Harley Davidson 2005 touring models. Service repair manual — page 57
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CRUISE CONTROL
7.1
GENERAL
f1368a8x
The Cruise Control system provides automatic vehicle speed
control. The electronics and stepper motor are contained in a
control module mounted under the left side cover. The step-
per motor actuates the cruise control cable through a gear
train and ribbon reel.
SYSTEM OPERATION
Set/Resume
Switch
To engage and disengage the cruise control system, proceed
as follows:
1.
While riding in fourth or fifth gear, turn the Cruise ON/
OFF Switch to the ON position. See Figure 7-1. The
switch is located on the fairing cap of FLHTCU models,
the instrument nacelle of FLTR models, and the left han-
dlebar lower switch housing on FLHRC models. The
Figure 7-2. Right Handlebar Switch Assembly
Cruise Enabled/Engaged lamp in the tachometer face
(FLTR, FLHTCU)
(speedometer on FLHRC models) turns red to indicate
that the system is activated. See Figure 7-3. A red lamp
in the switch on both FLHTCU and FLTR models also
f2160x8x
Tachometer
indicates this condition to the rider.
2.
Power (12 vdc) is supplied to the cruise control module
through a 15 amp fuse located in the fuse block mounted
under the left side cover.
60
40
50
70
30
50
40
80
3.
With the motorcycle traveling at the desired
“cruise”
30
90
20
60
speed (30 mph/48 km/h to 85 mph/137 km/h), momen-
MPH
RPM x100
20
100
tarily push the Cruise SET/RESUME switch to SET. See
10
70
Figure 7-2.
10
110
0
120
0
80
Ignition/Light
TI
-D
-D
Key Switch
Cruise ON/OFF
Switch
Cruise Enabled/Engaged Lamp
Figure 7-3. Instrument Panel (FLHTCU)
The cruise control module “reads” the vehicle speed sen-
sor (VSS) output to establish the desired vehicle speed.
The module then sends a signal to the stepper motor
which drives the ribbon reel to take up the slack in the
cruise cable. The Cruise Enabled/Engaged lamp in the
tachometer face (speedometer on FLHRC models) turns
from red to green to indicate that the cruising speed is
locked in. See Figure 7-3.
f2031x8x
4.
The cruise control module monitors both the engine
RPM and the VSS output speed signal. The module sig-
Figure 7-1. Fairing Cap (FLHTCU)
nals the stepper motor to open or close the throttle to
keep the speedometer output speed signal constant. The
engine RPM is monitored to detect engine
2005 Touring: Cruise Control
7-1
HOME
ENGAGE SEQUENCE
DISENGAGE SEQUENCE
CRUISE SWITCH ON
FRONT/REAR BRAKE
SET/RESUME
SWITCH TO SET
IDLE CABLE ROLL-OFF
READS VSS
(DISENGAGE) SWITCH
OUTPUT SPEED SIGNAL
CRUISE
CRUISE SWITCH OFF
STEPPER MOTOR
MODULE
GEAR TRAIN
& RIBBON REEL
CRUISE ENGAGED
HANDLEBAR
LAMP
ENGINE STOP
SWITCH OFF
THROTTLE
ACTUATION
ENGINE RPM
MONITORED*
CLUTCH DISENGAGE
(ENGINE RPM)
*Tachometer receives signal from ignition coil on
carbureted models, and from ECM on EFI models.
Figure 7-4. Cruise System Diagram
overspeed, a condition which automatically causes
f.
Handlebar mounted Cruise SET/RESUME switch is
cruise disengagement.
pushed to SET and held in that position until vehicle
speed drops below 30 mph (48 km/h).
5.
The cruise control automatically disengages
(stepper
motor drives cruise cable to the full-out position) when-
NOTE
ever the cruise control module receives one of the follow-
ing inputs:
If the vehicle speed is above 30 mph (48 km/h) when the
Cruise SET/RESUME Switch is released, then the cruise sys-
a. Front or rear brake is applied.
tem automatically re-engages.
b. Throttle is “rolled back” or closed, thereby actuating
idle cable roll-off (disengage) switch.
c. Motorcycle clutch is disengaged (module senses too
great an increase in RPM).
TROUBLESHOOTING
d. Cruise ON/OFF Switch placed in the OFF position.
The switch is located on the fairing cap of FLHTCU
The cruise module circuitry provides on-board diagnostics to
models, the instrument nacelle of FLTR models, and
help isolate any problems that might occur with the cruise
the left handlebar lower switch housing on FLHRC
system.
models. The green Cruise Enabled/Engaged lamp in
the tachometer face (speedometer on FLHRC mod-
If the cruise is inoperative or fails to set, begin troubleshooting
els) is extinguished to indicate that the system is
with 7.2 CRUISE INOPERATIVE DIAGNOSTICS. If the cruise
deactivated. The red lamp in the fairing cap switch of
seems to disengage or drop out for no apparent reason, then
FLHTCU models and the instrument nacelle switch
see 7.3 CRUISE DROPOUT DIAGNOSTICS.
of FLTR models is also extinguished.
