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 General Information 2 Initial Diagnostics and Serial Data 3 Starting and Charging 4 Instruments 5 Accessories, Horn, Lighting and Security 6 Engine Management 7 ABS A Appendix A Connector Repair B Appendix B Wiring C Appendix C Conversions D Appendix D Glossary Use the TABLE OF CONTENTS (which follows this FOREWORD) and the INDEX (at the back of this manual) to quickly locate subjects.
Chapters and topics in this manual are sequentially numbered for easy navigation. For example, a cross-reference shown as 2.2 SPECIFICATIONS refers to chapter 2 CHASSIS, heading 2.2 SPECIFICATIONS. For quick and easy reference, all pages contain a chapter number followed by a page number. For example, page 3-5 refers to page 5 in Chapter 3.
A number of acronyms and abbreviations are used in this document. See the D.1 GLOSSARY for a list of acronyms, abbreviations and definitions. PREPARATION FOR SERVICE PART NUMBER TOOL NAME HD-48650 DIGITAL TECHNICIAN II Stop the engine when refueling or servicing the fuel system. Do not smoke or allow open flame or sparks near gasoline.
Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00002a) Good preparation is very important for efficient service work. Start each job with a clean work area. This will allow the repair to proceed as smoothly as possible. It will also reduce the incidence of misplaced tools and parts. Clean a motorcycle that is excessively dirty before work starts.
Cleaning will occasionally uncover sources of trouble. Gather any tools, instruments and any parts needed for the job before work begins. Interrupting a job to locate tools or parts is a distraction and causes needless delay.
FOREWORD........................................................................................................ 7
TABLE OF CONTENTS............................................................................................... 9
1. GENERAL INFORMATION.......................................................................................... 23
1.1 SPECIFICATIONS AND COMPONENT LOCATIONS.................................................................. 25
Specifications.......................................................................................... 25
Component Locations..................................................................................... 25
1.2 DIAGNOSTIC TOOLS........................................................................................ 32
How To Use Diagnostic Tools............................................................................. 32
1.3 DIAGNOSTICS AND TROUBLESHOOTING......................................................................... 36
Voltage Drop............................................................................................ 36
Wiggle Test............................................................................................. 37
Job/Time Codes Values................................................................................... 37
2. INITIAL DIAGNOSTICS AND SERIAL DATA.......................................................................... 39
2.1 INITIAL DIAGNOSTICS..................................................................................... 41
Description and Operation............................................................................... 41
Retrieving Trouble Codes................................................................................ 41
Odometer Self-Diagnostics............................................................................... 41
Initial Diagnostics..................................................................................... 41
Diagnostics............................................................................................. 42
Code Types.............................................................................................. 48
Multiple Trouble Codes.................................................................................. 48
Clearing DTCs........................................................................................... 48
Security Lamp........................................................................................... 48
Check Engine Lamp....................................................................................... 48
Symptoms................................................................................................ 49
2.2 SERIAL DATA COMMUNICATION............................................................................... 51
Description and Operation............................................................................... 51
Components.............................................................................................. 51
Communication DTCs and Error Messages................................................................... 51
2.3 ODOMETER SELF-DIAGNOSTIC INOPERATIVE: DTC U0001, U0011, B2274........................................... 53
Description and Operation............................................................................... 53
Odometer Self-Diagnostic Inoperative: DTC U0001, U0011, B2274........................................... 55
2.4 NO VEHICLE POWER OR DTC U0100, U0121, U0140, U0141, U0142, U0156, U0157, U0002.......................... 60
Description and Operation............................................................................... 60
DTC U0100............................................................................................... 62
DTC U0121............................................................................................... 63
No Vehicle Power: DTC U0140............................................................................. 64
Left Hand Controls Inoperative: DTC U0141............................................................... 65
DTC U0142............................................................................................... 65
Speedometer Inoperative: DTC U0156...................................................................... 66
Tachometer Inoperative: DTC U0157....................................................................... 66
DTC U0002............................................................................................... 67
3. STARTING AND CHARGING........................................................................................ 69
3.1 BATTERY TESTING......................................................................................... 71
General................................................................................................. 71
Voltmeter Test.......................................................................................... 71
Battery Diagnostic Test................................................................................. 71
Load Test............................................................................................... 71
3.2 STARTING SYSTEM......................................................................................... 73
Description and Operation............................................................................... 73
Components.............................................................................................. 73
Starter Troubleshooting................................................................................. 76
Starter Testing......................................................................................... 77
Nothing Clicks.......................................................................................... 77
Starter Solenoid Clicks................................................................................. 78
Starter Spins But Does Not Engage....................................................................... 79
Starter Stalls or Spins Too Slowly...................................................................... 79
3.3 DTC B2121, B2122, B2123, B2124.......................................................................... 81
Description and Operation............................................................................... 81
DTC B2121............................................................................................... 82
