Harley Davidson 2005 touring models. Service repair manual — page 48

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f2332e8x

[156B] [156A]

Main to Interconnect

Harness

LtGN/V

4 5 6 7 8 9 10 11 12

[30B]

BN/GY

4 5 6 7 8 9 10 11 12

[30A]

TSM/TSSM

BN/GY

[39B]

4 5 6 7 8 9 10 11 12

[39A]

4 5 6 7 8 9 10 11 12

[8B]

Speedometer

4 5 6 7 8 9 10 11 12

[8A]

[108B]

4 5 6 7 8 9 10 11 12

Ignition

Harness

[108A]

Tachometer

Ignition

Keyswitch

Relay

15A

Instruments

[1B] [1A]

Fuse

Main to Interconnect

[2A]

4 5 6 7 8 9 10 11 12

Harness

Data Link

[2B]

4 5 6 7 8 9 10 11 12

[91A]

Main to Interconnect

15A

Harness

Ignition

Fuse

15A

[10B]

Battery

[10A]

Ignition Control Module

Fuse

Figure 4-45. Serial Data Circuit (FLHT/C)

Table 4-33. Wire Harness Connectors in Figure 4-45.

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

4-62

2005 Touring: Engine Management (Carbureted)

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f2332d8x

LtGN/V

BN/GY

5 6 7 8 9 10 11 12

[30B]

5 6 7 8 9 10 11 12

[30A]

BN/GY

TSM/TSSM

4 5 6 7 8 9 10 11 12

[39B]

4 5 6 7 8 9 10 11 12

[39A]

Speedometer

10 11 12

[8B] Ignition

15A

10 11 12

[8A] Harness

Instruments

Fuse

15A

Battery

Fuse

Ignition

Keyswitch

Relay

Data Link

[91A]

15A

Ignition

Fuse

[10B]

[10A]

Ignition Control Module

Figure 4-46. Serial Data Circuit (FLHR/S)

Table 4-34. Wire Harness Connectors in Figure 4-46.

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)

4-63

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Test 4.21

LOSS OF SPEEDOMETER SERIAL DATA:

DTC U1097

IMPORTANT: ALWAYS START FROM INITIAL

DIAGNOSTIC CHECK ICM 4.4

Can you read ECM/ICM hardware part number?

See 4.5 SPEEDOMETER SELF DIAGNOSTICS.

YES

NO or “No Rsp”

While wiggling harness, check continuity

Check continuity between terminal 2 (black) of

between terminal 2 (black) of Breakout

Breakout Box and terminal 12 of connector [10B].

Box and terminal 12 of connector [10B].

Continuity present?

YES

Replace speedometer.

Repair open on

Clear codes. Test ride.

Repair intermittent

Lt GN/V wire.

Does DTC U1097

on LtGN/V wire.

return?

Clear codes using speedometer self diagnostics.

YES

See 4.5 SPEEDOMETER SELF DIAGNOSTICS.

Confirm proper operation with no check engine

lamp.

Replace ICM.

No trouble found.

Reprogram and learn

password.

4-64

2005 Touring: Engine Management (Carbureted)

Table Of Contents

ENGINE MANAGEMENT (EFI)

SUBJECT

PAGE NO.

5.1 Specifications

5-1

5.2 EFI System

5-3

5.3 EFI Diagnostic Introduction

5-5

5.4 Checking For Diagnostic Trouble Codes: EFI

5-6

5.5 Initial Diagnostic Check: EFI

5-8

5.6 Speedometer Self Diagnostics

5-17

5.7 Breakout Box

5-19

5.8 Wiggle Test

5-20

5.9 Intake Leak Test

5-21

5.10 Engine Cranks, But Will Not Start

5-23

5.11 No ECM Power

5-30

5.12 Starts, Then Stalls

5-35

5.13 Fuel System Electrical Test

5-40

5.14 System Relay Check

5-45

5.15 Fuel Pressure Test

5-50

5.16 Idle Air Control

5-54

5.17 Misfire at Idle or Under Load

5-59

5.18 Combustion Absent/Intermittent

5-64

5.19 DTC P0107, P0108

5-69

5.20 DTC P0112, P0113

5-73

5.21 DTC P0117, P0118

5-77

5.22 DTC P0122, P0123

5-81

5.23 DTC P0261, P0262, P0263, P0264

5-85

5.24 DTC P0373, P0374

5-91

5.25 DTC P0501, P0502

5-94

5.26 DTC P0562, P0563

5-98

5.27 DTC P0603, P0605

5-103

5.28 DTC P1009, P1010

5-104

5.29 DTC P1351, P1352, P1354, P1355

5-108

5.30 DTC U1064, U1255

5-113

5.31 DTC U1097, U1255

5-117

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SPECIFICATIONS

5.1

System Fuse Block (Under Left Side Cover)

