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2008 Harley Davidson Softail Models Electrical Diagnostics Manual – PDF DOWNLOAD 
2008 Harley Davidson Softail Models Electrical Diagnostics Manual – PDF DOWNLOAD
2008 Harley Davidson Softail Models Electrical Diagnostics Manual – PDF DOWNLOAD
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2008 Harley Davidson Softail Models Electrical Diagnostics Manual – PDF DOWNLOAD
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Description
2008 Harley Davidson Softail Models Electrical Diagnostics Manual – PDF DOWNLOAD
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
2008 Harley Davidson Softail Models Electrical Diagnostics Manual – PDF DOWNLOAD
ABOUT THIS MANUAL
GENERAL
- This electrical diagnostic service manual has been prepared with two purposes in mind. First, it will acquaint the user with the construction of the Harley-Davidson product and assist in the performance of repair.
- Secondly, it will introduce to the professional Harley-Davidson Technician the latest field-tested and factory-approved diagnostic methods.We sincerely believe that this manual will make your association with Harley-Davidson products more pleasant and profitable.
HOW TO USE YOUR SERVICE MANUAL :
Refer to the table below for the content layout of this manual.
NO. CHAPTER
1 Starting / Charging
2 Instruments
3 TSM/HFSM
4 Engine Management
A Appendix A Connector Repair
B Appendix B Wiring
C Appendix C Conversions
D Appendix D Glossary
E Appendix E TSM/TSSM (Japan/Korea)
- Use the TABLE OF CONTENTS (which follows this FOREWORD) and the INDEX (at the back of this manual) to quickly locate subjects. Sections and topics in this manual are sequentially numbered for easy navigation.
- For example, a cross-reference shown as 2.1 SPECIFICATIONS refers to chapter 2 CHASSIS, heading 2.1 SPECIFICATIONS.
- For quick and easy reference, all pages contain a section number followed by a page number. For example, page 3-5 refers to page 5 in section 3.
- A number of acronyms and abbreviations are used in this document. See the D.1 GLOSSARY for a list of acronyms, abbreviations and definitions.
TABLE OF CONTENTS:
2008 Harley Davidson Softail Models Electrical Diagnostics Manual – PDF DOWNLOAD
COVER............................................................ 1 FOREWORD......................................................... 2 TABLE OF CONTENTS................................................ 4 1. STARTING / CHARGING........................................... 12 1.1 STARTER TROUBLESHOOTING.................................. 14 General.................................................. 14 Starter Troubleshooting.................................. 14 1.2 STARTING SYSTEM DIAGNOSIS................................ 16 Diagnostics.............................................. 16 1.3 DIAGNOSTICS/TROUBLESHOOTING.............................. 26 Voltage Drop............................................. 26 1.4 STARTER ACTIVATION CIRCUITS.............................. 27 Starter Activation Circuits.............................. 27 1.5 TESTING STARTER ON MOTORCYCLE............................ 28 Start Relay Test......................................... 28 Starter Current Draw Test................................ 29 1.6 TESTING STARTER ON BENCH................................. 30 Free Running Current Draw Test........................... 30 Starter Solenoid......................................... 30 Solenoid Pull-In Test.................................... 30 Solenoid Hold-In Test.................................... 30 Solenoid Return Test..................................... 31 1.7 CHARGING SYSTEM.......................................... 32 General.................................................. 32 Troubleshooting.......................................... 32 Testing.................................................. 36 1.8 BATTERY TESTING.......................................... 40 General.................................................. 40 Voltmeter Test........................................... 40 Conductance Test......................................... 40 Load Test................................................ 40 2. INSTRUMENTS................................................... 42 2.1 CHECKING FOR DIAGNOSTIC TROUBLE CODES.................... 44 Check Engine Lamp........................................ 44 Security Lamp............................................ 45 Code Types............................................... 45 Retrieving Diagnostic Trouble Codes...................... 46 Multiple Diagnostic Trouble Codes........................ 46 2.2 INITIAL DIAGNOSTIC CHECK: SPEEDOMETER.................... 47 General.................................................. 47 Initial Diagnostics...................................... 47 2.3 SPEEDOMETER SELF DIAGNOSTICS............................. 53 General.................................................. 53 Diagnostics.............................................. 53 2.4 SPEEDOMETER.............................................. 55 General.................................................. 55 Speedometer Theory of Operation.......................... 55 Odometer Theory of Operation............................. 55 2.5 BREAKOUT BOX: SPEEDOMETER................................ 56 General.................................................. 56 Installation............................................. 56 Removal.................................................. 56 2.6 FUEL GAUGE............................................... 57 Theory of Operation...................................... 57 Fuel Gauge and Sender Test............................... 57 2.7 INDICATOR LAMPS.......................................... 58 General.................................................. 