Harley Davidson 2005 touring models. Service repair manual — page 45
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DIAGNOSTIC INTRODUCTION
4.2
SYSTEM PROBLEMS
All system problems fall into at least one of three general cat-
egories.
60
40
50
70
30
50
40
80
No Start
30
90
20
MPH
RPM x100
20
100
The engine cranks over freely, but will not start. This does not
10
10
110
include situations where the engine will not crank, such as a
0
120
0
bad starter, dead battery, etc. This condition assumes that all
obvious checks (fuel in tank, etc.) have been made.
TI
-D
-D
Poor Performance
The engine starts but there are performance problems. These
problems may include poor fuel economy, rough idle, engine
misfire, engine hesitation, severe spark knock, etc.
Check Engine Lamp
f2160x8x
Check Engine Lamp
Figure 4-2. Speedometer
See Figure 4-2. The check engine lamp indicates the ignition
control module (ICM) has determined a fault condition exists.
There may also be starting or performance problems.
RESOLVING PROBLEMS
To resolve system problems, five basic steps are involved. In
order of occurrence, they are:
1.
Check for diagnostic trouble codes (DTCs) by observing
check engine lamp. See 4.3 CHECKING FOR TROUBLE
CODES.
2.
Retrieve DTCs using speedometer self diagnostics. See
4.5 SPEEDOMETER SELF DIAGNOSTICS.
3.
Diagnose system problems. This involves using special
tools and the diagnostic flow charts in this section.
4.
Correct problems through the replacement and/or repair
of the affected components.
5.
After repairs are performed, the work must be validated.
This involves clearing the DTCs and confirming proper
vehicle operation as indicated by the behavior of the
check engine lamp.
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2005 Touring: Engine Management (Carbureted)
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CHECKING FOR TROUBLE CODES
4.3
CHECK ENGINE LAMP
To diagnose system problems, start by observing the behav-
ior of the check engine lamp.
NOTE
●
See Figure 4-3. “Key ON” means that the ignition key is
turned to ON and the engine stop switch is set to RUN
(although the engine is not running).
●
When the ignition switch is turned ON, the check engine
lamp will illuminate for approximately four seconds and
then turn off.
●
If the check engine lamp is not illuminated at key ON or if
it fails to turn OFF after the ititial four second period, then
f1240x2x
see 4.5 SPEEDOMETER SELF DIAGNOSTICS.
●
If the check engine lamp comes on late (after 20 sec-
Figure 4-3. Ignition Switch (FLHT/C)
onds), the problem is likely a serial data bus failure. Test
for codes using speedometer self diagnostics. See 4.5
SPEEDOMETER SELF DIAGNOSTICS.
c. Come back on, and remain on, if a current trouble
●
If the check engine lamp fails to turn OFF after the initial
code exists. See C of Figure 4-4.
four second period, then a problem exists in the instru-
mentation. See 4.5 SPEEDOMETER SELF DIAGNOS-
2.
See CODE TYPES which follows for a complete descrip-
TICS.
tion of trouble code formats.
NOTE
1.
When the lamp turns off after being illuminated for the
Trouble codes relating to the ignition coil can only be fully
first four second period, it will:
diagnosed during actuation. For example, a problem with the
a. Remain off if there are no fault conditions or trouble
ignition coil will be considered a current fault even after the
codes currently detected by the ignition control mod-
problem is corrected, since the ignition control module will not
ule. See A of Figure 4-4.
know of its resolution until after the coil is exercised by vehicle
b. Come back on for an 8 second period if only historic
start sequence. In this manner, there may sometimes be a
codes exist. See B of Figure 4-4.
false indication of the current trouble code.
ON
4 Sec.
A
Lamp OFF: No Current or Historic Trouble Codes
OFF
Key On
Lamp ON 8 Seconds:
Only Historic Trouble Codes Exist
ON
4 Sec.
8 Sec.
B
Lamp OFF
OFF
4 Sec.
Key On
Lamp Remains ON: Current Trouble Code *
ON
4 Sec.
C
OFF
4 Sec.
Key On
* Historic Trouble Codes May Also Exist
Figure 4-4. Check Engine Lamp Operation
2005 Touring: Engine Management (Carbureted)
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CODE TYPES
RETRIEVING DIAGNOSTIC
TROUBLE CODES
There are two types of diagnostic trouble codes (DTCs):
current and historic. If a trouble code is stored, it can be read
using the speedometer self diagnostics. See 4.5 SPEEDOM-
The engine management system provides two levels of diag-
ETER SELF DIAGNOSTICS.
nostics.
