Harley Davidson Sportster Models 2009. Service Repair Manual

2.4

SPEEDOMETER/TACHOMETER

GENERAL

. The speedometer on XL and tachometer on

XR consists of a warning display and four status lamps. The
lamps include: check engine, low fuel, battery, and security.

Trip Odometer Reset Switch

Figure 2-7

. 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 DTCs. See

2.3 ODOMETER SELF-DIAGNOSTICS

•

Display odometer while ignition switch is OFF. Press and
hold trip odometer reset switch while ignition switch is OFF
and odometer mileage will be displayed.

•

On models with dual scale speedometers, toggle between
miles/kilometers on odometer and trip odometer display.
To toggle display, turn ignition switch ON. Press and hold
trip odometer reset switch while odometer is displayed.
Release switch when change is noted. (If trip odometer
reset switch is held while trip odometer is displayed, trip
odometer will reset).

ed01721

Sixth gear indicator (not used)

Check engine lamp

Low fuel lamp

Battery lamp

Security lamp (key icon)

Figure 2-6. Indicator Lamps (Typical)

ed02816

Figure 2-7. Trip Odometer Reset Switch (Typical)

SPEEDOMETER THEORY OF OPERATION

The speedometer circuit consists of a Vehicle Speed Sensor
(VSS), the ECM, the trip odometer reset switch and the
speedometer. The VSS is mounted on the rear of the engine
crankcase behind the starter motor assembly. The sensor cir-
cuitry is that of a Hall-effect sensor triggered by the gear teeth
of 5th gear on the transmission mainshaft.

The output from the sensor is a series of pulses that are inter-
preted by the ECM circuitry, converted into serial data then
sent to the speedometer. The vehicle speed serial data is also
transmitted to the TSM/TSSM/HFSM for turn signal cancella-
tion.

ODOMETER THEORY OF OPERATION

The odometer mileage is permanently stored and will not be
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.

TACHOMETER THEORY OF OPERATION

See

Figure 2-8

. The tachometer receives serial data from the

ECM. The tachometer interprets the serial data and converts
it into tachometer needle movement.

NOTE

Indicator lamps in the tachometer face may illuminate during
a "WOW" test, even though they do not function during normal
vehicle operation.

HOME

2009 Sportster Diagnostics: Instruments 2-15

ed02817

Figure 2-8. Tachometer (Typical)

DIAGNOSTICS

TOOL NAME

PART NUMBER

HARNESS CONNECTOR TEST KIT

HD-41404-B

BREAKOUT BOX

HD-42682

INSTRUMENT HARNESS ADAPTERS

HD-46601

Diagnostic Notes

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

If problems are intermittent, wiggle harness while per-
forming tests.

Connect BREAKOUT BOX (Part No. HD-42682) (black)
between tachometer connector [108A] (at the back of the
tachometer) and wire harness connector [108B] using
INSTRUMENT HARNESS ADAPTERS (Part No. HD-
46601). See

2.5 BREAKOUT BOX: SPEEDO-

METER/TACHOMETER

Use HARNESS CONNECTOR TEST KIT (Part No. HD-
41404-B), black pin probe and patch cord.

ed01765

Engine temperature lamp

Check engine lamp

Low fuel lamp

Battery lamp

Security lamp

Figure 2-9. Instruments (XR)

O/W

LGN/V

BN/GY

BN/V

Ignition

Serial data

Battery

Accessory

Ground

1
2

5
6
7

1
2

5
6
7

RPM x 100

Ignition

Serial data

Battery

Accessory

Ground

Trip SW

1
2

6
7

11
12

1
2

4
5
6
7
8

1
2

4
5
6
7
8

[39A] [39B]

[108A] [108B]

Tachometer

(if equipped)

Speedometer

Odometer
Reset Switch

[20A]

Security LP

em01124

Figure 2-10. Speedometer/Tachometer Circuit (XL)

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2-16 2009 Sportster Diagnostics: Instruments

O/W

LGN/V

BN/GY

BN/V

Serial Data

Battery

Accessory

Ground

B
A
D

RPM x 100

Ignition

Serial Data

Battery

Accessory

Ground

Trip/Reset

1
2

6
7

11
12

1
2

4
5
6
7
8

1
2

4
5
6
7
8

[108A] [108B]

[39A] [39B]

Tachometer

Speedometer

Trip/Reset
Switch

[20A]

[154]

Security LP

em01305

Figure 2-11. Speedometer/Tachometer Circuit (XR)

Table 2-5. Wire Harness Connectors

LOCATION

TYPE

DESCRIPTION

NO.

