2004 Harley Davidson Touring Models Service Manual - English

Section 4: Fuel System (No content)
Section 5: Starter (No content)
Section 6: Drive (No content)
Section 7: Transmission (No content)
Section 8: Electrical
ELECTRICAL DIAGNOSTICS
Section 6: Sound System
Section 7: Cruise Control
Section 5: Starter
Section 6: Drive
Section 7: Transmission
Section 8: Electrical

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STARTER TROUBLESHOOTING 1.1
Table 1-1. Starter Does Not Run or Runs At Very Low Speeds
SOURCE OF
Short-circuited or open between electrodes. Replace battery.
Poor contact condition of battery terminal(s). Clean and retighten.
Wiring
Poor or no connection at either battery positive or
negative cable, at either end. Repair or replace cable(s).
Cracked or corroded battery cable ends. Clean, tighten or replace cable(s) as needed.
Open wire(s) or poor connection at handlebar
switch or starter relay, especially relay ground wire. Tighten connections or repair or replace wire(s).
Handlebar
start switch Poor switch contacts or open switch. Replace switch.
Starter relay
Poor or no continuity at relay points. Replace relay.
TSM/TSSM has disabled starter relay. Check for open on wire to TSM/TSSM. Correct
lack of ground.
Solenoid
Poor contact condition caused by burnt contact. Polish contact surface or replace solenoid
assembly.
Pull-in winding open or short-circuited. Repair or replace solenoid assembly.
Hold-in winding open or short-circuited. Repair or replace solenoid assembly.
Starting motor
Brushes worn below specification. Check brush spring tension. Replace field frame
and holder.
Commutator high mica. Correct by undercutting.
Field winding grounded. Replace.
Reduction gears damaged. Replace.
Disconnected lead wire between solenoid and field
windings. Repair or replace lead wire.
Ball bearing sticks. Replace bearing.
5
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Table 1-2. Pinion Does Not Engage With Ring Gear While Starter is Cranked or Engine Cannot Be Cranked
SOURCE OF
Short-circuited or open between electrodes. Replace battery.
Poor contact condition of battery terminal(s). Clean and retighten.
Overrunning
clutch.
sion spring). Replace overrunning clutch.
Pinion teeth worn out. Replace pinion.
Pinion does not run in overrunning direction. Replace overrunning clutch.
Poor sliding condition of spline teeth. Remove foreign materials, dirt or replace over-
running clutch or pinion shaft.
Reduction gears damaged. Replace overrunning clutch and idler gear.
Jackshaft
assembly Improper jackshaft par ts assembly. Disassemble and assemble par ts properly.
Gear teeth on
Table 1-3. Starter Does Not Stop Running
SOURCE OF
Poor return caused by sticky switch
or relay contacts. Replace starting switch or starter relay.
Gear teeth on
Solenoid.
Contact plate melted and stuck. Replace solenoid.

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bers on the starter system flow charts.
1. See Section 1.4 DIAGNOSTICS/TROUBLESHOOTING,
VOLTAGE DROPS.
described under Section 1.6 TESTING ASSEMBLED
STARTER, FREE RUNNING CURRENT DRAW TEST.
3. Remove TSSM and use HARNESS CONNECTOR TEST
KIT (Part No. HD-41404) to short Pin 9 on connector [30]
to ground. If starter motor cranks, replace TSSM.
4. See Section 1.5 STARTER SYSTEM TESTING,
STARTER CURRENT DRAW TEST.
FREE RUNNING CURRENT DRAW TEST.
6. Connect BREAKOUT BOX (Part No. HD-42682) to TSM/
TSSM. See BREAKOUT BOX, TSM/TSSM.
7. Connect BREAKOUT BOX (Part No. HD-42682) (black)
and 6-pin Harness Adapters (Part no. HD-42962)
between wiring harness connector [22A] and Right Hand
Control harness connector [22B] (adapters not used on
FLHR/C/S models).
job/time code values printed in bold text underneath the
appropriate repair.
Check battery using visual inspection, voltage test and load test.
Check connections at battery and starter components. Is system operational?
STARTER SPINS, BUT DOES NOT ENGAGE.
YES
YES
NO
See Starter Testing 5: Starter Spins, But Does Not Engage .
See Starter Testing 6: Starter Stalls or Spins Too Slowly .
Disconnect solenoid relay terminal from solenoid. Is 12V
present on GN wire with starter button not pressed?
OR
OR
Is 12V present on starter relay Terminal 86 with starter button
not pressed?
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Starter Testing 2: Solenoid Clicks
Starter Testing 3: Relay Clicks
Perform voltage drop tests from battery positive to starter motor terminal. Crank engine. Voltage
greater than 1 volt?
YES
Perform voltage drop tests between battery and relay terminal on solenoid.
Less than 1.0 volt?
Backtrack to pinpoint poor connections or relay contact problems using voltage drop
tests.
NO
Perform voltage drop tests from battery positive to starter battery terminal. Crank engine. Voltage
YES
Perform voltage drop tests between battery negative and starter studs or bolts. Voltage
starter.
YES
NO
5824
5845
NO
box marked with bold asterisk.
STOP
1
1
1
1
5823
5824
YES
Test for voltage at solenoid relay terminal on starter. Is 12V present when
starter button is pressed?
Test for voltage to relay. Is 12V present on relay terminal 30?
NO
BLED STARTER. Solenoid OK?
NO
(dirt or corrosion).
Test for voltage from relay. Is 12V present on relay
Terminal 87 when starter button is pressed?
YES
on starter relay.
and solenoid.
HOME
Check for ground at relay Terminal 85. Ground present?
YES
5832
With ignition switch ON and starter button depressed, check for battery voltage from starter
button to relay Terminal 86. Battery voltage present?
Check for battery voltage from starter button, terminal 6 (black). Bat- tery voltage present with starter but-
ton pressed?
NO
YES
Check for continuity from relay Terminal 85 to Pin 9 on TSSM connector [30]. Continuity present?
NO

YES
Check for battery voltage to starter button, terminal 4 (black). Battery volt-
age present?
NO
NOYES
key ON. Voltage present?
(Part Number 99483-04).
YES
3
5838
5830
Continuity to ground on Pin 12 of TSM/TSSM?
Continuity on Pin 1 to battery fuse?
Continuity on Pin 2 to Ignition fuse?
Sidecar BAS installed?
6791
6793
6806
6805
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Remove starter. Disassemble drive housing assembly. Inspect for damage to armature
gear or idler gear. Damage present?
YES
5850
Assemble jackshaft properly.
YES
NO
58375825
starter battery terminal. Crank engine.
Voltage greater than 1 volt?
YES
5824
Perform voltage drop tests from battery positive to starter motor terminal. Crank
engine. Voltage greater than 1 volt?
NO
starter.
YES
NO
starter studs or bolts. Voltage greater than 1 volt?
Clean ground connections.
Perform starter motor free draw bench test.
Are test results within range?
NO
Remove spark plugs while in 5th gear. Rotate rear wheel. Check for engine, primary
and/or crankshaft bind.
NO
5845
5835
5817
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STARTER ACTIVATION CIRCUITS 1.3
Figure 1-1. Typical Circuity. Refer to wiring diagrams for more information.
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
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detailed procedures to solve and correct problems. Follow the
1.2 STARTING SYSTEM DIAGNOSIS diagram to diagnose
starting system problems. The VOLTAGE DROPS procedure
below will help you to locate poor connections or components
with excessive voltage drops.
Check the integrity of all wiring, switches, circuit breakers and
connectors between the source and destination.
The voltage drop test measures the difference in potential or the
actual voltage dropped between the source and destination.
1. See ITEM A in Figure 1-1. Attach your red meter lead to
the most positive part of the circuit, which in this case
would be the positive post of the battery.
2. See ITEM B in Figure 1-1. Attach the black meter lead to
the final destination or component in the circuit (solenoid
terminal from relay).
3. Activate the starter and observe the meter reading. The
meter will read the voltage dropped or the difference in
potential between the source and destination.
4. An ideal circuit’s voltage drop would be 0 volts or no volt-
age dropped, meaning no difference in potential.
5. See ITEM C in Figure 1-1. An open circuit should read
12 volts, displaying all the voltage dropped, and the
entire difference in potential displayed on the meter.
NOTE
Open circuits on the ground side will read zero.
6. Typically, a good circuit will drop less than 1 volt.
7. If the voltage drop is greater, back track through the con-
nections until the source of the potential difference is
found. The benefit of doing it this way is speed.
a. Your readings aren’t as sensitive to real battery volt-
age.
just the presence of voltage.
c. This tests the system as it is actually being used. It
is more accurate and will display hard to find poor
connections.
d. This approach can be used on lighting circuits, igni-
tion circuits, etc. Start from most positive and go to
most negative (the destination or component).
8. See ITEM D in Figure 1-1. The negative or ground circuit
can be checked as well.
a. Place the negative lead on the most negative part of
the circuit (or the negative battery post). Remember,
there is nothing more negative than the negative
post of the battery.
b. Place the positive lead to the ground you wish to
check.
c. Activate the circuit. This will allow you to read the
potential difference or voltage dropped on the nega-
tive or ground circuit. This is very effective for identi-
fying poor grounds due to powdered paint. Even the
slightest connection may cause an ohmmeter to give
a good reading. However, when sufficient current is
passed through, the resistance caused by the pow-
dered paint will cause a voltage drop, or potential
difference in the ground circuit.

