Harley Davidson 2018 softail models. Service manual — page 33
Refer to the table below for the content layout of this manual.
Generated list of chapters
Use the TABLE OF CONTENTS (which follows this FOREWORD) and the INDEX (at the back of this manual) to quickly
locate subjects. Chapters and topics in this manual are sequentially numbered for easy navigation.
For example, a cross-reference shown as 2.2 SPECIFICATIONS refers to chapter 2 CHASSIS, heading 2.2
SPECIFICATIONS.
For quick and easy reference, all pages contain a chapter number followed by a page number. For example, page 3-5
refers to page 5 in Chapter 3.
A number of acronyms and abbreviations are used in this document. See the Acronyms and Abbreviations for a list of
acronyms, abbreviations and definitions.
Special Tools
Description
Part Number
Qty.
DIGITAL TECHNICIAN II
HD-48650
1
WARNING
Stop the engine when refueling or servicing the fuel system. Do not smoke or allow open flame or sparks near
gasoline. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00002a)
Good preparation is very important for efficient service work. Start each job with a clean work area. This will allow the
repair to proceed as smoothly as possible. It will also reduce the incidence of misplaced tools and parts.
Clean a motorcycle that is excessively dirty before work starts. Cleaning will occasionally uncover sources of trouble.
Gather any tools, instruments and any parts needed for the job before work begins. Interrupting a job to locate tools or
parts is a distraction and causes needless delay.
NOTE
To avoid unnecessary disassembly, carefully read all related service information before repair work begins.
In figure legends, the number which follows the name of a part indicates the quantity necessary for one complete
assembly.
When servicing a vehicle equipped with the Harley-Davidson Smart Security System (H-DSSS), first disarm the
system. Keep the fob close to the vehicle or use DIGITAL TECHNICIAN II (Part Number:HD-48650) to disable
the system. Activate the system after service is completed.
In addition to the information presented in this manual, Harley-Davidson Motor Company will periodically issue service
bulletins to Harley-Davidson dealers. Service bulletins cover interim engineering changes and supplementary information.
Consult the service bulletins to keep your product knowledge current and complete.
WARNING
Harley-Davidson parts and accessories are designed for Harley-Davidson motorcycles. Using non-Harley-Davidson
parts or accessories can adversely affect performance, stability or handling, which could result in death or serious
injury. (00001b)
To achieve satisfactory and lasting repairs, carefully follow the service manual instructions and use only genuine Harley-
Davidson replacement parts. Behind the emblem bearing the words GENUINE HARLEY-DAVIDSON stand more than 100
years of design, research, manufacturing, testing and inspecting experience. This is your assurance that the parts you are
using will fit right, operate properly and last longer.
Statements in this manual preceded by the following words are of special significance.
WARNING
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
(00119a)
CAUTION
CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.
(00139a)
NOTICE
NOTICE indicates a potentially hazardous situation which, if not avoided, may result in property damage. (00140b)
NOTE
Refers to important information. It is recommended that you take special notice of these items.
Proper service and repair are important for the safe, reliable operation of all mechanical products. The service procedures
recommended and described in this manual are effective methods for performing service operations.
WARNING
Always wear proper eye protection when using hammers, arbor or hydraulic presses, gear pullers, spring compressors,
slide hammers and similar tools. Flying parts could result in death or serious injury. (00496b)
Some of these service operations require the use of tools specially designed for the purpose. These special tools should
be used when and as recommended. It is important to note that some warnings against the use of specific service
methods, which could damage the motorcycle or render it unsafe, are stated in this manual. However, remember that
these warnings are not all-inclusive. Inadequate safety precautions could result in death or serious injury.
Since Harley-Davidson could not possibly know, evaluate or advise the service trade of all possible ways in which service
might be performed, or of the possible hazardous consequences of each method, we have not undertaken any such broad
evaluation. Accordingly, anyone who uses a service procedure or tool which is not recommended by Harley-Davidson
must first thoroughly satisfy himself that neither his nor the operator's safety will be jeopardized as a result. Failure to do
so could result in death or serious injury.
WARNING
Read and follow warnings and directions on all products. Failure to follow warnings and directions can result in death
or serious injury. (00470b)
When reference is made in this manual to a specific brand name product, tool or instrument, an equivalent product, tool or
instrument may be substituted.
Special Tools
All tools mentioned in this manual with a part number beginning with "HD", "J" or "B" must be ordered through your
local Harley-Davidson dealer. Special tools may only be purchased, serviced or warrantied through a Harley-Davidson
dealer.
Specific use of special tools is not discussed in this manual. Refer to the tool instruction sheet for instructions. If the
tool instructions are misplaced, a copy can be obtained online at H-Dnet.com > My Toolbox > Edit > Bosch Tool Site.
LOCTITE Sealing and Threadlocking Products
Some procedures in this manual call for the use of LOCTITE products. If you have any questions regarding LOCTITE
product usage or retailer/wholesaler locations, contact Loctite Corp. at www.loctite.com.
