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2009 Harley-Davidson Sportster Electrical Diagnostic Manual – PDF DOWNLOAD 
2009 Harley-Davidson Sportster Electrical Diagnostic Manual – PDF DOWNLOAD
2009 Harley-Davidson Sportster Electrical Diagnostic Manual – PDF DOWNLOAD
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2009 Harley-Davidson Sportster Electrical Diagnostic Manual – PDF DOWNLOAD
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Description
2009 Harley-Davidson Sportster Electrical Diagnostic Manual – PDF DOWNLOAD
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
2009 Harley-Davidson Sportster Electrical Diagnostic Manual – PDF DOWNLOAD
ABOUT THIS MANUAL
GENERAL
This electrical diagnostic service manual has been prepared with two purposes in mind. First, it will acquaint the user with the construction of the Harley-Davidson product and assist in the performance of repair. Secondly, it will introduce to the professional Harley-Davidson Technician the latest field-tested and factory-approved diagnostic methods.We sincerely believe that this manual will make your association with Harley-Davidson products more pleasant and profitable.
HOW TO USE YOUR SERVICE MANUAL :
Refer to the table below for the content layout of this manual.
NO. CHAPTER
1 Starting / Charging
2 Instruments
3 TSM/HFSM
4 Engine Management
A Appendix A Connector Repair
B Appendix B Wiring
C Appendix C Conversions
D Appendix D Glossary
E Appendix E TSM/TSSM (Japan/Korea)
- Use the TABLE OF CONTENTS (which follows this FOREWORD) and the INDEX (at the back of this manual) to quickly locate subjects. Sections and topics in this manual are sequentially numbered for easy navigation.
- For example, a cross-reference shown as 2.1 SPECIFICATIONS refers to chapter 2 CHASSIS, heading 2.1 SPECIFICATIONS. For quick and easy reference, all pages contain a section number followed by a page number. For example, page 3-5 refers to page 5 in section 3.
TABLE OF CONTENTS:
2009 Harley-Davidson Sportster Electrical Diagnostic Manual – PDF DOWNLOAD
FOREWORD................................................................................. 7 TABLE OF CONTENTS........................................................................ 9 1. STARTING / CHARGING................................................................... 17 1.1 STARTER TROUBLESHOOTING.......................................................... 19 General.......................................................................... 19 Starter Troubleshooting.......................................................... 19 1.2 STARTING SYSTEM DIAGNOSIS........................................................ 21 Diagnostics...................................................................... 21 1.3 DIAGNOSTICS/TROUBLESHOOTING...................................................... 29 Voltage Drop..................................................................... 29 1.4 STARTER ACTIVATION CIRCUITS...................................................... 30 Starter Activation Circuits...................................................... 30 1.5 TESTING STARTER ON MOTORCYCLE.................................................... 31 Start Relay Test................................................................. 31 Starter Current Draw Test........................................................ 31 1.6 TESTING STARTER ON BENCH......................................................... 33 Free Running Current Draw Test................................................... 33 Starter Solenoid................................................................. 33 Solenoid Pull-In Test............................................................ 33 Solenoid Hold-In Test............................................................ 33 Solenoid Return Test............................................................. 34 Testing.......................................................................... 34 1.7 CHARGING SYSTEM.................................................................. 38 General.......................................................................... 38 Troubleshooting.................................................................. 38 Testing.......................................................................... 42 1.8 BATTERY TESTING.................................................................. 46 General.......................................................................... 46 Voltmeter Test................................................................... 46 Conductance Test................................................................. 46 Load Test........................................................................ 46 2. INSTRUMENTS........................................................................... 49 2.1 CHECKING FOR DIAGNOSTIC TROUBLE CODES............................................ 51 Check Engine Lamp................................................................ 51 Security Lamp.................................................................... 52 Code Types....................................................................... 53 Retrieving Diagnostic Trouble Codes.............................................. 53 Multiple Diagnostic Trouble Codes................................................ 53 2.2 INITIAL DIAGNOSTIC CHECK: ODOMETER............................................... 54 General.......................................................................... 54 Initial Diagnostics.............................................................. 55 2.3 ODOMETER SELF-DIAGNOSTICS........................................................ 63 General.......................................................................... 63 Diagnostics...................................................................... 63 2.4 SPEEDOMETER/TACHOMETER........................................................... 65 General.......................................................................... 65 Speedometer Theory of Operation.................................................. 65 Odometer Theory of Operation..................................................... 65 Tachometer Theory of Operation................................................... 65 Diagnostics...................................................................... 66 2.5 BREAKOUT BOX: SPEEDOMETER/TACHOMETER............................................. 70 General.......................................................................... 70 Speedometer: XL only............................................................. 70 Tachometer....................................................................... 70 2.6 INDICATOR LAMPS.................................................................. 71 General.......................................................................... 71 Diagnostics...................................................................... 71 2.7 DTC B1004, B1005................................................................. 76 General.......................................................................... 76 Diagnostics...................................................................... 76 2.8 DTC B1006, B1007................................................................. 80 General.......................................................................... 80 2.9 DTC B1008........................................................................ 