Harley Davidson 2004 Touring Models. Service Manual — page 20
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2.
Remove the outer fairing. Remove the antenna cable
9. If SWR is more than 3:1, remove antenna cable from
and connect the SWR meter to the radio. Connect the
transceiver under Tour-Pak. Using clip-on test leads,
antenna cable to the SWR meter. The SWR meter is
connect one lead of ohmmeter to center pin in antenna
connected in series with the antenna cable so the
lead and other lead to antenna mast. Meter must read 1
antenna will be connected to the SWR meter.
ohm or less. Wiggle or flex mast while observing meter. If
resistance is more than 1 ohm or varies when mast is
3.
Check that the antenna loading coil bracket in Tour-Pak
wiggled, replace mast. Inspect connections at base of
is tight and that antenna cable is tightly connected to
loading coil and at mounting bracket. If the SWR is less
loading coil.
than 3:1, loosen antenna set screw and change mast
length.
4.
Check that antenna mast is threaded securely on to base
and set screw is tight.
NOTE
5.
Before measuring the SWR, the SWR meter must be cal-
It is normal to observe a reading of less than one ohm
ibrated. Follow the instructions for the meter being used.
between the center conductor and ground due to the configu-
The following procedure is the general calibration most
ration of the loading coil.
meter instructions specify.
10. Repeat Step 8. If SWR became higher, adjust antenna
mast in opposite direction. Continue adjusting antenna
CAUTION
until the minimum SWR is achieved. If you cannot obtain
Do not touch the antenna or meter during calibration or
an SWR of 2:1 or less by adjusting the antenna length,
SWR measurement. Move CAL knob and then move your
make the mast shorter to improve the SWR. Remove
hand away from meter while calibrating.
mast and use grinder to shorten mast (grind in small
increments).
6. With ignition and CB switches ON, the SWR meter set on
11. After SWR is adjusted on channel 20, check SWR on
“FWD”, Channel 20 selected, press either PTT switches.
channels 1 and 40. Adjust the mast length to obtain a
Hold the PTT switch and rotate the calibration (CAL)
balance between channels 1 and 40.
control until the meter needle aligns with the “CAL” mark.
7. Release the PTT switch and move the FWD/REF switch
NOTE
to “REF” (reflected).
Check the SWR if a luggage rack is installed on the Tour-Pak
cover. Be sure that the Tour-Pak cover is closed when the
check is performed. Accessories mounted on the Tour Pak
CAUTION
may affect the SWR reading and broadcast range, so the lug-
Do not touch the antenna or meter during calibration or
gage rack should be mounted as far forward as possible. The
SWR measurement. Move CAL knob and then move your
Ultra Tour-Pak chrome accent rail also can adversely affect
hand away from meter while calibrating. Do not press
SWR.
PTT switches with antenna and SWR meter discon-
nected. Transceiver damage could result.
8.
Press and hold either PTT switch. The meter reading is
the SWR.
6-44
2004 Touring: Sound System
HOME
RADIO SYMPTOM 13
6.16
GENERAL
Not Applicable to Classic/Road Glide Models
C4
C3
C2
C1
CO
Problem
(BN/W)
(O/BK)
(BN/BK)
(GY/GN)
(GN/BE)
PTT/Squelch control inoperative.
RO
MODE UP
REAR
AUDIO
AUDIO
AUDIO
(PK/W)
FF
VOLUME
IN
-
+
UP
REAR
R1
MODE DN
RADIO
VOLUME
EJECT
LO/DX
Setup
(GY/W)
RW
POWER
DOWN
R2
MODE
SQUELCH
SQUELCH
SEEK
● Press the POWER button to turn the radio ON.
PTT
(V/BK)
IN
DOWN
UP
SCAN
● Press and hold the INT button to turn the Intercom OFF.
R3
NOT
PRESET
PRESET
PRESET
PRESET
(INT)
USED
4
3
2
1
● Press and hold the CB button to turn the Citizen Band
radio ON.
Figure 6-28. Diagnostic Mode Group 1 Switch Matrix
● Set fairing mounted Headset/Speaker Switch to
SPEAKER.
f2123x8x
C3
C1
Functionality
Depressing any PTT switch will change
the radio display to
reflect CB mode and cause the transmitter to transmit. Press-
ing the Squelch Control in either direction will cause the hori-
zontal bar graph display to change. Are these your
observations?
● Yes - System is OK.
● No - See Test 6.16 (Part 1 of 2).
C2
Figure 6-29. PTT/Squelch Control Switch Input Bits
DIAGNOSTICS
3. Revalidate failure. Reconnect all connectors. If problem
Diagnostic Notes
still exists, replace radio. If problem is gone, look for
intermittents.
The reference numbers below correlate with the circled num-
bers in the Test 6.16 flow charts.
4. Use HARNESS CONNECTOR KIT (Part No. HD-41404),
black pin probes and patch cord.
1. This also may be an open. First go to SHORT TO VOLT-
AGE in Test 6.16 (Part 2 of 2).
2. Install BREAKOUT BOX (Part No. HD-44608). See Sec-
tion 6.3 BREAKOUT BOX, INSTALLATION.
2004 Touring: Sound System
6-45
HOME
Test 6.16 (Part 1 of 2)
PTT/SQUELCH CONTROL INOPERATIVE: SOFTWARE DIAGNOSIS
Enter Diagnostic Mode
by Pressing Any Two Pre-
set Buttons While Turning
Ignition Switch to On.
Look at Input Bits C1,
C2 and C3 in LCD Dis-
play. See Figure 6-29.
Do Any of the Input Bits
Display “0?”
YES
NO
Move to Test 6.16 (Part 2 of 2) to Find
Exercise All Three Posi-
Short to Ground on Any Wire Where
tions of PTT/SQUELCH
Corresponding Input Bit Displays “0.”
