam), read the total current draw.
4. Compare this reading to the reading obtained after per­forming the CURRENT AND VOLTAGE OUTPUT TEST.
a. The current output should exceed current draw by
3.5 amps minimum.
b. If output does not meet specifications, there may be
too many accessories for the charging system to handle.
5. Reconnect voltage regulator after testing.
1-22 2008 Sportster Diagnostics: Starting / Charging
Page 36
1
2
3
ed02802
1. Load tester
ed02804
2. Induction pickup
3. Battery
Figure 1-16. Check Current Draw (Ignition Switch On)
Current and Voltage Output Test: Using HD-48053
1. Connect the ADVANCED BATTERY CONDUCTANCE AND ELECTRICAL SYSTEM ANALYZER (Part No. HD-
48053) leads to the vehicle's battery.
2. Follow the instructions in the analyzer's instruction manual to perform a Charging System Test.
See Figure 1-17.The test results will include a decision on the charging system's condition and the measured output voltage at idle and at 3000 RPM. The analyzer's printer will provide you with a printout including one of two possible test results:
CHARGING SYSTEM NORMAL - No problem found.
CHARGING SYSTEM PROBLEM - The analyz er detected
a problem and will display one of the three following res­ults:
1. LOW CHARGING VOLTS - The alternator is not supplying sufficient current for the system's electrical loads.
2. HIGH CHARGING VOLTS - The voltage output from the alternator exceeds the normal regulator limits.
3. INVESTIGATE VOLT OUTPUT - The rev voltage is lower than the idle voltage.
Figure 1-17. Charging System Test Results Printout
Current and Voltage Output Test: Using Load Tester
1. See Figure 1-18. Connect load tester. a. Connect negative and positive leads to battery ter-
minals.
b. Place load tester induction pickup over positiv e regu-
lator cable.
2. Run the engine at 3000 RPM. Increase the load as required to obtain a constant 13.0 VDC . Do not leave any load switch turned on for more than 20 seconds or over­heating and tester damage can occur.
3. The current output should be 28-34 amps. Make note of measurement for use in Total Current Draw Test.
NOTE
Rider's habits may require output test at lower RPM.
4. See Figure 1-18. After removing the load, read the load tester voltage meter.
a. If voltage to the battery is not more than 15 VDC,
voltage output is within specifications. Investigate other possible problems.
b. If voltage is higher , voltage regulator is not functioning
properly or connections are loose or dirty.
2008 Sportster Diagnostics: Starting / Charging 1-23
Page 37
1
2
3
4
5
ed02803
1. Load tester
1
3
2
4
ed02805
2. Battery
3. Voltage regulator
4. To MAXIFUSE (DC output)
5. To stator Figure 1-18. Current and Voltage Output Test
Stator Check
1. Turn ignition switch OFF.
2. Connect an ohmmeter. a. Open latch and separate socket connector from pin
connector.
b. See Figure 1-19. Insert one ohmmeter lead into a
stator connector (1) socket.
c. Attach the other lead to a suitable ground (4).
3. Test for continuity with ohmmeter set to the ohms scale (2).
a. A good stator will show no continuity between either
stator socket and ground.
b. Any other reading indicates a grounded stator which
4. See Figure 1-20. Remo ve ground lead. Check resistance
5. Test for resistance with ohmmeter set on the RX1 scale.
must be replaced.
across stator sockets.
a. Resistance across the stator sockets should be 0.1-
0.3 ohms.
b. If the resistance is higher, the stator is damaged and
must be replaced.
1. Alternator stator connector [46B]
2. DVOM set to ohms scale
3. Positive meter lead to either stator connector socket
4. Negative meter lead grounded to engine
Figure 1-19.Test for Grounded Stator
NOTE
Verify that meter reads 0 ohms when probes are shorted together. If not, subtract lowest value from resistance value of stator.
1-24 2008 Sportster Diagnostics: Starting / Charging
Page 38
2
1
3
ed02809
2. Compare test results to specifications.
1
2
3
ed02810
a. If the output is below specifications, charging problem
could be a faulty rotor or stator.
b. If output is good, charging problem might be faulty
voltage regulator. Replace as required.
3. Check the output again as previously described under CURRENT AND VOLTAGE OUTPUT TEST.
1. Alternator stator connector [46B]
2. DVOM set to ohms scale
3. Meter leads to stator connector sockets Figure 1-20. Check for Stator Resistance
AC Output Check
1. See Figure 1-21.Test AC output. a. Disconnect voltage regulator connector from alternator
stator wiring.
b. Connect an AC voltmeter across both stator connector
sockets.
c. Run the engine at 2000 RPM. The AC output should
be 40-56 volts AC (appro ximately 20-28 v olts A C per 1000 RPM).
1. Alternator stator connector [46B]
2. DVOM set to AC volts scale
3. Meter leads to stator connector sockets Figure 1-21. Check Stator AC Voltage Output
2008 Sportster Diagnostics: Starting / Charging 1-25
Page 39

1.8BATTERY TESTING

ed02811

GENERAL

Three different procedures may be performed to provide a good indicator of battery condition: a voltage test, a conduct­ance test, or a load test.
A battery may be tested, whether fully charged or not, via conductance test. In order to perf orm a load test, howe ver, the battery must be fully charged.

VOLTMETER TEST

The voltmeter test provides a general indicator of battery state of charge or condition. Chec k the voltage of the battery to verify that it is in a 100% fully charged condition. Refer to Table 1-5.
If the open circuit (disconnected) voltage reading is below
12.6V, charge the battery and then recheck the voltage after the battery has set for one to two hours. If the voltage reading is 12.7V or above, perform the LOAD TEST described in this section.
Table 1-5.Voltmeter Test For Battery Charge Conditions
STATE OF CHARGEVOLTAGE (OCV)
100%12.7
75%12.6 50%12.3 25%12.0
0%11.8
See Figure 1-22. The analyzer printer will provide you with a printout including one of five possible test results:
GOOD BATTERY - Return the battery to service.
GOOD-RECHARGE - Fully charge the battery and return
to service.
CHARGE & RETEST - Fully charge the battery and retest.
REPLACE BATTERY - Replace the battery and retest.
BAD CELL-REPLACE - Replace the battery and retest.
BATTERY NOISE - Remove surface charge from battery
and retest.
NOTES
A REPLACE BATTERY test result may also mean a poor connection between the battery cables and the vehicle. After disconnecting the battery cables from the battery, retest the battery using the out-of-vehicle test before replacing.
Connect the tester directly to the lead terminals of the battery, and not the bolts.

CONDUCTANCE TEST

TOOL NAMEPART NUMBER
HD-48053
Test the battery using the AD VANCED BATTERY CONDUCT­ANCE AND ELECTRICAL SYSTEM ANAL YZER (P art No. HD-
48053). Perform a battery test as follows:
1. Connect the HD-48053 analyzer leads to the vehicle bat­tery lead terminal, not to bolt or wire terminal.
Connect the tester directly to the lead terminals of the battery, and not the bolts.
2. Follow the instructions in the analyzer instruction manual to perform a battery test.
The test results will include a decision on the battery condition and the measured state of charge.
ADVANCED BATTERY CONDUCT­ANCE AND ELECTRICAL SYSTEM ANALYZER
NOTE
Figure 1-22. Battery Test Results Printout

LOAD TEST

To load test the battery, proceed as follows:
Disconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable con­nected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00049a)
1. Remove battery from motorcycle.
2. Always fully charge the battery before testing or test readings will be incorrect. Load testing a discharged bat­tery can also result in permanent battery damage.
3. After charging, allow battery to stand for at least one hour before testing.
1-26 2008 Sportster Diagnostics: Starting / Charging
Page 40
Turn battery load tester OFF before connecting tester
1
2
3
ed02876
cables to battery terminals. Connecting tester cables with load tester ON can cause a spark and battery explosion, which could result in death or serious injury. (00252a)
4. See Figure 1-23. Connect tester leads to battery posts and place induction pickup over negative (black) cable.
NOTE To avoid load tester and/or battery damage, do not leave the load tester switch turned ON for more than 20 seconds.
5. Refer to Table 1-6. Load battery at 50% of CCA rating
using the load tester. Voltage reading after 15 seconds should be 9.6V or more at 70° F (21° C).
Turn battery load tester OFF before disconnecting tester cables to battery terminals. Disconnecting tester cables with load tester ON can cause a spark and battery explo­sion, which could result in death or serious injury . (00253a)
6. Install the battery in the motorcycle.
Connect positive (+) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00068a)
Do not over-tighten bolts on battery terminals. Use recommended torque values. Over-tightening battery ter­minal bolts could result in damage to battery terminals. (00216a)
1. Load tester
2. Induction pickup
3. Battery Figure 1-23. Load Test Battery
Table 1-6. Battery Load Test
50%100%COLD CRANKING
AMPERAGE (CCA)
102.5205Sportster models
2008 Sportster Diagnostics: Starting / Charging 1-27
Page 41
NOTES
1-28 2008 Sportster Diagnostics: Starting / Charging
Page 42
SUBJECT............................................................................................................................PAGE NO.
2.1 CHECKING FOR DIAGNOSTIC TROUBLE CODES................................................................2-1
2.2 INITIAL DIAGNOSTIC CHECK: SPEEDOMETER....................................................................2-4
2.3 SPEEDOMETER SELF DIAGNOSTICS.................................................................................2-10
2.4 SPEEDOMETER/TACHOMETER...........................................................................................2-12
2.5 BREAKOUT BOX: SPEEDOMETER/TACHOMETER..............................................................2-16
2.6 INDICATOR LAMPS................................................................................................................2-17
2.7 DTC B1004, B1005.................................................................................................................2-21
2.8 DTC B1006, B1007.................................................................................................................2-25
2.9 DTC B1008..............................................................................................................................2-27
2.10 DTC U1016, U1255...............................................................................................................2-30
2.11 DTC U1064, U1255...............................................................................................................2-33
2.12 DTC U1300, U1301 OR BUS ER..........................................................................................2-37

INSTRUMENTS

Page 43
NOTES
Page 44

CHECK ENGINE LAMP

2
3
5
4
6
1
ed02813
OFF
ACC.
IGNITION
3
1
2
ed02814
See Figure 2-1.To diagnose Electronic Control Module (ECM) system problems, begin by observing the behavior of the check engine lamp (1).
NOTES
See Figure 2-2. "Key ON" means that the Ignition Switch is turned to IGNITION and the Engine Stop Switch is set to RUN (although the engine is not running).
When the Ignition Switch is turned to IGNITION, the check engine lamp will illuminate for approximately f our seconds and then turn off.
If the check engine lamp is not illuminated at Ignition ON, the problem is likely to be an instrument failure. See
2.2 INITIAL DIAGNOSTIC CHECK: SPEEDOMETER.
If the check engine lamp illuminates late (after 20 seconds), the problem is most likely a serial data bus failure. Test for Diagnostic Trouble Codes (DTCs) using speedometer self diagnostics. See 2.2 INITIAL DIA-
GNOSTIC CHECK: SPEEDOMETER.
If the check engine lamp fails to turn off after the initial four-second period, see 2.2 INITIAL DIAGNOSTIC
CHECK: SPEEDOMETER.
1. See Figure 2-3. After the check engine lamp turns off fol­lowing the first four-second illumination period, one of three events may occur:
a. The lamp remains off. This indicates there are no
current fault conditions or stored DTCs currently detected by the ECM.
b. The lamp remains off for only four seconds and then
illuminates for an eight-second period.This indicates a DTC is stored, but no current DTC exists.
c. The lamp remains on beyond the eight-second period.
This indicates a current DTC exists.

2.1CHECKING FOR DIAGNOSTIC TROUBLE CODES

1. Check engine lamp
2. Low fuel lamp
3. Battery lamp
4. Security lamp (key icon)
5. Odometer display
6. Sixth gear indicator (not used) Figure 2-1. Speedometer
2. See 2.1 CHECKING FOR DIAGNOSTIC TROUBLE
CODES, Code Types which follows for a complete
description of DTC formats.
NOTE
Some DTCs can only be fully diagnosed during actuation. F or example, a problem with the ignition coil will be considered a current fault ev en after the problem is corrected, since the ECM will not know of its resolution until after the coil is ex ercised by the vehicle start sequence. In this manner, there may some­times be a false indication of the current DTC.
1. Ignition OFF
2. Accessory (ACC) ON
3. Ignition ON Figure 2-2. Ignition Switch
2008 Sportster Diagnostics: Instruments 2-1
Page 45