All trouble codes reside in the memory of the ignition control
● The most sophisticated mode employs a computer
module (ICM) until cleared using the speedometer self diag-
based diagnostic package called DIGITAL TECHNICIAN
nostics. See 4.5 SPEEDOMETER SELF DIAGNOSTICS.
(Part No. HD-44750).
A trouble code is also cleared after a total of 50 trips has
elasped. A trip consists of a start and run cycle, the run cycle
● The second mode requires using the speedometer self
lasting at least 30 seconds. After the 50 trip retention period,
diagnostics. Speedometer, tachometer
(if equipped),
the trouble code is automatically erased from memory provid-
TSM/TSSM and ECM codes can be accessed and
ing that no subsequent faults of the same type are detected in
cleared. See
4.5 SPEEDOMETER SELF DIAGNOS-
that period.
TICS.
Current
MULTIPLE DIAGNOSTIC TROUBLE
Current trouble codes are those which presently disrupt
CODES
motorcycle operation. See the appropriate flow charts for
solutions.
While it is possible for more than one fault to occur and set
Historic
more than one trouble code, there are several conditions
which may result in one fault setting multiple trouble codes:
If a particular problem happens to resolve itself, the active
status is dropped and it becomes a historic fault rather than a
● Serial data codes (DTC U1016, U1064, U1097, U1255,
current fault.
U1300 and U1301) may be accompanied by other
codes. Always correct the serial data codes before
Historic trouble codes can only be retrieved using a computer
resolving the other codes.
based diagnostic package called DIGITAL TECHNICIAN
(Part No. HD-44750).
For proper resolution to multiple trouble codes refer to diag-
Historic trouble codes are stored for a length of time to assist
nostic code priority chart (Table 4-5.)
in the diagnosis of intermittent faults.
It is important to note that historic trouble codes may also be
present whenever the system indicates the existence of a
current fault. See MULTIPLE DIAGNOSTIC TROUBLE
CODES if multiple trouble codes are found.
Diagnostic charts are designed for use with current trouble
codes and as a result they frequently suggest wire repair or
part replacement.
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INITIAL DIAGNOSTIC CHECK: ICM
4.4
GENERAL
INITIAL DIAGNOSTICS
To locate faulty circuits or other system problems, follow the
diagnostic flow charts in this section. For a systematic
General Information
approach, always begin with INITIAL DIAGNOSTICS which
The diagnostic check is an organized approach to identifying
follows. Read the general information and then work your way
a problem caused by an electronic control system malfunc-
through the flow chart box by box.
tion. If no problems are found after completion of the diagnos-
tic check, a comparison of running parameters may be used
to help locate intermittents and out-of-specification sensors.
Diagnostic Notes
See Table 4-1.
If a numbered circle appears adjacent to a flow chart box,
then more information is offered in the diagnostic notes. Many
diagnostic notes contain supplemental information, descrip-
Diagnostic Tips
tions of various diagnostic tools or references to other parts
● If Speedometer reads “BUS Er” with the ignition key
of the manual.
turned ON (engine stop switch at RUN with the engine
off), check data bus for an open or short to ground
between data connector [91A] terminal 3 and ICM con-
Circuit Diagram/Wire Harness Connector
nector [10B] terminal 12, TSSM connector [30B] terminal
Table
3, Speedometer connector [39B] terminal 2 or tachome-
ter (if equipped) connector [108B] terminal 2.
When working through a flow chart, refer to the illustrations,
the associated circuit diagram and the wire harness connec-
● Check for an open diagnostic test terminal between data
tor table as necessary. The wire harness connector table for
link connector [91A] terminal 3 and TSM/TSSM connec-
each circuit diagram identifies the connector number, descrip-
tor [30B] terminal 3. With ignition key turned ON, serial
tion, type and general location.
data bus voltage should be typically 0.6-0.8 volts. The
range of acceptable voltage is 0-7.0 volts.
In order to perform most diagnostic routines, a Breakout Box
and a DVOM are required. See 4.6 BREAKOUT BOX: ICM.
To perform the circuit checks with any degree of efficiency, a
Diagnostic Notes
familiarity with the various wire connectors is necessary.
The reference numbers below correlate with the circled num-
bers on the diagnostic check flow charts. See page 4-10.
Reprogramming ICM
1. Compare engine behavior to symptoms tables in this
section.
Diagnostic charts frequently suggest ICM replacement. In the
event an ignition control module (ICM) needs to be replaced,
a. Starts hard. See Table 4-2.
it must be reprogrammed using a computer based diagnostic
b. Hesitates, stumbles, surges, misfires and/or slug-
package called DIGITAL TECHNICIAN (Part No. HD-44750).
gish performance. See Table 4-3.
See your dealer. Password learn procedure must also be per-
formed. See 3.24 PASSWORD LEARN.
c. Engine exhaust emits black smoke or fouls plugs.
