Harley Davidson 2004 Touring Models. Service Manual — page 8

    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]
    Ignition
    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 3-43. Serial Data Circuit: FLHR/C/S (Fuel Injected)
    Table 3-29. Wire Harness Connectors in Figure 3-43.
    NO.
    DESCRIPTION
    TYPE
    LOCATION
    [8]
    Ignition Harness
    12-Place Deutsch
    Under Right Side Cover
    [10]
    Ignition Control Module
    12-Place Deutsch
    Under Right Side Cover
    Cavity in Crossmember at Rear of
    [30]
    Turn Signal/Security Module
    12-Place Deutsch
    Battery Box (Under Seat)
    [39]
    Speedometer
    12-Place Packard
    Under Console (Back of Speedometer)
    [78]
    Electronic Control Module
    36-Place Packard
    Under Right Side Cover
    [91]
    Data Link
    4-Place Deutsch
    Under Right Side Cover
    3-72
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    Test 3.21
    LOSS OF ICM/ECM SERIAL DATA: DTC U1016
    Can you read ECM/ICM hardware P/N?
    See 3.10 SPEEDOMETER SELF DIAGNOSTICS.
    NO or “No Rsp”
    YES
    Install Breakout Box on TSM/TSSM.
    1
    Install Breakout Box on TSM/TSSM.
    1
    CARBURETED
    2
    EFI MODELS
    MODELS
    3
    Check continuity between
    Check continuity between termi-
    CARBURETED
    breakout box terminal 3
    2
    EFI MODELS
    nal 3 (gray) of TSM/TSSM break-
    MODELS
    3
    (gray) and breakout box
    out box and terminal 5 of ECM
    terminal 12 (black).
    breakout box.
    Continuity present?
    Continuity present?
    YES
    YES
    NO
    Replace ECM.
    Replace ICM.
    Reprogram and learn
    Reprogram and learn
    password.
    password.
    Repair open on
    LtGN/V wire.
    While wiggling harness, check
    While wiggling harness, check conti-
    continuity between breakout box
    nuity between terminal 3 (gray) of
    terminal 3 (gray) and breakout
    TSM/TSSM breakout box and termi-
    box terminal 12 (black).
    nal 5 of ECM Breakout Box.
    Continuity present?
    Continuity present?
    YES
    YES
    NO
    Clear codes. Test ride. Did DTC
    U1016 return?
    Clear codes. Test ride.
    Does DTC U1016
    Repair intermittent
    return?
    on Lt GN/V wire.
    YES
    NO
    Replace ECM.
    No trouble found.
    YES
    NO
    Reprogram and learn
    password.
    Replace ICM.
    No trouble found.
    Reprogram and learn
    password.
    Clear codes using speedometer self diagnostics.
    See 3.10 SPEEDOMETER SELF DIAGNOSTICS.
    Confirm proper operation with no check engine
    lamp.
    2004 Touring: TSM & TSSM
    3-73
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    DTC U1097, U1255
    3.22
    GENERAL
    Loss of Speedometer Serial Data
    The serial data line provides a means for the speedometer,
    ICM/ECM and TSM/TSSM to communicate their current sta-
    tus. When all operating parameters 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 3-30. Code Description
    DTC
    DESCRIPTION
    Loss of all speedometer serial data
    U1097
    (state of health)
    f2191x8x
    U1255
    Serial data error/missing message
    Ignition Control Module
    Connector [10]
    Carbureted
    DIAGNOSTICS
    f1917x9x
    Diagnostic Notes
    The reference numbers below correlate with the circled num-
    bers on the test 3.22 flow chart.
    1. For carbureted models, connect BREAKOUT BOX (Part
    No. HD-42682) between wire harness and ICM. See 4.6
    BREAKOUT BOX: ICM. For EFI models, connect BREA-
    KOUT BOX (Part No. HD-43876) between wire harness
    and ECM. See 5.7 BREAKOUT BOX: EFI.
    2. Connect BREAKOUT BOX (Part No. HD-42682) (black)
    as follows:
    1
    6924
    4
    5
    3
    Electronic Control
    Fuel Injected
    Module Connector [78]
    2
    Figure 3-45. Electrical Bracket (Under Right Side Cover)
    1. Terminal 1: flash pin-EFI models (Lt GN/R)
    2. Terminal 2: ground (BK)
    a. Mate black socket housing on Breakout Box with
    3.
    Terminal 3: serial data (Lt GN/V)
    speedometer connector [39A] (at the back of the
    4.
    Terminal 4: power (GY)
    speedometer) using INSTRUMENT HARNESS
    5.
