Harley Davidson 2005 touring models. Service repair manual — page 55

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RADIO SYMPTOM 3

6.6

GENERAL

DIAGNOSTICS

Problem

Diagnostic Notes

No sound in one or more speakers (external).

The reference numbers below correlate with the circled num-

bers in the Test 6.6 flow charts.

For input bit location see illustration inside flow chart.

Setup

If both motorcycle speakers and sidecar speakers are

● Press the POWER button to turn the radio ON.

inoperative, first go to Test 6.6 (Part 2 of 3).

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

Perform following:

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

a. Impedance Check: With ohmmeter set on R x 1,

Intercom OFF.

measure impedance or resistance of the speaker

voice coil. Place probes of ohmmeter on the speaker

● Set fairing mounted Headset/Speaker Switch to

terminals and observe the reading. Reading must

SPEAKER (red lamp illuminated).

be 6-10 ohms. Replace the speaker if any other

● Set radio frequency to known strong station.

reading is observed.

● Set Volume and Fader to Middle position on horizontal

b. Cone Inspection: Inspect the speaker cone for

bar graph display.

damage. Replace the speaker if torn or warped.

Check for binding voice coil. Remove speaker and

● If performing sidecar diagnosis, rotate sidecar volume

place four fingers evenly across the face of the

control clockwise to middle or full volume position.

speaker cone. Very gently press inward evenly on

the cone. The cone must move smoothly without

binding. Release finger pressure. Cone must move

Functionality

outward smoothly. Replace the speaker if the cone

does not move without binding.

Sound should be audible in all speakers. Is it?

Assumes Speaker Switch B input bit displays “0.”

● Yes - System is OK.

Revalidate failure. Reconnect all connectors. If problem

● No - See Test 6.6 (Part 1 of 3).

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

intermittents.

Use HARNESS CONNECTOR TEST KIT (Part No. HD-

41404A), black pin probes and patch cord.

Use HARNESS CONNECTOR TEST KIT (Part No. HD-

41404A), black socket probes and patch cord.

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)

Figure 6-14. Diagnostic Mode Group 2 Matrix

6-14

2005 Touring: Sound System

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Test 6.6 (Part 1 of 3)

NO SOUND IN ONE OR MORE SPEAKERS/SIDECAR SPEAKERS: SOFTWARE DIAGNOSIS

Is Vehicle Ultra or

Classic/Road Glide?

Ultra

Classic/Road Glide

Does Any

Go to

Enter Diagnostic Mode 2 by

Speaker Work?

Test 6.6 (Part 2 of 3).

Holding Any Two Preset

Buttons and Turning Igni-

tion Switch to ON. Then

Push LO/DX Button Once

to Obtain “d2” in LCD.

YES

Are Both Speaker Switch A

and Speaker Switch B Dis-

Optional Side-

played in LCD as “1?”

car Speakers

Inoperative?

YES

Is Handheld Micro-

Go to Test 6.6

phone PTT Displayed

(Part 2 of 3).

in LCD as “1?”

Go to Test 6.6

(Part 3 of 3).

(Part 2 of 3).

YES

Is Intercom ON/OFF

Go to Test 6.17

Switch Displayed in

(Part 2 of 2).

LCD as “0?”

YES

After correction of problem, refer to SETUP and

Is CB ON/OFF

Replace

FUNCTIONALITY to verify proper operation.

Switch Displayed

Radio.

in LCD as “0?”

6601

YES

Go to

Replace

Test 6.6 (Part 2 of 3).

Radio.

6601

Speaker

Switch B

Switch A

f2122x8x

Figure 6-15. Speaker Switch B and

Speaker Switch A Input Bits

2005 Touring: Sound System

6-15

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Test 6.6 (Part 2 of 3)

NO SOUND IN ONE OR MORE SPEAKERS: HARDWARE DIAGNOSIS

Do Any

Speakers

Work?

YES

Individual Speakers Inoperative

Speaker Switch Malfunction

Measure Voltage at

With Ignition Switch ON,

Speaker Leads With

Measure Voltage Between

Reference to Ground.

BN/O Wire on Connector [105]

Is 5-7 volts DC

(While Connected) and

Present?

Ground. Voltage Must Approxi-

mate Battery Voltage. Does It?

YES

Perform

Connect Breakout Box to Harness Only,

Speaker Test.

Leaving Radio Disconnected. Check for

Replace

Disconnect Connector [105].

Speaker OK?

Continuity as Follows:

Radio.

Repeat Voltage Test on BN/O

Wire in Connector [105A].

Wire

6601

Voltage Must Approximate

Speaker

Connector

Terminal

Color

Battery Voltage. Does It?

