harley davidson service manual dyna 2008 electrical diagnostic manual

2008 Dyna Models ElectricalDiagnostics Manual

©2007 H-D.ALL RIGHTS RESERVED

99496-08

Printed in the U.S.A.

VISIT THE HARLEY-DAVIDSON WEB SITEhttp://www.harley-davidson.com

ABOUT THIS MANUAL

GENERALThis electrical diagnostic service manual has been preparedwith two purposes in mind. First, it will acquaint the user withthe construction of the Harley-Davidson product and assist inthe performance of repair. Secondly, it will introduce to theprofessional Harley-Davidson Technician the latest field-testedand factory-approved diagnostic methods.We sincerely believethat this manual will make your association with Harley-Dav-idson products more pleasant and profitable.

HOW TO USE YOUR SERVICE MANUALRefer to the table below for the content layout of this manual.

CHAPTERNO.

Starting / Charging1

Instruments2

TSM/HFSM3

Engine Management4

Appendix A Connector RepairA

Appendix B WiringB

Appendix C ConversionsC

Appendix D GlossaryD

Appendix E TSM/TSSM (Japan/Korea)E

Use the TABLE OF CONTENTS (which follows this FORE-WORD) and the INDEX (at the back of this manual) to quicklylocate subjects. Sections and topics in this manual aresequentially numbered for easy navigation.

For example, a cross-reference shown as 2.1 SPECIFICA-TIONS refers to chapter 2 CHASSIS, heading 2.1 SPECIFIC-ATIONS.

For quick and easy reference, all pages contain a sectionnumber followed by a page number. For example, page 3-5refers to page 5 in section 3.

A number of acronyms and abbreviations are used in thisdocument. See the D.1 GLOSSARY for a list of acronyms,abbreviations and definitions.

PREPARATION FOR SERVICE

Stop the engine when refueling or servicing the fuelsystem. Do not smoke or allow open flame or sparks neargasoline. Gasoline is extremely flammable and highlyexplosive, which could result in death or serious injury.(00002a)

Good preparation is very important for efficient service work.A clean work area at the start of each job will allow you toperform the repair as easily and quickly as possible, and willreduce the incidence of misplaced tools and parts. A motorcyclethat 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 begathered before work is started. Interrupting a job to locatetools 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 ofa part indicates the quantity necessary for one completeassembly.

• When servicing a vehicle equipped with the Harley-Dav-idson Smart Security System (H-DSSS), you must firstdisarm the security system. Either keep the fob in closeproximity to the vehicle, or use Digital Technician to disablethe security system while the vehicle is being serviced andre-enable the system after service is completed.

SERVICE BULLETINSIn addition to the information presented in this Service Manual,Harley-Davidson Motor Company will periodically issue ServiceBulletins to Harley-Davidson dealers. Service Bulletins coverinterim engineering changes and supplementary information.Consult the Service Bulletins to keep your product knowledgecurrent and complete.

USE GENUINE REPLACEMENT PARTS

Do not use aftermarket parts and custom made front forkswhich can adversely affect performance and handling.Removing or altering factory installed parts can adverselyaffect performance and could result in death or seriousinjury. (00001a)

To ensure satisfactory and lasting repairs, carefully follow theService Manual instructions and use only genuine Harley-Davidson replacement parts. Behind the emblem bearing thewords GENUINE HARLEY-DAVIDSON stand more than 100years of design, research, manufacturing, testing and inspectingexperience.This is your assurance that the parts you are usingwill fit right, operate properly and last longer.

WARNINGS AND CAUTIONSStatements in this service manual preceded by the followingwords are of special significance.

WARNING indicates a potentially hazardous situationwhich, if not avoided, could result in death or seriousinjury. (00119a)

CAUTION indicates a potentially hazardous situationwhich, if not avoided, may result in minor or moderateinjury. (00139a)

CAUTION used without the safety alert symbol indicatesa potentially hazardous situation which, if not avoided,may result in property damage. (00140a)

I

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RD

NOTE

Refers to important information, and is placed in italic type. Itis recommended that you take special notice of these items.

Proper service and repair is important for the safe, reliableoperation of all mechanical products. The service proceduresrecommended and described in this service manual areeffective 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 partscould result in death or serious injury. (00496b)

Some of these service operations require the use of toolsspecially designed for the purpose.These special tools shouldbe used when and as recommended. It is important to notethat some warnings against the use of specific service methods,which could damage the motorcycle or render it unsafe, arestated in this service manual. However, please remember thatthese warnings are not all-inclusive. Inadequate safety precau-tions could result in death or serious injury.

Since Harley-Davidson could not possibly know, evaluate oradvise the service trade of all possible ways in which servicemight be performed, or of the possible hazardous con-sequences of each method, we have not undertaken any suchbroad evaluation. Accordingly, anyone who uses a serviceprocedure or tool which is not recommended by Harley-Dav-idson must first thoroughly satisfy himself that neither his northe operator's safety will be jeopardized as a result. Failure todo so could result in death or serious injury.

PRODUCT REFERENCES

Read and follow warnings and directions on all products.Failure to follow warnings and directions can result indeath or serious injury. (00470b)

When reference is made in this manual to a specific brandname product, tool or instrument, an equivalent product, toolor instrument may be substituted.

Kent-Moore ProductsAll tools mentioned in this manual with an "HD", "J" or "B"preface must be ordered through SPX Kent-Moore. For ordering

information or product returns, warranty or otherwise, visitwww.spx.com.

Loctite Sealing and Threadlocking ProductsSome procedures in this manual call for the use of Loctiteproducts. If you have any questions regarding Loctite productusage or retailer/wholesaler locations, please contact LoctiteCorp. at www.loctite.com.

PRODUCT REGISTERED MARKSAllen, Amp Multilock, Bluetooth, Brembo, Delphi, Deutsch,Dunlop, Dynojet, Fluke, G.E. Versilube, Gunk, Hydroseal,Hylomar, Kevlar, Lexan, Loctite, Lubriplate, Keps, K&N, Mag-naflux, Marson Thread-Setter Tool Kit, MAXI fuse, Molex, MPZ,Mulitilock, Novus, Packard, Pirelli, Permatex, Philips, PJ1,Pozidriv, Robinair, S100, Sems, Snap-on, Teflon, Threadlocker,Torca, Torco, TORX, Tufoil, Tyco, Ultratorch, Velcro, X-Acto,and XM Satellite Radio are among the trademarks of theirrespective owners.

H-D MICHIGAN, INC.TRADEMARKINFORMATIONHarley, Harley-Davidson, H-D, Bar & Shield, Digital Tech,Digital Technician, Destroyer, Deuce, Dyna, Electra Glide,Evolution, Fat Boy, Glaze, Gloss, H-D, H-Dnet.com, HD, Harley,Heritage Softail, Heritage Springer, Low Rider, Night Rod, NightTrain, Profile, Revolution, Road Glide, Road King, Rocker,Softail, Sportster, Sun Ray, Sunwash, Tech Link, Twin Cam88, Twin Cam 88B, Twin Cam 96, Twin Cam 96B, Twin Cam103, Twin Cam 103B, Twin Cam 110, Twin Cam 110B, Tour-Pak, Screamin' Eagle, Softail, Super Guide, Super Premium,SYN3, Ultra Glide, V-Rod, VRSC, V-Rod, VRSC, Wide Glide,and Harley-Davidson Genuine Motor Parts and Genuine MotorAccessories are among the trademarks of H-D Michigan, Inc.

CONTENTSAll photographs, illustrations and procedures may not neces-sarily depict the most current model or component, but arebased on the latest production information available at the timeof publication.

Since product improvement is our continual goal, Harley-Dav-idson reserves the right to change specifications, equipmentor designs at any time without notice and without incurringobligation.

II FOREWORD

STARTING / CHARGING

1.1 STARTER TROUBLESHOOTINGGeneral...............................................................................1-1Starter Troubleshooting......................................................1-1

1.2 STARTING SYSTEM DIAGNOSISDiagnostics.........................................................................1-3

Diagnostic Notes.........................................................1-3Job/Time Code Values................................................1-3

1.3 DIAGNOSTICS/TROUBLESHOOTINGVoltage Drop.....................................................................1-12

1.4 STARTER ACTIVATION CIRCUITSStarter Activation Circuits.................................................1-13

1.5 TESTING STARTER ON MOTORCYCLEStart Relay Test................................................................1-14Starter Current Draw Test.................................................1-14

1.6 TESTING STARTER ON BENCHFree Running Current Draw Test......................................1-15Starter Solenoid................................................................1-15Solenoid Pull-In Test.........................................................1-15Solenoid Hold-In Test........................................................1-15Solenoid Return Test........................................................1-16

1.7 CHARGING SYSTEMGeneral.............................................................................1-17

Alternator...................................................................1-17Voltage Regulator......................................................1-17

Troubleshooting................................................................1-17Battery.......................................................................1-17Wiring........................................................................1-17Voltage Regulator Inspection....................................1-17Job/Time Code Values..............................................1-17

Testing..............................................................................1-21Milliampere Draw Test...............................................1-21Total Current Draw Test.............................................1-21Current and Voltage Output Test: Using HD-48053....1-22Current and Voltage Output Test: Using LoadTester.........................................................................1-22Stator Check..............................................................1-23AC Output Check......................................................1-23

1.8 BATTERY TESTINGGeneral.............................................................................1-24Voltmeter Test...................................................................1-24Conductance Test.............................................................1-24Load Test..........................................................................1-24

INSTRUMENTS

2.1 CHECKING FOR DIAGNOSTIC TROUBLECODESCheck Engine Lamp...........................................................2-1Security Lamp....................................................................2-2

Turn Signal Module (TSM)..........................................2-2Turn Signal Security Module (TSSM) or Hands FreeSecurity Module (HFSM).............................................2-2

Code Types.........................................................................2-3Current........................................................................2-3Historic........................................................................2-3

Retrieving Diagnostic Trouble Codes..................................2-3Multiple Diagnostic Trouble Codes.....................................2-4

2.2 INITIAL DIAGNOSTIC CHECK:SPEEDOMETERGeneral...............................................................................2-5

Diagnostic Notes.........................................................2-5Circuit Diagram/Wire Harness Connector Table..........2-5Job/Time Code Values................................................2-5Reprogramming ECM..................................................2-5

Initial Diagnostics...............................................................2-6Diagnostic Tips............................................................2-6Diagnostic Notes.........................................................2-6Other Diagnostic Trouble Codes (DTCs).....................2-7

2.3 SPEEDOMETER SELF DIAGNOSTICSGeneral.............................................................................2-12Diagnostics.......................................................................2-12

Diagnostic Tips..........................................................2-12Diagnostic Notes.......................................................2-12

2.4 SPEEDOMETER/TACHOMETERGeneral.............................................................................2-15

Trip Odometer Reset Switch.....................................2-15Speedometer Theory of Operation...................................2-15Odometer Theory of Operation.........................................2-16Tachometer Theory of Operation......................................2-16Diagnostics.......................................................................2-16

Diagnostic Notes.......................................................2-16

2.5 BREAKOUT BOX:SPEEDOMETER/TACHOMETERGeneral.............................................................................2-19Speedometer....................................................................2-19

Installation.................................................................2-19Removal....................................................................2-19

Tachometer.......................................................................2-19Installation.................................................................2-19Removal....................................................................2-19

2.6 FUEL GAUGETheory of Operation.........................................................2-20Fuel Gauge and Sender Test............................................2-20

2.7 INDICATOR LAMPS: ALL BUTFXDWG/FXDC/FXDFGeneral.............................................................................2-21

Job/Time Code Values..............................................2-21DIAGNOSTICS.................................................................2-21


2.8 INDICATOR LAMPS: FXDWG/FXDC/FXDFGeneral.............................................................................2-24

Job/Time Code Values..............................................2-24Diagnostics.......................................................................2-24


2.9 DTC B1004, B1005General.............................................................................2-27Diagnostics.......................................................................2-27


III

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2.10 DTC B1006, B1007General.............................................................................2-31

Accessory or Ignition Line Overvoltage.....................2-31

2.11 DTC B1008General.............................................................................2-33

Trip Odometer Reset Switch Closed.........................2-33Diagnostics.......................................................................2-33


2.12 DTC U1016, U1255General.............................................................................2-36

Loss of ECM Serial Data...........................................2-36Diagnostics.......................................................................2-36


2.13 DTC U1064, U1255General.............................................................................2-39

Loss of TSM/TSSM/HFSM Serial Data.....................2-39Diagnostics.......................................................................2-39


2.14 DTC U1300, U1301 OR BUS ERGeneral.............................................................................2-42

Serial Data Low or Serial Data Open/High................2-42Diagnostics.......................................................................2-42


TSM/HFSM

3.1 TURN SIGNAL OVERVIEWGeneral...............................................................................3-1Security System: Japan/Korea...........................................3-1Turn Signal Functions.........................................................3-1Manual Cancellation...........................................................3-1Automatic Cancellation.......................................................3-1Bank Angle Functions........................................................3-1Bank Angle Restart............................................................3-1Clutch/Neutral Interlock......................................................3-1Security System H-DSSS...................................................3-1

3.2 HARLEY-DAVIDSON SMART SECURITYSYSTEMComponents.......................................................................3-2Security Immobilization......................................................3-2HFSM Features..................................................................3-3

3.3 H-DSSS ACTUATIONGeneral...............................................................................3-5Sidecar Configuration.........................................................3-5Actuation............................................................................3-5Fob Assignment..................................................................3-5Power Disruption and Configuring......................................3-5

3.4 PERSONAL IDENTIFICATION NUMBER(PIN)General...............................................................................3-6Initial Pin Entry...................................................................3-6

Changing the Pin................................................................3-6Modifying an Existing Pin............................................3-6

3.5 ARMING/DISARMING SECURITYSYSTEMHands-Free Fob..................................................................3-8Security Lamp (Key Icon)...................................................3-8Arming................................................................................3-8Disarming...........................................................................3-9Disarming with a Personal Identification Number (PIN).....3-9

3.6 WARNINGS AND ALARMSWarnings..........................................................................3-10Alarm................................................................................3-10

Activation...................................................................3-10Deactivation...............................................................3-10

Siren Chirp Mode (Confirmation)......................................3-10Chirpless Mode.........................................................3-10Chirp Mode................................................................3-10Switching Modes.......................................................3-10

3.7 SERVICE/EMERGENCY FUNCTIONSTransport Mode................................................................3-11

To Enter Transport Mode...........................................3-11To Exit Transport Mode..............................................3-11

Service Mode...................................................................3-11Four-Way Flashing...........................................................3-11

To Arm the HFSM with the Hazard Warning FlashersON.............................................................................3-11To Disarm the HFSM and Turn the Hazard WarningFlashers OFF............................................................3-11

3.8 TROUBLESHOOTINGTurn Signals (TSM/HFSM)...............................................3-12Security System (HFSM)..................................................3-12Diagnostics Mode.............................................................3-12Troubleshooting................................................................3-12

3.9 CHECKING FOR DIAGNOSTIC TROUBLECODESGeneral.............................................................................3-13Security Lamp Diagnostics...............................................3-13Code Types.......................................................................3-14

Current......................................................................3-15Historic......................................................................3-15

Retrieving DTCs...............................................................3-15Multiple DTCs/Priority Order............................................3-15

3.10 INITIAL DIAGNOSTIC CHECK:TSM/HFSMGeneral.............................................................................3-17

Diagnostic Notes.......................................................3-17Circuit Diagram/Wire Harness Connector Table........3-17Job/Time Codes........................................................3-17Reprogramming ECM................................................3-17

Initial Diagnostics.............................................................3-17Diagnostic Tips..........................................................3-17Diagnostic Notes.......................................................3-17Other Diagnostic Trouble Codes (DTCs)...................3-17

IV TABLE OF CONTENTS

TABLE OF CONTENTS



3.12 BREAKOUT BOX:TSM/HFSMGeneral.............................................................................3-24Installation........................................................................3-24Removal...........................................................................3-24

3.13 FAILS TO DISARM (HFSM ONLY)General.............................................................................3-26Job/Time Codes...............................................................3-26Diagnostics.......................................................................3-26


3.14 DTC B0563General.............................................................................3-29Diagnostics.......................................................................3-29


3.15 TSM/HFSM:TURN SIGNAL ERRORSAND DTCSGeneral.............................................................................3-30Diagnostics.......................................................................3-30

Job/Time Codes........................................................3-30Diagnostic Tips..........................................................3-30Diagnostic Notes: All Turn Signal Flow Charts..........3-32

3.16 DTC B1131, B1132 (HFSM ONLY)General.............................................................................3-43Diagnostics.......................................................................3-43


3.17 DTC B1134 STARTER OUTPUT HIGHGeneral.............................................................................3-46Diagnostics.......................................................................3-46


3.18 DTC B1135Diagnostics.......................................................................3-49

DTC B1135 Accelerometer Fault..............................3-49

3.19 DTC B1136, B1142 (HFSM ONLY)Diagnostics.......................................................................3-50

DTC B1136 Accelerometer Tip-Over Self-TestFault..........................................................................3-50DTC B1142 Internal Fault..........................................3-50

3.20 DTC B1141 (HFSM ONLY)Diagnostics.......................................................................3-51


3.21 DTC B1143, B1144, B1145 (HFSMONLY)General.............................................................................3-56Diagnostics.......................................................................3-56


3.22 DTC B1154, B1155Diagnostics.......................................................................3-61


3.23 DTC U1016, U1255General.............................................................................3-65Diagnostics.......................................................................3-65


3.24 DTC U1300, U1301 OR BUS ERDiagnostics.......................................................................3-68


3.25 TSM/HFSM: PASSWORD LEARNGeneral.............................................................................3-69Password Learning...........................................................3-69

3.26 HFSM MAINTENANCEGeneral.............................................................................3-70Hands-Free Fob................................................................3-70

Schedule...................................................................3-70Battery Replacement.................................................3-70

Smart Siren (If Installed)...................................................3-70Schedule...................................................................3-70Battery Replacement - Early Siren............................3-70Battery Replacement - Late Siren.............................3-70

ENGINE MANAGEMENT

4.1 SPECIFICATIONSSpecifications.....................................................................4-1

4.2 EFI SYSTEMGeneral...............................................................................4-2Troubleshooting..................................................................4-2

4.3 EFI DIAGNOSTIC INTRODUCTIONSystem Problems...............................................................4-4

No Start.......................................................................4-4Poor Performance.......................................................4-4Check Engine Lamp....................................................4-4

Resolving Problems............................................................4-4

4.4 CHECKING FOR DIAGNOSTIC TROUBLECODES: EFICheck Engine Lamp...........................................................4-5Code Types.........................................................................4-6

Current........................................................................4-6Historic........................................................................4-6

Retrieving Diagnostic Trouble Codes..................................4-6Multiple Diagnostic Trouble Codes.....................................4-6

TABLE OF CONTENTS V

TABLE OF CONTENTS

4.5 INITIAL DIAGNOSTIC CHECK: EFIGeneral...............................................................................4-8

Diagnostic Notes.........................................................4-8Circuit Diagram/Wire Harness Connector Table..........4-8Reprogramming ECM..................................................4-8

Initial Diagnostics...............................................................4-8General Information.....................................................4-8Diagnostic Tips............................................................4-8Diagnostic Notes.........................................................4-8Other Diagnostic Trouble Codes (DTCs).....................4-8



4.7 BREAKOUT BOX: EFIGeneral.............................................................................4-20Installation........................................................................4-20Removal...........................................................................4-20

4.8 WIGGLE TESTGeneral.............................................................................4-21Procedure.........................................................................4-21

4.9 INTAKE LEAK TESTGeneral.............................................................................4-22Leak Tester.......................................................................4-22

Parts List...................................................................4-22Tester Assembly........................................................4-22Tester Adjustment......................................................4-22

Procedure.........................................................................4-22

4.10 ENGINE CRANKS, BUT WILL NOTSTARTGeneral.............................................................................4-24Diagnostics.......................................................................4-24

Diagnostic Notes.......................................................4-24Diagnostic Tips..........................................................4-24

4.11 NO ECM POWERGeneral.............................................................................4-31

No Spark/No Check Engine Lamp at Key On............4-31Diagnostics.......................................................................4-31


4.12 STARTS,THEN STALLSGeneral.............................................................................4-35

Diagnostic Trouble Codes U1300, U1301, or BUSER.............................................................................4-35

Diagnostics.......................................................................4-35Diagnostic Tips..........................................................4-35Diagnostic Notes.......................................................4-35

4.13 FUEL SYSTEM ELECTRICAL TESTGeneral.............................................................................4-40Diagnostics.......................................................................4-40


4.14 SYSTEM RELAY FAULTGeneral.............................................................................4-47

System Relay............................................................4-47Diagnostics.......................................................................4-47


4.15 FUEL PRESSURE TESTGeneral.............................................................................4-53Testing..............................................................................4-53Diagnostics.......................................................................4-54


4.16 IDLE AIR CONTROLGeneral.............................................................................4-57

IAC Operation............................................................4-57Diagnostic Trouble Code P0505: Loss of Idle SpeedControl.......................................................................4-57

Diagnostics.......................................................................4-57Diagnostic Tips..........................................................4-57Diagnostic Notes.......................................................4-57

4.17 MISFIRE AT IDLE OR UNDER LOADGeneral.............................................................................4-62

Misfire at Idle or Under Load.....................................4-62Diagnostics.......................................................................4-62


4.18 COMBUSTION ABSENT INTERMITTENTGeneral.............................................................................4-68

Diagnostic Trouble Codes P1353, P1356, P1357, P1358:No Combustion..........................................................4-68

Diagnostics.......................................................................4-68Diagnostic Notes.......................................................4-68

4.19 DTC P0107, P0108General.............................................................................4-73

MAP Sensor..............................................................4-73Diagnostics.......................................................................4-73


4.20 DTC P0112, P0113General.............................................................................4-77

IAT Sensor.................................................................4-77Diagnostics.......................................................................4-77


4.21 DTC P0117, P0118General.............................................................................4-81

ET Sensor.................................................................4-81Diagnostics.......................................................................4-81


4.22 DTC P0122, P0123General.............................................................................4-85

TP Sensor.................................................................4-85Diagnostics.......................................................................4-85

Diagnostic Tips..........................................................4-85

VI TABLE OF CONTENTS

TABLE OF CONTENTS


4.23 DTC P0131, P0132, P0134, P0151,P0152, P0154General.............................................................................4-89

Oxygen Sensor.........................................................4-89Diagnostics.......................................................................4-89


4.24 DTC P0261, P0262, P0263, P0264General.............................................................................4-95

Fuel Injectors.............................................................4-95Diagnostics.......................................................................4-95


4.25 DTC P0373, P0374General...........................................................................4-101

Crankshaft Position (CKP) Sensor..........................4-101Diagnostics.....................................................................4-101

Diagnostic Tips........................................................4-101Diagnostic Notes.....................................................4-101

4.26 DTC P0501, P0502General...........................................................................4-104

Vehicle Speed Sensor (VSS)..................................4-104Diagnostics.....................................................................4-104

Diagnostic Notes.....................................................4-104

4.27 DTC P0562, P0563General...........................................................................4-108

Battery Voltage........................................................4-108Diagnostics.....................................................................4-108

Diagnostic Tips........................................................4-108Diagnostic Notes.....................................................4-108

4.28 DTC P0603, P0605General...........................................................................4-112

ECM Failure............................................................4-112Diagnostics.....................................................................4-112

DTC P0603.............................................................4-112DTC P0605.............................................................4-112

4.29 DTC P0661, P0662General...........................................................................4-113

Active Intake Solenoid (HDI Models Only)..............4-113Diagnostics.....................................................................4-113


4.30 DTC P1009, P1010General...........................................................................4-117

Password Problem..................................................4-117Diagnostics.....................................................................4-117


4.31 DTC P1351, P1352, P1354, P1355General...........................................................................4-120

Ignition Coil.............................................................4-120Diagnostics.....................................................................4-120


4.32 DTC P1475, P1477, P1478General...........................................................................4-125

Exhaust Actuator (HDI Models)...............................4-125Diagnostics.....................................................................4-125


4.33 DTC P1501, P1502General...........................................................................4-131

Jiffy Stand Sensor (HDI Models Only).....................4-131Diagnostics.....................................................................4-131


4.34 DTC U1064, U1255General...........................................................................4-136

Loss of TSM/TSSM/HFSM Serial Data...................4-136Diagnostics.....................................................................4-136


4.35 DTC U1097, U1255General...........................................................................4-139

Loss of TSM/TSSM/HFSM Serial Data...................4-139Diagnostics.....................................................................4-139


APPENDIX A CONNECTOR REPAIR

A.1 AMP 1-PLACE CONNECTORSAMP 1-Place Connector Repair.........................................A-1

General.......................................................................A-1Separating Pin and Socket Housings.........................A-1Mating Pin and Socket Housings................................A-1Removing Socket Terminals........................................A-1Installing Socket Terminal...........................................A-1Removing Pin Terminal...............................................A-1Installing Pin Terminal.................................................A-2

A.2 AMP MULTILOCK CONNECTORSAMP Multilock Connector Repair.......................................A-3

General.......................................................................A-3Separating Pin and Socket Housings.........................A-3Mating Pin and Socket Housings................................A-3Removing Terminals from Housing.............................A-3Inserting Terminals into Housing.................................A-4Preparing Wire Leads for Crimping.............................A-4Crimping Terminals to Leads......................................A-6Inspecting Crimped Terminals.....................................A-6

A.3 DELPHI CONNECTORSDelphi Connector Repair....................................................A-8

General.......................................................................A-8Separating Pin and Socket Housings.........................A-8Mating Pin and Socket Housings................................A-8Removing Socket Terminals........................................A-8Installing Socket Terminals..........................................A-8

A.4 DEUTSCH 1-PLACE ELECTRICALCONNECTORSDeutsch 1-Place Connector Repair..................................A-10

Separating Pin and Socket Housings.......................A-10Mating Pin and Socket Housings..............................A-10

TABLE OF CONTENTS VII

TABLE OF CONTENTS

Removing Socket Terminals......................................A-10Installing Socket Terminals........................................A-10

A.5 DEUSCH ELECTRICAL CONNECTORSDeutsch Connector Repair...............................................A-11

General.....................................................................A-11Separating Pin and Socket Housings.......................A-11Mating Pin and Socket Housings..............................A-11Removing Socket Terminals......................................A-11Installing Socket Terminals........................................A-11Removing Pin Terminals...........................................A-13Installing Pin Terminals.............................................A-13Crimping Terminals...................................................A-14

A.6 DEUTSCH STANDARD TERMINALSDeutsch Standard Terminal Crimps.................................A-15

Preparing Wire Leads for Crimping...........................A-15Crimping Terminal to Lead........................................A-15Inspecting Crimps.....................................................A-15

A.7 DEUTSCH MINI-TERMINAL CRIMPSDeutsch Mini Terminal Crimps.........................................A-16

Preparing Wire Leads for Crimping...........................A-16Crimping a Mini Terminal to Wire Lead.....................A-16Inspecting Crimps.....................................................A-16

A.8 DEUTSCH SOLID BARREL TERMINALSDeutsch Solid Barrel Terminal Crimps.............................A-17

Preparing Wire Leads For Crimping.........................A-17Adjusting Crimper Tool..............................................A-17Crimping a Barrel Contact To Wire Lead...................A-17Inspecting Crimps.....................................................A-17

A.9 RELAY AND FUSE BLOCKSFuse Block Repair............................................................A-19

Removing Socket Terminals......................................A-19Installing Socket Terminals........................................A-19Crimping Terminals...................................................A-19

A.10 150 METRI-PACK CONNECTORS150 Metri-Pack Connector Repair....................................A-20

General.....................................................................A-20Separating Pin and Socket Housings.......................A-20Mating Pin and Socket Housings..............................A-20Removing Socket Terminal.......................................A-20Inserting Socket Terminal..........................................A-20


General.....................................................................A-22Separating Pin and Socket Housings.......................A-22Mating Pin and Socket Housings..............................A-22Removing Socket Terminals......................................A-22Installing Socket Terminals........................................A-22Crimping Terminals...................................................A-22


General.....................................................................A-24Separating Pin and Socket Housings.......................A-24Mating Pin and Socket Housings..............................A-24

Removing Socket Terminals......................................A-24Installing Socket Terminals........................................A-24


General.....................................................................A-25Separating Pin and Socket Housings.......................A-25Mating Pin and Socket Housings..............................A-25Removing Socket Terminal.......................................A-25Installing Socket Terminal.........................................A-25

A.14 800 METRI-PACK CONNECTORSDelphi Maxi-Fuse Housing Repair...................................A-26

General.....................................................................A-26Removing Maxi-Fuse................................................A-26Installing Maxi-Fuse..................................................A-26Removing Socket Terminals......................................A-26Installing Socket Terminals........................................A-26

A.15 METRI-PACK TERMINALSMetri-Pack Terminal Crimps.............................................A-28

Matching Terminal To Crimper..................................A-28Preparing Wire Lead.................................................A-28Crimping Wire Core..................................................A-28Crimping Insulation/Seal...........................................A-28Inspecting Crimps.....................................................A-29

A.16 MOLEX CONNECTORSMolex Connector Repair..................................................A-30

Separating Pin and Socket Housings.......................A-30Mating Pin and Socket Housings..............................A-30Removing Terminals.................................................A-30Installing Terminals...................................................A-30

A.17 PACKARD ECM CONNECTORPackard 100W Connector Repair.....................................A-32

General.....................................................................A-32Separating Socket Housing From ECM....................A-32Mating Socket Housing To ECM...............................A-32Removing Socket Terminal.......................................A-32Installing Socket Terminal.........................................A-32Crimping Terminals...................................................A-32

A.18 PACKARD MICRO-64 CONNECTORSPackard Micro-64 Connector Repair................................A-34

General.....................................................................A-34Separating Pin and Socket Housings.......................A-34Mating Pin and Socket Housings..............................A-34Removing Terminal...................................................A-34Installing Terminal.....................................................A-34Preparing Wire Leads for Crimping...........................A-35Crimping Terminals...................................................A-35Inspecting Crimps.....................................................A-35

A.19 SEALED SPLICE CONNECTORSSealed Splice Connector Repair......................................A-37

General.....................................................................A-37Preparing Wire Leads...............................................A-37Splicing Wire Leads..................................................A-37Inspecting Seals.......................................................A-37

VIII TABLE OF CONTENTS

TABLE OF CONTENTS

APPENDIX B WIRING

B.1 CONNECTORSConnector Locations..........................................................B-1

Function/Location.......................................................B-1Place and Color..........................................................B-1Connector Number......................................................B-1Repair Instructions......................................................B-1

B.2 WIRING DIAGRAMSWiring Diagram Information...............................................B-3

Wire Color Codes........................................................B-3Wiring Diagram Symbols............................................B-3

2008 Dyna Wiring Diagrams..............................................B-4

APPENDIX C CONVERSIONS

C.1 METRIC CONVERSIONConversion Table................................................................C-1

C.2 FLUID CONVERSIONSUnited States System........................................................C-2Metric System....................................................................C-2British Imperial System......................................................C-2

C.3 TORQUE CONVERSIONSUnited States System........................................................C-3Metric System....................................................................C-3

APPENDIX D GLOSSARY

D.1 GLOSSARYAcronyms and Abbreviations.............................................D-1

APPENDIX E TSM/TSSM(JAPAN/KOREA)

E.1 TSM/TSSM (JAPAN/KOREA) OVERVIEWGeneral..............................................................................E-1Troubleshooting..................................................................E-1

E.2 TSM/TSSM FEATURESGeneral..............................................................................E-3Turn Signal Functions........................................................E-3

TSSM/TSSM Features................................................E-3Bank Angle Function..........................................................E-3Clutch/Neutral Interlock Functions.....................................E-3

TSM/TSSM Features..................................................E-3Security Alarm and Immobilization Functions....................E-3

TSSM Feature.............................................................E-3

E.3 VEHICLE DELIVERYGeneral..............................................................................E-5Configuring A TSSM..........................................................E-5Sidecar Configuration.........................................................E-5Power Disruption and Configuring.....................................E-5Key Fob Assignment: TSSM...............................................E-5Pin Entry: TSSM.................................................................E-6

Changing the Pin: TSSM....................................................E-8

E.4 TURN SIGNAL FUNCTIONSGeneral..............................................................................E-9Automatic Cancellation......................................................E-9Manual Cancellation...........................................................E-9Four-Way Flashing.............................................................E-9Diagnostics Mode..............................................................E-9

E.5 BANK ANGLE FUNCTIONGeneral............................................................................E-10Operation.........................................................................E-10

E.6 SECURITY SYSTEM FUNCTIONS (TSSMONLY)General............................................................................E-11

Security System Operation.......................................E-11Security System Options: TSSM...............................E-11

Alarm Sensitivity: TSSM...................................................E-11Sensitivity..................................................................E-11Transport Mode.........................................................E-12

Auto-Arming Function: TSSM...........................................E-12Storage Mode: TSSM.......................................................E-13

E.7 ARMING/DISARMING (TSSM ONLY)General............................................................................E-14Security Lamp..................................................................E-14Using Key FOB: TSSM.....................................................E-14

General.....................................................................E-14Arming the System...................................................E-14Disarming the System...............................................E-14Troubleshooting.........................................................E-14

Using the Pin....................................................................E-14General.....................................................................E-14Disarming the System...............................................E-14

E.8 DIAGNOSTIC TROUBLE CODES (DTC)TSM/TSSM......................................................................E-16Code Types......................................................................E-17

Current......................................................................E-17Historic......................................................................E-17

Retrieving Diagnostic Trouble Codes...............................E-18Multiple Diagnostic Trouble Codes...................................E-18

E.9 INITIAL DIAGNOSTIC CHECK:TSM/TSSMGeneral............................................................................E-19

Diagnostic Notes.......................................................E-19Circuit Diagram/Wire Harness Connector Table.......E-19Job/Time Code Values..............................................E-19Reprogramming ECM...............................................E-19

Initial Diagnostics.............................................................E-19Diagnostic Tips.........................................................E-19Diagnostic Notes.......................................................E-19Other Diagnostic Trouble Codes (DTCs)...................E-20

E.10 SPEEDOMETER SELF DIAGNOSTICSGeneral............................................................................E-25Diagnostics......................................................................E-25

Diagnostic Tips.........................................................E-25Diagnostic Notes.......................................................E-25

TABLE OF CONTENTS IX

TABLE OF CONTENTS

E.11 BREAKOUT BOX:TSM/TSSMGeneral............................................................................E-28Installation........................................................................E-28Removal...........................................................................E-28

E.12 FAILS TO DISARM (TSSM ONLY)General............................................................................E-29

Security Equipped Vehicles Only..............................E-29Job/Time Code Values..............................................E-29

Diagnostics......................................................................E-29Diagnostic Tips.........................................................E-29Diagnostic Notes.......................................................E-29

E.13 TURN SIGNAL ERRORS: B1121, B1122,B1141General............................................................................E-32

Job/Time Code Values..............................................E-32Diagnostics......................................................................E-32

Diagnostic Tips: All....................................................E-32Diagnostic Notes: All Turn Signal Flow Charts..........E-34

E.14 DTC B0563General............................................................................E-42

Battery Voltage High.................................................E-42Diagnostics......................................................................E-42


E.15 DTC B1131, B1132General............................................................................E-43

Alarm Output Low (DTC B1131) or Alarm Output High(DTC B1132).............................................................E-43

Diagnostics......................................................................E-43Diagnostic Tips.........................................................E-43Diagnostic Notes.......................................................E-43

E.16 DTC B1134General............................................................................E-46

Starter Output High...................................................E-46Diagnostics......................................................................E-46

Diagnostic Notes.......................................................E-46

E.17 DTC B1135General............................................................................E-49

Accelerometer Fault: B1135......................................E-49

E.18 DTC B1154, B1155General............................................................................E-50Diagnostic Notes..............................................................E-50

E.19 DTC U1016, U1255General............................................................................E-54

Loss of ECM Serial Data..........................................E-54Diagnostics......................................................................E-54

Diagnostic Notes.......................................................E-54

E.20 DTC U1300, U1301 OR BUS ERGeneral............................................................................E-57

Serial Data Low or Serial Data Open/High...............E-57Diagnostics......................................................................E-57


E.21 TSM/TSSM: PASSWORD LEARNGeneral............................................................................E-58Password Learning..........................................................E-58

E.22 TSSM MAINTENANCEGeneral............................................................................E-59Key FOB...........................................................................E-59

Schedule...................................................................E-59Battery Replacement................................................E-59

Siren (If Installed).............................................................E-59Schedule...................................................................E-59Battery Replacement - Early Siren...........................E-59Battery Replacement - Late Siren.............................E-60

REFERENCE MATERIAL

TOOLS..........................................................?

TORQUE VALUES........................................?

INDEX........................................................LXI

X TABLE OF CONTENTS

TABLE OF CONTENTS

SUBJECT............................................................................................................................PAGE NO.1.1 STARTER TROUBLESHOOTING..............................................................................................1-11.2 STARTING SYSTEM DIAGNOSIS............................................................................................1-31.3 DIAGNOSTICS/TROUBLESHOOTING...................................................................................1-121.4 STARTER ACTIVATION CIRCUITS.........................................................................................1-131.5 TESTING STARTER ON MOTORCYCLE...............................................................................1-141.6 TESTING STARTER ON BENCH............................................................................................1-151.7 CHARGING SYSTEM.............................................................................................................1-171.8 BATTERY TESTING................................................................................................................1-24

STA

RT

ING

/ C

HA

RG

ING

1.1STARTER TROUBLESHOOTING

GENERALThe troubleshooting tables contain detailed procedures to solveand correct problems. Follow 1.2 STARTING SYSTEM DIA-GNOSIS to diagnose starting system problems. The 1.3 DIA-

GNOSTICS/TROUBLESHOOTING, Voltage Drop procedurewill help you to locate poor connections or components withexcessive voltage drops.

STARTER TROUBLESHOOTING

Table 1-1. Starter Does Not Run or Runs at Very Low Speeds

SOLUTIONPROBABLE CAUSESOURCE OFPROBLEM

Charge battery.Voltage drop due to discharged battery.Battery

Replace battery.Short-circuited or open between electrodes.

Clean and retighten.Poor contact condition of battery terminal(s).

Repair or replace cable(s).Poor or no connection at either battery positive ornegative cable, at either end.

Wiring

Clean, tighten or replace cable(s) as needed.Cracked or corroded battery cable ends.

Tighten connections or repair or replace wire(s).Open wire(s) or poor connection at handlebar switchor start relay, especially relay ground wire (groundsthrough TSM/TSSM/HFSM).

Replace switch.Poor switch contacts or open switch.Start switch, clutchswitch, engine stopswitch or neutralswitch

Replace relay.Open coil winding.Start relay

Replace relay.Poor or no continuity at relay points.

Disarm security system.TSM/TSSM/HFSM has disabled start relay.

Polish contact surface or replace solenoidassembly.

Poor contact condition caused by burned contact.Solenoid

Repair or replace solenoid assembly.Pull-in winding open or short-circuited.

Repair or replace solenoid assembly.Hold-in winding open or short-circuited.

Check brush spring tension. Replace field frameand holder or starter assembly.

Brushes worn below specification.Starter motor

Re-face or replace.Commutator burned.

Correct by undercutting.Commutator high mica.

Replace starter.Field winding grounded.

Replace armature.Armature winding grounded or short-circuited.

Replace starter.Free running current draw out of range.

Replace starter.Reduction gears damaged.

Replace starter.Insufficient brush spring tension.

Repair or replace lead wire.Disconnected lead wire between solenoid and fieldwindings.

Replace bearing.Ball bearing sticks.

Use recommended viscosity oil for temperaturerange. Consult owner's manual.

Incorrect oil for low temperature.Temperature

2008 Dyna Diagnostics: Starting / Charging 1-1

Table 1-2. Pinion Does Not Engage With Ring Gear While Starter is Cranked or Engine Cannot Be Cranked

SOLUTIONPROBABLE CAUSESOURCE OF PROBLEM

Charge battery.Voltage drop due to discharged battery.Battery

Replace battery.Short-circuited or open between electrodes.

Clean and retighten.Poor contact condition of battery terminal(s).

Replace overrunning clutch.Overrunning clutch malfunction (rollers orcompression spring).

Overrunning clutch

Replace Starter clutch sub-assembly.Pinion teeth worn out.

Replace overrunning clutch.Pinion does not run in overrunning direction.

Remove foreign materials, dirt or replaceoverrunning clutch or pinion shaft.

Poor sliding condition of spline teeth.

Replace overrunning clutch and idler gear.Reduction gears damaged.

Replace clutch shell.Excessively worn teeth.Gear teeth on clutch shell

Table 1-3. Starter Does Not Stop Running

SOLUTIONPROBABLE CAUSESOURCE OF PROBLEM

Replace start switch or start relay.Unopened contacts.Start switch or start relay

Replace start switch or start relay.Poor return caused by sticky switch or relay contacts.

Replace clutch shell.Excessively worn teeth.Gear teeth on clutch shell

Replace spring.Return spring worn.Solenoid

Replace solenoid.Coil layer shorted.

Replace solenoid.Contact plate melted and stuck.

1-2 2008 Dyna Diagnostics: Starting / Charging

1.2STARTING SYSTEM DIAGNOSIS

DIAGNOSTICS

TOOL NAMEPART NUMBER

HARNESS CONNECTOR TEST KITHD-41404-B

BREAKOUT BOXHD-42682

Diagnostic NotesEach reference number below correlates to a circled numberon the flow chart(s).

1. See Figure 1-1. Test for VOLTAGE DROP under1.3 DIAGNOSTICS/TROUBLESHOOTING.

2. Remove starter motor. Connect jumper wires as describedin 1.6 TESTING STARTER ON BENCH, Free RunningCurrent Draw Test.

3. Connect BREAKOUT BOX (Part No. HD-42682) to TSM/TSSM/HFSM as follows:

a. On models with a TSM/HFSM, see 3.12 BREAKOUTBOX: TSM/HFSM.

b. On models with a TSSM (Japan/Korea), seeE.11 BREAKOUT BOX: TSM/TSSM.

4. Use HARNESS CONNECTOR TEST KIT (Part No. HD-41404-B) purple terminal socket probe and patch cord.

5. See 1.5 TESTING STARTER ON MOTORCYCLE, StarterCurrent Draw Test.

6. If the neutral switch or ground is open, a reading of severalhundred ohms is normal due to the neutral indicator lamp(LED).

7. Closely inspect handlebar controls for pinched wiring.

Job/Time Code ValuesDealership technicians filing warranty claims should use thejob/time code values printed in bold text underneath theappropriate repair.

1

3

2

ed02860

1. Motor terminal2. Battery terminal3. Relay terminal

Figure 1-1. Starter Terminals


[5]

40A

mp

MA

XIF

US

E

BA

R

R

BK

Red

Ban

d

Sta

rter

Bat

tery

GN

BK[62B

]

Sta

rtR

elay

(Gra

y)

K T E S U

87 87A

30 85 86

5 4 3 2 1T

N/G

NB

K/R

R/B

K

GN

R/B

K RR

R/B

K

IGN

15A

GH

INS

TR

15A

B

Bat

tery

15A

IJ

EC

M15

AA

BB

E/G

Y

BN

/GY

OGY

[33A

]

[128

]

[33B

]

A B C

R/B

K

RA

CC

−B

ATT

−IG

N−

Igni

tion

Sw

itch CBA

[64B

]

GN

D1

Rea

rG

roun

dS

tud

Und

erE

lect

rical

Cen

ter

Rig

htTu

rnS

witc

hE

ngin

eS

top

Sw

itch

Sta

rtS

witc

h

Fron

tSto

pLa

mp

Sw

itch

Rig

htH

and

Con

trol

s[1

62]

GN

D2

BK/GN

BK

GYW/BK

BK/R

GYW/BK

BK/R

43

43

6 6

[22B

]

[22A

]C

lutc

hS

witc

hH

orn

Sw

itch

Hea

dlam

pH

i/Lo

Sw

itch

Left

Turn

Sw

itch

Left

Han

dC

ontr

ols

[163

]

BK/GN

LGN/V

67

812

[20B

]

Toin

stru

men

tass

embl

y

TNBK

TN

O

AB

[30B

][3

0A]

[131

]

Neu

tral

Sw

itch

BN

/GY

TN

/GN

GY

LGN

/V

BK

/GN

BK

/R

TN

Bat

tery

Igni

tion

Ser

iald

ata

Neu

tral

switc

h

Sta

rtre

lay

cont

rol

Clu

tch

switc

h

Gro

und

Bat

tery

Ser

iald

ata

Gro

und

Sw

itche

dpo

wer

Gro

und

See

secu

rity

circ

uitf

orha

nds

free

secu

rty

mod

ule

TurnSignal&SecurityModule

TSM/TSSM21 43 109 12

21 43 109 12

BK/GNBK

/GN

LGN

/V

W/B

K BE/GY

[24B

]

[24A

]

5 10 13 28 31

5 10 13 28 31

BK/RBK/GN 8

7

87

BK/RBK

[78B

][7

8A]

EC

M

em01165

Figure 1-2. Starting Circuit Schematic


Starter Testing 1

Check Battery using visual inspection, voltagetest, and either conductance test or load test.

Check connections at battery and startercomponents.

Is system operational?

YES

STARTERRUNS ON.

YES YES NO

STARTER SPINS,BUT DOES NOT

ENGAGE.

STARTER STALLSOR SPINS TOO

SLOWLY.

Check for audibleclicking noise.

Disconnect starter solenoidconnector [128].

Is 12V present on (GN) wirewith Start Switch not

pressed?

See StarterTesting 5: StarterSpins But Does

Not Engage.

See StarterTesting 6: Starter

Stalls or Spins TooSlowly.

Solenoid clicks.See StarterTesting 2:

Solenoid Clicks.

YES NO

Is 12V present on start relay terminal “1” withStart Switch not pressed?

NOTEDepending on relay used, relay socket terminal

could be shown as “86” or “U”.

ReplaceStarter Solenoid.

YES NO

ReplaceStart Switch.

ReplaceStart Relay.

OR

Relay clicks. SeeStarter Testing 3:

Relay Clicks.

OR

Nothing clicks. See StarterTesting 4: Nothing Clicks

(Part 1 of 2).

5818 5832

5845

5822

fc01148_en


Starter Testing 2: Solenoid Clicks

Perform voltage drop tests between batteryand relay terminal on solenoid.

Is voltage drop less than 1.0 volt?

YES NO

Backtrack to pinpoint poorconnections or relay contact

problems using voltage drop tests.

Perform voltage drop tests frombattery positive to starter motor

terminal. Crank engine.Is voltage drop greater than 1.0 volt?

YES

Perform voltage drop tests frombattery positive to starter battery


YES

Repair connection betweenbattery and starter.

NO

Perform voltage drop testsbetween battery negative and

starter studs or bolts.Is voltage drop greater than 1.0 volt?

NO

Repair or replacesolenoid (contacts).

YES

Clean groundconnections. STOP

NO

5824 5845 5824

5823

1

1 1

1

Go to Starter Testing 3:Relay Clicks. Begin with boxmarked with bold asterisk.

fc01149_en


Starter Testing 3: Relay Clicks

Test for voltage at starter solenoid connector[128] (GN) wire.

Is 12V present when Start Switch is pressed?

YES NO

Does Starterturn if jumped?

YES

ReplaceStarter Solenoid.

NO

Replace or repairStarter.

Test for voltage to Start Relay.Is 12V present on start relay socket terminal “3”?

NOTEDepending on relay used, relay socket terminal

could be shown as “30” or “E”.

YES NO

Test for voltage from Start Relay.Is 12V present on start relay socket terminal “5” when

Start Switch is pressed?NOTE

Depending on relay used, relay socket terminal couldbe shown as “87” or “K”.

Repair open or poorconnections on (R/BK)wire feeding start relay

socket terminal “3”.

YES

Repair open or poor connections on (GN) wirebetween Start Relay and Starter Solenoid.

NO

ReplaceStart Relay.

5827 5832

5827

5860 5817

2

fc01150_en


Starter Testing 4: Nothing Clicks (Part 1 of 2)

Do turn signals work properly?

YES

Turn the Ignition Switch toIGNITION. With the Engine Stop

Switch in the RUN position,depress the start switch whilechecking for battery voltage at

start relay terminal “86”.Is battery voltage present?

NO

Is TSM/TSSM/HFSM connector[30] fully mated?

YES NO

Continuity to ground on TSM/TSSM/HFSM terminal “12”?

Mate connector [30].

YES

Continuity on TSM/TSSM/HFSMterminal “1” to battery fuse?

Repair open.

NO

YES

Continuity on TSM/TSSM/HFSMterminal “2” to IGN fuse?

NO

Repair open.

YES

Replace TSM/TSSM/HFSM. Learnpassword and perform set-up.

NO

Repair open.

6792

6805

6806

67936791

3

YES

Check for continuity to chassisground at start relay terminal “85”.

Is continuity present?

YES

Substitute goodrelay or test relay.

NO

Check for continuity from start relayterminal “85” to terminal “9” on TSM/

TSSM/HFSM connector [30].Is continuity present?

NO

Repair open.

YES

STOP

Go to Starter Testing 4:Nothing Clicks (Part 2 of 2).

5828

NO

Disconnect connector [22]. Check for continuitybetween terminal “4” (W/BK) and terminal “6”

(BK/R) of connector [22A].Continuity present with start switch pressed?

4

NO

Turn the Ignition Switch to IGNITION.Check for voltage to start switch, atconnector [22B] terminal “3” (GY).

Battery voltage present?

YES

NOYES

Locate and repairopen in (GY) wire

from connector [22B]to IGN fuse.

Locate and repairopen in (BK/R) wire

from connector [22B]to start relay.

5831 5831

Replacestart switch.

5818

7

fc01647_en


Starter Testing 4: Nothing Clicks (Part 2 of 2)

Continued fromStarter Testing 4: Nothing Clicks (Part 1 of 2).

Install breakout box HD-42682. Shift transmission to neutral. Measure continuityto chassis ground at breakout box terminal “4” (gray) (neutral switch).

Is continuity (less than 10 ohms) present?

YES

Disengage clutch (pull in clutch lever). Measurecontinuity to chassis ground at breakout box terminal

“10” (gray) (clutch switch) with clutch disengaged.Is continuity present?

NO

YES NO

Locate and repair open on(TN) wire between neutralswitch and TSM/TSSM/

HFSM.

YES

Turn Ignition Switch to IGNITION. Check forvoltage on breakout box terminal “9” (gray).

Is voltage present?

YES

Locate and repairshort to voltage on

(TN/GN).

NO

Replace TSM/TSSM/HFSM.Learn password and

perform set-up.

5157

5862

5830 5838

6

fc01648_en

Disconnect neutral switch connector [131]. Checkfor continuity between breakout box terminal “4”

(gray) and connector [131] terminal “B” (TN).Is continuity present?

Replace NeutralSwitch.

Check for continuity fromconnector [131] terminal “A”

(BK) to chassis ground.Is continuity present?

Locate and repair open on(BK) wire between neutral

switch and ground.

5861

YES NO

Locate and repair open on(BK/R) wire between clutch

switch and TSM/TSSM/HFSM.

5168

Disconnect left hand controls connector [24]. Checkfor continuity between breakout box terminal “10”(gray) and connector [24B] terminal “7” (BK/R).


Replace ClutchSwitch.

Check for continuity fromconnector [24B] terminal “8”(BK/GN) to chassis ground.


Locate and repair open on(BK/GN) wire between clutch

switch and ground.

NO

YES NO

YES NO


Starter Testing 5: Starter Spins But Does Not Engage

Remove Starter. Disassemble DriveHousing assembly. Inspect for damage

to Armature Gear or Idler Gear.Is damage present?

YES

Replace damaged IdlerGear and Armature.

NO

Starter Clutch failure.Replace Starter Clutch.

5825 5837

fc01153_en


Starter Testing 6: Starter Stalls or Spins Too Slowly

Perform voltage drop tests from batterypositive to starter terminal. Crank engine.

Is voltage drop greater than 1.0 volt?

YES NO

Perform voltage drop tests betweenbattery positive to starter battery


Perform voltage drop testsbetween battery negative and

starter studs or bolts.Is voltage drop greater than 1.0 volt?

1 1

YES

Repair connectionbetween Battery

and Starter.

NO

Repair or replaceStarter Solenoid

(contacts).

5824 5845

NOYES

Clean groundconnections.

Perform Starter Current Draw Test (onvehicle).

Perform Free Running Current DrawTest (on bench).

Are test results within range?

5

2

YES NO

With the spark plugs removed and thetransmission in 5th gear, rotate rear wheel.

Check for engine, primaryand/or crankshaft bind.

Replace or repairStarter.

5817

5835

1

Use appropriate codefc01154_en


1.3DIAGNOSTICS/TROUBLESHOOTING

VOLTAGE DROPCheck the integrity of all wiring, switches, fuses and connectorsbetween the source and destination.

The voltage drop test measures the difference in potential orthe actual voltage dropped between the source and destination.

1. See ITEM A in Figure 1-3. Attach your red meter lead tothe most positive part of the circuit, which in this casewould be the positive post of the battery (5).

2. See ITEM B in Figure 1-3. Attach the black meter lead tothe final destination or component in the circuit (solenoidterminal from relay).

3. Activate the starter and observe the meter reading. Themeter will read the voltage dropped or the difference inpotential between the source and destination. An idealcircuit's voltage drop would be 0 volt or no voltagedropped, meaning no difference in potential.

4. See ITEM C in Figure 1-3. An open circuit should read 12volts, displaying all the voltage dropped, and the entiredifference in potential displayed on the meter.

NOTEOpen circuits on the ground side will read zero.

5. Typically, a good circuit will drop less than 1.0 volt. If thevoltage drop is greater, back track through the connections

until the source of the potential difference is found. Thebenefits of doing it this way are speed and accuracy.

a. Readings are not as sensitive to real battery voltage.

b. Readings show the actual voltage dropped, not justthe presence of voltage.

c. This tests the system as it is actually being used. Itis more accurate and will display hard to find poorconnections.

d. This approach can be used on lighting circuits, ignitioncircuits, etc. Start from most positive and go to mostnegative (the destination or component).

6. See ITEM D in Figure 1-3. The negative or ground circuitcan be checked as well.

a. Place the negative lead on the most negative part ofthe circuit (or the negative battery post). Remember,there is nothing more negative than the negative postof the battery.

b. Place the positive lead to the ground you wish tocheck.

c. Activate the circuit. This will allow you to read thepotential difference or voltage dropped on the neg-ative or ground circuit.This technique is very effectivefor identifying poor grounds due to powdered paint.Even the slightest connection may cause an ohm-meter to give a good reading. However, when suffi-cient current is passed through, the resistance causedby the powdered paint will cause a voltage drop orpotential difference in the ground circuit.


1.4STARTER ACTIVATION CIRCUITS

STARTER ACTIVATION CIRCUITS

200A

20A

20A

0.1A

200A

0.1A

200A

20A

20A

0.1A

200A

0.1A

200A

20A

20A

0.1A

200A

0.1A

200A

20A 20A

0.1A

200A

0.1A

ITEM A

ITEM COPEN CIRCUIT

ITEM DGROUND CIRCUIT

ITEM BIDEAL CLOSEDCIRCUIT

VDC

OV

VDC

VDC

VOV21

435

6

7

8

1

2

1

2

3 4

8

7

6

5

1

3 4

2

3 45

6

7

2

1

8

7

6

5

ed02788

1. Start switch2. Relay3. Solenoid4. Starter5. Battery6. MAXIFUSE7. Ignition switch8. Ignition fuse

Figure 1-3.Typical Circuitry. Refer to wiring diagrams for more information.


1.5TESTING STARTER ON MOTORCYCLE

START RELAY TEST1. See Figure 1-4. Locate start relay (2) behind the electrical

caddie cover on the motorcycle's left side.

2. See Figure 1-5. The start relay can be tested using themotorcycle's 12 volt battery and a multimeter.

a. Unplug connector from relay.

b. To energize the relay, connect the negative batteryterminal to the relay terminal "85" or "2" and relayterminal "86" or "1" to the positive battery terminal.Improper connections will damage the diode con-nected across the relay windings.

c. Check for continuity between the "30" or "3" and "87"or "5" terminals. A good relay shows continuity (con-tinuity tester lamp "on" or a zero ohm reading on theohmmeter). A malfunctioning relay will not showcontinuity and must be replaced.

3. If starter relay is functioning properly, proceed to1.5 TESTING STARTER ON MOTORCYCLE, StarterCurrent Draw Test.

132

ed02862

1. MAXIFUSE2. Start relay3. System relay

Figure 1-4. Fuses

3

12

87A(4)

87(5)

30(3)

86(1)

85(2)

ed01166

1. Ohmeter2. Battery3. Start relay

Figure 1-5. Start Relay Test

STARTER CURRENT DRAW TESTNOTES

• Engine temperature should be stable and at room temper-ature.

• Battery should be fully charged.

See Figure 1-6. Check starter current draw with an inductionammeter before disconnecting battery. Proceed as follows:

1. Verify that transmission is in neutral. Disconnect sparkplug wires from spark plug terminals.

2. See Figure 1-6. Clamp induction ammeter over positivebattery cable next to starter.

3. With ignition switch to IGNITION, turn engine over bypressing starter switch while reading the ammeter. Dis-regard initial high current reading which is normal whenengine is first turned over.

a. Typical starter current draw will range from 160 to200 amperes.

b. If starter current draw exceeds 250 amperes, theproblem may be in the starter or starter drive. Removestarter for further tests. See 1.6 TESTING STARTERON BENCH, Free Running Current Draw Test theService Manual.

NOTE

A DC current probe may be used if an induction ammeter isnot available.

1

2

3

ed02864

1. Starter2. Induction Ammeter3. Battery

Figure 1-6. Starter Current Draw Test


1.6TESTING STARTER ON BENCH

FREE RUNNING CURRENT DRAW TEST1. Place starter in vise, using a clean shop towel to prevent

scratches or other damage.

2. See Figure 1-7. Attach one heavy jumper cable (6 gaugeminimum).

a. Connect one end to the starter mounting flange (1).

b. Connect the other end to the negative (-) terminal ofa fully charged battery (2).

3. Connect a second heavy jumper cable (6 gauge minimum).

a. Connect one end to the positive (+) terminal of thebattery (2).

b. Connect the other end to the battery terminal (4) onthe starter solenoid. Place an induction ammeter (3)over cable.

4. Connect a smaller jumper cable (14 gauge minimum).

a. Connect one end to the positive (+) terminal of thebattery (2).

b. Connect the other end to the solenoid relay terminal(5).

5. Check ammeter reading.

a. Ammeter should show 90 amperes maximum.

b. If reading is higher, disassemble starter for inspection.See the Service Manual.

c. If starter current draw on vehicle was over 200 ampsand this test was within specification, there may be aproblem with engine or primary drive.

2

3

4

5

1

ed02865

1. Mounting flange2. Battery3. Induction ammeter4. Battery terminal5. Solenoid relay terminal

Figure 1-7. Free Running Current Draw Test

STARTER SOLENOIDNOTE

Do not disassemble solenoid. Before testing, disconnect fieldwire from motor terminal as shown in Figure 1-8.

NOTE

Each test should be performed for only 3-5 seconds to preventdamage to solenoid.

NOTE

The solenoid Pull-in, Hold-in, and Return tests must be per-formed together in one continuous operation. Conduct all threetests one after the other in the sequence given without interrup-tion.

SOLENOID PULL-IN TEST1. See Figure 1-8. Using a 12 volt battery, connect three

separate test leads as follows:

a. Solenoid housing to negative battery post.

b. Solenoid motor terminal to negative battery post.

c. Solenoid relay terminal to positive battery post.

2. Observe starter shaft.

a. If starter shaft extends strongly, solenoid is workingproperly.

b. If starter shaft does not extend strongly, replace thesolenoid.

1

2

3

4

ed02866

1. Battery2. Solenoid housing3. Solenoid relay terminal4. Solenoid motor terminal

Figure 1-8.Test 1: Solenoid Pull-In Test

SOLENOID HOLD-IN TEST1. See Figure 1-9. With test leads still connected in the

manner specified in the previous 1.6 TESTING STARTERON BENCH, Solenoid Pull-In Test, disconnect solenoidmotor terminal/battery negative test lead at negativebattery post only; reconnect loose end of this test leadto positive battery post instead.


2. Observe starter shaft.

a. If starter shaft remains extended, solenoid is workingproperly.

b. If starter shaft retracts, replace the solenoid.

1

23

4

ed02867


Figure 1-9.Test 2: Solenoid Hold-In Test

SOLENOID RETURN TEST1. See Figure 1-10. With test leads still connected in the

manner specified at the end of the previous 1.6 TESTING

STARTER ON BENCH, Solenoid Hold-In Test, disconnectsolenoid relay terminal/positive battery post test leadat either end.

2. Observe starter pinion.

a. If starter shaft retracts, solenoid is working properly.

b. If starter shaft does not retract, replace the solenoid.

1

23

4

ed02868


Figure 1-10.Test 3: Solenoid Return Test


1.7CHARGING SYSTEM

GENERALThe charging system consists of the alternator and regulator.The charging system circuits are shown in Figure 1-12.

AlternatorThe alternator consists of two main components:

• The rotor which mounts to the engine sprocket shaft.

• The stator which bolts to the engine crankcase.

Voltage RegulatorSee Figure 1-11. The voltage regulator is a series regulator.The circuit combines the functions of rectifying and regulating.

ed02869

Figure 1-11. Voltage Regulator

TROUBLESHOOTING


ELECTRICAL SYSTEM TESTERHD-48053

When the charging system fails to charge or does not chargeat a satisfactory rate, make the following recommended checks.

BatteryCheck for a weak or dead battery. See 1.8 BATTERY TESTINGfor battery testing procedures. Battery must be fully chargedin order to perform a load test, or starting or charging tests.However, a partially discharged battery may be tested usingthe BATTERY TEST function of the ELECTRICAL SYSTEMTESTER (Part No. HD-48053).

WiringThe stator and battery connector plug and socket connectionsmust be clean and tight.

See Figure 1-12. Check for corroded or loose connections inthe charging system circuit.

Voltage Regulator InspectionThe voltage regulator must have a clean, tight connection forproper grounding. Check by using an ohmmeter with one leadon a known good ground, such as battery ground cable, andthe other on the regulator ground lead.



BKBK

321

321

_+

_+

[47B][47A]

[77B][77A]

GND 3Front groundstud under

electrical center

IgnitionSwitch

Battery

40 AmpMAXIFUSE

Stator

Starter

[128A]

StarterSolenoidConnectionRed

Band

BK BK

BK

BK

BK

RR

R

BA

em01167

Figure 1-12. Charging System Circuit


Charging System Test (Part 1 of 2)

Test Battery.Charge or replace as required.

Inspect Voltage Regulator.See Voltage Regulator Inspection.

PASS FAIL

Perform Milliampere DrawTest (If applicable).

Correct asrequired.

5306

PASS

Perform Total Current Draw Test.Record measurement.

FAIL

Isolate damagedcomponent or wiring.

5308

PASS FAIL

Isolate damaged wiring orexcessive accessories.

5310Go to ChargingSystem Test (Part 2 of 2).

NOTE

Whenever a charging system component fails a test andis replaced, re-test the system to be sure the problemhas been corrected.

STOP

fc01155_en


Charging System Test (Part 2 of 2)

From Charging System Test (Part 1 of 2).

Perform CURRENT OUTPUT TEST. Recordmeasurement and compare with TOTAL

CURRENT DRAW TEST before proceeding.

PASS FAIL

PerformVOLTAGE

OUTPUT TEST.

PerformSTATOR CHECK.

PASS FAIL

Replace voltageregulator.

System tests good up to this point.Suspect:

Accessories on for long periods whenvehicle is parked and not running.

Accessories on when vehicle is riddenvery slowly for long periods.

Battery self-discharge and/oraccessory

draw because vehicle was notoperated

for a long period.

5316

PASS FAIL

Perform ACOUTPUT TEST.

Replacestator.

5312

PASS

Replace voltageregulator.

Perform CURRENTOUTPUT TEST.

Inspect rotor.

FAIL

FAILPASS

Damaged orslipping rotor.

SystemOK.

5315

NOTE

Whenever a charging system component fails a test andis replaced, re-test the system to be sure the problemhas been corrected.

5319

FAILPASS

Replacestator.

Replacerotor.

5314 5319

fc01156_en


TESTING

Milliampere Draw TestNOTES

• Be sure accessories are not wired so they stay on at alltimes. This condition could drain battery completely ifvehicle is parked for a long time. Check for this by con-necting ammeter between negative battery terminal andbattery.

• TSM/TSSM/HFSM will continue to draw 16-25 mA for 30seconds after ignition is turned OFF. Any disruption andreconnection of battery power, such as disconnecting thebattery to place a meter in series, will cause TSM/TSSM/HFSM to draw 16-25 mA for 30 seconds.

1. See Figure 1-13. Connect ammeter between negativebattery terminal and battery. With this arrangement, youwill also pick up any regulator drain.

2. With ignition switch turned to OFF and all lights andaccessories off, observe current reading.

a. Refer to Table 1-4. Add voltage regulator draw toappropriate value for the other components. If sumis less than reading observed on ammeter, draw iswithin limits.

b. A higher reading indicates excessive current draw.Any accessories must be considered and checkedfor excessive drain.

NOTE

A battery with a surface discharge condition could suffer astatic drain. Correct by cleaning battery case.

2

13

ed02871

1. Battery2. Ammeter3. Battery negative cable

Figure 1-13. Milliampere Draw Test (Ignition turned to OFF)

Table 1-4. Milliampere Draw Test

MAXIMUM DRAW IN MILLI-AMPERES

ITEM

1.0ECM

1.0Speedometer

1.0Tachometer

1.0TSM (non security models)

1.0TSSM (disarmed)

1.0TSSM (armed)

0.1TSSM (storage mode)

1.0HFSM

20.0*Security siren (optional)

1.0Voltage regulator

* Siren will draw for 2-24 hours from time motorcycle batteryis connected and 0.05 milliamperes once siren battery ischarged. Disconnect siren during milliampere draw test.

Total Current Draw TestIf battery runs down during use, the current draw of themotorcycle components and accessories may exceed outputof the charging system.

NOTE

If a load tester is unavailable, an ammeter with current probemay be used.

Turn battery load tester OFF before connecting testercables to battery terminals. Connecting tester cables withload tester ON can cause a spark and battery explosion,which could result in death or serious injury. (00252a)

1. See Figure 1-14. To check for this condition, place loadtester induction pickup or current probe pickup over batterynegative cable.

2. Disconnect stator plug from voltage regulator. Start themotorcycle and run the engine at 2000 RPM.

3. With ignition and all continuously running lights andaccessories turned on (headlamp on high beam), read thetotal current draw.

4. Compare this reading to the reading obtained after per-forming the CURRENT AND VOLTAGE OUTPUT TEST.

a. The current output should exceed current draw by3.5 amps minimum.

b. If output does not meet specifications, there may betoo many accessories for the charging system tohandle.

5. Reconnect voltage regulator after testing.


1

2

3

ed02802

1. Load tester2. Induction pickup3. Battery

Figure 1-14. Check Current Draw (Ignition Switch On)

Current and Voltage Output Test: UsingHD-480531. Connect the HD-48053 leads to the vehicle's battery.

2. Follow the instructions in the analyzer's instruction manualto perform a Charging System Test.

See Figure 1-15.The test results will include a decision on thecharging system's condition and the measured system voltageat idle and at 3000 RPM. The analyzer's printer will provideyou with a printout including one of two possible test results:

1. CHARGING SYSTEM NORMAL - No problem found.

2. CHARGING SYSTEM PROBLEM - The analyzer detecteda problem and will display one of the three following res-ults:

a. LOW CHARGING VOLTS - The alternator is notsupplying sufficient voltage for the system's electricalloads.

b. HIGH CHARGING VOLTS - The system voltageexceeds the normal set point of the regulator.

c. INVESTIGATE VOLT OUTPUT - The rev voltage islower than the idle voltage.

Current and Voltage Output Test: UsingLoad Tester1. See Figure 1-16. Connect load tester.

a. Connect negative and positive leads to battery ter-minals.

b. Place load tester induction pickup over positive regu-lator cable.

2. Run the engine at 3000 RPM. Increase the load asrequired to obtain a constant 13.0 VDC. Do not leave anyload switch turned on for more than 20 seconds or over-heating and tester damage are possible.

3. The current output should be 35-50 amps. Make note ofmeasurement for use in TOTAL CURRENT DRAW TEST.

NOTERider's habits may require output test at lower RPM.

4. See Figure 1-16. After removing the load, read the loadtester voltage meter.

a. If voltage to the battery is not more than 15 VDC,voltage output is within specifications. Investigateother possible problems. See Charging System Test.

b. If voltage is higher, voltage regulator is not functioningproperly.

ed02804

Figure 1-15. Charging System Test Results Printout

1

23

4

5

ed01509

1. Load tester2. Battery3. Voltage regulator4. To MAXIFUSE (DC output)5. To stator

Figure 1-16. Current and Voltage Output Test


Stator Check1. Turn ignition switch OFF.

2. See Figure 1-17. Connect an ohmmeter.

a. Disconnect voltage regulator connector from alternatorstator wiring.

b. Insert one ohmmeter lead into a stator connectorsocket.

c. Attach the other lead to a suitable ground.

3. Test for continuity with ohmmeter set to the ohms scale.

a. A good stator will show no continuity (open circuit)between any stator sockets and ground.

b. Any other reading indicates a grounded stator whichmust be replaced.

4. See Figure 1-18. Check resistance across stator sockets1-2, 2-3 and 3-1.

5. Test for resistance with ohmmeter set on the ohms scale.

a. Resistance across all the stator sockets should be0.1-0.2 ohms.

b. If the resistance is higher, the stator is damaged andmust be replaced.

c. If resistance is lower, this could indicate an internalshort between the windings.

NOTEVerify the meter reads 0 ohms when probes are shortedtogether. If not, subtract lowest value to resistance value ofstator.

ed01510

Figure 1-17.Test for Grounded Stator (Typical)

ed01511

Figure 1-18. Check for Stator Resistance (Typical)

AC Output Check1. See Figure 1-19. Test AC output.

a. Disconnect voltage regulator connector from alternatorstator wiring.

b. Connect an AC voltmeter across stator connectorsockets 1-2.

c. Run the engine at 2000 RPM. The AC output shouldbe 32-46 volts AC (approximately 16-23 per 1000RPM).

d. Repeat test across stator sockets 2-3 and 3-1.

2. Compare test results to specifications.

a. If the output is below specifications, charging problemcould be a faulty rotor or stator.

b. If output is within specification, charging problemmight be faulty regulator. Replace as required.

3. Check the output again as previously described underCurrent and Voltage Output Test.

ed01512

Figure 1-19. Check Stator AC Voltage Output (Typical)


1.8BATTERY TESTING

GENERALThree different procedures may be performed to provide agood indicator of battery condition: a voltage test, a conduct-ance test, or a load test.

A battery may be tested, whether fully charged or not, viaconductance test. In order to perform a load test, however, thebattery must be fully charged.

VOLTMETER TESTThe voltmeter test provides a general indicator of battery stateof charge or condition. Check the voltage of the battery to verifythat it is in a 100% fully charged condition. Refer to Table 1-5.

If the open circuit (disconnected) voltage reading is below12.6V, charge the battery and then recheck the voltage afterthe battery has set for one to two hours. If the voltage readingis 12.7V or above, perform the LOAD TEST described in thissection.

Table 1-5. Voltmeter Test For Battery Charge Conditions

STATE OF CHARGEVOLTAGE (OCV)

100%12.7

75%12.6

50%12.3

25%12.0

0%11.8

CONDUCTANCE TEST


ADVANCED BATTERY CONDUCT-ANCE AND ELECTRICAL SYSTEMANALYZER

HD-48053

Test the battery using the ADVANCED BATTERY CONDUCT-ANCE AND ELECTRICAL SYSTEM ANALYZER (Part No. HD-48053). Perform a battery test as follows:

1. Connect the HD-48053 analyzer leads directly to the leadterminals of the vehicle's battery, not to the bolts or cableends.

2. Follow the instructions in the analyzer's instruction manualto perform a battery test.

The test results will include a decision on the battery's condi-tion, the measured state of charge The test results will includea decision on the battery's condition and the measured stateof charge.

See Figure 1-20. The analyzer's printer will provide you witha printout including one of five possible test results:

• GOOD BATTERY - Return the battery to service.

• GOOD-RECHARGE - Fully charge the battery and returnto service.

• CHARGE & RETEST - Fully charge the battery and retest.

• REPLACE BATTERY - Replace the battery and retest.

• BAD CELL-REPLACE - Replace the battery and retest.

NOTE

A REPLACE BATTERY test result may also mean a poorconnection between the battery cables and the vehicle. Afterdisconnecting the battery cables from the battery, retest thebattery using the out-of-vehicle test before replacing.

Be sure to connect the tester directly to the lead terminals ofthe battery, and not the bolts.

ed02811

Figure 1-20. Battery Test Results Printout

LOAD TESTTo load test the battery, proceed as follows:

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 battery from motorcycle.

2. Always fully charge the battery before testing or testreadings will be incorrect. Load testing a discharged bat-tery can also result in permanent battery damage.

3. After charging, allow battery to stand for at least one hourbefore testing.

Turn battery load tester OFF before connecting testercables to battery terminals. Connecting tester cables withload tester ON can cause a spark and battery explosion,which could result in death or serious injury. (00252a)

4. See Figure 1-21. Connect tester leads directly to batteryposts, not mounting screws, and place induction pickupover negative (black) cable.

NOTETo avoid load tester and/or battery damage, do not leave theload tester switch turned ON for more than 20 seconds.


5. Refer to Table 1-6. Load battery at 50% of CCA ratingusing the load tester. Voltage reading after 15 secondsshould be 9.6V or more at 70° F (21° C).

Turn battery load tester OFF before disconnecting testercables to battery terminals. Disconnecting tester cableswith load tester ON can cause a spark and battery explo-sion, which could result in death or serious injury. (00253a)

Connect positive (+) battery cable first. If positive (+) cableshould contact ground with negative (-) cable connected,the resulting sparks can cause a battery explosion, whichcould result in death or serious injury. (00068a)

Do not over-tighten bolts on battery terminals. Userecommended torque values. Over-tightening battery ter-minal bolts could result in damage to battery terminals.(00216a)

6. Install the battery in the motorcycle.

1

2

3

ed02876

1. Load tester2. Induction pickup3. Battery

Figure 1-21. Load Test Battery

Table 1-6. Battery Load Test

50%100%COLD CRANKINGAMPERAGE (CCA)

135270Dyna models



NOTES

SUBJECT............................................................................................................................PAGE NO.2.1 CHECKING FOR DIAGNOSTIC TROUBLE CODES................................................................2-12.2 INITIAL DIAGNOSTIC CHECK: SPEEDOMETER....................................................................2-52.3 SPEEDOMETER SELF DIAGNOSTICS.................................................................................2-122.4 SPEEDOMETER/TACHOMETER...........................................................................................2-152.5 BREAKOUT BOX: SPEEDOMETER/TACHOMETER..............................................................2-192.6 FUEL GAUGE..........................................................................................................................2-202.7 INDICATOR LAMPS: ALL BUT FXDWG/FXDC/FXDF............................................................2-212.8 INDICATOR LAMPS: FXDWG/FXDC/FXDF............................................................................2-242.9 DTC B1004, B1005.................................................................................................................2-272.10 DTC B1006, B1007...............................................................................................................2-312.11 DTC B1008............................................................................................................................2-332.12 DTC U1016, U1255...............................................................................................................2-362.13 DTC U1064, U1255...............................................................................................................2-392.14 DTC U1300, U1301 OR BUS ER..........................................................................................2-42

INS

TR

UM

EN

TS

2.1CHECKING FOR DIAGNOSTIC TROUBLE CODES

CHECK ENGINE LAMPSee Figure 2-1 or Figure 2-2. To diagnose Electronic ControlModule (ECM) system problems, start by observing the beha-vior of the check engine lamp.

NOTES

• See Figure 2-1 or Figure 2-2. "Key ON" means that theIgnition Switch is turned to IGNITION (IGN) and the EngineStop Switch is set to RUN (although the engine is notrunning).

• When the Ignition Switch is turned to IGNITION (IGN), thecheck engine lamp will illuminate for approximately fourseconds and then turn off.

• If the check engine lamp is not illuminated at Key ON theproblem is likely to be an instrument failure. See 2.2 INI-TIAL DIAGNOSTIC CHECK: SPEEDOMETER.

• If the check engine lamp illuminates late (after 20seconds), the problem is most likely a serial data busfailure. Test for Diagnostic Trouble Codes (DTCs) usingspeedometer self diagnostics. See 2.2 INITIAL DIA-GNOSTIC CHECK: SPEEDOMETER.

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

1. See Figure 2-1 or Figure 2-2. After the check engine lampturns off following the first four-second illumination period,one of three events may occur:

a. The lamp remains off. This indicates there are nocurrent fault conditions or stored DTCs currentlydetected by the ECM.

b. The lamp stays off for only four seconds and thencomes back on for an eight-second period. Thisindicates a DTC is stored, but no current DTC exists.

c. If the lamp remains on beyond the eight-secondperiod, a current DTC exists.

2. See 2.1 CHECKING FOR DIAGNOSTIC TROUBLECODES, Code Types which follows for a completedescription of DTC formats.

NOTE

Some DTCs can only be fully diagnosed during actuation. Forexample, a problem with the ignition coil will be considered acurrent fault even after the problem is corrected, since the ECMwill not know of its resolution until after the coil is exercised bythe vehicle start sequence. In this manner, there may some-times be a false indication of the current DTC.

2

1

ed02879

1. Check engine lamp2. Security lamp (key icon)

Figure 2-1. Speedometer: All but FXDWG, FXDC, FXDF

2

1

ed02880

1. Check engine lamp2. Security lamp (key icon)

Figure 2-2. Speedometer: FXDWG, FXDC, FXDF

2008 Dyna Diagnostics: Instruments 2-1

32

1

ed02877

1. Ignition OFF2. Ignition ON3. Marker Lights (ACC) ON

Figure 2-3. Ignition Switch (U.S. Models, Except FXDWG,FXDC, FXDF)

312

ed02878

1. Ignition OFF2. Ignition ON3. Marker lights (ACC) ON

Figure 2-4. Ignition Switch: FXDWG, FXDC, FXDF

SECURITY LAMP

Turn Signal Module (TSM)If the turn signals flash six four-way flashes shortly after keyON, it indicates a Diagnostic Trouble Code (DTC) has beenlogged sometime in the last three ignition cycles.

Turn Signal Security Module (TSSM) orHands Free Security Module (HFSM)See Figure 2-1 or Figure 2-2.To diagnose Turn Signal SecurityModule (TSSM) or Hands-Free Security Module (HFSM)system problems, begin by observing the behavior of thesecurity lamp.

NOTES

• To provide an indication of TSSM/HFSM DTCs, thesecurity lamp is enabled on TSSM/HFSM models.

• See Figure 2-5. "Key ON" means that the Ignition Switchis turned to IGNITION (IGN) and the Engine Stop Switchis set to RUN (although the engine is not running).

• When the Ignition Switch is turned to IGNITION (IGN), thesecurity lamp will illuminate for approximately four secondsand then turn off.

• If the security lamp is not illuminated at Key ON, theproblem is likely to be an instrument failure. See 2.2 INI-TIAL DIAGNOSTIC CHECK: SPEEDOMETER

• If the security lamp illuminates late (after 20 seconds), theproblem is most likely a serial data bus failure. Test forDTCs using speedometer self diagnostics. See 2.2 INITIALDIAGNOSTIC CHECK: SPEEDOMETER.

• If the security lamp fails to turn off after the initial four-second period, a problem exists in the instrumentation.See 2.2 INITIAL DIAGNOSTIC CHECK: SPEEDOMETER.

1. See Figure 2-5. After the security lamp turns off followingthe first four-second illumination period, one of threeevents may occur:

a. The lamp remains off. This indicates there are nocurrent fault conditions or stored DTCs currentlydetected by the TSSM/HFSM.

b. The lamp stays off for only four seconds and thencomes back on for an eight-second period. Thisindicates a DTC is stored, but no current DTC exists.

c. If the lamp remains on beyond the eight-secondperiod, a current DTC exists.

2. See 2.1 CHECKING FOR DIAGNOSTIC TROUBLECODES, Code Types for a complete description of DTCformats.

NOTE

Some DTCs can only be fully diagnosed during actuation. Forexample, a problem with the turn signals will be considered acurrent fault even after the problem is corrected, since theTSM/TSSM/HFSM will not know of its resolution until after theturn signals are activated. In this manner, there may sometimesbe a false indication of the current DTC.

