2004 CHECKING FOR DIAGNOSTIC TROUBLE CODES 2 · 2004 Touring: Instruments 2-3 HOME CODE TYPES There...

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2

2004 CHECKING FOR DIAGNOSTIC TROUBLE CODES 2.1

CHECK ENGINE LAMP

To diagnose electronic control module (ECM) or ignition con-trol module (ICM) system problems, start by observing thebehavior of the check engine lamp.

NOTES

● See Figure 2-2. “Key ON” means that the ignition key isturned to ON and the engine stop switch is set to RUN(although the engine is not running).

● When the ignition switch is turned ON, the check enginelamp will illuminate for approximately four seconds andthen turn off.

● If the check engine lamp is not illuminated at Key ON.See 2.2 INITIAL DIAGNOSTIC CHECK: SPEEDOME-TER.

● If the check engine lamp comes on late (after 20 sec-onds). See 2.2 INITIAL DIAGNOSTIC CHECK: SPEED-OMETER.

● If the check engine lamp fails to turn OFF after the initialfour second period. See 2.2 INITIAL DIAGNOSTICCHECK: SPEEDOMETER.

1. See Figure 2-3. After lamp turns off after being illumi-nated for the first four second period, one of three situa-tions may occur.

a. The lamp remains off. This indicates there are nocurrent fault conditions or stored diagnostic troublecodes (DTC) currently detected by the ignition con-trol module (ICM) or electronic control module(ECM).

b. The lamp stays off for only four seconds and thencomes back on for an eight second period. This indi-cates an diagnostic trouble code is stored, but nocurrent diagnostic trouble code exists.

c. If the lamp remains on beyond the eight secondperiod, then a current diagnostic trouble code exists.

2. See CODE TYPES which follows for a complete descrip-tion of diagnostic trouble code formats.

NOTES

Some diagnostic trouble codes can only be fully diagnosedduring actuation. For example, a problem with the ignition coilwill be considered a current fault even after the problem iscorrected, since the ECM/ICM will not know of its resolutionuntil after the coil is exercised by vehicle start sequence. Inthis manner, there may sometimes be a false indication of thecurrent diagnostic trouble code.

Figure 2-2. Ignition Switch (FLTR, FLHT/C/U)

Figure 2-1. Speedometer

f1240x2x

010

3020

5040

110120

60 7080

90100

0

20

3040

50

10

MPH

HARLEY-DAVIDSONCERTIFIED

RPMx100

HARLEY-DAVIDSON

f2160x8xCheck Engine Lamp

2004 Touring: Instruments 2-1

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SECURITY LAMP

To diagnose TSM/TSSM system problems, start by observingthe behavior of the security lamp.

NOTES

● To provide an indication of TSM/TSSM diagnostic troublecodes, the security lamp is enabled on all models.

● See Figure 2-2. “Key ON” means that the ignition key isturned to ON and the engine stop switch is set to RUN(although the engine is not running).

● When the ignition switch is turned ON, the check enginelamp will illuminate for approximately four seconds andthen turn off.

● If the check engine lamp is not illuminated at Key ON,see 2.2 INITIAL DIAGNOSTIC CHECK: SPEEDOME-TER.

● If the check engine lamp comes on late (after 20 sec-onds), see 2.2 INITIAL DIAGNOSTIC CHECK: SPEED-OMETER.

● If the check engine lamp fails to turn OFF after the initialfour second period, see 2.2 INITIAL DIAGNOSTICCHECK: SPEEDOMETER.

1. See Figure 2-3. After lamp turns off after being illumi-nated for the first four second period, one of three situa-tions may occur.

a. The lamp remains off. This indicates there are nocurrent fault conditions or stored diagnostic troublecodes currently detected by the ignition control mod-ule (ICM) or electronic control module (ECM).

b. The lamp stays off for only four seconds and thencomes back on for an eight second period. This indi-cates an diagnostic trouble code is stored, but nocurrent diagnostic trouble code exists.

c. If the lamp remains on beyond the eight secondperiod, then a current diagnostic trouble code exists.

2. See CODE TYPES which follows for a complete descrip-tion of diagnostic trouble code formats.

NOTE

Some diagnostic trouble codes can only be fully diagnosedduring actuation. For example, a problem with the turn signalswill be considered a current fault even after the problem iscorrected, since the TSM/TSSM will not know of its resolutionuntil after the turn signals are activated. In this manner, theremay sometimes be a false indication of a diagnostic troublecode.

Figure 2-3. Check Engine and Security Lamp Operation

ON

OFF

ON

OFF

ON

OFF

Key ON

Key ON

A

B

C

Lamp ON 8 Seconds:Only Historic DTCs Exist

Lamp OFF: No Current or Historic DTCs

Lamp Remains ON: Current DTC *

Lamp OFF

* Historic DTCs May Also Exist

4 Sec.

4 Sec.

8 Sec.

Key ON

4 Sec.

4 Sec.

4 Sec.

2-2 2004 Touring: Instruments

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CODE TYPES

There are two types of diagnostic trouble codes (DTCs): cur-rent and historic. If a diagnostic trouble code is stored, it canbe read using speedometer self diagnostics. See 2.3SPEEDOMETER SELF DIAGNOSTICS.

All diagnostic trouble codes reside in the memory of theECM/ICM, TSM/TSSM, speedometer or tachometer until thecode is cleared by use of the speedometer self diagnostics.See 2.3 SPEEDOMETER SELF DIAGNOSTICS.

A historic diagnostic trouble code is also cleared after a totalof 50 trips has elapsed. A trip consists of a start and runcycle. After the 50 trip retention period, the diagnostic troublecode is automatically erased from memory providing that nosubsequent faults of the same type are detected in thatperiod.

Current

Current diagnostic trouble codes are those which presentlydisrupt motorcycle operation. See the appropriate flow chartsfor solutions.

Historic

Historic diagnostic trouble codes can only be identified as his-toric using a computer based diagnostic package called DIG-ITAL TECHNICIAN (Part No. HD-44750), when historicdiagnostic codes are present.

If a particular problem happens to resolve itself, the activestatus problem is dropped and it becomes a historic faultrather current fault.

Historic diagnostic trouble codes are stored for a length oftime to assist in the diagnosis of intermittent faults.

It is important to note that historic diagnostic trouble codesmay also be present whenever the system indicates the exist-ence of a current fault. See MULTIPLE DIAGNOSTIC TROU-BLE CODES if multiple diagnostic trouble codes are found.

Diagnostic charts are designed for use with current diagnos-tic trouble codes and as a result they frequently suggest wirerepair or part replacement.

RETRIEVING DIAGNOSTIC TROUBLE CODES

The engine management system provides two levels of diag-nostics.

● The most sophisticated mode employs a computerbased diagnostic package called DIGITAL TECHNICIAN(Part No. HD-44750).

● The second mode requires using the speedometer selfdiagnostics. Speedometer, tachometer (if equipped),TSM/TSSM and ECM diagnostic trouble codes can beaccessed and cleared. See 2.3 SPEEDOMETER SELFDIAGNOSTICS.

MULTIPLE DIAGNOSTIC TROUBLE CODES

While it is possible for more than one fault to occur and setmore than one diagnostic trouble code, there are several con-ditions which may result in one fault setting multiple diagnos-tic trouble codes:

Serial data diagnostic trouble codes (DTC U1016, U1064,U1097, U1255, U1300 and U1301) may be accompanied byother codes. Always correct the serial data diagnostic troublecodes before resolving the other codes.

For proper resolution to multiple diagnostic trouble codesrefer to diagnostic trouble code priority chart page 2-6,Table2-2.


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INITIAL DIAGNOSTIC CHECK: SPEEDOMETER 2.2

GENERAL

● Constant power is supplied to the speedometer throughterminal 5 of connector [39]. The speedometer turns onwhen power is applied to terminal 1 of connector [39].The speedometer goes through an initializationsequence every time power is removed and re-applied toterminal 6. The visible part of this sequence is the checkengine lamp (in “run” mode), security lamp (models withsecurity only), backlighting, odometer and fuel level (EFIonly). Upon key ON, the check engine lamp and securitylamp will illuminate for 4 seconds and then (if parametersare normal) go out.