In the diagnostic mode, the Cruise Enabled/Engaged lamp is
e. Handlebar mounted Engine Stop Switch placed in
employed as a test indicator. The lamp is in the tachometer
the OFF position. (This removes tachometer input
face (speedometer on FLHRC models). See Figure 7-3.
signal which results in module disengagement.)
7-2
2005 Touring: Cruise Control
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CRUISE INOPERATIVE DIAGNOSTICS
7.2
GENERAL
Table 7-1. Cruise Module Connector [17A]
WIRE
FUNCTION AND
Perform the following diagnostic procedures in the order pre-
TERMINAL
sented. If the test sequence is not followed precisely, the
COLOR
CONNECTION
diagnostic mode may not be exited at conclusion of the diag-
A
Red/Green
ON/OFF switch enable
nostic routine and the test indicator (Cruise Engaged Lamp)
may continue to flash while the engine is running.
SET input from SET/RESUME
B
Blue/Black
switch
RESUME input from SET/RESUME
C
White/Blue
switch
INOPERATIVE DIAGNOSTICS
Idle cable disengage switch
D
Violet/Yellow
(12 vdc from 15 amp fuse)
Refer to Table 7-2. All diagnostic steps are listed in table for-
E
Black
Cruise module ground
mat. Follow the numbered steps to test the system. Compare
the system behavior to CORRECT FUNCTION or INCOR-
F
Orange/Violet
12 vdc power from 15 amp fuse
RECT FUNCTION columns and advance to the next step
Disengage from brake relay
listed.
G
Red/Blue
(12 vdc)
H
Blue/Orange
Tachometer input
Diagnostic Notes
12 vdc from “CRUISE” indicator in
J
Green/Red
instrument panel
The diagnostic notes below provides supplementary informa-
(module provides ground)
tion for Table 7-2.
K
White/Green
Vehicle speed signal input
1.
If the cruise engaged lamp does not illuminate at all,
check for one or more of the following conditions:
a. SET/RESUME switch faulty or not wired correctly.
g.
Brake light on constantly.
b. Broken or pinched wire to SET switch or cruise mod-
h.
Throttle cables too tight.
ule.
i.
Bad cruise control fuse.
c. Cruise engaged lamp burned out or miswired. Lamp
is turned on by module supplied ground.
2.
Repeat Steps 1 and 2. If the cruise engaged lamp still
d. Main 10-place connector not plugged into cruise
does not illuminate, see 7.4 CRUISE CHART A: INITIAL
module.
DIAGNOSTICS. For cruise module connector wire color
locations and functions, refer to Table 7-1. Repair any
e. Faulty cruise main switch and associated wiring.
problems and recheck by repeating Steps 1 and 2.
f.
No module ground at Terminal E of 10-place module
connector.
2005 Touring: Cruise Control
7-3
HOME
Table 7-2. Cruise Inoperative Diagnostics
NO.
ACTION
CORRECT FUNCTION
INCORRECT FUNCTION
Turn the Ignition/Light Key Switch to
OFF. Connect Speedometer Tester
1
(HD-41354).
Enter the diagnostic mode: With the
If the cruise engaged lamp remains illumi-
The cruise engaged lamp will illuminate and
fairing cap Cruise ON/OFF Switch at
nated after the switch is released, then either
remain on as long as the Cruise SET/
ON, and the handlebar mounted
the switch or related wiring is shorted. See
RESUME switch is held in the SET position.
2
Cruise SET/RESUME Switch held
Diagnostic Note 1 for possible causes.
at SET, turn the Ignition/Light Key
Continue with steps listed under Diagnos-
Switch to IGNITION.
Continue with Step 3.
tic Note 2.
If the cruise engaged lamp does not illuminate
at all, check for one or more of the following
The cruise engaged lamp will illuminate and
conditions:
remain on as long as the SET/RESUME
Push the handlebar mounted Cruise
● RES(UME) switch not wired correctly.
Switch is held in the RES(UME) position.
3
SET/RESUME Switch to RES(UME)
● Broken or pinched wire to RES(UME)
and hold in this position.
switch or cruise module.
Continue with Step 4.
Continue with 7.5 CRUISE CHART B:
RESUME SWITCH.
If the cruise engaged lamp does not illuminate
at all, check for one or more of the following
The cruise engaged lamp will illuminate when
conditions:
the switch is closed, and then be extinguished
● Throttle grip switch not wired correctly.
Next, turn the throttle grip tightly
when the throttle grip returns to its free posi-
● Broken or pinched wire to throttle grip
4
closed to check the throttle grip
tion.
switch.
switch or cruise module.
● Throttle grip switch not working correctly.
Continue with Step 5.
Continue with 7.11 CRUISE CHART G:
THROTTLE SWITCH.
If the cruise engaged lamp does not illuminate
at all, check for one or more of the following
conditions:
● Front brake switch not wired correctly.
The cruise engaged lamp will illuminate and
● Broken or pinched wire to front brake
remain on until the brake lever is released.
5
Apply the brake hand lever.
switch or cruise module.
● Front brake switch not working properly.
Continue with Step 6.
See 7.9 CRUISE CHART F-1: BRAKE
LIGHTS ON (constant brake light input) or
7.10 CRUISE CHART F-2: BRAKE LIGHTS
OFF (no front and/or rear brake lights).