Apple, Alcantara S.p.A., Allen, Amp Multilock, Bluetooth, Brembo, City Navigator, Delphi, Deutsch, Dunlop, Dynojet, Fluke,
G.E. Versilube, Garmin, Gunk, Hydroseal, Hylomar, iPhone, iPod, Kevlar, Lexan, Loctite, Lubriplate, Keps, K&N,
Magnaflux, Marson Thread-Setter Tool Kit, MAXI fuse, Molex, Michelin, MPZ, Mulitilock, nano, NGK, Novus, Packard,
Pirelli, Permatex, Philips, PJ1, Pozidriv, Road Tech, Robinair, S100, Sems, SiriusXM, Snap-on, Teflon, Threadlocker,
Torca, Torco, TORX, Tufoil, Tyco, Ultratorch, Velcro, X-Acto and XM Satellite Radio are among the trademarks of their
respective owners.
Bar & Shield, Boom!, Cross Bones, Cruise Drive, CVO, Digital Tech, Digital Technician, Digital Technician II, Dyna, Electra
Glide, Evolution, Fat Bob, Fat Boy, Forty-Eight, Glaze, Gloss, H-D, H-Dnet.com, Harley, Harley-Davidson, HD, Heritage
Softail, Iron 883, Low Rider, Milwaukee-eight, Night Rod, Nightster, Night Train, Profile, Reflex, Revolution, Road Glide,
Road King, Road Tech, Rocker, Screamin' Eagle, Seventy-Two, Softail, Sportster, Street Glide, Street Rod, Sun Ray,
Sunwash, Super Glide, SuperLow, Supersmart, Switchback, SYN3, TechLink, TechLink II, Tour-Pak, Tri Glide, Twin Cam
88, Twin Cam 88B, Twin Cam 96, Twin Cam 96B, Twin Cam 103, Twin Cam 103B, Twin Cam 110, Twin Cam 110B, Twin-
Cooled, Ultra Classic, V-Rod, VRSC and Harley-Davidson Genuine Motor Parts and Genuine Motor Accessories are
among the trademarks of H-D U.S.A., LLC.
All photographs, illustrations and procedures may not necessarily depict the most current model or component, but are
based on the latest production information available at the time of publication.
Since product improvement is our continual goal, Harley-Davidson reserves the right to change specifications, equipment
or designs at any time without notice and without incurring obligation.
Table 1. Fuel System Specifications
FUEL SYSTEM
TYPE
Recommended fuel
91 Octane
Table 2. Fuel Pump Pressure Specifications
RANGE
VALUE
Normal
376-425 kPa (54-62 psi)
Table 3. Idle Speed Specifications
ADJUSTMENT
RPM
Normal idle speed
850 Nominal, non-adjustable
Table 4. Battery Specifications
BATTERY
SPECIFICATIONS
Size
12 V/ 17.5 Ah/315 CCA
Type
Sealed, AGM (Absorbed glass mat) battery
Table 5. Spark Plug Specifications
SPARK PLUG
SPECIFICATIONS
Gap
.031-.035 in.
.80-.90 mm
Table 6. Spark Plug Cables
LOCATION
LENGTH
RESISTANCE
Left front and rear
187-194 mm (7.36-7.64 in)
1,840-5,085 Ω
Right front and rear
381-387 mm (15.00-15.24 in)
3,750-10,070 Ω
Table 7. Ignition Coil Specifications
WINDING
RESISTANCE
Primary resistance
0.2-0.5 Ω
Secondary resistance
5,500-8,000 Ω
Table 8. Starter Specifications
STARTER
SPECIFICATIONS
Cranking current
250 A maximum
Free current
90 A maximum
Table 9. Alternator Specifications
ALTERNATOR
VALUE
Three phase
42 A system
AC voltage output
16-28 VAC per 1,000 rpm
Stator coil resistance
0.1-0.3 Ω
Table 10. Regulator Specifications
REGULATOR
VALUE
Amperes @ 3,600 rpm
40-44 A
Voltage @ 3,600 rpm
14.1-14.5 V @ 24 °C (75.2 °F)
Table 11. Fuse Specifications
ITEM
RATING
Main
40 A
Battery
5 A
Battery tender
7.5 A
System
7.5 A
Use initial diagnostics as a starting point to efficiently troubleshoot concerns. A basic understanding of electronics and a
general knowledge of the vehicle are necessary to effectively use this manual.
NOTE
Certain diagnostic procedures require part removal. See the service manual for details.
Before diagnosing a concern, perform a general functional test of the vehicle to verify the concern. This will also identify
any other issues that may affect diagnostics. Use the procedures in this chapter for initial diagnostics.
NOTE
When working through a diagnostic procedure follow the steps in the order instructed. Never jump to a test in another
procedure. All "Go to test" statements refer to a test in that procedure.
NOTE
Always inspect connectors for backed out terminals, improper mating, inoperative locks, improperly formed or
damaged terminals, poor terminal-to-wire connection and damaged harnesses when disconnecting any connector.
1. Fuse Test
1. Verify all fuses are good.
2. Are all fuses good?
a. Yes. Go to Test 2.
b. No. Replace fuse. If fuse opens again, repair short to ground in that circuit.
