Harley Davidson 1986-2003 XL/XLH Sportster. Service Manual - page 10

TROUBLESHOOTING

Connect both test harnesses (Figure 44) be-
tween the ignition module and the module
connectors. Check the continuity between
Terminal A in the ignition coil connector
[83B] and Pin 7 on the black test harness.
Measure the resistance between Terminal C
in the ignition coil connector and Pin 6 in the
black test harness. Is the resistance less
than 1.0 ohm?

Poor connection at the ignition mod-
ule connector [10B] or an open in the
harness between the coil and ignition
module. Repair open.

Yes

Disconnect the cam position sensor connec-
tor [14]. With the ignition on, measure volt-
age between terminal A and terminal C of
connector [14B]. Is 5VDC present?

Yes

Reconnect the cam position sensor [14] con-
nector. Turn the ignition on, and measure the
voltage between Pins 3 and 8 on the gray
test harness while cranking the engine. Is
the voltage 0-5 volts?

Yes

Remove the test harnesses. Reconnect both
ignition module connectors to the ignition
module and reconnect the cam position sen-
sor connector to the sensor. Try to start the
engine. Does it start?

The crankshaft and
camshaft may be out
of time. Check for
proper cam timing,
pinion gear key fail-
ure, loose rotor cup
or other mechanical
failure.

Replace the cam po-
sition sensor.

Repair.

Turn the ignition off. Measure the resis-
tance between Terminal A in the cam
position sensor connector [14B] and
Pin 1 in the gray test harness. Measure
the resistance between Terminal C in
the cam position sensor connector and
Pin 8 on the gray test harness. Is the re-
sistance greater than 1.0 ohm?

Repair short to
ground the on
red/white wire.

Repair the
open in the
connection.

Remove the cam
timing cover and
crank the engine.
Does the rotor cup
rotate?

Replace the
cam posi-
tion sensor.

Mechanical failure
indicated. Inspect
for a loose rotator
cup and sheared
pinion gear key
(Chapter Five).

Yes

Repair
open.

Yes

Check continuity between
terminal A in the cam po-
sition sensor connector
[14B] and ground. Is con-
tinuity present?

*Replace igni-
tion module.

Yes

Disconnect the cam position sensor
connector [14]. Measure the resistance
between terminal B on the connector
and Pin 3 in the gray test harness. Is the
resistance greater than 1.0 ohm?

With the engine
running, wiggle
the cam position
sensor and wires
to identify any
loose connections
(engine misfires or
stalls). Were any
found?

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

CHAPTER TWO

Drain and flush the tank. (Chapter Eleven)
Refill with fresh fuel.

Check for:
• Faulty, worn or cracked spark plugs.
• Plug fouling due to engine mechanical

•

fault.

• Faulty or poor connection at plugs.

Replace the faulty wires.

Replace the ignition coil.

The original ignition coil is defec-
tive.

Find the short and repair.

*Replace the ignition module.

The system is OK.

Is the fuel contaminated?

Perform a spark test as described in
Starting the Engine in this chapter. Is
a good spark present?

Check the spark plug wire resistance
on any plug that did not fire. Is the re-
sistance within the specification in
Table 2?

Yes

The coils should be free of carbon
tracking. Are they?

Yes

Switch the coil a known-good unit. Is
a good spark present with the
known-good coil?

Disconnect the negative battery termi-
nal (Chapter Twelve). Measure the re-
sistance between the positive battery
terminal and Terminal B in the ignition
coil connector [83B]. Also measure
the resistance while wiggling the har-
ness. Is the resistance less than 1.0
ohm?

Yes

Replace the cam position sensor with
a known-good sensor. Static time the
engine and recheck the resistance.
Does the problem still exist?