YES

Front

GY/R

[27B]

Right

L.GN/BK

[27B]

Replace

Front

W/O

[27B]

YES

Radio.

Speaker.

Left

L.GN/W

[27B]

6601

Rear

[28B]

Right

L.GN/BN

[28B]

Replace

Disconnect Connec-

Switch.

tor [27B]. Measure

Rear

W/BN

[28B]

Continuity to Ground

Left

[28B]

5192

Front

Rear

on BN/O Wire in

Speaker.

Each Wire Should be Less than 0.5 Ohms.

Connector [105A].

Is It?

Continuity Present?

6605

6606

YES

Locate and Repair

Replace

Grounded BN/O

Radio.

Replace

Locate and

Wire Between

Radio.

Repair Open

Connectors [105A]

6601

in Wire.

and [27B].

6601

6531

Front

Rear

Speaker.

6532

6561

After correction of problem, refer to SETUP and

FUNCTIONALITY to verify proper operation.

Table 6-4. Wire Harness Connectors

NO.

DESCRIPTION

MODEL

TYPE

LOCATION

[27]

Radio

All

23-Place Amp (Black)

Inner Fairing- Back of Radio (Right Side)

Inner Fairing - Below Upper Fork Bracket

Fairing Cap Switches

FLHTC/U

12 - Place Multilock

(Right Side)

[105]

Instrument Nacelle Switches

FLTR

12 - Place Multilock

Inside Instrument Nacelle (Under Bezel)

6-16

2005 Touring: Sound System

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Test 6.6 (Part 3 of 3)

NO SOUND IN ONE OR MORE SIDECAR SPEAKERS: HARDWARE DIAGNOSIS

Do Any Sidecar

Speakers Work?

YES

Check for Continuity Between Each Speaker Terminal

and Connector [149B] as Follows:

FROM

Amplifier

Speaker/

Speaker

Terminal

Connector

input/Output

Connector

Left +

OUT

Speaker

Lt. BE/W

Left -

OUT

Speaker

Lt. BE/BK

Right +

OUT

Speaker

Lt. GN/W

Right -

OUT

Speaker

Lt. GN/BK

Check for Power on [149B] at

[149B]

Left +

[42D]

5 BN

Terminal 21 (+) and Terminal

Left -

[42D]

6 W/BN

20 (-). With Ignition Switch ON,

Measure Voltage. Is Battery

Right +

[41D]

5 GN

Voltage Present?

Right -

[41D]

6 Lt. G/BN

Continuity Present?

YES

Check for Continuity Between Connector [149B] and

Check for Continuity

YES

Rear Speaker Connectors [41] and [42] as Follows:

Between Connector [149B]

Terminal 21 and Connector

Test Speakers.

Locate and

FROM

[53D] O/V Wire. Also Check

Speakers OK?

Repair Open or

Speaker

Connector

Terminal

Connector

for Continuity Between Con-

Replace Sidecar

Left +

5 BN

nector [149B] Terminal 20

Audio Harness.

[42D]

and Connector [53D] BK

Left -

6 W/BN

[149B]

Wire. Continuity Present on

6940

Right +

5 GN

[41D]

Both Wires?

YES

Right -

6 Lt. G/BN

Continuity Present?

Replace

Sidecar

Amplifier.

Speaker.

YES

6949

6943

Locate and

Repair Open or

Replace

Locate and

Replace Sidecar

Sidecar

Repair Open or

Audio Harness.

Amplifier.

Replace Sidecar

YES

Audio Harness.

6940

6949

6940

Check for Continu-

ity to Ground on BK

Wire of Connector

[53A]. Continuity

Present?

YES

Do Brake

Locate and

Lights Work?

Repair Open in

Ground Circuit.

6561

After correction of problem, refer to SETUP and

YES

FUNCTIONALITY to verify proper operation.

Locate and

Check for

Repair Open

Blown Fuse.

on O/V Wire.

Replace if Nec-

essary.

6561

5145

2005 Touring: Sound System

6-17

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RADIO SYMPTOM 4

6.7

GENERAL

AVC Adjustment Mode

Problem

Automatic volume control (AVC) inoperative.

Setup

● Press the POWER button to turn the radio ON.

● Press and hold the CB button

to turn the Citizen Band

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

Intercom OFF.

f2124x8x

Automatic Volume Level

● Set fairing mounted Headset/Speaker Switch to

SPEAKER (red lamp illuminated).

Figure 6-16. Adjust Automatic Volume Control

● Set radio frequency to known strong station.

● Set Volume and Fader to Middle position on horizontal

bar graph display.