2. Current DTC Test
1. Check for current DTCs. See Odometer Self-Diagnostics.
NOTE
Historic DTCs are not to be diagnosed unless the condition is reoccurring and intermittent.
2. Are current DTCs present?
a. Yes. Refer to Diagnostics.
b. No. Go to Test 3.
3. Odometer Function Test
1. Enter odometer self-diagnostics.
2. Did odometer self-diagnostics mode function properly?
a. Yes. Refer to Diagnostics.
b. No. Go to Test 4.
4. Odometer Inoperative Test
1. Turn IGN ON.
2. Does the odometer display illuminate?
a. Yes. Go to Test 7.
b. No. Go to Test 5.
5. Battery Power Test
1. Turn engine stop switch ON.
2. Does headlamp and/or tail lamp illuminate?
a. Yes. Go to Test 6.
b. No. Verify battery condition and connections. If all are good, see No Vehicle Power: DTC U0140.
6. Starter Test
1. Attempt to start vehicle.
2. Does starter crank?
a. Yes. See Description and Operation.
b. No. See Description and Operation.
7. LHCM Test
1. With IGN ON, operate all left hand control functions.
2. Do any left hand controls function properly?
a. Yes. All controls are operational except the trip switch. See Description and Operation.
b. No. All left hand control functions are inoperative. See Left Hand Controls Inoperative: DTC U0141.
Diagnostic Tips
The trip odometer reset switch is located in the left hand control module. The switch signal is sent to the
speedometer over the CAN bus. If there is a problem with the CAN bus, the odometer self-diagnostic mode may
not function.
For a quick check of instrument function, perform a "WOW" test by entering odometer self-diagnostics. Background
lighting will illuminate, gauge needles will sweep their full range of motion and all indicator lamps controlled by the
CAN circuit will illuminate.
If the instrument fails "WOW" test, check for battery power and ground to the instrument. If any feature in the IM is
non-functional, see Description and Operation.
Table 1. Diagnostic Trouble Codes (DTCs) and Fault Conditions
DTC
PRIORITY
FAULT CONDITION
SOLUTION
ORDER
B1101
206
LHCM turn signal bulb out
Description and
Operation
B1103
47
LHCM internal error
Description and
Operation
B1151
205
RHCM turn signal bulb out
Description and
Operation
B1153
46
RHCM internal error
Description and
Operation
B1200
37
IM internal fault
Description and
Operation
B1201
40
Internal fault - default cal
Description and
Operation
B1214
316
External indicator bar short to battery
Description and
Operation
B1215
317
External indicator bar open load
Description and
Operation
B1216
318
External indicator bar short to ground
Description and
Operation
B2102
4
System power output shorted high
Description and
Operation
B2103
5
System power output shorted low
Description and
Operation
B2104
6
System power output overloaded
Description and
Operation
B2106
257
L4 output open
Description and
Operation
B2107
225
L4 output shorted high
Description and
Operation
B2108
226
L4 output shorted low
Description and
Operation
B2109
227
L4 output overloaded
Description and
Operation
B2112
132
ACC output shorted high
Description and
Operation
B2113
134
ACC output shorted low
Description and
Operation
B2114
136
ACC output overloaded
Description and
Operation
B2116
92
Fuel pump output open
Description and
Operation
B2117
93
Fuel pump output shorted high
Description and
Operation
B2118
94
Fuel pump output shorted low
Description and
Operation
B2119
95
Fuel pump output overloaded
Description and
Operation
B2121
58
Starter output open
Description and
Operation
B2122
59
Starter output shorted high
Description and
Operation
B2123
60
Starter output shorted low
Description and
Operation
B2124
61
Starter output overloaded
Description and
Operation
B2127
243
E4 output shorted high
Description and
Operation
B2128
244
E4 output shorted low
Description and
Operation
B2129
245
E4 output overloaded
Description and
Operation
B2131
233
High beam output open
Description and
Operation
B2132
234
High beam output shorted high
Description and
Operation
B2133
235
High beam output shorted low
Description and
Operation
B2134
236
High beam output overloaded
Description and
Operation
B2136
229
Low beam output open
Description and
Operation
B2137
230
Low beam output shorted high
Description and
Operation
B2138
231
Low beam output shorted low
Description and
Operation
B2139
232
Low beam output overloaded
Description and
Operation
B2141
207
Left front turn signal output open
Description and
Operation
B2143
214
Left front turn signal output shorted low
Description and
Operation
B2144
215
Left front turn signal output overloaded
Description and
Operation
B2146
216
Right front turn signal output open
Description and
Operation
B2148
217
Right front turn signal output shorted low
Description and
Operation
B2149
218
Right front turn signal output overloaded
Description and
Operation
B2151
219
Left rear turn signal output open
Description and
Operation
B2153
220
Left rear turn signal output shorted low
Description and
Operation
B2154
221
Left rear turn signal output overloaded
Description and
Operation
B2156
222
Right rear turn signal output open
Description and
Operation
B2158
223
Right rear turn signal output shorted low
Description and
Operation
B2159
224
Right rear turn signal output overloaded
Description and
Operation
B2161
198
Brake lamp output open
Description and
Operation
B2163
199
Brake lamp output shorted low
Description and
Operation
B2164
200
Brake lamp output overloaded
Description and
Operation
B2168
172
Running lights output shorted low
Description and
Operation
B2169
173
Running lights output overloaded
Description and
Operation
B2172
237
H2 output shorted high
Description and
Operation
B2173
238
H2 output shorted low
Description and
Operation
B2176
239
Security antenna output open
Description and
Operation
B2177
240
Security antenna output shorted high
Description and
Operation
B2178
241
Security antenna output shorted low
Description and
Operation
B2183
249
G2 output shorted low
Description and
Operation
B2188
254
G3 output shorted low
Description and
Operation
B2193
257
H4 output shorted low
Description and
Operation
B2198
259
H3 output shorted low
Description and
Operation
B2206
51
Run/stop switch input open/shorted high
Description and
Operation
B2208
54
Run/stop switch input shorted low
Description and
Operation
B2210
55
Run/stop switch inputs both open
Description and
Operation
B2212
56
Run/stop switch inputs both closed
Description and
Operation
B2218
131
Neutral switch shorted low
Description and
Operation
B2223
197
Rear brake switch shorted low (light on)
Description and
Operation
B2226
247
BAS input open
BCM not configured
properly.
