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2008 Buell 1125R Electrical Diagnostic Manual 99949-08Y

1. Wi CE atase 145A 1 9 9 1108 VERRE gt d 9 N 10A Chassis Ground Engine mq Wiring Diagram Stop Cluster a Switch ECM gt c i T T 9 23 Lights 12 Accessory 10A 15A 10A 17 6 Fuse T 4 IS 1 Block Relay Block A a Vehicle Start o A Spoed 658 65 Att708 41218 24 1 1170 1 Y 248 Front Rar Brake Brake Switch Switch z z TI 1 458 1 A 93B 1 45 1 9 128B 128A l lee Horn m ail Stop Plate Lam Swich 3 5 2 248 38A fs 2jYl TEL l Starter sod Solenoid 5 8 m m x x LI m 5 5 Left Left Right H Right Low Marker Marker Low Turn Signal Headlamp Flash To Lamp Lamp H 8 Beam Switch Switch Pass Head Head Switch lamp lamp B 6 2008 Buell 1125R Appendix B Wiring Figure B 3 Ignition and Accessory Power 2008 1125R Model 00249
2. Key Relay Ignition Relay Auxiliary Relay H O R 17 5 87 2 2 R BK 14 5 87 GY a 4 5 87 i 13 4 gt 3 4 B AI gt gt R 15 3 30 GY O 5 30 te 41 1 1 7B rd dl Gv 20 1 86 978 1 11 1215 1 1 1 215A 62 Relay Block J oa ao Ignition 1 Cooling Cooling Power Ax Fan Right Fan Left Wiring 12V Auxiliary Diagram Connector Front Front Ignition Fuel Coil Injector gt 1 Data Link 23 3 8 3 1 844 4 3 1 AA 2 5 Yare 1 Y 848 5 z GY Start Switch T 1 1 1 1458 gt gt A 83RB 1 85B gt 11788 83RA 1 85A 2 178 Rear Active Ignition Fuel Intake Coil Injector Solenoid Figure B 2 Battery Power Distribution 2008 1125R Model 2008 Buell 1125R Appendix B Wiring B 5 Relay Block em00240 Ignition Lock Off Lock Off Switch On e e gt x 9 m u 1 2 4 4 2 4 338 x 9 g Power m r m Wiring Diagram
3. 00274 Vehicle Bank Throttle Absolute Barometric Speed Angle Position Pressure Fuel BARO Side Sensor Sensor TP MAP Pressure Pressure Stand VSS BAS Sensor Sensor Sensor Sensor Sensor B 65 4 5 6 4 1 2 3 88 1_2 80 4 2278 1 2 228 1 2 3334 A B 658 4 s 1348 1 2 888 1 2 s Y 80B aA 227 1 2 s YI228B 2 s Y 133B JT Im mw Tn Ww T n Ww gt gt gt gt 9 9 Y m 5 ev 8 gt 2 m gt t z m 2 m m e 2 iL I m a _ _ 101 01 1 iAUIogEESoO 5 16 1458 S TVA i DLC E z 5 2 8 2 Q a E 5 Z 2 1 1L m n 13 19 25 17 4 24 27 6 10 28 5 34 11 13 19 25 17 4 24 27 6 10 28 5 N 11A 5 g 7 8 5 E 3 5 5 GY 8 H 8 s B 2 3 5 2 5 2 5 5 8 5 gt Figure 6 12 Bank Angle Sensor 6 28 2008 Buell 1125R Engine Management P1151 and P1152 Part 1 of 2 Is BAS connected Disconnect BAS connector 134 Measure voltage on 1348 between terminal 5 LGN GY and terminal 6 BK W What is the voltage 4 75 5 25 Volts Measure volta
4. 1378 m Brake Horn Fuse oe R amp K Ignition Switch Ignition Relay Auxiliary GY Sensor 4 Relay Start Switch ae Fuel Pump Fuse 65A 658 ZZ a Vehicle 22 170B 170A O GY B Fuel Speed C E BKW ree Sensor B BEW n D es egi 5 d 5 og 66 868 Bank Angle pe ew i nun 5 1388 458115164 19 18 13 780 Data Link 145A 15 15 Low Fuel Instrument Connector FE IN 54 19 18 13 780 Lamp Cluster Sensor A 398 39 90 908 Ene c g lt lt Engine gt gt Coolant 2 2 E wi 87B 87 Tempera 1 BKW 2 lt lt BK O 1 1 Idle Air Sensor B9B EM 2 gt Control Intake Air 2 ___ _ ____ AX BE GN w 3 3 1 LGN Y BN R 4 4 2 EBKW 858 85 88 88 lt lt 22 GY Rear Fuel Postion 212600 tink z C HH TP ERW 4 84 E i l 22B la GY 1 1 gt WY 2 2 Injector Barometric 1 R W 91 BK pes 8388 83RA lt 80 808 1 1 Manifold __ gt gt BK 2 2 Ignition Absolute 1111 ERW GY 313 Coil Pressure 2
5. 00274 Vehicle Bank Throttle Absolute Barometric Speed Angle Position Pressure Fuel BARO Side Sensor Sensor TP MAP Pressure Pressure Stand VSS BAS Sensor Sensor Sensor Sensor Sensor B 65 4 5 6 4 1 2 3 88 1_2 80 4 2278 1 2 228 1 2 3334 A B 658 4 s 1348 1 2 888 1 2 s Y 80B aA 227 1 2 s YI228B 2 s Y 133B gt gt 2 ul u E gt 9 9 vc gt 2 m gt t z m 2 m m e 2 LL I m a _ _ 101 01 1 iAUIogEESoO 5 16 1458 S TVA i DLC E z 5 2 8 2 Q a E 5 Z 2 1 1L m n 13 19 25 17 4 24 27 6 10 28 5 34 11 13 19 25 17 4 24 27 6 10 28 5 N 11A 5 g a 5 5 5 5 5 5 GY 2 e 2 2 vo 2 5 5 5608 8 5 g 5 8 25 3 58 5 o 5 a 9 g 5 o g o 5 2 5 m 8 5 lt S o m gt Figure 6 41 Vehicle Speed Sensor 6 72 2008 Buell 1125R Engine Management DTCs P0502 and P0503 Disconnect VSS connector 65 With the ignition switch ON check the voltage between connector 65B terminals A and C Is battery voltage present Connect Speedometer Tester Part No HD 41354 with the Input Output cable sup
6. 5 Jojoefu jan Jojoefu Jen4 10014 jan4 Jejsnio vz8 828 ves 965 uj 4 E z J lt lt amp N5 38 906 06 koma je Nona d i L lt lt 2 2 857 8 vi punoi sosuag 6 6 9 81 gt a punos sz E maa XQ 9821 2 2 punoio 8 1 x8 22 L4 punoi5 5 14 105095 ZG MAg O 8912 lt E S gt or for vse z e O A 4192 92 437 z uea il oo bod Gy NS A v O A 4 9L 91 f O A O A 481 81 427 G st alla z z koma z oma st bona Query M 1
7. SYMPTOM DIAGNOSTIC PROCEDURE Check Engine Lamp Always or 2 1 INITIAL DIAGNOSTICS ative Oil Pressure Lamp Always On 4 3 OIL PRESSURE LAMP ALWAYS ON OR INOPERATIVE Oil Pressure Lamp Inoperative 4 3 OIL PRESSURE LAMP ALWAYS ON OR INOPERATIVE Turn Signal Indicators Inoperative 4 4 TURN SIGNAL INDICATOR INOPERATIVE Instrument Cluster IC Inoperative 4 5 INSTRUMENT CLUSTER INOPERATIVE Low Fuel Lamp Always On 4 6 LOW FUEL LAMP ALWAYS ON OR INOPERATIVE Low Fuel Lamp Inoperative 4 6 LOW FUEL LAMP ALWAYS ON OR INOPERATIVE 2008 Buell 1125R Instruments 4 5 FUEL LEVEL SENDER LOW HIGH OPEN B1004 B1005 4 2 DESCRIPTION AND OPERATION See Figure 4 5 The IC has a direct input from the fuel level sender The IC monitors this input and sets a DTC if the input falls out of range The IC provides battery voltage to the fuel level sender on the Y R wire The fuel level sender is a thermistor device that is cooled by fuel in the tank keeping the resistance value high As the fuel drops below the sender the thermistor is allowed to warm which lowers the resistance value The IC constantly monitors this signal and when the resistance value changes at approximately 0 8 gallons 3 0 liters of fuel is left in the tank the IC illuminates the low fuel lamp Table 4 5 Code Description Table DTC DESCRIPTION B1004 Fuel level sender low
8. lt E GND 1 Block 12 Lights Accessory 15 10 7 6 Re 5 Start 86 1 10 m o O W Relay 2 2 1 30 3 6 OW 4 mm BE 1 87 5 7 BK 2 Relay Block 62 GY BK amp 1 lt lt owg 1 1 Instrument High Beam 6 GY BK amp 1 1 Cluster Input wW 2 2 3 3 2 2 39 1398 BK 4 4 R BK BK 5 5 mm BK 6 lt E m gt Ze B B m E Rod 24 3 2 4 38B 38A I T 248 2 1 Le R BK 9 Headlamp lt lt High Low pem BE Switch A lt lt Low Nu High mA i nasel rounds In Wiring pm i Diagrams x Right Marker Lamp Left High Beam Headlamp Right High Beam Headlamp Left Low Beam Headlamp Right Low Beam Headlamp Figure 5 11 Headlamp and Marker Lamps 5 12 2008 Buell 1125R Accessories Horn Lights and Security Headlamps Inoperative Part 1 of 2 Are the low beam headlamps inoperative Are both low beam headlamps inoperative
9. Lock BE B Fuse Block _ E j 2 24 11 Battery Ignition Fu Fuse 8 18 F F l gt c Battery Ignition Relay 5 3 30 BKE 9 2 85 W BK3 1 1 86 lt lt Relay Block 62B 62A Gv m Lock Off On e gt 9 m a H B NB 1 2 3 4 JJ 1 2 4 338 5 a Right Handlebar Switch 22B 22A lt lt W BK3 R BK 4 5 gt gt R GY 1458 E Ground In Wiring LORS T Diagrams gt 91 amp gt o 4 Data Link 1 Connector 3 2 Start Switch Front Fuel Ignition Coil njector Front 2 PK GY 1 2 2 Terminating Resistor gt gt 2434 12438 5 x 66 5 vc A gt aa oc a oma I mu m m Bu B m 11B A 5 16 19 29 30 8 9 16 2433 108 15 16 19 2930 9 16 2433 10A
10. SUBJECT PAGE NO 5 2 aes 5 53 LIGHTS 9 4 5 4 SYSTEM nnnm ee ee ae 25 29 5 ACCESSORIES 5 1 DESCRIPTION AND OPERATION The auxiliary connector supplies power for accessories that may be added to the motorcycle This two terminal connector is located behind the fairing below the Instrument Cluster IC If the ECM recognizes a low battery voltage condition it will not energize the auxiliary relay and therefore the auxiliary connector will not have power COMPONENTS Auxiliary Connector See Figure 5 1 The auxiliary connector receives power when the auxiliary relay is energized The connector has a constant ground to GND1 Ignition switch 33 Instrument Cluster IC 39 Headlamp 38 Left front turn signal 31L Right front turn signal 31R Left hand controls 24 Right hand controls 22 12 V auxiliary connector X or eras Figure 5 1 Behind Fairing Connectors Auxiliary Relay See Figure 5 2 The auxiliary relay receives power from the auxiliary fuse The ECM grounds the coil side of the relay causing the relay to energize and supply power to the auxiliary connector The ECM monitors the ground circuit for an open or shorted condition and sets a code if a condition is present Refer to Table 5 1 4 1 Start relay 2 Auxiliary rel
11. 6 4 Crank Position 6 4 Engine Coolant Temperature ECT Sensor 6 4 Fuel Pressure 6 4 Intake Air Temperature IAT 6 5 Manifold Absolute Pressure MAP sensor 6 5 Neutral 6 4 02 SeriSOF1 5452 rss e br pene PS 6 5 Side Stand 6 4 Throttle Position TP 6 4 Vehicle Speed Sensor 55 6 5 Serial Data 2 12 Service i l Service i l Setup Mode Functions hae Re ee S e UA 4 2 Side Stand 6 22 Specifications Alternator 1 1 Battery 1 1 Electrical System Specifications 1 1 Fuel Pump 1 1 Fuel System 1 1 Idle Speed 1 1 Ignition Coil 5 1 1 Regulator 1 1 Relay 1 1 Spark Plug
12. A 16 2 07 A 16 Separating Pin and Socket Housings A 16 Mating Pin and Socket Housings A 16 Removing Socket A 16 Installing Socket Terminals A 16 Terminale iecore tenia erret A 16 A 8 480 METRI PACK CONNECTORS 480 Metri Pack Connector A 18 jc d ETT A 18 Separating Pin and Socket Housings A 18 Mating Pin and Socket Housings A 18 Removing Socket Terminals A 18 Installing Socket Terminals A 18 A 9 630 METRI PACK CONNECTORS 630 Metri Pack Connector A 19 Jeet M e A 19 Separating Pin and Socket Housings A 19 Mating Pin and Socket Housings A 19 Removing Socket A 19 Installing Socket A 19 A 10 SEALED SPLICE CONNECTORS Sealed Splice Connector A 20 c r A 20 Preparing Wire Lesdls ir eno ts err artes A 20 Splicing Wire Less cie rrr rores A 20 ers
13. ALPHA CODE WIRE COLOR BE Blue BK Black BN Brown GN Green GY Gray LGN Light Green O Orange PK Pink R Red TN Tan V Violet W White Y Yellow 2008 Buell 1125R Appendix B Wiring B 3 2008 11258 WIRING DIAGRAMS Wiring Diagram List Control Switches 2008 1125R Model DIAGRAM LOCATION Battery Power Distribution 2008 1125R Model Figure B 2 Ignition and Accessory Power 2008 1125R Model Figure B 3 Sensor Grounds 2008 1125R Model Figure B 4 ECM Power Grounds 2008 1125R Model Figure B 5 Chassis Grounds 2008 1125R Model Figure B 6 Main Chassis Wiring Harness 2008 1125R Model Figure B 7 Main Engine Wiring Harness 2008 1125R Model Figure B 8 Component Wiring Diagrams Headlamp Assembly Sub Harness Cooling Fan Sub Harness and Hand Figure B 9 B 4 2008 Buell 1125R Appendix B Wiring 00239 A c Starter BK Starter Solenoid Battery 2 Chassis Ground Wiring Diagram ult Fuse Block 86A Y 86B V 234A uN A T1458 GER Yeas 145A Pump 108 10A BK lt lt mm gt 17 Battery ECM 778 33B 83A Ignition Switch Pak On e e On Voltage 9 Lock Off Lock Off Regulator
14. 6 3 D Data Link 2 12 DDFI 3 Op ration lt r dee walks 6 1 6 1 Delphi Connector OY BRS Le 5 Deutsch Connector Crimping Standard A 11 c 7 Diagnostic Trouble Code Checking 2 1 Clearing 2 1 DTC Priority 2 1 Multiple 2 1 Retrieving ee E h 2 1 Diagnostic Trouble Code Types ERSESEBEREEREEREEDEDIEIE 2 4 _ 2 4 Drivers Adiye 6 6 Coolie FSUE 6 6 o 6 5 ON 6 5 Idle Air Control 6 5 Ignition Goils 52 5 ire eg rr tege 6 5 Start 6 6 B1004 ein chee srt es 4 6 DIG B1005 c eeu m RR SERE E RES 4 6 DTG mete AP 6 15 DIG POOSI tos utu DP es 6 15 DIG 2008721 2 ix i dts 6 63 DTG P0107 A aene 6 90 DIG POTS secre eem
15. 86B J 86A 3188 31RA lt lt Instrument 39 398 a Right Front BN 1 Cluster gt gt Chassis Grounds Turn Signal Low Fuel Lamp 15 15 Y R In Wiring Diagrams 18B 18A lt lt Right Rear Right Turn Driver 11 11 jE BN BNmg Turn Signal 145B 145A lt lt Oil Pressure Input 8 8 EGN Y e eny g 1 1 Qil T TOsgure lt lt 120B 120A High Beam Input 6 6 Right Turn Input 5 5 lt lt Right High Left Turn Input 4 4 Eww 38B 38A Headlamp Left High Left Turn Driver 1 1mv Headlamp wo Flash To Pass Switch Headllamp High Low w43 3 Switch 7 7 BN BN ul Right Turn Switch WNa6 6 m mmm V m Left Turn Switch gt gt 311 31LA 24 248 e Left Front Turn Signal Left Rear Vet os Turn Signal lt lt 19 19 Figure 4 13 Instrument Cluster Inputs and Outputs 2008 Buell 1125R Instruments 4 21 Low Fuel Lamp Always On Enter the Onboard Diagnostic Information System on the IC Is a code present See the appropriate DTC diagnostics Verify there is suffic
16. 1 1 Starter 1 1 Temperature 1 1 4 1 SPX Kent Moore Lob i Il 3 1 Starter Solenoid eee es 3 1 Starter 3 12 Free Running Current 3 12 Starting 3 1 Start Relay cua x nice Rede 3 2 Start Relay Diagnostics 6 45 Starts dnt nue te Lui Pe Ln cfe s 3 1 Stator p hate dace pratt 3 19 Symptoms Symptom 2 5 T 4 1 Theft Mode RR RS 4 2 Throttle Position TP 6 18 TOGGLE Switch 522 462 Gans 4 2 Torque C 3 Trademarks BOSI bees denies Referenced Products Turn Signal Diagnostic 4 15 V Vehicle Speed 6 71 Voltage 1 11 Voltage 3 3 Warning 4 2 Che
17. WV 6 6 m V mum V m Left Turn Switch gt gt 311 31LA 24 248 lt e Left Front VE Turn Signal Left Rear Turn Signal lt 19 19 Figure 4 9 Instrument Cluster Inputs and Outputs 4 12 2008 Buell 1125R Instruments Oil Pressure Lamp Always Turn the ignition on Does the low oil light illuminate for two seconds and then turn off Verify there is sufficient oil in the engine Start the engine Does the low oil light stay on Disconnect the oil pressure sensor Does the low oil light stay on Replace the instrument cluster 6006 The system is operating properly Test the GN Y wire from the oil pressure sensor to the IC for a short to ground Is a short to ground present Locate and repair the short to ground in the GN Y wire Replace the instrument cluster 6008 6024 Check for any mechanical issues that could cause low oil pressure See Diagnostic Tips Was the problem found Operate the engine and confirm the repair Replace the oil pressure switch Use 5161 appropriate code fc01786 en 2008 Buell 1125R Instruments 4 13 Oil Pressure Lamp Inoperative Turn the ignition on Does the low oil light illuminate for two seconds and then
18. 1 11 5 SPECIFICATIONS Table 1 8 Alternator Specifications Table 1 1 Fuel System Specifications MEASUREMENT VALUE FUEL SYSTEM TYPE AC voltage output 32 Amp three phase Intake Dual 61 mm down draft throttle Stator coil resistance 0 1 0 3 Ohms bodies Fuel delivery DDFI Fuel Injection Recommended fuel 91 Octane Table 1 9 Regulator Specifications Table 1 2 Idle Speed Specifications MEASUREMENT VALUE Voltage output 3600 RPM 14 3 14 7 75 F 24 C ADJUSTMENT RPM Amperes 3600 RPM 45 Amps three phase shunt Normal idle speed 1250 Nominal non adjustable Table 1 10 Electrical System Specifications Table 1 3 Battery Specifications ELECTRICAL SYSTEM AMPERES BATTERY SPECIFICATIONS Main fuse battery fuse 30 Size 12 VDC 12 200 Ignition fuse 15 Type Sealed AGM Light fuse 15 Accessory fuse 10 Table 1 4 Spark Plug Specifications Brake horn 10 SPARK PLUG SPECIFICATIONS aw i 10 5 Key switch fuse 15 Type CR9EKB Cooling fan fuse 15 Gap 0 032 in 0 81 mm Bua power 19 Torque 22 fuses are located in the tool kit Table 1 5 Starter Specifications STARTER SPECIFICATIONS Table 1 11 Ignition Coil Specifications Type 900 W electric wi
19. STARTING SYSTEM DIAGNOSTICS 3 1 DESCRIPTION AND OPERATION When the ignition switch is turned on power is supplied to the coil side of the key relay and energizes the relay This allows battery power to flow through the relay to the lights fuse and to the switch side of the start relay When the engine stop switch is in the RUN position with the ignition switch turned on power is supplied to the ignition relay causing the relay to energize This supplies power to the start switch When the start switch is pressed power flows to the coil side of the start relay The ECM grounds the coil side of the start relay The ECM monitors the clutch switch neutral switch and the state of the security system If the security system is not locked and either the clutch lever is pulled in or the motorcycle is in neutral the ECM supplies ground to the Coil side of the start relay allowing power to flow to the solenoid This energizes the solenoid and full battery power is sent to the starter Once the engine is running the alternator starts supplying the power to charge the battery and run all of the electrical com ponents on the motorcycle The voltage regulator regulates the power coming from the alternator and charges the battery using the circuitry through the battery fuse COMPONENTS Starter See Figure 3 1 The electric starter is located on the front of the engine The starter drive gear transfers rotatio
20. Go to Headlamps Inoperative Part 2 of 2 Are the front marker lamps also inoperative NO Disconnect the inoperative headlamp Inspect the bulb Is the bulb good Are the high beam headlamps inoperative also Repair the open on the ground circuit between GND 1 and the low beam headlamps Test for voltage from terminal B of the Replace the 5038 Disconnect the lights fuse Inspect the fuse Is the fuse good Turn the ignition switch on Test for battery voltage at terminal 23 R BK of the lights fuse Is battery voltage present Locate and repair the short to ground Refer to diagnostic tips Replace the lights fuse 5194 inoperative headlamp to a good ground Is battery voltage present bulb Locate and repair open in BE wire terminal B of inoperative headlamp Locate and repair open in BK ground circuit of inoperative headlamp Disconnect the headlamp connector 38 Turn the ignition switch on Test for battery voltage on terminal 3 BE of connector 38B to a good ground Is battery voltage present 5038 5194 NO Disconnect the start relay Test the start relay Is the relay good NOTE See 1 3 DIAGNOSTICS TROUBLESHOOTING If the relay terminal called out does not match the relay being checked Locate and repair
21. Coolant Temperature ECT Sensor BKWZ Intake Air Temperature IAT Sensor Ar m Barametric BARO Throttle Fuel Pressure Position TP Pressure Data Link Sensor Sensor Sensor Connector 2 1 ir 5 2 228A 1 88 227 E Y 228B Y B8B Y 227B 5 i 5 Bank Angle Sensor BAS 134A e Y 134B IT 5 BK W Manifold Vehicle BKW Absolute Speed Side Stand Pressure Sensor Sensor MAP Sensor VSS Es iem 3 2 n ELLE gt S BK W BK W si gt gt 145A 145B T T T J1 28 27 19 A 1B 28 27 19 1 S 5 g GY Figure B 4 Sensor Grounds 2008 1125R Model 2008 Buell 1125R Appendix B Wiring B 7 00244 Front Ignition Coil V 83FA Y B3FB 2 2 La Y ru Rear Ignition Coil 2 2 La ru V 83RA Y B3RB ECM e 5 5 z 5 5 v v E b gt gt gt gt n n 8 24 33 16 8 24 33 16 P x m m m m V 10A Y 108 Crankshaft Position CKP Sen
22. Block 4 BR Starter Starter Solenoid ult Voltage Regulator 33B 33 Ignition Switch Pak On Lock Off e e On Lock Off V 234A uN A 1458 tuis EX N 145A 86A Y 86B Fuel Pump 10B 10A BK lt lt 17 Battery Key Relay Ignition Relay Auxiliary Relay O R 8 17 5 87 2 2 R BK 14 5 87 GY d 4 5 87 18 4 87 a a 4 87 4 87 gt gt 15 30 2 avio 5 30 7 i AN 1 da TRIAL Coarse x 1 1 2 62 Relay Block J oa ao Ignition 1 Cooling Cooling Power Ax Fan Right Fan Left Wiring 12V Auxiliary Diagram Connector Front Front Ignition Fuel Coil Injector gt 1 Data Link 23 3 8 3 1 844 4 3 1 AA 2 5 Yare 1 Y 848 5 z Start Switch 14587 gt gt A 83RB 1 85B gt 11788 83RA 1 85A 2 178 Rear Active I
23. P0117 and 0118 Part 2 of 2 Continued from DTCs P0117 and P0118 Part 1 of 2 With DVOM still connected check for intermittents Are intermittents present YES Perform wiggle test See 1 3 DIAGNOSTICS TROUBLESHOOTING Repair as necessary Connect Breakout Box to ECM and disconnect ECT sensor connector Turn ignition switch ON Using a DVOM measure the voltage between Breakout Box connector 11 Gray terminals 9 and 28 Is voltage approximately 5 0 Volts Replace ECT sensor and road test Did check engine lamp turn on and set DTCs P0117 or P0118 NO System OK Install original ECT sensor and replace then road test NO Less than 4 7 Volts With ECT sensor disconnected disconnect ECM connector 11 Measure resistance between ECM connector 11 Gray terminal 9 and ground Is resistance less than 1 megohm Locate and repair short to ground on ier W R wire 6 54 2008 Buell 1125R Engine Management NO Greater than 5 3 Volts Unplug ECM leaving Breakout Box connected at the vehicle harness Measure voltage between Breakout Box connector 11 Gray terminal 9 and ground Is the voltage 0 0 Volt Check ECT sensor signal wire W R for short to 12 Volts and repair Replace
24. stu e 2 E o 2 589g 2 8E 30 3 3 3 55 8 BP 5506 9 oS o0 OG 5 5 Zg S 0 62 Ji J2 11 10 Figure 6 3 Power Circuit 2008 Buell 1125R Engine Management 6 11 Errors Attach Breakout B 48115 to the Place ignition switch ON Check for battery voltage between Breakout Box 10 terminals 8 Black and 9 Black Is voltage present YES NO Check for battery voltage between Check for continuity to ground on Breakout Box 10 terminals 8 Black Breakout Box terminal 8 Black and 17 Black Is continuity present Is battery voltage present NO Disconnect interface connector 145 and check for battery voltage on 145B terminal 19 R GY Is battery voltage present Disconnect interface connector 145 and check for battery voltage on 145B terminal 6 Y Is battery voltage present Replace Locate repair open YES Locate and repair open Locate and repair Locate and repair open Check for continuity from between ECM 10 open between between ECM 10 terminal terminal 2 of 33B R GY Black terminal 17 and interface 9 and interface connector and terminal 19 of 145A interface connector connector 145B 145A terminal 19 R
25. Connector Information For additional information on the connectors in the following diagram s see B 1 CONNECTORS 00257 Battery Power Distribution Wiring Diagrams gt 7 Fuse 21 Block Auxiliary 10 fis 1 ECM J2 10A 10B BK 145A 145B O R 17 5 FA Auxiliary Z ela gt gt gt gt R ml 16 30 Auxiliary Relay Ground 19 9 2 BK GN Bi 12 2 85 ON uxiliary Relay Groun ao 2o GY 1 86 62 Relay Block gt O R 1 12V Auxiliary Connector Battery BK m 2 Power Distribution lt In Wiring 160B Diagrams Chassis Grounds In Wiring Diagrams Figure 5 4 Auxiliary Power Connector 5 4 2008 Buell 1125R Accessories Horn Lights and Security Auxiliary Power Inoperative Verify the auxiliary power fuse is good Is the fuse good YES 5 Disconnect the auxiliary relay Turn the ignition on with voltage at socket terminal 16 R of the auxiliary relay the engine stop switch in the run position Test for battery Test R wire from auxiliary power fuse Socket terminal 15 to auxiliary relay Socket terminal 16 for a short to ground Is a short to ground present Is battery voltage presen
26. 5 9 m 5 9 ee 5 9 5 9 Flash to Pass 5 9 Low Beam 5 10 High Beam 5 10 Marker Lamp 5 10 Turn Signal 5 10 IV TABLE OF CONTENTS Bis ori m 5 10 Eel Bet ONT 5 10 License Pate reis iode 5 10 Stop Lamp GWIICHes 5 10 cns e 5 10 Headamps P 5 10 5 11 Gonnector ImormallOl 5 11 SONA Eir 5 15 Bishop CE 5 15 Connector Information 5 15 5 20 cea Prep UG boe ADAE OMM 5 20 5 20 barker ESO 5 24 Connector 5 24 5 4 SECURITY SYSTEM Description and 5 29 COMPONE 5 29 ure 5 29 istrument AR n 5 29 Thet Mode LED BER Rada nU oceans 5 29 Selecting the Security 5 29 iu me PIN est eer
27. 80B terminal 2 and Breakout Box terminal 27 Gray Is resistance less than 1 Ohm Check resistance between Breakout Box terminals 24 and 27 gray Is resistance greater than 1 megohm Locate and repair open wire Locate and repair short TE between R W and BK W wires 1 01918 en 2008 Buell 1125R Engine Management 6 93 BATTERY VOLTAGE P0562 P0563 6 26 DESCRIPTION AND OPERATION See Figure 6 50 The DTCs set if the ECM detects battery positive voltage less than 9 6 Volts or greater than 16 Volts Refer to Table 6 27 for DTC descriptions Alow voltage condition typically occurs during the first 10 seconds of starter activation and the ECM does not detect a voltage rise as engine RPM increases This could also indicate a charging system fault and loose wire connec tions high voltage condition is usually caused by a faulty voltage regulator Table 6 27 Code Description DTC DESCRIPTION P0562 Battery voltage low Figure 6 50 Battery Location P0563 Battery voltage high Connector Information Diagnostic Tips n For additional information on the connectors in the following This test checks for voltage drops in the ECM power circuit If diagram s see 1 CONNECTORS a significant voltage drop is not present the condition may be caused by excessive starter current draw 6 94 2008 Buell
28. Airtemp Voltage Volts TPS Percent Percent open TPS Voltage Volts Clutch State 0 or 1 V Speed State 0 or 1 MAP KPA Pressure KPA MAP Voltage Volts 1 Steps Steps open Fuel KPA Pressure KPA Fuel Voltage Volts FRT 02 Voltage Volts Rear 02 Voltage Volts Tipover Voltage Volts S Stand Voltage 0 6 stand up 2 6 stand down F adapt fuel Percent R adapt fuel Percent Starter Relay St 0 or 1 Aux Power State 0 or 1 4 4 2008 Buell 1125R Instruments Instrument Cluster IC Diagnostics The IC sets codes when the parameters for the inputs are out of range These codes begin with a B prefix to separate them from an ECM or a communication code Refer to Table 4 3 for B codes The IC monitors direct inputs from sensors and switches along with receiving information from the ECM over the CAN lines Table 4 3 Diagnostic Trouble Codes DTC Priority Table DTC PRIORITY FAULT CONDITION DIAGNOSTIC PROCEDURE ORDER B1004 69 Fuel Level Sender Low 4 2 FUEL LEVEL SENDER LOW HIGH OPEN B1004 B1005 B1005 68 Fuel Level Sender 4 2 FUEL LEVEL SENDER LOW HIGH OPEN DTC B1004 B1005 High Open Some sensors and switches send direct inputs to the IC and may occur indicating a fault without any present Refer do not have DTCs associated with them Therefore symptoms to Table 4 4 for a list of symptoms Table 4 4 Instrument Cluster IC Symptom Table
29. e gt a 5 8 cod z 8 3 i amp BL gt 118 118 26 28 14 31 32 2 3 18 26 108 18 26 9 28 14 31 32 2 3 18 26 10 GY gt 5 8 g gg g 80 2 g c qm me uh 3 5 5 g 3 x z 55 8 ES 8 5 5 5 2i 1 2 O E 8 8 p 8 ECM Figure 6 30 CKP ECT IAT O2 Sensors and Cooling Fans 6 52 2008 Buell 1125R Engine Management P0117 and 0118 Part 1 of 2 Disconnect the ECT sensor connector 90 Measure the resistance between 90A terminals 1 and 2 Is the resistance between 33 761 74 328 Ohms when engine temperature ranges 68 86 F 20 30 Attach Breakout Box B 48115 to the ECM harness leaving the ECM disconnected Measure the resistance between ECT sensor connector 90B terminal 2 and Replace ECT Breakout Box Gray terminal 9 and 90B sensor terminal 1 and Breakout Box Gray terminal 28 Are both circuits less than 1 0 Ohm YES NO Using a DVOM measure the resistance between Breakout Box terminal 9 W R of 11 Gray and ground Is it greater than 1 0 megohm Locate and repair open or poor connection on faulty circuit Locate and repair short to ground on W R wire Go to DTCs P0117 and P0118 Part 2 of 2 1 01887 en 2008 Buell 1125R Engine Management 6 53
30. A 7 Installing Socket Terminals esse A 7 Removing Terminale cereo A 9 letali Pii Tenninar A 9 Grinping TMINA 10 4 DEUTSCH STANDARD TERMINAL REPAIR Deutsch Standard Terminal Crimps A 11 Preparing Wire Leads for A 11 Crimping Terminal to Lead eee A 11 IIS qb RR ra Rd SERO RA ARIS A 11 A 5 METRI PACK TERMINALS Metri Pack Terminal cesta caes A 12 Matching Terminal To A 12 Preparing Wire Lead 12 12 Crimping Insulation Seal A 12 inspectio 9 A 13 A 6 150 METRI PACK CONNECTORS 150 Metri Pack Connector A 14 AME 14 Separating Pin and Socket Housings A 14 Mating Pin and Socket Housings A 14 Removing Socket A 14 Inserting Socket A 14 A 7 280 METRI PACK CONNECTORS 280 Metri Pack Connector
31. Install original O2 sensor and replace ECM Road test again to verify repair Replace O2 sensor Clear DTCs and road test Did check engine lamp illuminate and set DTC P0131 P0132 P0134 P0151 P0152 or P0154 System operating normally NO 0 0 0 4 Volts Inspect fuel pressure within Onboard Diagnostic Information System See 4 1 INSTRUMENT CLUSTER AND GAUGES Is the pressure too low NO 0 6 1 0 Volts Inspect fuel pressure within Onboard Diagnostic Information System See 4 1 INSTRUMENT CLUSTER AND GAUGES Is the pressure too high NO Slow or no change Connect breakout box to ECM harness leaving ECM disconnected Check continuity between terminal 31 front Gray and 138B PK O or terminal 32 rear Gray and 137B PK GN Is continuity present NO Check for air If no fuel _ Check for eaks at pressure injectors stuck Replace front Locate and fuel i i open See repair open ressure induction sensor codes or rear O2 on module are present 6 13 FUEL sensor as or PK GN Are air leaks Replace fuel INJECTORS indicated ir present pump 0261 wire P0262 P0264 P0265 ves Locat and Fuel injectors repair may be dirty leaks See the service manual fc001902_en 6 78 2008 Bu
32. 6 90 DIG POlT2 UU e Eee 6 55 hem REO 6 55 DTG 6 51 Rn REP 6 51 DTG P0122 c ia tcr oce ente ar et as 6 18 DIG P0129 eee uer a US 6 18 Bund ae re tft 6 74 DIG P0132 Goi ia ex RP E 6 74 DTG P0194 noe dama pa 6 74 Tie eo Pil RIS pu per Emus 6 74 eU UE RR REN 6 74 DIG P0154 el pase ee ee Bases 6 74 DIG P0192 de Aes Be RR 6 63 P0193 5 PPP 6 63 0261 2 6 40 DTG P0262 vu teur ect eas 6 40 DIG 0264 c esr e es 6 40 DIGC P0205 AT 6 40 P0338 6 15 P0502 tee 6 71 INDEX DIC P0503 6 71 0506 eh As 6 79 DIG RIED E 6 79 DTG POSTI th et e DA 6 79 DIG P0562 cute S 6 94 DIG 20563 6 94 DIG LEE due e 6 11 DIG P0604 osi uc cR thas ERR REA 6 11 DTC POCOS Gridi a VERE Rea Dette eret 6 11 DIG P0607 Ep 6 11
33. 3 22 COMM 2 12 Connector Locations Behind Fairing 5 1 1 Chassis Top 1 5 Clutch Switch Connector 95 1 2 Cooling Fan Right 1 3 a eje peas ades 1 5 1 5 Front Brake Switch Connectors 170 1 3 Ground Wieser E LASER ELE 1 5 ueterum RE eed 1 2 LH Air Scoop Connectors 1 3 LH Engine i ttr ERRARE RI 1 5 O2 and IAT Connectors 1 3 Oil Pressure Switch Location 1 4 Rear Brake Switch Connector 121 1 3 Rear Lamp 1 4 Side Stand Sensor Connector 133 1 4 Throttle Body Connectors 1 4 Connectors ees 1 Controller Area Network CAN 2 12 Conversions D C 2 Length user A ees EA EVI C 1 TORGQUO Wa RE C 3 Cooling fan 6 84 Cooling fan 6 84 Crank Position 6 15 Crank Position Signal Synchronization 6 3 Engine 6 3 Engine Run
34. 86 87 85 e A 30 c o j 1 Battery 2 Start Relay 3 Ohmmeter Figure 1 30 Relay Test JOB TIME CODES VALUES PART NUMBER TOOL NAME HD 48650 DIGITAL TECHNICIAN Dealership technicians filing warranty claims should use the job time code values printed in bold text underneath the appropriate repair When using DIGITAL TECHNICIAN II Part No HD 48650 dealership technicians filling out warranty claims should use the job time code values in DIGITAL TECHNICIAN Part No HD 48650 TABLE OF CONTENTS SUBJECT PAGE NO 2 1 INITIAL DIAGNOSTICS m 2 2 SERIAL DATA COMMUNICATION 5 INITIAL DIAGNOSTICS 2 1 DESCRIPTION AND OPERATION Initial diagnostics are a starting point to navigate through the EDM in a manner to efficiently troubleshoot any concerns A basic understanding of electronics and a general knowledge of the motorcycle are necessary to effectively use this manual Before diagnosing a concern perform a general functional test of the motorcycle to verify the concern and to make sure there is nothing else that could cause problems with accurately dia gnosing the motorcycle Use the flowcharts in this chapter for initial diagnostics CHECKING FOR DIAGNOSTIC TROUBLE CODES DTCS Part of this initial test is checking for DTCs Some concerns only exhibit
35. Turn the ignition on Test for battery voltage on the GY BK wire from terminal 1 of the open in the O wire to a good ground of the 38A to terminal 1 of the W wire inoperative lamp the bulb front marker lamp 5043 Is battery voltage present 5197 Is continuity present Locate and repair the open in the BK ground circuit 5038 Locate and repair the open in the GY BK wire 5039 Locate and repair the open in the BK Locate and repair the ground circuit open in the GY BK wire 5038 5039 1001930 en 5 28 2008 Buell 1125R Accessories Horn Lights and Security SECURITY SYSTEM 5 4 DESCRIPTION AND OPERATION SELECTING THE SECURITY SETTING The security system is a start disable system only It does not control the lights or the horn When the security system is active the ECM does not energize the start relay the fuel injectors or the ignition coils unless the correct Personal Identification Number PIN is entered in the IC When the security system is active the security indicator flashes once every few seconds ed01694 8888 2 8888888 FIENT Ds LCD Screen Tachometer TOGGLE switch MODE switch Indicator lamps Warning lamps Theft mode LED Figure 5 23 Instrument Cluster COMPONENTS ECM The ECM controls the start relay fuel injectors and ignition coils in order to disable sta
36. 1 8 Fuel Pressure 6 63 Fuel PUMP eet ate is 6 68 G Glossary Acronyms and Abbreviations D 1 H HD 26792 Spark 1 7 HD 34730 2D Fuel Injector Test Light 1 8 HD 39978 Digital Multimeter Fluke 78 1 8 HD 41354 1 Input Output 1 9 HD 41354 Speedometer 1 9 HD 41404 Harness Test 1 7 HD 41417 Propane Enrichment 1 9 VI INDEX HD 48053 Advanced Battery Conductance and Electrical System 1 8 HD 48650 Digital Technician 1 7 Idle Air Control 6 79 Ignition 6 35 Ignition 3 2 Ignition 3 2 Indicator Lamps Headlamp High Beam Indicator 4 1 Left Turn Signal Indicator 4 1 Neutral Indicator 4 1 Right Turn Signal Indicator 4 1 Initial 2 1 Instrument Cluster 2 12 Instrument Cluster and 4 1 4 1 Instrument Cluster Diagnostic 4
37. P0506 P0507 P0511 Fault P0562 39 Battery Voltage Low 6 26 BATTERY VOLTAGE DTC P0562 P0563 P0563 38 Battery Voltage High 6 26 BATTERY VOLTAGE DTC P0562 P0563 P0603 3 ECM EEPROM Failure 6 5 ECM ERRORS DTC P0603 P0604 P0605 P0607 P0604 1 ECM RAM Failure 6 5 ECM ERRORS DTC P0603 P0604 P0605 P0607 P0605 2 ECM ROM Failure 6 5 ECM ERRORS DTC P0603 P0604 P0605 P0607 P0607 4 ECM Microprocessor 6 5 ERRORS P0603 P0604 P0605 P0607 Failure P0616 61 Starter Relay Circuit Low 6 14 START RELAY P0617 P0617 60 Starter Relay Circuit 6 14 START RELAY DTC P0617 High P0628 28 Fuel Pump Circuit Low 6 20 FUEL PUMP P0628 P0629 P0629 27 Fuel Pump Circuit High 6 20 FUEL PUMP DTC P0628 P0629 2008 Buell 1125R Engine Management 6 9 Table 6 4 Diagnostic Trouble Codes DTC Priority Table DTC PRIORITY FAULT CONDITION DIAGNOSTIC PROCEDURE ORDER P0691 58 Right Fan Control Circuit 6 24 RIGHT AND LEFT FAN CONTROL P0691 P0692 P0693 P0694 Low P0692 56 Right Fan Control Circuit 6 24 RIGHT AND LEFT FAN CONTROL P0691 P0692 P0693 P0694 High P0693 59 Left Fan Control Circuit 6 24 RIGHT AND LEFT FAN CONTROL DTC P0691 P0692 P0693 P0694 Low P0694 57 Left Fan Control Circuit 6 24 RIGHT AND LEFT FAN CONTROL DTC P0691 P0692 P0
38. vr FEES 4 11 Connector tnn timentes 4 11 4 4 TURN SIGNAL INDICATOR INOPERATIVE Description and 4 15 Bie mE 4 15 Diagnostic Procede 4 15 4 5 INSTRUMENT CLUSTER INOPERATIVE Description and 4 16 Diagnostie 4 16 Connector Informalion e rrr ertt 4 16 4 6 LOW FUEL LAMP ALWAYS ON OR INOPERATIVE Description Operatii ecce ett erc none 4 20 Bc peris D mrt E 4 20 Connector icit etia 4 20 ACCESSORIES HORN LIGHTS AND SECURITY 5 1 ACCESSORIES Description and Operation 8 80 P 5 1 a 5 1 5 1 Auxiliary Relay 5 1 DTC P1601 Auxiliary Relay Driver Circuit Fault 5 1 Comector Inroim Sllofu 5 1 Auxiliary Power 5 4 Connector MENMAN 5 4 5 2 Description and acier ip ti ear ad s Pc 5 6 COMPONENTS T ann 5 6 Honn eee Er 5 6 POW 5 6 cs 5 6 Brig C 5 6 Hom Always D essersi bri 5 6 Gofhimector MOMAN 5 7 5 3 5 Description and
39. B High Beam 38B 38A Headlam EU 24A 21 s 38B 38A p 9 24817 4 3 2 1 lt TE T Right gt High Beam ww Headlamp lt lt High Low p Switch Low Beam BK m A A Headlamp E lt lt Right e e Low Beam High w BK A A Headlamp i rounds In Wiring E Diagrams N GND 1 Figure 5 21 and Marker Lamps 2008 Buell 1125R Accessories Horn Lights and Security 5 25 00254 Ignition And p Pover In gt Wiring Diagrams Fuse IEEE OO DEG 4 Block 2 9 Brake Horn 10 10 6 3 NG 5 Do RY 8 2 2 Switch X 1708 170A Ignition And Rear Accessory m Brake Power ow RY 2 2 Switch In Wiring Diagrams gt gt 121A 121B RY 2 2 owe 1 1 BE W 5 1 Left 6 lt lt 938 93A 7 Right 4 License LE Plate Turn Signal 24B 24A Lamp Switch BK mt 1 lt lt 45 45 T Right Tum Input 5 5 WBN Left Turn Input
40. Cooling fan s inoperative Repair the circuit If DTC P0691 P0692 P0693 or P0694 are present diagnose and correct DTCs Table 6 3 Engine Emits Black Exhaust or Fouls Plugs CAUSE SOLUTION Engine coolant temperature circuit Repair the circuit If DTC P0117 or P0118 is present diagnose and correct DTCs Improper fuel pressure Repair the circuit If DTC P0192 P0193 or P0087 are present diagnose and correct DTCs Clogged air filter Repair the circuit If DTC P0112 or P0113 is present diagnose and correct DTCs Leaky injectors Repair the circuit If DTC P0117 or P0118 is present diagnose and correct DTCs Table 6 4 Diagnostic Trouble Codes DTC Priority Table DTC PRIORITY FAULT CONDITION DIAGNOSTIC PROCEDURE ORDER P0087 29 Fuel Rail System 6 19 FUEL PRESSURE SENSOR P0192 P0193 P0087 sure Too Low P0107 63 Map Sensor Low Open 6 25 MANIFOLD ABSOLUTE PRESSURE MAP SENSOR P0107 P0108 P0108 62 Map Sensor High 6 25 MANIFOLD ABSOLUTE PRESSURE MAP SENSOR DTC P0107 P0108 P0112 22 Intake Air Temperature 6 17 INTAKE AIR TEMPERATURE SENSOR DTC P0112 P0113 Sensor Voltage Low P0113 21 Intake Air Temperature 6 17 INTAKE AIR TEMPERATURE IAT SENSOR DTC P0112 P0113 Sensor High Open P0117 20 Engine Coolant 6 16 ENGINE COOLANT TEMPERA
41. Disconnect IAC motor and connect test lamp Turn ignition switch ON for two seconds then turn ignition switch OFF Check test lamp during ignition switch ON OFF cycle Problem Normal indicated behavior 6 82 2008 Buell 1125R Engine Management Remove test lamp Connect Breakout Box Part No B 48115 to connector 10B leaving the ECM disconnected Is battery voltage present on terminal 17 Black Repair faulty IAC connection or replace IAC motor assembly YES Measure resistance of the wires between motor connector 89B and corresponding Breakout Box connector 11 Does resistance on each wire measure 0 5 Ohms or less See 6 5 ECM ERRORS DTC P0603 P0604 P0605 P0607 YES Turn ignition switch ON With ECM still disconnected check voltage on all four terminals at connector 89B Is voltage present Locate and repair poor connection at connectors 89B or 11B or repair open wire in harness Locate and repair short to voltage Go to DTCs P0506 P0507 and P0511 Part 2 of 2 fc01903 en DTCs P0506 P0507 and P0511 Part 2 of 2 Continued from DTCs P0506 P0507 and P0511 Part 1 of 2 Turn ignition switch OFF Measure resistance between each terminal on connector B9B and ground Is resistance greater than 1 megohm for all terminals YES Check co
42. Replace spring Operation normal 1001876 en 6 26 2008 Buell 1125R Engine Management BANK ANGLE SENSOR BAS P1151 P1152 6 10 DESCRIPTION AND OPERATION See Figure 6 11 The Bank Angle Sensor BAS is located above the ECM inside the left radiator shroud The BAS oper ates from a 5V sensor reference voltage and sensor ground provided by the ECM The BAS sends a signal to the ECM ranging from 0 24 3 4V under normal operating conditions A BAS signal between 3 5 4 79V indicates to the ECM that the vehicle has tipped over and will turn off the engine When the vehicle is righted turn the ignition OFF and then ON again to restart the engine If the signal from the BAS is below 0 24V or above 4 79V the sets a code Refer to Table 6 10 and Table 6 11 A BAS code will not disable the vehicle and the engine will continue to run A tipped vehicle will not set a DTC Table 6 10 Code Description DTC DESCRIPTION P1151 BAS shorted low P1152 BAS shorted high Table 6 11 Bank Angle Sensor Voltage MODE VOLTS Run 0 24 3 4 Disable 3 5 4 79 ed01728 Figure 6 11 Bank Angle Sensor Location Connector end showing Connector Information For additional information on the connectors in the following diagram s see B 1 CONNECTORS 2008 Buell 1125R Engine Management 6 27
43. ed01705 B1005 Fuel level sender high open 4 6 2008 Buell 1125R Instruments Figure 4 5 Fuel Pump Connector 86 Diagnostic Tips The IC may take a few minutes to update When using a new IC to test wait a few minutes to verify what codes are set The new IC updates to the ECM after 30 minutes and cannot be restocked Watch the timer on the IC so it does not update to the ECM before diagnostics are complete The IC can only have a VIN written to it once It cannot learn a new VIN if one has already been written to it Therefore when replacing the IC it must be a new IC Connector Information For additional information on the connectors in the following diagram s see B 1 CONNECTORS 00245 Battery Power Distribution In Wiring Diagrams Y Ignition Lock Off Lock Off Switch Park On Park On ee par Instrument 39 398 Cluster S5 Ignition Switch 14 Chassis Ground 13 Constant Battery 12 CAN Low 10 CAN High 9 Chassis Ground 3 Constant Battery 2 xe 9 m E pc oa i 1 2 4 1 2 Y 33B W f Ignition R Gv gt Power In Wiring Diagrams m R GY m BK mR e E CAN Terminating Connector Resistor lm PK GY PK GY ml 2 2 Ziza PK
44. the relay being checked YES Replace the key relay Locate and repair the open in the R wire 5832 5827 Replace the Locate and repair ignition relay the R BK wire 5832 5827 fc01782 en 2008 Buell 1125R Starting Charging 3 11 TESTING STARTER ON MOTORCYCLE 3 2 STARTER CURRENT DRAW TEST 1 See Figure 3 10 Disconnect fuel pump connector 86 located under the seat 2 Verify the transmission is in neutral 3 Clamp induction ammeter over positive cable from the starter to the solenoid NOTE Engine could start and run until the fuel in the lines is purged 4 Turn the ignition switch on While reading the ammeter push the starter button Disregard initial high current reading that is normal when engine is first turned over a Typical starter current draw ranges between 140 180 amps If starter current draw exceeds 180 amps the problem may be in the starter or the starter drive Remove the starter for further tests See 3 2 TESTING STARTER ON MOTORCYCLE Free Running Current Draw Test ed01705 FREE Figure 3 10 Fuel Pump Connector 86 RUNNING CURRENT DRAW TEST 1 Place the starter in a vise Use a clean shop towel to pre vent scratches or other damage 3 12 2008 Buell 1125R Starting Charging See Figure 3 11 attach one heavy jumper cable 6 gauge minimum as follows a b Connect one en
45. 2 EBKW A MAP IB V GN 83FB 83FA Sensor 227A 227B 1 1 Front gt gt 2 2 Ignition Fuel GY 3 Coil B BERW IE Sensor EGN BE 178B 6 lt 79 798 sj 1 Active Intake Crank 22 ECM ies Y m 2 Solenoid Position 1 1RH BE enp CKP 2 2 Sensor 3J 3 gt gt 2 2 gt m 32222225555 352 228 852s Pe 11B 2618 6 4 10 514 9 19 24 1328 2731 32 20 21 22 23 8 9 10 24 25 29 30 27 28 31 32 333416 A 10B GND2 11 2618 6 4 10 5 14 919 24 13 28 27 31 32 20 21 22 23 8 9 10 24 25 29 30 27 28 31 32 33 3416 10A 2 95855909 9 09954555 5 5 85 28 65 2 2288888 SSSEEG 5 620605 2 5 050 255 BRELES 2855888888 ESSE 25566 TELE 2 5 COO 9929 st lt 5855 28 1045500555555 EE 2 58 25 580202 5 x 24 ZF 29995 555 oo 8565 5 555 82588 5 665555 5 55 J2 11A S S 10 gt a Figure 6 28 Dynamic Input Sensors and Drivers 6 50 2008 Buell 1125R Engine Management ENGINE COOLANT TEMPERATURE ECT P0117 P0118 DESCRIPTION AND OPERATION
46. 5 WBN Left Turn Input 4 4 E w v Right Turn Driver 11 11 BN Left Turn Driver 1 1 gt gt 39 398 Left 1 Front Signal 1 So 31LA 31LB Left 1 1 Rear gt gt 19 198 x m GND 2 Ignition And Accessory Power In Wiring Diagrams 1 Front 1 1 Ry g 2 2 Switch lt lt 1708 1704 RY g 2 2 Switch gt gt 121A 121B RY 2 2 ee ows 1 1 1 1 lt 938 93 1 1 License Plate Lamp 1 1 lt lt 45 45 BNE 1 1 Right Front Turn BKE 1 1 Signal lt 31RB 31 Right BNE 1 1 Turn BK mt Signal lt 188 18A BK 4 Wiring Diagrams Figure 5 18 Tail Stop and Turn Signal Lamps 2008 Buell 1125R Accessories Horn Lights and Security 5 21 Stop Lamp Inoperative Part 1 of 2 Turn the ignition switch on Is the tail lamp part of the tail stop lamp inoperative as well YES Refer to Marker Lamps Inoperative Does the horn work Disconnect the rear brake switch Jumper terminals 1 and 2 Do
47. Does the IC backlighting and display illuminate brightly Use the setup menu to adjust the brightness setting in the IC Is the problem solved Does the engine start ond See 3 1 STARTING The repair is Go to Instrument warning lamps SYSTEM 4 Cluster Inoperative inoperative DIAGNOSTICS Part 2 of 2 Refer to Instrument Cluster Is the speedometer IC Symptom Table for or tachometer appropriate diagnostics inoperative YES Check for DTCs Is the instrument Are any DTCs present cluster malfunctioning YES Replace the Replace the See 1 3 instrument instrument DIAGNOSTICS cluster cluster TROUBLESHOOTING See 2 1 INITIAL DIAGNOSTICS 6006 6006 fc01801 en 4 18 2008 Buell 1125R Instruments Instrument Cluster Part 2 of 2 Continued from Instrument Cluster Inoperative Part 1 of 2 Turn the ignition off Disconnect the IC connector 39 Turn ignition on Test for voltage on terminal 14 of connector 39A Is battery voltage present s Test terminals 13 and 3 for continuity to ground Test for continuity between terminal 14 of connector 39B and terminal 2 of connector 33B Is continuity present Is continuity present Test terminals 12 and 2 for voltage Is batter
48. e 5 5 5 5 8 5 2 5 8 25 3 58 5 5 8 9 g 5 5 8 E m 8 5 lt 8 m gt Figure 6 56 5V Reference Circuit 2008 Buell 1125R Engine Management 6 105 00275 11 11 Idle Air Neutral Clutch Control Switch Switch 1 1 3 95A 1 2 87A 1 Y 131B 1 Y 95B 1 2 4 Y1 87B gt 2 z t 2 o x amp gt m em Chassis GND 2 Chassis GND 1 2 g gt 175 1458 17 145 2 g gt 2 gt g of 6a 2 2 X uZ uH Hz sm 8 23 20 21 22 8 2 23 20 21 22 E 5 5555 5 5 gees g gees 3 5 8888 E EX XE 2 000 Fuel Pump B C 868 B C D 86A BK O GY BN Y Y R Instrument gt Cluster n pa e gt Fuel Pum Fuse 78411458 E BN Y BN Y BN Y A 10B N 10A BK N Fuel Pump Output Fuel Pump Output ECM Figure 6 57 Neutral and Clutch Switches IAC and Fuel Pump 6 106 2008 Buell 1125R Engine Management Engine Starts Then Stalls Fresh fuel in fuel tank 4 Check for DTCs See Chapter 2 Initial Diagnostics and Serial Data Are
49. 00274 Vehicle Bank Throttle Absolute Barometric Speed Angle Position Pressure Fuel BARO Side Sensor Sensor TP MAP Pressure Pressure Stand VSS BAS Sensor Sensor Sensor Sensor Sensor B 65 4 5 6 4 1 2 3 88 1 1 2 80 2278 1 2 228 1 2 3334 A B 658 4 s 1348 1 2 888 1 2 s Y 80B A c I227A 2 s YI228B 2 s Y 133B gt gt gt Z v gt 9 m s ev 8 gt m 2 m m gt t z m 2 m m e 2 rm I S m 5 16 1458 S TVA ae DLC E z 2 B B z 2 Q E 2 5 Z 2 1 1L m n 13 19 25 17 4 24 27 6 10 28 5 34 13 19 25 17 4 24 27 6 10 28 5 N 11A E g 7 8 5 E 3 0V a 8 B x 8 s B 8 3 2 3 E 2 5 8 5 lt 8 m gt Figure 6 8 5V Reference Circuit 2008 Buell 1125R Engine Management 6 19 DTCs P0122 and 0123 Part 1 of 2 Attach the to Breakout Box 48115 Plug the DVOM Part No HD 39978 into terminal 4 and terminal 27 of Breakout Box connector 11 Gray With ignition switch ON gradually open the throttle while observing voltage Does the voltage steadily increase with no voltage spikes or drops observed from 0 3 1 0 volt at i