CONTROL SWITCH. Do
All of the Corresponding
Switch
Input
Wire
Input Bits Toggle
Position
Bit
Color
Between “1” and “0?”
Squelch +
C1
GY/GN
Squelch -
C2
BN/BK
PTT
C3
O/BK
YES
NO
Switch and
Activate Switch Where
Wiring are OK.
Corresponding Input Bit
Replace Radio.
Does Not Toggle
Between “1” and “0?” Is it
6601
a “0” or a “1” While Switch
is Activated?
0
1
Move to Test 6.16
1
Move to Test 6.16 (Part 2 of 2) to
(Part 2 of 2) to
Find Short to Voltage on Wire
Find Short to
Where Corresponding Input Bit Dis-
Ground on R2
plays “1” (With No Switches
(V/BK) Wire.
Depressed).
Switch
Input
Wire
Position
Bit
Color
Squelch +
C1
GY/GN
Squelch -
C2
BN/BK
PTT
C3
O/BK
All Positions
All
V/BK
After correction of problem, refer to SETUP and
FUNCTIONALITY to verify proper operation.
Table 6-9. FLHTCU Wire Harness Connectors
NO.
DESCRIPTION
TYPE
LOCATION
Interconnect Harness to
[24]
12-Place Deutsch (Gray)
Inner Fairing- Left Fairing Support Brace
Left Handlebar Switch Controls
[27]
Radio
23-Place Amp (Black)
Inner Fairing- Back of Radio (Right Side)
6-46
2004 Touring: Sound System
HOME
Test 6.16 (Part 2 of 2)
PTT/SQUELCH CONTROL INOPERATIVE: HARDWARE DIAGNOSIS
What Did
Test 6.16 (Part 1 of 2) Indicate?
SHORT to VOLTAGE
SHORT to GROUND
Remove Outer Fairing. Connect Breakout Box
2
2
Remove Outer Fairing. Connect Breakout
leaving Connector [27B] Disconnected from
Box leaving Connector [27B] Discon-
Radio. With Key ON, Check for Power at
nected from Radio. With Key OFF, Check
Connector [27B].
for Continuity to Ground at Connector
[27B].
From (-)
To Terminal (+)
5 (V/BK)
From
To Terminal
7 (O/BK)
5 (V/BK)
Ground
8 (BN/BK)
7 (O/BK)
Ground
22 (GY/GN)
8 (BN/BK)
22 (GY/GN)
Is Voltage Present?
Any Continuity Present?
YES
NO
YES
NO
With Key ON, Check for Power
4
OPEN
With Key OFF, Check for
3
Replace
at Connector [24B].
Continuity to Ground at
Radio.
Disconnect Connector [27B]. With
Connector [24B].
To
From
Switch Depressed, Check for
6601
Terminal
(-)
Continuity at Connector [27B].
To
(+)
From
Terminal
7 (V/BK)
Switch
From
To
(-)
(+)
8 (BN/BK)
Position
Terminal
Terminal
Ground
7 (V/BK)
11 (GY/GN)
Squelch +
5 (V/BK)
22 (GY/GN)
8 (BN/BK)
12 (O/BK)
Squelch -
5 (V/BK)
8 (BN/BK)
Ground
11 (GY/GN)
PTT
5 (V/BK)
7 (O/BK)
Is Voltage Present?
12 (O/BK)
Each Wire Pair Should be Less than 0.5
Any Continuity Present?
4
Ohms While Switch is Depressed and
Infinity While Switch is Open. Is It?
YES
NO
YES
NO
YES
NO
Locate
Locate and
and
Repair Short
Locate and
Locate and
Repair
in Interconnect
3
Replace
With Switch Depressed, Check for
Repair Short in
Repair Short
Short in
Harness.
Radio.
Continuity at Connector [24B].
Handlebar
in Interconnect
Handle-
bar Har-
6531
6601
Harness.
Harness.
Switch
From
To
ness.
Position
Terminal
Terminal
6551
6531
6551
Squelch +
7 (V/BK)
11 (GY/GN)
Squelch -
7 (V/BK)
8 (BN/BK)
PTT
7 (V/BK)
12 (O/BK)
Each Wire Pair Should be Less than 0.5
Ohms While Switch is Depressed and
Infinity While Switch is Open. Is It?
4
YES
NO
Locate and Repair
Replace PTT/
Open or Replace
Squelch Control
Interconnect
Switch or Repair
Harness.
Switch Wiring.
6532
5184
After correction of problem, refer to SETUP and
FUNCTIONALITY to verify proper operation.
2004 Touring: Sound System
6-47
HOME
RADIO SYMPTOM 14
6.17
GENERAL
DIAGNOSTICS
Problem
Diagnostic Notes
Handheld microphone PTT inoperative.
The reference numbers below correlate with the circled num-
bers in the Test 6.17 flow charts.
Setup
1.
Install BREAKOUT BOX (Part No. HD-44608). See Sec-
tion 6.3 BREAKOUT BOX, INSTALLATION.
● Press the POWER button to turn the radio ON.
2.
Use HARNESS CONNECTOR TEST KIT (Part No. HD-
● Press and hold the INT button to turn the Intercom OFF.
41404), black pin probes and patch cords.
● Press and hold the CB button to turn the Citizen Band
radio ON.
3.
Use HARNESS CONNECTOR KIT (Part No. HD-41404),
black socket probes and patch cord.
● Set fairing mounted Headset/Speaker Switch to
SPEAKER.
Functionality
Depressing handheld PTT switch will change the radio dis-
play to reflect CB mode and cause the transmitter to transmit.
In CB Setup mode, the squelch display will disappear when
PTT is depressed. Are these your observations?
● Yes - System is OK.
● No - See Test 6.17 (Part 1 of 2).