2-2 2008 Dyna Diagnostics: Instruments

ONA

B

C

ON

ON

OFF

OFF

OFF

Key On

Key On

Key On

Lamp OFF: No Current or Historic DTCs

Lamp OFF

Lamp ON 8 Seconds:Only Historic DTCs Exist

Lamp Remains ON: Current DTC*

* Historic DTCs May Also Exist

4 Sec.

4 Sec.

4 Sec.

4 Sec.

8 Sec.

4 Sec.

ed01046

Figure 2-5. Check Engine and Security Lamp Operation

CODE TYPES


DIGITAL TECHNICIANHD-44750

There are two types of DTCs: current and historic. If a DTC isstored, it can be read using either a computer based diagnosticpackage called DIGITAL TECHNICIAN (Part No. HD-44750)or Speedometer Self Diagnostics. See 2.3 SPEEDOMETERSELF DIAGNOSTICS.

NOTES

• Speedometer Self Diagnostics will display both currentand historic DTCs. To differentiate between current andhistoric DTCs a computer based diagnostic package calledDIGITAL TECHNICIAN (Part No. HD-44750) must beemployed.

• All DTCs reside in the memory of ECM,TSM/TSSM/HFSM, Speedometer, Tachometer, or ABSModule until the DTC is cleared by using SpeedometerSelf Diagnostics. See 2.3 SPEEDOMETER SELF DIA-GNOSTICS.

• A historic DTC is also cleared after a total of 50 ignitioncycles (start and run cycle) has elapsed. After the 50ignition cycle retention period, the DTC is automaticallyerased from memory providing that no subsequent faultsof the same type are detected in that period.

CurrentCurrent DTCs are those which are present during the currentignition cycle. See the appropriate flow charts for solutions.

HistoricIf a particular problem happens to resolve itself, the activestatus problem is dropped and it becomes a historic DTC ratherthan a current DTC.

Historic DTCs are stored for 50 ignition cycles after any DTCwas last set as current to assist in the diagnosis of intermittentfaults. On the 50th cycle, the DTC will clear itself. The securitylamp will only indicate the existence of historic DTCs for twoignition cycles.

It is important to note that historic DTCs may also be presentwhenever the system indicates the existence of a current fault.See 2.1 CHECKING FOR DIAGNOSTIC TROUBLE CODES,Multiple Diagnostic Trouble Codes if multiple DTCs are found.

Diagnostic charts are designed for use with current DTCs andas a result they frequently suggest wire repair or part replace-ment.When diagnosing a historic DTC the charts can be helpfulbut should not lead to part replacement without verification thepart is faulty.

RETRIEVING DIAGNOSTIC TROUBLECODES



The speedometer provides two modes of diagnostics.

• The most sophisticated mode employs a computer baseddiagnostic package called DIGITAL TECHNICIAN (PartNo. HD-44750).

• The second mode requires using the speedometer selfdiagnostics. Speedometer, tachometer (if equipped)TSM/TSSM/HFSM and ECM DTCs can be accessed andcleared. See 2.3 SPEEDOMETER SELF DIAGNOSTICS.

Use of speedometer self diagnostics assumes that DigitalTechnician is not available.


MULTIPLE DIAGNOSTIC TROUBLE CODESWhile it is possible for more than one fault to occur and setmore than one DTC, there are several conditions which mayresult in one fault setting multiple DTCs. For example, serial

data DTCs (DTC U1016, U1064, U1097, U1255, U1300 andU1301) may be accompanied by other DTCs. Always correctthe serial data DTCs before resolving other DTCs.

For proper resolution of multiple DTCs refer to DiagnosticTrouble Code (DTC) priority chart Table 2-2.


2.2INITIAL DIAGNOSTIC CHECK: SPEEDOMETER

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 proceeds through an initializationsequence every time power is removed and re-applied toterminal "1".The visible part of this sequence is the checkengine lamp (in "run" mode), security lamp (models with

security only), backlighting, odometer and fuel level. Uponkey ON (Engine Stop Switch set to RUN), the check enginelamp and security lamp will illuminate for four seconds andthen (if parameters are normal) will turn off.

• To locate faulty circuits or other system problems, followthe diagnostic flow charts and tests in this section. For asystematic approach, always begin with 2.2 INITIAL DIA-GNOSTIC CHECK: SPEEDOMETER, Initial Diagnosticswhich follows. Read the general information and then workyour way through the flow chart box by box.

• Loss of power on any of the three power inputs will changespeedometer behavior. Refer to Table 2-1.

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

Terminal 8 and 11(Trip Odometer Reset

Switch)

Terminal 7 (GRD)Terminal 6 (ACC)Terminal 1 (IGN)

• No Trip OdometerReset Switch function

• Will not "WOW"

• Speedometer com-pletely non-functional

• Diagnostics absent• Tachometer non-func-

tional

• Speedometer will benon-functional inaccessory mode

• Security lamp stillperforms 4-secondbulb check in ignitionmode

• Will not "WOW"• Turn signals still functional• Speedometer will indicate vehicle speed

(zero)• Security lamp still functional• Check engine lamp and battery lamp

non-functional• Diagnostics absent

Diagnostic NotesIf a numbered circle appears adjacent to a flow chart box, moreinformation is offered in the diagnostic notes. Many diagnosticnotes contain supplemental information, descriptions of variousdiagnostic tools or references to other parts of the manualwhere information on the location and removal of componentsmay be obtained.

Circuit Diagram/Wire Harness ConnectorTableWhen working through a flow chart, refer to the illustrations,the associated circuit diagram and the wire harness connectortable as necessary.The wire harness connector table for eachcircuit diagram identifies the connector number, description,type and general location.

In order to perform most diagnostic routines, a Breakout Boxand a digital volt/ohmmeter (DVOM) are required. See2.5 BREAKOUT BOX: SPEEDOMETER/TACHOMETER.

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


Reprogramming ECMDiagnostic charts frequently suggest Electronic Control Module(ECM) replacement. In the event an ECM needs to be replaced,

it must be reprogrammed using a computer-based diagnosticpackage called DIGITAL TECHNICIAN (Part No. HD-44750).See your dealer. Password learn procedure must also be per-formed. See 3.25 TSM/HFSM: PASSWORD LEARN orE.21 TSM/TSSM: PASSWORD LEARN.

ed02881

Figure 2-6. Fuse Block Location:Typical


INITIAL DIAGNOSTICS



INSTRUMENT HARNESS ADAPTERSHD-46601

Diagnostic Tips• See Figure 2-8. If Odometer reads "BUS Er" while Ignition

Switch is turned to IGNITION (Engine Stop Switch at RUNwith the engine off), check diagnostic link for an open orshort to ground between data link connector [91A] terminal"3" and ECM connector [78B] terminal "5",TSM/TSSM/HFSM connector [30B] terminal "3", speedo-meter connector [39B] terminal "2" or tachometer (ifequipped) connector [108B] terminal "2".

• Check for an open data test terminal between data linkconnector [91A] terminal "3" and TSM/TSSM/HFSM con-nector [30B] terminal "3". With ignition switch turned toIGNITION, serial data bus voltage should be typically 0.6-0.8 volts. The range of acceptable operation is greaterthan 0.0 volts and less than 7.0 volts.

• To identify intermittents, wiggle wire harness while per-forming steps in the Initial Diagnostic Check charts.

4

5

6

7

8

9

12

13

14

10

11

2 31ed02882

1. Start relay2. System relay3. MAXIFUSE4. ECM fuse5. Fuel pump fuse6. Engine control fuse7. Spare fuse8. Spare fuse9. Customer accessory fuse10. Battery fuse11. Accessories fuse12. Instruments fuse13. Ignition fuse14. Lights fuse

Figure 2-7. Fuses

Diagnostic NotesThe reference number below correlates with the circled numberon the initial diagnostic check flow charts.

1. Connect BREAKOUT BOX (Part No. HD-42682) betweenspeedometer connector [39A] and wire harness connector[39B] using INSTRUMENT HARNESS ADAPTERS (PartNo. HD-46601). See 2.5 BREAKOUT BOX: SPEEDO-METER/TACHOMETER.

All Speedometer Diagnostic Trouble Codes (DTCs) are listedin Table 2-2.

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

MODULESOLUTIONFAULT CONDITIONRANKINGDTC

Speedometer2.14 DTC U1300, U1301 ORBUS ER

Serial data bus shorted low/open/high1"BUSER"

Speedometer/tachometer2.14 DTC U1300, U1301 ORBUS ER

Serial data bus shorted low2U1300

Speedometer/tachometer2.14 DTC U1300, U1301 ORBUS ER

Serial data bus shorted open/high3U1301

Speedometer/tachometer2.12 DTC U1016, U1255Loss of ECM serial data4U1016

Speedometer/tachometer2.13 DTC U1064, U1255Loss of TSM/TSSM/HFSM serial data5U1064

Speedometer/tachometer2.13 DTC U1064, U1255Missing response from other module(TSM/TSSM/HFSM and/or ECM) atstartup

6U1255

Speedometer/tachometer2.10 DTC B1006, B1007Ignition line overvoltage7B1007

Speedometer/tachometer2.10 DTC B1006, B1007Accessory line overvoltage8B1006

Speedometer2.11 DTC B1008Reset switch closed9B1008

Speedometer2.9 DTC B1004, B1005Fuel level sending unit low10B1004

Speedometer2.9 DTC B1004, B1005Fuel level sending unit high/open11B1005


Other Diagnostic Trouble Codes (DTCs)See 3.10 INITIAL DIAGNOSTIC CHECK: TSM/HFSM for anyDTCs related to the Turn Signal Module (TSM), Turn SignalSecurity Module (TSSM) or Hands-Free Security Module(HFSM).

See E.9 INITIAL DIAGNOSTIC CHECK: TSM/TSSM for anyDiagnostic Trouble Codes (DTCs) related to the turn signalsecurity module (TSSM).

See 4.5 INITIAL DIAGNOSTIC CHECK: EFI for any DiagnosticTrouble Codes (DTCs) related to the Electronic Control Module(ECM).

3

1

2

4

321 12

3

Bat

tery

Igni

tion

Ser

iald

ata

Gro

und

21 1221 65 7

21 65 7

21

Igni

tion

Ser

iald

ata

Bat

tery

Acc

esso

ryG

roun

d

Igni

tion

Ser

iald

ata

Bat

tery

Acc

esso

ryG

roun

d

65 7

21 65 7

21 6 7 12

21 6 7 12

5

5

GY

O

O

GY

BN

/GY

BN

/GY

LGN

/V

LGN

/V

LGN

/V

O/W

O/W

O/W

BN

/GY

O

O

BN

/GY

LGN

/V

O/W

BK

/GN

BK/GN

LGN/V

LGN

/V

BN

/GY

BK

/GN

LGN

/V

ECM

Ser

iald

ata

[30B][30A]

[91A]

GND 1

[108B][108A]

[20B][20A]

[39B][39A]

[78B][78A]

Speedometer

Toignitionfuse

Toinstrument

fuse

Toaccessory

fuse

Tobattery

fuse

Tachometer: FXDLModels

Data LinkConnector

NOTE: Connector [20] not presenton FXDWG/FXDC/FXDF models

TSM/TSSM/HFSM

BK

BK

BK

em01195

Figure 2-8. Diagnostic Check


Table 2-3. Wire Harness Connectors

LOCATIONTYPEDESCRIPTIONNO.

Inside top frame tube12-place DeutschConsole gauges/indicator lamps (allexcept FXDWG, FXDC, FXDF)

[20]

Under electrical caddie cover12-place DeutschTSM/TSSM/HFSM[30]

Back of speedometer12-place PackardSpeedometer[39]

Under electrical caddie cover36-place PackardElectronic Control Module (ECM)[78]

Under electrical caddie cover4-place DeutschData link connector[91]

Back of tachometer12-place PackardTachometer (if equipped)[108]


Initial Diagnostic Check (Part 1 of 3)

Does enginestart?

YES.Starts and runs.

YES.Starts, then stalls.

NO.Cranks, but will not start.

NO.Engine will not crank.

Check for DTCs. See2.3 SPEEDOMETER

SELF DIAGNOSTICS.Were DTCs found?

See 4.12 STARTS,THEN STALLS.

See 4.10 ENGINE CRANKS,BUT WILL NOT START.

See 1.2 STARTINGSYSTEM DIAGNOSIS.

YES

Refer to applicable DTC prioritychart. All DTCs are listed by

priority in Table 2-2.

NOUnable to enter

diagnostic mode.

With Ignition Switch OFF, press andrelease Trip Odometer Reset Switch.Does odometer display appear with

display backlighting?

YES NO

Test for continuity to chassis ground atbreakout box terminal “7” (Black). Wiggle

harness during continuity test.Is there continuity?

YES NO

Test for battery voltage at breakout boxterminal “5” (Black) while wiggling

harness.Is battery voltage continuously present?

Locate andrepair open.

YES NO

With Ignition Switch OFF and speedometerconnector [39] disconnected, test for continuitybetween breakout box terminals “8” and “11”.

Is continuity present when Trip Odometer ResetSwitch is depressed and infinity when released?


YES NO

ReplaceSpeedometer.

Replace Trip OdometerReset Switch.

STOP

Go to Initial DiagnosticCheck (Part 2 of 3).

1

fc01178_en



Continued from Initial Diagnostic Check (Part 1 of 3).Turn Ignition Switch to IGNITION (IGN).

Is odometer backlight present?

YES NO

ReplaceSpeedometer.Perform “WOW” test.

See 2.3 SPEEDOMETER SELF DIAGNOSTICS.The following features should be functional:

1) Backlight should illuminate.2) Needles should sweep full range of motion.3) LEDs should illuminate:

• check engine• battery• security• low fuel• sixth gear

Are all features functional?

YES

Turn Ignition Switch to ACC.Is backlight present?

YES NO

Check for battery voltage atbreakout box terminal “6”.Is battery voltage present?

YES NO

ReplaceSpeedometer.

Is accessoryfuse good?

YES NO

Locate and repair open on(O/W) wire between

terminal “6” of connector[39] and accessory fuse.

Locate and repairsource of fault.Replace fuse.

STOP

Go to InitialDiagnostic

Check (Part 3 of 3).

1

NO

Turn Ignition Switch to IGN. Checkfor battery voltage at breakout

box terminal “1”.Is battery voltage present?

YES NO

ReplaceSpeedometer.

Is instrumentfuse good?

YES NO

Locate and repair openbetween terminal “1” of

connector [39] andinstrument fuse.


1

fc01179_en



Continued from Initial Diagnostic Check (Part 2 of 3).Is problem intermittent?

YES

NO.Speedometer

inoperative(no vehicle speed).

NO.Tachometerinoperative

(no engine speed).

Repeat diagnosticcheck while wiggling

harnesses.Was intermittent found?

Remove and inspectVehicle Speed Sensor.

Debris present?

See TachometerInoperative (Part 1 of 2).

YES NO

Locate and repairintermittent.

No troublefound.

YES NO

Remove debris.Reinstall

Vehicle Speed Sensor.

Check for damaged wiring/loose connection between

Vehicle Speed Sensor and ECM.Is wiring damage/loose

connection present?

YES NO

Locate and repairsource of fault.

ReplaceSpeedometer.

fc01637_en


2.3SPEEDOMETER SELF DIAGNOSTICS

GENERALThe speedometer is capable of displaying and clearingspeedometer, tachometer, TSM/TSSM/HFSM, and ECM Dia-gnostic Trouble Codes (DTCs) (diagnostic mode).

DIAGNOSTICS

Diagnostic Tips• For a quick check of Speedometer function, a "WOW" test

can be performed. Press and hold Trip Odometer ResetSwitch, then turn Ignition Switch ON. Release Trip Odo-meter Reset Switch. See Figure 2-9 or Figure 2-10.Background lighting should illuminate, gauge needleshould sweep its full range of motion, and indicator lamps(sixth gear indicator, check engine, low fuel, battery,security and pursuit (tachometer)) should illuminate. Alllamps should illuminate even those not used in normalvehicle operations.

• If Speedometer fails "WOW" test, check for battery,ground, ignition, Trip Odometer Reset Switch andaccessory wiring to Speedometer. If any feature in theSpeedometer is non-functional, see 2.2 INITIAL DIA-GNOSTIC CHECK: SPEEDOMETER.


1. To exit diagnostic mode, turn Ignition Switch OFF.

2. To clear DTCs for the selected module:

a. Press and hold the Trip Odometer Reset Switch formore than 5 seconds to display available modules,release.

b. Press the Trip Odometer Reset Switch to choose themodule.

c. Press and hold the Trip Odometer Reset Switch formore than 5 seconds to display the DTC, release.

d. Press and hold the Trip Odometer Reset Switch formore than 5 seconds to clear the DTCs for theselected module.

4

5

321

ed02883

1. Sixth gear indicator2. Check engine lamp3. Low fuel lamp4. Battery lamp5. Security lamp (key icon)

Figure 2-9. Speedometer: All but FXDWG, FXDF


6

5431

2

ed02884

1. Sixth gear indicator2. Cruise lamp (not used)3. Check engine lamp4. Low fuel lamp5. Battery lamp6. Security lamp (key icon)



Speedometer Self Diagnostics (chart)

1

While holding Trip Odometer ResetSwitch in, turn Ignition Switch to

IGNITION (IGN).Make sure Engine Stop Switch is in

RUN position.

Release Trip Odometer Reset Switch.Does “diag” appear?

YES

”P” flashing.

To display DTCs for theECM, press and holdTrip Odometer Reset

Switch for morethan 5 seconds.

To display DTCs forTSM/TSSM/HFSM,press and hold Trip

Odometer Reset Switchfor more than 5

seconds.

To choose TSM/TSSM/HFSM, press

and release TripOdometer Reset

Switch.

”S” flashing.

To chooseSpeedometer,

press and releaseTrip Odometer Reset

Switch.

”SP” flashing.

To chooseTachometer,


Switch.

To choose ABS,press and release

Trip Odometer ResetSwitch.

”T” flashing.

To display DTCs forspeedometer, press and

hold Trip OdometerReset Switch for more

than 5 seconds.

To display DTCs forTachometer (if

equipped), press andhold Trip Odometer

Reset Switch for morethan 5 seconds.

Press and release TripOdometer Reset Switch again

to continue to next module.

See 2.2 INITIALDIAGNOSTIC

CHECK: SPEEDOMETER.

YES

YES

NO

NO

NO

Deviceresponse?

Press andrelease

Trip OdometerReset Switch.Part number ofmodule will be

displayed.

Press andrelease

Trip OdometerReset Switch.

Are more DTCsdisplayed?

“end” displayed.To clear all DTCs for selected

module hold Trip Odometer ResetSwitch for more than 5 seconds.

If DTCs are not to be cleared,Press and release Trip Odometer

Reset Switch. Part number ofmodule will be displayed.

“no rsp” displayed. Seeapplicable code from

other modules. Modelsnot equipped with a

tachometer or ABS willdisplay “no rsp” normally.

If “no rsp” displayed onodometer on tachometer

equipped vehicle,See 2.4

SPEEDOMETER/TACHOMETER.

“none”displayed.

DTCdisplayed.

Press and release Trip Odometer Reset Switch.“PSSPtb” appears.

2

fc01638_en

”b” flashing.

To choose ECM,press and release


To display DTCs forABS (if equipped),

press andhold Trip Odometer



2.4SPEEDOMETER/TACHOMETER

GENERALNOTES

• See Figure 2-11 or Figure 2-12.The speedometer consistsof a speedometer display and four status lamps.The lampsinclude: check engine, low fuel, battery, security and sixthgear indicator.

• Some icons may illuminate during the "WOW" test thoughthe icon has no functionality on that vehicle.

• The speedometer consists of a speedometer display andseveral icons. The icons include: check engine, security,battery, low fuel and sixth gear indicator.

Trip Odometer Reset SwitchSee Figure 2-12. Pressing the Trip Odometer Reset Switchprovides the following capabilities:

• Change the odometer display between mileage, trip A andtrip B values and clock (press and immediately release).

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

• Gain access to the diagnostic mode and clear DiagnosticTrouble Codes (DTCs). See 2.3 SPEEDOMETER SELFDIAGNOSTICS.

• Display odometer while Ignition Switch is OFF. Press andhold Trip Odometer Reset Switch while Ignition Switch isOFF and odometer mileage or clock will be displayed.

• On models with dual scale speedometers, toggle betweenmiles/kilometers on odometer and trip odometer display.To toggle display, turn Ignition Switch ON. Press and holdTrip Odometer Reset Switch while odometer is displayed.Release switch when change is noted. (If Trip OdometerReset Switch is held while trip odometer is displayed, tripodometer will reset).

ed02885


ed02886

Figure 2-12. Speedometer: FXD, FXDB, FXDL

SPEEDOMETER THEORY OF OPERATIONThe Speedometer system consists of a Vehicle Speed Sensor(VSS), the ECM, Trip Odometer Reset Switch and thespeedometer. The Vehicle Speed Sensor (VSS) is mountedon the right side of transmission case below the starter. The


sensor circuitry is that of a Hall-effect sensor triggered by thegear teeth of 4th gear on the transmission mainshaft.

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

ODOMETER THEORY OF OPERATIONThe odometer mileage is permanently stored and will not belost when electrical power is turned off or disconnected. Thetrip odometer reset switch allows switching between the odo-meter, trip odometer A and trip odometer B displays.

To zero the trip odometer, have the desired trip odometer dis-play visible and press and hold the trip odometer reset switch.The trip odometer mileage will be displayed for 2-3 secondsand then the trip mileage will return to zero miles.

The odometer can display six numbers to indicate a maximumof 999999 miles/kilometers.The trip odometers can display sixnumbers with a tenth of a mile accuracy for a maximum of9999.9 miles/kilometers.

The speedometer indicates when vehicle is in sixth gear.Selection of sixth gear is inferred as the system identifies whencorrect RPM and vehicle speed concide.

TACHOMETER THEORY OF OPERATIONSee Figure 2-13. The Tachometer receives serial data fromthe ECM. The Tachometer interprets the serial data and con-verts it into tachometer needle movement.

ed02817

Figure 2-13.Tachometer: FXDL

DIAGNOSTICS






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 connector and tachometer.

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


Tachometer Inoperative (Part 1 of 2)

Perform “WOW” test. See 2.3 SPEEDOMETERSELF DIAGNOSTICS.

The following features should be functional:1) Backlight should illuminate.2) Needles should sweep full range of motion.3) LED’s should illuminate:

• cruise (although not cruise equipped)• pursuit (although not a police vehicle)


YES

Is problem intermittent?

YES NO


harnesses.

No trouble found.

NO


YES NO

Is instrument fuse good?

YES NO

Locate and repairopen in (O) wire

between terminal “1” ofconnector [108] and

instrument fuse.


Check for continuitybetween breakout box

terminal “2” and terminal“7” of connector [20].Is continuity present?

YES NO

Locate and repair openon (LGN/V) wire.STOP

Go to TachometerInoperative (Part 2 of 2).

2

1

3

fc01182_en


Tachometer Inoperative (Part 2 of 2)

Continued from TachometerInoperative (Part 1 of 2).

Check for continuity to chassis ground onbreakout box terminal "7". Wiggleharness during continuity check.


YES NO

Check for battery voltage at breakoutbox terminal “5” while wiggling

harness.Is battery voltage continuously

present?

Locate and repair open on (BK/GN) wirebetween terminal “7” of connector [108]

and chassis ground.

YES NO


Locate and repair open on (BN/GY)wire between terminal “5” of connector

[108] and battery fuse.

YES NO

ReplaceTachometer.

Locate and repair openon (O/W) wire between

terminal “6” ofconnector [108] and

accessory fuse. fc01183_en


2.5BREAKOUT BOX:SPEEDOMETER/TACHOMETER

GENERAL




The BREAKOUT BOX (Part No. HD-42682) and INSTRUMENTHARNESS ADAPTERS (Part No. HD-46601) connect to thespeedometer connector [39] or tachometer connector [108].Used in conjunction with a digital volt/ohmmeter (DVOM), itallows circuit diagnosis of wiring harness and connectionswithout having to probe with sharp objects

NOTE

See wiring diagrams for speedometer and tachometer terminalfunctions.

SPEEDOMETER

Installation1. See Figure 2-14. Bend back the external latches slightly

and remove connector [39B].

2. Connect instrument harness adapters to connectors [39A]and [39B].

3. Attach connectors from Breakout Box to instrument har-ness adapters.

Removal1. Disconnect Breakout Box from harness adapters.

2. See Figure 2-14. Detach instrument harness adaptersfrom connectors [39A] and [39B].

3. Install wire harness connector [39B] to speedometer.

ed02887

Figure 2-14. Speedometer Connector [39]

TACHOMETER

Installation1. Bend back the external latches slightly and remove con-

nector [108B].

2. Connect instrument harness adapters to connectors [108A]and [108B].

3. Attach connectors from Breakout Box to instrument har-ness adapters.

Removal1. Disconnect Breakout Box from harness adapters.

2. Disconnect harness adapters from connectors [108A] and[108B].

3. Install wire harness connector [108B] to speedometer.


2.6FUEL GAUGE

THEORY OF OPERATIONWith Ignition Switch turned to IGNITION (IGN), the fuel gaugeis connected to 12V. Current flows through the gauge andvariable resistor in the fuel gauge sending unit to ground. Thesending unit float controls the amount of resistance in thevariable resistor.

Inoperative gauges may be caused by several circumstances

• Sender or fuel gauge not grounded.

• Malfunction in sender or fuel gauge.

• Broken or disconnected wire from ignition switch to fuelgauge.

• Corroded connections at fuel gauge.

Use the 4.13 FUEL SYSTEM ELECTRICAL TEST to test sus-pected components.

FUEL GAUGE AND SENDER TEST


MULTI-METERHD-35500

NOTE

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

1. Remove fuel gauge. Ground (Y/W) wire of fuel gaugesender located at bottom of fuel gauge.Turn ignition switchto IGNITION.

a. Fuel gauge must indicate FULL. If gauge indicatedFULL, gauge is functioning correctly. Proceed to step2

b. If fuel gauge did not indicate FULL, proceed to step3.

2. Set MULTI-METER (Part No. HD-35500) to Rx1 scale tomeasure the resistance of the sending unit. Place oneprobe on (Y/W) and on the other probe on chassis ground.

a. If fuel tank is full, the reading should be 27-40 ohms.An empty tank should have a 240-264 ohm resist-ance. A half full tank will be approximately 97-118ohms.

b. If a very high resistance or infinity is indicated on themeter, the sender may be "open" or not grounded.Check that sender and fuel tank are grounded byplacing one probe of Multi-Meter on sender flangeand the other probe on crankcase. Meter mustindicate one ohm or less. Replace sender if one ohmor less was present. If a higher resistance is present,check for poor connection on ground wire.

3. Check voltage to (O/W) and (BK) wire of fuel gauge con-nector [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.

ed02888

Figure 2-15. Fuel Gauge Connector


2.7INDICATOR LAMPS: ALL BUTFXDWG/FXDC/FXDF

GENERALSee Figure 2-16. All models are equipped with Light EmittingDiode (LED) indicator lamps which must be replaced as acomplete assembly with harness.


3

2

1

ed02889

1. LED assembly2. Release latch (4)3. Connector [21]

Figure 2-16. LED Assembly: FXDB

Table 2-4. FXD/FXDB/FXDL Connector [20] Terminals

FUNCTIONWIRE COLORTERMINALON [20]

Right turnBrown3

High beamWhite4

Left turnViolet5

Neutral/oil pressure powerOrange6

Neutral lamp to switchTan8

Oil pressure lamp to switchGreen/Yellow9

Turn signal/high beam groundBlack12

Table 2-5. Indicator Lamp Wiring

CONNECTIONINDICATOR LAMP

Ground through switchOil pressure

Ground through switchNeutral

12V when activeHigh beam

12V when activeRight/left turn

DIAGNOSTICS




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

2. When an open circuit is present, a resistance reading ofseveral hundred ohms may be possible due to the neutrallamp (LED).


Oil Pressure or Neutral Indicator Will Not Function

Turn Ignition Switch to IGN. Checkfor 12V at connector [20] terminal “6”.

Turn off Ignition Switch.Was 12V present?

1

YES

With transmission in neutral, check forcontinuity to chassis ground at breakout box

terminal “8” (neutral) andterminal “9” (oil pressure).

Is continuity (less than 10 ohms) present?

YES

Replace indicatorlamp assembly.

NO

Check for bad fusesor locate open.

NO

Check each terminal for continuitythrough switch.


YES NO NO

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

Replace OilPressure Switch.


5048

5191

5048

5161 5157

fc01184_en

2


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

Check for continuity tochassis ground at

breakout box terminal “12”.Is continuity present?

YES NO

Check for 12V when circuit is active:Breakout box terminal “5” (left turn), terminal “3”

(right turn) or terminal “4” (high beam).Is 12V present?

YES

Replace indicator lampassembly.

Locate and repairopen in circuit.

NO


1

5048

5191 5048

fc01185_en


2.8INDICATOR LAMPS: FXDWG/FXDC/FXDF

GENERALSee Figure 2-17. All Models are equipped with Light EmittingDiode (LED) indicator lamps which must be replaced as acomplete assembly with harness.


21

3

ed02890

1. Nut2. Console3. LED assembly

Figure 2-17. LED Assembly: FXDWG/FXDF

2

1

3

2

ed02891

1. LED assembly2. Clips (2 pair)3. Connector [21]

Figure 2-18. FXDWG Connector [21]

Table 2-6. FXD/FXDB/FXDL Connector [20] Terminals

FUNCTIONWIRE COLORTERMINALON [20]

Left turnViolet1

High beamWhite2

Oil pressureGreen/Yellow3

Right turnBrown4

NeutralTan5

Neutral/oil pressureOrange6

Left turn/high beamBlack7

n/aNot used8

Table 2-7. LED Assembly Wiring

CONNECTIONINDICATOR LAMP

Ground through switchOil pressure

Ground through switchNeutral

12V when activeHigh beam

12V when activeRight/left turn

DIAGNOSTICS


1. When an open circuit is present, a resistance reading ofseveral hundred ohms may be possible due to the neutrallamp (LED).


Oil Pressure or Neutral Indicator Will Not Function

Turn Ignition Switch to IGNITION(IGN). Check for 12V at terminal

“6” of connector [21A].Turn off Ignition Switch.

Was 12V present?

1

YES

With transmission in neutral, check forcontinuity to chassis ground on connector

[21] terminal “5” (neutral) andterminal “3” (oil pressure).


YES


NO

Check for bad fusesor locate open.

NO

Check each terminal for continuityto chassis ground through switch.


YES NO NO

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

Replace OilPressure Switch.


5048

5191

50485161 5157

fc01186_en


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

Check for continuity to chassisground at connector [21A]

terminal “7”.Is continuity present?

YES NO

Check for 12V when circuit is active:Use terminal “1” (left turn), terminal “4”

(right turn) and terminal “2” (high beam).Is voltage present?

YES



NO


5048

5191 5048 fc01187_en


2.9DTC B1004, B1005

GENERALSee Figure 2-19. The fuel level is monitored by the speedo-meter terminal "9" of connector [39] (Y/W).

• If the voltage on terminal "9" of connector [39] exceedsthe lower limit for greater than or equal to 15 seconds DTCB1004 will set.

• If the voltage on terminal "9" of connector [39] exceedsthe upper limit (or is open) for greater than or equal to 15seconds DTC B1005 will set.

Table 2-8. Code Description

DESCRIPTIONDTC

Fuel level sending unit lowB1004

Fuel level sending unit high/openB1005

ed02887


DIAGNOSTICS





Diagnostic TipsIf fuel gauge is performing erratically (possible false diagnostictrouble codes ), inspect for unobstructed movement of sendingunit arm. Repair or align as necessary.


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

2. Connect BREAKOUT BOX (Part No. HD-42682) andINSTRUMENT HARNESS ADAPTERS (Part No. HD-416061) between wire harness and speedometer.


Data LinkConnector

[91A]

[78B]

[78A]

[39B]

NOTE: Connector [20] not presenton FXDWG, FXDC, FXDF models

[39A]

[20B]

[20A]

[141B]

[141A]

To ignitionfuse

2

1

B C

BA C D

3

4

1 2 5 6 7 9

1 2

1 2 4

6 7 10 12

1 2 6 7 10 12

1 2 5 6 7 9

Speedometer

[117B]

FuelGauge

Fuel LevelSender

To batteryfuse

To accessoryfuse

To instrumentfuse

O

O

O

O

GY

BK

BKY/W

Y/W

Y/W

Y/W

Y/W

BK

LGN/V

LGN

/VLG

N/V

BN/GY

BN

/GY

BN

/GY

O/W

O/W

O/W

LGN

/V

5

5

ECM

Ser

iald

ata

Igni

tion

Ser

iald

ata

Bat

tery

Acc

esso

ryG

roun

d

Fue

llev

el

BK

/GN

O

Y/W

LGN

/V

BN

/GY

O/W

BK

/GN

BK

/GN

BK

/GN

BK/GN

em01196

Figure 2-20. Fuel Sender Circuit



Back of speedometer12-place PackardSpeedometer/Main Harness Intercon-nect

[20]




Under fuel tank4-place MultilockFuel gauge[117]

Top of fuel tank4-place PackardFuel pump and sender[141]


Fuel Level Sending Unit Low: DTC B1004

Clear codes using Speedometer Self Diagnostics. Disconnect fuellevel sender connector [141B]. Use Speedometer Self Diagnostics

to display current speedometer DTCs.Does DTC B1004 return?

NOTEDTC B1005 may set with connector [141B] disconnected.

NOYES

Replace the fuellevel sending unit.

Replace speedometer.

Clear codes using Speedometer Self Diagnostics. Disconnect fuelgauge connector [117B]. Use Speedometer Self Diagnostics to

display current speedometer DTCs.Does DTC B1004 return?

NOTEDTC B1005 may set with connector [117B] disconnected.

YES NO

Replace thefuel gauge.

YES

Locate and repairshort to ground.

Disconnect speedometer connector [39B].Check for continuity to ground in (Y/W) wire at

connector [39B].Is continuity less then 10 ohms?

NO

fc01188_en

Clear DTCs using speedometer self diagnostics.See 2.3 SPEEDOMETER SELF DIAGNOSTICS.Confirm proper operation with no check engine lamp.

1


Fuel Level Sending Unit High/Open: DTC B1005

Disconnect speedometer connector [39].Measure voltage on terminal “B” of

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

YES NO

Check continuity between terminal“B” of connector [141B] (Y/W) andbreakout box terminal “9” (Black).


Locate and repair shortto voltage.

YES NO

Check continuity to chassis ground onterminal “C” of connector [141B].


Locate and repair openon (Y/W) wire.

YES NO

Repair/replace FuelLevel Sending Unit.

Locate and repair open on(BK/GN) wire (ground

circuit).

1

1

2

1

Clear DTCs using speedometer self diagnostics.See 2.3 SPEEDOMETER SELF DIAGNOSTICS.Confirm proper operation with no check engine lamp. fc01189_en


2.10DTC B1006, B1007

GENERAL

Accessory or Ignition Line OvervoltageIgnition and accessory voltage is constantly monitored by thespeedometer (terminal "1" ignition and terminal "6" accessory).If the battery voltage fails to meet normal operating parameters,a Diagnostic Trouble Code (DTC) 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.

NOTE

ECM or TSM/TSSM/HFSM may also set a battery voltage DTC.


DESCRIPTIONDTC

Accessory line overvoltageB1006

Ignition line overvoltageB1007


Accessory Or Ignition Line Overvoltage: DTC B1006, B1007

Has battery charger beenrecently connected?

YES NO

Diagnose charging system.See 1.7 CHARGING SYSTEM.

Disconnect battery charger. Clear codes.

NOTEBattery charger may cause overvoltage

condition which will set codes.

Start vehicle. Run at 3000RPM for 5 seconds.Does DTC reset?

YES NO

Diagnose charging system.See 1.7 CHARGING SYSTEM.

Systemnormal.



2.11DTC B1008

GENERAL

Trip Odometer Reset Switch ClosedDiagnostic Trouble Code (DTC) B1008 will be set if Trip Odo-meter Reset Switch terminals are in a constant shorted state.


DESCRIPTIONDTC

Trip Odometer Reset Switch closedB1008

DIAGNOSTICS


ADAPTERSHD-41606



1. Connect BREAKOUT BOX (Part No. HD-42682) andADAPTERS (Part No. HD-41606) between wire harnessand speedometer, leaving speedometer disconnected.

ed02892

Figure 2-21.Trip Odometer Reset Switch: FXDWG, FXDC,FXDF

ed02893

Figure 2-22.Trip Odometer Reset Switch: FXDL


8

11

8

11

Trip odometer reset switch


Speedometer

Trip OdometerReset Switch

[39A] [39B]

BK

BK

BK

BK

em01197

Figure 2-23.Trip Odometer Reset Switch Circuit





Trip Odometer Reset Switch Closed: DTC B1008

Remove Trip Odometer Reset Switch rubber boot.Clear DTCs.

See 2.3 SPEEDOMETER SELF DIAGNOSTICS.Are DTCs still present?


YES NO

With speedometer connector [39] disconnected, measureresistance between breakout box terminals “8” and “11” (Black).Resistance should be less than 1 ohm with Trip Odometer Reset

Switch depressed and infinity ohms when released.Is it?

1

YES NO

ReplaceSpeedometer.


Replace Trip OdometerReset Switch rubber boot.

fc01191_en


2.12DTC U1016, U1255

GENERAL

Loss of ECM Serial DataThe serial data line provides a means for the electronic controlmodule (ECM), TSM/TSSM/HFSM, and Speedometer tocommunicate their current status. When all operating para-meters on the serial data line are within specifications, a stateof health message is sent between the components. A Dia-gnostic Trouble Code (DTC) U1016 indicates that the ECM isnot capable of sending this state of health message. A DTCU1255 indicates that no messages were present during powerup of the current key cycle. A DTC U1016 indicates that therewas communication on the data bus since power up, butcommunication was lost or interrupted during that key cycle.


DESCRIPTIONDTC

Loss of all ECM serial data (state of health)U1016

Serial data error/missing messageU1255

DIAGNOSTICS





1. Connect BREAKOUT BOX (Part No. HD-42682) (gray)between TSM/TSSM/HFSM connector [30A] and wireharness connector [30B]. See 2.5 BREAKOUT BOX:SPEEDOMETER/TACHOMETER.

2. Use BREAKOUT BOX (Part No. HD-43876) between wireharness and ECM. See 4.7 BREAKOUT BOX: EFI.

ed02894

Figure 2-24. ECM Location

3

21

ed02982

1. Terminal 2: ground (BK/GN)2. Terminal 3: serial data (LGN/V)3. Terminal 4: power (GY)

Figure 2-25. Data Link Connector


3

1

2

4

321 12

3

Bat

tery

Igni

tion

Ser

iald

ata

Gro

und

21 1221 65 7

21 65 7

21

Igni

tion

Ser

iald

ata

Bat

tery

Acc

esso

ryG

roun

d

Igni

tion

Ser

iald

ata

Bat

tery

Acc

esso

ryG

roun

d

65 7

21 65 7

21 6 7 12

21 6 7 12

5

5

GY

O

O

GY

BN

/GY

BN

/GY

LGN

/V

LGN

/V

LGN

/V

O/W

O/W

O/W

BN

/GY

O

O

BN

/GY

LGN

/V

O/W

BK

/GN

BK/GN

LGN/V

LGN

/V

BN

/GY

BK

/GN

LGN

/VECM

Ser

iald

ata

[30B][30A]

[91A]

GND 1

[108B][108A]

[20B][20A]

[39B][39A]

[78B][78A]

Speedometer

Toignitionfuse

Toinstrument

fuse

Toaccessory

fuse

Tobattery

fuse


Data LinkConnector


TSM/TSSM/HFSM

BK

BK

BK

em01195

Figure 2-26. Serial Data Circuit



Inside top frame tube12-place DeutschConsole gauges (all except FXDWG,FXDC, FXDF)

[20]







Loss of ECM Serial Data: DTC U1016, U1255

Can you read ECM hardware part number?(see 2.3 SPEEDOMETER SELF DIAGNOSTICS)

YES NO or “No Rsp”

While wiggling harness, check continuitybetween TSM/TSSM/HFSM breakout box

terminal “3” (Gray) and ECM breakoutbox terminal “5”.


Check continuity betweenTSM/TSSM/HFSM breakout box

terminal “3” (Gray) and ECMbreakout box terminal “5”.


YES NO

Clear codes. Test ride.Does DTC U1016

return?

Repair intermittenton (LGN/V) wire.

YES

Replace ECM.Reprogram and learn

password.

No trouble found.

NO

2 2

YES NO


password.

Repair open on(LGN/V) wire.

Clear DTCs using speedometer selfdiagnostics. See 2.3 SPEEDOMETER SELFDIAGNOSTICS. Confirm proper operationwith no check engine lamp.

1 1

fc01192_en


2.13DTC U1064, U1255

GENERAL

Loss of TSM/TSSM/HFSM Serial DataThe serial data line provides a means for the electronic controlmodule (ECM), TSM/TSSM/HFSM, and Speedometer tocommunicate their current status. When all operating para-meters on the serial data bus are within specifications, a stateof health message is sent between the components. A Dia-gnostic Trouble Code (DTC) U1064 indicates that the TSM/TSSM/HFSM is not receiving this state of health message. ADTC U1255 indicates that no messages were present duringpower up of the current key cycle. A DTC U1064 indicates thatthere was communication on the data bus since power up, butcommunication was lost or interrupted during that key cycle.


DESCRIPTIONDTC

Loss of TSM/TSSM/HFSM serial dataU1064


DIAGNOSTICS



SPEEDOMETER HARNESSADAPTERS

HD-46601


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

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

b. Mate black pin housing on Breakout Box withspeedometer connector [39B] using SPEEDOMETERHARNESS ADAPTERS (Part No. HD-46601).

c. See Figure 2-27. Mate gray socket housing onBreakout Box with TSM/TSSM/HFSM connector[30A].

d. Mate gray pin housing on Breakout Box with wireharness connector [30B].

ed02895

Figure 2-27.TSM/TSSM/HFSM:Typical

3

21

ed02982




3

1

2

4

321 12

3

Bat

tery

Igni

tion

Ser

iald

ata

Gro

und

21 1221 65 7

21 65 7

21

Igni

tion

Ser

iald

ata

Bat

tery

Acc

esso

ryG

roun

d

Igni

tion

Ser

iald

ata

Bat

tery

Acc

esso

ryG

roun

d

65 7

21 65 7

21 6 7 12

21 6 7 12

5

5

GY

O

O

GY

BN

/GY

BN

/GY

LGN

/V

LGN

/V

LGN

/V

O/W

O/W

O/W

BN

/GY

O

O

BN

/GY

LGN

/V

O/W

BK

/GN

BK/GN

LGN/V

LGN

/V

BN

/GY

BK

/GN

LGN

/V

ECM

Ser

iald

ata

[30B][30A]

[91A]

GND 1

[108B][108A]

[20B][20A]

[39B][39A]

[78B][78A]

Speedometer

Toignitionfuse

Toinstrument

fuse

Toaccessory

fuse

Tobattery

fuse


Data LinkConnector


TSM/TSSM/HFSM

BK

BK

BK

em01195




Inside top frame tube12-place DeutschConsole gauges (all except FXDG,FXDC, FXDF)

[20]







Loss of TSM/TSSM/HFSM Serial Data: DTC U1064, U1255

Can you read TSM/TSSM/HFSM hardware part number?(see 2.3 SPEEDOMETER SELF DIAGNOSTICS)


While wiggling harness, check continuitybetween speedometer breakout boxterminal “2” (Black) and TSM/TSSM/

HFSM breakout box terminal “3” (Gray).Is continuity present?

Check continuity betweenspeedometer breakout box terminal“2” (Black) and TSM/TSSM/HFSMbreakout box terminal “3” (Gray).


YES NO

Clear codes. Test ride.Does DTC U1064

return?


YES

Replace TSM/TSSM/HFSM.

Perform password learn.

No trouble found.

NO

YES NO


Perform password learn.



1 1

fc01193_en


2.14DTC U1300, U1301 OR BUS ER

GENERAL

Serial Data Low or Serial Data Open/HighSee Figure 2-30.The typical serial data voltage range is 0 volts(inactive) to 7 volts (active). Due to the short pulse, voltageswill be much lower on a DVOM. In analog mode, a DVOMreading serial data will show continuous voltage when active,typically 0.6-0.8 volts. The range for acceptable operations is0-7.0 volts.


DESCRIPTIONDTC

Serial data lowU1300

Serial data open/highU1301

ed02896

Figure 2-30. Data Link Connector [91A] (typical)

DIAGNOSTICS

Diagnostic Tips• If serial data is shorted, these Diagnostic Trouble Codes

(DTCs) will automatically cause the check engine lamp toilluminate. The odometer will read "Bus Er" in this condi-tion.

• DTCs P1009 and P1010 may accompany DTCs U1300and U1301.

Diagnostic NotesIf a U1300, U1301 or "Bus Er" is present, perform diagnosticprocedures listed in 4.12 STARTS, THEN STALLS.


SUBJECT............................................................................................................................PAGE NO.3.1 TURN SIGNAL OVERVIEW.......................................................................................................3-13.2 HARLEY-DAVIDSON SMART SECURITY SYSTEM.................................................................3-23.3 H-DSSS ACTUATION................................................................................................................3-53.4 PERSONAL IDENTIFICATION NUMBER (PIN)........................................................................3-63.5 ARMING/DISARMING SECURITY SYSTEM............................................................................3-83.6 WARNINGS AND ALARMS.....................................................................................................3-103.7 SERVICE/EMERGENCY FUNCTIONS...................................................................................3-113.8 TROUBLESHOOTING.............................................................................................................3-123.9 CHECKING FOR DIAGNOSTIC TROUBLE CODES..............................................................3-133.10 INITIAL DIAGNOSTIC CHECK: TSM/HFSM.........................................................................3-173.11 SPEEDOMETER SELF DIAGNOSTICS...............................................................................3-223.12 BREAKOUT BOX: TSM/HFSM..............................................................................................3-243.13 FAILS TO DISARM (HFSM ONLY)........................................................................................3-263.14 DTC B0563............................................................................................................................3-293.15 TSM/HFSM: TURN SIGNAL ERRORS AND DTCS..............................................................3-303.16 DTC B1131, B1132 (HFSM ONLY)........................................................................................3-433.17 DTC B1134 STARTER OUTPUT HIGH.................................................................................3-463.18 DTC B1135............................................................................................................................3-493.19 DTC B1136, B1142 (HFSM ONLY)........................................................................................3-503.20 DTC B1141 (HFSM ONLY)....................................................................................................3-513.21 DTC B1143, B1144, B1145 (HFSM ONLY)...........................................................................3-563.22 DTC B1154, B1155...............................................................................................................3-613.23 DTC U1016, U1255...............................................................................................................3-653.24 DTC U1300, U1301 OR BUS ER..........................................................................................3-683.25 TSM/HFSM: PASSWORD LEARN.........................................................................................3-693.26 HFSM MAINTENANCE.........................................................................................................3-70

TS

M/H

FS

M

3.1TURN SIGNAL OVERVIEW

GENERALSee Figure 3-1. The Turn Signal Module (TSM) has two majorfunctions:

• Control turn signals.

• Serve as Bank Angle Sensor (BAS).

The optional, factory-installed, Harley-Davidson Smart SecuritySystem (H-DSSS) includes a Hands-Free Security Module(HFSM) which provides the same functions as the TSM, butalso includes security and immobilization functions.

SECURITY SYSTEM: JAPAN/KOREAThe security system on motorcycles sold in Japan and Koreameets the regulatory requirements for those countries. Thesystem incorporates a Turn Signal Security Module (TSSM).Complete details on operation, troubleshooting, and diagnosticsare found in E.1 TSM/TSSM (JAPAN/KOREA) OVERVIEW.

TURN SIGNAL FUNCTIONS• Manual turn signal control: Manual activation/deactiva-

tion of left and right turn signal flashing sequences.

• Automatic turn signal cancellation: Automatic cancella-tion of left and right turn signal flashing sequences basedon either vehicle speed, vehicle acceleration or turn com-pletion.

• Hazard warning 4-way flashers: Four-way left and rightturn signal flashing capability.

• Turn signal lamp diagnostics: Self-diagnostics for shortcircuit and open lamp conditions on both left and right turnsignal systems. See 3.9 CHECKING FOR DIAGNOSTICTROUBLE CODES.

NOTE

The turn signals cannot be activated or deactivated when theIgnition Switch is in the ACC position. The turn signals canonly be activated or deactivated with the Ignition Switch in theIGNITION position.

MANUAL CANCELLATIONTo stop the turn signals from flashing, briefly depress the turnsignal switch a second time.

To switch turn direction signals, depress the switch for theopposite turn signal. The first signal is cancelled and theopposite side begins flashing.

AUTOMATIC CANCELLATIONPress the left or right turn switch to activate automatic turnsignal cancellation. There is no need to hold the turn switch in

when approaching the turn. The TSM/HFSM will not cancelthe signal before the turn is actually completed.

• When the directional switch is released, the system startsa 20 count. As long as the vehicle is traveling above 7MPH (11.3 km/h) the directional will always cancel after20 flashes if the system does not recognize any otherinput.

• If the vehicle speed drops to 7 MPH (11.3 km/h) or less,including stopped, the directionals will continue to flash.Counting will resume when vehicle speed reaches 8MPH (12.9 km/h) and will automatically cancel when thecount total equals 20 as stated above.

• The turn signals will cancel within two seconds upon turncompletion. A sensor inside the TSM/HFSM cancels thesignal after the vehicle has been returned to an uprightposition.

NOTE

The bank angle cancellation function has an automatic calibra-tion feature. Ride the motorcycle for 0.25 miles (0.4 km) atsteady speeds (upright) to calibrate the system. Performanceof bank angle function may not be optimal until this calibrationis performed. This self-calibration is performed automaticallyevery time the vehicle is started and ridden.

BANK ANGLE FUNCTIONS• Emergency engine shutdown: Will provide engine

shutdown when vehicle is tipped over.

• Emergency outputs disable: Will disable turn signallamps and starter motor when vehicle is tipped over.

BANK ANGLE RESTARTThe engine will shut off automatically if the vehicle is tippedover.The turn signals, starter motor, Electronic Control Module(ECM), fuel pump and coil will be disabled.

The odometer displays "tIP" when a tip over condition isdetected.

To restart the motorcycle after shutdown has occurred:

1. Return the motorcycle to an upright position.

2. Cycle the Ignition Switch OFF-IGNITION before restartingthe motorcycle.

CLUTCH/NEUTRAL INTERLOCK• Disables starter: Disables starter until either the clutch

lever is pulled in or transmission neutral is selected.

• Diagnostics: Provides diagnostics for clutch and neutralswitch faults.

SECURITY SYSTEM H-DSSSSee 3.2 HARLEY-DAVIDSON SMART SECURITY SYSTEM.

2008 Dyna Diagnostics: TSM/HFSM 3-1

3.2HARLEY-DAVIDSON SMART SECURITY SYSTEM

COMPONENTSThe Harley-Davidson Smart Security System (H-DSSS) con-sists of three components:

• Hands-Free Security Module: See Figure 3-1. A elec-tronic module that functions both as the Turn SignalModule (TSM) and as the Hands-Free Security Module(HFSM).

• Hands-Free Antenna: See Figure 3-1. Mounted underthe seat of the motorcycle.

• Hands-Free Fob: See Figure 3-2. A remote control device,intended to be carried by the rider whenever the vehicleis being operated.

NOTE

Do not relocate any of the Security System components.

ed02826

Figure 3-1. Hands-Free Security Module w/Antenna

ed02044

Figure 3-2. Hands-Free Fob w/Serial Number Label

SECURITY IMMOBILIZATIONThe Hands Free Security Module (HFSM) provides securityand immobilization functions not found on the Turn SignalModule (TSM). The HFSM will disable the starter and ignitionsystem. Additional functions include the ability to alternatelyflash the left and right turn signals and sound a siren (ifequipped) if a theft attempt is detected.

NOTE

The siren must be in the Chirp Mode for the siren to chirp onarming or disarming. See 3.6 WARNINGS AND ALARMS,Siren Chirp Mode (Confirmation).

Conditions that activate the security system when system isarmed include:

• Detecting tampering of the ignition circuit: Turn signalsflash three times, optional siren chirps once and then turnsoff. If the tampering continues, a second warning willactivate after four seconds. Continued tampering will causethe alarm to activate for 30 seconds and then turn off.Thetwo warnings/alarm cycle is repeated for each tamperingincident.

• Detecting vehicle movement: Turn signals flash threetimes, optional siren chirps once and then turns off. If thevehicle is not returned to its original position, a secondwarning will activate after four seconds. If the vehicle isnot returned to its original position, the alarm activates for30 seconds then turns off. The two warnings/alarm cyclemay repeat a maximum of 10 times with a 10 secondpause between cycles.

• Detecting that a battery or ground disconnect hasoccurred while armed: Siren, if installed, activates itsself-alarm mode. Turn signals will not flash.

3-2 2008 Dyna Diagnostics: TSM/HFSM

See 3.5 ARMING/DISARMING SECURITY SYSTEM for moreinformation.

NOTE

Disconnect the battery to prevent the siren (if installed) fromactivating within 5 seconds of turning the Ignition Switch toOFF/FORK LOCK. If the HFSM is armed, you must turn theIgnition Switch to IGNITION with a fob within range, again turnthe Ignition Switch to OFF/FORK LOCK and remove theMAXIFUSE before the 5-second arming period expires. Withthe MAXIFUSE removed, the battery can be disconnected.

HFSM FEATURESThe following information applies only to motorcycles equippedwith the Hands-Free Security Module (HFSM).

• Security lamp: See Figure 3-3. A lamp (key icon) withinthe display face tells the rider if the system is armed ordisarmed.

• Personal code disarming: If the fob is not available, theHFSM allows the rider to disable the security alarm andimmobilization functions with a five-digit personal code.

• Arming confirmation: When the HFSM is armed, thesystem provides visual feedback (confirmation) to the riderby flashing the turn signals and an audible "chirp" ifequipped with the optional smart siren and chirp mode isenabled.

• Disarming confirmation: When the HFSM is disarmed,the system provides an audible "chirp" (confirmation) ifequipped with the optional smart siren and chirp mode isenabled.

• Transport mode: It is possible to arm the security systemwithout enabling the motion detector for one ignition cycle.This allows the vehicle to be moved in an immobilizedstate.

• Starter/ignition disable: When armed the starter andignition system are disabled.

• Security system alarm: See Figure 3-4. The system willalternately flash the left and right turn signals and soundan optional Smart Siren if a vehicle security condition isdetected while the system is armed.

• Dealer service mode: This mode allows the dealer todisable security system via DIGITAL TECHNICIAN. Dealerservice mode is exited when module detects an assignedfob in range.

ed02827

Figure 3-3. Security Lamp (key icon): Dyna Models

ed02047

Figure 3-4. Security Siren


1

3

3

Battery

Serialdata

Serialdata

+ -

BatteryFuse

IGN Fuse

ACC Fuse

421

2

1 Receive antenna

Transmit antenna A

Transmit antenna B3

2

1

2

1

2

5

2 2

5

12

4

7

8

2

1

3

12

4

7

8

2

1

3

22

6

5

9

10

11

6

5

9

86 30

8783

10

11

40 AmpMAXIFUSE

FuseBlock

IgnitionSwitch

Data LinkConnector

ECM

Speedometer

Right TurnSwitch

StartRelay

Starter

EngineStop Switch

StartSwitch

ClutchSwitch

BatteryBackedSiren(Optional)

Tobatterypositive

Toignitionswitch

ToIGNfuse

ToECM

Left TurnSwitch

NeutralSwitch

Receive

HandsFree

Antenna

HFSM

TSM/HFSM

Right TurnLamps

Left TurnLamps

BK

BK

BN

BN

BN

BN

BN

BK BK

BK

BK

BKB

KB

K

GN

BK

BK

GY

BK

GY

TN

R

V

V V

V V

RR

R

R/BK

R/GYR/BK

W/BK

W/BK W/BK

BK

/R

BK/R

BN/GY

LGN/V LGN/V

TN/GN

BK/GN

BK

/GN

LGN/BNLG

N/V

LGN

/V

LGN

/V

Y/BK

O/Y

O/W

O/W

W/BN

W/V

O/W

[78B]

[91A]

[78A]

[39A] [39B]

[209B] [209A]

[208B] [208A]

[142B] [142A]

[30B] [30A] [30A] [30B]

Alarmsignal

Battery

Clutchswitch

Ignition

Start relaycontrol

Left turnswitch input

Right turnswitch input

Serial data

Left turnfeed

Neutralswitch

Right turnfeed

Ground

em01219

Figure 3-5. Simplified TSM/HFSM Wiring


3.3H-DSSS ACTUATION

GENERALSetting up a vehicle TSM/HFSM depends on whether thevehicle has a Turn Signal Module (TSM) or the optional HandsFree Security Module (HFSM) security system installed.

SIDECAR CONFIGURATION

Only Touring Harley-Davidson Motorcycles are suitablefor sidecar use. Consult a Harley-Davidson dealer. Use ofmotorcycles other than Touring models with sidecarscould result in death or serious injury. (00040a)

All motorcycles ship with the H-DSSS set for use without asidecar installed. If a motorcycle is equipped with a TSM, nofurther actuation is required.

ACTUATIONActuation consists of assigning two fobs to the system, andentering an initial Personal Identification Number (PIN). ThePIN can be changed by the rider at any time.

1. Configure HFSM motorcycles by assigning both fobs tothe vehicle.

2. Configure HFSM motorcycles by entering a PIN pickedby the owner. The personal code allows the owner tooperate the system if the fob is lost or inoperable. Recordthe PIN in the Owner's Manual and instruct the customerto carry a copy (use the wallet card found in the Owner'sManual). See 3.4 PERSONAL IDENTIFICATION NUMBER(PIN).

Once the system has been activated, it will always "arm" within5 seconds of turning the Ignition Switch to OFF and no motor-cycle motion.

FOB ASSIGNMENT



Use DIGITAL TECHNICIAN (Part No. HD-44750) to assignboth fobs to the H-DSSS. Follow the menu prompts in theDigital Technician display and scan the fob serial number withthe bar code reader, or key-in the number from the keyboard.See a Harley-Davidson dealer.

NOTE

Each fob has a unique serial number. The label should beremoved from the fob and attached to a blank NOTES pagein the Owner's Manual for reference.

POWER DISRUPTION AND CONFIGURING



The HFSM will not enter PIN entry mode on the first attemptafter battery voltage has been removed from terminal "1".Thiswill occur after any of the following:

• Battery disconnect or power drain.

• Battery fuse removal.

• Connecting BREAKOUT BOX (Part No. HD-42682) toHFSM connector.

Therefore, after all battery reconnects, the configurationsequence must be modified as follows:

1. Set Engine Stop Switch to OFF, cycle Ignition SwitchIGNITION-OFF-IGNITION-OFF-IGNITION and press leftturn signal switch twice.

2. Repeat steps listed above.

3. Continue with PIN entry sequence listed.


3.4PERSONAL IDENTIFICATION NUMBER (PIN)

GENERALThe Personal Identification Number (PIN) consists of five digits.Each digit can be any number from 1-9.There can be no zeros(0) in the PIN. The PIN must be used to disarm the securitysystem in case the fob becomes unavailable.

INITIAL PIN ENTRYTo enter a PIN on a motorcycle with no PIN previously installedduring HFSM actuation, refer to Table 3-1.

Table 3-1. Entering an Initial PIN: HFSM

CONFIRMATIONACTIONSTEP

Select a 5-digit (1 through 9) initial PIN and record in the Owner'sManual and on the wallet card.

1

With an assigned fob present, set Engine Stop Switch to OFF.2

Cycle Ignition Switch IGNITION-OFF-IGNITION-OFF-IGNITION.3

Turn signals will flash 3 times.Press left turn signal button 2 times.4

Five dashes will appear in the odometerwindow. The first dash will flash.

Press right turn signal button 1 time.5

Enter first digit (a) of initial PIN by pressing left turn signal button untildesired digit is displayed in odometer.

6

The digit (a) will replace the dash in theodometer. The second dash will flash.


Enter second digit (b) of initial PIN by pressing left turn signal buttonuntil desired digit is displayed in odometer.

8

The digit (b) will replace the dash in theodometer. The third dash will flash.


Enter third digit (c) of initial PIN by pressing left turn signal button untildesired digit is displayed in odometer.

10

The digit (c) will replace the dash in theodometer. The fourth dash will flash.


Enter fourth digit (d) of initial PIN by pressing left turn signal buttonuntil desired digit is displayed in odometer.

12

The digit (d) will replace the dash in theodometer. The fifth dash will flash.


Enter fifth digit (e) of initial PIN by pressing left turn signal button untildesired digit is displayed in odometer.

14

The digit (e) will replace the dash in theodometer. The first digit will flash.


Turn the Ignition Switch to OFF.16

CHANGING THE PINTo change a PIN, refer to Table 3-2. The rider can change thePIN at any time.

Modifying an Existing PinIf a PIN was previously entered, the odometer will display theequivalent digit. Each additional press of the left turn switchwill increment the digit.

Examples:

• To advance from 5 to 6, press and release the left turnswitch 1 time.

• To advance from 8 to 2, press and release the left turnswitch 3 times (9-1-2).


Table 3-2. Changing the PIN: HFSM

NOTESCONFIRMATIONACTIONSTEP

Select a 5-digit (1 through 9) personalcode and record in the Owner's Manualand on the wallet card.

1

With fobs present, cycle Ignition SwitchIGNITION-OFF-IGNITION-OFF-IGNITION.

2

Turn signals will flash 3 times.Press left turn signal button 2 times.3

Current PIN will appear in odometer. Thefirst digit will flash.


Enter first digit (a) of new PIN by pressingleft turn signal button until desired digit isdisplayed in odometer.

5

The new digit will replace the current inthe odometer. The second digit will flash.


Enter second digit (b) of new PIN bypressing left turn signal button untildesired digit is displayed in odometer.

7

The new digit will replace the current inthe odometer. The third digit will flash.


Enter third digit (c) of new PIN by pressingleft turn signal button until desired digit isdisplayed in odometer.

9

The new digit will replace the dash in theodometer. The fourth digit will flash.


Enter fourth digit (d) of new PIN bypressing left turn signal button untildesired digit is displayed in odometer.

11

The new digit will replace the current inthe odometer. The fifth digit will flash.


Enter fifth digit (e) of new PIN by pressingleft turn signal button until desired digit isdisplayed in odometer.

13

The new digit will replace the current inthe odometer. The first digit will flash.


Turning Ignition Switch to OFFstores the PIN.

Turn the Ignition Switch to OFF.15


3.5ARMING/DISARMING SECURITY SYSTEM

HANDS-FREE FOBSee Figure 3-6. The HFSM's reception range for the Hands-Free Fob signal depends on a specific receiver pattern. Therange will be an arm's length.

NOTES

• Environmental and geographic conditions may affect signalrange.

• Always have the fob present whenever the motorcycle isoperated.

• Do not place fob in metal enclosure, and do not place itcloser than 3.0 in. (80.0 mm) to the hands-free antenna,cellular phones, PDAs, displays and other electronicdevices while operating the motorcycle.That may preventthe fob from disarming the security system.

• Fob battery should be replaced every year. See3.26 HFSM MAINTENANCE.

ed02049

Figure 3-6. Hands-Free Fob

SECURITY LAMP (KEY ICON)Refer to Table 3-3. See Figure 3-7. The security lamp (keyicon) in the speedometer face provides feedback to the riderconfirming armed or disarmed status.

Table 3-3. Security Lamp Status

MODELAMP

No security system (TSM only), securitysystem not armed.

Does not flash.

Two minute timeout after failed PIN entryattempt or a battery reconnect hasoccurred while armed.

Flashes everysecond.

Security system armed.Flashes every 2.5seconds.

PIN entry mode.Flashes 4 times asecond.

Arming is starting up. You have 5seconds before system is armed.

Stays on solid withIgnition SwitchOFF.

If solid for more than 4 seconds afterIgnition Switch is turned to IGNITION, acurrent DTC is present.

Stays on solid withIgnition Switch ON.

ed02920

Figure 3-7. Security Lamp (Key Icon)

ARMINGThe H-D Smart Security System automatically arms within fiveseconds when the motorcycle is parked and the Ignition Switchis turned to OFF and motion is not detected.

Confirmation: On arming, the turn signals flash twice and theSmart Siren will "chirp" twice if chirp function is activated.Whilearmed, the security lamp (key icon) will flash every 2.5 seconds.Refer to Table 3-3.


DISARMINGThere are two ways to disarm the H-D Smart Security System:

• Automatic disarming.

• Using the PIN.

Automatic Disarming: Always have the fob present whenriding, loading, fueling, moving, parking or servicing themotorcycle. Carry the fob in a convenient pocket. The H-DSmart Security System disarms automatically when the IgnitionSwitch is turned to IGNITION.

Confirmation: On disarming, the Smart Siren will chirp once(if chirp function is activated) and the security lamp (key icon)

will turn ON solid for four seconds then go out. Refer toTable 3-3.

DISARMING WITH A PERSONALIDENTIFICATION NUMBER (PIN)See 3.4 PERSONAL IDENTIFICATION NUMBER (PIN) toenter an initial PIN to actuate the system.

Refer to Table 3-4. If you make an error while disarming theHFSM using the PIN, the alarm will activate for 30 secondsafter the last digit is entered. After a failed attempt, the securitylamp will flash once every second for 2 minutes. During thistime, the vehicle will not accept any attempt to enter a PIN.

Table 3-4. Entering the PIN to Disarm HFSM (Example: 3-1-3-1-3)

NOTESWAIT FOR CONFIRMATIONACTIONNO.

Set Engine Stop Switch to OFF.1

Turn Ignition Switch to IGNITION.2

System is ready for PINentry.

Security lamp blinks at fast rate and "0-- - - " is displayed in the odometer. Thefirst digit will flash.

Hold both turn switches in until confirm-ation. *

3

Enter first digit of code (3) by pressingleft turn switch 3 times.

4

Serves as "enter" key.The first digit will be displayed and thenext dash will flash in the odometer.

Press right turn switch 1 time.5

Enter second digit of code (1) bypressing left turn switch 1 time.

6

Serves as "enter" key.The first two digits will be displayed andthe next dash will flash in the odometer.


Enter third digit of code (3) by pressingleft turn switch 3 times.

8

Serves as "enter" key.The first three digits will be displayedand the next dash will flash in the odo-meter.


Enter fourth digit of code (1) bypressing left turn switch 1 time.

10

Serves as "enter" key.The first four digits will be displayedand the next dash will flash in the odo-meter.


Enter fifth digit of code (3) by pressingleft turn switch 3 times.

12

System is disarmed.Security lamp stops blinking and theodometer displays miles.


* This must be done within two seconds of turning the Ignition Switch to IGNITION. If system issues a warning before the securitysystem flashes at a fast rate, then cycle Ignition Switch OFF until security key icon flashes at 2.5 second rate before re-attemptingPIN entry.


3.6WARNINGS AND ALARMS

WARNINGSA warning consists of three alternate flashes of the turn signalsand chirp from the optional Smart Siren. Warnings are issuedfrom an armed HFSM in the following order:

1. First Warning: A warning is issued whenever a personwithout a fob present attempts to move the motorcycle orturns the Ignition Switch to IGNITION.

2. Second Warning: If the motion continues or the IgnitionSwitch is not turned back to OFF, a second warning isissued within four seconds of the first.

3. Alarm: If the motion continues or the Ignition Switch isnot turned to OFF past the second warning, the SmartSecurity System will go into full alarm.

ALARM

ActivationIn the full alarm state, the turn signals flash alternately, and ifequipped with the Smart Siren, the siren will sound.

After 30 seconds of alarm, if no further motorcycle motion isdetected, the alarm will stop.

NOTE

Motorcycle must be returned to original parked position withIgnition Switch turned to OFF.

If motorcycle motion continues, the alarm will start again con-tinue for another 30 seconds.

The HFSM will repeat the alarm cycles 10 times for a total offive minutes, with a 10-second pause between alarm cycles.

NOTES

• During warnings and alarms, the starter motor and theignition remain disabled.

• The alarm will also activate the LED and vibration or aud-ible modes of a Harley-Davidson Security Pager. A pager

can operate either in silent or in combination with anoptional Smart Siren. The range of the pager can be upto 1/2 mile (0.89 km).

DeactivationThe alarm cycles can be discontinued at any time by movingan assigned fob to the motorcycle. The presence of the fobwill terminate the alarm.

SIREN CHIRP MODE (CONFIRMATION)

Chirpless ModeIn the chirpless mode, the siren does not chirp on arming ordisarming.

NOTE

Even when armed in the chirpless mode, the siren still chirpswarnings on movement and will activate the alarm throughcycles.

Chirp ModeOn arming in the chirp mode, the siren responds with twochirps.When disarming, the siren responds with a single chirp.

Switching ModesCycling quickly through two armings and disarmings will switchthe system from either the chirpless mode or the chirp modeto its opposite.

1. With the fob present, the Ignition Switch to IGNITION andthe system disarmed, turn the Ignition Switch OFF.

2. When the system arms (2 flashes of turn signals), imme-diately turn the Ignition Switch to IGNITION.

3. Wait until the security lamp goes out, then immediatelyturn the Ignition Switch OFF.

4. When the system arms (2 flashes of turn signals), imme-diately turn the Ignition Switch to IGNITION and wait forsystem to disarm.


3.7SERVICE/EMERGENCY FUNCTIONS

TRANSPORT MODEIt is possible to arm the security system without enabling themotion detector for one ignition cycle. This allows the vehicleto be picked up and moved in an armed state, however, anyattempt to start the engine will trigger the alarm.

To Enter Transport Mode1. Turn the Ignition Switch to IGNITION.

2. Set the Engine Stop Switch to OFF.

3. With an assigned fob within range, turn the Ignition Switchfrom IGNITION to ACCESS.

4. Simultaneously press both the left and the right turn signalswitches.This must be done within five seconds of turningthe Ignition Switch to ACCESS.

5. After the turn signals flash once, turn the Ignition Switchto OFF and the module is armed.

6. The turn signals flash three times to confirm modulearming in transfer mode for one ignition cycle.

To Exit Transport ModeReturn the system to normal operation:

1. With the fob present, turn the Ignition Switch to IGNITIONto disarm the HFSM. To cancel the transport mode, setthe Engine Stop Switch to RUN.

SERVICE MODE



With a fob present, the HFSM can be configured for serviceby disabling the security system with DIGITAL TECHNI-CIAN (Part No. HD-44750).

Once disabled, the motorcycle can be operated without anassigned fob present. To maintain the Service Mode, theassigned fobs must be kept out of range. If the fob appears inrange, the Service Mode will be exited.

FOUR-WAY FLASHINGIf it is necessary to leave a motorcycle parked along side theroad, the hazard warning four-way flashers can be turned ONwith the Smart Security System armed.

To Arm the HFSM with the Hazard WarningFlashers ON1. Turn the Ignition Switch to IGNITION.

2. Simultaneously press both left and right turn signalswitches to turn the four-way flashers ON. The four-wayflashers will continue for two hours.

3. Turn the Ignition Switch to OFF to arm the Smart SecuritySystem.

To Disarm the HFSM and Turn the HazardWarning Flashers OFF1. With a fob present, turn the Ignition Switch to IGNITION.

2. Simultaneously press the left and right turn signal switches.


3.8TROUBLESHOOTING

TURN SIGNALS (TSM/HFSM)Verify the operation of the turn signals and the integrity of thefuse protecting the turn signals before further troubleshooting.

SECURITY SYSTEM (HFSM)If the fob is present, and the security system is issuing "warn-ings" or "Alarm" when the motorcycle is moved, the reasonmay be one of the following:

1. Strong electromagnetic interference in the area you haveparked.

a. Verify you have not placed your fob in metalenclosure, or within 3.0 in. (80.0 mm) of the hands-free antenna or other electronic devices.

b. Place fob next to motorcycle and turn the IgnitionSwitch to IGNITION. After the system disarms, thefob can be placed back in its carrying location.

c. Try moving the motorcycle approximately 15feet (4.57 m) away from the current parking spot.

2. The fob battery is dead. Use PIN to disarm the vehicle.Replace fob battery.

3. Fob is damaged. Use PIN to disarm the vehicle. Replacethe fob.

NOTES

• If your Security Lamp (key icon) is staying solid ON whileyou are riding the vehicle, take your vehicle to your dealeras soon as practical.

• Always lock the fork and take the ignition key with you foradded protection.

DIAGNOSTICS MODEThe TSM/HFSM measures the current when the turn signalsare used. If there is a burned out light bulb on one side, theremaining light and the corresponding turn signal indicator flashat double the normal rate starting with the fifth flash.

Other diagnostic conditions monitored include:

• Short circuit in the turn signal wiring.

• Open circuit in the turn signal wiring.

• Stuck turn signal switch.

NOTES

• A stuck turn signal switch will disable the automatic turnsignal cancellation feature.

• If a stuck switch is detected, you must hold the left andright turn signal switches in for more than one second toactivate the four-way flashers.

See 3.9 CHECKING FOR DIAGNOSTIC TROUBLE CODESfor more information.

TROUBLESHOOTINGTo resolve TSM/HFSM faults, follow three basic steps:

1. Retrieve Diagnostic Trouble Codes (DTCs) usingspeedometer self diagnostics. See 3.11 SPEEDOMETERSELF DIAGNOSTICS.

2. Diagnose system problems. This involves using specialtools and the diagnostic flow charts in this section.

3. Correct problems through the replacement and/or repairof the affected components.

After repairs are performed, the work must be validated. Thisinvolves clearing the DTCs and confirming proper vehicleoperation as indicated by the behavior of the turn signals.


3.9CHECKING FOR DIAGNOSTIC TROUBLE CODES

GENERALProblems fall into at least one of five categories:

• Turn signal malfunction.

• Bank angle (engine disable).

• Clutch/neutral interlock (starter enable).

• Security lamp problem.

• Security system malfunction.

SECURITY LAMP DIAGNOSTICSTo diagnose system problems, start by observing the behaviorof the security lamp.

NOTES

• See Figure 3-8 or Figure 3-9. "Key ON" means that theIgnition Switch is turned to IGNITION and the Engine StopSwitch is set to RUN (although the engine is not running).

• See Figure 3-10. When the Ignition Switch is turned toIGNITION, the security lamp will illuminate for approxim-ately four seconds and then turn off.

• If the security lamp is not illuminated at Key ON or if it failsto turn off after the initial four-second period, the speedo-meter may need to be replaced. See 3.11 SPEEDO-METER SELF DIAGNOSTICS. If "BUS Er" is displayedon the odometer, it may take up to twenty seconds for thesecurity lamp to illuminate.

• The security lamp will also light for eight seconds after thebulb check if historic Diagnostic Trouble Codes (DTCs)are present.The security lamp will stay on if current DTCsare set. If a historic DTC is present, the security lamp willlight for 2 ignition cycles or until the DTC is clearedmanually.

See Figure 3-11. After the lamp turns off after being illuminatedfor the first four-second period, one of three events may occur:

• The lamp remains off. This indicates there are no currentfault conditions or stored historic DTCs currently detectedby the HFSM.

• The lamp stays off for only four seconds and then comesback on for an eight-second period. This indicates a his-toric DTC is stored, but no current DTC exists.

• The lamp remains on beyond the eight-second period.This indicates a current DTC exists.

NOTE

See 3.9 CHECKING FOR DIAGNOSTIC TROUBLE CODES,Code Types for a complete description of DTC formats.

32

1

ed02877



312

ed02878




ed02827

Figure 3-10. Security Lamp (key icon): Dyna Models

ONA

B

C

ON

ON

OFF

OFF

OFF

Key On

Key On

Key On


Lamp OFF




4 Sec.

4 Sec.

4 Sec.

4 Sec.

8 Sec.

4 Sec.

ed01046

Figure 3-11. Security Lamp Operation

CODE TYPES



There are two types of DTCs:

• Current

• Historic

If a DTC is stored, it can be read using either a computer-baseddiagnostic package called DIGITAL TECHNICIAN (Part No. HD-

44750) or speedometer self diagnostics. See 3.11 SPEEDO-METER SELF DIAGNOSTICS.

NOTES

• Speedometer self diagnostics will display both current andhistoric DTCs.To differentiate between current and historicDTCs, a computer-based diagnostic package calledDIGITAL TECHNICIAN (Part No. HD-44750) must beemployed.

• All DTCs reside in the memory of the Electronic ControlModule (ECM), TSM/HFSM, speedometer or tachometer


until the DTC is cleared by use of the speedometer selfdiagnostics. See 3.11 SPEEDOMETER SELF DIA-GNOSTICS.

• A historic DTC is also cleared after a total of 50 ignitioncycles has elapsed. After the 50 ignition cycle retentionperiod, the DTC is automatically erased from memoryproviding that no subsequent faults of the same type aredetected in that period.


HistoricIf a particular problem happens to resolve itself, the activestatus problem is dropped and it becomes a historic DTC ratherthan a current DTC. For example, intermittent output shortscan become typical historic DTCs.

Historic DTCs are stored for 50 ignition cycles after any DTCwas last set as current to assist in the diagnosis of intermittentfaults. On the 50th cycle, the DTC will clear itself. The securitylamp will only indicate the existence of historic DTCs for twoignition cycles.

It is important to note that historic DTCs will exist wheneverthe system indicates the existence of a current fault. See3.9 CHECKING FOR DIAGNOSTIC TROUBLE CODES, Mul-tiple DTCs/Priority Order if multiple DTCs are found.

Diagnostic charts are designed for use with current DTCs andas a result they frequently suggest part replacement. Whendiagnosing a historic DTC the charts can be helpful but should

not lead to part replacement without verification the part isfaulty.

RETRIEVING DTCS



The TSM/HFSM supports two levels of diagnostics.

• The most sophisticated mode employs a computer-baseddiagnostic package called DIGITAL TECHNICIAN (PartNo. HD-44750).

• The second mode requires using the speedometer selfdiagnostics. Speedometer, tachometer (if equipped),TSM/HFSM and ECM DTCs can be accessed and cleared.See 3.11 SPEEDOMETER SELF DIAGNOSTICS.

Use of speedometer self diagnostics assumes the DigitalTechnician is not available.

MULTIPLE DTCS/PRIORITY ORDERWhile it is possible for more than one fault to occur and setmore than one DTC, there are several conditions which mayresult in one fault setting multiple DTCs:

Serial data DTCs (U1016, U1300 and U1301) may be accom-panied by other DTCs. Always correct the serial data DTCsbefore resolving the other DTCs.

Refer to Table 3-5. This table lists the DTCs in priority order.Correct DTCs in priority order.

Refer to Table 3-6. This table lists symptoms that may not setdiagnostic trouble codes.

Table 3-5.TSM/HFSM DTCs and Fault Conditions

DIAGNOSTICSFAULT CONDITIONDTCPRIORITY

3.24 DTC U1300, U1301 OR BUS ER.J1850 Short-to-groundU13001

3.24 DTC U1300, U1301 OR BUS ER.J1850 Short-to-batteryU13012

3.23 DTC U1016, U1255.Loss of serial communications - ECMU10163

3.23 DTC U1016, U1255Loss of serial communications - GeneralU12554

3.19 DTC B1136, B1142 (HFSM ONLY).HFSM2 Internal faultB11425

3.18 DTC B1135.Accelerometer periodic test faultB11356

3.19 DTC B1136, B1142 (HFSM ONLY).Accelerometer tip-over self-test faultB1136(HFSM)

7

3.22 DTC B1154, B1155.Clutch switch input short-to-groundB11548

3.22 DTC B1154, B1155.Neutral switch input short-to-batteryB11559

3.17 DTC B1134 STARTER OUTPUT HIGH.Starter relay output short-to-batteryB113410

3.15 TSM/HFSM:TURN SIGNAL ERRORS AND DTCS.Left turn lamp output open circuitB1121 (TSM)11

3.15 TSM/HFSM:TURN SIGNAL ERRORS AND DTCS.Left turn lamp output open circuitB1121(HFSM)

3.15 TSM/HFSM:TURN SIGNAL ERRORS AND DTCS.Right turn lamp output open circuitB1122 (TSM)12

3.15 TSM/HFSM:TURN SIGNAL ERRORS AND DTCS.Right turn lamp output open circuitB1122(HFSM)

3.15 TSM/HFSM:TURN SIGNAL ERRORS AND DTCS.Left turn lamp output short-to-groundB1123(HFSM)

13

3.15 TSM/HFSM:TURN SIGNAL ERRORS AND DTCS.Right turn lamp output short-to-groundB1124(HFSM)

14


Table 3-5.TSM/HFSM DTCs and Fault Conditions

DIAGNOSTICSFAULT CONDITIONDTCPRIORITY

3.15 TSM/HFSM:TURN SIGNAL ERRORS AND DTCS.Left turn lamp output short-to-batteryB1125(HFSM)

15

3.15 TSM/HFSM:TURN SIGNAL ERRORS AND DTCS.Right turn lamp output short-to-batteryB1126(HFSM)

16

3.21 DTC B1143, B1144, B1145 (HFSM ONLY).Security antenna short-to-groundB1143(HFSM)

17

3.21 DTC B1143, B1144, B1145 (HFSM ONLY).Security antenna short-to-batteryB1144(HFSM)

18

3.21 DTC B1143, B1144, B1145 (HFSM ONLY).Security antenna openB1145(HFSM)

19

3.14 DTC B0563.Battery voltage highB056320

3.16 DTC B1131, B1132 (HFSM ONLY).Alarm output short-to-groundB1131(HFSM)

21

3.16 DTC B1131, B1132 (HFSM ONLY).Alarm output short-to-batteryB1132(HFSM)

22

3.15 TSM/HFSM:TURN SIGNAL ERRORS AND DTCS.Ignition switch open/lowB1141 (TSM)23

3.20 DTC B1141 (HFSM ONLY).Ignition switch open/lowB1141(HFSM)

24

Table 3-6. Symptoms That May Not Set Diagnostic Trouble Codes

SOLUTIONSYMPTOM

HFSM Fails to Disarm.HFSM: Fails to disarm

Turn Signal Error 1A (Part 1 of 2) Will Not Cancel Upon TurnCompletion.

