Harley Davidson 2011 Touring Models. Electrical Diagnostic Manual — page 11
4.4
NO INSTRUMENT POWER
DESCRIPTION AND OPERATION
. The speedometer and tachometer (if equipped)
receive battery power at terminal 5 and ignition power at ter-
minal 1. This is supplied through the battery fuse and the
instrument fuse located in fuse block [64]. Accessory power is
supplied through the ACCY fuse at terminal 6. The speedo-
meter and tachometer (if equipped) go through an initialization
sequence every time power is removed and re-applied to ter-
minal 1. The visible part of this sequence is the illumination of
check engine lamp, security lamp, backlighting, odometer and
fuel level. With IGN ON, the check engine lamp and security
lamp will illuminate for 4 seconds and then (if parameters are
normal) go out.
Loss of power on any of the inputs will change the instruments
behavior. Refer to
1
2
3
4
5
6
ed03111
1.
Security siren [142]
2.
Security siren (if equipped)
3.
Fuse block
4.
Main fuse [5]
5.
DLC [91]
6.
ABS diode pack [201] (if equipped)
Figure 4-4. Under Left Side Cover: Except FLTRX, FLHX,
FLHTC
Connector Information
For additional information about the connectors in the following
diagram(s) and diagnostic procedure(s), including the color of
the harness test kit terminal probes, see
Table 4-7. Function Chart - Loss of Input
TERMINAL 7 (GND)
TERMINAL 6 (ACC)
TERMINAL 1 (IGN)
TERMINAL 5 (BATTERY)
Instrument completely non-func-
tional
Speedometer non-func-
tional in ACC position.
Will not "WOW". See
Speedometer is non-functional
Diagnostics absent
Check engine, low fuel,
battery, cruise and ABS
lamps non-functional
Needles freeze, backlighting is
functional
Check engine lamp, low fuel and
battery lamp are non-functional.
Diagnostics absent.
4-8 2011 Touring Diagnostics: Instruments
R/GY
R/BK
R/BK
R/GY
Right GND 2
TSM/TSSM/HSFM
Tachometer
Speedometer
(All)
Radio
FLHX,FLHTC/CU,FLTR
FLHX,FLHTC/CU,FLTR
FLHR/C
ABS
(Optional)
ECM
DLC
[64-1B]
9
9
2
3
4
1
2
3
12
1
2
3
12
4
1
5
13
1
5
13
1
1
2
2
3
3
4
4
5
5
12
4
12
69
69
73
73
BK/GN
BK/GN
BK/GN
BK/GN
BK/GN
BK/GN
LGN/V
LGN/V
LGN/V
LGN/V
LGN/V
LGN/V
BN/GY
BN/GY
BN/GY
BN/GY
BK/GN
BN/GY
BK/GN
BN/GY
BK/GN
BN/GY
BN/GY
GY
GY
GY
O/W
O/W
O/W
O
O
R
R
O
LGN/V
O/W
O
LGN/V
LGN/V
LGN/V
LGN/V
O/W
O/W
O/W
O
O
O
BK/GN
LGN/V
BN/GY
O/W
O
BK/GN
BK/GN
LGN/V
BN/GY
O/W
O
[20A]
[20B]
1
1
2
2
5
5
6
6
7
7
BK/GN
LGN/V
BN/GY
O/W
O
1
1
2
2
5
5
6
6
7
7
[166A]
[166B]
[78A]
[78B]
[1B]
[1A]
[2B]
[2A]
12
12
[27B]
[27A]
[108B]
[108A]
[39B]
[39A]
[30B]
[30A]
[91A]
2C
2D
1C
1D
Battery
15A
Accessory
15A
[64-2B]
1C
1D
1E
1F
INSTRS
15A
Ignition
15A
Accessory
Power
Battery
Power
Ignition
Power
em00825
Figure 4-5. Instruments Power Circuit Diagram
2011 Touring Diagnostics: Instruments 4-9
SPEEDOMETER INOPERATIVE
TOOL NAME
PART NUMBER
HARNESS CONNECTOR TEST KIT
HD-41404-C
BREAKOUT BOX
HD-42682
BREAKOUT BOX ADAPTERS
HD-46601
Table 4-8. Speedometer Inoperative Diagnostic Faults
POSSIBLE CAUSES
Instrument malfunction
Open accessory circuit
Open battery circuit
Open ignition circuit
Short to ground in cooling fan circuit
Ignition switch malfunction
Short to ground in ignition circuit
Open ground circuit
Short in accessory circuit
1. Battery and Ignition Function Test
1.