See Table 4-4.
2. Use HARNESS CONNECTOR TEST KIT (Part No. HD-
41404A), black socket probes and patch cord.
3. Connect BREAKOUT BOX (Part No. HD-42682) to igni-
tion control module. See 4.6 BREAKOUT BOX: ICM.
All diagnostic codes are listed in Table 4-5.
See 3.9 INITIAL DIAGNOSTIC CHECK: TSM/TSSM for any
codes related to the turn signal module (TSM) or turn signal
security module (TSSM).
See 2.5 BREAKOUT BOX: SPEEDOMETER for any codes
related to the speedometer.
2005 Touring: Engine Management (Carbureted)
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Table 4-1. Typical Running Values
Table 4-3. Engine Performance Problems
MIN.
MAX.
HOT
SYMPTOM
SOLUTION
ITEM
VALUE
VALUE
IDLE
Perform intake leak test.
4.96 V
Manifold leak
See 4.8 INTAKE LEAK
0.1 V
(atmo-
TEST.
MAP sensor
(high
1.5-3.0 V
spheric
vacuum)
MAP sensor plugged or not
4.13 DTC P0106, P0107,
pressure)
operating properly
P0108
RPM
0
5600
1000
Drain and refill with fresh
Bank angle
Run mode
Disable
Run mode
Water or dirt in fuel system
fuel.
sensor
0.45-1.1 V
1.8-3.2 V
0.45-1.1 V
Spark plugs
4.12 MISFIRE.
EVAP hose disconnected
Connect.
from induction module (CA)
Table 4-2. Engine Starts Hard
See throttle cable adjust-
Throttle plates not opening
SYMPTOM
SOLUTION
ment in Touring Service
fully
Manual.
See charging system trouble-
Battery discharged
shooting in this section.
Spark plugs
4.12 MISFIRE.
Table 4-4. Engine Exhaust Emits
Spark plug wires
4.12 MISFIRE
Black Smoke or Fouls Plugs
Ignition coil
4.12 MISFIRE.
See Section 3 in Touring Ser-
SYMPTOM
SOLUTION
Valve sticking
vice Manual.
See Section 1 in Touring
Clogged air filter
Water or dirt in fuel system
Drain and refill with fresh fuel.
Service Manual.
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2005 Touring: Engine Management (Carbureted)
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Table 4-5. Diagnostic Trouble Codes (DTC) and Fault Conditions
PRIORITY
DTC NO.
FAULT CONDITION
SOLUTION
RANKING
1
P0605
Flash memory error
4.19 DTC P0602, P0603, P0604, P0605, P0607
2
P0603
EEProm memory error
4.19 DTC P0602, P0603, P0604, P0605, P0607
3
P0602
Flash memory error
4.19 DTC P0602, P0603, P0604, P0605, P0607
4
P0604
RAM memory error
4.19 DTC P0602, P0603, P0604, P0605, P0607
5
P0607
A to D error
4.19 DTC P0602, P0603, P0604, P0605, P0607
6
“BUS Er”
Serial data bus shorted low/open/high
4.10 STARTS, THEN STALLS
7
U1300
Serial data shorted low
4.10 STARTS, THEN STALLS
8
U1301
Serial data shorted high
4.10 STARTS, THEN STALLS
9
U1064
Lost TSM/TSSM communication
4.20 DTC U1064
10
U1097
Lost speedometer communication
4.21 DTC U1097
11
U1255
Missing response at TSSM
4.20 DTC U1064
12
U1255
Missing response at speedometer
4.21 DTC U1097
TSM/TSSM disabled fuel due to bad
13
P1009
4.15 DTC P1009, P1010
password
TSM/TSSM disabled fuel due to no pass-
14
P1010
4.15 DTC P1009, P1010
word (starts then stalls)
15
P0371
Crankshaft position sensor shorted low
4.17 DTC P0371, P0372, P0374
16
P0372
Crankshaft position sensor shorted high
4.17 DTC P0371, P0372, P0374
Crankshaft position sensor not detected/
17
P0374
4.17 DTC P0371, P0372, P0374
cannot synchronize
B1151
Sidecar BAS low
Sidecar DTCs apply only to Touring models
equipped with sidecars. If these DTCs are
18
B1152
Sidecar BAS high
present on non sidecar equipped motorcycles,
B1153
Sidecar BAS out of range
the TSM/TSSM is not properly configured.
