Harley Davidson Sportster Models 2009. Service Repair Manual - page 81

3.22

DTC U1300, U1301 OR BUS ER

DIAGNOSTICS

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.

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.

•

DTCs P1009 and P1010 may accompany DTCs U1300
and U1301.

Diagnostic Notes

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

4.11 STARTS, THEN STALLS

ed01340

Figure 3-34. Data Link Connector [91A]

Table 3-25. Code Description

START WITH FLOWCHART

DESCRIPTION

DTC

4.11 STARTS, THEN STALLS

Serial data low

U1300

4.11 STARTS, THEN STALLS

Serial data open/high

U1301

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3-70 2009 Sportster Diagnostics: TSM/HFSM

3.23

TSM/HFSM: PASSWORD LEARN

GENERAL

If the ECM or TSM/HFSM is faulty, follow the instructions in
the service manual for ECM or TSM/HFSM replacement. Then,
to determine if password learn is necessary, refer to

Table 3-26

Table 3-26. Password Learn

IS PASSWORD LEARN

NECESSARY?

DEVICE REPLACED

Yes

ECM

No *

TSM

Yes

TSM/HFSM

* If a TSM has been replaced by a HFSM, or a HFSM has
been replaced by a TSM, password learn is necessary.

PASSWORD LEARNING

TOOL NAME

PART NUMBER

DIGITAL TECHNICIAN II

HD-48650

To perform password learning procedure, refer to

Table 3-27

When finished, continue with all instructions under

3.3 H-DSSS

ACTUATION

Always perform all appropriate instructions under

3.3 H-DSSS

ACTUATION

after TSM/HFSM replacement or removal.

NOTE

Fob assignment must be performed at an authorized Harley-
Davidson dealer using DIGITAL TECHNICIAN II (Part No. HD-
48650).

Table 3-27. Setting TSM/HFSM and ECM Password

NOTES

CONFIRMATION

ACTION

NO.

With Ignition Switch turned off,
Check Engine Lamp and
Security Lamp will be off.

Ignition must be turned off for at least 15 seconds.

Install new TSM/HFSM or ECM. Perform all steps under

3.3 H-DSSS ACTUATION

Set Engine Stop Switch to RUN.

TSM/HFSM enables start
relay.

Verify Check Engine Lamp
and Security Lamp illuminate
and then turn off.

Turn Ignition Switch ON.

Password has not been
learned. ECM sets DTC
P1009.

Engine starts and stalls.
Check Engine Lamp illumin-
ates and stays on.

Attempt normal start one time.

ECM enters Password
Learning mode for ten
minutes. Do not cycle Ignition
Switch or interrupt vehicle
power or Password Learn will
be unsuccessful.

Security Lamp illuminates.

Wait ten seconds. Security Lamp will illuminate and stay
on.

This takes ten minutes.

Wait until Security Lamp turns off.

ECM must not be allowed to
shutdown.

Quickly (within two seconds) turn Ignition Switch
OFF-ON.

This takes ten minutes.

Wait until Security Lamp turns off.

ECM must not be allowed to
shutdown.

Quickly (within two seconds) turn Ignition Switch
OFF-ON.

This takes ten minutes.

Wait until Security Lamp turns off.

ECM must not be allowed to
shutdown.

Quickly (within two seconds) turn Ignition Switch
OFF-ON.

Turn Ignition Switch OFF. Wait 15 seconds before
turning Ignition Switch on. Turn Ignition Switch ON and
start engine to confirm successful Password Learn
procedure. Clear DTCs.

Perform all steps under

3.3 H-DSSS ACTUATION

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2009 Sportster Diagnostics: TSM/HFSM 3-71

3.24

HFSM MAINTENANCE

GENERAL

The HFSM uses a battery in the fob and siren. These are the
only parts requiring periodic maintenance.

HANDS-FREE FOB

Schedule

Replace the fob battery every year.

Battery Replacement

See

Figure 3-35

. Open the fob case.

Place a thin blade in the thumbnail slot (1) between
the 2 halves of the case.

Slowly twist the blade.

Replace battery (2).

Remove the original battery.

Install a new battery with the positive (+) side down.
Use a Panasonic® 2032 or equivalent.

With O-ring (3) in place, align case halves and snap case
halves together.

ed02055

Thumbnail slot

Battery (Panasonic 2032)

O-ring

Figure 3-35. Open Fob: HFSM

SMART SIREN (IF INSTALLED)

Schedule

The siren's internal 9 volt battery is rechargeable and does not
need to be replaced on a regular basis. Battery life under
normal conditions is approximately three to six years.

