Harley Davidson 2008 Sportster Models. Electrical Diagnostics Manual — page 21
em01187
Neutral
Indicator
Lamp
[20A]
6
8
[20B]
6
8
BK
BK/R
[24A]
7
8
[24B]
7
8
15 Amp
Ignition
Instruments
Switch
[136B]
Fuse
[136A]
I
C
R/BK
B
B
R
A
A
[33A] [33B]
Neutral
Switch
Powertrain
Ground
Point
GND 1
[30B]
4
10
12
30 Amp
[30A]
4
10
12
MAXIFUSE
R
R
+
-
Battery
TSM/TSSM
Engine Case
Ground Point
Figure E-25. Clutch and Neutral Interlock Circuits
Table E-19. Wire Harness Connectors
NO.
DESCRIPTION
TYPE
LOCATION
[20]
Instruments
12-place Molex
Under fuel tank
[24]
Left handlebar controls (gray)
8-place Molex
Under fuel tank
[30]
TSM/TSSM
12-place Deutsch
Under battery
[33]
Ignition switch
-
Right side of frame behind neck
[136]
Neutral switch
1-place molded jumper, black
Right side frame, beneath gear case
cover
E-52 2008 Sportster Diagnostics: Appendix E TSM/TSSM (Japan/Korea)
Clutch Switch Short-to-Ground: DTC B1154
Connect Breakout Box HD-42682 to the main harness, leaving the
CONNECTOR [30] disconnected. Measure continuity between
1
terminal “10” (Gray) (+) and terminal “12” (Gray) (-). Is continuity
present?
YES
NO
Disconnect connector [24]. Measure
continuity between terminal “10” (Gray)
Replace TSSM. Learn password
(+) and terminal “12” (Gray) (-) on
2
and perform set-up.
Breakout
Box. Is continuity present?
6791
YES
NO
Locate and repair short-to-
Locate and repair
ground on (BK/R) wire in main
short-to-ground in
wiring harness
left handlebar switch
between [30B] and [24B).
wiring.
5861
5861
NOTE
This DTC may occur if the vehicle is ridden with clutch disengaged
(pulled in) at speeds greater than 10 MPH (16 km/h)
for more than 60 seconds (coasting down a long mountain road.
fc01171_en
2008 Sportster Diagnostics: Appendix E TSM/TSSM (Japan/Korea) E-53
Neutral Switch Short-to-Ground: DTC B1155
Connect Breakout Box HD-42682 to the main harness, leaving the
TSSM disconnected. Measure continuity between terminal “4” (Gray)
1
(+) and terminal “12” (Gray) (-).
Is continuity present?
YES
NO
Disconnect neutral switch connector [136].
Measure continuity between terminal “4” (Gray)
Replace TSSM. Learn password
3
2
(+) and terminal “12” (Gray) (-) on Breakout Box.
and perform set-up.
Is continuity present?
6791
YES
NO
Locate and repair short-to-ground
Replace Neutral Switch.
on (TN) wire in main wiring harness.
5157
5862
NOTE
This DTC may occur if the vehicle is ridden with clutch disengaged
(pulled in) at speeds greater than 10 MPH (16 km/h)
for more than 60 seconds (coasting down a long mountain road.
fc01172_en
E-54 2008 Sportster Diagnostics: Appendix E TSM/TSSM (Japan/Korea)
DTC U1016,
U1255
E.19
GENERAL
ed02821
Loss of ECM Serial Data
The serial data connector provides a means for the Electronic
Control Module (ECM), TSM/TSSM, and speedometer to
communicate their current status. When all operating para-
meters on the serial data bus are within specifications, a state
of health message is sent between the components. A Dia-
gnostic Trouble Code (DTC) U1016 indicates that the ECM is
not capable of sending this state of health message. A DTC
U1255 indicates that no messages were present during power
up of the current key cycle. A DTC U1016 indicates that there
was communication on the data bus since power up, but
communication was lost or interrupted during that key cycle.
Table E-20. Code Description
DTC
DESCRIPTION
Figure E-26. ECM Location
U1016
Loss of all ECM serial data (state of
health)
DIAGNOSTICS
U1255
Serial data error/missing message
PART NUMBER
TOOL NAME
HD-42682
BREAKOUT BOX
HD-43876
BREAKOUT BOX
Diagnostic Notes
Each reference number below correlates to a circled number
on the flow chart(s).
1. Connect BREAKOUT BOX (Part No. HD-42682) (gray)
between TSM/TSSM connector [30A] and wire harness
connector [30B]. See E.11 BREAKOUT BOX: TSM/TSSM.
2. Connect BREAKOUT BOX (Part No. HD-43876) between
wire harness and ECM. See 4.7 BREAKOUT BOX: EFI.