50. 4 4 Right Turn Driver 11 11 IB BN Bad 1 4 Right Left Turn Driver 1 1 Turn Bkm 1 1 Signal Kem lt lt 39 398 31 31 et BE 1 J E ron Turn Turn Signal 1 1 Signal gt gt lt 31LA 3118 18B 18A Left 1 Chassis Signal 11 mm gt gt Diagrams 19A 198 x GND 2 Figure 5 22 Tail Stop and Turn Signal Lamps 5 26 2008 Buell 1125R Accessories Horn Lights and Security Marker Lamps Inoperative Part 1 of 2 Turn the ignition on Observe the tail lamp license plate lamp and front marker lamps Do they all illuminate Turn the ignition to the park position Do all the same lamps illuminate Do any of the marker lamps illuminate System operating normally See 1 3 Are the front marker lamps inoperative Replace the ignition switch 5129 DIAGNOSTICS TROUBLESHOOTING YES NO Go to Marker Lamps Inoperative Part 2 of 2 YES NO Turn the ignition on Test for battery voltage on the O W wire at the Replace bulb 5197 inoperative lamp to a good ground Is battery voltage present YES Locate and repair the open in the BK ground circuit Locate and repair the open in the O W wire 5038
51. Disconnect the inoperative lamp Inspect the bulb Is the bulb good 5043 Is the fuse good With the ignition on test for battery voltage at terminal 12 R GY of the accessory fuse Is battery voltage present Inspect the accessory fuse Locate and repair the short to ground in the O W wire Replace the accessory fuse 5043 YES Install the accessory fuse Disconnect the license plate lamp Turn the ignition on Test for battery voltage on the O W wire on connector 45B to a good ground Is battery voltage present Locate and repair open in R GY wire to accessory fuse 5043 Locate and repair the open in the BK ground circuit 5038 Locate and repair the open in the O W wire 5043 fc01886_en 2008 Buell 1125R Accessories Horn Lights and Security 5 27 Marker Lamps Inoperative Part 2 of 2 Continued from Marker Lamps Inoperative Part 1 of 2 Are both front marker lamps inoperative Disconnect the headlamp connector 38 Turn the ignition on Test for battery voltage on inoperative front marker terminal 1 O W of connector lamp Inspect the bulb 38B to a good ground Is the bulb good Is battery voltage present Disconnect the YES Disconnect one of the front marker lamps Test for continuity on the GY BK Locate and repair
52. See Figure A 21 Called Packard connectors Metri Pack series connectors are embossed with the initials P E D Separating Pin and Socket Housings Depress the wireform and use a rocking motion to detach the socket connector half Mating Pin and Socket Housings Align the groove in the socket housing with the tab in the pin housing Push the pin and socket halves of the connector together until the latch clicks Removing Socket Terminals 1 See Figure A 22 Pry rubber seal from wire end of con nector and move seal down wires 1 toward conduit Hold the connector so that the wireform is facing down 2 Looking into the wire end of the connector insert the point of a safety pin 2 between the top of the terminal and the inside chamber wall 3 Push safety pin completely into chamber while watching terminal on mating end of connector When terminal is observed moving forward slightly tang is depressed Remove safety pin NOTE Repeat as necessary until the terminal can be pushed out of the connector 4 Push on wire end of the lead to extract the terminal from the mating end of the connector 5 f necessary crimp new terminals on wires See 5 METRI PACK TERMINALS Metri Pack Terminal Crimps Installing Socket Terminals NOTE Terminal cavities are lettered on the socket housing To match the wire lead colors to the terminal cavity refer to the wiring diagram 1 SeeFigure A 22 Using a thin flat blade l
53. Y R wire Measure the resistance between terminals A and D of connector 86B Is the resistance between 850 1200 Ohms Locate and repair the open in the Y R wire Replace the IC with a new IC Connect connectors 39 and 86 Turn the ignition on for a few minutes to give it time to update See Diagnostic Tips Did DTC B1005 set Replace the fuel pump assembly Remove the new IC and install the original IC The repair is complete Allow sufficient time for the new IC to Replace the fuel pump update to the ECM assembly 1001920 en 4 10 2008 Buell 1125R Instruments OIL PRESSURE LAMP ALWAYS INOPERATIVE 4 3 DESCRIPTION AND OPERATION See Figure 4 8 The oil pressure lamp illuminates at key on for two seconds when the IC performs the bulb check and then goes out It will not stay on under normal conditions if the engine is not running When the engine is running the IC sends out a voltage on terminal 8 GN Y to the oil pressure switch When the oil pressure drops the switch closes grounding the circuit through the switch When the IC sees this it illuminates the oil pressure lamp 1 Oil pressure switch 120 2 Hydraulic clutch pressure hose Figure 4 8 Oil Pressure Switch Location Diagnostic Tips Verify oil pressure using an oil pressure gauge set Several non electr
54. 1 Bd don Fc BNS 38 vsr lasti asol vso em vec 45 1 vsv ond quejoog 6 6 10 8 22 Jeay osu Ze 22 NO Md lt E 21 Od die Le uoniuB 8822 8 elle BAD 1 LE NO AHE 105495 EL ELEM vues 8828 205095 39 38 A 496 ainssaig 9 9 lt I IOSUBS oJnsse Moo aati ainjosay popen 9 9 908 08 m AO 10sues 41 21 9 9 josues v4c8 8428 uonisog yeusxuei 92 9 E 3858 AO NS14S S ndino z ADIND HOE 0 jon gt 108095 lei ler p lt lt n Do are 4 nano osues 504 eo S gt 2 2820 ong won 10sueg aout v v E A A M SI vss 998 lagst lt lt 47 ayeyu 7 az 8 382 ez 1ndino dung jan4 z z qu y me Ainaa ze is eri 10sueg ainssaig
55. 6 108 DisgnostiC TIS uice tecto 6 108 SPAK IBSE xi T EM A PRIOR T 6 108 In line Spark Tester ner rre treten 6 108 APPENDIX A CONNECTOR REPAIR A 1 AMP MULTILOCK CONNECTORS Multilock Connector A 1 c lo t EE A 1 Separating Pin and Socket Housings A 1 Mating Pin and Socket Housings A 1 Removing Terminals from Housing A 1 Inserting Terminals into A 2 Preparing Wire Leads for Crimping A 2 Crimping Terminals 19 Leads iecit ces A 3 Inspecting Crimped Terminals 4 2 DELPHI CONNECTORS Delphi Connector A 5 p ario ee DN A 5 VI TABLE OF CONTENTS Separating Pin and Socket Housings A 5 Mating Pin and Socket Housings A 5 Removing Socket Terminals A 5 Installing Socket Terminals A 5 A 3 DEUTSCH ELECTRICAL CONNECTORS Deutsch Connector A 7 cr E E 7 Separating Pin and Socket 5 7 Mating Pin and Socket Housings A 7 Removing Socket
56. BAS Sensor Sensor Sensor Sensor Sensor B 65 4 5 6 4 1 2 3 88 1 1 2 80 2278 1 2 228 1 2 3334 A B 658 4 s 1348 1 2 888 1 2 s Y 80B A c I227A 2 s YI228B 2 s Y 133B gt gt gt Z v gt 9 m s ev 8 gt m 2 m m gt t z m 2 m m e 2 rm I S m 5 16 1458 S TVA ae DLC E z 2 B B z 2 Q E 2 5 Z 2 1 1L m n 13 19 25 17 4 24 27 6 10 28 5 34 13 19 25 17 4 24 27 6 10 28 5 N 11A E g 7 8 5 E 3 a 8 B x 8 s B 8 3 2 3 E 2 5 8 5 lt 8 m gt Figure 6 49 5V Reference Circuit 2008 Buell 1125R Engine Management 6 91 DTCs P0107 and 0108 Part 1 of 2 Connect Breakout Box 481150 With ignition ON measure voltage between Breakout Box connector 11 Gray terminals 6 and 27 Is voltage between 3 5 5 0 Volts with engine not running and 1 5 3 0 Volts at hot idle T Perform wiggle test to check for intermittents See 1 3 DIAGNOSTICS TROUBLESHOOTING Are intermittents present Go to DTCs P0107 and P0108 Part 2 of 2 Replace MAP sensor Perform road test Did
57. Black terminal 9 with ignition switch ON Is voltage drop greater than 0 5 Volt Locate and repair poor connection between terminal 9 of ECM connector 10 and R Y wire at starter solenoid ON MOTORCYCLE Check for excessive starter current draw See 3 2 TESTING STARTER 6 96 2008 Buell 1125R Engine Management Fc01907_en INTAKE SYSTEM P1110 P1111 P1112 6 27 DESCRIPTION AND OPERATION See Figure 6 52 The active intake system uses a solenoid which is connected to the throttle valve via a cable The throttle valve is automatically closed by the solenoid under certain conditions to reduce engine noise Refer to Table 6 28 for DTCs that set if the ECM detects the output for the active intake control is not in agreement with the feedback circuit minimum TP sensor voltage when actuated Likely causes for a DTC are e Mechanical fault in the active intake solenoid throttle valve or cable Electrical fault in the solenoid circuit Electrical fault in the throttle position sensor circuit TPS reading not changing to low voltage when the solenoid is activated Table 6 28 Code Description Connector Information For additional information on the connectors in the following diagram s see B 1 CONNECTORS 1 Active Intake Solenoid Connector 178 sensor feedback failure DTC DESCRIPTION 2 Act
58. Controller Area Network CAN connector 2 Electronic Control Module ECM 3 Data Link Connector DLC Figure 2 7 Inside Left Radiator Outer Shroud The Instrument Cluster IC and ECM share a Controller Area Network CAN line The CAN consists of a low and high circuit There is also a CAN connector 243 used for initial program ming when the motorcycle is built This connector has a plug in it that is a terminating resistor The ECM and IC send information back and forth over the CAN lines For example the ECM sends the vehicle speed and engine RPM to the IC over the CAN line The IC communicates the security code when entered to the ECM These are just a few examples of the information the ECM and IC share over the CAN The ECM also has a transmit and a receive serial data line going to the DLC 91 This connector is used to connect to the 2 12 2008 Buell 1125R Initial Diagnostics and Serial Data computer based diagnostic system DIGITAL TECHNICIAN Part No HD 48650 The is not connected to the serial data line Therefore any information going from DIGITAL TECHNICIAN Part No HD 48650 to the motorcycle has to be sent to the ECM and then communicated over the CAN lines to the IC COMPONENTS Electronic Control Module ECM See Figure 2 7 The is located inside the left radiator outer shroud The ECM monitors the sensors from the engine and fuel systems in order to manage the fuel and spark del
59. DTCs P0628 and P0629 Attach Breakout Box B 48115 to ECM Measure voltage between Breakout Box 10 Black terminals 27 and 28 and ground Turn ignition switch ON Does meter read battery voltage NOTE The voltage reading will fluctuate for 2 3 seconds while the fuel pump is cycled With DVOM still connected check for intermittents by performing wiggle test while repeating first test of this flowchart See 1 3 DIAGNOSTICS TROUBLESHOOTING Are intermittents present YES Repair as necessary Replace ECM Clear DTCs and road test Did check engine lamp illuminate and set DTC P0628 Replace fuel pump System operating normally 6 70 2008 Buell 1125R Engine Management Does the fuel pump run continuously Disconnect ECM Does fuel pump run continuously YES Locate and repair short Replace to ground on BN Y wire Check continuity of O GY wire between fuel pump fuse and fuel pump connector 86A terminal B Is continuity present Check continuity of BN Y wire between connector 10 Black terminals 27 and 28 and connector 86A terminal C with pin probes Is continuity less than 1 0 Ohm Locate and repair the open wire or poor connection in the O GY wire Check fuel pump fuse Is fuse good Check continuity between O GY w
60. Fuel Injectors The ignition relay provides battery power to the fuel injectors The ECM provides the path to ground to trigger the injectors The fuel injectors are pulse width modulated solenoids for metering fuel into the intake tract The pulse width of the ground path to the injectors is varied by the ECM in response to inputs from the various sensors thus varying the length of time the injector is open If the ECM senses the fuel pressure is less or greater than required for the engine cycle it increases or decreases the injector open time to maintain the proper air fuel mixture In the event of the engine or coolant overheating the ECM can skip an injector hold it closed when in the skip spark mode Both injectors are required for proper operation The ECM monitors the ground signal to provide a diagnostic indication of a failed injector or injector circuit Idle Air Control IAC The idle air control motor is a stepper motor used to regulate the amount of air entering the intake manifold during idle The ECM controls engine idle speed by moving the Idle Air Control IAC pintle to open or close a passage around the throttle plate It does this by sending voltage pulses to the proper motor winding of the IAC This causes the pintle to move in or out of the IAC a given distance for each pulse received To increase idle speed the ECM retracts the pintle allowing more air to flow through the throttle body To decrease idle
61. Is fuel injector connected YES Disconnect and attach Fuel Injector Test Lamp Crank engine Does the Fuel Injector Test Lamp flash Reconnect and install airbox Check voltage on connector 84 or 85 terminal 1 GY wire on fuel injector connector to ground Is measured voltage equivalent to battery voltage after ignition switch is ON and run stop to RUN Measure resistance of the suspect fuel injector Is resistance across terminals 11 5 12 25 Ohms Check for loose or Attach Breakout Box B 48115 to ECM corroded terminals Replace fuel If DTC P0261 P0262 measure resistance in harness Repair injector between ECM connector 10 BK terminal as necessary 29 W Y wire and terminal 2 of the front fuel injector connector 84 If DTC P0264 P0265 measure resistance between ECM connector 10 BK terminal 30 GN GY wire and terminal 2 of the rear fuel injector connector 85 Is resistance less than 0 5 Ohms Go to DTCs P0261 P0262 P0264 and P0265 Part 2 of 2 Using Breakout Box check with test lamp between 10 terminal 29 DTC P0261 P0262 or ECM 10 terminal 30 DTC P0264 P0265 and 10 terminal 9 Does the Fuel Injector Test Lamp flash when engine is cranked Locate and repair open or poor connection Recheck connections Perform wiggle test See 1 3 DIAGNOSTICS
62. NOTE If wire leads require new terminals see the instructions for crimping terminals Installing Socket Terminals 1 Match wire lead color to connector cavity 2 SeeFigure A 13 Fit rear wire seal 1 into back of socket housing 2 if removed 3 Grasp wire lead 3 approximately 1 0 in 25 4 mm behind the socket terminal Gently push socket through hole in wire seal into its chambers until it clicks in place 4 Atug on the wire will confirm that it is properly locked in place 2008 Buell 1125R Appendix A Connector Repair A 7 Seal plugs 6 are installed through the wire seals of unused chambers If removed seal plugs must be replaced to seal the connector 5 Install internal seal 4 on lip of socket housing if removed 6 Insert tapered end of secondary locking wedge 5 into socket housing and press down until it snaps in place The wedge fits into the center groove within the socket housing and holds the terminal latches tightly closed NOTES See Figure A 12 While rectangular wedges do not require a special orientation the conical secondary locking wedge of the 3 place connector must be installed with the arrow 1 pointing toward the external latch If the secondary locking wedge does not slide into the installed position easily verify that all terminals are fully installed in the socket housing The lock indicates when terminals are not properly installed by not entering its fully ins
63. P0117 P0118 ature Sensor Circuit Low P0118 19 Engine Coolant 6 16 ENGINE COOLANT TEMPERATURE P0117 P0118 ature Sensor Circuit High P0131 50 Front Oxygen Sensor 6 22 OXYGEN O2 SENSOR P0131 P0132 P0134 P0151 P0152 Circuit Low Engine Lean 154 P1047 P0132 46 Front Oxygen Sensor 16 22 OXYGEN O2 SENSOR DTC P0131 P0132 P0134 P0151 P0152 Circuit High Engine Rich PO154 P1047 P0134 48 Front Oxygen Sensor 16 22 OXYGEN O2 SENSOR P0131 P0132 P0134 P0151 P0152 Open Inactive P0154 P1047 P0151 51 Rear Oxygen Sensor 6 22 OXYGEN O2 SENSOR P0131 P0132 P0134 P0151 P0152 Circuit Low Engine Lean P0154 P1047 P0152 47 Rear Oxygen Sensor 6 22 OXYGEN O2 SENSOR P0131 P0132 P0134 P0151 P0152 Circuit High Engine Rich P0154 P1047 P0154 49 Rear Oxygen Sensor 6 22 OXYGEN O2 SENSOR DTC P0131 P0132 P0134 P0151 P0152 Open Inactive P0154 P1047 P0192 26 Fuel Pressure Sensor 6 19 FUEL PRESSURE SENSOR DTC P0192 P0193 P0087 Circuit Low P0193 25 Fuel Pressure Sensor 6 19 FUEL PRESSURE SENSOR DTC P0192 P0193 P0087 Circuit High P0261 35 Front Fuel Injector Circuit 6 13 FUEL INJECTORS DTC P0261 P0262 P0264 P0265 Low P0262 34 Front Fuel Injector Circuit 6 13 FUEL INJECTORS DTC P0261 P0262 P0264 P0265 High P0264 37 Rear Fuel Injector Circuit 6 18 FUEL INJECTORS DTC P0261 P0262 P0264 P0265 Low P0265 36 Rear Fuel Injector Circuit 6 13
64. Part No HD 41404 B gray pin probes and patch cords See Figure 6 19 Does test lamp flash when engine is cranked Measure resistance from terminal 2 of connector 83RB to ground Is resistance less than 0 5 Ohms Faulty ignition coil connection or ignition coil Repair wiring as necessary If wiring is okay replace ignition coil Locate and repair open or connection from terminal 2 of connector B3RB to ground BK wire Install breakout box between harness and ECM Insert test lamp adapter into terminals 9 and 31 of the black side of the breakout box Next insert test lamp adapter into terminals 9 and 32 of the black side of the breakout box See Figure 6 20 Does test lamp flash when engine is cranked Check for voltage at terminal of 83RB Is battery voltage present Disconnect ECM from breakout box Measure resistance between terminal 1 of connector 83RB to terminals 31 and 32 of breakout box Black Is resistance less than 0 5 Ohms Perform wiggle test See 1 3 DIAGNOSTICS TROUBLESHOOTING Any Intermittents found Replace Locate and repair open or poor connection between terminal 3 of connector B3RB and terminal 87 of ignition relay GY wire Repair as necessary Locate and repair open or poor connection between terminal 1 of connector 83RB and terminals 31
65. See Figure 6 29 The ECM supplies and monitors a 5 Volt signal applied to one side of the ECT sensor The ECT sensor is a thermistor device meaning that at a specific temperature the sensor has a specific resistance across its terminals As this resistance varies so does the voltage at the temperature sensor input at the ECM Refer to Table 6 16 Athigh temperatures the resistance of the sensor is very low with a corresponding lowering of the signal voltage Atlow temperatures the resistance of the sensor is very high This allows the voltage to rise close to the supplied voltage of 5 volts The ECM monitors this voltage to com pensate for various operating conditions An overheated engine represented by hot engine coolant temperature causes the ECM to command a soft skip spark 1 of 4 removed and then a hard skip spark 1 of 2 removed when the engine is above a certain RPM and throttle threshold Table 6 16 Code Description DTC DESCRIPTION P0117 Engine coolant temperature circuit low ed01733 P0118 Engine coolant temperature circuit high Figure 6 29 ECT Sensor Location Engine Removed for Clarity Diagnostic Tips An intermittent may be caused by any of the following condi tions Poor Connection Inspect ECM harness connector 11 for backed out terminals improper mating inoperative locks improperly formed or damaged terminals poor ter minal to wire connection
66. TABLE OF 5 6 24 RIGHT AND LEFT FAN CONTROL DTC P0691 P0692 P0693 P0694 Description 6 84 6 84 Connector 6 84 6 25 MANIFOLD ABSOLUTE PRESSURE MAP SENSOR DTC P0107 P0108 Description and 6 90 Bc nsi si p es 6 90 Connector Informatio sasainn cttm 6 90 6 26 BATTERY VOLTAGE DTC P0562 P0563 Description 6 94 Discogs TP irde 6 94 Gonrector IBformabloh 6 94 6 27 INTAKE SYSTEM P1110 P1111 P1112 Description and 6 97 Gonhector Infortmalion uuu iet coi 6 97 6 28 ENGINE CRANKS BUT WILL NOT START Description and Operation gem 6 101 Diagnostic 6 101 Spark Plug _ RET 6 101 Spark PME 6 101 Fuel Injector Test mmm 6 101 6 29 STARTS THEN STALLS Description and 6 104 Ta 6 104 Connector 1 2 2 22 6 104 6 30 MISFIRE AT IDLE OR UNDER LOAD Description and
67. TROUBLESHOOTING Repair as necessary Replace ECM fc01877 en 2008 Buell 1125R Engine Management 6 43 DTCs P0261 P0262 P0264 and P0265 Part 2 of 2 Continued from DTCs P0261 P0262 P0264 and P0265 Part 1 of 2 Turn ignition OFF Check resistance between terminal 1 of connector 848 858 and terminal 87 of ignition relay Is resistance less than 1 Ohm rp YES No Ignition relay is OK NOTE Locate and repair open See 1 3 DIAGNOSTICS TROUBLESHOOTING or poor connection on If the relay terminal called out does not match GY wire the relay being checked Locate and repair open in GY O wire from terminal 30 of ignition relay to ignition fuse 6 44 2008 Buell 1125R Engine Management Replace ignition relay 1001878 START RELAY P0617 6 14 DESCRIPTION AND OPERATION See Figure 6 26 When the starter switch is pushed the start relay is activated and battery current flows to the starter solenoid and removes power from the lighting circuit allowing maximum battery current to flow to the starter motor When the starter switch is released the start relay de energizes the starter solenoid disconnects voltage from the starter motor and the lighting circuit functions normally The ECM controls the ground to the relay which it disables during security and tip o
68. When the side stand is fully retracted the sensor picks up the presence of the metal bolt fastened to the aluminum side stand When the side stand is extended the engine starts and runs only if the ECM receives a signal from the neutral switch indicating the transmission is in neutral or a signal from the clutch switch indicating that the clutch is engaged Otherwise the engine stalls as the clutch is released with the transmission in gear The ECM provides 5 Volt power and ground to the side stand sensor A signal is sent on the TN W wire to the ECM based on the side stand position This signal allows the ECM to determine whether the side stand is retracted or extended The side stand circuit also provides a fail enable mode This mode allows the engine to start and run if the system recog nizes a problem with the side stand sensor circuit Table 6 9 Code Description ed01727 6 22 2008 Buell 11258 Engine Management DTC DESCRIPTION P1501 Side stand sensor low aus Side stand sengpr high Figure 6 9 Side Stand Sensor P1503 Side stand down at vehicle speed Diagnostic Tips Unplug the neutral switch connector 131 Use the DVOM to test for continuity to ground When in neutral continuity should exist can be verified by the neutral light being illuminated on the instrument cluster When the transmission is in gear there should be no continuity to ground through the neutral switch ver
69. 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 CRIMPER Part No HD 41609 Separating Pin and Socket Housings 1 If necessary slide connector attachment clip T stud to the large end of the opening MULTILOCK 2 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 1 Hold the housings to match wire color to wire color 2 Insertthe socket housing into the pin housing until it snaps in place 3 location is 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 1 2 3 Socket housing 4 Pin housing Figure A 1 AMP Multilock Connector Removing Terminals from Housing 1 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 2 Look in the terminal side of the connector opposite the secondary lock and note the cavity next to each terminal 3 Insert a pick or pin into the terminal cavity until it stops NOTE If socke
70. minal from the mating end of the connector b For push to seat Pull on the lead to draw the ter minal out the wire end A 14 2008 Buell 1125R Appendix A Connector Repair Inserting Socket Terminal NOTE For wire location purposes alpha characters are stamped into the socket housings 1 SeeFigure A 19 for pull to seat connector or Figure A 20 for push to seat connector Using a thin flat blade like that on a hobby knife carefully bend the tang outward away from the terminal body 2 Gently pull or push on the lead to install the terminal back into the chamber A click is heard when the terminal is properly seated 3 Gently pull or push on the lead to verify that the terminal is locked in place For push to seat See Figure A 20 Seat wires in separate channels of wire lock and then push channels inside chambers at wire end of socket housing Fully installed slot on each side of wire lock engages ear on socket housing sm00027 sm00028 1 Locate tang in chamber 1 Remove wire lock 2 Pivot to depress tang 2 Pivot pin to depress tang 3 Push to remove A E to remove 4 Raise tang to install Raise tang to insta Figure A 19 150 Metri Pack Connector Pull to Seat Figure A 20 150 Metri Pack Connector Push to Seat 2008 Buell 1125R Appendix A Connector Repair A 15 280 5 7 280 METRI PACK CONNECTOR REPAIR General
71. starter solenoid Crank the starter 3 Move the black meter lead to the battery side post on the starter solenoid Crank the starter 4 Finally move the black meter lead to the negative battery post and the red meter lead to the starter case Crank the starter When testing a typical ground circuit place the black meter lead on the negative battery post Place the red meter lead at the negative side of the connector in question Move the red meter lead through the circuit until the high voltage drop is found WIGGLE TEST PART NUMBER TOOL NAME B 48115 BREAKOUT BOX HD 39978 DIGITAL MULTIMETER FLUKE 78 HD 48650 DIGITAL TECHNICIAN II The Wiggle Test checks for the presence of intermittents in a wiring harness The DIGITAL TECHNICIAN II Part No HD 48650 can be used to perform the Wiggle Test 1 SeeFigure 1 28 Connect DIGITAL MULTIMETER FLUKE 78 Part No HD 39978 to wiring harness between the suspect connections When diagnosing ECM connections use BREAKOUT BOX Part No B 48115 to simplify the procedure See 1 2 DIAGNOSTIC TOOLS 2 Setthe DVOM to read voltage changes 3 Start the motorcycle engine and run at idle 2008 Buell 1125R General Information 1 11 4 Shake wiggle the harness to detect intermittents If intermittents are present radical voltage changes register on the DVOM ed02008 Figure 1 28 Digital Multimeter Fluke 78 Part N
72. terminal A terminal 10 to 227A terminal C BK W and 11B Gray terminal 24 to GN BE 227A terminal B R W Is resistance less than 0 5 Ohms Is resistance less than 0 5 Ohms Check continuity between 227A Locate and repair Replace terminal C GN BE to open GN BE EOM ground and retest Is continuity present Measure resistance from 227A terminal C GN BE to 227A terminal A and then terminal B Is resistance greater than 1 0 megohms Locate and repair short GN BE and retest Locate and repair shorted wiring and retest Replace fuel pressure sensor Locate and repair open wiring and retest 1001895 en 2008 Buell 1125R Engine Management 6 67 FUEL PUMP 0628 P0629 6 20 DESCRIPTION AND OPERATION See Figure 6 37 The pump is located inside the fuel tank The fuel pump provides the means for moving fuel from the fuel tank to the fuel injectors See Figure 6 38 for major components of the fuel pump The fuel pump is controlled through a ground in the ECM Refer to Table 6 20 The DTCs set if BN Y wire is shorted to 12 Volts BN Y wire is shorted to ground This causes the fuel pump to run continuously even when the motor is not running Fuel pump motor stalls NOTE If the fuel pump is faulty DTC P0087 sets Table 6 20 Code Description DTC DESCRIPTION P0628 Fuel pump co
73. the rear cylinder approaches TDC earlier than the front cylinder engine phase can be readily discriminated Phasing is normally accomplished on the first TDC cycle after engine synchronization Once phased the ECM can begin normal ignition events If the ECM experiences a system reset or loss of synchroniza tion while the engine is running it also loses phase When phase is lost one of the following occurs 1 If an engine not running Crank Mode RPM is detected the ECM executes the normal start up phasing process 2 f Engine Run Mode is detected the ECM executes a running re phase sequence The front cylinder is fired every engine revolution The ECM monitors the power stroke after the fire event to determine if sufficient acceler ation occurred to indicate the ECM fired on the compres sion stroke When two valid power strokes are detected the ECM locks phase and resumes normal ignition events Engine Run Mode Many functions of the DDFI 3 system require an engine run mode determination Engine run is determined by the level of engine RPM Generally the engine is considered to be running when engine RPM exceeds a minimum of 450 RPM 2008 Buell 1125R Engine Management 6 3 SENSORS AND DRIVERS 6 3 DESCRIPTION AND OPERATION Sensors and drivers play an important part in the ECM s ability to provide the proper operational parameters for engine effi ciency emissions control and fuel economy When a
74. wire between the the open in the solenoid terminal Spin GY O wire 1 and battery 5831 Replace the solenoid NO 1 01780 en Locate and repair the open on the R wire 5824 2008 Buell 1125R Starting Charging 3 9 Starter Does Not Spin Part 2 of 3 Continued from Starter Does Not Spin Part 1 of 3 Check for voltage on ignition relay socket terminal 86 Is battery voltage present NOTE See 1 3 DIAGNOSTICS TROUBLESHOOTING If the relay terminal called out does not match the relay being checked Check for continuity to ground on ignition relay Disconnect connector 22 RH socket terminal 85 controls Check for battery voltage Is there continuity on terminal 4 R BK wire of 22A NOTE 15 battery voltage present See 1 3 DIAGNOSTICS TROUBLESHOOTING If the relay terminal called out does not match I relay being checked YES NO I Check for continuity between terminal 3 of connector 22A W BK wire and ignition relay Socket terminal 86 Is continuity present NOTE See 1 3 DIAGNOSTICS TROUBLESHOOTING If the relay terminal called out does not match the relay being checked Locate and repair the open on the R BK wire 5831 Remove start relay Check for voltage on start relay socket terminal 86 with the start switch pressed Is battery voltage present NOTE See 1 3 DIAGNOSTICS Locate and
75. 0 25 11 8 0 CONDUCTANCE TEST PART NUMBER TOOL NAME HD 48053 ADVANCED BATTERY CONDUCT ANCE AND ELECTRICAL SYSTEM ANALYZER Use the ADVANCED BATTERY CONDUCTANCE AND ELECTRICAL SYSTEM ANALYZER Part No HD 48053 and perform a battery test as follows 1 Connect the HD 48053 analyzer directly to the lead ter minals of the battery not to the bolt or wire terminal 2 Follow the instructions in the analyzer instruction manual to perform a battery test The test results include a decision on the battery condition and the measured state of charge See Figure 3 20 The analyzer printer provides a printout including one of the following test results GOOD BATTERY Return the battery to service GOOD RECHARGE Fully charge the battery and return to service CHARGE amp RETEST Fully charge the battery and retest REPLACE BATTERY Replace the battery CELL REPLACE Replace the battery and retest BATTERY NOISE Remove surface charge from battery and retest NOTES REPLACE BATTERY test result may also mean a poor connection between the battery cables and the vehicle After disconnecting the battery cables from the battery retest the battery using the out of vehicle test before replacing Connect the tester directly to the lead terminals of the battery not the bolts MCR 101 HD V1 0 C MIDTRONICS ed02811 MON 02 21 05 3 45 PM LAST 6 OF VIN 012345 DATE
76. 1 3 DIAGNOSTICS TROUBLESHOOTING If the relay terminal called out does not match the relay being checked See 1 3 DIAGNOSTICS TROUBLESHOOTING Disconnect the ECM connector 10 BK Test the BK GN wire between terminal 19 of connector 10B and terminal 12 of the auxiliary connector for an open Is an open present Replace the auxiliary relay Test the BK GN wire between terminal 19 of connector 10B and terminal 12 of the auxiliary connector for a short to ground Is a short to ground present Locate and repair the open in the BK GN wire Test the BK GN wire between terminal 19 of Locate and repair the short to connector 10B and terminal 12 of the auxiliary ground in the BK GN wire connector for a short to voltage Is a short to voltage present Locate and repair the short to voltage in the BK GN wire Replace and program the ECM 1 01843 en 2008 Buell 1125R Accessories Horn Lights and Security 5 3 AUXILIARY POWER iliary relay Therefore faults could occur that would affect the The ECM only monitors the ground to the coil side of the aux set Table 5 2 Auxiliary Power Symptom Table operation of the auxiliary power circuit without it causing a DTC SYMPTOM COMMON CAUSE Auxiliary Power Inoperative Poor ground or open in the switch side circuit of the relay
77. 10 x i 5 3 8 gg 2 g g c p 3 5 5 AEN 3 x z 5 5 8 2 8 5 5 5 5 8 9 8 S 4E o o 24 5 5008 8 E ECM Figure 6 47 CKP ECT IAT O2 Sensors and Cooling Fans 2008 Buell 1125R Engine Management 6 85 DTCs P0691 and P0692 Part 1 of 2 Does right fan run continuously Disconnect connector 10 Black at EOM Turn ignition switch ON Does right fan run Repair short to ground in BK O wire between ECM and right fan Go to DTCs P0691 and P0692 Part 2 of 2 Is engine hot NOTE Fan operates when engine coolant temperature exceeds 170 F 77 Allow engine to cool Connect connector 10 Black and turn ignition Switch ON Does the right fan run continuously Defective ECM or ECM connection 6 86 2008 Buell 1125R Engine Management Turn ignition switch OFF Connect Breakout Box Part No B 48115 to ECM connector 11 Gray Turn ignition switch ON Measure voltage at Breakout Box connector 11 Gray terminal 9 Is voltage greater than 1 3 Volts See 6 16 ENGINE COOLANT TEMPERATURE ECT DTC P0117 P0118 and retest System operating normally 1 01910 en DTCs P0691 and P0692 Part 2 of 2 Is fuse ok Connect Breakout Box Part No B 48115 to ECM co
78. 1125R Engine Management 00276 Ignition Start Fuse Switch Switch vod RIGY BK R za 5 87 Start 4 7 7 gt 3 30 L y wy 2 2 85 BK R 10 1 86 n 62B Relay Block 5 Q gt 5 E H ic 19 14 S 11458 19 14 145 E 6 gt a 10 10 lt lt 7 7 Starter Enable 9 9 Ignition Switch 9817 17 Battery BK 8 8 System Ground 4 BK EE 16 16 System Ground 3 424 24 System Ground 2 33 33 System Ground 1 GND 1 O O 28 ND 2 Figure 6 51 ECM Power and Ground 2008 Buell 1125R Engine Management 6 95 DTCs P0562 and P0563 See 3 4 BATTERY TESTING Perform battery and charging system tests Is the battery and charging system OK Disconnect fuel pump connector 86 to purge fuel from system Attach Breakout Box B 48115 to ECM Measure voltage at Breakout Repair charging Box connector 10 Black terminal 9 and System or replace ground while cranking engine Disregard battery voltage during first two seconds of cranking Is voltage above 9 6 Volts System Measure voltage drop between battery operation positive terminal Breakout Box connector normal 10
79. 16 Intake Air Temperature IAT 6 55 Intake Leak 1 9 J Job Time Codes 1 12 K Key nolo epe ERR e 3 1 L LED TITE cocco E BERBERBEREERTODBETERESDIID 4 3 9 M Low Fuel Lamp Diagnostic 4 20 M Manifold Absolute Pressure MAP 6 90 2 2 Metri Pack Terminals Grimbping 12 Misfire Diagnostics 6 108 MODE nis sx e ERE 4 2 N Neutral 6 31 O2 Sensor civ eee REP RA EP RR REND 6 74 ceci p emt rk ines 4 1 Oil Pressure Lamp 4 11 Onboard Diagnostic Information System ODIS Live Data 4 3 Screen Messages 4 3 Oxygen 6 74 Relay ctor ee e A E ERE du 1 12 OVErVIOW ees 1 12 1 12 Running Sensors and 6 48 S Sealed nee EL AE EN A 20 Sensors Bank Angle Sensor 5 6 4 6 5 Clutch
80. 2 2008 Buell 1125R General Information 1 O2 sensor front 138 above snorkel 2 IAT sensor 89 Figure 1 4 O2 and IAT Connectors ed01753 p 1 Cooling fan right connector 97 2 RHair scoop Figure 1 5 Cooling Fan Right Connector ed01736 WONOAPWNn gt BAS 134 CAN connector 243 ECM 10 BK ECM 11 GY CKP sensor 79 Interface connector 145 Fan sub harness 234 DLC 91 Cooling fan left connector 215 Figure 1 6 Rear Brake Switch Connector 121 Figure 1 8 LH Air Scoop Connectors 2008 Buell 1125R General Information 1 3 ae 001 n A _ gt EL 1 TP sensor 88 2 ECT sensor 90 3 IAC 87 Figure 1 9 Throttle Body Connectors Left rear turn signal 19 GND Right rear turn signal 18 Power License plate lamp 45 Power Tail stop lamp 93 Power Tail stop lamp 93 GND License plate lamp 45 GND Right rear turn signal 18 GND Left rear turn signal 19 Power gt Figure 1 11 Rear Lamp Connectors Figure 1 10 Side Stand Sensor Connector 133 1 4 2008 Buell 1125R General Information 1 Oil pressure switch 120 2 Hydraulic clutch pressure hose Figure 1 12 Oil Pressure Switch Location 1 Neutral switch 131 2 Shift shaft F
81. 24B 38A fs 2jYl TEL l Starter Solenoid n x M 8 Es 8 x x LI m 5 5 m Left Left Right Right Low Marker Marker Low Turn Signal Headlamp H Lamp Lamp H 8 Beam Switch Switch Pass Head Head Switch lamp lamp Figure 2 5 Ignition Accessory Power 2 8 2008 Buell 1125R Initial Diagnostics and Serial Data 00243 3 3 E a Horn Switch L1 A 122A 1 1228 en Left Front Turn Signal Y 3118 BK Clutch Switch V 95A s 7 1958 12 Auxiliary Connector 2 Y 160B Instrument i Cluster pod Plate 13 4 39 1 13 Y 398 1 45 Tail Stop Em Lamp Right Front Left Rear 1 93A Turn Signal Turn Signal 938 1 NLISTRA 1 AVIA T Y 81RB 1 Y 198 Y Y Right Rear 5 5 Turn Signal 1 18 1 Y 18B i Right Right Left Left High Low Low High Beam Beam Right Left Beam Beam Head Head Marker Marker Head Head lamp lamp Lamp Lamp lamp lamp Voltage Regulator B A 2 2 es B A 2 2 77B 77A T 4 x m a m m a Starter Solenoid 1284 Y 112
82. 3 Volts YES Connect connector 10 Black and turn ignition switch ON Does the left fan run continuously 6 16 ENGINE COOLANT TEMPERATURE ECT DTC P0117 P0118 and retest Repair ECM connector or replace 6 88 2008 Buell 1125R Engine Management System operating normally fc01912 en DTCs P0693 and 0694 Part 2 of 2 Continued from DTCs P0693 and P0694 Part 1 of 2 Check fan fuse 10 Amp Is fuse ok Connect Breakout Box to ECM Black connector leave ECM disconnected With ignition switch ON check for voltage at Breakout Box terminals 18 and 26 Is battery voltage present With ignition switch ON check for battery voltage at 215B terminal 1 fan connector Is battery voltage present Connect jumper wire between ground and the following Breakout Box connector 10 Black terminals 18 and 26 Does the left fan run Check for continuity between Breakout Box connector 10 terminals 18 and 26 and terminal 2 of 215B Is continuity present Locate and repair open in circuit between left fan connector 215B Y BN wire and fuse block Replace ECM Locate and repair open in circuit between ECM connector 10 Black and Y O wire of left fan connector 215B Check for continuity Between terminals 1 and 2 of 215A Is continuity prese
83. 3ERW 2 Ignition Sensor 3 Coil 131A 131B I Neutral EMEN Switch GND 1 2 gt 5 gt gt zu x 9 V 55 B82 vanim uun umu 11B J 2 8 417 18 19 25 24 34 28 26 27 GND 8 9 16 2425 29 30 31 32 33 34 2 8 4 17 18 19 25 24 34 28 26 27 1 o 16 2425 29 30 31 32 34 10 4 de mo Snir N 5555 mo omms Coe gore 132229 EB 8858 222255224553 59555 55 85 EES ss Poro 85885 55 22 6 aage8522858 5 ceee 72E ga 885 82 F ZHVEOD eo B E Jp ma E 8 5 GY o BK Figure 6 4 Primary Input Sensors and Drivers CRANK POSITION SENSOR P0337 P0338 P0339 6 7 DESCRIPTION AND OPERATION See Figure 6 5 The CKP sensor is located on the left side engine cover below the base of the rear cylinder The ECM monitors the CKP signal AC voltage on terminals 18 R BE and 26 BK BE of connector 11 If the CKP signal is not detected or cannot synchronize the engine will not start and DTC P0339 sets NOTE The engine must be cranked for more than five seconds without CKP signal to set codes Table 6 7 Code Description DTC DESCRIPTION P0337 Crank position sensor circuit low P0338 Crank position sen
84. 8 2008 Buell 1125R Accessories Horn Lights and Security LIGHTS 5 3 DESCRIPTION AND OPERATION COMPONENTS See The lighting system includes the headlamps turn signals marker lamps license plate lamp tail and brake lamps The lights are powered by the accessory brake horn and lights fuse The accessory fuse circuit supplies power for the front marker lamps the turn signal switch the license plate lamp and the tail lamp The accessory circuit receives power when the ignition switch is in the ON or the PARK position The headlamps each have an individual connection that runs through a sub harness and is attached to the main harness through the headlamp connector 38 Ignition switch 33 Instrument Cluster IC 39 Headlamp 38 Left front turn signal 31L Right front turn signal 31R Left hand controls 24 Right hand controls 22 0 o m dw 12 V auxiliary connector Figure 5 8 Behind Fairing Connectors Park Lighting The park position allows the lamps to operate when the motorcycle is parked with the ignition and forks locked In the park position the power from the ignition switch is supplied to front marker lamps e turn signal switch e IC tail lamps e license plate lamp The IC backlighting illuminates and the front marker lamps are on The tail lamp and license plate lamp illuminate and the turn signals flash if the turn signal switch is operated Headlamp Switc
85. CAN Low 10 1pR CAN High Dm P s Subharness Oil Pressure Input Instrument Cluster Sensor Ground 3 CAN High CAN Low Oxygen Sensor Rear 1 High Beam Input 8 3 4 E Vehicle Speed Sensor 7 8 Right Turn Input Left Turn Input Chassis Ground Constant Battery Left Turn Driver Vehicle Battery Fuel Pump Output Fuel Pump Output WO WO 12 Pressure Switch GY 13 Switched Ignition 2 14 Starter Enable 15 Fan 1 2 16 17 Clutch Switch 18 Switched Ignition 1 20 m dH Ignition Switch gt gt ux Relay GND as 1458 1 Im gt 31LB 95B a E Left Front Turn Signal Clutch 2 BK Switch 4 TN LGN gt 24
86. Continued from DTCs P1501 P1502 and P1508 Part 1 of 3 Disconnect side stand sensor connector and ECM connector 11 Gray Test for continuity between connector 133B terminal 3 and connector 11 Gray terminal 28 Is continuity present Reconnect ECM Turn ignition switch ON and engine stop switch in RUN Test for voltage on terminal 1 connector 133B Is voltage present Locate and repair open Is voltage approximately 5V Turn off ignition switch Connect Breakout Box Part No B 48115 to wiring harness connector 11B Gray leaving ECM connector 11 Gray disconnected Test for continuity from connector 11B Gray terminal 34 to connector 133B terminal 2 Disconnect ECM connector 11 Test for voltage on terminal 1 of connector 1338 Is voltage present Is continuity present NO Locate and repair Replace short to voltage ECM Connect Breakout Box Part No B 48115 to ECM connector 11A Connect side stand sensor connector 133 Test terminal 34 of the Breakout Box for voltage with the side stand retracted and extended Are the voltages within the specification Locate and repair open Replace side stand sensor Replace Turn off ignition switch and disconnect Test for continuity from connector 133B terminal 1 to ground Is continuity present Test
87. DIG EAR IO SE AS 6 45 DIC P0628 e Rem eas 6 68 DTC P0629 eee Age 6 68 P0691 de AG Ae 6 84 DTG P0692 oce E ERG ence o o e era en 6 84 P0699 p Ep etes 6 84 P0694 he EEG Se a TS 6 84 DIO ER Lever Ae Poe pe 6 97 EX 6 97 6 18 A EU RES 6 97 DIG Jd de ERRORES DURS eene 6 27 DIC P1152 Ree eres 6 27 P1154 tie Carat bete T rete As 6 31 6 31 DIG Recta 6 22 DIC P1502 FRIES 6 22 DTC P1503 e a BR ENS 6 22 2228 6 59 2229 6 59 2300 6 35 2301 6 35 2303 m 6 35 2304 E 6 35 U0001 999 2 12 ise eiie ben elk och dnd a 6 3 E BAUR 6 11 Electronic Control Module 6 3 Engine Coolant Temperature 6 51 Engine Stop 3 1 F Fluid C 2 Fuel Injector necp ERES 6 40 Fuel Injector Test
88. EF E T 5 m ontrols gt 2 1 ri 7 EWEN 8 _ 18 15 2 4 16 a7 6 3 17 e iN 5 EIS 5 AS 55885 3 dxs 5 4 5 118 lt lt 1234 234 2 24 21 0 10 22 12 9 23 vl Kk 1234 Y 2348 111915 14 02687 195 4 201216 17 A 62B oc oc oc c 5 EX x 1 2345 12345 12345 62A Fan Subharnees l la 8530 37 868530 87 868536 7 868530 87 i ne ll Connector 12V 27 N N N N bs M lt Block Fuse GND 1 Connector m __ Start Ignition Auxiliary Figure B 7 Main Chassis Wiring Harness 2008 1125R Model Figure B 7 Figure B 7 Main Chassis Wiring Harness 2008 1125R Model Main Chassis Wiring Harness 2008 1125R Model et00095 Oil Crank Position Engine Coolant Ox Neutral Idle Air pied Switch 22 ECT Sensor ee Controller IAC ntake ron gt Solenoid 07 D L 79A 123 138A 74 1234 87A 120A 1 191A 1 E 90A J 2 1788 12 i IEEE A y may s 908 Y 12 178AI4 12 B EA x 4 11B 11A 2 Clutch Switch 4 Throttle Position Sensor 5 Barometric Pressure Sensor 6 Manifold Absolu
89. Engine Management 6 13 Connector Information For additional information on the connectors in the following diagram s see B 1 CONNECTORS 00230 Switch Side Stand Sensor E E 3 2 1 TN LGN in pad 127 95 95 gt gt o 3 BK Grounds m Chassis Grounds In Wiring Diagrams GND 1 TN LGN R GY 145B 145A TNLGN Ignition Switch Battery Power Distribution 858 85 lt lt 6 14 2008 Buell 11258 Engine Management In Wiring 1 1 Rear Fuel 79A 79B Diagrams GN GY E 2 2 Injector gt gt Crank 1 1 Position 2 2 84 84 lt av m 1 1 Front Fuel 134A 134B 2 2 Injector gr m Bank 4 ER 83RB 83RA Angle 5 5 Jp LGN GY LE Sensor 6 6 FB BAS BEOmB 1 1 Rear BK m 2 2 Ignition Sensor Grounds GY m Coil In Wiring Diagrams 88A 88B gt gt 83FB 83FA Throttle J1 1 lt lt Position 2 2 1 1 Front TP
90. FUEL INJECTORS DTC P0261 P0262 P0264 P0265 High P0502 40 Vehicle Speed Sensor 6 21 VEHICLE SPEED SENSOR VSS P0502 AND P0503 Low P0503 41 Vehicle Speed Sensor 6 21 VEHICLE SPEED SENSOR VSS P0502 AND P0503 Intermittent Erratic High P0506 54 Idle Air Control System 6 23 IDLE AIR CONTROL IAC DTC P0506 P0507 P0511 RPM Higher Than Expected 6 48 2008 Buell 1125R Engine Management Table 6 15 Diagnostic Trouble Codes Priority Table DTC PRIORITY FAULT CONDITION DIAGNOSTIC PROCEDURE ORDER P0507 55 Idle Air Control System 6 23 IDLE AIR CONTROL IAC DTC P0506 P0507 P0511 RPM Lower Than Expected P0511 53 Idle Air Control Circuit 6 23 IDLE AIR CONTROL IAC DTC P0506 P0507 P0511 Fault P0562 39 Battery Voltage Low 6 26 BATTERY VOLTAGE DTC P0562 P0563 P0563 38 Battery Voltage High 6 26 BATTERY VOLTAGE DTC P0562 P0563 P0628 28 Fuel Pump Circuit Low 6 20 FUEL PUMP DTC P0628 P0629 P0629 27 Fuel Pump Circuit High 6 20 FUEL PUMP DTC P0628 P0629 P0691 58 Right Fan Control Circuit 6 24 RIGHT AND LEFT FAN CONTROL P0691 P0692 P0693 P0694 Low P0692 56 Right Fan Control Circuit 6 24 RIGHT AND LEFT FAN CONTROL P0691 P0692 P0693 P0694 High P0693 59 Left Fan Control Circuit 6 24 RIGHT AND LEFT FAN CONTROL DTC P0691 P0692 P0693 P06
91. IGNITION COILS DTC P2300 P2301 P2303 P2304 trol Circuit Low P2301 30 Front Ignition Coil Con 6 12 IGNITION COILS DTC P2300 P2301 P2303 P2304 trol Circuit High P2303 33 Rear Ignition Coil Control 6 12 IGNITION COILS DTC P2300 P2301 P2303 P2304 Circuit Low P2304 32 Rear Ignition Coil Control 6 12 IGNITION COILS DTC P2300 P2301 P2303 P2304 Circuit High 6 10 2008 Buell 1125R Engine Management ERRORS P0603 P0604 P0605 P0607 6 5 DESCRIPTION AND OPERATION The ignition switch supplies power to the ECM If the ECM does not appear to receive power check the ground sources An open ECM fuse can also disable the ECM When the ignition relay is energized by the run switch power is applied to the DLC 91A at terminal 4 GY wire The flowchart in this section is concerned with an ECM that is either not receiving power or is not operational For all DTCs listed in Table 6 5 replace the ECM Table 6 5 Code Description DTC DESCRIPTION SOLUTION P0603 ECM EEPROM failure Replace ECM P0604 ECM RAM failure Replace ECM P0605 ROM failure Replace ECM P0607 microprocessor failure Replace ECM CONNECTOR INFORMATION For additional information on the connectors in the following diagram s see B 1 CONNECTORS 00231 Ignition Switch Battery Power Distribution In Wiring Diagrams
