Harley Davidson Sportster Models 2009. Service Repair Manual

4.13

SYSTEM RELAY CHECK

GENERAL

System Relay

. With the ignition switch ON and the engine

stop switch at RUN, the ECM will energize the system relay to
complete the circuit to the in-tank fuel pump, ignition coil, and
fuel injectors. They will remain powered as long as the engine
is cranking or running, and the ECM is receiving ignition refer-
ence pulses from the CKP sensor. If there are no reference
pulses, the ECM will de-energize the system relay within 2
seconds after ignition is ON or engine has stalled, or immedi-
ately after the ignition is shut OFF.

Table 4-14. Code Description

DESCRIPTION

DTC

System relay coil open/low

P1001

System relay coil high/shorted

P1002

System relay contacts open

P1003

System relay contacts closed

P1004

ed02845

Figure 4-24. System Relay

DIAGNOSTICS

TOOL NAME

PART NUMBER

HARNESS CONNECTOR TEST KIT

HD-41404-B

BREAKOUT BOX

HD-43876

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.

Connect BREAKOUT BOX (Part No. HD-43876) to ECM.
See

4.7 BREAKOUT BOX: EFI

Table 4-15. Wire Harness Connectors

LOCATION

TYPE

DESCRIPTION

NO.

Under fuel tank

6-place Molex

Right handlebar controls

[22]

Under battery

12-place Deutsch, gray

TSM/TSSM/HFSM

[30]

Under seat

36-place Packard

ECM

[78]

Back of coil

4-place Delphi

Ignition coil

[83]

Top of intake manifold

2-place Delphi, black

Front injector

[84]

Top of intake manifold

2-place Delphi, black

Rear injector

[85]

Under left side cover

5-place Amp

System relay

[119]

Forward of relay/fuse blocks

4-place Molex, black

Fuel pump and low fuel switch

[141]

Under seat

16-place Molex

Engine harness

[145]

HOME

4-50 2009 Sportster Diagnostics: Engine Management

System
Relay

Front Injector

Rear Injector

15 Amp

ECM Fuse

15 Amp

Fuel Pump

Fuse

30 Amp

MAXIFUSE

15 Amp

IGN Fuse

Engine Stop

Switch

Ignition

TSM/TSSM/HFSM

Fuel

Pump

Ignition

Coil

Battery

System Relay

Front Injector

Rear Injector

Rear Coil

Front Coil

Battery

Switch Power

Ground

W/Y

GN/GY

BE/GY

GN/O

Y/GN

Y/BE

BE/O

Y/BE

BE/O

R/BK

W/BK

GN/O

Y/GN

O/GY

Y/GN

W/BK

Y/GN

W/BK

[145A] [145B]

ECM

Fuse Block

GND 1

Engine Case

Ground Point

[22B]

[22A]

[30B]

[30A]

[83A]

[83B]

[119A]

[119B]

[85A]

[85B]

[84A]

[84B]

[141B]

[141A]

[78B]

[78A]

87A

Ignition

Switch

em00263

Figure 4-25. System Relay Circuit

HOME

2009 Sportster Diagnostics: Engine Management 4-51

DTCs P1001 and P1003

Check for battery voltage at terminal 87 of system relay (with relay

installed) during first 2-3 seconds after key ON.

Is battery voltage (10-13 volts) present for 2-3 seconds after key ON?

YES

System relay OK. Measure resistance

(with relay removed) between terminal

87 of the system relay and coil

connector [83B] at terminal A.

Is resistance less than 0.5 ohm?

YES

Recheck connections.

Wiggle harness while

repeating test. Repair

intermittent.

Find and repair

connection or

open wire (Y/GN).

YES

With ignition ON, check for

10-13 volts at terminal 86 of

the system relay.

Is voltage present?

Check for continuity to

ground on (BE/GY) wire.

Is continuity present?

Check for 10-13 volts at

terminal 30 of the system relay.

Is voltage present?

No voltage or voltage always

present.

YES

Measure resistance

between terminal 85 of

system relay and

terminal 2 on Breakout

Box.