    Protective cap
    ADAPTERS (Part No.HD-46601).
    Figure 3-44. Data Link Connector
    b. Mate black pin housing on Breakout Box with wire
    harness connector [39B] using INSTRUMENT HAR-
    NESS ADAPTERS (Part No.HD-46601).
    3-74
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    f2208z8x
    [156B] [156A]
    Main to Interconnect
    6
    6
    Harness
    5
    5
    4
    4
    3
    3
    GY
    BK
    2
    2
    BK
    LtGN/V
    1
    1
    LtGN/V
    O
    1
    2
    3
    4 5 6 7 8 9 10 11 12
    [30B]
    BN/GY
    1
    2
    3
    4 5 6 7 8 9 10 11 12
    [30A]
    TSM/TSSM
    BN/GY
    [39B]
    GY
    BK
    1
    2
    3
    4 5 6 7 8 9 10 11 12
    [39A]
    1
    2
    3
    4 5 6 7 8 9 10 11 12
    1
    2
    3
    4 5 6 7 8 9 10 11 12
    [8B]
    Speedometer
    1
    2
    3
    4 5 6 7 8 9 10 11 12
    1
    2
    3
    4 5 6 7 8 9 10 11 12
    [8A]
    [108B]
    1
    2
    3
    4 5 6 7 8 9 10 11 12
    Ignition
    [108A]
    Tachometer
    Harness
    15A
    [1B] [1A]
    Accessory
    Fuse
    1
    2
    Main to Interconnect
    3
    [2A]
    1
    2
    3
    4 5 6 7 8 9 10 11 12
    Harness
    4
    Data Link
    [2B]
    1
    2
    3
    4 5 6 7 8 9 10 11 12
    [91A]
    Main to Interconnect
    15A
    Harness
    Ignition
    Fuse
    12
    15A
    [10B]
    Battery
    12
    [10A]
    Ignition Control Module
    Fuse
    Figure 3-46. Serial Data Circuit: FLHT/C (Carbureted)
    Table 3-31. Wire Harness Connectors in Figure 3-46.
    NO.
    DESCRIPTION
    TYPE
    LOCATION
    [1]
    Main to Interconnect Harness
    12-Place Deutsch (Black)
    Inner Fairing - Right Radio Support Bracket
    [2]
    Main to Interconnect Harness
    12-Place Deutsch (Gray)
    Inner Fairing - Right Fairing Support Brace
    [8]
    Ignition Harness
    12-Place Deutsch
    Under Right Side Cover
    [10]
    Ignition Control Module
    12-Place Deutsch
    Under Right Side Cover
    Cavity in Crossmember at Rear of
    [30]
    Turn Signal/Security Module
    12-Place Deutsch
    Battery Box (Under Seat)
    [39]
    Speedometer
    12-Place Packard
    Inner Fairing (Back of Speedometer)
    [91]
    Data Link
    4-Place Deutsch
    Under Right Side Cover
    [108]
    Tachometer
    12-Place Packard
    Inner Fairing (Back of Tachometer)
    [156]
    Main to Interconnect Harness
    6-Place Deutsch
    Inner Fairing - Right Fairing Support Brace
    2004 Touring: TSM & TSSM
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    HOME
    f2208y8x
    BK
    GY
    LtGN/V
    LtGN/V
    BK
    BN/GY
    O
    1
    2
    3
    4
    5 6 7 8 9 10 11 12
    [30B]
    1
    2
    3
    4
    5 6 7 8 9 10 11 12
    [30A]
    BN/GY
    TSM/TSSM
    BK
    1
    2
    3
    4 5 6 7 8 9 10
    11 12
    [39B]
    1
    2
    3
    4 5 6 7 8 9 10
    11 12
    [39A]
    GY
    Speedometer
    1
    2
    3
    4 5
    6
    7
    8
    9
    10 11 12
    [8B] Ignition
    1
    2
    3
    4 5
    6
    7
    8
    9
    10 11 12
    [8A] Harness
    15A
    Battery
    Fuse
    15A
    Accessory
    Fuse
    1
    2
    3
    4
    Data Link
    [91A]
    15A
    Ignition
    Fuse
    12
    [10B]
    [10A]
    Ignition Control Module
    12
    Figure 3-47. Serial Data Circuit: FLHR/S (Carbureted)
    Table 3-32. Wire Harness Connectors in Figure 3-47.
    NO.
