2007 Harley-Davidson Touring Electrical Diagnostics Manual – PDF DOWNLOAD
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2007 Harley-Davidson Touring Electrical Diagnostics Manual – PDF DOWNLOAD
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2007 Harley-Davidson Touring Electrical Diagnostics Manual – PDF DOWNLOAD2007 Harley-Davidson Touring Electrical Diagnostics Manual – PDF DOWNLOAD
TABLE OF CONTENTS:
2007 Harley-Davidson Touring Electrical Diagnostics Manual – PDF DOWNLOAD
STARTING AND CHARGING 1
................................................................... 1
STARTER TROUBLESHOOTING 1.1............................................................ 3
STARTING SYSTEM DIAGNOSIS 1.2.......................................................... 7
DIAGNOSTICS........................................................................ 7
Diagnostic Notes............................................................... 7
Job/Time Code Values........................................................... 7
Starter Testing 1.............................................................. 7
Starter Testing 2: Solenoid Clicks............................................. 8
Starter Testing 3: Relay Clicks................................................ 8
Starter Testing 4: Nothing Clicks (Part 1 of 2)................................ 9
Starter Testing 4: Nothing Clicks (Part 2 of 2)................................ 10
Starter Testing 5: Starter Spins, But Does Not Engage.......................... 11
Starter Testing 6: Starter Stalls or Spins Too Slowly.......................... 11
STARTER ACTIVATION CIRCUITS 1.3........................................................ 12
DIAGNOSTICS/TROUBLESHOOTING 1.4........................................................ 13
GENERAL............................................................................ 13
VOLTAGE DROPS...................................................................... 13
STARTER SYSTEM TESTING 1.5............................................................. 14
GENERAL............................................................................ 14
STARTER RELAY TEST 1............................................................... 14
STARTER RELAY TEST 2............................................................... 14
STARTER CURRENT DRAW TEST.......................................................... 14
TESTING ASSEMBLED STARTER 1.6.......................................................... 16
STARTER SOLENOID................................................................... 16
SOLENOID PULL-IN TEST.............................................................. 16
SOLENOID HOLD-IN TEST.............................................................. 16
SOLENOID RETURN TEST............................................................... 17
FREE RUNNING CURRENT DRAW TEST..................................................... 17
CHARGING SYSTEM 1.7.................................................................... 18
GENERAL............................................................................ 18
Alternator..................................................................... 18
Voltage Regulator.............................................................. 18
TROUBLESHOOTING.................................................................... 18
Battery........................................................................ 18
Wiring......................................................................... 19
Voltage Regulator Inspection................................................... 19
Job/Time Code Values........................................................... 19
Test 1.7 (Part 1 of 2)......................................................... 20
Test 1.7 (Part 2 of 2)......................................................... 21
TESTING............................................................................ 22
MILLIAMP DRAW TEST............................................................. 22
TOTAL CURRENT DRAW TEST........................................................ 22
CURRENT OUTPUT TEST............................................................ 23
VOLTAGE OUTPUT TEST............................................................ 23
STATOR CHECK................................................................... 23
AC OUTPUT CHECK................................................................ 24
BATTERY TESTING 1.8.................................................................... 25
GENERAL............................................................................ 25
VOLTMETER TEST..................................................................... 25
CONDUCTANCE TEST................................................................... 25
LOAD TEST.......................................................................... 26
INSTRUMENTS 2.............................................................................. 29
CHECKING FOR DIAGNOSTIC TROUBLE CODES 2.1.............................................. 31
CHECK ENGINE LAMP.................................................................. 31
SECURITY LAMP...................................................................... 32
CODE TYPES......................................................................... 33
Current........................................................................ 33
Historic....................................................................... 33
RETRIEVING DIAGNOSTIC TROUBLE CODES................................................ 33
MULTIPLE DIAGNOSTIC TROUBLE CODES.................................................. 33
INITIAL DIAGNOSTIC CHECK: SPEEDOMETER 2.2.............................................. 34
GENERAL............................................................................ 34
Diagnostic Notes............................................................... 34
Circuit Diagram/Wire Harness Connector Table................................... 34
INITIAL DIAGNOSTICS................................................................ 35
Diagnostic Tips................................................................ 35
Diagnostic Notes............................................................... 35
Other Codes.................................................................... 35
Diagnostic Check (Part 1 of 2)................................................. 39
Diagnostic Check (Part 2 of 2)................................................. 40
SPEEDOMETER SELF DIAGNOSTICS 2.3....................................................... 41
GENERAL............................................................................ 41
DIAGNOSTICS........................................................................ 41
Diagnostic Tips................................................................ 41
Diagnostic Notes............................................................... 41
Speedometer Self Diagnostics (chart)........................................... 42
SPEEDOMETER/TACHOMETER 2.4............................................................. 43
GENERAL............................................................................ 43
Reset Switch................................................................... 43
SPEEDOMETER THEORY OF OPERATION.................................................... 44
Job/Time Code Values........................................................... 44
TACHOMETER THEORY OF OPERATION..................................................... 44
DIAGNOSTICS........................................................................ 44
Diagnostic Notes............................................................... 44
Test 2.4 (Part 1 of 2)......................................................... 45
Test 2.4 (Part 2 of 2)......................................................... 46
BREAKOUT BOX: SPEEDOMETER 2.5.......................................................... 47
GENERAL............................................................................ 47
INSTALLATION....................................................................... 47
REMOVAL............................................................................ 47
FUEL GAUGE 2.6......................................................................... 48
THEORY OF OPERATION................................................................ 48
FUEL GAUGE AND SENDER TEST......................................................... 48
OIL, AIR AND VOLTMETER GAUGES 2.7...................................................... 49
Oil Pressure Gauge and Indicator Light............................................. 49
Problem........................................................................ 49
Ambient Air Temperature Gauge...................................................... 50
Problem........................................................................ 50
Voltmeter Gauge.................................................................... 50
Problem........................................................................ 50
INDICATOR LIGHTS: FLHX, FLHT/C/U, FLTR 2.8............................................. 51
GENERAL............................................................................ 51
Job/Time Code Values........................................................... 51
DIAGNOSTICS........................................................................ 52
Oil Pressure or Neutral Indicator Will Not Function............................ 52
High Beam or R/L Turn Signal Indicator Will Not Function....................... 52
INDICATOR LIGHTS: FLHR/C/S 2.9......................................................... 53
GENERAL............................................................................ 53
Job/Time Code Values........................................................... 53
DIAGNOSTICS........................................................................ 54
Oil Pressure or Neutral Indicator Will Not Function............................ 54
High Beam or R/L Turn Signal Indicator Will Not Function....................... 54
DTC B1004, B1005 2.10.................................................................. 55
GENERAL............................................................................ 55
