Harley Davidson 2011 Touring Models. Electrical Diagnostic Manual — page 1

GENERAL INFORMATION

1.1 SPECIFICATIONS AND COMPONENT
LOCATIONS

Specifications. . . . . . . . . . . . . . . . . .1-1
Component Locations. . . . . . . . . . . . . . 1-2

1.2 DIAGNOSTIC TOOLS

How To Use Diagnostic Tools. . . . . . . . . . ...1-13

HD-26792 Spark Tester. . . . . . . . . . . .1-13
HD-34730-2D Fuel Injector Test Light. . . . . ...1-13
HD-39978 Digital Multimeter (Fluke 78). . . . . 1-13
HD-41404-C Harness Connector Test Kit. . . . .1-14
HD-42682 Breakout Box (Instruments). . . . . .1-14
HD-42682 Breakout Box (TSM/TSSM/HFSM). . ..1-14
HD-48637 Breakout Box (ECM). . . . . . . . 1-15
HD-48642 Breakout Box (ABS). . . . . . . . .1-15
HD-47918 Advanced Audio System Breakout Box. 1-16
HD-44687 Ignition Coil Circuit Test Adapter. . . ..1-16
HD-48053 Advanced Battery Conductance and Electrical
System Analyzer. . . . . . . . . . . . . ...1-17
HD-48650 Digital Technician II. . . . . . . . ..1-17

1.3 DIAGNOSTICS AND
TROUBLESHOOTING

Voltage Drop. . . . . . . . . . . . . . . . . .1-18

Voltage Drop Test. . . . . . . . . . . . . ..1-18

Wiggle Test. . . . . . . . . . . . . . . . . ...1-19
Relay Diagnostics. . . . . . . . . . . . . . . .1-19

Relay Variation. . . . . . . . . . . . . . ..1-19
Relay Test. . . . . . . . . . . . . . . . ..1-19

Job/Time Codes Values. . . . . . . . . . . . . 1-20

INITIAL DIAGNOSTICS AND SERIAL
DATA

2.1 INITIAL DIAGNOSTICS

Description and Operation. . . . . . . . . . . . ..2-1
Retrieving Trouble Codes. . . . . . . . . . . . ...2-1
Odometer Self-Diagnostics. . . . . . . . . . . . .2-1

Diagnostic Mode. . . . . . . . . . . . . . ..2-1

Diagnostics. . . . . . . . . . . . . . . . . . .2-1

Diagnostic Tips. . . . . . . . . . . . . . . 2-1

Code Types. . . . . . . . . . . . . . . . . . .2-6

Current. . . . . . . . . . . . . . . . . . 2-6
Historic. . . . . . . . . . . . . . . . . . 2-6

Multiple Trouble Codes. . . . . . . . . . . . . ...2-6
Clearing DTCs. . . . . . . . . . . . . . . . . 2-6
Security Lamp. . . . . . . . . . . . . . . . . 2-6
Check Engine Lamp. . . . . . . . . . . . . . ...2-6
Symptoms. . . . . . . . . . . . . . . . . . ..2-7

Connector Information. . . . . . . . . . . . .2-8

Initial Diagnostics. . . . . . . . . . . . . . . .2-21

1. Verifying Current DTC Test. . . . . . . . . 2-21
2. Battery Power Test. . . . . . . . . . . . .2-21
3. Ignition Power Test. . . . . . . . . . . . .2-21
4. Engine Stop Switch Circuit Test. . . . . . . .2-21
5. Security System Test. . . . . . . . . . . .2-21
6. Starter System Test. . . . . . . . . . . ...2-21
7. Engine Running Test. . . . . . . . . . . ..2-21
8. Verification Test. . . . . . . . . . . . . ..2-21

2.2 SERIAL DATA COMMUNICATION

Description and Operation. . . . . . . . . . . . 2-22

Components. . . . . . . . . . . . . . . . . .2-23

Electronic Control Module (ECM). . . . . . . ..2-23
Speedometer and Tachometer. . . . . . . . ..2-23
TSM/TSSM/HFSM. . . . . . . . . . . . . .2-23
Data Link Connector (DLC). . . . . . . . . ...2-23

Communication DTCs and "Bus Er". . . . . . . . .2-23

Diagnostic Tips. . . . . . . . . . . . . . ..2-23

2.3 DTC U1016, U1040, U1064, U1097, U1255

Description and Operation. . . . . . . . . . . . 2-24

Diagnostic Tips. . . . . . . . . . . . . . ..2-24
Connector Information. . . . . . . . . . . ...2-24

DTC U1016. . . . . . . . . . . . . . . . . ..2-25

1. Open Ground Test. . . . . . . . . . . . .2-25
2. Switched Power Circuit Open Test. . . . . . .2-25
3. TSM/TSSM/HFSM Serial Data Circuit Continuity
Test. . . . . . . . . . . . . . . . . . . 2-26
4. Speedometer Serial Data Circuit Continuity Test. 2-26
5. Tachometer Serial Data Circuit Continuity Test. ..2-26

DTC U1040, U1255. . . . . . . . . . . . . . ..2-26

1. ABS Fuse Visual Test. . . . . . . . . . . 2-26
2. Loss of Power Test. . . . . . . . . . . . .2-26
3. Loss of Ground Test. . . . . . . . . . . ...2-26
4. Instrument Serial Data Circuit Continuity Test. ...2-26
5. Power Circuit Short to Ground Test. . . . . ...2-27

