Harley Davidson 2004 Touring Models. Service Manual — page 18
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DIAGNOSTIC MODE GROUP 2
Input Bits
GENERAL
When the radio Diagnostic Mode is first accessed, Diagnostic
Group 1 appears on the LCD display, as indicated by the “d1”
in the lower portion. Push the LO/DX
button on the front panel
to sequence to Diagnostic Group 2.
See Figure 6-5.
The upper portion of the Diagnostic Group 2 display shows a
line of eight input bits each of which
correlates to a particular
switch function. The characters “d2”
appear in the lower por-
tion.
SAMPLE DIAGNOSTIC
Diagnostic Mode Group 2
f2122x8x
Operate the switch while observing the input bit. The input bit
Figure 6-5. Front Panel LCD Display
to watch correlates with the position of the switch in the line.
For example, the INTERCOM OFF/ON SWITCH is the fifth
input bit from the left hand side. If the input bit toggles
Unlike the Diagnostic Group 1 input bits, whether the problem
between “1” and “0” as the console mounted rocker switch is
is a short to ground, a short to +12 volts or an open is not so
turned ON and then OFF, respectively, then the switch is
readily apparent. See Figure 6-6 for further explanation of the
functioning normally. However, if the switch is locked on “1” or
Diagnostic Group 2 input bits and then refer to the appropri-
“0,” then a problem exists.
ate flow chart under SOFTWARE DIAGNOSIS.
Not Applicable to Classic/Road Glide Models
10=Headset
11=Speaker
0=PTT
0 or 1
1=Break
1=ON
1=ON
01=Center
AVC
HAND-
CB
INTERCOM
CB
SPEAKER
SPEAKER
VEHICLE
VOX
HELD MIC.
SQUELCH
OFF/ON
OFF/ON
SWITCH
SWITCH
SPEED
BREAK
PTT
BREAK
SWITCH
SWITCH
“B”
“A”
SIGNAL
7
6
5
4
3
2
1
0
(BE/Y)
(W/GN)
Internal
Internal
Internal
Internal
(BN/O)
(V/O)
Diagnostic Mode 2, which displays the logic states of various
●
* CB Squelch Break: When CB receives signal strong
signals, functions as follows (left to right):
enough to exceed threshold (set by squelch level setting),
● Handheld Microphone PTT: input bit on LCD appears as
input bit on LCD appears as “1.” When CB Squelch is not
“1” when PTT button is not depressed, “0” when button is
broken, display appears as “0.”
depressed. (This should not be confused with the handle-
● Intercom OFF/ON: When switch is ON, input bit on LCD
bar mounted PTT Switch.)
display appears as
“1.” When switch is OFF, display
● AVC Vehicle Speed Signal: Input bit normally toggles
appears as “0.”
between “1” and “0” as the rear wheel is rotated greater
● CB OFF/ON: When switch is ON, input bit on LCD
than 3 mph. The rate at which it toggles is proportional to
appears as “1.” When switch is OFF, display appears as
the speed of the wheel.
“0.”
●
* VOX Break: When the microphone signal is strong
● Speaker Switch A, Speaker Switch B: When fairing cap
enough to exceed threshold
(set in Intercom Set Up
rocker switch is in the HEADSET position, input bits on
Mode), input bit on LCD appears as “1.” When VOX is not
LCD display appears as “10.” Display is
“11” in the
broken, display appears as “0.”
SPEAKER position and “01” in the Center position.
* CB or Intercom must be turned on and VOX or Squelch settings must be established before entering diagnostic mode.
Figure 6-6. Diagnostic Mode Group 2
6-4
2004 Touring: Sound System
HOME
BREAKOUT BOX
6.3
GENERAL
hd44608
The RADIO BREAKOUT BOX (Part No. HD-44608), used in
conjunction with a DVOM, allows circuit diagnosis without
having to probe connectors with sharp objects. See Figure 6-
7.
INSTALLATION
1. Remove the outer fairing. See 2004Touring Service Man-
Figure 6-7. Radio Breakout Box (HD-44608)
ual (Part Number 99483-04).
2. Remove black connector
[27] from back of radio to
f2238x8x
release interconnect harness. See Figure 6-8.
Radio [28]
Ultra Only
3. Remove gray connector
[28] from back of radio to
release audio harness (Ultra models only).
4. Install black connectors on Breakout Box to black radio
Radio [27]
and interconnect harness connectors.
5. Install gray connectors on Breakout Box to gray radio and
audio harness connectors.
REMOVAL
1.
Remove Breakout Box between radio and wiring harness
connectors.
2.
Install black connector [27] at back of radio to connect
interconnect harness. See Figure 6-8.
3.
Install gray connector [28] at back of radio to connect
audio harness (Ultra models only).
4.
Install the outer fairing. See 2004Touring Service Manual
(Part Number 99483-04).
Figure 6-8. Radio Connections -
FLHTCU
RT FRONT HEADSET(+)
1
1 RT FRT SPEAKER (+)
FRT HEADSET COMMON 2
HANDLEBAR MATRIX
2 PUSH TO TALK (MIC)
LFT RR SPEAKER ()
3
C0
C1
C2
C3
C4
3 R0 (HANDLEBAR MATRIX)
RT RR SPEAKER()
4
4 R1 (HANDLEBAR MATRIX)
C4 (RR CNTL MATRIX)
5
R0
VOL UP
VOL DWN
MENU
UP TUNE / FF
5 R2 (HANDLEBAR MATRIX)
R1 (RR CNTL MATRIX)
6
6 C4 (HANDLEBAR MATRIX)
R1
DWN TUNE / REWIND
RR MIC SHIELD
7
7 C3 (HANDLEBAR MATRIX)
RR MIC COMMON
8
R2
SQUELCH UP
SQUELCH DWN
PUSH TO TALK
BAND
8 C2 (HANDLEBAR MATRIX)
LFT FRT HEADSET
9
9 VEHICLE SPEED SIGNAL
LFT RR SPEAKER (+) 10
10 BATTERY
RT RR SPEAKER (+) 11
11 GROUND
RR CONTROL MATRIX
C3 (RR CNTL MATRIX) 12
12 IGNITION
R0 (RR CNTL MATRIX) 13
C3
C4
13 HEADSET SPEAKERS B
R2 (RR CNTL MATRIX) 14
14 N/C
R0
RR VOL UP
UP TUNE / FF
FRT MIC SHIELD 15
15 N/C
RT RR HEADSET (+) 16
R1
RR VOL DWN
DWN TUNE / REWIND
16 LFT FRT SPEAKER (+)
LFT RR HEADSET (+) 17
17 LFT FRT SPEAKER ( )
RR HEADSET COMMON 18
R2
PUSH TO TALK
BAND
18 RT FRT SPEAKER (+)
N/C 19
19 GROUND
N/C 20
20 BATTERY
RR MIC 21
21 HEADSET SPEAKERS A
ULTRA RADIO
BASE RADIO
FRT MIC 22
22 C1 (HANDLEBAR MATRIX)
FRT MIC COMMON 23
CONNECTOR
CONNECTOR
23 C0 (HANDLEBAR MATRIX)
[28A]
[27A]
Figure 6-9. Radio Pinouts
2004 Touring: Sound System
6-5
HOME
RADIO SYMPTOM 1
6.4
GENERAL
Not Applicable to Classic/Road Glide Models
C4
C3
C2
C1
CO
Problem
(BN/W)
(O/BK)
(BN/BK)
(GY/GN)
(GN/BE)
Audio control inoperative.
