2008 Harley-Davidson Touring Models Electrical Diagnostics Manual 99497-08 – PDF DOWNLOAD

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2008 Harley-Davidson Touring Models Electrical Diagnostics Manual 99497-08 – PDF DOWNLOAD

FILE DETAILS:

2008 Harley-Davidson Touring Models Electrical Diagnostics Manual 99497-08 – PDF DOWNLOAD

Language : English
Pages : 816
Downloadable : Yes
File Type : PDF
Size: 44.7 MB

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DESCRIPTION:

2008 Harley-Davidson Touring Models Electrical Diagnostics Manual 99497-08 – 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
5 Audio System
6 ABS
A Appendix A Connector Repair
B Appendix B Wiring
C Appendix C Conversions
D Appendix D Glossary
E Appendix E TSM/TSSM (Japan/Korea)

TABLE OF CONTENTS:

2008 Harley-Davidson Touring Models Electrical Diagnostics Manual 99497-08 – PDF DOWNLOAD

FOREWORD 7
TABLE OF CONTENTS 9
1 STARTING / CHARGING 21
1 1 STARTER TROUBLESHOOTING 23
General 23
Starter Troubleshooting 23
1 2 STARTING SYSTEM DIAGNOSIS 25
Diagnostics 25
1 3 DIAGNOSTICS/TROUBLESHOOTING 35
Voltage Drop 35
1 4 STARTER ACTIVATION CIRCUITS 36
Starter Activation Circuits 36
1 5 TESTING STARTER ON MOTORCYCLE 37
Start Relay Test 37
Starter Current Draw Test 37
1 6 TESTING STARTER ON BENCH 38
Free Running Current Draw Test 38
Starter Solenoid 38
Solenoid Pull-In Test 38
Solenoid Hold-In Test 38
Solenoid Return Test 39
1 7 CHARGING SYSTEM 40
General 40
Troubleshooting 40
Testing 44
1 8 BATTERY TESTING 48
General 48
Voltmeter Test 48
Conductance Test 48
Load Test 48
2 INSTRUMENTS 51
2 1 CHECKING FOR DIAGNOSTIC TROUBLE CODES 53
Check Engine Lamp 53
Security Lamp 54
Code Types 55
Retrieving Diagnostic Trouble Codes 55
Multiple Diagnostic Trouble Codes 55
2 2 INITIAL DIAGNOSTIC CHECK: SPEEDOMETER 56
General 56
Initial Diagnostics 56
2 3 SPEEDOMETER SELF DIAGNOSTICS 63
General 63
Diagnostics 63
2 4 SPEEDOMETER/TACHOMETER 65
General 65
Speedometer Theory of Operation 65
Odometer Theory of Operation 65
Tachometer Theory of Operation 65
Diagnostics 65
2 5 BREAKOUT BOX: SPEEDOMETER/TACHOMETER 68
General 68
Installation 68
Removal 68
2 6 FUEL GAUGE 69
Theory of Operation 69
Fuel Gauge and Sender Test 69
2 7 OIL, AIR AND VOLTMETER GAUGES 70
Oil Pressure Gauge and Indicator Light 70
Ambient Air Temperature Gauge 70
Voltmeter Gauge 70
2 8 INDICATOR LIGHTS: ALL 72
General 72
Diagnostics 73
2 9 DTC B1004, B1005 76
General 76
Diagnostics 76
2 10 DTC B1006, B1007 80
General 80
2 11 DTC B1008 82
General 82
Diagnostics 82
2 12 DTC U1016 84
General 84
Diagnostics 84
2 13 DTC U1064, U1255 89
General 89
Diagnostics 89
2 14 DTC U1300, U1301 OR BUS ER 94
General 94
Diagnostics 94
3 TSM/HFSM 95
3 1 TURN SIGNAL OVERVIEW 97
General 97
Security System: Japan/Korea 97
Turn Signal Functions 97
Manual Cancellation 97
Automatic Cancellation 97
