Harley Davidson Sportster Models 2009. Service Repair Manual

1.1

STARTER TROUBLESHOOTING

GENERAL

The troubleshooting tables contain detailed procedures to solve
and correct problems. Follow

1.2 STARTING SYSTEM DIA-

GNOSIS

to diagnose starting system problems. The

1.3 DIA-

GNOSTICS/TROUBLESHOOTING, Voltage Drop

procedure

will help you to locate poor connections or components with
excessive voltage drops.

STARTER TROUBLESHOOTING

Table 1-1. Starter Does Not Run or Runs at Very Low Speeds

SOLUTION

PROBABLE CAUSE

SOURCE OF

PROBLEM

Charge battery.

Voltage drop due to discharged battery.

Battery

Replace battery.

Short-circuited or open between electrodes.

Clean and retighten.

Poor contact condition of battery terminal(s).

Repair or replace cable(s).

Poor or no connection at either battery positive or
negative cable, at either end.

Wiring

Clean, tighten or replace cable(s) as needed.

Cracked or corroded battery cable ends.

Tighten connections or repair or replace wire(s).

Open wire(s) or poor connection at handlebar switch
or start relay, especially relay ground wire (grounds
through TSM/TSSM/HFSM).

Replace switch.

Poor switch contacts or open switch.

Start switch, engine
stop switch, clutch
switch or neutral
switch

Replace relay.

Open coil winding.

Start relay

Replace relay.

Poor or no continuity at relay points.

Disarm security system.

TSM/TSSM/HFSM has disabled start relay.

Polish contact surface or replace solenoid assembly

Poor contact condition caused by burnt contact.

Solenoid

Repair or replace solenoid assembly.

Pull-in winding open or short-circuited.

Repair or replace solenoid assembly.

Hold-in winding open or short-circuited.

Check brush spring tension. Replace field frame
and holder.

Brushes worn below specification.

Starting motor

Re-face or replace.

Commutator burnt.

Correct by undercutting.

Commutator high mica.

Replace starter.

Field winding grounded.

Replace starter.

Armature winding grounded or short-circuited.

Replace starter.

Free running current draw out of range.

Replace starter.

Reduction gears damaged.

Replace starter.

Insufficient brush spring tension.

Repair or replace lead wire.

Disconnected lead wire between solenoid and field
windings.

Replace bearing.

Ball bearing sticks.

Use recommended viscosity oil for temperature
range. Consult Owner's Manual.

Incorrect oil for low temperature.

Temperature

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2009 Sportster Diagnostics: Starting / Charging 1-1

Table 1-2. Pinion Does Not Engage With Ring Gear While Starter is Cranked or Engine Cannot Be Cranked

SOLUTION

PROBABLE CAUSE

SOURCE OF PROBLEM

Charge battery.

Voltage drop due to discharged battery.

Battery

Replace battery.

Short-circuited or open between electrodes.

Clean and retighten.

Poor contact condition of battery terminal(s).

Replace overrunning clutch.

Overrunning clutch malfunction (rollers or
compression spring).

Overrunning clutch

Replace pinion.

Pinion teeth worn out.

Replace overrunning clutch.

Pinion does not run in overrunning direction.

Remove foreign materials, dirt or replace
overrunning clutch or pinion shaft.

Poor sliding condition of spline teeth.

Replace overrunning clutch and idler gear.

Reduction gears damaged.

Replace clutch shell.

Excessively worn teeth.

Gear teeth on clutch shell

Table 1-3. Starter Does Not Stop Running

SOLUTION

PROBABLE CAUSE

SOURCE OF PROBLEM

Replace start switch or start relay.

Unopened contacts.

Start switch or start relay

Replace start switch or start relay.

Poor return caused by sticky switch or relay contacts.

Replace clutch shell.

Excessively worn teeth.

Gear teeth on clutch shell

Replace spring.

Return spring worn.

Solenoid

Replace solenoid.

Coil layer shorted.

Replace solenoid.

Contact plate melted and stuck.

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1-2 2009 Sportster Diagnostics: Starting / Charging

1.2

STARTING SYSTEM DIAGNOSIS

DIAGNOSTICS

TOOL NAME

PART NUMBER

HARNESS CONNECTOR TEST KIT

HD-41404-B

BREAKOUT BOX

HD-42682

Diagnostic Notes

Each reference number below correlates to a circled number
on the flowchart(s).

See

1.3 DIAGNOSTICS/TROUBLESHOOTING, Voltage

Drop

Remove starter motor. Connect jumper wires as described
in

1.6 TESTING STARTER ON BENCH, Free Running

Current Draw Test

Connect BREAKOUT BOX (Part No. HD-42682) to
TSM/TSSM/HFSM as follows:

On models with a TSM/HFSM, see

3.12 BREAKOUT

BOX: TSM/HFSM

On models with a TSSM (Japan/Korea), see

E.11 BREAKOUT BOX: TSM/TSSM

Use HARNESS CONNECTOR TEST KIT (Part No. HD-
41404-B) gray terminal socket probe and patch cord.

