Harley Davidson 2008 Sportster Models. Electrical Diagnostics Manual

Oil Pressure or Neutral Indicator Will Not Function

Turn on ignition switch. Check

for 12 VDC at connector [20B]

terminal “6”. Turn off ignition switch.

Was 12 VDC present?

YES

Check for continuity to ground at

Check for open fuses

Breakout Box terminal “8” (Neutral) and

or locate open circuit.

terminal “9” (oil pressure).

5048

Is continuity present?

YES

Check each terminal for continuity

Replace indicator lamp.

to ground through switch.

5191

Is continuity present?

YES

Repair open in (GN/Y)

Replace oil

Replace neutral

wire (oil pressure) or

pressure switch.

switch.

(TN) wire (neutral).

5161

5157

5048

fc01068_en

2008 Sportster Diagnostics: Instruments 2-19

High Beam or R/L Turn Signal Indicator Will Not Function

Check for ground at

connector [20B] terminal “12”.

Is ground present?

YES

Check for 12 VDC when circuit is active:

Locate and repair

Breakout Box terminal “5” (left turn), terminal “3”

open in circuit.

(right turn) or terminal “4” (high beam).

Is voltage present?

5048

YES

Locate and repair

Replace indicator lamp.

open in circuit.

5191

5048

fc01069_en

2-20 2008 Sportster Diagnostics: Instruments

DTC B1004,

B1005

2.7

GENERAL

DIAGNOSTICS

See Figure 2-12. The fuel level is monitored by the speedo-

PART NUMBER

TOOL NAME

meter terminal "9" of connector [39] (Y/W).

HD-41404-B

HARNESS CONNECTOR TEST KIT

•

If the voltage on terminal "9" of connector [39] exceeds

HD-42682

BREAKOUT BOX

the lower limit for greater than or equal to 15 seconds DTC

B1004 will set.

HD-46601

INSTRUMENT HARNESS ADAPTERS

•

If the voltage on terminal "9" of connector [39] exceeds

Diagnostic Tips

the upper limit (or is open) for greater than or equal to 15

If fuel gauge is performing erratically (possible false DTCs),

seconds DTC B1005 will set.

review Table 2-9 for proper functionality.

Table 2-8. Code Description

Diagnostic Notes

DTC

DESCRIPTION

Each reference number below correlates to a circled number

on the flow chart(s).

B1004

Fuel level sending unit low

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

B1005

Fuel level sending unit high/open

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

2. Connect BREAKOUT BOX (Part No. HD-42682) and

ed02819

INSTRUMENT HARNESS ADAPTERS (Part No. HD-

46601) between wire harness and speedometer.

Table 2-9. Testing Fuel Sender Resistor Assembly

FUEL LEVEL

[39B] PIN 2 RESISTANCE TO GROUND

Low

2000 ohms ±200

High

10000 ohms ±200

Figure 2-12. Speedometer Connector [39] (Typical)

2008 Sportster Diagnostics: Instruments 2-21

em01122

Fuel Sender

Resistor

[86]

Assembly

3 2

[200A]

3 2

[200B]

[39A]

[39B]

Ignition

1 2 3

[141B]

Serial data

LGN/V

Fuel Pump And

1 2 3

[141A]

Low Fuel Switch

Battery

BN/GY

Accessory

O/W

Ground

Fuel level

Y/W

Y/R

Speedometer

[20A]

[20B]

12V

System

Y/GN

(Switched)

Relay

Fuel Pump

[GND1]

Fuse

R/GY

O/W

Y/W

[GND1]

Accessory

Fuse

12V

(Switched)

12V

(BATT)

R/BK

BN/GY

Ignition

Fuse

Battery

Data Link

12V

Fuse

LGN/V

Connector

(Switched)

R/BK

[91A]

Instrument

Fuse

[78B]

[GND1]

[78A]

ECM

Figure 2-13. Fuel Sender Circuitry

Table 2-10. Wire Harness Connectors

NO.

DESCRIPTION

TYPE

LOCATION

[20]

Instruments

12-place Molex

Under fuel tank

[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

[141]

Fuel pump and low fuel switch

4-place Molex

Forward of relay/fuse blocks

[200]

Fuel sender resistor assembly

3-place Molex

Under seat

2-22 2008 Sportster Diagnostics: Instruments

Fuel Level Sending Unit Low: DTC B1004

Disconnect speedometer connector [39].

Measure resistance between terminal “2”

of connector [141B] and ground.