REAR
RO
MODE UP
AUDIO
AUDIO
AUDIO
(PK/W)
VOLUME
FF
IN
-
+
UP
REAR
R1
MODE DN
RADIO
Setup
VOLUME
EJECT
LO/DX
(GY/W)
RW
POWER
DOWN
● Press the POWER button to turn the radio ON.
R2
MODE
SQUELCH
SQUELCH
SEEK
(V/BK)
PTT
IN
DOWN
UP
SCAN
● Press and hold the CB button to turn the Citizen Band
R3
NOT
PRESET
PRESET
PRESET
PRESET
(INT)
USED
4
3
2
1
radio OFF. Press and hold the INT button to turn the
Intercom OFF.
● Set fairing mounted Headset/Speaker Switch to
Figure 6-10. Diagnostic Mode Group 1 Switch Matrix
SPEAKER.
f2123x8x
C2
C0
Functionality
Locate the Audio Control Switch on the left handlebar. Push
the switch in to sequence to Bass, Treble, Fader and then
back to Volume. The front panel LCD display indicates the
function selected.
Momentarily push the switch upward (+)
to raise the volume,
downward (-) to lower the volume. The front panel LCD
annunciates volume level through a horizontal bar graph dis-
play and stereo audio should be present in all four speakers
(front speakers on non-Ultra). The display reverts to the time
C1
of day approximately two seconds after the switch is
released.
Figure 6-11. Audio Control Switch Input Bits
Are these your observations?
● Yes - System is OK. See Section 6.6 RADIO SYMPTOM
3.
2.
Install BREAKOUT BOX (Part No. HD-44608). See Sec-
● No - See Test 6.4 (Part 1 of 2).
tion 6.3 BREAKOUT BOX, INSTALLATION.
3.
Revalidate failure. Reconnect all connectors. If problem
still exists, replace radio. If problem is gone, look for
DIAGNOSTICS
intermittents.
4.
Use HARNESS CONNECTOR KIT (Part No. HD-41404),
black pin probes and patch cord.
Diagnostic Notes
The reference numbers below correlate with the circled num-
bers in the Test 6.4 flow charts.
1. This also may be an open. First go to SHORT TO VOLT-
AGE in Test 6.4 (Part 2 of 2).
6-6
2004 Touring: Sound System
HOME
Test 6.4 (Part 1 of 2)
AUDIO CONTROL INOPERATIVE: SOFTWARE DIAGNOSIS
Enter Diagnostic Mode
by Pressing Any Two Pre-
set Buttons While Turning
Ignition Switch to On.
Look at Input Bits C0,
C1 and C2 in LCD
Display. See Figure 6-
11. Do Any of the
Input Bits Display “0?”
YES
NO
Move to Test 6.4 (Part 2 of 2). Find
Exercise All Three Posi-
Short to Ground on Any Wire Where
tions of AUDIO CON-
Corresponding Input Bit Displays “0”
TROL SWITCH. Do All of
(With No Switches Depressed).
the Corresponding Input
Bits Toggle Between “1”
Switch
Input
Wire
and “0?”
Position
Bit
Color
Audio +
C0
GN/BE
Audio -
C1
GY/GN
YES
NO
Audio In
C2
BN/BK
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 6.4
1
Move to Test 6.4 (Part 2 of 2). Find
(Part 2 of 2).
Short to Voltage on Wire Where
Find Short to
Corresponding Input Bit Displays “1.”
Ground on R0
(PK/W) Wire.
Switch
Input
Wire
Position
Bit
Color
Audio +
C0
GN/BE
Audio -
C1
GY/GN
Audio In
C2
BN/BK
All Positions
All
PK/W
Table 6-2. Wire Harness Connectors
NO.
DESCRIPTION
MODEL
TYPE
LOCATION
Interconnect Harness to Left
FLHTC/U
12-Place Deutsch (Gray)
Inner Fairing- Left Fairing Support Brace
[24]
Handlebar Switch Controls
FLTR
12-Place Deutsch (Gray)
Inner Fairing- Left Side of Radio Bracket
[27]
Radio
All
23-Place Amp (Black)
Inner Fairing- Back of Radio (Right Side)
2004 Touring: Sound System
6-7
HOME
Test 6.4 (Part 2 of 2)
AUDIO CONTROL INOPERATIVE: HARDWARE DIAGNOSIS
What Did Test 6.4 (Part 1 of 2)
Indicate?
SHORT to VOLTAGE
SHORT to GROUND
Remove Outer Fairing. Connect Breakout Box
2
2
Remove Outer Fairing. Connect
leaving Connector [27B] disconnected from
Breakout Box leaving Connector
Radio. With Key ON, Check for Power at Con-
[27B] disconnected from Radio. With
nector [27B]. Is Voltage Present?.
Key OFF, Check for Continuity
to Ground on Breakout Box at
To
Connector [27B].