IGNITION

DATA

0°-45° BTDC (range)

FLHR/C/S

Spark timing advance

12° BTDC@1000 RPM

Idle speed

990 ± 50 RPM

Spark plug size

12 mm

0.038-0.043 in

Spark plug gap

0.97-1.09 mm

Harley-Davidson

Spark plug type

No. 6R12 (no substitute)

Ignition coil primary

0.3-0.5 ohms

resistance

f2210x8x

Ignition coil secondary

2500-3500 ohms

resistance

FLTR, FLHT/C/U

Rating

Circuit

Color

(Amperes)

System Fuses

Maxi-Fuse

Orange

Headlamp

Blue

Ignition

Blue

Lighting

Blue

f2204x8x

Instruments

Blue

Brakes/Cruise

Blue

Headlamp

Radio Power

Ignition

Accessory

Radio Memory

Blue

Lighting

Battery

Radio Power

Red

Instruments

10.

Brake Light Relay

Brakes/Cruise

11.

P&A

Accessory

Blue

Radio Memory

12.

Starter Relay

Battery

Blue

EFI Fuse Block (Under Right Side Cover)

P & A

Blue

EFI Fuses

EFI System

Relay

Fuel Pump

Blue

Spare

ECM Power

Blue

Fuel Pump

ECM Power

f2223x9x

Figure 5-1. Fuse Locations

2005 Touring: Engine Management (EFI)

5-1

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NOTES

5-2

2005 Touring: Engine Management (EFI)

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EFI SYSTEM

5.2

The bank angle sensor is within the TSM/TSSM. If the vehicle

GENERAL

lean angle exceeds 45 degrees for one second, the fuel

pump is shut off. Once the sensor is tripped, the motorcycle

The engine management system consists of the following

must be uprighted, turned off and then on again before the

components:

engine can be restarted. This is communicated across the

data bus.

● Electronic control module (ECM).

Front and rear coils fire each spark plug independently (one

● Crank position sensor (CKP).

cylinder at a time - no wasted spark). The coil also has an

extra terminal to monitor current on the coil secondary circuit.

● Manifold absolute pressure sensor (MAP).

This is used for knock detection and combustion diagnostics.

● Intake air temperature sensor (IAT).

The ignition system gives a spark near top dead center for

● Engine temperature sensor (ET).

starting. At RPM and loads above this, the system gives a

spark advance that varies between 0° and 50°.

● Idle air control (IAC).

The IAT, ET and TP sensors are used to provide information

● Throttle position sensor (TP).

to the ECM to fine tune spark and fuel delivery. The VSS is

used as an input for idle speed control.

● Vehicle speed sensor (VSS).

● Turn signal module (TSM) or optional, factory-installed

EFI ENGINE HEAT MANAGEMENT

turn signal security module (TSSM). This includes an

integrated bank angle sensor (BAS).

● Ignition coil.

Injected Twin Cam High Temperature Idle

The ECM is mounted to the electrical bracket under the right

NOTE

side cover. It computes the spark advance for proper ignition

Fuel injected Twin Cam engines use a three phase heat man-

timing based on sensor inputs (from CKP, MAP and TP sen-

agement system to reduce engine temperature under

sor) and regulates the low-voltage circuits between battery

extreme conditions. A rider with a very hot engine may notice

and ignition coil.

the effects of this three phase heat management system and

incorrectly assume an idle problem exists.

The ECM contains all of the solid state components used in

the ignition system. The dwell time for the ignition coil is also

Phase 1

calculated in the microprocessor and is dependent upon bat-

tery voltage. The programmed dwell is an added feature to

When the engine temperature sensor signals that the cylinder

give adequate spark at all speeds. (The ECM has added pro-

head has reached approximately 320°F (160°C) the ECM will

tection against transient voltages, continuous reverse voltage

gradually reduce engine idle speed until the engine tempera-

protection, and damage due to jump starts.) The ECM is fully

ture drops or the engine reaches 800 rpm.

enclosed to protect it from vibration, dust, water or oil. This

unit is a non-repairable item. If it fails, it must be replaced.