    DESCRIPTION
    TYPE
    LOCATION
    [8]
    Ignition Harness
    12-Place Deutsch
    Under Right Side Cover
    [10]
    Ignition Control Module
    12-Place Deutsch
    Under Right Side Cover
    Cavity in Crossmember at Rear of
    [30]
    Turn Signal/Security Module
    12-Place Deutsch
    Battery Box (Under Seat)
    [39]
    Speedometer
    12-Place Packard
    Under Console (Back of Speedometer)
    [91]
    Data Link
    4-Place Deutsch
    Under Right Side Cover
    3-76
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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]
    Ignition
    [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 3-48. Serial Data Circuit: FLTR, FLHT/C/U (Fuel Injected)
    Table 3-33. Wire Harness Connectors in Figure 3-48.
    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]
    Ignition Harness
    All
    12-Place Deutsch
    Under Right Side Cover
    [10]
    Ignition Control Module
    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)
    [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: TSM & TSSM
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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]
    Ignition
    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 3-49. Serial Data Circuit: FLHR/C/S (Fuel Injected)
    Table 3-34. Wire Harness Connectors in Figure 3-49.
    NO.
    DESCRIPTION
    TYPE
    LOCATION
    [8]
    Ignition Harness
    12-Place Deutsch
    Under Right Side Cover
    [10]
    Ignition Control Module
    12-Place Deutsch
    Under Right Side Cover
    Cavity in Crossmember at Rear of
    [30]
    Turn Signal/Security Module
    12-Place Deutsch
    Battery Box (Under Seat)
    [39]
    Speedometer
    12-Place Packard
    Under Console (Back of Speedometer)
    [78]
    Electronic Control Module
    36-Place Packard
    Under Right Side Cover
    [91]
    Data Link
    4-Place Deutsch
    Under Right Side Cover
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    Test 3.22
    LOSS OF SPEEDOMETER SERIAL DATA: DTC
    U1097, U1255
    Can you read TSM/TSSM hardware P/N?
    See 3.10 SPEEDOMETER SELF DIAGNOSTICS
    YES
    NO or “No rsp”
    1
    1
    While wiggling harness, check for
    Check for continuity between
    continuity between Breakout Box
    Breakout Box terminal 3 (gray)
    terminal 3 (gray) and terminal 2 (black).
    and terminal 2 (black).
    Is continuity present?
    Is continuity present?
    YES
    NO
    YES
    NO
    Clear DTCs. Test Ride.
    Repair intermittent on
    Replace speedometer.
    Repair open on
    Did DTC U1097 return?
    Lt GN/V wire.
    Lt GN/V wire.
    Clear codes using speedometer self diagnostics.
    See 3.10 SPEEDOMETER SELF DIAGNOSTICS.
    YES
    NO
    Confirm proper operation with no check engine
    lamp.
    Replace speedometer
    No trouble found
    2004 Touring: TSM & TSSM
    3-79
    HOME
    DTC U1300, U1301 OR “BUS ER”
    3.23
    GENERAL
    Serial Data Low or Serial data Open/High
    See Figure 3-50. The typical serial data voltage range is 0
    volts (inactive) to 7 volts (active). Due to the short pulse, volt-
    ages will be much lower on a DVOM. In analog mode, a
    DVOM reading serial data will show continuous voltage when
    active, typically 0.6-0.8 volts. The range for acceptable opera-
    tions is 0-7.0 volts.
    Table 2-35. Code Description
    DTC
    DESCRIPTION
    f2191x8x
    U1300
    Serial data low
    Data Link
    U1301
    Serial data open/high
    Connector [91]
    Carbureted
    DIAGNOSTICS
    f1917x9x
    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 con-
    dition.
    ● Diagnostic trouble codes (DTCs) P1009 and P1010 may
    accompany DTCs U1300 and U1301.
    Diagnostic Notes
    ● If a U1300, U1301 or “BUS Er” is present on carbureted
    models, perform diagnostic procedures listed in
    4.10
    STARTS, THEN STALLS.
    Data Link
    ● If a U1300, U1301 or “BUS Er” is present on EFI models,
    Fuel Injected
    Connector [91]
    perform diagnostic procedures listed in 5.12 STARTS,
    THEN STALLS.
    Figure 3-50. Electrical Bracket (Under Right Side Cover)
    3-80
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    PASSWORD LEARN
    3.24
    GENERAL
    PASSWORD LEARNING
    If the ECM/ICM or TSM/TSSM is faulty, follow the instructions
    To perform password learning procedure, refer to Table 3-37.
    in the Touring Service Manual for ECM/ICM or TSM/TSSM
    When finished, continue with all instructions under 3.3 TSM/
    replacement. Then, to determine if password learn is neces-
    TSSM VEHICLE DELIVERY.
    sary, refer to Table 3-36.
