Harley Davidson 2004 Touring Models. Service Manual — page 14
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Test 5.13 (Part 3 of 4)
FUEL SYSTEM ELECTRICAL TEST
Continued from Test 5.13 (Part 2 of 4).
Probe system relay connector Terminal 85 with
a test light to 12 volts. Does test light illuminate
for 2 seconds after key ON?
YES
NO
Replace system
Probe Breakout Box Terminal 4 with a test light
relay.
3
connected to 12 volts. Does test light illuminate
for 2 seconds after key ON?
YES
NO
Locate and repair open
Replace ECM. Reprogram
on GN/O wire.
and learn password.
Test 5.13 (Part 4 of 4)
FUEL SYSTEM ELECTRICAL TEST
Continued from Test 5.13 (Part 1 of 4) or
Test 5.13 (Part 2 of 4).
Check for intermittent short to ground on
terminal 1 of connector [141B]. Short to
ground present?
YES
NO
Reconnect fuel pump connector [141]
Repair short to
and Install fuel pressure gauge.
See 5.15 FUEL PRESSURE TEST.
ground on O/GY wire
and replace fuse.
With fuel system intact and battery fully charged,
remove fuel pump fuse.
Connect DVOM across fuel pump fuse terminals using probe.
Place male positive probe in H slot. Turn key ON. With pump run-
ning, check current and fuel pressure. Is current draw under 4.5
amps and fuel pressure between 55-62 PSI (380-425 kPA)?
YES
Substitute known good relay for system relay. Test
4
for current draw across fuel pump fuse. terminals.
Replace fuse.
Is current draw less than 4.5 amps?
YES
NO
Current draw now
Replace fuel
in range. Replace
pump and replace fuse.
system relay and replace fuse.
5-44
2004 Touring: Engine Management (EFI)
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SYSTEM RELAY CHECK
5.14
GENERAL
EFI System Relay
System Relay
Spare
See Figure 5-28. With ignition switch turned to IGNITION and
the engine stop/run switch at RUN, the ECM energizes the
system relay to complete the circuit to the in-tank fuel pump,
ignition coil and fuel injectors. They will remain powered as
Fuel
long as the engine is cranking or running, and the ECM is
Pump
receiving ignition reference pulses from the CKP. If there are
no reference pulses, the ECM will de-energize the system
f2223x9x
relay within 2 seconds after ignition is ON or engine has
stalled, or immediately after the ignition is shut OFF.
ECM Power
Table 5-15. Code Description
DTC
DESCRIPTION
P1001
System relay coil open/low
Figure 5-28. EFI Fuse Block
P1002
System relay coil high/shorted
P1003
System relay contacts open
P1004
System relay contacts closed
DIAGNOSTICS
Diagnostic Notes
The reference numbers below correlate with the circled num-
bers on the Test 5.16 flow charts.
1. Use HARNESS CONNECTOR TEST KIT (Part No. HD-
41404), gray pin probe and patch cord.
2. Connect BREAKOUT BOX (Part No. HD-43876) to ECM.
See Section 5.7 BREAKOUT BOX: EFI.
2004 Touring: Engine Management (EFI)
5-45
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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
2
1
[1B]
12 11 10 9 8 7 6 5 4 3
2
1
[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 5-29. System Relay Circuit (FLTR, FLHT/C/U)
Table 5-16. Wire Harness Connectors in Figure 5-29.
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)
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2004 Touring: Engine Management (EFI)
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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 5-30. System Relay Circuit (FLHR/C/S)
Table 5-17. Wire Harness Connectors in Figure 5-30.
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)
2004 Touring: Engine Management (EFI)
5-47
HOME
Test 5.14 (Part 1 of 3)
SYSTEM RELAY: DTC P1001, P1003
With relay in, check for battery voltage at Termi-
nal 87 of system relay during first 2-3 seconds
after key ON. Battery voltage (10-13 volts)
present for 2-3 seconds after key ON?