TSM/HFSM: Turn signal will not cancel

Turn Signal Error 1A (Part 2 of 2) Cancels Erratically.TSM/HFSM: Turn signal cancels erratically

Turn Signal Error 2A Flash at Double Normal Rate, All BulbsWork.

TSM/HFSM: Turn signal flashes double normal rate, all bulbsgood

Turn Signal Error 3A Will Not Flash, 4-Way Flashers Inoperable.TSM: Turn signals will not flash

Will Not Flash, No Codes (Part 1 of 2) DTC: B1141 IgnitionSwitch Open/Low

HFSM: Symptom - Will not flash. No codes or DTC B1141


3.10INITIAL DIAGNOSTIC CHECK:TSM/HFSM

GENERAL



To locate faulty circuits or other system problems, follow thediagnostic flow charts. For a systematic approach, always beginwith INITIAL DIAGNOSTICS. Read the general informationand then work your way through the flow chart box by box.

Diagnostic NotesIf a numbered circle appears adjacent to a flow chart box, thenmore information is offered in the diagnostic notes. Many dia-gnostic notes contain supplemental information, descriptionsof various diagnostic tools or references to other parts of themanual where information on the location and removal ofcomponents may be obtained.


In order to perform most diagnostic routines, a Breakout Boxand a digital volt/ohmmeter (DVOM) are required. See3.12 BREAKOUT BOX: TSM/HFSM.


Job/Time CodesSome charts may contain warranty job/time codes. Dealershiptechnicians filing warranty claims should use the job/time codevalues printed in bold text underneath the appropriate repair.

Reprogramming ECMDiagnostic charts frequently suggest Electronic Control Module(ECM) replacement. In the event an ECM needs to be replaced,it must be reprogrammed using a computer-based diagnosticpackage called DIGITAL TECHNICIAN (Part No. HD-44750).See your dealer. Password learn procedure must also be per-formed. See 3.25 TSM/HFSM: PASSWORD LEARN.

INITIAL DIAGNOSTICS




Diagnostic Tips• See Figure 3-12. If odometer reads "BUS Er" with the

Ignition Switch turned to IGNITION (Engine Stop Switchat RUN with the engine off), check data bus for an openor short to ground between data link connector [91A] ter-minal "3" and ECM connector [78B] terminal "5", HFSMconnector [30B] terminal "3", speedometer connector [39B]terminal "2" or tachometer (if equipped) connector [108B]terminal "2".

• Check for an open diagnostic test terminal between datalink connector [91A] terminal "3" and TSM/HFSM con-nector [30B] terminal "3". With Ignition Switch turned toIGNITION, serial data bus voltage should be typically 0.6-0.8 volts. The range of acceptable voltage is 0-7.0 volts.

• To identify intermittents, wiggle wire harness while per-forming steps in the diagnostic check charts.


1. Connect BREAKOUT BOX (Part No. HD-42682) betweenwire harness connector [39B] and speedometer connector[39A] using INSTRUMENT HARNESS ADAPTERS (PartNo. HD-46601). See 2.5 BREAKOUT BOX: SPEEDO-METER/TACHOMETER.

2. Compare TSM/HFSM system behavior to symptoms inTable 3-6.

Other Diagnostic Trouble Codes (DTCs)See 2.5 BREAKOUT BOX: SPEEDOMETER/TACHOMETERfor any DTCs related to the speedometer.

See 4.5 INITIAL DIAGNOSTIC CHECK: EFI for any DTCsrelated to the Electronic Control Module (ECM)


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5

GY

O

O

GY

BN

/GY

BN

/GY

LGN

/V

LGN

/V

LGN

/V

O/W

O/W

O/W

BN

/GY

O

O

BN

/GY

LGN

/V

O/W

BK

/GN

BK/GN

LGN/V

LGN

/V

BN

/GY

BK

/GN

LGN

/V

ECM

Ser

iald

ata

[30B][30A]

[91A]

GND 1

[108B][108A]

[20B][20A]

[39B][39A]

[78B][78A]

Speedometer

Toignitionfuse

Toinstrument

fuse

Toaccessory

fuse

Tobattery

fuse


Data LinkConnector


TSM/TSSM/HFSM

BK

BK

BK

em01195




Inside top frame tube12-place DeutschConsole gauges (all exceptFXDWG/FXDC/FXDF)

[20]

Under electrical caddie cover12-place DeutschTSM/HFSM[30]







Does enginestart?





Check for DTCs. See3.11 SPEEDOMETERSELF DIAGNOSTICS.

Were DTCs found?




YES



NOUnable to enter

diagnostic mode.

NONo codesdisplayed.



For a list of symptoms thatmay not set diagnostictrouble codes, refer to

Table 3-6.

YES NO

Test for continuity to chassis ground atBreakout Box terminal “7” (Black). Wiggle


YES NO

Test for battery voltage at Breakout Boxterminal “5” (Black) while wiggling harness.

Is battery voltage continuously present?


YES NO

With Ignition Switch OFF and speedometerconnector [39] disconnected, test for continuitybetween Breakout Box terminals “8” and “11”.



YES NO

ReplaceSpeedometer.


STOP


1

fc01252_en

2



Continued from Initial Diagnostic Check (Part 1 of 3).Turn Ignition Switch to IGN,


YES NO

Replace Speedometer.Perform “WOW” test.

See 3.11 SPEEDOMETER SELF DIAGNOSTICS.The following features should be functional:




YES


YES NO

Check for battery voltage atBreakout Box terminal “6”.Is battery voltage present?

YES NO

Replace Speedometer.Is AccessoryFuse good?

YES NO


terminal “6” of connector[39] and Accessory Fuse.


STOP


1

NO

Turn Ignition Switch to IGN. Checkfor battery voltage at Breakout

Box terminal “1”.Is battery voltage present?

YES NO

Replace Speedometer.Is InstrumentFuse good?

YES NO


connector [39] andInstrument Fuse.


1

fc01253_en




YES NO.Speedometer



(no engine speed).




Debris present?

See Test 2.4 TachometerInoperative (Part 1 of 2).

YES NO


No trouble found.

YES NO





connection present?

YES NO


ReplaceSpeedometer.

fc01254_en

2



GENERALThe speedometer is capable of displaying and clearingspeedometer, tachometer, TSM/HFSM, and Electronic ControlModule (ECM) Diagnostic Trouble Codes (DTCs) (diagnosticmode).

DIAGNOSTICS

Diagnostic Tips• For a quick check of Speedometer function, a "WOW" test

can be performed. Press and hold trip odometer resetswitch. See illuminate, gauge then turn Ignition Switch toIGNITION. Release trip odometer reset switch. SeeFigure 3-13. Background lighting should illuminate, gaugeneedles should sweep their full range of motion, andindicator lamps (battery, security, low fuel, check engineand sixth gear indicator) should illuminate. All lamps shouldilluminate, even those not used in normal vehicle opera-tions.

• If speedometer fails "WOW" test, check battery, ground,ignition, trip odometer reset switch and accessory wiringto speedometer. If any feature in the speedometer is non-functional, see 2.2 INITIAL DIAGNOSTIC CHECK:SPEEDOMETER.







d. Press and hold the Trip Odometer Reset Switch formore than 5 seconds to clear DTCs for the moduleselected.

12

34

5

ed02830


Figure 3-13. Speedometer: Dyna Models


Speedometer Self Diagnostics

1

While holding Trip Odometer ResetSwitch in, turn Ignition Switch to IGN.Make sure Engine Stop Switch is in

RUN position.


YES

”P” flashing.





seconds.



Switch.

”S” flashing.



Switch.

”SP” flashing.



Switch.



”T” flashing.



than 5 seconds.







CHECK: SPEEDOMETER.

YES

YES

NO

NO

NO

Deviceresponse?

Press andrelease


displayed.

Press andrelease














DTCdisplayed.


2

fc01126_en

”b” flashing.







3.12BREAKOUT BOX:TSM/HFSM

GENERAL



The BREAKOUT BOX (Part No. HD-42682) splices into themain harness. Used in conjunction with a digital volt/ohmmeter(DVOM), it allows circuit diagnosis of wiring harness and con-nections without having to probe with sharp objects.

INSTALLATIONNOTE

For HFSM, disarm security system, then remove MAXI-FUSEwhile the system remains disarmed.

1. Access TSM/HFSM. See Service Manual.

2. See Figure 3-15. Disconnect harness connector(s) fromTSM/HFSM:

a. For HFSM: Depress latches on antenna connector[208B] and remove from antenna connector [208A].

b. Depress latches on main harness connector [30B]and remove from main harness connector [30A].

3. See Figure 3-14. Attach Breakout Box to connectors:

a. Mate gray socket housing on Breakout Box withTSM/HFSM connector [30A].

b. Mate gray pin housing on Breakout Box with vehicleharness connector [30B].

4. For HFSM: Mate antenna connector [208B] to HFSM.

ed02899

Figure 3-14. Breakout Box:TSM/HFSM

2

1 3

4

ed02050

1. Connector [208A] terminal 12. Connector [208A] terminal 43. Connector [30A] terminal 124. Connector [30A] terminal 1

Figure 3-15.TSM/HFSM Terminal Numbers

Table 3-8.TSM/HFSM Connector [30B]

FUNCTIONTERMINALFUNCTIONTERMINAL

Right turn switch input7Battery1

Left turn switch input8Ignition2

Start relay control9Serial Data3

Clutch switch10Neutral switch4

Alarm signal11Left turn feed5

Ground12Right turn feed6

REMOVAL1. See Figure 3-15. For HFSM: Depress latches on antenna

connector [208B] and disconnect from HFSM antennaconnector [208A].


2. Disconnect Breakout Box from vehicle:

a. Depress latches and detach gray Breakout Box con-nector from TSM/HFSM main harness connector[30A].

b. Detach gray Breakout Box connector from TSM/HFSMmain harness connector [30B].

3. For HFSM: Mate the antenna connector [208B] beforemain harness connector [30B].

4. Mate TSM/HFSM main harness connector [30B] to TSM/HFSM.

5. Reinstall TSM/HFSM. See Dyna Service Manual.

6. Install parts removed for access.

NOTE

Vehicle will not start with TSM/HFSM disconnected or incor-rectly mounted.

Table 3-9.TSM/HFSM Connector [30B]




Start relay control9Serial Data3





3.13FAILS TO DISARM (HFSM ONLY)

GENERALSee Figure 3-16. If the HFSM does not respond or respondsweakly (limited range - will not consistently disarm with fobwithin normal range), follow the flow chart.

ed02826

Figure 3-16. HFSM and Antenna

JOB/TIME CODESDealership technicians filing warranty claims should use thejob/time codes printed in bold text underneath the appropriaterepair.

DIAGNOSTICS

Diagnostic Tips• Verify that a cell phone is not within 3.0 in. (80.0 mm) of

key fob.

• Interference from physical surroundings may affect RFtransmission. Place fob next to motorcycle or movemotorcycle to a new location and retest.

• See Figure 3-16.Verify that antenna is in OE location andthat seat has not been replaced with a metal base seat.

• Check for damage to antenna wire.

• See Figure 3-17. Verify fob battery (1) voltage is at least2.9 volts. See 3.26 HFSM MAINTENANCE.

• Fob serial number (2) is located inside fob. Open fob bytwisting a thin blade in the thumbnail slot between fobhalves.


1. After a battery disconnect, the HFSM will not enter theconfiguration mode on the first attempt. All attempts toassign a fob or enter the configuration mode will requireat least two attempts.

1

2

ed02051

1. Battery2. Fob serial number

Figure 3-17. Open Fob: HFSM


Antenna

HFSM

15 AmpBatteryFuse

40 AmpMAXIFUSE

Tran

smit

ante

nna

BTr

ansm

itan

tenn

aA

Rec

eive

ante

nna

Gro

und

Bat

tery

Battery

BK

O/Y

Y/B

K

BN

/GY

BK/GN

RRBK

1 12

1 12

– +

21

3

3

21

21

21

[30A][30B]

[208A][208B]

[209A]

[209B]

em01220

Figure 3-18. Security Antenna Circuit: HFSM



Under electrical caddie cover12-place DeutschHFSM[30]

Under electrical caddie cover4-place DeutschHFSM antenna harness[208]

Under seat2-place MolexHFSM antenna[209]


HFSM Fails to Disarm

Does any assignedFob work?

YES

Check battery on non-functional Fob.Is battery voltage greater than 2.9 volts?

Replace Fob.See a Harley-

Davidson dealer.Replace Battery.

YES NO

NO

Check for continuity betweenconnector [208B] terminal “1"

and end of (Y/BK) wire (pull backconduit to expose unterminated

end of wire).Continuity present?

YES

Check for continuity between connector[208B] terminal “1” and Ground.

Continuity present?

NO

Locate and repair open wirebetween connector [208B]

and end of (Y/BK) wire.

YES

Locate and repairshort to Ground.

NO

Replace HFSM.Learn password and

perform set-up.

6757

6879

67556756

6879

1

fc01102_en

NOTEThe fob for the HFSM must be assigned using DIGITALTECHNICIAN (Part No. HD-44750). DIGITAL TECHNICIANcan also validate fob operation when connected to the motorcycle.

Replace the security antenna with aknown good security antenna.

Does the security system now disarm?

YES NO

Replace thesecurity antenna.

6879


3.14DTC B0563

GENERALDTC B0563 Battery Voltage High: The TSM/HFSM continuallychecks the battery voltage during IGN/OFF and IGN/RUNpower modes. If the voltage exceeds 16.0 volts for more than5 seconds, the TSM/HFSM sets Diagnostic Trouble Code(DTC) B0563.

DIAGNOSTICS

Diagnostic Tips• This DTC may set when the vehicle is placed on a battery

charger, on fast charge, for a long period of time.

• The HFSM does not illuminate the security lamp when thisDTC is set.

Diagnostic NotesSee 1.7 CHARGING SYSTEM tests to correct. Problem maybe faulty voltage regulator.


3.15TSM/HFSM:TURN SIGNAL ERRORS AND DTCS

GENERALThe turn signals will automatically cancel either based on thespeed/acceleration of the vehicle or based upon turn comple-tion. See 3.1 TURN SIGNAL OVERVIEW.

TSM/HFSM: For turn signal diagnostics based on symptoms,refer to Table 3-11.

TSM DTCs Only: Refer to Table 3-12.

HFSM DTCs Only: Refer to Table 3-13.

Table 3-11.Turn Signal Symptoms:TSM/HFSM

START WITH FLOW CHARTSYMPTOMDTC

Turn Signal Error 1A. (Part 1 of 2) Will Not Cancel Upon Turn CompletionWill not cancel on turn completionN/A

Turn Signal Error 1A. (Part 2 of 2) Cancels ErraticallyCancels erraticallyN/A

Turn Signal Error 2A. Flash at Double Normal Rate, All Bulbs WorkFlash at double normal rate while allbulbs are working

N/A

Table 3-12.Turn Signal DTCs:TSM Only


Turn Signal Error 3A. Will Not Flash, 4-Way Flashers Inoperable: DTCB1121, B1122, B1141

Turn signals will not flash, 4-wayflashers inoperable

B1121

B1122

B1141

Table 3-13.Turn Signal DTCs: HFSM Only


Turn Signal Error 4A. Turn Signal Lamp Open Circuit DTC: B1121 Left/B1122 Right

Left turn signal openB1121

Right turn signal openB1122

Turn Signal Error 5A. Turn Signal Lamp Short-to-Ground DTC: B1123Left/B1124 Right

Left turn signal short-to-groundB1123

Right turn signal short-to-groundB1124

Turn Signal Error 6A. Turn Signal Lamp Short-to-Voltage DTC: B1125Left/B1126 Right

Left turn signal short-to-voltageB1125

Right turn signal short-to-voltageB1126

DIAGNOSTICS


HARNESS CONNECTOR ADAPTERSAND PATCH CORDS

HD-41404-B

Job/Time CodesDealership technicians filing warranty claims should use thejob/time code printed in bold text underneath the appropriaterepair in the following diagnostic flow charts.

Diagnostic Tips• TSM Only: Diagnostic trouble codes B1121 and B1122

will illuminate the security lamp. DTC B1141 will not illu-minate the security lamp.

• HFSM Only: Diagnostic trouble codes B1121, B1122,B1123, B1124, B1125, and B1126 will illuminate thesecurity lamp.

• TSM/HFSM: When an over current or short-to-groundcondition is detected, it will turn off the turn lamp outputs.


IGN

AC

CY

15A

15A

[31A

R]

Igni

tion

Sw

itch

[7A

]

[33A

][3

3B]

To fron

ttu

rnsi

gnal

s

Tore

arlig

htin

g

BK/G

N

Bat

tery

EC

M

15A

15A

BE/G

Y

BN/G

Y

R/BK RR

Sec

urity

Sire

n(O

ptio

nal)

BN/G

Y

BKLG

N/BN

TN/G

N

AIPG

BJRH

Sta

rtR

elay

TN/G

N

GY

GY

O

LGN/

V

LGN/

V

O/W

O/W

LGN/

BN

21 321 3

V

V

BN/G

Y

BN

BN

BN

W/B

NW

/V

W/V

BK/G

N

W/B

K

BE/G

Y

[62B

]

R/BK

R/G

Y R/G

Y

BK/R

R

R

R/BK

GN

GN

BK

BK

BK

BK

[142

B]

[142

A]

[78B

]

[30B

]

Powe

rSi

gnal

Gro

und

BK/GN

[5]

40A

mp

MA

XIF

US

E

BA

GN

D1

Rea

rG

roun

dS

tud

Und

erE

lect

rical

Cen

ter

TN V

12

21

13

8

AC

C−

CB

ATT

−B

IGN

−A

[78A

]

[31A

L]

A B C

4 5 10 13 28 31

4 5 10 13 28 31

K T E S U

87 87A

30 85 86

5 4 3 2 1

EC

M

[24B

]1

57

8

15

78BK/R

BK/GN

BK/R

TS

M/

HF

SM

[64B

]

Hor

nS

witc

hH

eadl

amp

Hi/L

oS

witc

hLe

ftTu

rnS

witc

h

[24A

]

Left

Han

dC

ontr

ols

Clu

tch

Sw

itch

13

45

6

O/W

GYW/BKW/BNBK/R

W/BKW/BNBK/R

Rig

htTu

rnS

witc

hEn

gine

Stop

Switc

hS

tart

Sw

itch

Fron

tSto

pLa

mp

Sw

itch

[22A

]

Rig

htH

and

Con

trol

s

O/W

W/V

BK/RBK

13

45

6

R

Fus

eblo

ckTo

pvi

ewTo

pvi

ew

[64]

[62]

Acc

esso

ries

Ligh

ts

Igni

tion

CB

F L USKE

DC I

J RP

OMG

HBA

H O

G MA

I QP

R

E K TS

U

Fue

lpum

p

Sta

rtR

LYS

yste

mR

LYEC

M

Bat

tery

Spa

reP&

AIG

NIn

stru

men

ts

Spa

re

ENG

CTL

CUST

ACCY

Syst

emRe

lay

R/BK

BK/G

N

GN/

O

[22B

]

GY

O/W

INS

TR

15A

AB

O/W

BK/GN

[20B

]

BN/GY

LGN/VO

12

67

812

3

5 4 3 2 1G

N/O

BE/G

Y

W/B

K

87 87A

30 85 86

I Q C P R

BK

BK

Sta

rter

Bat

tery

Red

Ban

d

21 43 65 87 109 1211

[30A

]

Bat

tery

Igni

tion

Ser

iald

ata

Neu

tral

switc

hLe

fttu

rnfe

edR

ight

turn

feed

Rig

httu

rnsw

itch

inpu

tLe

fttu

rnsw

itch

inpu

tS

tart

rela

yco

ntro

lC

lutc

hsw

itch

inpu

tA

larm

sign

alG

roun

d

Sys

tem

rela

yS

eria

ldat

a

Gro

und

Gro

und

Bat

tery

Sw

itche

dpo

wer

21 3

21 43 65 87 109 1211 21 3

Rec

eive

ante

nna

XM

ITan

tenn

aA

XM

ITan

tenn

aB

2121

Ant

enna

’A’

Ant

enna

’B’

Y/BK

O/Y BK

O/Y BK

Han

dsFr

eeA

nten

na[2

09B

][2

09A

]

[208

A]

[208

B]

TNBK

TN

[131

]

Neu

tral

Sw

itch

Toin

stru

men

tas

sem

bly

AB

BN

5

V

Turn

Sig

nal&

Sec

urity

Mod

ule

GN

D2

em01221

Figure 3-19.Turn Signal Circuit:Typical




Under electrical caddie coverSpade terminalsMAXIFUSE[5]

Under seat8-place MultilockRear lighting[7]

Inside tail lamp lens2-place MultilockLeft rear turn signal[18]

Inside tail lamp lens2-place MultilockRight rear turn signal[19]


[20]

Under fuel tank console (FXDWG,FXDC, FXDF)

8-place Mini-DeutschIndicator lamps[21]

Inside top frame tube6-place MolexRight hand controls[22]

Inside top frame tube8-place MolexLeft hand controls and horn[24]


Inside top frame tube3-place MultilockFront turn signals (left)[31L]

Inside top frame tube3-place MultilockRight turn signals (left)[31R]

FXD, FXDL: Inside top frame tube3-place DelphiIgnition switch[33]FXDWG, FXDC, FXDF: Under fuel tankconsole

Under electrical caddie coverSpade terminalsFuse/relay block (starter relay, systemrelay)

[62]

Under electrical caddie coverSpade terminalsFuse block[64]


Top of transmissionPost terminalsNeutral switch[131]

Under seat3-place DelphiSecurity siren (optional)[142]



Diagnostic Notes: All Turn Signal FlowChartsThe reference numbers below correlate with the circled num-bers on the flow charts.

1. Gain access to vehicle's TSM/HFSM. Perform the followingprocedure:

a. See Figure 3-20. Position TSM/HFSM in same orient-ation it is mounted on vehicle. Turn Ignition Switch toIGNITION.Turn 4-way flashers on by depressing bothleft and right turn signal switches simultaneously.TurnIgnition Switch off; 4-way flashers should continue toflash.

b. Tilt TSM/HFSM greater than 45 degrees to the left.

c. Repeat step a.

d. Tilt TSM/HFSM greater than 45 degrees to the right.

2. To enable diagnostic mode, see 3.9 CHECKING FORDIAGNOSTIC TROUBLE CODES.

3. Connect BREAKOUT BOX (Part No. HD-42682) (gray)between TSM/HFSM connector [30A] and wiring harnessconnector [30B]. See 3.12 BREAKOUT BOX: TSM/HFSM


5. Connect gray HARNESS CONNECTOR ADAPTERS ANDPATCH CORDS (Part No. HD-41404-B) to connector [22](right) or connector [24] (left).

6. Replace HFSM if DTC is current (lamp ON continuously,cleared codes return during operation). If DTC is historic,check for intermittents.

ed02900

Figure 3-20.Tilting TSM/HFSM


Turn Signal Error 1A (Part 1 of 2) Will Not Cancel Upon Turn Completion

Is TSM/HFSM mounted properly?

YES NO

Mount correctly.Check if TSM/HFSM is configured forsolo or side car operation. See 3.3

HDSSS ACTUATION.Proper configuration?

YES NO

Select properVehicle configuration.

Do 4-way flashers cancel inboth directions?

YES NO

Operate motorcycle at a speedgreater than 7 MPH in a straight line.

Activate either turn signal. Turnsignals should cancel after 20 flashes.

Do turn signals cancel?

Replace TSM/HFSM.Perform setup and

password learn.

6773

YES NO

Does speedometerregister vehicle

speed?

YES

Replace TSM/HFSM.Perform password learn

and setup.

NO

Refer to 2.2 INITIALDIAGNOSTIC CHECK:

SPEEDOMETER.

6773

1

2

STOP

Go to Turn Signal Error1A (Part 2 of 2) Cancels

Erractically.

fc01257_en


Turn Signal Error 1A (Part 2 of 2) Cancels Erratically

Continued from Turn Signal Error 1A (Part 1 of 2) Will Not Cancel Upon Turn Completion.

Check for voltage between Breakout Box terminal “8” (Gray) and ground at Breakout Box terminal“12” (Gray): with left turn signal switch depressed, wiggle harness between TSM/HFSM and left

handlebar switches while monitoring for voltage fluctuations or changes in turn signal flash pattern.

Check for voltage between Breakout Box terminal “7” (Gray) and ground at Breakout Box terminal“12” (Gray): with right turn signal switch depressed, wiggle harness between TSM/HFSM and righthandlebar switches while monitoring for voltage fluctuations or changes in turn signal flash pattern.

Are voltage fluctuations present?

YES

Locate and repairintermittent open.

NO

Check for voltage between Breakout Box terminal “8” (Gray) and ground atBreakout Box terminal “12” (Gray): with left turn signal switch NOT depressed,

wiggle harness between TSM/HFSM and left handlebar switches whilemonitoring for voltage fluctuations or turn signal activation.

Check for voltage between Breakout Box terminal “7” (Gray) and ground atBreakout Box terminal “12” (Gray): with right turn signal switch depressed,wiggle harness between TSM/HFSM and right handlebar switches while

monitoring for voltage fluctuations or turn signal flash pattern.


YES

Locate and repairintermittent short to

voltage.

Turn ignition switch OFF.

Check for continuity between Breakout Box terminal “8” (Gray) and groundat Breakout Box terminal “12” (Gray): with left turn signal switch

depressed, wiggle harness between TSM/HFSM and left handlebarswitches.

Check for continuity between Breakout Box terminal “7” (Gray) and groundat Breakout Box terminal “12” (Gray): with right turn signal switch

depressed, wiggle harness between TSM/HFSM and right handlebarswitches.

Is continuity present at any time?

NO

YES NO

Locate and repairintermittent short

to ground.

System OK. Review turn signalcancellation function with customer. SeeAutomatic Cancellation under 3.1 TURN

SIGNAL OVERVIEW.

4

4

3

fc01258_en

6855

6856

6857


Turn Signal Error 2A Flash At Double Rate, All Bulbs Work

YES NO

YES NO

YES NO

YES NO

YES NO YES NO

Determine correct part number forall installed Turn Signal Bulbs and verify

against parts installed on motorcycle.Correct parts installed?

Check for corrosionon bulbs and/or sockets.

Corrosion present?

Check for corrosion on all lampconnection terminals.Corrosion present?

Remove corrosion with a wirebrush. Install ELECTRICAL

CONTACT LUBRICANT (PartNo. 99861-02) in bulb sockets.Do lamps flash at normal rate?

Clean corrosion fromwires and terminals.

Do lamps flash atnormal rate?

Replace Turn Signal Module/HandsFree Security Module (TSM/HFSM).

Learn password (if needed) andperform setup.

Clean or replace Bulb.Do lamps flash at

normal rate?

SystemOK.

SystemOK.

Replace LampAssembly.

SystemOK.

Replace TSM/HFSM.Learn password (if needed)

and perform setup.

Replace withcorrect Bulbs.

6821

6822 6823 6822

6824

6824

6820

fc01104_en

NOTE:Before troubleshooting this issue you should verifythat the lamp loads have been learned by:

1) Turn ignition switch Off-On.2) Activate left turn lamps for 4 or more flashes.3) Activate right turn lamps for 4 or more flashes.


Turn Signal Error 3A (Part 1 of 4) Will Not Flash, 4-Way Flashers Inoperable: DTC B1121,B1122, B1141

Turn ignition switch to IGN.Are turn signal lamps on continuously?

YES NO

Check for voltage on Breakout Box terminal “5” (Gray)(left turn signals) or terminal “6” (Gray) (right turn

signals) with TSM disconnected from Breakout Box.Is battery voltage present?

YES NO

Locate and repairshort to voltage.

Replace TSM. Learnpassword andperform setup.

Activate 4-way flashers.Do any lamps illuminate?

YES NO

Connector [30]mated fully?STOP

Go to Turn Signal Error 3A (Part 2 of 4)Will Not Flash, 4-Way Flashers

Inoperable: DTC B1121, B1122, B1141.

NOYES

Place red meter lead at terminal “1”(Gray) and black meter lead at

terminal “12” (Gray) of BreakoutBox.

Is battery voltage present?

Mateconnector.

NOYES

Move red meter lead toBreakout Box terminal “2”.Is battery voltage present?

STOP


Inoperable: DTC B1121, B1122, B1141.NO

Check for voltage atIgnition Fuse.

Is battery voltage presenton both terminals?

NO

YES

STOP

Go to 4.11 NO ECMPOWER.

3

67906791

3

6792

STOP


Inoperable: DTC B1121, B1122, B1141. YES

Locate and repairopen on (GY) wire

between Ignition Fuseand TSM.

6793

fc01260_en



Continued from Turn Signal Error 3A (Part 1 of 4) Will Not Flash,4-Way Flashers Inoperable: DTC B1121, B1122, B1141.

Inspect bulbs on side that will not flash.Are the bulbs OK?

YES NO

Place jumper wire betweenterminals “1” and “6” of Breakout Box.

Do the right turn signals (front andrear) illuminate?

Replace bulbsas necessary.

6796

YES

Place a jumper wire betweenterminals “1” and “5” of Breakout Box.

Do the left turn signals (front andrear) illuminate?

NO

Check for continuity betweenterminal “6” of Breakout Box and

lamps (front and rear).Continuity present?

YES

Repair openground circuit.

6797

NO

Repair open betweenlamps and TSMconnector [30].

6798

YES NO

Check for continuitybetween terminal “5” of

Breakout Box andlamps (front and rear).

Continuity present?

YES NO


Repair open betweenlamps and TSMconnector [30].6799

6800

STOP

Go to Turn SignalError 2A. Flash At Double

Rate, All Bulbs Work.

fc01261_en



Continued from Turn Signal Error 3A (Part 1 of 4)Will Not Flash, 4-Way Flashers Inoperable: DTC

B1121, B1122, B1141.

Check resistance to ground on Breakout Boxterminal “12” (Gray).

Is resistance less than 1 ohm?

YES

Check for 12 volts at bothterminals of 15 amp Battery Fuse.

Proper voltage present atboth terminals?

YES

Repair open in (BN/GY) wirebetween Battery Fuse and TSM.

6806

NO

NO

One Terminal?

Repair poorground.

6805

Neither terminal?

Replacefuse.

6807

Repair open between 40 AmpMAXIFUSE and fuse block.

6808

fc01262_en



Continued from Turn Signal Error 3A (Part 1 of 4) Will NotFlash, 4-Way Flashers Inoperable: DTC B1121, B1122,

B1141.

Check for battery voltage at breakout box terminal “7”(Gray) with right turn signal depressed and terminal “8”

(Gray) with left turn signal depressed.Is battery voltage present?

YES

Replace TSM.Learn password and

perform set-up.

NO

6791

3

Check for battery voltage on terminal“1” connector [22B] (right), or

connector [24B] (left).Is battery voltage present?

5

YES NO

With turn signal switch depressedon side under test, check for continuity

between terminal “1” and terminal“5” on connector [22A] (right), or

connector [24A] (left).Is continuity present?

Locate and repair open (O/W)wire between terminal “1” on connector

[22B] (right), or connector[24B] (left) and Accessory Fuse.

6814 - right

6812 - left

YES NO

Locate and repair open wirebetween terminal “5” on connector

[22B] (right), or connector [24B](left) and TSM connector [30].

Replace Turn SignalSwitch or repair wiring to

Turn Signal Switch.

6813 - right

6810 - left

6811

fc01263_en


Turn Signal Error 4A: DTC B1121 Left Turn Signal Lamp Open Circuit; DTC B1122 RightTurn Signal Lamp Open Circuit

Inspect bulbs on side that will notflash. Are the bulbs OK?

YES NO

Replace failedbulbs as

necessary.

Place jumper wire between terminals“1” and “6” (right, B1122) or “1” and“5” (left, B1121) on Breakout Box

(Gray).Do the respective turn signals illuminate?

YES NO

Replace HFSM.Learn password and

perform set-up.

3

6807

Check for continuity between BreakoutBox terminal “5” (left) or terminal “6”

(right) and front or rear lamps.Is continuity present?

YES NO


Repair wire betweenconnector [30B] and

turn signal lamp.6808

6805

fc012646790


Turn Signal Error 5A: DTC B1123 Left Turn Signal Lamp Short-To-Ground; DTC B1124Right Turn Signal Lamp Short-To-Ground

Remove turn signal bulbs. Disconnect instrument connector[20]. Check for continuity between terminals “12” and “6” (right,B1124) or “12” and “5” (left, B1123) on Breakout Box (Gray).


YES NO

Locate and repairshort-to-ground.

Replace HFSM. Learn passwordand perform set-up.

3

6

6810 6791

fc01265_en


Turn Signal Error 6A: DTC B1125 Left Turn Signal Lamp Short-To-Voltage; DTC B1126Right Turn Signal Lamp Short-To-Voltage

With ignition ON, check for voltage between terminals “12”and “6” (right, B1126) or “12” and “5” (left, B1125) on

Breakout Box (Gray) with [30] disconnected from HFSM.Voltage present?

YES NO

Locate and repairshort-to-voltage.


3

6

6790 6791

fc01266_en


3.16DTC B1131, B1132 (HFSM ONLY)

GENERALNOTE

This section applies only to those vehicles equipped with theoptional security system.

See Figure 3-21. An alarm cycle is activated when the HFSMis connected, the siren has been armed by the HFSM and asecurity event occurs. See 3.6 WARNINGS AND ALARMS.Under normal armed operation, the siren input (terminal "B")is driven low by the HFSM to trigger the audible alarm. Whenthe siren input is driven high by the HFSM the audible alarmstops.

ed02047

Figure 3-21. Security Siren

DIAGNOSTICS




Diagnostic Tips• If the siren is armed and the internal siren battery is dead,

shorted, disconnected, or has been charging for a period

longer than 24 hours, the siren will respond with threechirps on arming instead of two.

• The internal siren battery may not charge if the vehicle'sbattery is less than 12.5 volts.

• If the siren does not chirp two or three times on a validarming command from the HFSM, the chirp function hasbeen disabled, the siren is either not connected, notworking, or the siren wiring was opened or shorted whilethe siren was disarmed.

• If the siren enters the self-driven mode where it is poweredfrom the siren internal nine-volt battery, the turn-signallamps will not alternately flash. If the HFSM activates thesiren, the turn-signal lamps will flash. If the siren has beenarmed and a security event occurs, and the siren is in self-driven mode, the siren will alarm for 20 to 30 seconds andthen turn off for 5 to 10 seconds. This alarm cycle will berepeated ten times if the siren is in the self-driven mode.

• If the siren does not stop alarming after it has been armed,then either the HFSM output or siren input may be shortedto ground, or the siren vehicle battery connection is openor shorted to ground, or the siren vehicle ground connec-tion is open, or a security event has occurred. See3.6 WARNINGS AND ALARMS for a description of alarmfunctions.


1. Use BREAKOUT BOX (Part No. HD-42682) and HAR-NESS CONNECTOR TEST KIT (Part No. HD-41404-B),gray pin probe and patch cord. See 3.12 BREAKOUTBOX: TSM/HFSM.

2. Use HARNESS CONNECTOR TEST KIT (Part No. HD-41404-B), gray socket probe and patch cord.

3. Having the correct multimeter ohm scale is important forthis test. Some meters may read infinity for high ohmvalues. If this is the case, check your ohm scale and retest.

Table 3-15. Siren Alarm Output DTCs


Alarm Output Low: DTC B1131, Alarm Output High: DTC B1132Alarm output lowB1131

Alarm output highB1132


BK

BK

BK

RR

BN

/GY

BN/GY

BK

/GN

BN/GY

LGN/BN

– +

[30A][30B]

[142A] [142B]

HFSM

GND1 GND2

15 AmpBatteryFuse

40 AmpMAXIFUSE

Battery

SecuritySiren

(Optional)

1

1

Bat

tery

Ala

rmsi

gnal

Gro

und

1211

1211

1

2

3

1

2

3

em01222

Figure 3-22. Smart Siren Circuit




Under seat3-place DelphiSecurity siren[142]


DTC: B1131 Alarm Output Low; DTC: B1132 Alarm Output High

YES

NO

1

YES

2

YES NO

3

NO

NO

NO

NO

YES

YES

YES

Check for battery voltage at Security Sirenconnector [142B]. With ignition ON,

measure voltage between terminal “3” (BK)and terminal “1” (BN/GY).Is battery voltage present?

With ignition OFF, check continuity betweenSecurity Siren connector [142B] terminal “3” and

Breakout Box terminal “12”. Then measurecontinuity between Security Siren connector

[142B] terminal “1” and Breakout Box terminal “1”.Is continuity present?

With ignition OFF, measure resistance betweenSecurity Siren connector [142B] terminal “2” and

Breakout Box terminal “11” (Gray).Is resistance less than 1 ohm?

Measure resistance between BreakoutBox terminal “11” and chassis ground.


Disconnect Security Siren from Breakout Box.Measure resistance between security siren

connector [142A] terminal “2” and “3”.Is resistance between 120,000-200,000ohms with Security Siren disconnected?

Connect Security Siren to a known goodmotorcycle. Arm and activate Security

Siren to verify operation. DisarmSecurity Siren.

Did Security Siren operate correctly?

Replace HFSM. Learnpassword and perform setup.

Locate and repairshort between (BN/GY)

and (BK) wires.

Locate and repairgrounded (LGN/BN)

wire.

Locate and repairopen on (LGN/BN) wire.

ReplaceSecuritySiren.

ReplaceSecuritySiren.

Repairopen wire.


1

fc01112_en

Disconnect HFSM from breakoutbox. Check for voltage on HFSM

connector [30A] pin “11”.Voltage present?

NOYES

Locate and repairShort to voltage on

(LGN/BN) wire.

2

3


3.17DTC B1134 STARTER OUTPUT HIGH

GENERALWith the HFSM (if equipped) disarmed, Ignition Switch turnedto IGNITION, Engine Stop Switch set to RUN and the transmis-sion in neutral or clutch lever pulled in, the start relay isgrounded. Battery voltage is applied to the start relay and coilwhich are grounded through the TSM/HFSM.

DTC B1134: STARTER OUTPUT HIGH is set when that groundis not established through the TSM/HFSM.

DIAGNOSTICS




1. Connect BREAKOUT BOX (Part No. HD-42682) , gray towire harness connector [30] leaving TSM/HFSM discon-nected. See 3.12 BREAKOUT BOX: TSM/HFSM.

ed02901

Figure 3-23. Starter Relay: Dyna Models


IgnitionSwitch:All but

FXDWG/FXDC

40 AmpMAXIFUSE

15 AmpBatteryFuse

GND 1

[30B]

[30A]

[33A]

[33B]

[33A]

To start switchon right handcontrols [22]

Start relay

TSM/HFSM

Battery

- +

BK

R

RR

TN/GN

BN

/GY

BK

/GN

TN

/GN

BK/R

R/B

K

R

R/B

K

R/BK

A B C I B A

IgnitionSwitch:

FXDWG/FXDC/FXDF

I B A

A B C

1 9 12

1

Bat

tery

Sta

rtre

lay

cont

rol

Gro

und

9 12

8787

A30

8586

KT

ES

U

54

32

1

em01223

Figure 3-24. Starter TSM/HFSM Circuits





Inside top frame tube (FXD, FXDL)3-place DelphiIgnition switch[33]Under fuel tank (FXDWG, FXDC,FXDF)

Under electrical caddie cover5-place AmpStart relay[62B]


Starter Output High: DTC B1134

Remove Start Relay.Check for voltage on

Breakout Box terminal “9” (Gray).Voltage present?

YES

Locate and repairshort to voltage

on (TN/GN) wire.

NO

Install Start Relay.Is voltage present on

Breakout Boxterminal “9” (Gray)?

YES

Replace Start Relay.

NO

Replace TSM/HFSM.Learn password and

perform setup.

1


fc01268_en


3.18DTC B1135

DIAGNOSTICS

DTC B1135 Accelerometer FaultDTC B1135 indicates a failure which requires replacement ofthe TSM/HFSM.

NOTE

When DTC B1135 is set, the tip-over engine shutdown, HFSMtamper alarm and bank angle sensors are disabled. Thesecurity lamp will also illuminate when this code is set.


3.19DTC B1136, B1142 (HFSM ONLY)

DIAGNOSTICS

DTC B1136 Accelerometer Tip-OverSelf-Test FaultDTC B1136 indicates a failure which requires replacement ofthe HFSM.

DTC B1142 Internal FaultDTC B1142 indicates a failure which requires replacement ofthe HFSM.


3.20DTC B1141 (HFSM ONLY)

DIAGNOSTICS



Diagnostic TipsDTC B1141: IGNITION SWITCH OPEN/LOW or a symptomof Will Not Flash can be diagnosed using the flow charts.


1. Connect BREAKOUT BOX (Part No. HD-42682) (gray)between TSM/HFSM connector [30A] and wiring harnessconnector [30B]. See 3.12 BREAKOUT BOX:TSM/HFSM.

2. Use HARNESS CONNECTOR TEST KIT (Part No. HD-41404-B), gray terminal probe and patch cord.


IGN

AC

CY

15A

15A

[31A

R]

Igni

tion

Sw

itch

[7A

]

[33A

][3

3B]

To fron

ttu

rnsi

gnal

s

Tore

arlig

htin

g

BK/G

N

Bat

tery

EC

M

15A

15A

BE/G

Y

BN/G

Y

R/BK RR

Sec

urity

Sire

n(O

ptio

nal)

BN/G

Y

BKLG

N/BN

TN/G

N

AIPG

BJRH

Sta

rtR

elay

TN/G

N

GY

GY

O

LGN/

V

LGN/

V

O/W

O/W

LGN/

BN

21 321 3

V

V

BN/G

Y

BN

BN

BN

W/B

NW

/V

W/V

BK/G

N

W/B

K

BE/G

Y

[62B

]

R/BK

R/G

Y R/G

Y

BK/R

R

R

R/BK

GN

GN

BK

BK

BK

BK

[142

B]

[142

A]

[78B

]

[30B

]

Powe

rSi

gnal

Gro

und

BK/GN

[5]

40A

mp

MA

XIF

US

E

BA

GN

D1

Rea

rG

roun

dS

tud

Und

erE

lect

rical

Cen

ter

TN V

12

21

13

8

AC

C−

CB

ATT

−B

IGN

−A

[78A

]

[31A

L]

A B C

4 5 10 13 28 31

4 5 10 13 28 31

K T E S U

87 87A

30 85 86

5 4 3 2 1

EC

M

[24B

]1

57

8

15

78BK/R

BK/GN

BK/R

TS

M/

HF

SM

[64B

]

Hor

nS

witc

hH

eadl

amp

Hi/L

oS

witc

hLe

ftTu

rnS

witc

h

[24A

]

Left

Han

dC

ontr

ols

Clu

tch

Sw

itch

13

45

6

O/W

GYW/BKW/BNBK/R

W/BKW/BNBK/R

Rig

htTu

rnS

witc

hEn

gine

Stop

Switc

hS

tart

Sw

itch

Fron

tSto

pLa

mp

Sw

itch

[22A

]

Rig

htH

and

Con

trol

s

O/W

W/V

BK/RBK

13

45

6

R

Fus

eblo

ckTo

pvi

ewTo

pvi

ew

[64]

[62]

Acc

esso

ries

Ligh

ts

Igni

tion

CB

F L USKE

DC I

J RP

OMG

HBA

H O

G MA

I QP

R

E K TS

U

Fue

lpum

p

Sta

rtR

LYS

yste

mR

LYEC

M

Bat

tery

Spa

reP&

AIG

NIn

stru

men

ts

Spa

re

ENG

CTL

CUST

ACCY

Syst

emRe

lay

R/BK

BK/G

N

GN/

O

[22B

]

GY

O/W

INS

TR

15A

AB

O/W

BK/GN

[20B

]

BN/GY

LGN/VO

12

67

812

3

5 4 3 2 1G

N/O

BE/G

Y

W/B

K

87 87A

30 85 86

I Q C P R

BK

BK

Sta

rter

Bat

tery

Red

Ban

d

21 43 65 87 109 1211

[30A

]

Bat

tery

Igni

tion

Ser

iald

ata

Neu

tral

switc

hLe

fttu

rnfe

edR

ight

turn

feed

Rig

httu

rnsw

itch

inpu

tLe

fttu

rnsw

itch

inpu

tS

tart

rela

yco

ntro

lC

lutc

hsw

itch

inpu

tA

larm

sign

alG

roun

d

Sys

tem

rela

yS

eria

ldat

a

Gro

und

Gro

und

Bat

tery

Sw

itche

dpo

wer

21 3

21 43 65 87 109 1211 21 3

Rec

eive

ante

nna

XM

ITan

tenn

aA

XM

ITan

tenn

aB

2121

Ant

enna

’A’

Ant

enna

’B’

Y/BK

O/Y BK

O/Y BK

Han

dsFr

eeA

nten

na[2

09B

][2

09A

]

[208

A]

[208

B]

TNBK

TN

[131

]

Neu

tral

Sw

itch

Toin

stru

men

tas

sem

bly

AB

BN

5

V

Turn

Sig

nal&

Sec

urity

Mod

ule

GN

D2

em01221

Figure 3-25.Turn Signal Circuit:Typical





Under seat8-place MultilockRear lighting[7]




[20]

Under fuel tank console (FXDWG,FXDC, FXDF)

8-place Mini-DeutschIndicator lamps[21]




Inside top frame tube3-place MultilockFront turn signals (left)[31L]

Inside top frame tube3-place MultilockRight turn signals (left)[31R]

FXD, FXDL: Inside top frame tube3-place DelphiIgnition switch[33]FXDWG, FXDC, FXDF: Under fuel tankconsole


[62]








Will Not Flash, No Codes (Part 1 of 2): DTC B1141 Ignition Switch Open/Low

Turn ignition switch to IGN.Activate 4-way flashers.

Do any turn signals illuminate?

YES NO

Connector [30]fully mated?

YES NO

Place red meter lead at terminal “1”(Gray) and black meter lead at terminal

“12” (Gray) of Breakout Box.Is battery voltage present?

YES

Place red meter lead at terminal“2” (Gray) of Breakout Box.Is battery voltage present?

NO

Check resistance to ground onbreakout box terminal “12” (Gray).Is resistance less than one ohm?

YES NO

Check for battery voltageat both terminals of Ignition Fuse.Is ignition voltage present at both

terminals?

YES NO


between Ignition Fuseand HFSM.

STOP

Go to Will Not Flash,No Codes (Part 2 of 2)DTC: B1141 IgnitionSwitch Open/Low.

Mate connector.

YES NO

Check for battery voltage atboth terminals of Battery Fuse.

Is battery voltagepresent at both terminals?

Locate and repair openor poor ground circuit.

STOP

Go to Will Not Flash, No Codes(Part 2 of 2) DTC: B1141

Ignition Switch Open/Low.

1

6792

6805

6793

YES

Repair open on (BN/GY) wire betweenBattery Fuse and

HFSM.

NO

One terminal?

Replace fuse.

Neither terminal?

Repair openbetween MAXIFUSE

and fuse block.6806

6807

6808

fc01269_en

STOP



Will Not Flash, No Codes (Part 2 of 2): DTC B1141 Ignition Switch Open/Low

Continued from Will Not Flash, NoCodes (Part 1 of 2) DTC: B1141

Ignition Switch Open/Low.

Check for battery voltage at BreakoutBox terminal “7” (Gray) with right

turn signal depressed and terminal “8”(Gray) with left turn signal depressed.


YES


NO

Check for battery voltage on terminal “1”connector [22B] (right), or connector

[24B] (left).Is battery voltage present?

YES NO

With turn signal switch depressed on sideunder test, check for continuity between

terminal “1” and terminal “5” on connector[22A] (right), or connector [24A] (left).

Continuity present?

Locate and repair open (O/W) wirebetween terminal “1” on connector

[22B] (right), or connector [24B}(left) and Accessory Fuse.

YES NO


[22B] (right), or connector [24B](left) and HFSM connector [30].


Turn Signal Switch.

68116813 - right

6810 - left

6814 - right6812 - left

6791

1

2

fc01270_en


3.21DTC B1143, B1144, B1145 (HFSM ONLY)

GENERALDiagnostic Trouble Codes (DTCs) B1143, B1144 and B1145will set when faults occur to the security antenna circuit usedto transmit to the fob. Refer to Table 3-19.

Table 3-19. Security Antenna DTCs

START WITH FLOWCHARTCONDITIONDTC

Security Antenna Short-to-Ground: DTC B1143Security antenna short-to-groundB1143

Security Antenna Short-to-Voltage: DTC B1144Security antenna short-to-batteryB1144

Security Antenna Open: DTC B1145Security antenna openB1145

DIAGNOSTICS


HARNESS CONNECTOR ADAPTERSAND PATCH CORDS

HD-41404-B


1. Use black male HARNESS CONNECTOR ADAPTERSAND PATCH CORDS (Part No. HD-41404-B) to connector[208B].

2. Connect light blue male HARNESS CONNECTORADAPTERS AND PATCH CORDS (Part No. HD-41404-B) to connector [209B] and black male HARNESS CON-NECTOR ADAPTERS AND PATCH CORDS (Part No. HD-41404-B) to connector [208B].

3. If DTC is current (lamp on continuously, cleared codesreturn during operation), replace HFSM. If DTC is historic,check for intermittents.

Antenna

HFSM

15 AmpBatteryFuse

40 AmpMAXIFUSE

Tran

smit

ante

nna

BTr

ansm

itan

tenn

aA

Rec

eive

ante

nna

Gro

und

Bat

tery

Battery

BK

O/Y

Y/B

K

BN

/GY

BK/GN

RRBK

1 12

1 12

– +

21

3

3

21

21

21

[30A][30B]

[208A][208B]

[209A]

[209B]

em01220

Figure 3-26. Security Antenna Circuit: HFSM


Security Antenna Short-To-Ground: DTC B1143

Disconnect antenna connector [208] fromHFSM. Check for continuity between [208B]

terminal “2” and “3” and ground.Is continuity (less than 1 ohm) present?

YES NO

Locate and repairshort-to-ground.


1

3

6879 6791

fc01271_en


Security Antenna Short-To-Voltage: DTC B1144

With the Ignition Switch turned to IGN, check forvoltage between [208B] terminals “2” and “3” and

ground. Is voltage present?

YES NO

Locate and repairshort-to-voltage.


1

3

6879 6791

fc01272_en


Security Antenna Open: DTC B1145

Check for resistance between connector [208B]terminals “2” and “3”.

Is resistance between 3.7K ohms and 5.7K ohms?

YES NO


Check for continuity between [208B] terminal “3”and [209B] terminal “2”, and also between [208B]

terminal “2” and [209B] terminal “1”.Is continuity present?

1

2

6791

3

YES NO

Replace Security Antenna. Locate and repair open wirebetween connectors [208B]

and [209B].6878

6879

fc01273_en


3.22DTC B1154, B1155

DIAGNOSTICS



Diagnostic TipsDiagnostic Trouble Codes (DTCs) B1154 and B1155 will setwhen either the clutch switch circuit or neutral switch circuit is

shorted to ground at speeds greater than 10 MPH (16 km/h)for more than 60 seconds. Refer to Table 3-21.

Table 3-21. Clutch/Neutral Switch DTCs


Clutch Switch Short-to-Ground: DTC B1154Clutch switch short-to-groundB1154

Neutral Switch Short-to-Ground: DTC B1155Neutral switch short-to-groundB1155


1. Connect BREAKOUT BOX (Part No. HD-42682) to HFSM.3.12 BREAKOUT BOX: TSM/HFSM

2. If DTC is current (lamp on continuously, clear codes returnduring operation), replace HFSM. If DTC is historic, checkfor intermittents.

3. A reading of several hundred ohms is normal due to theneutral indicator lamp (LED).


TSM/HFSM

4

10

4

10

Neutral switch

Clutch switch

[20B]

[30B]

AB

[30A]

8

[131]

NeutralSwitch

To 15 Ampinstrument

fuse

[GND2][GND1]Rear groundstud underelectrical

center

[20A] [20A]

Clutch Switch

[163]

Left HandControls

[24A]

[24B]

7 8

7 8

[21A]

[21B]

FXDL Configuration

FXDB Configuration

8

7

7

6

6

8

8

86

[21A]

[21B]

5

5

6

6

FXDWG/FXDC/FXDF Configuration

To mainharness

TN

TN

TN

TN

TN

TN

TN

TN

TN

TN

BK

BK

BK

BK

BK

BK/R

BK

/RB

K/R

OO

O

O

OO

O

O

O

O

BK

/GN

BK

/GN

em01224

Figure 3-27. Clutch and Neutral Interlock Circuits



Inside top frame tube12-place DeutschConsole gauges/indicator lamps[20]

Under fuel tank console8-place Mini-DeutschIndicator lamps[21]

Inside top frame tube8-place MolexLeft handlebar controls[24]




Clutch Switch Short-To-Ground: DTC B1154

Connect Breakout Box HD-42682 to the main harness, leavingconnector [30] disconnected. Measure continuity between

terminal “10” (Gray) and terminal “12” (Gray).Is continuity present?

YES NO

Disconnect connector [24]. Measurecontinuity between terminal “10” (Gray) and

terminal “12” (Gray) on Breakout Box.Is continuity present?


1

2

6791

YES NO

Locate and repair short-to-ground on (BK/R) wire in mainwiring harness between [30B]

and [24B).

Locate and repairshort-to-ground in

left handlebar switchwiring.

5861 5861

NOTEThis DTC may occur if the vehicle is ridden with clutch disengaged(pulled in) at speeds greater than 10 MPH (16 km/h) for more than 60seconds (coasting down a long mountain road).

fc01274_en


Neutral Switch Short-To-Ground: DTC B1155

WIth the transmission in 1st or 2nd gear, connectBreakout Box HD-42682 to the main harness, leavingthe HFSM disconnected. Measure continuity between

terminal “4” (Gray) and terminal “12” (Gray).Is continuity (less than 10 ohms) present?

YES NO

Disconnect neutral switch [131]. Measurecontinuity between terminal “4” (Gray) and

terminal “12” (Gray) on Breakout Box.Is continuity (less than 10 ohms) present?


1

2

6791

3

3

YES NO

Locate and repair short-to-ground on (TN) wire in main

wiring harness.

Replace Neutral Switch.

5862

5157

NOTEThis DTC may occur if the vehicle is ridden with transmission inneutral at speeds greater than 10 MPH (16 km/h) for more than60 seconds (coasting down a long mountain road).

fc01275_en


3.23DTC U1016, U1255

GENERALThe serial data connector provides a means for the ElectronicControl Module (ECM) (see Figure 3-28), TSM/HFSM, andspeedometer to communicate their current status. When alloperating parameters on the serial data bus are within specific-ations, a state of health message is sent between the compon-ents. A Diagnostic Trouble Code (DTC) U1016 indicates thatthe ECM is not capable of sending this state of health message.A DTC U1016 indicates that there was communication on thedata bus since power up, but communication was lost orinterrupted during that key cycle.


CONDITIONDTC

Loss of all ECM serial data (state ofhealth)

U1016


ed02894

Figure 3-28. ECM Location: Dyna Models

DIAGNOSTICS





1. Connect BREAKOUT BOX (Part No. HD-42682) (gray)between TSM/HFSM connector [30A] and wire harnessconnector [30B]. See 3.12 BREAKOUT BOX:TSM/HFSM.

2. Connect BREAKOUT BOX (Part No. HD-43876) betweenwire harness and ECM. See 4.7 BREAKOUT BOX: EFI.


3

1

2

4

321 12

3

Bat

tery

Igni

tion

Ser

iald

ata

Gro

und

21 1221 65 7

21 65 7

21

Igni

tion

Ser

iald

ata

Bat

tery

Acc

esso

ryG

roun

d

Igni

tion

Ser

iald

ata

Bat

tery

Acc

esso

ryG

roun

d

65 7

21 65 7

21 6 7 12

21 6 7 12

5

5

GY

O

O

GY

BN

/GY

BN

/GY

LGN

/V

LGN

/V

LGN

/V

O/W

O/W

O/W

BN

/GY

O

O

BN

/GY

LGN

/V

O/W

BK

/GN

BK/GN

LGN/V

LGN

/V

BN

/GY

BK

/GN

LGN

/V

ECM

Ser

iald

ata

[30B][30A]

[91A]

GND 1

[108B][108A]

[20B][20A]

[39B][39A]

[78B][78A]

Speedometer

Toignitionfuse

Toinstrument

fuse

Toaccessory

fuse

Tobattery

fuse


Data LinkConnector


TSM/TSSM/HFSM

BK

BK

BK

em01195




Inside top frame tube12-place DeutschConsole gauges/indicator lamps(all except FXDWG, FXDC, FXDF)

[20]







Loss of ECM Serial Data: DTC U1016; Serial Data Error/Missing Message: DTC U1255

Can you read ECM hardware part number?See 3.11 SPEEDOMETER SELF

DIAGNOSTICS.


While wiggling harness, check continuitybetween terminal “3” (Gray) of

TSM/HFSM Breakout Box and terminal“5” of ECM Breakout Box.


Check continuity between terminal“3” (Gray) of TSM/HFSM Breakout

Box and terminal “5” of ECMBreakout Box.


1

2


1

2

YES

Clear codes. Test ride.Did DTC U1016 return?

YES


password.

NO


NO

No trouble found.

YES


password.

NO


fc01276_en


3.24DTC U1300, U1301 OR BUS ER

DIAGNOSTICSSee Figure 3-30.The typical serial data voltage range is 0 volts(inactive) to 7 volts (active). Due to the short pulse, voltageswill be much lower on a DVOM. In analog mode, a DVOMreading serial data will show continuous voltage when active,typically 0.6-0.8 volts. The range for acceptable operations is0-7.0 volts.

Diagnostic Tips• If serial data is shorted, these Diagnostic Trouble Codes



Diagnostic NotesIf a U1300, U1301 or "BUS Er" is present, perform diagnosticprocedures listed in 4.12 STARTS, THEN STALLS.

ed02896

Figure 3-30. Data Link Connector [91A]: Dyna Models


START WITH FLOWCHARTDESCRIPTIONDTC

4.12 STARTS, THEN STALLSSerial data lowU1300

4.12 STARTS, THEN STALLSSerial data open/highU1301


3.25TSM/HFSM: PASSWORD LEARN

GENERALIf the ECM or TSM/HFSM is faulty, follow the instructions inthe Service Manual for ECM or TSM/HFSM replacement.Then,to determine if password learn is necessary, refer to Table 3-26.

Table 3-26. Password Learn

IS PASSWORD LEARNNECESSARY?

DEVICE REPLACED

YesECM

No *TSM

YesTSM/HFSM

* If a TSM has been replaced by a HFSM, or a HFSM hasbeen replaced by a TSM, password learn is necessary.

PASSWORD LEARNINGTo perform password learning procedure, refer to Table 3-27.When finished, continue with all instructions under 3.3 H-DSSSACTUATION.

Always perform all appropriate instructions under 3.3 H-DSSSACTUATION after TSM/HFSM replacement or removal.

NOTE

Fob assignment must be performed at an authorized Harley-Davidson dealer using Digital Technician.

Table 3-27. Setting TSM/HFSM and ECM Password

NOTESCONFIRMATIONACTIONNO.

With Ignition Switch turned off,Check Engine Lamp andSecurity Lamp will be off.

Ignition must be turned off for at least 15 seconds.

Install new TSM/HFSM or ECM. Perform all steps under3.3 H-DSSS ACTUATION.

1

Set Engine Stop Switch to RUN.2

TSM/HFSM enables startrelay.

Verify Check Engine Lampand Security Lamp illuminateand then turn off.

Turn Ignition Switch ON.3

Password has not beenlearned. ECM sets DTCP1009.

Engine starts and stalls.Check Engine Lamp illumin-ates and stays on.

Attempt normal start one time.4

ECM enters PasswordLearning mode for tenminutes. Do not cycle IgnitionSwitch or interrupt vehiclepower or Password Learn willbe unsuccessful.

Security Lamp illuminates.Wait ten seconds. Security Lamp will illuminate and stayon.

5

This takes ten minutes.Wait until Security Lamp turns off.6

ECM must not be allowed toshutdown.

Quickly (within two seconds) turn Ignition SwitchOFF-ON.

7




9




11

Turn Ignition Switch OFF. Wait 15 seconds beforeturning Ignition Switch on. Turn Ignition Switch ON andstart engine to confirm successful Password Learnprocedure. Clear DTCs.

12

Perform all steps under 3.3 H-DSSS ACTUATION.13


3.26HFSM MAINTENANCE

GENERALThe HFSM uses a battery in the fob and siren. These are theonly parts requiring periodic maintenance.

HANDS-FREE FOB

ScheduleReplace the fob battery every year.

Battery Replacement1. See Figure 3-31. Open the fob case.

a. Place a thin blade in the thumbnail slot (1) betweenthe 2 halves of the case.

b. Slowly twist the blade.

2. Replace battery (2).

a. Remove the original battery.

b. Install a new battery with the positive (+) side down.Use a Panasonic 2032 or equivalent.

3. With O-ring (3) in place, align case halves and snap casehalves together.

1

2

3

1

ed02055

1. Thumbnail slot2. Battery (Panasonic 2032)3. O-ring

Figure 3-31. Open Fob: HFSM

SMART SIREN (IF INSTALLED)

ScheduleThe siren's internal 9 volt battery is rechargeable and does notneed to be replaced on a regular basis. Battery life undernormal conditions is approximately three to six years.

NOTES

See Figure 3-32 and Figure 3-33. Early style siren will workwith both TSSM and HFSM. Late style siren will only work withHFSM.

The internal siren battery may not charge if the vehicle's batteryis less than 12.5 volts.

Battery Replacement - Early Siren1. Disarm system and remove siren.

2. See Figure 3-32. Remove battery cover.

a. Place the siren module on a flat and sturdy table withthe potted section (area with epoxy covering circuitboard) facing up and towards you.

b. Position a knife blade at a 45 degree angle to the longside of the siren case. Insert the knife blade betweenthe siren case and battery cover at one of the twoaccessible corners of the battery cover. Keep theblade slightly higher towards the battery cover as thishelps keep the blade away from the battery seal.

c. Slowly twist the blade towards the battery cover andthe cover will pop off.

NOTES• For protection against corrosion, battery terminals and

battery clip are covered with a special grease. Do not wipeaway this substance. Apply all available existing greaseto terminals on new battery.

• Only a 9 volt nickel metal hydride battery should be usedin the siren.

3. Replace battery by removing old battery from polarizedbattery clip. Install a new 9 volt nickel metal hydride bat-tery.

4. Reinstall battery cover.

a. Carefully replace the rubber seal.

b. Align battery cover with case placing round cornerson cover away from connector [142A]. Snap coverinto place.

5. Install siren and check operation. If siren is working prop-erly, it will respond with two chirps after receiving the armcommand.

Battery Replacement - Late Siren1. Disarm system and remove siren.

2. See Figure 3-33. With a small screwdriver or pick, pushthe catches (1) in through the two slots (2) in the end ofthe siren to release the battery cover (3).



• Only a nickel metal hydride nine-volt battery should beused in the siren.


3. Replace battery (4) by removing old battery from polarizedbattery clip.

4. Recharge and re-install or install a new 9 volt nickel metalhydride battery.

5. Reinstall battery cover (3).

a. Carefully replace the rubber seal (5) on the cover.

b. Align battery cover with case placing round cornerson cover away from connector [142A] (6).

c. Snap cover into place.


1 23

ed03016

1. Cover2. Battery3. Connector [142A]

Figure 3-32. Battery Compartment (Early Style Siren)

4

5

6

3

1

2

ed02958

1. Catch2. Slot3. Cover4. 9 volt battery5. Rubber seal6. Connector [142A]

Figure 3-33. Siren Battery Compartment (Late Style Siren)



NOTES

SUBJECT............................................................................................................................PAGE NO.4.1 SPECIFICATIONS.....................................................................................................................4-14.2 EFI SYSTEM.............................................................................................................................4-24.3 EFI DIAGNOSTIC INTRODUCTION.........................................................................................4-44.4 CHECKING FOR DIAGNOSTIC TROUBLE CODES: EFI.........................................................4-54.5 INITIAL DIAGNOSTIC CHECK: EFI..........................................................................................4-84.6 SPEEDOMETER SELF DIAGNOSTICS.................................................................................4-174.7 BREAKOUT BOX: EFI.............................................................................................................4-204.8 WIGGLE TEST........................................................................................................................4-214.9 INTAKE LEAK TEST................................................................................................................4-224.10 ENGINE CRANKS, BUT WILL NOT START..........................................................................4-244.11 NO ECM POWER..................................................................................................................4-314.12 STARTS, THEN STALLS.......................................................................................................4-354.13 FUEL SYSTEM ELECTRICAL TEST....................................................................................4-404.14 SYSTEM RELAY FAULT........................................................................................................4-474.15 FUEL PRESSURE TEST.......................................................................................................4-534.16 IDLE AIR CONTROL.............................................................................................................4-574.17 MISFIRE AT IDLE OR UNDER LOAD...................................................................................4-624.18 COMBUSTION ABSENT INTERMITTENT...........................................................................4-684.19 DTC P0107, P0108...............................................................................................................4-734.20 DTC P0112, P0113...............................................................................................................4-774.21 DTC P0117, P0118...............................................................................................................4-814.22 DTC P0122, P0123...............................................................................................................4-854.23 DTC P0131, P0132, P0134, P0151, P0152, P0154..............................................................4-894.24 DTC P0261, P0262, P0263, P0264.......................................................................................4-954.25 DTC P0373, P0374.............................................................................................................4-1014.26 DTC P0501, P0502.............................................................................................................4-1044.27 DTC P0562, P0563.............................................................................................................4-1084.28 DTC P0603, P0605.............................................................................................................4-1124.29 DTC P0661, P0662.............................................................................................................4-1134.30 DTC P1009, P1010.............................................................................................................4-1174.31 DTC P1351, P1352, P1354, P1355.....................................................................................4-1204.32 DTC P1475, P1477, P1478.................................................................................................4-1254.33 DTC P1501, P1502.............................................................................................................4-1314.34 DTC U1064, U1255.............................................................................................................4-1364.35 DTC U1097, U1255.............................................................................................................4-139

EN

GIN

E M

AN

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T

4.1SPECIFICATIONS

SPECIFICATIONS

Table 4-1. General Specifications

DATAIGNITION

1000 ± 50 RPMIdle speed

12 mmSpark plug size

0.038-0.043 in (0.97-1.09 mm)Spark plug gap

Harley-DavidsonNo. 6R12 (no substitute)

Spark plug type

0.3-0.5 ohmsIgnition coil primary res-istance at room temper-ature

2750-3250 ohmsIgnition coil secondaryresistance at room tem-perature

Table 4-2. Fuse Ratings

RATING (AMPERES)ITEM

40MAXIFUSE

15Ignition fuse

15Lights fuse

15Accessory fuse

15Instruments fuse

15Battery fuse

15Fuel pump fuse

15ECM power fuse

15Engine control fuse

15Headlamp fuse

4

5

6

7

8

9

12

13

14

10

11

2 31ed02882


Figure 4-1. Fuses

2008 Dyna Diagnostics: Engine Management 4-1

4.2EFI SYSTEM

GENERALThe engine management system consists of the followingcomponents:

• Electronic Control Module (ECM).

• Crankshaft Position (CKP) Sensor.

• Manifold Absolute Pressure (MAP) Sensor.

• Intake Air Temperature (IAT) sensor.

• Engine Temperature (ET) sensor.

• Idle Air Control (IAC).

• Throttle Position (TP) Sensor.

• Vehicle Speed Sensor (VSS).

• Turn Signal Module (TSM) or optional, factory-installedTurn Signal Security Module (TSSM). Depending on des-tination, the security module consists of either a TurnSignal Security Module (TSSM) or a hands-free securitymodule (HFSM). Each of these modules include a integ-rated Bank Angle Sensor (BAS).

• Ignition Coil.

• Oxygen Sensors (domestic models only).

• Active Intake Solenoid (HDI only).

• Active Exhaust Solenoid (HDI only).

• Jiffy Stand Sensor (HDI only).

The ECM is mounted under the electrical caddie cover (leftside of vehicle). It computes the spark advance for properignition timing based on sensor inputs (from CKP, TMAP andTP sensor) and regulates the low-voltage circuits betweenbattery and ignition coil.

The ECM contains all of the solid state components used inthe ignition system. The dwell time for the ignition coil is alsocalculated in the microprocessor and is dependent upon batteryvoltage. The programmed dwell is an added feature to giveadequate spark at all speeds. (The ECM has added protectionagainst transient voltages, continuous reverse voltage protec-tion, and damage due to jump starts.) The ECM is fullyenclosed to protect it from vibration, dust, water or oil.This unitis a non-repairable item. If it fails, it must be replaced.

The crankshaft position (CKP) sensor is located in the frontleft side of the crankcase. The CKP generates an AC signalwhich is sent to the ECM where it is used to reference engine

position (TDC) and speed. It functions by taking readings offthe 30 teeth on the left side flywheel (two teeth are missing toestablish a reference point).

The MAP sensor is located on top of the intake manifold. TheMAP sensor monitors the intake manifold pressure (vacuum)and sends the information to the ECM where the moduleadjusts the spark and fuel timing advance curve for optimumperformance.

The bank angle sensor is within the TSM/TSSM/HFSM. TheTSM/TSSM/HFSM will shut the engine down if the vehicle istipped over. Once the sensor is tripped, the motorcycle mustbe uprighted, turned off and then on again before the enginecan be restarted. This is communicated across the data bus.

Front and rear coils fire each spark plug independently (onecylinder at a time - no wasted spark).The coil also has an extraterminal to monitor current on the coil secondary circuit. Thisis used for knock detection and combustion diagnostics.

The ignition system gives a spark near top dead center forstarting. At RPM and loads above this, the system gives aspark advance that varies between 0 and 50.

The IAT, ET, TP and O2 sensors are used to provide informa-tion to the ECM to fine tune spark and fuel delivery. The VSSis used as an input for idle speed control.

The oxygen sensor (O2, domestic models only) monitors theexhaust gas for oxygen content. The fuel/air mixture is thenadjusted to maintain an optimal 14.6:1 air/fuel ratio.

O2 sensor diagnostic codes may be seen during the vehiclebreak-in period. The O2 sensor diagnostic codes will not illu-minate the check engine lamp for historic or current codes andwill only be indicated by Digital Technician or speedometer selfdiagnostics. If the diagnostic codes are reported during thebreak-in period, clear or ignore the codes until the break-inperiod is completed.

The active intake solenoid (HDI models) opens a valve in theair cleaner to allow more air to enter at speeds greater than43 MPH (70 km/h) with a throttle opening greater than 50%.

The active exhaust system (HDI models) utilizes an actuatorvalve located in the rear exhaust pipe which is connected toan actuator via a cable.The valve position automatically adjuststo enhance engine performance.

TROUBLESHOOTINGSee the diagnostic charts that follow troubleshooting information

4-2 2008 Dyna Diagnostics: Engine Management

10

11

29

19

21

4

30CKP (+)CKP (-)

System relay

Rear coil

Front coil

Battery

Front injector

Rear injector

IAC (A) lowIAC (B) high

IAC (B) low

IAC (A) high

Switched powerMAP sensor input

Engine temp

5V sensor powerTPS input

Oxygen sensor A (DOM)5V sensor ground

Oxygen sensor B (DOM)

Serial data

VSS inputGround

Ground

12

31

13

26

1424

6

25

28

– +

18

3635

17

A

B

C

D

A

B

C

D

5

32

4

[79A]

CKP

GND 1

[78A]ECM

[78B]GND 1

[84B] [84A]

[87B]

[91A]

[90B] [90A]

[88B] [88A]

[80B] [80A]

[87A]

[83B] [83A]

[33]

[79B][178A][178B]

23

8

ABC

[141A][141B]

GND 2

D

ABCD

AB

1

AB

3

ABC

ABC

1

23

123

A

B

A

B

12

[22A]33

10

11

27ION sense 27

29

19

21

4

30

22Active intake solenoid(HDI)

22

1Active exhaustfeedback (HDI) 1

20Active exhaust (HDI) 20

12

31

13

26

1424

6

25

Intake air temp 7 7

28

18

3635

17

5

Jiffy stand sensor (HDI) 9 9

23

8

33

[65B] [65A]

[133A][133B]

2

2

1

1

[137A]

[137B]2

2

1

1

[138A]

[138B]

123

123

[85B] [85A]

3

[22B]

12

4 4

A

B

A

B

87

87A

30

85

86

I

Q

C

P

R

5

4

3

2

1

A

B

C

D

A

B

C

D

[30B]

[30A]

2

2

3

3

AB

SystemRelay

Spark PlugsIgnition

Coil

Battery

IgnitionSwitch

FrontInjector

RearInjector

IdleAirControl

MAPSensor

Front O2Sensor

Rear O2Sensor

Tospeedometerandtachometer

Data LinkConnector

EngineStopSwitch

TPSensor

ETSensor

TSM/TSSM/HFSMJiffy Stand

Sensor

VehicleSpeedSensor

Igni

tion

Ser

iada

ta

Fuel Pump15 Amp

Fuel PumpFuse

15 AmpIgnition Fuse

15 AmpENG Fuse

15 AmpECM Fuse

40 AmpMAXIFUSE

R R

R

RR R

R

BK BK

GY

GY

GY GY

GY

BK

BK

GN/O

GY/O GY/O

GN/O

W/BK

Y/GN

Y/GN

Y/GN

Y/GN

Y/BE

BE/O

Y/BE

BE/O

R/BKR/BK

Y/GN O/GY O/GY

BN/R

BK/O

W/BK

BK/W

BK/W

W/BK W/BK

PK/O

W/GN

PK/Y PK/Y

GY/V GY/VBK/W

BK/W

PK

/O

BK

/W

BK

/W

W/Y W/Y

R/WV/W V/W

R/W

R/W

R/W

R/W

BE/GY

LGN/V

LGN/Y

LGN/V

LGN

/V

LGN/V

PK

/GN

BK/PK

BK/GNGND 1

BK/GNBK/GN

GN/BN

BK/GN

BK/GN

BE/GN

BN/R

BK/O

BK/PK

BE/GN

GN/GY GN/GY

BE/GY BE/GY

GY/BE GY/BE

[62B]

[89A][89D][89B] [89C]

12

12

12

12 IAT SensorLGN/Y

BK/W

1

2

3

4

1

2

3

4

[179A][179B]

21

21

V/BE

LGN/R

LGN/RLGN/R

BK/GN

LGN/R

ActiveExhaustActuator

ActiveIntake

Solenoid

V/O

V/BE

V/O

1 2 3

1 2 3

BKR W

em00038

Figure 4-2. EFI System Circuit


4.3EFI DIAGNOSTIC INTRODUCTION

SYSTEM PROBLEMSAll system problems fall into at least one of three general cat-egories.

No StartThe engine cranks over freely, but will not start. This does notinclude situations where the engine will not crank, such as asecurity disabled starter, dead battery, etc. This conditionassumes that all obvious checks (fuel in tank, etc.) have beenmade.

Poor PerformanceThe engine starts but there are performance problems. Theseproblems may include poor fuel economy, rough idle, enginemisfire, engine hesitation, severe spark knock, etc.

Check Engine LampSee Figure 4-3.The check engine lamp indicates the ElectronicControl Module (ECM) has determined a fault condition exists.There may also be starting or performance problems.

ed02903

Figure 4-3. Check Engine Lamp

RESOLVING PROBLEMSTo resolve system problems, five basic steps are involved. Inorder of occurrence, they are:

1. Check for Diagnostic Trouble Codes (DTCs) by usingspeedometer self diagnostics. See 4.4 CHECKING FORDIAGNOSTIC TROUBLE CODES: EFI.

2. Retrieve DTCs by using speedometer self diagnostics.See 4.6 SPEEDOMETER SELF DIAGNOSTICS.



5. After repairs are performed, the work must be validated.This involves clearing the trouble codes and confirmingproper vehicle operation as indicated by the lack of DTCs.


4.4CHECKING FOR DIAGNOSTIC TROUBLECODES: EFI

CHECK ENGINE LAMPTo diagnose system problems, start by observing the behaviorof the check engine lamp.

NOTES

• See Figure 4-4 or Figure 4-5. "Key ON" means that theIgnition Switch is turned to IGN and the Engine StopSwitch is set to RUN (although the engine is not running).

• When the Ignition Key is turned to IGN, the check enginelamp will illuminate for approximately four seconds andthen turn off.

• If the check engine lamp is not illuminated at Key ON orif it fails to turn OFF after the initial four-second period,then see 4.6 SPEEDOMETER SELF DIAGNOSTICS.

• If the check engine lamp comes on late (after 20 seconds),the problem is likely a serial data bus failure. Test forDiagnostic Trouble Codes (DTCs) using speedometer selfdiagnostics. See 4.6 SPEEDOMETER SELF DIA-GNOSTICS.

1. See Figure 4-6. After lamp turns off after being illuminatedfor the first four-second period, one of three situations mayoccur.

a. The lamp remains off. This indicates there are nocurrent fault conditions or stored DTCs currentlydetected by the Electronic Control Module (ECM).

b. The lamp stays off for only four seconds and thencomes back on for an eight-second period. Thisindicates a code is stored, but no current DTC exists.

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

2. See 4.4 CHECKING FOR DIAGNOSTIC TROUBLECODES: EFI, Code Types for a complete description ofDTC formats.

NOTE

Some DTCs can only be fully diagnosed during actuation. Forexample, a problem with the ignition coil will be considered acurrent fault even after the problem is corrected, since the ECMwill not know of its resolution until after the coil is exercised byvehicle start sequence. In this manner, there may sometimesbe a false indication of the current trouble code.

32

1

ed02877



312

ed02878




ON

ON

ON

OFF

OFF

OFF

Key On

Key On

Key On


Lamp OFF




4 Sec.

4 Sec.

4 Sec.

4 Sec.

8 Sec.

4 Sec.

em01046

Figure 4-6. Check Engine Lamp Operation

CODE TYPES



There are two types of Diagnostic Trouble Codes (DTCs):current and historic. If a DTC is stored, it can be read usingeither a computer based diagnostic package called DIGITALTECHNICIAN (Part No. HD-44750) or speedometer self dia-gnostics. See 4.6 SPEEDOMETER SELF DIAGNOSTICS.

NOTES

• Speedometer self diagnostics will display both current andhistoric Diagnostic Trouble Codes a computer based dia-gnostic package called DIGITAL TECHNICIAN (PartNo. HD-44750) must be employed.

• All DTCs reside in the memory of the ECM, TSM/TSSM/HFSM, speedometer or tachometer until the DTC iscleared by use of the speedometer self diagnostics. See4.6 SPEEDOMETER SELF DIAGNOSTICS.

• A historic DTC is also cleared after a total of 50 trips haselapsed. A trip consists of a start and run cycle. After the50 trip retention period, the DTC is automatically erasedfrom memory providing that no subsequent faults of thesame type are detected in that period.


HistoricIf a particular problem happens to resolve itself, the activestatus problem is dropped and it becomes a historic DTC ratherthan a current DTC.

