Harley Davidson 2011 Touring Models. Electrical Diagnostic Manual — page 5
ed02008
Figure 1-32. Digital Multimeter (Fluke 78) (Part No.
HD-39978)
HD-41404-C Harness Connector Test Kit
The HARNESS CONNECTOR TEST KIT (Part No. HD-41404-
C) contains pin and socket terminals and stackable banana
jack patch cords used to test circuits. The pin and socket ter-
minals are used to connect to various connectors used on the
vehicle. See the tool instruction sheet for specific terminal
usage.
NOTE
To prevent terminal damage while using the probe tips, insert
the probe tip straight into the cavity and keep it stable during
the test. Do not wiggle or move the probe tip once it has been
inserted into the terminal. Do not use more than one probe per
terminal or cavity at any one time.
HD-42682 Breakout Box (Instruments)
The BREAKOUT BOX (Part No. HD-42682) and BREAKOUT
BOX ADAPTERS (Part No. HD-46601) connect to the
speedometer [39]. Used in conjunction with a multimeter, it
allows circuit diagnosis of wiring harness and connections
without having to probe with sharp objects. Install breakout
box in series using the black connectors as follows:
1.
Access the speedometer [39]. See the service manual.
2.
. Press latch and disconnect speedometer
[39B].
3.
Connect BREAKOUT BOX ADAPTERS (Part No. HD-
46601) to [39A] and [39B] (speedometer) or [108A] and
[108B] (tachometer).
4.
Attach black connectors from BREAKOUT BOX (Part
No. HD-42682) to BREAKOUT BOX ADAPTERS (Part
No. HD-46601). All tests will be performed using the black
side of the breakout box.
5.
When testing is completed, remove the breakout box and
jumper harness, and restore connections.
1
2
3
5
4
ed03109
1.
Breakout box HD-42682
2.
Breakout box adapter HD-46601
3.
Speedometer [39]
4.
Breakout box adapter HD-46601
5.
Speedometer [39]
Figure 1-33. Breakout Box Connection
HD-42682 Breakout Box (TSM/TSSM/HFSM)
The BREAKOUT BOX (Part No. HD-42682) splices into the
main harness. Used in conjunction with a multimeter, it allows
circuit diagnosis of wiring harness and connections without
having to probe with sharp objects. Install breakout box in
series as follows:
NOTE
For HFSM: Disarm security system, then remove main fuse
while the system remains disarmed.
1.
Access TSM/TSSM/HFSM. See the service manual.
2.
Disconnect HFSM antenna jumper [208] and
TSM/TSSM/HFSM [30].
a.
For HFSM: Press latches and disconnect [208].
b.
Press latches and disconnect [30].
3.
See
. Connect BREAKOUT BOX (Part No. HD-
42682) to connectors.
4.
For HFSM: Mate antenna [208B] to HFSM.
5.
When testing is completed remove the breakout box and
restore connections.
NOTE
Vehicle will not start with TSM/TSSM/HFSM disconnected or
incorrectly mounted.
1-14 2011 Touring Diagnostics: General Information
1
2
3
ed03097
1.
Breakout box
2.
Breakout box to TSM/TSSM/HFSM connection
3.
Breakout box to harness connection
Figure 1-34. Breakout Box Connection Point at
TSM/TSSM/HFSM (Typical)
HD-48637 Breakout Box (ECM)
The BREAKOUT BOX (Part No. HD-48637) splices into the
main harness. Used in conjunction with a multimeter, it allows
circuit diagnosis of wiring harness and connections without
having to probe with sharp objects. Install breakout box in
series as follows:
NOTE
See wiring diagrams for ECM terminal functions. ECM is loc-
ated under passenger seat.
1.
Access the ECM. See the service manual.
2.
Press latch and disconnect ECM [78].
3.
. Connect BREAKOUT BOX (Part No. HD-
48637) to connectors.
4.
When testing is completed, remove the breakout box and
restore connections.
1
2
3
ed03096
1.
Breakout box
2.
Wiring harness connector
3.
ECM connector
Figure 1-35. Breakout Box
1
2
3
4
ed03095
1.
Breakout box
2.
Breakout box to ECM connector disconnected
3.
Breakout box to harness connection
4.
