Harley Davidson 2004 Touring Models. Service Manual — page 6

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    BREAKOUT BOX: TSM/TSSM
    3.11
    GENERAL
    Pin 12
    The BREAKOUT BOX (Part No. HD-42682) splices into the
    main harness. Used in conjunction with a DVOM, it allows cir-
    cuit diagnosis of wiring harness and connections without hav-
    ing to probe with sharp objects.
    INSTALLATION
    1.
    Gain access to TSM/TSSM.
    s0474x9x
    Pin 1
    2.
    See Figure 3-17. Depress latches on connector [30B].
    Figure 3-17. TSM/TSSM Connector
    3.
    See Figure 3-18. Attach Breakout Box to connector.
    a. Mate gray socket housing on breakout box with
    TSM/TSSM connector [30A].
    b. Mate gray pin housing on breakout box with wire
    harness connector [30B].
    REMOVAL
    1.
    See Figure 3-17. Depress latches on connector [30B].
    2.
    Detach gray breakout box connector from TSM/TSSM
    connector [30A].
    f2001x8x
    3.
    Detach gray breakout box connector from wire harness
    connector [30B].
    Connect Gray Side
    4.
    Reattach TSM/TSSM connector to wiring harness.
    Only for Tests
    5.
    Install parts removed for access.
    f1998x9x
    NOTE
    Figure 3-18. Breakout Box (Part No. HD-42682)
    Vehicle will not start with TSM/TSSM disconnected or incor-
    rectly mounted.
    Table 3-16. TSM/TSSM Connector [30B]
    PIN
    FUNCTION
    PIN
    FUNCTION
    1
    Battery
    7
    Right turn switch input
    2
    Ignition
    8
    Left turn switch input
    3
    serial data
    9
    Start relay control
    4
    Security lamp
    10
    Ignition enable signal (not used)
    5
    Left turn feed
    11
    Alarm signal
    6
    Right turn feed
    12
    Ground
    3-32
    2004 Touring: TSM & TSSM
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    NO SECURITY LAMP AT KEY ON
    3.12
    GENERAL
    System Fuse Block (Under Left Side Cover)
    8
    No TSSM Power
    FLHR/C/S
    (Security Equipped Vehicles Only)
    9
    10
    See Figure 3-19. When the Ignition/Light Key Switch is turned
    to IGNITION, the security lamp should illuminate for 4 sec-
    5
    onds. Following the initial period of illumination, the lamp
    11
    should go off for 4 seconds. It may then come back on for an
    8 second period, indicating a historic diagnostic trouble code
    (DTC) or remain on, indicating a current DTC.
    4
    Power and ground are supplied to the Security lamp from the
    12
    speedometer circuitry. The TSSM activates an LED driver cir-
    cuit in the speedometer to illuminate the security lamp. A lack
    of power to the TSSM will cause the security lamp to be inop-
    f2210x8x
    3
    1
    2
    erative and will also create a no start situation.
    8
    7
    FLTR, FLHT/C/U
    Job/Time Code Values
    9
    6
    Dealership technicians filing warranty claims should use the
    10
    job/time code values printed in bold text underneath the
    5
    appropriate repair.
    11
    DIAGNOSTICS
    4
    Diagnostic Tips
    ● Check for open in BN/V wire.
    f2204x8x
    1
    2
    3
    ● Check for blown battery fuse. See Figure 3-19.
    1.
    Headlamp
    7.
    Radio Power
    2.
    Ignition
    8.
    Accessory
    Diagnostic Notes
    3.
    Lighting
    9.
    Battery
    4.
    Instruments
    10.
    Brake Light Relay
    The reference numbers below correlate with the circled num-
    5.
    Brakes/Cruise
    11.
    P&A
    bers on the Test 3.12 flow charts.
    6.
    Radio Memory
    12.
    Starter Relay
    1. Connect BREAKOUT BOX (Part No. HD-42682) (gray)
    as follows:
    Figure 3-19. Fuse Locations
    a. Mate gray socket housing on Breakout Box with
    TSM/TSSM connector [30A].
    b. Mate gray pin housing on Breakout Box with wire
    harness connector [30B].