SECURITY LAMP

ON
A
B
C
ON
ON
OFF
OFF
OFF
Key On
Key On
Key On
Lamp OFF: No Current or Historic DTCs
Lamp OFF
Lamp ON 8 Seconds:
Only Historic DTCs Exist
Lamp Remains ON: Current DTC*
* Historic DTCs May Also Exist
4 Sec.
4 Sec.
4 Sec.
4 Sec.
8 Sec.
4 Sec.
ed01046
Turn Signal Module (TSM)
If the turn signals flash six 4-way flashes shortly after key ON, it indicates a Diagnostic Trouble Code (DTC) has been logged sometime in the last three ignition cycles.
Turn Signal Security Module (TSSM) or Hands-Free Security Module (HFSM)
See Figure 2-1. To diagnose Turn Signal Security Module (TSSM) or Hands-Free Security Module (HFSM) system problems, begin by observing the behavior of the security lamp (4).
NOTES
To provide an indication of TSSM/HFSM DTCs, the security lamp is enabled on TSSM/HFSM models.
See Figure 2-2. "Key ON" means that the Ignition Switch is turned to IGNITION and the Engine Stop Switch is set to RUN (although the engine is not running).
When the Ignition Switch is turned ON, the security lamp will illuminate for approximately four seconds and then turn off.
If the security lamp is not illuminated at Key ON, the problem is likely to be an instrument failure. See 2.2 INI-
TIAL DIAGNOSTIC CHECK: SPEEDOMETER.
If the security lamp illuminates late (after 20 seconds), the problem is most likely a serial data bus failure. Test for
DTCs using speedometer self diagnostics. See 2.2 INITIAL
DIAGNOSTIC CHECK: SPEEDOMETER.
If the security lamp fails to turn off after the initial four­second period, a problem exists in the instrumentation. See 2.2 INITIAL DIAGNOSTIC CHECK: SPEEDOMETER.
1. See Figure 2-3. After the security lamp turns off following the first four-second illumination period, one of three events may occur:
a. The lamp remains off. This indicates there are no
current fault conditions or stored DTCs currently detected by the TSSM/HFSM.
b. The lamp stays off for only four seconds and then
comes back on for an eight-second period. This indicates a DTC is stored, but no current DTC exists.
c. The lamp remains on beyond the eight-second period.
This indicates a current DTC exists.
2. See 2.1 CHECKING FOR DIAGNOSTIC TROUBLE
CODES, Code Types for a complete description of DTC
formats.
NOTE
Some DTCs can only be fully diagnosed during actuation. F or example, a problem with the turn signals will be considered a current fault even after the problem is corrected, since the TSM/TSSM/HFSM will not know of its resolution until after the turn signals are activated. In this manner , there ma y sometimes be a false indication of the current DTC.
Figure 2-3. Check Engine and Security Lamp Operation
2-2 2008 Sportster Diagnostics: Instruments
Page 46

CODE TYPES

TOOL NAMEPART NUMBER
DIGITAL TECHNICIANHD-44750
There are two types of DTCs: current and historic. If a DTC is stored, it can be read using DIGITAL TECHNICIAN (Part No. HD-44750) or speedometer self diagnostics. See
2.3 SPEEDOMETER SELF DIAGNOSTICS.
All DTCs reside in the memory of the ECM, TSM/TSSM/HFSM, speedometer or tachometer until the code is cleared.
See 2.1 CHECKING FOR DIAGNOSTIC TROUBLE CODES,
Multiple Diagnostic Trouble Codes if multiple DTCs are found.
Diagnostic charts are designed for use with current DTCs and as a result they frequently suggest wire repair or part replace­ment.

RETRIEVING DIAGNOSTIC TROUBLE CODES

TOOL NAMEPART NUMBER
DIGITAL TECHNICIANHD-44750
Current
Current DTCs are those which presently disrupt motorcycle operation. See the appropriate flow charts for solutions.
Historic
If a particular problem happens to resolve itself, the active status problem is dropped and it becomes a historic fault rather than a current fault. Historic DTCs are stored for a length of time to assist in the diagnosis of intermittent faults.
Historic DTCs are cleared after a total of 50 trips has elapsed. A trip consists of a start and run cycle. After the 50 trip retention period, the historic DTC is automatically erased from memory providing no subsequent faults of the same type are detected in that period.
DTCs can only be identified as historic using DIGITAL TECH­NICIAN (Part No. HD-44750), a computer-based diagnostic package.
It is important to note that historic DTCs may also be present whenever the system indicates the e xistence of a current fault.
The engine management system provides two levels of dia­gnostics.
The most sophisticated mode employs DIGITAL TECHNI­CIAN (Part No. HD-44750), a computer-based diagnostic package.
The second mode requires using the speedometer self diagnostics. See 2.3 SPEEDOMETER SELF DIA-
GNOSTICS.

MULTIPLE DIAGNOSTIC TROUBLE CODES

While it is possible for more than one fault to occur and set more than one DTC, there are several conditions which may result in one fault setting multiple DTCs. For example, serial data DTCs (DTC U1016, U1064, U1097, U1300 and U1301) may be accompanied by other DTCs.Always correct the serial data DTCs before resolving other DTCs.
For proper resolution of multiple DTCs, refer to Speedo­meter/Tachometer Diagnostic Trouble Code (DTC) Priority Chart Table 2-2.
2008 Sportster Diagnostics: Instruments 2-3
Page 47

2.2INITIAL DIAGNOSTIC CHECK: SPEEDOMETER

GENERAL

TOOL NAMEPART NUMBER
DIGITAL TECHNICIANHD-44750
See Figure 2-4. Constant power is supplied to the speedometer through terminal "5" of connector [39]. The speedometer turns on when power is applied to terminal "1". The speedometer proceeds through an initialization sequence every time power is removed and re-applied to terminal "6". See Figure 2-1. The visible part of this sequence is the check engine lamp (1), security lamp (4),
Table 2-1. Speedometer Function Chart - Loss of Input
(Constant)
Security lamp glows dimly during 4-second bulb check
Will not "WOW"
Turn signals still functional
Speedometer will indicate
vehicle speed (zero)
Tachometer unaffected
Security lamp still functions
Check engine lamp and battery
lamp non-functional
Diagnostics absent
Speedometer
Security lamp
backlighting and odometer display (5). Upon key ON (Engine Stop Switch set to RUN), the check engine lamp and security lamp will illuminate for four seconds and then (if parameters are normal) will turn off.
To locate faulty circuits or other system problems, follow the diagnostic flow charts and tests in this section. For a systematic approach, always begin with 2.2 INITIAL DIA-
GNOSTIC CHECK: SPEEDOMETER, Initial Diagnostics.
Read the general information and then work your way through the flow chart box by box.
Loss of power on any of the four po wer inputs will change speedometer behavior. Refer to Table 2-1.
Terminal 8 and 11
(Trip Odometer
Reset Switch)
No trip odometer reset switch func­tion
Will not "WOW"
will be non-func­tional in accessory and ignition modes
still performs 4­second bulb check in ignition mode
Terminal 7 (GRD)Terminal 6 (ACC)Terminal 1 (IGN)Terminal 5
Speedometer completely non­functional
Diagnostic absent
Diagnostic Notes
If a numbered circle appears adjacent to a flow chart box, more information is offered in the diagnostic notes. Many diagnostic notes contain supplemental information, descriptions of various diagnostic tools or references to other parts of the manual where information on the location and removal of components may be obtained.
Circuit Diagram/Wire Harness Connector Table
When working through a flow chart, refer to the illustrations, the associated circuit diagram and the wire harness connector table as necessary .The wire harness connector table for each circuit diagram identifies the connector number, description, type and general location.
In order to perform most diagnostic routines, a Breakout Box and a DVOM are required. See 2.5 BREAKOUT BOX:
SPEEDOMETER/TACHOMETER.
To perform the circuit checks with any degree of efficiency, a familiarity with the various wire connectors is also necessary.
Job/Time Code Values
Dealership technicians filing warranty claims should use the job/time code values printed in bold text underneath the appropriate repair.
Reprogramming ECM
Diagnostic charts frequently suggest Electronic Control Module (ECM) replacement. In the e vent an ECM needs to be replaced, it must be reprogrammed using a computer-based diagnostic package called DIGITAL TECHNICIAN (Part No. HD-44750). See your dealer. Password learn procedure must also be per­formed. See 3.25 TSM/HFSM: PASSWORD LEARN or
E.21 TSM/TSSM: PASSWORD LEARN.

INITIAL DIAGNOSTICS

TOOL NAMEPART NUMBER
BREAKOUT BOXHD-42682 INSTRUMENT HARNESS AD APTERSHD-46601
Diagnostic Tips
See Figure 2-4. If Speedometer reads "BUS Er" while Ignition Switch is turned to ON (Engine Stop Switch at RUN with the engine off), check diagnostic link f or an open or short to ground between data link connector [91A] ter­minal "3" and ECM connector [78] terminal "5", TSM/TSSM/HFSM connector [30] terminal "3", speedo­meter connector [39] terminal "2" or tachometer (if equipped) connector [108] terminal "2".
Check for an open diagnostic test terminal between data link connector [91A] terminal "3" and TSM/TSSM/HFSM connector [30] terminal "3".With Ignition Switch turned to
2-4 2008 Sportster Diagnostics: Instruments
Page 48
ON, transmit data should be typically 0.6-0.8 volts. The range of acceptable operation is greater than 0.0 v olts and less than 7.0 volts.
To identify intermittents, wiggle instrument and/or vehicle harness while performing steps in the Initial Diagnostic Check charts.
Diagnostic Notes
Each reference number below correlates to a circled number on the flow chart(s).
Table 2-2. Speedometer Diagnostic Trouble Code (DTC) Priority Chart
5U1255
and/or ECM) at startup
1. Connect BREAKOUT BOX (Part No. HD-42682) (black) between speedometer connector [39A] (at the back of the speedometer) and wire harness connector [39B] using INSTRUMENT HARNESS ADAPTERS (Part No. HD-
46601). See 2.5 BREAKOUT BOX: SPEEDO-
METER/TACHOMETER.
All Speedometer Diagnostic Trouble Codes (DTCs) are listed in Table 2-2.
SOLUTIONFAULT CONDITIONRANKINGDTC
2.12 DTC U1300, U1301 OR BUS ERSerial data bus shorted low1U1300
2.12 DTC U1300, U1301 OR BUS ERSerial data bus shorted high2U1301
2.10 DTC U1016, U1255Loss of ECM serial data3U1016
2.11 DTC U1064, U1255Loss of TSM/TSSM/HFSM serial data4U1064
2.11 DTC U1064, U1255Missing response from other module (TSM/TSSM/HFSM
2.8 DTC B1006, B1007Ignition line overvoltage6B1007
2.8 DTC B1006, B1007Accessory line overvoltage7B1006
2.9 DTC B1008Reset switch closed8B1008
2.7 DTC B1004, B1005Fuel level sending unit low9B1004
2.7 DTC B1004, B1005Fuel level sending unit high/open10B1005
Other Diagnostic Trouble Codes
See 3.10 INITIAL DIAGNOSTIC CHECK: TSM/HFSM or
E.9 INITIAL DIAGNOSTIC CHECK:TSM/TSSM for any DTCs
related to the Turn Signal Module (TSM), Turn Signal Security Module (TSSM) or Hands-Free Security Module (HFSM).
See 4.5 INITIAL DIAGNOSTIC CHECK: EFI for any DTCs related to the Electronic Control Module (ECM).
2008 Sportster Diagnostics: Instruments 2-5
Page 49
BK
BK
BK
GY GY
GY
O/W
O/W
O/W
O
O
R
BN/GY
BN/GYBN/GY
BN/GY BN/GY
LGN/V
BK
BK
BK
O/W
O
O
BN/GY
LGN/V
LGN/V
LGN/V
LGN/V
LGN/V
LGN/V
R/BK
R/BK
R/GY
1 2 3 12
1 2 3 12
1 2 5 76
1 2 5 76
1 2 5 6 7
1 2 5 6 7
Ignition
Serial data
Battery
Accessory
Ground
Ignition
Serial data
Battery
Battery
Ignition
Serial data
Ground
Accessory
Ground
[39B]
[39A]
[108B]
[108A]
[30B]
[30A]
[91A]
Speedometer
TSM/TSSM/HFSM
Tachometer (Optional)
To ACCY fuse
To BATT fuse
To INSTR fuse
To IGN fuse
12V ACCY
Fuse
12V BATT
Fuse
12V INSTR
Fuse
12V IGN
Fuse
3
1 2
4
Data Link Connector
21 6 7
12
21 6 7 12
[20A] [20B]
ECM
Serial data
[78A]
[78B]
5
5
[GND1]
[GND1]
[GND1]
em01120
Figure 2-4. Serial Data Circuit
Table 2-3.Wire Harness Connectors
LOCATIONTYPEDESCRIPTIONNO.
Under fuel tank12-place MolexInstruments[20] Under battery12-place DeutschTSM/TSSM/HFSM[30] Back of speedometer12-place PackardSpeedometer[39] Under seat36-place PackardElectronic Control Module (ECM)[78] On battery strap, behind left side cover4-place DeutschData link connector[91A] Back of tachometer12-place PackardTachometer (if equipped)[108]
2-6 2008 Sportster Diagnostics: Instruments
Page 50
Initial Diagnostic Check (Part 1 of 3)
Does engine
start?
YES.
Starts and runs.
YES.
Starts, then stalls.
NO.
Cranks, but will not start.
NO.
Engine will not crank.
Check for DTCs. See
2.3 SPEEDOMETER
SELF DIAGNOSTICS
Were DTCs found?
See 4.12 STARTS,
THEN STALLS.
See 4.10 ENGINE CRANKS,
BUT WILL NOTSTART.
See 1.2 STARTING
SYSTEM DIAGNOSIS.
YES
Refer to applicable DTC priority
chart. All DTCs are listed by
priority in Table 2-2.
NO
Unable to enter
diagnostic mode.
NO
No codes
displayed.
With ignition switch OFF, press and
release trip odometer reset switch.
Does odometer display appear with
backlighting?
For a list of symptoms that
may not set diagnostic
trouble codes, referto
Table 3-6.
YES NO
Check for continuity to ground at
Breakout Box terminal 7(black). Wiggle
harness during continuity check.
Is continuity present?
YES NO
Check for battery voltage at
Breakout Box terminal 5(black)
while wiggling harness.
Is battery voltage continuously
present?
Locate and
repair open.
YES NO
With ignition switch OFF and speedometer
connector [39] disconnected, check continuity
between Breakout Box terminals 8and 11(black).
Is continuity present when trip odometer reset
switch is depressed and infinity when released?
Locate and
repair open.
YES NO
Replace
Speedometer.
Replace trip odometer
reset switch.
STOP
Go to Initial Diagnostic
Check (Part 2 of 3).
1
fc01062_en
2008 Sportster Diagnostics: Instruments 2-7
Page 51
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
Replace Speedometer.
Perform WOWtest.
See 2.3 SPEEDOMETER SELF DIAGNOSTICS.
The following features should be functional
1) backlight should illuminate
2) needle should sweep its full range of motion
3) LEDs should illuminate:
check engine
battery
security (all models)
low fuel
sixth gear
Are all features functional?
YES
Turn Ignition Switch to ACC.
Is backlight present?
YES NO
Check for battery voltage at
Breakout Box terminal 6 (Black). Is battery voltage
present?
YES NO
Replace Speedometer.
Is accessory
fuse good?
YES
Locate and repair open
on (O/W) wire between terminal 6of connector [39] and accessory fuse.
Locate and repair
source of fault.
Replace fuse.
STOP
Go to Initial Diagnostic
Check (Part 3 of 3).
1
NO
Turn Ignition Switch to IGNITION.
Check for
battery voltage at Breakout
Box terminal 1(Black).
Is battery voltage present?
YES NO
Replace Speedometer.
Is instrument
fuse good?
YES NO
Locate and repair open between terminal 1of
connector [39] and
instrument fuse.
Locate and repair
source of fault.
Replace fuse.
1
fc01063_en
NO
2-8 2008 Sportster Diagnostics: Instruments
Page 52
Initial Diagnostic Check (Part 3 of 3)
Continued from Initial Diagnostic Check (Part 2 of 3).
Is problem intermittent?
YES NO.
Speedometer
Inoperative
(no vehicle speed).
NO.
Tachometer
Inoperative
(no engine speed).
Repeat Diagnostic
Check while wiggling
harnesses.
Was intermittent found?
Remove and inspect
VehicleSpeed Sensor.
Is debris present?
See Tachometer
Inoperative (Part 1 of 2).
YES NO
Locate and repair
intermittent.
No trouble found.
YES NO
Remove debris.
Reinstall
VehicleSpeed Sensor.
Check for damaged wiring/
loose connection between
VehicleSpeed Sensor and ECM.
Is wiring damage/loose
connection present?
YES NO
Locate and repair
source of fault.
Replace
Speedometer.
fc01064_en
2008 Sportster Diagnostics: Instruments 2-9
Page 53