DTC U1064, U1255. . . . . . . . . . . . . . ..2-27

1. Fuse Test. . . . . . . . . . . . . . . ...2-27
2. Loss of Battery Power Test. . . . . . . . . 2-27
3. Loss of Ignition Power Test. . . . . . . . . 2-27
4. Loss of Ground Test. . . . . . . . . . . ...2-27
5. Speedometer Serial Data Circuit Continuity Test. 2-27
6. Power Circuit Short to Ground Test. . . . . ...2-27
7. ECM Serial Data Circuit Continuity Test. . . . 2-27
8. Tachometer Serial Data Circuit Continuity Test. ..2-28

DTC U1097, U1255. . . . . . . . . . . . . . ..2-28

1. Fuse Test. . . . . . . . . . . . . . . ...2-28
2. Loss of Power Test. . . . . . . . . . . . .2-28
3. Loss of Ground Test. . . . . . . . . . . ...2-28
4. Speedometer Serial Data Circuit Continuity Test. 2-28
5. Power Circuit Short to Ground Test. . . . . ...2-28
6. ECM Serial Data Circuit Continuity Test. . . . 2-28

2.4 DTC U1300, U1301 OR BUS ER

Description and Operation. . . . . . . . . . . . 2-29

Diagnostic Tips. . . . . . . . . . . . . . ..2-29
Connector Information. . . . . . . . . . . ...2-29

DTC U1300. . . . . . . . . . . . . . . . . ..2-30

1. Serial Data Short to Ground Test. . . . . . ...2-30
2. ECM Test. . . . . . . . . . . . . . . ...2-30
3. TSM/TSSM/HFSM Test. . . . . . . . . . ..2-30
4. ABS Module Test (If Vehicle is not Equipped with ABS,
Go to Test 5.). . . . . . . . . . . . . . . .2-30
5. Tachometer Test (If Vehicle is not Equipped with
Tachometer, Go to Test 6.). . . . . . . . . . 2-30
6. Radio Test (If Vehicle is not Equipped with Radio, Go
to Test 7.). . . . . . . . . . . . . . . . ...2-30
7. Serial Data Short to Ground Test. . . . . . ...2-30
8. Serial Data Circuit Open Test. . . . . . . . 2-30
9. Intermittent Test. . . . . . . . . . . . . .2-30

DTC U1301. . . . . . . . . . . . . . . . . ..2-31

1. Serial Data Short to Voltage Test. . . . . . ...2-31
2. ECM Test. . . . . . . . . . . . . . . ...2-31
3. TSM/TSSM/HFSM Test. . . . . . . . . . ..2-31
4. ABS Module Test (If Vehicle is not Equipped with ABS,
Go to Test 5.). . . . . . . . . . . . . . . .2-31
5. Tachometer Test (If Vehicle is not Equipped with
Tachometer, Go to Test 6.). . . . . . . . . . 2-31

III

T

ABLE OF CONTENTS

6. Radio Test (If Vehicle is not Equipped with Radio, Go
to Test 7.). . . . . . . . . . . . . . . . ...2-31
7. Serial Data Short to Voltage Test. . . . . . ...2-31
8. Serial Data Circuit Open Test. . . . . . . . 2-31
9. Intermittent Test. . . . . . . . . . . . . .2-32

STARTING AND CHARGING

3.1 BATTERY TESTING

General. . . . . . . . . . . . . . . . . . . ...3-1
Voltmeter Test. . . . . . . . . . . . . . . . . .3-1
Conductance Test. . . . . . . . . . . . . . . ...3-1
Load Test. . . . . . . . . . . . . . . . . . . 3-1

3.2 STARTING SYSTEM

Description and Operation. . . . . . . . . . . . ..3-3
Components. . . . . . . . . . . . . . . . . ...3-3

Starter. . . . . . . . . . . . . . . . . . .3-3
Starter Solenoid. . . . . . . . . . . . . . ..3-3
Engine Stop Switch. . . . . . . . . . . . . .3-3
Start Switch. . . . . . . . . . . . . . . . .3-3
Start Relay. . . . . . . . . . . . . . . . ..3-3
Ignition Switch. . . . . . . . . . . . . . . .3-3
Battery. . . . . . . . . . . . . . . . . . .3-4
Grinding Noise Or Erratic Starting. . . . . . . ...3-4
Job/Time Code Values. . . . . . . . . . . . 3-4
Connector Information. . . . . . . . . . . . .3-4

Starter Troubleshooting. . . . . . . . . . . . . ..3-6
Starter Testing. . . . . . . . . . . . . . . . . 3-7

1. Starting System Operational Test. . . . . . . 3-7
2. Audible Noise Test. . . . . . . . . . . . ...3-7
3. Starter Solenoid Test. . . . . . . . . . . ...3-7
4. Start Switch Circuit Test. . . . . . . . . . ...3-7
5. Start Switch Circuit Short to Voltage Test. . . . 3-7
6. Start Switch Circuit Short to Voltage [2B] Test. . .3-7
7. Start Switch Circuit Short to Voltage [2A] Test . . 3-7
8. Start Switch Test. . . . . . . . . . . . . ..3-7
9. Start Relay Test. . . . . . . . . . . . . ...3-8