    2. Connect BREAKOUT BOX (Part No. HD-42682) (black)
    as follows:
    a. Mate black socket housing on Breakout Box with
    speedometer connector [39A] (at the back of the
    speedometer) using INSTRUMENT HARNESS
    ADAPTERS (Part No.HD-46601).
    b. Mate black pin housing on Breakout Box with wire
    harness connector [39B] using INSTRUMENT HAR-
    NESS ADAPTERS (Part No.HD-46601).
    Figure 3-20. Instrument Harness Adapters
    (Part No. HD-46601)
    2004 Touring: TSM & TSSM
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    3.
    Use HARNESS CONNECTOR TEST KIT (Part No. HD-
    4. Security lamp failure requires speedometer replacement.
    41404), purple pin probe and patch cord between break-
    See the Touring Service Manual.
    out Breakout Box and ground. Align blade with slot in ter-
    minal of Breakout Box.
    3-34
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    f2208r8x
    Ground
    BK
    Battery
    BN/GY
    Security LED
    BN/V
    Ignition
    O
    [39A]
    [39B]
    Security Lamp
    [1A]
    1
    2
    3
    4 5 6 7 8 9 10 11
    12
    [2A]
    1
    2
    3
    4
    5 67 8 9
    10
    11 12
    [1B]
    1
    2
    3
    4 5 6 7 8 9 10 11
    12
    [2B]
    1
    2
    3
    4
    5 67 8 9
    10
    11 12
    FLTR, FLHT/C/U
    [156B]
    1
    2
    3
    4
    5
    6
    Only
    [156A]
    1
    2
    3
    4
    5
    6
    R
    R
    -
    +
    40 Amp
    15 Amp
    Maxi Fuse
    Battery
    Battery
    Fuse
    BN/GY
    +12V
    GY
    15 Amp
    Ignition Fuse
    O
    +12V
    15 Amp
    BN/V
    Instrument Fuse
    BK
    [30B]
    1
    2
    3
    4 5 6 7 8 9 10 11 12
    1
    2
    3
    4 5 6 7 8 9 10 11 12
    [30A]
    TSSM
    Figure 3-21. Security Lamp Circuit
    Table 3-17. Wire Harness Connectors in Figure 3-21.
    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)
    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)
    FLHR/C/S
    12-Place Packard
    Under Console (Back of Speedometer)
    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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    Test 3.12 (Part 1 of 3)
    NO SECURITY LAMP AT KEY ON
    Security equipped vehicles only.
    Turn Ignition/Light Key Switch to IGNITION.
    Set engine stop switch to RUN. Press starter
    button. Turn ignition switch to OFF.
    Did engine crank when starter button was pressed?
    YES
    NO
    1
    Check for continuity between
    Breakout Box terminal 4 (black)
    2
    STOP
    and terminal 4 (gray).
    Is continuity present?
    Go to Test 3.12
    (Part 2 of 3).
    YES
    NO
    Check for continuity to
    Repair open on BN/V wire
    ground on Breakout
    between connectors [30B]
    Box terminal 4 (black).
    and [39B].
    Is continuity present?
    6735
    YES
    NO
    3
    Locate and repair short to
    Reconnect connector [39]. Place
    ground on BN/V wire.
    jumper between Breakout Box terminal
    4 (gray) and battery positive terminal.
    6736
    Does security lamp illuminate?
    YES
    NO
    4
    Replace TSSM. Learn
    Replace
    password and perform setup.
    speedometer.
    6737
    6738
    Clear codes using speedometer self diagnostics.
    See 3.10 SPEEDOMETER SELF DIAGNOSTICS.
    Confirm proper operation with no check engine
    lamp.
    3-36
    2004 Touring: TSM & TSSM
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    Test 3.12 (Part 2 of 3)
    NO SECURITY LAMP AT KEY ON
    Continued from Test 3.12 (Part 1 of 3).
    Is connector [30] fully mated?
    YES
    NO
    1
    Place red meter lead at Breakout
    Mate
    Box terminal 1 (gray) and black
    connector.
    meter lead at Breakout Box
    terminal 12 (gray).
    6739
    Is battery voltage present?
    YES
    NO
    Move red meter lead to
    Breakout Box terminal 2 (gray).
    Is battery voltage present?