DIAGNOSTICS........................................................................ 55
Diagnostic Tips................................................................ 55
Diagnostic Notes............................................................... 55
Test 2.10...................................................................... 57
Test 2.10...................................................................... 58
DTC B1006, B1007 2.11.................................................................. 59
GENERAL............................................................................ 59
Accessory or Ignition Line Overvoltage......................................... 59
Test 2.11...................................................................... 60
DTC B1008 2.12......................................................................... 61
GENERAL............................................................................ 61
Reset Switch Closed............................................................ 61
DIAGNOSTICS........................................................................ 61
Diagnostic Notes............................................................... 61
Test 2.12...................................................................... 63
DTC U1016 2.13......................................................................... 64
GENERAL............................................................................ 64
Loss of ECM Serial Data........................................................ 64
DIAGNOSTICS........................................................................ 64
Diagnostic Notes............................................................... 64
Test 2.13...................................................................... 67
DTC U1064, U1255 2.14.................................................................. 68
GENERAL............................................................................ 68
Loss of TSM/TSSM/HFSM Serial Data.............................................. 68
DIAGNOSTICS........................................................................ 68
Diagnostic Notes............................................................... 68
Test 2.14...................................................................... 71
DTC U1300, U1301 or “BUS ER” 2.15...................................................... 72
GENERAL............................................................................ 72
Serial Data Low or Serial Data Open/High....................................... 72
DIAGNOSTICS........................................................................ 72
Diagnostic Tips................................................................ 72
TSM/TSSM/HFSM 3
........................................................................... 73
TURN SIGNAL OVERVIEW 3.1............................................................... 75
GENERAL............................................................................ 75
SECURITY SYSTEM: JAPAN/KOREA....................................................... 75
TURN SIGNAL FUNCTIONS.............................................................. 75
MANUAL CANCELLATION................................................................ 75
AUTOMATIC CANCELLATION............................................................. 75
BANK ANGLE FUNCTIONS............................................................... 76
BANK ANGLE RESTART................................................................. 76
CLUTCH/NEUTRAL INTERLOCK........................................................... 76
SECURITY SYSTEM: H-DSSS............................................................ 76
HARLEY-DAVIDSON SMART SECURITY SYSTEM 3.2.............................................. 77
COMPONENTS......................................................................... 77
SECURITY IMOBILIZATION............................................................. 78
HFSM FEATURES...................................................................... 78
H-DSSS ACTUATION 3.3................................................................... 80
GENERAL............................................................................ 80
SIDECAR CONFIGURATION.............................................................. 80
ACTUATION.......................................................................... 80
FOB ASSIGNMENT..................................................................... 80
POWER DISRUPTION AND CONFIGURING................................................... 80
PERSONAL IDENTIFICATION NUMBER (PIN) 3.4............................................... 81
GENERAL............................................................................ 81
INITIAL PIN ENTRY.................................................................. 81
CHANGING THE PIN................................................................... 82
Modifying an Existing PIN...................................................... 82
ARMING/DISARMING SECURITY SYSTEM 3.5................................................... 83
HANDS-FREE FOB..................................................................... 83
SECURITY LAMP (KEY ICON)........................................................... 83
ARMING............................................................................. 84
DISARMING.......................................................................... 84
DISARMING WITH A PERSONAL IDENTIFICATION NUMBER (PIN).............................. 84
WARNINGS AND ALARM 3.6................................................................. 85
WARNINGS........................................................................... 85
ALARM.............................................................................. 85
SIREN CHIRP MODE (CONFIRMATION).................................................... 85
Chirpless Mode................................................................. 85
Chirp Mode..................................................................... 85
Switching Modes................................................................ 85
SERVICE/EMERGENCY FUNCTIONS 3.7........................................................ 86
TRANSPORT MODE..................................................................... 86
SERVICE MODE....................................................................... 86
FOUR-WAY FLASHING.................................................................. 86
TROUBLESHOOTING 3.8.................................................................... 87
TURN SIGNALS (TSM/HFSM)............................................................ 87
SECURITY SYSTEM (HFSM)............................................................. 87
DIAGNOSTICS MODE................................................................... 87
TROUBLESHOOTING.................................................................... 87
CHECKING FOR DTCS 3.9.................................................................. 88
GENERAL............................................................................ 88
SECURITY /LAMP DIAGNOSTICS......................................................... 88
CODE TYPES......................................................................... 89
Current........................................................................ 89
Historic....................................................................... 89
RETRIEVING DTCs.................................................................... 90
MULTIPLE DTCs/PRIORITY RANKING..................................................... 90
INITIAL DIAGNOSTIC CHECK 3.10.......................................................... 93
GENERAL............................................................................ 93
Diagnostic Notes............................................................... 93
Circuit Diagram/Wire Harness Connector Table................................... 93
Job/Time Codes................................................................. 93
Reprogramming ECM.............................................................. 93
INITIAL DIAGNOSTICS................................................................ 93
Diagnostic Tips................................................................ 93
Diagnostic Notes............................................................... 93
Other DTCs..................................................................... 93
Initial Diagnostic Check (Part 1 of 3)......................................... 96
Initial Diagnostic Check (Part 2 of 3)......................................... 97
Initial Diagnostic Check (Part 3 of 3)......................................... 98
SPEEDOMETER SELF DIAGNOSTICS 3.11...................................................... 99
GENERAL............................................................................ 99
DIAGNOSTICS........................................................................ 99
Diagnostic Tips................................................................ 99
Diagnostic Notes............................................................... 99
Speedometer Self Diagnostics...................................................100
BREAKOUT BOX 3.12......................................................................101
GENERAL............................................................................101
INSTALLATION.......................................................................101
REMOVAL............................................................................101
FAILS TO DISARM (HFSM ONLY) 3.13.......................................................103
GENERAL............................................................................103
JOB/TIME CODES.....................................................................103
DIAGNOSTICS........................................................................103
Diagnostic Tips................................................................103
Diagnostic Notes...............................................................103
Test 3.13......................................................................105
SYMPTOM: HFSM FAILS TO DISARM..................................................105
