Harley Davidson 2005 touring models. Service repair manual — page 54

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Test 5.30

LOSS OF TSM/TSSM SERIAL DATA: DTC U1064,

U1255

Can you read TSM/TSSM hardware part number?

See 5.6 SPEEDOMETER SELF DIAGNOSTICS.

YES

NO or “No Rsp”

While wiggling harness, check for continuity

Check for continuity between

between TSSM Breakout Box terminal 3

TSSM Breakout Box terminal 3

(gray) and ECM Breakout Box terminal 5.

(gray) and ECM Breakout Box ter-

Continuity present?

minal 5. Continuity present?

YES

Replace TSM/TSSM.

Repair open on

Clear DTCs. Test ride.

Repair intermittent

Perform password learn.

Lt GN/V wire.

Does DTC U1064 return?

on Lt GN/V wire.

Clear codes using speedometer self diagnostics.

See 5.6 SPEEDOMETER SELF DIAGNOSTICS.

YES

Confirm proper operation with no check engine

lamp.

Replace TSM/TSSM.

No trouble found.

Perform password learn.

5-116

2005 Touring: Engine Management (EFI)

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DTC U1097, U1255

5.31

GENERAL

f2013x8x

Loss of Speedometer Serial Data

The serial data connector provides a means for the speedom-

eter, ECM and TSM/TSSM to communicate their current sta-

tus. When all operating parameters on the serial data link are

within specifications, a state of health message is sent

between the components. A DTC U1255 (only reported by

the TSM/TSSM or speedometer) indicates that no messages

were present during power up of the current key cycle. A DTC

U1097 indicates that there was communication on the data

bus since power up, but was lost or interrupted during that

key cycle.

Table 5-57. Code Description

Turn Signal/Security

DTC

DESCRIPTION

Module

Loss of all speedometer serial data

U1097

(state of health)

Figure 5-75. Remove Seat

U1255

Missing message at speedometer

6924c

DIAGNOSTICS

NOTE

If DTC is historic and not current, wiggle wire harness while

performing voltage and continuity tests to identify intermit-

tents.

Diagnostic Notes

1. Terminal 2: ground (BK)

2. Terminal 3: serial data (Lt GN/V)

The reference numbers below correlate with the circled num-

3. Terminal 4: power (GY)

bers on the test 5.31 flow chart.

1. Mate black pin housing on breakout box with wire har-

Figure 5-76. Data Link Connector

ness connector [39B] using INSTRUMENT HARNESS

ADAPTERS (Part No. HD-46601). Leave speedometer

connector [39A] disconnected.

2. Connect BREAKOUT BOX (Part No. HD-43876) to wire

harness connector [78B]. Leave ECM connector [78A]

disconnected. See Section 5.7 BREAKOUT BOX: EFI.

2005 Touring: Engine Management (EFI)

5-117

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[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 5-77. Serial Data Circuit (FLTR, FLHT/C/U)

Table 5-58. Wire Harness Connectors in Figure 5-77.

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

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)

5-118

2005 Touring: Engine Management (EFI)

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f2332b8x

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

[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 5-78. Serial Data Circuit (FLHR/C/S)

Table 5-59. Wire Harness Connectors in Figure 5-78.

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

2005 Touring: Engine Management (EFI)

5-119

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Test 5.31

LOSS OF SPEEDOMETER SERIAL DATA: DTC

U1097, U1255

IMPORTANT: ALWAYS START FROM INITIAL

DIAGNOSTIC CHECK EFI 5.5

Can you read ECM hardware P/N?

See 5.6 SPEEDOMETER SELF DIAGNOSTICS.

YES

NO or “No rsp”

While wiggling harness, check for

Check for continuity between

continuity between ECM breakout box

ECM breakout box terminal 5

terminal 5 and speedometer breakout

and speedometer breakout

box terminal 2 (black).

Is continuity present?

YES

Clear DTCs. Test Ride.

Repair intermittent on

Did DTC U1097 return?

Lt GN/V wire.

Replace speedometer.

Repair open on

LtGN/V wire.

YES

Clear codes using speedometer self diagnostics.

Replace speedometer

No trouble found.

See 5.6 SPEEDOMETER SELF DIAGNOSTICS.

Confirm proper operation with no check engine

lamp.

5-120

2005 Touring: Engine Management (EFI)

Table Of Contents

SUBJECT

PAGE NO.

6.1 Diagnostic Introduction

6-1

6.2 Diagnostic Mode Overview

6-2

6.3 Breakout Box

6-5

6.4 Radio Symptom 1: Audio Control Inoperative

6-6

6.5 Radio Symptom 2: Mode Control Inoperative

6-9

6.6 Radio Symptom 3: No Sound In External Speakers

6-14

6.7 Radio Symptom 4: AVC Inoperative

6-18

6.8 Radio Symptom 5: Poor Stereo Reception

6-21

6.9 Radio Symptom 6: No Power

6-22

6.10 Radio Symptom 7: CD Will Not Eject

6-25

6.11 Radio Symptom 8: Headset/Microphone Inoperative

6-28

6.12 Radio Symptom 9: Headset Volume/PTT Inoperative

6-31

6.13 Radio Symptom 10: Intercom Inoperative

6-36

6.14 Radio Symptom 11: CB Receiver Inoperative

6-38

6.15 Radio Symptom 12: CB Transmitter Inoperative

6-41

6.16 Radio Symptom 13: PTT/Squelch Inoperative

6-45

6.17 Radio Symptom 14: Handheld Microphone PTT Inoperative

6-48

6.18 Radio Symptom 15: No CB Audio in Headset

6-51

PREMIUM SOUND

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DIAGNOSTIC INTRODUCTION

6.1

GENERAL

Table 6-1. Symptom Table

SYMPTOM

SOLUTION

The radio diagnostics for the Premium Sound System is

symptom based.