Yes

MISFIRE

TROUBLESHOOTING

[83A] [83B]

Ignition coil

[22B]

[22A]

15 Amp

ignition fuse

Red/black to ignition switch

[10B] [10A] B*

Rear coil

Front coil

Key on
power

Ignition module

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

Yellow/blue

Blue/orange

White/black

Grey

CHAPTER TWO

MAP SENSOR

Connect both test harnesses
(Figure 44) between the ignition
module and the module connec-
tors. With the ignition on, mea-
sure the voltage between pin 2
and pin 8 on the gray test har-
ness.

Yes

Perform a wiggle test. Large voltage
changes or setting a trouble code while
wiggling the harness indicates the location
of an intermittent. Is an intermittent pres-
ent?

Check the reference voltage. With the ignition on,
measure the voltage between terminal 1 (Red/white)
and terminal 3 (Black/whte) of the MAP-sensor con-
nector [80B]. Is the voltage approximately 5 VDC?

Yes

No;

Greater

than 5V.

Find and repair the
short or bad connec-
tion.

Replace the MAP
sensor. Clear the
codes and road test.
Did the check engine
lamp come on and
set Code 12?

Yes

Install the original MAP sensor.
*Replace the ignition module and
road test again to verify.

No;

Less

than 5V.

Remove the test
harness and
check for an
open. Check the
resistance be-
tween Terminal 2
on the MAP sen-
sor connector
[80B] and Pin 2
in the gray igni-
tion-module con-
nector [11B]. Is
the resistance
less than 1 ohm?

Locate short to
12 Volts on the
Red/white wire
in wire har-
ness. Repair
as necessary.

Connect both test harnesses
(Figure 44) between the ignition
module and the module connec-
tors. Check the continuity be-
tween terminal 1 and the MAP
sensor connector [80B] and Pin
1 in the gray test harness. Check
the continuity between terminal 3
in the MAP-sensor connector
and pin 8 in the gray test har-
ness. Is there continuity?

Repair the
open wire.

Disconnect the ignition module.
Check the resistance between
the MAP connector [80B], termi-
nal 1 and terminal 3. Is it greater
than 1 megohm?

Yes

Replace the
MAP sensor.

Locate and re-
pair grounded
violet/white
wire.

*Replace the ig-
nition module.

Locate and repair the
short between the
red/white and
black/white wires.

Check for short to ground.
Measure the resistance
between Terminal 1 in
MAP sensor connector
[80B] and chassis ground.
Is resistance greater than
1 megohm?

Yes

With the key on and engine off, the
voltage must be between 4.2 and
4.95 VDC. With the engine idling at
operating temperature, voltage must
be 1.5-3.0 VDC. Is it?

System
is now
OK.

Locate and re-
pair grounded vi-
olet/white wire.

TROUBLESHOOTING

MAP

sensor

[80B]

Ignition module

connector

MAP sensor

signal

5v REF

Ignition module

[11B] (Gr) [11A]

To cam

position

sensor

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

Red/white

Black/white

Violet/white

CHAPTER TWO

BATTERY VOLTAGE

Perform charging system tests as described
in this chapter. Is the charging system OK?

System OK.

With the ignition on, measure the
voltage drop between the positive
battery terminal, and pin 4 in the
handlebar connector [22A]. Is the
voltage drop greater than 0.5 volt?

Repair the charging system.

Replace white/
black wire or ter-
minals.

Locate and repair
any bad connec-
tions.

Problem is intermit-
tent. Perform wiggle
test.

Inspect the handlebar
connector [22] for
corrosion or loose
wires. If not present,
replace the right-hand
run/star t switch
(Chapter Twelve).

With the ignition
on, measure the
voltage drop be-
tween the positive
battery terminal
and grey terminal
on the ignition
fuse. Is the voltage
drop greater than
0.5 volt?

With the ignition on, measure the voltage
drop between the positive battery termi-
nal and the silver post on the circuit
breaker. Is the voltage drop greater than
0.5 volt?