From
Terminal
(-)
To
(+)
From
Terminal
3 (PK/W)
3 (PK/W)
8 (BN/BK)
Ground
8 (BN/BK)
22 (GY/GN)
Ground
22 (GY/GN)
23 (GN/BE)
23 (GN/BE)
Any Continuity Present?
YES
NO
YES
NO
4
Disconnect [24]. With Key
OPEN
Disconnect [24]. With Key
3
ON, Check for Power at
Replace
Connector [24B]. Is Voltage
OFF, Check for Continuity
Radio.
Present?.
Disconnect Connector [27]. from radio
to Ground at Connector
With Switch Depressed, Check for
[24B]. Any Continuity
6601
To
Continuity at Connector [27B].
Present?
From
Terminal
(-)
Switch
From
To
To
(+)
From
Position
Terminal
Terminal
Terminal
8 (BN/BK)
(-)
Audio +
3 (PK/W)
23 (GN/BE)
(+)
9 (PK/W)
Ground
Audio -
3 (PK/W)
22 (GY/GN)
8 (BN/BK)
10 (GN/BE)
Audio In
3 (PK/W)
8 (BN/BK)
9 (PK/W)
11 (GY/GN)
Ground
10 (GN/BE)
Each Wire Pair Should be Less than 0.5
11 (GY/GN)
Ohms While Switch is Depressed and
4
Infinity While Switch is Open. Is It?
YES
NO
YES
NO
Locate and
Locate and
YES
NO
Repair Short
Repair Short
Locate and
Locate and
in Handlebar
in Interconnect
3
Replace
Disconnect [24]. With Switch Depressed,
Repair Short in
Repair Short
Harness.
Harness.
Radio.
Check for Continuity at Connector [24B].
Handlebar
in Interconnect
6551
6531
Harness.
Harness.
6601
Switch
From
To
Position
Terminal
Terminal
6551
6531
Audio +
9 (PK/W)
10 (GN/BE)
Audio -
9 (PK/W)
11 (GY/GN)
Audio In
9 (PK/W)
8 (BN/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 Audio
Open or Replace
Switch or
Interconnect
Repair Switch
Harness.
Wiring.
6532
5186
After correction of problem, refer to SETUP and
FUNCTIONALITY to verify proper operation.
6-8
2004 Touring: Sound System
HOME
RADIO SYMPTOM 2
6.5
GENERAL
Not Applicable to Classic/Road Glide Models
Problem
C4
C3
C2
C1
CO
(BN/W)
(O/BK)
(BN/BK)
(GY/GN)
(GN/BE)
Mode control inoperative.
REAR
RO
MODE UP
AUDIO
AUDIO
AUDIO
(PK/W)
VOLUME
FF
IN
-
+
UP
REAR
R1
MODE DN
RADIO
Setup
VOLUME
EJECT
LO/DX
(GY/W)
RW
POWER
DOWN
● Press the POWER button to turn the radio ON.
R2
MODE
SQUELCH
SQUELCH
SEEK
(V/BK)
PTT
IN
DOWN
UP
SCAN
● Press and hold the CB button to turn the Citizen Band
R3
NOT
PRESET
PRESET
PRESET
PRESET
radio OFF. Press and hold the INT button to turn the
(INT)
USED
4
3
2
1
Intercom OFF.
Figure 6-12. Diagnostic Mode Group 1 Switch Matrix
Functionality
Locate the Mode Select Switch on the right handlebar.
f2123x8x
Momentarily push the switch in to sequence between the AM,
C4
FM and WB bands. The LCD display indicates the band
selected.
Momentarily push the Mode Select Switch in an upward
direction (UP) to cause the receiver to increment one step on
the frequency scale. Similarly, push the
Mode Select Switch
in a downward direction (DN) to cause the receiver to decre-
ment one step on the frequency scale.
NOTE
In Intercom Setup Mode (Ultra models only), the UP and DN
functions adjust the VOX sensitivity level. Press UP to
increase microphone sensitivity, press DN to decrease sensi-
tivity. In CB Setup Mode, UP and DN allow for channel selec-
Figure 6-13. Mode Control Switch Input Bit
tion.
Are these your observations?
3.
Revalidate failure. Reconnect all connectors. If problem
● Yes - System is OK. See Owner’s Manual.
still exists, replace radio. If problem is gone, look for
intermittents.
● No - See Test 6.5 (Part 1 of 4).
4.
Mode Control switch is integral part of sidecar amplifier.
Replace sidecar amplifier if switch fails.
DIAGNOSTICS
5.
Use HARNESS CONNECTOR KIT (Part No. HD-41404),
black pin probes and patch cord.
Diagnostic Notes
6.
Use HARNESS CONNECTOR KIT (Part No. HD-41404),
black socket probes and patch cord.
The reference numbers below correlate with the circled num-
bers in the Test 6.5 flow charts.
1. To eliminate Rear Mode Control Switch from diagnosis,
disconnect Connector [28]. If problem is eliminated, see
REAR MODE CONTROL INOPERATIVE. If problem re-
mains, continue with present flow chart.
2. Install BREAKOUT BOX (Part No. HD-44608). See Sec-
tion 6.3 BREAKOUT BOX, INSTALLATION.
2004 Touring: Sound System
6-9
HOME
Test 6.5 (Part 1 of 4)
MODE CONTROL INOPERATIVE: SOFTWARE DIAGNOSIS
Enter Diagnostic Mode
by Pressing Any Two Pre-
set Buttons While Turning
Ignition Switch to On.
Look at Input Bit C4 in
LCD Display. See Fig-
ure 6-13. Does the
Input Bit Display “0?”
YES
NO
Move to Hardware Chart to Find
Exercise All Three Posi-
Short to Ground on Wire Where
tions of MODE CONTROL
Corresponding Input Bit Displays “0”
SWITCH. Does the Corre-
(With No Switches Depressed).
sponding Input Bit Toggle
Between “1” and “0” For
Switch
Input
Wire
Each Switch Position?
Position
Bit
Color
Mode Up
Mode Dn
C4
BN/W
YES
NO
Mode In
Switch and
Is it a “0” or a “1”
Wiring are OK.
While Switch Posi-
Replace Radio.
tion is Activated?
6601
0
1
Move to Hardware Chart to Find
Move to Hardware Chart to Find
Short to Ground on Wire Where
Short to Voltage on Wire Where
Corresponding Input Bit Displays “0.”