Audio Control Inoperative

6.4 RADIO SYMPTOM 1

Simply locate the apparent problem from the list of 15 symp-

Mode Control Inoperative

6.5 RADIO SYMPTOM 2

toms listed in Table 6-1. Take note of the section number and

turn to the flow chart that addresses the problem.

No Sound in One or More

6.6 RADIO SYMPTOM 3

Speakers (External)

NOTE

Automatic Volume Control

6.7 RADIO SYMPTOM 4

If the problem is not listed or is intermittent, locate the most

(AVC) Inoperative

relative symptom and inspect connectors for moisture or cor-

rosion. Also look for backed out terminals, improper mating,

Poor Stereo Reception

6.8 RADIO SYMPTOM 5

broken locks, improperly formed or damaged terminals, poor

No Power

6.9 RADIO SYMPTOM 6

terminal-to-wire connection and damaged harness.

CD Will Not Eject

6.10 RADIO SYMPTOM 7

At the beginning of the section, follow the SETUP instructions

and then review the FUNCTIONALITY description to deter-

No Sound in One or More

mine whether the system is operating as intended. If it

Headsets/Microphone

6.11 RADIO SYMPTOM 8

appears that the system is not working correctly, validate the

Inoperative

problem by performing the flow chart under SOFTWARE

DIAGNOSIS. (See Section 6.2 DIAGNOSTIC MODE OVER-

Rear Headset Volume/PTT

6.12 RADIO SYMPTOM 9

VIEW to gain a general understanding of how the on-board

Inoperative

diagnostics work.)

Intercom Inoperative

6.13 RADIO SYMPTOM 10

If the Diagnostic Mode indicates that a malfunction exists,

CB Receiver Inoperative

6.14 RADIO SYMPTOM 11

refer to the flow chart under HARDWARE DIAGNOSIS for

correction of the problem.

CB Transmitter Inoperative

(With CB Antenna Test and

6.15 RADIO SYMPTOM 12

Work your way through each flow chart box by box. If a num-

SWR Adjustment)

bered circle appears adjacent to a box, then more information

is offered in the Diagnostic Notes. Many Diagnostic Notes

PTT/Squelch Control

6.16 RADIO SYMPTOM 13

contain supplemental information, helpful tips or references

Inoperative

to other parts of the manual.

Handheld Microphone PTT

6.17 RADIO SYMPTOM 14

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

Inoperative

and the Wire Harness Connector table as necessary. The

No CB Audio in Headset in

wire harness connector table identifies the connector num-

6.18 RADIO SYMPTOM 15

Center Position

ber, description, type and general location.

After correction of the problem, refer back to SETUP and

Not Applicable to Classic/Road Glide Models

FUNCTIONALITY to verify proper operation.

2005 Touring: Sound System

6-1

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DIAGNOSTIC MODE OVERVIEW

6.2

GENERAL

Push any two Preset buttons and turn

the Ignition/Light Key Switch to IGNITION.

Push any two of four Preset buttons on the front panel of the

radio. See Figure 6-1. With the buttons depressed, turn the

Ignition/Light Key Switch to IGNITION. Diagnostic Group 1,

the first of five diagnostic screens, appears on the LCD dis-

play, as indicated by the “d1” in the lower portion. Figure 6-2.

The upper portion of the display shows a line of input bits

which correlate to a particular set of switch functions.

Whether the display shows a “0,” a “1” or is able to toggle

between “0” and “1” indicates whether or not the switch is

working.

Push the LO/DX button on the front panel to sequence from

f2125x8x

Diagnostic Group 1 to Diagnostic Group 2. Figure 6-3. Press

the button again to advance to Diagnostic Group 3. After all

Figure 6-1. Access Radio Diagnostic Mode

modes have been accessed, the final push of the LO/DX but-

ton will cause the system to revert back to normal radio oper-

ation. The Diagnostic Mode can also be exited at any time by

Input Bits

simply turning the Ignition/Light Key Switch to OFF.

NOTE

Diagnostic Groups 3, 4 and 5 are for factory use only, while

the last display, which follows Diagnostic Group 5, allows the

user to adjust the rate of volume change for the Automatic

Volume Control (AVC). See Automatic Volume Control (AVC)

Adjustment under Section 6.7 RADIO SYMPTOM 4 for addi-

tional information.

