Harley Davidson Sportster Troubleshooting. Manual

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Begin any troubleshooting procedure by defining the

If one basic requirement is missing, the engine will not

symptoms as precisely as possible. Gather as much infor-

run. Refer to Figure 1 for four-stroke engine operating

mation as possible to aid diagnosis. Never assume any-

principles.

thing and do not overlook the obvious. Make sure there is

fuel in the tank, and the fuel valve is in the on position.

ENGINE STARTING

Make sure the engine stop switch is in the run position and

the spark plug wires are attached to the spark plugs.

If a quick check does not reveal the problem, turn to the

Engine Fails to Start (Spark Test)

troubleshooting procedures described in this chapter.

Perform the following spark test to determine if the ig-

Identify the procedure that most closely describes the

nition system is operating properly:

symptoms, and perform the indicated tests.

In most cases, expensive and complicated test equip-

CAUTION

ment is not needed to determine whether repairs can be

Before removing the spark plugs in Step 1,

performed at home. A few simple checks could prevent an

clean all dirt and debris away from the plug

unnecessary repair charge. On the other hand, be realistic

base. Dirt that falls into the cylinder causes

and do not attempt repairs beyond your capabilities. Many

rapid engine wear.

service departments will not take work that involves the

assembly of damaged or abused equipment. If they do, ex-

1. Disconnect the spark plug wire and remove the spark

pect the cost to be high.

plug as described in Chapter Three.

Refer to Tables 1-3, at the end of this chapter, for elec-

trical specifications and diagnostic trouble codes.

NOTE

A spark tester is a useful tool for testing

spark output. Figure 2 shows the Motion

ENGINE OPERATING

Pro Ignition System Tester

(part No.

REQUIREMENTS

08-0122). This tool is inserted in the spark

plug cap and its base is grounded against

An engine needs three basics to run properly: correct

the cylinder head. The tool’s air gap is ad-

air/fuel mixture, compression and a spark at the right time.

justable, and it allows the visual inspection

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of the spark. This tool is available at motor-

cycle repair shops.

2. Cover the spark plug hole with a clean shop cloth to re-

duce the chance of gasoline vapors being emitted from the

hole.

3. Insert the spark plug (Figure 3), or spark tester (Fig-

ure 4), into its plug cap and ground the spark plug base

against the cylinder head. Position the spark plug so the

electrode is visible.

WARNING

Mount the spark plug, or tester, away from

the spark plug hole in the cylinder so the

spark plug or tester cannot ignite the gaso-

line vapors in the cylinder. If the engine is

flooded, do not perform this test. The firing

of the spark plug can ignite fuel that is

ejected through the spark plug hole.

4. Turn the ignition switch on.

WARNING

Do not hold the spark plug, wire or connec-

tor, or a serious electrical shock may result.

5. Turn the engine over with the starter. A crisp blue

spark should be evident across the spark plug electrode or

spark tester terminals. If there is strong sunlight on the

plug, shade the plug to better see the spark.

Contaminated fuel system.

6. If the spark is good, check for one or more of the fol-

Improperly adjusted carburetor.

lowing possible malfunctions:

Defective ignition module.

a. Obstructed fuel line or fuel filter.

Defective ignition coil.

b. Low compression or engine damage.

10. Damaged ignition coil primary

and/or

secondary

c. Flooded engine.

wires.

d. Incorrect ignition timing.

11. Incorrect ignition timing.

12. Low engine compression.

NOTE

13. Discharged battery.

If the engine backfires during starting, the

ignition timing may be incorrect due to a de-

14. Defective starter.

fective ignition component. Refer to Igni-

15. Loose or corroded starter and/or battery cables.

tion Timing in Chapter Three.

16. Loose ignition sensor and module electrical connec-

tor.

7. If the spark is weak or if there is no spark, refer to En-

17. Incorrect pushrod length (intake and exhaust valve

gine is Difficult to Start in this section.

pushrods interchanged).

Engine is Difficult to Start

Engine Does Not Crank

Check for one or more of the following possible mal-

functions:

Check for one or more of the following possible mal-

1. Fouled spark plug(s).

functions:

2. Improperly adjusted enrichment valve.

1. Ignition switch turned off.

3. Intake manifold air leak.

2. Faulty ignition switch.

4. Plugged fuel tank filler cap.

3. Engine run switch in off position.

5. Clogged fuel line.

4. Defective engine run switch.

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9. Wiring or connector damage.

10. Water or other contaminates in the fuel.

11. Weak or damaged valve springs.

12. Incorrect camshaft/valve timing.

13. Damaged valve(s).

14. Dirty electrical connections.

15. Intake manifold or carburetor air leak.

16. Plugged carburetor vent hose.

17. Plugged fuel tank vent system.

Engine Overheating

1. Incorrect carburetor adjustment or jet selection.

5. Loose or corroded starter and battery cables (solenoid

2. Incorrect ignition timing or defective ignition system

chatters).

components.

6. Discharged or defective battery.

3. Improper spark plug heat range. Refer to

Chapter

7. Defective starter.

Three.

8. Defective starter solenoid.

4. Damaged or blocked cooling fins.

9. Defective starter shaft pinion gear.

10. Slipping overrunning clutch assembly.

5. Low oil level.

11. Seized piston(s).

6. Oil not circulating properly.

12. Seized crankshaft bearings.

7. Leaking valves.

13. Broken connecting rod.

8. Heavy combustion chamber carbon deposits.

ENGINE PERFORMANCE

Engine Runs Rough with Excessive

Exhaust Smoke

If the engine runs, but is not operating at peak perfor-

mance, refer to the following as a starting

point from

1. Clogged air filter element.

which to isolate a performance malfunction.

2. Rich carburetor adjustment.

3. Choke not operating correctly.

Spark Plugs Fouled

4. Water or other fuel contaminants.

5. Clogged fuel line and/or filter.

1. Severely contaminated air filter element.

6. Spark plug(s) fouled.

2. Incorrect spark plug heat range. Refer

Chapter

7. Defective ignition coil.

Three.

8. Defective ignition module or sensor(s).

3. Rich fuel mixture.

9. Loose or defective ignition circuit wire.

4. Worn or damaged piston rings.

10. Short circuits from damaged wire insulation.

5. Worn or damaged valve guide oil seals.

11. Loose battery cable connections.

6. Excessive valve stem-to-guide clearance.

12. Incorrect camshaft/valve timing.

7. Incorrect carburetor float level.

13. Intake manifold or air filter air leak.

Engine Misfire

Engine Lacks Power

1. Fouled or improper spark plug gap.

2. Damaged spark plug cables.

1. Incorrect carburetor adjustment.

3. Incorrect ignition timing.

2. Clogged fuel line.

4. Defective ignition components.

3. Incorrect ignition timing.

5. Obstructed fuel line or fuel shutoff valve.

4. Dragging brake(s).

6. Obstructed fuel filter.

5. Engine overheating.

7. Clogged carburetor jets.

6. Incorrect ignition timing.

8. Loose battery connection.

7. Incorrect spark plug gap.

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Valve Train Noise

Battery

1. Bent pushrod(s).

terminal

2. Defective hydraulic lifter(s).

Starter/field wire

terminal

3. Bent valve(s).

4. Rocker arm seizure or damage (binding on shaft).

5. Worn or damaged camshaft gear bushing(s).

Field

6. Worn or damaged camshaft gear(s).

wire

Solenoid

STARTING SYSTEM

The starting system consists of the battery, starter,

starter relay, solenoid, start button, and related wiring.

When the ignition switch is turned on and the start but-

ton is pushed in, current is transmitted from the battery to

Starter

the starter relay. When the relay is activated, it activates

the starter solenoid that mechanically engages the starter

Relay

terminal

with the engine.

Starting system problems are most often related to a

loose or corroded electrical connection.

Refer to Figure 5 for starter and solenoid terminal iden-

tification.

Troubleshooting Preparation

0.1 amp

Start switch

Before troubleshooting the starting system, check for

the following:

0.1 amp

1. The battery is fully charged.

20 amp

Relay

2. Battery cables are the proper size and length. Replace

damaged or undersized cables.

Ignition fuse

3. All electrical connections are clean and tight. High re-

sistance caused from dirty or loose connectors can affect

VOM

voltage and current levels.

Ignition switch

4. The wiring harness is in good condition, with no worn

or frayed insulation or loose harness sockets.

5. The fuel tank is filled with an adequate supply of fresh

Maxi

fuse

gasoline.

6. The spark plugs are in good condition and properly

gapped.

7. The ignition system is working correctly.

Solenoid

200 amp

Battery

200 amp

Voltage Drop Test

Prior to performing procedures in the Starter Testing

Starter

section, perform a voltage drop test.

1. To check voltage drop in the solenoid circuit, connect

the positive voltmeter lead to the positive battery terminal.

Connect the negative voltmeter lead to the solenoid termi-

nal (Figure 6).

2. Turn the ignition switch on and push the starter button

while reading the voltmeter scale. Note the following:

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any ground circuit in the starting circuit,

repeat this test and leave the negative volt-

meter lead connected to the battery and

connect the positive voltmeter lead to the

0.1 amp

ground in question.

Start switch

0.1 amp

Starter Testing

20 amp

Relay

CAUTION

Never operate the starter for more than 30

Ignition fuse

seconds at a time. Allow the starter to cool

VOM

before reusing it. Failing to allow the starter

to cool after continual starting attempts can

Ignition switch

damage the starter.

The basic starter-related troubles are:

Maxi

1. Starter does not spin.

fuse

2. Starter spins but does not engage.

3. The starter does not disengage after the start button is

released.

Solenoid

200 amp

4. Loud grinding noises when starter turns.

Battery

200 amp

5. Starter stalls or spins too slowly.

Starter

Starter does not spin

1. Turn the ignition switch on and push the starter button

while listening for a click at the starter relay. Turn the ig-

nition switch off and note the following:

a. If the starter relay clicks, test the starter relay as de-

scribed in this section. If the starter relay test read-

ings are correct, continue with Step 2.

b. If the solenoid clicks, go to Step 3.

The circuit is operating correctly if the voltmeter

c. If there was no click, go to Step 5.

reading is 1.0 volt or less. A voltmeter reading of 12

2. Check the wiring connectors between the starter relay

volts indicates an open circuit.

and solenoid. Note the following:

A voltage drop of more than 1.0 volt indicates a

a. Repair any dirty, loose-fitting or damaged connec-

problem in the solenoid circuit.

tors or wiring.

If the voltage drop reading is correct, continue with

b. If the wiring is in good condition, remove the starter

Step 3.

as described in Chapter Nine. Perform the solenoid

To check the starter ground circuit, connect the nega-

and starter bench tests as described in this section.

tive voltmeter lead to the negative battery terminal. Con-

3. Perform a voltage drop test between the battery and so-

nect the positive voltmeter lead to the starter housing

lenoid terminals as described in Voltage Drop Test in this

(Figure 7).

section. The normal voltage drop is less than 1.0 volt.

4. Turn the ignition switch on and push the starter button

Note the following:

while reading the voltmeter scale. The voltage drop must

a. If the voltage drop is less than 1.0 volt, perform Step

not exceed 0.2 volt. If it does, check the ground connec-

tions between the meter leads.

b. If the voltage drop is more than 1.0 volt, check the

5. If the problem is not found, refer to the Starter Testing

solenoid and battery wires and connections for dirty

section.

or loose fitting terminals; clean and repair as re-

quired.

NOTE

Step 3 and Step 4 check the voltage drop

4. Remove the starter as described in Chapter Nine. Mo-

across the starter ground circuit. To check

mentarily connect a fully charged 12-volt battery to the

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Battery

Field wire

terminal

starter as shown in Figure 8. If the starter is operational, it

will turn when connected to the battery. Disconnect the

battery and note the following:

a. If the starter turns, perform the solenoid pull-in and

hold-in tests as described in Solenoid Testing

(Bench Tests) in this section.

b. If the starter does not turn, disassemble the starter as

described in Chapter Nine, and check it for opens,

shorts and grounds.

5. If there is no click when performing Step 1, measure

voltage between the starter button and the starter relay.

The voltmeter must read battery voltage. Note the follow-

ing:

a. If there is battery voltage, continue with Step 6.

b. If there is no voltage, go to Step 6.

