Differences

This shows you the differences between two versions of the page.

Link to this comparison view

Both sides previous revision Previous revision
Next revision
Previous revision
techtalk:evo:engctl03 [2020/01/24 21:56]
ixl2relax [IAC - Idle Air Control]
techtalk:evo:engctl03 [2020/09/15 05:36] (current)
ixl2relax [Sensor Power - 5 volts]
Line 10: Line 10:
 **(2007-2013)** The engine management system is designed around the Engine Control Module (ECM) along with a number of sensors and controls, such as the following: **(2007-2013)** The engine management system is designed around the Engine Control Module (ECM) along with a number of sensors and controls, such as the following:
   * CKP - Crankshaft Position (CKP) Sensor   * CKP - Crankshaft Position (CKP) Sensor
 +  * MAP - Manifold Absolute Pressure (MAP) Sensor
   * TMAP - Combined Intake Air Temperature (IAT) & Manifold Absolute Pressure (MAP) Sensor   * TMAP - Combined Intake Air Temperature (IAT) & Manifold Absolute Pressure (MAP) Sensor
   * TPS - Throttle Position Sensor   * TPS - Throttle Position Sensor
Line 82: Line 83:
 | Hot Idle = Engine temp 260° at 1000 RPM with stock exhaust ||||| | Hot Idle = Engine temp 260° at 1000 RPM with stock exhaust |||||
 | * Not included in original table - taken from EDM section 4.21 |||||  | * Not included in original table - taken from EDM section 4.21 ||||| 
 +
 +
 +\\
 +
 +
 +==== Sensor Power - 5 volts ====
 +
 +Starting with the 1998 Sport Model, some of the sensors required a 5-volt power supply. This was accomplished by the Ignition Control Module (or later, the Engine Control Module) converting the normal 12-volt system power to a 5-volt power level that is supplied to some sensors. The table below shows how to track down the 5-volt connections & the potential ground connections that might create issues or cause Diagnostic Codes to be set. If a problem is indicated, you can check the information related to the individual sensors further down the page. ((See discussion here: http://​xlforum.net/​forums/​showthread.php?​p=5604118))
 +
 +
 +^1998-2003 Sport Model Only |
 +| Start at the ICM (RED/White wire) on Gray Connector Pin-1\\ This is +5v Output from the ICM as Sensor Power Supply.\\ \\ Check for +5v at:\\ Cam Position Sensor (RED/White wire) on Connector 14B Pin-A\\ MAP Sensor (RED/White wire) - Connector 80B Pin-C\\ \\ Check ICM Gray Connector Pin-8 for Sensor Ground\\ -- Be sure it is equal to Battery Negative\\ Check ICM Black Connector Pin-2&​11 for ICM Ground\\ Check ICM Black Connector Pin-1 for Switched 12v Power (RUN/STOP SWITCH) |
 +^ 2004-2006 (Serial Data Bus) |
 +| Start at the ICM (RED/White wire) on Connector Pin-3\\ This is +5v Output from the ICM as Sensor Power Supply.\\ \\ Check for +5v at:\\ VSS (BLACK/Red wire) on Connector 65B Pin-1 (might be RED/White wire)\\ MAP Sensor (RED/White wire) - Connector 80B Pin-C\\ \\ Check ICM Connector Pin-4 for Sensor Ground\\ -- Be sure it is equal to Battery Negative\\ Check ICM Connector Pin-5 for ICM Ground\\ Check ICM Connector Pin-1 for Switched 12v Power (RUN/STOP SWITCH)\\ Check ICM Connector Pin-2 for 12v Battery Power |
 +^ 2007-2013 (Serial Data Bus) |
 +| Start at the ECM (RED/White wire) on Connector Pin-14\\ This is +5v Output from the ECM as Sensor Power Supply to:\\ Engine Harness (R/W wire) on Connector 145A/B Pin-5\\ \\ Check for +5v at:\\ VSS (R/W wire) on Connector 65B Pin-A\\ TMAP Sensor (R/W wire) - Connector 80B Pin-C\\ TPS Sensor (R/W wire) - Connector 88B Pin-B\\ Jiffy Stand (R/W wire) on Connector 133B Pin-1\\ -- Even if not HDI model, this connector can be an issue\\ \\ Check ECM Connector Pin-26 for Sensor Ground\\ -- Be sure it is equal to Battery Negative\\ Check ECM Connector Pin-10 & Pin-28 for ECM Ground\\ Check ECM Connector Pin-13 for Switched 12v Power\\ Check ECM Connector Pin-31 for 12v Battery Power |
 +^ 2014-later (CANbus) |
 +| Start at the ECM (RED/White wire) on ECM Connector-2 Pin-9\\ This is +5v Output from the ECM as Sensor Power Supply to:\\ Engine Harness (R/W wire) on Connector 145A/B Pin-8\\ \\ Check for +5v at:\\ VSS (R/W wire) on Connector 65B Pin-A\\ TMAP Sensor (R/W wire) - Connector 80B Pin-3\\ TPS Sensor (R/W wire) - Connector 88B Pin-B\\ Jiffy Stand (R/W wire) on Connector 133B Pin-1\\ -- Even if not HDI model, this connector can be an issue\\ \\ Check ECM Connector 1&2 Pin-10 as both Sensor Ground & ECM Ground\\ -- Be sure it is equal to Battery Negative\\ Check ECM Connector-2 Pin-16 for Switched 12v Power\\ Check ECM Connector-2 Pin-18 for 12v Battery Power |
 +
 +
 +
  