Diagnostic Mode Group 1

f2123x8x

Figure 6-2. Front Panel LCD Display

f2122x8x

Figure 6-3. LO/DX Button

6-2

2005 Touring: Sound System

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DIAGNOSTIC MODE GROUP 1

Not Applicable to Classic/Road Glide Models

(BN/W)

(O/BK)

(BN/BK)

(GY/GN)

(GN/BE)

GENERAL

REAR

MODE UP

AUDIO

(PK/W)

VOLUME

When the Diagnostic Mode is first accessed, a line of five

REAR

input bits appears in the upper portion of the front panel LCD

MODE DN

RADIO

VOLUME

EJECT

LO/DX

(GY/W)

POWER

DOWN

display. See Figure 6-2.

MODE

SQUELCH

SEEK

(V/BK)

PTT

DOWN

SCAN

NOT

PRESET

(INT)

USED

SAMPLE DIAGNOSTIC

Cx = C0 thru C4. Rx = R0 thru R3.

For explanatory purposes, assume that the REAR VOLUME

● If Cx and Rx are normal, input bit on LCD display toggles

UP control is inoperative. Referencing the matrix at the top of

between “1” and “0” at a one second rate while button is

Figure 6-4, note that this switch function is found at the inter-

depressed.

section of the C3 and R0 lines. The matrix indicates that the

● If Cx is shorted to ground, input bit on LCD display

appears as “0” whether switch is open or closed. See Fig-

problem either involves the O/BK or the PK/W wires.

ure A below.

● If Cx is shorted to +12 volts, input bit on LCD display

Operate the switch while observing the input bit. The input bit

appears as “1” whether switch is open or closed. See Fig-

to watch correlates with the position of the switch in the

ure B below.

matrix. Therefore, the REAR VOLUME UP control is the sec-

● If Rx is shorted to ground, input bit on LCD display

ond bit from the left hand side. If the input bit toggles between

appears as “1” when switch is open and “0” when switch is

“1” and

“0” at a one second rate while the switch is

closed (depressed), but does not toggle at a one second

depressed, then the switch is functioning normally. However,

rate as occurs when switch is normal. See Figure C below.

if the switch is locked on “1” or “0” and fails to toggle, then a

● If Rx is shorted to +12 volts, input bit on LCD display

appears as “1” whether switch is open or closed. See Fig-

problem exists.

ure D below.

● If all other switch functions on the Cx and Rx lines toggle

Now assume that the input bit of the REAR VOLUME UP con-

between “1” and “0,” then an open is indicated. See Figure

trol is locked on “1.” Review the text below the matrix in Figure

E and Figure F below.

6-4. From this information, we see that when the input bit is

locked on “1,” then either the O/BK or the PK/W wires are

shorted to +12 volts.

To further pinpoint the problem, exercise the MODE UP or

FAST FORWARD functions, or any other switch function on

the R0 line, which also utilize the PK/W wire. If the input bit

toggles, then one can conclude that the PK/W wire is alright

and the problem involves the O/BK lead. Now operate the

C3 is shorted to ground.

C3 is shorted to +12 volts.

REAR VOLUME DOWN switch to verify the conclusion. As

seen from the matrix, this switch function also utilizes the O/

[1/0]

BK wire. If the input bit is still locked on “1” then the O/BK wire

is confirmed as the source of the problem. Operation of the

PTT and PRESET 4 buttons (the remaining switch functions

on the C3 line) would serve to confirm the same conclusion.

On the other hand, if all other switch functions on the C3 line

R0 is shorted to ground.

R0 is shorted to +12 volts.

toggle between “1” and “0” at a one second rate, indicating

that the switch is functioning normally, then an open exists on

the R0 line. Conversely, if all other switch functions on the R0

(1/0)

line toggle between “1” and “0” at a one second rate, then an

(1/0)

open exists on the C3 line.

(1/0)

Therefore, a continuous “0” is a short to ground, while a con-

(1/0)

tinuous “1” is a short to +12 volts, but ONLY if all other switch

functions on that respective Cx or Rx line are also locked on

C3 is open.

R0 is open.

“0” or “1,” respectively. If all other switch functions on the Cx

[1/0] = Displays “1” when open, “0” when button is depressed.

and Rx lines toggle between “1” and “0,” then an open is indi-

(1/0) = Toggles between “1” and “0” while button is depressed.

cated.

Figure 6-4. Diagnostic Mode Group 1 Matrix

2005 Touring: Sound System

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DIAGNOSTIC MODE GROUP 2

Input Bits

GENERAL

When the radio Diagnostic Mode is first accessed, Diagnostic

Group 1 appears on the LCD display, as indicated by the “d1”

in the lower portion. Push the LO/DX

button on the front panel

to sequence to Diagnostic Group 2.

See Figure 6-5.

The upper portion of the Diagnostic Group 2 display shows a

line of eight input bits each of which

correlates to a particular

switch function. The characters “d2”

appear in the lower por-

tion.

SAMPLE DIAGNOSTIC

Diagnostic Mode Group 2

f2122x8x

Operate the switch while observing the input bit. The input bit

Figure 6-5. Front Panel LCD Display

to watch correlates with the position of the switch in the line.