Under fuel tank

12-place Molex

Instruments

[20]

Back of speedometer

12-place Packard

Speedometer (XL)

[39]

Back of speedometer

5-place Packard

Speedometer (XR)

[39]

Back of tachometer

12-place Packard

Tachometer (if equipped)

[108]

HOME

2009 Sportster Diagnostics: Instruments 2-17

Tachometer Inoperative (Part 1 of 2)

Perform “WOW” test. See 2.3 ODOMETER

SELF-DIAGNOSTICS.

The following features should be functional

1) backlight should illuminate
2) needle should sweep its full range of motion
3) LED’s may illuminate (XL only):

• cruise (although not cruise equipped)
• pursuit (although not a police vehicle)

Are all features functional?

YES

Is problem intermittent?

YES

Repeat “WOW” test

while wiggling

harnesses.

No trouble

found.

Check for battery voltage at

Breakout Box terminal 1.

Is battery voltage present?

YES

Is instrument

fuse good?

YES

Locate and

repair

source of

fault.

Replace

fuse.

Locate and repair

open in (O) wire

between terminal

1 of connector

[108] and

instrument fuse.

Check for continuity

between Breakout Box

terminal 2 and terminal 7

of connector [20].

Is continuity present?

YES

Locate and

repair open
on (LGN/V)

wire.

fc01966_en

Go to

Tachometer

Inoperative

(Part 2 of 2).

HOME

2-18 2009 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

Check for battery voltage at Breakout Box

terminal 5 while wiggling harness.

Is battery voltage continuously present?

Locate and repair open on (BK) wire

between terminal 7 of connector [108]

and ground.

YES

Check for battery voltage at Breakout

Box terminal 6.

Is battery voltage present?

Locate and repair open on (BN/GY)

wire between terminal 5 of connector

[108] and battery fuse.

YES

Replace tachometer.

Locate and repair open
on (O/W) wire between

terminal 6 of connector

[108] and accessory

fuse.

fc01067_en

HOME

2009 Sportster Diagnostics: Instruments 2-19

2.5

BREAKOUT BOX:
SPEEDOMETER/TACHOMETER

GENERAL

TOOL NAME

PART NUMBER

BREAKOUT BOX

HD-42682

INSTRUMENT HARNESS ADAPTERS

HD-46601

The BREAKOUT BOX (Part No. HD-42682) and INSTRUMENT
HARNESS ADAPTERS (Part No. HD-46601) connect to the
speedometer connector [39] (XL only) 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: XL ONLY

TOOL NAME

PART NUMBER

BREAKOUT BOX

HD-42682

INSTRUMENT HARNESS ADAPTERS

HD-46601

Installation

See

Figure 2-12

. Press latch on connector [39B].

Connect INSTRUMENT HARNESS ADAPTERS (Part
No. HD-46601) to connectors [39A] and [39B].

Attach black connectors from BREAKOUT BOX (Part
No. HD-42682) to INSTRUMENT HARNESS
ADAPTERS (Part No. HD-46601).

Removal

Disconnect BREAKOUT BOX (Part No. HD-42682)from
INSTRUMENT HARNESS ADAPTERS (Part No. HD-
46601).

Detach INSTRUMENT HARNESS ADAPTERS (Part
No. HD-46601) from connectors [39A] and [39B].

See

Figure 2-12

. Plug wire harness connector [39B] into

speedometer connector [39A].

ed02819

Figure 2-12. Speedomter Connector [39] on XL or

Tachometer Connector [108] on XR (Typical)

TACHOMETER

TOOL NAME

PART NUMBER

BREAKOUT BOX

HD-42682

INSTRUMENT HARNESS ADAPTERS

HD-46601

Installation

Press latch on connector [108B].

Connect INSTRUMENT HARNESS ADAPTERS (Part
No. HD-46601) to connectors [108A] and [108B].

