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Harley Davidson 2008 Sportster Models. Electrical Diagnostics Manual - page 3

CHECKING

FOR DIAGNOSTIC TROUBLE CODES

2.1

CHECK ENGINE LAMP

ed02813

See Figure 2-1. To diagnose Electronic Control Module (ECM)

system problems, begin by observing the behavior of the check

engine lamp (1).

2

1

NOTES

3

•

See Figure 2-2. "Key ON" means that the Ignition Switch

is turned to IGNITION and the Engine Stop Switch is set

to RUN (although the engine is not running).

•

When the Ignition Switch is turned to IGNITION, the check

engine lamp will illuminate for approximately four seconds

and then turn off.

•

If the check engine lamp is not illuminated at Ignition ON,

the problem is likely to be an instrument failure. See

2.2 INITIAL DIAGNOSTIC CHECK: SPEEDOMETER.

•

If the check engine lamp illuminates late

(after

20

seconds), the problem is most likely a serial data bus

failure. Test for Diagnostic Trouble Codes (DTCs) using

6

4

speedometer self diagnostics. See

2.2 INITIAL DIA-

5

GNOSTIC CHECK: SPEEDOMETER.

•

If the check engine lamp fails to turn off after the initial

four-second period, see

2.2 INITIAL DIAGNOSTIC

1. Check engine lamp

CHECK: SPEEDOMETER.

2. Low fuel lamp

3. Battery lamp

1.

See Figure 2-3. After the check engine lamp turns off fol-

4. Security lamp (key icon)

lowing the first four-second illumination period, one of

5. Odometer display

three events may occur:

6. Sixth gear indicator (not used)

a. The lamp remains off. This indicates there are no

current fault conditions or stored DTCs currently

Figure 2-1. Speedometer

detected by the ECM.

b. The lamp remains off for only four seconds and then

illuminates for an eight-second period. This indicates

ed02814

a DTC is stored, but no current DTC exists.

2

c. The lamp remains on beyond the eight-second period.

3

This indicates a current DTC exists.

1

ACC.

2.

See 2.1 CHECKING FOR DIAGNOSTIC TROUBLE

CODES, Code Types which follows for a complete

description of DTC formats.

NOTE

Some DTCs can only be fully diagnosed during actuation. For

example, a problem with the ignition coil will be considered a

current fault even after the problem is corrected, since the ECM

will not know of its resolution until after the coil is exercised by

the vehicle start sequence. In this manner, there may some-

times be a false indication of the current DTC.

1. Ignition OFF

2. Accessory (ACC) ON

3. Ignition ON

Figure 2-2. Ignition Switch

2008 Sportster Diagnostics: Instruments 2-1

DTCs using speedometer self diagnostics. See 2.2 INITIAL

SECURITY LAMP

DIAGNOSTIC CHECK: SPEEDOMETER.

Turn Signal Module (TSM)

•

If the security lamp fails to turn off after the initial four-

If the turn signals flash six 4-way flashes shortly after key ON,

second period, a problem exists in the instrumentation.

it indicates a Diagnostic Trouble Code (DTC) has been logged

See 2.2 INITIAL DIAGNOSTIC CHECK: SPEEDOMETER.

sometime in the last three ignition cycles.

1. See Figure 2-3. After the security lamp turns off following

Turn Signal Security Module (TSSM) or

the first four-second illumination period, one of three

events may occur:

Hands-Free Security Module (HFSM)

a. The lamp remains off. This indicates there are no

See Figure 2-1. To diagnose Turn Signal Security Module

current fault conditions or stored DTCs currently

(TSSM) or Hands-Free Security Module (HFSM) system

detected by the TSSM/HFSM.

problems, begin by observing the behavior of the security lamp

(4).

b. The lamp stays off for only four seconds and then

comes back on for an eight-second period. This

NOTES

indicates a DTC is stored, but no current DTC exists.