B2228
250
BAS input shorted low
BCM not configured
properly.
B2250
128
Clutch switch stuck
Description and
Operation
B2251
242
Horn switch stuck
Description and
Operation
B2253
228
FTP switch stuck
Description and
Operation
B2254
203
Left turn switch stuck
Description and
Operation
B2255
246
Trip switch stuck
Description and
Operation
B2259
206
Aux lamp switch stuck
Description and
Operation
B2260
57
Start switch stuck
Description and
Operation
B2261
204
Right turn switch stuck
Description and
Operation
B2262
196
Front brake switch stuck
Description and
Operation
B2263
202
Hazard switch stuck
Description and
Operation
B2270
27
BCM internal error
Description and
Operation
B2271
26
BCM voltage low
Description and
Operation
B2272
33
BCM/IM voltage high
Description and
Operation
B2274
49
Constant battery line error
Description and
Operation
C0562
38
ABS voltage low
Description and
Operation
C0563
40
ABS voltage high
Description and
Operation
C1014
183
ABS ECU relay error
Description and
Operation
C1021
191
ABS front WSS always zero
Description and
Operation
C1023
192
ABS rear WSS always zero
Description and
Operation
C1025
194
ABS front wheel speed intermittent
Description and
Operation
C1027
195
ABS rear wheel speed intermittent
Description and
Operation
C1029
193
ABS wheel speed difference too high
Description and
Operation
C1032
189
ABS front wheel speed circuit open/shorted
Description and
Operation
C1034
190
ABS rear wheel speed circuit open/shorted
Description and
Operation
C1040
184
ABS pump/motor error
Description and
Operation
C1055
39
ABS ECU internal error
Description and
Operation
C1061
185
ABS front apply solenoid circuit open/high
Description and
resistance
Operation
C1062
187
ABS front release solenoid circuit open/high
Description and
resistance
Operation
C1065
186
ABS rear apply solenoid circuit open/high resistance
Description and
Operation
C1066
188
ABS rear release solenoid circuit open/high
Description and
resistance
Operation
C1159
43
ABS invalid stored VIN
Description and
Operation
C1178
41
ABS no VIN received from ECM
Description and
Operation
C1184
42
ABS invalid VIN from ECM
Description and
Operation
P0031
153
Front HO2S low/open
Description and
Operation
P0032
156
Front HO2S shorted high
Description and
Operation
P0051
154
Rear HO2S low/open
Description and
Operation
P0052
155
Rear HO2S shorted high
Description and
Operation
P0107
100
MAP sensor failed low/open
Description and
Operation
P0108
101
MAP sensor failed high/open port
Description and
Operation
P0112
123
IAT sensor shorted low
Description and
Operation
P0113
125
IAT sensor high/open
Description and
Operation
P0117
102
ET sensor shorted low
Description and
Operation
P0118
107
ET sensor high/open
Description and
Operation
P0120
76
TPS 1 range error
Description and
Operation
P0122
74
TPS 1 low
Description and
Operation
P0123
75
TPS 1 high/open
Description and
Operation
P0131
157
O2 sensor low/engine lean (front)
Description and
Operation
P0132
159
Engine running rich (front)
Description and
Operation
P0134
161
Oxygen sensor high/open (front)
Description and
Operation
P0151
158
O2 sensor low/engine lean (rear)
Description and
Operation
P0152
160
Engine running rich (rear)
Description and
Operation
P0154
162
O2 sensor high/open (rear)
Description and
Operation
P0220
79
TPS 2 range error
Description and
Operation
P0222
77
TPS 2 low/open
Description and
Operation
P0223
78
TPS 2 high
Description and
Operation
P0261
96
Fuel injector low/open (front)
Description and
Operation
P0262
97
Fuel injector shorted high (front)
Description and
Operation
P0264
98
Fuel injector low/open (rear)
Description and
Operation
P0265
99
Fuel injector shorted high (rear)
Description and
Operation
P0325
139
Knock sensor front open circuit
Description and
Operation
P0327
140
Knock sensor front circuit low
Description and
Operation
P0328
141
Knock sensor front circuit high
Description and
Operation
P0330
142
Knock sensor rear open circuit
Description and
Operation
P0332
143
Knock sensor rear circuit low
Description and
Operation
P0333
144
Knock sensor rear circuit high
Description and
Operation
P0371
65
CKP sensor wrong number of pulses
Description and
Operation
P0374
64
CKP sensor no pulses
Description and
Operation
P0444
147
Purge solenoid low/open
Description and
Operation
P0445
148
Purge solenoid shorted high
Description and
Operation