92. License plate lamp 45 GND Right rear turn signal 18 GND Left rear turn signal 19 Power Figure 5 13 Rear Lamp Connectors Diagnostic Tips When testing voltage for LED turn signals be sure to use a voltmeter The current used to operate LEDs may not be suffi cient to light a test lamp and may cause false diagnostics Connector Information For additional information on the connectors in the following diagram s see B 1 CONNECTORS _ _ Instrument Cluster 39 12 V auxiliary connector Headlamp 38 Left front turn signal 31L Right front turn signal 31R Left hand controls 24 Right hand controls 22 Ignition switch 33 Figure 5 12 Behind Fairing Connectors 2008 Buell 1125R Accessories Horn Lights and Security 5 15 00254 Ignition And p Pover In gt Wiring Diagrams Fuse IEEE OO DEG 4 Block 2 9 Brake Horn 10 10 6 3 NG 5 Do RY 8 2 2 Switch X 1708 170A Ignition And Rear Accessory m Brake Power ow RY 2 2 Swit
93. NO Recharge battery YES Place transmission in neutral and engine stop switch to ON Did fuel pump run for 2 3 seconds and the check engine lamp illuminate Install fuel pressure gauge Crank Turn ignition switch Replace battery No fuel pump response but check engine lamp is OK See FUEL engine for more than two seconds to verify proper system operation Does pressure rise to 58 75 PSI 400 517 kPa Incorrect pressure See FUEL PRESSURE SENSOR DTC P0192 P0193 P0087 Go to Engine Cranks But Will Not Start Part 2 of 2 6 102 2008 Buell 1125R Engine Management PRESSURE SENSOR DTC P0192 P0193 P0087 Short fuel pump response check engine lamp OK See 6 10 BANK ANGLE SENSOR BAS DTC P1151 P1152 No fuel pump response or check engine lamp See ECM ERRORS DTC P0603 P0604 P0605 P0607 1 01914 en Engine Cranks But Will Not Start Part 2 of 2 Continued from Engine Cranks But Will Not Start Test Part 1 of 2 Check spark plug condition Replace if fouled Check spark at both plugs while cranking Is spark present YES Disconnect fuel injector connector and attach Fuel Injector Test Lamp HD 34730 2C Crank engine Does lamp flash ves NO Using DVOM check for battery voltage at ignition coils
94. ON MOTORCYCLE Perform starter current draw test on 5824 pisci motorcycle ground Perform Starter Motor Free Running connections Current Draw Test on bench 5835 Are test results within range YES NO With the spark plugs removed and the transmission in 6 gear rotate rear wheel Check for engine and or crankshaft bind Replace the starter Use appropriate code 5817 fc01779 Starter Does Not Spin Part 1 of 3 Test for voltage at terminal 1 starter solenoid relay connector 128B GN wire Is battery voltage present when start switch is pressed Turn the ignition switch ON Did the headlamps turn on With the engine stop switch in the run position and the start switch pressed Did the headlamps shut off Spin Part 3 073 Go to Starter Does Not NO S YES Check for continuity at terminal 2 starter solenoid relay connector 128B BK wire to ground Is there continuity Connect starter solenoid relay connector 128 Locate and Test for battery voltage repair the at the starter with the open in the start switch pressed ground circuit Is voltage present Replace the starter Make sure the transmission is in neutral disengage clutch and verify the security system is disarmed With the start switch pressed did the headlamps hut
95. Part 1 of 2 With a DVOM still connected check for intermittents Are intermittents present Connect Breakout Box to ECM and disconnect IAT sensor connector Turn ignition switch ON Using a DVOM measure the voltage between Breakout Box connector 11 Gray terminal 14 and 28 Is voltage approximately 5 0 Volts Perform wiggle test See 1 3 DIAGNOSTICS TROUBLESHOOTING Repair as necessary YES iu ie Less than 4 7 Volts Greater than 5 3 Volts Unplug ECM leaving Breakout Box Replace sensor Clear With IAT sensor disconnected connected at vehicle harness and road test disconnect ECM connector 11 Measure Measure voltage between Did check engine lamp turn on resistance between ECM connector 11 Breakout Box connector 11 and set DTCs P0112 or Gray terminal 14 and ground Gray terminal 14 and ground P0113 Is resistance less than 1 megohm Is the voltage 0 0 Volt Install original Locate and repair Check IAT sensor sensor and System OK short to Replace Replace signal wire LGN Y replace ECM y LGN Y wire ECM ECM for short to 12 Volts then road test and repair fc01890_en 6 58 2008 Buell 1125R Engine Management BAROMETRIC PRESSURE BARO SENSOR DTC P2228 P2229 DESCRIPTION AND OPERATION See Figure 6 33 The BARO sensor functions similar to the
96. Rear oxygen sensor open inactive P1047 Feedback fuel cylinder difference too great Figure 6 43 Rear O2 Sensor Location Diagnostic Tips The DVOM Part No HD 39978 displays the signal from the oxygen sensors in volts This voltage is an average value tending towards lean rich or ideal value depending on the operating temperature of the engine engine speed and throttle position An open short to voltage or short to ground in the V GY wire causes the engine to run rich short to ground or lean short to voltage When a fault is detected the ECM remains in an open loop The engine must be running below 5000 RPM for the to detect O2 sensor failure Check for the following conditions Poor Connection Inspect harness connector fuel injector connectors and O2 sensor connector 137 wiring for backed out terminals improper mating inoperative locks improperly formed or with damaged terminals poor terminal to wire connection and damaged harness Dirty Stuck Open Injectors The motorcycle may run lean dirty clogged injectors or rich stuck open injectors if there is an injector problem This could also cause poor fuel economy and performance Loose O2 Sensor If the O2 sensor is loose engine per formance may be affected This could also show up as a slow changing O2 sensor voltage Loose Leaking Exhaust or Cracked Leaking Intake Manifolds This can cause a poo
97. Repair DEUTSCH ELECTRICAL CONNECTORS A 3 DEUTSCH CONNECTOR REPAIR TOOL NAME DEUTSCH CONNECTOR SERVICE KIT FLAT BLADE L HOOK PART NUMBER HD 41475 HD 41475 100 General Deutsch connectors are colored coded for location purposes Those connectors associated with left side accessories such as the front and rear left turn signals are gray All other con nectors including those associated with right side accessories are black NOTE A DEUTSCH CONNECTOR SERVICE KIT Part No HD 41475 contains a selection of wire seals internal seals seal plugs secondary locking wedges attachment clips and socket pin terminals Also included is a compartmented storage box carrying case and a FLAT BLADE L HOOK Part No HD 41475 100 is used for the removal of all types of locking wedges Separating Pin and Socket Housings See Figure A 10 To separate the connector halves depress the external latch es 1 on the socket housing 2 while rocking the pin 3 and socket housings NOTES Generally the socket housing is found on the accessory side while the pin housing is plumbed to the wiring har ness Two three four and six place Deutsch connectors one latch on the connector Eight and twelve place connectors have a latch on each side Simultaneously press both latches to separate the connector Mating Pin and Socket Housings 1 Align the connectors
98. a symptom while others cause a DTC to set along with the symptom When a is stored the sends signal to the Instrument Cluster IC The IC illuminates the check engine lamp If more than one DTC exists diagnose them in the order of priority starting with the lowest number Refer to Table 2 1 for a complete list of DTCs and the order of priority RETRIEVING DIAGNOSTIC TROUBLE CODES DTCS PART NUMBER HD 48650 TOOL NAME DIGITAL TECHNICIAN There are two ways to retrieve DTCs DIGITAL TECHNICIAN Part No HD 48650 a com puter based diagnostics package See Figure 2 1 The Instrument Cluster IC to view the DTCs In order to view the DTCs on the IC perform the following procedure 1 Hold down the MODE and TOGGLE switches at the same time as the ignition is turned on 2 displays DIAG MODE Press the TOGGLE switch again to display the first DTC 3 Continue pressing and releasing the TOGGLE switch to move to the next stored DTC 4 When all DTCs have been scrolled through the IC displays the message LIVE DATA NOTE If the security system is armed when entering DIAG MODE the message ENTER PIN displays when the ignition is turned on Once the correct pin is entered the display changes to DIAG MODE The TOGGLE switch then cycles through the DTCs normally ed01694 LCD screen Tachometer TOGGLE switch MODE switch Indicator lamps Warnin
99. and damaged harness Shifted Sensor Resistance Value Compare the temper atures of the ECT and IAT sensors with the engine at ambient temperature in order to evaluate the possibility of a shifted out of calibration sensor which may result in driveability problems The sensor temperatures should be within 10 degrees of each other Connector Information For additional information on the connectors in the following diagram s see B 1 CONNECTORS 2008 Buell 1125R Engine Management 6 51 00277 Intake Crank Coolant Air Position Temperature Temperature Oxygen Cooling CKP ECT IAT Sensor Fan 1 Sensor Sensor Sensor Rear Right eren 1 2 3 79 2 1 9041 1 89 1 137A 221 974 1 2 3 Y 79B 2 1 YI90B 2 1 YI898 1 Y 1378 2 1 YI97Bl x gt 2 Cooling a a gt 2 m 2 d T m g amp 2 Left Oxygen Baro Sensor Front Side Stand F Y 2 1 215A L 2 1 Y 215B amp 2 1 J 138A Y 11388 gt d 2 E gt gt gt 5 2 1 3 4 2348 2 1 AJ 2344 ain Kw eee re gt gt 5 2 m Cooling Y BN Fan Fuse v a gt E m T 4 15 16 V A 1458 4 15 16 145 o o 5 Y 3
100. approx imately 60 MPH ed01338 WALEY 2402900 41354 SPEEDO TESTER ENTER Figure 1 23 Speedometer Tester Part HD 41354 Leak Tester The leak tester contains Standard 14 oz propane cylinder PROPANE ENRICHMENT KIT Part No HD 41417 121 305 mm long section of 1 4 in 6 mm diameter copper tubing To assemble the leak tester 1 Cutrubber hose from kit to 18 in 457 mm in length 2 See Figure 1 24 Flatten one end of copper tube to form a nozzle 3 SeeFigure 1 25 and insert round side of copper tube into end of 18 in 457 mm tubing ed02009 Ew Figure 1 24 Nozzle ed02010 G Nozzle Copper tubing Hose Valve Knob Propane bottle o gt Figure 1 25 Leak Tester 2008 Buell 1125R General Information 1 9 Intake Leak Testing WARNING Do not allow open flame or sparks near propane Propane is extremely flammable which could cause death or ser ious injury 00521b NOTE Perform test with adequate ventilation 1 Start the engine 2 Warm the engine to operating temperature 3 Turn knob on propane bottle counterclockwise to open NOTE Do not direct propane stream toward the front of the engine If propane enters the air cleaner a false reading will be obtained 4 SeeFigure 1 26 and aim nozzle toward possible sources of leak such as fuel injectors and inta
101. battery and other vehicle systems Figure 3 12 Voltage Regulator Location ANCE AND ELECTRICAL SYSTEM ANALYZER When the charging system fails to charge or does not charge at the normal rate check the battery wiring and voltage regu lator Battery Check for a weak or dead battery See 3 4 BATTERY TESTING for battery testing procedures Battery must be fully charged in order to perform a load test and starting or charging tests However a partially discharged battery may be tested using the BATTERY TEST function of the ADVANCED BATTERY CONDUCTANCE AND ELECTRICAL SYSTEM LYZER Part No HD 48053 Wiring The stator s plug and socket connections must be clean and tight Check for corroded or loose connections in the charging circuit Voltage Regulator Inspection The voltage regulator ground must have a clean tight connec tion for proper grounding Check by using an ohmmeter with one lead on a known good ground such as battery ground cable and the other on the regulator body Job Time Code Values Dealership technicians filing warranty claims should use the job time code values printed in bold text underneath the appropriate repair Connector Information For additional information on the connectors in the following diagram s see B 1 CONNECTORS 2008 Buell 1125R Starting Charging 3 13 00248 77A 4 778 Y 30Amp_ si B
102. check engine lamp illuminate and set DTC P0107 or P0108 Identify the source of intermittents and repair as necessary Replace ECM System Road test to verify operating repair normally fc01917 en 6 92 2008 Buell 1125R Engine Management DTCs P0107 and 0108 Part 2 of 2 Continued from DTCs P0107 and P0108 Part 1 of 2 Disconnect connector 80 Removal of throttle body is necessary to access connector With ignition ON measure voltage between terminal 1 R W and terminal 2 BK W of BOA Is voltage approximately 5 0 Volts YES Connect Breakout Box to 11B leaving disconnected Measure resistance between MAP sensor connector 808 terminal 3 and Breakout Box terminal 6 Gray Is resistance less than 1 Ohm NO Greater than 6V Less than 4 5V Connect Breakout Box to 11B leaving Locate short to 12 Volts on R W wire in wire harness Repair as necessary ECM disconnected Check continuity between MAP connector B0B terminal 1 and Breakout Box terminal 24 Gray Then measure continuity between MAP sensor connector YES Measure the resistance between MAP sensor connector 80B terminal 3 and chassis ground Is resistance greater than 1 megohm ERG Locate and repair open on V GN wire Replace MAP Sensor Locate and repair grounded V GN wire
103. does not flash or the flash is interrupted during the misfire event the problem is ignition related NOTE An In line Spark Tester can also be used in conjunction with a load able dynamometer to diagnose misfire under load ed01780 Figure 6 59 Inline Spark Tester Misfire Idle or Under Load Is fuel contaminated YES Drain and flush fuel tank Refill with fresh fuel Perform Spark Test Did spark jump gap at both coils YES NO Check for Faulty worn or cracked spark plug s Spark plug gap too great Spark plug fouling due to engine mechanical fault Faulty or poor connection at spark plug s Loose wires on primary side of ignition coils Intermittent ECM operation power input and output Exchange ignition coil with known good unit Perform spark test Did spark jump gap during engine cranking YES Original ignition coil is faulty Replace Check for faulty ignition coil to spark plug connection and evidence of carbon tracking Stick coils can crack and cause a short circuit around the spark plug Are connections OK and no evidence of carbon tracking m LIE NO Replace faulty ignition coil s and spark plugs Test the CKP sensor to verify signal Is the CKP sensor signal present If problem
104. en 6 62 2008 Buell 1125R Engine Management FUEL PRESSURE SENSOR P0192 P0193 P0087 DESCRIPTION AND OPERATION See Figure 6 35 The fuel pressure sensor is mounted in the fuel line feeding the fuel rail Variations in fuel rail pressure are converted to a voltage output to the ECM for fuel pump control For all fuel pressure sensor DTCs the ECM drives the pump to maximum pressure Refer to Table 6 19 The ECM incorpor ates automatic compensation for differences of the desired pressure versus the actual pressure For instance if the pres sure is lower than desired the ECM opens the injectors for a longer time to adjust the amount of fuel delivered NOTE If the fuel pump fails or when the vehicle is out of fuel DTC P0087 sets The output of the ECM still attempts to drive the fuel pump to maximum output under these conditions Table 6 19 Code Description DTC DESCRIPTION P0192 Fuel pressure sensor circuit low P0193 Fuel pressure sensor circuit high P0087 Fuel pressure sensor too low Figure 6 35 Fuel Pressure Sensor Location Connector Information For additional information on the connectors in the following diagram s see B 1 CONNECTORS 2008 Buell 1125R Engine Management 6 63 0027
105. failure occurs is generated by and stored in the These codes help the technician diagnose engine trouble to the proper sensor or driver See 2 1 INITIAL DIAGNOSTICS SENSORS Not all sensor problems cause an engine shutdown but sensor failure can seriously degrade overall engine performance A notable exception is the CKP sensor which if faulty completely disables engine operation The following are brief explanations of sensor types and their functions within the DDFI 3 system Crank Position CKP Sensor The sensor is a variable reluctance device that generates AC voltage as the teeth on the alternator rotor pass by the sensor The signal is routed to the ECM where it is used to determine crankshaft position engine speed RPM and engine phase TDC compression Without the presence of the CKP signal the ECM will not allow the ignition and fuel injection drivers to operate and thus the engine will not run The ECM uses crankshaft compression slow down events to determine engine phase Therefore the spark plugs must be installed when checking for spark Throttle Position TP Sensor The TP sensor is a variable resistor potentiometer having a linear resistance range mounted on the throttle plate shaft The 1125R uses one sensor mounted on the left side of the forward cylinder throttle body The output of the sensor is a voltage dependent on the position of the throttle plate and used b
106. from socket terminal 85 to terminal 7 of connector 10A GN O wire Test start relay NOTE See 1 3 DIAGNOSTICS TROUBLESHOOTING If the relay terminal called out does not match the relay being checked YES Replace ECM 56 Replace start relay 1 01905 en 2008 Buell 1125R Engine Management 6 47 RUNNING SENSORS AND DRIVERS DESCRIPTION AND OPERATION Dynamic sensors and drivers are the devices that manage engine operation between start up and WOT If these devices Table 6 15 Diagnostic Trouble Codes DTC Priority Table 6 15 Refer to Table 6 15 for devices in this category are not in proper operating condition the engine may idle or run rough lack power overheat or use excessive amounts of fuel DTC PRIORITY FAULT CONDITION DIAGNOSTIC PROCEDURE ORDER P0087 29 Fuel Rail System Pres 6 19 FUEL PRESSURE SENSOR DTC P0192 P0193 P0087 sure Too Low P0107 63 MAP Sensor Low Open 6 25 MANIFOLD ABSOLUTE PRESSURE MAP SENSOR P0107 P0108 P0108 62 MAP Sensor High 6 25 MANIFOLD ABSOLUTE PRESSURE MAP SENSOR DTC P0107 P0108 P0113 21 Intake Air Temperature 6 17 INTAKE AIR TEMPERATURE IAT SENSOR DTC P0112 P0113 Sensor High Open P0117 20 Engine Coolant Temper 6 16 ENGINE COOLANT TEMPERATURE
107. gt gt gt 9 9 Y m 5 ev 8 gt 2 m gt t z m 2 m m e 2 iL I m a _ _ 101 01 1 iAUIogEESoO 5 16 1458 S TVA i DLC E z 5 2 8 2 Q a E 5 Z 2 1 1L m n 13 19 25 17 4 24 27 6 10 28 5 34 11 13 19 25 17 4 24 27 6 10 28 5 N 11A 5 g 7 8 5 E 3 5 5 GY 8 H lt 8 s B 2 3 5 2 5 2 5 5 8 5 gt Figure 6 34 5V Reference Circuit 6 60 2008 Buell 1125R Engine Management DTCs P2228 and P2229 Part 1 of 2 Connect Breakout Box B 48115 With ignition ON measure voltage between Breakout Box connector 11 Gray terminals 5 and 28 Is voltage between 3 5 and 5 0 Volts Perform wiggle test See 1 3 DIAGNOSTICS TROUBLESHOOTING Are intermittents present Go to DTCs P2228 and P2229 Part 2 of 2 Replace BARO sensor Perform road test Did check engine lamp illuminate and set DTC P2228 or P2229 Install original BARO sensor Replace ECM System reprogram relearn and operating road test again normally to verify repair fc01921 en 2008 Buell 1125R Engine Management 6 61 2228 2229 2 012 Continued from DTCs P2228 and P2229 Part 1 of 2 With the
108. ignition switch ON check the 5 Volt reference supply at the BARO sensor connector 228B Is the voltage between terminal 1 R W and terminal 2 BK W approximately 5 0 Volts NO NO Greater than 6V Less than 4 5V Connect Breakout Box to 11B leaving ECM disconnected Connect Breakout Box to 11B leaving ECM disconnected Check continuity between OPEN CHECK Measure Locate short to 12 volts on barometric pressure connector 228 terminal 1 resistance between BARO R W wire in wire harness and Breakout Box terminal 24 Then measure connector 228B terminal 3 and Repair as necessary continuity between BARO connector 228B Breakout Box terminal 5 terminal 2 and Breakout Box terminal 28 Is resistance less than 1 Ohm Is resistance less than 1 Ohm Check resistance between SHORT CHECK Measure resistance BARO connector 228B between BARO sensor connector Locate and repair terminal 1 and Breakout Box Locate and repair terminal 3 and chassis ground open on BN BE wire terminal 28 Is resistance greater than 1 megohm Is resistance greater than open wire 1 megohm YES No YES No Locate and repair short between R W and BK W wires Locate and repair Replace ECM Replace BARO grounded BN BE Reprogram and learn sensor wire password fc01922
109. illuminates The IC receives the RPM data over the CAN lines from the ECM Odometer The odometer displays the distance traveled by the motorcycle There are five different odometer settings that can be displayed by clicking the MODE switch These include the main odometer ODO trip odometer 1 TRIP 1 trip odometer 2 TRIP 2 service odometer SERVICE and the low fuel odometer F trip The trip odometers record mileage until they are reset and then start over The fuel odometer is only available when the low fuel light is on and tracks the mileage traveled since the low fuel light came on The service odometer tracks the number of miles kilometers left until the next regular mainten ance is due Clock The clock displays the current time and can be set for either a 12 or 24 hour format Indicator Lamps See Figure 4 2 The indicator lamps are located at the top edge of the IC and inform the operator of turn signal headlamp and neutral positions ed01695 Left turn signal indicator Neutral indicator Headlamp high beam indicator Right turn signal indicator Pens Figure 4 2 Indicator Lamp Left Turn Signal Indicator The IC uses a direct input on ter minal 4 from the left turn switch to determine when to flash the left turn signal indicator The IC then supplies the voltage to the left turn signals Neutral Indicator The IC receives a message from the ECM over the CAN lines letting the IC know w
110. in the British Imperial system 1pint Imp 20 fluid ounces Imp 1 quart Imp 2 pints Imp 1 gallon Imp 4 quarts Imp Although the same unit of measure terminology as the U S system is used in the British Imperial Imp system the actual volume of each British Imperial unit of measure differs from its U S counterpart The U S fluid ounce is larger than the British Imperial fluid ounce However the U S pint quart and gallon are smaller than the British Imperial pint quart and gallon respectively Should you need to convert from U S units to British Imperial units or vice versa refer to the following e fluid ounces U S x 1 042 fluid ounces Imp e pints U S x 0 833 pints Imp quarts U S x 0 833 quarts Imp gallons U S x 0 833 gallons Imp e fluid ounces Imp x 0 960 fluid ounces U S pints Imp x 1 201 pints U S quarts Imp x 1 201 quarts U S e gallons Imp x 1 201 gallons U S TORQUE CONVERSION C 3 UNITED STATES SYSTEM METRIC SYSTEM The U S units of torque foot pounds and inch pounds are used in this service manual To convert units use the following equations foot pounds ft lbs X 12 00000 inch pounds in Ibs inch pounds in Ibs X 0 08333 foot pounds ft lbs metric torque specifications are written in Newton meters Nm To convert metric to United States units and Unite
111. leads were connected at those points on the circuit Most of the voltage on a good working circuit drops across the components the circuit is powering Typically a good circuit drops less than 1 0 volt If the voltage drop is greater backtrack the connections until the source of the potential difference is found Always start at the destination then move upstream if there is an issue The benefits of doing it this way are Readings are not as sensitive to real battery voltage 2 Readings show the actual voltage dropped not just the presence of voltage 3 The system is tested as it is actually being used 4 Testing is more accurate and displays hard to find poor connections 5 Starting circuits lighting circuits or ignition circuits can be tested with this approach Start from the most positive and go to the most negative destination or component When testing a starter circuit measure the voltage drop across the following sections of the circuit If the voltage drop increases over 1 0 volt on any of the tests then the wire or connection tested contains the high resistance and should be repaired 1 Connect the red meter lead to the positive battery post Connect the black meter lead to the battery power starter post on the starter and observe the meter reading Crank the starter and observe the meter reading The difference in the voltage is the voltage drop 2 Move the black meter lead to the starter side post of the
112. lines are shorted together Locate and repair the short Replace the instrument cluster Disconnect IC connector 39 Test the PK V wire for continuity between terminal 1 of connector 243B and terminal 9 of connector 39B Is continuity present Disconnect IC connector 39 Test terminals 1 and 2 of connector 243B for a short to ground Is a short to ground present YES Test for continuity in the PK GY wire between terminal 2 of connector 243B and terminal 10 of connector 39B Is continuity present Locate and repair open in PK GY wire Replace the instrument cluster Test terminal 1 and terminal Locate and 2 2 of connector 2438 for a PK V PK GY short to voltage PK V wire wire Is a short to voltage present YES NO Locate and repair short to voltage in PK V or Replace and program the PK GY wire ECM 1001927 en 2008 Buell 1125R Accessories Horn Lights and Security 5 33 5 5 34 2008 Buell 1125R Accessories Horn Lights and Security TABLE OF CONTENTS SUBJECT PAGE NO aS t 6 2 ELECTRONIC CONTROL MOD LEs 6 3 SENSORS AND DRIVERS 6 4 SYMPTOM DIAGNOSTICS 6 5 ECM ERRORS DTC P0603 P0604 P0605 P0607 6 6 STARTING SENSORS AND DRIVERS m 6 7 CRANK POSITION CK
113. manifold absolute pressure sensor It is located under the seat at the rear of the throttle body baseplate In this position the sensor monitors the ambient air pressure located outside of the airbox When the ambient air pressure drops less fuel is needed to maintain the proper air fuel mixture The output of the sensor allows the ECM to compensate for changes in barometric pressure due to altitude or weather variations Table 6 18 Code Description DTC DESCRIPTION P2228 P2229 Barometric pressure sensor circuit low Barometric pressure sensor circuit high Figure 6 33 Barometric Pressure Sensor Connector Information For additional information on the connectors in the following diagram s see B 1 CONNECTORS 2008 Buell 1125R Engine Management 6 59 00274 Vehicle Bank Throttle Absolute Barometric Speed Angle Position Pressure Fuel BARO Side Sensor Sensor TP MAP Pressure Pressure Stand VSS BAS Sensor Sensor Sensor Sensor Sensor B 65 4 5 6 4 1 2 3 88 1_2 80 4 2278 1 2 228 1 2 3334 A B 658 4 s 1348 1 2 888 1 2 s Y 80B aA 227 1 2 s YI228B 2 s Y 133B JT Im mw Tn Ww T n Ww gt
114. off NO YES Remove the start relay Check for continuity on the GN wire from terminal 1 connector 128B to relay socket terminal 87 of the start relay Is there continuity See 6 11 CLUTCH AND NEUTRAL SWITCHES NOTE DTC P1154 P1155 See 1 3 DIAGNOSTICS TROUBLESHOOTING If the relay terminal called out does not match the relay being checked Test the ignition fuse Did fuse test OK YES Locate and repair Repare ms the open in the Remove the ignition relay GN wire Is battery voltage present on 5832 ignition relay socket terminal 30 252 1 3 DIAGNOSTICS TROUBLESHOOTING If the relay terminal called out does not match the relay being checked Test for battery voltage on R wire at solenoid terminal 1 Test the GY O wire between the ignition fuse and the ignition relay for short to ground Repair the circuit and replace the fuse Is battery voltage present 5831 at solenoid terminal 2 With the start switch pressed Locate and repair Check for voltage on R wire Is battery voltage present the open intha R Go to Starter Does Not With the start switch pressed Check for voltage on the R wire at the starter terminal Is battery voltage present YES Replace the starter 5825 Locate and repair
115. over the insulation seal See Figure A 17 A completed crimp may require two different crimping dies found PACKARD TERMINAL TOOL Part No HD 38125 6 and or PACKARD TERMINAL CRIMPER Part No HD 38125 7 The terminal pin or socket and the wire lead gauge will determine the core crimp die and the insulator seal die NOTE The PACKARD CRIMPING TOOL Part No HD 38125 8 will also crimp sealed splice connectors in wire gauge sizes 18 20 14 16 and 10 12 Preparing Wire Lead Use a wire striper to strip off the insulation and expose 5 32 in 4 0 mm of wire core Crimping Wire Core NOTE Metri Pack terminal crimps require two steps Always perform Crimping Wire Core before Crimping Insulation Seal 1 Squeeze and release handles until ratchet automatically opens 2 Identify the corresponding sized nest for the core crimp 3 Position the core crimp in the die Be Sure the core crimp tails are facing the forming jaws 4 Gently squeeze the handles until crimpers just secure the core crimp tails 5 Insert stripped wire between crimp tails Verify that wire is positioned so that short pair of crimp tails squeeze core wire strands while long pair is positioned over the insula tion or seal material 6 Squeeze handles tightly closed Release grip and the tool will automatically open A 12 2008 Buell 1125R Appendix A Connector Repair sm00035 1 HD 38125 6 sealed terminals 2 HD 38125 7 non seal
116. peccet A 20 APPENDIX B WIRING B 1 CONNECTORS Connector LOGSIOFiuu eso erdt A B 1 EP E CER a dE B 1 Place apa REC 1 Connector Number ro rrrr rrr tiet B 1 Repair ISI ICTIONS eee B 1 B 2 WIRING DIAGRAMS Wiring Diagram normalen Wire Color Codes Wiring Diagram Symbols 2008 1125R Wiring Diagrams TABLE OF CONTENTS APPENDIX C CONVERSIONS C 1 METRIC CONVERSION ep rt tree fermen 1 C 2 FLUID CONVERSIONS United States 202222221 2 Metric SV SIE pe SD kt tee ERI RR CURES 2 British Imperial 2 TORQUE CONVERSION United States 2 3 C 3 APPENDIX D GLOSSARY D 1 GLOSSARY Acronyms and D 1 REFERENCE MATERIAL TOOL mte P C TORQUE 2 oce pU nn dA V TABLE OF CONTENTS VII 5 Vill TABLE OF CONTENTS 5 SUBJECT PAGE NO LJ SONPONENT LOCATION HI REPRE 1 2 DIAGNOSTIC TOOLS ms T M e 1 3 DIAGNOSTICS TROUBLESHOOTING
117. persists source is most likely mechanical rather than electrical Repair as indicated by results of crank position sensor test and recheck problem fc01924 en 2008 Buell 1125R Engine Management 6 109 5 6 110 2008 Buell 11258 Engine Management TABLE OF CONTENTS SUBJECT PAGE NO MULTILOCK rts enero tetti erit tegere Ferrer ette A AS DELPHI CONNMEGTORS s dert agis e M oun A 3 DEUTSCH ELECTRICAL CONNECTORS Ns d A 4 DEUTSCH STANDARD TERMINAL REPAIR saei 5 METRI PACK TERMINALS 12 A 6 150 METRI PACK M A 290 8 480 METRI PACK CONNECTORS 18 9 630 METRI PACK CONNECTORS 19 SEALED SPLICE CONNEC TOR eire tio 5 MULTILOCK CONNECTORS AMP MULTILOCK CONNECTOR REPAIR PART NUMBER TOOL NAME HD 41609 AMP MULTILOCK CRIMPER 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
118. protective face shield rubberized gloves and protective clothing when working with batteries KEEP BATTERIES AWAY FROM CHILDREN 00063a WARNING Never remove warning label attached to top of battery Failure to read and understand all precautions contained in warning could result in death or serious injury 00064a WARNING Explosive hydrogen gas which escapes during charging could cause death or serious injury Charge battery in a well ventilated area Keep open flames electrical sparks and smoking materials away from battery at all times KEEP BATTERIES AWAY FROM CHILDREN 00065a WARNING If battery becomes hot gassing or spewing of electrolyte can occur which could cause death or serious injury Unplug or turn OFF the charger until battery cools 00412b WARNING Batteries battery posts terminals and related accessories contain lead and lead compounds and other chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Wash hands after handling 00019e CAUTION If battery releases an excessive amount of gas during charging decrease the charging rate Overheating can result in plate distortion internal shorting drying out or damage 00413b See Figure 3 6 The Absorbed Glass Mat AGM battery stores energy in chemical form to provide electrical power for the vehicle The AGM batteries are permanently sealed mainten ance fr
119. pushed to the left voltage is supplied through the W V wire at terminal 4 of the IC Turn Signals The front turn signals are located on the housings of the rear view mirrors The rear turn signals are located at the sides of the rear fender The turn signals use LEDs instead of conven tional bulbs The IC controls the turn signals When the turn signal switch is pressed voltage is sent to the IC The IC then drives the turn signals for the appropriate side Tail Stop Lamp The tail stop lamp illuminates with the ignition switch the ON or PARK position When either the front or rear stop lamp switches are applied the second filament in the bulb illuminates to light the brake lamp The tail lamp portion of the lamp is powered by the accessory fuse through the O W wire The stop lamp portion of the lamp receives power through the R Y wire when either one of the stop lamp switches are applied License Plate Lamp The accessory fuse supplies power to the license plate lamp on the O W wire The license plate lamp illuminates when the ignition is in the ON or PARK position Stop Lamp Switches The front and rear stop lamp switches control the stop lamp portion of the tail stop lamp The front stop lamp switch is a mechanical switch When the front stop lamp lever is applied the lever presses a mechanical switch and closes the contacts on the switch The rear stop lamp switch is a pressure switch When the rear stop lamp sw
120. repair the ground circuit TROUBLESHOOTING If the relay terminal called out does not match 5828 5 the relay being checked Replace the right Locate and repair the Switchgear open on the W BK wire 5818 5831 YES NO Disconnect connector 22 Check for continuity on terminal 1 connector 22A BK R wire to Connect voltmeter from socket terminal 10 to Socket terminal 86 of the start relay socket terminal 2 in the relay block Check for Is continuity present voltage with start switch pressed NOTE Is battery voltage present See 1 3 DIAGNOSTICS TROUBLESHOOTING If the relay terminal called out does not match the relay being checked NO Check for open on GN O wire from start relay socket terminal 85 to the ECM Is open present NOTE See 1 3 DIAGNOSTICS TROUBLESHOOTING With the start switch pressed check for continuity between terminals 1 and 2 of connector Locate and repair the BK R wire Replace the start relay 5832 If the relay terminal called out does not match 22B 5827 the relay being checked YES Check continuity on terminal 2 connector 22A Locate and repair Replace GY wire to socket terminal 87 on ignition relay the GN O wire the ECM NOTE Replace the See 1 3 DIAGNOSTICS TROUBLESHOOTING right switchgear 5827 5820 If the rel
121. resistance greater than 1 0 megohm Turn ignition switch OFF Disconnect ECM connector 11 Gray Check for continuity between connector 88 terminal 3 R W wire and connector 11 Gray terminal 24 Is continuity present ves Check continuity from connector 11 terminal 4 to connector 88 terminal 2 Is continuity present Locate and Check continuity between connector repair short 88 terminal 1 BK W wire and to ground on connector 11 Gray terminal 27 V Y wire Is continuity present Locate and repair open in V Y wire YES Locate and jas V Y wire Locate and repair open in BK W wire Measure resistance between connector 88 terminals 1 and 3 Is resistance greater than 1 megohm NO Disconnect TP sensor connector 88 Measure resistance between connector 88B terminals 1 and 3 Is resistance greater than 1 megohm Replace ECM No Locate and repair short between R W and BK W wires ves Replace TP sensor 1001867 en 2008 Buell 1125R Engine Management 6 21 SIDE STAND SENSOR P1501 P1502 P1503 HDI ONLY 6 9 DESCRIPTION AND OPERATION See Figure 6 9 The side stand sensor uses a Hall effect sensor to monitor side stand position
122. signal 18 Power License plate lamp 45 Power Tail stop lamp 93 Power Tail stop lamp 93 GND License plate lamp 45 GND Right rear turn signal 18 GND gt Left rear turn signal 19 Power Figure 5 15 Front Brake Switch Connectors 170 ed01736 Figure 5 16 Rear Brake Switch Connector 121 Figure 5 17 Rear Lamp Connectors Diagnostic Tips When testing for a short to ground due to an open fuse check the R Y wire between the brake switches and the stop lamp A short to ground on these wires causes the fuse to open only when the brake switches are closed A short to ground in the Y BK wire between the horn switch and the horn causes this fuse to open when the horn switch is pressed and needs to be checked for a short to ground as well Connector Locations For additional information on the connectors in the following diagram s see B 1 CONNECTORS 5 20 2008 Buell 1125R Accessories Horn Lights and Security 00254 p m is R GY 10 e Brake Horn 10A OW OW Turn Ignition And Accessory Power In Wiring Diagrams 5 Left 6 BN 7 Right lt lt Turn Signal 24B 24A Switch cn Right Tum Input 5
123. spark tester to ignition coil Clip tester to cylinder head bolt 4 While cranking engine watch for spark to jump spark tester gap on leads 5 Reinstall and repeat procedure on front ignition coil and spark plug NOTE Engine will not spark with spark plugs removed When checking for spark use SPARK TESTER Part No HD 26792 with both plugs installed When performing the steps in the flowcharts a known good part can be used to verify whether a suspected part is faulty The ignition coils do not require full installation to be functional Verify faulty ignition coil by performing resistance test See DTCs P2300 P230 P2303 and P2304 6 108 2008 Buell 1125R Engine Management ed02012 Figure 6 58 Spark Tester In line Spark Tester See Figure 6 59 The use of an In line Spark Tester Snap on YA840 or equivalent can help determine whether the problem exists in the ignition system or the fuel system 1 Turn ignition switch OFF 2 Remove rear ignition coil and install In line Spark Tester between coil and spark plug 3 Startengine and inspect tester light The light will flash on each spark event if power is transmitted to the plug 4 Reinstall and repeat procedure on front ignition coil and spark plug If the tester lamp flashes without interruption on both cylinders during the misfire event verify spark plug condition and gap and inspect the fuel system for proper operation If the test lamp
124. speed the ECM extends the pintle allowing less air to flow through the throttle 2008 Buell 1125R Engine Management 6 5 Cooling Fans The cooling fans run continuously once the engine operating temperature is reached The cooling fans are provided battery voltage from the Y BN wire The ECM controls the fan by providing ground Start Relay When the starter switch is pushed the start relay is activated and battery voltage is sent to the starter solenoid and power is interrupted on the light circuit The ECM controls the ground 6 6 2008 Buell 1125R Engine Management to the relay which it disables during security and tip over con ditions Active Intake The active intake system uses a solenoid under the airbox which is connected to the throttle valve via a cable The throttle valve is automatically closed by the solenoid under certain operating conditions to reduce engine noise The active intake solenoid is provided battery voltage by the ignition relay The ECM provides ground to activate the solenoid SYMPTOM DIAGNOSTICS 6 4 DESCRIPTION AND OPERATION PART NUMBER TOOL NAME B 48115 BREAKOUT BOX HD 39978 DVOM Symptom Diagnostics identifies problems caused by an elec tronic control system malfunction that does not generate DTCs Make sure all current DTCs are corrected before moving to these tests Engine Cranks But Will Not Start Engine Sta
125. to match the wire lead colors a ForOne External Latch Two three four and six place Deutsch connectors have one external latch on the socket half of the connector To fit the halves of the connector together the latch on the socket side must be aligned with the latch cover on the pin side b For Two External Latches 8 place and 12 place Align the tabs on the socket housing with the grooves on the pin housing 2 Insert socket housing into pin housing until it snaps or clicks into place For Two External Latches 8 place and 12 place If latches do not click latch press on one side of the con nector until that latch engages then press on the opposite side to engage the other latch 3 If necessary fit the attachment clip to the pin housing 4 Place large end of slot on attachment clip over T stud on frame Push assembly forward to engage small end of slot 5 00017 1 External latch 2 Socket housing 3 Pin housing Figure A 10 Deutsch Connector Removing Socket Terminals 1 See Figure A 11 Insert a small screwdriver between the socket housing and locking wedge in line with the groove in line with the pin holes if the groove is absent Turn the screwdriver 90 degrees to pop the wedge up and remove the secondary locking wedge 2 See Figure A 14 Use a pick or small screwdriver to depress terminal latches inside socket housing and back out sockets through holes in rear wire seal
126. 01882 en 2008 Buell 1125R Accessories Horn Lights and Security 5 17 Turn Signals Inoperative Part 2 of 3 Disconnect the inoperative turn signal Turn the ignition switch on and activate the right turn signals Using a voltmeter do not use a test light test for voltage from the BN wire at the inoperative turn signal to a good ground Does the voltage cycle on and off as the other turn signal flashes YES Continued from Turn Signals Inoperative Part 1 of 3 Do both left turn signals operate YES Do both of the right turn signals operate D System operating properly See 1 3 DIAGNOSTICS Do turn TROUBLESHOOTING 9 Go to Signals Inoperative Part 3 of 3 Connect voltmeter from the BN wire to the BK wire at the inoperative turn signal Does voltage continue to cycle on and off as the other turn signal flashes vo Does the right turn signal indicator in the instrument cluster operate Repair the open in Disconnect the IC connector the BN wire at the 39 Test for continuity on inoperative turn BN wire from terminal 11 signal to inoperative turn signal Is continuity present Replace the turn signal 5205 Locate and repair the open in the BK wire between the turn signal and ground 6797 Replace the Locate and instr ieri
127. 0563 38 Battery Voltage High 6 26 BATTERY VOLTAGE DTC P0562 P0563 P0603 3 ECM EEPROM Failure 6 5 ECM ERRORS DTC P0603 P0604 P0605 P0607 P0604 1 ECM RAM Failure 6 5 ECM ERRORS DTC P0603 P0604 P0605 P0607 P0605 2 ECM ROM Failure 6 5 ECM ERRORS DTC P0603 P0604 P0605 P0607 P0607 4 ECM Microprocessor 6 5 ERRORS P0603 P0604 P0605 P0607 Failure P0616 61 Starter Relay Circuit Low 6 14 START RELAY DTC P0617 P0617 60 Starter Relay Circuit 6 14 START RELAY DTC P0617 High P0628 28 Fuel Pump Circuit Low 6 20 FUEL PUMP DTC P0628 P0629 P0629 27 Fuel Pump Circuit High 6 20 FUEL PUMP DTC P0628 P0629 P0691 58 Right Fan Control Circuit 6 24 RIGHT AND LEFT FAN CONTROL P0691 P0692 P0693 P0694 Low P0692 56 Right Fan Control Circuit 6 24 RIGHT AND LEFT FAN CONTROL P0691 P0692 P0693 P0694 High P0693 59 Left Fan Control Circuit 6 24 RIGHT AND LEFT FAN CONTROL DTC P0691 P0692 P0693 P0694 Low P0694 57 Left Fan Control Circuit 6 24 RIGHT AND LEFT FAN CONTROL DTC P0691 P0692 P0693 P0694 High P1009 6 Security System Fault 5 4 SECURITY SYSTEM P1047 52 Feedback Fuel Cylinder 6 22 OXYGEN O2 SENSOR P0131 P0132 P0134 P0151 P0152 Difference too Great P0154 P1047 P1110 66 Active Intake Control 6 27 ACTIVE INTAKE SYSTEM DTC P1110 P1111 P1112 Circuit Short Low Open P1111 65 Active Intake Control 6 27 ACTIVE INTAKE SYSTEM DTC P1110 P1111 P1112 Circuit Short High P1112 64 Active Intake Control
128. 1 ed01704 CALIFORNIA PROP posts terminala a reed rt et WASH HANDS AFTER it XR ed01701 ME CALIFORNIA PROP posts terminals and PE propt WASH HANDS AFTER Figure 3 3 Key Relay Ignition Relay See The ignition relay is located in the relay box under the seat When the ignition switch is turned on and the engine stop switch is in the RUN position the ignition relay is activated EK ed01702 CALIFOR posts termi nds Figure 3 4 Ignition Relay Start Relay See The start relay is located in the relay box under the seat When the ignition switch is turned on and the engine stop switch is in the RUN position the ignition relay is activated With the start switch pressed the ECM verifies the clutch is engaged or the transmission is in neutral The ECM then sup plies the ground circuit activating the start relay to transfer power to the starter solenoid Simultaneously power is removed from the headlamps for the duration of the start switch activation 3 2 2008 Buell 1125R Starting Charging Figure 3 5 Start Relay Ignition Switch The ignition switch is located on the handlebars below the Instrument Cluster IC The ignition switch locks the handlebars and turns the electrical power to the motorcycle on and or off Battery WARNING Batteries contain sulfuric acid which could cause severe burns to eyes and skin Wear a
129. 1 A All modes DTCs P0603 P0604 P0605 and P0607 6 104 2008 Buell 1125R Engine Management Diagnostic Tips The vehicle will stall on HDI models if the sidestand is extended when the transmission is in gear and the clutch is released Connector Information For additional information on the connectors in the following diagram s see B 1 CONNECTORS 00274 Vehicle Bank Throttle Absolute Barometric Speed Angle Position Pressure Fuel BARO Side Sensor Sensor TP MAP Pressure Pressure Stand VSS BAS Sensor Sensor Sensor Sensor Sensor B 65 4 5 6 4 1 2 3 88 1 1 2 80 2278 1 2 228 1 2 3334 A B 658 4 s 1348 1 2 888 1 2 s Y 80B A c I227A 2 s YI228B 2 s Y 133B gt gt gt Z v gt 9 m s ev 8 gt m 2 m m gt t z m 2 m m e 2 LL I S m 5 16 1458 S TVA ae DLC E z 2 B B z 2 Q E 2 5 Z 2 1 1L m n 13 19 25 17 4 24 27 6 10 28 5 34 13 19 25 17 4 24 27 6 10 28 5 N 11A E g 7 8 5 E 3 0V E 5 5 S 5 5 8 72 2 o 8