19
P0106
MAP sensor rate-of-change error
4.13 DTC P0106, P0107, P0108
20
P0107
MAP sensor failed open/low
4.13 DTC P0106, P0107, P0108
21
P0108
MAP sensor failed high
4.13 DTC P0106, P0107, P0108
22
P1351
Ignition coil driver front low/open
4.16 DTC P1351, P1352, P1354, P1355
23
P1354
Ignition coil driver rear low/open
4.16 DTC P1351, P1352, P1354, P1355
24
P1352
Ignition coil driver front high
4.16 DTC P1351, P1352, P1354, P1355
25
P1355
Ignition coil driver rear high
4.16 DTC P1351, P1352, P1354, P1355
26
P0562
System voltage low
4.14 DTC P0562, P0563
27
P0563
System voltage high
4.14 DTC P0562, P0563
28
P0501
VSS failed low
4.18 DTC P0501, P0502
29
P0502
VSS failed high/open
4.18 DTC P0501, P0502
2005 Touring: Engine Management (Carbureted)
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f2332e8x
[156B] [156A]
Main to Interconnect
6
6
Harness
5
5
4
4
3
3
GY
BK
2
2
BK
LtGN/V
1
1
LtGN/V
O
1
2
3
4 5 6 7 8 9 10 11 12
[30B]
BN/GY
1
2
3
4 5 6 7 8 9 10 11 12
[30A]
TSM/TSSM
BN/GY
[39B]
GY
BK
1
2
3
4 5 6 7 8 9 10 11 12
[39A]
1
2
3
4 5 6 7 8 9 10 11 12
1
2
3
4 5 6 7 8 9 10 11 12
[8B]
Speedometer
1
2
3
4 5 6 7 8 9 10 11 12
1
2
3
4 5 6 7 8 9 10 11 12
[8A]
[108B]
1
2
3
4 5 6 7 8 9 10 11 12
Ignition
To
[108A]
Harness
Ignition
Tachometer
Keyswitch
Relay
15A
Instruments
[1B] [1A]
Fuse
1
2
Main to Interconnect
3
[2A]
1
2
3
4 5 6 7 8 9 10 11 12
Harness
4
Data Link
[2B]
1
2
3
4 5 6 7 8 9 10 11 12
[91A]
Main to Interconnect
15A
Harness
Ignition
Fuse
12
15A
[10B]
Battery
12
[10A]
Ignition Control Module
Fuse
Figure 4-5. Diagnostic Check (FLHT/C)
Table 4-6. Wire Harness Connectors in Figure 4-5.
NO.
DESCRIPTION
TYPE
LOCATION
[1]
Main to Interconnect Harness
12-Place Deutsch (Black)
Inner Fairing - Right Radio Support Bracket
[2]
Main to Interconnect Harness
12-Place Deutsch (Gray)
Inner Fairing - Right Fairing Support Brace
[8]
Ignition Harness
12-Place Deutsch
Under Right Side Cover
[10]
Ignition Control Module
12-Place Deutsch
Under Right Side Cover
Cavity in Crossmember at Rear of
[30]
Turn Signal/Security Module
12-Place Deutsch
Battery Box (Under Seat)
[39]
Speedometer
12-Place Packard
Inner Fairing (Back of Speedometer)
[91]
Data Link
4-Place Deutsch
Under Right Side Cover
[108]
Tachometer
12-Place Packard
Inner Fairing (Back of Tachometer)
[156]
Main to Interconnect Harness
6-Place Deutsch
Inner Fairing - Right Fairing Support Brace
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f2332d8x
BK
GY
LtGN/V
LtGN/V
BK
BN/GY
O
1
2
3
4
5 6 7 8 9 10 11 12
[30B]
1
2
3
4
5 6 7 8 9 10 11 12
[30A]
BN/GY
TSM/TSSM
BK
1
2
3
4 5 6 7 8 9 10 11 12
[39B]
1
2
3
4 5 6 7 8 9 10 11 12
[39A]
GY
Speedometer
1
2
3
4
5
6
7
8
9
10 11 12
[8B] Ignition
15A
1
2
3
4
5
6
7
8
9
10 11 12
[8A] Harness
Instruments
Fuse
15A
Battery
Fuse
1
To
2
Ignition
Keyswitch
3
Relay
4
Data Link
[91A]
15A
Ignition
Fuse
12
[10B]
[10A]
Ignition Control Module
12
Figure 4-6. Diagnostic Check (FLHR/S)
Table 4-7. Wire Harness Connectors in Figure 4-6.
NO.
DESCRIPTION
TYPE
LOCATION
[8]
Ignition Harness
12-Place Deutsch
Under Right Side Cover
[10]
Ignition Control Module
12-Place Deutsch
Under Right Side Cover
Cavity in Crossmember at Rear of
[30]
Turn Signal/Security Module
12-Place Deutsch
Battery Box (Under Seat)
[39]
Speedometer
12-Place Packard
Under Console (Back of Speedometer)
[91]
Data Link
4-Place Deutsch
Under Right Side Cover
2005 Touring: Engine Management (Carbureted)
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Initial Diagnostic Check (Part 1 of 2)
Does engine
start?