Turn IGN ON.
2.
Does the speedometer have full function?
a.
Yes.
b.
No, check engine lamp, battery lamp and security
lamp are inoperative but backlighting is func-
tional.
c.
No, speedometer does not operate at all.
2. Accessory Function Test
1.
Turn IGN to ACC.
2.
Does the instrument have full ACC function?
a.
Yes. Concern is intermittent, perform a wiggle test to
test for intermittent. See
.
b.
No.
3. Accessory Fuse Test
1.
With IGN OFF, connect BREAKOUT BOX
ADAPTERS (Part No. HD-46601) to [39]. Attach con-
nectors from BREAKOUT BOX (Part No. HD-42682) to
harness adapters leaving [39A] disconnected. See
2.
Turn IGN ON.
3.
Using the HARNESS CONNECTOR TEST KIT (Part
No. HD-41404-C) and a multimeter, test for voltage at
breakout box terminal 6.
4.
Is battery voltage present?
a.
Yes. Replace the speedometer. See the service
manual. (7311)
b.
No. Repair open in (O/W) wire. (5043)
4. Battery Fuse Test
1.
Inspect the battery fuse.
2.
Is the fuse good?
a.
Yes.
b.
No.
5. Battery Circuit to Battery Fuse Test
1.
Test for voltage at [64-1B] socket terminal 2C.
2.
Is battery voltage present?
a.
Yes.
b.
No. Repair open between battery fuse and main fuse
(R) wire. (5041)
6. Battery Circuit to Speedometer Test
1.
With IGN OFF, connect BREAKOUT BOX
ADAPTERS (Part No. HD-46601) to [39]. Attach con-
nectors from BREAKOUT BOX (Part No. HD-42682) to
harness adapters leaving [39A] disconnected. See
.
2.
Install battery fuse in fuse block.
3.
Test for voltage at breakout box terminal 5.
4.
Is battery voltage present?
a.
Yes.
b.
No. Repair open between [39B] terminal 5 and [64-
1B] socket terminal 2D (BN/GY) wire. (5041)
7. Battery Circuit Short to Ground Test
1.
With IGN OFF, connect BREAKOUT BOX
ADAPTERS (Part No. HD-46601) to [39]. Attach con-
nectors from BREAKOUT BOX (Part No. HD-42682) to
harness adapters leaving [39A] disconnected. See
.
2.
Test for continuity between breakout box terminal 5 and
ground.
3.
Is continuity present?
a.
Yes. Repair short to ground in (BN/GY) wire. (5041)
b.
No. Concern is intermittent, perform a wiggle test to
test for intermittent. See
. Replace the
battery fuse.
8. Ignition Circuit Test
1.
Turn IGN OFF for at least 15 seconds.
2.
Turn IGN ON and the engine stop switch to RUN.
3.
Does the fuel pump run and then shut off?
a.
Yes.
b.
No.
9. Instrument Power Circuit Test
1.
With IGN OFF, disconnect speedometer [39].
4-10 2011 Touring Diagnostics: Instruments
2.
Connect BREAKOUT BOX ADAPTERS (Part No. HD-
46601) to [39]. Attach connectors from BREAKOUT
BOX (Part No. HD-42682) to harness adapters leaving
[39A] disconnected. See
.