DTC B0563 3.14.........................................................................106
GENERAL............................................................................106
DIAGNOSTICS........................................................................106
Diagnostic Tips................................................................106
Diagnostic Notes...............................................................106
TSM/HFSM: TURN SIGNAL ERRORS AND DTCS 3.15.............................................107
GENERAL............................................................................107
DIAGNOSTICS........................................................................107
Job/Time Codes.................................................................107
Diagnostic Tips................................................................107
Diagnostic Notes: All Turn Signal Flow Charts..................................110
TSM/HFSM: Test 3.15a (Part 1 of 2).............................................111
TURN SIGNAL SYMPTOM- WILL NOT CANCEL ON TURN COMPLETION........................111
TSM/HFSM: Test 3.15b (Part 2 of 2).............................................112
TURN SIGNAL SYMPTOM- CANCELS ERRATICALLY.......................................112
TSM/HFSM: Test 3.15c...........................................................113
TSM Only: Test 3.15d (Part 1 of 4).............................................114
SYMPTOM- WILL NOT FLASH, 4-WAY FLASHERS INOPERABLE: DTC B1121, B1122, B1141....114
TSM Only: Test 3.15e (Part 2 of 4).............................................115
SYMPTOM- WILL NOT FLASH, 4-WAY FLASHERS INOPERABLE: DTC B1121, B1122, B1141....115
TSM Only: Test 3.15f (Part 3 of 4).............................................116
SYMPTOM- WILL NOT FLASH, 4-WAY FLASHERS INOPERABLE: DTC B1121, B1122, B1141....116
TSM Only: Test 3.15g (Part 4 of 4).............................................117
SYMPTOM- WILL NOT FLASH, 4-WAY FLASHERS INOPERABLE: DTC B1121, B1122, B1141....117
HFSM: Test 3.15h...............................................................118
HFSM: Test 3.15i...............................................................119
HFSM: Test 3.15j...............................................................120
DTC B1131, B1132 (HFSM ONLY) 3.16......................................................121
GENERAL............................................................................121
DIAGNOSTICS........................................................................121
Diagnostic Tips................................................................121
Diagnostic Notes...............................................................121
HFSM Only: Test 3.16...........................................................123
DTC B1134 3.17.........................................................................124
GENERAL............................................................................124
DIAGNOSTICS........................................................................124
Diagnostic Notes...............................................................124
TSM/HFSM: Test 3.17............................................................126
DTC B1135 3.18.........................................................................127
DIAGNOSTICS........................................................................127
DTC B1136, B1142 (HFSM ONLY) 3.19......................................................128
DIAGNOSTICS........................................................................128
DTC B1136 Accelerometer Tip-Over Self-Test Fault...............................128
DTC B1142 Internal Fault.......................................................128
DTC B1141 (HFSM ONLY) 3.20.............................................................129
DIAGNOSTICS........................................................................129
Diagnostic Tips................................................................129
Diagnostic Notes...............................................................129
HFSM: Test 3.20 (Part 1 of 2)..................................................130
HFSM: Test 3.20 (Part 2 of 2)..................................................131
DTC B1143, B1144, B1145 (HFSM ONLY) 3.21...............................................132
GENERAL............................................................................132
DIAGNOSTICS........................................................................132
Diagnostic Notes...............................................................132
HFSM: Test 3.21a...............................................................133
HFSM: Test 3.21b...............................................................134
HFSM: Test 3.21c...............................................................135
DTC B1151, B1152, B1153 3.22...........................................................136
GENERAL............................................................................136
Sidecar BAS....................................................................136
DIAGNOSTICS........................................................................136
Diagnostic Tips................................................................136
Diagnostic Notes...............................................................136
Test 3.22......................................................................138
DTC B1154, B1155 3.23..................................................................139
Diagnostics........................................................................139
Diagnostic Tips................................................................139
Diagnostic Notes...............................................................139
HFSM: Test 3.23a...............................................................141
HFSM: Test: 3.23b..............................................................142
DTC U1016, U1255 3.24..................................................................143
GENERAL............................................................................143
DIAGNOSTICS........................................................................143
Diagnostic Notes...............................................................143
TSM/HFSM: Test 3.24............................................................146
DTC U1300, U1301 or “BUS ER” 3.25......................................................147
DIAGNOSTICS........................................................................147
Diagnostic Tips................................................................147
Diagnostic Notes...............................................................147
HFSM: PASSWORD LEARN 3.26..............................................................148
GENERAL............................................................................148
PASSWORD LEARNING..................................................................148
HFSM: MAINTENANCE 3.27.................................................................150
GENERAL............................................................................150
HANDS-FREE FOB.....................................................................150
Schedule.......................................................................150
Battery Replacement............................................................150
SMART SIREN (IF INSTALLED).........................................................151
Schedule.......................................................................151
Battery Replacement............................................................151
ENGINE MANAGEMENT 4
.......................................................................153
SPECIFICATIONS 4.1.....................................................................155
EFI SYSTEM 4.2.........................................................................157
GENERAL............................................................................157
HEAT MANAGEMENT SYSTEM.........................................................157
TROUBLESHOOTING....................................................................157
EFI DIAGNOSTIC INTRODUCTION 4.3........................................................159
SYSTEM PROBLEMS....................................................................159
No Start.......................................................................159
Poor Performance...............................................................159
Check Engine Lamp..............................................................159
RESOLVING PROBLEMS.................................................................159
CHECKING FOR DIAGNOSTIC TROUBLE CODES: EFI 4.4.........................................160
CHECK ENGINE LAMP..................................................................160
CODE TYPES.........................................................................161
Current........................................................................161
Historic.......................................................................161
RETRIEVING DIAGNOSTIC TROUBLE CODES................................................161
MULTIPLE DIAGNOSTIC TROUBLE CODES..................................................161
INITIAL DIAGNOSTIC CHECK: EFI 4.5......................................................162
GENERAL............................................................................162
Diagnostic Notes...............................................................162
Circuit Diagram/Wire Harness Connector Table...................................162
Reprogramming ECM..............................................................162
INITIAL DIAGNOSTICS................................................................162
General Information............................................................162
Diagnostic Tips................................................................162
Diagnostic Notes...............................................................162
Other Codes....................................................................162
Diagnostic Check (Part 1 of 2).................................................169
