EXCELSIOR-HENDERSON MOTORCYCLE MANUFACTURING COMPANY805 HANLON DRIVE • BELLE PLAINE, MINNESOTA 56011 • TELE: 612.873.7000/FAX: 612.873.7030

Copyright ©1999 Excelsior-Henderson Motorcycle Manufacturing Company. All rights reserved. Excelsior-Henderson, Examinator, and the X & Bar logo are trademarks of the Excelsior-Henderson MotorcycleManufacturing Company.

All text, photographs, and illustrations in this handbook are based on the most currentproduct information available at the time of publication. Product improvements or otherchanges may result in differences between this handbook and the motorcycle.Excelsior-Henderson reserves the right to make production changes at any time, withoutnotice and without incurring any obligation to make the same or similar changes tomotorcycles previously built.

ONTENTSCONTENTS

bout This HOverview iSymbols ATechnicalWarranty i

. DescriptioExaminatoBreakout BHandling a

. Using theBasic Ope

UsingUsingGettingConneAdjust

odes 2-8ts 2-8rm Idle Fuel Trim 2-9Term Idle Fuel Trim 2-9

ed Throttle Position 2-10alve Adaption 2-10

nes 2-10

Boxter 3-1x Overlay 3-1ut Box 3-4

C

A

1

2

ii

UsingRemov

DiagnosticEnterinDisplaDisplaClearin

andbook

nd Terms iSupport ii

nr Diagnostic Tool 1-2ox 1-3nd Care 1-4

Examinatorration 2-1the Menus 2-1the Keypad 2-2

Help 2-3cting to the ECM 2-3ing Screen Contrast 2-4the Multimeter 2-4ing and Installing the Memory Card 2-5

s 2-6g Service Data 2-6

ying Engine Data 2-6ying Fault Codes 2-7g Fault Codes 2-8

Diagnosing Fault CTesting ComponenAdjusting Short TeResetting the LongResetting the ClosResetting the IAC VLoading Engine Tu

3. Using the BreakoutInstalling the Pin AdapUsing the Breakout BoConnecting the Breako

BOOKHANDBOOK

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.apter 1 Description preaminator Diagnostic Torpose. It also includesapter 2 Using the Exan of the Examinator diam diagnostic tasks.apter 3 Using the Breannect and operate the

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ABOUT THIS HANDABOUT THIS

e use of the equipmentDiagnostic Tool Kit. It alsoon for the kit.the use of the Examinatort box. It does not attempt torepair of malfunctions in theto the Excelsior-Hender-r detailed information aboutcomponents, and operation.

t you will find in this hand-

sents the components of theol Kit and describes their

a part number list.minator describes the opera-gnostic tool and how to per-

kout Box describes how tobreakout box.

Symbol s And TermsThe hazard symbol indicateshazard to yourself, others, orPay special attention to informbegins with this symbol.

The following term has special meaningunderstand the meaning of this term, ascommunicates important information abmotorcycle, its operation, and maintena

Caution• Indicate s a potentia l hazard that

age the diag nosti c too l or the mo

Technica l Suppo rtIf you experience difficulty using your Enostic tool, you can call Excelsior-Hendsupport at 1-800-873-4957 Monday throAM to 5:00 PM, Central Time.

!

6999-0007 Rev. A iii

ABOUT THIS HANDBOOK

iv

WaExcepanymateto ause,Comat nodateThe• All• Te• CaEXCFACRANEITHWARFOR

6999-0007 Rev. A

rrantylsior-Henderson Motorcycle Manufacturing Com-warrants this product to be free from defects inrials and workmanship. Should the product fail due

defect in material and/or workmanship after normalExcelsior-Henderson Motorcycle Manufacturingpany will, at its option, repair or replace the productcharge for a period of twelve (12) months from the

of purchase.following items are excluded from this warranty:cables

st probesseELSIOR-HENDERSON MOTORCYCLE MANU-TURING COMPANY MAKES NO OTHER WAR-TIES OR REPRESENTATIONS OF ANY KIND, ER EXPRESSED OR IMPLIED INCLUDING ANY RANTY OF MERCHANTABILITY OR FITNESS- A PARTICULAR PURPOSE.