Bank Angle Functions 97
Bank Angle Restart 97
Clutch/Neutral Interlock 97
Security System H-DSSS 97
3 2 HARLEY-DAVIDSON SMART SECURITY SYSTEM 98
Components 98
Security Immobilization 98
HFSM Features 99
3 3 H-DSSS ACTUATION 101
General 101
Sidecar Configuration 101
Actuation 101
Fob Assignment 101
Power Disruption and Configuring 101
3 4 PERSONAL IDENTIFICATION NUMBER (PIN) 102
General 102
Initial Pin Entry 102
Changing the PIN 102
3 5 ARMING/DISARMING SECURITY SYSTEM 104
Hands-Free Fob 104
Security Lamp (Key Icon) 104
Arming 104
Disarming 104
3 6 WARNINGS AND ALARMS 106
Warnings 106
Alarm 106
Siren Chirp Mode (Confirmation) 106
3 7 SERVICE/EMERGENCY FUNCTIONS 107
Transport Mode 107
Service Mode 107
Four-Way Flashing 107
3 8 TROUBLESHOOTING 108
Turn Signals (TSM/HFSM) 108
Security System (HFSM) 108
Diagnostics Mode 108
Troubleshooting 108
3 9 CHECKING FOR DIAGNOSTIC TROUBLE CODES 109
General 109
Security Lamp Diagnostics 109
Code Types 110
Retrieving DTCs 111
Multiple DTCs/Priority Order 111
3 10 INITIAL DIAGNOSTIC CHECK: TSM/HFSM 113
General 113
Initial Diagnostics 113
3 11 SPEEDOMETER SELF-DIAGNOSTICS 120
General 120
Diagnostics 120
3 12 BREAKOUT BOX: TSM/HFSM 122
General 122
Installation 122
Removal 122
3 13 FAILS TO DISARM (HFSM ONLY) 123
General 123
Job/Time Codes 123
Diagnostics 123
3 14 DTC B0563 126
General 126
Diagnostics 126
3 15 TSM/HFSM: TURN SIGNAL ERRORS AND DTCS 127
General 127
Diagnostics 128
3 16 DTC B1131, B1132 (HFSM ONLY) 143
General 143
Diagnostics 143
3 17 DTC B1134 146
General 146
Diagnostics 146
3 18 DTC B1135 149
Diagnostics 149
3 19 DTC B1136, B1142 (HFSM ONLY) 150
Diagnostics 150
3 20 DTC B1141 (HFSM ONLY) 151
Diagnostics 151
3 21 DTC B1143, B1144, B1145 (HFSM ONLY) 157
General 157
Diagnostics 157
3 22 DTC B1151, B1152, B1153 162
General 162
Diagnostics 162
3 23 DTC B1154, B1155 165
Diagnostics 165
3 24 DTC U1016, U1255 171
General 171
Diagnostics 171
3 25 DTC U1300, U1301 OR BUS ER 176
Diagnostics 176
3 26 TSM/HFSM: PASSWORD LEARN 177
General 177
Password Learning 177
3 27 HFSM MAINTENANCE 178
General 178
Hands-Free Fob 178
Smart Siren (If Installed) 178
4 ENGINE MANAGEMENT 181
4 1 SPECIFICATIONS 183
Specifications 183
4 2 EFI SYSTEM 185
General 185
Troubleshooting 186
4 3 EFI DIAGNOSTIC INTRODUCTION 189
System Problems 189
Resolving Problems 189
4 4 CHECKING FOR DIAGNOSTIC TROUBLE CODES: EFI 190
Check Engine Lamp 190
Code Types 191
Retrieving Diagnostic Trouble Codes 191
Multiple Diagnostic Trouble Codes 191
4 5 INITIAL DIAGNOSTIC CHECK: EFI 193
General 193
Initial Diagnostics 193
4 6 SPEEDOMETER SELF-DIAGNOSTICS 202
General 202
Diagnostics 202
4 7 BREAKOUT BOX: EFI 204
General 204
Installation 204
Removal 204
4 8 WIGGLE TEST 205
General 205
Procedure 205
4 9 INTAKE LEAK TEST 206
General 206
Leak Tester 206
Intake Leak Testing 206
4 10 ENGINE CRANKS, BUT WILL NOT START 208
General 208