ECM [78A]
Figure 1-36. ECM Breakout Box Disconnected
HD-48642 Breakout Box (ABS)
The ABS BREAKOUT BOX (Part No. HD-48642) connects to
the ABS module [166]. Used in conjunction with a multimeter,
it allows circuit diagnosis of wiring harness and connections
without having to probe with sharp objects. Install breakout
box in series as follows:
1.
Remove the right side cover. See the service manual.
2.
Press latch and disconnect ABS module [166B].
3.
. Connect ABS BREAKOUT BOX (Part
No. HD-48642) to connectors.
2011 Touring Diagnostics: General Information 1-15
1
2
3
ed03099
1.
Breakout box to ABS unit connection
2.
HD-48642 breakout box
3.
Breakout box to harness connection
Figure 1-37. Typical HD-48642 Connection
4.
See
. In some cases it is necessary to leave
the ABS module disconnected.
1
2
3
4
ed03098
1.
ABS [166A]
2.
HD-48642 breakout box
3.
Breakout box harness disconnected
4.
Breakout box harness connection
Figure 1-38. Typical HD-48642 With ABS Module
Disconnected
5.
When testing is completed remove the breakout box and
restore connections.
6.
Install the right side cover. See the service manual.
HD-47918 Advanced Audio System Breakout
Box
The ADVANCED AUDIO SYSTEM BREAKOUT BOX (Part
No. HD-47918) connects to the radio at [27] and [28]. Used in
conjunction with a multimeter, it allows circuit diagnosis of
wiring harness and connections without having to probe with
sharp objects. Install breakout box in series as follows:
1.
Remove the upper fairing and windshield. See the service
manual.
2.
Press the latch and disconnect radio [27] and radio [28].
3.
See
. Connect BREAKOUT BOX (Part No. HD-
47918) to connectors.
4.
When testing is completed remove the breakout box and
restore connections.
5.
Install the upper fairing and windshield. See the service
manual.
1
2
3
4
5
ed03091
1.
HD-47918 breakout box
2.
Breakout box to radio connection
3.
Breakout box to harness connection
4.
Breakout box to harness connection
5.
Breakout box to radio connection
Figure 1-39. Typical HD-47918 Connection
HD-44687 Ignition Coil Circuit Test Adapter
The IGNITION COIL CIRCUIT TEST ADAPTER (Part No. HD-
44687) and FUEL INJECTOR TEST LIGHT (Part No. HD-
34730-2D) are used to test the fuel injector drivers as well as
the ignition coil drivers in the ECM.
1.
Connect the BREAKOUT BOX (Part No. HD-48637).
1-16 2011 Touring Diagnostics: General Information
2.
Disconnect the fuel injector connectors.
3.
See
for typical setup. Connect one side of the
fuel injector test light to power and the other to the terminal
on the ECM for the circuit you are testing.
4.
Crank the engine.
5.
If the test light flashes, the circuit is working properly.
HD-48053 Advanced Battery Conductance
and Electrical System Analyzer
Follow the instructions in the ADVANCED BATTERY CON-
DUCTANCE AND ELECTRICAL SYSTEM ANALYZER (Part
No. HD-48053) instruction manual to perform a battery test.
The test results include a decision on the battery condition and
the measured state of charge.
ed01776
Figure 1-40. HD-48053 Advanced Battery Conductance
and Electrical System Analyzer Kit
HD-48650 Digital Technician II
DIGITAL TECHNICIAN II (Part No. HD-48650) is a computer
based diagnostic device used to communicate/diagnose and
program systems/modules.
Diagnostics in this manual are developed under the assumption
that DTII is not available.