DTC B2122............................................................................................... 82
DTC B2123............................................................................................... 82
DTC B2124............................................................................................... 83
3.4 TESTING STARTER ON MOTORCYCLE........................................................................... 84
Starter Current Draw Test............................................................................... 84
3.5 TESTING STARTER ON BENCH................................................................................ 85
Free Running Current Draw Test.......................................................................... 85
Starter Solenoid........................................................................................ 85
Solenoid Pull-In Test................................................................................... 85
Solenoid Hold-In Test................................................................................... 86
Solenoid Return Test.................................................................................... 86
3.6 CHARGING SYSTEM......................................................................................... 87
Description and Operation............................................................................... 87
Troubleshooting......................................................................................... 87
Low or No Charging...................................................................................... 88
Overcharging............................................................................................ 88
Low Battery After Extended IGN OFF...................................................................... 89
Battery Runs Down During Use............................................................................ 89
Battery Charging Tests.................................................................................. 89
3.7 DTC C0562, C0563........................................................................................ 92
Description and Operation............................................................................... 92
Diagnostics............................................................................................. 92
DTC C0562............................................................................................... 94
DTC C0563............................................................................................... 95
3.8 DTC P0562............................................................................................... 96
Description and Operation............................................................................... 96
Diagnostics............................................................................................. 96
DTC P0562............................................................................................... 98
3.9 DTC B2203...............................................................................................100
Description and Operation...............................................................................100
DTC B2203...............................................................................................102
3.10 DTC B2206, B2208.......................................................................................103
Description and Operation...............................................................................103
DTC B2206...............................................................................................104
DTC B2208...............................................................................................104
3.11 DTC B2271, B2272.......................................................................................105
Description and Operation...............................................................................105
DTC B2271...............................................................................................107
DTC B2272...............................................................................................107
4. INSTRUMENTS..................................................................................................109
4.1 INSTRUMENTS.............................................................................................111
Description and Operation...............................................................................111
Speedometer Theory of Operation.........................................................................111
Tachometer Theory of Operation..........................................................................111
Instrument Diagnostics..................................................................................111
4.2 FUEL GAUGE INACCURATE, DTC B1210, B1211.................................................................112
Description and Operation...............................................................................112
DTC B1210...............................................................................................114
DTC B1211...............................................................................................115
4.3 TRIP ODOMETER FUNCTIONS INOPERATIVE, DTC B2255..........................................................116
Description and Operation...............................................................................116
Trip Odometer Functions Inoperative, DTC B2255..........................................................118
4.4 NO INSTRUMENT POWER, DTC B1200..........................................................................119
Description and Operation...............................................................................119
No Instrument Power.....................................................................................121
DTC B1200...............................................................................................121
4.5 INDICATOR LAMPS.........................................................................................122
Description and Operation...............................................................................122
Oil Pressure Lamp Always On.............................................................................125
Oil Pressure Lamp Inoperative...........................................................................125
Neutral Lamp Always On..................................................................................126
Neutral Lamp Inoperative................................................................................126
High Beam Indicator Lamp Always On......................................................................127
High Beam Indicator Lamp Inoperative....................................................................127
Turn Signal Indicator Lamp Always On....................................................................127
Turn Signal Indicator Inoperative.......................................................................128
4.6 GAUGES..................................................................................................129
Theory of Operation.....................................................................................129
Fuel Gauge Inaccurate, No DTCs..........................................................................130
Fuel Gauge Inoperative..................................................................................130
5. ACCESSORIES, HORN, LIGHTING AND SECURITY.....................................................................131
5.1 ACCESSORIES: DTC B2112, B2113, B2114....................................................................133
Description and Operation...............................................................................133
DTC B2112...............................................................................................135
DTC B2113, B2114........................................................................................135