Diagnostics 208
4 11 NO ECM POWER 215
General 215
Diagnostics 216
4 12 STARTS, THEN STALLS 220
General 220
Diagnostics 220
4 13 FUEL SYSTEM ELECTRICAL TEST 226
General 226
Diagnostics 226
4 14 SYSTEM RELAY FAULT 234
General 234
Diagnostics 235
4 15 FUEL PRESSURE TEST 243
General 243
Testing 244
Diagnostics 246
4 16 MISFIRE AT IDLE OR UNDER LOAD 248
General 248
Diagnostics 248
4 17 COMBUSTION ABSENT/INTERMITTENT 254
General 254
Diagnostics 254
4 18 DTC P0107, P0108, P0112, P0113 259
General 259
Diagnostics 260
4 19 DTC P0117, P0118 267
General 267
Diagnostics 267
4 20 DTC P0120, P0122, P0123, P0220, P0222, P0223 271
General 271
Diagnostics 271
4 21 DTC P0131, P0132, P0134, P0151, P0152, P0154 278
General 278
Diagnostics 278
4 22 DTC P0261, P0262, P0263, P0264 284
General 284
Diagnostics 284
4 23 DTC P0373, P0374 290
General 290
Diagnostics 290
4 24 DTC P0444, P0445 293
General 293
Diagnostics 294
4 25 DTC P0501, P0502 301
General 301
Diagnostics 301
4 26 DTC P0562, P0563 305
General 305
Diagnostics 307
4 27 DTC P0572 312
General 312
Diagnostics 312
4 28 DTC P0577 318
General 318
System Operation 318
Troubleshooting 320
Diagnostics 320
Cruise Inoperative Diagnostics 325
Cruise Disengage Causes 326
4 29 DTC P0603, P0605 327
General 327
Diagnostics 327
4 30 DTC P0641, P0651 328
General 328
Diagnostics 328
4 31 DTC P1009, P1010 334
General 334
Diagnostics 334
4 32 DTC P1270 340
General 340
Diagnostics 340
4 33 DTC P1351, P1352, P1354, P1355 342
General 342
Diagnostics 342
4 34 DTC P1475, P1477, P1478 347
General 347
Diagnostics 348
4 35 DTC P1501, P1502 354
General 354
Diagnostics 354
4 36 DTC P1510, P1511, P1512 359
General 359
Diagnostics 359
4 37 DTC P1514 361
General 361
Diagnostics 361
4 38 DTC P1600 363
General 363
Diagnostics 363
4 39 DTC P2100, P2101, P2102, P2103 365
General 365
Diagnostics 365
4 40 DTC P2105 369
General 369
Diagnostics 369
4 41 DTC P2107 371
General 371
Diagnostics 372
4 42 DTC P2119 375
General 375
Diagnostics 375
4 43 DTC P2122, P2123, P2127, P2128 377
General 377
Diagnostics 377
4 44 DTC P2135, P2138 381
General 381
Diagnostics 381
4 45 DTC P2176 385
General 385
Diagnostics 385
4 46 DTC U1064 387
General 387
Diagnostics 387
4 47 DTC U1097 392
General 392
Diagnostics 392
5 AUDIO SYSTEM 397
5 1 RADIO DIAGNOSTICS 399
System Description 399
Onboard Diagnostics 399
5 2 RADIO SWITCH DIAGNOSTICS: DTC B2006-B2015 404
General 404
Diagnostics 404
5 3 RADIO SPEAKER DIAGNOSTICS: DTC B2016-B2027 442
General 442
Diagnostics 442
5 4 SERIAL DATA BUS DIAGNOSTICS 459
General 459
Diagnostics 459
5 5 ADVANCED AUDIO SYSTEM SYMPTOMS 480
General 480
Factory Defaults 480
Diagnostics 481
6 ABS 547
6 1 ANTILOCK BRAKE SYSTEM (ABS) GENERAL INFORMATION 549
Antilock Brake System (ABS) Description 549
Code Types 551
Retrieving Diagnostic Trouble Codes 551
Multiple Trouble Codes 551
6 2 SPEEDOMETER SELF DIAGNOSTICS 552