2011 Touring Diagnostics: General Information 1-17
[76B]
[28B]
Ultra Radio
LFT Rear HDSET SPKR (+)
LFT FRT HDSET SPKR (+)
RT Rear HDSET SPKR (+)
RT FRT HDSET SPKR (+)
RT SDCAR HDSET SPKR (+)
HDSET SPKR Shared (-)
LFT SDCAR HDSET SPKR (+)
(BK)
[28A]
DIN On Ultra
(BK)
5
6
15
16
17
28
29
Passenger
Headset
2
3
5
1
2
3
4
5
6
7
MIC IN SHARED (-)
BK
Y/BK
HDSET SPKR SHARED (-)
GY/Y
RT REAR HDSET SPKR (+)
R
REAR MIC (+)
GY/O
LFT REAR HDSET SPKR (+)
TAB
SHIELD
MIC SHARED SHIELD
Driver
Headset
(BK)
2 3
7 8 9
2 3
7 8 9
Y/W
Y/R
GY/BK
GY/O
GY/Y
GN/V
Y/BK
GY/O
GY/Y
Y/BK
Y/W
Y/R
GY/BK
GN/V
Y/BK
Y/W
Y/R
Y/BK
CAV
CIR
DESCRIPTION
1
2
3
4
5
6
7
MIC IN SHARED (-)
BK
Y/BK
HDSET SPKR SHARED (-)
Y/R
RT HDSET SPKR (+)
R
FRT MIC (+)
Y/W
LFT HDSET SPKR (+)
BE/Y
PUSH-TO-TALK
TAB
SHIELD
MIC SHARED SHIELD
CAV
CIR
DESCRIPTION
[53A]
[53B]
em00866
Figure 8-16. Headset Speaker Circuit
Table 8-47. Symptom 9: Headset Speakers Inoperative
Diagnostic Faults
POSSIBLE CAUSES
Headset speaker malfunction
Radio malfunction
1. Headset Speaker Operational Test
1.
Connect headsets to the appropriate DIN connectors.
2.
Turn radio ON, tune to a station and place speaker switch
to HEADSET.
3.
Do both helmet speakers work?
a.
Yes. System okay.
b.
No. Both helmet speakers inoperative. Substitute
or swap headsets and coil cords. If the problem clears
in the suspect unit, replace that component.
c.
No. Rider headset.
d.
No. Passenger headset.
2. Rider Headset Speaker Continuity Test
1.
Install ADVANCED AUDIO SYSTEM BREAKOUT
BOX (Part No. HD-47918) harness [27B] and harness
[28B], leaving radio disconnected. Refer to
2.
Test for continuity between breakout box [28] and rider
DIN, using HARNESS CONNECTOR TEST KIT (Part
No. HD-41404-C).
3.
Is continuity present?
a.
Yes.
b.
No. Repair open wire between radio harness [28B]
and [53A], or [53B] and rider DIN. (5041)
Table 8-48. Rider Headset Speaker Terminations and Wire
Colors
WIRE COLOR
DIN CONNECTOR
TERMINAL
RADIO HARNESS
[28B] TERMINAL
(Y/W)
5
6
(Y/BK)
2
17
(Y/R)
3
29
3. Rider Headset Speaker Shorted Wires
Test
1.
Test for continuity between breakout box [28] terminals 6,
17 and 29.
2.
Is continuity present between any two terminals?
a.
Yes. Repair shorted wires between radio harness
[28B] and [53A], or [53B] and rider DIN. (5041)
b.
No.
4. Rider Headset Speaker Short to Voltage
Test
1.
Connect radio breakout box to radio [28A], and turn radio
ON.
2.
Measure voltage between breakout box [28] terminals 6
(left) or 29 (right), to ground.
8-42 2011 Touring Diagnostics: Audio System
3.
Is voltage greater than 9V?
a.
Yes. Repair short to voltage between radio harness
[28B] and [53A], or [53B] and rider DIN. (5041)
b.
No.
5. Rider Headset Speaker Short to Ground
Test
1.
Turn radio off and disconnect radio breakout box from
radio [28A].
2.
Test for continuity between breakout box [28] terminals 6
(left), 17 or 29 (right) to ground.
3.
Is continuity present on any terminals?
a.
Yes. Repair short to ground between radio harness
[28B] and [53A], or [53B] and rider DIN. (5041)
b.
No. Replace radio. See the service manual. (6103)
6. Passenger Headset Speaker Continuity
Test
1.
Install ADVANCED AUDIO SYSTEM BREAKOUT
BOX (Part No. HD-47918) harness [27B] and harness
[28B] leaving radio disconnected.
2.
Test for continuity between breakout box [28] and rider
DIN, using HARNESS CONNECTOR TEST KIT (Part
No. HD-41404-C). Refer to
3.
Is continuity present?
a.
Yes.
b.