HOME
Before removing the starter, perform one of the Starter Relay
Tests which follow. If the relay is known to be good, perform
the STARTER CURRENT DRAW TEST in this section.
STARTER RELAY TEST 1
1. Remove relay. For FLHR/C/S models, see upper frame
of Figure 1-2. For all other models, see upper frame of
Figure 1-3.
2. Substitute a new relay known to be good and verify oper-
ation. For convenience, use the brake light relay as a
temporary substitute on FLHR/C/S models, or use the
ignition keyswitch relay as a temporary substitute on
FLTR and FLHT/C/U models.
STARTER RELAY TEST 2
The starter relay can be tested using the vehicle’s 12 volt bat-
tery and a continuity tester or ohmmeter (HD-35500B). Pro-
ceed as follows:
1. Remove relay. For FLHR/C/S models, see upper frame
of Figure 1-2. For all other models, see upper frame of
Figure 1-3.
2. To energize the relay, connect the battery leads to termi-
nals 86 and 85. For FLHR/C/S models, see lower frame
of Figure 1-2. For all other models, see lower frame of
Figure 1-3.
3. Check for continuity between terminals 30 and 87. Figure 1-2. Locate Relay Under Left Side Cover
FLHR/C/S
85
O
86
30
87
87A
f1741x5x
Battery
Ohmmeter
f2192x8x
NOTE
Check the wire tags for positive identification of relays. Starter relay can be positively identified by heavy gauge Green wire.
FLTR, FLHT/C/U
HOME
4. If the tester lamp illuminates or there is a zero ohm read-
ing on the ohmmeter, then continuity is present and the
relay is good. Replace the relay if continuity is not
present.
CAUTION
battery terminal to avoid damaging the diode connected
across the relay winding.
STARTER CURRENT DRAW TEST
Check the starter current draw with an inductive amp probe
(HD-39617) or induction ammeter. Before proceeding, be
sure that the battery is fully charged and that the engine tem-
perature is stable and at room temperature.
1. Verify that the transmission is in neutral.
2. Disconnect the spark plug wires from the spark plug ter-
minals.
See Figure 1-4.
4. With the ignition ON, turn the engine over by pressing
start switch while taking a reading on the ammeter. Dis-
regard initial high current reading which is normal during
time the engine is first turned over.
a. Typical starter current draw will range between 160
and 200 amperes.
b. If the starter current draw exceeds 250 amperes, the
problem may be in the starter or star ter drive.
5. Remove the starter for testing, if necessary. See the
2004 Touring Models Service Manual (Part Number
99483-04), STARTER, REMOVAL.
FREE RUNNING CURRENT DRAW TEST.
Figure 1-4. Starter Current Draw Test
f1334x2x
Battery
HOME
death or serious injury.
wire from motor terminal as shown in Figure 1-5.
CAUTION
Each test should be performed for only 3-5 seconds to
prevent damage to solenoid.
The solenoid Pull-in, Hold-in, and Return tests must be per-
formed together in one continuous operation. Conduct all
three tests one after the other in the sequence listed.
SOLENOID PULL-IN TEST
1. See Figure 1-5. 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.
properly.
b. If starter shaft does not extend strongly, replace the
solenoid.
SOLENOID HOLD-IN TEST
1. See Figure 1-6. With test leads still connected in the
manner specified in the previous SOLENOID PULL-IN
TEST, disconnect solenoid motor terminal/battery nega-
tive test lead (B) at negative battery post only; reconnect
loose end of this test lead to positive battery post
instead.
ing properly.
c. If starter shaft does not retract, replace the solenoid.
Figure 1-5. Test 1: Pull-In Test
Figure 1-6. Test 2: Hold-In Test
b0161a5x
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SOLENOID RETURN TEST
1. See Figure 1-7. With test leads still connected in the
manner specified at the end of the previous SOLENOID
HOLD-IN TEST, disconnect solenoid relay terminal/posi-
tive battery post test lead (C) at either end.
2. Observe starter pinion.
b. If starter shaft does not retract, replace the solenoid.
FREE RUNNING CURRENT
DRAW TEST
1. Place starter in vise, using a clean shop towel to prevent
scratches or other damage.
2. Connect a heavy jumper cable (6 gauge minimum) to
starter mounting flange as shown in Figure 1-8.
3. Connect other end to the negative (-) terminal of a fully
charged battery.
4. Connect a heavy jumper cable (6 gauge minimum) to the
positive (+) terminal of the battery.
5. Attach an inductive ammeter to positive cable and con-
nect the other end of the positive cable to the “Battery”
terminal of the starter solenoid.
6. Use a smaller jumper cable (14 gauge) and connect to
the positive (+) terminal of the battery.
7. Connect other end of small jumper cable to the solenoid
“Relay” terminal.
maximum. If reading is higher, disassemble starter for
inspection.
NOTE
If starter current draw on vehicle was over 200 amps and the
starter FREE RUNNING CURRENT DRAW TEST was within
specification, there may be a problem with engine, primary
drive or starter jackshaft.
Figure 1-8. Free Running Current Draw Test
Battery
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Alternator
The alternator consists of two main components: the rotor
which is mounted on the engine sprocket shaft, and the stator
which is bolted to the engine crankcase.
Voltage Regulator
A series regulator with a circuit that combines the functions of
rectifying and regulating.
TROUBLESHOOTING
When the charging system fails to charge or does not charge
at a satisfactory rate, it is recommended that the following
checks be made.
Battery
Check for a weak or dead battery. Battery must be fully
charged in order to perform any electrical tests. Under certain
operating conditions, battery icon may illuminate if battery
voltage is out of range.
Wiring
See charging system circuit in Figure 1-9. Check for corroded
or loose connections.
Voltage Regulator Inspection
The regulator must have a clean, tight ground connection for
proper operation. Check by using an ohmmeter with one lead
on the battery ground cable and the other on the regulator
ground terminal (on r ight side transmission exhaust bracket)
Job/Time Code Values
appropriate repair..
BK
BK
BK
BK
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SYMPTOM: BATTERY BECOMES DISCHARGED
FAIL
STOP
FAILPASS
5310
Perform TOTAL CURRENT DRAW TEST.
Record measurement.
Whenever a charging system component fails a test and
is replaced, retest the system to be sure the problem has
been corrected.

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SYMPTOM: BATTERY BECOMES DISCHARGED
System tests good up to this point. Suspect:
Accessories on for long periods when vehicle is parked and not running.
Accessories on when vehicle is ridden very slowly for long periods.
Battery self-discharge and/or accessory draw because vehicle was not operated for a long period.
Replace Regulator.
From Test 1.7 (Part 1 of 2).
Perform CURRENT OUTPUT TEST. Record measurement and compare with TOTAL CUR-
RENT DRAW TEST before proceeding.
FAILPASS
Whenever a charging system component fails a test and
is replaced, retest the system to be sure the problem has
been corrected.
HOME
TESTING
NOTES
Be sure accessories are not wired so they stay on at all
times. Check for this by connecting ammeter between
negative battery terminal and battery.
TSM/TSSM will continue to draw 16-25 mA for 30 sec-
onds after ignition is turned OFF. Any disruption and
reconnection of battery power, such as disconnecting the
battery to place a meter in series, will cause TSM/TSSM
to draw 16-25 mA for 30 seconds.
See Figure 1-10. Connect ammeter between negative battery
terminal and battery. With this arrangement, you will also pick
up any regulator drain.
The limits for these drains are listed in Table 1-4.
Any accessories must be considered and checked for
excessive drain.
parked for a long time.
NOTES
static drain. Correct by cleaning battery case.
Any reading that exceeds the “Average Meter Reading”
values below indicates excessive current draw. Check for
bad radio, voltage regulator or a short in the intercon-
necting wiring. Alarms and customer accessories are
also prime suspects. Isolate problem by disconnecting
suspect components and observe change in meter read-
ing.
TOTAL CURRENT DRAW TEST
If the battery runs down during use, the current draw of the
motorcycle components and accessories may exceed the
output of the charging system. To check for this condition,
place load tester induction pickup or current probe pickup
over battery negative cable as shown in Figure 1-11. Discon-
nect regulator from stator. Start engine and run at 3000 rpm.
With ignition and all continuously running lights and accesso-
ries turned on (headlamp on high beam), read the total cur-
rent draw. Compare this reading to the reading obtained in
CURRENT OUTPUT TEST. The current output should
exceed current draw by 3.5 amps, minimum. If not, there may
be too many accessories for the charging system to handle.
Reconnect regulator when test is complete.
NOTE
Rider’s habits may require output test at lower RPM.
Table 1-4. Milliampere Draw Test
COMPONENT DRAW IN MILLIAMPERES
Figure 1-11. Check Current Draw (Ignition Switch On)
FLT0808A
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1. Connect load tester negative and positive leads to bat-
tery terminals and place load tester induction pickup over
positive regulator cable as shown in Figure 1-12.
2. Run the engine at 3000 rpm and increase the load as
required to obtain a constant 13.0 volts.
3. The current output should be as follows. Make note of
the measurement.
38 amp (Low Output) .................... 34-40 amperes
FLHTI, FLHTCI, FLHTCUI, FLTRI
VOLTAGE OUTPUT TEST
See Figure 1-12. After removing the load, read the load tester
voltage meter. Voltage to the battery must be less than 15
volts. If voltage is higher, regulator is not functioning properly
or connections are loose or dirty.