2.3SPEEDOMETER SELF DIAGNOSTICS

GENERAL

The speedometer is capable of displaying and clearing speedometer, tachometer, TSM/TSSM/HFSM, and ECM Dia­gnostic Trouble Codes (DTCs) (diagnostic mode).
DIAGNOSTICS Diagnostic Tips
For a quick check of speedometer function, a "W O W" test can be performed. Press and hold trip odometer reset switch (Figure 2-5), then turn Ignition Switch ON. Release trip odometer reset switch. Background lighting should illuminate, gauge needle should sweep its full range of motion, and indicator lamps (check engine, low fuel, bat­tery and security) should illuminate.
If instrument module fails "WOW" test, check for battery, ground, ignition, trip odometer reset switch and accessory wiring to speedometer. If any feature in the speedometer
is non-functional, see 2.2 INITIAL DIAGNOSTIC CHECK:
SPEEDOMETER.
Diagnostic Notes
Each reference number below correlates to a circled number on the flow chart(s).
1. To exit diagnostic mode, turn ignition switch OFF.
2. To clear DTCs for the selected module: a. Press and hold the trip odometer reset switch for more
than 5 seconds to display av ailable modules, release.
b. Press the trip odometer reset switch to choose the
module.
c. Press and hold the trip odometer reset switch for more
than 5 seconds to display the DTC, release.
d. Press and hold the trip odometer reset switch for more
than 5 seconds to clear the DTCs for the selected module.
2-10 2008 Sportster Diagnostics: Instruments
Page 54
Speedometer Self Diagnostics
1
While holding trip odometer reset
switch in, turn ignition switch to
IGNITION.
Make sure Engine Stop Switch is in
RUN position.
Release trip odometer reset switch.
Does diagappear?
YES
Pflashing.
To display DTCs for the
ECM, press and hold trip
odometer reset switch for more
than 5 seconds.
To display DTCs for
TSM/TSSM, press and hold trip
odometer reset switch for more
than 5 seconds.
To choose TSM/
TSSM/HFSM, press
and release trip odometer
reset switch.
Sflashing.
To choose Speedometer,
press and release trip
odometer reset switch.
SPflashing.
To choose Tachometer,
press and release trip odometer
reset switch.
To choose ABS, press
and release trip odometer
reset switch.
Tflashing.
To display DTCs for
speedometer, press and
hold trip odometer reset
switch for more than 5
seconds.
To display DTCs for tachometer,
press and hold trip odometer
reset switch for more than 5
seconds.
Press and release trip
odometer reset switch again to
continue to next module.
See 2.2 INITIAL
DIAGNOSTIC
CHECK: SPEEDOMETER.
YES
YES
NO
NO
NO
Device
response?
Press and release
trip odometer reset
switch. Part number
of module will be
displayed.
Press and release trip odometer reset switch.
Are more DTCs displayed?
enddisplayed. To clear all DTCs for selected
module hold trip odometer reset switch for more than
5 seconds. If DTCs are not to be cleared, Press and
release trip odometer reset switch.Part number of
module will be displayed.
no rspdisplayed.See applicable code from
other modules. Models not equipped with a
tachometer or ABS will display no rspnormally.
If no rspdisplayed on odometer on tachometer
equipped vehicle, See Section 2.4
SPEEDOMETER/TACHOMETER.
nonedisplayed.
DTC
displayed.
Press and release trip odometer reset switch.
PSSPtbappears.
2
bflashing.
To display DTCs for
ABS, press and
hold trip odometer reset
switch for more than 5 seconds.
To choose ECM, press
and release trip odometer
reset switch.
fc01065_en
2008 Sportster Diagnostics: Instruments 2-11
Page 55

GENERAL

2
3
5
4
6
1
ed02813
ed02816
See Figure 2-5.The speedometer consists of a speedometer display and five status lamps.The lamps include: check engine (1), low fuel (2), battery (3), security (4) and sixth gear indicator (6).
Trip Odometer Reset Switch
Figure 2-6. Pressing the trip odometer reset switch provides
the following capabilities:
Change the odometer display between mileage, trip A and trip B values (press and immediately release).
Reset an individual trip odometer (press and hold 2-3 seconds).
Gain access to the diagnostic mode and clear Diagnostic Trouble Codes (DTCs). See 2.3 SPEEDOMETER SELF
DIAGNOSTICS.
Display odometer while ignition switch is OFF. Press and hold trip odometer reset switch while ignition switch is OFF and odometer mileage will be displayed.
On models with dual scale speedometers, toggle between miles/kilometers on odometer and trip odometer display. To toggle display, turn ignition switch ON. Press and hold trip odometer reset switch while odometer is displayed. Release switch when change is noted. (If trip odometer reset switch is held while trip odometer is displayed, trip odometer will reset).

2.4SPEEDOMETER/TACHOMETER

Figure 2-6.Trip Odometer Reset Switch (Typical)

SPEEDOMETER THEORY OF OPERATION

The speedometer circuit consists of a Vehicle Speed Sensor (VSS), the ECM, the trip odometer reset switch and the speedometer.The VSS is mounted on the rear of the engine crankcase behind the starter motor assembly.The sensor cir­cuitry is that of a Hall-effect sensor triggered by the gear teeth of 5th gear on the transmission mainshaft.
The output from the sensor is a series of pulses that are inter­preted by the ECM circuitry, converted into serial data then sent to the speedometer to control the position of the speedo­meter needle and the odometer Liquid Crystal Display (LCD). The vehicle speed serial data is also transmitted to the TSM/TSSM/HFSM for turn signal cancellation.
1. Check engine lamp
2. Low fuel lamp
3. Battery lamp
4. Security lamp (key icon)
5. Odometer display
6. Sixth gear indicator (not used) Figure 2-5. Speedometer

ODOMETER THEORY OF OPERATION

The odometer mileage is permanently stored and will not be lost when electrical power is turned off or disconnected. The trip odometer reset switch allows switching between the odo­meter, trip odometer A and trip odometer B displays.
To zero the trip odometer, have the desired trip odometer dis­play visible and press and hold the trip odometer reset switch. The trip odometer mileage will be displayed for 2-3 seconds and then the trip mileage will return to zero miles.
The odometer can display six numbers to indicate a maximum of 999999 miles/kilometers.The trip odometers can display six numbers with a tenth of a mile accuracy for a maximum of
99999.9 miles/kilometers.

TACHOMETER THEORY OF OPERATION

See Figure 2-7.The tachometer receives serial data from the ECM.The tachometer inter prets the serial data and converts it into tachometer needle movement.
NOTE
Indicator lamps in the tachometer face may illuminate during a "WOW" test, e ven though the y do not function during normal vehicle operation.
2-12 2008 Sportster Diagnostics: Instruments
Page 56
ed02817
Figure 2-7.Tachometer
BK
BKBK
BK
BK
O/W
O/W
O/W
O
OO
LGN/V
LGN/VLGN/V
BN/GY
BN/GY
BN/GY
BN/V
BN/V
Ignition
Serial data
Battery
Accessory
Ground
1 2
5 6 7
1 2
5 6 7
RPM x 100
Ignition
Serial data
Battery
Accessory
Ground
Trip SW
Trip SW
1 2
6 7
11 12
1 2
4 5 6 7 8
11
1 2
4 5 6 7 8
11
[39A]
[39B]
[108A]
[108B]
Tachometer
(if equipped)
Speedometer
Odometer Reset Switch
[20A]
Security LP
em01124

DIAGNOSTICS

TOOL NAMEPART NUMBER
HARNESS CONNECTOR TEST KITHD-41404-B BREAKOUT BOXHD-42682 INSTRUMENT HARNESS AD APTERSHD-46601
Diagnostic Notes
Each reference number below correlates to a circled number on the flow chart(s).
1. If problems are intermittent, wiggle harness while per­forming tests.
2. Connect BREAKOUT BOX (Part No. HD-42682) (black) between tachometer connector [108A] (at the back of the tachometer) and wire harness connector [108B] using INSTRUMENT HARNESS ADAPTERS (Part No. HD-
46601). See 2.5 BREAKOUT BOX: SPEEDO-
METER/TACHOMETER.
3. Use HARNESS CONNECTOR TEST KIT (Part No. HD­41404-B), black pin probe and patch cord.
Figure 2-8. Speedometer/Tachometer Circuitry
Table 2-4.Wire Harness Connectors
2008 Sportster Diagnostics: Instruments 2-13
Under fuel tank12-place MolexInstruments[20] Back of speedometer12-place PackardSpeedometer[39] Back of tachometer12-place PackardTachometer (if equipped)[108]
LOCATIONTYPEDESCRIPTIONNO.
Page 57
Tachometer Inoperative (Part 1 of 2)
Perform WOWtest. See 2.3 SPEEDOMETER
SELF DIAGNOSTICS.
The following features should be functional
1) backlight should illuminate
2) needle should sweep its full range of motion
3) LEDs may illuminate:
cruise (although not cruise equipped)
pursuit (although not a police vehicle)
Are all features functional?
YES
Is problem intermittent?
YES NO
Repeat WOWtest
while wiggling
harnesses.
No trouble
found.
NO
Check for battery voltage at
Breakout Box terminal 1. Is battery voltage present?
YES NO
Is instrument
fuse good?
YES NO
Locate and repair
source of fault.
Replace fuse.
Locate and repair
open in (O) wire between
terminal 1of
connector [108] and
instrument fuse.
Check for continuity
between Breakout Box
terminal 2and terminal
7of connector [20].
Is continuity present?
YES NO
Locate and repair open on (LGN/V)
wire.
STOP
Go to Tachometer
Inoperative (Part 2 of 2).
3
2
fc01066_en
1
2-14 2008 Sportster Diagnostics: Instruments
Page 58
Tachometer Inoperative (Part 2 of 2)
Continued from Tachometer
Inoperative (Part 1 of 2).
Check for continuity to ground on
Breakout Box terminal 7. Wiggle
harness during continuity check.
Is continuity present?
YES NO
Check for battery voltage at Breakout Box
terminal 5while wiggling harness.
Is battery voltage continuously present?
Locate and repair open on (BK) wire
between terminal 7of connector [108]
and ground.
YES NO
Check for battery voltage at Breakout
Box terminal 6. Is battery voltage
present?
Locate and repair open on (BN/GY)
wire between terminal 5of connector
[108] and battery fuse.
YES NO
Replace tachometer.
Locate and repair open on (O/W) wire between
terminal 6of
connector [108] and
accessory fuse.
fc01067_en
2008 Sportster Diagnostics: Instruments 2-15
Page 59
BREAKOUT BOX:
ed02819
SPEEDOMETER/TACHOMETER

GENERAL

TOOL NAMEPART NUMBER
BREAKOUT BOXHD-42682 INSTRUMENT HARNESS AD APTERSHD-46601
The BREAKOUT BO X (P art No. HD-42682) and INSTR UMENT HARNESS ADAPTERS (Part No. HD-46601) connect to the speedometer connector [39] or tachometer connector [108]. Used in conjunction with a DVOM, the breakout box allows circuit diagnosis of wiring harness and connections without having to probe with sharp objects
NOTE
See wiring diagrams for speedometer and tachometer terminal functions.
SPEEDOMETER Installation
1. See Figure 2-9. Depress latch on connector [39B].
2. Connect instrument harness adapters to connectors [39A] and [39B].
3. Attach black connectors from Breakout Bo x to instrument harness adapters.
2.5
Figure 2-9. Speedometer Connector [39] (Typical)
Removal
1. Disconnect Breakout Box from instrument harness adapters.
2. Detach instrument harness adapters from connectors [39A] and [39B].
3. See Figure 2-9. Plug wire harness connector [39B] into speedometer connector [39A].
TACHOMETER Installation
1. Depress latch on connector [108B].
2. Connect instrument harness adapters to connectors [108A] and [108B].
3. Attach black connectors from Breakout Bo x to instrument harness adapters.
Removal
1. Disconnect Breakout Box from instrument harness adapters.
2. Detach instrument harness adapters from connectors [108A] and [108B].
3. Plug wire harness connector [108B] into tachometer con­nector [108A].
2-16 2008 Sportster Diagnostics: Instruments
Page 60