● To locate faulty circuits or other system problems, followthe diagnostic flow charts and tests in this section. For asystematic approach, always begin with INITIAL DIAG-NOSTICS which follows. Read the general informationand then work your way through the flow chart box bybox.

● Loss of power on any of the four power inputs willchange speedometer behavior. Refer to Table 2-1.Speedometer Function Chart-Loss Of Input.

Diagnostic Notes

If a numbered circle appears adjacent to a flow chart box,then more information is offered in the diagnostic notes. Manydiagnostic notes contain supplemental information, descrip-tions of various diagnostic tools or references to other partsof the manual where information on the location and removalof components may be obtained.

Circuit Diagram/Wire HarnessConnector Table

When working through a flow chart, refer to the illustrations,the associated circuit diagram and the wire harness connec-tor table as necessary. The wire harness connector table foreach circuit diagram identifies the connector number, descrip-tion, type and general location.

In order to perform most diagnostic routines, a Breakout Boxand a digital volt/ohm meter (DVOM) are required. See 2.5BREAKOUT BOX: SPEEDOMETER.

To perform the circuit checks with any degree of efficiency, afamiliarity with the various wire connectors is also necessary.

Figure 2-4. Remove Left Side Cover

Figure 2-5. Remove Maxi-Fuse Cover

Maxi-FuseCover

Fuse Block

f2206x8x

Maxi-Fusef2207x8x


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INITIAL DIAGNOSTICS

Diagnostic Tips

● If Speedometer reads “BUS Er” with the ignition keyturned ON (engine stop switch at RUN with the engineoff), check data bus for an open or short to ground.between data link connector [91A] terminal 3 and ICMconnector [10B] terminal 12 (carbureted models), ECMconnector [78B] terminal 5 (EFI models), TSSM connec-tor [30B] terminal 3, Speedometer connector [39B] termi-nal 2 or tachometer (if equipped) connector [108B]terminal 2.

● Check for an open data test terminal between data linkconnector [91A] terminal 3 and TSM/TSSM connector[30B] terminal 3. With ignition key turned ON, serial databus voltage should be typically 0.6-0.8 volts. The rangeof acceptable voltage is greater than 0 and less than 7.0volts.

● To identify intermittents, wiggle instrument and/or vehicleharness while performing steps in the Diagnostic Checkcharts.

Diagnostic Notes

The reference numbers below correlate with the circled num-bers on the diagnostic check flow charts. See page 2-11.

1. Connect BREAKOUT BOX (Part No. HD-42682) andINSTRUMENT HARNESS ADAPTERS (Part No. HD-46601) between wire harness and speedometer.

All Speedometer diagnostic trouble codes are listed on page2-6 in Table 2-2.

Other Codes

See 3.9 INITIAL DIAGNOSTIC CHECK: TSM/TSSM for anydiagnostic trouble codes related to the turn signal module(TSM) or turn signal security module (TSSM).

See 4.4 INITIAL DIAGNOSTIC CHECK: ICM for any diagnos-tic trouble codes related to the ignition control module (ICM).

See 5.5 INITIAL DIAGNOSTIC CHECK: EFI for any diagnos-tic trouble codes related to the electronic control module(ECM).

Figure 2-6. Fuse Block (FLTR, FLHTC/U)

1. Headlamp 2. Ignition3. Lighting4. Instruments5. Brakes/Cruise6. Radio Memory

7. Radio Power8. Accessory9. Battery10. Brake Light Relay11. P&A

Fuse BlockCover

Spare Fuse Holder

f2209x8x

f2203x8x

11

109

1

8 7

6

5

4

32

2004 T
ouring: Instruments 2-5

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Table 2-1. Speedometer Function Chart-Loss Of Input

Terminal 5 (Constant)

Terminal 1 (IGN) Terminal 6 (ACC) Terminal 7 (GRD)Terminal 8 and 11

(Reset Switch)

● Security lamp glows dimly dur-ing 4-second bulb check

● Will not “wow”

● Turn signals still functional

● Speedometer will indicate vehicle speed (zero)

● Tachometer unaffected

● Security lamp still func-tional

● Check engine lamp and battery lamp non-func-tional

● Diagnostics absent

● Speedometer will be non-functional in accessory and ignition modes

● Security lamp still performs 4-sec-ond bulb check in ignition mode

● Speedometer com-pletely non-functional

● Diagnostics absent

● No reset switch function

● Will not “wow”

Table 2-2. Speedometer/Tachometer Diagnostic Trouble Codes (DTC) Priority Chart

DTC PRIORITY FAULT CONDITION SOLUTION MODULE

“BUS Er” 1 Serial data bus shorted low/open/high 2.15 DTC U1300, U1301 or “BUS ER”

Speedometer/tachometer

U1300 2 Serial data bus shorted low2.15 DTC U1300, U1301 or “BUS ER”


U1301 3 Serial data bus shorted open/high2.15 DTC U1300, U1301 or “BUS ER”


U1016 4 Loss of ECM serial data 2.13 DTC U1016 Speedometer/tachometer

U1064 5 Loss of TSM/TSSM serial data 2.14 DTC U1064, U1255 Speedometer/tachometer

U1255 6Missing response from other module (TSM/TSSM and/or ICM/ECM) at startup

2.14 DTC U1064, U1255 Speedometer/tachometer

B1007 7 Ignition line overvoltage 2.11 DTC B1006, B1007 Speedometer/tachometer

B1006 8 Accessory line overvoltage 2.11 DTC B1006, B1007 Speedometer/tachometer

B1008 9 Reset switch closed 2.12 DTC B1008 Speedometer

B1004 10 Fuel level sending unit low 2.10 DTC B1004, B1005 Speedometer

B1005 11 Fuel level sending unit high/open 2.10 DTC B1004, B1005 Speedometer


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Figure 2-7. Diagnostic Check: FLHT/C (Carbureted)

Table 2-3. Wire Harness Connectors in Figure 2-7.

NO. DESCRIPTION TYPE LOCATION

[1] Main to Interconnect Harness 12-Place Deutsch (Black) Inner Fairing - Right Radio Support Bracket

[2] Main to Interconnect Harness 12-Place Deutsch (Gray) Inner Fairing - Right Fairing Support Brace

[8] Ignition Harness 12-Place Deutsch Under Right Side Cover

[10] Ignition Control Module 12-Place Deutsch Under Right Side Cover

[30] Turn Signal/Security Module 12-Place DeutschCavity in Crossmember at Rear of Battery Box

(Under Seat)

[39] Speedometer 12-Place Packard Inner Fairing (Back of Speedometer)

[91] Data Link 4-Place Deutsch Under Right Side Cover

[108] Tachometer 12-Place Packard Inner Fairing (Back of Tachometer)

[156] Main to Interconnect Harness 6-Place Deutsch Inner Fairing - Right Fairing Support Brace

12

12

3

1

2

4

321 654 987 121110321 654 987 121110

321 654 987 121110321 654 987 121110

321 654 987 121110321 654 987 121110

1011

127

89

45

61

23

1011

127

89

45

61

23

321 654 987 121110321 654 987 121110

2

43

1

56

2

43

1

56

321 654 987 121110321 654 987 121110

Ignition Control Module

Data Link

TSM/TSSM

LtG

N/V

15AIgnition

Fuse

GY

[8B][8A]

[91A]

LtGN/V

BK

LtGN/V

[39B][39A]

[10B][10A]

Speedometer

O

BK

Ser

ial d

ata

[108B][108A] Tachometer

BN/GY

[156B] [156A]

[30B][30A]

15AAccessory

Fuse

[1B] [1A]

Main to InterconnectHarness

Ignition Harness


f2208z8x

15ABattery

Fuse

[2A][2B]


BK

GY

BN/GY


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Figure 2-8. Diagnostic Check: FLHR/S (Carbureted)





[30] Turn Signal/Security Module 12-Place DeutschCavity in Crossmember at Rear of

Battery Box (Under Seat)

[39] Speedometer 12-Place Packard Under Console (Back of Speedometer)


321 654 987 121110321 654 987 121110

321 654 987 121110321 654 987 121110

321 654 987 121110321 654 987 121110

3

1

2

4

12

12

Data Link

TSM/TSSM

LtG

N/V

GY

[30B][30A]

[91A]

LtGN/V

BK[39B][39A]

[10B][10A]