•

To provide an indication of TSSM/HFSM DTCs, the

c. The lamp remains on beyond the eight-second period.

security lamp is enabled on TSSM/HFSM models.

This indicates a current DTC exists.

•

See Figure 2-2. "Key ON" means that the Ignition Switch

is turned to IGNITION and the Engine Stop Switch is set

2. See

2.1 CHECKING FOR DIAGNOSTIC TROUBLE

to RUN (although the engine is not running).

CODES, Code Types for a complete description of DTC

formats.

•

When the Ignition Switch is turned ON, the security lamp

will illuminate for approximately four seconds and then

NOTE

turn off.

Some DTCs can only be fully diagnosed during actuation. For

•

If the security lamp is not illuminated at Key ON, the

example, a problem with the turn signals will be considered a

problem is likely to be an instrument failure. See 2.2 INI-

current fault even after the problem is corrected, since the

TIAL DIAGNOSTIC CHECK: SPEEDOMETER.

TSM/TSSM/HFSM will not know of its resolution until after the

turn signals are activated. In this manner, there may sometimes

•

If the security lamp illuminates late (after 20 seconds), the

be a false indication of the current DTC.

problem is most likely a serial data bus failure. Test for

ed01046

ON

4 Sec.

A

Lamp OFF: No Current or Historic DTCs

OFF

Key On

Lamp ON 8 Seconds:

Only Historic DTCs Exist

ON

4 Sec.

8 Sec.

B

Lamp OFF

OFF

4 Sec.

Key On

Lamp Remains ON: Current DTC*

ON

4 Sec.

C

OFF

4 Sec.

Key On

* Historic DTCs May Also Exist

Figure 2-3. Check Engine and Security Lamp Operation

2-2 2008 Sportster Diagnostics: Instruments

INITIAL DIAGNOSTIC CHECK:

SPEEDOMETER

2.2

backlighting and odometer display (5). Upon key ON

GENERAL

(Engine Stop Switch set to RUN), the check engine lamp

PART NUMBER

TOOL NAME

and security lamp will illuminate for four seconds and then

(if parameters are normal) will turn off.

HD-44750

DIGITAL TECHNICIAN

•

To locate faulty circuits or other system problems, follow

•

See Figure

2-4. Constant power is supplied to the

the diagnostic flow charts and tests in this section. For a

speedometer through terminal "5" of connector [39]. The

systematic approach, always begin with 2.2 INITIAL DIA-

speedometer turns on when power is applied to terminal

GNOSTIC CHECK: SPEEDOMETER, Initial Diagnostics.

"1". The speedometer proceeds through an initialization

Read the general information and then work your way

sequence every time power is removed and re-applied to

through the flow chart box by box.

terminal "6". See Figure 2-1. The visible part of this

sequence is the check engine lamp (1), security lamp (4),

•

Loss of power on any of the four power inputs will change

speedometer behavior. Refer to Table 2-1.

Table 2-1. Speedometer Function Chart - Loss of Input

Terminal 5

Terminal 1 (IGN)

Terminal 6 (ACC)

Terminal 7 (GRD)

Terminal 8 and 11

(Constant)

(Trip Odometer

Reset Switch)

•

Security lamp

•

Will not "WOW"

•

Speedometer

•

Speedometer

•

No trip odometer

glows

dimly

•

Turn signals still functional

will be non-func-

completely non-

reset switch func-

during 4-second

•

Speedometer will indicate

tional

in

functional

tion

bulb check

vehicle speed (zero)

accessory and

•

Diagnostic absent

•

Will not "WOW"

•

Tachometer unaffected

ignition modes

•

Security lamp still functions

•

Security lamp

•

Check engine lamp and battery

still performs 4-

lamp non-functional

second

bulb

•

Diagnostics absent

check in ignition

mode

Diagnostic Notes

Reprogramming ECM

If a numbered circle appears adjacent to a flow chart box, more

Diagnostic charts frequently suggest Electronic Control Module

information is offered in the diagnostic notes. Many diagnostic

(ECM) replacement. In the event an ECM needs to be replaced,

notes contain supplemental information, descriptions of various

it must be reprogrammed using a computer-based diagnostic

diagnostic tools or references to other parts of the manual

package called DIGITAL TECHNICIAN (Part No. HD-44750).

where information on the location and removal of components

See your dealer. Password learn procedure must also be per-

may be obtained.

formed. See

3.25 TSM/HFSM: PASSWORD LEARN or

E.21 TSM/TSSM: PASSWORD LEARN.

