Harley Davidson 2004 Touring Models. Service Manual — page 17

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    DTC P1009, P1010
    5.28
    GENERAL
    f1917x9x
    Password Problem
    The ECM, TSM/TSSM and speedometer exchange pass-
    words during operation. 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 5-47. Code Description
    DTC
    DESCRIPTION
    P1009
    Incorrect password
    P1010
    Missing password
    Data Link
    Connector [91]
    DIAGNOSTICS
    Figure 5-63. Electrical Bracket (Under Right Side Cover)
    Diagnostic Notes
    The reference numbers below correlate with the circled num-
    7844
    bers on the Test 5.28 flow charts.
    1.
    DTC P1009 may be set if a recent ECM or TSM/TSSM
    replacement did not follow the correct password assign-
    ment procedure. See
    3.24 PASSWORD LEARN for
    details.
    2.
    Use HARNESS CONNECTOR TEST KIT (Part No. HD-
    41404), black socket probes and patch cord.
    3.
    Connect BREAKOUT BOX
    (Part No. HD-43876)
    between wire harness and ECM. See 5.7 BREAKOUT
    BOX: EFI.
    4.
    Historic codes DTC U1300 or DTC U1301 would also
    have been set. Clear codes.
    5.
    See the Touring Service Manual for TSM/TSSM replace-
    ment. See PASSWORD LEARNING under 3.24 PASS-
    WORD LEARN for the password learning procedure.
    Figure 5-64. TSM/TSSM
    5-104
    2004 Touring: Engine Management (EFI)
    HOME
    [156B] [156A]
    f2208u8x
    Main to Interconnect
    6
    6
    5
    5
    Harness
    4
    4
    BK
    3
    3
    GY
    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]
    BN/GY
    TSM/TSSM
    BK
    [39B]
    1
    2
    3
    4 5 6 7 8 9 10 11 12
    GY
    1
    2
    3
    4 5 6 7 8 9 10 11 12
    [39A]
    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
    [8B]
    EFI
    [108B]
    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]
    Harness
    [108A]
    Tachometer
    [1B] [1A]
    15A
    1
    Accessory
    Fuse
    2
    Main to Interconnect
    3
    Harness
    1
    2
    3
    4 5 6 7 8 9 10 11 12
    4
    [2B]
    Data Link
    1
    2
    3
    4 5 6 7 8 9 10 11 12
    15A
    [2A]
    Ignition
    Main to Interconnect
    Fuse
    [91A]
    Harness
    [78B]
    15A
    1
    5
    ECM
    Battery
    [78A]
    Fuse
    Figure 5-65. Serial Data Circuit (FLTR, FLHT/C/U)
    Table 5-48. Wire Harness Connectors in Figure 5-65.
    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 (Left 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 (Left 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 - Front of Right Fairing Bracket
    2004 Touring: Engine Management (EFI)
    5-105
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    f2208t8x
    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]
    EFI
    1
    2
    3
    4
    5
    6
    7
    8 9 10 11 12
    [8A]
    Harness
    15A
    15A
    Accessory
    Battery
    Fuse
    Fuse
    1
    15A
    2
    Ignition
    3
    Fuse
    4
    Data Link
    [91A]
    [78B]
    1
    5
    ECM
    [78A]
    Figure 5-66. Serial Data Circuit (FLHR/C/S)
    Table 5-49. Wire Harness Connectors in Figure 5-66.
    NO.
    DESCRIPTION
    TYPE
    LOCATION
    [8]
    Main to EFI Harness
    12-Place Deutsch
    Under Right Side Cover
    Cavity in Crossmember at Rear of
    [30]
    Turn Signal/Security Module
    12-Place Deutsch
    Battery Box (Under Seat)
    [39]
    Speedometer
    12-Place Packard
    Under Console (Back of Speedometer)
    [78]
    Electronic Control Module
    36-Place Packard
    Under Right Side Cover
    [91]
    Data Link
    4-Place Deutsch
    Under Right Side Cover
    5-106
    2004 Touring: Engine Management (EFI)
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    Test 5.28
    PASSWORD PROBLEM: DTC P1009, P1010
    Which diagnostic trouble
    code was set?