Closely inspect handlebar controls for pinched wiring.

If the neutral switch or ground is open, a reading of several
hundred ohms is normal due to the neutral indicator lamp
(LED).

See

1.5 TESTING STARTER ON MOTORCYCLE, Starter

Current Draw Test

Job/Time Code Values

Dealership technicians filing warranty claims should use the
job/time code values printed in bold text underneath the
appropriate repair.

ed02787

Motor terminal

Battery terminal

Relay terminal

Figure 1-1. Starter Terminals

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2009 Sportster Diagnostics: Starting / Charging 1-3

BN/GY

TN/GN

BK/R

W/BK

R/BK

GND 1

Battery

Ignition

Neutral Switch

Start Relay Control

Ground

Engine Stop Switch
Start Switch

Front Stop Lamp Switch

Right Turn Switch

TSM/TSSM/HFSM

Neutral
Switch

Right
Hand Controls

Clutch Switch

1
2

To System Relay

ECM

1
2
3

HFSM ONLY

Starter

Ignition 15A

Battery 15A

30 Amp

Main Fuse

[5B]

IGN

Switch

[33]

[61B]

Powertrain

Ground

Point

Battery

B I

[119B]

SWITCH
POSITION

RED/BLACK RED

RED/GRAY

OFF

ACC

IGNITION

Ignition Switch Legend

Dot Indicates Continuity With Red
Wire In Switch Position Indicated

START RELAY

SYSTEM RELAY

FUEL PUMP

SPARE

ECM

15A

BATTERY

LIGHTS

ACCESSORIES

15A

INSTRUMENTS

SPARE

IGNITION

15A

SPARE(XL) ENG CTL(XR)

OPEN

P&A IGN

15A

Top View

[119]

[61]

Start Relay

Receive Antenna

Transmit Antenna A
Transmit Antenna B

Switch Power 13

Left Hand
Controls

Clutch Switch

[22A]

[22B]

[24A]

[24B]

[208A]

[30B]

[30A]

[136B]

[136A]

[78B]

[78A]

em00280

Figure 1-2. Starting Circuit Schematic

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1-4 2009 Sportster Diagnostics: Starting / Charging

Initial Starter Test

Check battery using visual inspection, voltage
test, and either conductance test or load test.

Check connections at battery and starter

components. Is system operational?

YES

Starter

runs on.

YES

Starter spins, but

does not

engage.

Starter stalls

or spins too

slowly.

Check for audible

clicking noise.

Disconnect solenoid relay

terminal from solenoid.

Is 12V present on (GN) wire

with starter button not

pressed?

Go to Starter

Stalls or Spins Too

Slowly.

Solenoid clicks.

Go to Solenoid

Clicks.

YES

Is 12V present on start relay

terminal 86 (1) with starter

button not pressed?

Replace

solenoid.

YES

Replace

start relay.

Relay clicks.

Go to Relay

Clicks.

Nothing clicks.

Go to Nothing Clicks (Part

1 of 2).

5818

5832

5845

fc01944_en

Replace

starter button.

Remove starter. Disassemble drive

housing assembly. Inspect for damage

to armature gear or idler gear.

Is damage present?

YES

Replace damaged idler

gear and armature.

Starter clutch failure.

Replace starter clutch.

5825

5837

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2009 Sportster Diagnostics: Starting / Charging 1-5

Solenoid Clicks

Perform voltage drop tests between battery

and relay terminal on solenoid.

Is voltage drop less than 1.0 volt?

YES

Backtrack to pinpoint poor

connections or relay contact

problems using voltage drop tests.

Perform voltage drop tests from

battery positive to starter motor

terminal. Crank engine.

Is voltage drop greater than 1.0 volt?

YES

Perform voltage drop tests from

battery positive to starter battery

terminal. Crank engine.

Is voltage drop greater than 1.0 volt?

YES

Repair connection

between battery and

starter.

Perform voltage drop tests between battery

negative and starter ground studs or bolts.

Is voltage drop greater than 1.0 volt?

Repair or replace

solenoid (contacts).

YES

Clean ground

connections.

5824

5845

5824

5823

fc01945_en

Go to Relay Clicks.

Begin with box marked

with bold asterisk.

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1-6 2009 Sportster Diagnostics: Starting / Charging

Relay Clicks

Test for voltage at solenoid relay terminal (GN) on

starter.

Is 12V present when starter button is pressed?

YES

Does starter motor

turn if jumped?

