Content .. 7 8 9 10 ..

Harley Davidson 1986-2003 XL/XLH Sportster. Service Manual - page 9

jumper from two lengths of 16-gauge wire,
three clips and a 0.33 microfarad (MFD) ca-
pacitor (

Figure 46

). The test jumper must be

long enough to reach from the ignition coil to
a good engine ground.

3. Perform the following:

a. Connect

the

positive

voltmeter

lead

the

white/black ignition coil wire terminal and the nega-
tive voltmeter lead to ground (Figure 47).

b. With the ignition switch on. The voltmeter should

read 11-13 volts.

c. If the voltage is correct, proceed to Step 4.

TROUBLESHOOTING

FEMALE

MALE

0.33 MFD capacitor

16 ga. wire

Test jumper

Voltmeter

Ignition coil

White/black

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

wiring as described in

Ignition Circuit Wiring Check

section in this section.

4. Perform the following:

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

nal (Figure 48).

b. Turn the ignition switch on.
c. Connect the negative voltmeter lead to ground. Con-

nect the postive voltmeter lead to the white/black and
pink ignition coil terminals separately. The voltmeter
should read 12 volts at both terminals.

d. If the voltage is correct, proceed to Step 5.
e. If the voltage is incorrect, replace the ignition coil.

5. Perform the following:

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

nal (Figure 49).

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

plug wire and connector to the spark plug and ground
the spark plug base to the engine cylinder head (Fig-
ure 50). Position the spark plug so the electrodes are
visible.

c. Turn the ignition switch on.
d. Connect the jumper wire without the capacitor be-

tween a good engine ground and the ignition coil
pink wire terminal, as shown in Figure 49. Momen-
tarily touch the jumper wire with the capacitor to the
ignition coil pink wire terminal (Figure 49) while ob-
serving the spark plug firing tip. The spark plug
should fire. Turn the ignition switch off and remove
the jumper wire assembly.

e. If there is spark, proceed to Step 6.
f. If there is no spark, replace the ignition coil.
g. Reinstall the spark plug.

6. Perform the following:

a. Reconnect the ignition coil pink wire to its terminal

on the ignition coil.

b. Turn the ignition switch on.
c. Disconnect the 6-terminal ignition connector (Figure

45).

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

positve voltmeter lead to the ignition module socket
No. 1 (white/black wire) and the negative voltmeter
lead to the ignition module socket No. 6 (black wire).
The voltmeter should read 11-13 volts. Disconnect
the voltmeter and turn the ignition switch off.

e. If the voltage is correct, proceed to Step 7.
f. If the voltage is incorrect, check the continuity be-

tween socket No. 1 (white/black wire) on the ignition
module connector and the white/black wire at the igni-
tion coil. If there is continuity, repair the open between
socket No. 6 (black wire) and ground. If there is no
continuity, repair the open in the white/black wire.

7. Perform the following:

a. Disconnect the 6-terminal ignition module connector

(Figure 45).

b. Turn the ignition switch on.

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

tive voltmeter lead to socket No. 5 (pink wire) and the
black voltmeter lead to socket No. 6 (black wire). The
voltmeter should read 11-13 volts. Disconnect the
voltmeter and turn the ignition switch off.

d. If the voltage is correct, proceed to Step 8.
e. If the voltage is incorrect, check the continuity be-

tween socket No. 5 (pink wire) and the pink-wire ter-
minal at the ignition coil. If there is continuity, repair
the short to ground on the pink wire. If there is no
continuity repair the open circuit in the pink wire.

8. Perform the following:

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

tion coil connector (Figure 45), and check the volt-
age between the green/gray wire and the black wire.

b. Turn the ignition switch on.
c. Connect the red voltmeter lead to terminal No. 4 on

the test harness, and connect the negative voltmeter
lead to terminal No. 6 on the test harness. The volt-
meter should read 0.6-1.1 volts. Disconnect the volt-
meter and turn the ignition switch off.

CHAPTER TWO

Voltmeter

Ignition coil

Pink

White/black

Pink

White/black

Ignition coil

Jumper wire

White/black

d. If the voltage is correct, proceed to Step 9.
e. If the voltage is incorrect, check the bank angle sen-

sor as described in this section.

9. Perform the following:

a. Remove the timing cover.
b. Crank the engine and observe the rotor LED. If it is

flashing, replace the ignition module. If it is not flash-
ing, proceed to substep c.