Diagnostic Check (Part 2 of 2).................................................170
SPEEDOMETER SELF DIAGNOSTICS 4.6.......................................................171
GENERAL............................................................................171
DIAGNOSTICS........................................................................171
Diagnostic Tips................................................................171
Diagnostic Notes...............................................................171
Speedometer Self Diagnostics (chart)...........................................172
BREAKOUT BOX: EFI 4.7..................................................................173
GENERAL............................................................................173
INSTALLATION.......................................................................173
REMOVAL............................................................................173
WIGGLE TEST 4.8........................................................................174
GENERAL............................................................................174
PROCEDURE..........................................................................174
INTAKE LEAK TEST 4.9...................................................................175
GENERAL............................................................................175
LEAK TESTER........................................................................175
Parts List.....................................................................175
Tester Assembly................................................................175
INTAKE LEAK TESTING................................................................176
ENGINE CRANKS, BUT WILL NOT START 4.10.................................................177
GENERAL............................................................................177
DIAGNOSTICS........................................................................177
Diagnostic Notes...............................................................177
Diagnostic Tips................................................................177
Test 4.10 (Part 1 of 4)........................................................180
Test 4.10 (Part 2 of 4)........................................................181
Test 4.10 (Part 3 of 4)........................................................182
Test 4.10 (Part 4 of 4)........................................................183
NO ECM POWER 4.11......................................................................184
GENERAL............................................................................184
No Spark/No Check Engine Lamp at Key ON........................................184
DIAGNOSTICS........................................................................184
Diagnostic Notes...............................................................184
Test 4.11 (Part 1 of 2)........................................................187
Test 4.11 (Part 2 of 2)........................................................188
STARTS, THEN STALLS 4.12...............................................................189
GENERAL............................................................................189
Diagnostic Trouble Codes U1300, U1301 or “BUS Er”..............................189
DIAGNOSTICS........................................................................189
Diagnostic Tips................................................................189
Diagnostic Notes...............................................................189
Test 4.12 (Part 1 of 2)........................................................192
Test 4.12 (Part 2 of 2)........................................................193
FUEL SYSTEM ELECTRICAL TEST 4.13.......................................................194
GENERAL............................................................................194
DIAGNOSTICS........................................................................194
Diagnostic Notes...............................................................194
Test 4.13 (Part 1 of 4)........................................................196
Test 4.13 (Part 2 of 4)........................................................197
Test 4.13 (Part 3 of 4)........................................................198
Test 4.13 (Part 4 of 4)........................................................198
SYSTEM RELAY CHECK 4.14................................................................199
GENERAL............................................................................199
System Relay...................................................................199
DIAGNOSTICS........................................................................199
Diagnostic Notes...............................................................199
Test 4.14 (Part 1 of 3)........................................................202
Test 4.14 (Part 2 of 3)........................................................203
Test 4.14 (Part 3 of 3)........................................................203
FUEL PRESSURE TEST 4.15................................................................204
GENERAL............................................................................204
TESTING............................................................................204
DIAGNOSTICS........................................................................206
Diagnostic Notes...............................................................206
Test 4.15......................................................................207
IDLE AIR CONTROL, DTC P0505 4.16.......................................................208
GENERAL............................................................................208
IAC Operation..................................................................208
Diagnostic Trouble Code P0505: Loss of Idle Speed Control......................208
DIAGNOSTICS........................................................................208
Diagnostic Tips................................................................208
Diagnostic Notes...............................................................209
Test 4.16 (Part 1 of 2)........................................................211
Test 4.16 (Part 2 of 2)........................................................212
MISFIRE AT IDLE OR UNDER LOAD 4.17.....................................................213
GENERAL............................................................................213
Misfire at Idle or Under Load..................................................213
DIAGNOSTICS........................................................................213
Diagnostic Notes...............................................................213
Test 4.17 (Part 1 of 3)........................................................215
Test 4.17 (Part 2 of 3)........................................................216
Test 4.17 (Part 3 of 3)........................................................217
COMBUSTION ABSENT/INTERMITTENT 4.18....................................................218
GENERAL............................................................................218
Diagnostic Trouble Codes P1353, P1356, P1357, P1358: No Combustion.............218
DIAGNOSTICS........................................................................218
Diagnostic Notes...............................................................218
Test 4.18 (Part 1 of 2)........................................................221
Test 4.18 (Part 2 of 2)........................................................222
DTC P0107, P0108 4.19..................................................................223
GENERAL............................................................................223
MAP Sensor.....................................................................223
DIAGNOSTICS........................................................................223
Diagnostic Tips................................................................223
Diagnostic Notes...............................................................223
Test 4.19 (Part 1 of 2)........................................................225
Test 4.19 (Part 2 of 2)........................................................226
DTC P0112, P0113 4.20..................................................................227
GENERAL............................................................................227
IAT Sensor.....................................................................227
DIAGNOSTICS........................................................................227
Diagnostic Tips................................................................227
Diagnostic Notes...............................................................227
Test 4.20 (Part 1 of 2)........................................................229
Test 4.20 (Part 2 of 2)........................................................230
DTC P0117, P0118 4.21..................................................................231
GENERAL............................................................................231
ET Sensor......................................................................231
DIAGNOSTICS........................................................................231
Diagnostic Tips................................................................231
Diagnostic Notes...............................................................231
Test 4.21 (Part 1 of 2)........................................................233
Test 4.21 (Part 2 of 2)........................................................234
DTC P0122, P0123 4.22..................................................................235
GENERAL............................................................................235
TP Sensor......................................................................235
DIAGNOSTICS........................................................................235
Diagnostic Tips................................................................235
Diagnostic Notes...............................................................235