6-48
2004 Touring: Sound System
HOME
Test 6.17 (Part 1 of 2)
HANDHELD MICROPHONE PTT INOPERATIVE: SOFTWARE DIAGNOSIS
Which PTT Switch
Does Not Work?
Rider/Passenger
Handheld Microphone
Enter Diagnostic Mode
Enter Diagnostic Mode
1. Is Input Bit C3 Dis-
2. With Microphone
played in LCD as “1?”
Disconnected, Is PTT
Input Bit Displayed in
LCD as “0?”
YES
NO
YES
NO
Press Rider/Passen-
Go to Test 6.17
ger PTT Switch. Does
(Part 2 of 2).
Input Bit C3 Displayed
Go to Test 6.17
Plug In Handheld
in LCD Toggle
(Part 2 of 2).
Microphone. Is PTT
Between “1” and “0”
Input Bit Displayed in
While PTT Switch is
LCD as “0” While PTT
Depressed?
IS NOT Depressed on
Microphone.
YES
NO
YES
NO
Rider/Pas-
Which PTT
Replace Microphone
Depress Microphone
senger PTT
Switch is
Switch OK.
Inoperative?
With Unit Known To Be
PTT Switch. Does
Good. Does New
PTT Input Bit Dis-
Microphone Work?
played in LCD
Change From “1” to
“0” When Button is
Depressed?
YES
NO
Handheld Micro-
Go to Test 6.17
YES
NO
phone PTT Circuit
(Part 2 of 2).
is OK.
Handheld
Replace Microphone
Microphone
With Unit Known To Be
PTT Circuit is
Good. Does New
OK.
Microphone Work?
YES
NO
Rider
Rear Passenger
Sidecar
Handheld
Go to
Microphone
Test 6.17
Go to Test 6.16
Go to Test 6.12
Go to Test 6.12
PTT Circuit
(Part 2 of 2).
(Part 2 of 2).
(Part 2 of 3).
(Part 3 of 3).
is OK.
After correction of problem, refer to SETUP and
FUNCTIONALITY to verify proper operation.
Table 6-10. FLHTCU Wire Harness Connectors
NO.
DESCRIPTION
TYPE
LOCATION
[27]
Radio
23-Place Amp (Black)
Inner Fairing- Back of Radio (Right Side)
[28]
Radio
23-Place Amp (Gray)
Inner Fairing- Back of Radio (Left Side)
[53]
Console Pod
12-Place Mini-Deutsch (Black)
Rear of Battery Box (Under Seat)
2004 Touring: Sound System
6-49
HOME
Test 6.17 (Part 2 of 2)
HANDHELD MICROPHONE PTT INOPERATIVE: HARDWARE DIAGNOSIS
Use Microphone
Known to be Good.
Problem Still Exists?
YES
NO
Place in Diagnostic Mode.
Replace
What did Test 6.17 (Part 1
Microphone.
of 2) Indicate?
OPEN
SHORT
Connect Breakout Box to Harness Only.
1
1
Check for Continuity as Follows:
Check for Continuity as Follows:
2
FROM
TO
2
FROM
TO
Connector
Terminal
Connector
Terminal
Connector
Terminal
Ground
Front
[27B]
2 (BE/Y)
[27B]
2 (BE/Y)
7
Headset DIN
Should Read Infinity. Does It?
Front
[28B]
2 (Y/BK)
6
Headset DIN
Each Wire Should be Less than 0.5 Ohms. Is It?
YES
NO
YES
NO
Replace
Disconnect Connector [53]. Check
Radio.
for Continuity as Follows:
Replace
2
Check for Continuity as Follows:
6601
FROM
TO
Radio.
Connector
Terminal
FROM
TO
Ground
6601
[27B]
2 (BE/Y)
Connector
Terminal
Connector
Terminal
[27B]
2 (BE/Y)
[53B]
6
Should Read Infinity. Does It?
[28B]
2 (Y/BK)
[53B]
7
Each Wire Should be Less than 0.5 Ohms. Is It?
YES
NO
Replace Pod
Repair
YES
Y/BK
BE/Y
Headset
Audio
NO
NO
Harness.
Harness.
6616
6560
Replace Pod
Repair
Check for Continuity as Follows:
Headset
Audio
Harness.
Harness.
FROM
TO
Connector
Terminal
Connector
Terminal
6616
6561
[27B]
2 (BE/Y)
[6A]
4 (BE/Y)
Continuity Present?
3
YES
NO
Replace Pod
Repair
Headset
Audio
Harness.
Harness.
6616
6561
After correction of problem, refer to SETUP and
FUNCTIONALITY to verify proper operation.
6-50
2004 Touring: Sound System
HOME
RADIO SYMPTOM 15
6.18
GENERAL
Functionality
Problem
CB audio should be heard in headset and stereo audio
should be heard in fairing speakers. Is it?
No CB audio in headset in center position.
● Yes - System is OK.
● No - See Test 6.18.
Setup
● Press the POWER button to turn the radio ON.
DIAGNOSTICS
● Press and hold the INT button to turn the Intercom OFF.
● Press and hold the CB button to turn the Citizen Band
radio ON.
Diagnostic Notes
● Set fairing mounted Headset/Speaker Switch to CEN-
The reference number below correlates with the circled num-
TER position.
ber in the Test 6.18 flow chart.
● Set Volume Control to Middle position on horizontal bar
1. If the lamp is missing or the filament is broken, Speaker
graph display.
B, Speaker A input bits are displayed in LCD as “11” with
the Headset/Speaker Switch in the center position. In
● Set Squelch Control to receive incoming CB signals.
other words, the system functions as though the switch is
in the SPEAKER position.
Test 6.18
NO CB AUDIO IN HEADSET IN CENTER POSITION: SOFTWARE DIAGNOSIS
Enter Diagnostic Mode “d2.”
Set Fairing Mounted Headset/
Speaker Switch to SPEAKER.