2. Check the starter pinion gear (A, Figure 9). If the teeth

6. Check for voltage at the starter button. Note the fol-

are chipped or worn, inspect the clutch shell ring gear (B,

lowing:

Figure 9) for the same problems. Note the following:

a. If there is voltage at the starter button, test the starter

a. If the starter pinion gear or clutch ring gear is dam-

relay as described in this section.

aged, service the parts.

b. If there is no voltage at the starter button, check

b. If the starter pinion gear and clutch shell ring gear

continuity across the starter button. If there is volt-

are not damaged, continue with Step 3.

age leading to the starter button, but no voltage

c. Make sure the pinion does not run in overrunning

leaving the starter button, replace the button switch

direction.

and retest. If there is no voltage leading to the starter

button, check the starter button wiring for dirty or

3. Remove and disassemble the starter as described in

loose-fitting terminals or damaged wiring; clean

Chapter Nine. Then check the overrunning clutch assem-

and/or repair as required.

bly (Figure 10 and Figure 11) components for wear

and/or damage:

a. Rollers (Figure 12).

Starter spins but does not engage

b. Compression spring (A, Figure 13).

If the starter spins but the pinion gear does not engage

c. Pinion teeth.

the clutch shell ring gear, perform the following:

d. Clutch shaft splines (B, Figure 13).

1. Remove the primary drive cover as described in Chap-

ter Six.

4. Replace worn or damaged parts as required.

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3. Check the start button switch and starter relay for inter-

nal damage. Test the start switch as described in Chapter

Eight. Test the starter relay as described in this chapter.

Loud grinding noises when the starter turns

Incorrect starter pinion gear and clutch shell ring gear

engagement (B, Figure 9) or a broken overrunning clutch

mechanism (Figure 11) can cause this problem. Remove

and inspect the starter as described in Chapter Nine.

Starter stalls or spins too slowly

1. Perform a voltage drop test between the battery and so-

lenoid terminals as described under Voltage Drop Test in

this section. The normal voltage drop is less than 1.0 volt.

Note the following:

a. If the voltage drop is less than 1.0 volt, continue

with Step 2.

b. If the voltage drop exceeds 1.0 volt, check the sole-

noid and battery wires and connections for dirty or

loose-fitting terminals; clean and repair as required.

2. Perform a voltage drop test between the solenoid ter-

minals and the starter. The normal voltage drop is less

than 1.0 volt. Note the following:

a. If the voltage drop is less than 1.0 volt, continue

with Step 3.

b. If the voltage drop exceeds 1.0 volt, check the sole-

noid and starter wires and connections for dirty or

loose-fitting terminals; clean and repair as required.

3. Perform a voltage drop test between the battery ground

wire and the starter as described under Voltage Drop Test

in this section. The normal voltage drop is less than 0.2

volt. Note the following:

a. If the voltage drop is less than 0.2 volt, continue

with Step 4.

b. If the voltage drop exceeds 0.2 volt, check the bat-

tery ground wire connections for dirty or loose-fit-

ting terminals; clean and repair as required.

4. Refer to Starter Current Draw Testing in this section

Starter does not disengage after releasing

and perform the first test. Note the following:

the start button

a. If the current draw is excessive, check for a dam-

aged starter. Remove the starter as described in

1. A sticking solenoid, caused by a worn solenoid com-

Chapter Nine and perform the second test.

pression spring (A, Figure 13), can cause this problem.

b. If the current draw reading is correct, continue with

Replace the solenoid if damaged.

Step 5.

2. On high-mileage motorcycles, the starter pinion gear

5. Remove the primary cover as described in Chapter Six.

(A, Figure 9) can jam on a worn clutch ring gear (B). Un-

Check the starter pinion gear (A, Figure 9). If the teeth are

able to return, the starter will continue to run. This condi-

chipped or worn, inspect the clutch ring gear (B, Figure

tion usually requires ring gear replacement.

9) for the same problem.

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a. If the starter pinion gear or clutch ring gear is dam-

aged, service it.

b. If the starter pinion gear and clutch ring gear are not

Inductive

ammeter

damaged, continue with Step 6.

6. Remove and disassemble the starter as described in

Chapter Nine. Check the disassembled starter for opens,

shorts and grounds.

Starter Current Draw Testing

Solenoid

A short circuit in the starter or a damaged pinion gear

assembly can cause excessive current draw. If the current

draw is low, suspect an undercharged battery or an open

circuit in the starting circuit.

Battery

Refer to Table 1 for current draw specifications.

Starter

Starter installed

This test requires a fully charged battery and an induc-

tive ammeter.

1. Shift the transmission into neutral.

2. Disconnect the two spark plug caps from the spark

plugs. Then ground the plug caps with two extra spark

Battery

plugs. Do not remove the spark plugs from the cylinder

terminal

heads.

3. Connect an inductive ammeter between the battery ter-

minal and positive battery terminal (Figure 14). Connect

Ammeter

a jumper cable from the negative battery terminal to

ground.

4. Turn the ignition switch on and press the start button

Relay

terminal

for approximately ten seconds. Note the ammeter reading.

NOTE

The current draw is high when the start but-

ton is first pressed, then it will drop and sta-

bilize at a lower reading. Refer to the lower

stabilized reading during this test.

5. If the current draw exceeds the specification in Table

1, check for a defective starter or starter drive mechanism.

Starter

Battery

Remove and service these components as described in

mounting

flange

Chapter Nine.

6. Disconnect the ammeter and jumper cables.

Starter removed

NOTE

The solenoid must be installed on the starter

This test requires a fully charged 12-volt battery, an in-

during the following tests.

ductive ammeter, a jumper wire (14-gauge minimum) and

three jumper cables (6-gauge minimum).

Mount the starter in a vise with soft jaws.

Refer to Figure 15.

Connect the 14-gauge jumper cable between the posi-

1. Remove the starter as described in Chapter nine.

tive battery terminal and the solenoid relay terminal.

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4. Connect a jumper cable (6-gauge minimum) between

the positive battery terminal and the ammeter.

5. Connect the second jumper cable between the amme-

ter and the battery terminal on the starter solenoid.

6. Connect the third jumper cable between the battery

ground terminal and the starter mounting flange.

7. Read the ammeter and refer to the maximum no-load

current specification in Table 1. A damaged pinion gear

assembly will cause an excessively high current draw

reading. If the current draw reading is low, check for an

undercharged battery, or an open field winding or arma-

ture in the starter.

Solenoid Testing (Bench Tests)

This test requires a fully charged 12-volt battery and

three jumper wires.

1. Remove the starter as described in Chapter Nine.

NOTE

Field wire

terminal

The solenoid (A, Figure 16) must be in-

stalled on the starter during the following

tests.

Solenoid

2. Disconnect the field wire (B, Figure 16) from the sole-

noid before performing the following tests. Insulate the

Battery

end of the wire terminal so it cannot short out on any of

the test connectors.

CAUTION

Starter

Because battery voltage is being applied di-

rectly to the solenoid and starter in the fol-

Relay

lowing tests, do not leave the jumper cables

terminal

connected to the solenoid for more than

three-five seconds; otherwise, the voltage

will damage the solenoid.

NOTE

Thoroughly read the following procedure to

become familiar with and understand the

procedures and test connections, then per-

form the tests in the order listed and without

interruption.

3. Refer to Figure 17 and perform the solenoid pull-in

test as follows:

a. Connect one jumper wire from the negative battery

terminal to the field wire terminal on the solenoid.

b. Connect one jumper wire from the negative battery

terminal to the solenoid housing (ground).

c. Touch a jumper wire from the positive battery ter-

minal to the starter relay terminal. The pinion shaft

(Figure 18) should pull into the housing.

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d. Leave the jumper wires connected and continue

with Step 4.

4. To perform the solenoid hold-in test, perform the fol-

Field wire

lowing:

terminal

a. With the pinion shaft pulled in (Step 3), disconnect

the field wire terminal jumper wire from the nega-

tive battery terminal and connect it to the positive

Solenoid

battery terminal

(Figure

19). The pinion shaft

should remain in the housing. If the pinion shaft re-

turns to its original position, replace the solenoid.

Battery

b. Leave the jumper wires connected and continue

with Step 5.

5. To perform the solenoid return test, perform the fol-

Starter

lowing:

a. Disconnect the jumper wire from the starter relay

Relay

terminal

terminal (Figure 20); the pinion shaft should return

to its original position.

b. Disconnect all the jumper wires from the solenoid

and battery.

6. Replace the solenoid if the starter shaft failed to oper-

ate as described in Steps 3-5. Refer to Solenoid Replace-

ment in Chapter Nine.

Field wire

terminal

Starter Relay Test

Check the starter relay operation with an ohmmeter,

Solenoid

jumper wires and a fully charged 12-volt battery.

1. Remove the starter relay as described in Chapter Nine.

Battery

CAUTION

The battery negative lead must be con-

nected to the relay terminal No. 2 to avoid

Starter

internal diode damage.

2. Connect an ohmmeter and 12-volt battery between the

Relay

terminal

relay terminals as shown in Figure 21. This setup will en-

ergize the relay for testing.

3. Check for continuity through the relay contacts using

an ohmmeter while the relay coil is energized. The correct

A malfunction in the charging system generally causes

reading is 0 ohm. If resistance is excessive or if there is no

the battery to remain undercharged.

continuity, replace the relay.

4. If the starter relay passes this test, reinstall the relay.

Precautions

Before testing the charging system, observe the follow-

CHARGING SYSTEM

ing precautions to prevent damage to the system:

The charging system consists of the battery, alternator

1. Never reverse battery connections.

and voltage regulator/rectifier.

2. Do not short across any connection.

The alternator generates alternating current (AC) which

3. Never start the engine with the alternator disconnected

the rectifier converts to direct current (DC). The regulator

from the voltage regulator/rectifier unless instructed to do

maintains the voltage to the battery and load (lights, igni-

so during testing.

tion and accessories) at a constant voltage despite varia-

4. Never start or run the engine with the battery discon-

tions in engine speed and load.

nected.

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8. Do not mount the voltage regulator/rectifier in another

location.

9. Make sure the negative battery terminal is connected

to the terminal on the engine.

Troubleshooting Sequence

If the battery is discharged, perform the following:

12-volt battery

1. Test the battery as described in Chapter Nine. Charge

the battery if necessary. If the battery does hold a charge

while riding, perform the Charging System Output Test.

2. If the charging system output is within specification,

determine the total amount of current demand by the elec-

trical system and all accessories as described in Electrical

System Current Load Test.

3. If the charging system output exceeds the current de-

mand and the battery continues to not hold a charge, per-

Ohmmeter

form the Battery Current Draw Test.

4. If the charging system output is not within specifica-

tion, test the stator and voltage regulator as described in

Chapter Nine.

Charging System Output Test

CAUTION

When using a load tester, refer to the manu-

facturer’s instructions. To prevent tester

damage caused by overheating, do not leave

the load switch on for more than 20 seconds

at a time.

This test requires a load tester.

1. To perform this test, the battery must be fully charged.

2. Connect the load tester negative and positive leads to

the battery terminals. Then place the load tester’s induc-

tion pickup around the Maxi-fuse to voltage regulator red

wire (B, Figure 22).

3. Start the engine and slowly bring the speed up to 3000

rpm while reading the load tester scale. With the engine

running at 3000 rpm, operate the load tester switch until

the voltage scale reads 13.0 volts. The tester should show

a regulated (DC) current output reading of 19-23 amps.

5. Never use a high-output battery charger to help start

4. With the engine still running at 3000 rpm, turn the load

the engine.

off and read the load tester voltage scale. Battery voltage

should not exceed 15 volts. Turn the engine off and dis-

6. Before charging the battery, remove it from the motor-

connect the load tester from the motorcycle.

cycle as described in Chapter Nine.

5. Refer to Alternator in Chapter Nine and test the stator.

7. Never disconnect the voltage regulator/rectifier con-

If the stator tests acceptable, there is a defective voltage

nector with the engine running. The voltage regulator/rec-

regulator/rectifier or a wiring short circuit. Make sure to

tifier (A, Figure 22) is mounted on the front frame cross

eliminate the possibility of a poor connection or damaged

member.

wiring before replacing the voltage regulator/rectifier.