Test 4.22 (Part 1 of 2)........................................................237
Test 4.22 (Part 2 of 2)........................................................238
DTC P0131, P0132, P0134, P0151, P0152, P0154 4.23......................................239
GENERAL............................................................................239
O2 Sensor......................................................................239
DIAGNOSTICS........................................................................239
Diagnostic Tips................................................................239
Diagnostic Notes...............................................................239
Test 4.23 (Part 1 of 3)........................................................241
Test 4.23 (Part 2 of 3)........................................................242
Test 4.23 (Part 3 of 3)........................................................243
DTC P0261, P0262, P0263, P0264 4.24....................................................244
GENERAL............................................................................244
Fuel Injectors.................................................................244
DIAGNOSTICS........................................................................244
Diagnostic Notes...............................................................244
Test 4.24 (Part 1 of 3)........................................................247
Test 4.24 (Part 2 of 3)........................................................248
Test 4.24 (Part 3 of 3)........................................................249
DTC P0373, P0374 4.25..................................................................250
GENERAL............................................................................250
CKP Sensor.....................................................................250
DIAGNOSTICS........................................................................250
Diagnostic Tips................................................................250
Diagnostic Notes...............................................................250
Test 4.25......................................................................252
DTC P0501, P0502 4.26..................................................................253
GENERAL............................................................................253
Vehicle Speed Sensor...........................................................253
DIAGNOSTICS........................................................................253
Diagnostic Notes...............................................................253
Test 4.26 (Part 1 of 2)........................................................255
Test 4.26 (Part 2 of 2)........................................................256
DTC P0562, P0563 4.27..................................................................257
GENERAL............................................................................257
Battery Voltage................................................................257
DIAGNOSTICS........................................................................257
Diagnostic Tips................................................................257
Diagnostic Notes...............................................................257
Test 4.27 (Part 1 of 2)........................................................260
Test 4.27 (Part 2 of 2)........................................................261
DTC P0603, P0605 4.28..................................................................262
GENERAL............................................................................262
ECM Failure....................................................................262
DIAGNOSTICS........................................................................262
DTC P0603......................................................................262
DTC P0605......................................................................262
DTC P0661, P0662 4.29..................................................................263
GENERAL............................................................................263
Active Intake Solenoid (HDI Models Only).......................................263
DIAGNOSTICS........................................................................263
Diagnostic Notes...............................................................263
Test 4.29 (Part 1 of 2)........................................................265
Test 4.29 (Part 2 of 2)........................................................266
DTC P1009, P1010 4.30..................................................................267
GENERAL............................................................................267
Password Problem...............................................................267
DIAGNOSTICS........................................................................267
Diagnostic Notes...............................................................267
Test 4.30......................................................................270
DTC P1351, P1352, P1354, P1355 4.31....................................................271
GENERAL............................................................................271
Ignition Coil..................................................................271
DIAGNOSTICS........................................................................271
Diagnostic Notes...............................................................271
Test 4.31 (Part 1 of 2)........................................................274
Test 4.31 (Part 2 of 2)........................................................275
DTC P1475, P1477, P1478 4.32...........................................................276
GENERAL............................................................................276
Active Exhaust Actuator (HDI Models)...........................................276
DIAGNOSTICS........................................................................276
Diagnostic Notes...............................................................276
Test 4.32 (Part 1 of 4)........................................................278
Test 4.32 (Part 2 of 4)........................................................279
Test 4.32 (Part 3 of 4)........................................................280
Test 4.32 (Part 4 of 4)........................................................281
DTC U1064, U1255 4.33..................................................................282
GENERAL............................................................................282
Loss of TSM/TSSM/HFSM Serial Data..............................................282
DIAGNOSTICS........................................................................282
Diagnostic Notes...............................................................282
Test 4.33......................................................................285
DTC U1097, U1255 4.34..................................................................286
GENERAL............................................................................286
Loss of Speedometer Serial Data................................................286
DIAGNOSTICS........................................................................286
Diagnostic Notes...............................................................286
Test 4.34......................................................................289
ADVANCED AUDIO SYSTEM 5
...................................................................291
RADIO DIAGNOSTICS 5.1..................................................................293
SYSTEM DESCRIPTION.................................................................293
ONBOARD DIAGNOSTICS................................................................293
General........................................................................293
Radio Diagnostic Display.......................................................293
RADIO SWITCH DIAGNOSTICS: DTC B2006-B2015 5.2..........................................298
GENERAL............................................................................298
DIAGNOSTICS........................................................................298
Diagnostic Notes...............................................................298
Test 5.2a......................................................................299
Test 5.2b (Part 1 of 3)........................................................300
Test 5.2b (Part 2 of 3)........................................................301
Test 5.2b (Part 3 of 3)........................................................302
Test 5.2c (Part 1 of 3)........................................................303
Test 5.2c (Part 2 of 3)........................................................304
Test 5.2c (Part 3 of 3)........................................................305
Test 5.2d (Part 1 of 3)........................................................306
Test 5.2d (Part 2 of 3)........................................................307
Test 5.2d (Part 3 of 3)........................................................308
Test 5.2e (Part 1 of 2)........................................................309
Test 5.2e (Part 2 of 2)........................................................310
Test 5.2f (Part 1 of 2)........................................................311
Test 5.2f (Part 2 of 2)........................................................312
Test 5.2g (Part 1 of 2)........................................................313
Test 5.2g (Part 2 of 2)........................................................314
Test 5.2h......................................................................315
Test 5.2i......................................................................316
Test 5.2j......................................................................317
RADIO SPEAKER DIAGNOSTICS: DTC B2016-B2027 5.3.........................................318
GENERAL............................................................................318
DIAGNOSTICS........................................................................318
Diagnostic Notes...............................................................318