Historic DTCs are stored for 50 ignition cycles after any DTCwas last set as current to assist in the diagnosis of intermittentfaults. On the 50th cycle, the DTC will clear itself. The checkengine lamp will not indicate the existence of only historicDTCs.

It is important to note that historic DTCs will exist wheneverthe system indicates the existence of a current fault. See4.4 CHECKING FOR DIAGNOSTIC TROUBLE CODES: EFI,Multiple Diagnostic Trouble Codes if multiple DTCs are found.

Diagnostic charts are designed for use with current DTCs andas a result they frequently suggest part replacement. Whendiagnosing a historic DTC the charts can be helpful but shouldnot lead to part replacement without verification the part isfaulty.




The engine management system provides two levels of dia-gnostics.


• The second mode requires using the speedometer selfdiagnostics. Speedometer, tachometer (if equipped),TSM/TSSM/HFSM and ECM DTCs can be accessed andcleared. See 4.6 SPEEDOMETER SELF DIAGNOSTICS.

MULTIPLE DIAGNOSTIC TROUBLE CODESWhile it is possible for more than one fault to occur and setmore than one DTC, there are several conditions which mayresult in one fault setting multiple DTCs:


Serial data DTCs (U1016, U1064, U1097, U1255, U1300 andU1301) may be accompanied by other DTCs. Always correctthe serial data DTCs before resolving the other DTCs.

Refer to Table 4-7. This table gives most ECM DTCs a priorityranking.


4.5INITIAL DIAGNOSTIC CHECK: EFI

GENERAL



To locate faulty circuits or other system problems, follow thediagnostic flow charts in this section. For a systematicapproach, always begin with 4.5 INITIAL DIAGNOSTICCHECK: EFI, Initial Diagnostics. Read the general informationand then work your way through the flow chart box by box.



In order to perform most diagnostic routines, a Breakout Boxand a digital volt/ohmmeter (DVOM) are required. See4.7 BREAKOUT BOX: EFI.


Reprogramming ECMDiagnostic charts frequently suggest ECM replacement. In theevent an electronic control module (ECM) needs to be replaced,it must be reprogrammed using a computer based diagnosticpackage called DIGITAL TECHNICIAN (Part No. HD-44750).See your dealer. Password learn procedure must also be per-formed. See 3.25 TSM/HFSM: PASSWORD LEARN.

INITIAL DIAGNOSTICS




General InformationThe diagnostic check is an organized approach to identifyinga problem caused by an electronic control system malfunction.

Diagnostic Tips• If Odometer reads "BUS Er" with the Ignition Switch turned

to IGN (Engine Stop Switch at RUN with the engine off),check data bus for an open or short to ground. betweendata link connector [91A] terminal "3" and ECM connector[78B] terminal "5", TSSM/HFSM connector [30B] terminal"3", speedometer connector [39B] terminal "2" or tacho-meter (if equipped) connector [108B] terminal "2".

• Check for an open data test terminal between data linkconnector [91A] terminal "3" and TSM/TSSM/HFSM con-nector [30B] terminal "3". With Ignition Switch turned toIGN, serial data bus voltage should be typically 0.6-0.8volts. The range of acceptable voltage is 0-7.0 volts.

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


1. Compare engine behavior to symptoms tables.

a. Starts hard. Refer to Table 4-4.

b. Hesitates, stumbles, surges, misfires and/or sluggishperformance. Refer to Table 4-5.

c. Engine exhaust emits black smoke or fouls plugs.Refer to Table 4-6.

2. Connect BREAKOUT BOX (Part No. HD-42682) andINSTRUMENT HARNESS ADAPTERS (Part No. HD-46601) between wire harness and speedometer. See2.5 BREAKOUT BOX: SPEEDOMETER/TACHOMETER.

All EFI diagnostic codes are listed in Table 4-7.

Other Diagnostic Trouble Codes (DTCs)See 2.2 INITIAL DIAGNOSTIC CHECK: SPEEDOMETER forany codes related to the speedometer or tachometer.

See 3.10 INITIAL DIAGNOSTIC CHECK: TSM/HFSM for anycodes related to the turn signal module (TSM) or hands freesecurity module (HFSM).

See E.9 INITIAL DIAGNOSTIC CHECK: TSM/TSSM for anycodes related turn signal security module (TSSM).


Table 4-3.Typical Scan Values for Engine Data

HOTIDLE

MAX.VALUE

MIN.VALUE

ITEM

10.3-13.3 in. Hg (35-45 kPa)104 kPa10 kPaMAP sensor

5.1 Volts0 Volt

0%1000TP sensor

0.2-1.0 Volt4.5 Volts0.2 Volt

20-50 steps1550IAC pintle

10005600800RPM

230-300° F (110-150° C)464° F (240° C)3° F (-16° C)ET sensor

0.5-1.5 Volts5.0 Volts0.0 Volts

104-140° F (40-60° C)248° F (120° C)3° F (-16° C)IAT sensor

2.0-3.5 Volts5.0 Volts0.0 Volts

2-4 ms50 ms0INJ PW front

2-4 ms50 ms0INJ PW rear

10-15°50°0Advance front

10-15°50°0Advance rear

0 MPH (km/h)1200VSS

13.4 Volts1510Battery voltage

RunRunOffENG RUN

10001250800Idle RPM

NOTE

Hot idle specifications are with stock exhaust, the engineoperating at 1000 RPM and an engine temperature of approx-

imately 260° F (127° C). Idle settings may be changed withthe idle set procedure. See the Dyna Service Manual.

Table 4-4. Engine Starts Hard

SOLUTIONCAUSE

1.7 CHARGING SYSTEM, Troubleshooting.Battery discharged

4.17 MISFIRE AT IDLE OR UNDER LOAD.Spark plugs

4.17 MISFIRE AT IDLE OR UNDER LOAD.Spark plug wires

4.17 MISFIRE AT IDLE OR UNDER LOAD.Ignition coil

See Section 3 in the Service Manual.Valve sticking

Drain and refill with fresh fuel.Water or dirt in fuel system

4.11 NO ECM POWER.Loss of battery power to ECM terminal 31*

* Diagnostic trouble codes will not clear (although they appear to).

Table 4-5. Engine Performance Problems

SOLUTIONCAUSE

4.9 INTAKE LEAK TESTManifold leakA low IAC count may also indicate an air leak.NOTE: When manifold leak is large enough, IAC will close to 0

and code P0505 will set.

4.19 DTC P0107, P0108MAP sensor plugged or not operating properly

Drain and refill with fresh fuel.Water or dirt in fuel system


Table 4-5. Engine Performance Problems

SOLUTIONCAUSE

4.17 MISFIRE AT IDLE OR UNDER LOADSpark plugs

See Throttle Cable Adjustment in the Service Manual.Throttle plate not opening fully

4.15 FUEL PRESSURE TEST.Low fuel pressure

Table 4-6. Engine Exhaust Emits Black Smoke or Fouls Plugs

SOLUTIONCAUSE

See Air Cleaner Filter in the Service Manual.Clogged air filter

4.19 DTC P0107, P0108MAP sensor plugged or not operating properly

Table 4-7. EFI Diagnostic Trouble Codes (DTC) and Fault Conditions

SOLUTIONFAULT CONDITIONDTCRANKING

4.28 DTC P0603, P0605ECM flash errorP06051

4.28 DTC P0603, P0605ECM EEPROM errorP06032

4.12 STARTS, THEN STALLSSerial data bus shorted low/open/high"BUS Er"3

4.12 STARTS, THEN STALLSECM serial data lowU13004

4.12 STARTS, THEN STALLSECM serial data open/highU13015

4.12 STARTS, THEN STALLSTSM/HFSM serial data lowU13006

4.12 STARTS, THEN STALLSTSM/HFSM serial data open/highU13017

4.12 STARTS, THEN STALLSspeedometer/tachometer serial data lowU13008

4.12 STARTS, THEN STALLSspeedometer/tachometer serial dataopen/high

U13019

4.34 DTC U1064, U1255Loss of TSM/HFSM serial data at ECMU106410

4.34 DTC U1064, U1255Loss of TSM/HFSM serial data atspeedometer

U106411

3.23 DTC U1016, U1255Loss of all ECM serial data (state ofhealth) at TSSM

U101612

3.23 DTC U1016, U1255Loss of all ECM serial data (state ofhealth) at speedometer

3.23 DTC U1016, U1255Loss of vehicle speed

3.23 DTC U1016, U1255Loss of vehicle inhibit motion

3.23 DTC U1016, U1255Loss of powertrain security status

4.35 DTC U1097, U1255Loss of speedometer serial data atTSM/HFSM

U109713

3.23 DTC U1016, U1255Missing response at TSM/HFSMU125514

4.35 DTC U1097, U1255Missing response at speedometerU125515

4.14 SYSTEM RELAY FAULTSystem relay contacts openP100316

4.14 SYSTEM RELAY FAULTSystem relay coil high/shortedP100217

4.14 SYSTEM RELAY FAULTSystem relay coil open/lowP100118

4.14 SYSTEM RELAY FAULTSystem relay contacts closedP100419

4.30 DTC P1009, P1010Incorrect passwordP100920

4.30 DTC P1009, P1010Missing password (starts then stalls)P101021




4.25 DTC P0373, P0374CKP sensor intermittentP037322

4.25 DTC P0373, P0374CKP sensor synch errorP037423

4.22 DTC P0122, P0123TP sensor open/lowP012224

4.22 DTC P0122, P0123TP sensor highP012325

4.19 DTC P0107, P0108MAP sensor open/lowP010726

4.19 DTC P0107, P0108MAP sensor highP010827

4.33 DTC P1501, P1502Jiffy stand sensor lowP150128

4.33 DTC P1501, P1502Jiffy stand sensor highP150229

4.21 DTC P0117, P0118ET sensor voltage lowP011730

4.21 DTC P0117, P0118ET sensor open/highP011831

4.20 DTC P0112, P0113IAT sensor voltage lowP011232

4.20 DTC P0112, P0113IAT sensor open/highP011333

4.31 DTC P1351, P1352, P1354, P1355Front ignition coil open/lowP135134

4.31 DTC P1351, P1352, P1354, P1355Rear ignition coil open/lowP135435

4.31 DTC P1351, P1352, P1354, P1355Front ignition coil high/shortedP135236

4.31 DTC P1351, P1352, P1354, P1355Rear ignition coil high/shortedP135537

4.18 COMBUSTION ABSENT INTERMIT-TENT

Front cylinder combustion intermittentP135738


Rear cylinder combustion intermittentP135839

4.24 DTC P0261, P0262, P0263, P0264Front injector open/lowP026140

4.24 DTC P0261, P0262, P0263, P0264Rear injector open/lowP026341

4.24 DTC P0261, P0262, P0263, P0264Front injector highP026242

4.24 DTC P0261, P0262, P0263, P0264Rear injector highP026443

4.27 DTC P0562, P0563Battery voltage lowP056244

4.27 DTC P0562, P0563Battery voltage highP056345

4.33 DTC P1501, P1502VSS sensor lowP050146

4.26 DTC P0501, P0502VSS sensor highP050247


Rear cylinder no combustionP135648


Front cylinder no combustionP135349

4.16 IDLE AIR CONTROLLoss of idle speed controlP050550

4.32 DTC P1475, P1477, P1478Exhaust actuation position errorP147551

4.32 DTC P1475, P1477, P1478Exhaust actuator open/lowP147752

4.32 DTC P1475, P1477, P1478Exhaust actuator shortedP147853

4.29 DTC P0661, P0662Intake solenoid low/openP066154

4.29 DTC P0661, P0662Intake solenoid high/shortedP066255

4.23 DTC P0131, P0132, P0134, P0151,P0152, P0154

Front O2 sensor low or engine running leanP013156

4.23 DTC P0131, P0132, P0134, P0151,P0152, P0154


4.23 DTC P0131, P0132, P0134, P0151,P0152, P0154

Engine running richP013258

4.23 DTC P0131, P0132, P0134, P0151,P0152, P0154





4.23 DTC P0131, P0132, P0134, P0151,P0152, P0154

Front O2 sensor open/not respondingP013460

4.23 DTC P0131, P0132, P0134, P0151,P0152, P0154

Rear O2 sensor open/not respondingP015461

3

1

2

4

321 12

3

Bat

tery

Igni

tion

Ser

iald

ata

Gro

und

21 1221 65 7

21 65 7

21

Igni

tion

Ser

iald

ata

Bat

tery

Acc

esso

ryG

roun

d

Igni

tion

Ser

iald

ata

Bat

tery

Acc

esso

ryG

roun

d

65 7

21 65 7

21 6 7 12

21 6 7 12

5

5

GY

O

O

GY

BN

/GY

BN

/GY

LGN

/V

LGN

/V

LGN

/V

O/W

O/W

O/W

BN

/GY

O

O

BN

/GY

LGN

/V

O/W

BK

/GN

BK/GN

LGN/V

LGN

/V

BN

/GY

BK

/GN

LGN

/V

ECM

Ser

iald

ata

[30B][30A]

[91A]

GND 1

[108B][108A]

[20B][20A]

[39B][39A]

[78B][78A]

Speedometer

Toignitionfuse

Toinstrument

fuse

Toaccessory

fuse

Tobattery

fuse


Data LinkConnector


TSM/TSSM/HFSM

BK

BK

BK

em01195






[20]








Does enginestart?





Check for DTCs. See4.6 SPEEDOMETER

SELF DIAGNOSTICS.Were DTCs found?




YES



NOUnable to enter

diagnostic mode.




For a list of symptoms thatmay not set diagnostic trouble

codes, refer to Table 4-4, Table4-5, and Table 4-6.

YES NO



YES NO

Test for battery voltage at Breakout Boxterminal “5” (Black) while wiggling

harness.Is battery voltage continuously present?


YES NO




YES NO

ReplaceSpeedometer.


STOP


2

fc01334_en

1



Continued from Initial Diagnostic Check (Part 1 of 3).Turn Ignition Switch to IGN.


YES NO

Replace Speedometer.Perform “WOW” test.See 4.6 SPEEDOMETER SELF DIAGNOSTICS.

The following features should be functional:1) Backlight should illuminate.2) Needles should sweep full range of motion.3) LEDs should illuminate:



YES


YES NO


YES NO


YES NO




STOP


2

NO

Turn Ignition Switch to IGN. Checkfor battery voltage at Breakout


YES NO


YES NO




2

fc01335_en




YES NO.Speedometer



(no engine speed).




Debris present?

See 2.4 SPEEDOMETER/TACHOMETER.

YES NO


No trouble found.

YES NO





connection present?

YES NO


ReplaceSpeedometer.

fc01336_en



GENERALThe speedometer is capable of displaying and clearingspeedometer, tachometer, TSM/TSSM/HFSM, and ECM troublecodes (DTCs) (diagnostic mode).

DIAGNOSTICS

Diagnostic Tips• For a quick check of speedometer function, a "WOW" test

can be performed. Press and hold Trip Odometer ResetSwitch then turn Ignition Switch to IGN. Release trip odo-meter reset switch. See Figure 4-8. Background lightingshould illuminate, speedometer needle should sweep itsfull range of motion, and indicator lamps (battery, security,low fuel, check engine gear indicator and pursuit (tacho-meter)) should illuminate. All lamps should illuminate, eventhose not used in normal vehicle operations.

• If speedometer fails "WOW" test, check for battery, ground,ignition, Trip Odometer Reset Switch and accessory wiringto speedometer. If any feature in the speedometer is non-functional, see 2.2 INITIAL DIAGNOSTIC CHECK:SPEEDOMETER.




a. Press and hold the Trip Odometer Rest Switch formore than 5 seconds to display available modules,release.

b. Press the Trip Odometer Reset Button to choose themodule.


d. Press and hold the Trip Odometer Reset Switch formore than 5 seconds to clear the DTCs for the moduleselected.

ed02904

1. Cruise (not used)2. Check engine lamp3. Low fuel lamp4. Battery lamp5. Security lamp (key icon)

Figure 4-8. Speedometer

32

1

ed02877




312

ed02878





1


RUN position.


YES

”P” flashing.





seconds.



Switch.

”S” flashing.



Switch.

”SP” flashing.



Switch.



”T” flashing.



than 5 seconds.







CHECK: SPEEDOMETER.

YES

YES

NO

NO

NO

Deviceresponse?

Press andrelease


displayed.

Press andrelease














DTCdisplayed.


2

fc01642_en

”b” flashing.







4.7BREAKOUT BOX: EFI

GENERAL



The BREAKOUT BOX (Part No. HD-43876) splices into themain harness. Used in conjunction with a digital volt/ohmmeterDVOM, it allows circuit diagnosis of wiring harness and connec-tions without having to probe with sharp objects.

NOTE

See wiring diagrams for ECM terminal functions.

INSTALLATION1. See Figure 4-11. Remove the electrical caddie cover to

gain access to Electronic Control Module (ECM).

2. Depress latch on ECM connector to separate pin andsocket halves [78B].

3. See Figure 4-12. Attach Breakout Box to connector.

a. Attach connector from Breakout Box (1) to ECMconnector.

b. Attach connector from the wiring harness to connectoron Breakout Box.

ed02894

Figure 4-11. ECM Location

3

2

1

ed02905

1. Breakout Box2. ECM connection3. Wiring harness connection

Figure 4-12. Installed Breakout Box

REMOVAL1. See Figure 4-12. Depress latch on ECM connection.

2. Detach Breakout Box connector from ECM connector.

3. Detach Breakout Box connector from wiring harness.

4. Reattach ECM connector to wiring-harness.

5. Install electrical caddie cover.


4.8WIGGLE TEST

GENERALThe wiggle test indicates the presence of intermittents in awiring harness.

PROCEDURE



NOTE

When diagnosing Electronic Control Module (ECM) connec-tions, use a BREAKOUT BOX (Part No. HD-43876) to simplifythe procedure. See 4.7 BREAKOUT BOX: EFI.

1. See Figure 4-13. Connect digital volt/ohmmeter (DVOM)to wiring harness between the suspect connections. SetDVOM to read voltage changes.

2. Start motorcycle engine and run at idle.

3. Shake or wiggle harness to detect intermittents. If intermit-tents are present, radical voltage changes will register onthe DVOM.

sm00202

Figure 4-13. Fluke 78 Multimeter (DVOM) (Part No.HD-39978)


4.9INTAKE LEAK TEST

GENERAL

Do not allow open flame or sparks near propane. Propaneis extremely flammable, which could cause death or ser-ious injury. (00521b)

NOTES

• To prevent false readings, keep airbox cover installedwhen performing test.

• Do not direct propane into air cleaner, false readings willresult.

LEAK TESTER


PROPANE ENRICHMENT KITHD-41417

Parts List• Standard 14 oz. propane cylinder.

• PROPANE ENRICHMENT KIT (Part No. HD-41417).

Tester Assembly1. See Figure 4-14. Make sure valve knob (6) is closed (fully

clockwise).

2. Screw valve assembly (5) onto propane bottle (1).

Tester Adjustment1. See Figure 4-14. Press and hold trigger button (8).

2. Slowly open valve knob (6) until pellet in flow gauge (7)rises to between 5 and 10 SCFH on gauge.

3. Release trigger button.

89

7

6

5

1

2

3

4

ed02843

1. Propane bottle2. Nozzle3. Copper tube4. Hose5. Valve assembly6. Valve knob7. Flow gauge8. Trigger button9. Hanger

Figure 4-14. Leak Tester

PROCEDURE1. Start engine.

2. Warm engine to operating temperature.

NOTEDo not direct propane stream toward front of engine. If propaneenters air cleaner, a false reading will be obtained.

3. See Figure 4-15. Aim nozzle (3) toward possible sourcesof leak such as intake manifold mating surfaces.


4. Push trigger button (2) to release propane.Tone of enginewill change when propane enters source of leak.

5. When test is finished, release trigger button and closevalve knob (turn knob fully clockwise).

3 2

1

ed02906

1. Propane bottle2. Trigger button3. Nozzle

Figure 4-15. Checking for Leaks


4.10ENGINE CRANKS, BUT WILL NOT START

GENERALIf the starter will not crank the engine, the problem is not EFIrelated. Refer to 1.1 STARTER TROUBLESHOOTING or3.1 TURN SIGNAL OVERVIEW.

DIAGNOSTICS


SPARK TESTERHD-26792

FUEL INJECTOR TEST LAMPHD-34730-2C




IGNITION COIL CIRCUIT TESTADAPTER

HD-44687

ELECTRICAL SYSTEM ANALYZERMCR-101 HD


1. Check for Diagnostic Trouble Codes (DTCs). See4.4 CHECKING FOR DIAGNOSTIC TROUBLE CODES:EFI, Retrieving Diagnostic Trouble Codes.

2. Check the condition of the battery. Perform a voltage testand recharge if below 12.60V. Check battery connectionsand perform either a conductance test (using ELEC-TRICAL SYSTEM ANALYZER (Part No. MCR-101 HD))or load test. Replace the battery if necessary. See BAT-TERY in the Service Manual.

3. Connect BREAKOUT BOX (Part No. HD-43876). See4.7 BREAKOUT BOX: EFI.

4. Remove spark plug cable from spark plug.

a. Visually check condition of plug.

b. See Figure 4-16. Attach cable to SPARKTESTER (Part No. HD-26792). Clip tester to cylinderhead bolt.

c. While cranking engine, look for spark. Repeat pro-cedure on other spark plug cables.

NOTEEngine will not spark with both spark plugs removed. Whenchecking for spark, use SPARK TESTER (Part No. HD-26792)with both plugs installed.

5. Use HARNESS CONNECTOR TEST KIT (Part No. HD-41404-B), gray pin probe and patch cord.

6. Typically, when IAC is not functioning, the engine will notstart unless throttle is opened and the engine will stallwhen throttle is closed.

7. See Figure 4-17. Plug IGNITION COIL CIRCUIT TESTADAPTER (Part No. HD-44687) and FUEL INJECTORTEST LAMP (Part No. HD-34730-2C) into Breakout Box

terminals "13" and "11". Start engine. If lamp flashes, noproblem is found. Repeat for Breakout Box terminals "13"and "29".

8. Use HARNESS CONNECTOR TEST KIT (Part No. HD-41404-B), brown socket probe and patch cord.

Diagnostic TipsCheck TP sensor value with a digital volt/ohmmeter (DVOM).If TP sensor is equal to or greater than 3.8 volts, system is in"clear flood" mode and engine will not start. While spark ispresent, fuel is shut off. Problem can be mechanical, such asthrottle cables stuck

ed02012

Figure 4-16. Spark Tester

ed02013

Figure 4-17. Ignition Coil Circuit Test


10

11

29

19

21

4

30CKP (+)CKP (-)

System relay

Rear coil

Front coil

Battery

Front injector

Rear injector

IAC (A) lowIAC (B) high

IAC (B) low

IAC (A) high

Switched powerMAP sensor input

Engine temp

5V sensor powerTPS input

Oxygen sensor A (DOM)5V sensor ground

Oxygen sensor B (DOM)

Serial data

VSS inputGround

Ground

12

31

13

26

1424

6

25

28

– +

18

3635

17

A

B

C

D

A

B

C

D

5

32

4

[79A]

CKP

GND 1

[78A]ECM

[78B]GND 1

[84B] [84A]

[87B]

[91A]

[90B] [90A]

[88B] [88A]

[80B] [80A]

[87A]

[83B] [83A]

[33]

[79B][178A][178B]

23

8

ABC

[141A][141B]

GND 2

D

ABCD

AB

1

AB

3

ABC

ABC

1

23

123

A

B

A

B

12

[22A]33

10

11

27ION sense 27

29

19

21

4

30

22Active intake solenoid(HDI)

22

1Active exhaustfeedback (HDI) 1

20Active exhaust (HDI) 20

12

31

13

26

1424

6

25

Intake air temp 7 7

28

18

3635

17

5

Jiffy stand sensor (HDI) 9 9

23

8

33

[65B] [65A]

[133A][133B]

2

2

1

1

[137A]

[137B]2

2

1

1

[138A]

[138B]

123

123

[85B] [85A]

3

[22B]

12

4 4

A

B

A

B

87

87A

30

85

86

I

Q

C

P

R

5

4

3

2

1

A

B

C

D

A

B

C

D

[30B]

[30A]

2

2

3

3

AB

SystemRelay

Spark PlugsIgnition

Coil

Battery

IgnitionSwitch

FrontInjector

RearInjector

IdleAirControl

MAPSensor

Front O2Sensor

Rear O2Sensor

Tospeedometerandtachometer

Data LinkConnector

EngineStopSwitch

TPSensor

ETSensor

TSM/TSSM/HFSMJiffy Stand

Sensor

VehicleSpeedSensor

Igni

tion

Ser

iada

ta

Fuel Pump15 Amp

Fuel PumpFuse

15 AmpIgnition Fuse

15 AmpENG Fuse

15 AmpECM Fuse

40 AmpMAXIFUSE

R R

R

RR R

R

BK BK

GY

GY

GY GY

GY

BK

BK

GN/O

GY/O GY/O

GN/O

W/BK

Y/GN

Y/GN

Y/GN

Y/GN

Y/BE

BE/O

Y/BE

BE/O

R/BKR/BK

Y/GN O/GY O/GY

BN/R

BK/O

W/BK

BK/W

BK/W

W/BK W/BK

PK/O

W/GN

PK/Y PK/Y

GY/V GY/VBK/W

BK/W

PK

/O

BK

/W

BK

/W

W/Y W/Y

R/WV/W V/W

R/W

R/W

R/W

R/W

BE/GY

LGN/V

LGN/Y

LGN/V

LGN

/V

LGN/V

PK

/GN

BK/PK

BK/GNGND 1

BK/GNBK/GN

GN/BN

BK/GN

BK/GN

BE/GN

BN/R

BK/O

BK/PK

BE/GN

GN/GY GN/GY

BE/GY BE/GY

GY/BE GY/BE

[62B]

[89A][89D][89B] [89C]

12

12

12

12 IAT SensorLGN/Y

BK/W

1

2

3

4

1

2

3

4

[179A][179B]

21

21

V/BE

LGN/R

LGN/RLGN/R

BK/GN

LGN/R


ActiveIntake

Solenoid

V/O

V/BE

V/O

1 2 3

1 2 3

BKR W

em00038

Figure 4-18. EFI Circuit Diagram





Inside top frame tube (FXD, FXDL)3-place DelphiIgnition switch[33]Under fuel tank console (FDWG, FXDCFXDF)


Under electrical caddie coverSpade terminalsFuse/relay block[62]

Rear of transmission case3-place DelphiVehicle Speed Sensor (VSS)[65]


Inside front electrical caddie2-place Mini-DeutschCrankshaft Position (CKP) sensor[79]

Top of induction module3-place DelphiManifold Absolute Pressure (MAP)sensor

[80]

Back of coil4-place DelphiIgnition coil[83]

Beneath fuel tank2-place DelphiFront injector[84]

Beneath fuel tank2-place DelphiRear injector[85]

Beneath fuel tank4-place DelphiIdle Air Control (IAC)[87]

Behind air cleaner backing plate2-place DeutschIntake Air Temperature (IAT) sensor[89]

Back of front cylinder, left side2-place DelphiEngine Temperature (ET) sensor[90]


Left side of along frame toward front ofengine

3-place MolexJiffy stand sensor[133]

Inside front electrical caddie2-place AmpRear oxygen sensor[137]

Top of fuel tank2-place DelphiFront oxygen sensor[138]

Top of fuel tank4-place DelphiFuel pump and sender[141]

Behind rear cylinder head5-place AmpActive exhaust[179]

Air cleaner backing plate2-place AmpActive intake solenoid[178]


Engine Cranks, But Will Not Start (Part 1 of 4)

Fresh fuel in tank?

NOTE:Refer to IGNITION COIL in the SERVICE MANUAL for proper

coil terminal location.

Spark plug wires firmly connected to proper coil terminals?

Add fuel /connectspark plugs.

YES NO

2

1

3

YES NO

NO

NO

NO

NO

YES

YES

YES

YES

YES

STOP

Check for diagnostic troublecodes (DTCs).DTCs found?

Refer to Table 4-7.Start with the lowest

ranking DTC.

Is TSM/TSSM/HFSM mountedin proper orientation?

Install TSM/TSSM/HFSM properly.Check battery connectionsand voltage.

Is voltage above 12.6 volts?

Does battery pass conductancetest or load test?

Was battery allowed to discharge?Was battery drawn down by starting

problem?Recharge battery.

Turn Ignition Switch to IGN and Engine StopSwitch to RUN.

Did fuel pump run for 2 seconds and checkengine lamp illuminate for 4 seconds?

Replace battery.

NONo pump, light OK.

See4.13 FUEL SYSTEMELECTRICAL TEST.

NONo light or pump

See 4.11 NO ECM POWER.

Connect Breakout Box to ECM [78]. Measurevoltage to Breakout Box with DVOM at terminal “13”

(+) and terminal “4” (-). Crank engine for greaterthan 2 seconds to insure proper system operation.

Is 6-12 volts present continuously?

Go to BOLD ASTERISK inEngine Cranks, But Will Not

Start (Part 4 of 4).

At some point in the flow chart youmay be instructed to jump directlyto a the box with the bold asterisk.Disregard the asterisk (but not theInstruction box) if your normalprogression through the chart bringsyou to this location.

Go to Engine Cranks, But Will NotStart (Part 2 of 4). fc01338_en



Clear DTCs using speedometer self diagnostics.See 4.6 SPEEDOMETER SELF DIAGNOSTICS.Confirm proper operation with no check enginelamp.

STOP

YES NO

4

5

6

YES

YES

YES

YES

YES

NO

NO

NO

NO

NO

Continued from Engine Cranks, But Will Not Start(Part 1 of 4).

Install fuel pressure gauge (Part No. HD-41182).See 4.15 FUEL PRESSURE TEST. While

cranking engine (for more than 2 seconds toensure proper system operation), verify that

fuel pressure rises to 55-62 PSI (380-427 kPa).Adequate fuel pressure present?

Check spark plug condition, replace if fouled.Reinstall spark plugs before checking spark.Check spark at both plugs while cranking.

Spark present?

Incorrect pressure. See 4.15FUEL PRESSURE TEST.

Verify connector is securely attached to eachinjector. If so, disconnect fuel injector

connector and attach fuel injector test lamp(HD-34730-2C). Crank engine.

Does lamp flash?

Check battery voltage at terminal “A” (+)of coil connector [83B] using DVOM.

Is battery voltage present for 2 secondsafter key ON?

Monitor IAC pintle for 10 secondsafter turning ignition OFF.

Does pintle extend and then retractduring 10 second key OFF

reset procedure?

Correct problems withfuel injectors. See 4.22

DTC P0261, P0262,P0263, P0264.

Repair open in (Y/GN)wire between splice for

fuel pump wire andignition coil.

Check engine compression.Is compression within

specifications?

See 4.16 IDLEAIR CONTROL.

Replace pluggedfuel injector(s).

See Service Manual.

Go to EngineCranks, But Will

Not Start(Part 3 of 4).

fc01339_en




STOP

YES NO

YES

YES

YES

YES

NO

NONO

NO

Continued from Engine Cranks, But WillNot Start (Part 2 of 4).

Perform coil circuit test.Does lamp flash?

Check coil connections.Connections OK?

Disconnect ECM connector [78]. Inspectfor damaged terminals, terminals backed

out or corroded.Terminal problems present?

Test spark plug cable resistance.See 4.17 MISFIRE AT

IDLE OR UNDER LOAD.Resistance OK?

Repair.

Repair terminaldamage.

Reconnect. Problemstill exist?

Replace sparkplug cables.

Replacecoil.

Problemfixed.

Go to EngineCranks, But Will

Not Start(Part 4 of 4).

fc01340_en

7




8

YES NO

YES

YES

YES YES

NO

NO

NO

Continued from Engine Cranks, But Will Not Start(Part 3 of 4).

Check connectors for moisture and corrosion.Check CKP sensor and harness wires for chafing.Connect DVOM to ECM terminals “12” and “30” onBreakout Box and set it for AC volts. Crank engine.

Does DVOM read 1.0 VAC minimum?

Replace ECM.Reprogram andlearn password.

Disconnect CKP sensor connector[79]. Check connectors for moisture

and corrosion. Check wires forchafing.

Is connector or wire damage present?

Connect DVOM to terminals “1” and “2”of [79A]. Crank engine.

Does DVOM read 1.0 VAC minimum?

Check for continuity betweenterminal “30” on Breakout Box and

terminal “1” of connector [79B].Is continuity present?

Locate and repair open on (BK)wire between terminal “2” ofconnector [79B] and terminal

“12” on Breakout Box.

Locate and repair open on(R) wire between terminal “1”

of connector[79B] and terminal “30” on

Breakout Box.

Loose sensor at crankcase.Check for contamination ordamage. Tighten sensor.

Replace Crank PositionSensor.

See Service Manual.

With meter still connected,check for resistance.

Is resistance 600-1200 ohms?

Replace CKPsensor.

NO

fc01341_en


4.11NO ECM POWER

GENERAL

No Spark/No Check Engine Lamp at Key OnConstant power is supplied to the ECM through terminal "31".The ECM turns on when power is applied to terminal "13" ofconnector [78]. The ECM goes through an initializationsequence every time power is removed and re-applied to ter-minal "13". The only visible part of this sequence is the checkengine lamp. Upon starting, the check engine lamp will illu-minate for 4 seconds and then (if parameters are normal) goout.

If battery power is absent at ECM terminal "31":

• DTCs cannot be cleared. Tool will show them as clearedbut will be present next time Ignition Switch is cycled.

• ECM cannot be re-flashed.

• Vehicle will start but IAC pintle will not reset at key OFF.Eventually pintle will be out of position causing perform-ance problems.

NOTE

The key ON sequence also activates the idle air control motor.If power from terminal "31" is disrupted (blown fuse, etc.)always turn the Ignition Switch OFF wait 10 seconds then turnthe Ignition Switch to IGN to reset the motor to the defaultposition.

DIAGNOSTICS






2. Use HARNESS CONNECTOR TEST KIT (Part No. HD-41404-B); gray probes and patch cords.

4

5

6

7

8

9

12

13

14

10

11

2 31ed02882


Figure 4-19. Fuses and Relays


[78A] [78B]

[22B]

[22A][33B]

[33A]

4 3A B C

I B A4 3

BK

GY

GY

R

R

R R

R

BE/GY

BK/GN

BK/GN

W/BK

W/B

K

RBK

RB

K

31

13

10

28

31

13

10

28

Ignition SwitchFXDWG/FXDC/FXDF

[33B]

[33A]

A B C

A B C

Ignition SwitchAll but FXDWG/FXDC/FXDF

15 AmpIgnition Fuse

15 AmpECM Fuse

40 AmpMAXIFUSE

Engine StopSwitch

Battery

Switched power

Ground

Ground

ECM

GND 1

–+

Battery

em00039

Figure 4-20. ECM Power Circuit Diagram



Under fuel tank6-place MolexRight hand controls[22]

Inside top frame tube (FXD, FXDL)3-place DelphiIgnition Switch[33]Under fuel tank console (FXDWG,FXDC, FXDF)


Under seatRing terminalsECM ground[GND 1]


No ECM Power (Part 1 of 2)

Check ECM and Ignition Fuses.Are fuses OK?

YES NO

Disconnect ECM connector [78]. Inspect for damagedterminals, terminals backed out or corrosion.

Terminal problems present?

YES NO

Repair terminaldamage.

Reconnect.Problem still exist?

YES NO

With Ignition Switch turned to IGN, probe ECMterminal “13” on Breakout Box with a circuit test

lamp connected to ground.Does test lamp illuminate?

Problemfixed.

YES NO

Probe ECM terminal “31” on BreakoutBox with test lamp connected to ground.

Does test lamp illuminate?

Locate and repair shortto ground. Replace 15

amp fuse.

YES NO

Probe ECM terminals “10” and “28” onBreakout Box with test lamp connected to

+12V (battery positive terminal).Does test lamp illuminate?

1

STOP

Go to No ECM Power(Part 2 of 2).

Probe red wire terminal in 15 ampECM fuse holder with test lamp

connected to ground.Does test lamp illuminate?

YES NO


password.

Repair open in(BK) wire between

connector [78B] andground 1.

YES NO

Repair open in (BE/GY)wire between fuse holderand ECM connector [78].

Repair open inred wire between 40

amp MAXIFUSE and 15amp fuse holder.

fc01342_en


No ECM Power (Part 2 of 2)

Continued from No ECM Power (Part 1 of 2).

With Ignition Switch turned to IGN, measurevoltage at terminal “3” (BK) of connector [22B].


YES NO

With Ignition Switch OFF and Engine StopSwitch in RUN position, measure

resistance at terminals “3” and “4” ofconnector [22A].

Resistance less than one ohm?

Repair open (GY) wire betweenconnector [22] and fuse.

YES NO

Repair open circuit on (W/BK) wirebetween ECM and connector [22A].

Repair/Replace Engine StopSwitch or wiring.

2


fc01343_en


4.12STARTS,THEN STALLS

GENERAL

Diagnostic Trouble Codes U1300, U1301, orBUS ERThe typical serial data voltage range is 0 volt (inactive) to 7volts (active). Due to the short pulse, voltages will be muchlower on a digital volt/ohmmeter (DVOM). In analog mode, aDVOM reading serial data will show continuous voltage whenactive, typically 0.6-0.8 volt. The range for acceptable opera-tions is greater than 0 and less than 7.0 volts.

NOTE

Problems in the fuel system or idle air control system may alsocreate this symptom.


DESCRIPTIONDTC



ed02896

Figure 4-21. Data Link Connector [91A] (typical)

DIAGNOSTICS



Diagnostic Tips• If serial data is shorted, these codes will automatically trip

the check engine light.



1. Unplug the neutral switch connector [131]. Using a DVOM,test for continuity between terminals "A" and "B" of theNeutral Switch. When the transmission is in NEUTRAL,continuity should not exist. When the transmission is ingear, there should be continuity through the NeutralSwitch.

2. Use HARNESS CONNECTOR TEST KIT (Part No. HD-41404-B), black socket probes and patch cord.


3

1

2

4

32 4

4

1 12

3

Bat

tery

Igni

tion

Ser

iald

ata

Neu

tral

switc

h

Gro

und

21 1221 65 7

21 65 7

21

Igni

tion

Ser

iald

ata

Bat

tery

Ace

ssor

yG

roun

d

Igni

tion

Ser

iald

ata

Bat

tery

Ace

ssor

yG

roun

d

65 7

B A

21 65 7

21 6 7 12

21 6 7 12

5

5

GY

O

O

GY

BN

/GY

BN

/GY

LGN

/V

LGN

/V

LGN

/V

O/W

O/W

O/W

BN

/GY

BK

/GN

BK

/GN

BK

/GN

O

O

BN

/GY

LGN

/V

O/W

BK

/GN

BK/GN

LGN/V

LGN

/V

BN

/GY

BK

/GN

LGN

/V

ECM

Ser

iald

ata

[30B][30A]

[91A]

[108B]

[131]

[108A]

[20B][20A]

[39B][39A]

[78B][78A]

Speedometer

Toignitionfuse

Toinstrument

fuse

Toaccessory

fuse

Tobattery

fuse


Data LinkConnector

NeutralSwitch


TSM/TSSM/HFSM

BK

TN

TN

em01302





[20]






Starts,Then Stalls: DTC U1300, U1301 or "BUS ER" (Part 1 of 2)

Fresh gasolinein tank?

YES NO

Add gasoline.

YES.DTC P1009,

P1010 found. See4.30 DTC P1009,

P1010.

YES NO

Check fuel pressure whilecranking engine. See 4.15FUEL PRESSURE TEST.

Is fuel pressure OK?

Check for diagnostic trouble codes (DTCs) using4.6 SPEEDOMETER SELF DIAGNOSTICS.

DTCs found?

Will engine start with throttleopened partially and stall when

throttle is closed?

See 4.16 IDLEAIR CONTROL.

YES.U1300 or U1301

codes found.

STOP

NO.No codes found.

YES.BUS Er present.

speedometer will notcommunicate with other

modules.

STOP

Go to Starts, Then Stalls:DTC U1300, U1301 or –BUS

ER– (Part 2 of 2).

Go to Starts, Then Stalls:DTC U1300, U1301 or –BUS

ER– (Part 2 of 2).

YES NO

Fuel pressure problem.See flow chart under 4.15FUEL PRESSURE TEST.

Tap lightly on fuelinjectors.

Problem still exist?

YES NO

Replace fuel injectors.Problem still exist?

SystemOK.

YES NO


password.

SystemOK.


With Ignition Switch turned to IGN, EngineStop Switch in the Run position and the

Jiffy Stand down.Does the odometer display “SIdE StAnd”?

YES NO

Turn the Ignition Switch OFF. Raise the Jiffy Stand. Turn the IgnitionSwitch to IGN with the Enigine Stop Switch in the RUN position.

Does the odometer display “SIdE StAnd”?

YES

YESYES

YES

NO

NONO

NO

Inspect the Jiffy Stand Sensor forcorrect mounting and clearance to

Jiffy Stand tab (4.5mm) max.Is sensor mounted correctly?

Check for an open in theneutral switch circuits.

Is there an open?

Replace JiffyStand Sensor.

Test Neutral switch.Is Neutral switch

operating properly?

Install JiffyStand Sensor

correctly.

Correct openin circuit.

Replace TSM/TSSM.

ReplaceNeutral switch.

fc01344_en

1


Starts,Then Stalls: DTC U1300, U1301 or "BUS ER" (Part 2 of 2)

Continued from Starts, Then Stalls: DTC U1300, U1301 or“BUS ER” (Part 1 of 2)

Set Engine Stop switch to RUN. Turn Ignition Switch to IGN.Is BUS Er present?

YES NO

Turn Ignition Switch OFF.Disconnect ECM at connector [78].

Turn Ignition Switch to IGN.Is BUS Er present?

Turn Ignition Switch OFF. While wigglingharness, check for continuity to ground at

terminal “3” of connector [91A].Is continuity to ground present at any time?

YES NO

Turn Ignition Switch OFF. DisconnectTSM/TSSM/HFSM at connector [30].

Turn Ignition Switch to IGN.Is BUS Er present?

Replace ECM.Reprogram and

performpassword learn.

YES

Is vehicle equippedwith a tachometer?

NO

Replace TSM/TSSM/HFSM.Perform password learn.

YES

Turn Ignition Switch OFF. Disconnecttachometer at connector [108]. Turn Ignition

Switch to IGN.Is BUS Er present?

NO

YES NO

Turn ignition switch OFF. Disconnectspeedometer at connector [39].Check for continuity to ground atterminal “3” of connector [91A].Is continuity to ground present?

Replace tachometer.

YES

Locate and repair shortto ground.

NO

Turn Ignition Switch to IGN.Check for voltage at terminal

“3” of connector [91A].Is voltage present?

YES

Locate and repair shortto voltage.

NO

ReplaceSpeedometer.

YES NO


to ground.

Turn Ignition Switch to IGN.While wiggling harness,

check for voltage at terminal“3” of connector [91A].Is voltage present at

any time?

YES NO


to voltage.

No problemfound.

2

2


fc01345_en


4.13FUEL SYSTEM ELECTRICAL TEST

GENERALWith the Ignition Switch turned to IGN and the Engine StopSwitch at RUN, the Electronic Control Module (ECM) willenergize the system relay to complete the circuit to the in-tankfuel pump. It will remain on as long as the engine is crankingor running, and the ECM is receiving ignition reference pulsesfrom the CKP. If there are no reference pulses, the ECM willde-energize the system relay within 2 seconds after ignition isON or engine has stalled, or immediately after the ignition isshut OFF.

The fuel pump delivers fuel to the injectors. The pressure reg-ulator is where the system pressure is controlled. Excess fuelflow is bypassed into the fuel tank through the pressure regu-lator. When the engine is stopped, the pump can be turned onby applying battery voltage and ground to the fuel pump con-nector [141A]. See Figure 4-23. The fuel pump connector islocated on top of the fuel tank. Improper fuel system pressuremay contribute to one or all of the following symptoms.

• Engine cranks, but won't run.

• Engine cuts out (may feel like ignition problems).

• Hesitation, loss of power and poor fuel economy.

NOTE

After turning Ignition Switch OFF, you must wait 10 secondsbefore turning the Ignition Switch back to IGN to get the fuelpump to reprime.This time out period is necessary for the fuelpump and IAC to reset.

ed01493

Figure 4-23. Fuel Pump Connector [141] (typical)

DIAGNOSTICS





1. Turns on fuel pump if wiring is OK. If pump runs, problemis in basic fuel delivery.

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

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


4

5

6

7

8

9

12

13

14

10

11

2 31ed02882


Figure 4-24. Fuses and Relays


BK

BK

BK

GY

GY

BK

R R

R

R

R

BE/GY

GN/GY GN/GY

BE/GY

BK/GN

BK/GN

BE/GY

Y/GN

Y/GN

W/BKW

/BK

GY

W/B

K

O/GY

R/BK

R/B

K

RR/B

K

O/GYY/GN

Y/GN

GN/OGN/O

W/BK

–+

[62] [64]

Ground

Rear injector

Front Injector

System relay

Battery

Switched power

Ground

[78A] [78B] GND 1

[84B] [84A]

Front Injector

Rear Injector

15 AmpFuel Pump

Fuse

SystemRelay

FuelPump

40 AmpMAXIFUSE

15 AmpECM Fuse

15 AmpIGN Fuse

Engine StopSwitch

StarterMotor

Battery

[85B] [85A]

[62B]

87

87A

30

85

86

I

Q

C

P

R

5

4

3

2

1

AB A

[141B]

GND 2

[141A]

D

AB

AB

AB

A

B B

C C

D

10

19

21

4

31

13

28

10

19

21

4

31

13

28

4 3

[22A][22B]

4 3

[33B]

[33A]

A B C

A B C


[33B]

[33A]

A B C

I B A


Fuse Blocks

E

K

T SU

C

I

Q PR

B A

H G

O M

ENG CTL

Fuel Pump

ECMStarter Relay System Relay

Top view Top view

D C

J I

R P

F E

L K

U S

H G

B A

MO

Cust ACCY

Spare

ACC

Battery

P&A

Lights

Ignition

Instruments

Spare

W/Y W/Y

em00040

Figure 4-25. Fuel Pump Circuit




FXD, FXDL: inside top frame tube3-place DelphiIgnition switch[33]FXDWG, FXDC: under fuel tank con-sole





Fuel System Electrical Test (Part 1 of 4)

YES NO

YES NO

Check for 12 volts at terminals “A” (+) and “D” (-)of fuel pump connector [141A] during first 2-3seconds after Ignition Switch is turned to IGN.

Is voltage present?

YES NO

Check for corrodedconnections or loose

connectors between fuel pumpand pump connector [141B].

Poor connections?

Check for continuity toground on [141A] terminal “D”.

Continuity present?

NOYES

With Ignition Switch OFF, check foropen pump circuit. Connect ohmmeterbetween terminal “A” and terminal “D”

of connector [141B].Is continuity present?

Repair asnecessary.

Is ECM fuse OK?

Is fuel pump fuse OK?

NOYES

Remove fuel pump. Checkfor continuity across fuel

pump terminals.Is continuity present?

Check pumpconnections and repair

as required.If good, replace Fuel Pump.

NOYES

Check for openin wiring.

ReplaceFuel Pump.

STOP

STOP

NOYES

STOP

Locate and repairopen on (BK) wire

between [141A] andground.

Go to Fuel SystemElectrical Test(Part 2 of 4).

Go to Fuel SysytemElectrical Test(Part 4 of 4).

Go to 4.11 NOECM POWER.

1

2

fc01346_en



YES NO

NOYES

Continued from Fuel SystemElectrical Test (Part 1 of 4).

Is 12 volts present at terminal “87” of system relay (with relayin place) during first two seconds after Ignition Switch

is turned to IGN?NOTE

Depending on relay used, relay socket terminal could beshown as “5” or “I”.

Locate and repair open betweenterminal “1” of [141A] and terminal “87”

of system relay?NOTE

Depending on relay used, relay socketterminal could be shown as “5” or “I”.

STOP

Is 12 volts present at terminal “30” ofsystem relay?

NOTEDepending on relay used, relay socketterminal could be shown as “3” or “C”.

With Ignition Switch turned to IGN andEngine Stop Switch set to RUN, is 12 voltspresent at terminal “86” of system relay?

NOTEDepending on relay used, relay socketterminal could be shown as “1” or “R”.

Locate and repair open on (BE/GY)wire between ECM fuse and terminal

“30” of system relay.NOTE

Depending on relay used, relay socketterminal could be shown as “3” or “C”.

NOYES

Locate and repair open on(W/BK) wire to system relay.

Go to Fuel SystemElectrical Test(Part 3 of 4). fc01347_en

3

3

3



YES NO

NOYES

Continued from Fuel System Electrical Test (Part 2 of 4).

Probe system relay connector terminal “85” with a test light to 12 volts.Does test light illuminate for 2 seconds after Ignition Switch is turned to IGN?

NOTEDepending on relay used, relay socket terminal could be shown as “2” or “P”.

Replace SystemRelay.

Probe Breakout Box terminal “4” with a test lightconnected to 12 volts.

Does test light illuminate for 2 seconds after IgnitionSwitch is turned to IGN?

Locate and repair openon (GN/O) wire.

Replace ECM. Reprogramand learn password.

4

fc01348_en



YES NO

NOYES

Continued from Fuel System Electrical Test (Part 1 of 4)or

Fuel System Electrical Test (Part 2 of 4).

Check for intermittent short to ground on terminal “1”of connector [141A].

Short to ground present?

Repair short to ground on(O/GY) wire and replace

fuse.

Reconnect fuel pump connector [141] and install fuel pressure gauge.See 4.15 FUEL PRESSURE TEST.

With fuel system intact and battery fully charged, removefuel pump fuse.

Connect DVOM across fuel pump fuse terminals using probe. Placemale positive probe in H slot. Turn Ignition Switch to IGN. With pump

running, check current and fuel pressure.Is current draw under 4.5 amps and fuel pressure between 55-62 PSI

(380-425 kPa)?

Replace fuse. Substitute known good relay for system relay. Testfor current draw across fuel pump fuse terminals.

Is current draw less than 4.5 amps?

3

NOYES

Current draw now in range. ReplaceSystem Relay and replace fuse.

Replace FuelPump and replace fuse.

fc01349_en

3


4.14SYSTEM RELAY FAULT

GENERAL

System RelaySee Figure 4-26. With the Ignition Switch turned to IGN andthe Engine Stop Switch at RUN, the ECM will energize thesystem relay to complete the circuit to the in-tank fuel pump,ignition coil, and fuel injectors. They will remain powered aslong as the engine is cranking or running, and the ECM isreceiving ignition reference pulses from the CKP. If there areno reference pulses, the ECM will de-energize the system relaywithin 2 seconds after the Ignition Switch is turned to IGN orengine has stalled, or immediately after Ignition Switch is turnedOFF.


DESCRIPTIONDTC

System relay coil open/lowP1001

System relay coil high/shortedP1002

System relay contacts openP1003

System relay contacts closedP1004

ed02933

Figure 4-26. System Relay

DIAGNOSTICS







2. Connect BREAKOUT BOX (Part No. HD-43876) to ECM.See 4.7 BREAKOUT BOX: EFI.

3. Connect HARNESS CONNECTOR TEST KIT (PartNo. HD-41404-B)purple pin probe and patch cord.


BK

BKBK

GY

GY

GY

GY

BK

R

BE/GY

GN/GY GN/GY

GY/BE

BE/GY

BK/GN

BK/GN

BE/GY

Y/BE

BE/O

GY/BE

Y/BE

BE/O

W/BK

W/B

KW

/BK

O/GY

R/BK

R/B

K

O/GY

Y/GN

Y/GN

Y/GN

GN/OGN/OW/BK

Ground

Rear injector

Front injector

System relay

Battery

Switched power

Ground

[78A] [78B]

[30A]

GND 1

[30B]

TSM/TSSM/HFSM

[84B] [84A]

Front Injector

Rear Injector

15 AmpFuel Pump

Fuse

SystemRelay

FuelPump

IgnitionCoil

15 AmpECM Fuse

15 AmpIGN Fuse

Engine StopSwitch

[85B] [85A]

[62B]

87

87A

30

85

86

I

Q

C

P

R

5

4

3

2

1

AB A

[141B]

GND 2

Spark Plugs

[141A]

D

AB

AB

AB

A

B B

C C

D

Rear coil

Front coil

10

19

21

4

31

13

2

2

Igni

tion

28

11

29

10

19

21

4

31

13

28

11

ION sense 2727

29

A

B

C

D

[83B] [83A]

A

B

C

D

4 3

[22A][22B]

4 3

R R

R

R R/B

KR

–+40 Amp

MAXIFUSE

StarterMotor

Battery

[33B]

[33A]

A B C

A B C


[33B]

[33A]

A B C

I B A


Y/GN

Y/GN

W/Y W/Y

em00041

Figure 4-27. Sytem Relay Circuit





Inside top frame tube (FXD, FXDL)3-place DelphiIgnition switch[33]Under fuel tank console (FXDWG,FXDC, FXDF)









Top of fuel tank4-place DelphiFuel pump and sensor[141]


System Relay: DTC P1001, P1003 (Part 1 of 3)

Check for battery voltage at terminal “87” of system relay(with relay installed) during first 2-3 seconds after Ignition

Switch is turned to IGN.Is battery voltage (10-13 volts) present for 2-3 seconds after

Ignition Switch is turned to IGN?

YES

System relay OK. Measure resistance(with relay removed) between

terminal “87” of system relay andcoil connector [83B] at terminal “A”.

Is resistance less than 0.5 ohm?

YES NO

Recheck connections.Wiggle harness whilerepeating test. Repair

intermittent.

Find and repairconnection or

open wire (Y/GN).

YES NO

With Ignition Switch turned toIGN, check for 10-13 volts at

terminal “86” of the system relay.Is voltage present?

Check for continuity toground on (BE/GY) wire.


Check for 10-13 volts atterminal “30” of the system relay.

Is voltage present?

2

1

NO.No voltage or voltage

always present.

YES NO

Measure resistance between terminal “85” ofSystem Relay and terminal “4” on Breakout Box.

Is resistance less than 0.5 ohm?

Is IgnitionFuse good?

YES NO

Find and repairopen betweenfuse and relay.

Repair short toground and replace

ECM fuse.

YES NO

Check for continuity toground at terminal “4” on

Breakout Box.Is continuity present?

Locate andrepair open on(GN/O) wire.

YES NO

Repair shortto ground and replace

Ignition Fuse.

Find and repairopen on (W/BK) wire

between connector [22]and relay.

YES NO

Repair shortto ground.

Replace System Relay.Does fuel pump run for the first2 seconds after Ignition Switch

is turned to IGN?

YES

SystemOK.


NO


fc01350_en

3

3

3


System Relay: DTC P1002 (Part 2 of 3)

Remove system relay. Check forvoltage on terminal “4” of Breakout Box.

Is voltage present?

YES NO

Remove Breakout Boxconnector from ECM.

Is voltage still present on terminal “4”?

YES NO

Repair shortto voltage on(GN/O) wire.


password.

ReplaceSystem Relay.


fc01351_en


System Relay: DTC P1004 (Part 3 of 3)

Check for poor connections, damaged terminals,poor ground or wires reversed at Fuel Pump.

Do any of these conditions exist?

YES NO

Repair. Condition: Fuel Pump continues torun with Ignition Switch OFF.

Remove System Relay.Does pump continue to run?


YES NO

Replace short tovoltage on (Y/GN) wire.

ReplaceSystem Relay.

fc01352_en


4.15FUEL PRESSURE TEST

GENERALThe fuel pump delivers fuel to the fuel line, to a cavity in theinduction module that supplies the fuel injectors and to thepressure regulator, where the system pressure is controlled.Excess fuel pressure is bypassed to the fuel tank through thepressure regulator.

See Figure 4-28.The fuel pump fuse is located under the seat.The fuel pump can be turned on by applying battery voltageto the fuel pump fuse.

Improper fuel system pressure may contribute to one of thefollowing conditions:

• Cranks, but won't run.

• Cuts out (may feel like ignition problem).

• Hesitation, loss of power or poor fuel economy.

ed02936

Figure 4-28. Fuel Pump Fuse

TESTING


FUEL PRESSURE GAUGEHD-41182

FUEL PRESSURE GAUGE ADAPTERHD-44061

The fuel pressure gauge allows for fuel injector and fuel systempressure diagnosis. A special adapter allows the gauge to beattached to the external fuel supply line.

1. Remove electrical caddie cover (left side of vehicle).

To prevent spray of fuel, purge system of high-pressurefuel before supply line is disconnected. Gasoline isextremely flammable and highly explosive, which couldresult in death or serious injury. (00275a)

2. Purge fuel supply line of high pressure gas.

a. See Figure 4-28. Disconnect the fuel pump fuse fromthe fuse block.

b. Start engine and allow vehicle to run.

c. When the engine stalls, operate the starter for 3seconds to remove any remaining fuel from the fuellines.

Gasoline can drain from quick-connect fitting whenremoving fuel line. Gasoline is extremely flammable andhighly explosive, which could result in death or seriousinjury. Wipe up spilled fuel immediately and dispose ofrags in a suitable manner. (00267a)

3. Pull up on chrome sleeve of quick-connect fitting (fittingon left side of fuel tank) and pull down on fuel supply lineto disconnect.

NOTEThe next step requires two fuel pressure gauge adapters.Failure to use two adapters will cause the fuel line to twist.Thismay result in a broken fuel line or fuel line fitting.

4. Attach fuel line to gauge assembly.

a. See Figure 4-29 Install a second adapter in serieswith the first.

b. See Figure 4-30. Pull up on chrome sleeve of quick-connect fitting and insert neck of FUEL PRESSUREGAUGE ADAPTER (Part No. HD-44061) into fuelsupply line.

c. While pushing up on bottom of adapter, pull down onchrome sleeve until it "clicks" into the locked position.Tug on adapter to be sure that it will not come free.

d. See Figure 4-31. In the same manner, install neck ofsecond fuel supply line fitting into adapter quick-con-nect fitting on fuel tank. Tug on fuel supply line to besure that it will not come free.

To prevent spray of fuel, be sure quick-connect fittingsare properly mated. Gasoline is extremely flammable andhighly explosive, which could result in death or seriousinjury. (00268a)

5. Verify that fuel valve and air bleed petcock on FUELPRESSURE GAUGE (Part No. HD-41182) are closed.

6. See Figure 4-29. Remove protective cap from free end offuel pressure gauge adapter. Connect fuel pressure gaugeto Schroeder valve.

7. See Figure 4-28. Install fuel pump fuse.

8. Start and idle engine to pressurize the fuel system. Openthe fuel valve to allow the flow of fuel down the hose ofthe pressure gauge.

9. Position clear air bleed tube in a suitable container. Openand close air bleed petcock to purge gauge and hose ofair. Repeat this step several times until only solid fuel(without bubbles) flows from air bleed tube. Close petcock.

10. Open and close throttle to change engine speed. Note thereading of the pressure gauge. Fuel pressure shouldremain steady at 55-62 psi (380-425 kPa).

11. Turn the engine off. Position the air bleed tube in a suitablecontainer. Open the air bleed petcock to relieve the fuel


system pressure and purge the pressure gauge of gas-oline.

Gasoline can drain from the adapter when gauge isremoved. Gasoline is extremely flammable and highlyexplosive, which could result in death or serious injury.Wipe up spilled fuel immediately and dispose of rags in asuitable manner. (00254a)

12. Remove fuel pressure gauge from the adapter. Installprotective cap over Schroeder valve.

Gasoline can drain from the fuel line and adapter whenremoved. Gasoline is extremely flammable and highlyexplosive, which could result in death or serious injury.Wipe up spilled fuel immediately and dispose of rags in asuitable manner. (00255a)

13. Pull up on sleeve of quick-connect fitting and remove fuelsupply line from fuel pressure gauge adapter. Releaseadapter from fuel tank in the same manner.

14. Pull up on chrome sleeve of fuel tank quick-connect fitting(forward fitting on left side of tank) and insert neck of fuelsupply line fitting. While pushing up on bottom of fuelsupply line fitting, pull down on chrome sleeve until it"clicks" into the locked position. Tug on fuel supply line tobe sure that it will not come free.

15. Install electrical caddie cover (left side of vehicle).

ed02016

Figure 4-29. Fuel Pressure Gauge Adapters

5

43

2

1

ed02017

1. Fuel supply line2. Adapter to fuel line3. Adapter to fuel tank4. Pressure adapter/Schroeder valve union5. Fuel valve (closed position)

Figure 4-30. Fuel Line

ed02848

Figure 4-31. Fuel Pressure Gauge Installed

DIAGNOSTICS

Diagnostic NotesThe reference numbers below correlate with the circled num-bers on the flow chart.

1. If the regulator is faulty, see Service Manual.


2. If fuel system has pressure, but it is less than specification,check for the following conditions.

a. The amount of fuel to the injectors is within limits, butpressure is too low. Also, hard starting cold andoverall poor performance condition may exist.

b. Restricted fuel flow causing pressure drop. However,if pressure drop occurs only when driving, engine may

surge and lose power as pressure begins to droprapidly.

3. This condition may be identified when the fuel level is lowand the fuel pump turned on for the first two seconds afterkey ON. A metallic ringing sound can be heard as the highpressure fuel is sprayed against the inside wall of the fueltank.


Fuel Pressure Test

Install fuel pressure gauge. See TESTINGunder 4.15 FUEL PRESSURE TEST.

Start and idle engine.Open and close throttle to change engine speed.

Does fuel pressure remain steadyat 55-62 PSI (380-425 kPa)?

YESSteady pressure.

Inspect check valve fittingassembly and fuel tank.If OK, replace faulty fuel

pressure regulator.


YES NO

Replace Filter or clean PumpInlet Screen. Retest.

No trouble found.Review symptoms.

NOLow pressure.

NOHigh pressure.

Check for restricted fuel filteror pump inlet screen.

Are filter and screen OK?

Check for restricted pressure line or flex hose betweentank and test gauge. If lines are OK, check for:

• Faulty fuel pump.• Restricted check valve fitting assembly.• Leak inside tank caused by faulty coupling

hose or connection, such as hose at filteror pump.

• Faulty fuel pressure regulator.

3

1

2 1

fc01353_en


4.16IDLE AIR CONTROL

GENERAL



IAC OperationThe ECM controls engine idle speed by moving the Idle AirControl (IAC) to open or close a passage around the throttleplate. It does this by sending voltage pulses to the proper motorwinding of the IAC. This causes the pintle to move in or out ofthe 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 speed, the ECM extends the pintle,allowing less air to flow through the throttle body.

The IAC position is measured in steps. This can only be doneby using a computer based diagnostic package called DIGITALTECHNICIAN (Part No. HD-44750).

• A high number of steps represents a retracted pintle andopen passage around throttle plate. This correlates withan increase in the amount of air flowing through the throttlebody.

• Zero steps represents a fully extended pintle. A zeroreading indicates an abnormal condition in which the pintlehas been fully extended and has consequently closed thepassage around throttle plate.

Each time the Ignition Switch is turned off, the ECM resets theIAC by sending enough pulses to extend the pintle and effect-ively close the throttle body. The fully extended value is theECM reference point. A given number of steps are then calcu-lated by the ECM for use in setting the proper idle speed andIAC position.

NOTE

Warm idle speed is controlled by the ECM and can only beadjusted by using a computer based diagnostic package calledDIGITAL TECHNICIAN (Part No. HD-44750).

Diagnostic Trouble Code P0505: Loss ofIdle Speed ControlLoss of idle speed control will result if the idle RPM is 200 frompreset idle speed and IAC motor is at zero or maximum forgreater than 5 seconds. This code may occur with others for

a multiple code situation. Resolve the other codes first to cor-rect.


DESCRIPTIONDTC

Loss of idle speed controlP0505

DIAGNOSTICS




Diagnostic TipsEngine idle speed can be adversely affected by the following:

• A loss of idle speed control does not necessarily imply theIAC actuator or wiring has failed. It can be caused by anumber of conditions such as an intake air leak, improperlyadjusted throttle stop (factory set) or a misfiring cylinder.

• Leaking injectors will cause fuel imbalance and poor idlequality due to different air/fuel ratios in each cylinder. Tocheck for leaky injectors, first remove the air cleaner. See4.16 IDLE AIR CONTROL. Then, with the throttle wideopen, turn Ignition Switch to IGN for 2 seconds and thenOFF for 2 seconds five consecutive times. Replace thefuel injector if there is any evidence of raw fuel in thebores. See 4.15 FUEL PRESSURE TEST.

• Vacuum leaks. To check for vacuum, see 4.9 INTAKELEAK TEST.

• Contaminated fuel.

• Excessive oil in the crankcase (oil sumping).

• TPS reading of greater than 1% (possible throttle cablemisadjustment) or battery voltage reading of less than 9volts or a Vehicle Speed Sensor (VSS) greater than 0 willdisable idle speed control.

• If there is a loss of battery power at ECM terminal "31",vehicle will start but IAC pintle will not reset at key OFF.Eventually pintle will be out of position causing perform-ance problems.


1. When the engine is stopped, the IAC pintle extends andthen retracts to a fixed "Park" position for increased air-flow and idle speed during the next engine start sequence.This key OFF reset procedure takes 10 seconds to per-form.


2. Test lamp behavior may follow two patterns. The color ofthe lights is not relevant to IAC operation.

a. Normal behavior: At key ON, test lights will altern-ately flash and then remain steady on to confirm ECMsignals. At key OFF lights alternately flash and go outafter 10 second reset procedure.

b. Problem indicated: One or more lights fail to illu-minate during key ON/key OFF cycle.

NOTEThere is a remote possibility that one of the circuits is shortedto voltage which would have been indicated by a steady light.Disconnect ECM and turn Ignition Switch to IGN. Probe ter-minals to check for this condition.

3. Connect BREAKOUT BOX (Part No. HD-43876) to EFIwire harness only, leaving ECM disconnected. See4.15 FUEL PRESSURE TEST.


5. Repair faulty ECM connection or replace ECM. If ECMrequires replacement, see ECM in the Service Manual.

ed02020

Figure 4-32. IAC Test Lamp (Part No. HD-41199-3)

ed02970

Figure 4-33. IAC Connector

ed02851

Figure 4-34. IAC Pintle


[87A]

[87B]

[78B]

[78A]

ECM

IACMotor

BE

/GN

BE

/GN

BK

/PK

BK

/PK

BN

/R

BN

/R

BK

/O

BK

/O

A

17 18 35 36

17

IAC

(A)

high

IAC

(B)

low

IAC

(A)

low

IAC

(B)

high

18 35 36

B C D

A B C D

em00145

Figure 4-35. IAC Circuit






Idle Air Control: DTC P0505 (Part 1 of 2)

YES NO

NOYES

Remove air cleaner cover and element.Is throttle valve completely closed?

Monitor IAC pintle for 10 seconds after turningIgnition Switch OFF.

Does pintle extend and then retract within 10seconds of the Ignition Switch OFF reset

procedure?

STOP

Lubricate andadjust throttle

cables.

Check intake manifold for leaks,see 4.9 INTAKE LEAK TEST.

Leaks found?

Disconnect IAC and connect test lamp(Part No. HD-41199-3).

Turn Ignition Switch to IGN for 2 seconds, then turnIgnition Switch OFF for 10 seconds.

Check test lamp during the switch ON/OFF cycle.

NOYES

Check fuel pressure.See 4.15 FUEL

PRESSURE TEST.

Repair intakeleak. Normal behavior?Problem indicated?

Remove test lamp.Connect Breakout Box to connector[78B] leaving ECM disconnected.

Check terminal “31” for battery voltage.Battery voltage present?

YES NO

YES NO

YES NO

Turn Ignition Switch to IGN. With ECM stilldisconnected, check voltage on all four

terminals at connector [87B].Is voltage present?

Repair poor connectionat connectors [87B] or

[78B] or repair open wirein harness.

Repair shortto voltage.

Go to Idle Air Control:DTC P0505(Part 2 of 2).


Repair faulty IACconnection or IAC assembly.


3

4

4

2

1

fc01354_en

Using DVOM, measure resistancebetween IAC connector [87B]

and Breakout Box.

Does each wire measure 0.5 ohms or less?

WIRE COLOR(BK/PK)(BN/R)

(BE/GN)(BK/O)

ECMto “18”to “36”to “35”to “17”

IAC“A”“B”“C”“D”


Idle Air Control: DTC P0505 (Part 2 of 2)

YES NO

NOYES

Continued from Idle Air Control: DTC P0505(Part 1 of 2).

Turn Ignition Switch OFF. Measure resistance betweeneach terminal on connector [87B] and ground.

Is resistance greater than 1 megohm for all terminals?

Inspect ECMconnections.

Connections OK?



password.

Repair ECMconnections.

5

4


fc01355_en


4.17MISFIRE AT IDLE OR UNDER LOAD

GENERAL

Misfire at Idle or Under Load• Battery condition and connections may also cause misfires.

See 1.8 BATTERY TESTING or more information.

• Fuel system problems may also cause misfires. Consult4.15 FUEL PRESSURE TEST and then see symptomtables under 4.5 INITIAL DIAGNOSTIC CHECK: EFI.

• Mechanical problems with the engine may cause misfires.See 3.1 TURN SIGNAL OVERVIEW for more information.

• Vehicle modifications including intake and exhaust maycause misfires.

DIAGNOSTICS


SPARK TESTERHD-26792



Diagnostic Notes

Wipe up spilled fuel and dispose of rags in a suitablemanner. An open spark around gasoline could cause afire or explosion, resulting in death or serious injury.(00518b)

Each reference number below correlates to a circled numberon the flow chart(s).


NOTEEngine will not spark with both spark plugs removed. Whenchecking for spark, use SPARK TESTER (Part No. HD-26792)with both plugs installed.

2. See Figure 4-36. A SPARK TESTER (Part No. HD-26792)must be used to verify adequate secondary voltage(25,000 volts) at the spark plug.

a. Turn Ignition Switch OFF.

b. Remove spark plug cable from spark plug. Visuallycheck plug condition.

c. Attach cable to SPARK TESTER. Clip tester to cyl-inder head bolt.

d. While cranking engine, watch for spark to jump testergap on leads.

e. Reinstall and repeat procedure on other spark plugcable.

Table 4-18. Spark Plug Cables

REARFRONTSPECIFICATION

7.25-7.5019.0-19.25Length in.

184.2-190.5482.6-489.0Length mm

1812-43754750-11,230Resistance-ohms

3. Perform spark plug cable resistance test.

a. Remove spark plug cable from spark plug and ignitioncoil. For best results, use a needle nose pliers forremoval/installation on coil. Gently grasp cable asclose to terminals as possible.

b. Using an ohmmeter, touch probes to terminals oneach end plug cable.

c. Compare resistance values to Table 4-18. Replacecables not meeting specifications. Reinstall and repeatprocedure on other spark plug cable.

4. If carbon tracking is evident on outside of coil towers,replace ignition coil and inspect spark plug cables. Cablesmust be clean and tight. Excessive cable resistance orfaulty connections can cause coil damage.

5. This test can also be performed by substituting a knowngood coil for one causing the no spark condition. The coildoes not require full installation to be functional. Verifyfaulty coil by performing resistance test. See 4.10 ENGINECRANKS, BUT WILL NOT START.

6. Use HARNESS CONNECTOR TEST KIT (Part No. HD-41404-B) , red pin probe and patch cord to relay and graypin probe and patch cord to the coil connector [83B].

ed02012

Figure 4-36. Spark Tester


BK

BKBK

GY

GY

GY

GY

BK

R

BE/GY

GN/GY GN/GY

GY/BE

BE/GY

BK/GN

BK/GN

BE/GY

Y/BE

BE/O

GY/BE

Y/BE

BE/O

W/BK

W/B

KW

/BK

O/GY

R/BK

R/B

K

O/GY

Y/GN

Y/GN

Y/GN

GN/OGN/OW/BK

Ground

Rear injector

Front injector

System relay

Battery

Switched power

Ground

[78A] [78B]

[30A]

GND 1

[30B]

TSM/TSSM/HFSM

[84B] [84A]

Front Injector

Rear Injector

15 AmpFuel Pump

Fuse

SystemRelay

FuelPump

IgnitionCoil

15 AmpECM Fuse

15 AmpIGN Fuse

Engine StopSwitch

[85B] [85A]

[62B]

87

87A

30

85

86

I

Q

C

P

R

5

4

3

2

1

AB A

[141B]

GND 2

Spark Plugs

[141A]

D

AB

AB

AB

A

B B

C C

D

Rear coil

Front coil

10

19

21

4

31

13

2

2

Igni

tion

28

11

29

10

19

21

4

31

13

28

11

ION sense 2727

29

A

B

C

D

[83B] [83A]

A

B

C

D

4 3

[22A][22B]

4 3

R R

R

R R/B

KR

–+40 Amp

MAXIFUSE

StarterMotor

Battery

[33B]

[33A]

A B C

A B C


[33B]

[33A]

A B C

I B A


Y/GN

Y/GN

W/Y W/Y

em00041

Figure 4-37. Ignition Coil Circuit Diagram





FXD, FXDL: inside top frame tube3-place DelphiIgnition switch[33]FXDWG, FXDC, FXDF: under fuel tankconsole




Misfire At Idle Or Under Load (Part 1 of 3)

Is fuel contaminated?

YES NO

Drain and flushtank. Refill with

fresh fuel.

Connect Breakout Box. Check for continuitybetween terminal “10 “of ECM and battery

negative and terminal “28” of ECM and batterynegative. Resistance should be less than 1 ohm.

Is it?

YES NO

Use spark tester to checkcables.

Did spark jump tester gap?

Locate and repair poorground connection.

YES NO

Check for:• Faulty, worn or cracked spark plug(s).• Plug fouling due to engine

mechanical fault.• Faulty or poor connection at plug or coil.

Check resistance of each spark plugcable that did not fire the spark tester.

Also, check for faulty plug cableconnections and wires for carbon

tracking.Are spark plug cables OK?

YES NO

Coils should be free ofcarbon tracking.

Are they?

Replace faulty sparkplug cables.

YES

Switch coil with unit known to be good.Re-perform spark test.

Did spark jump gapduring engine cranking?

NO

ReplaceIgnition Coil.

YES

Original Ignition Coilis faulty. Replace

NO

STOP

Go to Misfire At IdleOr Under Load

(Part 2 of 3).

1

2

3

4

2

5

fc01356_en



Continued from Misfire At Idle Or Uunder Load (Part 1 of 3).

Measure resistance between system relay terminal “87” and ignitioncoil connector [83B] terminal “A” (Y/GN) wire. Wiggle harness.

Is resistance continuously less than 0.5 ohms?NOTE

Depending on relay used, relay socket terminal couldbe shown as “5” or “I”.

YES NO

Reassemble Coil and Fuel Tank. Measure voltage dropbetween battery (positive lead) and terminal “87” (negative

lead) on System Relay.With engine running, is voltage drop less than 1.0 volt?

NOTEDepending on relay used, relay socket terminal could

be shown as “5” or “I”.

Find source ofintermittent and

repair.

YES

Problem is fuel related.Refer to Table 4-5. Engine

Performance Problems under4.5 INITIAL DIAGNOSTIC

CHECK: EFI.

NO

Repeat voltage drop test after moving negative lead to terminal “30”.With engine running, is voltage drop less than 1.0 volt?

NOTEDepending on relay used, relay socket terminal could

be shown as “3” or “C”.

YES

Replace SystemRelay.

NO

Repeat voltage drop test after moving negativelead to 15 amp ECM Fuse (BE/GY) wire.

With engine running,is voltage drop less than 1.0 volt?

YES NO

Repair (BE/GY) wire. Repeat voltage drop test after moving negativelead to 15 amp ECM Fuse (R) wire.

With engine running, is voltage drop less than1.0 volt?

YES

Replace 15 ampECM Fuse.

NO

STOP

Go to Misfire At IdleOr Under Load

(Part 3 of 3).

6

fc01357_en



Continued from Misfire At IdleOr Under Load (Part 2 of 3).

Repeat voltage drop test after moving negativelead to 40 amp MAXIFUSE (left side).

With engine running,is voltage drop less than 1.0 volt?

YES

Check terminalor repair wire.

NO

Repeat voltage drop test aftermoving negative lead to 40 amp

MAXIFUSE (right side).With engine running,

is voltage drop less than 1.0 volt?

YES NO

Check terminalor replace

MAXIFUSE.

Repeat voltage drop test aftermoving negative lead to starter

motor battery terminal.With engine running, is voltage

drop less than 1.0 volt?

YES NO

Repair wirebetween

MAXIFUSE andstarter motor.

Repair or replacebattery cable.

fc01358_en


4.18COMBUSTION ABSENT INTERMITTENT

GENERAL

Diagnostic Trouble Codes P1353, P1356,P1357, P1358: No CombustionSee Figure 4-38. A feedback voltage signal in the secondaryignition circuit detects the presence of combustion each timea cylinder fires on ECM terminal "27". For diagnostic purposes,this signal is only analyzed at high speed and load where itmay be easily measured. Failure to detect combustion at highspeed and load means one of the following conditions is true.

• Cylinder is truly misfiring.

• There is a lack of continuity in the ignition coil secondarycircuit.


DESCRIPTIONDTC

Front cylinder no combustionP1353

Rear cylinder no combustionP1356

Front cylinder no combustion intermittentP1357

Rear cylinder no combustion intermittentP1358

DIAGNOSTICS






2. Resistance vales will only be correct if using the HarleyDavidson spark plugs specified for that vehicle.

3. Use HARNESS CONNECTOR TEST KIT (Part No. HD-41404-B), purple pin probes and patch cords.

4. Perform spark plug cable resistance test.

a. Remove spark plug cable from spark plug and ignitioncoil. For best results, use a needle nose pliers forremoval/installation on coil. Gently grasp cable asclose to terminals as possible.

b. Using an ohmmeter, touch probes to terminals oneach and plug wire.

c. Compare resistance values to Table 4-21. Replacecables not meeting specifications. Reinstall and repeatprocedure on other spark plug cable.

Table 4-21. Spark Plug Cables

REARFRONTSPECIFICATION

7.25-7.5019.0-19.25Length in.

184.2-190.5482.6-489.0Length mm

1812-43754750-11,230Resistance-ohms

ed02972

Figure 4-38. Feedback Signal Pin B


BK

BKBK

GY

GY

GY

GY

BK

R

BE/GY

GN/GY GN/GY

GY/BE

BE/GY

BK/GN

BK/GN

BE/GY

Y/BE

BE/O

GY/BE

Y/BE

BE/O

W/BK

W/B

KW

/BK

O/GY

R/BK

R/B

K

O/GY

Y/GN

Y/GN

Y/GN

GN/OGN/OW/BK

Ground

Rear injector

Front injector

System relay

Battery

Switched power

Ground

[78A] [78B]

[30A]

GND 1

[30B]

TSM/TSSM/HFSM

[84B] [84A]

Front Injector

Rear Injector

15 AmpFuel Pump

Fuse

SystemRelay

FuelPump

IgnitionCoil

15 AmpECM Fuse

15 AmpIGN Fuse

Engine StopSwitch

[85B] [85A]

[62B]

87

87A

30

85

86

I

Q

C

P

R

5

4

3

2

1

AB A

[141B]

GND 2

Spark Plugs

[141A]

D

AB

AB

AB

A

B B

C C

D

Rear coil

Front coil

10

19

21

4

31

13

2

2

Igni

tion

28

11

29

10

19

21

4

31

13

28

11

ION sense 2727

29

A

B

C

D

[83B] [83A]

A

B

C

D

4 3

[22A][22B]

4 3

R R

R

R R/B

KR

–+40 Amp

MAXIFUSE

StarterMotor

Battery

[33B]

[33A]

A B C

A B C


[33B]

[33A]

A B C

I B A


Y/GN

Y/GN

W/Y W/Y

em00041

Figure 4-39. Secondary Ignition Circuit Diagram





Inside top frame tube (FXD, FXDL3-place DelphiIgnition switch[33]Under fuel tank console (FXDWG,FXDC, FXDF




Combustion Absent: DTC P1353, P1356, P1357, P1358 (Part 1 of 2)

YES NO

YES NO

Is vehiclerunning properly?

Has vehicle run outof fuel recently?

Check fuel pressure. See4.15 FUEL PRESSURE

TEST.Is fuel pressure 55-62PSI (380-425 kPa)?

See 4.17MISFIRE AT IDLEOR UNDER LOAD.

See 4.13FUEL SYSTEM

ELECTRICAL TEST.

YES NO

Clear codes, refill with freshfuel and restart.

Does code return?

Check if spark plug terminal is fullyconnected on Spark Plug.

YES NO

SystemOK.

NOYES

Seat terminalon Spark Plug.

Remove spark plug terminal fromSpark Plug. Inspect cable and spark plugterminals for carbon tracking or evidence

of a loose terminal.Loose terminal present?