YES
NO.
No voltage or voltage always
present.
System relay OK. With relay out,
measure resistance between
Terminal 87 of the system relay and
Check for 10-13 volts at
Socket A of Connector [83B].
Terminal 30 of the system relay.
Is resistance less than 0.5 ohm?
1
Voltage present?
YES
NO
YES
NO
Recheck connections.
Locate and repair
With ignition ON, check for
Check for continuity to
Wiggle harness while
connection or
10-13 volts at Terminal 86 of
ground on BE/GY wire.
repeating test. Repair
open on Y/GN
the system relay.
Continuity present?
intermittent.
wire.
Voltage present?
YES
NO
YES
NO
Locate and repair short
Locate and repair
to ground and replace
open between fuse
ECM fuse.
and relay.
Measure resistance
Was Ignition
2
between Terminal 85 of
fuse blown?
system relay and Terminal 4
on Breakout Box.
Is resistance less than
0.5 ohm?
YES
NO
YES
NO
Check for continuity to ground
Locate and
on Terminal 4 of Breakout
repair open on
Locate and repair short
Locate and repair
Box. Continuity present?
GN/O wire.
to ground and replace
open on W/BK wire
Ignition fuse.
between Connector [22]
and system relay.
YES
NO
Locate and
Replace system relay. Does
repair short
fuel pump run for the first 2
to ground.
seconds after key ON?
YES
NO
Clear codes using speedometer self diagnostics.
See 5.6 SPEEDOMETER SELF DIAGNOSTICS.
System
Replace ECM. Reprogram
Confirm proper operation with no check engine
OK.
and learn password.
lamp.
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2004 Touring: Engine Management (EFI)
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Test 5.14 (Part 2 of 3)
SYSTEM RELAY: DTC P1002
Remove system relay.
Check for voltage on
Terminal 4 of Breakout Box.
Voltage present?
YES
NO
Remove Breakout Box
Replace
connector from ECM.
system relay.
Is voltage still present on
Terminal 4?
YES
NO
Locate and repair
Replace ECM.
short to voltage
Reprogram and learn
on GN/O wire.
password.
Clear codes using speedometer self diagnostics.
See 5.6 SPEEDOMETER SELF DIAGNOSTICS.
Confirm proper operation with no check engine
lamp.
Test 5.14 (Part 3 of 3)
SYSTEM RELAY: DTC P1004
Check connectors [13] (except FLHR/C/S) and [141] for
corrosion, damaged terminals, improper wire location, or
poor ground. Do any of these conditions exist?
YES
NO
Repair.
Condition: Fuel pump continues to run
with key OFF.
Remove system relay.
Does pump continue to run?
YES
NO
Locate and repair short
Replace
to voltage on Y/GN wire.
system relay.
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)
5-49
HOME
FUEL PRESSURE TEST
5.15
GENERAL
EFI System Relay
The fuel pump delivers fuel to the fuel line, to a cavity in the
Spare
induction module that supplies the fuel injectors and to the
pressure regulator, where the system pressure is controlled.
Excess fuel pressure is bypassed to the fuel tank through the
pressure regulator.
See Figure 5-31. The fuel pump fuse is located in the fuse
Fuel
block under the right side cover. The fuel pump can be turned
Pump
on with the Scanalyzer or by applying battery voltage to the
fuel pump fuse.
f2223x9x
Improper fuel system pressure may contribute to one of the
following conditions:
ECM Power
● Cranks, but won’t run.
● Cuts out (may feel like ignition problem).
Figure 5-31. EFI Fuse Block
● Hesitation, loss of power or poor fuel economy.