Test 5.3a......................................................................319
Test 5.3b......................................................................321
Test 5.3c......................................................................322
Test 5.3d......................................................................323
Test 5.3e......................................................................324
Test 5.3f......................................................................326
Test 5.3g......................................................................327
Test 5.3h......................................................................328
Test 5.3i......................................................................329
Test 5.3j......................................................................331
Test 5.3k......................................................................332
Test 5.3l......................................................................333
SERIAL DATA BUS DIAGNOSTICS 5.4........................................................335
GENERAL............................................................................335
LOSS OF SERIAL DATA: DTC U1016.................................................335
STARTS, THEN STALLS: DTC U1300, U1301..........................................335
DIAGNOSTICS........................................................................335
Diagnostic Notes...............................................................335
Test 5.4a......................................................................336
Test 5.4b......................................................................338
Test 5.4c (Part 1 of 3)........................................................339
Test 5.4c (Part 2 of 3)........................................................341
Test 5.4c (Part 3 of 3)........................................................342
Test 5.4d......................................................................343
Test 5.4e......................................................................345
Test 5.4f......................................................................347
Test 5.4g......................................................................349
Test 5.4h......................................................................350
ADVANCED AUDIO SYSTEM SYMPTOMS 5.5.....................................................352
GENERAL............................................................................352
FACTORY DEFAULTS...................................................................352
DIAGNOSTICS........................................................................353
Diagnostic Notes...............................................................353
Test 5.5a......................................................................354
Test 5.5b......................................................................356
Test 5.5c......................................................................357
Test 5.5d......................................................................357
Test 5.5e......................................................................358
Test 5.5f......................................................................359
Test 5.5g (Part 1 of 4)........................................................360
Test 5.5g (Part 2 of 4)........................................................361
Test 5.5g (Part 3 of 4)........................................................362
Test 5.5g (Part 4 of 4)........................................................363
Test 5.5h (Part 1 of 3)........................................................364
Test 5.5h (Part 2 of 3)........................................................366
Test 5.5h (Part 3 of 3)........................................................367
Test 5.5i......................................................................368
Test 5.5j (Part 1 of 2)........................................................369
Test 5.5j (Part 2 of 2)........................................................370
Test 5.5k......................................................................372
Test 5.5l (Part 1 of 5)........................................................374
Test 5.5l (Part 2 of 5)........................................................375
Test 5.5l (Part 3 of 5)........................................................376
Test 5.5l (Part 4 of 5)........................................................377
Test 5.5l (Part 5 of 5)........................................................378
Test 5.5m (Part 1 of 4)........................................................380
Test 5.5m (Part 2 of 4)........................................................381
Test 5.5m (Part 3 of 4)........................................................382
Test 5.5m (Part 4 of 4)........................................................383
Test 5.5n (Part 1 of 2)........................................................385
Test 5.5n (Part 2 of 2)........................................................387
Test 5.5o (Part 1 of 2)........................................................388
Test 5.5o (Part 2 of 2)........................................................389
Test 5.5p......................................................................391
Test 5.5q (Part 1 of 2)........................................................392
Test 5.5q (Part 2 of 2)........................................................393
Test 5.5r......................................................................394
Test 5.5s (Part 1 of 4)........................................................395
Test 5.5s (Part 2 of 4)........................................................396
Test 5.5s (Part 3 of 4)........................................................398
Test 5.5s (Part 4 of 4)........................................................400
Test 5.5t......................................................................401
Test 5.5u (Part 1 of 5)........................................................402
Test 5.5u (Part 2 of 5)........................................................403
Test 5.5u (Part 3 of 5)........................................................405
Test 5.5u (Part 4 of 5)........................................................407
Test 5.5u (Part 5 of 5)........................................................408
CRUISE CONTROL 6
..........................................................................409
CRUISE CONTROL 6.1.....................................................................411
GENERAL............................................................................411
SYSTEM OPERATION...................................................................411
TROUBLESHOOTING....................................................................412
CRUISE INOPERATIVE DIAGNOSTICS 6.2.....................................................413
GENERAL............................................................................413
INOPERATIVE DIAGNOSTICS............................................................413
Diagnostic Notes...............................................................413
CRUISE DROPOUT DIAGNOSTICS 6.3.........................................................416
GENERAL............................................................................416
DROPOUT DIAGNOSTICS................................................................416
CRUISE CHART A: INITIAL DIAGNOSTICS 6.4................................................419
DIAGNOSTICS........................................................................419
Test 6.4 (Part 1 of 2).........................................................419
Test 6.4 (Part 2 of 2).........................................................420
CRUISE CHART B: RESUME SWITCH 6.5......................................................421
DIAGNOSTICS........................................................................421
Test 6.5.......................................................................421
CRUISE CHART C: CRUISE ENGAGED LAMP 6.6................................................422
DIAGNOSTICS........................................................................422
Test 6.6.......................................................................422
CRUISE CHART D: CRUISE POWER 6.7.......................................................423
DIAGNOSTICS........................................................................423
Test 6.7.......................................................................423
CRUISE CHART E: CRUISE ENABLE 6.8......................................................425
DIAGNOSTICS........................................................................425
Test 6.8.......................................................................425
Diagnostic Notes...............................................................425
CRUISE CHART F-1: BRAKE LIGHTS ON 6.9..................................................426
DIAGNOSTICS........................................................................426
Test 6.9.......................................................................426
CRUISE CHART F-2: BRAKE LIGHTS OFF 6.10................................................427
DIAGNOSTICS........................................................................427
Test 6.10 (Part 1 of 2)........................................................427
Test 6.10 (Part 2 of 2)........................................................428
Diagnostic Notes...............................................................428
CRUISE CHART G: THROTTLE SWITCH 6.11...................................................429
DIAGNOSTICS........................................................................429
Test 6.11......................................................................429
CRUISE CHART H: SPEEDOMETER INPUT 6.12.................................................430
DIAGNOSTICS........................................................................430
Diagnostic Notes...............................................................430
Test 6.12......................................................................430