Circuit Diagram/Wire Harness Connector

INITIAL DIAGNOSTICS

Table

When working through a flow chart, refer to the illustrations,

PART NUMBER

TOOL NAME

the associated circuit diagram and the wire harness connector

HD-42682

BREAKOUT BOX

table as necessary. The wire harness connector table for each

HD-46601

INSTRUMENT HARNESS ADAPTERS

circuit diagram identifies the connector number, description,

type and general location.

Diagnostic Tips

In order to perform most diagnostic routines, a Breakout Box

•

See Figure 2-4. If Speedometer reads "BUS Er" while

and a DVOM are required. See

2.5 BREAKOUT BOX:

Ignition Switch is turned to ON (Engine Stop Switch at

SPEEDOMETER/TACHOMETER.

RUN with the engine off), check diagnostic link for an open

To perform the circuit checks with any degree of efficiency, a

or short to ground between data link connector [91A] ter-

familiarity with the various wire connectors is also necessary.

minal "3" and ECM connector

[78] terminal "5",

TSM/TSSM/HFSM connector [30] terminal "3", speedo-

Job/Time Code Values

meter connector

[39] terminal "2" or tachometer

(if

Dealership technicians filing warranty claims should use the

equipped) connector [108] terminal "2".

job/time code values printed in bold text underneath the

•

Check for an open diagnostic test terminal between data

appropriate repair.

link connector [91A] terminal "3" and TSM/TSSM/HFSM

connector [30] terminal "3". With Ignition Switch turned to

2-4 2008 Sportster Diagnostics: Instruments

ON, transmit data should be typically 0.6-0.8 volts. The

1. Connect BREAKOUT BOX (Part No. HD-42682) (black)

range of acceptable operation is greater than 0.0 volts and

between speedometer connector [39A] (at the back of the

less than 7.0 volts.

speedometer) and wire harness connector [39B] using

INSTRUMENT HARNESS ADAPTERS (Part No. HD-

•

To identify intermittents, wiggle instrument and/or vehicle

46601). See

2.5 BREAKOUT BOX: SPEEDO-

harness while performing steps in the Initial Diagnostic

METER/TACHOMETER.

Check charts.

All Speedometer Diagnostic Trouble Codes (DTCs) are listed

Diagnostic Notes

in Table 2-2.

Each reference number below correlates to a circled number

on the flow chart(s).

Table 2-2. Speedometer Diagnostic Trouble Code (DTC) Priority Chart

DTC

RANKING

FAULT CONDITION

SOLUTION

U1300

1

Serial data bus shorted low

2.12 DTC U1300, U1301 OR BUS ER

U1301

2

Serial data bus shorted high

2.12 DTC U1300, U1301 OR BUS ER

U1016

3

Loss of ECM serial data

2.10 DTC U1016, U1255

U1064

4

Loss of

TSM/TSSM/HFSM serial data

2.11 DTC U1064, U1255

U1255

5

Missing

response from other module (TSM/TSSM/HFSM

2.11 DTC U1064, U1255

and/or ECM) at startup

B1007

6

Ignition line overvoltage

2.8 DTC B1006, B1007

B1006

7

Accessory line overvoltage

2.8 DTC B1006, B1007

B1008

8

Reset switch closed

2.9 DTC B1008

B1004

9

Fuel level sending unit low

2.7 DTC B1004, B1005

B1005

10

Fuel level sending unit high/open

2.7 DTC B1004, B1005

related to the Turn Signal Module (TSM), Turn Signal Security

Other Diagnostic Trouble Codes

Module (TSSM) or Hands-Free Security Module (HFSM).