    STOP
    Go to Test 3.12
    YES
    NO
    (Part 3 of 3).
    Replace TSSM.
    Remove left side cover.
    Learn password
    Check for voltage at ignition
    and perform setup.
    fuse. See Figure 3-19.
    Is battery voltage present
    6740
    on both terminals?
    YES
    NO
    Clear codes using speedometer self diagnostics.
    See 3.10 SPEEDOMETER SELF DIAGNOSTICS.
    Locate and repair open
    Confirm proper operation with no check engine
    on gray wire between
    lamp.
    STOP
    ignition fuse and TSSM.
    6741
    On carbureted models go
    to 4.11 NO SPARK/NO ICM
    POWER. On EFI models go
    to 5.11 NO ECM POWER.
    2004 Touring: TSM & TSSM
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    Test 3.12 (Part 3 of 3)
    NO SECURITY LAMP AT KEY ON
    Continued from
    Test 3.12 (Part 2 of 3).
    Check resistance to ground at
    Breakout Box terminal 12 (gray).
    Is resistance less than 1 ohm?
    YES
    NO
    Check for 12 volts at both terminals of
    15 amp battery fuse. See Figure 3-19.
    Locate and
    Is proper voltage present at
    repair poor
    both terminals?
    ground.
    6742
    YES
    NO
    Locate and repair open in BN/GY
    wire between
    One terminal.
    Neither terminal.
    battery fuse and TSM/TSSM.
    6743
    Replace
    Locate and repair
    battery fuse.
    open between main
    fuse and fuse block.
    6744
    6745
    Clear codes using speedometer self diagnostics.
    See 3.10 SPEEDOMETER SELF DIAGNOSTICS.
    Confirm proper operation with no check engine
    lamp.
    3-38
    2004 Touring: TSM & TSSM
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    SECURITY LAMP ON CONTINUOUSLY
    3.13
    GENERAL
    See Figure 3-22. When the Ignition/Light Key Switch is turned
    to IGNITION, the security lamp should illuminate for 4 sec-
    60
    40
    50
    70
    30
    50
    onds. Following the initial period of illumination, the lamp
    40
    80
    should go off for 4 seconds. It may then come back on for an
    30
    90
    20
    MPH
    RPM x100
    8 second period, indicating a historic diagnostic trouble code
    20
    100
    (DTC) or remain on, indicating a current DTC.
    10
    10
    110
    0
    120
    0
    DIAGNOSTICS
    TI
    -D
    -D
    Diagnostic Notes
    The reference number below correlates with the circled num-
    ber on the Test 3.13 flow chart.
    Security Lamp
    f2160x8x
    1. Connector [39B] is on the back of the speedometer. Use
    Figure 3-22. Speedometer
    HARNESS CONNECTOR TEST KIT (Part No. HD-
    41404), black pin probe and patch cord.
    2004 Touring: TSM & TSSM
    3-39
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    f2208r8x
    Ground
    BK
    Battery
    BN/GY
    Security LED
    BN/V
    Ignition
    O
    [39A]
    [39B]
    Security Lamp
    [1A]
    1
    2
    3
    4 5 6 7 8 9 10 11 12
    [2A]
    1
    2
    3
    4
    5 67 8 9
    10 11 12
    [1B]
    1
    2
    3
    4 5 6 7 8 9 10 11 12
    [2B]
    1
    2
    3
    4
    5 67 8 9
    10 11 12
    FLTR, FLHT/C/U
    [156B]
    1
    2
    3
    4
    5
    6
    Only
    [156A]
    1
    2
    3
    4
    5
    6
    R
    R
    -
    +
    15 Amp
    40 Amp
    Maxi Fuse
    Battery
    Battery
    Fuse
    BN/GY
    +12V
    GY
    15 Amp
    Ignition Fuse
    O
    +12V
    15 Amp
    BN/V
    Instrument Fuse
    BK
    [30B]
    1
    2
    3
    4 5 6 7 8 9 10 11 12
    1
    2
    3
    4 5 6 7 8 9 10 11 12
    [30A]
    TSSM
    Figure 3-23. Security Lamp Circuit
    Table 3-18. Wire Harness Connectors in Figure 3-23.