2008 Sportster Diagnostics: Appendix E TSM/TSSM (Japan/Korea) E-55
Speedometer
Tachometer (Optional)
em01182
TSM/TSSM
1
2
5
6
7
[39A]
1
2
5
6 7
[108A]
1
2
5
6
7
[39B]
1
2
5
6 7
[108B]
O
[30A]
1
2
3
12
[30B]
1
2
3
12
LGN/V
BN/GY
O/W
BK
[GND1]
1
2
6
7
12
[20A]
To ACCY fuse
1
2
6
7
12
[20B]
R/GY
O/W
12V ACCY
Fuse
To BATT fuse
[GND1]
R
BN/GY
BN/GY
12V BATT
GY
Fuse
To INSTR fuse
LGN/V
R/BK
O
12V INSTR
1
Fuse
To IGN fuse
BK
2
Data Link
Connector
LGN/V
3
R/BK
GY
GY
4
12V IGN
Fuse
[91A]
[GND1]
[78B]
5
[78A]
5
ECM
Figure E-27. Serial Data Circuit
Table E-21. Wire Harness Connectors
NO.
DESCRIPTION
TYPE
LOCATION
[20]
Instruments
12-place Molex
Under fuel tank
[30]
TSM/TSSM
12-place Deutsch
Under battery
[39]
Speedometer
12-place Packard
Back of speedometer
[78]
Electronic Control Module (ECM)
36-place Packard
Under seat
[91]
Data link connector
4-place Deutsch
Under left side cover
[108]
T
achometer (if equipped)
12-place Packard
Back of tachometer
E-56 2008 Sportster Diagnostics: Appendix E TSM/TSSM (Japan/Korea)
Loss of ECM Serial Data: DTC U1016
Can you read ECM hardware part number?
See 3.11 SPEEDOMETER SELF
DIAGNOSTICS.
YES
NO or “No Rsp”
1
Check continuity between
1
While wiggling harness, check continuity
terminal “3” (Gray) of TSM/TSSM
between terminal “3” (Gray) of
Breakout
TSM/HFSM Breakout Box and terminal
Box and terminal “5” of ECM
2
“5” of ECM Breakout Box.
2
Breakout Box.
Continuity present?
YES
NO
YES
NO
Replace ECM.
Repair open on
Clear codes. Test ride.
Repair intermittent
Reprogram and learn
(LGN/V) wire.
Did DTC U1016 return?
on (LGN/V) wire.
password.
YES
NO
Replace ECM.
No trouble found.
Reprogram and learn
password.
Clear DTCs using speedometer self diagnostics. See 3.11
SPEEDOMETER SELF DIAGNOSTICS. Confirm proper
operation with no check engine lamp.
fc01173_en
2008 Sportster Diagnostics: Appendix E TSM/TSSM (Japan/Korea) E-57
DTC U1300,
U1301 OR BUS ER
E.20
GENERAL
ed01340
Serial Data Low or Serial Data Open/High
The typical serial data voltage range is 0 volts (inactive) to 7
volts (active). Due to the short pulse, voltages will be much
lower on a digital/voltmeter (DVOM). In analog mode, a DVOM
reading serial data will show continuous voltage when active,
typically 0.6 to 0.8 volts. The range for acceptable operations
is 0 to 7.0 volts.
Table E-22. Code Description
DTC
DESCRIPTION
U1300
Serial data low
U1301
Serial data open/high
Figure E-28. Data Link Connector [91A]
DIAGNOSTICS
Diagnostic Tips
•
If serial data is shorted, these Diagnostic Trouble Codes
(DTCs) will automatically cause the check engine lamp to
illuminate. The odometer will read "BUS Er" in this condi-
tion.
•
DTCs P1009 and P1010 may accompany DTCs U1300
and U1301.
Diagnostic Notes
If a U1300, U1301 or "BUS Er" is present, perform diagnostic
procedures listed in 4.12 STARTS, THEN STALLS.
E-58 2008 Sportster Diagnostics: Appendix E TSM/TSSM (Japan/Korea)
TSM/TSSM:
PASSWORD LEARN
E.21
GENERAL
PASSWORD LEARNING
If the ECM or TSM/TSSM is faulty, follow the instructions in
To perform password learning procedure, refer to Table E-24.
the Service Manual for ECM or TSM/TSSM replacement. Then,
When finished, continue with all instructions under
to determine if password learn is necessary, refer to
E.3 VEHICLE DELIVERY.
Table E-23.
Always perform all appropriate instructions under E.3 VEHICLE
DELIVERY after TSM/TSSM replacement or removal.
Table E-23. Password Learn
NOTE
DEVICE REPLACED
IS PASSWORD LEARN
Do not forget to enter a Personal Identification Number (PIN)
NECESSARY?
for TSSM vehicles. If a code is not assigned and the key fob
ECM
Yes
is lost or damaged while the vehicle is armed, the TSSM must
be replaced.
TSM
No *
TSSM
Yes
* If a TSM has been replaced by a TSSM, or a TSSM has
been replaced by a TSM, password learn is necessary.
Table E-24. Setting TSM/TSSM and ECM Password
NO.
ACTION
CONFIRMATION
NOTES
Ignition must be turned off for at least
With ignition turned off, Check Engine
15 seconds.
Lamp and Security Lamp will be off.
1
Install new TSM/TSSM or ECM. Per-
form all steps under E.3 VEHICLE
DELIVERY.
2
Set Engine Stop Switch to RUN.
3
Turn Ignition Switch ON.
Verify Check Engine Lamp and
TSM/TSSM enables starter
Security Lamp illuminate and then turn
relay.
off.
4
Attempt normal start one time.
Engine starts and stalls. Check Engine
Password has not been
Lamp illuminates and stays on.
learned. ECM sets DTC
P1009.