The cruise engaged lamp will not illuminate if
any of the following conditions exist:
● Rear brake switch not wired correctly.
The cruise engaged lamp will illuminate. After
● Broken or pinched wire to rear brake
switch or cruise control module.
depressing and holding the brake foot pedal
for 5 seconds, the lamp will be extinguished.
● Rear brake switch not working properly.
Press and hold the brake foot pedal
Release the brake pedal and the cruise mod-
The throttle will not open if the following condi-
6
for at least 5 seconds.
ule will momentarily pull the throttle open
tions exist:
slightly and then release.
● Cables not adjusted properly.
● Faulty cruise control module.
Continue with Step 7.
See 7.9 CRUISE CHART F-1: BRAKE
LIGHTS ON (constant brake light input) or
7.10 CRUISE CHART F-2: BRAKE LIGHTS
OFF (no front and/or rear brake lights).
7-4
2005 Touring: Cruise Control
HOME
Table 7-2. Cruise Inoperative Diagnostics
NO.
ACTION
CORRECT FUNCTION
INCORRECT FUNCTION
The cruise engaged lamp will not illuminate if
any of the following conditions exist:
● Vehicle speed signal not wired correctly.
The cruise engaged lamp will flash on and off
indicating that the vehicle speed signal is
● Broken or pinched wire to speedometer.
wired properly and working correctly.
● Speedometer not working properly.
7
Rotate rear wheel.
● Vehicle speed signal wiring discon-
Continue with Step 8.
nected.
See 7.12 CRUISE CHART H: SPEEDOME-
TER INPUT.
Turn the fairing cap Cruise ON/OFF
Switch and the Ignition/Light Key
8
Switch to OFF. Disconnect spark
Continue with Step 9.
plug wires.
Press SET/RESUME Switch to
9
RES(UME), and hold.
Continue with Step 10.
While holding SET/RESUME Switch
at RES(UME), turn Ignition/Light Key
The cruise engaged lamp flashes with RPM
The cruise engaged lamp does not flash with
Switch to ON and crank engine. (If
input.
RPM input.
10
weak battery or poor connections
See 7.13 CRUISE CHART I: TACHOMETER
result in low system voltage, Diag-
Continue with Step 11.
INPUT.
nostic Mode may be aborted.)
Cruise engaged lamp blinks twice.
While continuing to hold SET/
NOTE: Lamp may go on for three seconds if
RESUME Switch at RES(UME), turn
11
RPM signal was above cranking speed.
fairing cap Cruise ON/OFF Switch to
ON. Release SET/RESUME Switch.
DIAGNOSTIC ROUTINE EXITED
To restart or repeat the diagnostic
12
sequence, return to Step 1.
2005 Touring: Cruise Control
7-5
HOME
CRUISE DROPOUT DIAGNOSTICS
7.3
count the number of times the lamp flashes in order to
GENERAL
retrieve the first digit of the dropout code.
To check for diagnostic codes, see DROPOUT DIAGNOS-
4.
Following transmission of the first digit, there is a one
TICS below. If other problems are experienced, such as
second pause in which the lamp is off. The lamp will then
harsh cruise engagement or speed loss, see Table 7-4.
flash one or more times to indicate the second digit of the
dropout code. Count the number of times the lamp
flashes to retrieve the second digit. See Figure 7-5.
DROPOUT DIAGNOSTICS
5.
Following transmission of the second digit, there is a
another one second pause in which the lamp is off. The
The last eight diagnostic codes for cruise disengagement are
lamp will then flash one or more times to indicate the
stored in memory.
third digit of the dropout code. Again, count the number
of times the lamp flashes to retrieve the third digit.
1.
To enter the diagnostic mode, turn the engine off and
proceed as follows:
6.
Write down the dropout code on a piece of paper. To
identify the reason for cruise disengagement see Table
a. Turn the fairing cap Cruise ON/OFF switch to OFF.
7-3. The last column of the table suggests the appropri-
The light in the rocker switch is extinguished to indi-
ate corrective action.
cate this condition to the operator.
7.
To verify the dropout code, toggle the Cruise SET/
b. Push the Cruise SET/RESUME Switch on the right
RESUME Switch to RESUME. The transmission of the
handlebar to SET and hold.
most recent dropout code is repeated. To continue with
c. Turn the Ignition/Light Key Switch to IGNITION, but
the next code, simply toggle the Cruise Switch to SET. All
do not start the engine.
subsequent codes are sent in the same manner as the
first, after which the operator may repeat the code or
d. Release the Cruise SET/RESUME Switch from the
move on to the next in the series.
SET position while observing the behavior of the
Cruise Enabled/Engaged Lamp on the tachometer
8.
After the eighth (or oldest) dropout code is flashed, the
gauge (speedometer on FLHRC models).
Cruise Engaged Lamp remains illuminated to indicate
that the end of the dropout code buffer has been
2.
The system transmits the most recent cruise dropout
reached.
code. Each dropout code consists of 3 digits and is sent
out as a series of flashes.
9.
To start the sequence at the beginning, that is, with
transmission of the most recent dropout code, momen-
3.
The lamp will begin by flashing one or more times to indi-
tarily push the Cruise SET/RESUME Switch to SET.
cate the first digit of the dropout code. The length of time
the lamp is illuminated and the length of time in which it
10.