Phase 2

The crank position sensor (CKP) is located in the front left

If engine temperature reaches 338°F (170°C), the ECM rich-

side of the crankcase. The CKP generates an AC signal

ens the air/fuel ratio to provide additional cooling.

which is sent to the ECM where it is used to reference engine

position (TDC) and speed. It functions by taking readings off

Phase 3

the 30 teeth on the left side flywheel (two teeth are missing to

establish a reference point).

If the engine temperature reaches 356° F (180° C), fuel injec-

tor pulses are interrupted. The air drawn in and expelled

The MAP sensor is located on top of the intake manifold. The

helps cool the engine further. Since there is no combustion it

MAP sensor monitors the intake manifold pressure (vacuum)

would be perceived as a misfire. This third stage will only hap-

and sends the information to the ECM where the module

pen when the motorcycle is stationary.

adjusts the spark and fuel timing advance curve for optimum

performance.

TROUBLESHOOTING

See the diagnostic charts that follow for troubleshooting infor-

mation.

2005 Touring: Engine Management (EFI)

5-3

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[62B]

CKP

To Tachometer

Y/GN

[78]

(FLHR/C/S Optional)

System

relay

BE/GY

[79A]

GN/O

[79B]

W/BK

15 Amp

fuel pump

[13A] [13B]

fuse

System relay

GN/O

Fuel

O/GY

pump

Y/GN

Inj. F

W/Y

[141B] [141A]

[84B]

[84A]

Y/GN

All Except

FLHR/C/S

[83B]

[83A]

Inj. R

GN/GY

[85B]

[85A]

Coil

Ion sense

GY/BE

Coil R

Y/BE

Coil F

BE/O

BE/GN

40 Amp

BN/R

Maxi fuse

BK/PK

BK/O

15 Amp

Battery

ECM fuse

[87A]

[87B]

Constant

BE/GY

Intake air

power

control

15 Amp

IGN fuse

Switch power

W/BK

R/BK

Ignition switch

BK/W

R/W

sensor

TP sensor

GY/V

To right

[90B] [90A]

hand controls

[88B] [88A]

ET sensor

PK/Y

ET sensor

BK/W

Engine

IAT sensor

LT GN/Y

stop

IAT sensor

5v sensor gnd.

BK/W

[22A]

switch

[89B] [89A]

[80B] [80A]

BK/W

MAP

MAP sensor

V/W

sensor

5v sensor pwr.

R/W

Vehicle

Vehicle speed sensor

speed

W/GN

sensor

[65B] [65A]

Serial data

LT GN/V

To speedometer

and tachometer

[91A]

Data link

connector

[30B]

TSM/

Power gnd.

TSSM

[30A]

Power gnd.

f2332g8x

Figure 5-2. EFI System Circuit - Simplified

5-4

2005 Touring: Engine Management (EFI)

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EFI DIAGNOSTIC INTRODUCTION

5.3

SYSTEM PROBLEMS

All system problems fall into at least one of three general cat-

egories.

No Start

MPH

RPM x100

100

The engine cranks over freely, but will not start. This does not

110

include situations where the engine will not crank, such as a

security disabled starter, dead battery, etc. This condition

120

assumes that all obvious checks (fuel in tank, etc.) have been

made.

-D

Poor Performance

The engine starts but there are performance problems. These

problems may include poor fuel economy, rough idle, engine

Check Engine Lamp

misfire, engine hesitation, severe spark knock, etc.

f2160x8x

Figure 5-3. Speedometer

Check Engine Lamp

See Figure 5-3. The check engine lamp indicates the ECM

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 by using speedome-

ter self diagnostics. See 5.4 CHECKING FOR DIAG-

NOSTIC TROUBLE CODES: EFI.

2. Retrieve diagnostic trouble codes by using speedometer

self diagnostics. See 5.6 SPEEDOMETER SELF DIAG-

NOSTICS.

Diagnose system problems. This involves using special

tools and the diagnostic flow charts in this section.

Correct problems through the replacement and/or repair

of the affected components.

After repairs are performed, the work must be validated.

This involves clearing the trouble codes and confirming

proper vehicle operation as indicated by the lack of trou-

ble codes.

2005 Touring: Engine Management (EFI)

5-5

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CHECKING FOR DIAGNOSTIC TROUBLE CODES: EFI

5.4

CHECK ENGINE LAMP

To diagnose system problems, start by observing the behav-

ior of the check engine lamp.