82 General.......................................................................... 82 Diagnostics...................................................................... 82 2.10 DTC U1016, U1255................................................................ 84 General.......................................................................... 84 Diagnostics...................................................................... 84 2.11 DTC U1064, U1255................................................................ 89 General.......................................................................... 89 Diagnostics...................................................................... 89 2.12 DTC U1300, U1301 OR BUS ER...................................................... 94 General.......................................................................... 94 Diagnostics...................................................................... 94 3. TSM/HFSM.............................................................................. 95 3.1 TURN SIGNAL OVERVIEW............................................................. 97 General.......................................................................... 97 Security System: Japan/Korea..................................................... 97 Turn Signal Functions............................................................ 97 Manual Cancellation.............................................................. 97 Automatic Cancellation........................................................... 97 Bank Angle Functions............................................................. 97 Bank Angle Restart............................................................... 97 Clutch/Neutral Interlock......................................................... 97 Security System H-DSSS........................................................... 97 3.2 HARLEY-DAVIDSON SMART SECURITY SYSTEM............................................ 98 Components....................................................................... 98 Security Immobilization.......................................................... 98 HFSM Features.................................................................... 99 3.3 H-DSSS ACTUATION.................................................................101 General..........................................................................101 Sidecar Configuration............................................................101 Actuation........................................................................101 Fob Assignment...................................................................101 Power Disruption and Configuring.................................................101 3.4 PERSONAL IDENTIFICATION NUMBER (PIN).............................................102 General..........................................................................102 Initial Pin Entry................................................................102 Changing the Pin.................................................................102 3.5 ARMING/DISARMING SECURITY SYSTEM.................................................104 Hands-Free Fob...................................................................104 Security Lamp (Key Icon).........................................................104 Arming...........................................................................104 Disarming........................................................................105 3.6 WARNINGS AND ALARMS..............................................................106 Warnings.........................................................................106 Alarm............................................................................106 Siren Chirp Mode (Confirmation)..................................................106 3.7 SERVICE/EMERGENCY FUNCTIONS......................................................107 Transport Mode...................................................................107 Service Mode.....................................................................107 Four-Way Flashing................................................................107 3.8 TROUBLESHOOTING..................................................................108 Turn Signals (TSM/HFSM)..........................................................108 Security System (HFSM)...........................................................108 Diagnostics Mode.................................................................108 Troubleshooting..................................................................108 3.9 CHECKING FOR DIAGNOSTIC TROUBLE CODES............................................109 General..........................................................................109 Security/Lamp Diagnostics........................................................109 Code Types.......................................................................110 Retrieving DTCs..................................................................110 Multiple DTCs/Priority Order.....................................................111 3.10 INITIAL DIAGNOSTIC CHECK: TSM/HFSM..............................................112 General..........................................................................112 Initial Diagnostics..............................................................112 3.11 ODOMETER SELF-DIAGNOSTICS.......................................................120 General..........................................................................120 Diagnostics......................................................................120 3.12 BREAKOUT BOX: TSM/HFSM..........................................................122 General..........................................................................122 Installation.....................................................................122 Removal..........................................................................122 3.13 FAILS TO DISARM (HFSM ONLY).....................................................124 General..........................................................................124 Job/Time Codes...................................................................124 Diagnostics......................................................................124 3.14 DTC B0563.......................................................................127 General..........................................................................127 Diagnostics......................................................................127 3.15 TSM/HFSM: TURN SIGNAL ERRORS AND DTCS...........................................128 General..........................................................................128 Diagnostics......................................................................128 3.16 DTC B1131, B1132 (HFSM ONLY)....................................................144 General..........................................................................144 Diagnostics......................................................................144 3.17 DTC B1134.......................................................................147 General..........................................................................147 Diagnostics......................................................................147 3.18 DTCS B1135, B1136, B1141, AND B1142.............................................150 