Harley Davidson 2005 touring models. Service repair manual — page 46
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Test 4.9 (Part 3 of 3)
ENGINE CRANKS, BUT WILL NOT START
Continued from Test 4.9 (Part 2 of 3).
Replace ignition control module (ICM). Reprogram and
perform password learn. Does vehicle start?
YES
NO
System OK.
Mechanical failure. Inspect for
sprocket gear, timing chain or
other mechanical failure.
4-22
2005 Touring: Engine Management (Carbureted)
HOME
STARTS, THEN STALLS
4.10
GENERAL
f2191x8x
Diagnostic Trouble Codes U1300, U1301,
P1009, P1010 or “BUS Er”
See Figure 4-18. The typical serial data voltage range is 0
volts (inactive) to 7 volts (active). Due to the short pulse, volt-
ages will be much lower on a DVOM. In analog mode, a
DVOM reading serial data will show continuous voltage when
active, typically 0.6-0.8 volts. The range for acceptable opera-
tions is 0-7.0 volts.
NOTE
Problems in the fuel system or idle air control system may
also create this symptom.
Table 4-9. Code Description
DTC
DESCRIPTION
Data Link
Connector [91]
U1300
Serial data low
U1301
Serial data open/high
Figure 4-18. Electrical Bracket (Under Right Side Cover)
DIAGNOSTICS
3.
Use HARNESS CONNECTOR TEST KIT (Part No. HD-
41404A), black socket probes and patch cord.
Diagnostic Tips
4.
Historic code U1300 would have been set. Clear historic
● If serial data is shorted, these codes will automatically
codes.
trip the check engine light. The odometer will read “Bus
Er” in this condition.
● DTCs P1009 and P1010 may accompany DTCs U1300
and U1301.
Diagnostic Notes
The reference numbers below correlate with the circled num-
bers on the Test 4.10 flow charts.
1.
Check for trouble codes. See RETRIEVING DIAGNOS-
TIC TROUBLE CODES under 4.3 CHECKING FOR
TROUBLE CODES.
2.
Connect BREAKOUT BOX (Part No. HD-42682) as fol-
lows:
a. Mate black socket housing on Breakout Box with
ICM connector [10A].
b. Mate black pin housing on Breakout Box with har-
ness connector [10B].
c. Mate gray socket housing on Breakout Box with
TSM/TSSM connector [30A].
d. Mate gray pin housing on Breakout Box with har-
ness connector [30B].
2005 Touring: Engine Management (Carbureted)
4-23
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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 4-19. Serial Data Circuit (FLHT/C)
Table 4-10. Wire Harness Connectors in Figure 4-19.
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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2005 Touring: Engine Management (Carbureted)
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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 4-20. Serial Data Circuit (FLHR/S)
Table 4-11. Wire Harness Connectors in Figure 4-20.
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)
4-25
HOME
Test 4.10 (Part 1 of 2)
ASTARTS, THEN STALLS: DTC U1300, U1301,
P1009, P1010 or “BUS Er”
Is there fresh
fuel in tank?
YES
NO
1
Check for DTCs using 4.5 SPEEDOMETER
Add fuel.
SELF DIAGNOSTICS.
Any DTCs found?
YES.
YES.
YES.
NO.
DTC P1009,
DTC U1300 or
BUS Er present.
No DTCs found.
P1010 found. See
U1301 are found.
Speedometer will not
4.15 DTC P1009,
communicate with other
P1010.
modules.
Inspect intake manifold for
leaks using intake leak test.
See 4.8 INTAKE LEAK TEST.
Are leaks present (runs longer
when propane is present)?
STOP
YES
NO
Go to Test 4.10
(Part 2 of 2).
Replace intake
Replace ICM.
manifold seals.
Reprogram and learn
password.
Clear codes using speedometer self diagnostics.
See 4.5 SPEEDOMETER SELF DIAGNOSTICS.
Confirm proper operation with no check engine
lamp.
4-26
2005 Touring: Engine Management (Carbureted)
HOME
Test 4.10 (Part 2 of 2)
STARTS, THEN STALLS: DTC U1300, U1301, P1009,
P1010 or “BUS Er”
Continued from Test 4.10 (Part 1 of 2)
2
Test the three data link connector terminals for continuity.