5.2 HORN: DTC B2126, B2127, B2128, B2129....................................................................136
Description and Operation...............................................................................136
DTC B2126...............................................................................................137
DTC B2127...............................................................................................138
DTC B2128, B2129........................................................................................138
5.3 TURN SIGNALS............................................................................................139
Description and Operation...............................................................................139
Will Not Cancel Upon Turn Completion, No DTCs...........................................................143
5.4 DTC B1101, B1151........................................................................................144
Description and Operation...............................................................................144
DTC B1101, B1151........................................................................................146
5.5 DTC B2141, B2143, B2144, B2146, B2148, B2149............................................................147
Description and Operation...............................................................................147
DTC B2141...............................................................................................150
DTC B2143, B2144........................................................................................150
DTC B2146...............................................................................................151
DTC B2148, B2149........................................................................................151
5.6 DTC B2151, B2153, B2154, B2156, B2158, B2159............................................................152
Description and Operation...............................................................................152
DTC B2151...............................................................................................155
DTC B2153, B2154........................................................................................155
DTC B2156...............................................................................................156
DTC B2158, B2159........................................................................................156
5.7 HEADLAMPS: DTC B2131, B2132, B2133, B2134, B2136, B2137, B2138, B2139...................................157
Description and Operation...............................................................................157
DTC B2131...............................................................................................159
DTC B2132...............................................................................................159
DTC B2133, B2134........................................................................................160
DTC B2136...............................................................................................160
DTC B2137...............................................................................................161
DTC B2138, B2139........................................................................................161
5.8 STOP LAMPS: DTC B2161, B2163, B2164, B2223..............................................................162
Description and Operation...............................................................................162
Stop Lamp Always On, DTC B2223..........................................................................165
DTC B2161...............................................................................................165
DTC B2163, B2164........................................................................................166
5.9 DTC B1103, B1153, B2210, B2212, B2250, B2251, B2252, B2253, B2254, B2260, B2261, B2262, B2263, B2270....167
Description and Operation...............................................................................167
DTC B1103, B1153........................................................................................169
DTC B2210, B2212, B2250, B2251, B2252, B2253, B2254, B2260, B2261, B2262, B2263.........................169
DTC B2270...............................................................................................169
Any Hand Control Switch Inoperative.....................................................................169
5.10 RUNNING LAMPS: DTC B2107, B2108, B2109, B2166, B2168, B2169............................................170
Description and Operation...............................................................................170
Front Running Lamps Inoperative.........................................................................173
Rear Running Lamps Inoperative..........................................................................173
License Plate Lamp Inoperative: FXDWG (without Center Stop Lamp)........................................173
License Plate Lamp Inoperative: Except FXDWG (without Center Stop Lamp).................................174
DTC B2107...............................................................................................174
DTC B2108, B2109........................................................................................175
DTC B2166 (Domestic Only)...............................................................................175
DTC B2168, B2169........................................................................................176
5.11 SECURITY SYSTEM........................................................................................177
Security Lamp...........................................................................................177
Security Immobilization.................................................................................177
Security System Features................................................................................177
Security System Warnings................................................................................178
Arming..................................................................................................178
Disarming...............................................................................................178
Alarm...................................................................................................179
5.12 KEY FOB................................................................................................180
Description and Operation...............................................................................180
Fob Assignment..........................................................................................180
5.13 SIREN..................................................................................................181
Description and Operation...............................................................................181
Siren Chirp Mode Confirmation...........................................................................181
5.14 SERVICE AND EMERGENCY FUNCTIONS AND CONFIGURATIONS.....................................................182
General.................................................................................................182
Actuation...............................................................................................182
Selecting a PIN.........................................................................................182
Initial PIN Entry.......................................................................................182
Changing the PIN........................................................................................182
Transport Mode..........................................................................................183
Service Mode............................................................................................183
Four-Way Flashing.......................................................................................183
5.15 DTC B2172, B2173.......................................................................................184