ESCRIPTION1DESCRIPTION

The ExaExaminaExaminacorrectindisconneModule (breakoutaccess ttem. Multact poinmeasureThe folloKit comp

PART NUMBERool Kit 6999-0088

ool

1-1

6999-0007 Rev. A

1. D

minator Diagnostic Tool Kit consists of thetor diagnostic tool and breakout box. Thetor diagnostic tool assists you in identifying andg engine management system malfunctions. Bycting the harness from the Engine ControlECM) and reconnecting the harness to thebox, the breakout box provides convenient

o the circuitry of the engine management sys-timeter test probes can be inserted into the con-ts of the breakout box to test for continuity,resistance, or measure voltage.

wing table lists the Examinator Diagnostic Toolonents.

ITEMExaminator Diagnostic T

Examinator Case

Examinator Handbook

Examinator Diagnostic T

Examinator Cable

Memory Card

Test Probe Set

Breakout Box

Pin Adapter

Breakout Box Overlay

Breakout Box Cable

Y-Cable

DESCRIPTION

1-2

ExThelowin• A• A• A• Mu

me• Te• A

anThefollo• Re• Ide

fun• Di• Di• Se• Re• Re• Re• Lo

3. MEMORY CARD4. TEST PROBES5. MULTIMETER

CONNECTORS

10450

6999-0007 Rev. A

aminator Diagnostic ToolExaminator diagnostic tool is equipped with the fol-g:

160 by 128 pixel display with adjustable contrastkeypad to select and perform diagnostic taskscable to connect to the motorcycle wiring harnessltimeter connectors for continuity tests, resistanceasurements, and voltage measurements

st probesmemory card containing the Examinator softwared engine tunes.Examinator diagnostic tool enables you to do thewing:ad and clear fault codes that are stored in the ECMntify and correct engine management system mal-ctions.

splay output from the sensorssplay engine performance informationt the short term idle fuel trimset the long term idle fuel trimset the closed throttle positionset the idle air control (IAC) valve adaptionad engine tunes into the ECM

1. EXAMINATOR2. EXAMINATOR CABLE

DESCRIPTION

1-3

ERLAYBLE

5. Y-CABLE6. Y-CABLE FEMALE

CONNECTORS7. Y-CABLE MALE

CONNECTORS

10494

6999-0007 Rev. A

Breakout BoxThe breakout box is equipped with the following:• A pin adapter that routes the connections from the wir-

ing harness ECM connectors to the contact points onthe breakout box board.

• An overlay that labels the contact points on the break-out box board.

• A breakout box cable and a Y-cable that attach thebreakout box to the wiring harness and ECM.

Using the multimeter built in to the Examinator diagnos-tic tool, you can test individual circuits of the enginemanagement system.

1. BREAKOUT BOX2. BREAKOUT BOX OV3. BREAKOUT BOX CA4. PIN ADAPTER

DESCRIPTION

1-4

HaThedesielecto ening:• Ke• Cl• Av• St

no• Do

pe• To

Exex

Han• Ke• To

ca• Av

32

6999-0007 Rev. A

ndling and CareExaminator diagnostic tool and breakout box aregned for the shop environment. However, like othertrical equipment, they should be handled with caresure a long service life. We recommend the follow-

ep the Examinator diagnostic tool clean and dry.ean with a clean, damp cloth and mild detergent.oid dropping the Examinator diagnostic tool.ore the Examinator diagnostic tool in the case whent in use.not expose the Examinator diagnostic tool to tem-

ratures below 32° or above 130° F.protect the liquid crystal display, do not expose theaminator diagnostic tool to direct sunlight fortended periods.dle memory cards with care also.ep memory cards clean and dryprotect the stored data, avoid exposing memory

rds to direct sunlight or to magnetic fields.oid exposing memory cards to temperatures below° or above 130° F.

XAMINATOR2USING THE EXAMINATOR

This chanostic totion. Thediagnost

BasicBasic op• Using• Using• Getting• Conne• Adjust• Using• Remov

Using tThe follo

2-1

menus.

10488

6999-0007 Rev. A

2. USING THE E

pter describes how to use the Examinator diag-ol. The first section describes the basic opera-Diagnostics section describes how to perform

ic tasks.