P0462
174
Fuel sender shorted low
Description and
Operation
P0463
175
Fuel sender shorted high/open
Description and
Operation
P0502
137
VSS failed low
Description and
Operation
P0503
138
VSS failed high
Description and
Operation
P0505
148
Idle speed control - unstable
Loss of Idle Speed
Control
P0522
168
Engine oil pressure sensor/switch shorted low
Description and
Operation
P0523
169
Engine oil pressure sensor/switch shorted
Description and
high/open
Operation
P0562
127
ECM voltage low
Description and
Operation
P0563
34
ECM voltage high
Description and
Operation
P0572
202
Brake switch low
Description and
Operation
P0577
163
Cruise control input error
Description and
Operation
P0603
29
ECM EEPROM memory error
Description and
Operation
P0605
28
ECM FLASH memory error
Description and
Operation
P0641
62
5 Volt reference out of range
Description and
Operation
P0651
63
5 Volt reference 2 out of range
Description and
Operation
P1009
32
VTD disabled fuel due to bad password
General
P1270
67
TGS 2 A/D validation error
Description and
Operation
P1501
166
JSS low
Description and
Operation
P1502
167
JSS high/open
Description and
Operation
P1505
445
Power limit violation
Description and
Operation
P1510
447
ETC limited performance mode
Description and
Operation
P1511
448
ETC power management mode
Description and
Operation
P1512
449
ETC forced idle mode
Description and
Operation
P1514
87
ETC airflow error
Description and
Operation
P1600
66
ETC watchdog error
Description and
Operation
P1655
164
ACR solenoid low/open
Description and
Operation
P1656
165
ACR solenoid shorted high
Description and
Operation
P2100
82
ETC driver open circuit
Description and
Operation
P2101
83
ETC actuation error
Description and
Operation
P2102
84
ETC driver shorted low
Description and
Operation
P2103
85
ETC driver shorted high
Description and
Operation
P2105
446
ETC forced shutdown mode
Description and
Operation
P2107
68
ETC driver internal error
Description and
Operation
P2119
81
ETC actuator return error
Description and
Operation
P2122
69
TGS 1 low/open
Description and
Operation
P2123
70
TGS 1 high
Description and
Operation
P2127
71
TGS 2 low/open
Description and
Operation
P2128
72
TGS 2 high
Description and
Operation
P2135
80
TPS correlation error
Description and
Operation
P2138
73
TGS correlation error
Description and
Operation
P2176
86
ETC zero position learning error
Description and
Operation
P2300
88
Ignition coil driver low/open (front)
Description and
Operation
P2301
89
Ignition coil driver shorted high (front)
Description and
Operation
P2303
90
Ignition coil driver low/open (rear)
Description and
Operation
P2304
91
Ignition coil driver shorted high (rear)
Description and
Operation
U0001
1
CAN BUS error
Description and
Operation
U0002
16
CAN comm bus perf error
Description and
Operation
U0003
13
Network management monitoring
Description and
Operation
U0011
2
CAN bus low shorted to CAN bus high
Description and
Operation
U0100
7
Lost comm w/ECM
Description and
Operation
U0121
11
Lost comm w/ABS
Description and
Operation
U0140
3
Lost comm w/BCM
Description and
Operation
U0141
9
Lost comm w/LHCM
Description and
Operation
U0142
8
Lost comm w/RHCM
Description and
Operation
U0156
10
Lost comm w/speedo
Description and
Operation
U0157
14
Lost comm w/tach
Description and
Operation
U0300
15
Internal control module software incompatibility
Description and
Operation
Special Tools
Description
Part Number
Qty.
DIGITAL TECHNICIAN II
HD-48650
1
There are two levels of diagnostics.
The most sophisticated mode uses a computer-based diagnostic package called DIGITAL TECHNICIAN II (Part
Number:HD-48650).
The second mode requires using the odometer self-diagnostics. Speedometer, BCM, ECM and ABS (if equipped)
DTCs can be accessed and cleared.
See Figure 1 and Figure 2. All codes will be displayed with either a "c" or a "h" after them. This indicates a current or
historic code. Diagnostic procedures are designed for use with current DTCs. Current DTCs will frequently suggest part
replacement. When diagnosing a historic DTC, the procedures can be helpful but should not lead to part replacement
without verification that the part is faulty.
Figure 1. Current Code
Figure 2. Historic Code
Diagnostic Mode
1. To enter diagnostic mode, press and hold the trip odometer reset switch located on the left handlebar controls,
while turning the IGN ON.