    DTC P1009.
    DTC P1010.
    1
    Bad password.
    No password.
    Reprogram password.
    Are there any
    See 3.24 PASSWORD
    U-codes set?
    5
    LEARN.
    YES
    NO
    YES
    NO
    Replace TSSM and
    System
    Troubleshoot
    Remove ECM connector [78]. Check
    relearn password.
    OK.
    lowest U-code.
    for continuity to ground at data
    5
    2
    System OK?
    connector [91A] Terminal 3.
    Continuity present?
    YES
    NO
    YES
    NO
    4
    System
    Repair short
    Check for battery voltage on termi-
    Reinstall original TSSM.
    OK.
    to ground.
    nal 3.
    Replace ECM.
    5
    Battery voltage present?
    Reprogram and relearn
    password.
    YES
    NO
    4
    Repair short
    Test data connector [91A]
    2
    to voltage.
    Terminal 3 against Breakout Box termi-
    nal 5 for continuity. Continuity present?
    3
    YES
    NO
    Inspect terminals
    for damage or repair
    Replace TSM/TSSM and relearn
    5
    2
    opens as necessary.
    password. System OK?
    YES
    NO
    System
    Reinstall original TSSM.
    OK.
    Replace ECM.
    5
    Reprogram and relearn
    password.
    Clear codes using speedometer self diagnostics.
    See 5.6 SPEEDOMETER SELF DIAGNOSTICS.
    Confirm proper operation with no check engine
    lamp.
    2004 Touring: Engine Management (EFI)
    5-107
    HOME
    DTC P1351, P1352, P1354, P1355
    5.29
    GENERAL
    7863
    Ignition Coil
    Ignition coil codes will set if the ignition coil primary voltage is
    out of range. This could occur if there is an open coil or loss of
    power to the coil. If front and rear codes are set simulta-
    neously, it is likely a coil power failure or a coil failure.
    The coil receives power from the system relay at the same
    time that the fuel pump and injectors are activated. The sys-
    tem relay is active for the first 2 seconds after the ignition is
    turned ON and then shuts off until RPM is detected from the
    CKP sensor, at which time it is reactivated. The ECM is
    responsible for turning on the system relay by providing the
    ground to activate the relay, which in turn powers the coil.
    Figure 5-67. Ignition Coil Circuit Test
    Table 5-50. Code Description
    DTC
    DESCRIPTION
    s0475x9x
    P1351
    Front ignition coil open/low
    P1352
    Front ignition coil high/shorted
    P1354
    Rear ignition coil open/low
    D
    P1355
    Rear ignition coil high/shorted
    C
    DIAGNOSTICS
    B
    A
    Diagnostic Notes
    The reference numbers below correlate with the circled num-
    bers on the Test 5.29 flow charts.
    1.
    Use HARNESS CONNECTOR TEST KIT (Part No. HD-
    Figure 5-68. Ignition Coil Connector Terminals
    41404), gray pin probes and patch cord.
    Table 5-51. Coil Terminal Description
    CAUTION
    Gently connect test lamp to connector [83B]. Forcefully
    TERMINAL
    DESCRIPTION
    inserting test lamp will result in ignition connector termi-
    nal damage.
    A
    Power
    2. See Figure 5-67. Plug IGNITION COIL CIRCUIT TEST
    B
    Feedback signal pin
    ADAPTER (Part No. HD-44687) and FUEL INJECTOR
    C
    Rear coil
    TEST LAMP (Part No. HD-34730-2C) into Breakout Box.
    Note that cranking the engine with test lamp in place of
    D
    Front coil
    the ignition coil can sometimes cause a DTC P1351,
    P1352, P1354 or P1355. This condition is normal and
    does not by itself indicate a malfunction. Codes must be
    cleared if this condition occurs.