Speedometer

O

BK

Ser

ial d

ata


BN/GY

15AIgnition

Fuse

15AAccessory

Fuse

LtGN/V

[8B][8A]

Ignition Harness

15ABattery

Fuse

f2208y8x

BK

BN/GY

GY


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Figure 2-9. Diagnostic Check: FLTR, FLHT/C/U (Fuel Injected)


NO. DESCRIPTION MODEL TYPE LOCATION

[1]Main to Interconnect Harness

FLHT/C 12-Place Deutsch (Black) Inner Fairing - Right Radio Support Bracket

FLTR 12-Place Deutsch (Black) Inner Fairing - Below Radio (Left Side)


FLHT/C 12-Place Deutsch (Gray) Inner Fairing - Right Fairing Support Brace

FLTR 12-Place Deutsch (Gray) Inner Fairing - Below Radio (Left Side)

[8] Ignition Harness All 12-Place Deutsch Under Right Side Cover

[10] Ignition Control Module All 12-Place Deutsch Under Right Side Cover

[30]Turn Signal/Security Module

All 12-Place DeutschCavity in Crossmember at Rear of


[39] SpeedometerFLHT/C 12-Place Packard Inner Fairing (Back of Speedometer)

FLTR 12-Place Packard Under Bezel (Back of Speedometer)

[91] Data Link All 4-Place Deutsch Under Right Side Cover

[108] TachometerFLHT/C 12-Place Packard Inner Fairing (Back of Tachometer)

FLTR 12-Place Packard Under Bezel (Back of Tachometer)


FLHT/C 6-Place Deutsch Inner Fairing - Right Fairing Support Brace

FLTR 6-Place Deutsch Inner Fairing - Front of Right Fairing Bracket

51

3

1

2

4

321 654 987 121110321 654 987 121110

321 654 987 121110321 654 987 121110

321 654 987 121110321 654 987 121110

1011

127

89

45

61

23

1011

127

89

45

61

23

321 654 987 121110321 654 987 121110

321 654 987 121110321 654 987 121110

2

43

1

56

2

43

1

56

ECM

Data Link

TSM/TSSM

LtG

N/V

15AIgnition

Fuse

GY

[8B][8A]

[91A]

LtGN/V

BK

LtGN/V

[39B][39A]

[78B][78A]

Speedometer

O

BK

Ser

ial d

ata

[108B][108A]

Tachometer

BN/GY

[156B] [156A]

[30B][30A]

15AAccessory

Fuse

[1B] [1A]


Ignition Harness


f2208u8x

15ABattery

Fuse

[2B][2A]


LtG

N/R

BK

BN/GY

GY

Fla

sh p

in


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Figure 2-10. Diagnostic Check: FLHR/C/S (Fuel Injected)







[39] Speedometer 12-Place Mini-Deutsch Under Console (Back of Speedometer)

[78] Electronic Control Module 36-Place Packard Under Right Side Cover


51

321 654 987 121110321 654 987 121110

321 654 987 121110321 654 987 121110

321 654 987 121110321 654 987 121110

3

1

2

4

f2208t8x

Data Link

TSM/TSSM

LtG

N/V

GY

[30B][30A]

[91A]

LtGN/V

BK[39B][39A]

[78B][78A]

Speedometer

O

BK

Ser

ial d

ata

ECM

BN/GY

15AIgnition

Fuse

15AAccessory

Fuse

LtGN/V

[8B][8A]

Ignition Harness

15ABattery

Fuse

LtG

N/R

BK

BN/GY

GY

Fla

sh p

in


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Diagnostic Check (Part 1 of 2)

YES.Starts and

runs.

For carbureted models, see 4.10 STARTS, THEN STALLS.

For EFI models, see 5.12 STARTS, THEN STALLS.

See 1.2 STARTING SYSTEM DIAGNOSIS.

YES.Starts, then

stalls.

NO.Cranks, but will not start.

NO. Engine will not

crank.

For carbureted models, see 4.9 ENGINE CRANKS, BUT WILL NOT START. For EFI models, see 5.10 ENGINE CRANKS,

BUT WILL NOT START.

NO

Check for continuity to ground on terminal 7 of speedometer. Wiggle harness during con-

tinuity check. Continuity present?

YES

YES NO

YES NO

Check for battery voltage at terminal 5 of speedometer

while wiggling harness. Bat-tery voltage continuously

present?

Replace speedometer. Replace speedometer reset switch.

1

Check for diagnostic trouble codes. See 2.3 SPEEDOMETER SELF

DIAGNOSTICSCodes found?

Refer to applicable diagnostic trouble code priority chart. All diagnostic codes

are listed on page 2-6 in Table 2-2. Codes are listed by priority.

STOP

Go to Diagnostic Check (Part 2 of 2).

Locate and repair open between terminal 5 and

battery fuse.

Locate and repair open between terminal 7

and ground.

NO

Unable to enter diagnostic mode. With ignition switch OFF, press and

release odometer reset switch. Does odometer display appear with

display backlighting?

NO

No codes displayed. For symptoms that may not set diagnostic trouble codes,

refer to Table 2-1.

NOYES

YES

With connector [39] disconnected from speedometer, check continuity (with ignition switch OFF) between terminals 8 and 11 on

Breakout Box. Continuity present when speedometer reset switch is depressed and

infinity when released?

Does enginestart?


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Diagnostic Check (Part 2 of 2)

YES

Remove and inspect vehi-cle speed sensor. Debris

present?

Remove debris. Reinstall vehicle speed sensor.

NO

YES

Continued from Diagnostic Check (Part 1 of 2).Perform “wow” test. See 2.3 SPEEDOMETER SELF DIAGNOSTICS.

The following features should be functional1) backlight should illuminate2) needle should sweep its full range of motion3) LED’s that should illuminate:

• check engine• battery• security (all models)

4) LED’s that may illuminate: • low fuel (EFI models)• cruise (although not cruise equipped on some models)

Are all features functional?

Turn key to ACC. Is backlight present?

YES NO

Is instrument fuse blown?

Replace Speedometer.

YES NO

Locate and repair source of fault. Replace fuse.

Locate and repair open between terminal 1 of

connector [39] and instrument fuse.

Is problem intermittent?

YES

NO

Check for battery voltage at breakout box terminal 6. Battery voltage present?

Replace speedometer.

YES

1

NO

Tachometer Inoperative (no engine speed).

See Test 2.4 (Part 1 of 2).

YES

YESIntermittent vehicle speed

indication.

NO

With ignition switch turned to IGN, check for battery voltage at terminal 1 of Breakout Box.

Battery voltage present?

Is accessory fuse blown?

YES


NO

Locate and repair open on O/W wire between termin al 6 of con-nector [39] and accessory fuse.

Repeat Diagnostic Check while wiggling harnesses.

Intermittent present?

Locate and repair intermittent.

YES NO

No trouble found.

NO

Check for damaged wiring/loose connection between

vehicle speed sensor and ICM/ECM. Is wiring damage/loose

connection present?

YES NO

Replace Speedometer.Locate and repair source of fault.


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SPEEDOMETER SELF DIAGNOSTICS 2.3

GENERAL

The speedometer is capable of displaying and clearingspeedometer, tachometer, TSM/TSSM, and ICM/ECM diag-nostic trouble codes (diagnostic mode).

DIAGNOSTICS

Diagnostic Tips

● For a quick check of speedometer function, a “wow” testcan be performed. Press and hold odometer reset switchthen turn ignition switch ON. Release reset switch. Back-ground lighting should illuminate, speedometer needleshould sweep its full range of motion, and indicatorlamps [battery, security, low fuel (EFI models) checkengine and cruise should illuminate. Some lamps mayilluminate even though they do not apply to the vehicle.For example, the cruise lamp may illuminate althoughthis feature does not apply to some models.

● If instrument module fails “wow” test, check for battery,ground, ignition, speedometer reset switch and acces-sory to speedometer. If any feature in the speedometer isnon-functional, see 2.2 INITIAL DIAGNOSTIC CHECK:SPEEDOMETER.

Diagnostic Notes

Use of speedometer self diagnostics assumes that DIGITALTECHNICIAN (Part No. HD-44750) is not available.

The reference numbers below correlate with the circled num-bers in the Speedometer Self Diagnostics (chart)

1. To exit diagnostic mode, turn ignition switch OFF.

2. To clear diagnostic trouble codes (DTCs) for selectedmodule, press speedometer reset switch for more than 5seconds when code is displayed. This procedure willclear all diagnostic trouble codes for selected module.