Corresponding Input Bit Displays “1.”
Switch
Input
Wire
Switch
Input
Wire
Position
Bit
Color
Position
Bit
Color
Mode Up
PK/W
Mode Up
PK/W
Mode Dn
C4
GY/W
Mode Dn
GY/W
C4
Mode In
V/BK
Mode In
V/BK
All Positions
BN/W
HARDWARE CHART
CONTINUE WITH
Front Mode Control
Test 6.5 (Part 2 of 4)
After correction of problem, refer to SETUP and
FUNCTIONALITY to verify proper operation.
Rear Mode Control
Test 6.5 (Part 3 of 4)
Sidecar Mode Control
Test 6.5 (Part 4 of 4)
Table 6-3. Wire Harness Connectors
NO.
DESCRIPTION
MODEL
TYPE
LOCATION
Inner Fairing - Fork Stem Nut
Interconnect Harness to Right
FLHTC/U
12-Place Deutsch (Black)
[22]
Lock Plate (Left Side)
Handlebar Switch Controls
FLTR
12-Place Deutsch (Black)
Inner Fairing- Right Side of Radio Bracket
[27]
Radio
All
23-Place Amp (Black)
Inner Fairing- Back of Radio (Right Side)
[28]
Radio
FLHTCU
23-Place Amp (Gray)
Inner Fairing- Back of Radio (Left Side)
Rear Left Speaker/Passenger
6-Place Mini-Deutsch
[42]
FLHTCU
Inside Rear Left Speaker Box
Controls
(Black)
6-10
2004 Touring: Sound System
HOME
Test 6.5 (Part 2 of 4)
FRONT MODE CONTROL INOPERATIVE: HARDWARE DIAGNOSIS
What Did Test 6.5
(Part 1 of 4)
Indicate?
SHORT to VOLTAGE
SHORT to GROUND
1
Remove Outer Fairing. Connect Breakout Box
1
Remove Outer Fairing. Connect Breakout Box
leaving [27B] disconnected from Radio. With
leaving [27B] disconnected from Radio. With
2
Key ON, Check for Power at Connector [27B].
2
Key OFF, Check for Continuity to Ground at
Connector [27B].
To
From
Terminal
To
(-)
From
(+)
Terminal
3 (PK/W)
3 (PK/W)
4 (GY/W)
4 (GY/W)
Ground
Ground
5 (V/BK)
5 (V/BK)
6 (BN/W)
6 (BN/W)
Is Voltage Present?
Any Continuity Present?
YES
NO
YES
NO
5
With Key ON, Check for
OPEN
5
3
With Key OFF, Check for
Replace
Power at Connector [22B].
Check for Continuity to
Radio.
Ground at Connector [22B].
To
With Switch Depressed, Check for
6601
From
Terminal
Continuity at Connector [27B].
To
(-)
(+)
From
Terminal
Switch
From
To
(-)
(+)
7 (BN/W)
Position
Terminal
Terminal
8 (GY/W)
7 (BN/W)
Ground
Mode Up
6 (BN/W)
3 (PK/W)
9 (PK/W)
8 (GY/W)
Mode Dn
6 (BN/W)
4 (GY/W)
Ground
10 (V/BK)
9 (PK/W)
Mode In
6 (BN/W)
5 (V/BK)
Is Voltage Present?
10 (V/BK)
Each Wire Pair Should be Less than
Any Continuity Present?
0.5 Ohms While Switch is Depressed
and Infinity While Switch is Open. Is It?
YES
NO
YES
NO
Locate and
Locate and
YES
NO
Repair Short in
Repair Repair
Locate and
Locate and
Handlebar
Short
Repair Short in
Repair Short
3
Replace
With Switch Depressed, Check for
Harness.
in Interconnect
Handlebar
in Interconnect
Harness.
Radio.
Continuity at Connector [22B].
Harness.
Harness.
6551
6531
6601
Switch
From
To
6551
6531
Position
Terminal
Terminal
Mode Up
7 (BN/W)
9 (PK/W)
Mode Dn
7 (BN/W)
8 (GY/W)
Mode In
7 (BN/W)
10 (V/BK)
Each Wire Pair Should be Less
than 0.5 Ohms While Switch is
Depressed and Infinity While
5
Switch is Open. Is It?
YES
NO
Locate and
Replace Mode
Repair or Replace
Switch or Repair
Interconnect
Switch Wiring.
Harness.
5183
After correction of problem, refer to SETUP and
6532
FUNCTIONALITY to verify proper operation.
2004 Touring: Sound System
6-11
HOME
Test 6.5 (Part 3 of 4)
REAR MODE CONTROL INOPERATIVE: HARDWARE DIAGNOSIS
What Did Test 6.5 (Part 1 of 4)
Indicate?
SHORT to VOLTAGE
SHORT to GROUND
2
Remove Outer Fairing. Connect Breakout Box leaving
2
Remove Outer Fairing. Connect Breakout Box
Connector [28B] disconnected from Radio.
leaving Connector [28B] disconnected from
With Key ON, Check for Power at Connector [28B].
Radio. With Key OFF, Check for Continuity to
Ground at Connector [28B].
To
From
Terminal
To
(-)
From
(+)
Terminal
(-)
13 (PK/W)
(+)
6 (GY/W)
13 (PK/W)
Ground
14 (V/BK)
6 (GY/W)
Ground
5 (BN/W)
14 (V/BK)
5 (BN/W)
Is Voltage Present?
Any Continuity Present?
YES
NO
YES
NO
Locate and
OPEN
Repair Short in
3
Locate and
Replace
Audio
Harness.
With Switch Depressed, Check for
Repair Short in
Radio.
Continuity at Connector [28B].
Audio
6601
6560
Harness.
Switch
From
To
Position
Terminal
Terminal
6560
Mode Up
5 (BN/W)
13 (PK/W)
Mode Dn
5 (BN/W)
6 (GY/W)
Mode In
5 (BN/W)
14 (V/BK)
Each Wire Pair Should be Less than
0.5 Ohms While Switch is Depressed
and Infinity While Switch is Open.
5
Is It?
YES
NO
3
Replace
Disconnect Connector [42]. With
Radio.
Switch Depressed, Check for
Continuity at Connector [42B].