Crimp spark plug terminalslightly to improve connectionor replace Spark Plug Cable.

STOP

YES NO

Go to CombustionAbsent: DTC P1353,P1356, P1357, P1358

(Part 2 of 2).

Clear codes using speedometer self diagnostics.See 4.6 SPEEDOMETER SELF DIAGNOSTICS.Confirm proper operation with no check engine lamp.

fc01359_en


Combustion Absent: DTC P1353, P1356, P1357, P1358 (Part 2 of 2)

Continued from Combustion Absent: DTC P1353, P1356,P1357, P1358 (Part 1 of 2).

Using Breakout Box, measure resistance betweenSpark Plug center electrode and Breakout Box terminal "27".

Is resistance less than 60,000 ohms?

Replace Spark Plug.Condition still present?

Check continuity betweenIgnition Coil terminal “B” andBreakout Box terminal “27”.


Replace Spark PlugCable.

Condition still present?

Measure resistance betweenterminal “A” and “B” at Ignition

Coil.Is resistance greater than

100k ohms?

ReplaceIgnition Coil.

Check Spark Plug Cable resistance.Resistance meet specifications?

Replace SparkPlug Cable.

YES NO

1

YES

YESYES

YES

NO

NO

NO


2

3

4

Replace SparkPlug.

NO

SystemOK.

SystemOK.


password.

YES NO

Replace Ignition Coil andECM. Reprogram and

learn password.fc01360_en


4.19DTC P0107, P0108

GENERAL

MAP SensorSee Figure 4-40.The Manifold Absolute Pressure (MAP) sensoris supplied 5 volts from the ECM (terminal "14") and sends asignal back to the ECM (terminal "25"). This signal varies inaccordance with engine vacuum and atmospheric barometricpressure. Changes in barometric pressure are influenced byweather and altitude.


DESCRIPTIONDTC

MAP sensor open/lowP0107

MAP sensor highP0108

ed02908

Figure 4-40. MAP Sensor

DIAGNOSTICS


VACUUM PUMPHD-23738



Diagnostic Tips• These codes will set if the MAP sensor signal is out of

range. Code P0108 can only be detected with the enginerunning.

• MAP sensor output check. Using the VACUUMPUMP (Part No. HD-23738), apply a vacuum to the pres-sure port of the MAP sensor. The signal voltage shouldlower as the vacuum is applied.

• The MAP, TP, Jiffy Stand and VSS sensors are connectedto the same reference line (+5V Vref). If the reference linegoes to ground or open, multiple codes will be set (DTCP0107, P0108, P0122, P0123).



2. Use HARNESS CONNECTOR TEST KIT (Part No. HD-41404-B), purple pin probes and patch cords.


V/W

V/W

R/W

R/W

BK

/W

BK

/W

[80A]

MapSensor

To TP, ET &IAT sensors

To TP and VSS sensorsand jiffy stand sensor (HDI)

ECM

[80B]

[78B]

[78A]

A B C

A

14 25 26

14

5Vse

nsor

pow

er

MA

Pse

nsor

inpu

t

5Vse

nsor

grou

nd25 26

B C

em00043

Figure 4-41. MAP Sensor Circuit




Top of induction module3-place PackardManifold Absolute Pressure (MAP)Sensor

[80]


Map Sensor: DTC P0107, P0108 (Part 1 of 2)

Connect Breakout Box. With Ignition Switchturned to IGN,

measure voltage between terminal “25”and terminal “26” on Breakout Box.

With Ignition Switch turned to IGN and engine OFF, voltagemust be between 3.5 and 5.0 volts.

With Ignition Switch turned to IGN and engine running,voltage must be between 1.5-3.0 volts at hot idle.

Does voltage fit specifications?

YES NO

Perform 4.8 WIGGLE TESTto check for intermittents.

Intermittents present?

YES

To identify the source of intermittents,start with box marked by Bold Asteriskunder MAP Sensor: DTC P0107, P0108

(Part 2 of 2). Wiggle harness whilewatching DVOM.

NO

Replace MAP sensor. Clear DiagnosticTrouble Codes (DTCs) and road test.

Did check engine lamp illuminate and setDTC P0107 or P0108?

YES

Install original MAP sensor.Replace ECM (reprogram,

relearn) and road test againto verify.

NO

Systemnow OK.

STOP

At some point in the flow chart you maybe instructed to jump directly to a thebox with the bold asterisk. Disregard theasterisk (but not the instruction box) ifyour normal progression through thechart brings you to this location.


1

Go to MAP Sensor:DTC P0107, P0108

(Part 2 of 2).

fc01361_en


Map Sensor: DTC P0107, P0108 (Part 2 of 2)

Continued fromMAP Sensor: DTC P0107, P0108 (Part 1 of 2).

Check the 5 volt reference supply at the MAP sensorconnector [80B]. With Ignition Switch turned to IGN,measure voltage between terminal “C” (R/W) and

terminal “A” (BK/W).Voltage approximately 5.0 volts?

YES NO.Greater than 6V.

Connect Breakout Box to connector[78B] leaving ECM disconnected.Check continuity between MAP

connector [80B] terminal “C” andBreakout Box terminal “14”. Then

measure continuity betweenMAP connector [80B] terminal “A” and

Breakout Box terminal “26”.Resistance less than 1 ohm?

NO.Less than 4.5V.

Locate short to 12volts on (R/W)

wire in wire harness.Repair as necessary.

Connect Breakout Box to connector [78B]leaving ECM disconnected.

OPEN CHECK: Measure resistancebetween MAP connector [80B] terminal “B”

and Breakout Box terminal “25”.Resistance less than 1 ohm?

YES NO

SHORT CHECK: Measure resistancebetween MAP connector terminal “B”

and chassis ground.Resistance greater than 1 megohm?

Locate and repairopen on (V/W)

wire.

YES

Replace MAP sensor.See Service Manual.

NO

Locate and repairgrounded (V/W)

wire.

YES

Check resistance betweenMAP connector [80B]

terminal “C” and Breakout Boxterminal “26”.

Resistance greater than 1megohm?

NO

Repairopen wire.

YES NO


Locate and repairshort between

(R/W) and (BK/W)wires.

At some point in the flow chart youmay be instructed to jump directlyto a the box with the bold asterisk.Disregard the asterisk (but not theinstruction box) if your normal progressionthrough the chart bringsyou to this location.


2

22

2

fc01362_en


4.20DTC P0112, P0113

GENERAL

IAT SensorThe ECM supplies and monitors a voltage signal (terminal "7")to one side of the Intake Air Temperature (IAT) Sensor. Theother side of the IAT sensor is connected to a common sensorground, which is also connected to the ECM (terminal "26").

The IAT sensor is a thermistor device, meaning that at a spe-cific temperature, it will have a specific resistance across itsterminals. As this resistance varies, so does the voltage on(terminal "7").

• At high temperatures, the resistance of the sensor is verylow, which effectively lowers the signal voltage on (terminal"7").

• At low temperatures, the resistance is very high, allowingthe voltage to rise close to 5 volts.

The ECM monitors this voltage to compensate for variousoperating conditions.


DESCRIPTIONDTC

IAT sensor voltage lowP0112

IAT sensor open/highP0113

Table 4-26. IAT Sensor Table

TEMP °FVOLTAGERESISTANCETEMP °C

-44.929121-20

144.816599-10

324.697500

504.3597010

684.0374720

773.8300025

863.6241730

1043.1159840

1222.6108050

1402.274660

1581.752670

1761.437780

1941.127590

2120.9204100

DIAGNOSTICS




Diagnostic TipsCheck the following conditions:

• Poor connection: Inspect ECM and harness connector[78] for backed out terminals, improper mating, brokenlocks, improperly formed or damaged terminals, poor ter-minal- to-wire connection and damaged harness.

• Perform 4.8 WIGGLE TEST to locate intermittents: Ifconnections and harness check out OK, use a DVOM tocheck the intake air temperature sensor voltage readingwhile moving related connectors and wiring harness. Ifthe failure is induced, the intake air temperature sensorvoltage reading will change.

• Shifted sensor: Refer to Table 4-26. This table may beused to test the intake air temperature sensor at varioustemperature levels in order to evaluate the possibility of ashifted (out-of-calibration) sensor which may result indriveability problems.

• An intermittent may be caused by a poor connection,rubbed through wire insulation or a wire broken inside theinsulation.

NOTE

All voltage and resistance values are approximate (20%).Measure IAT sensor resistance between ECM terminal "7" andsystem ground (ECM terminal "26").


1. Connect BREAKOUT BOX (Part No. HD-43876) to EFIwire harness only (leave ECM disconnected). See4.8 WIGGLE TEST.

2. Use HARNESS CONNECTOR TEST KIT (Part No. HD-41404-B), gray pin probes and patch cords.

3. Use HARNESS CONNECTOR TEST KIT (Part No. HD-41404-B), gray socket probes and patch cords.

4. Replace IAT sensor. See Service Manual.


B/W

B/W

LGN

/Y

LGN

/Y

7

1 2

1 2

1 2

1 2

Inta

keai

rte

mpe

ratu

re

5Vse

nsor

grou

nd

26

7 26

[89A]

[89D]

ECM

[89B]

[89C]

[78B]

[78A]

To TP, ET &MAP sensors

IATSensor

em00044

Figure 4-42. IAT Sensor Circuit




Behind air cleaner backing plate2-place DelphiIntake Air Temperature (IAT) Sensor[89]


IAT Sensor: DTC P0112, P0113 (Part 1 of 2)

Connect Breakout Box to connector [78B] leaving ECM disconnected. Withengine at room temperature (60-90° F or 16-32° C), use a DVOM to

measure resistance across terminals “7” and “26” on Breakout Box. Ifengine is warm, refer to Table 4-26.

Is resistance between 2.0k ohms and 5.0k ohms at room temperature?

YES NO

Connect ECM to Breakout Box.Perform 4.8 WIGGLE TEST to

check for intermittents.Intermittents present?

YES

While wiggling harness, performsteps marked by BOLD ASTERISKS

under IAT Sensor:DTC P0112, P0113 (Part 2 of 2).

Repair as necessary.

NO

Disconnect IAT sensor connector [89].Turn Ignition Switch to IGN. Using a

DVOM, measure the voltage betweenECM terminal “7” (positive) and terminal

“26” (negative) on Breakout Box.Voltage approximately 5 volts?

YES NO. Less than 4.7 volts. NO. Greater than 5.3 volts.

Replace IAT sensor, clearcodes and road test.

Did check engine lampilluminate and set DTC

P0112 or P0113?

With IAT sensor disconnected,disconnect ECM from Breakout Box.

Measure resistance betweenBreakout Box terminal “7” and

terminals “10” or “28”.Is resistance less than 1 megohm?

Unplug ECM leavingBreakout Box connected at

vehicle harness.Measure voltage betweenBreakout Box terminal “7”and terminals “10” or “28”.

Voltage 0 volts?

YES NOYES NO

YES NO

Install original IATsensor, replace ECM,

perform passwordlearning and road test.

SystemOK. Repair short to

ground on(LGN/Y) wire.



Examine IAT signalwire (LGN/Y) for

short to voltage andrepair.



1

1 1

STOP

Go to IAT Sensor:DTC P0112, P0113

(Part 2 of 2).

fc01363_en


IAT Sensor: DTC P0112, P0113 (Part 2 of 2)

Continued from IAT Sensor: DTC P0112,P0113 (Part 1 of 2).

Disconnect IAT sensor connector [89B]and examine for damage.

Connector OK?

YES

Repairconnector.

NO

Using a DVOM, measure the resistance between IATsensor connector [89B] Terminal “1” and ECM terminal

“7” on Breakout Box.Resistance less than 1.0 ohm?

YES

Using a DVOM, measure the resistance between IATsensor connector [89B] terminal “2” and ECM terminal

“26” on Breakout Box.Resistance less than 1.0 ohm?

YES

Using a DVOM, measure the resistance between ECMterminal “7” and terminal “26” on Breakout Box.

Resistance greater than 1.0 megohm?

YES

Using a DVOM, measure the resistance between ECMterminal “7” on Breakout Box and chassis ground.


YES

Remove IAT sensor and measure resistanceacross the terminals of the IAT sensor directly.

Again, with sensor at room temperature(60-90°F or 16-32°C), is resistance between

2.0k ohms and 5.0k ohms?

YES

Perform 4.8 WIGGLE TEST on steps marked with aBOLD ASTERISK above to locate intermittents.


2

2

3

NO

Examine (LGN/Y) wirein harness for opencircuit and repair.

NO

Examine (BK/W) wirein harness for opencircuit and repair.

NO

Examine (LGN/Y) and (BK/W)wires in harness for short between

these two circuits and repair.

NO

Examine harness forshort to ground and

repair.

NO

ReplaceIAT sensor.4

At some point in the flow chart youmay be instructed to jump directlyto a the box with the bold asterisk.Disregard the asterisk (but not theinstruction box) if your normalprogression through the chartbrings you to this location.



4.21DTC P0117, P0118

GENERAL

ET SensorThe ECM supplies and monitors a voltage signal (terminal "6")to one side of the Engine Temperature (ET) sensor. The otherside of the ET sensor is connected to a common sensor ground(terminal "26") of the ECM.

The ET sensor is a thermistor device, which means that at aspecific temperature it will have a specific resistance acrossits terminals. As this resistance varies, so does the voltage(terminal "6").

• At high temperatures, the resistance of the sensor is verylow, which effectively lowers the signal voltage on terminal"6".

• At low temperatures, the resistance is very high, allowingthe voltage to rise close to 5 volts.

The ECM monitors this voltage to compensate for variousoperating conditions. The ECM also uses the sensor input asa reference for determining IAC pintle position.


DESCRIPTIONDTC

ET sensor voltage lowP0117

ET sensor open/highP0118

DIAGNOSTICS




Diagnostic TipsOnce the engine is started, the ET voltage should lower steadilyin two stages.

Check the following conditions:

• Poor connection Inspect ECM and harness connector[78] for backed out terminals, improper mating, brokenlocks, improperly formed or damaged terminals, poor ter-minal- to-wire connection and damaged harness.

• Perform: 4.8 WIGGLE TEST to locate intermittents: Ifconnections and harness check out OK, use a DVOM tocheck the engine temperature sensor voltage readingwhile moving related connectors and wiring harness. Ifthe failure is induced, the engine temperature sensorvoltage reading will change.

• Shifted sensor: Refer to Table 4-29. This table may beused to test the engine temperature sensor at various

temperature levels in order to evaluate the possibility of ashifted (out-of-calibration) sensor which may result indriveability problems.

• An intermittent may be caused by a poor connection,rubbed through wire insulation or a wire broken inside theinsulation.

NOTE

All voltage and resistance values are approximate (20%).Measure ET sensor resistance between ECM terminal "6" andsystem ground (ECM terminal "26").

Table 4-29. ET Sensor Table

TEMP °FVOLTAGERESISTANCETEMP °C

-44.428144-20

144.015873-10

323.592550

503.0557110

682.4375720

772.1275025

861.8220530

1043.1 or 4.1*144240

1221.0 or 3.7*96550

1403.366160

1582.946270

1762.532980

1942.123890

2121.7175100

* Between 40-50°C the ECM changes scaling. Voltages forECT sensor will shift scales in that range.This provides propersensor resolution for all temperatures.

Scaling changes between 176-194° F (80-90° C).


1. Connect BREAKOUT BOX (Part No. HD-43876) to EFIwire harness only (leave ECM disconnected). See4.7 BREAKOUT BOX: EFI.


3. Use HARNESS CONNECTOR TEST KIT (Part No. HD-41404-B), gray socket probes and patch cords.

4. Replace ET sensor. See the Service Manual.


A

6

Eng

ine

tem

pera

ture

5Vse

nsor

grou

nd

26

6 26

B

A B

[78A]

[78B]

[90A]

[90B]

ECM

ETSensor

PK

/Y

BK

/W

BK

/W

PK

/Y

em00045

To TP, MAP, IAT, O 2 sensors and jiffy stand sensor (HDI)

Figure 4-43. ET Sensor Circuit




Back of front cylinder, left side2-place DelphiEngine Temperature (ET) Sensor[90]


ET Sensor: DTC P0117, P0118 (Part 1 of 2)

Connect Breakout Box to connector [78B] leaving ECMdisconnected. With engine at room temperature (60-90° For 16-32° C), use a DVOM to measure resistance acrossterminals “6” and “26” on Breakout Box. If engine is warm,

refer to Table 4-29.Resistance between 2.0k ohms and 5.0k ohms?

YES NO

Connect ECM to Breakout Box.Perform 4.8 WIGGLE TEST to

check for intermittents.Intermittents present?

YES

While wiggling harness, performsteps marked by BOLD

ASTERISKS under ET Sensor:DTC P0117, P0118 (Part 2 of 2).


NO

Disconnect ET sensor connector [90].Turn Ignition Switch to IGN. Using a

DVOM, measure the voltage betweenterminal “6” (positive) and terminal “26”

(negative) on Breakout Box.Voltage approximately 5 volts?

YES NO. Less than 4.7 volts. NO. Greater than 5.3 volts.

Replace ET sensor, clearDiagnostic Trouble Codes

(DTCs) and road test.Did check engine lamp

illuminate and set DTC P0117 orP0118?

With ET sensor disconnected,disconnect ECM connector [78B].

Measure resistance between terminal“6” and terminals “10” or “28”.

Resistance less than 1 megohm?

Unplug ECM leaving Breakout Boxconnected at vehicle harness.

Measure voltage between terminal“6” and terminals “10” or “28”.

Voltage 0 volts?

YES NOYES NO YES NO

Install original ETsensor, replaceECM, perform

password learningand road test.

SystemOK.

Repair short toground on

(PK/Y) wire.



Examine ET signalwire (PK/Y) forshort to voltage

and repair.



1

STOP

Go to ET Sensor:DTC P0117, P0118

(Part 2 of 2).

fc01365_en


ET Sensor: DTC P0117, P0118 (Part 2 of 2)

Continued fromET Sensor: DTC P0117, P0118 (Part 1 of 2).

Disconnect ET sensor connector [90B] and examine for damage.Connector OK?

YES

Repairconnector.

NO

Using a DVOM, measure the resistancebetween ET sensor connector [90B] terminal “A” and

ECM terminal “6” on Breakout Box.Resistance less than 1.0 ohm?

YES

Using a DVOM, measure the resistancebetween ET sensor connector [90B] terminal “B” and

ECM terminal “26” on Breakout Box.Resistance less than 1.0 ohm?

YES

Using a DVOM, measure the resistance between ECMterminal “6” and terminal “26” on Breakout Box.


YES

Using a DVOM, measure the resistance between ECMterminal “6” on Breakout Box and chassis ground.


YES

Remove ET sensor and measure resistance across theterminals of the ET sensor directly.

Again, with sensor at room temperature (60-90°F or 16-32°C), is resistance between 2.0k ohms and 5.0k ohms?

YES

Perform 4.8 WIGGLE TEST on steps marked with a BOLDASTERISK above to locate intermittents.


2

2

3

NO

Examine (PK/Y) wire in harnessfor open circuit and repair.

NO

Examine (BK/W) wire in harnessfor open circuit and repair.

NO

Examine (PK/Y) and (BK/W) wiresin harness for short between these

two circuits and repair.

NO

Examine harnessfor short to ground

and repair.

NO

ReplaceET sensor.

4

At some point in the flow chartyou may be instructed to jumpdirectly to a the box with the boldasterisk. Disregard the asterisk(but not the instruction box) if yournormal progression through thechart brings you to this location.


fc01366_en


4.22DTC P0122, P0123

GENERAL

TP SensorThe ECM supplies a 5 volt signal (terminal "14") to the ThrottlePosition (TP) Sensor. The TP sensor sends a signal back tothe ECM (terminal "24"). The returned signal varies in voltageaccording to throttle position.

• At idle (closed throttle), the signal is typically in the rangeof 0.20-0.80 volts.

• At wide open throttle, the signal is normally 4.0-4.9 volts.

A code P0122 or P0123 will set if the TP sensor voltage signaldoes not fall within the acceptable range.


DESCRIPTIONDTC

TP sensor open/lowP0122

TP sensor highP0123

DIAGNOSTICS




Diagnostic TipsThe DVOM reads throttle position in volts. Voltage shouldincrease at a steady rate as the throttle is moved from idle towide open. A short to ground or open on the (GY/V) or (R/W)wires also will result in a DTC P0122. A short to ground or openon the (R/W) wire (+5v REF) sets multiple codes as describedbelow.

NOTE

The MAP, TP, Jiffy Stand and VSS sensors are connected tothe same reference line (+5V Vref). If the reference line goesto ground or open, multiple codes will be set (DTC P0107,

P0108, P0122, P0123, P0501, P0502, P1501, P1502). Startwith the trouble code having the lowest ranking value.

Check for the following conditions:

• Poor Connection: Inspect ECM and harness connector[78B] for backed out terminals, improper mating, brokenlocks, improperly formed or damaged terminals, poor ter-minal- to-wire connection and damaged harness.

• Perform4.8 WIGGLE TEST to locate intermittents: Ifconnections and harness check out OK, monitor TP sensorvoltage using a DVOM while moving related connectorsand wiring harness. If the failure is induced, the TP sensorvoltage reading will change.

• TP sensor scaling: Observe the TP sensor voltage dis-play while opening the throttle with engine stopped andIgnition Switch ON. Display should vary from closed throttleTP sensor voltage (when throttle is closed) to greater than4.0 volts (when throttle is held wide open). As the throttleis slowly moved, the voltage should change graduallywithout spikes or low voltages being observed.

• Check TP sensor voltage reading with DVOM. If TP sensoris equal to or greater than 3.8 volts then the system is in"clear flood" mode and engine will not start. While sparkis present, fuel is shut off. Problem can be mechanical,such as stuck throttle cables.


1. Connect a BREAKOUT BOX (Part No. HD-43876) betweenEFI wire harness and ECM before measuring voltage. See4.7 BREAKOUT BOX: EFI. Using a DVOM to measurevoltage, take reading across terminal "24" (positive lead)and terminal "26" (negative lead) on Breakout Box.

2. Replace TP sensor. See Service Manual.



R/W

R/W

R/W

BK

/W

BK/W

BK

/W

GY

/V

GY

/V

[88B]

[88A]

[78A]

[78B]

21 3

21 3

TPSensor

To MAP, ET, IAT, TP and O2 sensors

To VSS, TP, MAP sensors and jiffy stand sensor (HDI)

14

5Vse

nsor

pow

er

5Vse

nsor

grou

nd

TP

Sin

put

26

14 26

24

24

ECM

2

em00046

Figure 4-44.TP Sensor Circuit



Under seat36-place PackardElectronic Control Module (ECM)[78]

Behind air cleaner backing plate3-place DelphiThrottle Position (TP) Sensor[88]


TP Sensor: DTC P0122, P0123 (Part 1 of 2)

With Ignition Switch turned to IGN, measure TP Sensorvoltage while gradually opening throttle.

Does voltage increase steadily with no spikes or lowvoltages from 0.2-0.8 volts at idle (closed throttle) to 4.0-

4.9 volts at wide open throttle?

YES NO

Voltage is greater than4.95 volts.

Low voltage or spikesobserved.

Unplug TP Sensor connector[88B] and measure voltage

between terminal “1” (+) andterminal “2” (-) with Ignition

Switch turned to IGN.Is reading 4.8-5.0 volts?

YES NO

Disconnect ECM fromBreakout Box. Check

resistance between ECMterminal “24” on Breakout

Box to chassis ground.Greater than 1 megohm?

Measure Resistancebetween TP Sensor

connector [88B]terminal “1” to ECM

terminal “14” onBreakout Box.

Less than 1.0 ohm?

NO

Find short toground on (GY/V)

signal wire.

YES

ReplaceTP Sensor.

NO

Repair openin (R/W)

wire.

YES

Repair openin (BK/W)

wire.

Check engine lamp ONcontinuously and DTC P0122or P0123 the only one set?

YES


NO

Perform 4.8 WIGGLETEST to check for

intermittents.Intermittents present?

NO

Replace TP Sensor,clear codes and

road test.Did check engine

lamp illuminate andset DTC P0122 or

P0123?

YES

To identify the source ofintermittents,

start with box marked byBold Asterisk

under TP Sensor: DTCP0122, P0123 (Part 2 of 2).

Wiggle harness whilewatching DVOM.

YES NO

Install originalTP Sensor, replace ECM

(reprogram and learnpassword) and road test.

SystemOK.

STOP

Go to TP Sensor:DTC P0122, P0123

(Part 2 of 2).

2

2

At some point in the flow chart you may be instructed to jumpdirectly to a the box with the bold asterisk. Disregard theasterisk (but not the instruction box) if your normal progressionthrough the chart brings you to this location.Clear DTCs using speedometer self diagnostics.

See 4.6 SPEEDOMETER SELF DIAGNOSTICS.Confirm proper operation with no check engine lamp.

fc01367_en

1


TP Sensor: DTC P0122, P0123 (Part 2 of 2)

Continued from TP Sensor:DTC P0122, P0123 (Part 1 of 2).

With Ignition Switch OFF, disconnect ECM connector [78B].Turn Ignition Switch to IGN.

Voltage greater than 0 volts across terminal “24” andterminal “26” on Breakout Box?

YES

Repair shortbetween (GY/V) signal

wire and 12 volts.

NO

Measure resistance between ECMterminal “24” on Breakout Box and TPsensor connector [88B] terminal “3”.

Less than 0.5 ohm?

YES NO

Measure resistance fromTP sensor connector [88B]terminal “3” to terminal “1”.Less than 1.0 megohm?

Repair open(GY/V)

signal wire.

NOYES

Repair shortbetween (R/W) and(GY/V) signal wire.

ReplaceTP sensor.

3

3

2

At some point in the flow chart youmay be instructed to jump directly toa the box with the bold asterisk.Disregard the asterisk (but not theinstruction box) if your normalprogression through the chart bringsyou to this location.


fc01368_en


4.23DTC P0131, P0132, P0134, P0151, P0152, P0154

GENERAL

Oxygen SensorSee Figure 4-45. The Oxygen (O2) Sensor provides a signalto the ECM which indicates whether the engine is running richor lean.

• A P0131 (front) or P0151 (rear) is set when the ECMdetects an excessively lean condition for a specified lengthof time. Codes may also set if O2 Sensor fails.

• A P0132 (front) or P0152 (rear) is set when the ECMdetects an excessively rich condition for a specified lengthof time.

• A P0134 is set when the front O2 Sensor circuit is openor sensor is too cold to respond. A P0154 is set when therear oxygen sensor circuit is open or sensor is too cold torespond.

When the air/fuel mixture is ideal, approximately 14.6 parts airto 1 part fuel, the voltage will be approximately 0.45 V.


DESCRIPTIONDTC



Front O2 sensor open/not responding/highP0134

Rear O2 sensor low or engine running leanP0151


Rear O2 sensor open/not responding/highP0154

ed02909

Figure 4-45. Oxygen Sensor

DIAGNOSTICS



Diagnostic TipsO2 Sensor diagnostic codes may be seen during the vehiclebreak-in period. The O2 Sensor diagnostic codes will not illu-minate the check engine lamp for current or historic codes andwill only be indicated by Digital Technician or speedometer selfdiagnostics. If the diagnostic codes are reported during thebreak-in period, clear or ignore the codes until the break-inperiod is completed.

The DVOM displays the signal from the O2 sensor in volts.Thisvoltage will have an average value tending towards lean, richor ideal value depending on operating temperature of theengine, engine speed and throttle position. An open/short tovoltage or short to ground in the (PK/O) wire (front) and(PK/GN) wire (rear) will cause the engine to run rich (short toground) or lean (short to voltage) until fault is detected. Oncefault is detected, vehicle will run in open loop.

Check for the following conditions:

• Poor connection. Inspect the ECM harness connector[78], fuel injector connectors [84, 85] and O2 Sensor con-nector wiring for backed out terminals, improper mating,broken locks, improperly formed or 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) ifthere is an injector problem. This could also cause poorfuel economy and performance.

• Loose O2 sensor. If the O2 Sensor is loose, engine per-formance may be affected. This could also show up as aslow changing O2 Sensor voltage.

• Loose/leaking exhaust. This can allow fresh air into theexhaust system, causing the O2 sensor to read a leancondition, causing the system to go rich.

• Engine misfire. See 4.17 MISFIRE AT IDLE OR UNDERLOAD.


1. Connect a BREAKOUT BOX (Part No. HD-43876) betweenEFI wire harness and ECM before measuring voltage. See4.7 BREAKOUT BOX: EFI.

2. See 4.9 INTAKE LEAK TEST.


BE

GY

/BK

BE

GY

/BK

PK

/GN

PK

/O

BK

/W

8

Oxy

gen

sens

or(A

)

5Vse

nsor

grou

nd

Oxy

gen

sens

or(B

)

26

8 26

23

23

ECM

[78A]

[78B]

[138A]

[138B]

[137A]

To ET, IAT, TP,MAP sensors

[137B]

Front OxygenSensor

Rear OxygenSensor

1 2

1 2

1 2

1 2

em00047

Figure 4-46. Oxygen Sensor Circuit





Under seat2-place AmpRear oxygen sensor[137]

Inside front electrical caddie2-place AmpFront oxygen sensor[138]


Oxygen Sensor: DTC P0131, P0132, P0134, P0151, P0152, P0154 (Part 1 of 3)

Disconnect O2 sensor from harness. Connect DVOM to terminal “8” (+)and terminal “26” (-) for front O2 sensor, and terminal “23” (+) andterminal “26” (-) for rear O2 sensor at connector [78] (gray). Turn

Ignition Switch to IGN. Observe O2 voltage.Is it approximately 5.0 volts?

YESNO.

0 volts.NO.

Greater than 5 volts.

Install Breakout Box (HD-43876)leaving ECM [78] disconnectedfrom the Breakout Box. Measure

continuity to ground on terminal “8”(front) or terminal “23” (rear).


Install Breakout Box (HD-43876)leaving ECM [78] disconnected

from the Breakout Box.Is voltage present?

YES NOYES NO

Locate and repairshort to ground on

(PK/O) (front) and/or(PK/GN) (rear) wire.

Replace ECM.See Service Manual.

Inspect (PK/O) (front)and/or (PK/GN) (rear)

wire for shorts tovoltage and repair.

Replace ECM.See Service Manual.

11

Go to Oxygen Sensor:DTC P0131, P0132,

P0134, P0151, P0152,P0154

(Part 2 of 3).

STOP


1

fc01369_en



Continued from Oxygen Sensor: DTC P0131, P0132, P0134, P0151,P0152, P0154 (Part 1 of 3).

Turn Ignition Switch OFF and reconnect O2 sensor. Turn Ignition Switch toIGN and start engine. Allow engine to reach operating temperature.

With engine idling, does voltage at terminal “8” (+) and terminal “26” (-)(front) and terminal “23” (+) and terminal “26” (-) (rear) quickly fluctuate

between 0 and 1.0 volts?

NO.0.0-0.4 volts.

NO.0.6-1.0 volts.

NO.Slow or no change. YES

Perform 4.15 FUELPRESSURE TEST.Pressure too low?

Perform 4.15 FUELPRESSURE TEST.Pressure too high?

Check continuity between terminal“8” [78] (front) and terminal “1”

[138] (front) or terminal “23” [78](rear) and terminal “1” [137] (rear).


YES NO

Repair lowpressure problem.

See 4.15 FUELPRESSURE

TEST.

Check forrestricted fuel filter

or fuel line.Restrictionpresent?

YES NO

Replace fuelpressure regulator.

See ServiceManual.

Check forinjectors stuckopen. See 4.24

DTC P0261,P0262, P0263,P0264. Retest.

YES NO

Replace O2 Sensor.See Service

Manual.

Repair openon (PK/O) (front)and/or (PK/GN)

(rear) wire.

STOP

Go toOxygen Sensor: DTCP0131, P0132, P0134,P0151, P0152, P0154

(Part 3 of 3)

YES NO

Replace fuel lineor filter

Check for air leaksat induction

module.Air leak present?

YES

Repair.

NO

Fuel injectors maybe dirty.

See Service Manual.


fc01370_en

2



Continued from Oxygen Sensor: DTC P0131,P0132, P0134, P0151, P0152, P0154 (Part 2 of 3).

Check for intermittents by performing 4.8 WIGGLETEST starting from beginning of chart.


YES NO

Repairas necessary.

Replace O2 Sensor. See ServiceManual. Clear codes and road

test. Check for DTCs.Did O2 Sensor set a P0131,

P0132, P0134, P0151, P0152or P0154?

YES NO

Install original O2 Sensorand replace ECM.

See Service Manual.Road test again to verify.

Systemnow OK.

Clear DTCs using speedometer selfdiagnostics. See 4.6 SPEEDOMETERSELF DIAGNOSTICS. Confirm properoperation with no check engine lamp.

fc01371_en


4.24DTC P0261, P0262, P0263, P0264

GENERAL

Fuel InjectorsThe fuel injectors are solenoids that allow pressurized fuel intothe intake tract.The injectors are timed to the engine cycle andtriggered sequentially. The power for the injectors comes fromthe system relay. The system relay also provides power forthe fuel pump and the ignition coil.The ECM provides the pathto ground to trigger the injectors.

NOTE

ECM fuse and system relay failures or wiring harness problemswill cause 12 volt power to be lost to both injectors, ignitioncoils and fuel pump.


DESCRIPTIONDTC

Front injector open/lowP0261

Front injector highP0262

Rear injector open/lowP0263

Rear injector highP0264

DIAGNOSTICS





1. See Service Manual for all service information.


3. Connect a BREAKOUT BOX (Part No. HD-43876) betweenEFI wire harness and ECM. See 4.7 BREAKOUT BOX:EFI.

ed02060

Figure 4-47. Fuel Injector Test Lamp (Part No. HD-34730-2C)


BK

BKBK

GY

GY

GY

GY

BK

R

BE/GY

GN/GY GN/GY

GY/BE

BE/GY

BK/GN

BK/GN

BE/GY

Y/BE

BE/O

GY/BE

Y/BE

BE/O

W/BK

W/B

KW

/BK

O/GY

R/BK

R/B

K

O/GY

Y/GN

Y/GN

Y/GN

GN/OGN/OW/BK

Ground

Rear injector

Front injector

System relay

Battery

Switched power

Ground

[78A] [78B]

[30A]

GND 1

[30B]

TSM/TSSM/HFSM

[84B] [84A]

Front Injector

Rear Injector

15 AmpFuel Pump

Fuse

SystemRelay

FuelPump

IgnitionCoil

15 AmpECM Fuse

15 AmpIGN Fuse

Engine StopSwitch

[85B] [85A]

[62B]

87

87A

30

85

86

I

Q

C

P

R

5

4

3

2

1

AB A

[141B]

GND 2

Spark Plugs

[141A]

D

AB

AB

AB

A

B B

C C

D

Rear coil

Front coil

10

19

21

4

31

13

2

2

Igni

tion

28

11

29

10

19

21

4

31

13

28

11

ION sense 2727

29

A

B

C

D

[83B] [83A]

A

B

C

D

4 3

[22A][22B]

4 3

R R

R

R R/B

KR

–+40 Amp

MAXIFUSE

StarterMotor

Battery

[33B]

[33A]

A B C

A B C


[33B]

[33A]

A B C

I B A


Y/GN

Y/GN

W/Y W/Y

em00041

Figure 4-48. Fuel Injector Circuit





FXD, FXDL: inside top frame tube3-place DelphiIgnition switch[33]FXDWG, FXDC, FXDF: under fuel tankconsole




Fuel Injectors: DTC P0261, P0262, P0263, P0264 (Part 1 of 3)

Is wire bail on connector securelyattached to the fuel injector?

1

YES NO

Reconnect.Using Fuel Injector Test Lamp (PartNo. HD-34730-2c), crank engine.

Does lamp flash?

YES

Recheck connections.Perform 4.8 WIGGLE TEST

to check for intermittents.Intermittents present?

NO

Check terminal “A” (Y/GN) wire oninjector connector to ground.Voltage equivalent to battery

voltage for 2 seconds after IgnitionSwitch is turned to IGN?

YES

Repairintermittent.

NO

Measure resistance ofsuspect injector across

injector terminals.Resistance 10.0-25.0

ohms?

YES

Check for looseor corroded terminals

in harness.

NO

Replaceinjector.

2

1

NO

Check for 12 volts at terminal “87” ofSystem Relay during first 2 secondsafter Ignition Switch is turned to IGN.

Correct voltage present?NOTE:

Depending on relay used, relay socketterminal could be shown as “5” or “I”.

YES

STOP

Go toFuel Injectors: DTC

P0261, P0262,P0263, P0264(Part 3 of 3).

NO

STOP

YES

System Relay OK. Measure resistancebetween terminal “87” of System Relayand terminal “A” (Y/GN) wire at injector

connector.Resistance less than 0.5 ohm?

NOTE:Depending on relay used, relay socketterminal could be shown as “5” or “I”.

YES NO

Perform 4.8 WIGGLETEST to check for

intermittents.Repair as necessary.

Find and repairbad connectionor open wire.

Go toFuel Injectors:

DTC P0261,P0262, P0263,

P0264(Part 3 of 3).

2


fc01372_en



Front Injector: DTC P0261 or P0262.

Measure resistance between Breakout Boxterminal “21” (W/Y) wire and terminal “B” of

front injector connector [84B].

Rear Injector: DTC P0263 or P0264.

Measure resistance between Breakout Boxterminal “19” (GN/GY) wire and terminal “B”

of rear injector connector [85B].

2

3

2

3

Resistanceless than 0.5 ohm?

YES NO

Check for continuity betweenterminal “10” and ground.


Repair open orpoor connection.

Front injector codes: Checkcontinuity between terminal “21”

and terminal “10”. orRear injector codes: Check

continuity between terminal “19”and terminal “10”.


NO

Repair open

YES


NO

Check for voltage with IgnitionSwitch turned to IGN.

Front injector codes: CheckBreakout Box terminal “21”.Rear injector codes: CheckBreakout Box terminal “19”.

Voltage present after 2 seconds?

YES NO


Replace ECM.Reprogram

and learn password.


fc01373_en

YES



Continued from Fuel Injectors: DTC P0261, P0262, P0263,P0264 (Part 1 of 3).

Check for 12 volts at terminal “30” of the System Relay.Correct voltage present?

NOTEDepending on relay used, relay socket terminal could be

shown as “3” or “C”.

YES NO

Check for 12 volts at terminal “86” of theSystem Relay.

Correct voltage present?NOTE

Depending on relay used, relay socket terminalcould be shown as “1” or “R”.

YES

Measure resistance between terminal “86” of theSystem Relay and ECM terminal “13” on Breakout Box.

Resistance less than 0.5 ohm?NOTE

Depending on relay used, relay socket terminal couldbe shown as “1” or “R”.

YES

Measure resistance between terminal “85” of theSystem Relay and ECM terminal “4” on Breakout Box.

Resistance less than 0.5 ohm?NOTE

Depending on relay used, relay socket terminal couldbe shown as “2” or “P”.

YES

Install known good relay.Does fuel pump run for first 2 secondsafter Ignition Switch is turned to IGN?

YES

Replacerelay.

Find and repair open on(BE/GY) wire between

fuse and relay.

NO

See 4.11 NO ECMPOWER.

NO

Find and repairopen on (W/BK)

wire.

NO

Find and repairopen on (GN/O)

wire.

NO

Reinstall original relay.Replace ECM. Reprogram

and learn password.


3

fc01374_en


4.25DTC P0373, P0374

GENERAL

Crankshaft Position (CKP) SensorIf the Crankshaft Position CKP Sensor signal is weak or absent,Diagnostic Trouble Codes (DTCs) P0373 or P0374 will be set.

NOTE

If signal is not detected or cannot synchronize (DTC P0374),engine will not start.

ed02930

Figure 4-49. CKP Sensor

ed02931

Figure 4-50. CKP Sensor Connector Location


DESCRIPTIONDTC

CKP sensor intermittentP0373

CKP sensor synch errorP0374

DIAGNOSTICS



Diagnostic Tips• Engine must be cranked for more than five seconds

without CKP sensor signal to set code.


1. Connect BREAKOUT BOX (Part No. HD-43876) to ECMwire harness only (leave ECM disconnected). See4.7 BREAKOUT BOX: EFI.

2. One megohm is very high resistance. Some meters willread OL.

3. Use HARNESS CONNECTOR TEST KIT (Part No. HD-41404-B), brown socket probes and patch cords.

4. For testing purposes, install sensor without running wiringalong normal path. Disconnect and route wiring properlyif system is now OK.


BK

BK

BK

1 2

1 2[79B]

CKPSensor

[79A]

[78B]

[78A]

12

CK

P(-

)

CK

P(+

)

Gro

und

30

12

10

Gro

und

10 30

28

28

ECM

GND 1

BK

/GN

BK

/GN

RR

R

em00048

Figure 4-51. CKP Circuit




Inside front electrical caddie2-place Mini-DeutschCrankshaft Position (CKP) Sensor[79]


CKP Sensor: DTC P0373, P0374

Connect Breakout Box to harness only,leaving ECM disconnected.

Measure resistance between terminals “30” and “28”and between terminals “12” and “28” on Breakout Box.

Is resistance more than 1 megohm?

YES NO

Check for intermittent connection, pinchedor damaged wires, and loose CKP Sensor

fasteners.Conditions found?

Disconnect connector [79]. LeavingECM disconnected, measure resistance

between terminals “12” and “28” andterminals “30” and “28” on Breakout Box.

Is there continuity to ground(less than 1 megohm resistance)?

YES

Repair asnecessary.

NO

Connect DVOM to terminals “12” and “30” onBreakout Box. Set DVOM to AC volts and

crank engine.Does DVOM read 1.0 VAC minimum

during cranking?

NO

Connect DVOM at Terminals “1” and“2” of connector [79A].

Does DVOM read 1.0 VACminimum while cranking?

With DVOM still connected,check for intermittents using

4.8 WIGGLE TEST.Intermittents present?

YES

Repair asnecessary.

YES

Install known goodCKP Sensor.

Clear codes andretest. DTC P0373

or P0374 set?

NOYES

Check for continuitybetween terminal

“1” of connector [79B]and terminal “30” on

Breakout Box.Is continuity present?

NO

Replace CKPSensor. See

Service Manual.

YES NO

Reinstall originalCKP Sensor.


Replace CKPSensor.

YES NO

Repair open on (BK)wire between terminal“2” of connector [79B]and terminal “12” of

connector [78B].

Repair open on (R)wire between terminal“1” of connector [79B]and terminal “30” of

connector [78B].

YES

Repair short toground on (R) or

(BK) wire betweenconnectors [78B]

and [79B].

NO

Replace CKPSensor. See

Service Manual.


1

2

3

4

fc01375_en


4.26DTC P0501, P0502

GENERAL

Vehicle Speed Sensor (VSS)See Figure 4-52.The Vehicle Speed Sensor (VSS) is poweredand monitored by the ECM. The ECM processes the vehiclespeed signal and transmits this signal to the TSM/TSSM/ HFSMand speedometer through serial data.


DESCRIPTIONDTC

VSS lowP0501

VSS high/openP0502

ed02932

Figure 4-52. Vehicle Speed Sensor and Connector

NOTE

The MAP, TP, Jiffy Stand, and VSS sensors are connected tothe same reference line (+5V Vref). If the reference line goesto ground or open, multiple codes will be set (DTC P0107,P0108, P0122, P0123, P0501, P0502, P1501, P1502). Startwith the trouble code having the lowest ranking value.

DIAGNOSTICS






1. The speedometer has a built-in diagnostic mode. See4.6 SPEEDOMETER SELF DIAGNOSTICS.

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




R/W

LGN

/V

LGN

/VLG

N/V

W/GN

W/G

N

Speedometer

VehicleSpeedSensor

[65A]

[39A]

[39B]

7

7

2

A

B

C

A

B

C

2

[20A]

NOTE:Connector [20] notpresent onFXDWG/FXDC/FXDFmodels

[20B]

[78A]

[78B]

[65B]

GND 1

To TP, MAP, andjiffy standsensor

Ser

iald

ata

5

Ser

iald

ata

VS

Sin

put

5Vse

nsor

pow

er

33

5

10

Gro

und

10 33

14

14

ECM

R/W

R/W

BK

/GN

BK/GN

em00049

Figure 4-53. Vehicle Speed Sensor Circuit



Inside top frame tube12-place DeutschConsole Gauges/Indicator Lamps (allexcept FXDWG, FXDC, FXDF)

[20]





Vehicle Speed Sensor: DTC P0501, P0502 (Part 1 of 2)

STOP

1

YES NO

2

3

4

NO

NO

NOYES

NO

YES

YES


Inspect connector [65].Is connector mated properly?

Remove and inspect Vehicle Speed Sensor. Inspect fordebris and clean if necessary. Place speedometer intodiagnostic mode and clear diagnostic trouble codes.

Connect all circuits and ride motorcycle for approximately1.0 mile (1.6 km). Check for speedometer function.

Speedometer functioning properly?

Mate connector [65].

System OK. Check for continuity between terminal “A”of connector [65B] (R/W) wire and ground.


Check for continuity between terminal “A”of connector [65B] (R/W) wire and

terminal “14” of Breakout Box.Is continuity present?

Check for continuity between terminal“C” of connector [65B] (BK/GN) wire and

ground.Is continuity present?

Locate and repair open on(R/W) wire between [78B]

and [65B].

Repair open on (BK/GN) wirebetween connector [65B] and

ground.


YES

Go toVehicle

Speed Sensor: DTCP0501, P0502(Part 2 of 2). fc01376_en


Vehicle Speed Sensor: DTC P0501, P0502 (Part 2 of 2)


4

YES NO

3

YES

YES

NONO NO

NO

Continued from VehicleSpeed Sensor: DTC P0501, P0502 (Part 1 of 2).

Check for continuity between terminal “B” ofconnector [65B] and terminal “33” of Breakout Box.


Check for voltage at terminal “33” on BreakoutBox. Meter should read 4-6 volts when gear toothabsent and 0-1 volts when gear tooth is present.

Does voltage fall within specifications?

Locate and repair open on(W/GN) wire between [78B]

and [65B].

No voltage fluctuation from high(4-6 volts) to low (0-1 volts).

Battery voltagepresent.

Voltage fluctuates from high(4.6 Volts) to low (0-1 volts).


Locate and repair short tovoltage on (W/GN) wire

between [78B] and [65B].

Measure continuity to groundfrom terminal “33” on

breakout box.Is resistance less than 100

ohms?

Replace VehicleSpeed Sensor.

Locate and repair short toground on (W/GN) wire

between [78B] and [65B].


No voltage present.

fc01377_en


4.27DTC P0562, P0563

GENERAL

Battery VoltageSee Figure 4-54. Battery voltage is monitored by the ECM(terminal "13"). If the battery voltage fails to meet normaloperating parameters, a code is set.

NOTE

When either Diagnostic Trouble Code (DTC) P0562 or P0563is set, the battery icon in the speedometer will illuminate.

• DTC P0562 is displayed when battery voltage is less than12.2 volts at idle and voltage does not increase whenengine speed is greater than 2000 RPM.

• DTC P0563 is displayed when battery positive voltage isgreater than 15.0 volts for more than 4 seconds.

NOTES

• Warm idle speed will be automatically increased if batteryvoltage is low at idle.

• TSSM/HFSM problems may also set a DTC P0562 orP0563.


DESCRIPTIONDTC

Battery voltage lowP0562

Battery voltage highP0563

ed02933

Figure 4-54. System Relay

DIAGNOSTICS




Diagnostic Tips• Low voltage generally indicates a loose wire, corroded

connections, battery and/or a charging system problem.

• A high voltage condition may be caused by a faulty voltageregulator.


1. Was battery allowed to discharge? Was battery drawndown by a starting problem?

a. Yes. Charge battery.

b. No. See charging system troubleshooting.


3. Use DVOM with RPM Pick-up to check RPM on vehicleswithout tachometers.

4. This checks for voltage drops in the ECM circuit.

a. Place (+) probe to battery positive terminal.

b. Place (-) probe to W/BK terminal on Breakout Box.

5. Use HARNESS CONNECTOR TEST KIT (Part No. HD-41404-B), purple terminal and patch cords.

6. Problem is most likely the ground connection at the frame.


GYG

Y

BK

R R

R

R

BE/GY

BE/GY

BK/GN

BK/GN

BE/GY

GN/O GN/O

Y/GN

W/BK

W/BK

W/B

K

GY

W/B

K

R/BK

R/B

K

RR/B

K

4

31

13

10

28

System relay

[78A] [78B]

GND 1

[22B]

[62B]

[22A]

4

Battery

4 3

4 3

31

Switched power

40 AmpMAXIFUSE

Battery

+ -

SystemRelay

To ignition circuit

Engine StopSwitch

I

Q

C

P

R

5

4

3

2

1

87

87A

30

85

86

15 AmpIGN Fuse

15 AmpECM Fuse

13

Ground 10

Ground 28

[33B]

[33A]

A B C

I B A


[33B]

[33A]

A B C

A B C


em00050

Figure 4-55. Battery Voltage Circuit Diagram



Inside top frame tube6-place MolexRight Hand Controls[22]

FXD, FXDL: inside top frame tubeFXDWG, FXDC, FXDF: under fuel tankconsole

3-place DelphiIgnition Switch[33]

Under electrical caddie coverSpade terminalsFuse/Relay Block[62]



Battery Voltage: DTC P0562, P0563 (Part 1 of 2)


STOP

2

YES NO

3

4

5

1

YES

YES

YES

YES

YES

NO

NO

NO

NO

NO

Perform charging system tests.Charging system OK?

With Ignition Switch turned to IGN, measurevoltage drop between battery positive (+)

terminal and Breakout Box terminal “13” (-).Is voltage drop greater than 0.5 volt?

Repair charging system.See Section 1.

Connect Breakout Box. Measure voltage onBreakout Box between terminal “13” (+) and

terminal “10” (-) and again between terminal “13”(+) and terminal “28” (-) with engine running at2000 RPM or higher for 10 seconds or longer.

Is voltage above 11.0 volts?

SystemOK.

1

Repair open on (W/BK)wire between [22B]

and [78B] or terminals.Locate and repairbad connection.

Problem is intermittent.Perform 4.8 WIGGLE

TEST.Locate and

repair bad connection.

With Ignition Switch turned to IGN,measure resistance between ignition fuseterminal and connector [22B] terminal “3".

Is resistance greater than 1 ohm?

Check for voltage drop between batterynegative (-) terminal and terminal “10” (+) onBreakout Box connector and between battery

negative (-) terminal and terminal “28” OnBreakout Box.


With Ignition Switch OFF, measureresistance between Breakout Box terminal

“13” and connector [22B] terminal “4”.Is resistance greater than 1 ohm?

Inspect [22] for corrosion orloose wires.

If above conditionsare not present, replace Engine

Stop Switch.Go toBattery Voltage: DTC

P0562, P0563(Part 2 of 2).

fc01378_en

6


Battery Voltage: DTC P0562, P0563 (Part 2 of 2)


YES NO

YES

YES

YES

NO

NO

NO

Continued from Battery Voltage: DTC P0562, P0563(Part 1 of 2).

With Ignition Switch turned to IGN, measure voltagedrop between battery positive (+) terminal and (GY)

terminal on 15 amp Ignition Fuse (-).Is voltage drop greater than 0.5 volt?

With Ignition Switch turned to IGN, measurevoltage drop between battery positive (+) terminal

and (R/BK) terminal at 15 amp Ignition Fuse.Is voltage drop greater than 0.5 volt?

With Ignition Switch turned to IGN, measurevoltage drop between battery positive (+) and

MAXIFUSE terminal “A” (-).Is voltage drop greater than 0.5 volt?

With Ignition Switch turned to IGN, measurevoltage drop between battery positive (+)terminal and MAXIFUSE terminal “B” (-).


High resistance betweenMAXIFUSE and battery.

Replace wire or terminals.

Replace (GY) wireor terminals.

Replace fuse orfuse terminals.

Replace ignitionswitch or terminals.

Replace MAXIFUSE.

fc01379_en


4.28DTC P0603, P0605

GENERAL



ECM FailureRefer to Table 4-43. The codes listed indicate a failure whichrequires replacement of the ECM. See the Dyna ServiceManual for replacement information.

NOTE

After replacing ECM, reprogram, perform password learningprocedure and clear Diagnostic Trouble Codes (DTCs). ECMmust be reprogrammed using a computer based diagnosticpackage called DIGITAL TECHNICIAN (Part No. HD-44750).See your dealer. Password learn procedure must also be per-formed. See 3.25 TSM/HFSM: PASSWORD LEARN.


DESCRIPTIONDTC

ECM EEPROM errorP0603

ECM flash errorP0605

DIAGNOSTICSNOTE

These codes are set under two conditions.

• If DTC P0603 or P0605 occur during normal operation,replace ECM. Reprogram and learn password.

• If DTC P0603 or P0605 occur during or after reprogram-ming, perform the following:

DTC P06031. Clear DTCs.

2. Power down the vehicle. Wait 10 seconds.

3. Turn ignition switch to IGN.

4. Replace ECM if codes reappear.

DTC P06051. Clear DTCs.

2. Power down the vehicle.

3. Attempt to reprogram ECM using correct calibration.

4. Restart vehicle. If code reappears, replace ECM.


4.29DTC P0661, P0662

GENERAL

Active Intake Solenoid (HDI Models Only)The active intake solenoid regulates the amount of air thatenters the air cleaner. The active intake solenoid opens whenvehicle speed exceeds 45 MPH (70 km/h) with 50% or greaterthrottle opening. Once open, active intake will close whenvehicle speed falls below 40 MPH (65 km/h). The power forthe active intake solenoid comes from the engine control fuse.The ECM provides the path to ground to trigger the activeintake solenoid.


DESCRIPTIONDTC

Active intake solenoid open/lowP0661

Active intake high/shortedP0662

1

23

ed02979

1. Intake module2. Intake solenoid connector [178]3. Air cleaner backing plate

Figure 4-56. Intake Solenoid Connector Location

DIAGNOSTICS





1. See Dyna Service Manual for all service information.

2. Connect a BREAKOUT BOX (Part No. HD-43876) betweenEFI wire harness and ECM. See 4.7 BREAKOUT BOX:EFI

3. Use HARNESS CONNECTOR TEST KIT (Part No. HD-41404-B), purple terminal probe and patch cord.


–+

22

10

28

A B

21

21

C

I B A

A B C

A B C

22

10

28

ECM

ActiveIntake

Solenoid

Battery

40 AmpMAXIFUSE

To active exhaust (HDI)

To automatic compression release (if equipped)

[178B] [178A]

[78A] [78B]

[33A]


GND 1

[33B]

[33A]

Ignition SwitchAll But FXDWG/FXDC/FXDF

15 AmpEngine Control

Fuse

[33B]

Active intake solenoid HDI

Ground

Ground

BKR R

BK/GN

BK/GN

LGN/R

LGN/R

LGN/R

LGN/R

GY/OGY/O

R/BK

RR/B

K

RR/B

K

em00051

Figure 4-57. Active Intake Solenoid Circuit



FXD, FXDL: inside top frame tubeFXDWG, FXDC, FXDF: under fuel tankconsole

3-place DelphiIgnition Switch[33]


Air cleaner backing plate2-place AmpActive Intake Solenoid (HDI)[178]


Active Intake Solenoid: DTC P0661, P0662 (Part 1 of 2)

Is connector securely attached to theactive intake solenoid?

YES

1

Reconnect.Turn active intake solenoid on bygrounding Terminal “22” on breakout box.

Solenoid should activate immediatelyafter Ignition Switch is turned to IGN.

Does it?

YES NO

Recheck connections. Perform4.8 WIGGLE TEST to check for

intermittents.Intermittents present?

Check Terminal “1” (LGN/R) wire onactive intake solenoid connector

[178B] to ground.Voltage equivalent to battery voltageafter Ignition Switch is turned to IGN?

YES NO

Measure resistance ofactive intake solenoid

across solenoid terminals.Resistance 16-20 ohms?

Repairintermittent.

NO

YES NO

Check for looseor corroded terminals

in harness.

ReplaceActive Intake

Solenoid.

YES NO

Inspect EngineControl Fuse.

Fuse OK?

Locate and repairbad connection

or open on (LGN/R)wire between Engine

Control Fuse andconnector [178B].

3

YES NO

Check for 12 volts at terminal “M”of fuse block after Ignition Switch

is turned to IGN.Battery voltage present?

STOP

Go to Active IntakeSolenoid: DTCP0661, P0662(Part 2 of 2).

YES NO

Replacefuse.

Locate and repairopen on (R/BK) wire toEngine Control Fuse.


2

fc01380_en


Active Intake Solenoid: DTC P0661, P0662 (Part 2 of 2)

Continued from Active Intake Solenoid: DTCP0661, P0662 (Part 1 of 2).

Measure resistance between Breakout Boxterminal “22” (GY/O) wire and Terminal “2” of

active intake solenoid connector [178B].Resistance less than 0.5 ohm?

YES NO

Check for continuity to groundon Breakout Box terminal “22”.

Is continuity present(less than 1000 ohms)?

Repair open orpoor connection.

YES NO

Repair short to ground on(GY/O) wire.

Disconnect connectors [178] and [78]. Checkfor voltage at Breakout Box terminal “22” with

Ignition Switch turned to IGN.Voltage present?

Locate and repairshort to voltage on

(GY/O) wire.

YES NO

Replace ECM.Reprogram

and learn password.


2

3

fc01381_en


4.30DTC P1009, P1010

GENERAL

Password ProblemThe ECM, TSM/TSSM/HFSM and speedometer exchangepasswords during operation. An incorrect password or missingpassword will set a diagnostic code.

NOTE

If the TSM/TSSM/HFSM is not connected to the wiring harness,the vehicle will not start.


DESCRIPTIONDTC

Incorrect passwordP1009

Missing passwordP1010

DIAGNOSTICS






1. DTC P1009 may be set if a recent ECM or TSM/TSSM/HFSM replacement did not follow the correct passwordassignment procedure. See 3.25 TSM/HFSM: PASS-WORD LEARN for details.

2. Use HARNESS CONNECTOR TEST KIT (Part No. HD-41404-B), black socket probes and patch cord.


4. Historic codes DTC U1300 or DTC U1301 would also havebeen set. Clear codes.

5. See the Service Manual for TSM/TSSM/HFSM replace-ment. See 3.25 TSM/HFSM: PASSWORD LEARN,Password Learning for the password learning procedure.

6. Use HARNESS CONNECTOR TEST KIT (Part No. HD-41404-B), purple socket probes and patch cord.

ed02896

Figure 4-58. Data Link Connector [91] (typical)

sm01275

Figure 4-59.TSM/TSSM/HFSM


3

1

2

4

321 12

3

Bat

tery

Igni

tion

Ser

iald

ata

Gro

und

21 1221 65 7

21 65 7

21

Igni

tion

Ser

iald

ata

Bat

tery

Acc

esso

ryG

roun

d

Igni

tion

Ser

iald

ata

Bat

tery

Acc

esso

ryG

roun

d

65 7

21 65 7

21 6 7 12

21 6 7 12

5

5

GY

O

O

GY

BN

/GY

BN

/GY

LGN

/V

LGN

/V

LGN

/V

O/W

O/W

O/W

BN

/GY

O

O

BN

/GY

LGN

/V

O/W

BK

/GN

BK/GN

LGN/V

LGN

/V

BN

/GY

BK

/GN

LGN

/V

ECM

Ser

iald

ata

[30B][30A]

[91A]

GND 1

[108B][108A]

[20B][20A]

[39B][39A]

[78B][78A]

Speedometer

Toignitionfuse

Toinstrument

fuse

Toaccessory

fuse

Tobattery

fuse


Data LinkConnector


TSM/TSSM/HFSM

BK

BK

BK

em01195





[20]







Password Problem: DTC P1009, P1010


YES NO

YES

YESYES

YES

YES

YES

NO

NO

NO

NO

NO

45

5

5

1

5

4

5

3

2

6

Which diagnostic troublecode was set?

DTC P1010.No password.Are there anyU-codes set?

DTC P1009.Bad password.

Perform password learn.See 3.25 TSM/HFSM:PASSWORD LEARN.DTC P1009 still exist?

Remove ECM connector [78]. Checkfor continuity to ground at data link

connector [91A] terminal “3”.Is continuity present?

Replace TSM/TSSM/HFSM and relearn

password.System OK?

SystemOK.

Troubleshootlowest U-code.


SystemOK.

Reinstall originalTSM/TSSM/HFSM.

Replace ECM.Reprogram and relearn

password.


Check for battery voltage on terminal “3”.Battery voltage present?

Test data link connector [91A]terminal “3” against BreakoutBox terminal “5” for continuity.


Replace TSM/TSSM/HFSMand relearn password.

System OK?

Reinstall original TSM/TSSM/HFSM.Replace ECM. Reprogram and

relearn password.

SystemOK.

Inspect terminalsfor damage or repairopens as necessary.

NO

fc01382_en


4.31DTC P1351, P1352, P1354, P1355

GENERAL

Ignition CoilIgnition coil codes will set if the ignition coil primary voltage isout of range. This could occur if there is an open coil or lossof power to the coil. If front and rear codes are set simultan-eously, it is likely a coil power failure or a coil failure.

The coil receives power from the system relay at the sametime that the fuel pump and injectors are activated.The systemrelay is active for the first 2 seconds after the ignition is turnedON and then shuts off until RPM is detected from the CKPsensor, at which time it is reactivated. The ECM is responsiblefor turning on the system relay by providing the ground toactivate the relay, which in turn powers the coil.


DESCRIPTIONDTC

Front ignition coil open/lowP1351

Front ignition coil high/shortedP1352

Rear ignition coil open/lowP1354

Rear ignition coil high/shortedP1355

DIAGNOSTICS


FUEL INJECTOR TEST LAMPHD-34730-2C


IGNITION COIL CIRCUIT TESTADAPTER

HD-44687


1. Use HARNESS CONNECTOR TEST KIT (Part No. HD-41404-B), purple pin probes and patch cord.

NOTEGently connect test lamp to connector [83B]. Forcefully insertingtest lamp will result in ignition connector terminal damage.

2. See Figure 4-61. Plug IGNITION COIL CIRCUIT TESTADAPTER (Part No. HD-44687) and FUEL INJECTORTEST LAMP (Part No. HD-34730-2C) into Breakout Box.Note that cranking the engine with test lamp in place ofthe ignition coil can sometimes cause a DTC P1351,P1352, P1354 or P1355. This condition is normal anddoes not by itself indicate a malfunction. Codes must becleared if this condition occurs.

3. Connect BREAKOUT BOX (Part No. HD-43876) betweenEFI wire harness and ECM. See 4.7 BREAKOUT BOX:EFI.

ed02013

Figure 4-61. Ignition Coil Circuit Test

4

3

2

1

ed02980

1. Power2. Feedback signal pin3. Rear coil4. Front coil

Figure 4-62. Ignition Coil Connector Terminals


BK

BKBK

GY

GY

GY

GY

BK

R

BE/GY

GN/GY GN/GY

GY/BE

BE/GY

BK/GN

BK/GN

BE/GY

Y/BE

BE/O

GY/BE

Y/BE

BE/O

W/BK

W/B

KW

/BK

O/GY

R/BK

R/B

K

O/GY

Y/GN

Y/GN

Y/GN

GN/OGN/OW/BK

Ground

Rear injector

Front injector

System relay

Battery

Switched power

Ground

[78A] [78B]

[30A]

GND 1

[30B]

TSM/TSSM/HFSM

[84B] [84A]

Front Injector

Rear Injector

15 AmpFuel Pump

Fuse

SystemRelay

FuelPump

IgnitionCoil

15 AmpECM Fuse

15 AmpIGN Fuse

Engine StopSwitch

[85B] [85A]

[62B]

87

87A

30

85

86

I

Q

C

P

R

5

4

3

2

1

AB A

[141B]

GND 2

Spark Plugs

[141A]

D

AB

AB

AB

A

B B

C C

D

Rear coil

Front coil

10

19

21

4

31

13

2

2

Igni

tion

28

11

29

10

19

21

4

31

13

28

11

ION sense 2727

29

A

B

C

D

[83B] [83A]

A

B

C

D

4 3

[22A][22B]

4 3

R R

R

R R/B

KR

–+40 Amp

MAXIFUSE

StarterMotor

Battery

[33B]

[33A]

A B C

A B C


[33B]

[33A]

A B C

I B A


Y/GN

Y/GN

W/Y W/Y

em00041

Figure 4-63. Ignition Coil Circuit Diagram











Back of coil4-place PackardIgnition coil[83]





Ignition Coil: DTC P1351, P1352, P1354, P1355 (Part 1 of 2)

STOP

2

NOYES


STOP

1

3

1

Disconnect coil connector [83]. Measure voltage onterminal “A” of wire harness.

Voltage equal to battery voltage during first 2seconds after Ignition Switch is turned to IGN?

Use Breakout Box and testlight for the next inspection.

Front coil codes: Check betweenECM terminal “29” and ECM terminal “13”.

Rear coil codes: Check betweenECM terminal “11” and ECM terminal “13”.

Does test lamp flash when engine is cranked?

Measure Ignition coil resistance.Front coil codes: Check betweencoil terminal “A” and terminal “D”.Rear coil codes: Check betweencoil terminal “A” and terminal “C”.

Resistance 0.3-0.7 ohms?

Measure voltage at system relay terminal “30” duringfirst 2 seconds after Ignition Switch is turned to IGN.

Is voltage equivalent to battery voltage?NOTE

Depending on relay used, relay socket terminal couldbe shown as “3” or “C”.

Check for multiple codes. SeeMultiple Diagnostic

Trouble Codes under 4.4CHECKING FOR DIAGNOSTIC

TROUBLE CODES: EFI.

Repair open wire orconnection on (Y/GN) wire.

Replace Ignition Coil.See Service Manual.

YES

YESYES

NO

NONO

Go toIgnition Coil: DTC

P1351, P1352,P1354, P1355(Part 2 of 2).

Go toIgnition Coil: DTC

P1351, P1352,P1354, P1355(Part 2 of 2).

fc01383_en


Ignition Coil: DTC P1351, P1352, P1354, P1355 (Part 2 of 2)

1

YES NO


3

Perform 4.8 WIGGLE TESTto check for intermittents.


Repair open wireor connection.

Repairintermittent.

NOYES

YES NO

Check for continuity to ground.Front coil codes: Check

Breakout Box terminal “29”.Rear coil codes: Check

Breakout Box terminal “11”.Is continuity present?

Check for voltage.Front coil codes: Check

Breakout Box terminal “29”.Rear coil codes: Check

Breakout Box terminal “11”.Voltage present?



Continued from Ignition Coil: DTC P1351, P1352,P1354, P1355 (Part 1 of 2).

Using Breakout Box, measure resistance betweenECM and coil terminals as follows.

COIL

TERMINAL

D

(BE/O wire)

C

(Y/BE wire)

BREAKOUTBOX

TERMINAL

29

11

DTC

P1351/

P1352

P1353/

P1354

Resistance less than 0.5 ohms?


YES NO

fc01384_en

COILTERMINAL

“D”(BE/O) wire

“C”(Y/BE) wire

DTC

P1351/P1352

P1353/P1354

BREAKOUTBOX

TERMINAL

“29”

“11”


4.32DTC P1475, P1477, P1478

GENERAL

Exhaust Actuator (HDI Models)The active exhaust system utilizes an actuator valve locatedin the rear exhaust pipe which is connected to servo motor viaa cable. The valve position automatically adjusts to enhanceengine performance.


DESCRIPTIONDTC

Exhaust actuation position errorP1475

Exhaust actuator open/lowP1477

Exhaust actuator highP1478

DIAGNOSTICS




1. Connect BREAKOUT BOX (Part No. HD-43876) betweenEFI wire harness and ECM. See 4.7 BREAKOUT BOX:EFI.


1

2

ed02981

1. Open position2. Closed position

Figure 4-64. Bellcrank


To active intake (HDI)

GND 1

To automatic compression release (if equipped)

Active exhaust (HDI)

Active exhaust feedback (HDI)

Ground

15 AmpEngineControlFuse


40 AmpMAXIFUSE

Battery


V/O

R R

R

LGN/R

LGN/R

LGN/R

LGN/R

BK/GN

BK/GN

V/BE

V/O

V/BE

R/BK

R/B

K

RR/B

K

10

–+

[33B][33A]

[78A] [78B]ECM

20

21

21

3 3

4 4

5

BA C

BI A

Ignition SwitchAll But FXDWG/FXDC/FXDF

[33B][33A]

BA C

BI C

51

10

Ground BK/GN28 28

20

1

[179B] [179A]

BK

em00052

Figure 4-65. Exhaust Actuator Circuit



Inside top frame tube (FXD, FXDL)3-place DelphiIgnition switch[33]Under fuel tank console F(XDWG,FXDC, FXDF)


Behind rear cylinder head5-place AmpActive exhaust (HDI)[179]


Exhaust Actuator: DTC P1475, P1477, P1478 (Part 1 of 4)

DTC P1475,P1477 or

P1478 present?

YESP1475 present.

Is voltage present at bothterminals of Engine Control Fuse

with Ignition Switch turned to IGN?

YESP1477 present

YESP1478 present

YES ONE TERMINAL

Replace Engine ControlFuse. Find source

of wiring fault.

Disconnect connector [179].Measure voltage between

terminal “1” (+) and terminal“2” (-) on [179B].

Is Battery voltage present?

YES NO

Reconnect connector [179]. Detachcable housing from actuator leavingcable attached to actuator pulley.

Pull on cable near actuator to rotatebellcrank manually.

Does bellcrank rotate freely stop tostop?

YES NO

Disconnect cable fromactive exhaust valve.

Rotate bellcrankmanually.

Does bellcrank rotatefreely stop to stop?

YES NO

Replace Active Exhaustcable assembly.

Replace exhaust pipeand valve assembly.

Check continuity between connector[179B] terminal “2” and ground.


YES

Locate and repair openon (LGN/R) wire betweenEngine Control Fuse and

connector [179].

NO

Locate and repair openon (BK) wire betweenconnector [179B] and

ground.

STOP STOP

STOP

Go to ExhaustActuator: DTC P1475,

P1477, P1478(Part 2 of 4).


P1477, P1478(Part 3 of 4).


P1477, P1478(Part 4 of 4).

Clear codes using speedometer selfdiagnostics. See 4.6 SPEEDOMETERSELF DIAGNOSTICS. Confirm properoperation with no check engine lamp.

fc01385_en

1



Continued from Exhaust Actuator: DTC P1475, P1477, P1478 (Part 1of 4)

Reattach cable housing to actuator. Connect ECM breakout box HD-43876. Turn Ignition Switch to IGN with Engine Stop Switch set to

RUN. Measure voltage between terminal “1” (+) and “10” (-).Is voltage between 4.5 to 5.5 volts?

YESNO

Battery voltage.NO

0.0 volts.

Check continuity betweenconnector [179B] terminal “4”

and Breakout Box terminal “1”.Is continuity present?

Disconnect ECM, leaving harnessconnected to Breakout Box. With theIgnition Switch turned to IGN, check

voltage between Breakout Box terminal “1”and ground.

Is voltage present?

Disconnect breakout boxfrom ECM leaving harnessconnected to breakout box.

Check continuity between connector[179B] terminal “4” and Ground.


YES NO YES NO

Locate and repair short tovoltage on (V/BE) wirebetween connectors

[179B] and [78B].


Locate and repairshort to ground on

(V/BE) wirebetween

connectors [179B]and [78B].


YES

Turn Ignition Switch to IGN with EngineStop Switch set to RUN. Measure

voltage between terminal “1” (+) and“10” (-). Connect a jumper wire between

terminals “28” and “20” on BreakoutBox. Each time the jumper wire is

connected, the valve should open andvoltage should change from 4.5-5.5

volts to less than 1.0 volt.Does it?

Locate and repairopen on (V/BE) wirebetween connectors

[179B] and [78B].

NO

YES

Clear codes and run engine in neutral atspeeds between 1500-2500. Valve

should close above 1800 RPM and openwhen RPM drops below 1600 RPM.

Does valve operate improperly or doesDTC return?

YES


NO

System ok. Problem may be intermittent due topoor connections or moisture in connectors.Inspect or repair connections at connectors

[179B] or [78B] as necessary.

NO

Replace ActiveExhaust actuator.

Clear codes using speedometer selfdiagnostics. See 4.6 SPEEDOMETERSELF DIAGNOSTICS. Confirm properoperation with no check engine lamp.

fc01386_en

1

2

2 2



Continued from Exhaust Actuator:DTC P1475, P1477, P1478 (Part 1 of 4)

Connect ECM Breakout Box to harness leavingECM disconnected. Disconnect connector [179]. Measure continuitybetween Breakout Box terminal “20” and connector [179] terminal “3”

while wiggling harnesses.Is continuity present?

YES NO

Connect Breakout Box to ECM connector [78].Measure continuity between terminal “3” and

chassis ground while wiggling harnesses.Is continuity present?

Locate and repair open on(V/O) wire between

connectors[179B] and [78B].

YES NO

Disconnect Connector [179].Measure continuity between

terminal “20” and chassis ground atBreakout Box while wiggling harnesses.



YES NO

Locate and repair short toground on (V/O) wire between connectors

[179B] and [78B].

Replace ActiveExhaust Control

Module.


2

fc01387_en

1

2

1

2



Continued from Exhaust Actuator: DTC P1475, P1477, P1478(Part 1 of 4)

Connect ECM Breakout Box to harness leaving ECMdisconnected. Turn Ignition Switch to IGN, and Engine StopSwitch to RUN. Measure voltage between terminal “20” and

Ground while wiggling harnesses.Is voltage present?

YES NO

Disconnect connector [179] at the ActiveExhaust Control Module. Measure voltage

between terminal “20” and chassis ground atBreakout Box while wiggling harnesses.

Is voltage present?


YES NO

Locate and repair short tovoltage on (V/O) wirebetween connectors

[179B] and [78B].

Replace ActiveExhaust Control

Module.


fc01388_en

2

1


4.33DTC P1501, P1502

GENERAL

Jiffy Stand Sensor (HDI Models Only)The Jiffy Stand Sensor utilizes a Hall effect sensor to monitorJiffy Stand position. When the Jiffy Stand is fully retracted thesensor picks up the presence of the metal tab mounted to theJiffy Stand. The metal tab is moved away from the sensor asthe Jiffy Stand is extended. When the Jiffy Stand is extendedthe engine will start and run only if the TSM/TSSM/HFSMdetermines the transmission is in neutral. Otherwise the enginewill start and stall.This is done by monitoring the neutral switchinput to the TSM/TSSM/HFSM and communicating that inputover the serial data circuit to the Engine Control Module (ECM).

See Figure 4-66. The Jiffy Stand Sensor is powered andmonitored by the ECM. The ECM connector [78] "14" suppliesthe 5V reference to the Jiffy Stand Sensor connector [133]terminal "1".The Jiffy Stand Sensor terminal "2" sends a signalback to the ECM connector [78] terminal "9".This signal is howthe ECM determines if the Jiffy Stand is retracted or extended.The Jiffy Stand Sensor terminal "3" is grounded through chassisground (GND 1).

The Jiffy Stand Sensor also has a Fail Enable Mode.This modeallows the engine to start and run if the system recognizes aproblem with the Jiffy Stand Sensor circuit. If a problem existsor if the transmission is put in gear with the Jiffy Stand extendedthe odometer will display "SIdE Stand". Code P1501 or P1502will set if the Jiffy Stand Sensor circuits are out of range.

NOTE

The ECM supplies not only the Jiffy Stand Sensor but also theVehicle Speed Sensor, the Throttle Position (TP) Sensor, andthe Manifold Air Pressure (MAP) Sensor with a 5V referencesignal from terminal "14".


DESCRIPTIONDTC

Jiffy Stand Sensor LowP1501

Jiffy Stand Sensor HighP1502

ed01247

Figure 4-66. Jiffy Stand Sensor

DIAGNOSTICS





1. See the Service Manual for TSM/TSSM/HFSM replace-ment. See 3.25 TSM/HFSM: PASSWORD LEARN,Password Learning for the password learning procedure.

2. Unplug the neutral switch connector [131]. Using a DVOM,test for continuity between terminals "A" and "B" of theNeutral Switch. When the transmission is in gear, thereshould not be continuity through the neutral switch.

3. When the Jiffy Stand is retracted, voltage on terminal "9"should be approximately 1.65-2.47V.When the Jiffy Standis extended, the voltage on terminal "9" should beapproximately 2.94-4.41V.

4. Connect BREAKOUT BOX (Part No. HD-43876) betweenwire harness and ECM. See 4.7 BREAKOUT BOX: EFI,General

5. Use HARNESS CONNECTOR TEST KIT (Part No. HD-41404-B), purple pin probes, socket probes and patchcords.


R/W

R/W

GN

/BN

GN

/BN

BK

/GN

BK

/GN

BK

/GN

9

Jiffy

stan

dse

nsor

(HD

I)

Gro

und

5Vse

nsor

pow

er

28

9 28

Gro

und

10

10

14

14

ECM

Jiffy StandSensor

[133A]

To MAP, VSS and TP sensor

[GND1]

[133B]

[78B]

[78A]

1 2 3

1 2 3

em00053

Figure 4-67. Jiffy Stand Sensor Circuit




Left side along frame toward front ofengine

3-place MolexJiffy Stand Sensor[133]


SIdE StAnd Displayed On Odometer

NOYES


2

Is the transmission in neutral?

Check for DTCs Areany DTCs present?

See 4.12 STARTS,THEN STALLS

Diagnostics.

Replace Jiffy StandSensor.

Test Neutral Switch.Is Neutral Switch

operating correctly?

Is Neutral Lamp ON?Go to appropriate DTCDiagnostics.

YES

YES

YES

NO

NO

NO

1

Doses the enginestart then stall?

Place transmission inNeutral.

Check for an open in theneutral switch circuits.

Is there and open?

Inspect the Jiffy Stand Sensor and the Jiffy Standfor correct mounting and clearance to Jiffy Stand

tab (4.5mm) max.Is sensor and stand mounted correctly?

YES NOYES

YES

NO

NO

Install Jiffy StandSensor or Jiffy Stand

correctly.

Correct open in circuit.



fc01389_en


Jiffy Stand Sensor Low: DTC P1501

NOYES


If DTC P1501 is displayed, disconnect Jiffy Stand Sensorconnector [133]. Turn Ignition Switch to IGN and make sure theEngine Stop Switch is in the RUN position. Test terminal “1” of

connector [133B] for voltage.Is voltage present?

Locate and repair open in5V reference circuit.


Disconnect connector [78] Engine ControlModule (ECM). Test circuit terminal “9”

connector [78B] for continuity to ground.Is continuity present?


Locate and repair short toground.

YES

YES

NO

NO

Check for DTCs. Did DTCP1501 clear or go to history and

P1502 set as a current DTC?

fc01390_en


Jiffy Stand Sensor High: DTC P1502

NOYES


If DTC P1502 is displayed, then disconnect Jiffy Stand Sensorconnector [133]. Test for continuity between connector [133B]

terminal “3” and Ground.Is continuity present?


Is voltageapproximately 5V?

Turn off Ignition Switch. Test for continuity fromconnector [133B] terminal “1” to chassis ground.


Test for continuity from connector[133B] terminal “1” to connector

[78B] terminal “14”.Is continuity present?

Locate and repair shortto ground.

YES

YES

NO

NO

Turn Ignition Switch to IGN with Engine StopSwitch in RUN. Test for voltage on

terminal “1” connector [133B].Is voltage present?

YES NO



YES NO

Disconnect ECM. Measurevoltage at terminal 9 (+) onBreakout Box to ground (-).

Voltage present?

NOYES

Locate andrepair short to

voltage.


Turn off Ignition Switch. ConnectECM Breakout Box (Part No. HD-

43876) to wiring harness connector[78B] leaving ECM connector [78A]

disconnected. Test for continuityfrom connector [78B] terminal “9” to

connector [133B] terminal “2”Is continuity present?

NOYES

YES NO


Connect ECM Breakout Box (Part No.HD-43876) to ECM connector [78A].Connect jiffy stand sensor connector

[133]. Test terminal “9” of theBreakout Box for voltage with the Jiffy

Stand retracted and extended.Are the voltages within the

specification?


password.


fc01391_en

3

4

4

5

5


4.34DTC U1064, U1255

GENERAL

Loss of TSM/TSSM/HFSM Serial DataThe serial data connector provides a means for the ElectronicControl Module (ECM), TSM/TSSM/HFSM and speedometerto communicate their current status. When all operating para-meters on the serial data link are within specifications, a stateof health message is sent between the components.