DIAGNOSTIC LINK
BREAKOUT BOX
3
CONNECTOR [91A]
(BLACK)
Terminal
Wire Color
Terminal
1
N/A
N/A
2
BK
5
3
Lt. GN/V
12
4
GY
GY terminal on left
side of ignition fuse
Continuity present in all three circumstances?
YES
NO
Leave ICM disconnected
Inspect terminals
at connector [10]. Does
for damage or repair
speedometer display TSM/
opens as necessary.
TSSM data?
YES
NO
Replace ICM. Reprogram
Disconnect connector [30]. Check for
and learn password.
4
continuity to ground at terminal 3 of con-
nector [91A]. Continuity to ground?
YES
NO
Locate and repair short
Check for voltage at
to ground.
terminal 3 of connector
[91A]. Voltage present?
YES
NO
Locate and repair short
Replace TSM/TSSM. Repro-
to voltage.
gram and learn password.
System OK?
YES
NO
System
Disconnect connector
OK.
[39]. System OK?
YES
NO
Replace
Replace
speedometer.
tachometer if
equipped.
2005 Touring: Engine Management (Carbureted)
4-27
HOME
NO SPARK/NO ICM POWER
4.11
GENERAL
DIAGNOSTICS
The ignition control module turns on when power is applied to
Pin 1 of [10], the black connector. The ignition control module
Diagnostic Notes
goes through an initialization sequence every time power is
removed and re-applied to Pin 1. The only visible part of this
The reference numbers below correlate with the circled num-
sequence is the check engine lamp. Upon starting, the check
bers on the Test 4.11 flow chart.
engine lamp will illuminate for 4 seconds and then (if parame-
ters are normal) go out.
1. See FUSES in the Touring Service Manual.
2. Connect BREAKOUT BOX (Part No. HD-42682). See 4.6
BREAKOUT BOX: ICM.
3. Use HARNESS CONNECTOR TEST KIT (Part No. HD-
4104), black pin probe and patch cord.
4. Remove headlamp assembly on FLHR/S models or
outer fairing on FLHT/C.
R/BK To Ignition Switch
Ignition Control Module
[83B]
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 4-21. Ignition Control Module Power Circuit
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2005 Touring: Engine Management (Carbureted)
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Test 4.11
NO SPARK/NO ICM POWER
1
Check Ignition
Fuse. Is Fuse
OK?
NO
YES
Replace Fuse
2
Connect Breakout Box. With Igni-
and Find
tion ON, Place Multimeter Red
Source of Fault.
3
Wire to Terminal 1 of Connector
[10] on Breakout Box, Multimeter
Black Wire to Terminal 5 of Con-
nector [10] on Breakout Box. Is
Voltage 12V± 1.0V.?
YES
NO
Replace ICM.
3
Check Continuity Between Terminal
5 of Connector [10] on Breakout Box
and Ground. Continuity Present in
Both Places?
NO
YES
Repair Open in BK
3
Check Continuity Between Pin
Wire (Pin 5) to
4 (W/BK) of Connector [22A]
4
Ground.
and Terminal 1 of Connector
[10] on Breakout Box.
Is Continuity Present?
YES
NO
3
Check Continuity
Locate and Repair
Between Sockets 4
Open in W/BK Wire
(W/BK) and 3 (GY) of
Between Connectors
Connector [22B]. With
[22] and [10].
Engine Stop Switch
ON, Is Continuity
Present?
YES
NO
Locate and Repair
Replace
Open in GY Wire
Engine Stop
Between Connector
Switch.
[22A] and Fuse Block.
Table 4-12. Wire Harness Connectors in Figure 4-21.
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
2005 Touring: Engine Management (Carbureted)
4-29
HOME
MISFIRE
4.12
GENERAL
d0273x8x
Misfire at Idle or Under Load
● Battery condition and connections may also cause mis-
fires.
● Fuel system problems may also cause misfires. Refer to
Table 4-3.
DIAGNOSTICS
Figure 4-22. Spark Tester
Diagnostic Notes
The reference numbers below correlate with the circled num-
c. Compare resistance values to Table 4-13. Replace
bers on the Test 4.12 flow chart.
cables not meeting specifications. Reinstall and
repeat procedure on other spark plug cable.