See 3.10 INITIAL DIAGNOSTIC CHECK: TSM/HFSM or

See 4.5 INITIAL DIAGNOSTIC CHECK: EFI for any DTCs

E.9 INITIAL DIAGNOSTIC CHECK: TSM/TSSM for any DTCs

related to the Electronic Control Module (ECM).

2008 Sportster Diagnostics: Instruments 2-5

Speedometer

em01120

Tachometer (Optional)

TSM/TSSM/HFSM

1

2

5

6

7

[39A]

1

2

5

6 7

[108A]

1

2

5

6

7

[39B]

1

2

5

6 7

[108B]

[30A]

1

2

3

12

[30B]

1

2

3

12

[GND1]

1

2

6

7

12

[20A]

1

2

6

7

12

[20B]

To ACCY fuse

R/GY

O/W

To BATT fuse

12V ACCY

Fuse

[GND1]

R

BN/GY

BN/GY

12V BATT

GY

Fuse

To INSTR fuse

LGN/V

R/BK

O

12V INSTR

1

Fuse

To IGN fuse

BK

2

Data Link

Connector

LGN/V

3

R/BK

GY

GY

4

12V IGN

Fuse

[91A]

[GND1]

[78B]

5

[78A]

5

ECM

Figure 2-4. Serial Data Circuit

Table 2-3. Wire Harness Connectors

NO.

DESCRIPTION

TYPE

LOCATION

[20]

Instruments

12-place Molex

Under fuel tank

[30]

TSM/TSSM/HFSM

12-place Deutsch

Under battery

[39]

Speedometer

12-place Packard

Back of speedometer

[78]

Electronic Control Module (ECM)

36-place Packard

Under seat

[91A]

Data link connector

4-place Deutsch

On battery strap, behind left side cover

[108]

T

achometer (if equipped)

12-place Packard

Back of tachometer

2-6 2008 Sportster Diagnostics: Instruments

Initial Diagnostic Check (Part 1 of 3)

Does engine

start?

YES.

YES.

NO.

NO.

Starts and runs.

Starts, then stalls.

Cranks, but will not start.

Engine will not crank.

Check for DTCs. See

See 4.12 STARTS,

See 4.10 ENGINE CRANKS,

See 1.2 STARTING

2.3 SPEEDOMETER

THEN STALLS.

BUT WILL NOT START.

SYSTEM DIAGNOSIS.

SELF DIAGNOSTICS

Were DTCs found?

YES

NO

NO

Unable to enter

No codes

diagnostic mode.

displayed.

Refer to applicable DTC priority

With ignition switch OFF, press and

For a list of symptoms that

chart. All DTCs are listed by

release trip odometer reset switch.

may not set diagnostic

priority in Table 2-2.

Does odometer display appear with

trouble codes, refer to

backlighting?

Table 3-6.

YES

NO

Check for continuity to ground at

Breakout Box terminal “7” (black). Wiggle

1

STOP

harness during continuity check.

Is continuity present?

Go to Initial Diagnostic

Check (Part 2 of 3).

YES

NO

Check for battery voltage at

Breakout Box terminal “5” (black)

Locate and

while wiggling harness.

repair open.

Is battery voltage continuously

present?

YES

NO

With ignition switch OFF and speedometer

Locate and

connector [39] disconnected, check continuity

repair open.

between Breakout Box terminals “8” and “11” (black).

Is continuity present when trip odometer reset

switch is depressed and infinity when released?

YES

NO

Replace

Replace trip odometer

Speedometer.

reset switch.

fc01062_en

2008 Sportster Diagnostics: Instruments 2-7

Initial Diagnostic Check (Part 2 of 3)

Continued from Initial Diagnostic Check (Part 1 of 3).