    4.
    Use HARNESS CONNECTOR TEST KIT (Part No. HD-
    41404), gray socket probes and patch cord.
    3. Connect BREAKOUT BOX
    (Part No. HD-43876)
    between EFI wire harness and ECM. See 5.7 BREAK-
    OUT BOX: EFI.
    5-108
    2004 Touring: Engine Management (EFI)
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    f2208h8x
    [62B]
    System relay
    Y/GN
    [78A]
    [78B]
    BE/GY
    GN/O
    W/BK
    [13A] [13B]
    Fuel pump
    O/GY
    System relay
    GN/O
    Y/GN
    15 amp
    fuel pump
    W/Y
    fuse
    [141B] [141A]
    [84B] [84A]
    BK
    Y/GN
    Power gnd.
    Coil R
    Y/BE
    [85B] [85A]
    GY/BE
    Ignition
    Switch power
    Y/BE
    coil
    BE/O
    ECM
    W/BK
    [83B] [83A]
    Inj. R
    GN/GY
    BE/GY
    +
    -
    15 amp
    Inj. F
    W/Y
    Battery
    ECM fuse
    R
    BK
    40 Amp
    R
    R
    Maxi Fuse
    R/BK
    12
    12
    BK
    11
    11
    DCBA
    10
    10
    [33B]
    Ion sense
    9
    9
    [33A]
    Power gnd.
    15 amp
    8
    8
    Coil F
    BE/O
    7
    7
    IGN fuse
    6
    6
    Ignition
    5
    5
    GY
    Constant power
    switch
    4
    4
    3
    3
    2
    2
    W/BK
    1
    1
    12 11 10 9 8 7 6 5 4 3
    21
    [1B]
    12 11 10 9 8 7 6 5 4 3
    21
    [1A]
    [8B] [8A]
    BK
    12 11 10 9 8 7 6 5 4 3
    2
    1
    [22A]
    BK
    12 11 10 9 8 7 6 5 4 3
    2
    1
    [22B]
    Engine stop
    switch
    Figure 5-69. Battery Voltage Circuit (FLTR, FLHT/C/U)
    Table 5-52. Wire Harness Connectors in Figure 5-69.
    NO.
    DESCRIPTION
    TYPE
    LOCATION
    [1]
    Main to Interconnect Harness
    12-Place Deutsch (Black)
    Inner Fairing (Right Fairing Bracket)
    [8]
    Main to EFI Harness
    12-Place Deutsch (Gray)
    Under Right Side Cover
    [22]
    Right Handlebar Switches
    12-Place Deutsch (Black)
    Inner Fairing (Right Fairing Support Brace)
    [33]
    Ignition/Light Key Switch
    4-Place Packard
    Inner Fairing (Top Fork Bracket)
    [78]
    ECM
    36-Place Packard
    Under Right Side Cover
    [83]
    Ignition Coil
    4-Place Packard
    Below Fuel Tank (Left Side)
    [84]
    Front Injector
    2-Place Packard
    Below Fuel Tank (Left Side)
    [85]
    Rear Injector
    2-Place Packard
    Below Fuel Tank (Left Side)
    2004 Touring: Engine Management (EFI)
    5-109
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    [62B]
    System relay
    f2208m8x
    Y/GN
    [78A]
    [78B]
    BE/GY
    GN/O
    W/BK
    Fuel pump
    Y/GN
    System relay
    GN/O
    Y/GN
    15 amp
    fuel pump
    W/Y
    fuse
    [141B] [141A]
    [84B] [84A]
    BK
    Y/GN
    Power gnd.
    Coil R
    Y/BE
    [85B] [85A]
    GY/BE
    Ignition
    Switch power
    Y/BE
    coil
    BE/O
    ECM
    W/BK
    [83B] [83A]
    BE/GY
    Inj. R
    GN/GY
    15 amp
    +
    -
    W/Y
    ECM fuse
    Inj. F
    Battery
    R
    BK
    R
    40 Amp
    R
    R/BK
    Maxi Fuse
    12
    12
    BK
    11
    11
    I B A
    10
    10
    [33B]
    Ion sense
    9
    9
    [33A]
    Power gnd.