Is resistance between 1800 and 10200 ohms?

YES

Replace fuel level switch.

Disconnect [200].

Continuity to ground?

6035

YES

Replace fuel sender

Locate and repair short to

resistor assembly.

ground in harness.

6083

7182

Clear DTCs using speedometer self diagnostics. See 2.3

SPEEDOMETER SELF DIAGNOSTICS. Confirm proper operation with

no check engine lamp.

fc01070_en

2008 Sportster Diagnostics: Instruments 2-23

Fuel Level Sending Unit High/Open: DTC B1005

Disconnect Speedometer connector [39].

Measure voltage on terminal “2” of connector

[141B] (Y/W). Should be 0 volts.

Is it?

YES

Check continuity between terminal

Locate and repair short

“2” of connector [141B] (Y/W) and

to voltage.

Breakout Box terminal “11” (BK).

Continuity present?

6069

YES

Check continuity to ground on terminal

Locate and repair short

“4” of connector [141B] (BK).

to voltage.

Is continuity present?

6069

YES

Replace fuel sender

Locate and repair open on

resistor assembly.

(BK) wire (ground circuit).

6069

6083

Clear DTCs using speedometer self diagnostics. See 2.3

SPEEDOMETER SELF DIAGNOSTICS. Confirm proper operation

with no check engine lamp.

fc01071_en

2-24 2008 Sportster Diagnostics: Instruments

DTC B1006,

B1007

2.8

GENERAL

NOTE

Accessory or Ignition Line Overvoltage

ECM or TSM/TSSM/HFSM may also set a battery voltage DTC.

Ignition and accessory voltage is constantly monitored by the

Table 2-11. Code Description

speedometer (terminal "1" ignition and terminal "6" accessory).

If the battery voltage fails to meet normal operating parameters,

DTC

DESCRIPTION

a Diagnostic Trouble Code (DTC) is set.

B1006

Accessory line overvoltage

•

DTC B1006 is displayed when accessory line voltage is

B1007

Ignition line overvoltage

greater than 16.0 volts for longer than 5 seconds.

•

DTC B1007 is displayed when ignition line voltage is

greater than 16.0 volts for longer than 5 seconds.

2008 Sportster Diagnostics: Instruments 2-25

Accessory or Ignition Line Overvoltage: DTC B1006, 1007

Has battery charger been

recently connected?

YES

NOTE: Sometimes battery charger

Diagnose charging system.

may cause over voltage condition

See 1.7 CHARGING SYSTEM.

which will set codes.

Clear codes.

Start vehicle. Run at 3000

RPM for 5 seconds.

Does code reset?

YES

Diagnose charging system.

System normal.

See 1.7 CHARGING SYSTEM.

Clear DTCs using speedometer self diagnostics. See 2.3

SPEEDOMETER SELF DIAGNOSTICS. Confirm proper operation with

no check engine lamp.

fc01072_en

2-26 2008 Sportster Diagnostics: Instruments

DTC B1008

2.9

1. Disconnect speedometer connector [39] (at the back of

GENERAL

the speedometer). See 2.5 BREAKOUT BOX: SPEEDO-

Trip Odometer Reset Switch Closed

METER/TACHOMETER.

Diagnostic Trouble Code (DTC) B1008 will be set if trip odo-

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

meter reset switch terminals are in a constant shorted state.

to wire harness connector [39B] using INSTRUMENT

HARNESS ADAPTERS (Part No. HD-46601), leaving

speedometer disconnected.

ed02816

Figure 2-14. Trip Odometer Reset Switch (Typical)

Table 2-12. Code Description

DTC

DESCRIPTION

B1008

Trip odometer reset switch closed

DIAGNOSTICS

PART NUMBER

TOOL NAME

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).

em01123

[39A]

[39B]

Reset

Switch

TRIP SW

Speedometer

Figure 2-15. Trip Odometer Reset Switch Circuit

2008 Sportster Diagnostics: Instruments 2-27

Trip Odometer Reset Switch Closed: DTC B1008

Remove trip odometer reset switch rubber boot.

Clear codes. See 2.3 SPEEDOMETER

SELF DIAGNOSTICS.

Are codes still present?

YES

With speedometer connector [39] disconnected,

Replace boot.

measure resistance between Breakout Box

terminal “8” and “11' (black). Resistance should be

less than 1 ohm with switch depressed and infinity

ohms when released. Is it?

YES

Replace trip odometer

Replace Speedometer.

reset switch.