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Electrical System Current Load Test

Ammeter

CAUTION

When using a load tester, refer to the manu-

facturer’s instructions. To prevent tester

damage caused by overheating, do not leave

the load switch on for more than 20 seconds

at a time.

This test, requiring a load tester, measures the total cur-

rent load of the electrical system and any additional acces-

sories while the engine is running. Perform this test if the

battery is continually discharged, yet the charging system

Negative

output is within specification.

battery cable

If aftermarket electrical components have been added

Ground

to the motorcycle, the increased current demand may ex-

stud

ceed the charging system's capacity and cause a dis-

charged battery.

1. Connect a load tester to the battery per the manufac-

turer’s instructions.

2. Turn the ignition switch on, but do not start the engine.

Then turn on all electrical accessories and switch the

headlight beam to HIGH.

3. Read the ampere reading (current draw) on the load

tester and compare it to the Charging System Output Test.

The charging system output test results (current reading)

must exceed the electrical system current load by 3.5

amps for the battery to remain sufficiently charged.

4. If aftermarket accessories have been added to the mo-

torcycle, disconnect them and repeat Step 3. If the electri-

cal system current load is now within the specification,

the problem is with the additional accessories.

5. If no accessories have been added to the motorcycle, a

short circuit may be causing the battery to discharge.

Battery Current Draw Test

This test measures the current draw on the battery when

all electrical systems and accessories are off. Perform this

test if the battery does not hold a charge when the motor-

cycle is not being used. A current draw that exceeds 3.5

mA will discharge the battery. The voltage regulator (0.5

Refer to the appropriate wiring diagram at the end of

mA), TSM (0.5 mA) and TSSM (2.5 mA) account for a

this manual. Check the charging system wires and con-

3.5 mA current draw. The battery must be fully charged to

nectors for shorts or other damage.

perform this test.

1. Disconnect the negative battery cable as described in

5. Unplug each electrical connector separately and check

Chapter Nine.

for a reduction in the current draw. If the meter reading

2. Connect an ammeter between the negative battery ca-

changes after a connector is disconnected, the source of

ble end and the ground stud on the engine crankcase as

the current draw has been found. Check the electrical con-

shown in Figure 23.

nectors carefully before testing the individual component.

3. With the ignition switch, lights and all accessories

turned off, read the ammeter. If the current exceeds 3.5

6. After completing the test, disconnect the ammeter and

mA, continue with Step 4.

reconnect the negative battery cable.

-------------------------------------------------------------------------------------------------------------------------------------------------------------

4. Check all electrical components for a good ground to

the engine.

5. Check all wiring for short circuits or open circuits.

6. Remove the rear fender inner panel as described in

Chapter Fourteen.

7. Remove the left side cover and check for a blown igni-

tion circuit fuse (Figure 25).

8. Make sure the fuel tank has an adequate supply of

fresh gasoline.

9. Check the spark plug cable routing and the connections at

the spark plugs. If there is no spark or only a weak one, re-

peat the test with new spark plugs. If the condition remains

Terminal A

Terminal C

the same with new spark plugs and if all external wiring con-

rear coil

nections are good, the problem is most likely in the ignition

Terminal B

+12 V

system. If a strong spark is present, the problem is probably

not in the ignition system. Check the fuel system.

IGNITION SYSTEM

Ignition Coil Testing

Precautions

Use an ohmmeter to check the ignition coil secondary

and primary resistance. Test the coil twice: first when it is

Before testing the ignition system, observe the follow-

cold (room temperature), then at normal operating tem-

ing precautions to prevent damage to the system.

perature. If the engine does not start, heat the coil with a

1. Never disconnect any of the electrical connectors

hair dryer, then test with the ohmmeter.

while the engine is running.

1. Remove the ignition coil as described in Chapter Nine.

2. Apply dielectric grease to all electrical connectors prior

to reconnecting them. This will help seal out moisture.

2. Measure the ignition coil primary resistance between

3. Make sure all electrical connectors are free of corro-

the primary coil terminals. Refer to Figure 26. Compare

sion and are completely coupled to each other.

the reading to the specification in Table 2. Replace the ig-

4. The ignition module (Figure 24) must always be

nition coil if the reading is not within specification.

mounted securely to the mounting bracket under the seat.

3. Measure the resistance between the secondary termi-

nals. Refer to Figure 26. Compare the reading to the spec-

ification in Table

2. Replace the ignition coil if the

Troubleshooting Preparation

reading is not within specification.

1. Refer to the wiring diagram at the end of this manual

for the specific model.

Spark Plug Cable and Cap Inspection

2. Check the wiring harness for visible signs of damage.

3. Make sure all connectors are properly attached to each

All models are equipped with resistor-type spark plug

other and locked in place.

cables (Figure 27). These cables reduce radio interfer-

-------------------------------------------------------------------------------------------------------------------------------------------------------------

ence. The cable’s conductor consists of a carbon-impreg-

nated fabric core material instead of solid wire.

Spark plug cable resistance will increase in a corroded,

broken or otherwise damaged cable. Excessive cable re-

sistance will cause engine misfire and other ignition or

drivability problems.

When troubleshooting the ignition system, inspect the

spark plug cables for:

1. Corroded or damaged connector ends.

2. Breaks in the cable insulation that could allow arcing.

3. Split or damaged plug caps that could allow arcing to

the cylinder heads.

4. Replace damaged or questionable spark plug cables.

ELECTRONIC DIAGNOSTIC SYSTEM

All models are equipped with an electronic diagnostic

system that monitors the operating condition of the speed-

ometer, ignition control module (ICM), turn signal/secu-

rity module (TSM/TSSM) and tachometer, if so equipped.

A serial data bus connects the components. If a malfunc-

tion occurs, a diagnostic trouble code (DTC) may be gen-

erated.

The DTC identifies an anamoly detected by an electri-

cal component. The trouble code is retained in the mem-

ory of the ICM, TSM/TSSM, speedometer and

Note the following indications of potential problems

tachometer, if so equipped. A DTC is categorized as cur-

during startup:

rent or historic.

a. If the check engine symbol or security symbol does

A current DTC identifies a problem that affects present

not illuminate, an instrument may be faulty. Refer to

motorcycle operation.

Initial Diagnostic Check.

A historic DTC identifies a problem that has been re-

b. If the check engine symbol or security symbol illu-

solved either through servicing or a changed condition.

minates after 20 seconds, a serial data bus problem

Historic DTCs are retained to provide information should

may exist. Check for a DTC.

an intermittent problem exist. A historic DTC is retained

c. If the check engine symbol or security symbol stays

in memory until fifty start/run cycles have occurred, at

on, an instrument may be faulty or a DTC exists.

which point the DTC is erased.

Refer to Initial Diagnostic Check.

Not all malfunctions cause the generation of a DTC.

Refer to No-DTC Fault.

DTC Retrieval

Startup Check

Trouble codes are configured in a five digit format consist-

ing of a letter prefix followed by four numbers.

The diagnostic system indicates a normal condition or

an operating problem each time the ignition key is turned

NOTE

The message BusEr is a trouble code which

on (ignition).

may appear during diagnostic troubleshoot-

1. During normal startup, the following occurs after the

ing. BusEr indicates a problem in the serial

key is turned on:

bus data circuit.

a. The check engine symbol (A, Figure 28) illumi-

nates for four seconds, then goes out.

Two methods may be used to retrieve trouble codes, either

b. The security symbol (B, Figure 28) illuminates for

through performing the retrieval sequence at the speedome-

four seconds, then goes out.

ter or using the H-D Digital Technician tool. The following

-------------------------------------------------------------------------------------------------------------------------------------------------------------

4. Press and release the odometer reset button. The letters

PSSPt appear in the odometer window (Figure 30). The

letter P will flash indicating that information concerning

the ICM is obtainable. The letters PSSPt identify the fol-

lowing components:

a. The letter P identifies the ICM.

b. The letter S identifies the TSM/TSSM.

c. The letters SP identify the speedometer.

d. The letter t identifies the tachometer.

5. To cycle through the PSSPt letter identifiers, push and

quickly release the odometer reset button. The selected

component letter identifier will flash.

6. To obtain a DTC, select a component (identifier let-

ter(s) flashes) then push and hold in the odometer reset

button for at least 5 seconds. Release the button. The code

will appear in the odometer window (Figure 31), or none.

Record the DTC.

NOTE

When reading codes in Step 7 push in and

release the reset button only long enough to

retreive the next code. Holding in the reset

button for more than 5 seconds will erase

the codes.

7. Press and release the reset button as needed to read ad-

ditional trouble codes until end appears.

describes using the speedometer to retrieve DTCs. If neces-

NOTE

sary, take the motorcycle to a dealership equipped with the

On models not equipped with a tachometer,

H-D Digital Technician.

No Rsp will appear when the tachometer

identifier is selected.

Perform the following to read a DTC:

8. If none appears, pushing and releasing the reset button

NOTE

will cause the display of the component part number. For

Make sure the run/stop handlebar switch is

in the run position.

instance, the display may read Pn 32478-04 for the ICM.

9. Push and release the reset button to return to the PSSPt

1. Push and hold in the odometer reset button on the back

display.

of the speedometer.

10. Turn off the ignition key to exit the diagnostic pro-

2. Turn the ignition key on, then release the reset button.

gram.

The following should occur:

a. The speedometer backlighting comes on.

Diagnostic Tools

b. The speedometer needle rotates to full deflection

position (A, Figure 29).

The troubleshooting steps in some of the flowcharts in this

chapter require using H-D breakout box part No. HD-42682

NOTE

(Figure 32) and adapters HD-46601.

The security symbol may come on even

The H-D computer program Digital Technician (part

though the motorcycle is not equipped with

No. HD-44750) must be used to read historic DTCs, and

a security system.

to erase them. The Digital Technician is also necessary to

c. The check engine, battery and security symbols il-

reprogram a new ICM.

luminate.

The H-D breakout box is separated into two panels (black

3. The message diag appears in the odometer window on

and gray). The panel colors relate to the box connector colors:

the speedometer (B, Figure 29).

one pair black and one pair gray.

-------------------------------------------------------------------------------------------------------------------------------------------------------------

Refer to the following when connecting the breakout

box:

1. Speedometer/tachometer—Refer to Chapter Nine and

remove the back of the speedometer or tachometer. Dis-

connect the connector (Figure 33) and attach the adapt-

HD 42682

ers. Connect the black breakout box connectors to the

adapters. Use the sockets on the black breakout box panel

during testing.

2. TSM/TSSM—Refer to Chapter Nine and remove the

TSM/TSSM. Connect the gray breakout box connectors to

BLACK

the TSM/TSSM and to the connector. Use the sockets on the

GRAY

gray breakout box panel during testing. Reinstall the battery.

3. ICM—Remove the seat. Disconnect the ICM connec-

tor (Figure 34). Connect the black breakout box connec-

tors to the ICM and to the connector. Use the sockets on

the black breakout box panel during testing.

Data Link Connector

A data link connector provides access to the data bus

No-DTC fault

and provides a testing terminal when troubleshooting.

The connector is located behind the left side cover. Re-

Some malfunctions, such as fuel and starting system prob-

move the connector cap (Figure 35) for access to the con-

lems, do not trigger a DTC. In those cases, the troubleshoot-

nector terminals.

ing guidelines found in this chapter will serve to locate the

problem. However, there are faults that can be diagnosed us-

ing the procedures implemented when diagnosing a DTC.

DTC Troubleshooting

The following faults may not generate a DTC, but the speci-

A list of DTCs is found in Table 3 at the end of this

fied flowchart will help identify the problem.

chapter, which also identifies the possible problem and a

1. No spark or ICM power—Figure 55.

troubleshooting flowchart. Refer to the applicable

2. Tachometer faulty—Figure 56.

flowchart in Figures 36-60. Note the following before be-

3. No security lamp—Figure 57.

ginning troubleshooting:

4. Security lamp always on—Figure 58.

1. Before retrieving DTCs, refer to Initial Diagnostic

5. Key fob signal weak to TSSM—Figure 59.

Check in this section.

6. Turn signal cancels improperly—Figure 60.

2. Not all malfunctions will set a DTC. If this occurs, refer

to Chapter Nine and the wiring diagrams at the end of this

Initial diagnostic check

manual to assist in troubleshooting.

