2011 Touring Models Electrical

Diagnostic Manual
99497-11
©2010 H-D.
 IMPORTANT NOTICE

Harley-Davidson motorcycles conform to all applicable U.S.A. Federal Motor Vehicle Safety Standards
and U.S.A. Environmental Protection Agency regulations effective on the date of manufacture.

To maintain the safety, dependability, and emission and noise control performance, it is essential that
the procedures, specifications and service instructions in this manual are followed.

Any substitution, alteration or adjustment of emission system and noise control components outside of
factory specifications may be prohibited by law.

Harley-Davidson Motor Company

 2011 Touring Models
Electrical Diagnostic Manual

©2010 H-D.
ALL RIGHTS RESERVED
99497-11

Printed in the U.S.A.

VISIT THE HARLEY-DAVIDSON WEB SITE

http://www.harley-davidson.com
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2011 Touring Models Electrical Diagnostic Manual (99497-11)

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NOTES
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-Dav-
idson 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
8 Audio System
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 FORE-
WORD) 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 SPECIFICA-
TIONS refers to chapter 2 CHASSIS, heading 2.2 SPECIFIC-
ATIONS.
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
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.
A clean work area at the start of each job will allow you to
perform the repair as easily and quickly as possible, and will
reduce the incidence of misplaced tools and parts. A motorcycle
that is excessively dirty should be cleaned before work starts.
Cleaning will occasionally uncover sources of trouble. Tools,
instruments and any parts needed for the job should be
gathered before work is started. Interrupting a job to locate
tools or parts is a distraction and causes needless delay.
NOTES
• To avoid unnecessary disassembly, carefully read all rel-
ative service information before repair work is started.
• In figure legends, the number which follows the name of
a part indicates the quantity necessary for one complete
assembly.
• When servicing a vehicle equipped with the Harley-Dav-
idson Smart Security System (H-DSSS), you must first
disarm the security system. Either keep the fob in close
proximity to the vehicle, or use Digital Technician II to
disable the security system while the vehicle is being ser-
viced and re-enable the system after service is completed.
SERVICE BULLETINS
In addition to the information presented in this manual, Harley-
Davidson Motor Company will periodically issue service bul-
letins to Harley-Davidson dealers. Service bulletins cover
interim engineering changes and supplementary information.
Consult the service bulletins to keep your product knowledge
current and complete.
USE GENUINE REPLACEMENT PARTS
FOREWORD
Harley-Davidson parts and accessories are designed for
Harley-Davidson motorcycles. Using non-Harley-Davidson
parts or accessories can adversely affect performance,
stability or handling, which could result in death or serious
injury. (00001b)
To achieve satisfactory and lasting repairs, carefully follow the
service manual instructions and use only genuine Harley-
Davidson replacement parts. Behind the emblem bearing the
words GENUINE HARLEY-DAVIDSON stand more than 100
years of design, research, manufacturing, testing and inspecting
experience.This is your assurance that the parts you are using
will fit right, operate properly and last longer.
WARNINGS AND CAUTIONS
Statements in this manual preceded by the following words
are of special significance.
WARNING indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury. (00119a)
CAUTION indicates a potentially hazardous situation
which, if not avoided, may result in minor or moderate
injury. (00139a)
NOTICE indicates a potentially hazardous situation which,
if not avoided, may result in property damage. (00140b)
I
 NOTE
Refers to important information, and is placed in italic type. It
is recommended that you take special notice of these items.
Proper service and repair is important for the safe, reliable
operation of all mechanical products. The service procedures
recommended and described in this manual are effective
methods for performing service operations.
Always wear proper eye protection when using hammers,
arbor or hydraulic presses, gear pullers, spring com-
pressors, slide hammers and similar tools. Flying parts
could result in death or serious injury. (00496b)
Some of these service operations require the use of tools
specially designed for the purpose. These special tools should
be used when and as recommended. It is important to note
that some warnings against the use of specific service methods,
which could damage the motorcycle or render it unsafe, are
stated in this manual. However, remember that these warnings
are not all-inclusive. Inadequate safety precautions could result
in death or serious injury.
Since Harley-Davidson could not possibly know, evaluate or
advise the service trade of all possible ways in which service
might be performed, or of the possible hazardous con-
sequences of each method, we have not undertaken any such
broad evaluation. Accordingly, anyone who uses a service
procedure or tool which is not recommended by Harley-Dav-
idson must first thoroughly satisfy himself that neither his nor
the operator's safety will be jeopardized as a result. Failure to
do so could result in death or serious injury.
PRODUCT REFERENCES
Read and follow warnings and directions on all products.
Failure to follow warnings and directions can result in
death or serious injury. (00470b)
When reference is made in this manual to a specific brand
name product, tool or instrument, an equivalent product, tool
or instrument may be substituted.
Kent-Moore Products
All tools mentioned in this manual with an "HD", "J" or "B"
preface must be ordered through SPX Kent-Moore. For ordering
II FOREWORD
information or product returns, warranty or otherwise, visit
www.spx.com.
Loctite Sealing and Threadlocking Products
Some procedures in this manual call for the use of Loctite
products. If you have any questions regarding Loctite product
usage or retailer/wholesaler locations, please contact Loctite
Corp. at www.loctite.com.
PRODUCT REGISTERED MARKS
Apple, Alcantara S.p.A., Allen, Amp Multilock, Bluetooth,
Brembo, Delphi, Deutsch, Dunlop, Dynojet, Fluke, G.E.
Versilube, Garmin, Gunk, Hydroseal, Hylomar, iPhone, iPod,
Kevlar, Lexan, Loctite, Lubriplate, Keps, K&N, Magnaflux,
Marson Thread-Setter Tool Kit, MAXI fuse, Molex, Michelin,
MPZ, Mulitilock, nano, NGK, Novus, Packard, Pirelli, Permatex,
Philips, PJ1, Pozidriv, Robinair, S100, Sems, Snap-on, Teflon,
Threadlocker, Torca, Torco, TORX, Tufoil, Tyco, Ultratorch,
Velcro, X-Acto, XM Satellite Radio, and zumo are among the
trademarks of their respective owners.
H-D MICHIGAN, INC. TRADEMARK
INFORMATION
Harley, Harley-Davidson, H-D, Bar & Shield, Cross Bones,
Digital Tech, Digital Technician, Digital Technician II, Dyna,
Electra Glide, Evolution, Fat Bob, Fat Boy, Glaze, Gloss, H-D,
H-Dnet.com, HD, Harley, Harley-Davidson, Heritage Softail,
Low Rider, Night Rod, Nightster, Night Train, Profile, Revolu-
tion, Road Glide, Road King, Road Tech, Rocker, Softail,
Sportster, Street Glide, Street Rod, Sun Ray, Sunwash, Tech
Link, Twin Cam 88, Twin Cam 88B, Twin Cam 96, Twin Cam
96B, Twin Cam 103, Twin Cam 103B, Twin Cam 110, Twin
Cam 110B, Tour-Pak, Screamin' Eagle, Softail, Super Glide,
SYN3, Ultra Classic, V-Rod, VRSC and Harley-Davidson
Genuine Motor Parts and Genuine Motor Accessories are
among the trademarks of H-D Michigan, Inc.
CONTENTS
All photographs, illustrations and procedures may not neces-
sarily depict the most current model or component, but are
based on the latest production information available at the time
of publication.
Since product improvement is our continual goal, Harley-Dav-
idson reserves the right to change specifications, equipment
or designs at any time without notice and without incurring
obligation.
GENERAL INFORMATION
1.1 SPECIFICATIONS AND COMPONENT
LOCATIONS
Specifications.....................................................................1-1
Component Locations........................................................1-2
1.2 DIAGNOSTIC TOOLS
How To Use Diagnostic Tools...........................................1-13
HD-26792 Spark Tester.............................................1-13
HD-34730-2D Fuel Injector Test Light.......................1-13
HD-39978 Digital Multimeter (Fluke 78)....................1-13
HD-41404-C Harness Connector Test Kit.................1-14
HD-42682 Breakout Box (Instruments).....................1-14
HD-42682 Breakout Box (TSM/TSSM/HFSM)..........1-14
HD-48637 Breakout Box (ECM)................................1-15
HD-48642 Breakout Box (ABS).................................1-15
HD-47918 Advanced Audio System Breakout Box....1-16
HD-44687 Ignition Coil Circuit Test Adapter..............1-16
HD-48053 Advanced Battery Conductance and Electrical
System Analyzer.......................................................1-17
HD-48650 Digital Technician II..................................1-17
1.3 DIAGNOSTICS AND
TROUBLESHOOTING
Voltage Drop.....................................................................1-18
Voltage Drop Test......................................................1-18
Wiggle Test.......................................................................1-19
Relay Diagnostics.............................................................1-19
Relay Variation..........................................................1-19
Relay Test..................................................................1-19
Job/Time Codes Values....................................................1-20
INITIAL DIAGNOSTICS AND SERIAL
DATA
2.1 INITIAL DIAGNOSTICS
Description and Operation..................................................2-1
Retrieving Trouble Codes...................................................2-1
Odometer Self-Diagnostics.................................................2-1
Diagnostic Mode..........................................................2-1
Diagnostics.........................................................................2-1
Diagnostic Tips............................................................2-1
Code Types.........................................................................2-6
Current........................................................................2-6
Historic........................................................................2-6
Multiple Trouble Codes.......................................................2-6
Clearing DTCs....................................................................2-6
Security Lamp....................................................................2-6
Check Engine Lamp...........................................................2-6
Symptoms..........................................................................2-7
Connector Information.................................................2-8
Initial Diagnostics.............................................................2-21
1. Verifying Current DTC Test....................................2-21
2. Battery Power Test.................................................2-21
3. Ignition Power Test.................................................2-21
4. Engine Stop Switch Circuit Test.............................2-21
5. Security System Test.............................................2-21
6. Starter System Test...............................................2-21
7. Engine Running Test..............................................2-21
8. Verification Test......................................................2-21
2.2 SERIAL DATA COMMUNICATION
Description and Operation................................................2-22
Components.....................................................................2-23
Electronic Control Module (ECM)..............................2-23
Speedometer and Tachometer..................................2-23
TSM/TSSM/HFSM.....................................................2-23
Data Link Connector (DLC).......................................2-23
Communication DTCs and "Bus Er".................................2-23
Diagnostic Tips..........................................................2-23
2.3 DTC U1016, U1040, U1064, U1097, U1255
Description and Operation................................................2-24
Diagnostic Tips..........................................................2-24
Connector Information...............................................2-24
DTC U1016......................................................................2-25
1. Open Ground Test.................................................2-25
2. Switched Power Circuit Open Test.........................2-25
3. TSM/TSSM/HFSM Serial Data Circuit Continuity
Test............................................................................2-26
4. Speedometer Serial Data Circuit Continuity Test....2-26
5. Tachometer Serial Data Circuit Continuity Test......2-26
DTC U1040, U1255..........................................................2-26
1. ABS Fuse Visual Test............................................2-26
2. Loss of Power Test.................................................2-26
3. Loss of Ground Test...............................................2-26
4. Instrument Serial Data Circuit Continuity Test.......2-26
5. Power Circuit Short to Ground Test.......................2-27
DTC U1064, U1255..........................................................2-27
1. Fuse Test...............................................................2-27
2. Loss of Battery Power Test....................................2-27
TABLE OF CONTENTS
3. Loss of Ignition Power Test....................................2-27
4. Loss of Ground Test...............................................2-27
5. Speedometer Serial Data Circuit Continuity Test....2-27
6. Power Circuit Short to Ground Test.......................2-27
7. ECM Serial Data Circuit Continuity Test................2-27
8. Tachometer Serial Data Circuit Continuity Test......2-28
DTC U1097, U1255..........................................................2-28
1. Fuse Test...............................................................2-28
2. Loss of Power Test.................................................2-28
3. Loss of Ground Test...............................................2-28
4. Speedometer Serial Data Circuit Continuity Test....2-28
5. Power Circuit Short to Ground Test.......................2-28
6. ECM Serial Data Circuit Continuity Test................2-28
2.4 DTC U1300, U1301 OR BUS ER
Description and Operation................................................2-29
Diagnostic Tips..........................................................2-29
Connector Information...............................................2-29
DTC U1300......................................................................2-30
1. Serial Data Short to Ground Test...........................2-30
2. ECM Test...............................................................2-30
3. TSM/TSSM/HFSM Test..........................................2-30
4. ABS Module Test (If Vehicle is not Equipped with ABS,
Go to Test 5.).............................................................2-30
5. Tachometer Test (If Vehicle is not Equipped with
Tachometer, Go to Test 6.)........................................2-30
6. Radio Test (If Vehicle is not Equipped with Radio, Go
to Test 7.)...................................................................2-30
7. Serial Data Short to Ground Test...........................2-30
8. Serial Data Circuit Open Test................................2-30
9. Intermittent Test.....................................................2-30
DTC U1301......................................................................2-31
1. Serial Data Short to Voltage Test...........................2-31
2. ECM Test...............................................................2-31
3. TSM/TSSM/HFSM Test..........................................2-31
4. ABS Module Test (If Vehicle is not Equipped with ABS,
Go to Test 5.).............................................................2-31
5. Tachometer Test (If Vehicle is not Equipped with
Tachometer, Go to Test 6.)........................................2-31
III
TABLE OF CONTENTS
6. Radio Test (If Vehicle is not Equipped with Radio, Go
to Test 7.)...................................................................2-31
7. Serial Data Short to Voltage Test...........................2-31
8. Serial Data Circuit Open Test................................2-31
9. Intermittent Test.....................................................2-32
STARTING AND CHARGING
3.1 BATTERY TESTING
General...............................................................................3-1
Voltmeter Test.....................................................................3-1
Conductance Test...............................................................3-1
Load Test............................................................................3-1
3.2 STARTING SYSTEM
Description and Operation..................................................3-3
Components.......................................................................3-3
Starter.........................................................................3-3
Starter Solenoid..........................................................3-3
Engine Stop Switch.....................................................3-3
Start Switch.................................................................3-3
Start Relay..................................................................3-3
Ignition Switch.............................................................3-3
Battery.........................................................................3-4
Grinding Noise Or Erratic Starting...............................3-4
Job/Time Code Values................................................3-4
Connector Information.................................................3-4
Starter Troubleshooting......................................................3-6
Starter Testing....................................................................3-7
1. Starting System Operational Test............................3-7
2. Audible Noise Test...................................................3-7
3. Starter Solenoid Test...............................................3-7
4. Start Switch Circuit Test...........................................3-7
5. Start Switch Circuit Short to Voltage Test................3-7
6. Start Switch Circuit Short to Voltage [2B] Test.........3-7
7. Start Switch Circuit Short to Voltage [2A] Test ........3-7
8. Start Switch Test......................................................3-7
9. Start Relay Test.......................................................3-8
Nothing Clicks.....................................................................3-8
1. Battery Test..............................................................3-8
2. Fuse Test.................................................................3-8
3. Ignition Circuit Test..................................................3-8
4. Ignition Switch Supply Voltage Test.........................3-8
5. Ignition Switch to [222] Test ....................................3-8
6. Ignition Switch Test..................................................3-8
7. Ignition Switch to [222] Continuity Test....................3-9
8. Start Switch Circuit Voltage Test..............................3-9
9. Start Switch Test......................................................3-9
10. Start Switch Circuit Continuity Test........................3-9
11. Start Switch Circuit Continuity [2B] Test................3-9
12. Start Switch Circuit Continuity [2A] Test................3-9
13. Start Relay Control Circuit Test..............................3-9
14. Start Relay Control Circuit Open Test....................3-9
15. TSM/TSSM/HFSM Ground Test.............................3-9
16. Continuity at Neutral Switch Test...........................3-9
17. Neutral Switch Ground Circuit Test......................3-10
18. Start Relay Coil Control Circuit Short to Voltage
Test............................................................................3-10
19. Engine Stop Switch Voltage Test.........................3-10
20. Relay Enable Circuit Continuity Test....................3-10
21. Anti-Theft Tracking Module Test...........................3-10
Start Relay Clicks.............................................................3-10
IV TABLE OF CONTENTS
1. Battery Test............................................................3-10
2. Starter Solenoid Control Coil Voltage Test.............3-10
3. Starter Solenoid Control Coil Continuity Test........3-10
4. Start Solenoid Wiring Inspection Test....................3-10
5. Starter Solenoid Test.............................................3-11
Starter Solenoid Clicks.....................................................3-11
1. Battery Test............................................................3-11
2. Starter Voltage Drop Test.......................................3-11
3. Starter Solenoid Voltage Drop Starter Side Test.....3-11
4. Starter Solenoid Battery Side Voltage Drop Test....3-11
5. Starter Ground Circuit Voltage Drop Test..............3-11
6. Starter Ground Test...............................................3-11
7. Starter Draw Test...................................................3-11
8. Mechanical Binding Test........................................3-11
Starter Spins But Does Not Engage.................................3-12
1. Pinion Gear and Clutch Shell Test.........................3-12
Starter Stalls or Spins Too Slowly.....................................3-12
1. Battery Test............................................................3-12
2. Starter Stud Voltage Drop Test..............................3-12
3. Starter Ground Circuit Voltage Drop Test..............3-12
4. Starter Draw Test...................................................3-12
5. Starter Solenoid Voltage Drop Starter Side Test.....3-12
6. Starter Solenoid Battery Side Voltage Drop Test....3-12
3.3 TESTING STARTER ON MOTORCYCLE
Starter Current Draw Test.................................................3-13
3.4 TESTING STARTER ON BENCH
Free Running Current Draw Test......................................3-14
Starter Solenoid................................................................3-14
Solenoid Pull-In Test.........................................................3-14
Solenoid Hold-In Test........................................................3-14
Solenoid Return Test........................................................3-15
3.5 CHARGING SYSTEM
Description and Operation................................................3-16
Alternator...................................................................3-16
Voltage Regulator......................................................3-16
Troubleshooting................................................................3-16
Battery.......................................................................3-16
Wiring........................................................................3-16
Voltage Regulator Inspection....................................3-16
Job/Time Code Values..............................................3-16
Connector Information...............................................3-16
Low or No Charging..........................................................3-17
1. Battery Test............................................................3-17
2. Off Idle Voltage Test...............................................3-17
3. AC Output Test......................................................3-17
4. Stator Test..............................................................3-17
5. Rotor Inspection Test.............................................3-17
6. Voltage Regulator Power Circuit Test.....................3-17
7. Voltage Regulator Ground Circuit Test...................3-17
Overcharging....................................................................3-17
1. Battery Voltage Test...............................................3-17
2. Voltage Regulator Ground Circuit Test...................3-17
Low Battery After Extended IGN OFF..............................3-18
1. Battery Test............................................................3-18
2. Amp Draw Test......................................................3-18
Battery Runs Down During Use.......................................3-18
1. Total Current Draw Test.........................................3-18
2. Battery Test............................................................3-18
Battery Charging Tests.....................................................3-18

Milliampere Draw Test...............................................3-18
Total Current Draw and Output Test..........................3-19
Stator Test.................................................................3-20
AC Output Test..........................................................3-21
3.6 DTC B0563, P0562, P0563
Description and Operation................................................3-22
DTC B0563...............................................................3-22
DTC P0562 and P0563.............................................3-22
Diagnostics.......................................................................3-22
Diagnostic Tips..........................................................3-22
Connector Information...............................................3-22
DTC P0562.......................................................................3-24
1. Battery Test............................................................3-24
2. Charging System Test............................................3-24
3. ECM Switched Voltage Test...................................3-24
4. ECM Switched Voltage Drop Test..........................3-24
5. ECM Ground Circuit Voltage Drop Test.................3-24
6. ECM Switched Power Circuit Resistance Test.......3-24
7. Switched Power Circuit Resistance Test................3-24
8. Switched Power Circuit Resistance [1A] Test........3-24
9. Switched Power Circuit Resistance [1B] Test........3-24
10. Ignition Circuit Resistance Test............................3-25
11. Ignition Circuit Resistance [1A] Test....................3-25
12. Ignition Circuit Resistance [1B] Test....................3-25
13. Engine Stop Switch Test......................................3-25
14. Ignition Circuit Voltage Drop Test.........................3-25
15. Ignition Circuit Resistance Test............................3-25
16. Ignition Switch To [222] Resistance Test..............3-25
17. Ignition Switch Battery Circuit Voltage Drop
Test............................................................................3-25
18. Battery Voltage to Main Fuse Voltage Drop
Test............................................................................3-25
19. Main Fuse to Ignition Switch Resistance Test.....3-25
20. Main Fuse to [222] Resistance Test.....................3-25
21. Repair Validation Test .........................................3-26
DTC B0563, P0563..........................................................3-26
1. Charging System Test............................................3-26
2. Repair Validation Test............................................3-26
3.7 DTC B1006, B1007
Description and Operation................................................3-27
Diagnostic Tips..........................................................3-27
DTC B1006, B1007..........................................................3-27
1. Charging System Test............................................3-27
2. Repair Validation Test............................................3-27
INSTRUMENTS
4.1 INSTRUMENTS
Description and Operation..................................................4-1
Trip Odometer Reset Switch Operation.......................4-1
Speedometer Theory of Operation.....................................4-1
Tachometer Theory of Operation........................................4-2
Instrument Diagnostics.......................................................4-2
4.2 DTC B1004, B1005
Description and Operation..................................................4-3
Connector Information.................................................4-3
DTC B1004.........................................................................4-5
1. Fuel Level Sender Voltage Test...............................4-5
TABLE OF CONTENTS
2. Fuel Pump and Sender Test....................................4-5
3. Fuel Gauge Voltage Test..........................................4-5
4. Fuel Level Sender Circuit Continuity Test................4-5
5. Fuel Level Sender Circuit Test.................................4-5
DTC B1005.........................................................................4-5
1. Fuel Level Sender Voltage Test...............................4-5
2. Fuel Pump and Sender Test....................................4-5
3. Fuel Level Sender Circuit Test.................................4-6
4. Fuel Level Sender Circuit Continuity Test................4-6
5. Fuel Gauge Ground Circuit Test..............................4-6
6. Fuel Sender Resistance Test...................................4-6
4.3 DTC B1008
Description and Operation..................................................4-7
Trip Odometer Reset Switch Closed...........................4-7
DTC B1008.........................................................................4-7
1. Rubber Boot Test.....................................................4-7
2. Trip Odometer Reset Switch Test.............................4-7
4.4 NO INSTRUMENT POWER
Description and Operation..................................................4-8
Connector Information.................................................4-8
Speedometer Inoperative.................................................4-10
1. Battery and Ignition Function Test ........................4-10
2. Accessory Function Test........................................4-10
3. Accessory Fuse Test.............................................4-10
4. Battery Fuse Test...................................................4-10
5. Battery Circuit to Battery Fuse Test.......................4-10
6. Battery Circuit to Speedometer Test......................4-10
7. Battery Circuit Short to Ground Test......................4-10
8. Ignition Circuit Test................................................4-10
9. Instrument Power Circuit Test................................4-10
10. Ignition Fuse Test.................................................4-11
11. Ignition Power to Instrument Fuse Test................4-11
12. Ignition Power Short to Ground Test....................4-11
13. Ground Circuit Test..............................................4-11
4.5 INDICATOR LAMPS
Description and Operation................................................4-12
Low Fuel Indicator.....................................................4-12
Neutral Indicator........................................................4-15
Oil Pressure Indicator................................................4-15
Turn Signal Indicators................................................4-15
High Beam Indicator..................................................4-15
Sixth Gear Indicator...................................................4-15
Connector Information...............................................4-15
Oil Pressure Lamp Always On..........................................4-17
1. Oil Pressure Lamp Function Test...........................4-17
2. Engine Running Test..............................................4-17
3. Oil Pressure Sensor Test.......................................4-17
4. Oil Pressure Circuit Test........................................4-17
5. Mechanical Test.....................................................4-17
Oil Pressure Lamp Inoperative.........................................4-17
1. Oil Pressure Lamp Function Test...........................4-17
2. Oil Pressure Switch Test........................................4-17
3. Oil Pressure Circuit Test........................................4-17
Neutral Lamp Always On..................................................4-18
1. Neutral Lamp Function Test...................................4-18
2. Transmission Operation Test..................................4-18
3. Neutral Switch Test ...............................................4-18
4. TSM/TSSM/HFSM Test..........................................4-18
5. Neutral Switch Circuit Test.....................................4-18
TABLE OF CONTENTS V
TABLE OF CONTENTS
Neutral Lamp Inoperative.................................................4-18
1. Neutral Lamp Function Test...................................4-18
2. Neutral Switch Test................................................4-18
3. Neutral Switch Power Circuit Open Test................4-18
High Beam Indicator Lamp Inoperative............................4-19
1. High Beam Indicator Function Test........................4-19
2. High Beam Indicator Circuit Test ..........................4-19
Turn Signal Indicator Inoperative......................................4-19
1. Turn Signal Function Test......................................4-19
2. Turn Signal Indicator Circuit Test ..........................4-19
4.6 GAUGES
Theory of Operation.........................................................4-20
Fuel Gauge and Sender Test............................................4-20
Oil Pressure Gauge and Indicator Light...........................4-21
Problem.....................................................................4-21
Ambient Air Temperature Gauge......................................4-21
Problem.....................................................................4-21
Voltmeter Gauge...............................................................4-22
Problem.....................................................................4-22
ACCESSORIES, HORN, LIGHTING
AND SECURITY
5.1 ACCESSORIES
Description and Operation..................................................5-1
Components.......................................................................5-1
P&A Connectors..........................................................5-1
P&A Fuses..................................................................5-1
Connector Information.................................................5-2
Rear Auxiliary Power Outlet Inoperative.............................5-3
1. Power Outlet Fuse Test............................................5-3
2. Power Outlet Test.....................................................5-3
3. Power Outlet Ground Circuit Test............................5-3
4. Power Outlet Short to Ground Test..........................5-3
Cigar Lighter Inoperative....................................................5-3
1. P&A Fuse Test.........................................................5-3
2. Cigar Lighter Test.....................................................5-3
3. Cigar Lighter Ground Circuit Test............................5-3
4. Power Outlet Short to Ground Test..........................5-3
5.2 HEATED HAND GRIPS
Description and Operation..................................................5-4
Diagnostic Tips............................................................5-4
Connector Information.................................................5-4
Heated Handgrips Inoperative............................................5-6
1. P&A Fuse Test.........................................................5-6
2. Current Draw Test....................................................5-6
3. Power Supply Test...................................................5-6
4. Heated Grips Ground Circuit Test............................5-6
5. Heated Grips Test....................................................5-6
6. Heated Grips Short to Ground Test.........................5-6
7. Heated Grip Power Circuit Short to Ground Test.....5-6
8. Heated Grips Resistance Test.................................5-6
5.3 CRUISE CONTROL
Description and Operation..................................................5-7
System Operation...............................................................5-7
Troubleshooting..................................................................5-8
Diagnostic Tips............................................................5-8
Cruise Inoperative Diagnostics...........................................5-8
VI TABLE OF CONTENTS
Cruise Control Inoperative Conditions..............................5-10
5.4 DTC P0577
Cruise Control..................................................................5-11
Connector Information...............................................5-11
DTC P0577.......................................................................5-13
1. Cruise Set/Coast Circuit Voltage Test....................5-13
2. Cruise Set/Coast Switch Test................................5-13
3. Cruise Resume/Accelerate Circuit Voltage Test.....5-13
4. Cruise Circuit Voltage Test.....................................5-13
5.5 HORN
Description and Operation................................................5-14
Components.....................................................................5-14
Horn Switch...............................................................5-14
Horn..........................................................................5-14
Symptoms........................................................................5-14
Diagnostic Tips..........................................................5-14
Connector Information...............................................5-14
Horn Always On................................................................5-15
1. Horn Switch Test....................................................5-15
Horn Inoperative...............................................................5-15
1. Accessory Circuit Open or Shorted Test...............5-15
2. Horn Test...............................................................5-15
3. Ground Circuit Open Test......................................5-15
4. Horn Switch Malfunction Test................................5-15
5. Horn Power Circuit Open Test...............................5-15
5.6 TURN SIGNALS
Description and Operation................................................5-16
BAS Operation..........................................................5-16
BAS Restart..............................................................5-16
Manual Cancellation..................................................5-16
Automatic Cancellation..............................................5-16
Four-Way Flashing....................................................5-16
Will Not Cancel Upon Turn Completion, No DTCs...........5-19
1. TSM/TSSM/HFSM Mounting Test..........................5-19
2. Correct Configuration Test.....................................5-19
3. 4-Way Cancellation Test........................................5-19
4. Turn Signals Cancel Test.......................................5-19
5. Speedometer Test..................................................5-19
Flash at Double Normal Rate, All Bulbs Work, No DTCs..5-19
1. Lamp Load Calibration Test...................................5-19
2. Lamp Verification Test............................................5-19
3. Bulb Corrosion Test...............................................5-19
4. Lamp Connection Terminal Corrosion Test............5-19
5. Verification Test......................................................5-20
6. Lamp Operation Test.............................................5-20
7. Lamp Assembly Test..............................................5-20
Both Turn Signal Lamps on One Side Inoperative, No
DTCs................................................................................5-20
1. Left or Right Turn Signal Malfunction Test.............5-20
2. Right Turn Signal Circuit Test.................................5-20
3. Right Turn Signal Switch Test................................5-20
4. Right Turn Signal Circuit Continuity Test................5-20
5. Left Turn Signal Circuit Test...................................5-20
6. Left Turn Signal Switch Test...................................5-20
7. Left Turn Signal Circuit Continuity Test..................5-20
8. Right Turn Signal Short to Voltage Test.................5-21
9. Left Turn Signal Short to Voltage Test....................5-21
10. Anti-Theft Tracking Module Test...........................5-21
One Turn Signal Lamp Inoperative, No DTCs..................5-21

1. Inoperative Signal Location Test............................5-21
2. Right Front Turn Signal Bulb Test..........................5-21
3. Right Front Turn Signal Circuit Test.......................5-21
4. Right Front Turn Signal Ground Circuit Test..........5-21
5. Left Front Turn Signal Bulb Test.............................5-21
6. Left Front Turn Signal Circuit Test..........................5-21
7. Left Front Turn Signal Ground Circuit Test.............5-22
8. Right Rear Turn Signal Bulb Test...........................5-22
9. Right Rear Turn Signal Circuit Test: Except LED
Lights.........................................................................5-22
10. Right Rear Turn Signal Ground Circuit Component
Test............................................................................5-22
11. Left Rear Turn Signal Bulb Test...........................5-22
12. Left Rear Turn Signal Circuit Test: Except LED
Lights.........................................................................5-22
13. Left Rear Turn Signal Component Test................5-22
14. Right Rear Turn Signal Ground Circuit Test.........5-22
15. Right Rear Turn Signal Circuit Test: LED Lights...5-22
16. Left Rear Turn Signal Ground Circuit Test...........5-23
17. Left Rear Turn Signal Circuit Test: LED Lights.....5-23
5.7 HEADLAMPS
Description and Operation................................................5-24
Diagnostic Tips..........................................................5-24
Connector Information...............................................5-24
Headlamp Inoperative, No DTCs......................................5-26
1. Operational Test.....................................................5-26
2. High Beam Indicator Test.......................................5-26
3. Headlamp High Beam Circuit Switch Test.............5-26
4. High Beam Headlamp Test....................................5-26
5. Headlamp Low Beam Switch Test.........................5-26
6. Low Beam Headlamp Test.....................................5-26
7. High Beam Indicator Test.......................................5-26
8. Headlamp Power Circuit Open Test.......................5-26
9. Headlamp Fuse Test..............................................5-27
10. Power Circuit Test................................................5-27
Auxiliary Lamps Inoperative.............................................5-27
1. Auxiliary Lamps Operation Test.............................5-27
2. Auxiliary Bulb Test.................................................5-27
3. Auxiliary Lamp Circuit Test: FLHR/C......................5-27
4. Auxiliary Lamp Switch Test....................................5-27
5. Auxiliary Lamp Power Circuit Test: FLHR/C...........5-27
6. Auxiliary Lamp Circuit Test: Except FLHR/C..........5-27
7. Auxiliary Lamp Power Circuit Test: Except
FLHR/C.....................................................................5-27
5.8 STOP LAMPS
Description and Operation................................................5-28
Diagnostic Tips..........................................................5-28
Connector Information...............................................5-28
Stop Lamp Inoperative.....................................................5-31
1. Accessory Circuit Test...........................................5-31
2. ACCY Fuse Test....................................................5-31
3. ACCY Circuit from Ignition Switch Test..................5-31
4. Ignition Switch Test................................................5-31
5. Accessory Circuit Resistance Test........................5-31
6. Fuel Level Sensor Test..........................................5-31
7. Speedometer Test..................................................5-31
8. Stop Lamp Switch Test..........................................5-31
9. Brake Relay Test....................................................5-31
10. Relay Coil Circuit Test..........................................5-31
11. Stop Lamp Switch Power Circuit Test..................5-32
TABLE OF CONTENTS
12. Rear Stop Lamp Switch Test...............................5-32
13. Rear Stop Lamp Switch ACCY Circuit Test.........5-32
14. Front Stop Lamp Switch Test...............................5-32
15. Front Stop Lamp Switch ACCY Circuit Test.........5-32
16. Rear Stop Lamp to ABS Diode Pack Circuit
Test............................................................................5-32
17. ABS Diode Pack Rear Circuit Test.......................5-32
18. Front Stop Lamp to ABS Diode Pack Circuit
Test............................................................................5-32
19. ABS Diode Pack Front Circuit Test......................5-32
20. Relay Power Test.................................................5-32
21. Stop Lamp Test....................................................5-32
22. Circuit Board Test................................................5-32
23. Stop Lamp Circuit Test.........................................5-33
24. Lightbar Circuit Test.............................................5-33
25. Stop Lamp Circuit Test.........................................5-33
26. Facia/Converter Module Test...............................5-33
5.9 RUNNING LAMPS
Description and Operation................................................5-34
Connector Information...............................................5-34
Position Lamp Inoperative: HDI........................................5-36
1. Accessory Circuit Test...........................................5-36
2. Position Lamp Test.................................................5-36
3. Ground Circuit Test................................................5-36
Running Lamps Inoperative..............................................5-36
1. Running Lamp Test................................................5-36
2. General Lamp Test................................................5-36
3. Single Lamp Power Test........................................5-36
4. Lights Fuse Test.....................................................5-36
5.10 DTC B1121, B1122, B1123, B1124,
B1125, B1126
Description and Operation................................................5-37
Connector Information...............................................5-37
DTC B1121: HFSM...........................................................5-40
1. Turn Signal Lamp Inspection Test..........................5-40
2. Turn Signal Circuit Open Test................................5-40
DTC B1121: TSM/TSSM..................................................5-40
1. Operational Test.....................................................5-40
2. Indicator Short to Voltage Test...............................5-40
3. TSM/TSSM Short to Voltage Test..........................5-40
4. Indicator Shorted Test............................................5-40
5. Shorted Turn Signal Circuit Test............................5-40
6. Turn Signal Circuit Open Test................................5-40
DTC B1122: HFSM...........................................................5-41
1. Turn Signal Lamp Inspection Test..........................5-41
2. Turn Signal Circuit Open Test................................5-41
DTC B1122: TSM/TSSM..................................................5-41
1. Operational Test.....................................................5-41
2. Indicator Short to Voltage Test...............................5-41
3. TSM/TSSM/HFSM Short to Voltage Test...............5-41
4. Indicator Shorted Test............................................5-41
5. Turn Signal Circuit Shorted Test............................5-41
6. Turn Signal Circuit Open Test................................5-41
DTC B1123.......................................................................5-42
1. Turn Signal Lamp Inspection Test..........................5-42
2. Turn Signal Circuit Short to Ground Test...............5-42
3. Indicator Test.........................................................5-42
4. Facia/Converter Module Test.................................5-42
DTC B1124.......................................................................5-42
1. Turn Signal Lamp Inspection Test..........................5-42
TABLE OF CONTENTS VII
TABLE OF CONTENTS
2. Turn Signal Circuit Short to Ground Test...............5-42
3. Indicator Test.........................................................5-42
4. Facia/Converter Module Test.................................5-42
DTC B1125.......................................................................5-43
1. Turn Signal Circuit Short to Ground Test...............5-43
2. Rear Turn Signal Test............................................5-43
DTC B1126.......................................................................5-43
1. Turn Signal Circuit Short to Ground Test...............5-43
2. Rear Turn Signal Test............................................5-43
5.11 DTC B1135, B1136, B1141, B1142
Diagnostics.......................................................................5-44
DTC B1135 Accelerometer Fault..............................5-44
DTC B1136 Accelerometer Tip-Over Self-Test
Fault..........................................................................5-44
DTC B1141 Ignition Switch Open/Low......................5-44
DTC B1142 Internal Fault..........................................5-44
DTC B1141.......................................................................5-44
1. Ignition Circuit Open Test.......................................5-44
5.12 SECURITY SYSTEM
Security Lamp..................................................................5-45
Security Immobilization....................................................5-45
TSSM/HFSM Features.....................................................5-46
Security System Options: TSSM...............................5-46
Warnings..........................................................................5-46
Arming: HFSM..................................................................5-46
Arming: TSSM..................................................................5-46
Auto-Arming Function: TSSM....................................5-47
Disarming: HFSM.............................................................5-47
Automatic Disarming.................................................5-47
Disarming with a PIN.................................................5-47
Disarming: TSSM..............................................................5-47
Alarm................................................................................5-48
Activation...................................................................5-48
Deactivation...............................................................5-48
Alarm Sensitivity: TSSM...................................................5-48
Sensitivity..................................................................5-48
5.13 KEY FOB
HFSM Fob........................................................................5-50
TSSM Fob........................................................................5-50
Arming the System....................................................5-50
Disarming the System...............................................5-50
Troubleshooting.........................................................5-50
Fob Assignment: HFSM....................................................5-50
Fob Assignment: TSSM....................................................5-50
5.14 SIREN
Description and Operation................................................5-52
Siren Chirp Mode Confirmation: HFSM............................5-52
Chirpless Mode.........................................................5-52
Chirp Mode................................................................5-52
Switching Modes.......................................................5-52
5.15 SERVICE AND EMERGENCY
FUNCTIONS AND CONFIGURATIONS
General.............................................................................5-53
Actuation: HFSM..............................................................5-53
Configuring a TSSM.........................................................5-53
Selecting a PIN.................................................................5-53
VIII TABLE OF CONTENTS
Initial Pin Entry: HFSM.....................................................5-53
Initial Pin Entry: TSSM......................................................5-54
Changing the Pin..............................................................5-56
Transport Mode................................................................5-57
To Enter Transport Mode: HFSM...............................5-57
To Exit Transport Mode: HFSM..................................5-57
To Enter Transport Mode: TSSM...............................5-57
To Exit Transport Mode: TSSM..................................5-57
Service Mode...................................................................5-57
Four-Way Flashing...........................................................5-57
To Arm the HFSM with the Hazard Warning Flashers
ON.............................................................................5-57
To Disarm the HFSM and Turn the Hazard Warning
Flashers OFF............................................................5-57
Storage Mode: TSSM.......................................................5-57
Power Disruption and Configuring: HFSM........................5-58
Power Disruption and Configuring: TSSM........................5-59
5.16 FAILS TO DISARM
Description and Operation................................................5-60
HFSM........................................................................5-60
TSSM........................................................................5-60
Diagnostic Tips..........................................................5-60
Connector Information...............................................5-60
Fails to Disarm: TSSM......................................................5-62
1. Key Fob Test..........................................................5-62
2. Left Turn Signal Test..............................................5-62
3. Fob Battery Test.....................................................5-62
4. TSSM Test.............................................................5-62
Fails to Disarm: HFSM......................................................5-62
1. Fob Test.................................................................5-62
2. Antenna Circuit Short to Ground Test....................5-62
3. Antenna Circuit Open Test.....................................5-62
4. Security System Antenna Test...............................5-62
5. Non-Functional Fob Test........................................5-62
5.17 DTC B1131, B1132
Description and Operation................................................5-63
Diagnostic Tips..........................................................5-63
Connector Information...............................................5-63
DTC B1131.......................................................................5-64
1. Siren Verification Test............................................5-64
2. Alarm Signal Short to Ground Test........................5-64
3. Battery Circuit Test................................................5-64
4. Power Supply and Ground Test.............................5-64
5. Alarm Signal Circuit Open Test..............................5-64
6. Alarm Signal Short to Ground Test........................5-64
7. Security Siren Resistance Test..............................5-65
8. Security Siren Validation Test................................5-65
DTC B1132.......................................................................5-65
1. Siren Verification Test............................................5-65
2. Alarm Signal Circuit Short to Voltage Test.............5-65
3. Alarm Signal Short to Voltage Test........................5-65
5.18 DTC B1134
Description and Operation................................................5-66
Connector Information...............................................5-66
DTC B1134.......................................................................5-67
1. Relay Control Circuit Short to Voltage Test............5-67
2. Start Relay Test.....................................................5-67

5.19 DTC B1143, B1144, B1145
Description and Operation................................................5-68
Connector Information...............................................5-68
DTC B1143.......................................................................5-68
1. Security Antenna Visual Test.................................5-68
2. Security Antenna Short to Ground Test.................5-68
DTC B1144.......................................................................5-69
1. Security Antenna Visual Test.................................5-69
2. Security Antenna Short to Voltage Test.................5-69
DTC B1145.......................................................................5-69
1. Security Antenna Resistance Test.........................5-69
2. Antenna B Circuit Open Test.................................5-69
3. Antenna A Circuit Open Test.................................5-69
5.20 DTC B1154, B1155
Description and Operation................................................5-70
Diagnostic Tips..........................................................5-70
Connector Information...............................................5-70
DTC B1154.......................................................................5-72
1. Clutch Circuit Short to Ground Test.......................5-72
2. Clutch Switch Circuit Test......................................5-72
3. Clutch Switch Test.................................................5-72
DTC B1155.......................................................................5-72
1. Neutral Circuit Short to Ground Test......................5-72
2. Neutral Switch Short to Ground Test.....................5-72
ENGINE MANAGEMENT
6.1 EFI SYSTEM
General...............................................................................6-1
Heat Management System..........................................6-2
Enable/Disable EITMS................................................6-2
6.2 ELECTRONIC CONTROL MODULE
General...............................................................................6-4
ECM............................................................................6-4
32-2 Flywheel..............................................................6-4
Crank Position Signal Synchronization........................6-5
Engine Phase..............................................................6-5
Engine Run Mode.......................................................6-5
6.3 SENSORS AND DRIVERS
Description and Operation..................................................6-6
Sensors..............................................................................6-6
Crank Position (CKP) Sensor......................................6-6
Twist Grip Sensor (TGS).............................................6-6
Twist Control Actuator (TCA).......................................6-6
Jiffy Stand Sensor (JSS): HDI.....................................6-6
Bank Angle Sensor (BAS)...........................................6-6
Clutch Switch...............................................................6-6
Neutral Switch.............................................................6-6
Engine Temperature (ET) Sensor................................6-6
Temperature Manifold Absolute Pressure (TMAP)
Sensor.........................................................................6-6
Manifold Absolute Pressure (MAP) Sensor ................6-6
Intake Air Temperature (IAT) Sensor...........................6-6
Vehicle Speed Sensor (VSS)......................................6-7
HO2S: Front and Rear.................................................6-7
Drivers................................................................................6-7
Fuel Pump...................................................................6-7
Ignition Coil and Spark Plugs......................................6-7
TABLE OF CONTENTS
Fuel Injectors...............................................................6-7
Start Relay..................................................................6-7
Purge Solenoid (If Equipped)......................................6-7
6.4 DTC P0107, P0108, P0112, P0113
Description and Operation..................................................6-9
TMAP: MAP Signal......................................................6-9
TMAP: IAT Signal........................................................6-9
Diagnostics.........................................................................6-9
Diagnostic Tips: MAP Portion of TMAP Sensor...........6-9
Diagnostic Tips: IAT Portion of TMAP Sensor.............6-9
Connector Information.................................................6-9
DTC P0107.......................................................................6-10
1. MAP Sensor Test...................................................6-10
2. MAP Sensor Signal Voltage Test...........................6-10
3. MAP Sensor Signal Wire Continuity Test...............6-10
4. MAP Sensor Signal Wire Shorted to Ground
Test............................................................................6-11
5. MAP Sensor Signal Wire Shorted to Sensor Ground
Test............................................................................6-11
6. MAP Sensor 5V Reference Wire Open Test..........6-11
7. MAP Sensor 5V Reference Shorted to Signal Ground
Test............................................................................6-11
DTC P0108.......................................................................6-11
1. MAP Sensor Test...................................................6-11
2. MAP Sensor Signal Wire Short to 5V Test.............6-11
3. MAP Sensor Signal Wire Short to Voltage Test.....6-11
4. MAP Sensor 5V Reference Shorted to Battery Voltage
Test............................................................................6-11
5. MAP Sensor Ground Wire Open Test....................6-11
DTC P0112.......................................................................6-12
1. IAT Sensor Test......................................................6-12
2. IAT Sensor Signal Wire Shorted to Ground Test.....6-12
3. IAT Sensor Signal Voltage High Test.....................6-12
4. IAT Sensor Signal Wire Shorted to Sensor Ground
Test............................................................................6-12
DTC P0113.......................................................................6-12
1. IAT Sensor Test......................................................6-12
2. IAT Sensor Signal Wire Open Test.........................6-12
3. IAT Sensor Open Ground Wire Test.......................6-12
4. IAT Sensor Signal Wire Shorted to Sensor Power
Test............................................................................6-12
6.5 DTC P0117, P0118
Description and Operation................................................6-13
Diagnostic Tips..........................................................6-13
Connector Information...............................................6-13
DTC P0117.......................................................................6-14
1. ET Sensor Test .....................................................6-14
2. ET Sensor Signal Wire Shorted to Ground Test.....6-14
3. ET Sensor Signal Wire Shorted to Sensor Ground
Test............................................................................6-14
DTC P0118.......................................................................6-14
1. ET Sensor Test......................................................6-15
2. ET Sensor Signal Wire Open Test.........................6-15
3. ET Sensor Open Ground Wire Test.......................6-15
4. ET Sensor Signal Wire Shorted to Power Test......6-15
5. ET Sensor Resistance Test...................................6-15
6.6 DTC P0120, P0122, P0123, P0220, P0222,
P0223
Description and Operation................................................6-16
TABLE OF CONTENTS IX
TABLE OF CONTENTS
Connector Information...............................................6-17
DTC P0120.......................................................................6-17
1. Sensor Power-1 Circuit Test..................................6-17
2. TPS-1 Circuit Shorted Test....................................6-17
3. TPS-1 Circuit Continuity Test.................................6-17
4. TPS-1 Circuit Short to Ground Test.......................6-18
5. TPS-1 Circuit Short to Voltage Test.......................6-18
6. Sensor Ground Continuity Test..............................6-18
7. TCA Test................................................................6-18
DTC P0122.......................................................................6-18
1. TCA Sensor-1 Circuit Test.....................................6-18
2. TCA Sensor-1 Circuit Short to Ground Test...........6-18
3. TCA Power-1 Circuit Open Test.............................6-18
4. TCA Sensor Test....................................................6-18
5. ECM Test...............................................................6-18
DTC P0123.......................................................................6-19
1. TPS-1 Voltage Test................................................6-19
2. TPS-1 Circuit Test..................................................6-19
3. Sensor Power Circuit Test......................................6-19
4. TCA Test................................................................6-19
5. Sensor Ground Test...............................................6-19
6. Sensor Ground Circuit Shorted Test......................6-19
7. Sensor Ground Circuit Test....................................6-19
8. TPS-1 Circuit Function Test...................................6-19
9. Sensor Ground Continuity Test..............................6-19
10. Ground Circuit Open Test....................................6-19
11. TPS-1 Continuity Test..........................................6-20
DTC P0220.......................................................................6-20
1. Sensor Power-2 Circuit Test..................................6-20
2. Sensor Power-2 Short to Voltage Test...................6-20
3. TPS-2 Circuit Shorted Test....................................6-20
4. TPS-2 Circuit Continuity Test.................................6-20
5. TPS-1 Circuit Short to Ground Test.......................6-20
6. TPS-1 Circuit Short to Voltage Test.......................6-20
7. Sensor Ground Continuity Test..............................6-20
8. TCA Test................................................................6-20
DTC P0222.......................................................................6-21
1. TCA Sensor-2 Circuit Test.....................................6-21
2. TCA Sensor-2 Circuit Short to Ground Test...........6-21
3. TCA Power-1 Circuit Open Test.............................6-21
4. TCA 5V Ref Circuit Short to Ground Test..............6-21
5. ECM Test...............................................................6-21
DTC P0223.......................................................................6-21
1. TPS-2 Voltage Test................................................6-21
2. TPS-2 Circuit Test..................................................6-21
3. Sensor Power Circuit Test......................................6-22
4. Sensor Ground Test...............................................6-22
5. Shorted 5V Circuit Test..........................................6-22
6. Sensor Ground Circuit Test....................................6-22
7. TPS-2 Circuit Test..................................................6-22
8. Sensor Ground Continuity Test..............................6-22
9. Ground Circuit Open Test......................................6-22
6.7 DTC P0031, P0032, P0131, P0132, P0134,
P0151, P0152, P0154
Description and Operation................................................6-23
Diagnostic Tips..........................................................6-23
Connector Information...............................................6-24
DTC P0031.......................................................................6-26
1. HO2S Voltage Test.................................................6-26
2. HO2S Ground Test................................................6-26
3. HO2S Resistance Test...........................................6-26
X TABLE OF CONTENTS
DTC P0032.......................................................................6-26
1. Rear HO2S Resistance Test..................................6-26
2. Front HO2S Resistance Test.................................6-26
3. HO2S Short to Voltage Test...................................6-26
DTC P0131.......................................................................6-26
1. Front HO2S Test....................................................6-26
2. Front HO2S Signal Wire Shorted to Sensor Ground
Test............................................................................6-26
3. Front HO2S Signal Wire Shorted to Ground Test...6-27
4. Front HO2S Operation Test...................................6-27
DTC P0132.......................................................................6-27
1. Front HO2S Operation Test...................................6-27
DTC P0134.......................................................................6-27
1. Front HO2S Signal Wire Short Circuit Voltage
Test............................................................................6-27
2. Front HO2S Open Sensor Ground Test.................6-27
3. Front HO2S Signal Wire Open Test.......................6-27
DTC P0151.......................................................................6-28
1. Rear HO2S Test.....................................................6-28
2. Rear HO2S Signal Wire Shorted to Sensor Ground
Test............................................................................6-28
3. Rear HO2S Signal Wire Shorted to Ground Test....6-28
4. Rear HO2S Operation Test....................................6-28
DTC P0152.......................................................................6-28
1. Rear HO2S Operation Test....................................6-28
DTC P0154.......................................................................6-29
1. Rear HO2S Signal Wire Short Circuit Voltage
Test............................................................................6-29
2. Rear HO2S Open Sensor Ground Test.................6-29
3. Rear HO2S Signal Wire Open Test.......................6-29
6.8 DTC P0261, P0262, P0263, P0264
Description and Operation................................................6-30
Connector Information...............................................6-30
DTC P0261.......................................................................6-32
1. Front Fuel Injector Test..........................................6-32
2. Front Fuel Injector Power Wire Open Circuit Test...6-32
3. Front Fuel Injector Power Wire Shorted to Ground
Test............................................................................6-32
4. Fuel Injector/System Relay Test............................6-32
5. Injector Resistance Test.........................................6-32
6. Driver Short to Ground Test...................................6-32
DTC P0262.......................................................................6-32
1. Front Fuel Injector Control Wire Shorted to Voltage
Test............................................................................6-32
2. Injector Resistance Test.........................................6-32
DTC P0263.......................................................................6-33
1. Rear Fuel Injector Test...........................................6-33
2. Rear Fuel Injector Power Wire Open Circuit Test...6-33
3. Rear Fuel Injector Power Wire Shorted to Ground
Test............................................................................6-33
4. Fuel Injector/System Relay Test............................6-33
5. Injector Resistance Test.........................................6-33
6. Driver Short to Ground Test...................................6-33
DTC P0264.......................................................................6-33
1. Rear Fuel Injector Control Wire Shorted to Voltage
Test............................................................................6-33
2. Injector Resistance Test.........................................6-33
6.9 DTC P0373, P0374
Description and Operation................................................6-34
Diagnostic Tips..........................................................6-34

Connector Information...............................................6-34
DTC P0373.......................................................................6-35
1. CKP Sensor Test...................................................6-35
DTC P0374.......................................................................6-35
1. CKP Sensor Connections Test..............................6-35
2. CKP Sensor Signal Wire Continuity Test...............6-35
3. CKP Sensor Ground Wire Continuity Test.............6-35
4. CKP Sensor Signal Wire Shorted to CKP Ground Wire
Test............................................................................6-35
5. CKP Sensor Low Shorted to Ground Test.............6-35
6. CKP Sensor Output Test........................................6-35
7. CKP Sensor Signal Wire Shorted to Ground Test..6-35
6.10 DTC P0444, P0445
Description and Operation................................................6-36
Purge Solenoid (If Equipped)....................................6-36
Connector Information...............................................6-36
DTC P0444.......................................................................6-38
1. Purge Solenoid Test...............................................6-38
2. Purge Solenoid Voltage Test..................................6-38
3. Purge Solenoid Control Wire Shorted to Ground
Test............................................................................6-38
4. Purge Solenoid Control Wire Open Test................6-38
DTC P0445.......................................................................6-38
1. Purge Solenoid Test...............................................6-38
2. Purge Solenoid Short to Voltage Test ...................6-38
6.11 DTC P0501, P0502
Description and Operation................................................6-39
Connector Information...............................................6-39
DTC P0501.......................................................................6-41
1. VSS Connections Test...........................................6-41
2. VSS Sensor Power Short to Ground Test..............6-41
3. VSS Signal Wire Short to Ground Test..................6-41
4. VSS Signal Wire Open Test...................................6-41
5. VSS Dirty or Damaged Test...................................6-41
DTC P0502.......................................................................6-41
1. VSS Sensor Power Shorted to Voltage Test..........6-41
2. VSS Signal Wire Short to Voltage Test..................6-41
3. VSS Ground Wire Open Test.................................6-41
4. VSS Signal Wire Shorted to Sensor Power Test.....6-42
5. VSS Test................................................................6-42
6.12 DTC P0505
Loss of Idle Speed Control...............................................6-43
Connector Information...............................................6-43
DTC P0505.......................................................................6-44
1. Fuel Quality Test....................................................6-44
2. Vacuum Leak Test..................................................6-44
6.13 DTC P0572
Description and Operation................................................6-45
Brake Switch.............................................................6-45
Diagnostic Tips..........................................................6-45
DTC P0572.......................................................................6-46
1. Stop Lamp Switch Validation Test..........................6-46
2. Brake Input Circuit Test..........................................6-46
3. Accessory Circuit Test...........................................6-47
4. Rear Stop Lamp Switch Circuit Test......................6-47
5. Rear Stop Lamp Switch Test.................................6-47
6. ABS Diode Pack Test.............................................6-47
7. ECM Circuit Test....................................................6-47
TABLE OF CONTENTS
8. Front Stop Lamp Switch Circuit Test......................6-47
9. Front Stop Lamp Switch Test.................................6-47
10. ABS Diode Pack Test...........................................6-47
11. ECM Circuit Test..................................................6-47
6.14 DTC P0603, P0605
Description and Operation................................................6-48
DTC P0603 Test........................................................6-48
DTC P0605 Test........................................................6-48
6.15 DTC P0641, P0651
Description and Operation................................................6-49
DTC P0641.......................................................................6-50
1. Sensor Power-1 Circuit Test..................................6-50
2. Sensor Power-1 Circuit Resistance Test................6-50
3. TCA Test................................................................6-50
4. JSS Test.................................................................6-50
5. TGS Test................................................................6-50
6. VSS Test................................................................6-50
DTC P0651.......................................................................6-50
1. Sensor Power-2 Circuit Test..................................6-50
2. Sensor Power-2 Circuit Resistance Test................6-50
3. TMAP Test.............................................................6-51
4. TGS Test................................................................6-51
6.16 DTC P1001, P1002, P1003, P1004
Description and Operation................................................6-52
Connector Information...............................................6-52
DTC P1001.......................................................................6-54
1. System Relay Test.................................................6-54
2. System Relay Coil Power Circuit Test....................6-54
3. System Relay Coil Control Short to Ground Test....6-54
4. System Relay Coil Control Circuit Test..................6-54
DTC P1002.......................................................................6-54
1. System Relay Test.................................................6-54
2. System Relay Coil Short to Voltage Test...............6-54
DTC P1003.......................................................................6-54
1. System Relay Test.................................................6-54
2. System Relay Power Supply Test..........................6-54
3. System Relay Switch Side Circuit Test..................6-55
4. System Relay Power Supply Circuit Test...............6-55
DTC P1004.......................................................................6-55
1. System Relay Test.................................................6-55
2. System Relay Switch Side Short to Voltage Test....6-55
3. System Relay Coil Short to Ground Test...............6-55
4. Rear Ignition Coil Short to Voltage Test ................6-55
5. Front Ignition Coil Short to Voltage Test.................6-55
6.17 DTC P1009, P1010
Description and Operation................................................6-56
Password Problem....................................................6-56
Connector Information...............................................6-56
DTC P1009, P1010..........................................................6-57
1. Incorrect Password Test.........................................6-57
2. TSM/TSSM/HFSM Replacement Test...................6-57
6.18 DTC P1270
Description and Operation................................................6-58
TGS2 Validation.........................................................6-58
Connector Information...............................................6-58
DTC P1270.......................................................................6-60
1. ECM Connector Test..............................................6-60
TABLE OF CONTENTS XI
TABLE OF CONTENTS
2. ECM Circuit Test....................................................6-60
3. Relay Circuit Test...................................................6-60
6.19 DTC P1351, P1352, P1354, P1355
Description and Operation................................................6-61
Connector Information...............................................6-61
DTC P1351.......................................................................6-63
1. Ignition Coil Test....................................................6-63
2. Ignition Coil Input Voltage Test...............................6-63
3. Ignition Coil Control Wire Continuity Test...............6-63
4. Ignition Coil Control Wire Shorted to Ground
Test............................................................................6-63
DTC P1352.......................................................................6-63
1. Ignition Coil Shorted to Voltage Test......................6-63
2. Ignition Coil Open Test...........................................6-63
DTC P1354.......................................................................6-64
1. Ignition Coil Test....................................................6-64
2. Ignition Coil Input Continuity Test..........................6-64
3. Ignition Coil Control Wire Continuity Test...............6-64
4. Ignition Coil Control Wire Shorted to Ground
Test............................................................................6-64
DTC P1355.......................................................................6-64
1. Ignition Coil Shorted to Voltage Test......................6-64
2. Ignition Coil Open Test...........................................6-64
6.20 DTC P1353, P1356, P1357, P1358
Description and Operation................................................6-65
Connector Information...............................................6-65
DTC P1353, P1356..........................................................6-67
1. Absence of Fuel Test.............................................6-67
2. Ignition Coil Primary Resistance Test....................6-67
3. Spark Plug Wire Test.............................................6-67
4. Ignition Coil Secondary Resistance Test ..............6-67
DTC P1357, P1358..........................................................6-67
1. Ion Sense Continuity Test......................................6-67
2. Ion Sense Resistance Test....................................6-67
3. Ion Sense Short to Voltage Test............................6-67
6.21 DTC P1475, P1477, P1478
Description and Operation................................................6-68
Connector Information...............................................6-68
DTC P1475.......................................................................6-70
1. Exhaust Actuator Test............................................6-70
2. Exhaust Actuator Voltage Test...............................6-70
3. Exhaust Actuator Motor Ground Wire Continuity
Test............................................................................6-70
4. Exhaust Actuator Motor Power Wire Continuity
Test............................................................................6-70
5. Exhaust Actuator Feedback Voltage Test..............6-70
6. Exhaust Actuator Feedback Continuity Test..........6-70
7. Exhaust Actuator Feedback Control Test...............6-70
8. Exhaust Actuator Feedback Run Test....................6-70
9. Exhaust Actuator Feedback Short to Voltage
Test............................................................................6-70
10. Exhaust Actuator Feedback Short to Ground
Test............................................................................6-71
DTC P1477.......................................................................6-71
1. Exhaust Actuator Motor Open Test........................6-71
2. Exhaust Actuator Motor Shorted to Ground Test....6-71
3. Exhaust Actuator Feedback Shorted to Ground
Test............................................................................6-71
DTC P1478.......................................................................6-71
XII TABLE OF CONTENTS
1. Exhaust Actuator Motor High Test.........................6-71
2. Exhaust Actuator Motor Shorted to Voltage Test....6-71
6.22 DTC P1501, P1502
Description and Operation................................................6-72
Connector Information...............................................6-72
DTC P1501.......................................................................6-73
1. JSS 5V Reference Open Circuit Test.....................6-73
2. JSS 5V Reference Shorted to Ground Test...........6-73
3. JSS Signal Wire Shorted to Ground Test...............6-73
4. JSS Signal Wire Open Circuit Test........................6-74
DTC P1502.......................................................................6-74
1. JSS Ground Wire Test...........................................6-74
2. JSS 5V Reference Wire Short to Voltage Test.......6-74
3. JSS Signal Wire Short to Voltage Test...................6-74
4. JSS 5V Reference and Signal Shorted Together
Test............................................................................6-74
Side Stand Displayed on Odometer.................................6-74
1. Starts, Then Stalls Test..........................................6-74
2. Neutral Test ...........................................................6-74
3. JSS Clearance Test...............................................6-74
6.23 DTC P1510, P1511, P1512
Description and Operation................................................6-75
Throttle Actuation Control Management....................6-75
DTC P1510, P1511, P1512..............................................6-75
1. DTC Verification Test.............................................6-75
6.24 DTC P1514
Description and Operation................................................6-76
Air Flow Fault.............................................................6-76
DTC P1514.......................................................................6-76
1. DTC Verification Test.............................................6-76
6.25 DTC P1600
Description and Operation................................................6-77
DTC P1600.......................................................................6-77
1. DTC Verification Test.............................................6-77
6.26 DTC P1655, P1656
Description and Operation................................................6-78
Connector Information...............................................6-78
DTC P1655.......................................................................6-80
1. Front ACR Test......................................................6-80
2. Rear ACR Test.......................................................6-80
3. Rear ACR Control Circuit Test...............................6-80
4. Front ACR Control Circuit Short to Ground Test.....6-80
5. Rear ACR Control Circuit Short to Ground Test.....6-80
6. Shorted ACR Test..................................................6-80
7. ACR Supply Circuit Open Test...............................6-80
8. ACR Control Circuit Continuity Test.......................6-80
DTC P1656.......................................................................6-81
1. Front ACR Test......................................................6-81
2. Rear ACR Control Circuit Test...............................6-81
3. Rear ACR Test.......................................................6-81
4. Front ACR Control Circuit Test...............................6-81
6.27 DTC P2100, P2101, P2102, P2103
Description and Operation................................................6-82
Connector Information...............................................6-82
DTC P2100.......................................................................6-83

1. TCA Test................................................................6-83
2. TCA High Circuit Test.............................................6-83
3. TCA Low Circuit Test.............................................6-83
DTC P2101.......................................................................6-84
1. TCA Circuit Resistance Test..................................6-84
2. TCA Test................................................................6-84
3. TCA High Circuit Test.............................................6-84
4. TCA Low Circuit Test.............................................6-84
DTC P2102.......................................................................6-84
1. TCA High Circuit Test.............................................6-84
2. TCA Test................................................................6-84
DTC P2103.......................................................................6-84
1. TCA High Circuit Test.............................................6-84
2. TCA Low Circuit Test.............................................6-85
6.28 DTC P2105, P2107
Description and Operation................................................6-86
DTC P2105.......................................................................6-88
1. DTC Verification Test.............................................6-88
DTC P2107.......................................................................6-88
1. ECM Connector Test..............................................6-88
2. ECM Circuit Test....................................................6-88
3. Relay Circuit Test...................................................6-88
6.29 DTC P2119
Description and Operation................................................6-89
DTC P2119.......................................................................6-89
1. Air Inlet Interference Test.......................................6-89
2. Validation Test........................................................6-89
6.30 DTC P2122, P2123, P2127, P2128
Description and Operation................................................6-90
DTC P2122.......................................................................6-90
1. TGS-1 Voltage Test................................................6-90
2. TGS-1 Circuit Open Test........................................6-90
3. TGS-1 Short to Ground Test..................................6-90
4. Twist Grip Sensor Test...........................................6-90
5. TGS-1 Test.............................................................6-90
6. TGS-1 Open Test...................................................6-90
7. Sensor Power-1 Continuity Test.............................6-90
8. Sensor Power Resistance Test..............................6-91
9. TCA Test................................................................6-91
10. JSS Test...............................................................6-91
11. VSS Test..............................................................6-91
DTC P2123.......................................................................6-91
1. TGS-1 Voltage Test................................................6-91
2. TGS-1 Short to Voltage Test..................................6-91
3. TGS-1 Short to Ground Test..................................6-91
4. TGS Test................................................................6-91
5. TGS-1 Test.............................................................6-92
6. TGS-1 Open Test...................................................6-92
7. Sensor Power-1 Continuity Test.............................6-92
8. Sensor Power Resistance Test..............................6-92
9. TCA Test................................................................6-92
DTC P2127.......................................................................6-92
1. TGS-2 Voltage Test................................................6-92
2. TGS-2 Open Test...................................................6-92
3. TGS-2 Short to Ground Test..................................6-92
4. TGS Test................................................................6-92
5. TGS-2 Test.............................................................6-93
6. TGS-2 Open Test...................................................6-93
7. Sensor Power-2 Continuity Test.............................6-93
TABLE OF CONTENTS
8. Sensor Power Resistance Test..............................6-93
9. TMAP Test.............................................................6-93
DTC P2128.......................................................................6-93
1. TGS-1 Voltage Test................................................6-93
2. TGS-1 Short to Voltage Test..................................6-93
3. TGS-1 Short to Ground Test..................................6-93
4. TGS Test................................................................6-93
5. TGS-1 Test.............................................................6-94
6. TGS-1 Open Test...................................................6-94
7. Sensor Power-1 Continuity Test.............................6-94
8. Sensor Power Resistance Test..............................6-94
9. TCA Test................................................................6-94
6.31 DTC P2135, P2138
Description and Operation................................................6-95
DTC P2135.......................................................................6-95
1. TPS-2 Voltage Test................................................6-95
2. TPS-2 Circuit Test..................................................6-95
3. Sensor Power Circuit Test......................................6-95
4. Sensor Ground Test...............................................6-95
5. Shorted 5V Circuit Test..........................................6-95
6. Sensor Ground Circuit Test....................................6-95
7. TPS-2 Circuit Test..................................................6-95
8. Sensor Ground Continuity Test..............................6-95
9. Ground Circuit Open Test......................................6-96
DTC P2138.......................................................................6-96
1. TGS-2 Voltage Test................................................6-96
2. TGS-2 Circuit Test..................................................6-96
3. Sensor Power Circuit Test......................................6-96
4. Sensor Ground Test...............................................6-96
5. Shorted 5V Circuit Test..........................................6-96
6. Sensor Ground Circuit Test....................................6-96
7. Sensor Ground-2 Open Circuit Test.......................6-96
8. TGS-2 Circuit Test..................................................6-96
9. Sensor Ground Continuity Test..............................6-96
10. Ground Circuit Open Test....................................6-97
6.32 DTC P2176
Description and Operation................................................6-98
DTC P2176.......................................................................6-98
1. Air Inlet Interference Test.......................................6-98
2. Validation Test........................................................6-98
6.33 ENGINE CRANKS, BUT WILL NOT
START
Description and Operation................................................6-99
Connector Information...............................................6-99
Engine Cranks But Will Not Start....................................6-101
1. Preliminary Engine Tests.....................................6-101
2. Check Engine Lamp Test.....................................6-101
3. Spark Present Test..............................................6-101
6.34 NO ECM POWER
Description and Operation..............................................6-102
Connector Information.............................................6-102
No ECM Power...............................................................6-103
1. ECM Fuse Test....................................................6-103
2. IGN Fuse Test......................................................6-103
3. ECM Connector Test............................................6-103
4. ECM Battery Wire Test........................................6-103
5. ECM Switched Voltage Test.................................6-104
TABLE OF CONTENTS XIII
TABLE OF CONTENTS
6. ECM Ground Wires Test......................................6-104
7. Engine Stop Switch Battery Voltage Test.............6-104
8. Engine Stop Switch Test......................................6-104
6.35 STARTS, THEN STALLS
Description and Operation..............................................6-105
Diagnostic Tips........................................................6-105
Connector Information.............................................6-105
Starts, Then Stalls..........................................................6-105
1. Throttle Test.........................................................6-105
2. Jiffy Stand Test....................................................6-105
3. Neutral Switch Test..............................................6-105
4. Fuel System Test.................................................6-105
6.36 FUEL SYSTEM ELECTRICAL TEST
Description and Operation..............................................6-106
Connector Information.............................................6-106
Fuel System Electrical Test............................................6-108
1. ECM Fuse Test....................................................6-108
2. Fuel Pump Voltage Test.......................................6-108
3. Fuel Pump Open Circuit Test...............................6-108
6.37 MISFIRE AT IDLE OR UNDER LOAD
Description and Operation..............................................6-109
Diagnostic Tips........................................................6-109
In-line Spark Tester.........................................................6-109
Connector Information.............................................6-109
Misfire At Idle or Under Load..........................................6-111
1. Power Ground Continuity Test.............................6-111
2. Spark Test............................................................6-111
3. Spark Plug Wire Test...........................................6-111
4. Carbon Tracking Inspection Test..........................6-111
5. Ignition Coil Primary Wire Continuity Test ...........6-111
6. Battery to System Relay Voltage Drop Test.........6-111
7. System Relay Test ..............................................6-111
8. Battery to ECM Fuse Voltage Drop Test..............6-111
9. Battery to Fuse Block Voltage Drop Test.............6-111
10. Battery to Main Fuse Voltage Drop Test ...........6-112
11. Battery to Main Fuse Block Voltage Drop Test....6-112
ABS
7.1 ANTI-LOCK BRAKE SYSTEM (ABS)
GENERAL INFORMATION
Description and Operation..................................................7-1
Pressure Hold..............................................................7-2
Pressure Decrease......................................................7-2
Pressure Increase.......................................................7-2
Initialization Self-Test...................................................7-2
ABS Indicator..............................................................7-3
7.2 DTC C1017, C1018
Description and Operation..................................................7-4
Conditions for Setting the DTC....................................7-4
Action Taken When the DTC Sets...............................7-4
Conditions for Clearing the DTC.................................7-4
Diagnostic Tips............................................................7-4
Connector Information.................................................7-4
DTC C1017........................................................................7-5
1. ABS Fuse Test.........................................................7-5
2. Battery Circuit Short to Ground Test........................7-5
XIV TABLE OF CONTENTS
3. Battery Voltage Circuit Test......................................7-5
4. Ground Circuit Open Test........................................7-6
DTC C1018........................................................................7-6
1. Ground Circuit Open Test........................................7-6
7.3 DTC C1021, C1023
Description and Operation..................................................7-7
Conditions for Setting the DTC....................................7-7
Action Taken When the DTC Sets...............................7-7
Conditions for Clearing the DTC.................................7-7
Diagnostic Tips............................................................7-7
Connector Information.................................................7-7
DTC C1021, C1023............................................................7-8
1. DTC Verification Test...............................................7-8
2. Validation of Current DTC Test................................7-8
7.4 DTC C1025, C1027, C1206, C1208
Description and Operation..................................................7-9
Conditions for Setting the DTC....................................7-9
Action Taken When the DTC Sets...............................7-9
Conditions for Clearing the DTC.................................7-9
Diagnostic Tips............................................................7-9
Connector Information.................................................7-9
DTC C1025 (Front), C1027 (Rear), C1206, C1208..........7-10
1. Electrical Interference Test....................................7-10
2. Loose or Damaged Connections Test....................7-10
3. Validation of Current DTC Test..............................7-10
4. WSS Circuit Open Test..........................................7-10
5. Worn or Damaged Components Test.....................7-10
7.5 DTC C1032, C1034
Description and Operation................................................7-11
Conditions for Setting the DTC..................................7-11
Action Taken When the DTC Sets.............................7-11
Conditions for Clearing the DTC...............................7-11
Diagnostic Tips..........................................................7-11
Connector Information...............................................7-11
DTC C1032......................................................................7-12
1. Validation of Current DTC Test..............................7-12
2. Front WSS Low Circuit Test...................................7-12
3. Front WSS Circuits Short to Ground Test..............7-12
4. Front WSS High Circuit Test..................................7-12
5. Front WSS Low Circuit Open Test.........................7-12
6. Front WSS Short to Ground Test...........................7-12
7. Front WSS Circuits Short to Voltage Test..............7-12
8. Front WSS Circuits Shorted Together Test............7-12
9. Front WSS Continuity Test.....................................7-12
10. Front WSS Short to Voltage Test.........................7-12
DTC C1034......................................................................7-13
1. Validation of Current DTC Test..............................7-13
2. Rear WSS Low Circuit Test....................................7-13
3. Rear WSS Circuits Short to Ground Test...............7-13
4. Rear WSS High Circuit Test...................................7-13
5. Rear WSS Low Circuit Open Test..........................7-13
6. Rear WSS Circuits Short to Ground Test...............7-13
7. Rear WSS Circuits Short to Voltage Test...............7-13
8. Rear WSS Circuits Shorted Together Test.............7-13
9. Rear WSS Continuity Test.....................................7-13
10. Rear WSS Short to Voltage Test..........................7-13
7.6 DTC C1042, C1043
Description and Operation................................................7-14

Conditions for Setting the DTC..................................7-14
Action Taken When the DTC Sets.............................7-14
Conditions for Clearing the DTC...............................7-14
Diagnostic Tips..........................................................7-14
DTC C1042......................................................................7-14
1. Ground Circuit Open Test......................................7-14
2. Pump Motor Test....................................................7-14
DTC C1043......................................................................7-15
1. Ground Circuit Open Test......................................7-15
7.7 DTC C1094
Description and Operation................................................7-16
Conditions for Setting the DTC..................................7-16
Action Taken When the DTC Sets.............................7-16
Conditions for Clearing the DTC...............................7-16
Diagnostic Tips..........................................................7-16
Connector Information...............................................7-16
DTC C1094......................................................................7-17
1. Validation of Current DTC Test..............................7-17
2. Front Brake Input Short to Voltage Test.................7-17
3. Front Stop Lamp Switch Test.................................7-18
7.8 DTC C1095
Description and Operation................................................7-19
Conditions for Setting the DTC..................................7-19
Action Taken When the DTC Sets.............................7-19
Conditions for Clearing the DTC...............................7-19
Connector Information...............................................7-19
DTC C1095......................................................................7-20
1. Validation of Current DTC Test..............................7-20
2. DTC Verification Test.............................................7-20
3. Tail/Stop Lamp Test................................................7-21
4. Ground Circuit Open Test......................................7-21
5. Front Stop Lamp Switch Test.................................7-21
6. Front Stop Lamp Switch Input Circuit Open Test....7-21
7. ABS Diode Pack Test.............................................7-21
8. Tail/Stop Lamp Circuit Open Test...........................7-21
9. Front Stop Lamp Switch Test.................................7-21
10. Accessory Circuit Test.........................................7-21
7.9 DTC C1151
Description and Operation................................................7-22
Conditions for Setting the DTC..................................7-22
Action Taken When the DTC Sets.............................7-22
Conditions for Clearing the DTC...............................7-22
Diagnostic Tips..........................................................7-22
Connector Information...............................................7-22
DTC C1151......................................................................7-23
1. Validation of Current DTC Test..............................7-23
2. Brake Lines Installation Test..................................7-23
3. ECU Test................................................................7-23
7.10 DTC C1153
Description and Operation................................................7-24
Conditions for Setting the DTC..................................7-24
Action Taken When the DTC Sets.............................7-24
Conditions for Clearing the DTC...............................7-24
Diagnostic Tips..........................................................7-24
Connector Information...............................................7-24
DTC C1153......................................................................7-25
1. Validation of Current DTC Test..............................7-25
2. Brake Lines Installation Test..................................7-25
TABLE OF CONTENTS
3. ECU Test................................................................7-25
7.11 DTC C1158
Description and Operation................................................7-26
Conditions for Setting the DTC..................................7-26
Action Taken When the DTC Sets.............................7-26
Conditions for Clearing the DTC...............................7-26
DTC C1158......................................................................7-26
1. Validation of Current DTC Test..............................7-26
2. Successful Calibration Test....................................7-26
7.12 DTC C1212
Description and Operation................................................7-27
Conditions for Setting the DTC..................................7-27
Action Taken When the DTC Sets.............................7-27
Conditions for Clearing the DTC...............................7-27
Diagnostic Tips..........................................................7-27
Connector Information...............................................7-27
DTC C1212......................................................................7-28
1. Validation of Current DTC Test..............................7-28
2. Stop Lamp Switch Input Circuits Voltage Test.......7-28
3. Rear Stop Lamp Switch Input Test........................7-29
4. Rear Stop Lamp Circuit Test..................................7-29
5. Rear Stop Lamp Switch Test.................................7-29
6. Rear Stop Lamp Switch Accessory Circuit Open
Test............................................................................7-29
7. Front Stop Lamp Switch Accessory Circuit Open
Test............................................................................7-29
8. Front Stop Lamp Switch Test.................................7-29
7.13 DTC C1214
Description and Operation................................................7-30
Conditions for Setting the DTC..................................7-30
Action Taken When the DTC Sets.............................7-30
Conditions for Clearing the DTC...............................7-30
Diagnostic Tips..........................................................7-30
Connector Information...............................................7-30
DTC C1214......................................................................7-31
1. Validation of Current DTC Test..............................7-31
2. Rear Stop Lamp Switch Input Voltage Test............7-31
3. Rear Stop Lamp Switch Test.................................7-32
7.14 DTC C1216
Description and Operation................................................7-33
Conditions for Setting the DTC..................................7-33
Action Taken When the DTC Sets.............................7-33
Conditions for Clearing the DTC...............................7-33
Diagnostic Tips..........................................................7-33
Connector Information...............................................7-33
DTC C1216......................................................................7-34
1. Validation of Current DTC Test..............................7-34
2. DTC Verification Test.............................................7-34
3. Tail/Stop Lamp Test................................................7-34
4. Rear Stop Lamp Switch Input Circuit Open Test....7-35
5. ABS Diode Pack Test ............................................7-35
6. Tail/Stop Lamp Circuit Open Test...........................7-35
7. Rear Stop Lamp Switch Test.................................7-35
8. Accessory Circuit Test ..........................................7-35
TABLE OF CONTENTS XV
TABLE OF CONTENTS
7.15 DTC C1014, C1055-C1066, C1118,
C1121
Description and Operation................................................7-36
Circuit Description.....................................................7-36
Conditions for Setting the DTC..................................7-36
Action Taken When the DTC Sets.............................7-36
Conditions for Clearing the DTC...............................7-36
Connector Information...............................................7-36
DTC C1014, C1055-C1066, C1118, C1121.....................7-38
1. Battery Circuit Voltage Test....................................7-38
2. Battery Power Circuit Resistance Test...................7-38
3. Ignition Circuit Test................................................7-38
4. Ground Circuit Resistance Test.............................7-38
7.16 ABS INDICATOR ALWAYS ON OR
INOPERATIVE
Description and Operation................................................7-39
Diagnostic Tips..........................................................7-39
Connector Information...............................................7-39
ABS Indicator Always On or Inoperative...........................7-41
1. DTC Test................................................................7-41
2. ABS Lamp Function Test.......................................7-41
3. Serial Data Circuit Test..........................................7-41
4. ABS Fuse Test.......................................................7-41
5. ABS Power Circuit Test..........................................7-41
6. ABS Ground Circuit Test........................................7-41
7. ABS Power Circuit Short to Ground Test...............7-41
AUDIO SYSTEM
8.1 RADIO DIAGNOSTICS
Description and Operation..................................................8-1
Diagnostics.........................................................................8-1
Diagnostic Tips............................................................8-1
Radio Diagnostic Display............................................8-1
8.2 DTC B2006-B2015, RADIO SWITCH
DIAGNOSTICS
Description and Operation..................................................8-6
Diagnostics.........................................................................8-6
Diagnostic Tips............................................................8-6
Radio Switch Diagnostics...................................................8-8
1. Checking for Diagnostic Trouble Codes (DTCs)
Test..............................................................................8-8
2. Switch Function Test ...............................................8-9
3. DTC B2007, Handlebar Audio Switch Shorted High
(Part A) Test.................................................................8-9
4. DTC B2007, Handlebar Audio Switch Shorted High
(Part B) Test.................................................................8-9
5. DTC B2007, Handlebar Mode Switch Shorted High (Part
A) Test.........................................................................8-9
6. DTC B2007, Handlebar Mode Switch Shorted High (Part
B) Test.........................................................................8-9
7. DTC B2007, Handlebar PTT/Squelch Switch Shorted
High (Part A) Test........................................................8-9
8. DTC B2007, Handlebar PTT/Squelch Switch Shorted
High (Part B) Test......................................................8-10
9. DTC B2008, Handlebar Audio Switch Shorted Low (Part
A) Test.......................................................................8-10
XVI TABLE OF CONTENTS
10. DTC B2008, Handlebar Audio Switch Shorted Low
(Part B) Test...............................................................8-10
11. DTC B2008, Handlebar Mode Switch Shorted Low
(Part A) Test...............................................................8-10
12. DTC B2008, Handlebar Mode Switch Shorted Low
(Part B) Test...............................................................8-10
13. DTC B2008, Handlebar PTT/Squelch Switch Shorted
Low (Part A) Test.......................................................8-10
14. DTC B2008, Handlebar PTT/Squelch Switch Shorted
Low (Part B) Test.......................................................8-10
15. DTC B2009, Handlebar Audio Switch Stuck or Open
(Part A) Test...............................................................8-10
16. DTC B2009, Handlebar Audio Switch Stuck or Open
(Part B) Test...............................................................8-11
17. DTC B2009, Handlebar Mode Switch Stuck or Open
(Part A) Test...............................................................8-11
18. DTC B2009, Handlebar Mode Switch Stuck or Open
(Part B) Test...............................................................8-11
19. DTC B2009, Handlebar PTT/Squelch Switch Stuck or
Open (Part A) Test.....................................................8-11
20. DTC B2009, Handlebar PTT/Squelch Switch Stuck or
Open (Part B) Test.....................................................8-11
21. DTC B2010, Passenger Audio/PTT Switch Shorted
High (Part A) Test......................................................8-12
22. DTC B2010, Passenger Audio/PTT Switch Shorted
High (Part B) Test......................................................8-12
23. DTC B2010, Passenger Mode Switch Shorted High
(Part A) Test...............................................................8-12
24. DTC B2010, Passenger Mode Switch Shorted High
(Part B) Test...............................................................8-12
25. DTC B2011, Passenger Audio/PTT Switch Shorted
Low (Part A) Test.......................................................8-13
26. DTC B2011, Passenger Audio/PTT Switch Shorted
Low (Part B) Test.......................................................8-13
27. DTC B2011, Passenger Mode Switch Shorted Low
(Part A) Test...............................................................8-13
28. DTC B2011, Passenger Mode Switch Shorted Low
(Part B) Test...............................................................8-13
29. DTC B2012, Passenger Audio/PTT Switch Stuck or
Open (Part A) Test.....................................................8-13
30. DTC B2012, Passenger Audio/PTT Switch Stuck or
Open (Part B) Test.....................................................8-13
31. DTC B2012, Passenger Mode Switch Stuck or Open
(Part A) Test...............................................................8-14
32. DTC B2012, Passenger Mode Switch Stuck or Open
(Part B) Test...............................................................8-14
8.3 DTC B2016-B2027, RADIO SPEAKER
DIAGNOSTICS
Description and Operation................................................8-15
Diagnostic Tips..........................................................8-15
B2016 Front Speakers Shorted: Without Amplifier...........8-15
1. Front Speakers Shorted (Part A) Test....................8-15
2. Front Speakers Shorted (Part B) Test....................8-15
B2016 Front Speakers Shorted: With Amplifier................8-15
1. Front Speakers Shorted (Part A) Test....................8-15
2. Front Speakers Shorted (Part B) Test....................8-15
B2017 Front Speakers Open: Without Amplifier...............8-16
1. Front Speakers Open (Part A) Test........................8-16
2. Front Speakers Open (Part B) Test........................8-16
B2017 Front Speakers Open: With Amplifier....................8-17
1. Front Speakers Open (Part A) Test........................8-17

2. Front Speakers Open (Part B) Test........................8-17
B2018 Front Speakers Shorted to Ground: Without
Amplifier...........................................................................8-17
1. Front Speakers Shorted to Ground Test................8-17
B2018 Front Speakers Shorted to Ground: With
Amplifier...........................................................................8-17
1. Front Speakers Shorted to Ground.......................8-17
B2019 Front Speakers Shorted to Battery: Without
Amplifier...........................................................................8-18
1. Front Speakers Shorted to Battery Test.................8-18
B2019 Front Speakers Shorted to Battery: With
Amplifier...........................................................................8-18
1. Front Speakers Shorted to Battery Test.................8-18
B2020 Rear Speakers Shorted: Without Amplifier............8-18
1. Rear Speakers Shorted (Part A) Test....................8-19
2. Rear Speakers Shorted (Part B) Test....................8-19
B2020 Rear Speakers Shorted: With Amplifier.................8-20
1. Rear Speakers Shorted (Part A) Test....................8-20
2. Rear Speakers Shorted (Part B) Test....................8-20
B2021 Rear Speakers Open: Without Amplifier................8-20
1. Rear Speakers Open (Part A) Test........................8-20
2. Rear Speakers Open (Part B) Test........................8-20
B2021 Rear Speakers Open: With Amplifier.....................8-20
1. Rear Speakers Open (Part A) Test........................8-20
2. Rear Speakers Open (Part B) Test........................8-20
B2022 Rear Speakers Shorted to Ground: Without
Amplifier...........................................................................8-21
1. Rear Speakers Shorted to Ground Test................8-21
B2022 Rear Speakers Shorted to Ground: With
Amplifier...........................................................................8-21
1. Rear Speakers Shorted to Ground Test................8-21
B2023 Rear Speakers Shorted to Battery: Without
Amplifier...........................................................................8-21
1. Rear Speakers Shorted to Battery Test.................8-21
B2023 Rear Speakers Shorted to Battery: With
Amplifier...........................................................................8-21
1. Rear Speakers Shorted to Battery Test.................8-21
8.4 SERIAL DATA BUS DIAGNOSTICS
Description and Operation................................................8-22
Loss of Serial Data: DTC U1016...............................8-22
Starts then Stalls: DTC U1300, U1301......................8-22
Diagnostic Tips..........................................................8-22
DTC U1016 J1850 Loss of Communication with ECM.....8-22
1. Speed Pulse Availability Test.................................8-23
2. Serial Data Continuity Test....................................8-23
DTC U1302 Infotainment Bus Off Error............................8-24
1. Infotainment Bus Voltage Test................................8-24
2. Infotaintment Bus Shorted to Ground Test............8-24
3. Infotainment Bus Wires Shorted Together Test......8-24
4. Infotainment Bus Shorted to Voltage Test..............8-25
DTC U1306 Infotainment Bus Lost Communication with
Hands-Free Phone Module..............................................8-25
1. Hands-Free Phone Module Voltage Test...............8-27
2. Hands-Free Phone Module Jumper Harness Voltage
Test............................................................................8-27
3. Hands-Free Phone Module CAN Test....................8-27
4. Hands-Free Phone Module Jumper Harness CAN
Test............................................................................8-27
DTC U1307 Infotainment Bus Lost Communication with CB
Module..............................................................................8-27
1. CB Module Voltage Test.........................................8-27
TABLE OF CONTENTS
2. CB Module CAN Test.............................................8-27
DTC U1308 Infotainment Bus Lost Communication with Future
Accessory Module (4-Pin)................................................8-27
1. Future Accessory Voltage Test..............................8-27
2. Future Accessory CAN Test..................................8-27
DTC U1310 Infotainment Bus Lost Communication with
iPod..................................................................................8-28
1. iPod Voltage Test...................................................8-28
2. iPod CAN Test........................................................8-28
DTC U1312 Infotainment Bus Lost Communication with Future
Accessory Module (12-Pin)..............................................8-28
1. Future Accessory Voltage Test..............................8-28
2. Future Accessory CAN Test..................................8-28
DTC U1313 Infotainment Bus Lost Communication with XM
Module..............................................................................8-28
1. XM Module Voltage Test........................................8-28
2. XM Module CAN Test............................................8-28
DTC U1314 Infotainment Bus Lost Communications with
Navigation Module............................................................8-28
1. Navigation Module Test.........................................8-28
DTC U1317 Infotainment Bus Lost Communication with High
Output Amplifier................................................................8-29
1. Amplifier Module Voltage Test................................8-29
2. Amplifier Module CAN Test....................................8-29
3. CAN Short to Voltage Test.....................................8-29
4. CAN Short to Ground Test.....................................8-29
5. CAN Open Test......................................................8-29
8.5 ADVANCED AUDIO SYSTEM SYMPTOMS
General.............................................................................8-30
Factory Defaults...............................................................8-30
Diagnostics.......................................................................8-31
Diagnostic Tips..........................................................8-31
Symptom 1: Radio Inoperative.........................................8-32
1. Radio Power Test...................................................8-32
2. Radio Power Continuity Test..................................8-32
3. Radio Memory Continuity Test...............................8-33
Symptom 2: Poor or No Reception...................................8-33
1. Low-Band Radio Operation Test............................8-33
2. FM-Band Radio Operation Test.............................8-33
3. Antenna Cable Test...............................................8-34
4. Antenna Cable Open Circuit Test..........................8-34
5. Antenna Cable Short Circuit Test..........................8-34
6. Antenna Base Shorted to Ground Test..................8-34
7. Antenna Base Open to Ground Plate Test.............8-34
Symptom 3: Static Present with Engine Running.............8-36
1. Static Observation Test..........................................8-36
2. Regulator Test........................................................8-36
3. Regulator Connectors Test....................................8-36
4. Ignition System Test...............................................8-36
Symptom 4: CB Transmitter Inoperative...........................8-36
1. Set-Up Test............................................................8-36
2. Push-to-Talk (PTT) Test.........................................8-36
3. CB Transmission Test............................................8-36
4. CB Reception Test.................................................8-36
5. CB Modulation Test................................................8-36
6. Microphone Test....................................................8-36
7. CB Antenna Cable Open Circuit Test....................8-37
8. CB Antenna Cable Shield Open Circuit Test.........8-37
9. CB Antenna Cable Shorted Test............................8-37
Symptom 5: CB Receiver Inoperative...............................8-37
1. Set-Up Test............................................................8-37
TABLE OF CONTENTS XVII
TABLE OF CONTENTS
2. Receiver Audio Test...............................................8-37
3. Squelch Operation Test.........................................8-37
4. Receiver Operation Test........................................8-37
5. Receiver Audio Voltage Test..................................8-37
6. Receiver Audio Open Circuit Test..........................8-38
7. Receiver Audio Short to Ground Test....................8-38
8. Receiver Audio Shorted Together Test..................8-38
9. Receiver Audio Harness Shorted to Voltage Test...8-38
Symptom 6: Intercom Inoperative.....................................8-38
1. Set-Up Mode Test..................................................8-38
2. Intercom Speech Test............................................8-38
3. VOX Maximum (Open) Test...................................8-38
4. VOX Adjustment Test.............................................8-38
5. Headset Test..........................................................8-38
Symptom 7: Handheld Microphone/PTT Inoperative........8-39
1. Set-Up Test............................................................8-39
2. Switch Diagnostic Test...........................................8-39
3. PTT Open Circuit Test...........................................8-39
4. PTT Short Circuit to Ground Test..........................8-40
Symptom 8: Fairing Mounted Speaker Switch
Malfunction.......................................................................8-40
1. Speaker Switch Headset Mode Test......................8-40
2. Speaker Switch Speaker and Headset Mode
Test............................................................................8-40
3. Speaker Switch Mode Test....................................8-40
4. Headset SpkA Voltage Test...................................8-41
5. Headset SpkA Continuity Test...............................8-41
6. Headset SpkA Short to Ground Test.....................8-41
7. Headset SpkA Short to Voltage Test......................8-41
8. Headset SpkB Voltage Test...................................8-41
9. Headset SpkB Continuity Test...............................8-41
10. Headset SpkB Short to Voltage Test....................8-41
11. Headset SpkB Short to Ground Test...................8-41
Symptom 9: Headset Speakers Inoperative.....................8-41
1. Headset Speaker Operational Test........................8-42
2. Rider Headset Speaker Continuity Test.................8-42
3. Rider Headset Speaker Shorted Wires Test..........8-42
4. Rider Headset Speaker Short to Voltage Test.......8-42
5. Rider Headset Speaker Short to Ground Test.......8-43
6. Passenger Headset Speaker Continuity Test........8-43
7. Passenger Headset Speaker Shorted Wires Test...8-43
8. Passenger Headset Speaker Short to Voltage
Test............................................................................8-43
9. Passenger Headset Speaker Short to Ground
Test............................................................................8-43
Symptom 10: No or Low Audio from Microphones...........8-43
1. Headset Microphone Set-Up Test..........................8-43
2. Headset Microphone Voltage Test.........................8-44
3. Microphone Sum Out Voltage Test........................8-44
4. Headset Microphone Circuit Continuity Test..........8-44
5. Headset Microphone Circuit Short to Ground
Test............................................................................8-45
6. Headset Microphone Circuit Wires Shorted Together
Test............................................................................8-45
7. Headset Microphone Circuit Short to Voltage
Test............................................................................8-45
Symptom 11: No or Low Audio with High Output
Amplifier...........................................................................8-45
1. Amplifier Power Voltage Test.................................8-45
2. Amplifier CAN Test.................................................8-45
3. Amplifier Power Open Ground Test.......................8-45
4. Amplifier Power Open to Battery Test....................8-45
XVIII TABLE OF CONTENTS
Symptom 12: No or Low Audio from XM or XM
Inoperative........................................................................8-46
1. XM Radio Operation Test.......................................8-46
2. XM Audio Voltage Output Test...............................8-48
3. XM Audio Output Continuity Test...........................8-48
4. XM Audio Output Short to Ground Test.................8-48
5. XM Audio Output Wires Shorted Together Test.....8-48
6. XM Audio Output Shorted to Voltage Test.............8-48
7. XM Module Power Test..........................................8-48
8. XM Module CAN Voltage Test................................8-48
9. XM Module CAN Continuity Test...........................8-48
10. XM Module Power/Ground Bus Continuity Test....8-49
Symptom 13: No or Intermittent Reception on XM
Module..............................................................................8-49
1. XM Antenna Power Test .......................................8-49
2. XM Antenna Resistance Test.................................8-49
Symptom 14: Navigation Inoperative................................8-49
1. Navigation Module Activation Test.........................8-49
2. GPS Antenna Error Test........................................8-49
3. GPS Antenna Resistance Test..............................8-49
4. GPS Module Error Test..........................................8-50
5. Screen Speed Test................................................8-50
6. Navigation CD Operation Test...............................8-50
Symptom 15: AVC Inoperative..........................................8-50
1. AVC Speed Test.....................................................8-50
2. Screen Speed Test................................................8-50
Symptom 16: Handlebar, Passenger or Sidecar Switches
Inoperative........................................................................8-50
Symptom 17: CD Skipping...............................................8-50
1. CD Player to CB/Intercom Interactivity Test...........8-50
2. Radio Input (Power) Positive Voltage Drop Test.....8-50
3. Radio Input (Power) Negative Voltage Drop Test....8-51
4. Front Motor Mount Inspection Test........................8-51
5. Exhaust System Mounts Inspection Test...............8-51
Symptom 18: Hands-Free Phone Module Initial
Diagnostics.......................................................................8-51
1. Phone Mode Enable Test.......................................8-51
2. Phone Pairing Test.................................................8-51
3. Phone Communication Test...................................8-51
4. Phonebook Download Test....................................8-51
5. Signal Strength Test...............................................8-51
6. Phone Module Power Test.....................................8-53
7. CAN Communication Test......................................8-53
8. Phone Module Continuity Test...............................8-53
9. Phone Module Open Ground Test.........................8-53
10. Phone Mode Entry Test.......................................8-53
11. Phone Module Output Test..................................8-53
12. Phone Module Continuity Test.............................8-53
13. Phone Module Audio Short to Low Test...............8-53
14. Phone Module Audio Short to Ground Test.........8-53
15. Phone Module Audio Short to Voltage Test.........8-53
16. Phone Module Antenna Test................................8-53
APPENDIX A CONNECTOR REPAIR
A.1 AUTOFUSE UNSEALED ELECTRICAL
CONNECTORS
Autofuse Unsealed Connector Repair................................A-1
General.......................................................................A-1
Disassembly................................................................A-1
Assembly....................................................................A-1

A.2 DELPHI 100W MICRO-PACK SEALED
CONNECTOR
Delphi 100W Micro-Pack Sealed Connector Repair..........A-2
General.......................................................................A-2
Separating Socket Housing From ECM......................A-2
Mating Socket Housing To ECM.................................A-2
Removing Socket Terminal.........................................A-2
Installing Socket Terminal...........................................A-2
Crimping Terminals.....................................................A-2
A.3 DELPHI 150 METRI-PACK SEALED
CONNECTORS
Delphi 150 Metri-Pack Sealed Connector Repair..............A-4
General.......................................................................A-4
Separating Pin and Socket Housings.........................A-4
Mating Pin and Socket Housings................................A-4
Removing Socket Terminal.........................................A-4
Inserting Socket Terminal............................................A-4
A.4 DELPHI 280 METRI-PACK UNSEALED
CONNECTORS
Fuse Block Repair..............................................................A-6
Removing Socket Terminals........................................A-6
Installing Socket Terminals..........................................A-6
Crimping Terminals.....................................................A-6
A.5 DELPHI 480 METRI-PACK UNSEALED
CONNECTORS
Delphi 480 Metri-Pack Unsealed Connector Repair..........A-7
General.......................................................................A-7
Separating Pin and Socket Housings.........................A-7
Mating Pin and Socket Housings................................A-7
Removing Socket Terminals........................................A-7
Installing Socket Terminals..........................................A-7
A.6 DELPHI 630 METRI-PACK UNSEALED
CONNECTORS
Delphi 630 Metri-Pack Unsealed Connector Repair..........A-8
Separating Pin and Socket Housings.........................A-8
Mating Pin and Socket Housings................................A-8
Removing Socket Terminal.........................................A-8
Installing Socket Terminal...........................................A-8
A.7 DELPHI 800 METRI-PACK SEALED MAIN
FUSE HOUSING
Delphi 800 Metri-Pack Sealed Main Fuse Housing
Repair................................................................................A-9
Removing Socket Terminals........................................A-9
Installing Socket Terminals..........................................A-9
A.8 DELPHI METRI-PACK TERMINAL
REPAIR
Metri-Pack Terminal Crimps.............................................A-11
Matching Terminal To Crimper..................................A-11
Preparing Wire Lead.................................................A-11
Crimping Wire Core..................................................A-11
Crimping Insulation/Seal...........................................A-11
Inspecting Crimps.....................................................A-12
TABLE OF CONTENTS
A.9 DELPHI MICRO 64 SEALED
CONNECTORS
Delphi Micro 64 Sealed Connector Repair.......................A-13
General.....................................................................A-13
Separating Pin and Socket Housings.......................A-13
Mating Pin and Socket Housings..............................A-13
Removing Terminal...................................................A-13
Installing Terminal.....................................................A-14
Preparing Wire Leads for Crimping...........................A-14
Crimping Terminals...................................................A-14
Inspecting Crimps.....................................................A-14
A.10 DELPHI GT 150 SEALED
CONNECTORS
Delphi GT 150 Sealed Connector Repair.........................A-16
General.....................................................................A-16
Separating Pin and Socket Housings.......................A-16
Mating Pin and Socket Housings..............................A-16
Removing Socket Terminals......................................A-16
Installing Socket Terminals........................................A-16
A.11 DELPHI GT 280 SEALED 73-TERMINAL
ECM CONNECTOR
Delphi GT 280 Sealed 73-Terminal ECM Connector.......A-18
Separating Socket Housing From ECM....................A-18
Mating Socket Housing To ECM...............................A-18
Socket Terminal.........................................................A-18
ECM Ground Terminal..............................................A-18
A.12 DEUTSCH DT SEALED CONNECTORS
Deutsch DT Sealed Connector Repair.............................A-20
General.....................................................................A-20
Separating Pin and Socket Housings.......................A-20
Mating Pin and Socket Housings..............................A-20
Removing Socket Terminals......................................A-20
Installing Socket Terminals........................................A-20
Removing Pin Terminals...........................................A-22
Installing Pin Terminals.............................................A-22
Crimping Terminals...................................................A-23
A.13 DEUTSCH DT SEALED TERMINAL
REPAIR
Deutsch DT Sealed Terminal Crimps...............................A-24
Preparing Wire Leads for Crimping...........................A-24
Crimping Terminal to Lead........................................A-24
Inspecting Crimps.....................................................A-24
A.14 DEUTSCH DTM SEALED MINI
TERMINAL REPAIR
Deutsch DTM Sealed Mini Terminal Crimps....................A-25
Preparing Wire Leads for Crimping...........................A-25
Crimping a Mini Terminal to Wire Lead.....................A-25
Inspecting Crimps.....................................................A-25
A.15 DEUTSCH DTM SEALED SOLID
BARREL MINI TERMINAL REPAIR
Deutsch DTM Sealed Solid Barrel Terminal Crimps........A-26
Preparing Wire Leads For Crimping.........................A-26
Adjusting Crimper Tool..............................................A-26
TABLE OF CONTENTS XIX
TABLE OF CONTENTS
Crimping a Barrel Contact To Wire Lead...................A-26 Splicing Wire Leads..................................................A-39
Inspecting Crimps.....................................................A-26 Inspecting Seals.......................................................A-39

A.16 JAE MX19 SEALED CONNECTORS APPENDIX B WIRING

JAE MX19 Sealed Connectors.........................................A-28
Connector Housings.................................................A-28 B.1 CONNECTORS
Removing Terminals.................................................A-28
Connector Locations..........................................................B-1
Installing Terminals...................................................A-28
Function/Location.......................................................B-1
A.17 MOLEX CMC SEALED CONNECTORS Place and Color..........................................................B-1
Connector Number......................................................B-1
Molex CMC Sealed Connectors.......................................A-29 Repair Instructions......................................................B-1
Separating the Connector.........................................A-29
Removing Terminals.................................................A-29 B.2 WIRING DIAGRAMS
Installing Terminals...................................................A-29
Wiring Diagram Information...............................................B-7
A.18 MOLEX MX 150 SEALED Wire Color Codes........................................................B-7
Wiring Diagram Symbols............................................B-7
CONNECTORS 2011 Touring Wiring Diagrams...........................................B-9
Molex MX 150 Sealed Connector Repair.........................A-31
Separating Pin and Socket Housings.......................A-31 APPENDIX C CONVERSIONS
Mating Pin and Socket Housings..............................A-31
Removing Terminals.................................................A-31 C.1 METRIC CONVERSION
Installing Terminals...................................................A-31
Crimp Terminal to Lead....................................................A-32 Conversion Table................................................................C-1
Prepare Lead............................................................A-32
Prepare Tool..............................................................A-32
C.2 FLUID CONVERSIONS
Position Terminal in the Punch/Die...........................A-33 United States System........................................................C-2
Insert Stripped Lead.................................................A-33 Metric System....................................................................C-2
Crimp Terminal to Lead.............................................A-34 British Imperial System......................................................C-2
Inspect Crimp............................................................A-34
C.3 TORQUE CONVERSIONS
A.19 TYCO 070 MULTILOCK UNSEALED United States System........................................................C-3
CONNECTOR Metric System....................................................................C-3
Tyco 070 Multilock Unsealed Connector Repair..............A-35
General.....................................................................A-35
APPENDIX D GLOSSARY
Separating Pin and Socket Housings.......................A-35
Mating Pin and Socket Housings..............................A-35 D.1 GLOSSARY
Removing Terminals from Housing...........................A-35 Acronyms and Abbreviations.............................................D-1
Inserting Terminals into Housing...............................A-36
Preparing Wire Leads for Crimping...........................A-36 REFERENCE MATERIAL
Crimping Terminals to Leads....................................A-37
Inspecting Crimped Terminals...................................A-38
TOOLS...........................................................I
A.20 SEALED SPLICE CONNECTORS
TORQUE VALUES.....................................XIII
Sealed Splice Connector Repair......................................A-39
General.....................................................................A-39
INDEX.........................................................XV
Preparing Wire Leads...............................................A-39

XX TABLE OF CONTENTS
TABLE OF CONTENTS

SUBJECT............................................................................................................................PAGE NO.
1.1 SPECIFICATIONS AND COMPONENT LOCATIONS ..............................................................1-1
1.2 DIAGNOSTIC TOOLS.............................................................................................................1-13
1.3 DIAGNOSTICS AND TROUBLESHOOTING...........................................................................1-18

GENERAL INFORMATION
NOTES
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SPECIFICATIONS AND COMPONENT

LOCATIONS 1.1
SPECIFICATIONS
Table 1-7. Starter Specifications
Table 1-1. Fuel System Specifications STARTER SPECIFICATIONS
FUEL SYSTEM TYPE Cranking current 200A
Intake Side draft throttle body Free speed 3000 rpm (min)
Recommended fuel 91 Octane Free current 90A
Stall torque 8.0 ft-lbs (10.8 Nm)
Table 1-2. Idle Speed Specifications

ADJUSTMENT RPM Table 1-8. Fuel Pump Pressure Specifications

Normal idle speed 950-1050 Nominal, non- RANGE VALUE
adjustable
Normal 55-62 psi (380-425 kPA)

Table 1-3. Battery Specifications

Table 1-9. Alternator Specifications
BATTERY SPECIFICATIONS
MEASUREMENT VALUE
Size 12V/28 AH/405CCA
AC voltage output 16-23 VAC per 1000 rpm
Type Sealed, AGM
Stator coil resistance 0.1-0.2 Ohm

Table 1-4. Spark Plug Specifications

Table 1-10. Regulator Specifications
SPARK PLUG SPECIFICATIONS
MEASUREMENT VALUE
Gap 0.038-0.043 in. 0.97-1.09 mm
Amperes @ 3000 rpm 35-50A
Torque with anti-seize 12-18 ft-lbs 16.3-24.4 Nm
Voltage @ 3600 rpm 14.3-14.7V @ 75 °F (24 °C)
applied to threads
Type Harley-Davidson No. 6R12
Table 1-11. Fuse Specifications
Table 1-5. Spark Plug Cables ITEM RATING (AMPERES)
SPECIFICA- FRONT REAR Instruments fuse 15
TION Accessory fuse 15
Length in. 34.5-35 16.5-17 Battery fuse 15
Length mm 876-889 419-431 ECM PWR fuse 15
Resistance- 8625-23,334 4125-11,334 Fuel pump fuse 15
ohms
Ignition fuse 15
Lights fuse 15
Table 1-6. Ignition Coil Specifications
Main fuse 40
WINDING RESISTANCE P&A IGN fuse 2
Ignition coil primary resistance 0.5-0.7 Ohm Exhaust control 15
at room temperature
Brake fuse 15
Ignition coil secondary resist- 5500-7500 Ohms
P&A fuse 15
ance at room temperature
Radio power/siren fuse 15
Headlamp fuse 15
ABS fuse 30
Radio memory fuse 15
Power outlet fuse 15

2011 Touring Diagnostics: General Information 1-1

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COMPONENT LOCATIONS the motorcycle. The following graphics show locations for these
components and connectors. The graphics are generally
Some components and connectors are not easily located on ordered from front to back around the motorcycle.

ed03066

6
1 2 4
5

7
3 8

12

11

16

14
15
9

13 10

1. Right front speaker [34+] 9. Radio [28]

2. Right front speaker [34-] 10. Radio [27]
3. Voltmeter [111] 11. GPS [193]
4. Voltmeter lamp [110] 12. Main to interconnect harness [1]
5. Tachometer [108] 13. Main to interconnect harness [15]
6. Speedometer [39] 14. TGS harness [204]
7. Indicator lamps [21] 15. Interconnect to right handle bar switches [22]
8. CB antenna cable [50] 16. Right front turn signal/auxiliary lamp [31R]
Figure 1-1. Right Side Behind Upper Fairing

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ed03067
2 3 4 5 6
1

10
11
8
18

17
7

12

14
16
15
13

1. Indicator lamps [21] 10. Audio to interconnect harness [6]

2. Tachometer [108] 11. Main to interconnect harness [2]
3. Speedometer [39] 12. Heated grips [189]
4. Fuel gauge lamp [116] 13. Cigar lighter [132]
5. Left front speaker [35+] 14. CB module [184]
6. Left front speaker [35-] 15. Radio [28]
7. Left front turn signal/auxiliary lamp [31L] 16. Radio [27]
8. Fuel gauge [117] 17. GPS [193]
9. Interconnect to left handlebar switches [24] 18. CB antenna cable [50]
Figure 1-2. Left Side Inner Fairing: Except FLT models

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ed03068 ed03069
1 2
1 3
2

6
4

1. Steering head 1. Indicator lamps [21]

2. Ground to upper triple clamp [GND3] 2. Instrument nacelle switches [105 A/B]
3. Ambient air temperature sensor [107]
Figure 1-3. Steering Head Ground
4. Tachometer [108]
5. Speedometer [39]
6. Speaker switches [105 C/D]
Figure 1-4. FLTR Instruments

ed03070
1

2
3

4
13

12

11 8
10
5
7

1. Voltmeter lamp [110] 8. Fairing cap switches [105]

2. Voltmeter [111] 9. Right front turn signal [31RA]
3. Main to interconnect harness [1] 10. Right front speaker [34B-2]
4. Radio [27] 11. Right front speaker [34B-1]
5. Audio to interconnect harness [6] 12. Oil pressure gauge [113]
6. Main to interconnect harness [15] 13. Oil pressure gauge lamp [112]
7. Interconnect to right handlebar switches [22]
Figure 1-5. FLTR Right Side Behind Upper Fairing

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ed03071
1 2 3

5 6

4
8
10

16
9

11
14

12
15

13

1. Radio [27] 9. Ambient air temperature gauge [115]

2. CB antenna cable [50] 10. Left front speaker [35B-]
3. CB module [184] 11. Left front speaker [35B+]
4. Ground to upper triple clamp [GND3] 12. Cigar lighter [132]
5. Interconnect to left handlebar switches [24] 13. Left front turn signal [31L]
6. Fuel gauge lamp [116] 14. Main to interconnect harness [2]
7. Fuel gauge [117] 15. HDI position lamps [29]
8. Ambient air temperature gauge lamp [114] 16. Radio [28]
Figure 1-6. Left Side Inner Fairing: FLT models

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ed03072 ed03073
1 2
1

3 2
3

1. HDI position lamp [29-2] 1. Ambient air temperature sensor [107]

2. HDI position lamp [29-1] 2. Fuel tank
3. Headlamp [38R] 3. Front WSS [167]
4. Headlamp [38L]
Figure 1-9. Front WSS and Ambient Air Temperature
Figure 1-7. Headlamp: FLT Models Sensor

ed03110 ed01799
11 1 3
10 2

4
9
8
5

7
6

1. Front turn signals [31]

2. Accessories off/on switch [67] 2
3. Left hand controls [24] 1
4. Left cruise controls [158]
5. Front wheel speed sensor [167]
6. Head lamp [38]
7. Twist grip sensor [204]
8. Right cruise controls [159]
9. Passing lamps off/on switch [109] 1. Voltage regulator [77]
10. Right hand controls [22] 2. Stator [47]
11. Passing lamps [73] Figure 1-10. Voltage Regulator: Left Side View
Figure 1-8. Head Lamp Nacelle: FLH Models

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ed01823 ed03076

1 2

6 3
5

1. Rear spark plug wire

Figure 1-11. CKP Sensor [79] (from underneath)
2. Front spark plug wire
3. Ignition coil [83]
4. Starter solenoid [128]
5. Starter
ed03074 6. Battery to starter cable
Figure 1-14. Starter Area From Left Side

ed03111

2 3
1
4

5
Figure 1-12. Horn [122]

6
ed03075

1. Security siren [142]

2. Security siren (if equipped)
1 2 3. Fuse block
4. Main fuse [5]
5. DLC [91]
6. ABS diode pack [201] (if equipped)
Figure 1-15. Under Left Side Cover: Except FLTRX, FLHX,
FLHTC

3
1. Front fuel injector [84]
2. Rear fuel injector [85]
3. ET sensor [90]
Figure 1-13. Between Cylinders Left Side

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ed03125 ed02694
3
1 2
4 4
2
1 3
5

1. Fuse block 1. Tail lamp [93]

2. Main fuse [5] 2. Fender tip lamp [45]
3. Tour-Pak [12] 3. Left turn signal lamp [19]
4. Main to rear lighting interconnect harness [257] 4. Right turn signal lamp [18]
5. DLC [91] 5. Fender lights harness [94]
6. Security siren [142]
Figure 1-18. Rear Fender Lights Assembly
Figure 1-16. Under Left Side Cover: FLTRX, FLHX, FLHTC

ed03079
ed03077

1
3
1

2
9 5 4
6 4 2
7

3
8
1. Tail lamp
1. Tour-Pak lights (rear lamp fascia on FLHX) [12] 2. Fascia/converter module [262]
2. Power outlet [258] 3. Rear fender
3. Power outlet 4. Fascia/converter module [226]
4. Right marker light [12-2]
Figure 1-19. Fascia/Converter Module
5. CB antenna cable [104]
6. CB antenna ground
7. Radio antenna cable ground
8. Left marker light [12-3]
9. Radio antenna cable [52]
Figure 1-17. Tour-Pak Interior

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ed03080 ed03081
1 2

7
2
1 6

5
4
3
3

1. Right rear speaker [36D-1] 1. Front HO2S [138]

2. Right rear speaker [36D-2] 2. ABS module [166] (if equipped)
3. Right rear speaker controls [41] 3. Active exhaust [179]
4. Rear WSS [168]
Figure 1-20. Rear Speaker
5. Rear HO2S [137]
6. TSM/TSSM/HFSM [30]
7. HFSM antenna jumper harness [208]
Figure 1-21. Under Right Side Cover

2011 Touring Diagnostics: General Information 1-9

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ed01820

1 3

2 9

1. Tail light connector [7]: except FLHX, FLTRX

2. Console pod [53]
3. Positive battery terminal
4. Hands-free antenna connector [209]
5. Fuel pump subharness connector [13]
6. Purge solenoid [95]
7. P&A accessory connector [4]
8. Negative battery terminal
9. ECM [78]
Figure 1-22. Electrical Connectors Under Seat

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ed01800 ed01275

Figure 1-23. [95] Purge Solenoid (Under seat) Figure 1-25. Throttle Control Connector [211]

ed03082 ed03085
1
1

2
1. Clutch cover 1. Oil pressure [139]
2. Rear brake switch [121] 2. Front frame down tube
3. Exhaust pipe
Figure 1-26. Oil Pressure Switch
Figure 1-24. Rear Brake Switch

2011 Touring Diagnostics: General Information 1-11

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ed02699

1. Ignition/light key switch [33]

2. Indicator lights [21]
3. Speedometer [39]
Figure 1-27. Instrument Console Connectors: FLHR, FLHRC

ed03083 ed03084
1

2 3

1
2

1. Fuel pump [141] 1. Rear ACR [203R]

2. Fuel tank 2. TMAP [80]
3. Front ACR [203F]
Figure 1-28. Under Console
Figure 1-29. Between Cylinders Right Side

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DIAGNOSTIC TOOLS 1.2

HOW TO USE DIAGNOSTIC TOOLS 1. Connect the BREAKOUT BOX (Part No. HD-48637).
2. Disconnect the fuel injector connectors.
PART NUMBER TOOL NAME
HD-26792 SPARK TESTER 3. See Figure 1-31 for typical setup. Connect one side of the
fuel injector test light to power and the other to the terminal
HD-34730-2D FUEL INJECTOR TEST LIGHT on the ECM for the circuit you are testing.
HD-39978 DIGITAL MULTIMETER (FLUKE 78)
4. Crank the engine.
HD-41404-C HARNESS CONNECTOR TEST KIT
5. If the test light flashes, the circuit is working properly.
HD-42682 BREAKOUT BOX
HD-44687 IGNITION COIL CIRCUIT TEST
ed01945
ADAPTER
2
HD-46601 BREAKOUT BOX ADAPTERS
1
HD-47918 ADVANCED AUDIO SYSTEM
BREAKOUT BOX
HD-48053 ADVANCED BATTERY CONDUCT-
ANCE AND ELECTRICAL SYSTEM
ANALYZER
HD-48637 BREAKOUT BOX
HD-48642 ABS BREAKOUT BOX
HD-48650 DIGITAL TECHNICIAN II

HD-26792 Spark Tester

See Figure 1-30. The SPARK TESTER (Part No. HD-26792)
is used to verify adequate spark at the spark plug. Attach the
tester to the spark plug wire and to ground. While cranking the
engine, a spark should jump across the gap on the tester leads. 3
NOTE
Engine will not spark with both spark plugs removed. When
checking for spark, use SPARK TESTER (Part No. HD-26792)
with both plugs installed. 1. HD-34730-2D Fuel Injector Test Light
2. HD-44687 Ignition Coil Circuit Test Adapter
3. HD-43876 Breakout Box
ed02012
Figure 1-31. Fuel Injector Test Light

HD-39978 Digital Multimeter (Fluke 78)

The DIGITAL MULTIMETER (FLUKE 78) (Part No. HD-39978)
is used for various tests throughout this manual.

Figure 1-30. Spark Tester

HD-34730-2D Fuel Injector Test Light

The FUEL INJECTOR TEST LIGHT (Part No. HD-34730-2D)
and IGNITION COIL CIRCUIT TEST ADAPTER (Part No. HD-
44687) are used to test the fuel injector drivers as well as the
ignition coil drivers in the ECM.

2011 Touring Diagnostics: General Information 1-13

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ed02008 ed03109
2
3

1 4

1. Breakout box HD-42682

Figure 1-32. Digital Multimeter (Fluke 78) (Part No.
2. Breakout box adapter HD-46601
HD-39978)
3. Speedometer [39]
4. Breakout box adapter HD-46601
5. Speedometer [39]
HD-41404-C Harness Connector Test Kit
Figure 1-33. Breakout Box Connection
The HARNESS CONNECTOR TEST KIT (Part No. HD-41404-
C) contains pin and socket terminals and stackable banana
jack patch cords used to test circuits. The pin and socket ter-
minals are used to connect to various connectors used on the
HD-42682 Breakout Box (TSM/TSSM/HFSM)
vehicle. See the tool instruction sheet for specific terminal The BREAKOUT BOX (Part No. HD-42682) splices into the
usage. main harness. Used in conjunction with a multimeter, it allows
circuit diagnosis of wiring harness and connections without
NOTE
having to probe with sharp objects. Install breakout box in
To prevent terminal damage while using the probe tips, insert series as follows:
the probe tip straight into the cavity and keep it stable during
the test. Do not wiggle or move the probe tip once it has been NOTE
inserted into the terminal. Do not use more than one probe per For HFSM: Disarm security system, then remove main fuse
terminal or cavity at any one time. while the system remains disarmed.

HD-42682 Breakout Box (Instruments) 1. Access TSM/TSSM/HFSM. See the service manual.

The BREAKOUT BOX (Part No. HD-42682) and BREAKOUT 2. Disconnect HFSM antenna jumper [208] and
BOX ADAPTERS (Part No. HD-46601) connect to the TSM/TSSM/HFSM [30].
speedometer [39]. Used in conjunction with a multimeter, it a. For HFSM: Press latches and disconnect [208].
allows circuit diagnosis of wiring harness and connections
without having to probe with sharp objects. Install breakout b. Press latches and disconnect [30].
box in series using the black connectors as follows:
3. See Figure 1-34. Connect BREAKOUT BOX (Part No. HD-
1. Access the speedometer [39]. See the service manual. 42682) to connectors.
2. See Figure 1-33. Press latch and disconnect speedometer 4. For HFSM: Mate antenna [208B] to HFSM.
[39B].
5. When testing is completed remove the breakout box and
3. Connect BREAKOUT BOX ADAPTERS (Part No. HD- restore connections.
46601) to [39A] and [39B] (speedometer) or [108A] and
[108B] (tachometer). NOTE
Vehicle will not start with TSM/TSSM/HFSM disconnected or
4. Attach black connectors from BREAKOUT BOX (Part
incorrectly mounted.
No. HD-42682) to BREAKOUT BOX ADAPTERS (Part
No. HD-46601). All tests will be performed using the black
side of the breakout box.
5. When testing is completed, remove the breakout box and
jumper harness, and restore connections.

1-14 2011 Touring Diagnostics: General Information

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ed03097 ed03096 1

3
3
1. Breakout box
2. Wiring harness connector
2 3. ECM connector
Figure 1-35. Breakout Box

1. Breakout box ed03095

2. Breakout box to TSM/TSSM/HFSM connection 1 2
3. Breakout box to harness connection
Figure 1-34. Breakout Box Connection Point at
TSM/TSSM/HFSM (Typical)

HD-48637 Breakout Box (ECM)

The BREAKOUT BOX (Part No. HD-48637) splices into the 3
main harness. Used in conjunction with a multimeter, it allows
circuit diagnosis of wiring harness and connections without
having to probe with sharp objects. Install breakout box in
series as follows:
4
NOTE
1. Breakout box
See wiring diagrams for ECM terminal functions. ECM is loc-
2. Breakout box to ECM connector disconnected
ated under passenger seat.
3. Breakout box to harness connection
1. Access the ECM. See the service manual. 4. ECM [78A]
2. Press latch and disconnect ECM [78]. Figure 1-36. ECM Breakout Box Disconnected
3. See Figure 1-35. Connect BREAKOUT BOX (Part No. HD-
48637) to connectors.
HD-48642 Breakout Box (ABS)
4. When testing is completed, remove the breakout box and
The ABS BREAKOUT BOX (Part No. HD-48642) connects to
restore connections.
the ABS module [166]. Used in conjunction with a multimeter,
it allows circuit diagnosis of wiring harness and connections
without having to probe with sharp objects. Install breakout
box in series as follows:
1. Remove the right side cover. See the service manual.
2. Press latch and disconnect ABS module [166B].
3. See Figure 1-37. Connect ABS BREAKOUT BOX (Part
No. HD-48642) to connectors.

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5. When testing is completed remove the breakout box and

ed03099
restore connections.

1 6. Install the right side cover. See the service manual.

HD-47918 Advanced Audio System Breakout

Box
2
The ADVANCED AUDIO SYSTEM BREAKOUT BOX (Part
No. HD-47918) connects to the radio at [27] and [28]. Used in
conjunction with a multimeter, it allows circuit diagnosis of
wiring harness and connections without having to probe with
sharp objects. Install breakout box in series as follows:
3
1. Remove the upper fairing and windshield. See the service
manual.
2. Press the latch and disconnect radio [27] and radio [28].
3. See Figure 1-39. Connect BREAKOUT BOX (Part No. HD-
47918) to connectors.
4. When testing is completed remove the breakout box and
restore connections.
5. Install the upper fairing and windshield. See the service
manual.
1. Breakout box to ABS unit connection
2. HD-48642 breakout box
3. Breakout box to harness connection ed03091

Figure 1-37. Typical HD-48642 Connection

1
4. See Figure 1-38. In some cases it is necessary to leave
the ABS module disconnected.

ed03098
5
2
1

4
2

4
3

1. HD-47918 breakout box

2. Breakout box to radio connection
3. Breakout box to harness connection
4. Breakout box to harness connection
3 5. Breakout box to radio connection
Figure 1-39. Typical HD-47918 Connection

1. ABS [166A]
2. HD-48642 breakout box HD-44687 Ignition Coil Circuit Test Adapter
3. Breakout box harness disconnected The IGNITION COIL CIRCUIT TEST ADAPTER (Part No. HD-
4. Breakout box harness connection 44687) and FUEL INJECTOR TEST LIGHT (Part No. HD-
34730-2D) are used to test the fuel injector drivers as well as
Figure 1-38. Typical HD-48642 With ABS Module
the ignition coil drivers in the ECM.
Disconnected
1. Connect the BREAKOUT BOX (Part No. HD-48637).

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2. Disconnect the fuel injector connectors.

ed01776
3. See Figure 1-31 for typical setup. Connect one side of the
fuel injector test light to power and the other to the terminal
on the ECM for the circuit you are testing.
4. Crank the engine.
5. If the test light flashes, the circuit is working properly.

HD-48053 Advanced Battery Conductance

and Electrical System Analyzer
Follow the instructions in the ADVANCED BATTERY CON-
DUCTANCE AND ELECTRICAL SYSTEM ANALYZER (Part
No. HD-48053) instruction manual to perform a battery test.
The test results include a decision on the battery condition and
the measured state of charge.
Figure 1-40. HD-48053 Advanced Battery Conductance
and Electrical System Analyzer Kit

HD-48650 Digital Technician II

DIGITAL TECHNICIAN II (Part No. HD-48650) is a computer
based diagnostic device used to communicate/diagnose and
program systems/modules.
Diagnostics in this manual are developed under the assumption
that DTII is not available.

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DIAGNOSTICS AND TROUBLESHOOTING 1.3

VOLTAGE DROP 1. Disconnect the fuel pump connector [86] to prevent the
engine from starting.
Voltage Drop Test a. Connect the red meter lead to the positive battery
The voltage drop test: post.

• Helps locate poor connections or components with
excessive voltage drops.
• Measures the difference in potential or the actual voltage
dropped between the source and destination.
• Checks the integrity of the wiring, switches, fuses, con-
nectors and contacts between the source and destination.
• Identifies poor grounds.
b. Connect the black meter lead to the battery power
starter post on the starter and observe the meter
reading.
c. Crank the starter and observe the meter reading. The
difference in the voltage is the voltage drop.
2. See Figure 1-41. Move the black meter lead to the starter
side post of the starter solenoid. Crank the starter.

A voltage drop test measures the difference in voltage between

two points in a circuit. The amount of voltage dropped over ed03112
any part of a circuit is directly related to the amount of resist-
ance in that part of the circuit.
Components such as wires, switches and connectors are
designed to have very little resistance and therefore very little

R
BK
voltage drop. A voltage drop greater than 1.0V across these
components indicates a high resistance and possible fault.
1

BK
The benefits of doing it this way are: 2

R
• Readings are not as sensitive to real battery voltage.
R
• Readings show the actual voltage dropped not just the
BK

presence of voltage. 3

BK
• The system is tested as it is actually being used.
• Testing is more accurate and displays hard-to-find poor 1. Battery
connections. 2. Starter solenoid
• Starting circuits, lighting circuits or ignition circuits can be 3. Starter motor
tested with this approach. (Start from the most positive Figure 1-41. To Starter Solenoid Starter Terminal
and go to the most negative destination or component.)
When testing a typical power circuit, place the positive (red)
meter lead on the most positive part of the circuit (or the pos- 3. See Figure 1-42. Move the black meter lead to the battery
itive battery post). Remember, there is nothing more positive side post on the starter solenoid. Crank the starter.
than the positive post of the battery. Place the negative (black)
meter lead at the positive side of the connector in question. ed03113
Activate the circuit. Move the negative meter lead through the
circuit until the high voltage drop is found.
When testing a typical ground circuit, place the negative lead
on the most negative part of the circuit (or the negative battery 2
R
BK

post). Remember, there is nothing more negative than the

negative post of the battery. Place the positive meter lead at
1
BK

the negative side of the connector in question. Activate the

circuit. Move the positive meter lead through the circuit until
the high voltage drop is found.
R

The following steps demonstrate a typical starter circuit voltage

BK

3
BK

drop test:

1. Battery
2. Starter solenoid
3. Starter motor
Figure 1-42. To Starter Solenoid Battery Terminal

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4. See Figure 1-43. Finally move the black meter lead to the
ed02008
negative battery post and the red meter lead to the starter
case. Crank the starter.

ed03114

BK
R
1 2
BK

R R

3 Figure 1-44. Digital Multimeter (Fluke 78) (Part No.

BK

HD-39978)

BK
1. Battery RELAY DIAGNOSTICS
2. Starter solenoid
3. Starter motor Relay Variation
Figure 1-43. Starter Ground Circuit See Figure 1-45. Relays normally have four or five terminals.
The circuitry inside the relays are very similar with the exception
of the normally closed contact being eliminated in the four ter-
WIGGLE TEST minal relay. Some relays have five terminals at the base, even
though internally 4 or 87A are not connected. See this topic
PART NUMBER TOOL NAME whenever a relay terminal is referenced in this manual to make
HD-39978 DIGITAL MULTIMETER (FLUKE 78) sure the proper terminal is being accessed.
HD-48637 BREAKOUT BOX
ed01769
HD-48650 DIGITAL TECHNICIAN II

The wiggle test checks for the presence of intermittents in a

wiring harness. The DIGITAL TECHNICIAN II (Part No. HD- 5 87 5 87
48650) can be used to perform the wiggle test. 4 87A
3 30 3 30
1. See Figure 1-44. Connect DIGITAL MULTIMETER (FLUKE
78) (Part No. HD-39978) to wiring harness between the 1 86 1 86
suspect connections. When diagnosing ECM connections, 2 85 2 85
use BREAKOUT BOX (Part No. HD-48637) to simplify the
procedure. See 1.2 DIAGNOSTIC TOOLS.
2. Set the multimeter to read voltage changes. 1 2
3. Start the motorcycle engine and run at idle.
4. Shake or wiggle the harness to detect intermittents. If
intermittents are present, radical voltage changes register 1. Standard 5 terminal relay
on the multimeter. 2. Standard 4 terminal relay
Figure 1-45. Standard Relays

Relay Test
A relay can be tested using the motorcycle's 12V battery and
a multimeter.
1. Unplug the relay from relay block.
2. See Figure 1-46 and Figure 1-47 to energize the relay.
Connect relay terminal 85 to the negative battery terminal
and relay terminal 86 to the positive battery terminal.

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NOTE
ed01446
Some relays contain internal diodes. If the applied voltage is
not the correct polarity, the diode could be damaged. 2 3
3. Test for continuity between terminals 30 and 87.
1
a. A good relay shows continuity (continuity tester lamp
on or a zero Ohm reading on the ohmmeter).
b. A malfunctioning relay will not show continuity and
must be replaced.

ed01000 3 1
2
- + 30 (3) 86 (1)

1. Battery
85 (2) 87 (5) 2. Start relay
3. Ohmmeter
1. Ohmmeter
Figure 1-47. Five Terminal Relay Test
2. Battery
3. Start relay
Figure 1-46. Four Terminal Relay Test JOB/TIME CODES VALUES
PART NUMBER TOOL NAME
HD-48650 DIGITAL TECHNICIAN II

Dealership technicians filing warranty claims should use the

job/time code values printed in bold text at the end of the
appropriate repair. When using DIGITAL TECHNICIAN II (Part
No. HD-48650), dealership technicians filling out warranty
claims should use the job/time code given by the computer.