Clear DTCs using speedometer self diagnostics. See 2.3

SPEEDOMETER SELF DIAGNOSTICS. Confirm proper operation

with no check engine lamp.

fc01073_en

2008 Sportster Diagnostics: Instruments 2-29

DTC U1016,

U1255

2.10

GENERAL

ed02824

Loss of ECM Serial Data

The serial data line provides a means for the Electronic Control

Module (ECM), TSM/TSSM/HFSM, and speedometer to com-

municate their current status. When all operating parameters

on the serial data line are within specifications, a state of health

message is sent between the components. A Diagnostic

Trouble Code (DTC) U1016 indicates that the ECM is not

capable of sending this state of health message. A DTC U1255

indicates that no messages were present during power up of

the current key cycle. A DTC U1016 indicates that there was

communication on the data bus since power up, but commu-

nication was lost or interrupted during that key cycle.

Table 2-14. Code Description

1. Terminal 1: no connection

DTC

DESCRIPTION

2. Terminal 2: ground (BK)

U1016

Loss of all ECM serial data (state of health)

3. Terminal 3: serial data (LGN/V)

4. Terminal 4: power (GY)

U1255

Serial data error/missing message

5. Protective cap

DIAGNOSTICS

Figure 2-17. Data Link Connector [91A] Terminals

PART NUMBER

TOOL NAME

HD-42682

BREAKOUT BOX

HD-46601

INSTRUMENT HARNESS ADAPTERS

ed02819

HD-48637

ECM BREAKOUT BOX

Diagnostic Notes

Each reference number below correlates to a circled number

on the flow chart(s).

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

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

speedometer) and wire harness connector [39B] using

INSTRUMENT HARNESS ADAPTERS (Part No. HD-

46601). See

2.5 BREAKOUT BOX: SPEEDO-

METER/TACHOMETER.

2. Use ECM BREAKOUT BOX (Part No. HD-48637).

ed01340

Figure 2-18. Speedometer Connector [39] (Typical)

Figure 2-16. Data Link Connector [91A] (Behind Left Side

Cover)

2-30 2008 Sportster Diagnostics: Instruments

Speedometer

em01120

Tachometer (Optional)

TSM/TSSM/HFSM

[39A]

6 7

[108A]

[39B]

6 7

[108B]

[30A]

[30B]

[GND1]

[20A]

[20B]

To ACCY fuse

R/GY

O/W

To BATT fuse

12V ACCY

Fuse

[GND1]

BN/GY

12V BATT

Fuse

To INSTR fuse

LGN/V

R/BK

12V INSTR

Fuse

To IGN fuse

Data Link

Connector

LGN/V

R/BK

12V IGN

Fuse

[91A]

[GND1]

[78B]

[78A]

ECM

Figure 2-19. Serial Data Circuit

Table 2-15. 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]

achometer (if equipped)

12-place Packard

Back of tachometer

2008 Sportster Diagnostics: Instruments 2-31

Loss of ECM Serial Data: DTC U1016, U1255

Can you read ECM hardware Part No.?

See 2.3 SPEEDOMETER SELF DIAGNOSTICS.

YES

NO or “No Rsp”

Check continuity between

While wiggling harness, check

Breakout Box terminal ‘2" (Black)

continuity between Breakout Box

and terminal “5” of ECM

terminal “2” (Black) and terminal “5” of

Breakout Box.

ECM Breakout Box.

Is continuity present?

YES

Clear codes. Test ride.

Repair intermittent

Replace ECM.

Repair open on

Does DTC U1016

on (LGN/V) wire.

Reprogram and learn

(LGN/V) wire.

return?

password.

YES

Replace ECM.

No trouble found.

Reprogram and learn

password.

Clear DTCs using speedometer self diagnostics. See 2.3

SPEEDOMETER SELF DIAGNOSTICS. Confirm proper operation

with no check engine lamp.

fc01083_en

2-32 2008 Sportster Diagnostics: Instruments

DTC U1064,

U1255

2.11

GENERAL

ed02825

Loss of TSM/TSSM/HFSM Serial Data

The serial data line provides a means for the Electronic Control

Module (ECM), TSM/TSSM/HFSM, and speedometer to com-

municate their current status. When all operating parameters

on the serial data line are within specifications, a state of health

message is sent between the components. A Diagnostic

Trouble Code

(DTC) U1064 indicates that the TSM/

TSSM/HFSM is not receiving this state of health message. A

DTC U1255 indicates that no messages were present during

power up of the current key cycle. A DTC U1064 indicates that

there was communication on the data bus since power up, but

communication was lost or interrupted during that key cycle.

