Harley Davidson Sportster Models 2009. Service Repair Manual

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 4-60. Serial Data Circuit (XL)

HOME

2009 Sportster Diagnostics: Engine Management 4-125

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 4-61. Serial Circuit Data (XR)

Table 4-48. Wire Harness Connectors

LOCATION

TYPE

DESCRIPTION

NO.

Under fuel tank

12-place Molex

Instruments

[20]

Under battery

12-place Deutsch

TSM/TSSM/HFSM

[30]

Back of speedometer

12-place Packard

Speedometer (XL)

[39]

Back of speedometer

5-place Packard

Display (XR)

[39]

Under seat

36-place Packard

ECM

[78]

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4-126 2009 Sportster Diagnostics: Engine Management

DTCs U1064 and U1255

Can you read TSM/TSSM/HFSM hardware part number?

See 4.6 ODOMETER SELF-DIAGNOSTICS.

Install Breakout Box on speedometer.

While wiggling harness, check for continuity

between terminal 3 (gray) and terminal 2

(black) of Breakout Box.

Is continuity present?

Install Breakout Box on speedometer on XL,

tachometer on XR.

Check for continuity between terminal 3 (gray)

and terminal 2 (black) of Breakout Box

Is continuity present?

Replace TSM/TSSM/HFSM.

Learn password.

Repair open on

(LGN/V) wire.

Repair intermittent

on (LGN/V) wire.

Clear DTCs. Test ride.

Does DTC U1064 return?

No trouble found.

Replace TSM/TSSM/HFSM.

Learn password.

YES

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

YES

NO or “No Rsp”

fc01863_en

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4-128 2009 Sportster Diagnostics: Engine Management

4.30

DTC U1097, U1255

GENERAL

Loss of Speedometer Serial Data

The serial data connector provides a means for the speedo-
meter on XL, and tachometer on XR, Electronic Control Module
(ECM) and TSM/TSSM/HFSM to communicate their current
status. When all operating parameters on the serial data link
are within specifications, a state of health message is sent
between the components. A Diagnostic Trouble Code (DTC)
U1097 indicates that the speedometer on XL, and tachometer
on XR, is not capable of sending this state of health message.
A DTC U1255 indicates that no messages were present during
power up of the current key cycle. A DTC U1097 indicates that
there was communication on the data bus since power up, but
communication was lost or interrupted during that key cycle.

Table 4-49. Code Description

DESCRIPTION

DTC

Loss of all speedometer serial data (state
of health)

U1097

Missing message at speedometer

U1255

DIAGNOSTICS

TOOL NAME

PART NUMBER

BREAKOUT BOX

HD-42682

BREAKOUT BOX

HD-43876

INSTRUMENT HARNESS ADAPTER

HD-46601

NOTE

If DTC is historic and not current, wiggle wire harness while
performing voltage and continuity tests to identify intermittents.

Diagnostic Notes

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

Connect BREAKOUT BOX (Part No. HD-43876) to wire
harness connector [78B]. Leave ECM [78A] disconnected.
See

4.7 BREAKOUT BOX: EFI

Connect BREAKOUT BOX (Part No. HD-42682) (black)
to wire harness connector [39B] on XL, and connector
[108B] on XR, using INSTRUMENT (Part No. HD-46601).
Leave speedometer [39A] on XL, and connector [108A]
on XR, disconnected. See

2.5 BREAKOUT BOX:

SPEEDOMETER/TACHOMETER

ed02819

Figure 4-62. Speedometer Connector [39] on XL, and

tachometer connector [108A] on XR (Typical)

HOME

2009 Sportster Diagnostics: Engine Management 4-129

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 4-63. Serial Data Circuit (XL)

HOME

4-130 2009 Sportster Diagnostics: Engine Management

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 4-64. Serial Data Circuit (XR)

Table 4-50. Wire Harness Connectors

LOCATION

TYPE

DESCRIPTION

NO.

Under fuel tank

12-place Molex

Instruments

[20]

Under battery

12-place Deutsch

TSM/TSSM/HFSM

[30]

Back of speedometer

12-place Packard

Speedometer (XL)

[39]

Back of speedometer

5-place Packard

Display (XR)

[39]

Under seat

36-place Packard

ECM

[78]

HOME

2009 Sportster Diagnostics: Engine Management 4-131

DTCs U1097 and U1255

YES

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

YES

IMPORTANT:

Always start from

4.5 INITIAL DIAGNOSTIC CHECK: EFI.

Can you read ECM hardware part number?