Yes

Remove the spark plug wires. Install the test har-
nesses (Figure 44) between the ignition module
and the module connectors. While cranking the
engine, measure the voltage between Pin 1 and
Pin 11 on the black test harness and between Pin
1 and Pin 2 on the black test harness. Ignore
readings during the first 2 seconds of cranking.
Is the voltage above 8 volts? Reconnect the
spark plug cables.

Check the voltage drop in the ignition module
power circuit. Refer to

Electrical Testing in this

chapter With the ignition on, measure the voltage
drop between the positive battery terminal and
Pin 1 on the black test harness. Is the voltage
drop greater than 0.5 volt?

Check the voltage drop between the negative bat-
tery terminal and Pin 2 on the black test harness.
Is the voltage drop greater than 0.5 volt?

Yes

With the ignition on,
measure the voltage
drop between the
positive battery ter-
minal, and pin 3 in
the handlebar con-
nector [22A]. Is the
voltage drop greater
than 0.5 volt?

Yes

With the ignition on, measure the volt-
age drop between the positive battery
terminal and red/black terminal on the
ignition fuse. Is the voltage drop greater
than 0.5 volt?

Replace the ignition
switch (Chapter
Twelve) or terminals.

Yes

Replace the gray
wire or terminals.

TROUBLESHOOTING

Ignition module

[10B] [10A]

15 Amp

fuse

Battery

Ignition

switch

30 amp

main circuit breaker

(silver post)

Run/stop

switch

[22B] [22A]

High resistance between
the circuit breaker and
battery. Replace the wire
or terminals.

Replace the ignition switch (Chapter Twelve) or terminals.

With the ignition ON, measure the voltage drop between the
positive battery terminal and the copper post on the circuit
breaker. Is the voltage drop greater than 0.5 volt?

Replace the circuit
breaker (Chapter
Twelve).

Yes

Grey

White/black

Red/black

Black

Red

Silver post

Copper post

CHAPTER TWO

IGNITION COIL

Disconnect the coil connector
[83B]. Connect a test light to the
positive battery terminal and to ter-
minal C (front cylinder) or terminal
A (rear cylinder) of the coil
connector [83B]. Crank the engine.
Does the test light flash?

Perform a wiggle test. Any intermittents
found?

Install the test harnesses (Figure 44) be-
tween the ignition module and the mod-
ule connectors. Measure the resistance
between the indicated points on the test
harness and coil terminal connector
[83B]:

Is the resistance less than 0.5 ohms?

TROUBLE COIL

TEST

CODE

TERMINAL

HARNESS
(B)

Pin 6

(Blue/orange)

Pin 7

(Yellow/Blue)

Repair the open wire or connection
on the white/black wire.

Repair open wire
or connection.

* Replace the ignition
module.

Repair as necessary.

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

Yes

With the ignition on, measure the
voltage between terminal B con-
nector [83B] (white/black), and
ground. Is it equal to the battery
voltage?

Yes

Repair as
necessary.

Replace the
ignition coil.

Yes

Perform a wig-
gle test. Any
intermittents
found?

Yes

TROUBLESHOOTING

TACHOMETER (1998 1200S MODELS)

Disconnect the black ignition mod-
ule connector [10] from the ignition
module, and disconnect the meter
connector [20]. With the ignition
on, measure the voltage between
pin 11 and pin 12 on the ignition
module connector [10B]. Is battery
voltage present?

Check for continuity between pin 6 and pin 7 in
the meter connector [20]. Is continuity present?

Install the test harnesses (Figure 44) between
the ignition module and the module connectors.
Check for continuity between pin 11 and pin 12
in the black test harness. Is continuity present?

Repair short to
ground.

Check the continuity be-
tween pin 12 in the black
test harness and pin 7 in
the meter connector [20A].
Is continuity present?

Repair short to
voltage.

Reconnect the black igni-
tion module connector
[10] and start the engine.
Does the voltage

Locate
intermittents
and repair.