A Diagnostic Trouble Code (DTC) U1064 indicates that theTSM/TSSM/HFSM is not receiving this state of health message.A DTC U1255 indicates that no messages were present duringpower up of the current key cycle. A DTC U1064 indicates thatthere was communication on the data bus since power up, butwas lost or interrupted during that key cycle.


DESCRIPTIONDTC



DIAGNOSTICS



SPEEDOMETER HARNESS ADAPTERHD-46601


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

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

b. Mate black pin housing on Breakout Box withspeedometer harness connector [39B] usingSPEEDOMETER HARNESS ADAPTER (Part No. HD-46601).

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

d. Mate gray pin housing on Breakout Box with harnessconnector [30B].

ed02895

Figure 4-68.TSM/TSSM/HFSM:Typical

3

21

ed02982




3

1

2

4

321 12

3

Bat

tery

Igni

tion

Ser

iald

ata

Gro

und

21 1221 65 7

21 65 7

21

Igni

tion

Ser

iald

ata

Bat

tery

Acc

esso

ryG

roun

d

Igni

tion

Ser

iald

ata

Bat

tery

Acc

esso

ryG

roun

d

65 7

21 65 7

21 6 7 12

21 6 7 12

5

5

GY

O

O

GY

BN

/GY

BN

/GY

LGN

/V

LGN

/V

LGN

/V

O/W

O/W

O/W

BN

/GY

O

O

BN

/GY

LGN

/V

O/W

BK

/GN

BK/GN

LGN/V

LGN

/V

BN

/GY

BK

/GN

LGN

/VECM

Ser

iald

ata

[30B][30A]

[91A]

GND 1

[108B][108A]

[20B][20A]

[39B][39A]

[78B][78A]

Speedometer

Toignitionfuse

Toinstrument

fuse

Toaccessory

fuse

Tobattery

fuse


Data LinkConnector


TSM/TSSM/HFSM

BK

BK

BK

em01195




FXD: under headlight bracket12-place DeutschConsole Gauges/Indicator Lamps (allexcept FXDWG/FXDC/FXDF)

[20]FXDL: under fuel tank console







Loss Of TSM/TSSM/HFSM Serial Data: DTC U1064, U1255

See 4.6 SPEEDOMETER SELFDIAGNOSTICS.

Can you read TSM/TSSM/HFSMhardware part number?

Install Breakout Box on Speedometer.While wiggling harness, check for continuitybetween terminal “3” (Gray) and terminal “2”

(Black) of Breakout Box.Is continuity present?

Install Breakout Box on Speedometer.Check for continuity between terminal “3”

(Gray) and terminal “2” (Black) of Breakout BoxIs continuity present?

Replace TSM/TSSM/HFSM.Learn password.



Clear DTCs. Test ride.Does DTC U1064

return?

No trouble found.Replace TSM/TSSM/HFSM.Learn password.

1

YES

NO


NO

NO

YESYES

YES

NO or “No Rsp”

1

fc01392_en


4.35DTC U1097, U1255

GENERAL

Loss of TSM/TSSM/HFSM Serial DataThe serial data connector provides a means for the ElectronicControl Module (ECM), TSM/TSSM/HFSM and speedometerto communicate their current status. When all operating para-meters on the serial data link are within specifications, a stateof health message is sent between the components.

A Diagnostic Trouble Code (DTC) U1064 indicates that theTSM/TSSM/HFSM is not receiving this state of health message.A DTC U1255 indicates that no messages were present duringpower up of the current key cycle. A DTC U1064 indicates thatthere was communication on the data bus since power up, butwas lost or interrupted during that key cycle.


DESCRIPTIONDTC



DIAGNOSTICS




SPEEDOMETER HARNESS ADAPTERHD-46601

NOTE

If code is historic and not current, wiggle wire harness whileperforming voltage and continuity tests to identify intermittents.


1. Connect BREAKOUT BOX (Part No. HD-43876) to wireharness connector [78B]. Leave ECM [78A] disconnected.See 4.7 BREAKOUT BOX: EFI.

2. Connect BREAKOUT BOX (Part No. HD-42682) (black)to wire harness connector [39B] using SPEEDOMETERHARNESS ADAPTER (Part No. HD-46601). Leavespeedometer [39A] disconnected. See 2.5 BREAKOUTBOX: SPEEDOMETER/TACHOMETER.

ed02887



3

1

2

4

321 12

3

Bat

tery

Igni

tion

Ser

iald

ata

Gro

und

21 1221 65 7

21 65 7

21

Igni

tion

Ser

iald

ata

Bat

tery

Acc

esso

ryG

roun

d

Igni

tion

Ser

iald

ata

Bat

tery

Acc

esso

ryG

roun

d

65 7

21 65 7

21 6 7 12

21 6 7 12

5

5

GY

O

O

GY

BN

/GY

BN

/GY

LGN

/V

LGN

/V

LGN

/V

O/W

O/W

O/W

BN

/GY

O

O

BN

/GY

LGN

/V

O/W

BK

/GN

BK/GN

LGN/V

LGN

/V

BN

/GY

BK

/GN

LGN

/V

ECM

Ser

iald

ata

[30B][30A]

[91A]

GND 1

[108B][108A]

[20B][20A]

[39B][39A]

[78B][78A]

Speedometer

Toignitionfuse

Toinstrument

fuse

Toaccessory

fuse

Tobattery

fuse


Data LinkConnector


TSM/TSSM/HFSM

BK

BK

BK

em01195




Inside top frame tube12-place DeutschConsole Gauges/Indicator Lamps (allexcept FXDWG/FXDC/FXDF)

[20]




Under electrical caddie cover4-place DeutschData Link Connector[91]



Loss of Speedometer Serial Data: DTC U1097, U1255

1

YES

NO


YES

YES

YESNO

NO

1

22

IMPORTANT:Always start from

4.5 INITIAL DIAGNOSTIC CHECK: EFI.

See 4.6 SPEEDOMETER SELFDIAGNOSTICS.

Can you read ECM hardware part number?

While wiggling harness, check forcontinuity between ECM Breakout Box

terminal “5” and speedometer Breakout Boxterminal “2” (Black).


Check for continuity betweenECM Breakout Box terminal “5”

and speedometer BreakoutBox terminal “2” (Black).


Replace Speedometer. Repair open on(LGN/V) wire.

Clear DTCs. Test Ride.Did DTC U1097 return?

Repair intermittent on(LGN/V) wire.

No trouble found.Replace Speedometer.

NO or “No rsp”

fc01393_en



NOTES

SUBJECT............................................................................................................................PAGE NO.A.1 AMP 1-PLACE CONNECTORS................................................................................................A-1A.2 AMP MULTILOCK CONNECTORS..........................................................................................A-3A.3 DELPHI CONNECTORS..........................................................................................................A-8A.4 DEUTSCH 1-PLACE ELECTRICAL CONNECTORS.............................................................A-10A.5 DEUSCH ELECTRICAL CONNECTORS...............................................................................A-11A.6 DEUTSCH STANDARD TERMINALS.....................................................................................A-15A.7 DEUTSCH MINI-TERMINAL CRIMPS...................................................................................A-16A.8 DEUTSCH SOLID BARREL TERMINALS..............................................................................A-17A.9 RELAY AND FUSE BLOCKS..................................................................................................A-19A.10 150 METRI-PACK CONNECTORS.......................................................................................A-20A.11 280 METRI-PACK CONNECTORS.......................................................................................A-22A.12 480 METRI-PACK CONNECTORS.......................................................................................A-24A.13 630 METRI-PACK CONNECTORS.......................................................................................A-25A.14 800 METRI-PACK CONNECTORS.......................................................................................A-26A.15 METRI-PACK TERMINALS...................................................................................................A-28A.16 MOLEX CONNECTORS.......................................................................................................A-30A.17 PACKARD ECM CONNECTOR............................................................................................A-32A.18 PACKARD MICRO-64 CONNECTORS................................................................................A-34A.19 SEALED SPLICE CONNECTORS.......................................................................................A-37

AP

PE

ND

IX A

CO

NN

EC

TOR

RE

PAIR

A.1AMP 1-PLACE CONNECTORS

AMP 1-PLACE CONNECTOR REPAIR


PACKARD TERMINAL CRIMPERHD-38125-7

SOCKET TERMINAL TOOLHD-39621-27

PIN TERMINAL REMOVERHD-39621-28

GeneralObtain the necessary tools to repair the connector or terminals.

For terminal crimping, use the PACKARD TERMINALCRIMPER (Part No. HD-38125-7).

Separating Pin and Socket HousingsBend back the ears on the pin housing slightly and separatethe pin and socket halves of the connector.

Mating Pin and Socket HousingsPush the pin and socket halves of the connector together untilthe latches click.

Removing Socket Terminals1. See Figure A-1. Grasp the lead on the wire end of the

socket housing (1) and push the terminal forward towardthe mating end of the connector until it stops. This willdisengage the locking tang from the groove in the con-nector.

2. Fit the barrel (2) of the SOCKET TERMINAL TOOL (PartNo. HD-39621-27) over the socket.

3. While rotating the tool slightly, push until it bottoms (3) inthe socket housing.

4. Allow the plunger (4) to "back out" of the handle.

5. Holding the socket housing while keeping the tool firmlybottomed (5), depress the plunger (6). The terminal (7)pops out the wire end of the connector.

NOTE

If the terminal is not released from the socket housing, thenthe terminal was not pushed forward far enough before place-ment of the tool or the tool was not bottomed in the connectorhousing.

Installing Socket Terminal1. Note the lip at the middle of the socket housing. One side

of the lip is flat while the other side is tapered. Insert thewire terminal into the socket housing on the flat (lip) side.

2. Push the lead into the socket housing until it stops. A clickis heard when the terminal is properly seated.

3. Gently tug on the lead to verify that the terminal is lockedin place.

1

8

2

3

7

6

4

5

sm00011

1. Socket housing2. Barrel3. Barrel bottomed in connector4. Plunger "backed out"5. Hold barrel bottomed6. Plunger pressed7. Socket terminal8. Connector lip

Figure A-1. Socket Terminal Tool (HD-39621-27)

Removing Pin Terminal1. Grasp the lead on the wire end of the pin housing and

push the terminal forward toward the mating end of theconnector until it stops. This will disengage the lockingtang from the groove in the connector.

2008 Dyna Diagnostics: Appendix A Connector Repair A-1

2. See Figure A-2.

a. Fit the barrel of the PIN TERMINAL REMOVER (PartNo. HD-39621-28) over the pin, and while rotatingthe tool slightly, push until it bottoms in the housing.Allow the plunger to "back out" of the handle.

b. Holding the pin housing while keeping the tool firmlybottomed, depress the plunger. The terminal popsout the wire end of the connector.

NOTE

If the terminal is not released from the pin housing, then theterminal was not pushed forward far enough before placementof the tool or the tool was not bottomed in the connectorhousing.

Installing Pin Terminal1. Push the lead into the pin housing until it stops. A click is

heard when the terminal is properly seated.

2. Gently tug on the lead to verify that the terminal is lockedin place.

1

3

4

5

6

2

sm00012

1. Pin housing2. Barrel3. Barrel bottomed in connector4. Plunger backed out of the handle5. Depressed plunger6. Pin terminal

Figure A-2. AMP Pin Terminal Remover (HD-39621-28)

A-2 2008 Dyna Diagnostics: Appendix A Connector Repair

A.2AMP MULTILOCK CONNECTORS

AMP MULTILOCK CONNECTOR REPAIR


AMP MULTILOCK CRIMPERHD-41609

GeneralAMP Multilock connectors are found between wire harnessesand component wiring and may be either floating or anchoredto the frame with attachment clips.

See Figure A-3. Attachment clips (1) on the pin housings arefitted to T-studs on the motorcycle frame. The T-studs identifyOE connector locations. To maintain serviceability, alwaysreturn connectors to OE locations after service.

Obtain the necessary tools to repair the connector and ter-minals.

NOTE

For terminal crimping use the AMP MULTILOCKCRIMPER (Part No. HD-41609).

Separating Pin and Socket Housings1. If necessary, slide connector attachment clip T-stud to the

large end of the opening.

2. See Figure A-3. Depress the release button (2) on thesocket terminal side of the connector and pull the sockethousing (3) out of the pin housing (4).

Mating Pin and Socket Housings1. Hold the housings to match wire color to wire color.

2. Insert the socket housing into the pin housing until it snapsin place.

3. If OE location is a 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.

23

1

4

sm00002

1. Attachment clip2. Release button3. Socket housing4. Pin housing

Figure A-3. AMP Multilock Connector

Removing Terminals from Housing1. See Figure A-4. 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 thesecondary lock) and note the cavity next to each terminal.

3. Insert a pick or pin into the terminal cavity until it stops.

NOTEIf socket/pin terminal tool is not available, a push pin/safety pinor a Snap-on pick (Part No. TT600-3) may be used.

4. Press the tang in the housing to release the terminal.

a. Socket: Lift the socket tang (8) up.

b. Pin: Press the pin tang (7) down.

NOTEA "click" is heard if the tang is released.

5. Gently tug on wire to pull wire and terminal from cavity.


5

2

7

1

3

61

24

8

sm00013

1. Latch2. Secondary lock open3. Pin housing4. Socket housing5. Pin terminal6. Socket terminal7. Tang (pin)8. Tang (socket)

Figure A-4. AMP Multilock Connector: Socket and PinHousings

Inserting Terminals into HousingNOTE

See Figure A-5. Cavity numbers are stamped into the sec-ondary locks of both the socket and pin housings. Match thewire color to the cavity number found on the wiring diagram.

1. Hold the terminal so the catch faces the tang in thechamber. Insert the terminal into its numbered cavity untilit snaps in place.

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 atthe 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 are at the top of each cavity, sothe socket terminal slot (on the same side as the crimptails) must face upward.

2. Gently tug on wire end to verify that the terminal is lockedin place.

3. Rotate the hinged secondary lock inward until tabs fullyengage latches on both sides of connector.

– AMP

1 2 3

– AMP

1 2 3 4 5 6

5 6 7 8 9 10

4321

1

2

3

sm00005

1. 3-place housing2. 6-place housing3. 10-place housing

Figure A-5. AMP Multilock Connector: Cavity Numbers onSecondary Locks (Socket Housings Shown)

Preparing Wire Leads for Crimping1. Strip 5/32 in. (4.0 mm) of insulation from the wire lead.


2. See Figure A-4 and Figure A-7. Select the pin/socket ter-minals from the parts catalog and identify the insulationcrimp tails (1) and the wire crimp tails (2) and the groovefor the crimp tool locking bar (3).

3. Identify the wire lead gauge and the corresponding crimpertool and nesting die. Refer to Table A-1.

Table A-1. AMP Multilock Connector: Crimp Tool WireGauge/Nest

NESTWIRE GAUGE

Front20

Middle16

Rear18

5

2

7

1

3

61

24

8

sm00013

1. Latch2. Secondary lock open3. Pin housing4. Socket housing5. Pin terminal6. Socket terminal7. Tang (pin)8. Tang (socket)

Figure A-6. AMP Multilock Connector: Socket and PinHousings


2

3

1sm00001

1. Insulation crimp tail2. Wire crimp tail3. Locking bar groove

Figure A-7. AMP Multilock Connector: Socket Terminal

Crimping Terminals to LeadsNOTE

Crimping with an Amp Multilock tool is a one step operation.One squeeze crimps both the wire core and the insulation tails.

1. See Figure A-8. Squeeze the handles to cycle the AMPMULTILOCK CRIMPER (Part No. HD-41609) to the fullyopen position (1).

2. Raise locking bar by pushing up on bottom flange (2).

NOTESee Figure A-4 and Figure A-7. Hold the terminal with theinsulation crimp tail (1) facing up.The tool will hold the terminalby the locking bar groove (3) and crimp the wire crimp tail (2)around the bare wire of the stripped lead and the insulationcrimp tail around the insulation.

3. See Figure A-8. With the insulation crimp tail facingupward, insert terminal (pin or socket) (3) through thelocking bar, so that the closed side of the terminal restson the nest of the crimp tool.

4. Release locking bar to lock position of contact (4). Whencorrectly positioned, the locking bar fits snugly in the spaceat the front of the core crimp tails.

5. Insert stripped end of lead (5) until ends make contact withlocking bar.

6. Verify that wire is positioned so that wire crimp tailssqueeze bare wire strands, while insulation crimp tails foldover the wire lead insulation.

7. Squeeze handle of crimp tool until tightly closed. Toolautomatically opens when the crimping sequence is com-plete.

8. Raise up locking bar (8) and remove crimped terminal.

4

6

7

3

1

2

5

8

sm00007

1. Open position2. Locking bar flange3. Insert contact4. Release locking bar5. Insert lead6. Squeeze7. Raise locking bar8. Remove crimped terminal

Figure A-8. AMP Multilock Connector:Terminal CrimpingProcedure

Inspecting Crimped TerminalsSee Figure A-9. Inspect the wire core crimp (2) and insulationcrimp (1). Distortion should be minimal.


1

2

sm00008

1. Insulation crimp2. Wire core crimp

Figure A-9. AMP Multilock Connector:Terminal Crimp


A.3DELPHI CONNECTORS

DELPHI CONNECTOR REPAIR

GeneralDelphi connectors are embossed with the brand name, Delphi,on the housing latch.

Separating Pin and Socket HousingsSee Figure A-10. Bend back the external latch(es) slightly andseparate pin and socket halves of connector.

Mating Pin and Socket HousingsPush pin and socket halves of connector together until externallatch(es) engage.

Removing Socket TerminalsNOTE

Although the parts of the different Delphi connectors vary inappearance, the instructions which follow will work for all. Theonly exception is the oil pressure sender connector [139B], theterminals of which are removed like the Packard push-to-seatconnectors. Therefore, see A.10 150 METRI-PACK CON-NECTORS to remove/install terminals in this connector.

1. See Figure A-11. If present, free one side of wire lock (1)from ear on wire end of socket housing, then release theother side. Release wires from channels in wire lock andremove from socket housing.

2. Use a fingernail to pry colored terminal lock (2) loose andthen remove from mating end of socket housing.

3. Using a thin flat blade, like the unsharpened edge of ahobby knife, gently pry tang (3) outward away from ter-minal, and then tug on wire to back terminal out wire endof chamber. Do not pull on wire until tang is released orterminal will be difficult to remove.

Installing Socket TerminalsNOTE

For wire location purposes, alpha or numeric characters arestamped into the wire end of each socket housing.

1. Gently push tang on socket housing inward towardchamber. With the open side of the terminal facing thetang, push terminal into chamber at wire end of sockethousing.

2. Gently tug on wire to verify that terminal is locked and willnot back out of chamber. If necessary, use fingernail topush tang into engagement with terminal.

3. Install colored terminal lock onto mating end of sockethousing.

4. If present, seat wires in separate channels of wire lockand then push channels inside chambers at wire end ofsocket housing. Fully installed, slot on each side of wirelock engages ear on socket housing.

sm00014

Figure A-10. Delphi Connector: Socket Housing Latch


2

3

1

sm00015

1. Remove wire lock2. Remove terminal lock3. Pry tang outward

Figure A-11. Delphi Connector: Removing SocketTerminals


A.4DEUTSCH 1-PLACE ELECTRICAL CONNECTORS

DEUTSCH 1-PLACE CONNECTOR REPAIR

Separating Pin and Socket HousingsDepress external latch and separate the pin and socket hous-ings of the Deutsch one place connector found on voltageregulators.

Mating Pin and Socket HousingsOrient the housings so the latch faces the catch and push thehousings together until it clicks.

Removing Socket TerminalsNOTE

Rough handling or careless storage can result in tool damage.Exercise care to avoid cracking or breaking the thin plasticconstruction.

1. Pull rear wire seal from back of housing and slide downvoltage regulator cable to move out of the way.

2. See Figure A-12. Using terminal pick tool (Deutsch®114008) (1), install tool onto voltage regulator cable sothat the tapered end is in the wire end of the housing (2).

3. Push tool into wire end of housing until it bottoms. Gentlytug on housing to pull from terminal (3).

4. Remove tool from voltage regulator cable.

Installing Socket Terminals1. Insert terminal into wire end of housing until it "clicks" in

place. Verify that terminal will not back out of housing. Aslight tug on the voltage regulator cable will confirm thatit is properly locked in place.

2. Fit rear wire seal into back of housing.

1

2

3

sm00016

1. Deutsch terminal pick tool (114008)2. Tool installed in housing3. Terminal removed from housing

Figure A-12. Deutsch 1-Place Connector: RemoveSocket/Pin Housing


A.5DEUSCH ELECTRICAL CONNECTORS

DEUTSCH CONNECTOR REPAIR


DEUTSCH CONNECTOR SERVICEKIT

HD-41475

FLAT BLADE L-HOOKHD-41475-100

GeneralDeutsch connectors are colored coded for location purposes.Those connectors associated with left side accessories, suchas 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, sealplugs, secondary locking wedges, attachment clips andsocket/pin terminals. Also included is a compartmented storagebox, carrying case and a FLAT BLADE L-HOOK (Part No. HD-41475-100) is used for the removal of all types of lockingwedges.

Separating Pin and Socket HousingsSee Figure A-12. To separate the connector halves, depressthe external latch(es) (1) on the socket housing (2) whilerocking the pin (3) and socket housings.

NOTES

• Generally, the socket housing is found on the accessoryside, while the pin housing is plumbed to the wiring har-ness.

• Two-, three-, four- and six-place Deutsch connectors haveone latch on the connector.

• Eight- and twelve-place connectors have a latch on eachside. Simultaneously press both latches to separate theconnector.

Mating Pin and Socket Housings1. Align the connectors to match the wire lead colors.

a. For One External Latch: Two-, three-, four- and six-place Deutsch connectors have one external latch onthe socket half of the connector. To fit the halves ofthe connector together, the latch on the socket sidemust 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 grooveson the pin housing.

2. Insert socket housing into pin housing until it snaps orclicks into place.

For Two External Latches: (8-place and 12-place) Iflatches do not click (latch), press on one side of the con-nector until that latch engages, then press on the oppositeside 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 onframe. Push assembly forward to engage small end ofslot.

2

3

1

1

sm00017

1. External latch2. Socket housing3. Pin housing

Figure A-13. Deutsch Connector

Removing Socket Terminals1. See Figure A-14. 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 thescrewdriver 90 degrees to pop the wedge up and removethe secondary locking wedge.

2. See Figure A-17. Use a pick or small screwdriver todepress terminal latches inside socket housing and backout sockets through holes in rear wire seal.

NOTE

If wire leads require new terminals, see the instructions forcrimping terminals.

Installing Socket Terminals1. Match wire lead color to connector cavity.

2. See Figure A-16. Fit rear wire seal (1) into back of sockethousing (2), if removed.

3. Grasp wire lead (3) approximately 1.0 in. (25.4 mm)behind the socket terminal. Gently push socket throughhole in wire seal into its chambers until it "clicks" in place.

4. A tug on the wire will confirm that it is properly locked inplace.

NOTESeal plugs (6) are installed through the wire seals of unusedchambers. If removed, seal plugs must be replaced to seal theconnector.


5. Install internal seal (4) on lip of socket housing, if removed.

6. Insert tapered end of secondary locking wedge (5) intosocket housing and press down until it snaps in place.Thewedge fits into the center groove within the socket housingand holds the terminal latches tightly closed.

NOTES• See Figure A-15.While rectangular wedges do not require

a special orientation, the conical secondary locking wedgeof 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 theinstalled position easily, verify that all terminals are fullyinstalled in the socket housing. The lock indicates whenterminals are not properly installed by not entering its fullyinstalled position.

sm00009

Figure A-14. Deutsch Connector: Remove SecondaryLocking Wedge

2

1

sm00018

1. Arrow on socket locking wedge2. Arrow on pin locking wedge

Figure A-15. Deutsch Connector: 3-Place Locking Wedges


DEU

TSC

H

6

1

2

3

4

5

sm00010

1. Wire seal2. Socket housing3. Wire lead4. Internal seal5. Secondary locking wedge6. Seal plug

Figure A-16. Deutsch Connector: 2, 3, 4 and 12-PlaceSocket Housings

Removing Pin Terminals1. Use the hooked end of a stiff piece of mechanics wire, a

needle nose pliers or the FLAT BLADE L-HOOK (PartNo. HD-41475-100) to remove the secondary lockingwedge.

2. Gently depress terminal latches inside pin housing andback out pins through holes in wire seal.

NOTES

• If wire leads require new terminals, see the instructionsfor crimping terminals.

• If it should become necessary to replace a pin or sockethousing, please note that the 8-place and 12-place grayand black connectors are not interchangeable. Since loc-ation of the alignment tabs differ between the black and

gray connectors, plugs or receptacles must be replacedby those of the same color.

• When replacing both socket and pin housings, then theblack may be substituted for the gray, and vice versa. Thesocket and pin housings of all other connectors are inter-changeable, that is, the black may be mated with the gray,since the alignment tabs are absent and the orientationof the external latch is the same.

sm00019

Figure A-17. Deutsch Connector: Depress Terminal Latchand Back Out Pin

Installing Pin Terminals1. See Figure A-18. Fit wire seal (1) into back of pin housing

(2).

2. Grasp wire lead approximately 1.0 in. (25.4 mm) behindthe pin terminal (3). Gently push pin through holes in wireseal into its respective numbered chamber until it "clicks"in place.

NOTEA tug on the wire lead will confirm that a pin is locked in place.

3. Insert tapered end of secondary locking wedge (4) intopin housing and press down until it snaps in place.

NOTES

• The wedge fits in the center groove of the pin housing andholds the terminal latches tightly closed.

• See Figure A-15.While rectangular wedges do not requirea special orientation, the conical secondary locking wedgeof the 3-place connector must be installed with the arrow(2) pointing toward the external latch.

• If the secondary locking wedge does not slide into theinstalled position easily, verify that all terminals are fullyinstalled in the pin housing. The lock indicates when ter-minals are not properly installed by not entering its fullyinstalled position.


DEU

TSC

H

1

2

3

4

sm00020

1. Wire seal2. Pin housing3. Pin terminal4. Locking wedge

Figure A-18. Deutsch Connector: 2, 3, 4 and 12-Place PinHousings

Crimping TerminalsIdentify which of the types of Deutsch terminals are used withthe connector and follow the corresponding crimping instruc-tions. Refer to Table A-2.

Table A-2. Deutsch Connector:Terminal Crimping Instructions

CRIMPING INSTRUCTIONSTYPE

A.6 DEUTSCH STANDARD TERMINALSStandard (with crimp tails)

A.8 DEUTSCH SOLID BARREL TERMINALSMini Terminal (solid barrel)

A.7 DEUTSCH MINI-TERMINAL CRIMPSMini Terminal (with crimp tails)


A.6DEUTSCH STANDARD TERMINALS

DEUTSCH STANDARD TERMINAL CRIMPS


DEUTSCH TERMINAL CRIMP TOOLHD-39965-A

Preparing Wire Leads for Crimping1. Use a shop gauge to determine gauge of wire lead.

2. Strip lead removing 5/32 in. (4.0 mm) of insulation.

Crimping Terminal to Lead1. See Figure A-19. Squeeze the handles of the DEUTSCH

TERMINAL CRIMP TOOL (Part No. HD-39965-A) to openthe jaws. Push the locking bar (1) up.

2. Insert (2) terminal (socket/pin) through hole of the lockingbar, so that the rounded side of the contact barrel rests inthe nest (concave split level area) with the crimp tailsfacing upward. To match the wire gauge to the crimp tooldie, refer to Table A-3.

3. Release locking bar to lock terminal in die.

NOTEIf the crimp tails are slightly out of vertical alignment, the crimptool automatically rotates the terminal so that the tails face

straight upward. When positioned, the locking bar fits snuglyin the space between the contact band and the core crimp tails.

4. Insert stripped wire core between crimp tails until endsmake contact with locking bar.Verify that wire is positionedso that short pair of crimp tails squeeze bare wire strands,while long pair folds over the insulation.

5. Squeeze handle of crimp tool until tightly closed. Toolautomatically opens after the terminal is crimped.

6. Raise locking bar up and remove wire lead and terminal.

Inspecting CrimpsInspect the wire core and insulation crimps. Distortion shouldbe minimal.

Table A-3. Deutsch Standard Terminal Crimp:Wire GaugeTo Die

CRIMP TOOL DIEWIRE GAUGE (AWG)

Front20

Middle16-18

2

5

4

6

1

3

sm00021

4.1. Insert stripped leadOpen jaws and raise locking bar2. 5.Insert terminal in locking bar Squeeze crimper

6.3. Raise locking bar and remove terminalRelease locking bar to lock terminal in die

Figure A-19. Crimping a Deutsch Standard Terminal


A.7DEUTSCH MINI-TERMINAL CRIMPS

DEUTSCH MINI TERMINAL CRIMPS



Preparing Wire Leads for CrimpingStrip wire lead removing 5/32 in. (4.0 mm) of insulation.

Crimping a Mini Terminal to Wire Lead1. See Figure A-20. Compress the handles of PACKARD

TERMINAL CRIMPER (Part No. HD-38125-7) until theratchet (2) automatically opens.

NOTEAlways perform core crimp before insulation crimp.

2. Position the core crimp on die E (1) of the crimper. Besure the core crimp tails are facing the forming jaws.

3. Gently apply pressure to handles of tool until crimpers justsecure the core crimp tails.

4. Insert stripped wire core stands between crimp tails. Pos-ition wire so that short pair of crimp tails squeeze barewire strands, while long pair squeeze over the insulation.

5. Squeeze handle of crimper until tightly closed. Tool auto-matically opens when the crimping sequence is complete.

NOTEIf the crimper does not open, it can be opened by squeezingthe ratchet trigger (2).

6. Position the insulation crimp on nest C of the crimper. Besure the insulation crimp tails are facing the forming jaws.

7. Squeeze handle of crimp tool until tightly closed. Toolautomatically opens when the crimping sequence is com-plete.

Inspecting CrimpsInspect the core and insulation crimps. Distortion should beminimal.

2

1

sm00022

1. E die2. Crimper ratchet trigger

Figure A-20. Packard Terminal Crimper (HD-38125-7)


A.8DEUTSCH SOLID BARREL TERMINALS

DEUTSCH SOLID BARREL TERMINALCRIMPS


ELECTRICAL CRIMPER TOOLHD-42879

Preparing Wire Leads For CrimpingFor size 20, 16 and 12 contacts, wire ranges 26-12 AWG.

Strip wire lead removing 1/4 in. (6.4 mm) of insulation.

Adjusting Crimper Tool1. See Figure A-21. Squeeze the ELECTRICAL CRIMPER

TOOL (Part No. HD-42879) handles to cycle the crimptool to open.

2. Remove locking pin (1) from selector knob (2).

3. Raise selector knob and rotate until selected wire sizestamped on wheel is aligned with "SEL. NO." arrow (3).

4. Loosen knurled locknut (4) and turn adjusting screw (5)clockwise (in) until it stops.

Crimping a Barrel Contact To Wire Lead1. See Figure A-22. Turn tool over and drop contact barrel

(1) into indentor cover (2) hole with the wire end out.

2. Turn adjusting screw counterclockwise (out) until contactis flush with bottom of depression in indentor cover.Tighten knurled locknut.

3. Slowly squeeze handles of crimp tool until contact iscentered between the four indentor points (3).

4. Insert bare wire core strands of stripped wire lead (4) intocontact barrel. Squeeze handle of crimp tool until tightlyclosed. Tool automatically opens when the crimpingsequence is complete.

5. Remove wire lead with crimped contact from indentor.

NOTETool must be readjusted when changing contact size/type.

6. Install pin to lock selector knob.

Inspecting CrimpsInspect the crimp. All core wire strands are to be crimped inthe barrel.

This

HA

ND

toolm

ustnot

be

used

inany

pow

ere

d

"PR

ES

S''

as

defin

ed

by

OS

HA

CFR

1910.2

11

(46)

2

4

5

1

3

sm00023

1. Locking pin2. Selector knob3. SEL. NO. arrow4. Knurled locknut5. Adjusting screw

Figure A-21. Electrical Crimper Tool (HD-42879)


HDT - 48 - 00JDG360-1

HEMET RYAN AIRPORT, P.O. BOX 878

HEMET, CA. 92343-0161 (714) 929-1200

INDUSTRIAL PRODUCTS DIVISION

HDT - 48 - 00JDG360-1

HEMET RYAN AIRPORT, P.O. BOX 878

HEMET, CA. 92343-0161 (714) 929-1200

INDUSTRIAL PRODUCTS DIVISION

2

1

3

4

3

sm00024

1. Contact barrel2. Indentor cover3. Indentor point4. Stripped wire lead

Figure A-22. Deutsch Solid Barrel


A.9RELAY AND FUSE BLOCKS

FUSE BLOCK REPAIR

Removing Socket Terminals1. See Figure A-23. To remove secondary locks, insert end

of small flat blade screwdriver (1) under lip of lockingwedge (2) and gently pry up secondary lock.

NOTEFor best results, start with locking wedge on outboard side ofsecondary lock.

2. Looking into chamber at top of fuse block, note the tangnext to each socket terminal.

3. Using a thin flat blade, like that on a hobby knife, gentlypush tang away from terminal, and then tug on wire toback terminal out.

Installing Socket Terminals1. Match the wire lead color to the fuse block terminal cavity.

NOTES• Refer to the main harness wiring diagram for wire lead

color codes.

• See Figure A-24. The main fuse block terminal cavity isidentified as alpha (1) and numeric (2) coordinates. Referto the main harness wiring diagram for fuse block terminalcavity coordinates.

2. With the open side of the socket terminal facing the tang,push lead into chamber at the wire end of the fuse block.A click is heard when the terminal is properly engaged.

3. Gently tug on the wire to verify that the terminal is lockedin place and will not back out of the chamber.

4. Install the secondary locks. With the locking wedgespositioned above the tangs in each chamber, slide flatside of secondary lock into slot (between rows), and pushdown until it bottoms.

Crimping TerminalsTerminals are crimped twice; once over the wire core and asecond time over the insulation/seal.

A correctly crimped terminal may require different crimpingdies found on separate crimpers.

NOTE

The wiring diagram indicates when one socket terminal is becrimped to two wire leads.

1

2

sm00025

1. Pry up secondary lock2. Lip of locking wedge

Figure A-23. Fuse Block: Remove Secondary Locks

3

A C

D

E

F

G

H

J1

2

4B

1

2

sm00026

1. Alpha2. Numeric

Figure A-24. Fuse Block: Coordinates (typical)


A.10150 METRI-PACK CONNECTORS

150 METRI-PACK CONNECTOR REPAIR

GeneralMetri-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 HousingsBend back the external latch slightly and separate the pin andsocket halves of the connector.

Mating Pin and Socket HousingsAlign the wire colors and push the pin and socket halves of theconnector together.

Removing Socket Terminal1. See Figure A-25 for pull-to-seat connector or Figure A-26

for push to seat connector. Remove wire lock (1) from wireend of socket housing on push-to-seat type connectors.

NOTEFor best results, free one side of wire lock first and then releasethe other side.

2. Find the locking tang in the mating end of the connector.

NOTEThe tangs are always positioned in the middle of the chamberand are on the same side as the external latch.

3. Gently insert a safety pin into the chamber about 1/8in. (3.2 mm).

a. For pull-to-seat: Stay between the terminal and thechamber wall and pivot the end of the pin toward theterminal body.

b. For push-to-seat: There is a small opening for thepin.

4. When a click is heard, remove the pin and repeat theprocedure.

NOTEThe click is the sound of the tang returning to the locked posi-tion as it slips from the point of the pin.

5. Pick at the tang until the clicking stops and the pin seemsto slide in deeper than it had previously. This is an indica-tion that the tang has been depressed.

NOTEOn those terminals that have been extracted on multipleoccasions, the click may not be heard, but pivot the pin as ifthe click was heard at least 3 times.

6. Remove the pin.

a. For pull-to-seat: Push on the lead to extract the ter-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.

Inserting Socket TerminalNOTE

For wire location purposes, alpha characters are stamped intothe socket housings.

1. See Figure A-25 for pull-to-seat connector or Figure A-26for push to seat connector. Using a thin flat blade, like thaton a hobby knife, carefully bend the tang outward awayfrom the terminal body.

2. Gently pull or push on the lead to install the terminal backinto the chamber. A click is heard when the terminal isproperly seated.

3. Gently pull or push on the lead to verify that the terminalis locked in place.

For push-to-seat: See Figure A-26. Seat wires in separatechannels of wire lock and then push channels insidechambers at wire end of socket housing. Fully installed,slot on each side of wire lock engages ear on sockethousing.


4

2

3

1

sm00027

1. Locate tang in chamber2. Pivot pin to depress tang3. Push to remove4. Raise tang to install

Figure A-25. 150 Metri-Pack Connector: Pull-to-Seat

3

4

2

1

sm00028

1. Remove wire lock2. Pivot pin to depress tang3. Pull to remove4. Raise tang to install

Figure A-26. 150 Metri-Pack Connector: Push-to-Seat




GeneralSee Figure A-27. Called Packard connectors, Metri-Pack seriesconnectors are embossed with the initials (P.E.D.)

Separating Pin and Socket HousingsDepress the wireform and use a rocking motion to detach thesocket connector half.

Mating Pin and Socket HousingsAlign the groove in the socket housing with the tab in the pinhousing. Push the pin and socket halves of the connectortogether until the latch clicks.

Removing Socket Terminals1. See Figure A-28. Pry rubber seal from wire end of con-

nector and move seal down wires (1) toward conduit. Holdthe connector so that the wireform is facing down.

2. Looking into the wire end of the connector, insert the pointof a safety pin (2) between the top of the terminal and theinside chamber wall.

3. Push safety pin completely into chamber while watchingterminal on mating end of connector. When terminal isobserved moving forward slightly, tang is depressed.Remove safety pin.

NOTERepeat as necessary until the terminal can be pushed out ofthe connector.

4. Push on wire end of the lead to extract the terminal fromthe mating end of the connector.

5. If necessary, crimp new terminals on wires. See **METRI-PACK TERMINAL CRIMPS**.

Installing Socket TerminalsNOTE

Terminal cavities are lettered on the socket housing. To matchthe wire lead colors to the terminal cavity, refer to the wiringdiagram.

1. See Figure A-28. Using a thin flat blade, like an X-Actoknife (4), carefully bend the tang outward away from theterminal body.

2. Gently pull on the wire lead (5) to draw the terminal backinto the chamber. The tang faces opposite the wireformas it enters the chamber.

NOTEA "click" is heard when the terminal is properly seated.

3. Push on lead to verify that terminal is locked in place.

4. Fit rubber wire seal back into wire end of connector.

Crimping TerminalsIf necessary, crimp new terminals on the wire leads. Refer to**METRI-PACK TERMINAL CRIMPS**.

sm00029

Figure A-27. 280 Metri-Pack Connector (P.E.D.)


3

5

2

4

1

sm00030

1. Pry rubber seal from connector2. Insert safety pin to depress tang3. Push on lead to remove terminal4. Raise tang with X-Acto knife5. Pull on lead to draw terminal into chamber

Figure A-28. 280 Metri-Pack Connector: Remove/InstallSocket Terminal




GeneralA 480 Metri-Pack (P.E.D.) connector is frequently used for theB+ (battery voltage) connector to power P&A accessories.

Referred to as Packard connectors, Metri-Pack connectors areembossed with the initials P.E.D.

Separating Pin and Socket HousingsNOTE

Cut any cable strap anchoring the wire conduits of the pin(accessory connector housing) and the socket (B+) housing.

See Figure A-29. Using small flat blade screwdriver, depressbutton (1) on pin housing (red wire) side of the connector andpull apart the pin and socket housings.

Mating Pin and Socket HousingsOrient the latch on the socket housing to the button catch onthe pin housing and press the housings together.

Removing Socket Terminals1. See Figure A-29. Bend back the latch (2) slightly and free

one side of secondary lock, then repeat to release theopposite side. Rotate the secondary lock outward on hingeto access terminal in chamber of connector housing.

2. On the mating end of the connector, note the tang in thesquare shaped opening centered next to the terminal.Gently insert the point of a stick pin or large safety pin intothe opening (3) between the tang and the chamber walluntil it stops.

3. Pivot the end of the pin toward the terminal body todepress the tang.

4. Remove the pin and then pull terminal out of the wire endof connector housing.

5. If necessary, crimp new terminals on wires. SeeA.15 METRI-PACK TERMINALS.

Installing Socket Terminals1. Carefully bend the tang outward away from the terminal

body.

2. With the tang on the same side as the square shapedopening in the mating end of the connector housing, feedterminal into wire end of connector housing until it "clicks"in place.

3. Verify that terminal will not back out of the chamber. Aslight tug on the cable will confirm that it is locked.

4. Rotate the hinged secondary lock inward until latches fullyengage 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) fromhousings.

1

2

3

sm00031

1. Button on pin housing2. Secondary lock latch3. Opening between tang and chamber wall

Figure A-29. 480 Metri-Pack Connector: Remove SocketTerminal





SNAP-ON PICKTT600-3

GeneralReferred to as Packard connectors, Metri-Pack 630 seriesconnectors are embossed with the initials P.E.D.

Separating Pin and Socket HousingsNOTE

If necessary, remove connector from barbed anchor or otherretaining device.

Bend back the external latch slightly and separate pin andsocket halves of the connector.

Mating Pin and Socket HousingsOrient the latch to the catch and push the pin and socket halvesof the connector together until the latch "clicks".

NOTE

If removed, install connector on barbed anchor or other OEretaining device.

Removing Socket Terminal1. Bend back the 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 theterminals in the chambers of the connector housing. Thelocking tang is on the side opposite the crimp tails and

engages a rib in the chamber wall to lock the terminal inplace.

3. Moving to the mating end of the connector, take note ofthe small opening on the chamber wall side of each ter-minal.

4. Insert SNAP-ON PICK (Part No. TT600-3) into openinguntil it stops. Pivot the end of the pick toward the terminalto depress the locking tang.

5. Remove the pick and gently tug on the wire to pull theterminal from the wire end of the connector. Repeat stepsif the terminal is still locked in place.

6. If necessary, crimp new terminals on wires. Refer toA.15 METRI-PACK TERMINALS.

Installing Socket TerminalNOTE

Refer to the wiring diagrams to match wire lead colors to alphacharacters molded into the secondary locks of each connectorhousing.

1. Using a thin flat blade, like that of a hobby knife, carefullybend the tang outward away from the terminal body.

2. With the tang facing the chamber wall, push the lead intothe chamber at the wire end of the connector. A click isheard when the terminal is properly seated.

3. Gently tug on the wire end to verify that the terminal islocked in place and will not back out of the chamber.

4. Rotate the hinged secondary lock inward until tabs fullyengage latches on both sides of connector.



DELPHI MAXI-FUSE HOUSING REPAIR

GeneralA Delphi Maxi-fuse connector completes the circuit throughthe main fuse (Maxi-fuse).

Removing Maxi-Fuse1. See Figure A-30. Depress latches on Maxi-fuse cover (1)

and then slide cover off of connector (2).

2. Holding the connector (fuse holder), pull the Maxi-fuse outof the connector.

Installing Maxi-Fuse1. Insert the blade terminals of the Maxi-fuse into the sockets

of the connector and press the Maxi-fuse into the con-nector.

2. Slide the cover over the fuse until the cover clicks intoplace.

NOTE

If removed from an OE attachment such as a grooved fuseblock cover, engage cover and slide into place.

Removing Socket Terminals1. See Figure A-31. Gently pull socket housing to disengage

slots (1) on secondary lock (2) from tabs (3) on sockethousing. Free secondary lock from cables and set aside.

2. Take note of the opening on one side of the socket ter-minal. Gently insert flat blade of pick (Snap-On TT600-5)or small screwdriver into opening (4) until it stops. Pivotthe pick toward the terminal body and hold in position.

3. Tug on cable to pull socket from wire end of sockethousing. A firm tug is necessary to overcome the resist-ance of the rubber seal.

4. Repeat to remove remaining socket terminal.

Installing Socket Terminals1. See Figure A-32. Carefully bend tang outward away from

the terminal body.

2. Feed socket into wire end of socket housing until it clicksin place. Verify that socket will not back out of chamber.A slight tug on the cable will confirm that it is locked.

3. Push rubber seal into wire end of socket housing.

4. Repeat to install remaining socket terminal.

5. Install secondary lock onto cables and then push onto wireend of socket housing until slots engage tabs on sides ofsocket housing.

1

2

sm00032

1. Maxi-fuse cover2. Delphi Maxi-fuse housing

Figure A-30. Delphi Connector Housing: Maxi-Fuse

3

4

12

sm00033

1. Secondary lock slot2. Secondary lock3. Tab4. Insert flat blade into opening

Figure A-31. Delphi Maxi-Fuse Housing: Remove SocketTerminals


sm00034

Figure A-32. Delphi Maxi-Fuse Housing: Bend Tang


A.15METRI-PACK TERMINALS

METRI-PACK TERMINAL CRIMPS


PACKARD TERMINAL CRIMP TOOLHD-38125-6


PACKARD CRIMPING TOOLHD-38125-8

Matching Terminal To CrimperMetri-Pack connectors embossed with the initials P.E.D. requirePackard crimp tools to crimp terminals to wire leads.

Terminals are crimped twice to a wire lead, once over the wirecore and a second time over the insulation/seal.

See Figure A-33. A completed crimp may require two differentcrimping dies found on PACKARD TERMINAL CRIMPTOOL (Part No. HD-38125-6) and/or PACKARD TERMINALCRIMPER (Part No. HD-38125-7).The terminal (pin or socket)and the wire lead gauge will determine the core crimp die andthe insulator/seal die.

NOTE

The PACKARD CRIMPING TOOL (Part No. HD-38125-8) willalso crimp sealed splice connectors in wire gauge sizes 18-20,14-16 and 10-12.

Preparing Wire LeadUse a wire striper to strip off the insulation and expose 5/32in. (4.0 mm) of wire core.

Crimping Wire CoreNOTE

Metri-Pack terminal crimps require two steps. Always performCrimping Wire Core before Crimping Insulation/Seal.

1. Squeeze and release handles until ratchet automaticallyopens.

2. Identify the corresponding sized nest for the core crimp.

3. Position the core crimp in the die. Be Sure the core crimptails are facing the forming jaws.

4. Gently squeeze the handles until crimpers just secure thecore crimp tails.

5. Insert stripped wire between crimp tails. Verify that wireis positioned so that short pair of crimp tails squeeze corewire strands, while long pair is positioned over the insula-tion or seal material.

6. Squeeze handles tightly closed. Release grip and the toolwill automatically open.

1

2

3

sm00035

1. HD-38125-6 sealed terminals2. HD-38125-7 non-sealed terminals3. HD-38125-8 non-sealed terminals

Figure A-33. Metri-Pack Terminal Crimp Tools

Crimping Insulation/SealNOTE

Always perform Crimping Wire Core before Crimping Insu-lation/Seal.

1. See Figure A-34. Identify the correct die for the insula-tion/seal crimp (2).


2. Position the insulation/seal crimp in the nest. Be sure theinsulation/seal crimp tails are facing the forming jaws.

3. Squeeze handle of crimp tool until tightly closed. Toolautomatically opens when the crimp is complete.

Inspecting Crimps1. See Figure A-34. Inspect the wire core crimp (1).The tails

should be folded in on the wire core without any distortionor excess wire strands.

2. Inspect the insulation (2) or seal (3) crimp.The tails of theterminal should be wrapped around the insulation withoutdistortion.

3

2 1

sm00036

1. Wire core crimp2. Insulation crimp3. Seal crimp

Figure A-34. Metri-Pack Connector: Inspect Core andInsulation/Seal Crimps


A.16MOLEX CONNECTORS

MOLEX CONNECTOR REPAIR


MOLEX ELECTRICAL CONNECTORTERMINAL REMOVER

HD-48114

Separating Pin and Socket HousingsSee Figure A-35. Depress the latch while pulling the pin andsocket housings apart.

Mating Pin and Socket Housings1. Orient the latch on the pin housing to the latch pocket on

the socket housing so the rails on the outside of the pinhousings lines up with the tunnels on the socket housing.

2. Press the housings together until the latch clicks.

Removing Terminals1. Pull the secondary lock up, approximately 3/16 in. (4.8

mm), until it stops.

a. Socket Housing: See Figure A-36. Use a smallscrewdriver in the pry slot. The slot next to theexternal latch provides a pivot point.

b. Pin Housing: See Figure A-37. Use needle nosepliers to engage the D-holes in the center of the sec-ondary lock.

NOTEDo not remove the secondary lock from the connector housing.

2. See Figure A-38. Insert MOLEX ELECTRICAL CON-NECTOR TERMINAL REMOVER (Part No. HD-48114)into the pin hole next to the terminal until the tool bottoms.

a. Socket Housing: The pin holes are inside the ter-minal openings.

b. Pin Housing: The pin holes are outside the pins.

3. Pressing the terminal remover to the bottom of the pinhole, gently pull on the wire to remove wire terminal fromits cavity.

Installing Terminals1. See Figure A-39. From the wiring diagram, match the wire

color to its numbered terminal cavity.

NOTECavity numbers (1) are stamped on the housing at the endsof the cavity rows. The cavity number can be determined bycounting the cavities up or down along the row from eachstamped number.

2. Orient the terminal so that the tang (2) opposite the opencrimp engages the slot (3) in the cavity.

3. Push the terminal into the cavity.

4. Gently tug on wire to verify that the terminal is capturedby the secondary lock.

5. With all terminals installed, push the secondary lock intothe socket housing to lock the wire terminals into thehousing.

sm00040

Figure A-35. Molex Connector: Latch

sm00041

Figure A-36. Molex Connector: Secondary Lock Pry Slot(Socket Housing)


sm00042

Figure A-37. Molex Connector: Secondary Lock D-Holes(Pin Housing)

sm00043

Figure A-38. Molex Connector:Terminal Remover(HD-48114)

13

2

sm00044

1. Cavity number2. Tang3. Cavity slot

Figure A-39. Molex Connector: Pin Cavities and WireTerminal


A.17PACKARD ECM CONNECTOR

PACKARD 100W CONNECTOR REPAIR

GeneralA Packard 100W connector connects the the electronic controlmodule (ECM) to the main harness.

NOTE

For vehicles with 73-pin connectors, see A.18 PACKARDMICRO-64 CONNECTORS and A.15 METRI-PACK TER-MINALS.

Separating Socket Housing From ECMSee Figure A-40. While pressing the connector into the ECM,press the thumb lever (1) against the connector until the latch(2) pops out of the catch (3) on the ECM.

Mating Socket Housing To ECMPush the connector into the ECM until the latch is captured bythe catch on the ECM.

Removing Socket Terminal1. See Figure A-41. Gently depress latch (1) on each side

of the clear plastic secondary lock (2) and remove. Forbest results, release one side at a time.

2. Carefully cut cable strap (3) to free strain relief collar (4)from conduit (5).

3. See Figure A-42. Using a thin blade, gently pry at seamat back of socket housing to release three plastic pins (1)from slots in housing. Separate and spread halves ofsocket housing.

4. Push on wire lead to free terminal from chamber.

Installing Socket Terminal1. From inside socket housing, gently pull on wire to draw

terminal into chamber.

2. Exercising caution to avoid pinching wires, press halvesof socket housing together until three plastic pins fullyengage slots in housing.

3. Install new cable strap in groove of strain relief collarcapturing cable conduit.

4. With the two ribs on the secondary lock on the same sideas the external latch, install over terminals until latcheslock in place.

Crimping TerminalsIf necessary, crimp new terminals on wire leads. SeeA.15 METRI-PACK TERMINALS.

2

3

1

sm00037

1. Thumb lever2. Latch3. Catch (ECM)

Figure A-40. Packard 100W to ECM (Typical)


1

3

5 1

4

2

sm00038

1. Latch2. Secondary lock3. Cable strap4. Strain relief collar5. Conduit

Figure A-41. Packard 100W Connector 2

1

1

1

sm00039

1. Pins2. Socket terminal

Figure A-42. Packard 100W Connector: Separate Halvesof Socket Housing


A.18PACKARD MICRO-64 CONNECTORS

PACKARD MICRO-64 CONNECTOR REPAIR


PACKARD MICRO-64 TERMINALREMOVER

HD-45928

PACKARD MICRO-64 TERMINALCRIMPER

HD-45929

GeneralPackard Micro-64 connectors are frequently found onspeedometers, tachometers and the ECM of Touring Models.For pin 73 of these ECMs, see A.10 150 METRI-PACK CON-NECTORS.

Separating Pin and Socket HousingsBend back the external latches slightly and separate the pinand socket housings.

Mating Pin and Socket HousingsOrient the wire lead colors and push the pin and socket hous-ings of the connector together until the latches click.

Removing Terminal1. See Figure A-45. Locate the head of the secondary lock

(1) on one side of the connector housing.

2. Insert the blade of a small screwdriver between the centerear of the lock and the connector housing and gently pryout lock.When partially removed, pull lock from connectorhousing.

3. Locate pin hole (2) between terminals on mating end ofconnector.

4. See Figure A-46. Obtain the PACKARD MICRO-64 TER-MINAL REMOVER (Part No. HD-45928).

5. See Figure A-44. Push the adjacent terminals all the wayinto the connector housing and then insert tool into holeuntil it bottoms.

6. Leaving the tool installed, gently tug on wires to pull eitherone or both terminals from wire end of connector. Removetool.

sm00046

Figure A-43. Packard Micro 64 Terminal Remover(HD-45928)

sm00048

Figure A-44. Packard Micro 64 Connector: Insert Tool andRemove Terminal

Installing Terminal1. Insert terminal into its respective numbered chamber on

wire end of connector. No special orientation of the ter-minal is necessary.

NOTESee Figure A-45. For wire location purposes, the corners ofthe socket housing are stamped (3) with the numbers 1, 6, 7and 12, representing terminals 1-6 on one side, and 7-12 onthe other.

2. Bottom the terminal in the chamber and then gently tugon the wire to verify that it is locked in place.

NOTEOnce the terminal is removed it may not lock in place whenfirst reinstalled. Until the lock engages, move the terminal backand forth slightly while wiggling the lead.

3. Since the terminal remover tool releases two terminalssimultaneously, repeat step 2 on the adjacent terminaleven if it was not pulled from the connector housing.


4. With the center ear on the head of the secondary lockpinfacing the mating end of the connector, push secondarylock in until head is flush with the connector housing.

Preparing Wire Leads for CrimpingStrip lead removing 1/8 in. (3.0 mm) of insulation.

Crimping Terminals1. Inspect new socket terminal for bent or deformed contact

and crimp tails. Replace as necessary.

2. See Figure A-47. Squeeze the handles of the PACKARDMICRO-64 TERMINAL CRIMPER (Part No. HD-45929)to cycle the tool to the fully open position (1).

3. Raise locking bar and barrel holder by pushing up onbottom tab with index finger (2).

4. With the crimp tails facing upward, insert terminal throughlocking bar into front hole in barrel holder (20-22 gaugewire) (3).

5. Release locking bar to lock position of contact. Whencorrectly positioned, the locking bar fits snugly in the spaceat the front of the core crimp tails and the closed side ofthe terminal rests on the outer nest of the crimp tool.

6. Insert wires between crimp tails until ends make contactwith locking bar. Verify that wire is positioned so that widepair of crimp tails squeeze bare wire strands, while thenarrow pair folds over the insulation material.

7. Squeeze handle of crimp tool until tightly closed (4). Toolautomatically opens when the crimping sequence is com-plete.

8. Raise locking bar and barrel holder to remove contact.

Inspecting CrimpsInspect the quality of the core and insulation crimps. Distortionshould be minimal.

1 2 3 4 5 6

7 8 9 10 11 12

1 6

7 12

1

23

sm00047

1. Secondary lock2. Pin hole3. Stamped number

Figure A-45. Packard Micro 64 Connector: Housing

sm00045

Figure A-46. Packard Micro 64 Terminal Crimper (HD-45929)


3

1

2

4

sm00049

1. Open position2. Raising locking bar3. Insert terminal4. Crimp terminal

Figure A-47. Packard Micro 64 Connector:Terminal inCrimper


A.19SEALED SPLICE CONNECTORS

SEALED SPLICE CONNECTOR REPAIR


ROBINAIR HEAT GUNHD-25070

PACKARD CRIMPING TOOLHD-38125-8

ULTRA-TORCH UT-100HD-39969

HEAT SHIELD ATTACHMENTHD-41183

GeneralSplice connectors and several OE ring terminal connectorsuse heat shrink covering to seal the connection.

Preparing Wire LeadsNOTE

If adjacent wires are to be spliced, stagger the splices so thatthe sealed splice connectors will not touch each other but arelocated 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 colorand part number. Refer to Table A-4.

3. Using a wire stripper, cut and strip a length of insulationoff the wire ends. Refer to Table A-4 for the strip length.

Table A-4. Sealed Splice Connectors

STRIPLENGTH

CONNECTORPART NO.

CONNECTORCOLOR

WIRE GAUGE

3/8 in. (9.5mm)

70585-93Red18-20(0.5-0.8 mm)

3/8 in. (9.5mm)

70586-93Blue14-16(1.0-2.0 mm)

3/8 in. (9.5mm)

70587-93Yellow10-12(3.0-5.0 mm)

NOTE

If any copper wire strands are cut off of the wire core, trim theend and strip the wire again in a larger gauge stripper.

Splicing Wire LeadsNOTE

See Figure A-49. The connector is crimped twice - one sideand then the other.

1. See Figure A-48. Open the PACKARD CRIMPINGTOOL (Part No. HD-38125-8) ratchet by squeezing thehandles closed.

2. Match the connector color to the wire gauge crimp die inthe jaws and insert one end of the sealed connector.

3. Gently squeeze the handles until the connector is held inthe jaws.

4. See Figure A-49. Feed the stripped end of a wire into theconnector until the wire stops inside the metal insert (1).

5. Squeeze the handles tightly closed to crimp the lead inthe insert (2). The tool automatically opens when thecrimping is complete.

6. Slide the connector to the other half of the metal insert.Insert the stripped wire lead (1) until it stops, and crimpthe lead in the insert (2).

Be sure to follow manufacturer's instructions when usingthe UltraTorch UT-100 or any other radiant heating device.Failure to follow manufacturer's instructions can cause afire, which could result in death or serious injury. (00335a)

• Avoid directing heat toward any fuel system component.Extreme heat can cause fuel ignition/explosion resultingin death or serious injury.

• Avoid directing heat toward any electrical system com-ponent other than the connectors on which heat shrinkwork is being performed.

• Always keep hands away from tool tip area and heat shrinkattachment.

7. Use an ULTRA-TORCH UT-100 (Part No. HD-39969), ora ROBINAIR HEAT GUN (Part No. HD-25070) with aHEAT SHIELD ATTACHMENT (Part No. HD-41183), toheat the connector from the center of the crimp (3) out toeach end.

NOTE

It is acceptable for the splice to rest against the heat shrinktool attachment.

Inspecting SealsSee Figure A-49. Allow the splice to cool and inspect the seal.The insulation should appear smooth and cylindrical. Meltedsealant will have extruded out the ends (4) of the insulation.


1

2

3

sm00050

1. Red connector die2. Blue connector die3. Yellow connector die

Figure A-48. Packard Crimping Tool (HD-38125-8)

1

1

4

2

2

4

3

sm00051

1. Wire lead in metal insert2. Crimp metal insert3. Center of crimp4. Melted sealant

Figure A-49. Sealed Splice Connector


SUBJECT............................................................................................................................PAGE NO.B.1 CONNECTORS........................................................................................................................B-1B.2 WIRING DIAGRAMS.................................................................................................................B-3

AP

PE

ND

IX B

WIR

ING

B.1CONNECTORS

CONNECTOR LOCATIONS

Function/LocationRefer to Table B-1. On the motorcycle, a connector can beidentified by its function and location.

Place and ColorThe place (number of wire cavities of a connector housing)and color of the connector can also aid identification.

Connector NumberOn wiring diagrams and in service/repair instructions, con-nectors are identified by a number in brackets.

Repair InstructionsThe repair instructions in this Service Manual are by connectortype. Refer to Table B-1.

Table B-1. Dyna Connector Locations

LocationTypeDescriptionConnectorNo.

Under Seat4-place DeutschAccessory connector[4]


Under seat8-place MultilockTail lamp harness to main harness[7]



Inside top frame tube12-place DeutschConsole gauges/indicator lamps (all exceptFXDWG, FXDC, FXDF)

[20]

Under fuel tank console8-place Mini-Deutsch(FXDWG, FXDC, FXDF)

Indicator lamps[21]

10-place Mini-Deutsch(FXDB)

Inside top frame tube6-place MolexRight Hand Controls[22]

Inside top frame tube8-place MolexLeft Hand Controls and Horn[24]


Inside top frame tube3-place MultilockFront Turn Signals (left)[31 L]

Inside top frame tube3-place MultilockFront Turn Signals (right)[31 R]

Inside top frame tube (FXD, FXDL)3-place DelphiIgnition Switch[33]Under fuel tank console (FXDWG, FXDC,FXDF)

Inside top frame tube4-place MultilockHeadlamp[38]


Back of voltage regulator3-place DeutschVoltage Regulator to Stator[47]

Under electrical caddie coverSpade terminalsFuse/Relay Block (Starter Relay, SystemRelay)

[62]

Under electrical caddie coverSpade terminalsFuse Block[64]


Back of voltage regulator2-place DeutschVoltage Regulator[77]


Inside front electrical caddie2-place Mini-DeutschCrankshaft Position (CKP) Sensor[79]

Top of induction module3-place DelphiManifold Absolute Pressure (MAP) Sensor[80]

Back of coil4-place DelphiIgnition Coil[83]

Beneath fuel tank2-place DelphiFront Injector[84]

Beneath fuel tank2-place DelphiRear Injector[85]


Behind air cleaner backing plate3-place DelphiThrottle Position (TP) Sensor[88]

Behind air cleaner backing plate2-place DeutschIntake Air Temperature (IAT) Sensor[89]

2008 Dyna Diagnostics: Appendix B Wiring B-1

Table B-1. Dyna Connector Locations

LocationTypeDescriptionConnectorNo.

Back of front cylinder, left side2-place DelphiEngine Temperature (ET) Sensor[90]

Under electrical caddie cover4-place DeutschData Link Connector[91]

Inside tail lamp lens4-place MultilockTail Lamp[93]

Inside tail lamp lens6-place MultilockTail Lamp Power In[94]

Back of tachometer12-place PackardTachometer[108]

Under fuel tank4-place MultilockFuel Gauge[117]

Oil pressure switch, front of right crank-case

Post terminalOil Pressure Switch[120]

Behind rear brake master cylinderSpade terminalsRear Stop Lamp Switch[121]

Between cylinders, left sideSpade terminalsHorn[122]

Top of starterSpade terminalStarter Solenoid[128]

Top of transmissionPost terminalsNeutral Switch[131]

Left side along frame, toward front ofengine

3-place MolexJiffy Stand Sensor (HDI)[133]

Under seat2-place AmpRear Oxygen Sensor (Domestic only)[137]

Inside front electrical caddie2-place AmpFront Oxygen Sensor (Domestic only)[138]

Top of fuel tank4-place DelphiFuel Pump and Sender[141]

Under seat3-place DelphiSecurity Siren (optional)[142]

Back of speedometer (FXD)-Trip Odometer Reset Switch[154]On console (FXDB, FXDL, FXDWG,FXDC, FXDF)

Under seat1-place PackardB+ Connector[160]

Air cleaner backing plate2-place AmpActive Intake Solenoid (HDI)[178]

Behind rear cylinder head5-place AmpActive Exhaust (HDI)[179]

Under electrical caddie cover4-place DeutschHFSM Antenna Harness[208]

Under seat2-place MolexHFSM Antenna[209]

Under seatRing terminalsHarness Grounds (3)[GND1][GND2][GND3]

B-2 2008 Dyna Diagnostics: Appendix B Wiring

B.2WIRING DIAGRAMS

WIRING DIAGRAM INFORMATION

Wire Color CodesWire traces on wiring diagrams are labeled with alpha codes.Refer to Table B-2.

For Solid Color Wires: See Figure B-1. The alpha codeidentifies wire color (3).

For Striped Wires: The code is written with a slash (/) betweenthe solid color code and the stripe code (4). For example, atrace labeled GN / Y is a green wire with a yellow stripe.

Wiring Diagram SymbolsSee Figure B-1. On wiring diagrams and in service/repairinstructions, connectors are identified by a number in brackets(1). The letter (2) inside the brackets identifies whether thehousing is a socket or pin housing.

A=Pin: The letter A after a connector number and the pinsymbol (6) identifies a pin housing.

B=Socket: The letter B after a connector number and thesocket symbol (5) identifies a socket housing.

Other symbols found on the wiring diagrams include the symbolfor a diode (7), a symbol for a wire-to-wire connection (8), asymbol that verifies that no connection (9) between two wiretraces exists and a symbol identifying two wires that are twistedtogether (10).

910

1 2

1 2

8

7

6

5

3 4

TN

TN

WW

GN

/YG

N/Y

1 2 4

1 2 4

[21A]

[21B]

ed01269

1. Connector number2. Terminal code (A=pin, B=socket)3. Solid wire color4. Striped wire color5. Socket symbol6. Pin symbol7. Diode8. Connection9. No connection10. Twisted pair

Figure B-1. Connector/Wiring Diagram Symbols (typical)

Table B-2. Wire Color Codes

WIRE COLORALPHA CODE

BlueBE

BlackBK

BrownBN

GreenGN

GreyGY

Light GreenLGN

OrangeO

PinkPK

RedR

TanTN

VioletV

WhiteW

YellowY

2008 Dyna Diagnostics: Appendix B Wiring B-3

2008 DYNA WIRING DIAGRAMS Refer to the table below for wiring diagram information.

Wiring Diagram ListLOCATIONDIAGRAM

Figure B-22008 ALL DYNA DOM. and INT. MODELS (Except FXDWG, FXDC, FXDF), MAIN HARNESS, SHEET 1OF 3

Figure B-32008 ALL DYNA DOM. and INT. MODELS (Except FXDWG, FXDC, FXDF), MAIN HARNESS, SHEET 2OF 3

Figure B-42008 ALL DYNA DOM. and INT. MODELS (Except FXDWG, FXDC, FXDF), MAIN HARNESS, SHEET 3 of3

Figure B-52008 ALL DYNA DOM. and INT. MODELS (Except FXDWG, FXDC, FXDF), CHARGING CIRCUIT

Figure B-62008 ALL DYNA DOM. and INT. MODELS (Except FXDWG, FXDC, FXDF), STARTING CIRCUIT

Figure B-72008 ALL DYNA DOM. and INT. MODELS (Except FXDWG, FXDC, FXDF), IGNITION CIRCUIT

Figure B-82008 ALL DYNA DOM. and INT. MODELS (Except FXDWG, FXDC, FXDF), LIGHTS, SHEET 1 OF 2

Figure B-92008 ALL DYNA DOM. and INT. MODELS (Except FXDWG, FXDC, FXDF), LIGHTS, SHEET 2 OF 2

Figure B-102008 ALL DYNA DOM. and INT. MODELS (Except FXDWG, FXDC, FXDF), HORN & INSTRUMENTSCIRCUIT

Figure B-112008 ALL DYNA DOM. and INT. MODELS (Except FXDWG, FXDC, FXDF), SECURITY, SHEET 1 OF 2

Figure B-122008 ALL DYNA DOM. and INT. MODELS (Except FXDWG, FXDC, FXDF), SECURITY, SHEET 2 OF 2

Figure B-132008 ALL FXDWG, FXDC, FXDF DYNA DOM. and INT. MODELS, MAIN HARNESS, SHEET 1 OF 3



Figure B-162008 ALL FXDWG, FXDC, FXDF DYNA DOM. and INT. MODELS, CHARGING CIRCUIT

Figure B-172008 ALL FXDWG, FXDC, FXDF DYNA DOM. and INT. MODELS, STARTING CIRCUIT

Figure B-182008 ALL FXDWG, FXDC, FXDF DYNA DOM. and INT. MODELS, IGNITION CIRCUIT

Figure B-192008 ALL FXDWG, FXDC, FXDF DYNA DOM. and INT. MODELS, LIGHTS, SHEET 1 OF 2

Figure B-202008 ALL FXDWG, FXDC, FXDF DYNA DOM. and INT. MODELS, LIGHTS, SHEET 2 OF 2

Figure B-212008 ALL FXDWG, FXDC, FXDF DYNA DOM. and INT. MODELS, HORN & INSTRUMENTS CIRCUIT

Figure B-222008 ALL FXDWG, FXDC, FXDF DYNA DOM. and INT. MODELS, SECURITY CIRCUIT, SHEET 1 OF 2

Figure B-232008 ALL FXDWG, FXDC, FXDF DYNA DOM. and INT. MODELS, SECURITY CIRCUIT, SHEET 2 OF 2

B-4 2008 Dyna Diagnostics: Appendix B Wiring

[22B]

IGN - 15A

INSTR - 15A

Lights - 15A

ACCY - 15A

[31RA]

[24B]

[91A](Gray)

DataLink

Connector

IgnitionSwitch

Toheadlamp

see sheet 3

[7A]

[33A] [33B]

[64B]

Tofrontturn

signalssee sheet 3

[38A]

To rearlightingharness

seesheet 3

[79A]

[79B]

Fuel Pump& SenderAssembly

see sheet 2

Intake AirTemp

Sensor

ThrottlePositionSensor Engine

TempSensor

FrontInjector

RearInjector

Idle AirControl

SystemRelay

Battery - 15A

Fuel Pump - 15A

ECM - 15A

Y/GN

R/BK

R/BK

R/BK

R

R

Turn

Sig

nal&

Sec

urity

Mod

ule

TS

M/T

SS

M/H

FS

M

Toleft handcontrols(gray)

see sheet 3

Toright handcontrols(black)

see sheet 3

SecuritySiren

To instrumentassembly

see sheet 3

A

G

I

P

M

A

G

B

H

J

R

O

B

H

StartRelay(Gray)

54321

GN/O

KTESU

BE/GY

GY

FuelGauge

seesheet 2

(Optional)

O

BE

BE

21

43

65

87

109

1211

21

43

65

87

109

1211

BA

CBA

C

VO

/WBN

[62B]

[87B]

[87A]

[88A]

[90A]

R/GY

VehicleSpeedSensor

BK/R

R/Y

R/BK

GN

StarterSolenoid

BK

BK

BK

[142B][142A]

[20A]

[65B]

[117B] [141B]

[84B] [85B]

[90B][88B]

[89D]

[89A]

[83B][83A]

[78B]

[30B]

Power

SignalGround

[30A]

[84A] [85A]

[128B]

IgnitionCoil

P & ABattery[160B]

R/BKP&A IGN - 15A C

[5]

40 AmpMAXIFUSE

A B

See chargingcircuit for furtherconnectionsto chargingsystem

[GND1]Rear ground stud under

electrical center

RearStop LampSwitch

[121]

1 2 3 4 5 6

1 2 3 4 5 6 7 8

A B

A B

1 432 5 6

CBA

CBA

ManifoldAbsolutePressureSensor

[80A]

[80B]

234

R BK

Crank Position Sensor

321 4

21

21

8787A308586

8787A308586

BA

BA

BA

BA

Battery

System relay


Serial dataEngine temperature

Intake air temperatureOxygen sensor (A)

Jiffy stand sensor (HDI)Ground

Coil rearCrank POS sensor (−)

Switched power5V sensor power

Idle air control (A) HiIdle air control (B) Low

Injector rearActive exhaust (HDI)

Injector frontActive intake solenoid (HDI)

Oxygen sensor (B)Throttle POS sensor input

Map sensor input5V sensor ground

Ion senseGround

Coil frontCrank POS sensor (+)

Battery

Vehicle speed sensor input

Idle air control (A) LowIdle air control (B) Hi

IgnitionSerial data

Neutral switchLeft turn feed

Right turn feedRight turn switch input

Left turn switch inputStart relay control

Clutch switchAlarm signal

Ground

1 2 4

A

B

C

D

A

B

C

D

PowerIon sense

Coil rear

Coil front

1 2

1 2

B A

B A

1

A B C D

A B C D

ECM

[78A]

1

4567891011121314

171819202122232425262728293031

33

3536

1

4567891011121314

171819202122232425262728293031

33

3536

ABC

A B C D

121 2 3 4 5 6 7 8 9 10

[131]

NeutralSwitch

[120]

[62] [64]

Oil PressureSending Unit

[31LA]

123321

A

B

C

[122]Horn

CustomerAccessoryConnector4

321

CUST ACCY - 15A U

Spare - 15A E

S

F

ENG CTL - 15ASeesheet 2 R/BK

O M

O/R

21

3

21 3

See sheet 2

21

[89B]

[89C]

21

IQCPR

54321

[4A]

7 8

See sheet 2See sheet 2

See sheet 2

See sheet 2

Seesheet 2

AB

[GND2]

B

A

LGN/R

D

1

See sheet 4 for handsfree security antenna

ACC − CBATT − B

IGN − A

GN/BN

BK/PKGN/GY

BE/GY

BE/GN

GYBE

LGN/V

GY/BEBK/GN

BK/GN

BK/GN

LGN/V

LGN/Y

V/BE

GN/O

W/BN

BK/R

PK/Y

PK/O

GY/O

BK/O

W/GN

BE/O

GY/V

Y/BE

W/BK

BK/W

W/GN

BN/R

Y/GN

Y/BE

BE/O

GY

TN

BN

BK

BK

W/V

R/W

V

BN/GY

BN/GY

LGN/BN

LGN/BN

TN/GN

LGN/V

V/W

R/W

V/OW/Y

R

PK/GN

BNBK

TN

TN

BK

BK

BK

BE

BE

BN

BK

BE

GY

GN

GN

BK

BK BK

BK

BE

GY

BK

BK

BK

BE

BK

BN

BK

GY

W/Y

Y/W

Y/W

Y/W

R/W

V/W

O/W

O/R

O/R

O/RR/Y

O/W

O/W

O/W

O/W

R/Y

O/W

W/V

R/Y

R/Y

R/W

O

R

OVW

V

R

R

RR

R

R

O

V

Y

Y

W

W

LGN

/V

BN

/GY

GN

/GY

BK

/GN

BK

/GN

BK

/GN

BN/GY

TN/GN

BE/GY

BE/GY

LGN/R

BK

/PK

BE

/GNLG

N/Y

GN

/Y

GN/Y

O/W

BK

/W

Y/G

N

Y/G

N

O/G

Y

Y/GN

R/BK

R/BK

R/BK

R/BK

R/BK

R/BK

R/GY

R/GY

R/GY

R/BK

BK/R

W/BK

Y/GN

O/GY

GN/O

Y/BK

Y/B

K

W/B

KW

/BN

BK

/R

BK

/R

GY

/V

BK

/WLG

N/Y

BK

/W

BK

/W

BN

/R

BK

/O

BK

/W

PK

/Y

BK/GN

BK/GN

BK

/GN

BK

/GN

Fuseblocks

Accessories Lights

Ignition

Instruments

Top ViewTop View

F E D C B A

L K J I H G

U S R P O M

B A

H G

O M

C

I

Q PR

E

K

T SU

Fuel Pump

Start RLY System RLY ECM P&A IGN

Battery

Spare

Spare

Eng CTL Cust ACCY

et01125

Figure B-2. 2008 ALL DYNA DOM. and INT. MODELS (Except FXDWG, FXDC, FXDF), MAIN HARNESS, SHEET 1 OF 3

Figure B-2.Figure B-2.2008 ALL DYNA DOM. and INT. MODELS (Except FXDWG, FXDC,

FXDF), MAIN HARNESS, SHEET 1 OF 32008 ALL DYNA DOM. and INT. MODELS (Except FXDWG, FXDC,

FXDF), MAIN HARNESS, SHEET 1 OF 3

S U

IGN - 15A

INSTR - 15A

Lights - 15A

ACCY - 15A

[33A] [33B]

[64B]

[62B]

Battery - 15A

Fuel Pump - 15A

ECM - 15AA

G

I

P

M

A

G

B

H

J

R

O

B

H

P & ABattery

[160B]

P&A IGN - 15A C [5]

40AMAXIFUSE

A B

1

Cust ACCY - 15A

ENG CTL - 15A MO

[138A]

[138B]21

21 [137A]

[137B]21

1 2

[178B]

[178A]

BK

BK

GY

/OLG

N/R

2

1 2 3

1 2 3

1

2 1

BK

BK

Rear O2Sensor

Front O2Sensor


Oxygen sensor (A)Jiffy stand sensor (HDI)

Ground

5V sensor power


Active intake solenoid (HDI)Oxygen sensor (B)

5V sensor ground

Ground

Battery

IgnitionSwitch ACC − C

BATT − BIGN − A A

BC

ECM

1

8910

14

20

2223

26

28

31

1

89

10

14

20

2223

26

28

31

Domestic only

HDI only

[78B][78A]

Active Intake Solenoid

4

4

3

3

2

2

1

1R W BK [179B]

[179A]

[133B]

[133A]

5

HDI only

Rear groundstud underelectrical

center

HDI only

D

Exhaust Actuator

[GND1]

Jiffy Stand Sensor

BE

GY

BK

BK

BK

BK

BK

O/R

O/W

V/O

R/W

R/W

V/O

R

R

R

R

R

O

R W

LGN/R

BN/GY

BE/GY

LGN

/RB

K/G

N

BK

/GN

BK

/GN

GN

/BN

LGN

/R

GN/BN

PK/GN

BE/GY

R/BK

R/BK

R/BK

R/BK

R/BK

R/GY

R/BK

R/GY

R/GY

Y/GNO/GY

V/B

E

GY

/O

V/BE

PK/O

GY/O

BK/W

BE

GY

/BK

BE

GY

/BK

PK

/GN

BK

/W

BK

/WP

K/O

BK/GN

BK/GN

[117A]

Pow

erS

igna

lG

roun

d

Fuel Gauge

421

Full: 39.5 / 27.51/2 : 118.0 / 97.0Empty: 260.0 / 240.0

A B C D

[86]

BK

BK

BK

Y/W

Y/W

O

O/G

Y

Fuel Pump & Sender In Tank [141A]

et01126

Figure B-3. 2008 ALL DYNA DOM. and INT. MODELS (Except FXDWG, FXDC, FXDF), MAIN HARNESS, SHEET 2 OF 3


FXDF), MAIN HARNESS, SHEET 2 OF 32008 ALL DYNA DOM. and INT. MODELS (Except FXDWG, FXDC,

FXDF), MAIN HARNESS, SHEET 2 OF 3

FrontRightTurn

[31R]

[31RB]Front

LeftTurn

RunningLamp(DOMonly)

[38B]

To mainharness[38A]

To mainharness[31L&R]

FXDL

Tomainharness

Tomainharness

Tomainharness

[7B]

[7A]RightRearTurn[31R]

LeftRearTurn[31L]

[18B]

[19B]

[93B]

[94B]

Front Lighting

Rear Lighting

Position Lamp(HDI only)

[29]

123

Headlamp

[38]

1234

[31L]

123456789101112


123456789

101112


Taillamp

12

123 1

234

123456

12

12

12

123456

1234

1234567

[39A] [39B]

[108A] [108B]

[39A] [39B]

[20A]

[20B]

[20A]

[31LB]

123

[93A]

[94A]

[18A]

[19A]

High

Low

RunningLight (HDI)

RunningLight (DOM)

Brake Light

FXD FXDB

Tomain

harness

123456789

101112


1 12 2

7 78 8

3456

910

3456

910

[21B] [21A]

[39A] [39B]

[20B]

[20A]

Speedometer

Tachometer

Serial data

Security LPBattery

AccessoryGround

Trip odometer reset switchFuel level


RPM x 100

IgnitionSerial data

BatteryAccessory

Ground

2

456789

11

2Ignition 1 1

456789

11

SpeedometerIgnition

Serial data

Security LPBattery

AccessoryGround



12

456789

11

12

456789

11

Speedometer

IgnitionSerial data

Security LPBattery 12V

AccessoryGround



12

456789

11

12

456789

11

12

567

12

567

Horn SwitchHeadlamp Hi/Lo SwitchLeft Turn Switch

[24A]

[163]

Left HandControls

1 2 3 4 5 6 7 8

Clutch Switch

123456

Right Turn SwitchEngine Stop SwitchStart Switch

Front Stop Lamp Switch

[22A]

[162]