Is Red Lamp Illuminated?
YES
1
NO
Are Speaker B, Speaker
Go to Test 6.6 (Part 2 of 3)
A Input Bits Displayed in
(speakers) or Test 6.11
YES
LCD as “11?”
(Part 2 of 2) (headsets).
Set Fairing Mounted
Headset/Speaker Switch
to HEADSET.
YES
NO
Are Speaker B, Speaker
A Input Bits Displayed in
LCD as “10?”
Set Fairing Mounted
Go to Test 6.6 (Part 2 of 3)
Headset/Speaker Switch
(speakers) or Test 6.11
to CENTER Position.
(Part 2 of 2) (headsets).
Are Speaker B, Speaker A
YES
NO
Input Bits Displayed in
LCD as “01?”
Headset/
Go to Test 6.6 (Part 2 of 3)
Speaker Switch
(speakers) or Test 6.11
and Wiring OK.
(Part 2 of 2) (headsets).
NO
Go to Test 6.6 (Part 2 of 3)
(speakers) or Test 6.11
(Part 2 of 2) (headsets).
2004 Touring: Sound System
6-51
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NOTES
6-52
2004 Touring: Sound System
HOME
CRUISE CONTROL
7.1
GENERAL
f1368a8x
The Cruise Control system provides automatic vehicle speed
control. The electronics and stepper motor are contained in a
control module mounted under the left side cover. The step-
per motor actuates the cruise control cable through a gear
train and ribbon reel.
SYSTEM OPERATION
Set/Resume
Switch
To engage and disengage the cruise control system, proceed
as follows:
1.
While riding in fourth or fifth gear, turn the Cruise ON/
OFF Switch to the ON position. See Figure 7-1. The
switch is located on the fairing cap of FLHTCU models,
the instrument nacelle of FLTR models, and the left han-
dlebar lower switch housing on FLHRC models. The
Figure 7-2. Right Handlebar Switch Assembly
Cruise Enabled/Engaged lamp in the tachometer face
(FLTR, FLHTCU)
(speedometer on FLHRC models) turns red to indicate
that the system is activated. See Figure 7-3. A red lamp
in the switch on both FLHTCU and FLTR models also
f2160x8x
Tachometer
indicates this condition to the rider.
2.
Power (12 vdc) is supplied to the cruise control module
through a 15 amp fuse located in the fuse block mounted
under the left side cover.
60
40
50
70
30
50
40
80
3.
With the motorcycle traveling at the desired
“cruise”
30
90
20
60
speed (30 mph/48 km/h to 85 mph/137 km/h), momen-
MPH
RPM x100
20
100
tarily push the Cruise SET/RESUME switch to SET. See
10
70
Figure 7-2.
10
110
0
120
0
80
Ignition/Light
TI
-D
-D
Key Switch
Cruise ON/OFF
Switch
Cruise Enabled/Engaged Lamp
Figure 7-3. Instrument Panel (FLHTCU)
The cruise control module “reads” the vehicle speed sen-
sor (VSS) output to establish the desired vehicle speed.
The module then sends a signal to the stepper motor
which drives the ribbon reel to take up the slack in the
cruise cable. The Cruise Enabled/Engaged lamp in the
tachometer face (speedometer on FLHRC models) turns
from red to green to indicate that the cruising speed is
locked in. See Figure 7-3.
f2031x8x
4.
The cruise control module monitors both the engine
RPM and the VSS output speed signal. The module sig-
Figure 7-1. Fairing Cap (FLHTCU)
nals the stepper motor to open or close the throttle to
keep the speedometer output speed signal constant. The
engine RPM is monitored to detect engine
2004 Touring: Cruise Control
7-1
HOME
ENGAGE SEQUENCE
DISENGAGE SEQUENCE
CRUISE SWITCH ON
FRONT/REAR BRAKE
SET/RESUME
SWITCH TO SET
IDLE CABLE ROLL-OFF
READS VSS
(DISENGAGE) SWITCH
OUTPUT SPEED SIGNAL
CRUISE
CRUISE SWITCH OFF
STEPPER MOTOR
MODULE
GEAR TRAIN
& RIBBON REEL
CRUISE ENGAGED
HANDLEBAR
LAMP
ENGINE STOP
SWITCH OFF
THROTTLE
ACTUATION
ENGINE RPM
MONITORED*
CLUTCH DISENGAGE
(ENGINE RPM)
*Tachometer receives signal from ignition coil on
carbureted models, and from ECM on EFI models.
Figure 7-4. Cruise System Diagram
overspeed, a condition which automatically causes
f.
Handlebar mounted Cruise SET/RESUME switch is
cruise disengagement.
pushed to SET and held in that position until vehicle
speed drops below 30 mph (48 km/h).
5.
The cruise control automatically disengages
(stepper
motor drives cruise cable to the full-out position) when-
NOTE
ever the cruise control module receives one of the follow-
ing inputs:
If the vehicle speed is above 30 mph (48 km/h) when the
Cruise SET/RESUME Switch is released, then the cruise sys-
a. Front or rear brake is applied.
tem automatically re-engages.
b. Throttle is “rolled back” or closed, thereby actuating
idle cable roll-off (disengage) switch.
c. Motorcycle clutch is disengaged (module senses too
great an increase in RPM).
TROUBLESHOOTING
d. Cruise ON/OFF Switch placed in the OFF position.
The switch is located on the fairing cap of FLHTCU
The cruise module circuitry provides on-board diagnostics to
models, the instrument nacelle of FLTR models, and
help isolate any problems that might occur with the cruise
the left handlebar lower switch housing on FLHRC
system.
models. The green Cruise Enabled/Engaged lamp in
the tachometer face (speedometer on FLHRC mod-
If the cruise is inoperative or fails to set, begin troubleshooting
els) is extinguished to indicate that the system is
with 7.2 CRUISE INOPERATIVE DIAGNOSTICS. If the cruise
deactivated. The red lamp in the fairing cap switch of
seems to disengage or drop out for no apparent reason, then
FLHTCU models and the instrument nacelle switch
see 7.3 CRUISE DROPOUT DIAGNOSTICS.
of FLTR models is also extinguished.