*Replace ignition
module.

Repair or re-
place pink wire.

Yes

Remove the black test
harness and disconnect
the meter connector
[20A]. Measure the volt-
age between pin 11 and
pin 12 in the discon-
nected ignition module
connector [10B]. Is bat-
tery voltage present?

Replace the
tachometer.

*Replace the ignition
module.

Tachometer

[20]

Ignition module

[10A] [10B] (Black)

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

Yes

Orange

Black

Pink

Black

Red/blue

CHAPTER TWO

TACHOMETER (1999-2003 1200S MODELS)

Disconnect the black ignition
module connector [10] from the
ignition module, and disconnect
connector [108] from the tachom-
eter. With the ignition on, mea-
sure the voltage between pin 11
and pin 12 on the ignition module
connector [10B]. Is battery volt-
age present?

Check for continuity between pin 6 and
pin 7 in the meter connector [20]. Is
continuity present?

Repair short.

Reconnect the ignition
module connector [10]
and start the engine.
Does the voltage change?

Yes

*Replace the ig-
nition module.

Locate intermittents
and repair.

Yes

Reconnect con-
nector [108] to
the tachometer.
Check the resis-
tance between
pin 11 and pin 12
in the black test
harness. Is resis-
tance less than
5000 ohms?

Yes

Replace the
tachometer.

*Replace the ignition
module.

Yes

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

Install the test harnesses (Figure 44)
between the ignition module and the
module connectors. Check the conti-
nuity between pin 11 and pin 12 in
the black test harness and between
pin 2 and pin 12 in the black test har-
ness. Is continuity present?

Disconnect the
meter connector
[20]. Check for
continuity be-
tween pin 11 and
pin 12 in the
black test har-
ness. Is continu-
ity present?

Repair the short
to ground on the
pink wire between
the ignition mod-
ule connector
[10B] and the me-
ter connector
[20A].

Repair the short
to ground on the
pink wire be-
tween the meter
connector [20B]
and the tachome-
ter connector
[108B].

TROUBLESHOOTING

Tachometer

[10B] [10A] (Black)

[108B]

[108A]

[20B]

[20A]

Ignition module

Orange

Red/black

Black

Pink

Black

CHAPTER TWO

CAM POSITION SENSOR

Replace the
ignition
module*

Install both test harnesses
(Figure 44) between the igni-
tion module and the ignition
module connectors. Turn the
ignition on. Measure the
voltage between pin 1 and
pin 8 at the gray test har-
ness. What is the voltage?

Yes

Intermittent open in
green/white wire or short in
the white/blue or red/white
wires. Repair intermittent.

Repair.

Check the rotor for damage. Is the
rotor loose or damaged?

Is the rotor attached properly?

Repair.

Remove the
gearcase
cover and in-
spect for
damage.

Yes

Replace the rotor and retest.

Yes

Locate and repair the
short to ground on the
red/white wire.

Locate and repair the
open in the red/white
wire or the green/white
wire between the cam
position sensor con-
nector [14] and the
gray ignition module
connector [11].

Locate and re-
pair the short to
voltage on the
red/white wire.

0 volts

5 volts

12 volts

Disconnect the gray ignition module con-
nector [11B] from the ignition module. Turn
the ignition on. Measure the voltage be-
tween pin 1 and pin 8 on the ignition mod-
ule. Is the voltage 5 ± 0.25 volts?

Remove the timing
cover and cam po-
sition sensor
(Chapter Twelve).
Observe the rotor
cup while cranking
the engine. Does
the rotor turn?

Yes

Replace the cam posi-
tion sensor plate and
clear the code. Retest.
Does the problem still
exist?

Yes

*Replace igni-
tion module.

Disconnect the cam position sensor
connector [14]. Turn the ignition on.
Measure the voltage between terminal
A and terminal C in the sensor con-
nector [14B]. Is the voltage 5 ± 0.25
VDC?

