Harley Davidson Sportster Models 2009. Service Repair Manual - page 51

DTCs P0501 and P0502 (Part 1 of 2)

YES

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

Inspect connector [65].

Is connector mated properly?

Remove and inspect VSS. Inspect for debris and clean if

necessary. Place odometer into diagnostic mode and clear

DTCs. Connect all circuits and ride motorcycle for

approximately 1.0 mile (1.6 km). Check for speedometer

function.

Is speedometer functioning properly?

Mate connector [65].

System OK.

Check for continuity between terminal

A of connector [65B] (BK/R) wire and

ground.

Is continuity present?

Check for continuity between terminal A

of connector [65B] (BK/R) wire and

terminal 14 of Breakout Box.

Is continuity present?

Check for continuity between terminal C

of connector [65B] (BK) wire and ground.

Is continuity present?

Locate and repair open on

(R/W) and (BK/R) wires

between [78B] and [65B].

Repair open on (BK) wire between

connector [65B] and ground.

Repair short to ground.

YES

fc01988_en

Go to DTCs

P0501 and P0502

(Part 2 of 2).

HOME

4-98 2009 Sportster Diagnostics: Engine Management

DTCs P0501 and P0502 (Part 2 of 2)

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

YES

Continued from DTCs P0501 and P0502 (Part 1 of 2).

Check for continuity between terminal B of connector [65B] (BK/BE) wire and

terminal 33 of Breakout Box.

Is continuity present?

Check for voltage at terminal 33 on breakout

box. DVOM should read 4-6 volts when gear tooth

absent and 0-1 volts when gear tooth is present.

Does voltage fall within specifications?

Locate and repair open on

(BK/BE) wire between [78B]

and [65B].

No voltage fluctuation from

high (4-6 volts) to low (0-1

volts).

Battery voltage is

present.

Voltage fluctuates from high

(4.6 volts) to low (0-1 volts).

Replace ECM. Reprogram

and learn password.

Locate and repair short to

voltage on (BK/BE) wire

between [78B] and [65B].

Measure resistance between

ground and terminal 33 on

breakout box.

Is resistance less than 100

ohms?

Replace VSS.

Locate and repair short to

ground on (BK/BE) wire

between [78B] and [65B].

Replace ECM. Reprogram

and learn password.

No voltage

present.

fc01989_en

HOME

2009 Sportster Diagnostics: Engine Management 4-99

4.23

DTC P0562, P0563

GENERAL

Battery Voltage

See

Figure 4-48

. Battery voltage is monitored by the Electronic

Control Module (ECM) (terminal "13"). If the battery voltage
fails to meet normal operating parameters, a code is set.

NOTE

When either Diagnostic Trouble Code (DTC) P0562 or P0563
is set, the battery icon in the speedometer on XL, tachometer
on XR, will illuminate.

•

DTC P0562 is displayed when battery voltage is less than
12.2 volts at idle and voltage does not increase when
engine speed is greater than 2000 RPM.

•

DTC P0563 is displayed when battery positive voltage is
greater than 15.0 volts for more than 4 seconds.

NOTES

•

Warm idle speed will be automatically increased if battery
voltage is low at idle.

•

TSM/TSSM/HFSM problems may also set DTC P0562 or
P0563.

Table 4-36. Code Description

DESCRIPTION

DTC

Battery voltage low

P0562

Battery voltage high

P0563

ed02845

Figure 4-47. System Relay

DIAGNOSTICS

TOOL NAME

PART NUMBER

BREAKOUT BOX

HD-43876

Diagnostic Tips

•

Low voltage generally indicates a loose wire, corroded
connections, battery and/or a charging system problem.

•

A high voltage condition may be caused by a faulty voltage
regulator.

Diagnostic Notes

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

Was battery allowed to discharge or be drawn down by a
starting problem?

Yes. Charge battery.

No. See

1.7 CHARGING SYSTEM, Troubleshooting

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

4.7 BREAKOUT BOX: EFI

Use DVOM with RPM Pick-up to check RPM on vehicles
without tachometers.

This checks for voltage drops in the ECM circuit.

Place (+) probe to battery positive terminal.

Place (-) probe to (W/BK) terminal on Breakout Box.

Problem is most likely the ground connection at the frame.