    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)
    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)
    FLHR/C/S
    12-Place Packard
    Under Console (Back of Speedometer)
    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
    3-40
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    Test 3.13
    SECURITY LAMP ON CONTINUOUSLY
    Turn Ignition/Light Key Switch to IGNITION.
    Does security lamp turn ON for 4 seconds
    and then turn OFF for 4 seconds?
    YES
    NO
    Security lamp function OK. Check for trouble
    Turn Ignition/Light Key Switch to OFF.
    codes. See Section 3.8 CHECKING FOR
    Disconnect TSM/TSSM connector [30].
    DIAGNOSTIC TROUBLE CODES.
    Turn switch to IGNITION.
    Does security lamp illuminate?
    YES
    NO
    1
    Disconnect connector [39].
    Replace TSSM.
    Check for voltage on terminal 4
    Learn password and
    (BN/V wire) of connector [30].
    perform setup.
    Is voltage present?
    6750
    YES
    NO
    Repair short to battery
    Replace
    on BN/V wire between
    speedometer.
    connectors [30A] and [39B].
    6752
    6751
    Clear codes using speedometer self diagnostics.
    See 3.10 SPEEDOMETER SELF DIAGNOSTICS.
    Confirm proper operation with no check engine
    lamp.
    2004 Touring: TSM & TSSM
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    NOTES
    3-42
    2004 Touring: TSM & TSSM
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    KEY FOB SIGNAL TO TSSM WEAK OR FAILS
    3.14
    GENERAL
    o0235xox
    Security Equipped Vehicles Only
    This section applies only to those vehicles equipped with the
    optional security system.
    NOTE
    Disarming function may require practice. The key fob button
    must be pressed twice within 1.5 seconds to send the disarm
    command. The action is very similar to double-clicking a com-
    puter mouse. Light quick taps work best; very hard or very
    slow taps are less likely to work.
    Figure 3-24. Key Fob Battery
    See Figure 3-24. The key fob sends a RF signal to activate all
    remote TSSM functions. The left front turn signal switch wire
    serves as the vehicle’s antenna. If the TSSM does not
    respond (no confirmation at arming/disarming system) or
    Diagnostic Notes
    responds weakly (limited range, won’t consistently arm/dis-
    arm or synchronize), follow the Test 3.14 flow chart.
    The reference numbers below correlate with the circled num-
    bers on the Test 3.14 flow charts.
    1.
    After a battery disconnect, the TSSM will not enter the
    configuration mode on the first attempt. All attempts to
    DIAGNOSTICS
    assign a fob or enter the configuration mode will require
    at least two attempts.
    Diagnostic Tips
    ● Verify key fob battery voltage is at least 2.9 volts. See
    3.25 TSSM MAINTENANCE.
    ● Interference from physical surroundings may affect RF
    transmission. Place fob next to left handgrip and disarm
    with two clicks or move motorcycle to a new location and
    retest.
    ● Check for damage to antenna wire. Does left turn signal
    work?
    NOTE
    See
    3.7 ARMING/DISARMING SECURITY SYSTEM
    (TSSM). Use only the proper key fob for your market and
    TSSM package.
    2004 Touring: TSM & TSSM
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    f2208q8x
    12
    11
    10
    9
    Also Functions as Key
    8
    Fob Antenna
    7
    6-Place on FLHR/C/S
    6
    W/V
    5
    4
    3
    2
    1
    All but FLHR/C/S
    Left Turn Signal
    [1A]
    [24B] [24A]
    Switch
    [1B]
    40 Amp
    Maxi Fuse
    R
    R
    –
    +
    Battery
    15 Amp
    Battery Fuse
    [30B]
    1
    2
    3
    4 5 6 7 8 9 10 11 12
    1
    2
    3
    4 5 6 7 8 9 10 11 12
    [30A]
    TSSM
    Figure 3-25. Antenna Circuit
    Table 3-19. Wire Harness Connectors in Figure 3-25.