Is resistance less than

0.5 ohm?

Is ignition

fuse good?

YES

Find and repair

open between fuse

and relay.

Repair short

to ground and

replace

ECM fuse.

YES

Check for continuity to

ground

on terminal 2 on Breakout

Box.

Is continuity present?

Locate and

repair open on

(GN/O) wire.

YES

Repair short

to ground and replace

ignition fuse.

Find and repair

open on (W/BK) wire

between connector [22]

and relay.

YES

Repair short

to ground.

Replace system relay. Does

fuel pump run for the first 2

seconds after key ON?

YES

System

OK.

Replace ECM. Reprogram

and learn password.

Clear DTCs using odometer self-diagnostics. See
4.6 ODOMETER SELF-DIAGNOSTICS. Confirm
proper operation with no check engine lamp.

fc01828_en

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4-52 2009 Sportster Diagnostics: Engine Management

4.14

IDLE AIR CONTROL

GENERAL

TOOL NAME

PART NUMBER

DIGITAL TECHNICIAN II

HD-48650

IAC Operation

The ECM controls engine idle speed by moving the Idle Air
Control (IAC) to open or close a passage around the throttle
plate. It does this by sending voltage pulses to the proper motor
winding of the IAC. This causes the pintle to move in or out of
the IAC a given distance for each pulse received.

•

To increase idle speed, the ECM retracts the pintle,
allowing more air to flow through the throttle body.

•

To decrease idle speed, the ECM extends the pintle,
allowing less air to flow through the throttle body.

The IAC position is measured in steps. This can be done only
by using the DIGITAL TECHNICIAN II (Part No. HD-48650).

•

A high number of steps represents a retracted pintle and
open passage around throttle plate. This correlates with
an increase in the amount of air flowing through the throttle
body.

•

Zero steps represents a fully extended pintle. A zero
reading indicates an abnormal condition in which the pintle
has been fully extended and has consequently closed the
passage around throttle plate.

Each time the ignition is turned off, the ECM resets the IAC by
sending enough pulses to extend the pintle and effectively
close the throttle body. The fully extended value is the ECM
reference point. A given number of steps are then calculated
by the ECM for use in setting the proper idle speed and IAC
position.

NOTE

Warm idle speed is controlled by the ECM and can be adjusted
only by using the DIGITAL TECHNICIAN II (Part No. HD-
48650).

Diagnostic Trouble Code P0505: Loss of
Idle Speed Control

Loss of idle speed control will result if the idle RPM is 200 from
preset idle speed and IAC motor is at zero or maximum for
greater than 5 seconds. This code may occur with others for

a multiple code situation. Resolve the other codes first to cor-
rect.

Table 4-16. Code Description

DESCRIPTION

DTC

Loss of idle speed control

P0505

DIAGNOSTICS

TOOL NAME

PART NUMBER

HARNESS CONNECTOR TEST KIT

HD-41404-B

BREAKOUT BOX

HD-43876

Diagnostic Tips

Engine idle speed can be adversely affected by the following:

•

A loss of idle speed control does not necessarily imply the
IAC actuator or wiring has failed. It can be caused by a
number of conditions such as an intake air leak, improperly
adjusted throttle stop (factory set) or a misfiring cylinder.

•

Leaking injectors will cause fuel imbalance and poor idle
quality due to different air/fuel ratios in each cylinder. To
check for leaky injectors, first remove the air cleaner. See
Air Cleaner in the service manual. Then, with the throttle
wide open, turn key ON for 2 seconds and then OFF for
2 seconds five consecutive times. Replace the fuel injector
if there is any evidence of raw fuel in the bores. See Fuel
Injectors in the service manual.

•

Vacuum leaks. To check for vacuum, see Intake Leak Test
in the service manual.

•

Contaminated fuel.

•

Excessive oil in the crankcase (oil sumping).

•

TP sensor reading of greater than 1% (possible throttle
cable misadjustment) or battery voltage reading of less
than 9 volts or a VSS greater than 0 will disable idle speed
control.