1WARNING
Table 4-13. Spark Plug Cables
Any open spark around gasoline or other combustibles
may result in fire or explosion. Thoroughly wipe up any
LOCATION
LENGTH
RESISTANCE
spilt fuel and dispose of rags in a suitable manner. Inade-
quate safety precautions could result in death or serious
Front/Rear
20.2 inch (513 mm)
4975-11960
injury.
1. See Figure 4-22. Use the SPARK TESTER (Part No. HD-
3.
This test can also be performed by substituting a known
26792) to verify adequate secondary voltage (25,000
good coil for one causing the no spark condition. The coil
volts) at the spark plug.
does not require full installation to be functional. Verify
faulty coil by performing resistance test.
a. Turn Ignition/Light Key Switch to IGNITION.
4.
Use HARNESS CONNECTOR TEST KIT (Part No. HD-
b. Remove spark plug cable from spark plug. Visually
41404A), gray pin probe and patch cord to the coil con-
check plug condition.
nector [83B].
c. Attach cable to SPARK TESTER. Clip tester to cylin-
der head bolt.
5.
Inspect for corrosion at battery terminals, maxi fuse ter-
minals, ignition fuse terminals GY and R/BK, right han-
d. While cranking engine, watch for spark to jump
dlebar switch controls connector [22], and ignition coil
tester gap on leads.
connector [83].
IMPORTANT NOTE
Spark will not be present when cranking with both spark
plugs removed. When checking for spark, use SPARK
TESTER with both spark plugs installed and one plug
wire connected to SPARK TESTER.
e. Reinstall and repeat procedure on other spark plug
cable.
2. Perform spark plug cable resistance test.
a. Remove spark plug cable from spark plug and igni-
tion coil. For best results, use a needle nose pliers
for removal/installation on coil. Gently grasp cable
as close to terminals as possible.
b. Using an ohmmeter, touch probes to terminals on
each end plug wire.
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2005 Touring: Engine Management (Carbureted)
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R/BK To Ignition Switch
Ignition Control Module
[83B]
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 4-23. Ignition Coil Circuit
Table 4-14. Wire Harness Connectors in Figure 4-23.
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)
4-31
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Test 4.12
MISFIRE AT IDLE OR UNDER LOAD
Is fuel contaminated?
YES
NO
Drain and flush
Remove air cleaner cover. Start engine.
tank. Refill with
Open throttle quickly. Does slide move up
fresh fuel.
and down with throttle opening?
YES
NO
Inspect intake manifold for leaks.
See 4.8 INTAKE LEAK TEST.
Inspect CV carburetor dia-
Leaks present?
phragm for leaks. Replace
or repair as necessary.
YES
NO
Turn Ignition Switch OFF.
Replace
Disconnect one spark plug lead at a time
1
intake seals.
and install Spark Tester (HD-26792). See
Figure 4-22.
Crank engine to induce spark. Observe
spark tester during test.
Spark should jump tester lead gap during
test. Did it?
YES
NO
Check for:
Check resistance of each spark plug
2
cable that did not fire the spark tester.
• Faulty, worn or cracked spark plug(s).
• Plug fouling due to engine
mechanical fault.
Also, check for faulty plug wire connections.
• Faulty or poor connection at plug.
Are wires OK?
YES
NO
Switch coil with unit
3
known to be good.
Replace
Perform spark test.
faulty wires.
Did spark jump gap
during engine cranking?
YES
NO
Remove test coil. Disconnect negative bat-
Original ignition coil
4
tery cable. Measure resistance between bat-
is faulty. Replace.
tery positive and coil connector [83B]
Terminal B (W/BK). Wiggle harness. Is resis-
5
tance continuously less than 1.0 ohm?
YES
NO
Clear codes using speedometer self diagnostics.
Replace ignition control
See 4.5 SPEEDOMETER SELF DIAGNOSTICS.
Find source of
module. Reprogram and
Confirm proper operation with no check engine
intermittent and repair.
learn password.
lamp.
4-32
2005 Touring: Engine Management (Carbureted)
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DTC P0106, P0107, P0108
4.13
GENERAL
7351
MAP Sensor
See Figure 4-24. The manifold absolute pressure sensor
(MAP sensor) is supplied 5 volts from the ignition control
module and sends a signal back to the ignition control mod-
ule. This signal varies in accordance with engine vacuum and
atmospheric barometric pressure. Changes in barometric
pressure are influenced by weather and altitude.