NOTE
"IGN ON" means that the engine stop switch is set to RUN (although the engine is not running).
The trip odometer reset switch is located in the left hand control module. The switch signal is sent to the
speedometer over the CAN bus. Any CAN bus issues may interrupt odometer self-diagnostics.
2. Release the trip odometer reset switch. "diag" will appear on the odometer display.
3. Press and release the trip odometer reset switch. ECM will appear on the odometer display. It will have either a
"Y" or an "N" after it, depending if there are any ECM codes or not.
4. Quickly press and release the trip odometer reset switch to cycle through the modules. The modules include
the BCM, SPDO and ABS.
5. Once the desired module is displayed, press and hold the trip odometer reset switch.
6. If any DTCs are stored in the module, the odometer will display the DTC. Quickly pressing and releasing the
trip odometer reset switch will cycle through the stored DTCs.
NOTE
When reading DTCs be sure to note whether there is a "c" or a "h" behind the code.
7. When all the DTCs have been cycled the odometer will display "end".
8. To clear all the DTCs in that module press and hold the trip odometer reset switch, while a DTC is displayed. If
DTCs are not to be cleared quickly press and release the trip odometer reset switch. The part number of the
module will be displayed.
9. Press and release the trip odometer reset switch again to continue to the next module.
10. Make note of all DTCs. Clear all the DTCs and operate the vehicle to verify DTCs set and are current. Historic
DTCs are not to be diagnosed unless the condition is reoccurring and intermittent.
11. Turn the IGN OFF to exit diagnostic mode. If IGN is not turned off, vehicle will exit diagnostics mode when
vehicle starts moving.
Special Tools
Description
Part Number
Qty.
DIGITAL TECHNICIAN II
HD-48650
1
There are two types of DTCs: current and historic. The odometer self-diagnostics displays all codes and differentiates
between current and historic with a "c" for current and an "h" for historic. The computer-based diagnostic package called
DIGITAL TECHNICIAN II (Part Number:HD-48650) differentiates between these two types.
NOTE
Current DTCs reside in the memory of the ECM, BCM, instruments or ABS module (if equipped) until the DTC is
resolved.
DTCs are designated by a P, C, B or U depending on the type of code and what module sets them. The ECM sets
"P" codes to indicate issues monitored by the ECM. The ABS module sets "C" codes indicating an issue with the
ABS on the vehicle. The instruments or BCM can all set "B" codes. All the modules set "U" codes when there is
an issue causing the modules not to communicate properly.
Current
Current DTCs are those which presently disrupt motorcycle operation and are set during the current ignition cycle. To
determine if current DTCs are present, clear the DTCs and operate the vehicle within the parameters for setting the
DTC. See the appropriate diagnostic procedures for solutions.
Historic
If a particular problem happens to resolve itself, the active status problem is dropped and it becomes a historic DTC
rather than a current DTC. DTCs will also lose their current status when the ignition is turned off. If the problem still
exists when the ignition is turned ON, the code will show as current.
A historic DTC can be cleared by use of the odometer self-diagnostics or after a total of 40 error-free ignition cycles
(start and run cycle) have elapsed.
It is important to note that historic DTCs will exist whenever the system indicates the existence of a current fault. See
Multiple Trouble Codes if multiple DTCs are found.
Diagnostic procedures are designed for use with current DTCs. Current DTCs will frequently suggest part replacement.
When diagnosing a historic DTC, the procedures can be helpful but should not lead to part replacement without
verification that the part is faulty.
All DTCs are assigned a priority number to determine the order in which they should be diagnosed. If there are multiple
DTCs present, always diagnose the highest priority first. Refer to Diagnostics.
1. Complete the repair.
2. Restore connections.
3. Clear DTCs.
4. Start vehicle. Perform several cycles to verify a code did not return.
5. Perform odometer self-diagnostics test to verify repair and DTCs have been cleared. If any DTCs are still present,
refer to Diagnostics.
Clear DTCs after any diagnostic or repair procedure. The odometer is capable of displaying and clearing ECM, BCM, IM,
tachometer and ABS DTCs. Once the DTCs are cleared perform a road test to verify DTCs do not return. It is important to
perform a road test and not simply start the motorcycle since some DTCs may require vehicle speed or other inputs in
order to validate repair.
See Figure 1. The security lamp is controlled by the BCM. The security lamp will be turned on when non-emmisions
related current codes are present.
Figure 1. Security Lamp Operation
To diagnose ECM system problems, start by observing the behavior of the check engine lamp.
NOTE
"IGN ON" means that the engine stop switch is set to RUN (although the engine is not running).
When the IGN is turned ON, check engine lamp will illuminate.
Start engine, if it fails to turn off after start up, DTC exists.
Emissions related DTCs illuminate the check engine lamp for three warm up cycles after the DTC has transitioned
from current to historic.
1. See Figure 1. After engine startup, one of two events may occur.
a. The lamp turns off, which indicates there are no current fault conditions or stored DTCs currently detected
by the ECM.
b. If the lamp continues to illuminate and remains illuminated, a current or historic DTC exists.