2.6INDICATOR LAMPS

2
3
1
ed02820

GENERAL

See Figure 2-10. Sportsters are equipped with LED indicator lamps which must be replaced as a complete assembly with harness. See the Service Manual for replacement procedure. See 2.6 INDICATOR LAMPS, Diagnostics for troubleshooting procedures.
Job/Time Code Values
Dealership technicians filing warranty claims should use the job/time code values printed in bold text underneath the appropriate repair.
1. LED assembly
2. Release latch (4)
3. Lamp bezel Figure 2-10. Indicator Lamp Assembly (Typical)

DIAGNOSTICS

TOOL NAMEPART NUMBER
HARNESS CONNECTOR TEST KITHD-41404-B
Table 2-5. Indicator Lamp Connector [20] Terminals
FUNCTIONWIRE COLORTERMINAL
ON [20]
Right turnBrown3 High beamWhite4 Left turnViolet5 Neutral/oil pressure powerOrange6 Neutral lamp to switchTan8 Oil pressure lamp to switchGreen/Yellow9 T urn signal/high beam groundBlack12
Table 2-6. Indicator Lamp Wiring
CONNECTIONINDICATOR LAMP
Ground through switchOil pressure Ground through switchNeutral 12 VDC when activeHigh beam 12 VDC when activeRight/left turn
Diagnostic Notes
Each reference number below correlates to a circled number on the flow chart(s).
1. Use HARNESS CONNECTOR TEST KIT (Part No. HD­41404-B), gray pin probe and patch cord.
2008 Sportster Diagnostics: Instruments 2-17
Page 61
TN
TN
BK
BK
BKBK
BK BK
BK
BK
BK
BN
BN
O
O
OOO
O
W
W
V
V
GN/Y
GN/Y
3 654 98 12
Main Harness Connector
[20A]
[39A]
[39B]
Speedometer
[108A]
Tachometer
(if equipped)
[108B]
1 7 1 7
1 7
Ignition
Ground
Ground
Ignition
1 7
em01121
2-18 2008 Sportster Diagnostics: Instruments
Figure 2-11. Indicator Lamp Circuitry
Table 2-7.Wire Harness Connectors
LOCATIONTYPEDESCRIPTIONNO.
Under fuel tank12-place MolexInstruments[20] Back of speedometer12-place PackardSpeedometer[39] Back of tachometer12-place PackardTachometer (if equipped)[108]
Page 62
Oil Pressure or Neutral Indicator Will Not Function
Turn on ignition switch. Check for 12 VDC at connector [20B]
terminal 6. Turn off ignition switch.
Was 12 VDC present?
1
YES
Check for continuity to ground at
Breakout Box terminal 8(Neutral) and
terminal 9(oil pressure).
Is continuity present?
YES
Replace indicator lamp.
NO
Check for open fuses or locate open circuit.
NO
Check each terminal for continuity
to ground through switch.
Is continuity present?
YES
NO
NO
Repair open in (GN/Y)
wire (oil pressure) or
(TN) wire (neutral).
Replace oil
pressure switch.
Replace neutral
switch.
5048
5191
5048
5161 5157
fc01068_en
2008 Sportster Diagnostics: Instruments 2-19
Page 63
High Beam or R/L Turn Signal Indicator Will Not Function
Check for ground at
connector [20B] terminal 12.
Is ground present?
YES NO
Check for 12 VDC when circuit is active:
Breakout Box terminal 5(left turn), terminal 3
(right turn) or terminal 4(high beam).
Is voltage present?
YES
Replace indicator lamp.
Locate and repair
open in circuit.
NO
Locate and repair
open in circuit.
1
5048
5191
5048
fc01069_en
2-20 2008 Sportster Diagnostics: Instruments
Page 64

2.7DTC B1004, B1005

ed02819

GENERAL

See Figure 2-12. The fuel level is monitored by the speedo­meter terminal "9" of connector [39] (Y/W).
If the voltage on terminal "9" of connector [39] exceeds the lower limit for greater than or equal to 15 seconds DTC B1004 will set.
If the voltage on terminal "9" of connector [39] exceeds the upper limit (or is open) for greater than or equal to 15 seconds DTC B1005 will set.
Table 2-8. Code Description
DESCRIPTIONDTC
Fuel level sending unit lowB1004 Fuel level sending unit high/openB1005

DIAGNOSTICS

TOOL NAMEPART NUMBER
HARNESS CONNECTOR TEST KITHD-41404-B BREAKOUT BOXHD-42682 INSTRUMENT HARNESS AD APTERSHD-46601
Diagnostic Tips
If fuel gauge is performing erratically (possible false DTCs), review Table 2-9 for proper functionality.
Diagnostic Notes
Each reference number below correlates to a circled number on the flow chart(s).
1. Use HARNESS CONNECTOR TEST KIT (Part No. HD­41404-B), brown pin probe and patch cord.
2. Connect BREAKOUT BOX (Part No. HD-42682) and INSTRUMENT HARNESS ADAPTERS (Part No. HD-
46601) between wire harness and speedometer.
Table 2-9.Testing Fuel Sender Resistor Assembly
[39B] PIN 2 RESISTANCE TO GROUNDFUEL LEVEL
2000 ohms ±200Low 10000 ohms ±200High
Figure 2-12. Speedometer Connector [39] (Typical)
2008 Sportster Diagnostics: Instruments 2-21
Page 65
1 2
6
5
9
7
1 2
6
5
9
7
[39A]
[39B]
[20A] [20B]
1
3
2
4
[91A]
1210
10
71 62
1271 62
3 2 1
3 2 1
41 32
41 32
[200A] [200B]
[141A]
[141B]
Ignition
Serial data
Battery
Accessory
Ground
Fuel level
Speedometer
12V
(Switched)
Accessory
Fuse
Battery
Fuse
Instrument
Fuse
12V
(Switched)
12V
(Switched)
12V
(BATT)
Ignition
Fuse
Fuel Pump
Fuse
[GND1]
[GND1]
[GND1]
System
Relay
BN/GY
R/GY
Data Link Connector
Fuel Pump And Low Fuel Switch
Fuel Sender
Resistor
Assembly
2000
2000
[86]
BK
BK
GY
BK
BK
BK
BK
Y/GN
Y/W
Y/W
Y/W
Y/W
Y/W
Y/R
O
R
O
LGN/V
LGN/V
LGN/VLGN/V
BN/GY
O/GY
R/BK
R/BK
O/W
O/W
ECM
Serial data
[78A]
[78B]
5
5
em01122
2-22 2008 Sportster Diagnostics: Instruments
Figure 2-13. Fuel Sender Circuitry
Table 2-10.Wire Harness Connectors
Under fuel tank12-place MolexInstruments[20] Back of speedometer12-place PackardSpeedometer[39] Under seat36-place PackardElectronic Control Module (ECM)[78] On battery strap, behind left side cover4-place DeutschData link connector[91A] Forward of relay/fuse blocks4-place MolexFuel pump and low fuel switch[141] Under seat3-place MolexFuel sender resistor assembly[200]
LOCATIONTYPEDESCRIPTIONNO.
Page 66
Fuel Level Sending Unit Low: DTC B1004
Disconnect speedometer connector [39].
Measure resistance between terminal 2
of connector [141B] and ground.
Is resistance between 1800 and 10200 ohms?
YES NO
Replace fuel levelswitch.
6035
Disconnect [200].
Continuity to ground?
NO YES
Replace fuel sender
resistor assembly.
Locate and repair short to
ground in harness.
6083 7182
Clear DTCs using speedometer self diagnostics. See 2.3 SPEEDOMETER SELF DIAGNOSTICS. Confirm proper operation with no check engine lamp.
fc01070_en
2008 Sportster Diagnostics: Instruments 2-23
Page 67
Fuel Level Sending Unit High/Open: DTC B1005
Disconnect Speedometer connector [39].
Measure voltage on terminal 2of connector
[141B] (Y/W). Should be 0 volts.
Is it?
YES NO
Check continuity between terminal 2of connector [141B] (Y/W) and
Breakout Box terminal 11(BK).
Continuity present?
Locate and repair short
to voltage.
YES NO
Check continuity to ground on terminal
4of connector [141B] (BK).
Is continuity present?
Locate and repair short
to voltage.
YES NO
Replace fuel sender
resistor assembly.
Locate and repair open on
(BK) wire (ground circuit).
1
1
2
1
6083
6069
6069
6069
Clear DTCs using speedometer self diagnostics. See 2.3 SPEEDOMETER SELF DIAGNOSTICS. Confirm proper operation with no check engine lamp.
fc01071_en
2-24 2008 Sportster Diagnostics: Instruments
Page 68

2.8DTC B1006, B1007

GENERAL Accessory or Ignition Line Overvoltage
Ignition and accessory voltage is constantly monitored by the speedometer (terminal "1" ignition and terminal "6" accessory). If the battery voltage fails to meet normal operating parameters, a Diagnostic Trouble Code (DTC) is set.
DTC B1006 is displayed when accessory line voltage is greater than 16.0 volts for longer than 5 seconds.
DTC B1007 is displayed when ignition line voltage is greater than 16.0 volts for longer than 5 seconds.
NOTE
ECM or TSM/TSSM/HFSM ma y also set a battery voltage DTC.
Table 2-11. Code Description
DESCRIPTIONDTC
Accessory line overvoltageB1006 Ignition line overvoltageB1007
2008 Sportster Diagnostics: Instruments 2-25
Page 69
Accessory or Ignition Line Overvoltage: DTC B1006, 1007
Has battery charger been
recently connected?
YES NO
Diagnose charging system.
See 1.7 CHARGING SYSTEM.
NOTE: Sometimes battery charger
may cause over voltage condition
which will set codes.
Clear codes.
Start vehicle. Run at 3000
RPM for 5 seconds.
Does code reset?
YES NO
Diagnose charging system.
See 1.7 CHARGING SYSTEM.
System normal.
Clear DTCs using speedometer self diagnostics. See 2.3 SPEEDOMETER SELF DIAGNOSTICS. Confirm proper operation with no check engine lamp.
fc01072_en
2-26 2008 Sportster Diagnostics: Instruments
Page 70

2.9DTC B1008

ed02816
8118
11
TRIP SW
TRIP SW
[39A]
[39B]
Speedometer
Reset Switch
BK
BK
em01123
GENERAL Trip Odometer Reset Switch Closed
Diagnostic Trouble Code (DTC) B1008 will be set if trip odo­meter reset switch terminals are in a constant shorted state.
Figure 2-14.Trip Odometer Reset Switch (Typical)
Table 2-12. Code Description
1. Disconnect speedometer connector [39] (at the back of the speedometer). See 2.5 BREAKOUT BOX: SPEEDO-
METER/TACHOMETER.
2. Connect BREAKOUT BOX (Part No. HD-42682) (black) to wire harness connector [39B] using INSTRUMENT HARNESS ADAPTERS (Part No. HD-46601), leaving
speedometer disconnected.
DESCRIPTIONDTC
Trip odometer reset switch closedB1008

DIAGNOSTICS

TOOL NAMEPART NUMBER
BREAKOUT BOXHD-42682 INSTRUMENT HARNESS AD APTERSHD-46601
Diagnostic Notes
Each reference number below correlates to a circled number on the flow chart(s).
Figure 2-15.Trip Odometer Reset Switch Circuit
2008 Sportster Diagnostics: Instruments 2-27
Page 71
Table 2-13.Wire Harness Connectors
LOCATIONTYPEDESCRIPTIONNO.
Back of speedometer12-place PackardSpeedometer[39]
2-28 2008 Sportster Diagnostics: Instruments
Page 72
Trip Odometer Reset Switch Closed: DTC B1008
Remove trip odometer reset switch rubber boot.
Clear codes. See 2.3 SPEEDOMETER
SELF DIAGNOSTICS.
Are codes still present?
Clear DTCs using speedometer self diagnostics. See 2.3 SPEEDOMETER SELF DIAGNOSTICS. Confirm proper operation with no check engine lamp.
YES NO
With speedometer connector [39] disconnected,
measure resistance between Breakout Box
terminal 8and 11' (black).Resistance should be
less than 1 ohm with switch depressed and infinity
ohms when released. Is it?
1
YES NO
Replace Speedometer.
Replace trip odometer
reset switch.
Replace boot.
fc01073_en
2
2008 Sportster Diagnostics: Instruments 2-29
Page 73

GENERAL

ed01340
4
3
2
1
5
ed02824
ed02819
Loss of ECM Serial Data
The serial data line provides a means for the Electronic Control Module (ECM), TSM/TSSM/HFSM, and speedometer to com­municate their current status.When all operating parameters on the serial data line are within specifications, a state of health message is sent between the components. A Diagnostic Trouble Code (DTC) U1016 indicates that the ECM is not capable of sending this state of health message. A DTC U1255 indicates that no messages were present during power up of the current key cycle. A DTC U1016 indicates that there was communication on the data bus since power up, but commu­nication was lost or interrupted during that key cycle.