See 4.6 ODOMETER SELF-DIAGNOSTICS.

While wiggling harness, check for continuity between ECM

Breakout Box terminal 5 and speedometer Breakout Box

terminal 2 (black).

Is continuity present?

Check for continuity between

ECM Breakout Box terminal 5

and speedometer Breakout

Box terminal 2 (black).

Is continuity present?

Replace

speedometer on XL,

tachometer on XR.

Repair open

(LGN/V) wire.

Clear DTCs. Test Ride.

Did DTC U1097 return?

Repair intermittent on

(LGN/V) wire.

No trouble found.

Replace speedometer.

NO or “No rsp”

fc01864_en

HOME

2009 Sportster Diagnostics: Engine Management 4-133

4.31

FUEL PRESSURE TEST

GENERAL

The fuel pump delivers fuel through the fuel line, to a cavity in
the induction module. This cavity directs the fuel to the fuel
injectors and pressure regulator. The pressure regulator con-
trols the fuel pressure by passing excess fuel back to the fuel
tank. Improper fuel pressure may contribute to one of the fol-
lowing symptoms:

•

cranks, but won't run

•

cut out (may feel like ignition problem)

•

hesitation, loss of power, or poor fuel economy

If incorrect fuel pressure is suspected, perform a fuel pressure
test. See the service manual for the required tools and pro-
cedure for performing a fuel pressure test.

DIAGNOSTICS

Perform a fuel pressure test. See the service manual. The fuel
pressure should remain steady between 55-62 PSI (380-425
KPa). If pressure does not hold steady, follow either the low
fuel pressure or high fuel pressure procedure, depending on
the symptom.

Low Fuel Pressure

Check the fuel filter or pump inlet screen for restrictions.
If the concern is found, clean the pump inlet screen or
replace the fuel filter.

If the concern was not corrected, inspect for a:

•

restricted pressure line or flex hose between the fuel tank
and the test gauge.

•

faulty fuel pump.

•

restricted check valve fitting assembly.

•

leak inside the tank caused by faulty coupling hose or
connection, such as a hose at the filter or pump. This
condition can be identified, if the fuel level in the tank is
low, by a ringing sound inside the tank during the first 2
seconds after key on. This is caused by the high pressure
fuel spraying against the inside of the tank.

•

faulty fuel pressure regulator.

Once the concern is located, repair as needed.

High Fuel Pressure

Inspect the check valve fitting assembly and the fuel tank.
If the concern is found correct as needed.

If the concern was not corrected, replace the fuel regulator.

HOME

4-134 2009 Sportster Diagnostics: Engine Management

A.1

AMP MULTILOCK CONNECTORS

AMP MULTILOCK CONNECTOR REPAIR

TOOL NAME

PART NUMBER

AMP MULTILOCK CRIMPER

HD-41609

General

AMP Multilock connectors are found between wire harnesses
and component wiring and may be either floating or anchored
to the frame with attachment clips.

See

Figure A-1

. Attachment clips (1) on the pin housings are

fitted to T-studs on the motorcycle frame. The T-studs identify
OE connector locations. To maintain serviceability, always
return connectors to OE locations after service.

Obtain the necessary tools to repair the connector and ter-
minals.

NOTE

For terminal crimping use the AMP MULTILOCK
CRIMPER (Part No. HD-41609).

Separating Pin and Socket Housings

If necessary, slide connector attachment clip T-stud to the
large end of the opening.

See

Figure A-1

. Depress the release button (2) on the

socket terminal side of the connector and pull the socket
housing (3) out of the pin housing (4).

Mating Pin and Socket Housings

Hold the housings to match wire color to wire color.

Insert the socket housing into the pin housing until it snaps
in place.

If OE location is a T-stud, fit large opening end of attach-
ment clip over T-stud and slide connector to engage T-
stud to small end of opening.

sm00002

Attachment clip

Release button

Socket housing

Pin housing

Figure A-1. AMP Multilock Connector

Removing Terminals from Housing

See

Figure A-2

. Bend back the latch (1) to free one end

of secondary lock (2) then repeat on the opposite end.
Hinge the secondary lock outward.

Look in the terminal side of the connector (opposite the
secondary lock) and note the cavity next to each terminal.

Insert a pick or pin into the terminal cavity until it stops.

NOTE

If socket/pin terminal tool is not available, a push pin/safety pin
or a Snap-on pick (Part No. TT600-3) may be used.

Press the tang in the housing to release the terminal.

Socket: Lift the socket tang (8) up.