Nothing Clicks. . . . . . . . . . . . . . . . . .3-8

1. Battery Test. . . . . . . . . . . . . . . ..3-8
2. Fuse Test. . . . . . . . . . . . . . . . .3-8
3. Ignition Circuit Test. . . . . . . . . . . . ..3-8
4. Ignition Switch Supply Voltage Test. . . . . . .3-8
5. Ignition Switch to [222] Test . . . . . . . . . 3-8
6. Ignition Switch Test. . . . . . . . . . . . ..3-8
7. Ignition Switch to [222] Continuity Test. . . . . 3-9
8. Start Switch Circuit Voltage Test. . . . . . . ..3-9
9. Start Switch Test. . . . . . . . . . . . . ..3-9
10. Start Switch Circuit Continuity Test. . . . . . 3-9
11. Start Switch Circuit Continuity [2B] Test. . . . 3-9
12. Start Switch Circuit Continuity [2A] Test. . . . 3-9
13. Start Relay Control Circuit Test. . . . . . . ..3-9
14. Start Relay Control Circuit Open Test. . . . . 3-9
15. TSM/TSSM/HFSM Ground Test. . . . . . . .3-9
16. Continuity at Neutral Switch Test. . . . . . ...3-9
17. Neutral Switch Ground Circuit Test. . . . . ..3-10
18. Start Relay Coil Control Circuit Short to Voltage
Test. . . . . . . . . . . . . . . . . . . 3-10
19. Engine Stop Switch Voltage Test. . . . . . .3-10
20. Relay Enable Circuit Continuity Test. . . . . 3-10
21. Anti-Theft Tracking Module Test. . . . . . ...3-10

Start Relay Clicks. . . . . . . . . . . . . . . .3-10

1. Battery Test. . . . . . . . . . . . . . . 3-10
2. Starter Solenoid Control Coil Voltage Test. . . .3-10
3. Starter Solenoid Control Coil Continuity Test. . 3-10
4. Start Solenoid Wiring Inspection Test. . . . . 3-10
5. Starter Solenoid Test. . . . . . . . . . . .3-11

Starter Solenoid Clicks. . . . . . . . . . . . . .3-11

1. Battery Test. . . . . . . . . . . . . . . 3-11
2. Starter Voltage Drop Test. . . . . . . . . ...3-11
3. Starter Solenoid Voltage Drop Starter Side Test. .3-11
4. Starter Solenoid Battery Side Voltage Drop Test. 3-11
5. Starter Ground Circuit Voltage Drop Test. . . ..3-11
6. Starter Ground Test. . . . . . . . . . . ...3-11
7. Starter Draw Test. . . . . . . . . . . . ...3-11
8. Mechanical Binding Test. . . . . . . . . . 3-11

Starter Spins But Does Not Engage. . . . . . . . .3-12

1. Pinion Gear and Clutch Shell Test. . . . . . .3-12

Starter Stalls or Spins Too Slowly. . . . . . . . . .3-12

1. Battery Test. . . . . . . . . . . . . . . 3-12
2. Starter Stud Voltage Drop Test. . . . . . . ..3-12
3. Starter Ground Circuit Voltage Drop Test. . . ..3-12
4. Starter Draw Test. . . . . . . . . . . . ...3-12
5. Starter Solenoid Voltage Drop Starter Side Test. .3-12
6. Starter Solenoid Battery Side Voltage Drop Test. 3-12

3.3 TESTING STARTER ON MOTORCYCLE

Starter Current Draw Test. . . . . . . . . . . . .3-13

3.4 TESTING STARTER ON BENCH

Free Running Current Draw Test. . . . . . . . . ..3-14
Starter Solenoid. . . . . . . . . . . . . . . . 3-14
Solenoid Pull-In Test. . . . . . . . . . . . . . .3-14
Solenoid Hold-In Test. . . . . . . . . . . . . . 3-14
Solenoid Return Test. . . . . . . . . . . . . . 3-15

3.5 CHARGING SYSTEM

Description and Operation. . . . . . . . . . . . 3-16

Alternator. . . . . . . . . . . . . . . . ...3-16
Voltage Regulator. . . . . . . . . . . . . ..3-16

Troubleshooting. . . . . . . . . . . . . . . . 3-16

Battery. . . . . . . . . . . . . . . . . ...3-16
Wiring. . . . . . . . . . . . . . . . . . 3-16
Voltage Regulator Inspection. . . . . . . . . 3-16
Job/Time Code Values. . . . . . . . . . . ..3-16
Connector Information. . . . . . . . . . . ...3-16

Low or No Charging. . . . . . . . . . . . . . ..3-17

1. Battery Test. . . . . . . . . . . . . . . 3-17
2. Off Idle Voltage Test. . . . . . . . . . . ...3-17
3. AC Output Test. . . . . . . . . . . . . ..3-17
4. Stator Test. . . . . . . . . . . . . . . ..3-17
5. Rotor Inspection Test. . . . . . . . . . . .3-17
6. Voltage Regulator Power Circuit Test. . . . . .3-17
7. Voltage Regulator Ground Circuit Test. . . . ...3-17