YES.
YES.
NO.
NO.
Starts and
Starts, then
Cranks, but
Engine will not
runs.
stalls.
will not start.
crank.
Check for trouble
See 4.10 STARTS, THEN
See 4.9 ENGINE CRANKS,
See 1.2 STARTING SYSTEM
1
codes. See 4.5
STALLS.
BUT WILL NOT START.
DIAGNOSIS.
SPEEDOMETER
SELF DIAGNOSTICS
Codes found?
NO
YES
With ignition switch OFF, press and
Refer to applicable trouble code priority chart.
release odometer reset switch. Does
All diagnostic codes are listed on page 4-7 in
odometer display appear?
Table 4-5. Codes are listed by priority.
YES
NO
STOP
Check for continuity to ground on terminal 7
of speedometer. Wiggle harness during con-
tinuity check. Continuity present?
Go to Initial Diagnostic
Check (Part 2 of 2).
YES
NO
Check for battery voltage at
Locate and
terminal 5 of speedometer
repair open.
while wiggling harness. Bat-
tery voltage continuously
present?
YES
NO
Check continuity (with ignition
switch OFF) between terminals
Locate and
8 and 11 on breakout box. Con-
repair open.
tinuity present when speedome-
ter reset switch is depressed?
YES
NO
Replace speedometer.
Replace speedometer
reset switch.
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2005 Touring: Engine Management (Carbureted)
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Initial Diagnostic Check (Part 2 of 2)
Continued from Initial Diagnostic
Check (Part 1 of 2).Turn ignition
switch ON, is odometer backlight
present?
YES
NO
Perform “wow” test. See 4.5 SPEEDOMETER SELF DIAGNOSTICS.
The following features should be functional
Replace Speedometer.
1) backlight should illuminate
2) needle should sweep its full range of motion
3) LED’s should illuminate:
• check engine
• battery
• security (all models)
• low fuel (EFI models)
• cruise (even though not cruise equipped)
Are all features functional?
YES
NO
Turn key to ACC. Is
Check for battery voltage at
backlight present?
1
terminal 1 of breakout box.
Battery voltage present?
YES
NO
YES
NO
No trouble found.
Check for battery voltage
Replace speedometer.
Is instrument
at terminal 6. Battery volt-
Is problem intermittent?
fuse blown?
age present?
YES
YES
NO
NO
Replace speedometer.
Locate and repair open on
Locate and repair
Locate and repair open
O/W wire between terminal 6
source of fault.
between terminal 1 and
and accessory fuse.
Replace fuse.
instrument fuse.
NO.
NO.
YES
Speedometer Inoperative
Tachometer Inoperative
(no vehicle speed).
(no engine speed).
Repeat Diagnostic
Check while wiggling
Remove and inspect vehi-
harnesses.
cle speed sensor. Debris
See Test 2.4 (Part 1 of 2)
present?
under 2.4 SPEEDOMETER/
TACHOMETER.
YES
NO
Remove debris. Reinstall
Check for damaged wiring/
Vehicle speed sensor.
loose connection between
vehicle speed sensor and ICM.
Is wiring damage/loose
connection present?
YES
NO
Locate and repair
Replace Speedometer.
source of fault.
2005 Touring: Engine Management (Carbureted)
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SPEEDOMETER SELF DIAGNOSTICS
4.5
GENERAL
d0715x8x
The speedometer is capable of displaying and clearing
speedometer, tachometer, TSM/TSSM, and ICM/ECM trouble
codes (diagnostic mode).
DIAGNOSTICS
Diagnostic Tips
● For a quick check of speedometer function, a “wow” test
can be performed. Press and hold odometer reset switch
then turn ignition switch ON. Release reset switch. Back-
ground lighting should illuminate, speedometer needle
should sweep its full range of motion, and indicator
lamps [battery, security, low fuel
(EFI models) check
engine and cruise] should illuminate. Some lamps may
1
5
illuminate even though they do not apply to the vehicle.
2
3
4
For example, the cruise lamp may illuminate even though
the motorcycle may not be cruise equipped.
1.
Cruise On/Engaged
4.
Battery
● If instrument module fails “wow” test, check for battery,
2.
Check Engine
5.
Security
ground, ignition, speedometer reset switch and acces-
3.
Low Fuel
sory to speedometer. If any feature in the speedometer is
non-functional, see 2.2 INITIAL DIAGNOSTIC CHECK:
SPEEDOMETER.