Right HandControls

BN

TN

BK

BKBK

BK

BK

BK

BK

BK

BKBK

BK

BK

BK

BN

BN

TN

TN

BK

BK

BK

BK

BN

TN

BKO/W

Y/W

Y/W

O/W

O/W

O/W

O/W

O/W

OVW

WV O O

O

O

BN/GY

LGN/V

BN/GY

BN/GY

LGN/V

LGN/V

GN/Y

BN/V

GN

/Y

BN/V

Y/W

Y/WY/W

O

W

W

V

V

O

O

O O

BN/GY

BN/GY

BN/GY

LGN/V

LGN/VLGN/V

GN/Y

GN

/Y

BN/V

BN/V

BN/V

BK

BK

BK

BK

BK

BK

BK

BK

BKBK

BK

BK

BK

BN

BE

BK

BK

BEBE

BK

BKBK

BK

BK

BK

BK

BK

BK

BK

BK

BK

BK

BKBKBKBKBKBKBKBKBK

BN

BN

BN

TN

TN

O/W

Y/W

O

O

O

V

V

V

V

W

W

BN/GY

LGN/V

BN/V

GN/Y

GN/Y

R/Y

R/Y

O/W

BN

BN

BN

BE

BE

BE

BE

BE

BEBE

V

V

V

W

W

Y

Y

R/Y

R/Y

O/W

O/W

O/W

BE

GY

W/V

O/W

O/W

R/Y

WY

Y/B

K

W/B

KW

/BN

BK

/R

BK

/R

[20B]

et01127

Figure B-4. 2008 ALL DYNA DOM. and INT. MODELS (Except FXDWG, FXDC, FXDF), MAIN HARNESS, SHEET 3 of 3


FXDF), MAIN HARNESS, SHEET 3 of 32008 ALL DYNA DOM. and INT. MODELS (Except FXDWG, FXDC,

FXDF), MAIN HARNESS, SHEET 3 of 3

See sheet 1for further

connections

Starter solenoidconnection

Starter

Battery

A B

Red Band

[5B]

BK

BK

BK

BK

[47B]

[47A]

VoltageRegulator

Front groundstud under

electrical center

40AMAXIFUSE

[77B]

[GND3]

Stator

[77A]

[128A]

+ –

+ –

1 3

1 3

2

2

BK BK

BK

RR

R

et01131

Figure B-5. 2008 ALL DYNA DOM. and INT. MODELS (Except FXDWG, FXDC, FXDF), CHARGING CIRCUIT


FXDF), CHARGING CIRCUIT2008 ALL DYNA DOM. and INT. MODELS (Except FXDWG, FXDC,

FXDF), CHARGING CIRCUIT

[22B]

IGN - 15A

IgnitionSwitch

[33A] [33B]

[128]

Battery - 15A

ECM - 15AA

I

G

B

J

H

StartRelay(Gray)

21

43

109

12

21

43

109

12

[62B]

[78B]

[30B][30A]

[5]

40 AmpMAXIFUSE

A B

[GND1]Rear groundstud underelectrical

center

3 4 6

ACC − CBATT − B

IGN − A

BatteryIgnition

Serial dataNeutral switch

Start relay controlClutch switch

Ground

[78A]

5Serial data

Ground

Ground

Battery

Switched power

10

13

28

31

5

10

13

28

31

KTESU

8787A308586

54321

ECM

[24B] 7 8

7 8

Turn

Sig

nal&

Sec

urity

Mod

ule

TS

M/T

SS

M

[64B]

See security circuit for hands free security module

6 7 8 12[20A]

[24A]

[163]

Left HandControls

Clutch Switch

Engine Stop SwitchStart Switch

[22A]

[162]

Right HandControls

Starter

Battery

RedBand

3 4 6

[131]

NeutralSwitch

Toinstrumentassembly

AB

[GND2]

INSTR - 15AA B

ABC

BK

BK

GY

GY

TN

TN

BK

/GN

BK

BK

GN

BK

BK

/GN

BN/GY

BK/GN

BK/GN

BK/GN

BE/GY

LGN/V

LGN/V

TN/GN

BK

/R BK

/R

BK

/R

W/BK

W/B

KG

Y

BK

/R

W/B

K

R/BK

GN

GY

R

R

R

R R

O

TN/GN

BN/GY

BE/GY

R/BK

R/BK

R/BK

R/BK

R/BK

BK/R

TNO

LGN

/V

BK

/GN

et01132

Figure B-6. 2008 ALL DYNA DOM. and INT. MODELS (Except FXDWG, FXDC, FXDF), STARTING CIRCUIT


FXDF), STARTING CIRCUIT2008 ALL DYNA DOM. and INT. MODELS (Except FXDWG, FXDC,

FXDF), STARTING CIRCUIT

[22B]

IGN - 15A

DataLink

Connector

[91A]

(Gray)

IgnitionSwitch

[33A] [33B][79A]

[79B]

Fuel Pump& Sender Assy

ThrottlePositionSensor

EngineTempSensor

FrontInjector

RearInjector

Idle SpeedControl

SystemRelay

Battery - 15A

Fuel pump - 15A

ECM - 15A

Toright hand

controls

A

G

I

G

B

H

J

H

21

3

12

21

3

12

[62B]

[87B]

[87A]

[88A][90A]

[141B]

[84B] [85B]

[90B][88B]

[83B][83A]

[30B][30A]

[84A] [85A]

Ignition Coil

[5]

40 AmpMAXIFUSE

A B

[GND1]

[133B]

[133A]


center32

A B C

A B C


[80A][80B]

234

Crank PositionSensor

ACC − CBATT − B

IGN − A

21

21

A

A

B

B

A

A

B

B

BatteryIgnition

Serial data

Ground

ABCD

ABC

D

PowerIon sense

Coil rearCoil front

1 2

1 2

1 2

3

1 2 3 B A

B A

CBA D

CBA D

A CB D

ENG CTL - 15AO M

ABC

1

456789

1011121314

171819202122232425262728293031

3536

1

456789

1011121314

171819202122232425262728293031

3536

Intake AirTemp

Sensor

[89D]

[89A]

2121

[89B]

[89C]

54321

8787A308586

IQCPR

ECM

Turn Signal &Security Module

TSM/TSSM

[64B]

4

4

3

3

2

2

1

1[179B]

[179A] 5

Exhaust Actuator

HDI only

[138A]

[20A]

[138B]

1 21 2

1 2 1 2

[137A][137B]

FrontO2

Sensor

RearO2

Sensor

Domestic only

12

12

[178B]

[178A]

IntakeActuatorSolenoid

HDI only

[78B][78A]


2 7 12

1 2 3

1 2 3

HDIonly

Jiffy Stand Sensor


System relay

Engine temperatureIntake air temperature


GroundCoil rear

Crank POS sensor (-)Switched power

5V sensor power




Oxygen sensor (B)Throttle POS sensor input

MAP sensor input5V sensor ground

Ion senseGround

Coil frontCrank POS sensor (+)

Battery


Serial data

GY

BK

GY

R/W

V/O

V/W

R

LGN/Y

BK/PK

BK/GN

BK/GN

PK/GN

BE/GY

BE/GN

BK/GNLGN/V

LGN

/Y

GY/BE

GN/GY

GY/BE

LGN/V

LGN/V

BN/GY

BK/GN

GN/BN

Y/BE

GY/O

GY/V

Y/GN

Y/BE

BE/O

BE/O

V/BE

GN/O

PK/Y

PK/O

W/BK

W/Y

BK/O

BK/W

BN/R

GY

GY

BK

BE

BE

BK

BK

BK

R/W

V/W

V/O

R/W

R/W

W

RB

KR

R

R

R

R

R

LGN

/V

BN

/GY

PK

/GN

GY

/BK

GY

/BK

BK

/GN

BK

/GN

BK

/PK

BE

/GN

LGN

/R

LGN

/RB

K/G

N

BK

/GN

BK

/GN

GN

/BN

BE/GY

BN/GY

LGN/R

GN

/GY

BE/GY

V/B

E

Y/GN

Y/GN

GY

/V

BN

/R

BK

/W

BK

/W

BK

/W

BK

/W

BK

/O

GY

/O

BK

/W

GN/OW/BK

O/GY

R/BK

R/BK

R/BK

Y/G

N

Y/G

N

W/B

KBK

/WLG

N/Y

BK

/W

O/G

Y

PK

/O

PK

/Y

W/Y

et01133

Figure B-7. 2008 ALL DYNA DOM. and INT. MODELS (Except FXDWG, FXDC, FXDF), IGNITION CIRCUIT


FXDF), IGNITION CIRCUIT2008 ALL DYNA DOM. and INT. MODELS (Except FXDWG, FXDC,

FXDF), IGNITION CIRCUIT

IGN - 15A

INSTR - 15A

Lights - 15A

ACCY - 15A

[31RA]

IgnitionSwitch

Toheadlamp

see sheet 2

[7A]

[33A] [33B]

Tofrontturn

signalssee sheet 2

[38A] To rearlighting

see sheet 2

Battery - 15AI

P

O

A

G

J

R

M

B

H

21

3

65

87

12

21

3

65

87

12

[78B]

[30B][30A]

[5]

40 AmpMAXIFUSE

A B

GND1


centerRearStop LampSwitch

[121]

123321

BatteryIgnition

Serial data

Left turn feedRight turn feed

Right turn switch inputLeft turn switch input

Ground

[78A]

[31LA]ABC

5

28

5

10

Serial data

Ground

Ground 10

28

A B

ECM

[24B] 1 2 3 41 2 3 4

1 2 3 4 5 6 7 85

1 2 3 4 5

Turn

Sig

nal&

Sec

urity

Mod

ule

TS

M/T

SS

M[64B]

See security circuit forhands free security module

1235

Right Turn SwitchEngine Stop Switch


[22A]

[162]

Right HandControls

1235To instrumentassembly

see sheet 21 2 76 12

ACC − CBATT − B

IGN − A

[22B]


[24A]

[163]

Left HandControls

[62B]

Starter

Battery

RedBand

GND2

BE

GY

GY

BE

GY

BN

BK

BK

BK

BK

BK

BK

BK

BK

BK

O/W

R/Y

O/W

O/W

W/V

O/W

O/W

O/W

O/W

R/Y

R/Y

W/V

O

O

R

R

RR

W

W

Y

Y

V

V

BE B

E

BE

BE

BN

BN

W/V

O/W Y W

V

BN/GY

BN

/GY

BN/GY

LGN/V

LGN

/V

LGN/V

BK/GN

BK/GN

BK

/GN

BK

/GN

BK/GN

W/B

N

GY

O/W

R/Y

W/B

N

R/GY

R/GY

R/BK

R/BK

R/BK

R/BK

W/BN

A B

[20A]

et01128

Figure B-8. 2008 ALL DYNA DOM. and INT. MODELS (Except FXDWG, FXDC, FXDF), LIGHTS, SHEET 1 OF 2


FXDF), LIGHTS, SHEET 1 OF 22008 ALL DYNA DOM. and INT. MODELS (Except FXDWG, FXDC,

FXDF), LIGHTS, SHEET 1 OF 2

FrontRightTurn

[31R]

[31RB]Front

LeftTurn


[38B]

To mainharness[38A]


FXDL

Tomainharness

Tomainharness

Tomainharness

[7B]


LeftRearTurn[31L]

[18B]

[19B]

[93B]

[94B]

Front Lighting

Rear Lighting


[29]

123

Headlamp

[38]

1234

[31L]

1234567

101112


1234567

101112


Taillamp

12

123 1

234

123456

12

12

12

123456

1234

1234567

[39A] [39B]

[108A] [108B]

[39A] [39B]

[20A]

[20B]

[20A]

[31LB]

123

[93A]

[94A]

[18A]

[19A]

High

Low

RunningLight (HDI)

RunningLight (DOM)

Brake Light

FXD FXDB

Tomain

harness

1234567

101112


1 12345

910

345

910

[21B] [21A]

[39A] [39B]

[20B][20B]

[20A]

Speedometer

Tachometer

Serial data

Security LPBattery

AccessoryGround



RPM x 100

IgnitionSerial data

BatteryAccessory

Ground

2

456789

11

2

456789

11

SpeedometerIgnition

Serial data

Security LPBattery

AccessoryGround



12

456789

11

12

456789

11

Speedometer

IgnitionSerial data


AccessoryGround



12

456789

11

12

456789

11

12

567

12

567

BN

BK

BKBK

BK

BK

BK

BK

BK

BKBK

BK

BK

BK

BN

BN

BK

BK

BK

BK

BN

BKO/W

Y/W

Y/W

O/W

O/W

O/W

O/W

O/W

OVW

WV

O

BN/GY

LGN/V

BN/GY

BN/GY

LGN/V

LGN/V

BN/V

BN/V

Y/W

Y/WY/W

O

W

W

V

V

O

O

BN/GY

BN/GY

BN/GY

LGN/V

LGN/VLGN/V

BN/V

BN/V

BN/V

BK

BK

BK

BK

BK

BK

BK

BKBK

BK

BK

BK

BN

BE

BK

BK

BEBE

BK

BKBK

BK

BK

BK

BK

BK

BK

BK

BKBKBKBKBK

BN

BN

BN

O/W

Y/W

O

O

V

V

V

V

W

W

BN/GY

LGN/V

BN/V

R/Y

R/Y

O/W

BN

BN

BN

BE

BE

BE

BE

BE

BEBE

V

V

V

W

W

Y

Y

R/Y

R/Y

O/W

O/W

O/W

et01129

Figure B-9. 2008 ALL DYNA DOM. and INT. MODELS (Except FXDWG, FXDC, FXDF), LIGHTS, SHEET 2 OF 2


FXDF), LIGHTS, SHEET 2 OF 22008 ALL DYNA DOM. and INT. MODELS (Except FXDWG, FXDC,

FXDF), LIGHTS, SHEET 2 OF 2

INSTR - 15A

IgnitionSwitch

[33A] [33B]

A

ACCY - 15AP R

B

3

12

3

12

[78B]

[30B][30A]

[5]

40 AmpMAXIFUSE

A B

[GND1]Rear ground stud

under electrical center

ACC − CBATT − B

IGN − A

Serial data4 4Neutral switch

Ground

Serial data

Ground

Ground

[78A]

ABC

5

10

28

5

10

28

ECM

[24B]

1 6

TS

M/T

SS

M

[64B]


[117B] [141B]

Horn Switch

[24A]

[163]

Left HandControls

1 6

B C

[120]

Oil PressureSending Unit

[131]

NeutralSwitch

B A

Fuel Pump & Sender Assembly(In fuel tank)

[117A] [141A]

Fuel Gauge

421

421

Full: 39.5 / 27.51/2 : 118.0 / 97.0Empty: 260.0 / 240.0 A D

[86]

B C


[20A]

1 6 7 98 10 12

Starter

Battery

RedBand

[GND2]

Pow

erS

igna

lG

roun

d

FXDL

123456789101112


123456789

101112


[39A] [39B]

[108A] [108B]

[39A] [39B]

[20B]

[20B]

FXD

FXDB

123456789

101112


1 12 2

7 78 8

3456

910

3456

910

[21B] [21A]

[39A] [39B]

[20B]

Speedometer

Tachometer

Serial data

Security LPBattery

AccessoryGround



RPM x 100

IgnitionSerial data

BatteryAccessory

Ground

2

456789

11

2Ignition 1 1

456789

11

SpeedometerIgnition

Serial data

Security LPBattery

AccessoryGround



12

456789

11

12

456789

11

SpeedometerIgnition

Serial data

Security LPBattery

AccessoryGround



12

456789

11

12

456789

11

12

567

12

567

BN

TN

BK

BKBK

BK

BK

BK

BK

BK

BKBK

BK

BK

BK

BN

TN

TN

BK

BK

BK

BK

BN

TN

BKO/W

Y/W

Y/W

O/W

O/W

O/W

O/W

O/W

OVW

WV O O

O

O

BN/GY

LGN/V

BN/GY

BN/GY

LGN/V

LGN/V

GN/Y

BN/VG

N/Y

BN/V

Y/W

Y/W

Y/W

O

BNW

W

V

V

O

O

O O

BN/GY

BN/GY

BN/GY

LGN/V

LGN/V

LGN/V

GN/Y

GN

/Y

BN/V

BN/V

BN/V

BK

BK

BKBK

BK

BK

BK

BK

BK

BK

BK

BK

BK

BK

BK

BK

BK

BK

BK

BK

BK

BK

BK

BKBK

BKBKBKBKBKBKBKBK

BN

BN

TN

TN

O/W

Y/W

O

O

O

V

V

W

W

BN/GY

LGN/V

BN/V

Y/W

Y/W

O/W

Y/W

Y/W

GN/Y

O/G

Y

GN/Y

[122]Horn

B

A

TN

TN

TN

O/W

O/W

O/W

R

R R

R

O

O

O

Y/WO

BK

/GN

BK

/GN

BK

/GN

BK/GN

BK/GN

BK

/GNBK/GN

LGN

/V

LGN/V

LGN/V

Y/B

K

Y/BK

R/GY

R/GY

R/BK

R/BK

Y/B

K

GN

/Y

GN

/Y

et01130

Figure B-10. 2008 ALL DYNA DOM. and INT. MODELS (Except FXDWG, FXDC, FXDF), HORN & INSTRUMENTS CIRCUIT


FXDF), HORN & INSTRUMENTS CIRCUIT2008 ALL DYNA DOM. and INT. MODELS (Except FXDWG, FXDC,

FXDF), HORN & INSTRUMENTS CIRCUIT

NeutralSwitch

AB

IGN - 15A

ACCY - 15A

[31RA]IgnitionSwitch

[7A]

[33A] [33B]

Tofrontturn

signalssee sheet 2

To rearlighting

see sheet 2

Battery - 15A

ECM - 15A

SecuritySiren

(Optional)

A

I

P

G

B

J

R

H

StartRelay

BA

CBA

C

[62B]

[142B]

[142A]

[78B]

[30B]

PowerSignal

Ground

[5]40 AMP

MAXIFUSE

A B


1221

1 3 8

ACC −BATT −

IGN −

[78A]

[31LA]ABC

45

10

13

28

31

45

10

13

28

31

KTESU

8787A308586

54321

ECM

[24B] 1 5 7 8

1 5 7 8

[64B]

Horn Switch

Left Turn Switch

[24A]

Left HandControls[163]

Clutch Switch

13456


[22A]

Right HandControls[162]

13456

FuseblockTop viewTop view

[64][62]

Accessories Lights

IgnitionCB F

L

U S

K

E D C

IJ

R P O M

GH

B A

H

O

G

M

A

I

Q PR

E

K

T SU

Fuel pump

Start RLY System RLY ECM

Battery

Spare P&A IGN Instruments

Spare

ENG CTL CUST ACCY

ABC

SystemRelay

[22B]

INSTR - 15AA B

[20A] 6 7 82 3 51 12

54321

8787A308586

IQCPR

Starter

[128]

Battery

Redband

21

43

65

87

109

1211

[30A]

BatteryIgnition

Serial dataNeutral switchLeft turn feed




Ground

21

3

21

43

65

87

109

1211

21

3

Receive antennaTransmit antenna ATransmit antenna B

21

21 Antenna ’A’

Antenna ’B’

Hands Free Antenna[209B] [209A]

[208A] [208B]

[131]

Turn Signal &SecurityModule

TSM/HFSM

[GND2]

System relaySerial data

Ground

Ground

Switched power

Battery

GY

BK

BK

GN

BKG

Y

BK

BN

GN

BN

BK

BK

BK

BK

GY

TN

BN

BK

BK

O/W

O/W

W/V

W/V

O/Y

O/Y

R

R

R

O

V

R

R

V

V

BN/GY

BE/GY

BE/GY

TN/GN

LGN/BN

BN/GY

BN/GY

BK/GN

BK/GN

BK/GN

BK

/GN

BK

/GN

BE/GY

TN/GN

LGN/V

LGN/V

LGN/BN

W/BKGN/O

R/BK

R/BK

BK/R

R/BK

R/BK

R/GY

R/GY

BK

/R

O/W

W/V

BK

/R

W/BK

GN/O

BK/R

W/BN

Y/BK

BKTN

TN

BN

O/W

O/W

OV

LGN

/V

BK

/GN

BN

/GY

W/B

KW

/BN

BK

/R

GY

O/W

W/B

KW

/BN

BK

/R


see sheet 2

et01134

Figure B-11. 2008 ALL DYNA DOM. and INT. MODELS (Except FXDWG, FXDC, FXDF), SECURITY, SHEET 1 OF 2


FXDF), SECURITY, SHEET 1 OF 22008 ALL DYNA DOM. and INT. MODELS (Except FXDWG, FXDC,

FXDF), SECURITY, SHEET 1 OF 2

FrontRightTurn

[31R]

[31RB]Front

LeftTurn


[38B]

To mainharness[38A]


FXDL

Tomainharness

Tomainharness

Tomainharness

[7B]


LeftRearTurn[31L]

[18B]

[19B]

[93B]

[94B]

Front Lighting

Rear Lighting


[29]

123

Headlamp

[38]

1234

[31L]

123

5678

101112


123

5678

101112


Taillamp

12

123 1

234

123456

12

12

12

123456

1234

1234567

[39A] [39B]

[108A] [108B]

[39A] [39B]

[20B]

[20A]

[20B]

[20A]

[31LB]

123

[93A]

[94A]

[18A]

[19A]

High

Low

RunningLight (HDI)

RunningLight (DOM)

Brake Light

FXD FXDB

Tomain

harness

123

5678

101112


1 1

7 7

456

10

456

10

[21B] [21A]

[39A] [39B]

[20B]

[20A]

Speedometer

Tachometer

Serial data

Security LPBattery

AccessoryGround



RPM x 100

IgnitionSerial data

BatteryAccessory

Ground

2

456789

11

2Ignition 1 1

456789

11

SpeedometerIgnition

Serial data

Security LPBattery

AccessoryGround



12

456789

11

12

456789

11

Speedometer

IgnitionSerial data


AccessoryGround



12

456789

11

12

456789

11

12

567

12

567

BN

TN

BK

BKBK

BK

BK

BK

BK

BK

BKBK

BK

BK

BN

BN

TN

TN

BK

BK

BK

BN

TN

BKO/W

Y/W

Y/W

O/W

O/W

O/W

O/W

O/W

OV

V O

O

O

BN/GY

LGN/V

BN/GY

BN/GY

LGN/V

LGN/V

BN/V

BN/V

Y/W

Y/WY/W

O

V

V

O

O

O

BN/GY

BN/GY

BN/GY

LGN/V

LGN/VLGN/V

BN/V

BN/V

BN/V

BK

BK

BK

BK

BK

BK

BK

BKBK

BK

BK

BK

BN

BE

BK

BK

BEBE

BK

BKB

KB

K

BK

BK

BK

BK

BKBKBKBK

BK

BN

BN

BN

TN

TN

O/W

Y/W

O

O

V

V

V

V

BN/GY

LGN/V

BN/V

R/Y

R/Y

O/W

BN

BN

BN

BE

BE

BE

BE

BE

BEBE

V

V

V

W

W

Y

Y

R/Y

R/Y

O/W

O/W

O/W

et01135

Figure B-12. 2008 ALL DYNA DOM. and INT. MODELS (Except FXDWG, FXDC, FXDF), SECURITY, SHEET 2 OF 2


FXDF), SECURITY, SHEET 2 OF 22008 ALL DYNA DOM. and INT. MODELS (Except FXDWG, FXDC,

FXDF), SECURITY, SHEET 2 OF 2

[22B]

IGN - 15A

INSTR - 15A

Lights - 15A

ACCY - 15A

[31RA]

DataLink

Connector

[91A]

(GY)

IgnitionSwitch

Toheadlamp

see sheet 3

[7A]

[33A] [33B]

To FrontTurnSignal

see sheet 3

[38A]

To rearlightingharness

see sheet 3

[79A]

[79B]

Fuel Pump &SenderASSY

see sheet 2


EngineTemp

Sensor

FrontInjector

RearInjector

Idle SpeedControl

SystemRelay

Battery - 15A

Fuel pump - 15A

ECM - 15A

[21A]

Toindicators

see sheet 3

Toright handcontrols

see sheet 3

SecuritySiren

(Optional)

Speedometersee sheet 3

A

G

I

P

O

A

G

B

H

J

R

M

B

H

StartRelay(GY)

FuelGauge

seesheet 2

21

43

65

87

109

1211

21

43

65

87

109

1211

BA

CBA

C

[62B]

[87B]

[87A]

[88A][90A]

VehicleSpeedSensor

Start Solenoid

[142B]

[142A]

[39B]

[154A]

[65B]

[117B] [141B]

[84B] [85B]

[90B][88B][83B][83A]

[78B]

[30B]

PowerSignal

Ground

[30A]

[84A] [85A]

[128B]

IgnitionCoil

P & ABattery[160B]

P&A IGN - 15A C

[5]40 Amp

MAXIFUSE

A B

See chargingcircuit for further

connectionsto charging

system

[GND1] [GND2]Rear Ground

Stud

RearStop Lamp

Switch[121]

123321

1

1 2 3 4 5 6 7 8

432 5 6

C

A B

A B

C


[80A]

[80B]

21

34

Crank Position Sensor

ACC − ABATT − B

IGN − I

4321

21

21

BA

BA

BA

BA

BatteryIgnition

Serial dataNeutral switchLeft turn feed




Ground

AB

C

D

A

B

C

D

Power

Ion sense

Coil rear

Coil front

21 3

21 3 B A

B A

1

A B C D

A B C D

[78A]

1 2 5 6 7 8 9 11Trip OdometerReset Switch

ABC

1A B1 2 4 C D

[31LA]

CustomerAccessoryConnector4

321

CUST ACCY - 15A

ENG CTL - 15AOSeesheet 2

M

ABC

1

4567891011121314

171819202122232425262728293031

33

3536

1

4567891011121314

171819202122232425262728293031

33

3536

Intake AirTemp

Sensor

[89D]

[89A]

2121

21

21

[89B]

[89C]

A B

A B

[4A]

54321

KTE

SU

8787A308586

8787A30

8586

IQCPR

543

21

ECM

[24B]

Toleft handcontrols

see sheet 3

1 2 3 4 5 6 7 8

Seesheet 2

See sheet 2

Turn signal &security module

TSM/TSSM

[64B]

D

S U

F E

See security circuit forhands free securty module

See sheet 2

Seesheet 2

[122]Horn

B

A

underelectrical

center

FuseblocksTop ViewTop View

[64][62]

Accessories Lights

IgnitionCB F

L

U S

K

E D C

IJ

R P O M

GH

B A

H

O

G

M

A

I

Q PR

E

K

T SU

Fuel Pump

Start Rly System Rly ECM

Battery


Spare

Eng Ctl Cust Accy

System relay


Serial dataEngine temperature

Intake air temperatureOxygen sensor (A)

Jiffy stand sensor (HDI)Ground

Coil rearCrank pos sensor (−)

Switched power5V sensor power

Idle air control (A) HIIdle air control (B) LOW



Oxygen sensor (B)Throttle pos sensor input

MAP sensor input5V sensor ground

Ion senseGround

Coil frontCrank pos sensor (+)

Battery

Vehicle speed sensor input

Idle air control (A) LOWIdle air control (B) HI

Spare - 15ABK

BK

BK

BK

BK

BK

LGN/V

W/BN

BK/R

GY

TN

BN

BK

W/V

V

BN/GY

BN/GY

LGN/BN

LGN/BN

TN/GN

LGN/V

BK/GN

GN/BN

BK/PKGN/GY

BE/GY

BE/GN

GY/BEBK/GN

LGN/V

LGN/Y

V/BE

GN/O

PK/Y

PK/O

GY/O

BK/O

W/GN

BE/O

GY/V

Y/BE

W/BK

BK/W

BN/R

BK

R/W

V/W

V/OW/Y

R

PK/GN

BK/GN

GY/BE

LGN/V

BK/GN

BK/GN

W/GN

Y/GN

Y/BE

BE/O

R/W

GY

BE GY

BK

BK

BK

BE

BK

BN

BN

TN

BK

O/W O/W

O/W

O/R

O/W

O/W

R/Y

O/W

W/V R/Y

R/Y

R/W

V

V

O

V

R

R

R

R

R

R

O

Y

Y

W

W

W

BK

/PK

BE

/GN

LGN

/Y

Y/B

K

W/B

KW

/BN

BK

/R

R/B

K

GY

/V

BK

/WLG

N/Y

BK

/W

BK

/W

BN

/R

BK

/O

BK

/W

PK

/Y

BK

/GN

BK

/GN

BK

/GN

GN

BE

BE

BE

BE

BN

BN

GY

GN

BK

BK

O/R

O/RR/Y

TN/GN

BE/GY

BE/GY

BN/GY

LGN/R

R/BK

BK/R

W/BK

Y/GN

Y/GN

GN/O

O/GY

R/BK

R/BK

R/BK

R/BK

R/BK

R/BK

R/GY

R/GY

R/GY

Y/BK

BK

BK

BK

BK

BK

BK

W/Y

Y/W

Y/W

Y/W

R/W

V/W

O

RB

KR

OLG

N/V

BN

/GY

GN

/GY

BK

/GN

BK

/GNB

K/G

N

O/W

BK

/W

Y/G

N

Y/G

N

O/G

Y

et01136

Figure B-13. 2008 ALL FXDWG, FXDC, FXDF DYNA DOM. and INT. MODELS, MAIN HARNESS, SHEET 1 OF 3

Figure B-13.Figure B-13.2008 ALL FXDWG, FXDC, FXDF DYNA DOM. and INT. MODELS,

MAIN HARNESS, SHEET 1 OF 32008 ALL FXDWG, FXDC, FXDF DYNA DOM. and INT. MODELS,

MAIN HARNESS, SHEET 1 OF 3

[33A] [33B]

ECM - 15AA B

A B

ENG CTL - 15A MO

[138A]

[138B]

[137A]

[137B]

[178B]

[178A]2 1

2 1

RearO2Sensor(DOM only)

FrontO2

Sensor(DOM only)

IgnitionSwitch

ACC − ABATT − B

IGN − I ABC

ECM

1Active exhaust feedback (HDI)


Ground

5V sensor power


Active intake solenoid (HDI)Oxygen sensor (B)

5V sensor ground

Ground

Battery

89

10

14

20

2223

26

28

31

1

89

10

14

20

2223

26

28

31

Domestic Only

HDI only

[78B][78A]

Active Intake Solenoid

4

4

3

3

2

2

1

1[179B]

[179A]

[133B]

[133A]

5

Exhaust Actuator

HDI only

[62B]

[5]

40 AMPMAXIFUSE

1 2

1 21 2

1 2


center

1 2 3

1 2 3

HDI only

Jiffy Stand Sensor

[117A]

Pow

erS

igna

lG

roun

d

Fuel Gauge

421

Full: 39.5 / 27.51/2 : 118.0 / 97.0Empty: 260.0 / 240.0

A B C D

[86]

BK

BK

BK

Y/W

Y/W

O

O/G

Y

Fuel Pump & Sender In Tank [141A]

BK

BK

BK

BE

V/O

R/W

R/W

V/O

R

R

R

R W

BE/GY

LGN/R

GN

/BN

LGN

/R

GY

/BK

GN/BNBK/GN

BK/GN

BK

/GN

BK

/GN

BK

/GN

BE/GY

LGN

/R

PK/GN

BE

GY

/BK

PK

/GN

R/BK

R/BK

V/B

E

BK

/WP

K/O

PK/O

BK/W

GY/O

GY

/O

V/BE

BK

/W

et01137


B A

(From sheet 1)

[94B]

[7B]

Rear Lighting HarnessFXDWG/FXDF

1234567

123456

Left RearDirectionalLamp

Taillamp

Right RearDirectionalLamp

Rear Lighting

[94B]

[7B]

1234567

1

23456

TailHDI only


To rear lighting harness[94B]

BrakeLight

[18A]

[18B]

[19B]

[19A]

TailDOM only

[93A] [93B]

[94A]

12

123 1

234

123456

12

1

2

12

4321


Rear LightingFXDWG/FXDF

Rear Lighting HarnessFXDC

[21A]

[21B]

[131]

NeutralSwitch

[120]

OilPressureSendingUnit

7

[GND2]

Taillamp

[94B]

[45A]

[18A]

[19A]

[93A]

[94A]

12

123

123456

12

1

2

1

2

4321

4321

7

6

6

5

5

4

4

3

3

2

2

1

1

TailHDI only

To rear lighting harness BrakeLight

[19B]

[18B]

TailDOM only

[93B]

FXDC

FrontRightTurn

[31R]

[31RB]Front

LeftTurn

DOM only

[38B]

To mainharness[38A]


Front Lighting


[29]

123

Headlamp

[38]

1234

[31L]

[31LB]

123

High

Low


[24A]

[163]

Left HandControls

Clutch Switch

123456

87654321



[22A]

[162]

Right HandControls

BK

BK

BK

BK

BKBK

BK

BK

BN

BN

BE

BE

BE

BE

V

V

W

W

Y

Y O/W

O/W

BE

GY

W/V

O/W

O/W

R/Y

WY

Y/B

K

W/B

KW

/BN

R/B

K

BK

/R

BEBE

BK

BK

BK

BK

BKR/Y

V/BN

V/BN

V/BN

V/BN

BNBK

BE

O/W

R/Y

V

BN

BK

BK

BK

BK

BK

BK

TN

BN

BE

O/W

R/Y V

BN

BK

BE

O/W

R/YV

BN

BK

BE

O/W

R/Y V

O

OO

WV

GN

/Y

TN

TN

BN

OWV GN

/Y

BK

BK

BK

BK

BE

R/Y

V/BN

V/BN

V/BN

BK

V/BN

BE

[39A]

Sec

urity

LP

1 2 4 5 6 7 8 9 11

Igni

tion

Ser

ial d

ata

Bat

tery

Acc

esso

ryG

roun

dTr

ipod

omet

erre

set s

witc

h

Trip

odom

eter

rese

t sw

itch

Fue

l lev

el

Speedometer

BK

/GN

et01138


See sheet 1for further

connections

Starter solenoidconnection

Starter

Battery

A B

Red Band

[5B]

BK

BK

BK

BK

[47B]

[47A]

VoltageRegulator

Front groundstud under

electrical center

40AMAXIFUSE

[77B]

[GND3]

Stator

[77A]

[128A]

+ –

+ –

1 3

1 3

2

2

BK BK

BK

RR

R

et01131

Figure B-16. 2008 ALL FXDWG, FXDC, FXDF DYNA DOM. and INT. MODELS, CHARGING CIRCUIT


CHARGING CIRCUIT2008 ALL FXDWG, FXDC, FXDF DYNA DOM. and INT. MODELS,

CHARGING CIRCUIT

[22B]

IGN - 15A

IgnitionSwitch

[33A] [33B]

Battery - 15A

ECM - 15A

Speedometer

A

I

G

B

J

H

StartRelay(Gray)

21

43

109

12

21

43

109

12

[62B]

[64B]

[39B]

[78B]

[30B][30A]

[5]

40 AmpMAXIFUSE

A B


center

3 4 6

3 4 6

ACC − ABATT − B

IGN − I

BatteryIgnition

Serial dataNeutral switch

Start relay controlClutch switch

Ground

2 7

[78A]

ABC

5Serial data

Ground

Switched power

Ground

Battery

10

13

28

31

5

10

13

28

31

KTESU

8787A308586

54321

ECM

[24B] 7 8

7654321 8


TSM/TSSM


Horn Switch

Headlamp Hi/Lo Switch

Left Turn Switch

[24A]

[163]

Left HandControls

Clutch Switch

Engine Stop Switch

Start Switch

[22A]

[162]

Right HandControls [128A]

Starter

Battery

RedBand

[131]

NeutralSwitch

AB

[GND2]

[21B]

INSTR - 15AA B

[21A] 5 6

5 6

GY

TN

TN

TN

BK

BN/GY

BK/GN

BK

/GN

BK/GN

BK/GN

BK

/GN

BK

/GN

LGN/V

LGN

/V

LGN/V

BE/GY

TN/GNBK/R

W/BK

BK

GN

BK

BK

GN

GY

R

R

R R

O

O

OT

N O

BN/GY

BE/GY

TN/GN

R/BK

R/BK

R/BK

R/BK

R/B

K

R/B

KR

/BK

R/BK

BK

BE

GY

W/V

O/W YY

Y/B

K

W/B

K

R/B

K

GY

W/B

K

et01143

Figure B-17. 2008 ALL FXDWG, FXDC, FXDF DYNA DOM. and INT. MODELS, STARTING CIRCUIT


STARTING CIRCUIT2008 ALL FXDWG, FXDC, FXDF DYNA DOM. and INT. MODELS,

STARTING CIRCUIT

[22B]

IGN 15A

DataLink

Connector(Gray)

[91A]

IgnitionSwitch

[33A] [33B]

[64B]

[79A]

[79B]

Fuel Pump &Sender Assy


EngineTemp

Sensor

FrontInjector

RearInjector

Idle SpeedControl

SystemRelay

Battery 15A

Fuel Pump 15A

ECM 15A

Toright handcontrols

Speedometer

A

G

I

G

B

H

J

H

21

3

12

21

3

12

[62B]

[87B]

[178B]

[178A]

[87A]

[88A] [90A]

[39B]

[141B]

[84B] [85B]

[90B][88B]

[83B][83A]

[30B][30A]

[84A] [85A]

Ignition Coil

[5]40 Amp

MAXIFUSE

BA

GND1Rear groundstud underelectrical

center3 4


[80A]

[80B]

21

34

Crank PositionSensor

ACC −ABATT − B

IGN − I

21

21

BA

BAB CA

B CA

BA

BA

BatteryIgnition

Serial data

Ground


System relaySerial data

Engine temperatureIntake air temperature


GroundCoil rear

Crank pos sensor (−)Switched power5V sensor power




Oxygen sensor (B)Throttle pos sensor input

Map sensor input5V sensor ground

Ion senseGround

Coil front outputCrank pos sensor (+)

Battery


ABCD

ABC

D

PowerIon sense

Coil rearCoil front

21 3

21 3 B A

B A

CBA D

CBA D

2 5 7

A B C D

ENG CTL 15AO M

ABC

1

456789

1011121314

171819202122232425262728293031

3536

1

456789

1011121314

171819202122232425262728293031

3536

Intake AirTemp

Sensor

[89D]

[89A]1

1

2

2

2121

[89B]

[89C]

54321

8787A308586

IQCPR

ECM

Turn Signal & Security Module

TSM/TSSM

4

4

3

3

2

2

1

1[179B]

[179A]

[133B]

[133A]

5

Exhaust ActuatorHDI Only

IntakeActuatorSolenoid HDI Only

21

21

[138A]

[138B]

21

21

[137A]

[137B]

FrontO2

Sensor

RearO2

Sensor

Domestic Only

[78B][78A]

1 2 3

1 2 3

HDIOnly

Jiffy Stand Sensor

2 1

2 1

GY

GY

BK

GYB

E

BE

BK

GY

BK

BK

BK

V/W

R/W

W/Y

R/W

V/O

V/W

W/Y

R/W

R/W

V/O

RB

KR

R

R

R

R

R

BN/GY

LGN

/V

BN

/GY

GY

/BK

PK

/GN

GY

/BK

GN

/GY

GN/BN

BK/GN

BK/GN

GN/GY

BK/GN

BK

/GN

LGN

/R BK

/GN B

K/G

N

BK

/GN

BK/GN

BK

/GN

BK/PK

PK/GN

BK

/PK

GY/BE

BE/GY

BE/GN

GY/BEB

E/G

N

LGN

/R

LGN/R

BE/GY

BE/GY

BN/GY

GN

/BN

LGN/Y

LGN

/Y

LGN/V

LGN

/V

LGN/V

LGN/V

BK

/W

BK

/W

BK

/W

O/G

Y

W/BK

BK/O

BE/O

W/B

K

GY/V

GY

/V

BK/W

BK

/WLG

N/Y

BK

/W

BK

/W

BK

/W

GY/O

GY

/O

Y/BE

BN/R

Y/GN

BE/OY/BE

BN

/R

PK/O

PK

/O

PK/Y

PK

/Y BK

/O

V/BE

V/B

E

GN/O

Y/GN

Y/G

N

Y/G

N

Y/GN

R/BK

R/BK

R/BK

O/GY

W/BK

GN/O

R W

et01144

Figure B-18. 2008 ALL FXDWG, FXDC, FXDF DYNA DOM. and INT. MODELS, IGNITION CIRCUIT


IGNITION CIRCUIT2008 ALL FXDWG, FXDC, FXDF DYNA DOM. and INT. MODELS,

IGNITION CIRCUIT

IGN - 15A

INSTR - 15A

Lights - 15A

ACCY - 15A

[31RA]IgnitionSwitch

Toheadlamp

see sheet 2

[7A]

[33A] [33B]

Tofrontturn

signalssee sheet 2

[38A]To

rearlighting

see sheet 2

Battery - 15ABN/GY

R/BK

R/BK

R/BK

RI

P

O

A

G

J

R

M

B

HGY

GY

LGN/V

LGN/V

O

BE

BE

BE BE

BE

O/W

O/W

O/W

21

3

65

87

12

21

3

65

87

12

V

VO

/W

V BN

BN

BN

W/BNW/V

W/B

N

W/V

BK

O/W

YWO/W

BK

R/BK

R/GY

R/GY

W

R

R

Y

R/Y

R/Y

R/Y

O/W

BKBK

BKBKBK

BK

[39B]

[78B]

[30B][30A]

O

BN/G

Y

LGN/

V

[5]

40 AmpMAXIFUSE

A B

[GND1] [GND2]


centerRearStop LampSwitch

[121]

123321

ACC − ABATT − B

IGN − I

43211 2 3 4 5 6 7 8

Battery 12VBattery 12V IGN

Serial data

Left turn feed outputRight turn feed outputRight turn switch input

Left turn switch input

Chassis ground

Serial data

Ground

[78A]

[31LA]ABC

5

28

5

28

Ground 10 10

A B

A B

ECM

[24B] 1 2 3 4 5

1 2 3 4 5


TSM/TSSM

[64B]

See security circuit forhands free securty module

1235

O/W

R/YGY

W/B

N

Right Turn Switch

Engine Stop Switch

Front Stop Lamp Switch[22B]

[162]

Right HandControls

1235

Speedometer

[39A]1 7

Igni

tion

Ser

ial d

ata

Bat

tery

Acc

esso

ryG

roun

d

2 5 6

1 72 5 6

R

[22A]

Headlamp Hi/Lo Switch

Left Turn Switch

[24A]

[163]

Left HandControls

O/W Y BE W W/V

[62B]

Starter

Battery

RedBand

BN

BN

BK

BK

WV

[21A]

[21B]

1 2 4 7

1 2 4 7

WV

BK

BNWV

BNWV

BK

BE

BE

BN

BK

BK

BK

BK

GY

O/W

O/W

R/Y

O

V

LGN

/V

BN

/GY

BK

/GN

BK

/GN

W/B

N

GY

O/W

R/YW/B

N

BE

GY

O/W

R

R

R R

O

BN/GY

R/BK

R/BK

R/BK

R/BK

R/GY

R/GY

GY

BN

BK

BN

BK

BK

BK

BE

BE

W/VW/BN

R/Y

R/Y

O/W

O/W

O/W

W/V

W/V

O/W

V

VW

W

Y

YB

E

O/W WY

LGN/V

BN/GY

BK/GN

BK/GN

BK/GN

LGN/V

BK

/GN

et01139

Figure B-19. 2008 ALL FXDWG, FXDC, FXDF DYNA DOM. and INT. MODELS, LIGHTS, SHEET 1 OF 2


LIGHTS, SHEET 1 OF 22008 ALL FXDWG, FXDC, FXDF DYNA DOM. and INT. MODELS,

LIGHTS, SHEET 1 OF 2

[94B]

[7B]


1234567

123456


Taillamp


Rear Lighting

[94B]

[7B]

1234567

1

23456

TailHDI only



BrakeLight

[18A]

[18B]

[19B]

[19A]

TailDOM only

[93A] [93B]

[94A]

12

123 1

234

123456

12

1

2

12

4321




Taillamp

[94B]

[45A]

[18A]

[19A]

[93A]

[94A]

12

123

123456

12

1

2

1

2

4321

4321

TailHDI only


[19B]

[18B]

TailDOM only

[93B]

FXDC

FrontRightTurn

[31R]

[31RB]Front

LeftTurn

DOM only

[38B]

To mainharness[38A]


Front Lighting


[29]

123

Headlamp

[38]

1234

[31L]

[31LB]

123

High

Low

BK

BK

BK

BKBK

BK

BK

BN

BN

BE

BE

BE

BE

V

V

W

W

Y

Y O/W

O/W

BEBE

BK

BK

BK

BK

BKR/Y

V/BN

V/BN

V/BN

V/BN

BNBK

BE

O/W

R/Y

V

BN

BK

BE

O/W

R/YV

BN

BK

BE

O/W

R/Y V

BN

BK

BE

O/W

R/Y V

BK

BK

BK

BK

BE

R/Y

V/BN

V/BN

V/BN

BK

V/BN

BE

et01140

Figure B-20. 2008 ALL FXDWG, FXDC, FXDF DYNA DOM. and INT. MODELS, LIGHTS, SHEET 2 OF 2


LIGHTS, SHEET 2 OF 22008 ALL FXDWG, FXDC, FXDF DYNA DOM. and INT. MODELS,

LIGHTS, SHEET 2 OF 2

INSTR - 15A

ACCY - 15A

IgnitionSwitch

[33A] [33B]

P

A

R

B

3

12

3

12

BK

[39B]

[78B]

[30B][30A]

BK

[5]

40 AmpMAXIFUSE

A B

A B


center

ACC − ABATT − B

IGN − I

Serial data

Ground

[78A]

[154]

TripOdometer

ResetSwitch

ABC

5

10Ground

Ground

Serial data

28

5

10

28

ECM

[24B] 1

1

6

TSM/TSSM

[64B]See security circuit forhands free securty module

Speedometer

[39A] 1 11

Igni

tion

Ser

ial d

ata

Acc

esso

ryG

roun

dTr

ipod

omet

erR

eset

switc

h

Trip

odom

eter

Res

etsw

itch

Fue

l lev

el

2 6

[117B][141B]

Horn Switch

[24A]

[163]

Left HandControls

6

[21A]

[21B]3 5 6

3 5 6

[120]

OilPressureSendingUnit

[131]

NeutralSwitch

B A

Fuel Pump & Sender Assembly(In fuel tank)

[117A] [141A]

Fuel Gauge

Pow

erS

igna

lG

roun

d

42

987

1 112 6 987

1

421

Full: 39.5 / 27.51/2 : 118.0 / 97.0Empty: 260.0 / 240.0 A D

[86]

B C

A DB C

[GND2]

BK

BK

BK

BK

BK

O/W

LGN/V

LGN/V

GN

/YG

N/Y

O/G

Y

Y/B

K

O/W

Y/B

K

TN

Y/W

Y/W

O/W

Y/W

R

OT

N

BK

BK

O

BK

/GN

BK/GN

BK/GN

BK/GN

BK

/GN

LGN

/V

BK

/GN

BK

/GN

O/W

O

O

Y/W

Y/W

O

R

O

R/GY

R/GY

R/BK

R/BK

Y/BK

BK[122]Horn

B

A

et01141

Figure B-21. 2008 ALL FXDWG, FXDC, FXDF DYNA DOM. and INT. MODELS, HORN & INSTRUMENTS CIRCUIT


HORN & INSTRUMENTS CIRCUIT2008 ALL FXDWG, FXDC, FXDF DYNA DOM. and INT. MODELS,

HORN & INSTRUMENTS CIRCUIT

IGN

ACCY

15A

15A

[31RA]

IgnitionSwitch

[7A]

[33A] [33B]

ToFrontTurn

Signalssee sheet 2

To rear lightingsee sheet 2

Battery

ECM

15A

15A

SecuritySiren

(Optional)

Speedometer

A

I

P

G

B

J

R

H

StartRelay

[62B]

[142B]

[142A]

[39B]

[78B]

[30B]

PowerSignal

Ground

[5]40 Amp

MAXIFUSE

A B

GND1 GND2Rear groundstud underelectrical

1221

1 3 8

ACC − ABATT − B

IGN − I

1 2 5 6 7

[78A]

[31LA]

ABC

4

5

10

13

28

31

4

5

10

13

28

31

KTES

8787A308586

54321

ECM

[24B] 1 5 7 8

Turn

Sig

nal&

Sec

urity

Mod

ule

TS

M/H

FS

M

[64B]

Horn Switch

Headlamp Hi/Lo SwitchLeft Turn Switch

[24A]

LeftHand Controls

1 2 3 4 5 6 7 8

Clutch Switch

123456



[22A]

[162]

RightHand Controls

13456

FuseblockTop viewTop view

[64][62]

Accessories Lights

IgnitionCB F

L

U S

K

E D C

IJ

R P O M

GH

B A

H

O

G

M

A

I

Q PR

E

K

T SU

Fuel pump

Start RLY System RLY ECM

Battery


Spare

ENG CTL CUST ACCY

[21A]

[21B]

1 4 5 6 7

1 4 5 6 7

SystemRelay

54321

8787A308586

IQCPR

[22B]

INSTR 15AA B

Starter

Battery

RedBand

21

43

65

87

109

1211

[30A]

Battery

21

3

21

21 Antenna ‘A’

Antenna ‘B’

Hands FreeAntenna[209B] [209A]

[208B]

[131]

NeutralSwitch

AB

21

43

65

87

109

1211

21

3

BA

CBA

C

[208A]

[163]

IgnitionSerial data

Neutral switchLeft turn feed

Right turn feedRight turn switch nputLeft turn switch input

Start relay controlClutch switch control

Alarm signalGround

Receive antennaTransmit antenna ATransmit antenna B

(GRAY)

BK

BK

TN

GY

TN

BN

BK

W/V

O/Y

BKO/Y

V

BN/GY

BN/GY

BE/GY

TN/GN

LGN/V

LGN/V

LGN/BN

LGN/BN

W/BN

W/BK

BK/R

GN/O

Y/BK

System relay

Serial data

Battery

Ground

Ground

Switched power

BK

BE

O/W

O/W

W/V

W/V

BK

/RB

K/R

Y/B

KY W

BK

BN V

BK

BK

BK

BK

GN

BN

TNV O

BN

TNV O

BE/GY

BE/GY

BN/GY

GN

R/BK

R/BK

R/BK

R/GY

BK/R

W/BKGN/O

GY

O/W

O

R

R

R R

R/BK

R/GYR

BK

BK

BNV

GY

GY

O/W

O/W

R/Y

W/B

NW

/BN

W/B

KW

/BK

BK

/RB

K/R

O/W

BN

/GY

BK

/GN

LGN

/VO

BK

/GN

BK/GN

BK/GN

BK/GN

[128]

BK

/GN

BK

/GN

TN/GNU

et01145

Figure B-22. 2008 ALL FXDWG, FXDC, FXDF DYNA DOM. and INT. MODELS, SECURITY CIRCUIT, SHEET 1 OF 2


SECURITY CIRCUIT, SHEET 1 OF 22008 ALL FXDWG, FXDC, FXDF DYNA DOM. and INT. MODELS,

SECURITY CIRCUIT, SHEET 1 OF 2

[94B]

[7B]


1234567

123456


Taillamp


Rear Lighting

[94B]

[7B]

1234567

1

23456

TailHDI only



BrakeLight

[18A]

[18B]

[19B]

[19A]

TailDOM only

[93A] [93B]

[94A]

12

123 1

234

123456

12

1

2

12

4321




Taillamp

[94B]

[45A]

[18A]

[19A]

[93A]

[94A]

12

123

123456

12

1

2

1

2

4321

4321

TailHDI only


[19B]

[18B]

TailDOM only

[93B]

FXDCFrontRightTurn

[31R]

[31RB]Front

LeftTurn

DOM only

[38B]

To mainharness[38A]


Front Lighting


[29]

123

Headlamp

[38]

1234

[31L]

[31LB]

123

High

Low

BK

BK

BK

BKBK

BK

BK

BN

BN

BE

BE

BE

BE

V

V

W

W

Y

Y O/W

O/W

BEBE

BK

BK

BK

BK

BK

R/Y

V/BN

V/BN

V/BN

V/BN

BNBK

BE

O/W

R/Y

V

BN

BK

BE

O/W

R/YV

BN

BK

BE

O/W

R/Y V

BN

BK

BE

O/W

R/Y V

BK

BK

BK

BK

BE

R/Y

V/BN

V/BN

V/BN

BK

V/BN

BE

[39A]

Sec

urity

LP

1 2 4 5 6 7 8 9 11

Igni

tion

Ser

ial d

ata

Bat

tery

Acc

esso

ryG

roun

dTr

ipod

omet

erre

set s

witc

h

Trip

odom

eter

rese

t sw

itch

Fue

l lev

el

Speedometer

et01146

Figure B-23. 2008 ALL FXDWG, FXDC, FXDF DYNA DOM. and INT. MODELS, SECURITY CIRCUIT, SHEET 2 OF 2


SECURITY CIRCUIT, SHEET 2 OF 22008 ALL FXDWG, FXDC, FXDF DYNA DOM. and INT. MODELS,

SECURITY CIRCUIT, SHEET 2 OF 2

SUBJECT............................................................................................................................PAGE NO.C.1 METRIC CONVERSION...........................................................................................................C-1C.2 FLUID CONVERSIONS............................................................................................................C-2C.3 TORQUE CONVERSIONS.......................................................................................................C-3

AP

PE

ND

IX C

CO

NV

ER

SIO

NS

C.1METRIC CONVERSION

CONVERSION TABLE

Table C-1. Metric Conversions

INCHES to MILLIMETERS(IN. x 25.40 = MM)

MILLIMETERS to INCHES(MM x 0.03937 = IN.)

MMIN.MMIN.MMIN.MMIN.IN..MMIN.MMIN.MMIN.MM

84.143-5/1649.211-15/1615.240.6.025.0013.582912.28358.984225.0039.1

85.723-3/850.80215.8755/8.051.0023.622922.323591.02426.0078.2

86.363.452.392-1/1617.46211/16.076.0033.661932.362601.06327.0118.3

87.313-7/1653.342.117.780.7.102.0043.701942.401611.10228.0157.4

88.903-1/253.972-1/819.0503/4.127.0053.740952.441621.14229.0197.5

90.493-9/1655.562-3/1620.320.8.152.0063.779962.480631.18130.0236.6

91.443.655.882.220.63813/16.178.0073.819972.519641.22031.0275.7

92.073-5/857.152-1/422.2257/8.203.0083.858982.559651.26032.0315.8

93.663-11/1658.422.322.860.9.229.0093.897992.598661.29933.0354.9

93.983.758.742-5/1623.81215/16.254.0103.9371002.638671.33834.03941

95.253-3/460.322-3/825.401.3971/643.9761012.677681.37835.07872

96.523.860.962.426.991-1/16.508.0204.0161022.716691.41736.11813

96.843-13/1661.912-7/1627.941.1.762.0304.0551032.756701.45637.15754

98.423-7/863.502-1/228.571-1/8.7941/324.0941042.795711.49638.19685

99.063.965.092-9/1630.161-3/161.016.0404.1341052.834721.53539.23626

100.013-15/1666.042.630.481.21.270.0504.1731062.874731.57540.27567

101.6466.672-5/831.751-1/41.524.0604.2121072.913741.61441.31498

102.194-1/1668.262-11/1633.021.31.5881/164.2521082.953751.65342.35439

104.144.168.582.733.341-5/161.778.0704.2911092.992761.69343.393710

104.774-1/869.852-3/434.921-3/82.032.0804.3311103.031771.73244.433111

106.364-3/1671.122.835.561.42.286.0904.3701113.071781.77245.472412

106.684.271.442-13/1636.511-7/162.540.14.4091123.110791.81146.511813

107.954-1/473.022-7/838.101-1/23.1751/84.4491133.149801.85047.551214

109.224.373.662.939.691-9/164.7623/164.4881143.189811.89048.590515

109.544-5/1674.612-15/1640.641.65.080.24.5271153.228821.92949.629916

111.124-3/876.20341.271-5/86.3501/44.5671163.268831.96850.669317

111.764.477.793-1/1642.861-11/167.620.34.6061173.307842.00851.708618

112.714-7/1678.743.143.181.77.9385/164.6451183.346852.04752.748019

114.304-1/279.373-1/844.451-3/49.5253/84.6851193.386862.08653.787420

115.894-9/1680.963-3/1645.721.810.160.44.7241203.425872.12654.826821

116.844.681.283.246.041-13/1611.1127/164.7641213.464882.16555.866122

117.474-5/882.553-1/447.621-7/812.7001/24.8031223.504892.20556.905523

119.064-11/1683.823.348.261.914.2889/164.8421233.543902.24457.944924

2008 Dyna Diagnostics: Appendix C Conversions C-1

C.2FLUID CONVERSIONS

UNITED STATES SYSTEMUnless otherwise specified, all fluid volume measurements inthis Service Manual are expressed in United States (U.S.)units-of-measure. See below:

• 1 pint (U.S.) = 16 fluid ounces (U.S.)

• 1 quart (U.S.) = 2 pints (U.S.) = 32 fl. oz. (U.S.)

• 1 gallon (U.S.) = 4 quarts (U.S.) = 128 fl. oz. (U.S.)

METRIC SYSTEMFluid volume measurements in this Service Manual includethe 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.)

BRITISH IMPERIAL SYSTEMFluid volume measurements in this Service Manual do notinclude the British Imperial (Imp.) system equivalents. The fol-lowing conversions exist in the British Imperial system:

• 1 pint (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 actualvolume of each British Imperial unit-of-measure differs from itsU.S. counterpart.The U.S. fluid ounce is larger than the BritishImperial fluid ounce. However, the U.S. pint, quart, and gallonare smaller than the British Imperial pint, quart, and gallon,respectively. Should you need to convert from U.S. units toBritish Imperial units (or vice versa), refer to the following:

• fluid ounces (U.S.) x 1.042 = fluid ounces (Imp.)

• pints (U.S.) x 0.833 = pints (Imp.)

• quarts (U.S.) x 0.833 = quarts (Imp.)

• gallons (U.S.) x 0.833 = gallons (Imp.)

• 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.)

• gallons (Imp.) x 1.201 = gallons (U.S.)

C-2 2008 Dyna Diagnostics: Appendix C Conversions

C.3TORQUE CONVERSIONS

UNITED STATES SYSTEMThe U.S. units of torque, foot pounds and inch pounds, areused in this service manual.To convert units, use the followingequations:

• foot pounds (ft-lbs) X 12.00000 = inch pounds (in-lbs).

• inch pounds (in-lbs) X 0.08333 = foot pounds (ft-lbs).

METRIC SYSTEMAll metric torque specifications are written in Newton-meters(Nm). To convert metric to United States units and UnitedStates to metric, use the following equations:

• Newton meters (Nm) X 0.737563 = foot pounds (ft-lbs).

• Newton meters (Nm) X 8.85085 = inch pounds (in-lbs).

• foot pounds (ft-lbs) X 1.35582 = Newton meters (Nm).

• inch pounds (in-lbs) X 0.112985 = Newton meters (Nm).

2008 Dyna Diagnostics: Appendix C Conversions C-3

C-4 2008 Dyna Diagnostics: Appendix C Conversions

NOTES

SUBJECT............................................................................................................................PAGE NO.D.1 GLOSSARY..............................................................................................................................D-1

AP

PE

ND

IX D

GL

OS

SA

RY

D.1GLOSSARY

ACRONYMS AND ABBREVIATIONS

Table D-1. Acronyms and Abbreviations

DESCRIPTIONACRONYM OR ABBREVIATION

AmperesA

Alternating CurrentAC

AccessoryACC

Automatic Compression ReleaseACR

Absorbed Glass Mat (battery)AGM

AmpereAMP

American Wire GaugeAWG

Battery VoltageB+

Bank angle sensorBAS

Before Top Dead CenterBTDC

Celsius (Centigrade)C

CaliforniaCA

CalibrationCAL

Cubic CentimetersCC

Cold Cranking AmpsCCA

Crankshaft PositionCKP

Centimetercm

Direct CurrentDC

Data Link ConnectorDLC

DomesticDOM

Diagnostic Trouble CodeDTC

Digital Volt Ohm MeterDVOM

Electronic Control ModuleECM

Engine Coolant TemperatureECT

Electrically Erasable Programmable Read Only MemoryEEPROM

Electronic Fuel InjectionEFI

Engine TemperatureET

Evaporative Emissions Control SystemEVAP

FahrenheitF

Foot-Poundsft-lbs

Fluid Ouncefl oz.

Gramg

GallonGAL

Gross Axle Weight RatingGAWR

Ground (electrical)GND

Gross Vehicle Weight RatingGVWR

Harley-Davidson InternationalHDI

Harley-Davidson Smart Security SystemH-DSSS

Hands Free Security ModuleHFSM

MercuryHg

Idle Air ControlIAC

2008 Dyna Diagnostics: Appendix D Glossary D-1

Table D-1. Acronyms and Abbreviations

DESCRIPTIONACRONYM OR ABBREVIATION

Intake Air TemperatureIAT

Inside DiameterID

Ignition Light/Key SwitchIGN

Instrument ModuleIM

InchIn.

Injector Pulse WidthINJ PW

Inch-Poundsin-lbs

KilogramKg

KilometerKm

KilopascalkPa

Kilometers Per Hourkm/hr

LiterL

Liquid Crystal DisplayLCD

Light Emitting DiodeLED

MilliamperemA

Manifold Absolute PressureMAP

milliliterml

millimetermm

Miles Per HourMPH

millisecondms

Newton-MeterNm

Not ApplicableN/A

Numberno.

OxygenO2

Outside DiameterOD

Original Equipment ManufacturerOEM

Ounceoz

Parts and AccessoriesP&A

Part NumberPN

Pounds per Square InchPSI

ReserveRES

Revolutions Per MinuteRPM

Cubic Feet per Hour at Standard ConditionsSCFH

Top Dead CenterTDC

Throttle PositionTP

Intake Air Temperature/Manifold Absolute PressureTMAP

Turn Signal ModuleTSM

Turn Signal/Security ModuleTSSM

VoltV

Volts of Alternating CurrentVAC

Volts of Direct CurrentVDC

Vehicle Identification NumberVIN

Vehicle Speed SensorVSS

D-2 2008 Dyna Diagnostics: Appendix D Glossary

SUBJECT............................................................................................................................PAGE NO.E.1 TSM/TSSM (JAPAN/KOREA) OVERVIEW...............................................................................E-1E.2 TSM/TSSM FEATURES............................................................................................................E-3E.3 VEHICLE DELIVERY................................................................................................................E-5E.4 TURN SIGNAL FUNCTIONS....................................................................................................E-9E.5 BANK ANGLE FUNCTION.....................................................................................................E-10E.6 SECURITY SYSTEM FUNCTIONS (TSSM ONLY)................................................................E-11E.7 ARMING/DISARMING (TSSM ONLY)....................................................................................E-14E.8 DIAGNOSTIC TROUBLE CODES (DTC)...............................................................................E-16E.9 INITIAL DIAGNOSTIC CHECK: TSM/TSSM..........................................................................E-19E.10 SPEEDOMETER SELF DIAGNOSTICS...............................................................................E-25E.11 BREAKOUT BOX: TSM/TSSM..............................................................................................E-28E.12 FAILS TO DISARM (TSSM ONLY)........................................................................................E-29E.13 TURN SIGNAL ERRORS: B1121, B1122, B1141................................................................E-32E.14 DTC B0563...........................................................................................................................E-42E.15 DTC B1131, B1132...............................................................................................................E-43E.16 DTC B1134...........................................................................................................................E-46E.17 DTC B1135...........................................................................................................................E-49E.18 DTC B1154, B1155...............................................................................................................E-50E.19 DTC U1016, U1255..............................................................................................................E-54E.20 DTC U1300, U1301 OR BUS ER.........................................................................................E-57E.21 TSM/TSSM: PASSWORD LEARN........................................................................................E-58E.22 TSSM MAINTENANCE.........................................................................................................E-59

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E.1TSM/TSSM (JAPAN/KOREA) OVERVIEW

GENERALTSM: The Turn Signal Module (TSM) has two major functions:

• Control turn signals.

• Serve as Bank Angle Sensor (BAS).

TSSM: See Figure E-1.The optional, factory-installed, Harley-Davidson Factory Security System (H-DFSS) includes a TurnSignal Security Module (TSSM) which provides the samefunctions as the TSM, but also includes security and immobil-ization functions.

sm01275

Figure E-1.TSSM (Japan/Korea)

ed02895

Figure E-2.TSM/TSSM Location:Typical

TROUBLESHOOTINGProblems fall into at least one of five categories:

• Turn signal malfunction.

• Bank angle (engine disable).

• Clutch/neutral interlock (starter enable).

• Security lamp problem.

• Security system malfunction.

To resolve TSM/TSSM problems, four basic steps are involved.In order of occurrence, they are:

1. Retrieve Diagnostic Trouble Codes (DTCs) usingspeedometer self diagnostics. See E.10 SPEEDOMETERSELF DIAGNOSTICS.



4. After repairs are performed, the work must be validated.This involves clearing the DTCs and confirming propervehicle operation as indicated by the behavior of the turnsignals.

2008 Dyna Diagnostics: Appendix E TSM/TSSM (Japan/Korea) E-1

Battery

+ -

BatteryFuse

IGN Fuse

ACC Fuse

321 4

12

4

7

8

2

1

3

12

4 Neutralswitch

Serialdata

Right turnswitchinput

Left turnswitchinput

Ignition

Battery

Alarmsignal

Clutchswitch

Startrelay

control

Leftturnfeed

Rightturnfeed

Ground

7

8

2

1

3

BB

6

5

9

30

87

86

85

10

11

6

5

9

10

11

40 AmpMAXIFUSE

[30B] [30A]

[142B] [142A]

[78A]

[78B]

[39A]

[39B]

[30A] [30B]

FuseBlock

IgnitionSwitch

Data LinkConnector

Speedometer

Right TurnSwitch

StartRelay

Starter

EngineStop Switch

StartSwitch

ClutchSwitch

Smart Siren(Optional)

Tobatterypositive

Toignitionswitch

Toignition

fuse

ToECM

Left TurnSwitch

NeutralSwitch

TSM/TSSM

Right TurnLamps

Left TurnLamps

BK

BN

BN

BN

BN BN

BK BK

BK

BK

BK

GN

BK

GY

BK

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TN

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V V

V V

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R

R/BK

R/GY

W/BN

R/BK

W/BK

BK

/R

BK/R

BN/GY

LGN/V LGN/V

TN/GN

BK/GN

LGN/BN

LGN

/VLG

N/V

LGN

/V

5

5

Ser

iald

ata

2

2

Ser

iald

ata

ECM

W/V

O/W

O/W

BK/GN

[GND1]

em00030

Figure E-3. Simplified TSM/TSSM Wiring

E-2 2008 Dyna Diagnostics: Appendix E TSM/TSSM (Japan/Korea)

E.2TSM/TSSM FEATURES

GENERALThe Turn Signal Module (TSM) and the Turn Signal SecurityModule (TSSM) provide the following capabilities.

TURN SIGNAL FUNCTIONS

TSSM/TSSM FeaturesSee E.4 TURN SIGNAL FUNCTIONS for complete details.

• Manual turn signal control: Manual activation/deactiva-tion of left and right turn signal flashing sequences.

• Automatic turn signal cancellation: Automatic cancella-tion of left and right turn signal flashing sequences basedon either vehicle speed, vehicle acceleration or turn com-pletion.

• Emergency flashers: Four-way left and right turn signalflashing capability.

• Turn signal lamp diagnostics: Self-diagnostics for shortcircuit and open lamp conditions on both left and right turnsignal systems.

BANK ANGLE FUNCTIONSee E.5 BANK ANGLE FUNCTION for complete details.

• Emergency engine shutdown: Will provide engineshutdown when vehicle is tipped over.

• Emergency outputs disable: Will disable turn signallamps and starter motor when vehicle is tipped over.

CLUTCH/NEUTRAL INTERLOCKFUNCTIONS

TSM/TSSM Features• Disables starter: Disables starter until either the clutch

lever is pulled in or transmission neutral is selected.

• Diagnostics: Provides diagnostics for clutch and neutralswitch faults.

SECURITY ALARM AND IMMOBILIZATIONFUNCTIONS

TSSM FeatureThe following information applies only to motorcycles with thesecurity option (TSSM). See E.6 SECURITY SYSTEMFUNCTIONS (TSSM ONLY) for more information.

• Remote arming/disarming: See Figure E-4. Owners mayenable and disable security alarm and immobilizationfunctions with a personally carried transmitter. This trans-mitter is referred to as a key fob. Remote arming/dis-arming is a function of the TSSM (Japan/Korea) only.

• Security lamp: See Figure E-5. A lamp within thespeedometer face tells the rider if the system is armed ordisarmed.

• PIN disarming: If a key fob is not available, the TSSMallows the rider to disable the security alarm and immobil-

ization functions if the rider knows the previously enteredpersonal identification number (PIN).

• Arming/disarming confirmation: When the TSSM isarmed, the system provides visual feedback to the riderby flashing the turn signals and sounding the optionalSiren.

• Auto-arming: Automatically enables the security alarmand immobilization functions within 30 seconds after theIgnition Switch is switched OFF.

NOTE

Motorcycles sold with a TSSM have auto-arming disabled, butit can be activated. See E.3 VEHICLE DELIVERY.

• Transport mode: It is possible to arm the security systemwithout enabling the motion detector for one ignition cycle.This allows the vehicle to be moved in an immobilizedstate.

• Starter/ignition disable: Should the security alarm andimmobilization functions be triggered by a vehicle securitycondition, the starter and ignition system will be disabled.

• Security system alarm: See Figure E-6. The system willalternately flash the left and right turn signals and soundan optional Siren if a vehicle security condition is detectedwhile the system is armed.

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Figure E-4. Key Fob:TSSM


ed02827

Figure E-5. Security Lamp (key icon): Dyna Models

ed02047

Figure E-6. Siren


E.3VEHICLE DELIVERY

GENERAL


Setting up a vehicle TSM/TSSM depends on whether thevehicle has a Turn Signal Module (TSM) or the optional TurnSignal Security Module (TSSM) installed.

All motorcycles ship with the TSM/TSSM set for use withouta sidecar installed. If a motorcycle is equipped with a TSM, nofurther configuration is required.

However, if a motorcycle has an optional security system(TSSM) installed, perform the following steps as necessary.

1. Configure TSSM motorcycles by assigning both key fobsto the vehicle. See E.3 VEHICLE DELIVERY, Key FobAssignment: TSSM.

2. Configure TSSM motorcycles by entering a PersonalIdentification Number (PIN) picked by the owner. The PINallows the owner to operate the system if the key fob islost or inoperable. Record this PIN in the Owner's Manualand instruct the customer to carry a copy.

CONFIGURING A TSSMNOTE

Do not forget to enter a Personal Identification Number (PIN)for TSSM motorcycles. If a PIN is not assigned and both keyfobs are lost or damaged while the motorcycle is armed, theTSSM must be replaced.

Changes to TSSM settings are made by a series of program-ming operations involving the ignition switch, left/right turnsignal switches and key fob (security systems).

At certain steps in the programming sequence, the motorcyclemay provide confirmation of settings by flashing the turn sig-nals, turn signal indicators and/or security lamp. In addition,when programming a PIN into a TSSM system, the odometerdisplays the PIN to the user and dynamically updates it as thecode is entered or changed.

All programming operations are listed in table format. Followthe numbered steps to configure the system. If a confirmation

response is listed, wait for the confirmation before continuingto the next step. Important information pertaining to certainactions will be found in the NOTES column.

SIDECAR CONFIGURATION


POWER DISRUPTION AND CONFIGURINGThe TSM/TSSM will not enter configuration mode on the firstattempt after battery voltage has been removed from terminal"1". This will occur after any of the following situations:

• Battery disconnect or power drain.

• Battery fuse removal.

• Connecting Breakout Box to TSM/TSSM connector.

Therefore, after all battery reconnects, the configurationsequence must be modified as follows.

1. Set Engine Stop Switch to OFF, cycle Ignition SwitchON-OFF-ON-OFF-ON and press left turn signal switchtwice.

2. Repeat step listed above.

3. Continue with configuration sequence listed.

KEY FOB ASSIGNMENT:TSSMRefer to Table E-1 to assign a key fob to a motorcycle equippedwith a TSSM.

The key fob on TSSM motorcycles must be set so it will operatethe alarm system on the vehicle. This assignment must becompleted with no pauses between steps greater than 10seconds. Turn the Ignition Switch to OFF after all key fobshave been assigned. The programming mode will also exitafter 60 seconds has elapsed without detecting any fob sign-up messages or turn signal switch activity.

Two key fobs may be assigned to the TSSM. The first suc-cessful attempt to program a fob will disable all previouslyassigned fobs. If a second fob is to be programmed, it mustbe done in the same programming sequence as the initial fob.

Table E-1. Key FOB Assignment:TSSM


Verify the security lamp is notblinking (vehicle is disarmed).

Set Engine Stop Switch to OFF1

This assignment procedure must becompleted with no pauses betweensteps greater than 10 seconds.

Cyc le the Ign i t ion Swi tchIGN-OFF-IGN-OFF-IGN

2


Table E-1. Key FOB Assignment:TSSM


One flash - Worldwide TSM, nosecurity.

One to four flashes turn signals andindicators depending on vehicle config-uration

Press left turn switch 2 times and release.3

Two flashes - Japan/Korea configur-ation TSSM.(See E.3 VEHICLE DELIVERY

regarding battery disconnects).

One flash turn signals and indicators.Press right turn switch 1 time and release.4

Two flashes turn signals and indicators.Press left turn switch 1 time and release.5

This may take 10-25 seconds.Two flashes turn signals and indicators.Press and hold key fob button until confirm-ation is received.

6

Optional step.Two flashes turn signals and indicators.If you have two key fobs, press and holdbutton on second key fob until confirmationis received.

7

Turn Ignition Switch to OFF.8

PIN ENTRY:TSSMNOTE

Do not forget to enter a Personal Identification Number (PIN)for TSSM vehicles. If a PIN is not assigned and the key fob islost or damaged while the vehicle is armed, the TSSM mustbe replaced.

The TSSM PIN consists of five digits. Each digit can be anynumber from 1-9. There can be no zeros (0) in the PIN. ThePIN must be used to disarm the security system in case thekey fob becomes unavailable.

Refer to Table E-2 to enter an initial PIN with no PIN previouslyinstalled. The procedure listed uses 3-1-3-1-3 as the desiredPIN.

NOTE

For better security, do not use 3-1-3-1-3 as a PIN. It is shownas an example only.

Decide what five-digit PIN the owner would like to use. Thecode will be programmed using the turn signal switches and

key fob. Keep a record of the PIN in a secure place such asyour wallet or the Owner's Manual.

• When programming the PIN, the security lamp flashes toprovide feedback when entering each digit.The Odometeralso displays the PIN and the change dynamically.

• The number of security lamp flashes corresponds to thenumber currently selected for a given digit. Therefore, thelamp may flash 1-9 times depending on the numberentered. The five-digit PIN will change in the Odometerwindow and the active digit will blink.

• Press the left turn switch one time to increment each digit.

• Quickly press the key fob button twice to advance to thenext digit.

NOTE

The programming mode exits upon turning the Ignition Switchto OFF, or if no turn signal switch/key fob button activity occursfor 60 seconds. No data is saved for partial configurationattempts if entering a PIN for the first time. If a PIN has previ-ously been entered, the user can change any digit or group ofdigits.

Table E-2. Entering an Initial TSSM PIN (Example: 3-1-3-1-3) with No PIN Previously Entered




This assignment proceduremust be completed with nopauses between steps greaterthan 10 seconds.

C y c l e t h e I g n i t i o n S w i t c hIGN-OFF-IGN-OFF-IGN.

2

One flash - Worldwide TSM, nosecurity.

One to four flashes turn signals andindicators depending on vehicle config-uration


Two flashes - Japan/Koreaconfiguration TSSM.(See E.3 VEHICLE DELIVERY

regarding battery disconnects).




Vehicle is in PIN entry modeready to enter or modify firstdigit.

One flash turn signals and indicatorsOdometer displays current five-digitPIN (five dashes if no code entered),first digit blinks.

Quickly press key fob button 2 times andrelease.

4

A lack of confirmation flashesindicates no digit is entered.

Security lamp flashes 1 - 9 times ifcode was previously entered.

Press left turn switch 1 time and release.5

You have selected 3 as anumber for the first digit.

Blinking digit in odometer displayincrements, security lamp flashes toindicate each digit selected.

Press and release left turn switch to advancethrough the digits.In this example, you will press and releasethree times.

6

In this example, the blinking digit dis-played is 3 and the security lamp willflash three times.

You have confirmed 3 as anumber for the first digit andhave advanced to entering thesecond digit.

Two flashes turn signals and indicatorssecond digit in odometer displayblinks.


7


NonePress left turn switch 1 time and release.8

You have selected 1 as anumber for the second digit.


Press and release left turn switch to advancethrough the digits.In this example, you will perform this stepone time.

9

In this example, the blinking digit dis-played is 1 and the security lamp willflash one time.

You have confirmed 1 as anumber for the second digit andhave advanced to entering thethird digit.

Three flashes turn signals and indic-ators third digit in odometer displayblinks.


10



You've selected 3 as a numberfor the third digit.


Press and release left turn switch to advancethrough the digits.In this example, you will repeat this step threetimes.

12


You have confirmed 3 as anumber for the third digit andhave advanced to entering thefourth digit.

Four flashes turn signals and indic-ators fourth digit in odometer displayblinks.


13



You've selected 1 as a numberfor the fourth digit.


Press and release left turn switch to advancethrough the digits.In this example, you will perform this stepone time.

15

In this example, the blinking digit dis-played is 1 and the security lamp willflash one time.

You have confirmed 1 as anumber for the fourth digit andhave advanced to entering thefifth digit.

Five flashes turn signals and indicatorsfifth digit in odometer display blinks.


16






You have selected 3 as anumber for the fifth digit.


Press and release left turn switch to advancethrough the digits.In this example, you will repeat this step threetimes.

18


You have confirmed 3 as anumber for the fifth digit andhave gone back to the first digit.

One flash turn signals and indicatorsfirst digit in odometer display blinks.


19


Write down code in Owner's Manual.21

Arm the security system and attempt todisarm using PIN entry. Refer to Table E-8.

22

CHANGING THE PIN:TSSMIf a PIN has been previously entered, the security lamp willflash the equivalent digit, and the odometer will display the

existing PIN with the active digit blinking. Each additional pressof the left turn switch will increment the digit.

• To advance from 5 to 6, press and release the left turnswitch 1 time.

• To advance from 8 to 2, press and release the left turnswitch 3 times (9-1-2).


E.4TURN SIGNAL FUNCTIONS

GENERALThe TSM/TSSM turn signal feature has several modes:

• Automatic cancellation.

• Manual cancellation.

• Four-way flashing.

• Diagnostics mode.

The turn signals cannot be activated or deactivated when theIgnition Switch is in the ACC position. The turn signals canonly be activated or deactivated with the Ignition Switch in theIGNITION position.


AUTOMATIC CANCELLATIONPress the left or right turn switch to activate automatic turnsignal cancellation. There is no need to hold the turn switch inwhen approaching the turn. The TSM/TSSM will not cancelthe signal before the turn is actually completed.

• When the directional switch is released, the system startsa 20 count. As long as the vehicle is traveling above 7MPH (11.3 km/h), the directional will always cancel after20 flashes if the system does not recognize any otherinput.

• If the vehicle speed drops to 7 MPH (11.3 km/h) or less,including stopped, the directionals will continue to flash.Counting will resume when vehicle speed reaches 8MPH (13 km/h) and will automatically cancel when thecount total equals 20 as stated above.

• The turn signals will cancel within two seconds upon turncompletion. A sensor inside the TSM/TSSM cancels thesignal after the vehicle has been returned to an uprightposition.

NOTE

The bank angle cancellation function has an automatic calibra-tion feature. Ride the motorcycle for 1/4 mile (0.4 km) at steadyspeeds (upright) to calibrate the system. Performance of bankangle function may not be optimal until this calibration is per-formed. This self-calibration is performed automatically everytime the vehicle is started and ridden.

MANUAL CANCELLATIONIf you want to stop the turn signals from flashing, briefly depressthe turn signal switch a second time.

If you are signalling to turn in one direction and you depressthe switch for the opposite turn signal, the first signal is can-celled and the opposite side begins flashing.

FOUR-WAY FLASHINGUse the following method to activate the four-way flashers:

1. With the Ignition Switch turned to IGN and the securitysystem disarmed (models with security only), press theleft and right turn signal switches at the same time.

2. Turn the Ignition Switch OFF and arm the security systemif present and desired.The four-way flashers will continuefor two hours.

3. To cancel four-way flashing, disarm the security systemif necessary, turn the Ignition Switch to IGN and press theleft and right turn signal switches at the same time.

This system allows a stranded vehicle to be left in the four-wayflashing mode and secured until help is found.