NOTES

● See Figure 5-4. “Key ON” means that the ignition key is

turned to IGN and the engine stop switch is set to RUN

(although the engine is not running).

● When the ignition key is turned ON, the check engine

lamp will illuminate for approximately four seconds and

then turn off.

f1240x2x

● If the check engine lamp is not illuminated at Key ON or if

it fails to turn OFF after the initial four second period,

then the speedometer may need to be replaced. See 5.5

Figure 5-4. Ignition Switch (FLTR, FLHT/C/U)

INITIAL DIAGNOSTIC CHECK: EFI.

1. When the lamp turns off after being illuminated for the

See CODE TYPES which follows for a complete descrip-

first four second period, it will:

tion of trouble code formats.

a. Remain off if there are no fault conditions or trouble

NOTE

codes currently detected by the ignition control mod-

Some trouble codes can only be fully diagnosed during actu-

ule. See A of Figure 5-5.

ation. For example, a problem with the ignition coil will be

b. Come back on for an 8 second period if only historic

considered a current fault even after the problem is corrected,

codes exist. See B of Figure 5-5.

since the ECM will not know of its resolution until after the coil

is exercised by vehicle start sequence. In this manner, there

c. Come back on, and remain on, if a current trouble

may sometimes be a false indication of the current trouble

code exists. See C of Figure 5-5.

code.

4 Sec.

Lamp OFF: No Current or Historic Trouble Codes

OFF

Key On

Lamp ON 8 Seconds:

Only Historic Trouble Codes Exist

4 Sec.

8 Sec.

Lamp OFF

OFF

4 Sec.

Key On

Lamp Remains ON: Current Trouble Code *

4 Sec.

OFF

4 Sec.

* Historic Trouble Codes May Also Exist

Key On

Figure 5-5. Check Engine Lamp Operation

5-6

2005 Touring: Engine Management (EFI)

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CODE TYPES

RETRIEVING DIAGNOSTIC

TROUBLE CODES

There are two types of diagnostic trouble codes (DTCs): cur-

rent and historic. If a diagnostic trouble code is stored, it can

be read using speedometer self diagnostics. See

5.6

The engine management system provides two levels of diag-

SPEEDOMETER SELF DIAGNOSTICS.

nostics.

All diagnostic trouble codes reside in the memory of the

● The most sophisticated mode uses a computer based

ECM/ICM, TSM/TSSM, speedometer or tachometer until the

diagnostic package called the DIGITAL TECHNICIAN

code is cleared by use of the speedometer self diagnostics.

(Part No. HD-44750).

See 5.6 SPEEDOMETER SELF DIAGNOSTICS.

● The second mode requires using the speedometer self

A historic diagnostic trouble code is also cleared after a total

diagnostics. Speedometer, tachometer

(if equipped),

of 50 trips has elapsed. A trip consists of a start and run

TSM/TSSM and ECM codes can be accessed and

cycle. After the 50 trip retention period, the diagnostic trouble

cleared. See 5.6 SPEEDOMETER SELF DIAGNOSTICS

code is automatically erased from memory providing that no

for more information.

subsequent faults of the same type are detected in that

period.

MULTIPLE DIAGNOSTIC TROUBLE

Current

CODES

Current trouble codes are those which occur during the

present ignition cycle. See the appropriate flow charts for

solutions.

While it is possible for more than one fault to occur and set

more than one trouble code, there are several conditions

Historic

which may result in one fault setting multiple trouble codes:

If a particular problem happens to resolve itself, the active

● The MAP and TP and vehicle speed sensors are con-

status problem is dropped and it becomes a historic code

nected to the same reference line (+5V Vref). If the refer-

rather current code.

ence line goes to ground or open, multiple codes will be

Historic codes are stored for a length of time to assist in the

set (DTC P0107, P0122 and P0501).

diagnosis of intermittent faults. See Figure 5-5. The check

● Serial data codes (DTC U1300, U1301, U1016, U1064,

engine lamp will come back on for 8 seconds to indicate the

U1097 and U1255) may be accompanied by other

existence of only historic codes.

codes. Always correct the serial data codes before

It is important to note that historic codes may also be present

resolving the other codes.

whenever the system indicates the existence of a current

Refer to Table 5-5. This table gives most ECM DTCs a priority

code. See MULTIPLE DIAGNOSTIC TROUBLE CODES if

multiple trouble codes are found.

ranking.