CAUTION
Do not leave any load switch turned on for more than 20
seconds or overheating and tester damage are possible.

STATOR CHECK
1. To check for a grounded stator, turn off ignition and dis-
connect the regulator from the stator.
2. See Figure 1-13. Connect an ohmmeter on the RX1
scale between primary cover bolt and either stator
socket. Use Harness Connector Test Kit (HD-41404), red
pin probes and patch cords. There should be no continu-
ity (∞ ohms) across either test point. Any other reading
indicates a grounded stator which must be replaced.
3. See Figure 1-14. Check the resistance using an ohmme-
ter set on the RX1 scale. Resistance should be less than
0.5 ohms across the stator socket. If it is not, then the
stator is damaged and must be replaced. Figure 1-12. Current and Voltage Output Test
f1314x8x
f2251x8x
f2252x8x
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AC OUTPUT CHECK
1. See Figure 1-15. To test AC output, disconnect the regu-
lator and connect an AC voltmeter across both stator
sockets. Run the engine at 2000 RPM. The AC output
should be as follows.
38 amp (Low Output) ...... 16-20 VAC per 1000 RPM
FLHTI, FLHTCI, FLHTCUI, FLTRI
45 amp (High Output) ..... 19-26 VAC per 1000 RPM
2. If the output is below specifications, charging problem
could be a faulty rotor or stator. Replace the rotor or sta-
tor.
SYSTEM OUTPUT TEST given earlier.
Figure 1-15. Check AC Output