    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)
    FLHT/C/U
    12-Place Deutsch
    Inner Fairing - Left Fairing Support Brace
    Left Handlebar Switch
    [24]
    FLTR
    12-Place Deutsch
    Inner Fairing - Left Side of Radio Bracket
    Controls
    FLHR/C/S
    6-place Deutsch
    Inside Headlamp Nacelle
    Cavity in Crossmember
    [30]
    TSSM
    All
    12-Place Deutsch
    at Rear of Battery Box (Under Seat)
    3-44
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    Test 3.14
    FOB SIGNAL TO TSSM WEAK OR FAILS
    Correct key fob for vehicle?
    YES
    NO
    Does left turn
    Obtain correct fob or replace
    signal function?
    fob. Verify fob is synchronized
    to vehicle’s TSSM.
    YES
    NO
    Replace fob battery and
    See 3.15 TURN SIGNAL
    retest. See 3.25 TSSM
    ERRORS.
    MAINTENANCE.
    Does fob work?
    YES
    NO
    System
    Attempt to assign new fob
    1
    OK.
    to TSSM and retest.
    Does fob work?
    YES
    NO
    System
    Replace TSSM.
    OK.
    Learn password and
    perform setup.
    2004 Touring: TSM & TSSM
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    TURN SIGNAL ERRORS
    3.15
    GENERAL
    7844
    The turn signals will automatically cancel either based on the
    speed/acceleration of the vehicle or based upon turn comple-
    tion. See 3.4 TSM/TSSM TURN SIGNAL FUNCTIONS.
    For turn signal diagnostics, refer to Table 3-20.
    DIAGNOSTICS
    Diagnostic Tips
    ● Diagnostic trouble code DTC B1121 and B1122 will illu-
    minate the security lamp.
    ● DTC B1141 will not illuminate the security lamp.
    ● When the TSM/TSSM is in four-way flasher mode, a fault
    Figure 3-26. TSM/TSSM
    on either the left or right turn lamp output will not cause
    either DTC B1121 and DTC B1122 to be set as current.
    If fault occurs on both left and right outputs, then both
    DTC B1121 and DTC B1122 will be set as current.
    ● When the TSM/TSSM detects an over current (or short to
    ground) condition, it will turn off the turn lamp outputs.
    The outputs will be automatically reactivated once the
    fault is removed.
    Table 3-20. Turn Signal Errors
    START WITH
    SYMPTOM
    DTC(S)
    FLOW CHART
    Turn signals will not cancel upon turn completion
    Turn Signal Error 1A (Part 1 of 2)
    N/A
    Turn signals cancel erratically
    Turn Signal Error 1A (Part 2 of 2)
    N/A
    Turn signals will not flash, 4-way flashers inoperable
    Turn Signal Error 2A
    B1121, B1122, B1141
    Left or right turn signals flash at double the normal rate
    Turn Signal Error 3A
    N/A
    while all bulbs are working
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    TSM/TSSM
    BATTERY
    1
    BN/GY
    OPTIONAL SECURITY
    IGNITION
    2
    GY
    SIREN
    VSS/SERIAL DATA LINK
    3
    LGN/V
    SECURITY INDICATOR
    4
    BN/V
    LEFT TURN FEED
    5
    V
    RIGHT TURN FEED
    6
    BN
    IGNITION SWITCH LEGEND (HDI)
    RIGHT TURN SW INPUT
    7
    W/BN
    BK
    LEFT TURN SW INPUT
    8
    W/V
    "X" INDICATES CONTINUITY
    TN/GN
    [142A]
    BK
    MAXI-FUSE
    BETWEEN LEAD WIRES
    START RELAY CONTROL
    9
    SWITCH
    IN POSITION INDICATED
    IGNITION ENABLE
    10
    40 A
    POSITION
    ALARM SIGNAL
    11
    LGN/BN
    RED
    RED/
    RED/
    GROUND
    12
    BK
    A B C
    GRAY
    BLACK
    BATTERY
    LOCK
    X
    [30A]
    [30B]
    [142B]
    R
    OFF
    X
    TURN SIGNAL/
    IGN
    X
    X
    X
    TURN SIGNAL SECURITY
    MODULE
    [128A]
    [128B]
    ACC
    X
    X
    GN
    [5B]
    [8A]
    (GY)
    [33D] [33C]
    12
    B A
    [33B]
    11
    LGN/V
    STARTER
    TO CARB
    10
    OR E.F.I.