    Always perform all appropriate instructions under 3.3 TSM/
    TSSM VEHICLE DELIVERY after TSM/TSSM replacement or
    Table 3-36. Password Learn
    removal.
    IS PASSWORD LEARN
    IMPORTANT NOTE
    DEVICE REPLACED
    NECESSARY
    Do not forget to enter a personal code for TSSM vehicles.
    If a code is not assigned and both key fobs are lost or
    ECM
    Yes
    damaged while the vehicle is armed, the TSSM must be
    ICM
    Yes
    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.
    2004 Touring: TSM & TSSM
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    HOME
    Table 3-37. Setting TSM/TSSM and ECM/ICM Password
    NO.
    ACTION
    CONFIRMATION
    NOTES
    Ignition must be turned off for at least 15
    With ignition turned off, Check Engine
    seconds.
    Lamp and Security Lamp will be off.
    Install new TSM/TSSM or ECM/ICM.
    1
    Perform all steps under 3.3 TSM/TSSM
    VEHICLE DELIVERY.
    2
    Set RUN/OFF switch to RUN.
    Verify Check Engine Lamp and Security
    TSM/TSSM enables starter
    3
    Turn IGN key ON.
    Lamp illuminate and then turn off.
    relay.
    Carbureted models: Engine starts and
    stalls. Check Engine Lamp performs 4
    seconds on, 4 seconds off, 8 seconds on,
    Password has not been
    4
    Attempt normal start one time.
    off sequence.
    learned. ECM/ICM sets DTC
    EFI models: Engine starts and stalls.
    P1009.
    Check Engine Lamp illuminates and
    stays on.
    ECM/ICM enters Password
    Learning mode for ten min-
    Wait ten seconds. Security lamp will illu-
    utes. Do not cycle ignition
    5
    Security Lamp illuminates.
    minate and stay on.
    switch or interrupt vehicle
    power or Password Learn will
    be unsuccessful.
    6
    Wait until Security Lamp turns off.
    This takes ten minutes.
    Quickly (within two seconds) turn IGN
    ECM/ICM must not be
    7
    key OFF-ON.
    allowed to shutdown.
    8
    Wait until Security Lamp turns off.
    This takes ten minutes.
    Quickly (within two seconds) turn IGN
    ECM/ICM must not be
    9
    key OFF-ON.
    allowed to shutdown.
    10
    Wait until Security Lamp turns off.
    This takes ten minutes.
    Quickly (within two seconds) turn IGN
    ECM/ICM must not be
    11
    key OFF-ON.
    allowed to shutdown.
    Turn IGN key OFF. Wait 15 seconds
    before turning IGN on. Turn IGN switch
    12
    ON and start engine to confirm success-
    ful Password Learn procedure. Clear
    trouble codes.
    Perform all steps under 3.3 TSM/TSSM
    13
    VEHICLE DELIVERY.
    3-82
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    TSSM MAINTENANCE
    3.25
    GENERAL
    o0235xox
    1
    The TSSM system uses batteries in the key fob and siren.
    2
    These are the only parts requiring periodic maintenance.
    KEY FOB
    Schedule
    Replace the key fob battery every 2 years.
    3
    1. Battery
    Battery Replacement
    2. Battery contact
    3. Circuit board
    1. Open the key fob case.
    a. Place a thin blade between the 2 halves of the case.
    Figure 3-51. Open Key Fob Case
    b. Slowly twist the blade.
    o0234xox
    2. See Figure 3-51. Replace battery.
    a. Remove the original battery.
    b. Install a new battery with the positive (+) side down.
    Use a Panasonic® 2032 or equivalent.
    3.
    See Figure 3-52. Align case and circuit board as shown.
    Snap case halves together.
    4. While standing next to the motorcycle, press and hold
    the key fob button for 10-15 seconds until the security
    system responds with two turn signal flashes/siren
    chirps.
    Figure 3-52. Key Fob Assembly
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    SIREN (IF INSTALLED)
    7867
    Schedule
    The siren’s internal 9 volt battery is rechargeable and does
    not need to be replaced on a regular basis. Battery life under
    normal conditions is approximately three to six years.
    NOTE
    The internal siren battery may not charge if the vehicle’s bat-
    tery is less than 12.5 volts.
    1
    2
    3
    Battery Replacement
    1.
    Cover
    1.
    Disarm system and remove siren.
    2.
    Battery
    2.
    See Figure 3-53. Remove battery cover.
    3.
    Siren Connector [142A]
    a. Place the siren module on a flat and sturdy table
    Figure 3-53. Siren Battery Compartment
    with the potted section (area with epoxy covering cir-
    cuit 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 the siren case and battery cover at one of
    the two accessible corners of the battery cover.