If the AVC does not adequately compensate for ambient

noise (or if it overcompensates), adjust as follows:

Functionality

Push any two Preset buttons on the front panel of the

To compensate for higher background noise, volume should

radio. With the buttons depressed, turn the Ignition/Light

increase with increasing motorcycle speed

(most evident

Key Switch to IGNITION. Diagnostic Group 1 appears on

above 40 MPH). Does it?

the LCD display, as indicated by the “d1” in the lower por-

tion.

● Yes - System is OK.

Push the LO/DX button on the front panel of the radio

● No - See Test 6.7 (Part 1 of 2).

three times to sequence to the model year configuration

screen. “Press 1 for bikes before MY2004, press 2 for

NOTE

MY2004 and later” is displayed in the upper portion of

Since AVC function is not as obtrusive as that seen in previ-

the LCD display, while the current selection is displayed

ous model years, providing a very smooth transition from no

in the lower portion. If the number displayed is not cor-

AVC effect up to full AVC effect, it may be most easily

rect, simply change the display by pressing the appropri-

observed in the headsets (Ultra models only). To ramp the

ate preset button. Entering the wrong digit will adversely

affect AVC operation.

AVC up or down, that is, to change the rate of volume

increase, see Automatic Volume Control (AVC) Adjustment

Push the LO/DX button two more times to sequence to

below.

the AVC adjustment screen. The letters “AVC” are dis-

played in the upper portion of the LCD display, while the

automatic volume level number appears in the lower por-

tion. See Figure 6-16.

DIAGNOSTICS

To ramp the AVC up, press the Mode Select Switch on

the right handlebar in an upward direction (UP). To ramp

Automatic Volume Control (AVC)

the AVC down, press the switch in a downward direction

(DN). Although the factory presets the volume level at

Adjustment

number “2,” it is adjustable from “0” (AVC least aggres-

Active in CB, INTERCOM and music, Automatic Volume Con-

sive) to

“4”

(AVC most aggressive). Any adjustment

trol (AVC) automatically adjusts volume level to compensate

affects the AVC schedules of both headset and external

for ambient noise associated with motorcycle speed. Since

speakers.

wind and road noise is less of a factor with headset speakers,

After making the desired change, continue pushing the

headset and external speakers are provided with separate

LO/DX button until the system reverts back to normal

AVC schedules.

radio operation. The Diagnostic Mode also can be exited

by simply turning the Ignition/Light Key Switch to OFF.

6-18

2005 Touring: Sound System

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Diagnostic Notes

Test 6.7 (Part 1 of 2)

The reference numbers below correlate with the circled num-

AUTOMATIC VOLUME CONTROL (AVC)

bers in the Test 6.7 flow charts.

INOPERATIVE: SOFTWARE DIAGNOSIS

1. The circuit that recognizes the vehicle speed signal is the

same one that controls the AVC. If the bit alternates

between “0” and “1,” then the AVC is functioning as

Enter Diagnostic Mode 2.

designed.

Does AVC Bit in LCD Dis-

play Alternate Between “0”

2. Connect Speedometer Tester (HD-41354) to speedome-

and “1” When Rear Wheel

is Rotated.

ter sensor connector [65] located under the seat (3-place

Deutsch). Enter a speed greater than 40 MPH (see table

2-7), and observe speedometer needle and radio vol-

YES

ume. Volume should begin to increase around 40 MPH

and further increase as indicated speed rises above 40

MPH.

Test Ride Above

Go to Test 6.7

40 MPH. Does

(Part 2 of 2)

3. To enable Diagnostic Mode, see 2.3 SPEEDOMETER

Volume Increase

With Speed?

SELF DIAGNOSTICS.

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

YES

tion 6.3 BREAKOUT BOX, INSTALLATION.

5. Use HARNESS CONNECTOR TEST KIT (Part No. HD-

No Problem. See Auto-

Does Model Year

matic Volume Control

Configuration

41404A), black pin probe and patch cord.

(AVC) Adjustment to

Screen Display 1

Change Rate of Volume

or 2?

Increase.

Change selection to

Replace

number 2. See step 2

Radio.

under Automatic Vol-

6601

ume Control (AVC)

Adjustment.

AVC Vehicle

Speed Signal

f2122x8x

Figure 6-17. LCD Input Bit Display

2005 Touring: Sound System

6-19

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Test 6.7 (Part 2 of 2)

AUTOMATIC VOLUME CONTROL (AVC) INOPERATIVE: HARDWARE DIAGNOSIS

Perform speedometer

self-diagnostics.

Is P0501 or P0502 set?

YES

See P0501/P0502.

Disconnect ECM connector [78B].

Disconnect connector

[27]. Con-

nect Breakout Box. Measure volt-

age at Terminal

9. Is voltage

present?