CRUISE CHART I: TACHOMETER INPUT 6.13..................................................431
DIAGNOSTICS........................................................................431
Test 6.13......................................................................431
WIRING 7
..................................................................................433
DEUTSCH ELECTRICAL CONNECTORS 7.1......................................................435
GENERAL............................................................................435
REMOVING/DISASSEMBLING.............................................................435
REMOVING/INSTALLING SOCKETS........................................................435
REMOVING/INSTALLING PINS...........................................................436
ASSEMBLING/INSTALLING..............................................................438
CRIMPING INSTRUCTIONS..............................................................438
STANDARD TERMINALS.............................................................438
MINI TERMINALS.................................................................440
SOLID BARREL CONTACTS..........................................................440
MULTILOCK ELECTRICAL CONNECTORS 7.2....................................................442
REMOVING SOCKET/PIN TERMINALS......................................................442
INSTALLING SOCKET/PIN TERMINALS....................................................442
CRIMPING INSTRUCTIONS..............................................................446
DELPHI ELECTRICAL CONNECTORS 7.3.......................................................447
GENERAL............................................................................447
REMOVING SOCKET TERMINALS..........................................................447
INSTALLING SOCKET TERMINALS........................................................447
PACKARD ELECTRICAL CONNECTORS 7.4......................................................449
150 METRI-PACK SERIES..............................................................449
General........................................................................449
Disassembly....................................................................449
Assembly.......................................................................449
280 METRI-PACK SERIES..............................................................449
General........................................................................449
System Fuse Block..............................................................449
480 METRI-PACK SERIES..............................................................451
General........................................................................451
Disassembly....................................................................451
Assembly.......................................................................452
630 METRI-PACK SERIES..............................................................453
General........................................................................453
Disassembly....................................................................453
Assembly.......................................................................453
800 METRI-PACK SERIES..............................................................453
General........................................................................453
Disassembly....................................................................453
Assembly.......................................................................453
PACKARD MICRO 64...................................................................454
General........................................................................454
Disassembly....................................................................454
Assembly.......................................................................455
Crimping Instructions..........................................................455
PACKARD 100W.......................................................................456
General........................................................................456
Disassembly....................................................................456
Assembly.......................................................................457
Crimping Instructions..........................................................457
AUTOFUSE ELECTRICAL CONNECTOR 7.5......................................................459
GENERAL............................................................................459
DISASSEMBLY........................................................................459
ASSEMBLY...........................................................................459
SEALED BUTT SPLICE CONNECTORS 7.6......................................................460
PROCEDURE..........................................................................460
MOLEX ELECTRICAL CONNECTORS 7.7........................................................462
REMOVING TERMINALS.................................................................462
INSTALLING TERMINALS...............................................................462
ELECTRICAL CONNECTOR LOCATIONS 7.8.....................................................464
FLHX, FLHT/C/U.....................................................................464
FLHX, FLHT/C/U (Continued).....................................................466
FLTR...............................................................................470
FLTR (Continued)...............................................................471
FLTR (Continued)...............................................................472
FLHR/C/S...........................................................................473
FLHR/C/S (Continued)...........................................................474
FLHR/C/S (Continued)...........................................................475
WIRING DIAGRAMS 7.9....................................................................477
APPENDICES
................................................................................503
ACRONYMS AND ABBREVIATIONS A.1.........................................................505
TSM/TSSM (JAPAN/KOREA) OVERVIEW B.1....................................................507
GENERAL............................................................................507
TROUBLESHOOTING....................................................................507
TSM/TSSM FEATURES B.2..................................................................509
GENERAL............................................................................509
TURN SIGNAL FUNCTIONS..............................................................509
TSM/TSSM Features..............................................................509
BANK ANGLE FUNCTION................................................................509
CLUTCH/NEUTRAL INTERLOCK FUNCTIONS.................................................509
TSM/TSSM Features..............................................................509
SECURITY ALARM AND IMMOBILIZATION FUNCTIONS........................................510
TSSM Feature...................................................................510
TSM/TSSM VEHICLE DELIVERY B.3..........................................................511
GENERAL............................................................................511
CONFIGURING A TSSM.................................................................511
SIDECAR CONFIGURATION..............................................................511
POWER DISRUPTION AND CONFIGURING...................................................511
KEY FOB ASSIGNMENT: TSSM...........................................................512
PIN ENTRY: TSSM....................................................................512
CHANGING THE PIN: TSSM.............................................................512
TSM/TSSM TURN SIGNAL FUNCTIONS B.4.....................................................516
GENERAL............................................................................516
AUTOMATIC CANCELLATION.............................................................516
MANUAL CANCELLATION................................................................516
FOUR-WAY FLASHING..................................................................517
DIAGNOSTICS MODE...................................................................517
TSM/TSSM BANK ANGLE FUNCTION B.5.......................................................518
GENERAL............................................................................518
OPERATION..........................................................................518
SECURITY SYSTEM FUNCTIONS: TSSM B.6....................................................519
GENERAL............................................................................519
Security System Operation......................................................519
Security System Options: TSSM..................................................519
ALARM SENSITIVITY: TSSM............................................................520
Sensitivity....................................................................520
Transport Mode.................................................................520
AUTO-ARMING FUNCTION: TSSM.........................................................520
STORAGE MODE: TSSM.................................................................520
ARMING/DISARMING: TSSM B.7.............................................................523
GENERAL............................................................................523
SECURITY LAMP......................................................................523
USING KEY FOB: TSSM................................................................523
General........................................................................523
Arming the System..............................................................523
Disarming the System...........................................................523
Troubleshooting................................................................523