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

tor is rotating, replace the ignition module. If it does
not rotate, remove the gearcase cover (Chapter Five)
and check for an engine mechanical failure.

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

Ignition Circuit Wiring Check

1. Check the ignition circuit fuse. If the fuse is burned out,
find the source of the problem.
2. Check the voltage at the gray wire at the fuse block.

a. Turn the ignition switch on.
b. Connect the positve voltmeter lead to the gray-wire

terminal and connect the negative voltmeter lead to a

good ground. The voltmeter should read battery volt-
age. Disconnect the voltmeter and turn the ignition
switch off.

c. If the voltage is correct, perform Step 3.
d. If the voltage is incorrect, check for an open circuit

between the battery, 30-amp circuit breaker, ignition
switch, and fuse block. Make the necessary repairs.

3. Check for voltage at the right control switch connector.

a. Disconnect the right control connector from the switch

(Chapter Twelve).

b. Turn the ignition switch on.
c. On the harness side of the connector, attach the

positve voltmeter lead to pin No. 3 (gray wire) and
connect the negative voltmeter lead to a good ground.
The voltmeter should read battery voltage. Discon-
nect the voltmeter and turn the ignition switch off.

d. If voltage is correct, perform step 4.
e. If voltage is incorrect, repair the open in the gray wire

between the connector and fuse block.

4. Perform the following:

a. Connect the right control switch connector to its mate.
b. Turn the ignition switch on.
c. Turn the engine stop switch to the run position.
d. Connect the positive voltmeter lead to pin No. 5

(white/black wire) on the harness side of the connec-
tor, and connect the negative voltmeter lead to a good
ground. The voltmeter should read battery voltage.
Disconnect the voltmeter and turn the ignition switch
off.

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

white/black wire between the ignition coil and
right-hand switch connector (No. 22).

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

and its wiring. Repair or replace the faulty compo-
nent as necessary.

Bank Angle Sensor Check

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

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

secure against the battery case and sit upright on the
case.

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

the side, face or top of the sensor.

CAUTION

To avoid damaging the terminals in Step 2, re-
move the bank angle sensor before discon-
necting the connector.

2. Remove the bank angle sensor (A, Figure 51) and dis-
connect the sensor connector (B).
3. Turn the ignition on.
4. Measure the voltage between socket A (green/gray wire)
on the sensor connector and socket B (black wire) of the

TROUBLESHOOTING

connector. Disconnect the voltmeter and turn the ignition
switch off. Note the following:

a. If the voltage was zero volts, perform Step 5.
b. If the voltage was 3.0-3.5 volts, perform Step 6.
c. If the voltage measured 11-13 volts, repair the short

in the green/gray wire.

5. Perform the following:

a. Disconnect the bank angle sensor connector.
b. Disconnect the 6-terminal ignition module connector

(Figure 45).

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

wire) on the sensor connector and socket No. 4 (light
green/gray wire) on the harness end of the ignition
module connector. If there is continuity, perform
substep d. If there is no continuity, repair the open
circuit in the green/gray wire.

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

on the sensor connector and ground. If there is conti-
nuity, perform substep e. If there is no continuity, re-
pair the open circuit in the black wire.

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

wire) on the sensor connector and ground. If continu-
ity is present, repair the short to ground in the
green/gray wire. If continuity is not present, perform
substep f.

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

the harness is not damaged, replace the ignition module.

6. Perform the following:

a. Turn the ignition on.
b. Measure the voltage between socket B (black wire)

on the sensor connector and socket C (gray wire) on
the connector. If the voltmeter reads 11-13 volts, per-
form Step c. If the voltage is not 11-13 volts, repair
the open circuit in the gray wire between the sensor
connector and the ignition fuse.

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

mounting location/position were not the source of the
malfunction. See Step 1.

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

IGNITION SYSTEM

(1998-2003 1200S MODELS)

Review

Precautions and Troubleshooting Preparation

Ignition System (1986-1997 Models)

in this chapter.

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

Tools

Troubleshooting the ignition system requires a breakout

box (part No. HD-42682). The breakout box connects
inline between the ignition module and the wiring harness.
It provides test points for checking a live circuit.