TESTING
1WARNING
A small amount of gasoline may drain from the quick-
The fuel pressure gauge (0-100 PSI) allows for fuel injector
connect fitting when the fuel supply line is removed.
and fuel system pressure diagnosis. Special adapters allow
Thoroughly wipe up any spilt fuel immediately. Dispose
the gauge to be attached to the external fuel supply line.
of rags in a suitable manner. Gasoline is extremely flam-
mable and highly explosive. Inadequate safety precau-
tions could result in death or serious injury.
PART NO.
SPECIALTY TOOL
3. Locate quick-connect fitting on left side of fuel tank. Pull
HD-41182
Fuel pressure gauge
up on chrome sleeve, and then pull down on fuel supply
HD-44061
Fuel pressure gauge adapters (2)
line to disconnect.
1.
Remove right side saddlebag and side cover.
CAUTION
The next step requires two fuel pressure gauge adapters.
1WARNING
Failure to use two adapters will cause the fuel line to
The gasoline in the fuel supply line downstream of the
twist. This may result in a broken fuel line or fuel line fit-
fuel pump is under high pressure (58 psi). To avoid an
ting.
uncontrolled discharge or spray of gasoline, always
purge the system of high pressure gas before removing
4.
Attach fuel line to gauge assembly.
the fuel supply line from the fuel tank. Gasoline is
a. See Figure 5-32. Install a second adapter in series
extremely flammable and highly explosive. Inadequate
safety precautions could result in death or serious injury.
with the first.
b. See Figure 5-33. Pull up on chrome sleeve of quick-
2. Purge the fuel supply line of high pressure gas.
connect fitting and insert neck of FUEL PRESSURE
a. See Figure 5-31. Pull the fuel pump fuse from the
GAUGE ADAPTER (Part No. HD-44061) into fuel
EFI fuse block.
supply line.
b. Start the engine and allow the vehicle to run.
c. While pushing up on bottom of adapter, pull down on
c. When the engine stalls, operate the starter for 3 sec-
chrome sleeve until it “clicks” into the locked posi-
onds to remove any remaining fuel from the fuel
tion. Tug on adapter to be sure that it will not come
lines.
free.
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2004 Touring: Engine Management (EFI)
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d. See Figure 5-34. In the same manner, install neck of
second fuel supply line fitting into quick-connect fit-
7822
ting on fuel tank. Tug on fuel supply line to be sure
that it will not come free.
1WARNING
To avoid an uncontrolled discharge or spray of gasoline,
always be sure the quick-connect fittings are properly
mated. A slight tug on the fuel pressure gauge adapter
and fuel supply line will verify this condition. Gasoline is
extremely flammable and highly explosive. Inadequate
safety precautions could result in death or serious injury.
Figure 5-32. Fuel Pressure Gauge Adapters
5.
Verify that the fuel valve and air bleed petcock on the
7833
FUEL PRESSURE GAUGE (Part No. HD-41182) are
closed.
3
4
2
6.
See Figure 5-32. Remove protective cap from free end of
fuel pressure gauge adapter. Connect fuel pressure
gauge to Schroeder valve.
7.
See Figure 5-31. Install fuel pump fuse.
8.
Start and idle engine to pressurize the fuel system. Open
the fuel valve to allow the flow of fuel down the hose of
the pressure gauge.
1
9.
Position the clear air bleed tube in a suitable container
and open and close the air bleed petcock to purge the
5
gauge and hose of air. Repeat this step several times
until only solid fuel (without bubbles) flows from the air
bleed tube. Close the petcock.
1.
Fuel supply line
10.
Open and close throttle to change engine speed. Note
2.
Adapter to fuel line
the reading of the pressure gauge. Fuel pressure should
3.
Adapter to fuel tank
remain steady at 55-62 psi (380-425 kPa).
4.
Pressure adapter/Schroeder valve union
5.
Fuel valve (closed position)
11.
Turn the engine off. Position the air bleed tube in a suit-
able container. Open the air bleed petcock to relieve the
Figure 5-33. Fuel Line
fuel system pressure and purge the pressure gauge of
gasoline.