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See Table 1-5. The voltmeter test provides a general indicator
of battery condition. Check the voltage of the battery to verify
that it is in a 100% fully charged condition. If the open circuit
(disconnected) voltage reading is below 12.6V, charge the
battery and then recheck the voltage after the battery has set
for one to two hours. If the voltage reading is 12.8V or above,
perform the LOAD TEST described in this section.
LOAD TEST
The load test measures battery performance under full cur-
rent load and is the best indicator of battery condition. To load
test the battery, proceed as follows:
1. Remove seat.
positive cable should contact ground with the negative
cable installed, the resulting sparks may cause a battery
explosion which could result in death or serious injury.
2. Unthread bolt and remove battery negative cable (black)
from battery negative (-) terminal.
from battery positive (+) terminal.
4. Using a T-40 TORX drive head, loosen bolt to move lip of
hold-down clamp off edge of battery. Remove battery
from battery box.
nent battery damage.
5. Always fully charge the battery before testing or test
readings will be incorrect. Load testing a discharged bat-
tery can also result in permanent battery damage.
6. After charging, allow battery to stand for at least one
hour before testing.
Always turn the battery load tester OFF before connect-
ing the tester cables to the battery terminals. Connecting
tester cables with the load tester ON could cause a spark
resulting in a battery explosion. A battery explosion may
rupture the battery case causing a discharge or spray of
sulfuric acid which could result in death or serious
injury.
7. Connect tester leads to battery posts and place induction
pickup over negative (black) cable. See Figure 1-16.
CAUTION
To avoid load tester and/or battery damage, do not leave
the load tester switch turned ON for more than 20 sec-
onds.
8. Load battery at 50% of CCA rating using the load tester.
Voltage reading after 15 seconds should be 9.6V or more
at 70°F. (21°C).
Table 1-5. Voltmeter Test
12.8 100%
12.6 75%
12.3 50%
12.0 25%
11.8 0%
COLD CRANKING
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1WARNING
cause a spark resulting in a battery explosion. A battery
explosion may rupture the battery case causing a dis-
charge or spray of sulfuric acid which could result in
death or serious injury.
9. Place the fully charged battery into the battery box, ter-
minal side forward.
damage to the motorcycle electrical system will occur.
1WARNING
Always connect the positive battery cable first. If the pos-
itive cable should contact ground with the negative cable
installed, the resulting sparks may cause a battery explo-
sion which could result in death or serious injury.
CAUTION
10. Insert bolt through battery positive cable (red) into
threaded hole of battery positive (+) terminal. Tighten
bolt to 60-96 in-lbs (6.8-10.9 Nm).
11. Insert bolt through battery negative cable (black) into
threaded hole of battery negative (-) terminal. Tighten
bolt to 60-96 in-lbs (6.8-10.9 Nm).
12. Apply a light coat of petroleum jelly or corrosion retardant
material to both battery terminals.
13. Rotate the hold-down clamp so that the lip (with rubber
pad) rests on the edge of the battery. Using a T-40 TORX
drive head, tighten the clamp bolt to 15-20 ft-lbs (20-27
Nm).
1.4 Diagnostics/Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
1.7 Charging System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Table Of Contents
CHECK ENGINE LAMP
behavior of the check engine lamp.
NOTES
See Figure 2-2. “Key ON” means that the ignition key is
turned to ON and the engine stop switch is set to RUN
(although the engine is not running).
When the ignition switch is turned ON, the check engine
lamp will illuminate for approximately four seconds and
then turn off.
If the check engine lamp is not illuminated at Key ON.
See 2.2 INITIAL DIAGNOSTIC CHECK: SPEEDOME-
TER .
If the check engine lamp comes on late (after 20 sec-
onds). See 2.2 INITIAL DIAGNOSTIC CHECK: SPEED-
OMETER .
If the check engine lamp fails to turn OFF after the initial
four second period. See 2.2 INITIAL DIAGNOSTIC
CHECK: SPEEDOMETER .
1. See Figure 2-3. After lamp turns off after being illumi-
nated for the first four second period, one of three situa-
tions may occur.
a. The lamp remains off. This indicates there are no
current fault conditions or stored diagnostic trouble
codes (DTC) currently detected by the ignition con-
trol module (ICM) or electronic control module
(ECM).
b. The lamp stays off for only four seconds and then
comes back on for an eight second period. This indi-
cates an diagnostic trouble code is stored, but no
current diagnostic trouble code exists.
c. If the lamp remains on beyond the eight second
period, then a current diagnostic trouble code exists.
2. See CODE TYPES which follows for a complete descrip-
tion of diagnostic trouble code formats.
NOTES
during actuation. For example, a problem with the ignition coil
will be considered a current fault even after the problem is
corrected, since the ECM/ICM will not know of its resolution
until after the coil is exercised by vehicle start sequence. In
this manner, there may sometimes be a false indication of the
current diagnostic trouble code.
Figure 2-1. Speedometer
50
10
MPH
H AR L E Y -DA V I D S O N C E RTI F I E D
RPMx100
H AR L E Y -DA V I D S O
f2160x8x Check Engine Lamp
the behavior of the security lamp.
NOTES
codes, the security lamp is enabled on all models.
See Figure 2-2. “Key ON” means that the ignition key is
turned to ON and the engine stop switch is set to RUN
(although the engine is not running).
When the ignition switch is turned ON, the check engine
lamp will illuminate for approximately four seconds and
then turn off.
If the check engine lamp is not illuminated at Key ON,
see 2.2 INITIAL DIAGNOSTIC CHECK: SPEEDOME-
TER .
If the check engine lamp comes on late (after 20 sec-
onds), see 2.2 INITIAL DIAGNOSTIC CHECK: SPEED-
OMETER .
If the check engine lamp fails to turn OFF after the initial
four second period, see 2.2 INITIAL DIAGNOSTIC
CHECK: SPEEDOMETER .
1. See Figure 2-3. After lamp turns off after being illumi-
nated for the first four second period, one of three situa-
tions may occur.
a. The lamp remains off. This indicates there are no
current fault conditions or stored diagnostic trouble
codes currently detected by the ignition control mod-
ule (ICM) or electronic control module (ECM).
b. The lamp stays off for only four seconds and then
comes back on for an eight second period. This indi-
cates an diagnostic trouble code is stored, but no
current diagnostic trouble code exists.
c. If the lamp remains on beyond the eight second
period, then a current diagnostic trouble code exists.
2. See CODE TYPES which follows for a complete descrip-
tion of diagnostic trouble code formats.
NOTE
during actuation. For example, a problem with the turn signals
will be considered a current fault even after the problem is
corrected, since the TSM/TSSM will not know of its resolution
until after the turn signals are activated. In this manner, there
may sometimes be a false indication of a diagnostic trouble
code.
ON
OFF
ON
OFF
ON
OFF
Lamp OFF: No Current or Historic DTCs
Lamp Remains ON: Current DTC *
Lamp OFF
4 Sec.
4 Sec.
8 Sec.
Key ON
4 Sec.
4 Sec.
4 Sec.
There are two types of diagnostic trouble codes (DTCs): cur-
rent and historic. If a diagnostic trouble code is stored, it can
be read using speedometer self diagnostics. See 2.3
SPEEDOMETER SELF DIAGNOSTICS.
All diagnostic trouble codes reside in the memory of the
ECM/ICM, TSM/TSSM, speedometer or tachometer until the
code is cleared by use of the speedometer self diagnostics.
See 2.3 SPEEDOMETER SELF DIAGNOSTICS.
A historic diagnostic trouble code is also cleared after a total
of 50 trips has elapsed. A trip consists of a start and run
cycle. After the 50 trip retention period, the diagnostic trouble
code is automatically erased from memory providing that no
subsequent faults of the same type are detected in that
period.
Current
for solutions.
Historic diagnostic trouble codes can only be identified as his-
toric using a computer based diagnostic package called DIG-
ITAL TECHNICIAN (Part No. HD-44750), when historic
diagnostic codes are present.
If a particular problem happens to resolve itself, the active
status problem is dropped and it becomes a historic fault
rather current fault.
Historic diagnostic trouble codes are stored for a length of
time to assist in the diagnosis of intermittent faults.
It is important to note that historic diagnostic trouble codes
may also be present whenever the system indicates the exist-
ence of a current fault. See MULTIPLE DIAGNOSTIC TROU-
BLE CODES if multiple diagnostic trouble codes are found.
Diagnostic charts are designed for use with current diagnos-
tic trouble codes and as a result they frequently suggest wire
repair or part replacement.
nostics.
based diagnostic package called DIGITAL TECHNICIAN
(Part No. HD-44750).
diagnostics. Speedometer, tachometer (if equipped),
TSM/TSSM and ECM diagnostic trouble codes can be
accessed and cleared. See 2.3 SPEEDOMETER SELF
DIAGNOSTICS.
CODES
While it is possible for more than one fault to occur and set
more than one diagnostic trouble code, there are several con-
ditions which may result in one fault setting multiple diagnos-
tic trouble codes:
U1097, U1255, U1300 and U1301) may be accompanied by
other codes. Always correct the serial data diagnostic trouble
codes before resolving the other codes.
For proper resolution to multiple diagnostic trouble codes
refer to diagnostic trouble code priority chart page 2-6,Table
2-2.
GENERAL
terminal 5 of connector [39]. The speedometer turns on
when power is applied to terminal 1 of connector [39].
The speedometer goes through an initialization
sequence every time power is removed and re-applied to
terminal 6. The visible part of this sequence is the check
engine lamp (in “run” mode), security lamp (models with
security only), backlighting, odometer and fuel level (EFI
only). Upon key ON, the check engine lamp and security
lamp will illuminate for 4 seconds and then (if parameters
are normal) go out.
To locate faulty circuits or other system problems, follow
the diagnostic flow charts and tests in this section. For a
systematic approach, always begin with INITIAL DIAG-
NOSTICS which follows. Read the general information
and then work your way through the flow chart box by
box.
Loss of power on any of the four power inputs will
change speedometer behavior. Refer to Table 2-1.
Speedometer Function Chart-Loss Of Input.
Diagnostic Notes
If a numbered circle appears adjacent to a flow chart box,
then more information is offered in the diagnostic notes. Many
diagnostic notes contain supplemental information, descrip-
tions of various diagnostic tools or references to other parts
of the manual where information on the location and removal
of components may be obtained.
Circuit Diagram/Wire Harness Connector Table
When working through a flow chart, refer to the illustrations,
the associated circuit diagram and the wire harness connec-
tor table as necessary. The wire harness connector table for
each circuit diagram identifies the connector number, descrip-
tion, type and general location.
In order to perform most diagnostic routines, a Breakout Box
and a digital volt/ohm meter (DVOM) are required. See 2.5
BREAKOUT BOX: SPEEDOMETER.
To perform the circuit checks with any degree of efficiency, a
familiarity with the various wire connectors is also necessary.
Figure 2-4. Remove Left Side Cover
Figure 2-5. Remove Maxi-Fuse Cover
Maxi-Fuse Cover
Fuse Block
turned ON (engine stop switch at RUN with the engine
off), check data bus for an open or short to ground.
between data link connector [91A] terminal 3 and ICM
connector [10B] terminal 12 (carbureted models), ECM
connector [78B] terminal 5 (EFI models), TSSM connec-
tor [30B] terminal 3, Speedometer connector [39B] termi-
nal 2 or tachometer (if equipped) connector [108B]
terminal 2.
Check for an open data test terminal between data link
connector [91A] terminal 3 and TSM/TSSM connector
[30B] terminal 3. With ignition key turned ON, serial data
bus voltage should be typically 0.6-0.8 volts. The range
of acceptable voltage is greater than 0 and less than 7.0
volts.
harness while performing steps in the Diagnostic Check
charts.
The reference numbers below correlate with the circled num-
bers on the diagnostic check flow char ts. See page 2-11.
1. Connect BREAKOUT BOX (Part No. HD-42682) and
INSTRUMENT HARNESS ADAPTERS (Part No. HD-
46601) between wire harness and speedometer.
All Speedometer diagnostic trouble codes are listed on page
2-6 in Table 2-2.
diagnostic trouble codes related to the turn signal module
(TSM) or turn signal security module (TSSM).
See 4.4 INITIAL DIAGNOSTIC CHECK: ICM for any diagnos-
tic trouble codes related to the ignition control module (ICM).
See 5.5 INITIAL DIAGNOSTIC CHECK: EFI for any diagnos-
tic trouble codes related to the electronic control module
(ECM).
1. Headlamp
2. Ignition
3. Lighting
4. Instruments
5. Brakes/Cruise
Terminal 5
(Constant) Terminal 1 (IGN) Terminal 6 (ACC) Terminal 7 (GRD)
Terminal 8 and 11
DTC PRIORITY FAULT CONDITION SOLUTION MODULE
“BUS Er” 1 Serial data bus shorted low/open/high 2.15 DTC U1300, U1301
or “BUS ER” Speedometer/tachometer
U1300 2 Serial data bus shorted low 2.15 DTC U1300, U1301
U1301 3 Serial data bus shorted open/high 2.15 DTC U1300, U1301
U1016 4 Loss of ECM serial data 2.13 DTC U1016 Speedometer/tachometer
U1064 5 Loss of TSM/TSSM serial data 2.14 DTC U1064, U1255 Speedometer/tachometer
U1255 6 Missing response from other module
(TSM/TSSM and/or ICM/ECM) at startup 2.14 DTC U1064, U1255 Speedometer/tachometer
B1007 7 Ignition line overvoltage 2.11 DTC B1006, B1007 Speedometer/tachometer
B1006 8 Accessory line overvoltage 2.11 DTC B1006, B1007 Speedometer/tachometer
B1008 9 Reset switch closed 2.12 DTC B1008 Speedometer