6601
Switch
From
To
Position
Terminal
Terminal
Mode Up
4 (BN/W)
1 (PK/W)
Mode Dn
4 (BN/W)
2 (GY/W)
Mode In
4 (BN/W)
3 (V/BK)
Each Wire Pair Should be Less than
0.5 Ohms While Switch is Depressed
and Infinity While Switch is Open. Is It?
5
YES
NO
Locate and
Replace
Repair open
Mode Switch
or Replace
or Repair
Audio
Switch Wiring.
Harness.
6627
6561
After correction of problem, refer to SETUP and
FUNCTIONALITY to verify proper operation.
6-12
2004 Touring: Sound System
HOME
Test 6.5 (Part 4 of 4)
SIDECAR MODE CONTROL INOPERATIVE: HARDWARE DIAGNOSIS
What Did Test 6.5 (Part 1 of 4)
Indicate?
SHORT to VOLTAGE
SHORT to GROUND
5
Disconnect Connectors [42B]
6
Disconnect Connector [42B] and [42C].
and [42C]. With Key ON, Check
With Key OFF, Check for Continuity to
for Power at Connector [42B].
Ground at Connector [42C].
To
To
From
From
Terminal
Terminal
(-)
(+)
1 (PK/W)
1 (PK/W)
2 (GY/W)
Ground
2 (GY/W)
3 (V/BK)
Ground
3 (V/BK)
4 (BN/W)
4 (BN/W)
Any Continuity Present?
Is Voltage Present?
YES
NO
YES
NO
Replace Sidecar
Go to Test 6.5
Replace Sidecar
OPEN
Audio Harness or
(Part 3 of 4).”
Audio Harness or
Locate and Repair
Locate and
Short to Ground.
Repair Short to
Disconnect Connector [42]. With
6940
Voltage.
Sidecar Mode Switch Depressed, Check
for Continuity at Connector [42C].
6940
Switch
From
To
Position
Terminal
Terminal
Mode Up
4 (BN/W)
1 (PK/W)
Mode Dn
4 (BN/W)
2 (GY/W)
Mode In
4 (BN/W)
3 (V/BK)
Each Wire Pair Should be Less than 0.5
Ohms While Switch is Depressed and
Infinity While Switch is Open. Is It?
YES
NO
2
5
Reconnect Connector [42]. Remove
Remove Sidecar Speaker Console. Disconnect
Outer Fairing and Disconnect Connector
Connector [149] From Sidecar Speaker Amplifier.
6
[28]. With Switch Depressed, Check for
Check Continuity as Follows:
Continuity at Connector [28B].
FROM
TO
Switch
From
To
Connector
Terminal
Connector
Terminal
Position
Terminal
Terminal
15
1 (PK/W)
Mode Up
5 (BN/W)
13 (PK/W)
23
2 (GY/W)
Mode Dn
5 (BN/W)
6 (GY/W)
[149B]
[42C]
22
3 (V/BK)
Mode In
5 (BN/W)
14 (V/BK)
17
4 (BN/W)
Each Wire Pair Should be Less than 0.5
Continuity Present?
Ohms While Switch is Depressed and
Infinity While Switch is Open. Is It?
YES
NO
YES
NO
4
Replace
Locate and
Sidecar
Repair Open or
Replace
Locate and
Amplifier.
Replace Sidecar
Radio.
Repair Open in
Audio Harness.
Audio Harness.
6949
6601
6561
6940
After correction of problem, refer to SETUP and
FUNCTIONALITY to verify proper operation.
2004 Touring: Sound System
6-13
HOME
RADIO SYMPTOM 3
6.6
GENERAL
DIAGNOSTICS
Problem
Diagnostic Notes
No sound in one or more speakers (external).
The reference numbers below correlate with the circled num-
bers in the Test 6.6 flow charts.
1.
For input bit location see illustration inside flow chart.
Setup
2.
If both motorcycle speakers and sidecar speakers are
● Press the POWER button to turn the radio ON.
inoperative, first go to Test 6.6 (Part 2 of 3).
● Press and hold the CB button to turn the Citizen Band
3.
Perform following:
radio OFF. Press and hold the INT button to turn the
a. Impedance Check: With ohmmeter set on R x 1,
Intercom OFF.
measure impedance or resistance of the speaker
voice coil. Place probes of ohmmeter on the speaker
● Set fairing mounted Headset/Speaker Switch to
terminals and observe the reading. Reading must
SPEAKER (red lamp illuminated).
be 6-10 ohms. Replace the speaker if any other
● Set radio frequency to known strong station.
reading is observed.
● Set Volume and Fader to Middle position on horizontal
b. Cone Inspection: Inspect the speaker cone for
bar graph display.
damage. Replace the speaker if torn or warped.
Check for binding voice coil. Remove speaker and
● If performing sidecar diagnosis, rotate sidecar volume
place four fingers evenly across the face of the
control clockwise to middle or full volume position.
speaker cone. Very gently press inward evenly on
the cone. The cone must move smoothly without
binding. Release finger pressure. Cone must move
Functionality
outward smoothly. Replace the speaker if the cone
does not move without binding.
Sound should be audible in all speakers. Is it?
4.
Assumes Speaker Switch B input bit displays “0.”
● Yes - System is OK.
5.
Revalidate failure. Reconnect all connectors. If problem
● No - See Test 6.6 (Part 1 of 3).
still exists, replace radio. If problem is gone, look for
intermittents.
6.
Use HARNESS CONNECTOR KIT (Part No. HD-41404),
black pin probes and patch cord.
7.
Use HARNESS CONNECTOR KIT (Part No. HD-41404),
black socket probes and patch cord.
Not Applicable to Classic/Road Glide Models
10=Headset
11=Speaker
0=PTT
0 or 1
1=Break
1=ON
1=ON
01=Center
AVC
HAND-
CB
INTERCOM
CB
SPEAKER
SPEAKER
VEHICLE
VOX
HELD MIC.