    Keep the blade slightly higher towards the battery
    cover as this helps keep the blade away from the
    battery seal.
    c. Slowly twist the blade towards the battery cover and
    the cover will pop off.
    NOTE
    For protection against corrosion, battery terminals and bat-
    tery clip are covered with a special grease. Do not wipe away
    this substance. Apply all available existing grease to termi-
    nals on new battery.
    3.
    See Figure 3-53. Replace battery by removing old bat-
    tery from polarized battery clip. Install a new 9 volt nickel
    metal hydride battery.
    NOTE
    Only a nickel metal hydride nine-volt battery should be used
    in the siren.
    4. See Figure 3-53. 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.
    3-84
    2004 Touring: TSM & TSSM
    HOME
    SPECIFICATIONS
    4.1
    System Fuse Block (Under Left Side Cover)
    IGNITION
    DATA
    8
    0°-50° BTDC (range)
    FLHR/S
    Spark timing advance
    30° BTDC@1000 RPM
    9
    10
    Idle speed
    1000 ± 50 RPM
    5
    Spark plug size
    12 mm
    11
    0.038-0.043 in
    Spark plug gap
    0.97-1.09 mm
    Harley-Davidson
    4
    Spark plug type
    No. 6R12 (no substitute)
    12
    Ignition coil primary
    0.5-0.7 ohms
    resistance
    f2210x8x
    3
    1
    2
    Ignition coil secondary
    5500-7500 ohms
    resistance
    8
    7
    FLHT/C
    9
    6
    RATING
    10
    CIRCUIT
    COLOR
    (AMPERES)
    5
    11
    System Fuses
    Maxi-Fuse
    40
    Orange
    Headlamp
    15
    Blue
    4
    Ignition
    15
    Blue
    Lighting
    15
    Blue
    f2204x8x
    2
    3
    Instruments
    15
    Blue
    1
    Brakes/Cruise
    15
    Blue
    1.
    Headlamp
    7.
    Radio Power
    2.
    Ignition
    8.
    Accessory
    Radio Memory
    15
    Blue
    3.
    Lighting
    9.
    Battery
    Radio Power
    10
    Red
    4.
    Instruments
    10.
    Brake Light Relay
    5.
    Brakes/Cruise
    11.
    P&A
    Accessory
    15
    Blue
    6.
    Radio Memory
    12.
    Starter Relay
    Battery
    15
    Blue
    P & A
    15
    Blue
    Figure 4-1. Fuse Locations
    2004 Touring: Engine Management (Carbureted)
    4-1
    HOME
    DIAGNOSTIC INTRODUCTION
    4.2
    SYSTEM PROBLEMS
    All system problems fall into at least one of three general cat-
    egories.
    60
    40
    50
    70
    30
    50
    40
    80
    No Start
    30
    90
    20
    MPH
    RPM x100
    20
    100
    The engine cranks over freely, but will not start. This does not
    10
    10
    110
    include situations where the engine will not crank, such as a
    0
    120
    0
    bad starter, dead battery, etc. This condition assumes that all
    obvious checks (fuel in tank, etc.) have been made.
    TI
    -D
    -D
    Poor Performance
    The engine starts but there are performance problems. These
    problems may include poor fuel economy, rough idle, engine
    misfire, engine hesitation, severe spark knock, etc.
    Check Engine Lamp
    f2160x8x
    Check Engine Lamp
    Figure 4-2. Speedometer
    See Figure 4-2. The check engine lamp indicates the ignition
    control module (ICM) has determined a fault condition exists.
    There may also be starting or performance problems.
    RESOLVING PROBLEMS
    To resolve system problems, five basic steps are involved. In
    order of occurrence, they are:
    1.
    Check for diagnostic trouble codes (DTCs) by observing
    check engine lamp. See 4.3 CHECKING FOR TROUBLE
    CODES.
    2.
    Retrieve DTCs using speedometer self diagnostics. See
    4.5 SPEEDOMETER SELF DIAGNOSTICS.
    3.
    Diagnose system problems. This involves using special
    tools and the diagnostic flow charts in this section.
    4.
    Correct problems through the replacement and/or repair
    of the affected components.
    5.
    After repairs are performed, the work must be validated.
    This involves clearing the DTCs and confirming proper
    vehicle operation as indicated by the behavior of the
    check engine lamp.
    4-2
    2004 Touring: Engine Management (Carbureted)
    HOME
    CHECKING FOR TROUBLE CODES
    4.3
    CHECK ENGINE LAMP
    To diagnose system problems, start by observing the behav-
    ior of the check engine lamp.