2.10DTC U1016, U1255

Table 2-14. Code Description
DESCRIPTIONDTC
Loss of all ECM serial data (state of health)U1016 Serial data error/missing messageU1255

DIAGNOSTICS

TOOL NAMEPART NUMBER
BREAKOUT BOXHD-42682 INSTRUMENT HARNESS AD APTERSHD-46601 ECM BREAKOUT BOXHD-48637
Diagnostic Notes
Each reference number below correlates to a circled number on the flow chart(s).
1. Connect BREAKOUT BOX (Part No. HD-42682) (black) between speedometer connector [39A] (at the back of the speedometer) and wire harness connector [39B] using INSTRUMENT HARNESS ADAPTERS (Part No. HD-
46601). See 2.5 BREAKOUT BOX: SPEEDO-
METER/TACHOMETER.
2. Use ECM BREAKOUT BOX (Part No. HD-48637).
1. Terminal 1: no connection
2. Terminal 2: ground (BK)
3. Terminal 3: serial data (LGN/V)
4. Terminal 4: power (GY)
5. Protective cap Figure 2-17. Data Link Connector [91A] Terminals
Figure 2-16. Data Link Connector [91A] (Behind Left Side
Cover)
2-30 2008 Sportster Diagnostics: Instruments
Figure 2-18. Speedometer Connector [39] (Typical)
Page 74
BK
BK
BK
GY GY
GY
O/W
O/W
O/W
O
O
R
BN/GY
BN/GYBN/GY
BN/GY BN/GY
LGN/V
BK
BK
BK
O/W
O
O
BN/GY
LGN/V
LGN/V
LGN/V
LGN/V
LGN/V
LGN/V
R/BK
R/BK
R/GY
1 2 3 12
1 2 3 12
1 2 5 76
1 2 5 76
1 2 5 6 7
1 2 5 6 7
Ignition
Serial data
Battery
Accessory
Ground
Ignition
Serial data
Battery
Battery
Ignition
Serial data
Ground
Accessory
Ground
[39B]
[39A]
[108B]
[108A]
[30B]
[30A]
[91A]
Speedometer
TSM/TSSM/HFSM
Tachometer (Optional)
To ACCY fuse
To BATT fuse
To INSTR fuse
To IGN fuse
12V ACCY
Fuse
12V BATT
Fuse
12V INSTR
Fuse
12V IGN
Fuse
3
1 2
4
Data Link Connector
21 6 7
12
21 6 7 12
[20A] [20B]
ECM
Serial data
[78A]
[78B]
5
5
[GND1]
[GND1]
[GND1]
em01120
Figure 2-19. Serial Data Circuit
Table 2-15.Wire Harness Connectors
Under fuel tank12-place MolexInstruments[20] Under battery12-place DeutschTSM/TSSM/HFSM[30] Back of speedometer12-place PackardSpeedometer[39] Under seat36-place PackardElectronic Control Module (ECM)[78] On battery strap, behind left side cover4-place DeutschData link connector[91A] Back of tachometer12-place PackardTachometer (if equipped)[108]
LOCATIONTYPEDESCRIPTIONNO.
2008 Sportster Diagnostics: Instruments 2-31
Page 75
Loss of ECM Serial Data: DTC U1016, U1255
Can you read ECM hardware Part No.?
See 2.3 SPEEDOMETER SELF DIAGNOSTICS.
YES NO or No Rsp
While wiggling harness, check
continuity between Breakout Box
terminal 2(Black) and terminal 5of
ECM Breakout Box.
Is continuity present?
Check continuity between
Breakout Box terminal 2" (Black)
and terminal 5of ECM
Breakout Box.
Is continuity present?
YES NO
Clear codes. Test ride.
Does DTC U1016
return?
Repair intermittent
on (LGN/V) wire.
YES
Replace ECM.
Reprogram and learn
password.
No trouble found.
NO
1
2
1
2
YES NO
Replace ECM.
Reprogram and learn
password.
Repair open on
(LGN/V) wire.
Clear DTCs using speedometer self diagnostics. See 2.3 SPEEDOMETER SELF DIAGNOSTICS. Confirm proper operation with no check engine lamp.
fc01083_en
2-32 2008 Sportster Diagnostics: Instruments
Page 76

GENERAL

ed02825
ed01340
Loss of TSM/TSSM/HFSM Serial Data
The serial data line provides a means for the Electronic Control Module (ECM), TSM/TSSM/HFSM, and speedometer to com­municate their current status.When all operating parameters on the serial data line are within specifications, a state of health message is sent between the components. A Diagnostic Trouble Code (DTC) U1064 indicates that the TSM/ TSSM/HFSM is not receiving this state of health message. A DTC U1255 indicates that no messages were present during power up of the current key cycle . A DTC U1064 indicates that there was communication on the data bus since power up , b ut communication was lost or interrupted during that key cycle.
Table 2-16. Code Description
DESCRIPTIONDTC
Loss of TSM/TSSM/HFSM serial dataU1064 Serial data error/missing messageU1255

DIAGNOSTICS

TOOL NAMEPART NUMBER
BREAKOUT BOXHD-42682 INSTRUMENT HARNESS AD APTERSHD-46601

2.11DTC U1064, U1255

Figure 2-20.TSM/TSSM/HFSM Location
Diagnostic Notes
Each reference number below correlates to a circled number on the flow chart(s).
1. Connect BREAKOUT BOX (Part No. HD-42682) as fol­lows:
a. Mate black socket housing on Breakout Box with
speedometer connector [39A] (at the back of the speedometer) using INSTRUMENT HARNESS ADAPTERS (Part No. HD-46601).
b. Mate black pin housing on Breakout Box with wire
harness connector [39B] using INSTRUMENT HAR­NESS ADAPTERS (Part No. HD-46601).
c. See Figure 2-20. Mate gray socket housing on
Breakout Box with TSM/TSSM/HFSM connector [30A].
d. Mate gray pin housing on Breakout Box with wire
harness connector [30B].
Figure 2-21. Data Link Connector [91A] (Behind Left Side
Cover)
2008 Sportster Diagnostics: Instruments 2-33
Page 77
4
3
2
1
5
ed02824
1. Terminal 1: no connection
2. Terminal 2: ground (BK)
3. Terminal 3: serial data (LGN/V)
4. Terminal 4: power (GY)
5. Protective cap Figure 2-22. Data Link Connector [91A] Terminals
2-34 2008 Sportster Diagnostics: Instruments
Page 78
BK
BK
BK
GY GY
GY
O/W
O/W
O/W
O
O
R
BN/GY
BN/GYBN/GY
BN/GY BN/GY
LGN/V
BK
BK
BK
O/W
O
O
BN/GY
LGN/V
LGN/V
LGN/V
LGN/V
LGN/V
LGN/V
R/BK
R/BK
R/GY
1 2 3 12
1 2 3 12
1 2 5 76
1 2 5 76
1 2 5 6 7
1 2 5 6 7
Ignition
Serial data
Battery
Accessory
Ground
Ignition
Serial data
Battery
Battery
Ignition
Serial data
Ground
Accessory
Ground
[39B]
[39A]
[108B]
[108A]
[30B]
[30A]
[91A]
Speedometer
TSM/TSSM/HFSM
Tachometer (Optional)
To ACCY fuse
To BATT fuse
To INSTR fuse
To IGN fuse
12V ACCY
Fuse
12V BATT
Fuse
12V INSTR
Fuse
12V IGN
Fuse
3
1 2
4
Data Link Connector
21 6 7
12
21 6 7 12
[20A] [20B]
ECM
Serial data
[78A]
[78B]
5
5
[GND1]
[GND1]
[GND1]
em01120
Figure 2-23. Serial Data Circuit
Table 2-17.Wire Harness Connectors
LOCATIONTYPEDESCRIPTIONNO.
Under fuel tank12-place MolexInstruments[20] Under battery12-place DeutschTSM/TSSM/HFSM[30] Back of speedometer12-place PackardSpeedometer[39] Under seat36-place PackardElectronic Control Module (ECM)[78] On battery strap, behind left side cover4-place DeutschData link connector[91A] Back of tachometer12-place PackardTachometer (if equipped)[108]
2008 Sportster Diagnostics: Instruments 2-35
Page 79
Loss of TSM/TSSM/HFSM Serial Data: DTC U1064, U1255
Can you read TSM/TSSM/HFSM hardware Part No.?
See 2.3 SPEEDOMETER SELF DIAGNOSTICS.
YES NO
While wiggling harness, check for continuity
between Breakout Box terminal 3(Gray) and
Breakout Box terminal 2(Black).
Is continuity present?
Check for continuity between
Breakout Box terminal 3(Gray) and
Breakout Box terminal 2(Black).
Is continuity present?
YES NO
Clear codes. Test ride.
Does DTC U1064
return?
Repair intermittent
on (LGN/V) wire.
YES NO
Replace ECM.
Reprogram and learn
password.
No trouble found.
YES NO
Replace TSM/TSSM/
HFSM. Perform
password learn.
Repair open on
(LGN/V) wire.
1
1
Clear DTCs using speedometer self diagnostics. See 2.3 SPEEDOMETER SELF DIAGNOSTICS. Confirm proper operation with no check engine lamp.
fc01084_en
2-36 2008 Sportster Diagnostics: Instruments
Page 80

GENERAL

ed01340
4
3
2
1
5
ed02824
Serial Data Low or Serial Data Open/High
The typical serial data voltage range is 0 volts (inactive) to 7 volts (active). Due to the short pulse, voltages will be much lower on a DVOM. In analog mode, a DVOM reading serial data will show continuous voltage when active, typically 0.6-
0.8 volts.The range for acceptable operations is 0-7.0 volts.
Table 2-18. Code Description
DESCRIPTIONDTC
Serial data lowU1300 Serial data open/highU1301

2.12DTC U1300, U1301 OR BUS ER

1. Terminal 1: no connection
2. Terminal 2: ground (BK)
3. Terminal 3: serial data (LGN/V)
4. Terminal 4: power (GY)
5. Protective cap Figure 2-25. Data Link Connector [91A] Terminals
Figure 2-24. Data Link Connector [91A] (Behind Left Side
Cover)
DIAGNOSTICS Diagnostic Tips
If serial data is shorted, these Diagnostic Trouble Codes (DTCs) will automatically cause the check engine lamp to illuminate.The odometer will read "BUS Er" in this condi­tion.
DTCs P1009 and P1010 may accompany DTCs U1300 and U1301.
Diagnostic Notes
If a U1300, U1301 or "BUS Er" is present, perform diagnostic procedures listed in 4.12 STARTS, THEN STALLS.
2008 Sportster Diagnostics: Instruments 2-37
Page 81
NOTES
2-38 2008 Sportster Diagnostics: Instruments
Page 82
SUBJECT............................................................................................................................PAGE NO.
3.1 TURN SIGNAL OVERVIEW.......................................................................................................3-1
3.2 HARLEY-DAVIDSON SMART SECURITY SYSTEM.................................................................3-2
3.3 H-DSSS ACTUATION................................................................................................................3-5
3.4 PERSONAL IDENTIFICATION NUMBER (PIN)........................................................................3-6
3.5 ARMING/DISARMING SECURITY SYSTEM............................................................................3-8
3.6 WARNINGS AND ALARMS.....................................................................................................3-10
3.7 SERVICE/EMERGENCY FUNCTIONS...................................................................................3-11
3.8 TROUBLESHOOTING.............................................................................................................3-12
3.9 CHECKING FOR DIAGNOSTIC TROUBLE CODES..............................................................3-13
3.10 INITIAL DIAGNOSTIC CHECK:TSM/HFSM.........................................................................3-16
3.11 SPEEDOMETER SELF DIAGNOSTICS...............................................................................3-22
3.12 BREAKOUT BOX:TSM/HFSM..............................................................................................3-24
3.13 FAILS TO DISARM (HFSM ONLY)........................................................................................3-26
3.14 DTC B0563............................................................................................................................3-29
3.15 TSM/HFSM:TURN SIGNAL ERRORS AND DTCS..............................................................3-30
3.16 DTC B1131, B1132 (HFSM ONLY)........................................................................................3-46
3.17 DTC B1134............................................................................................................................3-49
3.18 DTC B1135............................................................................................................................3-52
3.19 DTC B1136, B1142 (HFSM ONLY)........................................................................................3-53
3.20 DTC B1141 (HFSM ONLY)....................................................................................................3-54
3.21 DTC B1143, B1144, B1145 (HFSM ONLY)...........................................................................3-57
3.22 DTC B1154, B1155...............................................................................................................3-62
3.23 DTC U1016, U1255...............................................................................................................3-66
3.24 DTC U1300, U1301 OR BUS ER..........................................................................................3-69
3.25 TSM/HFSM: PASSWORD LEARN.........................................................................................3-70
3.26 HFSM MAINTENANCE.........................................................................................................3-71

TSM/HFSM

Page 83
NOTES
Page 84

3.1TURN SIGNAL OVERVIEW

GENERAL

The Turn Signal Module (TSM) has two major functions:
Control turn signals.
Serve as Bank Angle Sensor (BAS).
The optional, factory-installed, Harley-Davidson Smart Security System (H-DSSS) includes a Hands-Free Security Module (HFSM) which provides the same functions as the TSM, but also includes security and immobilization functions.

SECURITY SYSTEM: JAPAN/KOREA

The security system on motorcycles sold in Japan and Korea meet the regulatory requirements for those countries. The system incorporates a Tur n Signal Security Module (TSSM). Complete details on operation, troubleshooting, and diagnostics are found in E.1 TSM/TSSM (JAPAN/KOREA) OVERVIEW.

TURN SIGNAL FUNCTIONS

Manual turn signal control: Manual activation/deactiv a- tion of left and right turn signal flashing sequences.
Automatic turn signal cancellation: Automatic cancella- tion of left and right turn signal flashing sequences based on either vehicle speed, vehicle acceleration or turn com­pletion.
Hazard warning 4-way flashers: Four-way left and right turn signal flashing capability.
T urn signal lamp diagnostics: Self-diagnostics for short circuit and open lamp conditions on both left and right turn signal systems. See 3.9 CHECKING FOR DIAGNOSTIC
TROUBLE CODES.
NOTE
The turn signals cannot be activated or deactivated when the Ignition Switch is in the ACC position. The turn signals can only be activated or deactivated with the Ignition Switch in the IGNITION position.