YES

Locate and repair

Measure continuity to ground from

short to voltage on

Terminal

9 on Breakout Box. Is

W/GN wire.

continuity present?

6531

YES

Locate and repair

Check continuity between Termi-

short to ground on

nal 9 on Breakout Box and con-

W/GN wire.

nector

[65B], terminal B. Is

continuity present?

6531

YES

Replace

Locate and

radio.

repair open

on W/GN

6601

wire.

After correction of problem, refer to SETUP and

FUNCTIONALITY to verify proper operation.

6532

Table 6-5. FLHTC/U Wire Harness Connectors

NO.

DESCRIPTION

TYPE

LOCATION

[27]

Radio

23-Place Amp (Black)

Inner Fairing- Back of Radio (Right Side)

Under Right Side Cover

[65]

Speedometer Speed Sensor

3-Place Deutsch

(Behind Electrical Bracket)

[78]

ECM

36-Place Packard

Under Right Side Cover

6-20

2005 Touring: Sound System

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RADIO SYMPTOM 5

6.8

GENERAL

Less than 1 ohm

on X1 scale

Problem

Poor stereo reception.

Infinite on

X1000

scale

Setup

● Press the POWER button to turn the radio ON.

● Select AM mode.

● Set LO/DX Switch to LO(CAL).

● Select SEEK function and use MODE CONTROL

SWITCH to select station with strong signal.

f1859xed

Functionality

Figure 6-18. Antenna Test Hookup

Radio should lock onto strong station. Does it?

● Yes - System is OK.

● No - See Radio Antenna Test below. If antenna passes

Test 6.8

test, continue with the Test 6.8 flow chart.

POOR STEREO RECEPTION

DIAGNOSTICS

Antenna

OK?

Radio Antenna Test

YES

A faulty antenna can cause poor reception. Check it in three

steps after cleaning the mast.

Replace

Repair/Replace

Radio.

Antenna.

1. See Figure 6-18. Set your ohmmeter to the X 1 scale and

6601

connect the leads as shown. If the reading is more than 1

ohm, replace the antenna or cable. If less than 1 ohm,

Replace

Mast.

Antenna

proceed to Step 2.

Cable.

6617

2. Using the same scale, connect the leads as shown. If the

6609

reading is greater than 1 ohm, replace the antenna or

cable. If less than 1 ohm, proceed to Step 3.

3. Set the meter to the X 1,000 scale and connect the leads

as shown. If the reading is not infinite, replace the

antenna or cable. If replacement parts are necessary,

retest after installation of new parts.

2005 Touring: Sound System

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RADIO SYMPTOM 6

6.9

GENERAL

f2203x8x

Radio Memory

Radio Power

O/BE

R/O

Problem

No power.

Setup

● Turn the Ignition/Light Key Switch to IGNITION.

Functionality

The radio LCD should illuminate. The LCD should display the

time or an operational mode (radio, CD, etc.), depending on

the last state of the POWER button on the radio front panel.

The radio should toggle between the time display and an

Figure 6-19. Fuse Block (FLTR, FLHTC/U)

operational mode when the POWER button is repeatedly

pushed. Does it?

● Yes - System is OK.

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

● No - See Test 6.9 (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-

Diagnostic Notes

41404A), black pin probes and patch cord.

The reference numbers below correlate with the circled num-

bers in the Test 6.9 flow charts.

See Test 6.9 (Part 1 of 2).

Perform tests to ensure that battery is fully charged.

6-22

2005 Touring: Sound System

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Test 6.9 (Part 1 of 2)

NO POWER: SOFTWARE DIAGNOSIS

Does LCD Lighting

Illuminate?

YES

Does Time Display

Do Other Lights

Appear in LCD?

Illuminate?

YES

Push Power Button on

Does Opera-

Go to Test 6.9

Check Battery.

Radio Front Panel.

tional Mode

(Part 2 of 2).

Charge or

Did Radio Display

Appear in LCD?

Replace.

Change to Operational

Mode (i.e., Radio,

CD, Etc.)?

YES

Power

Replace

YES

OK.

Radio.

6601

Power

Access Radio

OK.

Diagnostic Mode

1. Were You

Successful?

YES

With No Switches

Replace

Active, Are All Five

Radio.

Input Bits in LCD

6601

Displayed as “1?”

YES

Push Each of the Switches in the Left Hand Column While Observing

Input Bit on Cx Line Displaying “0” in LCD is Grounded.

the LCD Display. Match Your Observations to the Table Below.

See Short to Ground in Associated Hardware Chart.