To exit the diagnostic mode, turn the Ignition/Light Key
is off are each about 1/4 second in duration. Simply
Switch to OFF.
1st Digit
2nd Digit
3rd Digit
ON
1/4
1/4
1/4
1/4
1/4
Sec.
Sec.
Sec.
Sec.
Sec.
Toggle Cruise Switch to RESUME
to Verify Code.
1 Sec.
1/4
1 Sec.
1/4
OFF
Sec.
Sec.
Toggle Cruise Switch to SET
to Continue With Next Code.
Cruise
Pause After
Pause After
Engaged
1st Digit
2nd Digit
Lamp
NOTE
Looking at the above transmission, we can see that the dropout code is 122.
See Table 7-3. The reason for cruise disengagement is identified as applica-
tion of front or rear brakes.
Figure 7-5. Cruise Engaged Lamp Dropout Code Timing Diagram
7-6
2005 Touring: Cruise Control
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Table 7-3. Cruise Dropout Code Key
ACTION
CODE
CONDITION
NOTE
While performing instructions under applicable flow chart, wiggle con-
nectors and wires to identify intermittents.
111
Initial State or Cleared Memory (No Codes Recorded)
-
112
Throttle Roll Off
7.11 CRUISE CHART G: THROTTLE SWITCH
113
Fairing Cap Cruise Switch Turned OFF
7.8 CRUISE CHART E: CRUISE ENABLE
7.4 CRUISE CHART A: INITIAL DIAGNOSTICS or 7.5
121
Short in Wiring Between Set/Resume
CRUISE CHART B: RESUME SWITCH
Application of Front or Rear Brakes
122
NOTE
7.9 CRUISE CHART F-1: BRAKE LIGHTS ON
May require inspection of brake levers
or front brake light switch mounting.
211
Coast (S/C Button Engaged) Interval Longer than 6 Seconds
7.4 CRUISE CHART A: INITIAL DIAGNOSTICS
Speed Drops Below 30 MPH While in Coast
7.4 CRUISE CHART A: INITIAL DIAGNOSTICS or 7.12
212
(S/C Button Engaged)
CRUISE CHART H: SPEEDOMETER INPUT
213
Speed Drops Below 26 MPH or Exceeds 90 MPH
7.12 CRUISE CHART H: SPEEDOMETER INPUT
Speed Drops 15 MPH Below Set Speed
221
7.12 CRUISE CHART H: SPEEDOMETER INPUT
(Such as When Climbing a Steep Hill)
222
Speed Decreases Greater than 20 MPH per Second
7.12 CRUISE CHART H: SPEEDOMETER INPUT
223
Vehicle Speed Sensor Input
7.12 CRUISE CHART H: SPEEDOMETER INPUT
231
Over 5000 RPM
7.13 CRUISE CHART I: TACHOMETER INPUT
232
Loss of Tachometer Signal
7.13 CRUISE CHART I: TACHOMETER INPUT
High Rate of Change of RPM Detected
242
(Such as When Clutch is Pulled In or Contact is Made
7.13 CRUISE CHART I: TACHOMETER INPUT
With Ice Patch or Slippery Surface)
311
312
313
321
Replace cruise module. See the Touring Models Service Man-
Internal Failure
323
ual.
331
332
333
341
Low Voltage
7.7 CRUISE CHART D: CRUISE POWER
342
343
351
352
353
361
Replace cruise module. See the
Internal Failure
362
Touring Models Service Manual.
363
371
423
432
777
2005 Touring: Cruise Control
7-7
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Table 7-4. Other Malfunctions
CONDITION
SYMPTOM
CHECK FOR
Harsh
Cruise control opens
Check for a cruise cable that is too tight. See CABLE LASH INI-
engagement
throttle abruptly or harshly
TIALIZATION in the Touring Models Service Manual.
● Cruise cable too loose. See CABLE LASH INITIALIZATION in
Loses speed
the Touring Models Service Manual.
● Set switch held too long.
● Cruise cable too tight. See CABLE LASH INITIALIZATION in
Gains speed
the Touring Models Service Manual.
Speed
● Intermittent vehicle speed signal.
variation
● Intermittent speedometer.
● Defective cruise module. See CRUISE MODULE, REMOVAL/
Speed surges
INSTALLATION, in the Touring Models Service Manual.
NOTE
Check for surging with cruise control turned OFF. If surging is still
present, a lean fuel mixture may be the cause.
7-8
2005 Touring: Cruise Control
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CRUISE CHART A: INITIAL DIAGNOSTICS
7.4
DIAGNOSTICS
Test 7.4 (Part 1 of 2)
Remove Left Saddlebag and Sidecover.
Is 10-place Connector [17B] Plugged Into
FLH TCU-I, FLTR/I
Cruise Module? See Figure 7-6.
Remove the Outer Fairing. Locate the 12-
Place Connector [22] for Right Handlebar
YES
NO
Switch Controls. See Figure 7-7 or Figure
7-8. Measure Between the O/W and BE/
BK Terminals at Connector [22B]. Resis-
Unplug Connector [17B].
Plug In Connector [17B].
tance Must Be ∞ Ohms. Pressing SET/
RESUME Switch to SET Should Produce
a Reading of Less Than 0.5 Ohms. Are
SET SWITCH
These Your Observations?