3.
With IGN ON, test for voltage between breakout box ter-
minal 1 and ground.
4.
Is battery voltage present?
a.
Yes. Replace speedometer. See the service manual.
(7311)
b.
No. Repair open in (O) ignition wire. (5041)
10. Ignition Fuse Test
1.
Inspect the ignition fuse.
2.
Is the fuse good?
a.
Yes.
b.
No.
11. Ignition Power to Instrument Fuse Test
1.
With IGN ON, test for battery voltage between [64-2B]
socket terminal 1D and ground.
2.
Is battery voltage present?
a.
Yes. Repair open in (O) wire. (5041)
b.
No. Inspect wiring from instrument fuse to ignition
switch for an open or damaged condition. If the wiring
is good replace the ignition switch. See the service
manual. (7287)
12. Ignition Power Short to Ground Test
1.
Test for continuity between [64-2B] socket terminal 1D
and ground.
2.
Is continuity present?
a.
Yes. Repair short to ground in (O) wire. Replace
instrument fuse. (5041)
b.
No. Replace the ignition fuse and verify operation.
(6729)
13. Ground Circuit Test
1.
Using the HARNESS CONNECTOR TEST KIT (Part
No. HD-41404-C) and a multimeter, test for continuity
between breakout box terminal 7 and ground.
2.
Is continuity present?
a.
Yes. Replace the speedometer. See the service
manual. (7311)
b.
No. Repair open in (BK/GN) wire. (5041)
2011 Touring Diagnostics: Instruments 4-11
4.5
INDICATOR LAMPS
DESCRIPTION AND OPERATION
. The battery, check engine, security and low
fuel indicators are located in the speedometer. The other
indicators are located separately from the speedometer.
0
10
30
20
50
40
110
120
60 70
80
90
100
0
20
30
70
80
40
50
60
10
MPH
H
ARLEY-DAVIDSON
CERTIFIED
RPM x100
H
ARLEY-DAVIDSON
1
1
2
2
3
4
10
4
5
5
6
6
7
7
9
9
8
11
11
8
10
ed03170
7.
1.
Check engine lamp
Speedometer
2.
8.
Security lamp (key icon)
Battery discharge lamp
9.
3.
Sixth gear lamp
Tachometer
4.
10.
Cruise lamp
ABS lamp
11.
5.
Pursuit lamp (Police models)
Odometer/trip odometer/clock
6.
Low fuel warning lamp
Figure 4-6. Speedometer
Table 4-9. Indicator Lamp Wiring
CONNECTION
INDICATOR LAMP
Serial data
Check engine
Serial data
Security
Serial data
Battery
Serial data
Sixth gear indicator
Ground through switch
Oil pressure
Ground through switch
Neutral
12V when active
High beam
12V when active
Right/left turn
1.0 gal (3.8 L)
Low fuel
Low Fuel Indicator
. The low fuel indicator is controlled at terminal
9 (Y/W) of the speedometer. The fuel gauge sends voltage on
the (Y/W) wire to the low fuel lamp and fuel level sender. When
the fuel drops below 1.0 gal (3.8L), the resistance in the fuel
level sender reaches a point that causes enough of a change
in the voltage on the (Y/W) wire it signals the speedometer to
activate the low fuel lamp.
4-12 2011 Touring Diagnostics: Instruments
1
2
3
ed02699
1.
Ignition/light key switch [33]
2.
Indicator lights [21]
3.
Speedometer [39]
Figure 4-7. Instrument Console Connectors: FLHR, FLHRC
2011 Touring Diagnostics: Instruments 4-13
1
2
5
7
12
9
10
13
14
15
16
8
11
6
3
4
ed03066
9.
1.
Radio [28]
Right front speaker [34+]
2.
10.
Right front speaker [34-]
Radio [27]
11.
3.
GPS [193]
Voltmeter [111]
4.
12.