Diagnostics......................................................................150 DTC B1136 Accelerometer Tip-Over Self-Test Fault and DTC B1142 Internal Fault....150 DTC B1141 Ignition Switch Open/Low...............................................150 3.19 DTC B1143, B1144, B1145 (HFSM ONLY).............................................154 General..........................................................................154 Diagnostics......................................................................154 3.20 DTC B1154, B1155................................................................157 Diagnostics......................................................................157 3.21 DTC U1016, U1255................................................................161 General..........................................................................161 Diagnostics......................................................................161 3.22 DTC U1300, U1301 OR BUS ER......................................................166 Diagnostics......................................................................166 3.23 TSM/HFSM: PASSWORD LEARN........................................................167 General..........................................................................167 Password Learning................................................................167 3.24 HFSM MAINTENANCE................................................................168 General..........................................................................168 Hands-Free Fob...................................................................168 Smart Siren (If Installed).......................................................168 4. ENGINE MANAGEMENT.....................................................................171 4.1 SPECIFICATIONS...................................................................173 Specifications...................................................................173 4.2 EFI SYSTEM.......................................................................175 General..........................................................................175 Troubleshooting..................................................................175 4.3 EFI DIAGNOSTIC INTRODUCTION......................................................177 System Problems..................................................................177 Resolving Problems...............................................................177 4.4 CHECKING FOR DIAGNOSTIC TROUBLE CODES: EFI.......................................178 Check Engine Lamp................................................................178 Code Types.......................................................................179 Retrieving Diagnostic Trouble Codes..............................................179 Multiple Diagnostic Trouble Codes................................................180 4.5 INITIAL DIAGNOSTIC CHECK: EFI....................................................181 General..........................................................................181 Initial Diagnostics..............................................................181 4.6 ODOMETER SELF-DIAGNOSTICS........................................................192 General..........................................................................192 Diagnostics......................................................................192 4.7 BREAKOUT BOX: EFI................................................................194 General..........................................................................194 Installation.....................................................................194 Removal..........................................................................194 4.8 WIGGLE TEST......................................................................195 General..........................................................................195 Procedure........................................................................195 4.9 ENGINE CRANKS, BUT WILL NOT START................................................196 General..........................................................................196 Diagnostics......................................................................196 4.10 NO ECM POWER....................................................................203 General..........................................................................203 Diagnostics......................................................................203 4.11 STARTS, THEN STALLS.............................................................208 General..........................................................................208 Diagnostics......................................................................208 4.12 FUEL SYSTEM ELECTRICAL TEST.....................................................214 General..........................................................................214 Diagnostics......................................................................214 4.13 SYSTEM RELAY CHECK..............................................................222 General..........................................................................222 Diagnostics......................................................................222 4.14 IDLE AIR CONTROL................................................................227 General..........................................................................227 Diagnostics......................................................................227 4.15 MISFIRE AT IDLE OR UNDER LOAD...................................................232 General..........................................................................232 Diagnostics......................................................................232 4.16 DTC P0107, P0108, P0112, P0113..................................................238 General..........................................................................238 Diagnostics......................................................................238 4.17 DTC P0117, P0118................................................................245 General..........................................................................245 Diagnostics......................................................................245 4.18 DTC P0122, P0123................................................................249 General..........................................................................249 Diagnostics......................................................................249 4.19 DTC P0131, P0132, P0134, P0151, P0152, P0154....................................254 General..........................................................................254 Diagnostics......................................................................254 4.20 DTC P0261, P0262, P0263, P0264..................................................259 General..........................................................................259 Diagnostics......................................................................259 4.21 DTC P0373, P0374................................................................265 General..........................................................................265 Diagnostics......................................................................265 4.22 DTC P0501, P0502................................................................268 