Figure 2-11. Icons

Figure 2-12. Ignition Switch (FLTR, FLHT/C/U)

010

3020

5040

110120

60 7080

90100

0

20

3040

50

10

MPH


RPMx100

HARLEY-DAVIDSON

f2160x8x

1. Check Engine2. Low Fuel3. Battery4. Security5. Cruise (Where Applicable)

12 3

45

f1240x2x


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Speedometer Self Diagnostics (chart)

Figure 2-13. Speedometer Self Diagnostics

”P” flashing.

”S” flashing.

”SP” flashing.

To choose TSM/TSSM, press and

release reset switch.

YESTo choose ICM, press and

release reset switch.

“none” displayed.

To display DTCs for speedometer, press and

hold reset switch for more than 5 seconds.

To display DTCs for the ECM/ICM, press and hold reset switch for

more than 5 seconds.

To display DTCs for TSM/TSSM, press and


To choose Speedometer, press and release reset

switch.

NO

YES

2

”T” flashing.

To choose Tachometer, press and release reset

switch.

To display DTCs for tachometer, press and


Press and release reset switch. Part num-ber of module will be

displayed.

Press and release reset switch again to continue to

next module.

Device response?

“no rsp” displayed.* Tachometer malfunction. See 2.4 SPEEDOMETER/

TACHOMETER.

* Models not equippedwith a tachometer willdisplay “no rsp” nor-mally.

DTC displayed.

NO

Press and release reset switch.

Are more DTCs displayed?

1

While holding odometer reset switch in, turn ignition switch to IGN. Make sure Run/Stop switch is in RUN position.

Release reset switch. Does “diag” appear?

YES NO

“end” displayed.To clear all DTCs for

selected module hold reset switch for more than 5 sec-onds. If DTCs are not to be cleared, Press and release reset switch. Part number of

module will be displayed.

See 2.2 INITIAL DIAGNOSTIC CHECK: SPEEDOMETER.

Press and release reset switch.

“PSSPT” appears.


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SPEEDOMETER/TACHOMETER 2.4

GENERAL

NOTE

Some icons may illuminate during “wow” test though the iconhas no functionality on that vehicle.

The speedometer consists of a speedometer display and sev-eral icons. The icons include: check engine, security, battery,and low fuel (EFI only).

Reset Switch

See Figure 2-14. Pressing the odometer reset switch pro-vides the following capabilities:

● Change the odometer display between mileage, trip Aand trip B values (press and immediately release).

● Reset an individual trip odometer (press and hold 2-3seconds).

● Gain access to the diagnostic mode, clear diagnostictrouble codes and exit diagnostic mode. See 2.3SPEEDOMETER SELF DIAGNOSTICS.

● Display odometer while key is OFF. Press and hold resetswitch while key is OFF and odometer mileage will bedisplayed.

● On models with dual scale speedometers, togglebetween miles/kilometers on odometer and trip odome-ter display. To toggle display, turn key ON. Press andhold reset switch while odometer is displayed. Releaseswitch when change is noted. (If reset switch is heldwhile trip odometer is displayed, trip odometer will reset.)

Figure 2-14. Icons (FLHT/C/U)

010

3020

5040

110120

60 7080

90100

0

20

3040

50

10

MPH


RPMx100

HARLEY-DAVIDSON

f2160x8x

1. Check Engine2. Low Fuel3. Battery4. Security5. Cruise (Where Applicable)

12 3

45


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SPEEDOMETER THEORYOF OPERATION

The speedometer consists of a vehicle speed sensor, ICM/ECM, odometer reset switch and the speedometer. The vehi-cle speed sensor is mounted on the right side of transmissioncase below the starter. The sensor circuitry is that of a Hall-Effect sensor that is triggered by the gear teeth of 4th gear onthe transmission mainshaft.

The output from the sensor is a series of pulses that are inter-preted by ICM/ECM circuitry, converted into serial data insidethe ICM/ECM then sent to the speedometer to control theposition of the speedometer needle and the liquid crystal(LCD) odometer display. The vehicle speed serial data is alsotransmitted to the TSM/TSSM for turn signal cancellation.

The odometer mileage is permanently stored and will not belost when electrical power is turned off or disconnected. Theodometer reset switch allows switching between the odome-ter, trip odometer A and trip odometer B displays.

To zero the trip odometer, have the desired trip odometer dis-play visible, press and keep the reset switch depressed. Thetrip odometer mileage will be displayed for 2-3 seconds andthen the trip mileage will return to zero miles.

The odometer can display six numbers to indicate a maxi-mum of 999999 miles/kilometers. The trip odometers can dis-play six numbers with a tenth of a mile accuracy for amaximum of 99999.9 miles/kilometers.

Job/Time Code Values

Dealership technicians filing warranty claims should use thejob/time code values in Digital Technician.

TACHOMETER THEORYOF OPERATION

The tachometer receives serial data from the ICM/ECM. Thetachometer interprets the serial data and converts it intotachometer needle movement.

DIAGNOSTICS

Diagnostic Notes

The reference numbers below correlate with circled numberson the tachometer diagnostic flow chart.

1. If problems are intermittent, wiggle harness while per-forming tests.

2. Connect BREAKOUT BOX (Part No. HD-42682) andINSTRUMENT HARNESS ADAPTERS (Part No. HD-46601) between wire harness and tachometer.

3. Use HARNESS CONNECTOR TEST KIT (Part No. HD-41404), black pin probe and patch cord.


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Test 2.4 (Part 1 of 2)TACHOMETER INOPERATIVE

Perform “wow” test. See 2.3 SPEEDOMETER SELF DIAGNOSTICS.

The following features should be functional1) backlight should illuminate2) needle should sweep its full range of motion3) LED’s may illuminate:

cruise (although not cruise equipped on some models)pursuit (although may not be a police vehicle)

Are all features functional?

YES NO


Locate and repair open in orange wire

between terminal 1 of connector [108] and

instrument fuse.

STOP

Go to Test 2.4 (Part 2 of 2).

YES

Check for battery voltage at terminal 1 of breakout box. Is battery voltage

present?

NO

NO

Is instrument fuse blown?

YES

Repeat Diagnostic Check while wiggling

harnesses.

NO

No trouble found.

Is problem intermittent?

YES

NO

Locate and repair open on LGN/V wire.

Check for continuity between breakout box terminal 2 and terminal 7 of connector [20].

Is continuity present?

YES


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Test 2.4 (Part 2 of 2)TACHOMETER INOPERATIVE

Check for battery voltage at breakout box terminal 6.

Is battery voltage present?

Check for battery voltage at breakout box terminal 5

while wiggling harness. Is battery voltage

continuously present?

Replace tachometer. Locate and repair open on O/W wire between terminal 6 of con-

nector [108] and accessory fuse.

Continued from Test 2.4 (Part 1 of 2).Check for continuity to ground on breakout box

terminal 7. Wiggle harness during continuity check. Is continuity present?

YES NO

YES NO

Locate and repair open on BK wire between ter-

minal 7 of connector [108] and ground.

NO

Locate and repair open on BN/GY wire between terminal 5 of connector [108] and battery fuse.

YES


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BREAKOUT BOX: SPEEDOMETER 2.5

GENERAL

The BREAKOUT BOX (Part No. HD-42682) and INSTRU-MENT HARNESS ADAPTERS (Part No. HD-46601) connectto speedometer connector [39]. Used in conjunction with aDVOM, it allows circuit diagnosis of wiring harness and con-nections without having to probe with sharp objects

NOTE

See wiring diagrams for speedometer terminal functions.

INSTALLATION

1. See Figure 2-16. Bend back the external latches slightlyand remove connector [39B].

2. Connect Instrument Harness Adapters to connectors[39A] and [39B].

3. Attach connectors from Breakout Box to Instrument Har-ness Adapters.

REMOVAL

1. Detach connectors from Breakout Box to Instrument Har-ness Adapters.

2. See Figure 2-15. Detach Instrument Harness Adaptersfrom connectors [39A] and [39B].

3. Install connector [39B] to speedometer.

Figure 2-15. Instrument Harness Adapters (Part No. HD-46601)

Figure 2-16. Speedometer Connector [39]

Figure 2-17. Breakout Box (Part No. HD-42682)

10086

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SPEEDOMETER PERFORMANCE CHECK 2.6

GENERAL

See Figure 2-18. Use the SPEEDOMETER TESTER (PartNo. HD-41354) for speedometer diagnostics. These diagnos-tics may include:

● Checking speedometer operation.