Operationeration includes the following:the Menusthe Keypad

Helpcting to the ECMing Screen Contrastthe Multimetering and Installing the Memory Card

he Menuswing diagram illustrates the major Examinator

USING THE EXAMINATOR

2-2

UsinThekeysthe cDatadate

Funcitemmenscre

The

• OK• ∗• HE

ite• BA• QU

ou• MO

as• MA• NE• FIX• DA

co• LIS 3. FUNCTION KEYS

4. FUNCTION KEY LABELS

10489

MAIN MENU

HELP *

DATADESNT TESTS

6999-0007 Rev. A

g the Keypadkey pad has three types of keys: cursor keys, data, and function keys. Cursor keys are used to moveursor up and down through the list of menu items.keys are used to enter information such as theof service.

tion keys are used to initiate selected menus, complete tasks, or to navigate through theu system. Function key labels appear on eachen identifying the purpose of each function key.

following function key labels are used:

- Complete an operation.- Initiate a menu selectionLP - Display help for the screen or selected menu

m.CK - Return to the previous screen.IT - Cancel the operation and return to the previ-

s menu.RE/LESS - Increase or decrease something, such

screen contrast.IN - Return to the Main menu.XT - Advance to the next screen.- Resolve the selected fault code.

TA - Display history data for the selected faultde.T - Return to the list of fault codes 1. CURSOR KEYS

2. DATA KEYS

BACK

CURRENTFAULT COCOMPONETUNING

USING THE EXAMINATOR

2-3

ior-Henderson logo appearsby the Function menu.

CTOR 2. EXAMINATOR CABLE

10493

6999-0007 Rev. A

Getting HelpTo display help information for a screen or a selectedmenu item, press the HELP function key. For help with aparticular menu item, move the cursor to that item andpress the HELP function key.

Connecting to the ECMThe Examinator diagnostic tool connects to the ECM bymeans of a diagnostic cable. This cable has a 25-socketconnector that attaches to the Examinator diagnostictool and a 16-pin connector that attaches to the diag-nostic connector on the motorcycle wiring harness. Thisconnector provides power to the Examinator diagnostictool and access to the ECM. The Examinator diagnostictool requires a minimum of 8 volts. Do the following:1.Connect the diagnostic cable to the Examinator diag-

nostic tool and ensure that a memory card is installed.See Removing and Installing the Memory Card onpage 2-5.

2.Connect the Examinator diagnostic tool to the diag-nostic connector on the motorcycle wiring harness.

3.Remove the Lights fuse to minimize battery drain.4.Move the main switch to the On position to energize

the Examinator diagnostic tool.5.Move the engine Stop/Run switch to the Run position

to energize the ECM.The Examinator diagnostic tool performs a self-test andchecks for the presence of a memory card. When this is

complete, the Excelsmomentarily followed

1. DIAGNOSTIC CONNE

USING THE EXAMINATOR

2-4

AdjuSeleandincre

UsinTheconn• Re

gro• Bla

tes• Gr

suna

•

•

Thecle g

hat ground require only onemeasure motorcycle battery

m the Function menu and

ss ∗.e to the red multimeter con-

to the positive battery post

o the following:m the Function menu and

ONTINUITY and press ∗.obe to the black multimeter

e to the circuit and observe

tances on components thatthe motorcycle require two

asurements, attach testand green (negative) muli-

istance measurements andprobes to the black andrs. For example, to measureperature sensor, do the fol-

6999-0007 Rev. A

sting Screen Contrastct SCREEN CONTRAST from the Function menupress ∗. In the next screen, press MORE toase the contrast, LESS to decrease.

g the MultimeterExaminator diagnostic tool has three mulitimeterectors:d for voltage measurements relative to motorcycleundck for resistance measurements and continuityts relative to motorcycle groundeen for voltage measurements, resistance mea-rements, and continuity tests relative to the Exami-tor diagnostic tool ground.

CautionApplying a voltage to a test probe attachedto the green multimeter connector while theExaminator diagnostic tool is connected tothe motorcycle could damage the Examina-tor diagnostic tool.Applying a voltage to a test probe attachedto the black multimeter connector coulddamage the Examinator diagnostic tool.