For example, the INTERCOM OFF/ON SWITCH is the fifth

input bit from the left hand side. If the input bit toggles

Unlike the Diagnostic Group 1 input bits, whether the problem

between “1” and “0” as the console mounted rocker switch is

is a short to ground, a short to +12 volts or an open is not so

turned ON and then OFF, respectively, then the switch is

readily apparent. See Figure 6-6 for further explanation of the

functioning normally. However, if the switch is locked on “1” or

Diagnostic Group 2 input bits and then refer to the appropri-

“0,” then a problem exists.

ate flow chart under SOFTWARE DIAGNOSIS.

Not Applicable to Classic/Road Glide Models

10=Headset

11=Speaker

0=PTT

0 or 1

1=Break

1=ON

01=Center

AVC

HAND-

INTERCOM

SPEAKER

VEHICLE

VOX

HELD MIC.

SQUELCH

OFF/ON

SWITCH

SPEED

BREAK

PTT

BREAK

SWITCH

“B”

“A”

SIGNAL

(BE/Y)

(W/GN)

Internal

(BN/O)

(V/O)

Diagnostic Mode 2, which displays the logic states of various

●

* CB Squelch Break: When CB receives signal strong

signals, functions as follows (left to right):

enough to exceed threshold (set by squelch level setting),

● Handheld Microphone PTT: input bit on LCD appears as

input bit on LCD appears as “1.” When CB Squelch is not

“1” when PTT button is not depressed, “0” when button is

broken, display appears as “0.”

depressed. (This should not be confused with the handle-

● Intercom OFF/ON: When switch is ON, input bit on LCD

bar mounted PTT Switch.)

display appears as

“1.” When switch is OFF, display

● AVC Vehicle Speed Signal: Input bit normally toggles

appears as “0.”

between “1” and “0” as the rear wheel is rotated greater

● CB OFF/ON: When switch is ON, input bit on LCD

than 3 mph. The rate at which it toggles is proportional to

appears as “1.” When switch is OFF, display appears as

the speed of the wheel.

“0.”

●

* VOX Break: When the microphone signal is strong

● Speaker Switch A, Speaker Switch B: When fairing cap

enough to exceed threshold

(set in Intercom Set Up

rocker switch is in the HEADSET position, input bits on

Mode), input bit on LCD appears as “1.” When VOX is not

LCD display appears as “10.” Display is

“11” in the

broken, display appears as “0.”

SPEAKER position and “01” in the Center position.

* CB or Intercom must be turned on and VOX or Squelch settings must be established before entering diagnostic mode.

Figure 6-6. Diagnostic Mode Group 2

6-4

2005 Touring: Sound System

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BREAKOUT BOX

6.3

GENERAL

hd44608

The RADIO BREAKOUT BOX (Part No. HD-44608), used in

conjunction with a DVOM, allows circuit diagnosis without

having to probe connectors with sharp objects. See Figure 6-

INSTALLATION

1. Remove the outer fairing. See Touring Models Service

Figure 6-7. Radio Breakout Box (HD-44608)

Manual.

2. Remove black connector

[27] from back of radio to

f2238x8x

release interconnect harness. See Figure 6-8.

Radio [28]

Ultra Only

3. Remove gray connector

[28] from back of radio to

release audio harness (Ultra models only).

4. Install black connectors on Breakout Box to black radio

Radio [27]

and interconnect harness connectors.

5. Install gray connectors on Breakout Box to gray radio and

audio harness connectors.

REMOVAL

Remove Breakout Box between radio and wiring harness

connectors.

Install black connector [27] at back of radio to connect

interconnect harness. See Figure 6-8.

Install gray connector [28] at back of radio to connect

audio harness (Ultra models only).

4. Install the outer fairing. See Touring Models Service

Manual.

Figure 6-8. Radio Connections -

FLHTCU

RT FRONT HEADSET(+)

1 RT FRT SPEAKER (+)

FRT HEADSET COMMON 2

HANDLEBAR MATRIX

2 PUSH TO TALK (MIC)

LFT RR SPEAKER ()

3 R0 (HANDLEBAR MATRIX)

RT RR SPEAKER()

4 R1 (HANDLEBAR MATRIX)

C4 (RR CNTL MATRIX)

VOL UP

VOL DWN

MENU

UP TUNE / FF

5 R2 (HANDLEBAR MATRIX)

R1 (RR CNTL MATRIX)

6 C4 (HANDLEBAR MATRIX)

DWN TUNE / REWIND

RR MIC SHIELD

7 C3 (HANDLEBAR MATRIX)

RR MIC COMMON

SQUELCH UP

SQUELCH DWN

PUSH TO TALK

BAND

8 C2 (HANDLEBAR MATRIX)

LFT FRT HEADSET

9 VEHICLE SPEED SIGNAL

LFT RR SPEAKER (+) 10

10 BATTERY

RT RR SPEAKER (+) 11

11 GROUND

RR CONTROL MATRIX

C3 (RR CNTL MATRIX) 12

12 IGNITION

R0 (RR CNTL MATRIX) 13

13 HEADSET SPEAKERS B

R2 (RR CNTL MATRIX) 14

14 N/C

RR VOL UP

UP TUNE / FF

FRT MIC SHIELD 15

15 N/C

RT RR HEADSET (+) 16

RR VOL DWN

DWN TUNE / REWIND

16 LFT FRT SPEAKER (+)

LFT RR HEADSET (+) 17

17 LFT FRT SPEAKER ( )

RR HEADSET COMMON 18

PUSH TO TALK

BAND

18 RT FRT SPEAKER (+)

N/C 19

19 GROUND

N/C 20

20 BATTERY

RR MIC 21

21 HEADSET SPEAKERS A

ULTRA RADIO

BASE RADIO

FRT MIC 22

22 C1 (HANDLEBAR MATRIX)

FRT MIC COMMON 23

CONNECTOR

23 C0 (HANDLEBAR MATRIX)

[28A]