1-20 2011 Touring Diagnostics: General Information

TABLE OF CONTENTS

SUBJECT............................................................................................................................PAGE NO.
2.1 INITIAL DIAGNOSTICS.............................................................................................................2-1
2.2 SERIAL DATA COMMUNICATION..........................................................................................2-22
2.3 DTC U1016, U1040, U1064, U1097, U1255...........................................................................2-24
2.4 DTC U1300, U1301 OR BUS ER............................................................................................2-29

INITIAL DIAGNOSTICS AND SERIAL DATA

NOTES
HOME
INITIAL DIAGNOSTICS
DESCRIPTION AND OPERATION
Use initial diagnostics as a starting point to efficiently
troubleshoot concerns. A basic understanding of electronics
and a general knowledge of the motorcycle are necessary to
effectively use this manual.
Before diagnosing a concern, perform a general functional test
of the motorcycle to verify the concern and to make sure there
is nothing else that could cause problems with accurately dia-
gnosing the motorcycle. Use the procedures in this chapter for
initial diagnostics.
NOTE
When working through a diagnostic procedure follow the steps
in the order instructed. Never jump to a test in another pro-
cedure. All "Go to test" statements refer to a test in that pro-
cedure.
RETRIEVING TROUBLE CODES
PART NUMBER TOOL NAME
HD-48650 DIGITAL TECHNICIAN II
There are two levels of diagnostics.
• The most sophisticated mode uses a computer-based
diagnostic package called DIGITAL TECHNICIAN II (Part
No. HD-48650).
• The second mode requires using the odometer self-dia-
gnostics. Speedometer, tachometer, TSM/TSSM/HFSM,
ECM and ABS (if equipped) codes can be accessed and
cleared.
On vehicles equipped with a radio, the radio DTCs are not read
with either DTII or the odometer self-diagnostics. The radio
DTCs are retrieved through the radio and shown on the radio
display. See 8.1 RADIO DIAGNOSTICS for the procedure to
retrieve radio DTCs.
ODOMETER SELF-DIAGNOSTICS
Diagnostic Mode
1. To enter diagnostic mode press and hold the trip odometer
reset switch while turning the IGN ON.
2. Release the trip odometer reset switch. "diag" will appear
on the odometer display.
3. Press and release the trip odometer reset switch. "PSSPtb"
will appear on the odometer display.
2011 Touring Diagnostics: Initial Diagnostics and Serial Data 2-1
2.1
4. PSSPtb indicates the different modules that could display
codes if equipped.
• P - ECM codes
• S - TSM/TSSM/HFSM codes
• SP - Speedometer codes
• t - Tachometer codes
• b - ABS codes
5. Quickly press and release the trip odometer reset switch
to cycle through the letters. The letters will flash as they
are selected.
6. Once the corresponding letter is flashing to the desired
module press and hold the trip odometer reset switch.
7. If no DTCs are present, "none" will appear on display.
8. If any DTCs are stored in the module, either current or
historic, they will appear on the odometer. Quickly pressing
and releasing the trip odometer reset switch will cycle
through the stored DTCs.
NOTE
The ECM will show "no rsp" if the engine stop switch is not in
the RUN position. Verify the engine stop switch is in the RUN
position.
9. If odometer displays "no rsp" then the motorcycle may not
be equipped with the module. If the motorcycle is equipped
with the selected module then go to other modules and
look for applicable communication codes.
10. When all the DTCs have been cycled the odometer will
display "end".
11. To clear all the DTCs in that module press and hold the
trip odometer reset switch. If DTCs are not to be cleared
quickly press and release the trip odometer reset switch.
The part number of the module will be displayed.
12. Press and release the trip odometer reset switch again to
continue to the next module.
13. Turn the IGN OFF to exit diagnostic mode.
DIAGNOSTICS
Diagnostic Tips
• For a quick check of instrument function, a "WOW" test
can be performed by entering odometer self-diagnostics.
Background lighting should illuminate, gauge needles
should sweep their full range of motion, and indicator
lamps controlled by the serial data circuit (battery, security
and check engine) should illuminate.
• If the instrument fails "WOW" test, check for battery,
ground and ignition voltage to the instrument. If any feature
in the speedometer or tachometer is non-functional, see
4.1 INSTRUMENTS.
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Table 2-1. Diagnostic Trouble Codes (DTCs) and Fault Conditions

DTC PRIORITY FAULT CONDITION SOLUTION

ORDER
B0563 138 Battery voltage high 3.6 DTC B0563, P0562, P0563
B1004 145 Fuel sender low 4.2 DTC B1004, B1005
B1005 146 Fuel sender open/high 4.2 DTC B1004, B1005
B1006 143 Accessory line overvoltage 3.7 DTC B1006, B1007
B1007 142 Ignition line overvoltage 3.7 DTC B1006, B1007
B1008 144 Trip odometer rest switch closed 4.3 DTC B1008
B1121 129 Left turn output fault 5.10 DTC B1121, B1122, B1123, B1124, B1125, B1126
B1122 130 Right turn output fault 5.10 DTC B1121, B1122, B1123, B1124, B1125, B1126
B1123 131 Left turn signal short-to-ground 5.10 DTC B1121, B1122, B1123, B1124, B1125, B1126
B1124 132 Right turn signal short-to-ground 5.10 DTC B1121, B1122, B1123, B1124, B1125, B1126
B1125 133 Left turn signal short-to-voltage 5.10 DTC B1121, B1122, B1123, B1124, B1125, B1126
B1126 134 Right turn signal short-to-voltage 5.10 DTC B1121, B1122, B1123, B1124, B1125, B1126
B1131 139 Alarm output low 5.17 DTC B1131, B1132
B1132 140 Alarm output high 5.17 DTC B1131, B1132
B1134 128 Start relay output high 5.18 DTC B1134
B1135 23 Accelerometer fault 5.11 DTC B1135, B1136, B1141, B1142
B1136 24 Accelerometer tip-over self-test fault 5.11 DTC B1135, B1136, B1141, B1142
B1141 141 Ignition switch open/low 5.11 DTC B1135, B1136, B1141, B1142
B1142 22 Internal fault 5.11 DTC B1135, B1136, B1141, B1142
B1143 135 Security antenna short-to-ground 5.19 DTC B1143, B1144, B1145
B1144 136 Security antenna short-to-battery 5.19 DTC B1143, B1144, B1145
B1145 137 Security antenna open 5.19 DTC B1143, B1144, B1145
B1151 25 BAS short to ground See the Trike or Sidecar supplement manual.
B1152 26 BAS short to battery See the Trike or Sidecar supplement manual.
B1153 27 Bank angle switch high See the Trike or Sidecar supplement manual.
B1154 28 Clutch switch short-to-ground 5.20 DTC B1154, B1155
B1155 29 Neutral switch short-to-ground 5.20 DTC B1154, B1155
C0562 111 System voltage low 3.6 DTC B0563, P0562, P0563
C0563 112 System voltage high 3.6 DTC B0563, P0562, P0563
C1014 105 ECU internal solid state relay fault 7.15 DTC C1014, C1055-C1066, C1118, C1121
C1017 110 Pump motor power circuit open fault 7.2 DTC C1017, C1018
C1018 109 Pump motor ground high resistance fault 7.2 DTC C1017, C1018
C1021 115 Front wheel speed sensor always equals 7.3 DTC C1021, C1023
zero kph
C1023 116 Rear wheel speed sensor always equals 7.3 DTC C1021, C1023
zero kph
C1025 117 Front wheel speed sensor signal intermit- 7.4 DTC C1025, C1027, C1206, C1208
tent
C1027 118 Rear wheel speed sensor signal intermit- 7.4 DTC C1025, C1027, C1206, C1208
tent
C1032 113 Front wheel speed sensor circuit open or 7.5 DTC C1032, C1034
shorted
C1034 114 Rear wheel speed sensor circuit open or 7.5 DTC C1032, C1034
shorted

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Table 2-1. Diagnostic Trouble Codes (DTCs) and Fault Conditions

DTC PRIORITY FAULT CONDITION SOLUTION

ORDER
C1042 107 Pump motor open 7.6 DTC C1042, C1043
C1043 108 Pump motor stalled 7.6 DTC C1042, C1043
C1055 96 ECU internal fault 7.15 DTC C1014, C1055-C1066, C1118, C1121
C1056 97 ECU internal fault - solid state relay 7.15 DTC C1014, C1055-C1066, C1118, C1121
shorted ON
C1057 98 ECU internal fault - solid state relay 7.15 DTC C1014, C1055-C1066, C1118, C1121
shorted to ground
C1061 99 ECU internal fault - front apply solenoid 7.15 DTC C1014, C1055-C1066, C1118, C1121
C1062 100 ECU internal fault - front release solenoid 7.15 DTC C1014, C1055-C1066, C1118, C1121
C1065 101 ECU internal fault - rear apply solenoid 7.15 DTC C1014, C1055-C1066, C1118, C1121
C1066 102 ECU internal fault - rear release solenoid 7.15 DTC C1014, C1055-C1066, C1118, C1121
C1094 121 Front brake switch always on 7.7 DTC C1094
C1095 122 Front brake switch open 7.8 DTC C1095
C1118 103 ECU internal fault - front apply solenoid 7.15 DTC C1014, C1055-C1066, C1118, C1121
correlation
C1121 104 ECU internal fault - rear apply solenoid 7.15 DTC C1014, C1055-C1066, C1118, C1121
correlation
C1151 126 Front wheel ABS release too long 7.9 DTC C1151
C1153 127 Rear wheel ABS release too long 7.10 DTC C1153
C1158 106 Calibration programming required 7.11 DTC C1158
C1206 119 Front wheel speed sensor frequency out 7.4 DTC C1025, C1027, C1206, C1208
of range
C1208 120 Rear wheel speed sensor frequency out 7.4 DTC C1025, C1027, C1206, C1208
of range
C1212 125 Front or rear brake not applied with decel 7.12 DTC C1212
C1214 123 Rear brake switch always on 7.13 DTC C1214
C1216 124 Rear brake switch open 7.14 DTC C1216
P0031 82 O2 heater low/open 6.7 DTC P0031, P0032, P0131, P0132, P0134, P0151,
P0152, P0154
P0032 82 O2 heater shorted/high 6.7 DTC P0031, P0032, P0131, P0132, P0134, P0151,
P0152, P0154
P0107 19 MAP sensor open/low 6.4 DTC P0107, P0108, P0112, P0113
P0108 20 MAP sensor high 6.4 DTC P0107, P0108, P0112, P0113
P0112 58 IAT sensor voltage low 6.4 DTC P0107, P0108, P0112, P0113
P0113 59 IAT sensor open/high 6.4 DTC P0107, P0108, P0112, P0113
P0117 56 ET sensor voltage low 6.5 DTC P0117, P0118
P0118 57 ET sensor open/high 6.5 DTC P0117, P0118
P0120 38 Throttle position sensor 1 range error 6.6 DTC P0120, P0122, P0123, P0220, P0222, P0223
P0122 40 TP sensor open/low 6.6 DTC P0120, P0122, P0123, P0220, P0222, P0223
P0123 41 TP sensor high 6.6 DTC P0120, P0122, P0123, P0220, P0222, P0223
P0131 84 Front O2 sensor low (lean) 6.7 DTC P0031, P0032, P0131, P0132, P0134, P0151,
P0152, P0154
P0132 86 Front O2 sensor high (rich) 6.7 DTC P0031, P0032, P0131, P0132, P0134, P0151,
P0152, P0154
P0134 88 Front O2 sensor open/not responding 6.7 DTC P0031, P0032, P0131, P0132, P0134, P0151,
P0152, P0154

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Table 2-1. Diagnostic Trouble Codes (DTCs) and Fault Conditions

DTC PRIORITY FAULT CONDITION SOLUTION

ORDER
P0151 85 Rear O2 sensor low (lean) 6.7 DTC P0031, P0032, P0131, P0132, P0134, P0151,
P0152, P0154
P0152 87 Rear O2 sensor high (rich) 6.7 DTC P0031, P0032, P0131, P0132, P0134, P0151,
P0152, P0154
P0154 89 Rear O2 sensor open/not responding 6.7 DTC P0031, P0032, P0131, P0132, P0134, P0151,
P0152, P0154
P0220 39 Throttle position sensor 2 range error 6.6 DTC P0120, P0122, P0123, P0220, P0222, P0223
P0222 42 Throttle position sensor 2 low/open 6.6 DTC P0120, P0122, P0123, P0220, P0222, P0223
P0223 43 Throttle position sensor 2 high 6.6 DTC P0120, P0122, P0123, P0220, P0222, P0223
P0261 66 Front injector open/low 6.8 DTC P0261, P0262, P0263, P0264
P0262 68 Front injector high 6.8 DTC P0261, P0262, P0263, P0264
P0263 67 Rear injector open/low 6.8 DTC P0261, P0262, P0263, P0264
P0264 69 Rear injector high 6.8 DTC P0261, P0262, P0263, P0264
P0373 18 CKP sensor intermittent 6.9 DTC P0373, P0374
P0374 21 CKP sensor synch error 6.9 DTC P0373, P0374
P0444 77 Purge control open/low 6.10 DTC P0444, P0445
P0445 78 Purge control high 6.10 DTC P0444, P0445
P0501 72 VSS low 6.11 DTC P0501, P0502
P0502 73 VSS high 6.11 DTC P0501, P0502
P0505 76 Loss of idle speed control 6.12 DTC P0505
P0562 70 Battery voltage low 3.6 DTC B0563, P0562, P0563
P0563 71 Battery voltage high 3.6 DTC B0563, P0562, P0563
P0572 55 Brake switch low 6.13 DTC P0572
P0577 93 Cruise control input high 5.4 DTC P0577
P0603 2 ECM EEPROM error 6.14 DTC P0603, P0605
P0605 1 ECM flash error 6.14 DTC P0603, P0605
P0641 16 5V ref 1 out of range 6.15 DTC P0641, P0651
P0651 17 5V ref 2 out of range 6.15 DTC P0641, P0651
P0661 48 Intake solenoid low/open 6.15 DTC P0641, P0651
P0662 49 Intake solenoid high/shorted 6.15 DTC P0641, P0651
P1001 12 System relay coil open/low 6.16 DTC P1001, P1002, P1003, P1004
P1002 11 System relay coil high/shorted 6.16 DTC P1001, P1002, P1003, P1004
P1003 10 System relay contacts open 6.16 DTC P1001, P1002, P1003, P1004
P1004 13 System relay contacts closed 6.16 DTC P1001, P1002, P1003, P1004
P1009 14 Incorrect password 6.17 DTC P1009, P1010
P1010 15 Missing password 6.17 DTC P1009, P1010
P1270 31 Twistgrip position sensor 2 A/D validation 6.18 DTC P1270
error
P1351 60 Front ignition coil open/low 6.19 DTC P1351, P1352, P1354, P1355
P1352 62 Front ignition coil high/shorted 6.19 DTC P1351, P1352, P1354, P1355
P1353 75 Front cylinder no combustion detected 6.20 DTC P1353, P1356, P1357, P1358
P1354 61 Rear ignition coil open/low 6.19 DTC P1351, P1352, P1354, P1355
P1355 63 Rear ignition coil high/shorted 6.19 DTC P1351, P1352, P1354, P1355
P1356 74 Rear cylinder no combustion detected 6.20 DTC P1353, P1356, P1357, P1358

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Table 2-1. Diagnostic Trouble Codes (DTCs) and Fault Conditions

DTC PRIORITY FAULT CONDITION SOLUTION

ORDER
P1357 64 Front ignition coil intermittent secondary 6.20 DTC P1353, P1356, P1357, P1358
detected
P1358 65 Rear ignition coil intermittent secondary 6.20 DTC P1353, P1356, P1357, P1358
detected
P1475 79 Exhaust position actuation error 6.21 DTC P1475, P1477, P1478
P1477 80 Exhaust actuator low/open 6.21 DTC P1475, P1477, P1478
P1478 81 Exhaust actuator high/shorted 6.21 DTC P1475, P1477, P1478
P1501 53 JSS low 6.22 DTC P1501, P1502
P1502 54 JSS high 6.22 DTC P1501, P1502
P1510 90 Throttle actuator control limited perform- 6.23 DTC P1510, P1511, P1512
ance
P1511 91 Throttle actuator limited power manage- 6.23 DTC P1510, P1511, P1512
ment mode
P1512 92 Throttle actuator control forced idle mode 6.23 DTC P1510, P1511, P1512
P1514 51 Throttle actuator control system airflow 6.24 DTC P1514
fault
P1600 30 TAC module - internal fault 6.25 DTC P1600
P1653 Tachometer low
P1654 Tachometer high
P1655 94 ACR solenoid low 6.26 DTC P1655, P1656
P1656 95 ACR solenoid high 6.26 DTC P1655, P1656
P2100 46 Throttle actuator control motor circuit/open 6.27 DTC P2100, P2101, P2102, P2103
P2101 47 Throttle actuator control motor circuit 6.27 DTC P2100, P2101, P2102, P2103
range error
P2102 48 Throttle actuator control motor circuit low 6.27 DTC P2100, P2101, P2102, P2103
P2103 49 Throttle actuator control motor circuit high 6.27 DTC P2100, P2101, P2102, P2103
P2105 52 Throttle actuator control system - forced 6.28 DTC P2105, P2107
engine shutdown
P2107 32 Throttle actuator control module processor 6.28 DTC P2105, P2107
P2119 45 Throttle actuator control system throttle 6.29 DTC P2119
return error
P2122 33 Twistgrip position sensor 1 low/open 6.30 DTC P2122, P2123, P2127, P2128
P2123 34 Twistgrip position sensor 1 high 6.30 DTC P2122, P2123, P2127, P2128
P2127 35 Twistgrip position sensor 2 low/open 6.30 DTC P2122, P2123, P2127, P2128
P2128 36 Twistgrip position sensor 2 high 6.30 DTC P2122, P2123, P2127, P2128
P2135 44 Throttle position sensor correlation error 6.31 DTC P2135, P2138
P2138 37 Twistgrip position sensor correlation error 6.31 DTC P2135, P2138
P2176 50 Throttle actuator control system - closed 6.32 DTC P2176
position not learned
U1016 7 Loss of ECM serial data 2.3 DTC U1016, U1040, U1064, U1097, U1255
U1040 8 Loss of ABS serial data 2.3 DTC U1016, U1040, U1064, U1097, U1255
U1064 6 Loss of TSM/TSSM/HFSM serial data 2.3 DTC U1016, U1040, U1064, U1097, U1255
U1097 5 Loss of speedometer serial data 2.3 DTC U1016, U1040, U1064, U1097, U1255
U1255 9 Missing response at module 2.3 DTC U1016, U1040, U1064, U1097, U1255

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Table 2-1. Diagnostic Trouble Codes (DTCs) and Fault Conditions
DTC PRIORITY FAULT CONDITION
ORDER
U1300 3 Serial data low
U1301 4 Serial data open/high
CODE TYPES
PART NUMBER TOOL NAME
HD-48650 DIGITAL TECHNICIAN II
There are two types of DTCs: current and historic. If a DTC is
stored, it can be read using either a computer-based diagnostic
package called DIGITAL TECHNICIAN II (Part No. HD-48650)
or odometer self-diagnostics.
NOTES
• Odometer self-diagnostics will display both current and
historic DTCs. To differentiate between current and historic
DTCs, a computer-based diagnostic package called
DIGITAL TECHNICIAN II (Part No. HD-48650) must be
employed.
• Current DTCs reside in the memory of the ECM,
TSM/TSSM/ HFSM, speedometer, tachometer or ABS (if
equipped) until the DTC is resolved.
• A historic DTC can be cleared by use of the odometer self-
diagnostics or after a total of 50 ignition cycles (start and
run cycle) have elapsed. After the 50 ignition cycle reten-
tion period, the DTC is automatically erased from memory
providing that no subsequent faults of the same type are
detected in that period.
Current
Current DTCs are those which presently disrupt motorcycle
operation and are set during the current ignition cycle. See the
appropriate diagnostic procedures for solutions.
Historic
If a particular problem happens to resolve itself, the active
status problem is dropped and it becomes a historic DTC rather
than a current DTC. DTCs will also lose their current status
when the ignition is turned off. If the problem still exists when
the ignition is turned on the code will show as current.
Historic DTCs are stored for 50 ignition cycles after any DTC
was last set as current to assist in the diagnosis of intermittent
faults. On the 50th cycle, the DTC will clear itself. The security
lamp will only indicate the existence of historic DTCs for two
ignition cycles.
It is important to note that historic DTCs will exist whenever
the system indicates the existence of a current fault. See
2.1 INITIAL DIAGNOSTICS, Multiple Trouble Codes if multiple
DTCs are found.
Diagnostic procedures are designed for use with current DTCs.
As a result, they frequently suggest part replacement. When
diagnosing a historic DTC, the procedures can be helpful but
2-6 2011 Touring Diagnostics: Initial Diagnostics and Serial Data
SOLUTION
2.4 DTC U1300, U1301 OR BUS ER
2.4 DTC U1300, U1301 OR BUS ER
should not lead to part replacement without verification that
the part is faulty.
MULTIPLE TROUBLE CODES
All DTCs are assigned a priority number to determine the order
in which they should be diagnosed. In the event there are
multiple DTCs present always diagnose the highest priority
first. Refer to Table 2-1.
After each DTC is repaired, restore connections, clear DTCs
and start vehicle. Perform self-diagnostics test and verify repair,
verify if DTCs are present, and if DTCs are still present. Refer
to Table 2-1.
CLEARING DTCS
DTCs should be cleared after any diagnostic or repair pro-
cedure is performed. The odometer is capable of displaying
and clearing ECM, TSM/TSSM/HFSM, speedometer, tacho-
meter and ABS DTCs. Once the DTCs are cleared perform a
road test to verify DTCs do not return. It is important to perform
a road test and not simply start the motorcycle since some
DTCs may require vehicle speed or other inputs in order to
validate repair.
SECURITY LAMP
The security lamp functions in the same manner as the check
engine lamp, except that it is controlled by the TSSM/HFSM.
The security lamp will be turned on when codes are present
in the TSSM/HFSM. When B1004 or B1005 codes are present
in the TSSM/HFSM, the low fuel lamp on the speedometer or
tachometer will also be illuminated.
CHECK ENGINE LAMP
To diagnose ECM system problems, start by observing the
behavior of the check engine lamp.
NOTES
• "IGN ON" means that the ignition switch is turned to IGN
and the engine stop switch is set to RUN (although the
engine is not running).
• When the IGN is turned ON, the check engine lamp will
illuminate for approximately four seconds and then turn
off.
• If the check engine lamp is not illuminated at IGN ON or
if it fails to turn off after the initial four-second period, then
see 6.34 NO ECM POWER.
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1. See Figure 2-1. After the check engine lamp turns off fol-
lowing the first four second illumination period, one of three
events may occur.
a. The lamp remains off. This indicates there are no
current fault conditions or stored DTCs currently
detected by the ECM.
b. The lamp stays off for only four seconds and then
comes back on for an eight second period. This
indicates a DTC is stored, but no current DTC exists.
c. If the lamp remains on beyond the eight-second
period, a current DTC exists.
2. See 2.1 INITIAL DIAGNOSTICS, Code Types for a com-
plete description of DTC formats.
NOTE
Some DTCs can only be fully diagnosed during actuation. For
example, a problem with the ignition coil will be considered a
current fault even after the problem is corrected, since the ECM
will not know of its resolution until after the coil is exercised by
the vehicle start sequence. In this manner, there may some-
times be a false indication of the current DTC.

ed03179

ON 4 Sec.
A
Lamp OFF: No Current DTCs
OFF
Ignition ON

Lamp Remains ON: Current DTC*

ON 4 Sec.
B

OFF 4 Sec.
Ignition ON

* Historic DTCs May Also Exist

Figure 2-1. Check Engine Lamp and Security Lamp Operation

SYMPTOMS is not a normal characteristic of the system. Refer to Table 2-2

for a list of symptoms.
If no DTCs are present but there is a symptom or concern
indicating a malfunction, address and repair the symptom if it

Table 2-2. Symptom Table

SYMPTOM DIAGNOSTIC PROCEDURE

Ambient temperature gauge inoperative 4.6 GAUGES
Auxiliary lamps inoperative 5.7 HEADLAMPS
Battery runs down during use 3.5 CHARGING SYSTEM
Both turn signals on one side inoperative, 5.6 TURN SIGNALS
no DTCs
"Bus Er" displayed 2.2 SERIAL DATA COMMUNICATION
Charging system inoperative 3.5 CHARGING SYSTEM
Check engine lamp inoperative 6.34 NO ECM POWER
Engine cranks, but will not start 6.33 ENGINE CRANKS, BUT WILL NOT START
Fuel gauge inoperative 4.6 GAUGES
Headlamp inoperative 5.7 HEADLAMPS
High beam indicator inoperative 4.5 INDICATOR LAMPS

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Table 2-2. Symptom Table

SYMPTOM DIAGNOSTIC PROCEDURE

Horn always on 5.5 HORN
Horn inoperative 5.5 HORN
Low battery after extended IGN OFF 3.5 CHARGING SYSTEM
Low fuel lamp always on 4.5 INDICATOR LAMPS
Low fuel lamp inoperative 4.5 INDICATOR LAMPS
Low or no charging 3.5 CHARGING SYSTEM
Neutral lamp always on 4.5 INDICATOR LAMPS
Neutral lamp inoperative 4.5 INDICATOR LAMPS
No ECM power 6.34 NO ECM POWER
Misfire at idle or under load 6.37 MISFIRE AT IDLE OR UNDER LOAD
Oil pressure gauge inoperative 4.6 GAUGES
Oil pressure lamp always on 4.5 INDICATOR LAMPS
Oil pressure lamp inoperative 4.5 INDICATOR LAMPS
One turn signal lamp inoperative, no DTCs 5.6 TURN SIGNALS
Overcharging 3.5 CHARGING SYSTEM
P&A battery power inoperative 5.1 ACCESSORIES
Position lamp inoperative (HDI) 5.9 RUNNING LAMPS
Running lamps inoperative 5.9 RUNNING LAMPS
Security lamp inoperative 5.12 SECURITY SYSTEM
Speedometer inoperative 4.1 INSTRUMENTS
Starter does not spin 3.2 STARTING SYSTEM
Starter inoperative 3.2 STARTING SYSTEM
Starter solenoid clicks 3.2 STARTING SYSTEM
Starter spins, but does not engage 3.2 STARTING SYSTEM
Starter stalls or spins too slowly 3.2 STARTING SYSTEM
Starts, then stalls 6.35 STARTS, THEN STALLS
Stop lamp inoperative 5.8 STOP LAMPS
Tachometer inoperative 4.1 INSTRUMENTS
Tail lamp inoperative 5.9 RUNNING LAMPS
Turn signal indicator inoperative 4.5 INDICATOR LAMPS
Turn signal inoperative 5.6 TURN SIGNALS
Turn signals flash at double normal rate 5.6 TURN SIGNALS
Turn signals will not cancel on turn comple- 5.6 TURN SIGNALS
tion
Voltmeter gauge inoperative 4.6 GAUGES

Connector Information
For additional information about the connectors in the following
diagram(s) and diagnostic procedure(s), including the color of
the harness test kit terminal probes, see B.1 CONNECTORS.

2-8 2011 Touring Diagnostics: Initial Diagnostics and Serial Data

HOME

em00683

Speedometer Ignition Switch

Red
5 [39A] Band ACC
IGN

5 [39B] OFF

B+ ACC IGN [33A]

BN/GY
B [33B]
Battery

R
Main Power Main Fuse Voltage B+
3 [20A] At Starter 40A Regulator Connector
3 [20B] A B [5B] + [77B] [160B]
Optional
Security

R
[BATT]
BN/GY

BK
Siren BK

R
A [142A]
R R
A [142B] B [222A]
BN/GY
64-1B B [222B]
R

R
2A

Battery 15A
BN/GY 2D 2C R

ECM ECM Power 15A

71 71 BE/GY BE/GY 2F 2E R

[78A] [78B]

BE/GY 3D 3 30
System
Relay

TSM/TSSM/HFSM
1 1 BN/GY

Lighting 30 3 1J R
[30A] [30B] Relay
(GY)
64-2B

Figure 2-2. Battery Power: FLHR/C

2011 Touring Diagnostics: Initial Diagnostics and Serial Data 2-9

HOME

em00852
BK

Red
Band

Ignition Switch

ACC
Battery OFF
IGN
Main Power Main Fuse Voltage
At Starter B+
TSM/TSSM/ Optional 40A Regulator Connector B+ IGN ACC [33A]
HFSM Security [33B]
A B [5B] + [77B] [160B] 2
1 1 BN/GY Siren

BK
R

R
BK
[BATT]

R
[30A] [30B] A [142A]
(GY) A
BN/GY
[142B] R R

ECM 64-1B
Radio Memory 15A
71 71 BE/GY R/O 2B 2A R
Battery 15A
[78A] [78B] BN/GY 2D 2C R

ECM Power 15A

BE/GY 2F 2E R

BE/GY 3D 3 30
System
Relay

4 4 BN/GY R/O A A R/O Lighting 30 3 1J R

Relay
[2A] [2B] [15A] [15B]
[185B]
BN/GY

64-2B
R/O 9 XM
5 [108B]
5 [108A] [186B]

R/O 9 Future
BN/GY

Tachometer ACC

[184D]
5 [39B]
5 [39A] R/O 3 3 R/O R/O 9 9 R/O R/O 9 C.B.

[6B] [6A] C.B. [184B] [184C]

Speedometer
R/O

R/O

(If Equipped)

10 20 [27B]
10 20 [27A]
R/O

R/O

Radio Future ACC

[175B] 1 5 [187B]
5 [187A]
R/O

Bluetooth
Antenna

[194B]
(Beige)
R/O 1

Hands Free Module

Figure 2-3. Battery Power: Except FLHR/C

2-10 2011 Touring Diagnostics: Initial Diagnostics and Serial Data

HOME

em00685
Oil Active Exhaust Ignition Switch
Pressure Neutral (HDI Only)
ACC

1 [179A] OFF
IGN

O
ABS
Module 1 [179B] [33A] B+ IGN ACC
(If Equipped) [33B]

LGN/R
A
TSM/
TSSM/

R/BK
19 [166A]
HFSM Speedometer
19 [166B]

O
2 2 GY
A [222A]
GY
6 [21B] 1 [39A]
[21A] A [222B]
[30A] [30B] 6 1 [39B]
(GY) 64-1B

R/BK
O
Exhaust Control 15A

O
DLC LGN/R 3B 3A R/BK
Fuel Gauge
4 4 GY 1 [117B]
[20A] 1
1 [20B] P&A IGN (MAX) 2A

O
[91B] [91A] 1B 1A
O

Instruments 15A
Engine O 1D 1C R/BK
Stop
Switch Ignition 15A
3 3 GY GY 1F 1E R/BK

[22A] [22B] 87 5
Lighting 30 3
Relay
86 1 1G
85 2

64-2B

Figure 2-4. Ignition Power: FLHR/C

2011 Touring Diagnostics: Initial Diagnostics and Serial Data 2-11

HOME

em00814

Oil Oil Air

Pressure Neutral Fuel Voltmeter Pressure Temperature
[116A] [110A] [112A] [114A]
[116B] [110B] [112B] [114B]
O

O 1 O 1 O 1 O 1
+ [117A] + [111A] + [113A] + [115A]
1 1 1 1
O

[117B] [111B] [113B] [115B]

Indicator 6 [21B]
O

O
Lamps 6 [21A]
(BK)
O

Ignition Switch
TSM/TSSM/HFSM 2 2 GY GY 19 19
ABS Module
(If Equipped)
ACC
OFF
[30A] [30B] [166B] [166A]

GY
IGN

(GY)
[33A] B+ IGN ACC

DLC 4 4 GY [33B] 3
Right Active Exhaust

R/BK
Turn [22A] [22B] 64-1B
GY

[91B] [91A] (HDI Only) Exhaust Control 15A

Switch
1 1 LGN/R 3B 3A R/BK
BE 3 3 GY GY 3 3 GY

O 1 1 O [179A] [179B]
P&A IGN (MAX) 2A
[1A] [1B] 1B 1A
(BK) Instruments 15A
O

O 1D 1C R/BK
[39B] 1 [108B] 1 Ignition 15A
[39A] [108A] GY 1F 1E R/BK
1 1
(BK) (GY)
87 5
Speedometer Tachometer
Lighting 30 3
Relay
86 1 1G
85 2

64-2B

Figure 2-5. Ignition Power: Except FLHR/C

2-12 2011 Touring Diagnostics: Initial Diagnostics and Serial Data

HOME

em00681 Ignition Switch

Tail Lamp
2 [93A]
2 [93B] ACC
IGN

OFF
Speedometer

O/W
[33A] B+ ACC IGN

6 [39A] 1 [94A] [33B] B A C

Rear
[39B] Lighting [94B]

R/GY
6 1

O/W

O/W
C [222A]
4 [20A] 2 [7B] C [222B]
4 [20B] 2 [7A] 64-1B

R/GY
Brake 15A
O/V 1B 1A
O/W

O/W
Accessory 15A
O/W 1D 1C R/GY

P&A 15A
O/R 1F 1E R/GY

R/GY 3H 3 30 Start
Relay
Accessory
Switch
[67A] 4 O/R
O/W

O/V 3A 5 87
1 2
O/W

Brake
Relay
O/R

1 [32A]
1 [32B] 1 [4A] 64-2B
Rear
Fender Stop Lamp Accessory
Tip Lamp Switch Connector
[121B-2]

Position Lamp
(HDI Only) Right Turn
Switch
O/W [29B-1]
O/W

[22B] [22A]

O/W 1 1 O/W O/W

Front Stop/Lamp
Switch

[24B] [24A]

O/W 1 1 O/W O/W Cruise On/Off

Switch

O/W
Horn
Switch
O/W

Left Turn
Switch

Figure 2-6. Accessory Power: FLHR/C

2011 Touring Diagnostics: Initial Diagnostics and Serial Data 2-13

 Ignition
SPKR Switch ACC
HOME

CRUISE ACC OFF

IGN
em00853

Connectors Power
On FLTR Outlet [133A] B+ IGN ACC
Only (If Equipped)

O/BE
1

O/V
[133B]

O/R
[258B] 1
1 [105D]
R/GY

1 [105C] 64-1B
[121B-2] Brake 15A

BN/BE
Rear O/V 1B 1A
Stop Lamp Accessory 15A

O/BE
O/V
O/R
Switch O/W 1D 1C R/GY
9 4 1 [105B] P&A 15A
Accessory O/R 1F 1E R/GY
9 4 1 [105A] Connector Radio PWR/
(BK) (BK) 2 Siren 5A
[4A] 1

O/R
O/W
[1A] [1B] O/BE 1H 1G

O/BE
(BK)
HDI Only

O/W
O/R
Power Outlet
O/BE 9 9 O/BE BN/BE 2H 2G

[29B-1] [29B]
O/W
O/W 5 5 O/W Start
R/GY 3H 3 30
O/R 4 4 O/R
Relay
Right Turn
Switch Cigar

O/W
Lighter
(Except
O/R (FL/HTCU/HTK/TRU) FL/HTCU/HTK/TRU) O/V 3A 5 87
[22A] [22B] Brake

O/W
Relay

O/R
O/W O/W 1 1 O/W
64-2B

O/W
[132B] [132A]
O/W

[189B] 1

2-14 2011 Touring Diagnostics: Initial Diagnostics and Serial Data

Front
Stop/ [189A] 1 2 [7A]
(FLHTC 2 [257A] (FL/TRX/HX)
Lamp 2 [7B]
Switch [24A] [24B] Heated Only) Canada Only) (FL/TRX/HX)
Hand Grips

O/W
(If Equipped) 2 [257B] 2 [257B] 2 [257B]
O/W 1 1 O/W
1 [94B] Facia/
Rear Converter
O/W

Lighting
O/W

1 [94A] Module
O/W

Figure 2-7. Accessory Power: Except FLHR/C

12 [226B] 12 [226B]
Horn Circuit 2 [7A]
Switch Board 12 [226A] 12 [226A]
2 [7B]
[27A] [27B] 2 [93A] Facia/
Taillamp Converter
O/W

2 [93B] Module
12 12 O/BE
1 10 [262A]
Rear [94B]

O/W
O/W
Radio

O/W
Lighting 1 [94A] 10 [262B]
[39B] 6 [108B] 6
Circuit
O/W

[39A] 6 [108A] 6 Board 10

Left Turn Rear 1 [94A]
Switch 2 [93A]
Taillamp Lighting 1 [94B]
2 [93B]

Accessory
Accessory Circuit
Speedometer Board
Tachometer
2 [93A]
Taillamp
2 [93B]
HOME

em00679
TMAP
TCA TGS Sensor

1 [211A] 4 1 [204A] 1 [80A]

1 [211B] 4 1 [204B] 1 [80B]
Front HO2 Rear HO2

BK/W

BK/W

BK/GY

BK/GY
Sensor Sensor

2 [138B] 2 [137B]
2 [138A] 2 [137A]
GN/W

GN/W ET
Sensor

B [90A]
B [90B]
BK/W

CKP

2 [79A]
2 [79B]
BK

BK/GY
GN/W

BK/W
BK

31 43 61 62 [78B]
31 43 61 62 [78A]

ECM

Figure 2-8. Sensor Grounds

2011 Touring Diagnostics: Initial Diagnostics and Serial Data 2-15

HOME

em00678
BK
Right Fuel Pump
Turn Assembly Intank
BK
High C [141A]
Beam
C [141B]
BK Left
Turn

BK/GN
BK
[39A] [39B]

Indicator
7 [21B]
Speedometer 7 7 BK/GN
Lamps 7 [21A]

BK/GN

Optional

BK/GN
Fuel Security
DLC Gauge Siren
TSM/TSSM/HFSM
[91A] 2 [20A] 5 [117A] 4 C [142A]
12 12 BK/GN
(GY) [20B] [117B] 4 C [142B]
BK/GN

[30A] [30B]

BK/GN

BK/GN
BK/GN
[78A] [78B] (GY)

ECM 73 73 BK/GN
BK/GN

[133B] 3

[133A] 3

JSS
(HDI Only)
[24A] [24B]

BK/GN
Clutch
Lockout BK 8 8 BK/GN
Switch

Right GND 2

Figure 2-9. Right GND2: FLHR/C

2-16 2011 Touring Diagnostics: Initial Diagnostics and Serial Data

HOME

em00854

Fuel Pump
Assembly In Tank
C [141A]
C [141B] Optional
Security

BK/GN
Siren
70369-06 C [142A]
Fuel Tank [142B]
C
Harness

BK/GN
BK/GN
DLC
[91A] 2 TSM/TSSM/HFSM 3 [13B]
(GY)
[13A]

BK/GN
12 12 BK/GN 3

BK/GN
[30A] [30B]
[78A] [78B]
(GY)
ECM 73 73 BK/GN

BK/GN

[133B] 3
JSS
(HDI Only)

[2A] [2B]

BK/GN 12 12 BK/GN

[24A] [24B] (GY)(GY)

Clutch
Lockout BK 12 12 BK/GN
Switch [15A] [15B]

[27A] [27B] BK/GN C C BK/GN BK/GN

BK/GN
(BK)(BK)
11 11
BK/GN

BK/GN

Radio
19 19 BK/GN
Right GND 2
[39B] 7 [108B] 7
BK/GN

[39A] 7 [108A] 7
(BK) (BK)
[6B] 6 Speedometer Tachometer
[6A] 6
BK/GN

XM
BK/GN 10
[185B]
Future
BK/GN 10 ACC
[186B]

C.B.
BK/GN 10 10 BK/GN BK/GN 10 [184D]
[53A] [53B]
BK/GN

BK/GN

C.B. [184B] [184C]

BK/GN 4 4 (If Equipped) P&A ULTRA
Future ACC Overlay Harness
[175B] 2 6 [187B] (If Equipped)
6 [187A]
BK/GN

BK/GN 2 Differential Mic Out (-)

Hands Free Module

Figure 2-10. Right GND2: Except FLHR/C

2011 Touring Diagnostics: Initial Diagnostics and Serial Data 2-17

HOME

em00855 [166B]
Left Turn And DOM
Running Lamp ABS 1 BK
Module
Right Turn And DOM (If Equipped)
Running Lamp 11 BK Fuel Sender/Pump
[13A] 4
Harness

BK

BK

BK
1 6 [31B]
1 6 [31A] [20A] 15

[20B] 15

BK

BK

BK
Active Exhaust
(HDI Only) GND 3
[179B] 2 BK 1

BK
Voltage
Regulator
- [77B]

BK
87 5
Lighting 30 3
Relay
86 1
85 2 2J BK

5 87

3 30 Brake
1 86
Relay
BK

BK 3B 2 85
(BK) A 64-2B
BK

BK

Fender
Tip Lamp
[38B]
BK

3 2 [32A]
BK

BK

Headlamp 2 [32B] [29B]

2 Neutral [4A]
Switch
4 5 [7A]
BK

HDI Position [131] Accessory 5 [7B]

Lamp Connector
BK

Front Fender
Tip Lamp
BK

(DOM only) Horn

BK

BK

3 [109A]
6 [94B]
AUX
Lamp [18B] 6 [94A]
Switch
[122]
[122B-1] Right Rear BK 2 2 [18A]
Turn Lamp
[19B]

Left Rear BK 2 2 [19A]

Turn Lamp Tail Lamp
4 4 BK
1 1 License
BK

BK
BK

BK 3 3 Plate Lamp
(HDI Only)
BK
[45B] [45A] [93A] [93B] BK
Left
GND 1 Chassis Grounds
Handlebar BK Fork Bracket
Ground Grounds
Frame BK BK
BK
Ground
Fender Tip
Lamp
(DOM Only)

Figure 2-11. Left GND1: FLHR/C

2-18 2011 Touring Diagnostics: Initial Diagnostics and Serial Data

 Ground To Upper Spot SPKR Cruise ACC
HOME

Triple Clamp Right

em00827

BK
[GND 3] Turn

BK
BK
High BK BK/GN
Beam

BK/GN
BK
FLT Models Only Left
BK
Turn
3 BK
GND
[38B-2]
Indicator

BK
Lamps 4 [105D]

BK
BK

BK/GN
[21B] 5
12 8 3 [105B] 4 [105C]
3 BK

BK/GN
[21A] 5
GND 12 8 3 [105A]
(BK) Connectors,
[38B] (BK)

BK
FLT Models

BK
BK
BK
Only
[29B-2] BK

Headlamp
[38A]
HDI Only
BK 3 3 TEMP Signal Air Temperature
Ground
Sensor
[107B] [107A]
On FLH Models Only (BK)
BK D

BK
[15A]

BK
BK
Fender BK
Tip 2 [32A] Cigar (BK)
3 [31RA] 3 [31LA] 2
[189B]
Lamp 2 Lighter
(DOM [143B] [143A] [32B] 2 BK
[189A]

BK
BK
Only)

BK
Heated [132B-2] [132A-2]
BK 2 2 BK Hand Grips
(If Equipped)

[31LB] 3

Figure 2-12. Left GND1: Except FLHR/C (Part 1 of 2)

BK
BK
3 [31RB] Oil Air
Fuel Voltmeter Pressure Temperature

BK
[116A] [110A] [112A] [114A]
[116B] [110B] [112B] [114B]
1 2 BK 1 2 BK 1 2 BK 1 2 BK
Left + S + S + S + S
1 3 [117A] 1 3 [111A] 1 3 [113A] 1 3 [115A]
Directional 2
2 - - 2 - 2 -
And DOM [117B] [111B] [113B] [115B]
Running
BK
BK
BK
BK

Right Lamp
Directional
And DOM
Running
Lamp

2011 Touring Diagnostics: Initial Diagnostics and Serial Data 2-19

 Horn Voltage Fuel Sender/Pump 4 [13A]
D BK
Regulator Jumper Harness
[166B] Active Exhaust
HOME

-
em00826

(HDI Only) [15B] [77B]

1 BK 2 87 5

BK
ABS [179B] (BK)

BK

BK
Module [122A] [122B] Lighting 30 3

BK
(If Equipped) Relay

BK
11 BK 86 1
85 2 2J BK

5 87
Brake
3 30 Relay
1 86

BK
BK
BK 3B 2 85
[64-2B]

BK

BK
BK
BK

BK
(BK) To Rear
B A Lighting
Left GND 1 [12B] 3 [4A] 4 2 [258B]
Stud 3
[12A] Accessory Power
Connector Outlet
BK

Neutral

BK
(If
Switch Equipped) (Except
[131] [257A] 4 FL/HTCU/TRU)
(FL/TRX/HX
(FL/HTCU/HTK/TRU) Canada Only) (FLHTC Only) (FL/TRX/HX HDI Only) (FL/TRX/HX DOM Only)

[257B] 4 [257B] 4 [257B] 4 [257B] 4

[12-3B] [12-3A] [12-2A] [12-2B]

BK
BK

BK
BK

BK
BK

BK 2 2 BK BK 2 2 BK
[7A] 5 [7A] 5
Tour-Pak Tour-Pak

BK
BK
BK
BK
BK
BK

Left Side Right Side [7B] 5 [7B] 5

[226B] 1 7
Marker Lights Marker Lights [226B] 1 7 [226B]

2-20 2011 Touring Diagnostics: Initial Diagnostics and Serial Data

[226A] 1 7

BK
BK

1 7 [226A] [226A]
Facia/ 1 7 1 7
[94B] 6 Converter Facia/ Facia/
[94B] 6

BK
BK
Module 4 5 Converter Converter
[262A] Module 5 10
Module
5 6 7 11
[12-5B] [12-4B] 4 5 [262A]
[262B] [262A]
[262B] 5 10 5 6 7 11
[262B]
BK
BK
Ultra Tour-Pak
Rear Marker/
BK
BK
BK
BK
BK
BK

Figure 2-13. Left GND1: Except FLHR/C (Part 2 of 2)

Stop Lights
BK

(If Equipped)
[94B] 6

Right Rear [18B] 654321 [94A]

Turn
Lamp 1 1 [18A]
BK 2 2
Rear Lighting
[19B]
Left Rear 1
1 [19A]
Turn BK 2 2
Lamp
4 4 BK
BK 1 1 3 3
2 2 2 2
Fender Tip/ BK 3 3 1 1
License Plate Lamp Tail Lamp
[45B] [45A] [93A] [93B]
HOME

INITIAL DIAGNOSTICS 5. Security System Test

1. Verifying Current DTC Test 1. Turn the IGN OFF-ON.

1. Check for DTCs. See 2.1 INITIAL DIAGNOSTICS, Odo- 2. Observe the security lamp.
meter Self-Diagnostics. 3. Does the security lamp illuminate for a few seconds and
2. Are any DTCs present? then turn off?
a. Yes. Refer to Table 2-1. a. Yes. Go to Test 6.

b. No. Go to Test 2. b. No. See 5.12 SECURITY SYSTEM.

2. Battery Power Test 6. Starter System Test

1. Verify battery is charged. See 3.1 BATTERY TESTING. 1. Press the start button.

2. Does vehicle have battery power? 2. Does the starter spin and crank the engine?
a. Yes. Go to Test 4. a. Yes. Go to Test 7.

b. No. Go to Test 3. b. No. See 3.2 STARTING SYSTEM.

3. Ignition Power Test 7. Engine Running Test

1. With the engine stop switch in the off position, turn IGN 1. Start the engine.
ON. 2. Does the engine start and run correctly?
2. Do the headlamps and instruments illuminate? a. Yes. Go to Test 8.
a. Yes. Go to Test 4. b. No. See 6.1 EFI SYSTEM.
b. No. Refer to Table 2-2.
8. Verification Test
4. Engine Stop Switch Circuit Test 1. Operate the systems of the vehicle to verify the concern.
1. Turn the engine stop switch to the RUN position. 2. Was the concern duplicated?
2. Does the check engine lamp illuminate for a few seconds, a. Yes. See appropriate diagnostic. Refer to Table 2-2.
then turn off?
b. No. Concern is intermittent. See 1.3 DIAGNOSTICS
a. Yes. Go to Test 5. AND TROUBLESHOOTING, Wiggle Test.
b. No. See 6.34 NO ECM POWER.

2011 Touring Diagnostics: Initial Diagnostics and Serial Data 2-21

HOME

SERIAL DATA COMMUNICATION 2.2

DESCRIPTION AND OPERATION The speedometer, ECM, TSM/TSSM/HFSM, radio, ABS and
tachometer (if equipped) all communicate on the serial data
PART NUMBER TOOL NAME circuit. The serial data circuit is a (LGN/V) wire that runs to all
HD-48650 DIGITAL TECHNICIAN II the modules and is used to transfer data from one module to
the other. This line also runs to the DLC [91] and is used to
Serial data communication circuits are used by modules and communicate with the modules using DIGITAL TECHNICIAN
diagnostic tools to share information. II (Part No. HD-48650).

ed01820

1 3

2 9

1. Tail light connector [7]: except FLHX, FLTRX

2. Console pod [53]
3. Positive battery terminal
4. Hands-free antenna connector [209]
5. Fuel pump subharness connector [13]
6. Purge solenoid [95]
7. P&A accessory connector [4]
8. Negative battery terminal
9. ECM [78]
Figure 2-14. Electrical Connectors Under Seat

2-22 2011 Touring Diagnostics: Initial Diagnostics and Serial Data

HOME

ECM over the serial data circuit letting the ECM know to
ed03081
1 2 activate the fuel injectors. The TSSM/HFSM also controls the
security functions on the motorcycle if equipped with the factory
security system.
7 Data Link Connector (DLC)
6 See Figure 2-16. The DLC is located under the left side cover.
The DLC is used to connect the DIGITAL TECHNICIAN II (Part
No. HD-48650) to the motorcycle.
5
4
ed03111

2 3
3 1
4
1. Front HO2S [138]
2. ABS module [166] (if equipped)
3. Active exhaust [179]
4. Rear WSS [168]
5. Rear HO2S [137] 5
6. TSM/TSSM/HFSM [30]
7. HFSM antenna jumper harness [208]
Figure 2-15. Under Right Side Cover
6
1. Security siren [142]
COMPONENTS 2. Security siren (if equipped)
PART NUMBER TOOL NAME 3. Fuse block
4. Main fuse [5]
HD-48650 DIGITAL TECHNICIAN II 5. DLC [91]
6. ABS diode pack [201] (if equipped)
Electronic Control Module (ECM)
Figure 2-16. Under Left Side Cover: Except FLTRX, FLHX,
See Figure 2-14. The ECM is located under the seat. The ECM
FLHTC
monitors the sensors from the engine and fuel systems in order
to manage the fuel and spark delivery to the motorcycle which
enhances performance and driveability.
COMMUNICATION DTCS AND "BUS ER"
Speedometer and Tachometer There are several DTCs that may set due to and issue with
The speedometer and tachometer contain part of the indicator the serial data circuit. Different DTCs are set by different
and warning lamps for the motorcycle. They use the serial data modules. If a module loses communication it is not able to
circuit to receive information from the other modules to know generate a DTC. Therefore, the other modules will set DTCs
which lamps to illuminate at any given time. for that module indicating they are not able to communicate
with it.
TSM/TSSM/HFSM
See Figure 2-15. The TSM/TSSM/HFSM is located under the
Diagnostic Tips
right side cover. It monitors the turn signals switches and con- Modules must have power and be grounded in order to com-
trols the turn signals. The clutch and neutral switches are also municate. Therefore, when checking any communication DTC
inputs to the TSM/TSSM/HFSM. It uses these inputs to be sure to check the power and ground connections on the
determine when it is safe to allow the motorcycle to start. It suspected module. In some cases "Bus Er" will show on the
allows starter engagement and sends the information to the odometer.

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DTC U1016, U1040, U1064, U1097, U1255 2.3

DESCRIPTION AND OPERATION
Table 2-3. Code Description
The serial data circuit provides a means for the ECM,
speedometer, tachometer, TSM/TSSM/HFSM, radio and ABS DTC DESCRIPTION
(if equipped) to communicate their current status. When all U1016 Loss of all ECM serial data (state of
operating parameters on the serial data link are within specific- health)
ations, a state of health message is sent between the compon- U1040 Loss of ABS serial data (state of health)
ents.
U1064 Loss of TSM/TSSM/HFSM serial data
• DTC U1016 indicates that the ECM is not capable of (state of health)
sending this state of health message. It also indicates that
there was communication on the data bus since power U1097 Loss of speedometer serial data (state
up, but communication was lost or interrupted during that of health)
key cycle. U1255 Serial data error/missing message
• DTC U1040 indicates that the ABS module is not capable
of sending its state of health message.
Diagnostic Tips
The TSM/TSSM/HFSM controls the turn signals and supplies
• DTC U1064 indicates that the TSM/TSSM/HSFM is not
voltage for the turn signals to operate. A short on the turn signal
capable of sending this state of health message. It also
circuits can cause the battery fuse to open. If no short to ground
indicates that there was communication on the data bus
is found in the battery fuse circuit check the turn signal circuits
since power up, but was lost or interrupted during that key
between the TSM/TSSM/HFSM and the turn signals for a short
cycle.
to ground.
• DTC U1097 indicates the speedometer is not capable of
sending its state of health message. Connector Information
For additional information about the connectors in the following
• DTC U1255 indicates that no messages were present
diagram(s) and diagnostic procedure(s), including the color of
during power up of the current key cycle.
the harness test kit terminal probes, see B.1 CONNECTORS.
NOTE
Always start with 2.1 INITIAL DIAGNOSTICS before proceeding
with this test.

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em00701
Radio Speedometer Tachometer Speedometer

Stop Switch
Serial Data
Serial Data

Serial Data

Serial Data
Stop Switch
Engine
Ground
Ground

Battery

Ignition
Battery

Ignition

Ground

Ignition
Battery
Engine
[27A] 9 [39A] 7 5 2 1 [108A] 7 5 2 1
[39A] 7 5 2 1

BK
[27B] 9 [39B] 7 5 2 1 [108B] 7 5 2 1
[39B] 7 5 2 1

BK
[22A] 4

BN/GY

BN/GY
LGN/V

LGN/V

LGN/V
BK/GN

BK/GN
O

BK/GN

BN/GY
LGN/V
O
[22B] 4 [22A] 4

[22B]

W/BK
4

W/BK
[20A] 3 2 1

[20B] 3 2 1

[2A] 4

BN/GY
LGN/V
O
13 6 1 [1A]
[2B] 4
13 6 1 [1B]
BN/GY

W/BK
LGN/V

O
To Instruments
Fuse

Except FLHR/C To Instruments Fuse FLHR/C

To BK
Battery BN/GY To
Fuse GY GY Ignition
Fuse
To ABS To ECM Power Fuse
LGN/V

Fuse
R/V

R/V
BK

BK

BK/GN

BE/GY
LGN/V
W/BK

W/BK
BN/GY

LGN/V

BK/GN 1 9 10 11 20 [166B]
GY

1 9 10 11 20 [166A] 69 71 72 73 [78B]

LGN/V
To BK/GN
Serial Data
ECU/Solenoid Ground

Motor Ground
ECU/ Solenoid Power

Motor Power

1 2 3 12 [30B] [78A]

GY
System 69 71 72 73
1 2 3 12 [30A] Relay

12V Battery
Serial Data

Ground
Engine Stop Switch
4 3 2 [91A]
Battery

Serial Data
Ignition

Ground

DLC

TSM/TSSM/HFSM
ABS (Optional)
ECM

Figure 2-17. Serial Data Circuit

DTC U1016 1. Open Ground Test

PART NUMBER TOOL NAME 1. Connect BREAKOUT BOX (Part No. HD-48637) between
wire harness [78B] and ECM [78A]. See 1.2 DIAGNOSTIC
HD-41404-C HARNESS CONNECTOR TEST KIT TOOLS.
HD-42682 BREAKOUT BOX
2. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
HD-46601 BREAKOUT BOX ADAPTERS 41404-C) and a multimeter, test for continuity from
HD-48637 BREAKOUT BOX breakout box terminal 73 to ground.
3. Is continuity present?
Table 2-4. DTC U1016 Diagnostic Faults a. Yes. Go to Test 2.
POSSIBLE CAUSES b. No. Repair open in ground circuit.
Open ground
2. Switched Power Circuit Open Test
Open switched power
1. With IGN ON and engine stop switch in the RUN position,
ECM malfunction test for voltage at breakout box terminal 72.
Open serial data circuit

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2. Is battery voltage present? DTC U1040, U1255

a. Yes. The TSM/TSSM/HFSM is reporting the
DTC. Go to Test 3. PART NUMBER TOOL NAME
HD-42682 BREAKOUT BOX
b. Yes. The speedometer is reporting the DTC. Go
to Test 4. HD-46601 BREAKOUT BOX ADAPTERS
c. Yes. The tachometer is reporting the DTC. Go to HD-48642 ABS BREAKOUT BOX
Test 5.
d. No. Repair open in (W/BK) wire. Table 2-5. DTC U1040, U1255 Diagnostic Faults

POSSIBLE CAUSES
3. TSM/TSSM/HFSM Serial Data Circuit
Open ABS fuse
Continuity Test
Open battery circuit
1. With the IGN OFF, install BREAKOUT BOX (Part No. HD-
42682) at the TSM/TSSM/HFSM. See 1.2 DIAGNOSTIC Open ground circuit
TOOLS. Open serial data circuit
2. Using HARNESS CONNECTOR TEST KIT (Part No. HD- Short to ground in power circuit
41404-C) and a multimeter, test for continuity between ECU malfunction
TSM/TSSM/HFSM breakout box terminal 3 and ECM
breakout box terminal 69. 1. ABS Fuse Visual Test
3. Is continuity present? 1. Inspect the ABS fuse.
a. Yes. Replace ECM. See the service manual. 2. Is the ABS fuse good?
b. No. Repair open on (LGN/V) wire. a. Yes. Go to Test 2.

4. Speedometer Serial Data Circuit b. No. Go to Test 5.

Continuity Test 2. Loss of Power Test

1. Connect harness BREAKOUT BOX ADAPTERS (Part 1. Connect ABS BREAKOUT BOX (Part No. HD-48642)
No. HD-46601) to [39A] and [39B]. Attach connectors from leaving [166A] disconnected. See 1.2 DIAGNOSTIC
BREAKOUT BOX (Part No. HD-42682) to harness TOOLS.
adapters, leaving [39A] disconnected. See 1.2 DIA-
GNOSTIC TOOLS. 2. Test for voltage at breakout box terminals 10 and 20 to
ground.
2. Test for continuity between speedometer breakout box
terminal 2 and ECM breakout box terminal 69. 3. Is battery voltage present on both terminals?

3. Is continuity present? a. Yes. Go to Test 3.

a. Yes. Replace ECM. See the service manual. b. No. Repair open in (R/V) wire.

b. No. Repair open on (LGN/V) wire. 3. Loss of Ground Test

5.Tachometer Serial Data Circuit Continuity 1. Test for continuity from breakout box terminals 1 and 11
to ground.
Test
2. Is continuity present on both terminals?
1. Connect harness BREAKOUT BOX ADAPTERS (Part
No. HD-46601) to [108A] and [108B]. Attach connectors a. Yes. Go to Test 4.
from BREAKOUT BOX (Part No. HD-42682) to harness b. No. Repair open in ground circuit.
adapters, leaving [108A] disconnected. See 1.2 DIA-
GNOSTIC TOOLS.
4. Instrument Serial Data Circuit Continuity
2. Test for continuity between tachometer breakout box ter- Test
minal 2 and ECM breakout box terminal 69.
1. Connect harness BREAKOUT BOX ADAPTERS (Part
3. Is continuity present? No. HD-46601) to [39] (FLHR/C) or [108] (except FLHR/C).
a. Yes. Replace ECM. See the service manual. Attach connectors from BREAKOUT BOX (Part No. HD-
42682) to harness adapters, leaving [39A] or [108A] dis-
b. No. Repair open on (LGN/V) wire. connected. See 1.2 DIAGNOSTIC TOOLS.
2. Test for continuity between the instrument breakout box
terminal 2 and ABS breakout box terminal 9.
3. Is continuity present?
a. Yes. Replace the ECU. See the service manual.
b. No. Repair open in (LGN/V) wire.

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5. Power Circuit Short to Ground Test 3. Loss of Ignition Power Test

1. Remove the ABS fuse. 1. Test for voltage at terminal 2 of the TSM/TSSM/HFSM
breakout box.
2. Connect ABS BREAKOUT BOX (Part No. HD-48642)
leaving [166A] disconnected. See 1.2 DIAGNOSTIC 2. Is battery voltage present?
TOOLS. a. Yes. Go to Test 4.
3. Test for continuity between terminal 10 and battery neg- b. No. Repair open in (GY) wire.
ative.
4. Is continuity present? 4. Loss of Ground Test
a. Yes. Repair short to ground in (R/V) wire. 1. Turn IGN OFF.
b. No. Replace the ABS fuse and test for intermittent 2. Test for continuity to ground from TSM/TSSM/HFSM
short to ground. See 1.3 DIAGNOSTICS AND breakout box terminal 12.
TROUBLESHOOTING, Wiggle Test.
3. Is continuity present?
DTC U1064, U1255 a. Yes. The speedometer is reporting the DTC. Go
to Test 5.
PART NUMBER TOOL NAME
b. Yes. The ECM is reporting the DTC. Go to Test 7.
HD-41404-C HARNESS CONNECTOR TEST KIT
c. Yes. The tachometer is reporting the DTC. Go to
HD-42682 BREAKOUT BOX Test 8.
HD-46601 BREAKOUT BOX ADAPTERS
d. No. Repair open in ground circuit.
HD-48637 BREAKOUT BOX
5. Speedometer Serial Data Circuit
Table 2-6. DTC U1064, U1255 Diagnostic Faults Continuity Test
POSSIBLE CAUSES 1. Test for continuity between speedometer breakout box
terminal 2 and TSM/TSSM/HFSM breakout box terminal
Open battery fuse 3.
Open battery circuit
2. Is continuity present?
Open ground circuit
a. Yes. Replace the TSM/TSSM/HFSM. See the service
Open serial data circuit manual.
TSM/TSSM/HFSM malfunction b. No. Repair open on (LGN/V) wire.
Short to ground in power circuit
6. Power Circuit Short to Ground Test
1. Fuse Test 1. Disconnect the siren (if equipped).
1. Inspect battery fuse.
2. Connect BREAKOUT BOX (Part No. HD-42682) between
2. Is battery fuse good? wire harness [30B] and TSM/TSSM/HFSM [30A].
a. Yes. Go to Test 2. 3. Connect BREAKOUT BOX (Part No. HD-42682) using
b. No. Go to Test 6. BREAKOUT BOX ADAPTERS (Part No. HD-46601) to
the speedometer [39]. See 1.2 DIAGNOSTIC TOOLS.
2. Loss of Battery Power Test 4. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
1. Connect BREAKOUT BOX (Part No. HD-42682) between 41404-C) and a multimeter, test for continuity between
wire harness [30B] and TSM/TSSM/HFSM [30A]. speedometer breakout box terminal 5 to ground.

2. Connect BREAKOUT BOX (Part No. HD-42682) using 5. Is continuity present?

BREAKOUT BOX ADAPTERS (Part No. HD-46601) to
the speedometer [39]. See 1.2 DIAGNOSTIC TOOLS.
3. With IGN ON and engine stop switch in the RUN position,
use HARNESS CONNECTOR TEST KIT (Part No. HD-
41404-C) and a multimeter to test for voltage at
TSM/TSSM/HFSM breakout box terminal 1.
4. Is battery voltage present?
a. Yes. Go to Test 3.
b. No. Repair open in (BN/GY) wire.
a. Yes. Repair short to ground in (BN/GY) wire and
replace battery fuse.
b. No. See diagnostic tips. Replace battery fuse and
test for intermittent short to ground. See 1.3 DIA-
GNOSTICS AND TROUBLESHOOTING, Wiggle Test.
7. ECM Serial Data Circuit Continuity Test
1. Connect BREAKOUT BOX (Part No. HD-48637) between
wire harness [78B] and ECM [78A]. at the ECM. See
1.2 DIAGNOSTIC TOOLS.
2. Test for continuity between TSM/TSSM/HFSM breakout
box terminal 3 and ECM breakout box terminal 69.

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3. Is continuity present? 4. Is battery voltage present?

a. Yes. Replace TSM/TSSM/HFSM. See the service a. Yes. Go to Test 3.
manual.
b. No. Repair open in (BN/GY) wire.
b. No. Repair open on (LGN/V) wire.
3. Loss of Ground Test
8.Tachometer Serial Data Circuit Continuity 1. Turn IGN OFF.
Test
2. Test for continuity to ground from speedometer breakout
1. Test for continuity between tachometer breakout box ter- box terminal 7.
minal 2 and TSM/TSSM/HFSM breakout box terminal 3.
3. Is continuity present?
2. Is continuity present?
a. Yes. The TSM/TSSM/HFSM is reporting the
a. Yes. Replace the TSM/TSSM/HFSM. See the service DTC. Go to Test 4.
manual.
b. Yes. The ECM is reporting the DTC. Go to Test 6.
b. No. Repair open on (LGN/V) wire.
c. No. Repair open in ground circuit.
DTC U1097, U1255
4. Speedometer Serial Data Circuit
PART NUMBER TOOL NAME Continuity Test
HD-41404-C HARNESS CONNECTOR TEST KIT 1. Test for continuity between speedometer breakout box
HD-42682 BREAKOUT BOX terminal 2 and TSM/TSSM/HFSM breakout box terminal
HD-46601 BREAKOUT BOX ADAPTERS 3.

HD-48637 BREAKOUT BOX 2. Is continuity present?

a. Yes. Replace the speedometer. See the service
manual.
Table 2-7. DTC U1097, U1255 Diagnostic Faults
b. No. Repair open on (LGN/V) wire.
POSSIBLE CAUSES
Open battery fuse 5. Power Circuit Short to Ground Test
Open ignition circuit 1. Connect BREAKOUT BOX (Part No. HD-42682), using
Open ground circuit BREAKOUT BOX ADAPTERS (Part No. HD-46601)
between wire harness [39B] and speedometer [39A]. See
Speedometer malfunction
1.2 DIAGNOSTIC TOOLS.
Open serial data circuit
2. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
Short to ground in power circuit 41404-C) and a multimeter, test for short to ground
breakout box terminal 5.
1. Fuse Test
3. Is a short to ground present?
1. Inspect battery fuse.
a. Yes. Repair short to ground in (BN/GY) wire and
2. Is battery fuse good? replace battery fuse.
a. Yes. Go to Test 2.
b. No. Replace battery fuse and test for intermittent short
b. No. Go to Test 5. to ground. See 1.3 DIAGNOSTICS AND
TROUBLESHOOTING, Wiggle Test.
2. Loss of Power Test
6. ECM Serial Data Circuit Continuity Test
1. Connect BREAKOUT BOX (Part No. HD-42682) between
wire harness [30B] and TSM/TSSM/HFSM [30A]. 1. Connect BREAKOUT BOX (Part No. HD-48637) between
wire harness [78B] and ECM [78A]. See 1.2 DIAGNOSTIC
2. Connect BREAKOUT BOX (Part No. HD-42682) using TOOLS.
BREAKOUT BOX ADAPTERS (Part No. HD-46601) to
the speedometer [39]. See 1.2 DIAGNOSTIC TOOLS. 2. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
41404-C) and a multimeter test for continuity between
3. With IGN ON and engine stop switch in the RUN position, speedometer breakout box terminal 2 and ECM breakout
use HARNESS CONNECTOR TEST KIT (Part No. HD- box terminal 69.
41404-C) and a multimeter to test for voltage at speedo-
meter breakout box terminal 5. 3. Is continuity present?
a. Yes. Replace speedometer. See the service manual.
b. No. Repair open on (LGN/V) wire.

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DTC U1300, U1301 OR BUS ER 2.4

DESCRIPTION AND OPERATION Diagnostic Tips
The typical serial data voltage range is 0V (inactive) to 7V • If serial data is shorted, these DTCs will automatically
(active). Due to the high speed voltage fluctuations of the cause the check engine lamp to illuminate. The odometer
signal, voltages will be much lower on a multimeter. In analog will read "BUS Er" in this condition.
mode, a multimeter reading serial data will show continuous • DTCs P1009 and P1010 may accompany DTCs U1300
voltage when active, typically 0.6-0.8V. The range for accept- and U1301.
able operations is 0-7.0V.
Connector Information
Table 2-8. Code Description For additional information about the connectors in the following
DTC DESCRIPTION diagram(s) and diagnostic procedure(s), including the color of
the harness test kit terminal probes, see B.1 CONNECTORS.
U1300 Serial data open/low
U1301 Serial data high

em00701
Radio Speedometer Tachometer Speedometer

Stop Switch
Serial Data
Serial Data

Serial Data

Serial Data
Stop Switch
Engine
Ground
Ground

Battery

Ignition
Battery

Ignition

Ground

Ignition
Battery
Engine
[27A] 9 [39A] 7 5 2 1 [108A] 7 5 2 1
[39A] 7 5 2 1

BK
[27B] 9 [39B] 7 5 2 1 [108B] 7 5 2 1
[39B] 7 5 2 1

BK
[22A] 4
BN/GY

BN/GY
LGN/V

LGN/V

LGN/V
BK/GN

BK/GN
O

BK/GN

BN/GY
LGN/V
O
[22B] 4 [22A] 4

W/BK [22B] 4

W/BK
[20A] 3 2 1

[20B] 3 2 1

[2A] 4

BN/GY
LGN/V
O
13 6 1 [1A]
[2B] 4
13 6 1 [1B]
BN/GY

W/BK
LGN/V

To Instruments
Fuse

Except FLHR/C To Instruments Fuse FLHR/C

To BK
Battery BN/GY To
Fuse GY GY Ignition
Fuse
To ABS To ECM Power Fuse
LGN/V

Fuse
R/V

R/V
BK

BK

BK/GN
BE/GY
LGN/V
W/BK

W/BK
BN/GY

LGN/V

BK/GN 1 9 10 11 20 [166B]
GY

1 9 10 11 20 [166A] 69 71 72 73 [78B]
LGN/V

To BK/GN
Serial Data
ECU/Solenoid Ground

Motor Ground
ECU/ Solenoid Power

Motor Power

1 2 3 12 [30B] [78A]
GY

System 69 71 72 73
1 2 3 12 [30A] Relay
12V Battery
Serial Data

Ground
Engine Stop Switch

4 3 2 [91A]
Battery

Serial Data
Ignition

Ground

DLC

TSM/TSSM/HFSM
ABS (Optional)
ECM

Figure 2-18. Serial Data Circuit

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DTC U1300 4. Does "BUS Er" appear on odometer display?

a. Yes. Go to Test 5.
PART NUMBER TOOL NAME
b. No. Replace ECU of ABS module. See the service
HD-41404-C HARNESS CONNECTOR TEST KIT
manual.
HD-42682 BREAKOUT BOX
HD-45325 JUMPER HARNESS 5. Tachometer Test (If Vehicle is not
Equipped with Tachometer, Go to Test 6.)
Table 2-9. DTC U1300 Diagnostic Faults 1. Turn IGN OFF.

POSSIBLE CAUSES 2. Disconnect tachometer [108B].

ECM malfunction 3. Turn IGN ON.
TSM/TSSM/HFSM malfunction 4. Does "BUS Er" appear on odometer display?
ECU malfunction a. Yes. Go to Test 6.
Short to ground in serial data wire b. No. Replace the tachometer. See the service manual.
Radio malfunction
Open in serial data circuit 6. Radio Test (If Vehicle is not Equipped
Speedometer malfunction
with Radio, Go to Test 7.)
Tachometer malfunction 1. Turn IGN OFF.
2. Disconnect the radio [27B].
1. Serial Data Short to Ground Test
3. Turn IGN ON.
1. Turn IGN ON.
4. Does "BUS Er" appear on odometer display?
2. Does "BUS Er" appear on odometer display?
a. Yes. Go to Test 7.
a. Yes. Go to Test 2.
b. No. Replace the radio. See the service manual.
b. No. Go to Test 9.
7. Serial Data Short to Ground Test
2. ECM Test
1. Turn IGN OFF.
1. Turn IGN OFF.
2. Disconnect speedometer [39B].
2. Disconnect the ECM [78B].
3. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
3. Turn IGN ON. 41404-C), test for continuity from DLC [91A] terminal 3 to
4. Does "BUS Er" appear on odometer display? ground.
a. Yes. Go to Test 3. 4. Is continuity present?
b. No. Replace ECM. See the service manual. a. Yes. Repair short to ground in (LGN/V) wire.
b. No. Go to Test 8.
3. TSM/TSSM/HFSM Test
1. Turn IGN OFF. 8. Serial Data Circuit Open Test
2. Disconnect the TSM/TSSM/HFSM [30A]. 1. Connect BREAKOUT BOX (Part No. HD-42682) and
JUMPER HARNESS (Part No. HD-45325) to the wiring
3. Turn IGN ON. harness [39B] leaving the speedometer disconnected. See
4. Does "BUS Er" appear on odometer display? 1.2 DIAGNOSTIC TOOLS.
a. Yes. Go to Test 4. 2. Test for continuity from terminal 7 of breakout box to DLC
[91A] terminal 3.
b. No. Replace TSM/TSSM/HFSM. See the service
manual. 3. Is continuity present?
a. Yes. Replace speedometer. See the service manual.
4. ABS Module Test (If Vehicle is not
b. No. Repair open in (LGN/V) wire.
Equipped with ABS, Go to Test 5.)
1. Turn IGN OFF. 9. Intermittent Test
2. Disconnect ABS module [166B]. 1. Turn IGN OFF.
3. Turn IGN ON. 2. Disconnect the ECM [78B], speedometer [39B],
TSM/TSSM/HFSM [30B], tachometer [108], radio [27] and
ABS module [166B] (if equipped).

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3. Test for continuity between DLC [91A] terminal 3 and 4. ABS Module Test (If Vehicle is not
ground while performing a wiggle test. See 1.3 DIA-
GNOSTICS AND TROUBLESHOOTING, Wiggle Test.
Equipped with ABS, Go to Test 5.)
1. Turn IGN OFF.
4. Is continuity present?
a. Yes. Repair short to ground in (LGN/V) wire. 2. Disconnect the ABS module [166B].

b. No. Verify that current DTC U1300 is set. 3. Turn IGN ON.
4. Does "BUS Er" appear on odometer display?
DTC U1301 a. Yes. Go to Test 5.
PART NUMBER TOOL NAME b. No. Replace ECU of ABS module. See the service
HD-41404-C HARNESS CONNECTOR TEST KIT manual.
HD-42682 BREAKOUT BOX
5. Tachometer Test (If Vehicle is not
HD-45325 JUMPER HARNESS
Equipped with Tachometer, Go to Test 6.)
1. Turn IGN OFF.
Table 2-10. DTC U1301 Diagnostic Faults
2. Disconnect tachometer [108B].
POSSIBLE CAUSES
3. Turn IGN ON.
ECM malfunction
TSM/TSSM/HFSM malfunction 4. Does "BUS Er" appear on odometer display?

ECU malfunction a. Yes. Go to Test 6.

Short to voltage in serial data circuit b. No. Replace the tachometer. See the service manual.
Radio malfunction
6. Radio Test (If Vehicle is not Equipped
Speedometer malfunction with Radio, Go to Test 7.)
Tachometer malfunction
1. Turn IGN OFF.
1. Serial Data Short to Voltage Test 2. Disconnect the radio [27B].
1. Turn IGN ON. 3. Turn IGN ON.
2. Does "BUS Er" appear on odometer display? 4. Does "BUS Er" appear on odometer display?
a. Yes. Go to Test 2. a. Yes. Go to Test 7.
b. No. Go to Test 9. b. No. Replace the radio. See the service manual.

2. ECM Test 7. Serial Data Short to Voltage Test

1. Turn IGN OFF. 1. Turn the IGN OFF.
2. Disconnect the ECM [78B]. 2. Disconnect speedometer [39B].
3. Turn IGN ON. 3. Turn IGN ON.
4. Does "BUS Er" appear on odometer display? 4. Using the HARNESS CONNECTOR TEST KIT (Part
a. Yes. Go to Test 3. No. HD-41404-C), test for voltage from DLC [91A] terminal
3 to ground.
b. No. Replace ECM. See the service manual.
5. Is battery voltage present?
3. TSM/TSSM/HFSM Test a. Yes. Repair short to voltage in (LGN/V) wire.
1. Turn IGN OFF. b. No. Go to Test 8.
2. Disconnect the TSM/TSSM/HFSM [30B].
8. Serial Data Circuit Open Test
3. Turn IGN ON.
1. Turn IGN OFF.
4. Does "BUS Er" appear on odometer display?
2. Connect BREAKOUT BOX (Part No. HD-42682) and
a. Yes. Go to Test 4. JUMPER HARNESS (Part No. HD-45325) to the wiring
b. No. Replace TSM/TSSM/HFSM. See the service harness [39B] leaving the speedometer disconnected. See
manual. 1.2 DIAGNOSTIC TOOLS.
3. Test for continuity from breakout box terminal 7 to DLC
[91A] terminal 3.

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4. Is continuity present? 3. Turn IGN ON.

a. Yes. Replace speedometer. See the service manual. 4. Test for voltage between DLC [91A] terminal 3 and ground
b. No. Repair open in (LGN/V) wire. while performing a wiggle test. See 1.3 DIAGNOSTICS
AND TROUBLESHOOTING, Wiggle Test.
9. Intermittent Test 5. Is voltage present?
1. Turn IGN OFF. a. Yes. Repair short to voltage in (LGN/V) wire.
2. Disconnect the ECM [78B], speedometer [39B], b. No. Verify that current DTC U1301 is set.
TSM/TSSM/HFSM [30B], tachometer [108], radio [27] and
ABS module [166B] (if equipped).

2-32 2011 Touring Diagnostics: Initial Diagnostics and Serial Data

TABLE OF CONTENTS

SUBJECT............................................................................................................................PAGE NO.
3.1 BATTERY TESTING..................................................................................................................3-1
3.2 STARTING SYSTEM.................................................................................................................3-3
3.3 TESTING STARTER ON MOTORCYCLE...............................................................................3-13
3.4 TESTING STARTER ON BENCH............................................................................................3-14
3.5 CHARGING SYSTEM.............................................................................................................3-16
3.6 DTC B0563, P0562, P0563.....................................................................................................3-22
3.7 DTC B1006, B1007.................................................................................................................3-27

STARTING AND CHARGING

NOTES
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BATTERY TESTING 3.1

GENERAL
Three different procedures may be performed to provide a
good indication of battery condition: a voltage test, a conduct-
ance test or a load test.
A battery may be tested, whether fully charged or not, using a
conductance test. In order to perform a load test, however, the
battery must be fully charged.
VOLTMETER TEST
The voltmeter test provides a general indication of battery state
of charge or condition. Check the voltage of the battery to verify
that it is in a 100% fully charged condition. Refer to Table 3-1.
If the open circuit (disconnected) voltage reading is below
12.6V, charge the battery and then recheck the voltage after
the battery has set for one to two hours. If the voltage reading
is 12.7V or above, perform a load test. See 3.1 BATTERY
TESTING, Load Test.
disconnecting the battery cables from the battery, retest the
battery using the out-of-vehicle test before replacing.
• GOOD BATTERY - Return the battery to service.
• GOOD-RECHARGE - Fully charge the battery and return
to service.
• CHARGE & RETEST - Fully charge the battery and then
check the voltage after the battery has set for one to two
hours, and retest. If battery fails retest, replace battery.
• REPLACE BATTERY - Replace the battery.
• BAD CELL-REPLACE - Replace the battery.
• BATTERY NOISE - Remove surface charge from battery
and retest.
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Table 3-1. Voltmeter Test For Battery Charge Conditions

VOLTAGE STATE OF CHARGE

12.7 100%
12.6 75%
12.3 50%
12.0 25%
11.8 0%

CONDUCTANCE TEST
PART NUMBER TOOL NAME Figure 3-1. Battery Test Results Printout
HD-48053 ADVANCED BATTERY CONDUCT-
ANCE AND ELECTRICAL SYSTEM
ANALYZER LOAD TEST
Test the battery using the ADVANCED BATTERY CONDUCT-
ANCE AND ELECTRICAL SYSTEM ANALYZER (Part No. HD-
48053). Perform a battery test as follows: Disconnect negative (-) battery cable first. If positive (+)
1. Connect the analyzer leads to the vehicle battery terminal, cable should contact ground with negative (-) cable con-
not to the bolt or wire terminal. nected, the resulting sparks can cause a battery explosion,
which could result in death or serious injury. (00049a)
NOTE
Connecting the analyzer to the bolt or wire terminal may not 1. With vehicle battery on a bench, charge the battery.
give an accurate reading of battery condition. NOTE
2. Follow the instructions in the analyzer instruction manual Always fully charge the battery before testing or test readings
to perform a battery test. will be incorrect. Load testing a discharged battery can also
result in permanent battery damage.
The test results will include a decision on the battery condition
and the measured state of charge.
See Figure 3-1. The analyzer printer will provide a printout
including the possible test results: Turn battery load tester OFF before connecting tester
cables to battery terminals. Connecting tester cables with
NOTE load tester ON can cause a spark and battery explosion,
A REPLACE BATTERY test result may also mean a poor which could result in death or serious injury. (00252a)
connection between the battery cables and the vehicle. After
2. See Figure 3-2. Connect tester leads to battery posts and
place induction pickup over negative (black) cable.

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NOTE
ed02812
To avoid load tester and/or battery damage, do not leave the VOLTS
load tester switch turned ON for more than 20 seconds.
AMPS
3. Load battery at 50% of CCA rating using the load tester.
Voltage reading after 15 seconds should be 9.6V or more 1
at 70 °F (21 °C). Refer to Table 3-2.

Turn battery load tester OFF before disconnecting tester

cables to battery terminals. Disconnecting tester cables
with load tester ON can cause a spark and battery explo-
sion, which could result in death or serious injury. (00253a)
2

Connect positive (+) battery cable first. If positive (+) cable

should contact ground with negative (-) cable connected, 3
the resulting sparks can cause a battery explosion, which
could result in death or serious injury. (00068a)

Do not over-tighten bolts on battery terminals. Use 1. Load tester

recommended torque values. Over-tightening battery ter- 2. Induction pickup
minal bolts could result in damage to battery terminals. 3. Battery
(00216a) Figure 3-2. Load Test Battery

Table 3-2. Battery Load Test

COLD CRANKING 100% 50%

AMPERAGE (CCA)
Touring models 405 200

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STARTING SYSTEM 3.2

DESCRIPTION AND OPERATION
ed03124
With IGN ON, battery voltage is supplied to the start relay and
ignition fuse. The ignition fuse supplies battery voltage to the
engine stop switch and TSM/TSSM/HFSM.
With engine stop switch to RUN, battery voltage is supplied to 1 2
the start switch and the ECM.The TSM/TSSM/HFSM monitors
the clutch switch, neutral switch and the state of the security
system. If the security system is not armed and either the clutch
lever is pulled in or the motorcycle is in neutral, the
TSM/TSSM/HFSM provides ground to the start relay coil.
When the start switch is pressed, power flows to the coil side
of the start relay. The TSM/TSSM/HFSM supplies the ground
to the start relay, energizing the start relay. This allows battery
voltage from the ignition switch to flow through the start relay
to the starter solenoid. This energizes the solenoid and full
battery power is sent to the starter.

COMPONENTS 3

Starter
The starter receives power from the battery through the starter
solenoid and is grounded through the starter case. When the
starter solenoid is energized, two actions happen: 1. Starter
• The plunger pulls inward which allows current to flow to 2. Starter solenoid [128]
the starter motor. 3. Neutral switch [131]

• The pinion gear engages with the ring gear on the clutch
shell.
With the starter motor turning, the rotation is transferred to the
following:
• The starter armature gear transfers rotation to the idler
gear.
• The idler gear transfers rotation to the starter clutch.
• The starter clutch transfers rotation through a spline gear
to the starter drive shaft which also drives the pinion gear.
• The pinion gear transfers its rotation to the ring gear on
the clutch shell.
• The primary chain drives the alternator rotor sprocket on
the end of the crankshaft.
The starter clutch is equipped with one way clutch so when
the engine starts, it allows the clutch shell and sprocket to spin
freely without causing any damage to the starter motor. After
the engine starts and the start switch is released, the plunger
returns to its normal position, disengaging the pinion gear from
the clutch shell and sprocket.
Figure 3-3. Starter Solenoid [128]
Starter Solenoid
See Figure 3-3. The starter solenoid provides power to the
starter. The solenoid is a means of controlling a high amperage
device with a low amperage switch. The low amperage switch
in this circuit is the start relay. When the start relay is activated
it sends voltage to the starter solenoid making a magnetic field
that pulls a larger circuit closed, allowing voltage to the starter.
Engine Stop Switch
The engine stop switch is located on the right hand controls.
With the engine stop switch in the RUN position, battery voltage
is supplied to the start switch and the ECM.
Start Switch
The start switch is a push button switch located in the right
hand controls. When the start switch is pressed, power flows
to the coil side of the start relay.
Start Relay
The start relay is located in the fuse block under the left side
cover. Power is supplied to the coil side of the start relay when
the start switch is pressed. The TSM/TSSM/HFSM controls
the ground to the coil side of the relay. When the relay is
energized, it supplies power from the ignition switch to the
starter solenoid.

Ignition Switch
The ignition switch turns the electrical power to the vehicle on
and/or off. The ignition switch has three positions. In the OFF

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position, the ignition switch turns off all power to the vehicle
except for the components powered directly by the battery.
When the ignition switch is in the ACC position it allows power
to flow through the ACCY fuse and supplies power to only
certain parts of the vehicle such as the lights. In the ON or IGN
position the ignition switch supplies power for all the systems
on the vehicle.
Battery
Batteries contain sulfuric acid, which could cause severe
burns to eyes and skin. Wear a protective face shield,
rubberized gloves and protective clothing when working
with batteries. KEEP BATTERIES AWAY FROM CHILDREN.
(00063a)
Never remove warning label attached to top of battery.
Failure to read and understand all precautions contained
in warning, could result in death or serious injury. (00064a)
Explosive hydrogen gas, which escapes during charging,
could cause death or serious injury. Charge battery in a
well-ventilated area. Keep open flames, electrical sparks
and smoking materials away from battery at all times.
KEEP BATTERIES AWAY FROM CHILDREN. (00065a)
If battery becomes hot, gassing or spewing of electrolyte
can occur, which could cause death or serious injury.
Unplug or turn OFF the charger until battery cools.
(00412b)
Batteries, battery posts, terminals and related accessories
contain lead and lead compounds, and other chemicals
known to the State of California to cause cancer, and birth
defects or other reproductive harm. Wash hands after
handling. (00019e)
3-4 2011 Touring Diagnostics: Starting and Charging
If battery releases an excessive amount of gas during
charging, decrease the charging rate. Overheating can
result in plate distortion, internal shorting, drying out or
damage. (00413b)
The AGM batteries are permanently sealed, maintenance-free,
valve-regulated, lead/calcium and sulfuric acid batteries.
The battery is recharged by the alternator and kept from over-
charging by the regulator during use.
Battery condition can be determined by a voltage test, a con-
ductance test or a load test. See 3.1 BATTERY TESTING.
A battery may be tested, whether fully charged or not, using
the conductance test. However, the battery must be fully
charged to perform a load test.
Grinding Noise Or Erratic Starting
1. Remove starter. See the service manual.
2. Inspect the starter mounting surface and mating area on
inner primary for arcing and pitting. This condition is
caused by insufficient ground and or clamp load.
3. Clean mating surfaces.
4. Inspect starter pinion gear. Replace starter clutch
assembly if damaged (cracked or missing teeth). Rounding
of pinion gear teeth is considered normal. If pinion gear
needs to be replaced, inspect ring gear on clutch. Replace
clutch ring gear if damaged. See the service manual.
5. Install starter. See the service manual.
Job/Time Code Values
Dealership Technicians filing warranty claims should use the
job/time code values printed in (bold text) beside the appro-
priate repair.
Connector Information
For additional information about the connectors in the following
diagram(s) and diagnostic procedure(s), including the color of
the harness test kit terminal probes, see B.1 CONNECTORS.
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em00691 BK BK

Right
Hand Controls Red Battery
Band Ground
Battery

Right Turn Switch

BK
Engine Stop Switch

R
Start Switch 1
Front Stop Lamp Switch
[128B]
GN

W/BK
BK/R

GY
6 4 3 [22A]
Starter
6 4 3 [22B] 2

W/BK
GY
BK/R
Ignition Switch

IGN IGN
ACC ACC

OFF OFF

[33A] B+ ACC IGN B+ ACC IGN [33A]

[33B]
W/BK

2 1 3 B C A [33B]
GY

R/GY

R/BK

R/GY

R/BK
R
R
Except [1A] 6 3
FLHR/C [1B] 6 3 B C A [222A]
B C A [222B]
W/BK

GY

[78A] [78B]

R/GY

R/BK
ECM

R
Switch Power 72 72 W/BK

All Except FLHR/C

FLHR/C

R/GY

R/BK
R
[131B] IGN 15A
TN
BK

GY 1F 1E R/BK
[131A]
BK

[64-2B]
Neutral
Switch
Battery 15A
BN/GY 2D 2C R
Left Main Fuse
GND 1 40A

TSM/TSSM/HFSM [30A] [30B] Start Relay

GN 4G 5 87 [5B]
Battery 1 1 BN/GY R/GY 3H 3 30
Ignition 2 2 GY B A
TN/GN 3G 1 86
BK/R 4H 2 85
Neutral Switch 4 4 TN
R

[64-1B]
Start Relay Control 9 9 TN/GN
Except
Clutch Switch 10 10 BK/R
BK/R 2 2 BK/R FLHR/C
Ground 12 12 BK/GN
BK/R 11 11 BK/R BK/R 7 7 BK/R
BK/GN 12 12 BK/GN BK/GN 12 12 BK
BK/R
Receive Antenna 1 Clutch Switch
BK
Transmit Antenna A 2 [2B] [2A]
Transmit Antenna B 3 [24B] [24A]
Except
BK/GN

FLHRC BK/R 7 7 BK/R

HFSM ONLY [208A] BK/GN 8 8 BK

Left Hand
[24B] [24A] Controls
Right FLHR/C
GND 2

Figure 3-4. Starting Circuit

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STARTER TROUBLESHOOTING gnose starting system problems. The 1.3 DIAGNOSTICS AND
TROUBLESHOOTING, Voltage Drop procedure will help you
The troubleshooting tables contain detailed procedures to solve to locate poor connections or components with excessive
and correct problems. Follow 3.2 STARTING SYSTEM to dia- voltage drops.

Table 3-3. Starter Does Not Run or Runs at Very Low Speeds

SOURCE OF PROBLEM POSSIBLE CAUSE SOLUTION

Battery Voltage drop due to discharged battery. Charge battery.
Short-circuit or open between electrodes. Replace battery.
Poor contact condition of battery ter- Clean and retighten.
minal(s).
Wiring Poor or no connection at either end of the Repair or replace cable(s).
battery positive or negative cable.
Cracked or corroded battery cable ends. Clean, tighten or replace cable(s) as
needed.
Open wire(s) or poor connection at Tighten connections or repair or replace
handlebar switch or start relay, especially wire(s).
relay ground wire (grounds through
TSM/TSSM/HFSM).
Start switch, clutch switch, engine stop Poor switch contacts or open switch. Replace switch.
switch or neutral switch
Start relay Open coil winding. Replace relay.
Poor or no continuity at relay points. Replace relay.
TSM/TSSM/HFSM has disabled start Disarm security system inspect for neutral
relay. or clutch circuit issue.
Starter solenoid Poor contact condition caused by burned Replace solenoid assembly.
contacts.
Windings open or short-circuited. Replace solenoid assembly.
Starter motor Brushes worn below specification. Replace starter.
Commutator burnt. Replace starter.
Commutator high mica. Replace starter.
Field winding grounded. Replace starter.
Armature winding grounded or short-cir- Replace starter.
cuited.
Free running current draw out of range. Replace starter.
Insufficient brush spring tension. Replace starter.
Starter clutch Starter clutch failure. Replace starter clutch assembly.

Table 3-4. Starter Spins But Does Not Engage

SOURCE OF PROBLEM POSSIBLE CAUSE SOLUTION

Battery Voltage drop due to discharged battery. Charge battery.
Short-circuit or open between electrodes. Replace battery.
Poor contact condition of battery ter- Clean and retighten.
minal(s).
Starter motor Pinion gear teeth worn out. Replace starter clutch assembly.
Gear teeth on clutch shell and sprocket. Excessively worn teeth. Replace clutch shell and sprocket.
Starter clutch Starter clutch failure. Replace starter clutch assembly.

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Table 3-5. Starter Does Not Stop Running

SOURCE OF PROBLEM POSSIBLE CAUSE SOLUTION

Start switch or start relay Unopened contacts. Replace start switch or start relay.
Poor return caused by sticky switch or Replace start switch or start relay.
relay contacts.
Starter solenoid Coil shorted. Replace starter solenoid assembly.
Contact plate melted and stuck. Replace starter solenoid assembly.

STARTER TESTING 4. Start Switch Circuit Test

PART NUMBER TOOL NAME 1. Turn IGN OFF, remove start relay.

HD-41404-C HARNESS CONNECTOR TEST KIT 2. Turn IGN ON. Using HARNESS CONNECTOR TEST
KIT (Part No. HD-41404-C) test for voltage at fuse block
[64-1B] socket terminal 4H (BK/R) wire.
Table 3-6. Starter Testing Diagnostic Faults
3. Is battery voltage present?
POSSIBLE CAUSES
a. Yes. Go to Test 5.
Short to voltage at starter solenoid
b. No. Go to Test 7.
Start switch malfunction
Short to voltage on start relay supply circuit 5. Start Switch Circuit Short to Voltage Test
Start relay malfunction 1. Turn IGN OFF, disconnect right hand controls [22].

1. Starting System Operational Test 2. Turn IGN ON, test for voltage at [22B] terminal 6.

1. With IGN ON, transmission in neutral and the engine stop 3. Is voltage present?
switch in the RUN position, press the start switch. a. Yes. Except FLHR/C. Go to Test 6.
2. Does the starter spin? b. Yes. FLHR/C. Repair short to voltage between [22B]
a. Yes. Starter spins, but does not engage. See terminal 6 and [64-1B] socket terminal 4H (BK/R) wire.
3.2 STARTING SYSTEM, Starter Spins But Does Not c. No. Go to Test 8.
Engage.
b. Yes. Starter stalls or spins too slowly. See 6. Start Switch Circuit Short to Voltage [2B]
3.2 STARTING SYSTEM, Starter Stalls or Spins Too Test
Slowly.
1. Turn IGN OFF, disconnect interconnect harness [2].
c. Yes. Starter runs on. Go to Test 3.
2. Turn IGN ON, test for voltage at [2B] terminal 2.
d. No. Go to Test 2.
3. Is voltage present?
2. Audible Noise Test a. Yes. Repair short to voltage between [2B] terminal 2
and [22B] terminal 6 (BK/R) wire. (5041)
1. While listening for audible clicking noises from the start
relay and starter solenoid, press the start switch. b. No. Go to Test 7.
2. Is there a click?
7. Start Switch Circuit Short to Voltage [2A]
a. Yes. Start solenoid clicks. See 3.2 STARTING
SYSTEM, Starter Solenoid Clicks.
Test
1. Test for voltage at [2A] terminal 2.
b. Yes. Start relay clicks. See 3.2 STARTING
SYSTEM, Start Relay Clicks. 2. Is voltage present?

c. No. See 3.2 STARTING SYSTEM, Nothing Clicks. a. Yes. Repair short to voltage between [2A] terminal 2
and [64-1B] socket terminal 4H (BK/R) wire. (5041)
3. Starter Solenoid Test b. No. Go to Test 8.
1. Disconnect starter solenoid [128].
8. Start Switch Test
2. Does starter stop?
1. Test for continuity between [22A] terminal 4 (W/BK) wire
a. Yes. Go to Test 4. and terminal 6 (BK/R) wire.
b. No. Replace starter solenoid assembly. (5845)

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2. Is continuity present? 2. Is battery condition good?

a. Yes. Replace start switch. See the service manual. a. Yes. Go to Test 2.
(5818)
b. No. Charge or replace battery as needed, attempt to
b. No. Repair short to voltage on [22A] terminal 6 (BK/R) start engine, if nothing clicks continue with tests. Go
wire. (5041) to Test 2.

9. Start Relay Test 2. Fuse Test

1. Perform relay test. See 1.3 DIAGNOSTICS AND 1. Verify that all fuses including main fuse are good.
TROUBLESHOOTING, Relay Diagnostics.
2. Are all fuses good?
2. Is the start relay good? a. Yes. Go to Test 3.
a. Yes. Perform wiggle test to locate short to voltage
b. No. Replace fuse and repair circuit accordingly. If
between [64-1B] socket terminals 4G (GN) wire or
problem is still present, continue with tests. Go to
3H (R/GY) wire. See 1.3 DIAGNOSTICS AND
Test 3.
TROUBLESHOOTING, Wiggle Test. (5041)
b. No. Replace start relay. (5832) 3. Ignition Circuit Test
1. With IGN ON, verify that ignition circuit is working properly.
NOTHING CLICKS
2. Do lights illuminate?
PART NUMBER TOOL NAME
a. Yes. Go to Test 6.
HD-41404-C HARNESS CONNECTOR TEST KIT
b. No. Go to Test 4.
HD-42682 BREAKOUT BOX
4. Ignition Switch Supply Voltage Test
Table 3-7. Nothing Clicks Diagnostic Faults 1. With IGN OFF, disconnect ignition switch [33].
POSSIBLE CAUSES 2. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
Low battery 41404-C) and multimeter, test for battery voltage at ignition
switch [33B] terminal 2 on all vehicles except for FLHR/C
Open fuse
and terminal B on FLHR/C (R) wire.
Open ignition switch feed circuit
3. Is battery voltage present?
Start switch malfunction
a. Yes. Go to Test 6.
Start relay malfunction
b. No. Except FLHR/C. Repair open between ignition
TSM/TSSM/HFSM malfunction switch [33B] terminal 2 and main fuse [5B] terminal
Ignition switch malfunction B (R) wire. (5041)
Open ignition circuit c. No. FLHR/C. Go to Test 5.
Open start switch circuit
5. Ignition Switch to [222] Test
Neutral switch malfunction
1. Disconnect console ignition switch [222].
Open neutral circuit
Clutch switch malfunction 2. Test for continuity between ignition switch [33B] terminal
B and [222A] terminal B.
Open clutch switch circuit
3. Is continuity present?
Engine stop switch malfunction
a. Yes. Repair open in (R) wire from [222B] terminal B
Open ignition circuit and [64-1B] socket terminal 2C.
Open security circuit
b. No. Repair open in (R) wire from [222A] terminal B
and ignition switch [33B] terminals B.
NOTE
Verify that vehicle is in neutral and that the key fob is present 6. Ignition Switch Test
and in working order (if security equipped) and that the engine
1. With IGN ON, test for continuity between ignition switch
stop switch is in RUN position.
[33A] terminals B+ and IGN.
1. Battery Test
1. Verify battery condition. See 3.1 BATTERY TESTING.

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2. Is continuity present? 3. Is continuity present?

a. Yes. On all vehicles except for FLHR/C, repair open a. Yes. Repair open between [2B] terminal 2 and [22B]
in (R/BK) wire from [33B] terminal 3. (5041) terminal 6 (BK/R) wire. (5041)
b. No. Except FLHR/C. Replace ignition switch. See b. No. Go to Test 13.
the service manual. (7287)
c. No. FLHR/C. Go to Test 7.
12. Start Switch Circuit Continuity [2A] Test
1. Test for continuity between [2A] terminal 2 and [64-1B]
7. Ignition Switch to [222] Continuity Test socket terminal 4H (BK/R) wire.
1. Test for continuity between ignition switch [33B] terminal 2. Is continuity present?
A and [222A] terminal A. a. Yes. Go to Test 8.
2. Is continuity present? b. No. Repair open between [2A] terminal 2 and [64-1B]
a. Yes. Repair open in (R/BK) wire from [222B] terminal socket terminal 4H (BK/R) wire. (5041)
B and [64-2B] socket terminal 1E.
b. No. Repair open in (R/BK) wire from [222A] terminal
13. Start Relay Control Circuit Test
B and ignition switch [33B] terminals B. 1. Test for continuity between [64-1B] socket terminal 3G
(TN/GN) wire and ground.
8. Start Switch Circuit Voltage Test 2. Is continuity present?
1. With IGN OFF, remove start relay. a. Yes. Replace start relay. See the service manual. If
2. Turn IGN ON. problem is still present, see 3.2 STARTING SYSTEM,
Start Relay Clicks. (5832)
3. While pressing the start switch, using HARNESS CON-
NECTOR TEST KIT (Part No. HD-41404-C) and a multi- b. No. Go to Test 14.
meter, test for battery voltage at [64-1B] socket terminal
4H (BK/R) wire. 14. Start Relay Control Circuit Open Test
4. Is battery voltage present? 1. Connect BREAKOUT BOX (Part No. HD-42682) between
wire harness [30B] and TSM/TSSM/HFSM [30A]. See
a. Yes. Go to Test 11. 1.2 DIAGNOSTIC TOOLS.
b. No. Go to Test 9. 2. Test for continuity between [64-1B] socket terminal 3G
and breakout box terminal 9 (TN/GN) wire.
9. Start Switch Test
3. Is continuity present?
1. Turn IGN OFF and disconnect right hand controls [22].
a. Yes. Go to Test 15.
2. With the start switch pressed, test for continuity between
[22A] terminals 6 (BK/R) wire and 4 (W/B) wire. b. No, without anti-theft tracking module. Repair open
between [64-1B] socket terminal 3G and
3. Is continuity present? TSM/TSSM/HFSM [30B] terminal 9 (TN/GN) wire.
a. Yes. Go to Test 10. (5041)

b. No. Replace the start switch. See the service manual. c. No, with anti-theft tracking module. Go to Test 20.
(5818)
15. TSM/TSSM/HFSM Ground Test
10. Start Switch Circuit Continuity Test 1. Test for continuity between breakout box terminal 12 (BK)
1. Test for continuity between [22B] terminal 6 and [64-1B] wire and ground.
socket terminal 4H (BK/R) wire.
2. Is continuity present?
2. Is continuity present? a. Yes. Go to Test 16.
a. Yes. Go to Test 19.
b. No. Repair open between TSM/TSSM/HFSM [30B]
b. No. Except FLHR/C. Go to Test 11. terminal 12 and right GND 2 (BK/GN) wire. (5041)

c. No. FLHR/C. Repair (BK/R) wire between [22B] ter- 16. Continuity at Neutral Switch Test
minal 6 and [64-1B] socket terminal 4H.
1. Verify that transmission is in neutral.
11. Start Switch Circuit Continuity [2B] Test 2. Measure for resistance between breakout box terminal 4
1. Disconnect interconnect harness [2]. (TN) wire and ground.

2. Test for continuity between [2B] terminal 2 and [22B] ter- 3. Is resistance less than 10 Ohms?
minal 6. a. Yes. Go to Test 18.
b. No. Go to Test 17.

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17. Neutral Switch Ground Circuit Test START RELAY CLICKS

1. Test for continuity between neutral switch [131] (BK) wire PART NUMBER TOOL NAME
and ground.
HD-41404-C HARNESS CONNECTOR TEST KIT
2. Is continuity present?
a. Yes. Replace neutral switch. See the service manual. Table 3-8. Start Relay Clicks Diagnostic Faults
(5157)
POSSIBLE CAUSES
b. No. Repair open between neutral switch [131] and
GND 1 (BK) wire. (5041) Low battery
Starter solenoid malfunction
18. Start Relay Coil Control Circuit Short to Open starter solenoid control circuit
Voltage Test
Open starter solenoid ground circuit
1. Turn IGN ON.
2. Test for battery voltage on breakout box terminal 9.
1. Battery Test
1. Verify battery condition. See 3.1 BATTERY TESTING.
3. Is battery voltage present?
a. Yes. Repair short to voltage between 2. Is battery condition good?
TSM/TSSM/HFSM [30B] terminal 9 and [64-1B] a. Yes. Go to Test 2.
socket terminal 3G on (TN/GN) wire. (5041)
b. No. Charge or replace battery as needed, attempt to
b. No. Replace TSM/TSSM/HFSM. See the service start engine, if start relay continues to click and starter
manual. (5838) does not engage. Go to Test 2.

19. Engine Stop Switch Voltage Test 2. Starter Solenoid Control Coil Voltage Test
1. Test for voltage between [22B] terminal 3 and ground. 1. With IGN OFF, disconnect starter solenoid [128].
2. Is battery voltage present? 2. Turn IGN ON.
a. Yes. Replace engine stop switch. See the service 3. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
manual. 41404-C) and a multimeter, test for battery voltage on
b. No. Repair open between ignition fuse and [22B] (GY) [128B] terminal 1 (GN) wire.
wire. 4. Is battery voltage present when start switch is pressed?
a. Yes. Replace starter solenoid assembly. See the
20. Relay Enable Circuit Continuity Test service manual. (5845)
1. Disconnect the anti-theft tracking module.
b. No. Go to Test 3.
2. Test for continuity between [64-1B] socket terminal 3G
and anti-theft tracking module [266B] terminal C (TN/GN) 3. Starter Solenoid Control Coil Continuity
wire. Test
3. Is continuity present? 1. Turn IGN OFF and remove start relay.
a. Yes. Go to Test 21.
2. Test for continuity between [128B] terminal 1 and fuse
b. No. Repair open in (TN/GN) wire. (5041) block [64-1B] socket terminal 4G (GN) wire.
3. Is continuity present?
21. Anti-Theft Tracking Module Test
a. Yes. See 1.3 DIAGNOSTICS AND
1. Test for continuity between breakout box terminal 9 and TROUBLESHOOTING, Relay Diagnostics. If relay
anti-theft tracking module [266B] terminal D (TN/GN) wire. tests good, continue with tests. Go to Test 4.
2. Is continuity present? b. No. Repair open between [128B] terminal 1 and [64-
a. Yes. Replace the anti-theft tracking module. See the 1B] socket terminal 4G (GN) wire. (5041)
service manual. (6756)
b. No. Repair open in (GN) wire. (5041)
4. Start Solenoid Wiring Inspection Test
1. Inspect for corrosion or damage to the wiring from [128A]
to starter solenoid.
2. Are there any problems?
a. Yes. Repair damage or replace starter solenoid
assembly. See the service manual. If problem is still
present, then continue with tests. Go to Test 5. (5845)
b. No. Go to Test 5.

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5. Starter Solenoid Test 2. Is voltage drop greater than 1.0V?

1. With IGN ON, press the start switch. a. Yes. Repair or replace (BK) wire from starter solenoid
terminal 1 to battery (+) terminal. (5041)
2. Does starter solenoid click?
b. No. Replace starter solenoid assembly. See the ser-
a. Yes. See 3.2 STARTING SYSTEM, Starter Solenoid vice manual. (5845)
Clicks.
b. No. Repair open in [64-1B] socket terminal 3H (R/BK) 5. Starter Ground Circuit Voltage Drop Test
wire. 1. Perform voltage drop test from battery (-) terminal to
ground.
STARTER SOLENOID CLICKS
2. Is voltage drop greater than 1.0V?
Table 3-9. Starter Solenoid Clicks Diagnostic Faults a. Yes. Inspect (BK) wire for damage from battery (-)
terminal to chassis ground, repair or replace if
POSSIBLE CAUSES necessary. Go to Test 6.
Low battery b. No. Go to Test 7.
Starter malfunction
Starter solenoid malfunction
6. Starter Ground Test
1. Remove starter attaching bolts. See the service manual.
Open battery cable
Open starter cable 2. Clean bolts and starter base, install starter bolts.
Mechanical binding 3. Does engine crank?
a. Yes. Engine cranks at normal speed. Repair com-
1. Battery Test plete.
1. Verify battery condition. See 3.1 BATTERY TESTING. b. Yes. Engine cranks, but at a slower speed. See
2. Is battery condition good? 3.3 TESTING STARTER ON MOTORCYCLE, Starter
Current Draw Test.
a. Yes. Go to Test 2.
c. No. Replace starter. See the service manual. (5817)
b. No. Charge or replace battery as needed. Attempt to
start engine. If starter solenoid continues to click and
starter does not engage, then continue with tests. Go
7. Starter Draw Test
to Test 2. 1. Perform Starter Current Draw Test on motorcycle. See
3.3 TESTING STARTER ON MOTORCYCLE, Starter
2. Starter Voltage Drop Test Current Draw Test.
1. Perform voltage drop tests from battery (+) to starter stud 2. Perform Starter Motor Free Running Current Draw Test
on starter (BK) wire. See 1.3 DIAGNOSTICS AND (on bench). See 3.4 TESTING STARTER ON BENCH,
TROUBLESHOOTING, Voltage Drop. Free Running Current Draw Test.
2. Is voltage drop greater than 1.0V? 3. Are test results within range?
a. Yes. Go to Test 3. a. Yes. Go to Test 8.
b. No. Go to Test 5. b. No. Replace starter. See the service manual. (5817)

3. Starter Solenoid Voltage Drop Starter Side 8. Mechanical Binding Test

Test 1. Remove spark plugs and place transmission in 5th gear.
1. Perform voltage drop test from battery (+) terminal to 2. Raise vehicle.
starter solenoid terminal 2 (BK) wire.
3. Rotate rear wheel.
2. Is voltage drop greater than 1.0V?
4. Check for engine binding in the primary and/or crankshaft
a. Yes. Go to Test 4.
or starter clutch.
b. No. Replace starter solenoid assembly. See the ser-
5. Is engine binding? See the service manual.
vice manual. (5845)
a. Yes. Repair as needed. (Use appropriate code).
4. Starter Solenoid Battery Side Voltage b. No. Replace starter solenoid assembly. (5845)
Drop Test
1. Perform voltage drop test from battery (+) terminal to
starter solenoid terminal 1 (BK) wire.

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STARTER SPINS BUT DOES NOT ENGAGE 2. Is voltage drop greater than 1.0V?
a. Yes. Go to Test 5.
Table 3-10. Starter Spins But Does Not Engage Diagnostic b. No. Go to Test 3.
Faults

POSSIBLE CAUSES 3. Starter Ground Circuit Voltage Drop Test

Clutch assembly 1. Perform voltage drop test between battery (-) terminal and
starter attaching bolts.
Clutch shell and sprocket
2. Is voltage drop greater than 1.0V?
1. Pinion Gear and Clutch Shell Test a. Yes. Clean ground connections. (5041)
1. Remove primary cover. b. No. Go to Test 4.
2. Inspect for damage to starter pinion gear and clutch shell
and sprocket. 4. Starter Draw Test
3. Is damage present? 1. Perform Starter Current Draw Test on motorcycle. See
3.3 TESTING STARTER ON MOTORCYCLE, Starter
a. Yes. Replace the clutch assembly or clutch shell and Current Draw Test.
sprocket. See the service manual. (5825)
2. Perform Starter Motor Free Running Current Draw Test
b. No. Replace the clutch assembly. See the service (on bench). See 3.4 TESTING STARTER ON BENCH,
manual. (5837) Free Running Current Draw Test.
STARTER STALLS OR SPINS TOO SLOWLY 3. Are test results within range?
a. Yes. With the spark plugs removed and the transmis-
Table 3-11. Starter Stalls or Spins Too Slowly Diagnostic sion in 5th gear, rotate rear wheel. Check for engine,
Faults primary and/or crankshaft bind. (Use appropriate
code)
POSSIBLE CAUSES
b. No. Replace starter. See the service manual. (5817)
Low battery
Starter malfunction 5. Starter Solenoid Voltage Drop Starter Side
Starter solenoid malfunction Test
Poor connections at starter ground 1. Perform voltage drop test between battery (+) terminal to
Open battery cable starter solenoid terminal 2.

Open starter cable 2. Is voltage drop greater than 1.0V?

a. Yes. Go to Test 6.
1. Battery Test
b. No. Repair connection or (BK) wire between starter
1. Verify battery condition. See 3.1 BATTERY TESTING. solenoid and starter. (5041)
2. Is battery condition good?
a. Yes. Go to Test 2.
6. Starter Solenoid Battery Side Voltage
Drop Test
b. No. Charge or replace battery as needed. If symptom
is still present, then continue with tests. Go to Test 1. Perform voltage drop test between battery (+) terminal
2. and starter solenoid terminal 1 (R) wire.
2. Is voltage drop greater than 1.0V?
2. Starter Stud Voltage Drop Test a. Yes. Repair or replace connection between battery
1. Perform voltage drop test from battery (+) terminal to (+) terminal and starter solenoid terminal 1 (R) wire.
starter stud on starter (BK) wire. See 1.3 DIAGNOSTICS (5041)
AND TROUBLESHOOTING, Voltage Drop.
b. No. Repair or replace starter solenoid assembly. See
the service manual. (5845)

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TESTING STARTER ON MOTORCYCLE 3.3

STARTER CURRENT DRAW TEST 4. Clamp induction ammeter over positive starter cable to
starter solenoid.
PART NUMBER TOOL NAME
NOTE
HD-41404-C HARNESS CONNECTOR TEST KIT In next step with engine stop switch in OFF position and purple
male probes connected to the [64-1B] terminals 4G and 3H in
NOTES
place of the start relay, starter will turn but engine will not start.
• Engine temperature should be stable and at room temper- This configuration also prevents diagnostic trouble codes from
ature. being set.
• Battery should be fully charged. 5. With IGN ON, read the ammeter. Disregard initial high
Check starter current draw with an induction ammeter before current reading which is normal when engine is first turned
disconnecting battery. Proceed as follows: over.
a. Typical starter current draw will range between 160-
1. Verify that transmission is in neutral and engine stop switch
200A.
is in OFF position.
b. If starter current draw exceeds 250A, then the
2. Remove start relay.
problem may be in the starter or starter drive. See
3. Using HARNESS CONNECTOR TEST KIT (Part No. HD- 3.4 TESTING STARTER ON BENCH, Free Running
41404-C), connect patch cord to fuse block [64-1B] socket Current Draw Test.
terminals 4G and 3H.

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TESTING STARTER ON BENCH 3.4

FREE RUNNING CURRENT DRAW TEST STARTER SOLENOID
1. Place starter in vise, using a clean shop towel to prevent Do not disassemble solenoid. Before testing, disconnect field
scratches or other damage. wire from solenoid motor terminal as shown in Figure 3-6.
2. See Figure 3-5. Attach one heavy jumper cable (6 gauge Each test should be performed for only 3-5 seconds to prevent
minimum). damage to solenoid.
a. Connect one end to the starter mounting flange. The solenoid Pull-in, Hold-in and Return tests must be per-
formed together in one continuous operation. Conduct all three
b. Connect the other end to the battery (-) terminal of a
tests one after the other in the sequence given without interrup-
fully charged battery.
tion.
3. Connect a second heavy jumper cable (6 gauge minimum). SOLENOID PULL-IN TEST
a. Connect one end to the battery (+) terminal of the
battery. 1. See Figure 3-6. Using a 12V battery, connect three sep-
arate test leads as follows:
b. Connect the other end to the battery terminal on the
a. Solenoid housing to negative battery post.
starter. Place an induction ammeter over cable.
b. Solenoid motor terminal to negative battery post.
c. Solenoid relay terminal to positive battery post.

Keep fingers and clothing away from starter gear to pre- 2. Observe starter shaft.
vent personal injury. (00613b) a. If starter shaft extends strongly, solenoid is working
4. Connect a smaller jumper cable (14 gauge minimum). properly.
a. Connect one end to the positive (+) terminal of the b. If starter shaft does not extend strongly, replace
battery. solenoid assembly.
b. Connect the other end to the solenoid relay terminal.
ed02866
5. Check ammeter reading.
a. Ammeter should show 90A max.
b. If reading is higher, replace starter. See the service
manual.
1
c. If starter current draw on vehicle was over 120A and
this test was within specification, there may be a
problem with engine or primary drive.

ed02865
4 2
2 3

1 1. Battery
4 2. Solenoid housing
3. Solenoid relay terminal
4. Solenoid motor terminal
Figure 3-6. Pull-In Test
3

5 SOLENOID HOLD-IN TEST

1. See Figure 3-7. With test leads still connected in the
manner specified in the previous 3.4 TESTING STARTER
1. Mounting flange
ON BENCH, Solenoid Pull-In Test, disconnect solenoid
2. Battery
motor terminal/battery negative test lead at negative bat-
3. Induction ammeter
tery post only; reconnect loose end of this test lead to
4. Battery terminal
positive battery post instead.
5. Relay terminal
Figure 3-5. Free Running Current Draw Test

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2. Observe starter shaft. ON BENCH, Solenoid Hold-In Test, disconnect solenoid

a. If starter shaft remains extended, solenoid is working relay terminal/positive battery post test lead at either end.
properly. 2. Observe starter pinion.
b. If starter shaft retracts, replace solenoid assembly. a. If starter shaft retracts, solenoid is working properly.
b. If starter shaft does not retract, replace solenoid
assembly.
ed02867

ed02868

4
2
3
4
1. Battery
2. Solenoid housing
2
3
3. Solenoid relay terminal
1. Battery
4. Solenoid motor terminal
2. Solenoid housing
Figure 3-7. Hold-In Test 3. Solenoid relay terminal
4. Solenoid motor terminal
Figure 3-8. Return Test
SOLENOID RETURN TEST
1. See Figure 3-8. With test leads still connected in the
manner specified at the end of 3.4 TESTING STARTER

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CHARGING SYSTEM 3.5

DESCRIPTION AND OPERATION
The charging system is the source of electric current that sup-
plies power to run the ignition, lights, accessories and charge
the battery. AC voltage is generated by an alternator assembly
driven by the crankshaft. A rotor supplied with a magnetic field
spins around a stator. A rectifier (located in the regulator)
converts the voltage from AC to DC. A regulator ensures that
the output voltage is properly matched to the battery voltage
as engine speed varies. Even though the alternator provides
additional voltage at all engine speeds, it is not recommended
to idle the vehicle for long periods of time.
Alternator
The alternator consists of two main components:
• The rotor which mounts to the primary side of the crank-
shaft.
• The stator which is attached to the crankcase half.
Voltage Regulator
See Figure 3-9. The voltage regulator is a series regulator.
The circuit combines the functions of rectifying and regulating.
TROUBLESHOOTING
When the charging system fails to charge or does not charge
at a satisfactory rate, check the following items.
Battery
Test for a weak or dead battery. Battery must be fully charged
in order to perform a load test or starting or charging tests. See
3.1 BATTERY TESTING.
Wiring
The stator connections must be clean and tight.
Check for corroded or loose connections in the charging system
circuit.
Voltage Regulator Inspection
The voltage regulator must have clean, tight connections for
proper operation. Verify both AC and DC connectors are fully
inserted and locked with the regulator latch.
Job/Time Code Values
Dealership Technicians filing warranty claims should use the
job/time code values printed in bold text next to the appropriate
repair.
Connector Information
For additional information about the connectors in the following
diagram(s) and diagnostic procedure(s), including the color of
the harness test kit terminal probes, see B.1 CONNECTORS.

em00692

Stator
[77B] [77A] [47A] [47B]

+ + BK BK
- BK BK
- DC AC BK BK
BK
BK

Main Fuse
40A

[5B]
B A
R
R

BK
BK

R
BK

Red
Band

Left
GND1 Battery
(Dirty) Ground Battery Starter

Figure 3-9. Charging System Circuit

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LOW OR NO CHARGING 3. Verify that stator bolts have not backed out and contacted
the rotor.
Table 3-12. Low or No Charging Diagnostic Faults 4. Is rotor in good condition?
a. Yes. Go to Test 6.
POSSIBLE CAUSES
Low battery b. No. Replace rotor. See the service manual. (5319)
Stator malfunction
6. Voltage Regulator Power Circuit Test
Rotor malfunction
1. With IGN OFF, disconnect voltage regulator [77].
Voltage regulator malfunction
2. Test for continuity between voltage regulator [77B] terminal
Open voltage regulator circuit + and main fuse [5B].
Stator shorted to ground
3. Is continuity present?
AC wire shorted to ground a. Yes. Go to Test 7.
b. No. Repair open wire between voltage regulator [77B]
1. Battery Test terminal + and [5B]. (5041)
1. Verify battery condition. See 3.1 BATTERY TESTING.
2. Is battery condition good?
7. Voltage Regulator Ground Circuit Test
a. Yes. Go to Test 2. NOTE

b. No. Charge or replace battery as needed. Verify The voltage regulator ground must have a clean, tight connec-
repair. tion for proper grounding.
1. Test for continuity between voltage regulator [77B] terminal
NOTE - and ground.
A discharged battery may show a reading under 13V even 2. Is continuity present?
though the charging system is working properly.
a. Yes. Replace voltage regulator. See the service
2. Off Idle Voltage Test manual. (5316)
1. With the vehicle is neutral, start engine and run at 3000 b. No. Repair open wire between voltage regulator [77B]
rpm. terminal - and GND 1 (BK) wire. (5041)
2. Test battery voltage.
OVERCHARGING
3. Is voltage above 13V?
a. Yes. Charging system working properly. Table 3-13. Overcharging Diagnostic Faults
b. No. Go to Test 3. POSSIBLE CAUSES
Voltage regulator malfunction
3. AC Output Test
1. Perform an AC output test. See 3.5 CHARGING SYSTEM, 1. Battery Voltage Test
Battery Charging Tests.
1. With the vehicle in neutral, start engine and run at 3000
2. Did the output test pass? rpm, test battery voltage.
a. Yes. Go to Test 6. 2. Is voltage above 15.5V?
b. No. Go to Test 4. a. Yes. Go to Test 2.
b. No. Charging system working properly.
4. Stator Test
1. Perform a stator test. See 3.5 CHARGING SYSTEM, 2. Voltage Regulator Ground Circuit Test
Battery Charging Tests.
NOTE
2. Is the stator good? The voltage regulator ground must have a clean, tight connec-
a. Yes. Go to Test 5. tion for proper grounding.
b. No. Replace stator. See the service manual. (5309) 1. With IGN OFF, disconnect voltage regulator [77].
2. Test for continuity between voltage regulator [77B] terminal
5. Rotor Inspection Test - and ground.
1. Inspect the rotor for damage.
2. Remove center bolt and inspect for signs of the center
hole becoming oval. See the service manual.

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3. Is continuity present? 2. Is battery condition good?

a. Yes. Replace voltage regulator. See the service a. Yes. System is working properly.
manual. (5316)
b. No. Charge or replace battery as needed.
b. No. Repair open wire between voltage regulator [77B]
terminal - and GND 1 (BK) wire. (5041) BATTERY CHARGING TESTS
LOW BATTERY AFTER EXTENDED IGN OFF PART NUMBER TOOL NAME
HD-41404-C HARNESS CONNECTOR TEST KIT
Table 3-14. Low Battery After Extended IGN OFF
Diagnostic Faults Milliampere Draw Test
NOTE
POSSIBLE CAUSES
Be sure accessories are not wired so they stay on at all times.
Battery
This condition could drain battery completely if vehicle is parked
Accessories improperly wired to stay on at all times for a long time. Test for this by connecting ammeter between
Excessive draw from electrical component with IGN OFF negative battery terminal and battery.
Battery self-discharge and/or component draw because 1. If vehicle is equipped with HFSM, enable service mode
motorcycle was not operated for a long period before performing test.
2. Disconnect the security siren (if equipped).
1. Battery Test
3. Remove main fuse.
1. Verify battery condition. See 3.1 BATTERY TESTING.
NOTE
2. Is battery condition good?
With IGN OFF, an initial current draw of up to 200 mA will occur
a. Yes. Go to Test 2. directly after connecting meter. This should drop to the values
b. No. Charge or replace battery as needed. Verify shown in Table 3-16 in less than one minute.
repair. 4. See Figure 3-10. Using HARNESS CONNECTOR TEST
KIT (Part No. HD-41404-C), connect ammeter to main
2. Amp Draw Test fuse socket terminals. With this arrangement, you will pick
1. Perform a milliampere draw test. See 3.5 CHARGING up any drain.
SYSTEM, Battery Charging Tests. 5. With IGN OFF and all lights and accessories off, observe
2. Did the test exceed maximum draw? current reading.
a. Yes. Repair excessive draw and run test again. (5308) a. Add voltage regulator draw to appropriate value for
TSM/TSSM/HFSM and ECM. If observed ammeter
b. No. System is working properly. reading is less than listed in table, draw is within limits.
Refer to Table 3-16.
BATTERY RUNS DOWN DURING USE
b. A higher reading indicates excessive current draw.
Any accessories must be considered and checked
Table 3-15. Battery Runs Down During Use Diagnostic for excessive drain.
Faults

POSSIBLE CAUSES
Low battery
Excessive accessory draw
Accessories on when idling or low rpm riding for extended
period

1. Total Current Draw Test

1. Perform a Total Current Draw and Output Test. See
3.5 CHARGING SYSTEM, Battery Charging Tests.
2. Does charging system exceed current draw by 3.5A?
a. Yes. Go to Test 2.
b. No. System accessory power requirements exceed
charging system capability.

2. Battery Test
1. Verify battery condition. See 3.1 BATTERY TESTING.

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NOTE
Table 3-16. Milliampere Draw Test
If a load tester is unavailable, an ammeter with current probe
ITEM MAXIMUM DRAW may be used.
IN MILLIAMPERES
ECM 1.0
Speedometer 1.0 Turn battery load tester OFF before connecting tester
Tachometer 1.0 cables to battery terminals. Connecting tester cables with
load tester ON can cause a spark and battery explosion,
TSM (no security) 1.0 which could result in death or serious injury. (00252a)
TSSM (armed) 3.0
1. See Figure 3-11. Connect load tester.
TSSM (disarmed) 3.0 a. Connect negative and positive leads to battery ter-
TSSM (storage mode) 1.0 minals.
HFSM 1.0 b. Place load tester induction pickup over battery neg-
Security siren (optional) 20.0* ative cable.
Voltage regulator 2.0 2. With IGN OFF, disconnect voltage regulator [77].
Radio 2.0
3. Start engine.
High output amplifier 1.0
4. Turn all continuously running lights and accessories turned
CB module 1.0 ON (headlamp on high beam).
XM module 1.0 5. Run engine at 3000 rpm, and make note of the current
* Siren draws for 2-24 hours from the time the motorcycle draw.
battery is connected and 0.05 milliamperes once siren battery
is charged. Disconnect siren during milliampere draw test. 6. Turn engine OFF.
7. With IGN OFF, connect voltage regulator [77].
8. Remove the induction pickup from the battery negative
em00693 Stator
1 cable.
9. Place induction pickup over positive regulator cable.
BK
BK
BK

[47B] 1 2 3 10. Start engine and run at 3000 rpm.

[47A] 1 2 3
NOTE
Do not leave any load switch turned on for more than 20
3 seconds or overheating and tester damage are possible.
- + [77A] 11. Increase the load as required to obtain a constant 13.0V.
- + [77B]
12. Current output should be 35-50A. Make note of current
output.
BK
BK

2
NOTE
[5B]
B A Rider's habits may require output test at lower rpm.
R

13. Compare both of these readings.

a. The current output should exceed current draw by
3.5A minimum.
b. If output does not meet specifications, there may be
Left too many accessories for the charging system to
GND1
R

(Dirty) R
handle.

1. Ammeter
2. Main fuse socket
3. Voltage regulator
Figure 3-10. Milliampere Draw Test (Ignition Turned to
OFF)

Total Current Draw and Output Test

If battery runs down during use, the current draw of the
motorcycle components and accessories may exceed output
of the charging system.

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ed02802 ed02027

3
2

1. Load tester
2. Induction pickup
3. Battery
Figure 3-11. Check Current Draw (Ignition Switch On)

Stator Test
1. Turn IGN OFF. Figure 3-12. Test for Grounded Stator (Typical)
2. See Figure 3-12. Connect an ohmmeter.
a. Disconnect voltage regulator [47] from stator wiring.
b. Insert one ohmmeter lead into a stator connector ed02028
socket.
c. Attach the other lead to a suitable ground.

3. Test for continuity.

a. A good stator will show no continuity (open circuit)
between all stator sockets and ground.
b. Any other reading indicates a grounded stator which
must be replaced.

4. See Figure 3-13. Remove ground lead. Measure resist-

ance across stator [47B] terminals 1-2, 2-3 and 3-1.
a. Resistance across all the stator terminals should be
0.1-0.3 Ohm.
b. If the resistance is higher, the stator is damaged and
must be replaced.
c. If resistance is lower, the stator may have a turn-to-
turn short and should be replaced.

NOTE
When measuring resistance (Ohms), compensate for test lead
resistance before performing the measurement. Select the Figure 3-13. Check for Stator Resistance (Typical)
Ohms position and touch the test leads together. Refer to the
multimeter user's manual to either zero the display or manually
subtract the test lead resistance from the measured circuit's
value.

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AC Output Test ed02029

1. See Figure 3-14. Test AC output.

a. Disconnect voltage regulator [47] from alternator
stator wiring.
b. Test for VAC across stator [47B] terminals 1 to 2.
c. Run the engine at 2000 rpm. The VAC output should
be 32-46 VAC (approximately 16-22 per 1000 rpm).
d. Repeat test using terminals 2 to 3 and 1 to 3.

2. Compare test results to specifications.

a. If the output is below specifications, charging problem
could be a faulty rotor or stator.
b. If output is within specifications, charging problem
might be faulty voltage regulator. Replace as required.
See the service manual.

3. Check the output again as previously described under

Total Current Draw and Output Test.

Figure 3-14. Check Stator AC Voltage Output (Typical)

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DTC B0563, P0562, P0563 3.6

DESCRIPTION AND OPERATION DIAGNOSTICS
Battery voltage is monitored by several modules. If the battery Diagnostic Tips
voltage fails to meet normal operating parameters, a DTC is
set. Any of the following conditions could cause these DTCs to set:
• The vehicle is placed on a battery charger, on fast charge,
DTC B0563 for a long period of time.
Battery voltage is monitored by the TSM/TSSM/HFSM on ter-
• The charging system is malfunctioning
minal 1. DTC B0563 is displayed when the TSM/TSSM/HFSM
exceeds 16.0V for more than 5.0 ±0.5 seconds. • There is excessive battery draw and/or extended idling in
heavy traffic.
DTC P0562 and P0563
• A faulty system ground is present.
Battery voltage is monitored by the ECM on terminal 13.
Low voltage generally indicates a loose wire, corroded connec-
• DTC P0562 is displayed when battery voltage is less than
tions, battery and/or a charging system problem.
12.2V at idle and voltage does not increase when engine
speed is greater than 2000 rpm. High voltage DTC may set when the vehicle is placed on a
battery charger, for a long period of time.
• DTC P0563 is displayed when battery voltage is greater
than 15.0V for more than 4 seconds. Connector Information
For additional information about the connectors in the following
Table 3-17. Code Description diagram(s) and diagnostic procedure(s), including the color of
the harness test kit terminal probes, see B.1 CONNECTORS.
DTC DESCRIPTION
B0563 TSM/TSSM/HFSM voltage high
P0562 ECM voltage low
P0563 ECM voltage high

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em00694 Ignition Switch

IGN IGN
ACC ACC

OFF OFF

[33A] B+ ACC IGN B+ ACC IGN [33A]

[33B] 2 1 3 B C A [33B]
Main Fuse

R/GY
R/GY

R/BK
R/BK
40A

R
R
Battery B C A [222A]
Power [5B] B C A [222B]

R/GY

R/BK
A B

R
R

R
R
All Except FLHR/C
FLHR/C

R/GY

R/BK
R
Battery 15A
BK
BK

BN/GY 2D
L 2C
K R
[77B] - +
ACCY 15A
[77A] - + O/W 1D
U 1C
S R/GY

Left [64-1B]
GND 1 INSTR 15A
O 1D 1C R/BK
Ignition 15A
Voltage
GY 1F 1E R/BK
Regulator
System Relay
4C 5 87

3D 3 30
TSM/TSSM/HFSM 3C 1 86
W/BK 4D 2 85
Battery 1 1 BN/GY
[64-2B] [22B] [22A]
Ground 12 12 BK/GN

W/BK 6 6 W/BK W/BK 4 4 W/BK Engine

[30A] [30B] Stop Switch
GY 3 3 GY GY 3 3 GY

ECM O 1 1 O O 1 1 Ignition

Switch Power 72 72 W/BK

O/W 5 5 O/W O/W 6 6 ACCY Speedometer
BK/GN 7 7 Ground
Ground 73 73 BK/GN
[1B] [1A]
[39B] [39A]
[78A] [78B] BK/GN 12 12 BK/GN

Right
GND 2 [2B] [2A]
Except FLHR/C

Figure 3-15. High and Low Voltage Sensors

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DTC P0562 5. ECM Ground Circuit Voltage Drop Test

PART NUMBER TOOL NAME 1. Test for voltage drop test between breakout box terminal
73 and battery (-) terminal.
HD-41404-C HARNESS CONNECTOR TEST KIT
2. Is voltage drop greater than 0.5V?
HD-48637 BREAKOUT BOX
a. Yes. Repair wiring between ECM [78B] terminal 73
and battery negative.
Table 3-18. DTC P0562 Diagnostic Faults
b. No. Problem may be intermittent. Locate and repair
POSSIBLE CAUSES bad connection. Perform 1.3 DIAGNOSTICS AND
Low battery TROUBLESHOOTING, Wiggle Test. If no problem is
found, continue with tests. Go to Test 15.
Ignition switch malfunction
Engine stop switch malfunction 6. ECM Switched Power Circuit Resistance
ECM malfunction Test
Open ECM ground circuit 1. With IGN OFF, remove system relay.
Open ECM switched power circuit 2. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
Open ignition circuit 41404-C) and a multimeter, measure resistance between
breakout box terminal 72 and fuse block [64-2B] socket
1. Battery Test terminal 4D (W/BK) wire.
1. Verify battery condition. See 3.1 BATTERY TESTING. 3. Is resistance greater than 1 Ohm?
2. Is battery condition good? a. Yes. Repair (W/BK) wire between ECM [78B] terminal
72 and [64-1B] socket terminal 4D.
a. Yes. Go to Test 2.
b. No. Go to Test 7.
b. No. Charge or replace battery as needed. Verify
repair.
7. Switched Power Circuit Resistance Test
2. Charging System Test 1. Disconnect right hand controls [22].
1. Perform charging system test. See 3.5 CHARGING 2. Measure resistance between [22B] terminal 4 and [64-1B]
SYSTEM, Low or No Charging. socket terminal 4D (W/BK) wire.
2. Is charging system working properly? 3. Is resistance greater than 1 Ohm?
a. Yes. Go to Test 3. a. Yes. Except FLHR/C. Go to Test 8.
b. No. Repair charging system. Go to Test 15. b. Yes. FLHR/C. Repair (W/BK) wire between [22B]
terminal 4 and [64-2B] socket terminal 4D.
3. ECM Switched Voltage Test
c. No. Go to Test 10.
1. With IGN OFF, connect BREAKOUT BOX (Part No. HD-
48637) between wire harness [78A] and ECM [78B]. See 8. Switched Power Circuit Resistance [1A]
1.2 DIAGNOSTIC TOOLS.
Test
2. With the engine stop switch in the RUN position and the 1. Disconnect interconnect harness [1].
transmission in neutral, turn the IGN ON.
2. Measure resistance between [22B] terminal 4 and [1A]
3. Test for voltage on breakout box between terminals 72 terminal 6 (W/BK) wire.
and 73.
3. Is resistance greater than 1 Ohm?
4. Is battery voltage present?
a. Yes. Repair (W/BK) wire between [22B] terminal 4
a. Yes. System is working properly. Go to Test 15. and [1A] terminal 6.
b. No. Go to Test 4. b. No. Go to Test 9.

4. ECM Switched Voltage Drop Test 9. Switched Power Circuit Resistance [1B]
1. Perform a voltage drop test between battery (+) terminal Test
and breakout box terminal 72. See 1.3 DIAGNOSTICS
AND TROUBLESHOOTING, Voltage Drop. 1. Measure resistance between [64-2B] socket terminal 4D
and [1B] terminal 6 (W/BK) wire.
2. Is voltage drop greater than 0.5V?
2. Is resistance greater than 1 Ohm?
a. Yes. Go to Test 6.
a. Yes. Repair (W/BK) wire between [64-2B] socket
b. No. Go to Test 5. terminal 4D and [1B] terminal 6.
b. No. Go to Test 10.

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10. Ignition Circuit Resistance Test 3. Is resistance greater than 1 Ohm?

1. Measure resistance between ignition fuse [64-2B] socket a. Yes. Except FLHR/C. Repair wire between ignition
terminal 1F and [22B] terminal 3 (GY) wire. switch [33B] terminal A (R/BK) wire and [64-1B]
socket terminal 1E.
2. Is resistance greater than 1 Ohm?
b. Yes. FLHR/C. Go to Test 16.
a. Yes. Except FLHR/C. Go to Test 11.
c. No. Go to Test 17.
b. Yes. FLHR/C. Repair (GY) wire between [22B] ter-
minal 3 and [64-2B] socket terminal 1F. 16. Ignition Switch To [222] Resistance Test
c. No. Go to Test 13. 1. Disconnect console ignition switch [222].

11. Ignition Circuit Resistance [1A] Test 2. Measure resistance between ignition switch [33B] terminal
A and [222A] terminal A.
1. Disconnect interconnect harness [1].
3. Is resistance greater than 1 Ohm?
2. Measure resistance between [22B] terminal 3 and [1A]
terminal 3 (GY) wire. a. Yes. Repair wire between [222A] terminal A and [33B]
terminal A (R/BK) wire.
3. Is resistance greater than 1 Ohm?
b. No. Repair wire between [222B] terminal A and [64-
a. Yes. Repair (GY) wire between [22B] terminal 3 and 2B] socket terminals 1E (R/BK) wire.
[1A] terminal 3.
b. No. Go to Test 12. 17. Ignition Switch Battery Circuit Voltage
Drop Test
12. Ignition Circuit Resistance [1B] Test 1. Perform a voltage drop test between battery (+) terminal
1. Measure resistance between [64-1B] socket terminal 4D and ignition switch [33B] terminal 2 on all vehicles except
and [1B] terminal 3 (GY) wire. for FLHR/C and terminal B on FLHR/C (R) wire.
2. Is resistance greater than 1 Ohm? 2. Is voltage drop greater than 0.5V?
a. Yes. Repair (W/BK) wire between [64-1B] socket a. Yes. Go to Test 18.
terminal 4D and [1B] terminal 3.
b. No. Replace ignition switch. See the service manual.
b. No. Go to Test 10.
18. Battery Voltage to Main Fuse Voltage
13. Engine Stop Switch Test Drop Test
1. Measure resistance between [22A] terminals 4 (GY) wire 1. With IGN OFF, remove main fuse.
and 3 (W/BK) wire.
2. Perform a voltage drop test between battery (+) terminal
2. Is resistance greater than 1 Ohm? and main fuse [5B] terminal A (R) wire.
a. Yes. Replace the engine stop switch assembly. See
the service manual. 3. Is voltage drop greater than 0.5V?
a. Yes. Repair wire between battery (+) terminal and
b. No. Go to Test 14. main fuse [5B] terminal B (R) wire.

14. Ignition Circuit Voltage Drop Test b. No. Go to Test 19.

1. With IGN ON, perform a voltage drop test between battery
(+) terminal and [64-2B] socket terminal 1E. See 1.3 DIA-
19. Main Fuse to Ignition Switch Resistance
GNOSTICS AND TROUBLESHOOTING, Voltage Drop. Test
2. Is voltage drop greater than 0.5V? 1. Measure resistance between main fuse [5B] terminal 2
and ignition switch [33B] terminal B on all vehicles except
a. Yes. Go to Test 15.
for FLHR/C and terminal B on FLHR/C (R) wire.
b. No. Go to Test 17.
2. Is resistance greater than 1 Ohm?
15. Ignition Circuit Resistance Test a. Yes. Except FLHR/C. Inspect main fuse for corrosion.
If main fuse is good, repair wire between main fuse
1. With IGN OFF, disconnect ignition switch [33]. [5B] terminal B and ignition switch [33B] terminal 2
2. Measure resistance between ignition switch [33B] terminal (R) wire.
3 on all vehicles except for FLHR/C, terminal A on FLHR/C b. Yes. FLHR/C. Go to Test 20.
(R/BK) wire and [64-2B] socket terminal 1E.
c. No. Go to Test 21.

20. Main Fuse to [222] Resistance Test

1. Disconnect console ignition switch [222].

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2. Measure resistance between ignition switch [33B] terminal 1. Charging System Test
B and [222A] terminal B.
1. Perform charging system tests. See 3.5 CHARGING
3. Is resistance greater than 1 Ohm? SYSTEM.
a. Yes. Repair wire between [222A] terminal B and [33B] 2. Is charging system good?
terminal B (R) wire.
a. Yes. Go to Test 2.
b. No. Repair wire between [222B] terminal B and main
fuse [5B] terminal B (R) wire. b. No. Repair charging system. Go to Test 2.

21. Repair Validation Test 2. Repair Validation Test

1. Clear DTCs using odometer self-diagnostics. See 1. Clear DTCs using odometer self-diagnostics. See
2.1 INITIAL DIAGNOSTICS, Odometer Self-Diagnostics. 2.1 INITIAL DIAGNOSTICS, Odometer Self-Diagnostics.

2. Start vehicle. 2. Start vehicle.

3. Run at 3000 rpm for 5 seconds. 3. Run at 3000 rpm for 5 seconds.

4. Does code set? 4. Does code set?

a. Yes. Replace ECM. See the service manual. a. Yes, DTC B0563. Replace TSM/TSSM/HFSM. See
the service manual.
b. No. System working properly.
b. Yes, DTC P0563. Replace ECM. See the service
DTC B0563, P0563 manual.
c. No. System working properly.
Table 3-19. DTC B0563, P0563 Diagnostic Faults

POSSIBLE CAUSES
Charging system malfunction
TSM/TSSM/HFSM malfunction
ECM malfunction

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DTC B1006, B1007 3.7

DESCRIPTION AND OPERATION
Table 3-20. Code Description
Battery voltage is constantly monitored by the speedometer.
If the battery voltage fails to meet normal operating parameters, DTC DESCRIPTION
a DTC is set. B1006 Accessory line overvoltage
The speedometer monitors terminal 1 for ignition power and B1007 Ignition line overvoltage
terminal 6 for accessory power.
• DTC B1006 is displayed when accessory line voltage is
Diagnostic Tips
greater than 16.0V for longer than 5 seconds. Voltage high DTC may set when the vehicle is placed on a
battery charger, on fast charge, for a long period of time.
• DTC B1007 is displayed when ignition line voltage is
greater than 16.0V for longer than 5 seconds. DTC B1006, B1007
NOTE
Table 3-21. DTC B1006, B1007 Diagnostic Faults
ECM, ECU and/or TSM/TSSM/HFSM may also set a battery
voltage DTC. POSSIBLE CAUSES
Charging system malfunction
ed01795 Speedometer malfunction

1. Charging System Test

1. Perform charging system tests. See 3.5 CHARGING
SYSTEM.
2. Is charging system good?
a. Yes. Go to Test 2.
b. No. Repair charging system.

2. Repair Validation Test

1. Clear DTCs using odometer self-diagnostics. See
2.1 INITIAL DIAGNOSTICS, Odometer Self-Diagnostics.
2. Start vehicle.
Figure 3-16. Speedometer Connector [39]
3. Run at 3000 rpm for 5 seconds.
4. Does code reset?
a. Yes. Replace speedometer. See the service manual.
b. No. System working properly.

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3-28 2011 Touring Diagnostics: Starting and Charging

TABLE OF CONTENTS

SUBJECT............................................................................................................................PAGE NO.
4.1 INSTRUMENTS.........................................................................................................................4-1
4.2 DTC B1004, B1005...................................................................................................................4-3
4.3 DTC B1008................................................................................................................................4-7
4.4 NO INSTRUMENT POWER......................................................................................................4-8
4.5 INDICATOR LAMPS................................................................................................................4-12
4.6 GAUGES.................................................................................................................................4-20

INSTRUMENTS
NOTES
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INSTRUMENTS 4.1
DESCRIPTION AND OPERATION The odometer mileage is permanently stored and will not be
lost when electrical power is turned off or disconnected. The
See Figure 4-1.The speedometer and tachometer (if equipped) trip odometer reset switch allows switching between the odo-
contain several indicators. These indicators include the check meter, trip odometer and fuel range displays.
engine, security, low battery and low fuel lamps. The sixth gear
and cruise control indicators may also be shown depending To zero the trip odometer, have the odometer display visible,
on the model of vehicle. press and keep the trip odometer reset switch depressed. The
trip odometer mileage will be displayed for 2-3 seconds and
Trip Odometer Reset Switch Operation then the trip mileage will return to zero.
Pressing the trip odometer reset switch provides the following
capabilities:
• Change the odometer display between mileage, trip and
fuel range values (press and immediately release).
• Reset the trip odometer (press and hold 2-3 seconds).
• Gain access to self-diagnostic mode and clear diagnostic
codes. See 2.1 INITIAL DIAGNOSTICS, Odometer Self-
Diagnostics.

ed03170

1 8 3
2 11 1

11

50 60 70 40
30 50
40 80
30 90 20 60
MPH RPM x100
20 100
10 70
10 110
0 120 0 80

9 C
H A R ERT I FI ED
L EY -DA V I DSON
HAR
L EY -DA VI DSON

7 7 2
6
10 9 8
5 4 10
4 6 5

1. Speedometer 7. Check engine lamp

2. Security lamp (key icon) 8. Battery discharge lamp
3. Tachometer 9. Sixth gear lamp
4. Cruise lamp 10. ABS lamp
5. Odometer/trip odometer/clock 11. Pursuit lamp (Police models)
6. Low fuel warning lamp
Figure 4-1. Speedometer

SPEEDOMETER THEORY OF OPERATION
The speed sensor is mounted at the back of the transmission
case. The sensor circuitry is a Hall-Effect sensor that is
triggered by the gear teeth of 5th gear on the transmission
mainshaft.
The output from the sensor is a series of pulses that are inter-
preted by ECM circuitry, converted into serial data then sent
to the speedometer. The speedometer converts the data to
control the position of the speedometer needle. It also provides
input to the TSM/TSSM/HFSM for turn signal cancellation.

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TACHOMETER THEORY OF OPERATION

Table 4-1. Code Description
The tachometer receives serial data from the ECM. The ECM
converts the signal from the CKP to serial data and sends it to DTC DESCRIPTION
the tachometer. The tachometer interprets the serial data and B1004 Fuel level sensor low
converts it into tachometer needle movement.
B1005 Fuel level sensor high/open
INSTRUMENT DIAGNOSTICS B1006 Speedometer accessory voltage high
The speedometer and tachometer monitor direct inputs from B1007 Speedometer ignition voltage high
sensors and switches, along with receiving information from B1008 Trip switch closed
the ECM over the serial data circuit. They set codes when the
parameters for the inputs are out of range. These codes begin Some sensors and switches send direct inputs to the instru-
with a B prefix to separate them from other types of codes. ments and do not have DTCs associated with them. Therefore,
symptoms may occur indicating a fault without any DTCs
present.

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DTC B1004, B1005 4.2

DESCRIPTION AND OPERATION
ed03083
The fuel level is monitored by the speedometer [39] at terminal 1
9 (Y/W) wire.
• If the voltage on terminal 9 exceeds the lower limit for
greater than or equal to 15 seconds a DTC B1004 will be
set and the low fuel warning lamp will illuminate.
• If the voltage on terminal 9 exceeds the upper limit (or is
open) for greater than or equal to 15 seconds a DTC
B1005 will set and the low fuel warning lamp will illuminate.
2
Table 4-2. Code Description

DTC DESCRIPTION
B1004 Fuel level sensor or wiring shorted low
B1005 Fuel level sensor or wiring high/open 1. Fuel pump [141]
2. Fuel tank
Voltage is supplied to the fuel pump and sender from the fuel
Figure 4-2. Under Console
pump fuse through the (O/GY) wire. Voltage is also supplied
to the fuel level sender on the (Y/W) wire from the fuel gauge.
As the fuel level changes the resistance of the sender changes.
The fuel gauge and the low fuel lamp are controlled through
Connector Information
the (Y/W) wire based off the change in the resistance of the For additional information about the connectors in the following
fuel level sender. diagram(s) and diagnostic procedure(s), including the color of
the harness test kit terminal probes, see B.1 CONNECTORS.