Figure 4-7. Speedometer (FLHR/S)
Diagnostic Notes
Use of speedometer self diagnostics assumes that DIGITAL
TECHNICIAN (Part No. HD-44750) is not available.
The reference numbers below correlate with the circled num-
bers in the Speedometer Self Diagnostics (chart)
1. To exit diagnostic mode, turn ignition switch OFF.
2. To clear DTCs for selected module, press speedometer
reset switch for more than 5 seconds when code is dis-
played. This procedure will clear all codes for selected
module.
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2005 Touring: Engine Management (Carbureted)
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Speedometer Self Diagnostics (chart)
1
While holding odometer reset switch in,
turn ignition switch to IGN. Make sure
Run/Stop switch is in RUN position.
Release reset switch.
Does “diag” appear?
YES
NO
See 2.2 INITIAL DIAGNOSTIC
To display DTCs for the
CHECK: SPEEDOMETER.
ICM, press and hold
”P” flashing.
reset switch for more
than 5 seconds.
To choose TSM/
TSSM, press and
release reset switch.
To display DTCs for
TSM/TSSM, press and
”S” flashing.
hold reset switch for
more than 5 seconds.
To
choose Speedometer,
Device
response?
press and release reset
switch.
NO
YES
“no rsp” displayed.
To display DTCs for
See applicable code from
”SP” flashing.
speedometer, press and
other modules. Models not
hold reset switch for more
equipped with a tachometer
than 5 seconds.
will display “no rsp” normally.
If “no rsp” displayed on odom-
eter on tachometer equipped
To choose Tachometer,
“none” displayed.
vehicle, see 2.4 SPEEDOME-
press and release reset
TER/TACHOMETER.
switch.
DTC
2
displayed.
To display DTCs for
tachometer, press and
Press and release
Press and release
”T” flashing.
hold reset switch for more
reset switch. Part num-
reset switch.
than 5 seconds.
ber of module will be
Are more DTCs
displayed.
displayed?
NO
To choose ICM, press and
YES
release reset switch.
“end” displayed.
To clear all DTCs for
selected module hold reset
switch for more than 5 sec-
onds. If DTCs are not to be
cleared, Press and release
reset switch. Part number of
module will be displayed.
Press and release reset
switch again to continue to
next module.
Figure 4-8. Speedometer Self Diagnostics
2005 Touring: Engine Management (Carbureted)
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BREAKOUT BOX: ICM
4.6
GENERAL
f2191x8x
The BREAKOUT BOX (Part No. HD-42682) splices into the
main harness. Used in conjunction with a DVOM, it allows cir-
cuit diagnosis of wiring harness and connections without hav-
ing to probe with sharp objects.
INSTALLATION
1.
Remove right saddlebag and side cover.
2.
Depress latches on connector [10] to separate pin and
socket halves.
3.
Attach Breakout Box as follows:
a. Mate black socket housing on Breakout Box with
ICM connector [10A].
Ignition Control Module
Connector [10]
b. Mate black pin housing on Breakout Box with har-
ness connector [10B].
Figure 4-9. Electrical Bracket (Under Right Side Cover)
REMOVAL
1. Remove Breakout Box as follows:
a. Remove black socket housing on Breakout Box from
ICM connector [10A].
b. Remove black pin housing on Breakout Box from
harness connector [10B].
2. Mate pin and socket halves of ICM connector [10].
3. Install side cover and saddlebag.
f2001x8x
Connect Black Side
Only for Tests
f1998x9x
Figure 4-10. Breakout Box (Part No. HD-42682)
4-14
2005 Touring: Engine Management (Carbureted)
HOME
WIGGLE TEST
4.7
GENERAL
hd39978
The wiggle test indicates the presence of intermittents in a
wiring harness.
PROCEDURE
1. See Figure 4-11. Connect DVOM (Part No. HD-39978) to
wiring harness between the suspect connections. When
diagnosing ignition module connections, a BREAKOUT
Figure 4-11. Fluke 78 Multimeter (DVOM)
BOX (Part No. HD-42682) may be used to simplify the
(Part No. HD-39978)
procedure. See 4.6 BREAKOUT BOX: ICM.
2.
Set DVOM to read voltage changes.
3.
Start motorcycle engine and run at idle.
4.
Shake or wiggle harness to detect intermittents. If inter-
mittents are present, radical voltage changes will register
on the DVOM.
2005 Touring: Engine Management (Carbureted)
4-15
HOME
INTAKE LEAK TEST
4.8
GENERAL
9648
1WARNING
Propane is an extremely flammable liquid and vapor.
Vapor may cause flash fire. Keep away from heat, sparks
and flame. Keep container closed. Use only with ade-
quate ventilation. Failure to follow this alert can result in
death or serious injury.