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

nesses as shown in Figure 44. Make each test harness from
24 lengths of 18-gauge wire, a male Deutsch connector

(12-pin) and two female Deutsch connectors (12-socket).
Wire the No. 1 pin on the male connector to the No. 1 socket
on each female connector, No. 2 pin to No. 2 socket, etc.

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

fied as terminals on the black- or gray-colored harness, (ter-
minal No. 2 on the black test harness, for example).
Consequently, take care to identify one harness as black and
the other as gray. Use black connector housings on one har-
ness and gray housings on the other or wrap the wires of
one test harness with black electrical tape and wrap the
wires of the second harness with gray tape.

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

nector No. 10) and gray (connector No. 11) ignition-mod-
ule connectors from the ignition module. Connect the gray
test harness in-line between the ignition module and gray
ignition-module connector (A, Figure 52). Connect the
black test harness in-line between the ignition-module and
black ignition-module connector (B, Figure 52). Probe the
second female connector on each respective test harness at
the indicated test point.

Troubleshooting the ignition system also requires a har-

ness test kit (part No. HD-41404). Different-sized termi-
nals are used in the connectors on a Sportster. This kit is
equipped with different sized probes for checking the volt-
age and resistance of the various-sized terminals without
damaging the wire insulation.

CHAPTER TWO

Check engine light

Diagnostic Trouble Codes

The 1200S models have an on-board diagnostic system

to help troubleshoot the ignition system. During operation,
the system identifies faults and stores this information as a
two-digit diagnostic trouble code.

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

ure 53) will come on. During normal operation, the check
engine light illuminates for approximately four seconds
when the ignition is turned to on. The check-engine light
then turns off and remains off. If a diagnostic trouble code
has been set, the check-engine light turns on for four sec-
onds, turns off, and then turns back on for eight seconds or
it remains on beyond the eight-second period.

Trouble codes can be retrieved with the Scanalyzer (Part

No. HD-41325) or by counting the number of times the
check-engine light flashes. If using the Scanalyzer for code
retrieval, follow the manufacturer’s instructions. Code(s)
can also be retrieved by performing the procedure de-
scribed in this section. Use the chart in Figure 54 to identify
the defective system and to determine a course of action.

Retrieving codes

Diagnostic trouble codes are displayed as a series of

flashes at the check-engine light. To retrieve any stored di-
agnostic trouble codes, a jumper made of 18-gauge wire

and two Deutsch sockets (part No. 72191-94), as shown in
Figure 55, is required.

To retrieve the diagnostic trouble codes without the

Scanalyzer, perform the following:

1. Remove the left side cover from the motorcycle.

2. Remove the data link connector (Figure 56) from its
holder on the back of the side cover.

3. Remove the protective cover (A, Figure 57) from the
data link connector (B), and connect the jumper to pins No.
1 and No. 2 on the data link connector.

4. Turn the ignition switch to ignition. After approximately
eight seconds, the system enters the diagnostic mode.

a. The diagnostic mode begins with a ready signal,

which is a series of rapid flashes of approximately
three per second. The ready signal indicates that the
system is ready to flash a diagnostic trouble code.

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

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

agnostic trouble code. The check-engine light will il-
luminate for one second and then turn off for one
second. Count the number of flashes, and record this
number.

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

the second digit of the diagnostic trouble code. Count
the number of flashes, and record this number.

TROUBLESHOOTING

CODE DESCRIPTION TROUBLESHOOTING CHART

Code

Component/circuit

Action

MAP sensor

Figure 68

Battery voltage

Figure 69

Front coil

Figure 70

Rear coil

Figure 70

Tachometer

1998 models

Figure 71

1999-2003 models

Figure 72

Cam position sensor

Figure 73

Bank angle sensor

Figure 74

1998 models: RAM/ROM failure

Replace ignition module*

1999-2003 models: RAM failure

Replace ignition module*

1999-2003 models: ROM failure

Replace ignition module*

EE PROM failure

Replace ignition module*

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

2 in.

CHAPTER TWO

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

the ready signal, which indicates it is ready to flash
the next code.

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

the first digit of the next diagnostic trouble code.