HOME

4-100 2009 Sportster Diagnostics: Engine Management

BE/GY

GN/O

Y/GN

W/BK

R/BK

System Relay

ECM

Battery

Switch Power

30 Amp

MAXIFUSE

Battery

Ignition

Switch

To Fuel Pump Fuse

I - IGN

B - BATT

A - ACC

15 Amp

IGN Fuse

15 Amp

ECM fuse

Ground

Engine Case

Ground Point

GND 1

System
Relay

Fuse Block

[119A]

[119B]

87A

[22B]

[22A]

[78B]

[78A]

Engine Stop

Switch

em00266

Figure 4-48. Ignition Power Circuit

Table 4-37. Wire Harness Connectors

LOCATION

TYPE

DESCRIPTION

NO.

Under fuel tank

6-place Molex

Right handlebar controls

[22]

Under seat

36-place Packard

ECM

[78]

Under left side cover

5-place Amp

System relay

[119]

HOME

2009 Sportster Diagnostics: Engine Management 4-101

DTCs P0562 and P0563 (Part 1 of 2)

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

YES

Perform charging system tests.

Is charging system OK?

With ignition ON, measure voltage drop

between battery positive (+) terminal

and Breakout Box terminal “13” (-).

Is voltage drop greater than 0.5 volt?

Repair charging system.

See 1.7 CHARGING

SYSTEM.

Connect Breakout Box. Measure voltage on

Breakout Box between terminal 13 (+) and

terminal 10 (-) and again between terminal 13

and terminal 28 (-) with engine running at

2000 RPM or higher for 10 seconds or longer.

Is voltage above 11.0 volts?

System

OK.

Repair open on (W/BK)

wire between [22B]

and [78B] or terminals.

Locate and

repair

bad

connection.

Problem is intermittent.

Perform 4.8 WIGGLE TEST.

Locate and

repair bad connection.

With ignition ON, measure resistance

between ignition fuse and connector

[22B] terminal 3.

Is resistance greater than 1 ohm?

Check for voltage drop between battery

negative (-) terminal and terminal 10 (+)

on Breakout Box connector and between
battery negative (-) terminal and terminal

28 on Breakout Box.

Is voltage drop greater than 0.5 volt?

With ignition OFF, measure resistance

between Breakout Box terminal 13

and connector [22B] terminal 4.

Is resistance greater than 1 ohm?

Inspect [22] for

corrosion or loose

wires.

If above conditions are

not present, replace

engine stop switch.

fc01990_en

Go to DTCs P0562

and P0563 (Part 2

of 2).

HOME

4-102 2009 Sportster Diagnostics: Engine Management

Left Turn Switch

Left Hand
Controls

IGN

15A

ACCY

15A

Ignition

Switch

[7A]

[33]

Battery 15A

ECM 15A

Security

Siren

(Optional)

Start
Relay

B
C

Power

Signal

Ground

30 Amp

MAXIFUSE

GND1

Powertrain

Ground

Point

IGN − I

BATT – B

ACC – A

Q
C

P
R

87A

30
85
86

5
4
3
2
1

ECM

TSM/TSSM/HFSM

[61B]

Right Turn Switch
Engine Stop Switch
Start Switch

Right Hand
Controls

Fuseblocks

Top View

[119]

Accessories

Lights

Ignition

Fuel Pump

Start Relay

System Relay

ECM

Battery

Spare

P&A IGN

Instruments

Spare

System
Relay

Engine Control

Open

[119B]

[128]

6 5 4 3

6 5

2 1

6 5

To Front

Turn Signals

To Rear Lighting

To Instruments And

Indicator Lamps

[61]

K
T
E
S
U

87A

30
85
86

5
4
3
2
1

Starter

Battery

Red
Band

Antenna ‘A’
Antenna ‘B’

Hands Free Antenna

Battery

1
2
3

Battery

Ignition

Serial Data

Left Turn Feed

Right Turn Feed

Right Turn Switch Input

Left Turn Switch Input

Start Relay Control

Alarm Signal

Ground

Receive Antenna
XMIT Antenna A
XMIT Antenna B

System Relay

Serial Data

Ground

Switched Power

Ground

1
2
3

5
6
7
8
9

11
12

1
2
3

5
6
7
8
9

11
12

Socket Connector

Pin Connector

(A Side)

(B Side)

15A

SWITCH
POSITION

RED/BLACK

RED

RED/GRAY

OFF
ACC.
IGNITION

Ignition Switch Legend

Dot indicates continuity with red

Wire in switch position indicated

HFSM Only

[162]

[5]

[163]

[20A]

Page 2

[31B]

Page 2

[7B]