2. See Code Types for a complete description of DTC formats.
NOTE
Some DTCs can only be fully diagnosed during actuation. For example, a problem with the ignition coil will be
considered a current fault even after the problem is corrected. The ECM will not know of its resolution until after the
coil is exercised by the vehicle start sequence. In this manner, there may sometimes be a false indication of the
current DTC.
Figure 1. Check Engine Lamp
If no DTCs are present, address any symptoms indicating a malfunction. Refer to Table 1.
Table 1. Symptom Table
CHAPTER
SYMPTOM
DIAGNOSTIC PROCEDURE
Serial Data
IM inoperative
Description and Operation
Left hand controls inoperative
Description and Operation
No vehicle power
Description and Operation
Odometer self-diagnostics
Description and Operation
inoperative
Starting and Charging
Battery runs down during use
Description and Operation
Low battery after extended IGN OFF
Description and Operation
Low or no charging
Description and Operation
Nothing clicks
Description and Operation
Overcharging
Description and Operation
Starter solenoid clicks
Description and Operation
Starter spins but does not engage
Description and Operation
Starter stalls or spins too slowly
Description and Operation
Instruments
High beam indicator always on
Description and Operation
High beam indicator inoperative
Description and Operation
Low fuel lamp always on
Description and Operation
Low fuel lamp flashes at steady rate
Fuel sender DTC set. See Description and
Operation.
Low fuel lamp inoperative
Description and Operation
Neutral lamp always on
Description and Operation
Neutral lamp inoperative
Description and Operation
No instrument power
Description and Operation
Odometer displays "DIAG" at IGN
Description and Operation
ON
Oil pressure lamp always on
Description and Operation
Oil pressure lamp inoperative
Description and Operation
One or all indicator lamps
Description and Operation
inoperative
Trip odometer functions inoperative
Description and Operation
Turn signal indicator always on
Description and Operation
Turn signal indicator inoperative
Description and Operation
Accessories, Horn, Lighting and
ACC power inoperative
Description and Operation
Security
Any hand control switch inoperative
Description and Operation
Auxiliary lamps inoperative
Description and Operation
Front running lamps inoperative
Description and Operation
High beam headlamp inoperative
Description and Operation
Horn always on
Description and Operation
Horn inoperative
Description and Operation
License plate lamp inoperative
Description and Operation
Low beam headlamp inoperative
Description and Operation
Rear running lamps inoperative
Description and Operation
Signature headlamp inoperative
Description and Operation
Stop lamp always on
Description and Operation
USB port inoperative
Description and Operation
Will not cancel upon turn
Description and Operation
completion, no DTCs
Engine Management
Engine cranks but will not start
Description and Operation
Erratic idle
Description and Operation
Hesitation or loss of power
Description and Operation
Misfire at idle or under load
Description and Operation
Side stand displayed on
Description and Operation
speedometer
Starts hard or emits black smoke
Description and Operation
Starts, then stalls
Description and Operation
ABS
ABS indicator always on or
Description and Operation
inoperative
Special Tools
Description
Part Number
Qty.
HD BATTERY DIAGNOSTIC
GRX-3110HD
1
STATION
FLUKE AC/DC CURRENT PROBE
HD-39617
1
DIGITAL MULTIMETER (FLUKE 78)
HD-39978
1
TEST CONNECTOR KIT
HD-41404
1
BREAKOUT BOX
HD-42682
1
BREAKOUT BOX ADAPTERS
HD-46601
1
ABS BREAKOUT BOX
HD-48642
1
DIGITAL TECHNICIAN II
HD-48650
1
WHEEL SPEED SENSOR TEST
HD-50341
1
LEAD
BREAKOUT BOX
HD-50390-1
1
BCM CABLE
HD-50390-2
1
BCM OVERLAY
HD-50390-2-P
1
ECM CABLE
HD-50390-4
1
ECM OVERLAY
HD-50390-4-P
1
INLINE SPARK TESTER KIT
HD-51724
1
GRX-3110 HD Battery Diagnostic Station
Follow the instructions in the HD BATTERY DIAGNOSTIC STATION (Part Number:GRX-3110HD) instruction manual
to perform a battery test. The test results include a decision on the battery condition.
Figure 1. Advanced Battery Conductance and Electrical System Analyzer Kit
HD-51724 Inline Spark Tester Kit
See Figure 2. The INLINE SPARK TESTER KIT (Part Number:HD-51724) is used to verify adequate spark at the
spark plug. Install the inline spark tester between front ignition coil cable and spark plug. Start engine and inspect
tester light. The light will flash on each spark event if power is transmitted to the plug. Remove inline spark tester and
install cable on plug. Repeat procedure for rear cylinder.
NOTE
The coil will not produce spark voltage with both spark plugs removed. When checking for spark, use the inline
spark tester with both plugs installed.
Figure 2. Spark Tester
HD-39978 Digital Multimeter (Fluke 78)
The DIGITAL MULTIMETER (FLUKE 78) (Part Number:HD-39978) is used for various tests throughout this manual.