5. The system displays codes, sequentially, one-at-a-time,
until each diagnostic trouble code has been displayed. The
system then repeats. The check-engine light will continue
to flash stored codes until the jumper wire is disconnected.
When the codes repeat, this indicates that all the stored
codes have been displayed.
6. Find the diagnostic trouble code in Figure 54, and per-
form the procedure indicated in the chart. If multiple codes
have been set, troubleshoot the lowest numbered code first.
The source of subsequent codes may be the same malfunc-
tion that has caused the first.
7. Reinstall the protective cover onto the data link connec-
tor, and fit the connector into its holder in the back of the
left side cover.
8. Align the side cover pins with the grommets in the
frame, and push the side cover into place.

Clearing codes

The system will retain the trouble codes until they are

cleared with the Scanalyzer or until the motorcycle has
been run through 50 start-run cycles. After a fault has been
corrected, the memory is erased automatically after 50
start-run cycles if the fault does not reoccur. A start-run cy-
cle occurs when the engine is started and run for at least 30
seconds before being turned off.

Ignition Control Module Replacement

Before replacing the ignition module, confirm that the ig-

nition module is defective by having a dealership test it.
There are several ignition-module tests that can only be
performed with a Scanalyzer (part no. HD-41325).

Troubleshooting Tests

1. Review

Precautions

and

Troubleshooting Preparations

Ignition System (1986-1997 Models)

in this chapter. Re-

fer to the wiring diagrams at the end of this manual.
2. Peform the spark test as described in

Starting The En-

gine

in this chapter.

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

tem. Check the fuel system.

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

nition with new spark plugs. If the condition remains
the same with new spark plugs and if all external wir-
ing connections are good, the problem is most likely
in the ignition system; perform the procedure in Fig-
ure 58. Follow the procedure in the chart until the
problem is resolved.

Wiggle Test

Several troubleshooting procedures advise performing a

wiggle test. Perform the following when so advised:
1. Connect the meter as instructed in the flow chart.
2. Wiggle the wiring harness and observe the meter.
3. Large resistance fluctuations indicate the presence of an
intermittent short in the harness. Check the wiring harness.

TROUBLESHOOTING

RETRIEVING DIAGNOSTIC CODES (1998-2003 1200S MODELS)

Does the engine start?

Yes

Does the check engine
light display ignition
module data?

Yes

No light.

Perform the diagnostic procedure in Figure 62
(1998 models) or Figure 63 (1999 models).

Perform the diagnostic procedure in Figure 64.

Perform the diagnostic procedure in Figure 66.

Are any trouble codes
displayed?

Yes

Perform a wiggle
test and attempt to
reproduce the
symptoms. Repair
the harness as
required. If the
problem cannot be
reproduced, refer
to Figure 61.

Repair

short to
ground.

Is continuity present between pins
on data link connector and igni-
tion module?

Data

Ignition

Link

Module

terminal

1 (Green/red)

11 [11B]

2 (Black)

11 [10B]

3 (Violet/red)

12 [11B]

4 (White/black) to

1 [10B]

Yes

*Replace
the igni-
tion
module.

Inspect the
terminals for
damage or
repair opens
as neces-
sary.

*Note: Before replacing the ignition module, confirm
that it is defective by taking the motorcycle to a
Harley-Davidson dealership or other qualified service
shop. Further testing requires the use of a
Harley-Davidson Scanalyzer.

Yes

Refer to
applicable
trouble
code (Fig-
ure 54);
start with
lowest
numbered
code.

Disconnect the black (10B) and
gray (11B) connectors from the
ignitin module. Check for continu-
ity to ground at the indicated termi-
nals of the data link connector
[91A].
1998 models: Pins 1, 3 and 4.
1999-2003 models: Pins 1 and 3.
Continuity to ground?

Does light go off after 4 seconds?

Turn the ignition switch on,
Do not start the engine.
Note Check Engine light

Spark Plug Cable Resistance Test

1. Disconnect the spark plug cable from the spark plug and
from the ignition coil.
2. Connect the probes of an ohmmeter to the cable termi-
nals.
3. Replace the spark plug cable if the resistance is not
within the specification in Table 2.
4. Repeat this procedure for the remaining cables.

Ignition Coil Test (1998-2003 1200S Models)

1. Disconnect the spark plug wires (A, Figure 59) from the
coil towers on the coil.
2. Disconnect the ignition coil connector (B, Figure 59)
from the ignition-coil primary terminals.
3. Measure the resistance in the primary windings.

a. Measure the resistance between primary terminals A

and B on the ignition coil.

b. Measure the resistance between primary terminals B

and C on the coil.