Examinator diagnostic tool connects to the motorcy-round through the diagnostic connector. Therefore,

measurements relative to ttest probe. For example, tovoltage, do the following:1.Select MULTIMETER fro

press ∗.2.Select VOLTAGE and pre3.Connect the red test prob

nector.4.Apply the red test probe

and read the result.To test for a ground short, d1.Select MULTIMETER fro

press ∗.2.Select RESISTANCE or C3.Connect the black test pr

connector.4.Apply the black test prob

the result.Measuring voltages or resisare electrically isolated fromtest probes. For voltage meprobes to the red (positive)timeter connectors. For rescontinuity tests, attach testgreen multimeter connectothe resistance of an air temlowing:

USING THE EXAMINATOR

2-5

s a write-protect switch that is nor-switch must be in the On positionagnostic tool to work.

10492

6999-0007 Rev. A

1.Select MULTIMETER from the Function menu andpress ∗.

2.Select RESISTANCE and press ∗.3.Attach the black test probe to the black multimeter

connector and the red test probe to the green multim-eter connector.

4.Apply the test probes to the terminals of the sensorand read the result.

Removing and Installing the Memory CardThe memory card contains the menu software for theExaminator diagnostic tool and engine tune programsfor the ECM. There will be periodic updates to this soft-ware; so it will be necessary to install memory cards.To remove the memory card, press the eject button andremove the memory card. To install the memory card,insert the card into the slot with the label up and thearrow pointing into the slot.

The memory card hamally set to On. Thisfor the Examinator di

1. EJECT BUTTON

10491

1. WRITE-PROTECT ON

USING THE EXAMINATOR

2-6

DiaThisnost• En• Di• Di• Cl• Di• Te• Ad• Re• Re• Re• LoTo pmusDIAG

EnteAfterServtion.1.En

da2.En

digbe

.This creates a service his-he Main menu now appears.ost recent service and thee dealer performing that ser-

Main menu and press ∗.om the Tuning menu and

adings from the various sen-ce data calculated by thenostic tool presents thisand fault history data. Cur-

ne conditions. Fault historyc fault code providing enginecurred. See Displaying Faulte information about fault

6999-0007 Rev. A

gnosticssection describes how to use the Examinator diag-

ic tool to perform the following diagnostic tasks:tering Service Data

splaying Engine Datasplaying Fault Codesearing Fault Codesagnosing Fault Codessting Componentsjusting Short Term Idle Fuel Trimsetting the Long Term Idle Fuel Trimsetting the Closed Throttle Positionsetting the IAC Valve Adaptionading Engine Tuneserform diagnostic tasks, the engine Stop/Run switcht be set to Run to provide power to the ECM. Select

NOSTICS from the Function menu and press ∗.

ring Service Datayou select DIAGNOSTICS for the first time, the

ice Data screen prompts you for service informa-Do the following:ter the month, day, and year of service using theta keys. Press OK after each entry.ter your dealer number and press OK. This is a six-it field. Enter enough zeros plus your dealer num-r to fill six digits. For example, if you are dealer

number 34, enter 000034tory for the motorcycle. T

To display the date of the mcorresponding number of thvice, do the following:1.Select TUNING from the2.Select SERVICE DATA fr

press ∗.

Displaying Engine DatEngine data consists of reasors and engine performanECM. The Examinator diaginformation as current datarent describes current engidata is attached to a specifidata at the time the fault ocCodes on page 2-7 for morcodes.

USING THE EXAMINATOR

2-7

cursor to the chosen item and

y data, do the following:ES from the Main menu and

S from the Fault Codes screen,history data is stored only for thehe list. The word DATA appearsode for which fault history data is

Fault Detail screen.vailable from the Tuning menu.the Main menu, then select READ

odesaracter code, such as P0351, thatn. The letter identifies the func-

train, C-chassis, B-body. The firstng a generic or a specific code. As a malfunction; a specific codeation about the nature of the mal-, P0351 indicates a malfunction

ignition coil, where P1351 indicatesrt to ground condition on the num-

A specific fault code will always becorresponding general code.tifies one of the following systems:

6999-0007 Rev. A

The following data is available:

To display current data, do the following:1.Select CURRENT DATA from the Main menu and

press ∗.2.Start the engine as prompted by the next screen and

press OK.3.The Current Data screen displays the engine data.