In the diagnostic mode, the Cruise Enabled/Engaged lamp is
e. Handlebar mounted Engine Stop Switch placed in
employed as a test indicator. The lamp is in the tachometer
the OFF position. (This removes tachometer input
face (speedometer on FLHRC models). See Figure 7-3.
signal which results in module disengagement.)
7-2
2004 Touring: Cruise Control
HOME
CRUISE INOPERATIVE DIAGNOSTICS
7.2
GENERAL
Table 7-1. Cruise Module Connector [17A]
WIRE
FUNCTION AND
Perform the following diagnostic procedures in the order pre-
TERMINAL
COLOR
CONNECTION
sented. If the test sequence is not followed precisely, the
diagnostic mode may not be exited at conclusion of the diag-
A
Red/Green
ON/OFF switch enable
nostic routine and the test indicator (Cruise Engaged Lamp)
may continue to flash while the engine is running.
SET input from SET/RESUME
B
Blue/Black
switch
RESUME input from SET/RESUME
C
White/Blue
switch
INOPERATIVE DIAGNOSTICS
Idle cable disengage switch
D
Violet/Yellow
(12 vdc from 15 amp fuse)
See Table 7-2. All diagnostic steps are listed in table format.
E
Black
Cruise module ground
Follow the numbered steps to test the system. Compare the
F
Orange/Violet
12 vdc power from 15 amp fuse
system behavior to CORRECT FUNCTION or INCORRECT
FUNCTION columns and advance to the next step listed.
Disengage from brake relay
G
Red/Blue
(12 vdc)
H
Blue/Orange
Tachometer input
Diagnostic Notes
12 vdc from “CRUISE” indicator in
J
Green/Red
instrument panel
The diagnostic notes below provides supplementary informa-
(module provides ground)
tion for Table 7-2.
K
White/Green
Vehicle speed signal input
1.
If the cruise engaged lamp does not illuminate at all,
check for one or more of the following conditions:
a. SET/RESUME switch faulty or not wired correctly.
g.
Brake light on constantly.
b. Broken or pinched wire to SET switch or cruise mod-
h.
Throttle cables too tight.
ule.
i.
Bad cruise control fuse.
c. Cruise engaged lamp burned out or miswired. Lamp
is turned on by module supplied ground.
2.
Repeat Steps 1 and 2. If the cruise engaged lamp still
d. Main 10-place connector not plugged into cruise
does not illuminate, see 7.4 CRUISE CHART A: INITIAL
module.
DIAGNOSTICS. For cruise module connector wire color
e. Faulty cruise main switch and associated wiring.
locations and functions, see Table 7-1. Repair any prob-
lems and recheck by repeating Steps 1 and 2.
f.
No module ground at Terminal E of 10-place module
connector.
2004 Touring: Cruise Control
7-3
HOME
Table 7-2. Cruise Inoperative Diagnostics
NO.
ACTION
CORRECT FUNCTION
INCORRECT FUNCTION
Turn the Ignition/Light Key Switch to
OFF. Connect Speedometer Tester
1
(HD-41354).
Enter the diagnostic mode: With the
If the cruise engaged lamp remains illumi-
The cruise engaged lamp will illuminate and
fairing cap Cruise ON/OFF Switch at
nated after the switch is released, then either
remain on as long as the Cruise SET/
ON, and the handlebar mounted
the switch or related wiring is shorted. See
RESUME switch is held in the SET position.
2
Cruise SET/RESUME Switch held
Diagnostic Note 1 for possible causes.
at SET, turn the Ignition/Light Key
Continue with steps listed under Diagnos-
Switch to IGNITION.
Continue with Step 3.
tic Note 2.
If the cruise engaged lamp does not illuminate
at all, check for one or more of the following
The cruise engaged lamp will illuminate and
conditions:
remain on as long as the SET/RESUME
Push the handlebar mounted Cruise
● RES(UME) switch not wired correctly.
Switch is held in the RES(UME) position.
3
SET/RESUME Switch to RES(UME)
● Broken or pinched wire to RES(UME)
and hold in this position.
switch or cruise module.
Continue with Step 4.
Continue with 7.5 CRUISE CHART B:
RESUME SWITCH.
If the cruise engaged lamp does not illuminate
at all, check for one or more of the following
The cruise engaged lamp will illuminate when
conditions:
the switch is closed, and then be extinguished
● Throttle grip switch not wired correctly.
Next, turn the throttle grip tightly
when the throttle grip returns to its free posi-
● Broken or pinched wire to throttle grip
4
closed to check the throttle grip
tion.
switch.
switch or cruise module.
● Throttle grip switch not working correctly.
Continue with Step 5.
Continue with 7.11 CRUISE CHART G:
THROTTLE SWITCH.
If the cruise engaged lamp does not illuminate
at all, check for one or more of the following
conditions:
● Front brake switch not wired correctly.
The cruise engaged lamp will illuminate and
● Broken or pinched wire to front brake
remain on until the brake lever is released.
5
Apply the brake hand lever.
switch or cruise module.
● Front brake switch not working properly.
Continue with Step 6.
See 7.9 CRUISE CHART F-1: BRAKE
LIGHTS ON (constant brake light input) or
7.10 CRUISE CHART F-2: BRAKE LIGHTS
OFF (no front and/or rear brake lights).
The cruise engaged lamp will not illuminate if
any of the following conditions exist:
● Rear brake switch not wired correctly.
