Differences

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--- techtalk:evo:engctl03 [2020/12/27 14:47]
ixl2relax [IAC - Idle Air Control]
+++ techtalk:evo:engctl03 [2022/05/29 02:06]
ixl2relax [VSS - Vehicle Speed Sensor]
@@ Line 29: / Line 29: @@
 The ECM has protection against transient voltages, continuous reverse voltage protection, and damage due to jump starts. It is fully enclosed to protect it from vibration, dust, water or oil.
-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 32-2 teeth on the left side flywheel (two teeth are missing to establish a reference point).
+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 32minu2 teeth on the left side flywheel (two teeth are missing to establish a reference 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.
@@ Line 108: / Line 108: @@
 \\
-==== Cam Position Sensor ====
+==== CPS - Cam Position Sensor ====
 **1986-1997 All Models & 1998-2003 'S' Models**\\
-These models use a Cam Position Sensor Plate that is separate from the Ignition Control Module (ICM).\\
+These models use a Cam Position Sensor (CPS) Plate that is separate from the Ignition Control Module (ICM).\\
 The Cam Sensor is a Hall-effect device mounted on the Cam Sensor Plate. It is used in conjunction with a rotor 'cup' mounted to the end of the camshaft. As the cup rotates, it passes through the Cam Sensor. Slots in the cup walls are 'timed' to the engine, allowing the cam sensor to indicate to the ICM the position of the cam shaft, and therefore, the position of the crankshaft. This information is used to time the firing of the spark plugs.
-The Cam Sensor connects thru the main wire harness to the Ignition Control Module. It uses a 3-pin connector, known as 14A/B. It is located under the engine (left side near the kick stand). The 14A (plug) comes from the Cam Sensor Unit - the 14B (socket) is on the main harness and goes to the ICM.
+The CPS connects thru the main wire harness to the ICM. It uses a 3-pin connector, known as 14A/B. It is located under the engine (left side near the kick stand). The 14A (plug) comes from the CPS Unit - the 14B (socket) is on the main harness and goes to the ICM.
 The Cam Sensor Plate is used to set the base timing of the engine, from which the ICM will advance or retard the spark according to its determined needs. See the [[techtalk:evo:engctl01#ignition_timing|Ignition Timing]] information in the Sportsterpedia.
-(You can test fire the ICM from this connector: [[techtalk:evo:engctl01#manually_trigger_the_ignition_control_module_for_testing_spark|See Here]].)
+The 1980-1993 models use CPS P/N 32400-80B (current superceding P/N) and the 1994-1997 (and 1200S models, 1998-2003) use CPS P/N 32400-94A (current superceding P/N). (You can test fire the ICM from this connector: [[techtalk:evo:engctl01#manually_trigger_the_ignition_control_module_for_testing_spark|See Here]].)
-{{techtalk:evo:engctl:camsensorconnpins-evo1.jpg|}}((Illustration created by IXL2Relax at the XLForum)) {{techtalk:evo:engctl:camsensorconnpins-evo2.jpg|}}((Illustration created by IXL2Relax at the XLForum))\\
 On Connector 14B (3-pins), the wires function as follows:
    * Pin(A) Red/White - 12v Power from ICM to Cam Sensor - 5v power for 1998-2003 'S' Models (( IXL2Relax at XLForum.net ))
    * Pin(B) Green/White - Rotor Signal from Cam Sensor to ICM
    * Pin(C) Black/White - Ground from ICM to Cam Sensor
+These diagrams show the CPS mating connector on the Main Harness:\\
+{{techtalk:evo:engctl:camsensorconnpins-evo1.jpg|}}((Illustration created by IXL2Relax at the XLForum)) {{techtalk:evo:engctl:camsensorconnpins-evo2.jpg|}}((Illustration created by IXL2Relax at the XLForum))\\
 (Note: the 1998-2003 Sport model uses the same Cam Sensor & Connector as the 1994-1997 models. The slotted rotor cup is different on the Sport models, having additional slots to allow for the single-fire ignition. Note also, with the new ICM module and the addition of a MAP Sensor, the power to the CMP Sensor is 5v (also to the MAP Sensor) for the 1998-2003 'S' models.)