Attach black connectors from BREAKOUT BOX (Part
No. HD-42682) to INSTRUMENT HARNESS
ADAPTERS (Part No. HD-46601).

Removal

Disconnect BREAKOUT BOX (Part No. HD-42682) from
INSTRUMENT HARNESS ADAPTERS (Part No. HD-
46601).

Detach INSTRUMENT HARNESS ADAPTERS (Part
No. HD-46601)from connectors [108A] and [108B].

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

HOME

2-20 2009 Sportster Diagnostics: Instruments

2.6

INDICATOR LAMPS

GENERAL

See

Figure 2-13

. All models are equipped with Light Emitting

Diode (LED) indicator lamps, which must be replaced as a
complete assembly with harness.

Job/Time Code Values

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

ed02820

LED assembly

Release latch (4)

Lamp bezel

Figure 2-13. Indicator Lamp Assembly (Typical)

DIAGNOSTICS

TOOL NAME

PART NUMBER

HARNESS CONNECTOR TEST KIT

HD-41404-B

Diagnostic Notes

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

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

HOME

2009 Sportster Diagnostics: Instruments 2-21

GN/Y

Main Harness Connector

[20A]

[39A]

[39B]

Speedometer

[108A]

Tachometer

(if equipped)

[108B]

Ignition

Ground

Ignition

em01121

Figure 2-14. Indicator Lamp Circuit (XL)

HOME

2-22 2009 Sportster Diagnostics: Instruments

GN/Y

Main Harness Connector

[20A]

[108A]

[108B]

Speedometer

[39A]

Tachometer

[39B]

Ground

Ignition

em01306

Figure 2-15. Indicator Lamp Circuit (XR)

Table 2-6. Wire Harness Connectors

LOCATION

TYPE

DESCRIPTION

NO.

Under fuel tank

12-place Molex

Instruments

[20]

Back of speedometer

12-place Packard

Speedometer (XL)

[39]

Back of speedometer

5-place Packard

Speedometer (XR)

[39]

Back of tachometer

12-place Packard

Tachometer (if equipped)

[108]

HOME

2009 Sportster Diagnostics: Instruments 2-23

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 Breakout Box terminal 8 (Neutral)

and terminal 9 (oil pressure).

Is continuity present?

YES

Replace indicator

lamp.

Check for open fuses
or locate open circuit.

Check each terminal for continuity

to ground through switch.

Is continuity present?

YES

Repair open in (GN/Y)

wire (oil pressure) or

(TN) wire (neutral).

Replace oil

pressure switch.

Replace neutral

switch.

5048

5191

5048

5161

5157

fc01068_en

HOME

2-24 2009 Sportster Diagnostics: Instruments

O/W

BN/GY

LGN/V

O/W

BN/GY

LGN/V

R/BK

R/GY

1 2

5 6 7

1 2

5 6 7

Ignition

Ser

ial

data

Batter

Accessor

Ground

Ignition

Ser

ial

Data

Batter

Ignition

Ser

ial

Data

Ground

Accessor

Ground

Speedometer

TSM/TSSM/HFSM

Tachometer (Optional)

To ACCY Fuse

To BATT Fuse

To INSTR Fuse

To IGN Fuse

12V ACCY

Fuse

12V BATT

Fuse

12V INSTR

Fuse

12V IGN

Fuse

Data Link
Connector

ECM

Ser

ial

Data

GND1

[78B]

[78A]

[30A]

[30B]

[20A]

[20B]

[108A]

[108B]

[39A]

[39B]

[91A]

Ground

Serial Data

Power

em01120

Figure 4-6. Diagnostic Check (XL)

HOME

2009 Sportster Diagnostics: Engine Management 4-13

O/W

BN/GY

LGN/V

O/W

BN/GY

LGN/V

R/BK

R/GY

1 2

B A D

Ser

ial

Data

Batter

Accessor

Ground

Ignition

Ser

ial

Data

Batter

Ignition

Ser

ial

Data

Ground

Accessor

Ground

Speedometer

TSM/TSSM/HFSM

Tachometer

To ACCY Fuse

To BATT Fuse

To INSTR Fuse

To IGN Fuse

12V ACCY

Fuse

12V BATT

Fuse

12V INSTR

Fuse

12V IGN

Fuse

Ground

Serial Data

Power

Data Link
Connector

ECM

Ser

ial

Data

GND1

[78B]

[78A]

[108A]

[108B]

[20A]

[20B]

[39A]

[39B]

[30A]

[30B]

[91A]

em01304

Figure 4-7. Serial Data Circuit (XR)

Table 4-8. Wire Harness Connectors

LOCATION

TYPE

DESCRIPTION

NO.