USING THE PIN......................................................................524
General........................................................................524
Disarming the System...........................................................524
DIAGNOSTIC TROUBLE CODES (DTC) B.8.....................................................525
TSM/TSSM...........................................................................525
CODE TYPES.........................................................................526
Current........................................................................526
Historic.......................................................................526
RETRIEVING DIAGNOSTIC TROUBLE CODES................................................527
MULTIPLE DIAGNOSTIC TROUBLE CODES..................................................527
INITIAL DIAGNOSTIC CHECK: TSM/TSSM B.9.................................................528
GENERAL............................................................................528
Diagnostic Notes...............................................................528
Circuit Diagram/Wire Harness Connector Table...................................528
Job/Time Code Values...........................................................528
Reprogramming ECM..............................................................528
INITIAL DIAGNOSTICS................................................................528
Diagnostic Tips................................................................528
Diagnostic Notes...............................................................528
Other Diagnostic Trouble Codes (DTCs)..........................................528
Initial Diagnostic Check (Part 1 of 3).........................................532
Initial Diagnostic Check (Part 2 of 3).........................................533
Initial Diagnostic Check (Part 3 of 3).........................................534
SPEEDOMETER SELF DIAGNOSTICS B.10......................................................535
GENERAL............................................................................535
DIAGNOSTICS........................................................................535
Diagnostic Tips................................................................535
Diagnostic Notes...............................................................536
Speedometer Self Diagnostics...................................................537
BREAKOUT BOX: TSM/TSSM B.11............................................................538
GENERAL............................................................................538
INSTALLATION.......................................................................538
REMOVAL............................................................................538
FAILS TO DISARM B.12...................................................................539
GENERAL............................................................................539
Security Equipped Vehicles Only................................................539
Job/Time Code Values...........................................................539
DIAGNOSTICS........................................................................539
Diagnostic Tips................................................................539
Diagnostic Notes...............................................................539
Test B.12......................................................................541
TURN SIGNAL ERRORS: B1121, B1122, B1141 B.13...........................................542
GENERAL............................................................................542
Job/Time Code Values...........................................................542
DIAGNOSTICS........................................................................542
Diagnostic Tips: All...........................................................542
Diagnostic Notes: All Turn Signal Flow Charts..................................545
Test B.13a (Part 1 of 2).......................................................546
Turn Signal Error 1A (Part 1 of 2).............................................546
Test B.13a (Part 2 of 2).......................................................547
Turn Signal Error 1A (Part 2 of 2).............................................547
Test B.13b.....................................................................548
Turn Signal Error 2A...........................................................548
Test B.13c.....................................................................549
Turn Signal Error 2B...........................................................549
Test B.13d.....................................................................550
Turn Signal Error 2C...........................................................550
Test B.13e.....................................................................551
Turn Signal Error 2D...........................................................551
Test B.13f.....................................................................552
Turn Signal Error 3A...........................................................552
DTC B0563 B.14.........................................................................553
GENERAL............................................................................553
Battery Voltage High...........................................................553
DIAGNOSTICS........................................................................553
Diagnostic Tips................................................................553
Diagnostic Notes...............................................................553
DTC B1131, B1132 B.15..................................................................554
GENERAL............................................................................554
Alarm Output Low (DTC B1131) or Alarm Output High (DTC B1132)..................554
DIAGNOSTICS........................................................................554
Diagnostic Tips................................................................554
Diagnostic Notes...............................................................554
Test B.15......................................................................556
DTC B1134 B.16.........................................................................557
GENERAL............................................................................557
Starter Output High............................................................557
DIAGNOSTICS........................................................................557
Diagnostic Notes...............................................................557
Test B.16a.....................................................................559
DTC B1151, B1152, B1153 B.17...........................................................560
GENERAL............................................................................560
Sidecar BAS....................................................................560
DIAGNOSTICS........................................................................560
Diagnostic Tips................................................................560
Diagnostic Notes...............................................................560
Test B.17......................................................................562
DTC B1135 B.18.........................................................................563
GENERAL............................................................................563
Accelerometer Fault: B1135.....................................................563
DTC B1154, B1155 B.19..................................................................565
GENERAL............................................................................565
DIAGNOSTIC NOTES...................................................................565
Test B.19a.....................................................................566
CLUTCH SWITCH SHORT TO GROUND: DTC B1154.......................................566
Test B.19b.....................................................................567
DTC U1016, U1255 B.20..................................................................568
GENERAL............................................................................568
Loss of ECM Serial Data........................................................568
DIAGNOSTICS........................................................................568
Diagnostic Notes...............................................................568
Test B.20a.....................................................................571
DTC U1300, U1301 or “BUS ER” B.21......................................................572
GENERAL............................................................................572
Serial Data Low or Serial Data Open/High.......................................572
DIAGNOSTICS........................................................................572
Diagnostic Tips................................................................572
Diagnostic Notes...............................................................572
PASSWORD LEARN B.22....................................................................573
GENERAL............................................................................573
PASSWORD LEARNING..................................................................573
TSSM MAINTENANCE B.23..................................................................575
GENERAL............................................................................575
KEY FOB............................................................................575
Schedule.......................................................................575
Battery Replacement............................................................575
SIREN (IF INSTALLED)...............................................................576
Schedule.......................................................................576
Battery Replacement............................................................576
2007 HARLEY-DAVIDSON TOURING ELECTRICAL DIAGNOSTICS MANUAL – PDF DOWNLOAD:
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