YES

Replace

solenoid.

Replace or repair

starter motor.

Test for voltage to relay.

Is 12V present on relay terminal

30 (3)?

YES

Test for voltage to relay.

Is 12V present on relay

terminal 87 (5)?

Repair open on (R/BK)

wire feeding terminal 30

(3) on start relay.

YES

Repair open on

(GN) wire between
relay and solenoid.

Replace

start relay.

5827

5832

5827

5860

5817

fc01002_en

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2009 Sportster Diagnostics: Starting / Charging 1-7

Nothing Clicks (Part 1 of 2)

Do turn signals work properly?

YES

With the engine stop switch in

the RUN position, turn the

ignition switch on. With the

starter button depressed, check

for battery voltage from starter

button to relay terminal 86.
Is battery voltage present?

Is connector [30] fully mated?

YES

Is there continuity to ground on

TSM/TSSM/HFSM terminal 12?

Mate connector [30].

YES

Is there continuity on terminal 1

to battery fuse?

Repair open.

YES

Is there continuity on terminal 2

to ignition fuse?

Repair open.

YES

Replace TSM/TSSM/HFSM.

Repair open.

6792

6805

6806

6793

6791

YES

Check for ground at relay

terminal 85.

Is ground present?

YES

Substitute good

relay or test relay.

Check for continuity from relay terminal 85

to terminal 9 on TSM/TSSM/HFSM

connector [30].

Is continuity present?

Repair open.

YES

5828

Disconnect connector [22]. Check for continuity between

terminal 4 (W/BK) and terminal 6 (BK/R)

of connector [22A].

Is continuity present with starter button pressed?

Check for battery voltage to

starter button, at connector [22B]

terminal 3 (GY).

Is battery voltage present?

YES

Locate and repair
open in (GY) wire

connector [22B].

Locate and repair

open in (BK/R) wire

from connector

[22B] to relay.

5831

Replace

starter button.

5818

fc01946_en

Go to Nothing Clicks

(Part 2 of 2).

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1-8 2009 Sportster Diagnostics: Starting / Charging

Nothing Clicks (Part 2 of 2)

Continued from Nothing Clicks (Part 1 of 2).

Vehicle in neutral. Install Breakout Box HD-42682.

Measure resistance to ground on terminal 4 (Gray)

(neutral switch).

Is resistance (less than 10 ohms) present?

YES

Clutch disengaged (pulled in). Check for continuity to

ground on terminal 10 (Gray) (clutch switch)

with clutch disengaged.

Is continuity present?

Check for continuity to ground at

black female terminal at neutral

switch.

Is continuity present?

YES

Replace neutral

switch.

Locate and repair open on

black wire between neutral

switch and ground.

YES

Check for voltage on TSM/

TSSM/HSFM terminal 9 (Gray)

with key ON.

Is voltage present?

YES

Locate and repair

short to voltage.

Replace TSM/TSSM/

HFSM.

Check for continuity to ground on

terminal 8 on connector [24B].

Is continuity present?

YES

Replace clutch switch.

Locate and repair open

on black wire between

clutch switch and

ground.

5157

5862

5830

5838

5168

5861

fc01947_en

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2009 Sportster Diagnostics: Starting / Charging 1-9

Starter Stalls or Spins Too Slowly

Perform voltage drop tests from battery

positive to starter motor terminal. Crank engine.

Is voltage drop greater than 1.0 volt?

YES

Perform voltage drop tests between battery

positive to starter battery terminal. Crank engine.

Is voltage drop greater than 1.0 volt?

Perform voltage drop tests between battery

negative and starter studs or bolts.

Is voltage drop greater than 1.0 volt?

YES

Repair connection

between battery

and starter.

Repair or replace

solenoid

(contacts).

5824

5845

YES

Clean

ground

connections.

Perform starter motor current

draw test (on vehicle).

Perform starter motor free

running current draw bench test.

Are test results within range?

YES

Remove spark plugs. While in

5th gear, rotate rear wheel.

Check for engine, primary

and/or crankshaft bind.

Replace or repair

starter motor.

5817

5835

Use appropriate code

fc01006_en

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1-10 2009 Sportster Diagnostics: Starting / Charging

1.3

DIAGNOSTICS/TROUBLESHOOTING

VOLTAGE DROP

Check the integrity of all wiring, switches, fuses and connectors
between the source and destination.

The voltage drop test measures the difference in potential or
the actual voltage dropped between the source and destination.

See ITEM A in

Figure 1-3

. Attach your red meter lead to

the most positive part of the circuit, which in this case
would be the positive post of the battery (5).

See ITEM B in

Figure 1-3

. Attach the black meter lead to

the final destination or component in the circuit (solenoid
terminal from relay).