Check Continuity Between the O/V Termi-
nal (F) and BE/BK Terminal (B) of Connec-
tor [17B]. Resistance Must Be ∞ Ohms.
YES
NO
Pressing SET/RESUME Switch to SET
Should Produce a Reading of Less Than
0.5 Ohms. Are These Your Observations?
Check Continuity on O/V
Right Handlebar
and BE/BK Wires Between
Switch Wiring
NO
Connectors
[17B] and
Pinched or
[156A]. See Figure 7-7 and
Damaged?
YES
FLHRC-I
Figure
7-9.
Continuity
Present?
Remove the Headlamp Assembly. Discon-
YES
NO
nect 6-Place Connector [22] and 2-Place
STOP
Connector
[159]. Measure Resistance
Between O/W Wire on Connector [22B]
Repair
Replace Cruise
and BE/BK Wire on Connector [159B].
Wiring.
SET/RESUME
YES
NO
Go to Test 7.4 (Part 2 of 2)
Resistance Must Be ∞ Ohms. Pressing
Switch.
6552
SET/RESUME Switch to SET Should Pro-
5182
duce a Reading of Less Than 0.5 Ohms.
Repair
Repair Main
Are These Your Observations?
Interconnect
Harness.
Harness.
5028
6532
YES
NO
Locate and Repair
Right Handlebar
Open on BE/BK Wire
Switch Wiring Pinched
in Main Harness.
or Damaged?
5028
YES
NO
Repair
Replace Cruise
After correction of problem, restart 7.2 CRUISE
Wiring.
SET/RESUME
INOPERATIVE DIAGNOSTICS to verify proper per-
Switch.
6552
formance.
5182
Cruise Module
Connector [17]
f2206x8x
Figure 7-6. Left Side Cover Removed
2005 Touring: Cruise Control
7-9
HOME
Test 7.4 (Part 2 of 2)
Right Handlebar
INITIAL DIAGNOSTICS
Switch Controls [22]
Main to
Interconnect [156]
Continued from Test 7.4 (Part 1 of 2).
Connect a Jumper From the GN/R Termi-
nal (J) to Ground. The Cruise Engaged
Lamp Should Illuminate When the Igni-
tion/Light Key Switch is Positioned to
IGNITION. Does It?
YES
NO
Place the Positive Probe on the O/V Termi-
See 7.6 CRUISE
nal (F) and the Negative Probe on the BK
CHART C:
Terminal
(E). With the Ignition/Light Key
CRUISE
Switch Positioned to IGNITION, the Meter
ENGAGED LAMP.
Should Read Battery Voltage. Does It?
f2238x8x
YES
NO
Figure 7-7. Outer
Fairing
Removed
(FLHTC/U)
Place the Positive Probe on the R/GN Termi-
See 7.7 CRUISE
nal (A) and the Negative Probe on the BK
CHART D:
CRUISE POWER.
Main to
Right Handlebar
Terminal
(E). With the Ignition/Light Key
Switch Positioned to IGNITION and the Fair-
Interconnect [156]
Switch Controls [22]
ing Cap Cruise ON/OFF Switch Positioned
to ON, the Meter Should Read Battery Volt-
age. Does It?
YES
NO
Place the Positive Probe on the R/BE
See 7.8 CRUISE
Terminal (G) and the Negative Probe on
CHART E:
the BK Terminal (E). Meter Should Read
CRUISE
Between
11-13 Volts Only When the
ENABLE.
Brake is Applied and the Ignition/Light
Key Switch is Positioned to IGNITION.
Does It?
YES
NO
f2269x8x
Check Continuity Between the V/Y
See 7.9 CRUISE
CHART F-1: BRAKE
Figure 7-8. Outer Fairing Removed (FLTR)
Terminal (D) and the O/V Terminal (F)
With the Ignition/Light Key Switch
LIGHTS ON or 7.10
Positioned to OFF. The Meter Should
CRUISE CHART F-
Read Infinity When the Throttle Switch
2: BRAKE LIGHTS
is in the Relaxed Position, and Conti-
OFF.
nuity When the Throttle Grip is Rolled
Forward. Does It?
YES
NO
See 7.11 CRUISE
Reconnect All Connectors. Restart
7.2 CRUISE INOPERATIVE DIAG-
CHART G: THROTTLE
SWITCH.
NOSTICS if Cruise Engaged Lamp
has Never Illuminated. If the Lamp
Will Not Illuminate When the First Test
is Performed Now, Replace the
Cruise Module.
6635
7-10
2005 Touring: Cruise Control
HOME
CRUISE CHART B: RESUME SWITCH
7.5
DIAGNOSTICS
Test 7.5
Remove Left Saddlebag and Side Cover. Disconnect Connector [17B] From Cruise Module.
See Figure 7-6. Check Continuity Between the O/V Terminal (F) and the W/BE Terminal (C).
Resistance Must Be ∞ Ohms. Pressing SET/RESUME Switch to RESUME Should Pro-
duce a Reading of Less Than 0.5 Ohms. Are These Your Observations?
YES
NO
Replace
Cruise
FLH TCU-I, FLTR/I
FLHRC-I
Module.