Overcharging. . . . . . . . . . . . . . . . . 3-17

1. Battery Voltage Test. . . . . . . . . . . ...3-17
2. Voltage Regulator Ground Circuit Test. . . . ...3-17

Low Battery After Extended IGN OFF. . . . . . . ..3-18

1. Battery Test. . . . . . . . . . . . . . . 3-18
2. Amp Draw Test. . . . . . . . . . . . . ..3-18

Battery Runs Down During Use. . . . . . . . . ...3-18

1. Total Current Draw Test. . . . . . . . . . .3-18
2. Battery Test. . . . . . . . . . . . . . . 3-18

Battery Charging Tests. . . . . . . . . . . . . .3-18

IV TABLE OF CONTENTS

TABLE OF CONTENTS

Milliampere Draw Test. . . . . . . . . . . ...3-18
Total Current Draw and Output Test. . . . . . ..3-19
Stator Test. . . . . . . . . . . . . . . . .3-20
AC Output Test. . . . . . . . . . . . . . ..3-21

3.6 DTC B0563, P0562, P0563

Description and Operation. . . . . . . . . . . . 3-22

DTC B0563. . . . . . . . . . . . . . . ...3-22
DTC P0562 and P0563. . . . . . . . . . . .3-22

Diagnostics. . . . . . . . . . . . . . . . . ...3-22

Diagnostic Tips. . . . . . . . . . . . . . ..3-22
Connector Information. . . . . . . . . . . ...3-22

DTC P0562. . . . . . . . . . . . . . . . . ...3-24

1. Battery Test. . . . . . . . . . . . . . . 3-24
2. Charging System Test. . . . . . . . . . . 3-24
3. ECM Switched Voltage Test. . . . . . . . ...3-24
4. ECM Switched Voltage Drop Test. . . . . . ..3-24
5. ECM Ground Circuit Voltage Drop Test. . . . .3-24
6. ECM Switched Power Circuit Resistance Test. ...3-24
7. Switched Power Circuit Resistance Test. . . . 3-24
8. Switched Power Circuit Resistance [1A] Test. . 3-24
9. Switched Power Circuit Resistance [1B] Test. . 3-24
10. Ignition Circuit Resistance Test. . . . . . . 3-25
11. Ignition Circuit Resistance [1A] Test. . . . . 3-25
12. Ignition Circuit Resistance [1B] Test. . . . . 3-25
13. Engine Stop Switch Test. . . . . . . . . ..3-25
14. Ignition Circuit Voltage Drop Test. . . . . . .3-25
15. Ignition Circuit Resistance Test. . . . . . . 3-25
16. Ignition Switch To [222] Resistance Test. . . ..3-25
17. Ignition Switch Battery Circuit Voltage Drop
Test. . . . . . . . . . . . . . . . . . . 3-25
18. Battery Voltage to Main Fuse Voltage Drop
Test. . . . . . . . . . . . . . . . . . . 3-25
19. Main Fuse to Ignition Switch Resistance Test. .3-25
20. Main Fuse to [222] Resistance Test. . . . . .3-25
21. Repair Validation Test . . . . . . . . . . .3-26

DTC B0563, P0563. . . . . . . . . . . . . . ..3-26

1. Charging System Test. . . . . . . . . . . 3-26
2. Repair Validation Test. . . . . . . . . . . 3-26

3.7 DTC B1006, B1007

Description and Operation. . . . . . . . . . . . 3-27

Diagnostic Tips. . . . . . . . . . . . . . ..3-27

DTC B1006, B1007. . . . . . . . . . . . . . ..3-27

1. Charging System Test. . . . . . . . . . . 3-27
2. Repair Validation Test. . . . . . . . . . . 3-27

INSTRUMENTS

4.1 INSTRUMENTS

Description and Operation. . . . . . . . . . . . ..4-1

Trip Odometer Reset Switch Operation. . . . . ...4-1

Speedometer Theory of Operation. . . . . . . . . .4-1
Tachometer Theory of Operation. . . . . . . . . . 4-2
Instrument Diagnostics. . . . . . . . . . . . . ...4-2

4.2 DTC B1004, B1005

Description and Operation. . . . . . . . . . . . ..4-3

Connector Information. . . . . . . . . . . . .4-3

DTC B1004. . . . . . . . . . . . . . . . . . .4-5

1. Fuel Level Sender Voltage Test. . . . . . . ...4-5

2. Fuel Pump and Sender Test. . . . . . . . . 4-5
3. Fuel Gauge Voltage Test. . . . . . . . . . ..4-5
4. Fuel Level Sender Circuit Continuity Test. . . . 4-5
5. Fuel Level Sender Circuit Test. . . . . . . . .4-5

DTC B1005. . . . . . . . . . . . . . . . . . .4-5

1. Fuel Level Sender Voltage Test. . . . . . . ...4-5
2. Fuel Pump and Sender Test. . . . . . . . . 4-5
3. Fuel Level Sender Circuit Test. . . . . . . . .4-6
4. Fuel Level Sender Circuit Continuity Test. . . . 4-6
5. Fuel Gauge Ground Circuit Test. . . . . . . ..4-6
6. Fuel Sender Resistance Test. . . . . . . . ...4-6