Table 2-3. Wire Harness Connectors in Figure 2-7.
NO. DESCRIPTION TYPE LOCATION
[1] Main to Interconnect Harness 12-Place Deutsch (Black) Inner Fair ing - Right Radio Support Bracket
[2] Main to Interconnect Harness 12-Place Deutsch (Gray) Inner Fair ing - Right Fair ing Support Brace
[8] Ignition Harness 12-Place Deutsch Under Right Side Cover
[10] Ignition Control Module 12-Place Deutsch Under Right Side Cover
[30] Turn Signal/Security Module 12-Place Deutsch Cavity in Crossmember at Rear of Battery Box
(Under Seat)
[39] Speedometer 12-Place Packard Inner Fairing (Back of Speedometer)
[91] Data Link 4-Place Deutsch Under Right Side Cover
[108] Tachometer 12-Place Packard Inner Fairing (Back of Tachometer)
[156] Main to Interconnect Harness 6-Place Deutsch Inner Fairing - Right Fairing Support Brace
12
12
3
1
2
4
15A Ignition
S e r i a l d a t a
[108B]
[30] Turn Signal/Security Module 12-Place Deutsch Cavity in Crossmember at Rear of
Battery Box (Under Seat)
321 654 987 121110
321 654 987 121110
321 654 987 121110
321 654 987 121110
321 654 987 121110
321 654 987 121110
GY
[30B]
[30A]
[91A]
LtGN/V
S e r i a l d a t a
Ignition Control Module
NO. DESCRIPTION MODEL TYPE LOCATION
[1] Main to Interconnect
FLHT/C 12-Place Deutsch (Black) Inner Fairing - Right Radio Support Bracket
FLTR 12-Place Deutsch (Black) Inner Fair ing - Below Radio (Left Side)
FLHT/C 12-Place Deutsch (Gray) Inner Fairing - Right Fairing Support Brace
FLTR 12-Place Deutsch (Gray) Inner Fair ing - Below Radio (Left Side)
[8] Ignition Harness All 12-Place Deutsch Under Right Side Cover
[10] Ignition Control Module All 12-Place Deutsch Under Right Side Cover
[30] Turn Signal/Security
[39] Speedometer FLHT/C 12-Place Packard Inner Fairing (Back of Speedometer)
FLTR 12-Place Packard Under Bezel (Back of Speedometer)
[91] Data Link All 4-Place Deutsch Under Right Side Cover
[108] Tachometer FLHT/C 12-Place Packard Inner Fairing (Back of Tachometer)
FLTR 12-Place Packard Under Bezel (Back of Tachometer)
FLTR 6-Place Deutsch Inner Fairing - Front of Right Fairing Bracket
51
3
1
2
4
15A Ignition
S e r i a l d a t a
[108B]
BK
BN/GY
GY

[78] Electronic Control Module 36-Place Packard Under Right Side Cover
51
GY
[30B]
[30A]
[91A]
LtGN/V
S e r i a l d a t a
ECM
BN/GY
BK
BN/GY
GY

YES. Starts and
See 1.2 STARTING SYSTEM DIAGNOSIS.
YES. Starts, then
NO. Engine will not
crank.
For carbureted models, see 4.9 ENGINE CRANKS, BUT WILL NOT START. For EFI models, see 5.10 ENGINE CRANKS,
BUT WILL NOT START.
NO
Check for continuity to ground on terminal 7 of speedometer. Wiggle harness during con-
tinuity check. Continuity present?
while wiggling harness. Bat- tery voltage continuously
present?
1
DIAGNOSTICS Codes found?
Refer to applicable diagnostic trouble code priority chart. All diagnostic codes
are listed on page 2-6 in Table 2-2. Codes are listed by priority.
STOP
battery fuse.
and ground.
NO
Unable to enter diagnostic mode. With ignition switch OFF, press and
release odometer reset switch. Does odometer display appear with
display backlighting?
NO
No codes displayed. For symptoms that may not set diagnostic trouble codes,
refer to Table 2-1.
With connector [39] disconnected from speedometer, check continuity (with ignition switch OFF) between terminals 8 and 11 on
Breakout Box. Continuity present when speedometer reset switch is depressed and
infinity when released?
Does engine start?
YES
present?
NO
YES
Continued from Diagnostic Check (Part 1 of 2) . Perform “wow” test. See 2.3 SPEEDOMETER SELF DIAGNOSTICS .
The following features should be functional 1) backlight should illuminate 2) needle should sweep its full range of motion 3) LED’s that should illuminate:
• check engine • battery • security (all models)
4) LED’s that may illuminate: • low fuel (EFI models) • cruise (although not cruise equipped on some models)
Are all features functional?
YES NO
connector [39] and instrument fuse.
Is problem intermittent?
YES
NO
Check for battery voltage at breakout box terminal 6. Battery voltage present?
Replace speedometer.
See Test 2.4 (Part 1 of 2).
YES
indication.
NO
With ignition switch turned to IGN, check for battery voltage at terminal 1 of Breakout Box.
Battery voltage present?
NO
Locate and repair open on O/W wire between termin al 6 of connector [39] and accessory fuse.
Repeat Diagnostic Check while wiggling harnesses.
Intermittent present?
vehicle speed sensor and ICM/ ECM. Is wiring damage/loose
connection present?
YES NO

speedometer, tachometer, TSM/TSSM, and ICM/ECM diag-
nostic trouble codes (diagnostic mode).
DIAGNOSTICS
For a quick check of speedometer function, a “wow” test
can be performed. Press and hold odometer reset switch
then turn ignition switch ON. Release reset switch. Back-
ground lighting should illuminate, speedometer needle
should sweep its full range of motion, and indicator
lamps [battery, security, low fuel (EFI models) check
engine and cruise should illuminate. Some lamps may
illuminate even though they do not apply to the vehicle.
For example, the cruise lamp may illuminate although
this feature does not apply to some models.
If instrument module fails “wow” test, check for battery,
ground, ignition, speedometer reset switch and acces-
sory to speedometer. If any feature in the speedometer is
non-functional, see 2.2 INITIAL DIAGNOSTIC CHECK:
SPEEDOMETER.
TECHNICIAN (Part No. HD-44750) is not available.
The reference numbers below correlate with the circled num-
bers in the Speedometer Self Diagnostics (chart)
1. To exit diagnostic mode, turn ignition switch OFF.
2. To clear diagnostic trouble codes (DTCs) for selected
module, press speedometer reset switch for more than 5
seconds when code is displayed. This procedure will
clear all diagnostic trouble codes for selected module.

0
10
30
20
50
40
110
120
50
10
MPH
RPMx100
f2160x8x
”P” flashing.
”S” flashing.
”SP” flashing.
release reset switch.
release reset switch.
hold reset switch for more than 5 seconds.
To display DTCs for the ECM/ICM, press and hold reset switch for
more than 5 seconds.
To choose Speedometer, press and release reset
switch.
NO
YES
2
switch.
Press and release reset switch. Part number of module will be
displayed.
next module.
Device response?
TACHOMETER.
* Models not equipped with a tachometer will display “no rsp” nor- mally.
DTC displayed.
Are more DTCs displayed?
1
While holding odometer reset switch in, turn ignition switch to IGN. Make sure Run/Stop switch is in RUN position.
Release reset switch. Does “diag” appear?
YES NO
“end” displayed. To clear all DTCs for
selected module hold reset switch for more than 5 seconds. If DTCs are not to be cleared, Press and release reset switch. Part number of
module will be displayed.
Press and release reset switch.
“PSSPT” appears.
Some icons may illuminate during “wow” test though the icon
has no functionality on that vehicle.
The speedometer consists of a speedometer display and sev-
eral icons. The icons include: check engine, security, battery,
and low fuel (EFI only).
Reset Switch
vides the following capabilities:
Reset an individual trip odometer (press and hold 2-3
seconds).
SPEEDOMETER SELF DIAGNOSTICS.
Display odometer while key is OFF. Press and hold reset
switch while key is OFF and odometer mileage will be
displayed.
ter display. To toggle display, turn key ON. Press and
hold reset switch while odometer is displayed. Release
switch when change is noted. (If reset switch is held
while trip odometer is displayed, trip odometer will reset.)
Figure 2-14. Icons (FLHT/C/U)
50
10
MPH
RPMx100
f2160x8x
The speedometer consists of a vehicle speed sensor, ICM/
ECM, odometer reset switch and the speedometer. The vehi-
cle speed sensor is mounted on the right side of transmission
case below the starter. The sensor circuitry is that of a Hall-
Effect sensor that is triggered by the gear teeth of 4th gear on
the transmission mainshaft.
The output from the sensor is a series of pulses that are inter-
preted by ICM/ECM circuitry, converted into serial data inside
the ICM/ECM then sent to the speedometer to control the
position of the speedometer needle and the liquid crystal
(LCD) odometer display. The vehicle speed serial data is also
transmitted to the TSM/TSSM for turn signal cancellation.
The odometer mileage is permanently stored and will not be
lost when electrical power is turned off or disconnected. The
odometer reset switch allows switching between the odome-
ter, trip odometer A and tr ip odometer B displays.
To zero the trip odometer, have the desired trip odometer dis-
play visible, press and keep the reset switch depressed. The
trip odometer mileage will be displayed for 2-3 seconds and
then the trip mileage will return to zero miles.
The odometer can display six numbers to indicate a maxi-
mum of 999999 miles/kilometers. The trip odometers can dis-
play six numbers with a tenth of a mile accuracy for a
maximum of 99999.9 miles/kilometers.
job/time code values in Digital Technician.
TACHOMETER THEORY
OF OPERATION
tachometer needle movement.
on the tachometer diagnostic flow chart.
1. If problems are intermittent, wiggle harness while per-
forming tests.
46601) between wire harness and tachometer.
3. Use HARNESS CONNECTOR TEST KIT (Part No. HD-
41404), black pin probe and patch cord.