Voltmeter lamp [110]
Main to interconnect harness [1]
13.
5.
Main to interconnect harness [15]
Tachometer [108]
6.
14.
Speedometer [39]
TGS harness [204]
15.
7.
Interconnect to right handle bar switches [22]
Indicator lamps [21]
8.
16.
CB antenna cable [50]
Right front turn signal/auxiliary lamp [31R]
Figure 4-8. Right Side Behind Upper Fairing
4-14 2011 Touring Diagnostics: Instruments
1
2
3
ed03124
1.
Starter
2.
Starter solenoid [128]
3.
Neutral switch [131]
Figure 4-9. Starter Solenoid [128]
Neutral Indicator
. The neutral indicator is controlled through the
(TN) wire connected to the TSM/TSSM/HFSM and the neutral
switch. When the transmission is in neutral, the neutral switch
closes and illuminates the neutral indicator.
1
2
ed03085
1.
Oil pressure [139]
2.
Front frame down tube
Figure 4-10. Oil Pressure Switch
Oil Pressure Indicator
See
. The oil pressure indicator is connected to the
oil pressure switch. The switch closes when oil pressure is low
and illuminates the oil pressure indicator. This is why the oil
pressure indicator is illuminated with the IGN ON and the
engine OFF.
Turn Signal Indicators
The turn signal indicators are controlled by the
TSM/TSSM/HFSM. When the TSM/TSSM/HFSM receives an
input from the left or right turn signal switch it flashes the correct
turn signals including the turn signal indicators. When the left
turn signal switch is pressed voltage is supplied on the (V) wire
to the left turn signals including the turn signal indicator. When
the right turn signal switch is pressed, voltage is supplied on
the (BN) wire to the right turn signals including the indicator.
High Beam Indicator
This circuit is powered when the headlamp switch is placed in
the high beam position. In the high position, voltage is supplied
to the (W) wire and the high beam headlamps. This wire also
supplies power to the high beam indicator, causing it to illu-
minate.
Sixth Gear Indicator
The sixth gear indicator illuminates indicating the vehicle is in
sixth gear. This is done by the ECM. The ECM monitors the
vehicle speed and engine rpm with the clutch engaged. It then
sends a signal over the serial data circuit to illuminate the
indicator when the parameters are correct for sixth gear oper-
ation. Therefore, there may be a delay in the indicator illumin-
ating when shifting to sixth gear. The ECM recieves clutch
switch status from the TSM/TSSM/HFSM. Pulling in the clutch
lever will cause the sixth gear indicator to turn off.
If the sixth gear indicator is inoperative or always on check for
any DTCs. If no DTCs are present, verify the clutch switch is
operating properly. If the clutch is disengaged without moving
the clutch switch, the sixth gear indicator may come on briefly
due to reduced engine rpm during shifting. If none of these
conditions exist and the sixth gear indicator is malfunctioning
replace the speedometer.