5
Wait ten seconds.
Security Lamp will
Security Lamp illuminates.
ECM enters Password
illuminate and stay on.
Learning mode for ten
minutes. Do not cycle Ignition
Switch or interrupt vehicle
power or Password Learn will
be unsuccessful.
6
Wait until Security Lamp turns off
This takes ten minutes.
7
Quickly (within one second) turn Igni-
ECM must not be allowed to
tion Switch OFF-ON.
shutdown.
8
Wait until Security Lamp turns off
This takes ten minutes.
9
Quickly (within one second) turn Igni-
ECM must not be allowed to
tion Switch OFF-ON.
shutdown.
10
Wait until Security Lamp turns off
This takes ten minutes.
11
Quickly (within one second) turn Igni-
ECM must not be allowed to
tion Switch OFF-ON.
shutdown.
12
Turn Ignition Switch OFF. Wait
15
seconds before turning Ignition Switch
ON. Turn Ignition Switch ON and start
engine to confirm successful Password
Learn procedure. Clear Diagnostic
Trouble Codes (DTCs).
13
Perform all steps under E.3 VEHICLE
DELIVERY.
2008 Sportster Diagnostics: Appendix E TSM/TSSM (Japan/Korea) E-59
TSSM MAINTENANCE
E.22
GENERAL
ed03015
The TSSM system uses batteries in the key fob and siren.
These are the only parts requiring periodic maintenance.
KEY FOB
Schedule
Replace the key fob battery every 2 years.
Battery Replacement
1. See Figure E-29. Open the key fob case.
a. Place a thin blade between the 2 halves of the case.
b. Slowly twist the blade.
2. Replace battery (1).
a. Remove the original battery.
Figure E-30. Key Fob Assembly: TSSM
b. Install a new battery with the positive (+) side down.
Use a Panasonic® 2032 or equivalent.
SIREN (IF INSTALLED)
3. Align case and circuit board (3) as shown. Snap case
halves together.
Schedule
4. While standing next to the motorcycle, press and hold the
The siren's internal 9 volt battery is rechargeable and does not
key fob button for 10-15 seconds until the security system
need to be replaced on a regular basis. Battery life under
responds with two turn signal flashes/siren chirps.
normal conditions is approximately three to six years.
NOTES
See Figure E-31 and Figure E-32. Early style siren will work
ed030114
with both TSSM and HFSM. Late style siren will only work with
HFSM.
1
2
The internal siren battery may not charge if the vehicle's battery
is less than 12.5 volts.
Battery Replacement: Early Style Siren
1. Disarm system and remove siren.
2. See Figure E-31. Remove battery cover.
a. Place the siren module on a flat and sturdy table with
3
the potted section (area with epoxy covering circuit
board) facing up and towards you.
b. Position a knife blade at a 45 degree angle to the long
side of the siren case. Insert the knife blade between
1.
Battery
the siren case and battery cover at one of the two
2.
Battery Contact
accessible corners of the battery cover. Keep the
3.
Circuit Board
blade slightly higher towards the battery cover as this
Figure E-29. Open Key Fob: TSSM
helps keep the blade away from the battery seal.
c. Slowly twist the blade towards the battery cover and
the cover will pop off.
NOTES
•
For protection against corrosion, battery terminals and
battery clip are covered with a special grease. Do not wipe
away this substance. Apply all available existing grease
to terminals on new battery.
•
Only a 9 volt nickel metal hydride battery should be used
in the siren.
E-60 2008 Sportster Diagnostics: Appendix E TSM/TSSM (Japan/Korea)
3. Replace battery by removing old battery from polarized
ed03016
battery clip. Install a new 9 volt nickel metal hydride bat-
tery.
4. Reinstall battery cover.
a. Carefully replace the rubber seal.
b. Align battery cover with case placing round corners
on cover away from connector [142A]. Snap cover
into place.
5. Install siren and check operation. If siren is working prop-
erly, it will respond with two chirps after receiving the arm
command.
1
2
3
Battery Replacement: Late Style Siren
1.
Disarm system and remove siren.
1. Cover
2. Battery
2.
See Figure E-32. With a small screwdriver or pick, push
3. Connector [142A]
the catches (1) in through the two slots (2) in the end of
the siren to release the battery cover (3).
Figure E-31. Battery Compartment (Early Style Siren)
NOTES
•
For protection against corrosion, battery terminals and
battery clip are covered with a special grease. Do not wipe
away this substance. Apply all available existing grease
ed02958
to terminals on new battery.
4
•
Only a 9 volt nickel metal hydride battery should be used
in the siren.
2
3.
Replace battery (4) by removing old battery from polarized
1
battery clip.
4.
Recharge and re-install or install a new 9 volt nickel metal
hydride battery.
5.
Reinstall battery cover (3).
6
a. Carefully replace the rubber seal (5) on the cover.
b. Align battery cover with case placing round corners
3
5
on cover away from connector [142A] (6).
1. Catch
c. Snap cover into place.
2. Slot
6.
Install siren and check operation. If siren is working prop-
3. Cover
erly, it will respond with two chirps after receiving the arm
4.
9 volt battery
command.
5.
Rubber seal
6.