TACHOMETER INOPERATIVE
Perform “wow” test. See 2.3 SPEEDOMETER SELF DIAGNOSTICS.
The following features should be functional 1) backlight should illuminate 2) needle should sweep its full range of motion 3) LED’s may illuminate:
cruise (although not cruise equipped on some models) pursuit (although may not be a police vehicle)
Are all features functional?
Locate and repair open in orange wire
between terminal 1 of connector [108] and
instrument fuse.
YES
Check for battery voltage at terminal 1 of breakout box. Is battery voltage
present?
NO
NO
harnesses.
NO
Locate and repair open on LGN/V wire.
Check for continuity between breakout box terminal 2 and terminal 7 of connector [20].
Is continuity present?
TACHOMETER INOPERATIVE
Is battery voltage present?
while wiggling harness. Is battery voltage
continuously present?
Replace tachometer. Locate and repair open on O/W wire between terminal 6 of con-
nector [108] and accessory fuse.
Continued from Test 2.4 (Part 1 of 2). Check for continuity to ground on breakout box
terminal 7. Wiggle harness during continuity check. Is continuity present?
YES NO
YES NO
minal 7 of connector [108] and ground.
NO
Locate and repair open on BN/GY wire between terminal 5 of connector [108] and battery fuse.
YES
MENT HARNESS ADAPTERS (Part No. HD-46601) connect
to speedometer connector [39]. Used in conjunction with a
DVOM, it allows circuit diagnosis of wiring harness and con-
nections without having to probe with sharp objects
NOTE
INSTALLATION
1. See Figure 2-16. Bend back the external latches slightly
and remove connector [39B].
[39A] and [39B].
ness Adapters.
ness Adapters.
from connectors [39A] and [39B].
3. Install connector [39B] to speedometer.

(Part No. HD-46601)
Figure 2-17. Breakout Box (Part No. HD-42682)
10086
f2001x8x
f1998x9x
No. HD-41354) for speedometer diagnostics. These diagnos-
tics may include:
Checking speedometer operation.
The tester generates a simulated vehicle speed sensor signal
which is sent to the ICM/ECM. The ICM/ECM interprets the
signal then sends a message to the speedometer. This signal
aids in determining whether speedometer replacement is
necessary.
NOTES
manual supplied with the speedometer tester.
Test results may be inaccurate if tester battery is low.
TESTING
NOTE
The SPEEDOMETER TESTER (Part No. HD-41354) cannot
be used to verify the calibration of a speedometer and it will
not verify the speedometer’s function to support legal pro-
ceedings. It’s purpose is to verify speedometer function when
performing service diagnosis or repair. It can also assist in
determining if speedometer replacement is necessary.
Speedometer Operation Test
sensor connector [65] under right side cover (behind
electrical bracket). Attach speedometer tester connector.
2. Place speedometer tester power switch in the ON posi-
tion. Place signal switch in the OUT position.
3. Turn vehicle ignition switch ON and Run/Off switch to
Run.
a. Press 1 and ENTER on the tester keypad.
b. Enter a frequency from Table 2-7. Note that different
markets use different frequencies.
sponding speed. To change the test frequency,
press CLEAR to cancel and enter the new fre-
quency. Press ENTER to begin and reverify.
NOTE
The speedometer should be accurate within -0 to +4 MPH (0
to +6.5 KPH).
hd41354
Table 2-7. Speedometer Test Frequency in Hertz (All Models Except Police)
MARKET 20 MPH 40 MPH 60 MPH 80 MPH 30 KPH 60 KPH 100 KPH 130 KPH
DOMESTIC 442 885 1327 1770 - - - -
CANADA - - - - 413 825 1375 1788
HDI - - - - 413 825 1375 1788
GREAT BRITAIN 442 885 1327 1770 413 825 1375 1788
JAPAN - - - - 448 896 1493 1941
Table 2-8. Speedometer Test Frequency in Hertz (Police)
MARKET 20 MPH 40 MPH 60 MPH 80 MPH 30 KPH 60 KPH 100 KPH 130 KPH
DOMESTIC 462 924 1386 1848 - - - -
CANADA - - - - 431 861 1435 1866
HDI - - - - 431 861 1435 1866
GREAT BRITAIN 462 924 1386 1848 431 861 1435 1866
JAPAN - - - - 431 861 1435 1866