1WARNING
Read all directions and warnings on propane bottle. Fail-
ure to follow all directions and warnings on bottle could
result in death or serious injury.
Figure 4-12. Nozzle
● To prevent false readings, keep airbox cover installed
9649
when performing test.
1
4
● Do not direct propane into air cleaner, false readings will
result.
3
5
LEAK TESTER
2
Parts List
6
● Standard 14 oz. propane cylinder.
● Propane Enrichment Kit (HD-41417).
●
12 inches (304 mm) long-1/4 inch (6 mm) diameter cop-
per tubing.
Tester Assembly
1.
Nozzle
1. Cut rubber hose from kit to 18 inches (457 mm) in length.
2.
Copper tube
3.
Hose
2. See Figure 4-12. Flatten one end of copper tube to form
4.
Valve
a nozzle.
5.
Knob
3. Insert round side of copper tube into end of tubing.
6.
Propane bottle
Figure 4-13. Leak Tester
4-16
2005 Touring: Engine Management (Carbureted)
HOME
INTAKE LEAK TESTING
10054
1. Start engine.
2. Warm engine to operating temperature.
3. See Figure 4-13. Turn knob (5) counterclockwise to open
propane bottle.
1WARNING
Propane is an extremely flammable liquid and vapor.
Vapor may cause flash fire. Keep away from heat, sparks
and flame. Keep container closed. Use only with ade-
quate ventilation.
Figure 4-14. Checking for Leaks
NOTE
Do not direct propane stream toward front of engine. If pro-
pane enters air cleaner, a false reading will be obtained.
4. See Figure 4-14. Aim nozzle toward possible sources of
leak such as fuel injectors and intake tract.
5. See Figure 4-13. Push valve (4) to release propane.
Tone of engine will change when propane enters source
of leak.
2005 Touring: Engine Management (Carbureted)
4-17
HOME
ENGINE CRANKS, BUT WILL NOT START
4.9
GENERAL
d0273x8x
If starter will not crank engine, the problem is not ignition
related. Refer to SECTION 1-STARTING & CHARGING.
DIAGNOSTICS
Diagnostic Notes
The reference numbers below correlate with the circled num-
bers on the Test 4.9 flow charts.
Figure 4-15. Spark Tester
1.
Check for trouble codes. See RETRIEVING DIAGNOS-
TIC TROUBLE CODES under 4.3 CHECKING FOR
TROUBLE CODES.
2.
Check the condition of the battery. Perform a voltage test
and recharge if below 12.60V. Check battery connections
and perform load test. Replace the battery if necessary.
3.
Remove spark plug cable from spark plug.
a. Visually check condition of plug.
b. See Figure 4-15. Attach cable to SPARK TESTER
(Part No. HD-26792). Clip tester to cylinder head
bolt.
c. While cranking engine, look for spark. Repeat pro-
cedure on other spark plug cables.
NOTE
Engine will not spark with both spark plugs removed. When
10561
checking for spark, use SPARK TESTER (Part No. HD-
26792) with both plugs installed.
Figure 4-16. Ignition Coil Circuit Test
4.
Use HARNESS CONNECTOR TEST KIT (Part No. HD-
41404A) gray pin probes and patch cords.
7.
Use HARNESS CONNECTOR TEST KIT (Part No. HD-
5.
See Figure 4-16. Plug IGNITION COIL CIRCUIT TEST
41404A), gray pin probe and patch cord.
ADAPTER (Part No. HD-44687) and FUEL INJECTOR
TEST LAMP (Part No. HD-34730-2C) into Breakout Box.
8.
Use HARNESS CONNECTOR TEST KIT (Part No. HD-
Note that cranking the engine with test lamp in place of
41404A), brown socket probe and patch cord.
the ignition coil can sometimes cause a DTC P1351,
P1352, P1354 or P1355. This condition is normal and
does not by itself indicate a malfunction. Clear codes
afterward.
6.
Connect BREAKOUT BOX (Part No. HD-42682). See 4.6
BREAKOUT BOX: ICM.
4-18
2005 Touring: Engine Management (Carbureted)
HOME
Crankshaft
Position
Sensor
1
2
[79A]
[79B]
Ignition Control Module
R/BK To Ignition Switch
9
[83B]
BK
Crank Sensor (-)
8
R
Crank Sensor (+)
7
A
Y \ BE
Rear Coil
B
6
C
BE \ O
Front Coil
5
15 Amp
BK
Ground
Ignition Fuse
W
Ignition
\
B
Coil
K
GY
1
W \ BK
Key ON Power
To TSM/TSSM
[10B]
[10A]
[8A]
To
1
2
3
4
5
6
7
8
9
10
11
12
[8B]
Data Link
Ground Stud
[1B]
1
2
3
4
5
6
7
8
9
10
11
12
[1A]
FLHT/C Only
GY
Engine Stop Switch
W \ BK
6-Place on FLHR/S
[22B]
1
2
3
4
5
6
7
8
9
10
11
12
[22A]
Figure 4-17. Ignition Circuit
Table 4-8. Wire Harness Connectors in Figure 4-17.