MANUAL CANCELLATION

To stop the turn signals from flashing, briefly depress the turn signal switch a second time.
To switch turn direction signals, depress the switch for the opposite turn signal. The first signal is cancelled and the opposite side begins flashing.

AUTOMATIC CANCELLATION

Press the left or right turn switch to activate automatic turn signal cancellation.There is no need to hold the turn switch in when approaching the turn. The TSM/HFSM will not cancel the signal before the turn is actually completed.
When the directional switch is released, the system starts a 20 count. As long as the vehicle is traveling above 7
MPH (11.3 km/h) the directional will always cancel after 20 flashes if the system does not recognize any other input.
If the vehicle speed drops to 7 MPH (11.3 km/h) or less, including stopped, the directionals will continue to flash. Counting will resume when vehicle speed reaches 8 MPH (12.9 km/h) and will automatically cancel when the count total equals 20 as stated above.
The turn signals will cancel within two seconds upon turn completion. A sensor inside the TSM/HFSM cancels the signal after the vehicle has been returned to an upright position.
NOTE
The bank angle cancellation function has an automatic calibra­tion feature. Ride the motorcycle for 0.25 miles (0.4 km) at steady speeds (upright) to calibrate the system. Performance of bank angle function may not be optimal until this calibration is performed. This self-calibration is performed automatically every time the vehicle is started and ridden.

BANK ANGLE FUNCTIONS

Emergency engine shutdown: Will provide engine shutdown when vehicle is tipped over.
Emergency outputs disable: Will disable turn signal lamps and starter motor when vehicle is tipped over.

BANK ANGLE RESTART

The engine will shut off automatically if the vehicle is tipped over .The turn signals, starter motor, Electronic Control Module (ECM), fuel pump and coil will be disabled.
The odometer displays "tIP" when a tip over condition is detected.
To restart the motorcycle after shutdown has occurred:
1. Return the motorcycle to an upright position.
2. Cycle the Ignition Switch OFF-ON before restarting the motorcycle.

CLUTCH/NEUTRAL INTERLOCK

Disables starter: Disables starter until either the clutch lever is pulled in or transmission neutral is selected.
Diagnostics: Provides diagnostics for clutch and neutral switch faults.

SECURITY SYSTEM H-DSSS

See 3.2 HARLEY-DAVIDSON SMART SECURITY SYSTEM.
2008 Sportster Diagnostics: TSM/HFSM 3-1
Page 85

COMPONENTS

ed02826
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The Harley-Davidson Smart Security System (H-DSSS) con­sists of three components:
Hands-Free Security Module: See Figure 3-1. A elec- tronic module that functions both as the Turn Signal Module (TSM) and as the Hands-Free Security Module (HFSM).
Hands-Free Antenna: See Figure 3-1. Mounted under the seat of the motorcycle.
Hands-Free Fob: See Figure 3-2. A remote control de vice, intended to be carried by the rider whenever the vehicle is being operated.
NOTE
Do not relocate any of the Security System components.

3.2HARLEY-DA VIDSON SMART SECURITY SYSTEM

Figure 3-1. HFSM and Antenna
Figure 3-2. Hands-Free Fob w/Serial Number Label

SECURITY IMMOBILIZATION

The Hands-Free Security System (HFSM) provides security and immobilization functions not found on the Turn Signal Module (TSM).The HFSM will disable the starter and ignition system. Additional functions include the ability to alternately flash the left and right turn signals and sound a siren (if equipped) if a theft attempt is detected.
NOTE
The siren must be in the Chirp Mode for the siren to chirp on arming or disarming. See 3.6 WARNINGS AND ALARMS,
Siren Chirp Mode (Confirmation).
Conditions that activate the security system when system is armed include:
Detecting tampering of the ignition circuit:Turn signals flash three times, optional siren chirps once and then turns off. If the tampering continues, a second warning will activate after four seconds. Contin ued tampering will cause the alarm to activate for 30 seconds and then turn off.The two warnings/alarm cycle is repeated for each tampering incident.
Detecting vehicle movement: Turn signals flash three times, optional siren chirps once and then turns off. If the vehicle is not returned to its original position, a second warning will activate after four seconds. If the vehicle is not returned to its original position, the alarm activates for 30 seconds then turns off.The two warnings/alarm cycle may repeat a maximum of 10 times with a 10 second pause between cycles.
Detecting that a battery or ground disconnect has occurred while armed: Siren, if installed, activates its
self-alarm mode.Turn signals will not flash.
3-2 2008 Sportster Diagnostics: TSM/HFSM
Page 86
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ed02047
See 3.5 ARMING/DISARMING SECURITY SYSTEM for more information.
NOTE
Disconnect the battery to prevent the siren (if installed) from activating within 5 seconds of turning the Ignition Switch to OFF/FORK LOCK. If the HFSM is armed, you must turn the Ignition Switch to IGNITION with a fob within range, again turn the Ignition Switch to OFF/FORK LOCK and remove the MAXIFUSE before the 5-second arming period expires.With the MAXIFUSE removed, the battery can be disconnected.

HFSM FEATURES

The following inf ormation applies only to motorcycles equipped with the Hands-Free Security System (HFSM).
Security lamp: See Figure 3-3. A lamp (key icon) within the speedometer face tells the rider if the system is armed or disarmed.
Personal code disarming: If the f ob is not available, the HFSM allows the rider to disable the security alarm and immobilization functions with a five-digit personal code.
Arming confirmation: When the HFSM is armed, the system provides visual feedback (confirmation) to the rider by flashing the turn signals and an audible "chirp" if equipped with the optional smart siren and chirp mode is enabled.
Disarming confirmation: When the HFSM is disarmed, the system provides an audible "chirp" (confirmation) if equipped with the optional smart siren and chirp mode is enabled.
T ransport mode: It is possible to arm the security system without enabling the motion detector for one ignition cycle. This allows the vehicle to be moved in an immobilized state.
Starter/ignition disable: When armed the starter and ignition system are disabled.
Security system alarm: See Figure 3-4.The system will alternately flash the left and right turn signals and sound an optional Security Siren if a vehicle security condition is detected while the system is armed.
Dealer service mode: This mode allows the dealer to disable security system via Digital Technician. Dealer service mode is exited when module detects an assigned fob in range.
Figure 3-3. Security Lamp (Key Icon)
Figure 3-4. Security Siren
2008 Sportster Diagnostics: TSM/HFSM 3-3
Page 87
1
3
3
Battery
Serial
data
Serial
data
+ -
Battery
Fuse
15A
IGN Fuse
15A
ACC Fuse
15A
421
2
1 Receive antenna
Transmit antenna A
Transmit antenna B
3
2
121
2
5
2 2
5
12
4
7
8
2
1
3
12
4
7
8
2
1
3
BB
6
5
9
10
11
6
5
9
10
11
30 Amp MAXIFUSE
Fuse
Block
Ignition
Switch
Data Link
Connector
ECM
Speedometer
Right Turn
Switch
Clutch
Switch
SecuritySiren (Optional)
Left Turn
Switch
Neutral
Switch
Receive
Hands
Free
Antenna
HFSM
TSM/HFSM
Right Turn
Lamps
Left Turn
Lamps
BK
BK
BN BN
BN
BN
BN
BK BK
BK
BK
BK
BK
BK
BK
GY
TN
R
V
V
V
V V
RRR
R/BK
R/GY
BK/R
BN/GY
LGN/V LGN/V
LGN/BN
LGN/V LGN/V
LGN/V
Y/BK
O/Y
O/W
O/W
W/BN
W/V
O/W
[78B] [78A]
[91A]
[39A] [39B]
[209B] [209A]
[208B] [208A]
[142B] [142A]
[30B] [30A] [30A] [30B]
Alarm signal
Battery
Clutch
switch
Ignition
Start relay
control
Left turn switch input
Right turn switch input
Serial data
Left turn
feed
Neutral switch
Right turn
feed
Ground
30
87
86
85
Start Relay
Starter
Engine
Stop Switch
Start
Switch
To
battery
positive
To
ignition
switch
To
ignition
fuse
To
ECM
GN
BK
GY
BK
R/BK
W/BK
W/BKW/BK
BK/R
TN/GN
em01147
Figure 3-5. Simplified TSM/HFSM Wiring
3-4 2008 Sportster Diagnostics: TSM/HFSM
Page 88

3.3H-DSSS ACTUATION

GENERAL

Setting up a vehicle TSM/HFSM depends on whether the vehicle has a Turn Signal Module (TSM) or the optional Hands­Free Security Module (HFSM) security system installed.

SIDECAR CONFIGURATION

Only Touring Harley-Davidson Motorcycles are suitable for sidecar use. Consult a Harley-Davidson dealer. Use of motorcycles other than Touring models with sidecars could result in death or serious injury. (00040a)
All motorcycles ship with the H-DSSS set for use without a sidecar installed. If a motorcycle is equipped with a TSM, no further actuation is required.

ACTUATION

Actuation consists of assigning two fobs to the system, and entering an initial Personal Identification Number (PIN). The PIN can be changed by the rider at any time.
1. Configure HFSM motorcycles by assigning both fobs to the vehicle.
2. Configure HFSM motorcycles by entering a PIN picked by the owner. The personal code allows the owner to operate the system if the fob is lost or inoperable . Record the PIN in the Owner's Manual and instruct the customer to carry a copy (use the wallet card found in the Owner's Manual). See 3.4 PERSONAL IDENTIFICATION NUMBER
(PIN).
Once the system has been activated, it will always "arm" within 5 seconds of turning the Ignition Switch to OFF and no motor­cycle motion.

FOB ASSIGNMENT

TOOL NAMEPART NUMBER
DIGITAL TECHNICIANHD-44750
Use DIGITAL TECHNICIAN (Part No. HD-44750) to assign both fobs to the H-DSSS. Follow the menu prompts in the Digital Technician display and scan the fob serial number with the bar code reader, or key-in the number from the keyboard. See a Harley-Davidson dealer.
NOTE
Each fob has a unique serial number. The label should be removed from the fob and attached to a blank NOTES page in the Owner's Manual for reference.

POWER DISRUPTION AND CONFIGURING

TOOL NAMEPART NUMBER
BREAKOUT BOXHD-42682
The HFSM will not enter PIN entry mode on the first attempt after battery voltage has been removed from terminal "1".This will occur after any of the following:
Battery disconnect or power drain.
Battery fuse removal.
Connecting BREAKOUT BOX (Part No. HD-42682) to
HFSM connector.
Therefore, after all battery reconnects, the configuration sequence must be modified as follows:
1. Set Engine Stop Switch to OFF, cycle Ignition Switch IGNITION-OFF-IGNITION-OFF-IGNITION and press left turn signal switch twice.
2. Repeat steps listed above.
3. Continue with PIN entry sequence listed.
2008 Sportster Diagnostics: TSM/HFSM 3-5
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3.4PERSONAL IDENTIFICATION NUMBER (PIN)

GENERAL

The Personal Identification Number (PIN) consists of fiv e digits. Each digit can be any number from 1-9.There can be no zeros (0) in the PIN. The PIN must be used to disarm the secur ity system in case the fob becomes unavailable.
Table 3-1. Entering an Initial PIN: HFSM
1
6
8
10
12
14
Select a 5-digit (1 through 9) initial PIN and record in the Owner's Manual and on the wallet card.
With an assigned fob present, set Engine Stop Switch to OFF.2 Cycle Ignition Switch IGNITION-OFF-IGNITION-OFF-IGNITION.3
Press right turn signal button 1 time.5
Enter first digit (a) of initial PIN by pressing left turn signal button until desired digit is displayed in odometer.
Press right turn signal button 1 time.7
Enter second digit (b) of initial PIN by pressing left turn signal button until desired digit is displayed in odometer.
Press right turn signal button 1 time.9
Enter third digit (c) of initial PIN by pressing left turn signal button until desired digit is displayed in odometer.
Press right turn signal button 1 time.11
Enter fourth digit (d) of initial PIN by pressing left turn signal button until desired digit is displayed in odometer.
Press right turn signal button 1 time.13
Enter fifth digit (e) of initial PIN by pressing left turn signal button until desired digit is displayed in odometer.
Press right turn signal button 1 time.15
Turn the Ignition Switch to OFF.16

INITIAL PIN ENTRY

T o enter a PIN on a motorcycle with no PIN pre viously installed during HFSM actuation, refer to Table 3-1.
CONFIRMATIONACTIONSTEP
Turn signals will flash 3 times.Press left turn signal button 2 times.4 Five dashes will appear in the odometer
window.The first dash will flash.
The digit (a) will replace the dash in the odometer.The second dash will flash.
The digit (b) will replace the dash in the odometer.The third dash will flash.
The digit (c) will replace the dash in the odometer.The fourth dash will flash.
The digit (d) will replace the dash in the odometer.The fifth dash will flash.
The digit (e) will replace the dash in the odometer.The first digit will flash.