LCD Display

Cx Line

Hardware Chart

Push

1 = Short to Voltage

C0, C1, C2

Audio Control Inoperative

0 = Short

Switch

(1/0) = OK

(or Open Circuit Between Lines

Rear Headset Volume/PTT Inoperative

to Ground

When Switch Closed Equals “0”)

Mode Control Inoperative

Mode Up

R0 or C4

(if Front Mode Control OK, See Rear)

Rear Vol. -

R1 or C3

SQ -

R2 or C2

Audio -

R0 or C1

Audio +

R0 or C0

Do the Switches Work OK?

YES

Replace

Go to Corresponding

Radio.

Hardware Diagnosis for

Switch That is Inoperative.

6601

After correction of problem, refer to SETUP and

FUNCTIONALITY to verify proper operation.

2005 Touring: Sound System

6-23

HOME

Test 6.9 (Part 2 of 2)

NO POWER: HARDWARE DIAGNOSIS

Check Fuses.

Are Fuses OK?

YES

Remove Outer Fairing. Connect

Replace Fuse.

Breakout Box leaving [27B] dis-

Did Fuse Blow

connected from Radio. Check for

Again?

Resistance to Battery Ground at

Terminals 11 and 19 (BK/GN) of

Connector [27B]. Is Continuity to

Ground 1 Ohm or Less?

YES

Replace Fuse.

System

Disconnect Connector

OK.

[27]. Turn ignition ON.

With Key ON or OFF,

Did Fuse Blow Again?

Check for Voltage at

Terminals 10 and 20

(R/O) of Connector

[27B]. Battery Voltage

YES

Present?

Replace Fuse.

Replace

YES

Disconnect Connector

Radio.

[1]. Turn ignition ON.

6601

Did Fuse Blow Again?

With Key ON or

With Key ON, Check for

Power at Terminal 12

OFF, Check for Volt-

age at Terminal A

(O/BE) of Connector

[27B]. Battery Voltage

(R/O) of Connector

Present?

[15B]. Battery Volt-

YES

age Present?

Locate and

YES

Repair Short to

YES

Ground

Ground Between

Between

Connectors [1]

Replace

With Key ON,

Locate and

Fuse and Con-

and [27].

Radio.

Check for Voltage

Repair Open in

Repair Open

nector.

at Terminal 9

Interconnect

in Main Har-

6531

6601

(O/BE) of Connec-

Harness.

ness.

5028

tor [1B]. Battery

Voltage Present?

6532

5028

Check for Resistance

YES

at Terminal on Top of

Fork Bracket. Is Conti-

Locate and

nuity to Battery Ground

1 Ohm or Less?

Repair Open in

Interconnect

Main Harness.

Harness.

5028

YES

6532

Locate and

Repair Open

Repair Open in

in Intercon-

Ground Circuit

After correction of problem, refer to SETUP and

nect Harness.

Between Top

FUNCTIONALITY to verify proper operation.

Fork Bracket

6532

and Frame.

5038

Table 6-6. Wire Harness Connectors

NO.

DESCRIPTION

MODEL

TYPE

LOCATION

Main to Interconnect

FLHTC/U

12-Place Deutsch (Black)

Inner Fairing - Right Radio Support Bracket

[1]

Harness

FLTR

12-Place Deutsch (Black)

Inner Fairing - Below Radio (Right Side)

[27]

Radio

All

23-Place Amp (Black)

Inner Fairing- Back of Radio (Right Side)

6-24

2005 Touring: Sound System

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RADIO SYMPTOM 7

6.10

GENERAL

DIAGNOSTICS

Problem

Diagnostic Notes

CD will not eject.

The reference number below correlates with the circled num-

bers in the Test 6.10 flow charts.

Setup

● Press the POWER button to turn the radio ON.

CAUTION

Do not force mechanism or radio damage will occur.

Functionality

If ejection does not work, contact your Radio Sound rep-

CD should eject when EJECT button is pushed while radio is

resentative.

in either CD or radio mode. Does it?

● Yes - System is OK.

● No - See Test 6.10 (Part 1 of 2).

2005 Touring: Sound System

6-25

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Test 6.10 (Part 1 of 2)

CD WILL NOT EJECT: SOFTWARE DIAGNOSIS

Does EJECT Button Have

Any Effect? In Other Words,

Does EJECT Button Cause

CD to Move or LCD to

Change?

YES

Go to

Enter Diagnostic

Test 6.10 (Part 2 of 2).

Mode “d1.” Are All

Input Bits Displayed

If CD Successfully

in LCD as “1?”

Removed, Will CD Unit

Now Operate Correctly?

YES

Does Input Bit C2

Other Symptoms

System

Replace

Toggle Between “1”

Present?