58 Diagnostics.............................................. 59 2.8 DTC B1004, B1005......................................... 62 General.................................................. 62 Diagnostics.............................................. 62 2.9 DTC B1006, B1007......................................... 66 General.................................................. 66 2.10 DTC B1008............................................... 68 General.................................................. 68 Diagnostics.............................................. 68 2.11 DTC U1016, U1255........................................ 71 General.................................................. 71 Diagnostics.............................................. 71 2.12 DTC U1064, U1255........................................ 74 General.................................................. 74 Diagnostics.............................................. 74 2.13 DTC U1300, U1301 OR BUS ER.............................. 77 General.................................................. 77 Diagnostics.............................................. 77 3. TSM/HFSM...................................................... 78 3.1 TURN SIGNAL OVERVIEW..................................... 80 General.................................................. 80 Security System: Japan/Korea............................. 80 Turn Signal Functions.................................... 80 Manual Cancellation...................................... 80 Automatic Cancellation................................... 80 Bank Angle Functions..................................... 80 Bank Angle Restart....................................... 80 Clutch/Neutral Interlock................................. 80 Security System H-DSSS................................... 80 3.2 HARLEY-DAVIDSON SMART SECURITY SYSTEM.................... 81 Components............................................... 81 Security Immobilization.................................. 81 HFSM Features............................................ 82 3.3 H-DSSS ACTUATION......................................... 84 General.................................................. 84 Sidecar Configuration.................................... 84 Actuation................................................ 84 Fob Assignment........................................... 84 Power Disruption and Configuring......................... 84 3.4 PERSONAL IDENTIFICATION NUMBER (PIN)..................... 85 General.................................................. 85 Initial Pin Entry........................................ 85 Changing the Pin......................................... 85 3.5 ARMING/DISARMING SECURITY SYSTEM......................... 87 Hands-Free Fob........................................... 87 Security Lamp (Key Icon)................................. 87 Arming................................................... 87 Disarming................................................ 88 Disarming with a Personal Identification Number (PIN).... 88 3.6 WARNINGS AND ALARMS...................................... 89 Warnings................................................. 89 Alarm.................................................... 89 Siren Chirp Mode (Confirmation).......................... 89 3.7 SERVICE/EMERGENCY FUNCTIONS.............................. 90 Transport Mode........................................... 90 Service Mode............................................. 90 Four-Way Flashing........................................ 90 3.8 TROUBLESHOOTING.......................................... 91 Turn Signals (TSM/HFSM).................................. 91 Security System (HFSM)................................... 91 Diagnostics Mode......................................... 91 Troubleshooting.......................................... 91 3.9 CHECKING FOR DIAGNOSTIC TROUBLE CODES.................... 92 General.................................................. 92 Security/Lamp Diagnostics................................ 92 Code Types............................................... 93 Retrieving DTCs.......................................... 93 Multiple DTCs/Priority Order............................. 94 3.10 INITIAL DIAGNOSTIC CHECK: TSM/HFSM...................... 95 General.................................................. 95 Initial Diagnostics...................................... 95 3.11 SPEEDOMETER SELF DIAGNOSTICS............................100 General..................................................100 Diagnostics..............................................100 3.12 BREAKOUT BOX: TSM/HFSM..................................102 General..................................................102 Installation.............................................102 Removal..................................................102 3.13 FAILS TO DISARM (HFSM ONLY).............................103 General..................................................103 Job/Time Codes...........................................103 Diagnostics..............................................103 3.14 DTC B0563...............................................106 General..................................................106 Diagnostics..............................................106 3.15 TSM/HFSM: TURN SIGNAL ERRORS AND DTCS...................107 General..................................................107 Diagnostics..............................................107 3.16 DTC B1131, B1132 (HFSM ONLY)............................121 General..................................................121 Diagnostics..............................................121 3.17 DTC B1134...............................................124 General..................................................124 Diagnostics..............................................124 3.18 DTC B1135...............................................127 