Connector [142A]
Figure E-32. Siren Battery Compartment (Late Style Siren)
2008 Sportster Diagnostics: Appendix E TSM/TSSM (Japan/Korea) E-61
Tools Used in This Manual
PART NUMBER
TOOL NAME
NOTES
HD-23738
VACUUM PUMP
4.18 DTC P0107, P0108, P0112, P0113, Diagnostics
HD-25070
ROBINAIR HEAT GUN
A.19 SEALED SPLICE CONNECTORS, Sealed Splice
Connector Repair
HD-26792
SPARK TESTER
4.10 ENGINE CRANKS, BUT WILL NOT START, Dia-
gnostics
HD-26792
SP
ARK TESTER
4.17 MISFIRE AT IDLE OR UNDER LOAD, Diagnostics
HD-34730-2C
FUEL INJECTOR TEST LAMP
4.10 ENGINE CRANKS, BUT WILL NOT START, Dia-
gnostics
HD-34730-2C
FUEL INJECTOR
TEST LAMP
4.28 DTC P1351, P1352, P1354, P1355, Diagnostics
HD-38125-6
PACKARD TERMINAL CRIMP TOOL
A.15 METRI-PACK TERMINALS, Metri-Pack Terminal
Crimps
HD-38125-7
PACKARD TERMINAL CRIMPER
A.1 AMP 1-PLACE CONNECTORS, AMP 1-Place Con-
nector Repair
HD-38125-7
PACKARD TERMINAL CRIMPER
A.7 DEUTSCH MINI-TERMINAL CRIMPS, Deutsch Mini
Terminal Crimps
HD-38125-7
PACKARD TERMINAL CRIMPER
A.15 METRI-PACK TERMINALS, Metri-Pack Terminal
Crimps
HD-38125-8
PACKARD CRIMPING TOOL
A.15 METRI-PACK TERMINALS, Metri-Pack Terminal
Crimps
HD-38125-8
PACKARD CRIMPING TOOL
A.19 SEALED SPLICE CONNECTORS, Sealed Splice
Connector Repair
HD-39621-27
SOCKET TERMINAL TOOL
A.1 AMP 1-PLACE CONNECTORS, AMP 1-Place Con-
nector Repair
HD-39621-28
PIN TERMINAL REMOVER
A.1 AMP 1-PLACE CONNECTORS, AMP 1-Place Con-
nector Repair
HD-39965-A
DEUTSCH TERMINAL CRIMP TOOL
A.6 DEUTSCH STANDARD TERMINALS, Deutsch
Standard Terminal Crimps
HD-39969
ULTRA-TORCH UT-100
A.19 SEALED SPLICE CONNECTORS, Sealed Splice
Connector Repair
HD-41182
FUEL PRESSURE GAUGE
4.15 FUEL PRESSURE TEST, Testing
HD-41183
HEAT SHIELD ATTACHMENT
A.19 SEALED SPLICE CONNECTORS, Sealed Splice
Connector Repair
HD-41404-B
HARNESS CONNECTOR
TEST KIT
1.2 STARTING SYSTEM DIAGNOSIS, Diagnostics
HD-41404-B
HARNESS CONNECTOR
TEST KIT
2.4 SPEEDOMETER/TACHOMETER, Diagnostics
HD-41404-B
HARNESS CONNECTOR TEST KIT
3.15 TSM/HFSM: TURN SIGNAL ERRORS AND
DTCS, Diagnostics
HD-41404-B
HARNESS CONNECTOR
TEST KIT
3.16 DTC B1131, B1132 (HFSM ONLY), Diagnostics
HD-41404-B
HARNESS CONNECTOR
TEST KIT
3.20 DTC B1141 (HFSM ONLY), Diagnostics
HD-41404-B
HARNESS CONNECTOR TEST KIT
4.10 ENGINE CRANKS, BUT WILL NOT START, Dia-
gnostics
HD-41404-B
HARNESS CONNECTOR TEST KIT
4.10 ENGINE CRANKS, BUT WILL NOT START, Dia-
gnostics
HD-41404-B
HARNESS CONNECTOR
TEST KIT
4.11 NO ECM POWER, Diagnostics
HD-41404-B
HARNESS CONNECTOR
TEST KIT
4.13 FUEL SYSTEM ELECTRICAL TEST, Diagnostics
HD-41404-B
HARNESS CONNECTOR
TEST KIT
4.16 IDLE AIR CONTROL, Diagnostics
HD-41404-B
HARNESS CONNECTOR
TEST KIT
4.17 MISFIRE AT IDLE OR UNDER LOAD, Diagnostics
HD-41404-B
HARNESS CONNECTOR
TEST KIT
4.18 DTC P0107, P0108, P0112, P0113, Diagnostics
HD-41404-B
HARNESS CONNECTOR
TEST KIT
4.18 DTC P0107, P0108, P0112, P0113, Diagnostics
HD-41404-B
HARNESS CONNECTOR
TEST KIT
4.19 DTC P0117, P0118, Diagnostics
HD-41404-B
HARNESS CONNECTOR
TEST KIT
4.20 DTC P0122, P0123, Diagnostics
I
Tools Used in This Manual
PART NUMBER
TOOL NAME
NOTES
HD-41404-B
HARNESS CONNECTOR
TEST KIT
4.22 DTC P0261, P0262, P0263, P0264, Diagnostics
HD-41404-B
HARNESS CONNECTOR
TEST KIT
4.23 DTC P0373, P0374, Diagnostics
HD-41404-B
HARNESS CONNECTOR
TEST KIT