•

If there is a loss of battery power at ECM terminal 31,
vehicle will start but IAC pintle will not reset at key OFF.
Eventually pintle will be out of position causing perform-
ance problems.

Diagnostic Notes

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

When the engine is stopped, the IAC pintle extends and
then retracts to a fixed "Park" position for increased air-
flow and idle speed during the next engine start sequence.
This key OFF reset procedure takes 10 seconds to per-
form.

HOME

2009 Sportster Diagnostics: Engine Management 4-55

Test lamp behavior may follow two patterns. The color of
the lights is not relevant to IAC operation.

Normal behavior: At key ON, test lights will altern-
ately flash and then remain steady on to confirm ECM
signals. At key OFF lights alternately flash and go out
after 10 second reset procedure.

Problem indicated: One or more lights fail to illu-
minate during key ON/key OFF cycle.

NOTE

There is a remote possibility that one of the circuits is shorted
to voltage which would have been indicated by a steady light.
Disconnect ECM and turn the ignition ON. Probe terminals to
check for this condition.

Connect BREAKOUT BOX (Part No. HD-43876) to EFI
wire harness only, leaving ECM disconnected. See

4.7 BREAKOUT BOX: EFI

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

Repair faulty ECM connection or replace ECM. If ECM
requires replacement, see ECM in the service manual.

ed02020

Figure 4-26. IAC Test Lamp (Part No. HD-41199-3)

ed02850

Figure 4-27. IAC Connector (typical)

ed02851

Figure 4-28. IAC Pintle (typical)

HOME

4-56 2009 Sportster Diagnostics: Engine Management

[87A]

[87B]

[145A]

ECM

[145B]

[78A]

[78B]

IAC

Motor

(A)

(B)

(A)

BE/GN

BN/R

BK/PK

BK/O

em01204

Figure 4-29. IAC Circuit

Table 4-17. Wire Harness Connectors

LOCATION

TYPE

DESCRIPTION

NO.

Under seat

36-place Packard

ECM

[78]

Beneath fuel tank

4-place Delphi

IAC

[87]

Under seat

16-place Molex

Engine harness

[145]

HOME

2009 Sportster Diagnostics: Engine Management 4-57

DTC P0505 (Part 1 of 2)

YES

Remove air cleaner cover and element.

Is throttle valve completely closed?

Monitor IAC pintle for 10 seconds after turning ignition OFF.

Does pintle extend and then retract during 10 second key OFF

reset procedure?

Lubricate and
adjust throttle

cables.

Check intake manifold for leaks,

see service manual.

Are leaks found?

Disconnect IAC and connect test lamp. See Figure 4-32. Turn

ignition key ON for 2 seconds, then turn ignition key OFF for 10

seconds.

Check test lamp during key ON/OFF cycle.

YES

Check fuel

pressure.

See service

manual.

Repair intake

leak.

Normal

behavior.

Problem

indicated.

Remove test lamp.

Connect Breakout Box to connector

[78B] leaving ECM disconnected.

Check terminal 31 for battery voltage.

Is battery voltage present?

YES

Using DVOM, measure resistance

between IAC connector [87B]

and Breakout Box.

Does each wire measure 0.5 ohms or less?

IAC

A
B
C
D

ECM
to 35
to 36
to 18
to 17

WIRE COLOR

BE/GN

BN/R

BK/PK

BK/O

YES

Turn ignition ON. With ECM still disconnected, check voltage on all four

terminals at connector [87B].

Is voltage present?

Repair poor connection at

connectors [87B] or [78B] or repair

open wire in harness.

Repair short

to voltage.

Clear DTCs using odometer self-diagnostics. See 4.6
ODOMETER SELF-DIAGNOSTICS. Confirm proper
operation with no check engine lamp.

Repair faulty IAC

connection or IAC assembly.

Go to 4.10 NO ECM POWER.

fc01972_en

Go to DTC P0505

(Part 2 of 2).

HOME

4-58 2009 Sportster Diagnostics: Engine Management

4.15

MISFIRE AT IDLE OR UNDER LOAD

GENERAL

Misfire at Idle or Under Load

•

Battery condition and connections may also cause misfires.
See Battery in the service manual for more information.