7834
1WARNING
A small amount of gasoline may drain from the adapter
when the gauge is removed. Thoroughly wipe up any
spilt fuel immediately. Dispose of rags in a suitable man-
ner. Gasoline is extremely flammable and highly explo-
sive. Inadequate safety precautions could result in death
or serious injury.
12. Remove fuel pressure gauge from the adapter. Install
protective cap over Schroeder valve.
1WARNING
A small amount of gasoline may drain from the fuel sup-
ply line and adapter when these items are removed.
Thoroughly wipe up any spilt fuel immediately. Dispose
Figure 5-34. Fuel Pressure Gauge Installed (Typical)
of rags in a suitable manner. Gasoline is extremely flam-
mable and highly explosive. Inadequate safety precau-
tions could result in death or serious injury.
2004 Touring: Engine Management (EFI)
5-51
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DIAGNOSTICS
Diagnostic Notes
The reference numbers below correlate with the circled num-
bers on the Test 5.17 flow chart.
Fuel Pressure
1.
See FUEL PRESSURE REGULATOR, REMOVAL/IN-
Regulator
STALLATION, in the Touring Service Manual.
2.
If fuel system has pressure, but it is less than specifica-
tion, check for the following conditions.
a. The amount of fuel to the injectors is within limits,
but pressure is too low. Also, hard starting cold and
overall poor performance condition may exist.
f1940x9x
b. Restricted fuel flow causing pressure drop. How-
Figure 5-35. Underside of Canopy
ever, if pressure drop occurs only when driving,
engine may surge and lose power as pressure
begins to drop rapidly.
13. Pull up on sleeve of quick-connect fitting and remove fuel
3.
This condition may be identified when the fuel level is low
supply line from fuel pressure gauge adapter. Release
and the fuel pump is turned on for the first 2 seconds
adapter from fuel tank in the same manner.
after key ON. A metallic ringing sound can be heard as
the high pressure fuel is sprayed against the inside wall
of the fuel tank.
1WARNING
To avoid an uncontrolled discharge or spray of gasoline,
always be sure the quick-connect fitting is properly
mated. A slight tug on the fuel supply line will verify this
condition. Gasoline is extremely flammable and highly
explosive. Inadequate safety precautions could result in
death or serious injury.
14. Pull up on chrome sleeve of quick-connect fitting and
insert neck of fuel supply line fitting. While pushing up on
bottom of fuel supply line fitting, pull down on chrome
sleeve until it “clicks” into the locked position. Tug on fuel
supply line to be sure that it will not come free.
15. Install right side cover and saddlebag.
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2004 Touring: Engine Management (EFI)
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Test 5.15
FUEL PRESSURE TEST
Install fuel pressure gauge. See TESTING
under Section 5.15 FUEL PRESSURE TEST.
Start and idle engine.
Open and close throttle to change engine
speed. Does fuel pressure remain steady
at 55-62 PSI (380-425 kPa)?
YES
NO
NO
Steady pressure.
Low pressure.
High pressure.
No trouble found.
Check for restricted fuel filter
Inspect check valve fitting
Review symptoms.
or pump inlet screen. Are filter
assembly and fuel tank. If OK,
and screen OK?
replace faulty fuel pressure
2
1
regulator.
YES
NO
Check for restricted pressure line or flex hose between
Replace filter or clean pump
tank and test gauge. If lines are OK, check for:
inlet screen. Retest.
Faulty fuel pump.
Restricted check valve fitting assembly.
Leak inside tank caused by faulty coupling hose
3
or connection, such as hose at filter or pump.
Faulty fuel pressure regulator.