    8
    8
    15 amp
    Coil F
    BE/O
    7
    7
    IGN fuse
    6
    6
    Ignition
    5
    5
    GY
    Constant power
    switch
    4
    4
    3
    3
    2
    2
    W/BK
    1
    1
    12 11 10 9 8 7
    6543
    2
    1
    [22A]
    12 11 10 9 8 7
    6543
    2
    1
    [22B]
    [8B] [8A]
    12-Place on
    FLHP Only
    BK
    Engine stop
    BK
    switch
    Figure 5-70. Battery Voltage Circuit (FLHR/C/S)
    Table 5-53. Wire Harness Connectors in Figure 5-70.
    NO.
    DESCRIPTION
    TYPE
    LOCATION
    [8]
    Main to EFI Harness
    12-Place Deutsch (Gray)
    Under Right Side Cover
    [22]
    Right Handlebar Switches
    12-Place Deutsch (Black)
    Inside Headlamp Nacelle
    [33]
    Ignition/Light Key Switch
    3-Place Packard
    Under Console
    [78]
    ECM
    36-Place Packard
    Under Right Side Cover
    [83]
    Ignition Coil
    4-Place Packard
    Below Fuel Tank (Left Side)
    [84]
    Front Injector
    2-Place Packard
    Below Fuel Tank (Left Side)
    [85]
    Rear Injector
    2-Place Packard
    Below Fuel Tank (Left Side)
    5-110
    2004 Touring: Engine Management (EFI)
    HOME
    Test 5.29 (Part 1 of 2)
    IGNITION COIL: DTC P1351, P1352, P1354, P1355
    Disconnect coil connector [83]. Mea-
    sure voltage on Terminal A of coil.
    1
    Voltage equal to battery voltage during
    first 2 seconds after key ON?
    YES
    NO
    Use Breakout Box and test
    2
    light for the next inspection.
    STOP
    Front coil codes: Check between
    3
    ECM terminal 29 and ECM terminal 13.
    Go to Test 5.29
    (Part 2 of 2).
    Rear coil codes: Check between
    ECM terminal 11 and ECM terminal 13.
    Does test lamp flash when engine is cranked?
    YES
    NO
    Measure coil resistance.
    4
    Measure voltage at system
    Front coil codes: Check between
    relay Terminal 30 during first
    coil Terminal A and Terminal D.
    2 seconds after key ON?
    Voltage equivalent
    Rear coil codes: Check between
    to battery voltage?
    coil Terminal A and Terminal C.
    Resistance 0.3-0.5 ohms?
    YES
    NO
    YES
    NO
    Repair open wire or
    Check for multiple codes. See
    connection on Y/GN wire.
    MULTIPLE DIAGNOSTIC
    TROUBLE CODES under 5.4
    CHECKING FOR DIAGNOS-
    Replace coil. See Touring
    TIC TROUBLE CODES: EFI.
    Service Manual.
    STOP
    Go to Test 5.29
    (Part 2 of 2).
    Clear codes using speedometer self diagnostics.
    See 5.6 SPEEDOMETER SELF DIAGNOSTICS.
    Confirm proper operation with no check engine
    lamp.
    2004 Touring: Engine Management (EFI)
    5-111
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    Test 5.29 (Part 2 of 2)
    IGNITION COIL: DTC P1351, P1352, P1354, P1355
    Continued from Test 5.29 (Part 1 of 2).
    Using Breakout Box, measure resistance between
    ECM and coil terminals as follows.
    DTC
    COIL
    BREAK-
    TERMINAL
    OUT BOX
    TERMINAL
    P1351/
    D
    29
    P1352
    (BE/O wire)
    P1353/
    C
    1
    11
    P1354
    (Y/BE wire)
    3
    Resistance less than 0.5 ohms?