[27A]

Figure 6-9. Radio Pinouts

2005 Touring: Sound System

6-5

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RADIO SYMPTOM 1

6.4

GENERAL

Not Applicable to Classic/Road Glide Models

Problem

(BN/W)

(O/BK)

(BN/BK)

(GY/GN)

(GN/BE)

Audio control inoperative.

REAR

MODE UP

AUDIO

(PK/W)

VOLUME

REAR

MODE DN

RADIO

Setup

VOLUME

EJECT

LO/DX

(GY/W)

POWER

DOWN

● Press the POWER button to turn the radio ON.

MODE

SQUELCH

SEEK

(V/BK)

PTT

DOWN

SCAN

● Press and hold the CB button to turn the Citizen Band

NOT

PRESET

(INT)

USED

radio OFF. Press and hold the INT button to turn the

Intercom OFF.

● Set fairing mounted Headset/Speaker Switch to

Figure 6-10. Diagnostic Mode Group 1 Switch Matrix

SPEAKER.

f2123x8x

Functionality

Locate the Audio Control Switch on the left handlebar. Push

the switch in to sequence to Bass, Treble, Fader and then

back to Volume. The front panel LCD display indicates the

function selected.

Momentarily push the switch upward (+)

to raise the volume,

downward (-) to lower the volume. The front panel LCD

annunciates volume level through a horizontal bar graph dis-

play and stereo audio should be present in all four speakers

(front speakers on non-Ultra). The display reverts to the time

of day approximately two seconds after the switch is

released.

Figure 6-11. Audio Control Switch Input Bits

Are these your observations?

● Yes - System is OK. See Section 6.6 RADIO SYMPTOM

Install BREAKOUT BOX (Part No. HD-44608). See Sec-

● No - See Test 6.4 (Part 1 of 2).

tion 6.3 BREAKOUT BOX, INSTALLATION.

Revalidate failure. Reconnect all connectors. If problem

still exists, replace radio. If problem is gone, look for

DIAGNOSTICS

intermittents.

Use HARNESS CONNECTOR TEST KIT (Part No. HD-

41404A), black pin probes and patch cord.

Diagnostic Notes

The reference numbers below correlate with the circled num-

bers in the Test 6.4 flow charts.

1. This also may be an open. First go to SHORT TO VOLT-

AGE in Test 6.4 (Part 2 of 2).

6-6

2005 Touring: Sound System

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Test 6.4 (Part 1 of 2)

AUDIO CONTROL INOPERATIVE: SOFTWARE DIAGNOSIS

Enter Diagnostic Mode

by Pressing Any Two Pre-

set Buttons While Turning

Ignition Switch to On.

Look at Input Bits C0,

C1 and C2 in LCD

Display. See Figure 6-

11. Do Any of the

Input Bits Display “0?”

YES

Move to Test 6.4 (Part 2 of 2). Find

Exercise All Three Posi-

Short to Ground on Any Wire Where

tions of AUDIO CON-

Corresponding Input Bit Displays “0”

TROL SWITCH. Do All of

(With No Switches Depressed).

the Corresponding Input

Bits Toggle Between “1”

Switch

Input

Wire

and “0?”

Position

Bit

Color

Audio +

GN/BE

Audio -

GY/GN

YES

Audio In

BN/BK

Switch and

Activate Switch Where

Wiring are OK.

Corresponding Input Bit

Replace Radio.

Does Not Toggle

Between “1” and “0?” Is it

6601

a “0” or a “1” While Switch

is Activated?

Move to Test 6.4

Move to Test 6.4 (Part 2 of 2). Find

(Part 2 of 2).

Short to Voltage on Wire Where

Find Short to

Corresponding Input Bit Displays “1.”

Ground on R0

(PK/W) Wire.

Switch

Input

Wire

Position

Bit

Color

Audio +

GN/BE

Audio -

GY/GN

Audio In

BN/BK

All Positions

All

PK/W

Table 6-2. Wire Harness Connectors

NO.

DESCRIPTION

MODEL

TYPE

LOCATION

Interconnect Harness to Left

FLHTC/U

12-Place Deutsch (Gray)

Inner Fairing- Left Fairing Support Brace

[24]

Handlebar Switch Controls

FLTR

12-Place Deutsch (Gray)

Inner Fairing- Left Side of Radio Bracket

[27]

Radio

All

23-Place Amp (Black)

Inner Fairing- Back of Radio (Right Side)

2005 Touring: Sound System

6-7

HOME

Test 6.4 (Part 2 of 2)

AUDIO CONTROL INOPERATIVE: HARDWARE DIAGNOSIS

What Did Test 6.4 (Part 1 of 2)

Indicate?