SQUELCH
OFF/ON
OFF/ON
SWITCH
SWITCH
SPEED
BREAK
PTT
BREAK
SWITCH
SWITCH
“B”
“A”
SIGNAL
7
6
5
4
3
2
1
0
(BE/Y)
(W/GN)
Internal
Internal
Internal
Internal
(BN/O)
(V/O)
Figure 6-14. Diagnostic Mode Group 2 Matrix
6-14
2004 Touring: Sound System
HOME
Test 6.6 (Part 1 of 3)
NO SOUND IN ONE OR MORE SPEAKERS/SIDECAR SPEAKERS: SOFTWARE DIAGNOSIS
Is Vehicle Ultra or
Classic/Road Glide?
Ultra
Classic/Road Glide
NO
Does Any
Go to
Enter Diagnostic Mode 2 by
Speaker Work?
Test 6.6 (Part 2 of 3).
Holding Any Two Preset
Buttons and Turning Igni-
tion Switch to ON. Then
Push LO/DX Button Once
to Obtain “d2” in LCD.
YES
Are Both Speaker Switch A
1
and Speaker Switch B Dis-
Optional Side-
played in LCD as “1?”
car Speakers
Inoperative?
YES
NO
YES
NO
1
Is Handheld Micro-
Go to Test 6.6
phone PTT Displayed
(Part 2 of 3).
2
in LCD as “1?”
Go to Test 6.6
Go to Test 6.6
(Part 3 of 3).
(Part 2 of 3).
YES
NO
1
Is Intercom ON/OFF
Go to Test 6.17
Switch Displayed in
(Part 2 of 2).
LCD as “0?”
YES
NO
After correction of problem, refer to SETUP and
1
Is CB ON/OFF
Replace
FUNCTIONALITY to verify proper operation.
Switch Displayed
Radio.
in LCD as “0?”
6601
YES
NO
1
Go to
Replace
Test 6.6 (Part 2 of 3).
Radio.
6601
Speaker
Speaker
Switch B
Switch A
f2122x8x
Figure 6-15. Speaker Switch B and
Speaker Switch A Input Bits
2004 Touring: Sound System
6-15
HOME
Test 6.6 (Part 2 of 3)
NO SOUND IN ONE OR MORE SPEAKERS: HARDWARE DIAGNOSIS
Do Any
Speakers
Work?
YES
NO
Individual Speakers Inoperative
Speaker Switch Malfunction
4
Measure Voltage at
With Ignition Switch ON,
Speaker Leads With
Measure Voltage Between
Reference to Ground.
BN/O Wire on Connector [105]
Is 5-7 volts DC
(While Connected) and
Present?
Ground. Voltage Must Approxi-
mate Battery Voltage. Does It?
YES
NO
YES
NO
Perform
Connect Breakout Box to Harness Only,
Speaker Test.
Leaving Radio Disconnected. Check for
5
Replace
Disconnect Connector [105].
3
Speaker OK?
Continuity as Follows:
Radio.
Repeat Voltage Test on BN/O
Wire in Connector [105A].
Wire
6601
Voltage Must Approximate
Speaker
Connector
Terminal
Color
Battery Voltage. Does It?
YES
NO
Front
GY/R
[27B]
18
Right
L.GN/BK
[27B]
1
5
Replace
Replace
Front
W/O
[27B]
16
YES
NO
Radio.
Speaker.
Left
L.GN/W
[27B]
17
6601
Rear
GN
[28B]
11
Right
L.GN/BN
[28B]
4
Replace
Disconnect Connec-
Switch.
tor [27B]. Measure
Rear
W/BN
[28B]
3
Continuity to Ground
Left
BN
[28B]
10
5192
Front
Rear
on BN/O Wire in
Speaker.
Speaker.
Each Wire Should be Less than 0.5 Ohms.
Connector [105A].
Is It?
Continuity Present?
6605
6606
YES
NO
YES
NO
Locate and Repair
5
Replace
Grounded BN/O
Radio.
5
Replace
Locate and
Wire Between
Radio.
Repair Open
Connectors [105A]
6601
in Wire.
and [27B].
6601
6531
Front
Rear
Speaker.
Speaker.
6532
6561
After correction of problem, refer to SETUP and
FUNCTIONALITY to verify proper operation.
Table 6-4. Wire Harness Connectors
NO.
DESCRIPTION
MODEL
TYPE
LOCATION
[27]
Radio
All
23-Place Amp (Black)
Inner Fairing- Back of Radio (Right Side)
Inner Fairing - Below Upper Fork Bracket
Fairing Cap Switches
FLHTC/U
12 - Place Multilock
(Right Side)
[105]
Instrument Nacelle Switches
FLTR
12 - Place Multilock
Inside Instrument Nacelle (Under Bezel)
6-16
2004 Touring: Sound System
HOME
Test 6.6 (Part 3 of 3)
NO SOUND IN ONE OR MORE SIDECAR SPEAKERS: HARDWARE DIAGNOSIS
Do Any Sidecar
Speakers Work?
YES
Check for Continuity Between Each Speaker Terminal
6
and Connector [149B] as Follows:
FROM
TO
Amplifier
Speaker/
Speaker
Terminal
Terminal
Connector
input/Output
Connector
Left +
OUT
Speaker
Lt. BE/W
9
NO
Left -
OUT
Speaker
Lt. BE/BK
1
Right +
OUT
Speaker
Lt. GN/W
7
Right -
OUT
Speaker
Lt. GN/BK
8
6
Check for Power on [149B] at
[149B]
Left +
IN
[42D]
5 BN
3
Terminal 21 (+) and Terminal
Left -
IN
[42D]
6 W/BN
2
20 (-). With Ignition Switch ON,
Measure Voltage. Is Battery
Right +
IN
[41D]
5 GN
5
Voltage Present?
Right -
IN
[41D]
6 Lt. G/BN
4
Continuity Present?
YES
NO
6
Check for Continuity Between Connector [149B] and
Check for Continuity
YES
NO
Rear Speaker Connectors [41] and [42] as Follows:
Between Connector [149B]
Terminal 21 and Connector
Test Speakers.
Locate and
FROM
TO
[53D] O/V Wire. Also Check
Speakers OK?
Repair Open or
Speaker
Connector
Terminal
Terminal
Connector
for Continuity Between Con-
Replace Sidecar
Left +
5 BN
3
nector [149B] Terminal 20
Audio Harness.
[42D]
and Connector [53D] BK
Left -
6 W/BN
2
[149B]
Wire. Continuity Present on
6940
Right +
5 GN
5
[41D]
Both Wires?