NOTES

•

. Early style siren will

work with both TSSM and HFSM. Late style siren will only
work with HFSM.

•

The internal siren battery may not charge if the vehicle's
battery is less than 12.5 volts.

Battery Replacement: Early Style Siren

Disarm system and remove siren.

See

Figure 3-36

. Remove battery cover.

Place the siren module on a flat and sturdy table with
the potted section (area with epoxy covering circuit
board) facing up and towards you.

Position a knife blade at a 45 degree angle to the long
side of the siren case. Insert the knife blade between
the siren case and battery cover at one of the two
accessible corners of the battery cover. Keep the
blade slightly higher towards the battery cover as this
helps keep the blade away from the battery seal.

Slowly twist the blade towards the battery cover and
the cover will pop off.

NOTES

•

For protection against corrosion, battery terminals and
battery clip are covered with a special grease. Do not wipe
away this substance. Apply all available existing grease
to terminals on new battery.

•

Only a 9 volt nickel metal hydride battery should be used
in the siren.

Replace battery by removing old battery from polarized
battery clip. Install a new 9 volt nickel metal hydride bat-
tery.

Reinstall battery cover.

Carefully replace the rubber seal.

Align battery cover with case placing round corners
on cover away from connector [142A]. Snap cover
into place.

Install siren and check operation. If siren is working prop-
erly, it will respond with two chirps after receiving the arm
command.

Battery Replacement: Late Style Siren

Disarm system and remove siren.

See

Figure 3-37

. With a small screwdriver or pick, push

the catches (1) in through the two slots (2) in the end of
the siren to release the battery cover (3).

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3-72 2009 Sportster Diagnostics: TSM/HFSM

NOTES

•

Only a 9 volt nickel metal hydride battery should be used
in the siren.

Replace battery (4) by removing old battery from polarized
battery clip.

Recharge and re-install or install a new 9 volt nickel metal
hydride battery.

Reinstall battery cover (3).

Carefully replace the rubber seal (5) on the cover.

Align battery cover with case placing round corners
on cover away from connector [142A] (6).

Snap cover into place.

Install siren and check operation. If siren is working prop-
erly, it will respond with two chirps after receiving the arm
command.

ed03016

Cover

Battery

Connector [142A]

Figure 3-36. Battery Compartment (Early Style Siren)

ed02958

Catch

Slot

Cover

9 Volt battery

Rubber seal

Connector [142A]

Figure 3-37. Siren Battery Compartment (Late Style Siren)

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2009 Sportster Diagnostics: TSM/HFSM 3-73

3-74 2009 Sportster Diagnostics: TSM/HFSM

NOTES

TABLE OF CONTENTS

SUBJECT

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

PAGE NO.

ENGINE MANA

GEMENT

NOTES

4.1

SPECIFICATIONS

Table 4-1. General Specifications

DATA

IGNITION

1000 ± 50 RPM

Idle speed

12 mm

Spark plug size

0.038-0.043 in (0.97-1.09 mm)

Spark plug gap

0.032-0.038 in (0.81-0.97 mm)

Spark plug gap (XR)

Harley-Davidson

No. 6R12 (no substitute)

Spark plug type

Harley-Davidson

No. 10R12X

Spark plug type (XR)

0.3-0.7 ohms

Ignition coil primary res-
istance at room temper-
ature

1500-2400 ohms

Ignition coil secondary
resistance at room tem-
perature

Table 4-2. Fuse Ratings

RATING (AMPERES)

ITEM

ECM fuse

Fuel pump fuse

Ignition fuse

Instruments fuse

Accessory fuse

Battery fuse

Lights fuse

P&A ignition fuse

Main fuse

Engine Control

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2009 Sportster Diagnostics: Engine Management 4-1

ed02838

Accessories fuse

ECM fuse

Fuel pump fuse

Battery fuse

10.

Lights fuse

Spare

11.

Start relay

P&A ignition fuse

12.

Open

System relay

13.

Ignition fuse

MAXIFUSE

14.

Spare fuse (XL) - Engine Control (XR)

Instruments fuse

Figure 4-1. Fuses and Relays

HOME

4-2 2009 Sportster Diagnostics: Engine Management

4.2

EFI SYSTEM

GENERAL

The engine management system consists of the following
components:

•

Electronic Control Module (ECM).

•

Crankshaft Position (CKP) Sensor.