Description and Operation...............................................................................184
DTC B2172...............................................................................................185
DTC B2173...............................................................................................186
5.16 FAILS TO DISARM: DTC B2176, B2177, B2178...............................................................187
Description and Operation...............................................................................187
DTC B2176...............................................................................................188
DTC B2177...............................................................................................189
DTC B2178...............................................................................................189
Fails to Disarm.........................................................................................190
5.17 DTC B2218..............................................................................................191
Description and Operation...............................................................................191
DTC B2218...............................................................................................193
5.18 DTC B2183, B2188, B2193, B2198.........................................................................194
Description and Operation...............................................................................194
DTC B2183, B2188, B2193, B2198..........................................................................195
6. ENGINE MANAGEMENT............................................................................................197
6.1 EFI SYSTEM..............................................................................................199
General.................................................................................................199
6.2 ELECTRONIC CONTROL MODULE...............................................................................201
General.................................................................................................201
6.3 SENSORS AND DRIVERS.....................................................................................202
Description and Operation...............................................................................202
Sensors.................................................................................................202
Drivers.................................................................................................203
6.4 DTC B2102, B2103, B2104.................................................................................205
Description and Operation...............................................................................205
DTC B2102...............................................................................................207
DTC B2103, B2104........................................................................................207
6.5 DTC B2116, B2117, B2118, B2119..........................................................................210
Description and Operation...............................................................................210
DTC B2116...............................................................................................212
DTC B2117...............................................................................................212
DTC B2118, B2119........................................................................................212
6.6 DTC P0107, P0108........................................................................................214
Description and Operation...............................................................................214
DTC P0107...............................................................................................216
DTC P0108...............................................................................................217
6.7 DTC P0112, P0113........................................................................................218
Description and Operation...............................................................................218
DTC P0112...............................................................................................220
DTC P0113...............................................................................................220
6.8 DTC P0117, P0118........................................................................................222
Description and Operation...............................................................................222
DTC P0117...............................................................................................224
DTC P0118...............................................................................................224
6.9 DTC P0122, P0123........................................................................................226
Description and Operation...............................................................................226
DTC P0122...............................................................................................228
DTC P0123...............................................................................................228
6.10 DTC P0031, P0032, P0051, P0052, P0131, P0132, P0134, P0151, P0152, P0154...............................230
Description and Operation...............................................................................230
DTC P0031...............................................................................................232
DTC P0032...............................................................................................232
DTC P0051...............................................................................................233
DTC P0052...............................................................................................233
DTC P0131...............................................................................................234
DTC P0132...............................................................................................234
DTC P0134...............................................................................................235
DTC P0151...............................................................................................235
DTC P0152...............................................................................................236
DTC P0154...............................................................................................236
6.11 DTC P0261, P0262, P0264, P0265.........................................................................238
Description and Operation...............................................................................238
DTC P0261...............................................................................................240
DTC P0262...............................................................................................240
DTC P0264...............................................................................................241
DTC P0265...............................................................................................241
6.12 DTC P0371, P0372, P0374................................................................................243
Description and Operation...............................................................................243
DTC P0371, P0372, P0374.................................................................................244
6.13 DTC P0444, P0445.......................................................................................246
Description and Operation...............................................................................246
DTC P0444...............................................................................................248
DTC P0445...............................................................................................248
6.14 DTC P0502, P0503.......................................................................................249