1
2004 Touring: Engine Management (EFI)
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IDLE AIR CONTROL
5.16
GENERAL
DIAGNOSTICS
IAC Operation
Diagnostic Tips
The ECM controls engine idle speed by moving the idle air
Engine idle speed can be adversely affected by the following:
control (IAC) to open or close a passage around the throttle
plate. It does this by sending voltage pulses to the proper
●
A loss of idle speed control does not necessarily imply
motor winding of the IAC. This causes the pintle to move in or
the IAC actuator or wiring has failed. It can be caused by
out of the IAC a given distance for each pulse received.
a number of conditions such as an intake air leak,
improperly adjusted throttle stop or a misfiring cylinder.
● To increase idle speed, the ECM retracts the pintle,
allowing more air to flow through the throttle body.
●
Leaking injectors will cause fuel imbalance and poor idle
● To decrease idle speed, the ECM extends the pintle,
quality due to different air/fuel ratios in each cylinder. To
allowing less air to flow through the throttle body.
check for leaky injectors, first remove the air cleaner.
With the throttle wide open, turn key ON for 2 seconds
The IAC position is measured in steps. This can only be done
and then OFF for 2 seconds five consecutive times.
by using a computer based diagnostic package called DIGI-
Replace the fuel injector if there is any evidence of raw
TAL TECHNICIAN (Part No. HD-44750).
fuel in the bores. See FUEL INJECTORS, REMOVAL/IN-
STALLATION, in the Touring Service Manual.
● A high number of steps represents a fully retracted pintle
and open passage around throttle plate. This correlates
●
Vacuum leaks. To check for vacuum, see 5.9 INTAKE
with an increase in the amount of air flowing through the
LEAK TEST.
throttle body.
●
Contaminated fuel.
● Zero steps represents a fully extended pintle. A zero
reading indicates that the pintle has been fully extended
●
Excessive oil in the crankcase (oil sumping).
and has consequently closed the passage around throt-
tle plate, which is an abnormal condition.
●
TPS reading greater than 1% (possible throttle cable
misadjustment) or battery voltage reading of less than 9
Each time the ignition is turned off, the ECM resets the IAC
volts or a vehicle speed sensor (VSS) greater than 0 will
by sending enough pulses to extend the pintle and effectively
disable idle speed control.
close the throttle body. The fully extended value is the ECM
reference point. A given number of counts are then calculated
●
Loss of battery power to ECM pin 31.
by the ECM for use in setting the proper idle speed and IAC
position.
NOTE
Warm idle speed is controlled by the ECM and can only be
adjusted by using a computer based diagnostic package
called DIGITAL TECHNICIAN (Part No. HD-44750).
Diagnostic Trouble Code P0505:
Loss of Idle Speed Control
Loss of idle speed control will result if the idle RPM is ±200
from preset idle speed and IAC motor is at zero or maximum
for greater than 5 seconds. This code may occur with others
for a multiple code situation. Resolve the other codes first to
correct.
Table 5-18. Code Description
DTC
DESCRIPTION
P0505
Loss of idle speed control
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2004 Touring: Engine Management (EFI)
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Diagnostic Notes
The reference numbers below correlate with the circled num-
bers on the Test 5.18 flow charts.
1. When the engine is stopped, the IAC pintle extends and
then retracts to a fixed “Park” position for increased air-
flow and idle speed during the next engine start
sequence. This key OFF reset procedure takes 10 sec-
onds to perform.
b0426x9x
2. Test lamp behavior may follow two patterns. The color of
Figure 5-36. IAC Test Lamp (Part No. HD-41199-3)
the lights is not relevant to IAC operation.
a. Normal behavior: At key ON, test lights will alter-
Idle Air Control
nately flash and then remain steady on to confirm
ECM signals. At key OFF lights alternately flash and
go out after 10 second reset procedure.
b. Problem indicated: One or more lights fail to illumi-
nate during key ON/key OFF cycle.
NOTE
There is a remote possibility that one of the circuits is shorted
to voltage which would have been indicated by a steady light.