The cruise engaged lamp will illuminate. After
● Broken or pinched wire to rear brake
switch or cruise control module.
depressing and holding the brake foot pedal
for 5 seconds, the lamp will be extinguished.
● Rear brake switch not working properly.
Press and hold the brake foot pedal
Release the brake pedal and the cruise mod-
The throttle will not open if the following condi-
6
for at least 5 seconds.
ule will momentarily pull the throttle open
tions exist:
slightly and then release.
● Cables not adjusted properly.
● Faulty cruise control module.
Continue with Step 7.
See 7.9 CRUISE CHART F-1: BRAKE
LIGHTS ON (constant brake light input) or
7.10 CRUISE CHART F-2: BRAKE LIGHTS
OFF (no front and/or rear brake lights).
7-4
2004 Touring: Cruise Control
HOME
Table 7-2. Cruise Inoperative Diagnostics
NO.
ACTION
CORRECT FUNCTION
INCORRECT FUNCTION
The cruise engaged lamp will not illuminate if
any of the following conditions exist:
● Vehicle speed signal not wired correctly.
The cruise engaged lamp will flash on and off
indicating that the vehicle speed signal is
● Broken or pinched wire to speedometer.
wired properly and working correctly.
● Speedometer not working properly.
7
Rotate rear wheel.
● Vehicle speed signal wiring discon-
Continue with Step 8.
nected.
See 7.12 CRUISE CHART H: SPEEDOME-
TER INPUT.
Turn the fairing cap Cruise ON/OFF
Switch and the Ignition/Light Key
8
Switch to OFF. Disconnect spark
Continue with Step 9.
plug wires.
Press SET/RESUME Switch to
9
RES(UME), and hold.
Continue with Step 10.
While holding SET/RESUME Switch
at RES(UME), turn Ignition/Light Key
The cruise engaged lamp flashes with RPM
The cruise engaged lamp does not flash with
Switch to ON and crank engine. (If
input.
RPM input.
10
weak battery or poor connections
See 7.13 CRUISE CHART I: TACHOMETER
result in low system voltage, Diag-
Continue with Step 11.
INPUT.
nostic Mode may be aborted.)
Cruise engaged lamp blinks twice.
While continuing to hold SET/
NOTE: Lamp may go on for three seconds if
RESUME Switch at RES(UME), turn
11
RPM signal was above cranking speed.
fairing cap Cruise ON/OFF Switch to
ON. Release SET/RESUME Switch.
DIAGNOSTIC ROUTINE EXITED
To restart or repeat the diagnostic
12
sequence, return to Step 1.
2004 Touring: Cruise Control
7-5
HOME
CRUISE DROPOUT DIAGNOSTICS
7.3
count the number of times the lamp flashes in order to
GENERAL
retrieve the first digit of the dropout code.
To check for diagnostic codes, see DROPOUT DIAGNOS-
4.
Following transmission of the first digit, there is a one
TICS below. If other problems are experienced, such as
second pause in which the lamp is off. The lamp will then
harsh cruise engagement or speed loss, see Table 7-4.
flash one or more times to indicate the second digit of the
dropout code. Count the number of times the lamp
flashes to retrieve the second digit. See Figure 7-5.
DROPOUT DIAGNOSTICS
5.
Following transmission of the second digit, there is a
another one second pause in which the lamp is off. The
The last eight diagnostic codes for cruise disengagement are
lamp will then flash one or more times to indicate the
stored in memory.
third digit of the dropout code. Again, count the number
of times the lamp flashes to retrieve the third digit.
1.
To enter the diagnostic mode, turn the engine off and
proceed as follows:
6.
Write down the dropout code on a piece of paper. To
identify the reason for cruise disengagement see Table
a. Turn the fairing cap Cruise ON/OFF switch to OFF.
7-3. The last column of the table suggests the appropri-
The light in the rocker switch is extinguished to indi-
ate corrective action.
cate this condition to the operator.
7.
To verify the dropout code, toggle the Cruise SET/
b. Push the Cruise SET/RESUME Switch on the right
RESUME Switch to RESUME. The transmission of the
handlebar to SET and hold.
most recent dropout code is repeated. To continue with
c. Turn the Ignition/Light Key Switch to IGNITION, but
the next code, simply toggle the Cruise Switch to SET. All
do not start the engine.
subsequent codes are sent in the same manner as the
first, after which the operator may repeat the code or
d. Release the Cruise SET/RESUME Switch from the
move on to the next in the series.
SET position while observing the behavior of the
Cruise Enabled/Engaged Lamp on the tachometer
8.
After the eighth (or oldest) dropout code is flashed, the
gauge (speedometer on FLHRC models).
Cruise Engaged Lamp remains illuminated to indicate
that the end of the dropout code buffer has been
2.
The system transmits the most recent cruise dropout
reached.
code. Each dropout code consists of 3 digits and is sent
out as a series of flashes.
9.
To start the sequence at the beginning, that is, with
transmission of the most recent dropout code, momen-
3.
The lamp will begin by flashing one or more times to indi-
tarily push the Cruise SET/RESUME Switch to SET.
cate the first digit of the dropout code. The length of time
the lamp is illuminated and the length of time in which it
10.
To exit the diagnostic mode, turn the Ignition/Light Key
is off are each about 1/4 second in duration. Simply
Switch to OFF.
1st Digit
2nd Digit
3rd Digit
ON
1/4
1/4
1/4
1/4
1/4
Sec.
Sec.
Sec.
Sec.
Sec.
Toggle Cruise Switch to RESUME
to Verify Code.
1 Sec.
1/4
1 Sec.
1/4
OFF
Sec.
Sec.
Toggle Cruise Switch to SET
to Continue With Next Code.
Cruise
Pause After
Pause After
Engaged
1st Digit
2nd Digit
Lamp
NOTE
Looking at the above transmission, we can see that the dropout code is 122.