Diagnostic charts are designed for use with current trouble

codes and as a result they frequently suggest part replace-

ment. When diagnosing a historic code the charts can be

helpful but should not lead to part replacement without verifi-

cation the part is faulty.

2005 Touring: Engine Management (EFI)

5-7

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INITIAL DIAGNOSTIC CHECK: EFI

5.5

GENERAL

Diagnostic Tips

● If speedometer reads “No Rsp” (no response) while in

To locate faulty circuits or other system problems, follow the

diagnostic mode, check data bus for an open or short to

diagnostic flow charts in this section. For a systematic

ground between data connector [91A] Terminal 3 and

approach, always begin with INITIAL DIAGNOSTICS which

ECM, TSM/TSSM, tachometer (if equipped) or speedom-

follows. Read the general information and then work your way

eter. For more information on speedometer diagnostic

through the flow chart box by box.

mode see 5.6 SPEEDOMETER SELF DIAGNOSTICS.

Diagnostic Notes

● Check for an open diagnostic test terminal between data

Terminal 3 and ECM Terminal 5. With ignition key turned

If a numbered circle appears adjacent to a flow chart box,

ON, transmit data should be typically 0.6-0.8 volts. The

then more information is offered in the diagnostic notes. Many

range of acceptable voltage is greater than 0 and less

diagnostic notes contain supplemental information, descrip-

than 7.0 volts.

tions of various diagnostic tools or references to other parts

● If speedometer reads “BUS er” (serial data bus error),

of the manual where information on the location and removal

refer to flow charts in 5.12 STARTS, THEN STALLS.

of components may be obtained.

Diagnostic Notes

Circuit Diagram/Wire Harness

Connector Table

The reference numbers below correlate with the circled num-

bers on the diagnostic check flow charts. See page 5-15.

When working through a flow chart, refer to the illustrations,

the associated circuit diagram and the wire harness connec-

Compare engine behavior to symptoms tables.

tor table as necessary. The wire harness connector table for

each circuit diagram identifies the connector number, descrip-

a. Starts hard. Refer to Table 5-2.

tion, type and general location.

b. Hesitates, stumbles, surges, misfires and/or slug-

In order to perform most diagnostic routines, a Breakout Box

gish performance. Refer to Table 5-3.

and a DVOM are required. See 5.7 BREAKOUT BOX: EFI.

c. Engine exhaust emits black smoke or fouls plugs.

Refer to Table 5-4.

To perform the circuit checks with any degree of efficiency, a

familiarity with the various wire connectors is also necessary.

Connect BREAKOUT BOX (Part No. HD-43682) to

speedometer using HD-46601 adapters.

Reprogramming ECM

All EFI diagnostic codes are listed on page 5-11 in Table 5-5.

Diagnostic charts frequently suggest ECM replacement. In

the event an electronic control module (ECM) needs to be

Other Codes

replaced, it must be reprogrammed using a computer based

diagnostic package called DIGITAL TECHNICIAN (Part No.

See 3.9 INITIAL DIAGNOSTIC CHECK: TSM/TSSM for any

HD-44750). See your dealer. Password learn procedure must

codes related to the turn signal module (TSM) or turn signal

also be performed. See 3.24 PASSWORD LEARN.

security module (TSSM).

See 2.2 INITIAL DIAGNOSTIC CHECK: SPEEDOMETER for

any codes related to the speedometer or tachometer.

INITIAL DIAGNOSTICS

General Information

The diagnostic check

(see page

5-15) is an organized

approach to identifying a problem caused by an electronic

control system malfunction.

5-8

2005 Touring: Engine Management (EFI)

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Table 5-1. Typical Scan Values for

Table 5-2. Engine Starts Hard

Engine Data

SYMPTOM

SOLUTION

MIN.

MAX.

HOT

ITEM

See charging system trouble-

VALUE

IDLE

Battery discharged

shooting in this section.

10.3-13.3 in. Hg

10 kPa

104 kPa

5.17 MISFIRE AT IDLE OR

35-45 kPa

Spark plugs

MAP sensor

UNDER LOAD.

0 volts

5.1 volts

5.17 MISFIRE AT IDLE OR

Spark plug wires

100

UNDER LOAD.

TP sensor

0.2 volts

4.5 volts

0.2-1.0 volts

5.17 MISFIRE AT IDLE OR

Ignition coil

UNDER LOAD.