•

Fuel system problems may also cause misfires. See the
service manual and then see symptom tables under

4.5 INITIAL DIAGNOSTIC CHECK: EFI

•

Mechanical problems with the engine may cause misfires.
See service manual for more information.

•

Vehicle modifications including intake and exhaust may
cause misfires.

DIAGNOSTICS

TOOL NAME

PART NUMBER

SPARK TESTER

HD-26792

HARNESS CONNECTOR TEST KIT

HD-41404-B

BREAKOUT BOX

HD-43876

Diagnostic Notes

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

Wipe up spilled fuel and dispose of rags in a suitable
manner. An open spark around gasoline could cause a
fire or explosion, resulting in death or serious injury.
(00518b)

Connect BREAKOUT BOX (Part No. HD-43876) between
wire harness and ECM. See

4.7 BREAKOUT BOX: EFI

NOTE

Engine will not spark with both spark plugs removed. When
checking for spark, use SPARK TESTER (Part No. HD-26792)
with both plugs installed.

See

Figure 4-30

. A SPARK TESTER (Part No. HD-26792)

must be used to verify adequate secondary voltage
(25,000 volts) at the spark plug.

Turn ignition switch OFF.

Remove spark plug cable from spark plug. Visually
check plug condition.

Attach cable to SPARK TESTER (Part No. HD-
26792). Clip tester to cylinder head bolt.

While cranking engine, watch for spark to jump tester
gap on leads.

Reinstall and repeat procedure on other spark plug
cable.

Table 4-18. Spark Plug Cables

REAR

FRONT

SPECIFICATION

19.37-19.63

6.25-6.6

Length in.

492-499

158-168

Length mm

4842-13087

2159-3086

Resistance-ohms

Perform spark plug cable resistance test.

Remove spark plug cable from spark plug and ignition
coil. For best results, use a needle nose pliers for
removal/installation on coil. Gently grasp cable as
close to terminals as possible.

Using an ohmmeter, touch probes to terminals on
each end plug cable.

Compare resistance values to

Table 4-18

. Replace

cables not meeting specifications. Reinstall and repeat
procedure on other spark plug cable.

If carbon tracking is evident on outside of coil towers,
replace ignition coil and inspect spark plug cables. Cables
must be clean and tight. Excessive cable resistance or
faulty connections can cause coil damage.

This test can also be performed by substituting a known
good coil for one causing the no spark condition. The coil
does not require full installation to be functional. Verify
faulty coil by performing resistance test. See ignition coil
in the service manual.

Use HARNESS CONNECTOR TEST KIT (Part No. HD-
41404-B) , red pin probe and patch cord to relay and gray
pin probe and patch cord to the coil connector [83B].

ed02012

Figure 4-30. Spark Tester

HOME

4-60 2009 Sportster Diagnostics: Engine Management

System
Relay

Front Injector

Rear Injector

15 Amp

ECM Fuse

15 Amp

Fuel Pump

Fuse

30 Amp

MAXIFUSE

15 Amp

IGN Fuse

Fuel

Pump

Ignition

Coil

Battery

System Relay

Front Injector

Rear Injector

Rear Coil

Front Coil

Battery

Switch Power

Ground

W/Y

GN/GY

BE/GY

GN/O

Y/GN

Y/BE

BE/O

Y/BE

BE/O

R/BK

W/BK

GN/O

Y/GN

O/GY

Y/GN

W/BK

Y/GN

W/BK

ECM

Fuse Block

GND 1

[22B]

[22A]

[83A]

[83B]

[119A]

[119B]

[85A]

[85B]

[84A]

[84B]

[141B]

[141A]

[145B]

[145A]

[128B]

[128A]

[78B]

[78A]

87A

Starter

Motor

Engine Stop

Switch

Ignition

Switch

em00264

Figure 4-31. Ignition Coil Circuit Diagram

Table 4-19. Wire Harness Connectors

LOCATION

TYPE

DESCRIPTION

NO.