Press NEXT to display the next page. To display helptext for a data item, press HELP to suspend the dis-

play, then move thepress HELP again.

To display fault histor1.Select FAULT COD

press ∗.2.Select LIST FAULT

and press ∗. Faultfirst fault code on topposite the fault cavailable.

3. Press DATA in theSensor data is also aSelect TUNING fromSENSORS.

Displaying Fault CA fault code is a 5-chidentifies a malfunctiotional area: P-powerdigit is 0 or 1 indicatigeneric code indicateprovides some informfunction. For examplewith the number onean open circuit or shober one ignition coil.accompanied by theThe second digit iden

CALCULATED DATA SENSOR DATACalculated engine load Air temperature

Fuel system status Air temperature sensor voltage

Short term fuel trim Engine temperature

Long term fuel trim Engine temperature sensorvoltage

Injector pulse time Throttle position

Engine speed Throttle position sensor voltage

Road speed Purge valve duty cycle

Idle reference speed Oxygen sensor voltage

Ignition timing Air pressure

Target dwell time IAC valve position

IAC valve adaption Battery voltage

Sensor reference voltage

Main switch status

Neutral switch status

USING THE EXAMINATOR

2-8

1 - F2 - In3 - Ig4 - A5 - V6 - E7 - T8 - TThethe eIn thaffecServTo d1.Se

pre2.Se

an3.Th

cofau

CleTo cmem1.Se

pre

rom the Fault Codes screen

n, press OK.

stool contains a set of diag-ou identify the condition. To diagnose a fault code,

m the Main menu and

een, select LIST FAULTS

List Fault screen, and

reen, press FIX and followete description of the diag-so be found in the Excelsior-book.

tool enables you to isolateement system componentsts:

6999-0007 Rev. A

uel and air meteringjectorsnition systemuxiliary emissions controlsehicle speed or Idle controlsCM output circuitransmissionransmissionlast two digits identify the specific component. Fromxample, 51 identifies the number one ignition coil.

is case, P0351 identifies a general malfunctionting ignition coil 1. See the Excelsior-Hendersonice Handbook for a complete listing of fault codes.isplay fault codes, do the following:lect FAULT CODES from the Main menu andss ∗.lect LIST FAULTS from the Fault Codes screen,d press ∗.e List Faults screen displays the current faultdes. To display an explanation of the code, select alt code on the List Fault screen, and press ∗.

aring Fault Codeslear fault codes and fault history data from the ECMory, do the following:lect FAULT CODES from the Main menu andss ∗.

2.Select ERASE FAULTS fand press ∗.

3.In the Erase Faults scree

Diagnosing Fault CodeThe Examinator diagnosticnostic procedures to help ybehind a specific fault codedo the following:1.Select FAULT CODES fro

press ∗.2.From the Fault Codes scr

and press ∗.3.Select a fault code on the

press ∗.4.From the Fault Details sc

the instructions. A complnostic procedures can alHenderson Service Hand

Testing ComponentsThe Examinator diagnosticthe following engine managand perform operational tes

USING THE EXAMINATOR

2-9

erm Idle Fuel Trimel trim controls fueling at idle dur-ns. After making repairs to the fuelmay need to adjust the short terma smooth idle.rm idle fuel trim, do the following:

le and allow it to warm up.m the Main menu and press ∗.UES from the Tuning menu and

E TRIM from the Reset ValuesThe short term idle fuel trim mustarm engine. Therefore, if the

is too low, the Examinator diag-e until the temperature comes up

adjust the trim, press MORE toel trim, LESS to decrease. Observeand engine speed as you change

g Term Idle Fuel Trimel trim is a fueling correction factordle and stored in memory. Thejusts this factor within certain limitsrformance under closed loop con-

repairs to the fuel injection system,

6999-0007 Rev. A

• Tachometer• IAC valve• Fuel pump• Fuel pump prime• Purge valveTo test one of these components, do the following:1.Select COMPONENT TESTS from the Main menu

and press ∗.2.Select the component you want to test from the Com-

ponent Test menu and press ∗. If there are any faultcodes present, you will be prompted to erase thembefore performing the component test.