    YES
    NO
    Perform 5.8 WIGGLE TEST
    Repair open wire
    to check for intermittents.
    or connection.
    Intermittents present?
    YES
    NO
    Repair
    Check for continuity to ground.
    intermittent.
    Front coil codes: Check
    Breakout Box terminal 29.
    Rear coil codes: Check
    Breakout Box terminal 11.
    Continuity present?
    YES
    NO
    Repair short
    Check for voltage.
    to ground.
    Front coil codes: Check
    Breakout Box terminal 29.
    Rear coil codes: Check
    Breakout Box terminal 11.
    Voltage present?
    YES
    NO
    Repair short
    Replace ECM.
    Clear codes using speedometer self diagnostics.
    to voltage.
    Reprogram and
    See 5.6 SPEEDOMETER SELF DIAGNOSTICS.
    learn password.
    Confirm proper operation with no check engine
    lamp.
    5-112
    2004 Touring: Engine Management (EFI)
    HOME
    DTC U1064, U1255
    5.30
    GENERAL
    f2013x8x
    Loss of TSM/TSSM Serial Data
    The serial data connector provides a means for the electronic
    control module (ECM), TSM/TSSM and speedometer to com-
    municate their current status. When all operating parameters
    on the serial data link are within specifications, a state of
    health message is sent between the components. A DTC
    U1064 indicates that the TSM/TSSM is not receiving this
    state of health message.
    Table 5-54. Code Description
    DTC
    DESCRIPTION
    U1064
    Loss of TSM/TSSM serial data
    Turn Signal/Security
    Module
    U1255
    Serial data error/missing message
    Figure 5-71. Remove Seat
    DIAGNOSTICS
    6924
    Diagnostic Notes
    The reference numbers below correlate with the circled num-
    1
    4
    bers on the Test 5.30 flow chart.
    5
    1. Connect BREAKOUT BOX (Part No. HD-42682).
    3
    a. Mate gray socket housing on Breakout Box with
    2
    TSM/TSSM connector [30A].
    b. Mate gray pin housing on Breakout Box with har-
    ness connector [30B].
    2. Connect BREAKOUT BOX (Part No. HD-43876).
    1. Terminal 1: flash pin (Lt GN/R)
    2. Terminal 2: ground (BK)
    3. Terminal 3: serial data (Lt GN/V)
    4. Terminal 4: power (GY)
    5. Protective cap
    Figure 5-72. Data Link Connector Terminals
    2004 Touring: Engine Management (EFI)
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    [156B] [156A]
    f2208u8x
    Main to Interconnect
    6
    6
    5
    5
    Harness
    4
    4
    BK
    3
    3
    GY
    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]
    BN/GY
    TSM/TSSM
    BK
    [39B]
    1
    2
    3
    4 5 6 7 8 9 10 11 12
    GY
    1
    2
    3
    4 5 6 7 8 9 10 11 12
    [39A]
    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
    [8B]
    EFI
    [108B]
    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]
    Harness
    [108A]
    Tachometer
    [1B] [1A]
    15A
    1
    Accessory
    Fuse
    2
    Main to Interconnect
    3
    Harness
    1
    2
    3
    4 5 6 7 8 9 10 11 12
    4
    [2B]
    Data Link
    1
    2
    3
    4 5 6 7 8 9 10 11 12
    15A
    [2A]
    Ignition
    Main to Interconnect
    Fuse
    [91A]
    Harness
    [78B]
    15A
    1
    5
    ECM
    Battery
    [78A]
    Fuse
    Figure 5-73. ECM and TSM/TSSM Circuit (FLTR, FLHT/C/U)
    Table 5-55. Wire Harness Connectors in Figure 5-73.