130. 1 01888 en INTAKE AIR TEMPERATURE IAT SENSOR DTC P0112 P0113 6 17 DESCRIPTION AND OPERATION See Figure 6 31 The ECM supplies and monitors a 5 Volt signal applied to one side of the IAT sensor The IAT sensor is a thermistor device meaning that at a specific temperature the sensor has a specific resistance across its terminals As this temperature varies so will the voltage vary at the temper ature sensor input on the ECM Refer to Table 6 17 Athigh temperatures the resistance of the sensor is very low with a corresponding lowering of the signal voltage Atlow temperatures the resistance of the sensor is very high This allows the voltage to rise close to the supplied voltage of 5 Volts The ECM monitors this voltage to compensate for various operating conditions Table 6 17 Code Description ed01734 7 Li DTC DESCRIPTION P0112 Intake Air Temperature sensor voltage low P0113 Intake Air Temperature sensor high open Figure 6 31 IAT Sensor Location Diagnostic Tips An intermittent may be caused by any of the following condi tions Poor Connection Inspect ECM harness connector 11 for backed out terminals improper mating inoperative locks improperly formed or damaged terminals poor terminal to wire connection and damaged harness Shifted Sensor Resistance Value Compare the temperatures of the ECT and IAT s
131. 1 SPECIFICA TIONS refers to chapter 2 CHASSIS heading 2 1 SPECIFIC ATIONS 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 A number of acronyms and abbreviations are used in this document See the D 1 GLOSSARY for a list of acronyms abbreviations and definitions PREPARATION FOR SERVICE Stop the engine when refueling or servicing the fuel system Do not smoke or allow open flame or sparks near gasoline Gasoline is extremely flammable and highly explosive which could result in death or serious injury 00002 Good preparation is very important for efficient service work A clean work area at the start of each job will allow you to perform the repair as easily and quickly as possible and will reduce the incidence of misplaced tools and parts A motorcycle that is excessively dirty should be cleaned before work starts Cleaning will occasionally uncover sources of trouble Tools instruments and any parts needed for the job should be gathered before work is started Interrupting a job to locate tools or parts is a distraction and causes needless delay NOTES To avoid unnecessary disassembly carefully read all rel ative service information before repair work is started In figure legends the number which follows the name of a part indicates the quantity necessary for one complete assembly SERVICE BULLET
132. 134 P0151 P0152 0154 1047 0192 26 Fuel Pressure Sensor 6 19 FUEL PRESSURE SENSOR P0192 P0193 P0087 Circuit Low P0193 25 Fuel Pressure Sensor 6 19 FUEL PRESSURE SENSOR P0192 P0193 P0087 Circuit High P0261 35 Front Fuel Injector Circuit 6 13 FUEL INJECTORS DTC P0261 P0262 P0264 P0265 Low P0262 34 Front Fuel Injector Circuit 6 13 FUEL INJECTORS DTC P0261 P0262 P0264 P0265 High P0264 37 Rear Fuel Injector Circuit 6 13 FUEL INJECTORS DTC P0261 P0262 P0264 P0265 Low P0265 36 Rear Fuel Injector Circuit 6 13 FUEL INJECTORS DTC P0261 P0262 P0264 P0265 High P0337 7 Crank Position Sensor 6 7 CRANK POSITION CKP SENSOR P0337 P0338 P0339 Circuit Low P0338 8 Crank Position Sensor 6 7 CRANK POSITION SENSOR DTC P0337 P0338 P0339 Circuit High P0339 9 Crank Position Sensor 6 7 CRANK POSITION SENSOR P0337 P0338 P0339 Circuit Intermittent P0502 40 Vehicle Speed Sensor 6 21 VEHICLE SPEED SENSOR VSS P0502 AND P0503 Low P0503 41 Vehicle Speed Sensor 6 21 VEHICLE SPEED SENSOR VSS P0502 AND P0503 Intermittent Erratic High P0506 54 Idle Air Control System 6 23 IDLE AIR CONTROL IAC P0506 P0507 P0511 RPM Higher Than Expected P0507 55 Idle Air Control System 6 23 IDLE AIR CONTROL IAC P0506 P0507 P0511 RPM Lower Than Expected P0511 53 Idle Air Control Circuit 6 23 IDLE AIR CONTROL IAC
133. 18 26 10 GY gt 5 8 g gg g 80 2 g c qm me uh 3 5 5 g 3 x z 55 8 ES 8 5 5 5 2i 1 2 O E 8 8 p 8 ECM Figure 6 6 CKP ECT IAT O2 sensors and Cooling Fans 6 16 2008 Buell 1125R Engine Management DTCs P0337 P0338 and P0339 between Breakout Box connector 11 Gray terminals 18 and 26 Is resistance more than 1 megohm Connect Breakout Box Part No B 48115 to harness only leaving ECM disconnected Measure the resistance YES Check for intermittent connection pinched or damaged wires and loose CKP sensor fasteners Are any of these conditions found 36 Repair as necessary Connect DVOM Part No HD 39978 to terminals 18 and 26 on Breakout Box 11 Gray Set DVOM to AC volts and crank engine Does DVOM read 1 0V minimum during cranking With DVOM still connected check for intermittents while performing a wiggle test See 1 3 DIAGNOSTICS TROUBLESHOOTING Are intermittents present Repair as necessary Repair as necessary Reinstall original CKP sensor Replace ECM Check for continuity between terminal 3 of connector 79B and ground Is continuity present Install known good CKP sensor Clear codes and retest Did DTC P0339 set Replace CKP sensor 36 Disconnect connector 79 Le
134. 2 Useafingernail to pry colored terminal lock 2 loose and then remove from mating end of socket housing 3 Using a thin flat blade like the unsharpened edge of a hobby knife gently pry tang 3 outward away from ter minal and then tug on wire to back terminal out wire end of chamber Do not pull on wire until tang is released or terminal will be difficult to remove Installing Socket Terminals NOTE For wire location purposes alpha or numeric characters are stamped into the wire end of each socket housing 1 Gently push tang on socket housing inward toward chamber With the open side of the terminal facing the tang push terminal into chamber at wire end of socket housing 2 Gently tug on wire to verify that terminal is locked and will not back out of chamber If necessary use fingernail to push tang into engagement with terminal 3 Install colored terminal lock onto mating end of socket housing 4 f present seat wires in separate channels of wire lock and then push channels inside chambers at wire end of socket housing Fully installed slot on each side of wire lock engages ear on socket housing sm00014 Figure A 8 Delphi Connector Socket Housing Latch 2008 Buell 1125R Appendix A Connector Repair A 5 5100015 1 Remove wire lock 2 Remove terminal lock 3 Pry tang outward Figure A 9 Delphi Connector Removing Socket Terminals A 6 2008 Buell 1125R Appendix A Connector
135. 234 gt gt 1 2 3 Y BN gt gt 12 12 c V 97A Y 97B 2158 215A Cooling Fan 2 Left Hand Control Switches Brake Switch 121 4 170A Clutch Switch N 95A Start Switch L TS BK R Run Switch Low Beam LH Controls High Beam BE mi 2 wa 4 5 6 Switch ni adc owg 8 lt Left Turn 24B Right Turn Figure B 9 Component Wiring Diagrams Headlamp Assembly Sub Harness Cooling Fan Sub Harness and Hand Control Switches 2008 1125R Model Figure B 9 Figure B 9 Component Wiring Diagrams Headlamp Assembly Sub Harness Component Wiring Diagrams Headlamp Assembly Sub Harness Cooling Fan Sub Harness and Hand Control Switches 2008 Cooling Fan Sub Harness and Hand Control Switches 2008 1125R Model 1125R Model 5 SUBJECT PAGE NO 1 METRIC CONVERSION C 2 FLUID CONVERSIONS 5 2 ccsccsssssssesssesseese T AERE PARARI 76 3 5 METRIC CONVERSION C 1 CONVERSION TABLE Table
136. 26 28 14 31 32 2 3 18 26 108 18 26 9 28 14 31 32 2 3 18 26 10 GY gt 5 8 g gg g 80 2 g c qm me uh 3 5 5 g 3 x z 55 8 ES 8 5 5 5 2i 1 2 O E 8 8 p 8 ECM Figure 6 32 CKP ECT IAT O2 Sensors and Cooling Fans 6 56 2008 Buell 1125R Engine Management P0112 and 0113 Part 1 of 2 Disconnect the IAT sensor connector 89 Measure the resistance between 89A terminals 1 and 2 Is the resistance between 33 761 74 328 Ohms when engine temperature ranges 68 86 F 20 30 C Attach Breakout Box B 48115 to the ECM harness leaving the ECM disconnected Measure the resistance between IAT sensor connector 89B terminal 1 and Breakout Box Gray terminal 14 and 89B terminal 2 and Breakout Box 11 Gray terminal 28 Are both circuits less than 1 0 Ohm Replace IAT sensor Using a DVOM measure the resistance between Breakout Box terminal 14 LGN Y of 11 Gray and ground Is it greater than 1 0 megohm faulty circuit Locate and repair short to ground on LGN Y wire Go to DTCs P0112 and P0113 Part 2 of 2 2008 Buell 1125R Engine Management 6 57 Locate and repair open or poor connection on fc01889 en DTCs P0112 and 0113 Part 2 of 2 Continued from DTCs P0112 and P0113
137. 3 Verify that terminal will not back out of the chamber A slight tug on the cable will confirm that it is locked A 18 2008 Buell 1125R Appendix A Connector Repair 4 Rotate the hinged secondary lock inward until latches fully engage tabs on both sides of connector housing NOTE If removed install new anchored cable strap in O E location Tighten cable strap to capture conduit of both accessory con nector and B connector approximately 1 0 in 25 4 mm from housings 5 00031 1 Button on pin housing 2 Secondary lock latch 3 Opening between tang and chamber wall Figure A 23 480 Metri Pack Connector Remove Socket Terminal 630 5 9 630 METRI PACK CONNECTOR REPAIR PART NUMBER SNAP ON TT600 3 TOOL NAME SNAP ON PICK General Referred to as Packard connectors Metri Pack 630 series connectors are embossed with the initials P E D Separating Pin and Socket Housings NOTE If necessary remove connector from barbed anchor or other retaining device Bend back the external latch slightly and separate pin and socket halves of the connector Mating Pin and Socket Housings Orient the latch to the catch and push the pin and socket halves of the connector together until the latch clicks NOTE If removed install connector on barbed anchor or other OE retaining device Removing Socket Terminal 1 Bend back th
138. 32 2 3 18 26 108 18 26 9 28 14 31 32 2 3 18 26 10 GY gt 5 8 g gg g 80 2 g c qm me uh 3 5 5 g 3 x z 55 8 ES 8 5 5 5 2i 1 2 O E 8 8 p 8 ECM Figure 6 44 CKP ECT IAT O2 Sensors and Cooling Fans 6 76 2008 Buell 1125R Engine Management DTCs P0131 P0132 P0134 P0151 P0152 and P0154 Part 1 of 2 Disconnect O2 sensor from harness Check voltage on 138B front or 137B rear to ground with ignition switch ON Is circuit voltage approximately 0 5 Volts NO 0 Greater than 1 Volt Install Breakout Box leaving harness side connector 11 Go to DTCs P0131 Gray disconnected from the P0132 P0134 P0151 Breakout Box Turn ignition ON P0152 and P0154 Check voltage on terminal 31 Part 2 of 2 front or 32 rear to ground Is voltage approximately 0 5 volts Install Breakout Box leaving harness side connector 11 Gray disconnected from the Breakout Box Measure voltage to ground on terminal 31 front or 32 rear on the gray side of the Breakout Box Is voltage greater than 1 volt Connect breakout box to ECM harness leaving EOM disconnected Turn ignition switch ON Leaving appropriate O2 sensor disconnected check terminal 31 front Turn ignition switch OFF Connect breakout box to ECM harness lea
139. 4 Vehicle Bank Throttle Absolute Barometric Speed Angle Position Pressure Fuel BARO Side Sensor Sensor TP MAP Pressure Pressure Stand VSS BAS Sensor Sensor Sensor Sensor Sensor B 65 4 5 6 4 1 2 3 88 1_2 80 4 2278 1 2 228 1 2 3334 A B 658 4 s 1348 1 2 888 1 2 s Y 80B aA 227 1 2 s YI228B 2 s Y 133B JT Im mw Tn Ww T n Ww gt gt gt gt 9 9 Y m 5 ev 8 gt 2 m gt t z m 2 m m e 2 iL I m a _ _ 101 01 1 iAUIogEESoO 5 16 1458 S TVA i DLC E z 5 2 8 2 Q a E 5 Z 2 1 1L m n 13 19 25 17 4 24 27 6 10 28 5 34 11 13 19 25 17 4 24 27 6 10 28 5 N 11A 5 g 7 8 5 E 3 5 5 GY 8 H lt 8 s B 2 3 5 2 5 2 5 5 8 5 gt Figure 6 36 5V Reference Circuit 6 64 2008 Buell 1125R Engine Management DTCs P0192 P0193 and P0087 Part 1 of 3 Perform Fuel Pressure Test See 1 2 DIAGNOSTIC Is the fuel pressure approximately 75 PSI 517 kPa Is there fuel in fuel tank Fill fuel tank with TOOLS fresh fuel at ignition ON and fluctuates between 55 60 PSI 380 415 kPa while the engine is running No trouble found Review sy
140. 5 29 decia Em 5 30 Emor 5 30 and Instrument Cluster IC Matching 5 30 When Replacing the 5 30 When Replacing the Instrument Cluster IC 5 30 DTC P1009 Security System Fault or THEFT ERROR Message MS ee 5 30 VENTES Telnet 1 5 30 E 5 30 6 1 DDFI 3 OPERATION DOFRI I 6 1 CparetofT 6 1 Connector 6 1 6 2 ELECTRONIC CONTROL MODULE Electronic Control 6 3 ceci oto 6 3 Crank Position Signal Synchronization 6 3 mire iut Cue 5 2 Engine RUN MOSS uic assi nora aki ka and EA ad 6 3 6 3 SENSORS AND DRIVERS Description and 6 4 apo c 6 4 Crank Position Sensotr ener nnns 6 4 Throttle Position TP 6 4 Side Stand Sensor HDI Only 6 4 Bank Angle Sensor 6 4 T is E 6 4 6 4 Fuel Pross ro SONS Ol m 6 4 Engine Coolant Temperature Sensor 6 4 Intake Air Temperature IA
141. 51 Epi cce 6 51 Donnheetor 6 51 6 17 INTAKE AIR TEMPERATURE SENSOR DTC P0112 P0113 Description 6 55 TS 6 55 Connector Imoral ON a 6 55 6 18 BAROMETRIC PRESSURE BARO SENSOR DTC P2228 P2229 Desciipionjand 6 59 OPTS 6 59 6 19 FUEL PRESSURE SENSOR P0192 P0193 P0087 Description and 6 63 ences asado e EL 6 63 6 20 FUEL PUMP P0628 P0629 Description and 6 68 Connector eee 6 68 6 21 VEHICLE SPEED SENSOR VSS P0502 AND P0503 Description and Operation Diagnostic Tips Connector Informatloni uuui seii 6 71 6 22 OXYGEN O2 SENSOR DTC P0131 P0132 P0134 P0151 P0152 P0154 P1047 Description and 6 74 6 74 esca sie toss ni dd ect 6 75 6 23 IDLE AIR CONTROL IAC DTC P0506 P0507 P0511 Description and Diagnostic Tips Connector Information TABLE OF CONTENTS V
142. 5R Starting Charging Starter Testing Disconnect connector 22 Test the BK R Is short to voltage YES Check the battery using visual inspection voltage test and either a conductance test or load test Check the connections at battery starter solenoid ignition switch and the start key and ignition relays Is system operational Starter runs Disconnect starter solenoid relay connector 128B from solenoid Is battery voltage present on terminal 1 GN wire with the start Switch not pressed YES Remove the start relay Is battery voltage present on start relay socket terminal 86 with start Switch not pressed NOTE See 1 3 DIAGNOSTICS TROUBLESHOOTING If the relay terminal called out does not match the relay being checked Test the n terminal 1 wire for Wire ror horto vilia e to voltage 5 Is short to found voltage found GN Repair the short to voltage 5819 Replace the right handlebar switchgear 5818 Repair the short to voltage 5819 Replace the start relay 5832 6 Starter stalls or spins too Slowly Starter spins but does not engage Remove the alternator cover left side Rotate alternator rotor and ring gear assembly Does ring gear engage in one direction and slip in the oth
143. 6 7 2756 40 1 575 73 2 874 106 4 173 050 1 270 1 2 30 48 2 6 66 04 3 15 16 100 01 8 3149 41 1 614 74 2 913 107 4212 0060 1 524 1 1 4 31 75 2 5 8 66 67 4 101 6 9 3543 42 1 653 75 2 953 108 4252 1 16 1 588 1 3 33 02 2 11 16 68 26 4 1 16 102 19 10 3937 43 1 693 76 2 992 109 4291 070 1 778 1 5 16 33 34 2 7 68 58 4 1 104 14 11 4331 44 1 732 77 3 031 110 4331 080 2 032 1 38 3492 2 34 69 85 4 1 8 104 77 12 4724 45 1 772 78 3 071 111 4 370 090 2286 14 35 56 2 8 7112 4 3 16 106 36 13 5118 46 1 811 79 3 110 112 4 409 x 2 540 1 7 16 36 51 2 13 16 71 44 4 2 106 68 14 5512 47 1 850 80 3 149 113 4 449 1 8 3 175 1 1 2 38 10 2 7 8 73 02 4 1 4 107 95 15 5905 48 1 890 81 3 189 114 4488 3 16 4762 1 9 16 39 69 2 9 73 66 4 3 109 22 16 6299 49 1 929 82 3 228 115 4 527 2 5 080 1 6 40 64 2 15 16 74 61 4 5 16 109 54 17 6693 50 1 968 83 3 268 116 4 567 1 4 6 850 1 5 8 41 27 3 76 20 4 38 111 12 18 7086 51 2 008 84 3 307 117 4 606 3 7 620 1 11 16 42 86 3 1 16 77 79 44 111 76 19 7480 52 2 047 85 3 346 118 4645 5 16 7 988 17 43 18 3 1 78 74 4 716 112 71 20 7874 53 2 086 86 3 386 119 4 685 3 8 9 525 1 3 4 44 45 3 8 79 37 4 1 2 114 30 21 8268 54 2 126 87 3 425 120 4724 4 10 160 1 8 45 72 3 316 80 96 4 916 115 89 22 8661 55 2 165 88 3 464 121 4 764 7 16 11 112 1 13 16 46 04 3 2 81 28 4 6 116 84 23
144. 6 27 ACTIVE INTAKE SYSTEM DTC P1110 P1111 P1112 Throttle Position Sensor Feedback Failure P1151 16 Bank Angle Sensor 6 10 BANK ANGLE SENSOR BAS DTC P1151 P1152 Shorted Low P1152 15 Bank Angle Sensor 6 10 BANK ANGLE SENSOR BAS DTC P1151 P1152 Shorted High P1154 17 Clutch Position Sensor 6 11 CLUTCH AND NEUTRAL SWITCHES DTC P1154 P1155 Circuit Low P1155 18 Neutral Switch Input 16 11 CLUTCH AND NEUTRAL SWITCHES P1154 P1155 cuit Low P1501 13 Side Stand Sensor Low 6 9 SIDE STAND SENSOR P1501 P1502 P1503 HDI ONLY P1502 12 Side Stand Sensor 6 9 SIDE STAND SENSOR P1501 P1502 P1503 HDI ONLY High Open P1503 14 Side Stand Down at 6 9 SIDE STAND SENSOR DTC P1501 P1502 P1503 HDI ONLY Vehicle Speed 2008 Buell 1125R Initial Diagnostics and Serial Data 2 3 Table 2 1 Diagnostic Trouble Codes DTC Priority Table DTC PRIORITY FAULT CONDITION DIAGNOSTIC PROCEDURE ORDER P1601 67 Auxiliary Relay Driver 5 1 ACCESSORIES Circuit Fault P2228 24 BARO Pressure Sensor 6 18 BAROMETRIC PRESSURE BARO SENSOR DTC P2228 P2229 Circuit Low P2229 23 BARO Pressure Sensor 6 18 BAROMETRIC PRESSURE BARO SENSOR DTC P2228 P2229 Circuit High P2300 31 Front Ignition Coil Con 6 12 IGNITION COILS DTC P2300 P2301 P2303 P2304 trol Circuit Low P2301 30 Front Ignition Coil Con 6 12 IGNITION COILS DTC P2300 P2301
145. 693 P0694 High P1047 52 Feedback Fuel Cylinder 6 22 OXYGEN O2 SENSOR DTC P0131 P0132 P0134 P0151 P0152 Difference too Great P0154 P1047 P1110 66 Active Intake Control 6 27 ACTIVE INTAKE SYSTEM DTC P1110 P1111 P1112 Circuit Short Low Open P1111 65 Active Intake Control 6 27 ACTIVE INTAKE SYSTEM DTC P1110 P1111 P1112 Circuit Short High P1112 64 Active Intake Control 6 27 ACTIVE INTAKE SYSTEM DTC P1110 P1111 P1112 Throttle Position Sensor Feedback Failure P1151 16 Bank Angle Sensor 6 10 BANK ANGLE SENSOR BAS DTC P1151 P1152 Shorted Low P1152 15 Bank Angle Sensor 6 10 BANK ANGLE SENSOR BAS DTC P1151 P1152 Shorted High P1154 17 Clutch Position 6 11 CLUTCH AND NEUTRAL SWITCHES P1154 P1155 Circuit Low P1155 18 Neutral Switch Input Cir 6 11 CLUTCH AND NEUTRAL SWITCHES DTC P1154 P1155 cuit Low P1501 13 Side Stand Sensor Low 6 9 SIDE STAND SENSOR P1501 P1502 P1503 HDI ONLY P1502 12 Side Stand Sensor 6 9 SIDE STAND SENSOR P1501 P1502 P1503 HDI ONLY High Open P1503 14 Side Stand Down at 6 9 SIDE STAND SENSOR P1501 P1502 P1503 HDI ONLY Vehicle Speed P1601 67 Auxiliary Relay Driver 5 1 ACCESSORIES Circuit Fault P2228 24 BARO Pressure Sensor 6 18 BAROMETRIC PRESSURE BARO SENSOR P2228 P2229 Circuit Low P2229 23 BARPO Pressure Sensor 6 18 BAROMETRIC PRESSURE BARO SENSOR P2228 P2229 Circuit High P2300 31 Front Ignition Coil Con 6 12
146. 7 and 28 and ground Turn ignition switch ON Does meter read battery voltage NOTE The voltage reading will fluctuate for 2 8 seconds while the fuel pump is cycled Inspect fuel pump wiring Is wiring OK YES Replace fuel pump assembly Repair fuel pump wiring 6 66 2008 Buell 1125R Engine Management Locate and repair open in O GY wire Connect Breakout Box to ECM harness leaving ECM disconnected Check continuity between fuel pump connector 86A terminal C and ECM connector 10 Black terminals 27 and 28 Is continuity present Locate and repair open on BN Y wire Replace EOM fc01894 en DTCs P0192 P0193 and P0087 Part 3 of 3 Continued from DTCs P0192 P0193 and P0087 Part 1 of 3 Is the connector on the fuel pressure sensor 227 fully seated YES Connect Breakout Box With to terminal A the ignition switch ON and Disconnect clean and the fuel pressure sensor connect the fuel pressure disconnected check the sensor connector voltage at 227A terminal B Verify repair If DTC is still present retest Is 5V present Turn off ignition switch and Turn ignition switch OFF and disconnect disconnect Breakout Box from Breakout Box from ECM Measure Check resistance between resistance between Breakout Box 11B Breakout Box 11B Gray Gray terminal 27 and 227A
147. 88 R BK R BK 388 38 Ignition Relay EL 3 30 BKW 9 2 50 1 86 p Key Relay 30 E BK mi 19 2 50 gc Fue 62 Relay Block Pump A 868 86A Battery Figure 2 6 Chassis Grounds 2008 Buell 1125R Initial Diagnostics and Serial Data 2 9 Initial Diagnostics Part 1 of 2 Turn the ignition ON with the engine stop Switch in the RUN position Do the headlamps and the IC illuminate NO Press the start button Does the IC illuminate and Does the engine start sweep the tachometer needle Using the Onboard Diagnostic Information System ODIS check for DTCs Are any present Does the engine crank normally but not start Go to Initial See 5 3 LIGHTS Diagnostics Is the security lamp flashing or is there any indication the security System is active or locked Part 2 of 2 Refer to Diagnostic Trouble Codes DTC Priority Table in 2 1 INITIAL DIAGNOSTICS Operate the motorcycle under the conditions to duplicate the concern Is the symptom present See 6 1 DDFI 3 OPERATION YES YES Could not duplicate the See 2 1 INITIAL concern Perform a See 5 4 SECURI
148. 9055 56 2 205 89 3 504 122 4 803 1 2 12 700 1 78 47 62 3 1 4 82 55 4 5 8 117 47 24 9449 57 2 244 90 3 543 123 4 842 9 16 14 288 1 9 48 26 3 3 83 82 4 11 16 119 06 2008 Buell 1125R Appendix C Conversions C 1 FLUID CONVERSIONS 2 UNITED STATES SYSTEM BRITISH IMPERIAL SYSTEM Unless otherwise specified all fluid volume measurements in this Service Manual are expressed in United States U S units of measure See below 1pint U S 16 fluid ounces U S quart U S 2 pints U S 32 fl oz U S 1 gallon U S 4 quarts 0 5 128 fl oz U S METRIC SYSTEM Fluid volume measurements in this Service Manual include the metric system equivalents In the metric system 1 liter L 1 000 milliliters mL Should you need to convert from U S units of measure to metric units of measure or vice versa refer to the following fluid ounces U S x 29 574 milliliters pints U S x 0 473 liters quarts U S x 0 946 liters gallons U S x 3 785 liters milliliters x 0 0338 fluid ounces U S liters x 2 114 pints U S liters x 1 057 quarts U S liters x 0 264 gallons U S C 2 2008 Buell 1125R Appendix C Conversions Fluid volume measurements in this Service Manual do not include the British Imperial Imp system equivalents The fol lowing conversions exist
149. 94 Low P0694 57 Left Fan Control Circuit 6 24 RIGHT AND LEFT FAN CONTROL DTC P0691 P0692 P0693 P0694 High P1110 66 Active Intake Control 6 27 ACTIVE INTAKE SYSTEM DTC P1110 P1111 P1112 Circuit Short Low Open P1111 65 Active Intake Control 6 27 ACTIVE INTAKE SYSTEM P1110 P1111 P1112 Circuit Short High P1112 64 Active Intake Control 6 27 ACTIVE INTAKE SYSTEM P1110 P1111 P1112 Throttle Position Sensor Feedback Failure P2228 24 BARPO Pressure Sensor 6 18 BAROMETRIC PRESSURE BARO SENSOR DTC P2228 P2229 Circuit Low P2229 23 BARO Pressure Sensor 6 18 BAROMETRIC PRESSURE BARO SENSOR P2228 P2229 Circuit High P2300 31 Front Ignition Coil Con 6 12 IGNITION COILS DTC P2300 P2301 P2303 P2304 trol Circuit Low P2301 30 Front Ignition Coil Con 6 12 IGNITION COILS DTC P2300 P2301 P2303 P2304 trol Circuit High P2303 33 Rear Ignition Coil Control 6 12 IGNITION COILS P2300 P2301 P2303 P2304 Circuit Low P2304 32 Rear Ignition Coil Control 6 12 IGNITION COILS DTC P2300 P2301 P2303 P2304 Circuit High 2008 Buell 1125R Engine Management 6 49
150. Auxiliary Relay Ground 20 BK GN B HH _ System Ground 3 10 16 17 18 Fan 2 Left 19 24 lt Auxiliary Ri m y Ground 145A ______ ______ _ _ Il 24 System Ground 2 T ront Ignition J e 58 58 Fan 42 Lett 27 Fuel Pump Output 5 28 Fuel Pump Output j W Y 29 Front Injector Output ear Injector Outpu T T 5 BE O 31 Rear Ignition Coil 32 Rear Ignition Coil BK 33 System Ground 1 34 Front Ignition Coil LI lt lt 10 10 PKN 1 1 High 1200 PK GY 2 2 Low gt gt Terminating 243A 243B Resistor ECM ECM GND1 GND2 Co locate On Cylinder Head jore Slots In Ez gt Ground Os 0 gt 20 ano im gt zz zz gt 555 55 56 559 252 EO z 83FB 123 8388 A 123 med 12 A 89B S
151. B AMERICAN MOTORCYCLES 2008 Buell 1125R Electrical Diagnostic Manual 99949 08Y 2008 Buell Motorcycle Company Buell motorcycles conform to all applicable U S A Federal Motor Vehicle Safety Standards and U S A Environmental Protection Agency regulations effective on the date of manufacture To maintain the safety dependability and emission and noise control performance it is essential that the procedures specifications and service instructions in this manual are followed Any substitution alteration or adjustment of emission system and noise control components outside of factory specifications may be prohibited by law Buell Motorcycle Company AMERICAN MOTORCYCLES 2008 Buell 1125R Electrical Diagnostic Manual 2008 Buell Motorcycle Company ALL RIGHTS RESERVED Printed in the U S A VISIT THE BUELL WEB SITE http www buell com Cut READER COMMENTS The Buell Motorcycle Company maintains a continuous effort to improve the quality and usefulness of its publications To do this effectively we need user feedback your critical evaluation of this manual Please comment on the completeness accuracy organization usability and readability of this manual Please list the page item and part number s of any errors you find in this manual Please tell us how we can improve this manual
152. B 1 CONNECTORS em00250 Terminating Resistor 120 12 243 Connector gt 243A amp a Instrument Cluster ECM CAN High 9 9 PK V sem PK V 2 2 E PKV PK V 30 30 CAN High CAN Low 10 10 gm PK GY mem PK GY 3 3 PK GY PK GY ml 29 29 CAN Low lt BK W 19 19 Sensor Ground 3 1458 145A V R Bil 16 16 Serial Data Transmit LGN R 15 15 Serial Data Receive gt gt lt lt 39 39 11 11 Sensor Ground Wiring Diagram p skv ev Wiring Diagram c gt 2 8 5 6 1 2 3 YIDA Data Link Connector Figure 2 8 Serial Data Communication 2008 Buell 1125R Initial Diagnostics and Serial Data 2 13 COMM ERROR 00001 Disconnect the terminating resistor from connector 243 Turn the ignition on Is the THEFT ERROR or COMM ERROR message cleared from the IC plc YES Turn the ignition off Disconnect connector 11 Measure the resistance from terminal 1 to terminal Replace the 2 of the CAN connector 243B t resistor Is the resistance less then 100 Ohms i 8 i NOTE Use Harness Test Kit Part No HD 41404 See 1 2 DIAGNOSTIC TOOLS Disconnect the IC Test for continuity between termi
153. B3F and 838 terminal 3 Power present after ignition switch is ON YES NO See DTC P0261 2 P0262 P0264 and compression P0265 Connect Breakout Box to the ECM and use test adapter for testing ignition coils Perform Ignition Coils DTCs P2300 P2301 P2303 and P2304 tests Do ignition coils pass tests Locate and repair open in GY wire between ignition relay terminal 87 and ignition coil and P0339 the test See P0337 P0338 Did the CKP sensor pass Repair as indicated by results of ignition coil test If problem persists source is most likely mechanical rather than electrical Repair as indicated by results of CKP sensor test fc01915 en 2008 Buell 1125R Engine Management 6 103 STARTS THEN STALLS 6 29 DESCRIPTION AND OPERATION The starts then stalls condition may be created by the fuel system the idle air control system or an ECM failure There be DTCs set causing this condition Solve the problems with the DTCs before performing the tests in this section The DTCs that may be involved with starts then stalls are Fuel injectors DTCs P0261 P0262 P0264 and P0265 Fuel pump DTCs P0628 and P0629 Fuel pressure sensor DTCs P0087 P0192 and P0193 Ignition coils DTCs PP2300 P2301 P2303 and P2304 e Idle air control actuator DTCs P0506 P0507 and P051
154. BK Is continuity present 145A terminal 6 Y and ECM fuse Locate and repair open Replace ignition switch fc01865_en 6 12 2008 Buell 1125R Engine Management STARTING SENSORS AND DRIVERS 6 6 DESCRIPTION AND OPERATION condition the engine may not start may start then stall or misfire Primary sensors and drivers are the devices that manage engine start up If these devices are not in proper operating Refer to Table 6 6 for devices in this category listed in DTC ranking order Table 6 6 Diagnostic Trouble Codes DTC Priority Table DTC PRIORITY FAULT CONDITION DIAGNOSTIC PROCEDURE ORDER P0112 22 Intake Air Temperature 6 17 INTAKE AIR TEMPERATURE SENSOR DTC P0112 P0113 Sensor Voltage Low P0122 11 Throttle Position Sensor 6 8 THROTTLE POSITION TP SENSOR P0122 P0123 P1112 Circuit Low P0123 10 Throttle Position Sensor 6 8 THROTTLE POSITION TP SENSOR P0122 P0123 P1112 Circuit High P0261 35 Front Fuel Injector Circuit 6 13 FUEL INJECTORS P0261 P0262 P0264 P0265 Low P0262 34 Front Fuel Injector Circuit 6 13 FUEL INJECTORS DTC P0261 P0262 P0264 P0265 High P0264 37 Rear Fuel Injector Circuit 6 13 FUEL INJECTORS DTC P0261 P0262 P0264 P0265 Low P0265 36 Rear Fuel Injector Circ
155. BK wire between the turn signal and ground Replace the Replace the turn signal 5205 6797 instrument cluster Disconnect IC connector 39 Turn the ignition on and activate the left turn signals Test for battery voltage on terminal 4 W V of connector 39B Is battery voltage present Disconnect IC connector 39 Test for continuity on V wire from terminal 1 to inoperative turn signal Is continuity present Locate and repair the open in the V wire Disconnect connector 24 Test for continuity from terminal 6 W V of connector 24A to terminal 4 of connector 9 Is continuity present Replace the instrument cluster 5211 6006 YES Replace the left switchgear 5122 Locate and repair the open in the W V wire 5211 fc01884_en 2008 Buell 1125R Accessories Horn Lights and Security 5 19 STOP LAMPS See Figure 5 15 The front brake switch is a mechanical switch located under the fluid reservoir on the right handlebar See Figure 5 16 The rear brake switch is a pressure switch located on the right side to the rear of the footpeg See Figure 5 17 The brake switches receive power through the brake horn fuse When the front or rear brake switch is applied voltage travels through the switch to the tail stop lamp Left rear turn signal 19 GND Right rear turn
156. C 1 Metric Conversions MILLIMETERS to INCHES INCHES to MILLIMETERS MM x 0 03937 IN IN x 25 40 MM MM IN MM IN MM IN MM IN IN MM IN MM IN MM IN MM 4 0039 25 9842 58 2 283 91 3 582 001 025 6 15 240 1 15 16 49 21 3 5 16 84 14 2 0078 26 1 024 59 2 323 92 3 622 002 051 5 8 15 875 2 50 80 3 3 8 85 72 3 0118 27 1 063 60 2 362 93 3 661 003 076 11 16 17 462 2 1 16 52 39 3 4 86 36 4 0157 28 1 102 61 2 401 94 3 701 004 102 7 17 780 2 1 53 34 3 716 87 31 5 0197 29 1 142 62 2 441 95 3 740 005 127 3 4 19 050 2 18 53 97 3 1 2 88 90 6 0236 30 1 181 63 2 480 96 3 779 006 152 8 20 320 2 3 16 55 56 3 9 16 90 49 7 0275 31 1 220 64 2 519 97 3 819 007 178 13 16 20 638 2 2 55 88 3 6 91 44 8 0315 32 1 260 65 2 559 98 3 858 008 203 78 22 225 2 1 4 5715 3 5 8 92 07 9 0354 33 1 299 66 2 598 99 3 897 009 229 9 22 860 23 58 42 3 11 16 93 66 1 0394 34 1 338 67 2 638 100 3 937 010 254 15 16 23 812 2 5 16 58 74 37 93 98 2 0787 35 1 378 68 2 677 101 3 976 1 64 397 1 25 40 2 38 60 32 3 3 4 95 25 3 1181 36 1 417 69 2 716 102 4016 020 508 1 1 16 26 99 2 4 60 96 3 8 96 52 4 1575 37 1 456 70 2 756 103 4 055 030 762 11 27 94 2 716 61 91 3 13 16 96 84 5 1968 38 1 496 71 2 795 104 4 094 1 32 794 1 18 28 57 2 2 63 50 3 78 98 42 6 2362 39 1 535 72 2 834 105 4 134 040 1 016 1 3 16 3016 2 96 65 09 3 9 99 0
157. CODE B5 BATTERY TEST RATING 295 CCA 65958 94 12 32V 95CCA REPLACE BATTERY WARRANTY CODE 9J9G9N 0132N8 Figure 3 20 Battery Test Results Printout LOAD TEST To load test the battery proceed as follows WARNING Disconnect negative battery cable first If positive cable should contact ground with negative cable con nected the resulting sparks can cause a battery explosion which could result in death or serious injury 00049a 1 Remove the battery from the motorcycle 2 Always fully charge the battery before testing or test readings will be incorrect Load testing a discharged bat tery can result in permanent battery damage After charging allow the battery to stand for at least one hour before testing Turn battery load tester OFF before connecting tester cables to battery terminals Connecting tester cables with load tester ON can cause a spark and battery explosion which could result in death or serious injury 00252a 4 See Figure 3 21 Connect tester leads to battery posts and place induction pickup over negative black cable NOTE To avoid load tester and or battery damage do not leave the load tester switch turned ON for more than 20 seconds 2008 Buell 1125R Starting Charging 3 21 5 Load battery at 50 of CCA rating using the load tester Voltage reading after 15 seconds should be 9 6 V or more at 70 F 21 C Refer
158. CTRICAL CONNECTORS Deutsch Connector Repair HD 41475 100 FLAT BLADE L HOOK A 3 DEUTSCH ELECTRICAL CONNECTORS Deutsch Connector Repair HD 41609 AMP MULTILOCK CRIMPER AMP MULTILOCK CONNECTORS Multilock Connector Repair HD 48053 ADVANCED BATTERY CONDUCTANCE 1 2 DIAGNOSTIC TOOLS How Use Diagnostic Tools AND ELECTRICAL SYSTEM ANALYZER TOOLS Tools Used This Manual PART NUMBER TOOL NAME NOTES HD 48053 ADVANCED BATTERY CONDUCTANCE 3 3 CHARGING SYSTEM DIA AND ELECTRICAL SYSTEM ANALYZER GNOSTICS Troubleshooting HD 48053 ADVANCED BATTERY CONDUCTANCE 3 3 CHARGING SYSTEM DIAGNOSTICS Testing AND ELECTRICAL SYSTEM ANALYZER HD 48650 DIGITAL TECHNICIAN 1 2 DIAGNOSTIC TOOLS How To Use Diagnostic Tools HD 48650 DIGITAL TECHNICIAN II 1 3 DIAGNOSTICS TROUBLESHOOTING Wiggle Test HD 48650 DIGITAL TECHNICIAN 1 8 DIAGNOSTICS TROUBLESHOOTING Job Time Codes Values SNAP ON TT600 3 SNAP ON PICK A 9 630 METRI PACK CONNECTORS 630 Metri Pack Connector Repair TOOLS 2008 Buell 11258 Electrical Diagnostic Manual FASTENER TORQUE VALUE NOTES No torque values were found in this manual TORQUE VALUES 5 IV TORQUE VALUES 1 150 ee 14 2 280 Metri Pack Connector KIM E ue A 16 4 480 Metri Pack
159. Connector enki etos en A 18 6 630 Metri Pack Connector ECRIRE EE A 19 A Active Intake 6 97 Alternator ERR a ees 3 3 Alternator 6 3 AMP Multilock Connector 1 48115 Breakout 1 7 Bank Angle 6 27 Pressure BARO 6 59 BEA A ERE 3 3 Battery ode Ret a tine RE REST EE 3 3 Battery 3 21 Conductance 3 21 Load 3 21 Voltmeter 51 3 21 Battery Voltage EE 6 94 Charging System 3 13 Voltage Regulator 3 13 Charging System Testing Current and Voltage Output Test Using HD 48053 3 19 Current and Voltage Output Test Using Load I gebe ri eed e 3 19 Miliampere Draw 3 17 Total Current Draw 3 18 Check Engine Lamp 2 4 Gl Gk ons ee mS PASE ys 4 1 Gluteh SwItehz 2s iue eI ERES exe 6 31 Cold Cranking Amperage
160. DDFI 3 OPERATION The Buell DDFI 3 operates as an open or closed loop system allowing it to adjust for all possible operating conditions During open loop operation the system uses programmed fuel and spark maps in the ECM providing easy cold starting and max imum power at Wide Open Throttle WOT The adaptive fuel value learned during closed loop operation is applied to open loop operation to adjust fuel and spark maps for optimal per formance During closed loop operation the O2 sensors provide input for an optimal air fuel mixture resulting in reduced emissions good fuel economy and smooth power In order for the system to enter closed loop operation certain conditions must be met O2sensors must be at the normal operating temperature of the engine Operating below 4200 RPM with engine under steady or light load conditions By using both open and closed loop systems engine perform ance is continuously tuned to compensate for changing condi tions and providing maximum performance A simplified signal flow diagram for the DDFI 3 system is shown in Figure 6 1 For operational explanations of sensors and drivers see 6 6 STARTING SENSORS AND DRIVERS Connector Information For additional information on the connectors in the following diagram s see B 1 CONNECTORS 2008 Buell 1125R Engine Management 6 1 JOJO owl piousjos eyelu ye
161. DEMARK INFORMATION Blast Firebolt Glaze Gloss Harley Harley Davidson Light ning Sunwash Supersmart Tender Triple Tail Thunderstorm Ulysses Uniplanar and ZTL are among the trademarks of H D Michigan Inc CONTENTS All photographs illustrations and procedures in this manual may not necessarily depict the most current model or com ponent but are based on the latest production information available at the time of publication Since product improvement is our continual goal Buell Motor cycle Company reserves the right to change specifications equipment or designs at any time without notice and without incurring obligation GENERAL INFORMATION 1 1 COMPONENT LOCATIONS E 1 1 Component Locations eR pera erre rrr 1 1 1 2 DIAGNOSTIC TOOLS How To Use Diagnostic Tools omms 1 7 HD 48650 Digital Technician 1 7 HD 41404 Harness Test Kit 1 7 B49115 Breakout eio 1 7 70 26792 Spark 1 7 HD 39978 Digital Multimeter Fluke 78 1 8 HD 48053 Advanced Battery Conductance and Electrical System 1 8 Fuel Injector Test 1 8 HD 41354 Speedometer 1 9 Leak TS DI 1 9 Leak TesHrig uuie mero iere 1 10 1 3 DIAGNOSTICS TROUBLESH
162. DTCs found NO Refer to applicable DTC chart Start tests with the highest priority DTC co With ignition switch ON and run stop switch in RUN side stand up transmission in neutral lamp illuminated does the engine start and stay running YES Turn ignition switch OFF Place transmission in gear and hold in the clutch Turn ignition switch 57 See P1154 P1155 ON and attempt to start engine Does engine start and stay running Turn ignition switch OFF Lower the side stand Place transmission in gear and hold in the clutch Start engine and release clutch Does engine stall Is it a clutch switch or neutral Switch problem Repair circuitry or replace clutch or neutral switches Will engine start with throttle opened partially and stall when throttle is closed YES 67 5 Side stand sensor problem P1501 P1502 and P1503 HDI ONLY System operating normally See 6 23 IDLE AIR CONTROL IAC DTC P0506 P0507 and P0511 Check fuel pressure while cranking engine Is fuel pressure OK YES Fuel pressure problem See DTC P0192 P0193 P0087 and perform the steps in the flowcharts Replace fuel injectors Does the problem still exist YES No Replace System ECM operati
163. ENSOR DTC P1501 P1502 P1503 HDI ONLY Description and 6 22 Diagnostic 6 22 Connector 6 22 6 10 BANK ANGLE SENSOR BAS P1151 P1152 Description and OD6rallari 6 27 Connector 6 27 6 11 CLUTCH AND NEUTRAL SWITCHES DTC P1154 P1155 Description and Operations or rr nete per tetti 6 31 Diagnostie T 6 31 Connector oasis reda kid kk tie 6 31 6 12 IGNITION COILS DTC P2300 P2301 P2303 P2304 Description and 6 35 Dagnostie 6 35 Connector Information eese 6 36 TABLE OF CONTENTS 6 13 FUEL INJECTORS DTC P0261 P0262 P0264 P0265 Description arid echas eid 6 40 Bip Ecommerce 6 41 Connector OM eod etui taba eoo 6 41 6 14 START RELAY DTC P0617 Description arid ODeralloni i 2 6 45 Connector Imibrsllof susce ex rest re oder Y Pina 6 45 6 15 RUNNING SENSORS AND DRIVERS Description and OperatiOpi 6 48 6 16 ENGINE COOLANT TEMPERATURE ECT DTC P0117 P0118 Descriptlon arid ODOeHallofi ii c sevirsniapttiasccraccsneatavacs 6
164. ERATURE ECT DTC P0117 P0118 ature Sensor Circuit High P0122 11 Throttle Position Sensor 6 8 THROTTLE POSITION TP SENSOR DTC P0122 P0123 P1112 Circuit Low P0123 10 Throttle Position Sensor 6 8 THROTTLE POSITION TP SENSOR P0122 P0123 P1112 Circuit High P0131 50 Front Oxygen Sensor 6 22 OXYGEN O2 SENSOR DTC P0131 P0132 P0134 P0151 P0152 Circuit Low Engine Lean 154 P1047 P0132 46 Front Oxygen Sensor 6 22 OXYGEN O2 SENSOR P0131 P0132 P0134 P0151 P0152 Circuit High Engine Rich P0154 P1047 P0134 48 Front Oxygen Sensor 6 22 OXYGEN O2 SENSOR P0131 P0132 P0134 P0151 0152 Open Inactive P0154 P1047 P0151 51 Rear Oxygen Sensor 6 22 OXYGEN O2 SENSOR DTC P0131 P0132 P0134 P0151 P0152 Circuit Low Engine Lean 154 P1047 P0152 47 Rear Oxygen Sensor 6 22 OXYGEN O2 SENSOR DTC P0131 P0132 P0134 P0151 P0152 Circuit High Engine Rich P0154 P1047 P0154 49 Rear Oxygen Sensor 6 22 OXYGEN O2 SENSOR P0131 P0132 P0134 P0151 P0152 Open Inactive P0154 P1047 P0192 26 Fuel Pressure Sensor 6 19 FUEL PRESSURE SENSOR DTC P0192 P0193 P0087 Circuit Low P0193 25 Fuel Pressure Sensor 6 19 FUEL PRESSURE SENSOR DTC P0192 P0193 P0087 Circuit High P0261 35 Front Fuel Injector Circuit 6 13 FUEL INJECTORS DTC P0261 P0262 P0264 P0265 Low P0262 34 Front Fuel Injector Circuit 6 13 FUEL INJECTORS DTC P0261 P0262 P0264 P0265 High P0264 37 Rear Fuel I
165. INS In addition to the information presented in this manual Buell Motor Company will periodically issue Service Bulletins to Buell dealers Service Bulletins cover interim engineering changes and supplementary information Consult the Service Bulletins to keep your product knowledge current and complete USE GENUINE REPLACEMENT PARTS WARNING Do not use aftermarket parts and custom made front forks which can adversely affect performance and handling Removing or altering factory installed parts can adversely affect performance and could result in death or serious injury 00001a To verify satisfactory and lasting repairs carefully follow the manual instructions and use only genuine Buell replacement parts This is your assurance that the parts you are using will fit right operate properly and last longer WARNINGS AND CAUTIONS Statements in this manual preceded by the following words are of special significance FOREWORD WARNING WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injury 00119a AcAUTION CAUTION indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury 00139a CAUTION CAUTION used without the safety alert symbol indicates a potentially hazardous situation which if not avoided may result in property damage 00140a NOTE Refers to important information and is placed
166. K mi 19 2 50 gc Fue 62 Relay Block Pump A 868 86A Battery Figure B 6 Chassis Grounds 2008 1125R Model 2008 Buell 1125R Appendix B Wiring B 9 er ea i TECHNICIAN II HARLEY DAVIDSON Zz 4 Starter Fuel Pump Oxygen et00094 Vehicle 4 Starter Speed K Voltage Solenoid Battery Sensor Right Rear Turn Signal Rear 1 8B lt 590808 BE Regulator moar e e de Nie ex ABCD 65 Y 77B 1218 A 12 868 Front 121 Nr z 86A Brake 1708 RIETI xc EI 288 Y 1 2 WENT 1 e Switch gt HE 2 3 5526 B GND 2 T 2A lail Stop Lamp Controls lt ER 4 2 ii ows 1 BK R T RY 2 Right Front Turn Signal ENS __ License Plate 45B Lamp 3188 gt 1 d eee 1 19 Left Rear Signal w dl i S Low Fuel Lamp 12 ___ 11 gnition Switc 39 39B Chassis Ground 13 13 M gt Constant Battery 12 R 5553 10 D LE PK V 13 Interface Right Turn Driver 11 Connector
167. N Figure 5 19 Behind Fairing Connectors Left rear turn signal 19 GND Right rear turn signal 18 Power License plate lamp 45 Power Tail stop lamp 93 Power Tail stop lamp 93 GND License plate lamp 45 GND Right rear turn signal 18 GND gt Left rear turn signal 19 Power Figure 5 20 Rear Lamp Connectors Connector Information For additional information on the connectors in the following diagram s see B 1 CONNECTORS 5 24 2008 Buell 1125R Accessories Horn Lights and Security 00253 Ignition And Accessory Power In RIGY Wiring Diagrams R GY gt 5 o o Fuse Block 23 12 Lights Accessory 15A 10A 4 BE 6 NC Start 86 1 10 Relay 2 2 2 30 3 6 DE m OW lt lt lez 4 3 BE m Left ate Relay Block 62 GY BK amp 1 1 Lamp lt lt owg 1 1 Instrument High Beam elle 2 12 1 1 Right Cluster Input w w 3 mm BK 2 2 394 4 4 BK 5 5 BK 6 Left B gt ee
168. NOSTICS Description and Operations 3 1 COMPONE Wee c P 3 1 cuc 3 1 Solenoid users tie Pi EI ea Oii E edad 3 1 Engine Stop Switch RH Controls 3 1 Start Switch RH Controls iu essere 3 1 Key 3 1 lgnmon pm 3 2 sic mm 3 2 Lejos nei UA eer 3 2 zc AE M 3 2 Fd ipai 3 3 3 3 M 3 3 3 3 Connector INIGMNANON 3 5 3 2 TESTING STARTER ON MOTORCYCLE Starter Current Draw Test inm 3 12 Free Running Current Draw 3 12 3 3 CHARGING SYSTEM DIAGNOSTICS Descripllon and 3 13 oaa o aptae 3 13 Atema e 3 13 Voltage eT 3 13 3 13 2 13 WVU 3 13 Voltage Regulator 3 13 Job Time Code Values innen 3 13 Connector OM ean 3 13 TRS TUNG 3 17 Milllampore Draw 3 17 COMMON LCL 3 17 3 18 Cur
169. NOTE Cut any cable strap anchoring the wire conduits of the pin accessory connector housing and the socket B housing See Figure A 23 Using small flat blade screwdriver depress button 1 on pin housing red wire side of the connector and pull apart the pin and socket housings Mating Pin and Socket Housings Orient the latch on the socket housing to the button catch on the pin housing and press the housings together Removing Socket Terminals 1 See Figure A 23 Bend back the latch 2 slightly and free one side of secondary lock then repeat to release the opposite side Rotate the secondary lock outward on hinge to access terminal in chamber of connector housing 2 Onthe mating end of the connector note the tang in the square shaped opening centered next to the terminal Gently insert the point of a stick pin or large safety pin into the opening 3 between the tang and the chamber wall until it stops 3 Pivot the end of the pin toward the terminal body to depress the tang 4 Remove the pin and then pull terminal out of the wire end of connector housing 5 f necessary crimp new terminals on wires See A 5 METRI PACK TERMINALS Installing Socket Terminals 1 Carefully bend the tang outward away from the terminal body 2 With the tang on the same side as the square shaped opening in the mating end of the connector housing feed terminal into wire end of connector housing until it clicks in place
170. NT gt 2 Oo oS gt gt 2 5 m 2552 62 gt m o m 2 om Chassis Instrument ed GND 2 Bie YR gt Cluster assis gt 9 gt z T en tn Pump Gr 1458 Fuse Cr 11488 17 145 7 RANSA gt 5 gt 9 o gt gt 2 2 2 2 m e a E E a 2 23 20 21 22 27 28 8 2 23 20 21 22 27 28 5 5 TEE 5 5 BK E 9 92529 8 8 6 5555 5 5 868886 og 2222 2 0070 ECM Figure 6 46 Neutral and Clutch Switches IAC and Fuel Pump 2008 Buell 1125R Engine Management 6 81 DTCs P0506 P0507 and P0511 Part 1 of 2 Remove air cleaner cover and element Is throttle valve completely closed YES Remove the throttle body to observe IAC pintle operation Monitor IAC pintle for two seconds after turning ignition switch ON Does pintle extend and then retract during two second ignition switch ON reset procedure YES Check intake manifold for leaks See Intake Leak Test Are leaks present ves z o Inspect fuel pressure within Onboard Diagnostic Information System See 4 1 INSTRUMENT CLUSTER AND GAUGES Repair intake leak Lubricate and adjust throttle cables o
171. OMMUNICATION Engine cranks but will not start 6 28 ENGINE CRANKS BUT WILL NOT START Headlamp inoperative 5 3 LIGHTS Horn always on 5 2 HORN Horn inoperative 5 2 HORN Instrument Cluster IC inoperative 4 5 INSTRUMENT CLUSTER INOPERATIVE Low fuel lamp always on 4 6 LOW FUEL LAMP ALWAYS ON OR INOPERATIVE Low fuel lamp inoperative 4 6 LOW FUEL LAMP ALWAYS ON OR INOPERATIVE Marker lamps inoperative 5 3 LIGHTS Misfire at idle or under load 6 30 MISFIRE AT IDLE OR UNDER LOAD Oil pressure lamp always on 4 3 OIL PRESSURE LAMP ALWAYS ON OR INOPERATIVE Oil pressure lamp inoperative 4 3 OIL PRESSURE LAMP ALWAYS ON OR INOPERATIVE Starter does not spin 3 1 STARTING SYSTEM DIAGNOSTICS Starter stalls or spins too slowly 3 1 STARTING SYSTEM DIAGNOSTICS Starts then stalls 6 29 STARTS THEN STALLS Stop lamp inoperative 5 3 LIGHTS Tail lamp inoperative 5 3 LIGHTS THEFT ERROR displayed 5 4 SECURITY SYSTEM Turn signal indicator inoperative 4 4 TURN SIGNAL INDICATOR INOPERATIVE Turn signal inoperative 5 3 LIGHTS Connector Information For additional information on the connectors in the following diagram s see B 1 CONNECTORS 2 6 2008 Buell 1125R Initial Diagnostics and Serial Data 00239 2 Chassis Ground Wiring Diagram