    NOTE
    ●
    See Figure 4-3. “Key ON” means that the ignition key is
    turned to ON and the engine stop switch is set to RUN
    (although the engine is not running).
    ●
    When the ignition switch is turned ON, the check engine
    lamp will illuminate for approximately four seconds and
    then turn off.
    ●
    If the check engine lamp is not illuminated at key ON or if
    it fails to turn OFF after the ititial four second period, then
    f1240x2x
    see 4.5 SPEEDOMETER SELF DIAGNOSTICS.
    ●
    If the check engine lamp comes on late (after 20 sec-
    Figure 4-3. Ignition Switch (FLHT/C)
    onds), the problem is likely a serial data bus failure. Test
    for codes using speedometer self diagnostics. See 4.5
    SPEEDOMETER SELF DIAGNOSTICS.
    c. Come back on, and remain on, if a current trouble
    ●
    If the check engine lamp fails to turn OFF after the initial
    code exists. See C of Figure 4-4.
    four second period, then a problem exists in the instru-
    mentation. See 4.5 SPEEDOMETER SELF DIAGNOS-
    2.
    See CODE TYPES which follows for a complete descrip-
    TICS.
    tion of trouble code formats.
    NOTE
    1.
    When the lamp turns off after being illuminated for the
    Trouble codes relating to the ignition coil can only be fully
    first four second period, it will:
    diagnosed during actuation. For example, a problem with the
    a. Remain off if there are no fault conditions or trouble
    ignition coil will be considered a current fault even after the
    codes currently detected by the ignition control mod-
    problem is corrected, since the ignition control module will not
    ule. See A of Figure 4-4.
    know of its resolution until after the coil is exercised by vehicle
    b. Come back on for an 8 second period if only historic
    start sequence. In this manner, there may sometimes be a
    codes exist. See B of Figure 4-4.
    false indication of the current trouble code.
    ON
    4 Sec.
    A
    Lamp OFF: No Current or Historic Trouble Codes
    OFF
    Key On
    Lamp ON 8 Seconds:
    Only Historic Trouble Codes Exist
    ON
    4 Sec.
    8 Sec.
    B
    Lamp OFF
    OFF
    4 Sec.
    Key On
    Lamp Remains ON: Current Trouble Code *
    ON
    4 Sec.
    C
    OFF
    4 Sec.
    Key On
    * Historic Trouble Codes May Also Exist
    Figure 4-4. Check Engine Lamp Operation
    2004 Touring: Engine Management (Carbureted)
    4-3
    HOME
    CODE TYPES
    RETRIEVING DIAGNOSTIC
    TROUBLE CODES
    There are two types of diagnostic trouble codes (DTCs):
    current and historic. If a trouble code is stored, it can be read
    using the speedometer self diagnostics. See 4.5 SPEEDOM-
    The engine management system provides two levels of diag-
    ETER SELF DIAGNOSTICS.
    nostics.
    All trouble codes reside in the memory of the ignition control
    ● The most sophisticated mode employs a computer
    module (ICM) until cleared using the speedometer self diag-
    based diagnostic package called DIGITAL TECHNICIAN
    nostics. See 4.5 SPEEDOMETER SELF DIAGNOSTICS.
    (Part No. HD-44750).
    A trouble code is also cleared after a total of 50 trips has
    elasped. A trip consists of a start and run cycle, the run cycle
    ● The second mode requires using the speedometer self
    lasting at least 30 seconds. After the 50 trip retention period,
    diagnostics. Speedometer, tachometer
    (if equipped),
    the trouble code is automatically erased from memory provid-
    TSM/TSSM and ECM codes can be accessed and
    ing that no subsequent faults of the same type are detected in
    cleared. See
    4.5 SPEEDOMETER SELF DIAGNOS-
    that period.
    TICS.
    Current
    MULTIPLE DIAGNOSTIC TROUBLE
    Current trouble codes are those which presently disrupt
    CODES
    motorcycle operation. See the appropriate flow charts for
    solutions.
    While it is possible for more than one fault to occur and set
    Historic
    more than one trouble code, there are several conditions
    which may result in one fault setting multiple trouble codes:
    If a particular problem happens to resolve itself, the active
    status is dropped and it becomes a historic fault rather than a
    ● Serial data codes (DTC U1016, U1064, U1097, U1255,
    current fault.
    U1300 and U1301) may be accompanied by other
    codes. Always correct the serial data codes before
    Historic trouble codes can only be retrieved using a computer
    resolving the other codes.
    based diagnostic package called DIGITAL TECHNICIAN
    (Part No. HD-44750).