OK.

Radio.

and “0” When EJECT

Button is Pushed?

6601

YES

Diagnose

Go to

Other

Test 6.10 (Part 2 of 2).

Go to

Check Other C2

Symptoms.

If CD Successfully

Test 6.10 (Part 2 of 2).

Functions (Preset 3,

Removed, Will CD Unit

Audio In, Squelch -).

Now Operate Correctly?

If CD Successfully

Removed, Will CD Unit

Did They Work?

Now Operate Correctly?

YES

Go to

Go to Hardware

YES

System

Replace

Test 6.10 (Part 2 of 2).

Diagnosis for

OK.

Radio.

If CD Successfully

That Function.

System

Replace

Removed, Will CD Unit

6601

OK.

Radio.

Now Operate Correctly?

6601

YES

System

Replace

OK.

Radio.

6601

After correction of problem, refer to SETUP and

FUNCTIONALITY to verify proper operation.

6-26

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Test 6.10 (Part 2 of 2)

CD WILL NOT EJECT: HARDWARE DIAGNOSIS

Does Eject Button Function Per

Test 6.10 (Part 1 of 2)?

YES

Refer Customer to

Replace Radio. See Touring

Owner’s Manual for

Models Service Manual.

Proper Operation.

6601

After correction of problem, refer to SETUP and

FUNCTIONALITY to verify proper operation.

2005 Touring: Sound System

6-27

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RADIO SYMPTOM 8

6.11

GENERAL

DIAGNOSTICS

Problem

Diagnostic Notes

No sound in one or more headsets/microphone inoperative.

The reference numbers below correlate with the circled num-

bers in the Test 6.11 flow charts.

Setup

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

tion 6.3 BREAKOUT BOX, INSTALLATION.

● Press the POWER button to turn the radio ON.

● Set fairing mounted Headset/Speaker Switch to HEAD-

BE/Y Wire for Handheld PTT is also part of front Inter-

SET.

connect Harness.

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

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

Intercom OFF.

Microphone input

Index

Speaker ground

groove

● Set Front and Rear Volume Control to Middle position on

Right speaker

horizontal bar graph display.

positive

Microphone ground

● Set radio frequency to known strong station.

Left speaker

positive

Shield (ground)

Functionality

Handheld PTT

Sound should be audible in all headsets. Is it?

● Yes - System is OK.

f1355x8x

● No - See Test 6.11 (Part 1 of 2).

Figure 6-20. 7-place DIN Connector: Socket Side

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)

Figure 6-21. Diagnostic Mode Group 2

6-28

2005 Touring: Sound System

HOME

Test 6.11 (Part 1 of 2)

NO SOUND IN ONE OR MORE HEADSETS/MICROPHONE INOPERATIVE: SOFTWARE DIAGNOSIS

Does Any

Headset Work?

YES

Replace Inoperative

Enter Diagnostic Mode 2 by Holding Any

Headset With Known

Two Preset Buttons and Turning Ignition

Working Headset.

Switch to ON. Then Push LO/DX Button

Does It Work?

Once to Obtain “d2” in LCD.

Are Speaker Switch B and Speaker

Switch A Displayed in LCD as “10?”

YES

Replace

Go to

Headset.

Test 6.11 (Part 2 of 2)

Is Handheld Micro-

Go to Test 6.11

phone PTT Displayed

(Part 2 of 2)

in LCD as “1?”

YES

Is Intercom ON/OFF

Go to Test 6.17

Switch Displayed in

(Part 2 of 2).

LCD as “0?”

YES

Is CB ON/OFF

Replace

Switch Displayed

Radio.

in LCD as “0?”

6601

YES

Replace Inoperative

Replace

Headset With Known

Radio.

Working Headset.

Does It Work?

6601

YES

After correction of problem, refer to SETUP and

FUNCTIONALITY to verify proper operation.

Replace

Go to Test 6.11

Headset.

(Part 2 of 2).

Table 6-7. FLHTCU Wire Harness Connectors

NO.

DESCRIPTION

TYPE

LOCATION

[15]

Main to Interconnect Harness

4-Place Packard

Inner Fairing - Right Fairing Bracket

[27]

Radio

23-Place Amp (Black)

Inner Fairing- Back of Radio (Right Side)

[28]

Radio

23-Place Amp (Gray)

Inner Fairing- Back of Radio (Left Side)

[105]

Fairing Cap Switches

12-Place Multilock

Inner Fairing- Beneath Radio (Right Side)

2005 Touring: Sound System

6-29

HOME

Test 6.11 (Part 2 of 2)

NO SOUND IN ONE OR MORE HEADSETS/MICROPHONE INOPERATIVE: HARDWARE DIAGNOSIS

FRONT HEADSET or

REAR HEADSET

HANDHELD MICROPHONE

Remove Outer Fairing. Connect

Breakout Box leaving Connector [28]

Breakout Box leaving Connector [27]

Disconnected from Radio. Check for

and Connector [28] Disconnected from

Continuity as Follows:

Radio. Check for Continuity as Follows:

FROM

Rear

Front

Connector

Terminal

Connector

Terminal

Headset DIN

Speaker Switch Malfunction

[28B]

BOTH HEADSETS

[28B]

Tab (Shield)

Is Continuity Present?

