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
Page 3
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.
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
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.
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.
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.
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
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.
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.
* 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.
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
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.
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)
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.
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
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).
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
GYGY
GY
O/W
O/W
O/W
O
O
R
BN/GY
BN/GYBN/GY
BN/GYBN/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 2 312
1 2 312
1 2576
1 2576
1 25 6 7
1 25 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
216 7
12
216 712
[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.
YESNO
Check for continuity to ground at
Breakout Box terminal “7” (black). Wiggle
harness during continuity check.
Is continuity present?
YESNO
Check for battery voltage at
Breakout Box terminal “5” (black)
while wiggling harness.
Is battery voltage continuously
present?
Locate and
repair open.
YESNO
With ignition switch OFF and speedometer
connector [39] disconnected, check continuity
between Breakout Box terminals “8” and “11” (black).
Is continuity present when trip odometer reset
switch is depressed and infinity when released?
Locate and
repair open.
YESNO
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?
YESNO
Replace Speedometer.
Perform “WOW” test.
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?
YESNO
Check for battery voltage at
Breakout Box terminal “6”
(Black). Is battery voltage
present?
YESNO
Replace Speedometer.
Is accessory
fuse good?
YES
Locate and repair open
on (O/W) wire between
terminal “6” of 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?
YESNO
Replace Speedometer.
Is instrument
fuse good?
YESNO
Locate and repair open
between terminal “1” of
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?
YESNO.
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).
YESNO
Locate and repair
intermittent.
No trouble found.
YESNO
Remove debris.
Reinstall
VehicleSpeed Sensor.
Check for damaged wiring/
loose connection between
VehicleSpeed Sensor and ECM.
Is wiring damage/loose
connection present?
YESNO
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).
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 “diag” appear?
YES
”P” flashing.
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.
”S” flashing.
To choose Speedometer,
press and release trip
odometer reset switch.
”SP” flashing.
To choose Tachometer,
press and release trip odometer
reset switch.
To choose ABS, press
and release trip odometer
reset switch.
”T” flashing.
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?
“end” displayed. 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 rsp” displayed.See applicable code from
other modules. Models not equipped with a
tachometer or ABS will display “no rsp” normally.
If “no rsp” displayed on odometer on tachometer
equipped vehicle, See Section 2.4
SPEEDOMETER/TACHOMETER.
“none” displayed.
DTC
displayed.
Press and release trip odometer reset switch.
“PSSPtb” appears.
2
”b” flashing.
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.
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 “WOW” test. 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) LED’s may illuminate:
• cruise (although not cruise equipped)
• pursuit (although not a police vehicle)
Are all features functional?
YES
Is problem intermittent?
YESNO
Repeat “WOW” test
while wiggling
harnesses.
No trouble
found.
NO
Check for battery voltage at
Breakout Box terminal “1”.
Is battery voltage present?
YESNO
Is instrument
fuse good?
YESNO
Locate and repair
source of fault.
Replace fuse.
Locate and repair
open in (O) wire between
terminal “1” of
connector [108] and
instrument fuse.
Check for continuity
between Breakout Box
terminal “2” and terminal
“7” of connector [20].
Is continuity present?
YESNO
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?
YESNO
Check for battery voltage at Breakout Box
terminal “5” while wiggling harness.
Is battery voltage continuously present?
Locate and repair open on (BK) wire
between terminal “7” of connector [108]
and ground.
YESNO
Check for battery voltage at Breakout
Box terminal “6”. Is battery voltage
present?
Locate and repair open on (BN/GY)
wire between terminal “5” of connector
[108] and battery fuse.
YESNO
Replace tachometer.
Locate and repair open
on (O/W) wire between
terminal “6” of
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].
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.
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
BKBK
BK
BK
BK
BN
BN
O
O
OOO
O
W
W
V
V
GN/Y
GN/Y
36549812
Main Harness Connector
[20A]
[39A]
[39B]
Speedometer
[108A]
Tachometer
(if equipped)
[108B]
17
17
17
Ignition
Ground
Ground
Ignition
17
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
51615157
fc01068_en
2008 Sportster Diagnostics: Instruments 2-19
Page 63
High Beam or R/L Turn Signal Indicator Will Not Function
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?
YESNO
Replace fuel levelswitch.
6035
Disconnect [200].
Continuity to ground?
NOYES
Replace fuel sender
resistor assembly.
Locate and repair short to
ground in harness.
60837182
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 “2” of connector
[141B] (Y/W). Should be 0 volts.
Is it?
YESNO
Check continuity between terminal
“2” of connector [141B] (Y/W) and
Breakout Box terminal “11” (BK).
Continuity present?
Locate and repair short
to voltage.
YESNO
Check continuity to ground on terminal
“4” of connector [141B] (BK).
Is continuity present?
Locate and repair short
to voltage.
YESNO
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?
YESNO
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?
YESNO
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.
YESNO
With speedometer connector [39] disconnected,
measure resistance between Breakout Box
terminal “8” and “11' (black).Resistance should be
less than 1 ohm with switch depressed and infinity
ohms when released. Is it?
1
YESNO
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
GYGY
GY
O/W
O/W
O/W
O
O
R
BN/GY
BN/GYBN/GY
BN/GYBN/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 2 312
1 2 312
1 2576
1 2576
1 25 6 7
1 25 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
216 7
12
216 712
[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.
YESNO or “No Rsp”
While wiggling harness, check
continuity between Breakout Box
terminal “2” (Black) and terminal “5” of
ECM Breakout Box.
Is continuity present?
Check continuity between
Breakout Box terminal ‘2" (Black)
and terminal “5” of ECM
Breakout Box.
Is continuity present?
YESNO
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
YESNO
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
GYGY
GY
O/W
O/W
O/W
O
O
R
BN/GY
BN/GYBN/GY
BN/GYBN/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 2 312
1 2 312
1 2576
1 2576
1 25 6 7
1 25 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
216 7
12
216 712
[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.
YESNO
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?
YESNO
Clear codes. Test ride.
Does DTC U1064
return?
Repair intermittent
on (LGN/V) wire.
YESNO
Replace ECM.
Reprogram and learn
password.
No trouble found.
YESNO
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.
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
ed02044
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
ed02920
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
BNBN
BN
BN
BN
BKBK
BK
BK
BK
BK
BK
BK
GY
TN
R
V
V
V
VV
RRR
R/BK
R/GY
BK/R
BN/GY
LGN/VLGN/V
LGN/BN
LGN/VLGN/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
Page 89
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
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]
716212
716212
1352
13
12
122
1 25 6 7
1 25 6 7
17
Ignition
Serial data
Battery
Accessory
Ground
Ignition
Serial data
Battery
Battery
Ignition
Serial data
Ground
Accessory
Ground
652
17652
BK
BK
BK
BK
BK
BK
GYGY
GY
O/WO/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
Loading...
+ hidden pages
You need points to download manuals.
1 point = 1 manual.
You can buy points or you can get point for every manual you upload.