4.27 DTC P1009, P1010, Diagnostics
HD-41404-B
HARNESS CONNECTOR
TEST KIT
4.28 DTC P1351, P1352, P1354, P1355, Diagnostics
HD-41404-B
HARNESS CONNECTOR
TEST KIT
4.28 DTC P1351, P1352, P1354, P1355, Diagnostics
HD-41404-B
HARNESS CONNECTOR TEST KIT
E.13 TURN SIGNAL ERRORS: B1121, B1122,
B1141, Diagnostics
HD-41404-B
HARNESS CONNECTOR
TEST KIT
E.15 DTC B1131, B1132, Diagnostics
HD-41404-B
HARNESS CONNECTOR
TEST KIT
2.6 INDICATOR LAMPS, Diagnostics
HD-41417
PROP
ANE ENRICHMENT KIT
4.9 INTAKE LEAK TEST, Leak Tester
HD-41475
DEUTSCH CONNECTOR SERVICE KIT
A.5 DEUSCH ELECTRICAL CONNECTORS, Deutsch
Connector Repair
HD-41475-100
FLAT BLADE L-HOOK
A.5 DEUSCH ELECTRICAL CONNECTORS, Deutsch
Connector Repair
HD-41609
AMP MULTILOCK CRIMPER
A.2 AMP MULTILOCK CONNECTORS, AMP Multilock
Connector Repair
HD-4268
BREAKOUT BOX
E.13 TURN SIGNAL ERRORS: B1121, B1122,
B1141, Diagnostics
HD-42682
BREAKOUT BOX
1.2 STARTING SYSTEM DIAGNOSIS, Diagnostics
HD-42682
BREAKOUT BOX
2.2 INITIAL DIAGNOSTIC CHECK: SPEEDOMETER, Ini-
tial Diagnostics
HD-42682
BREAKOUT BOX
2.4 SPEEDOMETER/TACHOMETER, Diagnostics
HD-42682
BREAKOUT BOX
2.5 BREAKOUT BOX: SPEEDOMETER/TACHO-
METER, General
HD-42682
BREAKOUT BOX
2.7 DTC B1004, B1005, Diagnostics
HD-42682
BREAKOUT BOX
2.9 DTC B1008, Diagnostics
HD-42682
BREAKOUT BOX
2.10 DTC U1016, U1255, Diagnostics
HD-42682
BREAKOUT BOX
2.11 DTC U1064, U1255, Diagnostics
HD-42682
BREAKOUT BOX
3.3 H-DSSS ACTUATION, Power Disruption and Config-
uring
HD-42682
BREAKOUT BOX
3.10 INITIAL DIAGNOSTIC CHECK: TSM/HFSM, Initial
Diagnostics
HD-42682
BREAKOUT BOX
3.12 BREAKOUT BOX: TSM/HFSM, General
HD-42682
BREAKOUT BOX
3.16 DTC B1131, B1132 (HFSM ONLY), Diagnostics
HD-42682
BREAKOUT BOX
3.17 DTC B1134, Diagnostics
HD-42682
BREAKOUT BOX
3.22 DTC B1154, B1155, Diagnostics
HD-42682
BREAKOUT BOX
4.5 INITIAL DIAGNOSTIC CHECK: EFI, Initial Dia-
gnostics
HD-42682
BREAKOUT BOX
4.30 DTC U1064, U1255, Diagnostics
HD-42682
BREAKOUT BOX
E.9 INITIAL DIAGNOSTIC CHECK: TSM/TSSM, Initial
Diagnostics
HD-42682
BREAKOUT BOX
E.11 BREAKOUT BOX: TSM/TSSM, General
HD-42682
BREAKOUT BOX
E.15 DTC B1131, B1132, Diagnostics
HD-42682
BREAKOUT BOX
E.16 DTC B1134, Diagnostics
HD-42682
BREAKOUT BOX
4.31 DTC U1097, U1255, Diagnostics
II TOOLS
Tools Used in This Manual
PART NUMBER
TOOL NAME
NOTES
HD-42879
ELECTRICAL CRIMPER TOOL
A.8 DEUTSCH SOLID BARREL TERMINALS, Deutsch
Solid Barrel Terminal Crimps
HD-43876
BREAKOUT BOX
3.23 DTC U1016, U1255, Diagnostics
HD-43876
BREAKOUT BOX
4.7 BREAKOUT BOX: EFI, General
HD-43876
BREAKOUT BOX
4.10 ENGINE CRANKS, BUT WILL NOT START, Dia-
gnostics
HD-43876
BREAKOUT BOX
4.11 NO ECM POWER, Diagnostics
HD-43876
BREAKOUT BOX
4.13 FUEL SYSTEM ELECTRICAL TEST, Diagnostics
HD-43876
BREAKOUT BOX
4.14 SYSTEM RELAY CHECK, Diagnostics
HD-43876
BREAKOUT BOX
4.16 IDLE AIR CONTROL, Diagnostics
HD-43876
BREAKOUT BOX
4.17 MISFIRE AT IDLE OR UNDER LOAD, Diagnostics
HD-43876
BREAKOUT BOX
4.18 DTC P0107, P0108, P0112, P0113, Diagnostics
HD-43876
BREAKOUT BOX
4.18 DTC P0107, P0108, P0112, P0113, Diagnostics
HD-43876
BREAKOUT BOX
4.19 DTC P0117, P0118, Diagnostics
HD-43876
BREAKOUT BOX
4.20 DTC P0122, P0123, Diagnostics
HD-43876
BREAKOUT BOX
4.21 DTC P0131, P0132, P0134, P0151, P0152,
P0154, Diagnostics
HD-43876
BREAKOUT BOX
4.22 DTC P0261, P0262, P0263, P0264, Diagnostics