Turn ignition switch ON, is odometer backlight present?

YES

NO

Replace Speedometer.

Perform “WOW” test.

See 2.3 SPEEDOMETER SELF DIAGNOSTICS.

The following features should be functional

1) backlight should illuminate

2) needle should sweep its full range of motion

3) LEDs should illuminate:

• check engine

• battery

• security (all models)

• low fuel

• sixth gear

Are all features functional?

YES

NO

Turn Ignition Switch to ACC.

Turn Ignition Switch to IGNITION.

Is backlight present?

Check for

1

battery voltage at Breakout

Box terminal “1” (Black).

YES

NO

Is battery voltage present?

Check for battery voltage at

YES

NO

Breakout Box terminal “6”

1

(Black). Is battery voltage

present?

Is instrument

Replace Speedometer.

fuse good?

YES

NO

YES

NO

Is accessory

Locate and repair open

Locate and repair

Replace Speedometer.

fuse good?

between terminal “1” of

source of fault.

connector [39] and

Replace fuse.

instrument fuse.

YES

NO

Locate and repair open

Locate and repair

on (O/W) wire between

source of fault.

terminal “6” of connector

Replace fuse.

[39] and accessory fuse.

fc01063_en

STOP

Go to Initial Diagnostic

Check (Part 3 of 3).

2-8 2008 Sportster Diagnostics: Instruments

Initial Diagnostic Check (Part 3 of 3)

Continued from Initial Diagnostic Check (Part 2 of 3).

Is problem intermittent?

YES

NO.

NO.

Speedometer

Tachometer

Inoperative

Inoperative

(no vehicle speed).

(no engine speed).

Repeat Diagnostic

Remove and inspect

See Tachometer

Check while wiggling

Vehicle Speed Sensor.

Inoperative (Part 1 of 2).

harnesses.

Is debris present?

Was intermittent found?

YES

NO

YES

NO

No trouble found.

Check for damaged wiring/

Locate and repair

Remove debris.

loose connection between

intermittent.

Reinstall

Vehicle Speed Sensor and ECM.

Vehicle Speed Sensor.

Is wiring damage/loose

connection present?

YES

NO

Locate and repair

Replace

source of fault.

Speedometer.

fc01064_en

2008 Sportster Diagnostics: Instruments 2-9

Speedometer Self Diagnostics

While holding trip odometer reset

switch in, turn ignition switch to

1

IGNITION.

Make sure Engine Stop Switch is in

RUN position.

Release trip odometer reset switch.

Does “diag” appear?

YES

NO

Press and release trip odometer reset switch.

“PSSPtb” appears.

To display DTCs for the

ECM, press and hold trip

See 2.2 INITIAL

”P” flashing.

odometer reset switch for more

DIAGNOSTIC

than 5 seconds.

CHECK: SPEEDOMETER.

To choose TSM/

TSSM/HFSM, press

and release trip odometer

reset switch.

To display DTCs for

TSM/TSSM, press and hold trip

Device

”S” flashing.

odometer reset switch for more

response?

than 5 seconds.

NO

To choose Speedometer,

press and release trip

“no rsp” displayed. See applicable code from

odometer reset switch.

other modules. Models not equipped with a

tachometer or ABS will display “no rsp” normally.

To display DTCs for

speedometer, press and

YES

If “no rsp” displayed on odometer on tachometer

”SP” flashing.

hold trip odometer reset

equipped vehicle, See Section 2.4

switch for more than 5

SPEEDOMETER/TACHOMETER.

seconds.

To choose Tachometer,

press and release trip odometer

DTC

2

reset switch.

“none” displayed.

displayed.

To display DTCs for tachometer,

press and hold trip odometer

”T” flashing.

reset switch for more than 5

Press and release trip

seconds.

odometer reset switch.

Press and release

Are more DTCs displayed?

trip odometer reset

To choose ABS, press

switch. Part number

and release trip odometer

of module will be

reset switch.

displayed.