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em01047
Fuel Level
Sender

A C [141A]
Fuel Fuel Level Fuel A C [141B]
Gauge Sender Gauge

Y/W

BK/GN
[117A] 1 2 4 A C [141A] 1 2 3 [117A] 2 3 [13B]
[117B] 1 2 4 A C [141B] 1 2 3 [117B] 2 3 [13A]

Y/W

Y/W

Y/W

Y/W
BK/GN

BK/GN

BK/GN
O

O
BK
Instrument O
Fuse

Y/W

BK/GN
5 [2B]
5 [2A]
Y/W
O

Y/W
[20B] 1 6
[20A] 1 6
Y/W
O

Y/W

Y/W
O
Main O
Main
Harness Harness
Y/W

Y/W
O

FLHR Except
FLHR
Y/W
O

[39B] 1 9
[39A] 1 9

Speedometer

Figure 4-3. Fuel Sensor Circuit

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DTC B1004 4. Fuel Level Sender Circuit Continuity Test

PART NUMBER TOOL NAME 1. Test for continuity between [117B] terminal 3 and breakout
box terminal 9.
HD-41404-C HARNESS CONNECTOR TEST KIT
2. Is continuity present?
HD-42682 BREAKOUT BOX
a. Yes. Go to Test 5.
HD-46601 BREAKOUT BOX ADAPTERS
b. No. Repair open in (Y/W) wire between fuel gauge
and speedometer.
Table 4-3. DTC B1004 Diagnostic Faults

POSSIBLE CAUSES 5. Fuel Level Sender Circuit Test

Instrument malfunction 1. Test for continuity between [117B] terminal 3 and ground.
Short to ground in fuel level sender circuit 2. Is continuity present?
Fuel pump and sender assembly malfunction a. Yes. Repair short to ground in (Y/W) wire.
Open fuel level sender circuit b. No. Replace the fuel gauge. See the service manual.
Short to ground in accessory power circuit
DTC B1005
Ignition switch malfunction
Open ignition accessory circuit PART NUMBER TOOL NAME
HD-41404-C HARNESS CONNECTOR TEST KIT
1. Fuel Level Sender Voltage Test
HD-42682 BREAKOUT BOX
1. Disconnect the speedometer [39].
HD-46601 BREAKOUT BOX ADAPTERS
2. Connect BREAKOUT BOX ADAPTERS (Part No. HD-
46601) to [39]. Attach connectors from BREAKOUT
Table 4-4. DTC B1005 Diagnostic Faults
BOX (Part No. HD-42682) to harness adapters leaving
[39A] disconnected. POSSIBLE CAUSES
3. Turn IGN ON. Open ground circuit
4. Measure voltage between terminal 9 and ground of Short to voltage in fuel level sensor circuit
breakout box. Fuel gauge malfunction
5. Is voltage greater than 5.0V? Instrument malfunction
a. Yes. Replace the speedometer. See the service Fuel pump and sender malfunction
manual.
Open fuel level sensor circuit
b. No. Go to Test 2.
1. Fuel Level Sender Voltage Test
2. Fuel Pump and Sender Test 1. Disconnect the speedometer [39].
1. Disconnect the fuel pump and sender assembly. 2. Connect BREAKOUT BOX ADAPTERS (Part No. HD-
2. Measure voltage between breakout box terminal 9 and 46601) to [39]. Attach connectors from BREAKOUT
ground. BOX (Part No. HD-42682) to harness adapters leaving
[39A] disconnected.
3. Is voltage greater than 5.0V?
3. Turn IGN ON.
a. Yes. Replace the fuel pump and sender assembly.
See the service manual. 4. Measure voltage between breakout box terminal 9 and
ground.
b. No. Go to Test 3.
5. Is voltage greater than 7.0V?
3. Fuel Gauge Voltage Test a. Yes. Go to Test 2.
1. Disconnect the fuel gauge.
b. No. Replace the speedometer. See the service
2. Using the HARNESS CONNECTOR TEST KIT (Part manual.
No. HD-41404-C) and a multimeter, test for voltage
between fuel gauge [117B] terminal 1 and ground. 2. Fuel Pump and Sender Test
3. Is battery voltage present? 1. Disconnect the fuel gauge [117].
a. Yes. Go to Test 4. 2. Measure voltage between breakout box terminal 9 and
ground.
b. No. Repair Open in (O) wire between fuel gauge
terminal 1 and instrument fuse.

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3. Is voltage greater than 7.0V? 2. Is continuity present?

a. Yes. Go to Test 3. a. Yes. Go to Test 5.
b. No. Go to Test 4. b. No. Repair open in (Y/W) wire between fuel gauge
and speedometer.
3. Fuel Level Sender Circuit Test
1. Disconnect fuel level sender [141].
5. Fuel Gauge Ground Circuit Test
1. Test for continuity between [117B] terminal 2 and ground.
2. Measure voltage between breakout box terminal 9 and
ground. 2. Is continuity present?
3. Is voltage greater than 7.0V? a. Yes. Go to Test 6.
a. Yes. Repair short to voltage on (Y/W) wire. b. No. Repair open between [117] terminal 2 (BK) wire
and ground.
b. No. Replace the fuel pump and sender assembly.
See the service manual.
6. Fuel Sender Resistance Test
4. Fuel Level Sender Circuit Continuity Test 1. Disconnect fuel level sender [141].
1. Using the HARNESS CONNECTOR TEST KIT (Part 2. Measure resistance between [141A] terminal A and
No. HD-41404-C) and a multimeter, test for continuity ground.
between [117B] terminal 3 and breakout box terminal 9.
3. Is resistance greater than 350 Ohms?
a. Yes. Replace the fuel level sender. See the service
manual.
b. No. Replace the fuel gauge. See the service manual.

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DTC B1008 4.3

DESCRIPTION AND OPERATION 2. Remove rubber boot.
3. With the speedometer connected, clear DTCs using odo-
Trip Odometer Reset Switch Closed meter self-diagnostics. See 2.1 INITIAL DIAGNOSTICS,
Code B1008 will be set if trip odometer reset switch terminals Odometer Self-Diagnostics.
are closed for more than 2 minutes.
4. Did DTC B1008 set? This code may take up to 2 minutes
to set.
Table 4-5. Code Description
a. Yes. Go to Test 2.
DTC DESCRIPTION
b. No. Replace boot. See the service manual.
B1008 Trip odometer reset switch closed
2. Trip Odometer Reset Switch Test
DTC B1008
1. Disconnect speedometer [39]. Using terminal remover
HD-45928, remove terminal 11 from [39B]. Connect [39].
Table 4-6. DTC B1008 Diagnostic Faults
2. Turn IGN ON and observe the check engine lamp.
POSSIBLE CAUSES
3. Is the DTC current? See 2.1 INITIAL DIAGNOSTICS,
Trip odometer reset switch boot malfunction Check Engine Lamp.
Instrument malfunction a. Yes. Replace speedometer. See the service manual.
Trip odometer reset switch malfunction
b. No. Replace the trip odometer reset switch. See the
service manual.
1. Rubber Boot Test
1. Access the trip odometer reset switch.

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NO INSTRUMENT POWER 4.4

DESCRIPTION AND OPERATION
ed03111
See Figure 4-4.The speedometer and tachometer (if equipped)
receive battery power at terminal 5 and ignition power at ter-
2 3
minal 1. This is supplied through the battery fuse and the
1
instrument fuse located in fuse block [64]. Accessory power is 4
supplied through the ACCY fuse at terminal 6. The speedo-
meter and tachometer (if equipped) go through an initialization
sequence every time power is removed and re-applied to ter-
minal 1. The visible part of this sequence is the illumination of
check engine lamp, security lamp, backlighting, odometer and 5
fuel level. With IGN ON, the check engine lamp and security
lamp will illuminate for 4 seconds and then (if parameters are
normal) go out.
Loss of power on any of the inputs will change the instruments 6
behavior. Refer to Table 4-7.
1. Security siren [142]
2. Security siren (if equipped)
3. Fuse block
4. Main fuse [5]
5. DLC [91]
6. ABS diode pack [201] (if equipped)
Figure 4-4. Under Left Side Cover: Except FLTRX, FLHX,
FLHTC

Connector Information
For additional information about the connectors in the following
diagram(s) and diagnostic procedure(s), including the color of
the harness test kit terminal probes, see B.1 CONNECTORS.

Table 4-7. Function Chart - Loss of Input

TERMINAL 5 (BATTERY) TERMINAL 1 (IGN) TERMINAL 6 (ACC) TERMINAL 7 (GND)

Speedometer is non-functional
Will not "WOW". See 2.1 INITIAL Speedometer non-func- Instrument completely non-func-
DIAGNOSTICS, Diagnostics. tional in ACC position. tional
Needles freeze, backlighting is Check engine, low fuel, Diagnostics absent
functional battery, cruise and ABS
Check engine lamp, low fuel and lamps non-functional
battery lamp are non-functional.
Diagnostics absent.

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em00825
Ignition R/BK Battery R R/GY Accessory
Power Power Power

R/GY
R/BK

R
2C 1C

1C 1E
Battery Accessory
15A 15A
INSTRS Ignition
15A 15A 2D 1D
[64-1B]
1D 1F
[64-2B]

O/W
BN/GY
GY
O

[91A]

BK/GN 2
LGN/V 3 DLC
GY 4

BN/GY

BK/GN
LGN/V
[166B] [166A]

GY
BN/GY

BK/GN
LGN/V
O/W
O

1 2 3 12 [30B] ABS
LGN/V 9 9
(Optional)
1 2 3 12 [30A]
FLHR/C FLHX,FLHTC/CU,FLTR
[78B] [78A]
BN/GY

BK/GN

BN/GY

BK/GN
LGN/V

LGN/V
O/W

O/W
O

TSM/TSSM/HSFM LGN/V 69 69
ECM
1 2 3 4 5 [20A] 1 5 13 [1B] 4 12 [2B] BK/GN 73 73

1 2 3 4 5 [20B] 1 5 13 [1A] 4 12 [2A]

BK/GN
O/W
O/W

BN/GY

BK/GN
BN/GY

BK/GN

LGN/V
O
LGN/V
O

Right GND 2
BN/GY

BK/GN

BK/GN
BN/GY
LGN/V

LGN/V

BN/GY

BK/GN
O/W

O/W

LGN/V

LGN/V
O

O/W
O

1 2 5 6 7 [108B] 12 [27B]
1 2 5 6 7 [108A] 12 [27A]
BN/GY

BK/GN
LGN/V

Tachometer Radio
O/W
O

1 2 5 6 7 [39B] FLHX,FLHTC/CU,FLTR
1 2 5 6 7 [39A]
Speedometer
(All)

Figure 4-5. Instruments Power Circuit Diagram

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SPEEDOMETER INOPERATIVE 4. Battery Fuse Test

PART NUMBER TOOL NAME 1. Inspect the battery fuse.

HD-41404-C HARNESS CONNECTOR TEST KIT 2. Is the fuse good?

HD-42682 BREAKOUT BOX a. Yes. Go to Test 5.

HD-46601 BREAKOUT BOX ADAPTERS b. No. Go to Test 7.

Table 4-8. Speedometer Inoperative Diagnostic Faults

5. Battery Circuit to Battery Fuse Test
1. Test for voltage at [64-1B] socket terminal 2C.
POSSIBLE CAUSES
2. Is battery voltage present?
Instrument malfunction
a. Yes. Go to Test 6.
Open accessory circuit
b. No. Repair open between battery fuse and main fuse
Open battery circuit
(R) wire. (5041)
Open ignition circuit
Short to ground in cooling fan circuit 6. Battery Circuit to Speedometer Test
Ignition switch malfunction 1. With IGN OFF, connect BREAKOUT BOX
ADAPTERS (Part No. HD-46601) to [39]. Attach con-
Short to ground in ignition circuit
nectors from BREAKOUT BOX (Part No. HD-42682) to
Open ground circuit harness adapters leaving [39A] disconnected. See
Short in accessory circuit 1.2 DIAGNOSTIC TOOLS.
2. Install battery fuse in fuse block.
1. Battery and Ignition Function Test
3. Test for voltage at breakout box terminal 5.
1. Turn IGN ON.
4. Is battery voltage present?
2. Does the speedometer have full function?
a. Yes. Go to Test 13.
a. Yes. Go to Test 2.
b. No. Repair open between [39B] terminal 5 and [64-
b. No, check engine lamp, battery lamp and security
1B] socket terminal 2D (BN/GY) wire. (5041)
lamp are inoperative but backlighting is func-
tional. Go to Test 8.
7. Battery Circuit Short to Ground Test
c. No, speedometer does not operate at all. Go to
1. With IGN OFF, connect BREAKOUT BOX
Test 4.
ADAPTERS (Part No. HD-46601) to [39]. Attach con-
nectors from BREAKOUT BOX (Part No. HD-42682) to
2. Accessory Function Test harness adapters leaving [39A] disconnected. See
1. Turn IGN to ACC. 1.2 DIAGNOSTIC TOOLS.
2. Does the instrument have full ACC function? 2. Test for continuity between breakout box terminal 5 and
a. Yes. Concern is intermittent, perform a wiggle test to ground.
test for intermittent. See 1.3 DIAGNOSTICS AND 3. Is continuity present?
TROUBLESHOOTING, Wiggle Test.
a. Yes. Repair short to ground in (BN/GY) wire. (5041)
b. No. Go to Test 3.
b. No. Concern is intermittent, perform a wiggle test to
test for intermittent. See 1.3 DIAGNOSTICS AND
3. Accessory Fuse Test TROUBLESHOOTING, Wiggle Test. Replace the
1. With IGN OFF, connect BREAKOUT BOX battery fuse.
ADAPTERS (Part No. HD-46601) to [39]. Attach con-
nectors from BREAKOUT BOX (Part No. HD-42682) to 8. Ignition Circuit Test
harness adapters leaving [39A] disconnected. See
1. Turn IGN OFF for at least 15 seconds.
1.2 DIAGNOSTIC TOOLS.
2. Turn IGN ON and the engine stop switch to RUN.
2. Turn IGN ON.
3. Does the fuel pump run and then shut off?
3. Using the HARNESS CONNECTOR TEST KIT (Part
No. HD-41404-C) and a multimeter, test for voltage at a. Yes. Go to Test 9.
breakout box terminal 6. b. No. Go to Test 10.
4. Is battery voltage present?
a. Yes. Replace the speedometer. See the service
9. Instrument Power Circuit Test
manual. (7311) 1. With IGN OFF, disconnect speedometer [39].
b. No. Repair open in (O/W) wire. (5043)

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2. Connect BREAKOUT BOX ADAPTERS (Part No. HD- 2. Is battery voltage present?
46601) to [39]. Attach connectors from BREAKOUT a. Yes. Repair open in (O) wire. (5041)
BOX (Part No. HD-42682) to harness adapters leaving
[39A] disconnected. See 1.2 DIAGNOSTIC TOOLS. b. No. Inspect wiring from instrument fuse to ignition
switch for an open or damaged condition. If the wiring
3. With IGN ON, test for voltage between breakout box ter- is good replace the ignition switch. See the service
minal 1 and ground. manual. (7287)
4. Is battery voltage present?
a. Yes. Replace speedometer. See the service manual.
12. Ignition Power Short to Ground Test
(7311) 1. Test for continuity between [64-2B] socket terminal 1D
and ground.
b. No. Repair open in (O) ignition wire. (5041)
2. Is continuity present?
10. Ignition Fuse Test a. Yes. Repair short to ground in (O) wire. Replace
1. Inspect the ignition fuse. instrument fuse. (5041)

2. Is the fuse good? b. No. Replace the ignition fuse and verify operation.
(6729)
a. Yes. Go to Test 11.
b. No. Go to Test 12. 13. Ground Circuit Test
1. Using the HARNESS CONNECTOR TEST KIT (Part
11. Ignition Power to Instrument Fuse Test No. HD-41404-C) and a multimeter, test for continuity
1. With IGN ON, test for battery voltage between [64-2B] between breakout box terminal 7 and ground.
socket terminal 1D and ground.
2. Is continuity present?
a. Yes. Replace the speedometer. See the service
manual. (7311)
b. No. Repair open in (BK/GN) wire. (5041)

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INDICATOR LAMPS 4.5

DESCRIPTION AND OPERATION
See Figure 4-6. The battery, check engine, security and low
fuel indicators are located in the speedometer. The other
indicators are located separately from the speedometer.

ed03170

1 8 3
2 11 1

11

50 60 70 40
30 50
40 80
30 90 20 60
MPH RPM x100
20 100
10 70
10 110
0 120 0 80

9 C
H A R ERT I FI ED
L EY -DA V I DSON
HAR
L EY -DA VI DSON

7 7 2
6
10 9 8
5 4 10
4 6 5

1. Speedometer 7. Check engine lamp

2. Security lamp (key icon) 8. Battery discharge lamp
3. Tachometer 9. Sixth gear lamp
4. Cruise lamp 10. ABS lamp
5. Odometer/trip odometer/clock 11. Pursuit lamp (Police models)
6. Low fuel warning lamp
Figure 4-6. Speedometer

Low Fuel Indicator

Table 4-9. Indicator Lamp Wiring
See Figure 4-7. The low fuel indicator is controlled at terminal
INDICATOR LAMP CONNECTION 9 (Y/W) of the speedometer. The fuel gauge sends voltage on
Check engine Serial data the (Y/W) wire to the low fuel lamp and fuel level sender. When
the fuel drops below 1.0 gal (3.8L), the resistance in the fuel
Security Serial data
level sender reaches a point that causes enough of a change
Battery Serial data in the voltage on the (Y/W) wire it signals the speedometer to
Sixth gear indicator Serial data activate the low fuel lamp.

Oil pressure Ground through switch

Neutral Ground through switch
High beam 12V when active
Right/left turn 12V when active
Low fuel 1.0 gal (3.8 L)

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ed02699

1. Ignition/light key switch [33]

2. Indicator lights [21]
3. Speedometer [39]
Figure 4-7. Instrument Console Connectors: FLHR, FLHRC

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ed03066

6
1 2 4
5

7
3 8

12

11

16

14
15
9

13 10

1. Right front speaker [34+] 9. Radio [28]

2. Right front speaker [34-] 10. Radio [27]
3. Voltmeter [111] 11. GPS [193]
4. Voltmeter lamp [110] 12. Main to interconnect harness [1]
5. Tachometer [108] 13. Main to interconnect harness [15]
6. Speedometer [39] 14. TGS harness [204]
7. Indicator lamps [21] 15. Interconnect to right handle bar switches [22]
8. CB antenna cable [50] 16. Right front turn signal/auxiliary lamp [31R]
Figure 4-8. Right Side Behind Upper Fairing

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ed03124
Oil Pressure Indicator
See Figure 4-10. The oil pressure indicator is connected to the
oil pressure switch. The switch closes when oil pressure is low
and illuminates the oil pressure indicator. This is why the oil
1 2 pressure indicator is illuminated with the IGN ON and the
engine OFF.

Turn Signal Indicators

The turn signal indicators are controlled by the
TSM/TSSM/HFSM. When the TSM/TSSM/HFSM receives an
input from the left or right turn signal switch it flashes the correct
turn signals including the turn signal indicators. When the left
turn signal switch is pressed voltage is supplied on the (V) wire
to the left turn signals including the turn signal indicator. When
the right turn signal switch is pressed, voltage is supplied on
the (BN) wire to the right turn signals including the indicator.

3 High Beam Indicator

This circuit is powered when the headlamp switch is placed in
the high beam position. In the high position, voltage is supplied
to the (W) wire and the high beam headlamps. This wire also
supplies power to the high beam indicator, causing it to illu-
1. Starter minate.
2. Starter solenoid [128] Sixth Gear Indicator
3. Neutral switch [131]
The sixth gear indicator illuminates indicating the vehicle is in
Figure 4-9. Starter Solenoid [128] sixth gear. This is done by the ECM. The ECM monitors the
vehicle speed and engine rpm with the clutch engaged. It then
sends a signal over the serial data circuit to illuminate the
Neutral Indicator indicator when the parameters are correct for sixth gear oper-
See Figure 4-9. The neutral indicator is controlled through the ation. Therefore, there may be a delay in the indicator illumin-
(TN) wire connected to the TSM/TSSM/HFSM and the neutral ating when shifting to sixth gear. The ECM recieves clutch
switch. When the transmission is in neutral, the neutral switch switch status from the TSM/TSSM/HFSM. Pulling in the clutch
closes and illuminates the neutral indicator. lever will cause the sixth gear indicator to turn off.
If the sixth gear indicator is inoperative or always on check for
ed03085 any DTCs. If no DTCs are present, verify the clutch switch is
1 operating properly. If the clutch is disengaged without moving
the clutch switch, the sixth gear indicator may come on briefly
due to reduced engine rpm during shifting. If none of these
conditions exist and the sixth gear indicator is malfunctioning
replace the speedometer.

Connector Information
For additional information about the connectors in the following
diagram(s) and diagnostic procedure(s), including the color of
the harness test kit terminal probes, see B.1 CONNECTORS.

2
1. Oil pressure [139]
2. Front frame down tube
Figure 4-10. Oil Pressure Switch

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em00720 Indicators Indicators

GN/Y

BN
TN
BK

BK
V

W
BK

GN/Y

BN
TN
BK

BK
V

BK

O
GN/Y
GN/Y

BN
TN

BK
BN
TN

BK

O
V
W

O
V

4 3 7 6 2 5 1 [21B]
1 2 5 6 3 7 4 [21B]
4 3 7 6 2 5 1 [21A] 1 2 5 6 3 7 4 [21A]

GN/Y

BK/GN
BN
W

TN

O
V
GN/Y

BN
W

BK
TN

O
V

Headlamps [15A] [15B] O

Speedometer
BK/GN
W

Headlamp
[20A]
GN/Y

D D 9 10 13 1 11 5 12
Switch
BN

TN
O
V

Left 9 10 13 1 11 5 12 [20B]
[1A] 7 1 8 10 9 [2A] GND 1

GN/Y

BK/GN
BN
O
TN
V
[1B] 7 1 8 10 9 [2B]
Headlamps
GN/Y
BN

TN
V
O

Right

W
GND 2
Headlamp

GN/Y
Switch
BN

BN

TN
V
O

O
V
Except FLHR/C FLHR/C

GN/Y
BN

O
TN
V

[30A] [30B]

Right Turn Feed 6 6 BN

TSM/
TSSM/ Left Turn Feed 5 5 V
HFSM Neutral Switch 4 4 TN

Turn BN
Signals V

GN/Y
Ignition Power O

Except
FLHR/C FLHR/C
TN

BK

Chassis
[131B] B A
Ground
GN/Y

GN/Y
[131A] B A
BK

1 [120B] 1 [139B]
1 [120A] 1 [139A]
Left
GND 1
Neutral
Switch Oil Oil
BK

BK
Pressure Pressure
Switch Switch

Figure 4-11. Indicator Lamps

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OIL PRESSURE LAMP ALWAYS ON 2. Was the problem found?

a. Yes. Repair as needed.
PART NUMBER TOOL NAME
b. No. Replace the oil pressure switch. See the service
HD-41404-C HARNESS CONNECTOR TEST KIT
manual. (5161)

Table 4-10. Oil Pressure Lamp Always On Diagnostic OIL PRESSURE LAMP INOPERATIVE
Faults
PART NUMBER TOOL NAME
POSSIBLE CAUSES
HD-41404-C HARNESS CONNECTOR TEST KIT
Short to ground in oil pressure circuit
Indicator malfunction Table 4-11. Oil Pressure Lamp Inoperative Diagnostic
Mechanical issue Faults
Oil pressure switch malfunction POSSIBLE CAUSES
Oil pressure switch malfunction
1. Oil Pressure Lamp Function Test
Open oil pressure circuit
1. Turn IGN ON with the engine OFF.
Indicator malfunction
2. Does the oil pressure lamp illuminate?
a. Yes. Go to Test 2. 1. Oil Pressure Lamp Function Test
b. No. See 4.5 INDICATOR LAMPS, Oil Pressure Lamp 1. Turn IGN ON with the engine OFF.
Inoperative.
2. Does the oil pressure lamp illuminate?
2. Engine Running Test a. Yes. Test for intermittent. See 1.3 DIAGNOSTICS
AND TROUBLESHOOTING, Wiggle Test.
1. Start the engine.
b. No. Go to Test 2.
2. Does the oil pressure lamp turn OFF and stay off?
a. Yes. Oil pressure lamp is operating properly. Test for 2. Oil Pressure Switch Test
intermittent. See 1.3 DIAGNOSTICS AND
1. Disconnect the oil pressure sensor [120] or [139].
TROUBLESHOOTING, Wiggle Test.
2. Using the HARNESS CONNECTOR TEST KIT (Part
b. No. Go to Test 3.
No. HD-41404-C), connect [120B] terminal 1 to ground.
3. Oil Pressure Sensor Test 3. Does the oil pressure lamp turn ON?
1. Disconnect the oil pressure sensor [120] or [139]. a. Yes. Replace oil pressure switch. See the service
manual. (5161)
2. Does the oil pressure lamp turn OFF?
b. No. Go to Test 3.
a. Yes. Go to Test 5.
b. No. Go to Test 4. 3. Oil Pressure Circuit Test
1. With IGN OFF, disconnect console harness [20].
4. Oil Pressure Circuit Test
2. Test for continuity between indicator lamps [21A] terminal
1. With IGN OFF, disconnect indicator lamps [21].
3 (FLHR/C) or terminal 2 (except FLHR/C) and [120B]
2. Using the HARNESS CONNECTOR TEST KIT (Part terminal 1 or [139B] terminal A.
No. HD-41404-C) and a multimeter, test for continuity
3. Is continuity present?
between [21A] terminal 3 (FLHR/C) or terminal 2 (except
FLHR/C) and ground. a. Yes. Repair or replace the indicator harness. See the
service manual. (5191)
3. Is continuity present?
b. No. Repair open between [21] and [120] (GN/Y) wire.
a. Yes. Repair short to ground between [21A] terminal
(5041)
3 (FLHR/C) or terminal 2 (except FLHR/C) and [120B]
terminal 1 (GN/Y) wire. (5041)
b. No. Repair or replace the indicator harness. See the
service manual. (5191)

5. Mechanical Test
1. Inspect the engine for any issues that may affect oil pres-
sure. See the service manual.

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NEUTRAL LAMP ALWAYS ON 3. Is continuity present?

a. Yes. Repair short to ground in (TN) wire. (5041)
PART NUMBER TOOL NAME
b. No. Repair or replace the indicator harness. See the
HD-41404-C HARNESS CONNECTOR TEST KIT
service manual. (5191)

Table 4-12. Neutral Lamp Always On Diagnostic Faults NEUTRAL LAMP INOPERATIVE
POSSIBLE CAUSES PART NUMBER TOOL NAME
Neutral switch malfunction HD-41404-C HARNESS CONNECTOR TEST KIT
Short to ground in neutral circuit
Indicator malfunction Table 4-13. Neutral Lamp Inoperative Diagnostic Faults
TSM/TSSM/HFSM malfunction POSSIBLE CAUSES
Neutral switch malfunction
1. Neutral Lamp Function Test
Open ground circuit
1. With the vehicle in neutral, turn IGN ON with the engine
OFF. Open neutral switch circuit

2. Does the neutral lamp illuminate? Indicator malfunction

a. Yes. Go to Test 2. 1. Neutral Lamp Function Test
b. No. See 4.5 INDICATOR LAMPS, Neutral Lamp 1. With the vehicle in neutral, turn IGN ON with the engine
Inoperative. OFF.

2. Transmission Operation Test 2. Does the neutral lamp illuminate?

1. Shift the transmission out of neutral. a. Yes. Test for intermittent. See 1.3 DIAGNOSTICS
AND TROUBLESHOOTING, Wiggle Test.
2. Does the neutral lamp turn OFF and stay off?
b. No. Go to Test 2.
a. Yes. Neutral lamp is operating properly. Test for
intermittent. See 1.3 DIAGNOSTICS AND 2. Neutral Switch Test
TROUBLESHOOTING, Wiggle Test.
1. Disconnect the neutral switch [131].
b. No. Go to Test 3.
2. Using the HARNESS CONNECTOR TEST KIT (Part
3. Neutral Switch Test No. HD-41404-C), jump the (TN) wire to ground.

1. Disconnect the neutral switch [131]. 3. Does the neutral lamp turn ON?

2. Does the neutral lamp turn OFF? a. Yes. Replace the neutral switch. See the service
manual. (5157)
a. Yes. Replace the neutral switch. See the service
manual. (5157) b. No. Go to Test 3.

b. No. Go to Test 4. 3. Neutral Switch Power Circuit Open Test

4. TSM/TSSM/HFSM Test 1. With IGN OFF, disconnect indicator lamps [21].

1. Disconnect the TSM/TSSM/HFSM [30]. 2. Using the HARNESS CONNECTOR TEST KIT (Part
No. HD-41404-C) and a multimeter, test for continuity
2. Does the neutral lamp turn OFF? between [21A] terminal 5 (FLHR/C) or terminal 7 (except
a. Yes. Replace the TSM/TSSM/HFSM. See the service FLHR/C) and [131B] (TN) wire.
manual. (6845)
3. Is continuity present?
b. No. Go to Test 5. a. Yes. Repair or replace the indicator harness. See the
service manual. (5191)
5. Neutral Switch Circuit Test
b. No. Repair open in (TN) wire between [21] and neutral
1. Disconnect indicator lamps [21]. switch. (5041)
2. Using the HARNESS CONNECTOR TEST KIT (Part
No. HD-41404-C) and a multimeter, test for continuity
between [21A] terminal 5 (FLHR/C) or terminal 7 (except
FLHR/C) and ground.

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HIGH BEAM INDICATOR LAMP TURN SIGNAL INDICATOR INOPERATIVE

INOPERATIVE PART NUMBER TOOL NAME
PART NUMBER TOOL NAME HD-41404-C HARNESS CONNECTOR TEST KIT
HD-41404-C HARNESS CONNECTOR TEST KIT
Table 4-15. Turn Signal Indicator Inoperative Diagnostic
Table 4-14. High Beam Indicator Lamp Inoperative Faults
Diagnostic Faults POSSIBLE CAUSES
POSSIBLE CAUSES Indicator malfunction
Indicator malfunction Open turn signal circuit
Open High beam indicator circuit
1. Turn Signal Function Test
1. High Beam Indicator Function Test 1. With ignition ON, operate the turn signals.
1. With IGN ON, operate the headlamp switch. 2. Do the turn signals operate?
2. Do the high and low beam headlamps function correctly? a. Yes. Go to Test 2.
a. Yes. Go to Test 2. b. No. See 5.6 TURN SIGNALS.
b. No. See 5.7 HEADLAMPS.
2. Turn Signal Indicator Circuit Test
2. High Beam Indicator Circuit Test 1. With IGN OFF, disconnect indicator lamps [21].
1. With the IGN OFF, disconnect indicator lamps [21]. 2. With the IGN ON and the turn signals activated and using
2. With the IGN ON and the headlamp switch in the high the HARNESS CONNECTOR TEST KIT (Part No. HD-
position and using HARNESS CONNECTOR TEST 41404-C) and a multimeter, test for voltage at [21A] (V)
KIT (Part No. HD-41404-C) and a multimeter, test for and (BN) wires.
voltage at [21A] terminal 2 (FLHR/C) or terminal 3 (except 3. Is voltage cycling on and off?
FLHR/C).
a. Yes. Repair or replace the indicator harness. See the
3. Is voltage present? service manual. (5191)
a. Yes. Repair or replace the indicator harness. See the b. No. Repair open between [21A] and [30B] (V) or (BN)
service manual. (5191) wire. (5041)
b. No. Repair open in (W) wire between headlamp
switch and [21A]. (5041)

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GAUGES
THEORY OF OPERATION
See Figure 4-12. With ignition switch turned to IGNITION, the
fuel gauge is connected to +12 Volts. Current flows through
the gauge and variable resistor in the fuel gauge sending unit
to ground. The sending unit float controls the amount of resist-
ance in the variable resistor.
Inoperative gauges may be caused by any of the following:
• Sender or fuel gauge not grounded.
• Malfunction in sender or fuel gauge.
• Inoperative or disconnected wire from ignition switch to
fuel gauge.
• Corroded connections at fuel gauge.
4.6
1. Remove gauge. Ground (Y/W) wire of fuel level sender
located at bottom of gauge. Turn ignition switch to IGNI-
TION.
a. Fuel gauge must indicate FULL. If gauge indicates
FULL, gauge is functioning correctly. Proceed to step
2.
b. If gauge did not indicate FULL, proceed to step 3.
2. Set MULTI-METER (Part No. HD-35500) to RXI scale to
measure the resistance of the sending unit. Place one
probe on (Y/W) and the other probe on chassis ground.
a. If fuel tank is full, the reading should be 30-50 Ohms.
An empty tank should have a 240-260 Ohms resist-
ance. A half full tank is approximately 125-165 Ohms.

Use the 4.6 GAUGES, Fuel Gauge and Sender Test to test b. If a very high resistance or infinity is indicated on the
suspect components. meter, the sender may be open or not grounded.
Check that the sender and fuel tank are grounded by
FUEL GAUGE AND SENDER TEST placing one probe of Multi-Meter on sender flange
and the other probe on crankcase. Meter must
PART NUMBER TOOL NAME indicate one Ohm or less. Replace sender if one Ohm
HD-35500 MULTI-METER or less was present. If a higher resistance is present,
check for poor connection on ground wire.
NOTE
Always refer to the applicable wiring diagram when 3. Check voltage to (O/W) (+) and (BK) (-) wire of fuel gauge
troubleshooting instruments or gauges. connector [117] if gauge did not indicate FULL.
a. Correct reading is equivalent to battery voltage.
b. If battery voltage is not present, check for inoperative
or disconnected wire. Replace gauge if wiring problem
is not found.

em01174

BK

Light BK
Light
O O

Oil
Pressure Voltmeter

O BN/GN To Sender +
O
To +12V
BK GND
BK

NOTE
All gauges are shown
as viewed from rear.

Figure 4-12. Connections for Gauges

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OIL PRESSURE GAUGE AND INDICATOR Low oil pressure light remains on with engine running above
idle and/or oil pressure gauge does not work.
LIGHT
PART NUMBER TOOL NAME
HD-41404-C HARNESS CONNECTOR TEST KIT Do not operate the engine when the oil level is below the
add mark on the dipstick at operating temperature. Engine
Problem damage will result. (00187b)

Table 4-16. Oil Pressure Gauge and Indicator Light

CAUSE SOLUTION
No oil pressure due to lack of oil or faulty Check oil level. Add oil if low.
oil pump. Restart engine and verify oil pressure light goes off and gauge indicates pressure. If
problem still exists, refer to oil pump in the service manual.
Contacts in pressure sending unit not Locate the oil pressure sending unit on the front right side of the crankcase.
opening to shut off light. Variable resistor Verify the electrical connector is properly connected to the sending unit.
in sender is shorted to ground.
If the oil pressure gauge indicates pressure but the low oil pressure light remains on
proceed as follows:
• Remove electrical connector from oil pressure sending unit. Using ohmmeter
and HARNESS CONNECTOR TEST KIT (Part No. HD-41404-C) gray socket
probe and patch cord, place one probe on indicator lamp terminal (closest to
latch on sending unit), place the other probe on the crankcase. Ohmmeter must
read less than one Ohm.
• Start the engine and run at a fast idle. The ohmmeter must read infinity.
• Replace the sending unit if the above meter readings are not obtained.
If the low oil pressure light functions correctly, but the pressure gauge does not, then
proceed as follows:
• Remove electrical connector from oil pressure sending unit. Turn the ignition
switch to IGNITION. The gauge must read zero.
• Ground (BN/GN) wire terminal to crankcase. The gauge must read full scale 60
PSI (414 kPa).
• Replace the sending unit if the above gauge readings are obtained. If the gauge
readings are not obtained, then replace the pressure gauge.
No power to gauge. See Voltmeter Gauge. See 4.6 GAUGES, Voltmeter Gauge.

AMBIENT AIR TEMPERATURE GAUGE

Problem
Gauge inoperative.

Table 4-17. Ambient Air Temperature Gauge

CAUSE SOLUTION
Sensor not grounded or open between Test for continuity between terminal 1 and ground and terminal 3 and gauge. Repair
sensor and gauge. if open.
Broken or disconnected power or ground Check for battery voltage between terminals 1 and 3 at connector [115A]. Replace
wire to gauge. gauge if voltage is present. Use voltage drop tests and continuity checks to isolate if
voltage is not present.
Malfunction in gauge or sensor. Measure resistance between terminals 1 and 3 at 65-85 °F (18.3-29.4 °C). Resistance
should be 31-43 Ohms. Replace sensor if out of range, replace gauge if within range.

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VOLTMETER GAUGE Problem

Meter inoperative.

Table 4-18. Voltmeter Gauge

CAUSE SOLUTION
Inoperative or disconnected leads to meter With ignition switch turned to IGNITION, verify battery voltage is present at both
or open meter winding. positive and negative terminals on the voltmeter terminal on voltmeter. With ignition
switch turned to OFF, check ground terminal for continuity to ground.
Replace the voltmeter if battery voltage is present and ground terminal is grounded.
If battery voltage is not present, trace wiring until disconnected or inoperative wire is
found and repair as necessary. If ground terminal is not grounded, refer to wiring
diagram and repeat procedure given for 12V lead.

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TABLE OF CONTENTS

SUBJECT............................................................................................................................PAGE NO.
5.1 ACCESSORIES.........................................................................................................................5-1
5.2 HEATED HAND GRIPS.............................................................................................................5-4
5.3 CRUISE CONTROL...................................................................................................................5-7
5.4 DTC P0577..............................................................................................................................5-11
5.5 HORN......................................................................................................................................5-14
5.6 TURN SIGNALS......................................................................................................................5-16

ACCESSORIES, HORN, LIGHTING AND SECURITY

5.7 HEADLAMPS..........................................................................................................................5-24
5.8 STOP LAMPS..........................................................................................................................5-28
5.9 RUNNING LAMPS...................................................................................................................5-34
5.10 DTC B1121, B1122, B1123, B1124, B1125, B1126..............................................................5-37
5.11 DTC B1135, B1136, B1141, B1142.......................................................................................5-44
5.12 SECURITY SYSTEM.............................................................................................................5-45
5.13 KEY FOB...............................................................................................................................5-50
5.14 SIREN....................................................................................................................................5-52
5.15 SERVICE AND EMERGENCY FUNCTIONS AND CONFIGURATIONS..............................5-53
5.16 FAILS TO DISARM................................................................................................................5-60
5.17 DTC B1131, B1132...............................................................................................................5-63
5.18 DTC B1134............................................................................................................................5-66
5.19 DTC B1143, B1144, B1145...................................................................................................5-68
5.20 DTC B1154, B1155...............................................................................................................5-70
NOTES
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ACCESSORIES 5.1
DESCRIPTION AND OPERATION
ed03125
The battery circuit is connected to battery power after the 40 3
Amp main fuse and supplies constant power.The P&A 15 Amp 1
circuit is connected to the ACCY circuit of the ignition switch 4
and supplies power in the ignition switch ACCY and IGN posi-
2
tions.
The P&A IGN 2 Amp (maximum) circuit is connected to the
IGN circuit of the ignition switch and supplies power only when
the ignition switch is in the IGN position. These circuits can be
used to supply power to additional systems on the motorcycle.
6
NOTE
The FLHTCU/K also are equipped with an additional 15 Amp
circuit to supply power to an accessory power outlet in the
Tour-Pak.

COMPONENTS
P&A Connectors
See Figure 5-1. The P&A battery circuit [160] and the P&A
accessory circuit [4] are located under the seat. A cover is 5
plugged into them to keep them from being accidentally
grounded. The P&A ignition 2A circuit is wired directly into the
fuse block [64-2B]. See Figure 5-3.The power outlet is powered 1. Fuse block
through [258] and mounted in the Tour-Pak. The ACCY circuit 2. Main fuse [5]
also supplies power to the cigar lighter [132] mounted in the 3. Tour-Pak [12]
fairing and optional heated hand grips [189]. 4. Main to rear lighting interconnect harness [257]
5. DLC [91]
P&A Fuses 6. Security siren [142]
See Figure 5-2. All the fuses are located under the left side
cover. Figure 5-2. Under Left Side Cover: FLTRX, FLHX, FLHTC

ed03129
1
2 ed03077

3
1

2
9 5 4
3 6
7

1. ECM
8
2. P&A [4]
1. Tour-Pak lights (rear lamp fascia on FLHX) [12]
3. P&A [160]
2. Power outlet [258]
Figure 5-1. Under Seat (Rear) 3. Power outlet
4. Right marker light [12-2]
5. CB antenna cable [104]
6. CB antenna ground
7. Radio antenna cable ground
8. Left marker light [12-3]
9. Radio antenna cable [52]
Figure 5-3. Tour-Pak Interior

2011 Touring Diagnostics: Accessories, Horn, Lighting and Security 5-1

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Connector Information diagram(s) and diagnostic procedure(s), including the color of

the harness test kit terminal probes, see B.1 CONNECTORS.
For additional information about the connectors in the following

em00740 Accessory R/GY

Power

R/GY

R/GY
2G 1E
Power Outlet
15A P&A
(FLHTCU, 15A
FLHTK Only)
2H 1F
[64-1B]

O/R
BN/BE
[258A] [258B]

Power R 1 1 BN/BE
Outlet
BK 2 2 BK

Chassis
Grounds
BK

O/R
BK
(Except
FLHR/C) FLHR/C
GND 1

O/R
BK

O/R
BK
[132A] [132B]

1 1 O/R O/R 4 4 O/R

Cigar
Lighter 2 2 BK

O/R

O/R
BK
[1A] [1B]

O
O/R 1 1 O/R [4A] 1 2 3 4 [67A] 1 4
O 2 2 O O 7 7 O [67B] 1 4
BK 3 3 BK

BK

BK
[2A] [2B]
[105B] [105A]
O/R
BK

BK D D BK
O

BK
O/R 4 3 1 [4A]
[15A] [15B] Toggle
O Switch
O/R
BK

Accessory
Switch
1 2 [189B]
1 2 [189A]
BK
R

W 1 1 BK/W

BK 2 2 BK/W

[206B] [206A]
BK
W

1 2 [237A]
BK/W

BK/W

BK
R

1 2 [237B]

Right Hand Grip Left Hand Grip

Figure 5-4. Auxiliary Power Outlets

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REAR AUXILIARY POWER OUTLET CIGAR LIGHTER INOPERATIVE

INOPERATIVE PART NUMBER TOOL NAME
PART NUMBER TOOL NAME HD-41404-C HARNESS CONNECTOR TEST KIT
HD-41404-C HARNESS CONNECTOR TEST KIT
Table 5-2. Cigar Lighter Inoperative Diagnostic Faults
Table 5-1. Rear Auxiliary Power Outlet Inoperative POSSIBLE CAUSES
Diagnostic Faults
Cigar lighter malfunction
POSSIBLE CAUSES
Open in the ground circuit
Power outlet malfunction
Open in the power circuit
Open in the ground circuit
Short to ground in the power circuit
Open in the power circuit
Short to ground in the power circuit 1. P&A Fuse Test
Malfunction in the device attached to the power outlet 1. Inspect the P&A fuse.
2. Is the fuse good?
1. Power Outlet Fuse Test
a. Yes. Go to Test 2.
1. Inspect the power outlet fuse.
b. No. Go to Test 4.
2. Is the fuse good?
a. Yes. Go to Test 2. 2. Cigar Lighter Test
b. No. Go to Test 4. 1. Disconnect cigar lighter [132].
2. Turn IGN ON.
2. Power Outlet Test
3. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
1. Disconnect power outlet [258].
41404-C) and a multimeter, test for voltage between [132B]
2. Turn IGN ON. terminal 1 and terminal 2.

3. Using HARNESS CONNECTOR TEST KIT (Part No. HD- 4. Is battery voltage present?
41404-C) and a multimeter, test for voltage between [258B] a. Yes. Replace defective part of cigar lighter. See the
terminal 1 and terminal 2. service manual. (6077)
4. Is battery voltage present? b. No. Go to Test 3.
a. Yes. Replace auxiliary power outlet. See the service
manual. (5116) 3. Cigar Lighter Ground Circuit Test
b. No. Go to Test 3. 1. Test for voltage between [132B] terminal 1 and ground.
2. Is battery voltage present?
3. Power Outlet Ground Circuit Test
a. Yes. Repair open in (BK) wire. (5041)
1. Test for voltage between [258B] terminal 1 and ground.
b. No. Repair open in (O/R) wire. (5041)
2. Is battery voltage present?
a. Yes. Repair open in (BK) wire. (5041) 4. Power Outlet Short to Ground Test
b. No. Repair open in (BN/BE) wire. (5041) 1. Disconnect cigar lighter [132].
2. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
4. Power Outlet Short to Ground Test 41404-C) and a multimeter, test for continuity between
1. Disconnect power outlet [258]. [258B] terminal 1 and ground.

2. Using HARNESS CONNECTOR TEST KIT (Part No. HD- 3. Is continuity present?
41404-C) and a multimeter, test for continuity between a. Yes. Repair short to ground in (O/R) wire. (5041)
[258B] terminal 1 and ground.
b. No. Replace the P&A fuse. If the fuse opens again,
3. Is continuity present? replace the cigar lighter. See the service manual.
a. Yes. Repair short to ground in (BN/BE) wire. (5041) (6077)

b. No. Verify the component connected to the power

outlet did not cause the overload. If no issue with the
component was verified, then replace the power outlet
fuse. If the fuse opens again, replace the auxiliary
power outlet. See the service manual. (5116)

2011 Touring Diagnostics: Accessories, Horn, Lighting and Security 5-3

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HEATED HAND GRIPS 5.2

DESCRIPTION AND OPERATION
See Figure 5-5. The heated handgrips are controlled by the
rotating switch located at the end of the left handgrip. The
switch can be turned from an OFF position through 6 increas-
ingly warm settings.
ed01597
Diagnostic Tips
If the heating element controller, located in the left grip, detects
an open or short between the left and right grip circuit, the
system is disabled. To enable the heating element control cir-
cuit, the ignition switch must be re-cycled after the problem is
resolved.
Connector Information
For additional information about the connectors in the following
diagram(s) and diagnostic procedure(s), including the color of
the harness test kit terminal probes, see B.1 CONNECTORS.

2
1

P
T
T

Figure 5-5. Heated Handgrip Control Switch

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em00740 Accessory R/GY

Power

R/GY

R/GY
2G 1E
Power Outlet
15A P&A
(FLHTCU, 15A
FLHTK Only)
2H 1F
[64-1B]

O/R
BN/BE
[258A] [258B]

Power R 1 1 BN/BE
Outlet
BK 2 2 BK

Chassis
Grounds
BK

O/R
BK
(Except
FLHR/C) FLHR/C
GND 1

O/R
BK

O/R
BK
[132A] [132B]

1 1 O/R O/R 4 4 O/R

Cigar
Lighter 2 2 BK

O/R

O/R
BK
[1A] [1B]

O
O/R 1 1 O/R [4A] 1 2 3 4 [67A] 1 4
O 2 2 O O 7 7 O [67B] 1 4
BK 3 3 BK

BK

BK
[2A] [2B]
[105B] [105A]
O/R
BK

BK D D BK
O

BK
O/R 4 3 1 [4A]
[15A] [15B] Toggle
O Switch
O/R
BK

Accessory
Switch
1 2 [189B]
1 2 [189A]
BK
R

W 1 1 BK/W

BK 2 2 BK/W

[206B] [206A]
BK
W

1 2 [237A]
BK/W

BK/W

BK
R

1 2 [237B]

Right Hand Grip Left Hand Grip

Figure 5-6. Heated Handgrip Circuit

2011 Touring Diagnostics: Accessories, Horn, Lighting and Security 5-5

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HEATED HANDGRIPS INOPERATIVE 4. Heated Grips Ground Circuit Test

PART NUMBER TOOL NAME 1. Test for voltage between [189B] terminal 1 and ground.

HD-41404-C HARNESS CONNECTOR TEST KIT 2. Is battery voltage present?

a. Yes. Repair open in (BK) wire. (5041)
Table 5-3. Heated Handgrips Inoperative Diagnostic Faults b. No. Repair open in (O/R) wire. (5041)
POSSIBLE CAUSES
5. Heated Grips Test
Open in the ground circuit
1. Disconnect right heated handgrip [237].
Open in the power circuit
2. Test for continuity between [237A] terminal 1 and ground.
Short to ground in the power circuit
Right heated grip malfunction 3. Is continuity present?
a. Yes. Go to Test 7.
Left heated grip malfunction
b. No. Replace the right heated grip. See the service
1. P&A Fuse Test manual. (6553)
1. Inspect the P&A fuse.
6. Heated Grips Short to Ground Test
2. Is the fuse good?
1. Disconnect heated handgrip interconnect [206].
a. Yes. Go to Test 2.
2. Test for continuity between [206A] terminal 1 and ground.
b. No. Go to Test 5.
3. Is continuity present?
2. Current Draw Test a. Yes. Go to Test 8.
1. Turn the IGN ON. b. No. Repair short to ground between [237A] terminal
2. With the heated handgrips off, using HARNESS CON- 1 and [206B] terminal 1. (5041)
NECTOR TEST KIT (Part No. HD-41404-C) and a multi-
meter, measure the current draw across the fuse block 7. Heated Grip Power Circuit Short to
[64-1B] socket terminal 1E and terminal 1F. Ground Test
3. Turn the heated handgrips control to the maximum setting 1. Disconnect heated handgrip to main harness [189].
while watching the current draw.
2. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
4. Does the current draw increase to approximately 3.5 Amps 41404-C) and a multimeter, test for continuity between
above the original reading? [189B] terminal 1 and ground.
a. Yes. System functioning normally. 3. Is continuity present?
b. No. Go to Test 3. a. Yes. Repair short to ground in (O/R) wire. (5041)
b. No. Replace left hand grip. See the service manual.
3. Power Supply Test
1. Install the P&A fuse. 8. Heated Grips Resistance Test
2. Disconnect heated grips [189]. 1. Disconnect right heated handgrip [237].
3. Turn IGN ON. 2. Measure resistance between [237B] terminal 1 and ter-
minal 2.
4. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
41404-C) and a multimeter, test for voltage between [189B] 3. Is resistance 7-12 Ohms?
terminal 1 and terminal 2. a. Yes. Replace the left heated grip. See the service
5. Is battery voltage present? manual. (6553)
a. Yes. Go to Test 8. b. No. Replace the right heated grip. See the service
manual. (6554)
b. No. Go to Test 4.

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CRUISE CONTROL 5.3

DESCRIPTION AND OPERATION
The ECM controls and monitors the operation of the vehicle
cruise control. The cruise switch allows the control circuit to
be enabled or disabled and, when enabled, the lamp in the
switch illuminates.
Actual engagement of the vehicle cruise control is provided by
the cruise SET/RESUME switch, located on the operator right
hand controls.This switch is a three position momentary switch,
spring loaded to the center position.
Switch-Right Position (SET/COAST)
• When the switch is toggled to the right position and
released, the cruise control is engaged and set to current
vehicle speed.
(speedometer on FLHRC models) turns from orange to
green to indicate the cruising speed is locked in.
4. The ECM monitors both the engine rpm and the VSS
output speed signal. The ECM signals the throttle control
actuator to open or close the throttle to keep the speedo-
meter output speed signal constant. The engine rpm is
monitored to detect engine overspeed, a condition which
automatically causes cruise disengagement.
5. The ECM automatically disengages cruise mode whenever
the ECM receives one of the following inputs:
a. Front or rear brake is applied.
b. Throttle is "rolled forward" past closed, thereby actu-
ating throttle roll off (disengage) command.

• If the switch is toggled right and held momentarily, then c. Motorcycle clutch is engaged or wheel slip detected.
the cruise control enters the COAST mode. (ECM senses too great an increase in rpm).

Switch-Left Position (RESUME/ACCELERATE)
• After brakes are applied or throttle is forced towards the
stop or the clutch is disengaged, the cruise control is dis-
engaged. When the switch is toggled to the left position
then released, the cruise control is engaged and will
resume the previously set speed/condition.
• If the switch is toggled left and held momentarily while the
cruise control is engaged, acceleration is provided,
increasing the vehicle rpm/speed. If the switch is toggled
left and held, it continues to increase the vehicle speed
until the switch is released and allowed to return to the
neutral position.
d. Cruise on/off switch placed in the off position.
e. Handlebar-mounted engine stop switch placed in the
off position.
f. Handlebar-mounted cruise SET/RESUME switch is
pushed to SET and held in that position until vehicle
speed drops below 30 mph (48 km/h) or pushed to
RES until vehicle speed exceeds 93 mph (150 km/h).
NOTE
If the vehicle speed is above 30 mph (48 km/h) when the cruise
SET/RESUME switch is released, then the cruise system
automatically re-engages.

Table 5-4. Code Description

ed02072

DTC DESCRIPTION 1
P0577 Cruise Control Input Error

SYSTEM OPERATION 2
To engage and disengage the cruise control system, proceed
as follows:
1. While riding in fourth, fifth or sixth gear, turn the cruise
on/off switch to the ON (lamp illuminated) position. See
Figure 5-7. The switch is located on the fairing cap of
FLHTCU models, the instrument nacelle of FLTR models
and the left handlebar lower switch housing on FLHRC
models. The cruise enabled/engaged lamp in the tacho-
meter face (speedometer on FLHRC models) turns orange
to indicate the system is activated. See Figure 5-9. An
orange lamp in the switch on both FLHTCU and FLTR
models also indicates this condition to the rider.
2. See Figure 5-8. With the motorcycle traveling at the
desired cruise speed, 30-90 mph (48-145 km/h),
momentarily push the cruise SET/RESUME switch to SET.
3. See Figure 5-9. The ECM monitors the VSS to establish 1. Ignition switch
the desired vehicle speed. The ECM then modulates the 2. Cruise on/off switch
throttle control actuator to maintain vehicle speed. The
cruise enabled/engaged lamp in the tachometer face Figure 5-7. Fairing Cap (FLHTCU)

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ed01551
TROUBLESHOOTING
The ECM provides on-board diagnostics to help isolate any
problems that occur with the cruise system.
If the cruise is inoperative or fails to set, begin troubleshooting.
Refer to Table 5-5. If the cruise seems to disengage or drop
out for no apparent reason, see 5.4 DTC P0577.
See Figure 5-9. In the diagnostic mode, the cruise
enabled/engaged lamp is employed as a test indicator. The
lamp is in the tachometer face (speedometer on FLHR/C
models).
1
Diagnostic Tips
• An intermittent may be caused by poor connection, rubbed
through wire insulation or an inoperative wire inside the
1. Set/Resume switch insulation.
Figure 5-8. Right Handlebar Switch Assembly: FLHTCU, • Poor connection: Inspect component and harness con-
FLTRX, FLTRU nectors for backed out terminals, improper mating, inoper-
ative locks, improperly formed or damaged terminals, poor
terminal-to-wire connection and damaged harnesses.

ed02071
CRUISE INOPERATIVE DIAGNOSTICS
1
All diagnostics steps are listed in table format. Follow the
numbered steps to test the system. Compare the system
behavior CORRECT FUNCTION to INCORRECT FUNCTION
columns and advance to the next step listed. Refer to Table 5-5.

2
1. Tachometer
2. Cruise enabled/engaged lamp
Figure 5-9. Instrument Panel (FLHTCU - typical)

Table 5-5. Cruise Inoperative Diagnostics

NO. ACTION CORRECT FUNCTION INCORRECT FUNCTION

1 Enter the diagnostic mode: RUN switch
off, ignition switch at IGNITION. Hold
the SET/RESUME switch at SET while
turning the RUN switch on.
2 Push the SET/RESUME switch to
RES(UME) and hold in this position.
3 Turn the throttle grip tightly closed to
check the throttle roll-off command.
The green cruise lamp illuminates and If the green cruise lamp remains illumin-
remains on as long as the cruise ated after the switch is released then
SET/RESUME switch is held in the one of the switches or related wiring is
SET position. open or shorted.
Continue to next step.
The green cruise lamp illuminates and If the green cruise lamp does not illu-
remains on as long as the minate at all, check for one or more of
SET/RESUME switch is held in the the following conditions:
RES(UME) position. • RES(UME) switch not wired cor-
Continue to next step. rectly.
• Open or shorted wire to
RES(UME) switch.
The green cruise lamp illuminates If the green cruise lamp does not illu-
when the grip is closed (roll-off posi- minate, see 6.31 DTC P2135, P2138.
tion), and extinguishes when the
throttle grip returns to its free position.
Continue to next step.

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Table 5-5. Cruise Inoperative Diagnostics
NO. ACTION
4 Apply the front brake lever.
5 Apply the rear brake pedal.
6 To restart or repeat the diagnostic
sequence, return to Step 1.
CORRECT FUNCTION
The green cruise lamp will illuminate
and remain on until the brake lever is
released.
Continue to next step.
The green cruise lamp illuminates and
remains on until the brake pedal is
released.
Continue to next step.
2011 Touring Diagnostics: Accessories, Horn, Lighting and Security 5-9
INCORRECT FUNCTION
If the green cruise lamp does not illu-
minate, check for one or more of the
following conditions:
• Front brake switch not wired cor-
rectly.
• Open or shorted wire to front
brake switch.
• Front brake switch not working
properly.
See 6.13 DTC P0572.
If the green cruise lamp does not illu-
minate, check for one or more of the
following conditions:
• Rear brake switch not wired cor-
rectly.
• Inoperative or pinched wire to rear
brake switch.
• Rear brake switch not working
properly.
See 6.13 DTC P0572.
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CRUISE CONTROL INOPERATIVE hill)

CONDITIONS • Vehicle cannot decrease to cruise control set speed (down
hill)
The cruise control will become inoperative under the following
conditions: • Brake is applied
• Ignition is off • Twist grip roll-off
• Cruise control switch is off (open) • ECM seeing both the SET/RESUME switches pressed at
the same time
• Ignition voltage
• Engine has not been running enough
• Throttle position faults P0120 and P0220
• Clutch lever is pulled in (declutched)
• VSS faults P0501 and P0502
• Vehicle acceleration rate is too high
• Cruise control switch or brake switch failure P0577
• Vehicle deceleration rate is too high
• TPS correlation error P2135
• Vehicle speed is too high
• Flash checksum error P0605
• Vehicle speed is too low
• Brake switch fault P0572
• Engine rpm is too high
• TBW limited performance mode P1510
• Engine rpm is too low
• Cruise control set speed is too low
• Engine rpm acceleration is too high
• Cruise control set speed is too high
• Transmission is in too low of a gear or in neutral
• Vehicle cannot increase to cruise control set speed (up

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DTC P0577 5.4

CRUISE CONTROL switches and the ECM become shorted to voltage the ECM
will set DTC P0577 and disable the cruise control system.
The cruise control system in monitored and controlled through
the ECM. The set/coast and resume/accelerate switches are
Table 5-6. Code Description
inputs to the ECM. If the circuits between either one of the
DTC DESCRIPTION
P0577 Cruise Control Input High

Connector Information
For additional information about the connectors in the following
diagram(s) and diagnostic procedure(s), including the color of
the harness test kit terminal probes, see B.1 CONNECTORS.

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em00849 Cruise Set/

Resume Switch Cruise On/ Cruise Set/
Tachometer Off Switch Resume Switch

Serial Data
BE/BK
W/BE

O/W
W/BE
BE/BK
[22A] 12 11 [108A] 2
Speedometer
[22B] 12 11 [108B] 2

Serial Data
R/GN

W/BE
Cruise On/

BE/BK

LGN/V

R/GN
Off Switch O/V

O/W

O/W
[158A] 2 [24A] 1 [22A] 1 2 [39A]
BK/GN

R/GN

Dash Panel [158B] 2 [24B] 1 [22B] 1 [39B]

O/V

BE/BK
Switches

W/BE
O/W

O/W
R/GN
[105B] 12 5 4

LGN/V
[105A] 12 5 4 2 1 [159A]
2 1 [159B]
O/W
R/GN
BK

2 [20A]
FLHRC

W/BE
BE/BK
Only 2 [20B]

LGN/V
LGN/V

BE/BK
W/BE
R/GN
O/W

5 13 14 15 16 [1B]
5 13 14 15 16 [1A]
O/W

W/BE
R/GN
LGN/V

BE/BK

O/W

LGN/V
BE/BK
W/BE
R/GN
Except FLHRC
FLHRC Only
O/W

LGN/V
BE/BK
W/BE
R/GN

To
Accessory
Fuse 22 34 35 69
[78B]
[78A] 22 34 35 69
Serial Data
Cruise Resume/Accelerate
Cruise Enable
Cruise Set/Coast

ECM

Figure 5-10. Cruise Control Circuit

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DTC P0577 2. Measure voltage between breakout box terminal 22 and

ground.
PART NUMBER TOOL NAME
3. Is voltage greater than 1.0V?
HD-48637 BREAKOUT BOX
a. Yes. Repair short to voltage on (BE/BK) wire. (5041)
b. No. Replace Cruise Set/Coast Switch. See the service
Table 5-7. DTC P0577 Diagnostic Faults
manual.
POSSIBLE CAUSES
Short to voltage in cruise set/coast circuit
3. Cruise Resume/Accelerate Circuit Voltage
Cruise resume/accelerate switch malfunction
Test
1. Measure voltage between breakout box terminal 34 and
Cruise set/coast switch malfunction
ground.
Short to voltage in cruise resume/accelerate circuit
2. Is voltage greater than 1.0V?
1. Cruise Set/Coast Circuit Voltage Test a. Yes. Go to Test 4.
1. Connect BREAKOUT BOX (Part No. HD-48637) between b. No. See diagnostic tips.
wire harness [78B] and ECM [78A]. See 1.2 DIAGNOSTIC
TOOLS. 4. Cruise Circuit Voltage Test
2. Turn IGN ON. 1. Disconnect right hand controls [22].
3. Using a multimeter, measure voltage between breakout 2. Measure voltage between breakout box terminal 34 and
box terminal 22 and ground. ground.
4. Is voltage greater than 1.0V? 3. Is voltage greater than 1.0V?
a. Yes. Go to Test 2. a. Yes. Repair short to voltage on (W/BE) wire. (5041)
b. No. Go to Test 3. b. No. Replace Cruise Resume/Accelerate Switch. See
the service manual.
2. Cruise Set/Coast Switch Test
1. Disconnect right hand controls [22].

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HORN 5.5
DESCRIPTION AND OPERATION SYMPTOMS
The horn is powered through the horn switch from the The horn circuit does not set DTCs when there is a malfunction.
accessory fuse. The horn is grounded through GND 1. When Instead, one of the symptoms shown in Table 5-8 exists to
the horn switch is pressed, battery voltage is applied to the indicate a concern with the system.
horn [122] terminal 1, causing the horn to sound.

COMPONENTS Table 5-8. Horn Symptoms

SYMPTOM COMMON CAUSE

Horn Switch
Horn always on Short to voltage or a stuck
The horn switch is a push button switch on the left handlebar switch
controls.
Horn inoperative Open circuit, faulty horn or
Horn horn switch
See Figure 5-11. The horn is located on the left side of the
vehicle between the cylinders.
Diagnostic Tips
If the fuse is open, check the circuit between the horn switch
and the horn for a short to ground. This would cause the fuse
ed03074
to open only when the horn switch is pressed. A short between
the brake lamp switches and the tail/stop lamp causes this fuse
to open when the brakes are applied.
The (O/W) wire from the fuse supplies battery voltage to several
components. A short anywhere in the (O/W) wire causes the
fuse to open immediately.

Connector Information
For additional information about the connectors in the following
diagram(s) and diagnostic procedure(s), including the color of
the harness test kit terminal probes, see B.1 CONNECTORS.

Figure 5-11. Horn [122]

em00733

Ignition
Power
R/GY

1C

ACCY [64-1B]
15A Accessory Left
Power Turn Switch
1D
[1B] [1A]
Except
O/W

FLHR/C Horn
O/W

O/W

O/W 1 1 O/W [24B] [24A] Switch

O/W [2B] [2A] O/W 1 1 O/W O/W

Left BK Y/BK Y/BK 6 6 Y/BK Y/BK

GND1 Y/BK 6 6 Y/BK
Y/BK
BK

1 2 [122B]
1 2 [122A] O/W
FLHR/C
Y/BK

Horn

Figure 5-12. Horn

5-14 2011 Touring Diagnostics: Accessories, Horn, Lighting and Security

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HORN ALWAYS ON 2. Horn Test

1. Disconnect the horn [122].
Table 5-9. Horn Always On Diagnostic Faults
2. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
POSSIBLE CAUSES 41404-C), test for voltage at horn [122B] between terminal
Short to voltage in horn power circuit 1 and terminal 2.

Horn switch malfunction 3. Press the horn switch.

4. Is battery voltage present?
1. Horn Switch Test
a. Yes. Replace the horn. See the service manual.
1. Disconnect left hand controls [24]. (5765)
2. Does the horn turn off? b. No. Go to Test 3.
a. Yes. Replace the horn switch. See the service
manual. (5171) 3. Ground Circuit Open Test
b. No. Repair short to voltage in the (Y/BK) wire between 1. Test for continuity between horn [122B] terminal 1 and
horn and left hand controls. (5041) ground.
2. Is continuity present?
HORN INOPERATIVE
a. Yes. Go to Test 4.
PART NUMBER TOOL NAME
b. No. Repair open in the ground circuit. (5041)
HD-41404-C HARNESS CONNECTOR TEST KIT
4. Horn Switch Malfunction Test
Table 5-10. Horn Inoperative Diagnostic Faults 1. Connect the horn [122].
POSSIBLE CAUSES 2. Disconnect left hand controls [24].
Open accessory circuit 3. With IGN ON, using the HARNESS CONNECTOR TEST
Shorted accessory circuit KIT (Part No. HD-41404-C) jumper [24B] terminal 1 and
terminal 6.
Horn malfunction
4. Does the horn sound?
Open ground circuit
a. Yes. Replace the horn switch. See the service
Horn switch malfunction
manual. (5171)
Open horn power circuit
b. No. Go to Test 5.
1. Accessory Circuit Open or Shorted Test
5. Horn Power Circuit Open Test
1. With the IGN ON, activate the front and rear brakes.
1. Test for voltage from [24B] terminal 1 (O/W) to ground.
2. Does the tail/stop lamp illuminate?
2. Is battery voltage present?
a. Yes. Go to Test 2.
a. Yes. Repair open in (Y/BK) wire between [24B] and
b. No. Inspect the fuse. If fuse is good locate and repair horn. (5041)
open in (O/W) wire. If fuse is open repair short to
ground in circuits that may affect the fuse. See dia- b. No. Repair open (O/W) wire between [24A] and fuse
gnostic tips. (5043) block. (5043)

2011 Touring Diagnostics: Accessories, Horn, Lighting and Security 5-15

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TURN SIGNALS
DESCRIPTION AND OPERATION
TSM/TSSM/HFSM receives battery power through the ignition.
The operation functions the same way whether you have a
TSM, a TSSM or a HFSM. The TSM communicates with the
other modules on the vehicle through the serial data circuit.
The turn signal switches are inputs to the TSM. When the turn
signal switch is pressed the switch closes and power flows to
TSM. This signals the TSM to supply voltage and control the
flash rate to the turn signals and the turn signal indicator. If the
turn signal switches are pressed at the same time and held
down the TSM initiates the four-way flashers.
The TSM also monitors the position of the clutch and neutral
switches to determine if it is safe to start the vehicle. The BAS
is internal to the TSM and allows the TSM to determine if the
vehicle is tipped over. If a tip over event occurs, the TSM sends
a signal to the ECM to turn off the engine.
The TSM has three major functions:
• Controls the turn signals.
• Serves as the BAS.
• Monitors the clutch and neutral switches to prevent starter
engagement.
BAS Operation
The TSM/TSSM/HFSM uses an internal BAS to monitor vehicle
position. Under normal driving conditions the TSM/TSSM/HFSM
uses the BAS along with speed input provided from the ECM
to know when to automatically cancel the turn signals after a
turn. The TSM/TSSM/HFSM will disable turn signal lamps and
starter activation and will send a message to the ECM to shut
down the ignition and the fuel pump if the vehicle is tipped over.
The odometer will display "tIP" when a tip-over condition is
present.
BAS Restart
To restart the vehicle after shutdown has occurred:
1. Return the vehicle to an upright position.
2. Cycle the IGN OFF-ON before restarting the vehicle.
Manual Cancellation
If you want to stop the turn signals from flashing, briefly press
the turn signal switch a second time.
If you are signalling to turn in one direction and you press the
switch for the opposite turn signal, the first signal is cancelled
and the opposite side begins flashing.
Automatic Cancellation
Press the left or right turn switch to activate automatic turn
signal cancellation. There is no need to hold the turn switch in
when approaching the turn. The TSM/TSSM/HFSM will not
cancel the signal before the turn is actually completed.
• When the directional switch is released, the system starts
a 20 count. As long as the vehicle is traveling above 7
5-16 2011 Touring Diagnostics: Accessories, Horn, Lighting and Security
5.6
mph (11 km/h), the directional will always cancel after 20
flashes if the system does not recognize any other input.
• If the vehicle speed drops to 7 mph (11 km/h) or less,
including stopped, the directionals will continue to flash.
Counting will resume when vehicle speed reaches 8 mph
(12.9 km/h) and will automatically cancel when the count
total equals 20 as stated above.
• See Figure 5-13. The turn signals will cancel within two
seconds upon turn completion. A sensor inside the
TSM/TSSM/HFSM cancels the signal after the vehicle has
been returned to an upright position.
NOTE
The bank angle cancellation function has an automatic calibra-
tion feature. Ride the vehicle for 0.25 mile (0.4 km) at steady
speeds (upright) to calibrate the system. Performance of bank
angle function may not be optimal until this calibration is per-
formed. This self-calibration is performed automatically every
time the vehicle is started and ridden.
ed01792
1 2
1. Left 45 degrees
2. Right 45 degrees
Figure 5-13. Tilting TSM/HFSM
Four-Way Flashing
Use the following method to activate the four-way flashers:
1. With the ignition switch ON and the security system dis-
armed (models with security only), press the left and right
turn signal switches at the same time.
2. Turn the ignition switch OFF and arm the security system
if present and desired. The four-way flashers will continue
for two hours.
3. To cancel four-way flashing, disarm the security system
if necessary, turn the ignition switch ON and press the left
and right turn signal switches at the same time.
This system allows a stranded vehicle to be left in the four-way
flashing mode and secured until help is found.
If the security system is disarmed while the four-way flashers
are active, the lights will flash as follows:
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1. TSSM/HFSM stops four-way flashing mode. Vehicle sits 3. Vehicle sits for 1 second with turn signals off.
for 1 second with turn signals off.
4. Vehicle restarts four-way flashing mode.
2. TSSM/HFSM performs disarming confirmation (1 flash).

em00850
[22A] [22B] [64-1B]
Battery15A
O/W 1 1 O/W
Right Turn BN/GY 2D 2C R
Switch W/BN 5 5 W/BN Accessories 15A
O/W 1D 1C R/GY
O/W 1 1 O/W [64-2B]
Left Turn
Switch W/V 5 5 W/V
Lights
BE 2F 2E R/BK

[24A] [24B] Ignition 15A

GY 1F 1E R/BK

[30A] [30B]
TSM/HFSM Indicator
Battery 1 1 BN/GY Lamps
Ignition 2 2 GY Right
Left
Left Turn Feed Output 5 5 V Turn Turn
Right Turn Feed Output 6 6 BN

BN
BK

BK
V
Right Turn Switch Input 7 7 W/BN [20B] [20A] [21A] [21B]
Left Turn Switch Input 8 8 W/V
Ground 12 12 BK/GN BK/GN 5 5 BK/GN 7 7 BK

BN 12 12 BN 4 4 BN

V 9 9 V 1 1 V

GND
Right Turn BK 1 1 BK
And DOM BN 2 2 BN
Running Lamp Turn
BE 3 3 BE
Power
Left Turn BE 4 4 BE
And DOM Turn
V 5 5 V
Running Lamp

BN

BK

BE
BK 6 6 BK

V
GND

[31B] [31A] [7A] 1 3 5 6 7

[7B] 1 3 5 6 7

BN

BK

BE
V
Left GND 1 Right GND 2

BN
BK

BE
V
6 5 3 2 1 [94B]
6 5 3 2 1
[94A]
[18B]
Right Rear
Turn V/BN 1 1
Lamp BK 2 2 [18A]
[19B]
Left Rear
Turn V/BN 1 1
Lamp BK 2 2 [19A]

Figure 5-14. Turn Signal Circuit: FLHR/C

2011 Touring Diagnostics: Accessories, Horn, Lighting and Security 5-17

HOME

Left Right
em00824
Turn Turn
[22A] [22B] [64-1B]

BN
BK
BK
V
Battery15A
Indicator
BN/GY 2D 2C R
O/W 1 1 O/W Lamps
Right Turn

BN
BK
Switch Accessories 15A

V
W/BN 5 5 W/BN
O/W 1D 1C R/GY
5 4 1 [21B]
[64-2B]
O/W 1 1 O/W 4 1 [21A]
Left Turn Lights
Switch [1A] [1B]

BN
BE 2F 2E R/BK

V
W/V 5 5 W/V

W/V 11 11 W/V Ignition 15A

[24A] [24B] GY 1F 1E R/BK
W/BN 10 10 W/BN
BN 8 8 BN
V 7 7 V
[30A] [30B]
TSM/HFSM O/W 5 5 O/W
Battery 1 1 BN/GY
Ignition 2 2 GY
Left Turn Feed Output 5 5 V
Right Turn Feed Output 6 6 BN
Right Turn Switch Input 7 7 W/BN
Left Turn Switch Input 8 8 W/V
Ground 12 12 BK/GN BK/GN Right Left
GND 2 GND 1
BK D D BK BK

BE B B BE

RH Front LH Front [15A] [15B]

BE
BN

BK
BE
BK

BN

BK
V

V
Turn Signal Turn Signal
[31RA] 3 2 1 3 2 1 [31LA]
[31RB] 3 2 1 3 2 1 [31LB] (FL/TRX/HX
Canada Only) (FL/TRX/HX)
V/BN
BE

BE
BK
V/BK
BK

BN

BN
BK

BK
Right Turn Left Turn
V

V
And DOM And DOM
Running Running 1 3 4 [257A] 1 3 4 [257A]
Lamp Lamp 1 3 4 [257B] 1 3 4 [257B]
BN

BN
BK

BK
V

V
(FL/HTCU/HTK/TRU) (FLHTC Only)
BN

BN
BK

BN

BN
BK

BK

BK

BK

BK
V

[7A] 1 3 5 [257A] 2 5 4 [226B] 1 3 4 7 [226B] 1 3 4 7

[7B] 1 3 5 [257B] 2 5 4 [226A] 1 3 4 7 [226A] 1 3 4 7

Facia/ Facia/
BN

BK
V

Converter Converter
BN

BK
V

[262A] 1 4 5 7
Module [262A] 1 2 4 5 6 7 11
Module
[7A] 1 3 5
[262B] 1 4 5 7
[7B] 1 3 5
(DOM) (HDI)
BN
BK
BK
V
BN

BK
V

[262B] 1 2 5 6 [262B] 1 4 7 11
GN/W
V/BN

Y/W

GN
BK
BK
V

Y
BN

BN

BN
BK

BK

BK
V

V
V

[94B] 6 5 2 [94B] 6 5 2 [94B] 6 5 2

6 5 4 3 2 1 [94A]
Right Rear [18B]
Turn
Lamp V/BN 1 1
BK 2 2 [18A]
[19B]
Left Rear
Turn
Lamp V/BN 1 1
BK 2 2 [19A]

Figure 5-15. Turn Signal Circuit: Except FLHR/C

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WILL NOT CANCEL UPON TURN 5. Speedometer Test

COMPLETION, NO DTCS 1. Does speedometer register vehicle speed?
a. Yes. Replace TSM/TSSM/HFSM. See the service
Table 5-11. Will Not Cancel Upon Turn Completion, No manual. (6773)
DTCs Diagnostic Faults
b. No. See 2.1 INITIAL DIAGNOSTICS.
POSSIBLE CAUSES
Improper configuration FLASH AT DOUBLE NORMAL RATE, ALL
TSM/TSSM/HFSM malfunction
BULBS WORK, NO DTCS
PART NUMBER TOOL NAME
1. TSM/TSSM/HFSM Mounting Test
99861-02 ELECTRICAL CONTACT LUBRICANT
1. Verify TSM/TSSM/HFSM is mounted correctly.
2. Is TSM/TSSM/HFSM mounted correctly? Table 5-12. Flash at Double Normal Rate, All Bulbs Work,
a. Yes. Go to Test 2. No DTCs Diagnostic Faults
b. No. Mount correctly. POSSIBLE CAUSES
Incorrect lamps
2. Correct Configuration Test
TSM/TSSM/HFSM malfunction
1. Check if TSM/TSSM/HFSM is configured correctly. See
5.15 SERVICE AND EMERGENCY FUNCTIONS AND Lamp malfunction
CONFIGURATIONS.
1. Lamp Load Calibration Test
2. Proper configuration?
1. Disconnect the negative battery cable for at least one
a. Yes. Go to Test 3. minute.
b. No. Select proper vehicle configuration. 2. Connect the negative battery cable.

3. 4-Way Cancellation Test 3. Turn IGN ON.

1. Gain access to the vehicle's TSM/TSSM/HFSM. 4. Activate the left turn signals for more than four flashes.

2. See Figure 5-13. Position TSM/TSSM/HFSM in the same 5. Activate the right turn signals for more than four flashes.
orientation it is mounted on the vehicle. 6. Did the turn signals calibrate?
3. With IGN ON, turn on 4-way flashers by depressing both a. Yes. Go to Test 2.
left and right turn signal switches at the same time.
b. No. Correct issue and recalibrate.
4. Turn IGN OFF. The 4-way flashers should continue to
flash. 2. Lamp Verification Test
5. Tilt the module greater than 45 degrees to the left. 1. Determine correct part number for all installed turn signal
bulbs.
6. Repeat steps 2-4 then tilt the module greater than 45
degrees to the right. 2. Verify correct parts are installed on vehicle.
7. Do 4-way flashers cancel in both directions? 3. Are the correct parts installed?
a. Yes. Go to Test 4. a. Yes. Go to Test 3.
b. No. Replace TSM/TSSM/HFSM. See the service b. No. Replace with correct bulbs. See the service
manual. (6773) manual. (6820)

4. Turn Signals Cancel Test 3. Bulb Corrosion Test

1. Operate vehicle at a speed greater than 7 mph (11.2 km/h) 1. Check for corrosion on bulbs and/or sockets.
in a straight line.
2. Is corrosion present?
2. Activate either turn signal. a. Yes. Go to Test 6.
3. Turn signals should cancel after 20 flashes. b. No. Go to Test 4.
4. Do turn signals cancel?
a. Yes. System operating properly.
4. Lamp Connection Terminal Corrosion
Test
b. No. Go to Test 5.
1. Check for corrosion on all lamp connection terminals.

2011 Touring Diagnostics: Accessories, Horn, Lighting and Security 5-19

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2. Is corrosion present? 2. Right Turn Signal Circuit Test

a. Yes. Go to Test 5. 1. With IGN OFF, connect BREAKOUT BOX (Part No. HD-
b. No. Replace TSM/TSSM/HFSM. See the service 42682) between wire harness connector [30B] and
manual. (6791) TSM/TSSM/HFSM [30A]. See 1.2 DIAGNOSTIC TOOLS.
2. Turn IGN ON.
5. Verification Test
3. While pressing the right turn signal switch, using a multi-
1. Clean corrosion from wires and terminals.
meter, test for voltage on breakout box (gray) terminal 7.
2. Do lamps flash at normal rate?
4. Is battery voltage present when switch is pressed?
a. Yes. System OK. (6822)
a. Yes. Go to Test 8.
b. No. Replace TSM/TSSM/HFSM. See the service
b. No. Go to Test 3.
manual. (6791)
3. Right Turn Signal Switch Test
6. Lamp Operation Test
1. Disconnect right hand controls [22].
1. Remove corrosion with a wire brush.
2. Test for voltage between [22B] terminal 1 and ground.
2. Install ELECTRICAL CONTACT LUBRICANT (Part
No. 99861-02) in bulb sockets. 3. Is battery voltage present?
3. Do lamps flash at normal rate? a. Yes. Go to Test 4.
a. Yes. System OK. (6822) b. No. Repair open in (O/W) wire. (5041)
b. No. Go to Test 7.
4. Right Turn Signal Circuit Continuity Test
7. Lamp Assembly Test 1. Turn IGN OFF.
1. Clean or replace bulb. 2. Test for continuity between [22B] terminal 5 and breakout
box (gray) terminal 7.
2. Do lamps flash at normal rate?
a. Yes. System OK. (6822) 3. Is continuity present?
a. Yes. Replace the right turn signal switch. See the
b. No. Replace lamp assembly. See the service manual.
service manual. (6811)
(6823)
b. No. Repair open in (W/BN) wire. (5041)
BOTH TURN SIGNAL LAMPS ON ONE SIDE
INOPERATIVE, NO DTCS 5. Left Turn Signal Circuit Test
1. With IGN OFF, connect BREAKOUT BOX (Part No. HD-
PART NUMBER TOOL NAME 42682) between wire harness connector [30B] and
HD-42682 BREAKOUT BOX TSM/TSSM/HFSM [30A]. See 1.2 DIAGNOSTIC TOOLS.
2. Turn IGN ON.
Table 5-13. Both Turn Signal Lamps on One Side
Inoperative, No DTCs Diagnostic Faults 3. While pressing the left turn signal switch, using a multi-
meter, test for voltage on breakout box (gray) terminal 8.
POSSIBLE CAUSES
4. Is battery voltage present when switch is pressed?
Open on turn signal inputs
a. Yes. Go to Test 9.
Open accessory circuit
b. No. Go to Test 6.
Left turn signal switch malfunction
Right turn signal switch malfunction 6. Left Turn Signal Switch Test
TSM/TSSM/HFSM malfunction 1. Disconnect left hand controls [24].
2. Test for voltage between [24B] terminal 1 and ground.
1. Left or Right Turn Signal Malfunction Test
1. With IGN ON, operate the left and right turn signals. 3. Is battery voltage present?
a. Yes. Go to Test 7.
2. Are the right turn signals inoperative?
a. Yes. Go to Test 2. b. No. Repair open in (O/W) wire. (5043)

b. No. Go to Test 5. 7. Left Turn Signal Circuit Continuity Test

1. Turn IGN OFF.
2. Test for continuity between [24B] terminal 5 and breakout
box (gray) terminal 8.

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3. Is continuity present? 2. Do all the turn signals operate on both sides?

a. Yes. Replace the left turn signal switch. See the ser- a. Yes. System operating properly.
vice manual. (6811)
b. No, right front turn signal inoperative. Go to Test
b. No. Repair open in (W/V) wire. (5041) 2.
c. No, left front turn signal inoperative. Go to Test 5.
8. Right Turn Signal Short to Voltage Test
1. Release the right turn signal switch. d. No, right rear turn signal inoperative. Go to Test
8.
2. Test for voltage on breakout box (gray) terminal 7.
e. No, left rear turn signal inoperative. Go to Test 11.
3. Is battery voltage present?
a. Yes. Repair short to voltage on (W/BN) wire. 2. Right Front Turn Signal Bulb Test
b. No, without anti-theft tracking module. Replace 1. Remove the right front turn signal bulb.
the TSM/TSSM/HFSM. See the service manual. 2. Inspect the bulb.
c. No, with anti-theft tracking module. Go to Test 10. 3. Is the bulb good?
a. Yes. Go to Test 3.
9. Left Turn Signal Short to Voltage Test
1. Release the left turn signal switch. b. No. Replace the bulb. See the service manual. (6820)

2. Test for voltage on breakout box (gray) terminal 8. 3. Right Front Turn Signal Circuit Test
3. Is battery voltage present? 1. Disconnect front turn signal [31] (FLHR/C) or [31R] (except
a. Yes. Repair short to voltage on (W/V) wire. FLHR/C).

b. No, without anti-theft tracking module. Replace 2. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
the TSM/TSSM/HFSM. See the service manual. 41404-C), connect a test light to [31A] (FLHR/C) or [31RA]
(except FLHR/C) between terminals 1 and 2.
c. No, with anti-theft tracking module. Go to Test 10.
3. Press the right turn signal switch.
10. Anti-Theft Tracking Module Test 4. Does the test light flash?
1. Disconnect anti-theft tracking module. a. Yes. Replace the right front turn signal. See the ser-
vice manual. (6823)
2. Press the inoperative turn signal switch.
b. No. Go to Test 4.
3. Do the turn signals function properly?
a. Yes. Replace the anti-theft tracking module. See the 4. Right Front Turn Signal Ground Circuit
service manual.
Test
b. No. Replace the TSM/TSSM/HFSM. See the service
1. Test for voltage between [31A] (FLHR/C) or [31RA] (except
manual.
FLHR/C) terminal 2 and ground.
ONE TURN SIGNAL LAMP INOPERATIVE, 2. Does the voltage cycle on and off?
NO DTCS a. Yes. Repair open in (BK) wire between [31A]
(FLHR/C) or [31RA] (except FLHR/C) terminal 1 and
PART NUMBER TOOL NAME ground. (5041)
HD-41404-C HARNESS CONNECTOR TEST KIT b. No. Repair open in (BN) wire between [31A] (FLHR/C)
or [31RA] (except FLHR/C) terminal 2 and
Table 5-14. One Turn Signal Lamp Inoperative, No DTCs TSM/TSSM/HFSM. (5041)
Diagnostic Faults
5. Left Front Turn Signal Bulb Test
POSSIBLE CAUSES
1. Remove the left front turn signal bulb.
Open turn signal circuit
2. Inspect the bulb.
Open turn signal ground circuit
Inoperative turn signal 3. Is the bulb good?

TSM/TSSM/HFSM malfunction a. Yes. Go to Test 6.

b. No. Replace the bulb. See the service manual. (6820)
1. Inoperative Signal Location Test
1. With IGN ON, operate the left and right turn signals. 6. Left Front Turn Signal Circuit Test
1. Disconnect front turn signal [31] (FLHR/C) or [31L] (except
FLHR/C).

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2. Using HARNESS CONNECTOR TEST KIT (Part No. HD- 3. Does the voltage cycle off and on?
41404-C), connect a test light to [31A] between terminal a. Yes. Except FLTRX/FLHX. Replace the circuit board.
5 and terminal 6 (FLHR/C) or [31LA] between terminal 2 See the service manual. (5215)
and terminal 3 (except FLHR/C).
b. Yes. FLTRX/FLHX. Replace the facia/converter
3. Press the left turn signal switch. module. See the service manual. (6809)
4. Does the test light flash? c. No. Go to Test 14.
a. Yes. Replace the left front turn signal. See the service
manual. (6823) 11. Left Rear Turn Signal Bulb Test
b. No. Go to Test 7. 1. Remove the left rear turn signal bulb.
2. Inspect the bulb.
7. Left Front Turn Signal Ground Circuit Test
3. Is the bulb good?
1. Test for voltage between [31A] (FLHR/C) terminal 5 and
ground or [31LA] (except FLHR/C) terminal 2 and ground. a. Yes. Go to Test 12.

2. Does the voltage cycle on and off?
a. Yes. Repair open in (BK) wire between [31A] terminal
6 and ground (FLHR/C) or [31LA] terminal 3 and
ground (except FLHR/C). (5041)
b. No. Repair open in (V) wire between [31A] terminal
5 and TSM/TSSM/HFSM (FLHR/C) or [31LA] terminal
2 and TSM/TSSM/HFSM (except FLHR/C). (5041)
8. Right Rear Turn Signal Bulb Test
1. Remove the right rear turn signal bulb.
2. Inspect the bulb.
b. No. Lamp is LED. Go to Test 17.
c. No. Bulb does not work. Replace the bulb. See the
service manual. (6820)
12. Left Rear Turn Signal Circuit Test:
Except LED Lights
1. Disconnect left rear turn signal [19] (except FLTRX/FLHX)
or rear lighting jumper harness [262] (FLTRX/FLHX).
2. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
41404-C), connect a test light to [19A] terminal 1 and ter-
minal 2 or [262A] terminal 2 and terminal 5.

3. Is the bulb good? 3. Press the left turn signal switch.

a. Yes. Go to Test 9. 4. Does the test light flash?
b. No. Lamp is LED. Go to Test 15. a. Yes. Replace the left rear turn signal. See the service
manual. (6823)
c. No. Bulb does not work. Replace the bulb. See the
service manual. (6820) b. No. Go to Test 13.

9. Right Rear Turn Signal Circuit Test:
Except LED Lights
1. Disconnect right rear turn signal [18] (except FLTRX/FLHX)
or [262] (FLTRX/FLHX).
2. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
41404-C), connect a test light to [18A] terminal 1 and ter-
minal 2 or [262A] terminal 1 and terminal 6.
3. Press the right turn signal switch.
13. Left Rear Turn Signal Component Test
1. Test for voltage between [94B] terminal 5 and terminal 6
or [226B] terminal 1 and terminal 4.
2. Does the voltage cycle off and on?
a. Yes. Except FLTRX/FLHX. Replace the circuit board.
See the service manual. (5215)
b. Yes. FLTRX/FLHX. Replace the facia/converter
module. See the service manual. (6809)

4. Does the test light flash? c. No. Go to Test 16.

a. Yes. Replace the right rear turn signal. See the ser-
vice manual. (6823)
14. Right Rear Turn Signal Ground Circuit
Test
b. No. Go to Test 10.
1. Test for voltage between [94] terminal 2 or [226] terminal
10. Right Rear Turn Signal Ground Circuit 3 and ground.
Component Test 2. Does the voltage cycle on and off?
1. Disconnect rear fender lights [94] (except FLTRX/FLHX) a. Yes. Repair open in the (BK) wire. (5041)
or [226] (FLTRX/FLHX). b. No. Repair open in the (BN) wire. (5041)
2. Test for voltage between [94B] terminal 2 and terminal 6
or [226B] terminal 3 and terminal 7. 15. Right Rear Turn Signal Circuit Test: LED
Lights
1. Disconnect rear lighting jumper harness [262].

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2. Test for voltage at [262A] between terminal 1 and terminal 2. Does the voltage cycle on and off?
5. a. Yes. Repair open in the (BK) wire. (5041)
3. Does the voltage cycle on and off? b. No. Repair open in the (V) wire. (5041)
a. Yes. Replace the lightbar. See the service manual.
(6823) 17. Left Rear Turn Signal Circuit Test: LED
b. No. Go to Test 10. Lights
1. Disconnect rear lighting jumper harness [262].
16. Left Rear Turn Signal Ground Circuit
2. Test for voltage at [262A] between terminal 2 and terminal
Test 5.
1. Test for voltage between [94] terminal 5 or [226] terminal
3. Does the voltage cycle on and off?
4 and ground.
a. Yes. Replace the lightbar. See the service manual.
(6823)
b. No. Go to Test 12.

2011 Touring Diagnostics: Accessories, Horn, Lighting and Security 5-23

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HEADLAMPS 5.7
DESCRIPTION AND OPERATION
ed03072
When the ignition is turned ON the headlamp switch receives 1 2
power through the lights fuse.
• In the low position the headlamp switch directs voltage
through the (Y) wire to illuminate the low beam headlamp.
• In the high position voltage is directed through the (W)
wire to the high beam headlamp and the high beam
3
indicator.
See Figure 5-16 and Figure 5-17. The headlamp could have
one (FLH models) or two (FLT models) connectors depending
on the model. Most models have a single connector for the low
and high beam headlamp. However, the FLT model has a left 4
assembly connector and a right assembly connector.

ed03110 1. HDI position lamp [29-2]

11 1 2. HDI position lamp [29-1]
3
3. Headlamp [38R]
10 2
4. Headlamp [38L]
Figure 5-17. Headlamp: FLT Models
4
9
8 Diagnostic Tips
If the headlight fuse is open, test for short to ground on (BE)
5
wire from the fuse to the headlamp switch. Also, check for a
short to ground on the (W) wire from the headlamp switch. If
7 this circuit is grounded, it will open the fuse when the headlamp
6 switch is in the high position.

Connector Information
1. Front turn signals [31]
2. Accessories off/on switch [67] For additional information about the connectors in the following
3. Left hand controls [24] diagram(s) and diagnostic procedure(s), including the color of
4. Left cruise controls [158] the harness test kit terminal probes, see B.1 CONNECTORS.
5. Front wheel speed sensor [167]
6. Head lamp [38]
7. Twist grip sensor [204]
8. Right cruise controls [159]
9. Passing lamps off/on switch [109]
10. Right hand controls [22]
11. Passing lamps [73]
Figure 5-16. Head Lamp Nacelle: FLH Models

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[73A] [73B] Auxiliary

em00851
Lights
[109A] [109B]
GY/BK 2 2 GY/BK

4 4 GY/BK Auxiliary
Lights
Toggle 3 3 BK GY/BK 1 1 GY/BK
Switch
2 2

1 1 Y BK/GN Sensor
Grounds

BK/GN
Ignition

W
Power

BK/GN
R/BK
[20B] 10 5

[20A] 10 5
2C
FLHR/C

BK/GN
W
Headlamp
15A GND 2
[38B] [38A] 2 7
2D [21A]
[64-2B]
High [21B] 2 7
W 1 1 W
BE

Low

BK
Low
Y 2 2 Y Y 2 2 Y Headlamp
BE 3 3 BE
BK 3 3 BK Turn Signal
BK
W 4 4 W
Indicators
High Chassis
BK

BK
Ground

W
Headlamp [24A] [24B]
BK

Hi/Lo
Switch
High Beam
Indicator
GND 1

Except High Beam

FLHR/C Indicator GY/BK
Ignition
Power Y
R/BK

BK
W
BK

2C Turn Signal BK [31RA] [31RB] Auxiliary

GY/BK

Indicators
Headlamp Lights
BK
BK

15A
GY/BK 4 4 GY/BK
5 3 [21B] 8 7 6 [105B]
[64-2B] 2D
5 3 [21A] 8 7 6 [105A]
[31LA] [31LB] Auxiliary
BE

Lights
BK

BK
GY/BK
Y

GY/BK 4 4 GY/BK
3 [2B]
3 [2A]
[38B] [38A]
BE

[24A] [24B] W 1 1 W
High

Low Low
Y 2 2 Y Y 2 2 Y Headlamp
BE 3 3 BE
BK 2 3 BK

W 4 4 W
High [38B-2] [38A-2]

Headlamp High
W 1 1 W
Hi/Lo
Switch Y 2 2 Y
Low
Headlamp

BK 3 3 BK
BK

FLT Models Only

GND 1

Figure 5-18. Headlamp

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HEADLAMP INOPERATIVE, NO DTCS 2. With the IGN ON and the headlamp Hi/Lo switch in the
high position, using HARNESS CONNECTOR TEST
PART NUMBER TOOL NAME KIT (Part No. HD-41404-C) and a multimeter, test for
HD-41404-C HARNESS CONNECTOR TEST KIT voltage between [38A] (FLH models) or [38A-2] (FLT
models) terminals 1 and 3.

Table 5-15. Headlamp Inoperative, No DTCs Diagnostic 3. Is battery voltage present?

Faults a. Yes. Replace the headlamp. See the service manual.
(5185)
POSSIBLE CAUSES
b. No. Repair open in (W) wire to headlamp. (5041)
Open fuse
Open power to switch circuit 5. Headlamp Low Beam Switch Test
Headlamp Hi/Lo switch malfunction 1. With the IGN OFF, disconnect left hand controls [24].
Open ground circuit
2. Using a HARNESS CONNECTOR TEST KIT (Part No. HD-
Open high beam power circuit 41404-C), jumper [24B] terminals 2 and 3 together.
Open low beam power circuit 3. Turn IGN ON.
Headlamp malfunction
4. Does the low beam headlamp operate?
1. Operational Test a. Yes. Replace the left switch assembly. See the ser-
vice manual. (5171)
1. Turn IGN ON.
b. No. Go to Test 6.
2. Move the headlamp switch to the high and low positions.
3. Do the headlamps work in both positions? 6. Low Beam Headlamp Test
a. Yes. Concern is intermittent perform wiggle test. See 1. Connect [24].
1.3 DIAGNOSTICS AND TROUBLESHOOTING,
2. Disconnect the low beam headlamp.
Wiggle Test.
3. With the headlamp Hi/Lo switch in the low position using
b. No. High beam headlamp inoperative. Go to Test
HARNESS CONNECTOR TEST KIT (Part No. HD-41404-
2.
C) and a multimeter, test for voltage between [38A] (FLH
c. No. Low beam headlamp inoperative. Go to Test models) or [38A-2] (FLT models) terminals 2 and 3.
5.
4. Is battery voltage present?
d. No. Both headlamps inoperative. Go to Test 7. a. Yes. Replace the headlamp. See the service manual.
(5185)
2. High Beam Indicator Test
b. No. Repair open in (Y) wire to headlamp. (5041)
1. With the headlamp Hi/Lo switch in the high position,
observe the high beam indicator lamp. 7. High Beam Indicator Test
2. Does the high beam indicator illuminate? 1. With the headlamp Hi/Lo switch in the high position,
a. Yes. Go to Test 4. observe the high beam indicator lamp.
b. No. Go to Test 3. 2. Does the high beam indicator illuminate?
a. Yes. Repair open in (BK) ground circuit from head-
3. Headlamp High Beam Circuit Switch Test lamp. (5041)
1. With IGN OFF, disconnect left hand controls [24]. b. No. Go to Test 8.
2. Place the headlamp Hi/Lo switch in the high position.
8. Headlamp Power Circuit Open Test
3. Using a HARNESS CONNECTOR TEST KIT (Part No. HD-
41404-C), jumper [24B] terminals 3 and 4 together. 1. With the IGN OFF, disconnect left hand controls [24].

4. Turn IGN ON. 2. Using a HARNESS CONNECTOR TEST KIT (Part No. HD-
41404-C), jumper [24B] terminals 2 and 3 together.
5. Does the high beam headlamp operate?
3. Turn IGN ON.
a. Yes. Replace the left switch assembly. See the ser-
vice manual. (5171) 4. Does the low beam headlamp operate?
b. No. Repair open in (W) wire between [24B] and the a. Yes. Replace the left switch assembly. See the ser-
indicators. (5041) vice manual. (5171)
b. No. Repair open in (BE) wire to [24B]. (5039)
4. High Beam Headlamp Test
1. Disconnect the high beam headlamp.

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9. Headlamp Fuse Test 2. Test for battery voltage between inoperative circuit at [73B]
terminal 1 or 2 and ground.
1. Inspect the headlamp fuse.
3. Is battery voltage present?
2. Is the fuse good?
a. Yes. Replace the inoperative auxiliary lamp. (5227)
a. Yes. Go to Test 9.
b. No. Repair open in the (GY/BK) wire between the
b. No. Go to Test 10. toggle switch and [73]. (5041)

10. Power Circuit Test 4. Auxiliary Lamp Switch Test

1. Test for voltage on [64-2B] socket terminal 2D of the 1. Disconnect auxiliary lamp switch [109] (FLHR/C) models,
headlamp fuse. [105] on FLHT models.
2. Is battery voltage present? 2. Jumper [109B] terminals 1 and 3 (FLHR/C) or [105A] ter-
a. Yes. Repair open in (BE) wire between fuse block minals 6 and 7 (FLHT) together.
and headlamp Hi/Lo switch. (5039)
3. With the headlamp switch in the low position, turn IGN
b. No. Repair open in (R/BK) wire. (5041) ON.
4. Do the auxiliary lamps illuminate?
AUXILIARY LAMPS INOPERATIVE
a. Yes. Replace the auxiliary lamp toggle switch. (5167)
Table 5-16. Auxiliary Lamps Inoperative Diagnostic Faults b. No. FLHR/C. Go to Test 5.

POSSIBLE CAUSES c. No. Except FLHR/C. Go to Test 7.

Auxiliary lamp malfunction
5. Auxiliary Lamp Power Circuit Test:
Toggle switch malfunction
FLHR/C
Open in auxiliary power circuit
1. Test for battery voltage from auxiliary lamp switch [109B]
Open in auxiliary ground circuit terminal 1 (Y) to ground.

1. Auxiliary Lamps Operation Test 2. Is battery voltage present?

1. Place the headlamp switch in the low position. a. Yes. Repair open in (GY/BK) wire between [109B]
and [73B]. (5041)
2. Turn on the auxiliary lamps.
b. No. Repair open in (Y) wire between [109B] and
3. Do the auxiliary lamps illuminate? headlamp switch. (5041)
a. Yes. System operating properly. Intermittent perform
wiggle test. See 1.3 DIAGNOSTICS AND 6. Auxiliary Lamp Circuit Test: Except
TROUBLESHOOTING, Wiggle Test. FLHR/C
b. No. Auxiliary lamps and headlamps are inoper- 1. Disconnect left front turn signal [31L] or right front turn
ative. See 5.7 HEADLAMPS, Headlamp Inoperative, signal [31R].
No DTCs.
2. Test for battery voltage between inoperative circuit at [31]
c. No. Only one auxiliary lamp is operative. Go to terminal 4 and ground.
Test 2.
3. Is battery voltage present?
d. No. Both auxiliary lamps are inoperative. Go to a. Yes. Replace the inoperative auxiliary lamp. (5227)
Test 4.
b. No. Repair open in the (GY/BK) wire between the
2. Auxiliary Bulb Test toggle switch and [31]. (5041)
1. Inspect the bulb.
7. Auxiliary Lamp Power Circuit Test: Except
2. Is the bulb good? FLHR/C
a. Yes. FLHR/C. Go to Test 3. 1. Test for battery voltage from [105A] terminal 1 (Y) to
b. Yes. Except FLHR/C. Go to Test 6. ground.

c. No. Replace the bulb. See the service manual. (5227) 2. Is battery voltage present?
a. Yes. Repair open in (GY/BK) wire between [105A]
3. Auxiliary Lamp Circuit Test: FLHR/C and [31]. (5041)
1. Disconnect auxiliary lamps [73]. b. No. Repair open in (Y) wire between [105A] and
headlamp switch. (5041)

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STOP LAMPS 5.8

DESCRIPTION AND OPERATION
ed03082
The front stop lamp switch is a mechanical switch located in
the right handlebar switch assembly. See Figure 5-19. The 1
rear stop lamp switch is a pressure switch located on the right
side at the rear of the crankcase.
The brake switches receive power through the ACCY fuse. On 2
vehicles without ABS, When the front or rear stop lamp switch
is applied, voltage travels through the switch to the coil side of
the brake relay. 3
On vehicles with ABS the voltage from the stop lamp switch is
sent to the ABS module and also through an ABS diode pack
to the coil side of the brake relay.
The diode pack isolates the front and rear stop lamp voltages
so the ABS module can determine which stop lamp switch is
applied. 1. Clutch cover
2. Rear brake switch [121]
3. Exhaust pipe
Figure 5-19. Rear Brake Switch

Diagnostic Tips
When testing for a short to ground due to an open fuse, check
the (R/Y) wire between the brake relay and the stop lamp. A
short to ground on these wires causes the brake fuse to open
only when the brake switches are closed. A short to ground in
the (Y/BK) wire between the horn switch and the horn causes
the ACCY fuse to open when the horn switch is pressed and
needs to be checked for a short to ground as well.

Connector Information
For additional information about the connectors in the following
diagram(s) and diagnostic procedure(s), including the color of
the harness test kit terminal probes, see B.1 CONNECTORS.

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Accessory
em00823
Power

R/GY

R/GY
1A 1C

Brake ACCY Fuse [22B]

15A 15A
O/W 1
1B 1D [64-1] FLHR

O/W
2
O/V
R/BE
1 O/W
O/W
R/BE [1B] [1A] [22B]
2 R/Y

R/BE
O/W
O/W 5 5 O/W 1
[121-2B] Except Front
1 1 [121-1B] [22A] Stop Lamp
[121-2A] FLHR 1 1 2
[121-1A] R/BE R/BE Switch
1 1

Rear [78B] [78A]

Stop [2B] [2A]
Pressure Lamp
87 5 3A O/V Switch Switch R/BE 25 25 Brake Switch Input ECM
30 3 2B R/Y
Accessory
Connector
85 1 2A R/BE
86 2 3B BK

R/Y
Brake

BK
Relay
BK

[64-2] 3 2 [12B]
3 2 [12A]
Stop

R/Y
BK

Left GND 1
Tour-Pak
R/Y

R/Y

Stop Lamps

R/Y
BK
BK BK
[12-5B] [12-4B]

(FL/HTCU/HTK/TRU) (FLHTC Only) (FL/TRX/HX Canada Only) (FL/TRX/HX HDI Only) (FL/TRX/HX DOM Only)
R/Y

R/Y

R/Y
R/Y

R/Y

BK

BK

BK
BK

BK

[7A] 5 6 [257A] 4 5 [257A] 4 5 [257A] 4 5 [257A] 4 5

[7B] 5 6 [257B] 4 5 [257B] 4 5 [257B] 4 5 [257B] 4 5

R/Y

R/Y

R/Y
BK

BK

BK
R/Y

R/Y
BK

BK

[94B] 6 4 [7A] 5 6

[7B] 5 6
R/Y

R/Y

R/Y
BK

BK

BK

BK

BK

BK
R/Y
BK

[226B] 1 5 7 [226B] 1 5 7 [226B] 1 5 7

[94B] 6 4 [226A] 1 5 7 [226A] 1 5 7 [226A] 1 5 7
Facia/ Facia/ Facia/
Converter Converter Converter
Module Module Module
[262A] 3 4 5 [262A] 3 4 9 1 2 5 6
[262B] 3 4 5 [262B] 3 4 9
R/Y
BK
BK

V/BN

BK
BK
V
R/W
Y/W
R
R/Y
BK

[94B] 6 4

6 4
[94A] BK
R/Y
Rear Lighting
4 4 BK Tail Lamp
3 3 R/Y

[93A] [93B] Brake Light

Figure 5-20. Stop Lamps without ABS

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em00822

R/GY

R/GY
R/BN 13 13 Front Brake input ABS
PK/BN 3 3 Rear Brake input Module
1A 1C
[166B] [166A]
Brake ACCY Fuse
15A 15A
[22B]
1B 1D
[64-1]
O/W 1 [22A]
FLHR

O/W
O/V

R/BN 2
O/W 1 O/W

[1B] [1A]
R/BN 2 R/Y

PK/BN
O/W

O/W 5 5 O/W 1
Front

PK/BN
Except

R/BN
R/BE

R/BE
[121-2B] Stop Lamp
1 1 [121-1B] FLHR
[121-2A] R/BN 1 1 R/BE 2 Switch
1 1 [121-1A] 4 3 2 1 [201B]
[201A] [2B] [2A]
Rear Stop 4 3 2 1

Pressure Lamp Switch

Switch
Accessory
ABS Diode Connector [12A] [12B]
87 5 3A O/V Pack
30 3 2B R/Y R/Y 2 2 R/Y
85 1 2A R/BE
86 2 3B BK BK 3 3 BK
Brake Stop
Relay [64-2]
BK

Tour-Pak

R/Y

R/Y
ECM Brake Switch Input 25 25 R/BE Rear Marker/
Stop Lamps
R/Y
BK

BK BK
[78A] [78B] Left GND 1
[12-5B] [12-4B]

(FL/HTCU/HTK/TRU) (FLHTC Only) (FL/TRX/HX Canada Only) (FL/TRX/HX HDI Only) (FL/TRX/HX DOM Only)
R/Y

R/Y

R/Y
R/Y

R/Y

BK

BK

BK
BK

BK

[7A] 5 6 [257A] 4 5 [257A] 4 5 [257A] 4 5 [257A] 4 5

[7B] 5 6 [257B] 4 5 [257B] 4 5 [257B] 4 5 [257B] 4 5

R/Y

R/Y

R/Y
BK

BK

BK
R/Y

R/Y
BK

BK

[94B] 6 4 [7A] 5 6

[7B] 5 6
R/Y

R/Y

R/Y
BK

BK

BK

BK

BK

BK
R/Y
BK

[226B] 1 5 7 [226B] 1 5 7 [226B] 1 5 7

[94B] 6 4 [226A] 1 5 7 [226A] 1 5 7 [226A] 1 5 7
Facia/ Facia/ Facia/
Converter Converter Converter
Module Module Module
[262A] 3 4 5 [262A] 3 4 9 1 2 5 6

[262B] 3 4 5 [262B] 3 4 9
R/Y
BK
BK

V/BN

BK
BK
V
R/W
Y/W
R
R/Y
BK

[94B] 6 4

6 4
[94A] BK
R/Y
Rear Lighting
4 4 BK Tail Lamp
3 3 R/Y

[93A] [93B] Brake Light

Figure 5-21. Stop Lamps with ABS

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STOP LAMP INOPERATIVE meter, measure resistance between [64-1B] socket ter-
minal 1D and ground.
PART NUMBER TOOL NAME
2. Is resistance less than 10 Ohms?
HD-41404-C HARNESS CONNECTOR TEST KIT
a. Yes. Go to Test 6.
b. No. See diagnostic tips. Replace ACCY fuse and
Table 5-17. Stop Lamp Inoperative Diagnostic Faults
verify repair. (6822)
POSSIBLE CAUSES
Open fuse
6. Fuel Level Sensor Test
Short in stop lamp circuit 1. Disconnect fuel tank harness [13].

Open power to switch circuit 2. Measure resistance between [64-1B] socket terminal 1D
and ground.
Open ground circuit
Open stop lamp circuit 3. Is resistance less than 10 Ohms?
a. Yes. Go to Test 7.
Stop lamp malfunction
Rear stop lamp switch malfunction b. No. Replace fuel level sensor. See the service
manual. (6035)
Front stop lamp switch malfunction
7. Speedometer Test
1. Accessory Circuit Test
1. Disconnect the speedometer [39B].
1. Turn IGN to ACC.
2. Measure resistance between [64-1B] socket terminal 1D
2. Does the speedometer illuminate? and ground.
a. Yes. Go to Test 8.
3. Is resistance less than 10 Ohms?
b. No. Go to Test 2. a. Yes. Repair short to ground in accessory circuit (O/W)
wire. (5043)
2. ACCY Fuse Test
b. No. Replace the speedometer. See the service
1. Inspect the ACCY fuse.
manual. (6826)
2. Is the fuse good?
a. Yes. Go to Test 3. 8. Stop Lamp Switch Test
1. Apply the front brake while observing the stop lamp.
b. No. Go to Test 5.
2. Apply the rear brake while observing the stop lamp.
3. ACCY Circuit from Ignition Switch Test
3. Does the stop lamp illuminate?
1. With IGN in ACC, using HARNESS CONNECTOR TEST
a. Yes. Stop lamp illuminates only with front brake
KIT (Part No. HD-41404-C) and a multimeter, test for
applied. Go to Test 12.
voltage between [64-1B] socket terminal 1C and ground.
b. Yes. Stop lamp illuminates only with rear brake
2. Is battery voltage present?
applied. Go to Test 14.
a. Yes. Repair open in (O/W) wire from ACCY fuse.
(5043) c. No. Go to Test 9.

b. No. Go to Test 4. 9. Brake Relay Test

4. Ignition Switch Test 1. Test brake relay. See 1.3 DIAGNOSTICS AND
TROUBLESHOOTING, Relay Diagnostics.
1. With IGN OFF, disconnect the ignition switch [33].
2. Does relay pass test?
2. Test for continuity between ignition switch [33B] terminal
a. Yes. Go to Test 10.
1 and [64-1B] socket terminal 1C.
b. No. Replace brake relay. See the service manual.
3. Is continuity present?
(1407)
a. Yes. Replace the ignition switch. See the service
manual. (7287) 10. Relay Coil Circuit Test
b. No. Repair open between [64-1B] socket terminal 1C 1. Test for voltage between [64-2B] terminal 2A and terminal
and ignition switch [33B] terminal 1 (R/GY) wire. 3B.
(5041)
2. With the brake applied, is voltage present?
5. Accessory Circuit Resistance Test a. Yes. Go to Test 20.
1. With the ACCY fuse removed, using HARNESS CON- b. No. Go to Test 11.
NECTOR TEST KIT (Part No. HD-41404-C) and a multi-

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11. Stop Lamp Switch Power Circuit Test 3. With rear brake applied, test for voltage between ABS
diode pack [201B] terminal 1 and ground 2.
1. Test for voltage between [64-2B] terminal 2A and ground.
4. Is battery voltage present?
2. With the brake applied, is voltage present?
a. Yes. Go to Test 17.
a. Yes. Repair open in (BK) wire. (5041)
b. No. Repair open in (PK/BN) wire. (5041)
b. No. Repair open in (R/BE) wire. (5041)
17. ABS Diode Pack Rear Circuit Test
12. Rear Stop Lamp Switch Test
1. Test for continuity between ABS diode pack [201B] ter-
1. Disconnect rear stop lamp switch [121]. minal 4 and [64-2B] terminal 2A.
2. Jumper rear stop lamp switch [121B] terminal 1B and ter- 2. Is continuity present?
minal 2B together.
a. Yes. Replace ABS diode pack. See the service
3. Turn IGN ON. manual. (1404)
4. Does the brake lamp illuminate? b. No. Repair open in (R/BE) wire. (5041)
a. Yes. Replace the rear stop lamp switch. See the
service manual. (5141) 18. Front Stop Lamp to ABS Diode Pack
b. No. Go to Test 13.
Circuit Test
1. Connect [22].
13. Rear Stop Lamp Switch ACCY Circuit 2. Disconnect ABS diode pack [201].
Test
3. With front brake applied, test for voltage between terminal
1. Test for voltage between rear stop lamp switch [121B] 2 of ABS diode pack [201B] and ground.
terminal 2B and ground.
4. Is battery voltage present?
2. Is battery voltage present?
a. Yes. Go to Test 19.
a. Yes. Without ABS. Repair open in (R/BE) wire
between rear stop lamp switch and brake relay. (5041) b. No. Repair open in (R/BN) wire. (5041)

b. Yes. With ABS. Go to Test 16. 19. ABS Diode Pack Front Circuit Test
c. No. Repair open in (O/W) wire. (5043) 1. Test for continuity between ABS diode pack [201B] ter-
minal 3 and [64-2B] terminal 2A.
14. Front Stop Lamp Switch Test
2. Is continuity present?
1. With IGN OFF, disconnect right hand controls [22].
a. Yes. Replace ABS diode pack. See the service
2. Using HARNESS CONNECTOR TEST KIT (Part No. HD- manual. (1404)
41404-C) jumper [22B] terminals 1 and 2 together.
b. No. Repair open in (R/BE) wire. (5041)
3. Turn IGN ON.
4. Does the brake lamp illuminate?
20. Relay Power Test
a. Yes. Replace front stop lamp switch. See the service 1. Test for voltage between [64-2B] terminal 3A and ground.
manual. (5176) 2. Is battery voltage present?
b. No. Go to Test 15. a. Yes. Except FLTRX, FLHX, FLHTC. Go to Test 21.
b. Yes. FLTRX, FLHX, FLHTC. Go to Test 24.
15. Front Stop Lamp Switch ACCY Circuit
Test c. No. Repair open in (O/V) wire. (5041)

1. Test for voltage between [22B] terminal 1 and ground. 21. Stop Lamp Test
2. Is battery voltage present? 1. Install brake relay.
a. Yes. Without ABS. Repair open in (R/BE) wire
2. Disconnect tail lamp [93].
between front stop lamp switch and stop lamp. (5041)
3. With brake applied, test for voltage between [93A] ter-
b. Yes. With ABS. Go to Test 18.
minals 3 and 4.
c. No. Repair open in (O/W) wire. (5043)
4. Is battery voltage present?
16. Rear Stop Lamp to ABS Diode Pack a. Yes. Replace stop lamp assembly. (5215)
Circuit Test b. No. Go to Test 22.
1. Connect rear stop lamp switch [121].
22. Circuit Board Test
2. Disconnect ABS diode pack [201].
1. Disconnect rear fender lights [94].

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2. With brake applied, test for voltage between [94B] ter- 3. Is battery voltage present?
minals 4 and 6. a. Yes. Go to Test 26.
3. Is battery voltage present? b. No. Go to Test 25.
a. Yes. Replace the circuit board. See the service
manual. (5215) 25. Stop Lamp Circuit Test
b. No. Go to Test 23. 1. With brake applied, test for voltage between [226B] ter-
minal 5 and ground.
23. Stop Lamp Circuit Test 2. Is battery voltage present?
1. With brake applied, test for voltage between [94B] ter- a. Yes. Repair open in (BK) wire. (5041)
minals 4 and ground.
b. No. Repair open in (R/Y) wire. (5041)
2. Is battery voltage present?
a. Yes. Repair open in (BK) wire. (5041) 26. Facia/Converter Module Test
b. No. Repair open in (R/Y) wire. (5041) 1. Connect rear lighting jumper harness [226].
2. Disconnect rear lighting jumper harness [262].
24. Lightbar Circuit Test
3. With brake applied, test for voltage between [262A] ter-
NOTE minal 3 and terminal 4 (right) or terminal 9 and terminal 7
Only follow this test if the turn signals in the light bar also (left).
function as the stop lamps.
4. Is battery voltage present?
1. Disconnect rear lighting jumper harness [226].
a. Yes. Replace the lightbar. See the service manual.
2. With brake applied, test for voltage between [226B] ter- (6823)
minals 5 and 7.
b. No. Replace the facia/converter module. See the
service manual. (6809)

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RUNNING LAMPS 5.9

DESCRIPTION AND OPERATION
The running lamps consist of the front position lamp (HDI), the
license plate lamp, the tail lamp, the Tour-Pak lamps (FLHTCU,
FLHTK), the front and rear fender tip lamps, and on domestic
models the turn signals are used as well. The running lamps
are powered through the accessory fuse when the ignition
switch is in the IGN or ACCY position.
Connector Information
For additional information about the connectors in the following
diagram(s) and diagnostic procedure(s), including the color of
the harness test kit terminal probes, see B.1 CONNECTORS.

em00736
Ignition R/BK
Power R/BK

BK
[64-1B] 1C [64-2B] 2E

Accessory Lights
15A 15A
GND 1
1D 2F
O/W

BE

Fender Tip Lamp

(DOM Only)
BK 2 2 BK
O/W 1 1 O/W O/W

BK
BE
[32B] [32A]
O/W

BK

2 5 7 [7A]
1 2 [29B] 2 5 7 [7B]
O/W

Position Lamp
BK
BE

(HDI Only)
BK
BE

BE
BK

O/W
BK

BE

1 3 4 6 [31A] 6 3 1 [94B] Rear Lighting

1 3 4 6 [31B] 6 3 1 [94A]
BE

BE

BK
BK

Power
GND

GND

BK
4 4 BK O/W
BK 1 1
2 2 O/W
BK 3 3 1 1 BE/W BE/W
Right Turn Left Turn Fender Tip/License
And DOM And DOM Plate Lamp [45B] [45A] [93A] [93B] Running Running
Running Running Light (HDI) Light (DOM) Tail Lamp
Lamp Lamp

Figure 5-22. Running Lamps: FLHR/C

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Tour-Pak Left Side

em00821
Marker Lights
Left DOM
Running Lamp [31LB] [31LA] Position Lamp
(HDI Only)

BE
BK
BE 1 1 BE

BK 3 3 BK [29B] [12-3A] 1 2 FLH/TK/TCU Only

O/W
Fender Tip lamp [12-3B] 1 2 Tour-Pak
(DOM Only) Rear Marker Lights

BE
BK
O/W 1 1 BE
[21-5B]
BK 2 2 BK
BE
[32B] [32A]

BK
BE 1 1 BE [12A] 3 1
[12-3A] 1 2 BK

O/W
BK 3 3 BK [12B] 3 1 [12-3B] 1 2
BE
Right DOM

BE
BK
BE

BK
[1A]

BE
BK
5
Running Lamp [31RB] [31RA]
B D [15A] 5 [1B]
BK

O/W
B D [15B]
[21-4B]
FL/HTK/HTCU/TRU
BE

BK

Tour-Pak Right Side

Marker Lights
O/W

BE

O/W
[64-1B] 1D [64-2B] 2F

BK

BE
Accessory Lights
15A 15A

1C 2E
(FL/TRX/HX Canada Only) (FL/TRX/HX HDI Only) (FL/TRX/HX DOM Only)
R/BK

O/W

O/W
BK
BE

BK

BK

BE
Ignition R/BK
Power
2 4 6 [257A] 2 4 [257A] 4 6 [257A]
GND 1
2 4 6 [257B] 2 4 [257B] 4 6 [257B]
O/W

O/W
BK
BE

BK

BK

BE
(FL/HTCU/
HTK/TRU (FLHTC Only)
O/W
O/W

BK
BE
BK
BE

O/W

O/W
BK
BE
BK

BK

BK

BK
BE
BK
[7A] 2 5 7 [257A] 2 4 6

[7B] 2 5 7 [257B] 2 4 6 [226B] 1 6 7 12 [226B] 1 7 12 [226B] 1 6 7

[226A] [226A] [226A]

O/W
BK
BE

1 6 7 12 1 7 12 1 6 7
O/W

Facia/ Facia/ Facia/

BK
BE

Converter Converter Converter

[262A] 2 4 5 10
Module [262A] 2 8 11
Module [262A] 5 6 8
Module
[7A] 2 5 7

[7B] 2 5 7
[262B] 2 4 5 10 [262B] 2 8 11 [262B] 5 6 8
O/W
BE
BK
BK

W/BK
O/W
BK
BE

BK
BK
BE
Y
O/W

O/W

O/W
BK
BE

BK
BE

BK
BE

[94B] 6 3 1 [94B] 6 3 1 [94B] 6 3 1

6 5 4 3 2 1
[94A]
Rear Lighting
BK
4 4 BK O/W
BK 1 1
2 2 O/W
BK 3 3 1 1 BE/W BE/W
Fender Tip/License
Plate Lamp [45B] [45A] [93A] [93B] Running Running
Light (HDI) Light (DOM) Tail Lamp

Figure 5-23. Running Lamps: Except FLHR/C

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POSITION LAMP INOPERATIVE: HDI RUNNING LAMPS INOPERATIVE

PART NUMBER TOOL NAME PART NUMBER TOOL NAME
HD-41404-C HARNESS CONNECTOR TEST KIT HD-41404-C HARNESS CONNECTOR TEST KIT

Table 5-18. Position Lamp Inoperative Diagnostic Faults: Table 5-19. Running Lamps Inoperative Diagnostic Faults
HDI
POSSIBLE CAUSES
POSSIBLE CAUSES Open lights circuit
Open accessory circuit Lamp malfunction
Lamp malfunction Open ground
Open ground
1. Running Lamp Test
1. Accessory Circuit Test 1. Turn IGN ON.
1. Turn the IGN to ACC.
2. Do any of the running lamps work?
2. Apply either the front or rear brake. a. Yes. Go to Test 2.
3. Does the stop lamp illuminate? b. No. Go to Test 4.
a. Yes. Go to Test 2.
b. No. See 5.8 STOP LAMPS, Stop Lamp Inoperative.
2. General Lamp Test
1. Inspect the inoperative lamp and repair any issues.
2. Position Lamp Test 2. Disconnect inoperative lamp connector.
1. Disconnect position lamp [29].
3. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
2. With the IGN ON, using HARNESS CONNECTOR TEST 41404-C) and a multimeter, test for voltage between
KIT (Part No. HD-41404-C) and a multimeter, test for inoperative lamp power and ground terminals.
voltage between position lamp [29B] terminal A and ter-
4. Is battery voltage present?
minal B.
a. Yes. Replace the inoperative lamp.
3. Is battery voltage present?
b. No. Go to Test 3.
a. Yes. Replace position lamp. See the service manual.
(5143)
3. Single Lamp Power Test
b. No. Go to Test 3.
1. Test for voltage between inoperative lamp power terminal
and a good ground.
3. Ground Circuit Test
2. Is battery voltage present?
1. Test for voltage between position lamp [29B] terminal B
and ground. a. Yes. Repair open in ground circuit. (5041)

2. Is battery voltage present? b. No. Repair open in power circuit. (5041)

a. Yes. Repair open in (BK) ground wire. (5041)
4. Lights Fuse Test
b. No. Repair open in (O/W) wire. (5043)
1. Inspect the lights fuse.
2. Is the fuse good?
a. Yes. Repair open in (BE) wire. (5039)
b. No. Repair short to ground in (BE) wire and replace
lights fuse. (5039)

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DTC B1121, B1122, B1123, B1124, B1125, B1126 5.10

DESCRIPTION AND OPERATION
ed03081
See Figure 5-24. The TSM/TSSM/HFSM is located under the 1 2
right side cover.
• Terminal 1 receives battery power.
7
• Terminal 2 receives ignition power.
6
• Terminal 3 communicates with other modules on the
vehicle through the serial data circuit.
• Terminal 12 is ground through the TSM/TSSM/HFSM. 5
4
The turn signal switches are inputs to the TSM/TSSM/HFSM.
When the TSM/TSSM/HFSM receives voltage from either of
the turn signal switches it supplies voltage to the corresponding
turn signal lamps and sends a message to the indicator lamps 3
to flash the correct turn signal indicator.
1. Front HO2S [138]
The TSM/TSSM/HFSM also monitors the position of the clutch
2. ABS module [166] (if equipped)
and neutral switches to determine if it is safe to start the vehicle.
3. Active exhaust [179]
The BAS is internal to the TSM/TSSM/HFSM and allows the
4. Rear WSS [168]
TSM/TSSM/HFSM to determine if the vehicle is tipped over. If
5. Rear HO2S [137]
a tip over event occurs, the TSM/TSSM/HFSM shuts off the
6. TSM/TSSM/HFSM [30]
engine.
7. HFSM antenna jumper harness [208]
Figure 5-24. Under Right Side Cover

The TSM/TSSM/HFSM monitors the output circuits and sets

DTCs if faults are detected.

Table 5-20. Code Description

DTC DESCRIPTION
B1121 Left turn output fault
B1122 Right turn output fault
B1123 Left turn signal short-to-ground: HFSM
B1124 Right turn signal short-to-ground: HFSM
B1125 Left turn signal short-to-voltage: HFSM
B1126 Right turn signal short-to-voltage: HFSM

Connector Information
For additional information about the connectors in the following
diagram(s) and diagnostic procedure(s), including the color of
the harness test kit terminal probes, see B.1 CONNECTORS.

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em00850
[22A] [22B] [64-1B]
Battery15A
O/W 1 1 O/W
Right Turn BN/GY 2D 2C R
Switch W/BN 5 5 W/BN Accessories 15A
O/W 1D 1C R/GY
O/W 1 1 O/W [64-2B]
Left Turn
Switch W/V 5 5 W/V
Lights
BE 2F 2E R/BK

[24A] [24B] Ignition 15A

GY 1F 1E R/BK

[30A] [30B]
TSM/HFSM Indicator
Battery 1 1 BN/GY Lamps
Ignition 2 2 GY Right
Left
Left Turn Feed Output 5 5 V Turn Turn
Right Turn Feed Output 6 6 BN

BN
BK

BK
V
Right Turn Switch Input 7 7 W/BN [20B] [20A] [21A] [21B]
Left Turn Switch Input 8 8 W/V
Ground 12 12 BK/GN BK/GN 5 5 BK/GN 7 7 BK

BN 12 12 BN 4 4 BN

V 9 9 V 1 1 V

GND
Right Turn BK 1 1 BK
And DOM BN 2 2 BN
Running Lamp Turn
BE 3 3 BE
Power
Left Turn BE 4 4 BE
And DOM Turn
V 5 5 V
Running Lamp

BN

BK

BE
BK 6 6 BK

V
GND

[31B] [31A] [7A] 1 3 5 6 7

[7B] 1 3 5 6 7

BN

BK

BE
V
Left GND 1 Right GND 2

BN
BK

BE
V
6 5 3 2 1 [94B]
6 5 3 2 1
[94A]
[18B]
Right Rear
Turn V/BN 1 1
Lamp BK 2 2 [18A]
[19B]
Left Rear
Turn V/BN 1 1
Lamp BK 2 2 [19A]

Figure 5-25. Turn Signal Circuit: FLHR/C

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Left Right
em00824
Turn Turn
[22A] [22B] [64-1B]

BN
BK
BK
V
Battery15A
Indicator
BN/GY 2D 2C R
O/W 1 1 O/W Lamps
Right Turn

BN
BK
Switch Accessories 15A

V
W/BN 5 5 W/BN
O/W 1D 1C R/GY
5 4 1 [21B]
[64-2B]
O/W 1 1 O/W 4 1 [21A]
Left Turn Lights
Switch [1A] [1B]

BN
BE 2F 2E R/BK

V
W/V 5 5 W/V

W/V 11 11 W/V Ignition 15A

[24A] [24B] GY 1F 1E R/BK
W/BN 10 10 W/BN
BN 8 8 BN
V 7 7 V
[30A] [30B]
TSM/HFSM O/W 5 5 O/W
Battery 1 1 BN/GY
Ignition 2 2 GY
Left Turn Feed Output 5 5 V
Right Turn Feed Output 6 6 BN
Right Turn Switch Input 7 7 W/BN
Left Turn Switch Input 8 8 W/V
Ground 12 12 BK/GN BK/GN Right Left
GND 2 GND 1
BK D D BK BK

BE B B BE

RH Front LH Front [15A] [15B]

BE
BN

BK
BE
BK

BN

BK
V

V
Turn Signal Turn Signal
[31RA] 3 2 1 3 2 1 [31LA]
[31RB] 3 2 1 3 2 1 [31LB] (FL/TRX/HX
Canada Only) (FL/TRX/HX)
V/BN
BE

BE
BK
V/BK
BK

BN

BN
BK

BK
Right Turn Left Turn
V

V
And DOM And DOM
Running Running 1 3 4 [257A] 1 3 4 [257A]
Lamp Lamp 1 3 4 [257B] 1 3 4 [257B]
BN

BN
BK

BK
V

V
(FL/HTCU/HTK/TRU) (FLHTC Only)
BN

BN
BK

BN

BN
BK

BK

BK

BK

BK
V

V
[7A] 1 3 5 [257A] 2 5 4 [226B] 1 3 4 7 [226B] 1 3 4 7

[7B] 1 3 5 [257B] 2 5 4 [226A] 1 3 4 7 [226A] 1 3 4 7

Facia/ Facia/
BN

BK
V

Converter Converter
BN

BK
V

[262A] 1 4 5 7
Module [262A] 1 2 4 5 6 7 11
Module
[7A] 1 3 5
[262B] 1 4 5 7
[7B] 1 3 5
(DOM) (HDI)
BN
BK
BK
V
BN

BK
V

[262B] 1 2 5 6 [262B] 1 4 7 11
GN/W
V/BN

Y/W

GN
BK
BK
V

Y
BN

BN

BN
BK

BK

BK
V

V
V

[94B] 6 5 2 [94B] 6 5 2 [94B] 6 5 2

6 5 4 3 2 1 [94A]
Right Rear [18B]
Turn
Lamp V/BN 1 1
BK 2 2 [18A]
[19B]
Left Rear
Turn
Lamp V/BN 1 1
BK 2 2 [19A]

Figure 5-26. Turn Signal Circuit: Except FLHR/C

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DTC B1121: HFSM 2. Indicator Short to Voltage Test

PART NUMBER TOOL NAME 1. Turn IGN OFF.

HD-42682 BREAKOUT BOX 2. Disconnect indicator lamps [21].

3. Turn IGN ON.
Table 5-21. DTC B1121 Diagnostic Faults: HFSM
4. Are the turn signal lamps on continuously?
POSSIBLE CAUSES a. Yes. Go to Test 3.
Indicator malfunction b. No. Replace the indicator lamp assembly. See the
HFSM malfunction service manual.
Open left turn signal circuit
3. TSM/TSSM Short to Voltage Test
1. Turn Signal Lamp Inspection Test 1. With IGN OFF, connect BREAKOUT BOX (Part No. HD-
1. Remove and inspect left side turn signal bulbs. 42682) to TSM/TSSM wire harness [30B], leaving the
TSM/TSSM [30A] disconnected. See 1.2 DIAGNOSTIC
2. Confirm the turn signal bulbs are the correct part numbers TOOLS.
and the sockets are not corroded or damaged.
2. With IGN ON, using a multimeter, test for voltage between
3. Were any issues found with the lamps? breakout box terminal 5 and ground.
a. Yes. Repair as needed. 3. Is voltage present?
b. No. Go to Test 2. a. Yes. Repair short to voltage on the (V) wire.
b. No. Replace the TSM/TSSM. See the service manual.
2. Turn Signal Circuit Open Test
1. Connect BREAKOUT BOX (Part No. HD-42682) to HFSM 4. Indicator Shorted Test
wire harness [30B], leaving HFSM [30A] disconnected.
See 1.2 DIAGNOSTIC TOOLS. 1. With IGN OFF, disconnect indicator lamps [21].

2. Disconnect front turn signal [31] or [31L]. 2. Turn IGN ON.

3. Test for continuity between breakout box terminal 5 and 3. Operate the left turn signals.
[31A] terminal 5 or [31LA] terminal 2. 4. Do the turn signals flash?
4. Is continuity present? a. Yes. Replace the indicator lamp assembly. See the
a. Yes. Replace the HFSM. See the service manual. service manual.

b. No. Repair open in (V) wire. b. No. Go to Test 5.

DTC B1121: TSM/TSSM 5. Shorted Turn Signal Circuit Test

1. With IGN OFF, connect BREAKOUT BOX (Part No. HD-
PART NUMBER TOOL NAME 42682) to TSM/TSSM wire harness [30B] leaving
HD-42682 BREAKOUT BOX TSM/TSSM [30A] disconnected. See 1.2 DIAGNOSTIC
TOOLS.
Table 5-22. DTC B1121 Diagnostic Faults: TSM/TSSM 2. Test for continuity between breakout box terminal 5 and
ground.
POSSIBLE CAUSES
3. Is continuity present?
Indicator malfunction
a. Yes. Repair short to ground in (V) wire from terminal
Short to voltage on left turn signal circuit
5.
TSM/TSSM malfunction
b. No. Go to Test 6.
Short to ground on left turn signal circuit
Open left turn signal circuit 6. Turn Signal Circuit Open Test
1. Disconnect rear fender lights [94] (except FLTRX/FLHX)
1. Operational Test or rear lighting jumper harness [226] (FLTRX/FLHX).
1. Turn IGN ON.
2. Test for continuity between breakout box terminal 5 and
2. Are the turn signal lamps on continuously? [94A] (except FLTRX/FLHX) terminal 5 or [226B]
a. Yes. Go to Test 2. (FLTRX/FLHX) terminal 4.

b. No. Go to Test 4.

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3. Is continuity present? 2. Are the turn signal lamps on continuously?

a. Yes. Replace the TSM/TSSM. See the service a. Yes. Go to Test 2.
manual.
b. No. Go to Test 4.
b. No. Repair open in (V) wire.
2. Indicator Short to Voltage Test
DTC B1122: HFSM 1. With IGN OFF, disconnect indicator lamp [21].
PART NUMBER TOOL NAME 2. Turn IGN ON.
HD-42682 BREAKOUT BOX 3. Are the turn signal lamps on continuously?
a. Yes. Go to Test 3.
Table 5-23. DTC B1122 Diagnostic Faults: HFSM
b. No. Replace the indicator lamp assembly. See the
POSSIBLE CAUSES service manual.
Indicator malfunction
3. TSM/TSSM/HFSM Short to Voltage Test
HFSM malfunction
1. With IGN OFF, connect BREAKOUT BOX (Part No. HD-
Open right turn signal circuit
42682) to TSM/TSSM wire harness [30B], leaving
TSM/TSSM [30A] disconnected. See 1.2 DIAGNOSTIC
1. Turn Signal Lamp Inspection Test TOOLS.
1. Remove and inspect the right side turn signal bulbs.
2. With IGN ON, using a multimeter, test for voltage between
2. Confirm the turn signal bulbs are the correct part numbers breakout box terminal 6 and ground.
and the sockets are not corroded or damaged.
3. Is voltage present?
3. Were any issues found with the lamps? a. Yes. Repair short to voltage on the (BN) wire.
a. Yes. Repair as needed.
b. No. Replace the TSM/TSSM. See the service manual.
b. No. Go to Test 2.
4. Indicator Shorted Test
2. Turn Signal Circuit Open Test 1. With IGN OFF, disconnect indicator lamp[21].
1. Connect BREAKOUT BOX (Part No. HD-42682) to HFSM
wire harness [30B], leaving HFSM [30A] disconnected. 2. Turn IGN ON.
See 1.2 DIAGNOSTIC TOOLS. 3. Operate the left turn signals.
2. Disconnect front turn signal [31] or [31R]. 4. Do the turn signals flash?
3. Test for continuity between breakout box terminal 6 and a. Yes. Replace the indicator lamp assembly. See the
[31A] terminal 2 or [31RA] terminal 2. service manual.

4. Is continuity present? b. No. Go to Test 5.

a. Yes. Replace the HFSM. See the service manual.
5. Turn Signal Circuit Shorted Test
b. No. Repair open in (BN) wire.
1. With IGN OFF, connect BREAKOUT BOX (Part No. HD-
42682) to TSM/TSSM wire harness [30B] leaving
DTC B1122: TSM/TSSM TSM/TSSM [30A] disconnected. See 1.2 DIAGNOSTIC
PART NUMBER TOOL NAME TOOLS.
HD-42682 BREAKOUT BOX 2. Test for continuity between breakout box terminal 6 and
ground.
Table 5-24. DTC B1122 Diagnostic Faults: TSM/TSSM 3. Is continuity present?

POSSIBLE CAUSES a. Yes. Repair short to ground in (BN) wire.

Indicator malfunction b. No. Go to Test 6.

Short to voltage on right turn signal circuit
6. Turn Signal Circuit Open Test
TSM/TSSM malfunction
1. Disconnect rear fender lights [94] (except FLTRX/FLHX)
Short to ground on right turn signal circuit or [226] (FLTRX/FLHX).
Open right turn signal circuit 2. Test for continuity between breakout box terminal 6 and
[94A] (except FLTRX/FLHX) terminal 2 or [226B]
1. Operational Test (FLTRX/FLHX) terminal 3.
1. Turn IGN ON.