  
Line 114: Line 136:
 When the engine is rotated, the slotted cup rotor (in the '​nosecone'​) on the end of the camshaft will pass thru the cam sensor creating an alternating output on Pin(B). Since the sensor has a 12v power source, the measured voltage is predicted to be from below 2v to above 10v, alternating. When the engine is rotated, the slotted cup rotor (in the '​nosecone'​) on the end of the camshaft will pass thru the cam sensor creating an alternating output on Pin(B). Since the sensor has a 12v power source, the measured voltage is predicted to be from below 2v to above 10v, alternating.
  
-|  {{:​techtalk:​evo:​engctl:​camsensorplate.jpg?​300|}}\\ 1986-1993 All Models - 32400-80B Sensor Plate\\ 1994-1997 All Models - 32400-94A Sensor Plate  |  {{:common:space100x5px.jpg|}} ​ |  {{:​techtalk:​evo:​engctl:​camsensorcup.jpg?​250|}}\\ \\ 32402-83 Rotor Cup\\ Used in 1986-1997 All Models\\ Also 1998-2003 Models except 1200S  |  {{:​techtalk:​evo:​engctl:​camsensorcup-1200s.jpg?​250|}}((Pic - Steelworker http://​xlforum.net/​forums/​showthread.php?​t=1382357))\\ 1998-2003 1200S - 32422-98 Rotor Cup  |+Being in an enclosed area (nosecone) of the engine, the Cam Sensor is subject to high temperatures. The potting material is subject to melting and may cause erratic timing. (This location for the Ignition Module on the 1998-2003 models also created high heat failure issues.) 
 + 
 +|  {{:​techtalk:​evo:​engctl:​camsensorplate.jpg?​300|}}\\ 1986-1993 All Models - 32400-80B Sensor Plate\\ 1994-1997 All Models - 32400-94A Sensor Plate  |  {{:techtalk:evo:​engctl:​camsensorplate-97-melted.jpg?200|}}((Pic from BowOnly at http://​xlforum.net/​forums/​showthread.php?​t=2076330)) \\ 1997 Cam Position Sensor Melted ​ 
 +|  {{:​techtalk:​evo:​engctl:​camsensorcup.jpg?​250|}}\\ \\ 32402-83 Rotor Cup\\ Used in 1986-1997 All Models\\ Also 1998-2003 Models except 1200S  |  {{:​techtalk:​evo:​engctl:​camsensorcup-1200s.jpg?​250|}}((Pic - Steelworker http://​xlforum.net/​forums/​showthread.php?​t=1382357))\\ 1998-2003 1200S - 32422-98 Rotor Cup  |
  
 \\ \\
Line 124: Line 149:
 The new ICM/Cam Sensor Plate still operated the same way - There was a sensor on the back side of the plate - The sensor monitored a rotating cup mounted on the end of the cam - It had windows cut into the cup to create the spark timing for the ICM. The new ICM/Cam Sensor Plate still operated the same way - There was a sensor on the back side of the plate - The sensor monitored a rotating cup mounted on the end of the cam - It had windows cut into the cup to create the spark timing for the ICM.
  
-This design was problematic due to the high-heat location of the electronics. Due to the high failure rate, the MoCo did not continue the design nor a supply of stock replacement units. The only source for replacing a failed 1998-2003 nosecone ICM has been the aftermarket.+This design was problematic due to the high-heat location of the electronics. Due to the high failure rate, the MoCo did not continue the design nor a supply of stock replacement units. The only source for replacing a failed 1998-2003 nosecone ICM has been the aftermarket. ​([[techtalk:​ref:​engctl01#​ultima_-_nosecone_ignition|See the REF section regarding the Ultima Ignition Module.]])
  