    9
    8
    1
    IGNITION
    7
    A
    R
    2
    HARNESS
    6
    B
    R/GY
    3
    [8B]
    5
    4
    C
    R/BK
    3
    D
    IGNITION
    2
    RIGHT LEFT
    JUMPER HARNESS
    SWITCH, HDI
    1
    GROUND STUD
    (LOCATED IN
    12
    FRONT OF BATTERY)
    BK
    R/BK
    86
    11
    W/V
    BK
    85
    10
    W/BN
    R
    30
    9
    87A
    TO
    8
    BN
    [64B]
    87
    INTERCONNECT
    7
    V
    3D
    BATTERY
    3C
    HARNESS
    6
    BN/GY
    R
    [126B]
    [126A]
    [1A]
    5
    4
    KEYSWITCH IGN RELAY
    3
    2
    [33B]
    1
    [1B]
    [33A]
    (BK)
    R
    A
    A
    R
    1F
    IGNITION
    1E
    R/GY
    B
    B
    R/GY
    12
    GY
    R/BK
    R/BK
    C
    11
    C
    R/BK
    10
    D
    D
    9
    TO
    8
    IGNITION
    INTERCONNECT
    7
    SWITCH, DOM
    HARNESS
    6
    START RELAY
    (2A)
    5
    TN/GN
    S
    85
    4
    BK/R
    U
    86
    IGNITION SWITCH LEGEND (DOM)
    3
    R/GY
    E
    30
    2
    BK/R
    T
    87A
    "X" INDICATES CONTINUITY
    1
    GN
    K 87
    BETWEEN LEAD WIRES
    SWITCH
    IN POSITION INDICATED
    [2B]
    POSITION
    RED
    RED/
    RED/
    (GY)
    [123B]
    [123A]
    GRAY
    BLACK
    LOCK
    X
    OFF
    X
    IGN
    X
    X
    X
    ACC
    X
    X
    [156A]
    1 2 3
    4 5 6
    1
    2
    3
    4
    5
    6
    7
    8
    9 1011 12
    [39B]
    1 2 3
    4 5 6
    [7A]
    [156B]
    1 2 3 4 5 6 7
    8
    MAIN FUSE BLOCK
    INTERCONNECT
    HARNESS
    TO REAR
    LIGHTING
    [7B]
    P&A
    IGN
    RADIO PWR
    10A
    BRAKE
    BRAKE
    RELAY
    RELAY
    15A
    15A
    BATTERY
    RADIO MEM
    15A
    15A
    15A
    P&A
    ACCESS.
    CRUISE/BRK
    15A
    15A
    15A
    15A
    HEADLAMPS IGN
    LIGHTS
    INSTRUMENTS
    SPEEDOMETER
    BATTERY
    TO IGNITION
    HARNESS
    R
    SPEEDOMETER
    (CARBURETED
    VEHICLES)
    OR TO
    MAXI-FUSE
    1 2
    3 4
    5 6
    7
    8 9101112
    [39B]
    ECM HARNESS
    STARTER
    40 A
    (EFI
    VEHICLES)
    [128]
    1 2
    3 4
    5 6
    7 8
    9 101112
    [8A]
    [5B]
    RIGHT
    B A
    LEFT
    GROUND
    STUDS
    [64B]
    BATTERY 15A
    3C
    3D
    BN/GY
    R
    IGNITION
    OPTIONAL
    POWER
    A
    BN/GY
    SECURITY
    SIGNAL
    B
    LGN/BN
    IGN: 15A
    SWITCH (REAR VIEW)
    SIREN
    GROUND
    C
    BK
    GY
    1F
    1E
    R/BK
    [33A]
    [142A]
    [142B]
    A B I
    [33B]
    2D
    ACCY: 15A
    2C
    O/W
    R/GY
    P&A: 15A
    R/GY
    2J
    5
    IGNITION SWITCH LEGEND
    GN
    3H
    3
    POSITION
    A RED/GREY
    I RED/BLACK
    B RED
    3J
    ACCESSORY
    TN/GN
    1
    OFF
    [24A]
    IGNITION
    2H
    2
    1
    O/W
    TO LEFT
    2
    HAND
    3
    START
    CONTROLS
    4
    5
    W/V
    RELAY
    6
    [7A]
    BN
    1
    2
    V
    3
    TO REAR
    BK
    4
    LIGHTS
    [22A]
    5
    (7B)
    1
    O/W
    6
    TO RIGHT
    2
    7
    BK
    8
    HAND
    3
    CONTROLS
    4
    5
    W/BN
    6
    TURN SIGNAL/SECURITY