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3. Is continuity present? 3. Is continuity present?

a. Yes. Replace the TSM/TSSM. See the service a. Yes. Repair short to ground in left turn signal circuit
manual. (V) wire.
b. No. Repair open in (BN) wire. b. No. Replace the facia/converter module. See the
service manual.
DTC B1123
DTC B1124
PART NUMBER TOOL NAME
HD-42682 BREAKOUT BOX PART NUMBER TOOL NAME
HD-42682 BREAKOUT BOX
Table 5-25. DTC B1123 Diagnostic Faults
Table 5-26. DTC B1124 Diagnostic Faults
POSSIBLE CAUSES
Indicator malfunction POSSIBLE CAUSES

HFSM malfunction Indicator malfunction

Short to ground on left turn signal circuit HFSM malfunction

Short to ground on right turn signal circuit
1. Turn Signal Lamp Inspection Test
1. Remove and inspect left side turn signal bulbs.
1. Turn Signal Lamp Inspection Test
1. Remove and inspect right side turn signal lamps.
2. Confirm the turn signal bulbs are the correct part numbers
and the sockets are not corroded or damaged. 2. Confirm the turn signal bulbs are the correct part numbers
and the sockets are not corroded or damaged.
3. Were any issues found with the lamps?
a. Yes. Repair as needed. 3. Were any issues found with the lamps?
a. Yes. Repair as needed.
b. No. Go to Test 2.
b. No. Go to Test 2.
2. Turn Signal Circuit Short to Ground Test
1. With IGN OFF, connect BREAKOUT BOX (Part No. HD-
2. Turn Signal Circuit Short to Ground Test
42682) to HFSM wire harness [30B], leaving the HFSM 1. With IGN OFF, connect BREAKOUT BOX (Part No. HD-
[30A] disconnected. See 1.2 DIAGNOSTIC TOOLS. 42682) to HFSM wire harness [30B], leaving HFSM [30A]
disconnected. See 1.2 DIAGNOSTIC TOOLS.
2. Disconnect indicator lamps [21].
2. Disconnect indicator lamps [21].
3. Using a multimeter, test for continuity between breakout
box terminal 5 and terminal 12. 3. Using a multimeter, test for continuity between breakout
box terminal 6 and terminal 12.
4. Is continuity present?
a. Yes. Except FLTRX/FLHX. Repair short to ground 4. Is continuity present?
in left turn signal circuit (V) wire. a. Yes. Except FLTRX/FLHX. Repair short to ground
in right turn signal circuit (BN) wire.
b. Yes. FLTRX/FLHX. Go to Test 4.
b. Yes. FLTRX/FLHX. Go to Test 4.
c. No. Go to Test 3.
c. No. Go to Test 3.
3. Indicator Test
1. Install turn signal bulbs.
3. Indicator Test
1. Install turn signal bulbs.
2. Remove breakout box and connect HFSM [30].
2. Remove breakout box and connect HFSM [30].
3. With the indicator lamps disconnected, operate the left
turn signals. 3. With the indicator lamps disconnected, operate the right
turn signals.
4. Do the turn signals function and flash correctly?
a. Yes. Replace the indicator lamp assembly. See the 4. Do the turn signals function and flash correctly?
service manual. a. Yes. Replace the indicator lamp assembly. See the
service manual.
b. No. Replace the HFSM. See the service manual.
b. No. Replace the HFSM. See the service manual.
4. Facia/Converter Module Test
1. Disconnect rear lighting jumper harness [226].
4. Facia/Converter Module Test
1. Disconnect rear lighting jumper harness [226].
2. Test for continuity between breakout box terminal 5 and
terminal 12.

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2. Test for continuity between breakout box terminal 5 and DTC B1126
terminal 12.
PART NUMBER TOOL NAME
3. Is continuity present?
HD-42682 BREAKOUT BOX
a. Yes. Repair short to ground in left turn signal circuit
(V) wire.
Table 5-28. DTC B1126 Diagnostic Faults
b. No. Replace the facia/converter module. See the
service manual. POSSIBLE CAUSES
Indicator malfunction
DTC B1125
HFSM malfunction
PART NUMBER TOOL NAME
Short to voltage on right turn signal circuit
HD-42682 BREAKOUT BOX
1. Turn Signal Circuit Short to Ground Test
Table 5-27. DTC B1125 Diagnostic Faults 1. Connect BREAKOUT BOX (Part No. HD-42682) to HFSM
wire harness [30B], leaving HFSM [30A] disconnected.
POSSIBLE CAUSES See 1.2 DIAGNOSTIC TOOLS.
Indicator malfunction
2. With IGN ON, using a multimeter, test for voltage between
HFSM malfunction breakout box terminal 6 and terminal 12.
Short to voltage on left turn signal circuit 3. Is voltage present?

1. Turn Signal Circuit Short to Ground Test a. Yes. Go to Test 2.

1. Connect BREAKOUT BOX (Part No. HD-42682) to HFSM b. No. Replace HFSM. See the service manual.
wire harness [30B], leaving the HFSM [30A] disconnected.
See 1.2 DIAGNOSTIC TOOLS. 2. Rear Turn Signal Test
2. With IGN ON, using a multimeter, test for voltage between 1. With IGN OFF, disconnect rear fender lights [94] (except
breakout box terminal 5 and terminal 12. FLTRX/FLHX) or [226] (FLTRX/FLHX).

3. Is voltage present? 2. Turn IGN ON.

a. Yes. Go to Test 2. 3. Test for voltage between breakout box terminal 6 and
terminal 12.
b. No. Replace HFSM. See the service manual.
4. Is voltage present?
2. Rear Turn Signal Test a. Yes. Repair short to voltage in right turn signal circuit
1. With IGN OFF, disconnect rear fender lights [94] (except (V) wire.
FLTRX/FLHX) or [226] (FLTRX/FLHX). b. No. Except FLTRX/FLHX. Replace the circuit board.
2. Turn IGN ON. See the service manual.

3. Test for voltage between breakout box terminal 5 and c. No. FLTRX/FLHX. Replace the facia/converter
terminal 12. module. See the service manual.

4. Is voltage present?
a. Yes. Repair short to voltage in left turn signal circuit
(V) wire.
b. No. Except FLTRX/FLHX. Replace the circuit board.
See the service manual.
c. No. FLTRX/FLHX. Replace the facia/converter
module. See the service manual.

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DTC B1135, B1136, B1141, B1142 5.11

DIAGNOSTICS DTC B1141
DTC B1135 Accelerometer Fault PART NUMBER TOOL NAME
DTC B1135 indicates a failure which requires replacement of HD-42682 BREAKOUT BOX
the TSM/TSSM/HFSM.
NOTE Table 5-29. DTC B1141 Diagnostic Faults
When DTC B1135 is set, the tip-over engine shutdown, HFSM POSSIBLE CAUSES
tamper alarm and bank angle sensors are disabled. The
security lamp will also illuminate when this code is set. TSM/TSSM/HFSM malfunction
Open ignition circuit
DTC B1136 Accelerometer Tip-Over
Self-Test Fault 1. Ignition Circuit Open Test
DTC B1136 indicates a failure which requires replacement of 1. Connect TSM/TSSM/HFSM BREAKOUT BOX (Part
the HFSM. No. HD-42682) to TSM/TSSM/HFSM wire harness [30B],
leaving TSM/TSSM/HFSM [30A] disconnected. See
DTC B1141 Ignition Switch Open/Low 1.2 DIAGNOSTIC TOOLS.
DTC B1141 indicates the TSM/TSSM/HFSM is recognizing an 2. With the IGN ON, using a multimeter, test for voltage
open or low condition on the ignition circuit. between breakout box terminal 2 and ground.
DTC B1142 Internal Fault 3. Is voltage present?
DTC B1142 indicates a failure which requires replacement of a. Yes. Replace the TSM/TSSM/HFSM. See the service
the HFSM. manual.
b. No. Repair open in (GY) ignition wire.

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SECURITY SYSTEM 5.12

SECURITY LAMP
The security lamp (key icon) in the instrument face provides
feedback to the rider confirming armed or disarmed status.
Refer to Table 5-30.

ed03170

1 8 3
2 11 1

11

50 60 70 40
30 50
40 80
30 90 20 60
MPH RPM x100
20 100
10 70
10 110
0 120 0 80

9 C
H A R ERT I FI ED
L EY -DA V I DSON
HAR
L EY -DA VI DSON

7 7 2
6
10 9 8
5 4 10
4 6 5

1. Speedometer 7. Check engine lamp

2. Security lamp (key icon) 8. Battery discharge lamp
3. Tachometer 9. Sixth gear lamp
4. Cruise lamp 10. ABS lamp
5. Odometer/trip odometer/clock 11. Pursuit lamp (Police models)
6. Low fuel warning lamp
Figure 5-27. Speedometer

SECURITY IMMOBILIZATION
Table 5-30. Security Lamp Status
The TSSM/HFSM provides security and immobilization func-
LAMP MODE tions not found on the TSM. The TSSM/HFSM will disable the
Does not flash. No security system (TSM only), security starter and ignition system. Additional functions include the
system not armed. ability to alternately flash the left and right turn signals and
Flashes every 2 minute (HFSM) or ten minute (TSSM) sound a siren (if equipped) if a theft attempt is detected.
second. timeout after failed PIN entry attempt or NOTE
a battery reconnect has occurred while
The siren must be in the chirp mode for the siren to chirp on
armed.
arming or disarming. See 5.14 SIREN, Siren Chirp Mode
Flashes every 2.5 Security system armed. Confirmation: HFSM.
seconds.
Conditions that activate the security system when system is
Flashes 4 times a PIN entry mode. armed include:
second.
• Detecting tampering of the ignition circuit: Turn signals
Stays on solid with Arming is starting up. You have 5 flash three times, optional siren chirps once and then turns
IGN OFF. seconds (HFSM) or 30 seconds (TSSM) off. If the tampering continues, a second warning will
before system is armed. activate after four seconds. Continued tampering will cause
Stays on solid with If solid for more than 4 seconds after IGN the alarm to activate for 30 seconds and then turn off. The
IGN ON. ON, a current DTC is present.

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two warnings/alarm cycle is repeated for each tampering
incident.
• Detecting vehicle movement: Turn signals flash three
times, optional siren chirps once and then turns off. If the
vehicle is not returned to its original position, a second
warning will activate after four seconds. If the vehicle is
not returned to its original position, the alarm activates for
30 seconds then turns off. The two warnings/alarm cycle
may repeat a maximum of 10 times with a 10 second
pause between cycles.
• Detecting that a battery or ground disconnect has
occurred while armed: The optional siren activates its
self-alarm mode. Turn signals will not flash.
NOTE
Always disarm the TSSM/HFSM before removing or discon-
necting the battery to prevent the siren (if installed) from
activating. If the TSSM is in auto-arming mode, you must
disarm the system and disconnect the battery or remove the
battery fuse before the 30 second arming period expires.
TSSM/HFSM FEATURES
PART NUMBER TOOL NAME
HD-48650 DIGITAL TECHNICIAN II
The following information applies only to vehicles equipped
with the TSSM/HFSM.
• Security lamp: See Figure 5-27. The security lamp (key
icon) tells the rider if the system is armed or disarmed.
• Personal code disarming: If the fob is not available, the
TSSM/HFSM allows the rider to disable the security alarm
and immobilization functions with a five-digit personal
code.
• Arming confirmation: When the TSSM/HFSM is armed,
the system provides visual feedback (confirmation) to the
rider by flashing the turn signals and an audible "chirp" if
equipped with the optional smart siren and chirp mode is
enabled.
• Remote arming/disarming (TSSM only): See 5.13 KEY
FOB. Owners may enable and disable security alarm and
immobilization functions with a personally carried trans-
mitter. This transmitter is referred to as a key fob. Remote
arming/disarming is a function of the TSSM (Japan/Korea)
only.
• Auto-arming (TSSM only): Automatically enables the
security alarm and immobilization functions within 30
seconds after the ignition switch is switched OFF.
• Disarming confirmation: When the TSSM/HFSM is dis-
armed, the system provides an audible "chirp" (confirma-
tion) if equipped with the optional smart siren and chirp
mode is enabled.
• Transport mode: It is possible to arm the security system
without enabling the motion detector for one ignition cycle.
5-46 2011 Touring Diagnostics: Accessories, Horn, Lighting and Security
This allows the vehicle to be moved in an immobilized
state.
• Starter/ignition disable: When armed the starter and
ignition system are disabled.
• Security system alarm: See 5.14 SIREN. The system
will alternately flash the left and right turn signals and
sound an optional Smart Siren if a vehicle security condi-
tion is detected while the system is armed.
• Dealer service mode (HFSM only): This mode allows
the dealer to disable security system via DIGITAL TECH-
NICIAN II (Part No. HD-48650). Dealer service mode is
exited when module detects an assigned fob in range.
Security System Options: TSSM
The following options are only available on the TSSM unit:
alarm sensitivity, auto-arming feature and storage mode.
Default settings for the TSSM include:
• Solo vehicle configuration.
• Medium motion sensitivity on alarm sensitivity.
• All vehicles are shipped with auto-arming disabled.
• Storage mode set to 10 days.
WARNINGS
A warning consists of three alternate flashes of the turn signals
and chirp from the optional smart siren. Warnings are issued
from an armed TSSM/HFSM in the following order:
1. First Warning: A warning is issued whenever a person
without a fob present or with the system armed attempts
to move the vehicle or turns the ignition switch to IGN.
2. Second Warning: If the motion continues or the ignition
switch is not turned back to OFF, a second warning is
issued within four seconds of the first.
3. Alarm: If the motion continues or the ignition switch is not
turned to OFF past the second warning, the smart security
system will go into full alarm.
ARMING: HFSM
The H-DSSS automatically arms within five seconds when the
vehicle is parked and the ignition switch is turned to OFF and
motion is not detected.
On arming, the turn signals flash twice and the smart siren will
"chirp" twice if chirp function is activated. While armed, the
security lamp (key icon) will flash once every 2.5 seconds.
Refer to Table 5-30.
ARMING: TSSM
There are two methods to arm the security system:
• Using the key fob.
• Using auto-arming.
NOTE
The vehicle cannot be armed with the IGN ON.
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Auto-Arming Function: TSSM
Auto-arming causes the system to automatically arm itself (no
key fob needed) within 30 seconds after the ignition switch is
turned OFF. During this period, the security lamp stays illumin-
ated to indicate auto-arming is starting up.
The vehicle may be moved during these 30 seconds without
triggering the alarm. However, any motion after that period will
trigger the security alarm. Upon expiration of the auto-arming
period, the turn signals flash twice, the security lamp begins
to flash and the siren (if equipped) chirps twice.
The TSSM allows remote arming via the key fob at any time.
However, if the system is remotely disarmed (with the key fob)
but the ignition switch is not turned ON within 30 seconds, the
system will re-arm itself when auto-arming is enabled.
Japan and Korea vehicles have auto-arming disabled by
default. However, the feature may be enabled if the customer
desires.
When auto-arming is disabled, the key fob must be used to
arm the security system. To set the auto-arming function, refer
to Table 5-31.

Table 5-31. Selecting TSSM Auto-Arming Function

NO. ACTION WAIT FOR CONFIRMATION NOTES

1 Set engine stop switch to OFF
2 Turn IGN ON-OFF-ON-OFF-ON
3 Press left turn switch 2 times and
release
4 Press and hold key fob button until
confirmation is received
5 Press and hold key fob button until
confirmation is received
6 Press left turn switch 1 time and
release
7 Press and release left turn switch to
advance through options
8 Turn IGN OFF
Verify the security lamp is not flashing
(vehicle is disarmed)
Two flashes turn signals and indicators Two flashes - Japan/Korea configura-
(See 5.15 SERVICE AND EMER- tion TSSM
GENCY FUNCTIONS AND CONFIG-
URATIONS, Power Disruption and
Configuring: TSSM regarding battery
disconnects.)
One flash turn signals and indicators
Two flashes turn signals and indicators
Turn signals and indicators flash to One flash - auto-arming disabled
indicate option selected Two flashes - auto-arming enabled
Turn signals and indicators flash to
indicate option selected

DISARMING: HFSM
There are two ways to disarm the H-DSSS:
• Automatic Disarming.
• Using the PIN.
Automatic Disarming
Always have the fob present when riding, loading, fueling,
moving, parking or servicing the vehicle. Carry the fob in a
convenient pocket. The H-DSSS disarms automatically when
the ignition switch is turned to ON.
On disarming, the smart siren will chirp once (if chirp function
is activated) and the security lamp (key icon) will turn ON solid
for four seconds then go out. Refer to Table 5-30.
Disarming with a PIN
See 5.15 SERVICE AND EMERGENCY FUNCTIONS AND
CONFIGURATIONS to enter an initial PIN to enable the
system.
If you make an error while disarming the HFSM using the PIN,
the alarm will activate for 30 seconds after the last digit is
entered. After a failed attempt, the security lamp will flash once
every second for 2 minutes (HFSM) or ten minutes (TSSM).
During this time, the vehicle will not accept any attempt
to enter a PIN. Refer to Table 5-30.
DISARMING: TSSM
There are two ways to disarm the system:
• Using the key fob. This method works in all situations
except before turning ignition switch ON when TSSM
storage mode is activated.
• Using a PIN.
If you make an error while disarming the TSSM using a PIN,
the alarm will activate for 30 seconds after the last digit is
entered. After a failed attempt, the security lamp will flash once
every second for 10 minutes. During this time, the vehicle
will not accept any attempt to enter a PIN. Refer to
Table 5-32.

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Table 5-32. Disarming TSSM/HFSM with the PIN (Example: 3-1-3-1-3)

NO. ACTION WAIT FOR CONFIRMATION NOTES

1 Set engine stop switch to OFF
2 Turn IGN to the IGN position (HFSM)
Turn IGN to the ACC position (TSSM)
3 Hold both turn switches in until confirm- Security lamp flashes at fast rate System is ready for PIN entry
ation
4 Enter first digit of code (3) by pressing
left turn switch 3 times
5 Press right turn switch 1 time Serves as "enter" key for first digit
6 Enter second digit of code (1) by
pressing left turn switch 1 time
7 Press right turn switch 1 time Serves as "enter" key for second digit
8 Enter third digit of code (3) by pressing
left turn switch 3 times
9 Press right turn switch 1 time Serves as "enter" key for third digit
10 Enter fourth digit of code (1) by Serves as "enter" key for fourth digit
pressing left turn switch 1 time
11 Press right turn switch 1 time
12 Enter fifth digit of code (3) by pressing System is disarmed. You may use the
left turn switch 3 times vehicle or program another key fob
13 Press right turn switch 1 time Security lamps stop flashing

ALARM
Activation
In the full alarm state, the turn signals flash alternately, and if
equipped with the smart siren, the siren will sound.
After 30 seconds of alarm, if no further vehicle motion is
detected, the alarm will stop.
NOTE
Vehicle must be returned to original parked position with ignition
switch turned to OFF.
If vehicle motion continues, the alarm will start again continue
for another 30 seconds.
The TSSM/HFSM will repeat the alarm cycles 10 times for a
total of five minutes, with a 10-second pause between alarm
cycles.
During warnings and alarms, the starter motor and the ignition
remain disabled.
Deactivation
The alarm cycles can be discontinued at any time by moving
an assigned fob to the vehicle. The presence of the fob will
terminate the alarm.
ALARM SENSITIVITY: TSSM
Sensitivity
The TSSM has four sensitivity settings: extremely low, low,
medium or high. The selection chosen controls the sensitivity
of the security system regarding motion detection.
To set alarm sensitivity, refer to Table 5-33.

Table 5-33. TSSM Alarm Sensitivity

NO. ACTION WAIT FOR CONFIRMATION NOTES

1 Set engine stop switch to OFF Verify the security lamp is not flashing
(vehicle is disarmed)
2 Turn IGN ON-OFF-ON-OFF-ON

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Table 5-33. TSSM Alarm Sensitivity

NO. ACTION WAIT FOR CONFIRMATION NOTES

3 Press left turn switch 2 times and
release
4 Press and hold key fob button until
confirmation is received
5 Press left turn switch 1 time and
release
6 Press and release left turn switch to
advance through options
7 Turn IGN OFF
Two flashes turn signals and indicators Two flashes - Japan/Korea configura-
depending on vehicle configuration. tion TSSM
(See 5.15 SERVICE AND EMER-
GENCY FUNCTIONS AND CONFIG-
URATIONS, Power Disruption and
Configuring: TSSM regarding battery
disconnects.)
One flash turn signals and indicators
Turn signals and indicators flash to One flash - extremely low
indicate option selected Two flashes - low sensitivity
Three flashes - medium sensitivity
Four flashes - high sensitivity
Turn signals and indicators flash to One flash - extremely low
indicate option selected Two flashes - low sensitivity
Three flashes - medium sensitivity
Four flashes - high sensitivity

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KEY FOB 5.13

HFSM FOB
See Figure 5-28. The HFSM's reception range for the hands-
free fob signal depends on a specific receiver pattern. The
typical range will be an arm's length.
NOTES
• Environmental and geographic conditions may affect signal
range.
• Always have the fob present whenever the vehicle is
operated.
• Do not place fob in metal enclosure, and do not place it
closer than 3.0 in. (80.0 mm) to cellular phones, the
handsfree antenna, PDAs, displays and other electronic
devices while operating the vehicle. That may prevent the
fob from disarming the security system.
3. Hold down the key fob button until the system responds
with two turn signal flashes.
Disarming the System
1. Hold key fob horizontal at waist level.
2. Point key fob at the front of the vehicle.
3. Quickly press the key fob button twice. The system will
respond with one turn signal flash.
NOTE
Disarming function may require practice. The key fob button
must be pressed twice within 1.5 seconds to send the disarm
command. The action is very similar to double-clicking a com-
puter mouse. Light quick taps work best; very hard or very slow
taps are less likely to work.

• Fob battery should be replaced every year. See the service Troubleshooting
manual.
If the key fob button has been pressed numerous times while
away from the vehicle, the fob may fall out of synchronization
with the TSSM. If this happens, the TSSM might fail to recog-
ed02829
nize the key fob's commands.
To solve this problem, press and hold the key fob button for
10-15 seconds until the security system responds with two turn
signal flashes. After confirmation, you may resume normal fob
operation.

FOB ASSIGNMENT: HFSM

PART NUMBER TOOL NAME
HD-48650 DIGITAL TECHNICIAN II

Use DIGITAL TECHNICIAN II (Part No. HD-48650) to assign

both fobs to the H-DSSS. Follow the menu prompts in the
DIGITAL TECHNICIAN II (Part No. HD-48650) display and
scan the fob serial number with the bar code reader, or key-in
the number from the keyboard. See a Harley-Davidson dealer.
NOTE
Each fob has a unique serial number. The label should be
removed from the fob and attached to a blank NOTES page
in the Owner's Manual for reference.

FOB ASSIGNMENT: TSSM

Figure 5-28. Hands-Free Fob Refer to Table 5-34 to assign a key fob to a vehicle equipped
with a TSSM.

TSSM FOB The key fob on TSSM vehicles must be set so it will operate
the alarm system on the vehicle. This assignment must be
The TSSM reception range for the key fob signal depends on completed with no pauses between steps greater than 10
a specific receiver pattern. seconds. Turn the ignition OFF after all key fobs have been
assigned. The programming mode will also exit after 60
NOTE
seconds has elapsed without detecting any fob sign-up mes-
Environmental and geographic conditions may affect signal sages or turn signal switch activity.
range.
Two key fobs may be assigned to the TSSM. The first suc-
Arming the System cessful attempt to program a fob will disable all previously
1. Hold key fob horizontal at waist level. assigned fobs. If a second fob is to be programmed, it must
be done in the same programming sequence as the initial fob.
2. Point key fob at the front of the vehicle.

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Table 5-34. Key FOB Assignment: TSSM
NO. ACTION
1 Set engine stop to OFF
2 Turn ignition/headlamp switch
ON-OFF-ON-OFF-ON
3 Press left turn switch 2 times and
release
4 Press right turn switch 1 time and
release
5 Press left turn switch 1 time and
release
6 Press and hold key fob button until
confirmation is received
7 If you have two key fobs, press and
hold button on second key fob until
confirmation is received
8 Turn ignition/headlamp switch OFF
2011 Touring Diagnostics: Accessories, Horn, Lighting and Security 5-51
WAIT FOR CONFIRMATION NOTES
Verify the security lamp is not flashing
(vehicle is disarmed)
This assignment procedure must be
completed with no pauses between
steps greater than 10 seconds
One to four flashes turn signals and One flash - Worldwide TSM, no
indicators depending on vehicle config- security
uration Two flashes - Japan/Korea configura-
(See 5.15 SERVICE AND EMER- tion TSSM
GENCY FUNCTIONS AND CONFIG-
URATIONS, Power Disruption and
Configuring: TSSM regarding battery
disconnects.)
One flash turn signals and indicators
Two flashes turn signals and indicators
Two flashes turn signals and indicators This may take 10-25 seconds.
Two flashes turn signals and indicators Optional step
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SIREN 5.14
DESCRIPTION AND OPERATION SIREN CHIRP MODE CONFIRMATION: HFSM
See Figure 5-29. The Smart Siren is not a standard part of the Chirpless Mode
security system but can be added to the system. The siren is
attached at [142] off the TSSM/HFSM. Through this connector, In the chirpless mode, the siren does not chirp on arming or
it shares the battery circuit, the ground circuit and the alarm disarming.
signal circuit with the TSSM/HFSM. The siren is used to add NOTE
an audible warning to the visual warnings that are a standard
Even when armed in the chirpless mode, the siren still chirps
function of the security system.
warnings on movement and will activate the alarm through the
NOTE normal cycles.
Vehicles equipped with a siren and an external BAS, including Chirp Mode
Trikes or vehicles with an optional sidecar, will react differently
when starting than other vehicles. These vehicles should be On arming in the chirp mode, the siren responds with two
placed in gear when the ignition is turned OFF. If the ignition chirps. When disarming, the siren responds with a single chirp.
is turned ON with the vehicle in neutral the siren will sound
even if the security system is disabled. Therefore, the ignition
Switching Modes
switch should be turned ON with the vehicle in gear and then Cycling quickly through three armings and disarmings will
shifted to neutral. Once in neutral the vehicle can be started switch the system from either the chirpless mode or the chirp
normally. mode to its opposite.
1. With the fob present, the IGN ON and the system dis-
ed03111 armed, turn the IGN OFF.
2 3 2. When the security lamp turns off, immediately turn the
IGN ON. If the turn signals flash twice before the IGN is
1 turned ON, the system will drop out of the switching mode
4
sequence and will have to be started over from the
beginning.
3. Wait until the security lamp goes out, then immediately
turn the IGN OFF.
5
4. When the security lamp turns off, immediately turn the
IGN ON. If the turn signals flash twice before the IGN is
turned ON, the system will drop out of the switching mode
sequence and will have to be started over from the
6 beginning.
1. Security siren [142] 5. Wait until the security lamp goes out, then immediately
2. Security siren (if equipped) turn the IGN OFF.
3. Fuse block
6. When the security lamp turns off, immediately turn the
4. Main fuse [5]
IGN ON. If the turn signals flash twice before the IGN is
5. DLC [91]
turned ON, the system will drop out of the switching mode
6. ABS diode pack [201] (if equipped)
sequence and will have to be started over from the
Figure 5-29. Under Left Side Cover: Except FLTRX, FLHX, beginning.
FLHTC

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SERVICE AND EMERGENCY FUNCTIONS AND

CONFIGURATIONS
GENERAL
Setting up a vehicle's TSM/TSSM/HFSM depends on whether
the vehicle has a TSM or the optional TSSM or HFSM security
system installed.
ACTUATION: HFSM
Actuation consists of assigning two fobs to the system, and
entering an initial PIN. The PIN can be changed by the rider
at any time.
1. Configure HFSM vehicles by assigning both fobs to the
vehicle.
2. Configure HFSM vehicles by entering a PIN picked by the
owner. The personal code allows the owner to operate
the system if the fob is lost or inoperable. Record the PIN
in the owner's manual and instruct the customer to carry
a copy (use the wallet card found in the owner's manual).
Once the system has been activated, it will always "arm" within
5 seconds of turning the ignition switch to OFF and no vehicle
motion.
5.15
Changes to TSSM settings are made by a series of program-
ming operations involving the ignition key, left/right turn signal
switches and key fob (security systems).
At certain steps in the programming sequence, the vehicle may
provide confirmation of settings by flashing the turn signals,
turn signal indicators and/or security lamp. In addition, when
programming a PIN into a TSSM system, the odometer displays
the PIN to the user and dynamically updates it as the code is
entered or changed.
All programming operations are listed in table format. Follow
the numbered steps to configure the system. If a confirmation
response is listed, wait for the confirmation before continuing
to the next step. Important information pertaining to certain
actions will be found in the NOTES column.
SELECTING A PIN
The PIN consists of five digits. Each digit can be any number
from 1-9. There can be no zeros (0) in the PIN. The PIN must
be used to disarm the security system in case the fob becomes
unavailable.

CONFIGURING A TSSM INITIAL PIN ENTRY: HFSM

To enter a PIN on a vehicle with no PIN previously installed
NOTE
during HFSM actuation, refer to Table 5-35.
Do not forget to enter a PIN for TSSM vehicles. If a PIN is not
assigned and both key fobs are lost or damaged while the
vehicle is armed, the TSSM must be replaced.

Table 5-35. Entering an Initial PIN: HFSM

NO. ACTION WAIT FOR CONFIRMATION

1 Select a 5-digit (1 through 9) initial PIN and record in the
owner's manual and on the wallet card.
2 With an assigned fob present, set engine stop switch to
OFF.
3 Cycle IGN ON-OFF-ON-OFF-ON
4 Press left turn signal button 2 times. Turn signals will flash 3 times.
5 Press right turn signal button 1 time. Five dashes will appear in the odometer window. The
first dash will flash.
6 Enter first digit (a) of initial PIN by pressing left turn signal
button a times.
7 Press right turn signal button 1 time. The digit (a) will replace the dash in the odometer. The
second dash will flash.
8 Enter second digit (b) of initial PIN by pressing left turn
signal button until desired digit is displayed in odometer.
9 Press right turn signal button 1 time. The digit (b) will replace the dash in the odometer. The
third dash will flash.
10 Enter third digit (c) of initial PIN by pressing left turn
signal button c times.
11 Press right turn signal button 1 time. The digit (c) will replace the dash in the odometer. The
fourth dash will flash.
12 Enter fourth digit (d) of initial PIN by pressing left turn
signal button d times.

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Table 5-35. Entering an Initial PIN: HFSM

NO. ACTION WAIT FOR CONFIRMATION

13 Press right turn signal button 1 time. The digit (d) will replace the dash in the odometer. The
fifth dash will flash.
14 Enter fifth digit (e) of initial PIN by pressing left turn signal
button e times.
15 Press right turn signal button 1 time. The digit (e) will replace the dash in the odometer. The
first digit will flash.
16 Turn IGN OFF.

INITIAL PIN ENTRY: TSSM
NOTE
Do not forget to enter a PIN for TSSM vehicles. If a PIN is not
assigned and the key fob is lost or damaged while the vehicle
is armed, the TSSM must be replaced.
The TSSM PIN consists of five digits. Each digit can be any
number from 1-9. There can be no zeros (0) in the PIN. The
PIN must be used to disarm the security system in case the
key fob becomes unavailable.
Refer to Table 5-36 to enter an initial PIN with no PIN previously
installed. The procedure listed uses 3-1-3-1-3 as the desired
PIN.
NOTE
For better security, do not use 3-1-3-1-3 as a PIN. It is shown
as an example only.
Decide what five-digit PIN the owner would like to use. The
code will be programmed using the turn signal switches and
key fob. Keep a record of the PIN in a secure place such as
your wallet or the Owner's Manual.
• When programming the PIN, the security lamp flashes to
provide feedback when entering each digit. The odometer
also displays the PIN and the change dynamically.
• The number of security lamp flashes corresponds to the
number currently selected for a given digit. Therefore, the
lamp may flash 1-9 times depending on the number
entered. The five-digit PIN will change in the odometer
window and the active digit will blink.
• Press the left turn switch one time to increment each digit.
• Quickly press the key fob button twice to advance to the
next digit.
NOTE
The programming mode exits upon turning the ignition switch
to OFF, or if no turn signal switch/key fob button activity occurs
for 60 seconds. No data is saved for partial configuration
attempts if entering a PIN for the first time. If a PIN has previ-
ously been entered, the user can change any digit or group of
digits.

Table 5-36. Entering an Initial TSSM PIN (Example: 3-1-3-1-3) with No PIN Previously Entered

NO. ACTION WAIT FOR CONFIRMATION NOTES

1 Set engine stop switch to OFF
2 Turn IGN ON-OFF-ON-OFF-ON
3 Press left turn switch 2 times and
release
4 Quickly press key fob button 2 times One flash turn signals and indicators
and release
One to four flashes turn signals and
indicators depending on vehicle config-
uration
(See 5.15 SERVICE AND EMER-
GENCY FUNCTIONS AND CONFIG-
URATIONS, Power Disruption and
Configuring: TSSM regarding battery
disconnects)
Odometer displays current five-digit
PIN (five dashes if no code entered),
first digit flashes
Verify the security lamp is not flashing
(vehicle is disarmed)
This assignment procedure must be
completed with no pauses between
steps greater than 10 seconds
One flash - Worldwide TSM, no
security
Two flashes - Japan/Korea configura-
tion TSSM
Vehicle is in PIN entry mode ready to
enter or modify first digit

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Table 5-36. Entering an Initial TSSM PIN (Example: 3-1-3-1-3) with No PIN Previously Entered

NO. ACTION WAIT FOR CONFIRMATION NOTES

5 Press left turn switch 1 time and Security lamp flashes 1-9 times if code A lack of confirmation flashes indicates
release was previously entered no digit entered
6 Press and release left turn switch to Blinking digit in odometer display You have selected 3 as a number for
advance through the digits increments, security lamp flashes to the first digit
In this example, you will press and indicate each digit selected
release three times In this example, the blinking digit dis-
played is 3 and the security lamp will
flash three times
7 Quickly press key fob button 2 times Two flashes turn signals and indicators You have confirmed 3 as a number for
and release second digit in odometer display blinks the first digit and have advanced to
entering the second digit
8 Press left turn switch 1 time and None A lack of confirmation flashes indicates
release no digit entered
9 Press and release left turn switch to Blinking digit in odometer display You have selected 1 as a number for
advance through the digits increments, security lamp flashes to the second digit
In this example, you will perform this indicate each digit selected
step one time In this example, the blinking digit dis-
played is 1 and the security lamp will
flash one time
10 Quickly press key fob button 2 times Three flashes turn signals and indic- You have confirmed 1 as a number for
and release ators third digit in odometer display the second digit and have advanced to
blinks entering the third digit
11 Press left turn switch 1 time and None A lack of confirmation flashes indicates
release no digit entered
12 Press and release left turn switch to Blinking digit in odometer display You have selected 3 as a number for
advance through the digits increments, security lamp flashes to the third digit
In this example, you will repeat this indicate each digit selected
step three times In this example, the blinking digit dis-
played is 3 and the security lamp will
flash three times
13 Quickly press key fob button 2 times Four flashes turn signals and indicators You have confirmed 3 as a number for
and release fourth digit in odometer display blinks the third digit and have advanced to
entering the fourth digit
14 Press left turn switch 1 time and None A lack of confirmation flashes indicates
release no digit entered
15 Press and release left turn switch to Blinking digit in odometer display You have selected 1 as a number for
advance through the digits increments, security lamp flashes to the fourth digit
In this example, you will perform this indicate each digit selected
step one time In this example, the blinking digit dis-
played is 1 and the security lamp will
flash one time
16 Quickly press key fob button 2 times Five flashes turn signals and indicators You have confirmed 1 as a number for
and release fifth digit in odometer display blinks the fourth digit and have advanced to
entering the fifth digit
17 Press left turn switch 1 time and None A lack of confirmation flashes indicates
release no digit entered
18 Press and release left turn switch to Blinking digit in odometer display You have selected 3 as a number for
advance through the digits increments, security lamp flashes to the fifth digit
In this example, you will repeat this indicate each digit selected
step three times In this example, the blinking digit dis-
played is 3 and the security lamp will
flash three times
19 Quickly press key fob button 2 times One flash turn signals and indicators You have confirmed 3 as a number for
and release first digit in odometer display blinks the fifth digit and have gone back to
the first digit

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Table 5-36. Entering an Initial TSSM PIN (Example: 3-1-3-1-3) with No PIN Previously Entered

NO. ACTION WAIT FOR CONFIRMATION NOTES

20 Turn IGN OFF
21 Write down code in Owner's Manual
22 Arm the security system and attempt
to disarm using PIN entry. Refer to
Table 5-32.

CHANGING THE PIN Examples:

To change a PIN, refer to Table 5-37.
If a PIN was previously entered, the odometer will display the
equivalent digit. Each additional press of the left turn switch
will increment the digit.
• To advance from 5 to 6, press and release the left turn
switch 1 time.
• To advance from 8 to 2, press and release the left turn
switch 3 times (9-1-2).

Table 5-37. Changing the PIN: HFSM

NO. ACTION WAIT FOR CONFIRMATION NOTES

1 Select a 5-digit (1 through 9) personal
code and record in the owner's manual
and on the wallet card.
2 With fobs present, cycle IGN
ON-OFF-ON-OFF-ON
3 Press left turn signal button 2 times. Turn signals will flash 3 times.
4 Press right turn signal button 1 time. Current PIN will appear in odometer.
The first digit will flash.
5 Enter first digit (a) of new PIN by
pressing left turn signal button until
desired digit is displayed in odometer.
6 Press right turn signal button 1 time. The new digit will replace the current
in the odometer. The second digit will
flash.
7 Enter second digit (b) of new PIN by
pressing left turn signal button until the
desired digit is displayed in the odo-
meter.
8 Press right turn signal button 1 time. The new digit will replace the current
in the odometer. The third digit will
flash.
9 Enter third digit (c) of new PIN by
pressing left turn signal button until
desired digit is displayed in the odo-
meter.
10 Press right turn signal button 1 time. The new digit will replace the dash in
the odometer. The fourth digit will flash.
11 Enter fourth digit (d) of new PIN by
pressing left turn signal button until
desired digit is displayed in the odo-
meter.
12 Press right turn signal button 1 time. The new digit will replace the current
in the odometer. The fifth digit will flash.

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Table 5-37. Changing the PIN: HFSM

NO. ACTION WAIT FOR CONFIRMATION NOTES

13 Enter fifth digit (e) of new PIN by
pressing left turn signal button until
desired digit is displayed in the odo-
meter.
14 Press right turn signal button 1 time. The new digit will replace the current
in the odometer. The first digit will flash.
15 Turn the IGN OFF. Turning the ignition switch to OFF
stores the PIN.

TRANSPORT MODE 4. Turn IGN OFF.

Transport mode is especially useful when working on the 5. Press and hold key fob button until the turn signals and
vehicle. If it is not used, the alarm will activate under many indicators flash three times.
typical service activities.
To Exit Transport Mode: TSSM
To Enter Transport Mode: HFSM To exit from transport mode and return the system to normal
It is possible to arm the security system without enabling the operation/functions, disarm the system using either the key
motion detector for one ignition cycle. This allows the vehicle fob or PIN.
to be picked up and moved in an armed state, however, any
attempt to start the engine will trigger the alarm.
SERVICE MODE
1. Turn the ignition switch to IGN. PART NUMBER TOOL NAME

2. Set the engine stop switch to the OFF position. HD-48650 DIGITAL TECHNICIAN II

3. With an assigned fob within range, turn the ignition switch With a fob present, the HFSM can be configured for service
from OFF to ACC. by disabling the security system with DIGITAL TECHNICIAN
II (Part No. HD-48650).
4. Simultaneously, press both the left and the right turn signal
switches. This must be done within five seconds of turning Once disabled, the vehicle can be operated without an assigned
the ignition switch to ACC. fob present. To maintain the Service Mode, the assigned fobs
must be kept out of range. If the fob appears in range, the
5. After the turn signals flash once, turn the ignition switch Service Mode will be exited.
to OFF and the module is armed.
FOUR-WAY FLASHING
6. The turn signals flash three times to confirm module
arming in transfer mode for one ignition cycle. To Arm the HFSM with the Hazard Warning
To Exit Transport Mode: HFSM Flashers ON
Return the system to normal operation: If it is necessary to leave a vehicle parked along side the road,
the hazard warning four-way flashers can be turned ON with
1. With the fob present, turn the ignition switch to IGN to the smart security system armed.
disarm the HFSM.
1. Turn IGN ON.
2. To cancel the transport mode, set the engine stop switch
to RUN. 2. Simultaneously press both left and right turn signal
switches to turn the four-way flashers ON. The four-way
To Enter Transport Mode: TSSM flashers will continue for two hours.
It is possible to arm the security system without enabling the 3. Turn IGN OFF to arm the smart security system.
motion detector for one ignition cycle. This allows the vehicle
to be picked up and moved in an armed state. In this mode, To Disarm the HFSM and Turn the Hazard
any attempt to bypass the ignition system will trigger the Warning Flashers OFF
security system.
1. With a fob present, turn the ignition switch to IGN.
1. Turn the engine stop switch to the OFF position. Verify
2. Simultaneously press the left and right turn signal switches.
the security lamp is not flashing.
2. Turn IGN ON. STORAGE MODE: TSSM
3. Press and hold key fob button until the turn signals and The TSSM has a special mode for long term storage. This
indicators flash three times. mode prevents the security system from draining the battery

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after a period of days (10, 20, 60 or infinite) without any ignition
switch activity.
• If the TSSM is set to infinite, the system will not go into
storage mode.
• Vehicles will enter storage mode whether the security
system is armed or disarmed.
• If set to 20 days or greater, the customer must use an
approved trickle charger to keep the battery from dischar-
ging.
In storage mode, all alarm functions remain active but the
receiver is shut down and will not respond to the key fob. The
vehicle is immobilized because the starter motor and ECM are
disabled. When the storage mode is entered, the security lamp
stops flashing to conserve power.
To wake up the TSSM from storage mode, the ignition switch
must be turned ON. This will trigger a warning/alarm if the
system was previously armed. You must use the key fob or
PIN to disarm the system and stop the alarm.
To set the storage mode preferences, refer to Table 5-38.

Table 5-38. Storage Mode Preferences: TSSM

NO. ACTION WAIT FOR CONFIRMATION NOTES

1 Set engine stop switch to OFF
2 Turn IGN ON-OFF-ON-OFF-ON
3 Press left turn switch 2 times and
release
4 Press and hold key fob button until
confirmation is received
5 Release and then hold key fob button Two flashes turn signals and indicators
until confirmation is received
6 Release and then hold key fob button Three flashes turn signals and indic-
until confirmation is received
7 Press left turn switch 1 time and
release
8 Press left turn switch to advance
through options
9 Turn IGN OFF.
Verify the security lamp is not flashing
(vehicle is disarmed)
Two flashes turn signals and indicators Two flashes - Japan/Korea configura-
depending on vehicle configuration tion TSSM
(See 5.15 SERVICE AND EMER-
GENCY FUNCTIONS AND CONFIG-
URATIONS, Power Disruption and
Configuring: TSSM regarding battery
disconnects.)
One flash turn signals and indicators
ators
Turn signals and indicators flash to One flash - 10 days
indicate option selected Two flashes - 20 days
Three flashes - 60 days
Four flashes - Infinite
Turn signals and indicators flash to One flash - 10 days
indicate option selected Two flashes - 20 days
Three flashes - 60 days
Four flashes - Infinite

POWER DISRUPTION AND CONFIGURING: 1. Set engine stop switch to the OFF position, cycle ignition
switch IGN to ON-OFF-ON-OFF-ON and press left turn
HFSM signal switch twice.
PART NUMBER TOOL NAME 2. Repeat steps listed above.
HD-42682 BREAKOUT BOX 3. Continue with PIN entry sequence listed.
The HFSM will not enter PIN entry mode on the first attempt
after battery voltage has been removed from terminal 1. This
will occur after any of the following:
• Battery disconnect or power drain.
• Main fuse removal.
• Connecting BREAKOUT BOX (Part No. HD-42682) to
HFSM connector.
Therefore, after all battery reconnects, the configuration
sequence must be modified as follows:

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POWER DISRUPTION AND CONFIGURING: • Connecting BREAKOUT BOX (Part No. HD-42682) to
TSSM connector.
TSSM
Therefore, after all battery reconnects, the configuration
PART NUMBER TOOL NAME sequence must be modified as follows.
HD-42682 BREAKOUT BOX 1. Set engine stop switch to OFF, cycle ignition/headlamp
The TSSM will not enter configuration mode on the first attempt switch ON-OFF-ON-OFF-ON and press left turn signal
after battery voltage has been removed from terminal 1. This switch twice.
will occur after any of the following: 2. Repeat step listed above.
• Battery disconnect or power drain. 3. Continue with configuration sequence listed.
• Main fuse removal.

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FAILS TO DISARM
DESCRIPTION AND OPERATION
HFSM
If the HFSM does not respond, responds with limited range or
will not consistently disarm with fob within normal range, follow
the diagnostic procedure.
TSSM
This section applies only to those vehicles equipped with the
optional security system (TSSM).
NOTE
Disarming function may require practice. The key fob button
must be pressed twice within 1.5 seconds to send the disarm
command. The action is very similar to double-clicking a com-
puter mouse. Light quick taps work best; very hard or very slow
taps are less likely to work.
The key fob sends a RF signal to activate all remote TSSM
functions. The left front turn signal switch wire serves as the
vehicle's antenna. If the TSSM does not respond (no confirm-
ation at arming/disarming system) or responds weakly (limited
range, won't consistently arm/disarm or synchronize), follow
the diagnostic procedure.
ed01899
Figure 5-30. Key Fob Battery: TSSM
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5.16
Diagnostic Tips
• Verify that cell phone is not within 3.0 in. (80.0 mm) of key
fob.
• Interference from physical surroundings may affect RF
transmission. Place fob next to vehicle or move vehicle to
a new location and retest.
• See Figure 5-30. Verify that antenna is in OE location and
that seat has not been replaced with a metal base seat.
• Check for damage to antenna wire.
• See Figure 5-31. Verify fob battery voltage is at least 2.9V.
• Fob serial number is located inside fob. Open fob by
twisting a thin blade in the thumbnail slot between fob
halves.
ed02051
2
1. Battery
2. Fob serial number
Figure 5-31. Open Fob: HFSM
Connector Information
For additional information about the connectors in the following
diagram(s) and diagnostic procedure(s), including the color of
the harness test kit terminal probes, see B.1 CONNECTORS.
HOME

em00737
FLHR W/V

O/W

W/V 5 5 W/V
Key Fob Antenna
W/V (TSSM Only)
O/W 1 1 O/W Accessory
O/W
W/V 11 11 W/V Power
Left Turn
Signal O/W 5 5 O/W
[24A] [24B]
Switch Except
FLHR
[1A] [1B]
Main Fuse Battery Fuse

BK/GN
40A 15A
BK R R BN/GY

BN/GY

BK/GN
W/V
Battery [30B] 1 8 12

[30A] 1 8 12

Battery

GND
Left Turn Input
TSSM

Figure 5-32. Antenna Circuit: TSSM

em00728 Transmit
Antenna

1 2 [209A]
Receive 1 2 [209B]
Antenna

O/Y
BK
BK R R R R BN/GY

Main Fuse Battery Fuse

40A 15A
BN/GY

BK/GN
Y/BK

BK/GN
O/Y
BK
BK

[30B] 1 12 1 2 3 [208B]
[30A] 1 12 1 2 3 [208A]
Battery

Ground

Recieve Antenna
Transmit Antenna A
Transmit Antenna B

HFSM

Figure 5-33. Antenna Circuit: HFSM

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FAILS TO DISARM: TSSM 1. Fob Test

1. Test all assigned fobs.
Table 5-39. Fails to Disarm Diagnostic Faults: TSSM
2. Does any assigned fob work?
POSSIBLE CAUSES a. Yes. Go to Test 5.
Fob malfunction
b. No. Go to Test 2.
Fob battery discharged
TSSM malfunction 2. Antenna Circuit Short to Ground Test
1. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
1. Key Fob Test 41404-C) and a multimeter, test for continuity between
1. Verify the key fob is correct for the vehicle. HFSM antenna jumper harness [208B] terminal 1 and
ground.
2. Is the key fob correct for the vehicle?
2. Is continuity present?
a. Yes. Go to Test 2.
a. Yes. Repair short to ground. (5041)
b. No. Obtain correct fob or replace fob. See the service
manual. Verify fob is synchronized to vehicle's TSSM. b. No. Go to Test 3.

2. Left Turn Signal Test 3. Antenna Circuit Open Test

1. Operate the left turn signal. 1. Check for continuity between HFSM antenna jumper har-
ness [208B] terminal 1 and end of (Y/BK) wire (pull back
2. Does left turn signal function? conduit to expose unterminated end of wire).
a. Yes. Go to Test 3.
2. Is continuity present?
b. No. See 5.6 TURN SIGNALS. a. Yes. Go to Test 4.

3. Fob Battery Test b. No. Repair open on (Y/BK) wire. (5041)

1. Replace fob battery and retest. See the service manual. 4. Security System Antenna Test
2. Does fob work? 1. Replace the security antenna with a known good security
a. Yes. System OK. (6755) antenna. See the service manual.
b. No. Go to Test 4. 2. Does the security system now disarm?
a. Yes. Replace the security antenna. See the service
4. TSSM Test manual. (6878)
1. Attempt to assign new fob to TSSM and retest. b. No. Replace HFSM. See the service manual. (6757)
2. Does fob work?
a. Yes. System OK. (6756)
5. Non-Functional Fob Test
1. Check battery on non-functional fob.
b. No. Replace TSSM. See the service manual. (6757)
2. Is battery voltage greater than 2.9V?
FAILS TO DISARM: HFSM a. Yes. Replace fob. See the service manual. (6756)
PART NUMBER TOOL NAME b. No. Replace battery. See the service manual. (6755)
HD-41404-C HARNESS CONNECTOR TEST KIT

Table 5-40. Fails to Disarm Diagnostic Faults: HFSM

POSSIBLE CAUSES
Open antenna circuit
Short to ground in antenna circuit
Antenna malfunction
Fob malfunction
HFSM malfunction

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DTC B1131, B1132 5.17

DESCRIPTION AND OPERATION
NOTE
This section applies only to those vehicles equipped with the
optional security system.
See Figure 5-34. An alarm cycle is activated when the HFSM
is connected, the siren has been armed by the HFSM and a
security event occurs. See 5.12 SECURITY SYSTEM. Under
normal armed operation, the siren input (terminal B) is driven
low by the HFSM to trigger the audible alarm. When the siren
input is driven high by the HFSM the audible alarm stops.
Table 5-41. Code Description
Diagnostic Tips
• If the siren is armed and the internal siren battery is dead,
shorted, disconnected or has been charging for a period
longer than 24 hours, the siren will respond with three
chirps on arming instead of two.
• The internal siren battery may not charge if the vehicle's
battery is less than 12.5V.
• If the siren does not chirp two or three times on a valid
arming command from the HFSM, the chirp function has
been disabled, the siren is either not connected, not
working or the siren wiring was opened or shorted while
the siren was disarmed.

DTC DESCRIPTION • If the siren enters the self-driven mode where it is powered
from the siren internal 9V battery, the turn-signal lamps
B1131 Alarm output low will not alternately flash. If the HFSM activates the siren,
B1132 Alarm output high the turn-signal lamps will flash. If the siren has been armed
and a security event occurs, and the siren is in self-driven
mode, the siren will alarm for 20-30 seconds and then turn
ed03111
off for 5-10 seconds. This alarm cycle will be repeated ten
times if the siren is in the self-driven mode.
2 3
• If the siren does not stop alarming after it has been armed,
1 then either the HFSM output or siren input may be shorted
4 to ground, the siren vehicle battery connection is open or
shorted to ground, the siren vehicle ground connection is
open or a security event has occurred. See
5.12 SECURITY SYSTEM for a description of alarm
functions.
5
Connector Information
For additional information about the connectors in the following
diagram(s) and diagnostic procedure(s), including the color of
6 the harness test kit terminal probes, see B.1 CONNECTORS.

1. Security siren [142]

2. Security siren (if equipped)
3. Fuse block
4. Main fuse [5]
5. DLC [91]
6. ABS diode pack [201] (if equipped)
Figure 5-34. Under Left Side Cover: Except FLTRX, FLHX,
FLHTC

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em00632

To [142B] [142A]
Battery Fuse
15A
BK/GN C C

BN/GY
Security
[30A] [30B] B B Siren
LGN/BN
(Optional)
1 1 BN/GY BN/GY A A

TSM/TSSM/HFSM 11 11 LGN/BN

12 12 BK/GN

BK/GN
Figure 5-35. Smart Siren Circuit

DTC B1131 3. Battery Circuit Test

PART NUMBER TOOL NAME 1. Remove the security siren.

HD-41404-C HARNESS CONNECTOR TEST KIT 2. With IGN ON, and the engine stop switch in the RUN
position, using HARNESS CONNECTOR TEST KIT (Part
HD-42682 BREAKOUT BOX
No. HD-41404-C) and a multimeter, test for battery voltage
at [142B] between terminals A and C.
Table 5-42. DTC B1131 Diagnostic Faults
3. Is battery voltage present?
POSSIBLE CAUSES a. Yes. Go to Test 5.
Short to ground in alarm signal b. No. Go to Test 4.
Open ground circuit
Open power circuit 4. Power Supply and Ground Test
TSSM/HFSM malfunction 1. Test for battery voltage between [142B] terminal A and
ground.
Open alarm signal
2. Is battery voltage present?
Siren malfunction
a. Yes. Repair open in (BK/GN) ground wire between
1. Siren Verification Test [142B] terminal C and ground.
1. Disarm the security system. b. No. Repair open in (BN/GY) wire.
2. Inspect the vehicle for a security siren.
5. Alarm Signal Circuit Open Test
3. Is a security siren present? 1. Connect BREAKOUT BOX (Part No. HD-42682) to wire
a. Yes. Go to Test 3. harness [30B], leaving TSSM/HFSM [30A] disconnected.
See 1.2 DIAGNOSTIC TOOLS.
b. No. Go to Test 2.
2. Using a multimeter, test for continuity between [142B]
2. Alarm Signal Short to Ground Test terminal B and breakout box terminal 11.
1. Connect BREAKOUT BOX (Part No. HD-42682) to wire 3. Is continuity present?
harness [30B], leaving TSSM/HFSM [30A] disconnected. a. Yes. Go to Test 6.
See 1.2 DIAGNOSTIC TOOLS.
b. No. Repair open in (LGN/BN) wire between [142B]
2. Using a multimeter, test for continuity between breakout and [30B].
box terminals 11 and 12.
3. Is continuity present? 6. Alarm Signal Short to Ground Test
a. Yes. Repair short to ground in (LGN/BN) wire 1. Test for continuity between breakout box terminals 11 and
between [142B] terminal B and [30B] terminal 11. 12.
b. No. Replace the TSSM/HFSM. See the service 2. Is continuity present?
manual. a. Yes. Repair short to ground in (LGN/BN) wire.
b. No. Go to Test 7.

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7. Security Siren Resistance Test 1. Siren Verification Test

1. Measure resistance at [142A] between terminals B and 1. Disarm the security system.
C.
2. Inspect the vehicle for a security siren.
2. Is the security siren resistance between 40,000-160,000
3. Is a security siren present?
Ohms?
a. Yes. Go to Test 3.
a. Yes. Go to Test 8.
b. No. Go to Test 2.
b. No. Replace the security siren. See the service
manual.
2. Alarm Signal Circuit Short to Voltage Test
8. Security Siren Validation Test 1. Connect BREAKOUT BOX (Part No. HD-42682) to wire
harness [30B], leaving [30A] disconnected. See 1.2 DIA-
1. Connect and operate the security siren on a known good
GNOSTIC TOOLS.
vehicle.
2. With IGN ON, using a multimeter, test for voltage between
2. Does the siren function properly with no DTCs set?
breakout box terminal 11 and ground.
a. Yes. Replace the TSSM/HFSM. See the service
manual. 3. Is battery voltage present?
a. Yes. Repair short to voltage in (LGN/BN) wire.
b. No. Replace the security siren. See the service
manual. b. No. Replace the TSSM/HFSM. See the service
manual.
DTC B1132
3. Alarm Signal Short to Voltage Test
PART NUMBER TOOL NAME
1. Disconnect the security siren.
HD-42682 BREAKOUT BOX
2. Connect BREAKOUT BOX (Part No. HD-42682) to wire
harness [30B], leaving TSSM/HFSM [30A] disconnected.
Table 5-43. DTC B1132 Diagnostic Faults
See 1.2 DIAGNOSTIC TOOLS.
POSSIBLE CAUSES 3. With IGN ON, test for voltage between breakout box ter-
Short to ground in alarm signal minal 11 and ground.
Open ground circuit 4. Is battery voltage present?
Open power circuit a. Yes. Repair short to voltage on (LGN/BN) wire.
TSM/TSSM/HFSM malfunction b. No. Replace the TSSM/HFSM. See the service
Open alarm signal manual.
Siren malfunction

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DTC B1134 5.18

DESCRIPTION AND OPERATION
ed03111
See Figure 5-36. With the TSM/TSSM/HFSM (if equipped)
disarmed, IGN ON, engine stop switch in the RUN position,
2 3
and the transmission in neutral or clutch lever pulled in, the
1
start relay is grounded. Battery voltage is applied to the start 4
relay coil which is grounded through the TSM/TSSM/HFSM.
DTC B1134 is set when that ground is not established through
the TSM/TSSM/HFSM.

Connector Information
5
For additional information about the connectors in the following
diagram(s) and diagnostic procedure(s), including the color of
the harness test kit terminal probes, see B.1 CONNECTORS.
6
1. Security siren [142]
2. Security siren (if equipped)
3. Fuse block
4. Main fuse [5]
5. DLC [91]
6. ABS diode pack [201] (if equipped)
Figure 5-36. Under Left Side Cover: Except FLTRX, FLHX,
FLHTC

em00727

Start Relay
86 2 4H BK/R
85 1 3G TN/GN
30 3
87A
87 To Engine W/BK
[64-1B] Stop Switch

To Battery Fuse BN/GY

FLHR
To ECM W/BK

BN/GY

TN/GN

BK/GN

BK/GN
R/BK 6

To System
W/BK W/BK
[22B] Relay [30B] 1 9 12

BK/R [30A] 1 9 12
6 R/BK R/BK
Battery

Start Relay Control

Ground

R/BK 2 2 R/BK 6 [22A] Start

Switch
[2B] [2A] [22B] To Right Handlebar
Switch [22]
Except FLHR TSM/TSSM/HFSM

Figure 5-37. Starter TSM/TSSM/HFSM Circuit

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DTC B1134 2. Remove start relay.

3. With IGN ON, using a multimeter, test for voltage on
PART NUMBER TOOL NAME
breakout box (Gray) terminal 9.
HD-42682 BREAKOUT BOX
4. Is battery voltage present?
a. Yes. Repair short to voltage on (TN/GN) wire.
Table 5-44. DTC B1134 Diagnostic Faults
b. No. Go to Test 2.
POSSIBLE CAUSES
TSM/TSSM/HFSM malfunction 2. Start Relay Test
Start relay malfunction 1. Test start relay. See 1.3 DIAGNOSTICS AND
Short to voltage in start relay control circuit TROUBLESHOOTING, Relay Diagnostics.
2. Does relay pass test?
1. Relay Control Circuit Short to Voltage
a. Yes. Replace TSM/TSSM/HFSM. See the service
Test manual.
1. Connect BREAKOUT BOX (Part No. HD-42682) between
b. No. Replace start relay. See the service manual.
wire harness [30B] and TSM/TSSM/HFSM [30A]. See
1.2 DIAGNOSTIC TOOLS.

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DTC B1143, B1144, B1145 5.19

DESCRIPTION AND OPERATION
Table 5-45. Code Description
DTC B1143, B1144 or B1145 will set when a fault occurs to
the security antenna circuit used to transmit to the fob. Refer DTC DESCRIPTION
to Table 5-45. B1143 Security antenna short-to-ground
B1144 Security antenna short-to-voltage
B1145 Security antenna open

Connector Information
For additional information about the connectors in the following
diagram(s) and diagnostic procedure(s), including the color of
the harness test kit terminal probes, see B.1 CONNECTORS.

em00728 Transmit
Antenna

1 2 [209A]
Receive 1 2 [209B]
Antenna

O/Y
BK
BK R R R R BN/GY

Main Fuse Battery Fuse

40A 15A

BN/GY

BK/GN
Y/BK

BK/GN
O/Y
BK
BK

[30B] 1 12 1 2 3 [208B]
[30A] 1 12 1 2 3 [208A]

Battery

Ground

Recieve Antenna
Transmit Antenna A
Transmit Antenna B
HFSM

Figure 5-38. Antenna Circuit: HFSM

DTC B1143 2. Is the security antenna damaged?

a. Yes. Repair or replace security antenna as needed.
PART NUMBER TOOL NAME See the service manual.
HD-41404-C HARNESS CONNECTOR TEST KIT
b. No. Go to Test 2.

Table 5-46. DTC B1143 Diagnostic Faults 2. Security Antenna Short to Ground Test
POSSIBLE CAUSES 1. Disconnect HFSM antenna jumper [208].
Security antenna malfunction 2. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
HFSM malfunction 41404-C) and a multimeter, test for continuity between
terminal 2 and ground.
Open antenna circuit
3. Is continuity present?
1. Security Antenna Visual Test a. Yes. Repair short to ground in (O/Y) wire.
1. Inspect the security antenna for damage. b. No. Replace the HFSM. See the service manual.

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DTC B1144 DTC B1145

PART NUMBER TOOL NAME PART NUMBER TOOL NAME
HD-41404-C HARNESS CONNECTOR TEST KIT HD-41404-C HARNESS CONNECTOR TEST KIT

Table 5-47. DTC B1144 Diagnostic Faults Table 5-48. DTC B1145 Diagnostic Faults

POSSIBLE CAUSES POSSIBLE CAUSES

Security antenna malfunction Security antenna malfunction
HFSM malfunction HFSM malfunction
Short to voltage in antenna circuit Open antenna circuit

1. Security Antenna Visual Test 1. Security Antenna Resistance Test

1. Inspect the security antenna for damage. 1. Disconnect HFSM antenna [209].
2. Is the security antenna damaged? 2. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
a. Yes. Repair or replace security antenna as needed. 41404-C) and a multimeter, measure resistance at [209A]
See the service manual. between terminals 1 and 2.

b. No. Go to Test 2. 3. Is resistance greater than 5700 Ohms?

a. Yes. Replace the security antenna. See the service
2. Security Antenna Short to Voltage Test manual.
1. Disconnect HFSM antenna jumper [208]. b. No. Go to Test 2.
2. With IGN ON, using HARNESS CONNECTOR TEST
KIT (Part No. HD-41404-C) and a multimeter, test for
2. Antenna B Circuit Open Test
voltage between terminal 2 and ground. 1. Disconnect HFSM antenna jumper [208].
3. Is voltage present? 2. Test for continuity between [208B] terminal 3 and [209B]
a. Yes. Repair short to voltage in (O/Y) wire. terminal 2.

b. No. Replace the HFSM. See the service manual. 3. Is continuity present?
a. Yes. Go to Test 3.
b. No. Repair open in (BK) wire.

3. Antenna A Circuit Open Test

1. Test for continuity between [208B] terminal 2 and [209B]
terminal 1.
2. Is continuity present?
a. Yes. Replace the HFSM. See the service manual.
b. No. Repair open in (O/Y) wire.

2011 Touring Diagnostics: Accessories, Horn, Lighting and Security 5-69

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DTC B1154, B1155 5.20

DESCRIPTION AND OPERATION Diagnostic Tips
The TSM/TSSM/HFSM monitors the clutch and neutral switch DTCs B1154 and B1155 will set when either the clutch switch
circuits to determine whether or not to let the vehicle start. If circuit or neutral switch circuit is shorted to ground at speeds
the TSM/TSSM/HFSM does not see that the clutch switch is greater than 10 mph (16 km/h) for more than 60 seconds. Refer
closed (lever pulled in) or the neutral switch is closed (transmis- to Table 5-49.
sion in neutral) it will not activate the start relay. The
TSM/TSSM/HFSM controls the start relay by supplying the Table 5-49. Code Description
ground circuit to the coil of the start relay.
DTC DESCRIPTION

sm05247
B1154 Clutch switch short-to-ground
B1155 Neutral switch short-to-ground

Connector Information
For additional information about the connectors in the following
diagram(s) and diagnostic procedure(s), including the color of
the harness test kit terminal probes, see B.1 CONNECTORS.

Figure 5-39. Neutral Switch [131]

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em00691 BK BK

Right
Hand Controls Red Battery
Band Ground
Battery

Right Turn Switch

BK
Engine Stop Switch

R
Start Switch 1
Front Stop Lamp Switch
[128B]
GN

W/BK
BK/R

GY
6 4 3 [22A]
Starter
6 4 3 [22B] 2

W/BK
GY
BK/R
Ignition Switch

IGN IGN
ACC ACC

OFF OFF

[33A] B+ ACC IGN B+ ACC IGN [33A]

[33B]
W/BK

2 1 3 B C A [33B]
GY

R/GY

R/BK

R/GY

R/BK
R
R
Except [1A] 6 3
FLHR/C [1B] 6 3 B C A [222A]
B C A [222B]
W/BK

GY

[78A] [78B]

R/GY

R/BK
ECM

R
Switch Power 72 72 W/BK

All Except FLHR/C

FLHR/C

R/GY

R/BK
R
[131B] IGN 15A
TN
BK

GY 1F 1E R/BK
[131A]
BK

[64-2B]
Neutral
Switch
Battery 15A
BN/GY 2D 2C R
Left Main Fuse
GND 1 40A

TSM/TSSM/HFSM [30A] [30B] Start Relay

GN 4G 5 87 [5B]
Battery 1 1 BN/GY R/GY 3H 3 30
Ignition 2 2 GY B A
TN/GN 3G 1 86
BK/R 4H 2 85
Neutral Switch 4 4 TN
R

[64-1B]
Start Relay Control 9 9 TN/GN
Except
Clutch Switch 10 10 BK/R
BK/R 2 2 BK/R FLHR/C
Ground 12 12 BK/GN
BK/R 11 11 BK/R BK/R 7 7 BK/R
BK/GN 12 12 BK/GN BK/GN 12 12 BK
BK/R
Receive Antenna 1 Clutch Switch
BK
Transmit Antenna A 2 [2B] [2A]
Transmit Antenna B 3 [24B] [24A]
Except
BK/GN

FLHRC BK/R 7 7 BK/R

HFSM ONLY [208A] BK/GN 8 8 BK

Left Hand
[24B] [24A] Controls
Right FLHR/C
GND 2

Figure 5-40. Starting Circuit

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DTC B1154 2. Was a short to ground present?

a. Yes. Repair short to ground in left handlebar switch
PART NUMBER TOOL NAME wiring.
HD-42682 BREAKOUT BOX
b. No. Replace clutch switch. See the service manual.

Table 5-50. DTC B1154 Diagnostic Faults DTC B1155

POSSIBLE CAUSES PART NUMBER TOOL NAME
TSM/TSSM/HFSM malfunction HD-42682 BREAKOUT BOX
Switch malfunction
Short to ground in clutch switch circuit Table 5-51. DTC B1155 Diagnostic Faults

POSSIBLE CAUSES
NOTE
TSM/TSSM/HFSM malfunction
This DTC may occur if the vehicle is ridden with clutch disen-
gaged (pulled in) at speeds greater than 10 mph (16 km/h) for Short to ground in neutral circuit
more than 60 seconds (coasting down a long mountain road). Neutral switch malfunction
1. Clutch Circuit Short to Ground Test
NOTE
1. Connect BREAKOUT BOX (Part No. HD-42682) to wire
This DTC may occur if the vehicle is ridden in neutral at speeds
harness [30B], leaving HFSM [30A] disconnected. See
greater than 10 mph (16 km/h) for more than 60 seconds
1.2 DIAGNOSTIC TOOLS.
(coasting down a long mountain road).
2. Using a multimeter, test for continuity between breakout
box (Gray) terminal 10 and terminal 12. 1. Neutral Circuit Short to Ground Test
1. Shift the transmission into 1st or 2nd gear.
3. Is continuity present?
a. Yes. Go to Test 2. 2. Connect BREAKOUT BOX (Part No. HD-42682) to wire
harness [30B], leaving HFSM [30A] disconnected. See
b. No. Replace HFSM. See the service manual. 1.2 DIAGNOSTIC TOOLS.

2. Clutch Switch Circuit Test 3. Using a multimeter, measure resistance between breakout
box (Gray) terminal 4 and terminal 12.
1. Disconnect left hand controls [24].
4. Is resistance less than 10 Ohms?
2. Test for continuity between breakout box (Gray) terminal
10 and terminal 12. a. Yes. Go to Test 2.

3. Is continuity present? b. No. Replace HFSM. See the service manual.

a. Yes. Repair short to ground on (BK/R) wire in main 2. Neutral Switch Short to Ground Test
wiring harness between [30B] and [24B].
1. Disconnect neutral switch [131].
b. No. Go to Test 3.
2. Measure resistance between breakout box (Gray) terminal
3. Clutch Switch Test 4 and terminal 12.

1. Inspect left handlebar switch wiring for a short to ground. 3. Is resistance less than 10 Ohms?
a. Yes. Repair short to ground on (TN) wire.
b. No. Replace neutral switch. See the service manual.

5-72 2011 Touring Diagnostics: Accessories, Horn, Lighting and Security

TABLE OF CONTENTS

SUBJECT............................................................................................................................PAGE NO.
6.1 EFI SYSTEM.............................................................................................................................6-1
6.2 ELECTRONIC CONTROL MODULE.........................................................................................6-4
6.3 SENSORS AND DRIVERS.......................................................................................................6-6
6.4 DTC P0107, P0108, P0112, P0113...........................................................................................6-9
6.5 DTC P0117, P0118.................................................................................................................6-13
6.6 DTC P0120, P0122, P0123, P0220, P0222, P0223................................................................6-16
6.7 DTC P0031, P0032, P0131, P0132, P0134, P0151, P0152, P0154.......................................6-23
6.8 DTC P0261, P0262, P0263, P0264.........................................................................................6-30
6.9 DTC P0373, P0374.................................................................................................................6-34
6.10 DTC P0444, P0445...............................................................................................................6-36
6.11 DTC P0501, P0502...............................................................................................................6-39
6.12 DTC P0505............................................................................................................................6-43
6.13 DTC P0572............................................................................................................................6-45
6.14 DTC P0603, P0605...............................................................................................................6-48
6.15 DTC P0641, P0651...............................................................................................................6-49

ENGINE MANAGEMENT
6.16 DTC P1001, P1002, P1003, P1004.......................................................................................6-52
6.17 DTC P1009, P1010...............................................................................................................6-56
6.18 DTC P1270............................................................................................................................6-58
6.19 DTC P1351, P1352, P1354, P1355.......................................................................................6-61
6.20 DTC P1353, P1356, P1357, P1358.......................................................................................6-65
6.21 DTC P1475, P1477, P1478...................................................................................................6-68
6.22 DTC P1501, P1502...............................................................................................................6-72
6.23 DTC P1510, P1511, P1512...................................................................................................6-75
6.24 DTC P1514............................................................................................................................6-76
6.25 DTC P1600............................................................................................................................6-77
6.26 DTC P1655, P1656...............................................................................................................6-78
6.27 DTC P2100, P2101, P2102, P2103.......................................................................................6-82
6.28 DTC P2105, P2107...............................................................................................................6-86
6.29 DTC P2119............................................................................................................................6-89
6.30 DTC P2122, P2123, P2127, P2128.......................................................................................6-90
6.31 DTC P2135, P2138...............................................................................................................6-95
6.32 DTC P2176............................................................................................................................6-98
6.33 ENGINE CRANKS, BUT WILL NOT START..........................................................................6-99
6.34 NO ECM POWER................................................................................................................6-102
6.35 STARTS, THEN STALLS.....................................................................................................6-105
6.36 FUEL SYSTEM ELECTRICAL TEST..................................................................................6-106
6.37 MISFIRE AT IDLE OR UNDER LOAD.................................................................................6-109
NOTES
HOME
EFI SYSTEM
GENERAL
PART NUMBER TOOL NAME
HD-48650 DIGITAL TECHNICIAN II
See Figure 6-1. The engine management system consists of
the following components:
• ECM
• CKP sensor
• TMAP sensor
• ET sensor
• TGS
• TCA
• VSS
• HO2S
• Active exhaust actuator (HDI)
• Ignition coil
• Fuel pump
• Fuel injector
• Purge solenoid (if equipped)
The ECM is a solid state device mounted under the seat and
sealed to prevent contamination from dust/dirt, water and oil.
The ECM controls engine performance based upon input sup-
plied to the ECM from the ET, CKP, TMAP, TGS, HO2S and
the VSS sensors and other additional low-voltage circuits and
components between the battery and ignition coil.
• The ECM controls the dwell time for the ignition coil,
providing optimum ignition circuit performance for all
engine speeds/load conditions. Optimizing the ignition
system allows the ECM to control/vary engine timing (as
needed) from 0-50 degrees BTDC.
• The ECM also has built-in protection against transient
voltages, continuous reverse voltages and inadvertent
damage resulting from jump starts. The ECM is a non-
repairable item and must be replaced when it fails.
The CKP sensor is located in the front left side of the crank-
case. The CKP generates an AC signal that is sent to the ECM
where it is used to reference engine position (TDC) and speed.
It functions by taking readings off the 30 teeth on the left side
flywheel (two teeth are missing to establish a reference point).
The TMAP sensor is a dual-purpose sensor, mounted in the
top of the intake manifold. One portion is used to measure
temperature and the other portion is used to measure the air
pressure inside the intake manifold. The temperature part of
the TMAP contains a thermistor element, used to measure the
temperature of the air entering the intake manifold. The MAP
portion of this sensor is used to measure the difference
between atmospheric pressure and vacuum pressure, within
the intake manifold. The ECM processes information from the
TMAP (and other sensors) to adjust ignition timing and fuel to
achieve optimum engine performance.
6.1
The ET sensor contains a thermistor element that varies the
sensor's internal electrical resistance. As the engine temper-
ature changes the resistance in the ET sensor changes. The
ECM monitors this resistance to compensate for various
operating conditions.
The TGS, mounted on the right hand side of the handlebar,
houses two internal (opposing) Hall-effect sensors for operator
control of the engine's throttle. The opposing operation of the
sensors ensures that repositioning of the throttle twist grip,
forward and/or back, is accurately reported to the ECM. As the
throttle is operated, position changes are reported to the ECM
which controls the corresponding movement of the throttle
plate by the TCA.
The TCA, mounted to the intake manifold, operates the throttle
plate internal to the induction module on the engine. Two cor-
responding TP sensors receive input from the ECM, corres-
ponding to the position of the TGS, to adjust the position of the
throttle plates, accordingly. The ECM incorporates an H-Bridge
and WatchDog microprocessor, used as safety devices, to
control inadvertent or unexpected operations/conditions of the
TCA and TGS.
The VSS is mounted in the transmission, beneath the starter
motor. The VSS is a Hall-effect sensor, used to monitor and
report vehicle speed based upon a reference point on the 5th
gear of the transmission. A 5V reference signal and common
ground circuitry are provided to the VSS, from the ECM. The
VSS communicates electrical pulses to the ECM, where vehicle
speed is calculated and sent to the speedometer as a serial
data message.
The HO2S diagnostic codes may be seen during the vehicle
break-in period. The sensor diagnostic codes will not illuminate
the check engine lamp for current or historic codes and will
only be indicated by DIGITAL TECHNICIAN II (Part No. HD-
48650) or speedometer self-diagnostics. If the diagnostic codes
are reported during the break-in period, clear or ignore the
code(s) until the break-in period is complete.
There are two HO2S, one mounted in each of the two exhaust
pipes, to monitor the exhaust gas air/fuel mixture ratio. Each
HO2S samples the exhaust oxygen content and provides
specific voltage to the ECM. The ECM continuously adjusts
the air/fuel mixture to maintain an optimal air/fuel mixture. When
properly mixed, the HO2S voltage(s) will measure approxim-
ately 0.45V, each when measuring across the sensor.
The active exhaust system (HDI only) uses an actuator valve
located in the rear of the exhaust pipe that is connected via a
cable. The valve position automatically adjusts to enhance
engine performance.
The ignition coils, mounted rearward on the chassis beneath
the fuel tank, provide high voltage output to the spark plugs.
Each ignition coil is made up of a primary winding where low
voltage input creates a high voltage spike in the collapsible
field of the secondary winding. The front and rear coils are fired
independently (one cylinder at a time).The ignition coil contains
an extra terminal where the ECM monitors the current of the
secondary winding for knock detection and combustion dia-
gnostics.
2011 Touring Diagnostics: Engine Management 6-1
HOME
The fuel pump, mounted inside the fuel tank on the vehicle, is
a submersible pump used to provide fuel to the fuel injectors.
The fuel pump is protected by an in-line 15 amp replaceable
fuse.
• When the ignition switch is in the IGNITION position and
the engine stop switch is in the RUN position, the ECM
grounds the system relay supplying voltage to the fuel
pump.
• The fuel pump continues running during cranking and
normal running operation, as long as the ECM is receiving
input from the CKP sensor. If no CKP pulses are received,
the ECM shuts off the system relay within 2 seconds after
the ignition is turned on, the engine has stalled or immedi-
ately after the engine is shut off.
• The fuel pump contains a pressure regulator which main-
tains consistent fuel pressure to each of the fuel injectors.
Excess fuel flow is bypassed into the fuel tank by the
pressure regulator.
There are two fuel injectors mounted to the intake manifold.
The ECM controls the injectors by actuating the injector
solenoid enabling fuel to be metered through the injector and
atomized into the intake manifold.
• The injectors are timed to the combustion cycle and are
triggered sequentially. When the ECM determines that
fuel is required, the ECM supplies a short duration ground
to the fuel injector, which opens and releases fuel into the
air intake manifold.
• The ECM grounds the system relay, which supplies voltage
to the fuel injectors. Each injector is protected and
grounded by the ECM, through a common point ground
within the ECM.
The purge solenoid (working with the charcoal canister) allows
the vapors to escape back into the throttle body. The purge
solenoid is timed to the throttle position but is disabled at
startup, low engine temperature, low engine speed or low
6-2 2011 Touring Diagnostics: Engine Management
vehicle speed. The power for the purge solenoid comes from
the system relay. The ECM provides the path to ground to
trigger the purge solenoid.
Heat Management System
To improve rider comfort on all stock Touring model motor-
cycles, an optional heat management system may be enabled.
After being enabled, the heat management system improves
rider comfort by turning off the rear cylinder fuel injector when
all of the following conditions exist:
• High engine temperature
• Engine at idle speed
• Low or no vehicle speed
• Clutch lever pulled in or transmission in neutral
As the engine maintains idle speed, the rear cylinder functions
as an "air pump," helping to cool the engine. This continues
until one of the above listed conditions is no longer met, then
the rear cylinder fires normally again.
NOTE
When the engine is in heat management mode, a noticeable
difference in idle may be accompanied by a unique exhaust
odor. While these conditions are normal, a rider or technician
unaware of the heat management system may incorrectly
assume an idle problem is present.
Enable/Disable EITMS
1. Turn the ignition ON with the motorcycle at idle and not
moving (the motorcycle may be running or not running).
2. Push the throttle to roll-off position and hold.
3. After approximately 3 seconds, the cruise indicator will
flash either red (disabled) or green (enabled).
4. Repeat step two to change.
HOME

em00702
Fuel Pump
[141A] B D
Assembly In Tank
Front ACR Rear ACR
(If Equipped) (If Equipped)
[141B] B D [141B] B D

O/GY
O/GY
[203AF] 2 1 2 1 [203AR]

BK
BK
[203BF] 2 1 2 1 [203BR]
Fuel Tank [13B] 1 4 [20A] 14 15

V/GY

V/GY
Y/GN

Y/GN
Harness [13A] 1 4 [20B] 14 15

O/GY
O/GY

BK
EXCEPT BK FLHR/C TGS
O/GY

BK
FLHR/C ET

V/GY

Y/GN
Sensor
4B TCA [224A] 6 5 4 3 21
Fuel [224B] 6 5 4 3 21
Pump [90A] A B
Fuse

GY
BN
BE
BK
R
V
[211A] 1 2 3 4 5 6 [90B] A B TMAP
15A
4A [211B] 1 2 3 4 5 6 Sensor

BK/W
[204A]

PK/Y
6 5 4 3 21
Y/GN

System
BK/W

BN/O
BK/O
BN/R

BN/V
BK/PK
[204B] 6 5 4 3 2 1
[80A] 1 2 3 4
Relay

BK/W
BN/O

BK/GY
BE/GN

R/W
87 5 4C [80B]

V/Y
Y/GN 1 2 3 4
30 3 3D BE/GY

R/W
V/W
BK/GY
LGN/Y
86
85 To 15A
ECM Fuse
Ignition Coil [83A] [83B]
Power A A Y/GN
Ion Sense B B GY/BE
Coil Rear C C Y/BE
Coil Front D D BE/O
[65B] [65A]
[84A] [84B]
BN/O A A
Front Fuel A A Y/GN W/GN B B VSS
Injector B B W/Y
BK/Y C C
[85A] [85B]

Rear Fuel A A Y/GN BK/BN 4

Injector B B GN/GY
PK/O 3 Front
[95A] [95B] GN/W 2 HO2S
Y/GN 1
B B GY/Y
A A Y/GN [138A]
Purge Solenoid
(Optional)
BK/BN 4
Rear
PK/GN 3
To 15A 2
HO2S
GN/W
Exhaust Y/GN 1 (BK)
Control Fuse
[137A]

1 LGN/R
Active 2 BK
Exhaust 3 V/O
(HDI Only) 4 V/BE
BK
R

[179B]
GN/GY

PK/GN

BE/GN

BK/GN
GY/BE

BK/GY
BK/BN
LGN/Y
BK/PK
GN/W

W/GN

BK/W
BN/O

Y/GN
V/GY
GY/Y

BK/O

BN/R

BE/O

PK/O
BN/V
V/BE

PK/Y

Y/BE

BK/Y

R/W
V/W

W/Y
V/O

V/Y

BK

2 1 [79A]
R

Right
[78B] 19 20 21 2324 28 29 30 3133 363738 39 4043 46 484950 51 52 53 54 59 61 62 63 64 66 68 73 GND 2 2 1 [79B]
[78A] 19 20 21 2324 28 29 30 3133 363738 39 4043 46 484950 51 52 53 54 59 61 62 63 64 66 68 73
HO2S Return
Purge Solenoid
Exhaust Actuator
Rear Fuel Injector
TMAP Sensor Input

Throttle Actuator Control HI

Throttle Actuator Control LO
O2 Heater Ground
Ion Sense
TPS 2
TPS 1

TGS 2

CKP Sensor
Rear HO2 Sensor

ET Sensor

Rear Ignition Coil

TGS 1
5V Sensor Ground 1
5V Sensor Ground 2
CKP Sensor (+)

Ground
ACR Ground

Front Fuel Injector

Front Ignition Coil

Front HO2 Sensor

Exhaust Feedback

5V Sensor Power 1

12V Power

5V Sensor Power 2
Vehicle Speed Input

Vehicle Speed Ground

IAT Sensor

CKP
Sensor
ECM

Figure 6-1. EFI Simplified Schematic

2011 Touring Diagnostics: Engine Management 6-3

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ELECTRONIC CONTROL MODULE 6.2

GENERAL idle and run the engine.This section describes the configuration
of the ECM for this vehicle.
See Figure 6-2.The ECM receives and processes signals from
the sensors and applies output signals to the drivers to start,

ed01820

1 3

2 9

1. Tail light connector [7]: except FLHX, FLTRX

2. Console pod [53]
3. Positive battery terminal
4. Hands-free antenna connector [209]
5. Fuel pump subharness connector [13]
6. Purge solenoid [95]
7. P&A accessory connector [4]
8. Negative battery terminal
9. ECM [78]
Figure 6-2. Electrical Connectors Under Seat

ECM transient voltages, continuous reverse voltage protection and

The ECM is mounted under the seat. It computes the spark
advance for proper ignition timing and fuel control based on
sensor inputs (from ET, CKP, TMAP, TGS, HO2S and VSS
sensors) and controls the low-voltage circuits for the ignition
coils and injectors.
The ECM contains all of the components used in the ignition
system. The dwell time for the ignition coil is also calculated
in the microprocessor and is dependent upon battery voltage.
The programmed dwell is an added feature to give adequate
spark at all speeds. (The ECM has added protection against
damage due to jump starts.) The ECM is fully enclosed to
protect it from vibration, dust, water or oil. This unit is a non-
repairable item. If it fails, it must be replaced. When the ECM
is replaced, see the service manual.
32-2 Flywheel
The left flywheel has 32 teeth evenly spaced around its circum-
ference with two consecutive teeth missing (sync gap). In this
configuration, the ECM determines engine position, engine
phase and engine speed from the CKP sensor input. Phase
(TDC compression) is determined by the ECM during startup

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and, when necessary, while running. No engine ignition events
can occur until the ECM determines the relationship of piston
position to crankshaft position. The following paragraphs in
this section describe synchronization and phasing by the ECM
to provide smooth operation of the engine at all speeds.
Crank Position Signal Synchronization
In the 32-2 crank configuration, crankshaft position is determ-
ined by the ECM finding the two-tooth (sync gap) in the CKP
sensor signal. This is usually accomplished the first time the
sync gap is encountered. The ECM monitors the CKP signal
status every engine revolution. If the ECM determines synchron-
ization is lost, it immediately terminates ignition events and
synchronizes on the next occurrence of the sync gap.
Engine Phase
Phasing is accomplished by the ECM identifying a widening in
the CKP signal caused by the deceleration of the crankshaft,
as a piston approaches TDC on its compression stroke. Since
the rear cylinder approaches TDC earlier than the front cylinder,
engine phase can be readily discriminated. Phasing is normally
accomplished on the first TDC cycle after engine synchroniza-
tion. Once phased, the ECM can begin normal ignition events.
If the ECM experiences a system reset or loss of synchroniza-
tion while the engine is running it also loses phase.
When phase is lost one of the following occurs:
• If an engine-not-running (Crank Mode) rpm is detected,
the ECM executes the normal start-up phasing process.
• If Engine Run Mode is detected, the ECM executes a
running re-phase sequence.
The front cylinder is fired every engine revolution. The ECM
monitors the power stroke after the fire event to determine if
sufficient acceleration occurred to indicate the ECM fired on
the compression stroke. When two valid power strokes are
detected, the ECM locks phase and resumes normal ignition
events.
Engine Run Mode
Many functions of the EFI system require an engine run mode
determination. Engine run is determined by the level of engine
rpm. Generally, the engine is considered to be running when
engine rpm exceeds a minimum of 750 rpm.
2011 Touring Diagnostics: Engine Management 6-5
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SENSORS AND DRIVERS
DESCRIPTION AND OPERATION
Sensors and drivers play an important part in the ECM's ability
to provide the proper operational parameters for engine effi-
ciency, emissions control and fuel economy. When a failure
occurs, a DTC is generated by, and stored in, the ECM. These
codes help the technician diagnose engine trouble to the proper
sensor or driver. See 2.1 INITIAL DIAGNOSTICS.
SENSORS
PART NUMBER TOOL NAME
HD-48650 DIGITAL TECHNICIAN II
Not all sensor problems cause an engine shutdown, but sensor
failure can seriously degrade overall engine performance. A
notable exception is the CKP sensor, which if faulty, completely
disables engine operation. The following are brief explanations
of sensor types and their functions within the EFI system.
Crank Position (CKP) Sensor
The CKP sensor, located on the left front of the lower crankcase
half, is a variable reluctance sensor that generates AC voltage
as the teeth on the flywheel pass by the sensor. The signal is
routed to the ECM where it is used to determine crankshaft
position, engine speed (rpm) and engine phase (TDC compres-
sion). Without the presence of the CKP signal, the ECM will
not allow the ignition and fuel injection drivers to operate, and
thus the engine will not run. The ECM uses crankshaft com-
pression slow down events to determine engine phase.
Therefore, the spark plugs must be installed when checking
for spark.
Twist Grip Sensor (TGS)
The TGS, mounted on the right hand side of the handlebar,
houses two internal (opposing) Hall-effect sensors for operator
control of the engine's throttle. The opposing operation of the
sensors ensures that repositioning of the throttle twist grip,
forward and/or back, is accurately reported to the ECM. As the
throttle is operated, position changes are reported to the ECM
that controls the corresponding movement of the throttle plate
by the TCA.
Twist Control Actuator (TCA)
The TCA, mounted to the intake manifold, operates the throttle
plate internal to the induction module on the engine. Two cor-
responding TP sensors provide input to the ECM, so the ECM
may verify that plate position corresponds to TGS input (rider
desired position of the plate) and to adjust the position of the
throttle plate, accordingly.
Jiffy Stand Sensor (JSS): HDI
The JSS uses a Hall-effect device to monitor jiffy stand position.
When the jiffy stand is fully retracted, the sensor picks up the
presence of a metal tab mounted to the jiffy stand. When
extended, the engine only starts and runs if the ECM receives
a signal from the neutral switch indicating the transmission is
in neutral, or a signal from the clutch switch indicating the clutch
is engaged. Otherwise, the engine stalls as the clutch is
released with the transmission in gear.
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6.3
Bank Angle Sensor (BAS)
The BAS is within the TSM/TSSM/HFSM. The
TSM/TSSM/HFSM will shut the engine down if the vehicle is
tipped over. Once the sensor is tripped, the motorcycle must
be righted, the ignition turned off and then on again before the
engine can be restarted. This is communicated across the
serial data circuit.
Clutch Switch
The TSM/TSSM/HFSM provides voltage to the clutch switch,
which is open when the clutch is disengaged (released). With
the clutch engaged (pulled in), the switch closes, allowing
current flow to ground. The ECM will not allow the engine to
start unless the transmission is in neutral or the clutch is
engaged.
Neutral Switch
The instrument fuse provides voltage to the neutral switch,
which is open when the transmission is in gear. With the
transmission in neutral, the switch is closed, allowing current
flow to ground. The TSM/TSSM/HFSM will not allow the engine
to start unless the transmission is in neutral or the clutch is
engaged.
Engine Temperature (ET) Sensor
The ET sensor is a thermistor device, which means that at a
specific temperature it has a specific resistance across its ter-
minals. As this resistance varies, so does the voltage.
• At high temperatures, the resistance of the sensor is very
low, which effectively lowers the signal voltage on ECM
[78] terminal 51.
• At low temperatures, the resistance is very high, allowing
the voltage to rise close to 5V. The ECM monitors this
voltage to compensate for various operating conditions.
Temperature Manifold Absolute Pressure
(TMAP) Sensor
The TMAP sensor combines the MAP and IAT in a single
component. Each functions as described in the paragraphs
following, and are tested as separate units.
Manifold Absolute Pressure (MAP) Sensor
The MAP sensor is supplied 5V from the ECM and sends a
signal back to ECM. This signal varies in accordance with
engine vacuum, intake air temperature and atmospheric baro-
metric pressure. The MAP sensor monitors the intake manifold
pressure (vacuum) and sends the information to the ECM. The
ECM then adjusts the spark and fuel timing advance curves
for optimum performance. The output of the sensor can also
be used to determine if the engine is rotating when a fault with
the CKP sensor is present.
Intake Air Temperature (IAT) Sensor
The IAT sensor is a thermistor device. As such, it will have a
specific resistance across its terminals at a specific temper-
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ature. As the temperature varies, the thermistor resistance DRIVERS

varies, and so does the voltage on ECM [78] terminal 49.
• At high temperatures, the resistance of the sensor is very
low, which effectively lowers the signal voltage on ECM
[78] terminal 49.
• At low temperatures, the resistance is very high, allowing
the voltage to rise close to 5V. The ECM monitors this
voltage to compensate for various operating conditions.
Vehicle Speed Sensor (VSS)
The VSS is a Hall-effect device mounted close to the teeth of
the 5th gear in the transmission. The output signal frequency
varies with vehicle speed. The ECM processes the vehicle
speed signal and transmits it via the serial data circuit to the
speedometer to indicate vehicle speed.
The ECM drivers are the output devices or system outputs of
the EFI system. Drivers are provided ground by the ECM to
pump, inject and ignite the air/fuel mixture in the engine, and
to activate relays.
Fuel Pump
The fuel pump, located inside the fuel tank, is provided battery
voltage when the system relay is activated.
Ignition Coil and Spark Plugs
The ignition coil creates the energy to fire the spark plugs and
ignite the air/fuel mixture in the cylinders. Advancing or
retarding the spark is controlled by the ECM to suit load and
speed conditions of the engine.

HO2S: Front and Rear
The HO2S sensor detects unburned oxygen in the engine
exhaust. The output of the sensor is a voltage having a range
of about 0-1.0V. The normal output is 0.5V which represents
a balance between a lean (not enough fuel) and rich (too much
fuel) air/fuel mixture. An output less than 0.5V represents a
lean mixture; greater than 0.5V represents a rich mixture. The
change in output level signals the ECM to modify the air/fuel
ratio. This voltage is what is seen across the sensor. If the
voltage is measured from the sensor to ground or is displayed
on DIGITAL TECHNICIAN II (Part No. HD-48650) it will range
from 0.7-1.7V. This will cause the midpoint between rich and
lean to be 1.2V.
It is important to note the HO2S do not operate efficiently until
it is at operating temperature. Therefore, before any
troubleshooting takes place, bring the sensor to operating
temperature. Leaks in the exhaust system, leaky exhaust
valves, misfires or any engine problem allowing unburned
oxygen into the exhaust stream could create a DTC indicating
a bad sensor. Look for problems related to an improper air/fuel
mixture before replacing the sensor.
See Figure 1-14. The ignition coil is provided power by the
system relay.
Fuel Injectors
The system relay provides battery power to the fuel injectors.
The ECM provides the path to ground to trigger the injectors.
The fuel injectors are pulse-width modulated solenoids for
metering fuel into the intake tract.The pulse-width of the ground
path to the injectors is varied by the ECM in response to inputs
from the various sensors, thus varying the length of time the
injector is open.
Start Relay
Pressing the start switch activates the start relay, sending
battery voltage to the starter solenoid. The TSM/TSSM/HFSM
controls the ground to the start relay, disabling it during security
and tip over conditions.
Purge Solenoid (If Equipped)
The purge solenoid allows vapors from the charcoal canister
to flow to the throttle body. The timing and amount of solenoid
opening depends on engine speed, vehicle speed, engine
temperature and throttle position.

Table 6-1. Engine Starts Hard

CAUSE SOLUTION
Engine temperature circuit Repair the circuit. If DTC P0117 or P0118 is present, diagnose and correct DTCs.
Fuel or Ignition system fault Perform misfire diagnostics.
Battery discharged Charge and test the battery. Perform charging system diagnosis if problem continues.
Crank position sensor circuit Repair the circuit. If DTC P0373 or P0374 is present, diagnose and correct DTC.
Manifold leak Perform intake leak test. See the service manual.
Ignition coil circuit/spark plugs Repair the circuit. If DTC P1351, P1352, P1354 or P1355 is present, diagnose and
correct DTCs.
Leaky injectors Check for mechanical failures of the fuel injectors. If DTC P0261, P0262, P0263 or
P0264 is present, diagnose and correct them.
Clogged fuel injectors Clean or replace fuel injectors. See the service manual.
Valve sticking Perform compression test. See the service manual.

2011 Touring Diagnostics: Engine Management 6-7

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Table 6-2. Engine Performance Problems

CAUSE SOLUTION
Engine temperature circuit Repair the circuit. If DTC P0117 or P0118 are present, diagnose and correct DTCs.
Crank position sensor circuit Repair the circuit. If DTC P0373 and P0374 are present, diagnose and correct DTC.
Fuel or Ignition system fault Perform misfire diagnostics.
EVAP hose disconnected from induction Connect.
module (if equipped)
Fuel system contaminated Drain and refill with fresh fuel.

Table 6-3. Engine Emits Black Exhaust or Fouls Plugs

CAUSE SOLUTION
Engine temperature circuit Repair the circuit. If DTC P0117 or P0118 are present, diagnose and correct DTCs.
Clogged air filter Replace air filter.
Leaky injectors Repair the circuit. If DTC P0261, P0262, P0263 or P0264 are present, diagnose and
correct DTCs.

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DTC P0107, P0108, P0112, P0113
DESCRIPTION AND OPERATION
See Figure 6-3. The TMAP sensor provides the functions of
both an IAT sensor and a MAP sensor in one unit. The TMAP
sensor is supplied 5V from ECM terminal 68 and sends MAP
and IAT signals back to ECM terminals 24 and 49 respectively.
Refer to Table 6-4.
Table 6-4. Code Description
DTC DESCRIPTION
P0107 MAP sensor open/low
P0108 MAP sensor high
P0112 IAT sensor voltage low
P0113 IAT sensor open/high
TMAP: MAP Signal
The MAP signal varies in accordance with engine vacuum and
atmospheric pressure. Changes in atmospheric pressure are
influenced by weather and altitude.
TMAP: IAT Signal
The IAT portion of the TMAP sensor is a thermistor device,
meaning that at a specific temperature, it will have a specific
resistance across its terminals. As this resistance varies, so
does the voltage on terminal 49 of the ECM.
• At high temperatures, the resistance of the IAT sensor is
very low, which effectively lowers the signal voltage on
terminal 49.
• At low temperatures, the resistance is very high, allowing
the voltage to rise close to 5V. The ECM monitors this
voltage to compensate for various operating conditions.
DIAGNOSTICS
PART NUMBER TOOL NAME
HD-23738 VACUUM PUMP
Diagnostic Tips: MAP Portion of TMAP
Sensor
• DTCs P0107 or P0108 will set if the MAP sensor signal
is out of range. DTC P0108 can only be detected with the
engine running.
• MAP sensor output check. Using the VACUUM
PUMP (Part No. HD-23738), apply a vacuum to the pres-
sure port of the TMAP sensor. The MAP signal voltage
should lower as the vacuum is applied.
• The TMAP and TGS are connected to the same reference
line (+5V Vref). If the reference line goes to ground or
open, multiple codes will be set (DTCs P0107, P0108,
P0122, P0123, P1501 and P1502).
6.4
Diagnostic Tips: IAT Portion of TMAP
Sensor
Check the following conditions:
• Poor connection: Inspect ECM and harness connector
[78] for backed out terminals, improper mating, inoperative
locks, improperly formed or damaged terminals, poor ter-
minal- to-wire connection and damaged harness.
• Perform 1.3 DIAGNOSTICS AND TROUBLESHOOTING,
Wiggle Test to locate intermittents: If connections and
harness check out OK, use a multimeter to check the IAT
sensor voltage reading while moving related connectors
and wiring harnesses. If the failure is induced, then the
IAT sensor voltage reading will change.
• Shifted sensor resistance value: Compare the temper-
atures of the ET and IAT sensors with the engine at
ambient temperature in order to evaluate the possibility
of a shifted (out of calibration) sensor which may result in
driveability problems. The sensor temperatures should be
within 10 degrees of each other.
• An intermittent may be caused by poor connection, rubbed
through wire insulation or an inoperative wire within the
wire's insulation.
• A faulty sensor can negatively affect the signal voltage of
the other sensors sharing the same 5V reference. If the
wiring passes the following tests, disconnect one sensor
at a time on the 5V reference and verify the DTC is still
present. Additional DTCs will be set as each sensor is
disconnected, clear DTCs after this test. Be sure to per-
form this test before replacing a component.
ed03084
2 3
1
1. Rear ACR [203R]
2. TMAP [80]
3. Front ACR [203F]
Figure 6-3. Between Cylinders Right Side
Connector Information
For additional information about the connectors in the following
diagram(s) and diagnostic procedure(s), including the color of
the harness test kit terminal probes, see B.1 CONNECTORS.
2011 Touring Diagnostics: Engine Management 6-9
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em00700
TGS

[224A] 6 5 4 3 2 1
[224B] 6 5 4 3 2 1

TCA
TMAP Sensor

GY
BN
BE
BK
R
V
[211A] 6 5 4 3 2 1 [204A] 6 5 4 3 2 1 [80A] 1 2 3 4
[211B] 6 5 4 3 2 1 [204B] 6 5 4 3 2 1 [80B] 1 2 3 4

BN/O
BN/V

BN/O
BK/O

BK/W

R/W
BN/R

BK/W
BK/PK

BE/GN

BK/GY
V/Y

R/W
V/W
BK/GY
LGN/Y
[78A] [78B]
ECM
TMAP Sensor Input 24 24 V/W
Throttle Actuator Control HI 29 29 BK/O
Throttle Actuator Control LO 30 30 BK/PK
TPS-2 36 36 BN/R [90B] [90A]
TPS-1 37 37 BN/V
TGS-2 39 39 V/Y
PK/Y A A
Vehicle Speed Input 40 40 W/GN
BK/W B B
IAT 49 49 LGN/Y
5V Sensor Power-1 50 50 BN/O ET Sensor
ET Sensor 51 51 PK/Y
JSS 56 56 GN/BN [65B] [65A]
TGS-1 59 59 BE/GN
5V Sensor Ground-1 61 61 BK/W A A
BN/O
5V Sensor Ground-2 62 62 BK/GY W/GN B B VSS
Vehicle Speed Ground 64 64 BK/Y BK/Y C C
5V Sensor Power-2 68 68 R/W
Ground 73 73 BK/GN

GN/BN
BK/GN
BN/O
Right [133B] 1 2 3
GND 2 JSS
(HDI only)

Figure 6-4. Throttle Control Actuator Circuit

DTC P0107 5. Does the DTC P0107 reset?

a. Yes. Go to Test 2.
PART NUMBER TOOL NAME
b. No. Replace the TMAP sensor. See the service
HD-41404-C HARNESS CONNECTOR TEST KIT
manual.
HD-48637 BREAKOUT BOX
2. MAP Sensor Signal Voltage Test
Table 6-5. DTC P0107 Diagnostic Faults 1. Remove the test wire.
POSSIBLE CAUSES 2. With IGN ON, test for voltage from [80B] terminal 3 to
TMAP sensor malfunction ground.

ECM malfunction 3. Is voltage approximately 5V?

Open or shorted to ground signal wire a. Yes. Go to Test 3.

Open or shorted to ground 5V reference circuit b. No. Go to Test 6.

1. MAP Sensor Test 3. MAP Sensor Signal Wire Continuity Test

1. Disconnect the TMAP sensor [80]. 1. Connect BREAKOUT BOX (Part No. HD-48637) to wire
harness [78B], leaving ECM [78A] disconnected. See
2. Using the HARNESS CONNECTOR TEST KIT (Part 1.2 DIAGNOSTIC TOOLS.
No. HD-41404-C), connect a test wire between [80B] ter-
minals 3 and 4. 2. Test for continuity between [80B] terminal 4 and breakout
box terminal 24.
3. Clear DTCs using odometer self-diagnostics. See
2.1 INITIAL DIAGNOSTICS, Odometer Self-Diagnostics. 3. Is continuity present?
4. Turn IGN OFF and ON. a. Yes. Go to Test 4.
b. No. Repair open in (V/W) wire.

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4. MAP Sensor Signal Wire Shorted to 2. Clear DTCs using odometer self-diagnostics. 2.1 INITIAL
DIAGNOSTICS, Odometer Self-Diagnostics.
Ground Test
3. Start engine.
1. Test for continuity between breakout box terminal 24 and
ground. 4. Does the DTC P0108 reset?
2. Is continuity present? a. Yes. Go to Test 2.
a. Yes. Repair short to ground in (V/W) wire. b. No. Go to Test 4.
b. No. Go to Test 5.
2. MAP Sensor Signal Wire Short to 5V Test
5. MAP Sensor Signal Wire Shorted to 1. Connect BREAKOUT BOX (Part No. HD-48637) to wire
Sensor Ground Test harness [78B], leaving ECM [78A] disconnected. See
1.2 DIAGNOSTIC TOOLS.
1. Turn IGN OFF.
2. Test for continuity between breakout box terminals 24 and
2. Test for continuity between breakout box terminals 24 and 68.
62.
3. Is continuity present?
3. Is continuity present?
a. Yes. Repair short between (R/W) and (V/W) wires.
a. Yes. Repair short between (V/W) and (BK/GY) wires.
b. No. Go to Test 3.
b. No. See diagnostic tips before replacement. Replace
the ECM. See the service manual. 3. MAP Sensor Signal Wire Short to Voltage
6. MAP Sensor 5V Reference Wire Open Test Test
1. With IGN ON, test for voltage on breakout box terminal
1. Connect BREAKOUT BOX (Part No. HD-48637) to wire
24.
harness [78B], leaving ECM [78A] disconnected. See
1.2 DIAGNOSTIC TOOLS. 2. Is voltage present?
2. Test for continuity between [80B] terminal 3 and breakout a. Yes. Repair short to voltage in (V/W) wire.
box terminal 68. b. No. Go to Test 4.
3. Is continuity present?
a. Yes. Go to Test 7. 4. MAP Sensor 5V Reference Shorted to
Battery Voltage Test
b. No. Repair open in (R/W) wire.
1. With IGN ON, test for voltage between breakout box ter-
7. MAP Sensor 5V Reference Shorted to minal 68 and ground.
Signal Ground Test 2. Is voltage greater than 5.25V?
1. Test for continuity between breakout box terminals 68 and a. Yes. Repair short to voltage in (R/W) wire.
62. b. No. Go to Test 5.
2. Is continuity present?
a. Yes. Repair short between the (R/W) and (BK/GY) 5. MAP Sensor Ground Wire Open Test
wires. 1. Test for continuity between [80B] terminal 1 and breakout
box terminal 62.
b. No. See diagnostic tips before replacement. Replace
the ECM. See the service manual. 2. Is continuity present?
a. Yes. Replace the TMAP sensor. See the service
DTC P0108 manual.
PART NUMBER TOOL NAME b. No. Repair open in (BK/GY) wire.
HD-48637 BREAKOUT BOX

Table 6-6. DTC P0108 Diagnostic Faults

POSSIBLE CAUSES
MAP sensor malfunction
ECM malfunction
Short to voltage

1. MAP Sensor Test

1. Disconnect the TMAP sensor [80].

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DTC P0112 DTC P0113

PART NUMBER TOOL NAME PART NUMBER TOOL NAME
HD-41404-C HARNESS CONNECTOR TEST KIT HD-41404-C HARNESS CONNECTOR TEST KIT
HD-48637 BREAKOUT BOX HD-48637 BREAKOUT BOX

Table 6-7. DTC P0112 Diagnostic Faults Table 6-8. DTC P0113 Diagnostic Faults

POSSIBLE CAUSES POSSIBLE CAUSES

IAT sensor malfunction IAT sensor malfunction
ECM malfunction ECM malfunction
Short to ground in 5V reference circuit Open or short to voltage in 5V reference circuit

1. IAT Sensor Test 1. IAT Sensor Test

1. Disconnect TMAP sensor [80]. 1. Disconnect TMAP sensor [80].
2. Using HARNESS CONNECTOR TEST KIT (Part No. HD- 2. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
41404-C) and a multimeter, measure resistance between 41404-C) and a multimeter, measure voltage between
terminals 1 and 2 of [80A]. [80B] terminal 2 (LGN/Y) and ground.
3. Is the resistance reading between 500-5000 Ohms with 3. Is the voltage reading greater than 6V?
the vehicle and sensor at ambient room temperature? a. Yes. Repair short to voltage on (LGN/Y) wire.
a. Yes. Go to Test 2.
b. No. Voltage is less than 4V. Go to Test 2.
b. No. Replace TMAP sensor. See the service manual.
2. IAT Sensor Signal Wire Open Test
2. IAT Sensor Signal Wire Shorted to 1. Turn IGN OFF.
Ground Test
2. Connect BREAKOUT BOX (Part No. HD-48637) to wiring
1. Measure resistance between [80B] terminal 2 (LGN/Y) harness [78B], leaving ECM [78A] disconnected. See
and ground. 1.2 DIAGNOSTIC TOOLS.
2. Is resistance reading less than 1 Ohm? 3. Test for continuity between [80B] terminal 2 (LGN/Y) and
a. Yes. Repair short to ground on (LGN/Y) wire. breakout box terminal 49.
b. No. Go to Test 3. 4. Is continuity present?
a. Yes. Go to Test 3.
3. IAT Sensor Signal Voltage High Test
b. No. Repair open circuit in (LGN/Y) wire.
1. Connect BREAKOUT BOX (Part No. HD-48637) to wire
harness [78B], leaving ECM [78A] disconnected. See 3. IAT Sensor Open Ground Wire Test
1.2 DIAGNOSTIC TOOLS.
1. Test for continuity between breakout box terminal 62 and
2. Test continuity between breakout box terminals 49 and [80B] terminal 1 (BK/GY).
73.
2. Is continuity present?
3. Is continuity present?
a. Yes. Go to Test 4.
a. Yes. Go to Test 4.
b. No. Repair open in (BK/GY) wire.
b. No. Repair short to ground on (LGN/Y) wire.
4. IAT Sensor Signal Wire Shorted to Sensor
4. IAT Sensor Signal Wire Shorted to Sensor Power Test
Ground Test
1. Test for continuity between breakout box terminals 49 and
1. Test continuity between breakout box terminals 49 and 68.
62.
2. Is continuity present?
2. Is continuity present?
a. Yes. Repair short between (LGN/Y) and (R/W) wires.
a. Yes. Repair short between terminals 1 and 2 of [80B] Verify IAT sensor resistance value and if incorrect
(LGN/Y and BK/GY) wires. replace TMAP sensor. See the service manual.
b. No. Replace ECM. See the service manual. b. No. Replace ECM. See the service manual.

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DTC P0117, P0118 6.5

DESCRIPTION AND OPERATION
The ECM supplies and monitors a voltage signal terminal 51
to one side of the ET sensor. The other side of the ET sensor
is connected to a common sensor ground, which is also con-
nected to the ECM terminal 61.
The ET sensor is a thermistor device, which means that at a
specific temperature it will have a specific resistance across
its terminals. As this resistance varies, so does the voltage on
terminal 51.
• At high temperatures, the resistance of the sensor is very
low, which effectively lowers the signal voltage on terminal
51.
harness check out OK, use a multimeter to check the
engine temperature reading while moving related con-
nectors and wiring harness. If the failure is induced, the
engine temperature display will change.
• Shifted sensor resistance value: Compare the temper-
atures of the ET and IAT sensors with the engine at
ambient temperature in order to evaluate the possibility
of a shifted (out of calibration) sensor which may result in
driveability problems. The sensor temperatures should be
within 10 °F (10 °C) of each other.
ed03075

• At low temperatures, the resistance is very high, allowing

the voltage to rise close to 5V.
1 2
The ECM monitors this voltage to compensate for various
operating conditions.

Table 6-9. Code Description

DTC DESCRIPTION
P0117 ET sensor voltage low
P0118 ET sensor open/high
3
Diagnostic Tips
Once the engine is started, the temperature should rise steadily. 1. Front fuel injector [84]
2. Rear fuel injector [85]
An intermittent may be caused by a poor connection, rubbed 3. ET sensor [90]
through wire insulation or an inoperative wire inside the insula-
tion. Figure 6-5. Between Cylinders Left Side
Check the following conditions:
• Poor connection: Inspect ECM harness connector [78] Connector Information
for backed out terminals, improper mating, inoperative
For additional information about the connectors in the following
locks, improperly formed or damaged terminals, poor ter-
diagram(s) and diagnostic procedure(s), including the color of
minal-to-wire connection, loose sensor and damaged
the harness test kit terminal probes, see B.1 CONNECTORS.
harness.
• Perform 1.3 DIAGNOSTICS AND TROUBLESHOOTING,
Wiggle Test to locate intermittents: If connections and

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em00699 Crank Pos.

Sensor

[79A] 1 2
[79B] 1 2

BK
R
[78A] [78B]
ECM
To 15A
Exhaust Actuator 21 21 V/O Exhaust
Exhaust Feedback 38 38 V/BE [90B] [90A] Control
Crank Position Sensor 43 43 BK Fuse
Engine Temperature 51 51 PK/Y PK/Y A A ET
5V Sensor Ground 1 61 61 BK/W BK/W B B Sensor
Crank Pos Sensor (+) 63 63 R
Ground 73 73 BK/GN

LGN/R
V/BE
V/O
BK
Right
GND 2
[179B] 4 3 2 1

Active
Exhaust
(HDI Only)

Figure 6-6. ET Sensor, CKP Sensor and Active Exhaust Circuit

DTC P0117 2. Is resistance reading less than 1 Ohm?

a. Yes. Repair short to ground in (PK/Y) wire.
PART NUMBER TOOL NAME
b. No. Go to Test 3.
HD-41404-C HARNESS CONNECTOR TEST KIT
HD-48637 BREAKOUT BOX 3. ET Sensor Signal Wire Shorted to Sensor
Ground Test
Table 6-10. DTC P0117 Diagnostic Faults 1. Connect BREAKOUT BOX (Part No. HD-48637) to wire
POSSIBLE CAUSES harness [78B], leaving ECM [78A] disconnected. See
1.2 DIAGNOSTIC TOOLS.
ET sensor malfunction
2. Test continuity between to breakout box terminals 51 and
ECM malfunction
61.
Short to ground in 5V reference circuit
3. Is continuity present?
1. ET Sensor Test a. Yes. Repair short between terminal A (PK/Y) and B
1. Disconnect ET sensor [90]. (BK/W) of [90B] wires.

2. Using HARNESS CONNECTOR TEST KIT (Part No. HD- b. No. Replace ECM. See the service manual.
41404-C) and a multimeter, measure the resistance
between [90A] terminals A and B. DTC P0118
3. Is the resistance reading between 900-10,000 Ohms with PART NUMBER TOOL NAME
the vehicle and sensor at ambient room temperature? HD-41404-C HARNESS CONNECTOR TEST KIT
a. Yes. Go to Test 2. HD-48637 BREAKOUT BOX
b. No. Replace ET sensor. See the service manual.
Table 6-11. DTC P0118 Diagnostic Faults
2. ET Sensor Signal Wire Shorted to Ground
POSSIBLE CAUSES
Test
ET sensor malfunction
1. Measure resistance between ET sensor [90B] terminal A
(PK/Y) and ground. ECM malfunction
Open or short to voltage

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1. ET Sensor Test 3. ET Sensor Open Ground Wire Test

1. Disconnect ET sensor [90]. 1. Test for continuity between ET sensor [90B] terminal B
(BK/W) and breakout box terminal 61.
2. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
41404-C) and a multimeter, measure the voltage between 2. Is continuity present?
ET sensor [90B] terminal A (PK/Y) and ground. a. Yes. Go to Test 4.
3. Is the voltage reading greater than 6V? b. No. Repair open in (BK/W) wire.
a. Yes. Repair short to voltage on (PK/Y) wire.
b. No. Voltage is less than 4V. Go to Test 2.
4. ET Sensor Signal Wire Shorted to Power
Test
2. ET Sensor Signal Wire Open Test 1. Test for continuity voltage between breakout box terminals
1. Turn IGN OFF. 51 and 73.

2. Connect BREAKOUT BOX (Part No. HD-48637) to wiring 2. Is voltage present?

harness [78B], leaving ECM [78A] disconnected. See a. Yes. Repair short to voltage in the (PK/Y) wire. Verify
1.2 DIAGNOSTIC TOOLS. ET sensor resistance value and if incorrect replace
ET sensor. See the service manual.
3. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
41404-C) and a multimeter, test for continuity between ET b. No. Go to Test 5.
sensor [90B] terminal A (PK/Y) and breakout box terminal
51. 5. ET Sensor Resistance Test
4. Is continuity present? 1. Measure the resistance of the ET sensor at ambient room
a. Yes. Go to Test 3. temperature.

b. No. Repair open circuit in the (PK/Y) wire. 2. Is resistance reading between 900-10,000 Ohms?
a. Yes. Replace the ECM. See the service manual.
b. No. Replace the ET sensor. See the service manual.

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DTC P0120, P0122, P0123, P0220, P0222, P0223 6.6

DESCRIPTION AND OPERATION
ed01264
See Figure 6-7. A dual TPS is integrated into the TCA, mounted
to the induction module.
Within the TCA, a set of potentiometers are designated as TPS
(TPS1 and TPS2). The ECM drives the motor in the TCA to
open and close the throttle plate based on the signals from the
twist grip sensor. The TPS (TPS1 and TPS2) send signals
back to the ECM based on throttle plate position to verify the
throttle plate movement.
The ECM supplies a 5.0V signal from terminal 50 of [78] to
TPS1 and TPS2. The signals from TPS1 and TPS2 are sent
back to the ECM [78] terminals 37 and 36 and vary in voltage
according to actual throttle plate position.
The two TP sensors work opposite each other. When one
sensor reads high, the other reads low. The sum of TPS1 and
TPS2 signals should measure around 5.0V.
See Figure 6-1 for TCA (TPS1 and TPS2) circuitry diagram.
Refer to Table 6-12 for DTCs associated with TPS1 and TPS2
of the TCA. 1
2
Table 6-12. Code Description

DTC DESCRIPTION 1. TCA

2. Induction module
P0120 TPS1 range error
Figure 6-7. Throttle Control Actuator (TCA) Location
P0122 TPS1 low/open
P0123 TPS1 high
P0220 TPS2 range error NOTE
P0222 TPS2 low/open The TMAP and TGS are both connected to the same reference
line (+5V REF). If the line goes to ground or open, multiple
P0223 TPS2 high
trouble codes will be set (DTCs P0107, P0108 and P0122,
P0123, P1501 or P1502). Start with the highest priority DTC.
Refer to Table 2-1.
Check for the following conditions:
• Poor connection: Inspect ECM harness connector [78B]
for backed out terminals, improper mating, inoperative
locks, improperly formed or damaged terminals, poor ter-
minal-to-wire connection and damaged harness.
• Perform 1.3 DIAGNOSTICS AND TROUBLESHOOTING,
Wiggle Test to locate intermittents: If connections and
harness check out OK, monitor TPS voltage using a mul-
timeter while moving related connectors and wiring har-
ness. If the failure is induced, the TPS voltage will change.
• An intermittent may be caused by poor connection, rubbed
through wire insulation or an inoperative wire within the
wire insulation.
• A faulty sensor can negatively affect the signal voltage of
the other sensors sharing the same 5V reference. If the
wiring passes the following tests, disconnect one sensor
at a time on the 5V reference and verify the DTC is still
present. Additional DTCs will be set as each sensor is
disconnected, clear DTCs after this test. Be sure to per-
form this test before replacing a component.

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Connector Information diagram(s) and diagnostic procedure(s), including the color of

the harness test kit terminal probes, see B.1 CONNECTORS.
For additional information about the connectors in the following

em00700
TGS

[224A] 6 5 4 3 2 1
[224B] 6 5 4 3 2 1

TCA
TMAP Sensor

GY
BN
BE
BK
R
V
[211A] 6 5 4 3 2 1 [204A] 6 5 4 3 2 1 [80A] 1 2 3 4
[211B] 6 5 4 3 2 1 [204B] 6 5 4 3 2 1 [80B] 1 2 3 4

BN/O
BN/V

BN/O
BK/O

BK/W

R/W
BN/R

BK/W
BK/PK

BE/GN

BK/GY
V/Y

R/W
V/W
BK/GY
LGN/Y
[78A] [78B]
ECM
TMAP Sensor Input 24 24 V/W
Throttle Actuator Control HI 29 29 BK/O
Throttle Actuator Control LO 30 30 BK/PK
TPS-2 36 36 BN/R [90B] [90A]
TPS-1 37 37 BN/V
TGS-2 39 39 V/Y
PK/Y A A
Vehicle Speed Input 40 40 W/GN
BK/W B B
IAT 49 49 LGN/Y
5V Sensor Power-1 50 50 BN/O ET Sensor
ET Sensor 51 51 PK/Y
JSS 56 56 GN/BN [65B] [65A]
TGS-1 59 59 BE/GN
5V Sensor Ground-1 61 61 BK/W A A
BN/O
5V Sensor Ground-2 62 62 BK/GY W/GN B B VSS
Vehicle Speed Ground 64 64 BK/Y BK/Y C C
5V Sensor Power-2 68 68 R/W
Ground 73 73 BK/GN

GN/BN
BK/GN
BN/O
Right [133B] 1 2 3
GND 2 JSS
(HDI only)

Figure 6-8. Throttle Control Actuator Circuit

DTC P0120 2. Disconnect TCA [211].

3. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
PART NUMBER TOOL NAME
41404-C) and a multimeter, test for continuity between
HD-41404-C HARNESS CONNECTOR TEST KIT breakout box terminal 50 and TCA [211] terminal 5.
HD-48637 BREAKOUT BOX 4. Is continuity present?
a. Yes. Go to Test 2.
Table 6-13. DTC P0120 Diagnostic Faults
b. No. Repair open in (BN/O) wire.
POSSIBLE CAUSES
Open in sensor power circuit 2. TPS-1 Circuit Shorted Test
Short to voltage in TPS-1 circuit 1. Test continuity between breakout box terminal 50 and
terminal 37.
Open in TPS-1 circuit
Short to ground in TPS-1 circuit 2. Is continuity present?
a. Yes. Repair short between (BN/V) and (BN/O) wires.
Open n sensor ground circuit
ECM malfunction b. No. Go to Test 3.

TCA malfunction 3. TPS-1 Circuit Continuity Test

1. Sensor Power-1 Circuit Test 1. Test continuity between breakout box terminal 37 and TCA
[211B] terminal 6.
1. Connect BREAKOUT BOX (Part No. HD-48637) between
wire harness [78B] and ECM [78A], leaving [78A] discon-
nected. See 1.2 DIAGNOSTIC TOOLS.

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2. Is continuity present? 1. TCA Sensor-1 Circuit Test

a. Yes. Go to Test 4. 1. Connect BREAKOUT BOX (Part No. HD-48637) between
b. No. Repair open in (BN/V) wire. wire harness [78B] and ECM [78A]. See 1.2 DIAGNOSTIC
TOOLS.
4. TPS-1 Circuit Short to Ground Test 2. Turn IGN ON and engine stop switch to run.
1. Test continuity between breakout box terminal 37 and
3. Test for voltage at breakout box between terminal 37 and
ground.
terminal 61.
2. Is continuity present?
4. Is voltage greater than 0.2V?
a. Yes. Repair short to ground on (BN/V) wire.
a. Yes. Go to Test 2.
b. No. Go to Test 5.
b. No. Go to Test 4.
5. TPS-1 Circuit Short to Voltage Test 2. TCA Sensor-1 Circuit Short to Ground
1. Turn IGN ON. Test
2. Test for voltage between breakout box terminal 37 and 1. Turn IGN OFF.
ground.
2. Disconnect ECM [78A] from breakout box.
3. Is voltage present?
3. Disconnect TCA [211].
a. Yes. Repair short to voltage on (BN/V) wire.
4. Test for continuity between breakout box terminal 37 and
b. No. Go to Test 6.
ground.
6. Sensor Ground Continuity Test 5. Is continuity present?
1. Test continuity between breakout box terminal 61 and TCA a. Yes. Repair short to ground in (BN/V) wire.
[211B] terminal 1. b. No. Go to Test 3.
2. Is continuity present?
a. Yes. Go to Test 7.
3. TCA Power-1 Circuit Open Test
1. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
b. No. Repair open in (BK/W) wire.
41404-C) and a multimeter, test for continuity between
breakout box terminal 50 and TCA [211] terminal 5.
7. TCA Test
2. Is continuity present?
1. Turn IGN OFF.
a. Yes. Replace the TCA. See the service manual.
2. Connect ECM [78A] to breakout box.
b. No. Repair open in (BN/O) wire.
3. Connect TCA [211].
4. Turn IGN ON. 4. TCA Sensor Test
5. Measure voltage between breakout box terminals 37 and 1. Turn IGN OFF.
61. 2. Disconnect TCA [211].
6. Is voltage between 0.4-4.8V? 3. Test for voltage between breakout box terminal 50 and
a. Yes. Replace the ECM. See the service manual. ground.
b. No. Replace the TCA. See the service manual. 4. Is voltage greater than 4V?
a. Yes. Replace the TCA. See the service manual.
DTC P0122
b. No. Go to Test 5.
PART NUMBER TOOL NAME
HD-41404-C HARNESS CONNECTOR TEST KIT 5. ECM Test
HD-48637 BREAKOUT BOX 1. Disconnect ECM [78A] from breakout box.
2. Test for continuity at breakout box between terminals 37
Table 6-14. DTC P0122 Diagnostic Faults and ground.

POSSIBLE CAUSES 3. Is continuity present?

a. Yes. Repair short to ground in (BN/V) wire.
Short to ground in TPS-1 Circuit
TCA malfunction b. No. Replace the ECM. See the service manual.

Open in sensor power circuit

ECM malfunction

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DTC P0123 3. Is voltage greater than 1.0V?

a. Yes. Go to Test 5.
PART NUMBER TOOL NAME
b. No. Replace the TCA. See the service manual.
HD-41404-C HARNESS CONNECTOR TEST KIT
HD-48637 BREAKOUT BOX 5. Sensor Ground Test
1. Turn IGN OFF.
Table 6-15. DTC P0123 Diagnostic Faults
2. Measure resistance between TCA [211B] terminal 1 and
POSSIBLE CAUSES ground.
Open in TPS-1 circuit 3. Is resistance less than 2 Ohms?
Short to voltage in TPS-1 circuit a. Yes. Go to Test 6.
Short to voltage in sensor power circuit b. No. Go to Test 7.
TCA malfunction
ECM malfunction
6. Sensor Ground Circuit Shorted Test
Open in sensor ground circuit 1. Test for continuity between TCA [211B] terminals 5 and
6.
1. TPS-1 Voltage Test 2. Is continuity present?
1. Connect BREAKOUT BOX (Part No. HD-48637) between a. Yes. Repair short between (BN/V) and (BN/O) wires.
wire harness [78B] and ECM [78A]. See 1.2 DIAGNOSTIC
b. No. Replace the ECM. See the service manual.
TOOLS.
2. Turn IGN ON. 7. Sensor Ground Circuit Test
3. Using a multimeter, measure voltage between breakout 1. Disconnect the ECM [78A].
box terminals 37 and 61.
2. Test for continuity between TCA [211B] terminal 1 and
4. Is voltage less than 4.8V? breakout box terminal 61.
a. Yes. Go to Test 8. 3. Is continuity present?
b. No. Go to Test 2. a. Yes. Replace the ECM. See the service manual.
b. No. Repair open in (BK/W) wire.
2. TPS-1 Circuit Test
1. Disconnect TCA [211]. 8. TPS-1 Circuit Function Test
2. Using HARNESS CONNECTOR TEST KIT (Part No. HD- 1. Disconnect TCA [211].
41404-C) and a multimeter, measure voltage between
2. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
TCA [211B] terminal 6 and ground.
41404-C) and a multimeter, measure voltage between
3. Is voltage between 4-5.25V? [211B] terminal 6 and ground.
a. Yes. Go to Test 3. 3. Is voltage between 2-5.25V?
b. No. Less than 4V. Repair open in (BN/V) wire. a. Yes. Go to Test 9.
c. No. Greater than 5.25V. Repair short to voltage in b. No. Less than 2V. Repair open in (BN/V) wire.
(BN/V) wire.
c. No. Greater than 5.25V. Repair short to voltage on
(BN/V) wire.
3. Sensor Power Circuit Test
1. Measure voltage between TCA [211B] terminal 5 and 9. Sensor Ground Continuity Test
ground.
1. Measure voltage between TCA [211B] terminal 5 and
2. Is voltage less than 5.25V? ground.
a. Yes. Go to Test 4. 2. Is voltage less than 5.25V?
b. No. Repair short to voltage in (BN/O) wire. a. Yes. Go to Test 10.
b. No. Repair short to voltage on (BN/O) wire.
4. TCA Test
1. Jumper TCA [211B] terminals 6 and 1. 10. Ground Circuit Open Test
2. Measure voltage between breakout box terminals 37 and 1. Turn IGN OFF.
61.
2. Disconnect the ECM [78A].
3. Test for continuity between TCA [211B] terminal 1 and
breakout box terminal 61.

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4. Is continuity present? 2. Is continuity present?

a. Yes. Go to Test 11. a. Yes. Repair short between (BN/R) and (BN/O) wires.
b. No. Repair open in (BK/W) wire. b. No. Go to Test 4.

11. TPS-1 Continuity Test 4. TPS-2 Circuit Continuity Test

1. Test for continuity between TCA [211B] terminal 6 and 1. Test continuity between breakout box terminals 36 and
breakout box terminal 37. TCA [211B] terminal 4.
2. Is continuity present? 2. Is continuity present?
a. Yes. Replace the TCA. See the service manual. a. Yes. Go to Test 5.
b. No. Repair open in (BN/V) wire. b. No. Repair open in (BN/R) wire.

DTC P0220 5. TPS-1 Circuit Short to Ground Test

PART NUMBER TOOL NAME 1. Test continuity between breakout box terminal 36 and
ground.
HD-41404-C HARNESS CONNECTOR TEST KIT
2. Is continuity present?
HD-48637 BREAKOUT BOX
a. Yes. Repair short to ground on (BN/R) wire.

Table 6-16. DTC P0220 Diagnostic Faults b. No. Go to Test 6.

POSSIBLE CAUSES 6. TPS-1 Circuit Short to Voltage Test

Open in sensor power circuit 1. Turn IGN ON.
Short to voltage in sensor power circuit
2. Test for voltage between breakout box terminal 36 and
Open in TPS-2 circuit ground.
Short to voltage in TPS-2 circuit 3. Is continuity present?
Short to ground in TPS-2 circuit a. Yes. Repair short to voltage on (BN/R) wire.
Open in sensor ground circuit b. No. Go to Test 7.
ECM malfunction
TCA malfunction 7. Sensor Ground Continuity Test
1. Test continuity between breakout box terminal 61 and TCA
1. Sensor Power-2 Circuit Test [211B] terminal 1.
1. Connect BREAKOUT BOX (Part No. HD-48637) between 2. Is continuity present?
wire harness [78B] and ECM [78A], leaving [78A] discon-
a. Yes. Go to Test 8.
nected. See 1.2 DIAGNOSTIC TOOLS.
b. No. Repair open in (BK/W) wire.
2. Disconnect TCA [211].
3. Using HARNESS CONNECTOR TEST KIT (Part No. HD- 8. TCA Test
41404-C) and a multimeter, test for continuity between
1. Connect ECM [78A] to breakout box.
breakout box terminal 50 and TCA [211] terminal 5.
2. Connect TCA [211].
4. Is continuity present?
a. Yes. Go to Test 2. 3. Measure voltage between breakout box terminals 36 and
61.
b. No. Repair open in (BN/O) wire.
4. Is voltage between 0.4-4.8V?
2. Sensor Power-2 Short to Voltage Test a. Yes. Replace the ECM. See the service manual.
1. Test for voltage between breakout box terminal 50 and b. No. Replace the TCA. See the service manual.
ground.
2. Is battery voltage present?
a. Yes. Repair short to voltage (BN/O) wire.
b. No. Go to Test 3.

3. TPS-2 Circuit Shorted Test

1. Test continuity between breakout box terminals 50 and
36.

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DTC P0222 4. Is voltage greater than 4V?

a. Yes. Replace the TCA. See the service manual.
PART NUMBER TOOL NAME
b. No. Go to Test 5.
HD-41404-C HARNESS CONNECTOR TEST KIT
HD-48637 BREAKOUT BOX 5. ECM Test
1. Disconnect ECM [78A] from breakout box.
Table 6-17. DTC P0222 Diagnostic Faults
2. Test for continuity at breakout box between terminal 36
POSSIBLE CAUSES and ground.
Open in sensor power circuit 3. Is continuity present?
Short to ground in TPS-2 circuit a. Yes. Repair short to ground in (BN/R) wire.
TCA malfunction b. No. Replace the ECM. See the service manual.
ECM malfunction
DTC P0223
1. TCA Sensor-2 Circuit Test
PART NUMBER TOOL NAME
1. Connect BREAKOUT BOX (Part No. HD-48637) between
wire harness [78B] and ECM [78A]. See 1.2 DIAGNOSTIC HD-41404-C HARNESS CONNECTOR TEST KIT
TOOLS. HD-48637 BREAKOUT BOX
2. Turn IGN ON and engine stop switch to run.
Table 6-18. DTC P0223 Diagnostic Faults
3. Test for voltage at breakout box between terminal 36 and
terminal 61. POSSIBLE CAUSES
4. Is voltage greater than 0.2V? Open in sensor power circuit
a. Yes. Go to Test 2. Short to voltage in sensor power circuit
b. No. Go to Test 4. Open in TPS-2 circuit
Short to voltage in TPS-2 circuit
2. TCA Sensor-2 Circuit Short to Ground Short to ground in TPS-2 circuit
Test
Open in sensor ground circuit
1. Turn IGN OFF.
ECM malfunction
2. Disconnect ECM [78A] from breakout box. TCA malfunction
3. Disconnect TCA [211].
1. TPS-2 Voltage Test
4. Test for continuity between breakout box terminal 36 and
ground. 1. Connect BREAKOUT BOX (Part No. HD-48637) between
wire harness [78B] and ECM [78A]. See 1.2 DIAGNOSTIC
5. Is continuity present? TOOLS.
a. Yes. Repair short to ground in (BN/R) wire. 2. Turn IGN ON.
b. No. Go to Test 3. 3. Measure voltage between breakout box terminals 36 and
61.
3. TCA Power-1 Circuit Open Test
4. Is voltage less than 4.8V?
1. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
41404-C) and a multimeter, test for continuity between a. Yes. Go to Test 7.
breakout box terminal 50 and TCA [211] terminal 5. b. No. Go to Test 2.
2. Is continuity present?
2. TPS-2 Circuit Test
a. Yes. Replace the TCA. See the service manual.
1. Disconnect TCA [211].
b. No. Repair open in (BN/O) wire.
2. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
4. TCA 5V Ref Circuit Short to Ground Test 41404-C) and a multimeter, measure voltage between
TCA [211B] terminal 4 and ground.
1. Turn IGN OFF.
3. Is voltage less than 0.2V?
2. Disconnect TCA [211].
a. Yes. Go to Test 3.
3. Test for voltage between breakout box terminal 50 and
ground. b. No. Go to Test 5.

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3. Sensor Power Circuit Test 3. Is continuity present?

1. Measure voltage between TCA [211B] terminal 5 and a. Yes. Replace the ECM. See the service manual.
ground. b. No. Repair open in (BK/W) wire.
2. Is voltage less than 5.25V?
7. TPS-2 Circuit Test
a. Yes. Go to Test 4.
1. Disconnect TCA [211].
b. No. Repair short to voltage in (BN/O) wire.
2. Measure voltage between TCA [211B] terminal 4 and
4. Sensor Ground Test ground.

1. Turn IGN OFF. 3. Is voltage less than 1.0V?

2. Measure resistance between TCA [211B] terminal 1 and a. Yes. Go to Test 8.

ground. b. No. Repair short to voltage on (BN/R) wire.
3. Is resistance less than 2 Ohms?
8. Sensor Ground Continuity Test
a. Yes. Replace TCA. See the service manual.
1. Measure voltage between TCA [211B] terminal 5 and
b. No. Go to Test 6. ground.

5. Shorted 5V Circuit Test 2. Is voltage less than 5.25V?

1. Test for continuity between TCA [211B] terminals 4 and a. Yes. Go to Test 9.
5. b. No. Repair short to voltage on (BN/O) wire.
2. Is continuity present?
9. Ground Circuit Open Test
a. Yes. Repair short between (BN/R) and (BN/O) wires.
1. Turn IGN OFF.
b. No. Repair short to voltage on (BN/R) wire.
2. Disconnect the ECM [78A].
6. Sensor Ground Circuit Test 3. Test for continuity between TCA [211B] terminal 1 and
1. Disconnect the ECM [78A]. breakout box terminal 61.

2. Test for continuity between [211B] terminal 1 and breakout 4. Is continuity present?
box terminal 61. a. Yes. Replace the TCA. See the service manual.
b. No. Repair open in (BK/W) wire.

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DTC P0031, P0032, P0131, P0132, P0134, P0151,
P0152, P0154
DESCRIPTION AND OPERATION
PART NUMBER TOOL NAME
HD-48650 DIGITAL TECHNICIAN II
See Figure 6-9. The HO2S provides a signal to the ECM which
indicates whether the engine is running rich or lean.
• A P0131 (front) or P0151 (rear) is set when the ECM
detects an excessively lean condition for a specified length
of time. This can be caused by mechanical issues such
as exhaust leaks. DTCs may also set if HO2S sensor fails.
• A P0132 (front) or P0152 (rear) is set when the ECM
detects an excessively rich condition for a specified length
of time. This can be caused by oil contamination or fuel
injector malfunctions. DTCs may also set if HO2S sensor
fails.
• A P0134 is set when the front O2 sensor circuit is open
or sensor is too cold to respond. A P0154 is set when the
rear O2 sensor circuit is open or sensor is too cold to
respond. Excessive oil usage may also cause these codes
to set.
When the air/fuel mixture is ideal, approximately 14.6 parts air
to 1 part fuel, the voltage will be approximately 0.45V when
measuring across the sensor. If the voltage is measured from
the sensor (terminals 46 or 66) to ground, the voltage will read
approximately 1.2V. This difference is due to an internal bias
in the ECM. When using DIGITAL TECHNICIAN II (Part
No. HD-48650), the O2 voltage reading is displayed in the
higher range 0.7-1.7V.
Table 6-19. Code Description
DTC DESCRIPTION
P0031 Heater open/low
P0032 Heater shorted/high
P0131 Front O2 sensor low or engine running lean
P0132 Engine front O2 running rich
P0134 Front O2 sensor open/not responding/high
P0151 Rear O2 sensor low or engine running lean
P0152 Engine rear O2 running rich
P0154 Rear O2 sensor open/not responding/high
The heater portion of the HO2S is powered through the system
relay. The front and rear HO2S heaters share a common
ground through terminal 31 of the ECM. If the ECM recognizes
an open or short in the heater circuit it will set either DTC P0031
or P0032.
6.7
ed03081
1 2
7
6
5
4
3
1. Front HO2S [138]
2. ABS module [166] (if equipped)
3. Active exhaust [179]
4. Rear WSS [168]
5. Rear HO2S [137]
6. TSM/TSSM/HFSM [30]
7. HFSM antenna jumper harness [208]
Figure 6-9. Under Right Side Cover
Diagnostic Tips
HO2S diagnostic codes may be seen during the vehicle break-
in period. The HO2S DTCs will not illuminate the check engine
lamp for current or historic codes and will only be indicated by
DIGITAL TECHNICIAN II (Part No. HD-48650) or odometer
self-diagnostics. If the DTCs are reported during the break-in
period, clear or ignore the codes until the break-in period is
completed. All historic HO2S DTCs are to be ignored and
cleared.
The multimeter displays the signal from the HO2S in Volts.
This voltage will have an average value tending towards lean,
rich or ideal value depending on operating temperature of the
engine, engine speed and throttle position. An open/short to
voltage or short to ground in the (PK/O) wire (front) and
(PK/GN) wire (rear) will cause the engine to run rich (short to
ground) or lean (short to voltage) until fault is detected. Once
fault is detected, vehicle will run in open loop.
Check for the following conditions:
• Poor connection: Inspect the ECM [78], fuel injector [84,
85] and HO2S [137, 138] connectors for backed out ter-
minals, improper mating, inoperative locks, improperly
formed or damaged terminals, poor terminal-to-wire con-
nection and damaged harnesses.
• Dirty/stuck open injectors: The vehicle may run lean
(dirty/clogged injectors) or rich (stuck open injectors) if
2011 Touring Diagnostics: Engine Management 6-23
HOME

there are injector problems. This could also cause poor check for leaky injectors, first remove the air box and air
fuel economy and performance. filter. See the service manual. Then, with the throttle wide
open, turn IGN ON for 2 seconds and then OFF for 2
• Loose HO2S: If an HO2S is loose, engine performance
seconds five consecutive times. Replace the fuel injector
may be affected. This could also show up as a slow
if there is any evidence of raw fuel in the bores. See Fuel
changing HO2S voltage.
Injectors in the service manual.
• Loose/leaking exhaust: This can cause a poor ground
• Intake leaks: See the service manual.
connection for the sensor or allow fresh air into the exhaust
system. If fresh air enters exhaust system, the HO2S will Connector Information
read a lean condition, causing the system to go rich.
For additional information about the connectors in the following
• Engine misfire: See 6.37 MISFIRE AT IDLE OR UNDER diagram(s) and diagnostic procedure(s), including the color of
LOAD. the harness test kit terminal probes, see B.1 CONNECTORS.
• Leaking injectors: cause fuel imbalance and poor idle
quality due to different air/fuel ratios in each cylinder. To

6-24 2011 Touring Diagnostics: Engine Management

HOME

em00702
Fuel Pump
[141A] B D
Assembly In Tank
Front ACR Rear ACR
(If Equipped) (If Equipped)
[141B] B D [141B] B D

O/GY
O/GY
[203AF] 2 1 2 1 [203AR]

BK
BK
[203BF] 2 1 2 1 [203BR]
Fuel Tank [13B] 1 4 [20A] 14 15

V/GY

V/GY
Y/GN

Y/GN
Harness [13A] 1 4 [20B] 14 15

O/GY
O/GY

BK
EXCEPT BK FLHR/C TGS
O/GY

BK
FLHR/C ET

V/GY

Y/GN
Sensor
4B TCA [224A] 6 5 4 3 21
Fuel [224B] 6 5 4 3 21
Pump [90A] A B
Fuse

GY
BN
BE
BK
R
V
[211A] 1 2 3 4 5 6 [90B] A B TMAP
15A
4A [211B] 1 2 3 4 5 6 Sensor

BK/W
[204A]

PK/Y
6 5 4 3 21
Y/GN

System
BK/W

BN/O
BK/O
BN/R

BN/V
BK/PK
[204B] 6 5 4 3 2 1
[80A] 1 2 3 4
Relay

BK/W
BN/O

BK/GY
BE/GN

R/W
87 5 4C [80B]

V/Y
Y/GN 1 2 3 4
30 3 3D BE/GY

R/W
V/W
BK/GY
LGN/Y
86
85 To 15A
ECM Fuse
Ignition Coil [83A] [83B]
Power A A Y/GN
Ion Sense B B GY/BE
Coil Rear C C Y/BE
Coil Front D D BE/O
[65B] [65A]
[84A] [84B]
BN/O A A
Front Fuel A A Y/GN W/GN B B VSS
Injector B B W/Y
BK/Y C C
[85A] [85B]

Rear Fuel A A Y/GN BK/BN 4

Injector B B GN/GY
PK/O 3 Front
[95A] [95B] GN/W 2 HO2S
Y/GN 1
B B GY/Y
A A Y/GN [138A]
Purge Solenoid
(Optional)
BK/BN 4
Rear
PK/GN 3
To 15A 2
HO2S
GN/W
Exhaust Y/GN 1 (BK)
Control Fuse
[137A]

1 LGN/R
Active 2 BK
Exhaust 3 V/O
(HDI Only) 4 V/BE
BK
R

[179B]
GN/GY

PK/GN

BE/GN

BK/GN
GY/BE

BK/GY
BK/BN
LGN/Y
BK/PK
GN/W

W/GN

BK/W
BN/O

Y/GN
V/GY
GY/Y

BK/O

BN/R

BE/O

PK/O
BN/V
V/BE

PK/Y

Y/BE

BK/Y

R/W
V/W

W/Y
V/O

V/Y

BK

2 1 [79A]
R

Right
[78B] 19 20 21 2324 28 29 30 3133 363738 39 4043 46 484950 51 52 53 54 59 61 62 63 64 66 68 73 GND 2 2 1 [79B]
[78A] 19 20 21 2324 28 29 30 3133 363738 39 4043 46 484950 51 52 53 54 59 61 62 63 64 66 68 73
HO2S Return
Purge Solenoid
Exhaust Actuator
Rear Fuel Injector
TMAP Sensor Input

Throttle Actuator Control HI

Throttle Actuator Control LO
O2 Heater Ground
Ion Sense
TPS 2
TPS 1

TGS 2

CKP Sensor
Rear HO2 Sensor

ET Sensor

Rear Ignition Coil

TGS 1
5V Sensor Ground 1
5V Sensor Ground 2
CKP Sensor (+)

Ground
ACR Ground

Front Fuel Injector

Front Ignition Coil

Front HO2 Sensor

Exhaust Feedback

5V Sensor Power 1

12V Power

5V Sensor Power 2
Vehicle Speed Input

Vehicle Speed Ground

IAT Sensor

CKP
Sensor
ECM

Figure 6-10. EFI Simplified Schematic

2011 Touring Diagnostics: Engine Management 6-25

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DTC P0031 1. Rear HO2S Resistance Test

PART NUMBER TOOL NAME 1. Disconnect rear HO2S [137].