Diagnostics..............................................127 3.19 DTC B1136, B1142 (HFSM ONLY)............................128 Diagnostics..............................................128 3.20 DTC B1141 (HFSM ONLY)...................................129 Diagnostics..............................................129 3.21 DTC B1143, B1144, B1145 (HFSM ONLY).....................133 General..................................................133 Diagnostics..............................................133 3.22 DTC B1154, B1155........................................138 Diagnostics..............................................138 3.23 DTC U1016, U1255........................................142 General..................................................142 Diagnostics..............................................142 3.24 DTC U1300, U1301 OR BUS ER..............................145 Diagnostics..............................................145 3.25 TSM/HFSM: PASSWORD LEARN................................146 General..................................................146 Password Learning........................................146 3.26 HFSM MAINTENANCE........................................147 General..................................................147 Hands-Free Fob...........................................147 Siren (If Installed).....................................147 4. ENGINE MANAGEMENT.............................................150 4.1 SPECIFICATIONS...........................................152 Specifications...........................................152 4.2 EFI SYSTEM...............................................153 General..................................................153 Troubleshooting..........................................153 4.3 EFI DIAGNOSTIC INTRODUCTION..............................156 System Problems..........................................156 Resolving Problems.......................................156 4.4 CHECKING FOR DIAGNOSTIC TROUBLE CODES: EFI...............157 Check Engine Lamp........................................157 Code Types...............................................158 Retrieving Diagnostic Trouble Codes......................158 Multiple Diagnostic Trouble Codes........................158 4.5 INITIAL DIAGNOSTIC CHECK.................................159 General..................................................159 Initial Diagnostics......................................159 4.6 SPEEDOMETER SELF DIAGNOSTICS.............................167 General..................................................167 Diagnostics..............................................167 4.7 BREAKOUT BOX: EFI........................................169 General..................................................169 Installation.............................................169 Removal..................................................169 4.8 WIGGLE TEST..............................................171 General..................................................171 Procedure................................................171 4.9 INTAKE LEAK TEST.........................................172 General..................................................172 Leak Tester..............................................172 Procedure................................................172 4.10 ENGINE CRANKS, BUT WILL NOT START.......................174 General..................................................174 Diagnostics..............................................174 4.11 NO ECM POWER............................................181 General..................................................181 Diagnostics..............................................181 4.12 STARTS, THEN STALLS.....................................185 General..................................................185 Diagnostics..............................................185 4.13 FUEL SYSTEM ELECTRICAL TEST.............................190 General..................................................190 Diagnostics..............................................190 4.14 SYSTEM RELAY CHECK......................................198 General..................................................198 Diagnostics..............................................198 4.15 FUEL PRESSURE TEST......................................204 General..................................................204 Testing..................................................204 Diagnostics..............................................206 4.16 IDLE AIR CONTROL........................................208 General..................................................208 Diagnostics..............................................208 4.17 MISFIRE AT IDLE OR UNDER LOAD...........................213 General..................................................213 Diagnostics..............................................213 4.18 COMBUSTION ABSENT/INTERMITTENT..........................219 General..................................................219 Diagnostics..............................................219 4.19 DTC P0107, P0108........................................224 General..................................................224 Diagnostics..............................................224 4.20 DTC P0112, P0113........................................228 General..................................................228 Diagnostics..............................................228 4.21 DTC P0117, P0118........................................232 General..................................................232 Diagnostics..............................................232 4.22 DTC P0122, P0123........................................236 General..................................................236 Diagnostics..............................................236 4.23 DTC