YES
NO
Right -
6 Lt. G/BN
4
Continuity Present?
6
Replace
Replace
Sidecar
Sidecar
NO
Amplifier.
Speaker.
YES
NO
6949
6943
Locate and
Repair Open or
Replace
Locate and
Replace Sidecar
Sidecar
Repair Open or
Audio Harness.
Amplifier.
Replace Sidecar
YES
Audio Harness.
6940
6949
6940
Check for Continu-
ity to Ground on BK
Wire of Connector
[53A]. Continuity
Present?
7
YES
NO
Do Brake
Locate and
Lights Work?
Repair Open in
Ground Circuit.
6561
After correction of problem, refer to SETUP and
YES
NO
FUNCTIONALITY to verify proper operation.
Locate and
Check for
Repair Open
Blown Fuse.
on O/V Wire.
Replace if Nec-
essary.
6561
5145
2004 Touring: Sound System
6-17
HOME
RADIO SYMPTOM 4
6.7
GENERAL
AVC Adjustment Mode
Problem
Automatic volume control (AVC) inoperative.
Setup
● Press the POWER button to turn the radio ON.
● Press and hold the CB button
to turn the Citizen Band
radio OFF. Press and hold the INT button to turn the
Intercom OFF.
f2124x8x
Automatic Volume Level
● Set fairing mounted Headset/Speaker Switch to
SPEAKER (red lamp illuminated).
Figure 6-16. Adjust Automatic Volume Control
● Set radio frequency to known strong station.
● Set Volume and Fader to Middle position on horizontal
bar graph display.
If the AVC does not adequately compensate for ambient
noise (or if it overcompensates), adjust as follows:
Functionality
1.
Push any two Preset buttons on the front panel of the
To compensate for higher background noise, volume should
radio. With the buttons depressed, turn the Ignition/Light
increase with increasing motorcycle speed
(most evident
Key Switch to IGNITION. Diagnostic Group 1 appears on
above 40 MPH). Does it?
the LCD display, as indicated by the “d1” in the lower por-
tion.
● Yes - System is OK.
2.
Push the LO/DX button on the front panel of the radio
● No - See Test 6.7 (Part 1 of 2).
three times to sequence to the model year configuration
screen. “Press 1 for bikes before MY2004, press 2 for
NOTE
MY2004 and later” is displayed in the upper portion of
Since AVC function is not as obtrusive as that seen in previ-
the LCD display, while the current selection is displayed
ous model years, providing a very smooth transition from no
in the lower portion. If the number displayed is not cor-
AVC effect up to full AVC effect, it may be most easily
rect, simply change the display by pressing the appropri-
observed in the headsets (Ultra models only). To ramp the
ate preset button. Entering the wrong digit will adversely
affect AVC operation.
AVC up or down, that is, to change the rate of volume
increase, see Automatic Volume Control (AVC) Adjustment
3.
Push the LO/DX button two more times to sequence to
below.
the AVC adjustment screen. The letters “AVC” are dis-
played in the upper portion of the LCD display, while the
automatic volume level number appears in the lower por-
tion. See Figure 6-16.
DIAGNOSTICS
4.
To ramp the AVC up, press the Mode Select Switch on
the right handlebar in an upward direction (UP). To ramp
Automatic Volume Control (AVC)
the AVC down, press the switch in a downward direction
(DN). Although the factory presets the volume level at
Adjustment
number “2,” it is adjustable from “0” (AVC least aggres-
Active in CB, INTERCOM and music, Automatic Volume Con-
sive) to
“4”
(AVC most aggressive). Any adjustment
trol (AVC) automatically adjusts volume level to compensate
affects the AVC schedules of both headset and external
for ambient noise associated with motorcycle speed. Since
speakers.
wind and road noise is less of a factor with headset speakers,
5.
After making the desired change, continue pushing the
headset and external speakers are provided with separate
LO/DX button until the system reverts back to normal
AVC schedules.
radio operation. The Diagnostic Mode also can be exited
by simply turning the Ignition/Light Key Switch to OFF.
6-18
2004 Touring: Sound System
HOME
Diagnostic Notes
Test 6.7 (Part 1 of 2)
The reference numbers below correlate with the circled num-
AUTOMATIC VOLUME CONTROL (AVC)
bers in the Test 6.7 flow charts.
INOPERATIVE: SOFTWARE DIAGNOSIS
1. The circuit that recognizes the vehicle speed signal is the
same one that controls the AVC. If the bit alternates
between “0” and “1,” then the AVC is functioning as
1
Enter Diagnostic Mode 2.
designed.
Does AVC Bit in LCD Dis-
play Alternate Between “0”
2. Connect Speedometer Tester (HD-41354) to speedome-
and “1” When Rear Wheel
is Rotated.
ter sensor connector [65] located under the seat (3-place
Deutsch). Enter a speed greater than 40 MPH (see table
2-7), and observe speedometer needle and radio vol-
YES
NO
ume. Volume should begin to increase around 40 MPH
and further increase as indicated speed rises above 40
MPH.
2
Test Ride Above
Go to Test 6.7
40 MPH. Does
(Part 2 of 2)
3. To enable Diagnostic Mode, see 2.3 SPEEDOMETER
Volume Increase
With Speed?
SELF DIAGNOSTICS.
4. Install BREAKOUT BOX (Part No. HD-44608). See Sec-
YES
NO
tion 6.3 BREAKOUT BOX, INSTALLATION.
5. Use HARNESS CONNECTOR KIT (Part No. HD-41404),
No Problem. See Auto-
Does Model Year
matic Volume Control
Configuration
black pin probe and patch cord.
(AVC) Adjustment to
Screen Display 1
Change Rate of Volume
or 2?
Increase.
1
2
Change selection to
Replace
number 2. See step 2
Radio.
under Automatic Vol-
6601
ume Control (AVC)
Adjustment.
AVC Vehicle
Speed Signal
f2122x8x
Figure 6-17. LCD Input Bit Display
2004 Touring: Sound System
6-19
HOME
Test 6.7 (Part 2 of 2)
AUTOMATIC VOLUME CONTROL (AVC) INOPERATIVE: HARDWARE DIAGNOSIS
3
Perform speedometer self-
diagnostics in Section 2.3. Is
P0501 or P0502 set?