HD-41404-C HARNESS CONNECTOR TEST KIT 2. Turn IGN ON, using HARNESS CONNECTOR TEST
KIT (Part No. HD-41404-C) and a multimeter, measure
HD-48637 BREAKOUT BOX
resistance between rear HO2S [137B] terminal 1 and ter-
minal 2.
Table 6-20. DTC P0031 Diagnostic Faults
3. Is resistance between 13.5-23.5 Ohms?
POSSIBLE CAUSES a. Yes. Go to Test 2.
Open in sensor ground circuit b. No. Replace rear HO2S. See the service manual.
ECM malfunction
HO2 malfunction 2. Front HO2S Resistance Test
Open in sensor power circuit 1. With IGN OFF, disconnect front HO2S [138].
2. Measure resistance between front HO2S [138B] terminal
1. HO2S Voltage Test 1 and terminal 2.
1. Disconnect front HO2S [138]. 3. Is resistance between 13.5-23.5 Ohms?
2. Turn IGN ON using HARNESS CONNECTOR TEST a. Yes. Go to Test 3.
KIT (Part No. HD-41404-C) and a multimeter, test for
battery voltage between front HO2S [138A] terminal 1 and b. No. Replace front HO2S. See the service manual.
ground.
3. HO2S Short to Voltage Test
a. Yes. Go to Test 2.
1. With IGN ON, test for voltage between front HO2S [138A]
b. No. Repair open in (Y/GN). terminal 2 and ground.

2. HO2S Ground Test 2. Is voltage present?

1. With IGN OFF, connect BREAKOUT BOX (Part No. HD- a. Yes. Repair short to voltage in (GN/W) wire.
48637) between wire harness [78B] and ECM [78A]. See b. No. Replace ECM. See the service manual.
1.2 DIAGNOSTIC TOOLS.
2. Using HARNESS CONNECTOR TEST KIT (Part No. HD- DTC P0131
41404-C) and a multimeter, test for continuity between
PART NUMBER TOOL NAME
ECM [78A] terminal 31 and front HO2S [138A] terminal 2.
HD-48637 BREAKOUT BOX
3. Is continuity present?
a. Yes. Go to Test 3.
Table 6-22. DTC P0131 Diagnostic Faults
b. No. Repair open in (GN/W).
POSSIBLE CAUSES
3. HO2S Resistance Test Front HO2S malfunction
1. Measure resistance between front HO2S [138B] terminal ECM malfunction
1 and terminal 2. Short to ground in signal circuit
2. Is resistance between 13.5-23.5 Ohms? Fuel system malfunction
a. Yes. Replace ECM. See the service manual. Leak in exhaust system
b. No. Replace both HO2S. See the service manual.
1. Front HO2S Test
DTC P0032 1. Disconnect front HO2S [138].

PART NUMBER TOOL NAME 2. Turn IGN ON.

HD-41404-C HARNESS CONNECTOR TEST KIT 3. Measure voltage between front HO2S [138A] terminal 3
(PK/O), to chassis ground.
Table 6-21. DTC P0032 Diagnostic Faults 4. Is voltage approximately 5V?

POSSIBLE CAUSES a. Yes. Go to Test 4.

ECM malfunction b. No. Go to Test 2.

HO2 malfunction
2. Front HO2S Signal Wire Shorted to
Short to voltage in sensor ground circuit
Sensor Ground Test
1. Turn IGN OFF.

6-26 2011 Touring Diagnostics: Engine Management

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2. Disconnect ECM [78]. 4. With engine speed at a steady rpm, measure voltage
between breakout box terminals 66 and 73.
3. Test for continuity between front HO2S [138A] terminals
3 (PK/O) and 4 (BK/BN). 5. Is voltage approximately 1.2V?
4. Is continuity present? a. Yes. Replace the ECM. See the service manual.
a. Yes. Repair short between (PK/O) and (BK/BN) wires. b. No, constant 1.3-1.7V. Perform fuel pressure test.
See the service manual. Look for incorrect ECM cal-
b. No. Go to Test 3.
ibration, high fuel pressure, stuck open or leaking
injectors. If no issues are found, replace the HO2S.
3. Front HO2S Signal Wire Shorted to
Ground Test DTC P0134
1. Test for continuity between front HO2S [138A] terminal 3
PART NUMBER TOOL NAME
(PK/O) and vehicle ground.
HD-41404-C HARNESS CONNECTOR TEST KIT
2. Is continuity present?
HD-48637 BREAKOUT BOX
a. Yes. Repair short between (PK/O) wire and ground.
b. No. If ECM [78] connections are good, replace ECM. Table 6-24. DTC P0134 Diagnostic Faults
See the service manual.
POSSIBLE CAUSES
4. Front HO2S Operation Test Front HO2S malfunction
1. Connect BREAKOUT BOX (Part No. HD-48637) between ECM malfunction
wire harness [78B] and ECM [78A]. See 1.2 DIAGNOSTIC
TOOLS. Open or short to voltage in signal circuit
Open sensor ground
2. Place transmission in neutral, engine stop switch to RUN
and IGN ON. Start engine and allow to reach operating Heavy oil contamination
temperature.
1. Front HO2S Signal Wire Short Circuit
3. With engine speed at a steady rpm, measure voltage
between breakout box terminals 66 and 73.
Voltage Test
1. Disconnect front O2 sensor [138].
4. Is voltage approximately 1.2V?
a. Yes. Replace ECM. See the service manual. 2. Turn IGN ON.

b. No, constant 0.7-1.1V. Perform fuel pressure test. 3. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
See the service manual. Look for incorrect ECM cal- 41404-C) and a multimeter, measure voltage between
ibration, low fuel pressure, air leaks and dirty injectors. front HO2S [138A] terminal 3 to chassis ground.
If no issues are found, replace HO2S. 4. Is voltage greater than 5V?
a. Yes. Repair short to voltage on (PK/O) wire.
DTC P0132
b. No, voltage greater than 4V. Go to Test 2.
PART NUMBER TOOL NAME
c. No, voltage less than 4V. Go to Test 3.
HD-48637 BREAKOUT BOX
2. Front HO2S Open Sensor Ground Test
Table 6-23. DTC P0132 Diagnostic Faults
1. Turn IGN OFF.
POSSIBLE CAUSES 2. Connect BREAKOUT BOX (Part No. HD-48637) to wire
Front HO2S malfunction harness [78B], leaving ECM [78A] disconnected. See
ECM malfunction 1.2 DIAGNOSTIC TOOLS.

Fuel system malfunction 3. Test for continuity between front HO2S [138A] terminal 4
(BK/BN) and breakout box terminal 48.
Oil contamination on sensor
4. Is continuity present?
1. Front HO2S Operation Test a. Yes. Replace the front HO2S. See the service
1. Turn IGN OFF. manual.

2. Connect BREAKOUT BOX (Part No. HD-48637) between b. No. Repair open on (BK/BN) wire.
wire harness [78B] and ECM [78A]. See 1.2 DIAGNOSTIC
TOOLS. 3. Front HO2S Signal Wire Open Test
3. Start the engine and allow it to reach operating temper- 1. Test for continuity between front HO2S [138A] terminal 3
ature. (PK/O) and breakout box terminal 66.

2011 Touring Diagnostics: Engine Management 6-27

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2. Is continuity present? 4. Rear HO2S Operation Test

a. Yes. Replace ECM. See the service manual. 1. Connect BREAKOUT BOX (Part No. HD-48637) between
b. No. Repair open (PK/O) wire. wire harness [78B] and ECM [78A]. See 1.2 DIAGNOSTIC
TOOLS.
DTC P0151 2. Place transmission in neutral, engine stop switch to RUN
PART NUMBER TOOL NAME and IGN ON. Start engine and allow to reach operating
temperature.
HD-41404-C HARNESS CONNECTOR TEST KIT
3. With engine speed at a steady rpm, measure voltage
HD-48637 BREAKOUT BOX between ECM breakout box terminals 46 and 73.
4. Is voltage approximately 1.2V?
Table 6-25. DTC P0151 Diagnostic Faults
a. Yes. Replace ECM. See the service manual.
POSSIBLE CAUSES
b. No, constant 0.7-1.1V. Perform fuel pressure test.
Rear HO2S malfunction See the service manual. Look for incorrect ECM cal-
ECM malfunction ibration, low fuel pressure, air leaks and dirty injectors.
If no issues are found, replace HO2S.
Short to ground in signal circuit
Fuel system malfunction DTC P0152
Leak in exhaust system
PART NUMBER TOOL NAME
1. Rear HO2S Test HD-48637 BREAKOUT BOX
1. Disconnect rear HO2S [137].
Table 6-26. DTC P0152 Diagnostic Faults
2. Turn IGN ON.
POSSIBLE CAUSES
3. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
41404-C) and a multimeter, measure voltage between Rear HO2S malfunction
rear HO2S [137A] terminal 3 (PK/GN) to ground. ECM malfunction
4. Is voltage approximately 5V? Fuel system malfunction
a. Yes. Go to Test 4. Oil contamination on sensor
b. No. Go to Test 2.
1. Rear HO2S Operation Test
2. Rear HO2S Signal Wire Shorted to Sensor 1. Turn IGN OFF.
Ground Test 2. Connect BREAKOUT BOX (Part No. HD-48637) between
1. Turn IGN OFF. wire harness [78B] and ECM [78A]. See 1.2 DIAGNOSTIC
TOOLS.
2. Disconnect ECM [78].
3. Start the engine and allow it to reach operating temper-
3. Test for continuity between rear HO2S [137A] terminals ature.
3 (PK/GN) and 4 (BK/BN).
4. With engine speed at a steady rpm, measure voltage
4. Is continuity present? between breakout box terminals 46 and 73.
a. Yes. Repair short between (PK/GN) and (BK/BN)
5. Is voltage approximately 1.2V?
wires.
a. Yes. Replace the ECM. See the service manual.
b. No. Go to Test 3.
b. No, constant 1.3-1.7V. Perform fuel pressure test.
3. Rear HO2S Signal Wire Shorted to Ground See the service manual. Look for incorrect ECM cal-
ibration, high fuel pressure, stuck open or leaking
Test injectors. If no issues are found, replace the HO2S.
1. Test for continuity between rear HO2S [137A] terminal 3
(PK/GN) and ground.
2. Is continuity present?
a. Yes. Repair short between (PK/GN) wire and ground.
b. No. If ECM [78] connections are good, replace ECM.
See the service manual.

6-28 2011 Touring Diagnostics: Engine Management

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DTC P0154 4. Is voltage greater than 5.5V?

a. Yes. Repair short to voltage on (PK/GN) wire.
PART NUMBER TOOL NAME
b. No, voltage greater than 4V. Go to Test 2.
HD-48637 HARNESS CONNECTOR TEST KIT
c. No, voltage less than 4V. Go to Test 3.
Table 6-27. DTC P0154 Diagnostic Faults
2. Rear HO2S Open Sensor Ground Test
POSSIBLE CAUSES 1. Turn IGN OFF.
Rear HO2S malfunction
2. Connect BREAKOUT BOX (Part No. HD-48637) to wire
ECM malfunction harness [78B], leaving ECM [78A] disconnected. See
Open or short voltage in signal circuit 1.2 DIAGNOSTIC TOOLS.
Open sensor ground 3. Test for continuity between rear HO2S [137A] terminal 4
Heavy oil contamination (BK/BN) and breakout box terminal 48.
4. Is continuity present?
1. Rear HO2S Signal Wire Short Circuit a. Yes. Replace the rear HO2S. See the service manual.
Voltage Test
b. No. Repair open on (BK/BN) wire.
1. Disconnect rear HO2S [137].
2. Turn IGN ON. 3. Rear HO2S Signal Wire Open Test
3. Using HARNESS CONNECTOR TEST KIT (Part No. HD- 1. Test for continuity between rear HO2S [137A] terminal 3
48637) and a multimeter, measure voltage between rear (PK/GN) and breakout box terminal 46.
HO2S [137A] terminal 3 to chassis ground. 2. Is continuity present?
a. Yes. Replace ECM. See the service manual.
b. No. Repair open in (PK/GN) wire.

2011 Touring Diagnostics: Engine Management 6-29

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DTC P0261, P0262, P0263, P0264 6.8

DESCRIPTION AND OPERATION Connector Information
The fuel injectors are solenoids that allow pressurized fuel into For additional information about the connectors in the following
the intake tract. The injectors are timed to the engine cycle and diagram(s) and diagnostic procedure(s), including the color of
triggered sequentially. The power for the injectors comes from the harness test kit terminal probes, see B.1 CONNECTORS.
the system relay. The system relay also provides power for
the fuel pump and the ignition coil. The ECM provides the path ed03075
to ground to trigger the injectors.
NOTE
ECM fuse and system relay failures or wiring harness problems 1 2
will cause 12V power to be lost to both injectors, ignition coils
and fuel pump.

Table 6-28. Code Description

DTC DESCRIPTION
P0261 Front injector open/low
P0262 Front injector high
P0263 Rear injector open/low 3
P0264 Rear injector high 1. Front fuel injector [84]
2. Rear fuel injector [85]
3. ET sensor [90]
Figure 6-11. Between Cylinders Left Side

6-30 2011 Touring Diagnostics: Engine Management

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em00702
Fuel Pump
[141A] B D
Assembly In Tank
Front ACR Rear ACR
(If Equipped) (If Equipped)
[141B] B D [141B] B D

O/GY
O/GY
[203AF] 2 1 2 1 [203AR]

BK
BK
[203BF] 2 1 2 1 [203BR]
Fuel Tank [13B] 1 4 [20A] 14 15

V/GY

V/GY
Y/GN

Y/GN
Harness [13A] 1 4 [20B] 14 15

O/GY
O/GY

BK
EXCEPT BK FLHR/C TGS
O/GY

BK
FLHR/C ET

V/GY

Y/GN
Sensor
4B TCA [224A] 6 5 4 3 21
Fuel [224B] 6 5 4 3 21
Pump [90A] A B
Fuse

GY
BN
BE
BK
R
V
[211A] 1 2 3 4 5 6 [90B] A B TMAP
15A
4A [211B] 1 2 3 4 5 6 Sensor

BK/W
[204A]

PK/Y
6 5 4 3 21
Y/GN

System
BK/W

BN/O
BK/O
BN/R

BN/V
BK/PK
[204B] 6 5 4 3 2 1
[80A] 1 2 3 4
Relay

BK/W
BN/O

BK/GY
BE/GN

R/W
87 5 4C [80B]

V/Y
Y/GN 1 2 3 4
30 3 3D BE/GY

R/W
V/W
BK/GY
LGN/Y
86
85 To 15A
ECM Fuse
Ignition Coil [83A] [83B]
Power A A Y/GN
Ion Sense B B GY/BE
Coil Rear C C Y/BE
Coil Front D D BE/O
[65B] [65A]
[84A] [84B]
BN/O A A
Front Fuel A A Y/GN W/GN B B VSS
Injector B B W/Y
BK/Y C C
[85A] [85B]

Rear Fuel A A Y/GN BK/BN 4

Injector B B GN/GY
PK/O 3 Front
[95A] [95B] GN/W 2 HO2S
Y/GN 1
B B GY/Y
A A Y/GN [138A]
Purge Solenoid
(Optional)
BK/BN 4
Rear
PK/GN 3
To 15A 2
HO2S
GN/W
Exhaust Y/GN 1 (BK)
Control Fuse
[137A]

1 LGN/R
Active 2 BK
Exhaust 3 V/O
(HDI Only) 4 V/BE
BK
R

[179B]
GN/GY

PK/GN

BE/GN

BK/GN
GY/BE

BK/GY
BK/BN
LGN/Y
BK/PK
GN/W

W/GN

BK/W
BN/O

Y/GN
V/GY
GY/Y

BK/O

BN/R

BE/O

PK/O
BN/V
V/BE

PK/Y

Y/BE

BK/Y

R/W
V/W

W/Y
V/O

V/Y

BK

2 1 [79A]
R

Right
[78B] 19 20 21 2324 28 29 30 3133 363738 39 4043 46 484950 51 52 53 54 59 61 62 63 64 66 68 73 GND 2 2 1 [79B]
[78A] 19 20 21 2324 28 29 30 3133 363738 39 4043 46 484950 51 52 53 54 59 61 62 63 64 66 68 73
HO2S Return
Purge Solenoid
Exhaust Actuator
Rear Fuel Injector
TMAP Sensor Input

Throttle Actuator Control HI

Throttle Actuator Control LO
O2 Heater Ground
Ion Sense
TPS 2
TPS 1

TGS 2

CKP Sensor
Rear HO2 Sensor

ET Sensor

Rear Ignition Coil

TGS 1
5V Sensor Ground 1
5V Sensor Ground 2
CKP Sensor (+)

Ground
ACR Ground

Front Fuel Injector

Front Ignition Coil

Front HO2 Sensor

Exhaust Feedback

5V Sensor Power 1

12V Power

5V Sensor Power 2
Vehicle Speed Input

Vehicle Speed Ground

IAT Sensor

CKP
Sensor
ECM

Figure 6-12. EFI Simplified Schematic

2011 Touring Diagnostics: Engine Management 6-31

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DTC P0261 3. Is continuity present?

a. Yes. If connections are good, replace ECM. See the
PART NUMBER TOOL NAME service manual.
HD-34730-2D FUEL INJECTOR TEST LIGHT
b. No. Repair open (Y/GN) wire.
HD-48637 BREAKOUT BOX
5. Injector Resistance Test
Table 6-29. DTC P0261 Diagnostic Faults 1. Test resistance between terminal A and B of front fuel
injector [84A].
POSSIBLE CAUSES
Front fuel injector malfunction 2. Is resistance value between 10-20 Ohms?
a. Yes. Replace ECM. See the service manual.
ECM malfunction
Open signal circuit b. No. Replace front fuel injector. See the service
manual.
Open power circuit
6. Driver Short to Ground Test
1. Front Fuel Injector Test
1. Connect BREAKOUT BOX (Part No. HD-48637) to wire
1. Disconnect front fuel injector [84]. harness [78B], leaving ECM [78A] disconnected. See
2. Connect FUEL INJECTOR TEST LIGHT (Part No. HD- 1.2 DIAGNOSTIC TOOLS.
34730-2D) to front fuel injector [84B]. 2. Test for continuity between breakout box terminal 28 and
3. Crank engine. ground.

4. Does light flash when engine is cranking (or running)? 3. Is continuity present?
a. Yes. Go to Test 5. a. Yes. Repair short to ground on (W/Y) wire.

b. No. Lamp does not illuminate. Go to Test 2. b. No. Replace ECM. See the service manual.

c. No. Lamp is on steady. Go to Test 6. DTC P0262

2. Front Fuel Injector Power Wire Open
Table 6-30. DTC P0262 Diagnostic Faults
Circuit Test
POSSIBLE CAUSES
1. Turn IGN OFF and engine stop switch to RUN.
Front fuel injector malfunction
2. Remove fuel injector test light.
ECM malfunction
3. Connect BREAKOUT BOX (Part No. HD-48637) to ECM
harness [78B] leaving ECM [78A] disconnected. See Short to ground in signal circuit
1.2 DIAGNOSTIC TOOLS.
1. Front Fuel Injector Control Wire Shorted
4. Test for continuity between breakout box terminal 28 and to Voltage Test
front fuel injector [84B] terminal B (W/Y).
1. Disconnect front fuel injector [84].
5. Is continuity present?
2. Measure the voltage between front fuel injector [84B] ter-
a. Yes. Go to Test 3.
minal B (W/Y) and ground.
b. No. Repair open on (W/Y) wire.
3. Is voltage less than 1.0V?
3. Front Fuel Injector Power Wire Shorted a. Yes. Go to Test 2.
to Ground Test b. No. Repair short to voltage on (W/Y) wire.
1. Test for continuity between breakout box terminal 28 and
ground.
2. Injector Resistance Test
1. Test resistance between terminal A and B of front fuel
2. Is continuity present?
injector [84A].
a. Yes. Repair short in (W/Y) to ground.
2. Is resistance value between 10-20 Ohms?
b. No. Go to Test 4.
a. Yes. Replace ECM. See the service manual.
4. Fuel Injector/System Relay Test b. No. Replace front fuel injector. See the service
manual.
1. Remove system relay.
2. Test for continuity between system relay socket terminal
4C (Y/GN) wire and front fuel injector [84B] terminal A
(Y/GN).

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DTC P0263 2. Test for continuity between system relay socket terminal
4C (Y/GN) wire and rear fuel injector [85B] terminal A
PART NUMBER TOOL NAME (Y/GN).
HD-34730-2D FUEL INJECTOR TEST LIGHT 3. Is continuity present?
HD-48637 BREAKOUT BOX a. Yes. If connections are good, replace ECM. See the
service manual.
Table 6-31. DTC P0263 Diagnostic Faults b. No. Repair open (Y/GN) wire.
POSSIBLE CAUSES
5. Injector Resistance Test
Rear fuel injector malfunction
1. Test resistance between terminal A and B of rear fuel
ECM malfunction injector [85A].
Open signal circuit
2. Is resistance value between 10-20 Ohms?
Open power circuit a. Yes. Replace ECM. See the service manual.

1. Rear Fuel Injector Test b. No. Replace rear fuel injector. See the service
manual.
1. Disconnect rear fuel injector [85].
2. Connect FUEL INJECTOR TEST LIGHT (Part No. HD- 6. Driver Short to Ground Test
34730-2D) to rear fuel injector [85B]. 1. Connect BREAKOUT BOX (Part No. HD-48637) to wire
3. Crank engine. harness [78B], leaving ECM [78A] disconnected. See
1.2 DIAGNOSTIC TOOLS.
4. Does lamp flash when engine is cranking (or running)?
2. Test for continuity between breakout box terminal 23 and
a. Yes. Go to Test 5.
ground.
b. No. Lamp does not illuminate. Go to Test 2.
3. Is continuity present?
c. No. Lamp is on steady. Go to Test 6. a. Yes. Repair short to ground on (GN/GY) wire.

2. Rear Fuel Injector Power Wire Open b. No. Replace ECM. See the service manual.
Circuit Test
DTC P0264
1. Turn IGN OFF and engine stop switch to RUN.
2. Remove fuel injector test light. Table 6-32. DTC P0264 Diagnostic Faults
3. Connect BREAKOUT BOX (Part No. HD-48637) to ECM POSSIBLE CAUSES
harness [78B], leaving ECM [78A] disconnected. See Rear fuel injector malfunction
1.2 DIAGNOSTIC TOOLS.
ECM malfunction
4. Test for continuity between breakout box terminal 23 and
rear fuel injector [85B] terminal B (GN/GY). Short to ground in signal circuit

5. Is continuity present? 1. Rear Fuel Injector Control Wire Shorted

a. Yes. Go to Test 3. to Voltage Test
b. No. Repair open on (GN/GY) wire. 1. Disconnect rear fuel injector [85].
2. Measure the voltage between rear fuel injector [85B] ter-
3. Rear Fuel Injector Power Wire Shorted to minal B (GN/GY) and ground.
Ground Test
3. Is voltage less than 1.0V?
1. Test for continuity between breakout box terminal 23 and
a. Yes. Go to Test 2.
ground.
b. No. Repair short to voltage on (GN/GY) wire.
2. Is continuity present?
a. Yes. Repair short in (GN/GY) to ground. 2. Injector Resistance Test
b. No. Go to Test 4. 1. Test resistance between terminal A and B of rear fuel
injector [85A].
4. Fuel Injector/System Relay Test
2. Is resistance value between 10-20 Ohms?
1. Remove system relay.
a. Yes. Replace ECM. See the service manual.
b. No. Replace rear fuel injector. See the service
manual.

2011 Touring Diagnostics: Engine Management 6-33

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DTC P0373, P0374 6.9

DESCRIPTION AND OPERATION
ed01823
If the CKP sensor signal is weak or absent, DTCs P0373 or
P0374 will be set. DTC P0373 is usually set when several
attempts to crank the engine have failed.
NOTE
If signal is not detected or cannot synchronize (DTC P0374),
engine will not start.

Table 6-33. Code Description

DTC DESCRIPTION
P0373 CKP sensor intermittent
P0374 CKP not detected/cannot synchronize

Diagnostic Tips Figure 6-13. CKP Sensor [79] (from underneath)

Engine must be cranked for more than five seconds without
CKP signal to set P0374 code. Intermittent TMAP wiring or
sensor issues may cause these codes to set prior to setting Connector Information
TMAP codes. Verify TMAP wiring and sensor prior to replacing
For additional information about the connectors in the following
the ECM.
diagram(s) and diagnostic procedure(s), including the color of
the harness test kit terminal probes, see B.1 CONNECTORS.

em00699 Crank Pos.

Sensor

[79A] 1 2
[79B] 1 2
BK
R

[78A] [78B]
ECM
To 15A
Exhaust Actuator 21 21 V/O Exhaust
Exhaust Feedback 38 38 V/BE [90B] [90A] Control
Crank Position Sensor 43 43 BK Fuse
Engine Temperature 51 51 PK/Y PK/Y A A ET
5V Sensor Ground 1 61 61 BK/W BK/W B B Sensor
Crank Pos Sensor (+) 63 63 R
Ground 73 73 BK/GN
LGN/R
V/BE
V/O
BK

Right
GND 2
[179B] 4 3 2 1

Active
Exhaust
(HDI Only)

Figure 6-14. ET Sensor, CKP Sensor and Active Exhaust Circuit

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DTC P0373 4. Is resistance less than 1.0 Ohm?

a. Yes. Go to Test 3.
Table 6-34. DTC P0373 Diagnostic Faults b. No. Repair open wire (R).
POSSIBLE CAUSES
3. CKP Sensor Ground Wire Continuity Test
CKP sensor malfunction
1. Test continuity from breakout box terminal 43 to CKP
ECM malfunction sensor [79B] terminal 2 (BK).
Open or short to ground in signal circuit
2. Is resistance less than 1.0 Ohm?
1. CKP Sensor Test a. Yes. Go to Test 4.

1. Clear the DTC. 2.1 INITIAL DIAGNOSTICS, Odometer b. No. Repair open on (BK) wire.
Self-Diagnostics.
4. CKP Sensor Signal Wire Shorted to CKP
2. Start the vehicle.
Ground Wire Test
3. Did DTC P0373 reset?
1. Test for continuity between breakout box terminals 63 and
a. Yes. Inspect and verify battery and starting system. 43.
See 3.2 STARTING SYSTEM.
2. Is continuity present?
b. No. System functioning properly.
a. Yes. Repair short between CKP [79B] terminals 1 (R)
and 2 (BK).
DTC P0374
b. No. Go to Test 5.
PART NUMBER TOOL NAME
HD-41404-C HARNESS CONNECTOR TEST KIT 5. CKP Sensor Low Shorted to Ground Test
HD-48637 BREAKOUT BOX 1. Test for continuity between breakout box terminals 43 and
73.
Table 6-35. DTC P0374 Diagnostic Faults 2. Is continuity present?
POSSIBLE CAUSES a. Yes. Repair short to sensor ground on (BK) wire.
CKP sensor malfunction b. No. Go to Test 6.
ECM malfunction
6. CKP Sensor Output Test
Open or short to ground in signal circuit
1. Connect CKP sensor [79].
1. CKP Sensor Connections Test 2. Test for AC voltage at breakout box terminals 63 and 43.
1. With IGN OFF, disconnect ECM [78] and inspect for 3. Place transmission in neutral, turn IGN ON and engine
damaged, corroded or pushed out terminals. stop switch to RUN.
2. Are terminal problems present? 4. Crank engine for 5 seconds while observing multimeter.
a. Yes. Repair terminals as required.
5. Is AC voltage present?
b. No. Go to Test 2. a. Yes. Replace ECM. See the service manual.

2. CKP Sensor Signal Wire Continuity Test b. No. Go to Test 7.

1. Disconnect CKP sensor [79].
7. CKP Sensor Signal Wire Shorted to
2. Connect BREAKOUT BOX (Part No. HD-48637) to wire Ground Test
harness [78B], leaving ECM [78A] disconnected. See
1.2 DIAGNOSTIC TOOLS. 1. Disconnect CKP sensor [79].

3. Using HARNESS CONNECTOR TEST KIT (Part No. HD- 2. Test for continuity between breakout box terminals 63 and
41404-C) and a multimeter, test for continuity between 73.
breakout box terminal 63 to CKP sensor [79B] terminal 1 3. Is continuity present?
(R).
a. Yes. Repair shorted (R) wire to ground.
b. No. Replace the CKP sensor. See the service manual.

2011 Touring Diagnostics: Engine Management 6-35

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DTC P0444, P0445 6.10

DESCRIPTION AND OPERATION
ed01800
Purge Solenoid (If Equipped)
See Figure 6-15. To comply with emission standards in some
areas, a purge solenoid is required. The purge solenoid is
located under the seat. Two vent lines run from the purge
solenoid. One line connects to the top of the fuel tank and the
other connects to a vent canister mounted to the vehicle
chassis in front of the purge solenoid. A second return line from
the vent canister connects to the air intake manifold allowing
vented fumes to be recirculated into the engine.
The purge solenoid is timed to the throttle position and is dis-
abled during startup, low engine temperature, low engine speed
or low vehicle speed. Power for the purge solenoid is supplied
by the system relay. The system relay also provides power for
the VSS, fuel pump and the ignition coil. The ECM provides a
path to ground to trigger the purge solenoid.
NOTES
• System fuse and system relay failures or wiring harness
problems will cause 12V power to be lost to the VSS,
ignition coils, fuel pump and purge solenoid.
• Purge solenoid is not installed on non-California vehicles
and DTCs P0444 and P0445 are not available. If these
Figure 6-15. [95] Purge Solenoid (Under seat)
DTCs appear, the ECM is improperly programmed and
should be reprogrammed.
Connector Information
Table 6-36. Code Description
For additional information about the connectors in the following
DTC DESCRIPTION diagram(s) and diagnostic procedure(s), including the color of
P0444 Purge solenoid open/low the harness test kit terminal probes, see B.1 CONNECTORS.

P0445 Purge solenoid high

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em00702
Fuel Pump
[141A] B D
Assembly In Tank
Front ACR Rear ACR
(If Equipped) (If Equipped)
[141B] B D [141B] B D

O/GY
O/GY
[203AF] 2 1 2 1 [203AR]

BK
BK
[203BF] 2 1 2 1 [203BR]
Fuel Tank [13B] 1 4 [20A] 14 15

V/GY

V/GY
Y/GN

Y/GN
Harness [13A] 1 4 [20B] 14 15

O/GY
O/GY

BK
EXCEPT BK FLHR/C TGS
O/GY

BK
FLHR/C ET

V/GY

Y/GN
Sensor
4B TCA [224A] 6 5 4 3 21
Fuel [224B] 6 5 4 3 21
Pump [90A] A B
Fuse

GY
BN
BE
BK
R
V
[211A] 1 2 3 4 5 6 [90B] A B TMAP
15A
4A [211B] 1 2 3 4 5 6 Sensor

BK/W
[204A]

PK/Y
6 5 4 3 21
Y/GN

System
BK/W

BN/O
BK/O
BN/R

BN/V
BK/PK
[204B] 6 5 4 3 2 1
[80A] 1 2 3 4
Relay

BK/W
BN/O

BK/GY
BE/GN

R/W
87 5 4C [80B]

V/Y
Y/GN 1 2 3 4
30 3 3D BE/GY

R/W
V/W
BK/GY
LGN/Y
86
85 To 15A
ECM Fuse
Ignition Coil [83A] [83B]
Power A A Y/GN
Ion Sense B B GY/BE
Coil Rear C C Y/BE
Coil Front D D BE/O
[65B] [65A]
[84A] [84B]
BN/O A A
Front Fuel A A Y/GN W/GN B B VSS
Injector B B W/Y
BK/Y C C
[85A] [85B]

Rear Fuel A A Y/GN BK/BN 4

Injector B B GN/GY
PK/O 3 Front
[95A] [95B] GN/W 2 HO2S
Y/GN 1
B B GY/Y
A A Y/GN [138A]
Purge Solenoid
(Optional)
BK/BN 4
Rear
PK/GN 3
To 15A 2
HO2S
GN/W
Exhaust Y/GN 1 (BK)
Control Fuse
[137A]

1 LGN/R
Active 2 BK
Exhaust 3 V/O
(HDI Only) 4 V/BE
BK
R

[179B]
GN/GY

PK/GN

BE/GN

BK/GN
GY/BE

BK/GY
BK/BN
LGN/Y
BK/PK
GN/W

W/GN

BK/W
BN/O

Y/GN
V/GY
GY/Y

BK/O

BN/R

BE/O

PK/O
BN/V
V/BE

PK/Y

Y/BE

BK/Y

R/W
V/W

W/Y
V/O

V/Y

BK

2 1 [79A]
R

Right
[78B] 19 20 21 2324 28 29 30 3133 363738 39 4043 46 484950 51 52 53 54 59 61 62 63 64 66 68 73 GND 2 2 1 [79B]
[78A] 19 20 21 2324 28 29 30 3133 363738 39 4043 46 484950 51 52 53 54 59 61 62 63 64 66 68 73
HO2S Return
Purge Solenoid
Exhaust Actuator
Rear Fuel Injector
TMAP Sensor Input

Throttle Actuator Control HI

Throttle Actuator Control LO
O2 Heater Ground
Ion Sense
TPS 2
TPS 1

TGS 2

CKP Sensor
Rear HO2 Sensor

ET Sensor

Rear Ignition Coil

TGS 1
5V Sensor Ground 1
5V Sensor Ground 2
CKP Sensor (+)

Ground
ACR Ground

Front Fuel Injector

Front Ignition Coil

Front HO2 Sensor

Exhaust Feedback

5V Sensor Power 1

12V Power

5V Sensor Power 2
Vehicle Speed Input

Vehicle Speed Ground

IAT Sensor

CKP
Sensor
ECM

Figure 6-16. EFI Simplified Schematic

2011 Touring Diagnostics: Engine Management 6-37

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DTC P0444 4. Purge Solenoid Control Wire Open Test

PART NUMBER TOOL NAME 1. Connect BREAKOUT BOX (Part No. HD-48637) to wire
harness [78B], leaving ECM [78A] disconnected. See
HD-41404-C HARNESS CONNECTOR TEST KIT 1.2 DIAGNOSTIC TOOLS.
HD-48637 BREAKOUT BOX
2. Test continuity between purge solenoid [95B] terminal B
(GY/Y) and breakout box terminal 20.
Table 6-37. DTC P0444 Diagnostic Faults
3. Is continuity present?
POSSIBLE CAUSES a. Yes. If ECM connections are good, replace ECM. See
Purge solenoid malfunction the service manual.
ECM malfunction b. No. Repair open in (GY/Y) wire.
Short to ground in signal circuit
DTC P0445
1. Purge Solenoid Test PART NUMBER TOOL NAME
1. With IGN OFF, disconnect purge solenoid [95]. HD-41404-C HARNESS CONNECTOR TEST KIT
2. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
41404-C) and a multimeter, measure resistance between Table 6-38. DTC P0445 Diagnostic Faults
purge solenoid [95A] terminals A and B.
POSSIBLE CAUSES
3. Is resistance between 4-21 Ohms?
Purge solenoid malfunction
a. Yes. Go to Test 2.
ECM malfunction
b. No. Replace purge solenoid. See the service manual.
Short to voltage in signal circuit
2. Purge Solenoid Voltage Test
1. Purge Solenoid Test
1. Connect a multimeter to purge solenoid [95B] terminal A
and ground. 1. Disconnect purge solenoid [95].

2. With the engine stop switch in RUN and while observing 2. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
the multimeter, turn the IGN ON. 41404-C) and a multimeter, measure resistance between
purge solenoid [95A] terminals A and B.
3. Is battery voltage present on multimeter for approximately
two seconds after IGN ON? 3. Is resistance between 4-21 Ohms?

a. Yes. Go to Test 3. a. Yes. Go to Test 2.

b. No. Repair open (Y/GN) wire. b. No. Replace purge solenoid. See the service manual.

3. Purge Solenoid Control Wire Shorted to 2. Purge Solenoid Short to Voltage Test
Ground Test 1. Place transmission in neutral, IGN ON and set engine stop
switch to RUN.
1. Turn IGN OFF and leave engine stop switch in RUN.
2. Measure voltage between purge solenoid [95B] terminal
2. Disconnect ECM [78]. B (GY/Y) and ground.
3. Test for continuity between purge solenoid [95B] terminal 3. Is battery voltage present on multimeter?
B (GY/Y) and ground.
a. Yes. Repair short to voltage on (GY/Y) wire.
4. Is continuity present?
b. No. If ECM connections are good, replace ECM. See
a. Yes. Repair short to ground on (GY/Y) wire. the service manual.
b. No. Go to Test 4.

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DTC P0501, P0502 6.11

DESCRIPTION AND OPERATION
ed03010
See Figure 6-17. The VSS is powered and monitored by the
ECM. The ECM processes the vehicle speed signal and
transmits this signal to the TSM/TSSM/HFSM and speedometer
through serial data circuit.
NOTE
When the vehicle speed is greater than 0, the closed loop idle
speed control is inhibited.

Table 6-39. Code Description

DTC DESCRIPTION
P0501 VSS low
P0502 VSS high

Figure 6-17. VSS Location (Under Starter)

Connector Information
For additional information about the connectors in the following
diagram(s) and diagnostic procedure(s), including the color of
the harness test kit terminal probes, see B.1 CONNECTORS.

2011 Touring Diagnostics: Engine Management 6-39

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em00702
Fuel Pump
[141A] B D
Assembly In Tank
Front ACR Rear ACR
(If Equipped) (If Equipped)
[141B] B D [141B] B D

O/GY
O/GY
[203AF] 2 1 2 1 [203AR]

BK
BK
[203BF] 2 1 2 1 [203BR]
Fuel Tank [13B] 1 4 [20A] 14 15

V/GY

V/GY
Y/GN

Y/GN
Harness [13A] 1 4 [20B] 14 15

O/GY
O/GY

BK
BK

EXCEPT FLHR/C TGS

O/GY

BK

FLHR/C ET

V/GY

Y/GN
Sensor
4B TCA [224A] 6 5 4 3 21
Fuel [224B] 6 5 4 3 21
Pump [90A] A B
Fuse

GY
BN
BE
BK
R
V
[211A] 1 2 3 4 5 6 [90B] A B TMAP
15A
4A [211B] 1 2 3 4 5 6 Sensor

BK/W
[204A]

PK/Y
6 5 4 3 21
Y/GN

System
BK/W

BN/O
BK/O
BN/R

BN/V
BK/PK

[204B] 6 5 4 3 2 1
[80A] 1 2 3 4
Relay

BK/W
BN/O

BK/GY
BE/GN

R/W
87 5 4C [80B]

V/Y
Y/GN 1 2 3 4
30 3 3D BE/GY

R/W
V/W
BK/GY
LGN/Y
86
85 To 15A
ECM Fuse
Ignition Coil [83A] [83B]
Power A A Y/GN
Ion Sense B B GY/BE
Coil Rear C C Y/BE
Coil Front D D BE/O
[65B] [65A]
[84A] [84B]
BN/O A A
Front Fuel A A Y/GN W/GN B B VSS
Injector B B W/Y
BK/Y C C
[85A] [85B]

Rear Fuel A A Y/GN BK/BN 4

Injector B B GN/GY
PK/O 3 Front
[95A] [95B] GN/W 2 HO2S
Y/GN 1
B B GY/Y
A A Y/GN [138A]
Purge Solenoid
(Optional)
BK/BN 4
Rear
PK/GN 3
To 15A 2
HO2S
GN/W
Exhaust Y/GN 1 (BK)
Control Fuse
[137A]

1 LGN/R
Active 2 BK
Exhaust 3 V/O
(HDI Only) 4 V/BE
BK
R

[179B]
GN/GY

PK/GN

BE/GN

BK/GN
GY/BE

BK/GY
BK/BN
LGN/Y
BK/PK
GN/W

W/GN

BK/W
BN/O

Y/GN
V/GY
GY/Y

BK/O

BN/R

BE/O

PK/O
BN/V
V/BE

PK/Y

Y/BE

BK/Y

R/W
V/W

W/Y
V/O

V/Y

BK

2 1 [79A]
R

Right
[78B] 19 20 21 2324 28 29 30 3133 363738 39 4043 46 484950 51 52 53 54 59 61 62 63 64 66 68 73 GND 2 2 1 [79B]
[78A] 19 20 21 2324 28 29 30 3133 363738 39 4043 46 484950 51 52 53 54 59 61 62 63 64 66 68 73
HO2S Return
Purge Solenoid
Exhaust Actuator
Rear Fuel Injector
TMAP Sensor Input

Throttle Actuator Control HI

Throttle Actuator Control LO
O2 Heater Ground
Ion Sense
TPS 2
TPS 1

TGS 2

CKP Sensor
Rear HO2 Sensor

ET Sensor

Rear Ignition Coil

TGS 1
5V Sensor Ground 1
5V Sensor Ground 2
CKP Sensor (+)

Ground
ACR Ground

Front Fuel Injector

Front Ignition Coil

Front HO2 Sensor

Exhaust Feedback

5V Sensor Power 1

12V Power

5V Sensor Power 2
Vehicle Speed Input

Vehicle Speed Ground

IAT Sensor

CKP
Sensor
ECM

Figure 6-18. EFI Simplified Schematic

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DTC P0501 5. VSS Dirty or Damaged Test

PART NUMBER TOOL NAME 1. Remove VSS.

HD-41404-C HARNESS CONNECTOR TEST KIT 2. Check for debris on the sensor tip.
HD-48637 BREAKOUT BOX 3. Is debris present?
a. Yes. Clean debris from VSS and install.
Table 6-40. DTC P0501 Diagnostic Faults b. No. If VSS connections are good, replace VSS. See
POSSIBLE CAUSES the service manual.

VSS malfunction DTC P0502

ECM malfunction
PART NUMBER TOOL NAME
Open or short to ground in signal circuit
HD-41404-C HARNESS CONNECTOR TEST KIT
Open or short to ground in 5V reference circuit
HD-48637 BREAKOUT BOX
1. VSS Connections Test
1. With IGN OFF, disconnect VSS [65]. Table 6-41. DTC P0502 Diagnostic Faults

2. Inspect VSS [65] for damaged terminals, backed out or POSSIBLE CAUSES
bent terminals. Repair as necessary. VSS malfunction
3. Place transmission in neutral, turn IGN ON and engine ECM malfunction
stop switch to RUN.
Short to voltage in signal circuit
4. Using HARNESS CONNECTOR TEST KIT (Part No. HD- Open ground
41404-C) and a multimeter, measure voltage between
VSS [65B] terminal 1 and ground. 5V reference shorted to battery voltage

5. Is voltage reading approximately 5.0V? 1. VSS Sensor Power Shorted to Voltage

a. Yes. Go to Test 3. Test
b. No. Go to Test 2. 1. With IGN OFF, disconnect VSS [65].
2. Inspect VSS [65] for damaged, terminals backed out or
2. VSS Sensor Power Short to Ground Test
bent terminals. Repair as necessary.
1. Turn IGN OFF.
3. Place transmission in neutral, turn IGN ON and engine
2. Disconnect ECM [78]. stop switch to RUN.
3. Test continuity between VSS [65B] terminal 1 and ground. 4. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
41404-C) and a multimeter, measure voltage between
4. Is continuity present?
VSS [65B] terminals 1 (BN/O) and 3 (BK/Y).
a. Yes. Repair short to ground on (BN/O) wire.
5. Is voltage greater than 6.0V?
b. No. Repair open on (BN/O) wire.
a. Yes. Repair short to voltage on (BN/O) wire.
3. VSS Signal Wire Short to Ground Test b. No. Go to Test 2.
1. Connect BREAKOUT BOX (Part No. HD-48637) to wire
harness [78B], leaving ECM [78A] disconnected. See 2. VSS Signal Wire Short to Voltage Test
1.2 DIAGNOSTIC TOOLS. 1. Measure voltage between VSS [65B] terminal 2 (W/GN)
and ground.
2. Test for continuity between breakout box terminals 40 and
73. 2. Is voltage above 6.0V?
3. Is continuity present? a. Yes. Repair short to voltage on (W/GN) wire.
a. Yes. Repair short to ground on (W/GN) wire. b. No. Go to Test 3.
b. No. Go to Test 4.
3. VSS Ground Wire Open Test
4. VSS Signal Wire Open Test 1. Test continuity between breakout box terminal 64 and VSS
[65B] terminal 3 (BK/Y).
1. Test for continuity between breakout box terminals 40 and
VSS [65B] terminal 2. 2. Is continuity present?
2. Is continuity present? a. Yes. Go to Test 4.
a. Yes. Go to Test 5. b. No. Repair open on (BK/Y) wire.
b. No. Repair open on (W/GN) wire.

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4.VSS Signal Wire Shorted to Sensor Power 5. VSS Test

Test 1. Connect ECM [78A] to breakout box.
1. With IGN OFF, connect BREAKOUT BOX (Part No. HD- 2. Verify the VSS [65] is disconnected.
48637) to wire harness [78B], leaving ECM [78A] discon-
nected. See 1.2 DIAGNOSTIC TOOLS. 3. Clear the DTC. See 2.1 INITIAL DIAGNOSTICS, Odometer
Self-Diagnostics.
2. Test continuity between breakout box terminals 40 and
50. 4. Did the DTC P0502 return?
a. Yes. Replace the ECM. See the service manual.
3. Is continuity present?
a. Yes. Repair short between (W/GN) and (BN/O) wires. b. No. Replace the VSS. See the service manual.

b. No. Go to Test 5.

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DTC P0505 6.12

LOSS OF IDLE SPEED CONTROL
ed01275
The throttle control actuator uses a two wire DC motor to move
the throttle plate from the spring loaded off-idle detent. The
ECM supplies a pulse width modulated voltage signal through
[78B] terminals 29 and 30. The ECM monitors throttle position
through the dual position sensors (TPS1 and TPS2).This code
will set if the throttle actuation faults cause the idle to become
unstable. This can be caused by a loose TPS, throttle actuator
friction or an intermittent air leak.
NOTE
Although the ECM monitors terminals 29 and 30, faults on
these terminals will not cause this DTC. Faults on these ter-
minals will be higher priority DTCs, address them first.

Figure 6-19. Throttle Control Connector [211]

Connector Information
For additional information about the connectors in the following
diagram(s) and diagnostic procedure(s), including the color of
the harness test kit terminal probes, see B.1 CONNECTORS.

2011 Touring Diagnostics: Engine Management 6-43

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em00700
TGS

[224A] 6 5 4 3 2 1
[224B] 6 5 4 3 2 1

TCA
TMAP Sensor

GY
BN
BE
BK
R
V
[211A] 6 5 4 3 2 1 [204A] 6 5 4 3 2 1 [80A] 1 2 3 4
[211B] 6 5 4 3 2 1 [204B] 6 5 4 3 2 1 [80B] 1 2 3 4

BN/O
BN/V

BN/O
BK/O

BK/W

R/W
BN/R

BK/W
BK/PK

BE/GN

BK/GY
V/Y

R/W
V/W
BK/GY
LGN/Y
[78A] [78B]
ECM
TMAP Sensor Input 24 24 V/W
Throttle Actuator Control HI 29 29 BK/O
Throttle Actuator Control LO 30 30 BK/PK
TPS-2 36 36 BN/R [90B] [90A]
TPS-1 37 37 BN/V
TGS-2 39 39 V/Y
PK/Y A A
Vehicle Speed Input 40 40 W/GN
BK/W B B
IAT 49 49 LGN/Y
5V Sensor Power-1 50 50 BN/O ET Sensor
ET Sensor 51 51 PK/Y
JSS 56 56 GN/BN [65B] [65A]
TGS-1 59 59 BE/GN
5V Sensor Ground-1 61 61 BK/W A A
BN/O
5V Sensor Ground-2 62 62 BK/GY W/GN B B VSS
Vehicle Speed Ground 64 64 BK/Y BK/Y C C
5V Sensor Power-2 68 68 R/W
Ground 73 73 BK/GN

GN/BN
BK/GN
BN/O
Right [133B] 1 2 3
GND 2 JSS
(HDI only)

Figure 6-20. Throttle Control Actuator Circuit

DTC P0505 2. Is fuel quality and level acceptable?

a. Yes. Go to Test 2.
Table 6-42. DTC P0505 Diagnostic Faults b. No. Flush the fuel system and fill fuel tank.
POSSIBLE CAUSES
2. Vacuum Leak Test
TCA malfunction
1. Start the motorcycle and check for vacuum leaks.
Vacuum/air leaks
2. Were any leaks found?
Fuel system problems
a. Yes. Repair the vacuum leak.
1. Fuel Quality Test b. No. Replace the TCA. See the service manual.
1. Verify there is sufficient supply of fresh fuel in the fuel tank.

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DTC P0572 6.13

DESCRIPTION AND OPERATION
Brake Switch
There are two stop lamp switches. The front stop lamp switch
is a mechanical switch located on the right hand controls. The
rear stop lamp switch is a pressure switch located in the brake
line under the exhaust pipes.
During an ignition cycle, the ECM must receive a valid brake
switch input. During the same ignition cycle the vehicle has to
reach 31 mph (50 km/h) in third gear or higher and return to a
stop three times without any brake switch signals in order to
set DTC P0572.
Table 6-43. Code Description

On vehicles not equipped with ABS, when the stop lamp DTC DESCRIPTION
switches are closed they supply power to the coil side of the P0572 Brake switch input error
brake relay. This energizes the brake relay and supplies power
to the stop lamp. The stop lamp switches also supply an input Diagnostic Tips
to the ECM.
The accessory circuit supplies power to the stop lamp switches
On vehicles equipped with ABS, when the stop lamp switches and horn switch. A short to ground on the switch circuits will
are closed each switch supplies a separate input to the ABS cause the accessory fuse to open only when the switch is
module. Power is also supplied through the ABS diode pack applied. This includes a short in the ABS diode pack on ABS
to the ECM (as a brake input) and to the brake relay. The brake equipped vehicles.
relay energizes and supplies power to the stop lamps.

To
em00698
O/W Accessory
Fuse
3A 5 87

2B 3 30
O/W 5 5 O/W 1 86
R/BE 2A
BK 3B 2 85

Right Turn Except [1B] [1A] Brake Relay

Switch FLHR/C
[22A] [22B]
R/BE 1 1 R/BE
Rear
Front Stop O/W 1 1 O/W O/W 2 2 Stop
Lamp Switch R/Y 2 2 R/BE [2B] [2A] R/BE R/BE 1 1 Lamp
3 3
Switch
[121B] [121A]

O/W
FLHR/C R/BE
R/BE

[78B] 25
[78A] 25
Brake Switch

ECM

Figure 6-21. Brake Switches Schematic without ABS

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em00673
ABS Module
[64-1]
1C

ACCY

Front Brake Input

Rear Brake Input

Fuse
15A
1D
FLHR
O/W

[166A] 13 3 [22B]
See Figures
B-15, B-17 [166B] 13 3
O/W 1

R/BN

PK/BN
O/W

R/BN 2

O/W O/W O/W 1 O/W

[1A] [1B]
2 R/Y
R/BN
PK/BN
O/W

O/W 5 5 O/W 1

PK/BN
R/BN
R/BE

R/BE
Front
[22A] Stop Lamp
[121-2B] 1 1 [121-1B] R/BN 1 1 R/BE 2
Switch
[121-2A] 1 1 [121-1A] 4 3 2 1 [201B]
ABS 4 3 2 1 [201A] [2B] [2A] [22B]
Rear Diode
Stop Lamp Pack
Pressure Switch Except FLHR
Switch
R/BE

See Figures [78B] [78A]

B-15, B-17 ECM
R/BE 25 25 Brake Switch Input

87 5 3A O/V

30 3 2B R/Y R/Y
86 1 2A R/BE See Figure B-22
85 2 3B BK BK
[64-2] Brake Relay

Left GND 1

Figure 6-22. Brake Switches Schematic

DTC P0572 1. Stop Lamp Switch Validation Test

PART NUMBER TOOL NAME 1. Apply the front and rear brakes independently of each
other.
HD-41404-C HARNESS CONNECTOR TEST KIT
2. Does the stop lamp illuminate with either brake applied?
HD-48637 BREAKOUT BOX
a. Yes. Go to Test 2.

Table 6-44. DTC P0572 Diagnostic Faults b. No, it only illuminates when the front brake is
applied. Go to Test 4.
POSSIBLE CAUSES
c. No, it only illuminates when the rear brake is
Open in accessory circuit applied. Go to Test 8.
Stop lamp switch malfunction
d. No, it does not illuminate at all. Go to Test 3.
Open in stop lamp switch circuit
ABS diode pack malfunction 2. Brake Input Circuit Test
Open in brake switch input circuit 1. With IGN OFF, connect BREAKOUT BOX (Part No. HD-
48637) between wire harness [78B] and ECM [78A]. See
1.2 DIAGNOSTIC TOOLS.

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2. With IGN ON and the brake applied, using a multimeter, 3. Test for continuity between breakout box terminal 25 and
test for voltage between breakout box terminal 25 and ABS diode [201B] terminal 4.
ground.
4. Is continuity present?
3. Is battery voltage present? a. Yes. Replace ABS diode pack. See the service
a. Yes. Replace the ECM. See the service manual. manual.
b. No. Repair open in (R/BE) wire. b. No. Repair open in (R/BE) wire.

3. Accessory Circuit Test 8. Front Stop Lamp Switch Circuit Test

1. Inspect the accessory fuse. 1. Disconnect right hand controls [22].
2. Is the fuse good? 2. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
a. Yes. Repair open in (O/W) wire. 41404-C) and a multimeter, with IGN ON, test for voltage
between [22B] terminal 1 and ground.
b. No. Repair short to ground in accessory circuit. See
diagnostic tips. Replace the accessory fuse. 3. Is battery voltage present?
a. Yes. Go to Test 9.
4. Rear Stop Lamp Switch Circuit Test b. No. Repair open in (O/W) wire.
1. Disconnect rear stop lamp switch [121].
2. With IGN ON, using HARNESS CONNECTOR TEST
9. Front Stop Lamp Switch Test
KIT (Part No. HD-41404-C) and a multimeter, test for 1. Jumper [22B] terminal 1 to terminal 2.
voltage between rear stop lamp switch [121-2B] and
2. Turn IGN ON.
ground.
3. Does the stop lamp illuminate?
3. Is battery voltage present?
a. Yes. Replace the front stop lamp switch. See the
a. Yes. Go to Test 5.
service manual.
b. No. Repair open in (O/W) wire.
b. No. Without ABS. Repair open in (R/BE) wire.
5. Rear Stop Lamp Switch Test c. No. With ABS. Go to Test 10.
1. Jumper rear stop lamp switch [121-1B] to [121-2B].
10. ABS Diode Pack Test
2. Turn IGN ON.
1. Disconnect ABS diode [201].
3. Does the stop lamp illuminate?
2. Test for voltage at ABS diode [201B] terminal 2.
a. Yes. Replace the rear stop lamp switch. See the
service manual. 3. Is battery voltage present?
a. Yes. Go to Test 11.
b. No. Without ABS. Repair open in (R/BE) wire.
b. No. Repair open in (PK/BN) wire.
c. No. With ABS. Go to Test 6.

6. ABS Diode Pack Test 11. ECM Circuit Test

1. Turn IGN OFF.
1. Disconnect ABS diode [201].
2. Connect BREAKOUT BOX (Part No. HD-48637) between
2. Test for voltage at ABS diode [201B] terminal 1.
wire harness [78B] and ECM [78A], leaving [78A] discon-
3. Is battery voltage present? nected. See 1.2 DIAGNOSTIC TOOLS.
a. Yes. Go to Test 7. 3. Test for continuity between breakout box terminal 25 and
b. No. Repair open in (PK/BN) wire. ABS diode [201B] terminal 3.
4. Is continuity present?
7. ECM Circuit Test a. Yes. Replace ABS diode pack. See the service
1. Turn IGN OFF. manual.
2. Connect BREAKOUT BOX (Part No. HD-48637) between b. No. Repair open in (R/BE) wire.
wire harness [78B] and ECM [78A], leaving [78A] discon-
nected. See 1.2 DIAGNOSTIC TOOLS.

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DTC P0603, P0605 6.14

DESCRIPTION AND OPERATION NOTE
After replacing ECM, perform password learning procedure
See Figure 6-23. The DTCs listed indicate a failure which
and clear DTCs using odometer self-diagnostics. See 2.1 INI-
requires replacement of the ECM. See the service manual for
TIAL DIAGNOSTICS, Odometer Self-Diagnostics.
replacement information. Refer to Table 6-45.

ed01820

1 3

2 9

1. Tail light connector [7]: except FLHX, FLTRX

2. Console pod [53]
3. Positive battery terminal
4. Hands-free antenna connector [209]
5. Fuel pump subharness connector [13]
6. Purge solenoid [95]
7. P&A accessory connector [4]
8. Negative battery terminal
9. ECM [78]
Figure 6-23. Electrical Connectors Under Seat

2. Replace ECM if DTCs reappear. See the service manual.

Table 6-45. Code Description
DTC P0605 Test
DTC DESCRIPTION
1. Clear DTCs using odometer self-diagnostics. See
P0603 ECM EEPROM error 2.1 INITIAL DIAGNOSTICS, Odometer Self-Diagnostics.
P0605 ECM flash error
2. Attempt to program ECM using correct calibration.
DTC P0603 Test 3. Restart vehicle. If DTC reappears, replace ECM. See the
1. Clear DTCs using odometer self-diagnostics. See service manual.
2.1 INITIAL DIAGNOSTICS, Odometer Self-Diagnostics.

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DTC P0641, P0651 6.15

DESCRIPTION AND OPERATION VSS, jiffy stand sensor and sensor 2 of the TGS with a 5V
reference signal.
See Figure 6-24. The ECM controls 5V power from terminal
50 for sensor power-1 and terminal 68 for sensor power-2. The • DTC P0651 is displayed when sensor power-2 is out of
ECM provides a common ground point for components through range. The 5V sensor power-2 circuit supplies the TMAP
terminal 61 for sensor power-1 and terminal 62 for sensor sensor and sensor 1 of the TGS with a 5V reference signal.
power-2. The ECM monitors voltage on the 5V reference cir-
cuits and sets the DTCs below if the voltage goes out of range. Table 6-46. Code Description
Refer to Table 6-46.
DTC DESCRIPTION
• DTC P0641 is displayed when sensor voltage 1 is out of
P0641 5V reference-1 out of range
range. The 5V sensor power-1 circuit supplies the TCA,
P0651 5V reference-2 out of range

em00700
TGS

[224A] 6 5 4 3 2 1
[224B] 6 5 4 3 2 1

TCA
TMAP Sensor

GY
BN
BE
BK
R
V
[211A] 6 5 4 3 2 1 [204A] 6 5 4 3 2 1 [80A] 1 2 3 4
[211B] 6 5 4 3 2 1 [204B] 6 5 4 3 2 1 [80B] 1 2 3 4
BN/O
BN/V

BN/O
BK/O

BK/W

R/W
BN/R

BK/W
BK/PK

BE/GN

BK/GY
V/Y

R/W
V/W
BK/GY
LGN/Y
[78A] [78B]
ECM
TMAP Sensor Input 24 24 V/W
Throttle Actuator Control HI 29 29 BK/O
Throttle Actuator Control LO 30 30 BK/PK
TPS-2 36 36 BN/R [90B] [90A]
TPS-1 37 37 BN/V
TGS-2 39 39 V/Y
PK/Y A A
Vehicle Speed Input 40 40 W/GN
BK/W B B
IAT 49 49 LGN/Y
5V Sensor Power-1 50 50 BN/O ET Sensor
ET Sensor 51 51 PK/Y
JSS 56 56 GN/BN [65B] [65A]
TGS-1 59 59 BE/GN
5V Sensor Ground-1 61 61 BK/W A A
BN/O
5V Sensor Ground-2 62 62 BK/GY W/GN B B VSS
Vehicle Speed Ground 64 64 BK/Y BK/Y C C
5V Sensor Power-2 68 68 R/W
Ground 73 73 BK/GN
GN/BN
BK/GN
BN/O

Right [133B] 1 2 3
GND 2 JSS
(HDI only)

Figure 6-24. Throttle Control Actuator Circuit

2011 Touring Diagnostics: Engine Management 6-49

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DTC P0641 3. Is resistance greater than 100 Ohms?

a. Yes. Replace the JSS. See the service manual.
PART NUMBER TOOL NAME
b. No. Go to Test 5.
HD-48637 BREAKOUT BOX
5. TGS Test
Table 6-47. DTC P0641 Diagnostic Faults
1. Disconnect the TGS [224].
POSSIBLE CAUSES 2. Measure resistance between breakout box terminal 50
Short to voltage in sensor power-1 circuit and terminal 61.
Short to ground in sensor power-1 circuit 3. Is resistance greater than 100 Ohms?
ECM malfunction a. Yes. Replace the TGS. See the service manual.
TCA malfunction b. No. Go to Test 6.
JSS malfunction
TGS malfunction
6. VSS Test
VSS malfunction 1. Disconnect the VSS [65].
2. Measure resistance between breakout box terminal 50
1. Sensor Power-1 Circuit Test and terminal 61.
1. With IGN OFF, connect BREAKOUT BOX (Part No. HD- 3. Is resistance greater than 100 Ohms?
48637) between wire harness [78B] and ECM [78A]. See
a. Yes. Replace the VSS. See the service manual.
1.2 DIAGNOSTIC TOOLS.
b. No. Repair short to ground in (BN/O) wire.
2. Turn IGN ON.
3. Using a multimeter, test for voltage between breakout box DTC P0651
terminal 50 and terminal 61.
PART NUMBER TOOL NAME
4. Is voltage between 4-6V?
HD-48637 BREAKOUT BOX
a. Yes. Go to Test 2.
b. No. Greater than 6V. Repair short to voltage in Table 6-48. DTC P0651 Diagnostic Faults
(BN/O) wire.
POSSIBLE CAUSES
c. No. Less than 4V. Repair short to ground in (BN/O)
wire. Short to voltage in sensor power-2
Short to ground in sensor power-2
2. Sensor Power-1 Circuit Resistance Test ECM malfunction
1. Measure resistance between breakout box terminal 50
TMAP malfunction
and terminal 61.
TGS malfunction
2. Is resistance greater than 100 Ohms?
a. Yes. Replace the ECM. See the service manual. 1. Sensor Power-2 Circuit Test
b. No. Go to Test 3. 1. With IGN OFF, connect BREAKOUT BOX (Part No. HD-
48637) between wire harness [78B] and ECM [78A]. See
3. TCA Test 1.2 DIAGNOSTIC TOOLS.

1. Disconnect the TCA [211]. 2. Turn IGN ON.

2. Measure resistance between breakout box terminal 50 3. Using a multimeter, test for voltage between breakout box
and terminal 61. terminal 68 and terminal 62.

3. Is resistance greater than 100 Ohms? 4. Is voltage between 4-6V?

a. Yes. Replace the TCA. See the service manual. a. Yes. Go to Test 2.

b. No. Go to Test 4. b. No. Greater than 6V. Repair short to voltage in (R/W)
wire.
4. JSS Test c. No. Less than 4V. Repair short to ground in (R/W)
1. Disconnect the JSS [133]. wire.
2. Measure resistance between breakout box terminal 50
2. Sensor Power-2 Circuit Resistance Test
and terminal 61.
1. Measure resistance between breakout box terminal 68
and terminal 62.

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2. Is resistance greater than 100 Ohms? 4. TGS Test

a. Yes. Replace the ECM. See the service manual. 1. Disconnect the TGS [224].
b. No. Go to Test 3. 2. Measure resistance between breakout box terminal 68
and terminal 62.
3. TMAP Test
3. Is resistance greater than 100 Ohms?
1. Disconnect the TMAP [80].
a. Yes. Replace the TGS. See the service manual.
2. Measure resistance between breakout box terminal 68
and terminal 62. b. No. Repair short to ground in (R/W) wire.

3. Is resistance greater than 100 Ohms?

a. Yes. Replace the TMAP. See the service manual.
b. No. Go to Test 4.

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DTC P1001, P1002, P1003, P1004 6.16

DESCRIPTION AND OPERATION
Table 6-49. Code Description
With IGN ON and the engine stop switch at RUN, the ECM will
energize the system relay to complete the circuit to the in-tank DTC DESCRIPTION
fuel pump, ignition coils and fuel injectors. They will remain P1001 System relay coil open/low
powered as long as the engine is cranking or running, and the
P1002 System relay coil high/shorted
ECM is receiving ignition reference pulses from the CKP
sensor. If there are no reference pulses, the ECM will de- P1003 System relay contacts open
energize the system relay within 2 seconds after ignition is ON P1004 System relay contacts closed
or engine has stalled, or immediately after the ignition is shut
OFF. Connector Information
For additional information about the connectors in the following
diagram(s) and diagnostic procedure(s), including the color of
the harness test kit terminal probes, see B.1 CONNECTORS.

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em00703 Main Fuse

40A

Fuel Pump [5B]

Assembly In Tank B A

R
R
[141A] ECM Fuse

BK
B D
15A
BE/GY 2F 2E

[141B] B D [141B] B D

R
O/GY
O/GY

BK
BK
Battery

[13B] 1 4 [20A] 14 15 [33B] [33A] [222B] [222A]

Ignition
[13A] 1 4 [20B] 14 15 Fuse 1 1 R B B R
Fuel Tank 15A

O/GY
O/GY

R 2 2

BK
BK

R/BK A A R/BK
Harness 1F 1E R/BK 3 3

GY
Ignition
W/BK Switch [33B] A BC
EXCEPT FLHR/C [33A] A BCD
FLHR/C [1A] 3 6
O/GY

BK

[1B] 3 6 1F 1E Ignition
Switch

GY
15A
4B

W/BK
W/BK
Ignition

GY
Fuel Fuse
Pump
Fuse [22B] 3 4 [22B] 3 4

15A [22A] 3 4 [22A] 3 4

4A

W/BK
GY
W/BK
GY

W/BK
W/BK
Y/GN

System
Relay Engine Stop Switch Engine Stop Switch
87 5 4C Y/GN

30 3 3D BE/GY
86 1 3C GN/O
85 2 4D W/BK

Ignition Coil [83A] [83B]

Power A A Y/GN
Ion Sense B B GY/BE
Coil Rear C C Y/BE
Coil Front D D BE/O

BK/BN 4
[84A] [84B] PK/O 3 Front
GN/W 2 HO2S
Front Fuel Y/GN Y/GN 1
A A
Injector B B W/Y

[85A] [85B] [138A]

BK/BN 4
Rear Fuel A A Y/GN PK/GN 3 Rear
Injector B B GN/GY GN/W 2 HO2S
Y/GN 1
[95A] [95B]
[137A]
B B GY/Y
A A Y/GN
Purge Solenoid
(Optional)
GN/GY

PK/GN

BK/GN
GY/BE

BE/GY
BK/BN
GN/W
GN/O

Y/GN

W/BK
GY/Y

BE/O

PK/O
Y/BE
W/Y

Right
[78B] 20 23 27 28 31 33 46 48 52 53 54 66 71 72 73 GND 2
[78A] 20 23 27 28 31 33 46 48 52 53 54 66 71 72 73
Purge Solenoid

Rear Fuel Injector

HO2 Heater Ground

HO2S Return
Front Fuel Injector
System Relay Enable

Rear HO2 Sensor

Ion Sense

Rear Ignition Coil

12V Battery
Front Ignition Coil

12V Stop Switch

12V Power

Front HO2 Sensor

Ground

ECM

Figure 6-25. System Relay Circuit

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DTC P1001 DTC P1002

PART NUMBER TOOL NAME
Table 6-51. DTC P1002 Diagnostic Faults
HD-48637 BREAKOUT BOX
POSSIBLE CAUSES
Table 6-50. DTC P1001 Diagnostic Faults Relay malfunction
Short to voltage in coil control circuit
POSSIBLE CAUSES
ECM malfunction
Relay malfunction
Open in coil supply circuit 1. System Relay Test
Short to ground in coil control circuit 1. Remove the system relay.
ECM malfunction 2. Test the system relay. See 1.3 DIAGNOSTICS AND
Open in coil control circuit TROUBLESHOOTING, Relay Diagnostics.
3. Is the system relay OK?
1. System Relay Test
a. Yes. Go to Test 2.
1. Remove the system relay.
b. No. Replace the system relay. See the service
2. Test the system relay. See 1.3 DIAGNOSTICS AND manual.
TROUBLESHOOTING, Relay Diagnostics.
3. Is the system relay OK? 2. System Relay Coil Short to Voltage Test
a. Yes. Go to Test 2. 1. Test for voltage between [64-1B] socket terminal 3C and
ground.
b. No. Replace the system relay. See the service
manual. 2. Is voltage present?
a. Yes. Repair short to voltage in (GN/O) wire.
2. System Relay Coil Power Circuit Test
b. No. Replace the ECM. See the service manual.
1. With IGN ON and the engine stop switch in RUN, using a
multimeter, test for voltage at [64-1B] socket terminal 4D.
DTC P1003
2. Is battery voltage present?
PART NUMBER TOOL NAME
a. Yes. Go to Test 3.
HD-41404-C HARNESS CONNECTOR TEST KIT
b. No. Repair open in (W/BK) wire.

3. System Relay Coil Control Short to Table 6-52. DTC P1003 Diagnostic Faults

Ground Test POSSIBLE CAUSES

1. With IGN OFF, disconnect the ECM [78]. Relay malfunction

2. Test for continuity from [64-1B] socket terminal 3C to ECM malfunction

ground. Open in switch output circuit
3. Is continuity present? Short to ground in the switch supply circuit
a. Yes. Repair short to ground in (GN/O) wire. Open in switch supply circuit
b. No. Go to Test 4.
1. System Relay Test
4. System Relay Coil Control Circuit Test 1. Remove the system relay.
1. Connect BREAKOUT BOX (Part No. HD-48637) to wire 2. Test the system relay. See 1.3 DIAGNOSTICS AND
harness [78B], leaving ECM [78A] disconnected. See TROUBLESHOOTING, Relay Diagnostics.
1.2 DIAGNOSTIC TOOLS.
3. Is the system relay OK?
2. Test for continuity between [64-1B] socket terminal 3C a. Yes. Go to Test 2.
and breakout box terminal 27.
b. No. Replace the system relay. See the service
3. Is continuity present? manual.
a. Yes. Replace the ECM. See the service manual.
2. System Relay Power Supply Test
b. No. Repair open in (GN/O) wire.
1. Test for voltage between [64-1B] socket terminal 3D and
ground.

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2. Is battery voltage present? 3. Is the system relay OK?

a. Yes. Go to Test 3. a. Yes. Go to Test 2.
b. No. Go to Test 4. b. No. Replace the system relay. See the service
manual.
3. System Relay Switch Side Circuit Test
1. Disconnect the rear fuel injector [85].
2. System Relay Switch Side Short to
Voltage Test
2. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
41404-C) and a multimeter, test for continuity between 1. Using a multimeter, test for voltage on [64-1B] socket ter-
[64-1B] socket terminal 4C and [85B] terminal A. minal 4C.

3. Is continuity present? 2. Is voltage present?

a. Yes. Replace the ECM. See the service manual. a. Yes. Repair short to voltage in (Y/GN) wire.

b. No. Repair open in (Y/GN) wire. b. No. Go to Test 3.

4. System Relay Power Supply Circuit Test 3. System Relay Coil Short to Ground Test
1. Test for continuity between [64-1B] socket terminal 3D 1. Disconnect the ECM [78].
and ground. 2. Test for continuity between [64-1B] socket terminal 3C
2. Is continuity present? and ground.
a. Yes. Repair short to ground in (BE/GY) wire and 3. Is continuity present?
replace ECM fuse. a. Yes. Repair short to ground on (GN/O) wire.
b. No. Repair open in power supply to system relay. b. No. Go to Test 4.
This includes the (BE/GY) wire, ECM fuse and the
(R) wire between the ECM and 40A main fuse. 4. Rear Ignition Coil Short to Voltage Test
DTC P1004 1. Connect BREAKOUT BOX (Part No. HD-48637) to wire
harness [78B], leaving ECM [78A] disconnected. See
PART NUMBER TOOL NAME 1.2 DIAGNOSTIC TOOLS.
HD-48637 BREAKOUT BOX 2. With IGN ON, test for voltage on breakout box terminal
53 to ground.
Table 6-53. DTC P1004 Diagnostic Faults 3. Is voltage present?
POSSIBLE CAUSES a. Yes. Repair short to voltage on (Y/BE) wire.
Relay malfunction b. No. Go to Test 5.
Short to voltage in the switch circuit
5. Front Ignition Coil Short to Voltage Test
Short to ground in coil control circuit
1. With IGN ON, test for voltage on breakout box terminal
Short to voltage rear coil control circuit
54 to ground.
Short to voltage front coil control circuit
2. Is voltage present?
1. System Relay Test a. Yes. Repair short to voltage on (BE/O) wire.
1. Remove the system relay. b. No. Replace the ECM. See the service manual.
2. Test the system relay. See 1.3 DIAGNOSTICS AND
TROUBLESHOOTING, Relay Diagnostics.

2011 Touring Diagnostics: Engine Management 6-55

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DTC P1009, P1010 6.17

DESCRIPTION AND OPERATION
ed03081
Password Problem 1 2
The ECM, TSM/TSSM/HFSM, ABS and speedometer exchange
passwords during operation. An incorrect password or missing 7
password will set a diagnostic code. Refer to Table 2-1.
6
NOTE
If the TSM/TSSM/HFSM is not connected to the wiring harness,
the vehicle will not start. 5
4
Table 6-54. Code Description

DTC DESCRIPTION
3
P1009 Incorrect password
P1010 Missing password 1. Front HO2S [138]
2. ABS module [166] (if equipped)
Connector Information 3. Active exhaust [179]
For additional information about the connectors in the following 4. Rear WSS [168]
diagram(s) and diagnostic procedure(s), including the color of 5. Rear HO2S [137]
the harness test kit terminal probes, see B.1 CONNECTORS. 6. TSM/TSSM/HFSM [30]
7. HFSM antenna jumper harness [208]
Figure 6-26. Under Right Side Cover

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em00701
Radio Speedometer Tachometer Speedometer

Stop Switch
Serial Data
Serial Data

Serial Data

Serial Data
Stop Switch
Engine
Ground
Ground

Battery

Ignition
Battery

Ignition

Ground

Ignition
Battery
Engine
[27A] 9 [39A] 7 5 2 1 [108A] 7 5 2 1
[39A] 7 5 2 1

BK
[27B] 9 [39B] 7 5 2 1 [108B] 7 5 2 1
[39B] 7 5 2 1

BK
[22A] 4

BN/GY

BN/GY
LGN/V

LGN/V

LGN/V
BK/GN

BK/GN
O

BK/GN

BN/GY
LGN/V
O
[22B] 4 [22A] 4

[22B]

W/BK
4

W/BK
[20A] 3 2 1

[20B] 3 2 1

[2A] 4

BN/GY
LGN/V
O
13 6 1 [1A]
[2B] 4
13 6 1 [1B]
BN/GY

W/BK
LGN/V

O
To Instruments
Fuse

Except FLHR/C To Instruments Fuse FLHR/C

To BK
Battery BN/GY To
Fuse GY GY Ignition
Fuse
To ABS To ECM Power Fuse
LGN/V

Fuse
R/V

R/V
BK

BK

BK/GN

BE/GY
LGN/V
W/BK

W/BK
BN/GY

LGN/V

BK/GN 1 9 10 11 20 [166B]
GY

1 9 10 11 20 [166A] 69 71 72 73 [78B]

LGN/V
To BK/GN
Serial Data
ECU/Solenoid Ground

Motor Ground
ECU/ Solenoid Power

Motor Power

1 2 3 12 [30B] [78A]

GY
System 69 71 72 73
1 2 3 12 [30A] Relay

12V Battery
Serial Data

Ground
Engine Stop Switch
4 3 2 [91A]
Battery

Serial Data
Ignition

Ground

DLC

TSM/TSSM/HFSM
ABS (Optional)
ECM

Figure 6-27. Serial Data Circuit

DTC P1009, P1010 2. Does DTC P1009 or P1010 set?

a. Yes. Go to Test 2.
Table 6-55. DTC P1009, P1010 Diagnostic Faults b. No. System okay.
POSSIBLE CAUSES
2. TSM/TSSM/HFSM Replacement Test
ECM malfunction
1. Replace TSM/TSSM/HFSM. See the service manual.
TSM/TSSM/HFSM malfunction
2. Program password. See the service manual.
1. Incorrect Password Test 3. Does DTC P1009 or P1010 set?
1. Program password. See the service manual. a. Yes. Install original TSM/TSSM/HFSM and replace
ECM. See the service manual.
b. No. System okay.

2011 Touring Diagnostics: Engine Management 6-57

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DTC P1270 6.18

DESCRIPTION AND OPERATION NOTE
After replacing the ECM, perform password learning procedure
TGS2 Validation and clear codes.
Within the ECM, there are two independent Analog/Digital (A/D)
converter modules used to validate the input of Twist Grip Table 6-56. Code Description
Sensor 2 (TGS2). TGS2 inputs are sent into both converter
modules and if the output of the two readings are not within DTC DESCRIPTION
the designated value of each other, for a specified time, then P1270 TGS2 validation error
DTC P1270 fault is initiated.
Unless the ECM has a poor or intermittent connection, DTC Connector Information
P1270 indicates the ECM is defective and requires replace- For additional information about the connectors in the following
ment. See the service manual for replacement information. diagram(s) and diagnostic procedure(s), including the color of
the harness test kit terminal probes, see B.1 CONNECTORS.

6-58 2011 Touring Diagnostics: Engine Management

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em00703 Main Fuse

40A

Fuel Pump [5B]

Assembly In Tank B A

R
R
[141A] ECM Fuse

BK
B D
15A
BE/GY 2F 2E

[141B] B D [141B] B D

R
O/GY
O/GY

BK
BK
Battery

[13B] 1 4 [20A] 14 15 [33B] [33A] [222B] [222A]

Ignition
[13A] 1 4 [20B] 14 15 Fuse 1 1 R B B R
Fuel Tank 15A

O/GY
O/GY

R 2 2

BK
BK

R/BK A A R/BK
Harness 1F 1E R/BK 3 3

GY
Ignition
W/BK Switch [33B] A BC
EXCEPT FLHR/C [33A] A BCD
FLHR/C [1A] 3 6
O/GY

BK

[1B] 3 6 1F 1E Ignition
Switch

GY
15A
4B

W/BK
W/BK
Ignition

GY
Fuel Fuse
Pump
Fuse [22B] 3 4 [22B] 3 4

15A [22A] 3 4 [22A] 3 4

4A

W/BK
GY
W/BK
GY

W/BK
W/BK
Y/GN

System
Relay Engine Stop Switch Engine Stop Switch
87 5 4C Y/GN

30 3 3D BE/GY
86 1 3C GN/O
85 2 4D W/BK

Ignition Coil [83A] [83B]

Power A A Y/GN
Ion Sense B B GY/BE
Coil Rear C C Y/BE
Coil Front D D BE/O

BK/BN 4
[84A] [84B] PK/O 3 Front
GN/W 2 HO2S
Front Fuel Y/GN Y/GN 1
A A
Injector B B W/Y

[85A] [85B] [138A]

BK/BN 4
Rear Fuel A A Y/GN PK/GN 3 Rear
Injector B B GN/GY GN/W 2 HO2S
Y/GN 1
[95A] [95B]
[137A]
B B GY/Y
A A Y/GN
Purge Solenoid
(Optional)
GN/GY

PK/GN

BK/GN
GY/BE

BE/GY
BK/BN
GN/W
GN/O

Y/GN

W/BK
GY/Y

BE/O

PK/O
Y/BE
W/Y

Right
[78B] 20 23 27 28 31 33 46 48 52 53 54 66 71 72 73 GND 2
[78A] 20 23 27 28 31 33 46 48 52 53 54 66 71 72 73
Purge Solenoid

Rear Fuel Injector

HO2 Heater Ground

HO2S Return
Front Fuel Injector
System Relay Enable

Rear HO2 Sensor

Ion Sense

Rear Ignition Coil

12V Battery
Front Ignition Coil

12V Stop Switch

12V Power

Front HO2 Sensor

Ground

ECM

Figure 6-28. System Relay Circuit

2011 Touring Diagnostics: Engine Management 6-59

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DTC P1270 2. ECM Circuit Test

PART NUMBER TOOL NAME 1. Connect BREAKOUT BOX (Part No. HD-48637) between
wire harness [78B] and ECM [78A]. See 1.2 DIAGNOSTIC
HD-48637 BREAKOUT BOX TOOLS.
2. Start the engine.
Table 6-57. DTC P1270 Diagnostic Faults
3. Test for voltage between breakout box terminal 52 and
POSSIBLE CAUSES ground.Voltage is not present unless motorcycle is running
ECM malfunction or at IGN ON for 2 seconds.
Open system relay supply circuit 4. Is battery voltage present?
System relay malfunction a. Yes. Replace the ECM. See the service manual.
b. No. Go to Test 3.
1. ECM Connector Test
1. With IGN OFF, disconnect ECM [78] and inspect for 3. Relay Circuit Test
damaged, corroded or pushed out terminals.
1. Test the system relay. See 1.3 DIAGNOSTICS AND
2. Are terminal problems present? TROUBLESHOOTING, Relay Diagnostics.
a. Yes. Repair terminals as required. 2. Is the relay good?
b. No. Go to Test 2. a. Yes. Repair open or high resistance in (Y/GN) wire.
b. No. Replace the system relay.

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DTC P1351, P1352, P1354, P1355 6.19

DESCRIPTION AND OPERATION
ed02980
Ignition coil DTCs will set if the ignition coil primary voltage is
out of range. This could occur if there is an open coil or loss
of power to the coil. If front and rear DTCs are set simultan-
eously, it is likely a coil power failure or a coil failure.
4
The coil receives power from the system relay at the same
time that the fuel pump and injectors are activated.The system 3
relay is active for the first 2 seconds after the ignition switch is
turned ON and then shuts off until rpm is detected from the
CKP sensor, at which time system relay is reactivated. The 2
ECM is responsible for turning on the system relay by providing
the ground to activate the relay, which in turn powers the coil. 1

Table 6-58. Code Description

DTC DESCRIPTION
1. Terminal A: power
P1351 Front ignition coil open/low 2. Terminal B: ion sense
P1352 Front ignition coil high/shorted 3. Terminal C: rear coil
4. Terminal D: front coil
P1354 Rear ignition coil open/low
Figure 6-29. Ignition Coil
P1355 Rear ignition coil high/shorted

Connector Information
For additional information about the connectors in the following
diagram(s) and diagnostic procedure(s), including the color of
the harness test kit terminal probes, see B.1 CONNECTORS.

2011 Touring Diagnostics: Engine Management 6-61

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em00702
Fuel Pump
[141A] B D
Assembly In Tank
Front ACR Rear ACR
(If Equipped) (If Equipped)
[141B] B D [141B] B D

O/GY
O/GY
[203AF] 2 1 2 1 [203AR]

BK
BK
[203BF] 2 1 2 1 [203BR]
Fuel Tank [13B] 1 4 [20A] 14 15

V/GY

V/GY
Y/GN

Y/GN
Harness [13A] 1 4 [20B] 14 15

O/GY
O/GY

BK
BK

EXCEPT FLHR/C TGS

O/GY

BK

FLHR/C ET

V/GY

Y/GN
Sensor
4B TCA [224A] 6 5 4 3 21
Fuel [224B] 6 5 4 3 21
Pump [90A] A B
Fuse

GY
BN
BE
BK
R
V
[211A] 1 2 3 4 5 6 [90B] A B TMAP
15A
4A [211B] 1 2 3 4 5 6 Sensor

BK/W
[204A]

PK/Y
6 5 4 3 21
Y/GN

System
BK/W

BN/O
BK/O
BN/R

BN/V
BK/PK

[204B] 6 5 4 3 2 1
[80A] 1 2 3 4
Relay

BK/W
BN/O

BK/GY
BE/GN

R/W
87 5 4C [80B]

V/Y
Y/GN 1 2 3 4
30 3 3D BE/GY

R/W
V/W
BK/GY
LGN/Y
86
85 To 15A
ECM Fuse
Ignition Coil [83A] [83B]
Power A A Y/GN
Ion Sense B B GY/BE
Coil Rear C C Y/BE
Coil Front D D BE/O
[65B] [65A]
[84A] [84B]
BN/O A A
Front Fuel A A Y/GN W/GN B B VSS
Injector B B W/Y
BK/Y C C
[85A] [85B]

Rear Fuel A A Y/GN BK/BN 4

Injector B B GN/GY
PK/O 3 Front
[95A] [95B] GN/W 2 HO2S
Y/GN 1
B B GY/Y
A A Y/GN [138A]
Purge Solenoid
(Optional)
BK/BN 4
Rear
PK/GN 3
To 15A 2
HO2S
GN/W
Exhaust Y/GN 1 (BK)
Control Fuse
[137A]

1 LGN/R
Active 2 BK
Exhaust 3 V/O
(HDI Only) 4 V/BE
BK
R

[179B]
GN/GY

PK/GN

BE/GN

BK/GN
GY/BE

BK/GY
BK/BN
LGN/Y
BK/PK
GN/W

W/GN

BK/W
BN/O

Y/GN
V/GY
GY/Y

BK/O

BN/R

BE/O

PK/O
BN/V
V/BE

PK/Y

Y/BE

BK/Y

R/W
V/W

W/Y
V/O

V/Y

BK

2 1 [79A]
R

Right
[78B] 19 20 21 2324 28 29 30 3133 363738 39 4043 46 484950 51 52 53 54 59 61 62 63 64 66 68 73 GND 2 2 1 [79B]
[78A] 19 20 21 2324 28 29 30 3133 363738 39 4043 46 484950 51 52 53 54 59 61 62 63 64 66 68 73
HO2S Return
Purge Solenoid
Exhaust Actuator
Rear Fuel Injector
TMAP Sensor Input

Throttle Actuator Control HI

Throttle Actuator Control LO
O2 Heater Ground
Ion Sense
TPS 2
TPS 1

TGS 2

CKP Sensor
Rear HO2 Sensor

ET Sensor

Rear Ignition Coil

TGS 1
5V Sensor Ground 1
5V Sensor Ground 2
CKP Sensor (+)

Ground
ACR Ground

Front Fuel Injector

Front Ignition Coil

Front HO2 Sensor

Exhaust Feedback

5V Sensor Power 1

12V Power

5V Sensor Power 2
Vehicle Speed Input

Vehicle Speed Ground

IAT Sensor

CKP
Sensor
ECM

Figure 6-30. EFI Simplified Schematic

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DTC P1351 4. Ignition Coil Control Wire Shorted to

PART NUMBER TOOL NAME
Ground Test
HD-34730-2D FUEL INJECTOR TEST LIGHT 1. Disconnect ECM [78A] from breakout box.

HD-41404-C HARNESS CONNECTOR TEST KIT 2. Test for continuity between breakout box terminals 54 and
73.
HD-48637 BREAKOUT BOX
3. Is continuity present?
Table 6-59. DTC P1351 Diagnostic Faults a. Yes. Repair short to ground on (BE/O) wire.

POSSIBLE CAUSES b. No. Replace ECM. See the service manual.

Ignition coil malfunction DTC P1352

ECM malfunction
PART NUMBER TOOL NAME
Open or short to ground in signal circuit
HD-41404-C HARNESS CONNECTOR TEST KIT
Open power circuit

1. Ignition Coil Test Table 6-60. DTC P1352 Diagnostic Faults

1. Disconnect ignition coil [83]. Inspect for damaged or POSSIBLE CAUSES
backed out terminals and corrosion. Repair as required.
Front ignition coil malfunction
2. Use HARNESS CONNECTOR TEST KIT (Part No. HD- ECM malfunction
41404-C) to connect FUEL INJECTOR TEST LIGHT (Part
No. HD-34730-2D) into ignition coil harness [83B] terminals Short to voltage in signal circuit
A and D.
1. Ignition Coil Shorted to Voltage Test
3. Turn IGN ON and engine stop switch to RUN.
1. Disconnect ignition coil [83].
4. Does lamp flash when engine is cranked?
2. Turn IGN ON.
a. Yes. Replace ignition coil. See the service manual.
3. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
b. No. Go to Test 2. 41404-C) and a multimeter, measure voltage between
ignition coil [83B] terminal D and ground.
2. Ignition Coil Input Voltage Test
4. Is voltage more than 1.0V?
1. Disconnect the system relay.
a. Yes. Repair short to voltage on (BE/O) wire.
2. Turn IGN ON. Voltage will only be present for 2 seconds
b. No. Go to Test 2.
after ignition is turned on.
3. Test for battery voltage at ignition coil [83B] terminal A to 2. Ignition Coil Open Test
ground.
1. Test resistance between front ignition coil [83A] terminals
4. Is battery voltage present? A and D.
a. Yes. Go to Test 3. 2. Is resistance greater than 4.0 Ohms?
b. No. Repair open (Y/GN) wire between [83B] and a. Yes. If ECM connections are good, replace ECM. See
system relay [64-1B] terminal 4C. the service manual.
b. No. Replace ignition coil. See the service manual.
3. Ignition Coil Control Wire Continuity Test
1. Turn IGN OFF and engine stop switch to RUN.
2. Connect BREAKOUT BOX (Part No. HD-48637) between
wire harness [78B] and ECM [78A]. See 1.2 DIAGNOSTIC
TOOLS.
3. Test for continuity between breakout box terminal 54 and
ignition coil [83B] terminal D (BE/O).
4. Is continuity present?
a. Yes. Go to Test 4.
b. No. Repair open (BE/O) wire.

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DTC P1354 4. Is continuity present?

a. Yes. Go to Test 4.
PART NUMBER TOOL NAME
b. No. Repair open (Y/BE) wire.
HD-34730-2D FUEL INJECTOR TEST LIGHT
HD-41404-C HARNESS CONNECTOR TEST KIT 4. Ignition Coil Control Wire Shorted to
HD-48637 BREAKOUT BOX Ground Test
1. Disconnect ECM [78A] from breakout box.
Table 6-61. DTC P1354 Diagnostic Faults
2. Test for continuity between breakout box terminals 53 and
POSSIBLE CAUSES 73.
Rear ignition coil malfunction 3. Is continuity present?
ECM malfunction a. Yes. Repair short to ground on (Y/BE) wire.
Open or short to ground in signal circuit b. No. Replace ECM. See the service manual.
Open power circuit
DTC P1355
1. Ignition Coil Test
PART NUMBER TOOL NAME
1. Disconnect ignition coil [83]. Inspect for damaged or
HD-41404-C HARNESS CONNECTOR TEST KIT
backed out terminals and corrosion. Repair as required.
2. Turn IGN OFF.
Table 6-62. DTC P1355 Diagnostic Faults
3. Use HARNESS CONNECTOR TEST KIT (Part No. HD-
POSSIBLE CAUSES
41404-C) to connect FUEL INJECTOR TEST LIGHT (Part
No. HD-34730-2D) into ignition coil harness [83B] terminals Rear ignition coil malfunction
A and C. ECM malfunction
4. Turn IGN ON and engine stop switch to RUN. Short to voltage in signal circuit
5. Does lamp flash when engine is cranked?
1. Ignition Coil Shorted to Voltage Test
a. Yes. Replace ignition coil. See the service manual.
1. Disconnect ignition coil [83B].
b. No. Go to Test 2.
2. Turn IGN ON.
2. Ignition Coil Input Continuity Test 3. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
1. Disconnect the system relay. 41404-C), using a multimeter, measure voltage between
ignition coil [83B] terminal C and ground.
2. Test for continuity between system relay [64-1B] socket
terminal 4C and [83B] terminal A. 4. Is voltage more than 1.0V?
a. Yes. Repair short to voltage on (Y/BE) wire.
3. Is continuity present?
a. Yes. Go to Test 3. b. No. Go to Test 2.

b. No. Repair open (Y/GN) wire between [83B] and 2. Ignition Coil Open Test
system relay [64-1B] terminal 4C.
1. Measure resistance between rear ignition coil [83A] ter-
3. Ignition Coil Control Wire Continuity Test minals A and C.

1. Turn IGN OFF and engine stop switch to RUN. 2. Is resistance greater than 4.0 Ohms?
a. Yes. If ECM connections are good, replace ECM. See
2. Connect BREAKOUT BOX (Part No. HD-48637) between
the service manual.
wire harness [78B] and ECM [78A]. See 1.2 DIAGNOSTIC
TOOLS. b. No. Replace ignition coil. See the service manual.
3. Test for continuity between breakout box terminal 53 and
ignition coil [83B] terminal C (Y/BE).

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DTC P1353, P1356, P1357, P1358 6.20

DESCRIPTION AND OPERATION
ed02980
See Figure 6-31. A feedback voltage signal in the secondary
ignition circuit (terminal B) detects the presence of combustion
each time a cylinder fires on ECM terminal 33. For diagnostic
purposes, this signal is only analyzed at high speed and load
4
conditions where it may be easily measured. Failure to detect
combustion at high speed and load means one of following
conditions is true: 3
• Cylinder is truly misfiring.
2
• There is a lack of continuity in the ignition coil secondary
circuit. 1
NOTE
Make sure vehicle is running properly before performing the
tests in this section. Perform fuel pressure tests if required.
1. Terminal A: power
See the service manual. If fuel pressure is not within the proper
2. Terminal B: ion sense
range, see 6.36 FUEL SYSTEM ELECTRICAL TEST.
3. Terminal C: rear coil
4. Terminal D: front coil
Table 6-63. Code Description
Figure 6-31. Ignition Coil
DTC DESCRIPTION
P1353 Front cylinder no combustion
Connector Information
P1356 Rear cylinder no combustion
For additional information about the connectors in the following
P1357 Front cylinder combustion intermittent
diagram(s) and diagnostic procedure(s), including the color of
P1358 Rear cylinder combustion intermittent the harness test kit terminal probes, see B.1 CONNECTORS.

2011 Touring Diagnostics: Engine Management 6-65

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em00703 Main Fuse

40A

Fuel Pump [5B]

Assembly In Tank B A

R
R
[141A] ECM Fuse

BK
B D
15A
BE/GY 2F 2E

[141B] B D [141B] B D

R
O/GY
O/GY

BK
BK

Battery

[13B] 1 4 [20A] 14 15 [33B] [33A] [222B] [222A]

Ignition
[13A] 1 4 [20B] 14 15 Fuse 1 1 R B B R
Fuel Tank 15A
O/GY
O/GY

BK R 2 2
BK

R/BK A A R/BK
Harness 1F 1E R/BK 3 3

GY
Ignition
W/BK Switch [33B] A BC
EXCEPT FLHR/C [33A] A BCD
FLHR/C [1A] 3 6
O/GY

BK

[1B] 3 6 1F 1E Ignition
Switch

GY
15A
4B

W/BK
W/BK
Ignition

GY
Fuel Fuse
Pump
Fuse [22B] 3 4 [22B] 3 4

15A [22A] 3 4 [22A] 3 4

4A

W/BK
GY
W/BK
GY

W/BK
W/BK
Y/GN

System
Relay Engine Stop Switch Engine Stop Switch
87 5 4C Y/GN

30 3 3D BE/GY
86 1 3C GN/O
85 2 4D W/BK

Ignition Coil [83A] [83B]

Power A A Y/GN
Ion Sense B B GY/BE
Coil Rear C C Y/BE
Coil Front D D BE/O

BK/BN 4
[84A] [84B] PK/O 3 Front
GN/W 2 HO2S
Front Fuel Y/GN Y/GN 1
A A
Injector B B W/Y

[85A] [85B] [138A]

BK/BN 4
Rear Fuel A A Y/GN PK/GN 3 Rear
Injector B B GN/GY GN/W 2 HO2S
Y/GN 1
[95A] [95B]
[137A]
B B GY/Y
A A Y/GN
Purge Solenoid
(Optional)
GN/GY

PK/GN

BK/GN
GY/BE

BE/GY
BK/BN
GN/W
GN/O

Y/GN

W/BK
GY/Y

BE/O

PK/O
Y/BE
W/Y

Right
[78B] 20 23 27 28 31 33 46 48 52 53 54 66 71 72 73 GND 2
[78A] 20 23 27 28 31 33 46 48 52 53 54 66 71 72 73
Purge Solenoid

Rear Fuel Injector

HO2 Heater Ground

HO2S Return
Front Fuel Injector
System Relay Enable

Rear HO2 Sensor

Ion Sense

Rear Ignition Coil

12V Battery
Front Ignition Coil

12V Stop Switch

12V Power

Front HO2 Sensor

Ground

ECM

Figure 6-32. System Relay Circuit

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DTC P1353, P1356 2. Is resistance 3500-4500 Ohms?

a. Yes. Replace spark plug. See the service manual.
PART NUMBER TOOL NAME
b. No. Replace the ignition coil. See the service manual.
HD-41404-C HARNESS CONNECTOR TEST KIT
DTC P1357, P1358
Table 6-64. DTC P1353, P1356 Diagnostic Faults
PART NUMBER TOOL NAME
POSSIBLE CAUSES
HD-41404-C HARNESS CONNECTOR TEST KIT
Ignition coil malfunction
HD-48637 BREAKOUT BOX
ECM malfunction
Fuel system problems Table 6-65. DTC P1357, P1358 Diagnostic Faults
Open or short to voltage in signal circuit
POSSIBLE CAUSES
Spark plug wire connections faulty
Ignition coil malfunction
1. Absence of Fuel Test ECM malfunction
1. Verify vehicle has fuel. Fuel system problems

2. Has vehicle run out of fuel recently? Open or short to voltage in signal circuit
a. Yes. Clear DTCs using odometer self-diagnostics. Spark plug wire connections faulty
See 2.1 INITIAL DIAGNOSTICS, Odometer Self-
Diagnostics. Fill with fresh fuel and restart. If code 1. Ion Sense Continuity Test
returns, then continue with tests. Go to Test 2. 1. Connect BREAKOUT BOX (Part No. HD-48637) to wire
b. No. Go to Test 2. harness [78B], leaving ECM [78A] disconnected. See
1.2 DIAGNOSTIC TOOLS.
2. Ignition Coil Primary Resistance Test 2. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
1. Disconnect ignition coil [83]. 41404-C) and a multimeter, test for continuity between
the ignition coil [83B] terminal B and breakout box terminal
2. Using HARNESS CONNECTOR TEST KIT (Part No. HD- 33.
41404-C) and a multimeter, measure resistance between
ignition coil [83A] terminals A and C, and then from ter- 3. Is continuity present?
minals A and D. a. Yes. Replace spark plug. See the service manual. If
condition persists, then continue with tests. Go to
3. Is resistance 0.3-0.5 Ohms?
Test 2.
a. Yes. Go to Test 3.
b. No. Repair open in (GY/BE) wire.
b. No. Replace the ignition coil. See the service manual.
2. Ion Sense Resistance Test
3. Spark Plug Wire Test
1. Measure resistance between ignition coil [83A] terminals
1. Disconnect the spark plug wires. A and B.
2. Measure the resistance of the spark plug wires. 2. Is resistance greater than 100,000 Ohms?
3. Is the front and rear spark plug wire resistance within the a. Yes. Replace ECM. See the service manual.
specified range? Refer to Table 1-6.
b. No. Go to Test 3.
a. Yes. Go to Test 4.
b. No. Replace the out of range spark plug wire. See 3. Ion Sense Short to Voltage Test
the service manual. 1. Connect BREAKOUT BOX (Part No. HD-48637) between
wire harness [78B] and ECM [78A]. See 1.2 DIAGNOSTIC
4. Ignition Coil Secondary Resistance Test TOOLS.
1. Measure resistance between ignition coil [83A] terminal 2. With IGN ON, test for voltage between ignition coil [83B]
A to the front coil secondary. Repeat measurement for the terminal B and breakout box terminal 73.
rear coil secondary.
3. Is voltage present?
a. Yes. Repair short to voltage on (GY/BE) wire.
b. No. Replace ignition coil. See the service manual.

2011 Touring Diagnostics: Engine Management 6-67

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DTC P1475, P1477, P1478 6.21

DESCRIPTION AND OPERATION
ed02981
Active exhaust actuator is included on HDI vehicles only.
The active exhaust actuator system utilizes an actuator valve 1
located in the rear exhaust pipe which is connected to a servo
motor via a cable. The valve position automatically adjusts to
enhance engine performance.

Table 6-66. Code Description

DTC DESCRIPTION
P1475 Exhaust actuator position failure
P1477 Exhaust actuator open/low
P1478 Exhaust actuator high

NOTE 2
The AIS and active exhaust actuator share the same power
source and function simultaneously.

1. Open position
2. Closed position
Figure 6-33. Bellcrank

Connector Information
For additional information about the connectors in the following
diagram(s) and diagnostic procedure(s), including the color of
the harness test kit terminal probes, see B.1 CONNECTORS.

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em00702
Fuel Pump
[141A] B D
Assembly In Tank
Front ACR Rear ACR
(If Equipped) (If Equipped)
[141B] B D [141B] B D

O/GY
O/GY
[203AF] 2 1 2 1 [203AR]

BK
BK
[203BF] 2 1 2 1 [203BR]
Fuel Tank [13B] 1 4 [20A] 14 15

V/GY

V/GY
Y/GN

Y/GN
Harness [13A] 1 4 [20B] 14 15

O/GY
O/GY

BK
EXCEPT BK FLHR/C TGS
O/GY

BK
FLHR/C ET

V/GY

Y/GN
Sensor
4B TCA [224A] 6 5 4 3 21
Fuel [224B] 6 5 4 3 21
Pump [90A] A B
Fuse

GY
BN
BE
BK
R
V
[211A] 1 2 3 4 5 6 [90B] A B TMAP
15A
4A [211B] 1 2 3 4 5 6 Sensor

BK/W
[204A]

PK/Y
6 5 4 3 21
Y/GN

System
BK/W

BN/O
BK/O
BN/R

BN/V
BK/PK
[204B] 6 5 4 3 2 1
[80A] 1 2 3 4
Relay

BK/W
BN/O

BK/GY
BE/GN

R/W
87 5 4C [80B]

V/Y
Y/GN 1 2 3 4
30 3 3D BE/GY

R/W
V/W
BK/GY
LGN/Y
86
85 To 15A
ECM Fuse
Ignition Coil [83A] [83B]
Power A A Y/GN
Ion Sense B B GY/BE
Coil Rear C C Y/BE
Coil Front D D BE/O
[65B] [65A]
[84A] [84B]
BN/O A A
Front Fuel A A Y/GN W/GN B B VSS
Injector B B W/Y
BK/Y C C
[85A] [85B]

Rear Fuel A A Y/GN BK/BN 4

Injector B B GN/GY
PK/O 3 Front
[95A] [95B] GN/W 2 HO2S
Y/GN 1
B B GY/Y
A A Y/GN [138A]
Purge Solenoid
(Optional)
BK/BN 4
Rear
PK/GN 3
To 15A 2
HO2S
GN/W
Exhaust Y/GN 1 (BK)
Control Fuse
[137A]

1 LGN/R
Active 2 BK
Exhaust 3 V/O
(HDI Only) 4 V/BE
BK
R

[179B]
GN/GY

PK/GN

BE/GN

BK/GN
GY/BE

BK/GY
BK/BN
LGN/Y
BK/PK
GN/W

W/GN

BK/W
BN/O

Y/GN
V/GY
GY/Y

BK/O

BN/R

BE/O

PK/O
BN/V
V/BE

PK/Y

Y/BE

BK/Y

R/W
V/W

W/Y
V/O

V/Y

BK

2 1 [79A]
R

Right
[78B] 19 20 21 2324 28 29 30 3133 363738 39 4043 46 484950 51 52 53 54 59 61 62 63 64 66 68 73 GND 2 2 1 [79B]
[78A] 19 20 21 2324 28 29 30 3133 363738 39 4043 46 484950 51 52 53 54 59 61 62 63 64 66 68 73
HO2S Return
Purge Solenoid
Exhaust Actuator
Rear Fuel Injector
TMAP Sensor Input

Throttle Actuator Control HI

Throttle Actuator Control LO
O2 Heater Ground
Ion Sense
TPS 2
TPS 1

TGS 2

CKP Sensor
Rear HO2 Sensor

ET Sensor

Rear Ignition Coil

TGS 1
5V Sensor Ground 1
5V Sensor Ground 2
CKP Sensor (+)

Ground
ACR Ground

Front Fuel Injector

Front Ignition Coil

Front HO2 Sensor

Exhaust Feedback

5V Sensor Power 1

12V Power

5V Sensor Power 2
Vehicle Speed Input

Vehicle Speed Ground

IAT Sensor

CKP
Sensor
ECM

Figure 6-34. EFI Simplified Schematic

2011 Touring Diagnostics: Engine Management 6-69

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DTC P1475 2. Is continuity present?

a. Yes. Go to Test 5.
PART NUMBER TOOL NAME
b. No. Repair open on (LGN/R) wire.
HD-41404-C HARNESS CONNECTOR TEST KIT
HD-48637 BREAKOUT BOX 5. Exhaust Actuator Feedback Voltage Test
1. Turn IGN ON.
Table 6-67. DTC P1475 Diagnostic Faults
2. Measure the voltage between breakout box terminal 38
POSSIBLE CAUSES and terminal 73.
ECM malfunction 3. Is voltage 4.5-5.5V?
Exhaust actuator malfunction a. Yes. Go to Test 6.
Open in ground circuit b. No. Battery voltage. Go to Test 9.
Open in power circuit
c. No. 0V. Go to Test 10.
Open in exhaust feedback circuit
Short to voltage in exhaust feedback circuit 6. Exhaust Actuator Feedback Continuity
Short to ground in exhaust feedback circuit Test
1. Turn IGN OFF, disconnect exhaust actuator [179].
1. Exhaust Actuator Test
2. Using a multimeter, test for continuity between [179B]
1. Connect BREAKOUT BOX (Part No. HD-48637) between terminal 4 and breakout box terminal 38.
wire harness [78B] and ECM [78A]. See 1.2 DIAGNOSTIC
TOOLS. 3. Is continuity present?
a. Yes. Go to Test 7.
2. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
41404-C), jump breakout box terminal 21 to terminal 73. b. No. Repair open wire (V/BE).
3. Turn IGN ON.
7. Exhaust Actuator Feedback Control Test
4. Does actuator activate immediately?
1. Connect the exhaust actuator [179].
a. Yes. Replace ECM. See the service manual.
2. Turn IGN ON and engine stop switch to RUN.
b. No. Check exhaust control fuse. If fuse is okay, then
continue with tests. Go to Test 2. 3. Measure the voltage between breakout box terminal 38
and terminal 73.
2. Exhaust Actuator Voltage Test 4. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
1. Disconnect exhaust actuator [179]. 41404-C), jump between breakout box terminals 21 and
73 several times.
2. With IGN ON, measure the voltage between [179B] ter-
minals 1 and 2. 5. Does the voltage change to less than 1.0V and the exhaust
actuator valve open each time?
3. Is battery voltage present?
a. Yes. Go to Test 8.
a. Yes. Check the cable and bellcrank assembly from
exhaust actuator to exhaust valve for proper opera- b. No. Replace active exhaust actuator. See the service
tion. See the service manual. manual.

b. No. Go to Test 3. 8. Exhaust Actuator Feedback Run Test

3. Exhaust Actuator Motor Ground Wire 1. Clear DTCs using odometer self-diagnostics. See
2.1 INITIAL DIAGNOSTICS, Odometer Self-Diagnostics.
Continuity Test Start the engine.
1. Turn IGN OFF.
2. Run the engine in neutral between 1500-2500 rpm.
2. Test for continuity between active exhaust actuator [179B]
3. Does the exhaust valve open at 1600 rpm or less and
terminal 2 and ground.
close at 1800 or more?
3. Is continuity present? a. Yes. System okay.
a. Yes. Go to Test 4.
b. No. Check connectors for damaged, pushed out or
b. No. Repair open on (BK) wire. corroded pins. If no problems are found, replace ECM.
See the service manual.
4. Exhaust Actuator Motor Power Wire
Continuity Test 9. Exhaust Actuator Feedback Short to
1. With IGN OFF, test for continuity between active exhaust
Voltage Test
actuator [179B] terminal 1 and [64-1B] socket terminal 3B. 1. With IGN OFF, disconnect ECM [78A] from breakout box.

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2. With IGN ON and engine not running, test for voltage 3. Is continuity present?
between breakout box terminal 38 and ground. a. Yes. Go to Test 3.
3. Is voltage present? b. No. Replace ECM. See the service manual.
a. Yes. Repair short to voltage on (V/BE) wire.
b. No. Replace ECM. See the service manual.
3. Exhaust Actuator Feedback Shorted to
Ground Test
10. Exhaust Actuator Feedback Short to 1. Disconnect exhaust actuator [179] and disconnect ECM
Ground Test [78A] from breakout box.
1. Disconnect ECM [78A] from breakout box. 2. Test for continuity between breakout box terminal 21 and
ground.
2. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
41404-C) and multimeter, test for continuity between active 3. Is continuity present?
exhaust actuator [179B] terminal 4 and ground. a. Yes. Repair short to ground on (V/O) wire.
3. Is continuity present? b. No. Replace active exhaust actuator. See the service
a. Yes. Repair short to ground on (V/BE) wire. manual.
b. No. Replace ECM. See the service manual.
DTC P1478
DTC P1477 PART NUMBER TOOL NAME
PART NUMBER TOOL NAME HD-48637 BREAKOUT BOX
HD-41404-C HARNESS CONNECTOR TEST KIT
Table 6-69. DTC P1478 Diagnostic Faults
HD-48637 BREAKOUT BOX
POSSIBLE CAUSES
Table 6-68. DTC P1477 Diagnostic Faults ECM malfunction
POSSIBLE CAUSES Exhaust actuator malfunction
ECM malfunction Short to voltage in exhaust actuator circuit
Exhaust actuator malfunction 1. Exhaust Actuator Motor High Test
Open in exhaust actuator circuit
1. Connect BREAKOUT BOX (Part No. HD-48637) to har-
Short to ground in exhaust actuator circuit ness [78B], leaving ECM [78A] disconnected. See
1.2 DIAGNOSTIC TOOLS.
1. Exhaust Actuator Motor Open Test
2. Turn IGN ON and engine stop switch to RUN.
1. Connect BREAKOUT BOX (Part No. HD-48637) to har-
ness [78B], leaving ECM [78A] disconnected. See 3. Using a multimeter, test for voltage between breakout box
1.2 DIAGNOSTIC TOOLS. terminal 21 and ground.

2. Disconnect exhaust actuator [179]. 4. Is voltage present?

a. Yes. Go to Test 2.
3. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
41404-C), test for continuity between breakout box terminal b. No. Replace ECM. See the service manual.
21 to [179B] terminal 3.
4. Is continuity present?
2. Exhaust Actuator Motor Shorted to
a. Yes. Go to Test 2. Voltage Test
1. Disconnect exhaust actuator [179].
b. No. Repair open (V/O) wire.
2. Using a multimeter, test for voltage between breakout box
2. Exhaust Actuator Motor Shorted to terminal 20 and ground.
Ground Test 3. Is voltage present?
1. Connect ECM [78A] to breakout box. a. Yes. Repair short to voltage on (V/O) wire.
2. Test for continuity between breakout box terminal 21 and b. No. Replace active exhaust control actuator. See the
ground. service manual.

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DTC P1501, P1502 6.22

DESCRIPTION AND OPERATION NOTE
See Figure 6-36. The Jiffy Stand Sensor (JSS) uses a Hall- The ECM supplies 5V reference voltage to the VSS, TPS and
effect sensor to monitor jiffy stand position. When the jiffy stand MAP sensors, in addition to the JSS. Problems on the 5V ref-
is fully retracted the sensor picks up the presence of the metal erence will cause other DTCs.
tab mounted to the jiffy stand. The metal tab is moved away
from the sensor as the jiffy stand is extended. When the jiffy
ed01247
stand is extended the engine will only start and run if the
TSM/TSSM/HFSM determines the transmission is in neutral.
Otherwise the engine will stall as the clutch is released. This
is done by monitoring the neutral switch input to the
TSM/TSSM/HFSM and communicating that input over the serial
data circuit to the ECM.
The JSS is powered and monitored by the ECM. The ECM
supplies the 5V reference to the JSS. The JSS sends a signal
back to the ECM. This signal is used by the ECM to determine
when the jiffy stand is retracted or extended. The JSS is
grounded through the ECM.
The JSS also has a Fail Enable Mode. This mode allows the
engine to start and run if the system recognizes a problem with
the JSS circuit. When a problem exists or if the transmission
is put in gear with the jiffy stand extended, the odometer will Figure 6-35. JSS
display "SIdE Stand". DTC P1501 or P1502 will set if the JSS
circuits are out of range.
Connector Information
Table 6-70. Code Description
For additional information about the connectors in the following
DTC DESCRIPTION diagram(s) and diagnostic procedure(s), including the color of
the harness test kit terminal probes, see B.1 CONNECTORS.
P1501 JSS low
P1502 JSS high

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em00700
TGS

[224A] 6 5 4 3 2 1
[224B] 6 5 4 3 2 1

TCA
TMAP Sensor

GY
BN
BE
BK
R
V
[211A] 6 5 4 3 2 1 [204A] 6 5 4 3 2 1 [80A] 1 2 3 4
[211B] 6 5 4 3 2 1 [204B] 6 5 4 3 2 1 [80B] 1 2 3 4

BN/O
BN/V

BN/O
BK/O

BK/W

R/W
BN/R

BK/W
BK/PK

BE/GN

BK/GY
V/Y

R/W
V/W
BK/GY
LGN/Y
[78A] [78B]
ECM
TMAP Sensor Input 24 24 V/W
Throttle Actuator Control HI 29 29 BK/O
Throttle Actuator Control LO 30 30 BK/PK
TPS-2 36 36 BN/R [90B] [90A]
TPS-1 37 37 BN/V
TGS-2 39 39 V/Y
PK/Y A A
Vehicle Speed Input 40 40 W/GN
BK/W B B
IAT 49 49 LGN/Y
5V Sensor Power-1 50 50 BN/O ET Sensor
ET Sensor 51 51 PK/Y
JSS 56 56 GN/BN [65B] [65A]
TGS-1 59 59 BE/GN
5V Sensor Ground-1 61 61 BK/W A A
BN/O
5V Sensor Ground-2 62 62 BK/GY W/GN B B VSS
Vehicle Speed Ground 64 64 BK/Y BK/Y C C
5V Sensor Power-2 68 68 R/W
Ground 73 73 BK/GN

GN/BN
BK/GN
BN/O
Right [133B] 1 2 3
GND 2 JSS
(HDI only)

Figure 6-36. Throttle Control Actuator Circuit

DTC P1501 between breakout box terminal 50 and JSS [133B] terminal
1 (BN/O).
PART NUMBER TOOL NAME
5. Is continuity present?
HD-41404-C HARNESS CONNECTOR TEST KIT
a. Yes. Go to Test 2.
HD-48637 BREAKOUT BOX
b. No. Repair open on (BN/O) wire.

Table 6-71. DTC P1501 Diagnostic Faults 2. JSS 5V Reference Shorted to Ground Test
POSSIBLE CAUSES 1. Test for continuity between JSS [133B] terminal 1 (BN/O)
JSS malfunction to ground.

ECM malfunction 2. Is continuity present?

Open or short to ground in 5V reference circuit a. Yes. Repair short to ground on (BN/O) wire.

Open or short to ground in signal circuit b. No. Go to Test 3.

1. JSS 5V Reference Open Circuit Test 3. JSS Signal Wire Shorted to Ground Test
1. Disconnect the JSS [133]. 1. Test for continuity between breakout box terminal 56 and
ground.
2. Inspect the connection for corrosion or backed out ter-
minals. Repair as required. 2. Is continuity present?
3. Connect BREAKOUT BOX (Part No. HD-48637) to wire a. Yes. Repair short to ground on (GN/BN) wire.
harness [78B], leaving ECM [78A] disconnected. See b. No. Go to Test 4.
1.2 DIAGNOSTIC TOOLS.
4. Using the HARNESS CONNECTOR TEST KIT (Part
No. HD-41404-C) and a multimeter, test for continuity

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4. JSS Signal Wire Open Circuit Test 2. Is voltage greater than 5V?

1. Test for continuity between breakout box terminal 56 and a. Yes. Repair short to battery voltage in (GN/BN) wire.
JSS [133B] terminal 2 (GN/BN). b. No. Go to Test 4.
2. Is continuity present?
4. JSS 5V Reference and Signal Shorted
a. Yes. Replace JSS. See the service manual.
Together Test
b. No. Repair open on (GN/BN) wire.
1. With IGN OFF, disconnect the ECM [78].
DTC P1502 2. Test for continuity between terminals 1 and 2 of [133B].

PART NUMBER TOOL NAME 3. Is continuity present?

HD-41404-C HARNESS CONNECTOR TEST KIT a. Yes. Repair short between (BN/O) and (GN/BN)
wires.

Table 6-72. DTC P1502 Diagnostic Faults b. No. Replace JSS. See the service manual.

POSSIBLE CAUSES SIDE STAND DISPLAYED ON ODOMETER

JSS malfunction
ECM malfunction Table 6-73. Side Stand Displayed on Odometer Diagnostic
Faults
Short to voltage in signal circuit
Open ground POSSIBLE CAUSES
Short to voltage in 5V reference circuit Jiffy stand is down
Jiffy stand out of adjustment
1. JSS Ground Wire Test
1. Disconnect the JSS [133]. 1. Starts, Then Stalls Test
2. Using the HARNESS CONNECTOR TEST KIT (Part 1. Check for DTCs and diagnose them first.
No. HD-41404-C) and a multimeter, test for continuity 2. Does the engine start and stall?
between terminal 3 of [133B] and ground.
a. Yes. See 6.35 STARTS, THEN STALLS.
3. Is continuity present?
b. No. Go to Test 2.
a. Yes. Go to Test 2.
b. No. Repair open in (BK/GN) wire. 2. Neutral Test
1. Verify the transmission is in neutral.
2. JSS 5V Reference Wire Short to Voltage
2. Is the neutral indicator on?
Test
a. Yes. Go to Test 3.
1. Test for voltage at jiffy stand sensor [133B] terminal 1
(BN/O) wire. b. No. See 4.5 INDICATOR LAMPS.

2. Is voltage greater than 6V? 3. JSS Clearance Test

a. Yes. Repair short to battery voltage on (BN/O). 1. Inspect the JSS and the jiffy stand for correct mounting
b. No. Go to Test 3. and clearance to the jiffy stand tab.
2. Is the clearance less than 0.18 in (4.5 mm)?
3. JSS Signal Wire Short to Voltage Test
a. Yes. Replace the JSS. See the service manual.
1. Test for voltage on [133B] terminal 2.
b. No. Install the JSS and jiffy stand correctly. See the
service manual.

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DTC P1510, P1511, P1512
DESCRIPTION AND OPERATION
Throttle Actuation Control Management
The ECM constantly monitors throttle actuation and throttle
component positioning. Several safety features are pro-
grammed into the ECM to limit performance when an error or
fault in throttle actuation is detected. These DTCs always
accompany another code. Refer to Table 6-74.
Table 6-74. Code Description
DTC DESCRIPTION
P1510 Throttle actuator control limited perform-
ance mode
P1511 Throttle actuator control power manage-
ment mode
P1512 Throttle actuator control forced idle mode
Performance limitations are identified by code, as follows:
• P1510 Limited Performance: Enables near normal
operation of the vehicle, guarding against inadvertent wide
open throttle conditions. Typically this code is the result if
one of the TGS or TP sensors, or one of each, has failed.
• P1511 Power Management: Provides more limitation on
driveability, due to failure of the TCA, without a TGS, MAP
or airflow faults. The TCA is de-energized and the throttle
plate returns to its idle detent position. The ECM monitors
the operation of the TGS and adjusts the spark advance
6.23
and cylinder shutoff/rev limiting, allowing the vehicle to
reach traffic speeds (limp-home).
• P1512 Forced Idle Mode: Provides extreme limitation of
driveability, due to a failure of both TGS, TGS validation
error or failure of one TGS and the brake switch. The TCA
is de-energized and the throttle plate is forced to a fast
idle position providing enough torque to operate at a high
idle speed.
DTC P1510, P1511, P1512
Table 6-75. DTC P1510, P1511, P1512 Diagnostic Faults
POSSIBLE CAUSES
Other DTCs set
ECM malfunction
1. DTC Verification Test
1. Clear DTCs using odometer self-diagnostics. See
2.1 INITIAL DIAGNOSTICS, Odometer Self-Diagnostics.
2. Start and run the engine for a few seconds.
3. Cycle the engine on and off, for a few seconds each time
a total of three times.
4. Did DTC P1510, P1511 or P1512 set with no other DTCs?
a. Yes. Replace the ECM. See the service manual.
b. No. Other DTCs set. Refer to Table 2-1.
c. No. No DTCs set. DTC was properly cleared.
2011 Touring Diagnostics: Engine Management 6-75
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DTC P1514 6.24

DESCRIPTION AND OPERATION ECM only checks for DTC P1514 if power management mode
(DTC P1511) is present.
Air Flow Fault
The ECM uses the TMAP sensor to monitor air flow past the Table 6-76. Code Description
throttle plate. This ensures proper throttle plate positioning,
DTC DESCRIPTION
when the throttle is released and allowed to return to the
unpowered position. The unpowered position is typically 7% P1514 Air flow fault
of throttle plate range.
DTC P1514
In order to avoid inconsistent readings at low rpm (or at idle),
testing air flow is only performed at engine speeds above
normal idle (10% of throttle plate range or approximately 1300 Table 6-77. DTC P1514 Diagnostic Faults
rpm). POSSIBLE CAUSES
The ECM compares the intake manifold pressure value from Other DTCs set
the TMAP to the throttle plate position value from the TPS.
DTC 1514 sets if the manifold pressure is higher than it should ECM malfunction
be for that given throttle plate position for three consecutive
ignition cycles. If a TMAP sensor error is present, then the
1. DTC Verification Test
ECM does not check P1514 parameters and instead P2105 1. Clear DTCs using odometer self-diagnostics. See
(forced shutdown mode) is initiated, shutting down the fuel 2.1 INITIAL DIAGNOSTICS, Odometer Self-Diagnostics.
pump and fuel injectors. See 6.28 DTC P2105, P2107. The
2. Start and run the engine for a few seconds.
3. Cycle the engine on and off, for a few seconds each time
a total of three times.
4. Did DTC P1514 set with no other DTCs?
a. Yes. Replace the ECM. See the service manual.
b. No. Other DTCs set. Refer to Table 2-1.
c. No. No DTCs set. DTC was properly cleared.

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DTC P1600 6.25

DESCRIPTION AND OPERATION 1. DTC Verification Test
The ECM uses a main microprocessor and a monitoring 1. Clear DTCs using odometer self-diagnostics. See
microcontroller, to communicate with the throttle actuation 2.1 INITIAL DIAGNOSTICS, Odometer Self-Diagnostics.
control system.
2. Start and run the engine for a few seconds.
The microcontroller monitors the main microprocessor of the
3. Cycle the engine on and off, for a few seconds each time
ECM, and when a communication failure is identified, the
a total of three times.
microcontroller shuts down the TCA and fuel injectors.
An internal ignition delay timer monitors when the ignition circuit 4. Did DTC P1600 set with no other DTCs?
is energized. The microcontroller issues DTC P1600 if no a. Yes. Replace the ECM. See the service manual.
communication is established between the main microprocessor
b. No. Other DTCs set. Refer to Table 2-1.
or if a monitoring failure occurs within three consecutive ignition
cycles. c. No. No DTCs set. DTC was properly cleared.

Table 6-78. Code Description

DTC DESCRIPTION
P1600 TCA module processor - internal fault

DTC P1600

Table 6-79. DTC P1600 Diagnostic Faults

POSSIBLE CAUSES
Other DTCs set
ECM malfunction

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DTC P1655, P1656 6.26

DESCRIPTION AND OPERATION
ed01625
See Figure 6-37. The Automatic Compression Release (ACR)
is opened and closed by the ECM to assist starting.
See Figure 6-38. When open, compressed gases are released
through the exhaust port.

ed03084

2 3

1
Figure 6-38. ACR in Head

Connector Information
For additional information about the connectors in the following
1. Rear ACR [203R] diagram(s) and diagnostic procedure(s), including the color of
2. TMAP [80] the harness test kit terminal probes, see B.1 CONNECTORS.
3. Front ACR [203F]
Figure 6-37. Between Cylinders Right Side

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em00702
Fuel Pump
[141A] B D
Assembly In Tank
Front ACR Rear ACR
(If Equipped) (If Equipped)
[141B] B D [141B] B D

O/GY
O/GY
[203AF] 2 1 2 1 [203AR]

BK
BK
[203BF] 2 1 2 1 [203BR]
Fuel Tank [13B] 1 4 [20A] 14 15

V/GY

V/GY
Y/GN

Y/GN
Harness [13A] 1 4 [20B] 14 15

O/GY
O/GY

BK
EXCEPT BK FLHR/C TGS
O/GY

BK
FLHR/C ET

V/GY

Y/GN
Sensor
4B TCA [224A] 6 5 4 3 21
Fuel [224B] 6 5 4 3 21
Pump [90A] A B
Fuse

GY
BN
BE
BK
R
V
[211A] 1 2 3 4 5 6 [90B] A B TMAP
15A
4A [211B] 1 2 3 4 5 6 Sensor

BK/W
[204A]

PK/Y
6 5 4 3 21
Y/GN

System
BK/W

BN/O
BK/O
BN/R

BN/V
BK/PK
[204B] 6 5 4 3 2 1
[80A] 1 2 3 4
Relay

BK/W
BN/O

BK/GY
BE/GN

R/W
87 5 4C [80B]

V/Y
Y/GN 1 2 3 4
30 3 3D BE/GY

R/W
V/W
BK/GY
LGN/Y
86
85 To 15A
ECM Fuse
Ignition Coil [83A] [83B]
Power A A Y/GN
Ion Sense B B GY/BE
Coil Rear C C Y/BE
Coil Front D D BE/O
[65B] [65A]
[84A] [84B]
BN/O A A
Front Fuel A A Y/GN W/GN B B VSS
Injector B B W/Y
BK/Y C C
[85A] [85B]

Rear Fuel A A Y/GN BK/BN 4

Injector B B GN/GY
PK/O 3 Front
[95A] [95B] GN/W 2 HO2S
Y/GN 1
B B GY/Y
A A Y/GN [138A]
Purge Solenoid
(Optional)
BK/BN 4
Rear
PK/GN 3
To 15A 2
HO2S
GN/W
Exhaust Y/GN 1 (BK)
Control Fuse
[137A]

1 LGN/R
Active 2 BK
Exhaust 3 V/O
(HDI Only) 4 V/BE
BK
R

[179B]
GN/GY

PK/GN

BE/GN

BK/GN
GY/BE

BK/GY
BK/BN
LGN/Y
BK/PK
GN/W

W/GN

BK/W
BN/O

Y/GN
V/GY
GY/Y

BK/O

BN/R

BE/O

PK/O
BN/V
V/BE

PK/Y

Y/BE

BK/Y

R/W
V/W

W/Y
V/O

V/Y

BK

2 1 [79A]
R

Right
[78B] 19 20 21 2324 28 29 30 3133 363738 39 4043 46 484950 51 52 53 54 59 61 62 63 64 66 68 73 GND 2 2 1 [79B]
[78A] 19 20 21 2324 28 29 30 3133 363738 39 4043 46 484950 51 52 53 54 59 61 62 63 64 66 68 73
HO2S Return
Purge Solenoid
Exhaust Actuator
Rear Fuel Injector
TMAP Sensor Input

Throttle Actuator Control HI

Throttle Actuator Control LO
O2 Heater Ground
Ion Sense
TPS 2
TPS 1

TGS 2

CKP Sensor
Rear HO2 Sensor

ET Sensor

Rear Ignition Coil

TGS 1
5V Sensor Ground 1
5V Sensor Ground 2
CKP Sensor (+)

Ground
ACR Ground

Front Fuel Injector

Front Ignition Coil

Front HO2 Sensor

Exhaust Feedback

5V Sensor Power 1

12V Power

5V Sensor Power 2
Vehicle Speed Input

Vehicle Speed Ground

IAT Sensor

CKP
Sensor
ECM

Figure 6-39. EFI Simplified Schematic

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DTC P1655 4. Is continuity present?

a. Yes. Go to Test 5.
PART NUMBER TOOL NAME
b. No. Replace the ECM. See the service manual.
HD-34730-2D FUEL INJECTOR TEST LIGHT
HD-41404-C HARNESS CONNECTOR TEST KIT 5. Rear ACR Control Circuit Short to Ground
HD-48637 BREAKOUT BOX Test
1. Disconnect rear ACR [203RB].
Table 6-80. DTC P1655 Diagnostic Faults
2. Test for continuity between [203FB] terminal 2 and ground.
POSSIBLE CAUSES
3. Is continuity present?
ACR solenoid malfunction a. Yes. Repair short to ground in (V/GY) wire.
Open in ACR control circuit
b. No. Replace front and rear ACR solenoids. See the
Open in system relay circuit service manual.
ECM malfunction
Short to ground in ACR control circuit
6. Shorted ACR Test
1. Disconnect rear ACR [203RB].
1. Front ACR Test 2. Crank engine for 5 seconds.
1. Disconnect front ACR [203F].
3. Does the test light flash on and off?
2. Connect FUEL INJECTOR TEST LIGHT (Part No. HD- a. Yes. Replace front and rear ACR solenoids. See the
34730-2D). service manual.
3. Crank engine for 5 seconds. b. No. Go to Test 7.
4. Does the test light flash on and off?
a. Yes. Go to Test 2.
7. ACR Supply Circuit Open Test
1. Disconnect the test light.
b. No, test light stays on steady. Go to Test 4.
2. While cranking the engine, test for voltage between
c. No, did not stay on steady. Go to Test 6.
[203FB] terminal 1 and ground.
2. Rear ACR Test 3. Is battery voltage present?
1. Disconnect rear ACR [203R]. a. Yes. Go to Test 8.

2. Connect FUEL INJECTOR TEST LIGHT (Part No. HD- b. No. Repair open in (Y/GN) wire.
34730-2D).
8. ACR Control Circuit Continuity Test
3. Crank engine for 5 seconds.
1. With IGN OFF, connect BREAKOUT BOX (Part No. HD-
4. Does the test light flash on and off? 48637) between wire harness [78B] and ECM [78A] leaving
a. Yes. Replace front and rear ACR solenoids. See the [78A] disconnected. See 1.2 DIAGNOSTIC TOOLS.
service manual.
2. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
b. No. Go to Test 3. 41404-C) and a multimeter, test for continuity between
breakout box terminal 19 and [203FB] terminal 2.
3. Rear ACR Control Circuit Test 3. Is continuity present?
1. While cranking the engine, test for voltage between a. Yes. Replace the ECM. See the service manual.
[203RB] terminal 1 and ground.
b. No. Repair open in (V/GY) wire.
2. Is battery voltage present?
a. Yes. Repair open between [203RB] and [78] (V/GY)
wire.
b. No. Repair open in (Y/GN) wire.

4. Front ACR Control Circuit Short to

Ground Test
1. Turn IGN OFF.
2. Disconnect ECM [78].
3. Test for continuity between [203FB] terminal 2 and ground.

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DTC P1656 meter, test for measure voltage between [203FB] terminal
2 and ground.
PART NUMBER TOOL NAME
3. Is voltage greater than 1.0V?
HD-34730-2D FUEL INJECTOR TEST LIGHT
a. Yes. Repair short to voltage between [203FB] terminal
HD-41404-C HARNESS CONNECTOR TEST KIT 2 and [78B] terminal 19.
b. No. Replace front and rear ACR solenoids. See the
Table 6-81. DTC P1656 Diagnostic Faults service manual.
POSSIBLE CAUSES
3. Rear ACR Test
Short to voltage in ACR control circuit
1. Disconnect rear ACR [203R].
ACR solenoid malfunction
2. Crank engine for 5 seconds.
ECM malfunction
3. Does the test light flash on and off?
1. Front ACR Test a. Yes. Replace front and rear ACR solenoids. See the
1. Disconnect front ACR [203F]. service manual.

2. Connect FUEL INJECTOR TEST LIGHT (Part No. HD- b. No. Go to Test 4.
34730-2D).
4. Front ACR Control Circuit Test
3. Crank engine for 5 seconds.
1. Disconnect fuel injector test light.
4. Does the test light flash on and off?
2. While cranking the engine, using HARNESS CON-
a. Yes. Go to Test 2.
NECTOR TEST KIT (Part No. HD-41404-C) and a multi-
b. No. Go to Test 3. meter, test for voltage between [203FB] terminal 2 and
ground.
2. Rear ACR Control Circuit Test 3. Is voltage greater than 1.0V?
1. Disconnect rear ACR [203R]. a. Yes. Repair short to voltage between [203FB] terminal
2. While cranking the engine, using HARNESS CON- 2 and ECM [78B] terminal 19.
NECTOR TEST KIT (Part No. HD-41404-C) and a multi- b. No. Replace the ECM. See the service manual.

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DTC P2100, P2101, P2102, P2103
DESCRIPTION AND OPERATION
The TCA contains two potentiometers (designated as TPS1
and TPS2) and an electric DC motor for controlling the actu-
ation of the throttle. TPS1 and TPS2 are mounted in the TCA.
They are connected to the keyed shaft for the throttle plate
and used to communicate the position of the throttle plate.
Each TPS supplies input to the ECM in response to the posi-
tioning of the throttle plate. The ECM activates the motor in
the TCA to move the throttle plate, based on signals from the
TGS.
See Figure 6-40. The TCA motor receives input (position data)
from the ECM connector [78] terminal 29 for electronic throttle
control - HI and terminal 30 for electronic throttle control - LOW.
The TCA motor drives a series of gears to rotate the position
of the throttle plate. Refer to Table 6-82 for defect codes
associated with TCA drive motor.
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6.27
Table 6-82. Code Description
DTC DESCRIPTION
P2100 TAC motor open
P2101 TAC motor circuit range/performance
(actuation error)
P2102 TAC motor control circuit shorted low
P2103 TAC motor control circuit shorted high
• P2100 TAC Motor Circuit Open: Indicates the ECM
identified an open load fault for the TCA motor driver.
• P2101 TAC Motor Circuit Range/Performance: Indicates
the actual position of the throttle plate is out of range from
the commanded throttle plate position.
• P2102 TAC Motor Control Circuit Shorted Low: Indic-
ates the ECM identified that the drive motor is shorted to
ground within the TAC drive motor circuit.
• P2103 TAC Motor Control Circuit Shorted High: Indic-
ates the drive motor is shorted high within the TAC drive
motor circuit.
Connector Information
For additional information about the connectors in the following
diagram(s) and diagnostic procedure(s), including the color of
the harness test kit terminal probes, see B.1 CONNECTORS.
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em00700
TGS

[224A] 6 5 4 3 2 1
[224B] 6 5 4 3 2 1

TCA
TMAP Sensor

GY
BN
BE
BK
R
V
[211A] 6 5 4 3 2 1 [204A] 6 5 4 3 2 1 [80A] 1 2 3 4
[211B] 6 5 4 3 2 1 [204B] 6 5 4 3 2 1 [80B] 1 2 3 4

BN/O
BN/V

BN/O
BK/O

BK/W

R/W
BN/R

BK/W
BK/PK

BE/GN

BK/GY
V/Y

R/W
V/W
BK/GY
LGN/Y
[78A] [78B]
ECM
TMAP Sensor Input 24 24 V/W
Throttle Actuator Control HI 29 29 BK/O
Throttle Actuator Control LO 30 30 BK/PK
TPS-2 36 36 BN/R [90B] [90A]
TPS-1 37 37 BN/V
TGS-2 39 39 V/Y
PK/Y A A
Vehicle Speed Input 40 40 W/GN
BK/W B B
IAT 49 49 LGN/Y
5V Sensor Power-1 50 50 BN/O ET Sensor
ET Sensor 51 51 PK/Y
JSS 56 56 GN/BN [65B] [65A]
TGS-1 59 59 BE/GN
5V Sensor Ground-1 61 61 BK/W A A
BN/O
5V Sensor Ground-2 62 62 BK/GY W/GN B B VSS
Vehicle Speed Ground 64 64 BK/Y BK/Y C C
5V Sensor Power-2 68 68 R/W
Ground 73 73 BK/GN

GN/BN
BK/GN
BN/O
Right [133B] 1 2 3
GND 2 JSS
(HDI only)

Figure 6-40. Throttle Control Actuator Circuit

DTC P2100 3. Is resistance greater than 10 Ohms?

a. Yes. Go to Test 2.
PART NUMBER TOOL NAME
b. No. Perform wiggle test. See 1.3 DIAGNOSTICS AND
HD-41404-C HARNESS CONNECTOR TEST KIT
TROUBLESHOOTING, Wiggle Test. If resistance
HD-48637 BREAKOUT BOX below 10 Ohms, replace the ECM. See the service
manual.
Table 6-83. DTC P2100 Diagnostic Faults
2. TCA High Circuit Test
POSSIBLE CAUSES
1. Disconnect TCA [211].
ECM malfunction
2. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
Open in throttle actuator control circuit high 41404-C) and a multimeter, test for continuity between
TCA malfunction breakout box terminal 29 and TCA [211B] terminal 3.
Open in throttle actuator control circuit low 3. Is continuity present?
a. Yes. Go to Test 3.
1. TCA Test
b. No. Repair open in (BK/O) wire.
1. With IGN OFF, connect BREAKOUT BOX (Part No. HD-
48637) between wire harness [78B] and ECM [78A],
leaving [78A] disconnected. See 1.2 DIAGNOSTIC
3. TCA Low Circuit Test
TOOLS. 1. Test for continuity between breakout box terminal 30 and
TCA [211B] terminal 2.
2. Using a multimeter, measure resistance between breakout
box terminal 29 and terminal 30. 2. Is continuity present?
a. Yes. Replace the TCA. See the service manual.
b. No. Repair open in (BK/PK) wire.