P0131, P0132, P0134, P0151, P0152, P0154............240 General..................................................240 Diagnostics..............................................240 4.24 DTC P0261, P0262, P0263, P0264..........................245 General..................................................245 Diagnostics..............................................245 4.25 DTC P0373, P0374........................................251 General..................................................251 Diagnostics..............................................251 4.26 DTC P0501, P0502........................................254 General..................................................254 Diagnostics..............................................254 4.27 DTC P0562, P0563........................................258 General..................................................258 Diagnostics..............................................258 4.28 DTC P0603, P0605........................................262 General..................................................262 Diagnostics..............................................262 4.29 DTC P0661, P0662........................................263 General..................................................263 Diagnostics..............................................263 4.30 DTC P1009, P1010........................................267 General..................................................267 Diagnostics..............................................267 4.31 DTC P1351, P1352, P1354, P1355..........................271 General..................................................271 Diagnostics..............................................271 4.32 DTC P1475, P1477, P1478.................................276 General..................................................276 Diagnostics..............................................276 4.33 DTC P1501, P1502........................................282 General..................................................282 Diagnostics..............................................282 4.34 DTC U1064, U1255........................................287 General..................................................287 Diagnostics..............................................287 4.35 DTC U1097, U1255........................................290 General..................................................290 Diagnostics..............................................290 A. APPENDIX A CONNECTOR REPAIR...................................294 A.1 AMP 1-PLACE CONNECTORS...................................296 AMP 1-Place Connector Repair.............................296 A.2 AMP MULTILOCK CONNECTORS.................................298 AMP Multilock Connector Repair...........................298 A.3 DELPHI CONNECTORS........................................303 Delphi Connector Repair..................................303 A.4 DEUTSCH 1-PLACE ELECTRICAL CONNECTORS....................305 Deutsch 1-Place Connector Repair.........................305 A.5 DEUSCH ELECTRICAL CONNECTORS.............................306 Deutsch Connector Repair.................................306 A.6 DEUTSCH STANDARD TERMINALS...............................310 Deutsch Standard Terminal Crimps.........................310 A.7 DEUTSCH MINI-TERMINAL CRIMPS.............................311 Deutsch Mini Terminal Crimps.............................311 A.8 DEUTSCH SOLID BARREL TERMINALS...........................312 Deutsch Solid Barrel Terminal Crimps.....................312 A.9 RELAY AND FUSE BLOCKS....................................314 Fuse Block Repair........................................314 A.10 150 METRI-PACK CONNECTORS...............................315 150 Metri-Pack Connector Repair..........................315 A.11 280 METRI-PACK CONNECTORS...............................317 280 Metri-Pack Connector Repair..........................317 A.12 480 METRI-PACK CONNECTORS...............................319 480 Metri-Pack Connector Repair..........................319 A.13 630 METRI-PACK CONNECTORS...............................320 630 Metri-Pack Connector Repair..........................320 A.14 800 METRI-PACK CONNECTORS...............................321 Delphi Maxi-Fuse Housing Repair..........................321 A.15 METRI-PACK TERMINALS....................................323 Metri-Pack Terminal Crimps...............................323 A.16 MOLEX CONNECTORS........................................325 Molex Connector Repair...................................325 A.17 PACKARD ECM CONNECTOR...................................327 Packard 100W Connector Repair............................327 A.18 PACKARD MICRO-64 CONNECTORS.............................329 Packard Micro-64 Connector Repair........................329 A.19 SEALED SPLICE CONNECTORS................................332 Sealed Splice Connector Repair...........................332 B. APPENDIX B WIRING.............................................334 B.1 CONNECTORS...............................................336 Connector Locations......................................336 B.2 WIRING DIAGRAMS..........................................338 Wiring Diagram Information...............................338 2008 Softail Wiring Diagrams.............................339 C. APPENDIX C CONVERSIONS........................................374 C.1 METRIC CONVERSION........................................376 Conversion Table.........................................376 C.2 FLUID CONVERSIONS........................................377 United States System.....................................377 Metric System............................................377 British Imperial System..................................377 C.3 TORQUE CONVERSIONS.......................................378 United States System.....................................378 Metric