HD-43876
BREAKOUT BOX
4.24 DTC P0501, P0502, Diagnostics
HD-43876
BREAKOUT BOX
4.27 DTC P1009, P1010, Diagnostics
HD-43876
BREAKOUT BOX
4.28 DTC P1351, P1352, P1354, P1355, Diagnostics
HD-43876
BREAKOUT BOX
4.31 DTC U1097, U1255, Diagnostics
HD-43876
BREAKOUT BOX
E.19 DTC U1016, U1255, Diagnostics
HD-44061
FUEL PRESSURE GAUGE ADAPTER
4.15 FUEL PRESSURE TEST, Testing
HD-44687
IGNITION COIL CIRCUIT TEST ADAPTER
4.10 ENGINE CRANKS, BUT WILL NOT START, Dia-
gnostics
HD-44687
IGNITION COIL CIRCUIT
TEST ADAPTER
4.28 DTC P1351, P1352, P1354, P1355, Diagnostics
HD-44750
DIGITAL TECHNICIAN
2.1 CHECKING FOR DIAGNOSTIC TROUBLE
CODES, Code Types
HD-44750
DIGIT
AL TECHNICIAN
3.3 H-DSSS ACTUATION, Fob Assignment
HD-44750
DIGIT
AL TECHNICIAN
3.7 SERVICE/EMERGENCY FUNCTIONS, Service Mode
HD-44750
DIGITAL TECHNICIAN
4.4 CHECKING FOR DIAGNOSTIC TROUBLE CODES:
EFI, Code Types
HD-44750
DIGIT
AL TECHNICIAN
4.16 IDLE AIR CONTROL, General
HD-44750
DIGIT
AL TECHNICIAN
4.26 DTC P0603, P0605, General
HD-44750
DIGITAL TECHNICIAN
E.8 DIAGNOSTIC TROUBLE CODES (DTC), Code
Types
HD-45928
PACKARD MICRO-64 TERMINAL
A.18 PACKARD MICRO-64 CONNECTORS, Packard
REMOVER
Micro-64 Connector Repair
HD-45929
PACKARD MICRO-64 TERMINAL
A.18 PACKARD MICRO-64 CONNECTORS, Packard
CRIMPER
Micro-64 Connector Repair
HD-46601
INSTRUMENT HARNESS ADAPTERS
2.2 INITIAL DIAGNOSTIC CHECK: SPEEDOMETER, Ini-
tial Diagnostics
HD-46601
INSTRUMENT HARNESS ADAPTERS
2.4 SPEEDOMETER/TACHOMETER, Diagnostics
TOOLS III
Tools Used in This Manual
PART NUMBER
TOOL NAME
NOTES
HD-46601
INSTRUMENT HARNESS ADAPTERS
2.5 BREAKOUT BOX: SPEEDOMETER/TACHO-
METER, General
HD-46601
INSTRUMENT HARNESS ADAPTERS
2.7 DTC B1004, B1005, Diagnostics
HD-46601
INSTRUMENT HARNESS ADAPTERS
2.9 DTC B1008, Diagnostics
HD-46601
INSTRUMENT HARNESS ADAPTERS
2.10 DTC U1016, U1255, Diagnostics
HD-46601
INSTRUMENT HARNESS ADAPTERS
2.11 DTC U1064, U1255, Diagnostics
HD-46601
INSTRUMENT HARNESS ADAPTERS
3.10 INITIAL DIAGNOSTIC CHECK: TSM/HFSM, Initial
Diagnostics
HD-46601
INSTRUMENT HARNESS ADAPTERS
4.5 INITIAL DIAGNOSTIC CHECK: EFI, Initial Dia-
gnostics
HD-46601
SPEEDOMETER HARNESS ADAPTER
4.30 DTC U1064, U1255, Diagnostics
HD-46601
SPEEDOMETER HARNESS ADAPTER
4.31 DTC U1097, U1255, Diagnostics
HD-46601
INSTRUMENT HARNESS ADAPTERS
E.9 INITIAL DIAGNOSTIC CHECK: TSM/TSSM, Initial
Diagnostics
HD-48053
ELECTRICAL SYSTEM
TESTER
1.7 CHARGING SYSTEM, Troubleshooting
HD-48114
MOLEX ELECTRICAL CONNECTOR
TER-
A.16 MOLEX CONNECTORS, Molex Connector Repair
MINAL REMOVER
HD-48637
ECM BREAKOUT BOX
2.10 DTC U1016, U1255, Diagnostics
MCR-101 HD
ELECTRICAL SYSTEM ANALYZER
4.10 ENGINE CRANKS, BUT WILL NOT START, Dia-
gnostics
TT600-3
SNAP-ON PICK
A.13 630 METRI-PACK CONNECTORS, 630 Metri-Pack
Connector Repair
IV TOOLS
DTC B1007 Ignition Line Overvoltage
2-25
1
DTC B1008 Trip Odometer Reset Switch Closed
2-27
150 Metri-Pack Connector
DTC B1121, B1122, B1141 Turn Signals Will Not Flash, 4-Way
Repair
A-20
Flashers Inoperable
3-30
DTC B1123 Left Turn Signal Short-to-Ground
3-30
2
DTC B1124 Right Turn Signal Short-to-Ground
3-30
280 Metri-Pack Connector
DTC B1125 Left Turn Signal Short-to-Voltage
3-30
Repair
A-22
DTC B1126 Right Turn Signal Short-to-Voltage
3-30
4
DTC B1131 Alarm Output Low
3-46
DTC B1131 Alarm Output Low