YES

To display DTCs for

ABS, press and

NO

”b” flashing.

hold trip odometer reset

switch for more

than 5 seconds.

“end” displayed. To clear all DTCs for selected

To choose ECM, press

module hold trip odometer reset switch for more than

and release trip odometer

5 seconds. If DTCs are not to be cleared, Press and

reset switch.

release trip odometer reset switch. Part number of

module will be displayed.

Press and release trip

odometer reset switch again to

continue to next module.

fc01065_en

2008 Sportster Diagnostics: Instruments 2-11

SPEEDOMETER/TACHOMETER

2.4

GENERAL

ed02816

See Figure 2-5. The speedometer consists of a speedometer

display and five status lamps. The lamps include: check engine

(1), low fuel (2), battery (3), security (4) and sixth gear indicator

(6).

Trip Odometer Reset Switch

Figure 2-6. Pressing the trip odometer reset switch provides

the following capabilities:

•

Change the odometer display between mileage, trip A and

trip B values (press and immediately release).

•

Reset an individual trip odometer (press and hold 2-3

seconds).

•

Gain access to the diagnostic mode and clear Diagnostic

Trouble Codes (DTCs). See 2.3 SPEEDOMETER SELF

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

DIAGNOSTICS.

•

Display odometer while ignition switch is OFF. Press and

hold trip odometer reset switch while ignition switch is OFF

SPEEDOMETER THEORY OF OPERATION

and odometer mileage will be displayed.

The speedometer circuit consists of a Vehicle Speed Sensor

•

On models with dual scale speedometers, toggle between

(VSS), the ECM, the trip odometer reset switch and the

miles/kilometers on odometer and trip odometer display.

speedometer. The VSS is mounted on the rear of the engine

To toggle display, turn ignition switch ON. Press and hold

crankcase behind the starter motor assembly. The sensor cir-

trip odometer reset switch while odometer is displayed.

cuitry is that of a Hall-effect sensor triggered by the gear teeth

Release switch when change is noted. (If trip odometer

of 5th gear on the transmission mainshaft.

reset switch is held while trip odometer is displayed, trip

The output from the sensor is a series of pulses that are inter-

odometer will reset).

preted by the ECM circuitry, converted into serial data then

sent to the speedometer to control the position of the speedo-

meter needle and the odometer Liquid Crystal Display (LCD).

ed02813

The vehicle speed serial data is also transmitted to the

TSM/TSSM/HFSM for turn signal cancellation.

2

1

ODOMETER THEORY OF OPERATION

The odometer mileage is permanently stored and will not be

3

lost when electrical power is turned off or disconnected. The

trip odometer reset switch allows switching between the odo-

meter, trip odometer A and trip odometer B displays.

To zero the trip odometer, have the desired trip odometer dis-

play visible and press and hold the trip odometer reset switch.

The trip odometer mileage will be displayed for 2-3 seconds

and then the trip mileage will return to zero miles.

The odometer can display six numbers to indicate a maximum

of 999999 miles/kilometers. The trip odometers can display six

numbers with a tenth of a mile accuracy for a maximum of

99999.9 miles/kilometers.

6

TACHOMETER THEORY OF OPERATION

4

5

See Figure 2-7. The tachometer receives serial data from the

ECM. The tachometer interprets the serial data and converts

it into tachometer needle movement.

1. Check engine lamp

2. Low fuel lamp

NOTE

3. Battery lamp

Indicator lamps in the tachometer face may illuminate during

4. Security lamp (key icon)

a "WOW" test, even though they do not function during normal

5. Odometer display

vehicle operation.

6. Sixth gear indicator (not used)

Figure 2-5. Speedometer

2-12 2008 Sportster Diagnostics: Instruments

DIAGNOSTICS

ed02817

PART NUMBER

TOOL NAME

HD-41404-B

HARNESS CONNECTOR TEST KIT

HD-42682

BREAKOUT BOX

HD-46601

INSTRUMENT HARNESS ADAPTERS

Diagnostic Notes

Each reference number below correlates to a circled number

on the flow chart(s).