Description and Operation...............................................................................249
DTC P0502...............................................................................................251
DTC P0503...............................................................................................251
6.15 DTC P0506, P0507.......................................................................................253
Description and Operation...............................................................................253
DTC P0506, P0507........................................................................................255
6.16 DTC P0603, P0605.......................................................................................257
Description and Operation...............................................................................257
6.17 DTC P0641..............................................................................................258
Description and Operation...............................................................................258
DTC P0641...............................................................................................261
6.18 DTC P0661, P0662.......................................................................................262
Description and Operation...............................................................................262
DTC P0661...............................................................................................263
DTC P0662...............................................................................................264
6.19 DTC P1009..............................................................................................265
General.................................................................................................265
DTC P1009...............................................................................................265
6.20 DTC P1353, P1356.......................................................................................266
Description and Operation...............................................................................266
DTC P1353, P1356........................................................................................268
6.21 DTC P1475, P1478.......................................................................................269
Description and Operation...............................................................................269
DTC P1475...............................................................................................270
DTC P1478...............................................................................................271
6.22 DTC P1501, P1502.......................................................................................272
Description and Operation...............................................................................272
DTC P1501...............................................................................................274
DTC P1502...............................................................................................274
Side Stand Displayed on Speedometer.....................................................................274
6.23 DTC P1632..............................................................................................276
Description and Operation...............................................................................276
6.24 DTC P1655, P1656.......................................................................................277
Description and Operation...............................................................................277
DTC P1655...............................................................................................279
DTC P1656...............................................................................................280
6.25 DTC P2300, P2301, P2303, P2304.........................................................................281
Description and Operation...............................................................................281
DTC P2300...............................................................................................283
DTC P2301...............................................................................................283
DTC P2303...............................................................................................283
DTC P2304...............................................................................................284
6.26 ENGINE CRANKS, BUT WILL NOT START......................................................................285
Description and Operation...............................................................................285
Engine Cranks but Will Not Start........................................................................285
6.27 HESITATION, LOSS OF POWER..............................................................................287
Description and Operation...............................................................................287
Hesitation, Loss of Power Test..........................................................................288
6.28 STARTS, THEN STALLS....................................................................................290
Description and Operation...............................................................................290
Starts, Then Stalls.....................................................................................292
6.29 MISFIRE AT IDLE OR UNDER LOAD..........................................................................293
Description and Operation...............................................................................293
In-line Spark Tester....................................................................................293
Misfire At Idle or Under Load...........................................................................295
7. ABS..........................................................................................................297
7.1 ANTI-LOCK BRAKE SYSTEM (ABS) GENERAL INFORMATION........................................................299
Description and Operation...............................................................................299
7.2 DTC C1014, C1040, C1055, C1061, C1062, C1065, C1066.....................................................301
Description and Operation...............................................................................301
DTC C1014, C1040, C1055, C1061, C1062, C1065, C1066.....................................................303
7.3 DTC C1021, C1023, C1025, C1027, C1029...................................................................304
Description and Operation...............................................................................304
DTC C1021, C1023, C1025, C1027, C1029...................................................................305
7.4 DTC C1032, C1034........................................................................................307
Description and Operation...............................................................................307
DTC C1032...............................................................................................309
DTC C1034...............................................................................................310
7.5 DTC C1159, C1178, C1184.................................................................................311
Description and Operation...............................................................................311
DTC C1159, C1178, C1184.................................................................................311
7.6 ABS INDICATOR ALWAYS ON, FLASHING OR INOPERATIVE........................................................312
Description and Operation...............................................................................312
ABS Indicator Continuously Flashing, No DTCs............................................................314
ABS Indicator Always On or Inoperative..................................................................314
A. APPENDIX A CONNECTOR REPAIR..................................................................................317