General 552
Diagnostics 552
6 3 BREAKOUT BOX: ABS 555
General 555
Installation 555
Removal 555
6 4 INITIAL DIAGNOSTIC CHECK: ABS 556
General 556
Initial Diagnostics 556
6 5 ABS INDICATOR DIAGNOSTICS 561
ABS Indicator Always On or Inoperative 561
6 6 DTC C0562 565
DTC C0562: Device Voltage Low 565
6 7 DTC C0563 568
DTC C0563: Device Voltage High 568
6 8 DTC C1017 571
DTC C1017: Pump Motor Power Circuit Open Fault 571
6 9 DTC C1018 575
DTC C1018: Pump Motor Ground High Resistance Fault 575
6 10 DTC C1021, C1023 579
DTC C1021, C1023: Wheel Speed Sensor Equals Zero (Front or Rear) 579
6 11 DTC C1025, C1027, C1206, C1208 582
DTC C1025, C1027, C1206, C1208: Wheel Speed Signal Intermittent or Frequency Out Of Range 582
6 12 DTC C1032, C1034 585
DTC C1032, C1034: Wheel Speed Sensor Circuit Open Or Shorted (Front or Rear) 585
6 13 DTC C1042 591
DTC C1042: Pump Motor Open 591
6 14 DTC C1043 592
DTC C1043: Pump Motor Stalled 592
6 15 DTC C1094 593
DTC C1094: Front Brake Switch Always On 593
6 16 DTC C1095 597
DTC C1095: Front Brake Switch Open 597
6 17 DTC C1151 601
DTC C1151: Front Wheel Release Too Long 601
6 18 DTC C1153 604
DTC C1153: Rear Wheel Release Too Long 604
6 19 DTC C1158 607
DTC C1158: Calibration Programming Required 607
6 20 DTC C1212 611
DTC C1212: Front or Rear Brake Not Applied with Decel 611
6 21 DTC C1214 615
DTC C1214: Rear Brake Switch Always On 615
6 22 DTC C1216 619
DTC C1216: Rear Brake Switch Open 619
6 23 DTC C1014, C1055-C1066, C1118, C1121 623
DTC C1014, C1055-C1066, C1118, C1121: ECU Internal Fault 623
6 24 DTC U1300, U1301 OR BUS ER 627
Diagnostics 627
A APPENDIX A CONNECTOR REPAIR 629
A 1 AMP 1-PLACE CONNECTORS 631
AMP 1-Place Connector Repair 631
A 2 AMP MULTILOCK CONNECTORS 633
AMP Multilock Connector Repair 633
A 3 DELPHI CONNECTORS 638
Delphi Connector Repair 638
A 4 DEUTSCH 1-PLACE ELECTRICAL CONNECTORS 640
Deutsch 1-Place Connector Repair 640
A 5 DEUSCH ELECTRICAL CONNECTORS 641
Deutsch Connector Repair 641
A 6 DEUTSCH STANDARD TERMINALS 645
Deutsch Standard Terminal Crimps 645
A 7 DEUTSCH MINI-TERMINAL CRIMPS 646
Deutsch Mini Terminal Crimps 646
A 8 DEUTSCH SOLID BARREL TERMINALS 647
Deutsch Solid Barrel Terminal Crimps 647
A 9 RELAY AND FUSE BLOCKS 649
Fuse Block Repair 649
A 10 150 METRI-PACK CONNECTORS 650
150 Metri-Pack Connector Repair 650
A 11 280 METRI-PACK CONNECTORS 652
280 Metri-Pack Connector Repair 652
A 12 480 METRI-PACK CONNECTORS 654
480 Metri-Pack Connector Repair 654
A 13 630 METRI-PACK CONNECTORS 655
630 Metri-Pack Connector Repair 655
A 14 800 METRI-PACK CONNECTORS 656
Delphi Maxi-Fuse Housing Repair 656
A 15 METRI-PACK TERMINALS 658
Metri-Pack Terminal Crimps 658
A 16 MOLEX CONNECTORS 660
Molex Connector Repair 660
A 17 PACKARD ECM CONNECTOR 662
Packard 100W Connector Repair 662
A 18 PACKARD MICRO-64 CONNECTORS 664
Packard Micro-64 Connector Repair 664