172. OOTING D DS 1 11 voltage Drop 1 11 TSE e 1 11 Relay Vi 1 12 Figlio 1 12 Relay Test 5 sciri ratto EY rp rein 1 12 Job Time Codes Values seen 1 12 INITIAL DIAGNOSTICS AND SERIAL DATA 2 1 INITIAL DIAGNOSTICS Description and Operation Mmmm 68 2 1 Checking for Diagnostic Trouble Codes DTOs 2 1 Retrieving Diagnostic Trouble Codes DTOs 2 1 err APERTE TETTE 2 4 mem E E 2 4 2 4 Mya 2 4 2 4 Check Engine e 2 4 Diagnostic P 2 4 IAS paie Da PUTA MAKE ats ERAS 2 5 Connector MOMAN socii 2 6 2 2 SERIAL DATA COMMUNICATION Description and Operationens 2 12 JOMPO 1p MT ET 2 12 Electronic Control Module ECM 2 12 Instrument Cluster 2 12 Controller Area Network CAN connector 2 12 Data Link Connector DEG Li seruat Reb 2 12 COMM ERROR or DTC 1 ri ctr erre etti mr 2 12 Diagnostie eee 2 12 Connector cicer bra anxie 2 12 STARTING CHARGING 3 1 STARTING SYSTEM DIAG
173. OR 1 4 20 5 INSTRUMENT CLUSTER AND GAUGES 4 1 DESCRIPTION AND OPERATION The Instrument Cluster IC uses direct inputs along with communication from the ECM to display information The IC receives battery power through terminals 2 and 12 Ground is supplied through terminals 3 and 13 Ignition power comes from the ignition switch to terminal 14 There are two Controller Area Network CAN lines going to the ECM from terminals 9 and 10 of the IC See Figure 4 1 The TOGGLE and MODE switches are located on the IC along with the tachometer the theft mode LED and the indicator and warning lamps The LCD screen on the IC displays a digital speedometer odometer clock and informa tion messages ed01694 LCD screen Tachometer TOGGLE switch MODE switch Indicator lamps Warning lamps Theft mode LED NOOA OP Figure 4 1 Instrument Cluster COMPONENTS Speedometer The speedometer digitally displays the forward speed of the motorcycle in MPH or KPH depending on the configuration The configuration can be changed by using the TOGGLE and MODE switches on the IC The speedometer receives the vehicle speed data over the CAN lines from the ECM Tachometer The tachometer displays engine RPM The numbers on the tachometer multiplied by 1 000 equals engine RPM As the tachometer approaches approximately 10 000 RPM the needle
174. Occupation Name Dealership Street Department City State Zip 2008 Buell 1125R Electrical Diagnostic Manual 99949 08Y Please clip out and mail to Service Communications Department Buell Motorcycle Company P O Box 653 Milwaukee WI USA 53201 5 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 Buell product and assist in the perform ance of repair Secondly it will introduce to the professional Buell Technician the latest field tested and factory approved diagnostic methods We sincerely believe that this manual will make your association with Buell products more pleasant and profitable HOW TO USE YOUR SERVICE MANUAL Refer to the table below for the content layout of this manual z o CHAPTER General Information Initial Diagnostics and Serial Data Starting Charging Instruments Accessories Horn Lights and Security Engine Management Appendix A Connector Repair Appendix B Wiring Appendix C Conversions nom Appendix D Glossary Use the TABLE OF CONTENTS which follows this FORE WORD 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
175. P SENSOR DTC P0337 P0338 P0339 6 8 THROTTLE POSITION TP SENSOR DTC P0122 P0123 P111 6 9 SIDE STAND SENSOR DTC P1501 P1502 P1503 HDI ONLY 6 10 BANK ANGLE SENSOR BAS DTC P1151 1152 6 11 CLUTCH AND NEUTRAL SWITCHES DTC P1154 P11 6 12 IGNITION COILS DTC P2300 P2301 P2303 2304 6 13 FUEL INJECTORS DTC P0261 P0262 P0264 P0265 6 14 START RELAY DTC P0617 6 15 RUNNING SENSORS AND DRIVERS 6 16 ENGINE COOLANT TEMPERATURE ECT DTC 17 18 6 17 INTAKE AIR TEMPERATURE IAT SENSOR P0112 0113 6 18 BAROMETRIC PRESSURE BARO SENSOR DTC P2228 P222 6 19 FUEL PRESSURE SENSOR DTC P0192 P0193 P0087 6 20 FUEL PUMP DTG 0628 629 eere Ral SPERO igi 2 DTC P0502 AND P0503 6 27 ACTIVE INTAKE 6 28 ENGINE CRAN 5 DDFI 3 OPERATION 6 1 DDFI 3 OVERVIEW This chapter describes the operation of the 1125cc engine when coupled with the Buell Dynamic Digital Fuel Injection DDFI System It is essential to have a working knowledge of the many components surrounding the engine to accurately troubleshoot and correct problems that may occur 6 2 ELEC TRONIC CONTROL MODULE and 6 3 SENSORS AND DRIVERS briefly explains the operation of the ECM and func tion of the various sensors and drivers See 1 2 DIAGNOSTIC TOOLS for instructions on using the test equipment called out in the f
176. P2303 P2304 trol Circuit High P2303 33 Rear Ignition Coil Control 6 12 IGNITION COILS DTC P2300 P2301 P2303 P2304 Circuit Low P2304 32 Rear Ignition Coil Control 6 12 IGNITION COILS DTC P2300 P2301 P2303 P2304 Circuit High 00001 5 High Speed CAN Bus 2 2 SERIAL DATA COMMUNICATION Error CODE TYPES CHECK ENGINE LAMP DTCs are categorized as current and historic Both types are stored in the ECM and the IC Current Current DTCs failed the last time the module ran the para meters to set them Therefore the fault that caused them is normally present Historic If a particular problem happens to resolve itself the active status problem is dropped and it becomes a historic DTC Historic DTCs are stored for 50 run cycles after any DTC was last set as current to assist in the diagnosis of intermittent faults On the 50th cycle the DTC clears itself Diagnostic charts are designed for use with current DTCs As a result they frequently suggest part replacement When dia gnosing a historic DTC the charts can be helpful but should not lead to part replacement without verification the part is faulty MULTIPLE DTCS There are conditions where one fault may set several DTCs This is why it is important to follow the DTC priority table By following the order in the table it reduces the likelihood of per forming unnecessary diagnostics and possibly faulting the wrong component Refer to Table 2 1 CLEARING DTCS PART N
177. Refer to Table A 2 sm00020 Wire seal Pin housing Pin terminal Locking wedge gt Figure A 15 Deutsch Connector 2 3 4 and 12 Pin Housings Table A 2 Deutsch Connector Terminal Crimping Instructions TYPE CRIMPING INSTRUCTIONS Standard with crimp tails A 4 DEUTSCH STANDARD TERMINAL REPAIR A 10 2008 Buell 1125R Appendix A Connector Repair DEUTSCH STANDARD TERMINAL REPAIR 4 DEUTSCH STANDARD TERMINAL CRIMPS straight upward When positioned the locking bar fits snugly in the space between the contact band and the core crimp tails PART NUMBER TOOL NAME 3 4 Insert stripped wire core between crimp tails until ends HD 39965 A DEUTSCH TERMINAL CRIMP TOOL make contact with locking bar Verify that wire is positioned 5 so that short pair of crimp tails squeeze bare wire strands Preparing Wire Leads for Crimping while long pair folds over the insulation 1 Usea shop gauge to determine gauge of wire lead 5 Squeeze handle of crimp tool until tightly closed Tool 2 Strip lead removing 5 32 in 4 0 mm of insulation automatically opens after the terminal is crimped Crimping Terminal to Lead 6 Raise locking bar up and remove wire lead and terminal 1 SeeFigure A 16 Squeeze the handles of the DEUTSCH Inspecting Crimps TERMINAL CRIMP TOOL Part No HD 39965 A to open Inspect the wire core and insulation crimps Di
178. See Figure 3 17 and connect an ohmmeter as follows a Disconnect voltage regulator connector from alternator stator wiring b Insert one ohmmeter lead into a stator connector socket c Attach the other lead to a suitable ground 2008 Buell 1125R Starting Charging 3 19 3 Test for continuity with the ohmmeter set to the ohms scale a A good stator shows no continuity open circuit between any stator sockets and ground b Any other reading indicates a grounded stator which must be replaced 4 See Figure 3 18 To check the stator for resistance remove the ground lead 5 Test stator sockets 1 2 2 3 and 3 1 for resistance with the ohmmeter set on the ohms scale a Resistance across all the stator sockets should be 0 1 0 3 Ohms b Ifthe resistance is higher the stator is damaged and must be replaced If resistance is lower the stator may have a turn to turn short and should be replaced NOTE Verify the meter reads 0 Ohms when the probes are shorted together If not subtract lowest value to resistance value of stator Figure 3 17 Test for Grounded Stator typical 3 20 2008 Buell 1125R Starting Charging Figure 3 18 Check for Stator Resistance typical AC Output Check 1 Test AC output as follows a Disconnect voltage regulator connector 77 from alternator stator wiring b See Figure 3 19 Connect an AC voltmeter across stator connecto
179. Service Manual Turn key ON for two seconds five consecutive times Replace the fuel injector if there is any evidence of raw fuel in the bores See the service manual To confirm IAC function disconnect the fuel pump Turn engine stop and ignition switch and listen for IAC 2008 Buell 1125R Engine Management 6 79 movement clicking humming noise for a few seconds after the ignition switch is turned on e Vacuum leaks To check for vacuum see the service manual e Contaminated fuel Excessive oil in crankcase oil sumping sensor reading of greater than 5 possible throttle cable misadjustment or battery voltage reading of less than 9 volts will disable idle speed control 6 80 2008 Buell 1125R Engine Management NOTE Itis possible that one of the circuits is shorted to voltage which should have been indicated by a steady light Disconnect the connector and test for voltage at the harness terminals with the ignition switch ON after IAC has reset Connector Information For additional information on the connectors in the following diagram s see B 1 CONNECTORS 00275 Idle Air Control Fuel Switch Switch IAC Pump 1 131A 1 3 95A 1 2 4 Ay 87A ABCD A 86B 1 Y 131B 1 Y 95B 1 2 4 87B B D 86A EE
180. T Sensor 6 5 Barometric Pressure BARO 6 5 Vehicle Speed Sensor 55 6 5 02 Sensor Front and 6 5 Manifold Absolute Pressure MAP Sensor 6 5 pj HR 6 5 PUSI use Seir 6 5 Ignition Spark Plugs ee 6 5 Nes Me 6 5 Air Control DAD riu emer rtr ten ta 6 5 c MA 6 6 6 6 AK coca vtrcnsacadancttinchiventvaccnssastiontanreedtolesdactaged 6 6 6 4 SYMPTOM DIAGNOSTICS DeSGhiptlon 6 7 6 5 ERRORS P0603 P0604 P0605 P0607 Description and Operation 6 11 Connector OM uui er Rr re rider iie 6 11 6 6 STARTING SENSORS AND DRIVERS Description and 6 13 Connector IGfortfiatiobi s aui rena 6 14 6 7 CRANK POSITION CKP SENSOR DTC P0337 P0338 P0339 Description and amp 6 15 Connector Information 6 15 6 8 THROTTLE POSITION TP SENSOR DTC P0122 P0123 P1112 Description and Operation ts 6 18 Diagnostic 6 18 Gonpector crier rr etta 6 18 6 9 SIDE STAND S
181. TC current YES NO It is possible the VIN is mismatched Is DTC U0001 present Was the instrument cluster replaced Po YES NO YES Install the old instrument cluster Enter the SETUP MENU and select OFF AT KEY OFF Was the ECM replaced See 2 2 SERIAL DATA COMMUNICATION Replace the instrument cluster YES Was the ECM replaced with a used ECM Replace and program the Used ECM security setting is active Replace with new EOM Replace the instrument cluster 5 32 2008 Buell 1125R Accessories Horn Lights and Security Go to THEFT ERROR or DTC P1009 Part 2 of 2 Fc01926 en THEFT ERROR P1009 Part 2 of 2 Continued from THEFT ERROR or DTC P1009 Page 1 of 2 Disconnect the terminating resistor from connector 243 Turn the ignition on Is the THEFT ERROR or COMM ERROR message cleared from the IC YES Replace the terminating resistor Turn the ignition off Disconnect the connector 11 Measure the resistance from terminal 1 to terminal 2 of the CAN connector 243B Is the resistance less then 100 Ohms Disconnect IC connector 39 Test for continuity between terminals 1 and 2 of connector 243B Is continuity present Is the resistance greater than 150 Ohms YES NO CAN
182. TURE ECT DTC P0117 P0118 ature Sensor Circuit Low P0118 19 Engine Coolant 6 16 ENGINE COOLANT TEMPERATURE ECT P0117 P0118 ature Sensor Circuit High P0122 11 Throttle Position Sensor 6 8 THROTTLE POSITION TP SENSOR P0122 P0123 P1112 Circuit Low P0123 10 Throttle Position Sensor 6 8 THROTTLE POSITION TP SENSOR DTC P0122 P0123 P1112 Circuit High P0131 50 Front Oxygen Sensor 6 22 OXYGEN 02 SENSOR DTC P0131 P0132 P0134 P0151 P0152 Circuit Low Engine Lean P0154 P1047 P0132 46 Front Oxygen Sensor 6 22 OXYGEN O2 SENSOR DTC P0131 P0132 P0134 P0151 P0152 Circuit High Engine Rich P0154 P1047 P0134 48 Front Oxygen Sensor 6 22 OXYGEN O2 SENSOR DTC P0131 P0132 P0134 P0151 P0152 Open Inactive P0154 P1047 6 8 2008 Buell 1125R Engine Management Table 6 4 Diagnostic Trouble Codes DTC Priority Table DTC PRIORITY FAULT CONDITION DIAGNOSTIC PROCEDURE ORDER P0151 51 Rear Oxygen Sensor 6 22 OXYGEN O2 SENSOR DTC P0131 P0132 P0134 P0151 P0152 Circuit Low Engine Lean P0154 P1047 P0152 47 Rear Oxygen Sensor 6 22 OXYGEN O2 SENSOR DTC P0131 P0132 P0134 P0151 P0152 Circuit High Engine Rich P0154 P1047 P0154 49 Rear Oxygen Sensor 6 22 OXYGEN O2 SENSOR DTC P0131 P0132 P0
183. TY See 3 1 STARTING DIAGNOSTICS wiggle test See 1 3 SYSTEM SYSTEM DIAGNOSTICS DIAGNOSTICS TROUBLESHOOTING fc01790 en 2 10 2008 Buell 1125R Initial Diagnostics and Serial Data Initial Diagnostics 2 of 2 Continued from Initial Diagnostics Part 1 of 2 Verify the battery is fully charged See 3 4 BATTERY TESTING Is the battery charged Check the battery fuse Is the fuse good Charge battery and retest for an open or high resistance Is an open or high resistance present Test the ground circuits to the battery Test for a short to ground in the power circuits protected by the battery fuse Review the Battery Power Distribution Wiring Diagram in Appendix B Is a short to ground present 4 1 Locate and repair the Replace the battery fuse See PIE e INSTRUMENT short to ground in the 3 3 CHARGING SYSTEM 9 round circuit CLUSTER AND power circuit Replace the DIAGNOSTICS for additional 9 i GAUGES battery fuse information fc01794_en 2008 Buell 1125R Initial Diagnostics and Serial Data 2 11 SERIAL DATA COMMUNICATION 2 2 DESCRIPTION AND OPERATION TOOL NAME DIGITAL TECHNICIAN II PART NUMBER HD 48650 Serial data communication circuits are used by modules and diagnostic tools to share information 1
184. Turn Switch WV 6 6 m V mum V m Left Turn Switch gt gt 31LB 31LA 24A 24B uS Left Front VE Turn Signal Left Rear Turn Signal lt 19 19 Figure 4 7 Instrument Cluster Inputs and Outputs 4 8 2008 Buell 1125R Instruments DTC 1004 Disconnect fuel pump connector 86 Turn the ignition on Did DTC B1005 set Replace the fuel pump assembly Disconnect the IC connector 39 Test terminal D Y R wire of connector 86 for a short to ground Is a short to ground present Locate and repair the short to ground in the Y R wire Replace the IC with a new IC Connect connectors 39 and 86 Turn the ignition on for a few minutes to give it time to update See Diagnostic Tips Did DTC B1004 set Replace the fuel pump assembly Repair complete Allow sufficient time for the new IC to update to the ECM fc01919 en 2008 Buell 1125R Instruments 4 9 1005 Disconnect the fuel pump connector 86 and the IC connector 39 Test terminal D Y R wire of connector 86A for a short to voltage Is a short to voltage present Locate and repair the short to voltage in the Test terminal D Y R wire of connector 86A for an open Is an open present
185. UMBER HD 48650 TOOL NAME DIGITAL TECHNICIAN II The only way to clear DTCs is to use DIGITAL TECHNICIAN Part No HD 48650 2 4 2008 Buell 1125R Initial Diagnostics and Serial Data PART NUMBER HD 48650 TOOL NAME DIGITAL TECHNICIAN See Figure 2 2 for check engine lamp location When the ignition switch is turned on the check engine lamp illuminates for four seconds This is a bulb check to verify the lamp is working After the bulb check the lamp goes out and stays out if there are no DTCs If only historic DTCs are set then the lamp illuminates for an additional eight seconds If a current DTC is set the lamp goes through the four second bulb check and then stays on continuously If multiple DTCs are present use DIGITAL TECHNICIAN II Part No HD 48650 to determine which DTCs are current or historic See Figure 2 3 Diagnostic Procedure The IC illuminates the check engine lamp when the ignition is turned on for a bulb check The ECM sends a message to the IC to turn off the lamp If the IC does not receive this message it continues to illuminate the lamp If the check engine lamp does not illuminate even during the bulb check then replace the IC NOTE When the IC is replaced there is a 30 minute timer that counts down before the information is written to the IC This is done so the technician has time to test a new cluster to determine whether the fault is within the c
186. UP MENU is displayed 2 Press and release the MODE switch until PIN SETTING displays 3 Press and release the TOGGLE switch to select the set ting 4 Enter the current four digit PIN See Entering the PIN for instructions The IC displays either CORRECT PIN or WRONG PIN depending if the PIN was entered correctly After the correct PIN is entered the IC displays NEW PIN 5 Enter the new PIN 6 Enterthe new PIN again to confirm Both new PIN entries must match to continue 7 displays PIN CHANGED to confirm the two PIN entries matched and the PIN changed 8 The SETUP MENU advances to the next item Continue to press and release the MODE switch until TOGGLE TO EXIT is displayed Press and release the TOGGLE switch ERROR MESSAGES The IC displays error messages when it detects an issue with the security system LOCKED OUT The LOCKED OUT message displays when 20 incorrect PINs are entered This message displays for 30 minutes and the IC will not accept a PIN during that time THEFT ERROR The THEFT ERROR message displays when the IC and the ECM Vehicle Identification Numbers VINs do not match or when the IC has lost communication with the ECM ECM AND INSTRUMENT CLUSTER IC MATCHING The security system is designed to stay active in the event the or the IC has to be replaced The VIN the PIN the security status and the total mileage are stored in the ECM and the IC If either one of these
187. V PKN 1 1 lt lt KA 145B 145A 243A 243B m mR x 5 gt x m Y 2 gt 10B 24 17 16 9 29 30 A 11B 10A 24 17 16 9 29 Diii 4 P ECM Power 5 8 4 2 gt Grounds S 65 5 5 In Wiring EE Diagrams a Ba Chassis Grounds In Wiring ECM Diagrams BK GND 1 Figure 4 6 Instrument Cluster Power and Communication 2008 Buell 1125R Instruments 4 7 Fuel Level 00246 za Sender DA 86B DA 86A 3188 81RA lt lt Instrument 39 398 xm Right Front BNE 1 1 Cluster gt gt Chassis Grounds Turn Signal Low Fuel Lamp 15 15 Y R In Wiring Diagrams 18B 18A lt lt Right Rear Right Turn Driver 141 11 BN BNm 11 Turn Signal 145B 145A lt lt Oil Pressure Input 8 8 e 1 1 Qi Pressure lt lt W 120B 120A High Beam Input 6 6 Right Turn Input 5 5 lt lt Right High Left Turn Input 4 4 Eww 38B 38A Headlamp Left High Left Turn Driver 1 1 Headlamp wo Flash To Pass Switch Headllamp High Low w43 3 Ew Switch WBNS 7 7 BN BN ul Right
188. Volt VAC Volts of Alternating Current D 2 2008 Buell 1125R Appendix D Glossary Table 0 1 Acronyms and Abbreviations ACRONYM OR ABBREVIATION DESCRIPTION VDC Volts of Direct Current VIN Vehicle Identification Number VSS Vehicle Speed Sensor 2008 Buell 1125R Appendix D Glossary D 3 5 0 4 2008 Buell 11258 Appendix D Glossary Tools Used This Manual PART NUMBER TOOL NAME NOTES B 48115 BREAKOUT BOX 1 2 DIAGNOSTIC TOOLS How To Use Diagnostic Tools B 48115 BREAKOUT BOX 1 2 DIAGNOSTIC TOOLS How To Use Diagnostic Tools B 48115 BREAKOUT BOX 1 3 DIAGNOSTICS TROUBLESHOOTING Wiggle Test B 48115 BREAKOUT BOX 6 4 SYMPTOM DIAGNOSTICS Description and Opera tion B 48115 BREAKOUT BOX 6 12 IGNITION COILS DTC P2300 P2301 P2303 P2304 Description and Operation HD 23738 VACUUM PUMP 6 25 MANIFOLD ABSOLUTE PRESSURE MAP SENSOR DTC P0107 P0108 Description and Operation HD 25070 ROBINAIR HEAT GUN A 10 SEALED SPLICE CONNECTORS Sealed Splice Connector Repair HD 26792 SPARK TESTER 1 2 DIAGNOSTIC TOOLS How To Use Diagnostic Tools HD 26792 SPARK TESTER 6 28 ENGINE CRANKS BUT WILL NOT START Description and Operation HD 34730 2D FUEL INJECTOR TEST LIGHT 1 2 DIAGNOSTIC TOOLS How To Use Diagnostic Tools HD 38125 6 PACKARD TERMINAL CRIMP TOOL A 5 METRI PACK TERMINALS Metri Pack Terminal Cr
189. aced Figure 3 7 Voltage Regulator Battery Fuse See Figure 3 8 The 30 Amp battery fuse is located in the fuse box under the seat and is used to protect the circuits to most of the other fuses CALIFORNIA PROPOST posts terminals and related tompounds and other chemi 10 cause cancer and birth de WASH HANDS AFTER Figure 3 8 Battery Fuse SYMPTOMS The troubleshooting tables contain detailed procedures to solve and correct problems Follow 3 1 STARTING SYSTEM DIA GNOSTICS to diagnose starting system problems The 1 3 DIAGNOSTICS TROUBLESHOOTING Voltage Drop pro cedure helps locate poor connections or components with excessive voltage drops 2008 Buell 1125R Starting Charging 3 3 Table 3 1 Starter Does Not or Runs Very Low Speeds SOURCE OF PROBLEM POSSIBLE CAUSE SOLUTION Battery Voltage drop due to discharged battery Charge battery Short circuited or open between elec trodes Replace battery Poor contact condition of battery ter minal s Clean and retighten Wiring Poor or no connection at either end of the battery positive or negative cable Repair or replace cable s Cracked or corroded battery cable ends Clean tighten or replace cable s as needed Open wire s or poor connection at handlebar switch or start relay especially relay ground wire grounds through ECM Tighten connections
190. ach gray connector from the wiring harness to the gray connector on the Breakout Box ed01717 1 ECM black connector 2 Breakout Box 3 gray connector 4 ECM Figure 1 18 ECM and Breakout Box with Connections To remove the Breakout Box perform the following steps 1 Disconnect the ECM connectors 10 black and 11 gray 2 Disconnect Breakout Box connectors from ECM con nectors 3 Disconnect Breakout Box connectors from wiring harness 4 Reconnect harness to ECM HD 26792 Spark Tester 1 See Figure 1 19 The SPARK TESTER Part No HD 26792 is used to verify adequate spark at the spark plug Attach the tester to the coil top plug and to ground while cranking the engine a spark should jump across the gap on the tester leads NOTE Engine will not spark with both spark plugs removed When checking for spark use SPARK TESTER Part No HD 26792 with both plugs installed 2008 Buell 1125R General Information 1 7 ed02012 ed01776 Figure 1 19 Spark Tester HD 39978 Digital Multimeter Fluke 78 The DIGITAL MULTIMETER FLUKE 78 Part No HD 39978 is used for various tests throughout this manual ed02008 Figure 1 20 Digital Multimeter Fluke 78 Part No HD 39978 HD 48053 Advanced Battery Conductance and Electrical System Analyzer Follow the instructions in the ADVANCED BATTERY CON DUCTANCE AND ELECTRICAL SYSTEM ANALYZER Par
191. additional information on the connectors in the following diagram s see B 1 CONNECTORS 00278 Start Switch Active Auxiliary Relay 9Y Intake Solenoid nan GY m 4 A Ignition Ignition Fuse cvio 5 30 Te 2 85 178 2 185 X 62B Relay 628 Block 2 i 9 gt gt E E 1 18 1458 Gee Nasa gt gt Data Link Connector lt id m 5 a gt 2 1848 s BRA Front Front Rear Rear Fuel Ignition Ignition Fuel Injector Coil Coil j m 2 gt gt m m o 1 1 1 H m 10B 29 25 34 32 31 30 10 29 25 34 32 3 30 10 10 8 8 8 8 8 8 5 o 5 5 5 5 9 5 5 t 5 A 5 5 9 8 5 E g E i 8 lt Figure 6 21 Injectors Coils and Active Intake 2008 Buell 1125R Engine Management 6 37 DTCs P2300 and P2301 Front Ignition Coil Install test lamp into terminals 1 and 3 of connector B3FB Use Harness Connector Test Kit Part No HD 41404 B gray pin probes and patch cords See Figure 6 19 Does test lamp flash when engine is cranked Measure resistance from terminal 2 of connector 83FB to ground Is resistance less than 0 5 Ohms Faulty ignition coil con
192. al information on the connectors in the following diagram s see B 1 CONNECTORS 2008 Buell 1125R Engine Management 6 31 00275 11 11 Idle Air Neutral Clutch Control Switch Switch 1 1 3 95A 1 2 87A 1 Y 131B 1 Y 95B 1 2 4 Y1 87B gt 2 z t 2 o x amp gt m em Chassis GND 2 Chassis GND 1 2 g gt 175 1458 17 145 2 g gt 2 gt g of 6a 2 2 X uZ uH Hz sm 8 23 20 21 22 8 2 23 20 21 22 E 5 5555 5 5 gees g gees 3 5 8888 E EX XE 2 000 Fuel Pump B C 868 B C D 86A BK O GY BN Y Y R Instrument gt Cluster n pa e gt Fuel Pum Fuse 78411458 E BN Y BN Y BN Y A 10B N 10A BK N Fuel Pump Output Fuel Pump Output ECM Figure 6 15 Neutral and Clutch Switch and Fuel Pump 6 32 2008 Buell 1125R Engine Management 1154 Connect Breakout Box Part 48115 to the main harness leaving the connector 11 Gray disconnected Measure continuity between Breakout Box terminal 2 Gray and ground Is continuity present Disconnect connect
193. al slot on the same side as the crimp trails must face upward 2 Gently tug on wire end to verify that the terminal is locked in place 3 Rotate the hinged secondary lock inward until tabs fully engage latches on both sides of connector sm00005 1 3 place housing 2 6 place housing 3 10 place housing Figure A 3 AMP Multilock Connector Cavity Numbers on Secondary Locks Socket Housings Shown Preparing Wire Leads for Crimping 1 Strip 5 32 in 4 0 mm of insulation from the wire lead 2 SeeFigure 4 and Figure 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 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 WIRE GAUGE NEST 20 Front 16 Middle 18 Rear sm00004 1 Insulation crimp tail 2 Wire crimp tail 3 Locking bar groove Figure A 4 AMP Multilock Connector Pin Terminal sm00001 cM 1 Insulation crimp tail 2 Wire crimp tail 3 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 ta
194. and 32 of connector 10B Replace 1201932_ 2008 Buell 11258 Engine Management 6 39 FUEL INJECTORS P0261 P0262 P0264 P0265 DESCRIPTION AND OPERATION PART NUMBER TOOL NAME B 48115 BREAKOUT BOX See and The fuel injectors are solenoids that allow pressurized fuel to be sprayed into the engine combustion chambers through the intake flange The fuel injectors are timed to the engine cycle and triggered sequentially Electrical power for the fuel injectors comes from the ignition relay The ECM provides the ground path to trigger fuel injector operation Refer to for DTCs and explanations NOTE Front and rear fuel injectors are interchangeable on the 1125 engine Table 6 14 Code Description DTC DESCRIPTION P0261 Front fuel injector circuit low 1745 Figure 6 22 Fuel Injector Location Front 6 40 2008 Buell 1125R Engine Management P0262 Front fuel injector circuit high diss Rear fuel injectgr circuit low Figure 6 23 Fuel Injector Location Rear P0265 Rear fuel injector circuit high ed01546 B 481 15 KENT MOORE Figure 6 24 Fuel Injector Circuit Tester Typical Connections Diagnostic Tips Ignition relay failure or certain wiring harness problems causes 12V power to be lost to both fuel injectors both ignition coils and fuel pump Purge fuel li
195. ant temperature and atmospheric variables all contribute to determining the desired fuel pressure The ECM incorporates automatic compensation for differences of the desired pressure versus the actual pressure For instance if the pressure is lower than desired the ECM opens the injectors for a longer time to adjust the amount of fuel delivered Engine Coolant Temperature ECT Sensor The ECT sensor is a thermistor device which means that at a specific temperature it has a specific resistance across its ter minals As this resistance varies so does the voltage Athigh temperatures the resistance of the sensor is very low which effectively lowers the signal voltage on ECM 11 terminal 9 Atlow temperatures the resistance is very high allowing the voltage to rise close to 5 Volts The ECM monitors this voltage to compensate for various operating conditions The also uses the sensor input as a reference for determining Idle Air Control IAC pintle position At 230 F 110 C the ECM commands the instrument cluster to illuminate the over temperature lamp At the same time the ECM begins to soft skip spark 1 of 4 removed and then hard skip spark 1 of 2 removed when the engine is above a certain RPM and throttle threshold Spark skips will not occur at idle and lower operating conditions in order to prevent engine stalls Intake Air Temperature IAT Sensor The IAT sensor is a thermistor
196. ary lock inward until tabs fully engage latches on both sides of connector 2008 Buell 1125R Appendix A Connector Repair A 19 SEALED SPLICE CONNECTORS A 10 SEALED SPLICE CONNECTOR REPAIR PART NUMBER TOOL NAME HD 25070 ROBINAIR HEAT GUN HD 38125 8 PACKARD CRIMPING TOOL HD 39969 ULTRA TORCH UT 100 HD 41183 HEAT SHIELD ATTACHMENT General Splice connectors and several OE ring terminal connectors use heat shrink covering to seal the connection Preparing Wire Leads NOTE If adjacent wires are to be spliced stagger the splices so that the sealed splice connectors will not touch each other but are located at different positions along the length of the wires 1 Using a shop gauge identify the gauge of the wire 2 Match the wire gauge to a sealed splice connector by color and part number Refer to Table A 4 3 Using a wire stripper cut and strip a length of insulation off the wire ends Refer to Table A 4 for the strip length Table A 4 Sealed Splice Connectors WIRE GAUGE COLOR PART NO STRIP LENGTH 18 20 Red 70585 93 3 8 in 9 5 mm 0 5 0 8 mm 14 16 Blue 70586 93 3 8 in 9 5 mm 1 0 2 0 mm 10 12 Yellow 70587 93 3 8 in 9 5 mm 8 0 5 0 mm NOTE If any copper wire strands are cut off of the wire core trim the end and strip the wire again in a larger gauge stripper Splicing Wire Leads NOTE See Figure A 25 The c
197. asher in the wiring to the lamps If one bulb is inoperative the remaining bulb flashes at double the normal rate If both bulbs are inoperative the turn signal indicator flashes at double the normal rate The redundant battery and ground wires going to the IC are used to supply the current needed for the turn signal circuits Diagnostic Procedure 1 Turn the ignition on 2 Push the turn signal switch to either the left or right turn signal position 3 Ifthe turn signals are also inoperative see 5 3 LIGHTS to diagnose the turn signals 4 Ifthe turn signals operate normally but the indicators do not function replace the instrument cluster Use job code 6006 2008 Buell 1125R Instruments 4 15 INSTRUMENT CLUSTER INOPERATIVE 4 5 DESCRIPTION AND OPERATION The IC has two redundant battery feeds to support the current used to drive the turn signals The IC also uses an ignition feed that powers up the IC when the ignition switch is turned on Two redundant ground circuits supply ground for the IC Diagnostic Tips It may appear the backlighting on the IC is not functioning when the display brightness is set to the lowest setting If this is the 4 16 2008 Buell 1125R Instruments only concern toggle to the Display Brightness display option and check the setting The IC can only have a VIN written to it once It cannot learn a new VIN if one has already been written to it Therefore when replacing
198. attery RY S Auxiliary Fuse Battery Power Distribution nv In Wiring Diagrams Chassis Grounds In Wiring Diagrams BKE RE Fuel Pump And Rear Lamps GND 2 Figure 3 13 Charging System Circuit 3 14 2008 Buell 1125R Starting Charging Charging System Test Part 1 of 2 Test the battery Charge or replace as required Inspect the voltage regulator See 3 3 CHARGING SYSTEM DIAGNOSIS Correct as Perform Milliampere Draw Test required 5306 Perform Total Current Draw Test Disconnect the voltage regulator Record measurement Does milliampere draw drop Replace the grounded stator Isolate damaged component or wiring 5312 5308 Go to Charging System Test Part 2 of 2 Isolate damaged wiring or excessive accessories 5310 1001928 en 2008 Buell 1125R Starting Charging 3 15 Charging System Test Part 2 of 2 Continued from Charging System Test Part 1 of 2 Perform Current and Voltage Output Test Record measurement and compare with Total Current Draw Test before proceeding PASS Perform Voltage Output Test System tests good up to this point Suspect Accessories on for long periods when motorcycle is parked and not running Accessories on when motorcycle is ridden very slowly for long perio
199. aving the ECM disconnected measure the resistance between terminals 18 and 26 on Breakout Box 11 Gray Is continuity less than 1 megohm resistance Locate and repair short on R BE or BK BE wire between connectors 118 and 798 Replace sensor 56 Connect DVOM at terminals 1 and 2 of connector 79A Does DVOM read 1 0 VAC minimum while cranking YES Check for continuity between terminal 1 of connector 79B and terminal 18 on Breakout Box 11 Gray Is continuity present YES Locate and repair open on BK BE wire between terminal 2 of connector 79B and terminal 26 of connector 11B Gray 56 Replace CKP sensor Locate and repair open on R BE wire between terminal 1 of connector 798 and terminal 18 of connector 11B Gray 2008 Buell 1125R Engine Management 6 17 fc01871 en THROTTLE POSITION TP SENSOR P0122 P0123 P1112 6 8 DESCRIPTION AND OPERATION See Figure 6 7 The TP sensor is located on the left side of the forward throttle body The TP sensor operates from a 5V reference voltage from the ECM and returns a signal to the ECM on the V Y wire The output signal from the TP sensor varies from Approximately 0 3 1 0 Volts at idle closed throttle Approximately 3 5 4 5 Volts at WOT A DTC sets if the TP sensor out
200. ay 3 Battery 4 Key relay 5 Ignition relay Figure 5 2 Relay Block Location Table 5 1 Auxiliary Power DTCs DTC DESCRIPTION P1601 Auxiliary Relay Drive Circuit Fault DTC P1601 Auxiliary Relay Driver Circuit Fault The ECM controls the ground to the coil side of the auxiliary relay The ECM monitors this circuit and sets a code if it does not see the expected input Connector Information For additional information on the connectors in the following diagram s see B 1 CONNECTORS 2008 Buell 1125R Accessories Horn Lights and Security 5 1 00257 Battery Power Distribution In Wiring Diagrams Ls E 7 Fuse 21 Auxiliary Power 10A E ANM 1 42 10 10 145 145 O R ECM gt gt gt gt Auxili Relay d 19 19 E BK GN 20 20 B BK GN BK GN uxiliary Relay Groun 20 20 Eu O R Battery BK Power Distribution In Wiring Diagrams Chassis Grounds In Wiring Diagrams 71 87 Auxiliary 87 j 30 85 os Relay Block 1 12V Auxiliary Connector 2 lt 160 Figure 5 3 Auxiliary Power Connector 5 2 2008 Buell 1125R Accessories Horn Lights and Security 1601 Is P1601 present Disconnect and test the auxiliary relay Is the relay good NOTE See
201. ay terminal called out does not match SEIS the relay being checked No Replace the Locate and repair ignition relay the GY w i ia en 1c01781 en 5816 3 10 2008 Buell 1125R Starting Charging Starter Does Not Sp in Part 3 of 3 Continued from Starter Does Not Spin Part 1 of 3 Did the IC sweep YES Do the brake lamps or horn work See 2 1 INITIAL DIAGNOSTICS Remove the key relay Test for battery voltage at terminal 86 R BK wire with ignition ON Is battery voltage present See 5 3 LIGHTS NOTE See 1 3 DIAGNOSTICS TROUBLESHOOTING If the relay terminal called out does not match the relay being checked Check for continuity to ground on socket terminal 85 BK wire of the key relay Is continuity present NOTE See 1 3 DIAGNOSTICS TROUBLESHOOTING If the relay terminal called out does not match the relay being checked Disconnect connector 33 Check for continuity on terminal 3 connector 33B R BK wire to socket terminal 86 on the key relay NOTE See 1 3 DIAGNOSTICS TROUBLESHOOTING If the relay terminal called out does not match the relay being checked Check for voltage on socket terminal 30 R wire of the key relay Is battery voltage present Locate and NOTE repair the open See 1 3 DIAGNOSTICS TROUBLESHOOTING to ground If the relay terminal called out does not match 5828
202. ce 9 Gram GAL Gallon GAWR Gross Axle Weight Rating GND Ground electrical GVWR Gross Vehicle Weight Rating HDI Harley Davidson International H DSSS Harley Davidson Smart Security System HFSM Hands Free Security Module Hg Mercury 2008 Buell 1125R Appendix D Glossary D 1 Table 0 1 Acronyms and Abbreviations ACRONYM OR ABBREVIATION DESCRIPTION 1 Idle Air Control Intake Air Temperature IC Instrument Cluster ID Inside Diameter IGN Ignition Light Key Switch In Inch INJ PW Injector Pulse Width in lbs Inch Pounds Kg Kilogram Km Kilometer kPa Kilopascal km hr Kilometers Per Hour L Liter LCD Liquid Crystal Display LED Light Emitting Diode mA Milliampere MAP Manifold Absolute Pressure ml milliliter mm millimeter MPH Miles Per Hour ms millisecond Nm Newton Meter N A Not Applicable no Number 02 Oxygen OD Outside Diameter OEM Original Equipment Manufacturer 07 amp Parts and Accessories PN Part Number PSI Pounds per Square Inch RES Reserve RPM Revolutions Per Minute SCFH Cubic Feet per Hour at Standard Conditions TCA Throttle Control Actuator TDC Top Dead Center TGS Twist Grip Sensor TP Throttle Position TMAP Intake Air Temperature Manifold Absolute Pressure TSM Turn Signal Module TSSM Turn Signal Security Module V
203. ch In Wiring Diagrams gt gt 121A 121B RY 2 2 owe 1 1 BE W 5 1 Left 6 lt lt 938 93A 7 Right 4 License LE Plate Turn Signal 24B 24A Lamp Switch BK mt 1 lt lt 45 45 T Right Tum Input 5 5 WBN Left Turn Input 4 4 Right Turn Driver 11 11 IB BN Bad 1 4 Right Left Turn Driver 1 1 Turn Bkm 1 1 Signal Kem lt lt 39 398 31 31 et BE 1 J E ron Turn Turn Signal 1 1 Signal gt gt lt 31LA 3118 18B 18A Left 1 Chassis Signal 11 mm gt gt Diagrams 19A 198 x GND 2 Figure 5 14 Tail Stop and Turn Signal Lamps 5 16 2008 Buell 1125R Accessories Horn Lights and Security Turn Signals Part 1 of 3 Are all the turn signals inoperative Do the turn signal indicators in the IC operate Go to Turn Signals Inoperative Part 2 of 3 Replace the instrument cluster 6006 Do the headlamps operate Disconnect the left hand controls connector 24 Turn ignition on Test for battery voltage on terminal 5 O W of connector 24A Is battery voltage present NO See 5 3 LIGHTS Replace the instrument cluster 6006 Repair the open in the O W wire 6013 fc
204. ck Engine 4 2 Engine Over Temperature 4 2 Low Battery Voltage Lamp 4 2 Low Fuel 4 2 Oil Pressure 4 2 Wiggle 1 11 Wiring B 3 INDEX VII 5 Vill INDEX INSIDE BACK COVER GOES HERE OUTSIDE BACK COVER GOES HERE
205. cluster repair the open in the BN wire 6006 5211 Disconnect the IC connector 39 Turn the ignition on and activate the right turn signals Test for voltage on terminal 5 of connector 398 Is battery voltage present YES Replace the instrument Disconnect connector 24 Test for continuity from terminal 7 W BN of connector 24A to terminal 5 of connector 398 cluster 6006 Is continuity present 5 18 2008 Buell 1125R Accessories Horn Lights and Security 1 01883 en Turn Signals Inoperative Part 3 of 3 Continued from Turn Signals Inoperative Part 2 of 3 Do either of the left turn signals operate Disconnect the inoperative turn signal Turn the ignition switch on and activate the left turn signals Using a voltmeter do not use a test light test for voltage from the V wire at the inoperative turn signal to a good ground Does the voltage cycle on and off as the other turn signal flashes NO Does the left turn signal indicator in the IC operate Connect the voltmeter from the V wire to the BK wire at the inoperative turn signal Does voltage continue to cycle on and off as the other turn signal flashes Locate and repair the open in the V wire at the inoperative turn signal 5211 Locate and repair the open in the
206. components is replaced it learns the information from the other When Replacing the ECM When the ECM is replaced the new ECM copies the VIN and the mileage from the existing IC Once the VINs match the ECM matches the IC PIN and security setting This works with a used ECM as long as the ECM security is not active If the ECM security is active it sees the IC as an invalid VIN and displays THEFT ERROR on the IC When Replacing the Instrument Cluster IC The IC can only have a VIN written to it once It cannot learn a new VIN if a VIN has already been written to it Therefore when replacing the IC it must be a new IC NOTE When the IC is replaced there is a 30 minute timer that counts down before the information is written to the IC This is done so the technician has time to test a new cluster to determine whether the fault is within the cluster or not before the cluster is matched to the ECM Once the VIN is written to the IC it cannot be cleared If the ECM is in a secure state and a new IC is installed the ECM will not recognize it and the message THEFT ERROR displays on the IC Whether or not the ECM is in a secure state the IC begins to match to the ECM A 30 minute counter dis plays instead of the clock on the IC It counts down and when the 30 minutes are up the VIN is permanently written to the IC This 30 minute delay is so the new IC can be tested to verify a repair and removed if it did not resolve the is
207. d States to metric use the following equations Newton meters Nm X 0 737563 foot pounds ft Ibs Newton meters Nm X 8 85085 inch pounds in Ibs foot pounds ft lbs X 1 35582 Newton meters Nm inch pounds in Ibs X 0 112985 Newton meters Nm 2008 Buell 1125R Appendix C Conversions C 3 5 4 2008 Buell 1125R Appendix C Conversions TABLE CONTENTS SUBJECT PAGE NO 5 GLOSSARY D 1 ACRONYMS AND ABBREVIATIONS Table D 1 Acronyms and Abbreviations ACRONYM OR ABBREVIATION DESCRIPTION A Amperes AC Alternating Current ACC Accessory ACR Automatic Compression Release AGM Absorbed Glass Mat battery AMP Ampere AWG American Wire Gauge Battery Voltage BAS Bank Angle Sensor BTDC Before Top Dead Center C Celsius Centigrade CA California CAL Calibration CC Cubic Centimeters CCA Cold Cranking Amps CKP Crankshaft Position cm Centimeter DC Direct Current DLC Data Link Connector DOM Domestic DTC Diagnostic Trouble Code DVOM Digital Volt Ohm Meter ECM Electronic Control Module ECT Engine Coolant Temperature EEPROM Electrically Erasable Programmable Read Only Memory EFI Electronic Fuel Injection ET Engine Temperature EVAP Evaporative Emissions Control System F Fahrenheit ft lbs Foot Pounds fl oz Fluid Oun
208. d to the starter mounting flange Connect the other end to the negative terminal of a fully charged battery Connect a second heavy jumper cable 6 gauge minimum to one end to the positive terminal of the battery Connect the other end of the second jumper cable to the battery terminal on the starter Place an induction ammeter over cable Check ammeter reading a b C Ammeter should show 25 40 amps If reading exceeds 40 amps replace the starter motor If starter current draw on the vehicle was over 180 amps and this test was within specification there may be a problem with the engine or primary drive ed02985 Penna Mounting flange Battery Induction ammeter Battery terminal Figure 3 11 Free Running Current Draw Test CHARGING SYSTEM DIAGNOSTICS 3 3 DESCRIPTION AND OPERATION TROUBLESHOOTING See Figure 3 13 The charging system consists of the alternator PART NUMBER TOOL NAME 48053 ADVANCED BATTERY CONDUCT COMPONENTS Alternator The alternator consists of 2 main components The rotor which mounts to the left side of the crankshaft stator which bolts to the alternator cover Voltage Regulator See Figure 3 12 The voltage regulator is a shunt regulator The circuit combines the functions of rectifying the AC voltage from the alternator stator and regulating the charge voltage to the
209. device As such it will have a specific resistance across its terminals at a specific temper ature As the temperature varies the thermistor resistance varies and so does the voltage on ECM 11 terminal 14 Athigh temperatures the resistance of the sensor is very low which effectively lowers the signal voltage on ECM 11 terminal 14 Atlow temperatures the resistance is very high allowing the voltage to rise close to 5 Volts The ECM monitors this voltage to compensate for various operating conditions Barometric Pressure BARO Sensor The BARO sensor is supplied 5 Volts from the ECM and sends a signal back to the ECM which varies according to atmo spheric barometric pressure The BARO sensor is a constantly running direct fuel modifier It sends continuous information to the ECM where the signal is processed and the injectors adjusted for variations ambient barometric pressure Changes in barometric pressure are influenced by weather and altitude Air density is a combination of barometric pressure and air temperature When air is more dense lower altitudes and lower temperatures more fuel is needed to maintain the proper air fuel ratio for efficient engine operation Intake air temperature combined with barometric pressure is used by the to compensate for these variations Vehicle Speed Sensor VSS The VSS is a Hall effect device mounted close to the teeth of the trigger wheel The output signal freque
210. dle closed throttle to 3 5 4 5 volts at WOT Is the check engine lamp continuously ON and either DTC P0122 or P0123 set Was voltage greater than 4 5 volts YES YES Disconnect TP sensor connector 88 and ECM connector 11 Gray Measure voltage at 11B terminals 4 and 24 to ground Does voltage measure greater than 4 5 volts on either wire Check for intermittents See 1 3 DIAGNOSTICS TROUBLESHOOTING Are intermittents present Go to DTCs P0122 and P0123 Part 2 of 2 Replace ECM Replace TP sensor Clear codes Locate and repair Locate repair and road test short to voltage on System open or b 6 operating or connection Did check engine lamp come on wire showing correctl and set DTC P0122 or P0123 voltage Install original TP sensor System and replace ECM Road operating test again to verify correctly fc01866 en 6 20 2008 Buell 1125R Engine Management 0122 0123 1 2 012 Continued from DTCs 0122 and P0123 Part 1 of 2 Disconnect TP sensor connector 88 Measure voltage between terminal 3 R W wire 4 and terminal 1 BK W wire with ignition switch ON Does voltage measure 5 0 Volts 0 25 Volts Check resistance between connector 11 Gray terminal 4 to chassis ground Is
211. ds Battery self discharge and or accessory draw because motorcycle was not operated for a long period 3 16 2008 Buell 1125R Starting Charging FAIL Perf Stator Perform AC Output Test Replace the voltage regulator orm Check Replace the stator Replace voltage regulator Perform Current Output Test Inspect the rotor PASS PASS System Damaged or Replace the Replace the OK slipping rotor stator rotor 5319 5314 5319 fc01929 en TESTING PART NUMBER TOOL NAME HD 41404 B HARNESS TEST KIT HD 48053 ADVANCED BATTERY CONDUCT ANCE AND ELECTRICAL SYSTEM ANALYZER Milliampere Draw Test NOTE Be sure accessories are not wired so they stay on at all times This condition could drain the battery completely if the vehicle is parked for a long time Check for this by connecting ammeter between negative battery terminal and battery 1 Remove the 30 Amp battery fuse 2 See Figure 3 14 Using HARNESS TEST KIT Part No HD 41404 B purple male socket probes and patch cords connect ammeter to battery fuse socket terminals With this arrangement any regulator drain is picked up 3 With the ignition switch turned off and all lights and accessories off observe current reading a Add regulator draw to appropriate value for ECM If observed ammeter reading is less than listed in table draw