SHORT to VOLTAGE

SHORT to GROUND

Remove Outer Fairing. Connect Breakout Box

Remove Outer Fairing. Connect

leaving Connector [27B] disconnected from

Breakout Box leaving Connector

Radio. With Key ON, Check for Power at Con-

[27B] disconnected from Radio. With

nector [27B]. Is Voltage Present?.

Key OFF, Check for Continuity

to Ground on Breakout Box at

Connector [27B].

From

Terminal

(-)

(+)

From

Terminal

3 (PK/W)

8 (BN/BK)

Ground

8 (BN/BK)

22 (GY/GN)

Ground

22 (GY/GN)

23 (GN/BE)

Any Continuity Present?

YES

Disconnect [24]. With Key

OPEN

Disconnect [24]. With Key

ON, Check for Power at

Replace

Connector [24B]. Is Voltage

OFF, Check for Continuity

Radio.

Present?.

Disconnect Connector [27]. from radio

to Ground at Connector

With Switch Depressed, Check for

[24B]. Any Continuity

6601

Continuity at Connector [27B].

Present?

From

Terminal

(-)

Switch

From

(+)

From

Position

Terminal

8 (BN/BK)

(-)

Audio +

3 (PK/W)

23 (GN/BE)

(+)

9 (PK/W)

Ground

Audio -

3 (PK/W)

22 (GY/GN)

8 (BN/BK)

10 (GN/BE)

Audio In

3 (PK/W)

8 (BN/BK)

9 (PK/W)

11 (GY/GN)

Ground

10 (GN/BE)

Each Wire Pair Should be Less than 0.5

11 (GY/GN)

Ohms While Switch is Depressed and

Infinity While Switch is Open. Is It?

YES

Locate and

YES

Repair Short

Locate and

in Handlebar

in Interconnect

Replace

Disconnect [24]. With Switch Depressed,

Repair Short in

Repair Short

Harness.

Radio.

Check for Continuity at Connector [24B].

Handlebar

in Interconnect

6551

6531

Harness.

6601

Switch

From

Position

Terminal

6551

6531

Audio +

9 (PK/W)

10 (GN/BE)

Audio -

9 (PK/W)

11 (GY/GN)

Audio In

9 (PK/W)

8 (BN/BK)

Each Wire Pair Should be Less than 0.5

Ohms While Switch is Depressed and

Infinity While Switch is Open. Is It?

YES

Locate and Repair

Replace Audio

Open or Replace

Switch or

Interconnect

Repair Switch

Harness.

Wiring.

6532

5186

After correction of problem, refer to SETUP and

FUNCTIONALITY to verify proper operation.

6-8

2005 Touring: Sound System

HOME

RADIO SYMPTOM 2

6.5

GENERAL

Not Applicable to Classic/Road Glide Models

Problem

(BN/W)

(O/BK)

(BN/BK)

(GY/GN)

(GN/BE)

Mode control inoperative.

REAR

MODE UP

AUDIO

(PK/W)

VOLUME

REAR

MODE DN

RADIO

Setup

VOLUME

EJECT

LO/DX

(GY/W)

POWER

DOWN

● Press the POWER button to turn the radio ON.

MODE

SQUELCH

SEEK

(V/BK)

PTT

DOWN

SCAN

● Press and hold the CB button to turn the Citizen Band

NOT

PRESET

radio OFF. Press and hold the INT button to turn the

(INT)

USED

Intercom OFF.

Figure 6-12. Diagnostic Mode Group 1 Switch Matrix

Functionality

Locate the Mode Select Switch on the right handlebar.

f2123x8x

Momentarily push the switch in to sequence between the AM,

FM and WB bands. The LCD display indicates the band

selected.

Momentarily push the Mode Select Switch in an upward

direction (UP) to cause the receiver to increment one step on

the frequency scale. Similarly, push the

Mode Select Switch

in a downward direction (DN) to cause the receiver to decre-

ment one step on the frequency scale.

NOTE

In Intercom Setup Mode (Ultra models only), the UP and DN

functions adjust the VOX sensitivity level. Press UP to

increase microphone sensitivity, press DN to decrease sensi-

tivity. In CB Setup Mode, UP and DN allow for channel selec-

Figure 6-13. Mode Control Switch Input Bit

tion.

Are these your observations?

Revalidate failure. Reconnect all connectors. If problem

● Yes - System is OK. See Owner’s Manual.

still exists, replace radio. If problem is gone, look for

intermittents.

● No - See Test 6.5 (Part 1 of 4).

Mode Control switch is integral part of sidecar amplifier.

Replace sidecar amplifier if switch fails.

DIAGNOSTICS

Use HARNESS CONNECTOR TEST KIT (Part No. HD-

41404A), black pin probes and patch cord.

Diagnostic Notes

Use HARNESS CONNECTOR TEST KIT (Part No. HD-

41404A), black socket probes and patch cord.

The reference numbers below correlate with the circled num-

bers in the Test 6.5 flow charts.

1. To eliminate Rear Mode Control Switch from diagnosis,

disconnect Connector [28]. If problem is eliminated, see

REAR MODE CONTROL INOPERATIVE. If problem re-

mains, continue with present flow chart.