    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 (Left 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 (Left 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 - Front of Right Fairing Bracket
    5-114
    2004 Touring: Engine Management (EFI)
    HOME
    f2208t8x
    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]
    EFI
    1
    2
    3
    4
    5
    6
    7
    8 9 10 11 12
    [8A]
    Harness
    15A
    15A
    Accessory
    Battery
    Fuse
    Fuse
    1
    15A
    2
    Ignition
    3
    Fuse
    4
    Data Link
    [91A]
    [78B]
    1
    5
    ECM
    [78A]
    Figure 5-74. ECM and TSM/TSSM Circuit (FLHR/C/S)
    Table 5-56. Wire Harness Connectors in Figure 5-74.
    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
    2004 Touring: Engine Management (EFI)
    5-115
    HOME
    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.
    NO or “No Rsp”
    YES
    Check for continuity between
    1
    While wiggling harness, check for continuity
    TSSM Breakout Box terminal 3
    1
    between TSSM Breakout Box terminal 3
    (gray) and ECM Breakout Box ter-
    (gray) and ECM Breakout Box terminal 5.
    2
    minal 5. Continuity present?
    Continuity present?
    2
    YES
    YES
    NO
    NO
    Repair open on
    Repair intermittent
    Replace TSM/TSSM.
    Lt GN/V wire.
    Clear DTCs. Test ride.
    on Lt GN/V wire.
    Perform password learn.
    Does DTC U1064 return?
    Clear codes using speedometer self diagnostics.
    See 5.6 SPEEDOMETER SELF DIAGNOSTICS.
    YES
    NO
    Confirm proper operation with no check engine
    lamp.
    No trouble found.
    Replace TSM/TSSM.
    Perform password learn.
    5-116
    2004 Touring: Engine Management (EFI)
    HOME
    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 U1097 indicates that the
    speedometer is not capable of sending this state of health
    message.
    Table 5-57. Code Description
    DTC
    DESCRIPTION
    Loss of all speedometer serial data
    Turn Signal/Security
    U1097
    Module
    (state of health)
    U1255
    Missing message at speedometer
    Figure 5-75. Remove Seat
    6924
    DIAGNOSTICS
    NOTE
    1
    If DTC is historic and not current, wiggle wire harness while
    4
    5
    performing voltage and continuity tests to identify intermit-
    tents.
    3
    Diagnostic Notes
    2
    The reference numbers below correlate with the circled num-
    bers on the test 5.31 flow chart.
    1. Connect BREAKOUT BOX (Part No. HD-42682) as fol-
    lows:
    1.
    Terminal 1: flash pin (Lt GN/R)
    a. Mate black socket housing on breakout box with the
    2.
    Terminal 2: ground (BK)
    3.
    Terminal 3: serial data (Lt GN/V)
    speedometer connector [39A] (at the back of the
    speedometer) using INSTRUMENT HARNESS
    4.
    Terminal 4: power (GY)
    5.
    Protective cap
    ADAPTERS (Part No. HD-46601).
    b. Mate black pin housing on breakout box with wire
    Figure 5-76. Data Link Connector Terminals
    harness connector [39B] using INSTRUMENT HAR-
    NESS ADAPTERS (Part No. HD-46601).
    2. Connect BREAKOUT BOX
    (Part No. HD-43876)
    between wire harness and ECM. See Section 5.7 BREA-
    KOUT BOX: EFI.