212. e latch slightly and free one side of the sec ondary lock Repeat the step to unlatch the other side 2 Rotate the secondary lock outward on hinge to view the terminals in the chambers of the connector housing The locking tang is on the side opposite the crimp tails and engages a rib in the chamber wall to lock the terminal in place 3 Moving to the mating end of the connector take note of the small opening on the chamber wall side of each ter minal 4 Insert SNAP ON PICK Part No SNAP ON 600 3 into opening until it stops Pivot the end of the pick toward the terminal to depress the locking tang 5 Remove the pick and gently tug on the wire to pull the terminal from the wire end of the connector Repeat steps if the terminal is still locked in place 6 If necessary crimp new terminals on wires Refer to A 5 METRI PACK TERMINALS Installing Socket Terminal NOTE Refer to the wiring diagrams to match wire lead colors to alpha characters molded into the secondary locks of each connector housing 1 Using a thin flat blade like that of a hobby knife carefully bend the tang outward away from the terminal body 2 With the tang facing the chamber wall push the lead into the chamber at the wire end of the connector A click is heard when the terminal is properly seated 3 Gently tug on the wire end to verify that the terminal is locked in place and will not back out of the chamber 4 Rotate the hinged second
213. e the alignment tabs are absent and the orientation of the external latch is the same sm00019 Figure A 14 Deutsch Connector Depress Terminal Latch and Back Out Pin Installing Pin Terminals 1 SeeFigure A 15 Fit wire seal 1 into back of pin housing 2 2 Grasp wire lead approximately 1 0 in 25 4 behind the pin terminal 3 Gently push pin through holes in wire seal into its respective numbered chamber until it clicks in place NOTE A tug on the wire lead will confirm that a pin is locked in place 3 Insert tapered end of secondary locking wedge 4 into pin housing and press down until it snaps in place NOTES The wedge fits in the center groove of the pin housing and holds the terminal latches tightly closed SeeFigure A 12 While rectangular wedges do not require a special orientation the conical secondary locking wedge of the 3 place connector must be installed with the arrow 2 pointing toward the external latch f the secondary locking wedge does not slide into the installed position easily verify that all terminals are fully installed in the pin housing The lock indicates when ter minals are not properly installed by not entering its fully installed position 2008 Buell 1125R Appendix A Connector Repair A 9 Crimping Terminals Identify which of the types of Deutsch terminals are used with the connector and follow the corresponding crimping instruc tions
214. ed terminals 3 HD 38125 8 non sealed terminals Figure A 17 Metri Pack Terminal Crimp Tools Crimping Insulation Seal NOTE Always perform Crimping Wire Core before Crimping Insu lation Seal See Figure A 18 Identify the correct die for the insula tion seal crimp 2 Position the insulation seal crimp in the nest Be sure the insulation seal crimp tails are facing the forming jaws Squeeze handle of crimp tool until tightly closed Tool automatically opens when the crimp is complete Inspecting Crimps 1 See Figure 18 Inspect the wire core 1 The tails should be folded in on the wire core without any distortion or excess wire strands Inspect the insulation 2 or seal 3 crimp The tails of the terminal should be wrapped around the insulation without distortion sm00036 1 Wire core crimp 2 Insulation crimp 3 Seal crimp Figure A 18 Metri Pack Connector Inspect Core and Insulation Seal Crimps 2008 Buell 1125R Appendix A Connector Repair A 13 150 6 150 METRI PACK CONNECTOR REPAIR General Metri Pack connectors are embossed with the initials P E D There are two types of connectors in this series Pull to Seat Push to Seat Separating Pin and Socket Housings Bend back the external latch slightly and separate the pin and socket ha
215. ee valve regulated lead calcium and sulfuric acid bat teries The battery is recharged by the alternator and kept from over charging by the regulator during use Battery condition can be determined by a voltage test a con ductance test or a load test A battery may be tested whether fully charged or not using the conductance test However the battery must be fully charged to perform a load test Figure 3 6 Battery Alternator The alternator is located on the left side of the engine behind the alternator cover The alternator consists of permanent magnets mounted around the circumference of a rotor and a series of radial wire coils statically mounted in a stator assembly When rotated by the engine the rotor magnets cause a voltage in the wire coils of the stator alternately reversing poles The rotor of the alternator is bolted to the crankshaft The stator is bolted to the inside of the alternator cover and delivers voltage to a voltage regulator through a wire harness that passes through a boss in the side of the alternator cover Voltage Regulator See Figure 3 7 The voltage regulator is located under the seat on the left side frame rail The voltage regulator is a shunt regulator The circuit combines the functions of rectifying the AC voltage from the alternator stator and regulating the charge voltage to the battery and other vehicle systems The voltage regulator cannot be repaired only repl
216. ell 1125R Engine Management IDLE AIR CONTROL IAC DTC P0506 P0507 P0511 DESCRIPTION AND OPERATION See Figure 6 45 The ECM controls engine idle speed by moving the IAC motor to open or close a passage around the throttle plates It does this by sending voltage pulses to the proper motor winding of the IAC motor causing the pintle to move in or out of the IAC motor a given distance for each pulse received Refer to Table 6 23 To increase idle speed the ECM retracts the pintle allowing more air to flow through the throttle body To decrease idle speed the ECM extends the pintle allowing less air to flow through the throttle body The motor position steps can be observed by using the Onboard Diagnostic Information System ODIS See 4 1 INSTRUMENT CLUSTER AND GAUGES Ahigh number of steps represents a retracted pintle and an open passage around throttle plates This correlates with an increase in the amount of air flowing through the throttle body Five steps represents a fully extend pintle A five reading indicates an abnormal condition in which the pintle has been fully extended and has consequently closed the passage around the throttle plates Each time the ignition switch is turned ON the ECM resets the IAC motor by sending enough pulses to extend the pintle and effectively close the air passage around the throttle plates The fully extended value is the ECM reference poi
217. ensors with the engine at ambient temper ature in order to evaluate the possibility of a shifted out of calibration sensor which may result in driveability problems The sensor temperatures should be within 10 degrees of each other Connector Information For additional information on the connectors in the following diagram s see B 1 CONNECTORS 2008 Buell 1125R Engine Management 6 55 00277 Intake Crank Coolant Air Position Temperature Temperature Oxygen Cooling CKP ECT IAT Sensor Fan 1 Sensor Sensor Sensor Rear Right eren 1 2 3 79 2 1 9041 1 89 1 137A 221 974 1 2 3 Y 79B 2 1 YI90B 2 1 YI898 1 Y 1378 2 1 YI97Bl x gt 2 Cooling a a gt 2 m 2 d T m g amp 2 Left Oxygen Baro Sensor Front Side Stand F Y 2 1 215A L 2 1 Y 215B amp 2 1 J 138A Y 11388 gt d 2 E gt gt gt 5 2 1 3 4 2348 2 1 AJ 2344 ain Kw eee re gt gt 5 2 m Cooling Y BN Fan Fuse v a gt E m T 4 15 16 V A 1458 4 15 16 145 o o 5 Y 3 e gt a 5 8 cod z 8 3 i amp BL gt 118 118
218. ent run events and enables Spark Plug Cleaning if two out of the last four run events did not bring the engine to operating temper ature When the ECM enters Spark Plug Cleaning mode it alternately rapid fires the spark plugs when the ignition switch is turned ON This mode can also be manually enabled by holding the throttle wide open and turning the ignition ON Spark Test 1 Remove ignition coil from spark plug 2 Visually check condition of plug and ignition coil 3 SeeFigure 6 54 Attach ignition coil to SPARK TESTER Clip tester to cylinder head bolt NOTE Cranking the engine with the SPARK TESTER Part No HD 26792 in place of an ignition coil can sometimes cause DTC P2300 P2301 P2303 or P2304 to set This condition is normal and does not by itself indicate a malfunction Codes must be cleared if this condition occurs 4 While cranking starter look for spark 5 Repeat procedure on other ignition coil NOTE Engine will not spark with spark plugs removed When checking for spark use SPARK TESTER Part No HD 26792 with both plugs installed If spark is evident check the actual spark plugs for problems cracks open electrode inoperative insulator and others Replace questionable spark plugs Fuel Injector Test WARNING To prevent spray of fuel purge system of high pressure fuel before supply line is disconnected Gasoline is extremely flammable and highly explosive which could result in deat
219. er Go to Starter Stalls or Spins Too Slowly Replace the sprag clutch and inspect the freewheel gear for damage 5839 Inspect for damage to the starter pinion gear friction clutch and the freewheel gear Is damage present Replace Friction clutch damaged failure Replace gears as the friction needed clutch 5825 5837 Go to Starter Does Not Spin fc01778 en 2008 Buell 1125R Starting Charging 3 7 Starter Stalls Spins Too Slowly Perform voltage drop tests from battery positive to starter motor terminal See 1 3 DIAGNOSTICS TROUBLESHOOTING Crank the engine Is voltage drop greater than 1 0 Volt YES Perform voltage drop tests between battery positive to starter solenoid terminal 2 Crank the engine Is voltage drop greater than 1 0 Volt YES Perform voltage drop tests between battery negative and starter studs or bolts Is voltage drop greater than 1 0 Volt Perform voltage drop tests between battery positive and solenoid battery terminal 1 Is voltage drop greater than 1 0 Volt Repair the connection between battery and solenoid 5824 Locate and repair the connection between the solenoid and the starter Replace the starter solenoid 5845 3 8 2008 Buell 1125R Starting Charging See 3 2 TESTING STARTER
220. erminal 2 to ground 5038 the 12V auxiliary connector Replace and program the ECM 1730 NO Locate and repair the open in the BK GN wire from connector 10B socket terminal 19 to auxiliary relay socket terminal 12 1734 fc01842 2008 Buell 1125R Accessories Horn Lights and Security 5 5 HORN 5 2 DESCRIPTION AND OPERATION The horn is powered through the horn switch from the brake horn fuse The horn is grounded through terminal 1 of connector 122 to GND 1 When the horn switch is pressed battery voltage is applied to terminal 2 of connector 122 causing the horn to sound COMPONENTS Horn Switch See Figure 5 5 The horn switch is a pushbutton switch on the left handlebar controls ed01716 Flash to pass switch Headlamp switch Turn signal switch Horn switch PONS Figure 5 5 Left Handlebar Controls Horn See Figure 5 6 The horn is located behind the left radiator shroud near the oil cooler ed01714 1 Horn connectors 2 Horn 3 Oil cooler Figure 5 6 Horn Location SYMPTOMS The horn circuit does not set DTCs when there is a malfunction Instead one of the symptoms shown in Table 5 3 exists to indicate a concern with the system Table 5 3 Horn Symptom Table SYMPTOM COMMON CAUSE Horn Always On Short to voltage or a stuck switch Horn Inoperative Open circui
221. es the stop lamp illuminate Does the tail stop lamp illuminate with the front brake switch applied D Inspect the brake born fuse Is the fuse good Go to Stop Lamp Inoperative Part 2 of 2 YES Replace rear brake switch 5141 E Test for voltage from terminal 1 O of connector 121A to a Is battery voltage present good ground Locate and repair the Locate and repair the open in the R Y from terminal 2 of connector 121A 5142 5 22 2008 Buell 1125R Accessories Horn Lights and Security open in the O wire from terminal 3 of the brake horn fuse Locate and repair the open in the O from terminal 1 of connector 121A 5764 Turn the ignition on Test for voltage on the R BK wire on terminal 9 of the brake horn fuse Is battery voltage present present Locate and repair the open in the R BK wire from terminal 9 of the brake horn fuse Locate and repair the short to ground and replace the fuse fc01885 en Test for a short to ground See Diagnostic Tips Is a short to ground Replace the fuse and test operation 5145 Stop Lamp Inoperative Part 2 of 2 Continued from Stop Lamp Inoperative Part 1 of 2 Does the stop lamp illuminate with the rear brake Switch applied YES NO Di
222. et it know when to illu minate the check engine lamp See 6 1 DDFI 3 OPERATION for diagnosing the Check Engine Lamp Engine Over Temperature Lamp The ECM sends a commu nication over the CAN lines to the IC when the engine temper ature reaches 230 F 110 C The IC then illuminates the engine over temperature lamp and flashes the coolant temper 4 2 2008 Buell 1125R Instruments ature on the LCD screen See 6 1 DDFI 3 OPERATION for diagnosing the engine over temperature lamp Pressure Lamp The IC receives a direct input on terminal 8 from the oil pressure switch When oil pressure drops the switch closes and the IC illuminates the oil pressure lamp The oil pressure lamp comes on when the ignition is turned on Low Battery Voltage Lamp The IC illuminates the low battery voltage lamp when the battery voltage drops below 12V The IC also displays the message SYSTEM VOLTAGE on the LCD screen The IC receives the battery voltage signal over the CAN lines from the ECM and monitors the battery circuits to the IC Theft Mode LED The red theft mode LED flashes when the security system is armed The IC works with the ECM to disable the starter injectors and coils TOGGLE Switch The TOGGLE switch is located on the left edge of the IC With the engine running the TOGGLE switch changes the display options to Air temperature and coolant temperature Display brightness Average fuel consumption e nstantane
223. for continuity from connector 133B terminal 1 to connector 11B Gray terminal 24 Is continuity present Locate and repair short to ground Replace Locate and repair open 1 01875 2008 Buell 1125R Engine Management 6 25 DTCs P1501 P1502 and P1503 Part 3 of 3 Continued from DTCs P1501 P1502 and P1503 Part 1 of 3 Clear DTC 1501 and or DTC 1502 before proceeding Are the side stand and associated parts in good operating condition YES Inspect the side stand bolt for correct clearance to side stand sensor Clearance should be 0 18 in 4 5 mm maximum Is the sensor mounted correctly Inspect the side stand Is the side stand in good mechanical condition YES NO YES Turn ignition switch ON and run stop switch to RUN Replace side stand Is side stand mounted correctly Check voltage on side stand Make adjustments sensor connector 133B and retest terminal 1 Is 5V present 36 Turn off ignition switch and connect breakout box Check for continuity Check spring for proper between switch connector 133B tension terminal 1 and ECM connector 11B Does spring have correct Gray terminal 24 tension Is continuity present YES Replace side stand sensor Install side stand Replace EOM Repair open wire
224. g lamps Security LED gi gt Figure 2 1 Instrument Cluster Table 2 1 Diagnostic Trouble Codes DTC Priority Table DTC PRIORITY FAULT CONDITION DIAGNOSTIC PROCEDURE ORDER B1004 70 Fuel Level Sender Low 4 2 FUEL LEVEL SENDER LOW HIGH OPEN B1004 B1005 B1005 69 Fuel Level Sender 4 2 FUEL LEVEL SENDER LOW HIGH OPEN DTC B1004 B1005 High Open P0087 29 Fuel Rail System Pres 6 19 FUEL PRESSURE SENSOR P0192 P0193 P0087 sure Too Low P0107 63 Map Sensor Low Open 6 25 MANIFOLD ABSOLUTE PRESSURE MAP SENSOR P0107 P0108 P0108 62 Map Sensor High 6 25 MANIFOLD ABSOLUTE PRESSURE MAP SENSOR DTC P0107 P0108 2008 Buell 1125R Initial Diagnostics and Serial Data 2 1 Table 2 1 Diagnostic Trouble Codes DTC Priority Table DTC PRIORITY FAULT CONDITION DIAGNOSTIC PROCEDURE ORDER P0112 22 Intake Air Temperature 6 17 INTAKE AIR TEMPERATURE IAT SENSOR DTC P0112 P0113 Sensor Voltage Low P0113 21 Intake Air Temperature 6 17 INTAKE AIR TEMPERATURE IAT SENSOR DTC P0112 P0113 Sensor High Open P0117 20 Engine Coolant 6 16 ENGINE COOLANT TEMPERATURE ECT DTC P0117 P0118 ature Sensor Circuit Low P0118 19 Engine Coolant 6 16 ENGINE COOLANT TEMP
225. ge between terminal 4 R W and terminal 6 BK W Is voltage 4 6 Volts 11 13 Volts Repair short to voltage on LGN GY wire z Connect BAS and clear codes Cycle ignition switch Recheck for codes 0 0 Volt Go to DTCs P1151 and P1152 Part 2 of 2 Is BAS properly installed Repair open in R W wire between connector 134B terminal 4 and connector 11B terminal 25 Are ferrous metals located within 0 25 in 6 4 mm of sides face or top of BAS Install properly Return to original configuration No Replace BAS fc01869 en 2008 Buell 1125R Engine Management 6 29 P1151 and P1152 Part 2 of 2 Continued from DTCs P1151 and P1152 Part 1 of 2 Disconnect connectors 10 Black and 11 Gray from and plug into Breakout Box B 48115 Check continuity between connector 134 terminal 5 LGN GY and connector 11 Gray terminal 17 Is continuity present YES Check continuity between connector 134B terminal 6 and connector 11B Gray terminal 19 BK W Is continuity present Locate and repair open in LGN GY wire Check LGN GY circuit continuity to ground for connector 134B terminal 5 and connector 11B Gray terminal 17 Is continuity present Locate and repair open on BK W w
226. ghts and Security 00245 Battery Power Distribution In Wiring Diagrams Y par Instrument 39 398 Cluster S5 Ignition Switch 14 Chassis Ground 13 Constant Battery 12 CAN Low 10 CAN High 9 Chassis Ground 3 Constant Battery 2 mR s PK GY Bm BK Lock Off Park On Lock Off Park On e EA m tc 3 4 R GY B v gx m R GY 6 PK V 2 10B 10A 3 6 3 2 Ignition Switch x 33A 33B Ignition And Accessory gt Power In Wiring Diagrams m BK BK Y BK B lm PK GY 9 gt 4 Grounds In Wiring Diagrams Battery System Ground 1 System Ground 2 System Ground 3 Ignition Switch CAN Low CAN High ECM CAN Terminating Connector Resistor PK GY 2 2 Ziza PKV 1 1 gt gt 243A 243 ACB m Chassis Grounds In Wiring Diagrams GND 1 Figure 5 24 Security System 2008 Buell 1125R Accessories Horn Lights and Security 5 31 THEFT ERROR P1009 Part 1 of 2 Verify DTC P1009 is present Is D
227. gnition Fuel Intake Coil Injector Solenoid Figure 2 4 Battery Power 2008 Buell 1125R Initial Diagnostics and Serial Data 2 7 00240 Lock Off Lock Off On On e e gt 9 m i 1 2 3 4 1 2 3 4 W E ao gt 9 Power gt D Wiring Diagram Relay Block Ignition Switch 334 Y 33B 145 1 9 9 1108 VERRE gt d E 9 N 10A trument Chassis Ground Engine mq Wiring Diagram Stop Cluster a Switch ECM T 9 23 Lights 12 Accessory 10A 15A 10A 17 6 Fuse T 4 IS 1 Block Relay Block A a Vehicle Start qo Ta 58 658 65 Att708 41218 24 1 1170 1 Y 24B Front Rear IE 62 Brake Brake Switch Switch z z TI 1 458 938 1 45 1 93A a 128B 128A l l Horn m Ke Switch 4 ma Lamp p
228. gnostics in this manual are developed under the assumption that DTII is not available HD 41404 Harness Test Kit The HARNESS TEST KIT Part No HD 41404 contains pin and socket terminals and stackable banana jack patch cords used to test circuits The pin and socket terminals are used to connect to various connectors used on the vehicle See the tool instruction sheet for specific terminal usage NOTE To prevent terminal damage while using the probe tips insert the probe tip straight into the cavity and keep it stable during the test Do not wiggle or move the probe tip once it has been inserted into the terminal Do not use more than one probe per terminal or cavity at any one time B 48115 Breakout Box The BREAKOUT BOX Part No B 48115 is spliced into the main harness Used with a DIGITAL MULTIMETER FLUKE 78 Part No HD 39978 the Breakout Box allows circuit dia gnosis of the wiring harness and connections without having to probe with sharp objects To install the Breakout Box perform the following steps 1 Disconnect the ECM connectors 10 black and 11 gray from the ECM 2 See Figure 1 18 Attach the Breakout Box to the ECM connectors as follows a Attach black connector from Breakout Box to the 10 black ECM connector b Attach black connector from the wiring harness to the black connector on the Breakout Box Attach gray connector from Breakout Box to the 11 gray ECM connector d Att
229. h See The headlamp switch is located on the left handlebar controls This switch is used to select either the high beam or the low beam headlamps ed01716 Flash to pass switch Headlamp switch Turn signal switch Horn switch Pens Figure 5 9 Left Handlebar Controls Flash to Pass Switch See The flash to pass switch is a momentary switch used to briefly flash the high beam headlamps 2008 Buell 1125R Accessories Horn Lights and Security 5 9 Low Beam Headlamps The two inner headlamps are the low beam headlamps When the headlamp switch is in the low beam position the low beam headlamps and the marker lamps are illuminated High Beam Headlamps The two outer headlamps are the high beam headlamps When the headlamp switch is in the high position the high beam headlamps illuminate along with the low beam headlamps and the front marker lamps Marker Lamps The two front marker lamps are located in the fairing on the outside edge of the two high beam headlamps The license plate lamp and the tail lamp are also used as marker lamps These lamps illuminate when the ignition is in the ON or PARK position Turn Signal Switch See Figure 5 9 The turn signal switch is located on the left handlebar controls The turn signal switch is an input to the IC When the switch is pushed to the right voltage is supplied through the W BN wire at terminal 5 of the IC When the turn signal switch is
230. h or serious injury 00275a 1 Purge fuel line of high pressure gasoline 2 Access fuel injectors by removing the airbox and throttle cover plate See the service manual NOTE Cranking the engine with a test lamp in place of a fuel injector can sometimes cause DTC P0261 or P0264 This condition is normal and does not by itself indicate a malfunction Clear DTCs if this condition occurs 3 Remove connector from suspect injector and connect test lamp 4 Figure 6 55 The test lamp should flash as the engine is cranked ed02012 Figure 6 54 Spark Tester ed01546 B 48115 9999000 54444 2 Figure 6 55 Fuel Injector Test Lamp 2008 Buell 1125R Engine Management 6 101 Engine Cranks But Will Not Start Part 1 of 2 Is fresh gasoline in tank YES Check for DTCs DIAGNOSTICS Are DTCs found See 2 1 INITIAL Fill tank with fresh gasoline ves Refer to applicable DTC chart Start with highest priority code Check battery connections and voltage Is voltage above 12 70 Volts Connect Breakout Box 48115 Measure voltage between connector 11 Gray terminal 17 and terminal 19 Is voltage between 0 25 2 7 Volts Run Mode See 6 10 BANK ANGLE SENSOR BAS DTC P1151 P1152 YES Does battery pass load test
231. he information to the ECM The ECM then adjusts the spark and fuel timing advance curves for optimum perform ance The output of the sensor can also be used to determine if the engine is rotating when a fault with sensor is present DRIVERS Drivers ECM output devices or system outputs are the work horses of the DDFI 3 system Drivers are provided ground by the ECM to pump inject and ignite the air fuel mixture in the engine and to activate relays Fuel Pump The fuel pump located on the bottom right side of the fuel tank frame is provided battery voltage when the RUN STOP and IGNITION switches are on The pump is controlled on the ground side by the ECM which is monitoring the fuel pressure sensor Output pressure from the pump varies from 58 75 psi 400 517 kPA in response to engine demand Ignition Coils and Spark Plugs The ignition coils also referred to in the parts list as stick coils create the energy to fire the spark plugs and ignite the air fuel mixture in the cylinders Advancing or retarding the spark is controlled by the ECM to suit load and speed conditions of the engine Each cylinder has its own ignition coil which is provided power by the ignition relay Each coil is controlled independently by the In the event of the engine or coolant overheating the ECM can soft skip spark 1 of 4 removed or hard skip spark 1 of 2 removed when the engine is above a certain RPM and throttle threshold
232. hen the transmission is in neutral and the indicator should be illuminated 2008 Buell 1125R Instruments 4 1 Headlamp High Beam Indicator IC uses direct input on terminal 6 from the headlamp high low switch to determine when to illuminate the high beam indicator Right Turn Signal Indicator The IC uses a direct input on terminal 5 from the right turn switch to determine when to flash the right turn signal indicator The IC then supplies the voltage to the right turn signals Warning Lamps See Figure 4 3 The warning lamps are located at the right upper side of the IC These lamps illuminate to inform the operator of a concern within the different systems of the motorcycle ed01696 rpm 7 7 7 7 Low fuel lamp Check engine lamp Engine over temperature lamp Oil pressure lamp Low battery voltage lamp gt Figure 4 3 Warning Lamps Low Fuel Lamp The IC uses a direct input on terminal 15 from the fuel level sender to determine when to illuminate the low fuel warning indicator The IC also activates the F trip odometer when the low fuel indicator is illuminated This tracks the number of miles driven since the low fuel warning indicator was illuminated Check Engine Lamp The IC illuminates the check engine lamp when the ignition is turned on or when there is a malfunc tion with the engine management system The ECM sends a signal to the IC over the CAN lines to l
233. ic B3FA 123 83RA 1 23 123 1888 227 1 89A 1 2 A 84B 123 1808 123 12288 456 A 1348 1 23 11338 Mr 20 123 88 227 12 1 2 185 23 1 2 228 45 6 1134 123 133 LU Manifold tr ES E 5 anifo arometric Bank i Nu 7 Throttle Fuel Intake Air L Absolute BARO Angle Side Stand ONCE Front Ignition Rear Ignition Position Pressure Temperature IAT Front Fuel Rear Fuel Pressure Pressure Sensor Se Sensor Sensor Sensor Injector Injector Sensor Sensor BAS ensor Figure B 8 Main Engine Wiring Harness 2008 1125R Model Figure B 8 Figure B 8 Main Engine Wiring Harness 2008 1125R Model Main Engine Wiring Harness 2008 1125R Model 00110 Headlamp Assembly Subharness lt E BK A BE B 1 GY BK lt 2 Cw BK A A BE 4 R BK 5 lt 38 R BK B B lt R BK B Left Marker Lamp Right Marker Lamp Left Low Beam Headlamp Right Low Beam Headlamp Left High Beam Headlamp Right High Beam Headlamp Cooling Fan Subharness Cooling Fan 1 Right cd 12 12 TH zo
234. ical problems may cause low oil pressure It is important to test and rule these out to avoid unnecessary parts replacement Possible causes include Incorrect oil level or incorrect oil viscosity Clogged oil line Damaged or improper operation of the bypass Oil pump malfunction Connector Information For additional information on the connectors in the following diagram s see B 1 CONNECTORS 2008 Buell 1125R Instruments 4 11 Fuel Level 00246 za Sender DA 86B DA 86A 3188 81RA lt lt Instrument 39 398 xm Right Front BNE 1 1 Cluster gt gt Chassis Grounds Turn Signal Low Fuel Lamp 15 15 Y R In Wiring Diagrams 18B 18A lt lt Right Rear Right Turn Driver 141 11 BN BNm 11 Turn Signal 145B 145A lt lt Oil Pressure Input 8 8 e 1 1 Qi Pressure lt lt W 120B 120A High Beam Input 6 6 Right Turn Input 5 5 lt lt Right High Left Turn Input 4 4 Eww 38B 38A Headlamp Left High Left Turn Driver 1 1 Headlamp wo Flash To Pass Switch Headllamp High Low w43 3 Ew Switch WBNS 7 7 BN BN ul Right Turn Switch
235. ient fuel in the fuel tank Measure the resistance between terminals D and A of connector 86B Is the resistance 850 1200 Ohms Disconnect the IC connector 39 Test terminal 15 of connector 39B for a short to ground Is a short to ground present Replace the fuel pump assembly 7666 Locate and repair the short to ground in the Y R wire 6034 4 22 2008 Buell 1125R Instruments Replace the instrument cluster 6006 fc01788 en Low Fuel Lamp Inoperative Turn the ignition on Does the low fuel lamp illuminate for two seconds and then turn off Disconnect the fuel level sender connector 86 Using a jumper wire connect terminal D Y R to a good ground Turn the ignition on Wait a minute for the low Replace the instrument fuel lamp to update cluster Did the low fuel lamp illuminate 6006 Test for continuity between connector 39A and connector 86A on Y R wire Is continuity present Replace the fuel pump assembly 7666 YES NO Test for a short to voltage in Y R wire Locate and repair the Is a short to voltage present open in the Y R wire 6037 Locate and repair the short to voltage in the Y R wire Replace the instrument cluster 6034 6006 1201789_ 2008 Buell 11258 Instruments 4 23 5 4 24 2008 Buell 1125R Instruments
236. ies Horn Lights and Security 5 7 Horn Inoperative Activate front and rear brakes Does the tail stop lamp illuminate Disconnect the horn connector 122 Connect a test lamp between terminal 1 BK to terminal 2 Y BK of connector 1228 Press the horn switch Does the test lamp illuminate Inspect the brake horn fuse Is the fuse good Locate and repair the open in the fuse block Connect a test lamp between a good ground and terminal 2 Y BK of connector Locate and repair the short to ground Refer to Replace the horn 122B Press the horn switch connections to the Diagnostic Tips 5765 Does the test lamp illuminate brake horn fuse Replace the brake horn fuse 5764 Connect horn connector 122 Disconnect connector 24 Using the harness connector Locate and repair the open test kit and gray terminal probes jumper in the ground circuit terminal 8 O and terminal 4 Y BK of connector 24A 5764 Does the horn sound Connect a test lamp from terminal 8 O En s of connector 24A to a good ground gear Does the test lamp illuminate 5122 Locate and repair the open in the Y BK wire Locate and repair the open in b the O wire between connector etween connector 24A and the fuse block 24A and the horn 5764 5764 fc01784_en 5
237. ify by the neutral light on the instrument cluster being extinguished When the side stand is retracted voltage on the connector 11 terminal 34 GY should be approximately 0 6 V When the side stand is extended the voltage should jump to approxim ately 2 6 V Use brown pin probes when taking measurements at the side stand sensor connector 133 Connector Information For additional information on the connectors in the following diagram s see B 1 CONNECTORS 00277 Intake Crank Coolant Air Position Temperature Temperature Oxygen Cooling CKP ECT IAT Sensor Fan 1 Sensor Sensor Sensor Rear Right 1 79A 90A 2 1 J B9A 137A 2 1 97A 2 2 1 2 79 2 1 YI90B 2 1 Y 89B 1 1378 2 1 YI97Bl T x gt 2 gt Cooling a E 2 2 9 5 2 m S Left Oxygen Sensor Front Side Stand F 71 Y 2 11 215 L 2 1 215 5 5 9 v Y 1388 gt 8 ECM 2 E gt gt gt 5 2 1 3 4 234 2 1 3 4 234 ain Lm mm gt m m rs gt gt E z gt Cooling 5 Y a gt 4 15 16 1458 4 15 16 145 o o Y gt x e S g
238. igure 1 15 Ground 1 Figure 1 13 LH Engine Figure 1 14 ECM Ground Figure 1 16 ECM 2008 Buell 1125R General Information 1 5 1 Rear ignition coil connector 838 10 Starter solenoid 2 Active intake solenoid connector 178 11 Starter solenoid connector 128 3 Fuel pump connector 86 12 Voltage regulator 4 Voltage regulator connector 77 13 VSS connector 65 5 Relay block 14 O2 sensor rear connector 137 6 Battery ground 15 Stator connector 46 7 Battery 16 Barometric BARO pressure sensor connector 8 Battery positive 228 9 Fuse block 17 Rear fuel injector connector 85 18 Fuel pressure sensor connector 227 Figure 1 17 Chassis Top View 1 6 2008 Buell 1125R General Information DIAGNOSTIC TOOLS 1 2 HOW TO USE DIAGNOSTIC TOOLS PART NUMBER TOOL NAME B 48115 BREAKOUT BOX HD 26792 SPARK TESTER HD 34730 2D FUEL INJECTOR TEST LIGHT HD 39978 DIGITAL MULTIMETER FLUKE 78 HD 41354 SPEEDOMETER TESTER HD 41354 1 INPUT OUTPUT CABLE HD 41404 HARNESS TEST KIT HD 41417 PROPANE ENRICHMENT KIT HD 48053 ADVANCED BATTERY CONDUCT ANCE AND ELECTRICAL SYSTEM ANALYZER HD 48650 DIGITAL TECHNICIAN II HD 48650 Digital Technician 11 DIGITAL TECHNICIAN II Part No HD 48650 is a computer based diagnostic device used to communicate diagnose and reprogram systems modules Dia
239. ike a hobby knife 4 carefully bend the tang outward away from the terminal body 2 Gently pull on the wire lead 5 to draw the terminal back into the chamber The tang faces opposite the wireform as it enters the chamber NOTE A click is heard when the terminal is properly seated 3 Pushon lead to verify that terminal is locked in place 4 Fitrubber wire seal back into wire end of connector Crimping Terminals If necessary crimp new terminals on the wire leads Refer to A 5 METRI PACK TERMINALS Metri Pack Terminal Crimps A 16 2008 Buell 1125R Appendix A Connector Repair sm00029 Figure A 21 280 Metri Pack Connector P E D 5100030 Pry rubber seal from connector Insert safety pin to depress tang Push on lead to remove terminal Raise tang with X Acto knife Pull on lead to draw terminal into chamber Figure A 22 280 Connector Remove Install Socket Terminal 2008 Buell 1125R Appendix A Connector Repair A 17 480 5 8 480 METRI PACK CONNECTOR REPAIR General A 480 Metri Pack P E D connector is frequently used for the B battery voltage connector to power P amp A accessories Referred to as Packard connectors Metri Pack connectors are embossed with the initials P E D Separating Pin and Socket Housings
240. ils 1 See Figure A 6 Squeeze the handles to cycle the AMP MULTILOCK CRIMPER Part No HD 41609 to the fully open position 1 2 Raise locking bar by pushing up on bottom flange 2 NOTE See Figure A 4 and Figure A 5 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 3 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 4 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 5 Insert stripped end of lead 5 until ends make contact with locking bar 6 Verify that wire is positioned so that wire crimp tails squeeze bare wire strands while insulation crimp tails fold over the wire lead insulation 7 Squeeze handle of crimp tool until tightly closed Tool automatically opens when the crimping sequence is com plete 8 Raise up locking bar 8 and remove crimped terminal 2008 Buell 1125R Appendix A Connector Repair A 3 5100007 Open position Locking bar flange Insert contact Release locking bar Insert lead Squeeze Raise locking bar Remove cri
241. imps HD 38125 7 PACKARD TERMINAL CRIMPER A 5 METRI PACK TERMINALS Metri Pack Terminal Crimps HD 38125 8 PACKARD CRIMPING TOOL A 5 METRI PACK TERMINALS Metri Pack Terminal Crimps HD 38125 8 PACKARD CRIMPING TOOL A 10 SEALED SPLICE CONNECTORS Sealed Splice Connector Repair HD 39965 A DEUTSCH TERMINAL CRIMP TOOL A 4 DEUTSCH STANDARD TERMINAL REPAIR Deutsch Standard Terminal Crimps HD 39969 ULTRA TORCH UT 100 A 10 SEALED SPLICE CONNECTORS Sealed Splice Connector Repair HD 39978 DIGITAL MULTIMETER FLUKE 78 1 2 DIAGNOSTIC TOOLS How To Use Diagnostic Tools HD 39978 DIGITAL MULTIMETER FLUKE 78 1 2 DIAGNOSTIC TOOLS How To Use Diagnostic Tools HD 39978 DIGITAL MULTIMETER FLUKE 78 1 3 DIAGNOSTICS TROUBLESHOOTING Wiggle Test HD 39978 DVOM 6 4 SYMPTOM DIAGNOSTICS Description and Opera tion HD 39978 DVOM 6 22 OXYGEN 02 SENSOR DTC P0131 P0132 P0134 P0151 P0152 P0154 P1047 Description and Operation HD 41183 HEAT SHIELD ATTACHMENT A 10 SEALED SPLICE CONNECTORS Sealed Splice Connector Repair HD 41354 SPEEDOMETER TESTER 1 2 DIAGNOSTIC TOOLS How To Use Diagnostic Tools HD 41354 1 INPUT OUTPUT CABLE 1 2 DIAGNOSTIC TOOLS How To Use Diagnostic Tools HD 41404 HARNESS TEST KIT 1 2 DIAGNOSTIC TOOLS How To Use Diagnostic Tools HD 41404 B HARNESS TEST KIT 3 3 CHARGING SYSTEM DIAGNOSTICS Testing HD 41417 PROPANE ENRICHMENT KIT 1 2 DIAGNOSTIC TOOLS How To Use Diagnostic Tools HD 41475 DEUTSCH CONNECTOR SERVICE KIT DEUTSCH ELE
242. in italic type It is recommended that you take special notice of these items Proper service and repair is important for the safe reliable operation of all mechanical products The service procedures recommended and described in this manual are effective methods for performing service operations Always wear proper eye protection when using hammers arbor or hydraulic presses gear pullers spring com pressors slide hammers and similar tools Flying parts could result in death or serious injury 00496b Some of these service operations require the use of tools specially designed for the purpose These special tools should be used when and as recommended It is important to note that some warnings against the use of specific service methods which could damage the motorcycle or render it unsafe are stated in this manual However please remember that these warnings are not all inclusive Inadequate safety precautions could result in death or serious injury Since Buell Motorcycle Company could not possibly know evaluate or advise the service trade of all possible ways in which service might be performed or of the possible hazardous consequences of each method we have not undertaken any such broad evaluation Accordingly anyone who uses a service procedure or tool which is not recommended by Buell Motor cycle Company must first thoroughly satisfy himself that neither his nor the operator s safety will be jeopard
243. ion DTC DESCRIPTION P0691 Right fan control circuit low P0692 Right fan control circuit high P0693 Left fan control circuit low P0694 Left fan control circuit high Connector Information For additional information on the connectors in the following diagram s see B 1 CONNECTORS 00277 Intake Crank Coolant Air Position Temperature Temperature Oxygen Cooling CKP ECT IAT Sensor Fan 1 Sensor Sensor Sensor Rear Right 1 2 3 79 2 1 9041 1 J 89A 1 4 137A 2 1 JV 97A 1 2 3 Y 79B 2 1 YI90B 2 1 YI898 1 Y 1378 2 1 YI97Bl ID L T x gt 2 Cooling a a gt 2 2 d T TES amp zn Left Oxygen Sensor Front Side Stand pes Y 2 11 215 L 2 1 215 amp S 1 J 138A Y 11388 2 E gt gt gt 5 2 1 3 4 234 2 1 AJ 2344 amio o gt Bo B rs gt gt 5 z gt Cooling Y BN Fan Fuse Y a gt 4 15 16 1458 4 15 16 145 o o 5 2 gt x e gt m 5 gt 5 5555 18 26 28 14 31 32 2 3 18 26 108 18 26 9 28 14 31 32 2 3 18 26
244. ion has been lost LOCKED OUT Twenty consecutive PIN entry failures have been made causing the instrument cluster to lock out for 30 minutes A countdown timer is displayed to show the number of remaining minutes until the PIN can be re entered COMM ERROR A communications error has occurred The instrument cluster failed to receive messages from the ECM To enter the diagnostic part of the ODIS system hold down the TOGGLE and MODE switches simultaneously while turning the ignition on If the security system is active the PIN will have to be entered after the ignition is turned on Once the PIN is entered the message DIAG MODE displays on the LCD Pressing the TOGGLE switch again displays the current and historic DTCs and live data for the motorcycle After the last DTC is displayed the message LIVE DATA appears Pressing the TOGGLE switch scrolls through the list of available live data For a complete list of DTCs see Initial Diagnostics and Serial Data For live data refer to Table 4 2 The TOGGLE switch changes options and the MODE switch exits the dia gnostic mode NOTE The IC automatically exits the DIAG MODE if the speedometer reads vehicle speed greater than 0 Table 4 2 Live Data Display LIVE DATA DISPLAYED UNITS Battery Voltage Volts Coolant Celsius Temperature Celsius Coolant Voltage 5 Volt reference Airtemp Celsius Temperature Celsius
245. ire YES on LGN GY Locate and repair short to ground wire 6 30 2008 Buell 1125R Engine Management Replace ECM fc01870 en CLUTCH AND NEUTRAL SWITCHES P1154 P1155 6 11 DESCRIPTION AND OPERATION See Figure 6 13 The clutch position sensor is located and attached separately on the backside of the left hand control The sensor momentary contact switch is activated by the clutch lever See Figure 6 14 The neutral switch is located on the right side of the engine case under the front pulley The switch is activ ated when the shift lever is in neutral In addition to providing an interlock function in the starting circuit activation of the Switch also illuminates the neutral N lamp on the instrument cluster DTCs P1154 and P1155 set when either the clutch switch cir cuit or neutral switch circuit is shorted to ground at speeds greater than 10 mph 16 kph for more than 60 seconds Refer to Table 6 12 for the codes and their descriptions Table 6 12 Code Description DTC DESCRIPTION P1154 P1155 Clutch position sensor circuit low Neutral switch input circuit low Figure 6 13 Clutch Position Sensor Location D Figure 6 14 Neutral Switch Location Diagnostic Tips If the DTC is historic check for intermittents Connector Information For addition
246. ire at fuel pump fuse and ground Is continuity present Locate and repair short YES to ground on O GY wire Locate and repair the open or poor connection on the BN Y wire fc01896 en VEHICLE SPEED SENSOR 55 P0502 AND P0503 DESCRIPTION AND OPERATION See Figure 6 40 The VSS is a Hall effect device mounted close to the teeth of the trigger wheel The output signal fre quency varies with vehicle speed Output voltage from the sensor is 5V per increment of distance traveled The ECM processes the vehicle speed signal and transmits it via the CAN bus to the instrument cluster to indicate vehicle speed The VSS is supplied battery voltage from the brake horn circuit O The ECM provides ground BK W and receives the speed signal on the W wire Refer to Table 6 21 Table 6 21 Code Description DTC DESCRIPTION P0502 VSS ouput low P0503 VSS output high Figure 6 40 VSS Location Diagnostic Tips If a short low open or a short high condition DTC P0608 sets reflecting a problem in the 55 IC or wiring harness Connector Information For additional information on the connectors in the following diagram s see B 1 CONNECTORS 2008 Buell 1125R Engine Management 6 71
247. is within limits Refer to Table 3 4 b A higher reading indicates excessive current draw Check accessories for excessive drain NOTE A battery with a surface discharge condition could suffer a static drain Correct by cleaning battery case Table 3 4 Milliampere Draw Test ITEM MAXIMUM DRAW IN MILLIAMPERES Regulator 1 0 ECM 1 0 Instrument Cluster 1 0 IC Connector Information For additional information on the connectors in the following diagram s see B 1 CONNECTORS 2008 Buell 1125R Starting Charging 3 17 ed01708 L 778 Y x Battery Power Distribution In Wiring Diagrams 1 Ammeter 2 Battery fuse socket 3 Voltage regulator Chassis Grounds In Wiring Diagrams uid 7 And Rear Lamps M LL X Auxiliary Fuse R Fuel Pump GND 2 Figure 3 14 Milliampere Draw Test Ignition Turned to OFF Total Current Draw Test If the battery runs down during use the current draw of the motorcycle components and accessories may exceed output of the charging system NOTE If a load tester is unavailable use an ammeter with current probe 3 18 2008 Buell 1125R Starting Charging WARNING Turn battery load tester OFF before connecting tester cables to battery terminals Connecting tester cables with load tester ON can cause a spar
248. itch is applied it generates pres sure in the brake fluid This pressure in the fluid causes the contacts for the rear stop lamp switch to close The brake horn fuse supplies power to the stop lamp switches through the O wire When the front stop lamp switch closes front brake lever pulled in power flows through the switch to the tail stop lamp through the R Y wire When the rear stop lamp switch is applied rear brake pedal pressed power flows through the switch to the tail stop lamp SYMPTOMS The lighting circuit does not set DTCs when there is a malfunc tion Instead symptoms and common causes are described in Table 5 4 Table 5 4 Lighting Symptom Table SYMPTOM COMMON CAUSE Headlamps Burned lamp open fuse open power or ground circuits poor connection at connector 38 Turn Signals Inoperative Inoperative relay inoperative switch malfunctioning IC open fuse open in turn signal circuits Tail Lamp Inoperative Burned out lamp open circuits open fuse Stop Lamp Inoperative Inoperative brake switch open fuse open wires Marker Lamps Burned out lamp open fuse open in marker lamp circuits poor connection at the headlamp connector 38 HEADLAMPS See Figure 5 10 The headlamps receive power through the lights fuse and the start relay The headlamps turn on when the ignition switch is turned on The start relay energ
249. iter assembly Limiter assembly malfunction Replace limiter assembly Limiter assembly gears damaged Replace limiter assembly Gear teeth on freewheel gear Excessively worn teeth Replace freewheel gear Sprag clutch Sprag clutch failure Replace rotor sprag clutch assembly 3 4 2008 Buell 1125R Starting Charging Table 3 3 Starter Does Not Stop Running SOURCE OF PROBLEM POSSIBLE CAUSE SOLUTION Start switch or start relay Unopened contacts Replace start switch or start relay Poor return caused by sticky switch or Replace start switch or start relay relay contacts Solenoid Coil shorted Replace solenoid Contact plate melted and stuck Replace solenoid Sprag clutch Sprag clutch seizure Replace rotor sprag clutch assembly Connector Information For additional information on the connectors in the following diagram s see B 1 CONNECTORS 2008 Buell 1125R Starting Charging 3 5 00237 10 Headlamp and Marker Lamps Battery Brake Horn 128B 128A 2 Fu
250. ive Intake Solenoid P1110 Active intake control circuit short Figure 6 52 Active Intake Solenoid and Connector Location low open P1111 Active intake control circuit short high P1112 Active intake control throttle position 2008 Buell 1125R Engine Management 6 97 00278 Start Switch Auxiliary Relay v 1 GY m 4 A ER Ignition Ignition Fuse J cvio 5 30 2 85 628 Relay Block 55 gt gt E E SE 18 1458 gt gt Data Link Connector lt ax uid m 6 gt 2 1848 gt 1 84 8 2 8 Front Front Rear Fuel Ignition Ignition Injector Coil Coil 5 m 2 x gt gt m o 1 1 1 E E E 10B 29 25 34 32 83 30 10 JAI l 29 25 34 32 31 30 10 4 10 8 8 8 8 8 8 E 5 5 5 5 9 5 b 9 To dm 5588 5 Hie E g E 8 lt Active Intake Solenoid A 1788 178 GY GY O 1 B5A Rear Fuel Figure 6 53 Injectors Coils and Active Intake 6 98 2008 Buell 1125R Engine Management P1110 P1111 and P1112 Part 1 of 2 Are the active intake system moving parts pinched stuck or binding Remove the active intake Solenoid connector 178A and inspect connection