2. Install BREAKOUT BOX (Part No. HD-44608). See Sec-

tion 6.3 BREAKOUT BOX, INSTALLATION.

2005 Touring: Sound System

6-9

HOME

Test 6.5 (Part 1 of 4)

MODE CONTROL INOPERATIVE: SOFTWARE DIAGNOSIS

Enter Diagnostic Mode

by Pressing Any Two Pre-

set Buttons While Turning

Ignition Switch to On.

Look at Input Bit C4 in

LCD Display. See Fig-

ure 6-13. Does the

Input Bit Display “0?”

YES

Move to Hardware Chart to Find

Exercise All Three Posi-

Short to Ground on Wire Where

tions of MODE CONTROL

Corresponding Input Bit Displays “0”

SWITCH. Does the Corre-

(With No Switches Depressed).

sponding Input Bit Toggle

Between “1” and “0” For

Switch

Input

Wire

Each Switch Position?

Position

Bit

Color

Mode Up

Mode Dn

BN/W

YES

Mode In

Switch and

Is it a “0” or a “1”

Wiring are OK.

While Switch Posi-

Replace Radio.

tion is Activated?

6601

Move to Hardware Chart to Find

Short to Ground on Wire Where

Short to Voltage on Wire Where

Corresponding Input Bit Displays “0.”

Corresponding Input Bit Displays “1.”

Switch

Input

Wire

Switch

Input

Wire

Position

Bit

Color

Position

Bit

Color

Mode Up

PK/W

Mode Up

PK/W

Mode Dn

GY/W

Mode Dn

GY/W

Mode In

V/BK

Mode In

V/BK

All Positions

BN/W

HARDWARE CHART

CONTINUE WITH

Front Mode Control

Test 6.5 (Part 2 of 4)

After correction of problem, refer to SETUP and

FUNCTIONALITY to verify proper operation.

Rear Mode Control

Test 6.5 (Part 3 of 4)

Sidecar Mode Control

Test 6.5 (Part 4 of 4)

Table 6-3. Wire Harness Connectors

NO.

DESCRIPTION

MODEL

TYPE

LOCATION

Inner Fairing - Fork Stem Nut

Interconnect Harness to Right

FLHTC/U

12-Place Deutsch (Black)

[22]

Lock Plate (Left Side)

Handlebar Switch Controls

FLTR

12-Place Deutsch (Black)

Inner Fairing- Left Side of Radio Bracket

[27]

Radio

All

23-Place Amp (Black)

Inner Fairing- Back of Radio (Right Side)

[28]

Radio

FLHTCU

23-Place Amp (Gray)

Inner Fairing- Back of Radio (Left Side)

Rear Left Speaker/Passenger

6-Place Mini-Deutsch

[42]

FLHTCU

Inside Rear Left Speaker Box

Controls

(Black)

6-10

2005 Touring: Sound System

HOME

Test 6.5 (Part 2 of 4)

FRONT MODE CONTROL INOPERATIVE: HARDWARE DIAGNOSIS

What Did Test 6.5

(Part 1 of 4)

Indicate?

SHORT to VOLTAGE

SHORT to GROUND

Remove Outer Fairing. Connect Breakout Box

leaving [27B] disconnected from Radio. With

Key ON, Check for Power at Connector [27B].

Key OFF, Check for Continuity to Ground at

Connector [27B].

From

Terminal

(-)

From

(+)

Terminal

3 (PK/W)

4 (GY/W)

Ground

5 (V/BK)

6 (BN/W)

Is Voltage Present?

Any Continuity Present?

YES

With Key ON, Check for

OPEN

With Key OFF, Check for

Replace

Power at Connector [22B].

Check for Continuity to

Radio.

Ground at Connector [22B].

With Switch Depressed, Check for

6601

From

Terminal

Continuity at Connector [27B].

(-)

(+)

From

Terminal

Switch

From

(-)

(+)

7 (BN/W)

Position

Terminal

8 (GY/W)

7 (BN/W)

Ground

Mode Up

6 (BN/W)

3 (PK/W)

9 (PK/W)

8 (GY/W)

Mode Dn

6 (BN/W)

4 (GY/W)

Ground

10 (V/BK)

9 (PK/W)

Mode In

6 (BN/W)

5 (V/BK)

Is Voltage Present?

10 (V/BK)

Each Wire Pair Should be Less than

Any Continuity Present?

0.5 Ohms While Switch is Depressed

and Infinity While Switch is Open. Is It?

YES

Locate and

YES

Repair Short in

Repair Repair

Locate and

Handlebar

Short

Repair Short in

Repair Short

Replace

With Switch Depressed, Check for

Harness.

in Interconnect

Handlebar

in Interconnect

Harness.

Radio.

Continuity at Connector [22B].

Harness.

6551

6531

6601

Switch

From

6551

6531

Position

Terminal

Mode Up

7 (BN/W)

9 (PK/W)

Mode Dn

7 (BN/W)

8 (GY/W)

Mode In

7 (BN/W)

10 (V/BK)

Each Wire Pair Should be Less

than 0.5 Ohms While Switch is

Depressed and Infinity While

Switch is Open. Is It?