    2004 Touring: Engine Management (EFI)
    5-117
    HOME
    [156B] [156A]
    f2208u8x
    Main to Interconnect
    6
    6
    5
    5
    Harness
    4
    4
    BK
    3
    3
    GY
    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]
    BN/GY
    TSM/TSSM
    BK
    [39B]
    1
    2
    3
    4 5 6 7 8 9 10 11 12
    GY
    1
    2
    3
    4 5 6 7 8 9 10 11 12
    [39A]
    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
    [8B]
    EFI
    [108B]
    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]
    Harness
    [108A]
    Tachometer
    [1B] [1A]
    15A
    1
    Accessory
    Fuse
    2
    Main to Interconnect
    3
    Harness
    1
    2
    3
    4 5 6 7 8 9 10 11 12
    4
    [2B]
    Data Link
    1
    2
    3
    4 5 6 7 8 9 10 11 12
    15A
    [2A]
    Ignition
    Main to Interconnect
    Fuse
    [91A]
    Harness
    [78B]
    15A
    1
    5
    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 (Left 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 (Left 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 - Front of Right Fairing Bracket
    5-118
    2004 Touring: Engine Management (EFI)
    HOME
    f2208t8x
    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]
    EFI
    1
    2
    3
    4
    5
    6
    7
    8 9 10 11 12
    [8A]
    Harness
    15A
    15A
    Accessory
    Battery
    Fuse
    Fuse
    1
    15A
    2
    Ignition
    3
    Fuse
    4
    Data Link
    [91A]
    [78B]
    1
    5
    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
    2004 Touring: Engine Management (EFI)
    5-119
    HOME
    Test 5.31
    LOSS OF SPEEDOMETER SERIAL DATA: DTC
    U1097, U1255
    Can you read ECM hardware P/N?
    See 5.6 SPEEDOMETER SELF DIAGNOSTICS.
    YES
    NO or “No rsp”
    While wiggling harness, check for
    1
    Check for continuity between
    1
    continuity between ECM breakout box
    ECM breakout box terminal 5
    terminal 5 and speedometer breakout
    and speedometer breakout
    2
    box terminal 2 (black).
    2
    box terminal 2 (black).
    Is continuity present?
    Is continuity present?
    YES
    NO
    YES
    NO
    Clear DTCs. Test Ride.
    Repair intermittent on
    Did DTC U1097 return?
    Lt GN/V wire.
    Replace speedometer.
    Repair open on
    LtGN/V wire.
    YES
    NO
    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
    2004 Touring: Engine Management (EFI)
    HOME
    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.
    2004 Touring: Sound System
    6-1
    HOME
    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
    2004 Touring: Sound System
    HOME
    DIAGNOSTIC MODE GROUP 1
    Not Applicable to Classic/Road Glide Models
    C4
    C3
    C2
    C1
    CO
    (BN/W)
    (O/BK)
    (BN/BK)
    (GY/GN)
    (GN/BE)
    GENERAL
    REAR
    RO
    MODE UP
    AUDIO
    AUDIO
    AUDIO
    (PK/W)
    VOLUME
    FF
    IN
    -
    +
    UP
    When the Diagnostic Mode is first accessed, a line of five
    REAR
    input bits appears in the upper portion of the front panel LCD
    R1
    MODE DN
    RADIO
    VOLUME
    EJECT
    LO/DX
    (GY/W)
    RW
    POWER
    DOWN
    display. See Figure 6-2.
    R2
    MODE
    SQUELCH
    SQUELCH
    SEEK
    (V/BK)
    PTT
    IN
    DOWN
    UP
    SCAN
    R3
    NOT
    PRESET
    PRESET
    PRESET
    PRESET
    (INT)
    USED
    4
    3
    2
    1
    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
    A.
    B.
    locked on “1,” then either the O/BK or the PK/W wires are
    shorted to +12 volts.
    0
    1
    0
    1
    To further pinpoint the problem, exercise the MODE UP or
    0
    1
    FAST FORWARD functions, or any other switch function on
    the R0 line, which also utilize the PK/W wire. If the input bit
    0
    1
    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
    C.
    D.
    seen from the matrix, this switch function also utilizes the O/
    [1/0]
    [1/0]
    [1/0]
    [1/0]
    [1/0]
    1
    1
    1
    1
    1
    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
    E.
    F.
    the R0 line. Conversely, if all other switch functions on the R0
    (1/0)
    1
    (1/0)
    (1/0)
    (1/0)
    1
    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
    2004 Touring: Sound System
    6-3

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    Матвей Александрович10.06.2024 04:32
    Политика конфиденциальности