Connector Information
For additional information about the connectors in the following
diagram(s) and diagnostic procedure(s), including the color of
the harness test kit terminal probes, see
2011 Touring Diagnostics: Instruments 4-15
[30B]
[30A]
TN
TN
TN
TN
TN
TN
TN
BK
BK
BK
BK
BK
BK
BN
BN
BN
BN
BN
BN
O
O
O
O
W
W
V
O
V
BN
V
O
V
V
V
V
GN/Y
GN/Y
Chassis
Ground
TSM/
TSSM/
HFSM
Neutral
Switch
Left
GND 1
Right
GND 2
Ignition Power
Turn
Signals
6
4
6
4
B
B
A
A
Neutral Switch
5
5
Left Turn Feed
Right Turn Feed
FLHR/C
Speedometer
Headlamps
Headlamp
Switch
Except FLHR/C
GN/Y
GN/Y
GN/Y
GN/Y
Indicators
V
V
TN
TN
GN/Y
GN/Y
BN
BK
BN
W
W
O
O
O
O
TN
BK
BN
BN
O
V
O
V
GN/Y
TN
BK
BK
BK
BN
O
W
V
GN/Y
Indicators
O
1
6
5
2
7
3
4
1
6
5
2
7
3
4
[21B]
[21A]
4
7
3
6 2
4
7
3
6 2
5 1
D
D
5 1
[21B]
[21A]
BK/GN
BK/GN
Left
GND 1
BK/GN
V
V
TN
TN
GN/Y
GN/Y
BN
BN
W
W
Headlamps
Headlamp
Switch
W
W
O
O
9
1
13
10
5
11
12
9
1
13
10
5
11
12
[20A]
[20B]
10 9
10 9
7
1
8
7
1
8
[2A]
[2B]
[15B]
[15A]
[1A]
[1B]
[131B]
[131A]
[120B]
[120A]
BK
GN/Y
Oil
Pressure
Switch
1
1
[139B]
[139A]
BK
GN/Y
Oil
Pressure
Switch
1
1
FLHR/C
Except
FLHR/C
em00720
Figure 4-11. Indicator Lamps
4-16 2011 Touring Diagnostics: Instruments
OIL PRESSURE LAMP ALWAYS ON
TOOL NAME
PART NUMBER
HARNESS CONNECTOR TEST KIT
HD-41404-C
Table 4-10. Oil Pressure Lamp Always On Diagnostic
Faults
POSSIBLE CAUSES
Short to ground in oil pressure circuit
Indicator malfunction
Mechanical issue
Oil pressure switch malfunction
1. Oil Pressure Lamp Function Test
1.
Turn IGN ON with the engine OFF.
2.
Does the oil pressure lamp illuminate?
a.
Yes.
b.
No. See
4.5 INDICATOR LAMPS, Oil Pressure Lamp
2. Engine Running Test
1.
Start the engine.
2.
Does the oil pressure lamp turn OFF and stay off?
a.
Yes. Oil pressure lamp is operating properly. Test for
intermittent. See
.
b.
No.
3. Oil Pressure Sensor Test
1.
Disconnect the oil pressure sensor [120] or [139].
2.
Does the oil pressure lamp turn OFF?
a.
Yes.
b.
No.
4. Oil Pressure Circuit Test
1.
With IGN OFF, disconnect indicator lamps [21].
2.
Using the HARNESS CONNECTOR TEST KIT (Part
No. HD-41404-C) and a multimeter, test for continuity
between [21A] terminal 3 (FLHR/C) or terminal 2 (except
FLHR/C) and ground.
3.
Is continuity present?
a.
Yes. Repair short to ground between [21A] terminal
3 (FLHR/C) or terminal 2 (except FLHR/C) and [120B]
terminal 1 (GN/Y) wire. (5041)
b.
No. Repair or replace the indicator harness. See the
service manual. (5191)
5. Mechanical Test
1.
Inspect the engine for any issues that may affect oil pres-
sure. See the service manual.
2.
Was the problem found?
a.
Yes. Repair as needed.
b.
No. Replace the oil pressure switch. See the service
manual. (5161)
OIL PRESSURE LAMP INOPERATIVE
TOOL NAME
PART NUMBER
HARNESS CONNECTOR TEST KIT
HD-41404-C
Table 4-11. Oil Pressure Lamp Inoperative Diagnostic
Faults
POSSIBLE CAUSES
Oil pressure switch malfunction
Open oil pressure circuit
Indicator malfunction
1. Oil Pressure Lamp Function Test
1.
Turn IGN ON with the engine OFF.
2.
Does the oil pressure lamp illuminate?
a.
Yes. Test for intermittent. See
AND TROUBLESHOOTING, Wiggle Test
.
b.
No.
2. Oil Pressure Switch Test
1.
Disconnect the oil pressure sensor [120] or [139].
2.
Using the HARNESS CONNECTOR TEST KIT (Part
No. HD-41404-C), connect [120B] terminal 1 to ground.