Under fuel tank

6-place Molex

Right handlebar controls

[22]

Under seat

36-place Packard

ECM

[78]

Back of coil

4-place Delphi

Ignition coil

[83]

Top of intake manifold

2-place Delphi, black

Front injector

[84]

Top of intake manifold

2-place Delphi, black

Rear injector

[85]

Under left side cover

5-place Amp

System relay

[119]

HOME

2009 Sportster Diagnostics: Engine Management 4-61

Misfire at Idle or Under Load (Part 1 of 3)

Is fuel contaminated?

YES

Drain and flush
tank. Refill with

fresh fuel.

Connect Breakout Box. Measure resistance

between terminal 10 of ECM and battery

negative and terminal 28 of ECM and

battery negative. Resistance should be less

than 1 ohm.

Is it?

YES

Use spark tester to check

cables.

Did spark jump tester gap?

Locate and repair poor

ground connection.

YES

Check for:

• Faulty, worn or cracked spark plug(s).
• Plug fouling due to engine

mechanical fault.

• Faulty or poor connection at plug or coil.

Check resistance of each spark plug

cable that did not fire the spark tester.

Also, check for faulty plug wire

connections and wires for carbon

tracking.

Are spark plug cables OK?

YES

Coils should be free

of carbon tracking.

Are they?

Replace

faulty spark plug cables.

YES

Switch coil with unit

known to be good.

Re-perform spark test.

Did spark jump gap

during engine cranking?

Replace

ignition coil.

YES

Original ignition coil

is faulty.

Replace ignition coil.

fc01215_en

Go to Misfire At Idle Or

Under Load

(Part 2 of 3).

HOME

2009 Sportster Diagnostics: Engine Management 4-63

Misfire at Idle or Under Load (Part 2 of 3)

Continued from Misfire at Idle or Under Load (Part 1 of 3).

Measure resistance between relay terminal 87 and coil connector [83B]

terminal A (Y/GN) wire. Wiggle harness.

Is resistance continuously less than 0.5 ohms?

YES

Reassemble coil and fuel tank. Measure

voltage drop between battery (positive

lead) and terminal 87 (negative lead) on

System Relay with engine running.

Is voltage drop less than 1.0 volt?

Find source of

intermittent and

repair.

YES

Problem fuel related. Refer to Table

4-5. Engine Performance Problems

under 4.5 INITIAL DIAGNOSTIC

CHECK: EFI.

Repeat voltage drop test after moving negative

lead to terminal 30.

With engine running, is voltage drop less

than 1.0 volt?

YES

Replace system

relay.

Repeat voltage drop test after

moving negative lead to 15 amp ECM

fuse (BE/GY) wire.

With engine running, is voltage drop less than 1.0

volt?

YES

Repair (BE/GY) wire.

Repeat voltage drop test after

moving negative lead to 15 amp ECM

fuse (R) wire.

With engine running, is voltage drop less

than 1.0 volt?

YES

Replace 15 amp

ECM fuse.

fc01216_en

Go to Misfire at Idle or

Under Load (Part 3 of 3).

HOME

4-64 2009 Sportster Diagnostics: Engine Management

Misfire at Idle or Under Load (Part 3 of 3)

Continued from Misfire at Idle or Under Load (Part 2 of 3).

Repeat voltage drop test after moving negative lead to 30 amp

main fuse (left side).

With engine running, is voltage drop less than 1.0 volt?

YES

Check terminal

or repair wire.

Repeat voltage drop test after

moving negative lead to 30 amp main

fuse (right side).

With engine running, is voltage drop less

than 1.0 volt?

YES

Check terminal

or replace

main fuse.

Repeat voltage drop test after

moving negative lead to starter motor

battery terminal.

With engine running, is voltage drop less

than 1.0 volt?

YES

Repair wire

between main

fuse and starter

motor.

Repair or replace

battery cable.

fc01217_en

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2009 Sportster Diagnostics: Engine Management 4-65

Harley Davidson Sportster Models 2009. Service Repair Manual - page 48