1.

If problems are intermittent, wiggle harness while per-

forming tests.

2.

Connect BREAKOUT BOX (Part No. HD-42682) (black)

between tachometer connector [108A] (at the back of the

Figure 2-7. Tachometer

tachometer) and wire harness connector [108B] using

INSTRUMENT HARNESS ADAPTERS (Part No. HD-

46601). See

2.5 BREAKOUT BOX: SPEEDO-

METER/TACHOMETER.

3.

Use HARNESS CONNECTOR TEST KIT (Part No. HD-

41404-B), black pin probe and patch cord.

em01124

[39A] [39B]

Ignition

1

1

O

Serial data

2

2

LGN/V

Odometer

Reset Switch

Security LP

4

4

BN/V

Battery

5

5

BN/GY

Accessory

6

6

O/W

Ground

7

7

BK

Trip SW

8

8

BK

Trip SW

11

11

BK

[20A]

Speedometer

O/W

1

BN/GY

2

[108A] [108B]

Ignition

1

1

O

O

6

Serial data

2

2

LGN/V

LGN/V

7

RPM x 100

Battery

5

5

BN/GY

Accessory

6

6

O/W

BN/V

11

Ground

7

7

BK

BK

12

Tachometer

(if equipped)

Figure 2-8. Speedometer/Tachometer Circuitry

Table 2-4. Wire Harness Connectors

NO.

DESCRIPTION

TYPE

LOCATION

[20]

Instruments

12-place Molex

Under fuel tank

[39]

Speedometer

12-place Packard

Back of speedometer

[108]

T

achometer (if equipped)

12-place Packard

Back of tachometer

2008 Sportster Diagnostics: Instruments 2-13

Tachometer Inoperative (Part 1 of 2)

Perform “WOW” test. See 2.3 SPEEDOMETER

SELF DIAGNOSTICS.

The following features should be functional

1) backlight should illuminate

2) needle should sweep its full range of motion

1

3) LED’s may illuminate:

• cruise (although not cruise equipped)

• pursuit (although not a police vehicle)

Are all features functional?

YES

NO

Is problem intermittent?

Check for battery voltage at

2

Breakout Box terminal “1”.

Is battery voltage present?

YES

NO

Repeat “WOW” test

YES

NO

No trouble

while wiggling

found.

harnesses.

Check for continuity

between Breakout Box

Is instrument

3

terminal “2” and terminal

fuse good?

“7” of connector [20].

Is continuity present?

YES

NO

YES

NO

Locate and repair

open in (O) wire between

Locate and repair

Locate and

terminal “1” of

source of fault.

STOP

repair open

connector [108] and

Replace fuse.

on (LGN/V)

instrument fuse.

wire.

Go to Tachometer

Inoperative (Part 2 of 2).

fc01066_en

2-14 2008 Sportster Diagnostics: Instruments

Tachometer Inoperative (Part 2 of 2)

Continued from Tachometer

Inoperative (Part 1 of 2).

Check for continuity to ground on

Breakout Box terminal “7”. Wiggle

harness during continuity check.

Is continuity present?

YES

NO

Locate and repair open on (BK) wire

Check for battery voltage at Breakout Box

between terminal “7” of connector [108]

terminal “5” while wiggling harness.

and ground.

Is battery voltage continuously present?

YES

NO

Check for battery voltage at Breakout

Locate and repair open on (BN/GY)

Box terminal “6”. Is battery voltage

wire between terminal “5” of connector

present?

[108] and battery fuse.

YES

NO

Replace tachometer.