CHANGING THE PIN

To change a PIN, refer to Table 3-2.The rider can change the PIN at any time.
Modifying an Existing Pin
If a PIN was previously entered, the odometer will display the equivalent digit. Each additional press of the left turn switch will increment the digit.
3-6 2008 Sportster Diagnostics: TSM/HFSM
Examples:
To advance from 5 to 6, press and release the left turn switch 1 time.
To advance from 8 to 2, press and release the left turn switch 3 times (9-1-2).
Page 90
Select a 5-digit (1 thru 9) personal code
1
and record in the Owner's Manual and on the wallet card.
With fobs present, cycle Ignition Switch
2
IGNITION-OFF-IGNITION-OFF-IGNITION.
Press right turn signal button 1 time.4
Enter first digit (a) of new PIN by pressing
5
left turn signal button until desired digit is displayed in odometer.
Press right turn signal button 1 time.6
Enter second digit (b) of new PIN by
7
pressing left turn signal button until desired digit is displayed in odometer.
Press right turn signal button 1 time.8
Enter third digit (c) of new PIN by pressing
9
left turn signal button until desired digit is displayed in odometer.
Press right turn signal button 1 time.10
Enter fourth digit (d) of new PIN by
11
pressing left turn signal button until desired digit is displayed in odometer.
Press right turn signal button 1 time.12
Enter fifth digit (e) of new PIN by pressing
13
left turn signal button until desired digit is displayed in odometer.
Press right turn signal button 1 time.14
Turn the Ignition Switch to OFF.15
Table 3-2. Changing the PIN: HFSM
NOTESCONFIRMATIONACTIONSTEP
Turn signals will flash 3 times.Press left turn signal button 2 times.3 Current PIN will appear in odometer.The
first digit will flash.
The new digit will replace the current in the odometer.The second digit will flash.
The new digit will replace the current in the odometer.The third digit will flash.
The new digit will replace the dash in the odometer.The fourth digit will flash.
The new digit will replace the current in the odometer.The fifth digit will flash.
The new digit will replace the current in the odometer.The first digit will flash.
Turning Ignition Switch to OFF stores PIN.
2008 Sportster Diagnostics: TSM/HFSM 3-7
Page 91

3.5ARMING/DISARMING SECURITY SYSTEM

ed02829
ed02920

HANDS-FREE FOB

See Figure 3-6. The HFSM's reception range for the Hands­Free Fob signal depends on a specific receiver pattern. The range will be an arm's length.
NOTES
Environmental and geographic conditions may aff ect signal range.
Always have the fob present whenever the motorcycle is operated.
Do not place fob in metal enclosure, and do not place it closer than 3.0 in. (80.0 mm) to the hands-free antenna, cellular phones, PDAs, displays and other electronic devices while operating the motorcycle.That may prev ent the fob from disarming the security system.
Fob battery should be replaced every year. See
3.26 HFSM MAINTENANCE.
Table 3-3. Security Lamp Status
Does not flash.
Flashes every second.
seconds.
second. Stays on solid with
Ignition Switch OFF.
Stays on solid with Ignition Switch ON.
MODELAMP
No security system (TSM only), security system not armed.
T wo min ute timeout after failed PIN entry attempt or a battery reconnect has occurred while armed.
Security system armed.Flashes every 2.5
PIN entry mode.Flashes 4 times a
Arming is starting up. You have 5 seconds before system is armed.
If solid for more than 4 seconds after Ignition Switch is turned to IGNITION, a current DTC is present.
Figure 3-6. Hands-Free Fob

SECURITY LAMP (KEY ICON)

Refer to Table 3-3. See Figure 3-7. The security lamp (key icon) in the speedometer face provides feedback to the rider confirming armed or disarmed status.
3-8 2008 Sportster Diagnostics: TSM/HFSM
Figure 3-7. Security Lamp (Key Icon)

ARMING

The H-D Smart Security System automatically arms within five seconds when the motorcycle is parked and the Ignition Switch is turned to OFF and motion is not detected.
Confirmation: On arming, the turn signals flash twice and the Security Siren will "chirp" twice if chir p function is activated. While armed, the security lamp (key icon) will flash every 2.5 seconds. Refer to Table 3-3.
Page 92

DISARMING

There are two ways to disarm the H-D Smart Security System:
Automatic disarming.
is activated) and the security lamp (key icon) will turn ON solid for four seconds then go out. Refer to Table 3-3.
Disarming with a Personal Identification Number (PIN)
Disarming with a Personal Identification Number (PIN).
Automatic Disarming
Always have the fob present when riding, loading, fueling, moving, parking or servicing the motorcycle. Carry the fob in a convenient pock et.The H-D Smart Security System disarms automatically when the Ignition Switch is turned to IGNITION. On disarming, the Security Siren will chirp once (if chirp function
Table 3-4. Entering the PIN to Disarm HFSM (Example: 3-1-3-1-3)
Set Engine Stop Switch to OFF.1 Turn Ignition Switch to IGNITION.2
3
4
6
8
10
12
* This must be done within two seconds of turning the Ignition Switch to IGNITION. If system issues a warning before the security system flashes at a fast rate, then cycle Ignition Switch OFF until security ke y icon flashes at 2.5 second rate before re-attempting PIN entry.
Hold both turn switches in until confirm­ation. *
Enter first digit of code (3) by pressing left turn switch 3 times.
Press right turn switch 1 time.5
Enter second digit of code (1) by pressing left turn switch 1 time.
Press right turn switch 1 time.7
Enter third digit of code (3) by pressing left turn switch 3 times.
Press right turn switch 1 time.9
Enter fourth digit of code (1) by pressing left turn switch 1 time.
Press right turn switch 1 time.11
Enter fifth digit of code (3) by pressing left turn switch 3 times.
Press right turn switch 1 time.13
See 3.4 PERSONAL IDENTIFICATION NUMBER (PIN) to enter an initial PIN to actuate the system.
Refer to Table 3-3. If you make an error while disarming the HFSM using the PIN, the alarm will activate for 30 seconds after the last digit is entered. After a f ailed attempt, the security lamp will flash once every second for 2 minutes. During this
time, the vehicle will not accept any attempt to enter a PIN.
NOTESWAIT FOR CONFIRMATIONACTIONNO.
Security lamp blinks at fast rate and "0-
- - - " is displayed in the odometer.The first digit will flash.
next dash will flash in the odometer.
the next dash will flash in the odometer .
and the next dash will flash in the odo­meter.
and the next dash will flash in the odo­meter.
odometer displays miles.
System is ready for PIN entry.
Serves as "enter" key.The first digit will be displayed and the
Serves as "enter" key.The first two digits will be displayed and
Serves as "enter" key.The first three digits will be displayed
Serves as "enter" key.The first four digits will be displayed
System is disarmed.Security lamp stops blinking and the
2008 Sportster Diagnostics: TSM/HFSM 3-9
Page 93

3.6WARNINGS AND ALARMS

WARNINGS

A warning consists of three alternate flashes of the turn signals and chirp from the optional Security Siren.Warnings are issued from an armed HFSM in the following order:
1. First Warning: A warning is issued whenever a person without a fob present attempts to move the motorcycle or turns the Ignition Switch to IGNITION.
2. Second Warning: If the motion continues or the Ignition Switch is not turned back to OFF, a second warning is issued within four seconds of the first.
3. Alarm: If the motion continues or the Ignition Switch is not turned to OFF past the second warning, the Smar t Security System will go into full alarm.
ALARM Activation
In the full alarm state, the turn signals flash alternately, and if equipped with the Security Siren, the siren will sound.
After 30 seconds of alarm, if no further motorcycle motion is detected, the alarm will stop.
NOTE
Motorcycle must be returned to original parked position with Ignition Switch turned to OFF.
If motorcycle motion continues, the alarm will start again con­tinue for another 30 seconds.
The HFSM will repeat the alarm cycles 10 times for a total of five minutes, with a 10-second pause between alarm cycles.
NOTES
During warnings and alarms, the star ter motor and the ignition remain disabled.
The alarm will also activate the LED and vibration or aud­ible modes of a Harley-Davidson Security Pager. A pager
can operate either in silent or in combination with an optional Smart Siren. The range of the pager can be up to 0.50 mile (0.89 km).
Deactivation
The alarm cycles can be discontinued at any time by moving an assigned fob to the motorcycle. The presence of the fob will terminate the alarm.
SIREN CHIRP MODE (CONFIRMATION) Chirpless Mode
In the chirpless mode, the siren does not chirp on arming or disarming.
NOTE
Even when armed in the chirpless mode, the siren still chirps warnings on movement and will activate the alarm through cycles.
Chirp Mode
On arming in the chirp mode, the siren responds with two chirps.When disarming, the siren responds with a single chirp.
Switching Modes
Cycling quickly through two armings and disarmings will switch the system from either the chirpless mode or the chirp mode to its opposite.
1. With the fob present, the Ignition Switch to ON and the system disarmed, turn the Ignition Switch OFF.
2. When the system arms (2 flashes of turn signals), imme­diately turn the Ignition Switch to ON.
3. When the system disarms, then immediately turn the Ignition Switch OFF.
4. When the system arms (2 flashes of turn signals), imme­diately turn the Ignition Switch to ON and wait for system to disarm.
3-10 2008 Sportster Diagnostics: TSM/HFSM
Page 94

3.7SERVICE/EMERGENCY FUNCTIONS

TRANSPORT MODE

It is possible to arm the security system without enabling the motion detector for one ignition cycle.This allows the vehicle to be picked up and moved in an armed state, however, any attempt to start the engine will trigger the alarm.
To Enter Transport Mode
1. Turn the Ignition Switch to IGNITION.
2. Set the Engine Stop Switch to OFF.
3. With an assigned fob within range, turn the Ignition Switch from IGNITION to ACC.
4. Simultaneously press both the left and the right turn signal switches.This must be done within five seconds of turning the Ignition Switch to ACC.
5. After the turn signals flash once, turn the Ignition Switch to OFF and the module is armed.
6. Confirmation: Turn signal blinks three times when armed for one ignition cycle.
To Exit Transport Mode
Return the system to normal operation:
1. With the fob present, turn the Ignition Switch to IGNITION to disarm the HFSM. To cancel the transport mode, set the Engine Stop Switch to RUN.

SERVICE MODE

TOOL NAMEPART NUMBER
DIGITAL TECHNICIANHD-44750
With a fob present, the HFSM can be configured for service by disabling the security system with DIGITAL TECHNI­CIAN (Part No. HD-44750).
Once disabled, the motorcycle can be operated without an assigned fob present. To maintain the Service Mode, the assigned fobs must be kept out of range. If the fob appears in range, the Service Mode will be exited.

FOUR-WAY FLASHING

If it is necessary to leave a motorcycle parked along side the road, the hazard warning four-way flashers can be turned ON with the Smart Security System armed.
To Arm the HFSM with the Hazard Warning Flashers ON
1. Turn the Ignition Switch to IGNITION.
2. Simultaneously press both left and right turn signal switches to turn the four-way flashers ON. The four-way flashers will continue for two hours.
3. Turn the Ignition Switch to OFF to arm the Smart Security System.
To Disarm the HFSM and Turn the Hazard Warning Flashers OFF
1. With a fob present, turn the Ignition Switch to IGNITION.
2. Simultaneously press the left and right turn signal switches.
2008 Sportster Diagnostics: TSM/HFSM 3-11
Page 95

3.8TROUBLESHOOTING

TURN SIGNALS (TSM/HFSM)

Verify the operation of the turn signals and the integrity of the fuse protecting the turn signals before further troubleshooting.

SECURITY SYSTEM (HFSM)

If the fob is present, and the security system is issuing "warn­ings" or "Alarm" when the motorcycle is moved, the reason may be one of the following:
1. Strong electromagnetic interference in the area you have parked.
a. Verify you have not placed your fob in a metal
enclosure or within 3.0 in. (80.0 mm) of other elec­tronic devices.
b. Place fob on the vehicle seat and turn the Ignition
Switch to IGNITION. After the system disarms, the fob can be placed back in its carrying location.
c. Move the motorcycle approximately 15 feet (4.57 m)
away from the current parking spot.
2. The fob battery is dead. Use PIN to disarm the vehicle. Replace fob battery.
3. Fob is damaged. Use PIN to disarm the vehicle. Replace the fob.
NOTES
If your Security Icon is staying solid ON while you are riding the vehicle, take your v ehicle to your dealer as soon as practical.
Always lock the fork and take the ignition key with y ou for added protection.

DIAGNOSTICS MODE

The TSM/HFSM measures the current when the turn signals are used. If there is a burned out light bulb on one side, the remaining light and the corresponding turn signal indicator flash at double the normal rate starting with the fifth flash.
Other diagnostic conditions monitored include:
Short circuit in the turn signal wiring.
Open circuit in the turn signal wiring.
Stuck turn signal switch.
NOTES
A stuck turn signal switch will disable the automatic turn signal cancellation feature.
If a stuck switch is detected, you must hold the left and right turn signal switches in for more than one second to activate the four-way flashers.
See 3.9 CHECKING FOR DIAGNOSTIC TROUBLE CODES for more information.

TROUBLESHOOTING

To resolve TSM/HFSM faults, follow three basic steps:
1. Retrieve Diagnostic Trouble Codes (DTCs) using speedometer self diagnostics. See 3.11 SPEEDOMETER
SELF DIAGNOSTICS.
2. Diagnose system problems. This involves using special tools and the diagnostic flow charts in this section.
3. Correct problems through the replacement and/or repair of the affected components.
After repairs are performed, the work must be validated.This involves clearing the DTCs and confirming proper vehicle operation as indicated by the behavior of the turn signals.
3-12 2008 Sportster Diagnostics: TSM/HFSM
Page 96
OFF
ACC.
IGNITION
3
1
2
ed02814
ed02920

GENERAL

Problems fall into at least one of five categories:
Turn signal malfunction.
Bank angle (engine disable).
Clutch/neutral interlock (starter enable).
Security lamp problem.
Security system malfunction.