IAC pintle

155

30-45 steps

See Section 3 in the Touring

RPM

800

5600

990

Valve sticking

Service Manual.

3° F

464° F

230-300° F

Water or dirt in fuel system

Drain and refill with fresh fuel.

(-16° C)

(240° C)

(110-150° C)

ET sensor

Loss of battery power to

0.0 volts

5.0 volts

0.5-3.23 volts

5.11 NO ECM POWER

ECM terminal 31*

3° F

248° F

104-140° F

IAT sensor

(-16° C)

(120° C)

(40-60° C)

* Codes will not clear (although they appear to).

0.0 volts

5.0 volts

2.0-3.5 volts

INJ PW front

50 mS

2-4 mSec

INJ PW rear

50 mS

2-4 mSec

Advance front

45°

10-15°

Advance rear

45°

10-15°

VSS

120

0 MPH

Battery voltage

14.5 volts

ENG RUN

off

Run

Idle RPM

900

1250

990

NOTE

Hot idle specifications are with stock exhaust, the engine

operating at 990 RPM and an engine temperature of approxi-

mately 260° F (127° C). Idle settings may be changed with

the idle set procedure. See the Touring Service Manual.

2005 Touring: Engine Management (EFI)

5-9

HOME

Table 5-3. Engine Performance Problems

Table 5-4. Engine Exhaust Emits

Black Smoke or Fouls Plugs

SYMPTOM

SOLUTION

SYMPTOM

SOLUTION

Manifold leak

See

5.9 INTAKE LEAK

See AIR CLEANER FILTER

TEST.

Clogged air filter

in the Touring Service Man-

NOTE- When manifold leak

is large enough, IAC will

A low IAC count may also

ual.

close to 0 and code P0505

indicate an air leak.

MAP sensor plugged or not

5.19 DTC P0107, P0108.

will set

operating properly

MAP sensor plugged or not

5.19 DTC P0107, P0108.

operating properly

Drain and refill with fresh

Water or dirt in fuel system

fuel.

5.17 MISFIRE AT IDLE OR

Spark plugs

UNDER LOAD.

See throttle cable adjust-

Throttle plate not opening

ment in the Touring Service

fully

Manual.

5.15 FUEL PRESSURE

Low fuel pressure

TEST.

5-10

2005 Touring: Engine Management (EFI)

HOME

Table 5-5. EFI Diagnostic Trouble Codes (DTC) and Fault Conditions

PRIORITY

DTC NO.

FAULT CONDITION

SOLUTION

RANKING

P0605

ECM flash error

5.27 DTC P0603, P0605

P0603

ECM EEPROM error

5.27 DTC P0603, P0605

“BUS Er”

Serial data bus shorted low/open/high

5.12 STARTS, THEN STALLS

U1300

ECM serial data low

5.12 STARTS, THEN STALLS

U1301

ECM serial data open/high

5.12 STARTS, THEN STALLS

U1300

TSSM serial data low

5.12 STARTS, THEN STALLS

U1301

TSSM serial data open/high

5.12 STARTS, THEN STALLS

U1300

Speedometer/tachometer serial data low

5.12 STARTS, THEN STALLS

Speedometer/tachometer serial data open/

U1301

5.12 STARTS, THEN STALLS

high

U1064

Loss of TSM/TSSM serial data at ECM

5.30 DTC U1064, U1255

Loss of TSM/TSSM serial data at speedome-

U1064

5.30 DTC U1064, U1255

ter

Loss of all ECM serial data (state of health) at

3.21 DTC U1016, U1255

TSSM

U1016

Loss of all ECM serial data (state of health) at

3.21 DTC U1016, U1255

speedometer

U1097

Loss of speedometer serial data at TSSM

5.31 DTC U1097, U1255

U1255

Missing response at TSSM

3.21 DTC U1016, U1255

U1255

Missing response at speedometer

5.31 DTC U1097, U1255

P1003

System relay contacts open

5.14 SYSTEM RELAY CHECK

P1002

System relay coil high/shorted

5.14 SYSTEM RELAY CHECK

P1001

System relay coil open/low

5.14 SYSTEM RELAY CHECK

P1004

System relay contacts closed

5.14 SYSTEM RELAY CHECK

P1009

Incorrect password

5.28 DTC P1009, P1010

P1010

Missing password (starts then stalls)

5.28 DTC P1009, P1010

P0373

CKP sensor intermittent

5.24 DTC P0373, P0374

P0374

CKP sensor synch error

5.24 DTC P0373, P0374

B1151

Sidecar BAS low

Sidecar DTCs apply only to Touring models

B1152

Sidecar BAS high

equipped with sidecars. If these DTCs are present

on non sidecar equipped motorcycles,

B1153

Sidecar BAS out of range

the TSM/TSSM is not properly configured.