@@ Line 136: / Line 138: @@
 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.
-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.)
+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 for the module.)
 |  {{: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  |
@@ Line 176: / Line 178: @@
 ** RESULT **\\
-If any test fails - remove the CKP sensor from engine, clean any debri from sensor, reinstall properly - Recheck your results - If the unit still fails (especially if no voltage), replace the CKP.\\
+If any test fails - remove the CKP sensor from engine, clean any debris from sensor, reinstall properly - Recheck your results - If the unit still fails (especially if no voltage), replace the CKP.\\
 {{ :techtalk:evo:engctl:ckp-32707-01c.jpg?200|}}
@@ Line 250: / Line 252: @@
 The fuel injectors (see pic above) are electrical solenoids (switch valves for liquid) that allow the flow of pressurized fuel from the electric fuel pump. The injectors spray fuel (like a hose nozzle) into the intake manifold air tract.
-The injection time (therefore, fuel amount) is a matter of how long (in milliseconds) the injector solenoid is active. This is a very small time period.
+The injection time (therefore, fuel amount) is a matter of how long (in milliseconds) the injector solenoid is active. This is a very small time period controlled by the ECM. The injectors are timed by the ECM to inject fuel a the proper time during the engine cycle. The injectors are triggered individually for the front & rear cylinder intake.
+When the engine is operating, the ECM controls the path to ground for the injectors (solenoids) to trigger the injection of the appropriate amount of fuel (to meet the Air-Fuel-Ratio goals) at the proper time. Power is supplied to the injectors thru the system relay so that they can be turned off with the rest of the ignition components (the fuel pump and ignition coil).
+^ DTCode ^ Trouble Condition |
+| P0261 | Front Injector open/low |
+| P0262 | Front Injector high |
+| P0263 | Rear Injector open/low |
+| P0264 | Rear Injector high |
-The injectors are timed by the ECM to the engine cycle and are triggered individually. Power is supplied to the injectors thru the system relay so that they can be turned off with the rest of the ignition components - the fuel pump and ignition coil.
+Test the injector solenoid by measuring resistance between the two connector pins. It should read 10.0 - 25.0 ohms.
-When the engine is operating, the ECM controls the path to ground for the injectors (solenoids) to trigger the injection of the appropriate amount of fuel (to meet the Air-Fuel-Ratio goals) at the proper time.
+To test the injectors for leaking fuel into the manifold:
+  * Remove the air cleaner
+  * With the throttle wide open, turn key ON for 2 seconds and then OFF for 2 seconds five consecutive times.
+  * Replace the fuel injector if there is any evidence of raw fuel in the bores.
 To help in verifying the injectors are being triggered, since the pulses are very small, there are diagnostic sets called Noid Testers to help show that a pulse has been received. Tester sets come with various connectors to allow the Noid Tester to be used on fuel injectors, intake air controls and even on coils.
@@ Line 378: / Line 391: @@
 This code may occur under various conditions and along with other DTCs. Resolve the other codes first before addressing the P0505.
-A P0505 DTC is set if, during an Idle Condition, the idle RPM is 200 above the programmed idle speed and the IAC motor is at a '0' position count (fully closed) for greater than 5 seconds. Some failures that might create this condition are:
+A P0505 DTC is set if, during an Idle Condition, the idle RPM is 200 above the programmed idle speed and the IAC motor is at a '0' position count (fully closed) for greater than 5 seconds or if the idle RPM is 200 below the programmed idle speed and the IAC motor is at its maximum position count (fully open) for greater than 5 seconds. Some failures that might create this condition are:
   * if an intake manifold air leak is large enough to cause the IAC to reset to '0' position while the ECM is attempting to control the idle speed.