General..........................................................................268 Diagnostics......................................................................268 4.23 DTC P0562, P0563................................................................272 General..........................................................................272 Diagnostics......................................................................272 4.24 DTC P0603, P0605................................................................276 General..........................................................................276 Diagnostics......................................................................276 4.25 DTC P0661, P0662................................................................277 General..........................................................................277 Diagnostics......................................................................277 4.26 DTC P1009, P1010................................................................281 General..........................................................................281 Diagnostics......................................................................281 4.27 DTC P1351, P1352, P1354, P1355..................................................286 General..........................................................................286 Diagnostics......................................................................286 4.28 DTC P1501, P1502................................................................291 General..........................................................................291 Diagnostics......................................................................291 4.29 DTC U1064, U1255................................................................296 General..........................................................................296 Diagnostics......................................................................296 4.30 DTC U1097, U1255................................................................301 General..........................................................................301 Diagnostics......................................................................301 4.31 FUEL PRESSURE TEST..............................................................306 General..........................................................................306 Diagnostics......................................................................306 A. APPENDIX A CONNECTOR REPAIR...........................................................307 A.1 AMP MULTILOCK CONNECTORS.........................................................309 AMP Multilock Connector Repair...................................................309 A.2 DELPHI CONNECTORS................................................................314 Delphi Connector Repair..........................................................314 A.3 DEUTSCH 1-PLACE ELECTRICAL CONNECTORS............................................316 Deutsch 1-Place Connector Repair.................................................316 A.4 DEUSCH ELECTRICAL CONNECTORS.....................................................317 Deutsch Connector Repair.........................................................317 A.5 DEUTSCH STANDARD TERMINALS.......................................................321 Deutsch Standard Terminal Crimps.................................................321 A.6 DEUTSCH MINI-TERMINAL CRIMPS.....................................................322 Deutsch Mini Terminal Crimps.....................................................322 A.7 DEUTSCH SOLID BARREL TERMINALS...................................................323 Deutsch Solid Barrel Terminal Crimps.............................................323 A.8 RELAY AND FUSE BLOCKS............................................................325 Fuse Block Repair................................................................325 A.9 150 METRI-PACK CONNECTORS........................................................326 150 Metri-Pack Connector Repair..................................................326 A.10 280 METRI-PACK CONNECTORS.......................................................328 280 Metri-Pack Connector Repair..................................................328 A.11 480 METRI-PACK CONNECTORS.......................................................330 480 Metri-Pack Connector Repair..................................................330 A.12 630 METRI-PACK CONNECTORS.......................................................331 630 Metri-Pack Connector Repair..................................................331 A.13 800 METRI-PACK CONNECTORS.......................................................332 Delphi Main Fuse Housing Repair..................................................332 A.14 METRI-PACK TERMINALS............................................................334 Metri-Pack Terminal Crimps.......................................................334 A.15 MOLEX CONNECTORS................................................................336 Molex Connector Repair...........................................................336 A.16 PACKARD ECM CONNECTOR...........................................................338 Packard 100W Connector Repair....................................................338 A.17 PACKARD MICRO-64 CONNECTORS.....................................................340 Packard Micro-64 Connector Repair................................................340 A.18 SEALED SPLICE CONNECTORS........................................................343 Sealed Splice Connector Repair...................................................343 B. APPENDIX B WIRING.....................................................................345 B.1 CONNECTORS.......................................................................347 Connector Locations..............................................................347 B.2 WIRING DIAGRAMS..................................................................349 Wiring Diagram Information.......................................................349 2009 Sportster Wiring Diagrams...................................................350 C. APPENDIX C CONVERSIONS................................................................389 C.1 METRIC CONVERSION................................................................391 Conversion Table.................................................................391 C.2 FLUID CONVERSIONS................................................................392 United States System.............................................................392 Metric System....................................................................392 British Imperial System..........................................................392 C.3 TORQUE CONVERSIONS...............................................................393 United States System.............................................................393 Metric System....................................................................393 D. APPENDIX D GLOSSARY...................................................................395 D.1 GLOSSARY.........................................................................397 Acronyms and Abbreviations.......................................................397 E. APPENDIX E TSM/TSSM (JAPAN/KOREA).....................................................401 E.1 TSM/TSSM (JAPAN/KOREA) OVERVIEW..................................................403 General..........................................................................403 Troubleshooting..................................................................403 E.2 TSM/TSSM FEATURES................................................................404 Turn Signal Functions............................................................404 Bank Angle Function..............................................................404 Clutch/Neutral Interlock Functions...............................................404 Security Alarm and Immobilization Functions......................................404 E.3 VEHICLE DELIVERY.................................................................406 General..........................................................................406 Configuring A TSSM...............................................................406 Sidecar Configuration............................................................406 Power Disruption and Configuring.................................................406 Key Fob Assignment: TSSM.........................................................406 Pin Entry: TSSM..................................................................407 Changing the Pin: TSSM...........................................................409 E.4 TURN SIGNAL FUNCTIONS............................................................410 General..........................................................................410 Automatic Cancellation...........................................................410 Manual Cancellation..............................................................410 Four-Way Flashing................................................................410 Diagnostics Mode.................................................................410 E.5 BANK ANGLE FUNCTION..............................................................411 General..........................................................................411 Operation........................................................................411 E.6 SECURITY SYSTEM FUNCTIONS (TSSM ONLY)............................................412 General..........................................................................412 Alarm Sensitivity: TSSM..........................................................412 Auto-Arming Function: TSSM.......................................................413 Storage Mode: TSSM...............................................................414 E.7 ARMING/DISARMING (TSSM ONLY).....................................................415 General..........................................................................415 Security Lamp....................................................................415 Using Key FOB: TSSM..............................................................415 Using the Pin....................................................................415 E.8 DIAGNOSTIC TROUBLE CODES (DTC)...................................................417 TSM/TSSM.........................................................................417 Code Types.......................................................................418 Retrieving Diagnostic Trouble Codes..............................................418 Multiple Diagnostic Trouble Codes................................................419 E.9 INITIAL DIAGNOSTIC CHECK: TSM/TSSM...............................................420 General..........................................................................420 Initial Diagnostics..............................................................420 E.10 ODOMETER SELF-DIAGNOSTICS.......................................................428 General..........................................................................428 Diagnostics......................................................................428 E.11 BREAKOUT BOX: TSM/TSSM..........................................................430 General..........................................................................430 Installation.....................................................................430 Removal..........................................................................431 E.12 FAILS TO DISARM (TSSM ONLY).....................................................432 General..........................................................................432 Diagnostics......................................................................432 E.13 TURN SIGNAL ERRORS: B1121, B1122, B1141.........................................435 General..........................................................................435 Diagnostics......................................................................435 E.14 DTC B0563.......................................................................448 General..........................................................................448 Diagnostics......................................................................448 E.15 DTC B1131, B1132................................................................449 General..........................................................................449 Diagnostics......................................................................449 E.16 DTC B1134.......................................................................452 General..........................................................................452 Diagnostics......................................................................452 E.17 DTC B1135.......................................................................455 General..........................................................................455 E.18 DTC B1154, B1155................................................................456 General..........................................................................456 Diagnostic Notes.................................................................456 E.19 DTC U1016, U1255................................................................460 General..........................................................................460 Diagnostics......................................................................460 E.20 DTC U1300, U1301 OR BUS ER......................................................465 General..........................................................................465 Diagnostics......................................................................465 E.21 TSM/TSSM: PASSWORD LEARN........................................................466 General..........................................................................466 Password Learning................................................................466 E.22 TSSM MAINTENANCE................................................................467 General..........................................................................467 Key FOB..........................................................................467 Siren (If Installed).............................................................467 TOOLS....................................................................................469 TORQUE VALUES............................................................................473 INDEX....................................................................................475
2009 HARLEY-DAVIDSON SPORTSTER ELECTRICAL DIAGNOSTIC MANUAL – PDF DOWNLOAD:
PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
S.V