    For proper resolution to multiple trouble codes refer to diag-
    Historic trouble codes are stored for a length of time to assist
    nostic code priority chart (Table 4-5.)
    in the diagnosis of intermittent faults.
    It is important to note that historic trouble codes may also be
    present whenever the system indicates the existence of a
    current fault. See MULTIPLE DIAGNOSTIC TROUBLE
    CODES if multiple trouble codes are found.
    Diagnostic charts are designed for use with current trouble
    codes and as a result they frequently suggest part replace-
    ment.
    4-4
    2004 Touring: Engine Management (Carbureted)
    HOME
    INITIAL DIAGNOSTIC CHECK: ICM
    4.4
    GENERAL
    INITIAL DIAGNOSTICS
    To locate faulty circuits or other system problems, follow the
    diagnostic flow charts in this section. For a systematic
    General Information
    approach, always begin with INITIAL DIAGNOSTICS which
    The diagnostic check is an organized approach to identifying
    follows. Read the general information and then work your way
    a problem caused by an electronic control system malfunc-
    through the flow chart box by box.
    tion. If no problems are found after completion of the diagnos-
    tic check, a comparison of running parameters may be used
    to help locate intermittents and out-of-specification sensors.
    Diagnostic Notes
    See Table 4-1.
    If a numbered circle appears adjacent to a flow chart box,
    then more information is offered in the diagnostic notes. Many
    diagnostic notes contain supplemental information, descrip-
    Diagnostic Tips
    tions of various diagnostic tools or references to other parts
    ● If Speedometer reads “BUS Er” with the ignition key
    of the manual.
    turned ON (engine stop switch at RUN with the engine
    off), check data bus for an open or short to ground
    between data connector [91A] terminal 3 and ICM con-
    Circuit Diagram/Wire Harness Connector
    nector [10B] terminal 12, TSSM connector [30B] terminal
    Table
    3, Speedometer connector [39B] terminal 2 or tachome-
    ter (if equipped) connector [108B] terminal 2.
    When working through a flow chart, refer to the illustrations,
    the associated circuit diagram and the wire harness connec-
    ● Check for an open diagnostic test terminal between data
    tor table as necessary. The wire harness connector table for
    link connector [91A] terminal 3 and TSM/TSSM connec-
    each circuit diagram identifies the connector number, descrip-
    tor [30B] terminal 3. With ignition key turned ON, serial
    tion, type and general location.
    data bus voltage should be typically 0.6-0.8 volts. The
    range of acceptable voltage is 0-7.0 volts.
    In order to perform most diagnostic routines, a Breakout Box
    and a DVOM are required. See 4.6 BREAKOUT BOX: ICM.
    To perform the circuit checks with any degree of efficiency, a
    Diagnostic Notes
    familiarity with the various wire connectors is necessary.
    The reference numbers below correlate with the circled num-
    bers on the diagnostic check flow charts. See page 4-10.
    Reprogramming ICM
    1. Compare engine behavior to symptoms tables in this
    section.
    Diagnostic charts frequently suggest ICM replacement. In the
    event an ignition control module (ICM) needs to be replaced,
    a. Starts hard. See Table 4-2.
    it must be reprogrammed using a computer based diagnostic
    b. Hesitates, stumbles, surges, misfires and/or slug-
    package called DIGITAL TECHNICIAN (Part No. HD-44750).
    gish performance. See Table 4-3.
    See your dealer. Password learn procedure must also be per-
    formed. See 3.24 PASSWORD LEARN.
    c. Engine exhaust emits black smoke or fouls plugs.
    See Table 4-4.
    2. Use HARNESS CONNECTOR TEST KIT (Part No. HD-
    41404), black socket probes and patch cord.
    3. Connect BREAKOUT BOX (Part No. HD-42682) to igni-
    tion control module. See 4.6 BREAKOUT BOX: ICM.
    All diagnostic codes are listed in Table 4-5.
    See 3.9 INITIAL DIAGNOSTIC CHECK: TSM/TSSM for any
    codes related to the turn signal module (TSM) or turn signal
    security module (TSSM).
    See 2.5 BREAKOUT BOX: SPEEDOMETER for any codes
    related to the speedometer.
    2004 Touring: Engine Management (Carbureted)
    4-5
    HOME
    Table 4-1. Typical Running Values
    Table 4-3. Engine Performance Problems
    MIN.
    MAX.
    HOT
    SYMPTOM
    SOLUTION
    ITEM
    VALUE
    VALUE
    IDLE
    Perform intake leak test.