   * if the fuel injectors are leaking extra fuel into the manifold bypassing the EFI control and raising the engine RPM.
   * if there is a defective TPS reporting an incorrect throttle plate position.
+  * if there is a defective ETS reporting an incorrect engine temperature.
 Other conditions that might set a P0505 code are related to engine misfires, a vacuum leak, contaminated fuel or wet sumping.
@@ Line 469: / Line 483: @@
 Check [[http://xlforum.net/forums/showthread.php?t=800778|this XLForum thread]] for a 'FIX' to erratic speedo operation for 1995-2003 models.
-**(2004-2013)** (2004-2012 = P/N 74402-04A - 2013 = P/N 74402-05B)\\
+**(2004-2013)** (2004 only = P/N 74402-04A - 2005-2013 = P/N 74402-05B)\\
 The VSS is a 5v-based hall-effect sensor. The 5v power source for the sensor (BLACK/RED wire of the twisted pair) comes from the ICM/ECM and the pulsing output from the sensor (BLACK/BLUE wire of the twisted pair) goes to the ICM/ECM for processing. The ground connection (BLACK wire) is part of the main harness.
@@ Line 482: / Line 496: @@
 If you are able to observe the above voltage variations from the sensor, but the speedometer is still erratic or otherwise malfunctioning, be sure to test all the wiring between the sensor and the ICM/ECM as well as the Serial Data Bus connection. As a last resort, replacement of the VSS or the speedometer may be in order.
+(The 74402-04A sensor has a long attached cable while the later 74402-05B has a connector built on the sensor with the wiring being part of the main harness.)
 **(2014-on)** (P/N 74402-05B)\\
-The VSS sensor is the same 5v-based hall-effect sensor as 2013. The ECM (Engine Control Module) handles all the processing of the signals and sends data to the speedometer over the new CANbus communications connection.
+The VSS sensor is the same 5v-based hall-effect sensor as for 2013 models and the ECM (Engine Control Module) handles all the processing of the signals. The speedometer now utilizes the new CANbus to send the calculated data to the speedometer.
 Note this very informative [[http://xlforum.net/forums/showthread.php?t=1883180|__XLForum Thread__]] regarding the VSS.
@@ Line 493: / Line 508: @@
 ==== BAS - Bank Angle Sensor ====
-{{ techtalk:evo:engctl:98-03-b-bankanglesensor.jpg?100|Image from Shu XLForum threadid=619957}} {{ techtalk:evo:engctl:98-03-a-bankanglesensor.jpg?100|}} The Bank Angle Sensor, as an individual, external component, was used on Sportsters from 1998 to 2003. Using an internal v-shaped channel and steel ball, it is intended to kill the ignition if the bike lean angle exceeded 55 degrees, such as in an accident or tip over. It is attached, upright, to the side of the battery box, toward the rear, using a locating pin and one screw. It has a 3-wire connector.
+{{techtalk:evo:engctl:98-03-a-bankanglesensor.jpg?150|}}{{techtalk:evo:engctl:98-03-b-bankanglesensor.jpg?150|}} ((Image from Shu XLForum threadid=619957)) {{:techtalk:evo:engctl:98-03-c-bankanglesensor-internal.jpg?150|}}((pic from Diogenes415 of the XLForum http://xlforum.net/forums/showthread.php?t=2079288))\\
+The Bank Angle Sensor, as an individual, external component, was used on Sportsters from 1998 to 2003. Using an internal v-shaped channel and steel ball, it is intended to kill the ignition if the bike lean angle exceeded 55 degrees, such as in an accident or tip over. It is attached upright, on those models, to the side of the battery box, toward the rear, using a locating pin and one screw. It has a 3-wire connector.
 To reset the ignition function after the BAS has been triggered, turn off the keyswitch, set the bike upright, turn the keyswitch on.

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