Table 4-15. Code Description
DTC
DESCRIPTION
P0106
MAP sensor rate-of-change error
P0107
MAP sensor failed open/low
P0108
MAP sensor failed high
Figure 4-24. MAP Sensor
DIAGNOSTICS
Diagnostic Notes
The reference numbers below correlate with the circled num-
bers on the Test 4.13 flow charts.
Diagnostic Tips
1.
Connect BREAKOUT BOX
(Part No. HD-42682)
● DTC P0106 will set if the MAP sensor signal fluctuates
between wire harness and ignition control module. See
faster than normal operation.
4.6 BREAKOUT BOX: ICM.
● With the MAP sensor disconnected, the ignition control
2.
Use HARNESS CONNECTOR TEST KIT (Part No. HD-
module should recognize a low voltage. If low voltage is
41404A), gray pin probes and patch cords.
observed, the ignition control module and harness are
not at fault.
● Gently place a jumper wire across MAP Sensor connec-
tor [80B] Terminals B and C using HARNESS CONNEC-
TOR TEST KIT (Part No. HD-41404A), gray male probes
and patch cord. With the jumper in place, the ignition
control module should recognize a high voltage.
● MAP sensor output check. Using the VACUUM PUMP
(Part No. HD-23738A), apply a vacuum to the pressure
port of the MAP sensor. The signal voltage should lower
as the vacuum is applied.
2005 Touring: Engine Management (Carbureted)
4-33
HOME
s0587a8x
Manifold
absolute
pressure
sensor
(MAP)
[80A]
[80B]
To vehicle
speed sensor
(VSS)
[10B]
[10A]
Ignition control module
Figure 4-25. MAP Sensor Circuit
Table 4-16. Wire Harness Connectors in Figure 4-25.
NO.
DESCRIPTION
TYPE
LOCATION
[10]
Ignition Control Module
12-Place Deutsch
Under Right Side Cover
[80]
Manifold Absolute Pressure Sensor (MAP)
3 - Place Packard
Top of Intake Manifold
4-34
2005 Touring: Engine Management (Carbureted)
HOME
Test 4.13 (Part 1 of 2)
MAP SENSOR: DTC P0106, P0107, P0108
With ignition ON, measure voltage
1
between Breakout Box terminal 11 (+)
and terminal 4 (-). With key ON,
engine OFF, voltage must be between
4.2 and 4.95 volts. With key ON,
engine running, voltage must be
between 1.5-3.0 volts at hot idle.
Does voltage fit specifications?
YES
NO
Perform 4.7 WIGGLE TEST
to check for intermittents.
STOP
Intermittents present?
Go to Test 4.13
(Part 2 of 2).
YES
NO
To identify the source of inter-
Replace MAP sensor. See the Touring Ser-
mittents, start with box marked
vice Manual. Clear diagnostic trouble codes.
by Bold Asterisk under Test
See 4.5 SPEEDOMETER SELF DIAGNOS-
4.13 (Part 2 of 2). Wiggle har-
TICS. Road test. Did check engine lamp illu-
ness while watching DVOM.
minate and set Code P0106, P0107 or
YES
NO
Install original MAP sensor.
System
Replace ignition control module
now OK.
and road test again to verify.
Clear codes using speedometer self diagnostics.
See 4.5 SPEEDOMETER SELF DIAGNOSTICS.
Confirm proper operation with no check engine
lamp.
At some point in the flow chart you
may be instructed to jump directly
to a the box with the bold asterisk.
Disregard the asterisk (but not the
instruction box) if your normal pro-
gression through the chart brings
you to this location.
2005 Touring: Engine Management (Carbureted)
4-35
HOME
Test 4.13 (Part 2 of 2)
MAP SENSOR: DTC P0106, P0107, P0108
Continued from Test 4.13 (Part 1 of 2).
Check the 5 volt reference supply at
the MAP sensor connector [80B]. With
2
ignition ON, measure voltage between
terminal C (R/W) and terminal A (BK/W).
Is voltage approximately 5.0 volts?
YES
NO.
NO.
Greater
Less
than 6V.
than 4.5V.
Connect Breakout Box. Disconnect ignition
1
control module from Breakout Box.