See Table 7-3. The reason for cruise disengagement is identified as applica-
tion of front or rear brakes.
Figure 7-5. Cruise Engaged Lamp Dropout Code Timing Diagram
7-6
2004 Touring: Cruise Control
HOME
Table 7-3. Cruise Dropout Code Key
ACTION
CODE
CONDITION
NOTE
While performing instructions under applicable flow chart, wiggle con-
nectors and wires to identify intermittents.
111
Initial State or Cleared Memory (No Codes Recorded)
-
112
Throttle Roll Off
7.11 CRUISE CHART G: THROTTLE SWITCH
113
Fairing Cap Cruise Switch Turned OFF
7.8 CRUISE CHART E: CRUISE ENABLE
7.4 CRUISE CHART A: INITIAL DIAGNOSTICS or 7.5
121
Short in Wiring Between Set/Resume
CRUISE CHART B: RESUME SWITCH
Application of Front or Rear Brakes
122
NOTE
7.9 CRUISE CHART F-1: BRAKE LIGHTS ON
May require inspection of brake levers
or front brake light switch mounting.
211
Coast (S/C Button Engaged) Interval Longer than 6 Seconds
7.4 CRUISE CHART A: INITIAL DIAGNOSTICS
Speed Drops Below 30 MPH While in Coast
7.4 CRUISE CHART A: INITIAL DIAGNOSTICS or 7.12
212
(S/C Button Engaged)
CRUISE CHART H: SPEEDOMETER INPUT
213
Speed Drops Below 26 MPH or Exceeds 90 MPH
7.12 CRUISE CHART H: SPEEDOMETER INPUT
Speed Drops 15 MPH Below Set Speed
221
7.12 CRUISE CHART H: SPEEDOMETER INPUT
(Such as When Climbing a Steep Hill)
222
Speed Decreases Greater than 20 MPH per Second
7.12 CRUISE CHART H: SPEEDOMETER INPUT
223
Vehicle Speed Sensor Input
7.12 CRUISE CHART H: SPEEDOMETER INPUT
231
Over 5000 RPM
7.13 CRUISE CHART I: TACHOMETER INPUT
232
Loss of Tachometer Signal
7.13 CRUISE CHART I: TACHOMETER INPUT
High Rate of Change of RPM Detected
242
(Such as When Clutch is Pulled In or Contact is Made
7.13 CRUISE CHART I: TACHOMETER INPUT
With Ice Patch or Slippery Surface)
311
312
313
321
Replace cruise module. See the 2004 Touring Models Service
Internal Failure
323
Manual (Part Number 99483-04).
331
332
333
341
Low Voltage
7.7 CRUISE CHART D: CRUISE POWER
342
343
351
352
353
361
Replace cruise module. See the 2004 Touring Models Service
Internal Failure
362
Manual (Part Number 99483-04).
363
371
423
432
777
2004 Touring: Cruise Control
7-7
HOME
Table 7-4. Other Malfunctions
CONDITION
SYMPTOM
CHECK FOR
Check for a cruise cable that is too tight. See CABLE LASH INI-
Harsh
Cruise control opens
TIALIZATION in the 2004 Touring Models Service Manual (Part
engagement
throttle abruptly or harshly
Number 99483-04).
● Cruise cable too loose. See CABLE LASH INITIALIZATION in
the
2004 Touring Models Service Manual
(Part Number
Loses speed
99483-04).
● Set switch held too long.
● Cruise cable too tight. See CABLE LASH INITIALIZATION in
Gains speed
the
2004 Touring Models Service Manual
(Part Number
99483-04).
Speed
variation
● Intermittent vehicle speed signal.
● Intermittent speedometer.
● Defective cruise module. See CRUISE MODULE, REMOVAL/
INSTALLATION, in the 2004 Touring Models Service Manual
Speed surges
(Part Number 99483-04).
NOTE
Check for surging with cruise control turned OFF. If surging is still
present, a lean fuel mixture may be the cause.
7-8
2004 Touring: Cruise Control
HOME
CRUISE CHART A: INITIAL DIAGNOSTICS
7.4
DIAGNOSTICS
Test 7.4 (Part 1 of 2)
Remove Left Saddlebag and Sidecover.
Is 10-place Connector [17B] Plugged Into
FLH TCU-I, FLTR/I
Cruise Module? See Figure 7-6.
Remove the Outer Fairing. Locate the 12-
Place Connector [22] for Right Handlebar
YES
NO
Switch Controls. See Figure 7-8 or Figure
7-8. Measure Between the O/W and BE/
BK Terminals at Connector [22B]. Resis-
Unplug Connector [17B].
Plug In Connector [17B].
tance Must Be ∞ Ohms. Pressing SET/
RESUME Switch to SET Should Produce
a Reading of Less Than 0.5 Ohms. Are
SET SWITCH
These Your Observations?
Check Continuity Between the O/V Termi-
nal (F) and BE/BK Terminal (B) of Connec-
tor [17B]. Resistance Must Be ∞ Ohms.
YES
NO
Pressing SET/RESUME Switch to SET
Should Produce a Reading of Less Than
0.5 Ohms. Are These Your Observations?
Check Continuity on O/V
Right Handlebar
and BE/BK Wires Between
Switch Wiring
NO
Connectors
[17B] and
Pinched or
[156A]. See Figure 7-7 and
Damaged?
YES
FLHRC-I
Figure
7-9.
Continuity
Present?
Remove the Headlamp Assembly. Discon-
YES
NO
nect 6-Place Connector [22] and 2-Place
STOP
Connector
[159]. Measure Resistance
Between O/W Wire on Connector [22B]
Repair
Replace Cruise
and BE/BK Wire on Connector [159B].
Wiring.
SET/RESUME
YES
NO
Go to Test 7.4 (Part 2 of 2)
Resistance Must Be ∞ Ohms. Pressing
Switch.