A 19 SEALED SPLICE CONNECTORS 667
Sealed Splice Connector Repair 667
B APPENDIX B WIRING 669
B 1 CONNECTORS 671
Connector Locations 671
B 2 WIRING DIAGRAMS 688
Wiring Diagram Information 688
2008 Touring Wiring Diagrams 689
C APPENDIX C CONVERSIONS 721
C 1 METRIC CONVERSION 723
Conversion Table 723
C 2 FLUID CONVERSIONS 724
United States System 724
Metric System 724
British Imperial System 724
C 3 TORQUE CONVERSIONS 725
United States System 725
Metric System 725
D APPENDIX D GLOSSARY 727
D 1 GLOSSARY 729
Acronyms and Abbreviations 729
E APPENDIX E TSM/TSSM (JAPAN/KOREA) 733
E 1 TSM/TSSM (JAPAN/KOREA) OVERVIEW 735
General 735
Troubleshooting 735
E 2 TSM/TSSM FEATURES 737
General 737
Turn Signal Functions 737
Bank Angle Function 737
Clutch/Neutral Interlock Functions 737
Security Alarm and Immobilization Functions 737
E 3 TSM/TSSM VEHICLE DELIVERY 739
General 739
Configuring A TSSM 739
Sidecar Configuration 739
Power Disruption and Configuring 739
Key Fob Assignment: TSSM 739
Pin Entry: TSSM 740
Changing the Pin: TSSM 742
E 4 TSM/TSSM TURN SIGNAL FUNCTIONS 743
General 743
Automatic Cancellation 743
Manual Cancellation 743
Four-Way Flashing 743
Diagnostics Mode 743
E 5 TSM/TSSM BANK ANGLE FUNCTION 744
General 744
Operation 744
E 6 SECURITY SYSTEM FUNCTIONS (TSSM ONLY) 745
General 745
Alarm Sensitivity: TSSM 745
Auto-Arming Function: TSSM 746
Storage Mode: TSSM 747
E 7 ARMING/DISARMING (TSSM ONLY) 748
General 748
Security Lamp 748
Using Key FOB: TSSM 748
Using the Pin 748
E 8 DIAGNOSTIC TROUBLE CODES (DTC) 750
TSM/TSSM 750
Code Types 751
Retrieving Diagnostic Trouble Codes 751
Multiple Diagnostic Trouble Codes 752
E 9 INITIAL DIAGNOSTIC CHECK: TSM/TSSM 753
General 753
Initial Diagnostics 753
E 10 SPEEDOMETER SELF DIAGNOSTICS 760
General 760
Diagnostics 760
E 11 BREAKOUT BOX: TSM/TSSM 762
General 762
Installation 762
Removal 762
E 12 FAILS TO DISARM (TSSM ONLY) 763
General 763
Diagnostics 763
E 13 TSM/TSSM TURN SIGNAL ERRORS: B1121, B1122, B1141 766
General 766
Diagnostics 766
E 14 DTC B0563 778
General 778
Diagnostics 778
E 15 DTC B1131, B1132 779
General 779
Diagnostics 779
E 16 DTC B1134 782
General 782
Diagnostics 782
E 17 DTC B1135 785
General 785
E 18 DTC B1151, B1152, B1153 786
General 786
Diagnostics 786
E 19 DTC B1154, B1155 790
General 790
Diagnostic Notes 790
E 20 DTC U1016 795
General 795
Diagnostics 795
E 21 DTC U1300, U1301 OR BUS ER 800
General 800
Diagnostics 800
E 22 TSM/TSSM: PASSWORD LEARN 801
General 801
Password Learning 801
E 23 TSSM MAINTENANCE 803
General 803
Key FOB 803
Siren (If Installed) 803
TOOLS 805
TORQUE VALUES 811
INDEX 813

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PLEASE NOTE:

• This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
• Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.

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