OPEN CHECK: Measure resistance
Locate short to 12 volts on R/W
Disconnect ignition control module from
between MAP connector [80B] Terminal B
1
2
wire in wire harness. Repair as
Breakout Box.
and Breakout Box connector [10]
necessary.
Check continuity between MAP connector
terminal 11. Is resistance less than 1 ohm?
[80B] Terminal C and Breakout Box
2
connector [10] terminal 3. Then measure
continuity between MAP connector [80B]
Terminal A and Breakout Box connector [10]
terminal 4.
Continuity present?
YES
NO
SHORT CHECK: Measure
Locate and repair
2
resistance between MAP con-
open on V/W wire.
nector Terminal B and chassis
ground. Is resistance greater
than 1 meg ohm?
YES
NO
With MAP sensor connector
Repair
[80] disconnected, check
open wire.
resistance between Break-
YES
NO
out Box terminal 3 and 5
(black). Is it greater than 1
megohm?
Replace MAP sensor. See the
Locate and repair
Touring Service Manual.
grounded V/W wire.
YES
NO
Replace ICM.
Locate and repair
Reprogram and
short between
learn password.
R/W wire and
ground.
Clear codes using speedometer self diagnostics.
See 4.5 SPEEDOMETER SELF DIAGNOSTICS.
Confirm proper operation with no check engine
lamp.
At some point in the flow chart you
may be instructed to jump directly
to a the box with the bold asterisk.
Disregard the asterisk (but not the
instruction box) if your normal pro-
gression through the chart brings
you to this location.
4-36
2005 Touring: Engine Management (Carbureted)
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DTC P0562, P0563
4.14
GENERAL
DIAGNOSTICS
Battery Voltage
Diagnostic Notes
The ignition control module monitors battery positive voltage.
The reference numbers below correlate with the circled num-
The normal operating range is between 8-16 volts while
bers on the Test 4.14 flow charts.
engine is running.
1. Was battery allowed to discharge? Was battery drawn
NOTE
down by a starting problem?
When either a diagnostic trouble code P0562 or P0563 is set,
a. Yes. Charge battery.
the battery icon in the speedometer will illuminate.
b. No. See charging system troubleshooting.
● A DTC P0562 is set if the ignition module detects battery
2. Connect BREAKOUT BOX
(Part No. HD-42682)
positive voltage less than 8 volts while the engine is run-
between wire harness and ignition control module. See
ning.
4.6 BREAKOUT BOX: ICM.
● A DTC P0563 is set if the ignition module detects battery
3. The ignition control module is monitoring voltage at igni-
positive voltage greater than 16 volts.
tion control module connector [10] (black) Pin 1.
● Low voltage generally indicates a loose wire, corroded
4. This checks for voltage drops in the ignition control mod-
connections and/or a charging system problem.
ule circuit.
● A high voltage condition may be caused by a faulty volt-
a. Place (+) probe to battery positive terminal.
age regulator.
b. Place (-) probe to terminal 1 on Breakout Box.
Table 4-17. Code Description
5. Remove Breakout Box at ICM, reconnect ICM. Insert
Breakout Box at connector [22] (BK). On FLHR/S models
DTC
DESCRIPTION
(6-place connector), install Breakout Box adapters (HD-
42962).
P0562
battery voltage low
P0563
battery voltage high
2005 Touring: Engine Management (Carbureted)
4-37
HOME
R/BK To Ignition Switch
Ignition Control Module
[83B]
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 4-26. Battery Voltage Circuit
Table 4-18. Wire Harness Connectors in Figure 4-26.
NO.
DESCRIPTION
MODEL
TYPE
LOCATION
[1]
Main to Interconnect Harness
FLHT/C
12-Place Deutsch
Inner Fairing- Right Fairing Bracket
[8]
Ignition Harness
All
12-Place Deutsch
Under Right Side Cover
[10]
Ignition Control Module
All
12-Place Deutsch (Black)
Under Right Side Cover
Inner Fairing-
Interconnect to Right
FLHT/C
12-Place Deutsch
[22]
Right Fairing Support Brace
Handlebar Switch Controls
FLHR/S
6-Place Deutsch
Inside Headlamp Nacelle
[83]
Ignition Coil
All
3 - Place Packard
Below Fuel Tank (Left Side)
4-38
2005 Touring: Engine Management (Carbureted)
HOME
Test 4.14 (Part 1 of 2)
BATTERY VOLTAGE: DTC P0562, P0563
Perform charging system tests.