6552
SET/RESUME Switch to SET Should Pro-
5182
duce a Reading of Less Than 0.5 Ohms.
Repair
Repair Main
Are These Your Observations?
Interconnect
Harness.
Harness.
5028
6532
YES
NO
Locate and Repair
Right Handlebar
Open on BE/BK Wire
Switch Wiring Pinched
in Main Harness.
or Damaged?
5028
YES
NO
Repair
Replace Cruise
After correction of problem, restart 7.2 CRUISE
Wiring.
SET/RESUME
INOPERATIVE DIAGNOSTICS to verify proper per-
Switch.
6552
formance.
5182
Cruise Module
Connector [17]
f2206x8x
Figure 7-6. Left Side Cover Removed
2004 Touring: Cruise Control
7-9
HOME
Test 7.4 (Part 2 of 2)
Right Handlebar
INITIAL DIAGNOSTICS
Switch Controls [22]
Main to
Interconnect [156]
Continued from Test 7.4 (Part 1 of 2).
Connect a Jumper From the GN/R Termi-
nal (J) to Ground. The Cruise Engaged
Lamp Should Illuminate When the Igni-
tion/Light Key Switch is Positioned to
IGNITION. Does It?
YES
NO
Place the Positive Probe on the O/V Termi-
See 7.6 CRUISE
nal (F) and the Negative Probe on the BK
CHART C:
Terminal
(E). With the Ignition/Light Key
CRUISE
Switch Positioned to IGNITION, the Meter
ENGAGED LAMP.
Should Read Battery Voltage. Does It?
f2238x8x
YES
NO
Figure 7-7. Outer
Fairing
Removed
(FLHTC/U)
Place the Positive Probe on the R/GN Termi-
See 7.7 CRUISE
nal (A) and the Negative Probe on the BK
CHART D:
CRUISE POWER.
Main to
Terminal
(E). With the Ignition/Light Key
Right Handlebar
Switch Positioned to IGNITION and the Fair-
Interconnect [156]
Switch Controls [22]
ing Cap Cruise ON/OFF Switch Positioned
to ON, the Meter Should Read Battery Volt-
age. Does It?
YES
NO
Place the Positive Probe on the R/BE
See 7.8 CRUISE
Terminal (G) and the Negative Probe on
CHART E:
the BK Terminal (E). Meter Should Read
CRUISE
Between
11-13 Volts Only When the
ENABLE.
Brake is Applied and the Ignition/Light
Key Switch is Positioned to IGNITION.
Does It?
YES
NO
f2230x2x
Check Continuity Between the V/Y
See 7.9 CRUISE
CHART F-1: BRAKE
Figure 7-8. Outer Fairing Removed (FLTR)
Terminal (D) and the O/V Terminal (F)
With the Ignition/Light Key Switch
LIGHTS ON or 7.10
Positioned to OFF. The Meter Should
CRUISE CHART F-
Read Infinity When the Throttle Switch
2: BRAKE LIGHTS
is in the Relaxed Position, and Conti-
OFF.
nuity When the Throttle Grip is Rolled
Forward. Does It?
YES
NO
See 7.11 CRUISE
Reconnect All Connectors. Restart
7.2 CRUISE INOPERATIVE DIAG-
CHART G: THROTTLE
SWITCH.
NOSTICS if Cruise Engaged Lamp
has Never Illuminated. If the Lamp
Will Not Illuminate When the First Test
is Performed Now, Replace the
Cruise Module.
6635
7-10
2004 Touring: Cruise Control
HOME
CRUISE CHART B: RESUME SWITCH
7.5
DIAGNOSTICS
Test 7.5
Remove Left Saddlebag and Side Cover. Disconnect Connector [17B] From Cruise Module.
See Figure 7-6. Check Continuity Between the O/V Terminal (F) and the W/BE Terminal (C).
Resistance Must Be ∞ Ohms. Pressing SET/RESUME Switch to RESUME Should Pro-
duce a Reading of Less Than 0.5 Ohms. Are These Your Observations?
YES
NO
Replace
Cruise
FLH TCU-I, FLTR/I
FLHRC-I
Module.
6635
Remove the Outer Fairing. Locate the 12-Place Con-
Disconnect
6-Place Connector
[22] and
4-Place
nector [22] for Right Handlebar Switch Controls. See
Connector [159]. Measure Resistance Between O/W
Figure 7-8 or Figure 7-8. Measure Between O/W and
Wire at Connector [22B] and W/BE Wire at Connec-
W/BE Terminals at Connector [22B].
tor [159B].
Resistance Must Be
∞ Ohms. Pressing SET/
Resistance Must Be
∞ Ohms. Pressing SET/
RESUME Switch to RESUME Should Produce a
RESUME Switch to RESUME Should Produce a
Reading of Less Than 0.5 Ohms. Are These Your
Reading of Less Than 0.5 Ohms. Are These Your
Observations?
Observations?
YES
NO
YES
NO
Check Continuity on W/BE Wire
Right Handlebar
Locate and Repair
Right Handlebar
Between Connectors [17B] and
Switch Wiring Pinched
Open on W/BE Wires
Switch Wiring Pinched
[156A]. See Figure 7-7 and Fig-
or Damaged?
in Main Harness.
or Damaged?
ure 7-7. Continuity Present?
5028
YES
NO
YES
NO
YES
NO
Repair
Replace Cruise
Repair
Replace Cruise
Wiring.
SET/RESUME
Wiring.
SET/RESUME
Repair
Repair Main
Switch.
Switch.
Interconnect
Harness.
6552
6552
Harness.
5182
5182
5028
6532
After correction of problem, restart 7.2 CRUISE INOPERATIVE DIAGNOSTICS
to verify proper performance.
2004 Touring: Cruise Control
7-11
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