•

Combination Intake Air Temperature (IAT)/Manifold
Absolute Pressure (MAP) Sensor (TMAP).

•

Idle Air Control (IAC).

•

Throttle Position (TP) Sensor.

•

Vehicle Speed Sensor (VSS).

•

Turn Signal Module (TSM) or optional, factory-installed
Turn Signal Security Module (TSSM) (Japan/Korea) or
Hands-Free Security Module (HFSM). This includes an
integrated Bank Angle Sensor (BAS).

•

Ignition Coil.

•

Jiffy Stand Sensor (HDI).

•

Oxygen Sensors.

•

Active Intake Solenoid (HDI).

The ECM is mounted under the seat. It computes the spark
advance for proper ignition timing based on sensor inputs from
CKP, TMAP and TP sensors, and regulates the low-voltage
circuits between battery and ignition coil.

The ECM contains all of the solid state components used in
the ignition system. The dwell time for the ignition coil is also
calculated in the microprocessor and is dependent upon battery
voltage. The programmed dwell is an added feature to give
adequate spark at all speeds. (The ECM has added protection
against transient voltages, continuous reverse voltage protec-
tion, and damage due to jump starts.) The ECM is fully

enclosed to protect it from vibration, dust, water or oil. This unit
is a non-repairable item. If it fails, it must be replaced.

The CKP sensor is located in the front left side of the crank-
case. The CKP sensor generates an AC signal which is sent
to the ECM where it is used to reference engine position (TDC)
and speed. It functions by taking readings off the 30 teeth on
the left side flywheel (two teeth are missing to establish a ref-
erence point).

The TMAP sensor is located on top of the intake manifold. The
TMAP sensor monitors the intake manifold pressure (vacuum)
and intake air temperature and sends the information to the
ECM where the module adjusts the spark timing and fuel curve
for optimum performance.

The BAS is within the TSM/TSSM/HFSM. If the vehicle tips
over, the engine will be shut off. Once the sensor is tripped,
the motorcycle must be uprighted, turned off and then on again
before the engine can be restarted. This is communicated
across the data bus.

Front and rear coils fire each spark plug independently (one
cylinder at a time - no wasted spark). The coil also has an extra
terminal to monitor current on the coil secondary circuit. This
is used for knock detection and combustion diagnostics.

The ignition system gives a spark near top dead center for
starting. At RPM and loads above this, the system gives a
spark advance that varies between 0 and 50.

The IAT, ET, TP and oxygen sensors are used to provide
information to the ECM to fine tune spark and fuel delivery.
The VSS is used as an input for idle speed control.

The oxygen sensors monitor the exhaust gas for oxygen con-
tent. The fuel/air mixture is then adjusted to maintain an optimal
air/fuel ratio.

TROUBLESHOOTING

See the diagnostic charts for troubleshooting information.

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2009 Sportster Diagnostics: Engine Management 4-3

DTCs P0562 and P0563 (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 P0562 and P0563 (Part 2 of 2).

With ignition ON, measure voltage drop between battery positive (+) terminal and

(GY) terminal on 15 amp ignition fuse (-).

Is voltage drop greater than 0.5 volt?

With ignition ON, measure voltage drop

between battery positive (+) terminal and

(R/BK) terminal at 15 amp ignition fuse.

Is voltage drop greater than 0.5 volt?

With ignition ON, measure voltage drop

between battery positive (+) and both fuse

terminals (-).

Is voltage drop greater than 0.5 volt?

With ignition ON, measure voltage drop

between battery positive (+) terminal and

one fuse terminal (-).

Is voltage drop greater than 0.5 volt?

High resistance between

main fuse and battery.

Replace wire or terminals.

Replace GY wire

or terminals.

Replace fuse or

fuse terminals.

Replace ignition

switch or terminals.

Replace main fuse.

fc01991_en

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2009 Sportster Diagnostics: Engine Management 4-103

4.24

DTC P0603, P0605

GENERAL

TOOL NAME

PART NUMBER

DIGITAL TECHNICIAN II

HD-48650

ECM Failure

Refer to

Table 4-38

. The DTCs listed indicate a failure which

requires replacement of the ECM. See the Service Manual for
replacement information.

NOTE

After replacing ECM, reprogram, perform password learning
procedure and clear codes. ECM must be reprogrammed using
the DIGITAL TECHNICIAN II (Part No. HD-48650). See your
dealer. Password learn procedure must also be performed.
See

3.23 TSM/HFSM: PASSWORD LEARN

Table 4-38. Code Description

DESCRIPTION

DTC

ECM EEPROM error

P0603

ECM flash error

P0605

DIAGNOSTICS

These codes are set under two conditions.