Under fuel tank

12-place Molex

Instruments

[20]

Under battery tray

12-place Deutsch

TSM/TSSM/HFSM

[30]

Back of speedometer

12-place Packard

Speedometer (XL)

[39]

Back of speedometer

5-place Packard

Speedometer (XR)

[39]

Under seat

36-place Packard

ECM

[78]

HOME

4-14 2009 Sportster Diagnostics: Engine Management

Initial Diagnostic Check (Part 1 of 3)

Does engine

start?

YES.

Starts and runs.

YES.

Starts, then stalls.

NO.

Cranks, but will not start.

NO.

Engine will not crank.

Check for DTCs. See 4.6

ODOMETER

SELF-DIAGNOSTICS.

DTCs found?

See 4.11 STARTS,

THEN STALLS.

See 4.9 ENGINE CRANKS,

BUT WILL NOT START.

See 1.2 STARTING

SYSTEM DIAGNOSIS.

YES

Refer to applicable DTC priority

chart. All DTCs are listed in Table

4-7. DTCs are listed by priority.

Unable to enter

diagnostic mode.

No DTCs

displayed.

With ignition switch OFF, press and

release trip odometer reset switch.

Does odometer display appear with

backlighting?

For a list of symptoms that
may not set DTCs, refer to

Table 3-6.

YES

Check for continuity to ground at

Breakout Box terminal 7 (Black). Wiggle

harness during continuity check.

Is continuity present?

YES

Check for battery voltage at Breakout Box

terminal 5 (Black) while wiggling harness.

Is battery voltage continuously present?

Locate and repair open

between terminal 7 and

ground.

YES

With ignition switch OFF and speedometer

connector [39] on XL or tachometer connector [108]

on XR disconnected, check continuity

between Breakout Box terminals 8 and 11 (Black).

Is continuity present when trip odometer reset

switch is depressed and infinity when released?

Locate and repair open

between terminal 5 and

battery fuse.

YES

Replace

speedometer (XL),

tachometer (XR).

Replace trip odometer

reset switch.

fc01963_en

Go to Initial Diagnostic

Check (Part 2 of 3).

HOME

4-16 2009 Sportster Diagnostics: Engine Management

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

Replace speedometer (XL),

tachometer (XR).

Perform “WOW” test.

See 4.6 ODOMETER SELF-DIAGNOSTICS.

The following features should be functional

1) backlight should illuminate
2) needle should sweep its full range of motion
3) LED’s should illuminate:

• check engine
• battery

• security (all models)

4) LED’s that may illuminate:

• low fuel
• cruise (although not cruise equipped)

Are all features functional?

YES

Turn ignition switch to ACC.

Is backlight present?

YES

Check for battery voltage at

Breakout Box terminal 6 (Black).

Is battery voltage present?

YES

Replace

speedometer (XL),

tachometer (XR).

Is accessory

fuse good?

YES

Locate and repair

source of fault.

Replace fuse.

Locate and repair open
on (O/W) wire between

terminal 6 of connector

[39] on XL, or connector

[108] on XR and

accessory fuse.

With ignition switch turned to IGNITION, check for

battery voltage at terminal 1 of Breakout Box.

Is battery voltage present?

YES

Replace speedometer (XL),

tachometer (XR).

Is instrument

fuse good?

YES

Locate and

repair

source of fault.

Replace fuse.

Locate and repair open

between terminal 1 of

connector [39] on XL, or

connector [108] on XR

and

instrument fuse.

fc02006_en

Go to Initial

Diagnostic

Check (Part 3 of

3).

HOME

2009 Sportster Diagnostics: Engine Management 4-17

Harley Davidson Sportster Models 2009. Service Repair Manual - page 45