    MAIN FUSE BLOCK
    MODULE
    [30A]
    [30B]
    TS/TSSM
    BATTERY
    1
    BN/GY
    IGNITION
    2
    GY
    P&A
    IGN
    VSS / SERIAL DATA LINK
    3
    LGN/V
    SECURITY INDICATOR
    4
    BN/V
    BRAKE
    BRAKE
    LEFT TURN FEED
    5
    V
    RELAY
    RELAY
    RIGHT TURN FEED
    6
    BN
    BATTERY
    START
    15A
    RIGHT TURN SWITCH INPUT
    7
    W/BN
    LEFT TURN SWITCH INPUT
    8
    W/V
    [21A]
    START
    RELAY
    START RELAY CONTROL
    9
    TN/GN
    RELAY
    15A
    15A
    15A
    IGNITION ENABLE SIGNAL
    10
    1
    2 3
    4 5
    6 7
    8
    P&A
    ACCESS.
    CRUISE/BRK
    ALARM SIGNAL
    11
    LGN/BN
    TO INDICATOR
    15A
    15A
    15A
    15A
    GROUND
    12
    BK
    LAMPS
    HEADLAMPS IGN
    LIGHTS
    INSTRUMENTS
    [31A]
    1
    BK
    2
    BN
    TO FRONT
    3
    TURN
    4
    SIGNALS
    5
    V
    6
    BK
    HOME
    Diagnostic Notes:
    hd41354
    All Turn Signal Flow Charts
    The reference numbers below correlate with the circled num-
    bers on the turn signal flow charts.
    NOTE
    It is necessary to fabricate an adapter harness to connect the
    SPEEDOMETER TESTER (Part No. HD-41354) to the 3-
    place vehicle speed sensor connector [65]. See 2.6 SPEED-
    OMETER PERFORMANCE CHECK for instructions on fabri-
    cating this adapter harness.
    1.
    Gain access to vehicle’s TSM/TSSM. Perform the follow-
    ing procedure:
    a. See Figure 3-30. Position TSM/TSSM in same ori-
    Figure 3-29. Speedometer Tester
    entation it is mounted on vehicle. Turn on ignition
    switch. Turn on 4-way flashers by depressing both
    10095
    left and right turn signal switches simultaneously.
    Turn ignition off; 4-way flashers should continue to
    flash.
    b. Tilt module greater than 45 degrees to the left.
    c. Repeat step a.
    d. Tilt module greater than 45 degrees to the right.
    2.
    Connect SPEEDOMETER TESTER
    (Part No. HD-
    45o
    45o
    41354) to connector [65B]. Turn on ignition switch. set
    RUN/STOP switch to the RUN position. Use SPEEDOM-
    ETER TESTER to input a signal which duplicates a
    speed greater than or equal to 20 MPH (32.2 KPH).
    Enter 528 into the tester. If turn signals are working cor-
    rectly, they will flash 20 times and then cancel.
    3.
    To enable diagnostic mode, see 3.10 SPEEDOMETER
    SELF DIAGNOSTICS.
    Figure 3-30. Tilting TSM/TSSM
    4.
    Connect BREAKOUT BOX (Part No. HD-42682) (gray)
    between TSM/TSSM connector [30A] and wiring harness
    connector
    [30B]. See
    3.11 BREAKOUT BOX: TSM/
    TSSM.
    5.
    Closely inspect handlebar controls for pinched wiring.
    6.
    Remove BREAKOUT BOX (Part No. HD-42682) (gray)
    from between TSM/TSSM connector [30A] and wiring
    harness connector [30B]. Reconnect [30].
    7.
    Connect BREAKOUT BOX (Part No. HD-42682) (black)
    between wiring harness connector [24A] and left hand
    control harness connector [24B]. On FLHR/C/S use 6-
    pin Harness Adapters (Part no. HD-42962) to mate han-
    dlebar controls to Breakout Box.