P0122

TP sensor open/low

5.22 DTC P0122, P0123

P0123

TP sensor high

5.22 DTC P0122, P0123

P0107

MAP sensor open/low

5.19 DTC P0107, P0108

P0108

MAP sensor high

5.19 DTC P0107, P0108

P0117

ET sensor voltage low

5.21 DTC P0117, P0118

P0118

ET sensor open/high

5.21 DTC P0117, P0118

P0112

IAT sensor voltage low

5.20 DTC P0112, P0113

P0113

IAT sensor open/high

5.20 DTC P0112, P0113

P1351

Front ignition coil open/low

5.29 DTC P1351, P1352, P1354, P1355

P1354

Rear ignition coil open/low

5.29 DTC P1351, P1352, P1354, P1355

P1352

Front ignition coil high/shorted

5.29 DTC P1351, P1352, P1354, P1355

P1355

Rear ignition coil high/shorted

5.29 DTC P1351, P1352, P1354, P1355

P1357

Front cylinder combustion intermittent

5.18 COMBUSTION ABSENT/INTERMITTENT

P1358

Rear cylinder combustion intermittent

5.18 COMBUSTION ABSENT/INTERMITTENT

P0261

Front injector open/low

5.23 DTC P0261, P0262, P0263, P0264

P0263

Rear injector open/low

5.23 DTC P0261, P0262, P0263, P0264

2005 Touring: Engine Management (EFI)

5-11

HOME

Table 5-5. EFI Diagnostic Trouble Codes (DTC) and Fault Conditions

PRIORITY

DTC NO.

FAULT CONDITION

SOLUTION

RANKING

P0262

Front injector high

5.23 DTC P0261, P0262, P0263, P0264

P0264

Rear injector high

5.23 DTC P0261, P0262, P0263, P0264

P0562

Battery voltage low

5.26 DTC P0562, P0563

P0563

Battery voltage high

5.26 DTC P0562, P0563

P0501

VSS sensor low

5.25 DTC P0501, P0502

P0502

VSS sensor high

5.25 DTC P0501, P0502

P1356

Rear cylinder no combustion

5.18 COMBUSTION ABSENT/INTERMITTENT

P1353

Front cylinder no combustion

5.18 COMBUSTION ABSENT/INTERMITTENT

P0505

Loss of idle speed control

5.16 IDLE AIR CONTROL

B1135

Accelerometer fault

3.19 DTC B1135

B1134

Starter output high

3.18 DTC B1134

B1121

Left turn output fault

3.15 TURN SIGNAL ERRORS

B1122

Right turn output fault

3.15 TURN SIGNAL ERRORS

B0563

Battery voltage high

3.16 DTC B0563

B1131

Alarm output low

3.17 DTC B1131, B1132

B1132

Alarm output high

3.17 DTC B1131, B1132

B1141

Ignition switch open/low

3.15 TURN SIGNAL ERRORS

5-12

2005 Touring: Engine Management (EFI)

HOME

[156B] [156A]

f2332a8x

Main to Interconnect

Harness

LtGN/V

4 5 6 7 8 9 10 11 12

[30B]

BN/GY

4 5 6 7 8 9 10 11 12

[30A]

BN/GY

TSM/TSSM

[39B]

4 5 6 7 8 9 10 11 12

[39A]

Speedometer

4 5 6 7 8 9 10 11 12

[8B]

Ignition

[108B]

4 5 6 7 8 9 10 11 12

[8A]

Harness

[108A]

Tachometer

Ignition

15A

Keyswitch

Instruments

[1B] [1A]

Relay

Fuse

Main to Interconnect

Harness

4 5 6 7 8 9 10 11 12

Data Link

[2B]

4 5 6 7 8 9 10 11 12

15A

[2A]

Ignition

Main to Interconnect

Fuse

[91A]

Harness

[78B]

15A

ECM

Battery

[78A]

Fuse

Figure 5-6. Diagnostic Check (FLTR, FLHT/C/U)

Table 5-6. Wire Harness Connectors in Figure 5-6.