 {{:​techtalk:​evo:​engctl:​camsensorplate-icm-98-03-a.jpg?​300|}}{{common:​space100x5px.jpg|}}{{:​techtalk:​evo:​engctl:​camsensorplate-icm-98-03-b.jpg?​300|}} {{:​techtalk:​evo:​engctl:​camsensorplate-icm-98-03-a.jpg?​300|}}{{common:​space100x5px.jpg|}}{{:​techtalk:​evo:​engctl:​camsensorplate-icm-98-03-b.jpg?​300|}}
Line 245: Line 270:
  
 The TMAP sensor provides information to the ECM upon which the ECM alters the timing of the spark and the injection of fuel based on the current vacuum conditions in the manifold. By altering the spark timing and fuel, better combustion occurs in varied situations. The TMAP sensor provides information to the ECM upon which the ECM alters the timing of the spark and the injection of fuel based on the current vacuum conditions in the manifold. By altering the spark timing and fuel, better combustion occurs in varied situations.
 +
 +**The MAP Sensor** \\
 +
 +The MAP on 1998-2003 Sport models only and 2004-2006 Models Sportsters is a stand alone unit. Function and testing is the same as in 2007 models below. \\
  
 **The MAP Sensor in the TMAP Sensor** **The MAP Sensor in the TMAP Sensor**
  
-  * The MAP monitors the changing vacuum (pressure) in the manifold that occurs as you ride, change speeds and vary the engine load via the throttle position. It is temperature compensated and uses a complex algorithm to help offset the pulsating wobble effect of the HD V twin's assymetrical firing setup.+  * The MAP on monitors the changing vacuum (pressure) in the manifold that occurs as you ride, change speeds and vary the engine load via the throttle position. It is temperature compensated and uses a complex algorithm to help offset the pulsating wobble effect of the HD V twin's assymetrical firing setup.
  
   * It is a very major component of the final speed density calculation that ulimately determines the injector'​s pulse width required to sustain the best A/F ratio at any given time.   * It is a very major component of the final speed density calculation that ulimately determines the injector'​s pulse width required to sustain the best A/F ratio at any given time.
Line 255: Line 284:
  
 ^ DTCode ^ Trouble Indicated | ^ DTCode ^ Trouble Indicated |
 +|1998-2003 S-Models ((1998 HD Sportster FSM pg 7-33))||
 +| Code 12 | MAP Out Of Range or Fluctuates Faster Than Normal |
 +|2004-Up Models||
 +| P0106 | MAP Sensor Rate-Of-Change Error|
 | P0107 | Map Sensor Open/Low |  | P0107 | Map Sensor Open/Low | 
 | P0108 | Map Sensor High |  | P0108 | Map Sensor High | 
  
 +  * The P0106 will set if the MAP sensor signal fluctuates faster than normal operation. ((2005 Electrical Diagnostics Manual pg 4-35))
   * The P0107 indicates that the reading was either absent or fell below the minimum range for some period of time. If not calibrated correctly or working properly the ECM will assign a canned value and use the other inputs to adjust the A/F ratio. It will greatly affect your richness/​leaness if it is skewed or not registering accurate readings.   * The P0107 indicates that the reading was either absent or fell below the minimum range for some period of time. If not calibrated correctly or working properly the ECM will assign a canned value and use the other inputs to adjust the A/F ratio. It will greatly affect your richness/​leaness if it is skewed or not registering accurate readings.
  
-**TESTING the MAP SENSOR ​OPERATION** ((http://​xlforum.net/​forums/​showthread.php?​t=278587))+**TESTING the MAP SENSOR** ​ ((2005 HD Sportster Electrical Diagnostics Manual pg 4-35)) \\ 
 +The signal varies in accordance with engine vacuum and atmospheric barometric pressureChanges in barometric pressure are influenced by weather and altitude\\ 
 + 
 +**Bypassing the MAP for Testing**: ((1998 HD Sportster FSM pg 7-33)) \\ 
 +  * With the MAP sensor disconnected,​ the ignition control module should recognize a low voltage. If low voltage is observed, the ignition control module and harness are not at fault. 
 +  *You can gently place a jumper wire across the MAP Sensor connector power and feed terminals. With the jumper in place, the ignition control module should recognize a high voltage.
  