Activate the starter and observe the meter reading. The
meter will read the voltage dropped or the difference in
potential between the source and destination. An ideal
circuit's voltage drop would be 0 volt or no voltage
dropped, meaning no difference in potential.

See ITEM C in

Figure 1-3

. An open circuit should read 12

volts, displaying all the voltage dropped, and the entire
difference in potential displayed on the meter.

NOTE

Open circuits on the ground side will read zero.

Typically, a good circuit will drop less than 1.0 volt. If the
voltage drop is greater, backtrack through the connections

until the source of the potential difference is found. The
benefits of doing it this way are speed and accuracy.

Readings are not as sensitive to real battery voltage.

Readings show the actual voltage dropped, not just
the presence of voltage.

This tests the system as it is actually being used. It
is more accurate and will display hard to find poor
connections.

This approach can be used on lighting circuits, ignition
circuits, etc. Start from most positive and go to most
negative (the destination or component).

See ITEM D in

Figure 1-3

. The negative or ground circuit

can be checked as well.

Place the negative lead on the most negative part of
the circuit (or the negative battery post). Remember,
there is nothing more negative than the negative post
of the battery.

Place the positive lead to the ground you wish to
check.

Activate the circuit. This will allow you to read the
potential difference or voltage dropped on the neg-
ative or ground circuit. This technique is very effective
for identifying poor grounds due to powdered paint.
Even the slightest connection may cause an ohm-
meter to give a good reading. However, when suffi-
cient current is passed through, the resistance caused
by the powdered paint will cause a voltage drop or
potential difference in the ground circuit.

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2009 Sportster Diagnostics: Starting / Charging 1-11

1.4

STARTER ACTIVATION CIRCUITS

200A

20A

0.1A

200A

0.1A

200A

20A

0.1A

200A

0.1A

200A

20A

0.1A

200A

0.1A

200A

20A

0.1A

200A

0.1A

ITEM A

ITEM C

OPEN CIRCUIT

ITEM D

GROUND CIRCUIT

ITEM B

IDEAL CLOSED
CIRCUIT

VDC

ed02788

Start switch

Relay

Solenoid

Starter

Battery

MAXIFUSE

Ignition switch

Ignition fuse

Figure 1-3. Typical Circuitry. Refer to wiring diagrams for more information.

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1-12 2009 Sportster Diagnostics: Starting / Charging

1.5

TESTING STARTER ON MOTORCYCLE

START RELAY TEST

Open left side cover.

See

Figure 1-4

. Locate start relay (1) in relay/fuse block

(2) forward of battery (3) on motorcycle's left side.

If replacing old start relay:

To unplug old relay, grasp body of relay and with a
gentle rocking motion, pull straight out from relay/fuse
block.

To plug in new relay, line up spade terminals of relay
with sockets in relay/fuse block and push relay firmly
into sockets.

The start relay can be tested using the motorcycle's 12
volt battery and a multimeter.

See

Figure 1-4

. Unplug start relay (1) from relay/fuse

block (2).

See

Figure 1-5

. To energize the relay, connect the

negative battery terminal to the relay terminal "85" (or
"2") and relay terminal "86" (or "1") to the positive
battery terminal.

Check for continuity between relay terminals "3" (or
"30") and "5" (or "87"). A good relay shows continuity
(continuity tester lamp "on" or a zero ohm reading on
the ohmmeter). A malfunctioning relay will not show
continuity and must be replaced.

If start relay is functioning properly, plug it into relay/fuse
block and proceed to

1.5 TESTING STARTER ON

MOTORCYCLE, Starter Current Draw Test

ed02790

Start relay

Relay/fuse blocks

Battery

MAXIFUSE

Figure 1-4. Start Relay (Typical)

1 4

ed02791

Ohmmeter

Battery

Start relay

Figure 1-5. Start Relay Test

STARTER CURRENT DRAW TEST

NOTES

•

Engine temperature should be stable and at room temper-
ature.

•

Battery should be fully charged.

See

Figure 1-6

. Check starter current draw with an induction

ammeter before disconnecting battery. Proceed as follows:

Verify that transmission is in neutral. Disconnect spark
plug wires from spark plug terminals.

Clamp induction ammeter over positive battery cable next
to starter.

With Ignition Switch ON, turn engine over by pressing
starter switch while reading the ammeter. Disregard initial
high current reading which is normal when engine is first
turned over.

Typical starter current draw will range from 160 to
200 amperes.

If starter current draw exceeds 250 amperes, the
problem may be in the starter or starter drive. Remove
starter for further tests. See the Service Manual.

NOTE

A DC current probe may be used if an induction ammeter is
not available.

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2009 Sportster Diagnostics: Starting / Charging 1-13

Harley Davidson Sportster Models 2009. Service Repair Manual - page 42