Pin: Press the pin tang (7) down.

NOTE

A "click" is heard if the tang is released.

Gently tug on wire to pull wire and terminal from cavity.

HOME

2009 Sportster Diagnostics: Appendix A Connector Repair A-1

sm00013

Latch

Secondary lock open

Pin housing

Socket housing

Pin terminal

Socket terminal

Tang (pin)

Tang (socket)

Figure A-2. AMP Multilock Connector: Socket and Pin

Housings

Inserting Terminals into Housing

NOTE

See

Figure A-3

. Cavity numbers are stamped into the sec-

ondary locks of both the socket and pin housings. Match the
wire color to the cavity number found on the wiring diagram.

Hold the terminal so the catch faces the tang in the
chamber. Insert the terminal into its numbered cavity until
it snaps in place.

NOTES

•

Up and down can be determined by the position of the
release button, the button is the top of the connector.

•

On the pin side of the connector, tangs are positioned at
the bottom of each cavity, so the slot in the pin terminal
(on the side opposite the crimp tails) must face downward.

•

On the socket side, tangs are at the top of each cavity, so
the socket terminal slot (on the same side as the crimp
tails) must face upward.

Gently tug on wire end to verify that the terminal is locked
in place.

Rotate the hinged secondary lock inward until tabs fully
engage latches on both sides of connector.

– AMP

sm00005

3-place housing

6-place housing

10-place housing

Figure A-3. AMP Multilock Connector: Cavity Numbers on

Secondary Locks (Socket Housings Shown)

Preparing Wire Leads for Crimping

Strip 5/32 in. (4.0 mm) of insulation from the wire lead.

HOME

A-2 2009 Sportster Diagnostics: Appendix A Connector Repair

See

Figure A-2

and

Figure A-5

. Select the pin/socket ter-

minals from the parts catalog and identify the insulation
crimp tails (1) and the wire crimp tails (2) and the groove
for the crimp tool locking bar (3).

Identify the wire lead gauge and the corresponding crimper
tool and nesting die. Refer to

Table A-1

Table A-1. AMP Multilock Connector: Crimp Tool Wire

Gauge/Nest

NEST

WIRE GAUGE

Front

Middle

Rear

sm00013

Latch

Secondary lock open

Pin housing

Socket housing

Pin terminal

Socket terminal

Tang (pin)

Tang (socket)

Figure A-4. AMP Multilock Connector: Socket and Pin

Housings

HOME

2009 Sportster Diagnostics: Appendix A Connector Repair A-3

sm00001

Insulation crimp tail

Wire crimp tail

Locking bar groove

Figure A-5. AMP Multilock Connector: Socket Terminal

Crimping Terminals to Leads

NOTE

Crimping with an Amp Multilock tool is a one step operation.
One squeeze crimps both the wire core and the insulation tails.

See

Figure A-6

. Squeeze the handles to cycle the AMP

MULTILOCK CRIMPER (Part No. HD-41609) to the fully
open position (1).

Raise locking bar by pushing up on bottom flange (2).

NOTE

. Hold the terminal with the

insulation crimp tail (1) facing up. The tool will hold the terminal
by the locking bar groove (3) and crimp the wire crimp tail (2)
around the bare wire of the stripped lead and the insulation
crimp tail around the insulation.

See

Figure A-6

. With the insulation crimp tail facing

upward, insert terminal (pin or socket) (3) through the
locking bar, so that the closed side of the terminal rests
on the nest of the crimp tool.

Release locking bar to lock position of contact (4). When
correctly positioned, the locking bar fits snugly in the space
at the front of the core crimp tails.

Insert stripped end of lead (5) until ends make contact with
locking bar.

Verify that wire is positioned so that wire crimp tails
squeeze bare wire strands, while insulation crimp tails fold
over the wire lead insulation.

Squeeze handle of crimp tool until tightly closed. Tool
automatically opens when the crimping sequence is com-
plete.

Raise up locking bar (7) and remove crimped terminal.

sm00007

Open position

Locking bar flange

Insert contact

Release locking bar

Insert lead

Squeeze

Raise locking bar

Remove crimped terminal

Figure A-6. AMP Multilock Connector: Terminal Crimping

Procedure

Inspecting Crimped Terminals

See

Figure A-7

. Inspect the wire core crimp (2) and insulation

crimp (1). Distortion should be minimal.

HOME

A-4 2009 Sportster Diagnostics: Appendix A Connector Repair

Harley Davidson Sportster Models 2009. Service Repair Manual - page 83