No. Repair open wire between radio harness [28B]
and [76A], or [76B] and passenger DIN. (5041)
Table 8-49. Passenger Headset Speaker Terminations and
Wire Colors
WIRE COLOR
DIN CONNECTOR
TERMINAL
RADIO HARNESS
[28B] TERMINAL
(GY/O)
5
5
(Y/BK)
2
17
(GY/Y)
3
28
7. Passenger Headset Speaker Shorted
Wires Test
1.
Test for continuity between breakout box [28] terminals 5,
17 and 28.
2.
Is continuity present between any two terminals?
a.
Yes. Repair shorted wires between radio harness
[28B] and [76A], or [76B] and passenger DIN. (5041)
b.
No.
8. Passenger Headset Speaker Short to
Voltage Test
1.
Connect radio breakout box to radio [28A], and turn radio
ON.
2.
Measure voltage between breakout box [28] terminals 5
(left) or 28 (right), to ground.
3.
Is voltage greater than 9V?
a.
Yes. Repair short to voltage between radio harness
[28B] and [76A], or [76B] and passenger DIN. (5041)
b.
No.
9. Passenger Headset Speaker Short to
Ground Test
1.
Turn radio off and disconnect radio breakout box from
radio [28A].
2.
Test for continuity between breakout box [28] terminals 5
(left), 17 or 28 (right) to ground.
3.
Is continuity present on any terminals?
a.
Yes. Repair short to ground between radio harness
[28B] and [76A], or [76B] and passenger DIN. (5041)
b.
No. Replace radio. See the service manual. (6103)
SYMPTOM 10: NO OR LOW AUDIO FROM
MICROPHONES
TOOL NAME
PART NUMBER
HARNESS CONNECTOR TEST KIT
HD-41404-C
ADVANCED AUDIO SYSTEM
BREAKOUT BOX
HD-47918
Table 8-50. Symptom 10: No or Low Audio from
Microphones Diagnostic Faults
POSSIBLE CAUSES
Headset malfunction
Microphone malfunction
NOTE
Use PTT switch if intercom is not installed.
1. Headset Microphone Set-Up Test
1.
Plug a known good headset in rider DIN connector.
2.
Turn intercom ON, set VOX threshold to OPEN, intercom
volume to mid-level.
3.
Speak into the microphone.
4.
Can the audio be heard in the headset?
a.
Yes. Replace coil cord on faulty headset and retest.
If fault persists, then continue with tests.
b.
No. Perform test for each microphone driven source
installed. If no issues are found then continue with
testing.
2011 Touring Diagnostics: Audio System 8-43
1.3
DIAGNOSTICS AND TROUBLESHOOTING
VOLTAGE DROP
Voltage Drop Test
The voltage drop test:
•
Helps locate poor connections or components with
excessive voltage drops.
•
Measures the difference in potential or the actual voltage
dropped between the source and destination.
•
Checks the integrity of the wiring, switches, fuses, con-
nectors and contacts between the source and destination.
•
Identifies poor grounds.
A voltage drop test measures the difference in voltage between
two points in a circuit. The amount of voltage dropped over
any part of a circuit is directly related to the amount of resist-
ance in that part of the circuit.
Components such as wires, switches and connectors are
designed to have very little resistance and therefore very little
voltage drop. A voltage drop greater than 1.0V across these
components indicates a high resistance and possible fault.
The benefits of doing it this way are:
•
Readings are not as sensitive to real battery voltage.
•
Readings show the actual voltage dropped not just the
presence of voltage.
•
The system is tested as it is actually being used.
•
Testing is more accurate and displays hard-to-find poor
connections.
•
Starting circuits, lighting circuits or ignition circuits can be
tested with this approach. (Start from the most positive
and go to the most negative destination or component.)
When testing a typical power circuit, place the positive (red)
meter lead on the most positive part of the circuit (or the pos-
itive battery post). Remember, there is nothing more positive
than the positive post of the battery. Place the negative (black)
meter lead at the positive side of the connector in question.
Activate the circuit. Move the negative meter lead through the
circuit until the high voltage drop is found.
When testing a typical ground circuit, 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. Place the positive meter lead at
the negative side of the connector in question. Activate the
circuit. Move the positive meter lead through the circuit until
the high voltage drop is found.
The following steps demonstrate a typical starter circuit voltage
drop test:
1.
Disconnect the fuel pump connector [86] to prevent the
engine from starting.
a.
Connect the red meter lead to the positive battery
post.
b.