Page 2

W/V

BN/GY

LGN/BN

BN/GY

TN/GN

LGN/V

W/BN

O/W

W/V

O/W

W/V

O/W

O/Y

BN/GY

LGN/V

BE/GY

Y/BK

W/BK

R/GY

R/BK

R/GY

GN/O

TN/GN

BE/GY

BK/R

W/BK

GN/O

R/BK

O/W

W/BN

W/BK

BK/R

O/W

W/BN

W/BK

BK/R

LGN/V

Engine Case

Ground Point

[24B]

[24A]

[78B]

[78A]

[208B]

[208A]

[209A]

[209B]

[30B]

[30A]

[22A]

[22B]

[20B]

[31A]

[142B]

[142A]

et00126

Figure B-19. Security (1 of 2) (XR): 2009 Sportster DOM. and INT. Models

Figure B-19.

Security (1 of 2) (XR): 2009 Sportster DOM. and INT. Models

1
2

5
6

2
3

Configuration For XR

Front Turn Signals

Serial Data

Battery

Ground

Serial Data

Battery

Ground

From Main
Harness

LGN/V

BN/GY

LGN/V

Speedometer

Tachometer

BN/GY

LGN/V

To Main
Harness

Left

Turn

Right

Turn

SOCKET CONNECTOR

PIN CONNECTOR

(A SIDE)

(B SIDE)

[20B]
Page 1

[31A]
Page 1

BK
BN

[39B]

[39A]

[108B]

[108A]

[31B]

[20A]

et00127

Figure B-20. Security (2 of 2) (XR): 2009 Sportster DOM. and INT. Models

Figure B-20.

Security (2 of 2) (XR): 2009 Sportster DOM. and INT. Models

C.1

METRIC CONVERSION

CONVERSION TABLE

Table C-1. Metric Conversions

INCHES to MILLIMETERS

(IN x 25.40 = MM)

MILLIMETERS to INCHES

(MM x 0.03937 = IN)