6635
Remove the Outer Fairing. Locate the 12-Place Con-
Disconnect
6-Place Connector
[22] and
4-Place
nector [22] for Right Handlebar Switch Controls. See
Connector [159]. Measure Resistance Between O/W
Figure 7-7 or Figure 7-8. Measure Between O/W and
Wire at Connector [22B] and W/BE Wire at Connec-
W/BE Terminals at Connector [22B].
tor [159B].
Resistance Must Be
∞ Ohms. Pressing SET/
Resistance Must Be
∞ Ohms. Pressing SET/
RESUME Switch to RESUME Should Produce a
RESUME Switch to RESUME Should Produce a
Reading of Less Than 0.5 Ohms. Are These Your
Reading of Less Than 0.5 Ohms. Are These Your
Observations?
Observations?
YES
NO
YES
NO
Check Continuity on W/BE Wire
Right Handlebar
Locate and Repair
Right Handlebar
Between Connectors [17B] and
Switch Wiring Pinched
Open on W/BE Wires
Switch Wiring Pinched
[156A]. See Figure 7-7 and Fig-
or Damaged?
in Main Harness.
or Damaged?
ure 7-8. Continuity Present?
5028
YES
NO
YES
NO
YES
NO
Repair
Replace Cruise
Repair
Replace Cruise
Wiring.
SET/RESUME
Wiring.
SET/RESUME
Repair
Repair Main
Switch.
Switch.
Interconnect
Harness.
6552
6552
Harness.
5182
5182
5028
6532
After correction of problem, restart 7.2 CRUISE INOPERATIVE DIAGNOSTICS
to verify proper performance.
2005 Touring: Cruise Control
7-11
HOME
CRUISE CHART C: CRUISE ENGAGED LAMP
7.6
DIAGNOSTICS
Test 7.6
Remove Left Saddlebag and Side Cover. Disconnect Connector [17B] From
Cruise Module. See Figure 7-6. Connect a Jumper From the GN/R Terminal
(J) to Ground. The Cruise Engaged Lamp Should Illuminate When the Igni-
tion/Light Key Switch is Positioned to IGNITION. Does it?
YES
NO
Replace
FLH TCU-I, FLTR/I
FLHRC-I
Cruise
Module.
Remove Outer Fairing
(FLHTCU-I) or
Continuity Present on
6635
Instrument Bezel (FLTR/I). Remove GN/R
GN/R Wire Between
Wire From Connector
[108B] and Then
Connectors [39B] and
Reconnect. Connect a Jumper Wire to
[17B]?
Ground From the GN/R Wire That Feeds
the Tachometer. The Cruise Engaged Lamp
Should Illuminate When the Ignition/Light
Key Switch is Positioned to IGNITION.
YES
NO
Does It?
Battery Voltage
Locate and
Present on O/W Wire
Repair Open
YES
NO
at Connector [22A]?
on GN/R Wire.
5028
Repair
Replace
Interconnect
Tachometer.
YES
NO
Harness.
6009
6532
Handlebar Switch
Accessory
Wiring Pinched or
Fuse OK?
Damaged?
YES
NO
YES
NO
Locate and Repair
Replace 15 Amp
Open on O/W Wire
Accessory Fuse.
Repair
Replace Cruise
Between Accessory
Wiring.
Engaged Lamp.
5145
Fuse and Connector
6552
5182
[22A].
5028
After correction of problem, restart 7.2 CRUISE INOPERATIVE DIAGNOSTICS
to verify proper performance.
7-12
2005 Touring: Cruise Control
HOME
CRUISE CHART D: CRUISE POWER
7.7
DIAGNOSTICS
Test 7.7
Remove Left Saddlebag and Side Cover. Disconnect Connector [17B] From Cruise Module. See Figure 7-6.
Place the Positive Probe on the O/V Terminal (F) and the Negative Probe on the BK Terminal (E). With the Igni-
tion/Light Key Switch Positioned to IGNITION, the Meter Should Read Battery Voltage. Does It?
YES
NO
Replace
Check Continuity Between the
Cruise
BK Terminal (E) and Ground.
Module.
Continuity Present?
6635
YES
NO
Check for Continuity Between
Correct Open in
O/V Terminal (F) and the 15
Ground Wire.
Amp Cruise Fuse. Continuity
5038
Present? See Figure 7-10.
YES
NO
Check for Power at
Locate and Repair Open on
R/GY Wire in Fuse
O/V Wire Between Cruise
Block. Power Present?
Fuse and Connector [17B].
5028
YES
NO
Replace
Repair Open
15 Amp
Between Cruise
Fuse.
Fuse and R/GY
Wire of Ignition
5145
Switch.
5028
After correction of problem, restart 7.2 CRUISE INOPERATIVE DIAGNOSTICS
to verify proper performance.
2005 Touring: Cruise Control
7-13
HOME
1.
Right Handlebar Switch Controls [22]
5. Fairing Cap (FLHTCU)
2.
Main to Interconnect Harness [2]
6. Main to Interconnect Harness [1]
3.
Speedometer Gauge [39]
7. Main to Interconnect Harness [156]
4.