YES
NO
See P0501/P0502.
Disconnect ECM connector [78B].
4
Disconnect connector
[27]. Con-
nect Breakout Box. Measure volt-
age at Terminal
9. Is voltage
present?
YES
NO
Locate and repair
Measure continuity to ground from
short to voltage on
Terminal
9 on Breakout Box. Is
W/GN wire.
continuity present?
6531
YES
NO
Locate and repair
Check continuity between Termi-
5
short to ground on
nal 9 on Breakout Box and con-
W/GN wire.
nector
[65B], terminal B. Is
continuity present?
6531
YES
NO
Replace
Locate and
radio.
repair open
on W/GN
6601
wire.
After correction of problem, refer to SETUP and
FUNCTIONALITY to verify proper operation.
6532
Table 6-5. FLHTC/U Wire Harness Connectors
NO.
DESCRIPTION
TYPE
LOCATION
[27]
Radio
23-Place Amp (Black)
Inner Fairing- Back of Radio (Right Side)
Under Right Side Cover
[65]
Speedometer Speed Sensor
3-Place Deutsch
(Behind Electrical Bracket)
[78]
ECM
36-Place Packard
Under Right Side Cover
6-20
2004 Touring: Sound System
HOME
RADIO SYMPTOM 5
6.8
GENERAL
1
2
Less than 1 ohm
Less than 1 ohm
on X1 scale
on X1 scale
Problem
3
Poor stereo reception.
Infinite on
X1000
scale
Setup
● Press the POWER button to turn the radio ON.
● Select AM mode.
● Set LO/DX Switch to LO(CAL).
● Select SEEK function and use MODE CONTROL
SWITCH to select station with strong signal.
f1859xed
Functionality
Figure 6-18. Antenna Test Hookup
Radio should lock onto strong station. Does it?
● Yes - System is OK.
● No - See Radio Antenna Test below. If antenna passes
Test 6.8
test, continue with the Test 6.8 flow chart.
POOR STEREO RECEPTION
DIAGNOSTICS
Antenna
OK?
Radio Antenna Test
YES
NO
A faulty antenna can cause poor reception. Check it in three
steps after cleaning the mast.
Replace
Repair/Replace
Radio.
Antenna.
1. See Figure 6-18. Set your ohmmeter to the X 1 scale and
6601
connect the leads as shown. If the reading is more than 1
ohm, replace the antenna or cable. If less than 1 ohm,
Replace
Replace
Mast.
Antenna
proceed to Step 2.
Cable.
6617
2. Using the same scale, connect the leads as shown. If the
6609
reading is greater than 1 ohm, replace the antenna or
cable. If less than 1 ohm, proceed to Step 3.
3. Set the meter to the X 1,000 scale and connect the leads
as shown. If the reading is not infinite, replace the
antenna or cable. If replacement parts are necessary,
retest after installation of new parts.
2004 Touring: Sound System
6-21
HOME
RADIO SYMPTOM 6
6.9
GENERAL
f2203x8x
Radio Memory
Radio Power
O/BE
R/O
Problem
No power.
Setup
● Turn the Ignition/Light Key Switch to IGNITION.
Functionality
The radio LCD should illuminate. The LCD should display the
time or an operational mode (radio, CD, etc.), depending on
the last state of the POWER button on the radio front panel.
The radio should toggle between the time display and an
Figure 8-19. Fuse Block (FLTR, FLHTC/U)
operational mode when the POWER button is repeatedly
pushed. Does it?
● Yes - System is OK.
3.
Install BREAKOUT BOX (Part No. HD-44608). See Sec-
● No - See Test 6.9 (Part 1 of 2).
tion 6.3 BREAKOUT BOX, INSTALLATION.
4.
Revalidate failure. Reconnect all connectors. If problem
still exists, replace radio. If problem is gone, look for
DIAGNOSTICS
intermittents.
5.
Use HARNESS CONNECTOR KIT (Part No. HD-41404),
Diagnostic Notes
black pin probes and patch cord.
The reference numbers below correlate with the circled num-
bers in the Test 6.9 flow charts.
1.
See Test 6.9 (Part 1 of 2).
2.
Perform tests to ensure that battery is fully charged.
6-22
2004 Touring: Sound System
HOME
Test 6.9 (Part 1 of 2)
NO POWER: SOFTWARE DIAGNOSIS
Does LCD Lighting
Illuminate?
YES
NO
Does Time Display
Do Other Lights
Appear in LCD?
Illuminate?
YES
NO
YES
NO
Push Power Button on
Does Opera-
Go to Test 6.9
Check Battery.
Radio Front Panel.
tional Mode
(Part 2 of 2).
Charge or
Did Radio Display
Appear in LCD?
Replace.
Change to Operational
Mode (i.e., Radio,
CD, Etc.)?
YES
NO
Power
Replace
YES
NO
OK.
Radio.
6601
Power
Access Radio
OK.
Diagnostic Mode
1. Were You
Successful?
YES
NO
With No Switches
Replace
Active, Are All Five
Radio.
Input Bits in LCD
6601
Displayed as “1?”
YES
NO
Push Each of the Switches in the Left Hand Column While Observing
Input Bit on Cx Line Displaying “0” in LCD is Grounded.
the LCD Display. Match Your Observations to the Table Below.
See Short to Ground in Associated Hardware Chart.
LCD Display
Cx Line
Hardware Chart
Push
1 = Short to Voltage
C0, C1, C2
Audio Control Inoperative
0 = Short
Switch
(1/0) = OK
(or Open Circuit Between Lines
C3
Rear Headset Volume/PTT Inoperative
to Ground
When Switch Closed Equals “0”)
Mode Control Inoperative
C4
Mode Up
OK
R0
R0 or C4
(if Front Mode Control OK, See Rear)
Rear Vol. -
OK
R1
R1 or C3
SQ -
OK
R2
R2 or C2
Audio -
OK
R0
R0 or C1
Audio +
OK
R0
R0 or C0
Do the Switches Work OK?
YES
NO
Replace
Go to Corresponding
Radio.
Hardware Diagnosis for
Switch That is Inoperative.
6601
After correction of problem, refer to SETUP and
FUNCTIONALITY to verify proper operation.
2004 Touring: Sound System
6-23
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