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DTC P2101 DTC P2102

PART NUMBER TOOL NAME PART NUMBER TOOL NAME
HD-41404-C HARNESS CONNECTOR TEST KIT HD-41404-C HARNESS CONNECTOR TEST KIT
HD-48637 BREAKOUT BOX
Table 6-85. DTC P2102 Diagnostic Faults
Table 6-84. DTC P2101 Diagnostic Faults POSSIBLE CAUSES
POSSIBLE CAUSES Short to ground in throttle actuator control circuit low
ECM malfunction Short to ground in throttle actuator control circuit high
Short between throttle actuator control circuits TCA malfunction
Open in throttle actuator control circuit high
1. TCA High Circuit Test
TCA malfunction
1. Disconnect TCA [211].
Open in throttle actuator control circuit low
2. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
1. TCA Circuit Resistance Test 41404-C) and a multimeter test for measure resistance
between [211B] terminal 3 and ground.
1. With IGN OFF, connect BREAKOUT BOX (Part No. HD-
48637) between wire harness [78B] and ECM [78A], 3. Is resistance greater than 1000 Ohms?
leaving [78A] disconnected. See 1.2 DIAGNOSTIC a. Yes. Go to Test 2.
TOOLS.
b. No. Repair short to ground in (BK/O) wire.
2. Using a multimeter, measure resistance between breakout
box terminal 29 and terminal 30. 2. TCA Test
3. Is resistance less than 2 Ohms? 1. Measure resistance between TCA [211B] terminal 2 and
a. Yes. Go to Test 2. ground.

b. No. Go to Test 3. 2. Is resistance less than 2 Ohms?

a. Yes. Repair short to ground in (BK/PK) wire.
2. TCA Test
b. No. Replace the TCA. See the service manual.
1. Disconnect TCA [211].
2. Measure resistance between breakout box terminal 29 DTC P2103
and terminal 30.
PART NUMBER TOOL NAME
3. Is resistance less than 2 Ohms? HD-48637 BREAKOUT BOX
a. Yes. Repair short between the (BK/O) and (BK/PK)
wires.
Table 6-86. DTC P2103 Diagnostic Faults
b. No. Replace the TCA. See the service manual.
POSSIBLE CAUSES
3. TCA High Circuit Test Short to ground in throttle actuator control circuit low
1. Using HARNESS CONNECTOR TEST KIT (Part No. HD- Short to ground in throttle actuator control circuit high
41404-C) and a multimeter, test for continuity between ECM malfunction
breakout box terminal 29 and TCA [211B] terminal 3.
2. Is continuity present? 1. TCA High Circuit Test
a. Yes. Go to Test 4. 1. With IGN OFF, connect BREAKOUT BOX (Part No. HD-
48637) between wire harness [78B] and ECM [78A],
b. No. Repair open in (BK/O) wire. leaving [78A] disconnected. See 1.2 DIAGNOSTIC
TOOLS.
4. TCA Low Circuit Test
2. Disconnect TCA [211].
1. Test for continuity between breakout box terminal 30 and
TCA [211B] terminal 2. 3. Using a multimeter, test for continuity between breakout
box terminal 52 and terminal 29.
2. Is continuity present?
a. Yes. Replace the ECM. See the service manual. 4. Is continuity present?
a. Yes. Repair short between (BK/O) and (Y/GN) wires.
b. No. Repair open in (BK/PK) wire.
b. No. Go to Test 2.

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2. TCA Low Circuit Test 2. Is continuity present?

1. Test for continuity between breakout box terminal 52 and a. Yes. Repair short between (BK/PK) and (Y/GN) wires.
terminal 30. b. No. Replace the ECM. See the service manual.

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DTC P2105, P2107 6.28

DESCRIPTION AND OPERATION
Table 6-87. Code Description
The TAC system uses DTC P2105 as a vehicle safety device.
It provides a forced shut down of the engine when the perform- DTC DESCRIPTION
ance of the TCA cannot be verified. Refer to Table 6-87. P2105 TAC system forced engine shutdown
Initially, the ECM commands the fuel pump and fuel injectors P2107 TAC system module processor - internal
to be disabled until the actual fault is cleared. fault
The TAC system sets DTC P2107 to identify faults with the
ECM due to an internal over-temperature shutdown or a power
supply failure. Refer to Table 6-87.

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em00702
Fuel Pump
[141A] B D
Assembly In Tank
Front ACR Rear ACR
(If Equipped) (If Equipped)
[141B] B D [141B] B D

O/GY
O/GY
[203AF] 2 1 2 1 [203AR]

BK
BK
[203BF] 2 1 2 1 [203BR]
Fuel Tank [13B] 1 4 [20A] 14 15

V/GY

V/GY
Y/GN

Y/GN
Harness [13A] 1 4 [20B] 14 15

O/GY
O/GY

BK
EXCEPT BK FLHR/C TGS
O/GY

BK
FLHR/C ET

V/GY

Y/GN
Sensor
4B TCA [224A] 6 5 4 3 21
Fuel [224B] 6 5 4 3 21
Pump [90A] A B
Fuse

GY
BN
BE
BK
R
V
[211A] 1 2 3 4 5 6 [90B] A B TMAP
15A
4A [211B] 1 2 3 4 5 6 Sensor

BK/W
[204A]

PK/Y
6 5 4 3 21
Y/GN

System
BK/W

BN/O
BK/O
BN/R

BN/V
BK/PK
[204B] 6 5 4 3 2 1
[80A] 1 2 3 4
Relay

BK/W
BN/O

BK/GY
BE/GN

R/W
87 5 4C [80B]

V/Y
Y/GN 1 2 3 4
30 3 3D BE/GY

R/W
V/W
BK/GY
LGN/Y
86
85 To 15A
ECM Fuse
Ignition Coil [83A] [83B]
Power A A Y/GN
Ion Sense B B GY/BE
Coil Rear C C Y/BE
Coil Front D D BE/O
[65B] [65A]
[84A] [84B]
BN/O A A
Front Fuel A A Y/GN W/GN B B VSS
Injector B B W/Y
BK/Y C C
[85A] [85B]

Rear Fuel A A Y/GN BK/BN 4

Injector B B GN/GY
PK/O 3 Front
[95A] [95B] GN/W 2 HO2S
Y/GN 1
B B GY/Y
A A Y/GN [138A]
Purge Solenoid
(Optional)
BK/BN 4
Rear
PK/GN 3
To 15A 2
HO2S
GN/W
Exhaust Y/GN 1 (BK)
Control Fuse
[137A]

1 LGN/R
Active 2 BK
Exhaust 3 V/O
(HDI Only) 4 V/BE
BK
R

[179B]
GN/GY

PK/GN

BE/GN

BK/GN
GY/BE

BK/GY
BK/BN
LGN/Y
BK/PK
GN/W

W/GN

BK/W
BN/O

Y/GN
V/GY
GY/Y

BK/O

BN/R

BE/O

PK/O
BN/V
V/BE

PK/Y

Y/BE

BK/Y

R/W
V/W

W/Y
V/O

V/Y

BK

2 1 [79A]
R

Right
[78B] 19 20 21 2324 28 29 30 3133 363738 39 4043 46 484950 51 52 53 54 59 61 62 63 64 66 68 73 GND 2 2 1 [79B]
[78A] 19 20 21 2324 28 29 30 3133 363738 39 4043 46 484950 51 52 53 54 59 61 62 63 64 66 68 73
HO2S Return
Purge Solenoid
Exhaust Actuator
Rear Fuel Injector
TMAP Sensor Input

Throttle Actuator Control HI

Throttle Actuator Control LO
O2 Heater Ground
Ion Sense
TPS 2
TPS 1

TGS 2

CKP Sensor
Rear HO2 Sensor

ET Sensor

Rear Ignition Coil

TGS 1
5V Sensor Ground 1
5V Sensor Ground 2
CKP Sensor (+)

Ground
ACR Ground

Front Fuel Injector

Front Ignition Coil

Front HO2 Sensor

Exhaust Feedback

5V Sensor Power 1

12V Power

5V Sensor Power 2
Vehicle Speed Input

Vehicle Speed Ground

IAT Sensor

CKP
Sensor
ECM

Figure 6-41. EFI Simplified Schematic

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DTC P2105 1. ECM Connector Test

1. IGN OFF, disconnect ECM [78] and inspect for damaged,
Table 6-88. DTC P2105 Diagnostic Faults corroded or pushed out terminals.
POSSIBLE CAUSES 2. Are terminal problems present?
Other DTCs set a. Yes. Repair terminals as required.
ECM malfunction b. No. Go to Test 2.

1. DTC Verification Test 2. ECM Circuit Test

1. Clear DTCs using odometer self-diagnostics. See 1. With IGN OFF, connect BREAKOUT BOX (Part No. HD-
2.1 INITIAL DIAGNOSTICS, Odometer Self-Diagnostics. 48637) between wire harness [78B] and ECM [78A]. See
1.2 DIAGNOSTIC TOOLS.
2. Start and run the engine for a few seconds.
2. Start the engine.
3. Check for DTCs. See 2.1 INITIAL DIAGNOSTICS, Odo-
meter Self-Diagnostics. 3. Using a multimeter, test for voltage between breakout box
terminal 52 and ground.
4. Did DTC P2105 set with no other DTCs?
a. Yes. Replace the ECM. See the service manual. 4. Is battery voltage present?
a. Yes. Replace the ECM. See the service manual.
b. No. Other DTCs set. Refer to Table 2-1.
b. No. Go to Test 3.
c. No. No DTCs set. DTC was properly cleared.

DTC P2107 3. Relay Circuit Test

1. Test the system relay. See 1.3 DIAGNOSTICS AND
PART NUMBER TOOL NAME TROUBLESHOOTING, Relay Diagnostics.
HD-48637 BREAKOUT BOX
2. Is the system relay good?
a. Yes. Repair open or high resistance in (Y/GN) wire.
Table 6-89. DTC P2107 Diagnostic Faults
b. No. Replace the system relay.
POSSIBLE CAUSES
Open in system relay supply circuit
System relay malfunction
ECM malfunction

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DTC P2119 6.29

DESCRIPTION AND OPERATION 1. Air Inlet Interference Test
The TAC system sets DTC P2119 when the ECM determines 1. Inspect the air inlet and check for foreign debris and/or
the throttle plate does not return to the correct de-energized mechanical interference to the throttle plate.
position. This error primarily indicates there may be non-elec-
2. Were any issues found?
trical conditions which affect the throttle body range/perform-
ance. Refer to Table 6-90. a. Yes. Go to Test 2.
b. No. Replace the induction module. See the service
Table 6-90. Code Description manual.

DTC DESCRIPTION 2. Validation Test

P2119 TAC system throttle body range/perform-
1. Remove obstructions and foreign debris from inlet and
ance
check throttle plate movement.
This DTC, if initiated, may have the following probable condi- 2. Clear DTCs using odometer self-diagnostics. See
tions: 2.1 INITIAL DIAGNOSTICS, Odometer Self-Diagnostics.
• Something may be physically interfering with the throttle 3. Start the engine and operate the throttle.
plate operation (such as foreign material, debris, physical
obstruction or loosely/improperly mounted throttle plate). 4. Check for DTCs. See 2.1 INITIAL DIAGNOSTICS, Odo-
meter Self-Diagnostics.
• Damaged or inoperative throttle plate return spring.
5. Did DTC P2119 set?
• Defective mechanical component(s) internal to the TCA.
a. Yes. Replace the induction module. See the service
DTC P2119 manual.
b. No. Repair complete.
Table 6-91. DTC P2119 Diagnostic Faults

POSSIBLE CAUSES
Induction module malfunction
Mechanical interference

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DTC P2122, P2123, P2127, P2128 6.30

DESCRIPTION AND OPERATION 4. Is voltage greater than 0.2V?
a. Yes. Go to Test 2.
The TGS is an electronic assembly that replaces the conven-
tional throttle cable. Two opposing Hall-effect sensors transmit b. No. Go to Test 5.
signals to the ECM. The ECM uses these signals to determine
the desired throttle plate position. The ECM controls the motor 2. TGS-1 Circuit Open Test
in the TCA to move the throttle plate to the desired position.
1. Disconnect TGS [204].
The TGS receives a 5V reference signal from the ECM. As the
throttle plate is opened the TGS1 signal voltage increases and 2. Disconnect ECM [78].
TGS2 signal voltage decreases. By design, the sum of the 3. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
voltages when measured for both TGS1 and TGS2 should 41404-C) and a multimeter, test for continuity between
equal approximately 5.0V. If the sum of these voltages is not [204B] terminal 5 and breakout box terminal 59.
5.0V, then DTCs are initiated for TGS1 and/or TGS2.
4. Is continuity present?
The ECM monitors and controls the TAC system and generates
a. Yes. Go to Test 3.
DTCs when errors are reported by the ECM. Refer to
Table 6-92. b. No. Repair open in (BE/GN) wire.

Table 6-92. Code Description 3. TGS-1 Short to Ground Test

DTC DESCRIPTION 1. Test for continuity between breakout box terminal 59 and
ground.
P2122 TGS1 low/open
2. Is continuity present?
P2123 TGS1 high
a. Yes. Repair short to ground on (BE/GN) wire.
P2127 TGS2 low/open
b. No. Go to Test 4.
P2128 TGS2 high

DTC P2122 4. Twist Grip Sensor Test

1. Test for continuity between breakout box terminal 50 and
PART NUMBER TOOL NAME [204B] terminal 6.
HD-41404-C HARNESS CONNECTOR TEST KIT
2. Is continuity present?
HD-48637 BREAKOUT BOX a. Yes. Replace the TGS. See the service manual.
b. No. Repair open in (BN/O) wire.
Table 6-93. DTC P2122 Diagnostic Faults

POSSIBLE CAUSES 5. TGS-1 Test

Open in TGS-1 circuit 1. Measure voltage between breakout box terminal 59 and
61.
Short to ground in TGS-1 circuit
TGS malfunction 2. While watching the voltage slowly turn the throttle to the
wide open position.
Open in sensor power circuit
3. Does the voltage steadily increase to greater than 4.6V?
ECM malfunction
a. Yes. Replace the ECM. See the service manual.
TCA malfunction
b. No. Go to Test 6.
JSS malfunction
VSS malfunction 6. TGS-1 Open Test
1. TGS-1 Voltage Test 1. Test for continuity between breakout box terminal 59 and
[204B] terminal 5.
1. Connect BREAKOUT BOX (Part No. HD-48637) between
wire harness [78B] and ECM [78A]. See 1.2 DIAGNOSTIC 2. Is continuity present?
TOOLS. a. Yes. Go to Test 7.
2. Turn IGN ON. b. No. Repair open in (BE/GN) wire.
3. Using a multimeter, measure voltage between breakout
box terminals 59 and 61. 7. Sensor Power-1 Continuity Test
1. Disconnect TGS [204].
2. Disconnect ECM [78A] from breakout box.

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3. Test continuity between breakout box terminal 50 and DTC P2123

[204B] terminal 6.
PART NUMBER TOOL NAME
4. Is continuity present?
HD-41404-C HARNESS CONNECTOR TEST KIT
a. Yes. Go to Test 8.
HD-48637 BREAKOUT BOX
b. No. Repair open in (BN/O) wire.

8. Sensor Power Resistance Test Table 6-94. DTC P2123 Diagnostic Faults
1. Measure resistance between breakout box terminal 50 POSSIBLE CAUSES
and 61. Short to voltage in TGS-1 circuit
2. Is the resistance greater than 100 Ohms? Short to voltage in sensor power circuit
a. Yes. Replace the TGS. See the service manual. TGS malfunction
b. No. Go to Test 9. Open in sensor ground circuit
ECM malfunction
9. TCA Test
1. Disconnect the TCA [211]. 1. TGS-1 Voltage Test
2. Measure resistance between breakout box terminal 50 1. Connect BREAKOUT BOX (Part No. HD-48637) between
and 61. wire harness [78B] and ECM [78A]. See 1.2 DIAGNOSTIC
TOOLS.
3. Is the resistance greater than 100 Ohms?
a. Yes. Replace the TCA. See the service manual. 2. Turn IGN ON.

b. No. Go to Test 10. 3. Using a multimeter, measure voltage between breakout

box terminals 59 and 61.
10. JSS Test 4. Is voltage greater than 4.8V?
1. Disconnect the JSS [131]. a. Yes. Go to Test 5.
2. Measure resistance between breakout box terminal 50 b. No. Go to Test 2.
and 61.
2. TGS-1 Short to Voltage Test
3. Is the resistance greater than 100 Ohms?
a. Yes. Replace the JSS. See the service manual. 1. Disconnect TGS [204].

b. No. Go to Test 11. 2. Disconnect ECM [78].

3. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
11. VSS Test 41404-C) and a multimeter, measure voltage between
1. Disconnect the VSS [65]. [204B] terminal 5 and ground.

2. Measure resistance between breakout box terminal 50 4. Is voltage less than 1.0V?
and 61. a. Yes. Go to Test 3.
3. Is the resistance greater than 100 Ohms? b. No. Repair short to voltage in (BE/GN) wire.
a. Yes. Replace the VSS. See the service manual.
3. TGS-1 Short to Ground Test
b. No. Repair short to ground in (BN/O) wire.
1. Measure voltage between [204B] terminal 6 and ground.
2. Is voltage less than 5.25V?
a. Yes. Go to Test 4.
b. No. Repair short to voltage on (BN/O) wire.

4. TGS Test
1. Turn IGN OFF.
2. Test continuity between breakout box terminal 61 and
[204B] terminal 4.
3. Is continuity present?
a. Yes. Replace the TGS. See the service manual.
b. No. Repair open in (BK/W) wire.

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5. TGS-1 Test DTC P2127

1. Measure voltage between breakout box terminal 59 and PART NUMBER TOOL NAME
61.
HD-41404-C HARNESS CONNECTOR TEST KIT
2. Is voltage greater than 0.2V?
HD-48637 BREAKOUT BOX
a. Yes. Go to Test 6.
b. No. Go to Test 7. Table 6-95. DTC P2127 Diagnostic Faults

6. TGS-1 Open Test POSSIBLE CAUSES

1. Turn IGN OFF. Open in TGS-2 circuit

Short to ground in TGS-2 circuit
2. Disconnect ECM [78A].
TGS malfunction
3. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
41404-C) and a multimeter, test for continuity between Open in sensor power circuit
[204B] terminals 5 and [204B] terminal 6. ECM malfunction
4. Is continuity present? TMAP malfunction
a. Yes. Repair short between (BN/O) and (BE/GN) wires. Short to ground in sensor power circuit
b. No. Repair short to voltage in (BE/GN) wire.
1. TGS-2 Voltage Test
7. Sensor Power-1 Continuity Test 1. Connect BREAKOUT BOX (Part No. HD-48637) between
wire harness [78B] and ECM [78A]. See 1.2 DIAGNOSTIC
1. Using HARNESS CONNECTOR TEST KIT (Part No. HD- TOOLS.
41404-C) and a multimeter, measure voltage [204B] ter-
minal 6 and ground. 2. Turn IGN ON.
2. Is voltage greater than 5.25V? 3. Using a multimeter, measure voltage between breakout
a. Yes. Repair short to voltage on (BN/O) wire. box terminals 39 and 62.

b. No. Go to Test 8. 4. Is voltage greater than 0.2V?

a. Yes. Go to Test 2.
8. Sensor Power Resistance Test b. No. Go to Test 5.
1. Turn IGN OFF.
2. Measure resistance between [204B] terminal 4 and ground.
2. TGS-2 Open Test
1. Disconnect TGS [204].
3. Is the resistance less than 2 Ohms?
a. Yes. Replace the TGS. See the service manual. 2. Disconnect ECM [78].

b. No. Go to Test 9. 3. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
41404-C) and a multimeter, test for continuity between
9. TCA Test [204B] terminal 2 and breakout box terminal 39.

1. Disconnect the ECM [78A]. 4. Is continuity present?

a. Yes. Go to Test 3.
2. Test continuity between [204B] terminal 4 and breakout
box terminal 61. b. No. Repair open in (V/Y) wire.
3. Is continuity present?
3. TGS-2 Short to Ground Test
a. Yes. Replace the ECM. See the service manual.
1. Test for continuity between breakout box terminal 39 and
b. No. Repair open in (BK/W) wire. ground.
2. Is continuity present?
a. Yes. Repair short to ground on (V/Y) wire.
b. No. Go to Test 4.

4. TGS Test
1. Test for continuity between breakout box terminal 68 and
[204B] terminal 3.
2. Is continuity present?
a. Yes. Replace the TGS. See the service manual.
b. No. Repair open in (R/W) wire.

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5. TGS-2 Test DTC P2128

1. Measure voltage between breakout box terminal 59 and PART NUMBER TOOL NAME
61.
HD-41404-C HARNESS CONNECTOR TEST KIT
2. While watching the voltage slowly turn the throttle to the
HD-48637 BREAKOUT BOX
wide open position.
3. Does the voltage steadily increase to greater than 4.6V?
Table 6-96. DTC P2128 Diagnostic Faults
a. Yes. Replace the ECM. See the service manual.
POSSIBLE CAUSES
b. No. Go to Test 6.
Short to voltage in TGS-2 circuit
6. TGS-2 Open Test Short to voltage in sensor power circuit
1. Test continuity between breakout box terminal 39 and TGS malfunction
[204B] terminal 2. Open in sensor ground circuit
2. Is continuity present? ECM malfunction
a. Yes. Go to Test 7.
1. TGS-1 Voltage Test
b. No. Repair open in (V/Y) wire.
1. Connect BREAKOUT BOX (Part No. HD-48637) between
7. Sensor Power-2 Continuity Test wire harness [78B] and ECM [78A]. See 1.2 DIAGNOSTIC
TOOLS.
1. Disconnect TGS [204].
2. Turn IGN ON.
2. Disconnect ECM [78A] from breakout box.
3. Using a multimeter, measure voltage between breakout
3. Test continuity between breakout box terminal 68 and box terminals 39 and 62.
[204B] terminal 3.
4. Is voltage greater than 4.8V?
4. Is continuity present?
a. Yes. Go to Test 5.
a. Yes. Go to Test 8.
b. No. Go to Test 2.
b. No. Repair open in (R/W) wire.
2. TGS-1 Short to Voltage Test
8. Sensor Power Resistance Test
1. Disconnect TGS [204].
1. Measure resistance between breakout box terminal 68
and 62. 2. Disconnect ECM [78A].

2. Is the resistance greater than 100 Ohms? 3. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
41404-C) and a multimeter, measure voltage between
a. Yes. Replace the TGS. See the service manual.
[204B] terminal 2 and ground.
b. No. Go to Test 9.
4. Is voltage less than 1.0V?
9. TMAP Test a. Yes. Go to Test 3.

1. Disconnect the TMAP [80]. b. No. Repair short to voltage in (V/Y) wire.

2. Measure resistance between breakout box terminal 50 3. TGS-1 Short to Ground Test
and 61.
1. Measure voltage between [204B] terminal 3 and ground.
3. Is the resistance greater than 100 Ohms?
2. Is voltage less than 5.25V?
a. Yes. Replace the TMAP. See the service manual.
a. Yes. Go to Test 4.
b. No. Repair short to ground in (R/W) wire.
b. No. Repair short to voltage on (R/W) wire.

4. TGS Test
1. Turn IGN OFF.
2. Test continuity between breakout box terminal 62 and
[204B] terminal 1.
3. Is continuity present?
a. Yes. Replace the TGS. See the service manual.
b. No. Repair open in (BK/GY) wire.

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5. TGS-1 Test 2. Is voltage greater than 5.25V?

1. Measure voltage between breakout box terminal 39 and a. Yes. Repair short to voltage on (R/W) wire.
62. b. No. Go to Test 8.
2. Is voltage greater than 0.2V?
8. Sensor Power Resistance Test
a. Yes. Go to Test 6.
1. Turn IGN OFF
b. No. Go to Test 7.
2. Measure resistance between [204B] terminal 1 and ground.
6. TGS-1 Open Test 3. Is the resistance less than 2 Ohms?
1. Turn IGN OFF. a. Yes. Replace the TGS. See the service manual.
2. Disconnect ECM [78A]. b. No. Go to Test 9.
3. Test continuity between TGS [204B] terminals 2 and 3.
9. TCA Test
4. Is continuity present?
1. Disconnect the ECM [78A].
a. Yes. Repair short between (R/W) and (V/Y) wires.
2. Test continuity between [204B] terminal 1 and breakout
b. No. Repair short to voltage in (V/Y) wire. box terminal 62.

7. Sensor Power-1 Continuity Test 3. Is continuity present?

1. Measure voltage TGS [204B] terminal 3 and ground. a. Yes. Replace the ECM. See the service manual.
b. No. Repair open in (BK/GY) wire.

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DTC P2135, P2138 6.31

DESCRIPTION AND OPERATION 2. TPS-2 Circuit Test
The TAC system uses DTCs when the ECM determines that 1. Test for continuity between breakout box terminal 37 and
a correlation error exists for either the TP sensor or the TGS. 61.
The two TP sensors work opposite of each other. As the throttle 2. Is continuity present?
plate opens, TPS1 voltage ranges from 0.0-5.0V, while TPS2 a. Yes. Repair short to ground in (BN/V) wire.
voltage ranges from 5.0-0.0V. The sum of the two TPS voltages
should always measure approximately 5.0V. b. No. Go to Test 3.

The two TGSs work the same way. As the throttle plate is 3. Sensor Power Circuit Test
opened, TGS1 voltage increases and TGS2 voltage decreases.
The sum of these two voltages should always measure 1. Test for continuity between breakout box terminal 37 and
approximately 5.0V. If either component fails to correlate the 50.
proper voltage or has out-of-range voltage conditions, then the 2. Is continuity present?
ECM will initiate a DTC. Refer to Table 6-97.
a. Yes. Repair short between (BN/V) and (BN/O) wires.
Table 6-97. Code Description b. No. Go to Test 4.

DTC DESCRIPTION 4. Sensor Ground Test

P2135 TPS correlation error 1. Test for continuity between breakout box terminal 36 and
P2138 TGS correlation error TCA [211B] terminal 4.

DTC P2135 2. Is continuity present?

a. Yes. Go to Test 5.
PART NUMBER TOOL NAME
b. No. Repair open in (BN/R) wire.
HD-41404-C HARNESS CONNECTOR TEST KIT
HD-48637 BREAKOUT BOX 5. Shorted 5V Circuit Test
1. Test for continuity between breakout box terminals 36 and
Table 6-98. DTC P2135 Diagnostic Faults 61.

POSSIBLE CAUSES 2. Is continuity present?

Open in TPS-1 circuit a. Yes. Repair short to ground in (BN/R) wire.

Short to ground in TPS-1 circuit b. No. Go to Test 6.

Short to voltage in TPS-1 circuit
6. Sensor Ground Circuit Test
Open in TPS-2 circuit
1. Test for continuity between breakout box terminals 36 and
Short to ground in TPS-2 circuit 50.
Short to voltage in TPS-2 circuit
2. Is continuity present?
Short to voltage in sensor power circuit a. Yes. Repair short between (BN/R) and (BN/O) wires.
TCA malfunction
b. No. Go to Test 7.
1. TPS-2 Voltage Test
7. TPS-2 Circuit Test
1. Connect BREAKOUT BOX (Part No. HD-48637) between
wire harness [78B] and ECM [78A], leaving [78A] discon- 1. Turn IGN OFF.
nected. See 1.2 DIAGNOSTIC TOOLS. 2. Measure voltage between breakout box terminals 36 and
2. Disconnect TCA [211]. 61.

3. Turn IGN ON. 3. Is voltage greater than 5.25V?

a. Yes. Repair short to voltage on (BN/R) wire.
4. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
41404-C) and a multimeter, test for continuity between b. No. Go to Test 8.
breakout box terminal 37 and TCA [211B] terminals 6.
8. Sensor Ground Continuity Test
5. Is continuity present?
1. Measure voltage between breakout box terminals 37 and
a. Yes. Go to Test 2.
61.
b. No. Repair open in (BN/V) wire.

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2. Is voltage greater than 5.25V? 3. Sensor Power Circuit Test

a. Yes. Repair short to voltage on (BN/O) wire. 1. Test for continuity between breakout box terminal 59 and
b. No. Go to Test 9. 50.
2. Is continuity present?
9. Ground Circuit Open Test
a. Yes. Repair short between (BE/GN) and (BN/O) wires.
1. Connect TCA [211].
b. No. Go to Test 4.
2. Clear DTCs using odometer self-diagnostics. See
2.1 INITIAL DIAGNOSTICS, Odometer Self-Diagnostics. 4. Sensor Ground Test
3. Start the vehicle and operate the throttle. 1. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
41404-C) and a multimeter, test for continuity between
4. Did the DTC return?
breakout box terminal 39 and TGS [204B] terminal 4.
a. Yes. Replace the TCA. See the service manual.
2. Is continuity present?
b. No. Operation normal.
a. Yes. Go to Test 5.
DTC P2138 b. No. Repair open in (V/Y) wire.

PART NUMBER TOOL NAME 5. Shorted 5V Circuit Test

HD-41404-C HARNESS CONNECTOR TEST KIT
1. Test for continuity between breakout box terminals 39 and
HD-48637 BREAKOUT BOX 61.
2. Is continuity present?
Table 6-99. DTC P2138 Diagnostic Faults a. Yes. Repair short to ground in (V/Y) wire.
POSSIBLE CAUSES b. No. Go to Test 6.
Open in TGS-1 circuit
Short to ground in TGS-1 circuit 6. Sensor Ground Circuit Test
Short to voltage in TGS-1 circuit 1. Test for continuity between breakout box terminals 39 and
50.
Open in TGS-2 circuit
2. Is continuity present?
Short to ground in TGS-1 circuit
a. Yes. Repair short between (V/Y) and (BN/O) wires.
Short to voltage in TGS-1 circuit
b. No. Go to Test 7.
TCA malfunction

1. TGS-2 Voltage Test 7. Sensor Ground-2 Open Circuit Test

1. Connect BREAKOUT BOX (Part No. HD-48637) between 1. Test for continuity between breakout box terminal 62 and
wire harness [78B] and ECM [78A] leaving [78A] discon- [204B] terminal 1.
nected. See 1.2 DIAGNOSTIC TOOLS 2. Is continuity present?
2. Disconnect TCA [211]. a. Yes. Go to Test 8.
3. Disconnect TGS [204]. b. No. Repair open in (BK/GY) wire.
4. Using HARNESS CONNECTOR TEST KIT (Part No. HD- 8. TGS-2 Circuit Test
41404-C) and a multimeter, test for continuity between
breakout box terminal 59 and [204B] terminal 5. 1. Turn IGN ON.

5. Is continuity present? 2. Measure voltage between breakout box terminals 39 and

61.
a. Yes. Go to Test 2.
3. Is voltage greater than 5.25V?
b. No. Repair open in (BE/GN) wire.
a. Yes. Repair short to voltage on (V/Y) wire.
2. TGS-2 Circuit Test b. No. Go to Test 9.
1. Test for continuity between breakout box terminal 59 and
61. 9. Sensor Ground Continuity Test
2. Is continuity present? 1. Measure voltage between breakout box terminals 59 and
61.
a. Yes. Repair short to ground in (BE/GN) wire.
2. Is voltage greater than 5.25V?
b. No. Go to Test 3.
a. Yes. Repair short to voltage on (BE/GN) wire.
b. No. Go to Test 10.

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10. Ground Circuit Open Test 3. Start the vehicle and operate the throttle.

1. Connect [204]. 4. Did the DTC return?

2. Clear DTCs using odometer self-diagnostics. See a. Yes. Replace the TCA. See the service manual.
2.1 INITIAL DIAGNOSTICS, Odometer Self-Diagnostics. b. No. Operation normal.

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DTC P2176 6.32

DESCRIPTION AND OPERATION 1. Air Inlet Interference Test
The TAC system sets DTC P2176 when the ECM determines 1. Inspect the air inlet and check for foreign debris and/or
the zero position of the throttle plate has not been successfully mechanical interference to the throttle plate.
learned.
2. Were any issues found?
At power up, the ECM adjusts the throttle plate to the limp- a. Yes. Go to Test 2.
home position, then begins to move the throttle plate closed.
The ECM monitors and verifies the amount of movement that b. No. Replace the induction module. See the service
occurred. The throttle plate minimum position is held briefly manual.
then verified against the expected minimum and maximum
range of throttle. If the zero position is found within range, then 2. Validation Test
the position is stored. 1. Remove obstructions and foreign debris from inlet and
If the ECM is not able to learn the minimum position or if the check throttle plate movement.
learning fails four consecutive ignition cycles, the ECM initiates 2. Clear DTCs using odometer self-diagnostics. See
DTC P2176. Refer to Table 6-100. 2.1 INITIAL DIAGNOSTICS, Odometer Self-Diagnostics.

Table 6-100. Code Description 3. Start the engine and operate the throttle.
4. Check for DTCs. See 2.1 INITIAL DIAGNOSTICS, Odo-
DTC DESCRIPTION
meter Self-Diagnostics.
P2176 TCA close position not learned
5. Did DTC P2176 set?
DTC P2176 a. Yes. Replace the induction module. See the service
manual.
Table 6-101. DTC P2176 Diagnostic Faults b. No. Repair complete.
POSSIBLE CAUSES
Induction module malfunction
Mechanical interference

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ENGINE CRANKS, BUT WILL NOT START 6.33

DESCRIPTION AND OPERATION
ed02980
If the starter will not crank the engine, the problem is not EFI
related. See 3.2 STARTING SYSTEM or 5.12 SECURITY
SYSTEM.
There may be DTCs associated with this problem. Check for 4
DTCs and clear them before proceeding with this test.
NOTE 3
To set a CKP DTC, a start attempt must last at least 5 seconds.
2
ed02012
1

1. Terminal A: power
2. Terminal B: ion sense
3. Terminal C: coil rear
4. Terminal D: coil front
Figure 6-44. Ignition Coil Connector Terminals

Connector Information
For additional information about the connectors in the following
diagram(s) and diagnostic procedure(s), including the color of
Figure 6-42. Spark Tester
the harness test kit terminal probes, see B.1 CONNECTORS.

ed02013

Figure 6-43. Ignition Coil Circuit Test

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em00702
Fuel Pump
[141A] B D
Assembly In Tank
Front ACR Rear ACR
(If Equipped) (If Equipped)
[141B] B D [141B] B D

O/GY
O/GY
[203AF] 2 1 2 1 [203AR]

BK
BK
[203BF] 2 1 2 1 [203BR]
Fuel Tank [13B] 1 4 [20A] 14 15

V/GY

V/GY
Y/GN

Y/GN
Harness [13A] 1 4 [20B] 14 15

O/GY
O/GY

BK
BK

EXCEPT FLHR/C TGS

O/GY

BK

FLHR/C ET

V/GY

Y/GN
Sensor
4B TCA [224A] 6 5 4 3 21
Fuel [224B] 6 5 4 3 21
Pump [90A] A B
Fuse

GY
BN
BE
BK
R
V
[211A] 1 2 3 4 5 6 [90B] A B TMAP
15A
4A [211B] 1 2 3 4 5 6 Sensor

BK/W
[204A]

PK/Y
6 5 4 3 21
Y/GN

System
BK/W

BN/O
BK/O
BN/R

BN/V
BK/PK

[204B] 6 5 4 3 2 1
[80A] 1 2 3 4
Relay

BK/W
BN/O

BK/GY
BE/GN

R/W
87 5 4C [80B]

V/Y
Y/GN 1 2 3 4
30 3 3D BE/GY

R/W
V/W
BK/GY
LGN/Y
86
85 To 15A
ECM Fuse
Ignition Coil [83A] [83B]
Power A A Y/GN
Ion Sense B B GY/BE
Coil Rear C C Y/BE
Coil Front D D BE/O
[65B] [65A]
[84A] [84B]
BN/O A A
Front Fuel A A Y/GN W/GN B B VSS
Injector B B W/Y
BK/Y C C
[85A] [85B]

Rear Fuel A A Y/GN BK/BN 4

Injector B B GN/GY
PK/O 3 Front
[95A] [95B] GN/W 2 HO2S
Y/GN 1
B B GY/Y
A A Y/GN [138A]
Purge Solenoid
(Optional)
BK/BN 4
Rear
PK/GN 3
To 15A 2
HO2S
GN/W
Exhaust Y/GN 1 (BK)
Control Fuse
[137A]

1 LGN/R
Active 2 BK
Exhaust 3 V/O
(HDI Only) 4 V/BE
BK
R

[179B]
GN/GY

PK/GN

BE/GN

BK/GN
GY/BE

BK/GY
BK/BN
LGN/Y
BK/PK
GN/W

W/GN

BK/W
BN/O

Y/GN
V/GY
GY/Y

BK/O

BN/R

BE/O

PK/O
BN/V
V/BE

PK/Y

Y/BE

BK/Y

R/W
V/W

W/Y
V/O

V/Y

BK

2 1 [79A]
R

Right
[78B] 19 20 21 2324 28 29 30 3133 363738 39 4043 46 484950 51 52 53 54 59 61 62 63 64 66 68 73 GND 2 2 1 [79B]
[78A] 19 20 21 2324 28 29 30 3133 363738 39 4043 46 484950 51 52 53 54 59 61 62 63 64 66 68 73
HO2S Return
Purge Solenoid
Exhaust Actuator
Rear Fuel Injector
TMAP Sensor Input

Throttle Actuator Control HI

Throttle Actuator Control LO
O2 Heater Ground
Ion Sense
TPS 2
TPS 1

TGS 2

CKP Sensor
Rear HO2 Sensor

ET Sensor

Rear Ignition Coil

TGS 1
5V Sensor Ground 1
5V Sensor Ground 2
CKP Sensor (+)

Ground
ACR Ground

Front Fuel Injector

Front Ignition Coil

Front HO2 Sensor

Exhaust Feedback

5V Sensor Power 1

12V Power

5V Sensor Power 2
Vehicle Speed Input

Vehicle Speed Ground

IAT Sensor

CKP
Sensor
ECM

Figure 6-45. EFI Simplified Schematic

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ENGINE CRANKS BUT WILL NOT START 4. Does battery pass tests?
a. Yes. Go to Test 2.
PART NUMBER TOOL NAME
b. No. Charge or replace battery.
HD-26792 SPARK TESTER
2. Check Engine Lamp Test
Table 6-102. Engine Cranks But Will Not Start Diagnostic
1. Turn IGN ON and engine stop switch to RUN.
Faults
2. Does check engine lamp illuminate for 4 seconds immedi-
POSSIBLE CAUSES ately after key ON?
ECM malfunction a. Yes. Go to Test 3.
Battery voltage too low
b. No. See 6.34 NO ECM POWER.
Ignition system malfunction
Fuel system malfunction 3. Spark Present Test
No or low compression 1. Check spark plug condition and replace if fouled.
2. Using SPARK TESTER (Part No. HD-26792), check spark
1. Preliminary Engine Tests at both plugs while cranking engine.
1. Make sure there is fresh fuel in tank, spark plug wires
3. Is spark present?
firmly connected to coil terminals, fuel injectors are not
clogged and battery connections are in good condition. a. Yes. Perform compression test, check fuel system
and perform fuel pressure test. See the service
2. Check for DTCs. See 2.1 INITIAL DIAGNOSTICS, Odo- manual.
meter Self-Diagnostics. If DTCs are present, see the
appropriate DTC procedure. b. No. The spark plugs will not spark if there is low or
no compression. If spark is not present, test compres-
3. Verify battery condition. See 3.1 BATTERY TESTING. sion before troubleshooting ignition circuit. Once good
compression is confirmed, check condition of ignition
coils, coil primary wiring and spark plug boots. See
6.9 DTC P0373, P0374 or 6.19 DTC P1351, P1352,
P1354, P1355.

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NO ECM POWER 6.34

DESCRIPTION AND OPERATION
Constant power is supplied to the ECM through terminal 71.
The ECM turns on when power is applied to terminal 72 of
connector [78]. The ECM goes through an initialization
sequence every time power is removed and re-applied to ter-
minal 72. The only visible part of this sequence is the check
engine lamp. Upon starting, the check engine lamp will illu-
minate for 4 seconds and then (if parameters are normal) go
out.
If battery power is absent at ECM terminal 71:
• DTCs cannot be cleared. Tool will show them as cleared
but will be present next time ignition key is cycled.
• ECM cannot be re-flashed.

ed01820

1 3

2 9

1. Tail light connector [7]: except FLHX, FLTRX

2. Console pod [53]
3. Positive battery terminal
4. Hands-free antenna connector [209]
5. Fuel pump subharness connector [13]
6. Purge solenoid [95]
7. P&A accessory connector [4]
8. Negative battery terminal
9. ECM [78]
Figure 6-46. Electrical Connectors Under Seat

Connector Information
For additional information about the connectors in the following
diagram(s) and diagnostic procedure(s), including the color of
the harness test kit terminal probes, see B.1 CONNECTORS.

6-102 2011 Touring Diagnostics: Engine Management

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em00820
[30A] [30B]
TSM/
TSSM/ Ignition 2 2 GY
HFSM
[78A] [78B] Main Fuse
ECM 40A
To
12V Battery 71 71 BE/GY BE/GY
Engine Stop Switch 72 72
System
W/BK W/BK
Ground 73 73 BK/GN
Relay
B A
[5B]

R
R

BK
ECM
Fuse

W/BK
GY
15A
BE/GY 2F 2E R

Battery

W/BK
GY
FLHX, [1B] 3 6
FLHTC/CU, FLHX, FLHTC/CU, FLTR
FLTR [1A] 3 6 [33B]

W/BK
GY

Ignition R R 2
Fuse R/BK R/BK 3 Ignition
15A R
Switch
GY 1F 1E R/BK [33A]
R B B R B
R/BK A A R/BK A
W/BK
GY

[222B] [222A] [33B]

[22B] 3 4
FLHR/C FLHR/C
[22A] 3 4
W/BK
GY

Engine Stop
Switch

Figure 6-47. ECM Power Circuit

NO ECM POWER 2. Is fuse good?

a. Yes. Go to Test 3.
PART NUMBER TOOL NAME
b. No. Repair short to ground on (GY) or (W/BK) wire
HD-48637 BREAKOUT BOX
and replace IGN fuse.

Table 6-103. No ECM Power Diagnostic Faults 3. ECM Connector Test

POSSIBLE CAUSES 1. With IGN OFF, disconnect ECM [78].
ECM malfunction 2. Check for backed out, damaged and corroded terminals.
Electrical system malfunction Repair terminal damage as required.

Open or short to ground in ECM battery circuit 3. Connect ECM [78].

Open in ignition circuit 4. Turn IGN ON.
Engine stop switch malfunction 5. Does ECM have power?
a. Yes. Problem solved.
1. ECM Fuse Test
b. No. Go to Test 4.
1. Check ECM fuse.
2. Is fuse good? 4. ECM Battery Wire Test
a. Yes. Go to Test 2. 1. Connect BREAKOUT BOX (Part No. HD-48637) between
b. No. Repair short to ground on (BE/GY) wire and wire harness [78B] and ECM [78A]. See 1.2 DIAGNOSTIC
replace fuse. TOOLS.
2. Using a multimeter, test for battery voltage between
2. IGN Fuse Test breakout box terminal 71 (+) and ground.
1. Check IGN fuse.

2011 Touring Diagnostics: Engine Management 6-103

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3. Is battery voltage present? 7. Engine Stop Switch Battery Voltage Test

a. Yes. Go to Test 5. 1. Disconnect right hand controls [22].
b. No. Repair open in (BE/GY) wire. 2. Turn IGN ON.

5. ECM Switched Voltage Test 3. Measure voltage on [22B] terminal 3 (GY) and ground.
1. Turn IGN ON and engine stop switch to RUN. 4. Is battery voltage present?
2. Measure voltage between breakout box terminal 72 and a. Yes. Go to Test 8.
ground. b. No. Repair open wire (GY).
3. Is battery voltage present?
a. Yes. Go to Test 6.
8. Engine Stop Switch Test
1. Turn IGN OFF and engine stop switch to RUN.
b. No. Repair open (W/BK) wire. If wire is okay, then
continue with tests. Go to Test 7. 2. Measure the resistance between [22A] terminals 3 and 4.
3. Is resistance less than 1.0 Ohm?
6. ECM Ground Wires Test
a. Yes. Repair open in (W/BK) wire from terminal 4 of
1. Measure voltage between positive battery terminal and [22B] and ECM (78B).
breakout box terminal 73.
b. No. Repair or replace engine stop switch. See the
2. Is battery voltage present? service manual.
a. Yes. Replace ECM. See the service manual.
b. No. Repair open in (BK/GN) wire.

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STARTS, THEN STALLS 6.35

DESCRIPTION AND OPERATION STARTS, THEN STALLS
The starts, then stalls condition may be created by the fuel
system, the idle air control system or an ECM failure. When Table 6-104. Starts, Then Stalls Diagnostic Faults
this condition exists, see 2.4 DTC U1300, U1301 OR BUS ER.
POSSIBLE CAUSES
There may be DTCs set causing this condition. Solve the Fuel system malfunction
problems with the DTCs before performing the tests in this
section. The DTCs that may be involved with starts, then stalls Idle air control system malfunction
are: Open serial data circuit
• Fuel injectors: DTCs P0261, P0262, P0263 and P0264 Neutral switch malfunction
• Ignition coils: DTCs P1351, P1352, P1354 and P1355 TSM/TSSM/HFSM malfunction
• Lost idle: DTC P0505 1. Throttle Test
• TPS: DTCs P0122 and P0123 1. Start the engine.
• Password Problem: DTCs P1009 and P1010 2. Will engine start with the throttle partially opened and then
• JSS: DTCs P1501, P1502 and P1503 stall when closed?

• Neutral switch: DTC P1155 a. Yes. See 6.12 DTC P0505.

• All modes: DTCs P0603 and P0605 b. No. SidE StAnd displayed on odometer. Go to Test
2.
Diagnostic Tips c. No. Odometer display normal. Go to Test 4.
• The vehicle will stall on HDI models if the jiffy stand is
extended when the transmission is in gear and the clutch 2. Jiffy Stand Test
is released.
1. Turn IGN OFF.
• If serial data is shorted, U1300 and U1301 will automatic-
2. Raise jiffy stand.
ally set the check engine light.
• DTCs P1009 and P1010 may accompany DTCs U1300 3. Turn IGN ON and engine stop switch to RUN.
and U1301. 4. Does odometer display SidE StAnd?
• If this condition is fuel related, perform Fuel Pressure Test. a. Yes. Inspect JSS for correct mounting and clearance
See the service manual. to jiffy stand tab (0.18 in (4.5 mm). If sensor is
mounted correctly, replace JSS. See the service
• If the fuel system passes the pressure test, perform the
manual.
Fuel System Electrical Test. See 6.36 FUEL SYSTEM
ELECTRICAL TEST. b. No. Go to Test 3.

Connector Information 3. Neutral Switch Test

For additional information about the connectors in the following 1. Is neutral switch circuit operating normally?
diagram(s) and diagnostic procedure(s), including the color of
a. Yes. Replace TSM/TSSM/HFSM. See the service
the harness test kit terminal probes, see B.1 CONNECTORS.
manual.
b. No. Replace neutral switch. See the service manual.

4. Fuel System Test

1. Perform Fuel Pressure test. See the service manual.
2. Is fuel pressure normal?
a. Yes. If fuel injectors are okay, replace ECM. See the
service manual.
b. No. Repair fuel pressure problem. See the service
manual.

2011 Touring Diagnostics: Engine Management 6-105

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FUEL SYSTEM ELECTRICAL TEST 6.36

DESCRIPTION AND OPERATION
ed02014
With the IGN ON and the engine stop switch at RUN, the ECM
will energize the system relay to complete the circuit to the in-
tank fuel pump. It will remain on as long as the engine is
cranking or running and the ECM is receiving ignition reference
pulses from the CKP sensor. If there are no reference pulses,
the ECM will de-energize the system relay within 2 seconds
after ignition is turned on or the engine has stalled, or immedi-
ately after the ignition is shut off.
The fuel pump delivers fuel to the injectors. The pressure reg-
ulator controls system pressure.
See Figure 6-48. When the engine is stopped, the pump can
be turned on by applying battery voltage to the (O/GY) wire
and ground to the (BK) wire of the fuel pump connector [141B].
Improper fuel system pressure may contribute to the following
symptoms:
• Engine cranks, but will not run.
• Engine cuts out (may feel like ignition problems).
• Hesitation, loss of power and poor fuel economy.

NOTE
Figure 6-48. Fuel Pump/Fuel Level Sender Connector:
After turning ignition off, wait 10 seconds before turning the FLHX, FLHTC, FLHTCU, FLTRX
ignition back on to get the fuel pump to reprime. This time-out
period is necessary for the fuel pump and IAC to reset.
Connector Information
For additional information about the connectors in the following
diagram(s) and diagnostic procedure(s), including the color of
the harness test kit terminal probes, see B.1 CONNECTORS.

6-106 2011 Touring Diagnostics: Engine Management

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em00703 Main Fuse

40A

Fuel Pump [5B]

Assembly In Tank B A

R
R
[141A] ECM Fuse

BK
B D
15A
BE/GY 2F 2E

[141B] B D [141B] B D

R
O/GY
O/GY

BK
BK
Battery

[13B] 1 4 [20A] 14 15 [33B] [33A] [222B] [222A]

Ignition
[13A] 1 4 [20B] 14 15 Fuse 1 1 R B B R
Fuel Tank 15A

O/GY
O/GY

R 2 2

BK
BK

R/BK A A R/BK
Harness 1F 1E R/BK 3 3

GY
Ignition
W/BK Switch [33B] A BC
EXCEPT FLHR/C [33A] A BCD
FLHR/C [1A] 3 6
O/GY

BK

[1B] 3 6 1F 1E Ignition
Switch

GY
15A
4B

W/BK
W/BK
Ignition

GY
Fuel Fuse
Pump
Fuse [22B] 3 4 [22B] 3 4

15A [22A] 3 4 [22A] 3 4

4A

W/BK
GY
W/BK
GY

W/BK
W/BK
Y/GN

System
Relay Engine Stop Switch Engine Stop Switch
87 5 4C Y/GN

30 3 3D BE/GY
86 1 3C GN/O
85 2 4D W/BK

Ignition Coil [83A] [83B]

Power A A Y/GN
Ion Sense B B GY/BE
Coil Rear C C Y/BE
Coil Front D D BE/O

BK/BN 4
[84A] [84B] PK/O 3 Front
GN/W 2 HO2S
Front Fuel Y/GN Y/GN 1
A A
Injector B B W/Y

[85A] [85B] [138A]

BK/BN 4
Rear Fuel A A Y/GN PK/GN 3 Rear
Injector B B GN/GY GN/W 2 HO2S
Y/GN 1
[95A] [95B]
[137A]
B B GY/Y
A A Y/GN
Purge Solenoid
(Optional)
GN/GY

PK/GN

BK/GN
GY/BE

BE/GY
BK/BN
GN/W
GN/O

Y/GN

W/BK
GY/Y

BE/O

PK/O
Y/BE
W/Y

Right
[78B] 20 23 27 28 31 33 46 48 52 53 54 66 71 72 73 GND 2
[78A] 20 23 27 28 31 33 46 48 52 53 54 66 71 72 73
Purge Solenoid

Rear Fuel Injector

HO2 Heater Ground

HO2S Return
Front Fuel Injector
System Relay Enable

Rear HO2 Sensor

Ion Sense

Rear Ignition Coil

12V Battery
Front Ignition Coil

12V Stop Switch

12V Power

Front HO2 Sensor

Ground

ECM

Figure 6-49. System Relay Circuit

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FUEL SYSTEM ELECTRICAL TEST 2. Fuel Pump Voltage Test

PART NUMBER TOOL NAME 1. Disconnect fuel pump connector [141].

HD-41404-C HARNESS CONNECTOR TEST KIT 2. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
41404-C) and a multimeter, measure voltage between fuel
pump [141A] terminals B and D during the first 2-3 seconds
Table 6-105. Fuel System Electrical Test Diagnostic Faults after IGN ON.
POSSIBLE CAUSES 3. Is battery voltage present?
Fuel pump malfunction a. Yes. Replace fuel pump. See the service manual.
Fuel pump electrical system b. No. Go to Test 3.
ECM malfunction
Electrical system malfunction 3. Fuel Pump Open Circuit Test
System relay malfunction 1. Turn IGN OFF.
Open ground circuit 2. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
41404-C) and a multimeter, test for continuity between
1. ECM Fuse Test [141A] terminal B and system relay [64-1B] terminal 4C.
1. Check ECM fuse. 3. Is continuity present?
2. Is fuse good? a. Yes. Repair open on (BK) wire to ground.
a. Yes. Go to Test 2. b. No. Repair open (Y/GN) wire.
b. No. See 6.34 NO ECM POWER.

6-108 2011 Touring Diagnostics: Engine Management

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MISFIRE AT IDLE OR UNDER LOAD 6.37

DESCRIPTION AND OPERATION
Misfire conditions may be caused by:
• Battery condition and connections.
• Fuel system problems. Refer to Table 6-1, Table 6-2 and
Table 6-3.
• Ignition system faults.
Diagnostic Tips
Wipe up spilled fuel and dispose of rags in a suitable
manner. An open spark around gasoline could cause a
fire or explosion, resulting in death or serious injury.
(00518b)
When performing the steps in the diagnostic tests, a known
good part can be used to verify whether a suspected part is
faulty. The ignition coil does not require full installation to be
functional. Verify faulty ignition coil by performing resistance
test. See 6.19 DTC P1351, P1352, P1354, P1355.
whether a problem exists in the ignition or fuel systems. If the
test light flashes without interruption on both cylinders during
the misfire event, verify spark plug condition and gap and
inspect the fuel system for proper operation. If the test light
does not flash, or the flash is interrupted during the misfire
event, the problem is ignition related.
1. Turn IGN OFF.
2. Remove front spark plug wire and install SNAP-ON IN-
LINE SPARK TESTER (Part No. YA840) between spark
plug wire and spark plug.
3. Start engine and inspect tester light. The light will flash on
each spark event if power is transmitted to the plug.
4. Install and repeat procedure on rear cylinder.
NOTE
A SNAP-ON IN-LINE SPARK TESTER (Part No. YA840) can
also be used in conjunction with a load applying dynamometer
to diagnose misfire under load.
ed01780

ed02012

Figure 6-51. In-line Spark Tester

Figure 6-50. Spark Tester

Connector Information
For additional information about the connectors in the following
IN-LINE SPARK TESTER diagram(s) and diagnostic procedure(s), including the color of
the harness test kit terminal probes, see B.1 CONNECTORS.
PART NUMBER TOOL NAME
YA840 SNAP-ON IN-LINE SPARK TESTER

See Figure 6-51. The use of a SNAP-ON IN-LINE SPARK

TESTER (Part No. YA840) or equivalent can help determine

2011 Touring Diagnostics: Engine Management 6-109

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em00702
Fuel Pump
[141A] B D
Assembly In Tank
Front ACR Rear ACR
(If Equipped) (If Equipped)
[141B] B D [141B] B D

O/GY
O/GY
[203AF] 2 1 2 1 [203AR]

BK
BK
[203BF] 2 1 2 1 [203BR]
Fuel Tank [13B] 1 4 [20A] 14 15

V/GY

V/GY
Y/GN

Y/GN
Harness [13A] 1 4 [20B] 14 15

O/GY
O/GY

BK
BK

EXCEPT FLHR/C TGS

O/GY

BK

FLHR/C ET

V/GY

Y/GN
Sensor
4B TCA [224A] 6 5 4 3 21
Fuel [224B] 6 5 4 3 21
Pump [90A] A B
Fuse

GY
BN
BE
BK
R
V
[211A] 1 2 3 4 5 6 [90B] A B TMAP
15A
4A [211B] 1 2 3 4 5 6 Sensor

BK/W
[204A]

PK/Y
6 5 4 3 21
Y/GN

System
BK/W

BN/O
BK/O
BN/R

BN/V
BK/PK

[204B] 6 5 4 3 2 1
[80A] 1 2 3 4
Relay

BK/W
BN/O

BK/GY
BE/GN

R/W
87 5 4C [80B]

V/Y
Y/GN 1 2 3 4
30 3 3D BE/GY

R/W
V/W
BK/GY
LGN/Y
86
85 To 15A
ECM Fuse
Ignition Coil [83A] [83B]
Power A A Y/GN
Ion Sense B B GY/BE
Coil Rear C C Y/BE
Coil Front D D BE/O
[65B] [65A]
[84A] [84B]
BN/O A A
Front Fuel A A Y/GN W/GN B B VSS
Injector B B W/Y
BK/Y C C
[85A] [85B]

Rear Fuel A A Y/GN BK/BN 4

Injector B B GN/GY
PK/O 3 Front
[95A] [95B] GN/W 2 HO2S
Y/GN 1
B B GY/Y
A A Y/GN [138A]
Purge Solenoid
(Optional)
BK/BN 4
Rear
PK/GN 3
To 15A 2
HO2S
GN/W
Exhaust Y/GN 1 (BK)
Control Fuse
[137A]

1 LGN/R
Active 2 BK
Exhaust 3 V/O
(HDI Only) 4 V/BE
BK
R

[179B]
GN/GY

PK/GN

BE/GN

BK/GN
GY/BE

BK/GY
BK/BN
LGN/Y
BK/PK
GN/W

W/GN

BK/W
BN/O

Y/GN
V/GY
GY/Y

BK/O

BN/R

BE/O

PK/O
BN/V
V/BE

PK/Y

Y/BE

BK/Y

R/W
V/W

W/Y
V/O

V/Y

BK

2 1 [79A]
R

Right
[78B] 19 20 21 2324 28 29 30 3133 363738 39 4043 46 484950 51 52 53 54 59 61 62 63 64 66 68 73 GND 2 2 1 [79B]
[78A] 19 20 21 2324 28 29 30 3133 363738 39 4043 46 484950 51 52 53 54 59 61 62 63 64 66 68 73
HO2S Return
Purge Solenoid
Exhaust Actuator
Rear Fuel Injector
TMAP Sensor Input

Throttle Actuator Control HI

Throttle Actuator Control LO
O2 Heater Ground
Ion Sense
TPS 2
TPS 1

TGS 2

CKP Sensor
Rear HO2 Sensor

ET Sensor

Rear Ignition Coil

TGS 1
5V Sensor Ground 1
5V Sensor Ground 2
CKP Sensor (+)

Ground
ACR Ground

Front Fuel Injector

Front Ignition Coil

Front HO2 Sensor

Exhaust Feedback

5V Sensor Power 1

12V Power

5V Sensor Power 2
Vehicle Speed Input

Vehicle Speed Ground

IAT Sensor

CKP
Sensor
ECM

Figure 6-52. EFI Simplified Schematic

6-110 2011 Touring Diagnostics: Engine Management

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MISFIRE AT IDLE OR UNDER LOAD 2. Is carbon tracking present?

a. Yes. Switch ignition coil with known good unit and
PART NUMBER TOOL NAME perform Test 2. If spark jumps gap, replace ignition
HD-41404-C HARNESS CONNECTOR TEST KIT coil. See the service manual. If not, then continue with
tests. Go to Test 5.
HD-48637 BREAKOUT BOX
YA840 SNAP-ON IN-LINE SPARK TESTER b. No. Replace ignition coil. See the service manual.

5. Ignition Coil Primary Wire Continuity Test

Table 6-106. Misfire At Idle or Under Load Diagnostic
Faults 1. Turn IGN OFF.

POSSIBLE CAUSES 2. Remove system relay and disconnect ignition coil [83].

ECM malfunction 3. Measure resistance between [64-1B] socket terminal 4C

and [83B] terminal A. Wiggle connectors while measuring.
Ignition system malfunction
4. Is resistance continuously less than 0.5 Ohms?
Fuel system malfunction
a. Yes. Go to Test 6.
Electrical system malfunction
b. No. Repair intermittent on (Y/GN) wire.
1. Power Ground Continuity Test
1. Connect BREAKOUT BOX (Part No. HD-48637) between 6. Battery to System Relay Voltage Drop
wire harness [78B] and ECM [78A]. See 1.2 DIAGNOSTIC Test
TOOLS.
1. Reconnect ignition coil and install system relay.
2. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
2. Turn IGN ON, start engine.
41404-C) and a multimeter, check for continuity between
breakout box terminal 73 to ground. 3. With engine running, measure voltage drop between bat-
tery and system relay [64-1B] socket terminal 4C (under-
3. Is continuity present?
side of fuse/relay block). See 1.3 DIAGNOSTICS AND
a. Yes. Go to Test 2. TROUBLESHOOTING, Voltage Drop.
b. No. Repair poor ground on (BK) wire. 4. Is voltage drop less than 1.0V?
a. Yes. Problem is fuel related. Recheck symptoms.
2. Spark Test
b. No. Go to Test 7.
1. Connect SNAP-ON IN-LINE SPARK TESTER (Part
No. YA840) between front spark plug cable and ground.
See 1.2 DIAGNOSTIC TOOLS.
7. System Relay Test
1. With engine running, measure voltage drop between bat-
2. Crank engine for a few seconds.
tery and system relay [64-1B] socket terminal 3D (under-
3. Remove tester from front spark plug cable and connect side of fuse/relay block).
rear spark plug cable and ground.
2. Is voltage drop less than 1.0V?
4. Did spark jump gap on both cables? a. Yes. Replace system relay. See the service manual.
a. Yes. Check for faulty, worn or cracked spark plugs,
b. No. Go to Test 8.
plug fouling due to mechanical problems or faulty
connection at plug or coils. See the service manual
and repair as required.
8. Battery to ECM Fuse Voltage Drop Test
1. With engine running, measure voltage drop between bat-
b. No. Go to Test 3. tery and [64-1B] socket terminal 2F.

3. Spark Plug Wire Test 2. Is voltage drop less than 1.0V?

1. Disconnect the spark plug wires. a. Yes. Repair (BE/GY) wire or connections.

2. Measure the resistance of the spark plug wires. b. No. Go to Test 9.

3. Is the front and rear spark plug wire resistance within the 9. Battery to Fuse Block Voltage Drop Test
specified range? Refer to Table 1-5.
1. With engine running, measure voltage drop between bat-
a. Yes. Go to Test 4. tery and [64-1B] socket terminal 2E.
b. No. Replace the out of range spark plug wire. See 2. Is voltage drop less than 1.0V?
the service manual.
a. Yes. Repair ECM fuse connections or replace ECM
4. Carbon Tracking Inspection Test fuse.

1. Inspect top of ignition coils for carbon tracking. b. No. Go to Test 10.

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10. Battery to Main Fuse Voltage Drop Test 11. Battery to Main Fuse Block Voltage Drop
1. With engine running, measure voltage drop between bat- Test
tery (+) and main fuse [5B] terminal A. 1. With engine running, measure voltage drop between bat-
2. Is voltage drop less than 1.0V? tery (+) and main fuse [5B] terminal B.
a. Yes. Repair (R) wire. 2. Is voltage drop less than 1.0V?
b. No. Go to Test 11. a. Yes. Repair main fuse connections or replace main
fuse.
b. No. Repair (R) wire between battery and main fuse
[5B] terminal B, including connections at starter.

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TABLE OF CONTENTS

SUBJECT............................................................................................................................PAGE NO.
7.1 ANTI-LOCK BRAKE SYSTEM (ABS) GENERAL INFORMATION............................................7-1
7.2 DTC C1017, C1018...................................................................................................................7-4
7.3 DTC C1021, C1023...................................................................................................................7-7
7.4 DTC C1025, C1027, C1206, C1208..........................................................................................7-9
7.5 DTC C1032, C1034.................................................................................................................7-11
7.6 DTC C1042, C1043.................................................................................................................7-14
7.7 DTC C1094..............................................................................................................................7-16
7.8 DTC C1095..............................................................................................................................7-19
7.9 DTC C1151..............................................................................................................................7-22
7.10 DTC C1153............................................................................................................................7-24
7.11 DTC C1158............................................................................................................................7-26
7.12 DTC C1212............................................................................................................................7-27
7.13 DTC C1214............................................................................................................................7-30
7.14 DTC C1216............................................................................................................................7-33
7.15 DTC C1014, C1055-C1066, C1118, C1121..........................................................................7-36
7.16 ABS INDICATOR ALWAYS ON OR INOPERATIVE..............................................................7-39

ABS
NOTES
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ANTI-LOCK BRAKE SYSTEM (ABS) GENERAL

INFORMATION 7.1
DESCRIPTION AND OPERATION
ed03081
PART NUMBER TOOL NAME 1 2
HD-48650 DIGITAL TECHNICIAN II

The ABS module controls brake application under extreme 7

stopping conditions in order to keep the wheels from slipping. 6
When wheel slip is detected during a brake application, an
ABS event occurs. The hydraulic pressure to the individual
wheel is controlled to prevent slipping on that wheel. Specific
valves and individual hydraulic lines are provided for each
5
4
wheel. The ABS can decrease, hold or increase fluid pressure
to each brake. However, the ABS cannot increase hydraulic
pressure above the pressure being transmitted by the master
cylinder. 3
During an ABS event, a series of rapid pulsations may be felt
in either the front brake lever or rear brake pedal. These 1. Front HO2S [138]
pulsations are caused by the rapid changes in position of the 2. ABS module [166] (if equipped)
individual solenoid valves as the ABS responds to wheel speed 3. Active exhaust [179]
sensor inputs and attempts to prevent wheel slip. These 4. Rear WSS [168]
pulsations are present only during initialization and anti-lock 5. Rear HO2S [137]
braking. The pulsations stop when normal braking is resumed 6. TSM/TSSM/HFSM [30]
or when the vehicle comes to a stop. A ticking or popping noise 7. HFSM antenna jumper harness [208]
may also be heard as the solenoid valves cycle rapidly. During Figure 7-1. Under Right Side Cover
anti-lock braking on dry pavement intermittent chirping noises
may be heard as the tires approach slipping.These noises and
pulsations are considered normal during anti-lock operation.
Vehicles equipped with ABS may be stopped by applying ed03127
normal force to the brake pedal or lever. Brake operation during
normal braking is no different then that of previous non-ABS
systems. Maintaining a constant force on the brake pedal or
lever provides the shortest stopping distance while maintaining
vehicle stability.
In addition to the normal brake system, the ABS consists of
the following components.
• See Figure 7-1. The ECU contains the motor relay, valve
relay, system enable relay and the solenoids.
• See Figure 7-1. The HCU contains the four valves (an
apply valve and release valve for each wheel), two pumps,
pump motor and accumulators.
• See Figure 7-2. Front WSS.
Figure 7-2. Front WSS (ABS Only)
• See Figure 7-3. Rear WSS.
• See Figure 7-4. ABS Diode Pack.
• See Figure 7-2. Front WSS connector.
• See Figure 7-1. Rear WSS connector.
When referencing the ECU and the HCU as a unit they are
referred to as the ABS module. When the ECU is replaced,
use DIGITAL TECHNICIAN II (Part No. HD-48650) to program
the ECU.

2011 Touring Diagnostics: ABS 7-1

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ed03126 ed03073

2
3

1. Ambient air temperature sensor [107]

Figure 7-3. Rear WSS (ABS Only)
2. Fuel tank
3. Front WSS [167]
Figure 7-5. Front WSS and Ambient Air Temperature
ed03111
Sensor
2 3
1
Pressure Hold
4 The ECU closes the apply valve and keeps the release valve
closed in order to isolate the slipping wheel when wheel slip
occurs. This holds the pressure steady on the brake so that
the hydraulic pressure does not increase or decrease.

5 Pressure Decrease
If a pressure hold does not correct the wheel slip condition, a
pressure decrease occurs. The apply valve is closed and the
release valve is opened. The excess fluid is stored in the
6 accumulator until the pump can return the fluid to the master
cylinder or fluid reservoir.
1. Security siren [142]
2. Security siren (if equipped) Pressure Increase
3. Fuse block After the wheel slip is corrected, a pressure increase occurs.
4. Main fuse [5] The ECU increases the pressure to individual wheels during
5. DLC [91] deceleration in order to reduce the speed of the wheel. The
6. ABS diode pack [201] (if equipped) apply valve is opened and the release valve is closed. The
Figure 7-4. Under Left Side Cover: Except FLTRX, FLHX, increased pressure is delivered from the master cylinder and
FLHTC will not exceed the pressure from the master cylinder.

Initialization Self-Test
The ABS module performs one initialization test each ignition
cycle. The ABS module verifies internal circuitry and the wheel
speed sensor circuits.
As part of the initialization self-test the ABS module also does
a modulator test. This test consists of energizing the actuators
and commanding the motor and solenoids on and off.The ABS
module will run this test the first time the vehicle speed exceeds
10 mph (16 km/h) in an ignition cycle or when all the following
conditions are met for the first time in an ignition cycle:
• Brake is not applied.
• Engine is above 500 rpm.
• No ABS event present.
• The system ECU is enabled.
• The ABS system is not communicating with DIGITAL
TECHNICIAN II (Part No. HD-48650).

7-2 2011 Touring Diagnostics: ABS

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ABS Indicator the ECU.

See Figure 7-6.The speedometer illuminates the ABS indicator
when the following occurs.
• The ECU detects an ABS disabling malfunction. The ECU
sends a serial data message to the instrument requesting
illumination.
• The speedometer performs a bulb check.
• The speedometer detects a loss of communication with
The ECU sends a message to the instrument when a malfunc-
tion that disables ABS operation is detected. Depending on
the fault the ABS Indicator may stay on even after the malfunc-
tion is corrected. The indicator will not go off until the vehicle
is operated at speeds greater than 10 mph (16 km/h). It is
important to verify that this is not the cause of an ABS indicator
which is illuminated when no DTCs are set, before attempting
to diagnose other possible causes.

ed03170

1 8 3
2 11 1

11

50 60 70 40
30 50
40 80
30 90 20 60
MPH RPM x100
20 100
10 70
10 110
0 120 0 80

9 C
H A R ERT I FI ED
L EY -DA V I DSON
HAR
L EY -DA VI DSON

7 7 2
6
10 9 8
5 4 10
4 6 5

1. Speedometer 7. Check engine lamp

2. Security lamp (key icon) 8. Battery discharge lamp
3. Tachometer 9. Sixth gear lamp
4. Cruise lamp 10. ABS lamp
5. Odometer/trip odometer/clock 11. Pursuit lamp (Police models)
6. Low fuel warning lamp
Figure 7-6. Speedometer

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DTC C1017, C1018 7.2

DESCRIPTION AND OPERATION Conditions for Setting the DTC
PART NUMBER TOOL NAME DTC C1017 will set if any of the following conditions exist:

HD-48650 DIGITAL TECHNICIAN II • The voltage across the pump is below 8.0V for 0.2
seconds.
See Figure 7-7.
• The battery voltage to the pump is less than 8.84V.
• DTC C1017: The ABS module monitors the internal relay
for the pump motor along with the power circuit going to • The pump relay coil is NOT shorted to battery or open.
it. DTC C1018 will set if the following conditions exist when the
• DTC C1018: The ABS module monitors the internal pump pump motor is commanded off:
motor and the circuit supplying ground to the pump motor. • The system voltage is between 8.0-18.0V.
• The voltage at the low side of the pump is greater than
Table 7-1. Code Description 1.7V.
DTC DESCRIPTION DTC C1018 will set if the following conditions exist when the
C1017 Pump motor power circuit open fault pump is commanded on:
C1018 Pump motor ground high resistance fault • The system voltage is between 10.0-18.0V.
• The voltage across the pump motor is less than 8.4V.

ed01947
• The voltage at the high side of the pump motor is greater
2 4 than 8.84V.

Action Taken When the DTC Sets

• ABS is disabled.
• The ABS indicator is illuminated.
3
Conditions for Clearing the DTC
The condition for the DTC is no longer present and the DTC
has been cleared in self-diagnostic mode or DIGITAL TECHNI-
CIAN II (Part No. HD-48650).
The ABS module automatically clears the historic DTC when
1 5 a current DTC is not detected in 50 consecutive drive cycles.

1. Pump motor connector (ECU)

Diagnostic Tips
2. Solenoids The following conditions are possible causes for DTC C1017:
3. Pump motor
• High resistance or open pump motor battery circuit.
4. Valves
5. Pump motor connector (HCU) • Internal ECU pump relay fault.
Figure 7-7. ECU and HCU Pump Motor Connectors • Battery or charging malfunction.
The following conditions are possible causes for DTC C1018:
• Pump motor ground circuit has high resistance or open.
• Battery or charging malfunction.

Connector Information
For additional information about the connectors in the following
diagram(s) and diagnostic procedure(s), including the color of
the harness test kit terminal probes, see B.1 CONNECTORS.

7-4 2011 Touring Diagnostics: ABS

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em00858 ECU
HCU
1 1 Pump Motor Supply
[64-2B] Pump M
1E 4A Motor
2 2 Pump Motor Ground
Ignition ABS
15A 30A

1F 4B

GY

R/V
R/V 20 20 Battery (Motor)

R/V 10 10 Battery

GY 19 19 Ignition

Speedometer [39A] [39B] [20A] [20B]

FLHR/C Serial Data 2 2 LGN/V LGN/V 2 2 LGN/V

9 9 Serial Data
Except Serial Data 2 2 LGN/V LGN/V 13 13 LGN/V
FLHR/C

Tachometer [108A] [108B] [1B] [1A]

BK 1 1 Ground
Except Serial Data 2 2 LGN/V
FLHR/C BK 11 11 Ground (Motor)

Speedometer [39A] [39B]

ABS Module
GND 1 [166B] [166A]

Figure 7-8. ABS Power and Ground Schematic

DTC C1017 2. Battery Circuit Short to Ground Test

PART NUMBER TOOL NAME 1. Connect ABS BREAKOUT BOX (Part No. HD-48642)
between wire harness [166B] and ABS module [166A].
HD-41404-C HARNESS CONNECTOR TEST KIT See 1.2 DIAGNOSTIC TOOLS.
HD-48642 ABS BREAKOUT BOX
2. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
41404-C) and a multimeter, test for continuity between
Table 7-2. DTC C1017 Diagnostic Faults ABS [166B] terminals 1 and 20 at breakout box.

POSSIBLE CAUSES 3. Is continuity present?

ECU malfunction a. Yes. Repair short to ground ABS module [166B] ter-
minal 20 (R/V) wire and replace the 30A ABS fuse.
Open ABS fuse
Short to ground in battery circuit b. No. Replace ECU and 30A ABS fuse. See the service
manual.
Open battery circuit
Open ground circuit 3. Battery Voltage Circuit Test
1. Connect ABS BREAKOUT BOX (Part No. HD-48642)
1. ABS Fuse Test between wire harness [166B] and ABS module [166A].
1. Test the charging system for proper operation before See 1.2 DIAGNOSTIC TOOLS.
proceeding. See 3.5 CHARGING SYSTEM.
2. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
2. Inspect the 30A ABS fuse. 41404-C) and a multimeter, test for battery voltage
between breakout box terminals 1 and 20.
3. Is the fuse good?
a. Yes. Go to Test 3.
b. No. Go to Test 2.

2011 Touring Diagnostics: ABS 7-5

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3. Is battery voltage present? DTC C1018

a. Yes. Go to Test 4.
PART NUMBER TOOL NAME
b. No. Repair open in ABS module [166B] terminal 20
HD-41404-C HARNESS CONNECTOR TEST KIT
(R/V) wire.
HD-48642 ABS BREAKOUT BOX
4. Ground Circuit Open Test
1. Test for continuity between breakout box terminal 11 and Table 7-3. DTC C1018 Diagnostic Faults
ground.
POSSIBLE CAUSES
2. Is continuity present? ECU malfunction
a. Yes. Replace ECU. See the service manual.
Open ground circuit
b. No. Repair open in ground circuit ABS module [166B]
terminal 11 (BK) wire. 1. Ground Circuit Open Test
1. Connect ABS BREAKOUT BOX (Part No. HD-48642)
between wire harness [166B] and ABS [166A]. See
1.2 DIAGNOSTIC TOOLS.
2. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
41404-C) and a multimeter, test for continuity between
breakout box terminal 11 and ground.
3. Is continuity present?
a. Yes. Replace ECU. See the service manual.
b. No. Repair open in ground circuit ABS module [166B]
terminal 11 (BK) wire.

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DTC C1021, C1023 7.3

DESCRIPTION AND OPERATION DTC C1023 will set if the following conditions exist for over 20
seconds.
PART NUMBER TOOL NAME
• The rear wheel speed equals 0 mph (0 km/h).
HD-48650 DIGITAL TECHNICIAN II
• The front wheel speed is greater than 10 mph (16 km/h).
The active WSS is supplied system voltage from the ABS
• The difference between the two wheel speeds is greater
module. The sensor then returns a 7 mA or 14 mA signal back
than 11 mph (18 km/h).
to the ABS module.
Action Taken When the DTC Sets
Table 7-4. Code Description • The ABS module disables the ABS.
DTC DESCRIPTION • The ABS indicator is illuminated.
C1021 WSS equals 0 (Front)
Conditions for Clearing the DTC
C1023 WSS equals 0 (Rear)
The condition for the DTC is no longer present and the DTC
Conditions for Setting the DTC has been cleared in self-diagnostic mode or DIGITAL TECHNI-
CIAN II (Part No. HD-48650).
• Ignition voltage is greater than 6.5V.
The ABS module automatically clears the historic DTC when
• The ABS is inactive. a current DTC is not detected in 50 consecutive drive cycles.
• The brake is not depressed. Diagnostic Tips
• There are no WSS circuit malfunctions. The following conditions are possible causes for this fault:
• Vehicle must be driven above 10 mph (16 km/h) for 20 • Internal sensor fault.
seconds without a brake input.
• Spinning up the rear wheel over 10 mph (16 km/h) with
DTC C1021 will set if the following conditions exist for over 20 the vehicle in a stationary position for an extended period
seconds: of time (dynamometer).
• The front wheel speed equals 0 mph (0 km/h).
Connector Information
• The rear wheel speed is greater than 10 mph (16 km/h).
For additional information about the connectors in the following
• The difference between the two wheel speeds is greater diagram(s) and diagnostic procedure(s), including the color of
than 11 mph (18 km/h). the harness test kit terminal probes, see B.1 CONNECTORS.

em00463
ECU
Front Wheel Speed Sensor High
Rear Wheel Speed Sensor High

Front Wheel Speed Sensor Low

Rear Wheel Speed Sensor Low

7 8 17 18 [166A]
7 8 17 18 [166B]
BE/BN
BE/V

BK/BE
BK/V

Rear BK BK B B BE/V BK/V B B BK BK Front

WSS R R A A BE/BN BK/BE A A R R WSS

[168A] [168B] [167B] [167A]

Figure 7-9. WSS

2011 Touring Diagnostics: ABS 7-7

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DTC C1021, C1023 2. Validation of Current DTC Test

1. Clear the DTC. See 2.1 INITIAL DIAGNOSTICS.
Table 7-5. DTC C1021, C1023 Diagnostic Faults
2. Start engine and wait 10 seconds for ABS to complete
POSSIBLE CAUSES initialization test.
Faulty WSS 3. Did the DTC set?
Worn bearing assembly a. Yes. Replace appropriate bearing assembly and
Dynamometer test WSS. See the service manual.
b. No. This code may occur if the vehicle experiences
1. DTC Verification Test an abnormal amount of wheel slippage due to slippery
1. Check for DTCs. conditions under launch or intentional front or rear
wheel spin (dynamometer testing).
2. Are any other wheel speed DTCs present?
a. Yes. See 2.1 INITIAL DIAGNOSTICS.
b. No. Go to Test 2.

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DTC C1025, C1027, C1206, C1208 7.4

DESCRIPTION AND OPERATION Action Taken When the DTC Sets
PART NUMBER TOOL NAME • The ABS module disables the ABS.

HD-48650 DIGITAL TECHNICIAN II • The ABS indicator is illuminated.

The active WSS is supplied system voltage from the ABS Conditions for Clearing the DTC
module. The sensor then returns a 7 mA or 14 mA signal back The condition for the DTC is no longer present and the DTC
to the ABS module. has been cleared in self-diagnostic mode or DIGITAL TECHNI-
CIAN II (Part No. HD-48650).
Table 7-6. Code Description
The ABS module automatically clears the historic DTC when
DTC DESCRIPTION a current DTC is not detected in 50 consecutive drive cycles.
C1025 Wheel speed signal intermittent (Front) Diagnostic Tips
C1027 Wheel speed signal intermittent (Rear) The following conditions are possible causes for this fault:
C1206 Wheel speed signal frequency out of range • External or internal wheel speed circuit intermittent open.
(Front)
• Mismatched or improperly sized tires.
C1208 Wheel speed signal frequency out of range
(Rear) • Electrical noise on the WSS wires.
• Worn suspension components.
Conditions for Setting the DTC
The DTC will set if the following conditions exist. • Rough terrain.

• The ABS module detects a rapid variation in the wheel If the fault only occurs in moist conditions (rain, snow, vehicle
speed. The wheel speed changes by 12 mph (20 km/h) wash, etc.) inspect the wheel speed sensor and wiring for signs
or more in 0.01 second. The change must occur 3 times of water intrusion.
with no more than 0.2 seconds between occurrences. Connector Information
• The frequency of the wheel speed input goes above For additional information about the connectors in the following
2.5kHz for 20 milliseconds. diagram(s) and diagnostic procedure(s), including the color of
the harness test kit terminal probes, see B.1 CONNECTORS.

em00463
ECU
Front Wheel Speed Sensor High
Rear Wheel Speed Sensor High

Front Wheel Speed Sensor Low

Rear Wheel Speed Sensor Low

7 8 17 18 [166A]
7 8 17 18 [166B]
BE/BN
BE/V

BK/BE
BK/V

Rear BK BK B B BE/V BK/V B B BK BK Front

WSS R R A A BE/BN BK/BE A A R R WSS

[168A] [168B] [167B] [167A]

Figure 7-10. WSS

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DTC C1025 (FRONT), C1027 (REAR), C1206, 3. Validation of Current DTC Test
C1208 1. Clear the DTC. See 2.1 INITIAL DIAGNOSTICS.
PART NUMBER TOOL NAME 2. Operate vehicle under condition for running DTC.
HD-41404-C HARNESS CONNECTOR TEST KIT 3. Does DTC set?
HD-48642 ABS BREAKOUT BOX a. Yes. Go to Test 4.
b. No. See diagnostic tips.
Table 7-7. DTC C1025 (Front), C1027 (Rear), C1206, C1208
Diagnostic Faults 4. WSS Circuit Open Test
POSSIBLE CAUSES 1. Connect ABS BREAKOUT BOX (Part No. HD-48642)
between wire harness [166B] and ABS module [166A].
Electrical interference
See 1.2 DIAGNOSTIC TOOLS.
Poor connections
2. Turn IGN ON.
Intermittent open in WSS circuits
3. Start engine and wait 10 seconds for ABS to complete
Faulty WSS
initialization test.
Worn bearing assembly
4. While wiggling harness, using HARNESS CONNECTOR
1. Electrical Interference Test TEST KIT (Part No. HD-41404-C) and a multimeter, check
for voltage at breakout box terminal 18 to ground (front
1. Inspect vehicle for accessories that may cause electrical wheel) or terminal 7 to ground (rear wheel).
interference with the wheel speed sensors.
5. Does voltage drop out intermittently?
2. Electrical interference present?
a. Yes. Repair open in circuits.
a. Yes. Remove or relocate interference.
b. No. Go to Test 5.
b. No. Go to Test 2.
5. Worn or Damaged Components Test
2. Loose or Damaged Connections Test
1. Inspect for worn or damaged suspension components.
1. See Figure 7-2 and Figure 7-3. Inspect for loose or dam-
aged connections on WSS circuits. 2. Were worn or damaged components found?
a. Yes. Replace worn or damaged components as
2. Were poor connections found?
necessary.
a. Yes. Repair connections and circuits.
b. No. Replace the appropriate bearing assembly and
b. No. Go to Test 3. WSS. See the service manual.

7-10 2011 Touring Diagnostics: ABS

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DTC C1032, C1034 7.5

DESCRIPTION AND OPERATION Action Taken When the DTC Sets
PART NUMBER TOOL NAME • The ABS module disables the ABS.

HD-48650 DIGITAL TECHNICIAN II • The ABS indicator is illuminated.

The active WSS is supplied system voltage from the ABS Conditions for Clearing the DTC
module. The sensor then returns a 7 mA or 14 mA signal back The condition for the DTC is no longer present and the DTC
to the ABS module. has been cleared with in self-diagnostic mode or DIGITAL
TECHNICIAN II (Part No. HD-48650).
Table 7-8. Code Description
The ABS module automatically clears the historic DTC when
DTC DESCRIPTION a current DTC is not detected in 50 consecutive drive cycles.
C1032 Wheel speed sensor circuit open or shorted Diagnostic Tips
(Front)
The following conditions are possible causes for this fault:
C1034 Wheel speed sensor circuit open or shorted
(Rear) • Open in any of the WSS circuits.
• Short to ground in any of the WSS wires.
Conditions for Setting the DTC
• Front WSS open.
The DTC will set if there are no front or rear WSS circuit mal-
functions and the following conditions exist: • Front wheel speed circuit low shorted to battery.
• Short to ground on either the high or low side circuits of If the fault only occurs in moist conditions (rain, snow, vehicle
the front WSS. wash, etc.) inspect the WSS and wiring for signs of water
intrusion.
• Open on either the high or low side circuits of the front
WSS. Connector Information
• Short to voltage on the low side causing the voltage to go For additional information about the connectors in the following
above 0.79V. diagram(s) and diagnostic procedure(s), including the color of
the harness test kit terminal probes, see B.1 CONNECTORS.
• WSS open.

em00463
ECU
Front Wheel Speed Sensor High
Rear Wheel Speed Sensor High

Front Wheel Speed Sensor Low

Rear Wheel Speed Sensor Low

7 8 17 18 [166A]
7 8 17 18 [166B]
BE/BN
BE/V

BK/BE
BK/V

Rear BK BK B B BE/V BK/V B B BK BK Front

WSS R R A A BE/BN BK/BE A A R R WSS

[168A] [168B] [167B] [167A]

Figure 7-11. WSS

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DTC C1032 3. Is continuity present?

a. Yes. Go to Test 5.
PART NUMBER TOOL NAME
b. No. Repair open between ABS module [166B] ter-
HD-41404-C HARNESS CONNECTOR TEST KIT
minal 17 and front WSS [167B] terminal A (BK/BE)
HD-48642 ABS BREAKOUT BOX wire.

Table 7-9. DTC C1032 Diagnostic Faults 5. Front WSS Low Circuit Open Test
1. Test for continuity between breakout box terminal 18 and
POSSIBLE CAUSES
front WSS [167B] terminal B.
Open front WSS circuit
2. Is continuity present?
Short to ground in front WSS circuit
a. Yes. Replace front WSS. See the service manual.
Front WSS open
b. No. Repair open between ABS module [166B] ter-
Front wheel speed signal wire shorted to voltage minal 18 and front WSS [167B] terminal B (BK/V)
wire.
1. Validation of Current DTC Test
1. Clear the DTC. See 2.1 INITIAL DIAGNOSTICS. 6. Front WSS Short to Ground Test
2. Start engine and wait 10 seconds for ABS to complete 1. Disconnect front WSS [167].
initialization test. 2. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
3. Did the DTC set? 41404-C) and a multimeter, test breakout box terminals
17 and 18 for short to ground.
a. Yes. Go to Test 2.
3. Is a short to ground present?
b. No. See diagnostic tips.
a. Yes. Repair short to ground in appropriate circuit.
2. Front WSS Low Circuit Test b. No. Replace front WSS. See the service manual.
1. Connect ABS BREAKOUT BOX (Part No. HD-48642)
between wire harness [166B] and ABS [166A]. See 7. Front WSS Circuits Short to Voltage Test
1.2 DIAGNOSTIC TOOLS. 1. Disconnect ABS module [166A] from breakout box.
2. Turn IGN ON with the engine stop switch in the RUN 2. Test breakout box terminals 17 and 18 for short to voltage.
position.
3. Is a short to voltage present?
3. Wait 10 seconds for ABS module to complete initialization
test. a. Yes. Go to Test 10.

4. Using HARNESS CONNECTOR TEST KIT (Part No. HD- b. No. Go to Test 8.
41404-C) and a multimeter, measure voltage between
breakout box terminal 18 and ground. 8. Front WSS Circuits Shorted Together Test
5. Is voltage below 0.5V? 1. Disconnect front WSS [167].

a. Yes. Go to Test 3. 2. Test breakout box terminals 17 and 18 for continuity.

b. No. Go to Test 7. 3. Is continuity present?

a. Yes. Repair short in appropriate circuit.
3. Front WSS Circuits Short to Ground Test
b. No. Go to Test 9.
1. Disconnect ABS module [166A] from the breakout box.
2. Test breakout box terminal 17 for short to ground, and 9. Front WSS Continuity Test
terminal 18 for short to ground. 1. Test for continuity across terminals A and B at front WSS
3. Is short to ground present? [167A].

a. Yes. Go to Test 6. 2. Is continuity present?

b. No. Go to Test 4. a. Yes. Replace ECU. See the service manual.

b. No. Replace front WSS. See the service manual.
4. Front WSS High Circuit Test
1. Disconnect front WSS [167]. 10. Front WSS Short to Voltage Test
2. Test for continuity between breakout box terminal 17 and 1. Disconnect front WSS [167].
[167B] terminal A. 2. Test breakout box terminals 17 and 18 for short to voltage.

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3. Is short to voltage present? 2. Test for continuity between breakout box terminal 8 and
a. Yes. Repair short to voltage in appropriate circuit. [168B] terminal A.

b. No. Replace front WSS. See the service manual. 3. Is continuity present?
a. Yes. Go to Test 5.
DTC C1034 b. No. Repair open in rear WSS high circuit.
PART NUMBER TOOL NAME
5. Rear WSS Low Circuit Open Test
HD-41404-C HARNESS CONNECTOR TEST KIT
1. Test for continuity between breakout box terminal 7 and
HD-48642 ABS BREAKOUT BOX
[168B] terminal B.
2. Is continuity present?
Table 7-10. DTC C1034 Diagnostic Faults
a. Yes. Replace rear WSS. See the service manual.
POSSIBLE CAUSES
b. No. Repair open between ABS module [166B] ter-
Open rear WSS circuit minal 17 and [168B] terminal A (BE/BN) wire.
Short to ground in rear WSS circuit
Rear WSS open 6. Rear WSS Circuits Short to Ground Test
Rear wheel speed signal wire shorted to voltage 1. Disconnect rear WSS [168].
2. Test breakout box terminals 7 and 8 for continuity to
1. Validation of Current DTC Test ground.
1. Clear the DTC. See 2.1 INITIAL DIAGNOSTICS. 3. Is continuity present?
2. Start engine and wait 10 seconds for ABS to complete a. Yes. Replace rear WSS. See the service manual.
initialization test.
b. No. Repair short to ground in appropriate circuit.
3. Did the DTC set?
a. Yes. Go to Test 2. 7. Rear WSS Circuits Short to Voltage Test
b. No. See diagnostic tips. 1. Disconnect ABS module [166A] from the breakout box.
2. Test breakout box terminals 7 and 8 for short to voltage.
2. Rear WSS Low Circuit Test
3. Is a short to voltage present?
1. Connect ABS BREAKOUT BOX (Part No. HD-48642)
between wire harness [166B] and ABS module [166A]. a. Yes. Go to Test 10.
See 1.2 DIAGNOSTIC TOOLS. b. No. Go to Test 8.
2. Turn IGN ON with the engine stop switch in the RUN
position. 8. Rear WSS Circuits Shorted Together Test
3. Wait 10 seconds for ABS module to complete initialization 1. Disconnect rear WSS [168].
test. 2. Test breakout box terminals 7 and 8 for continuity.
4. Using HARNESS CONNECTOR TEST KIT (Part No. HD- 3. Is continuity present?
41404-C) and a multimeter, measure voltage at breakout
a. Yes. Repair short in appropriate circuit.
box between terminal 7 and ground.
b. No. Go to Test 9.
5. Is voltage below 0.5V?
a. Yes. Go to Test 3. 9. Rear WSS Continuity Test
b. No. Go to Test 7. 1. Test for continuity across terminals A and B at rear WSS
[168A].
3. Rear WSS Circuits Short to Ground Test
2. Is continuity present?
1. Disconnect ABS module [166A] from the breakout box.
a. Yes. Replace ECU. See the service manual.
2. Test breakout box [166B] terminals 7 and 8 for continuity
b. No. Replace rear WSS. See the service manual.
to ground.
3. Is continuity present? 10. Rear WSS Short to Voltage Test
a. Yes. Go to Test 4. 1. Disconnect rear WSS [168].
b. No. Go to Test 6. 2. Test breakout box terminals 7 and 8 for short to voltage.

4. Rear WSS High Circuit Test 3. Is a short to voltage present?

a. Yes. Repair short to voltage in appropriate circuit.
1. Disconnect rear WSS [168].
b. No. Replace rear WSS. See the service manual.

2011 Touring Diagnostics: ABS 7-13

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DTC C1042, C1043 7.6

DESCRIPTION AND OPERATION Conditions for Clearing the DTC
PART NUMBER TOOL NAME The condition for the DTC is no longer present and the DTC
has been cleared in self-diagnostic mode or DIGITAL TECHNI-
HD-48650 DIGITAL TECHNICIAN II CIAN II (Part No. HD-48650).
See Figure 7-12.The pump motor is located in the HCU portion The ECU automatically clears the historic DTC when a current
of the ABS module. Power is supplied through an internal pump DTC is not detected in 50 consecutive drive cycles.
motor relay when the ignition is turned on. The ECU monitors
pump motor feedback voltage after activation to detect a stalled Diagnostic Tips
or binding pump motor. The following conditions are possible causes for DTC C1042:
• Open or high resistance at the pump motor connector.
Table 7-11. Code Description
• Open or high resistance in the pump motor windings.
DTC DESCRIPTION
The following conditions are possible causes for DTC C1043:
C1042 Pump motor open
• High side of the pump motor is shorted to ground.
C1043 Pump motor stalled
• High or low resistance in the pump motor windings.
• The pump motor is seized or requires excessive torque
ed01947
to spin.
2 4
DTC C1042
PART NUMBER TOOL NAME
HD-41404-C HARNESS CONNECTOR TEST KIT
3
HD-48642 ABS BREAKOUT BOX

Table 7-12. DTC C1042 Diagnostic Faults

POSSIBLE CAUSES
Open or high resistance at the pump motor connector.
1 5
Open or high resistance in the pump motor windings.

1. Pump motor connector (ECU) 1. Ground Circuit Open Test

2. Solenoids
3. Pump motor 1. Connect ABS BREAKOUT BOX (Part No. HD-48642) to
4. Valves wire harness [166B] leaving ABS module [166A] discon-
5. Pump motor connector (HCU) nected. See 1.2 DIAGNOSTIC TOOLS.

Figure 7-12. ECU and HCU Pump Motor Connectors 2. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
41404-C) and a multimeter, test for continuity between
breakout box terminal 11 and ground.
Conditions for Setting the DTC 3. Is continuity present?
DTC C1042 will set if current did not exceed 15.6A within 0.1 a. Yes. Go to Test 2.
seconds of switching the pump motor on.
b. No. Repair open ABS module [166B] terminal 11 (BK)
DTC C1043 will set if the following conditions exist: wire.
• The pump takes less than 0.03 seconds to spin down.
2. Pump Motor Test
• The current exceeds 15.6A within 0.33 millisecond of
switching the pump motor on. 1. Remove the ABS module and separate the ABS ECU from
the ABS HCU. See the service manual.
Action Taken When the DTC Sets 2. Measure the resistance between HCU terminals 1 and 2.
• ABS is disabled.
3. Is resistance less than 2 Ohms?
• The ABS indicator is illuminated. a. Yes. Replace the ECU. See the service manual.
b. No. Replace the HCU. See the service manual.

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DTC C1043 1. Ground Circuit Open Test

PART NUMBER TOOL NAME 1. Connect ABS BREAKOUT BOX (Part No. HD-48642) to
wire harness [166B] leaving ABS module [166A] discon-
HD-41404-C HARNESS CONNECTOR TEST KIT nected. See 1.2 DIAGNOSTIC TOOLS.
HD-48642 ABS BREAKOUT BOX
2. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
41404-C) and a multimeter, test for continuity between
Table 7-13. DTC C1043 Diagnostic Faults breakout box terminal 11 and ground.

POSSIBLE CAUSES 3. Is continuity present?

Short to ground in high side pump motor circuit a. Yes. Replace the HCU. See the service manual.
High or low resistance in the pump motor windings b. No. Repair open ABS module [166B] terminal 11 (BK)
The pump motor is seized or requires excessive torque to wire.
spin

2011 Touring Diagnostics: ABS 7-15

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DTC C1094 7.7

DESCRIPTION AND OPERATION Action Taken When the DTC Sets
PART NUMBER TOOL NAME No action is taken when this code is set. The ABS indicator
does not illuminate and the ABS is still active.
HD-48650 DIGITAL TECHNICIAN II
Conditions for Clearing the DTC
The ABS module monitors the front brake switch input. When
the brake lever is applied the ABS module receives voltage on The condition for the DTC is no longer present and the DTC
the front brake switch circuit. The ABS module uses this signal has been cleared in self-diagnostic mode or DIGITAL TECHNI-
to enhance ABS operation. CIAN II (Part No. HD-48650).
The ECU automatically clears the historic DTC when a current
Table 7-14. Code Description DTC is not detected in 50 consecutive drive cycles.

DTC DESCRIPTION Diagnostic Tips

C1094 Front brake switch always on The following conditions are possible causes for this fault:
• Short to voltage between the front brake switch and the
Conditions for Setting the DTC
ECU.
The DTC will set if all of the following conditions exist for 2
seconds: • Front brake switch stuck closed or applied during acceler-
ation.
• The ECU sees a front brake input.
• Internal front brake sensing malfunction.
• The vehicle speed exceeds 25 mph (40 km/h).
Connector Information
• The vehicle acceleration exceeds 5 mph (8 km/h) per
second. For additional information about the connectors in the following
diagram(s) and diagnostic procedure(s), including the color of
the harness test kit terminal probes, see B.1 CONNECTORS.

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em00859
ABS Module
[64-1B]
1C 1A

Front Brake Input

Rear Brake Input

ACCY Brake
15A 15A
1D 1B
FLHR/C

O/W

O/V
[166A] 13 3 [22B]
[166B] 13 3
O/W 1

R/BN

PK/BN
R/BN 2

O/W 1 O/W

[1A] [1B]
2 R/Y
R/BN
PK/BN
O/W

O/W 5 5 O/W 1

PK/BN
R/BN
R/BE

R/BE
Front
[22A] Stop Lamp
[121-2B] 1 1 [121-1B] R/BN 1 1 R/BE 2
Switch
[121-2A] 1 1 [121-1A] 4 3 2 1 [201B]
ABS 4 3 2 1 [201A] [2B] [2A] [22B]
Rear Diode
Stop Lamp Pack
Pressure Switch Except FLHR/C
Switch
R/BE

[78B] [78A]
ECM
R/BE 25 25 Brake Switch Input

87 5 3A O/V

30 3 2B R/Y R/Y
86 1 2A R/BE To
85 2 3B BK BK Rear Lighting
[64-2] Brake Relay

GND 1

Figure 7-13. Brake Switches Schematic

DTC C1094 3. Did the DTC set?

a. Yes. Go to Test 2.
PART NUMBER TOOL NAME
b. No. See diagnostic tips.
HD-41404-C HARNESS CONNECTOR TEST KIT
HD-48642 ABS BREAKOUT BOX 2. Front Brake Input Short to Voltage Test
1. Connect ABS BREAKOUT BOX (Part No. HD-48642)
Table 7-15. DTC C1094 Diagnostic Faults between wire harness [166B] and ABS module [166A].
See 1.2 DIAGNOSTIC TOOLS.
POSSIBLE CAUSES
ECU malfunction 2. Turn IGN ON with the engine stop switch in the RUN
position.
Front brake switch malfunction
3. Wait 10 seconds for ABS module to complete initialization
Short to voltage in front brake switch circuit
test.
1. Validation of Current DTC Test 4. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
41404-C) and a multimeter, measure voltage at between
1. Clear the DTC. See 2.1 INITIAL DIAGNOSTICS.
breakout box terminal 13 and ground.
2. Start engine and wait 10 seconds for ABS to complete
initialization test.

2011 Touring Diagnostics: ABS 7-17

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5. Is voltage present? 2. Test for voltage on [22B] terminal 2.

a. Yes. Go to Test 3. 3. Is voltage present?
b. No. Replace ECU module. See the service manual. a. Yes. Repair short to voltage on front stop lamp switch
[22B] (R/BN) wire (FLHR/C) or (R/BE) wire (except
3. Front Stop Lamp Switch Test FLHR/C).
1. Disconnect right hand controls [22]. b. No. Replace front brake switch. See the service
manual.

7-18 2011 Touring Diagnostics: ABS

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DTC C1095 7.8

DESCRIPTION AND OPERATION Action Taken When the DTC Sets
PART NUMBER TOOL NAME No action is taken when this code is set. The ABS indicator
DOES NOT illuminate and the ABS is still active.
HD-48650 DIGITAL TECHNICIAN II
Conditions for Clearing the DTC
The ABS module monitors the front brake switch input. When
the brake lever is applied the ABS module receives voltage on The condition for the DTC is no longer present and the DTC
the front brake switch circuit. The ABS module uses this signal has been cleared in self-diagnostic mode or DIGITAL TECHNI-
to enhance ABS operation. CIAN II (Part No. HD-48650).
The ECU automatically clears the historic DTC when a current
Table 7-16. Code Description DTC is not detected in 50 consecutive drive cycles.

DTC DESCRIPTION Connector Information

C1095 Front brake switch open For additional information about the connectors in the following
diagram(s) and diagnostic procedure(s), including the color of
Conditions for Setting the DTC the harness test kit terminal probes, see B.1 CONNECTORS.
The DTC will set if the rear brake switch is not closed (brake
applied) and all of the following conditions exist for 2 seconds:
• The ABS module detects an open in the front brake input
circuit.
• The ABS module detects an open in the ground circuit to
the front brake switch.

2011 Touring Diagnostics: ABS 7-19

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em00859
ABS Module
[64-1B]
1C 1A

Front Brake Input

Rear Brake Input

ACCY Brake
15A 15A
1D 1B
FLHR/C
O/W

O/V
[166A] 13 3 [22B]
[166B] 13 3
O/W 1

R/BN

PK/BN
R/BN 2

O/W 1 O/W

[1A] [1B]
2 R/Y
R/BN
PK/BN
O/W

O/W 5 5 O/W 1

PK/BN
R/BN
R/BE

R/BE
Front
[22A] Stop Lamp
[121-2B] 1 1 [121-1B] R/BN 1 1 R/BE 2
Switch
[121-2A] 1 1 [121-1A] 4 3 2 1 [201B]
ABS 4 3 2 1 [201A] [2B] [2A] [22B]
Rear Diode
Stop Lamp Pack
Pressure Switch Except FLHR/C
Switch
R/BE

[78B] [78A]
ECM
R/BE 25 25 Brake Switch Input

87 5 3A O/V

30 3 2B R/Y R/Y
86 1 2A R/BE To
85 2 3B BK BK Rear Lighting
[64-2] Brake Relay

GND 1

Figure 7-14. Brake Switches Schematic

DTC C1095 1. Validation of Current DTC Test

PART NUMBER TOOL NAME 1. Clear the DTC. See 2.1 INITIAL DIAGNOSTICS.

HD-41404-C HARNESS CONNECTOR TEST KIT 2. Start engine and wait 10 seconds for ABS to complete
initialization test.
HD-48642 ABS BREAKOUT BOX
3. Did the DTC set?
Table 7-17. DTC C1095 Diagnostic Faults a. Yes. Go to Test 2.

POSSIBLE CAUSES b. No. See diagnostic tips.

Open front brake input circuit 2. DTC Verification Test

Open tail/stop lamp ground circuit
1. Check for additional DTCS.
Internal ABS module problem in the front brake circuitry
2. Is DTC C1216 set?
Tail/stop lamp malfunction
a. Yes. Go to Test 3.
ECU malfunction
b. No. Go to Test 5.
ABS Diode pack malfunction
Front stop lamp switch malfunction

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3. Tail/Stop Lamp Test 7. ABS Diode Pack Test

1. Disconnect tail lamp [93]. 1. Disconnect ABS diode [201].
2. Turn IGN ON. 2. Jumper [201B] terminal 1 and terminal 4.
3. While applying the brakes, use a multimeter to test for 3. Apply front brake.
voltage between [93A] terminal 3 and terminal 4.
4. Does tail/stop lamp illuminate?
4. Is battery voltage present? a. Yes. Replace ABS diode pack. See the service
a. Yes. Replace tail/stop lamp. See the service manual. manual.
b. No. Go to Test 4. b. No. Go to Test 8.

4. Ground Circuit Open Test 8. Tail/Stop Lamp Circuit Open Test

1. While applying the brakes, use HARNESS CONNECTOR 1. While applying the front brake, use HARNESS CON-
TEST KIT (Part No. HD-41404-C) and a multimeter to test NECTOR TEST KIT (Part No. HD-41404-C) and test for
for voltage between tail lamp [93A] terminal 3 and ground. voltage between [201B] terminal 1 and ground.
2. Is battery voltage present? 2. Is battery voltage present?
a. Yes. Repair open in (BK) wire between tail/stop lamp a. Yes. Repair open in (R/Y) wire between ABS diode
[93A] terminal 4 and battery negative. pack [201B] and tail/stop lamp [93A].
b. No. Repair open in (R/Y) wire between tail/stop lamp b. No. Go to Test 9.
[93A] terminal 3 and ABS diode pack [201B].
9. Front Stop Lamp Switch Test
5. Front Stop Lamp Switch Test 1. Disconnect right hand controls [22].
1. Apply the front brake.
2. Jumper [22B] terminal 1 and terminal 2.
2. Does the tail/stop lamp illuminate?
3. Test for voltage between [201B] terminal 1 and ground.
a. Yes. Go to Test 6.
4. Is battery voltage present?
b. No. Go to Test 7.
a. Yes. Replace front stop lamp switch. See the service
manual.
6. Front Stop Lamp Switch Input Circuit
Open Test b. No. Go to Test 10.

1. Connect ABS BREAKOUT BOX (Part No. HD-48642) to 10. Accessory Circuit Test
wiring harness [166B] leaving ABS module [166A] discon-
nected. See 1.2 DIAGNOSTIC TOOLS. 1. Test for voltage between front stop lamp switch [22B] ter-
minal 1 and ground.
2. Turn IGN ON with the engine stop switch in the RUN
position. 2. Is battery voltage present?
a. Yes. Repair open on front stop lamp switch [22B]
3. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
terminal 2 (R/BN) FLHR/C, (R/BE) except FLHR/C
41404-C), with the front brake applied, use a multimeter
wire.
test for voltage at breakout box terminal 13 to ground.
b. No. Repair open on front stop lamp switch [22B] ter-
4. Is battery voltage present?
minal 1 (O/W) wire.
a. Yes. Replace ECU. See the service manual.
b. No. Repair open in ABS module [166B] terminal 13
(R/BN) wire.

2011 Touring Diagnostics: ABS 7-21

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DTC C1151 7.9

DESCRIPTION AND OPERATION Action Taken When the DTC Sets
PART NUMBER TOOL NAME • ABS is disabled.

HD-48650 DIGITAL TECHNICIAN II • The ABS indicator is illuminated.

The ABS module activates the valve relay to supply voltage to Conditions for Clearing the DTC
the valve solenoids. This voltage is referred to as the system The condition for the DTC is no longer present and the DTC
voltage. The ABS module microprocessor activates individual has been cleared in self-diagnostic mode or DIGITAL TECHNI-
valve solenoids by grounding the valve solenoid control circuits. CIAN II (Part No. HD-48650).
The ABS module automatically clears the historic DTC when
Table 7-18. Code Description
a current DTC is not detected in 50 consecutive drive cycles.
DTC DESCRIPTION
Diagnostic Tips
C1151 Front wheel release too long
The following conditions are possible causes for this fault:
Conditions for Setting the DTC • An intermittent WSS.
The DTC will set if all of the following conditions exist. • A stuck or seized caliper or bald tires could contribute to
• The ABS is commanding a pressure release from the front this code setting.
wheel release valve.
Connector Information
• The front wheel speed is below 3 mph (5 km/h) for more For additional information about the connectors in the following
than 1 second. diagram(s) and diagnostic procedure(s), including the color of
the harness test kit terminal probes, see B.1 CONNECTORS.

em00463
ECU
Front Wheel Speed Sensor High
Rear Wheel Speed Sensor High

Front Wheel Speed Sensor Low

Rear Wheel Speed Sensor Low

7 8 17 18 [166A]
7 8 17 18 [166B]
BE/BN
BE/V

BK/BE
BK/V

Rear BK BK B B BE/V BK/V B B BK BK Front

WSS R R A A BE/BN BK/BE A A R R WSS

[168A] [168B] [167B] [167A]

Figure 7-15. WSS

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DTC C1151 2. Brake Lines Installation Test

1. Inspect brake lines at the ABS module for proper installa-
Table 7-19. DTC C1151 Diagnostic Faults tion.
POSSIBLE CAUSES 2. Are the lines installed properly?
WSS equals 0 mph (0 km/h) a. Yes. Go to Test 3.
Internal ECU problem in the release solenoid b. No. Correctly install brake lines.
Internal problem in the HCU
3. ECU Test
Brake lines reversed on the HCU inlet and outlet ports
1. Remove the ABS module and separate the ABS ECU from
1. Validation of Current DTC Test the ABS HCU. See the service manual.
1. Clear the DTC. See 2.1 INITIAL DIAGNOSTICS. 2. With the ECU connected to the harness, clear the DTCs.
2. Are any front WSS DTCs currently set? 3. Start the engine and wait 10 seconds for the ECU to per-
a. Yes. See appropriate diagnostic procedure. form an initialization test.

b. No. Go to Test 2. 4. Did DTC C1151 set?

a. Yes. Replace ECU module. See the service manual.
b. No. Replace HCU module. See the service manual.

2011 Touring Diagnostics: ABS 7-23

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DTC C1153 7.10

DESCRIPTION AND OPERATION Action Taken When the DTC Sets
PART NUMBER TOOL NAME • ABS is disabled.

HD-48650 DIGITAL TECHNICIAN II • The ABS indicator is illuminated.

The ABS module activates the valve relay to supply voltage to Conditions for Clearing the DTC
the valve solenoids. This voltage is referred to as the system The condition for the DTC is no longer present and the DTC
voltage. The ABS module microprocessor activates individual has been cleared in self-diagnostic mode or DIGITAL TECHNI-
valve solenoids by grounding the valve solenoid control circuits. CIAN II (Part No. HD-48650).
The ABS module automatically clears the historic DTC when
Table 7-20. Code Description
a current DTC is not detected in 50 consecutive drive cycles.
DTC DESCRIPTION
Diagnostic Tips
C1153 Rear wheel release too long
The following conditions are possible causes for this fault:
Conditions for Setting the DTC • An intermittent WSS.
The DTC will set if all of the following conditions exist: • A stuck or seized caliper or bald tires.
• The ABS is commanding a pressure release from the rear
Connector Information
wheel release valve.
For additional information about the connectors in the following
• The rear wheel speed is below 3 mph (5 km/h) for more diagram(s) and diagnostic procedure(s), including the color of
than 1 second. the harness test kit terminal probes, see B.1 CONNECTORS.

em00463
ECU
Front Wheel Speed Sensor High
Rear Wheel Speed Sensor High

Front Wheel Speed Sensor Low

Rear Wheel Speed Sensor Low

7 8 17 18 [166A]
7 8 17 18 [166B]
BE/BN
BE/V

BK/BE
BK/V

Rear BK BK B B BE/V BK/V B B BK BK Front

WSS R R A A BE/BN BK/BE A A R R WSS

[168A] [168B] [167B] [167A]

Figure 7-16. WSS

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DTC C1153 2. Brake Lines Installation Test

1. Inspect brake lines at the ABS module for correct installa-
Table 7-21. DTC C1153 Diagnostic Faults tion.
POSSIBLE CAUSES 2. Are the lines installed correctly?
WSS equals 0 mph (0 km/h) a. Yes. Go to Test 3.
Internal ECU problem in the release solenoid b. No. Install brake lines correctly.
Internal problem in the HCU
3. ECU Test
Brake lines reversed on the HCU inlet and outlet ports
1. Remove the ABS module and separate the ABS ECU from
1. Validation of Current DTC Test the ABS HCU. See the service manual.
1. Clear the DTC. See 2.1 INITIAL DIAGNOSTICS. 2. With the ECU connected to the harness, clear the DTCs.
2. Are any rear WSS DTCs currently set? 3. Start the engine and wait 10 seconds for the ECU to per-
a. Yes. See appropriate diagnostic procedure. form an initialization test.

b. No. Go to Test 2. 4. Did DTC C1153 set?

a. Yes. Replace ECU module. See the service manual.
b. No. Replace HCU module. See the service manual.

2011 Touring Diagnostics: ABS 7-25

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DTC C1158 7.11

DESCRIPTION AND OPERATION DTC C1158
PART NUMBER TOOL NAME PART NUMBER TOOL NAME
HD-48650 DIGITAL TECHNICIAN II HD-48650 DIGITAL TECHNICIAN II

The ECU is calibrated to maximize ABS performance. If the

correct calibration is not in the module the ABS may not perform Table 7-23. DTC C1158 Diagnostic Faults
correctly.
POSSIBLE CAUSES
An ECU that is not calibrated correctly or has an internal fault
Table 7-22. Code Description
All replacement ABS modules will have this DTC set
DTC DESCRIPTION
Any ECU calibration or update will cause code to set
C1158 Calibration programming required
1. Validation of Current DTC Test
Conditions for Setting the DTC
1. Clear the DTC. See 2.1 INITIAL DIAGNOSTICS.
The ABS module determines final calibration is not completed.
2. Start engine and wait 10 seconds for ABS to complete
Action Taken When the DTC Sets initialization test.
• ABS is disabled. 3. Does the DTC reset?
• The ABS indicator is illuminated. a. Yes. Go to Test 2.

Conditions for Clearing the DTC b. No. See diagnostic tips.

The condition for the DTC is no longer present and the DTC
2. Successful Calibration Test
has been cleared with DIGITAL TECHNICIAN II (Part No. HD-
48650). This code may be set whenever an ABS module is NOTE
replaced or calibrated. The code on the new module will have Front and rear brake light circuits must be operational to suc-
to be cleared using DIGITAL TECHNICIAN II (Part No. HD- cessfully complete Digital Technician ABS service.
48650).
1. Using DIGITAL TECHNICIAN II (Part No. HD-48650) (see
your dealer), attempt to calibrate the ECU using the ABS
service feature found in Vehicle Set Up.
2. Clear the DTC. See 2.1 INITIAL DIAGNOSTICS.
3. Does the DTC set?
a. Yes. Replace ECU module. See the service manual.
b. No. Calibration complete.

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DTC C1212 7.12

DESCRIPTION AND OPERATION Action Taken When the DTC Sets
PART NUMBER TOOL NAME No action is taken when this code is set. The ABS indicator
DOES NOT illuminate and the ABS is still active.
HD-48650 DIGITAL TECHNICIAN II
Conditions for Clearing the DTC
The ABS module monitors the front and rear brake switch
inputs through terminal 13 and terminal 3. This allows the ABS The condition for the DTC is no longer present and the DTC
to determine if the brake is being applied or not when a wheel has been cleared in self-diagnostic mode or DIGITAL TECHNI-
is decelerating. CIAN II (Part No. HD-48650).
The ECU automatically clears the historic DTC when a current
Table 7-24. Code Description DTC is not detected in 50 consecutive drive cycles.

DTC DESCRIPTION Diagnostic Tips

C1212 Front or rear brake not applied with decel
Conditions for Setting the DTC
The DTC will set if the following conditions exist. The first four
conditions have to occur twice.
• The front or rear brake is not applied.
• There is no current ABS event in progress.
• Vehicle speed exceeds 15 mph (24 km/h).
• Vehicle decelerates at a rate greater than 5 mph (8 km/h)
per second for more than two seconds.
• Vehicle speed drops below 15 mph (24 km/h).
The following conditions are possible causes for this fault:
• A short or open on the brake switch input circuits to the
ABS module.
• Downshifting up a steep hill without using the brakes two
consecutive times could cause this code.
Connector Information
For additional information about the connectors in the following
diagram(s) and diagnostic procedure(s), including the color of
the harness test kit terminal probes, see B.1 CONNECTORS.

2011 Touring Diagnostics: ABS 7-27

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em00859
ABS Module
[64-1B]
1C 1A

Front Brake Input

Rear Brake Input

ACCY Brake
15A 15A
1D 1B
FLHR/C
O/W

O/V
[166A] 13 3 [22B]
[166B] 13 3
O/W 1

R/BN

PK/BN
R/BN 2

O/W 1 O/W

[1A] [1B]
2 R/Y
R/BN
PK/BN
O/W

O/W 5 5 O/W 1

PK/BN
R/BN
R/BE

R/BE
Front
[22A] Stop Lamp
[121-2B] 1 1 [121-1B] R/BN 1 1 R/BE 2
Switch
[121-2A] 1 1 [121-1A] 4 3 2 1 [201B]
ABS 4 3 2 1 [201A] [2B] [2A] [22B]
Rear Diode
Stop Lamp Pack
Pressure Switch Except FLHR/C
Switch
R/BE

[78B] [78A]
ECM
R/BE 25 25 Brake Switch Input

87 5 3A O/V

30 3 2B R/Y R/Y
86 1 2A R/BE To
85 2 3B BK BK Rear Lighting
[64-2] Brake Relay

GND 1

Figure 7-17. Brake Switches Schematic

DTC C1212 2. Start engine and wait 10 seconds for ABS to complete
initialization test.
PART NUMBER TOOL NAME
3. Did the DTC set?
HD-41404-C HARNESS CONNECTOR TEST KIT
a. Yes. Go to Test 2.
HD-48642 ABS BREAKOUT BOX
b. No. See diagnostic tips.

Table 7-25. DTC C1212 Diagnostic Faults 2. Stop Lamp Switch Input Circuits Voltage
POSSIBLE CAUSES Test
ECU malfunction 1. Connect ABS BREAKOUT BOX (Part No. HD-48642)
between wire harness [166B] and ABS module [166A].
Open rear brake input circuit
See 1.2 DIAGNOSTIC TOOLS.
Open front brake input circuit
2. Turn IGN ON with the engine stop switch in the RUN
Rear stop lamp switch malfunction position.
Front stop lamp switch malfunction
3. Wait 10 seconds for ABS module to complete initialization
test.
1. Validation of Current DTC Test
1. Clear the DTC. See 2.1 INITIAL DIAGNOSTICS. 4. Apply front and rear stop lamp switches.

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5. Using HARNESS CONNECTOR TEST KIT (Part No. HD- 6. Rear Stop Lamp Switch Accessory Circuit
41404-C) and a multimeter, test for voltage on breakout
box terminal 13 to ground and terminal 3 to ground.
Open Test
1. Turn the IGN ON.
6. Is voltage present at both terminals?
a. Yes. Replace ECU module. See the service manual. 2. Test for voltage on rear stop lamp switch [121B] terminal
B to ground.
b. No. Go to Test 3.
3. Is voltage present?
3. Rear Stop Lamp Switch Input Test a. Yes. Repair open in rear stop lamp switch [121AB]
(PK/BN) wire.
1. Test for voltage on breakout box terminal 3 to ground.
b. No. Repair open in rear stop lamp switch [121BB]
2. Is voltage present at ABS module [166B] terminal 3?
(O/W) wire.
a. Yes. Go to Test 7.
b. No. Go to Test 4. 7. Front Stop Lamp Switch Accessory
Circuit Open Test
4. Rear Stop Lamp Circuit Test 1. Disconnect right hand controls [22B].
1. Apply the rear brake pedal.
2. Test for voltage on [22B] terminal 1 to ground.
2. Does the stop lamp illuminate?
3. Is voltage present?
a. Yes. Repair open in rear brake input circuit ABS
a. Yes. Go to Test 8.
module [166B] terminal 3.
b. No. Repair open in front stop lamp switch [22B] ter-
b. No. Go to Test 5.
minal 1 (O/W) wire.
5. Rear Stop Lamp Switch Test 8. Front Stop Lamp Switch Test
1. Disconnect rear stop lamp switch.
1. Connect jumper wire from [22B] terminal 1 to terminal 2.
2. Apply rear brake pedal and test for continuity between
2. Does the stop lamp illuminate?
rear stop lamp switch [121A] terminals 1 and 2.
a. Yes. Replace front stop lamp switch. See the service
3. Is continuity present? manual.
a. Yes. Go to Test 6.
b. No. Repair open in front stop lamp switch [22B] ter-
b. No. Replace rear stop lamp switch. See the service minal 2 (R/BN) FLHR/C, (R/BE) except FLHR/C wire.
manual.

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DTC C1214 7.13

DESCRIPTION AND OPERATION Action Taken When the DTC Sets
PART NUMBER TOOL NAME No action is taken when this code is set. The ABS indicator
does not illuminate and the ABS is still active.
HD-48650 DIGITAL TECHNICIAN II
Conditions for Clearing the DTC
The ABS module monitors the rear brake switch input. When
the brake pedal is applied the ABS module receives voltage The condition for the DTC is no longer present and the DTC
on the rear brake switch circuit. The ABS module uses this has been cleared in self-diagnostic mode or DIGITAL TECHNI-
signal to enhance ABS operation. CIAN II (Part No. HD-48650).
The ABS module automatically clears the historic DTC when
Table 7-26. Code Description a current DTC is not detected in 50 consecutive drive cycles.

DTC DESCRIPTION Diagnostic Tips

C1214 Rear brake switch always on The following conditions are possible causes for this fault:
• Rear brake switch stuck closed or applied during acceler-
Conditions for Setting the DTC
ation.
The DTC will set if all of the following conditions exist for 2
seconds: • Internal rear brake sensing malfunction.

• The ABS module sees a rear brake input. Connector Information

• The vehicle speed exceeds 25 mph (40 km/h). For additional information about the connectors in the following
diagram(s) and diagnostic procedure(s), including the color of
• The vehicle acceleration exceeds 5 mph (8 km/h) per the harness test kit terminal probes, see B.1 CONNECTORS.
second.

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em00859
ABS Module
[64-1B]
1C 1A

Front Brake Input

Rear Brake Input

ACCY Brake
15A 15A
1D 1B
FLHR/C

O/W

O/V
[166A] 13 3 [22B]
[166B] 13 3
O/W 1

R/BN

PK/BN
R/BN 2

O/W 1 O/W

[1A] [1B]
2 R/Y
R/BN
PK/BN
O/W

O/W 5 5 O/W 1

PK/BN
R/BN
R/BE

R/BE
Front
[22A] Stop Lamp
[121-2B] 1 1 [121-1B] R/BN 1 1 R/BE 2
Switch
[121-2A] 1 1 [121-1A] 4 3 2 1 [201B]
ABS 4 3 2 1 [201A] [2B] [2A] [22B]
Rear Diode
Stop Lamp Pack
Pressure Switch Except FLHR/C
Switch
R/BE

[78B] [78A]
ECM
R/BE 25 25 Brake Switch Input

87 5 3A O/V

30 3 2B R/Y R/Y
86 1 2A R/BE To
85 2 3B BK BK Rear Lighting
[64-2] Brake Relay

GND 1

Figure 7-18. Brake Switches Schematic

DTC C1214 2. Start engine and wait 10 seconds for ABS to complete
initialization test.
PART NUMBER TOOL NAME
3. Did the DTC set?
HD-41404-C HARNESS CONNECTOR TEST KIT
a. Yes. Go to Test 2.
HD-48642 ABS BREAKOUT BOX
b. No. See diagnostic tips.

Table 7-27. DTC C1214 Diagnostic Faults 2. Rear Stop Lamp Switch Input Voltage Test
POSSIBLE CAUSES 1. Connect ABS BREAKOUT BOX (Part No. HD-48642) to
ECU malfunction wire harness [166B] leaving ABS module [166A] discon-
nected. See 1.2 DIAGNOSTIC TOOLS.
Rear brake switch malfunction
2. Turn IGN ON with the engine stop switch in the RUN
Short to voltage between the rear brake switch and the ABS
position.
module
3. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
1. Validation of Current DTC Test 41404-C) and a multimeter, test for voltage on breakout
box terminal 3 to ground.
1. Clear the DTC. See 2.1 INITIAL DIAGNOSTICS.

2011 Touring Diagnostics: ABS 7-31

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4. Is voltage present? 2. Is voltage present?

a. Yes. Go to Test 3. a. Yes. Repair short to voltage on (PK/BN) wire.
b. No. Replace ECU module. See the service manual. b. No. Replace rear stop lamp switch. See the service
manual.
3. Rear Stop Lamp Switch Test
1. Test for voltage on [121AB] terminal 1 (PK/BN) wire to
ground.

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DTC C1216 7.14

DESCRIPTION AND OPERATION Action Taken When the DTC Sets
PART NUMBER TOOL NAME No action is taken when this code is set. The ABS indicator
DOES NOT illuminate and the ABS is still active.
HD-48650 DIGITAL TECHNICIAN II
Conditions for Clearing the DTC
The ABS module monitors the rear brake switch input. When
the brake pedal is applied the ABS module receives voltage The condition for the DTC is no longer present and the DTC
on the rear brake switch circuit. The ABS module uses this has been cleared in self-diagnostic mode or DIGITAL TECHNI-
signal to enhance ABS operation. CIAN II (Part No. HD-48650).
The ECU automatically clears the historic DTC when a current
Table 7-28. Code Description DTC is not detected in 50 consecutive drive cycles.

DTC DESCRIPTION Diagnostic Tips

C1216 Rear brake switch open The following conditions are possible causes for this fault:
• An open or loose connection in the rear brake input circuit.
Conditions for Setting the DTC
The DTC will set if the front brake switch is not closed (brake • All brake lamps are open or burned out.
applied) and all of the following conditions exist for 2 seconds: Connector Information
• The ABS module detects an open in the rear brake input For additional information about the connectors in the following
circuit. diagram(s) and diagnostic procedure(s), including the color of
• The ABS module detects an open in the ground circuit to the harness test kit terminal probes, see B.1 CONNECTORS.
the rear brake switch.

2011 Touring Diagnostics: ABS 7-33

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em00859
ABS Module
[64-1B]
1C 1A

Front Brake Input

Rear Brake Input

ACCY Brake
15A 15A
1D 1B
FLHR/C
O/W

O/V
[166A] 13 3 [22B]
[166B] 13 3
O/W 1

R/BN

PK/BN
R/BN 2

O/W 1 O/W

[1A] [1B]
2 R/Y
R/BN
PK/BN
O/W

O/W 5 5 O/W 1

PK/BN
R/BN
R/BE

R/BE
Front
[22A] Stop Lamp
[121-2B] 1 1 [121-1B] R/BN 1 1 R/BE 2
Switch
[121-2A] 1 1 [121-1A] 4 3 2 1 [201B]
ABS 4 3 2 1 [201A] [2B] [2A] [22B]
Rear Diode
Stop Lamp Pack
Pressure Switch Except FLHR/C
Switch
R/BE

[78B] [78A]
ECM
R/BE 25 25 Brake Switch Input

87 5 3A O/V

30 3 2B R/Y R/Y
86 1 2A R/BE To
85 2 3B BK BK Rear Lighting
[64-2] Brake Relay

GND 1

Figure 7-19. Brake Switches Schematic

DTC C1216 2. Start engine and wait 10 seconds for ABS to complete
initialization test.
PART NUMBER TOOL NAME
3. Did the DTC set?
HD-41404-C HARNESS CONNECTOR TEST KIT
a. Yes. Go to Test 2.
HD-48642 ABS BREAKOUT BOX
b. No. See diagnostic tips.

Table 7-29. DTC C1216 Diagnostic Faults 2. DTC Verification Test

POSSIBLE CAUSES 1. Check for additional DTCs.
ECU malfunction 2. Is DTC C1095 set?
Open rear brake input circuit a. Yes. See 7.8 DTC C1095.
ABS Diode Pack malfunction b. No. Go to Test 3.
Open tail/stop lamp circuit
Rear stop lamp switch
3. Tail/Stop Lamp Test
1. Apply the rear brake.
1. Validation of Current DTC Test
1. Clear the DTC. See 2.1 INITIAL DIAGNOSTICS.

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2. Does the tail/stop lamp illuminate? 6. Tail/Stop Lamp Circuit Open Test
a. Yes. Go to Test 4. 1. While applying the rear brake, test for voltage between
b. No. Go to Test 5. ABS diode [201B] terminal 2 and ground.
2. Is battery voltage present?
4. Rear Stop Lamp Switch Input Circuit
a. Yes. Repair open in between ABS diode pack [201B]
Open Test terminals 3 and 4 (R/Y) wire and tail/stop lamp [93A]
1. Connect ABS BREAKOUT BOX (Part No. HD-48642) to terminal 3.
wiring harness connector [166B] leaving ABS module
b. No. Go to Test 7.
[166A] disconnected. See 1.2 DIAGNOSTIC TOOLS.
2. Turn IGN ON with the engine stop switch in the RUN 7. Rear Stop Lamp Switch Test
position. 1. Disconnect rear stop lamp switch [121].
3. Using HARNESS CONNECTOR TEST KIT (Part No. HD- 2. Jumper terminal 1 of [121BB] and terminal 1 of [121AB].
41404-C) and a multimeter, with the rear brake applied,
measure voltage at breakout box terminal 3 to ground. 3. Test for voltage between [201B] terminal 2 and ground.
4. Is battery voltage present? 4. Is battery voltage present?
a. Yes. Replace ECU module. See the service manual. a. Yes. Replace rear stop lamp switch. See the service
manual.
b. No. Repair open in (PK/BN) wire.
b. No. Go to Test 8.
5. ABS Diode Pack Test
1. Disconnect ABS diode pack [201].
8. Accessory Circuit Test
1. Test for voltage between [121BB] terminal 1 and ground.
2. Jumper [201B] terminal 2 and terminal 3.
2. Is battery voltage present?
3. Apply rear brake.
a. Yes. Repair open on rear stop lamp switch [121AB]
4. Does tail/stop lamp illuminate? (PK/BN) wire.
a. Yes. Replace ABS diode pack. See the service b. No. Repair open on rear stop lamp switch [121BB]
manual. (O/W) wire.
b. No. Go to Test 6.

2011 Touring Diagnostics: ABS 7-35

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DTC C1014, C1055-C1066, C1118, C1121 7.15

DESCRIPTION AND OPERATION Conditions for Setting the DTC
PART NUMBER TOOL NAME The ABS module detects an internal malfunction.

HD-48650 DIGITAL TECHNICIAN II Action Taken When the DTC Sets

Circuit Description
The ABS module monitors the voltage level available for system
operation. A low voltage condition prevents the system from
operating properly. The ABS module also performs several
self-tests for internal problems which may affect proper opera-
tion.
Table 7-30. Code Description
• ABS is disabled.
• The ABS indicator is illuminated.
Conditions for Clearing the DTC
Certain conditions that may cause this DTC to set cannot be
cleared. Other conditions that may cause this DTC to set may
be cleared, at least temporarily, in self-diagnostic mode or
DIGITAL TECHNICIAN II (Part No. HD-48650).

DTC DESCRIPTION
Connector Information
C1014 ECU internal fault For additional information about the connectors in the following
diagram(s) and diagnostic procedure(s), including the color of
C1055-C1066 ECU internal fault the harness test kit terminal probes, see B.1 CONNECTORS.
C1118 ECU internal fault
C1121 ECU internal fault

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em00860 HCU ECU

1 1 Pump Motor Supply
[64-1B] [64-2B] Pump M
1A 1C 1E 4A Motor
2 2 Pump Motor Ground
Brake ACCY Ignition ABS
15A 15A 15A 30A
1B 1D 1F 4B

O/W
O/V

GY

R/V
R/V 20 20 Battery (Motor)
R/V 10 10 Battery

GY 19 19 Ignition

O/W [22B]
FLHR/C
(Except FLHR/C)
PK/BN

O/W 1
O/W

[1B] [1A]
R/BN 2 1 O/W Front
Stop
[121-2B] 1 1 [121-1B] O/W 5 5 O/W Lamp
[22B] 2
[121-2A] 1 1 [121-1A] R/Y Switch
[2B] [2A]
Rear O/W 1 [22A]
Stop
Pressure Lamp R/BN R/BN 1 1 R/BE R/BE 2
Switch Switch
PK/BN 3 3 Rear Brake Input
R/BN 13 13 Front Brake Input

Tachometer [108A] [108B] [1B] [1A]

PK/BN
R/BN
R/BE
R/BE

Except Serial Data 2 2 LGN/V 13 13 LGN/V

FLHR/C
[201B] 4 3 2 1 LGN/V 9 9 Serial Data
[201A] 4 3 2 1 FLHR/C Serial Data 2 2 LGN/V 2 2 LGN/V
ABS
Diode Speedometer [39A] [39B] [20A] [20B]
Pack
BK/V 18 18 Front Wheel Speed Sensor Low
BK/BE 17 17 Front Wheel Speed Sensor High
BE/BN 8 8 Rear Wheel Speed Sensor High
BE/V 7 7 Rear Wheel Speed Sensor Low
BK/BE

BE/BN
BK/V

BE/V

87 5 3A O/V
Brake [167B] B A A B [168B]
30 3 2B R/Y
Relay 86 1 2A R/BE
[167A] B A A B [168A]
85 2 3B BK
R

BK
R
BK

BK 1 1 Ground

Front Rear
WSS WSS 11 11 Ground (Motor)
BK

ABS Module
[166B] [166A]
R/Y To
BK

BK Rear Lighting
BK

BK
BK

GND 1

Figure 7-20. ABS Schematic

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DTC C1014, C1055-C1066, C1118, C1121 2. Battery Power Circuit Resistance Test
PART NUMBER TOOL NAME 1. Test resistance between breakout box terminals 10 and
20, and [64-2B] terminal 4B.
HD-41404-C HARNESS CONNECTOR TEST KIT
2. Is resistance greater than 1 Ohm?
HD-48642 ABS BREAKOUT BOX
a. Yes. Repair circuit.

Table 7-31. DTC C1014, C1055-C1066, C1118, C1121 b. No. Inspect battery and charging system. See
Diagnostic Faults 3.5 CHARGING SYSTEM.

POSSIBLE CAUSES 3. Ignition Circuit Test

Internal system malfunction 1. Test for voltage between breakout box terminal 19 and
A faulty system voltage supply to the module ground.
A faulty system ground 2. Is voltage above 10.5V?
a. Yes. Go to Test 4.
1. Battery Circuit Voltage Test
b. No. Repair high resistance in ABS module [166B]
1. Connect ABS BREAKOUT BOX (Part No. HD-48642)
terminal 19 (GY) wire.
between wire harness [166B] and ABS module [166A].
See 1.2 DIAGNOSTIC TOOLS.
4. Ground Circuit Resistance Test
2. Turn IGN ON.
1. Test the ground circuits at ABS module [166B] terminals
3. Using HARNESS CONNECTOR TEST KIT (Part No. HD- 1 and 11 for high resistance or an open.
41404-C) and a multimeter, test for voltage breakout box
2. Is high resistance or open present?
terminals 20 and 10 at battery negative.
a. Yes. Repair high resistance or open condition on
4. Is the voltage above 10.5V? ground circuits.
a. Yes. Go to Test 3.
b. No. Replace ECU module. See the service manual.
b. No. Go to Test 2.

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ABS INDICATOR ALWAYS ON OR INOPERATIVE 7.16

DESCRIPTION AND OPERATION
See Figure 7-21. The speedometer (FLHR/C) tachometer
(except FLHR/C) illuminates the ABS indicator by supplying
ground to the lamp. The ABS module sends a serial data
message to the speedometer (FLHR/C) tachometer (except
FLHR/C) in order to command the indicator ON or OFF.
Diagnostic Tips
The malfunction must be present during diagnosis in order to
prevent unnecessary parts replacement.
Connector Information
For additional information about the connectors in the following
diagram(s) and diagnostic procedure(s), including the color of
the harness test kit terminal probes, see B.1 CONNECTORS.

ed03170

1 8 3
2 11 1

11

50 60 70 40
30 50
40 80
30 90 20 60
MPH RPM x100
20 100
10 70
10 110
0 120 0 80

9 C
H A R ERT I FI ED
L EY -DA V I DSON
HAR
L EY -DA VI DSON

7 7 2
6
10 9 8
5 4 10
4 6 5

1. Speedometer 7. Check engine lamp

2. Security lamp (key icon) 8. Battery discharge lamp
3. Tachometer 9. Sixth gear lamp
4. Cruise lamp 10. ABS lamp
5. Odometer/trip odometer/clock 11. Pursuit lamp (Police models)
6. Low fuel warning lamp
Figure 7-21. Speedometer

2011 Touring Diagnostics: ABS 7-39

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em00860 HCU ECU

1 1 Pump Motor Supply
[64-1B] [64-2B] Pump M
1A 1C 1E 4A Motor
2 2 Pump Motor Ground
Brake ACCY Ignition ABS
15A 15A 15A 30A
1B 1D 1F 4B

O/W
O/V

GY

R/V
R/V 20 20 Battery (Motor)
R/V 10 10 Battery

GY 19 19 Ignition

O/W [22B]
FLHR/C
(Except FLHR/C)
PK/BN

O/W 1
O/W

[1B] [1A]
R/BN 2 1 O/W Front
Stop
[121-2B] 1 1 [121-1B] O/W 5 5 O/W Lamp
[22B] 2
[121-2A] 1 1 [121-1A] R/Y Switch
[2B] [2A]
Rear O/W 1 [22A]
Stop
Pressure Lamp R/BN R/BN 1 1 R/BE R/BE 2
Switch Switch
PK/BN 3 3 Rear Brake Input
R/BN 13 13 Front Brake Input

Tachometer [108A] [108B] [1B] [1A]

PK/BN
R/BN
R/BE
R/BE

Except Serial Data 2 2 LGN/V 13 13 LGN/V

FLHR/C
[201B] 4 3 2 1 LGN/V 9 9 Serial Data
[201A] 4 3 2 1 FLHR/C Serial Data 2 2 LGN/V 2 2 LGN/V
ABS
Diode Speedometer [39A] [39B] [20A] [20B]
Pack
BK/V 18 18 Front Wheel Speed Sensor Low
BK/BE 17 17 Front Wheel Speed Sensor High
BE/BN 8 8 Rear Wheel Speed Sensor High
BE/V 7 7 Rear Wheel Speed Sensor Low
BK/BE

BE/BN
BK/V

BE/V

87 5 3A O/V
Brake [167B] B A A B [168B]
30 3 2B R/Y
Relay 86 1 2A R/BE
[167A] B A A B [168A]
85 2 3B BK
R

BK
R
BK

BK 1 1 Ground

Front Rear
WSS WSS 11 11 Ground (Motor)
BK

ABS Module
[166B] [166A]
R/Y To
BK

BK Rear Lighting
BK

BK
BK

GND 1

Figure 7-22. ABS Schematic

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ABS INDICATOR ALWAYS ON OR between wire harness [108B] and tachometer [108A]
(except FLHR/C). See 1.2 DIAGNOSTIC TOOLS.
INOPERATIVE
3. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
PART NUMBER TOOL NAME 41404-C) and a multimeter, test the (LGN/V) wire between
HD-41404-C HARNESS CONNECTOR TEST KIT ABS module [166B] terminal 9 and speedometer [39B]
(FLHR/C) tachometer (except FLHR/C) terminal 7 for
HD-42682 BREAKOUT BOX
continuity.
HD-45325 JUMPER HARNESS
4. Is continuity present?
HD-48642 ABS BREAKOUT BOX
a. Yes. Go to Test 4.