3. Check for obvious causes before undertaking what

Because the speedometer provides the DTCs, it may be

may be a complicated troubleshooting procedure. Look

necessary to troubleshoot it before initiating a diagnostic

for loose or disconnected connectors, damaged wiring

sequence. Check speedometer operation as described,

and other possible causes.

then refer to Figure 36 and follow the Initial Checks

4. The DTCs are prioritized according to importance. If

flowchart.

multiple DTCs occur, correct the DTC with the highest

1. During normal operation the speedometer should op-

priority listed in Table 3. It is possible for one fault to trig-

erate as follows when the ignition key is turned on (make

ger more than one DTC.

sure the run/stop handlebar switch is in the run position):

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

a. The speedometer backlighting comes on.

identify connectors. Each connector is noted with a corre-

sponding number on the wiring diagram. This connector

NOTE

number is noted in the flow charts. Refer to the appropriate

The security symbol may come on even

sections in this chapter and Chapter Nine for additional com-

though the motorcycle is not equipped with

ponent testing.

a security system.

-------------------------------------------------------------------------------------------------------------------------------------------------------------

NOTE

The security symbol may come on even

though the motorcycle is not equipped with

a security system.

e. The check engine, battery and security symbols

should illuminate.

f. The message diag should appear in the odometer win-

dow on the speedometer (B, Figure 29).

3. If the speedometer operates abnormally, check the wir-

ing for the battery, ground, ignition, odometer reset switch

and accessories.

FUEL SYSTEM

WARNING

Gasoline is highly flammable. When servic-

ing the fuel system, work in a well-ventilated

area. Do not expose gasoline and gasoline

vapors to sparks or other ignition sources.

Begin fuel system troubleshooting with the fuel tank

and work through the system, reserving the carburetor as

the final point. Most fuel system problems result from an

empty fuel tank, a plugged fuel filter or fuel valve, old

fuel, a dirty air filter or clogged carburetor jets. Do not as-

sume the carburetor is the problem. Unnecessary carbure-

tor adjustment can compound the problem.

Running 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

b. The check engine and security symbols illuminate.

sound from the exhaust and an inability to clear the ex-

c. The odometer display illuminates.

haust with the throttle held wide open.

2. If the speedometer performs normally during startup,

perform the following WOW test:

Lean

a. Push in the odometer reset button on the back of the

speedometer.

1. Blistered or very white spark plug electrodes.

b. Turn the ignition key on and release the odometer

2. Engine overheats.

reset button.

3. Slow acceleration and engine power is reduced.

c. The speedometer backlighting should come on.

4. Flat spots on acceleration that are similar in feel to

d. The speedometer needle should rotate to the full de-

when the engine starts to run out of gas.

flection position (A, Figure 29).

5. Engine speed fluctuates at full throttle.

-------------------------------------------------------------------------------------------------------------------------------------------------------------

INITIAL CHECKS

Start engine.

Engine starts and

Engine starts,

Engine turns, but

Engine will not

runs.

but stalls.

does not start.

turn over.

Check for DTCs.

Refer to appro-

Refer to appropri-

priate trouble-

ate troubleshoot-

shooting section

ing section in this

in this chapter.

chapter.

DTC appears.

Diagnostic

No codes displayed.

mode would not

display.

Refer to DTC list in

Follow steps as outlined

Check for malfunctions that do not produce

Table 3.

in DTC Retrieval section

a DTC. Refer also to initial diagnostic notes

in this chapter. Speed-

in this chapter.

ometer backlighting

should appear and

odometer display

should illuminate.

OK.

No display or backlighting.

Go to Step A.

Connect breaker box to

speedometer. Check for con-

tinuity between breaker box

black terminal 7 and ground

while wiggling the harness.

Continuity.

No continuity.

Check for battery

Find and repair open wiring.

voltage at breaker

box black terminal 5

while wiggling the

harness. Is battery

voltage constant?

OK.

No battery

voltage.

(continued)

-------------------------------------------------------------------------------------------------------------------------------------------------------------

(continued)

Find and repair open wiring.

Make sure ignition key is

OFF. Disconnect speedome-

ter connector (Figure 39).

Check for continuity between

breaker box black terminals 8

and 11. Tester should indi-

cate continuity when odome-

ter reset button is pressed

and infinity when released.

OK.

Incorrect results.

Replace

Replace odometer

speedometer.

reset button

switch.

Turn ignition switch key to ON. Odometer

panel should illuminate.

OK.

No odometer illumination.

Replace speedometer.

Perform WOW test in Speedome-

ter Check section.

OK.

Fails WOW test.

Turn ignition key to ACC. Speed-

Check for battery voltage at

ometer backlighting should ap-

breakerbox black terminal 1.

pear.

OK.

No backlighting.

OK.

No battery

voltage.

Go to Step B.

Check for battery voltage at

breaker box black terminal 6.

Replace

Check instru-

speedometer.

ment fuse.

OK.

No battery voltage.

Fuse blown.

Fuse OK.

(continued)

-------------------------------------------------------------------------------------------------------------------------------------------------------------

(continued)

Locate and re-

Replace speed-

Check acces-

Find open be-

pair cause of

ometer.

sory fuse.

tween terminal

fuse blowing.

1 of speedome-

ter connector

39 and fuse.

Fuse blown.

Fuse OK.

Repair wire.

Locate and

Find open in orange/white wire be-

repair cause

tween terminal 6 of speedometer

of fuse blow-

connector (39) and fuse. Repair wire.

ing.

Is problem

intermittent?

If yes, repeat

No intermit-

diagnostic

tent problem.

checks while

Speedometer

Tachometer

wiggling har-

does not

ness and

function.

connectors.

Problem con-

Remove and

Check ta-

tinues.

inspect vehi-

chometer

cle speed

(Chapter

sensor (VSS)

Nine).

(Chapter

Nine).

Find and re-

Clean and re-

VSS OK. Check wiring and

install VSS.

connectors.

pair intermit-

tent cause.

Recheck.

OK.

Faulty wiring or

connector.

Replace

Find and repair faulty

speedometer.

wiring or connector.

-------------------------------------------------------------------------------------------------------------------------------------------------------------

DTC B1006, B1007: ACCESSORY OR

IGNITION LINE OVERVOLTAGE

Make sure battery

charger is connected.

If so, discon-

No battery

nect battery

charger con-

charger.

nected.

Clear DTCs.

Troubleshoot

charging

system.

Start engine, run at

3000 rpm for 5 seconds.

Check for DTC.

DTC appears.

No DTC.

Troubleshoot

System OK.

charging sys-

tem.

DTC B1008: RESET SWITCH CLOSED

Remove odometer reset

button rubber boot. Clear

DTC. Check for DTC.

DTC appears.

No DTC.

Make sure ignition key is OFF. Disconnect

Replace switch boot.

speedometer connector (39). Check for re-

sistance between breaker box black termi-

nals 8 and 11. Tester should indicate less

than 1 ohm when odometer reset button is

pressed and infinity when released.

Test OK.

Incorrect tester

reading.

Replace speed-

Replace reset

ometer.

switch.

-------------------------------------------------------------------------------------------------------------------------------------------------------------

DTC U1016, U1255: LOSS OF ICM SERIAL DATA

NOTE: This procedure applies to loss of serial data communication between the ICM and speedometer.

Refer to Figure 40 for DTC U1016 and U1255 related to the ICM and TSM/TSSM.

Check for ICM part number during speed-

ometer diagnostics check. Refer to Step 8 in

DTC Retrieval section.

Part number

No part num-

appears.

ber or No Rsp

is displayed.

Connect breaker box to

speedometer. Check for conti-

nuity between breaker box

black terminal 2 and terminal

12 of the ICM connector (10)

12 of the ICM connector (10).

while wiggling harness.

Continuity

No continuity.

exists.

Clear DTCs. Test

Repair light

Replace ICM.

Repair open

ride. Retrieve

green/violet

in light

DTCs.

wire.

green/violet

wire.

DTC U1016 ap-

DTC U1016 does

pears.

not appear.

Replace ICM.

System OK.

-------------------------------------------------------------------------------------------------------------------------------------------------------------

DTC U1016, U1255: LOSS OF ICM SERIAL DATA

NOTE: This procedure applies to loss of serial data communication between the ICM and

TSM/TSSM. Refer to Figure 39 for DTC U1016 and U1255 related to the ICM and speedometer.

Check for ICM part number

during speedometer diagnos-

tics check. Refer to Step 8 in

DTC Retrieval section.

Part number

No part num-

appears.

ber or No Rsp

is displayed.

Turn ignition key to

OFF. Connect breakout

box to ICM and connec-

tor (30). Remove

TSM/TSSM and connect

breakout box to

TSM/TSSM and connec-

tor (30). Check for conti-

nuity between breakout

box black terminal 12

and gray terminal 3

while wiggling harness.

Continuity exists.

No continuity.

Continuity exists.

No continuity.

Repair light

Replace ICM.

Repair open in

Clear DTCs. Test

green/violet

light green/vio-

ride. Retrieve

wire.

let wire.

DTCs.

DTC U1016 ap-

DTC U1016

pears.

does not ap-

pear.

Replace ICM.

System OK.

-------------------------------------------------------------------------------------------------------------------------------------------------------------

DTC U1064, U1255: LOSS OF TSM/TSSM SERIAL DATA

Check for TSM/TSSM part num-

ber during speedometer diag-

nostics check. Refer to Step 8 in

DTC Retrieval section.

Part number

No part

appears.

number or

No Rsp is

displayed.

Connect breaker box

to speedometer and

TSM/TSSM. Check

for continuity be-

tween breaker box

black terminal 2 and

gray terminal 3 while

gray terminal 3.

wiggling harness.

Contininuity

Continuity

continuity.

exists.

continuity.

exists.

Replace

Clear DTCs.

Repair light

Repair open

TSM/TSSM.

Test ride.

green/violet

in light

Retrieve

wire.

green/violet

DTCs.

wire.

DTC U1064

appears.

does not ap-

pear.

Replace

System OK.

ICM.

-------------------------------------------------------------------------------------------------------------------------------------------------------------

DTC U1300, U1301, BUS ER: SERIAL DATA LOW OR

SERIAL DATA OPEN/HIGH

Check for DTCs.

DTCs P1009 and

DTCs U1300 or

Bus Er ap-

No DTCs ap-

P1010 appear.

U1301 appear.

pears. Speed-

pear.

Refer to Figure

ometer does

52 and Figure 53.

not communi-

cate with other

modules.

Inspect intake

manifold for

leaks.

Go to Step A.

Leaks found.

No leaks

found.

Repair seals

Replace ICM.

or intake

manifold.

Turn ignition key to ON

(run/stop switch in RUN).

Bus Er appears.

Bus Er does not appear.

Turn ignition key to

Turn ignition key to OFF. Wig-

OFF. Disconnect ICM

gle harness and check for

connector (10). Turn ig-

continuity between terminal 3

nition key to ON.

of data link connector (91)

and ground.

Bus Er appears.

Bus Er does not

Continuity present.

No continuity.

appear.

Turn ignition key to

Replace ICM.

Find and repair

Turn ignition switch to

OFF. Disconnect

short to ground.

ON. Wiggle harness and

TSM/TSSM connec-

check for voltage at termi-

tor (30). Reinstall

nal 3 of data link connec-

battery. Turn ignition

tor (91).

key to ON.

(continued)

-------------------------------------------------------------------------------------------------------------------------------------------------------------

(continued)

Bus Er appears.

Bus Er does not

Voltage present.

No voltage.

appear.

Replace

Find and repair

OK.

TSM/TSSM.

short circuit.

If equipped with a ta-

If not equipped

chometer, turn ignition

with a tachome-

key to OFF. Disconnect

ter, proceed as

tachometer connector

follows.

(108) in tachometer

housing. Turn ignition

key to ON.

Bus Er appears.

Bus Er does not

appear.

Replace tachom-

eter.

Turn ignition key to

OFF. Disconnect

speedometer connec-

tor (39). Check for con-

tinuity between

terminal 3 of data link

connector (91) and

ground.

Continuity to

No continuity.

ground.

Find and repair

Turn ignition switch to ON.

short to ground.

Check for voltage at termi-

nal 3 of data link connector

(91).

Voltage present.

No voltage.

Remove fuses individually

Replace speed-

to isolate shorted circuit,

ometer.

then repair.