● Testing speedometer needle sweeping action.

The tester generates a simulated vehicle speed sensor signalwhich is sent to the ICM/ECM. The ICM/ECM interprets thesignal then sends a message to the speedometer. This signalaids in determining whether speedometer replacement isnecessary.

● Verifies serial data message to speedometer.

NOTES

● Use the following procedures in conjunction with themanual supplied with the speedometer tester.

● Test results may be inaccurate if tester battery is low.

TESTING

NOTE

The SPEEDOMETER TESTER (Part No. HD-41354) cannotbe used to verify the calibration of a speedometer and it willnot verify the speedometer’s function to support legal pro-ceedings. It’s purpose is to verify speedometer function whenperforming service diagnosis or repair. It can also assist indetermining if speedometer replacement is necessary.

Speedometer Operation Test1. See Figure 2-19. Disconnect the 3-place vehicle speed

sensor connector [65] under right side cover (behindelectrical bracket). Attach speedometer tester connector.

2. Place speedometer tester power switch in the ON posi-tion. Place signal switch in the OUT position.

3. Turn vehicle ignition switch ON and Run/Off switch toRun.

4. When speedometer tester displays “P_ _ _ _1”:

a. Press 1 and ENTER on the tester keypad.

b. Enter a frequency from Table 2-7. Note that differentmarkets use different frequencies.

c. Verify that speedometer display reads the corre-sponding speed. To change the test frequency,press CLEAR to cancel and enter the new fre-quency. Press ENTER to begin and reverify.

NOTEThe speedometer should be accurate within -0 to +4 MPH (0to +6.5 KPH).

Figure 2-18. Speedometer Tester (HD-41354)

hd41354

Table 2-7. Speedometer Test Frequency in Hertz (All Models Except Police)

MARKET 20 MPH 40 MPH 60 MPH 80 MPH 30 KPH 60 KPH 100 KPH 130 KPH

DOMESTIC 442 885 1327 1770 - - - -

CANADA - - - - 413 825 1375 1788

HDI - - - - 413 825 1375 1788

GREAT BRITAIN 442 885 1327 1770 413 825 1375 1788

JAPAN - - - - 448 896 1493 1941

Table 2-8. Speedometer Test Frequency in Hertz (Police)

MARKET 20 MPH 40 MPH 60 MPH 80 MPH 30 KPH 60 KPH 100 KPH 130 KPH

DOMESTIC 462 924 1386 1848 - - - -

CANADA - - - - 431 861 1435 1866

HDI - - - - 431 861 1435 1866

GREAT BRITAIN 462 924 1386 1848 431 861 1435 1866

JAPAN - - - - 431 861 1435 1866


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Speedometer Needle Sweep Test

The tester’s sweep function moves the speedometer needlethrough the full range of movement. This allows for testing thesmoothness of operation and checking for hesitancy or astuck needle.

1. See Figure 2-19. Disconnect vehicle speed sensor con-nector. Attach speedometer tester connector to speed-ometer sensor connector.

2. Place speedometer tester power switch in the ON posi-tion. Place signal switch in the OUT position.

3. Turn vehicle ignition switch ON.

4. Begin test by pressing 0 on the tester keypad and thenpressing ENTER. The tester will scan for two seconds,then the tester will put out a 1 Hz signal.

5. Select a test range.

a. Press 2 to select LO range (1-20 Hz).

b. Press 5 to select CEN range (21-999 Hz).

c. Press 8 to select HI range (1000-20,000 Hz).

6. After selecting a range, use the corresponding arrowkeys to accelerate through the range. As you movethrough the speed range, check for smooth needlemovement.

a. If testing LO range, press 1 or 3.

b. If testing CEN range, press 4 or 6.

c. If testing HI range, press 7 or 9.

Vehicle Speed Sensor Test

If the speedometer is inoperative, but backlighting and odom-eter work, the vehicle speed sensor may not be working.

See Figure 2-20. Fabricate a test harness using the followingparts. This harness can also be used to test the tachometer.

● Two Deutsch 3-place socket housings (Part No. 72113-94BK) and six socket terminals (Part No. 72191-94).

● Deutsch 3-place pin housing (Part No. 72103-94BK) andthree pin terminals (Part No. 72190-94).

● Six lengths of 18 gauge wire, each 6.0 in. (15 cm) long.

Before attempting the actual vehicle speed sensor check, twosystem checks must be made. Install the test harness at thespeedometer sensor connector.

● Test for voltage to sensor by checking for 8-12 volts onred wire in connector [65B].

● Then check for continuity to ground on black wire in con-nector [65B].

1. Raise rear wheel off floor.

2. Install the test harness between the vehicle speed sen-sor connectors.

3. Place speedometer tester power switch in the ON posi-tion. Place signal switch in the IN position.

4. Plug the speedometer tester into the test harness. Turnvehicle ignition switch ON.

5. Press ENTER on the tester keypad.

6. Rapidly rotate rear wheel of motorcycle.

a. If reading on speedometer tester changes as wheelis rotated, speedometer sensor is OK.

b. If reading does not change on carbureted models,see 4.18 DTC P0501, P0502. If reading does notchange on EFI models, see 5.25 DTC P0501,P0502.

Figure 2-19. Mate Sensor and Tester Connectors

5087

Speedometer SensorConnector [65]

Tester Connector

Figure 2-20. Test Harness

Deutsch Socket Housings

Deutsch PinHousing

f1437a8x


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FUEL GAUGE OPERATION 2.7

THEORY OF OPERATION

With ignition switch ON, the fuel gauge is connected to +12volts. Current flows through the gauge and variable resistor inthe fuel gauge sending unit to ground. The sending unit floatcontrols the amount of resistance in the variable resistor.

Inoperative gauges may be caused by three circumstances.

● Sender or fuel gauge not grounded.

● Malfunction in sender or fuel gauge.

● Broken or disconnected wire from ignition switch to fuelgauge.

Use the FUEL GAUGE AND SENDER TEST to test suspectcomponents.

FUEL GAUGE AND SENDER TEST

NOTE

Always refer to the applicable wiring diagram (at the rear ofthis manual) when troubleshooting instruments or gauges.

1. Remove gauge. Ground Y/W wire of fuel gauge senderlocated at bottom of gauge. Turn ignition switch ON.

a. Fuel gauge must indicate FULL. If gauge indicatedFULL, gauge is functioning correctly. Proceed tostep 2.

b. If gauge did not indicate FULL, proceed to step 3.

2. Set MULTI-METER (Part No. HD-35500) to RXI scale tomeasure the resistance of the sending unit. Place oneprobe on Y/W and the other probe on a good ground.

FLHT/C/U, FLTR:

If fuel tank is full, the reading should be 7-14 ohms. Anempty tank should have a 74-95 ohm resistance. A halffull tank will be approximately 30-38 ohms.

FLHR/C/S:

If fuel tank is full, the reading should be 27-40 ohms. Anempty tank should have a 240-264 ohm resistance. Ahalf full tank will be approximately 97-118 ohms.

ALL MODELS:

If a very high resistance or infinity is indicated on themeter, the sender may be “open” or not grounded. Checkthat sender and fuel tank are grounded by placing oneprobe of Multi-Meter on sender flange and the otherprobe on crankcase. Meter must indicate one ohm orless. Replace sender if one ohm or less was present. If ahigher resistance is present, check for poor connectionon ground wire.

3. Check voltage to O/W (+) and BK (-) wire of fuel gaugeconnector [117] if gauge did not indicate FULL.

a. Correct reading is equivalent to battery voltage.

b. If battery voltage is not present check for broken ordisconnected wire. Replace gauge if wiring problemis not found.


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INDICATOR LAMPS: FLTR, FLHT/C/U 2.8

GENERAL

See Figure 2-21. All models except FLHR/C/S are equippedwith incandescent indicator lamps which may be replacedindividually. See the Touring Models Service Manual for lampreplacement procedure. See DIAGNOSTICS which followsfor troubleshooting procedures.