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

4. Measure the resistance of the secondary windings.

a. Measure the resistance between both secondary ter-

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

b. Measure the resistance between both secondary ter-

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

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

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

Troubleshooting Symptoms

Refer to Figures 61-74 for various symptoms and testing

procedures.

FUEL SYSTEM

Begin fuel system troubleshooting with the fuel tank and

work through the system, reserving the carburetor as the fi-
nal point. Do not assume the carburetor is the problem. Un-
necessary carburetor adjustment can compound the problem.

Identifying Carburetor Conditions

Refer to the following conditions to identify whether the

engine is running lean or rich.

Rich

1. Fouled spark plugs.
2. Engine misfires and runs rough under load.
3. Excessive exhaust smoke as the throttle is increased.

4. An extreme rich condition causes a choked, or dull
sound from the exhaust and an inability to clear the exhaust
with the throttle held wide open.

Lean

1. Blistered or very white spark plug electrodes.

2. Engine overheats.

3. Slow acceleration and engine power is reduced.

4. Flat spots on acceleration that are similar in feel to when
the engine starts to run out of gas.

5. Engine speed fluctuates at full throttle.

Troubleshooting

Isolate fuel system problems to the fuel tank, fuel shutoff

valve and filter, fuel hoses, external fuel filter (if used) or
carburetor. In the following procedures, it is assumed that
the ignition system is working properly.

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

tions for possible causes of fuel system problems.

CHAPTER TWO

Fuel level system

The fuel level system is shown in Figure 77 or Figure

78. Proper carburetor operation depends on a constant and
correct carburetor fuel level. As fuel is drawn from the float
bowl during engine operation, the float level in the bowl
drops. As the float drops, the fuel valve moves from its seat
and allows fuel to flow through the seat into the float bowl.
Fuel entering the float bowl causes the float to rise and push
against the fuel valve. When the fuel level reaches a prede-
termined level, the fuel valve is pushed against the seat to
prevent the float bowl from overfilling.

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

flood with fuel. Symptoms of this problem are rough run-
ning, excessive black smoke and poor acceleration. This
condition will sometimes clear up when the engine is run at
wide-open throttle and the fuel is being drawn into the en-
gine before the float bowl can overfill. However, as the en-
gine speed is reduced, the rich running condition returns.

Several things can cause fuel overflow. In most in-

stances, a small piece of dirt is trapped between the fuel
valve and seat, or the float level is incorrect. If fuel is flow-
ing out of the overflow tube connected to the bottom of the
float bowl, the fuel valve inside the carburetor is being held
open. First check the position of the fuel shutoff valve lever
(A, Figure 79). Turn the fuel shutoff valve lever off. Then
lightly tap on the carburetor float bowl and turn the fuel
shutoff valve lever on. If the fuel flow stops running out of

the overflow tube, whatever was holding the fuel valve off
of its seat has been dislodged. If fuel continues to flow from
the overflow tube, remove and service the carburetor. See
Chapter Ten or Chapter Eleven.

NOTE

Fuel will not flow from the vacuum-operated
fuel shutoff valve on 1995-2003 models until
the engine is running.

Starting enrichment (choke) system

A cold engine requires a rich mixture to start and run

properly. On all models, a cable-actuated starter enrichment
valve is used for cold starting.

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

starting enrichment (choke) cable adjustment described in
Chapter Three.

Accelerator pump system

During sudden acceleration, the diaphragm type acceler-

ator pump system (Figure 80 or Figure 81) provides addi-
tional fuel to the engine. Without this system, the carburetor
would not be able to provide a sufficient amount of fuel.

The system consists of a spring-loaded neoprene dia-

phragm that is compressed by the pump lever during sudden

TROUBLESHOOTING

SYMPTOMS

Symptom

Possible cause

Action

Hard to Start

Battery discharged

Troubleshoot the charging system

as described in this chapter

Spark plugs

Perform the procedure in Figure 67

Ignition coil

Perform the procedure in Figure 67

Plug wires

Perform the procedure in Figure 67

Valve sticking

Refer to the Chapter Four

Water or dirt in

Drain the fuel system and refill

the fuel system

with fresh fuel

Engine hesitates,

Manifold leak

Spray water around the intake

stumbles, surges,

manifold seals while the engine

misfires or is sluggish

idles. If idle speed changes,
replace the seals.