-------------------------------------------------------------------------------------------------------------------------------------------------------------

DTC U1300, U1301, BUS ER: ENGINE STARTS, THEN STALLS

NOTE: If problem is not resolved, refer also to Figure 42.

Check for DTCs.

DTCs P1009 and

DTCs U1300 or

Bus Er ap-

No DTCs appear.

P1010 appear.

U1301 appear.

pears. Speed-

Refer to Figure

ometer does

52 and Figure 53.

not communi-

cate with other

Inspect intake

modules.

manifold for

leaks.

Leaks found.

No leaks found.

Repair seals or

Replace ICM.

intake mani-

fold.

Turn ignition key to OFF. Connect breakout box to ICM and connec-

tor (30). Remove TSM/TSSM and connect breakout box to TSM/TSSM

and connector (30). Check for continuity between terminal 2 of data

link connector (91) and box black terminal 5. Check for continuity

between terminal 3 of data link connector and box black terminal 12.

Check for continuity between terminal 4 of data link connector (91)

and gray terminal of ignition fuse.

Continuity exists.

No continuity.

Turn ignition key to OFF.

Repair open cir-

Disconnect ICM connec-

cuits.

tor (30). Verify that

TSM/TSSM information

appears during speedom-

eter diagnostics check.

Refer to Step 8 in DTC Re-

trieval section.

(continued)

-------------------------------------------------------------------------------------------------------------------------------------------------------------

(continued)

TSM/TSSM infor-

No TSM/TSSM

mation appears.

information.

Replace ICM.

Turn ignition key to OFF. Discon-

nect TSM/TSSM connector (30).

Check for continuity between

terminal 3 of data link connector

and ground.

Continuity exists.

No continuity.

Repair short cir-

Turn ignition switch to ON.

cuit to ground.

Check for voltage at terminal 3

of data link connector (91).

Voltage present.

No voltage.

Repair voltage

Replace

short.

TSM/TSSM. Re-

check operation.

Operation OK.

Abnormal

operation.

System OK.

Turn ignition key

to OFF. Discon-

nect speedometer

connector (39).

Recheck opera-

tion.

Operation OK.

Abnormal

operation.

Replace

Replace ta-

speedometer.

chometer,

if so

equipped.

-------------------------------------------------------------------------------------------------------------------------------------------------------------

DTC B1121, B1122, B1141: TURN SIGNALS WILL NOT FLASH;

4-WAY FLASHERS INOPERABLE

Turn ignition

key to ON.

Turn signals on

Turn signals not on.

continuously.

Turn ignition key to OFF. Remove

Operate 4-way flasher.

TSM/TSSM connector (30). Con-

nect breakout box to TSM/TSSM

connector (30), but not to

TSM/TSSM. Reinstall battery. Turn

ignition key to ON. Check for bat-

tery voltage at breakout box gray

terminal 5 (left turn signals) or

gray terminal 6 (right turn signals).

Battery voltage

No battery voltage.

Lamps illuminate.

Lamps not on.

present.

Find and repair

Replace TSM/TSSM.

Go to Step A.

Check TSM/TSSM

short.

connector (30).

Connector OK.

Faulty connection.

Turn ignition key to OFF. Remove

Mate connector cor-

TSM/TSSM connector (30). Con-

rectly.

nect breakout box to TSM/TSSM

connector (30), but not to

TSM/TSSM. Reinstall battery.

Check for battery voltage at break-

out box gray terminal 1 (positive)

and gray terminal 12 (negative).

Battery voltage present.

No battery voltage.

Check for battery volt-

Go to Step B.

age at breakout box gray

terminal 2 (positive) and

gray terminal 12 (nega-

tive).

(continued)

-------------------------------------------------------------------------------------------------------------------------------------------------------------

(continued)

Battery voltage present.

No battery voltage.

Go to Step C.

Check for voltage at

ignition fuse.

Battery voltage present.

No battery voltage.

Repair open circuit in

Go to Figure 55.

gray wire between igni-

tion fuse and TSM/TSSM.

Inspect inoperable

bulb(s).

Bulb(s) OK.

Faulty bulb(s).

Turn ignition key to OFF. Remove

Replace.

TSM/TSSM connector (30). Connect

breakout box to TSM/TSSM connector

(30), but not to TSM/TSSM. Reinstall

battery. Connect a jumper wire be-

tween breakout box gray terminal 1

and gray terminal 6.

Both right side

Right side turn

turn signals illu-

signals do not il-

minate.

luminate.

Connect a jumper wire

Check for continuity be-

between breakout box gray

tween breakout box gray

terminal 1 and gray terminal

terminal 6 and lamps.

Both left side turn

Left side turn sig-

Continuity exists.

No continuity.

signals illuminate.

nals do not illumi-

nate.

(continued)

-------------------------------------------------------------------------------------------------------------------------------------------------------------

(continued)

Go to Step D.

Check for continu-

Repair open

Repair open be-

ity between break-

ground circuit.

tween TSM/TSSM

out box gray

connector (30) and

terminal 5 and

lamps.

Continuity exists.

No continuity.

Repair open

Repair open be-

ground circuit.

tween TSM/TSSM

connector (30)

and lamps.

Turn ignition key to OFF. Discon-

nect the TSM/TSSM connector

(30). Connect breakout box to

TSM/TSSM connector (30), but

not to TSM/TSSM. Reinstall bat-

tery. Check resistance between

breakout box gray terminal 12

and ground.

Resistance less

Resistance greater

than 1 ohm.

Check for battery

Repair ground cir-

voltage at both

cuit.

15 amp battery

fuse terminals.

Voltage present

No voltage.

at both terminals.

Repair open in brown/gray

wire between TSM/TSSM

Voltage present

No voltage at ei-

and battery fuse.

at one terminal.

ther terminal.

(continued)

-------------------------------------------------------------------------------------------------------------------------------------------------------------

(continued)

Replace fuse.

Repair open cir-

cuit between fuse

block and 30 amp

Maxi-fuse.

Turn ignition key to OFF. Dis-

connect TSM/TSSM connec-

tor (30). Connect breakout

box to TSM/TSSM and con-

nector (30). Reinstall battery.

Turn ignition key to ON.

Check for battery voltage at

breakout box gray terminal 7

when right turn signal button

is depressed.

Battery volt-

No voltage.

age present.

Check for battery volt-

Remove fuel tank and connect breakout box

age at breakout box

and adapters between right handlebar switch

gray terminal 8 when left

connectors (22). Turn ignition switch to ON.

turn signal button is de-

Check voltage at breakout box black terminal 5

pressed.

when right turn signal button is depressed.

Battery volt-

No voltage.

Battery volt-

No voltage.

age present.

Go to Step A.

Remove fuel tank and connect

Repair open cir-

Turn ignition

breakout box and adapters be-

cuit between

switch to OFF.

tween left handlebar switch con-

TSM/TSSM and

Check for continu-

nectors (24). Turn ignition switch

right handlebar

ity between break-

to ON. Check voltage at breakout

switch connector

out box black

box black terminal 5 when left

(22).

terminal 5 and

turn signal button is depressed.

ground.

(continued)

-------------------------------------------------------------------------------------------------------------------------------------------------------------

(continued)

Battery voltage

No voltage.

Continuity exists.

No continuity.

present.

Repair open circuit

Turn ignition

Repair shorted cir-

Turn ignition key

between

switch to OFF.

cuit to ground.

to ON. Check for

TSM/TSSM and left

Check for continu-

battery voltage at

handlebar switch

ity between break-

breakout box black

connector (24).

out box black

terminal 1.

terminal 5 and

ground.

Continuity exists.

No continuity.

Battery voltage

No voltage.

present.

Repair shorted cir-

Turn ignition key to

Replace turn sig-

Repair open cir-

cuit to ground.

ON. Check for bat-

nal switch.

cuit between fuse

tery voltage at

block and right

breakout box black

handlebar switch

terminal 1.

connector (22).

Battery voltage

No voltage.

present.

Replace turn signal

Repair open circuit

switch.

between fuse block

and left handlebar

(continued)

switch connector

(24).

-------------------------------------------------------------------------------------------------------------------------------------------------------------

DTC B1131, B1132: ALARM OUTPUT

Disconnect alarm siren connector

(142). Turn ignition key to ON. Mea-

sure voltage between black wire ter-

minal and brown/gray wire terminal.

Battery voltage present.

No voltage.

Turn ignition key to OFF. Disconnect

TSM/TSSM connector (30). Connect breakout

TSM/TSSM connector (30). Connect break-

box to TSM/TSSM connector (30), but not to

out box to TSM/TSSM connector (30), but

TSM/TSSM. Check resistance between break-

not to TSM/TSSM. Check resistance be-

out box gray terminal 11 and light green/

tween breakout box gray terminal 12 and

brown wire terminal in siren connector.

black wire terminal in siren connector.

Less than 1 ohm.

Greater than 1 ohm.

Continuity exists.

No continuity.

Check resistance

Repair open in light

Repair shorted

Repair open in

between breakout

green/brown wire.

brown/gray and

black wire.

box gray terminal

black wires.

11 and chassis

ground.

With siren connector

(142) disconnected,

Less than 1 ohm.

Greater than 1 ohm.

measure resistance be-

tween siren terminals B

and C.

Repair grounded

light green/brown

wire.

Resistance read-

ing is 120k-200k

ing is not 120k-

ohms.

200k ohms.

Replace siren.

Install siren on a

motorcycle with a

known good sys-

tem and check

operation.

Siren does not

Siren operates.

operate.

Replace siren.

Replace

TSM/TSSM.

-------------------------------------------------------------------------------------------------------------------------------------------------------------

DTC B1134: STARTER OUTPUT HIGH

Turn ignition key to OFF. Remove

starter relay (Chapter Nine). Dis-

connect TSM/TSSM connector

(30). Connect breakout box to

TSM/TSSM connector (30), but not

to TSM/TSSM. Reinstall battery.

Battery voltage present.

Turn ignition key to ON. Check for

No voltage.

battery voltage at breakout box

gray terminal 9.

Repair short in

Install starter

tan/green wire.

relay. Check for

battery voltage

at breakout box

Battery voltage

No voltage.

gray terminal 9.

present.

Replace

starter relay.

TSM/TSSM.

DTC U1097, U1255: LOSS OF SPEEDOMETER

OR TSM/TSSM SERIAL DATA

Make sure TSM/TSSM part number appears during

speedometer diagnostics check. Refer to Step 8 in

DTC Retrieval section.

Part number appears.

No part number or No Rsp is displayed.

Turn ignition key to OFF. Connect breakout

box to speedometer connector (39). Discon-

nect TSM/TSSM and connect breakout box to

TSM/TSSM connector (30). Check for continu-

ity between breaker box black terminal 2 and

gray terminal 3 while wiggling harness.

gray terminal 3.

Continuity exists.

No continuity.

Continuity exists.

No continuity.

Clear DTCs. Test

Repair light

Replace speed-

Repair open in light

ride. Retrieve DTCs.

green/violet wire.

ometer.

green/violet wire.

DTC U1097 or U1255 (Figure 40) appears.

DTC U1097 or U1255 (Figure 40) does not appear.

Replace speedometer.

System OK.

-------------------------------------------------------------------------------------------------------------------------------------------------------------

(continued)

Disconnect the MAP sensor

connector (80). Turn the igni-

tion key to ON. Measure volt-

age at outer connector

terminals (A & C).

Voltage is 5.0 volts.

Voltage greater

Voltage less

than 6.0 volts.

than 4.5 volts.

Turn ignition key to OFF.

Repair short to

Turn ignition key to OFF.

Disconnect breakout box

12 volts in

Disconnect breakout box

from ICM, but not from the

red/white wire.

from ICM, but not from the

ICM connector (10). Mea-

ICM connector (10). Check

sure resistance between

continuity between MAP

MAP connector (80) mid-

connector (80) terminal (A)

dle terminal (B) and black

and black box terminal 4.

box terminal 11.

Check continuity between

MAP connector terminal (C)

and black box terminal 3.

Resistance less

Reisistance

Continuity

No conti-

than 1 ohm.

greater than 1

exists.

nuity.

ohm.

Measure resis-

Repair open in

Disconnect the

Repair

tance between

violet/white

MAP connector

open wire.

MAP connector

wire.