251. ivery to the motorcycle which enhances performance and driveability Instrument Cluster IC The IC uses the CAN communication to display information to the operator and to communicate to the ECM Controller Area Network CAN connector See Figure 2 7 The CAN connector 243 is located inside the left radiator outer shroud next to the ECM This connector is mainly used for initial programming of the modules when the motorcycle is built Check that this plug is present to verify proper CAN operation The CAN connector plug should have a resistance of approximately 120 Ohms Data Link Connector DLC See Figure 2 7 The DLC is located under the left radiator shroud The DLC is used to connect the DIGITAL TECHNICIAN Il to the motorcycle COMM ERROR OR 00001 The ECM sets 00001 if it loses communication to the IC When the IC recognizes a loss of communication with the ECM it displays either a THEFT ERROR message or a COMM ERROR message depending if there was any communication during that ignition cycle or not Diagnostic Tips The IC sets a THEFT ERROR message if the fault happened when the ignition is off It sets a COMM ERROR message if the ignition is on and the IC and ECM are communicating when the fault occurs Once the ignition is cycled off and back on the COMM ERROR message clears and THEFT ERROR dis plays Connector Information For additional information on the connectors in the following diagram s see
252. ized as a result Failure to do so could result in death or serious injury PRODUCT REFERENCES WARNING Read and follow warnings and directions on all products Failure to follow warnings and directions can result in death or serious injury 00470b When reference is made in this manual specific brand name product tool or instrument an equivalent product tool or instrument may be substituted Kent Moore Products All tools mentioned in this manual with an HD J or B preface must be ordered through SPX Kent Moore For ordering FOREWORD information or product returns warranty or otherwise visit WWW Spx com Loctite Sealing and Threadlocking Products Some procedures in this manual call for the use of Loctite products If you have any questions regarding Loctite product usage or retailer wholesaler locations please contact Loctite Corp at www loctite com PRODUCT REGISTERED MARKS Allen Amp Multilock Bluetooth Brembo Delphi Deutsch Dunlop Dynojet Fluke G E Versilube Gunk Hydroseal Hylomar Kevlar Lexan Loctite Lubriplate Keps K amp N Mag naflux Marson Thread Setter Tool Kit MAXI fuse Molex MPZ Mulitilock Novus Packard Pirelli Permatex Philips PJ1 Pozidriv Robinair 5100 Sems Snap on Teflon Threadlocker Torca Torco TORX Tufoil Tyco Ultratorch Velcro X Acto and XM Satellite Radio are among the trademarks of their respective owners H D MICHIGAN INC TRA
253. izes and turns off the power to the headlamps when the start switch closes This allows full battery power to the starter without the drain of the headlamps on the system The headlamp switch turns the high beam headlamps on and off The low beam headlamps and front marker lamps are illu minated in the high or low beam setting The flash to pass switch is a momentary switch that flashes the high beam headlamps as long as the switch is pressed 5 10 2008 Buell 1125R Accessories Horn Lights and Security CALIFORNIA PROPI posts terminais and p other m 8052 Figure 5 10 Start Relay Diagnostic Tips If the lights fuse is open test for short to ground on BE wire from the fuse to the headlamp and flash to pass switches Also check for a short to ground on the W wire from the headlamp and flash to pass switches If this circuit is grounded it only opens the fuse when the headlamp switch is in the high position or the flash to pass switch is pressed If a headlamp and front marker lamp are out on the same side test the shared ground wire to that side Connector Information For additional information on the connectors in the following diagram s see B 1 CONNECTORS 2008 Buell 1125R Accessories Horn Lights and Security 5 11 00253 Ignition And Accessory Power In RIGY Wiring Diagrams El R BK E R GY lt lt
254. jon4 01 0 lt lt z Ag Sz sz 86 1 vez 55 yada 6 6 uows uoniubi 78 grg A fz z Aieneg 1 20 5 AS 2 Ye E WH AlNiz E pe eam wyje 5 gt gt lt lt ollo kana voi voi NS 18 0 888 ves RFAS O lt q esn4 NO KE yard m 1 uous 998 v98 AD Buum uonnquisig lt lt 868 ves p esn4 uey d 3g No do stb osn dung Qe wies v 5s mei Buum Jamog fuosseooy puy y wuia 8 gt gt 221 221 205095 103 eum 12009 2 208095 EN Josueg ZO SSA JOSU8S peeds Josues ainssald oujeuiojeg 108095 91158914 einisqy sya 105 ojBuy yueg 108095 0011504 108095 91 108095 e4m 11y exei Josues eunssajg Figure 6 1 Simplified DDFI 3 Signal Flow Diagram 6 2 2008 Buell 1125R Engine Management ELECTRONIC CONTROL MODULE 6 2 ELECTRONIC CONTROL MODULE See Figure 6 2 The ECM receives and processes signals from the sensors and applies outp
255. k and battery explosion which could result in death or serious injury 00252a 1 See Figure 3 15 to check for this condition and place load tester induction pickup or current probe pickup over battery negative cable 5 Disconnect the stator plug from the voltage regulator Start the motorcycle and run the engine at 2000 RPM With the ignition and all continuously running lights and accessories turned on headlamp on high beam read the total current draw Compare this reading to the reading obtained after per forming a Current and Voltage Output Test a The current output should exceed current draw by a minimum of 3 5 amps b If output does not meet specifications there be too many accessories for the charging system to handle Reconnect voltage regulator after testing ed02802 5 1 1 Load tester 2 Induction pickup 3 Battery Figure 3 15 Check Current Draw Ignition Switch On Current and Voltage Output Test Using HD 48053 1 Connect the ADVANCED BATTERY CONDUCTANCE AND ELECTRICAL SYSTEM ANALYZER Part No HD 48053 leads to the vehicle battery Perform a charging system test following the instructions in the analyzer instruction manual See Figure 3 16 for an example of the analyzer s printout The test results include a decision on the charging system
256. k position sensor circuit Repair the circuit If DTC P0339 is present diagnose and correct DTC Manifold leak Perform intake leak test Ignition coil circuit Repair the circuit If DTCs P2300 P2301 P2303 or P2304 are present diagnose and correct DTCs Leaky injectors Check for mechanical failures of the fuel injectors If DTC P0117 or P0118 is present diagnose and correct them Valve sticking Perform compression test Table 6 2 Engine Performance Problems CAUSE SOLUTION Engine coolant temperature circuit Repair the circuit If DTC P0117 or P0118 is present diagnose and correct DTCs Crank position sensor circuit Repair the circuit If DTC P0339 is present diagnose and correct DTC Fuel or Ignition system fault Perform misfire diagnostics Improper fuel pressure Perform fuel pressure test If DTCs P0192 P0193 or P0087 are present diagnose and correct DTCs Manifold Leak Note If manifold leak is large enough the IAC closes and DTC P0506 sets Perform intake leak test Throttle plates not opening fully Perform Throttle Cable Adjustment See the service manual 2008 Buell 1125R Engine Management 6 7 Table 6 2 Engine Performance Problems CAUSE SOLUTION EVAP hose disconnected from induction module California models only Connect Fuel system contaminated Drain and refill with fresh fuel
257. ke tract 1 10 2008 Buell 1125R General Information 5 6 Push valve to release propane Tone of engine changes when propane enters source of leak Note which components fail the intake leak test for further servicing Figure 1 26 Checking for Leaks DIAGNOSTICS TROUBLESHOOTING 1 3 VOLTAGE DROP The amount of voltage dropped over any part of a circuit is directly related to the amount of resistance in that part of the circuit 00268 120 1 Entire circuit voltage drop through the starter 2 Circuit voltage drop through the solenoid 3 Circuit voltage drop through the relay Figure 1 27 Simplified Starter Circuit Voltage Drop Test The Voltage Drop test Helps locate poor connections or components with excessive voltage drops Measures the difference in potential or the actual voltage dropped between the source and destination Checks the integrity of the wiring switches fuses con nectors and contacts between the source and destination See Figure 1 27 for a simplified circuit diagram of how voltage drops can vary in a circuit The voltages represent what might be seen if the meter
258. l back to the ECM The signal varies with engine vacuum more vacuum lower signal output and atmospheric barometric pressure Barometric pressure is influenced by weather and altitude Table 6 26 Code Description DTC DESCRIPTION P0107 MAP sensor low open P0108 MAP sensor high Diagnostic Tips Codes set if the MAP sensor is out of range P0108 can only be set when the engine is running The MAP sensor uses the same power circuit as the fuel pressure barometric side stand and throttle position sensors Therefore if the 5 V power circuit is open or shorted to ground other codes set Refer to Table 6 26 for DTCs applicable to the MAP sensor NOTE Do not over pump vacuum pump when performing the MAP sensor output check Sensor damage could result 6 90 2008 Buell 1125R Engine Management Use a VACUUM PUMP Part No HD 23738 to apply a vacuum to the pressure port of the sensor The signal voltage should drop as vacuum is increased Figure 6 48 MAP Sensor Location Connector Information For additional information on the connectors in the following diagram s see B 1 CONNECTORS 00274 Vehicle Bank Throttle Absolute Barometric Speed Angle Position Pressure Fuel BARO Side Sensor Sensor TP MAP Pressure Pressure Stand VSS
259. lock terminal 4 and chassis ground Is continuity present Is there an obstruction preventing the right cooling fan from rotating Repair short to ground in Y BN wire Disconnect connector 97 Measure resistance between terminal 1 and terminal 2 of connector 97 Is resistance greater than 1 Ohm Remove obstruction Reinstall fan fuse Using connector kit HD 41404 and jumper wire connect Y BN terminal to battery positive Connect BK O terminal to ground Does right fan run Replace right fan System operating normally Replace right fan fc01911 2008 Buell 1125R Engine Management 6 87 DTCs P0693 and 0694 Part 1 of 2 Does left fan run continuously Disconnect connector 10 Black at EOM Turn ignition switch ON Does left fan run Repair short to ground in Y O wire between ECM and left fan z Go to DTCs P0693 and P0694 Part 2 of 2 Is engine hot NOTE Fan operates when cylinder head temperature exceeds 170 F 77 Allow engine to cool z o Turn ignition switch OFF Connect Breakout Box Part No B 48115 to ECM connector 11 Gray Turn ignition switch ON Measure voltage at Breakout Box connector 11 Gray terminal 9 Is voltage greater than 1
260. lowcharts and test procedures in this chapter The Buell DDFI System provides microprocessor based elec tronic engine management for the 1125cc high performance engine The DDFI system has the following features Independently mapped spark and fuel control Compensated fuel delivery through coolant temperature intake air temperature barometric and manifold air pres sure Engine load measurement via throttle position sensing Single point spark delivery Separate ignition coils for each cylinder Sequential port indirect manifold fuel injection Open closed loop air fuel control Automatic enrichment at start up Two electric cooling fans for improved thermal manage ment Engine speed and position determined by using a single CKP sensor Engine idle speed electronically managed with an IAC system Returnless fuel system The DDFI System performance is monitored by an ECM using sensors and switches to regulate engine operation The ECM makes decisions for enabling ignition starting spark and fuel delivery Sensors include e Crank Position Throttle Position TP Side stand HDI only Bank Angle Sensor BAS e Clutch switch Neutral switch Fuel Pressure Sensor FPS Engine Coolant Temperature ECT ntake Air Temperature IAT Barometric Pressure BARO e Vehicle Speed Sensor VSS Oxygen 02 Manifold Absolute Pressure MAP
261. luster or not before the cluster matches to the ECM Once the VIN is written to the IC it cannot be cleared If the check engine lamp is always on with the ignition on and no DTCs are present Replace the IC If the check engine lamp is still on install original IC and replace the ECM ed01696 rpm x1000 1 Low fuel lamp 2 Check engine lamp 3 Engine over temperature lamp 4 Oil pressure lamp 5 Low battery voltage lamp Figure 2 2 Warning Lamps ed01712 6 ON lt 4 Sec Lamp OFF No Current or Historic DTCs OFF gt Lamp 8 Seconds m ON Only Historic DTCs Exist ZN B 4 5 gt 8 Sec Lamp OFF OFF lt 4 5 p Key On gt Lamp Remains ON Current DTC ON 4Sec gt 6 OFF 45 gt Key On Historic May Also Exist Figure 2 3 Check Engine Lamp Operation SYMPTOMS is not a normal characteristic of the system Refer to Table 2 2 for a list of symptoms If no are present but there is a symptom or concern indicating a malfunction address and repair the symptom if it 2008 Buell 1125R Initial Diagnostics and Serial Data 2 5 Table 2 2 Symptom Table SYMPTOM DIAGNOSTIC PROCEDURE Auxiliary power inoperative 5 1 ACCESSORIES Charging system inoperative CHARGING SYSTEM DIAGNOSTICS COMM ERROR displayed 2 2 SERIAL DATA C
262. lves of the connector Mating Pin and Socket Housings Align the wire colors and push the pin and socket halves of the connector together Removing Socket Terminal 1 SeeFigure A 19 for pull to seat connector or Figure A 20 for push to seat connector Remove wire lock 1 from wire end of socket housing on push to seat type connectors NOTE For best results free one side of wire lock first and then release the other side 2 Find the locking tang in the mating end of the connector NOTE The tangs are always positioned in the middle of the chamber and are on the same side as the external latch 3 Gently insert a safety pin into the chamber about 1 8 in 8 2 mm a For pull to seat Stay between the terminal and the chamber wall and pivot the end of the pin toward the terminal b For push to seat There is a small opening for the pin 4 When a click is heard remove the pin and repeat the procedure NOTE The click is the sound of the tang returning to the locked posi lion as it slips from the point of the pin 5 Pickatthe tang until the clicking stops and the pin seems to slide in deeper than it had previously This is an indica tion that the tang has been depressed NOTE On those terminals that have been extracted on multiple occasions the click may not be heard but pivot the pin as if the click was heard at least 3 times 6 Remove the pin a For pull to seat Push on the lead to extract the ter
263. minal 1 to terminal 2 178B Is resistance less than 4 0 Ohms Use Harness Test Kit Part No HD 41404 See 1 2 DIAGNOSTIC YES Connect battery voltage to 178B terminal 2 of active intake solenoid Hold throttle wide open Observe throttle plate and connect active intake solenoid terminal 1 to ground Does the active air intake solenoid attempt to pull throttle almost closed NOTE Use Harness Test Kit Part No HD 41404 See 1 2 DIAGNOSTIC TOOLS Replace active intake solenoid YES Energize active intake solenoid Does throttle close to an angle Hold throttle wide open less than 11 degrees z Replace active intake solenoid Replace ECM 6 100 2008 Buell 1125R Engine Management See Cable Adjustment in service manual fc01909 en ENGINE CRANKS BUT WILL START 6 28 DESCRIPTION AND OPERATION PART NUMBER HD 26792 TOOL NAME SPARK TESTER If the starter will not crank engine the problem is not ignition related See 3 1 STARTING SYSTEM DIAGNOSTICS Diagnostic Tips There may be trouble codes associated with this problem Check for DTCs and clear them before proceeding to Spark and Fuel Injector tests Spark Plug Cleaning If the engine is run repeatedly for short periods of time the spark plugs can become fouled The ECM monitors rec
264. mped terminal gt ON Inspecting Crimped Terminals See Figure A 7 Inspect the wire core crimp 2 and insulation sm00008 crimp 1 Distortion should be minimal 1 Insulation crimp Figure A 6 AMP Multilock Connector Terminal Crimping Procedure 4 2008 Buell 1125R Appendix A Connector Repair 2 Wire core crimp Figure A 7 AMP Multilock Connector Terminal Crimp DELPHI CONNECTORS A 2 DELPHI CONNECTOR REPAIR General Delphi connectors are embossed with the brand name Delphi on the housing latch Separating Pin and Socket Housings See Figure A 8 Bend back the external latch es slightly and separate pin and socket halves of connector Mating Pin and Socket Housings Push pin and socket halves of connector together until external latch es engage Removing Socket Terminals NOTE Although the parts of the different Delphi connectors vary in appearance the instructions which follow will work for all The only exception is the oil pressure sender connector 139B the terminals of which are removed like the Packard push to seat connectors Therefore see 6 150 METRI PACK CON NECTORS to remove install terminals in this connector 1 See Figure A 9 If present free one side of wire lock 1 from ear on wire end of socket housing then release the other side Release wires from channels in wire lock and remove from socket housing
265. mptoms Low pressure or pressure too low Is DTC P0087 Set No pressure High pressure Go to DTCs P0192 P0193 and P0087 Part 2 of 3 Go to DTCs P0192 P0193 and P0087 Part 3 of 3 NO Check for restricted fuel pump inlet screen Is screen restricted Flush out fuel tank and fuel lines Refill fuel tank with fresh fuel and retest Did DTC P0087 reset Check voltage at fuel pump connector 86A terminal B O GY to ground Is battery voltage present Measure voltage drop between battery positive terminal B of connector 86A to locate source of voltage drop See 1 3 DIAGNOSTICS TROUBLESHOOTING YES Check for restrictions in the fuel line and fuel rail or for clogged fuel injectors Any restrictions found Replace fuel pressure sensor Replace fuel pump Flush out fuel lines fuel rail and fuel injectors System operating normally Replace fuel pump 1 01893 2008 Buell 1125R Engine Management 6 65 DTCs P0192 P0193 0087 Part 2 of 3 Continued from DTCs P0192 P0193 and P0087 Part 1 of 3 Check for battery voltage at terminal B O GY on fuel pump connector 86A Is battery voltage present YES Attach Breakout Box B 48115 to ECM Measure voltage between Breakout Box 10 Black terminals 2
266. n coil or loss of power to the ignition coil When multiple codes set the cause may be an ignition coil failure See Figure 6 17 and Figure 6 18 The ignition coils receive power on terminal 3 GY wire when the ignition relay ener gizes Refer to Table 6 13 for possible DTCs and their descriptions Table 6 13 Code Description DTC DESCRIPTION P2300 Front ignition coil control circuit low P2301 Front ignition coil control circuit high P2303 Rear ignition coil control circuit low P2304 Rear ignition coil control circuit high ed01742 Figure 6 16 Ignition Coil ed01743 m Figure 6 18 Ignition Coil Location Rear Diagnostic Tips Figure 6 19 Cranking the engine with a test lamp in place of the ignition coil may cause DTOs to set This 2008 Buell 1125R Engine Management 6 35 condition is normal and does not by itself indicate a mal function Clear the codes if this condition occurs Toisolate the wire harness during testing disconnect the ignition coil and install the BREAKOUT BOX Part No B 48115 to the harness leaving the ECM disconnected Use gray pin probes when checking ignition coil con nectors ed01779 Figure 6 19 Ignition Coil Circuit Test 6 36 2008 Buell 1125R Engine Management ed01546 B 48115 KENT MOORE Figure 6 20 ECM Driver Test Connector Information For
267. n to the limiter assembly Thelimiter assembly gear transfers rotation to the starter ring gear The starter ring gear drives the alternator rotor on the end of the crankshaft When the engine starts a sprag clutch on the backside of the alternator rotor disengages the starter ring gear and the rotor disengages allowing the starter ring gear and the rotor to rotate independently of each other Figure 3 1 Starter Terminal Starter Solenoid See Figure 3 2 The starter solenoid is located under the seat and is a switch to open and close the high current circuit to the electric starter motor ed01775 1 Solenoid stud to battery 2 Solenoid stud to starter 3 Starter solenoid connector 128 Figure 3 2 Starter Solenoid Terminals typical Engine Stop Switch RH Controls The engine stop switch is located on the RH controls When the engine stop switch is in the RUN position voltage is sup plied to the coil side of the ignition relay Start Switch RH Controls The start switch is a pushbutton switch located in the RH con trols When the start switch is pressed voltage is supplied to the coil of the ignition relay Key Relay See Figure 3 3 The key relay is located in the relay box under the seat When the ignition switch is turned on power is sup plied to the key relay The key relay energizes and provides power to the lights fuse 2008 Buell 1125R Starting Charging 3
268. nals 1 and 2 of connector 243B Is continuity present NOTE Use Harness Test Kit Part No HD 41404 See 1 2 DIAGNOSTIC TOOLS Is the resistance greater then 150 Ohms Disconnect the IC Test for continuity between terminal 1 of connector 243B and terminal 9 of connector 39B Is continuity present Disconnect the IC Test terminals 1 and 2 of connector 243B for a short to ground Is a short to ground present CAN lines are shorted together Locate and repair the short Replace the instrument cluster Test for continuity between terminal 2 Locate and Locate and repair Test terminals 1 and 2 of of connector 243B and terminal 10 of oen short to ground in connector 243B for a short connector 39B AA PK V or PK GY to voltage Is continuity present in PK V wire wire Is a short to voltage present YES NO Replace and program the Locate and Locate and repair short repair open in PK GY wire Replace the instrument cluster to voltage In PRIV PK GY wire ECM fc01791 en 2 14 2008 Buell 1125R Initial Diagnostics and Serial Data TABLE OF CONTENTS SUBJECT PAGE NO 3 2 TESTING STARTER ON MOTORCYCLE 3 3 CHARGING SYSTEM DIAGNOSTICS 3 4 BATTERY TESTING 5
269. ncy varies with vehicle speed Output voltage from the sensor is 5V per increment of distance traveled The ECM processes the vehicle speed signal and transmits it via the CAN bus to the instrument cluster to indicate vehicle speed O2 Sensor Front and Rear The O2 sensor detects unburned oxygen in the engine exhaust The output of the sensor is a voltage having a range of about 0 1 0 Volt The normal output is 0 5 Volts which represents a balance between a lean not enough fuel and rich too much fuel air fuel mixture An output less than 0 5 Volts represents alean mixture greater than 0 5 Volts represents a rich mixture The change in output level signals the ECM to modify the air fuel ratio It is important to note the O2 sensor does not operate efficiently until it is at vehicle operating temperature Therefore before any troubleshooting takes place bring the sensor to operating temperature Leaks in the exhaust system leaky exhaust valves misfires or any engine problem allowing unburned oxygen into the exhaust stream could create DTC indicating a bad sensor Look for problems related to an improper air fuel mixture before replacing the sensor Manifold Absolute Pressure MAP Sensor The MAP sensor is supplied 5 Volts from the ECM and sends a signal back to ECM This signal varies in accordance with engine vacuum and atmospheric barometric pressure The MAP sensor monitors the intake manifold pressure vacuum and sends t
270. nd repair open or poor connection on the O wire Replace ECM Locate and repair open or poor connection on the BK W wire 1001900 en 2008 Buell 1125R Engine Management 6 73 OXYGEN O2 SENSOR P0131 P0132 P0134 P0151 P0152 P0154 P1047 6 22 DESCRIPTION AND OPERATION PART NUMBER HD 39978 TOOL NAME DVOM See Figure 6 42 and Figure 6 43 for front and rear O2 sensor location The O2 sensor provides a signal to the ECM to indicate whether the engine is running rich or lean Alow voltage signal less than 0 41 V indicates the engine is running lean high voltage signal greater than 0 56 V indicates the engine is running rich When the air fuel mixture is ideal approximately 14 7 parts air to 1 part fuel the voltage is approximately 0 48 V Refer to Table 6 22 for possible DTCs associated with these sensors NOTE DTC P1047 could be caused by a mechanical concern and may cause O2 sensor codes to set Table 6 22 Code Description 6 74 2008 Buell 1125R Engine Management DTC DESCRIPTION P0131 Front oxygen sensor circuit low engine lean Figure 6 42 Front O2 Sensor Location P0132 Front oxygen sensor circuit high engine rich P0134 Front oxygen sensor open inactive P0151 Rear oxygen sensor circuit low engine lean 01739 0152 Rear oxygen sensor circuit high engine rich P0154
271. ne before testing fuel injector operation See the service manual Use BREAKOUT BOX Part No B 48115 as shown in Figure 6 24 but place jumpers in terminals 32 high and 33 low or 34 high and 33 low for the rear and front injectors respectively Connector Information For additional information on the connectors in the following diagram s see B 1 CONNECTORS 2008 Buell 1125R Engine Management 6 41 00278 Start Switch Auxiliary Relay v 1 GY m 4 A ER Ignition Ignition Fuse J cvio 5 30 2 85 628 Relay Block 55 gt gt E E SE 18 1458 gt gt Data Link Connector lt ax uid m 6 gt 2 1848 gt 1 84 8 2 8 Front Front Rear Fuel Ignition Ignition Injector Coil Coil 5 m 2 x gt gt m o 1 1 1 E E E 10B 29 25 34 32 83 30 10 JAI l 29 25 34 32 31 30 10 4 10 8 8 8 8 8 8 E 5 5 5 5 9 5 b 9 To dm 5588 5 Hie E g E 8 lt Active Intake Solenoid A 1788 178 GY GY O 1 B5A Rear Fuel Figure 6 25 Injectors Coils and Active Intake 6 42 2008 Buell 1125R Engine Management DTCs P0261 P0262 P0264 and P0265 1 of 2
272. nection or ignition coil Repair wiring as necessary If wiring is okay replace ignition coil Locate and repair open or connection from terminal 2 of connector 83FB to ground BK wire 6 38 2008 Buell 1125R Engine Management Install breakout box between harness and ECM Insert test lamp adapter into terminals 9 and 25 of the black side of the breakout box Next insert test lamp adapter into terminals 9 and 34 of the black side of the breakout box See Figure 6 20 Does test lamp flash when engine is cranked Check for voltage at terminal 3 of 83FB Is battery voltage present Replace Disconnect from breakout box Measure resistance between terminal 1 of connector 83FB to terminals 25 and 34 of breakout box Black Is resistance less than 0 5 Ohms Locate and repair open or poor connection between terminal 3 of connector B3FB and terminal 87 of ignition relay GY wire Locate and repair open or poor connection between terminal 1 of connector 83FB and terminals 25 and 34 of connector 10B Perform wiggle test See 1 3 DIAGNOSTICS TROUBLESHOOTING Any Intermittents found Repair as necessary Replace 1201868_ DTCs P2303 and P2304 Rear Ignition Coil Install test lamp into terminals 1 and 3 of connector B3RB Use Harness Connector Test Kit
273. nectors are identified by a number in brackets Repair Instructions The repair instructions in Appendix A are by connector type Refer to Table B 1 Table B 1 2008 1125R Connector Locations NO DESCRIPTION TYPE LOCATION 10 Electronic Control Module ECM black 34 place Amp Tyco Inside left radiator shroud 11 Electronic Control Module ECM gray 34 Amp Tyco Inside left radiator shroud 18 Right rear turn signal 2 1 place bullet Under tail section 19 Left rear turn signal 2 1 place bullet Under tail section 22 Right hand controls 4 place Amp Tyco Behind fairing 24 Left hand controls 8 place Amp Tyco Behind fairing 318 Right front turn signal 2 1 place bullet Behind fairing 311 Left front turn signal 2 1 place bullet Behind fairing 33 Ignition switch 4 place Amp Tyco Behind fairing 38 Headlamp connector 6 place Deutsch Behind fairing 39 Instrument cluster 20 place Amp Tyco Behind fairing 45 License plate lamp 2 1 place bullet Under tail section 46 Stator 4 place Deutsch Under seat 61 Fuse block Socket terminals Under seat 62 Relay block Spade terminals Under seat 65 Vehicle Speed Sensor VSS 3 place Deutsch Under seat 77 Voltage regulator 2 place Dekko Under seat 79 Crankshaft Position CKP sensor 2 place Amp Tyco Below left radiator shroud 80 Manifold Absolu
274. ng normally fc01923 en 2008 Buell 1125R Engine Management 6 107 MISFIRE AT IDLE OR UNDER LOAD 6 30 DESCRIPTION AND OPERATION PART NUMBER HD 26792 TOOL NAME SPARK TESTER Misfire conditions may be caused by Battery condition and connections Fuel system problems Refer to tables in 2 1 INITIAL DIAGNOSTICS Ignition system faults Diagnostic Tips If the engine is run repeatedly for short periods of time the spark plugs can become fouled The ECM monitors recent run events and enables Spark Plug Cleaning if two out of the last four run events did not bring the engine to operating temper ature When the ECM enters Spark Plug Cleaning mode it alternately rapid fires the spark plugs when the ignition switch is turned ON This mode can also be manually enabled by holding the throttle wide open and turning the ignition to ON WARNING Wipe up spilled fuel and dispose of rags in a suitable manner An open spark around gasoline could cause a fire or explosion resulting in death or serious injury 00518b Spark Test See Figure 6 58 Use SPARK TESTER Part No HD 26792 to verify adequate spark Perform the following pretest 1 Turn ignition switch OFF 2 Remove rear ignition coil and spark plug Visually check plug condition Check the spark plug and ignition coil for carbon tracking If evident replace spark plug s or ignition coil as required 3 Attach
275. njector Circuit 6 13 FUEL INJECTORS DTC P0261 P0262 P0264 P0265 Low P0265 36 Rear Fuel Injector Circuit 6 13 FUEL INJECTORS DTC P0261 P0262 P0264 P0265 High P0337 7 Crank Position Sensor 6 7 CRANK POSITION SENSOR DTC P0337 P0338 P0339 Circuit Low P0338 8 Crank Position Sensor 6 7 CRANK POSITION SENSOR P0337 P0338 P0339 Circuit High P0339 9 Crank Position Sensor 6 7 CRANK POSITION CKP SENSOR P0337 P0338 P0339 Circuit Intermittent P0502 40 Vehicle Speed Sensor 6 21 VEHICLE SPEED SENSOR VSS P0502 AND P0503 Low P0503 41 Vehicle Speed Sensor 6 21 VEHICLE SPEED SENSOR VSS P0502 AND P0503 Intermittent Erratic High P0506 54 Idle Air Control System 6 23 IDLE AIR CONTROL IAC P0506 P0507 P0511 RPM Higher Than Expected 2 2 2008 Buell 1125R Initial Diagnostics and Serial Data Table 2 1 Diagnostic Trouble Codes DTC Priority Table DTC PRIORITY FAULT CONDITION DIAGNOSTIC PROCEDURE ORDER P0507 55 Idle Air Control System 6 23 IDLE AIR CONTROL IAC P0506 P0507 P0511 RPM Lower Than Expected P0511 53 Idle Air Control Circuit 6 23 IDLE AIR CONTROL IAC DTC P0506 P0507 P0511 Fault P0562 39 Battery Voltage Low 6 26 BATTERY VOLTAGE DTC P0562 P0563 P
276. nnector 10 Black leave ECM disconnected With ignition Switch ON check for voltage at Breakout Box terminals 2 and 3 Is battery voltage present Continued from DTCs P0691 and P0692 Part 1 of 2 Check fan fuse 10 Amp Connect jumper wire between ground and the following Breakout Box connector 10 Black terminals 2 and 3 Does the right fan run With ignition switch ON check for battery voltage at 97B terminal 1 right fan connector Is battery voltage present Check for continuity between Breakout Box connector 10 Black terminals 2 and 3 and Terminal 2 of 97B Is continuity present Replace ECM Locate and repair open in circuit between right fan connector 97B Y BN wire and fuse block Check for continuity between terminals 1 and 2 of 97A Is continuity present Locate and repair open in circuit between ECM connector 10 Black and BK O wire of right fan connector 978 Disconnect right fan harness at the fan Place a jumper wire between terminal 1 and 2 of 97A and battery positive 4 Place a jumper between terminal 2 of 97A and ground Does the right fan run at full speed Replace right fan System operating normally Replace right fan Disconnect fan connector 97 Remove fan fuse Check for continuity to ground between fuse b
277. nt Disconnect fan connector 215 Remove fan fuse Check for continuity to ground between fuse block terminal 4 and chassis ground Is continuity present Is there an obstruction preventing the left fan from rotating Locate and repair short to ground in Y BN wire Disconnect connector 215 Measure resistance between terminal 1 and terminal 2 of connector 215A Is resistance greater than 1 Ohm Remove obstruction Reinstall fan fuse Using Harness Connector kit HD 41404 and jumper wire connect Y BN terminal to battery positive Connect Y O terminal to ground Does left fan run Replace left fan YES Disconnect left fan harness at the fan Place a jumper wire between terminal 1 of 215A and battery positive 4 Place a jumper between terminal 2 of 215A and ground Does the left fan run at full speed System operating normally Replace left fan System operating normally Replace left fan fc01913_en 2008 Buell 1125R Engine Management 6 89 MANIFOLD ABSOLUTE PRESSURE SENSOR DTC P0107 P0108 6 25 DESCRIPTION AND OPERATION PART NUMBER HD 23738 TOOL NAME VACUUM PUMP See Figure 6 48 The MAP sensor is supplied 5 Volts from the ECM and sends a signa
278. nt A given number of steps are then calculated by the ECM for use in setting the proper idle speed and IAC position Table 6 23 Code Description DTC DESCRIPTION P0506 Idle Air Control system RPM higher than expected P0507 Idle Air Control system RPM lower than expected P0511 Idle Air Control circuit fault Figure 6 45 IAC Motor Location Diagnostic Tips When the ignition is keyed ON the IAC motor pintle extends and then retracts to a fixed position for increased airflow and idle speed during the engine start sequence This ON reset procedure takes 2 seconds to perform Test lamp behavior may follow two patterns The color of the lights is not relevant to IAC motor operation Normal behavior At ignition switch ON test lights altern ately flash to confirm ECM signals Problem indicated One or more lights fail to illuminate during ignition switch ON OFF cycle Engine idle speed can be adversely affected by the following Aloss of idle speed control does not necessarily imply the 1 motor or wiring has failed It can be caused by a number of conditions such as an intake air leak improperly adjusted throttle stop factory set or a misfiring cylinder Leaking injectors cause fuel imbalance and poor idle quality due to different air fuel ratios in each cylinder To check for leaky injectors first remove the air cleaner Refer to Air Cleaner in the appropriate Buell
279. ntinuity Locate arid between IAC wires repair short with harness isolated to ground 15 continuity present Repair shorted IAC Inspect connections wires Are connections Repair ECM connections Replace EOM fc01904 en 2008 Buell 1125R Engine Management 6 83 RIGHT AND LEFT CONTROL P0691 P0692 P0693 P0694 6 24 DESCRIPTION AND OPERATION Cooling Fan An ECT sensor signal indicating the engine coolant temper ature is above a preset temperature causes the ECM to com mand the fans on The cooling fans run continuously once the engine operating temperature is reached The cooling fans are provided battery voltage from the Y BN wire The ECM con trols the fan by providing ground When the ignition is off the fans may run for approximately two and a half minutes depending on the temperature of vehicle when ignition was turned OFF Refer to Table 6 24 Table 6 24 Cooling Fan Specifications KEY FAN ON FAN OFF ON 170 F 77 C 160 F 71 C OFF 189 F 87 C 169 F 76 C 6 84 2008 Buell 1125R Engine Management DTCs occur when the ECM detects an open or short in the fan driver circuits can also set if the ECM detects high cur rent when the fans are turned on This can be caused by blocked fan blades or a fan motor issue Refer to Table 6 25 for possible DTCs Table 6 25 Code Descript
280. ntrol circuit low P0629 Fuel pump control circuit high ed01741 Figure 6 37 Fuel Pump Location 6 68 2008 Buell 1125R Engine Management ed01781 1 Sealing O rings 2 Wiring harness 3 Low fuel level sensor Figure 6 38 Fuel Pump Assembly Connector Information For additional information on the connectors in the following diagram s see B 1 CONNECTORS 00275 Idle Air Neutral Clutch Control Fuel Switch Switch IAC Pump 1 131A 1 3 95A 1 2 4 Ay 87A ABCD A 86B 1 Y 131B 1 Y 95B 1 2 4 87B B D 86A i gt 2 Oo oS gt gt 2 5 m 2552 62 gt m o m m Chassis Instrument ed GND 2 Bie YR gt Cluster assis Bk gt GND 1 gt o gt z T en 2 rr 1458 Fuse 7 0 1 1458 Ciz 145 7 RANSA gt 5 gt 9 o gt gt 2 2 2 2 m e a E E a 2 23 20 21 22 27 28 8 2 23 20 21 22 27 28 5 5 TEE 5 5 BK 8 E 85888 8 8 6 amp 5555 5 5 8888 E Ex XE 2 0070 ECM Figure 6 39 Neutral and Clutch Switches IAC and Fuel Pump 2008 Buell 1125R Engine Management 6 69
281. o HD 39978 RELAY DIAGNOSTICS Relay Variation See Figure 1 29 Relays used on this vehicle have five ter minals Schematically the relays are very similar with the exception being normally closed contact being eliminated in the four terminal relay Some relays have five terminals at the base even though internally 4 or 87A are not connected See this topic whenever a relay terminal is referenced in this manual to make sure the proper terminal is being accessed ed01769 5187 5 87 4 3 30 je 3 30 D 2 85 2 85 1 Standard 5 terminal relay 2 Standard 4 terminal relay Figure 1 29 Standard Relays 1 12 2008 Buell 1125R General Information Relay Test 5 Pin A relay can be tested using the motorcycle s 12 volt battery and a multimeter 1 Unplug the relay from relay block 2 See Figure 1 30 to energize the relay Connect relay ter minal 85 to the negative battery terminal and relay terminal 86 to the positive battery terminal NOTE Some relays contain internal diodes If the applied voltage is not the correct polarity the diode could be damaged 3 Check for continuity between terminals 30 and 87 good relay shows continuity continuity tester lamp on or a zero ohm reading on the ohmmeter A malfunctioning relay will not show continuity and must be replaced ed01446 2 BL A
282. onnector is crimped twice one side and then the other 1 See Figure A 24 Open the PACKARD CRIMPING TOOL Part No HD 38125 8 ratchet by squeezing the handles closed 2 Match the connector color to the wire gauge crimp die in the jaws and insert one end of the sealed connector 3 Gently squeeze the handles until the connector is held in the jaws 4 SeeFigure A 25 Feed the stripped end of a wire into the connector until the wire stops inside the metal insert 1 A 20 2008 Buell 1125R Appendix A Connector Repair 5 Squeeze the handles tightly closed to crimp the lead in the insert 2 The tool automatically opens when the crimping is complete 6 Slide the connector to the other half of the metal insert Insert the stripped wire lead 1 until it stops and crimp the lead in the insert 2 WARNING Be sure to follow manufacturer s instructions when using the UltraTorch UT 100 or any other radiant heating device Failure to follow manufacturer s instructions can cause a fire which could result in death or serious injury 00335a Avoid directing heat toward any fuel system component Extreme heat can cause fuel ignition explosion resulting in death or serious injury Avoid directing heat toward any electrical system com ponent other than the connectors on which heat shrink work is being performed Always keep hands away from tool tip area and heat shrink attachment 7 Use ULTRA TORCH UT 100 Pa
283. or 95 Measure continuity between Breakout Box terminal 2 Gray and ground Is continuity present Replace EOM Locate and repair short to ground on TN LGN wire in main wiring harness between 11B and 95B Replace clutch switch 1 01872 2008 Buell 1125R Engine Management 6 33 1155 With the ignition switch OFF and the transmission in 1st or 2nd gear connect Breakout Box Part No B 48115 to the main harness leaving the ECM disconnected Measure the resistance between Breakout Box terminal 8 Gray and ground Is the resistance less than 10 Ohms Disconnect neutral switch 131 Measure resistance between Breakout Box terminal 8 Gray and ground Is resistance less than 10 Ohms Locate and repair short to ground on TN Y wire in main wiring harness 6 34 2008 Buell 1125R Engine Management 36 Switch ace 1001873 en IGNITION COILS DTC P2300 P2301 P2303 2304 6 12 DESCRIPTION AND OPERATION PART NUMBER B 48115 TOOL NAME BREAKOUT BOX See Figure 6 16 There is no traditional spark plug wire when using this coil because the shaft connects directly to the spark plug itself A combination of codes set if the ignition coil rise time is out of range This could occur if there is an open ignitio
284. or repair or replace wire s Start switch clutch switch engine stop switch or neutral switch Poor switch contacts or open switch Replace switch contact Start relay Open coil winding Replace relay Poor or no continuity at relay points Replace relay has disabled start relay Disarm security system Solenoid Poor contact condition caused by burned Replace solenoid assembly Windings open or short circuited Replace solenoid assembly Starter motor Brushes worn below specification Replace starter Commutator burnt Replace starter Commutator high mica Replace starter Field winding grounded Replace starter Armature winding grounded or short cir cuited Replace starter Free running current draw out of range Replace starter Insufficient brush spring tension Replace starter Limiter assembly Limiter assembly failure Replace limiter assembly Sprag clutch Sprag clutch failure Replace rotor sprag clutch assembly Table 3 2 Engine Cannot Be Cranked SOURCE OF PROBLEM POSSIBLE CAUSE SOLUTION Battery Voltage drop due to discharged battery Charge battery Short circuited or open between elec trodes Replace battery Poor contact condition of battery ter minal s Clean and retighten Starter motor Starter gear teeth worn out Replace starter Lim
285. ound Is battery voltage present YES NO Locate and Replace the left Test for continuity Locate and repair the Locate and repair the repair the repair the switchgear between connector open in the BK ground open in the W wire open in the open in the 24B terminals 3 and circuit of the inoperative terminal A of the BK wire W wire 5122 2 with the headlamp headlamp inoperative headlamp 5038 5194 Switch in the high 5038 5194 position Is continuity present Turn ignition on Test for battery voltage on terminal 2 of Replace the left connector 24A switchgear Is battery voltage present 5122 Locate and repair open in Locate and repair open in W wire from connector BE wire from connector 24B terminal 3 24B terminal 2 5194 5194 fc01880 en 5 14 2008 Buell 1125R Accessories Horn Lights and Security TURN SIGNALS See Figure 5 12 and Figure 5 13 The turn signals are con trolled by the IC When the turn signal switch is pushed to the left or right voltage is sent to the IC on either the right input or the left input The IC then sends voltage to the corresponding turn signal and controls the flash rate of the turn signals Left rear turn signal 19 GND Right rear turn signal 18 Power License plate lamp 45 Power Tail stop lamp 93 Power Tail stop lamp 93 GND
286. ous fuel consumption MODE Switch The MODE switch is located on the left side of the IC The MODE switch changes the odometer between Main odometer ODO Trip 1 TRIP 1 2 TRIP 2 Service odometer SERVICE Low fuel odometer F trip Setup Mode The setup mode allows the operator to change certain settings in the IC With the ignition on press and hold the TOGGLE and MODE switch at the same time until SETUP MODE appears on the display The following functions are located in the setup menu e KEY OFF TO EXIT TIME SETTING SERVICE COUNTER e PIN SETTING e THEFT SETTING UNIT SETTING e CLOCK 12 24 e TOGGLE TO EXIT Pressing and releasing the MODE switch scrolls through the list Pressing and releasing the TOGGLE switch allows the operator to select the changes to the functions or exit the setup mode The different functions that can be set up are Setting the clock time and 12 or 24 hour formats Service mileage reset PIN change e Security system prompts Unit of measure Lap Timer To enter the lap timer mode with the engine running and the vehicle stopped hold down the TOGGLE switch and press the flash to pass switch on the left handlebar three times See Figure 4 4 for flash to pass switch location Once started the lap timer restarts a new lap each time the flash to pass switch is pressed The lap timer can store up to 99 lap times Each time a new lap is s
287. ove 4 79V the ECM sets a code DTC P1151 is set when the BAS output is shorted low to ground and P1152 is set when the BAS output is shorted high to voltage An open circuit output acts like a shorted high and set DTC P1152 If a code occurs the engine continues to run A tipped vehicle will not set a DTC Clutch Switch The ECM provides 5 Volts to the clutch switch which is open when the clutch is disengaged released With the clutch engaged pulled in the switch closes allowing voltage to ground The will not allow the engine to start unless the transmission is in neutral or the clutch is engaged Neutral Switch The ECM provides 5 Volts to the neutral switch which is open when the transmission is in gear With the transmission in neutral the switch is closed allowing voltage to ground The ECM will not allow the engine to start unless the transmission is in neutral or the clutch is engaged Fuel Pressure Sensor The duty cycle of the fuel pump is controlled by the ECM which supplies a pulse width modulated ground to the fuel pump Voltage for the fuel pump is supplied from the fuel pump fuse through the key switch relay The ECM can command a fuel pressure range from 58 75 psi 400 517 kPA depending upon demands of the engine The ECM provides 5 Volts to the sensor which varies the signal voltage back to the ECM based on fuel rail pressure low pressure low voltage signal Vehicle speed engine speed cool
288. p Tyco Under seat 131 Neutral switch 1 place slotted spade Under sprocket cover 133 Side stand sensor 3 place Deutsch Under sprocket cover 134 Bank Angle Sensor BAS 6 place Sumitomo Inside left radiator shroud 137 Oxygen sensor rear 1 place Delphi Under seat 138 Oxygen sensor front 1 place Delphi Behind intake snorkel 145 Interface connector 20 place Molex Behind left radiator shroud 160 12V Auxiliary Connector 2 place Sumitomo Behind fairing 170 Front brake switch 2 1 place spade Underside of front brake assembly 178 Active intake solenoid 2 place Deutsch Under seat 215 Cooling fan 2 left 2 place Sumitomo Inside left radiator shroud 227 Fuel pressure sensor 3 place Delphi Fuel line aft of throttle body 228 Barometric BARO pressure sensor 3 place Bosch Under seat rear of airbox 234 Fan sub harness connector 4 place Deutsch Behind left radiator shroud 243 CAN connector 2 place Deutsch Behind left radiator shroud B 2 2008 Buell 1125R Appendix B Wiring WIRING DIAGRAMS N WIRING DIAGRAM INFORMATION Wire Color Codes Wire traces on wiring diagrams are labeled with alpha codes Refer to Table B 2 For Solid Color Wires See Figure B 1 The alpha code identifies wire color 3 For Striped Wires The code is written with a slash between the solid color code and the stripe code 4 For example a trace labeled GN Y is a green wire with a