A.1 AUTOFUSE UNSEALED ELECTRICAL CONNECTORS.................................................................319
Autofuse Unsealed Connector Repair......................................................................319
A.2 BOSCH COMPACT 1.1M CONNECTOR............................................................................320
Bosch Compact 1.1M Connector............................................................................320
A.3 DELPHI 100W MICRO-PACK SEALED CONNECTOR.................................................................321
Delphi 100W Micro-Pack Sealed Connector Repair..........................................................321
Crimping Terminals......................................................................................322
A.4 DELPHI 150 METRI-PACK SEALED CONNECTORS.................................................................323
Delphi 150 Metri-Pack Sealed Connector Repair...........................................................323
A.5 DELPHI 280 METRI-PACK UNSEALED CONNECTORS...............................................................325
Fuse Block Repair.......................................................................................325
A.6 DELPHI 480 METRI-PACK UNSEALED CONNECTORS...............................................................326
Delphi 480 Metri-Pack Unsealed Connector Repair.........................................................326
A.7 DELPHI 630 METRI-PACK UNSEALED CONNECTORS...............................................................327
Delphi 630 Metri-Pack Unsealed Connector Repair.........................................................327
A.8 DELPHI 800 METRI-PACK SEALED MAIN FUSE HOUSING..........................................................328
Delphi 800 Metri-Pack Sealed Main Fuse Housing Repair...................................................328
A.9 DELPHI METRI-PACK TERMINAL REPAIR.......................................................................329
Metri-Pack Terminal Crimps..............................................................................329
A.10 DELPHI MICRO 64 SEALED CONNECTORS......................................................................331
Delphi Micro 64 Sealed Connector Repair.................................................................331
A.11 DELPHI GT 150 SEALED CONNECTORS........................................................................334
Delphi GT 150 Sealed Connector Repair...................................................................334
A.12 DELPHI GT 280 SEALED 73-TERMINAL ECM CONNECTOR.........................................................336
Delphi GT 280 Sealed 73-Terminal ECM Connector..........................................................336
A.13 DEUTSCH DT SEALED CONNECTORS...........................................................................338
Deutsch DT Sealed Connector Repair......................................................................338
A.14 DEUTSCH DT SEALED TERMINAL REPAIR......................................................................342
Deutsch DT Sealed Terminal Crimps.......................................................................342
A.15 DEUTSCH DTM SEALED MINI TERMINAL REPAIR................................................................343
Deutsch DTM Sealed Mini Terminal Crimps.................................................................343
A.16 DEUTSCH DTM SEALED SOLID BARREL MINI TERMINAL REPAIR...................................................344
Deutsch DTM Sealed Solid Barrel Terminal Crimps.........................................................344
A.17 JAE MX19 SEALED CONNECTORS.............................................................................346
JAE MX19 Sealed Connectors..............................................................................346
Crimping Terminals......................................................................................346
A.18 MOLEX CMC SEALED CONNECTORS............................................................................347
Molex CMC Sealed Connectors.............................................................................347
Crimping Terminals......................................................................................348
A.19 MOLEX MX 150 SEALED CONNECTORS.........................................................................349
Molex MX 150 Sealed Connector Repair....................................................................349
Crimp Terminal to Lead..................................................................................350
A.20 TYCO 070 MULTILOCK UNSEALED CONNECTOR..................................................................353
Tyco 070 Multilock Unsealed Connector Repair............................................................353
A.21 TYCO GET 64 SEALED CONNECTOR...........................................................................357
Tyco GET 64 Sealed Connector............................................................................357
Crimping Terminals......................................................................................358
A.22 TYCO MCP SEALED CONNECTOR..............................................................................359
Tyco MCP Sealed Connector...............................................................................359
Crimping Terminals......................................................................................360
A.23 SEALED SPLICE CONNECTORS...............................................................................361
Sealed Splice Connector Repair..........................................................................361
B. APPENDIX B WIRING............................................................................................363
B.1 CONNECTORS..............................................................................................365
Connector Locations.....................................................................................365
B.2 WIRING DIAGRAMS.........................................................................................368
Wiring Diagram Information..............................................................................368
2013 Dyna Wiring Diagrams...............................................................................370
C. APPENDIX C CONVERSIONS.......................................................................................381
C.1 METRIC CONVERSION.......................................................................................383
Conversion Table........................................................................................383
C.2 FLUID CONVERSIONS.......................................................................................384
United States System....................................................................................384
Metric System...........................................................................................384
British Imperial System.................................................................................384
C.3 TORQUE CONVERSIONS......................................................................................385
United States System....................................................................................385
Metric System...........................................................................................385
D. APPENDIX D GLOSSARY..........................................................................................387
D.1 GLOSSARY................................................................................................389
Acronyms and Abbreviations..............................................................................389
TOOLS...........................................................................................................393
TORQUE VALUES...................................................................................................411
INDEX...........................................................................................................413
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