Table 7-32. ABS Indicator Always On or Inoperative b. No. Repair open in (LGN/V) between [166B] terminal
Diagnostic Faults 9 and [39B] terminal 7.

POSSIBLE CAUSES 4. ABS Fuse Test

Speedometer (FLHR/C) or tachometer (except FLHR/C) 1. Inspect the ABS fuse.
malfunction
2. Is fuse good?
Open serial data circuit
a. Yes. Go to Test 5.
Open battery circuit
b. No. Go to Test 7.
ECU malfunction
Open ground circuit 5. ABS Power Circuit Test
Short to ground in battery circuit 1. Install ABS fuse and disconnect ABS module [166A] from
the breakout box.
1. DTC Test
2. Test for voltage at breakout box terminal 10 and 20 to
1. Verify that the vehicle is equipped with ABS and has the ground.
appropriate speedometer (FLHR/C) or tachometer (except
FLHR/C). 3. Is battery voltage present?
a. Yes. Go to Test 6.
2. Clear the DTCs. See 2.1 INITIAL DIAGNOSTICS.
b. No. Repair open in ABS module battery circuit.
3. Are any ABS DTCs present?
a. Yes. See appropriate diagnostic procedure. 6. ABS Ground Circuit Test
b. No. Go to Test 2. 1. Test for continuity at breakout box terminals 1 and 11 to
ground.
2. ABS Lamp Function Test
2. Is continuity present?
1. Perform a "WOW" test. See 2.1 INITIAL DIAGNOSTICS.
a. Yes. Replace ECU. See the service manual.
2. Does the ABS lamp function properly during the "WOW"
b. No. Repair open in ABS module ground circuit.
test?
a. Yes. Go to Test 3. 7. ABS Power Circuit Short to Ground Test
b. No. Replace the speedometer (FLHR/C) or tacho- 1. Disconnect ABS module [166A] from the breakout box.
meter (except FLHR/C). See the service manual.
2. Test for short to ground between breakout box terminal
3. Serial Data Circuit Test 10 and 20.

1. Connect ABS BREAKOUT BOX (Part No. HD-48642) 3.
between wire harness [166B] and ABS module [166A].
See 1.2 DIAGNOSTIC TOOLS.
2. Connect BREAKOUT BOX (Part No. HD-42682) and
JUMPER HARNESS (Part No. HD-45325) between wire
harness [39B] and speedometer [39A] (FLHR/C) or
Is continuity to ground present?
a. Yes. Repair short to ground between [166B] terminals
10 and 20 (R/V) wire and ABS fuse. Replace ABS
fuse.
b. No. Condition is intermittent. See 1.3 DIAGNOSTICS
AND TROUBLESHOOTING, Wiggle Test. Replace
ABS fuse.

2011 Touring Diagnostics: ABS 7-41

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TABLE OF CONTENTS

SUBJECT............................................................................................................................PAGE NO.
8.1 RADIO DIAGNOSTICS..............................................................................................................8-1
8.2 DTC B2006-B2015, RADIO SWITCH DIAGNOSTICS..............................................................8-6
8.3 DTC B2016-B2027, RADIO SPEAKER DIAGNOSTICS.........................................................8-15
8.4 SERIAL DATA BUS DIAGNOSTICS........................................................................................8-22
8.5 ADVANCED AUDIO SYSTEM SYMPTOMS............................................................................8-30

AUDIO SYSTEM
NOTES
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RADIO DIAGNOSTICS
DESCRIPTION AND OPERATION
Harley-Davidson's Advanced Audio System, developed in
partnership with Harman/Kardon, offers improved function and
sound quality with an all new integrated design. The base radio
features six AM and ten FM radio presets, integrated weather
band and a single disc CD player compatible with
CD/CDR/CDRW and MP3 format discs.The system also allows
for seamless hook up of optional accessories (both current and
future) to the base radio display and hand controls.
The Advanced Audio System consists of the following compon-
ents:
• Radio
• CB module
• Antennas (radio and CB)
• Fairing, rear and sidecar speakers, depending upon model
• Handlebar, rear and sidecar switches, depending upon
model
• High Output Amplifier. Standard on sidecar equipped Ultra
Classic, CVO Ultra Classic and also as an optional
accessory; located under the luggage rack
• Optional accessory XM satellite radio module and antenna;
located in fairing above radio
• Optional accessory navigation module and external
antenna; module plugs into radio chassis in fairing
DIAGNOSTICS
PART NUMBER TOOL NAME
HD-48650 DIGITAL TECHNICIAN II
Diagnostic Tips
The system has onboard diagnostics to detect most fault con-
ditions. Many faults are stored as diagnostic trouble codes
(DTCs). Fault conditions that do not generate DTCs, or those
for which DTCs cannot be read, can be identified by their
symptoms. For troubleshooting and resolving switch inoperative
without DTC conditions, as well as other symptoms, see
8.5 ADVANCED AUDIO SYSTEM SYMPTOMS.
Radio Diagnostic Display
See A of Figure 8-1. Press the eject button to remove any CD
in the unit. Press and hold any two softkeys (buttons 1-6), turn
the ignition switch ON. Once the H-D logo is displayed, the
system automatically performs a complete switch check, scans
for current DTCs and then displays the radio diagnostic display.
8.1
Release the softkeys only after the radio diagnostic display
appears.
See B of Figure 8-1. If, after the intial diagnostic check, any
switches are found to be shorted to B+ or ground, the radio
diagnostic display reports the applicable DTC and an abbrevi-
ated description. Refer to the appropriate diagnostic procedure
for resolution of the problem.
If no switches are found to be shorted to B+ or ground, the
technician may press selected switches to verify functionality.
If a switch is functioning properly, the display shows the switch
name and the word "OK."
NOTE
Verify the proper switch function is displayed when the radio
display says "OK". Switch wiring shorted together could cause
the radio to display "OK" for the wrong function.
See C of Figure 8-1. If the switch is not working correctly, then
the display does not change. All switches, handlebar, pas-
senger and sidecar may be tested in this manner.
See D of Figure 8-1. Pressing softkey 1 while in the radio dia-
gnostic display sets the system back to the factory defaults. If
a symptom is present without a DTC, restoring the factory
default settings may sometimes resolve the issue. For more
information, see 8.5 ADVANCED AUDIO SYSTEM SYMP-
TOMS.
Pressing softkey 2 displays "Speed Pulses" followed by a speed
pulse value. This feature may be employed to quickly verify
whether the radio is configured correctly or whether the AVC
or J1850 is working properly.
See E of Figure 8-1. To use this feature, turn the IGN ON, with
the engine stop switch RUN, access the radio diagnostic dis-
play, press softkey 2 to select AVC, and then walk or push the
motorcycle while viewing the speed pulse value. If a value
other than zero appears, it is an indication that J1850 and AVC
are working properly. If speed pulses are not present, either
the AVC needs to be reconfigured or another problem exists.
See 8.4 SERIAL DATA BUS DIAGNOSTICS, DTC U1016
J1850 Loss of Communication with ECM for resolution of the
problem if the system is configured correctly.
See F and G of Figure 8-1. Pressing softkey 3 displays the
region and other configuration data, while softkey 4 shows the
software version code.
Softkey 5 is reserved for software upgrades and prompts the
technician to install the appropriate CD, while softkey 6 causes
the system to exit the radio diagnostic mode and revert to the
normal radio display.
2011 Touring Diagnostics: Audio System 8-1
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ed03047

A B

Figure 8-1. Initial Diagnostics - Radio Diagnostic Display

8-2 2011 Touring Diagnostics: Audio System

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Table 8-1. Diagnostic Trouble Codes (DTCs) and Symptoms

DTC DESCRIPTION FAULT-SET CONDITION FAULT-CLEAR CONDITION

T=TIME; R=RESISTANCE
B0563 Battery voltage high t>=15 sec. V>= 16V Normal range for t>=15 seconds
B2006 Radio switch stuck or t>=15 sec. Normal range for t>=15 seconds
open
B2007 Handlebar switch Ignition ON after Ignition OFF for at least 10 sec., Normal range for t>=15 seconds*
shorted high t=instantaneous
B2008 Handlebar switch Ignition ON after Ignition OFF for at least 10 sec., Normal range for t>=15 seconds*
shorted low t=instantaneous
B2009 Handlebar switch stuck t>=15 sec. Normal range for t>=15 seconds
or open
B2010 Passenger switch Ignition ON after Ignition OFF for at least 10 sec., Normal range for t>=15 seconds*
shorted high t=instantaneous
B2011 Passenger switch Ignition ON after Ignition OFF for at least 10 sec., Normal range for t>=15 seconds*
shorted low t=instantaneous
B2012 Passenger switch stuck t>=15 sec. Normal range for t>=15 seconds
or open
B2016 Front speakers shorted R<1.5 Ohms tested once per ignition cycle R>1.0 R>1.5 Ohms tested once per ignition
Ohm when setup as line out ignition ON after Igni- cycle
tion OFF for at least 10 sec., t=instantaneous
B2017 Front speakers open R>100 Ohms tested once per ignition cycle ignition R<100 Ohms tested once per ignition
ON after Ignition OFF for at least 10 sec., cycle
t=instantaneous
B2018 Front speakers shorted Ignition ON after Ignition OFF for at least 10 sec.,
to ground t=instantaneous
B2019 Front speakers shorted Ignition ON after Ignition OFF for at least 10 sec.,
to battery t=instantaneous
B2020 Rear speakers shorted R<1.5 Ohms tested once per ignition cycle R>1.0 R>1.5 Ohms tested once per ignition
Ohm when setup as line out ignition ON after Igni- cycle
tion OFF for at least 10 sec., t=instantaneous
B2021 Rear speakers open R>100 Ohms tested once per ignition cycle ignition R<100 Ohms tested once per ignition
ON after Ignition OFF for at least 10 sec., cycle
t=instantaneous
B2022 Rear Speakers shorted Ignition ON after Ignition OFF for at least 10 sec.,
to ground t=instantaneous
B2023 Rear speakers shorted Ignition ON after Ignition OFF for at least 10 sec.,
to battery t=instantaneous
* Ignition ON after Ignition OFF for at least 10 seconds.

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Table 8-2. Diagnostic Trouble Codes (DTCs) and Symptoms

DTC/SYMPTOM DESCRIPTION GO TO
U1016 J1850 lost communications with ECM DTC U1304 through DTC U1317 can only be viewed as historic
U1300 J1850 bus shorted low codes using DIGITAL TECHNICIAN II (Part No. HD-48650).
The faults are detectable as current codes only if they happen
U1301 J1850 bus shorted high to occur while in the diagnostic mode. To diagnose these condi-
U1302 Infotainment bus off error tions without the use of DIGITAL TECHNICIAN II (Part No. HD-
48650), see 8.5 ADVANCED AUDIO SYSTEM SYMPTOMS.
U1304 Infotainment bus lost communications with
future
U1305 Infotainment bus lost communications with
future
U1306 Infotainment bus lost communications with
hands-free phone module
U1307 Infotainment bus lost communications with
CB
U1308 Infotainment bus lost communications with
future
U1309 Infotainment bus lost communications with
future
U1310 Infotainment bus lost communications with
future
U1311 Infotainment bus lost communications with
future
U1312 Infotainment bus lost communications with
future
U1313 Infotainment bus lost communications with
XM
U1314 Infotainment bus lost communications with
navigation
U1315 Infotainment bus lost communications with
future
U1316 Infotainment bus lost communications with
future
U1317 Infotainment bus lost communications with
high output amplifier
1 Radio Inoperative Symptom 1: Radio Inoperative
2 Poor or No Reception Symptom 2: Poor or No Reception
3 Static Present With Engine Running Symptom 3: Static Present with Engine Running
4 CB Transmitter Inoperative Symptom 4: CB Transmitter Inoperative
5 CB Receiver Inoperative Symptom 5: CB Receiver Inoperative
6 Intercom Inoperative Symptom 6: Intercom Inoperative
7 Handheld Microphone/PTT Inoperative Symptom 7: Handheld Microphone/PTT Inoperative
8 Speaker Switch Malfunction Symptom 8: Fairing Mounted Speaker Switch Malfunction
9 Headset Speakers Inoperative Symptom 9: Headset Speakers Inoperative
10 No or Low Audio From Microphones Symptom 10: No or Low Audio from Microphones
11 No or Low Audio With High Output Ampli- Symptom 11: No or Low Audio with High Output Amplifier
fier
12 No or Low Audio From XM or XM Inoper- Symptom 12: No or Low Audio from XM or XM Inoperative
ative
13 XM - No or Intermittent Reception Symptom 13: No or Intermittent Reception on XM Module
14 Navigation Inoperative Symptom 14: Navigation Inoperative

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Table 8-2. Diagnostic Trouble Codes (DTCs) and Symptoms

DTC/SYMPTOM DESCRIPTION GO TO
15 AVC Inoperative Symptom 15: AVC Inoperative
16 Handlebar, Passenger or Sidecar Switches Symptom 16: Handlebar, Passenger or Sidecar Switches Inop-
Inoperative erative
17 CD Skipping Symptom 17: CD Skipping
18 Hands-Free Phone Module Inoperative Symptom 18: Hands-Free Phone Module Initial Diagnostics
No or Low Audio To Hands-Free Phone
Module
No or Low Audio From Hands-Free Phone
Module
Hands-Free Phone Module - Phone Not
Pairing

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DTC B2006-B2015, RADIO SWITCH

DIAGNOSTICS 8.2
DESCRIPTION AND OPERATION The diagnostic tests in this section have been developed to
take into consideration the technician understands there are
The sound system is designed to capture faults for each of the connectors and jumper harness adapters in the audio system
radio switch inputs. When a fault is detected, a DTC is gener- that are not specifically called out in the tests. See B.1 CON-
ated. The DTC and related data appears on the radio display NECTORS for connector locations when necessary.
when the system is in the diagnostic mode. Refer to Table 8-3.
If two functional wires are crossed in the wiring harness, a code
may not set. The symptom experienced is that separate
Table 8-3. Code Description switches may operate the same function and the other function
DTC DESCRIPTION will not operate at all. Another indication of this is if the radio
face plate displays a different function than requested. For
B2006 Radio switch stuck or open example: when pressing the passenger PTT, the radio face
B2007 Handlebar switch shorted high plate display says "Audio Up OK". If any conditions similar to
B2008 Handlebar switch shorted low this exist, test the wiring of the desired and displayed functions
for continuity and repair any wires shorted together.
B2009 Handlebar switch stuck or open
B2010 Passenger switch shorted high ed02068
B2011 Passenger switch shorted low
B2012 Passenger switch stuck or open

DIAGNOSTICS
PART NUMBER TOOL NAME
HD-47918 ADVANCED AUDIO SYSTEM
BREAKOUT BOX

Diagnostic Tips
Unless specified otherwise, install ADVANCED AUDIO
SYSTEM BREAKOUT BOX (Part No. HD-47918) when called
for in the following diagnostic procedures.

Figure 8-2. Radio Breakout Box (Part No. HD-47918)

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em00713 Left Hand Interconnect

Controls Harness
O/BK 14 14 O/BK
GY/GN 11 11 GY/GN
GN/BE 10 10 GN/BE To
PK/W 9 9 PK/W PK/W Right Hand
BN/BK 8 8 BN/BK Controls
V/BK 13 13 V/BK

[24A] [24B]
SWITCH VIOLET/ GRAY/ ORANGE/ BROWN/
POSITION BLACK GREEN BLACK BLACK
+SQ UP X X
PTT (PUSH) X X
-SQ DN X X

PK/W 3
V/BK 5 To
PTT & SQ 7 Radio
O/BK
(Push To Talk & Squelch) BN/BK 8 [27A]
(Ultra Models Only) GY/GN 22 (BK)
GN/BE 23
Horn Switch
Headlamp Hi/Lo Switch [27B]
Left Directional Switch
Radio Audio Control

SWITCH PINK/ GREEN/ BROWN/ GRAY/

POSITION WHITE BLUE BLACK GREEN
+VOL X X
AUDIO X X
-VOL X X

Left Hand Controls

Figure 8-3. Handlebar Audio, PTT and Squelch Switch Circuit

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em00179

Right Hand Controls

SWITCH BROWN/ PINK/ VIOLET/ GRAY/
POSITION WHITE WHITE BLACK WHITE
UP X X
MODE X X
DOWN X X

To
PK/W Left Hand
Radio Function Switch Controls
PK/W 3 To
Right Directional Switch GY/W 4
V/BK 5 Radio
BN/W 6 [27A]
(BK)

[27B]

Stop Lamp Switch

BN/W 7 7 BN/W
GY/W 8 8 GY/W
PK/W 9 9 PK/W
V/BK 10 10 V/BK

Right Hand Interconnect

Controls [22A] [22B]

Figure 8-4. Handlebar Mode Switch Circuit

RADIO SWITCH DIAGNOSTICS 2. Does radio power up and enter diagnostic mode?
a. Yes. Tests should run automatically. If DTC B2007,
PART NUMBER TOOL NAME B2008, B2010, B2011, B2013 or B2014 is present,
HD-41404-C HARNESS CONNECTOR TEST KIT refer to Table 8-5.
HD-47918 ADVANCED AUDIO SYSTEM b. No, only radio powers up. Go to Test 2.
BREAKOUT BOX
c. No, the radio does not power up. See
8.5 ADVANCED AUDIO SYSTEM SYMPTOMS,
Table 8-4. Radio Switch Diagnostic Faults Symptom 1: Radio Inoperative.
POSSIBLE CAUSES
Mechanical switch malfunction
Electrical switch malfunction
Radio malfunction

1. Checking for Diagnostic Trouble Codes

(DTCs) Test
1. While pressing any two softkeys (presets), turn IGN ON
to enter diagnostic mode.

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Table 8-5. Shorted Switch Problems
DTC DESCRIPTION OF FAULT
B2007 Handlebar audio switch shorted high
Handlebar mode switch shorted high
Handlebar PTT/squelch switch
shorted high
B2008 Handlebar audio switch shorted low
Handlebar mode switch shorted low
Handlebar PTT/squelch switch
shorted low
B2010 Passenger audio/PTT switch shorted
high
Passenger mode switch shorted high
B2011 Passenger audio/PTT switch shorted
low
Passenger mode switch shorted low
2. Switch Function Test
1. While watching the radio display, press each switch; audio
up/down, audio, mode up/down, mode, PTT, squelch +/-.
NOTE
Verify the operated switch function is the same function being
displayed on the radio face plate. A different function displayed
on the face plate could indicate two function wires are shorted.
See diagnostic tips.
2. Does the display show the selected function when the
switch is pressed?
a. Yes. No fault found.
b. No. Refer to Table 8-6.
Table 8-6. Switch Mechanical Problems
DTC DESCRIPTION OF FAULT
B2006 Radio faceplate switches stuck or
open
B2009 Handlebar audio switch stuck or
open
Handlebar mode switch stuck or
open
Handlebar PTT/squelch switch stuck
or open
B2012 Passenger audio/PTT switch stuck
or open
Passenger mode switch stuck or
open
3. DTC B2007, Handlebar Audio Switch
Shorted High (Part A) Test
1. Remove outer fairing and connect ADVANCED AUDIO
SYSTEM BREAKOUT BOX (Part No. HD-47918) leaving
radio [27A] disconnected.
2. With IGN ON, measure voltage at breakout box terminals
3 (PK/W), 8 (BN/BK), 22 (GY/GN) or 23 (GN/BE) to ground
as indicated on the radio display.
GO TO
Test 3 3. Is voltage greater than 7V?
Test 5 a. Yes. Go to Test 4.
Test 7 b. No. Replace radio. See the service manual. (6101)
Test 9
4. DTC B2007, Handlebar Audio Switch
Shorted High (Part B) Test
Test 11
1. Disconnect left hand controls [24].
Test 13
2. With IGN ON, measure voltage using HARNESS CON-
Test 21 NECTOR TEST KIT (Part No. HD-41404-C) and multi-
meter from [24A] terminals 8 (BN/BK), 9 (PK/W), 10
(GN/BE) or 11 (GY/GN) to ground as indicated on the
Test 23 radio display.
Test 25
3. Is voltage greater than 7V?
a. Yes. Repair short in handlebar harness on wire
Test 27
indicated on radio display. (5041)
b. No. Repair short in interconnect harness on wire
indicated on radio display. (5041)
5. DTC B2007, Handlebar Mode Switch
Shorted High (Part A) Test
1. Remove outer fairing and connect ADVANCED AUDIO
SYSTEM BREAKOUT BOX (Part No. HD-47918) leaving
radio [27A] disconnected.
2. With IGN ON, measure voltage at breakout box terminals
3 (PK/W), 4 (GY/W), 5 (V/BK) or 6 (BN/W) to ground as
indicated on the radio display.
3. Is voltage greater than 7V?
a. Yes. Go to Test 6.
b. No. Replace radio. See the service manual. (6101)
GO TO 6. DTC B2007, Handlebar Mode Switch
Replace Shorted High (Part B) Test
radio.
(6101) 1. Disconnect right hand controls [22].
Test 15 2. With IGN ON, measure voltage using HARNESS CON-
NECTOR TEST KIT (Part No. HD-41404-C) and multi-
meter from [22A] terminals 7 (BN/W), 8 (GY/W), 9 (PK/W)
Test 17
or 10 (V/BK) to ground as indicated on the radio display.
Test 19 3. Is voltage greater than 7V?
a. Yes. Repair short in handlebar harness on wire
indicated on radio display. (5041)
Test 29
b. No. Repair short in interconnect harness on wire
Test 31 indicated on radio display. (5041)
7. DTC B2007, Handlebar PTT/Squelch
Switch Shorted High (Part A) Test
1. Remove outer fairing and connect ADVANCED AUDIO
SYSTEM BREAKOUT BOX (Part No. HD-47918), leaving
radio [27A] disconnected.
2011 Touring Diagnostics: Audio System 8-9
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2. With IGN ON, measure voltage at breakout box terminals
5 (V/BK), 7 (O/BK), 8 (BN/BK) or 22 (GY/GN) to ground
as indicated on the radio display.
3. Is voltage greater than 7V?
a. Yes. Go to Test 8.
b. No. Replace radio. See the service manual. (6101)
8. DTC B2007, Handlebar PTT/Squelch
Switch Shorted High (Part B) Test
1. Disconnect left hand controls [24].
2. With IGN ON, measure voltage using HARNESS CON-
NECTOR TEST KIT (Part No. HD-41404-C) and multi-
meter from [24A] terminals 8 (BN/BK), 11 (GY/GN), 13
(V/BK) or 14 (O/BK) to ground as indicated on the radio
display.
3. Is voltage greater than 7V?
a. Yes. Repair short in handlebar harness on wire
indicated on radio display. (5041)
b. No. Repair short in interconnect harness on wire
indicated on radio display. (5041)
9. DTC B2008, Handlebar Audio Switch
Shorted Low (Part A) Test
1. Remove outer fairing and connect ADVANCED AUDIO
SYSTEM BREAKOUT BOX (Part No. HD-47918), leaving
radio [27A] disconnected.
2. With IGN OFF, measure resistance using HARNESS
CONNECTOR TEST KIT (Part No. HD-41404-C) and
multimeter from [27B] terminals 3 (PK/W), 8 (BN/BK), 22
(GY/GN) or 23 (GN/BE) to ground as indicated on the
radio display.
3. Is resistance less than 5000 Ohms?
a. Yes. Go to Test 10.
b. No. Replace radio. See the service manual. (6101)
10. DTC B2008, Handlebar Audio Switch
Shorted Low (Part B) Test
1. Disconnect left hand controls [24].
2. With IGN OFF, measure resistance at breakout box ter-
minals 8 (BN/BK), 9 (PK/W), 10 (GN/BE) or 11 (GY/GN)
to ground as indicated on the radio display.
3. Is resistance less than 5000 Ohms?
a. Yes. Repair short in handlebar harness on wire
indicated on radio display. (5041)
b. No. Repair short in interconnect harness on wire
indicated on radio display. (5041)
11. DTC B2008, Handlebar Mode Switch
Shorted Low (Part A) Test
1. Remove outer fairing and connect ADVANCED AUDIO
SYSTEM BREAKOUT BOX (Part No. HD-47918), leaving
radio [27A] disconnected.
8-10 2011 Touring Diagnostics: Audio System
2. With IGN OFF, measure resistance at breakout box ter-
minals 3 (PK/W), 4 (GY/W), 5 (V/BK) or 6 (BN/W) to
ground as indicated on the radio display.
3. Is resistance less than 5000 Ohms?
a. Yes. Go to Test 12.
b. No. Replace radio. See the service manual. (6101)
12. DTC B2008, Handlebar Mode Switch
Shorted Low (Part B) Test
1. Disconnect right hand controls [22].
2. With IGN OFF, measure resistance using HARNESS
CONNECTOR TEST KIT (Part No. HD-41404-C) and
multimeter from [22A] terminals 7 (BN/W), 8 (GY/W), 9
(PK/W) or 10 (V/BK) to ground as indicated on the radio
display.
3. Is resistance less than 5000 Ohms?
a. Yes. Repair short in handlebar harness on wire
indicated on radio display. (5041)
b. No. Repair short in interconnect harness on wire
indicated on radio display. (5041)
13. DTC B2008, Handlebar PTT/Squelch
Switch Shorted Low (Part A) Test
1. Remove outer fairing and connect ADVANCED AUDIO
SYSTEM BREAKOUT BOX (Part No. HD-47918), leaving
radio [27A] disconnected.
2. With IGN OFF, measure resistance at breakout box ter-
minals 5 (V/BK), 7 (O/BK), 8 (BN/BK) or 22 (GY/GN) to
ground as indicated on the radio display.
3. Is resistance less than 5000 Ohms?
a. Yes. Go to Test 14.
b. No. Replace radio. See the service manual. (6101)
14. DTC B2008, Handlebar PTT/Squelch
Switch Shorted Low (Part B) Test
1. Disconnect left hand controls [24].
2. With IGN OFF, measure resistance using HARNESS
CONNECTOR TEST KIT (Part No. HD-41404-C) and
multimeter from [24A] terminals 8 (BN/BK), 11 (GY/GN),
13 (V/BK) or 14 (O/BK) to ground as indicated on the radio
display.
3. Is resistance less than 5000 Ohms?
a. Yes. Repair short in handlebar harness on wire
indicated on radio display. (5041)
b. No. Repair short in interconnect harness on wire
indicated on radio display. (5041)
15. DTC B2009, Handlebar Audio Switch
Stuck or Open (Part A) Test
1. Remove outer fairing and connect ADVANCED AUDIO
SYSTEM BREAKOUT BOX (Part No. HD-47918), leaving
radio [27A] disconnected.
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2. Test for continuity at the appropriate breakout box ter-

minals with the audio switch pressed as indicated in Table 8-9. Mode Switch Stuck or Open Test
Table 8-7.
SWITCH POSI- FROM TERMINAL TO TERMINAL
3. Is each wire pair less than 0.5 Ohms as each switch is TION
pressed, and not when the switch is released? Mode Up 6 (BN/W) 3 (PK/W)
a. Yes. Replace radio. See the service manual. (6101) Mode Dn 6 (BN/W) 4 (GY/W)
b. No. Go to Test 16. Mode In 6 (BN/W) 5 (V/BK)

Table 8-7. Audio Switch Stuck or Open Test

18. DTC B2009, Handlebar Mode Switch
Stuck or Open (Part B) Test
SWITCH POSI- FROM TERMINAL TO TERMINAL
TION 1. Disconnect right hand controls [22].

Audio + 3 (PK/W) 23 (GN/BE) 2. Test for continuity at [22A], using HARNESS CON-
NECTOR TEST KIT (Part No. HD-41404-C) with the mode
Audio - 3 (PK/W) 22 (GY/GN)
switch pressed as indicated in Table 8-10.
Audio (centered) 3 (PK/W) 8 (BN/BK)
3. Is each wire pair less than 0.5 Ohms as each switch is
16. DTC B2009, Handlebar Audio Switch pressed, and not when the switch is released?

Stuck or Open (Part B) Test a. Yes. Repair open in interconnect harness. (5041)

1. Disconnect left hand controls [24]. b. No. Replace switch or repair switch wiring. See the
service manual. (5183)
2. Test for continuity at [24A], using HARNESS CON-
NECTOR TEST KIT (Part No. HD-41404-C) with the audio
switch pressed as indicated in Table 8-8. Table 8-10. Mode Switch Stuck or Open Test

3. Is each wire pair less than 0.5 Ohms as each switch is SWITCH POSI- FROM TERMINAL TO TERMINAL
pressed, and not when the switch is released? TION
a. Yes. Repair open in interconnect harness. (5041) Mode Up 7 (BN/W) 9 (PK/W)
b. No. Replace switch or repair switch wiring. See the Mode Dn 7 (BN/W) 8 (GY/W)
service manual. (5186) Mode In 7 (BN/W) 10 (V/BK)

Table 8-8. Audio Switch Stuck or Open Test

19. DTC B2009, Handlebar PTT/Squelch
Switch Stuck or Open (Part A) Test
SWITCH POSI- FROM TERMINAL TO TERMINAL
TION 1. Remove outer fairing and connect ADVANCED AUDIO
SYSTEM BREAKOUT BOX (Part No. HD-47918), leaving
Audio + 9 (PK/W) 10 (GN/BE) radio [27A] disconnected.
Audio - 9 (PK/W) 11 (GY/GN)
2. Test for continuity at appropriate breakout box terminals
Audio (centered) 9 (PK/W) 8 (BN/BK) with the PTT/squelch switch pressed as indicated in
Table 8-11.
17. DTC B2009, Handlebar Mode Switch
3. Is each wire pair less than 0.5 Ohms as each switch is
Stuck or Open (Part A) Test pressed, and not when the switch is released?
1. Remove outer fairing and connect ADVANCED AUDIO a. Yes. Replace radio. See the service manual. (6101)
SYSTEM BREAKOUT BOX (Part No. HD-47918), leaving
radio [27A] disconnected. b. No. Go to Test 20.

2. Test for continuity at the appropriate breakout box ter-

minals with the mode switch pressed as indicated in Table 8-11. PTT/Squelch Switch Stuck or Open Test
Table 8-9.
SWITCH POSI- FROM TERMINAL TO TERMINAL
3. Is each wire pair less than 0.5 Ohms as each switch is TION
pressed, and not when the switch is released? Squelch + 5 (V/BK) 22 (GY/GN)
a. Yes. Replace radio. See the service manual. (6101) Squelch - 5 (V/BK) 8 (BN/BK)
b. No. Go to Test 18. PTT 5 (V/BK) 7 (O/BK)

20. DTC B2009, Handlebar PTT/Squelch

Switch Stuck or Open (Part B) Test
1. Disconnect left hand controls [24].

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2. Test for continuity at [24A] using HARNESS CONNECTOR

TEST KIT (Part No. HD-41404-C) with the PTT/squelch Table 8-12. PTT/Squelch Switch Stuck or Open Test
switch pressed as indicated in Table 8-12.
SWITCH POSI- FROM TERMINAL TO TERMINAL
3. Does continuity exist as each switch is pressed, and not TION
when the switch is released? Squelch + 13 (V/BK) 11 (GY/GN)
a. Yes. Repair open in interconnect harness. (5041) Squelch - 13 (V/BK) 8 (BN/BK)
b. No. Replace switch or repair switch wiring. See the PTT 13 (V/BK) 14 (O/BK)
service manual. (5184)

em00670 (BK) Right Rear Passenger Controls

[28A] [28B] COLOR
POSITION
ORANGE/
BLACK
PINK/
WHITE
VIOLET/
BLACK
GRAY/
WHITE
Radio
+VOL X X
PTT X X
PTT/Mode 11 V/BK -VOL X X
Common 12 BN/W
(BK)
[41A] [41B]

PK/W 1 1 PK/W PK/W VOL+ Right Rear

VOL-/Down 23 GY/W GY/W 2 2 GY/W GY/W
V/BK 3 3 V/BK V/BK
PTT Speaker &
O/BK 4 4 O/BK O/BK VOL- Controls

VOL+/Up 34 PK/W
(BK)
Common 35 O/BK [42A] [42B]

PK/W 1 1 PK/W PK/W UP Left Rear

GY/W 2 2 GY/W GY/W
V/BK 3 3 V/BK V/BK
MODE SEL Speaker &
BN/W 4 4 O/BK O/BK DOWN Controls

Left Rear Passenger Controls

COLOR BROWN/ PINK/ VIOLET/ GRAY/
POSITION WHITE WHITE BLACK WHITE

UP X X
MODE X X
DOWN X X

Figure 8-5. Passenger Audio/PTT and Mode Switch Circuit

21. DTC B2010, Passenger Audio/PTT 3. Is voltage greater than 7V?

Switch Shorted High (Part A) Test a. Yes. Repair short in audio harness on wire indicated
on radio display. (5041)
1. Remove outer fairing and connect ADVANCED AUDIO
SYSTEM BREAKOUT BOX (Part No. HD-47918), leaving b. No. Repair short in passenger rear control switch
radio [28A] disconnected. harness on wire indicated on radio display. (5041)

2. With IGN ON, measure voltage at breakout box terminals 23. DTC B2010, Passenger Mode Switch
34 (PK/W), 23 (GY/W), 11 (V/BK) or 35 (O/BK) to ground
as indicated on the radio display. Shorted High (Part A) Test
1. Remove outer fairing and connect ADVANCED AUDIO
3. Is voltage greater than 7V?
SYSTEM BREAKOUT BOX (Part No. HD-47918), leaving
a. Yes. Go to Test 22. radio [28A] disconnected.
b. No. Replace radio. See the service manual. (6101) 2. With IGN ON, measure voltage at breakout box terminals
34 (PK/W), 23 (GY/W), 11 (V/BK) or 12 (BN/W) to ground
22. DTC B2010, Passenger Audio/PTT as indicated on the radio display.
Switch Shorted High (Part B) Test 3. Is voltage greater than 7V?
1. Disconnect right rear speaker controls [41]. a. Yes. Go to Test 24.
2. With IGN ON, measure voltage using HARNESS CON- b. No. Replace radio. See the service manual. (6101)
NECTOR TEST KIT (Part No. HD-41404-C) and multi-
meter from [41A] terminals 1 (PK/W), 2 (GY/W), 3 (V/BK) 24. DTC B2010, Passenger Mode Switch
or 4 (O/BK) to ground as indicated on the radio display.
Shorted High (Part B) Test
1. Disconnect left rear speaker controls [42].

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2. With IGN ON, measure voltage using HARNESS CON- meter from [42A] terminals 1 (PK/W), 2 (GY/W), 3 (V/BK)
NECTOR TEST KIT (Part No. HD-41404-C) and multi- or 4 (BN/W) to ground as indicated on the radio display.
meter from [42A] terminals 1 (PK/W), 2 (GY/W), 3 (V/BK)
3. Is continuity present?
or 4 (BN/W) to ground as indicated on the radio display.
a. Yes. Repair short in audio harness on wire indicated
3. Is voltage greater than 7V? on radio display. (5041)
a. Yes. Repair short in audio harness on wire indicated
b. No. Repair short in passenger rear control switch
on radio display. (5041)
harness on wire indicated on radio display. [(BN/W)
b. No. Repair short in passenger rear control switch becomes (O/BK) in speaker box]. (5041)
harness on wire indicated on radio display. (5041)
29. DTC B2012, Passenger Audio/PTT
25. DTC B2011, Passenger Audio/PTT Switch Stuck or Open (Part A) Test
Switch Shorted Low (Part A) Test 1. Remove outer fairing and connect ADVANCED AUDIO
1. Remove outer fairing and connect ADVANCED AUDIO SYSTEM BREAKOUT BOX (Part No. HD-47918), leaving
SYSTEM BREAKOUT BOX (Part No. HD-47918), leaving radio [28A] disconnected.
radio [28A] disconnected.
2. Test for continuity at the appropriate breakout box ter-
2. With IGN OFF, test for continuity at breakout box terminals minals with the audio switch pressed as indicated in
34 (PK/W), 23 (GY/W), 11 (V/BK) or 35 (O/BK) to ground Table 8-13.
as indicated on the radio display.
3. Is each wire pair less than 0.5 Ohms as each switch is
3. Is continuity present? pressed, and not when the switch is released?
a. Yes. Go to Test 26. a. Yes. Switch operation normal. Replace radio. See
the service manual. (6101)
b. No. Replace radio. See the service manual. (6101)
b. No. Go to Test 30.
26. DTC B2011, Passenger Audio/PTT
Switch Shorted Low (Part B) Test Table 8-13. Audio/PTT Switch Stuck or Open Test
1. Disconnect right rear speaker controls [41].
SWITCH POSI- FROM TERMINAL TO TERMINAL
2. With IGN OFF, test for continuity using HARNESS CON- TION
NECTOR TEST KIT (Part No. HD-41404-C) and multi- Vol. Up 35 (O/BK) 34 (PK/W)
meter from [41A] terminals 1 (PK/W), 2 (GY/W), 3 (V/BK)
or 4 (O/BK) to ground as indicated on the radio display. Vol. Down 35 (O/BK) 23 (GY/W)
PTT 35 (O/BK) 11 (V/BK)
3. Is continuity present?
a. Yes. Repair short in audio harness on wire indicated 30. DTC B2012, Passenger Audio/PTT
on radio display. (5041)
Switch Stuck or Open (Part B) Test
b. No. Repair short in passenger rear control switch 1. Disconnect left rear speaker controls [41].
harness on wire indicated on radio display. (5041)
2. Test for continuity using HARNESS CONNECTOR TEST
27. DTC B2011, Passenger Mode Switch KIT (Part No. HD-41404-C) at [41B] with the audio switch
pressed as indicated in Table 8-14.
Shorted Low (Part A) Test
1. Remove outer fairing and connect ADVANCED AUDIO 3. Is each wire pair less than 0.5 Ohms as each switch is
SYSTEM BREAKOUT BOX (Part No. HD-47918), leaving pressed, and not when the switch is released?
radio [28A] disconnected. a. Yes. Repair open or replace audio harness. (5041)
2. With IGN OFF, test for continuity at breakout box terminals b. No. Replace rear volume/PTT switch or repair switch
34 (PK/W), 23 (GY/W), 11 (V/BK) or 12 (BN/W) to ground wiring. See the service manual. (6627)
as indicated on the radio display.
3. Is continuity present? Table 8-14. Audio/PTT Switch Stuck or Open Test
a. Yes. Go to Test 28. SWITCH POSI- FROM TERMINAL TO TERMINAL
b. No. Replace radio. See the service manual. (6101) TION
Vol. Up 4 (O/BK) 1 (PK/W)
28. DTC B2011, Passenger Mode Switch Vol. Dn 4 (O/BK) 2 (GY/W)
Shorted Low (Part B) Test
PTT 4 (O/BK) 3 (V/BK)
1. Disconnect left rear speaker controls [42].
2. With IGN OFF, test for continuity using HARNESS CON-
NECTOR TEST KIT (Part No. HD-41404-C) and multi-

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31. DTC B2012, Passenger Mode Switch 32. DTC B2012, Passenger Mode Switch
Stuck or Open (Part A) Test Stuck or Open (Part B) Test
1. Remove outer fairing and connect ADVANCED AUDIO 1. Disconnect left rear speaker controls [42].
SYSTEM BREAKOUT BOX (Part No. HD-47918), leaving
2. Test for continuity on [42B] terminals using HARNESS
radio [28A] disconnected.
CONNECTOR TEST KIT (Part No. HD-41404-C) with the
2. Test for continuity at the appropriate breakout box ter- mode switch pressed as indicated in Table 8-16.
minals with the mode switch pressed as indicated in
3. Does continuity exist as each switch is pressed, and not
Table 8-15.
when the switch is released?
3. Is each wire pair less than 0.5 Ohms as each switch is a. Yes. Repair open in audio harness. (5041)
pressed, and not when the switch is released?
b. No. Replace switch or repair switch wiring. See the
a. Yes. Switch operation normal. Replace radio. See
service manual. (6627)
the service manual. (6101)
b. No. Go to Test 32.
Table 8-16. Mode Switch Stuck or Open Test

Table 8-15. Mode Switch Stuck or Open Test SWITCH POSI- FROM TERMINAL TO TERMINAL
TION
SWITCH POSI- FROM TERMINAL TO TERMINAL Mode Up 4 (O/BK) 1 (PK/W)
TION
Mode Dn 4 (O/BK) 2 (GY/W)
Mode Up 12 (BN/W) 34 (PK/W)
Mode In 4 (O/BK) 3 (V/BK)
Mode Dn 12 (BN/W) 23 (GY/W)
Mode In 12 (BN/W) 11 (V/BK)

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DTC B2016-B2027, RADIO SPEAKER

DIAGNOSTICS 8.3
DESCRIPTION AND OPERATION 2. Measure the resistance between breakout box terminals
16 and 17 (left speaker) or terminals 1 and 18 (right
PART NUMBER TOOL NAME speaker).
HD-47918 ADVANCED AUDIO SYSTEM 3. Is resistance less than 1.0 Ohm?
BREAKOUT BOX
a. Yes. Go to Test 2.
The sound system is designed to capture faults for each of the b. No. Replace radio. See the service manual. (6101)
radio speaker outputs. When a fault is detected, a DTC is
generated. The DTC and related data appears on the radio 2. Front Speakers Shorted (Part B) Test
display when the system is in the diagnostic mode. Refer to
Table 8-17. 1. Disconnect the affected speaker(s).
2. Measure the resistance between breakout box terminals
Table 8-17. Code Description 16 and 17 (left speaker) or terminals 1 and 18 (right
speaker).
DTC DESCRIPTION
B2016 Front speakers shorted 3. Is resistance less than 1.0 Ohm?
a. Yes. Repair short between radio [27B] terminals 16
B2017 Front speakers open
(W/O) and 17 (LGN/W) (left speaker) or between ter-
B2018 Front speakers shorted to ground minals 1 (LGN/BK) and 18 (GY/R) (right speaker).
B2019 Front speakers shorted to battery (5041)
B2020 Rear speakers shorted b. No. Replace speaker. See the service manual. (6605)
B2021 Rear speakers open
B2016 FRONT SPEAKERS SHORTED:WITH
B2022 Rear speakers shorted to ground
AMPLIFIER
B2023 Rear speakers shorted to battery
PART NUMBER TOOL NAME
Diagnostic Tips HD-47918 BREAKOUT BOX
Unless specified otherwise, install ADVANCED AUDIO
SYSTEM BREAKOUT BOX (Part No. HD-47918) when called
Table 8-19. B2016 Front Speakers Shorted:With Amplifier
for in the following diagnostic procedures.
Diagnostic Faults
The diagnostic tests in this section have been developed to
take into consideration the technician understands there are POSSIBLE CAUSES
connectors and jumper harness adapters in the audio system Speaker malfunction
that are not specifically called out in the tests. See B.1 CON- Speaker wires shorted together
NECTORS for connector locations when necessary.
Amplifier malfunction
B2016 FRONT SPEAKERS SHORTED:
WITHOUT AMPLIFIER 1. Front Speakers Shorted (Part A) Test
1. Install BREAKOUT BOX (Part No. HD-47918) to amplifier
PART NUMBER TOOL NAME harness [149], leaving amplifier disconnected.
HD-47918 BREAKOUT BOX
2. Measure the resistance between breakout box terminals
7 and 14 (left speaker) or terminals 6 and 13 (right
Table 8-18. B2016 Front Speakers Shorted: Without speaker).
Amplifier Diagnostic Faults
3. Is resistance less than 1.0 Ohm?
POSSIBLE CAUSES a. Yes. Go to Test 2.
Speaker malfunction
b. No. Replace amplifier. (6107)
Speaker wires shorted together
Radio malfunction 2. Front Speakers Shorted (Part B) Test
1. Disconnect the affected speaker(s).
1. Front Speakers Shorted (Part A) Test
2. Measure the resistance between breakout box terminals
1. Install BREAKOUT BOX (Part No. HD-47918) to radio 7 and 14 (left speaker) or terminals 6 and 13 (right
harness [27] leaving radio disconnected. speaker).

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3. Is resistance less than 1.0 Ohm? B2017 FRONT SPEAKERS OPEN:WITHOUT

a. Yes. Repair short between amplifier [149B] terminals AMPLIFIER
7 (W/O) and 14 (LGN/W) (left speaker) or between
terminals 6 (GY/R) and 13 (LGN/BK) (right speaker). PART NUMBER TOOL NAME
(5041)
HD-47918 BREAKOUT BOX
b. No. Replace speaker. See the service manual. (6605)
Table 8-20. B2017 Front Speakers Open:Without Amplifier
Diagnostic Faults

POSSIBLE CAUSES
Speaker malfunction
Speaker wires open
Radio malfunction

em00184 [27B] Front Speakers Without Amplifier

Right
1 LGN/BK LGN/BK
Front
GY/R
Speaker
To
Radio [34B]
16 W/O
[27A] 17 LGN/W
(BK) 18 GY/R

LGN/W
Left
Front
W/O Speaker
[35B]

[27B] Front Speakers With Amplifier

1 LGN/BK

To
Radio 16 W/O
[27A] 17 LGN/W [149B]
18 GY/R
(BK)
[34B] [34A] GY/R 6
W/O 7

LGN/BK LGN/BK
[34B] GY/R GY/R LGN/W 11 To
Right LGN/BK 12 Amplifier
LGN/BK LGN/BK 13
Front LGN/W 14
[149A]
GY/R
Speaker (BK)
LGN/W LGN/W
W/O 18
W/O W/O GY/R 19

[35B] [35B] [35C]

Left
LGN/W
Front
W/O
Speaker

Figure 8-6. Front Speaker Circuit

1. Front Speakers Open (Part A) Test 2. Front Speakers Open (Part B) Test
1. Install BREAKOUT BOX (Part No. HD-47918) to radio 1. Disconnect the affected speaker(s).
harness [27] leaving radio disconnected.
2. Measure the resistance between speaker terminals at
2. Measure the resistance between breakout box terminals [34A] or [35A].
16 and 17 (left speaker) or terminals 1 and 18 (right
speaker).
3. Is resistance greater than 3.0 Ohms?
a. Yes. Go to Test 2.
b. No. Replace radio. See the service manual. (6101)

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3. Is resistance greater than 3.0 Ohms? B2018 FRONT SPEAKERS SHORTED TO

a. Yes. Replace speaker. See the service manual. GROUND: WITHOUT AMPLIFIER
(6605)
PART NUMBER TOOL NAME
b. No. Repair open wire(s) between radio [27B] terminals
16 (W/O) and 17 (LGN/W) (left speaker) or between HD-47918 BREAKOUT BOX
terminals 1 (LGN/BK) and 18 (GY/R) (right speaker).
(5041) Table 8-22. B2018 Front Speakers Shorted to Ground:
Without Amplifier Diagnostic Faults
B2017 FRONT SPEAKERS OPEN: WITH
AMPLIFIER POSSIBLE CAUSES
Speaker wires shorted to ground
PART NUMBER TOOL NAME
Radio malfunction
HD-47918 BREAKOUT BOX
1. Front Speakers Shorted to Ground Test
Table 8-21. B2017 Front Speakers Open: With Amplifier 1. Install BREAKOUT BOX (Part No. HD-47918) to radio
Diagnostic Faults harness [27] leaving radio disconnected.
POSSIBLE CAUSES 2. Test for continuity from breakout box terminals 16 and 17
Speaker malfunction (left speaker) or terminals 1 and 18 (right speaker) to
ground.
Speaker wires shorted to ground
3. Is continuity present?
Amplifier malfunction
a. Yes. Repair short to ground from radio [27B] terminals
1. Front Speakers Open (Part A) Test 16 (W/O) or 17 (LGN/W) (left speaker) or between
terminals 1 (LGN/BK) and 18 (GY/R) (right speaker).
1. Install BREAKOUT BOX (Part No. HD-47918) to amplifier (5041)
harness [149] leaving amplifier disconnected.
b. No. Replace radio. See the service manual. (6101)
2. Measure the resistance between breakout box terminals
7 and 14 (left speaker) or terminals 6 and 13 (right B2018 FRONT SPEAKERS SHORTED TO
speaker).
GROUND: WITH AMPLIFIER
3. Is resistance greater than 3.0 Ohms?
a. Yes. Go to Test 2. PART NUMBER TOOL NAME
HD-47918 BREAKOUT BOX
b. No. Replace amplifier. (6107)

2. Front Speakers Open (Part B) Test Table 8-23. B2018 Front Speakers Shorted to Ground:
With Amplifier Diagnostic Faults
1. Disconnect the affected speaker(s).
POSSIBLE CAUSES
2. Measure the resistance between speaker terminals at
[34A] or [35A]. Speaker wires shorted to ground
3. Is resistance greater than 3.0 Ohms? Amplifier malfunction
a. Yes. Replace speaker. See the service manual.
1. Front Speakers Shorted to Ground
(6605)
1. Install BREAKOUT BOX (Part No. HD-47918) to amplifier
b. No. Repair short between amplifier [149B] terminals harness [149] leaving amplifier disconnected.
7 (W/O) and 14 (LGN/W) (left speaker) or between
terminals 6 (GY/R) and 13 (LGN/BK) (right speaker). 2. Test for continuity from breakout box terminals 7 and 14
(5041) (left speaker) or terminals 6 and 13 (right speaker) to
ground.
3. Is continuity present?
a. Yes. Repair short to ground from amplifier [149B]
terminals 7 (W/O) or 14 (LGN/W) (left speaker) or
between terminals 6 (GY/R) or 13 (LGN/BK) (right
speaker). (5041)
b. No. Replace amplifier. (6107)

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B2019 FRONT SPEAKERS SHORTED TO 1. Front Speakers Shorted to Battery Test

BATTERY: WITHOUT AMPLIFIER 1. Install BREAKOUT BOX (Part No. HD-47918) to amplifier
harness [149] leaving amplifier disconnected.
PART NUMBER TOOL NAME
2. Turn IGN ON.
HD-47918 BREAKOUT BOX
3. Test for voltage between breakout box terminals 7 and 14
Table 8-24. B2019 Front Speakers Shorted to Battery: (left speaker) to ground, or terminals 6 and 13 (right
Without Amplifier Diagnostic Faults speaker) to ground.
4. Is voltage present?
POSSIBLE CAUSES
a. Yes. Repair short to voltage from amplifier [149B]
Speaker wires shorted to battery
terminals 7 (W/O) and 14 (LGN/W) (left speaker) or
Radio malfunction terminals 6 (GY/R) and 13 (LGN/BK) (right speaker).
(5041)
1. Front Speakers Shorted to Battery Test
b. No. Replace radio. See the service manual. (6107)
1. Install BREAKOUT BOX (Part No. HD-47918) to radio
harness [27] leaving radio disconnected. B2020 REAR SPEAKERS SHORTED:
2. Turn IGN ON. WITHOUT AMPLIFIER
3. Test for voltage between breakout box terminals 16 and PART NUMBER TOOL NAME
17 (left speaker) to ground, or terminals 1 and 18 (right
speaker) to ground. HD-47918 BREAKOUT BOX

4. Is voltage present?
Table 8-26. B2020 Rear Speakers Shorted: Without
a. Yes. Repair short to voltage from radio [27B] terminals Amplifier Diagnostic Faults
16 (W/O) and 17 (LGN/W) (left speaker) or terminals
1 (LGN/BK) and 18 (GY/R) (right speaker). (5041) POSSIBLE CAUSES

b. No. Replace radio. See the service manual. (6101) Speaker malfunction
Speaker wires shorted together
B2019 FRONT SPEAKERS SHORTED TO Radio malfunction
BATTERY: WITH AMPLIFIER
PART NUMBER TOOL NAME
HD-47918 BREAKOUT BOX

Table 8-25. B2019 Front Speakers Shorted to Battery:

With Amplifier Diagnostic Faults

POSSIBLE CAUSES
Speaker wires shorted to battery
Radio malfunction

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em00861
[41A] [41B]
(BK)
[36A]
Rear Speakers Without Amplifier
[28B] GN 5 5 GN
LGN/BN 6 6 LGN/BN

1 GN
2 BN
(BK) [36B]
To
Ultra [42A] [42B]
Radio
(BK)
[28A] [37A]
24 LGN/BN
25 W/BN
BN 5 5 BN
W/BN 6 6 W/BN

[37B]

Rear Speakers With Amplifier

[41B] LGN/BN
GN

[36A] [36D] [149B]

5 GN
[36B] BN 8
6 LGN/BN

LGN/BN
With Amplifier And No Sidecar
GN
These Leads Are Not Active
From The Radio And Should
Be Secured Inside The Speaker BN W/BN 15
Pods With No Connection
W/BN

5 BN GN 22

6 W/BN
[37B] LGN/BN 23

[42B ]
W/BN
BN

[37A] [37D]

Figure 8-7. Rear Speaker Circuit

1. Rear Speakers Shorted (Part A) Test 3. Is resistance less than 1.0 Ohm?

1. Install BREAKOUT BOX (Part No. HD-47918) to radio
harness [28] leaving radio disconnected.
2. Measure the resistance between breakout box terminals
2 and 25 (left speaker) or terminals 1 and 24 (right
speaker).
a. Yes. Repair short between radio [28B] terminals 2
(BN) and 25 (W/BN) (left speaker) or between ter-
minals 1 (GN) and 24 (LGN/BN) (right speaker).
(5041)
b. No. Replace speaker. See the service manual. (6606)

3. Is resistance less than 1.0 Ohm?

a. Yes. Go to Test 2.
b. No. Replace radio. See the service manual. (6101)

2. Rear Speakers Shorted (Part B) Test

1. Disconnect the affected speaker(s).
2. Measure the resistance between breakout box terminals
2 and 25 (left speaker) or terminals 1 and 24 (right
speaker).

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B2020 REAR SPEAKERS SHORTED: WITH 2. Measure the resistance between breakout box terminals
2 and 25 (left speaker) or terminals 1 and 24 (right
AMPLIFIER speaker).
PART NUMBER TOOL NAME 3. Is resistance greater than 3.0 Ohms?
HD-47918 BREAKOUT BOX a. Yes. Go to Test 2.
b. No. Replace radio. See the service manual. (6101)
Table 8-27. B2020 Rear Speakers Shorted: With Amplifier
Diagnostic Faults 2. Rear Speakers Open (Part B) Test
POSSIBLE CAUSES 1. Disconnect the affected speaker(s).
Speaker malfunction 2. Measure the resistance between breakout box terminals
Speaker wires shorted together 2 and 25 (left speaker) or terminals 1 and 24 (right
speaker).
Amplifier malfunction
3. Is resistance greater than 3.0 Ohms?
1. Rear Speakers Shorted (Part A) Test a. Yes. Repair open between radio [28B] terminals 2
1. Install BREAKOUT BOX (Part No. HD-47918) to amplifier (BN) and 25 (W/BN) (left speaker) or between ter-
harness [149] leaving amplifier disconnected. minals 1 (GN) and 24 (LGN/BN) (right speaker).
(5041)
2. Measure the resistance between breakout box terminals
8 and 15 (left speaker) or terminals 22 and 23 (right b. No. Replace speaker. See the service manual. (6606)
speaker).
B2021 REAR SPEAKERS OPEN: WITH
3. Is resistance less than 1.0 Ohm?
AMPLIFIER
a. Yes. Go to Test 2.
b. No. Replace amplifier. (6107) PART NUMBER TOOL NAME
HD-47918 BREAKOUT BOX
2. Rear Speakers Shorted (Part B) Test
1. Disconnect the affected speaker(s). Table 8-29. B2021 Rear Speakers Open: With Amplifier
Diagnostic Faults
2. Measure the resistance between breakout box terminals
8 and 15 (left speaker) or terminals 22 and 23 (right POSSIBLE CAUSES
speaker).
Speaker malfunction
3. Is resistance less than 1.0 Ohm? Speaker wires open
a. Yes. Repair short between radio [28B] terminals 8
Amplifier malfunction
(BN) and 15 (W/BN) (left speaker) or between ter-
minals 22 (GN) and 23 (LGN/BN) (right speaker). 1. Rear Speakers Open (Part A) Test
(5041)
1. Install BREAKOUT BOX (Part No. HD-47918) to amplifier
b. No. Replace speaker. See the service manual. (6606) harness [149] leaving amplifier disconnected.

B2021 REAR SPEAKERS OPEN: WITHOUT 2. Measure the resistance between breakout box terminals
8 and 15 (left speaker) or terminals 22 and 23 (right
AMPLIFIER speaker).
PART NUMBER TOOL NAME 3. Is resistance greater than 3.0 Ohms?
HD-47918 BREAKOUT BOX a. Yes. Go to Test 2.
b. No. Replace amplifier. (6107)
Table 8-28. B2021 Rear Speakers Open:Without Amplifier
Diagnostic Faults 2. Rear Speakers Open (Part B) Test
POSSIBLE CAUSES 1. Disconnect the affected speaker(s).
Speaker malfunction 2. Measure the resistance between breakout box terminals
Speaker wires open 8 and 15 (left speaker) or terminals 22 and 23 (right
speaker).
Radio malfunction
3. Is resistance greater than 3.0 Ohms?
1. Rear Speakers Open (Part A) Test a. Yes. Repair open between radio [28B] terminals 8
1. Install BREAKOUT BOX (Part No. HD-47918) to radio (BN) and 15 (W/BN) (left speaker) or between ter-
harness [28] leaving radio disconnected. minals 22 (GN) and 23 (LGN/BN) (right speaker).
(6117)
b. No. Replace speaker. See the service manual. (5041)

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B2022 REAR SPEAKERS SHORTED TO B2023 REAR SPEAKERS SHORTED TO

GROUND: WITHOUT AMPLIFIER BATTERY: WITHOUT AMPLIFIER
PART NUMBER TOOL NAME PART NUMBER TOOL NAME
HD-47918 BREAKOUT BOX HD-47918 BREAKOUT BOX

Table 8-30. B2022 Rear Speakers Shorted to Ground: Table 8-32. B2023 Rear Speakers Shorted to Battery:
Without Amplifier Diagnostic Faults Without Amplifier Diagnostic Faults

POSSIBLE CAUSES POSSIBLE CAUSES

Speaker wires shorted to ground Speaker wires shorted to battery
Radio malfunction Radio malfunction

1. Rear Speakers Shorted to Ground Test 1. Rear Speakers Shorted to Battery Test
1. Install BREAKOUT BOX (Part No. HD-47918) to radio 1. Install BREAKOUT BOX (Part No. HD-47918) to radio
harness [28] leaving radio disconnected. harness [28] leaving radio disconnected.
2. Test for continuity from breakout box terminals 2 or 25 2. With IGN ON, test for voltage from breakout box terminals
(left speaker) or terminals 1 or 24 (right speaker) to ground. 2 or 25 (left speaker) or terminals 1 or 24 (right speaker)
to ground.
3. Is continuity present?
a. Yes. Repair short to ground from radio [28B] terminals 3. Is voltage present?
2 (BN) or 25 (W/BN) (left speaker) or between ter- a. Yes. Repair short to voltage from radio [28B] terminals
minals 1 (GN) or 24 (LGN/BN) (right speaker) and 2 (BN) or 25 (W/BN) (left speaker) or between ter-
ground. (5041) minals 1 (GN) or 24 (LGN/BN) (right speaker) and
ground. (5041)
b. No. Replace radio. See the service manual. (6101)
b. No. Replace radio. See the service manual. (6101)
B2022 REAR SPEAKERS SHORTED TO
GROUND: WITH AMPLIFIER B2023 REAR SPEAKERS SHORTED TO
BATTERY: WITH AMPLIFIER
PART NUMBER TOOL NAME
HD-47918 BREAKOUT BOX PART NUMBER TOOL NAME
HD-47918 BREAKOUT BOX
Table 8-31. B2022 Rear Speakers Shorted to Ground:With
Amplifier Diagnostic Faults Table 8-33. B2023 Rear Speakers Shorted to Battery:With
Amplifier Diagnostic Faults
POSSIBLE CAUSES
Speaker wires shorted to ground POSSIBLE CAUSES

Amplifier malfunction Speaker wires shorted to battery

Amplifier malfunction
1. Rear Speakers Shorted to Ground Test
1. Install BREAKOUT BOX (Part No. HD-47918) to amplifier
1. Rear Speakers Shorted to Battery Test
harness [149] leaving amplifier disconnected. 1. Install BREAKOUT BOX (Part No. HD-47918) to amplifier
harness [149] leaving amplifier disconnected.
2. Test for continuity from breakout box terminals 8 or 15
(left speaker) or terminals 22 or 23 (right speaker) to 2. With IGN ON, test for voltage from breakout box terminals
ground. 8 or 15 (left speaker) or terminals 22 or 23 (right speaker)
to ground.
3. Is continuity present?
a. Yes. Repair short to ground from amplifier [149B] 3. Is voltage present?
terminals 8 (BN) or 15 (W/BN) (left speaker) or a. Yes. Repair short to voltage from amplifier [149B]
between terminals 22 (GN) or 23 (LGN/BN) (right terminals 8 (BN) or 15 (W/BN) (left speaker) or
speaker). (5041) between terminals 22 (GN) or 23 (LGN/BN) (right
speaker). (5041)
b. No. Replace amplifier. (6107)
b. No. Replace amplifier. (6107)

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SERIAL DATA BUS DIAGNOSTICS 8.4

DESCRIPTION AND OPERATION
There are two serial data busses. The first is the J1850 serial
data bus which communicates between the radio and the ECM,
TSSM and instruments. Refer to Table 8-34. The second serial
data bus is the Infotainment bus, which uses a CAN protocol
to communicate between the radio and the other radio
accessories. Refer to Table 8-35. The radio captures any errors
found on both serial data busses and stores them as DTCs.
Table 8-34. Code Description
DTC DESCRIPTION
U1016 J1850 lost communications with ECM
U1300 J1850 bus shorted low
U1301 J1850 bus shorted high
Table 8-35. Code Description
DTC DESCRIPTION
U1302 Infotainment bus off error
U1306 Infotainment bus lost communications with hands-
free phone module
U1307 Infotainment bus lost communications with CB
U1308 Infotainment bus lost communications with future
U1310 Infotainment bus lost communications with iPod
U1312 Infotainment bus lost communications with future
U1313 Infotainment bus lost communications with XM
U1314 Infotainment bus lost communications with naviga-
tion
U1317 Infotainment bus lost communications with high
output amplifier
Loss of Serial Data: DTC U1016
The serial data connector provides a means for the ECM,
TSM/TSSM and speedometer to communicate their current
status. When all operating parameters on the serial data bus
are within specifications, a state of health message is sent
between the components. DTC U1016 indicates that the ECM
is incapable of sending this state of health message.
Starts then Stalls: DTC U1300, U1301
The typical serial data voltage range is 0 (inactive) to 7V
(active). Due to the short pulse, voltages will be much lower
on a multimeter. In analog mode, a multimeter reading serial
data will show continuous voltage when active, typically 0.6-
0.8V. The range for acceptable operations is greater than 0
and less than 7V.
NOTE
Problems in the fuel system or idle air control system may also
create this symptom. If this symptom is present, see
6.35 STARTS, THEN STALLS before proceeding.
Diagnostic Tips
• If serial data is shorted, these codes will automatically trip
the check engine light.
• DTCs P1009 and P1010 may accompany DTCs U1300
and U1301.
• If radio ground and antenna ground are open, a serial data
BUS fault may occur causing a start and stall condition.
• The amplifier fuse is an inline fuse for all accessory
installations and is mounted in the fuse block.
DTC U1016 J1850 LOSS OF
COMMUNICATION WITH ECM
PART NUMBER TOOL NAME
HD-47918 BREAKOUT BOX
HD-48637 BREAKOUT BOX

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Radio ABS
em00187

[27A] 9 10 11 12 19 20 9 1 [166A]
[27B] 9 10 11 12 19 20 9 1 [166B]

LGN/V

BK
BN/GY

BK/GN

BK/GN

BN/GY
O/BE
LGN/V
[30B] [30A]

BK/GN 12 12
TSM/
TSSM/
LGN/V 3 3 HFSM
GY 2 2
BN/GY 1 1

BN/GY

BK/GN
LGN/V
BN/GY

BK/GN
LGN/V

O
O

1 2 5 7 [39B] [108B] 1 2 5 7

1 2 5 7 [39A] [108A] 1 2 5 7
1
BK/GN 2
To Tachometer Data
Speedometer LGN/V 3 Link
Lighting 15A GY 4
Relay Instruments [1B] [1A]
BN/GY

Fuse
To 15A

LGN/V
1 1 O Ignition [91A]
4 [2A] Main To Interconnect Fuse
Harness
4 [2B] 69 [78B]
69 [78A]
Main To Interconnect
Harness ECM

Serial Data
15A To 15A
Battery O/BE 9 9 Radio Power
Fuse Fuse

Figure 8-8. J1950 Serial Data Circuit

4. Are speed pulses on radio display greater than 0?

Table 8-36. DTC U1016 J1850 Loss of Communication
a. Yes. Install BREAKOUT BOX (Part No. HD-47918)
with ECM Diagnostic Faults
to radio harness [27] and perform wiggle test. Repair
POSSIBLE CAUSES intermittent on (LGN/V) wire if necessary. (6130)
VSS malfunction b. No. Go to Test 2.
Serial bus shorted to ground
2. Serial Data Continuity Test
ECM malfunction
1. Install radio BREAKOUT BOX (Part No. HD-47918) to
Radio malfunction radio harness [27], leaving radio [27A] disconnected, and
Speedometer malfunction ECM BREAKOUT BOX (Part No. HD-48637) to ECM
harness [78], leaving ECM [78A] disconnected.
1. Speed Pulse Availability Test
2. Test for continuity between radio breakout box terminal 9
1. Turn IGN ON and engine stop switch to RUN. and ECM breakout box terminal 69.
2. Enter radio diagnostics. 3. Does continuity exist?
3. Rotate rear wheel. a. Yes. Perform 2.1 INITIAL DIAGNOSTICS if DTC
U1016 has been set. If DTC U1016 is not present,
replace ECM. See the service manual. (6123)
b. No. Repair open on (LGN/V) wire. (5041)

2011 Touring Diagnostics: Audio System 8-23

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em00862 [175B] [185B]

Future XM Module
[175A] [185A]
3 Y/O Y/O 11
4 Y/V Y/V 12

To [186B]
Ultra 13 Y/O Y/O 11 11 Y/O
Radio 14 Y/V Y/V 12 12 Y/V
[28A]
[184B] [184C] Future
[186A]
Y/O
Y/V

[28B] To CB Module Y/O 11

(If Equipped) Y/V 12
(BK)
5 4 [6A] P&A Ultra [184D]
Overlay Harness
5 4 [6B]
For FLHTCU
Only CB Module
[184A]
Y/O
Y/V

Y/O 11
Y/V 12

Y/O
Y/V
[149B]

Y/O 1
Y/V 2 High Output
Amplifier [187B] 7 8

[149A] [187A] 7 8
[194B]

Y/O
Y/V
Hands Free
Module
17
[194A]
Y/O
Y/V 18

Figure 8-9. Infotainment CAN Bus Circuit

DTC U1302 INFOTAINMENT BUS OFF 3. Is voltage between 3.85-5.0V?

ERROR a. Yes. Bus voltage within range. System normal.
b. No. 0V. Go to Test 2.
PART NUMBER TOOL NAME
HD-41404-C HARNESS CONNECTOR TEST KIT c. No. Greater than 0V. Go to Test 4.

HD-47918 ADVANCED AUDIO SYSTEM 2. Infotaintment Bus Shorted to Ground Test

BREAKOUT BOX
1. Test for continuity from breakout box terminals 13 and 14
to ground.
Table 8-37. DTC U1302, Infotainment Bus Off Error
Diagnostic Faults 2. Is continuity present?
a. Yes. Disconnect each installed module, including
POSSIBLE CAUSES
audio harness [6], CB [184] and hands free module
Radio malfunction [187], and check future ACCY [175] and [186], while
Module shorted to ground or voltage observing multimeter. Replace module or repair (Y/O)
or (Y/V) wiring causing short to ground. (5041)
1. Infotainment Bus Voltage Test b. No. Go to Test 3.
1. Install radio ADVANCED AUDIO SYSTEM BREAKOUT
BOX (Part No. HD-47918) to radio [28A], leaving harness 3. Infotainment Bus Wires Shorted Together
[28B] disconnected. Test
2. With IGN ON, measure voltage between breakout box 1. Connect [6], [184] and [187], leaving installed modules
terminals 13 and 14 using HARNESS CONNECTOR TEST disconnected.
KIT (Part No. HD-41404-C).
2. Test for continuity between [28B] terminals 13 and 14.

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3. Is continuity present? 3. Is battery voltage present?

a. Yes. Repair shorted (Y/O) or (Y/V) wires. (5041) a. Yes. Disconnect each installed module, including
audio harness [6], CB [184] and hands free module
b. No. Replace radio. See the service manual. (6101)
[187], and check future ACCY [175] and [186], while
observing multimeter. Replace module or repair (Y/O)
4. Infotainment Bus Shorted to Voltage Test or (Y/V) wiring causing short to voltage. (5041)
1. Connect breakout box to radio [28A].
b. No. Replace radio. See the service manual. (6101)
2. With IGN ON, test for voltage between breakout box ter-
minals 13 and 14. DTC U1306 INFOTAINMENT BUS LOST
COMMUNICATION WITH HANDS-FREE
PHONE MODULE
PART NUMBER TOOL NAME
HD-41404-C HARNESS CONNECTOR TEST KIT

2011 Touring Diagnostics: Audio System 8-25

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em00863

Ultra Radio [28A] [28B]

(BK)
CB/GRMS
Audio (+) 3 3 R
HFM Audio (+) 4 4 R R/O 1 Future
BK/GN 2 ACC
7 7 W Y/O 3 [175B]
Left XM
Y/V 4

R 6
CAN (+) 13 13 Y/O W 7
CAN (-) 14 14 Y/V BK 8 XM
R/O 9
BK/GN 10 [185B]
Y/O 11
XM (-) 18 18 BK Y/V 12

++R 1
MIC Sum Out (-) 22 22 ++BK ++BK 2

R 4 Future
CB/GRMS BK 5 ACC
Audio (-) 26 26 BK
HFM Audio (-) 27 27 BK [186B]
R/O 9
Right XM (-) 30 30 R BK/GN 10
Y/O 11
Y/V 12
MIC Sum Out (+) 32 32 ++R

++R 1 1 ++R ++R 1

++BK 2 2 ++BK ++BK 2

R 4 4 R R 4
BK 5 5 BK BK 5 C.B.
R 6 6 R
W 7 7 W [184D]
BK 8 8 BK
R/O 9 9 R/O R/O 9
BK/GN 10 10 BK/GN BK/GN 10
Y/O 11 11 Y/O Y/O 11
Y/V 12 12 Y/V Y/V 12
Battery 10 10 R/O
Ground 11 11 BK/GN
C.B. [184B] [184C]
P&A ULTRA
(If Equipped) Overlay Harness
BK/GN 6 6 BK/GN For FL/HTCU/HTK/TRU
Y/V 5 5 Y/V Only
BK/GN
++BK

Y/O 4 4 Y/O
++R

R/O

Y/O
Y/V

Ground 19 19 BK/GN R/O 3 3 R/O

Battery 20 20 R/O
1 2 5 6 7 8 [187B]
[6A] [6B] 1 2 5 6 7 8 [187A]
[27A] [27B]
++BK

R/O
BK/GN
Y/O
Y/V
++R

Bluetooth
Antenna

[149B] [194B]
(Beige)
Y/O R/O 1 Battery
1
BK/GN 2 Ground
Y/V 2 To High
R 3 Output
30 30 R R 4
Amplifier
R 8 Audio Out (+)
Battery + [149A] BK 9 Audio Out (-)
BK/GN 20 (BK)
BK/GN BK/GN 21

Ground
Y/O 17 CAN (+)
Stud Y/V 18 CAN (-)
(Right)
Main
Harness ++R 45 Differential Mic Out (+)
++BK 46 Differential Mic Out (-)
BK/GN C C BK/GN BK/GN GND 2 Hands
R/O A A R/O BK 2B 2A Free
Module
Radio
[15A] [15B] Memory Fuse
(BK) 15A

Figure 8-10. Audio, Microphone, Power and CAN Circuits

8-26 2011 Touring Diagnostics: Audio System

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1. Hands-Free Phone Module Voltage Test 2. With IGN ON, and using the HARNESS CONNECTOR
TEST KIT (Part No. HD-41404-C), measure voltage
1. Disconnect hands-free phone module [194]. between [184B] terminals 9 and 10.
2. With IGN ON, and using the HARNESS CONNECTOR 3. Is battery voltage present?
TEST KIT (Part No. HD-41404-C), measure voltage
between [194B] terminals 1 and 2. a. Yes. Go to Test 2.

3. Is battery voltage present? b. No. Repair open wire between [184B] terminal 9 (R/O)
and radio memory fuse, or terminal 10 (BK/GN) and
a. Yes. Go to Test 3. ground. (5041)
b. No. Go to Test 2.
2. CB Module CAN Test
2. Hands-Free Phone Module Jumper 1. With IGN ON, and using the HARNESS CONNECTOR
Harness Voltage Test TEST KIT (Part No. HD-41404-C), measure voltage
between CB [184B] terminals 11 and 12.
1. Disconnect hands-free phone module jumper harness
[187]. 2. Is voltage between 3.85-5.0V?
2. With IGN ON, and using the HARNESS CONNECTOR a. Yes. Replace CB module. (6625)
TEST KIT (Part No. HD-41404-C), measure voltage b. No. Repair open wire between [184B] terminal 11
between [187B] terminals 5 and 6. (Y/O) and radio [28B] terminal 13, or terminal 12 (Y/V)
3. Is battery voltage present? and radio [28B] terminal 14. (5041)
a. Yes. Replace hands-free phone module jumper har-
ness or repair open (R/O) or (BK/GN) wire. (5041)
DTC U1308 INFOTAINMENT BUS LOST
COMMUNICATION WITH FUTURE
b. No. Repair open wire between [187B] terminal 5 (R/O)
and radio memory fuse, or terminal 6 (BK/GN) and
ACCESSORY MODULE (4-PIN)
ground. (5041) PART NUMBER TOOL NAME

3. Hands-Free Phone Module CAN Test HD-41404-C HARNESS CONNECTOR TEST KIT

1. With IGN ON, and using the HARNESS CONNECTOR 1. Future Accessory Voltage Test
TEST KIT (Part No. HD-41404-C), measure voltage
1. With IGN ON, and using the HARNESS CONNECTOR
between [194B] terminals 17 and 18.
TEST KIT (Part No. HD-41404-C), measure voltage
2. Is voltage between 3.85-5.0V? between future acc [175B] terminals 1 and 2.
a. Yes. Replace hands-free phone module. (6102) 2. Is battery voltage present?
b. No. Go to Test 4. a. Yes. Go to Test 2.
b. No. Repair open wire between [175B] terminal 1 (R/O)
4. Hands-Free Phone Module Jumper and radio memory fuse, or terminal 2 (BK/GN) and
Harness CAN Test ground. (5041)
1. Disconnect hands-free phone module jumper harness
[187]. 2. Future Accessory CAN Test
2. With IGN ON, and using the HARNESS CONNECTOR 1. With IGN ON, and using the HARNESS CONNECTOR
TEST KIT (Part No. HD-41404-C), measure voltage TEST KIT (Part No. HD-41404-C), measure voltage
between [187B] terminals 7 and 8. between [175B] terminals 3 and 4.

3. Is voltage between 3.85-5.0V? 2. Is voltage between 3.85-5.0V?

a. Yes. Replace hands-free phone module jumper har- a. Yes. System normal.
ness or repair open (Y/O) or (Y/V) wire. (5041) b. No. Repair open wire between [175B] terminal 3 (Y/O)
b. No. Repair open wire between [187B] terminal 7 (Y/O) and radio [28B] terminal 13, or terminal 4 (Y/V) and
and radio [28B] terminal 13, or terminal 8 (Y/V) and radio [28B] terminal 14. (5041)
radio [28B] terminal 14. (5041)

DTC U1307 INFOTAINMENT BUS LOST

COMMUNICATION WITH CB MODULE
PART NUMBER TOOL NAME
HD-41404-C HARNESS CONNECTOR TEST KIT

1. CB Module Voltage Test

1. Disconnect CB module [184].

2011 Touring Diagnostics: Audio System 8-27

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DTC U1310 INFOTAINMENT BUS LOST DTC U1313 INFOTAINMENT BUS LOST
COMMUNICATION WITH IPOD COMMUNICATION WITH XM MODULE
PART NUMBER TOOL NAME PART NUMBER TOOL NAME
HD-41404-C HARNESS CONNECTOR TEST KIT HD-41404-C HARNESS CONNECTOR TEST KIT

1. iPod Voltage Test 1. XM Module Voltage Test

1. With IGN ON, and using the HARNESS CONNECTOR 1. Disconnect XM module [185].
TEST KIT (Part No. HD-41404-C), measure voltage
2. With IGN ON, and using the HARNESS CONNECTOR
between future acc [186B] terminals 9 and 10.
TEST KIT (Part No. HD-41404-C), measure voltage
2. Is battery voltage present? between [185B] terminals 9 and 10.
a. Yes. Go to Test 2. 3. Is battery voltage present?
b. No. Repair open wire between [186B] terminal 9 (R/O) a. Yes. Go to Test 2.
and radio memory fuse, or terminal 10 (BK/GN) and
b. No. Repair open wire between [185B] terminal 9 (R/O)
ground. (5041)
and radio memory fuse, or terminal 10 (BK/GN) and
ground. (5041)
2. iPod CAN Test
1. With IGN ON, and using the HARNESS CONNECTOR 2. XM Module CAN Test
TEST KIT (Part No. HD-41404-C), measure voltage
1. With IGN ON, and using the HARNESS CONNECTOR
between [186B] terminals 11 and 12.
TEST KIT (Part No. HD-41404-C), measure voltage
2. Is voltage between 3.85-5.0V? between XM [185B] terminals 11 and 12.
a. Yes. Replace iPod. 2. Is voltage between 3.85-5.0V?
b. No. Repair open wire between [186B] terminal 11 a. Yes. Replace XM module. (6626)
(Y/O) and radio [28B] terminal 13, or terminal 12 (Y/V)
b. No. Repair open wire between [185B] terminal 11
and radio [28B] terminal 14. (5041)
(Y/O) and radio [28B] terminal 13, or terminal 12 (Y/V)
and radio [28B] terminal 14. (5041)
DTC U1312 INFOTAINMENT BUS LOST
COMMUNICATION WITH FUTURE DTC U1314 INFOTAINMENT BUS LOST
ACCESSORY MODULE (12-PIN) COMMUNICATIONS WITH NAVIGATION
PART NUMBER TOOL NAME MODULE
HD-41404-C HARNESS CONNECTOR TEST KIT NOTE
This test assumes the navigation module is installed. There
1. Future Accessory Voltage Test are no external connections to the navigation module except
1. With IGN ON, and using the HARNESS CONNECTOR for the GPS antenna located under the fairing above the right
TEST KIT (Part No. HD-41404-C), measure voltage front speaker.
between future acc [186B] terminals 9 and 10.
1. Navigation Module Test
2. Is battery voltage present?
1. Turn IGN and radio ON.
a. Yes. Go to Test 2.
2. Press NAV button on radio.
b. No. Repair open wire between [186B] terminal 9 (R/O)
and radio memory fuse, or terminal 10 (BK/GN) and 3. Does the radio show the navigation screen?
ground. (5041) a. Yes. System ok. Clear codes.

2. Future Accessory CAN Test b. No. Remove and install module and retest. If results
are the same, swap navigation module with a known
1. With IGN ON, and using the HARNESS CONNECTOR good module and retest. If results are the same,
TEST KIT (Part No. HD-41404-C), measure voltage replace radio.
between [186B] terminals 11 and 12.
2. Is voltage between 3.85-5.0V?
a. Yes. System normal.
b. No. Repair open wire between [186B] terminal 11
(Y/O) and radio [28B] terminal 13, or terminal 12 (Y/V)
and radio [28B] terminal 14. (5041)

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DTC U1317 INFOTAINMENT BUS LOST 2. Disconnect the radio.

COMMUNICATION WITH HIGH OUTPUT 3. Turn IGN ON.
AMPLIFIER 4. Test for voltage between breakout box terminal 1 and
ground or terminal 2 and ground.
PART NUMBER TOOL NAME
HD-41404-C HARNESS CONNECTOR TEST KIT 5. Is voltage present on either circuit?
a. Yes. Repair short to voltage on the (Y/O) or (Y/V)
HD-44608 RADIO BREAKOUT BOX
wire. (5041)
HD-47918 ADVANCED AUDIO SYSTEM
BREAKOUT BOX b. No. Replace the radio. See the service manual.
(6101)
1. Amplifier Module Voltage Test
4. CAN Short to Ground Test
1. Disconnect amplifier [149] and connect amplifier RADIO
BREAKOUT BOX (Part No. HD-44608) leaving amplifier 1. Turn IGN OFF.
disconnected. 2. Disconnect the radio.
2. With IGN ON, and using the HARNESS CONNECTOR 3. Test for continuity between breakout box terminal 1 and
TEST KIT (Part No. HD-41404-C), measure voltage ground or terminal 2 and ground.
between amplifier [149B] terminals 3 or 4 and 20 or 21.
4. Is continuity present on either circuit?
3. Is battery voltage present?
a. Yes. Repair short to ground on the (Y/O) or (Y/V)
a. Yes. Go to Test 2. wire. (5041)
b. No. Repair open wire between amplifier [149B] ter- b. No. Go to Test 5.
minals 3 and 4 (R) and 30A amplifier fuse, or amplifier
[149B] terminals 20 or 21 (BK/GN) and ground. (6131)
5. CAN Open Test
2. Amplifier Module CAN Test 1. Connect the radio ADVANCED AUDIO SYSTEM
BREAKOUT BOX (Part No. HD-47918) to wire harness
1. With IGN and radio ON, and using the HARNESS CON- [28B], leaving the radio [28A] disconnected.
NECTOR TEST KIT (Part No. HD-41404-C), measure
voltage between breakout box terminals 1 and 2. 2. Test for continuity between breakout box [149B] terminal
1 and breakout box [28B] 13 or terminals 2 and 14.
2. Is voltage between 3.85-5.0V?
a. Yes. Replace amplifier. (6109) 3. Is continuity present on both circuits?
a. Yes. Replace the radio. See the service manual.
b. No, voltage is greater than 5V. Go to Test 3. (6101)
c. No, voltage is less than 5V. Go to Test 4. b. No. Repair open on the (Y/O) or (Y/V) wire. (5041)

3. CAN Short to Voltage Test

1. Turn IGN OFF.

2011 Touring Diagnostics: Audio System 8-29

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ADVANCED AUDIO SYSTEM SYMPTOMS 8.5

GENERAL
Many faults may occur that will not set a DTC. These faults
are listed in Table 8-38.

Table 8-38. Advanced Audio System Symptoms

NO. SYMPTOM TEST

1 Radio Inoperative
2 Poor or No Reception
3 Static Present with Engine Running
4 CB Transmitter Inoperative
5 CB Receiver Inoperative
6 Intercom Inoperative
7 Handheld Microphone/PTT Inoperative
8 Speaker Switch Malfunction
9 Headset Speakers Inoperative
10 No or Low Audio From Microphones
11 No or Low Audio With High Output Amplifier
12 No or Low Audio From XM or XM Inoperative
13 XM - No or Intermittent Reception
14 Navigation Inoperative
15 AVC Inoperative
16 Handlebar, Passenger or Sidecar Switches Inoper- 8.5 ADVANCED AUDIO SYSTEM SYMPTOMS, Symptom
ative
17 CD Skipping
18 Hands-Free Phone Module Inoperative
No or Low Audio To Hands-Free Phone Module 18: Hands-Free Phone Module Initial Diagnostics
No or Low Audio From Hands-Free Phone Module
Hands-Free Phone Module - Phone Not Pairing
8.5 ADVANCED AUDIO SYSTEM SYMPTOMS, Symptom
1: Radio Inoperative
8.5 ADVANCED AUDIO SYSTEM SYMPTOMS, Symptom
2: Poor or No Reception
8.5 ADVANCED AUDIO SYSTEM SYMPTOMS, Symptom
3: Static Present with Engine Running
8.5 ADVANCED AUDIO SYSTEM SYMPTOMS, Symptom
4: CB Transmitter Inoperative
8.5 ADVANCED AUDIO SYSTEM SYMPTOMS, Symptom
5: CB Receiver Inoperative
8.5 ADVANCED AUDIO SYSTEM SYMPTOMS, Symptom
6: Intercom Inoperative
8.5 ADVANCED AUDIO SYSTEM SYMPTOMS, Symptom
7: Handheld Microphone/PTT Inoperative
8.5 ADVANCED AUDIO SYSTEM SYMPTOMS, Symptom
8: Fairing Mounted Speaker Switch Malfunction
8.5 ADVANCED AUDIO SYSTEM SYMPTOMS, Symptom
9: Headset Speakers Inoperative
8.5 ADVANCED AUDIO SYSTEM SYMPTOMS, Symptom
10: No or Low Audio from Microphones
8.5 ADVANCED AUDIO SYSTEM SYMPTOMS, Symptom
11: No or Low Audio with High Output Amplifier
8.5 ADVANCED AUDIO SYSTEM SYMPTOMS, Symptom
12: No or Low Audio from XM or XM Inoperative
8.5 ADVANCED AUDIO SYSTEM SYMPTOMS, Symptom
13: No or Intermittent Reception on XM Module
8.5 ADVANCED AUDIO SYSTEM SYMPTOMS, Symptom
14: Navigation Inoperative
8.5 ADVANCED AUDIO SYSTEM SYMPTOMS, Symptom
15: AVC Inoperative
16: Handlebar, Passenger or Sidecar Switches Inoperative
8.5 ADVANCED AUDIO SYSTEM SYMPTOMS, Symptom
17: CD Skipping
8.5 ADVANCED AUDIO SYSTEM SYMPTOMS, Symptom

FACTORY DEFAULTS NOTE

If a symptom is present without a DTC, restoring ROM defaults
to the factory settings may resolve the issue, which can
sometimes be caused by a unique sequence of rider interac-
tions with the system.
On FLHTCU, FLHTK, FLTRU models, set Intercom, VOX and
CB squelch to midpoint and turn Weather Alert to OFF.
Access the radio diagnostic display and press softkey 1
(DEFAULT), or proceed as follows:

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1. Turn IGN ON with the radio OFF.
2. Push and hold softkeys 1 and 3 and OK simultaneously
for 2 seconds.
3. Push the arrow up 2 times.
4. Push softkey 2.
5. Turn IGN OFF for more than 20 seconds.
6. Turn ignition on and verify all defaults have reset.
The following are reset to the factory ROM defaults:
• Radio presets.
• Volume levels, bass, treble, AVC, fader and VOX.
• Display contrast.
• External amplifier present is reset to no amplifier (if an
external amplifier is present, it will take two long ignition
cycles before the radio is set up to enable the external
amplifier).
• CB or PHONE present is reset to no phone (this is used
by the radio to enable the intercom setting if a CB or phone
are present, and like the amplifier, it will take two long
ignition cycles before the radio completely enables the
intercom).
• All DTCs are reset.
• Navigation saved data. This data is immediately updated
upon navigation startup, so the user should be unaffected.
DIAGNOSTICS
PART NUMBER TOOL NAME
HD-48037 SWR METER ADAPTERS
Before proceeding with the diagnostics, make sure the radio
is calibrated, any CD has been removed from the CD player
and reset factory defaults. Doing so can reduce or eliminate
needless troubleshooting of these symptoms.
If a CD is stuck in the player, the player must be reset. Remove
the main fuse and wait 5 minutes and then install fuse. Turn
radio power ON and press the EJECT button. If the CD does
not eject after performing the reset procedure, the radio is faulty
and must be replaced.
Diagnostic Tips
Reading and understanding these diagnostic tips will help make
troubleshooting symptomatic problems easier.
1. If radio is uncalibrated, CB is not functional. If the CB is
not allowed in a region (Japan, for example), then the unit
will not operate.
2. To use the dummy load, screw the lamp onto the antenna
jack of the CB using the appropriate SWR METER
ADAPTERS (Part No. HD-48037). Press the PTT switch.
If the CB is transmitting a carrier wave, the lamp should
illuminate. Speaking into the microphone should cause
the lamp to flicker. It should get brighter and dimmer
depending on how loud your voice is. A change in lamp
brilliance means the CB is modulating.
3. The amplifier fuse is an inline fuse for all accessory
installations and is mounted in the fuse block.
4. It is possible to have a fault on more than one handlebar
control as a result of the following configuration:
• Terminal 5 (V/BK) wire is common to both the PTT/
Squelch and Mode handlebar controls.
• Terminal 8 (BN/BK) wire is common to both the PTT/
Squelch and Audio handlebar controls.
• Terminal 22 (GY/GN) wire is common to both the
PTT/Squelch and Audio handlebar controls.
5. Terminal 3 (PK/W) wire is common to both the Mode and
Audio handlebar controls. Therefore, it is possible to have
a fault on more than one handlebar control as a result of
this configuration.
6. Some aftermarket exhaust systems may cause excessive
pressure on the rear mounts causing the exhaust system
to be put into a bind creating excessive vibration the CD
player may not be able to isolate.

2011 Touring Diagnostics: Audio System 8-31

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em00864

Mounting Stud AM/FM

On Rear Of Antenna Mast
Tour-Pak
Ground Plane
In Tour-Pak
[50D]
[50C]
Mounting Stud
On Left
Saddle Bag
Bracket
(FLHX,
FLTRX Only)
[104B] [104A] Mounting Stud
On Rear Of
Tour-Pak
C.B. Antenna
Back Of Antenna Cable Part Of
[50A] C.B. Module Main Harness And
Present On All Models

XM C.B. Ground For

Standard
To Radio Antenna Installations
[185D] XM Antenna [50B] C.B. Antenna [51B]
AM/FM Connector
[52B]
Antenna [51A]

NAV Antenna

Ground Wire On
Tour-Pak Only

Ground Plane
In Tour-Pak

Figure 8-11. AM/FM and CB Antenna System Circuit

SYMPTOM 1: RADIO INOPERATIVE 3. With IGN ON, measure voltage at breakout box terminals
10 or 20, to 11 or 19.
PART NUMBER TOOL NAME
4. Is battery voltage present?
HD-47918 ADVANCED AUDIO SYSTEM
a. Yes. Go to Test 2.
BREAKOUT BOX
b. No. Go to Test 3.
1. Radio Power Test
1. Remove outer fairing. 2. Radio Power Continuity Test
2. Connect ADVANCED AUDIO SYSTEM BREAKOUT 1. Measure voltage from breakout box terminal 12 to ground.
BOX (Part No. HD-47918), leaving radio [27A] discon-
nected.

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2. Is battery voltage present? 2. Is continuity present?

a. Yes. Replace radio. See the service manual. (6101) a. Yes. Repair open (R/O) wire between radio [27B] and
radio memory fuse terminal 2B.
b. No. Repair open (O/BE) wire between radio [27B]
terminal 12 and radio fuse. b. No. Repair open (BK/GN) wire between radio [27B]
and ground.
3. Radio Memory Continuity Test
1. Test for continuity from breakout box terminals 11 and 19
to ground.

em00386

To Dash Panel
Switches 9 O/BE
[105B]

[105A]
(BK)

[27B] (BK)
Interconnect [1A] [1B]
Harness

To 10 R/O Radio Power 15A

Radio 11 BK/GN
12 O/BE O/BE 9 9 O/BE O/BE 1H 1G R/GY
[27A]
(BK)
To Ground
19 BK/GN BK/GN C C BK/GN BK/GN
20 R/O R/O A A R/O R/O 2B 2A R
Radio MEM 15A
BK/GN

[15A] [15B]
R/O

(BK)
[6B] 6 3

To Audio
Harness
[6A]
(BK)

Figure 8-12. Radio Power

SYMPTOM 2: POOR OR NO RECEPTION 3. Does radio stop seeking on the strong station?
a. Yes. Go to Test 2.
Table 8-39. Symptom 2: Poor or No Reception Diagnostic b. No. Go to Test 3.
Faults

POSSIBLE CAUSES 2. FM-Band Radio Operation Test

Antenna and cable malfunctions 1. Switch to FM band.

Radio malfunction 2. Locate a strong station using the seek button.

Stations out of range 3. Does radio stop seeking on the strong station?
a. Yes. Operation normal. Review symptoms.
1. Low-Band Radio Operation Test
b. No. Go to Test 3.
1. Switch to AM (or LW/MW/W for HDI) band.
2. Locate a strong station using the seek button.

2011 Touring Diagnostics: Audio System 8-33

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3. Antenna Cable Test 2. Is continuity present?

1. Is antenna cable connected to mast and radio? a. Yes. Replace antenna cable. See the service manual.
(6609)
a. Yes. Disconnect antenna cable [51] and [52] and
check connectors for damaged, pushed out or cor- b. No. Go to Test 6.
roded terminals. Repair as required. If connectors are
okay, then continue with tests. Go to Test 4. 6. Antenna Base Shorted to Ground Test
b. No. Connect antenna cable. (6609) 1. With antenna cable disconnected from radio [51] and
antenna base [52], test for continuity between the antenna
4. Antenna Cable Open Circuit Test center conductor and the connector shell.

1. Disconnect antenna from radio [51] and antenna base 2. Is continuity present?
[52]. a. Yes. Replace antenna base assembly. See the ser-
2. Test for continuity between center conductor of antenna vice manual.
cable from radio to antenna base. b. No. Go to Test 7.
3. Is continuity present?
7. Antenna Base Open to Ground Plate Test
a. Yes. Go to Test 5.
1. With antenna cable disconnected from antenna base [52],
b. No. Replace antenna cable. See the service manual. test for continuity between the antenna shield (outer con-
(6609) ductor) and ground plate inside Tour-Pak.

5. Antenna Cable Short Circuit Test 2. Is continuity present?

1. With antenna cable disconnected from radio [51] and a. Yes. Replace radio. See the service manual. (6101)
antenna base [52], test for continuity between the antenna b. No. Repair ground connection or replace antenna
center conductor to antenna cable shield. base assembly.

8-34 2011 Touring Diagnostics: Audio System

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em00864

Mounting Stud AM/FM

On Rear Of Antenna Mast
Tour-Pak
Ground Plane
In Tour-Pak
[50D]
[50C]
Mounting Stud
On Left
Saddle Bag
Bracket
(FLHX,
FLTRX Only)
[104B] [104A] Mounting Stud
On Rear Of
Tour-Pak
C.B. Antenna
Back Of Antenna Cable Part Of
[50A] C.B. Module Main Harness And
Present On All Models

XM C.B. Ground For

Standard
To Radio Antenna Installations
[185D] XM Antenna [50B] C.B. Antenna [51B]
AM/FM Connector
[52B]
Antenna [51A]

NAV Antenna

Ground Wire On
Tour-Pak Only

Ground Plane
In Tour-Pak

Figure 8-13. AM/FM and CB Antenna System Circuit

2011 Touring Diagnostics: Audio System 8-35

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SYMPTOM 3: STATIC PRESENT WITH 1. Set-Up Test

ENGINE RUNNING 1. Perform the following:
a. Press POWER button to turn radio ON.
Table 8-40. Symptom 3: Static Present with Engine
b. Set Headset/Speaker switch on fairing to SPEAKER.
Running Diagnostic Faults
c. Press COM button.
POSSIBLE CAUSES
Alternator malfunction d. Press softkey 1 to turn CB radio ON.

Regulator malfunction e. Set volume control to middle position on horizontal

bar graph display.
Loose power connections
Loose antenna connections 2. Does CB radio power up?
a. Yes. Go to Test 2.
1. Static Observation Test
b. No. See 8.4 SERIAL DATA BUS DIAGNOSTICS,
1. Is static present only when the engine is operating? DTC U1307 Infotainment Bus Lost Communication
a. Yes. Go to Test 2. with CB Module.
b. No. See 8.5 ADVANCED AUDIO SYSTEM SYMP-
TOMS, Symptom 2: Poor or No Reception.
2. Push-to-Talk (PTT) Test
1. Press any PTT switch.
2. Regulator Test 2. Does the channel number on the display invert?
1. Disconnect alternator [47] and start engine. a. Yes. System okay.
2. Is static still present? b. No. Go to Test 3.
a. Yes. Go to Test 4.
b. No. Go to Test 3.
3. CB Transmission Test
1. Tune a known good receiver to the same channel as the
3. Regulator Connectors Test transmitter under test.
1. Inspect regulator connectors for damaged, pushed out or 2. Press any PTT switch.
corroded terminals.
3. Does transmitter transmit?
2. Are connector terminations okay and the connectors tight? a. Yes. Go to Test 4.
a. Yes. Replace voltage regulator. See the service
manual. (6134) b. No. See appropriate PTT switch inoperative test. If
switches are okay, perform CB antenna test.
b. No. Clean and tighten connections. (5041)
4. CB Reception Test
4. Ignition System Test 1. Tune to different CB channels while listening.
1. Test for proper spark plug wire resistance of 4975-11,950
Ohms. 2. Are any signals being received?
a. Yes. Go to Test 5.
2. Is resistance within the specified range?
a. Yes. If spark plug wires are in good condition, replace b. No. Replace CB Module. (6625)
spark plugs. (6132)
5. CB Modulation Test
b. No. Replace spark plug wires. See the service
1. Disconnect antenna [50] and connect CB MICROPHONE
manual. (6133)
LOAD DEVICE (Part No. HD-39448) or equivalent to
antenna jack [50B].
SYMPTOM 4: CB TRANSMITTER
INOPERATIVE 2. With CB ON, press any PTT button, and speak into the
microphone.
PART NUMBER TOOL NAME
3. Does dummy load change in brilliance when transmitting
HD-39448 CB MICROPHONE LOAD DEVICE while speaking?
a. Yes. Go to Test 7.
Table 8-41. Symptom 4: CB Transmitter Inoperative
b. No. Go to Test 6.
Diagnostic Faults

POSSIBLE CAUSES 6. Microphone Test

CB module malfunction 1. Repeat Test 5 with a known good microphone.
Radio malfunction

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2. Does dummy load change in brilliance when transmitting 1. Set-Up Test

while speaking?
1. Perform the following:
a. Yes. Replace microphone.
a. Press POWER button to turn radio ON.
b. No. See 8.5 ADVANCED AUDIO SYSTEM SYMP-
TOMS, Symptom 10: No or Low Audio from Micro- b. Set Headset/Speaker switch on fairing to SPEAKER.
phones. c. Press COM button.

7. CB Antenna Cable Open Circuit Test d. Press softkey 1 to turn CB radio ON.

1. Remove antenna mast from mounting stud. e. Set volume control to middle position on horizontal
bar graph display.
2. Test for continuity between the center conductor of [50A]
to mounting stud. 2. Does CB radio power up?
3. Is continuity present? a. Yes. Go to Test 2.
a. Yes. Go to Test 8. b. No. See 8.4 SERIAL DATA BUS DIAGNOSTICS,
DTC U1307 Infotainment Bus Lost Communication
b. No. Replace antenna cable assembly. (6609)
with CB Module.
8. CB Antenna Cable Shield Open Circuit 2. Receiver Audio Test
Test
1. Press squelch switch down until bar graph on display
1. Check for continuity between outer connector shell [50A] moves to the left most position (open). Doing so keeps
and ground plate inside Tour-Pak. the squelch open and independent of received signal
2. Is continuity present? strength.
a. Yes. Go to Test 9. 2. Is CB audio present? Unless a signal is actually present,
audio will be in the form of static hissing.
b. No. Replace antenna cable assembly. (6609)
a. Yes. Go to Test 3.
9. CB Antenna Cable Shorted Test b. No. Go to Test 4.
1. Check for continuity between the center conductor [50A]
and ground plate inside Tour-Pak. 3. Squelch Operation Test
2. Is continuity present? 1. Press squelch switch up until CB audio cuts out.
a. Yes. Replace antenna cable assembly. (6609) 2. Transmit a signal from a nearby known good transmitter
tuned to the same channel as the receiver under test.
b. No. Replace antenna mast. (6613)
3. Does the squelch open and is audio present?
SYMPTOM 5: CB RECEIVER INOPERATIVE a. Yes. Receiver okay.
PART NUMBER TOOL NAME b. No. Perform Symptom 4: CB Transmitter Inoperative,
tests 7 through 9.
HD-42662 BREAKOUT BOX
HD-45325 JUMPER HARNESS 4. Receiver Operation Test
HD-47918 ADVANCED AUDIO SYSTEM 1. Transmit a signal from a nearby known good transmitter
BREAKOUT BOX tuned to the same channel as the receiver under test.
2. Is CB receiver audio present?
Table 8-42. Symptom 5: CB Receiver Inoperative
Diagnostic Faults a. Yes. Receiver okay.
b. No. Go to Test 5.
POSSIBLE CAUSES
CB module malfunction 5. Receiver Audio Voltage Test
Antenna malfunction 1. Inspect for pushed out, damaged or corroded terminals
Radio malfunction on radio [28] and harness [184]. Repair as required.
2. Install BREAKOUT BOX (Part No. HD-42662) and
JUMPER HARNESS (Part No. HD-45325) between har-
ness [184D] and CB radio [184A], and Radio ADVANCED
AUDIO SYSTEM BREAKOUT BOX (Part No. HD-47918)
between radio [28A] and harness [28B].
3. Using an external transmitter (tuned to the same channel
as the receiver) for a test signal, measure the VAC
between radio breakout box terminals 3 and 26.

2011 Touring Diagnostics: Audio System 8-37

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4. Is voltage between 0-1 VAC? 1. Set-Up Mode Test

a. Yes. Replace radio. See the service manual. (6103) 1. Perform the following:
b. No, battery voltage present. Go to Test 9. a. Press POWER button to turn radio ON.
c. No, 0V present. Go to Test 7. b. Set Headset/Speaker switch on fairing to HEADSET.
d. No, less than battery voltage present. Go to Test c. Press COM button. Press softkey 1 to turn CB radio
6. OFF.

6. Receiver Audio Open Circuit Test d. Press INT button. Press softkey 1 to turn intercom
ON (Setup Mode).
1. Disconnect radio [28A] leaving breakout box connected
to harness [28B]. 2. Does intercom enter setup mode?
2. Test for continuity between radio breakout box terminal 3 a. Yes. Go to Test 2.
and terminal 4 of [184D], and then from radio breakout b. No. If intercom will not enter setup mode, the
box terminal 26 and terminal 5 of [184D]. intercom is not installed. See your dealer for assist-
3. Is continuity present? ance.
a. Yes. Go to Test 7.
2. Intercom Speech Test
b. No. Repair open wire(s) (R) or (BK) between harness 1. Speak into any microphone.
[184D] and radio [28B]. (5041)
2. Is voice heard in all headsets?
7. Receiver Audio Short to Ground Test a. Yes. Intercom okay.
1. Test for continuity between radio breakout box terminal 3 b. No. Go to Test 3.
and ground. Repeat for terminal 26 and ground.
2. Is continuity present? 3. VOX Maximum (Open) Test
a. Yes. Repair short to ground on (R) or (BK) wire(s). 1. Press softkey 4 to adjust VOX sensitivity to greater than
(5041) 10 bars. Set front intercom volume control to middle posi-
tion on horizontal bar graph display. Set rear volume to
b. No. Go to Test 8. middle position.

8. Receiver Audio Shorted Together Test 2. Is intercom audio present both ways when speaking?
1. Test for continuity between radio breakout box terminals a. Yes. Go to Test 4.
3 and 26. b. No. Go to Test 5.
2. Is continuity present?
a. Yes. Repair short circuit between (R) and (BK)
4. VOX Adjustment Test
wire(s). (5041) 1. Adjust VOX level down one step at a time using softkey
6 until VOX is no longer open.
b. No. Go to Test 9.
2. Speak loudly into any microphone.
9. Receiver Audio Harness Shorted to 3. Is audio present?
Voltage Test a. Yes. Intercom okay.
1. With IGN ON, test for voltage between radio breakout box
b. No. Replace radio. See the service manual. (6103)
terminal 3 to ground, and repeat for terminal 26 to ground.
2. Is battery voltage present on either terminal to ground? 5. Headset Test
a. Yes. Repair short to voltage on (R) or (BK) wire(s). 1. Determine which headset is faulty by swapping headset
(5041) positions, or by substituting a known good headset for one
b. No. Replace the CB Module. See the service manual. of the suspect units.
(6625) 2. Does the problem follow the suspect unit or does the
known good headset solve the problem?
SYMPTOM 6: INTERCOM INOPERATIVE a. Yes. Replace suspect headset.
b. No. Replace radio. See the service manual. (6101)
Table 8-43. Symptom 6: Intercom Inoperative Diagnostic
Faults

POSSIBLE CAUSES
Intercom not installed
Radio malfunction

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HOME

SYMPTOM 7: HANDHELD 2. Press the handheld PTT switch. The following should
occur:
MICROPHONE/PTT INOPERATIVE
a. Radio display shows CB mode.
PART NUMBER TOOL NAME
b. CB transmitter operates.
HD-41404-C HARNESS CONNECTOR TEST KIT
c. CB channel number inverts.
HD-47918 RADIO BREAKOUT BOX
3. Do these changes take place?
Table 8-44. Symptom 7: Handheld Microphone/PTT a. Yes. System okay.
Inoperative Diagnostic Faults
b. No. Go to Test 2.
POSSIBLE CAUSES
PTT switch malfunction
2. Switch Diagnostic Test
1. Enter switch diagnostics mode.
Radio malfunction
2. With handheld microphone disconnected, does display
1. Set-Up Test show "Handheld PTT"?
1. Perform the following: a. Yes. Go to Test 3.
a. Press POWER button to turn radio ON. b. No. Substitute microphone with a known good unit.
b. Press INT button. Press softkey 1 to turn intercom If display continues to show "Handheld PTT", then
OFF. continue with tests. Go to Test 4.

c. Press COM button. Press softkey 1 to turn CB radio

ON.
d. Set Headset/Speaker switch on fairing to SPEAKER.

em00723

(BK)
12 SHEILD
[28B] 11 BK
10 R
To 9 Y/R
Ultra 8 Y/W
Y/BK Y/BK 7 7 Y/BK
Radio 17 BE/Y 6 6 BE/Y
[28A]
[6B] [6A]

[53A] [53B]
BE/Y 2 2 BE/Y
[27B]

To
Radio 2 BE/Y
CAV CIR DESCRIPTION
Driver
[27A] 1 BK MIC IN SHARED (-)
Headset
(BK) 2 Y/BK HDSET SPKR SHARED (-)
3 Y/R RT FRT HDSET SPKR (+)
4 R FRT MIC (+)
5 Y/W LFT FRT HDSET SPKR (+)
6
7 BE/Y PUSH-TO-TALK
TAB SHIELD MIC SHARED SHIELD

Figure 8-14. Handheld Microphone PTT Circuit

3. PTT Open Circuit Test 3. Is continuity present?

1. Install RADIO BREAKOUT BOX (Part No. HD-47918) to
radio harness [27B] and [28B], leaving radio disconnected.
2. Test for continuity between breakout box [27] terminal 2
to breakout box [28] terminal 17 using HARNESS CON-
NECTOR TEST KIT (Part No. HD-41404-C), and press
handheld PTT switch.
a. Yes. Replace radio. See the service manual. (6103)
b. No. Substitute microphone with a known good unit
and perform step 2 again. If open still exists, repair
open wire between [27B] terminal 2 (BE/Y), or
between [28B] terminal 17 (Y/BK). (5041)

2011 Touring Diagnostics: Audio System 8-39

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4. PTT Short Circuit to Ground Test

Table 8-46. Symptom 8: Fairing Mounted Speaker Switch
1. Test for continuity between breakout box [27] terminal 2 Malfunction Diagnostic Faults
and from breakout box [28] terminal 17 to ground, using
HARNESS CONNECTOR TEST KIT (Part No. HD-41404- POSSIBLE CAUSES
C). Speaker switch malfunction
2. Is continuity present? Radio malfunction
a. Yes. Substitute microphone with known good unit and
perform step 1 again. If short still exists, repair short 1. Speaker Switch Headset Mode Test
to ground on [27B] terminal 2 (BE/Y) wire; or on [28B] 1. Put radio into diagnostic mode.
terminal 17 (Y/BK). (5041)
2. Place speaker switch in HEADSET (up position).
b. No. Replace radio. See the service manual. (6103)
3. Does radio display show SpkA only (not SpkB)?
SYMPTOM 8: FAIRING MOUNTED SPEAKER a. Yes. Go to Test 2.
SWITCH MALFUNCTION b. No. Go to Test 4.
PART NUMBER TOOL NAME 2. Speaker Switch Speaker and Headset
HD-41404-C HARNESS CONNECTOR TEST KIT Mode Test
HD-47918 ADVANCED AUDIO SYSTEM 1. Place speaker switch to SPEAKER and HEADSET mode
BREAKOUT BOX (middle position).
2. Does display show SpkB only (not SpkA)?
Table 8-45. Speaker Switch Function
a. Yes. Go to Test 3.
MODE SPEAKER SPEAKER DIAGNOSTIC
INPUT A INPUT B DISPLAY b. No. Go to Test 8.
(TERMINAL (TERMINAL
21) 13) 3. Speaker Switch Mode Test
Headset Battery 0-1.0V SpkA 1. Place speaker switch to SPEAKER mode (down position).
Voltage 2. Does display show SpkA and SpkB?
Speaker/Headset 0-1.0V 4.5-5.5V SpkB a. Yes. Speaker switch okay. Review symptoms list.
Speaker Battery 4.5-5.5V SpkA SpkB
b. No. Replace speaker switch. See the service manual.
Voltage
(6143)

em00865
O/BE 9 9 O/BE
V/O 10 10 V/O
SPKR

BN/O 11 11 BN/O
BK/GN 12 12 BK/GN

Connectors
[105C] [105D] On FLT Models
BK/GN
BN/O

O/BE

Only
V/O

12 11 10 9 [105B]
12 11 10 9 [105A] (BK)
[1A] [1B]
BN/O
V/O
O/BE
BK

Interconnect Harness Radio Power 15A

[27A] [27B]
O/BE 9 9 O/BE O/BE 1H 1G R/GY

Ground 11 11 BK/GN BK/GN GND 2

ACCY Enable 12 12 O/BE (Clean)
BN/O
[15A] [15B]
Headset SPKR B 13 13

BK D D BK BK GND 1
Headset SPKR A 21 21 V/O

Figure 8-15. Speaker Switch Circuit

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4. Headset SpkA Voltage Test 2. Measure voltage from breakout box [27] terminal 13 to
ground using HARNESS CONNECTOR TEST KIT (Part
1. Install ADVANCED AUDIO SYSTEM BREAKOUT No. HD-41404-C).
BOX (Part No. HD-47918) between radio [27A] and har-
ness [27B]. 3. Is voltage less than 2.5V?

2. Measure voltage from breakout box [27] terminal 21 to a. Yes. Go to Test 9.

ground using HARNESS CONNECTOR TEST KIT (Part b. No. Go to Test 10.
No. HD-41404-C).
3. Is voltage less than 4.5V? 9. Headset SpkB Continuity Test
a. Yes. Go to Test 5. 1. Disconnect radio breakout box from radio [27A], leaving
harness [27B] connected.
b. No. Go to Test 6.
2. Test for continuity between breakout box [27] terminal 13
5. Headset SpkA Continuity Test and switch harness [105A] terminal 11 using HARNESS
CONNECTOR TEST KIT (Part No. HD-41404-C).
1. Disconnect radio breakout box from radio [27A], leaving
harness [27B] connected. 3. Is continuity present?

2. Test for continuity between breakout box [27] terminal 21 a. Yes. Replace speaker switch. See the service
and switch harness [105A] terminal 10 using HARNESS manual. (6143)
CONNECTOR TEST KIT (Part No. HD-41404-C). b. No. Repair open (BN/O) wire between [27B] terminal
3. Is continuity present? 13 and [105A] terminal 11. (5041)

a. Yes. Replace speaker switch. See the service 10. Headset SpkB Short to Voltage Test
manual. (6143)
1. Test for voltage from breakout box [27] terminal 13 and
b. No. Repair open (V/O) wire between [27B] terminal ground using HARNESS CONNECTOR TEST KIT (Part
21 and [105A] terminal 10. (5041) No. HD-41404-C).

6. Headset SpkA Short to Ground Test 2. Is battery voltage present?

1. Test for continuity from breakout box [27] terminal 21 to a. Yes. Repair short to voltage on (BN/O) wire. (5041)
ground using HARNESS CONNECTOR TEST KIT (Part b. No. Go to Test 11.
No. HD-41404-C).
2. Is continuity present? 11. Headset SpkB Short to Ground Test
a. Yes. Repair short to ground. (5041) 1. Test for continuity from breakout box [27] terminal 13 to
ground using HARNESS CONNECTOR TEST KIT (Part
b. No. Go to Test 7. No. HD-41404-C).

7. Headset SpkA Short to Voltage Test 2. Is continuity present?

1. Test for voltage from breakout box [27] terminal 21 and a. Yes. Repair short to ground on (BN/O) wire. (5041)
ground using HARNESS CONNECTOR TEST KIT (Part b. No. Replace radio. See the service manual. (6103)
No. HD-41404-C).
2. Is battery voltage present? SYMPTOM 9: HEADSET SPEAKERS
a. Yes. Repair short to voltage on (V/O) wire. If wire is INOPERATIVE
okay, replace radio. (6103)
PART NUMBER TOOL NAME
b. No. Replace speaker switch. See the service manual. HD-41404-C HARNESS CONNECTOR TEST KIT
(6143)
HD-47918 ADVANCED AUDIO SYSTEM
8. Headset SpkB Voltage Test BREAKOUT BOX

1. Install ADVANCED AUDIO SYSTEM BREAKOUT Headset speakers rarely fail at the same time. Troubleshooting
BOX (Part No. HD-47918) between radio [27A] and har- time can be significantly reduced by substituting known good
ness [27B]. units for the suspect units. Alternatively substituting parts of
the suspect units (headsets and coil cords) can quickly
determine whether the headsets or coil cords are faulty, or
whether the fault lies elsewhere in the system.

2011 Touring Diagnostics: Audio System 8-41

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em00866
(BK)
[28B]
Ultra Radio
[28A] GY/O
LFT Rear HDSET SPKR (+) 5
(BK) LFT FRT HDSET SPKR (+) 6 Y/W DIN On Ultra
[76B]
LFT SDCAR HDSET SPKR (+) 15 GN/V Passenger CAV CIR DESCRIPTION
RT SDCAR HDSET SPKR (+) 16 GY/BK
HDSET SPKR Shared (-) 17 Y/BK Y/BK 2 Headset 1
2
BK
Y/BK
MIC IN SHARED (-)
HDSET SPKR SHARED (-)
GY/Y 3 3 GY/Y RT REAR HDSET SPKR (+)
4 R REAR MIC (+)
RT Rear HDSET SPKR (+) 28 GY/Y GY/O 5 5 GY/O LFT REAR HDSET SPKR (+)
6
RT FRT HDSET SPKR (+) 29 Y/R
7
TAB SHIELD MIC SHARED SHIELD

GY/BK
GN/V

Y/BK
Y/W
Y/R
[53A] 2 3 7 8 9
(BK)
[53B] 2 3 7 8 9

Driver

Y/W
Y/R
Y/BK
CAV CIR DESCRIPTION
Headset 1 BK MIC IN SHARED (-)
2 Y/BK HDSET SPKR SHARED (-)
3 Y/R RT HDSET SPKR (+)
4 R FRT MIC (+)
5 Y/W LFT HDSET SPKR (+)
6
7 BE/Y PUSH-TO-TALK
TAB SHIELD MIC SHARED SHIELD

Figure 8-16. Headset Speaker Circuit

3. Is continuity present?
Table 8-47. Symptom 9: Headset Speakers Inoperative
a. Yes. Go to Test 3.
Diagnostic Faults
b. No. Repair open wire between radio harness [28B]
POSSIBLE CAUSES and [53A], or [53B] and rider DIN. (5041)
Headset speaker malfunction
Radio malfunction Table 8-48. Rider Headset Speaker Terminations and Wire
Colors
1. Headset Speaker Operational Test
RADIO HARNESS DIN CONNECTOR WIRE COLOR
1. Connect headsets to the appropriate DIN connectors.
[28B] TERMINAL TERMINAL
2. Turn radio ON, tune to a station and place speaker switch 6 5 (Y/W)
to HEADSET.
17 2 (Y/BK)
3. Do both helmet speakers work?
29 3 (Y/R)
a. Yes. System okay.
b. No. Both helmet speakers inoperative. Substitute 3. Rider Headset Speaker Shorted Wires
or swap headsets and coil cords. If the problem clears Test
in the suspect unit, replace that component. 1. Test for continuity between breakout box [28] terminals 6,
c. No. Rider headset. Go to Test 2. 17 and 29.

d. No. Passenger headset. Go to Test 6. 2. Is continuity present between any two terminals?
a. Yes. Repair shorted wires between radio harness
2. Rider Headset Speaker Continuity Test [28B] and [53A], or [53B] and rider DIN. (5041)
1. Install ADVANCED AUDIO SYSTEM BREAKOUT b. No. Go to Test 4.
BOX (Part No. HD-47918) harness [27B] and harness
[28B], leaving radio disconnected. Refer to Table 8-48. 4. Rider Headset Speaker Short to Voltage
2. Test for continuity between breakout box [28] and rider Test
DIN, using HARNESS CONNECTOR TEST KIT (Part
1. Connect radio breakout box to radio [28A], and turn radio
No. HD-41404-C).
ON.
2. Measure voltage between breakout box [28] terminals 6
(left) or 29 (right), to ground.

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3. Is voltage greater than 9V? 2. Measure voltage between breakout box [28] terminals 5
a. Yes. Repair short to voltage between radio harness (left) or 28 (right), to ground.
[28B] and [53A], or [53B] and rider DIN. (5041) 3. Is voltage greater than 9V?
b. No. Go to Test 5. a. Yes. Repair short to voltage between radio harness
[28B] and [76A], or [76B] and passenger DIN. (5041)
5. Rider Headset Speaker Short to Ground b. No. Go to Test 9.
Test
1. Turn radio off and disconnect radio breakout box from 9. Passenger Headset Speaker Short to
radio [28A]. Ground Test
2. Test for continuity between breakout box [28] terminals 6 1. Turn radio off and disconnect radio breakout box from
(left), 17 or 29 (right) to ground. radio [28A].
3. Is continuity present on any terminals? 2. Test for continuity between breakout box [28] terminals 5
a. Yes. Repair short to ground between radio harness (left), 17 or 28 (right) to ground.
[28B] and [53A], or [53B] and rider DIN. (5041) 3. Is continuity present on any terminals?
b. No. Replace radio. See the service manual. (6103) a. Yes. Repair short to ground between radio harness
[28B] and [76A], or [76B] and passenger DIN. (5041)
6. Passenger Headset Speaker Continuity b. No. Replace radio. See the service manual. (6103)
Test
1. Install ADVANCED AUDIO SYSTEM BREAKOUT SYMPTOM 10: NO OR LOW AUDIO FROM
BOX (Part No. HD-47918) harness [27B] and harness MICROPHONES
[28B] leaving radio disconnected.
PART NUMBER TOOL NAME
2. Test for continuity between breakout box [28] and rider
DIN, using HARNESS CONNECTOR TEST KIT (Part HD-41404-C HARNESS CONNECTOR TEST KIT
No. HD-41404-C). Refer to Table 8-49. HD-47918 ADVANCED AUDIO SYSTEM
BREAKOUT BOX
3. Is continuity present?
a. Yes. Go to Test 7.
Table 8-50. Symptom 10: No or Low Audio from
b. No. Repair open wire between radio harness [28B] Microphones Diagnostic Faults
and [76A], or [76B] and passenger DIN. (5041)
POSSIBLE CAUSES
Headset malfunction
Table 8-49. Passenger Headset Speaker Terminations and
Wire Colors Microphone malfunction

RADIO HARNESS DIN CONNECTOR WIRE COLOR

NOTE
[28B] TERMINAL TERMINAL
Use PTT switch if intercom is not installed.
5 5 (GY/O)
17 2 (Y/BK) 1. Headset Microphone Set-Up Test
28 3 (GY/Y) 1. Plug a known good headset in rider DIN connector.
2. Turn intercom ON, set VOX threshold to OPEN, intercom
7. Passenger Headset Speaker Shorted volume to mid-level.
Wires Test
3. Speak into the microphone.
1. Test for continuity between breakout box [28] terminals 5,
17 and 28. 4. Can the audio be heard in the headset?
a. Yes. Replace coil cord on faulty headset and retest.
2. Is continuity present between any two terminals?
If fault persists, then continue with tests. Go to Test
a. Yes. Repair shorted wires between radio harness 2.
[28B] and [76A], or [76B] and passenger DIN. (5041)
b. No. Perform test for each microphone driven source
b. No. Go to Test 8. installed. If no issues are found then continue with
testing. Go to Test 2.
8. Passenger Headset Speaker Short to
Voltage Test
1. Connect radio breakout box to radio [28A], and turn radio
ON.

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em00867

Din On Ultra
[76B]

BK 1 Passenger CAV CIR DESCRIPTION

Headset 1
2
BK MIC IN SHARED (-)
Front Mic (+) 9 ++R Y/BK HDSET SPKR SHARED (-)
3 GY/Y RT REAR HDSET SPKR (+)
Rear Mic (+) 10 R R 4 4 R REAR MIC (+)
5 GY/O LFT REAR HDSET SPKR (+)
6
MIC Shared (-) 20 BK 7
MIC Shared SHLD 21 BK SHIELD TAB TAB SHIELD MIC SHARED SHIELD
MIC Sum Out (-) 22 ++BK
[186B]

MIC Sum Out (+) 33 ++R ++R 1 1 ++R ++R 1

++BK 2 2 ++BK ++BK 2
Future
++SHIELD
++BK [186A]
[28B]
++R

(BK) [184D]
[53A] 10 11 12 [184B] [184C]
(BK) To CB Module R 1
[53B] 10 11 12
(If Equipped) BK 2
CB Module
SHIELD
BK
R

[184A]
P&A Ultra
Overlay

++BK
++R
Harness
(FL/HTCU/HTK/TRU Only)
1 2 [187B]
1 2 [187A]

++R
++BK
Driver CAV CIR DESCRIPTION
[194B]
Headset 1 BK MIC IN SHARED (-)
2
3
Y/BK HDSET SPKR SHARED (-) Hands
Y/R RT FRT HDSET SPKR (+)
4 R FRT MIC (+)
Free
++R 45 Phone
5 Y/W RT FRT HDSET SPKR (+)
++BK 46 Module
6
7 BE/Y PUSH-TO-TALK [194A]
TAB SHIELD MIC SHARED SHIELD

Figure 8-17. Headset Microphone Circuit

2. Headset Microphone Voltage Test 3. Is voltage between 7.5-8.5V?

1. Remove all microphones from DIN connectors. a. Yes. Replace radio. See the service manual. (6103)

2. With radio/intercom ON, measure the voltage between b. No. Go to Test 4.

terminals 4 and 1 of each DIN connector.
4. Headset Microphone Circuit Continuity
3. Is the voltage between 7.5-8.5V? Test
a. Yes. Replace microphone in faulty headset and retest.
1. Disconnect breakout box from radio [28A].
If fault persists, then continue with tests. Go to Test
3. 2. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
41404-C), test for continuity from breakout box [28] ter-
b. No. Go to Test 3.
minal:
3. Microphone Sum Out Voltage Test a. 33 to CB module [184A] terminal 1.
1. Install ADVANCED AUDIO SYSTEM BREAKOUT b. 22 to CB module [184A] terminal 2.
BOX (Part No. HD-47918) between radio [28A] and har-
c. 33 to Hands-Free module [194A] terminal 45 if
ness [28B].
equipped.
2. With radio ON, measure the voltage from breakout box
d. 22 to Hands-Free module [194A] terminal 46 if
[28] terminals 33 to 22.
equipped.

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3. Is continuity present? SYMPTOM 11: NO OR LOW AUDIO WITH

a. Yes. Go to Test 5. HIGH OUTPUT AMPLIFIER
b. No. Repair open (R) or (BK) wires between radio
PART NUMBER TOOL NAME
harness [28B] terminals 33 or 22 and CB module
[184B] terminals 1 or 2 and Hands-Free module HD-44608 RADIO BREAKOUT BOX
[194B] terminals 45 and 46. (5041)
The high output amplifier is an option for some CVO models.
Before proceeding with tests, make sure the amplifier 30A fuse
5. Headset Microphone Circuit Short to is good.
Ground Test
1. Amplifier Power Voltage Test
1. Connect installed modules.
1. Install RADIO BREAKOUT BOX (Part No. HD-44608)
2. Test for continuity from breakout box terminals 33 and 22 between amplifier and harness [149].
to ground.
2. With IGN and radio ON, measure voltage between
3. Is continuity present on either terminal? breakout box terminals 3 or 4 and 20 or 21.
a. Yes. Repair short to ground on (R) or (BK) wires.
3. Is battery voltage present?
Installed modules may also be shorted to ground
internally. Disconnect each module while observing a. Yes. Go to Test 2.
multimeter. If disconnecting any module causes mul- b. No. Go to Test 3.
timeter to indicate infinity, replace that module. (5041)
b. No. Go to Test 6. 2. Amplifier CAN Test
1. Measure voltage between breakout box terminals 1 and
6. Headset Microphone Circuit Wires 2.
Shorted Together Test 2. Is voltage between 3.85-5V?
1. Test for continuity between breakout box terminals 33 and a. Yes. See 8.3 DTC B2016-B2027, RADIO SPEAKER
22. DIAGNOSTICS.
2. Is continuity present? b. No. See 8.4 SERIAL DATA BUS DIAGNOSTICS,
a. Yes. Repair short between (R) and (BK) wires. DTC U1317 Infotainment Bus Lost Communication
Installed modules may also be shorted internally. with High Output Amplifier.
Disconnect each module while observing multimeter.
If disconnecting any module causes multimeter to 3. Amplifier Power Open Ground Test
indicate infinity, replace that module. (5041)
1. Turn IGN OFF.
b. No. Go to Test 7.
2. Test for continuity between breakout box terminals 20 and
21 to ground.
7. Headset Microphone Circuit Short to
Voltage Test 3. Is continuity present?
a. Yes. Go to Test 4.
1. Connect breakout box to radio [28A].
b. No. Repair open to ground on (BK) wires between
2. With radio ON, test for voltage between breakout box ter-
[149B] terminals 20 and 21. (5041)
minals 33 and 22 to ground.
3. Is voltage greater than 9V? 4. Amplifier Power Open to Battery Test
a. Yes. Repair short to voltage on (R) or (BK) wire. 1. Measure voltage between breakout box terminals 3 and
Installed modules may also be shorted to voltage 4 to ground.
internally. Disconnect each module while observing
multimeter. If disconnecting any module causes mul- 2. Is battery voltage present?
timeter to indicate normal voltage (7.5-8.5V), replace a. Yes. Replace amplifier.
that module. (6155)
b. No. Repair open to battery on (R) wires between
b. No. Replace radio. See the service manual. (5041) [149B] terminals 3 and 4. (5041)

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em00388
(BK)
[28B]
[6B] [6A]

To Right
LGN/BN
Ultra 13 Y/O Y/O 4 4 Y/O Rear GN
Radio 14 Y/V Y/V 5 5 Y/V Speaker
[28A]
[36A] [36D]
Right [149B]
LGN/BK
Front GY/R
Speaker Y/O 1
Y/V 2
[34A] [34D] R 3
Battery + 30A R R 4
[35A] [35D]
GY/R 6
W/O 7
Left BN 8
Front LGN/W High Output
[27B] Speaker
W/O Amplifier
LGN/W 11
LGN/BK 12
1 LGN/BK LGN/BK 13
LGN/W 14
To Radio W/BR 15
[27A] LGN/W LGN/W
(BK) 16 W/O W/O W/O W/O 18
17 LGN/W GY/R 19
18 GY/R BK 20
[34B] [34C] BK 21
GN 22
[35B] [35C] LGN/BN 23

LGN/BK LGN/BK
GY/R GY/R

Left
W/BR
Rear BN
Speaker Ground Stud
(Right)
[37A] [37D]

Figure 8-18. Front/Rear Speaker Circuits with Amplifier

SYMPTOM 12: NO OR LOW AUDIO FROM 1. XM Radio Operation Test

XM OR XM INOPERATIVE NOTE
PART NUMBER TOOL NAME XM radio is not available in all areas. Verify region supports
XM radio.
HD-41404-C HARNESS CONNECTOR TEST KIT
1. Locate vehicle in an open area with line of site to southern
HD-42682 BREAKOUT BOX
sky.
HD-45325 JUMPER HARNESS
2. Turn radio ON.
HD-47918 ADVANCED AUDIO SYSTEM
BREAKOUT BOX 3. Does XM icon appear on radio display when moving
through the bands with two or more signal bars present?

Table 8-51. Symptom 12: No or Low Audio from XM or a. Yes. "Check Antenna" or "No Signal" appears on
XM Inoperative Diagnostic Faults radio display. See 8.5 ADVANCED AUDIO SYSTEM
SYMPTOMS, Symptom 13: No or Intermittent
POSSIBLE CAUSES Reception on XM Module.
XM module malfunction b. Yes. Icon appears with no error message. Go to
Antenna malfunction Test 2.
Satellite unavailable c. No. Go to Test 7.

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Ultra Radio [28A] [28B]

(BK)
CB/GRMS
Audio (+) 3 3 R
HFM Audio (+) 4 4 R R/O 1 Future
BK/GN 2 ACC
7 7 W Y/O 3 [175B]
Left XM
Y/V 4

R 6
CAN (+) 13 13 Y/O W 7
CAN (-) 14 14 Y/V BK 8 XM
R/O 9
BK/GN 10 [185B]
Y/O 11
XM (-) 18 18 BK Y/V 12

++R 1
MIC Sum Out (-) 22 22 ++BK ++BK 2

R 4 Future
CB/GRMS BK 5 ACC
Audio (-) 26 26 BK
HFM Audio (-) 27 27 BK [186B]
R/O 9
Right XM (-) 30 30 R BK/GN 10
Y/O 11
Y/V 12
MIC Sum Out (+) 32 32 ++R

++R 1 1 ++R ++R 1

++BK 2 2 ++BK ++BK 2

R 4 4 R R 4
BK 5 5 BK BK 5 C.B.
R 6 6 R
W 7 7 W [184D]
BK 8 8 BK
R/O 9 9 R/O R/O 9
BK/GN 10 10 BK/GN BK/GN 10
Y/O 11 11 Y/O Y/O 11
Y/V 12 12 Y/V Y/V 12
Battery 10 10 R/O
Ground 11 11 BK/GN
C.B. [184B] [184C]
P&A ULTRA
(If Equipped) Overlay Harness
BK/GN 6 6 BK/GN For FL/HTCU/HTK/TRU
Y/V 5 5 Y/V Only
BK/GN
++BK

Y/O 4 4 Y/O
++R

R/O

Y/O
Y/V
Ground 19 19 BK/GN R/O 3 3 R/O
Battery 20 20 R/O
1 2 5 6 7 8 [187B]
[6A] [6B] 1 2 5 6 7 8 [187A]
[27A] [27B]
++BK

R/O
BK/GN
Y/O
Y/V
++R

Bluetooth
Antenna

[149B] [194B]
(Beige)
Y/O R/O 1 Battery
1
BK/GN 2 Ground
Y/V 2 To High
R 3 Output
30 30 R R 4
Amplifier
R 8 Audio Out (+)
Battery + [149A] BK 9 Audio Out (-)
BK/GN 20 (BK)
BK/GN BK/GN 21

Ground
Y/O 17 CAN (+)
Stud Y/V 18 CAN (-)
(Right)
Main
Harness ++R 45 Differential Mic Out (+)
++BK 46 Differential Mic Out (-)
BK/GN C C BK/GN BK/GN GND 2 Hands
R/O A A R/O BK 2B 2A Free
Module
Radio
[15A] [15B] Memory Fuse
(BK) 15A

Figure 8-19. Audio, Microphone, Power and CAN Circuits

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2. XM Audio Voltage Output Test 2. Test for continuity between the following:

1. Connect ADVANCED AUDIO SYSTEM BREAKOUT a. Breakout box [28] terminals 18 and 7
BOX (Part No. HD-47918) between radio [28A] and radio b. Breakout box [28] terminal 7 and 30
harness [28B].
c. Breakout box [28] terminal 30 and 18
2. With radio ON and XM active, measure voltage on
breakout box [28] terminals 30 and 18 (right channel) and 3. Is continuity present?
between terminals 7 and 18 (left channel). a. Yes. Repair short between (R), (BK) or (W) wires in
3. Is varying AC voltage (0-1.5V) present when XM is active? radio harness. Installed modules may also be shorted
internally. Disconnect XM module while observing
a. Yes. Replace radio. See the service manual. (6103)
multimeter. If disconnecting any module causes mul-
b. No. Go to Test 3. timeter to indicate infinity, replace XM module. (5041)
b. No. Go to Test 6.
3. XM Audio Output Continuity Test
1. Turn radio off. 6. XM Audio Output Shorted to Voltage Test
2. Disconnect XM radio [185]. 1. Connect breakout box to radio [28A].

3. Disconnect radio [28A] from breakout box. 2. Test for voltage between the following:

4. Using HARNESS CONNECTOR TEST KIT (Part No. HD- a. Breakout box [28] terminal 18 and ground.
41404-C), test for continuity between the following: b. Breakout box [28] terminal 7 and ground.
a. Breakout box [28B] terminal 18 and XM [185B] ter-
c. Breakout box [28] terminal 30 and ground.
minal 8
b. Breakout box [28B] terminal 7 and XM [185B] terminal 3. Is voltage greater than 8V?
7 a. Yes. Repair short to voltage on (R), (BK) or (W) wires.
Installed modules may also be shorted internally.
c. Breakout box [28B] terminal 30 and XM [185B] ter-
Disconnect XM module while observing multimeter.
minal 6
If disconnecting any module causes multimeter to
5. Is continuity present? indicate normal voltage, replace XM module. (5041)

a. Yes. Connect XM module. Go to Test 4. b. No. Replace XM module. (6128)

b. No. Repair open on (R), (BK) or (W) wire between 7. XM Module Power Test
radio harness [28B] and XM [185B]. (5041)
1. Install BREAKOUT BOX (Part No. HD-42682) and
4. XM Audio Output Short to Ground Test JUMPER HARNESS (Part No. HD-45325) to XM [185B].

1. Test for continuity between the following: 2. With IGN ON, measure voltage between XM breakout box
a. Breakout box [28B] terminal 18 and XM [185B] ter- (black) terminals 9 and 10.
minal 8 3. Is battery voltage present?
b. Breakout box [28B] terminal 7 and XM [185B] terminal a. Yes. Go to Test 8.
7
b. No. Inspect [185] for damaged, pushed back or cor-
c. Breakout box [28B] terminal 30 and XM [185B] ter- roded terminals. Repair as required, then continue
minal 6 testing. Go to Test 10.

2. Is continuity present? 8. XM Module CAN Voltage Test

a. Yes. Repair short to ground on (R), (BK) or (W) wire 1. Measure voltage between XM breakout box (black) ter-
in radio harness to XM [185B]. Installed modules may minals 11 and 12.
also be shorted to ground internally. Disconnect XM
module while observing multimeter. If disconnecting 2. Is voltage between 4-6V?
any module causes multimeter to indicate infinity, a. Yes. Inspect [185] for damaged, pushed back or cor-
replace XM module. (6157) roded terminals. Repair as required. If connections
are okay, replace XM module. (6126)
b. No. Go to Test 5.
b. No. Go to Test 9.
5. XM Audio Output Wires Shorted Together
Test 9. XM Module CAN Continuity Test
1. Disconnect breakout box from radio [28A]. 1. Connect ADVANCED AUDIO SYSTEM BREAKOUT
BOX (Part No. HD-47918) between radio [28A] and radio
harness [28B].

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2. Test for continuity between the following: 2. Measure the resistance between XM antenna cable con-
a. Radio breakout box [28] terminal 13 and XM breakout nector center conductor and antenna cable shield.
box (black) terminal 11. 3. Is resistance between 35-55 Ohms?
b. Radio breakout box [28] terminal 14 and XM breakout a. Yes. Replace XM module. (6126)
box (black) terminal 12.
b. No. Replace antenna. (6146)
3. Is continuity present?
a. Yes. Replace radio. See the service manual. (6103)
SYMPTOM 14: NAVIGATION INOPERATIVE
b. No. Repair open on (Y/O) or (Y/V) wires. (6128) Table 8-53. Symptom 14: Navigation Inoperative
Diagnostic Faults
10. XM Module Power/Ground Bus
Continuity Test POSSIBLE CAUSES
Nav module malfunction
1. Connect ADVANCED AUDIO SYSTEM BREAKOUT
BOX (Part No. HD-47918) between radio [27A] and har- Antenna malfunction
ness [27B]. Satellite unavailable
2. With radio on, test for voltage between breakout box ter-
Before performing these tests, verify the following:
minal 10 and ground.
• Navigation CD is in good condition.
3. Is battery voltage present?
a. Yes. Repair open (R/O) wire between XM [185B] and • Navigation module is properly installed in radio including
radio memory fuse. (6129) screws.
• Vehicle is located in an open area with line of sight to the
b. No. Repair open (BK/GN) wire between XM [185B]
southern sky.
and ground. (6129)
• Navigation antenna is properly installed and connected to
SYMPTOM 13: NO OR INTERMITTENT navigation module.
RECEPTION ON XM MODULE • Any metal objects obstructing a properly installed antenna
are removed.
PART NUMBER TOOL NAME
HD-41404-C HARNESS CONNECTOR TEST KIT 1. Navigation Module Activation Test
1. Turn radio ON and press the NAV button.
Before proceeding with this test, verify the vehicle is located
in an open area with line of sight to the southern sky and all 2. Is the navigation screen displayed on the radio?
metal objects obstructing a properly installed antenna are a. Yes. "GPS Antenna Error" is displayed. Go to Test
removed. 2.