289. plays the correct security set ting 6 Press the MODE switch to select the displayed setting The IC returns to the setup menu 7 Press and release the MODE switch to continue through the setup menu until TOGGLE TO EXIT is displayed 8 Press the TOGGLE switch ENTERING THE PIN When activated a PIN is required to disarm the security system The PIN is entered using the TOGGLE switch on the IC Turn the ignition switch on 2 The displays ENTER PIN with four dashes above it 3 Press and release the TOGGLE switch until the correct number displays for the first digit If the TOGGLE switch is not pressed for 2 seconds the IC enters the number currently showing and moves to the next digit 4 Once the IC moves to the next digit repeat the above steps until all four digits are selected 5 The IC either displays WRONG PIN or CORRECT PIN depending whether or not the PIN entered matches Once the IC communicates the correct PIN was entered the allows the engine to start 2008 Buell 1125R Accessories Horn Lights and Security 5 29 The same process starting with Step 2 is used to enter the PIN when the ignition is turned off and the security is set to ASK AT KEY OFF CHANGING THE PIN The PIN is set to 0000 from the factory Perform the following procedure to change the PIN 1 With the ignition on and the security disarmed press and hold the TOGGLE and MODE switches until the SET
290. plied Part No HD 41354 1 or point to point leads to 55 connector 65B terminals B signal and C ground Turn Speedometer Tester power on and allow the tester to self test On the tester perform the following 1 Press the CLEAR button 2 Press 1 then 3 Press ENTER Enter 144Hz by pressing 144 and then press ENTER Does the speedometer on the instrument cluster indicate approximately 60 MPH 96 KPH YES Replace VSS Check short to ground on W wire harness leaving ECM Locate and repair short to ground on W wire NOTE Check and inspect interface continuity checks Locate and repair open or YES Replace ECM poor connection on W wire YES Remove Brake Horn fuse Check resistance between connector 65B terminal A and terminal 3 of the Brake Horn fuse Is resistance less than 1 Ohm Connect breakout box to ECM disconnected Check resistance between breakout box terminal 13 Gray and terminal B of 65B Is resistance less than 1 Ohm connector 145 when performing Does brake lamp illuminate and horn actuate Replace the Brake Horn fuse and retest YES Connect breakout box to ECM harness leaving ECM disconnected Check resistance between terminal 19 Gray of breakout box and terminal C of 65B Is resistance less than 1 Ohm Locate a
291. put falls outside the acceptable range See Figure 6 7 the for electrical connection NOTE If the TP sensor is removed and or replaced the zero set pro cedure must be performed Table 6 8 Code Description DTC DESCRIPTION P0122 Throttle position sensor circuit low P0123 Throttle position sensor circuit high P1112 Active intake control throttle position sensor feedback failure Diagnostic Tips An intermittent may be caused by any of the following condi tions Poor Connection Inspect the ECM harness connector for backed out terminals improper mating inoperative 6 18 2008 Buell 1125R Engine Management locks improperly formed or damaged terminals poor ter minal to wire connection and damaged harness TP Sensor Scaling Observe the TP sensor voltage dis play while operating the throttle with engine stopped and ignition switch on The TP sensor voltage displayed should vary from less than 1 Volt closed throttle to greater than 3 5 Volts WOT As the throttle is slowly moved the voltage change should be smooth without any observed spikes or drops in voltage Figure 6 7 Throttle Position TP Sensor Location Connector Information For additional information on the connectors in the following diagram s see B 1 CONNECTORS
292. r ground connection for the sensor or allow fresh air into the exhaust system or excessive air into the intake system If fresh air enters either system the O2 sensor reads a lean condition causing the system to go rich Connector Information For additional information on the connectors in the following diagram s see B 1 CONNECTORS 2008 Buell 1125R Engine Management 6 75 00277 Intake Crank Coolant Air Position Temperature Temperature Oxygen Cooling CKP ECT IAT Sensor Fan 1 Sensor Sensor Sensor Rear Right eren 1 2 3 79 2 1 9041 1 89 1 137A 221 974 1 2 3 Y 79B 2 1 YI90B 2 1 YI898 1 Y 1378 2 1 YI97Bl x gt 2 Cooling a a gt 2 m 2 d T m g amp 2 Left Oxygen Baro Sensor Front Side Stand F Y 2 1 215A L 2 1 Y 215B amp 2 1 J 138A Y 11388 gt d 2 E gt gt gt 5 2 1 3 4 2348 2 1 AJ 2344 ain Kw eee re gt gt 5 2 m Cooling Y BN Fan Fuse v a gt E m T 4 15 16 V A 1458 4 15 16 145 o o 5 Y 3 e gt a 5 8 cod z 8 3 i amp BL gt 118 118 26 28 14 31
293. r terminals 1 2 c Runthe engine at 3000 RPM The AC output should be 35 40 volts AC d Repeat the test across terminals 2 3 and 1 3 Compare the test results to specifications a If the output is below specifications charging problem could be a faulty rotor or stator Perform Stator Check b If output is within specifications charging problem might be faulty regulator Replace as required Repeat the Current and Voltage Output Test Figure 3 19 Check Stator AC Voltage Output typical BATTERY TESTING 3 4 DESCRIPTION AND OPERATION Battery condition can be determined by a voltage test a con ductance test or a load test A battery may be tested whether fully charged or not using the conductance test However the battery must be fully charged to perform a load test VOLTMETER TEST The voltmeter test provides a general indication of battery state of charge or condition Check the voltage of the battery to make sure it is in a 100 fully charged condition Refer to Table 3 5 If the open circuit disconnected voltage reading is below 12 6V charge the battery and then recheck the voltage after the battery has set for one to two hours If the voltage reading is 12 7V or above perform the 3 4 BATTERY TESTING Load Test Table 3 5 Voltmeter Test For Battery Charge Conditions VOLTAGE STATE OF CHARGE 12 7 100 12 6 75 12 3 50 12
294. rent and Voltage Output Test Using HD 48053 3 19 Current and Voltage Output Test Using Load ety T 01 M 3 19 3 19 3 20 3 4 BATTERY TESTING Description and 3 21 Lor P 3 21 olus Perl MI mM 3 21 EC p em 3 21 INSTRUMENTS 4 1 INSTRUMENT CLUSTER AND GAUGES Description and 4 1 Compone 4 1 4 1 4 1 4 1 Plo Go 4 1 jos ers rco M 4 1 Warming pet 4 2 Then Mode uH za o o 4 2 pete nm 4 2 MODE OVID ETUR 4 2 Setup meee 4 2 TIMET 4 3 Onboard Diagnostic Information System ODIS 4 3 Instrument Cluster IC Diagnostics 4 5 4 2 FUEL LEVEL SENDER LOW HIGH OPEN DTC B1004 B1005 D scription arid uu 4 6 TABLE OF CONTENTS TABLE OF 5 4 6 Connector DiormahO 4 6 4 3 OIL PRESSURE LAMP ALWAYS OR INOPERATIVE Description and OpersllOn soriano 4 11 Disgnostic cu reves ser traria terr ti
295. rt No HD 39969 or a ROBINAIR HEAT GUN Part No HD 25070 with a HEAT SHIELD ATTACHMENT Part No HD 41183 to heat the connector from the center of the crimp 3 out to each end NOTE It is acceptable for the splice to rest against the heat shrink tool attachment Inspecting Seals See Figure A 25 Allow the splice to cool and inspect the seal The insulation should appear smooth and cylindrical Melted sealant will have extruded out the ends 4 of the insulation 5100050 1 Red connector die 2 Blue connector die 3 Yellow connector die Figure A 24 Packard Crimping Tool HD 38125 8 sm00051 Wire lead in metal insert Crimp metal insert Center of crimp Melted sealant BASE Figure A 25 Sealed Splice Connector 2008 Buell 1125R Appendix A Connector Repair A 21 5 22 2008 Buell 11258 Appendix A Connector Repair TABLE OF CONTENTS SUBJECT PAGE NO B2 WIRING 7 5 CONNECTOR LOCATIONS B 1 Connector Number Function Location On the motorcycle a connector can be identified by its function and location Refer to Table B 1 Place and Color The place number of wire cavities of a connector housing and color of the connector can also aid identification On wiring diagrams and in service repair instructions con
296. rting the engine Instrument Cluster The IC sends a message to the ECM when the correct PIN is entered allowing the ECM to enable the start relay fuel injectors and ignition coils Theft Mode LED See Figure 5 23 The theft mode LED is the red indicator under the key icon on the IC The security system can be set up in any one of the following configurations ONATKEY OFF The security system automatically sets when the ignition switch is turned off When the ignition is keyed on the IC requests the PIN be entered before the motorcycle starts ASK AT KEY OFF When the ignition is turned off the IC requests the PIN to enter the security mode If the correct PIN is not entered within four minutes the IC shuts down and the security does not activate If the correct PIN is entered then the IC shuts down and the security system is active and requires a PIN for the motorcycle to start OFF AT KEY OFF The security system is disabled and does not activate No PIN is needed to start the motor cycle To select the desired security setting perform the following sequence 1 Turn the ignition switch on 2 Hold down the MODE and TOGGLE switches until SETUP MENU is displayed 3 Press and release the MODE switch to scroll through the menu until THEFT SETTING is displayed 4 Press the TOGGLE switch to access the mode list 5 Press and release the TOGGLE switch to scroll through the mode list until the IC dis
297. rts Then Stalls Misfire Fuel Pressure Test Intake Leak Test These symptoms do not generate DTCs but are an indication of system problems Correcting the DTCs may eliminate the need to perform the tests above To locate faulty circuits or other system problems follow the diagnostic flowcharts in this section Always begin with 2 1 INITIAL DIAGNOSTICS Refer to the information there and then work through the applicable flowchart box by box When working through a flowchart refer to the illustrations associated circuit diagram and the wire harness connector table in 1 CONNECTORS as necessary The wire harness connector table identifies the connector number description type and general location To perform the circuit checks efficiently it is necessary to be familiar with the wire connectors Use the BREAKOUT BOX Part No B 48115 and a DVOM Part No HD 39978 when performing diagnostic routines See 1 2 DIAGNOSTIC TOOLS Table 6 1 Engine Starts Hard CAUSE SOLUTION Engine coolant temperature circuit Repair the circuit If DTC P0117 or P0118 is present diagnose and correct DTCs Improper fuel pressure Perform fuel pressure test If DTCs P0192 P0193 or P0087 are present diagnose and correct DTCs Fuel or Ignition system fault Perform misfire diagnostics Battery discharged Charge and test the battery Perform charging system diagnosis if problem continues Cran
298. s Are all connections tight and free of corrosion Repair as needed Disconnect active intake solenoid Clean and repair connections 178A at the solenoid Measure voltage at terminal 2 with the ignition switch ON and the engine stop switch ON Is battery voltage present YES Disconnect ECM connector 10 Black Measure continuity to ground from connector 178A terminal 2 Is continuity present Measure voltage at 178A terminal 1 GY O Is battery voltage present Measure continuity from ignition relay 62 terminal 87 to connector 178B terminal 2 Connect breakout box to ECM Locate and repair harness leaving ECM short to ground Locate and repair disconnected Measure GY wire Is continuity present short to voltage on continuity between connector GY O wire 178A terminal 1 and 10B terminal 10 Is continuity present L NO Go to DTCs P1110 Locate and P1111 and P1112 repair open YES NO Part 2 of 2 on GY wire Go to DTCs P1110 Locate and P1111 and P1112 repair open in Part 2 of 2 GY O wire fc01908 en 2008 Buell 1125R Engine Management 6 99 DTCs P1110 P1111 and P1112 Part 2 of 2 Continued from DTC P1110 P1111 and P1112 Part 1 of 2 Measure the resistance from active intake solenoid ter
299. s condition and the measured voltage at idle and at 3000 RPM The analyzer provides a printout including possible test results CHARGING SYSTEM NORMAL No problem found CHARGING TEST PROBLEM The analyzer detected a problem and displays one of the following results a LOW CHARGING VOLTS The alternator is not supplying sufficient current for the system electrical loads b HIGH CHARGING VOLTS The voltage output from the alternator exceeds the normal regulator limits c INVESTIGATE VOLT OUTPUT The rev voltage is lower than the idle voltage Current and Voltage Output Test Using Load Tester 1 Connect the load tester as follows a Connect the negative and positive leads to the battery terminals b Placethe load tester induction pickup over the positive regulator cable Run the engine at 3000 RPM Do not leave any load switch turned on for more than 20 seconds or overheating and tester damage are possible Increase the load as required to obtain a constant 13 0 VDC The current output should be 19 23 Amps Make a note of the measurement for use in the Total Current Draw Test NOTE Rider s habits may require output test at lower RPM ed02804 KC SQ _CHARGING TEST PROBLEM LOW CHARGING VOLTS IDLE 12 32V REV 12 32V REFER TO H D SERVICE MANUAL Se Figure 3 16 Charging System Test Results Printout Stator Check 1 2 Turn ignition switch OFF
300. sconnect the front brake switch Jumper Disconnect the tail stop terminals 1 and 2 lamp Inspect the bulb Does the stop lamp Is the bulb good illuminate YES NO Replace front Test for voltage from terminal 1 of Locate and Replace the brake switch connector 170B to a good ground repair the open bulb Is battery voltage present in the R Y wire 5141 5197 5142 YES NO Locate and repair the open Locate and repair the open in the R Y from terminal 2 in the O from terminal 1 of of connector 170B connector 170B 5142 5764 fc01783 en 2008 Buell 1125R Accessories Horn Lights and Security 5 23 5 See Figure 5 19 The headlamp connector is located behind the front fairing See Figure 5 20 The rear tail stop lamp and license plate lamp connectors are bullet style connectors loc ated under the passenger seat in the tail section The marker lamps consist of the front markers lamps located on the outside edges of the headlamps the license plate lamp and the tail lamp The marker lamps are powered through the accessory fuse when the ignition switch is in the ON or PARK position Instrument Cluster IC 39 12 V auxiliary connector Headlamp 38 Left front turn signal 31L Right front turn signal 31R Left hand controls 24 Right hand controls 22 Ignition switch 33 EO
301. se w amp R md Battery Fuse Starter Bs 2 Solenoid 15 Amp als Lights BEM 4 eral gt c Ignition Switch mes 17 BE mum BE 8 6 3 30 1 e El e s E lt Relay 62B 62A Block a Starter gt gt om c c cr 338 1234 P RH Controls SBA 23 4 m 1 3 2 gt Start mox GY m 2 2 mien NES d Switch rc WKS 3 0 itch 15 Amp 4 GY e Switc Key Switch 24 19m 15 Amp gt Ignition 2 5 GY O nn m Battery Power Distribution 19 14 A 1458 In Wiring Diagrams 19 14 145A Main Engine Wiring Harness lt Relay In Wiring Diagrams 62B 62A Bock Fuel Pum Side Stand 6 Fuse Sensor HDI Only 86 B6B 11338 Sensor Grounds In gt gt Wiring Diagrams o GY E Neutral 1 TN BN IY C Switch pos gt 131A 131B gt gt 22 252 gt gt a Swit TNILGN 17 17 anl wite ET 118 28 283424 9 7 2728 1108 5 gt 145 145 2 2834 24 9 7 2728 N 10A 95B 55 Bs 53 888 5588 55 55 o o o zy 855 GY Figure 3 9 Starting Circuit 3 6 2008 Buell 112
302. sor V 79A Y 79B Figure B 5 ECM Power Grounds 2008 1125R Model B 8 2008 Buell 1125R Appendix B Wiring 00243 3 3 E a Horn Switch L1 A 122A 1 1228 en Left Front Turn Signal Y 3118 BK Clutch Switch L3 95 s 7 1958 12 Auxiliary Connector 2 Y 160B Instrument Cluster 13 4 39 13 Y 398 E Right Front Left Rear Turn Signal Turn Signal 1 NLISTRA 1 AVIA 1 31 1 98 E x a Right Right Left Left High Low Low High Beam Beam Right Left Beam Beam Head Head Marker Marker Head Head lamp lamp Lamp Lamp lamp lamp B A 2 2 B A 2 2 T 4 x m a m m EE R BK R BK 388 38 License Plate Lamp J 45A Yen 1 93 1 Y 93B Right Rear Turn Signal 1 18 1 Y 18B i Voltage Regulator RE lt lt 77 77 Starter Solenoid V 128A Y 128B Ignition Relay EL 3 30 BKW 9 2 50 1 86 p Key Relay BEE 3 30 E B
303. sor circuit high P0339 Crank position sensor circuit intermittent Wu ed01722 Figure 6 5 CKP Sensor Location Shroud removed for clarity Connector Information For additional information on the connectors in the following diagram s see B 1 CONNECTORS 2008 Buell 1125R Engine Management 6 15 00277 Intake Crank Coolant Air Position Temperature Temperature Oxygen Cooling CKP ECT IAT Sensor Fan 1 Sensor Sensor Sensor Rear Right eren 1 2 3 79 2 1 9041 1 89 1 137A 221 974 1 2 3 Y 79B 2 1 YI90B 2 1 YI898 1 Y 1378 2 1 YI97Bl x gt 2 Cooling a a gt 2 m 2 d T m g amp 2 Left Oxygen Baro Sensor Front Side Stand F Y 2 1 215A L 2 1 Y 215B amp 2 1 J 138A Y 11388 gt d 2 E gt gt gt 5 2 1 3 4 2348 2 1 AJ 2344 ain Kw eee re gt gt 5 2 m Cooling Y BN Fan Fuse v a gt E m T 4 15 16 V A 1458 4 15 16 145 o o 5 Y 3 e gt a 5 8 cod z 8 3 i amp BL gt 118 118 26 28 14 31 32 2 3 18 26 108 18 26 9 28 14 31 32 2 3
304. stortion should the jaws Push the locking bar 1 up be minimal 2 Insert 2 terminal socket pin through hole of the locking bar so that the rounded side of the contact barrel rests in Table A 3 Deutsch Standard Terminal Crimp Wire Gauge the nest concave split level area with the crimp tails To Die facing upward To match the wire gauge to the crimp tool die refer to Table A 3 WIRE GAUGE AWG CRIMP TOOL DIE 20 Front 3 Release locking bar to lock terminal in die NOTE If the crimp tails are slightly out of vertical alignment the crimp tool automatically rotates the terminal so that the tails face 16 18 Middle sm00021 1 Open jaws and raise locking bar 4 Insert stripped lead 2 Insert terminal in locking bar 5 Squeeze crimper 3 Release locking bar to lock terminal in die 6 Raise locking bar and remove terminal Figure A 16 Crimping a Deutsch Standard Terminal 2008 Buell 1125R Appendix A Connector Repair A 11 METRI PACK TERMINALS A 5 METRI PACK TERMINAL CRIMPS PART NUMBER TOOL NAME HD 38125 6 PACKARD TERMINAL CRIMP TOOL HD 38125 7 PACKARD TERMINAL CRIMPER HD 38125 8 PACKARD CRIMPING TOOL Matching Terminal To Crimper Metri Pack connectors embossed with the initials P E D require Packard crimp tools to crimp terminals to wire leads Terminals are crimped twice to a wire lead once over the wire core and a second time
305. sue If the ignition is turned off the timer stops but stays where it is and continues to count down when the ignition is turned back on In order to reset the timer back to 30 minutes disconnect the battery power completely from the IC DTC P1009 Security System Fault or THEFT ERROR Message The ECM sets a P1009 and THEFT ERROR displays on the IC when the security data shared between the IC and the ECM does not match or if there is a loss of communication between the IC and the If there is a loss of communication while the engine is running COMM ERROR displays until the ignition is turned off When the ignition is turned back on THEFT ERROR instead of COMM ERROR displays on the IC Vehicle Tampering If modifications have been made to the vehicle to bypass the security system the vehicle becomes immobilized unable to start and the LCD screen displays a THEFT ERROR message when the ignition key is turned to ON The indicator and warning lamps operate but the LCD screen functions cannot be accessed NOTE The PIN and theft mode settings are retained in memory when the battery is disconnected from the vehicle Connector Information For additional information on the connectors in the following diagram s see B 1 CONNECTORS Table 5 5 Symptom Table SYMPTOM COMMON CAUSE THEFT ERROR displayed Loss of communication on CAN BUS or a mismatched VIN 5 30 2008 Buell 1125R Accessories Horn Li
306. t m gt 5 gt 2 9 6 5 5 5 E E OA 18 26 28 14 31 32 2 3 18 26 108 18 26 9 28 14 31 32 2 3 18 26 0 MET H 68 3 5545 U 5 5 5 5 5 2 5 9 amp 5 8 8 2 8 5 5 tort B S E g 8 5 E 8 E ECM Figure 6 10 5V Reference 2008 Buell 1125R Engine Management 6 23 P1501 P1502 and P1503 Part 1 of 3 DTC P1501 DTC P1502 Disconnect side stand sensor connector 133 Turn Ignition Switch ON Place the Go to DTCs P1501 engine stop switch to RUN Test terminal 1 of P1502 and P1503 connector 133B for voltage Part 2 of 3 Is approximately 5 volts present Check for DTCs Did DTC P1501 clear or go to history and P1502 set as current DTC Check for DTCs P1501 P1502 and P1503 Are any DTCs present Locate and repair open in 5V sensor power circuit YES NO DTC P1503 Go to DTCs P1501 P1502 and P1503 Part 3 of 3 Replace side stand sensor Locate and repair Replace short to ground ECM lt m i 6 24 2008 Buell 1125R Engine Management Disconnect connector 11 Gray ECM Test for continuity between terminal 34 Gray to ground Is continuity present 57 System operating normally 1001874 en DTCs P1501 P1502 and P1503 Part 2 of 3
307. t NO Test the auxiliary relay Is the relay good NOTE See 1 3 DIAGNOSTICS TROUBLESHOOTING If the relay terminal called out does not match the relay being checked EA Test for battery voltage at socket terminal 20 GY of the auxiliary relay Is battery voltage present YES Connect the auxiliary relay Turn the ignition on with the engine stop switch in the run position Test for battery voltage from terminal 1 O R of connector 160B to a good ground Is battery voltage present Locate and repair the open in the R wire between the auxiliary fuse and auxiliary relay It is possible a component plugged into the 12V auxiliary connector caused the concern Replace the auxiliary power fuse Locate and repair the short to ground 1731 5145 1734 Replace the auxiliary relay 1733 Locate and repair the open in the GY wire socket terminal 20 of the auxiliary relay 1734 5 Disconnect Install breakout box Test for battery vol 1 to terminal 2 of tage from terminal connector 160B Using a patch cord connect terminal 19 black to ground Does the auxiliary relay energize and power Is battery voltage present System is operating properly Check connection to auxiliary components Locate and repair the open in the BK wire from t
308. t No HD 48053 instruction manual to perform a battery test The test results include a decision on the battery condition and the measured state of charge 1 8 2008 Buell 1125R General Information Figure 1 21 HD 48053 Advanced Battery Conductance and Electrical System Analyzer Kit Fuel Injector Test Lamp The FUEL INJECTOR TEST LIGHT Part No HD 34730 2D fuel injector test lamp is used to test the fuel injector drivers as well as the ignition coil drivers in the ECM 1 Connect the BREAKOUT BOX Part No B 48115 2 Disconnect the fuel injector connectors 3 See Figure 1 22 for typical setup Connect one side of the fuel injector test lamp to power and the other to the ter minal on the ECM for the circuit you are testing 4 Crank the engine 5 Ifthe test lamp flashes the circuit is working properly ed01546 KENT MOORE 48115 Figure 1 22 Fuel Injector Test Lamp HD 41354 Speedometer Tester See Figure 1 23 Connect SPEEDOMETER TESTER Part No HD 41354 with the INPUT OUTPUT CABLE Part No HD 41354 1 supplied or connect point to point leads to VSS connector 65B terminals 2 signal and 3 ground Turn Speedometer Tester power on and allow the tester to self test On the tester perform the following 1 Press the CLEAR button 2 Press 1 3 Press ENTER 4 Enter 144 Hz by pressing 144 and then press ENTER Does the speedometer on the instrument cluster read
309. t faulty horn or horn switch Diagnostic Tips If the fuse is open check the circuit between the horn switch and the horn for a short to ground This would cause the fuse to open only when the horn switch is pressed A short in the R Y wire between the brake lamp switches and the tail stop lamp causes this fuse to blow when the brakes are applied The O wire from the fuse supplies battery voltage to several components short anywhere in the wire causes the fuse to open immediately Horn Always On If the horn is always on perform the following steps 1 Disconnect the horn switch 5 6 2008 Buell 1125R Accessories Horn Lights and Security 2 If the horn turns off replace the left switchgear Connector Information 3 horn does not turn off repair the short to voltage in For additional information on the connectors in the following the Y BK wire diagram s see 1 CONNECTORS 00241 agi Ignition Accessory Power Wiring Diagram ik RBK tid 71 Fuse Block 10 LA Ignition Power Wiring Diagram 24A 24B Horn gt gt oms ow ome Switch 4 4 4 4 2 2 BKE 1 1 lt lt 1228 122 E m Wiring Diagram GND 1 Figure 5 7 Horn 2008 Buell 1125R Accessor
310. t pin terminal tool is not available a push pin safety pin or a Snap on pick Part No TT600 3 may be used 4 Pressthe tang in the housing to release the terminal a Socket Lift the socket tang 8 up b Pin Press the pin tang 7 down NOTE A click is heard if the tang is released 5 Gently tug on wire to pull wire and terminal from cavity 2008 Buell 1125R Appendix A Connector Repair A 1 5100013 Latch Secondary lock open Pin housing Socket housing Pin terminal Socket terminal Tang pin Tang socket 1 2 3 4 5 6 7 8 Figure 2 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 1 Hold the terminal so the catch faces the tang in the chamber Insert the terminal into its numbered cavity until it snaps in place A 2 2008 Buell 1125R Appendix A Connector Repair 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 at the top of each cavity so the socket termin
311. talled position sm00009 Figure A 11 Deutsch Connector Remove Secondary Locking Wedge A 8 2008 Buell 1125R Appendix A Connector Repair sm00018 1 Arrow on socket locking wedge 2 Arrow on pin locking wedge Figure A 12 Deutsch Connector 3 Place Locking Wedges 5100010 Wire seal Socket housing Wire lead Internal seal Secondary locking wedge Seal plug 1 2 3 4 5 6 Figure A 13 Deutsch Connector 2 3 4 and 12 Place Socket Housings Removing Pin Terminals 1 Use the hooked end of a stiff piece of mechanics wire needle nose pliers or the FLAT BLADE L HOOK Part No HD 41475 100 to remove the secondary locking wedge Gently depress terminal latches inside pin housing and back out pins through holes in wire seal NOTES If wire leads require new terminals see the instructions for crimping terminals If it should become necessary to replace a or socket housing please note that the 8 place and 12 place gray and black connectors are not interchangeable Since loc ation of the alignment tabs differ between the black and gray connectors plugs or receptacles must be replaced by those of the same color When replacing both socket and pin housings then the black may be substituted for the gray and vice versa The socket and pin housings of all other connectors are inter changeable that is the black may be mated with the gray sinc
312. tarted the timer displays the time for the last completed lap for 15 seconds To replay the stored times hold the flash to pass switch for 5 seconds It replays Individual lap times Fastest lap time Slowest lap time Average lap time To clear all laps in memory press and hold the TOGGLE switch for 3 seconds The LAPS CLEAR message is displayed when lap times are erased To exit the lap timer mode 1 Stopthe vehicle 2 Press and hold TOGGLE switch and quickly press the passing lamp switch three times NOTE Recorded lap times remain in memory until they are cleared Exiting lap timer mode turning off the vehicle or losing battery power will not affect lap times stored in memory ed01716 Flash to pass switch Headlamp high low beam switch Turn signal switch Horn switch Penn Figure 4 4 Left Hand Controls ONBOARD DIAGNOSTIC INFORMATION SYSTEM ODIS IC displays the 0015 at the bottom of the LCD The 0015 displays operational data configuration menus and messages for other features through the IC Refer to Table 4 1 for possible messages and their descriptions Table 4 1 General LCD Screen Messages MESSAGE DESCRIPTION BUELL WISCONSIN USA Introductory text displayed when ignition key is turned on SYSTEM VOLTAGE Displayed when the battery voltage is too low or too high AT XXX F CT COLD The word COLD flashes on the screen until the measured
313. te Pressure MAP sensor 3 place Bosch Under throttle body between cylinders 83F Front ignition coil 3 place Bosch Front cylinder head 83R Rear ignition coil 3 place Bosch Rear cylinder head 84 Front fuel injector 2 place Sumitomo Front intake flange 85 Rear fuel injector 2 place Sumitomo Rear intake flange 86 Fuel pump 4 place Delphi Right side of frame 87 Idle Air Control IAC 4 place Delphi Left side of throttle body 88 Throttle Position TP sensor 3 place Bosch Left side of throttle body 89 Intake Air Temperature IAT sensor 2 place Amp Tyco Left side of intake snorkel 90 Engine Coolant Temperature ECT sensor 2 place Bosch Front cylinder head under throttle body 91A Data link connector 4 place Deutsch Behind left radiator shroud 93 Tail stop lamp 2 place Amp Tyco and Back of tail lamp under tail section 1 place Amp Tyco 95 Clutch switch 2 place Sumitomo Underside of clutch lever assembly 97 Cooling fan 1 right 2 place Sumitomo Inside right radiator shroud 120 Oil pressure switch Spade terminal Right side of engine 121 Rear brake switch 2 place Amp Tyco Right side forward of rear wheel 2008 Buell 1125R Appendix B Wiring B 1 Table 1 2008 11258 Connector Locations DESCRIPTION TYPE LOCATION 122 Horn 2 1 place Fargo Behind left radiator shroud under fan 128 Starter solenoid 2 place Am
314. te Pressure Sensor 8 Neutral Switch 9 Coolant Temperature Input Fuel Pressure Sensor 0 3 Vehicle Speed Sensor 4 Intake Air Temperature Input 5 Serial Data Receive Serial Data Transmit 8 9 Bank Angle Sensor Crank Position Sensor 09 1001 co o 9 0 001 at rh rk ck cns Interface Connector Sensor Ground 3 V R 20 Idle Air Control Contro otor To Chassis Harness 21 Idle Air Control Motor 2 22 Idle Air Control Motor Sensor Ground 3 1 BK 23 Idle Air Control Motor CAN High 2 24 Sensor Power 1 CANLow 3 5 25 Sensor Power 2 Oxygen Sensor 2 Rear 1 pi E 26 Grank Position Sensor n a 0 ensor Groun Vehicle Battery 6 E Y I i F 28 Sensor Ground 2 8 ma ehicle Speed Sensor Fuel Pump Output Fuel Pump Output ee aoee n 29 GAN Low 1 ig DS er m PK 31 02 Sensor Front 11A 32 O2 Sensor Rear 34 Side Stand Sensor GY Oil Pressure Switch 12 Switched Ignition 2 13 Starter Enable 14 2 2 Fan 1 Right J2 randi de BKO AF _ 5 3 Ean 1 Right 10A arter Enable Clutch Switch 17 8 8 System Ground 4 C uit n IL AH 680
315. temperature is above the normal operating temperature range The display then changes to the Average Fuel Consumption screen The initial ambient temperature displays when the ignition is turned on and updates once the vehicle maintains a speed above 25 mph 40 kph for 1 minute SERVICE XXX Service interval is due at the displayed number of miles kilometers This message is displayed on the first startup after the service odometer falls below the 200 mile 322 Km and 1000 mile 1609 Km thresholds SERVICE NOW Service odometer has elapsed Vehicle is due for regular maintenance This message is displayed on each startup until the service counter is reset SIDE STAND Models The side stand is not in the fully retracted position On some models the vehicle shuts off power to the ignition and fuel pump when the side stand is down while the vehicle is in gear and the clutch is disengaged released 2008 Buell 1125R Instruments 4 3 Table 4 1 General LCD Screen Messages MESSAGE DESCRIPTION TIPPED KEY OFF The bank angle sensor has been tripped The vehicle shuts off power to the ignition and fuel pump when the tip angle is greater than a predetermined limit Turn the key switch off stand the motorcycle upright and restart ENTER PIN Displayed when the ignition is first turned on while the security system is armed THEFT ERROR A problem has been detected with the security system or serial communicat
316. th one way WINDING RESISTANCE cen Primary winding 0 5 1 0 Ohms Table 1 6 Fuel Pump Pressure Specifications Secondary winding Internal diode not accurately measurable with DVOM RANGE VALUE Normal 58 psi 400 kPA Table 1 12 Temperature Specifications Key ON OFF 75 psi 517 kPA RANGE VALUE ater Key Normal operating 140 220 60 104 100 80 Over temperature threshold 230 110 Table 1 7 Relay Specifications Fans on 170 F 77 C RELAY PART NO Fans off 160 71 Auxiliary 31522 00C COMPONENT LOCATIONS Ignition 31522 00 Some components and connectors are not easily located on Key Switch 31522 00C the motorcycle The following graphics show locations for these Start Y0175 1AM 2008 Buell 1125R General Information 1 1 components and connectors The graphics generally ordered from front to back around the motorcycle D Figure 1 2 Clutch Switch Connector 95 Instrument Cluster IC 39 12 V auxiliary connector Headlamp 38 Left front turn signal 31L Right front turn signal 31R Left hand controls 24 Right hand controls 22 Ignition switch 33 ON Oe Figure 1 1 Behind Fairing Connectors 1 Horn connector 122 2 Horn 3 Oil cooler Figure 1 3 Horn 1
317. the open on the R BK wire going to the lights fuse 5194 YES Locate and repair the open on the BE wire between the lights fuse and the headlamp switch 5194 vo Replace the start relay 1720 Locate and repair the open in the Y wire to headlamp connector 38A 5194 Locate and repair the open in the BE wire to headlamp connector 38B 5194 1 01879 2008 Buell 1125R Accessories Horn Lights and Security 5 13 Headlamps Inoperative Part 2 of 2 Continued from Headlamps Inoperative Part 1 of 2 Are the high beam headlamps inoperative Are both high beam headlamps inoperative Headlamps operating normally See 1 3 DIAGNOSTICS TROUBLESHOOTING With the ignition on and the headlamp switch in the high position Is the high beam indicator on the IC illuminated YES With the ignition on and the headlamp switch in the high position test for battery voltage from terminal A W of the high beam headlamp to a good ground 15 battery voltage present Press the flash to pass switch Does the high beam indicator illuminate Disconnect the inoperative headlamp Inspect the bulb Is the bulb good YES Replace the bulb Test for battery voltage from terminal A W of the inoperative headlamp to a good gr
318. the IC it must be a new IC Connector Information For additional information on the connectors in the following diagram s see B 1 CONNECTORS 00245 Battery Power Distribution In Wiring Diagrams Y Ignition Lock Off Lock Off Switch Park On Park On ee Instrument 39 398 Cluster S5 Ignition Switch 14 Chassis Ground 13 Constant Battery 12 CAN Low 10 CAN High 9 Chassis Ground 3 Constant Battery 2 gt x 9 m a Il 1 2 4 1 2 Y 33B 2 par Ignition And Accessory R Gv gt Power In Wiring Diagrams 14 B R GY 13 BK 12 e E CAN Terminating Connector Resistor 10 8 PK GY PK GY ml 2 2 Ziza 9 E 1 1 lt lt KA 145B 145A 243A 243B 3 2 mR x 5 gt x x x m 2 10B 24 17 16 9 29 30 A 11B 10A 24 17 16 9 29 5 2 2 E ECM Power 354 29 Grounds 8 8 8 8 Wiring 5 m Diagrams 85 as A Ba Chassis Grounds In Wiring Diagrams ECM 9 GND 1 Figure 4 11 Instrument Cluster Power and Communication 2008 Buell 1125R Instruments 4 17 Instrument Cluster Part 1 of 2
319. to Table 3 6 WARNING Turn battery load tester OFF before disconnecting tester cables to battery terminals Disconnecting tester cables with load tester ON can cause a spark and battery explo sion which could result in death or serious injury 00253a WARNING Connect positive battery cable first If positive cable should contact ground with negative cable connected the resulting sparks can cause a battery explosion which could result in death or serious injury 00068a CAUTION Do not over tighten bolts on battery terminals Use recommended torque values Over tightening battery ter minal bolts could result in damage to battery terminals 00216a 6 Install the battery in the motorcycle 3 22 2008 Buell 1125R Starting Charging ed02812 S VOLTS AMPS 1 Load tester 2 Induction pickup 3 Battery Figure 3 21 Load Test Battery Table 3 6 Battery Load Test COLD CRANKING 10095 5096 AMPERAGE CCA 1125R models 200 100 SUBJECT PAGE NO 4 1 INSTRUMENT CLUSTER AND GAUGES seis 4 2 FUEL LEVEL SENDER LOW HIGH OPEN DTC B1004 B100 4 3 OIL PRESSURE LAMP ALWAYS OR INOPERATIVE o0 4 4 TURN SIGNAL INDICATOR INOPERATIVE 4 5 INSTRUMENT CLUSTER INOPERATIVE 4 5 LOW FUEL LAMP ALWAYS ON
320. turn off Verify there is sufficient oil in the engine Disconnect the oil pressure switch Using a jumper connect the oil pressure switch connector 120B to a good ground Start the engine Does the low oil light illuminate Replace the instrument cluster 6006 Test the GN Y wire from the Replace the oil oil pressure sensor to the IC pressure switch for an open circuit Is an open present 5161 YES NO Locate and repair the Replace the instrument cluster open in the GN Y wire 6004 6024 fc01787 4 14 2008 Buell 1125R Instruments TURN SIGNAL INDICATOR INOPERATIVE 4 4 DESCRIPTION AND OPERATION See Figure 4 10 The IC receives a signal from the left or right turn signal switch on terminal 4 left or terminal 5 right The IC sends voltage to the right or left turn signal when it receives this signal to flash The flash for the indicators and the turn signal lamps is controlled internally by the IC The IC sends voltage through terminal 11 for the right turn signal and through terminal 1 for the left turn signal ed01695 Left turn signal indicator Neutral indicator Headlamp high beam indicator Right turn signal indicator Figure 4 10 Indicator Lamp Diagnostic Tips The IC controls the flash rate for the turn signals internally There is no fl
321. uit 6 13 FUEL INJECTORS DTC P0261 P0262 P0264 P0265 High P0337 7 Crank Position Sensor 6 7 CRANK POSITION SENSOR P0337 P0338 P0339 Circuit Low P0338 8 Crank Position Sensor 6 7 CRANK POSITION SENSOR P0337 P0338 P0339 Circuit High P0339 9 Crank Position Sensor 6 7 CRANK POSITION SENSOR P0337 P0338 P0339 Circuit Intermittent P0617 60 Starter Relay Circuit 6 14 START RELAY DTC P0617 High P1151 16 Bank Angle Sensor 6 10 BANK ANGLE SENSOR BAS DTC P1151 P1152 Shorted Low P1152 15 Bank Angle Sensor 6 10 BANK ANGLE SENSOR BAS DTC P1151 P1152 Shorted High P1154 17 Clutch Position Sensor 6 11 CLUTCH AND NEUTRAL SWITCHES P1154 P1155 Circuit Low P1155 18 Neutral Switch Input Cir 6 11 CLUTCH AND NEUTRAL SWITCHES DTC P1154 P1155 cuit Low P1501 13 Side Stand Sensor Low 6 9 SIDE STAND SENSOR DTC P1501 P1502 P1503 HDI ONLY P1502 12 Side Stand Sensor 6 9 SIDE STAND SENSOR DTC P1501 P1502 P1503 HDI ONLY High Open P1503 14 Side Stand Down at 6 9 SIDE STAND SENSOR DTC P1501 P1502 P1503 HDI ONLY Vehicle Speed P2300 31 Front Ignition Coil Con 6 12 IGNITION COILS DTC P2300 P2301 P2303 P2304 trol Circuit Low P2303 33 Rear Ignition Coil Control 6 12 IGNITION COILS P2300 P2301 P2303 P2304 Circuit Low P2304 32 Rear Ignition Coil Control 6 12 IGNITION COILS DTC P2300 P2301 P2303 P2304 Circuit High 2008 Buell 1125R
322. ut signals to the drivers to crank start idle and run the engine This topic describes the config uration of the ECM for this vehicle Figure 6 2 ECM 36 2 Alternator Rotor The alternator rotor has 36 teeth evenly spaced around its cir cumference with two consecutive teeth missing sync gap In this configuration the ECM determines engine position engine phase and engine speed from the CKP sensor input Phase TDC compression is determined by the ECM during startup and when necessary while running No engine ignition events can occur until the ECM determines the relationship of piston position to crankshaft position The following paragraphs in this section describe synchronization and phasing by the ECM to provide smooth operation of the engine at all speeds Crank Position Signal Synchronization In the 36 2 crank configuration crankshaft position is determ ined by the ECM finding the two tooth sync gap in the CKP sensor signal This is usually accomplished the first time the sync gap is encountered The ECM monitors the CKP signal status every engine revolution If the ECM determines synchronization is lost it immediately terminates ignition events and synchronizes on the next occurrence of the sync gap Engine Phase Phasing is accomplished by the ECM identifying a widening in the CKP signal caused by the deceleration of the crankshaft as a piston approaches TDC on its compression stroke Since
323. ver conditions The ECM sets DTC P0617 when it detects voltage always present on ECM terminal 7 of connector 10 NOTE The start relay is not repairable Replace the unit if it fails Connector Information For additional information on the connectors in the following diagram s see B 1 CONNECTORS AN ed01701 CALIFOR posts termi INIA PROPOSITION and related and other ch cer Figure 6 26 Start Relay 2008 Buell 1125R Engine Management 6 45 00276 Ignition Start Fuse Switch Switch vod RIGY BK R zm 10B 10 lt lt 24 33 Starter Enable Ignition Switch Battery System Ground 4 System Ground 3 System Ground 2 System Ground 1 5 87 Start 4 87 30 Ke GN Om 2 2 85 628 Relay Block 5 o gt E H 6 19 14 1458 19 14 1145 2 c Eg 7 9 Y 8417 BK 8 BK a 16 BK 24 33 x tn ECM GND 1 O og ND 2 ECM Figure 6 27 ECM Power and Ground 6 46 2008 Buell 1125R Engine Management 0617 Remove start relay Turn ignition to ON and the engine stop switch to RUN Measure voltage on Socket terminal 85 Is voltage present Locate and repair short to voltage
324. ving ECM disconnected Check resistance from terminal 31 of breakout box to terminal 1 of 138B front or terminal 32 of breakout box Replace ECM Replace ECM to terminal 1 of 137B rear or 32 rear for short to Is resistance less than 1 Ohm voltage Is voltage present YES Turn ignition switch OFF Check continuity between terminal 31 front or 32 rear of breakout box gray to all remaining terminals on the gray side of breakout box Locate and repair shorted wires Check terminal 31 front or 32 rear of breakout box gray for continuity to ground Locate and repair Locate and repair open or poor Locate and repair connection on short to voltage on PK O front or PK O or PK GN PK GN rear wire wire short to ground on PK O front or PK GN rear wire fc01901 en 2008 Buell 1125R Engine Management 6 77 DTCs P0131 P0132 P0134 P0151 P0152 and P0154 Part 2 of 2 Turn ignition OFF and reconnect O2 sensor Turn ignition switch ON and start engine Allow engine to reach operating Continued from DTCs P0131 P0132 P0134 P0151 P0152 and P0154 Part 1 of 2 With engine idling does voltage quickly fluctuate between 0 1 0 8 Volts temperature YES Perform wiggle test See 1 3 DIAGNOSTICS TROUBLESHOOTING Are intermittents present YES Repair as necessary
325. y the ECM to determine ignition timing and fuel required at any given RPM and engine load The output of the TP sensor is read by the ECM every 10mS In order to function properly the TP sensor must be mechan ically zeroed This procedure verifies the throttle plates are in their fully closed position while simultaneously requesting the software to record the electrical value at that position See the service manual Side Stand Sensor HDI Only The side stand sensor uses a Hall effect device to monitor side stand position When the side stand is fully retracted the sensor picks up the presence of a metal bolt fastened to the aluminum side stand When extended the engine only starts and runs if the ECM receives a signal from the neutral switch indicating the transmission is in neutral or a signal from the clutch switch indicating the clutch is engaged Otherwise the engine stalls as the clutch is released with the transmission in gear Bank Angle Sensor BAS The BAS operates from the ECM 5 Volt sensor reference and is grounded through the ECM on a common sensor ground circuit The BAS sends a signal to the ECM ranging from 0 24 3 4V under normal operating conditions A signal between 3 5 4 79V causes the ECM to turn off the engine When the vehicle 6 4 2008 Buell 1125R Engine Management is righted the ignition must be switched off and then on in order to restart the engine If the signal from the BAS is below 0 24V or ab
326. y voltage present Locate and repair the open in the ground circuit Replace the ignition Switch 5129 Replace the instrument Locate and repair the open in the battery circuit cluster to the instrument cluster 6006 6024 Locate and repair the open in the R GY wire 6024 fc01785 en 2008 Buell 1125R Instruments 4 19 LOW FUEL LAMP ALWAYS INOPERATIVE 4 6 DESCRIPTION AND OPERATION See Figure 4 12 The IC provides battery voltage to the fuel level sender on the Y R wire The fuel level sender is a ther mistor device that is cooled by fuel in the tank keeping the resistance value high As the fuel drops below the sender the thermistor is allowed to warm lowering the resistance value The IC constantly monitors this signal and when the resistance value changes at approximately 0 8 gallons 3 0 liters of fuel is left in the tank the IC illuminates the low fuel lamp ed01705 Figure 4 12 Fuel Pump Connector 86 4 20 2008 Buell 1125R Instruments Diagnostic Tips The fuel level sender will not show a resistance reading if the sensor is working properly and the fuel level is above the sensor Connector Information For additional information on the connectors in the following diagram s see B 1 CONNECTORS Fuel Level 00246
327. yellow stripe Wiring Diagram Symbols See Figure B 1 On wiring diagrams and in service repair instructions connectors are identified by a number in brackets 1 The letter 2 inside the brackets identifies whether the housing is a socket or pin housing A Pin The letter A after a connector number and the pin symbol 6 identifies a pin housing B Socket The letter B after a connector number and the Socket symbol 5 identifies a socket housing Other symbols found on the wiring diagrams include the symbol for a diode 7 a symbol for a wire to wire connection 8 a symbol verifying that no connection 9 between two wire traces exists symbols for actual 10 and virtual 11 splices and a symbol identifying two wires that are twisted together 12 Actual splices 10 are splices where two wires are connected together at a specific location along a wire Virtual splices 11 are splices shown connected anywhere along a wire usually used in a wiring or schematic diagram for clarity 01711 gt 21 12 4 21 12 4 8 I Sa 1 Connector number 2 Terminal code Azpin Bzsocket 3 Solid wire color 4 Striped wire color 5 Socket symbol 6 Pin symbol 7 Diode 8 Connection 9 No connection 10 Virtual splice 11 Physical splice 12 Twisted pair Figure B 1 Connector Wiring Diagram Symbols typical Table B 2 Wire Color Codes

2008 Buell 1125R Electrical Diagnostic Manual 99949-08Y

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