4.3 DTC B1008

Description and Operation. . . . . . . . . . . . ..4-7

Trip Odometer Reset Switch Closed. . . . . . ...4-7

DTC B1008. . . . . . . . . . . . . . . . . . .4-7

1. Rubber Boot Test. . . . . . . . . . . . . .4-7
2. Trip Odometer Reset Switch Test. . . . . . . .4-7

4.4 NO INSTRUMENT POWER

Description and Operation. . . . . . . . . . . . ..4-8

Connector Information. . . . . . . . . . . . .4-8

Speedometer Inoperative. . . . . . . . . . . . .4-10

1. Battery and Ignition Function Test . . . . . . 4-10
2. Accessory Function Test. . . . . . . . . . 4-10
3. Accessory Fuse Test. . . . . . . . . . . .4-10
4. Battery Fuse Test. . . . . . . . . . . . ...4-10
5. Battery Circuit to Battery Fuse Test. . . . . ...4-10
6. Battery Circuit to Speedometer Test. . . . . ..4-10
7. Battery Circuit Short to Ground Test. . . . . ..4-10
8. Ignition Circuit Test. . . . . . . . . . . . 4-10
9. Instrument Power Circuit Test. . . . . . . . 4-10
10. Ignition Fuse Test. . . . . . . . . . . . .4-11
11. Ignition Power to Instrument Fuse Test. . . . 4-11
12. Ignition Power Short to Ground Test. . . . . 4-11
13. Ground Circuit Test. . . . . . . . . . . ..4-11

4.5 INDICATOR LAMPS

Description and Operation. . . . . . . . . . . . 4-12

Low Fuel Indicator. . . . . . . . . . . . . .4-12
Neutral Indicator. . . . . . . . . . . . . . 4-15
Oil Pressure Indicator. . . . . . . . . . . . 4-15
Turn Signal Indicators. . . . . . . . . . . . 4-15
High Beam Indicator. . . . . . . . . . . . ..4-15
Sixth Gear Indicator. . . . . . . . . . . . ...4-15
Connector Information. . . . . . . . . . . ...4-15

Oil Pressure Lamp Always On. . . . . . . . . . ..4-17

1. Oil Pressure Lamp Function Test. . . . . . ...4-17
2. Engine Running Test. . . . . . . . . . . ..4-17
3. Oil Pressure Sensor Test. . . . . . . . . ...4-17
4. Oil Pressure Circuit Test. . . . . . . . . . 4-17
5. Mechanical Test. . . . . . . . . . . . . .4-17

Oil Pressure Lamp Inoperative. . . . . . . . . . .4-17

1. Oil Pressure Lamp Function Test. . . . . . ...4-17
2. Oil Pressure Switch Test. . . . . . . . . . 4-17
3. Oil Pressure Circuit Test. . . . . . . . . . 4-17

Neutral Lamp Always On. . . . . . . . . . . . ..4-18

1. Neutral Lamp Function Test. . . . . . . . ...4-18
2. Transmission Operation Test. . . . . . . . ..4-18
3. Neutral Switch Test . . . . . . . . . . . ...4-18
4. TSM/TSSM/HFSM Test. . . . . . . . . . ..4-18
5. Neutral Switch Circuit Test. . . . . . . . . .4-18

TABLE OF CONTENTS V

TABLE OF CONTENTS

Neutral Lamp Inoperative. . . . . . . . . . . . .4-18

1. Neutral Lamp Function Test. . . . . . . . ...4-18
2. Neutral Switch Test. . . . . . . . . . . . 4-18
3. Neutral Switch Power Circuit Open Test. . . . 4-18

High Beam Indicator Lamp Inoperative. . . . . . . 4-19

1. High Beam Indicator Function Test. . . . . . 4-19
2. High Beam Indicator Circuit Test . . . . . . ..4-19

Turn Signal Indicator Inoperative. . . . . . . . . ..4-19

1. Turn Signal Function Test. . . . . . . . . ..4-19
2. Turn Signal Indicator Circuit Test . . . . . . ..4-19

4.6 GAUGES

Theory of Operation. . . . . . . . . . . . . . .4-20
Fuel Gauge and Sender Test. . . . . . . . . . . 4-20
Oil Pressure Gauge and Indicator Light. . . . . . ...4-21

Problem. . . . . . . . . . . . . . . . . .4-21

Ambient Air Temperature Gauge. . . . . . . . . ..4-21

Problem. . . . . . . . . . . . . . . . . .4-21

Voltmeter Gauge. . . . . . . . . . . . . . . ...4-22

Problem. . . . . . . . . . . . . . . . . .4-22

ACCESSORIES, HORN, LIGHTING
AND SECURITY

5.1 ACCESSORIES

Description and Operation. . . . . . . . . . . . ..5-1
Components. . . . . . . . . . . . . . . . . ...5-1

P&A Connectors. . . . . . . . . . . . . . ..5-1
P&A Fuses. . . . . . . . . . . . . . . . ..5-1
Connector Information. . . . . . . . . . . . .5-2

Rear Auxiliary Power Outlet Inoperative. . . . . . . .5-3

1. Power Outlet Fuse Test. . . . . . . . . . . 5-3
2. Power Outlet Test. . . . . . . . . . . . . .5-3
3. Power Outlet Ground Circuit Test. . . . . . . 5-3
4. Power Outlet Short to Ground Test. . . . . . ..5-3

Cigar Lighter Inoperative. . . . . . . . . . . . . 5-3

1. P&A Fuse Test. . . . . . . . . . . . . . .5-3
2. Cigar Lighter Test. . . . . . . . . . . . . .5-3
3. Cigar Lighter Ground Circuit Test. . . . . . . 5-3
4. Power Outlet Short to Ground Test. . . . . . ..5-3