Reconnect the cam position sensor connector
[14]. Install both test harnesses between (Figure
44) the ignition module and the ignition module
connectors. Crank the engine, and measure the
voltage across pin 3 and pin 8 in the gray test
harness. Is voltage 2-3 volts?

Check for continuity on the
green/white wire. Is there
continuity on each wire?

TROUBLESHOOTING

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

[14B] [14A]

Cam position

sensor

Ignition module

Ground

Signal

[11B] [11A]

5 v REF

Red/white

Green/white

Black/white

CHAPTER TWO

BANK ANGLE SENSOR

Reconnect and clear the codes
as described in this section. Re-
check for codes.

11-13 VDC

Install properly.

Replace the bank
angle sensor.

Repair the
open in the
green/gray
wire.

Check continuity
to ground at
socket B on the
bank angle sen-
sor connector
[134B]. Is conti-
nuity present?

Yes

Repair the open to
ground in the black
wire.

Check continuity to
ground at socket A on
the bank angle sensor
connector [134B]. Is
continuity present?

Yes

Repair the
short to
ground on the
green/gray
wire.

*Replace
the ignition
module and
recheck for
codes.

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

Disconnect the bank angle sensor connector [134B]. Turn the ignition on. Measure the voltage between
socket A and socket B in the bank angle sensor connector. What is the voltage?

0 V

Repair short to
voltage on the
green/gray wire.

1998 models: 3.0-3.5 VDC
1999-2003 models: 4-6 VDC

Yes

Are ferrous met-
als within 1/4 in.
(6.4 mm) of the
sides, face or
top of sensor?

Yes

Reinstall
the sensor
correctly.

Yes

Is the bank angle sensor connected?

Repair the open in
the gray wire be-
tween the sensor
connector [134] and
the harness.

Yes

Measure the voltage between
socket B and socket C on the
bank angle sensor connector. Is
the voltage 11-13 volts?

Is the bank angle sensor correctly
installed as decribed in Chapter
Twelve?

Install the test harnesses (Figure
44) between the ignition module
and the module connectors. Check
the continuity between Terminal 10
in the black test harness and
Socket A in the bank angle sensor
connector [134B]. Is continuity
present?

TROUBLESHOOTING

[134B] [134A]

Bank angle sensor

Ignition module

[10]

To vehicle

ground

Green/gray

Black

Gray

Red/black

CHAPTER TWO

Check:

* Worn float needle valve or dirty seat
* Incorrect float level
* Damaged float bowl O-ring or loose float bowl

mounting screws

* Damaged float pin or loose locking screw
* Damaged float

Fuel overflows

Check:

* Dirty or plugged carburetor passages
* Clogged fuel lines
* Clogged fuel strainer in tank
* Air leak at carburetor mount
* Dirty air filter
* Loose carburetor jets

Low power at all speeds

Check:

* Clogged accelerator pump
* Worn accelerator pump diaphragm
* Idle mixture misadjusted (early models with

idle mixture adjustment)

* Clogged pilot jet
* Float level too high

Check:

* Idle misadjusted
* Worn idle mixture screw
* Blocked jet or port in carburetor bore
* Air leak at carburetor mounting
* Accelerator pump rod too long or misadjusted

Check:

* Loose or clogged main jet
* Incorrect float level
* Dirty or plugged carburetor passages

Poor power at high speeds

Poor acceleration

Poor idling

KEIHIN CARBURETOR TROUBLESHOOTING

(1986-1987 MODELS)

Check:

* Clogged fuel line
* Carburetor dirty
* Fuel tank strainers clogged or dirty
* Accelerating pump not operating correctly
* Fuel tank dirty

Poor fuel economy

Check:

* Float level too low
* Loose jets
* Clogged bleed tubes of jets
* Choke not opening fully
* Dirty air filter

Fuel starvation

Content .. 8 9 10 11 ..