Dealership technicians filing warranty claims should use thejob/time code values printed in bold text underneath theappropriate repair.

Diagnostic Notes

The reference number below correlates with the circled num-ber on the Diagnostics flow charts on the next page.

1. Connect BREAKOUT BOX (Part No. HD-42682) (black)between wire harness connector [20A] and instrumentsconnector [20B].

Table 2-9. Indicator Lamp Connector [20]

TERMINAL WIRE

COLORFUNCTION

3 Brown Right Turn

4 White High Beam

5 Violet Left Turn

6 Orange Neutral/Oil Pressure Power

8 Tan Neutral Lamp To Switch

9 Green/Yellow Oil Pressure Lamp To Switch

12 BlackTurn Signal/High Beam

Ground

Table 2-10. Indicator Lamp Wiring

INDICATOR LAMP CONNECTION

Oil pressure Ground Through Switch

Neutral Ground Through Switch

High beam 12 VDC When Active

Right/left turn 12 VDC When Active

Figure 2-21. Indicator Lamp Assembly(FLTR, FLHT/C/U)

N

f1346x2x

RubberBoot

BulbHousing

PaddleLense

Indicator LampConnector [21]


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DIAGNOSTICS

Oil Pressure or Neutral Indicator Will Not Function

High Beam or R/L Turn Signal Indicator Will Not Function

Turn on ignition switch. Check for 12 VDC at Breakout Box terminal 6.

Turn off ignition switch.Was 12 VDC present?

Check for continuity to ground at Breakout Box terminal 8 (neutral) and terminal 9 (oil pressure).


YES

5048

Replace indicator lamp.

YES

Check for blown fuses or locate open.

NO

Check each terminal for continuity to ground through switch.


NO

Repair open in GN/Y wire (oil pressure) or

TN wire (neutral).

YES

Replace oilpressure switch.

NO

Replace neutral switch.

NO

5048

5161 5157

5191

1

Check for ground at Breakout Box terminal 12.

Is ground present?

Check for 12 VDC when circuit is active: Breakout Box terminal 5 (left turn), terminal 3

(right turn) or terminal 4 (high beam). Is voltage present?

YES

5048

Replace indicator lamp.

YES

Locate and repair open in circuit.

NO

Locate and repairopen in circuit.

NO

5191

5048

1


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INDICATOR LAMPS: FLHR/C/S 2.9

GENERAL

FLHR/C/S models are equipped with Light Emitting Diode(LED) indicators. The indicator lamp assembly is not service-able. If one LED is bad, the entire assembly must bereplaced.

See DIAGNOSTICS which follows for troubleshooting proce-dures.


Dealership technicians filing warranty claims should use thejob/time code values printed in bold text underneath theappropriate repair.

Table 2-11. Indicator Lamp Connector [21]

TERMINAL WIRE COLOR FUNCTION

1 Violet Left Turn

2 White High Beam

3 Green/yellow Oil Pressure

4 Brown Right Turn

5 Tan Neutral

6 Orange Neutral/Oil Pressure

7 Black Left Turn/high Beam

8 Not used N/A

Table 2-12. LED Assembly Wiring

INDICATOR LAMP CONNECTION

Oil pressure Ground Through Switch

Neutral Ground Through Switch

High beam 12 VDC When Active

Right/left turn 12 VDC When Active

Figure 2-22. Release Paddles to Free Indicator Lights Assembly (FLHR/C/S)

f2095x8xPaddles


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DIAGNOSTICS

Oil Pressure or Neutral Indicator Will Not Function

High Beam or R/L Turn Signal Indicator Will Not Function

Check for 12 VDC at terminal 6 of connector [21A]. Is 12 VDC present?

Check for continuity to ground on connector [21] at terminal 5 (neutral) and ter-

minal 3 (oil pressure). Is continuity present?

YES

5048

Replace indicator lamp assembly.

YES

Check for blown fuses or find open.

NO

Check each terminal for continuity to ground through switch.


NO

Repair open in GN/Y wire (oil pressure) or

TN wire (neutral).

YES

Replace oilpressure switch.

NO

Replace neutral switch.

NO

5048

5161 5157

5191

Check for ground at terminal 2 of connector [21A]. Is ground present?

Check for 12 VDC when circuit is active. Use terminal 1 (left turn), ter-minal 4 (right turn) and terminal 2

(high beam). Voltage present?

YES

5048

Replace indicator lamp assembly.

YES

Locate and repair open in circuit.

NO

Locate and repairopen in circuit.

NO

5191 5048


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DTC B1004, B1005 2.10

GENERAL

The fuel level is monitored by the speedometer pin 9 of con-nector [39] (Y/W).

● If the voltage on pin 9 of connector [39] exceeds thelower limit for greater than or equall to 15 seconds a DTCB1004 will set.

● If the voltage on pin 9 of connector [39] exceeds theupper limit (or is open) for greater than or equall to 15seconds a DTC B1005 will set.

DIAGNOSTICS

Diagnostic Tips

If fuel gauge is performing erratically (possible false diagnos-tic trouble codes), inspect for unobstructed movement ofsending unit arm. Repair or align as necessary.

Diagnostic Notes

The reference numbers below correlate with the circled num-bers on the 2.10 flow chart.

1. Use HARNESS CONNECTOR TEST KIT (Part No. HD-41404), brown pin probe and patch cord.

2. Connect BREAKOUT BOX (Part No. HD-42682) andINSTRUMENT HARNESS ADAPTERS (Part No. HD-46601) between wire harness and speedometer.

Table 2-13. Code Description

DTC DESCRIPTION

B1004 Fuel level sending unit low.

B1005 Fuel level sending unit high/open.

Figure 2-23. Instrument Harness Adapters (Part No. HD-46601)

Figure 2-24. Speedometer Connector [39]

Figure 2-25. Breakout Box (Part No. HD-42682)

10086

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Figure 2-26. Fuel Sender Circuit



[2] Main to Interconnect HarnessFLHT/C 12-Place Deutsch (Gray)

Inner Fairing - Right Fairing Support Brace


[13] Fuel Tank HarnessFLHT/C 3-Place Multilock Behind Fuel Tank (Under Seat)

FLTR 3-Place Multilock Behind Fuel Tank (Under Seat)



[78] Electronic Control Module All 36-Place Packard Under Right Side Cover


[141] Fuel Level SenderFLHT/C 3-Place Mini-Deutsch Top of Canopy (Under Console)

FLTR 3-Place Mini-Deutsch Top of Canopy (Under Console)

1 5

2

2

6

6

9

9

1

1

7

7

5

5

1 2 3

1 2 3

3

1

2

4

1 2 3

1 2 3

5 5

ECM

Data LinkConnector

LG

N/V 12V

GY

[91A]

[78B]

[78A]

LGN/V

BK

Lt GN/V

Lt GN/R

[39B]

[39A]

Speedometer

BK

Fuel Level Sender

BK

To accessory fuse

To Instrument fuse

GY

O/W

LG

N/R

BK

Y/W

To battery fuse BN/GY[141B]

[141A]

Y/W

[13B]

[13A]

To Fuel Gauge

FLTR, FLHT/C/U Only

[2B][2A]

f2208s8x

Y/W


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Test 2.10: DTC 1004FUEL LEVEL SENDING UNIT

Disconnect speedometer con-nector [39]. Check continuity

between terminal 2 of connec-tor [141B] and ground.

Continuity present?

Locate and repair short to ground.

Repair/replace fuel level sending unit.

YES NO

Clear codes using speedometer self diagnostics.See 2.3 SPEEDOMETER SELF DIAGNOSTICS.Confirm proper operation with no check enginelamp.


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Test 2.10: DTC B1005FUEL LEVEL SENDING UNIT

Check continuity to ground on ter-minal 3 of connector [141B] (BK).


YES

Locate and repair open on BK wire (ground circuit).

NO

Repair/replace fuel level sending unit.

1

Disconnect Speedometer connector [39]. Measure voltage on terminal 2 of connector

[141B] (Y/W). Should be 0 volts. Is it?

YES

YES

Locate and repair short to voltage.

NO

Check continuity between terminal 2 of connector [141B] (Y/W) and breakout box terminal 11 (BK).

Continuity present?2

1

Locate and repair open on Y/W wire.