5.2 HEATED HAND GRIPS

Description and Operation. . . . . . . . . . . . ..5-4

Diagnostic Tips. . . . . . . . . . . . . . . 5-4
Connector Information. . . . . . . . . . . . .5-4

Heated Handgrips Inoperative. . . . . . . . . . . 5-6

1. P&A Fuse Test. . . . . . . . . . . . . . .5-6
2. Current Draw Test. . . . . . . . . . . . . 5-6
3. Power Supply Test. . . . . . . . . . . . ...5-6
4. Heated Grips Ground Circuit Test. . . . . . . 5-6
5. Heated Grips Test. . . . . . . . . . . . . 5-6
6. Heated Grips Short to Ground Test. . . . . . .5-6
7. Heated Grip Power Circuit Short to Ground Test. .5-6
8. Heated Grips Resistance Test. . . . . . . . .5-6

5.3 CRUISE CONTROL

Description and Operation. . . . . . . . . . . . ..5-7
System Operation. . . . . . . . . . . . . . . ...5-7
Troubleshooting. . . . . . . . . . . . . . . . ..5-8

Diagnostic Tips. . . . . . . . . . . . . . . 5-8

Cruise Inoperative Diagnostics. . . . . . . . . . ...5-8

Cruise Control Inoperative Conditions. . . . . . . ..5-10

5.4 DTC P0577

Cruise Control. . . . . . . . . . . . . . . . ..5-11

Connector Information. . . . . . . . . . . ...5-11

DTC P0577. . . . . . . . . . . . . . . . . ...5-13

1. Cruise Set/Coast Circuit Voltage Test. . . . . 5-13
2. Cruise Set/Coast Switch Test. . . . . . . . 5-13
3. Cruise Resume/Accelerate Circuit Voltage Test. .5-13
4. Cruise Circuit Voltage Test. . . . . . . . . .5-13

5.5 HORN

Description and Operation. . . . . . . . . . . . 5-14
Components. . . . . . . . . . . . . . . . . .5-14

Horn Switch. . . . . . . . . . . . . . . ...5-14
Horn. . . . . . . . . . . . . . . . . . ..5-14

Symptoms. . . . . . . . . . . . . . . . . . 5-14

Diagnostic Tips. . . . . . . . . . . . . . ..5-14
Connector Information. . . . . . . . . . . ...5-14

Horn Always On. . . . . . . . . . . . . . . . 5-15

1. Horn Switch Test. . . . . . . . . . . . . 5-15

Horn Inoperative. . . . . . . . . . . . . . . ...5-15

1. Accessory Circuit Open or Shorted Test. . . ...5-15
2. Horn Test. . . . . . . . . . . . . . . ...5-15
3. Ground Circuit Open Test. . . . . . . . . ..5-15
4. Horn Switch Malfunction Test. . . . . . . . 5-15
5. Horn Power Circuit Open Test. . . . . . . ...5-15

5.6 TURN SIGNALS

Description and Operation. . . . . . . . . . . . 5-16

BAS Operation. . . . . . . . . . . . . . ..5-16
BAS Restart. . . . . . . . . . . . . . . ..5-16
Manual Cancellation. . . . . . . . . . . . ..5-16
Automatic Cancellation. . . . . . . . . . . ..5-16
Four-Way Flashing. . . . . . . . . . . . . 5-16

Will Not Cancel Upon Turn Completion, No DTCs. . ...5-19

1. TSM/TSSM/HFSM Mounting Test. . . . . . ..5-19
2. Correct Configuration Test. . . . . . . . . .5-19
3. 4-Way Cancellation Test. . . . . . . . . . 5-19
4. Turn Signals Cancel Test. . . . . . . . . ...5-19
5. Speedometer Test. . . . . . . . . . . . ..5-19

Flash at Double Normal Rate, All Bulbs Work, No DTCs..5-19

1. Lamp Load Calibration Test. . . . . . . . ...5-19
2. Lamp Verification Test. . . . . . . . . . . 5-19
3. Bulb Corrosion Test. . . . . . . . . . . ...5-19
4. Lamp Connection Terminal Corrosion Test. . . 5-19
5. Verification Test. . . . . . . . . . . . . ..5-20
6. Lamp Operation Test. . . . . . . . . . . .5-20
7. Lamp Assembly Test. . . . . . . . . . . ..5-20

Both Turn Signal Lamps on One Side Inoperative, No
DTCs. . . . . . . . . . . . . . . . . . . . 5-20

1. Left or Right Turn Signal Malfunction Test. . . .5-20
2. Right Turn Signal Circuit Test. . . . . . . . .5-20
3. Right Turn Signal Switch Test. . . . . . . . 5-20
4. Right Turn Signal Circuit Continuity Test. . . . 5-20
5. Left Turn Signal Circuit Test. . . . . . . . ...5-20
6. Left Turn Signal Switch Test. . . . . . . . ...5-20
7. Left Turn Signal Circuit Continuity Test. . . . ..5-20
8. Right Turn Signal Short to Voltage Test. . . . .5-21
9. Left Turn Signal Short to Voltage Test. . . . . 5-21
10. Anti-Theft Tracking Module Test. . . . . . ...5-21

One Turn Signal Lamp Inoperative, No DTCs. . . . ..5-21

VI TABLE OF CONTENTS

TABLE OF CONTENTS

DTC B1154

TOOL NAME

PART NUMBER

BREAKOUT BOX

HD-42682

Table 5-50. DTC B1154 Diagnostic Faults

POSSIBLE CAUSES

TSM/TSSM/HFSM malfunction

Switch malfunction

Short to ground in clutch switch circuit

NOTE

This DTC may occur if the vehicle is ridden with clutch disen-
gaged (pulled in) at speeds greater than 10 mph (16 km/h) for
more than 60 seconds (coasting down a long mountain road).