NO.

DESCRIPTION

MODEL

TYPE

LOCATION

Main to Interconnect

FLHT/C

12-Place Deutsch (Black)

Inner Fairing - Right Radio Support Bracket

[1]

Harness

FLTR

12-Place Deutsch (Black)

Inner Fairing - Below Radio (Right Side)

Main to Interconnect

FLHT/C

12-Place Deutsch (Gray)

Inner Fairing - Right Fairing Support Brace

[2]

Harness

FLTR

12-Place Deutsch (Gray)

Inner Fairing - Below Radio (Right Side)

[8]

Main to EFI Harness

All

12-Place Deutsch (Gray)

Under Right Side Cover

Turn Signal/Security

Cavity in Crossmember at Rear of

[30]

All

12-Place Deutsch

Module

Battery Box (Under Seat)

FLHT/C

12-Place Packard

Inner Fairing (Back of Speedometer)

[39]

Speedometer

FLTR

12-Place Packard

Under Bezel (Back of Speedometer)

[78]

Electronic Control Module

All

36-Place Packard

Under Right Side Cover

[91]

Data Link

All

4-Place Deutsch

Under Right Side Cover

FLHT/C

12-Place Packard

Inner Fairing (Back of Tachometer)

[108]

Tachometer

FLTR

12-Place Packard

Under Bezel (Back of Tachometer)

Main to Interconnect

FLHT/C

6-Place Deutsch

Inner Fairing - Right Fairing Support Brace

[156]

Harness

FLTR

6-Place Deutsch

Inner Fairing - Below Radio (Right Side)

2005 Touring: Engine Management (EFI)

5-13

HOME

f2332b8x

LtGN/V

BN/GY

4 5 6 7 8 9 10 11 12

[30B]

4 5 6 7 8 9 10 11 12

[30A]

BN/GY

TSM/TSSM

4 5 6 7 8 9 10

[39B]

4 5 6 7 8 9 10

[39A]

Speedometer

8 9 10 11 12

[8B] Ignition

8 9 10 11 12

[8A] Harness

15A

Instruments

Fuse

15A

Ignition

Battery

Keyswitch

Fuse

Relay

15A

Ignition

Fuse

Data Link

[91A]

[78B]

ECM

[78A]

Figure 5-7. Diagnostic Check (FLHR/C/S)

Table 5-7. Wire Harness Connectors in Figure 5-7.

NO.

DESCRIPTION

TYPE

LOCATION

[8]

Main to EFI Harness

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)

[78]

Electronic Control Module

36-Place Packard

Under Right Side Cover

[91]

Data Link

4-Place Deutsch

Under Right Side Cover

5-14

2005 Touring: Engine Management (EFI)

HOME

Diagnostic Check (Part 1 of 2)

Does engine

start?

YES.

NO.

Starts and

Starts, then

Cranks, but

Engine will not

runs.

stalls.

will not start.

crank.

Check for trouble

See 5.12 STARTS, THEN

See 5.10 ENGINE CRANKS,

See 1.2 STARTING SYSTEM

codes. See 5.6

STALLS.

BUT WILL NOT START.

DIAGNOSIS.

SPEEDOMETER

SELF DIAGNOSTICS

Codes found?

YES

Unable to enter diagnostic mode.

No codes displayed. For

Refer to applicable trouble code priority chart.

With ignition switch OFF, press and

symptoms that may not set

All diagnostic codes are listed on page 5-11

release odometer reset switch.

diagnostic trouble codes,

in Table 5-5. Codes are listed by priority.

Does odometer display appear with

refer to table 5-2, Table 5-3

display backlighting?

and Table 5-4.

YES

STOP

Check for continuity to ground on terminal 7

of speedometer. Wiggle harness during con-

tinuity check. Continuity present?

Go to Diagnostic

Check (Part 2 of 2).

YES

Check for battery voltage at

terminal 5 of speedometer

Locate and repair open

while wiggling harness. Bat-

between terminal 7

tery voltage continuously

and ground.

present?

YES

Check continuity (with ignition

Locate and repair open

switch OFF) between terminals

between terminal 5 and

8 and 11 on breakout box. Con-

battery fuse.

tinuity present when speedome-

ter reset switch is depressed?

Replace speedometer.

Replace speedometer

reset switch.

2005 Touring: Engine Management (EFI)

5-15

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Harley Davidson 2005 touring models. Service repair manual — page 48

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