The tester’s sweep function moves the speedometer needle
through the full range of movement. This allows for testing the
smoothness of operation and checking for hesitancy or a
stuck needle.
nector. Attach speedometer tester connector to speed-
ometer sensor connector.
tion. Place signal switch in the OUT position.
3. Turn vehicle ignition switch ON.
4. Begin test by pressing 0 on the tester keypad and then
pressing ENTER. The tester will scan for two seconds,
then the tester will put out a 1 Hz signal.
5. Select a test range.
a. Press 2 to select LO range (1-20 Hz).
b. Press 5 to select CEN range (21-999 Hz).
c. Press 8 to select HI range (1000-20,000 Hz).
6. After selecting a range, use the corresponding arrow
keys to accelerate through the range. As you move
through the speed range, check for smooth needle
movement.
Vehicle Speed Sensor Test
eter work, the vehicle speed sensor may not be working.
See Figure 2-20. Fabricate a test harness using the following
parts. This harness can also be used to test the tachometer.
Two Deutsch 3-place socket housings (Part No. 72113-
94BK) and six socket terminals (Part No. 72191-94).
Deutsch 3-place pin housing (Part No. 72103-94BK) and
three pin terminals (Part No. 72190-94).
Six lengths of 18 gauge wire, each 6.0 in. (15 cm) long.
Before attempting the actual vehicle speed sensor check, two
system checks must be made. Install the test harness at the
speedometer sensor connector.
Test for voltage to sensor by checking for 8-12 volts on
red wire in connector [65B].
Then check for continuity to ground on black wire in con-
nector [65B].
2. Install the test harness between the vehicle speed sen-
sor connectors.
tion. Place signal switch in the IN position.
4. Plug the speedometer tester into the test harness. Turn
vehicle ignition switch ON.
a. If reading on speedometer tester changes as wheel
is rotated, speedometer sensor is OK.
b. If reading does not change on carbureted models,
see 4.18 DTC P0501, P0502. If reading does not
change on EFI models, see 5.25 DTC P0501,
P0502.
5087
THEORY OF OPERATION
With ignition switch ON, the fuel gauge is connected to +12
volts. Current flows through the gauge and variable resistor in
the fuel gauge sending unit to ground. The sending unit float
controls the amount of resistance in the variable resistor.
Inoperative gauges may be caused by three circumstances.
Sender or fuel gauge not grounded.
Malfunction in sender or fuel gauge.
Broken or disconnected wire from ignition switch to fuel
gauge.
Use the FUEL GAUGE AND SENDER TEST to test suspect
components.
NOTE
Always refer to the applicable wiring diagram (at the rear of
this manual) when troubleshooting instruments or gauges.
1. Remove gauge. Ground Y/W wire of fuel gauge sender
located at bottom of gauge. Turn ignition switch ON.
a. Fuel gauge must indicate FULL. If gauge indicated
FULL, gauge is functioning correctly. Proceed to
step 2.
b. If gauge did not indicate FULL, proceed to step 3.
2. Set MULTI-METER (Part No. HD-35500) to RXI scale to
measure the resistance of the sending unit. Place one
probe on Y/W and the other probe on a good ground.
FLHT/C/U, FLTR:
If fuel tank is full, the reading should be 7-14 ohms. An
empty tank should have a 74-95 ohm resistance. A half
full tank will be approximately 30-38 ohms.
FLHR/C/S:
If fuel tank is full, the reading should be 27-40 ohms. An
empty tank should have a 240-264 ohm resistance. A
half full tank will be approximately 97-118 ohms.
ALL MODELS:
If a very high resistance or infinity is indicated on the
meter, the sender may be “open” or not grounded. Check
that sender and fuel tank are grounded by placing one
probe of Multi-Meter on sender flange and the other
probe on crankcase. Meter must indicate one ohm or
less. Replace sender if one ohm or 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
connector [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 or
disconnected wire. Replace gauge if wiring problem
is not found.
GENERAL
with incandescent indicator lamps which may be replaced
individually. See the Touring Models Service Manual for lamp
replacement procedure. See DIAGNOSTICS which follows
for troubleshooting procedures.
Job/Time Code Values
appropriate repair.
Diagnostic Notes
ber on the Diagnostics flow charts on the next page.
1. Connect BREAKOUT BOX (Part No. HD-42682) (black)
between wire harness connector [20A] and instruments
connector [20B].
TERMINAL WIRE
COLOR FUNCTION
8 Tan Neutral Lamp To Switch
9 Green/Yellow Oil Pressure Lamp To Switch
12 Black Turn Signal/High Beam
Ground
INDICATOR LAMP CONNECTION
Neutral Ground Through Switch
Figure 2-21. Indicator Lamp Assembly
(FLTR, FLHT/C/U)
High Beam or R/L Turn Signal Indicator Will Not Function
Turn on ignition switch. Check for 12 VDC at Breakout Box terminal 6.
Turn off ignition switch. Was 12 VDC present?
Check for continuity to ground at Breakout Box terminal 8 (neutral) and terminal 9 (oil pressure).
NO
TN wire (neutral).
Is ground present?
Check for 12 VDC when circuit is active: Breakout Box terminal 5 (left turn), terminal 3
(right turn) or terminal 4 (high beam). Is voltage present?
YES
5048
NO
NO
5191
5048
1
(LED) indicators. The indicator lamp assembly is not service-
able. If one LED is bad, the entire assembly must be
replaced.
dures.
appropriate repair.
TERMINAL WIRE COLOR FUNCTION
1 Violet Left Turn
2 White High Beam
3 Green/yellow Oil Pressure
4 Brown Right Turn
8 Not used N/A
INDICATOR LAMP CONNECTION
Neutral Ground Through Switch
Indicator Lights Assembly (FLHR/C/S)
High Beam or R/L Turn Signal Indicator Will Not Function
Check for 12 VDC at terminal 6 of connector [21A]. Is 12 VDC present?
Check for continuity to ground on connector [21] at terminal 5 (neutral) and ter-
minal 3 (oil pressure). Is continuity present?
YES
5048
NO
TN wire (neutral).
5191
Check for ground at terminal 2 of connector [21A]. Is ground present?
Check for 12 VDC when circuit is active. Use terminal 1 (left turn), terminal 4 (right turn) and terminal 2
(high beam). Voltage present?
NO
NO
GENERAL
The fuel level is monitored by the speedometer pin 9 of con-
nector [39] (Y/W).
If the voltage on pin 9 of connector [39] exceeds the
lower limit for greater than or equall to 15 seconds a DTC
B1004 will set.
If the voltage on pin 9 of connector [39] exceeds the
upper limit (or is open) for greater than or equall to 15
seconds a DTC B1005 will set.
DIAGNOSTICS
tic trouble codes), inspect for unobstructed movement of
sending unit arm. Repair or align as necessary.
Diagnostic Notes
bers on the 2.10 flow chart.
1. Use HARNESS CONNECTOR TEST KIT (Part No. HD-
41404), brown pin probe and patch cord.
46601) between wire harness and speedometer.
Table 2-13. Code Description
Figure 2-23. Instrument Harness Adapters
(Part No. HD-46601)
Figure 2-25. Breakout Box (Part No. HD-42682)
10086
f2001x8x
f1998x9x
[2] Main to Interconnect Harness FLHT/C 12-Place Deutsch (Gray)
Inner Fairing - Right Fairing Support
Brace
FLTR 12-Place Deutsch (Gray) Inner Fairing - Below Radio (Left Side)
[13] Fuel Tank Harness FLHT/C 3-Place Multilock Behind Fuel Tank (Under Seat)
FLTR 3-Place Multilock Behind Fuel Tank (Under Seat)
[78] Electronic Control Module All 36-Place Packard Under Right Side Cover
[141] Fuel Level Sender FLHT/C 3-Place Mini-Deutsch Top of Canopy (Under Console)
FLTR 3-Place Mini-Deutsch Top of Canopy (Under Console)
1 5
[141A]
Y/W
[13B]
[13A]
between terminal 2 of connector [141B] and ground.
Continuity present?
Repair/replace fuel level sending unit.
YES NO

Test 2.10: DTC B1005
FUEL LEVEL SENDING UNIT
Check continuity to ground on terminal 3 of connector [141B] (BK).
NO
1
Disconnect Speedometer connector [39]. Measure voltage on terminal 2 of connector
[141B] (Y/W). Should be 0 volts. Is it?
YES
YES
NO
Check continuity between terminal 2 of connector [141B] (Y/W) and breakout box terminal 11 (BK).
Continuity present? 2
NO
1

Ignition and accessory voltage is constantly monitored by the
speedometer (terminal 1-ignition and terminal 6-accessory).
If the battery voltage fails to meet normal operating parame-
ters, a diagnostic trouble code is set.
DTC B1006 is displayed when accessory line voltage is
greater than 16.0 volts for longer than 5 seconds.
DTC B1007 is displayed when ignition line voltage is
greater than 16.0 volts for longer than 5 seconds.
NOTE
ICM/ECM or TSM/TSSM may also set a battery voltage diag-
nostic trouble codes.
DTC B1006/B1007
YES NO
NOTE Sometimes battery charger may cause
overvoltage condition which will set codes.
Start vehicle. Run at 3000 RPM for 5 seconds. Does
code reset?

Reset Switch Closed
DTC B1008 will be set if switch terminals are in a constant
shorted state.
bers on the 2.12 flow chart.
46601) between wire harness and speedometer, leaving
speedometer disconnected.
1
2
3
4
5
6
7
8
9
10
11
12
d0723x2x
Remove reset switch rubber boot. Clear codes using 2.3 SPEEDOM-
ETER SELF DIAGNOSTICS. Codes still present?
YES
NO
Clear codes using speedometer self diagnostics. See 2.3 SPEEDOMETER SELF DIAGNOSTICS . Confirm proper operation with no check engine lamp.
With speedometer disconnected, measure resistance between terminals 8 and 11
(black) on Breakout Box. Resistance should be less than 1 ohm with switch depressed
and infinity ohms when released. Is it?

The serial data connector provides a means for the ignition
control module (ICM) or electronic control module (ECM),
TSM/TSSM and speedometer to communicate their current
status. When all operating parameters on the serial data bus
are within specifications, a state of health message is sent
between the components. A DTC U1016 indicates that the
ICM/ECM is not capable of sending this state of health mes-
sage.
DIAGNOSTICS
bers on the Test 2.13 flow chart.
1. Connect BREAKOUT BOX (Part No. HD-42682) (gray)
between TSM/TSSM connector [30A] and wire harness
connector [30B]. See 3.11 BREAKOUT BOX: TSM/
TSSM.
nector [10B]. See 4.6 BREAKOUT BOX: ICM
3. Connect BREAKOUT BOX (Part No. HD-43876)
between wire harness and ICM/ECM. See 5.7 BREAK-
OUT BOX: EFI.
(state of health)
6924
2. Terminal 2: ground (BK)
3. Terminal 3: serial data (Lt GN/V)
4. Terminal 4: power (GY)
5. Protective cap
f2191x8x
f1917x9x
Carbureted
[2] Main to Interconnect Harness 12-Place Deutsch (Gray) Inner Fairing - Right Fair ing Support Brace
12
12
3
1
2
4
15A Ignition
S e r i a l d a t a
[108B]
321 654 987 121110
321 654 987 121110
321 654 987 121110
321 654 987 121110
321 654 987 121110
321 654 987 121110
GY
[30B]
[30A]
[91A]
LtGN/V
S e r i a l d a t a
51
3
1
2
4
15A Ignition
S e r i a l d a t a
[108B]
BK
BN/GY
GY

51
GY
[30B]
[30A]
[91A]
LtGN/V
BK
BN/GY
GY
S e r i a l d a t a
F l a s h p i n

LOSS OF ICM/ECM SERIAL DATA: DTC U1016
Can you read ECM/ICM hardware P/N? See 2.3 SPEEDOMETER SELF DIAGNOSTICS.
NO or “No Rsp” YES
YES
NO
Install Breakout Box on TSM/TSSM 1
Replace ICM. Reprogram and learn
password.
Check continuity between terminal 2 (black) of speedometer
Breakout Box and terminal 5 of ECM Breakout Box. Continuity present?
2 3
password.
Check continuity between terminal 3 (gray) of TSM/TSSM break-
out box and terminal 5 of ECM breakout box.
Continuity present?
CARBURETED MODELS EFI MODELS2
3
YES
NO
While wiggling harness, check continuity between breakout box terminal 3 (gray) and breakout
box terminal 12 (black). Continuity present?
YES
While wiggling harness, check continuity between terminal 3 (gray) of
TSM/TSSM breakout box and terminal 5 of ECM Breakout Box.
Continuity present?
return?
YES
password.
NO
Replace ECM. Reprogram and learn
password.
No trouble found.
Check continuity between breakout box terminal 3 (gray) and breakout box
terminal 12 (black). Continuity present?