Disconnect ECM and turn the ignition ON. Probe terminals to
check for this condition.
f1939x9x
3. Connect BREAKOUT BOX (Part No. HD-43876) to EFI
wire harness only, leaving ECM disconnected. See Sec-
Figure 5-37. Induction Module (Top View)
tion 5.7 BREAKOUT BOX: EFI.
7837
4. Use HARNESS CONNECTOR TEST KIT (Part No. HD-
41404), gray pin probe and patch cord.
5. Repair faulty ECM connection or replace ECM.
Figure 5-38. IAC Pintle
2004 Touring: Engine Management (EFI)
5-55
HOME
s0448x9x
IAC
motor
[87A]
A
B
C
D
[87B]
[78B]
17
18
35
36
[78A]
ECM
Figure 5-39. IAC Circuit
Table 5-19. Wire Harness Connectors in Figure 5-39.
NO.
DESCRIPTION
TYPE
LOCATION
[78]
ECM
36-Place Packard
Under Right Side Cover
[87]
IAC
4-Place Packard
Below Fuel Tank (Right Side)
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2004 Touring: Engine Management (EFI)
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Test 5.16 (Part 1 of 2)
IDLE AIR CONTROL: DTC P0505
Remove air cleaner cover
and element. Is throttle
valve completely closed?
YES
NO
Lubricate and adjust
Monitor IAC pintle for 10 seconds after turning
throttle cables.
ignition OFF. Does pintle extend and then retract
during 10 second key OFF reset procedure?
1
YES
NO
Check intake manifold for leaks. See
Disconnect IAC and connect test lamp.
5.9 INTAKE LEAK TEST. Leaks
See Figure 5-36.
found?
Turn ignition switch to IGNITION for 2 seconds,
and then OFF for 10 seconds.
2
Check test lamp during key ON/OFF cycle.
YES
NO
Repair intake
Check fuel pressure.
Problem
Normal
leak.
See Section 5.15 FUEL
indicated.
behavior.
PRESSURE TEST.
Remove test lamp.
Repair faulty IAC
Connect Breakout Box to Connector [78B]
connection or IAC assembly.
leaving ECM disconnected. Check Terminal 31
for 12 volts. Battery voltage present?
YES
NO
Using DVOM, measure resistance
Go to Test 5.13.
between IAC connector [87B]
No ECM Power.
and Breakout Box.
IAC
WIRE COLOR
ECM
A
BE/GN
to 35
B
BN/R
to 36
C
BK/PK
to 18
3
D
BK/O
to 17
4
Does each wire measure 0.5 ohms or less?
YES
NO
Turn ignition ON. With ECM still
Repair poor connection
4
disconnected, check voltage on all
at Connectors [87B] or
four sockets of Connector [87B].
[78B], or repair open
Is voltage present?
wire in harness.
YES
NO
Clear codes using speedometer self diagnostics.
Locate and repair
See 5.6 SPEEDOMETER SELF DIAGNOSTICS.
short to voltage.
STOP
Go to Test 5.16
Confirm proper operation with no check engine
(Part 2 of 2).
lamp.
2004 Touring: Engine Management (EFI)
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Test 5.16 (Part 2 of 2)
IDLE AIR CONTROL: DTC P0505
Continued from Test 5.16 (Part 1 of 2).
4
Turn ignition OFF. Measure resistance
between each socket of Connector [87B]
and ground.
Is resistance greater than 1 megohm
for all sockets?
YES
NO
Inspect ECM
Locate and
connections.
repair short to
Connections OK?
ground.
YES
NO
Replace ECM.
Repair ECM
Reprogram and learn
connections.
password.
5
Clear codes using speedometer self diagnostics.
See 5.6 SPEEDOMETER SELF DIAGNOSTICS.
Confirm proper operation with no check engine
lamp.
5-58
2004 Touring: Engine Management (EFI)
HOME
MISFIRE AT IDLE OR UNDER LOAD
5.17
GENERAL
d0273x8x
Misfire at Idle or Under Load
● Battery condition and connections may also cause mis-
fires. See BATTERY in the Touring Service Manual for
more information.