Left Handlebar Switch Controls [24]
7
FLHTC/U
2
6
3
4
f2238x8x
5
1
FLTR
4
6
7
1
2
f2269x8x
Figure
7-9. Outer Fairing Removed
7-14
2005 Touring: Cruise Control
HOME
CRUISE CHART E: CRUISE ENABLE
7.8
DIAGNOSTICS
Test 7.8
Diagnostic Notes
Remove Left Saddlebag and Side Cover. Disconnect Connector [17B] From Cruise Module.
See Figure 7-6.
1.
Use HARNESS CONNECTOR TEST KIT
Place Positive Probe on R/GN Terminal (A) and the Negative Probe on the BK Terminal (E).
(Part No. HD-41404A), black pin probes
With the ignition and Cruise Switches On, the Meter Should Read Battery Voltage. Does It?
and patch cords.
2.
Use HARNESS CONNECTOR TEST KIT
(Part No. HD-41404A),
black socket
NO
probes and patch cords.
YES
Replace
FLH TCU-I, FLTR/I
FLHRC-I
Cruise
Module.
Remove the Ignition/Light Key Switch
Battery Voltage
1
6635
Knob and Fairing Cap to Access
Present on Terminal 1
Switch Terminals.
(R/GN Wire) of
With the Ignition/Light Key Switch Posi-
Connector [158B]?
tioned to IGNITION and the Fairing
Cap Cruise ON/OFF Switch Positioned
to ON, the Meter Should Read Battery
YES
NO
Voltage on the R/GN Terminal of the
Cruise Switch. Does It?
Locate and
Battery Voltage
2
Repair Open
Present on Terminal
on R/GN Wire
1 (O/W Wire) of
YES
NO
Between Con-
Connector [24A]?
nectors [158A]
and [17B].
Check for Battery Voltage at R/GN
Measure Voltage at
Wire of Connector [105]. See Fig-
O/V Terminal of
5028
YES
NO
ure 7-9. Voltage Present?
Switch. Meter Should
Read Battery
NOTE
Voltage. Does It?
Handlebar Switch
Accessory
It may be necessary to open sec-
Wiring Pinched or
Fuse OK?
ondary lock to perform check.
Damaged?
YES
NO
YES
NO
YES
NO
YES
NO
2
Replace Cruise
Disconnect Connec-
Locate and
Replace
Enable
tor [105]. See Figure
Repair Open on
15 Amp
Check for Battery
Repair Wire
Repair
Replace
ON/OFF Switch.
7-9. Measure Volt-
O/W Wire
Accessory
Voltage at R/GN Wire
Between Switch
Handlebar
Cruise
age on O/V Wire of
Between Acces-
Fuse.
of Connector [156A].
and Connector
5192
Wiring.
Enable
Connector [105A].
sory Fuse and
See Figure 7-7 or
[105].
Switch.
Voltage Present?
6552
Connector [24A].
5145
Figure 7-8. Voltage
5192
5128
Present?
5028
YES
NO
YES
NO
Repair Open
Repair Open in
Repair Main
Repair or Replace
Between Cruise
Interconnect
Harness.
Interconnect
Switch and
Harness.
Harness.
Connector [105].
5028
6532
6532
5192
After correction of problem, restart 7.2 CRUISE INOPERATIVE DIAGNOSTICS
to verify proper performance.
2005 Touring: Cruise Control
7-15
HOME
CRUISE CHART F-1: BRAKE LIGHTS ON
7.9
DIAGNOSTICS
Test 7.9
CONSTANT BRAKE LIGHT INPUT
Verify That Front Brake Light Switch is Properly Positioned
Inside Lower Right Switch Housing (Retention Clip in Place).
Is It?
YES
NO
Remove Left Saddlebag and Side Cover. Mea-
Install
sure Voltage at R/BE Wire Terminal (86) of the
Retention Clip.
Brake Light Relay. See Figure
7-10. Meter
Should Read Battery Voltage
Only When
Brakes are Applied. Does It?
YES
NO
Replace Brake
Remove One of the Spade Termi-
Light Relay.
nals From the Rear Brake Light
Switch. Are Brake Lights Still Lit?
5169
YES
NO
Replace Front
Replace Rear
Brake Light Switch.
Brake Light Switch.
5176
5141
After correction of problem, restart 7.2 CRUISE INOPERATIVE DIAGNOSTICS
to verify proper performance.
Accessory
Brake Light
Relay
Brakes/Cruise
f2204x8x
Figure 7-10. Fuse Block (FLHTCU-I)
7-16
2005 Touring: Cruise Control
HOME
CRUISE CHART F-2: BRAKE LIGHTS OFF
7.10
DIAGNOSTICS
Test 7.10 (Part 1 of 2)
NO FRONT AND/OR REAR BRAKE LIGHTS
Remove Left Saddlebag and Side Cover to
Access Brake Light Relay. See Figure 7-10.
With Ignition/light Key Switch Positioned to
IGNITION and Brakes Applied, Check for
Power on R/BE Wire at Terminal (86) of the
Brake Light Relay.
Meter Should Read Battery Voltage. Does It?
YES
NO
Locate and
With Ignition/Light Key Switch
Repair Open on
Turned to IGNITION and Rear
R/BE Wire in
Brake Applied, Check for
Main Harness.