The serial data connector provides a means for the ignition
control module (ICM) or electronic control module (ECM),
TSM/TSSM and speedometer to communicate their current
status. When all operating parameters on the serial data bus
are within specifications, a state of health message is sent
between the components. A DTC U1064 indicates that the
TSM/TSSM is not receiving this state of health message.
DIAGNOSTICS
bers on the Test 2.14 flow chart.
1. Connect BREAKOUT BOX (Part No. HD-42682) as fol-
lows:
speedometer connector [39] using SPEEDOMETER
HARNESS ADAPTER (Part No. HD-46601).
b. Mate black pin housing on Breakout Box with speed-
ometer harness connector [39B] using SPEEDOM-
ETER HARNESS ADAPTER (Part No. HD-46601).
c. Mate gray socket housing on Breakout Box with
TSM/TSSM connector [30A].
d. Mate gray pin housing on Breakout Box with har-
ness connector [30B].
U1255 Serial data error/missing message
Figure 2-34. Frame Crossmember (Under Seat)
Figure 2-35. Data Link Connector
f2013x8x
2. Terminal 2: ground (BK)
3. Terminal 3: serial data (Lt GN/V)
4. Terminal 4: power (GY)
5. Protective cap
[2] Main to Interconnect Harness 12-Place Deutsch (Gray) Inner Fair ing - Right Fair ing Support Brace
12
12
3
1
2
4
15A Ignition
S e r i a l d a t a
[108B]
321 654 987 121110
321 654 987 121110
321 654 987 121110
321 654 987 121110
321 654 987 121110
321 654 987 121110
GY
[30B]
[30A]
[91A]
LtGN/V
S e r i a l d a t a
51
3
1
2
4
15A Ignition
BK
BN/GY
GY
S e r i a l d a t a
F l a s h p i n

51
GY
[30B]
[30A]
[91A]
LtGN/V
BK
BN/GY
GY
S e r i a l d a t a
F l a s h p i n

U1255
Can you read TSM/TSSM hardware P/N? See 2.3 SPEEDOMETER SELF DIAGNOSTICS.
NO or “No Rsp” YES
YES NO
Repair open on LtGN/V wire.
Install Breakout Box on speedometer. Check for continuity between terminal 3 (gray) and terminal 2 (black) of Breakout
Box Continuity present?
1Install Breakout Box on speedometer. While wiggling harness, check for continuity
between terminal 3 (gray) and terminal 2 (black) of Breakout Box.
Continuity present?
NO
1
return?

GENERAL
Serial Data Low or Serial data Open/High
See Figure 2-40. The typical serial data voltage range is 0
volts (inactive) to 7 volts (active). Due to the short pulse, volt-
ages will be much lower on a DVOM. In analog mode, a
DVOM reading serial data will show continuous voltage when
active, typically 0.6-0.8 volts. The range for acceptable opera-
tions is 0-7.0 volts.
(DTCs) will automatically cause the check engine lamp
to illuminate. The odometer will read “Bus Er” in this con-
dition.
accompany DTCs U1300 and U1301.
Diagnostic Notes
If a U1300, U1301 or “BUS Er” is present on carbureted
models, perform diagnostic procedures listed in 4.10
STARTS, THEN STALLS.
If a U1300, U1301 or “BUS Er” is present on EFI models,
perform diagnostic procedures listed in 5.12 STARTS,
THEN STALLS.
f2191x8x
Carbureted
2.2 Initial Diagnostic Check: Speedometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.3 Speedometer Self Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
2.4 Speedometer/Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
2.8 Indicator Lamps: FLTR, FLHT/C/U . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
2.9 Indicator Lamps: FLHR/C/S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
2.10 DTC B1004, B1005 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
2.11 DTC B1006, B1007 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
2.12 DTC B1008 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
2.13 DTC U1016 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
2.15 DTC U1300, U1301 or "BUS Er" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48
Table Of Contents
HOME
GENERAL
See Figure 3-1. The turn signal module (TSM) has two major
functions:
The optional, factory-installed, security system (turn signal
security module or TSSM) provides the same functionality as
the TSM, but also includes security and immobilization func-
tions.
TROUBLESHOOTING
Turn signal malfunction.
To resolve TSM/TSSM problems, four basic steps are
involved. In order of occurrence, they are:
1. Retrieve diagnostic trouble codes using speedometer
self diagnostics. See 3.10 SPEEDOMETER SELF DIAG-
NOSTICS.
tools and the diagnostic flow charts in this section.
3. Correct problems through the replacement and/or repair
of the affected components.
4. After repairs are performed, the work must be validated.
This involves clearing the diagnostic trouble codes and
confirming proper vehicle operation as indicated by the
behavior of the turn signals.

HOME
– +
ICM
BK
R
R
LtGN/BN
BN/GY
R/BK
R/BK
GY
TN/GN
BK/R
GN
BK
R/BK
GY
W/BK
LtGN/V
LtGN/V
BK
V
BK
BK
BN
R
BN/V
HOME
upon vehicle market specifications.
plete details.
tion of left and right turn signal flashing sequences.
Automatic turn signal cancellation: Automatic cancel-
lation of left and right turn signal flashing sequences
based on either vehicle speed, vehicle acceleration or
turn completion.
flashing capability.
short circuit and open lamp conditions on both left and
right turn signal systems.
details.
and will provide engine shutdown when lean exceeds
45° from vertical for more than one second.
Emergency outputs disable: Monitors vehicle lean and
will disable turn signal lamps and starter motor when
lean exceeds 45° from vertical for more than one sec-
ond.
security option (TSSM). See 3.6 SECURITY SYSTEM
(TSSM) FUNCTIONS for more information.
Remote arming/disarming: See Figure 3-4. Owners
may enable and disable security alarm and immobiliza-
tion functions with a remote, personally carried transmit-
ter. This transmitter is referred to as a key fob within this
document.
Security lamp: See Figure 3-5. A lamp within the speed-
ometer face tells the rider if the system is armed or dis-
armed.
Personal code disarming: If a key fob is not available,
the TSSM allows the rider to disable the security alarm
and immobilization functions if the rider knows the previ-
ously entered personal code.
armed or disarmed, the system provides visual feedback
to the rider by flashing the turn signals and sounding the
optional siren.
50
10
MPH
RPMx100
f2160x8x Security Lamp
HOME
and immobilization functions within 30 seconds after the
ignition key is switched OFF.
NOTE
All HDI vehicles have auto-arming by default. Motorcycles
sold in other markets have auto-arming disabled, but it may
be activated. See 3.3 TSM/TSSM VEHICLE DELIVERY .
Transport mode: It is possible to arm the security sys-
tem without enabling the motion detector for one ignition
cycle. This allows the vehicle to be moved in an immobi-
lized state.
immobilization functions be triggered by a vehicle secu-
rity condition, the starter and ignition system will be dis-
abled.
alternately flash the left and right turn signals and sound
an optional siren if a vehicle security condition is
detected while the system is armed.
Figure 3-6. Siren
HOME
for sidecar use. Consult a Harley-Davidson dealer. Use of
motorcycles other than Touring models with sidecars
could result in death or serious injury.
Setting up a vehicle TSM/TSSM depends on whether the
vehicle has a turn signal module (TSM) or the optional secu-
rity system (TSSM) installed.
All motorcycles ship with the TSM/TSSM set for use without
a sidecar installed. If a motorcycle is equipped with a TSM, no
further configuration is required. However, if a motorcycle has
an optional security system (TSSM) installed, perform the fol-
lowing steps as necessary.
to the vehicle.
code picked by the owner. The personal code allows the
owner to operate the system if the key fob is lost or inop-
erable. Record this code in the owner’s manual and
instruct the customer to carry a copy.
IMPORTANT NOTE
Do not forget to enter a personal code for TSSM vehicles.
If a code is not assigned and both key fobs are lost or
damaged while the vehicle is armed, the TSSM must be
replaced.
Changes to TSM/TSSM settings are made by a series of pro-
gramming operations involving the ignition key, left/right turn
signal switches and key fob (security systems).
At certain steps in the programming sequence, the motorcy-
cle may provide confirmation of settings by flashing the turn
signals, turn signal indicators and/or security lamp. In addi-
tion, when programming a persona

2004 Harley Davidson Touring Models Service Manual - English

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