If the security system is disarmed while the four-way flashersare active, the lights will flash as follows:

1. TSSM stops four-way flashing mode. Motorcycle sits for1 second with turn signals off.

2. TSSM performs disarming confirmation (1 flash).

3. Motorcycle sits for 1 second with turn signals off.

4. Motorcycle restarts four-way flashing mode.

DIAGNOSTICS MODEThe TSM/TSSM measures the current when the turn signalsare used. If there is a burned out light bulb on one side, theremaining light and the corresponding turn signal indicator flashat double the normal rate starting with the fifth flash.

Other diagnostic conditions monitored include:

• Short circuit in the turn signal wiring.

• Open circuit in the turn signal wiring.

• Stuck turn signal switch.

NOTES

• A stuck turn signal switch will disable the automatic turnsignal cancellation feature.

• If a stuck switch is detected, you must hold the left andright turn signal switches in for more than one second toactivate the four-way flashers.

See E.8 DIAGNOSTIC TROUBLE CODES (DTC) for moreinformation.


E.5BANK ANGLE FUNCTION

GENERALThe Turn Signals, Starter Motor, ECM, Fuel Pump, and IgnitionCoil will be disabled in the event the vehicle is tipped over.


OPERATIONThe engine will shut off automatically if the vehicle is tippedover. The odometer displays "tIP" when a tip over condition isdetected.

To restart the motorcycle after shutdown has occurred:

1. Return the motorcycle to an upright position.

2. Cycle the Ignition Switch OFF-IGN before restarting.


E.6SECURITY SYSTEM FUNCTIONS (TSSM ONLY)

GENERAL

Security System OperationThe TSSM provides security and immobilization functions notfound on the TSM. The TSSM will disable the starter and igni-tion system. Additional functions include the ability to alternatelyflash the left and right turn signals and sound a siren (if pur-chased as an option) if a theft attempt is detected.

Conditions that activate the security system when system isarmed include:

• Detecting tampering of the ignition circuit: Turn signalsflash three times, optional siren chirps once and then turnsoff. If the tampering continues, a second warning willactivate after four seconds. Continued tampering will causethe alarm to activate for 30 seconds and then turn off.Thetwo warnings/alarm cycle is repeated for each tamperingincident.

• Detecting vehicle movement: Turn signals flash threetimes, optional siren chirps once and then turns off. If thevehicle is not returned to its original position, a secondwarning will activate after four seconds. If the vehicle isnot returned to its original position, the alarm activates for30 seconds then turns off. The two warnings/alarm cyclemay repeat a maximum of 10 times with a 10 secondpause between alarm cycles.

• Detecting that a battery or ground disconnect hasoccurred while armed: Siren, if installed, activates itsself-alarm mode. Turn signals will not flash.

See E.7 ARMING/DISARMING (TSSM ONLY) for moreinformation.

NOTE

Always disarm the TSSM before removing or disconnectingthe battery to prevent the siren (if installed) from activating. Ifthe TSSM is in auto-arming mode, you must disarm the systemand disconnect the battery or remove the battery fuse beforethe 30 second arming period expires.

Security System Options:TSSMThe following options are only available on the TSSM unit:alarm sensitivity, auto-arming feature, and storage mode.

Default settings for the TSSM include:

• Solo vehicle configuration.

• Medium motion sensitivity on alarm sensitivity.

• All vehicles are shipped with auto-arming disabled.

• Storage mode set to 10 days.

ALARM SENSITIVITY:TSSM

SensitivityThe TSSM has four sensitivity settings: extremely low, low,medium or high. The selection picked controls the sensitivityof the security system in regards to motion detection.

To set alarm sensitivity, refer to Table E-3.

Table E-3.TSSM Alarm Sensitivity



Set engine stop Switch to OFF.1

Cycle the Ignition SwitchIGN-OFF-IGN-OFF-IGN.

2

Two flashes - Japan/Korea configur-ation TSSM.

Two flashes turn signals and indic-ators depending on vehicle configur-ation

Press left turn switch 2 times andrelease.

3

(See E.3 VEHICLE DELIVERYregarding battery disconnects).

One flash turn signals and indic-ators.

Press and hold key fob button untilconfirmation is received.

4

One flash - extremely lowTurn signals and indicators flash toindicate option selected.

Press left turn switch 2 time andrelease.

5Two flashes - low sensitivityThree flashes - medium sensitivityFour flashes - high sensitivity

One flash - extremely lowTurn signals and indicators flash toindicate option selected.

Press and release left turn switchto advance through options.

6Two flashes - low sensitivityThree flashes - medium sensitivityFour flashes - high sensitivity



Transport ModeIt is possible to arm the security system without enabling themotion detector for one ignition cycle. This allows the vehicleto be picked up and moved in an armed state. In this mode,any attempt to hot-wire the vehicle will trigger the securitysystem.

• To enter the transport mode, refer to Table E-4.

• To exit from transport mode and return the system tonormal operation/functions, disarm the system using eitherthe key fob or Personal Identification Number (PIN).

NOTE

Transport mode is especially useful when working on themotorcycle. If it is not used, the alarm will activate under manytypical service activities.

Table E-4.Transport Mode:TSSM




Turn Ignition Switch to IGN.2

Three flashes turn signals andindicators.


3


The vehicle can be moved withouttripping the alarm.

Three flashes turn signals andindicators.


5

AUTO-ARMING FUNCTION:TSSMAuto-arming causes the system to automatically arm itself (nokey fob needed) within 30 seconds after the Ignition Switch isturned OFF. During this period, the security lamp stays on solidto indicate auto-arming is starting up.

The vehicle may be moved during these 30 seconds withouttriggering the alarm. However, any motion after that period willtrigger the security alarm. Upon expiration of the auto-armingperiod, the turn signals flash twice, the security lamp beginsto flash and the siren (if equipped) chirps twice.

The TSSM allows remote arming via the key fob at any time.However, if the system is remotely disarmed (with the key fob)but the Ignition Switch is not turned to IGN within 30 seconds,the system will rearm itself when auto-arming is enabled.

Japan and Korea motorcycles have auto-arming disabled bydefault. However, the feature may be enabled if the customerdesires.

When auto-arming is disabled, the key fob must be used toarm the security system.To set the auto-arming function, referto Table E-5.

Table E-5. Selecting TSSM Auto-Arming Function





2

Two flashes - Japan/Korea configur-ation TSSM.

Two flashes turn signals and indic-ators (See E.3 VEHICLE DELIVERYregarding battery disconnects).


One flash turn signals and indic-ators.

Press and hold key fob button until confirma-tion is received.

4

Two flashes turn signals and indic-ators.

Press and hold key fob button until confirm-ation is received.

5

One flash - auto-arming disabledTurn signals and indicators flash toindicate option selected.

Press left turn switch 1 time and release.6Two flashes - auto-arming enabled

Turn signals and indicators flash toindicate option selected.

Press and release left turn switch to advancethrough options.

7



STORAGE MODE:TSSMThe TSSM has a special mode for long term storage. Thismode prevents the security system from draining the batteryafter a period of days (10, 20, 60 or infinite) without any IgnitionSwitch activity.

• If the TSSM is set to infinite, the system will not go intostorage mode.

• Vehicles will enter storage mode whether the securitysystem is armed or disarmed.

• If set to 20 days or greater, the customer must use anapproved trickle charger to keep the battery from dischar-ging.

In storage mode, all alarm functions remain active but thereceiver is shut down and will not respond to the key fob. Thevehicle is immobilized because the starter motor and ElectronicControl Module (ECM) are disabled. When the storage modeis entered, the security lamp stops flashing to conserve power.

To wake up the TSSM from storage mode, the Ignition Switchmust be turned to IGN. This will trigger a warning/alarm if thesystem was previously armed. You must use the key fob orPIN to disarm the system and stop the alarm.

To set the storage mode preferences, refer to Table E-6.

Table E-6. Storage Mode Preferences:TSSM


Verify the security lamp isnot blinking (vehicle is dis-armed).



2

Two flashes - Japan/Koreaconfiguration TSSM.

Two flashes turn signals and indicatorsdepending on vehicle configuration

Press left turn switch two times and release.3

(See E.3 VEHICLE DELIVERY regardingbattery disconnects).

One flash turn signals and indicators.Press and hold key fob button until confirma-tion is received.

4

Two flashes turn signals and indicators.Release and then hold key fob button untilconfirmation is received.

5

Three flashes turn signals and indicators.Release and then hold key fob button untilconfirmation is received.

6

One flash - 10 daysTurn signals and indicators flash to indicateoption selected.

Press left turn switch one time and release.7Two flashes - 20 daysThree flashes - 60 daysFour flashes - Infinite

One flash - 10 daysTurn signals and indicators flash to indicateoption selected.

Press left turn switch to advance throughoptions.

8Two flashes - 20 daysThree flashes - 60 daysFour flashes - Infinite



E.7ARMING/DISARMING (TSSM ONLY)

GENERALThere are two methods to arm the security system:

• Using the key fob.

• Using auto-arming. See E.6 SECURITY SYSTEMFUNCTIONS (TSSM ONLY).

NOTE

The vehicle cannot be armed with the Ignition Switch turnedto IGN.

There are two ways to disarm the system:

• Using the key fob. This method works in all situationsexcept before turning Ignition Switch to IGN when TSSMstorage mode is activated.

• Using a Personal Identification Number (PIN).

SECURITY LAMPRefer to Table E-7. The security lamp within the speedometerprovides feedback to the rider confirming armed or disarmedstatus.

Table E-7. Security Lamp Status:TSSM

MODELAMP

No security system (TSM),security system not armed orstorage mode active.

Does not flash.

Ten minute timeout after failedPIN entry attempt or a batteryreconnect has occurred whilearmed.

Flashes every second.

Security system armed.Flashes every 2 seconds.

PIN entry mode.Flashes 4 times a second.

Auto-arming is starting up.You have 30 seconds beforesystem is armed.

Stays on solid with IgnitionSwitch turned OFF.

If solid for more than 4seconds after Ignition Switchis turned to IGN, a currentDTC is present.

Stays on solid with IgnitionSwitch turned to IGN.

USING KEY FOB:TSSM

GeneralThe TSSM reception range for the key fob signal depends ona specific receiver pattern.

NOTE

Environmental and geographic conditions may affect signalrange.

Arming the System1. Hold key fob horizontal at waist level.

2. Point key fob at the front of the vehicle.

3. Hold down the key fob button until the system respondswith two turn signal flashes.

Disarming the System1. Hold key fob horizontal at waist level.

2. Point key fob at the front of the vehicle.

3. Quickly press the key fob button twice. The system willrespond with one turn signal flash.

NOTE

Disarming function may require practice. The key fob buttonmust be pressed twice within 1.5 seconds to send the disarmcommand. The action is very similar to double-clicking a com-puter mouse. Light quick taps work best; very hard or very slowtaps are less likely to work.

TroubleshootingIf the key fob button has been pressed numerous times whileaway from the vehicle, the fob may fall out of synchronizationwith the TSSM. If this happens, the TSSM might fail to recog-nize the key fob's commands.

To solve this problem, press and hold the key fob button for10-15 seconds until the security system responds with two turnsignal flashes. After confirmation, you may resume normal foboperation.

USING THE PIN

GeneralThe Personal Identification Number (PIN) consists of five digitsentered using the left and right turn signal switches. Each digitcan be any number from 1-9. The PIN is intended to be usedto disarm the motorcycle in case the key fob becomesunavailable or inoperable.

See E.3 VEHICLE DELIVERY to set a PIN.

Disarming the SystemRefer to Table E-8. If you make an error while disarming theTSSM using a PIN, the alarm will activate for 30 seconds afterthe last digit is entered. After a failed attempt, the security lampwill flash once every second for 10 minutes. During this time,the vehicle will not accept any attempt to enter a PIN.

Table E-8. Disarming TSSM with the PIN (Example: 3-1-3-1-3)



Turn Ignition Switch to ACC.2


Table E-8. Disarming TSSM with the PIN (Example: 3-1-3-1-3)


System is ready for PINentry.

Security lamp blinks at fast rate.Hold both turn switches in until confirm-ation.

3

Enter first digit of code (3) by pressingleft turn switch 3 times.

4

Serves as "enter" key for firstdigit.


Enter second digit of code (1) bypressing left turn switch 1 time.

6

Serves as "enter" key forsecond digit.


Enter third digit of code (3) by pressingleft turn switch 3 times.

8

Serves as "enter" key forthird digit.


Enter fourth digit of code (1) bypressing left turn switch 1 time.

10

Serves as "enter" key forfourth digit.


Enter fifth digit of code (3) by pressingleft turn switch 3 times.

12

System is disarmed. Youmay use the vehicle or pro-gram another key fob.

Security lamp stops blinking.Press right turn switch 1 time.13


E.8DIAGNOSTIC TROUBLE CODES (DTC)

TSM/TSSMTo diagnose system problems, start by observing the behaviorof the security lamp.

NOTES

• See Figure E-7 or Figure E-8. "Key ON" means that theIgnition Switch is turned to IGN and the Engine StopSwitch is set to RUN (although the engine is not running).

• See Figure E-9.When the Ignition Switch is turned to IGN,the security lamp will illuminate for approximately fourseconds and then turn off.

• If the security lamp is not illuminated at Key ON or if it failsto turn OFF after the initial four second period, thespeedometer may need to be replaced. SeeE.10 SPEEDOMETER SELF DIAGNOSTICS. If "BUS Er"is displayed on the odometer, it may take up to twentyseconds for the security lamp to illuminate.

• The security lamp will also light for eight seconds after thebulb check if historic Diagnostic Trouble Codes (DTCs)are present.The security lamp will stay on if current DTCsare set. If a historic DTC is present, the security lamp willlight for 2 ignition cycles or until the DTC is clearedmanually.

32

1

ed02877


Figure E-7. Ignition Switch (U.S. Models, Except FXDWG,FXDC, FXDF)

312

ed02878


Figure E-8. Ignition Switch: FXDWG, FXDC, FXDF

ed02920

Figure E-9. Security Lamp (key icon):Typical


1. See Figure E-10. After the lamp turns off after being illu-minated for the first four-second period, one of threeevents may occur:

a. The lamp remains off. This indicates there are nocurrent fault conditions or stored historic DTCs cur-rently detected by the TSSM.

b. The lamp stays off for only four seconds and then

comes back on for an eight-second period. Thisindicates a historic DTC is stored, but no current DTCexists.

c. The lamp remains on beyond the eight-second period.This indicates a current DTC exists.

2. See E.8 DIAGNOSTIC TROUBLE CODES (DTC), CodeTypes for a complete description of DTC formats.

ONA

B

C

ON

ON

OFF

OFF

OFF

Key On

Key On

Key On


Lamp OFF




4 Sec.

4 Sec.

4 Sec.

4 Sec.

8 Sec.

4 Sec.

ed01046

Figure E-10. Security Lamp Operation

CODE TYPES



There are two types of Diagnostic Trouble Codes (DTCs):current and historic. If a DTC is stored, it can be read usingeither a computer based diagnostic package called DIGITALTECHNICIAN (Part No. HD-44750) or speedometer self dia-gnostics. See E.10 SPEEDOMETER SELF DIAGNOSTICS.

NOTES

• Speedometer self diagnostics will display both current andhistoric DTCs.To differentiate between current and historicDTCs, a computer-based diagnostic package calledDIGITAL TECHNICIAN (Part No. HD-44750) must beemployed.

• All DTCs reside in the memory of the ECM, TSM/TSSM,speedometer or tachometer until the DTC is cleared byuse of the speedometer self diagnostics. SeeE.10 SPEEDOMETER SELF DIAGNOSTICS.

• A historic DTC is also cleared after a total of 50 ignitioncycles has elapsed. After the 50 ignition cycles retentionperiod, the DTC is automatically erased from memoryproviding that no subsequent faults of the same type aredetected in that period.


HistoricIf a particular problem happens to resolve itself, the activestatus problem is dropped and it becomes a historic DTC ratherthan a current DTC. For example, intermittent output shortscan become typical historic DTCs.

Historic DTCs are stored for 50 ignition cycles after any DTCwas last set as current to assist in the diagnosis of intermittentfaults. On the 50th cycle, the DTC will clear itself. The securitylamp will only indicate the existence of only historic DTCs fortwo ignition cycles.

It is important to note that historic DTCs will exist wheneverthe system indicates the existence of a current fault. SeeE.8 DIAGNOSTIC TROUBLE CODES (DTC), Multiple Dia-gnostic Trouble Codes if multiple DTCs are found.

Diagnostic charts are designed for use with current DTCs andas a result they frequently suggest part replacement. Whendiagnosing an historic DTC the charts can be helpful but shouldnot lead to part replacement without verification the part isfaulty.





The TSM/TSSM supports two levels of diagnostics.


• The second mode requires using speedometer self dia-gnostics. Speedometer, tachometer (if equipped),

TSM/TSSM and ECM DTCs can be accessed and cleared.See E.10 SPEEDOMETER SELF DIAGNOSTICS.

MULTIPLE DIAGNOSTIC TROUBLE CODESWhile it is possible for more than one fault to occur and setmore than one DTC, there are several conditions which mayresult in one fault setting multiple DTCs:

Serial data DTCs (U1016, U1255, U1300 and U1301) may beaccompanied by other DTCs. Always correct the serial dataDTCs before resolving the other DTCs.

Refer to Table E-9. This table gives most TSM/TSSM DTCs apriority ranking.


E.9INITIAL DIAGNOSTIC CHECK:TSM/TSSM

GENERAL



To locate faulty circuits or other system problems, follow thediagnostic flow charts. For a systematic approach, always beginwith E.9 INITIAL DIAGNOSTIC CHECK: TSM/TSSM, InitialDiagnostics. Read the general information and then work yourway through the flow chart box by box.



In order to perform most diagnostic routines, a Breakout Boxand a digital volt/ohmmeter (DVOM) are required. See3.12 BREAKOUT BOX:TSM/HFSM or E.11 BREAKOUT BOX:TSM/TSSM.


Job/Time Code ValuesSome charts may contain warranty job/time codes. Dealershiptechnicians filing warranty claims should use the job/time codevalues printed in bold text underneath the appropriate repair.

Reprogramming ECMDiagnostic charts frequently suggest Electronic Control Module(ECM) replacement. In the event an ECM needs to be replaced,

it must be reprogrammed using a computer-based diagnosticpackage called DIGITAL TECHNICIAN (Part No. HD-44750).See your dealer. Password learn procedure must also be per-formed. See E.21 TSM/TSSM: PASSWORD LEARN.

INITIAL DIAGNOSTICS




Diagnostic Tips• If speedometer reads "BUS Er" with the Ignition Switch

turned to IGN (Engine Stop Switch at RUN with the engineoff), check data bus for an open or short to groundbetween Data Link connector [91A] terminal "3" and ECMconnector [78B] terminal "5", TSSM connector [30B] ter-minal "3", speedometer connector [39B] terminal "2" ortachometer (if equipped) connector [108B] terminal "2".

• Check for an open diagnostic test terminal between DataLink connector [91A] terminal "3" and TSM/TSSM con-nector [30B] terminal "3". With Ignition Switch turned toIGN, serial data bus voltage should be typically 0.6-0.8volt. The range of acceptable voltage is 0-7.0 volts.

• To identify intermittents, wiggle vehicle harness whileperforming steps in the Diagnostic Check charts.


1. Connect BREAKOUT BOX (Part No. HD-42682) betweenwire harness connector [39B] and speedometer connector[39A] using INSTRUMENT HARNESS ADAPTERS (PartNo. HD-46601). See 2.5 BREAKOUT BOX: SPEEDO-METER/TACHOMETER.

2. Compare TSM/TSSM system behavior to symptoms inTable E-10.

All TSM/TSSM Diagnostic Trouble Codes (DTCs) are listed inTable E-9.

Table E-9.TSM/TSSM Diagnostic Trouble Codes (DTC) and Fault Conditions

SOLUTIONFAULT CONDITIONDTCPRI-ORITY

E.20 DTC U1300, U1301 OR BUS ER.J1850 short-to-groundU13001

E.20 DTC U1300, U1301 OR BUS ER.J1850 short-to-batteryU13012

E.19 DTC U1016, U1255.Loss of serial communications - ECMU10163

E.19 DTC U1016, U1255.Loss of serial communication - generalU12554

E.17 DTC B1135.Accelerometer faultB11355

E.18 DTC B1154, B1155.Clutch switch input short-to-groundB11546

E.18 DTC B1154, B1155.Neutral switch input short-to-groundB11557

E.16 DTC B1134.Start relay output short-to-groundB11348

E.13 TURN SIGNAL ERRORS: B1121, B1122,B1141.

Left turn lamp output faultB11219


Table E-9.TSM/TSSM Diagnostic Trouble Codes (DTC) and Fault Conditions

SOLUTIONFAULT CONDITIONDTCPRI-ORITY


Right turn lamp output faultB112210

E.14 DTC B0563.Battery voltage highB056311

E.15 DTC B1131, B1132.Alarm output short-to-groundB113112

E.15 DTC B1131, B1132.Alarm output short-to-groundB113213


Ignition switch input short-to-ground oropen

B114114

Table E-10. Symptoms That May Not Set Diagnostic Trouble Codes

SOLUTIONSYMPTOM

E.12 FAILS TO DISARM (TSSM ONLY).Fails to disarm

E.13 TURN SIGNAL ERRORS: B1121, B1122, B1141.Turn signal will not cancel or cancels erratically

E.13 TURN SIGNAL ERRORS: B1121, B1122, B1141.Turn signal flashes double normal rate, all bulbs good

Other Diagnostic Trouble Codes (DTCs)See 2.2 INITIAL DIAGNOSTIC CHECK: SPEEDOMETER forany DTCs related to the speedometer.

See 4.5 INITIAL DIAGNOSTIC CHECK: EFI for any DTCsrelated to the electronic control module (ECM).


3

1

2

4

321 12

321 12

21 65 7

2

Igni

tion

Ser

iald

ata

Bat

tery

Acc

esso

ryG

roun

d

Igni

tion

Ser

iald

ata

Bat

tery

Acc

esso

ryG

roun

d

Bat

tery

Igni

tion

Ser

iald

ata

Gro

und

1 65 7

21 65 7

21 65 7

21 6 7 12

21 6 7 12

5

5

GYGY

O

O

O/W

O

GY

BN/GY

BN

/GY

LGN/V

LGN

/V

O/W

O/W

BN/GY

LGN/V LGN/V

BN

/GY

LGN

/V

BN

/GY

LGN

/V

ECM

Ser

ialD

ata

[30B][30A]

[20B][20A]

[91A]

[108B][108A]

[39B][39A]

[78B][78A]

Speedometer

12VIgnitionFuse

12VInstrument

Fuse

12VAccessory

Fuse

12VBatteryFuse


Data LinkConnector

NOTE: Connector (20) not presenton FXDWG/FXDC/FXDF models

TSM/TSSM

BK

/GN

BK

/GN

BK

/GN

BK/GN

BK/GN

em00024

Figure E-11. Diagnostic Check

Table E-11. Wire Harness Connectors



[20]

Under electrical caddie cover12-place DeutschTSM/TSSM[30]







Does enginestart?





Check for DTCs. SeeE.10 SPEEDOMETERSELF DIAGNOSTICS.

Were DTCs found?




YES


priority in Table E-9.

NOUnable to enter

diagnostic mode.


With Ignition Switch OFF, press and release TripOdometer Reset Switch.

Does odometer display appear with displaybacklighting?

For a list of symptoms thatmay not set diagnostictrouble codes, refer to

Table E-10.

YES NO



YES NO

Test for battery voltage at Breakout Boxterminal “5” (Black) while wiggling harness.

Is battery voltage continuously present?


YES NO




YES NO

ReplaceSpeedometer.


STOP


1

fc01290_en

2



Continued from Initial Diagnostic Check (Part 1 of 3).Turn Ignition Switch to IGN.


YES NO

Replace Speedometer.Perform “WOW” test.

See E.10 SPEEDOMETER SELF DIAGNOSTICS.The following features should be functional:


• check engine• battery• security• low fuel• sixth gear• pursuit


YES


YES NO


YES NO


YES NO




STOP


1

NO

Turn Ignition Switch to IGN. Check forbattery voltage at Breakout


YES NO


YES NO




1

fc01291_en




YES NO.Speedometer



(no engine speed).




Debris present?

See 2.4 SPEEDOMETER/TACHOMETER.

YES NO


No trouble found.

YES NO





connection present?

YES NO


ReplaceSpeedometer.

fc01292_en

2


E.10SPEEDOMETER SELF DIAGNOSTICS

GENERALThe Speedometer is capable of displaying and clearingSpeedometer, Tachometer, TSM/TSSM, and Electronic ControlModule (ECM) Diagnostic Trouble Codes (DTCs) (diagnosticmode).

DIAGNOSTICS

Diagnostic Tips• For a quick check of speedometer function, a "WOW" test

can be performed. Press and hold Trip Odometer ResetSwitch then turn Ignition Switch to IGN. Release TripOdometer Reset Switch. See Figure E-12. Backgroundlighting should illuminate, gauge needles should sweeptheir full range of motion, and indicator lamps (battery,security, low fuel, check engine and sixth gear indicator)should illuminate. All lamps should illuminate, even thosenot used in normal vehicle operations.

• If speedometer fails "WOW" test, check for battery, ground,ignition, Trip Odometer Reset Switch and accessory wiringto speedometer. If any feature in the speedometer is non-functional, see 2.2 INITIAL DIAGNOSTIC CHECK:SPEEDOMETER.







d. Press and hold the Trip Odometer Reset Switch formore than 5 seconds to clear DTCs for the moduleselected.

4

5

321

ed02883


Figure E-12. Security Lamp (key icon): Dyna Models

32

1

ed02877


Figure E-13. Ignition Switch (U.S. Models, Except FXDWG,FXDC, FXDF)


312

ed02878


Figure E-14. Ignition Switch: FXDWG, FXDC, FXDF



1


RUN position.


YES

”P” flashing.



To display DTCs forTSM/TSSM, press and


than 5 seconds.



Switch.

”S” flashing.



Switch.

”SP” flashing.



Switch.



”T” flashing.



than 5 seconds.







CHECK: SPEEDOMETER.

YES

YES

NO

NO

NO

Deviceresponse?

Press andrelease


displayed.

Press andrelease














DTCdisplayed.


2

fc01640_en

”b” flashing.







E.11BREAKOUT BOX:TSM/TSSM

GENERAL



The BREAKOUT BOX (Part No. HD-42682) splices into themain harness. Used in conjunction with a digital volt/ohmmeter(DVOM), it allows circuit diagnosis of wiring harness and con-nections without having to probe with sharp objects.

INSTALLATION1. Disarm security system (if installed).

2. Gain access to TSM/TSSM. See Dyna Service Manual.

3. See Figure E-15. Depress latches on connector [30B].

4. See Figure E-16. Attach Breakout Box to connector.

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

b. Mate gray pin housing on Breakout Box with wireharness connector [30B].

1

2

ed03008

1. Connector [30A] terminal 12. Connector [30A] terminal 12

Figure E-15.TSM/TSSM Connector Pins

ed02899

Figure E-16. Breakout Box:TSSM

REMOVAL1. See Figure E-15. Depress latches on connector [30B].

2. Detach gray Breakout Box connector from TSM/TSSMconnector [30A].

3. Detach gray Breakout Box connector from wire harnessconnector [30B].

4. Reinstall TSM/TSSM. See Dyna Service Manual.

5. Install parts removed for access.

NOTE

Vehicle will not start with TSM/TSSM disconnected or incor-rectly mounted.

Table E-12.TSM/TSSM Connector [30B]




Start relay control9Serial data3





E.12FAILS TO DISARM (TSSM ONLY)

GENERAL

Security Equipped Vehicles OnlyThis section applies only to those vehicles equipped with theoptional security system (TSSM).

NOTE

Disarming function may require practice. The key fob buttonmust be pressed twice within 1.5 seconds to send the disarmcommand. The action is very similar to double-clicking a com-puter mouse. Light quick taps work best; very hard or very slowtaps are less likely to work.

See Figure E-17. The key fob sends a RF signal to activate allremote TSSM functions. The left front turn signal switch wireserves as the vehicle's antenna. If the TSSM does not respond(no confirmation at arming/disarming system) or respondsweakly (limited range, won't consistently arm/disarm or syn-chronize), follow the flow chart.


ed03009

Figure E-17. Key Fob Battery:TSSM

DIAGNOSTICS

Diagnostic Tips• Verify key fob battery voltage is at least 2.9 volts. See

E.22 TSSM MAINTENANCE.

• Interference from physical surroundings may affect RFtransmission. Place fob next to left handgrip and disarmwith two clicks or move motorcycle to a new location andretest.

• Check for damage to antenna wire. Does left turn signalwork?

NOTE

See E.7 ARMING/DISARMING (TSSM ONLY). Use only theproper key fob for your market and TSSM package.


1. After a battery disconnect, the TSSM will not enter theconfiguration mode on the first attempt. All attempts toassign a fob or enter the configuration mode will requireat least two attempts.


– +

Left Turn Signal Switch

40 AmpMAXIFUSE

15 AMPBatteryFuse

Battery

TSS/TSSM

[24B][24B]

[30B][30A]

RR

5 5Key fob antenna

(TSSM only)

W/V

W/V

BK

BN

/GY

1 8 12

1 8 12

BK

/GN

em00025

Figure E-18. Antenna Circuit






TSSM Fails to Disarm

Correct key fob forvehicle?

YES NO

Does left turn signal function? Obtain correct fob or replace fob.Verify fob is synchronized to vehicle’s

TSSM.

YES NO

Replace fob battery and retest.See E.22 TSSM MAINTENANCE.

Does fob work?

See E.13TURN SIGNAL ERRORS:

B1121, B1122, B1141.

1

YES NO

System OK. Attempt to assign newfob to TSSM and retest.

Does fob work?

YES NO

System OK.Replace TSSM.

Learn password andperform set-up.

67576756

6755

fc01294_en


E.13TURN SIGNAL ERRORS: B1121, B1122, B1141

GENERALThe turn signals will automatically cancel either based on thespeed/acceleration of the vehicle or based upon turn comple-tion. See E.4 TURN SIGNAL FUNCTIONS.

For turn signal diagnostics, refer to Table E-14.

Job/Time Code ValuesDealership technicians filing warranty claims should use thejob/time code printed in bold text underneath the appropriaterepair.

sm01275

Figure E-19.TSM/TSSM

DIAGNOSTICS


HARNESS CONNECTOR ADAPTERSHD-41404-B

BREAKOUT BOXHD-4268

Diagnostic Tips: All• Diagnostic Trouble Codes (DTCs) B1121 and B1122 will

illuminate the security lamp.

• DTC B1141 will not illuminate the security lamp.

• When the TSM/TSSM is in 4-way flasher mode, a fault oneither the left or right turn lamp output will not cause eitherDTC B1121 and DTC B1122 to be set. If fault occurs onboth left and right outputs, then both DTC B1121 and DTCB1122 will be set.

• When the TSM/TSSM detects an over current or short toground condition, it will turn off the turn lamp outputs.Theoutputs will be automatically reactivated once the fault isremoved.

Table E-14.Turn Signal Errors:TSM/TSSM


Turn Signal Error 1A (Part 2 of 2)Turn signals cancel erraticallyN/A

Turn Signal Error 2ATurn signals will not flash, 4-way flashers inoperableB1121, B1122,B1141

Turn Signal Error 1A (Part 1 of 2)Turn signals will not cancel upon turn completionN/A

Turn Signal Error 3ALeft or right turn signals flash at double the normal rate while all bulbsare working

N/A


IGN

AC

CY

15A

15A

[31A

R]

Igni

tion

Sw

itch

[7A

]

[33A

][3

3B]

Tofr

ont

turn

sign

als

Tore

arlig

htin

g

Bat

tery

EC

M

15A

15A

Sec

urity

Sire

n(o

ptio

nal)

AIPG

BJRH

Sta

rtR

elay

21 321 3

[62B

]

BK

[142

B]

[142

A]

[78B

]

[30B

]

Pow

erS

igna

lG

roun

d

[5]

40A

mp

MA

XIF

US

E

BA

GN

D1

Rea

rgr

ound

stud

unde

rel

ectr

ical

cent

er

12

21

13

8

AC

C−

BAT

T−

IGN

−

[78A

]

[31A

L]

A B C

4 5 10 13 28 31

4 5 10 13 28 31

K T E S U

87 87A

30 85 86

5 4 3 2 1

EC

M

[24B

]1

57

8

15

78

[64B

]

Hor

nS

witc

hH

eadl

amp

Hi/l

oS

witc

hLe

ftTu

rnS

witc

h

[24A

]

Left

Han

dC

ontr

ols

Clu

tch

Sw

itch

13

12

35

67

812

45

6

Rig

htTu

rnS

witc

hE

ngin

eS

top

Sw

itch

Sta

rtS

witc

h

Fron

tSto

pLa

mp

Sw

itch

[22A

]

Rig

htH

and

Con

trol

s

13

45

6

Fus

eblo

ckTo

pvi

ewTo

pvi

ew

[64]

[62]

Acc

esso

ries

Ligh

ts

Igni

tion

C

BF L U

SKED

C IJ R

PO

MGHB

A

H O

G MA

I QP

R

E K TS

U

Fue

lPum

p

Sta

rtR

LYS

yste

mR

LYE

CM

Bat

tery

Spa

reP

&A

IGN

Inst

rum

ents

Spa

re

EN

GC

TL

CU

ST

AC

CY

A B C

Sys

tem

Rel

ay

[22B

]

INS

TR

15A

AB

[20B

]

5 4 3 2 1

87 87A

30 85 86

I Q C P R

Sta

rter

Bat

tery

Red

band

[30A

]

Bat

tery

Sys

tem

rela

yS

eria

ldat

a

Gro

und

Gro

und

Bat

tery

Sw

itche

dpo

wer

Igni

tion

Ser

iald

ata

Neu

tral

switc

hLe

fttu

rnfe

edR

ight

turn

feed

Rig

httu

rnsw

itch

inpu

tLe

fttu

rnsw

itch

inpu

tS

tart

rela

yC

lutc

hsw

itch

Ala

rmsi

gnal

Gro

und

21 43 65 87 109 1211

21 43 65 87 109 1211

TNBK

[131

]

Neu

tral

Sw

itch

Toin

stru

men

tass

embl

yA

B

Turn

Sig

nal&

Sec

urity

Mod

ule

TS

M/T

SS

M

GN

D2

BK

BK

BK

BK

GN

BK

BN

BK

BK

TN

TN

BN

BK

/GN

BK

/GN

BK

/GN

TN

GY

O/W O/W

W/V W/V

W/V

V

VBN

/GY

LGN

/V

LGN/V

LGN

/V

BN

/GY

TN

/GN

BE

/GY

LGN

/BN

LGN

/BN

BK/R BK/R

GN

/O

W/B

N W/B

K

BK

/R

GY

BN

GY

BKBN

BK

GY

O/WO/W

O/W GNO

V

R R

R

R

R

R

BE

/GY

BE

/GY

BN

/GY

TN

/GN

BK/RBK/R

W/BK W/BKW/BNW/BN

W/B

KG

N/R

BK

/R

R/B

K

R/B

K

R/B

K

R/B

K

R/B

K

R/G

Y

R/G

Y

O/W

OV

BN/GY

BK/GN

BK/GN

BK/GN

em00026

Figure E-20.Turn Signal Circuit:Typical





Under seat8-place MolexRear lighting[7]

Inside top frame tube12-place DeutschConsole gauges/indicator lamps (allexcept FXDW/FXDC/FXDF)

[20]




Inside top frame tube3-place MultilockFront turn signals (left)[31 L]

Inside top frame tube3-place MultilockFront turn signals (right)[31 R]

FXD, FXDL: Inside top frame tube3-place DelphiIgnition Switch[33]FXDWG, FXDC, FXDF: Under fuel tankconsole


[62]



Top of transmissionPost terminalsNeutral Switch[131]


Diagnostic Notes: All Turn Signal FlowChartsEach reference number below correlates to a circled numberon the flow chart(s).

1. Gain access to vehicle's TSM/TSSM. Perform the followingprocedure:

a. See Figure E-21. Position TSM/TSSM in same orient-ation it is mounted on vehicle. Turn Ignition Switchon. Turn 4-way flashers on by depressing both leftand right turn signal switches simultaneously. TurnIgnition Switch off.The 4-way flashers should continueto flash.

b. Tilt module greater than 45 degrees to the left.

c. Repeat step a.

d. Tilt module greater than 45 degrees to the right.

2. To enable diagnostic mode, see E.10 SPEEDOMETERSELF DIAGNOSTICS.

3. Connect BREAKOUT BOX (Part No. HD-4268) (gray)between TSM/TSSM connector [30A] and wiring harnessconnector [30B]. See E.11 BREAKOUT BOX:TSM/TSSM.


5. Connect gray harness connector adapters HARNESSCONNECTOR ADAPTERS (Part No. HD-41404-B) andpatch cords to connector [22] (right) or connector [24] (left).

ed02900

Figure E-21.Tilting TSM/TSSM/HFSM


Turn Signal Error 1A Will Not Cancel Upon Turn Completion (Part 1 of 2)

Is TSM/TSSM mounted properly?

YES NO

Mount correctly.Check if TSM/TSSM is configured forsolo or side car operation.

See E.3 VEHICLE DELIVERY.Proper configuration?

YES NO

Select properVehicle configuration.

Do 4-way flashers cancel inboth directions?

YES NO

Operate motorcycle at a speed greaterthan 7 MPH (11.3 km/h) in a straight line.Activate either turn signal. Turn signals

should cancel after 20 flashes.Do turn signals cancel?

Replace TSM/TSSM.Perform setup and

password learn.

6773

YES NO

Does speedometerregister vehicle

speed?

YES

Replace TSM/TSSM.Perform password learn

and setup.

NO

Refer to 2.2 INITIALDIAGNOSTIC CHECK:

SPEEDOMETER.

6773

1

2

STOP

Go to Turn Signal Error1A Cancels Erratically

(Part 2 of 2).

fc01295_en


Diagnostic Flow Chart:Turn Signal Error 1A Cancels Erratically (Part 2 of 2)

Continued from Turn Signal Error 1A Will Not Cancel Upon Turn Completion(Part 1 of 2).

Check for voltage between Breakout Box terminal “8” (Gray) and ground atBreakout Box terminal “12” (Gray): with left turn signal switch depressed, wiggle

harness between TSM/TSSM and left handlebar switches whilemonitoring for voltage fluctuations or changes in turn signal flash pattern.

Check for voltage between Breakout Box terminal “7” (Gray) and ground atBreakout Box terminal “12” (Gray): with right turn signal switch depressed,wiggle harness between TSM/TSSM and right handlebar switches whilemonitoring for voltage fluctuations or changes in turn signal flash pattern.


YES

Locate and repairintermittent open.

NO

Check for voltage between Breakout Box terminal “8” (Gray) and ground atBreakout Box terminal “12” (Gray): with left turn signal switch NOT depressed,

wiggle harness between TSM/TSSM and left handlebar switches whilemonitoring for voltage fluctuations or turn signal activation.

Check for voltage between Breakout Box terminal “7” (Gray) and ground atBreakout Box terminal “12” (Gray): with right turn signal switch depressed,wiggle harness between TSM/TSSM and right handlebar switches while

monitoring for voltage fluctuations or turn signal flash pattern.


YES

Locate and repairintermittent short to

voltage.

Turn Ignition Switch OFF.

Check for continuity between Breakout Box terminal “8” (Gray) and groundat Breakout Box terminal “12” (Gray): with left turn signal switch

depressed, wiggle harness between TSM/TSSM and left handlebarswitches.

Check for continuity between Breakout Box terminal “7” (Gray) and groundat Breakout Box terminal “12” (Gray): with right turn signal switch

depressed, wiggle harness between TSM/TSSM and right handlebarswitches.

Is continuity present at any time?

NO

YES NO


to ground.

System OK. Review turn signalcancellation function with customer.See AUTOMATIC CANCELLATION

under E.4 TURN SIGNALFUNCTIONS.

4

4

3

fc01296_en

4


Turn Signal Error 2A Will Not Flash, 4-way Flashers Inoperable: DTC B1121, B1122, B1141

Turn Ignition Switch to IGN.Are turn signal lamps on continuously?

YES NO

Check for voltage on Breakout Box terminal “5”(Gray) (left turn signals) or terminal “6” (Gray) (rightturn signals) with TSM/TSSM disconnected from

Breakout Box.Is battery voltage present?

YES NO

Locate and repairshort to voltage.

Replace TSM/TSSM.Learn password and

perform setup.

Activate 4-way flashers.Do any lamps illuminate?

YES NO

Connector [30]mated fully?STOP

Go to Turn Signal Error2B Will Not Flash, 4-way

Flashers Inoperable:DTC B1121, B1122,

B1141.

NOYES

Place red meter lead at terminal “1”(Gray) and black meter lead at

terminal “12” (Gray) of Breakout Box.Is battery voltage present?

Mateconnector.

NOYES

Move red meter lead toBreakout Box terminal “2”.Is battery voltage present?

STOP

Go to Turn Signal Error2C Will Not Flash, 4-way


B1141.

NO

Check for voltage at IgnitionFuse.

Is battery voltage present onboth terminals?

NO

YES

STOP


3

67906791

3

6792

STOP

Go to Turn Signal Error2D Will Not Flash, 4-way


B1141.

YES


between Ignition Fuseand TSM/TSSM.

6793fc01297_en


Turn Signal Error 2B Will Not Flash, 4-way Flashers Inoperable: DTC B1121, B1122, B1141

Continued from Turn Signal Error 2AWill Not Flash, 4-way Flashers Inoperable:

DTC B1121, B1122, B1141.

Inspect bulbs on side that will not flash.Are the bulbs OK?

YES NO

Place jumper wire betweenterminals “1” and “6” of Breakout Box.

Do the right turn signals (front andrear) illuminate?

Replace bulbsas necessary.

6796

YES

Place a jumper wire betweenterminals “1” and “5” of Breakout Box.

Do the left turn signals (front andrear) illuminate?

NO

Check for continuity betweenterminal “6” of Breakout Box and

lamps (front and rear).Is continuity present?

YES


6797

NO

Repair open betweenlamps and TSM/TSSM

connector [30].

6798

YES NO

Check for continuitybetween terminal “5” of

Breakout Box andlamps (front and rear).Is continuity present?

YES NO


Repair open betweenlamps and TSM/TSSM

connector [30].6799

6800

STOP

Go to Turn SignalError 3A Flash at

Double Normal Rate,All Bulbs Working.

fc01298_en


Turn Signal Error 2C Will Not Flash, 4-way Flashers Inoperable: DTC B1121, B1122, B1141

Continued fromTurn Signal Error 2A Will Not

Flash, 4-way Flashers Inoperable:DTC B1121, B1122, B1141.

Check resistance to ground onBreakout Box terminal “12” (Gray).


YES

Check for 12 volts at bothterminals of 15 amp Battery Fuse.

Proper voltage present atboth terminals?

YES

Repair open in (BN/GY) wirebetween Battery Fuse and TSSM.

6806

NO

NO

One Terminal?

Repair poorground.

6805

Neither terminal?

Replacefuse.

6807

Repair open between 40 AmpMAXIFUSE and fuse block.

6808

fc01299_en


Turn Signal Error 2D Will Not Flash, 4-way Flashers Inoperable: DTC B1121, B1122, B1141

Continued from Turn Signal Error 2A WillNot Flash, 4-way Flashers Inoperable:

DTC B1121, B1122, B1141.

Check for battery voltage at breakout boxterminal “7” (Gray) with right turn signal

depressed and terminal “8” (Gray) with leftturn signal depressed.


YES

Replace TSSM.Learn password and

perform set-up.

NO

6791

3

Check for battery voltage on terminal“1” connector [22B] (right), or

connector [24B] (left).Is battery voltage present?

5

YES NO

With turn signal switch depressedon side under test, check for continuitybetween terminal “1” and terminal “5”

on connector [22A] (right), or connector[24A] (left).


Locate and repair open (O/W)wire between terminal “1” on connector

[22B] (right), or connector[24B] (left) and Accessory Fuse.

6814 - right

6812 - left

YES NO


[22B] (right), or connector [24B](left) and TSSM connector [30].


Turn Signal Switch?

6813 - right

6810 - left

6811

fc01300_en


Turn Signal Error 3A Flash at Double Normal Rate, All Bulbs Working

Determine correct part number forall installed turn signal bulbs and verifyagainst parts installed on motorcycle.

Correct parts installed?

YES NO

Check for corrosionon bulbs and/or sockets.

Corrosion present?

Replace withcorrect bulbs.

6820

NOYES

Remove corrosion with a wirebrush. Install ELECTRICAL

CONTACT LUBRICANT (PartNo. 99861-02) in bulb sockets.Do lamps flash at normal rate?

Check for corrosionon all lamp connectionterminals. Corrosion

present?

YES NO

SystemOK.

6821

Clean or replace bulb.Do lamps flashat normal rate?

YES NO

SystemOK.

Replacelamp

assembly.68226823

YES NO

Clean corrosion fromwires and terminals.

Do lamps flash atnormal rate?

Replace TSM/TSSM.Learn password (if

needed) and performsetup.

6824

YES

SystemOK.

6822

NO

Replace TSM/TSSMLearn password (if

needed) and performsetup.

6824

fc01168_en

Verify that lamps are learned:1) Turn ignition off - on2) Activate left turn lamp for 5 flashes.3) Activate right turn lamp for 5 flashes.Do the lamps flash at the normal rate?

NOYES

System OK.


E.14DTC B0563

GENERAL

Battery Voltage HighThe TSM/TSSM continually checks the battery voltage duringIGN/OFF and IGN/RUN power modes. If the voltage exceeds16.0 volts for more than 5.0 0.5 seconds, the TSM/TSSM setsdiagnostic trouble code (DTC) B0563.

DIAGNOSTICS

Diagnostic Tips• This DTC may set when the vehicle is placed on a battery

charger, on fast charge, for a long period of time.

• The TSSM does not illuminate the security lamp when thisDTC is set.

Diagnostic NotesSee 1.7 CHARGING SYSTEM tests to correct. Problem maybe faulty voltage regulator.


E.15DTC B1131, B1132

GENERALNOTE

This section applies only to those vehicles equipped with theoptional security system.

Alarm Output Low (DTC B1131) or AlarmOutput High (DTC B1132)See Figure E-22. An alarm cycle is activated when the TSSMis connected, the siren has been armed by the TSSM and asecurity event occurs. See E.6 SECURITY SYSTEM FUNC-TIONS (TSSM ONLY). Under normal armed operation, thesiren input (terminal "2") is driven low by the TSSM to triggerthe audible alarm. When the siren input is driven high by theTSSM the audible alarm stops.

ed02047

Figure E-22. Siren

DIAGNOSTICS




Diagnostic Tips• If the siren is armed and the internal siren battery is dead,

shorted, disconnected, or has been charging for a period

longer than 24 hours, the siren will respond with threechirps on arming instead of two.

• The internal siren battery may not charge if the vehicle'sbattery is less than 12.5 volts.

• If the siren does not chirp two or three times on a validarming command from the TSSM, the siren is either notconnected, not working, or the siren wiring was openedor shorted while the siren was disarmed.

• If the siren enters the self-driven mode where it is poweredfrom the siren internal nine-volt battery, the turn-signallamps will not alternately flash. If the TSSM activates thesiren, the turn-signal lamps will flash. If the siren has beenarmed and a security event occurs, and the siren is in self-driven mode, the siren will alarm for 20 to 30 seconds andthen turn off for 5 to 10 seconds. This alarm cycle will berepeated ten times if the siren is in the self-driven mode.

• If the siren does not stop alarming after it has been armed,then either the TSSM output or siren input may be shortedto ground, or the siren vehicle battery connection is openor shorted to ground, or the siren vehicle ground connec-tion is open, or a security event has occurred. SeeE.6 SECURITY SYSTEM FUNCTIONS (TSSM ONLY) fora description of alarm functions.


1. Use BREAKOUT BOX (Part No. HD-42682) and HAR-NESS CONNECTOR TEST KIT (Part No. HD-41404-B),gray pin probe and patch cord. See E.11 BREAKOUTBOX: TSM/TSSM.

2. Use HARNESS CONNECTOR TEST KIT (Part No. HD-41404-B), gray socket probe and patch cord.

3. Having the correct multimeter ohm scale is important forthis test. Some meters may read infinity for high ohmvalues. If this is the case, check your ohm scale and retest.


BK

BK

RRRR

BK

/GN

BN

/GY

BN/GY

BN/GY

LGN/BN

LGN

/BN

– +

[30A][30B]

[142A] [142B]

TSSM

GND 1

GND 2

15 AmpBatteryFuse

40 AmpMAXIFUSE

Battery

SecuritySiren

(Optional)

1

1

Bat

tery

Ala

rmsi

gnal

Gro

und

1211

1211

1

2

3

1

2

3

BK

/GN

em00027

Figure E-23. Siren Circuit




Under seat3-place DelphiSecurity siren[142]


Alarm Output Low: DTC B1131, DTC B1132

YES

NO

1

YES

2

YES NO

3

NO

NO

NO

NO

YES

YES

YES

Check for battery voltage at security sirenconnector [142B]. With ignition ON,

measure voltage between terminal “3” (BK)and terminal “1” (BN/GY).Is battery voltage present?

With ignition OFF, check continuity betweensecurity siren connector [142B] terminal “3” and

Breakout Box terminal “12”. Then measurecontinuity between security siren connector [142B]

terminal “1” and Breakout Box terminal “1”.Is continuity present?

With ignition OFF, measure resistance betweensecurity siren connector [142B] terminal “2” and

Breakout Box terminal “11” (gray).Is resistance less than 1 ohm?

Measure resistance between BreakoutBox terminal “11” and chassis ground.


Disconnect Security Siren from BreakoutBox. Measure resistance between securitysiren connector [142A] terminal “2” and “3”.

Is resistance between 120,000-200,000ohms with Security Siren disconnected?

Connect Security Siren to a knowngood motorcycle. Arm and activateSecurity Siren to verify operation.

Disarm Security Siren.Did Security Siren operate correctly?

Replace TSSM. Learnpassword and perform setup.

Locate and repairshort between (BN/GY)

and (BK) wires.

Locate and repairgrounded (LGN/BN)

wire.

Locate and repairopen on (LGN/BN) wire.

ReplaceSecurity Siren.

ReplaceSecurity Siren.

Repairopen wire.


1

fc01645_en

Disconnect TSSM from breakoutbox. Check for voltage on TSSM

connector [30A] terminal “11”.Voltage present?

NOYES

Locate and repairShort to voltage on

(LGN/BN) wire.

2

3


E.16DTC B1134

GENERAL

Starter Output HighWith the TSM/TSSM disarmed, Ignition Switch turned toIGNITION, Engine Stop Switch set to RUN and the transmissionin neutral or clutch lever pulled in, the start relay is grounded.Battery voltage is applied to the start relay and coil which aregrounded through the TSM/TSSM.

ed02901

Figure E-24. Start Relay

DIAGNOSTICS




1. Connect BREAKOUT BOX (Part No. HD-42682) (gray) towire harness connector [30] leaving TSM/TSSM discon-nected. See E.11 BREAKOUT BOX: TSM/TSSM.


IgnitionSwitch:All but

FXDWG/FXDC/FXDF

IgnitionSwitch:

FXDWG/FXDC/FXDF

40 AmpMAXIFUSE

15 AmpBatteryFuse

[GND1]

[30B]

[30A]

[33A]

[33B][33A]

To start switchon right hand controls

Start Relay

TSM/TSSM

Battery

- +

BK

R

RR

TN/GN

BN

/GY

TN

/GN

BK/R

R/B

K

R

R/B

K

R/BK

A B C

I B A

A B C

1 9 12

1 9

Bat

tery

Sta

rtre

lay

cont

rol

Gro

und

12

8787

A30

8586

KT

ES

U

54

32

1

[22]

BK

/GN

em00028

Figure E-25. Starter TSM/TSSM Circuit






Under electrical caddie cover5-place AmpStart relay[62B]


Starter Output High: DTC B1134

Remove Start Relay.Check for voltage on

Breakout Box terminal “9” (Gray).Is voltage present?

YES

Locate and repairshort to voltage

on (TN/GN) wire.

NO

Install Start Relay.Is voltage present on

Breakout Boxterminal “9” (Gray)?

YES

Replace Start Relay.

NO

Replace TSM/TSSM.Learn password and

perform setup.

1

Clear DTCs using speedometer self diagnostics.See E.10 SPEEDOMETER SELF DIAGNOSTICS.Confirm proper operation with no check engine lamp.

fc01303_en


E.17DTC B1135

GENERAL

Accelerometer Fault: B1135Diagnostic Trouble Code (DTC) B1135 indicates a failure whichrequires replacement of the TSM/TSSM.

NOTE

When DTC B1135 is set, the tip-over engine shutdown, TSSMtamper alarm and bank angle sensors are disabled. Thesecurity lamp will also illuminate when this code is set.


E.18DTC B1154, B1155

GENERALDTC B1154 may occur if the motorcycle is ridden with theclutch pulled at speeds greater than 10 MPH (16 km/h) formore than 60 seconds (as in coasting down a long mountainroad).

DIAGNOSTIC NOTES



Each reference number below correlates to a circled numberon the flow chart(s).

1. Connect BREAKOUT BOX (Part No. HD-42682) to TSSM.See E.11 BREAKOUT BOX: TSM/TSSM.

2. If DTC is current (lamp on continuously, clear codes returnduring operation), replace TSSM. If DTC is historic, checkfor intermittents.

3. A reading of several hundred ohms is normal due to theneutral indicator lamp (LED).

Table E-18. Clutch/Neutral Switch DTCs


Clutch Switch Short-to-Ground: DTC B1154Clutch switch short-to-groundB1154

Neutral Switch Short-to-Ground: DTC B1155Neutral switch short-to-groundB1155


O

O

TSM/TSSM

4

10

4Neutral switch

Clutch switch 10

[20B]

[30B][30A]

8

[131]

NeutralSwitch

GND2GND1Rear groundstud underelectrical

center

[20A]

Clutch Switch

[163]

LeftHand Controls

[24A]

[24B]

7 8

7 8

[21A]

[21B]

FXDL Configuration

FXDB Configuration

8

6

6

7

7

8

8

86

[20A]

[21A]

[21B]

5

5

AB

6

6

FXDWG/FXDC/FXDF Configuration

To mainharness

To ISAInstrument

fuse

TN

TN

TN

TN

TN

TN

TN

BK

BK

BK

BK

BK/R

BK

/RB

K/R

O

O

O

O

BK

/GN

BK

/GN

em00029

Figure E-26. Clutch and Neutral Interlock Circuits



Inside top frame tube12-place DeutschConsole gauges/indicator lamps[20]

Under fuel tank console8-place Mini-DeutschIndicator lamps[21]




Clutch Switch Short-to-Ground: DTC B1154

Connect Breakout Box HD-42682 to the main harness, leavingconnector [30] disconnected. Measure continuity between

terminal “10” (Gray) and terminal “12” (Gray).Is continuity present?

YES NO

Disconnect connector [24]. Measurecontinuity between terminal “10” (Gray) and

terminal “12” (Gray) on Breakout Box.Is continuity present?

Replace TSSM. Learn passwordand perform set-up.

1

6791

YES NO

Locate and repair short-to-ground on (BK/R) wire in mainwiring harness between [30B]

and [24B).

Locate and repairshort-to-ground in

left handlebar switchwiring.

5861 5861

NOTEThis DTC may occur if the vehicle is ridden with clutch disengaged(pulled in) at speeds greater than 10 MPH (16 km/h)for more than 60 seconds (coasting down a long mountain road).

fc01304_en

2


Neutral Switch Short-to-Ground: DTC B1155

WIth the transmission in 1st or 2nd gear, connectBreakout Box HD-42682 to the main harness, leavingthe TSSM disconnected. Measure continuity between

terminal “4” (Gray) and terminal “12” (Gray).Is continuity (less than 10 ohms) present?

YES NO

Disconnect Neutral Switch [131]. Measurecontinuity between terminal “4” (Gray) and

terminal “12” (Gray) on Breakout Box.Is continuity (less than 10 ohms) present?

Replace TSSM. Learn passwordand perform set-up.

1

6791

YES NO

Locate and repair short-to-ground on (TN) wire in main

wiring harness.

Replace Neutral Switch.

5862

5157

NOTEThis DTC may occur if the vehicle is ridden with transmission inneutral at speeds greater than 10 MPH (16 km/h) for more than60 seconds (coasting down a long mountain road).

fc01305_en

23

3


E.19DTC U1016, U1255

GENERAL

Loss of ECM Serial DataThe serial data connector provides a means for the ElectronicControl Module (ECM), TSM/TSSM, and speedometer tocommunicate their current status. When all operating para-meters on the serial data bus are within specifications, a stateof health message is sent between the components. A Dia-gnostic Trouble Code (DTC) U1016 indicates that the ECM isnot capable of sending this state of health message. A DTCU1255 indicates that no messages were present during powerup of the current key cycle. A DTC U1016 indicates that therewas communication on the data bus since power up, but waslost or interrupted during that key cycle.

Table E-20. Code Description

DESCRIPTIONDTC

Loss of all ECM serial data (state ofhealth)

U1016


ed02894

Figure E-27. ECM Location: Dyna Models

DIAGNOSTICS





1. Connect BREAKOUT BOX (Part No. HD-42682) (gray)between TSM/TSSM connector [30A] and wire harnessconnector [30B]. See E.11 BREAKOUT BOX:TSM/TSSM.



3

1

2

4

321 12

321 12

21 65 7

2

Igni

tion

Ser

iald

ata

Bat

tery

Acc

esso

ryG

roun

d

Igni

tion

Ser

iald

ata

Bat

tery

Acc

esso

ryG

roun

d

Bat

tery

Igni

tion

Ser

iald

ata

Gro

und

1 65 7

21 65 7

21 65 7

21 6 7 12

21 6 7 12

5

5

GYGY

O

O

O/W

O

GY

BN/GY

BN

/GY

LGN/V

LGN

/V

O/W

O/W

BN/GY

LGN/V LGN/V

BN

/GY

LGN

/V

BN

/GY

LGN

/V

ECM

Ser

ialD

ata

[30B][30A]

[20B][20A]

[91A]

[108B][108A]

[39B][39A]

[78B][78A]

Speedometer

12VIgnitionFuse

12VInstrument

Fuse

12VAccessory

Fuse

12VBatteryFuse


Data LinkConnector

NOTE: Connector (20) not presenton FXDWG/FXDC/FXDF models

TSM/TSSM

BK

/GN

BK

/GN

BK

/GN

BK/GN

BK/GN

em00024

Figure E-28. Serial Data Circuit




[20]





Back of tachometer12-place PackardTachometer[108]


Loss of ECM Serial Data: DTC U1016; Serial Data Error/Missing Message: DTC U1255

See E.10 SPEEDOMETER SELFDIAGNOSTICS.

Can you read ECM hardware part number?


While wiggling harness, check continuitybetween terminal “3” (Gray) of

TSM/TSSM Breakout Box and terminal“5” of ECM Breakout Box.


Check continuity between terminal “3”(Gray) of TSM/TSSM Breakout Boxand terminal “5” of ECM Breakout

Box.Is continuity present?

1

2

Clear DTCs using speedometer selfdiagnostics. See E.10 SPEEDOMETER SELFDIAGNOSTICS. Confirm proper operationwith no check engine lamp.

1

2

YES

Clear codes. Test ride.Did DTC U1016 return?

YES


password.

NO


NO

No trouble found.

YES


password.

NO


fc01306_en


E.20DTC U1300, U1301 OR BUS ER

GENERAL

Serial Data Low or Serial Data Open/HighThe typical serial data voltage range is 0 volts (inactive) to 7volts (active). Due to the short pulse, voltages will be muchlower on a digital/voltmeter (DVOM). In analog mode, a DVOMreading serial data will show continuous voltage when active,typically 0.6 to 0.8 volts. The range for acceptable operationsis 0 to 7.0 volts.

Table E-22. Code Description

DESCRIPTIONDTC



ed02896

Figure E-29. Data Link Connector [91A]: Dyna Models

DIAGNOSTICS

Diagnostic Tips• If serial data is shorted, these diagnostic trouble codes



Diagnostic Notes• If a U1300, U1301 or "BUS Er" is present, perform dia-

gnostic procedures listed in 4.12 STARTS, THEN STALLS.


E.21TSM/TSSM: PASSWORD LEARN

GENERALIf the ECM or TSM/TSSM is faulty, follow the instructions inthe Service manual for ECM or TSM/TSSM replacement.Then,to determine if password learn is necessary, refer toTable E-23.

Table E-23. Password Learn

IS PASSWORD LEARNNECESSARY?

DEVICE REPLACED

YesECM

No *TSM

YesTSSM

* If a TSM has been replaced by a TSSM, or a TSSM hasbeen replaced by a TSM, password learn is necessary.

PASSWORD LEARNINGTo perform password learning procedure, refer to Table E-24.When finished, continue with all instructions underE.3 VEHICLE DELIVERY.

Always perform all appropriate instructions under E.3 VEHICLEDELIVERY after TSM/TSSM replacement or removal.

NOTE

Do not forget to enter a Personal Identification Number (PIN)for TSSM vehicles. If a code is not assigned and the key fobis lost or damaged while the vehicle is armed, the TSSM mustbe replaced.

Table E-24. Setting TSM/TSSM and ECM Password

NOTESCONFIRMATIONACTIONNO.

With Ignition Switch turned to OFF, CheckEngine Lamp and Security Lamp will beoff.

Ignition must be turned off for at least 15seconds.

Install new TSM/TSSM or ECM. Performall steps under E.3 VEHICLE DELIVERY.

1

Set Engine Stop Switch to RUN.2

TSM/TSSM enables starterrelay.

Verify Check Engine Lamp and SecurityLamp illuminate and then turn off.

Turn Ignition Switch to IGN.3

Password has not been learned.ECM sets DTC P1009

Engine starts and stalls. Check EngineLamp illuminates and stays on.

Attempt normal start one time.4

ECM enters Password Learningmode for ten minutes. Do notcycle Ignition Switch or interruptvehicle power or PasswordLearn will be unsuccessful.

Security Lamp illuminates.Wait ten seconds. Security Lamp will illu-minate and stay on.

5


ECM must not be allowed toshutdown

Quickly (within one second) turn IgnitionSwitch OFF-IGN.

7




9




11

Turn Ignition Switch OFF. Wait 15 secondsbefore turning Ignition Switch to IGN. TurnIgnition Switch to IGN and start engine toconfirm successful Password Learn pro-cedure. Clear Diagnostic Trouble Codes(DTCs).

12

Perform all steps under E.3 VEHICLEDELIVERY.

13


E.22TSSM MAINTENANCE

GENERALThe TSSM system uses batteries in the key fob and siren.These are the only parts requiring periodic maintenance.

KEY FOB

ScheduleReplace the key fob battery every 2 years.

Battery Replacement1. See Figure E-31. Open the key fob case.

a. Place a thin blade between the 2 halves of the case.

b. Slowly twist the blade.

2. Replace battery (1).

a. Remove the original battery.

b. Install a new battery with the positive (+) side down.Use a Panasonic 2032 or equivalent.

3. Align case and circuit board (3) as shown. Snap casehalves together.

4. While standing next to the motorcycle, press and hold thekey fob button for 10-15 seconds until the security systemresponds with two turn signal flashes/siren chirps.

ed03015

Figure E-30. Key Fob Assembly:TSSM

1 2

3

ed030114

1. Battery2. Battery Contact3. Circuit Board

Figure E-31. Open Key Fob:TSSM

SIREN (IF INSTALLED)

ScheduleThe siren's internal 9 volt battery is rechargeable and does notneed to be replaced on a regular basis. Battery life undernormal conditions is approximately three to six years.

NOTES

See Figure E-32 and Figure E-33. Early style siren will workwith both TSSM and HFSM. Late style siren will only work withHFSM.

The internal siren battery may not charge if the vehicle's batteryis less than 12.5 volts.

Battery Replacement - Early Siren1. Disarm system and remove siren.

2. See Figure E-32. Remove battery cover.

a. Place the siren module on a flat and sturdy table withthe potted section (area with epoxy covering circuitboard) facing up and towards you.

b. Position a knife blade at a 45 degree angle to the longside of the siren case. Insert the knife blade betweenthe siren case and battery cover at one of the twoaccessible corners of the battery cover. Keep theblade slightly higher towards the battery cover as thishelps keep the blade away from the battery seal.

c. Slowly twist the blade towards the battery cover andthe cover will pop off.



• Only a 9 volt nickel metal hydride battery should be usedin the siren.


3. Replace battery by removing old battery from polarizedbattery clip. Install a new 9 volt nickel metal hydride bat-tery.

4. Reinstall battery cover.

a. Carefully replace the rubber seal.

b. Align battery cover with case placing round cornerson cover away from connector [142A]. Snap coverinto place.


Battery Replacement - Late Siren1. Disarm system and remove siren.

2. See Figure E-33. With a small screwdriver or pick, pushthe catches (1) in through the two slots (2) in the end ofthe siren to release the battery cover (3).



• Only a nickel metal hydride nine-volt battery should beused in the siren.

3. Replace battery (4) by removing old battery from polarizedbattery clip.

4. Recharge and re-install or install a new 9 volt nickel metalhydride battery.

5. Reinstall battery cover (3).

a. Carefully replace the rubber seal (5) on the cover.

b. Align battery cover with case placing round cornerson cover away from connector [142A] (6).

c. Snap cover into place.


1 23

ed03016

1. Cover2. Battery3. Connector [142A]

Figure E-32. Battery Compartment (Early Style Siren)

4

5

6

3

1

2

ed02958

1. Catch2. Slot3. Cover4. 9 volt battery5. Rubber seal6. Connector [142A]

Figure E-33. Siren Battery Compartment (Late Style Siren)


1150 Metri-Pack Connector

Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-20


Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-22


Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-24


Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-25

AActive Exhaust Solenoid (HDI only). . . . . . . . . . . . . . . . . . 4-2Active Intake Solenoid (HDI Models Only). . . . . . . . . . 4-113Active Intake Solenoid (HDI only). . . . . . . . . . . . . . . . . . . 4-2Alternator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17AMP 1-Place Connector

Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1AMP Multilock Connector

Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3Arming/Disarming (TSSM ONLY). . . . . . . . . . . . . . . . . . E-14

BBank Angle Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1Bank Angle Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2Bank Angle Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-3Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17Battery Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24

Conductance Test. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24Load Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24Voltmeter Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24

Bus ER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35

CCharging System Testing. . . . . . . . . . . . . . . . . . . . . . . . . 1-21

Current and Voltage Output Test: Using HD-48053. . 1-22Current and Voltage Output Test: Using LoadTester. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22Milliampere Draw Test. . . . . . . . . . . . . . . . . . . . . . . 1-21Total Current Draw Test. . . . . . . . . . . . . . . . . . . . . . 1-21

Check Engine Lamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1Check Engine Lamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4CKP Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-101Combustion Absent. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-68Connector Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1Conversions

Fluid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2Length. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3

Crankshaft Position (CKP) Sensor. . . . . . . . . . . . . . . . . . 4-2

DDelphi Connector

Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-8Deutsch 1-Place Connector

Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-10Deutsch Connector

Crimping Mini Terminals. . . . . . . . . . . . . . . . . . . . . . A-16Crimping Solid Barrel Terminals. . . . . . . . . . . . . . . . A-17Crimping Standard Terminals. . . . . . . . . . . . . . . . . . A-15Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-11

Diagnostic Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5Diagnostic Trouble Code Types. . . . . . . . . . . . . . . . . . . . . 2-3

Current. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3Historic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3Retrieving Diagnostic Trouble Codes. . . . . . . . . . . . . 2-3

DTC B0563. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-42DTC B0563 Battery Voltage High. . . . . . . . . . . . . . . . . . 3-29DTC B0563 Battery Voltage High. . . . . . . . . . . . . . . . . . E-42DTC B1004 Fuel level sending unit low. . . . . . . . . . . . . . 2-27DTC B1005 Fuel level sending unit high/open. . . . . . . . 2-27DTC B1006 Accessory line overvoltage. . . . . . . . . . . . . 2-31DTC B1007 Ignition line overvoltage. . . . . . . . . . . . . . . . 2-31DTC B1008 Trip Odometer Reset Switch closed. . . . . . . 2-33DTC B1121, B1122, B1141 Turn Signals Will Not Flash, 4-WayFlashers Inoperable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30DTC B1123 Left Turn Signal Short-to-Ground. . . . . . . . . 3-30DTC B1124 Right Turn Signal Short-to-Ground. . . . . . . 3-30DTC B1125 Left Turn Signal Short-to-Voltage. . . . . . . . . 3-30DTC B1126 Right Turn Signal Short-to-Voltage. . . . . . . 3-30DTC B1131 Alarm Output Low. . . . . . . . . . . . . . . . . . . . 3-43DTC B1131 Alarm Output Low. . . . . . . . . . . . . . . . . . . . E-43DTC B1132 Alarm Output High. . . . . . . . . . . . . . . . . . . . 3-43DTC B1132 Alarm Output High. . . . . . . . . . . . . . . . . . . . E-43DTC B1134 Starter Output High. . . . . . . . . . . . . . . . . . . 3-46DTC B1134 Starter Output High. . . . . . . . . . . . . . . . . . . E-46DTC B1135 Accelerometer Fault. . . . . . . . . . . . . . . . . . . 3-49DTC B1135 Accelerometer Fault. . . . . . . . . . . . . . . . . . E-49DTC B1136 Accelerometer Tip-Over Self-Test Fault. . . . 3-50DTC B1141 Ignition Switch Open/Low. . . . . . . . . . . . . . 3-51DTC B1142 Internal Fault. . . . . . . . . . . . . . . . . . . . . . . . 3-50DTC B1143 Security Antenna Short-to-Ground. . . . . . . 3-56DTC B1144 Security Antenna Short-to-Battery. . . . . . . . 3-56DTC B1145 Security Antenna Open. . . . . . . . . . . . . . . . 3-56DTC B1154 Clutch switch short-to-ground. . . . . . . . . . . 3-61DTC B1154 Clutch switch short-to-ground. . . . . . . . . . . E-50DTC B1155 Neutral switch short-to-ground. . . . . . . . . . . 3-61DTC B1155 Neutral switch short-to-ground. . . . . . . . . . E-50DTC P0107 MAP sensor open/low. . . . . . . . . . . . . . . . . 4-73DTC P0108 MAP sensor high. . . . . . . . . . . . . . . . . . . . . 4-73DTC P0112 IAT sensor voltage low. . . . . . . . . . . . . . . . . 4-77DTC P0113 IAT sensor open/high. . . . . . . . . . . . . . . . . . 4-77DTC P0117 ET sensor voltage low. . . . . . . . . . . . . . . . . 4-81DTC P0118 ET sensor open/high. . . . . . . . . . . . . . . . . . 4-81DTC P0122 TP sensor open/low. . . . . . . . . . . . . . . . . . . 4-85DTC P0123 TP sensor high. . . . . . . . . . . . . . . . . . . . . . . 4-85DTC P0131 Front O2 sensor low or engine running lean. 4-89DTC P0132 Engine running rich. . . . . . . . . . . . . . . . . . . 4-89DTC P0134 Front O2 sensor open/not responding/high. . 4-89DTC P0151 Rear O2 sensor low or engine running lean. 4-89DTC P0152 Engine running rich. . . . . . . . . . . . . . . . . . . 4-89DTC P0154 Rear O2 sensor open/not responding/high. . 4-89DTC P0261 Front injector open/low. . . . . . . . . . . . . . . . . 4-95DTC P0262 Front injector high. . . . . . . . . . . . . . . . . . . . 4-95DTC P0263 Rear injector open/low. . . . . . . . . . . . . . . . . 4-95DTC P0264 Rear injector high. . . . . . . . . . . . . . . . . . . . . 4-95DTC P0373 CKP sensor intermittent. . . . . . . . . . . . . . . 4-101DTC P0374 CKP sensor synch error. . . . . . . . . . . . . . . 4-101DTC P0501 VSS sensor low. . . . . . . . . . . . . . . . . . . . . 4-104DTC P0502 VSS sensor high/open. . . . . . . . . . . . . . . . 4-104DTC P0505 Loss of idle speed control. . . . . . . . . . . . . . 4-57DTC P0562 Battery voltage low. . . . . . . . . . . . . . . . . . 4-108DTC P0563 Battery voltage high. . . . . . . . . . . . . . . . . . 4-108DTC P0603 ECM EEPROM error. . . . . . . . . . . . . . . . . 4-112DTC P0605 ECM flash error. . . . . . . . . . . . . . . . . . . . . 4-112DTC P0661 Active intake solenoid open/low. . . . . . . . . 4-113DTC P0662 Active intake high/shorted. . . . . . . . . . . . . 4-113DTC P1001 System relay coil open/low. . . . . . . . . . . . . 4-47DTC P1002 System relay coil high/shorted. . . . . . . . . . . 4-47DTC P1003 System relay contacts open. . . . . . . . . . . . . 4-47

LXI

IND

EX

DTC P1004 System relay contacts closed. . . . . . . . . . . 4-47DTC P1009 Incorrect password. . . . . . . . . . . . . . . . . . 4-117DTC P1010 Missing password. . . . . . . . . . . . . . . . . . . 4-117DTC P1351 Front ignition coil open/low. . . . . . . . . . . . 4-120DTC P1352 Front ignition coil high/shorted. . . . . . . . . . 4-120DTC P1353 Front cylinder no combustion. . . . . . . . . . . . 4-68DTC P1354 Rear ignition coil open/low. . . . . . . . . . . . . 4-120DTC P1355 Rear ignition coil high/shorted. . . . . . . . . . 4-120DTC P1356 Rear cylinder no combustion. . . . . . . . . . . . 4-68DTC P1357 Front cylinder no combustion intermittent. . 4-68DTC P1358 Rear cylinder no combustion intermittent. . 4-68DTC P1475 Exhaust actuation position error. . . . . . . . 4-125DTC P1477 Exhaust actuator open/low. . . . . . . . . . . . 4-125DTC P1478 Exhaust actuator high. . . . . . . . . . . . . . . . 4-125DTC P1501 Jiffy Stand Sensor Low. . . . . . . . . . . . . . . 4-131DTC P1502 Jiffy Stand Sensor High. . . . . . . . . . . . . . . 4-131DTC U1016 Loss of all ECM serial data (state of health). 2-36DTC U1016 Loss of all ECM serial data (state of health). E-54DTC U1064 Loss of TSM/TSSM/HFSM serial data. . . . . 2-39DTC U1064 Loss of TSM/TSSM/HFSM serial data. . . . 4-136DTC U1064 Loss of TSM/TSSM/HFSM serial data. . . . 4-139DTC U1255 Serial data error/missing message. . . . . . . 2-36DTC U1255 Serial data error/missing message. . . . . . . 2-39DTC U1255 Serial data error/missing message. . . . . . 4-136DTC U1255 Serial data error/missing message. . . . . . 4-139DTC U1255 Serial data error/missing message. . . . . . . E-54DTC U1300 Serial data low. . . . . . . . . . . . . . . . . . . . . . . 2-42DTC U1300 Serial data low. . . . . . . . . . . . . . . . . . . . . . . 4-35DTC U1300 Serial data low. . . . . . . . . . . . . . . . . . . . . . . E-57DTC U1301 Serial data open/high. . . . . . . . . . . . . . . . . 2-42DTC U1301 Serial data open/high. . . . . . . . . . . . . . . . . 4-35DTC U1301 Serial data open/high. . . . . . . . . . . . . . . . . E-57

EElectronic Control Module (ECM). . . . . . . . . . . . . . . . . . . 4-2Electronic Fuel Injection (EFI). . . . . . . . . . . . . . . . . . . . . . 4-2Engine Temperature (ET) Sensor. . . . . . . . . . . . . . . . . . . 4-2ET Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-81Exhaust Actuator (HDI Models). . . . . . . . . . . . . . . . . . . 4-125

FFluid Conversions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2Fuel Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20Fuel Injectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-95Fuel Pressure Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-53Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40Fuse Block Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-19

GGlossary

Acronyms and Abbreviations. . . . . . . . . . . . . . . . . . . D-1

HHands-Free Fob Battery. . . . . . . . . . . . . . . . . . . . . . . . . 3-70Hands-Free Security Module (HFSM). . . . . . . . . . . . . . . . 3-2

IIAT Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-77Idle Air Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-57Idle Air Control (IAC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2Ignition Coil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2Ignition Coil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-120Indicator Lamps: All but FXDWG/FXDC/FXDF. . . . . . . . 2-21Indicator Lamps: FXDWG/FXDC/FXDF. . . . . . . . . . . . . . 2-24

Initial Diagnostic Check: TSM/TSSM. . . . . . . . . . . . . . . . E-19Intake Air Temperature (IAT) Sensor. . . . . . . . . . . . . . . . . 4-2Intake Leak Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

JJiffy Stand Sensor (HDI Models Only). . . . . . . . . . . . . . 4-131Jiffy Stand Sensor (HDI only). . . . . . . . . . . . . . . . . . . . . . 4-2

KKey Fob Assignment: TSSM. . . . . . . . . . . . . . . . . . . . . . . E-5Key Fob Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-59

LLoctite. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-II

MManifold Absolute Pressure (MAP) Sensor. . . . . . . . . . . . 4-2MAP Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-73Maxi-Fuse Housing

Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-26Metric System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2Metri-Pack Terminals

Crimping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-28Molex Connector

Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-30

OOdometer Theory of Operation. . . . . . . . . . . . . . . . . . . . 2-16Oxygen Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-89Oxygen Sensors (domestic models only). . . . . . . . . . . . . 4-2

PPackard 100W Connector

Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-32Packard Micro-64 Connector

Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-34Personal Identification Number (PIN). . . . . . . . . . . . . . . . 3-6Personal Identification Number (PIN). . . . . . . . . . . . . . . . E-6

RReprogramming ECM. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

SSealed Splice. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-37Security Lamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2Security Lamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3Security Lamp (Key Icon). . . . . . . . . . . . . . . . . . . . . . . . . 3-8Security Lamp Diagnostics. . . . . . . . . . . . . . . . . . . . . . . 3-13Security System Functions (TSSM ONLY). . . . . . . . . . . E-11Service Bulletins. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-IService Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-ISidecar Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5Sidecar Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . E-5Siren. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Service/Emergency Functions. . . . . . . . . . . . . . . . . 3-11Siren Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-70Siren Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-59Speedometer Functions. . . . . . . . . . . . . . . . . . . . . . . . . . 2-5Speedometer Theory of Operation. . . . . . . . . . . . . . . . . 2-15SPX Kent-Moore. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-IIStarter Activation Circuits. . . . . . . . . . . . . . . . . . . . . . . . 1-13Starter Current Draw Test. . . . . . . . . . . . . . . . . . . . . . . . 1-14Starter Free Running Current Draw Test. . . . . . . . . . . . . 1-15Starter Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

LXII INDEX

Solenoid Hold-In Test. . . . . . . . . . . . . . . . . . . . . . . . 1-15Solenoid Pull-In Test. . . . . . . . . . . . . . . . . . . . . . . . . 1-15Solenoid Return Test. . . . . . . . . . . . . . . . . . . . . . . . 1-16

Starter Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1Starting System Diagnosis. . . . . . . . . . . . . . . . . . . . . . . . 1-3Start Relay Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14Stator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23System Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47

TTachometer Theory of Operation. . . . . . . . . . . . . . . . . . . 2-16Throttle Position (TP) Sensor. . . . . . . . . . . . . . . . . . . . . . 4-2Torque Conversion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3TP Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-85Trademarks

Harley-Davidson. . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-IIReferenced Products. . . . . . . . . . . . . . . . . . . . . . . . . . I-II

Trip Odometer Reset Switch. . . . . . . . . . . . . . . . . . . . . . 2-15TSM/HFSM: Password Learn. . . . . . . . . . . . . . . . . . . . . 3-69TSM/TSSM: Password Learn. . . . . . . . . . . . . . . . . . . . . E-58TSM/TSSM (JAPAN/KOREA) Overview. . . . . . . . . . . . . . E-1TSM/TSSM Features - Security Lamp. . . . . . . . . . . . . . . E-3Turn Signal Functions

4-Way Flashing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-9Automatic Cancellation. . . . . . . . . . . . . . . . . . . . . . . E-9Manual Cancellation. . . . . . . . . . . . . . . . . . . . . . . . . E-9

Turn Signal Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1Turn Signal Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-3Turn Signal Security Module. . . . . . . . . . . . . . . . . . . . . . . E-3

VVehicle Delivery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-5Vehicle Speed Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . 4-104Vehicle Speed Sensor (VSS). . . . . . . . . . . . . . . . . . . . . . . 4-2Voltage Regulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

WWiggle Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21Wiring Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3WOW Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

INDEX LXIII

LXIV INDEX

NOTES

INSIDE BACK COVER GOES HERE

OUTSIDE BACK COVER GOES HERE

harley davidson service manual dyna 2008 electrical diagnostic manual

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