Connect the black meter lead to the battery power
starter post on the starter and observe the meter
reading.
c.
Crank the starter and observe the meter reading. The
difference in the voltage is the voltage drop.
2.
. Move the black meter lead to the starter
side post of the starter solenoid. Crank the starter.
BK
BK
BK
R
R
R
BK
1
2
3
ed03112
1.
Battery
2.
Starter solenoid
3.
Starter motor
Figure 1-41. To Starter Solenoid Starter Terminal
3.
See
. Move the black meter lead to the battery
side post on the starter solenoid. Crank the starter.
BK
R
R
R
BK
BK
BK
1
2
3
ed03113
1.
Battery
2.
Starter solenoid
3.
Starter motor
Figure 1-42. To Starter Solenoid Battery Terminal
1-18 2011 Touring Diagnostics: General Information
4.
See
. Finally move the black meter lead to the
negative battery post and the red meter lead to the starter
case. Crank the starter.
BK
R
R
R
BK
BK
BK
1
2
3
ed03114
1.
Battery
2.
Starter solenoid
3.
Starter motor
Figure 1-43. Starter Ground Circuit
WIGGLE TEST
TOOL NAME
PART NUMBER
DIGITAL MULTIMETER (FLUKE 78)
HD-39978
BREAKOUT BOX
HD-48637
DIGITAL TECHNICIAN II
HD-48650
The wiggle test checks for the presence of intermittents in a
wiring harness. The DIGITAL TECHNICIAN II (Part No. HD-
48650) can be used to perform the wiggle test.
1.
See
. Connect DIGITAL MULTIMETER (FLUKE
78) (Part No. HD-39978) to wiring harness between the
suspect connections. When diagnosing ECM connections,
use BREAKOUT BOX (Part No. HD-48637) to simplify the
procedure. See
2.
Set the multimeter to read voltage changes.
3.
Start the motorcycle engine and run at idle.
4.
Shake or wiggle the harness to detect intermittents. If
intermittents are present, radical voltage changes register
on the multimeter.
ed02008
Figure 1-44. Digital Multimeter (Fluke 78) (Part No.
HD-39978)
RELAY DIAGNOSTICS
Relay Variation
See
. Relays normally have four or five terminals.
The circuitry inside the relays are very similar with the exception
of the normally closed contact being eliminated in the four ter-
minal relay. Some relays have five terminals at the base, even
though internally 4 or 87A are not connected. See this topic
whenever a relay terminal is referenced in this manual to make
sure the proper terminal is being accessed.
85
86
30
87A
87
2
1
3
4
5
85
86
30
87
2
1
3
5
1
2
ed01769
1.
Standard 5 terminal relay
2.
Standard 4 terminal relay
Figure 1-45. Standard Relays
Relay Test
A relay can be tested using the motorcycle's 12V battery and
a multimeter.
1.
Unplug the relay from relay block.
2.
to energize the relay.
Connect relay terminal 85 to the negative battery terminal
and relay terminal 86 to the positive battery terminal.
2011 Touring Diagnostics: General Information 1-19
NOTE
Some relays contain internal diodes. If the applied voltage is
not the correct polarity, the diode could be damaged.
3.
Test for continuity between terminals 30 and 87.
a.
A good relay shows continuity (continuity tester lamp
on or a zero Ohm reading on the ohmmeter).
b.
A malfunctioning relay will not show continuity and
must be replaced.
-
+
86 (1)
30 (3)
87 (5)
85 (2)
1
2
3
ed01000
1.
Ohmmeter
2.
Battery
3.
Start relay
Figure 1-46. Four Terminal Relay Test
2
3
1
ed01446
1.
Battery
2.
Start relay
3.
Ohmmeter
Figure 1-47. Five Terminal Relay Test
JOB/TIME CODES VALUES
TOOL NAME
PART NUMBER
DIGITAL TECHNICIAN II
HD-48650
Dealership technicians filing warranty claims should use the
job/time code values printed in bold text at the end of the
appropriate repair. When using DIGITAL TECHNICIAN II (Part
No. HD-48650), dealership technicians filling out warranty
claims should use the job/time code given by the computer.
1-20 2011 Touring Diagnostics: General Information
SUBJECT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE NO.
INITIAL DIA
GNOSTICS AND SERIAL D
A
T
A
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