Remove Outer Fairing.

Connect Breakout Box

leaving Connector [27]

[27B]

Disconnected from Radio.

Is Continuity Present?

Check Continuity Between

Terminal 13 of Connector

[27B] and Ground.

YES

Continuity Present?

YES

Replace

Locate and

Radio.

Repair Open in

Audio Harness.

Replace

Check for Continuity as Follows:

YES

6601

Radio.

6561

FROM

6601

Replace

With Connector

Connector

Radio.

[105] Connected,

Connector

Terminal

[53B]

Check for Continu-

6601

ity to Ground on

BK/GN Wire of

[28B]

Connector [105].

Continuity Present?

[27B]

Is Continuity Present?

YES

Check Continuity

Check for Continu-

Between Terminal

ity to Ground on

YES

13 of Connector

BK/GN Wire of

[27B] and BN/O Wire

Connector [15B].

of Connector [105A].

Continuity Present?

Replace Head-

Locate and

Continuity Present?

set Harness.

Repair Open in

Audio Harness.

6616

6561

YES

Replace

Repair

Locate and Repair

Inspect BK/GN

Speaker

Open in

Open in BK/GN

Ground Terminal in

Switch.

BN/O Wire.

Wire Between Con-

Front of Battery.

nector [105A] and

Tighten and/or

5192

6532

Connector [15A].

Repair as Necessary.

6532

If Ground Connector

is Good, Locate and

Repair Open in BK/

GN Wire Between

Connector [15B] and

After correction of problem, refer to SETUP and

FUNCTIONALITY to verify proper operation.

Ground Terminal in

Main Wire Harness.

5038

6-30

2005 Touring: Sound System

HOME

RADIO SYMPTOM 9

6.12

GENERAL

Not Applicable to Classic/Road Glide Models

Problem

(BN/W)

(O/BK)

(BN/BK)

(GY/GN)

(GN/BE)

REAR

Rear headset volume/PTT inoperative.

MODE UP

AUDIO

(PK/W)

VOLUME

REAR

MODE DN

RADIO

VOLUME

EJECT

LO/DX

(GY/W)

POWER

Setup

DOWN

MODE

SQUELCH

SEEK

● Press the POWER button to turn the radio ON.

(V/BK)

PTT

DOWN

SCAN

NOT

PRESET

● Set fairing mounted Headset/Speaker Switch to HEAD-

(INT)

USED

SET.

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

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

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

Figure 6-22. Diagnostic Mode Group 1 Switch Matrix

Intercom OFF.

● Set radio frequency to known strong station.

f2123x8x

Functionality

Adjust the volume with the Audio Control Switch on the rear

right speaker box. Stereo audio should be present in the

headset. Push the switch upward (+) to raise the volume,

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

annunciates rear volume level through a

horizontal bar graph

display. The display reverts to the time of day approximately

two seconds after the switch is released.

Pressing PTT while

CB is OFF activates Intercom microphone. Pressing PTT

while CB is ON activates CB transmitter.

Are these your observations?

Figure 6-23. Rear Headset Volume/PTT Switch Input Bit

● Yes - System is OK.

● No - See Test 6.12 (Part 1 of 3).

2. Revalidate failure. Reconnect all connectors. If problem

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

intermittents.

DIAGNOSTICS

3. Use HARNESS CONNECTOR TEST KIT (Part No. HD-

41404A), black pin probes and patch cord.

4. Use HARNESS CONNECTOR TEST KIT (Part No. HD-

Diagnostic Notes

41404A), black socket probes and patch cord.

The reference numbers below correlate with the circled num-

bers in the Test 6.12 flow charts.

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

tion 6.3 BREAKOUT BOX, INSTALLATION.

2005 Touring: Sound System

6-31

HOME

Test 6.12 (Part 1 of 3)

REAR HEADSET VOLUME/PTT INOPERATIVE OR SIDECAR PTT INOPERATIVE: SOFTWARE DIAGNOSIS

Enter Diagnostic Mode

by Pressing Any Two Pre-

set Buttons While Turning

Ignition Switch to On.