MAP sensor is not

Check the vacuum hose connection and

operating properly

perform the procedure in Figure 68

Water or dirt in the fuel system

Drain the fuel system and

refill with fresh fuel

Spark plug

Perform the procedure in Figure 68

EVAP hose disconnected from

Reconnect

carburetor (California models)

Throttle plates not opening fully

Adjust the throttle cable as

described in Chapter Three

Engine exhaust emits

Clogged air filter

Replace the air filter (Chapter Three)

black smoke or spark

MAP sensor is not

Check the vacuum hose connection and

plugs are fouled

operating properly

perform the procedure in Figure 68

CHAPTER TWO

NO CHECK ENGINE LAMP WITH KEY ON (1998 MODELS)

*Before replacing the ignition module or
speedometer, confirm that it is defective by taking
the motorcycle to a dealership. Further testing
requires the use of a Scanalyzer.

Turn the ignition switch on. Turn
the engine stop switch to run.
Does the engine start?

Yes

*Replace faulty
ignition module.

Turn the ignition switch off. Con-
nect both test harnesses (Figure
44) between the ignition module
and the module connectors [10].
Place a jumper between Pin 4 on
the black test harness (B) and
ground. Is the check engine light
on?

Did the no check engine light and
no start conditions occur simulta-
neously?

Yes

No ignition module
power. Perform the
diagnostic proce-
dure in Figure 65.

If the engine will not
start, see Figure 66.
Then return to this chart
to resolve the no check
engine lamp condition.

Disconnect the 14-pin me-
ter-harness connector [20]. Re-
move the black/yellow wire from
connector [20B] and ground it. Re-
connect connector [20B]. Is the
check engine light on?

Yes

Repair open or short
to voltage on the
black/yellow wire be-
tween connector [20A]
and connector [10B].

Yes

Repair.

Replace
faulty ta-
chometer
(lamp not re-
placeable).

Is there an open in the or-
ange/white wire that
feeds the bulb or an open
in the wire from the bulb
to the connector [20B]?
*Replace the speedome-
ter if the LED has failed.

TROUBLESHOOTING

CHECK ENGINE LIGHT CIRCUIT (1998 MODELS)

From ignition switch

15 A accessory fuse

Check engine light

Ignition module

connector

Check engine light
ground circuit

Ignition module

[10B] [10A]

[20A] [20B]

Black/yellow

Orange/white

Black/yellow

Red/grey

CHAPTER TWO

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

Turn the ignition switch on. Turn
the engine stop switch to RUN.
Does the engine start?

Yes

Did no check engine light and no start
conditions occur simultaneously?

Yes

No ignition module
power. Perform the
diagnostic proce-
dure in Figure 66.

If the engine will not
start, see Figure 65. Then
return to this chart to re-
solve the no check en-
gine lamp condition.

Yes

Place a jumper wire between Pin
4 on the test harness (B) and
ground. Is the check engine light
on?

Yes

Repair the open on the
black/yellow wire be-
tween connector [20A]
and connector [10B].

Repair the open on the
black/yellow wire be-
tween harness connec-
tor [20B] and
speedometer connector
[39].
*Replace the speedom-
eter if the LED has
failed.

*Before replacing the ignition module or
speedometer, confirm that it is defective by taking
the motorcycle to a dealership. Further testing
requires the Scanalyzer.

Disconnect the 12-pin meter har-
ness connector [20]. Check the
continuity on the black/yellow
wire between the speedometer
connector [39] and connector
[20B]. Is the check engine light
on?

*Replace the
defective igni-
tion module.

*Replace
the speed-
ometer.

Yes

TROUBLESHOOTING

CHECK ENGINE LIGHT CIRCUIT (1999-2003 MODELS)

From ignition switch

15 A accessory
fuse

Check engine light

Ignition module

connector

Check engine light
ground circuit

Ignition module

[10B] [10A]

[39]

[20A] [20B]

Black/yellow

Orange/white

Black/yellow

Red/gray

CHAPTER TWO

CHECK ENGINE LIGHT CONTINUOUSLY ON

With ignition switch on, verify
that there is not a 4-second lamp
off period. Does the lamp go off?

Yes

Check engine light functioning
properly. Check for trouble
codes.

Yes

1998

models

Disconnect the 14-pin meter-harness
connector [20]. Remove the black/yel-
low wire from connector [20B]. Recon-
nect [20B] the connector
Is the check engine light on?