1. Clutch Circuit Short to Ground Test

1.

Connect BREAKOUT BOX (Part No. HD-42682) to wire
harness [30B], leaving HFSM [30A] disconnected. See

1.2 DIAGNOSTIC TOOLS

.

2.

Using a multimeter, test for continuity between breakout
box (Gray) terminal 10 and terminal 12.

3.

Is continuity present?

a.

Yes.

Go to Test 2.

b.

No. Replace HFSM. See the service manual.

2. Clutch Switch Circuit Test

1.

Disconnect left hand controls [24].

2.

Test for continuity between breakout box (Gray) terminal
10 and terminal 12.

3.

Is continuity present?

a.

Yes. Repair short to ground on (BK/R) wire in main
wiring harness between [30B] and [24B].

b.

No.

Go to Test 3.

3. Clutch Switch Test

1.

Inspect left handlebar switch wiring for a short to ground.

2.

Was a short to ground present?

a.

Yes. Repair short to ground in left handlebar switch
wiring.

b.

No. Replace clutch switch. See the service manual.

DTC B1155

TOOL NAME

PART NUMBER

BREAKOUT BOX

HD-42682

Table 5-51. DTC B1155 Diagnostic Faults

POSSIBLE CAUSES

TSM/TSSM/HFSM malfunction

Short to ground in neutral circuit

Neutral switch malfunction

NOTE

This DTC may occur if the vehicle is ridden in neutral at speeds
greater than 10 mph (16 km/h) for more than 60 seconds
(coasting down a long mountain road).

1. Neutral Circuit Short to Ground Test

1.

Shift the transmission into 1st or 2nd gear.

2.

Connect BREAKOUT BOX (Part No. HD-42682) to wire
harness [30B], leaving HFSM [30A] disconnected. See

1.2 DIAGNOSTIC TOOLS

.

3.

Using a multimeter, measure resistance between breakout
box (Gray) terminal 4 and terminal 12.

4.

Is resistance less than 10 Ohms?

a.

Yes.

Go to Test 2.

b.

No. Replace HFSM. See the service manual.

2. Neutral Switch Short to Ground Test

1.

Disconnect neutral switch [131].

2.

Measure resistance between breakout box (Gray) terminal
4 and terminal 12.

3.

Is resistance less than 10 Ohms?

a.

Yes. Repair short to ground on (TN) wire.

b.

No. Replace neutral switch. See the service manual.

HOME

5-72 2011 Touring Diagnostics: Accessories, Horn, Lighting and Security

TABLE OF CONTENTS

SUBJECT

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PAGE NO.

6.1 EFI SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
6.2 ELECTRONIC CONTROL MODULE. . . . . . . . . . . . . . . . . . . . . . .6-4
6.3 SENSORS AND DRIVERS. . . . . . . . . . . . . . . . . . . . . . . . . ...6-6
6.4 DTC P0107, P0108, P0112, P0113. . . . . . . . . . . . . . . . . . . . . . ...6-9
6.5 DTC P0117, P0118. . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-13
6.6 DTC P0120, P0122, P0123, P0220, P0222, P0223. . . . . . . . . . . . . . . . 6-16
6.7 DTC P0031, P0032, P0131, P0132, P0134, P0151, P0152, P0154. . . . . . . . . ...6-23
6.8 DTC P0261, P0262, P0263, P0264. . . . . . . . . . . . . . . . . . . . . . .6-30
6.9 DTC P0373, P0374. . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-34
6.10 DTC P0444, P0445. . . . . . . . . . . . . . . . . . . . . . . . . . . ...6-36
6.11 DTC P0501, P0502. . . . . . . . . . . . . . . . . . . . . . . . . . . ...6-39
6.12 DTC P0505. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43
6.13 DTC P0572. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45
6.14 DTC P0603, P0605. . . . . . . . . . . . . . . . . . . . . . . . . . . ...6-48
6.15 DTC P0641, P0651. . . . . . . . . . . . . . . . . . . . . . . . . . . ...6-49
6.16 DTC P1001, P1002, P1003, P1004. . . . . . . . . . . . . . . . . . . . . ...6-52
6.17 DTC P1009, P1010. . . . . . . . . . . . . . . . . . . . . . . . . . . ...6-56
6.18 DTC P1270. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-58
6.19 DTC P1351, P1352, P1354, P1355. . . . . . . . . . . . . . . . . . . . . ...6-61
6.20 DTC P1353, P1356, P1357, P1358. . . . . . . . . . . . . . . . . . . . . ...6-65
6.21 DTC P1475, P1477, P1478. . . . . . . . . . . . . . . . . . . . . . . . ...6-68
6.22 DTC P1501, P1502. . . . . . . . . . . . . . . . . . . . . . . . . . . ...6-72
6.23 DTC P1510, P1511, P1512. . . . . . . . . . . . . . . . . . . . . . . . ...6-75
6.24 DTC P1514. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-76
6.25 DTC P1600. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-77
6.26 DTC P1655, P1656. . . . . . . . . . . . . . . . . . . . . . . . . . . ...6-78
6.27 DTC P2100, P2101, P2102, P2103. . . . . . . . . . . . . . . . . . . . . ...6-82
6.28 DTC P2105, P2107. . . . . . . . . . . . . . . . . . . . . . . . . . . ...6-86
6.29 DTC P2119. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-89
6.30 DTC P2122, P2123, P2127, P2128. . . . . . . . . . . . . . . . . . . . . ...6-90
6.31 DTC P2135, P2138. . . . . . . . . . . . . . . . . . . . . . . . . . . ...6-95
6.32 DTC P2176. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-98
6.33 ENGINE CRANKS, BUT WILL NOT START. . . . . . . . . . . . . . . . . . ..6-99
6.34 NO ECM POWER. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-102
6.35 STARTS, THEN STALLS. . . . . . . . . . . . . . . . . . . . . . . . . .6-105
6.36 FUEL SYSTEM ELECTRICAL TEST. . . . . . . . . . . . . . . . . . . . ..6-106
6.37 MISFIRE AT IDLE OR UNDER LOAD. . . . . . . . . . . . . . . . . . . . .6-109