Power at R/BE Wire of Rear
Brake Light Switch. Battery
5028
Voltage Present?
YES
NO
With Ignition/Light Key
Switch Turned to IGNI-
STOP
TION, Check for Power at
O/W Terminal of Rear
Brake Light Switch. Battery
Go to Test 7.10 (Part 2 of 2)
Voltage Present?
YES
NO
Replace
Locate and Repair
Rear Brake
Open on O/W
Light Switch.
Wire in Main Har-
ness Between
5141
Rear Brake Light
Switch and Acces-
sory Fuse.
5028
After correction of problem, restart 7.2 CRUISE INOPERATIVE DIAGNOSTICS
to verify proper performance.
2005 Touring: Cruise Control
7-17
HOME
Test 7.10 (Part 2 of 2)
NO FRONT AND/OR REAR BRAKE LIGHTS
Diagnostic Notes
Continued from Test 7.10 (Part 1 of 2).
1.
Use HARNESS CONNECTOR TEST KIT
(Part No. HD-41404A), black pin probes
With Ignition/Light Key Switch Turned to IGNI-
and patch cords.
TION and Front Brake Applied, Check for
2.
Use HARNESS CONNECTOR TEST KIT
Power at R/BE Wire of Rear Brake Light
Switch. Battery Voltage Present?
(Part No. HD-41404A), black
socket
probes and patch cords.
YES
NO
Repair Open in
FLH TCU-I, FLTR/I
FLHRC-I
2
Main Harness
Between Rear
Remove Outer Fairing.
1
Battery Voltage
Brake Light
Switch and Brake
With Ignition/Light Key
Present on Terminal 1
Light Relay.
Switch Turned to IGNITION
(O/W Wire) of Con-
and Front Brake Applied,
nector [22A]?
5028
Check for Power at R/BE
Wire of Connector
[2B].
See Figure
7-9. Battery
Voltage Present?
YES
NO
2
Check for Continuity
Accessory
at Terminals 1 and 2
Fuse OK?
YES
NO
of Connector [22B]
With Front Brake
Applied. Continuity
Repair Open
1
With Ignition/Light Key
YES
NO
Present?
Between Connector
Switch turned to IGNITION
[2B] and Rear Brake
and Front Brake Applied,
Light Switch.
Check for Power at R/BE
Locate and
Replace
Wire of Connector [22A].
Repair Open on
15 Amp
5028
YES
NO
O/W Wire
Accessory
See Figure
7-9. Battery
Voltage Present?
Between Acces-
Fuse.
sory Fuse and
Locate and Repair
Handlebar
5145
Connector [22A].
Open on R/BE Wire
Switch Wiring
Between Connector
Pinched or
5028
YES
NO
[22A] and Brake
Damaged?
Light Relay.
Repair Open in
With Ignition/Light
Key
5028
R/BE Wire of
Switch Turned to IGNITION,
YES
NO
Interconnect
Check for Power at O/W
Harness.
Wire of Connector
[22A].
Battery Voltage Present?
6532
Repair
Replace
Handlebar
Front Brake
Wiring.
Light Switch.
YES
NO
6552
5176
Handlebar Switch
Repair Open
Wiring Pinched or
in O/W Wire.
Damaged?
6532
YES
NO
Repair
Replace
Wiring.
Front Brake
Light Switch.
6552
5176
After correction of problem, restart 7.2 CRUISE INOPERATIVE DIAGNOSTICS
to verify proper performance.
7-18
2005 Touring: Cruise Control
HOME
CRUISE CHART G: THROTTLE SWITCH
7.11
DIAGNOSTICS
Test 7.11
THROTTLE SWITCH
Remove Left Saddlebag and Side Cover. Disconnect Connector [17B] From
Cruise Module. See Figure 7-11.
With the Ignition/Light Key Switch Positioned to OFF, Check Continuity
Between the V/Y Terminal (D) and the O/V Terminal (F). The Meter Should
Read Infinity When the Throttle Switch is in the Relaxed Position and Continu-
ity When the Throttle Grip is Rolled Forward. Are These Your Observations?
YES
NO
Restart 7.2 CRUISE INOPERA-
Adjust the Idle Throttle Cable
TIVE DIAGNOSTICS to Verify
and Retest for Continuity.
That Problem is Corrected. If the
Continuity Present?
Cruise Engaged Lamp Will Not
Illuminate When This Step is
Performed Now, Replace The
Cruise Module.
YES
NO
6635
System
Check for Continuity Directly at
OK.
Throttle Switch. Continuity
Should Only be Present When
the Throttle is Rolled Forward
Under Pressure. Is It?
YES
NO
Battery Voltage
Replace Idle
Present on O/V
Throttle
Throttle Switch
Cable.
Terminal [75D]?
2241
YES
NO
After correction of problem, restart 7.2 CRUISE INOPERATIVE DIAGNOSTICS
to verify proper performance.
Locate and
Locate and Repair
Repair Open
Open on O/V Throttle
on Y/V Wire in
Switch Wires in Main
Main Harness.
Harness.
5028
5028
Cruise Module
Connector [17]
f2206x8x
Figure 7-11. Left Side Cover Removed
2005 Touring: Cruise Control
7-19
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