3.
Does the oil pressure lamp turn ON?
a.
Yes. Replace oil pressure switch. See the service
manual. (5161)
b.
No.
3. Oil Pressure Circuit Test
1.
With IGN OFF, disconnect console harness [20].
2.
Test for continuity between indicator lamps [21A] terminal
3 (FLHR/C) or terminal 2 (except FLHR/C) and [120B]
terminal 1 or [139B] terminal A.
3.
Is continuity present?
a.
Yes. Repair or replace the indicator harness. See the
service manual. (5191)
b.
No. Repair open between [21] and [120] (GN/Y) wire.
(5041)
2011 Touring Diagnostics: Instruments 4-17
NEUTRAL LAMP ALWAYS ON
TOOL NAME
PART NUMBER
HARNESS CONNECTOR TEST KIT
HD-41404-C
Table 4-12. Neutral Lamp Always On Diagnostic Faults
POSSIBLE CAUSES
Neutral switch malfunction
Short to ground in neutral circuit
Indicator malfunction
TSM/TSSM/HFSM malfunction
1. Neutral Lamp Function Test
1.
With the vehicle in neutral, turn IGN ON with the engine
OFF.
2.
Does the neutral lamp illuminate?
a.
Yes.
b.
No. See
4.5 INDICATOR LAMPS, Neutral Lamp
2. Transmission Operation Test
1.
Shift the transmission out of neutral.
2.
Does the neutral lamp turn OFF and stay off?
a.
Yes. Neutral lamp is operating properly. Test for
intermittent. See
.
b.
No.
3. Neutral Switch Test
1.
Disconnect the neutral switch [131].
2.
Does the neutral lamp turn OFF?
a.
Yes. Replace the neutral switch. See the service
manual. (5157)
b.
No.
4. TSM/TSSM/HFSM Test
1.
Disconnect the TSM/TSSM/HFSM [30].
2.
Does the neutral lamp turn OFF?
a.
Yes. Replace the TSM/TSSM/HFSM. See the service
manual. (6845)
b.
No.
5. Neutral Switch Circuit Test
1.
Disconnect indicator lamps [21].
2.
Using the HARNESS CONNECTOR TEST KIT (Part
No. HD-41404-C) and a multimeter, test for continuity
between [21A] terminal 5 (FLHR/C) or terminal 7 (except
FLHR/C) and ground.
3.
Is continuity present?
a.
Yes. Repair short to ground in (TN) wire. (5041)
b.
No. Repair or replace the indicator harness. See the
service manual. (5191)
NEUTRAL LAMP INOPERATIVE
TOOL NAME
PART NUMBER
HARNESS CONNECTOR TEST KIT
HD-41404-C
Table 4-13. Neutral Lamp Inoperative Diagnostic Faults
POSSIBLE CAUSES
Neutral switch malfunction
Open ground circuit
Open neutral switch circuit
Indicator malfunction
1. Neutral Lamp Function Test
1.
With the vehicle in neutral, turn IGN ON with the engine
OFF.
2.
Does the neutral lamp illuminate?
a.
Yes. Test for intermittent. See
AND TROUBLESHOOTING, Wiggle Test
.
b.
No.
2. Neutral Switch Test
1.
Disconnect the neutral switch [131].
2.
Using the HARNESS CONNECTOR TEST KIT (Part
No. HD-41404-C), jump the (TN) wire to ground.
3.
Does the neutral lamp turn ON?
a.
Yes. Replace the neutral switch. See the service
manual. (5157)
b.
No.
3. Neutral Switch Power Circuit Open Test
1.
With IGN OFF, disconnect indicator lamps [21].
2.
Using the HARNESS CONNECTOR TEST KIT (Part
No. HD-41404-C) and a multimeter, test for continuity
between [21A] terminal 5 (FLHR/C) or terminal 7 (except
FLHR/C) and [131B] (TN) wire.