Look at Input Bit C3 in LCD

Display. See Figure 6-23.

Does the Input Bit Display

“0” With the Switches Open?

YES

Move to Hardware Chart to Find

Exercise All Three Posi-

Short to Ground on Wire Where

tions of REAR VOLUME/

Corresponding Input Bit Displays “0”

PTT SWITCH or Single

(With No Switches Depressed).

Position of SIDECAR PTT

SWITCH. Does the Corre-

Rear Headset Volume/PTT

sponding Input Bit Toggle

Switch

Input

Wire

Between “1” and “0” For

Position

Bit

Color

Each Switch Position?

Vol +

Vol -

O/BK

PTT

YES

Sidecar PTT

Switch and

Is it a “0” or a “1”

Switch

Input

Wire

Wiring are OK.

While Switch Posi-

Position

Bit

Color

Replace Radio.

tion is Activated?

PTT

O/BK

6601

Move to Hardware Chart to Find

Does the Preset

Short to Ground on Wire Where

4 Button Work?

Corresponding Input Bit Displays “0.”

Rear Headset Volume/PTT

Switch

Input

Wire

YES

Position

Bit

Color

Vol +

PK/W

Move to

Move to Hardware Chart to Find

Vol -

GY/W

Hardware Chart

Short to Voltage on Wire Where

PTT

V/BK

to Find Open at

Corresponding Input Bit Displays “1.”

Bold Asterisk.

Sidecar PTT

Rear Headset Volume/PTT

Switch

Input

Wire

Switch

Input

Wire

Position

Bit

Color

Position

Bit

Color

PTT

V/BK

Vol +

PK/W

Vol -

GY/W

PTT

V/BK

All Positions

O/BK

Sidecar PTT

HARDWARE CHART

CONTINUE WITH

Switch

Input

Wire

Rear Headset Volume/PTT

Test 6.12 (Part 2 of 3)

Position

Bit

Color

PTT

V/BK

Sidecar PTT

Test 6.12 (Part 3 of 3)

After correction of problem, refer to SETUP and

FUNCTIONALITY to verify proper operation.

Table 6-8. FLHTCU Wire Harness Connectors

NO.

DESCRIPTION

TYPE

LOCATION

[28]

Radio

23-Place Amp (Gray)

Inner Fairing- Back of Radio (Left Side)

Rear Right Speaker/Passenger

[41]

6-Place Mini-Deutsch (Black)

Inside Rear Right Speaker Box

Controls

6-32

2005 Touring: Sound System

HOME

Test 6.12 (Part 2 of 3)

REAR HEADSET VOLUME/PTT INOPERATIVE: HARDWARE DIAGNOSIS

What Did Test 6.12 (Part 1 of 3)

Indicate?

SHORT to VOLTAGE

SHORT to GROUND

Remove Outer Fairing. Connect Breakout Box

Remove Outer Fairing. Connect Breakout

leaving Connector [28B] Disconnected from

Box leaving Connector [28B] Disconnected

Radio. With Key ON, Check for Power at

from Radio. With Key OFF, Check for Continu-

Connector [28B].

ity to Ground at Connector [28B].

From (-)

To Terminal (+)

From (-)

To Terminal (+)

13 (PK/W)

6 (GY/W)

Ground

14 (V/BK)

12 (O/BK)

Is Voltage Present?

Any Continuity Present?

YES

Locate and

Replace

Locate and

OPEN

Repair Short in

Radio.

Repair Short in

Audio

6601

Audio

Harness.

With Switch Depressed, Check for

6560

Continuity at Connector [28B].

6560

Switch

From

Position

Terminal

At some point in the Software flow chart you may be instructed

Vol. Up

12 (O/BK)

13 (PK/W)

to jump directly to the box marked by the asterisk. Disregard the

Vol. Dn

12 (O/BK)

6 (GY/W)

asterisk (but not the instruction box) if your normal progression

PTT

12 (O/BK)

14 (V/BK)

through the chart brings you to this location.

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 [41]. With

Radio.

Switch Depressed, Check for

Continuity at Connector [41B].

6601

Switch

From

Position

Terminal

Vol. Up

4 (O/BK)

1 (PK/W)

Vol. Dn

4 (O/BK)

2 (GY/W)

PTT

4 (O/BK)

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 Rear

Repair Open or

Volume/PTT

Replace Audio

Switch or Repair

Harness.

Switch Wiring.

6627

6561

After correction of problem, refer to SETUP and

FUNCTIONALITY to verify proper operation.

2005 Touring: Sound System

6-33

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Harley Davidson 2005 touring models. Service repair manual — page 55

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