NO

1

Clear diagnostic trouble codes using speedometerself diagnostics. See 2.3 SPEEDOMETER SELFDIAGNOSTICS. Confirm proper operation with nocheck engine lamp.


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DTC B1006, B1007 2.11

GENERAL

Accessory Or Ignition Line Overvoltage

Ignition and accessory voltage is constantly monitored by thespeedometer (terminal 1-ignition and terminal 6-accessory).If the battery voltage fails to meet normal operating parame-ters, a diagnostic trouble code is set.

● DTC B1006 is displayed when accessory line voltage isgreater than 16.0 volts for longer than 5 seconds.

● DTC B1007 is displayed when ignition line voltage isgreater than 16.0 volts for longer than 5 seconds.

NOTEICM/ECM or TSM/TSSM may also set a battery voltage diag-nostic trouble codes.


DTC DESCRIPTION

B1006 Accessory line overvoltage

B1007 Ignition line overvoltage


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Test 2.11ACCESSORY OR IGNITION LINE OVERVOLTAGE: DTC B1006/B1007

Is battery charger connected?

YES

System normal.

NO

Diagnose charging system. See Charging System.

YES NO

Disconnect battery charger. Clear codes.

NOTESometimes battery charger may cause

overvoltage condition which will set codes.

Start vehicle. Run at 3000 RPM for 5 seconds. Does

code reset?

Diagnose charging system. See Charging System.



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DTC B1008 2.12

GENERAL

Reset Switch Closed

DTC B1008 will be set if switch terminals are in a constantshorted state.

DIAGNOSTICS

Diagnostic Notes

The reference numbers below correlate with the circled num-bers on the 2.12 flow chart.

1. Connect BREAKOUT BOX (Part No. HD-42682) andINSTRUMENT HARNESS ADAPTERS (Part No. HD-46601) between wire harness and speedometer, leavingspeedometer disconnected.


DTC DESCRIPTION

B1008 Reset switch closed


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Figure 2-27. Reset Switch Circuit





123456789

101112

d0723x2x

[39B][39A]

BK

Speedometer

Reset Switch

BK


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Test 2.12

RESET SWITCH CLOSED: DTC B1008

Remove reset switch rubber boot. Clear codes using 2.3 SPEEDOM-

ETER SELF DIAGNOSTICS. Codes still present?

YES

NO

Replace switch.

NO

Replace boot.

YES

Replace speedometer.

1


With speedometer disconnected, measure resistance between terminals 8 and 11

(black) on Breakout Box. Resistance should be less than 1 ohm with switch depressed

and infinity ohms when released. Is it?


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DTC U1016 2.13

GENERAL

Loss of ICM/ECM Serial Data

The serial data connector provides a means for the ignitioncontrol module (ICM) or electronic control module (ECM),TSM/TSSM and speedometer to communicate their currentstatus. When all operating parameters on the serial data busare within specifications, a state of health message is sentbetween the components. A DTC U1016 indicates that theICM/ECM is not capable of sending this state of health mes-sage.

DIAGNOSTICS

Diagnostic Notes

The reference numbers below correlate with the circled num-bers on the Test 2.13 flow chart.

1. Connect BREAKOUT BOX (Part No. HD-42682) (gray)between TSM/TSSM connector [30A] and wire harnessconnector [30B]. See 3.11 BREAKOUT BOX: TSM/TSSM.

2. Connect BREAKOUT BOX (Part No. HD-42682) (black)between ICM connector [10A] and wiring harness con-nector [10B]. See 4.6 BREAKOUT BOX: ICM

3. Connect BREAKOUT BOX (Part No. HD-43876)between wire harness and ICM/ECM. See 5.7 BREAK-OUT BOX: EFI.


DTC DESCRIPTION

U1016

Loss of all ICM/ECM serial data (state of health)

Loss of vehicle speed

Loss of vehicle inhibit motion

Loss of powertrain security status

Figure 2-28. Data Link Connector

692414

32

5

1. Terminal 1: flash pin-EFI models (Lt GN/R)2. Terminal 2: ground (BK)3. Terminal 3: serial data (Lt GN/V)4. Terminal 4: power (GY)5. Protective cap

Figure 2-29. Electrical Bracket (Under Right Side Cover)

f2191x8x

Ignition Control ModuleConnector [10]

f1917x9x

Electronic ControlModule Connector [78]Fuel Injected

Carbureted


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Figure 2-30. Serial Data Circuit: FLHT/C (Carbureted)













12

12

3

1

2

4

321 654 987 121110321 654 987 121110

321 654 987 121110321 654 987 121110

321 654 987 121110321 654 987 121110

1011

127

89

45

61

23

1011

127

89

45

61

23

321 654 987 121110321 654 987 121110

2

43

1

56

2

43

1

56

321 654 987 121110321 654 987 121110


Data Link

TSM/TSSM

LtG

N/V

15AIgnition

Fuse

GY

[8B][8A]

[91A]

LtGN/V

BK

LtGN/V

[39B][39A]

[10B][10A]

Speedometer

O

BK

Ser

ial d

ata


BN/GY

[156B] [156A]

[30B][30A]

15AAccessory

Fuse

[1B] [1A]


Ignition Harness


f2208z8x

15ABattery

Fuse

[2A][2B]


BK

GY

BN/GY


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Figure 2-31. Serial Data Circuit: FLHR/S (Carbureted)









321 654 987 121110321 654 987 121110

321 654 987 121110321 654 987 121110

321 654 987 121110321 654 987 121110

3

1

2

4

12

12

Data Link

TSM/TSSM

LtG

N/V

GY

[30B][30A]

[91A]

LtGN/V

BK[39B][39A]

[10B][10A]

Speedometer

O

BK

Ser

ial d

ata


BN/GY

15AIgnition

Fuse

15AAccessory

Fuse

LtGN/V

[8B][8A]

Ignition Harness

15ABattery

Fuse

f2208y8x

BK

BN/GY

GY


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Figure 2-32. Serial Data Circuit: FLTR, FLHT/C/U (Fuel Injected)






















51

3

1

2

4

321 654 987 121110321 654 987 121110

321 654 987 121110321 654 987 121110

321 654 987 121110321 654 987 121110

1011

127

89

45

61

23

1011

127

89

45

61

23

321 654 987 121110321 654 987 121110

321 654 987 121110321 654 987 121110

2

43

1

56

2

43

1

56

ECM

Data Link

TSM/TSSM

LtG

N/V

15AIgnition

Fuse

GY

[8B][8A]

[91A]

LtGN/V

BK

LtGN/V

[39B][39A]

[78B][78A]

Speedometer

O

BK

Ser

ial d

ata

[108B][108A]

Tachometer

BN/GY

[156B] [156A]

[30B][30A]

15AAccessory

Fuse

[1B] [1A]


Ignition Harness


f2208u8x

15ABattery

Fuse

[2B][2A]


LtG

N/R

BK

BN/GY

GY

Fla

sh p

in


HOME

Figure 2-33. Serial Data Circuit: FLHR/C/S (Fuel Injected)










51

321 654 987 121110321 654 987 121110

321 654 987 121110321 654 987 121110

321 654 987 121110321 654 987 121110

3

1

2

4

f2208t8x

Data Link

TSM/TSSM

LtG

N/V

GY

[30B][30A]

[91A]

LtGN/V

BK[39B][39A]

[78B][78A]

Speedometer

O

BK

ECM

BN/GY

15AIgnition

Fuse

15AAccessory

Fuse

LtGN/V

[8B][8A]

Ignition Harness

15ABattery

Fuse

LtG

N/R

BK

BN/GY

GY

Ser

ial d

ata

Fla

sh p

in


HOME

Test 2.13

LOSS OF ICM/ECM SERIAL DATA: DTC U1016

Can you read ECM/ICM hardware P/N? See 2.3 SPEEDOMETER SELF DIAGNOSTICS.

NO or “No Rsp”YES

YES

NO

Repair open on LtGN/V wire.

Install Breakout Box on TSM/TSSM1

Replace ICM. Reprogram and learn

password.

CARBURETED MODELS

EFI MODELS

Check continuity between termi-nal 2 (black) of speedometer

Breakout Box and terminal 5 of ECM Breakout Box.Continuity present?

2 3

YES

Replace ECM. Reprogram and learn

password.