(80) from the

(80) middle ter-

breakout box.

minal (B) and

Meassure resis-

chassis ground.

tance between

black box termi-

nals 3 & 5.

Resistance

Resistance less

Resistance

Resistance less

greater than 1

than 1 megohm.

greater than

than 1 megohm.

megohm.

1 megohm.

Replace MAP

Repair

Replace ICM.

Repair short

sensor.

grounded

between

violet/white

red/white

wire.

wire and

ground wire.

-------------------------------------------------------------------------------------------------------------------------------------------------------------

(continued)

Disconnect the MAP sensor

connector (80). Turn the igni-

tion key to ON. Measure volt-

age at outer connector

terminals (A and C).

Voltage is 5.0 volts.

Voltage greater

Voltage less

than 6.0 volts.

than 4.5 volts.

Turn ignition key to OFF.

Repair short to

Turn ignition key to OFF.

Disconnect breakout box

12 volts in

Disconnect breakout box

from ICM, but not from the

red/white wire.

from ICM, but not from the

ICM connector (10). Mea-

ICM connector (10). Check

sure resistance between

continuity between MAP

MAP connector (80) mid-

connector (80) terminal (A)

dle terminal (B) and black

and black box terminal 4.

box terminal 11.

Check continuity between

MAP connector terminal (C)

and black box terminal 3.

Resistance less

Reisistance

Continuity

No conti-

than 1 ohm.

greater than 1

exists.

nuity.

ohm.

Measure resis-

Repair open in

Disconnect the

Repair

tance between

violet/white

MAP connector

open wire.

MAP connector

wire.

(80) from the

(80) middle ter-

breakout box.

minal (B) and

Meassure resis-

chassis ground.

tance between

black box termi-

nals 3 & 5.

Resistance

Resistance less

Resistance

Resistance less

greater than 1

than 1 megohm.

greater than

than 1 megohm.

megohm.

1 megohm.

Replace MAP

Repair

Replace ICM.

Repair short

sensor.

grounded

between

violet/white

red/white

wire.

wire and

ground wire.

-------------------------------------------------------------------------------------------------------------------------------------------------------------

(continued)

Repair shorted

Replace CKP

Repair as

Measure AC

red or black wire.

sensor.

needed.

volts at black

box terminals

8 and 9 while

cranking en-

gine.

Voltage at

Voltage less

least 1 volt.

than 1 volt.

Check for in-

Measure AC

termittent

volts at CKP

voltage.

sensor con-

nector (79)

terminals

while crank-

ing engine.

Intermittent volt-

Voltage OK.

Voltage at

Voltage less

age present.

least 1 volt.

than 1 volt.

Repair circuit.

Replace CKP

Check for con-

Replace CKP

sensor. Clear

tinuity be-

sensor.

codes and retest.

tween CKP

sensor con-

nector (79) red

wire terminal

and ICM con-

nector red wire

terminal.

Code P0371,

No codes appear.

Continuity ex-

No continuity.

P0372 or P0374

ists.

appears.

Replace ICM.

System OK.

Repair open

black wire.

red wire.

-------------------------------------------------------------------------------------------------------------------------------------------------------------

DTC P0501, P0502: VEHICLE SPEED SENSOR (VSS)

Remove, inspect and rein-

stall VSS (Chapter Nine).

Clear any DTCs. Ride mo-

torcycle at least 1 mile.

Check for DTCs.

DTCs appear.

No DTCs.

System OK.

Turn ignition

key to OFF.

Disconnect

VSS connec-

tor (65). Check

for continuity

between con-

nector

red/white wire

terminal and

ground.

Continuity exists.

No continuity.

Repair shorted

Turn ignition key

red/white wire.

to OFF. Connect

breakout box to

ICM and con-

nector (10).

Check for conti-

nuity between

black box termi-

nal 3 and VSS

connector

red/white wire

terminal.

Continuity exists.

No continuity.

Check for conti-

Repair open

nuity between

red/white wire

black box terminal

between VSS

4 and VSS con-

and ICM con-

nector (65) black

nector (10).

wire terminal.

(continued)

-------------------------------------------------------------------------------------------------------------------------------------------------------------

(continued)

Continuity exists.

No continuity.

Repair open black

wire between VSS

and ICM connector

(10).

Check for continuity between black

box terminal 10 and VSS connector

(65) white/green wire terminal.

Continuity exists.

No continuity.

Raise motorcycle so rear wheel

Repair open in

can be turned by hand. Turn ig-

white/green wire.

nition key to ON. Check for volt-

age at black box terminal 10.

Voltmeter should alternately

read 0-1 volts when VSS passes

a gear tooth and 4-6 volts when

no gear tooth is near.

Voltage OK.

Incorrect read-

No voltage.

Incorrect

ings. Battery volt-

readings.

age indicated.

Replace ICM.

Repair shorted

Turn ignition key

Replace VSS.

white/green wire.

to OFF. Measure

resistance be-

tween black box

terminal 10 and

ground.

Resistance is

less than 100

greater than

ohms.

100 ohms.

Repair short

Replace ICM.

to ground in

white/green

wire.

-------------------------------------------------------------------------------------------------------------------------------------------------------------

DTC P0562, P0563: SYSTEM VOLTAGE

Verify that charging

system operates prop-

erly. Refer to tests in

this chapter.

Charging

Charging sys-

system OK.

tem faulty.

Turn ignition key to OFF.

Repair system.

Connect breakout box to

ICM and connector (10).

Turn ignition key to ON.

Measure voltage drop be-

tween positive battery

terminal and black box

terminal 1 (negative).

Voltage drop is

greater than 0.5

0.5 volt or less.

volt.

Turn ignition key

to ON. Measure

voltage drop

between positive

between nega-

battery terminal

tive battery ter-

and black box

minal and black

terminal 4 (nega-

box terminal 5

tive).

(positive).

Voltage drop is

greater than 0.5

0.5 volt or less.

greater than 0.5

0.5 volt or less.

volt.

Turn ignition key

Repair or

Repair bad con-

Problem is inter-

to ON. Measure

replace

nection.

mittent. Wiggle

voltage drop

white/black wire

circuit compo-

between posi-

or terminals.

nents to find

tive battery ter-

fault.

minal and black

box terminal 3

(negative).

(continued)

-------------------------------------------------------------------------------------------------------------------------------------------------------------

(continued)

Voltage drop is

greater than

0.5 volt or

0.5 volt.

less.

Check for loose

wires or corro-

sion at engine

stop switch con-

nector. If OK, re-

place switch.

Turn ignition key to

ON. Measure voltage

drop between posi-

tive battery terminal

and gray wire termi-

nal of ignition fuse.

Voltage drop is

greater than

0.5 volt or

0.5 volt.

less.

Turn ignition key to

Repair or

ON. Measure voltage

replace

drop between positive

gray wire or

battery terminal and

terminal.

red/black wire termi-

nal of ignition fuse.

Voltage drop is

greater than

0.5 volt or

0.5 volt.

less.

Turn ignition key

Replace fuse

to ON. Measure

or terminals.

voltage drop be-

tween positive

battery terminal

and terminal A of

Maxi-fuse.

(continued)

-------------------------------------------------------------------------------------------------------------------------------------------------------------

DTC P1010: MISSING PASSWORD

Check for DTCs

with U prefix.

U DTC appears.

No U DTC appears.

Troubleshoot U

Turn ignition key to

DTC with lowest

OFF. Disconnect ICM

number.

connector (10). Check

for continuity between

terminal 3 of data link

connector (91) and

ground.

Continuity exists.

No continuity.

Repair short to

Check for battery volt-

ground.

age at terminal 3 of data

link connector (91).

Voltage exists.

No voltage.

Repair short to

Turn ignition key to OFF.

voltage.

Connect breakout box

to ICM and connector

(10). Check for continu-

ity between black box

terminal 12 and terminal

3 of data link connector

(91).

Continuity exists.

No continuity.

Replace

Repair open circuit.

TSM/TSSM.

System faulty.

System OK.

Install original

TSM/TSSM.

Replace ICM.

-------------------------------------------------------------------------------------------------------------------------------------------------------------

DTC P1351, P1352, P1354, P1355: IGNITION COIL

NOTE: This procedure uses H-D tools Ignition Coil Circuit Test Adapter (part No. HD-44687) and Fuel

Injector Test Lamp (part No. HD-34730-2C).

Turn ignition key to OFF. Discon-

nect ignition coil connector (83).

Measure voltage at white/black

wire connector terminal. Be sure

engine stop switch is in the RUN

position. Turn ignition switch to

ON.

Voltage equals bat-

Voltage does not

tery voltage in first

equal battery voltage

two seconds after ig-

in first two seconds

nition switch is ON.

after ignition switch

is ON.

Install Ignition Coil Circuit

Repair open

Test Adapter and Fuel Injec-

white/black wire

tor Test Lamp in black box

circuit.

terminals 1 and 6 to check

front cylinder coil. To check

rear cylinder coil, install

testers in black box termi-

nals 1 and 7. Crank engine

and observe test lamp.

Test lamp flashes.

Test lamp does

not flash.

Measure primary

Replace ICM.

coil resistance as

described in

Chapter Nine.

Correct test

Incorrect test

results.

Replace

igntion coil.

(continued)

-------------------------------------------------------------------------------------------------------------------------------------------------------------

(continued)

Turn ignition key to OFF. Connect

breakout box to ICM and connec-

tor (10). For DTCs P1351 and

P1352, measure resistance be-

tween black box terminal 6 and

blue/orange wire terminal in igni-

tion coil connector (83). For DTCs

P1354 and P1355, measure resis-

tance between black box terminal

7 and yellow/blue wire terminal in

ignition coil connector (83).

Resistance is less

Resistance is 0.5

than 0.5 ohms.

ohms or more.

Wiggle wires and re-

Repair open circuit.

check resistance.

Intermittent test

No intermittents

results.

found.

Repair circuit.

Check continuity

to ground from

black box termi-

nal 6 (front coil)

and black box ter-

minal 7 (rear coil).

Continuity exists.

No continuity.

Repair short cir-

Check for voltage

cuit to ground.

at black box ter-

minal 6 (front

coil) and black

box terminal 7

(rear coil).

Voltage exists.

No voltage.

Repair short to

Replace ICM.

voltage.

-------------------------------------------------------------------------------------------------------------------------------------------------------------

NO SPARK OR ICM POWER

Check ignition

fuse.

Fuse OK.

Fuse blown.

Turn ignition key to OFF. Con-

Replace fuse and deter-

nect breakout box to ICM and

mine cause.

connector (10). Turn ignition

key to ON. Measure voltage at

black box terminals 1 and 5.

Voltage is 11-13

Voltage is less

volts.

than 11 volts.

Replace ICM.

Turn ignition key to OFF.

Check continuity between

black box terminal 5 and

ground.

Continuity exists.

No continuity.

Check continuity be-

Repair open

tween black box terminal

black wire circuit.

1 and white/black wire

terminal in main harness

end of engine stop

switch connector (22).

Repair open

Continuity exists.

No continuity.

white/black wire

circuit.

With engine stop switch in

RUN position, check conti-

nuity between white/black

wire terminal and gray wire

Continuity

No continu-

terminal in switch end of

exists.

ity.

engine stop switch connec-

tor (22).

Repair open

Replace en-

in gray wire

gine stop

circuit.

switch.

-------------------------------------------------------------------------------------------------------------------------------------------------------------

TACHOMETER FAULTY

NOTE: The green and orange symbols in the initial test represent cruise (green) and pursuit

(orange) functions on models other than Sportsters.

Perform WOW test in speedometer

check section. The following

should occur:

1. Backlighting comes on.

2. Needle rotates to full deflection.

3. Both green and orange symbol

LEDs illuminate.

Test OK.

Faulty test.

Check for

Connect breaker box to

intermittents

speedometer and connector

while wiggling

(39). Measure voltage at

harness.

black box terminal 1.

Intermittents

Battery voltage

No voltage.

found.

intermittents.

present.

Repair inter-

System OK.

Check in-

mittent cir-

strument

cuit.

fuse.

Fuse blown.

Fuse OK.

Repair cause.

Repair open

Replace fuse.

in orange

wire circuit.

Turn ignition

key to OFF.

Check for conti-

nuity between

breaker box

black terminals

2 and 7.