● Fuel system problems may also cause misfires. Consult
5.15 FUEL PRESSURE TEST and then see symptom
tables under 5.5 INITIAL DIAGNOSTIC CHECK: EFI.
● Mechanical problems with the engine may cause mis-
fires. See Section 3 of the Touring Service Manual for
Figure 5-40. Spark Tester
more information.
● Vehicle modifications including intake and exhaust may
cause misfires.
Table 5-20. Spark Plug Cables
DIAGNOSTICS
LOCATION
LENGTH
RESISTANCE
Front/Rear
20.2 inch (513 mm)
4975-11960
Diagnostic Notes
The reference numbers below correlate with the circled num-
3.
Perform spark plug cable resistance test.
bers on the Test 5.17 flow charts.
a. Remove spark plug cable from spark plug and igni-
tion coil. For best results, use a needle nose pliers
1WARNING
for removal/installation on coil. Gently grasp cable
Any open spark around gasoline or other combustibles
as close to terminals as possible.
may result in fire or explosion. Thoroughly wipe up any
spilt fuel and dispose of rags in a suitable manner. Gaso-
b. Using an ohmmeter, touch probes to terminals on
line is extremely flammable and highly explosive. Inade-
each end plug cable.
quate safety precautions could result in death or serious
injury.
c. Compare resistance values to Table 5-20. Replace
cables not meeting specifications. Reinstall and
1. Connect BREAKOUT BOX
(Part No. HD-43876)
repeat procedure on other spark plug cable.
between wire harness and ECM. See 5.7 BREAKOUT
BOX: EFI.
4.
If carbon tracking is evident on outside of coil towers,
2. See Figure
5-40. A SPARK TESTER (Part No. HD-
replace ignition coil and inspect spark plug cables.
26792) must be used to verify adequate secondary volt-
Cables must be clean and tight. Excessive cable resis-
age (25,000 volts) at the spark plug.
tance or faulty connections can cause coil damage.
NOTE
5.
This test can also be performed by substituting a known
Engine will not spark with both spark plugs removed. When
good coil for one causing the no spark condition. The coil
checking for spark, use SPARK TESTER (Part No. HD-
26792) with both plugs installed.
does not require full installation to be functional. Verify
faulty coil by performing resistance test. See IGNITION
a. Turn ignition key OFF.
COIL in the Touring Service Manual.
b. Remove spark plug cable from spark plug. Visually
check plug condition.
6.
Use HARNESS CONNECTOR TEST KIT (Part No. HD-
c. Attach cable to SPARK TESTER. Clip tester to cylin-
41404), red pin probe and patch cord to relay and gray
der head bolt.
pin probe and patch cord to the coil connector [83B].
d. While cranking engine, watch for spark to jump
tester gap on leads.
e. Reinstall and repeat procedure on other spark plug
cable.
2004 Touring: Engine Management (EFI)
5-59
HOME
[62B]
f2208n8x
Y/GN
[78]
System
relay
BE/GY
GN/O
W/BK
[13A] [13B]
Fuel
System relay
4
GN/O
pump
O/GY
Y/GN
15 Amp
fuel pump
Inj. F
21
W/Y
fuse
[141B] [141A]
[84B]
[84A]
BK
Y/GN
All Except
FLHR/C/S
[83B]
[83A]
Inj. R
19
GN/GY
[85B]
[85A]
Ion sense
Coil
27
GY/BE
Coil R
11
Y/BE
Coil F
29
BE/O
40 Amp
Maxi Fuse
+
-
15 Amp
Battery
ECM fuse
R
Constant power
31
BE/GY
BK
Starter
Motor
Switch power
13
W/BK
GY
R/BK
Engine
15 Amp
stop
IGN fuse
Ignition
switch
switch
Power gnd.