3.Perform the test and observe the results.The tachometer, idle air control valve, and purge valvetests prompt you to observe the tachometer or listen forvalve operation. If a fault occurs during the test, a failurenotice will be displayed.There are two types of a fuel pump tests. The first is acontinuous test (FUEL PUMP TEST) that runs the fuelpump until you press QUIT.

Caution• Running the fuel pump test on an empty

tank could damage the fuel pump.

The second test is a fuel pump prime test. This testoperates the fuel pump for a few seconds and thenstops automatically.

Adjusting Short TThe short term idle fuing open loop conditioinjection system, youidle fuel trim to obtainTo adjust the short te

1.Start the motorcyc2.Select TUNING fro3.Select RESET VAL

press ∗.4.Select SHORT IDL

menu and press ∗.be adjusted on a wengine temperaturenostic tool will pausto the minimum.

5.When prompted toincrease the idle futhe calculated loadthe trim.

Resetting the LonThe long term idle futhat is calculated at iECM continuously adto optimize engine peditions. After making

USING THE EXAMINATOR

2-1

resefindTo re1.Se2.Se

pre3.Se

an

ResThebodyTheweaperiothrotTo re1.Se2.Se

pre3.Se

me

ResThethatECMthe I

tions. After making repairs toset the IAC valve adaption tonew optimal value more

tion, do the following:Main menu and press ∗.rom the Tuning menu and

from the Reset Values menu

f instructions that the ECMormance. As an enginenges or the addition ofnes will be provided.

ator menu system is pro-8-digit password:ur security needs whenrd.

into the ECM, do the follow-

Main menu and press ∗.om the Tuning menu and

0 6999-0007 Rev. A

t the long term idle fuel trim to enable the system toa new optimal value more quickly.set the long term idle fuel trim, do the following:lect TUNING from the Main menu and press ∗.lect RESET VALUES from the Tuning menu andss ∗.lect LONG IDLE TRIM from the Reset Values menud press ∗.

etting the Closed Throttle PositionECM calculates how much air flows into the throttlebased on the data from the throttle position sensor.

closed throttle position may vary slightly as partsr and seat together. Therefore it is necessary todically recalibrate the closed throttle position to thetle position sensor, particularly after repairs.set the closed throttle position, do the following:lect TUNING from the Main menu and press ∗.lect RESET VALUES from the Tuning menu andss ∗.lect CLOSED THROTTLE from the Reset Valuesnu and press ∗.

etting the IAC Valve AdaptionIAC valve adaption is an air flow correction factoris calculated at idle and stored in memory. The

continuously adjusts this factor and applies it toAC valve position to produce the target idle engine

speed for the current condithe fuel injection system, reenable the system to find aquickly.To reset the IAC valve adap1.Select TUNING from the2.Select RESET VALUES f

press ∗.3.Select IACV ADAPTION

and press ∗.

Loading Engine TunesAn engine tune is the set ouses to govern engine perfevolves through design chaaccessories, new engine tu

NOTE

• This part of the Examintected by the following13789440. Consider yodistributing this passwo

To load a new engine tuneing:1.Select TUNING from the2.Select RELOAD TUNE fr

press ∗.

USING THE EXAMINATOR

2-11

6999-0007 Rev. A

3.Enter the 8-digit Examinator password and press OK.4.Select a new engine tune from the list of available

tunes and press ∗.5.Confirm the selected engine tune by pressing OK.

The Examinator will report progress and successfulloading or failure. If the load fails, turn the main switchto Off then On and try again.

USING THE EXAMINATOR

2-1

2 6999-0007 Rev. A

NOTES

AKOUT BOX3USING THE BREAKOUT BOX

With thement systhe apprthrottle pthe blacknostic tocontact pThis chato test ciinvolves• Installi• Using• Conne

e Pin Adapteributes the ECM connections fromr the ECM) to the contact points onrd. To install the adapter, press theits receptacles on the breakout

reakout Box

erlay labels the contact points onthe corresponding circuits. The fol-in the contact point labels. See theExcelsior-Henderson Service

nformation about these circuits.