84.14

3-5/16

49.21

1-15/16

15.240

.025

.001

3.582

2.283

.9842

.0039

85.72

3-3/8

50.80

15.875

5/8

.051

.002

3.622

2.323

1.024

.0078

86.36

3.4

52.39

2-1/16

17.462

11/16

.076

.003

3.661

2.362

1.063

.0118

87.31

3-7/16

53.34

2.1

17.780

.102

.004

3.701

2.401

1.102

.0157

88.90

3-1/2

53.97

2-1/8

19.050

3/4

.127

.005

3.740

2.441

1.142

.0197

90.49

3-9/16

55.56

2-3/16

20.320

.152

.006

3.779

2.480

1.181

.0236

91.44

3.6

55.88

2.2

20.638

13/16

.178

.007

3.819

2.519

1.220

.0275

92.07

3-5/8

57.15

2-1/4

22.225

7/8

.203

.008

3.858

2.559

1.260

.0315

93.66

3-11/16

58.42

2.3

22.860

.229

.009

3.897

2.598

1.299

.0354

93.98

3.7

58.74

2-5/16

23.812

15/16

.254

.010

3.937

100

2.638

1.338

.0394

95.25

3-3/4

60.32

2-3/8

25.40

.397

1/64

3.976

101

2.677

1.378

.0787

96.52

3.8

60.96

2.4

26.99

1-1/16

.508

.020

4.016

102

2.716

1.417

.1181

96.84

3-13/16

61.91

2-7/16

27.94

1.1

.762

.030

4.055

103

2.756

1.456

.1575

98.42

3-7/8

63.50

2-1/2

28.57

1-1/8

.794

1/32

4.094

104

2.795

1.496

.1968

99.06

3.9

65.09

2-9/16

30.16

1-3/16

1.016

.040

4.134

105

2.834

1.535

.2362

100.01

3-15/16

66.04

2.6

30.48

1.2

1.270

.050

4.173

106

2.874

1.575

.2756

101.6

66.67

2-5/8

31.75

1-1/4

1.524

.060

4.212

107

2.913

1.614

.3149

102.19

4-1/16

68.26

2-11/16

33.02

1.3

1.588

1/16

4.252

108

2.953

1.653

.3543

104.14

4.1

68.58

2.7

33.34

1-5/16

1.778

.070

4.291

109

2.992

1.693

.3937

104.77

4-1/8

69.85

2-3/4

34.92

1-3/8

2.032

.080

4.331

110

3.031

1.732

.4331

106.36

4-3/16

71.12

2.8

35.56

1.4

2.286

.090

4.370

111

3.071

1.772

.4724

106.68

4.2

71.44

2-13/16

36.51

1-7/16

2.540

4.409

112

3.110

1.811

.5118

107.95

4-1/4

73.02

2-7/8

38.10

1-1/2

3.175

1/8

4.449

113

3.149

1.850

.5512

109.22

4.3

73.66

2.9

39.69

1-9/16

4.762

3/16

4.488

114

3.189

1.890

.5905

109.54

4-5/16

74.61

2-15/16

40.64

1.6

5.080

4.527

115

3.228

1.929

.6299

111.12

4-3/8

76.20

41.27

1-5/8

6.350

1/4

4.567

116

3.268

1.968

.6693

111.76

4.4

77.79

3-1/16

42.86

1-11/16

7.620

4.606

117

3.307

2.008

.7086

112.71

4-7/16

78.74

3.1

43.18

1.7

7.938

5/16

4.645

118

3.346

2.047

.7480

114.30

4-1/2

79.37

3-1/8

44.45

1-3/4

9.525

3/8

4.685

119

3.386

2.086

.7874

115.89

4-9/16

80.96

3-3/16

45.72

1.8

10.160

4.724

120

3.425

2.126

.8268

116.84

4.6

81.28

3.2

46.04

1-13/16

11.112

7/16

4.764

121

3.464

2.165

.8661

117.47

4-5/8

82.55

3-1/4

47.62

1-7/8

12.700

1/2

4.803

122

3.504

2.205

.9055

119.06

4-11/16

83.82

3.3

48.26

1.9

14.288

9/16

4.842

123

3.543

2.244

.9449

HOME

2009 Sportster Diagnostics: Appendix C Conversions C-1

C.2

FLUID CONVERSIONS

UNITED STATES SYSTEM

Unless otherwise specified, all fluid volume measurements in
this Service Manual are expressed in United States (U.S.)
units-of-measure. See below:

•

1 pint (U.S.) = 16 fluid ounces (U.S.)

•

1 quart (U.S.) = 2 pints (U.S.) = 32 fl. oz. (U.S.)

•

1 gallon (U.S.) = 4 quarts (U.S.) = 128 fl. oz. (U.S.)

METRIC SYSTEM

Fluid volume measurements in this Service Manual include
the metric system equivalents. In the metric system, 1 liter (L)
= 1,000 milliliters (mL). Should you need to convert from U.S.
units-of-measure to metric units-of-measure (or vice versa),
refer to the following:

•

fluid ounces (U.S.) x 29.574 = milliliters

•

pints (U.S.) x 0.473 = liters

•

quarts (U.S.) x 0.946 = liters

•

gallons (U.S.) x 3.785 = liters

•

milliliters x 0.0338 = fluid ounces (U.S.)

•

liters x 2.114 = pints (U.S.)

•

liters x 1.057 = quarts (U.S.)

•

liters x 0.264 = gallons (U.S.)

BRITISH IMPERIAL SYSTEM

Fluid volume measurements in this Service Manual do not
include the British Imperial (Imp.) system equivalents. The fol-
lowing conversions exist in the British Imperial system:

•

1 pint (Imp.) = 20 fluid ounces (Imp.)

•

1 quart (Imp.) = 2 pints (Imp.)

•

1 gallon (Imp.) = 4 quarts (Imp.)

Although the same unit-of-measure terminology as the U.S.
system is used in the British Imperial (Imp.) system, the actual
volume of each British Imperial unit-of-measure differs from its
U.S. counterpart. The U.S. fluid ounce is larger than the British
Imperial fluid ounce. However, the U.S. pint, quart, and gallon
are smaller than the British Imperial pint, quart, and gallon,
respectively. Should you need to convert from U.S. units to
British Imperial units (or vice versa), refer to the following:

•

fluid ounces (U.S.) x 1.042 = fluid ounces (Imp.)

•

pints (U.S.) x 0.833 = pints (Imp.)

•

quarts (U.S.) x 0.833 = quarts (Imp.)

•

gallons (U.S.) x 0.833 = gallons (Imp.)

•

fluid ounces (Imp.) x 0.960 = fluid ounces (U.S.)

•

pints (Imp.) x 1.201 = pints (U.S.)

•

quarts (Imp.) x 1.201 = quarts (U.S.)

•

gallons (Imp.) x 1.201 = gallons (U.S.)