E-44
480 Metri-Pack Connector
DTC B1132 Alarm Output High
3-46
Repair
A-24
DTC B1132 Alarm Output High
E-44
6
DTC B1134 Starter Output High
3-49
DTC B1134 Starter Output High
E-47
630 Metri-Pack Connector
DTC B1135 Accelerometer Fault
3-52
Repair
A-25
DTC B1135 Accelerometer Fault
E-50
A
DTC B1136 Accelerometer Tip-Over Self-Test Fault
3-53
AMP 1-Place Connector
DTC B1141 Ignition Switch Open/Low
3-54
Repair
A-1
DTC B1142 Internal Fault
3-53
AMP Multilock Connector
DTC B1143 Security Antenna Short-to-Ground
3-57
Repair
A-3
DTC B1144 Security Antenna Short-to-Battery
3-57
DTC B1145 Security Antenna Open
3-57
B
DTC B1154 Clutch Switch Short-to-Ground
3-62
Bank Angle Sensor
3-1
DTC B1154 Clutch Switch Short-to-Ground
E-51
Bank Angle Sensor
E-3
DTC B1155 Neutral Switch Short-to-Ground
3-62
Bank Angle Sensor (BAS)
4-2
DTC B1155 Neutral Switch Short-to-Ground
E-51
Battery Testing
1-26
DTC P0107 MAP Sensor Open/Low
4-64
Conductance Test
1-26
DTC P0112 IAT Sensor Voltage Low
4-64
Load Test
1-26
DTC P0113 IAT Sensor Voltage Open/High
4-64
Voltmeter Test
1-26
DTC P0117 ET Sensor Voltage Low
4-71
Bus ER
4-32
DTC P0118 ET Sensor Open/High
4-71
DTC P0122 TP Sensor Open/Low
4-75
C
DTC P0123 TP Sensor High
4-75
Charging System Testing
DTC P0131 Front Oxygen Sensor Low or Engine Running
Current Voltage Output Test: Using HD-48053
1-23
Lean
4-79
Current Voltage Output Test: Using Load Tester
1-23
DTC P0132 Engine Running Rich
4-79
Milliampere Draw Test
1-22
DTC P0134 Front Oxygen Sensor Open/Not
Total Current Draw Test
1-22
Responding/High
4-79
Check Engine Lamp
2-1
DTC P0151 Rear Oxygen Sensor Low or Engine Running
Check Engine Lamp
4-4
Lean
4-79
CKP Sensor
4-90
DTC P0152 Engine Running Rich
4-79
Connector Locations
B-1
DTC P0154 Rear Oxygen Sensor Open/Not
Conversions
Responding/High
4-79
Fluid
C-2
DTC P0261 Front Injector Open/Low
4-84
Length
C-1
DTC P0262 Front Injector High
4-84
Torque
C-3
DTC P0263 Rear Injector Open/Low
4-84
Crankshaft Position (CKP) Sensor
4-2
DTC P0264 Rear Injector High
4-84
D
DTC P0373 CKP Sensor Intermittent
4-90
DTC P0374 CKP Sensor Synch Error
4-90
Delphi Connector
DTC P0501 VSS Sensor Low
4-93
Repair
A-8
DTC P0502 VSS Sesnor High/Open
4-93
Deutsch 1-Place Connector
DTC P0505 Loss of Idle Speed Control
4-53
Repair
A-10
DTC P0562 Battery Voltage Low
4-97
Deutsch Connector
DTC P0563 Battery Voltage High
4-97
Crimping Mini Terminals
A-16
DTC P0603 ECM EEPROM Error
4-101
Crimping Solid Barrel Terminals
A-17
DTC P0605 ECM Flash Error
4-101
Crimping Standard Terminals
A-15
DTC P1001 Ssytem Relay Coil Open/Low
4-43
Repair
A-11
DTC P1002 System Relay Coil High/Shorted
4-43
Diagnostic Notes
2-4
DTC P1003 System Relay Contacts Open
4-43
Diagnostic Trouble Code Types
2-3
DTC P1004 System Relay Contacts Closed
4-43
Current
2-3
DTC P1009 Incorrect Password
4-102
Historic
2-3
DTC P1010 Missing Password
4-102
Retreiving Diagnostic Trouble Codes
2-3
DTC P1064 Loss of TSM/TSSM/HFSM Serial Data. . . 4-115
DTC B0563: Battery Voltage High
3-29
DTC P1097 Loss of All Speedometer Serial Data (State of
DTC B0563 Battery Voltage High
E-43
Health)
4-118
DTC B1004 Fuel Level Sending Unit Low
2-21
DTC P1351 Front Ignition Coil Open/Low
4-102
DTC B1005 Fuel Level Sending Unit High/Open
2-21