Figure 3. Digital Multimeter (Fluke 78)
HD-39617 Fluke AC/DC Current Probe
The FLUKE AC/DC CURRENT PROBE (Part Number:HD-39617) is used to measure current draw. Used in
conjunction with DIGITAL MULTIMETER (FLUKE 78) (Part Number:HD-39978). Connect the current probe to
positive (+) and negative (-) input terminals on the multimeter. Position the rotary switch to mV dc (millivolt direct
current). Push the ON/OFF button and the ON indicator will illuminate. With the inductive jaws empty, turn the zero
adjust so that the multimeter reads 0.000 mV. Clamp the inductive jaws around the conductor that is being tested.
With the circuit activated read the multimeter display, 1 mV = 1 A.
Figure 4. Fluke AC/DC Current Probe
HD-41404 Harness Connector Test Kit
The TEST CONNECTOR KIT (Part Number:HD-41404) contains pin and socket terminals and stackable banana jack
patch cords used to test circuits. The pin and socket terminals are used to connect to various connectors used on the
vehicle. See the tool instruction sheet for specific terminal usage.
NOTE
Insert probe tip straight into the terminal cavity.
Do not wiggle or move the probe tip once it is inserted into the terminal.
Do not use more than one probe per terminal or cavity at one time.
HD-50341 Wheel Speed Sensor Test Lead
The WHEEL SPEED SENSOR TEST LEAD (Part Number:HD-50341) is a stackable banana jack patch cord with a
built in resistor to test the wheels speed sensor circuit. Used in conjunction with TEST CONNECTOR KIT (Part
Number:HD-41404), connect the test lead in place of the WSS when required during diagnostics.
Figure 5. Wheel Speed Sensor Test Lead
HD-42682 Breakout Box (Instruments)
The BREAKOUT BOX (Part Number:HD-42682) and BREAKOUT BOX ADAPTERS (Part Number:HD-46601)
connect to the speedometer [39]. Used in conjunction with a multimeter, it allows circuit diagnosis of wiring harness
and connections without having to probe with sharp objects. Install breakout box in series using the black connectors
as follows:
1. Access the speedometer [39].
2. See Figure 6. Press latch and disconnect [39B].
3. Connect BREAKOUT BOX ADAPTERS (Part Number:HD-46601) to [39A] and [39B].
4. Attach black connectors from BREAKOUT BOX (Part Number:HD-42682) to BREAKOUT BOX ADAPTERS
(Part Number:HD-46601). All tests will be performed using the black side of the breakout box.
5. When testing is completed, remove the breakout box and jumper harness and restore connections.
1
Speedometer [39]
2
Breakout box adapter
3
Breakout box (BOB)
Figure 6. Breakout Box Connection
HD-50390-1 Breakout Box (ECM)
The BREAKOUT BOX (Part Number:HD-50390-1) and ECM CABLE (Part Number:HD-50390-4) splice into the main
harness. Used in conjunction with a multimeter, it allows circuit diagnosis of wiring harness and connections without
having to probe with sharp objects. Install breakout box in series as follows:
NOTE
See wiring diagrams for ECM terminal functions. ECM is located under the left side cover.
1. Access the ECM.
2. Press latch and disconnect ECM connectors [78B-1], [78B-2] and [78B-3].
3. See Figure 7. Connect BREAKOUT BOX (Part Number:HD-50390-1) and ECM CABLE (Part Number:HD-
50390-4) to connectors.
4. Verify ECM OVERLAY (Part Number:HD-50390-4-P) is in position on breakout box.
5. When testing is completed, remove the breakout box and restore connections.
1
ECM [78A-1], [78A-2] and [78A-3]
2
Breakout box (BOB)
3
Wire harness [78B-1], [78B-2] and [78B-3]
Figure 7. ECM Breakout Box Connection
HD-50390-1 Breakout Box (BCM)
The BREAKOUT BOX (Part Number:HD-50390-1) and BCM CABLE (Part Number:HD-50390-2) splice into the
main harness. Used in conjunction with a multimeter, it allows circuit diagnosis of wiring harness and connections
without having to probe with sharp objects. Install breakout box in series as follows:
NOTE
See wiring diagrams for BCM terminal functions. BCM is located in front of the rear tire.
1. Access the BCM.
2. Press latch and disconnect BCM [242B].
3. See Figure 8. Connect BREAKOUT BOX (Part Number:HD-50390-1) and BCM CABLE (Part Number:HD-
50390-2) to connectors.
4. Verify BCM OVERLAY (Part Number:HD-50390-2-P) is in position on breakout box.
5. When testing is completed, remove the breakout box and restore connections.
1
BCM [242A]
2
Breakout box (BOB)
3
Wiring harness [242B]
Figure 8. BCM Breakout Box Connection
HD-48642 Breakout Box (ABS)
The ABS BREAKOUT BOX (Part Number:HD-48642) connects to the ABS module [166]. Used in conjunction with a
multimeter, it allows circuit diagnosis of wiring harness and connections without having to probe with sharp objects.
Install breakout box in series as follows:
1. Access the ABS module.
2. Press latch and disconnect ABS module [166B].
3. See Figure 9. Connect ABS BREAKOUT BOX (Part Number:HD-48642) to connectors.
4. When testing is completed remove the breakout box and restore connections.
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