Check continuity between termi-nal 3 (gray) of TSM/TSSM break-

out box and terminal 5 of ECM breakout box.

Continuity present?

Install Breakout Box on TSM/TSSM.1

CARBURETED MODELS EFI MODELS2 3

YES

NO

While wiggling harness, check continuity between breakout box terminal 3 (gray) and breakout

box terminal 12 (black).Continuity present?

YES

While wiggling harness, check conti-nuity between terminal 3 (gray) of

TSM/TSSM breakout box and termi-nal 5 of ECM Breakout Box.

Continuity present?

Clear codes. Test ride. Does DTC U1016

return?Repair intermittent on LtGN/V wire.

YES

Replace ICM. Reprogram and learn

password.

NO

No trouble found.

Clear codes. Test ride. Did DTC U1016 return?

Replace ECM. Reprogram and learn

password.

YES NO

No trouble found.

Check continuity between breakout box terminal 3 (gray) and breakout box

terminal 12 (black).Continuity present?



HOME

DTC U1064, U1255 2.14

GENERAL

Loss of TSM/TSSM Serial Data

The serial data connector provides a means for the ignitioncontrol module (ICM) or electronic control module (ECM),TSM/TSSM and speedometer to communicate their currentstatus. When all operating parameters on the serial data busare within specifications, a state of health message is sentbetween the components. A DTC U1064 indicates that theTSM/TSSM is not receiving this state of health message.

DIAGNOSTICS

Diagnostic Notes

The reference numbers below correlate with the circled num-bers on the Test 2.14 flow chart.

1. Connect BREAKOUT BOX (Part No. HD-42682) as fol-lows:

a. Mate black socket housing on Breakout Box withspeedometer connector [39] using SPEEDOMETERHARNESS ADAPTER (Part No. HD-46601).

b. Mate black pin housing on Breakout Box with speed-ometer harness connector [39B] using SPEEDOM-ETER HARNESS ADAPTER (Part No. HD-46601).

c. Mate gray socket housing on Breakout Box withTSM/TSSM connector [30A].

d. Mate gray pin housing on Breakout Box with har-ness connector [30B].


DTC DESCRIPTION

U1064 Loss of TSM/TSSM serial data

U1255 Serial data error/missing message

Figure 2-34. Frame Crossmember (Under Seat)

Figure 2-35. Data Link Connector

f2013x8x

Turn Signal/SecurityModule

SpringClip

692414

32

5

1. Terminal 1: flash pin-EFI models (Lt GN/R)2. Terminal 2: ground (BK)3. Terminal 3: serial data (Lt GN/V)4. Terminal 4: power (GY)5. Protective cap


HOME

Figure 2-36. Serial Data Circuit: FLHT/C (Carbureted)













12

12

3

1

2

4

321 654 987 121110321 654 987 121110

321 654 987 121110321 654 987 121110

321 654 987 121110321 654 987 121110

1011

127

89

45

61

23

1011

127

89

45

61

23

321 654 987 121110321 654 987 121110

2

43

1

56

2

43

1

56

321 654 987 121110321 654 987 121110


Data Link

TSM/TSSM

LtG

N/V

15AIgnition

Fuse

GY

[8B][8A]

[91A]

LtGN/V

BK

LtGN/V

[39B][39A]

[10B][10A]

Speedometer

O

BK

Ser

ial d

ata


BN/GY

[156B] [156A]

[30B][30A]

15AAccessory

Fuse

[1B] [1A]


Ignition Harness


f2208z8x

15ABattery

Fuse

[2A][2B]


BK

GY

BN/GY


HOME

Figure 2-37. Serial Data Circuit: FLHR/S (Carbureted)









321 654 987 121110321 654 987 121110

321 654 987 121110321 654 987 121110

321 654 987 121110321 654 987 121110

3

1

2

4

12

12

Data Link

TSM/TSSM

LtG

N/V

GY

[30B][30A]

[91A]

LtGN/V

BK[39B][39A]

[10B][10A]

Speedometer

O

BK

Ser

ial d

ata


BN/GY

15AIgnition

Fuse

15AAccessory

Fuse

LtGN/V

[8B][8A]

Ignition Harness

15ABattery

Fuse

f2208y8x

BK

BN/GY

GY


HOME

Figure 2-38. Serial Data Circuit: FLTR, FLHT/C/U (Fuel Injected)






















51

3

1

2

4

321 654 987 121110321 654 987 121110

321 654 987 121110321 654 987 121110

321 654 987 121110321 654 987 121110

1011

127

89

45

61

23

1011

127

89

45

61

23

321 654 987 121110321 654 987 121110

321 654 987 121110321 654 987 121110

2

43

1

56

2

43

1

56

ECM

Data Link

TSM/TSSM

LtG

N/V

15AIgnition

Fuse

GY

[8B][8A]

[91A]

LtGN/V

BK

LtGN/V

[39B][39A]

[78B][78A]

Speedometer

O

BK

[108B][108A]

Tachometer

BN/GY

[156B] [156A]

[30B][30A]

15AAccessory

Fuse

[1B] [1A]


Ignition Harness


f2208u8x

15ABattery

Fuse

[2B][2A]


LtG

N/R

BK

BN/GY

GY

Ser

ial d

ata

Fla

sh p

in


HOME

Figure 2-39. Serial Data Circuit: FLHR/C/S (Fuel Injected)










51

321 654 987 121110321 654 987 121110

321 654 987 121110321 654 987 121110

321 654 987 121110321 654 987 121110

3

1

2

4

f2208t8x

Data Link

TSM/TSSM

LtG

N/V

GY

[30B][30A]

[91A]

LtGN/V

BK[39B][39A]

[78B][78A]

Speedometer

O

BK

ECM

BN/GY

15AIgnition

Fuse

15AAccessory

Fuse

LtGN/V

[8B][8A]

Ignition Harness

15ABattery

Fuse

LtG

N/R

BK

BN/GY

GY

Ser

ial d

ata

Fla

sh p

in


HOME

Test 2.14

LOSS OF TSM/TSSM SERIAL DATA: DTC U1064, U1255

Can you read TSM/TSSM hardware P/N? See 2.3 SPEEDOMETER SELF DIAGNOSTICS.

NO or “No Rsp”YES

YESNO

Repair open on LtGN/V wire.

Install Breakout Box on speedometer.Check for continuity between terminal 3 (gray) and terminal 2 (black) of Breakout

Box Continuity present?

1Install Breakout Box on speedometer.While wiggling harness, check for continuity

between terminal 3 (gray) and terminal 2 (black) of Breakout Box.

Continuity present?

YES

Repair intermittent on LtGN/V wire.

NO

1

Clear codes. Test ride. Does DTC U1064

return?

YES NO

No trouble found.

Replace TSM/TSSM. Learn password.

Replace TSM/TSSM. Learn password.



HOME

DTC U1300, U1301 OR “BUS ER” 2.15

GENERAL

Serial Data Low or Serial data Open/High

See Figure 2-40. The typical serial data voltage range is 0volts (inactive) to 7 volts (active). Due to the short pulse, volt-ages will be much lower on a DVOM. In analog mode, aDVOM reading serial data will show continuous voltage whenactive, typically 0.6-0.8 volts. The range for acceptable opera-tions is 0-7.0 volts.

DIAGNOSTICS

Diagnostic Tips

● If serial data is shorted, these diagnostic trouble codes(DTCs) will automatically cause the check engine lampto illuminate. The odometer will read “Bus Er” in this con-dition.

● Diagnostic trouble codes (DTCs) P1009 and P1010 mayaccompany DTCs U1300 and U1301.

Diagnostic Notes

● If a U1300, U1301 or “BUS Er” is present on carburetedmodels, perform diagnostic procedures listed in 4.10STARTS, THEN STALLS.

● If a U1300, U1301 or “BUS Er” is present on EFI models,perform diagnostic procedures listed in 5.12 STARTS,THEN STALLS.


DTC DESCRIPTION

U1300 Serial data low

U1301 Serial data open/high

Figure 2-40. Electrical Bracket (Under Right Side Cover)

f2191x8x

Data LinkConnector [91]

f1917x9x

Data LinkConnector [91]Fuel Injected

Carbureted


2004 CHECKING FOR DIAGNOSTIC TROUBLE CODES 2 · 2004 Touring: Instruments 2-3 HOME CODE TYPES There...

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