DTC P1352 Front Ignition Coil High/Shorted
4-102
DTC B1006 Accessory Line Overvoltage
2-25
VII
DTC P1354 Rear Ignition Coil Open/Low
4-102
Metric System
C-2
DTC P1355 Rear Ignition Coil High/Shorted
4-102
Metri-Pack Terminals
DTC P1501 Jiffy Stand Sensor Low
4-110
Crimping
A-28
DTC P1502 Jiffy Stand Sensor High
4-110
Molex Connector
DTC P-1-8 MAP Sensor High
4-64
Repair
A-30
DTC U1016 Loss of All ECM Serial Data
2-30
O
DTC U1016 Loss of All ECM Serial Data (State of
Health)
E-55
Odometer Theory of Operation
2-12
DTC U1064 Loss of TSM/TSSM/HFSM Serial Data
2-33
Oxygen Sensor
4-2
DTC U1255 Missing Message at Speedometer
4-118
Oxygen Sensor
4-79
DTC U1255 Serial Data Error/Missing Message
2-30
P
DTC U1255 Serial Data Error/Missing Message
4-115
Packard 100W Connector
DTC U1255 Serial Data Error/Missing Message
E-55
Repair
A-32
DTC U1300 Serail Data Low
E-58
Packard Micro-64 Connector
DTC U1300 Serial Data Low
2-37
Repair
A-34
DTC U1300 Serial Data Low
4-32
Personal Identification Number (PIN)
3-6
DTC U1301 Serial Data Open/High
2-37
PIN Entry:TSSM
E-6
DTC U1301 Serial Data Open/High
4-32
DTC U1301 Serial Data Open/High
E-58
R
E
Reprogramming ECM
2-4
Electronic Control Module (ECM)
4-2
S
Electronic Fuel Injection (EFI)
4-2
Sealed Splice
A-37
ET Sensor
4-71
Security Lamp
2-2
F
Security Lamp
3-3
Security Lamp
E-14
Fluid Conversions
C-2
Security Lamp (Key Icon)
3-8
Fuel Injectors
4-84
Security Lamp Diagnostics
3-13
Fuel Pressure Test
4-49
Security System Functions (TSSM Only)
E-11
Fuel System
4-36
Service/Emergency Functions
3-11
Fuse Block Repair
A-19
Service Bulletins
I-I
G
Service Preparation
I-I
Glossary
Sidecar Configuration
3-5
Acronyms and Abbreviations
D-1
Sidecar Configuration
E-5
Siren
3-10
H
Siren Battery
3-71
Hands-Free Fob Battery
3-71
Siren Battery
E-60
Hands-Free Security Module (HFSM)
3-2
Speedometer Functions
2-4
Speedometer Theory of Operation
2-12
I
SPX Kent-Moore
I-II
Idle Air Control
4-53
Starter Activation Circuits
1-12
Idle Air Control (IAC)
4-2
Starter Current Draw Test
1-14
Ignition Coil
4-2
Starter Free Running Current Draw Test
1-16
Ignition Coil
4-102
Starter Solenoid
Ignition Coil
4-105
Solenoid Hold-In Test
1-17
Indicator Lamps
2-17
Solenoid Pull-In Test
1-16
Intake Air Temperature (IAT)/Manifold Absolute Pressure
Solenoid Return Test
1-17
(TMAP) sensor
4-2
Starter Troubleshooting
1-1
Intake Leak Test
4-19
Starting System Diagnosis
1-3
Start Relay Test
1-14
J
Stator
1-24
Jiffy Stand Sensor
4-110
System Relay
4-43
K
T
Key Fob Assignment:TSSM
E-5
Tachometer Theory of Operation
2-12
Key Fob Battery
E-60
Throttle Position (TP) Sensor
4-2
L
Throttle Position (TP) Sensor
4-75
TMAP
4-64
Loctite
I-II
Torque Conversion
C-3
M
Trademarks
Harley-Davidson
I-II
Maxi-Fuse Housing
Referenced Products
I-II
Repair
A-26
Trip Odometer Reset Switch
2-12
VIII INDEX
TSM/HFSM: Password Learn
3-70
TSM/TSSM: Password Learn
E-59
Turn Signal Errors: B1121, B1122, B1141
E-31
Turn Signal Functions
4-Way Flashing
E-9
Automatic Cancellation
E-9
Manual Cancellation
E-9
Turn Signal Module
3-1
Turn Signal Module
E-3
Turn Signal Security Module
E-3
V
Vehicle Speed Sensor (VSS)
4-2
Vehicle Speed Sensor (VSS)
4-93
W
Wiggle Test
4-18
Wiring Diagrams
B-3
WOW Test
2-10
WOW Test
E-24
INDEX IX
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