    4.96 V
    Manifold leak
    See 4.8 INTAKE LEAK
    0.1 V
    (atmo-
    TEST.
    MAP sensor
    (high
    1.5-3.0 V
    spheric
    vacuum)
    MAP sensor plugged or not
    4.13 DTC P0106, P0107,
    pressure)
    operating properly
    P0108
    RPM
    0
    5600
    1000
    Drain and refill with fresh
    Bank angle
    Run mode
    Disable
    Run mode
    Water or dirt in fuel system
    fuel.
    sensor
    0.45-1.1 V
    1.8-3.2 V
    0.45-1.1 V
    Spark plugs
    4.12 MISFIRE.
    EVAP hose disconnected
    Connect.
    from induction module (CA)
    Table 4-2. Engine Starts Hard
    See throttle cable adjust-
    Throttle plates not opening
    SYMPTOM
    SOLUTION
    ment in Touring Service
    fully
    Manual.
    See charging system trouble-
    Battery discharged
    shooting in this section.
    Spark plugs
    4.12 MISFIRE.
    Table 4-4. Engine Exhaust Emits
    Spark plug wires
    4.12 MISFIRE
    Black Smoke or Fouls Plugs
    Ignition coil
    4.12 MISFIRE.
    See Section 3 in Touring Ser-
    SYMPTOM
    SOLUTION
    Valve sticking
    vice Manual.
    See Section 1 in Touring
    Clogged air filter
    Water or dirt in fuel system
    Drain and refill with fresh fuel.
    Service Manual.
    4-6
    2004 Touring: Engine Management (Carbureted)
    HOME
    Table 4-5. Diagnostic Trouble Codes (DTC) and Fault Conditions
    PRIORITY
    DTC NO.
    FAULT CONDITION
    SOLUTION
    RANKING
    1
    P0605
    flash memory error
    4.19 DTC P0602, P0603, P0604, P0605, P0607
    2
    P0603
    EEProm memory error
    4.19 DTC P0602, P0603, P0604, P0605, P0607
    3
    P0602
    Flash memory error
    4.19 DTC P0602, P0603, P0604, P0605, P0607
    4
    P0604
    RAM memory error
    4.19 DTC P0602, P0603, P0604, P0605, P0607
    5
    P0607
    A to D error
    4.19 DTC P0602, P0603, P0604, P0605, P0607
    6
    “BUS Er”
    Serial data bus shorted low/open/high
    4.10 STARTS, THEN STALLS
    7
    U1300
    serial data shorted low
    4.10 STARTS, THEN STALLS
    8
    U1301
    serial data shorted high
    4.10 STARTS, THEN STALLS
    9
    U1064
    lost TSM/TSSM communication
    4.20 DTC U1064
    10
    U1097
    lost speedometer communication
    4.21 DTC U1097
    11
    U1255
    Missing response at TSSM
    4.20 DTC U1064
    12
    U1255
    Missing response at speedometer
    4.21 DTC U1097
    TSM/TSSM disabled fuel due to bad
    13
    P1009
    4.15 DTC P1009, P1010
    password
    TSM/TSSM disabled fuel due to no pass-
    14
    P1010
    4.15 DTC P1009, P1010
    word (starts then stalls)
    15
    P0373
    crankshaft position sensor intermittent
    4.17 DTC P0373, P0374
    crankshaft position sensor not detected/
    16
    P0374
    4.17 DTC P0373, P0374
    cannot synchronize
    17
    P0106
    MAP sensor rate-of-change error
    4.13 DTC P0106, P0107, P0108
    18
    P0107
    MAP sensor failed open/low
    4.13 DTC P0106, P0107, P0108
    19
    P0108
    MAP sensor failed high
    4.13 DTC P0106, P0107, P0108
    21
    P1351
    Ignition coil driver front low/open
    4.16 DTC P1351, P1352, P1354, P1355
    20
    P1354
    Ignition coil driver rear low/open
    4.16 DTC P1351, P1352, P1354, P1355
    22
    P1352
    Ignition coil driver front high
    4.16 DTC P1351, P1352, P1354, P1355
    23
    P1355
    Ignition coil driver rear high
    4.16 DTC P1351, P1352, P1354, P1355
    24
    P0562
    system voltage low
    4.14 DTC P0562, P0563
    25
    P0563
    system voltage high
    4.14 DTC P0562, P0563
    26
    P0501
    VSS failed low
    4.18 DTC P0501, P0502
    27
    P0502
    VSS failed high/open
    4.18 DTC P0501, P0502
    2004 Touring: Engine Management (Carbureted)
    4-7

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    Матвей Александрович04.06.2024 01:18
    Политика конфиденциальности