1
Charging system OK?
YES
NO
2
With ignition ON, measure voltage drop
Repair
between battery positive (+) terminal
charging system.
3
and Breakout Box connector [10] (black)
Pin 1 (-). Is voltage drop greater
than 0.5 volt?
4
YES
NO
With ignition ON, measure voltage drop
Check for voltage drop between battery
5
between battery positive (+) terminal
negative (-) terminal and Pin 5 (+) on
and connector [22A] Pin 4 (-). Is voltage
connector [10B] (black) on Breakout Box.
drop greater than 0.5 volt?
Is voltage drop greater than 0.5 volt?
YES
NO
YES
NO
With ignition ON, measure voltage drop
Repair or replace
Locate and repair
Problem is intermittent.
between battery positive (+) terminal
W/BK wire or
bad connection.
Perform 4.7 WIGGLE
and connector [22A] Pin 3 (-). Is voltage
terminals.
TEST.
drop greater than 0.5 volt?
YES
NO
Inspect connector [22] for
corrosion or loose wires. If
STOP
above conditions are not
present, replace engine stop
switch.
Go to Test 4.14
(Part 2 of 2).
Clear codes using speedometer self diagnostics.
See 4.5 SPEEDOMETER SELF DIAGNOSTICS.
Confirm proper operation with no check engine
lamp.
2005 Touring: Engine Management (Carbureted)
4-39
HOME
Test 4.14 (Part 2 of 2)
BATTERY VOLTAGE: DTC P0562, P0563
Continued from Test 4.14 (Part 1 of 2). With
ignition ON, measure voltage drop between
battery positive (+) terminal and GY terminal
on 15 amp ignition fuse (-). Is voltage
drop greater than 0.5 volt?
YES
NO
With ignition ON, measure voltage drop
Repair or replace GY
between battery positive (+) terminal and
wire or terminals.
R/BK terminal on 15 amp ignition fuse. Is
voltage drop greater than 0.5 volt?
YES
NO
With ignition ON, measure voltage drop
Replace fuse or
between battery positive (+) terminal and
fuse terminals.
terminal A of maxi fuse (-).
Is voltage drop greater than 0.5 volt?
YES
NO
With ignition ON, measure voltage drop
Replace ignition
between battery positive (+) terminal and
switch or terminals.
terminal B of maxi fuse (-).
Is voltage drop greater than 0.5 volt?
YES
NO
High resistance between maxi
Replace maxi fuse.
fuse and battery. Replace wire or
terminals.
Clear codes using speedometer self diagnostics.
See 4.5 SPEEDOMETER SELF DIAGNOSTICS.
Confirm proper operation with no check engine
lamp.
4-40
2005 Touring: Engine Management (Carbureted)
HOME
DTC P1009, P1010
4.15
GENERAL
Password Problem
The ICM and TSM/TSSM exchange passwords during opera-
tion. An incorrect password or missing password will set a
diagnostic code.
NOTE
If the TSM/TSSM is not connected to the wiring harness, the
vehicle will not start.
Table 4-19. Code Description
DTC
DESCRIPTION
f2323x8x
P1009
Incorrect password
P1010
Missing password
Figure 4-27. TSM/TSSM
DIAGNOSTICS
6924c
3
Diagnostic Notes
The reference numbers below correlate with the circled num-
2
bers on the Test 4.15 flow charts.
1
1. DTC P1009 may be set if a recent ICM or TSM/TSSM
replacement did not follow the correct password assign-
1. Terminal 2: ground (BK)
ment procedure. See
3.24 PASSWORD LEARN for
2. Terminal 3: serial data (Lt GN/V)
details.
3. Terminal 4: power (GY)
2. Use HARNESS CONNECTOR TEST KIT (Part No. HD-
41404A), black socket probes and patch cord.
Figure 4-28. Data Link Connector
3. Connect BREAKOUT BOX
(Part No. HD-42682)
between wire harness and ICM. See 4.6 BREAKOUT
BOX: ICM.
4. See the Touring Service Manual for TSM/TSSM replace-
ment. See PASSWORD LEARNING under 3.24 PASS-
WORD LEARN for the password learning procedure.
2005 Touring: Engine Management (Carbureted)
4-41
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