•

If DTC P0603 or P0605 occur during normal operation,
replace ECM. Reprogram and learn password.

•

If DTC P0603 or P0605 occur during or after reprogram-
ming, perform the following:

DTC P0603

Clear DTCs.

Power down the vehicle. Wait 10 seconds.

Turn ignition ON.

Replace ECM if codes reappear.

DTC P0605

Clear DTCs.

Power down the vehicle.

Attempt to reprogram ECM using correct calibration.

Restart vehicle. If code reappears, replace ECM.

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4-104 2009 Sportster Diagnostics: Engine Management

4.25

DTC P0661, P0662

GENERAL

Active Intake Solenoid (HDI XR Models Only)

The active intake solenoid regulates the amount of air that
enters the air cleaner. The active intake solenoid opens when
vehicle speed exceeds 45 MPH (70 km/h) with 50% or greater
throttle opening. Once open, active intake will close when
vehicle speed falls below 40 MPH (65 km/h). The power for
the active intake solenoid comes from the engine control fuse.
The ECM provides the path to ground to trigger the active
intake solenoid.

Table 4-39. Code Description

DESCRIPTION

DTC

Active intake solenoid open/low

P0661

Active intake high/shorted

P0662

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).

See the service manual for all service information.

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

4.7 BREAKOUT BOX:

EFI

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

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2009 Sportster Diagnostics: Engine Management 4-105

ECM

Active
Intake

Solenoid

Battery

30 Amp

MAXIFUSE

GND 1

Ignition Switch

15 Amp

Engine Control

Fuse

Active Intake Solenoid HDI

Ground

LGN/R

GY/O

R/BK

[145B]

[145A]

[78B]

[78A]

−

IGN

−

I B A

[178A]

[178B]

em01307

Figure 4-49. Active Intake Solenoid Circuit

Table 4-40. Wire Harness Connectors

LOCATION

TYPE

DESCRIPTION

NO.

Under seat

36-place Packard

ECM

[78]

Rear of air box

2-place Amp

Active Intake Solenoid (HDI)

[178]

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4-106 2009 Sportster Diagnostics: Engine Management

DTCs P0661 and P0662 (Part 1 of 2)

Is connector securely attached to the

active intake solenoid?

YES

Reconnect.

Turn active intake solenoid on by

grounding terminal 20 on breakout box.

Solenoid should activate immediately

after ignition switch is turned to IGN.

Does it?

YES

Recheck connections. Perform

4.8 WIGGLE TEST to check for

intermittents.

Are intermittents present?

Check terminal 1 (LGN/R) wire on

active intake solenoid connector

[178B] to ground.

Is voltage equivalent to battery voltage

after ignition switch is turned to IGN?

YES

Measure resistance of

active intake solenoid

across solenoid terminals.

Is resistance 16-20 ohms?

Repair

intermittent.

YES

Check for loose

or corroded terminals

in harness.

Replace

active intake

solenoid.

YES

Inspect engine

control fuse.

Is fuse OK?

Locate and repair

bad connection

or open on (LGN/R)

wire between engine

control fuse and

connector [178B].

YES

Check for 12 volts at terminal L

of fuse block after ignition

switch is turned to IGN.

Is battery voltage present?

YES

Replace

fuse.

Locate and repair

open on (R/BK) wire to

engine control fuse.

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

fc01992_en

Go to DTCs

P0661 and

P0662

(Part 2 of 2).

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2009 Sportster Diagnostics: Engine Management 4-107

DTCs P0661 and P0662 (Part 2 of 2)

Continued from DTCs P0661 and P0662 (Part 1 of 2).

Measure resistance between Breakout Box

terminal 20 (GY/O) wire and terminal 2 of active intake solenoid connector [178B].

Is resistance less than 0.5 ohm?

YES

Measure resistance between ground

and Breakout Box terminal 20.

Is resistance less than 1000 ohms?

Repair open or

poor connection.

YES

Repair short to ground on

(GY/O) wire.

Disconnect connectors [178] and [78]. Check

for voltage at Breakout Box terminal 20 with

ignition switch turned to IGN.

Is voltage present?

Locate and repair

short to voltage on

(GY/O) wire.

YES

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.

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4-108 2009 Sportster Diagnostics: Engine Management

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