Locate and repair open

on (O/W) wire between

terminal “6” of

connector [108] and

accessory fuse.

fc01067_en

2008 Sportster Diagnostics: Instruments 2-15

BREAKOUT BOX:

SPEEDOMETER/TACHOMETER

2.5

GENERAL

ed02819

PART NUMBER

TOOL NAME

HD-42682

BREAKOUT BOX

HD-46601

INSTRUMENT HARNESS ADAPTERS

The BREAKOUT BOX (Part No. HD-42682) and INSTRUMENT

HARNESS ADAPTERS (Part No. HD-46601) connect to the

speedometer connector [39] or tachometer connector [108].

Used in conjunction with a DVOM, the breakout box allows

circuit diagnosis of wiring harness and connections without

having to probe with sharp objects

NOTE

See wiring diagrams for speedometer and tachometer terminal

functions.

SPEEDOMETER

Installation

1. See Figure 2-9. Depress latch on connector [39B].

2. Connect instrument harness adapters to connectors [39A]

and [39B].

3. Attach black connectors from Breakout Box to instrument

Figure 2-9. Speedometer Connector [39] (Typical)

harness adapters.

Removal

TACHOMETER

1. Disconnect Breakout Box from instrument harness

adapters.

Installation

1. Depress latch on connector [108B].

2. Detach instrument harness adapters from connectors [39A]

and [39B].

2. Connect instrument harness adapters to connectors [108A]

and [108B].

3. See Figure 2-9. Plug wire harness connector [39B] into

speedometer connector [39A].

3. Attach black connectors from Breakout Box to instrument

harness adapters.

Removal

1. Disconnect Breakout Box from instrument harness

adapters.

2. Detach instrument harness adapters from connectors

[108A] and [108B].

3. Plug wire harness connector [108B] into tachometer con-

nector [108A].

2-16 2008 Sportster Diagnostics: Instruments

INDICATOR LAMPS

2.6

GENERAL

DIAGNOSTICS

See Figure 2-10. Sportsters are equipped with LED indicator

PART NUMBER

TOOL NAME

lamps which must be replaced as a complete assembly with

HD-41404-B

HARNESS CONNECTOR TEST KIT

harness. See the Service Manual for replacement procedure.

See 2.6 INDICATOR LAMPS, Diagnostics for troubleshooting

procedures.

Table 2-5. Indicator Lamp Connector [20] Terminals

Job/Time Code Values

TERMINAL

WIRECOLOR

FUNCTION

ON [20]

Dealership technicians filing warranty claims should use the

job/time code values printed in bold text underneath the

3

Brown

Right turn

appropriate repair.

4

White

High beam

5

Violet

Left turn

ed02820

6

Orange

Neutral/oil pressure power

2

3

8

Tan

Neutral lamp to switch

9

Green/Yellow

Oil pressure lamp to switch

12

Black

Turn signal/high beam ground

Table 2-6. Indicator Lamp Wiring

INDICATOR LAMP

CONNECTION

Oil pressure

Ground through switch

1

Neutral

Ground through switch

High beam

12 VDC when active

Right/left turn

12 VDC when active

1. LED assembly

2. Release latch (4)

Diagnostic Notes

3. Lamp bezel

Each reference number below correlates to a circled number

Figure 2-10. Indicator Lamp Assembly (Typical)

on the flow chart(s).

1. Use HARNESS CONNECTOR TEST KIT (Part No. HD-

41404-B), gray pin probe and patch cord.

2008 Sportster Diagnostics: Instruments 2-17

em01121

BK

BK

BK

BN

GN/Y

TN

O

W

V

BK

3

4

5

6

8

9

12

[20A]

Main Harness Connector

1

7

[39B]

1

7

[39A]

[108B]

Speedometer

1

7

1

7

[108A]

Tachometer

(if equipped)

Figure 2-11. Indicator Lamp Circuitry

Table 2-7. Wire Harness Connectors

NO.

DESCRIPTION

TYPE

LOCATION

[20]

Instruments

12-place Molex

Under fuel tank

[39]

Speedometer

12-place Packard

Back of speedometer

[108]

T

achometer (if equipped)

12-place Packard

Back of tachometer

2-18 2008 Sportster Diagnostics: Instruments

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