Table 2-16. Code Description

Figure 2-20. TSM/TSSM/HFSM Location

DTC

DESCRIPTION

U1064

Loss of TSM/TSSM/HFSM serial data

U1255

Serial data error/missing message

ed01340

DIAGNOSTICS

PART NUMBER

TOOL NAME

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. Connect BREAKOUT BOX (Part No. HD-42682) as fol-

lows:

a. Mate black socket housing on Breakout Box with

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

speedometer) using INSTRUMENT HARNESS

Figure 2-21. Data Link Connector [91A] (Behind Left Side

ADAPTERS (Part No. HD-46601).

Cover)

b. Mate black pin housing on Breakout Box with wire

harness connector [39B] using INSTRUMENT HAR-

NESS ADAPTERS (Part No. HD-46601).

c. See Figure

2-20. Mate gray socket housing on

Breakout Box with TSM/TSSM/HFSM connector

[30A].

d. Mate gray pin housing on Breakout Box with wire

harness connector [30B].

2008 Sportster Diagnostics: Instruments 2-33

Speedometer

em01120

Tachometer (Optional)

TSM/TSSM/HFSM

[39A]

6 7

[108A]

[39B]

6 7

[108B]

[30A]

[30B]

[GND1]

[20A]

[20B]

To ACCY fuse

R/GY

O/W

To BATT fuse

12V ACCY

Fuse

[GND1]

BN/GY

12V BATT

Fuse

To INSTR fuse

LGN/V

R/BK

12V INSTR

Fuse

To IGN fuse

Data Link

Connector

LGN/V

R/BK

12V IGN

Fuse

[91A]

[GND1]

[78B]

[78A]

ECM

Figure 2-23. Serial Data Circuit

Table 2-17. 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]

achometer (if equipped)

12-place Packard

Back of tachometer

2008 Sportster Diagnostics: Instruments 2-35

Loss of TSM/TSSM/HFSM Serial Data: DTC U1064, U1255

Can you read TSM/TSSM/HFSM hardware Part No.?

See 2.3 SPEEDOMETER SELF DIAGNOSTICS.

YES

Check for continuity between

While wiggling harness, check for continuity

Breakout Box terminal “3” (Gray) and

between Breakout Box terminal “3” (Gray) and

Breakout Box terminal “2” (Black).

Is continuity present?

YES

Clear codes. Test ride.

Repair intermittent

Replace TSM/TSSM/

Repair open on

Does DTC U1064

HFSM. Perform

on (LGN/V) wire.

(LGN/V) wire.

return?

password learn.

YES

Replace ECM.

Reprogram and learn

No trouble found.

password.

Clear DTCs using speedometer self diagnostics. See 2.3

SPEEDOMETER SELF DIAGNOSTICS. Confirm proper operation with

no check engine lamp.

fc01084_en

2-36 2008 Sportster Diagnostics: Instruments

DTC U1300,

U1301 OR BUS ER

2.12

GENERAL

ed02824

Serial Data Low or Serial Data Open/High

The typical serial data voltage range is 0 volts (inactive) to 7

volts (active). Due to the short pulse, voltages will be much

lower on a DVOM. In analog mode, a DVOM reading serial

data will show continuous voltage when active, typically 0.6-

0.8 volts. The range for acceptable operations is 0-7.0 volts.

Table 2-18. Code Description

DTC

DESCRIPTION

U1300

Serial data low

U1301

Serial data open/high

1. Terminal 1: no connection

ed01340

2. Terminal 2: ground (BK)

3. Terminal 3: serial data (LGN/V)

4. Terminal 4: power (GY)

5. Protective cap

Figure 2-25. Data Link Connector [91A] Terminals

DIAGNOSTICS

Diagnostic Tips

•

If serial data is shorted, these Diagnostic Trouble Codes

(DTCs) will automatically cause the check engine lamp to

illuminate. The odometer will read "BUS Er" in this condi-

tion.

Figure 2-24. Data Link Connector [91A] (Behind Left Side

•

DTCs P1009 and P1010 may accompany DTCs U1300

Cover)

and U1301.

Diagnostic Notes

If a U1300, U1301 or "BUS Er" is present, perform diagnostic

procedures listed in 4.12 STARTS, THEN STALLS.

2008 Sportster Diagnostics: Instruments 2-37

Harley Davidson 2008 Sportster Models. Electrical Diagnostics Manual - page 4