-  ​* This requires a digital multi-meter set to the 0 - 20 volt dc setting. +**MAP Output Voltage**: \\ 
-  * Typically most MAP sensors are simply a set of resistive strain guages mounted on a suitable substrate and forming a bridge circuit.+  ​* This requires a digital multi-meter set to the 0 - 20 volt dc setting, MAP connected inline (and optional Mityvac or other hand held vacuum pump). \\ See also [[techtalk:​ref:​tools160#​mityvac_vacuum_pump_function_and_usage|MityVac Vacuum Pump Function and Usage]] in the Sportsterpedia\\ 
 +  * Typically most MAP sensors are simply a set of resistive strain guages mounted on a suitable substrate and forming a bridge circuit. ​((Fe Head of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=278587&​page=3))
   * With the ignition switch turned to ON, test the leads as follows:   * With the ignition switch turned to ON, test the leads as follows:
-  - (Input Power) Probe the R/W wire ((Hippysmack)) ​lead and verify it has +5 volts. +  - (Input Power) Probe the R/W wire lead and verify it has +5 volts. 
-  - (Signal Out) Remove the hose from intake manifold and if needed add an extension to it so you can easily apply a vacuum with with a vacuum ​gauge or your mouth. +  - (Signal Out) Remove the hose from intake manifold and if needed add an extension to it so you can easily apply a vacuum with the vacuum ​pump or your mouth. 
-  - Draw as much vacuum ​as you can and seal it (with your tongue) ​while probing the V/W wire ((Hippysmack)) to read between 1.5-3.0 volts.((original value was 3.5 to 4.5 volts in thread footnoted - but 2005 EDM says higher ​vacuum ​= lower voltage)+  - Draw up some vacuum while probing the V/W wire. The signal voltage should lower as the vacuum is applied ​(read between 1.5-3.0 volts)\\ **Caution**:​ Do not over-pump ​(or otherwise create too much vacuum) ​during MAP sensor output check as sensor damage may result. 
-  - Then release the vacuum slowly and see the voltage increase((footnoted thread says voltage drops - but 2005 EDM says less vacuum = higher voltage)) as you do, confirming the lead signal functions+  - Then release the vacuum slowly and see the voltage increase, confirming the output ​signal functions ​properly.
-  * This will confirm the functionality of the MAP sensor.+
   * This signal is the one that the ECM uses to assess the state of load on the engine relative to the Throttle Position Sensor and the tachometer reading.   * This signal is the one that the ECM uses to assess the state of load on the engine relative to the Throttle Position Sensor and the tachometer reading.
  
Line 515: Line 554:
 The EFI model Sportsters (2007-later) included an electric fuel pump with a Low Fuel Sensor. The sensor uses a float with a magnet to trigger the sensor when the fuel is low. Some owners found the low fuel indicator to be erratic and the consensus was that the float (white) that triggers the sensor was getting stuck. Eventually, HD released a corrected replacement Low Fuel Sensor used on all later models (75302-07B uses black float). The EFI model Sportsters (2007-later) included an electric fuel pump with a Low Fuel Sensor. The sensor uses a float with a magnet to trigger the sensor when the fuel is low. Some owners found the low fuel indicator to be erratic and the consensus was that the float (white) that triggers the sensor was getting stuck. Eventually, HD released a corrected replacement Low Fuel Sensor used on all later models (75302-07B uses black float).
  
-In the speedometer,​ there is a Low Fuel Indicator that responds to the Low Fuel Sensor. This is accomplished using a Fuel Sender Resistor Assembly, consisting of two resistors to allow altering the voltage on the connection to the speedometer. ​It seems that in the original version ​(72545-07) ​there were two 2K ohm resistors, while in the later version (72545-08 used on all later models) there was one 8K ohm resistor and one 2K ohm resistor.+In the speedometer,​ there is a Low Fuel Indicator that responds to the Low Fuel Sensor. This is accomplished using a Fuel Sender Resistor Assembly, consisting of two resistors to allow altering the voltage on the connection to the speedometer. ​The 2007 models came with a resistor pack (72545-07) ​that used two 240 ohm resistors, while in the later version (72545-08 used on all later models) there was one 8K ohm resistor and one 2K ohm resistor
 + 
 +The speedometer sends power to the Fuel Sender Resistor Assy (thru a pull up resistor) while monitoring the same line for a change in voltage level.
  
-The speedometer sends power to the Fuel Sender Resistor Assy (thru a pull up resistor) while monitoring the same line for a change in voltage level. When the fuel is above the Low Level, the resistor assembly presents a 10K resistance above ground, thus keeping the supplied voltage at a high level. When the fuel reaches the Low Level, the switch in the fuel pump assembly closes it's contacts and effectively shorts across the 8K resistor portion of the Fuel Sender Resistor Assy. There remains the 2K resistor to limit current draw, but the effect is to lower the voltage on the output line to a level which the speedometer interprets as a Low Fuel Level condition.+For 2008-later, when the fuel is above the Low Level, the resistor assembly presents a 10K resistance above ground, thus keeping the supplied voltage at a high level. When the fuel reaches the Low Level, the switch in the fuel pump assembly closes it's contacts and effectively shorts across the 8K resistor portion of the Fuel Sender Resistor Assy. The 2K resistor ​remains in the circuit ​to limit current draw, but the effect is to lower the voltage on the output line to a level which the speedometer interprets as a Low Fuel Level condition.
  
 The amount of fuel remaining (2013 models) when the Low Fuel Light activates will vary by model:\\ The amount of fuel remaining (2013 models) when the Low Fuel Light activates will vary by model:\\