NO.
DESCRIPTION
MODEL
TYPE
LOCATION
Main to Interconnect
[1]
FLHT/C
12-Place Deutsch (Black)
Inner Fairing - Right Radio Support Bracket
Harness
[8]
Ignition Harness
All
12-Place Deutsch
Under Right Side Cover
[10]
Ignition Control Module
All
12-Place Deutsch (Black)
Under Right Side Cover
Interconnect to Right
FLHT/C
12-Place Deutsch
Inner Fairing- Right Fairing Support Brace
[22]
Handlebar Switch Controls
FLHR/S
6-Place Deutsch
Inside Headlamp Nacelle
[83]
Ignition Coil
All
3-Place Packard
Below Fuel Tank (Left Side)
2005 Touring: Engine Management (Carbureted)
4-19
HOME
Test 4.9 (Part 1 of 3)
ENGINE CRANKS, BUT WILL NOT START
Fresh fuel in tank?
Spark plug wires firmly
connected to proper coil
terminals?
Add fuel and
NO
connect spark
plugs.
YES
Check battery connections
Check for trouble
and voltage. Is voltage
1
codes.
above 12.60?
Codes found?
2
NO
YES
NO
YES
Does battery pass
Recharge battery.
See priority listing
load test?
in Table 4-5.
YES
NO
Check spark plug condition,
Replace battery.
3
replace if fouled. Check
spark at both plugs while
cranking. Spark present?
YES
NO
Turn ignition ON and engine
Check compression. If compression is
stop switch to RUN.
good, check fuel system.
Does check engine lamp
illuminate for 4 seconds?
immediately after Key ON?
YES
NO
Check battery voltage at
See
4
Terminal B of coil connector
4.11 NO SPARK/NO ICM
[83B] using DVOM. Battery
POWER.
voltage present?
YES
NO
Locate and repair open on W/
Go to Test 4.9
STOP
BK wire to coil.
(Part 2 of 3).
4-20
2005 Touring: Engine Management (Carbureted)
HOME
Test 4.9 (Part 2 of 3)
ENGINE CRANKS, BUT WILL NOT START
Continued from Test 4.9 (Part 1 of 3).
Install Breakout Box and test light for the next
inspection.
Front coil code: Check between
5
Terminals 1 and 6 on Breakout Box.
Rear coil code: Check between
6
Terminals 1 and 7 on Breakout Box.
Does test lamp flash when engine is cranked?
YES
NO
Check coil connections.
Connect Breakout Box. Check continuity
Connections OK?
between socket A of connector [83B]
and terminal 7 (BK) on Breakout Box.
7
Measure resistance between socket C of
connector [83B] and terminal 6 (BK) on
Breakout Box.
Is resistance less than 1.0 ohm?
YES
NO
Test spark plug cable resis-
Repair.
tance. See 4.12 MISFIRE.
Resistance OK?
YES
NO
Connect DVOM to terminals 8 and 9
Poor connection at con-
(BK) of connector [10] on Breakout Box
nector [10B] or open in
YES
NO
and set it for AC volts. Crank engine.
harness between coil
Does DVOM read 1 VAC minimum?
and ICM. Repair open.
Plug wires in correct
Replace spark
coil towers?
plug cables.
YES
NO
YES
NO
Disconnect connector [79].
Replace
Route
8
Check connector for moisture
coil.
correctly.
STOP
and corrosion. Check wires for
chafing. Connect DVOM to ter-
minals 1 and 2 of connector
Go to Test 4.9
(Part 3 of 3).
[79A]. Crank engine. Does
DVOM read 1 VAC minimum?
YES
NO
Check for continuity between
With meter still connected,
socket 1 of connector [79B]
check for resistance.
and terminal 8 of connector
Is resistance 600-1200 ohms?
[10] on Breakout Box.
Continuity present?
YES
NO
YES
NO
Remove and inspect CKP
Replace CKP
Locate and repair open on
Locate and repair open on
sensor. Remove any debris on
sensor.
BK wire between socket 2 of
R wire between socket 1 of con-
sensor. Reinstall sensor.
connector [79B] and socket 9
nector [79B] and socket 8 of
of connector [10B].
connector [10B].
2005 Touring: Engine Management (Carbureted)
4-21
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