10
BK
Power gnd.
28
BK
Figure 5-41. Ignition Coil Circuit
Table 5-21. Wire Harness Connectors in Figure 5-41.
NO.
DESCRIPTION
TYPE
LOCATION
[78]
ECM
36-Place Packard
Under Right Side Cover
[83]
Ignition Coil
4-Place Packard
Below Fuel Tank (Left Side)
5-60
2004 Touring: Engine Management (EFI)
HOME
Test 5.17 (Part 1 of 3)
MISFIRE AT IDLE OR UNDER LOAD
Is fuel contaminated?
YES
NO
Connect breakout box. Check for continuity
1
between terminal 10 of ECM and battery neg-
Drain and flush
ative and terminal 28 of ECM and battery neg-
tank. Refill with
ative. Resistance should be less than 1 ohm.
fresh fuel.
Is it?
YES
NO
Use spark tester to check cables.
Locate and repair poor
2
Did spark jump tester lead gap?
ground connection.
Did it?
YES
NO
Check for:
Check resistance of each spark plug
• Faulty, worn or cracked spark plug(s).
cable that did not fire the spark tester.
• Plug fouling due to engine
3
mechanical fault.
Also, check for faulty plug cable connections
• Faulty or poor connection at plug or coil.
and wires for carbon tracking.
Are spark plug cables OK?
YES
NO
Coils should be free
Replace
4
of carbon tracking.
faulty spark plug cables.
Are they?
YES
NO
Switch coil with unit
Replace
known to be good.
ignition coil.
2
Re-perform spark test.
Did spark jump gap
5
during engine cranking?
Go to Test 5.17
NO
STOP
(Part 2 of 3).
YES
Original ignition coil
is faulty. Replace.
2004 Touring: Engine Management (EFI)
5-61
HOME
Test 5.17 (Part 2 of 3)
MISFIRE AT IDLE OR UNDER LOAD
Continued from Test 5.17 (Part 1 of 3).
6
Measure resistance between relay
Terminal 87 and Socket A (Y/GN wire)
of Connector [83B]. Wiggle harness.
Is resistance continuously less than 0.5 ohms?
YES
NO
Reassemble coil and fuel tank. Measure
Find source of
voltage drop between battery (positive
intermittent and repair.
lead) and Terminal 87 (negative lead) on
system relay with engine running.
Is voltage drop less than 1.0 volt?
YES
NO
Problem is fuel related.
Repeat voltage drop test after moving
See symptoms under
negative lead to Terminal 30. With
Table 5-3. Engine Performance
engine running, is voltage drop less
Problems.
than 1.0 volt?
YES
NO
Replace
Repeat voltage drop test after
system relay.
moving negative lead to 15 amp
ECM fuse (BE/GY wire). With
engine running, is voltage drop less
than 1.0 volt?
YES
NO
Repair.
Repeat voltage drop test after
BE/GY wire.
moving negative lead to 15 amp
ECM fuse (R wire). With engine
running, is voltage drop less than
1.0 volt?
YES
NO
Replace 15 amp
ECM fuse.
STOP
Go to Test 5.17
(Part 3 of 3).
5-62
2004 Touring: Engine Management (EFI)
HOME
Test 5.17 (Part 3 of 3)
MISFIRE AT IDLE OR UNDER LOAD
Continued from Test 5.17 (Part 2 of 3).
Repeat voltage drop test after
moving negative lead to 40 amp maxi-fuse, ter-
minal B. With engine running, is voltage drop
less than 1.0 volt?
YES
NO
Check terminal
Repeat voltage drop test after
or repair wire.
moving negative lead to 40 amp maxi-fuse,
terminal A. With engine running, is voltage
drop less than 1.0 volt?
YES
NO
Check terminal
Repair wire between
or replace
maxi-fuse and battery.
maxi-fuse or
terminals.
2004 Touring: Engine Management (EFI)
5-63
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