(continued)

-------------------------------------------------------------------------------------------------------------------------------------------------------------

SECURITY SYMBOL DOES NOT LIGHT WITH IGNITION KEY

TURNED TO ON

NOTE: This chart applies to motorcycles equipped with the security system.

Make sure engine stop

switch is in RUN. At-

tempt to start engine.

Engine cranks.

Engine does not crank.

Go to Step A.

Turn ignition key to OFF. Con-

nect breakout box to speed-

ometer and connector (39).

Remove TSM/TSSM (Chapter

Nine) and connect breakout

box to TSM/TSSM and con-

nector. Check for continuity

between breakout box black

terminal 4 and gray terminal 4.

Continuity present.

No continuity.

Check for continu-

Repair open in

ity between

brown/violet wire

breaker box black

circuit.

terminal 4 and

ground.

Continuity present.

No continuity.

Repair short to

Disconnect breakout

ground in

box and reconnect

brown/violet wire

speedometer connec-

circuit.

tor (39). Connect a

jumper wire between

gray box terminal 4

and positive battery

terminal.

(continued)

-------------------------------------------------------------------------------------------------------------------------------------------------------------

SECURITY SYMBOL ON CONTINUOUSLY

Turn ignition key to

ON. Security symbol

should illuminate for 4

seconds, then go out

for 4 seconds.

Operates properly.

Security symbol

remains on.

Check for DTCs.

Turn ignition

key to OFF.

Disconnect

TSM/TSSM con-

nector (30). Re-

install battery.

Turn ignition

key to ON.

Security symbol

illuminates.

does not illumi-

nate.

Turn igntion key

Replace

to OFF. Discon-

TSM/TSSM.

nect speedome-

ter connector

(39). Turn igni-

tion key to ON.

Check for volt-

age at brown/vi-

olet wire

terminal on

speedometer

connector (39).

Voltage exists.

No voltage.

Repair short

Replace

to battery volt-

speedometer.

age in

brown/violet

wire circuit.

-------------------------------------------------------------------------------------------------------------------------------------------------------------

TURN SIGNAL CANCELS IMPROPERLY

NOTE: The following troubleshooting requires H-D Speedometer tester (part No. HD-41354).

Make sure TSM/TSSM

is installed properly.

Make sure TSM/TSSM

is configured for solo

(not sidecar) opera-

tion.

Remove TSM/TSSM

and reconnect con-

nector (30). Reinstall

battery. Activate

4-way flashers. Verify

that 4-way flashers

cancel when

TSM/TSSM is tllted at

least 45 degrees in

both directions (as if

mounted in bike).

Operates properly.

Operates improperly.

Disconnect VSS connector (65).

Replace TSM/TSSM.

Connect speedometer tester to

VSS and connector (65). Connect

jumper wire between terminal B

of tester and white/green wire

terminal of VSS connector (65).

Connect jumper wire between

terminal C of tester and black

wire terminal of VSS connector

(65). Operate turn signals. Turn

ignition key to ON (engine stop

switch must be in the RUN posi-

tion). Set tester so speedometer

indicates greater than 20 mph.

Key number 528 into tester. Turn

signals should cancel after 20

flashes.

(continued)

-------------------------------------------------------------------------------------------------------------------------------------------------------------

(continued)

Turn signals cancel

Operates

after 20 flashes.

improperly.

Check speedom-

eter operation.

Speedometer indi-

Speedometer does

cates road speed.

not indicate road

speed.

Replace

Troubleshoot

TSM/TSSM.

speedometer.

Turn igntion key to

OFF. Remove

TSM/TSSM and con-

nect breakout box to

TSM/TSSM and con-

nector (30). Reinstall

battery. Turn ignition

key to ON. Check for

voltage as follows:

1. While depressing

right turn signal

switch, check for volt-

age at gray box termi-

nals 7 and 12. Wiggle

harness and note fluc-

tuations.

2. While depressing

left turn signal switch,

check for voltage at

gray box terminals 8

and 12. Wiggle har-

ness and note fluctua-

tions.

(continued)

-------------------------------------------------------------------------------------------------------------------------------------------------------------

(continued)

Voltage fluctuates.

No voltage

fluctuations.

Repair open in

Turn igntion key to ON.

circuit.

Check for voltage as follows:

1. With right turn signal

switch released, check for

voltage at gray box terminals

7 and 12. Wiggle harness

and note fluctuations.

2. With left turn signal

switch released, check for

voltage at gray box terminals

8 and 12. Wiggle harness

and note fluctuations.

Voltage fluctuates.

No voltage

fluctuations.

Repair short

Turn ignition key to OFF.

in circuit.

Check for continuity as fol-

lows:

1. While depressing right

turn signal switch, check for

continuity between gray box

terminals 7 and 12. Wiggle

harness and note fluctua-

tions.

2. While depressing left turn

signal switch, check for con-

tinuity between gray box ter-

minals 8 and 12. Wiggle

harness and note fluctua-

tions.

Continuity exists.

No continuity.

Repair short in

System OK.

circuit.

-------------------------------------------------------------------------------------------------------------------------------------------------------------

CARBURETOR TROUBLESHOOTING

Hard starting

• Fuel overflow from float assembly

• Enrichment system inoperative

• Plugged pilot jet and/or passage

• Fuel overflow

Fuel overflows

•

Incorrect fuel level

•

Damaged float assembly

•

Worn float needle valve or dirty seat

•

Incorrect float alignment

•

Damaged float bowl O-ring or loose

float bowl mounting screws

•

Plugged vent in fuel tank cap

•

Incorrect fuel tank cap installed

Poor idling

•

Incorrect idle speed

•

Plugged pilot jet system

•

Loose pilot jet

•

Air leak at carburetor mounting

•

Enrichment valve nut loose or

damaged

Poor acceleration

•

Fuel level too low

•

Clogged fuel passages

•

Clogged jets

•

Plugged vent in fuel tank cap

•

Incorrect fuel tank cap installed

(non-vent type)

•

Enrichment valve nut loose or

damaged

•

Worn or damaged needle jet or needle

•

Throttle cable misadjusted

•

Air leak at carburetor mounting

•

Damaged vacuum piston

Poor power at low engine speeds

•

Incorrect idle speed adjustment

•

Contaminated air filter element

•

Damaged vacuum piston

•

Worn or damaged needle jet or needle

•

Clogged pilot jet system

•

Plugged vent in fuel tank cap

•

Enrichment valve nut loose or

damaged

•

Clogged fuel supply

•

Air leak at carburetor mounting

(continued)

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(continued)

Poor power at high engine speeds

• Incorrect fuel level

• Loose or plugged main jet

• Contaminated air filter element

• Damaged vacuum piston

• Worn or damaged needle jet or needle

• Plugged float bowl vent or overflow

• Enrichment valve nut loose or damaged

• Plugged vent in fuel tank cap

• Clogged fuel supply

• Air leak at carburetor mounting

Poor fuel economy

• Incorrect enrichment use

• Damaged vacuum piston

• Contaminated air filter element

• Loose jets

• Fuel level too high

• Worn or damaged needle jet or needle

• Plugged float bowl vent

• Enrichment valve nut loose or damaged

• Incorrect carburetor adjustment

Vacuum piston does not rise in

• Vacuum piston binds in bore

bore correctly

• Diaphragm torn or damaged

• Vacuum piston spring binding

• Diaphragm cap loose or damaged

• Piston vent clogged

• Diaphragm incorrectly installed (pinched at

lip)

Vacuum piston does not close

• Broken spring

• Diaphragm torn or damaged

• Vacuum piston binds in bore

Troubleshooting

carburetor fuel level. As fuel is drawn from the float bowl

during engine operation, the float level in the bowl drops.

Isolate fuel system problems to the fuel tank, fuel shut-

As the float drops, the fuel valve moves from its seat and

off valve and filter, fuel hoses, external fuel filter (if used)

allows fuel to flow through the seat into the float bowl.

or carburetor. In the following procedures, it is assumed

Fuel entering the float bowl causes the float to rise and

that the ignition system is working properly.

push against the fuel valve. When the fuel level reaches a

Refer to Figure 61 for possible causes of fuel system

predetermined level, the fuel valve is pushed against the

problems.

seat to prevent the float bowl from overfilling.

If the fuel valve fails to close, the engine will run too

Fuel level system

rich or flood with fuel. Symptoms of this problem are

rough running, excessive black smoke and poor accelera-

The fuel level system is shown in Figure 62. Proper

tion. This condition sometimes clears up when the engine

carburetor operation depends on a constant and correct

is run at wide-open throttle and the fuel is being drawn

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Throttle rod

Pump

lever

Throttle shaft

Spring

Venturi

Pump

Float

nozzle

bowl

vent

Fuel inlet

(from inside)

Check

valve

Diaphragm

Inlet

valve

Pump

rod

Spring

Float

Overflow

line

into the engine before the float bowl can overfill. How-

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

ever, as the engine speed is reduced, the rich running con-

starting enrichment (choke) cable adjustment as described

dition returns.

in Chapter Three.

Several things can cause fuel overflow. In most in-

stances, a small piece of dirt is trapped between the fuel

Accelerator pump system

valve and seat, or the float level is incorrect. If fuel is

flowing out of the overflow tube connected to the bottom

During sudden acceleration, the diaphragm type accel-

of the float bowl, the fuel valve inside the carburetor is be-

erator pump system (Figure 63) provides additional fuel

ing held open. First check the position of the fuel shutoff

to the engine. Without this system, the carburetor would

valve lever. Turn the fuel shutoff valve lever off. Then

not be able to provide a sufficient amount of fuel.

lightly tap on the carburetor float bowl and turn the fuel

The system consists of a spring-loaded neoprene dia-

shutoff valve lever on. If fuel stops running out of the

phragm that is compressed by the pump lever during sud-

overflow tube, whatever was holding the fuel valve off of

den acceleration. This causes the diaphragm to force fuel

its seat has been dislodged. If fuel continues to flow from

from the pump chamber, through a check valve and into

the overflow tube, remove and service the carburetor. See

the carburetor venturi. The diaphragm spring returns the

Chapter Eight.

diaphragm to the uncompressed position, which allows

the chamber to refill with fuel.

NOTE

If the engine hesitates during sudden acceleration,

Fuel will not flow from the vacuum-operated

check the operation of the accelerator pump system. Car-

fuel shutoff valve until the engine is running.

buretor service is covered in Chapter Eight.

Starting enrichment (choke) system

Vacuum-operated fuel shutoff valve testing

A cold engine requires a rich mixture to start and run

All models are equipped with a vacuum-operated fuel

properly. On all models, a cable-actuated starter enrich-

shutoff valve. A vacuum hose is connected between the

ment valve is used for cold starting.

fuel shutoff valve diaphragm and the carburetor. When

-------------------------------------------------------------------------------------------------------------------------------------------------------------

CAUTION

In Step 8, do not apply more than 25 in. (635

mm) Hg vacuum or the fuel shutoff valve di-

aphragm will be damaged.

8. Apply 25 in. (635 mm) Hg of vacuum to the valve.

Fuel should flow through the fuel shutoff valve when the

vacuum is applied.

9. With the vacuum still applied, turn the fuel shutoff

valve lever to the reserve position. Fuel should continue

to flow through the valve.

10. Release the vacuum and make sure the fuel flow

stops.

11. Repeat Steps 8-10 five times. Fuel should flow with

vacuum applied and stop flowing when the vacuum is re-

leased.

12. Turn the fuel shutoff valve off. Disconnect the vac-

uum pump and drain hoses.

13. Reconnect the fuel hose (B, Figure 65) to the fuel

shutoff valve.

14. If the fuel valve failed this test, replace the fuel shut-

off valve as described in Chapter Eight.

ENGINE NOISES

1. Knocking or pinging during acceleration can be

caused by using a lower octane fuel than recommended or

the engine is running, vacuum is applied to the fuel shut-

a poor grade of fuel. Incorrect carburetor jetting and an in-

off valve through this hose. For fuel to flow through the

correct spark plug heat range (too hot) can cause pinging.

fuel valve, a vacuum must be present with the fuel shutoff

Refer to Spark Plugs in Chapter Three. Also check for ex-

valve handle in the on or reserve position. A Miti-Vac

cessive carbon buildup in the combustion chamber or a

hand-operated vacuum pump (Figure 64), gas can, drain

defective ignition module.

hose that is long enough to reach from the fuel valve to the

2. Slapping or rattling noise at low speed or during accel-

gas can, and hose clamp are required for this test.

eration can be caused by excessive piston-to-cylinder wall

1. Disconnect the negative battery cable as described in

clearance. Also check for a bent connecting rod(s) or

Chapter Nine.

worn piston pin and/or piston pin hole in the piston(s).