SECURITY/LAMP DIAGNOSTICS

T o diagnose system prob lems, start by observing the behavior of the security lamp.
NOTES
See Figure 3-8. "Key ON" means that the Ignition Switch is turned to IGNITION and the Engine Stop Switch is set to RUN (although the engine is not running).
See Figure 3-9.When the Ignition Switch is turned to ON, the security lamp will illuminate for approximately four seconds and then turn off.
If the security lamp is not illuminated at Key ON or if it f ails to turn OFF after the initial four-second period, the speedometer may need to be replaced. See
3.11 SPEEDOMETER SELF DIAGNOSTICS. If "BUS Er"
is displayed on the odometer, it may take up to twenty seconds for the security lamp to illuminate.
The security lamp will also light for eight seconds after the bulb check if historic Diagnostic Trouble Codes (DTCs) are present.The security lamp will stay on if current DTCs are set. If a historic DTC is present, the security lamp will light for 2 ignition cycles or until the DTC is cleared manually.
See Figure 3-10. After the lamp turns off after being illuminated for the first four-second period, one of three e vents ma y occur:
The lamp remains off.This indicates there are no current fault conditions or stored historic DTCs currently detected by the HFSM. (A)
The lamp stays off for only four seconds and then comes back on for an eight-second period.This indicates a his­toric DTC is stored, but no current DTC exists. (B)
The lamp remains on beyond the eight-second period. This indicates a current DTC exists. (C)

3.9CHECKING FOR DIAGNOSTIC TROUBLE CODES

1. Ignition OFF
2. Accessory (ACC) ON
3. Ignition ON Figure 3-8. Ignition Switch
Figure 3-9. Security Lamp (Key Icon)
NOTE
See 3.9 CHECKING FOR DIAGNOSTIC TROUBLE CODES,
Code Types for a complete description of DTC formats.
2008 Sportster Diagnostics: TSM/HFSM 3-13
Page 97
ON
A
B
C
ON
ON
OFF
OFF
OFF
Key On
Key On
Key On
Lamp OFF: No Current or Historic DTCs
Lamp OFF
Lamp ON 8 Seconds:
Only Historic DTCs Exist
Lamp Remains ON: Current DTC*
* Historic DTCs May Also Exist
4 Sec.
4 Sec.
4 Sec.
4 Sec.
8 Sec.
4 Sec.
ed01046
Figure 3-10. Security Lamp Operation

CODE TYPES

TOOL NAMEPART NUMBER
DIGITAL TECHNICIANHD-44750
There are two types of DTCs:
Current
Historic
If a DTC is stored, it can be read using either a computer-based diagnostic package called DIGIT AL TECHNICIAN (P art No. HD-
44750) or speedometer self diagnostics. See 3.11 SPEEDO-
METER SELF DIAGNOSTICS.
NOTES
Speedometer self diagnostics will display both current and historic DTCs.T o differentiate between current and historic DTCs, the DIGITAL TECHNICIAN (Part No. HD-44750) must be employed.
All DTCs reside in the memory of the Electronic Control Module (ECM), TSM/HFSM, speedometer or tachometer until the DTC is cleared by use of the speedometer self diagnostics. See 3.11 SPEEDOMETER SELF DIA-
GNOSTICS.
A historic DTC is also cleared after a total of 50 ignition cycles has elapsed. After the 50 ignition cycle retention period, the DTC is automatically erased from memory providing that no subsequent faults of the same type are detected in that period.
Current
Current DTCs are those which are present during the current ignition cycle. See the appropriate flow charts for solutions.
Historic
If a particular problem happens to resolve itself, the active status problem is dropped and it becomes a historic DTC rather than a current DTC. For example, intermittent output shorts can become typical historic DTCs.
Historic DTCs are stored for 50 ignition cycles after any DTC was last set as current to assist in the diagnosis of intermittent faults. On the 50th cycle, the DTC will clear itself.The security lamp will only indicate the existence of historic DTCs for two ignition cycles.
It is important to note that historic DTCs will exist whenever the system indicates the existence of a current fault. See
3.9 CHECKING FOR DIAGNOSTIC TROUBLE CODES, Mul­tiple DTCs/Priority Order if multiple DTCs are found.
Diagnostic charts are designed for use with current DTCs and as a result they frequently suggest part replacement. When diagnosing a historic DTC the charts can be helpful but should not lead to part replacement without verification the part is faulty.

RETRIEVING DTCS

TOOL NAMEPART NUMBER
DIGITAL TECHNICIANHD-44750
The TSM/HFSM supports two levels of diagnostics.
The most sophisticated mode employs a computer-based diagnostic package called DIGITAL TECHNICIAN (Part No. HD-44750).
The second mode requires using the speedometer self diagnostics. Speedometer, tachometer (if equipped), TSM/HFSM and ECM DTCs can be accessed and cleared. See 3.11 SPEEDOMETER SELF DIAGNOSTICS.
3-14 2008 Sportster Diagnostics: TSM/HFSM
Page 98

MULTIPLE DTCS/PRIORITY ORDER

While it is possible for more than one fault to occur and set more than one DTC, there are several conditions which may result in one fault setting multiple DTCs:
Table 3-5.TSM/HFSM DTCs and Fault Conditions
(HFSM)
(HFSM)
(HFSM)
(HFSM)
(HFSM)
(HFSM)
(HFSM)
(HFSM)
(HFSM)
(HFSM)
(HFSM)
(HFSM)
(HFSM)
Serial data DTCs (U1016, U1255, U1300 and U1301) may be accompanied by other DTCs. Always correct the serial data DTCs before resolving the other DTCs.
Refer to Table 3-5. This table lists the DTCs in priority order. Correct DTCs in priority order.
DIAGNOSTICSFAULT CONDITIONDTCPRIORITY
3.24 DTC U1300, U1301 OR BUS ER.J1850 Short-to-groundU13001
3.24 DTC U1300, U1301 OR BUS ER.J1850 Short-to-batteryU13012
3.23 DTC U1016, U1255Loss of serial communications - ECMU10163
3.23 DTC U1016, U1255Loss of serial communications - GeneralU12554
3.19 DTC B1136, B1142 (HFSM ONLY).HFSM2 Internal faultB11425
3.18 DTC B1135.Accelerometer periodic test faultB11356
3.19 DTC B1136, B1142 (HFSM ONLY).Accelerometer tip-over self-test faultB11367
3.22 DTC B1154, B1155.Clutch switch input short-to-groundB11548
3.22 DTC B1154, B1155.Neutral switch input short-to-batteryB11559
3.17 DTC B1134.Start relay output short-to-batteryB113410
3.15 TSM/HFSM:TURN SIGNAL ERRORS AND DTCS.Left turn lamp output open circuitB1121 (TSM)11
3.15 TSM/HFSM:TURN SIGNAL ERRORS AND DTCS.Left turn lamp output open circuitB1121
3.15 TSM/HFSM:TURN SIGNAL ERRORS AND DTCS.Right turn lamp output open circuitB1122 (TSM)12
3.15 TSM/HFSM:TURN SIGNAL ERRORS AND DTCS.Right turn lamp output open circuitB1122
3.15 TSM/HFSM:TURN SIGNAL ERRORS AND DTCS.Left turn lamp output short-to-groundB112313
3.15 TSM/HFSM:TURN SIGNAL ERRORS AND DTCS.Right turn lamp output short-to-groundB112414
3.15 TSM/HFSM:TURN SIGNAL ERRORS AND DTCS.Left turn lamp output short-to-batteryB112515
3.15 TSM/HFSM:TURN SIGNAL ERRORS AND DTCS.Right turn lamp output short-to-batteryB112616
3.21 DTC B1143, B1144, B1145 (HFSM ONLY).Security antenna short-to-groundB114317
3.21 DTC B1143, B1144, B1145 (HFSM ONLY).Security antenna short-to-batteryB114418
3.21 DTC B1143, B1144, B1145 (HFSM ONLY).Security antenna openB114519
3.14 DTC B0563.Battery voltage highB056320
3.16 DTC B1131, B1132 (HFSM ONLY).Alarm output short-to-groundB113121
3.16 DTC B1131, B1132 (HFSM ONLY).Alarm output short-to-batteryB113222
3.15 TSM/HFSM:TURN SIGNAL ERRORS AND DTCS.Ignition switch open/lowB1141 (TSM)23
3.20 DTC B1141 (HFSM ONLY).Ignition switch open/lowB114124
2008 Sportster Diagnostics: TSM/HFSM 3-15
Page 99

3.10INITIAL DIAGNOSTIC CHECK:TSM/HFSM

GENERAL

TOOL NAMEPART NUMBER
DIGITAL TECHNICIANHD-44750
To locate faulty circuits or other system problems, follow the diagnostic flow charts. F or a systematic approach, always begin with INITIAL DIAGNOSTICS. Read the general information and then work your way through the flow chart box by box.
Diagnostic Notes
If a numbered circle appears adjacent to a flow chart box, then more information is offered in the diagnostic notes. Many dia­gnostic notes contain supplemental information, descriptions of various diagnostic tools or references to other parts of the manual where information on the location and removal of components may be obtained.
Circuit Diagram/Wire Harness Connector Table
When working through a flow chart, refer to the illustrations, the associated circuit diagram and the wire harness connector table as necessary .The wire harness connector table for each circuit diagram identifies the connector number, description, type and general location.
In order to perform most diagnostic routines, a Breakout Box and a digital volt/ohmmeter (DVOM) are required. See
3.12 BREAKOUT BOX:TSM/HFSM.
To perform the circuit checks with any degree of efficiency, a familiarity with the various wire connectors is also necessary.
Job/Time Codes
Some charts may contain warranty job/time codes. Dealership technicians filing warranty claims should use the job/time code values printed in bold text underneath the appropriate repair.
Reprogramming ECM
Diagnostic charts frequently suggest Electronic Control Module (ECM) replacement. In the e vent an ECM needs to be replaced,
it must be reprogrammed using a computer-based diagnostic package called DIGITAL TECHNICIAN (Part No. HD-44750). See your dealer. Password learn procedure must also be per­formed. See 3.25 TSM/HFSM: PASSWORD LEARN.

INITIAL DIAGNOSTICS

TOOL NAMEPART NUMBER
BREAKOUT BOXHD-42682 INSTRUMENT HARNESS AD APTERSHD-46601
Diagnostic Tips
See Figure 3-11. If odometer reads "BUS Er" with the Ignition Switch turned to IGNITION (Engine Stop Switch at RUN with the engine off), check data bus for an open or short to ground between data link connector [91A] ter­minal "3" and ECM connector [78B] terminal "5", HFSM connector [30B] terminal "3", speedometer connector [39B] terminal "2" or tachometer (if equipped) connector [108B] terminal "2".
Check for an open diagnostic test terminal between data link connector [91A] terminal "3" and TSM/HFSM con­nector [30B] terminal "3".With Ignition Switch turned ON, serial data bus voltage should be typically 0.6-0.8 volts. The range of acceptable voltage is 0-7.0 volts.
To identify intermittents, wiggle wire harness while per­forming steps in the diagnostic check charts.
Diagnostic Notes
Each reference number below correlates to a circled number on the flow chart(s).
1. Connect BREAKOUT BOX (Part No. HD-42682) between wire harness connector [39B] and speedometer connector [39A] using INSTRUMENT HARNESS ADAPTERS (Part No. HD-46601). See 2.5 BREAKOUT BOX: SPEEDO-
METER/TACHOMETER.
2. Compare TSM/HFSM system behavior to symptoms in
Table 3-6.
Table 3-6. Symptoms That May Not Set Diagnostic Trouble Codes
TSM/HFSM:Turn signal will not cancel
TSM/HFSM: Turn signal flashes double normal rate, all bulbs good
TSM:Turn signals will not flash
3-16 2008 Sportster Diagnostics: TSM/HFSM
SOLUTIONSYMPTOM
HFSM Fails to Disarm.HFSM: Fails to disarm Turn Signal Error 1A (Part 1 of 2) Will Not Cancel Upon Tur n
Completion. Turn Signal Error 1A (Part 2 of 2) Cancels Erratically.TSM/HFSM:Turn signal cancels erratically Turn Signal Error 2A Flash at Double Normal Rate, All Bulbs
Work. T urn Signal Error 3A Will Not Flash, 4-W ay Flashers Inoperab le:
DTC B1121, B1122, B1141. Will Not Flash, No Codes: DTC B1141.HFSM: Symptom - Will not flash. No codes or DTC B1141
Page 100
Other Diagnostic Trouble Codes (DTCs)
Speedometer
12V
(Switched)
12V ACC
Fuse
12V BATT
Fuse
12V INSTR
Fuse
12V IGN
Fuse
ECM
Data Link Connector
12V
(Switched)
12V
(Switched)
12V
(Batt)
Tachometer (not present on all models)
TSM/TSSM/HFSM
Serial data
3
2
1
4
[78]
[39B]
[39A]
[108B]
[108A]
[20A] [20B]
[30B]
[30A]
[91A]
71 62 12 71 62 12
1 352
1 3
12
122
1 2 5 6 7
1 2 5 6 7
1 7
Ignition
Serial data
Battery
Accessory
Ground
Ignition
Serial data
Battery
Battery
Ignition
Serial data
Ground
Accessory
Ground
652
1 7652
BK
BK
BK
BK
BK
BK
GYGY
GY
O/W O/W
O/W
O/W
O
O
O
O
R
LGN/V
LGN/V
LGN/V
LGN/V
LGN/V
LGN/V
LGN/V
BN/GY
BN/GY
BN/GY
BN/GY
BN/GY
BN/GY
R/GY
R/BK
R/BK
em01181
See 2.5 BREAKOUT BOX: SPEEDOMETER/TACHOMETER
for any DTCs related to the speedometer. See 4.5 INITIAL DIAGNOSTIC CHECK: EFI for any DTCs
related to the Electronic Control Module (ECM).
Figure 3-11. Initial Diagnostic Check
Table 3-7.Wire Harness Connectors
Under console12-place MolexInstruments[20] Under battery12-place DeutschTSM/HFSM[30] Back of speedometer12-place PackardSpeedometer[39] Under seat36-place PackardElectronic Control Module (ECM)[78]
LOCATIONTYPEDESCRIPTIONNO.
2008 Sportster Diagnostics: TSM/HFSM 3-17
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