Yes

Repair the
short to
ground on the
black/yellow
wire between
the connector
[20B] and the
lamp in the
speedometer.

Repair the short
to ground on the
black/yellow wire
between the
12-pin connector
[20A] and the
ignition module
connector [10].

Disconnect the 12-pin speedometer
connector [39]. Check for continuity
to ground on the 4-pin black/yellow
wire in the igntion module connector
[10]. Is continuity present?

Yes

*Replace the
speedometer.

Disconnect the
12-pin me-
ter-harness con-
nector [20].
Remove the
black/yellow
wire, from the
connector. Re-
connect the me-
ter connector
[20]. Is the check
engine light on?

Yes

Repair the short to
ground on the black/yel-
low wire between the me-
ter connector [20B] and
the speedometer con-
nector [39B].

Repair the short to ground on
the black/yellow wire between
the meter connector [20A] and
ignition module connector [10B].

*Replace
ignition
module.

*Before replacing the ignition
module or the speedometer,
confirm it is defective by
taking the motorcycle to a
dealership. Further testing
requires the use of a
Scanalyzer.

Turn the ignition switch off. Dis-
connect the ignition module black
connector [10]. Turn the ignition
switch on. Is the check engine
lamp off?

1999-2003

models

TROUBLESHOOTING

Check the ignition fuse.
Is the fuse okay?

Yes

Replace and find the
source of the fault.

Connect both test harnesses (Figure
44) between the ignition module and
the module connectors. With the igni-
tion on, connect the positive voltmeter
lead to pin 1 on the black test harness.
Connect the negative voltmeter lead to
pin 2 on the black test harness. Does
the voltage equal 12 ± 1 volt?

Yes

* Replace the ig-
nition module.

Check continuity between Pin 2
on the black test harness and
ground. Is continuity present?

Replace the
engine stop
switch.

Ignition module

Engine stop switch

To ignition switch

15 Amp

ignition fuse

*Note: Before replacing the
ignition module, confirm it is
defective by taking the
motorcycle to a dealership.
Further testing requires the
Scanalyzer.

Repair the open in the
gray wire between the
handlebar connector
[22A] and the fuse block.

Yes

Check for continuity be-
tween pin 3 in the grey ig-
nition module connector
[11] and pin 4
(white/black) on the han-
dlebar connector [22B]. Is
continuity present?

Repair the
open in the
white/black
wire.

Is continuity present between pin
1 on the black test harness and
Pin 4 (white/black) of the right
handlebar connector [22B].

Yes

Repair the
open in the
white/black
wire.

Yes

NO SPARK, NO CHECK ENGINE LIGHT WITH KEY ON

Grey

White/
black

CHAPTER TWO

Check for trouble
codes. Codes found?

Yes

Find the code in Figure 54 and
turn to the indicated trouble-
shooting chart.

Check battery connec-
tions. Check voltage. Is
voltage above 12.80?

Yes

Recharge
the battery
and retest.

Replace the
battery and
retest.

Yes

Perform an engine com-
pression test (Chapter
Three). If compression is
good, check the fuel sys-
tem as described in this
chapter.

Turn the ignition on and the engine
stop switch to run. Does the check
engine light illuminate for 4 sec-
onds?

Yes

Perform the diag-
nostic procedure
in Figure 65.

Check for battery voltage at ter-
minal B of coil connector [83B]
as described in this section. Is
battery voltage present?

Yes

Open in the white/black
wire to coil. Repair the
open circuit.

Disconnect the ignition coil connector [83B].
Connect a test lamp to terminal A (rear cylinder) of
the connector and crank the engine. Repeat for ter-
minal C (front cylinder). Does the test light turn on
while cranking?

Yes

Test the resistance of
the spark plug wires.
Is the resistance
within the specifica-
tion in Table 2?

Replace the spark plug wires.

Yes

Replace the coil.

Correct the routing.

Are the plug
wires in the
correct coil
towers?

Are the coil connec-
tions in good condi-
tion?

Repair.

Yes

Check spark plug condi-
tion. Replace, if fouled.
Perform a spark test as
described in

Starting The

Engine in this chapter. Is
spark present?

ENGINE CRANKS BUT WILL NOT START

Does the battery pass the
load test (Chapter Twelve)?

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