3. Knocking or rapping during deceleration is usually

2. Visually check the amount of fuel in the tank. Add fuel

caused by excessive rod bearing clearance.

if necessary.

4. Persistent knocking and vibration or other noises are

3. Turn the fuel shutoff valve (A, Figure 65) off and dis-

usually caused by worn main bearings. If the main bear-

connect the fuel hose (B) from the fuel shutoff valve. Plug

ings are in good condition, consider the following:

the open end of the hose.

a. Loose engine mounts.

4. Connect the drain hose to the fuel shutoff valve and se-

b. Cracked frame.

cure it with a hose clamp. Insert the end of the drain hose

c. Leaking cylinder head gasket(s).

into a gas can.

d. Exhaust pipe leak at cylinder head(s).

e. Stuck piston ring(s).

5. Disconnect the vacuum hose from the fuel shutoff

f. Broken piston ring(s).

valve.

g. Partial engine seizure.

6. Connect a hand-operated vacuum pump to the fuel

h. Excessive connecting rod bearing clearance.

shutoff valve vacuum hose nozzle.

i. Excessive connecting rod side clearance.

7. Turn the fuel shutoff valve on.

j. Excessive crankshaft runout.

-------------------------------------------------------------------------------------------------------------------------------------------------------------

5. Rapid on-off squeal indicates a compression leak

around the cylinder head gasket or spark plug.

6. For valve train noise, check for the following:

a. Bent pushrod(s).

b. Defective lifter(s).

c. Valve sticking in guide.

d. Worn cam gears and/or cam.

e. Damaged rocker arm or shaft. Rocker arm may be

binding on shaft.

ENGINE LUBRICATION

An improperly operating engine lubrication system

Oil Fails to Return to Oil Tank

quickly leads to engine damage. The engine oil tank

should be checked weekly and the tank refilled as de-

1. Oil lines or fittings restricted or damaged.

scribed in Chapter Three.

2. Oil pump damaged or operating incorrectly.

Oil pump service is covered in Chapter Five.

3. Oil tank empty.

4. Oil filter restricted.

Oil Light

Excessive Engine Oil Leaks

The oil light, mounted on the indicator light panel (Fig-

ure 66), will come on when the ignition switch is turned on

1. Clogged air filter breather hose.

before starting the engine. After starting the engine, the oil

2. Restricted or damaged oil return line to oil tank.

light should go off when the engine speed is above idle.

3. Loose engine parts.

If the oil light does not come on when the ignition switch

4. Damaged gasket sealing surfaces.

is turned on and the engine is not running, check for a

5. Oil tank overfilled.

burned out oil light bulb. If the bulb is good, check the oil

pressure switch (Figure 67) as described in Chapter Nine.

CLUTCH

If the oil light remains on when the engine speed is

All clutch troubles, except adjustments, require partial

above idle, turn the engine off and check the oil level in

clutch disassembly to identify and repair the problem. Refer

the oil tank as described in Chapter Three. If the oil level

to Chapter Six for clutch service procedures.

is satisfactory, check the following:

1. Oil may not be returning to the tank from the return

line. Check for a clogged or damaged return line or a dam-

Clutch Chatter or Noise

aged oil pump.

This problem is generally caused by worn or warped

2. If operating the motorcycle in conditions where the

friction and steel plates. Also check for worn or damaged

ambient temperature is below freezing, ice and sludge

bearings.

may be blocking the oil feed pipe. This condition will pre-

vent the oil from circulating properly.

Clutch Slip

Oil Consumption High or Engine

1. Incorrect clutch adjustment.

Smokes Excessively

2. Worn friction plates.

3. Weak or damaged diaphragm spring.

1. Worn valve guides.

4. Damaged pressure plate.

2. Worn valve guide seals.

3. Worn or damaged piston rings.

Clutch Drag

4. Restricted oil tank return line.

5. Oil tank overfilled.

1. Incorrect clutch adjustment.

6. Oil filter restricted.

2. Warped clutch plates.

7. Leaking cylinder head surfaces.

3. Worn or damaged clutch shell or clutch hub.

-------------------------------------------------------------------------------------------------------------------------------------------------------------

4. Loose or damaged engine mounting bracket.

5. Improperly balanced wheel(s).

6. Defective or damaged wheel(s).

7. Defective or damaged tire(s).

8. Internal engine wear or damage.

SUSPENSION AND STEERING

Poor handling may be caused by improper pressure, a

damaged or bent frame or front steering components,

worn wheel bearings or dragging brakes. Possible causes

for suspension and steering malfunctions are listed below.

TRANSMISSION

Irregular or Wobbly Steering

Transmission symptoms are sometimes hard to distin-

1. Loose wheel axle nut(s).

guish from clutch symptoms. Refer to Chapter Seven for

2. Loose or worn steering head bearings.

transmission service procedures. Make sure the clutch is

3. Excessive wheel hub bearing play.

not causing the trouble before working on the transmission.

4. Damaged cast wheel.

5. Spoke wheel out of alignment.

6. Unbalanced wheel assembly.

Jumping Out of Gear

7. Worn hub bearings.

1. Incorrect shifter pawl adjuster.

8. Incorrect wheel alignment.

2. Worn or damaged shifter parts.

9. Bent or damaged steering stem or frame (at steering

3. Bent shift forks.

neck).

4. Excessively worn or damaged gears.

10. Tire incorrectly seated on rim.

11. Heavy front end loading from non-standard equip-

ment.

Difficult Shifting

1. Worn or damaged shift forks.

Stiff Steering

2. Loose or damaged detent plate.

3. Worn or damaged shifter shaft assembly.

1. Low front tire air pressure.

4. Worn or damaged detent arm.

2. Bent or damaged steering stem or frame (at steering

5. Worn shift fork drum groove(s).

neck).

6. Loose, worn or damaged shifter fork pin(s).

3. Loose or worn steering head bearings.

7. Damaged shifter shaft splines.

Stiff or Heavy Fork Operation

Excessive Gear Noise

1. Incorrect fork springs.

1. Worn or damaged bearings.

2. Incorrect fork oil viscosity.

2. Worn or damaged gears.

3. Excessive amount of fork oil.

3. Excessive gear backlash.

4. Bent fork tubes.

EXCESSIVE VIBRATION

Poor Fork Operation

Excessive vibration is usually caused by loose engine

1. Worn or damaged fork tubes.

mounting hardware. High speed vibration may be due to a

2. Fork oil capacity low due to leaking fork seals.

bent axle shaft or loose or faulty suspension components.

3. Bent or damaged fork tubes.

Vibration can also be caused by the following conditions:

4. Contaminated fork oil.

1. Broken frame.

5. Incorrect fork springs.

2. Excessively worn primary chain.

6. Heavy front end loading from non-standard equip-

3. Tight primary chain links.

ment.

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Poor Rear Shock Absorber Operation

Spongy Brake Feel

1. Weak or worn springs.

This problem is generally caused by air in the hydraulic

2. Damper unit leaking.

system. Bleed and adjust the brakes as described in Chap-

3. Shock shaft worn or bent.

ter Thirteen.

4. Incorrect rear shock springs.

5. Rear shocks adjusted incorrectly.

6. Heavy rear end loading from non-standard equipment.

Brake Drag

7. Incorrect loading.

Check brake adjustment, looking for insufficient brake

BRAKES

pedal and/or hand lever free play. Also check for worn, loose

or missing parts in the brake calipers. Check the brake disc

All models are equipped with front and rear disc brakes.

for warpage or excessive runout.

Brakes operation is vital to the safe operation of any vehicle.

Perform the maintenance specified in Chapter Three to mini-

mize brake system problems. Brake system service is cov-

Brakes Squeal or Chatter

ered in Chapter Thirteen. When refilling the front and rear

master cylinders, use only DOT 5 silicone-based brake fluid.

Check brake pad thickness and disc condition. Make

sure the pads are not loose; check that the anti-rattle

springs are properly installed and in good condition.

Insufficient Braking Power

Clean off any dirt on the pads. Loose components can also

Worn brake pads or disc, air in the hydraulic system,

cause this. Check for:

glazed or contaminated pads, low brake fluid level, or a

1. Warped brake disc.

leaking brake line or hose can cause this problem. Visually

2. Loose brake disc.

check for leaks. Check for worn brake pads. Check also for

3. Loose caliper mounting bolts.

a leaking or damaged primary cup seal in the master cylin-

4. Loose front axle nut.

der. Bleed and adjust the brakes. Rebuild a leaking master

cylinder or brake caliper. Brake drag will cause excessive

5. Worn wheel bearings.

heat and brake fade. See Brake Drag in this section.

6. Damaged hub.

Table 1 STARTER SPECIFICATIONS

Brush length (minimum)

0.443 in. (11.0 mm)

Commutator diameter (minimum)

1.141 in. (28.98 mm)

Commutator runout (maximum)

0.016 (0.41 mm)

Current draw

Normal

160-200 amps

Maximum

250 amps

Maximum no-load speed at 11.5 volts

90 amps

Minimum no-load current at 11.5 volts

3000 rpm

Table 2 ELECTRICAL SPECIFICATIONS

Battery capacity

12 volt, 12 amp hr.

Ignition coil

Primary resistance

0.5-0.7 ohms

Secondary resistance

5500-7500 ohms

Alternator

Stator coil resistance

0.2-0.4 ohms

AC voltage output

19-26 Vac per 1000 rpm

Voltage regulator

Voltage output

14.3-14.7 VDC at 75

Amps at 3600 rpm

22 amps

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Table 3 DIAGNOSTIC TROUBLE CODES

DTC

Problem

Priority

Troubleshooting chart

BusEr

Serial data bus fault

Figure 42 or 43

B0563²

Battery voltage high

B1006

Accessory line overvoltage

Figure 37

B1007

Ignition line overvoltage

Figure 37

B1008

Reset switch closed

Figure 38

B1121

Left turn output fault

Figure 44

B1122

Right turn output fault

Figure 44

B1131

Alarm output low

Figure 45

B1132

Alarm output high

Figure 45

B1134

Starter output high

Figure 46

B1135³

Accelerometer fault

B1141

Ignition switch open/low

Figure 44

B1151⁴

B1152⁴

B1153⁴

P0106

MAP sensor rate-of-change

Figure 48

error

P0107

MAP sensor failed open/low

Figure 48

P0108

MAP sensor failed high

Figure 48

P0371

CKP shorted low

Figure 49

P0372

CKP shorted high

Figure 49

P0374

CKP not detected/cannot

synchronize

Figure 49

P0501

VSS failed low

Figure 50

P0502

VSS failed high/open

Figure 50

P0562

System voltage low

Figure 51

P0563

System voltage high

Figure 51

P0602⁵

Calibration memory error

P0603⁵

EEProm memory error

P0604⁵

RAM memory error

P0605⁵

Program memory error

P0607⁵

A to D error

P1009

Incorrect password

Figure 52

P1010

Missing password

Figure 53

P1351

Ignition coil driver

front low/open

Figure 54

P1352

Ignition coil driver front

high/shorted

Figure 54

P1354

Ignition coil driver rear

low/open

Figure 54

P1355

Ignition coil driver rear

high/shorted

Figure 54

U1016

Loss of ICM serial data

Figure 39 or 40

U1064

Loss of TSM/TSSM

serial data

Figure 41

U1097

Loss of speedometer

serial data

Figure 47

U1255

Loss of ICM or TSM/TSSM

serial data

Figure 39, 40, 41 or 47

U1300

Serial data low

Figure 42 or 43

U1301

Serial data open/high

Figure 42 or 43

1. Priority numbers are relative. There may be more than one DTC for a specific priority number due to

differing systems, such as engine management and TSM/TSSM.

2. Follow the troubleshooting procedures for the charging system in this chapter.

3. Replace the TSM/TSSM due to an internal malfunction.

4. Not applicable to Sportster models. If DTC appears, reconfigure TSM/TSSM.

5. Replace the ICM due to an internal malfunction.