3-1

6999-0007 Rev. A

3. USING THE BRE

breakout box, you can test engine manage-tem circuits by inserting multimeter probes in

opriate contact points. For example, to test theosition sensor circuit for a ground short, usingmultimeter connector on the Examinator diag-

ol, insert the black test probe into the Throttleoint.

pter describes how to prepare the breakout boxrcuits of the engine management system. Thisthe following:ng the Pin Adapterthe Breakout Box Overlaycting the Breakout Box

Installing thThe pin adapter distrthe wiring harness (othe breakout box boaadapter firmly into tobox.

Using the BOverlayThe breakout box ovthe board identifyinglowing sections explawiring diagram in theHandbook for more i

USING THE BREAKOUT BOX

3-2

PowThisthe Ethe e

SenThisthe 5

e Engine Stop/Run switch

sis ground circuit.

air temperature sensor cir-

check engine lamp circuit.

f the number 1 and 2 ignition

negative lines of the crank-t.

of the diagnostic circuit.

6999-0007 Rev. A

er Relay: Output/Coilis the power latch relay which provides power toCM. Output is the power circuit to the ECM. Coil isnergizing circuit for the relay.

sor: 5V/Gndis the power circuit for some of the sensors. 5V isvolt power supply. Gnd is the ground connection.

Kill Switch: OutputThis is the output side of thcircuit.

Ground: EngineThis is the engine and chas

Air TempThis is the signal line of thecuit.

Check EngineThis is the signal line of the

Coils: 1/2These are the return lines ocoil circuits.

Crankshaft: Pos/NegThese are the positive andshaft position sensor circui

Diagnostic: K/LThese are the K and L lines

10490

Crankshaft

Ground

Coils

Diagnostic

K L

Engine Temp Injectors

1 2

1 2 Pos Neg

Idle Air Control

A B C D

Neutral

Fuel Pump

Output

Oxygen

Purge Speedometer Tachometer Throttle

Check EngineAir Temp

Kill Switch

Engine5V Gnd

SensorPower Relay

Output Coil

6899-0011

Breakout Box Overlay

USING THE BREAKOUT BOX

3-3

that drives the tachometer.

of the throttle position sensor cir-

6999-0007 Rev. A

Engine TempThis is the signal line of the engine temperature sensorcircuit.

Fuel PumpThis is the return line for the fuel pump circuit.

Injectors 1/2These are the return lines of the number 1 and 2 injectorcircuits.

Idle Air Control: A/B/C/DThese are the signal lines of the idle air control valvestepper motor circuit.

NeutralThis is the power line of the neutral switch circuit.

OxygenThis is the output line of the oxygen sensor circuit.

PurgeThis is the return line of the purge valve circuit.

SpeedometerThis is the output line of the road speed sensor circuit.

TachometerThis is the signal line

ThrottleThis is the signal linecuit.

USING THE BREAKOUT BOX

3-4

CoBoTherfirstcle wto thmenin th1.Co

ko2.Co3.Tu4.Di

froHa

5.Atcoanch

Thebetwratiosurinthis1.Co

pre

le connectors to the ECM.the On position.n switch to the Run position

3. Y-CABLE MALECONNECTORS

10495

6999-0007 Rev. A

nnecting the Breakoutxe are two ways to connect the breakout box. Theway is to connect the breakout box to the motorcy-iring harness. This configuration provides access

e wiring harness circuits for resistance measure-ts and continuity tests. To connect the breakout boxis way, do the following:nnect the breakout box cable to the top of the brea-ut box.nnect the Y-cable to the breakout box cable.rn the main switch to the Off position.sconnect the motorcycle harness ECM connectorsm the ECM. See the Excelsior-Henderson Servicendbook for service access to the ECM.

tach the harness connectors to the Y-cable malennectors. These connectors are color coded (grayd black) and keyed so that they are not inter-angeable.second way to connect the breakout box is in serieseen the wiring harness and the ECM. This configu-n maintains power to the ECM and is used for mea-g circuit voltages. To connect the breakout box in

way, do the following:nnect the breakout box to the harness as describedviously.

2.Connect the Y-cable fema3.Move the main switch to4.Move the engine Stop/Ru

to energize the ECM.

1. ECM CONNECTORS2. ECM