    8.
    Connect BREAKOUT BOX (Part No. HD-42682) (black)
    between wiring harness connector [22A] and right hand
    control harness connector [22B]. On FLHR/C/S use 6-
    pin Harness Adapters (Part no. HD-42962) to mate han-
    dlebar controls to Breakout Box.
    9.
    Check for corrosion at rear lighting harness connector
    [7], front lighting harness connector [31] and TSSM [30].
    2004 Touring: TSM & TSSM
    3-49
    HOME
    Turn Signal Error 1A (Part 1 of 2)
    WILL NOT CANCEL UPON TURN COMPLETION
    Is TSM/TSSM mounted properly?
    YES
    NO
    Check if TSM/TSSM is configured for
    Mount
    solo or side car operation. See 3.3
    correctly.
    TSM/TSSM VEHICLE DELIVERY.
    Proper configuration?
    YES
    NO
    Select proper
    1
    Do 4-way flashers cancel in both directions?
    vehicle
    configuration.
    YES
    NO
    Replace TSM/TSSM.
    Perform setup and
    Activate either turn signal. Turn signals
    password learn.
    should cancel after 20 flashes.
    2
    Do turn signals cancel?
    YES
    NO
    Does speedometer
    register vehicle speed?
    YES
    NO
    STOP
    Go to Turn Signal
    Replace TSM/TSSM.
    Refer to 2.2 INITIAL
    Error 1A (Part 2 of 2).
    Perform password learn
    DIAGNOSTIC CHECK:
    3
    and setup.
    SPEEDOMETER.
    3-50
    2004 Touring: TSM & TSSM
    HOME
    Turn Signal Error 1A (Part 2 of 2)
    CANCELS ERRATICALLY
    Continued from Turn Signal Error 1A (Part 1 of 2).
    ● Check for voltage between Breakout Box cavity 8
    (gray) and ground at Breakout Box cavity 12 (gray):
    with left turn signal switch depressed, wiggle harness
    4
    between TSM/TSSM and left handlebar switches while
    monitoring for voltage fluctuations or changes in turn
    signal flash pattern.
    ● Check for voltage between Breakout Box cavity 7
    (gray) and ground at Breakout Box cavity 12 (gray):
    with right turn signal switch depressed, wiggle harness
    between TSM/TSSM and right handlebar switches
    while monitoring for voltage fluctuations or changes in
    turn signal flash pattern.
    Are voltage fluctuations present?
    YES
    NO
    ● Check for voltage between Breakout Box cavity 8 (gray)
    Locate and repair
    5
    and ground at Breakout Box cavity 12 (gray): with left turn
    intermittent open.
    signal switch NOT depressed, wiggle harness between
    TSM/TSSM and left handlebar switches while monitoring
    for voltage fluctuations or turn signal activation.
    ● Check for voltage between Breakout Box cavity 7 (gray)
    and ground at Breakout Box cavity 12 (gray): with right turn
    signal switch NOT depressed, wiggle harness between
    TSM/TSSM and right handlebar switches while monitoring
    for voltage fluctuations or turn signal activation.
    Are voltage fluctuations present?
    YES
    NO
    Locate and repair
    ● Turn ignition switch OFF.
    5
    intermittent short to
    ● Check for continuity between Breakout Box cavity 8
    voltage.
    (gray) and ground at Breakout Box cavity 12 (gray):
    with left turn signal switch depressed, wiggle harness
    between TSM/TSSM and left handlebar switches.
    ● Check for continuity between Breakout Box cavity 7
    (gray) and ground at Breakout Box cavity 12 (gray):
    with right turn signal switch depressed, wiggle har-
    ness between TSM/TSSM and right handlebar
    switches.
    Is continuity present at any time?
    YES
    NO
    Locate and repair
    System OK.
    intermittent short to
    Review turn signal cancellation
    ground.
    function with customer. See
    AUTOMATIC CANCELLATION
    under 3.4 TSM/TSSM TURN
    SIGNAL FUNCTIONS.
    2004 Touring: TSM & TSSM
    3-51

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    Матвей Александрович04.06.2024 07:02
    Политика конфиденциальности