YES

Locate and

Replace Mode

Repair or Replace

Switch or Repair

Interconnect

Switch Wiring.

Harness.

5183

After correction of problem, refer to SETUP and

6532

FUNCTIONALITY to verify proper operation.

2005 Touring: Sound System

6-11

HOME

Test 6.5 (Part 3 of 4)

REAR MODE CONTROL INOPERATIVE: HARDWARE DIAGNOSIS

What Did Test 6.5 (Part 1 of 4)

Indicate?

SHORT to VOLTAGE

SHORT to GROUND

Remove Outer Fairing. Connect Breakout Box leaving

Remove Outer Fairing. Connect Breakout Box

Connector [28B] disconnected from Radio.

leaving Connector [28B] disconnected from

With Key ON, Check for Power at Connector [28B].

Radio. With Key OFF, Check for Continuity to

Ground at Connector [28B].

From

Terminal

(-)

From

(+)

Terminal

(-)

13 (PK/W)

(+)

6 (GY/W)

13 (PK/W)

Ground

14 (V/BK)

6 (GY/W)

Ground

5 (BN/W)

14 (V/BK)

5 (BN/W)

Is Voltage Present?

Any Continuity Present?

YES

Locate and

OPEN

Repair Short in

Locate and

Replace

Audio

Harness.

With Switch Depressed, Check for

Repair Short in

Radio.

Continuity at Connector [28B].

Audio

6601

6560

Harness.

Switch

From

Position

Terminal

6560

Mode Up

5 (BN/W)

13 (PK/W)

Mode Dn

5 (BN/W)

6 (GY/W)

Mode In

5 (BN/W)

14 (V/BK)

Each Wire Pair Should be Less than

0.5 Ohms While Switch is Depressed

and Infinity While Switch is Open.

Is It?

YES

Replace

Disconnect Connector [42]. With

Radio.

Switch Depressed, Check for

Continuity at Connector [42B].

6601

Switch

From

Position

Terminal

Mode Up

4 (BN/W)

1 (PK/W)

Mode Dn

4 (BN/W)

2 (GY/W)

Mode In

4 (BN/W)

3 (V/BK)

Each Wire Pair Should be Less than

0.5 Ohms While Switch is Depressed

and Infinity While Switch is Open. Is It?

YES

Locate and

Replace

Repair open

Mode Switch

or Replace

or Repair

Audio

Switch Wiring.

Harness.

6627

6561

After correction of problem, refer to SETUP and

FUNCTIONALITY to verify proper operation.

6-12

2005 Touring: Sound System

HOME

Test 6.5 (Part 4 of 4)

SIDECAR MODE CONTROL INOPERATIVE: HARDWARE DIAGNOSIS

What Did Test 6.5 (Part 1 of 4)

Indicate?

SHORT to VOLTAGE

SHORT to GROUND

Disconnect Connectors [42B]

Disconnect Connector [42B] and [42C].

and [42C]. With Key ON, Check

With Key OFF, Check for Continuity to

for Power at Connector [42B].

Ground at Connector [42C].

From

Terminal

(-)

(+)

1 (PK/W)

2 (GY/W)

Ground

2 (GY/W)

3 (V/BK)

Ground

3 (V/BK)

4 (BN/W)

Any Continuity Present?

Is Voltage Present?

YES

Replace Sidecar

Go to Test 6.5

Replace Sidecar

OPEN

Audio Harness or

(Part 3 of 4).”

Audio Harness or

Locate and Repair

Locate and

Short to Ground.

Repair Short to

Disconnect Connector [42]. With

6940

Voltage.

Sidecar Mode Switch Depressed, Check

for Continuity at Connector [42C].

6940

Switch

From

Position

Terminal

Mode Up

4 (BN/W)

1 (PK/W)

Mode Dn

4 (BN/W)

2 (GY/W)

Mode In

4 (BN/W)

3 (V/BK)

Each Wire Pair Should be Less than 0.5

Ohms While Switch is Depressed and

Infinity While Switch is Open. Is It?

YES

Reconnect Connector [42]. Remove

Remove Sidecar Speaker Console. Disconnect

Outer Fairing and Disconnect Connector

Connector [149] From Sidecar Speaker Amplifier.

[28]. With Switch Depressed, Check for

Check Continuity as Follows:

Continuity at Connector [28B].

FROM

Switch

From

Connector

Terminal

Connector

Terminal

Position

Terminal

1 (PK/W)

Mode Up

5 (BN/W)

13 (PK/W)

2 (GY/W)

Mode Dn

5 (BN/W)

6 (GY/W)

[149B]

[42C]

3 (V/BK)

Mode In

5 (BN/W)

14 (V/BK)

4 (BN/W)

Each Wire Pair Should be Less than 0.5

Continuity Present?

Ohms While Switch is Depressed and

Infinity While Switch is Open. Is It?

YES

Replace

Locate and

Sidecar

Repair Open or

Replace

Locate and

Amplifier.

Replace Sidecar

Radio.

Repair Open in

Audio Harness.

6949

6601

6561

6940

After correction of problem, refer to SETUP and

FUNCTIONALITY to verify proper operation.

2005 Touring: Sound System

6-13

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Harley Davidson 2005 touring models. Service repair manual — page 54

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