HOME

C-2 2009 Sportster Diagnostics: Appendix C Conversions

C.3

TORQUE CONVERSIONS

UNITED STATES SYSTEM

The U.S. units of torque, foot pounds and inch pounds, are
used in this service manual. To convert units, use the following
equations:

•

foot pounds (ft-lbs) X 12.00000 = inch pounds (in-lbs).

•

inch pounds (in-lbs) X 0.08333 = foot pounds (ft-lbs).

METRIC SYSTEM

All metric torque specifications are written in Newton-meters
(Nm). To convert metric to United States units and United
States to metric, use the following equations:

•

Newton meters (Nm) X 0.737563 = foot pounds (ft-lbs).

•

Newton meters (Nm) X 8.85085 = inch pounds (in-lbs).

•

foot pounds (ft-lbs) X 1.35582 = Newton meters (Nm).

•

inch pounds (in-lbs) X 0.112985 = Newton meters (Nm).

HOME

2009 Sportster Diagnostics: Appendix C Conversions C-3

D.1

GLOSSARY

ACRONYMS AND ABBREVIATIONS

Table D-1. Acronyms and Abbreviations

DESCRIPTION

ACRONYM OR ABBREVIATION

Amperes

Alternating Current

Accessory

ACC

Automatic Compression Release

ACR

Absorbed Glass Mat (battery)

AGM

Ampere

AMP

American Wire Gauge

AWG

Battery Voltage

B+

Bank Angle Sensor

BAS

Before Top Dead Center

BTDC

Celsius (Centigrade)

California

Calibration

CAL

Cubic Centimeters

Cold Cranking Amps

CCA

Crankshaft Position

CKP

Centimeter

Direct Current

Data Link Connector

DLC

Domestic

DOM

Diagnostic Trouble Code

DTC

Digital Volt Ohm Meter

DVOM

Electronic Control Module

ECM

Engine Coolant Temperature

ECT

Electrically Erasable Programmable Read Only Memory

EEPROM

Electronic Fuel Injection

EFI

Engine Temperature

Evaporative Emissions Control System

EVAP

Fahrenheit

Foot-Pounds

ft-lbs

Fluid Ounce

fl oz.

Gram

Gallon

GAL

Gross Axle Weight Rating

GAWR

Ground (electrical)

GND

Gross Vehicle Weight Rating

GVWR

Harley-Davidson International

HDI

Harley-Davidson Smart Security System

H-DSSS

Hands Free Security Module

HFSM

Mercury

HOME

2009 Sportster Diagnostics: Appendix D Glossary D-1

Table D-1. Acronyms and Abbreviations

DESCRIPTION

ACRONYM OR ABBREVIATION

Idle Air Control

IAC

Intake Air Temperature

IAT

Instrument Cluster

Inside Diameter

Ignition Light/Key Switch

IGN

Inch

In.

Injector Pulse Width

INJ PW

Inch-Pounds

in-lbs

Kilogram

Kilometer

Kilopascal

kPa

Kilometers Per Hour

km/hr

Liter

Liquid Crystal Display

LCD

Light Emitting Diode

LED

Milliampere

Manifold Absolute Pressure

MAP

milliliter

millimeter

Miles Per Hour

MPH

millisecond

Newton-Meter

Not Applicable

N/A

Number

no.

Oxygen

Outside Diameter

Original Equipment Manufacturer

OEM

Ounce

Parts and Accessories

P&A

Part Number

Pounds per Square Inch

PSI

Reserve

RES

Revolutions Per Minute

RPM

Cubic Feet per Hour at Standard Conditions

SCFH

Throttle Control Actuator

TCA

Top Dead Center

TDC

Twist Grip Sensor

TGS

Throttle Position

Intake Air Temperature/Manifold Absolute Pressure

TMAP

Turn Signal Module

TSM

Turn Signal/Security Module

TSSM

Volt

Volts of Alternating Current

VAC

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D-2 2009 Sportster Diagnostics: Appendix D Glossary

Table D-1. Acronyms and Abbreviations

DESCRIPTION

ACRONYM OR ABBREVIATION

Volts of Direct Current

VDC

Vehicle Identification Number

VIN

Vehicle Speed Sensor

VSS

HOME

2009 Sportster Diagnostics: Appendix D Glossary D-3

TABLE OF CONTENTS

SUBJECT

............................................................................................................................

PAGE NO.

APPENDIX E

TSM/TSSM (J

AN/K

OREA)

Content .. 49 50 51 52 ..