3.
Is continuity present?
a.
Yes. Repair or replace the indicator harness. See the
service manual. (5191)
b.
No. Repair open in (TN) wire between [21] and neutral
switch. (5041)
4-18 2011 Touring Diagnostics: Instruments
HIGH BEAM INDICATOR LAMP
INOPERATIVE
TOOL NAME
PART NUMBER
HARNESS CONNECTOR TEST KIT
HD-41404-C
Table 4-14. High Beam Indicator Lamp Inoperative
Diagnostic Faults
POSSIBLE CAUSES
Indicator malfunction
Open High beam indicator circuit
1. High Beam Indicator Function Test
1.
With IGN ON, operate the headlamp switch.
2.
Do the high and low beam headlamps function correctly?
a.
Yes.
b.
No. See
2. High Beam Indicator Circuit Test
1.
With the IGN OFF, disconnect indicator lamps [21].
2.
With the IGN ON and the headlamp switch in the high
position and using HARNESS CONNECTOR TEST
KIT (Part No. HD-41404-C) and a multimeter, test for
voltage at [21A] terminal 2 (FLHR/C) or terminal 3 (except
FLHR/C).
3.
Is voltage present?
a.
Yes. Repair or replace the indicator harness. See the
service manual. (5191)
b.
No. Repair open in (W) wire between headlamp
switch and [21A]. (5041)
TURN SIGNAL INDICATOR INOPERATIVE
TOOL NAME
PART NUMBER
HARNESS CONNECTOR TEST KIT
HD-41404-C
Table 4-15. Turn Signal Indicator Inoperative Diagnostic
Faults
POSSIBLE CAUSES
Indicator malfunction
Open turn signal circuit
1. Turn Signal Function Test
1.
With ignition ON, operate the turn signals.
2.
Do the turn signals operate?
a.
Yes.
b.
No. See
2. Turn Signal Indicator Circuit Test
1.
With IGN OFF, disconnect indicator lamps [21].
2.
With the IGN ON and the turn signals activated and using
the HARNESS CONNECTOR TEST KIT (Part No. HD-
41404-C) and a multimeter, test for voltage at [21A] (V)
and (BN) wires.
3.
Is voltage cycling on and off?
a.
Yes. Repair or replace the indicator harness. See the
service manual. (5191)
b.
No. Repair open between [21A] and [30B] (V) or (BN)
wire. (5041)
2011 Touring Diagnostics: Instruments 4-19
4.6
GAUGES
THEORY OF OPERATION
. With ignition switch turned to IGNITION, 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 resist-
ance in the variable resistor.
Inoperative gauges may be caused by any of the following:
•
Sender or fuel gauge not grounded.
•
Malfunction in sender or fuel gauge.
•
Inoperative or disconnected wire from ignition switch to
fuel gauge.
•
Corroded connections at fuel gauge.
Use the
4.6 GAUGES, Fuel Gauge and Sender Test
suspect components.
FUEL GAUGE AND SENDER TEST
TOOL NAME
PART NUMBER
MULTI-METER
HD-35500
NOTE
Always refer to the applicable wiring diagram when
troubleshooting instruments or gauges.
1.
Remove gauge. Ground (Y/W) wire of fuel level sender
located at bottom of gauge. Turn ignition switch to IGNI-
TION.
a.
Fuel gauge must indicate FULL. If gauge indicates
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 chassis ground.
a.
If fuel tank is full, the reading should be 30-50 Ohms.
An empty tank should have a 240-260 Ohms resist-
ance. A half full tank is approximately 125-165 Ohms.
b.
If a very high resistance or infinity is indicated on the
meter, the sender may be open or not grounded.
Check that the 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 inoperative
or disconnected wire. Replace gauge if wiring problem
is not found.
To +12V
To Sender
NOTE
All gauges are shown
as viewed from rear.