ENGINE MANA

GEMENT

4. Headset SpkA Voltage Test

1.

Install ADVANCED AUDIO SYSTEM BREAKOUT
BOX (Part No. HD-47918) between radio [27A] and har-
ness [27B].

2.

Measure voltage from breakout box [27] terminal 21 to
ground using HARNESS CONNECTOR TEST KIT (Part
No. HD-41404-C).

3.

Is voltage less than 4.5V?

a.

Yes.

Go to Test 5.

b.

No.

Go to Test 6.

5. Headset SpkA Continuity Test

1.

Disconnect radio breakout box from radio [27A], leaving
harness [27B] connected.

2.

Test for continuity between breakout box [27] terminal 21
and switch harness [105A] terminal 10 using HARNESS
CONNECTOR TEST KIT (Part No. HD-41404-C).

3.

Is continuity present?

a.

Yes. Replace speaker switch. See the service
manual. (6143)

b.

No. Repair open (V/O) wire between [27B] terminal
21 and [105A] terminal 10. (5041)

6. Headset SpkA Short to Ground Test

1.

Test for continuity from breakout box [27] terminal 21 to
ground using HARNESS CONNECTOR TEST KIT (Part
No. HD-41404-C).

2.

Is continuity present?

a.

Yes. Repair short to ground. (5041)

b.

No.

Go to Test 7.

7. Headset SpkA Short to Voltage Test

1.

Test for voltage from breakout box [27] terminal 21 and
ground using HARNESS CONNECTOR TEST KIT (Part
No. HD-41404-C).

2.

Is battery voltage present?

a.

Yes. Repair short to voltage on (V/O) wire. If wire is
okay, replace radio. (6103)

b.

No. Replace speaker switch. See the service manual.
(6143)

8. Headset SpkB Voltage Test

1.

Install ADVANCED AUDIO SYSTEM BREAKOUT
BOX (Part No. HD-47918) between radio [27A] and har-
ness [27B].

2.

Measure voltage from breakout box [27] terminal 13 to
ground using HARNESS CONNECTOR TEST KIT (Part
No. HD-41404-C).

3.

Is voltage less than 2.5V?

a.

Yes.

Go to Test 9.

b.

No.

Go to Test 10.

9. Headset SpkB Continuity Test

1.

Disconnect radio breakout box from radio [27A], leaving
harness [27B] connected.

2.

Test for continuity between breakout box [27] terminal 13
and switch harness [105A] terminal 11 using HARNESS
CONNECTOR TEST KIT (Part No. HD-41404-C).

3.

Is continuity present?

a.

Yes. Replace speaker switch. See the service
manual. (6143)

b.

No. Repair open (BN/O) wire between [27B] terminal
13 and [105A] terminal 11. (5041)

10. Headset SpkB Short to Voltage Test

1.

Test for voltage from breakout box [27] terminal 13 and
ground using HARNESS CONNECTOR TEST KIT (Part
No. HD-41404-C).

2.

Is battery voltage present?

a.

Yes. Repair short to voltage on (BN/O) wire. (5041)

b.

No.

Go to Test 11.

11. Headset SpkB Short to Ground Test

1.

Test for continuity from breakout box [27] terminal 13 to
ground using HARNESS CONNECTOR TEST KIT (Part
No. HD-41404-C).

2.

Is continuity present?

a.

Yes. Repair short to ground on (BN/O) wire. (5041)

b.

No. Replace radio. See the service manual. (6103)

SYMPTOM 9: HEADSET SPEAKERS
INOPERATIVE

TOOL NAME

PART NUMBER

HARNESS CONNECTOR TEST KIT

HD-41404-C

ADVANCED AUDIO SYSTEM
BREAKOUT BOX

HD-47918

Headset speakers rarely fail at the same time. Troubleshooting
time can be significantly reduced by substituting known good
units for the suspect units. Alternatively substituting parts of
the suspect units (headsets and coil cords) can quickly
determine whether the headsets or coil cords are faulty, or
whether the fault lies elsewhere in the system.

HOME

2011 Touring Diagnostics: Audio System 8-41