System............................................378 D. APPENDIX D GLOSSARY...........................................380 D.1 GLOSSARY.................................................382 Acronyms and Abbreviations...............................382 E. APPENDIX E TSM/TSSM (JAPAN/KOREA).............................384 E.1 TSM/TSSM (JAPAN/KOREA) OVERVIEW..........................386 General..................................................386 Troubleshooting..........................................386 E.2 TSM/TSSM FEATURES........................................388 General..................................................388 Turn Signal Functions....................................388 Bank Angle Function......................................388 Clutch/Neutral Interlock Functions.......................388 Security Alarm and Immobilization Functions..............388 E.3 VEHICLE DELIVERY.........................................390 General..................................................390 Configuring A TSSM.......................................390 Sidecar Configuration....................................390 Power Disruption and Configuring.........................390 Key Fob Assignment: TSSM.................................390 Pin Entry: TSSM..........................................391 Changing the Pin: TSSM...................................393 E.4 TURN SIGNAL FUNCTIONS....................................394 General..................................................394 Automatic Cancellation...................................394 Manual Cancellation......................................394 Four-Way Flashing........................................394 Diagnostics Mode.........................................394 E.5 BANK ANGLE FUNCTION......................................395 General..................................................395 Operation................................................395 E.6 SECURITY SYSTEM FUNCTIONS (TSSM ONLY)....................396 General..................................................396 Alarm Sensitivity: TSSM..................................396 Auto-Arming Function: TSSM...............................397 Storage Mode: TSSM.......................................398 E.7 ARMING/DISARMING (TSSM ONLY).............................399 General..................................................399 Security Lamp............................................399 Using Key FOB: TSSM......................................399 Using the Pin............................................399 E.8 DIAGNOSTIC TROUBLE CODES (DTC)...........................401 TSM/TSSM.................................................401 Code Types...............................................402 Retrieving Diagnostic Trouble Codes......................402 Multiple Diagnostic Trouble Codes........................402 E.9 INITIAL DIAGNOSTIC CHECK: TSM/TSSM.......................404 General..................................................404 Initial Diagnostics......................................404 E.10 SPEEDOMETER SELF DIAGNOSTICS............................409 General..................................................409 Diagnostics..............................................409 E.11 BREAKOUT BOX: TSM/TSSM..................................411 General..................................................411 Installation.............................................411 Removal..................................................411 E.12 FAILS TO DISARM (TSSM ONLY).............................412 General..................................................412 Diagnostics..............................................412 E.13 TURN SIGNAL ERRORS: B1121, B1122, B1141.................415 General..................................................415 Diagnostics..............................................415 E.14 DTC B0563...............................................427 General..................................................427 Diagnostics..............................................427 E.15 DTC B1131, B1132........................................428 General..................................................428 Diagnostics..............................................428 E.16 DTC B1134...............................................431 General..................................................431 Diagnostics..............................................431 E.17 DTC B1135...............................................434 General..................................................434 E.18 DTC B1154, DTC B1155....................................435 General..................................................435 Diagnostic Notes.........................................435 E.19 DTC U1016, U1255........................................439 General..................................................439 Diagnostics..............................................439 E.20 DTC U1300, U1301 OR BUS ER..............................442 General..................................................442 Diagnostics..............................................442 E.21 TSM/TSSM: PASSWORD LEARN................................443 General..................................................443 Password Learning........................................443 E.22 TSSM MAINTENANCE........................................444 General..................................................444 Key FOB..................................................444 Siren (If Installed).....................................444 TOOLS............................................................446 TORQUE VALUES....................................................450 INDEX............................................................452
2008 HARLEY DAVIDSON SOFTAIL MODELS ELECTRICAL DIAGNOSTICS MANUAL – PDF DOWNLOAD:
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