Oil
Pressure
Voltmeter
GND
+
BK
O
BK
BK
O
O
BK
O
BN/GN
Light
Light
em01174
Figure 4-12. Connections for Gauges
4-20 2011 Touring Diagnostics: Instruments
OIL PRESSURE GAUGE AND INDICATOR
LIGHT
TOOL NAME
PART NUMBER
HARNESS CONNECTOR TEST KIT
HD-41404-C
Problem
Low oil pressure light remains on with engine running above
idle and/or oil pressure gauge does not work.
Do not operate the engine when the oil level is below the
add mark on the dipstick at operating temperature. Engine
damage will result. (00187b)
Table 4-16. Oil Pressure Gauge and Indicator Light
SOLUTION
CAUSE
Check oil level. Add oil if low.
No oil pressure due to lack of oil or faulty
oil pump.
Restart engine and verify oil pressure light goes off and gauge indicates pressure. If
problem still exists, refer to oil pump in the service manual.
Locate the oil pressure sending unit on the front right side of the crankcase.
Contacts in pressure sending unit not
opening to shut off light. Variable resistor
in sender is shorted to ground.
Verify the electrical connector is properly connected to the sending unit.
If the oil pressure gauge indicates pressure but the low oil pressure light remains on
proceed as follows:
•
Remove electrical connector from oil pressure sending unit. Using ohmmeter
and HARNESS CONNECTOR TEST KIT (Part No. HD-41404-C) gray socket
probe and patch cord, place one probe on indicator lamp terminal (closest to
latch on sending unit), place the other probe on the crankcase. Ohmmeter must
read less than one Ohm.
•
Start the engine and run at a fast idle. The ohmmeter must read infinity.
•
Replace the sending unit if the above meter readings are not obtained.
If the low oil pressure light functions correctly, but the pressure gauge does not, then
proceed as follows:
•
Remove electrical connector from oil pressure sending unit. Turn the ignition
switch to IGNITION. The gauge must read zero.
•
Ground (BN/GN) wire terminal to crankcase. The gauge must read full scale 60
PSI (414 kPa).
•
Replace the sending unit if the above gauge readings are obtained. If the gauge
readings are not obtained, then replace the pressure gauge.
See Voltmeter Gauge. See
.
No power to gauge.
AMBIENT AIR TEMPERATURE GAUGE
Problem
Gauge inoperative.
Table 4-17. Ambient Air Temperature Gauge
SOLUTION
CAUSE
Test for continuity between terminal 1 and ground and terminal 3 and gauge. Repair
if open.
Sensor not grounded or open between
sensor and gauge.
Check for battery voltage between terminals 1 and 3 at connector [115A]. Replace
gauge if voltage is present. Use voltage drop tests and continuity checks to isolate if
voltage is not present.
Broken or disconnected power or ground
wire to gauge.
Measure resistance between terminals 1 and 3 at 65-85 °F (18.3-29.4 °C). Resistance
should be 31-43 Ohms. Replace sensor if out of range, replace gauge if within range.
Malfunction in gauge or sensor.
2011 Touring Diagnostics: Instruments 4-21
VOLTMETER GAUGE
Problem
Meter inoperative.
Table 4-18. Voltmeter Gauge
SOLUTION
CAUSE
With ignition switch turned to IGNITION, verify battery voltage is present at both
positive and negative terminals on the voltmeter terminal on voltmeter. With ignition
switch turned to OFF, check ground terminal for continuity to ground.
Inoperative or disconnected leads to meter
or open meter winding.
Replace the voltmeter if battery voltage is present and ground terminal is grounded.
If battery voltage is not present, trace wiring until disconnected or inoperative wire is
found and repair as necessary. If ground terminal is not grounded, refer to wiring
diagram and repeat procedure given for 12V lead.
4-22 2011 Touring Diagnostics: Instruments
SUBJECT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE NO.
A
CCESSORIES,
HORN,
LIGHTING AND SECURITY
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