Table 8-52. Symptom 13: No or Intermittent Reception on b. Yes. "GPS Module Error" is displayed. Substitute
XM Module Diagnostic Faults module with known good unit. If problem persists,
continue testing. Go to Test 4.
POSSIBLE CAUSES
c. No. If "Navigation is Not Installed" is displayed, swap
XM module malfunction module with known good unit and retest. If problem
Antenna malfunction persists replace radio. (6103)
Satellite unavailable
2. GPS Antenna Error Test
1. XM Antenna Power Test 1. Disconnect GPS antenna from navigation module.
1. Disconnect XM antenna from XM module and turn IGN 2. Measure the voltage at the module from the center con-
ON. ductor to radio case.
2. Using HARNESS CONNECTOR TEST KIT (Part No. HD- 3. Is voltage between 4.5-5.3V?
41404-C), measure the voltage at XM antenna connector a. Yes. Go to Test 3.
on back of XM module between center conductor and
radio case. b. No. Replace navigation module. (6182)
3. Is voltage 4.25-4.75V?
3. GPS Antenna Resistance Test
a. Yes. Go to Test 2.
1. Measure resistance at the GPS antenna connector
b. No. Replace XM module. (6126) between the center conductor and cable shield.
2. Is resistance between 105,000-122,000 Ohms?
2. XM Antenna Resistance Test
a. Yes. Replace navigation module. (6182)
1. Turn IGN OFF.
b. No. Replace antenna. (6183)

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4. GPS Module Error Test 3. Is speed type correct?

1. Activate the FM radio band and enter radio test menu a. Yes. Go to Test 2.
(softkey 1, softkey 3 and OK pressed simultaneously). b. No. Press CHANGE at softkey 4 until the correct
2. Press down arrow to select diagnostic speed type (J1850 speed type is displayed. Press EXIT at softkey 6 to
for model years 2006 and later). store setting. Cycle ignition switch and repeat
symptom test.
3. Is speed type correct?
a. Yes. Go to Test 5. 2. Screen Speed Test
b. No. Press CHANGE at softkey 4 until the correct 1. Press down arrow until diagnostic speed input appears.
speed type is displayed. Press EXIT at softkey 6 to Should read "O" if the vehicle is stationary.
store setting. Cycle ignition switch and repeat 2. Ride motorcycle with the speed screen displayed while
symptom tests. monitoring both the screen and the speedometer.

5. Screen Speed Test 3. Does the number on the screen increment?

1. Press down arrow until diagnostic speed input appears. a. Yes. Adjust AVC by pressing AUDIO + until one or
Should read "O" if the vehicle is stationary. more bars are present.

2. Ride motorcycle with the speed screen displayed while b. No. See 8.4 SERIAL DATA BUS DIAGNOSTICS,
monitoring both the screen and the speedometer. DTC U1016 J1850 Loss of Communication with ECM.

3. Does the number on the screen increment? SYMPTOM 16: HANDLEBAR, PASSENGER
a. Yes. Go to Test 6. OR SIDECAR SWITCHES INOPERATIVE
b. No. If the speedometer showed a speed value, repair See 8.2 DTC B2006-B2015, RADIO SWITCH DIAGNOSTICS.
the speed input to the radio. See 8.5 ADVANCED
AUDIO SYSTEM SYMPTOMS, Symptom 15: AVC SYMPTOM 17: CD SKIPPING
Inoperative, and repeat Test 4.
PART NUMBER TOOL NAME
6. Navigation CD Operation Test HD-47918 ADVANCED AUDIO SYSTEM
BREAKOUT BOX
1. Insert navigation CD and allow it to load.
2. Press OKAY when prompted and press softkey 5 to save Before proceeding with the following tests, verify the following:
the data. • CD is in good condition and properly formatted.
3. Press softkey 4 (GPS). • Radio is installed properly. (6171)
4. Observe the number of satellites and latitude/longitude • Handlebar risers do not contact bottom of radio chassis.
information.
5. Are there any satellites available (may take 5-10 minutes Table 8-55. Symptom 17: CD Skipping Diagnostic Faults
to acquire)? POSSIBLE CAUSES
a. Yes. Replace navigation module. (6182)
CD not formatted properly
b. No. Replace navigation antenna. (6183) Exhaust system not mounted correctly

SYMPTOM 15: AVC INOPERATIVE Radio malfunction

1. CD Player to CB/Intercom Interactivity

Table 8-54. Symptom 15: AVC Inoperative Diagnostic
Faults
Test
1. If the vehicle is equipped with a CB/Intercom, turn it OFF.
POSSIBLE CAUSES
2. Does the CD still skip?
VSS malfunction
a. Yes. Go to Test 2.
Loss of communication with ECM
b. No. Possible audio interruptions caused by incoming
1. AVC Speed Test CB or intercom signals.
1. Activate the FM radio band and enter radio test menu
(softkey 1, softkey 3 and OK pressed simultaneously).
2. Radio Input (Power) Positive Voltage Drop
Test
2. Press down arrow to select diagnostic speed type (J1850
for model years 2006 and later). 1. Install ADVANCED AUDIO SYSTEM BREAKOUT
BOX (Part No. HD-47918) to radio [27A] and radio harness
[27B].

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2. With IGN and radio ON, measure voltage drop between 1. Phone Mode Enable Test
battery positive (+) and breakout box terminals 10 and 20.
1. Can phone mode be enabled?
3. Is voltage drop greater than 0.5V? a. Yes. Go to Test 2.
a. Yes. Repair source of voltage drop between battery
positive and breakout box [27] terminals 10 and 20. b. No. Phone icon appears on radio display. Go to
(6172) Test 6.

b. No. Go to Test 3. c. No. Phone mode inoperative with no phone icon

on display. See 8.4 SERIAL DATA BUS DIA-
3. Radio Input (Power) Negative Voltage GNOSTICS, DTC U1306 Infotainment Bus Lost
Communication with Hands-Free Phone Module.
Drop Test
1. With IGN and radio ON, measure voltage drop between 2. Phone Pairing Test
battery negative (-) and breakout box terminals 11 and 1. Is phone able to pair with module?
19.
a. Yes. Go to Test 3.
2. Is voltage drop greater than 0.5V?
b. No. Phone may not be compatible. See phone com-
a. Yes. Repair source of voltage drop between battery patibility list on H-D Net or contact cellular provider
negative and breakout box [27] terminals 11 and 19. for technical service and source compatible phone.
(6172)
b. No. Go to Test 4. 3. Phone Communication Test
1. Can caller be heard by rider and the rider be heard by
4. Front Motor Mount Inspection Test caller?
1. Inspect front motor mount. a. Yes. Go to Test 4.
2. Is front motor mount damaged, loose or misaligned? b. No. Go to Test 6.
a. Yes. Align or replace front motor mount. See the
service manual. (6173) 4. Phonebook Download Test
b. No. Go to Test 5. 1. Does phonebook download completely?
a. Yes. If the name of the phone service provider is
5. Exhaust System Mounts Inspection Test displayed, then continue with tests. Go to Test 5.
1. Inspect exhaust system mounts. b. No. Some phones or sim cards do not support all
features. Contact cellular provider technical service
2. Do mounts allow muffler isolation so that vibration cannot
or obtain compatible phone.
reverberate through frame?
a. Yes. Replace radio. See the service manual. (6101) 5. Signal Strength Test
b. No. Correct exhaust mount alignment. See the ser- 1. Observe signal strength on display.
vice manual.
2. Is signal strength displayed in upper right hand corner of
SYMPTOM 18: HANDS-FREE PHONE display?
MODULE INITIAL DIAGNOSTICS a. Yes. System okay.
b. No. Go to Test 16.
PART NUMBER TOOL NAME
HD-41404-C HARNESS CONNECTOR TEST KIT
HD-47918 ADVANCED AUDIO SYSTEM
BREAKOUT BOX

Table 8-56. Symptom 18: Hands-free Phone Module Initial

Diagnostics Diagnostic Faults

POSSIBLE CAUSES
Phone incompatible with system
Phone won't pair
Phone malfunction

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Ultra Radio [28A] [28B]

(BK)
CB/GRMS
Audio (+) 3 3 R
HFM Audio (+) 4 4 R R/O 1 Future
BK/GN 2 ACC
7 7 W Y/O 3 [175B]
Left XM
Y/V 4

R 6
CAN (+) 13 13 Y/O W 7
CAN (-) 14 14 Y/V BK 8 XM
R/O 9
BK/GN 10 [185B]
Y/O 11
XM (-) 18 18 BK Y/V 12

++R 1
MIC Sum Out (-) 22 22 ++BK ++BK 2

R 4 Future
CB/GRMS BK 5 ACC
Audio (-) 26 26 BK
HFM Audio (-) 27 27 BK [186B]
R/O 9
Right XM (-) 30 30 R BK/GN 10
Y/O 11
Y/V 12
MIC Sum Out (+) 32 32 ++R

++R 1 1 ++R ++R 1

++BK 2 2 ++BK ++BK 2

R 4 4 R R 4
BK 5 5 BK BK 5 C.B.
R 6 6 R
W 7 7 W [184D]
BK 8 8 BK
R/O 9 9 R/O R/O 9
BK/GN 10 10 BK/GN BK/GN 10
Y/O 11 11 Y/O Y/O 11
Y/V 12 12 Y/V Y/V 12
Battery 10 10 R/O
Ground 11 11 BK/GN
C.B. [184B] [184C]
P&A ULTRA
(If Equipped) Overlay Harness
BK/GN 6 6 BK/GN For FL/HTCU/HTK/TRU
Y/V 5 5 Y/V Only
BK/GN
++BK

Y/O 4 4 Y/O
++R

R/O

Y/O
Y/V

Ground 19 19 BK/GN R/O 3 3 R/O

Battery 20 20 R/O
1 2 5 6 7 8 [187B]
[6A] [6B] 1 2 5 6 7 8 [187A]
[27A] [27B]
++BK

R/O
BK/GN
Y/O
Y/V
++R

Bluetooth
Antenna

[149B] [194B]
(Beige)
Y/O R/O 1 Battery
1
BK/GN 2 Ground
Y/V 2 To High
R 3 Output
30 30 R R 4
Amplifier
R 8 Audio Out (+)
Battery + [149A] BK 9 Audio Out (-)
BK/GN 20 (BK)
BK/GN BK/GN 21

Ground
Y/O 17 CAN (+)
Stud Y/V 18 CAN (-)
(Right)
Main
Harness ++R 45 Differential Mic Out (+)
++BK 46 Differential Mic Out (-)
BK/GN C C BK/GN BK/GN GND 2 Hands
R/O A A R/O BK 2B 2A Free
Module
Radio
[15A] [15B] Memory Fuse
(BK) 15A

Figure 8-20. Audio, Microphone, Power and CAN Circuits

8-52 2011 Touring Diagnostics: Audio System

HOME

6. Phone Module Power Test 2. Is voltage between 0-5VAC while voice prompt is
responding?
1. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
41404-C), measure voltage between hands-free module a. Yes. Replace radio. See the service manual. (6101)
[194B] terminals 1 and 2 (ground). b. No. Go to Test 15.
2. Is battery voltage present?
12. Phone Module Continuity Test
a. Yes. Go to Test 7.
1. Test for continuity between breakout box [28] terminal 4
b. No. Go to Test 9. and [194B] terminal 8 and then between breakout box [28]
terminal 27 and [194B] terminal 9.
7. CAN Communication Test
2. Is continuity present?
1. Measure voltage between [194B] terminals 17 and 18.
a. Yes. Go to Test 13.
2. Is measured voltage between 4.0-6.0V?
b. No. Repair open (R) or (BK) wire between [194B] and
a. Yes. Go to Test 10. [28B]. (5041)
b. No. Go to Test 8.
13. Phone Module Audio Short to Low Test
8. Phone Module Continuity Test 1. Test for continuity between breakout box [28] terminals 4
1. Connect ADVANCED AUDIO SYSTEM BREAKOUT and 27.
BOX (Part No. HD-47918) between radio [28A] and radio 2. Is continuity present?
harness [28B], leaving radio [28A] disconnected.
a. Yes. Go to Test 14.
2. Test for continuity between [194B] terminal 17 and
breakout box [28] terminal 13 and then between [194B] b. No. Repair short to low on (R) and (BK) wires. (5041)
terminal 18 and breakout box [28] terminal 14.
14. Phone Module Audio Short to Ground
3. Is continuity present? Test
a. Yes. Inspect [194] for damaged, pushed back or cor-
1. Test for continuity between breakout box [28] 4 and 27 to
roded terminals. Repair as required. If connector ter-
ground.
minals are okay, replace radio.
2. Is continuity present?
b. No. Repair open on (Y/O) or (Y/V) wires. (5041)
a. Yes. Repair short to ground on (R) or (BK) wire.
9. Phone Module Open Ground Test (5041)
1. Test for continuity between [194B] terminal 2 to ground. b. No. Go to Test 15.
2. Is continuity present? 15. Phone Module Audio Short to Voltage
a. Yes. Repair open on (R/O) wire between [194B] and
Test
radio memory fuse. (5041)
1. With IGN and radio ON, measure voltage between
b. No. Repair open on (BK/GN) wire between [194B] breakout box [28] 4 and 27 to ground.
and ground. (5041)
2. Is voltage greater than 9V?
10. Phone Mode Entry Test a. Yes. Repair short to voltage on (R) or (BK) wire.
1. Does radio enter phone mode when mode switch is (5041)
pressed? b. No. Replace hands-free module.
a. Yes. Go to Test 11.
16. Phone Module Antenna Test
b. No. Replace hands-free phone module.
1. Inspect the hands-free module antenna.
11. Phone Module Output Test 2. Is the hands-free module antenna good?
1. Measure voltage between breakout box [28] terminals 4 a. Yes. Contact cellular provider technical service and
and 27. verify phone is compatible. If phone is correct replace
the hands-free phone module.
b. No. Replace the hands-free module antenna.

2011 Touring Diagnostics: Audio System 8-53

NOTES

8-54 2011 Touring Diagnostics: Audio System

TABLE OF CONTENTS

SUBJECT............................................................................................................................PAGE NO.
A.1 AUTOFUSE UNSEALED ELECTRICAL CONNECTORS.........................................................A-1
A.2 DELPHI 100W MICRO-PACK SEALED CONNECTOR............................................................A-2
A.3 DELPHI 150 METRI-PACK SEALED CONNECTORS..............................................................A-4
A.4 DELPHI 280 METRI-PACK UNSEALED CONNECTORS........................................................A-6
A.5 DELPHI 480 METRI-PACK UNSEALED CONNECTORS........................................................A-7
A.6 DELPHI 630 METRI-PACK UNSEALED CONNECTORS........................................................A-8
A.7 DELPHI 800 METRI-PACK SEALED MAIN FUSE HOUSING..................................................A-9
A.8 DELPHI METRI-PACK TERMINAL REPAIR...........................................................................A-11
A.9 DELPHI MICRO 64 SEALED CONNECTORS.......................................................................A-13
A.10 DELPHI GT 150 SEALED CONNECTORS..........................................................................A-16
A.11 DELPHI GT 280 SEALED 73-TERMINAL ECM CONNECTOR...........................................A-18

APPENDIX A CONNECTOR REPAIR

A.12 DEUTSCH DT SEALED CONNECTORS.............................................................................A-20
A.13 DEUTSCH DT SEALED TERMINAL REPAIR......................................................................A-24
A.14 DEUTSCH DTM SEALED MINI TERMINAL REPAIR...........................................................A-25
A.15 DEUTSCH DTM SEALED SOLID BARREL MINI TERMINAL REPAIR................................A-26
A.16 JAE MX19 SEALED CONNECTORS...................................................................................A-28
A.17 MOLEX CMC SEALED CONNECTORS..............................................................................A-29
A.18 MOLEX MX 150 SEALED CONNECTORS..........................................................................A-31
A.19 TYCO 070 MULTILOCK UNSEALED CONNECTOR...........................................................A-35
A.20 SEALED SPLICE CONNECTORS.......................................................................................A-39
NOTES
HOME

AUTOFUSE UNSEALED ELECTRICAL

CONNECTORS A.1
AUTOFUSE UNSEALED CONNECTOR
REPAIR sm02849

PART NUMBER TOOL NAME

GA500A SNAP-ON TERMINAL PICK

General
Autofuse Unsealed connector terminals are found in ignition
switches and some fuse blocks.

Disassembly
1. Obtain SNAP-ON TERMINAL PICK (Part No. GA500A).
2. See Figure A-1 or Figure A-2. Insert smallest pair of pins
into chamber on mating end of socket housing to press
tangs on each side of terminal simultaneously.
3. Gently pull on wire to remove terminal from wire end of Figure A-1. Removing Autofuse Unsealed Terminal from
socket housing. Ignition Switch
4. If necessary, crimp new terminals on wires.

Assembly
sm03480
1. Using a thin flat blade, like that on a hobby knife, carefully
bend tang on each side of terminal outward away from
terminal body.
2. With the open side of the terminal facing rib on wire end
of socket housing, insert terminal into chamber until it locks
in place.

Figure A-2. Removing Autofuse Unsealed Terminal from

Fuse Block

2011 Touring Diagnostics: Appendix A Connector Repair A-1

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DELPHI 100W MICRO-PACK SEALED

CONNECTOR A.2
DELPHI 100W MICRO-PACK SEALED
sm00037
CONNECTOR REPAIR
General
A Delphi 100W Micro-Pack Sealed connector connects the 3
electronic control module (ECM) to the main harness.
NOTE
For vehicles with 73-pin connectors, see A.9 DELPHI MICRO
64 SEALED CONNECTORS and A.8 DELPHI METRI-PACK
TERMINAL REPAIR.

Separating Socket Housing From ECM 1 2

See Figure A-3. While pressing the connector into the ECM,
press the thumb lever (1) against the connector until the latch
(2) pops out of the catch (3) on the ECM.

Mating Socket Housing To ECM

Push the connector into the ECM until the latch is captured by
the catch on the ECM.

Removing Socket Terminal

1. See Figure A-4. Gently press latch (1) on each side of the
clear plastic secondary lock (2) and remove. For best
1. Thumb lever
results, release one side at a time.
2. Latch
2. Carefully cut cable strap (3) to free strain relief collar (4) 3. Catch (ECM)
from conduit (5).
Figure A-3. Delphi 100W Micro-Pack Sealed Connector to
3. See Figure A-5. Using a thin blade, gently pry at seam at ECM (typical)
back of socket housing to release three plastic pins (1)
from slots in housing. Separate and spread halves of
socket housing.
4. Push on wire lead to free terminal from chamber.

Installing Socket Terminal

1. From inside socket housing, gently pull on wire to draw
terminal into chamber.
2. Exercising caution to avoid pinching wires, press halves
of socket housing together until three plastic pins fully
engage slots in housing.
3. Install new cable strap in groove of strain relief collar
capturing cable conduit.
4. With the two ribs on the secondary lock on the same side
as the external latch, install over terminals until latches
lock in place.

Crimping Terminals
If necessary, crimp new terminals on wire leads. See
A.8 DELPHI METRI-PACK TERMINAL REPAIR.

A-2 2011 Touring Diagnostics: Appendix A Connector Repair

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sm00038 sm00039
1 1

2
1

5 1
4

1. Latch
2. Secondary lock
3. Cable strap
4. Strain relief collar
5. Conduit
Figure A-4. Delphi 100W Micro-Pack Sealed Connector
2

1. Pins
2. Socket terminal
Figure A-5. Delpi 100W Micro-Pack Sealed Connector:
Separate Halves of Socket Housing

2011 Touring Diagnostics: Appendix A Connector Repair A-3

HOME

DELPHI 150 METRI-PACK SEALED

CONNECTORS A.3
DELPHI 150 METRI-PACK SEALED 6. Remove the pin.
CONNECTOR REPAIR a. For pull-to-seat: Push on the lead to extract the ter-
minal from the mating end of the connector.
General b. For push-to-seat: Pull on the lead to draw the ter-
Delphi 150 Metri-Pack Sealed connectors are embossed with minal out the wire end.
the initials (P.E.D.).
There are two types of connectors in this series: Inserting Socket Terminal
• Pull-to-Seat NOTE
For wire location purposes, alpha characters are stamped into
• Push-to-Seat
the socket housings.
Separating Pin and Socket Housings 1. See Figure A-6 for pull-to-seat connector or Figure A-7
Bend back the external latch slightly and separate the pin and for push to seat connector. Using a thin flat blade, like that
socket halves of the connector. on a hobby knife, carefully bend the tang outward away
from the terminal body.
Mating Pin and Socket Housings
2. Gently pull or push on the lead to install the terminal back
Align the wire colors and push the pin and socket halves of the into the chamber. A click is heard when the terminal is
connector together. properly seated.
Removing Socket Terminal 3. Gently pull or push on the lead to verify that the terminal
1. See Figure A-6 for pull-to-seat connector or Figure A-7 is locked in place.
for push to seat connector. Remove wire lock (1) from wire For push-to-seat: See Figure A-7. Seat wires in separate
end of socket housing on push-to-seat type connectors. channels of wire lock and then push channels inside
chambers at wire end of socket housing. Fully installed,
NOTE
slot on each side of wire lock engages ear on socket
For best results, free one side of wire lock first and then release
housing.
the other side.
2. Find the locking tang in the mating end of the connector.
NOTE
The tangs are always positioned in the middle of the chamber
and are on the same side as the external latch.
3. Gently insert a safety pin into the chamber about 1/8 in.
(3.2 mm).
a. For pull-to-seat: Stay between the terminal and the
chamber wall and pivot the end of the pin toward the
terminal body.
b. For push-to-seat: There is a small opening for the
pin.

4. When a click is heard, remove the pin and repeat the

procedure.
NOTE
The click is the sound of the tang returning to the locked posi-
tion as it slips from the point of the pin.
5. Pick at the tang until the clicking stops and the pin seems
to slide in deeper than it had previously. This is an indica-
tion that the tang has been depressed.
NOTE
On those terminals that have been extracted on multiple
occasions, the click may not be heard, but pivot the pin as if
the click was heard at least 3 times.

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sm00027 sm00028

2
2

4
4

1. Locate tang in chamber 1. Remove wire lock

2. Pivot pin to depress tang 2. Pivot pin to depress tang
3. Push to remove 3. Pull to remove
4. Raise tang to install 4. Raise tang to install

Figure A-6. Delphi 150 Metri-Pack Sealed Connector: Figure A-7. Delphi 150 Metri-Pack Sealed Connector:
Pull-to-Seat Push-to-Seat

2011 Touring Diagnostics: Appendix A Connector Repair A-5

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DELPHI 280 METRI-PACK UNSEALED

CONNECTORS A.4
FUSE BLOCK REPAIR NOTE
The wiring diagram indicates when one socket terminal is be
Removing Socket Terminals crimped to two wire leads.
1. See Figure A-8. To remove secondary locks, insert end
of small flat blade screwdriver (1) under lip of locking sm00025
wedge (2) and gently pry up secondary lock.
NOTE 1
For best results, start with locking wedge on outboard side of
secondary lock. 2
2. Looking into chamber at top of fuse block, note the tang
next to each socket terminal.
3. Using a thin flat blade, like that on a hobby knife, gently
push tang away from terminal, and then tug on wire to
back terminal out.

Installing Socket Terminals

1. Match the wire lead color to the fuse block terminal cavity.
NOTES
• Refer to the main harness wiring diagram for wire lead 1. Pry up secondary lock
color codes. 2. Lip of locking wedge
• See Figure A-9. The main fuse block terminal cavity is Figure A-8. Fuse Block: Remove Secondary Locks
identified as alpha (1) and numeric (2) coordinates. Refer
to the main harness wiring diagram for fuse block terminal
cavity coordinates.
2. With the open side of the socket terminal facing the tang, sm00026
push lead into chamber at the wire end of the fuse block.
A click is heard when the terminal is properly engaged. 1
3. Gently tug on the wire to verify that the terminal is locked
in place and will not back out of the chamber. A C E G J
4. Install the secondary locks. With the locking wedges 2 1
positioned above the tangs in each chamber, slide flat 2
side of secondary lock into slot (between rows), and push
down until it bottoms. 3

Crimping Terminals 4
B D F H
Terminals are crimped twice; once over the wire core and a
second time over the insulation/seal.
A correctly crimped terminal may require different crimping
dies found on separate crimpers.
1. Alpha
2. Numeric
Figure A-9. Fuse Block: Coordinates (typical)

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DELPHI 480 METRI-PACK UNSEALED

CONNECTORS A.5
DELPHI 480 METRI-PACK UNSEALED 3. Verify that terminal will not back out of the chamber. A
slight tug on the cable will confirm that it is locked.
CONNECTOR REPAIR
4. Rotate the hinged secondary lock inward until latches fully
General engage tabs on both sides of connector housing.
A 480 Metri-Pack connector is frequently used for the B+
NOTE
(battery voltage) connector to power P&A accessories.
If removed, install new anchored cable strap in O.E. location.
See Figure A-10. An AFL housing (5) is used on many igni- Tighten cable strap to capture conduit of both accessory con-
tion/light switches. The secondary lock (4) must be opened nector and B+ connector approximately 1.0 in. (25.4 mm) from
before removing the terminal from the housing. housings.
Separating Pin and Socket Housings
sm00031a
NOTE 1
Cut any cable strap anchoring the wire conduits of the pin
(accessory connector housing) and the socket (B+) housing.
See Figure A-10. Using small flat blade screwdriver, press
button (1) on pin housing (red wire) side of the connector and
pull apart the pin and socket housings.
2
Mating Pin and Socket Housings
Orient the latch on the socket housing to the button catch on
the pin housing and press the housings together.

Removing Socket Terminals

1. See Figure A-10. Bend back the latch (2) slightly and free
one side of secondary lock, then repeat to release the
opposite side. Rotate the secondary lock outward on hinge
to access terminal in chamber of connector housing.
2. On the mating end of the connector, note the tang in the
square shaped opening centered next to the terminal.
Gently insert the point of a stick pin or large safety pin into 3
the opening (3) between the tang and the chamber wall
until it stops.
3. Pivot the end of the pin toward the terminal body to press
the tang.
4. Remove the pin and then pull terminal out of the wire end 4
of connector housing.
5. If necessary, crimp new terminals on wires. See 5
A.8 DELPHI METRI-PACK TERMINAL REPAIR.

Installing Socket Terminals

1. Carefully bend the tang outward away from the terminal
body. 1. Button on pin housing
2. With the tang on the same side as the square shaped 2. Secondary lock latch
opening in the mating end of the connector housing, feed 3. Opening between tang and chamber wall
terminal into wire end of connector housing until it "clicks" 4. Secondary Lock (shown open)
in place. 5. AFL housing
Figure A-10. Delphi 480 Metri-Pack Unsealed Connector:
Remove Socket Terminal

2011 Touring Diagnostics: Appendix A Connector Repair A-7

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DELPHI 630 METRI-PACK UNSEALED

CONNECTORS A.6
DELPHI 630 METRI-PACK UNSEALED 3. Moving to the mating end of the connector, take note of
the small opening on the chamber wall side of each ter-
CONNECTOR REPAIR minal.
PART NUMBER TOOL NAME 4. Insert SNAP-ON PICK (Part No. SNAP-ON TT600-3) into
SNAP-ON TT600-3 SNAP-ON PICK opening until it stops. Pivot the end of the pick toward the
terminal to press the locking tang.
Separating Pin and Socket Housings 5. Remove the pick and gently tug on the wire to pull the
NOTE terminal from the wire end of the connector. Repeat steps
If necessary, remove connector from barbed anchor or other if the terminal is still locked in place.
retaining device. 6. If necessary, crimp new terminals on wires. Refer to
Bend back the external latch slightly and separate pin and A.8 DELPHI METRI-PACK TERMINAL REPAIR.
socket halves of the connector.
Installing Socket Terminal
Mating Pin and Socket Housings NOTE
Orient the latch to the catch and push the pin and socket halves Refer to the wiring diagrams to match wire lead colors to alpha
of the connector together until the latch "clicks". characters molded into the secondary locks of each connector
NOTE housing.
If removed, install connector on barbed anchor or other OE 1. Using a thin flat blade, like that of a hobby knife, carefully
retaining device. bend the tang outward away from the terminal body.

Removing Socket Terminal
1. Bend back the latch slightly and free one side of the sec-
ondary lock. Repeat the step to unlatch the other side.
2. Rotate the secondary lock outward on hinge to view the
terminals in the chambers of the connector housing. The
locking tang is on the side opposite the crimp tails and
engages a rib in the chamber wall to lock the terminal in
place.
2. With the tang facing the chamber wall, push the lead into
the chamber at the wire end of the connector. A click is
heard when the terminal is properly seated.
3. Gently tug on the wire end to verify that the terminal is
locked in place and will not back out of the chamber.
4. Rotate the hinged secondary lock inward until tabs fully
engage latches on both sides of connector.

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DELPHI 800 METRI-PACK SEALED MAIN FUSE

HOUSING A.7
DELPHI 800 METRI-PACK SEALED MAIN
FUSE HOUSING REPAIR sm00033

3
Removing Socket Terminals
1. Disconnect battery.
2. See Figure A-11. Disengage slots (1) on secondary lock
(2) from tabs (3) and remove secondary lock.
3. Insert flat blade of pick or small screwdriver into opening
(4) until it stops.
4. Tug on cable to pull socket from connector housing. Pivot 1
2
the pick toward the terminal body to release the latch if
necessary.
5. Repeat to remove remaining socket terminal.
NOTE
The battery positive cable and power wire for the main fuse
are crimped together at the starter ring terminal. Both must be
replaced as an assembly if either requires replacement.

Installing Socket Terminals 4

1. See Figure A-12. Carefully bend tang outward away from
the terminal body.
2. Properly orient terminal to the cavity in the housing and
push terminal into connector housing until it clicks in place.
Verify that socket will not back out of chamber.
3. Push rubber seal into connector housing.
4. Repeat to install remaining socket terminal. 1. Secondary lock slot
5. Install secondary lock onto connector housing. be sure 2. Secondary lock
slots engage tabs on sides of connector housing. 3. Tab
4. Insert flat blade into opening
6. Connect battery cables.
Figure A-11. Delphi 800 Metri-Pack Sealed Main Fuse
Housing: Remove Socket Terminals

2011 Touring Diagnostics: Appendix A Connector Repair A-9

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sm00034

Figure A-12. Delphi 800 Metri-Pack Sealed Main Fuse

Housing: Bend Tang

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DELPHI METRI-PACK TERMINAL REPAIR A.8

METRI-PACK TERMINAL CRIMPS
sm00035
PART NUMBER TOOL NAME
HD-38125-6 PACKARD TERMINAL CRIMP TOOL
HD-38125-7 PACKARD TERMINAL CRIMPER
HD-38125-8 PACKARD CRIMPING TOOL

Matching Terminal To Crimper

Metri-Pack connectors embossed with the initials P.E.D. require
Packard crimp tools to crimp terminals to wire leads. 1
Terminals are crimped twice to a wire lead, once over the wire
core and a second time over the insulation/seal.
See Figure A-13. A completed crimp may require two different
crimping dies found on PACKARD TERMINAL CRIMP
TOOL (Part No. HD-38125-6) and/or PACKARD TERMINAL
CRIMPER (Part No. HD-38125-7). The terminal (pin or socket)
and the wire lead gauge will determine the core crimp die and
the insulator/seal die.
NOTE
The PACKARD CRIMPING TOOL (Part No. HD-38125-8) will
also crimp sealed splice connectors in wire gauge sizes 18-20,
14-16 and 10-12.
2

Preparing Wire Lead

Use a wire striper to strip off the insulation and expose 5/32
in. (4.0 mm) of wire core.

Crimping Wire Core

NOTE
Metri-Pack terminal crimps require two steps. Always perform
Crimping Wire Core before Crimping Insulation/Seal.
1. Squeeze and release handles until ratchet automatically
opens. 3
2. Identify the corresponding sized nest for the core crimp.
3. Position the core crimp in the die. Be Sure the core crimp
tails are facing the forming jaws.
4. Gently squeeze the handles until crimpers just secure the
core crimp tails.
5. Insert stripped wire between crimp tails. Verify that wire
is positioned so that short pair of crimp tails squeeze core
wire strands, while long pair is positioned over the insula-
tion or seal material.
1. HD-38125-6 sealed terminals
6. Squeeze handles tightly closed. Release grip and the tool 2. HD-38125-7 non-sealed terminals
will automatically open. 3. HD-38125-8 non-sealed terminals
Figure A-13. Metri-Pack Terminal Crimp Tools

Crimping Insulation/Seal
NOTE
Always perform Crimping Wire Core before Crimping Insu-
lation/Seal.

2011 Touring Diagnostics: Appendix A Connector Repair A-11

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1. See Figure A-14. Identify the correct die for the insula-
sm00036
tion/seal crimp (2).
2. Position the insulation/seal crimp in the nest. Be sure the 2 1
insulation/seal crimp tails are facing the forming jaws.
3. Squeeze handle of crimp tool until tightly closed. Tool
automatically opens when the crimp is complete.

Inspecting Crimps
1. See Figure A-14. Inspect the wire core crimp (1). The tails
should be folded in on the wire core without any distortion
or excess wire strands.
2. Inspect the insulation (2) or seal (3) crimp. The tails of the
terminal should be wrapped around the insulation without
distortion.

1. Wire core crimp

2. Insulation crimp
3. Seal crimp
Figure A-14. Metri-Pack Connector: Inspect Core and
Insulation/Seal Crimps

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DELPHI MICRO 64 SEALED CONNECTORS A.9

DELPHI MICRO 64 SEALED CONNECTOR 6. Leaving the tool installed, gently tug on wires to pull either
one or both terminals from wire end of connector. Remove
REPAIR tool.
PART NUMBER TOOL NAME
HD-45928 TERMINAL REMOVER sm00046

HD-45929 TERMINAL CRIMPER

General
Delphi Micro 64 Sealed connectors are frequently found on
speedometers, tachometers and the ECM of Touring Models.

Separating Pin and Socket Housings

Bend back the external latches slightly and separate the pin
and socket housings.

Mating Pin and Socket Housings

Orient the wire lead colors and push the pin and socket hous-
ings of the connector together until the latches click.
Figure A-16. Terminal Remover (HD-45928)
Removing Terminal
1. See Figure A-15. Locate the head of the secondary lock
(1) on one side of the connector housing.
sm00048
2. Insert the blade of a small screwdriver between the center
ear of the lock and the connector housing and gently pry
out lock. When partially removed, pull lock from connector
housing.
3. Locate pin hole (2) between terminals on mating end of
connector.

sm00047

3
2
1 6
1

1 2 3 4 5 6
7 8 9 10 11 12

7 12

1. Secondary lock
2. Pin hole
3. Stamped number
Figure A-15. Delphi Micro-64 Sealed Connector: Housing

4. See Figure A-16. Obtain the TERMINAL REMOVER (Part

No. HD-45928).
5. See Figure A-17. Push the adjacent terminals all the way
into the connector housing and then insert tool into hole Figure A-17. Delphi Micro-64 Sealed Connector: Insert Tool
until it bottoms. and Remove Terminal

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Installing Terminal sm00045

1. Insert terminal into its respective numbered chamber on

wire end of connector. No special orientation of the ter-
minal is necessary.
NOTE
See Figure A-15. For wire location purposes, the corners of
the socket housing are stamped (3) with the numbers 1, 6, 7
and 12, representing terminals 1-6 on one side, and 7-12 on
the other.
2. Bottom the terminal in the chamber and then gently tug
on the wire to verify that it is locked in place.
NOTE
Once the terminal is removed it may not lock in place when
first installed. Until the lock engages, move the terminal back
and forth slightly while wiggling the lead.
3. Since the terminal remover tool releases two terminals Figure A-18. Terminal Crimper (HD-45929)
simultaneously, repeat step 2 on the adjacent terminal
even if it was not pulled from the connector housing.
4. With the center ear on the head of the secondary lockpin
facing the mating end of the connector, push secondary
lock in until head is flush with the connector housing.

Preparing Wire Leads for Crimping

Strip lead removing 1/8 in. (3.0 mm) of insulation.

Crimping Terminals
1. Inspect new socket terminal for bent or deformed contact
and crimp tails. Replace as necessary.
2. See Figure A-19. Squeeze the handles of the TERMINAL
CRIMPER (Part No. HD-45929) to cycle the tool to the
fully open position (1).
3. Raise locking bar and barrel holder by pushing up on
bottom tab with index finger (2).
4. With the crimp tails facing upward, insert terminal through
locking bar into front hole in barrel holder (20-22 gauge
wire) (3).
5. Release locking bar to lock position of contact. When
correctly positioned, the locking bar fits snugly in the space
at the front of the core crimp tails and the closed side of
the terminal rests on the outer nest of the crimp tool.
6. Insert wires between crimp tails until ends make contact
with locking bar. Verify that wire is positioned so that wide
pair of crimp tails squeeze bare wire strands, while the
narrow pair folds over the insulation material.
7. Squeeze handle of crimp tool until tightly closed (4). Tool
automatically opens when the crimping sequence is com-
plete.
8. Raise locking bar and barrel holder to remove contact.

Inspecting Crimps
Inspect the quality of the core and insulation crimps. Distortion
should be minimal.

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sm00049

1. Open position
2. Raising locking bar
3. Insert terminal
4. Crimp terminal
Figure A-19. Delphi Micro-64 Sealed Connector: Terminal
in Crimper

2011 Touring Diagnostics: Appendix A Connector Repair A-15

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DELPHI GT 150 SEALED CONNECTORS A.10

DELPHI GT 150 SEALED CONNECTOR
REPAIR sm00014

General
Delphi connectors are embossed with the brand name, Delphi,
on the housing latch or terminal block.

Separating Pin and Socket Housings

See Figure A-20. Bend back the external latch(es) slightly and
separate pin and socket halves of connector.

Mating Pin and Socket Housings

Push pin and socket halves of connector together until external
latch(es) engage.

Removing Socket Terminals

NOTE
Although the parts of the different Delphi connectors vary in
appearance, the instructions which follow will work for all.
1. See Figure A-21. If present, free one side of wire lock (1)
from ear on wire end of socket housing, then release the
other side. Release wires from channels in wire lock and
remove from socket housing. Figure A-20. Delphi GT 150 Sealed Connector: Socket
Housing Latch
2. Use a fingernail to pry colored terminal lock (2) loose and
then remove from mating end of socket housing.
3. Using a thin flat blade, like the unsharpened edge of a
hobby knife, gently pry tang (3) outward away from ter-
minal, and then tug on wire to back terminal out wire end
of chamber. Do not pull on wire until tang is released or
terminal will be difficult to remove.

Installing Socket Terminals

NOTE
For wire location purposes, alpha or numeric characters are
stamped into the wire end of each socket housing.
1. Gently push tang on socket housing inward toward
chamber. With the open side of the terminal facing the
tang, push terminal into chamber at wire end of socket
housing.
2. Gently tug on wire to verify that terminal is locked and will
not back out of chamber. If necessary, use fingernail to
push tang into engagement with terminal.
3. Install colored terminal lock onto mating end of socket
housing.
4. If present, seat wires in separate channels of wire lock
and then push channels inside chambers at wire end of
socket housing. Fully installed, slot on each side of wire
lock engages ear on socket housing.

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sm00015

2
3

1. Remove wire lock

2. Remove terminal lock
3. Pry tang outward
Figure A-21. Delphi GT 150 Sealed Connector: Removing
Socket Terminals

2011 Touring Diagnostics: Appendix A Connector Repair A-17

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DELPHI GT 280 SEALED 73-TERMINAL ECM

CONNECTOR A.11
DELPHI GT 280 SEALED 73-TERMINAL ECM
CONNECTOR sm06098

NOTE
Do not operate latch lever when connector is not mated to
ECU. Damage will occur.

Separating Socket Housing From ECM

NOTE
Although this procedure shows the ECM removed, the ECM
connector can be removed and installed with the ECM removed
or in place.
1 2
See Figure A-22. Remove strap. While pressing latch (1), rotate
lock lever to the released position (2).
1. Latch
Mating Socket Housing To ECM 2. Lock lever released
Push the connector into the ECM and rotate lock lever to the
Figure A-22. Unlatch ECM Connector
locked position.

Socket Terminal
1. Cut cable strap to release harness from strain relief collar
sm06093
of connector housing.
2. See Figure A-23. Release latches (4) that retain cover (3)
3
to housing (2) and remove cover.
3. Follow instructions in A.9 DELPHI MICRO 64 SEALED
CONNECTORS to remove and service the Micro-64 ter- 2
minals.
4. Install connector housing cover. Verify all wires are within
the confines of the cover and that the cover latches are 4
engaged.
1
5. Install new cable strap cable to the strain relief of the 5
connector.

ECM Ground Terminal

1. See Figure A-23. Remove secondary lock (1).
2. See Figure A-24. Using a thin blade screwdriver, gently 1. Secondary lock
pry ground terminal retainer from connector housing. 2. Terminal housing
3. Cover
3. See Figure A-25. Using a thin blade screwdriver, release 4. Cover latch
latch and pull ground wire, wire seal and terminal from 5. Ground secondary lock
cover side of housing.
Figure A-23. Delphi 73-Terminal ECM Connector
4. Follow instructions in A.8 DELPHI METRI-PACK TER-
MINAL REPAIR to replace the terminal or wire seal.
5. Push the terminal into place from the cover side of the
connector housing until the latch engages. Pull on wire to
verify terminal is secure.
NOTE
Secondary lock has one short leg and one long leg. Be sure
to install correctly as shown in Figure A-23.
6. See Figure A-23. Install ground secondary lock (5) and
install secondary lock (1) as shown.

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sm06094 sm06095

Figure A-24. Remove Ground Secondary Lock

Figure A-25. Remove ECM Ground Terminal

2011 Touring Diagnostics: Appendix A Connector Repair A-19

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DEUTSCH DT SEALED CONNECTORS A.12

DEUTSCH DT SEALED CONNECTOR 4. Place large end of slot on attachment clip over T-stud on
frame. Push assembly forward to engage small end of
REPAIR slot.
PART NUMBER TOOL NAME
HD-41475 DEUTSCH TERMINAL REPAIR KIT sm00017

HD-41475-100 FLAT BLADE L-HOOK

General 3
Deutsch DT Sealed connectors are colored coded for location
purposes. Those connectors associated with left side
accessories, such as the front and rear left turn signals, are
gray. All other connectors, including those associated with
right side accessories, are black. 1
NOTE
A DEUTSCH TERMINAL REPAIR KIT (Part No. HD-41475)
contains a selection of wire seals, internal seals, seal plugs,
secondary locking wedges, attachment clips and socket/pin
terminals. Also included is a compartmented storage box,
carrying case and a FLAT BLADE L-HOOK (Part No. HD- 2
41475-100) is used for the removal of all types of locking
1
wedges.

Separating Pin and Socket Housings

See Figure A-26. To separate the connector halves, Press the 1. External latch
external latch(es) (1) on the socket housing (2) while rocking 2. Socket housing
the pin (3) and socket housings. 3. Pin housing

NOTES Figure A-26. Deutsch DT Sealted Connector

• Generally, the socket housing is found on the accessory
side, while the pin housing is plumbed to the wiring har-
ness.
• Two-, three-, four- and six-place Deutsch connectors have
one latch on the connector.
• Eight- and twelve-place connectors have a latch on each
side. Simultaneously press both latches to separate the
connector.
Mating Pin and Socket Housings
1. Align the connectors to match the wire lead colors.
a. For One External Latch: Two-, three-, four- and six-
place Deutsch connectors have one external latch on
the socket half of the connector. To fit the halves of
the connector together, the latch on the socket side
must be aligned with the latch cover on the pin side.
b. For Two External Latches: (8-place and 12-place)
Align the tabs on the socket housing with the grooves
on the pin housing.
Removing Socket Terminals
1. See Figure A-27. Insert a small screwdriver between the
socket housing and locking wedge in-line with the groove
(in-line with the pin holes if the groove is absent). Turn the
screwdriver 90 degrees to pop the wedge up and remove
the secondary locking wedge.
2. See Figure A-30. Use a pick or small screwdriver to Press
terminal latches inside socket housing and back out
sockets through holes in rear wire seal.
NOTE
If wire leads require new terminals, see the instructions for
crimping terminals.
Installing Socket Terminals
1. Match wire lead color to connector cavity.
2. See Figure A-29. Fit rear wire seal (1) into back of socket
housing (2), if removed.

2. Insert socket housing into pin housing until it snaps or
clicks into place.
For Two External Latches: (8-place and 12-place) If
latches do not click (latch), press on one side of the con-
nector until that latch engages, then press on the opposite
side to engage the other latch.
3. If necessary, fit the attachment clip to the pin housing.
3. Grasp wire lead (3) approximately 1.0 in. (25.4 mm) behind
the socket terminal. Gently push socket through hole in
wire seal into its chambers until it "clicks" in place.
4. A tug on the wire will confirm that it is properly locked in
place.

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NOTE
sm00018
Seal plugs (6) are installed through the wire seals of unused
chambers. If removed, seal plugs must be replaced to seal the
connector.
5. Install internal seal (4) on lip of socket housing, if removed.
2

6. Insert tapered end of secondary locking wedge (5) into

socket housing and press down until it snaps in place. The
wedge fits into the center groove within the socket housing
and holds the terminal latches tightly closed.
NOTES
• See Figure A-28. While rectangular wedges do not require 1
a special orientation, the conical secondary locking wedge
of the 3-place connector must be installed with the arrow
(1) pointing toward the external latch.
• If the secondary locking wedge does not slide into the
installed position easily, verify that all terminals are fully
installed in the socket housing. The lock indicates when
terminals are not properly installed by not entering its fully
installed position.

1. Arrow on socket locking wedge

sm00009
2. Arrow on pin locking wedge
Figure A-28. Deutsch DT Sealed Connector: 3-Place
Locking Wedges

Figure A-27. Deutsch DT Sealed Connector: Remove

Secondary Locking Wedge

2011 Touring Diagnostics: Appendix A Connector Repair A-21

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alignment tabs differ between the black and gray con-

sm00010
nectors, plugs or receptacles must be replaced by those
of the same color.
• When replacing both socket and pin housings, then the
black may be substituted for the gray. The socket and pin
housings of all other connectors are interchangeable, that
is, the black may be mated with the gray, since the align-
ment tabs are absent and the orientation of the external
latch is the same.

sm00019

DEUTSCH

4 6

1 Figure A-30. Deutsch DT Sealed Connector: Depress

Terminal Latch and Back Out Pin
3
Installing Pin Terminals
1. Wire seal
2. Socket housing 1. See Figure A-31. Fit wire seal (1) into back of pin housing
3. Wire lead (2).
4. Internal seal 2. Grasp wire lead approximately 1.0 in. (25.4 mm) behind
5. Secondary locking wedge the pin terminal (3). Gently push pin through holes in wire
6. Seal plug seal into its respective numbered chamber until it "clicks"
Figure A-29. Deutsch DT Sealed Connector: 2, 3, 4 and in place.
12-Place Socket Housings NOTE
A tug on the wire lead will confirm that a pin is locked in place.

Removing Pin Terminals
1. Use the hooked end of a stiff piece of mechanics wire, a
needle nose pliers or the FLAT BLADE L-HOOK (Part
No. HD-41475-100) to remove the secondary locking
wedge.
2. Gently Press terminal latches inside pin housing and back
out pins through holes in wire seal.
NOTES
• If wire leads require new terminals, see the instructions
for crimping terminals.
• If it should become necessary to replace a pin or socket
housing, note that the 8-place and 12-place gray and black
connectors are not interchangeable. Since location of the
3. Insert tapered end of secondary locking wedge (4) into
pin housing and press down until it snaps in place.
NOTES
• The wedge fits in the center groove of the pin housing and
holds the terminal latches tightly closed.
• See Figure A-28. While rectangular wedges do not require
a special orientation, the conical secondary locking wedge
of the 3-place connector must be installed with the arrow
(2) pointing toward the external latch.
• If the secondary locking wedge does not slide into the
installed position easily, verify that all terminals are fully
installed in the pin housing. The lock indicates when ter-
minals are not properly installed by not entering its fully
installed position.

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sm00020
Crimping Terminals
3 Identify which of the types of Deutsch terminals are used with
1 the connector and follow the corresponding crimping instruc-
tions. Refer to Table A-1.

DEUTSCH

1. Wire seal
2. Pin housing
3. Pin terminal
4. Locking wedge
Figure A-31. Deutsch DT Sealed Connector: 2, 3, 4 and
12-Place Pin Housings

Table A-1. Deutsch Connector: Terminal Crimping Instructions

TYPE CRIMPING INSTRUCTIONS

DT Sealed (with crimp tails) A.13 DEUTSCH DT SEALED TERMINAL REPAIR
DTM Mini Sealed Terminal (solid A.15 DEUTSCH DTM SEALED SOLID BARREL MINI TERMINAL REPAIR
barrel)
DTM Mini Sealed Terminal (with crimp A.14 DEUTSCH DTM SEALED MINI TERMINAL REPAIR
tails)

2011 Touring Diagnostics: Appendix A Connector Repair A-23

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DEUTSCH DT SEALED TERMINAL REPAIR A.13

DEUTSCH DT SEALED TERMINAL CRIMPS straight upward. When positioned, the locking bar fits snugly
in the space between the contact band and the core crimp tails.
PART NUMBER TOOL NAME
4. Insert stripped wire core between crimp tails until ends
HD-39965-A DEUTSCH TERMINAL CRIMP TOOL make contact with locking bar. Verify that wire is positioned
so that short pair of crimp tails squeeze bare wire strands,
Preparing Wire Leads for Crimping while long pair folds over the insulation.
1. Use a shop gauge to determine gauge of wire lead. 5. Squeeze handle of crimp tool until tightly closed. Tool
2. Strip lead removing 5/32 in. (4.0 mm) of insulation. automatically opens after the terminal is crimped.
6. Raise locking bar up and remove wire lead and terminal.
Crimping Terminal to Lead
1. See Figure A-32. Squeeze the handles of the DEUTSCH Inspecting Crimps
TERMINAL CRIMP TOOL (Part No. HD-39965-A) to open Inspect the wire core and insulation crimps. Distortion should
the jaws. Push the locking bar (1) up. be minimal.
2. Insert (2) terminal (socket/pin) through hole of the locking
bar, so that the rounded side of the contact barrel rests in Table A-2. Deutsch DT Sealed Terminal Crimp:Wire Gauge
the nest (concave split level area) with the crimp tails To Die
facing upward. To match the wire gauge to the crimp tool
die, refer to Table A-2. WIRE GAUGE (AWG) CRIMP TOOL DIE
20 Front
3. Release locking bar to lock terminal in die.
16-18 Middle
NOTE
If the crimp tails are slightly out of vertical alignment, the crimp
tool automatically rotates the terminal so that the tails face

sm00021

4
3

1. Open jaws and raise locking bar 4. Insert stripped lead

2. Insert terminal in locking bar 5. Squeeze crimper
3. Release locking bar to lock terminal in die 6. Raise locking bar and remove terminal
Figure A-32. Crimping a Deutsch DT Sealed Terminal

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DEUTSCH DTM SEALED MINI TERMINAL

REPAIR A.14
DEUTSCH DTM SEALED MINI TERMINAL Inspecting Crimps
CRIMPS Inspect the core and insulation crimps. Distortion should be
minimal.
PART NUMBER TOOL NAME
HD-38125-7 PACKARD TERMINAL CRIMPER
sm00022

Preparing Wire Leads for Crimping

Strip wire lead removing 5/32 in. (4.0 mm) of insulation. 1
Crimping a Mini Terminal to Wire Lead
1. See Figure A-33. Compress the handles of PACKARD
TERMINAL CRIMPER (Part No. HD-38125-7) until the
ratchet (2) automatically opens.
NOTE
Always perform core crimp before insulation crimp.
2. Position the core crimp on die E (1) of the crimper. Be
sure the core crimp tails are facing the forming jaws.
3. Gently apply pressure to handles of tool until crimpers just
secure the core crimp tails.
4. Insert stripped wire core stands between crimp tails. Pos-
ition wire so that short pair of crimp tails squeeze bare 2
wire strands, while long pair squeeze over the insulation.
5. Squeeze handle of crimper until tightly closed. Tool auto-
matically opens when the crimping sequence is complete.
NOTE
If the crimper does not open, it can be opened by squeezing
the ratchet trigger (2).
6. Position the insulation crimp on nest C of the crimper. Be
sure the insulation crimp tails are facing the forming jaws.
7. Squeeze handle of crimp tool until tightly closed. Tool 1. E die
automatically opens when the crimping sequence is com- 2. Crimper ratchet trigger
plete.
Figure A-33. Packard Terminal Crimper (HD-38125-7)

2011 Touring Diagnostics: Appendix A Connector Repair A-25

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DEUTSCH DTM SEALED SOLID BARREL MINI

TERMINAL REPAIR A.15
DEUTSCH DTM SEALED SOLID BARREL
sm00023
TERMINAL CRIMPS 5
PART NUMBER TOOL NAME
HD-42879 ELECTRICAL CRIMPER TOOL 4
Preparing Wire Leads For Crimping
For size 20, 16 and 12 contacts, wire ranges 26-12 AWG.

Th use S'' a 19
be RES CFR
"P HA
OS

is
Strip wire lead removing 1/4 in. (6.4 mm) of insulation.

HA in s de 0.2
d
ND any fine 11
to pow d b (46)
ol
mu ere
1

st d
Adjusting Crimper Tool

no
1

t
1. See Figure A-34. Squeeze the ELECTRICAL CRIMPER
TOOL (Part No. HD-42879) handles to cycle the crimp 3
tool to open.
2. Remove locking pin (1) from selector knob (2).
3. Raise selector knob and rotate until selected wire size
2
stamped on wheel is aligned with "SEL. NO." arrow (3).
4. Loosen knurled locknut (4) and turn adjusting screw (5)
clockwise (in) until it stops.

Crimping a Barrel Contact To Wire Lead

1. See Figure A-35. Turn tool over and drop contact barrel
(1) into indentor cover (2) hole with the wire end out.
2. Turn adjusting screw counterclockwise (out) until contact
is flush with bottom of depression in indentor cover.
Tighten knurled locknut.
3. Slowly squeeze handles of crimp tool until contact is
centered between the four indentor points (3).
4. Insert bare wire core strands of stripped wire lead (4) into
contact barrel. Squeeze handle of crimp tool until tightly
closed. Tool automatically opens when the crimping 1. Locking pin
sequence is complete. 2. Selector knob
5. Remove wire lead with crimped contact from indentor. 3. SEL. NO. arrow
4. Knurled locknut
NOTE 5. Adjusting screw
Tool must be readjusted when changing contact size/type.
Figure A-34. Electrical Crimper Tool (HD-42879)
6. Install pin to lock selector knob.

Inspecting Crimps
Inspect the crimp. All core wire strands are to be crimped in
the barrel.

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sm00024

3 HE
HE MET
ME R
T, C YAN
A. A IN
92 IRPO USTRIAL
D

34
3-0 RT, PR
OD
16 P.O UCTS D
HD 1
(71. BOX ISION
IV

3 T- 4)
92 878
9-1
48 20
0
-0
JD 0
G3
60
-1

HE
HE MET
ME R
T, C YAN
A. A IN
92 IRPO USTRIAL
D

34
3-0 RT, PR
OD
16 P.O UCTS D
HD 1
(71. BOX ISION
IV

T- 4)
92 878
9-1
48 20
0
-0
J 0 DG
36
0-1

1. Contact barrel
2. Indentor cover
3. Indentor point
4. Stripped wire lead
Figure A-35. Deutsch Solid Barrel

2011 Touring Diagnostics: Appendix A Connector Repair A-27

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JAE MX19 SEALED CONNECTORS A.16

JAE MX19 SEALED CONNECTORS 2. See Figure A-37. Insert the extractor (1) into the opening
above the terminal and press the plastic molding (2) up
PART NUMBER TOOL NAME and out of the way.
B-50085 TERMINAL EXTRACTOR 3. Pull the wire lead and terminal out of the back of the
housing.
Connector Housings
Separate Housings: See Figure A-36. Press the two release Installing Terminals
buttons on each side of the housing to separate the connector. 1. Inspect the plastic molding and replace the connector
Connect Housings: Align and press the housings together housing if necessary.
until the locking tabs click. 2. Orient the terminal to the housing and push terminal into
the housing until it snaps into place.
sm06925

sm06926
2

2 1
1

Figure A-36. Release Buttons: JAE MX19 Sealed Connector

1. Extractor tool
2. Molding
Removing Terminals
Figure A-37. JAE MX19 Terminal Removal
1. Modify a TERMINAL EXTRACTOR (Part No. B-50085)
by filing the front edge to 45 degrees.

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MOLEX CMC SEALED CONNECTORS A.17

MOLEX CMC SEALED CONNECTORS
sm06936
Separating the Connector
Release: See Figure A-38. Press the catch and rotate the lever
arm down.
Connect: Press on the front guard to release the latch and 2
rotate the lever arm up until the catch clicks in place.

1
sm06931

1. Press latch
Figure A-38. Release 2. Press cap and latch
3. Remove cap
Figure A-39. Remove the Wire Lead Cap
Removing Terminals
1. With the lever arm open, cut the cable strap around the
wire bundle.
2. See Figure A-39. Open a wire cap latch with a small sm06928

screwdriver (1).
3. Maintain pressure on the cap and open the opposite latch
with the screw driver (2).
4. Slide the cap off (3).
5. See Figure A-40. Use the screwdriver to open the sec-
ondary lock. Pull the locking bar all the way out.
6. See Figure A-41. Locate the wire lead cavity by the alpha-
numeric coordinates.
7. See Figure A-42. Insert the pins of the CMC extractor tool
(1) into the access slots (2) of the terminal cavity and
retract the lead and terminal.

Installing Terminals Figure A-40. Molex CMC Sealed Connector Secondary

1. Orient the terminal to the housing cavity and snap the Lock
terminal in place.
2. Slide the cap over the lead bundle and snap the cap in
place.
3. Install a cable strap through the guide and around the lead
bundle.

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sm06927 sm06935

1
2 1
2

1
2

1. Alpha
2. Numeric
Figure A-41. Alpha - Numeric Coordinates
2

1. Extractor tool
2. Access slots
Figure A-42. Terminal Removal

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MOLEX MX 150 SEALED CONNECTORS A.18

MOLEX MX 150 SEALED CONNECTOR 5. With all terminals installed, push the secondary lock into
the socket housing to lock the wire terminals into the
REPAIR housing.
PART NUMBER TOOL NAME
HD-48114 TERMINAL REMOVER sm00040

Separating Pin and Socket Housings

See Figure A-43. Press the latch while pulling the pin and
socket housings apart.

Mating Pin and Socket Housings

1. Orient the latch on the pin housing to the latch pocket on
the socket housing so the rails on the outside of the pin
housings lines up with the tunnels on the socket housing.
2. Press the housings together until the latch clicks.

Removing Terminals
1. Pull the secondary lock up, approximately 3/16 in. (4.8
mm), until it stops.
a. Socket Housing: See Figure A-44. Use a small
screwdriver in the pry slot. The slot next to the
external latch provides a pivot point. Figure A-43. Molex MX 150 Sealed Connector: Latch
b. Pin Housing: See Figure A-45. Use needle nose
pliers to engage the D-holes in the center of the sec-
ondary lock.
sm03332
NOTE
Do not remove the secondary lock from the connector housing.
2. See Figure A-46. Insert TERMINAL REMOVER (Part
No. HD-48114) into the pin hole next to the terminal until
the tool bottoms.
a. Socket Housing: The pin holes are inside the ter-
minal openings.
b. Pin Housing: The pin holes are outside the pins.

3. Pressing the terminal remover to the bottom of the pin

hole, gently pull on the wire to remove wire terminal from
its cavity.

Installing Terminals
1. See Figure A-47. From the wiring diagram, match the wire Figure A-44. Secondary Lock Pry Slot (Socket Housing)
color to its numbered terminal cavity.
NOTE
Cavity numbers (1) are stamped on the housing at the ends
of the cavity rows. The cavity number can be determined by
counting the cavities up or down along the row from each
stamped number.
2. Orient the terminal so that the tang (2) opposite the open
crimp engages the slot (3) in the cavity.
3. Push the terminal into the cavity.
4. Gently tug on wire to verify that the terminal is captured
by the secondary lock.

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sm02851 sm00044
3
1

Figure A-45. Pull Up Secondary Lock (Pin Housing)

2
sm00043

1. Cavity number
2. Tang
3. Cavity slot
Figure A-47. Molex MX 150 Sealed Connector: Pin Cavities
and Wire Terminal

CRIMP TERMINAL TO LEAD

PART NUMBER TOOL NAME
HD-48119 TERMINAL CRIMPER

Figure A-46. Molex MX 150 Sealed Connector: Terminal
Remover (HD-48114)
Prepare Lead
1. Cut the damaged terminal close to the back of the terminal
to leave as much wire length as possible.
2. Strip approximately 3/16 in. (4.70-5.60 mm) of insulation
from the end of the wire lead.

NOTE
The strip length is the same for both pin and socket terminals
and for wire gauges from 22 to 14.

Prepare Tool
1. Identify the punch/die in the jaws of the TERMINAL
CRIMPER (Part No. HD-48119) for the wire gauge. Refer
to Table A-3.
2. Squeeze and release the handles to open the tool.
NOTE
The crimp tool automatically opens when the handles are
released.
3. See Figure A-48. Hold fully open tool at approximately 45
degrees.
NOTE
Do NOT tighten the locknut holding the locator bars. The bars
must float to accommodate the different terminal gauges.

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Position Terminal in the Punch/Die

Table A-3. Crimp Tool Wire Gauge Punch/Die
1. See Figure A-50. With the crimp tails up, place the terminal
AWG (WIRE GAUGE) PUNCH/DIE through the punch/die into the square opening in the
22 Left socket locator bar.
18-20 Middle a. Socket Terminal: See Figure A-49. A socket terminal
stops against the back face of the socket locator bar
14-16* Right (1).
* Crimp 16 AWG pin terminals in the 18-20 middle die.
b. Pin Terminal: See Figure A-51. The tip of a pin ter-
minal passes through the socket locator bar and stops
in the notch in the face of the pin locator bar.
sm02853

2. See Figure A-52. Ratchet the handles together until the

crimp tails are held in vertical alignment between the punch
and the die.

sm02855

Figure A-48. Open Terminal Crimper (HD-48119) at 45

Degrees

Figure A-50. Square Openings in Socket Locator Bar

sm02854

Insert Stripped Lead

See Figure A-53. Insert the stripped end (wire core) between
the crimp tails at an up angle until the wire core touches the
1 face of the socket locator bar above the square opening.
2 NOTES
• The insulation must extend through the insulation crimp
tails.
• Insert the wire with little or no pressure. Pressing on the
lead will bend the wire core.

1. Socket locator bar

2. Pin locator bar
Figure A-49. Terminal Locator Bars

2011 Touring Diagnostics: Appendix A Connector Repair A-33

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sm02856 sm02858

Figure A-51. Pin Terminal against Pin Locator Bar

sm02857
Figure A-53. Stripped Lead at Up Angle

Inspect Crimp
1. Inspect Crimp: Inspect the core and insulation crimp.
a. See Figure A-54. The core tails should be creased
into the wire strands at the core crimp (1).
b. Strands (2) of wire should be visible beyond the core
crimp but not forward into the terminal shell.
c. The insulation tails should be folded into the insulation
(3) without piercing or cutting the insulation.
d. Distortion should be minimal.

2. Test Crimp: Hold the terminal and pull the lead.

Figure A-52. Crimp Tails in Vertical Alignment between
Punch and Die
sm02859

1 3
Crimp Terminal to Lead 2
1. Holding the wire lead in position touching the locator face
at an angle, quickly and smoothly squeeze the crimp tool
closed.
2. Final squeeze the handles to open the tool and release
the terminal.
NOTE
A stuck or jammed tool can be opened by pressing the ratchet
release lever found between the handles. Do not force the
handles open or closed.
1. Core crimp
2. Wire strands
3. Insulation crimp
Figure A-54. Terminal Crimp

A-34 2011 Touring Diagnostics: Appendix A Connector Repair

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TYCO 070 MULTILOCK UNSEALED CONNECTOR A.19

TYCO 070 MULTILOCK UNSEALED
CONNECTOR REPAIR sm00002

2
PART NUMBER TOOL NAME
3
HD-41609 AMP MULTI-LOCK CRIMPER
SNAP-ON TT600-3 SNAP-ON PICK 4
General
Tyco 070 Multilock Unsealed connectors are found between
wire harnesses and component wiring and may be either
floating or anchored to the frame with attachment clips.
See Figure A-55. Attachment clips (1) on the pin housings are
fitted to T-studs on the motorcycle frame. The T-studs identify
OE connector locations. To maintain serviceability, always
return connectors to OE locations after service.
Obtain the necessary tools to repair the connector and ter-
minals.
1
NOTE
For terminal crimping use the AMP MULTI-LOCK
CRIMPER (Part No. HD-41609).
1. Attachment clip
Separating Pin and Socket Housings 2. Release button
3. Socket housing
1. If necessary, slide connector attachment clip T-stud to the
4. Pin housing
large end of the opening.
Figure A-55. Tyco 070 Multilock Unsealed Connector
2. See Figure A-55. Press the release button (2) on the
socket terminal side of the connector and pull the socket
housing (3) out of the pin housing (4).
Removing Terminals from Housing
Mating Pin and Socket Housings 1. See Figure A-56. Bend back the latch (1) to free one end
1. Hold the housings to match wire color to wire color. of secondary lock (2) then repeat on the opposite end.
Hinge the secondary lock outward.
2. Insert the socket housing into the pin housing until it snaps
in place. 2. Look in the terminal side of the connector (opposite the
secondary lock) and note the cavity next to each terminal.
3. If OE location is a T-stud, fit large opening end of attach-
ment clip over T-stud and slide connector to engage T- 3. Insert a pick or pin into the terminal cavity until it stops.
stud to small end of opening. NOTE
If socket/pin terminal tool is not available, a push pin/safety pin
or a SNAP-ON PICK (Part No. SNAP-ON TT600-3) may be
used.
4. Press the tang in the housing to release the terminal.
a. Socket: Lift the socket tang (8) up.
b. Pin: Press the pin tang (7) down.

NOTE
A "click" is heard if the tang is released.
5. Gently tug on wire to pull wire and terminal from cavity.

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NOTES
sm00013
• Up and down can be determined by the position of the
release button, the button is the top of the connector.
• On the pin side of the connector, tangs are positioned at
the bottom of each cavity, so the slot in the pin terminal
(on the side opposite the crimp tails) must face downward.
• On the socket side, tangs are at the top of each cavity, so
the socket terminal slot (on the same side as the crimp
5 tails) must face upward.
7
2. Gently tug on wire end to verify that the terminal is locked
in place.
2
3. Rotate the hinged secondary lock inward until tabs fully
3
engage latches on both sides of connector.

sm00005
1

2 1
4

– AMP

1 2 3

1 6

8 – AMP

1 2 3 4 5 6

1 2 3 4

1. Latch
2. Secondary lock open
3. Pin housing
4. Socket housing
5. Pin terminal 3
6. Socket terminal
7. Tang (pin)
8. Tang (socket)
Figure A-56. Tyco 070 Multilock Unsealed Connector: 5 6 7 8 9 10
Socket and Pin Housings

1. 3-place housing
Inserting Terminals into Housing 2. 6-place housing
3. 10-place housing
NOTE
Figure A-57. Tyco 070 Multilock Unsealed Connector:
See Figure A-57. Cavity numbers are stamped into the sec-
Cavity Numbers on Secondary Locks (socket housings
ondary locks of both the socket and pin housings. Match the
shown)
wire color to the cavity number found on the wiring diagram.
1. Hold the terminal so the catch faces the tang in the
chamber. Insert the terminal into its numbered cavity until Preparing Wire Leads for Crimping
it snaps in place.
1. Strip 5/32 in. (4.0 mm) of insulation from the wire lead.

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2. See Figure A-58 and Figure A-59. Select the pin/socket Crimping Terminals to Leads
terminals from the parts catalog and identify the insulation
crimp tails (1) and the wire crimp tails (2) and the groove NOTE
for the crimp tool locking bar (3). Crimping with the AMP Multi-lock Crimper is a one step opera-
tion. One squeeze crimps both the wire core and the insulation
3. Identify the wire lead gauge and the corresponding crimper
tails.
tool and nesting die. Refer to Table A-4.
1. See Figure A-60. Squeeze the handles to cycle the AMP
Table A-4. AMP Multilock Connector: Crimp Tool Wire MULTI-LOCK CRIMPER (Part No. HD-41609) to the fully
Gauge/Nest open position (1).
2. Raise locking bar by pushing up on bottom flange (2).
WIRE GAUGE NEST
20 Front NOTE
See Figure A-58 and Figure A-59. Hold the terminal with the
16 Middle insulation crimp tail (1) facing up. The tool will hold the terminal
18 Rear by the locking bar groove (3) and crimp the wire crimp tail (2)
around the bare wire of the stripped lead and the insulation
crimp tail around the insulation.
sm00004
3. See Figure A-60. With the insulation crimp tail facing
1 upward, insert terminal (pin or socket) (3) through the
locking bar, so that the closed side of the terminal rests
3 on the nest of the crimp tool.
4. Release locking bar to lock position of contact (4). When
correctly positioned, the locking bar fits snugly in the space
at the front of the core crimp tails.
5. Insert stripped end of lead (5) until ends make contact with
locking bar.
2
6. Verify that wire is positioned so that wire crimp tails
squeeze bare wire strands, while insulation crimp tails fold
1. Insulation crimp tail over the wire lead insulation.
2. Wire crimp tail 7. Squeeze handle of crimp tool until tightly closed. Tool
3. Locking bar groove automatically opens when the crimping sequence is com-
Figure A-58. Tyco 070 Multilock Unsealed Connector: Pin plete.
Terminal 8. Raise up locking bar (7) and remove crimped terminal.

sm00001

1
3

1. Insulation crimp tail

2. Wire crimp tail
3. Locking bar groove
Figure A-59. Tyco 070 Multilock Unsealed Connector:
Socket Terminal

2011 Touring Diagnostics: Appendix A Connector Repair A-37

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sm00007
Inspecting Crimped Terminals
See Figure A-61. Inspect the wire core crimp (2) and insulation
1 crimp (1). Distortion should be minimal.

sm00008
3
1
2

2
4

1. Insulation crimp
5 2. Wire core crimp
Figure A-61. Tydo 070 Multilock Unsealed Connector:
Terminal Crimp

1. Open position
2. Locking bar flange
3. Insert contact
4. Release locking bar
5. Insert lead
6. Squeeze
7. Raise locking bar
8. Remove crimped terminal
Figure A-60. Tyco 070 Multilock Unsealed Connector:
Terminal Crimping Procedure

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SEALED SPLICE CONNECTORS A.20

SEALED SPLICE CONNECTOR REPAIR 5. Squeeze the handles tightly closed to crimp the lead in
the insert (2). The tool automatically opens when the
PART NUMBER TOOL NAME crimping is complete.
HD-25070 HEAT GUN 6. Slide the connector to the other half of the metal insert.
HD-38125-8 PACKARD CRIMPING TOOL Insert the stripped wire lead (1) until it stops, and crimp
the lead in the insert (2).
HD-39969 ULTRA TORCH
HD-41183 HEAT SHIELD ATTACHMENT

General Be sure to follow manufacturer's instructions when using

Splice connectors and several OE ring terminal connectors
use heat shrink covering to seal the connection.
Preparing Wire Leads
NOTE
If adjacent wires are to be spliced, stagger the splices so that
the sealed splice connectors will not touch each other but are
located at different positions along the length of the wires.
1. Using a shop gauge, identify the gauge of the wire.
the UltraTorch UT-100 or any other radiant heating device.
Failure to follow manufacturer's instructions can cause a
fire, which could result in death or serious injury. (00335a)
• Avoid directing heat toward any fuel system component.
Extreme heat can cause fuel ignition/explosion resulting
in death or serious injury.
• Avoid directing heat toward any electrical system com-
ponent other than the connectors on which heat shrink
work is being performed.

2. Match the wire gauge to a sealed splice connector by color • Always keep hands away from tool tip area and heat shrink
and part number. Refer to Table A-5. attachment.
7. Use an ULTRA TORCH (Part No. HD-39969), or a HEAT
3. Using a wire stripper, cut and strip a length of insulation
GUN (Part No. HD-25070) with a HEAT SHIELD
off the wire ends. Refer to Table A-5 for the strip length.
ATTACHMENT (Part No. HD-41183), to heat the connector
from the center of the crimp (3) out to each end.
Table A-5. Sealed Splice Connectors
NOTE
WIRE GAUGE COLOR PART NO. STRIP LENGTH
It is acceptable for the splice to rest against the heat shrink
18-20 Red 70585-93 3/8 in. (9.5 mm) tool attachment.
(0.5-0.8 mm)
14-16 Blue 70586-93 3/8 in. (9.5 mm) Inspecting Seals
(1.0-2.0 mm) See Figure A-63. Allow the splice to cool and inspect the seal.
10-12 Yellow 70587-93 3/8 in. (9.5 mm) The insulation should appear smooth and cylindrical. Melted
(3.0-5.0 mm) sealant will have extruded out the ends (4) of the insulation.

NOTE
If any copper wire strands are cut off of the wire core, trim the
end and strip the wire again in a larger gauge stripper.

Splicing Wire Leads

NOTE
See Figure A-63. The connector is crimped twice - one side
and then the other.
1. See Figure A-62. Open the PACKARD CRIMPING
TOOL (Part No. HD-38125-8) ratchet by squeezing the
handles closed.
2. Match the connector color to the wire gauge crimp die in
the jaws and insert one end of the sealed connector.
3. Gently squeeze the handles until the connector is held in
the jaws.
4. See Figure A-63. Feed the stripped end of a wire into the
connector until the wire stops inside the metal insert (1).

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sm00050 sm00051

1 1

2
2 1

1. Red connector die 3

2. Blue connector die
3. Yellow connector die
Figure A-62. Packard Crimping Tool (HD-38125-8)
4 4

1. Wire lead in metal insert

2. Crimp metal insert
3. Center of crimp
4. Melted sealant
Figure A-63. Sealed Splice Connector

A-40 2011 Touring Diagnostics: Appendix A Connector Repair

TABLE OF CONTENTS

SUBJECT............................................................................................................................PAGE NO.
B.1 CONNECTORS........................................................................................................................B-1
B.2 WIRING DIAGRAMS.................................................................................................................B-7

APPENDIX B WIRING
NOTES
HOME

CONNECTORS B.1
CONNECTOR LOCATIONS Connector Number
Function/Location On wiring diagrams and in service/repair instructions, con-
nectors are identified by a number in brackets.
On the motorcycle, a connector can be identified by its function
and location. Refer to Table B-1. Repair Instructions
Place and Color The repair instructions in this service manual are by connector
type. Refer to Table B-1.
The place (number of wire cavities of a connector housing)
and color of the connector can also aid identification.

Table B-1. Connector Locations

NO. DESCRIPTION TYPE TERMINAL LOCATION

PROBE
COLOR
[1] Main to interconnect harness 16-place Molex MX 150 Sealed Gray Inner fairing - right radio support
(BK) bracket (FLH models)
Inner fairing - right side below radio
(FLT models)
[2] Main to interconnect harness 12-place MX 150 Sealed (GY) Gray Inner fairing - left radio support
bracket
[4] P&A Accessory 4-place Deutsch DT Sealed Black Under seat
(BK)
[5] Main fuse 2-place Delphi 800 Metripack Red Under left side cover
Sealed (BK)
[6] Audio to interconnect harness 6-place Deutsch DT Sealed Black Inner fairing - left side of radio (FLH
(BK) models)
Inner fairing - right fairing support
brace (FLT models)
[7] Rear fender lights harness 8-place Tyco 070 Multilock Gray Top of rear fender (under seat)
Unsealed (BK)
[12] Tour-Pak lights (rear facia lamp 3-place Tyco 070 Multilock Gray Inside Tour-Pak (inboard of upper
on FLHX) Unsealed (BK) frame tube on FLHX)
[13] Fuel tank harness 4-place Tyco 070 Multilock Gray Behind fuel tank (under seat)
Unsealed (BK)
[15] Main to interconnect harness 4-place Delphi 630 Sealed (BK) Gray Inner fairing - right fairing bracket
(FLH models)
Inner fairing - below radio (right side
FLT models)
[18] Right rear turn signal 2-place Tyco 070 Multilock Gray Circuit board under tail lamp
Unsealed (BK) assembly
[19] Left rear turn signal 2-place Tyco 070 Multilock Gray Circuit board under tail lamp
Unsealed (BK) assembly
[20] Console harness 16-place Molex MX 150 Sealed Gray Under seat
(BK)
[21] Indicator lamps 10-place Tyco 070 Multilock Gray Inner fairing - above radio (All except
Unsealed (BK) (All except Black FLHR/C)
FLHR/C) Under console (FLHR/C)
8-place Deutsch DTM Sealed
(BK) (FLHR/C)
[22] Interconnect to right handlebar 12-place Molex MX 150 Sealed Gray Inner fairing - right fairing support
switches (BK) (All except FLHR/C) bracket (All except FLHR/C)
6-place Molex MX 150 Sealed Inside headlamp nacelle - fork stem
(BK) (FLHR/C) nut lock plate (right side) (FLHR/C)

2011 Touring Diagnostics: Appendix B Wiring B-1

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Table B-1. Connector Locations

NO. DESCRIPTION TYPE TERMINAL LOCATION

PROBE
COLOR
[24] Interconnect to left handlebar 16-place Molex MX 150 Sealed Gray Inner fairing - left fairing support
switches (GY) (All except FLHR/C) brace (All except FLHR/C)
8-place Molex MX 150 Sealed Inside headlamp nacelle - fork stem
(GY) (FLHR/C) nut (left side) (FLHR/C)
[27] Radio 23-place Tyco Superseal Breakout Box Inner fairing - back of radio (right
Sealed (BK) side)
[28] Radio 35-place Tyco Superseal Breakout Box Inner fairing - back of radio (left side)
Sealed (BK)
[29] HDI position lamp Flag terminals Gray Back of headlamp
[30] TSM/TSSM/HFSM 12-place Deutsch DT Sealed Breakout Box Under right side cover
(GY)
[31] Front turn signals 6-place Tyco 070 Multilock Gray Inside headlamp nacelle - fork stem
Unsealed (BK) nut lock plate (left side) (FLHR/C)
[31L] Left front turn signal/auxiliary 4-place Tyco 070 Multilock Gray Inner fairing - left fairing support
lamp Unsealed (BK) brace (outboard side) (FLH models)
Inner fairing - left (outboard side)
(FLT models)
[31R] Right front turn signal/auxiliary 4-place Tyco 070 Multilock Gray Inner fairing - right fairing support
lamp Unsealed (BK) brace (outboard side) (FLH models)
Inner fairing - right (outboard side)
(FLT models)
[32] Front fender tip lamp jumper 2-place Tyco 070 Multilock Gray Inner fairing - below upper for bracket
harness (DOM) Unsealed (BK) (left side) (All except FLHR/C)
Inside headlamp nacelle (FLHR/C)
[33] Ignition Switch 3-place AutoFuse Unsealed Red Bottom of ignition switch (All except
(FLHR/C) FLHR/C)
Faston 250 Spade terminals Under console (FLHR/C)
(FLHX, FLHTK, FLHTC/U,
FLTRX/U) (BK)
[34] Right front speaker Tyco Insulated Spade terminals Gray Inner fairing (back of speaker)
(BK)
[35] Left front speaker Tyco Insulated Spade terminals Gray Inner fairing (back of speaker)
(BK)
[38] Headlamp Tyco Unsealed Spade (BK) Gray Inner fairing (back of headlamp) (All
except FLHR/C)
Inside headlamp nacelle (FLHR/C)
[39] Speedometer 12-place Delphi Micro 64 Breakout Box Inner fairing (back of speedometer)
Sealed (GY) (FLHTC/U, FLHTK, FLHX)
Instrument nacelle (back of speedo-
meter) (FLT models)
Back of speedometer (back of con-
sole) (FLHR/C)
[41] Rear right speaker/passenger 6-place Molex MX 150 Sealed Black Inside rear right speaker box
controls (BK)
[42] Rear left speaker/passenger 6-place Molex MX 150 Sealed Black Inside rear left speaker box
controls (BK)
[45] Rear fender tip lamp (DOM) 3-place Tyco 070 Multilock Gray Circuit board under tail lamp
Unsealed (BK) assembly
[47] Stator 3-place Dekko (BK) Green Bottom of voltage regulator (left side)
[50] CB antenna cable Inner fairing - back of CB module
[51] Radio antenna cable Inner fairing - back of radio (left side)

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Table B-1. Connector Locations

NO. DESCRIPTION TYPE TERMINAL LOCATION

PROBE
COLOR
[52] Radio antenna cable to mast Inside of Tour-Pak
[53] Console pod 12-place Deutsch DTM Sealed Black Rear of battery box (under seat)
(BK)
[64] Fuse block/relays Delphi PED 280 Unsealed Gray Under left side cover
[65] VSS 3-place Delphi GT 150 Sealed Gray Top of transmission case (under
(BK) starter)
[67] Accessory switch 4-place Tyco Mate-N-lok Gray Inside headlamp nacelle (FLHR/C)
Unsealed (BK)
[73] Auxiliary lamps 2-place Tyco 070 Multilock Gray Inside headlamp nacelle (FLHR/C)
Unsealed (W)
[76] Passenger headset 7-place DIN (BK) Below rear left speaker box
[77] Voltage regulator 2-place Dekko (BK) Green Bottom of voltage regulator (right
side)
[78] ECM 73-place Delphi Micro 64 Breakout Box Under seat
Sealed (BK)
[79] CKP sensor 2-place Deutsch DTM Sealed Brown Rear of lower front frame cross-
(BK) member
[80] TMAP sensor 4-place Bosch Compact 1.1M Gray Top of induction module
Sealed (BK)
[83] Ignition coil 4-place Delphi GT 150 Sealed Gray Bottom front of battery tray
(BK)
[84] Front fuel injector 2-place Molex BPT Sealed (BK) Purple Below fuel tank (left side)
[85] Rear fuel injector 2-place Molex BPT Sealed (BK) Purple Below fuel tank (left side)
[90] ET sensor 2-place Delphi GT 150 Sealed Gray Back of front cylinder (left side)
(BK)
[91] DLC 4-place Deutsch DT Sealed Black Under left side cover
(GY)
[93] Tail lamp 4-place Tyco 070 Multilock Gray Circuit board under tail lamp
Unsealed (BK) assembly
[94] Rear fender lights harness in 6-place Tyco 070 Multilock Gray Circuit board under tail lamp
circuit board Unsealed (BK) assembly
[95] Purge solenoid 2-place Delphi 150 Metripack Purple Under seat
Sealed (BK)
[105] Fairing cap switches 12-place Tyco 070 Multilock Gray Inner fairing - above upper fork
Unsealed (BK) bracket (right side)
[105A, Interconnect to nacelle switch 12-place Tyco 070 Multilock Gray Inside instrument nacelle (under
105B] harness Unsealed (BK) bezel) (FLT models)
[105C, Nacelle switch harness to 4-place Tyco 070 Multilock Gray Inside instrument nacelle (under
105D] speaker switch Unsealed (BK) bezel) (FLT models)
[107] Ambient Air Temperature (AAT) 3-place Tyco 070 Multilock Gray Steering head, left side (FLHTC/U,
sensor Unsealed (BK) FLHTK)
Inside instrument nacelle (under
bezel) (FLT models)
[108] Tachometer 12-place Delphi Micro 64 Breakout Box Inner fairing (back of tachometer)
Sealed (GY) Red (FLH models)
Instrument nacelle (back of tacho-
meter) (FLT models)
[109] Auxiliary lamps switch 4-place Tyco Mate-N-Lok Gray Inside headlamp nacelle (FLHR/C)
Unsealed (BK)

2011 Touring Diagnostics: Appendix B Wiring B-3

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Table B-1. Connector Locations

NO. DESCRIPTION TYPE TERMINAL LOCATION

PROBE
COLOR
[110] Voltmeter lamp 2-way Tyco Positive Lock Red Inner fairing (back of voltmeter)
Spade Unsealed (BK)
[111] Voltmeter 3-way Faston 250 Spade Red Inner fairing (back of voltmeter)
Unsealed (BK)
[112] Oil pressure gauge lamp 2-way Tyco Positive Lock Red Inner fairing (back of oil pressure
Spade Unsealed (BK) gauge)
[113] Oil pressure gauge 3-way Faston 250 Spade Red Inner fairing (back of oil pressure
Unsealed (BK) gauge)
[114] Air temperature gauge lamp 2-way Tyco Positive Lock Red Inner fairing (back of air temperature
Spade Unsealed (BK) gauge)
[115] Air temperature gauge 3-way Faston 250 Spade Red Inner fairing (back of air temperature
Unsealed (BK) gauge)
[116] Fuel gauge lamp 2-way Tyco Positive Lock Red Inner fairing (back of fuel gauge)
Spade Unsealed (BK)
[117] Fuel gauge 3-way Faston 250 Spade Red Inner fairing (back of fuel gauge) (All
Unsealed (BK) except FLHR/C)
Bottom fuel tank left side (FLHR/C)
[120] Oil pressure switch Push On Right Angle Molded Black Front right crankcase (FLHR/C)
terminal (BK)
[121] Rear stop lamp switch Tyco Insulated Spade terminals Red Mid-chassis, lower right side between
(BK) frame and exhaust pipe)
[122] Horn Flag terminals (BK) Red Between cylinders (left side)
[128] Starter solenoid Delphi 56 Spade terminal (W) Red Top of starter
[131] Neutral switch Push On Right Angle Molded Top of transmission (right side)
terminals (BK)
[132] Cigar lighter Tyco Insulated Spade terminals Red Inner fairing
[133] Jiffy stand sensor (if equipped) 3-place Molex MX 150 Sealed Rear of lower front frame cross-
(BK) member.
Gray HDI: Rear of lower front frame
crossmember.
[134] Sidecar BAS 3-place Delphi GT 150 Sealed Gray Under seat
[137] HO2 sensor rear exhaust 4-place Molex MX 150 Sealed Gray Under right side cover
header (BK)
[138] HO2 sensor front exhaust 4-place Molex MX 150 Sealed Gray Under right side cover
header (GY)
[139] Oil pressure sender 4-place Delphi 150 Metripack Gray Front right crankcase (FLHX, FLHTK,
Sealed (BK) FLHTC/U, FLTR/U/X)
[141] Fuel pump and fuel level 4-place Delphi GT 280 Sealed Gray Under console on top of fuel tank
sender (BK) canopy
[142] Security siren (optional) 3-place Delphi GT 150 Sealed Gray Under left side cover
(BK)
[143] Front fender tip lamp (if 2-place Tyco 070 Multilock Gray Under front fender tip lamp bracket
equipped) Unsealed (BK)
[149] Audio amplifier 24-place Tyco Ampseal Sealed Under Tour-Pak
(BK)
[158] Left handlebar switches (cruise 3-place Molex MX 150 Sealed Gray Inside headlamp nacelle (FLHR/C)
control) (BK)
[159] Right handlebar switches 3-place Molex MX 150 Sealed Gray Inside headlamp nacelle (FLHR/C)
(cruise control) (GY)

B-4 2011 Touring Diagnostics: Appendix B Wiring

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Table B-1. Connector Locations

NO. DESCRIPTION TYPE TERMINAL LOCATION

PROBE
COLOR
[160] B+ 1-place Delphi 480 Metripack Red Under seat
Unsealed (GY)
[166] ABS module 20-place Molex MX 150 Sealed Breakout Box Under right side cover
(BK)
[167] Front WSS 2-place Delphi 150 Metripack Gray Inner fairing - below upper fork
Sealed (BK) bracket (left side) (All except
FLHR/C)
Inside headlamp nacelle (FLHR/C)
[168] Rear WSS 2-place Delphi 150 Metripack Gray Under right side cover
Sealed (BK)
[179] Active exhaust actuator (if 5-place Tyco Superseal 1.5 Gray HDI: Under right side cover
equipped) Sealed (BK)
[184] CB module 12-place Deutsch (BK) Black Inner fairing - left side of radio
(FLHTC/U, FLHTK, FLHX)
[185] XM module, antenna 12-place Deutsch DTM Sealed Black Inner fairing - back of radio
(BK)
[187] Hands-free module 8-place Deutsch DTM Sealed Black Inner fairing
(BK)
[189] Heated handgrip to main har- 3-place Tyco 040 Unsealed Inside outer fairing, left side (FLHTK)
ness
[201] ABS diode 4-place Deutsch DT Sealed Black Under left side cover (below fuse
(BK) box)
[203F] ACR (front) 2-place Tyco Superseal 1.5 Bracket attached to the throttle body
Sealed
[203R] ACR (rear) 2-place Tyco Superseal 1.5 Bracket attached to the throttle body
Sealed
[204] TGS harness 6-place Molex MX 150 Sealed Gray Inner fairing - right fairing support
(BK) bracket (FLHT/C/K, FLHX)
Inner fairing - right side below radio
(FLT models)
Inside headlamp nacelle - fork stem
nut lock plate (FLHR/C)
[206] Heated handgrip interconnect 2-place Tyco 040 Unsealed Inside outer fairing, right side
(FLHTK)
[208] HFSM antenna jumper harness 4-place Deutsch DT Sealed Black Under right side cover
(GY)
[209] HFSM antenna 2-place Molex MX 64 Unsealed Gray Under seat
(BK)
[211] TCA 6-place Molex MX 150 Sealed Gray Right side of engine (induction
(BK) module)
[222] Console ignition switch intercon- 4-place Delphi 630 Sealed (BK) Gray Under seat (FLHR/C)
nect
[224] TGS 7-place Tyco Mini Multilock Handlebar throttle (inside right side
(BK) handlebar)
[226] Rear lighting jumper harness 12-place Delphi Micro 64 Breakout Box Rear fender tip fascia module (FLHX,
Sealed (GY) FLTRX)
[237] Right heated grip 2-place Tyco 040 Unsealed Inside handlebars, right side
[257] Rear lighting jumper harness 6-place Molex MX 150 Sealed Gray Under left side cover
(BK)

2011 Touring Diagnostics: Appendix B Wiring B-5

HOME

Table B-1. Connector Locations

NO. DESCRIPTION TYPE TERMINAL LOCATION

PROBE
COLOR
[258] Power outlet 2-place Tyco 070 Multilock Gray Inside Tour-Pak (FLHTK)
Unsealed (BK)
[262] Rear lighting jumper harness 12-place Delphi Micro 64 Breakout Box Rear fender tip fascia module (FLHX,
Sealed (GY) FLTRX)
[GND1] Harness grounds Ring terminals Under seat
[GND1A]
[GND2]

B-6 2011 Touring Diagnostics: Appendix B Wiring

HOME

WIRING DIAGRAMS B.2

WIRING DIAGRAM INFORMATION
ed03175
Wire Color Codes 5
Wire traces on wiring diagrams are labeled with alpha codes.
Refer to Table B-2. 3 4 6
For Solid Color Wires: See Figure B-1. The alpha code
identifies wire color.
1 2 7
For Striped Wires: The code is written with a slash (/) between

GN/Y
W
the solid color code and the stripe code. For example, a trace
labeled GN/Y is a green wire with a yellow stripe. 8
[21A] 1 2

Wiring Diagram Symbols [21B] 1 2

See Figure B-1. On wiring diagrams and in service/repair 9

GN/Y
instructions, connectors are identified by a number in brackets
[ ]. The letter inside the brackets identifies whether the housing 10
is a socket or pin housing. 1 2
A=Pin: The letter A and the pin symbol after a connector
number identifies the pin side of the terminal connectors. 13 11
B=Socket: The letter B and the socket symbol after a con-
nector number identifies the socket side of the terminal con- 12
nectors. Other symbols found on the wiring diagrams include
the following: 1. Connector number
Diode: The diode allows current flow in one direction only in 2. Terminal code (A=pin, B=socket)
a circuit. 3. Solid wire color
4. Striped wire color
Wire break: The wire breaks are used to show option variances
5. Socket symbol
or page breaks.
6. Pin symbol
No Connection: Two wires crossing over each other in a wiring 7. Diode
diagram that are shown with no splice indicating they are not 8. Wire break
connected together. 9. No connection
10. Circuit to/from
Circuit to/from: This symbol is used to identify there is a more
11. Splice
complete circuit diagram on another page. The symbol is also
12. Ground
identifying the direction of current flow.
13. Twisted pair
Splice: Splices are where two or more wires are connected
Figure B-1. Connector/Wiring Diagram Symbols
together along a wiring diagram. The location of the splice
indicated in the wiring diagram is not the true location of the
splice in the actual harness but to identify that the wires are
spliced to that circuit.
Ground: Grounds can be classified as either clean or dirty
grounds. Clean grounds are identified by a (BK/GN) wire and
are normally used for sensors or modules. These grounds
usually do not have electric motors, coils or anything that may
cause electrical interference on the ground circuit. The dirty
grounds are identified by a (BK) wire and are used for compon-
ents that are not as sensitive to electrical interference.
Twisted pair: This symbol indicates the two wires are twisted
together in the harness.This minimizes the circuit's electromag-
netic interference from external sources. If repairs are neces-
sary to these wires they should remain as twisted wires.

2011 Touring Diagnostics: Appendix B Wiring B-7

HOME

ed03115 Table B-2. Wire Color Codes

ALPHA CODE WIRE COLOR

1 A C E G J BE Blue
2
15 3
15 4
15 5
15
1 BK Black
6
15 7
15 8
15 9
15
BN Brown
64-1 2
10
15 GN Green
3
11 12
13
15 GY Gray
4 B D F H LGN Light Green

14 O Orange
A C E
15
15 16
15 PK Pink
17
R Red
18 19
15 20
15
64-2 TN Tan
21
15
3
V Violet
22
30 23
30 W White
4 B D F H
Y Yellow

1. Fuse block [64-1]

2. Brake
3. Accessory
4. P&A
5. Radio power/siren
6. Radio memory
7. Battery
8. ECM power
9. Pwr outlet
10. Exhaust CNTRL
11. System relay
12. Start relay
13. Fuel pump
14. Fuse block [64-2]
15. Instruments
16. Ignition
17. Lighting relay
18. Brake relay
19. Headlamp
20. Lights
21. Spare
22. ABS
23. Spare
Figure B-2. Fuse Block and Socket Terminals

B-8 2011 Touring Diagnostics: Appendix B Wiring

HOME

2011 TOURING WIRING DIAGRAMS

Wiring Diagram List

DIAGRAM LOCATION
Battery Power: FLHR/C Figure B-3
Battery Power: Except FLHR/C Figure B-4
Ignition Power: FLHR/C Figure B-5
Ignition Power: Except FLHR/C Figure B-6
Accessory Power: FLHR/C Figure B-7
Accessory Power: Except FLHR/C Figure B-8
Sensor Grounds Figure B-9
Right GND2: FLHR/C Figure B-10
Right GND2: Except FLHR/C Figure B-11
Left GND1: FLHR/C Figure B-12
Left GND1: 2011 Touring (Except FLHR/C) Figure B-13
MAIN HARNESS (1 OF 5): 2011 Touring (Except FLHR/C) without ABS Figure B-14
MAIN HARNESS (2 OF 5): 2011 Touring (Except FLHR/C) with ABS Figure B-15
MAIN HARNESS (3 OF 5): 2011 Touring (FLHR/C) without ABS Figure B-16
MAIN HARNESS (4 OF 5): 2011 Touring (FLHR/C) with ABS Figure B-17
MAIN HARNESS (5 OF 5): 2011 Touring Figure B-18
Fairing Harness: 2011 Touring Figure B-19
Indicators, Fairing Switches, Handlebar Switches: 2011 Touring Figure B-20
Starting Circuit: 2011 Touring Figure B-21
Rear Lighting, Charging System: 2011 Touring Figure B-22
Front Lighting, Console Harness, ABS: 2011 Touring Figure B-23
Security Circuit: 2011 Touring Figure B-24
Security Circuit: 2011 Touring With Anti-Theft Tracking Module Figure B-25
Ultra Radio RF Interconnect Circuit: 2011 Touring Figure B-26
Classic Radio Circuit: 2011 Touring Figure B-27
Ultra Radio Circuit: 2011 Touring Figure B-28
2-Place Intercom and Headset Audio: 2011 Touring Figure B-29
CAN and Module Audio Inputs to Ultra Radio: 2011 Touring Figure B-30

2011 Touring Diagnostics: Appendix B Wiring B-9

HOME

em00683

Speedometer Ignition Switch

Red
5 [39A] Band ACC
IGN

5 [39B] OFF

B+ ACC IGN [33A]

BN/GY

B [33B]
Battery

R
Main Power Main Fuse Voltage B+
3 [20A] At Starter 40A Regulator Connector
3 [20B] A B [5B] + [77B] [160B]
Optional
Security

R
[BATT]
BN/GY

BK
Siren BK

R
A [142A]
R R
A [142B] B [222A]
B [222B]
BN/GY

64-1B
R

R
2A

Battery 15A
BN/GY 2D 2C R

ECM ECM Power 15A

71 71 BE/GY BE/GY 2F 2E R

[78A] [78B]

BE/GY 3D 3 30
System
Relay

TSM/TSSM/HFSM
1 1 BN/GY

Lighting 30 3 1J R
[30A] [30B] Relay
(GY)
64-2B

Figure B-3. Battery Power: FLHR/C

B-10 2011 Touring Diagnostics: Appendix B Wiring

HOME

em00852
BK

Red
Band

Ignition Switch

ACC
Battery OFF
IGN
Main Power Main Fuse Voltage
At Starter B+
TSM/TSSM/ Optional 40A Regulator Connector B+ IGN ACC [33A]
HFSM Security [33B]
A B [5B] + [77B] [160B] 2
1 1 BN/GY Siren

BK
R

R
BK
[BATT]

R
[30A] [30B] A [142A]
(GY) A [142B] R R

BN/GY
ECM 64-1B
Radio Memory 15A
71 71 BE/GY R/O 2B 2A R
Battery 15A
[78A] [78B] BN/GY 2D 2C R

ECM Power 15A

BE/GY 2F 2E R

BE/GY 3D 3 30
System
Relay

4 4 BN/GY R/O A A R/O Lighting 30 3 1J R

Relay
[2A] [2B] [15A] [15B]
[185B]
BN/GY

64-2B
R/O 9 XM
5 [108B]
5 [108A] [186B]

R/O 9 Future
BN/GY

Tachometer ACC

[184D]
5 [39B]
5 [39A] R/O 3 3 R/O R/O 9 9 R/O R/O 9 C.B.

[6B] [6A] C.B. [184B] [184C]

Speedometer
R/O

R/O

(If Equipped)

10 20 [27B]
10 20 [27A]
R/O

R/O

Radio Future ACC

[175B] 1 5 [187B]
5 [187A]
R/O

Bluetooth
Antenna

[194B]
(Beige)
R/O 1

Hands Free Module

Figure B-4. Battery Power: Except FLHR/C

2011 Touring Diagnostics: Appendix B Wiring B-11

HOME

em00685
Oil Active Exhaust Ignition Switch
Pressure Neutral (HDI Only)
ACC

1 [179A] OFF
IGN

O
ABS
Module 1 [179B] [33A] B+ IGN ACC
(If Equipped) [33B]

LGN/R
A
TSM/
TSSM/

R/BK
19 [166A]
HFSM Speedometer
19 [166B]

O
2 2 GY
A [222A]
GY

6 [21B] 1 [39A]
[21A] A [222B]
[30A] [30B] 6 1 [39B]
(GY) 64-1B

R/BK
O
O Exhaust Control 15A
DLC LGN/R 3B 3A R/BK
Fuel Gauge
4 4 GY 1 [117B]
[20A] 1
1 [20B] P&A IGN (MAX) 2A

O
[91B] [91A] 1B 1A
O

Instruments 15A
Engine O 1D 1C R/BK
Stop
Switch Ignition 15A
3 3 GY GY 1F 1E R/BK

[22A] [22B] 87 5
Lighting 30 3
Relay
86 1 1G
85 2

64-2B

Figure B-5. Ignition Power: FLHR/C

B-12 2011 Touring Diagnostics: Appendix B Wiring

HOME

em00814

Oil Oil Air

Pressure Neutral Fuel Voltmeter Pressure Temperature
[116A] [110A] [112A] [114A]
[116B] [110B] [112B] [114B]
O

O
O 1 O 1 O 1 O 1
+ [117A] + [111A] + [113A] + [115A]
1 1 1 1
O

[117B] [111B] [113B] [115B]

Indicator 6 [21B]

O
Lamps 6 [21A]
(BK)
O

Ignition Switch
TSM/TSSM/HFSM 2 2 GY GY 19 19
ABS Module
(If Equipped)
ACC
OFF
[30A] [30B] [166B] [166A]

GY
IGN

(GY)
[33A] B+ IGN ACC

DLC 4 4 GY [33B] 3
Right Active Exhaust

R/BK
Turn [22A] [22B] 64-1B
GY
[91B] [91A] (HDI Only) Exhaust Control 15A
Switch
1 1 LGN/R 3B 3A R/BK
BE 3 3 GY GY 3 3 GY

O 1 1 O [179A] [179B]
P&A IGN (MAX) 2A
[1A] [1B] 1B 1A
(BK) Instruments 15A
O

O 1D 1C R/BK
[39B] 1 [108B] 1 Ignition 15A
[39A] [108A] GY 1F 1E R/BK
1 1
(BK) (GY)
87 5
Speedometer Tachometer
Lighting 30 3
Relay
86 1 1G
85 2

64-2B

Figure B-6. Ignition Power: Except FLHR/C

2011 Touring Diagnostics: Appendix B Wiring B-13

HOME

em00681 Ignition Switch

Tail Lamp
2 [93A]
2 [93B] ACC
IGN

OFF
Speedometer

O/W
[33A] B+ ACC IGN

6 [39A] 1 [94A] [33B] B A C

Rear
[39B] Lighting [94B]

R/GY
6 1
O/W

O/W
C [222A]
4 [20A] 2 [7B] C [222B]
4 [20B] 2 [7A] 64-1B

R/GY
Brake 15A
O/V 1B 1A
O/W

O/W
Accessory 15A
O/W 1D 1C R/GY

P&A 15A
O/R 1F 1E R/GY

R/GY 3H 3 30 Start
Relay
Accessory
Switch
[67A] 4 O/R
O/W

O/V 3A 5 87
1 2
O/W

Brake
Relay
O/R

1 [32A]
1 [32B] 1 [4A] 64-2B
Rear
Fender Stop Lamp Accessory
Tip Lamp Switch Connector
[121B-2]

Position Lamp
(HDI Only) Right Turn
Switch
O/W [29B-1]
O/W

[22B] [22A]

O/W 1 1 O/W O/W

Front Stop/Lamp
Switch

[24B] [24A]

O/W 1 1 O/W O/W Cruise On/Off

Switch

O/W
Horn
Switch
O/W

Left Turn
Switch

Figure B-7. Accessory Power: FLHR/C

B-14 2011 Touring Diagnostics: Appendix B Wiring

 Ignition
SPKR Switch ACC
HOME

CRUISE ACC OFF

IGN
em00853

Connectors Power
On FLTR Outlet [133A] B+ IGN ACC
Only (If Equipped)

O/BE
1

O/V
[133B]

O/R
[258B] 1
1 [105D]
R/GY

1 [105C] 64-1B
[121B-2] Brake 15A

BN/BE
Rear O/V 1B 1A
Stop Lamp Accessory 15A

O/BE
O/V
O/R
Switch O/W 1D 1C R/GY
9 4 1 [105B] P&A 15A
Accessory O/R 1F 1E R/GY
9 4 1 [105A] Connector Radio PWR/
(BK) (BK) 2 Siren 5A
[4A] 1

O/R
O/W
[1A] [1B] O/BE 1H 1G

O/BE
(BK)
HDI Only

O/W
O/R
Power Outlet
O/BE 9 9 O/BE BN/BE 2H 2G

[29B-1] [29B]
O/W
O/W 5 5 O/W Start
R/GY 3H 3 30
O/R 4 4 O/R
Relay
Right Turn
Switch Cigar

O/W
Lighter
(Except
O/R (FL/HTCU/HTK/TRU) FL/HTCU/HTK/TRU) O/V 3A 5 87
[22A] [22B] Brake

O/W
Relay

O/R
O/W O/W 1 1 O/W
64-2B

O/W
[132B] [132A]
O/W

[189B] 1
Front
Stop/ [189A] 1 2 [7A]
(FLHTC 2 [257A] (FL/TRX/HX)
Lamp 2 [7B]
Switch [24A] [24B] Heated Only) Canada Only) (FL/TRX/HX)
Hand Grips O/W
(If Equipped) 2 [257B] 2 [257B] 2 [257B]
O/W 1 1 O/W
1 [94B] Facia/
Rear Converter
O/W

Lighting
O/W

1 [94A] Module
O/W

Figure B-8. Accessory Power: Except FLHR/C

12 [226B] 12 [226B]
Horn Circuit 2 [7A]
Switch Board 12 [226A] 12 [226A]
2 [7B]
[27A] [27B] 2 [93A] Facia/
Taillamp Converter
O/W

2 [93B] Module
12 12 O/BE
1 10 [262A]
Rear [94B]

O/W
O/W
Radio

O/W
Lighting 1 [94A] 10 [262B]
[39B] 6 [108B] 6
Circuit
O/W

[39A] 6 [108A] 6 Board 10

Left Turn Rear 1 [94A]
Switch 2 [93A]
Taillamp Lighting 1 [94B]
2 [93B]

Accessory
Accessory

Circuit
Speedometer Board
Tachometer
2 [93A]
Taillamp
2 [93B]

2011 Touring Diagnostics: Appendix B Wiring B-15

HOME

em00679
TMAP
TCA TGS Sensor

1 [211A] 4 1 [204A] 1 [80A]

1 [211B] 4 1 [204B] 1 [80B]
Front HO2 Rear HO2

BK/W

BK/W

BK/GY

BK/GY
Sensor Sensor

2 [138B] 2 [137B]
2 [138A] 2 [137A]
GN/W

GN/W

ET
Sensor

B [90A]
B [90B]
BK/W

CKP

2 [79A]
2 [79B]
BK

BK/GY
GN/W

BK/W
BK

31 43 61 62 [78B]
31 43 61 62 [78A]

ECM

Figure B-9. Sensor Grounds

B-16 2011 Touring Diagnostics: Appendix B Wiring

HOME

em00678
BK
Right Fuel Pump
Turn Assembly Intank
BK
High C [141A]
Beam
C [141B]
BK Left
Turn

BK/GN
BK
[39A] [39B]

Indicator
7 [21B]
Speedometer 7 7 BK/GN
Lamps 7 [21A]

BK/GN
Optional

BK/GN
Fuel Security
DLC Gauge Siren
TSM/TSSM/HFSM
[91A] 2 [20A] 5 [117A] 4 C [142A]
12 12 BK/GN
(GY) [20B] [117B] 4 C [142B]
BK/GN

[30A] [30B]

BK/GN

BK/GN
BK/GN
[78A] [78B] (GY)

ECM 73 73 BK/GN
BK/GN

[133B] 3

[133A] 3

JSS
(HDI Only)
[24A] [24B]

BK/GN
Clutch
Lockout BK 8 8 BK/GN
Switch

Right GND 2

Figure B-10. Right GND2: FLHR/C

2011 Touring Diagnostics: Appendix B Wiring B-17

HOME

em00854

Fuel Pump
Assembly In Tank
C [141A]
C [141B] Optional
Security

BK/GN
Siren
70369-06 C [142A]
Fuel Tank [142B]
C
Harness

BK/GN
BK/GN
DLC
[91A] 2 TSM/TSSM/HFSM 3 [13B]
(GY)
BK/GN 12 12 BK/GN 3 [13A]

BK/GN
[30A] [30B]
[78A] [78B]
(GY)
ECM 73 73 BK/GN
BK/GN

[133B] 3
JSS
(HDI Only)

[2A] [2B]

BK/GN 12 12 BK/GN

[24A] [24B] (GY)(GY)

Clutch
Lockout BK 12 12 BK/GN
Switch [15A] [15B]

[27A] [27B] BK/GN C C BK/GN BK/GN

BK/GN
(BK)(BK)
11 11
BK/GN

BK/GN

Radio
19 19 BK/GN
Right GND 2
[39B] 7 [108B] 7
BK/GN

[39A] 7 [108A] 7
(BK) (BK)
[6B] 6 Speedometer Tachometer
[6A] 6
BK/GN

XM
BK/GN 10
[185B]
Future
BK/GN 10 ACC
[186B]

C.B.
BK/GN 10 10 BK/GN BK/GN 10 [184D]
[53A] [53B]
BK/GN

BK/GN

C.B. [184B] [184C]

BK/GN 4 4 (If Equipped) P&A ULTRA
Future ACC Overlay Harness
[175B] 2 6 [187B] (If Equipped)
6 [187A]
BK/GN

BK/GN 2 Differential Mic Out (-)

Hands Free Module

Figure B-11. Right GND2: Except FLHR/C

B-18 2011 Touring Diagnostics: Appendix B Wiring

HOME

em00855 [166B]
Left Turn And DOM
Running Lamp ABS 1 BK
Module
Right Turn And DOM (If Equipped)
Running Lamp 11 BK Fuel Sender/Pump
[13A] 4
Harness

BK

BK

BK
1 6 [31B]
1 6 [31A] [20A] 15

[20B] 15

BK

BK

BK
Active Exhaust
(HDI Only) GND 3
[179B] 2 BK 1

BK
Voltage
Regulator
- [77B]

BK
87 5
Lighting 30 3
Relay
86 1
85 2 2J BK

5 87

3 30 Brake
1 86
Relay
BK

BK 3B 2 85
(BK) A 64-2B
BK

BK

Fender
Tip Lamp
[38B]
BK

3 2 [32A]
BK

BK

Headlamp 2 [32B] [29B]

2 Neutral [4A]
Switch
4 5 [7A]
BK

HDI Position [131] Accessory 5 [7B]

Lamp Connector
BK

Front Fender
Tip Lamp
BK

(DOM only) Horn

BK

BK

3 [109A]
6 [94B]
AUX
Lamp [18B] 6 [94A]
Switch
[122]
[122B-1] Right Rear BK 2 2 [18A]
Turn Lamp
[19B]

Left Rear BK 2 2 [19A]

Turn Lamp Tail Lamp
4 4 BK
1 1 License
BK

BK
BK

BK 3 3 Plate Lamp
(HDI Only)
BK
[45B] [45A] [93A] [93B] BK
Left
GND 1 Chassis Grounds
Handlebar BK Fork Bracket
Ground Grounds
Frame BK BK
BK
Ground
Fender Tip
Lamp
(DOM Only)

Figure B-12. Left GND1: FLHR/C

2011 Touring Diagnostics: Appendix B Wiring B-19

et00383 Ground To Fork Spot SPKR Cruise ACC Fuel Sender/Pump
Bracket BK Right
Turn Jumper Harness
[GND 3]
Oil Air 4 [13A]

BK
High

BK/GN
FLT Models Only BK BK BK/GN Fuel Voltmeter Pressure Temperature
Beam

BK
[116A] [110A] [112A] [114A]

BK
3 BK
Left
BK
Turn [116B] [110B] [112B] [114B]

BK/GN
GND Indicator

BK
Lamps [105D]

BK

BK
4 1 2 BK 1 2 BK 1 2 BK 1 2 BK
[38B-2] + S + S + S + S Voltage

BK/GN
[21B] 5 4 [105C] 1 3 [117A] 1 3 [111A] 1 3 [113A] 1 3 [115A] Regulator 87 5
12 8 3 [105B] 2 2 2 2
[21A] 5 [117B] [111B] [113B] [115B] Lighting
3 BK 12 8 3 [105A] Connectors - [77B] 30 3
(BK) Relay

BK

BK

BK

BK
86 1

BK
GND (BK) On FLT Models

BK
BK

BK

BK
85 2 2J BK
[38B] Only
[29B-2] BK 5 87
Brake
Headlamp BK 3 3 TEMP Signal Air Temperature 3 30 Relay
Ground
[38A] HDI Only Sensor 1 86
If Equipped BK 3B 2 85
[107B] [107A] [64-2B]
(BK) Horn

BK
D D

BK

BK
BK BK

BK
To Rear
Cigar B A Lighting
Lighter [15A] [15B] [4A] 4 2 [258B]
BK (BK) Accessory Power
BK

BK
BK

BK
Connector Outlet

BK
[132B-2] [132A-2] [122A] [122B]
2 [32A] Neutral (If
3 [31RA] 3 [31LA] Switch
2 [189B]
2
[166B] Equipped)
[32B] 3 [31RB] 3 [31LB] Active Exhaust [131]
[189A]
2
(HDI Only)

BK
BK

Heated 1 (Except FL/HTCU/TRU)

BK

BK

ABS BK
Fender 2 [179B]
Tip 2 [143A] Hand Grips Module [257A] 4
(If Equipped) (If Equipped)

BK
BK
Lamp 2 [143B] 11 BK
(DOM Right Left (FL/TRX/HX Canada Only) (FLHTC Only) (FL/TRX/HX HDI Only) (FL/TRX/HX DOM Only)
BK

Only) Directional Directional (FL/HTCU/HTK/TRU)

And DOM And DOM [257B] 4 [257B]
[257B] 4 [257B] 4
Running Running 4
Lamp Lamp

BK

BK

BK
BK

BK
BK

BK

BK
(BK) [7A] 5
[7A] 5
[12B]

BK
3 [7B]

BK
5

BK
BK

BK
BK
3
[7B] 5
[12A] [226B] 1 7

BK
Left GND 1 [226B] 1 7 [226B] 1 7
[226A]

BK
BK
Stud 1 7
[94B] 6 [226A] 1 7 [226A]
Facia/Converter 1 7
Module [94B] 6 Facia/Converter Facia/Converter
4 5 Module Module
[262A] 5 10 5 6 7 11
[262B] 4 5 [262A] [262A]
[12-3B] [12-3A] [12-2A] [12-2B] [262B] 5 10 [262B] 5 6 7 11

BK
BK

BK
BK

BK
BK
BK
BK
BK 2 2 BK BK 2 2 BK
Tour-Pak Right Side

BK
Tour-Pak Left Side Marker Lights
Marker Lights
[94B] 6
BK

BK

[12-4B] 6 5 4 3 2 1 [94A]
[12-5B] Right Rear [18B]
Turn
Ultra Tour-Pak Lamp 1 1
Rear Marker/ BK 2 2 [18A]
Stop Lights
(If Equipped) Rear Lighting
[19B]
Left Rear
1 1
Turn 2 [19A]
BK 2
Lamp
4 4 BK
BK 1 1 3 3
2 2 2 2
BK 3 3 1 1
Fender Tip/License
Plate Lamp [45B] [45A] [93A] [93B]

Tail Lamp

Figure B-13. Left GND1: 2011 Touring (Except FLHR/C)

 Figure B-13. Figure B-13.
Left GND1: 2011 Touring (Except FLHR/C) Left GND1: 2011 Touring (Except FLHR/C)
et00384 BK
Optional Red
Security Band
TSM/TSSM/HFSM Siren Main Power Main Fuse Voltage B+ Ignition
Battery 1 1 A B C D [141A] At Starter 40A Regulator Connector Switch
BN/GY Fuel
Ignition 2 2 GY Pump [5B] [160B] 1 2 3
A B C D [141B] Start A B - + [77B] 1 [33B]

Ground
Serial Data 3 3 LGN/V

Signal
Power
Neutral Switch 4 4 TN Solenoid Battery

R
R

R
O/GY

BK

BK

R/GY
Y/W

R/BK
BK/GN

R
BK
Left Turn Feed 5 5 V 1 [128B] [BATT]
Right Turn Feed 6 6 BN Fuel Pump BK
A B C [142A]

R
Right Turn Switch Input 7 7 W/BN Assembly In Tank

GN
Left Turn Switch Input 8 8 W/V
Start Relay Control 9 9 TN/GN
A B C [142B] R R
Clutch Lockout Switch 10 10 BK/R

LGN/BN
BN/GY

BK/GN
Alarm Signal 11 11 LGN/BN

BK/GN
O/GY
Ground 12 12 BK/GN Fuel Tank [64-1B]

Y/W
Brake 15A

BK
Harness O/V 1B 1A
[30A] [30B] 1 2 3 4 [13B] Accessory 15A
(GY) O/W 1D 1C R/GY
1 2 3 4 [13A]
R/BE P&A 15A
O/R 1F 1E R/GY

O/GY
Y/W
BK/GN
BK
GN/O
Radio Power/
Siren 15A
BK/GN O/BE 1H 1G R/GY
BE/BK
GN 4G 5 87
See W/BE
Main R/GN R/GY 3H 3 30 Start
Harness LGN/V TN/GN 3G 1 86 Relay
(5 Of 5) GY BK/R 4H 2 85
Y/GN Radio MEM 15A
BE/GY R/O 2B 2A R
W/BK
BK Battery 15A
LGN/R BN/GY 2D 2C R

16 BE/BK Left GND 1 BK ECM PWR 15A

15 R/GN
14 W/BE
Stud BE/GY 2F 2E R
13 LGN/V Dirty BK Power Outlet
BN/BE 2H 2G R/GY
11 W/V
See 10 W/BN
9 O/BE Exhaust CNTRL 15A
Fairing 8 BN LGN/R 3B 3A R/BK
Harness 7 V
6 W/BK Fuel Pump 15A
5 O/W O/GY 4B 4A
4 O/R
3 GY
Y/GN 4C 5 87
1 O System
BE/GY 3D 3 30
Right GND 2 Relay
Stud BK/GN GN/O 3C 1 86
[1B] W/BK 4D 2 85
Clean BK/GN
12 BK/GN
11 BK/R
10 TN P&A IGN (MAX) 2A
9 GN/Y
See 8 BN/GN 1B 1A
Fairing 7 O
Y/BK
Instruments 15A
Harness 6
5 Y/W O 1D 1C R/BK
4 BN/GY Ignition 15A
3 BE GY 1F 1E R/BK
2 BK/R
1 R/BE

87 5 2G
[2B]
Lighting 30 3 1J R
D BK Relay
See 86 1 1G
C BK/GN
Fairing BE 85 2 2J BK
B
Harness A R/O
Headlamp 15A
BE 2D 2C
[15B]
Lights 15A
BE 2F 2E
R/BE

Spare 15A
O/W
TN
BK

Horn 3H 3G
Y/BK

Oil B A 1 2
BK

Pressure B BN/GN 2
BN/BE

A GN/Y
R/Y
BK

BE
Sender
BK

O/R
R/Y

O/V 3A 5 87
BK

O/W

R/Y
O

BN

BK

BE
(BK) Brake

V
[139B] [12B] 3 2 1 R/Y 2B 3 30
[258B] 2 1
[4A] Relay
1 1 2 3 4 (BK) Tour-Pak See Rear Lighting, R/BE 2A 1 86
Power Neutral Rear
Accessory BK 3B 2 85
Outlet [122A] [122B] Switch Stop Lamp See Rear Charging Circuit
[131] Switch Connector Lighting, [64-2B]
(FLHTCU,
FLHTK ONLY) [121] Charging Circuit

Figure B-14. MAIN HARNESS (1 OF 5): 2011 Touring (Except FLHR/C) without ABS
 Figure B-14. Figure B-14.
MAIN HARNESS (1 OF 5): 2011 Touring (Except FLHR/C) MAIN HARNESS (1 OF 5): 2011 Touring (Except FLHR/C)
without ABS without ABS
 et00385 BK
TSM/TSSM/HFSM Optional Red
Security Band
Battery 1 1 BN/GY See Siren Start Main Power
Ignition 2 2 GY Main Fuse Voltage B+ Ignition
Serial Data 3 Front Lighting, Solenoid At Starter 40A Regulator Connector Switch
3 LGN/V A B C D [141A]
Neutral Switch 4 4 TN Console Harness, Fuel 1 [128B]
Left Turn Feed 5 5 V ABS Pump [141B] A B [5B] - + [77B] 1 [160B] 1 2 3 [33B]

Ground
A B C D

Signal
Power
Right Turn Feed 6 6 BN Battery

R
R

R
GN

BK
Right Turn Switch Input 7

BK

R/GY
7

R/BK
R
W/BN [BATT]

O/GY
R/BN

Y/W
R/BE

BK/GN
GY
PK/BN
R/V
LGN/V

BK
BK
Left Turn Switch Input 8 8 W/V BK
Fuel Pump A B C [142A]

R
Start Relay Control 9 9 TN/GN
Clutch Lockout Switch 10 10 BK/R Assembly In Tank [142B]
Alarm Signal 11 A B C R
11 LGN/BN
Ground 12 12 BK/GN

LGN/BN
BN/GY

BK/GN
BK/GN
Brake 15A [64-1B]

O/GY
[30A] [30B]

Y/W

BK
Fuel Tank O/V 1B 1A
(GY) Harness Accessory 15A
1 2 3 4 [13B] O/W 1D 1C R/GY
R/BE 1 2 3 4 [13A] P&A 15A
O/R 1F 1E R/GY
GN/O

O/GY
Y/W
BK/GN
BK
Radio Power/
Siren 5A
BK/GN O/BE 1H 1G R/GY
BE/BK
See W/BE GN 4G 5 87
Main R/GN R/GY 3H 3 30 Start
Harness Relay
LGN/V TN/GN 3G 1 86
(5 Of 5) BK/R 4H 2 85
GY
Y/GN Radio MEM 15A
BE/GY R/O R
2B 2A
W/BK
BK
Battery 15A
BN/GY 2D 2C R
LGN/R
16 BE/BK
ECM PWR 15A
15 R/GN BE/GY 2F 2E R
Left GND 1 BK
14 W/BE Power Outlet
13 LGN/V Stud BN/BE 2H 2G R/GY
Dirty BK
11 W/V Exhaust CNTRL 15A
10 W/BN LGN/R 3B 3A R/BK
See 9 O/BE
Fuel Pump 15A
Fairing 8 BN
7 V O/GY 4B 4A
Harness 6 W/BK
5 O/W
4 O/R Y/GN 4C 5 87
3 GY
BE/GY 3D 3 30
System
1 O Relay
Right GND 2 GN/O 3C 1 86
W/BK 4D 2 85
[1B] Stud BK/GN
Clean BK/GN
12 BK/GN P&A IGN (MAX) 2A
11 BK/R
1B 1A
10 TN
9 GN/Y
8 BN/GN
Instruments 15A
See 7 O O 1D 1C R/BK
Fairing 6 Y/BK
Harness 5 Y/W Ignition 15A
4 BN/GY GY 1F 1E R/BK
3 BE
2 BK/R 87 5 2G
1 R/BN
Lighting 30 3 1J R
Relay
86 1 1G
[2B] 85 2 2J BK

Headlamp 15A
BE 2D 2C
D BK
See C BK/GN Lights 15A
Fairing B BE BE 2F 2E
Harness A R/O Spare 15A
3H 3G BK
[15B] ABS 30A
PK/BN

R/V 4B 4A R
O/W
TN
BK

Horn
Y/BK

B A 1 2 O/V 3A 5 87
BK

2
BN/BE

Brake
R/Y
R/Y 2B 3 30
BE
BK

Relay
BK

O/R
R/Y

BK

O/W
R/BE 2A 1 86

R/Y
O

BN
Oil

BK

BE
(BK)

V
B BN/GN [12B] 3 2 1 3B 2 85
Pressure A GN/Y [258B] 2 1
Sender 1 [4A] 1 2 3 4 Spare 30A
Power Neutral Rear Tour-Pak See Rear Lighting,
Switch Stop Lamp Accessory See Rear Charging Circuit BK 4H 4G
[139B] Outlet [122] Connector
(FLHTCU, [131] Switch Lighting, [64-2B]
FLHTK ONLY) [121] Charging Circuit

Figure B-15. MAIN HARNESS (2 OF 5): 2011 Touring (Except FLHR/C) with ABS
 Figure B-15. Figure B-15.
MAIN HARNESS (2 OF 5): 2011 Touring (Except FLHR/C) MAIN HARNESS (2 OF 5): 2011 Touring (Except FLHR/C)
with ABS with ABS
 et00386
Front Turn Ground To Console Fuel Gauge Optional Red
Signals Upper Triple Harness Security Band
G Siren
TSM/TSSM/HFSM See Clamp See Main Power Main Fuse Voltage B+
Front Lighting, [GND 3] Front Lighting, At Starter 40A Regulator Connector

BK/GN
1 S I Start
Console Harness, Console Harness,
Solenoid A B [5B] - + [77B] 1 [160B]

Ground
Battery 1 1 BN/GY ABS ABS

Signal
Power
BK
Ignition 2 2 GY

Y/W

O
Serial Data 3 3 LGN/V [31A] [20B] 1 [128B] Battery

R
R

BK
1 2 3 4 5 6 1 2 3 4 5 6 9 101112 1314 15

BK
Neutral Switch 4 4 TN [BATT] Ignition
Left Turn Feed 5 5 V
A B C [142A] BK
Switch

GN

R
O/W

Y/W

O/GY
BN/GY

BK/GN

GN/Y
LGN/V

BN
BN

TN

BK
BK

BE
BE

BK

V
V
Right Turn Feed 6 6 BN
Right Turn Switch Input 7 7 W/BN A B C [142B]
R
Left Turn Switch Input 8 8 W/V IGN

LGN/BN
Start Relay Control 9 9

BN/GY

BK/GN
ACC
TN/GN
Clutch Lockout Switch 10 10 BK/R OFF
Alarm Signal 11 11 LGN/BN
Ground 12 12 BK/GN Cruise/Brake 15A [64-1B] [33A]

BK/GN
B+ ACC IGN
O/V 1B 1A

Y/W
B C A [33B]

O
[30A] [30B] Accessory 15A
(GY) [117A] 1 2 4 O/W 1D 1C R/GY
P&A 15A

R/GY

R/BK
[117B] 1 2 4

R
O/R 1F 1E
R/BE

Y/W

BK/GN
O
GN/O
B C A [222A]
BK/GN GN 4G 5 87 B C A [222B]
BE/BK
R/GY 3H 3 30 Start

R/GY

R/BK
W/BE

R
See Relay
R/GN TN/GN 3G 1 86
Main Harness BK/R 4H 2 85
(5 Of 5) LGN/V
GY
Y/GN 2A R
BE/GY Battery 15A
W/BK BN/GY 2D 2C R
BK
LGN/R
ECM Power 15A
BE/GY 2F 2E R

Left GND 1 BK Exhaust Control 15A

LGN/R 3B 3A R/BK
Stud
FLHRC Only Dirty Fuel Pump 15A
BK
Left Hand Cruise O/GY 4B 4A
See Indicators, 2 R/GN
Fairing Switches, Y/GN 4C 5 87
Handlebar Switches System
BE/GY 3D 3 30
[158B] Relay
GN/O 3C 1 86
W/BK 4D 2 85
FLHRC Only
Right Hand Cruise
See Indicators, 2 BE/BK
Fairing Switches, 1 W/BE Right GND 2 P&A IGN (MAX) 2A
Handlebar Switches Stud BK/GN 1B 1A
Clean Instruments 15A
[159B]
O 1D 1C R/BK
Ignition 15A
6 BK/R GY 1F 1E R/BK
Right Hand Controls 5 W/BN
See Indicators, 4 W/BK
Fairing Switches, 3 GY
2 R/BE
Handlebar Switches 1 O/W 87 5 2G
Lighting 30 3 1J R
[22B] Relay
86 1 1G
85 2 2J BK
8 BK/GN
7 BK/R
Left Hand Controls 6 Y/BK Headlamp 15A
See Indicators, 5 W/V BE 2D 2C
Fairing Switches, 4 W
Handlebar Switches 3 BE Lights 15A
2 Y
1 O/W BE 2F 2E

Spare 15A
[24B] 3H 3G
O/W

BK

GN/Y

R/BE
O/W
TN
BK
GY/BK

GY/BK
GY/BK

[29B] Horn
Y/BK

1 2
O/W

O/V 3A 5 87
BK
BK
BK

B A 1 2
BK
W

O/R
Y
Y

2 Brake
O
HDI Position 1 R/Y 2B 3 30
[109A] 1 3 4 [73A] 2 1 [38B] 1 2 3 1 2 [32A] Lamp Relay

O/W
O/R
R/Y

R/Y
R/BE 2A 1 86
BK

BN

BK

BE
See Oil [67A]
O

1 4

V
BK 3B 2 85
Auxiliary Auxiliary Lamps Head- Fender Tip Front Pressure
Lamp Switch lamps Lamp 1 [4A] Accessory Switch
See Lighting, Neutral [120B] Rear 1 2 3 4 See
See Front Lighting, See See Rear Lighting, [64-2B]
Console [122] Switch Stop Lamp Accessory Front Lighting,
Front Lighting, Console Harness, Front Lighting, Harness, [131] Switch Charging
Console Harness, Console Harness, Connector Console Harness,
ABS ABS [121] Circuit
ABS ABS ABS

Figure B-16. MAIN HARNESS (3 OF 5): 2011 Touring (FLHR/C) without ABS
 Figure B-16. Figure B-16.
MAIN HARNESS (3 OF 5): 2011 Touring (FLHR/C) without MAIN HARNESS (3 OF 5): 2011 Touring (FLHR/C) without
ABS ABS
 et00387 Ground To BK
Front Turn Signals Upper Triple Fuel Gauge Optional Red
See Clamp Security Band
Front Lighting, Console
See 1 [GND 3] Harness G Siren Main Power Main Fuse Voltage
TSM/TSSM/HFSM Console Harness, Start At Starter B+
ABS Front Lighting, See Solenoid 40A Regulator Connector

BK/GN
BK
Console Front Lighting, S I
Battery 1 1 BN/GY [31A] 1 2 3 4 5 6 Harness, Console Harness, ABS 1 [128B] A B [5B] - + [77B] 1 [160B]

Ground
Signal
GY

Power
Ignition 2 2 Battery
ABS

Y/W

GN
Serial Data 3 3 LGN/V

BK
BK
R

R
1 2 3 4 5 6 9 10 1112 1314 15 [BATT] Ignition

BN
BK

BE
BE

BK
V
Neutral Switch 4 4 TN BK
Left Turn Feed 5 5 V [20B] Switch

R
R/BN

GY
[142A]

PK/BN
R/V
LGN/V

R/BE
BK
A B C

O/W

Y/W

O/GY
BN/GY

BK/GN

GN/Y
LGN/V

BN
W

TN

BK
O

V
Right Turn Feed 6 6 BN
Right Turn Switch Input 7 7 W/BN R
Left Turn Switch Input 8 8 W/V
A B C [142B] IGN
Start Relay Control 9 9 TN/GN
ACC

LGN/BN
BN/GY

BK/GN
Clutch Lockout Switch 10 10 BK/R OFF

Alarm Signal 11 11 LGN/BN [64-1B]

Ground 12 12 BK/GN Brake 15A B+ ACC IGN [33A]

BK/GN
O/V 1B 1A
[33B]

Y/W
B C A
Accessory 15A

O
[30A] [30B]
O/W 1D 1C R/GY
(GY) [117A] 1 2 4
P&A 15A

R/GY

R/BK
R
[117B] 1 2 4 O/R 1F 1E R/GY

Y/W

BK/GN
O
GN/O
B C A [222A]
BK/GN GN 4G 5 87 B C A [222B]
BE/BK Start
R/GY 3H 3 30

R/GY

R/BK
R
W/BE Relay
TN/GN 3G 1 86
See R/GN
BK/R 4H 2 85
Main Harness LGN/V
(5 Of 5) GY
2A R
Y/GN
BE/GY Battery 15A
W/BK BN/GY 2D 2C R
BK ECM Power 15A
LGN/R BE/GY 2F 2E R
Left GND 1 BK Exhaust Control 15A
LGN/R 3B 3A R/BK
Stud
Dirty BK Fuel Pump 15A
FLHRC Only O/GY 4B 4A
Left Hand Cruise
See Indicators, 2 R/GN Y/GN 4C 5 87
Fairing Switches, BE/GY System
3D 3 30
Handlebar Switches Relay
[158B] GN/O 3C 1 86
W/BK 4D 2 85

FLHRC Only
Right Hand Cruise 2 BE/BK P&A IGN (MAX) 2A
See Indicators, Right GND 2
1 W/BE Stud BK/GN 1B 1A
Fairing Switches,
Handlebar Switches Clean Instruments 15A
[159B] O 1D 1C R/BK
Ignition 15A
6 BK/R GY 1F 1E R/BK
Right Hand Controls 5 W/BN
See Indicators, 4 W/BK
Fairing Switches, 3 GY
2 R/BN
Handlebar Switches 87 5 2G
1 O/W
Lighting 30 3 1J R
[22B] Relay
86 1 1G
85 2 2J BK
8 BK/GN
7 BK/R Headlamp 15A
Left Hand Controls 6 Y/BK
See Indicators, 5 W/V BE 2D 2C
Fairing Switches, 4 W
Handlebar Switches 3 BE Lights 15A
2 Y BE 2F 2E
1 O/W
Spare 15A
[24B] 3H 3G BK
ABS 30A
R/V 4B 4A R
PK/BN
GN/Y

O/W
TN
BK
GY/BK

GY/BK
GY/BK

O/V 3A 5 87
Y/BK

Horn
O/W

O/W

O/R
B A 1 2
BK
BK

BK

BK
BK

O Brake
W

2
Y
Y

R/Y 2B 3 30
1 Relay
[29B]
O/R

2A 2 86
R/Y

[109A] 1 3 4[73A] 2 1 [38B] 1 2 3 1 2 [32A] 1 2 R/BE

O/W
[67A]
BK

R/Y
1 4

BN

BK

BE
O

3B 1 85

V
Oil BK
Auxiliary Auxiliary Lamps Headlamps Fender HDI Position Lamp Pressure Accessory
Lamp Switch See Tip Lamp See Front 1 Neutral [120B] Rear [4A] 1 2 3 4 Switch See Rear Spare 30A
See Front Lighting, See Lighting, Switch Accessory See Lighting, BK 4H 4G
[122] Stop Front Lighting,
Front Lighting, Console Harness, Front Lighting, Console [131] Lamp Switch Connector Charging [64-2B]
Console Harness, ABS Console Harness, Harness, Console Harness, Circuit
[121] ABS
ABS ABS ABS

Figure B-17. MAIN HARNESS (4 OF 5): 2011 Touring (FLHR/C) with ABS
 Figure B-17. Figure B-17.
MAIN HARNESS (4 OF 5): 2011 Touring (FLHR/C) with ABS MAIN HARNESS (4 OF 5): 2011 Touring (FLHR/C) with ABS
et00388
TGS Ignition
Coil

CKP
Rear Front Sensor
Injector Injector TMAP
[224A] 1 2 3 4 5 6
TCA
Sensor
[224B] 1 2 3 4 5 6
ET

Ion Sense

Coil Front
Coil Rear
GY
Sensor

BN
BK
BE
R
V

Power
DLC [204A] 1 2 3 4 5 6 [79A] 1 2
[85A] A B [84A] A B
[91A] 1 2 3 4 [204B] 1 2 3 4 5 6 [83A] A B C D
[85B] A B [84B] A B [80A] 1 2 3 4 [211A] 6 5 4 3 2 1 [79B] 1 2
(GY) [83B] A B C D [80B] 1 2 3 4 [211B] 6 5 4 3 2 1

Y/GN
W/Y
Y/GN
GN/GY
BK/W
BK/GN

BN/O
GY

R/W
LGN/V

BE/GN
BK/GY
V/Y

BK
R
[90A] A B

BK/W
Y/GN

BE/O

BN/O
BN/R
BK/O
Y/BE

BN/V
GY/BE

R/W
V/W

BK/PK
BK/GY
LGN/Y
[90B] A B
ECM [78A] [78B]

BK/W
PK/Y
18 18 BK
ACR Ground 19 19 V/GY
Purge Solenoid 20 20 GY/Y
Exhaust Actuator 21 21 V/O
Cruise/Set/Coast 22 22 BE/BK BE/BK
Rear Fuel Injector 23 23 GN/GY
TMAP Sensor Input 24 24 V/W
Brake Switch 25 25 R/BE R/BE

System Relay Enable 27 27 GN/O GN/O

Front Fuel Injector 28 28 W/Y
Twist Grip Hi 29 29 BK/O
Twist Grip Lo 30 30 BK/PK
HO2 Heater Ground 31 31 GN/W
BK/GN
Ion Sense 33 33 GY/BE
Cruise Resume/Accelerate 34 34 W/BE W/BE
Cruise Enable 35 35 R/GN R/GN
TPS 2 36 36 BN/R
TPS 1 37 37 BN/V
Exhaust Feedback 38 38 V/BE
TGS 2 39 39 V/Y
Vehicle Speed Input 40 40 W/GN LGN/V

See Main Harness (1-4 Of 5)

CKP Sensor (-) 43 43 +BK
GY
Rear HO2 Sensor 46 46 PK/GN
HO2 Return 48 48 BK/BN
IAT 49 49 LGN/Y
5V Sensor Power 1 50 50 BN/O
ET 51 51 PK/Y
Twisted System Relay Power 52 52 Y/GN Y/GN
Pair Rear Ignition Coil 53 53 Y/BE
Front Ignition Coil 54 54 BE/O

JSS 56 56 GN/BN
57 57 BK
TGS 1 59 59 BE/GN

5V Sensor Ground 1 61 61 BK/W

5V Sensor Ground 2 62 62 BK/GY
CKP Sensor (+) 63 63 R
Vehicle Speed Ground 64 64 BK/Y

Front HO2 Sensor 66 66 PK/O

5V Sensor Power 2 68 68 R/W

Serial Data 69 69 LGN/V

12V Battery 71 71 BE/GY BE/GY

Engine Stop Switch 72 72 W/BK W/BK

Ground 73 73 BK/GN BK

LGN/R

GN/BN
BK/GN
PK/GN
LGN/R

BK/BN

BK/BN
GN/W

GN/W

Y/GN

Y/GN
W/GN

V/GY

V/GY
Y/GN

Y/GN

Y/GN

BN/O

BN/O
GY/Y

PK/O
V/BE

BK/Y
V/O
BK

[179B] 5 4 3 2 1 B A [95B] 1 2 3 4 [138A] 1 2 3 4 [137A] [65B] A B C [133B] 1 2 3 [203BF] 1 2 [203BR] 1 2

Active Purge Front Rear VSS JSS Front ACR Rear ACR
Exhaust Solenoid HO2S HO2S (HDI Only) (If Equipped) (If Equipped)
(HDI Only)

Figure B-18. MAIN HARNESS (5 OF 5): 2011 Touring

 Figure B-18. Figure B-18.
MAIN HARNESS (5 OF 5): 2011 Touring MAIN HARNESS (5 OF 5): 2011 Touring
et00389 Headlamp 2
FLTRX
[38A-2 ] Only Fairing Harness Fairing Harness
1 W See Indicators, See Indicators, Oil Air
Hi Beam Fairing Switches, Fairing Switches, Fuel Voltmeter Pressure Temperature
2 Y Handlebar Switches Handlebar Switches [116A] [110A] [112A] [114A]
Lo Beam
3 BK Ground [21A] [105A]
To Upper
1 2 3 4 5 6 7 12 11 10 9 8 7 6 5 4 3 2 1 [116B] [110B] [112B] [114B]
GND (BK) (BK)
Triple Clamp

O/W
R/GN
GN/Y

BN/O

O/R
V/O
O/BE

GY/BK
BN

BK

TN

BK

BK

BK
O

O
V

Y
[38B-2] O 1 2 BK O 1 2 BK O 1 2 BK O 1 2 BK
[GND 3] + S + S + S + S
1 3 [117A] 1
2
3 [111A] 1 3 [113A] 1 3 [115A]
2 2 2

BK
1 W [117B] [111B] [113B] [115B]
Headlamp Hi Beam

Y/W

BN/GN

BE/V
O

O
BK

BK

BK

BK
[38A] 2 Y
Lo Beam
3 BK
HDI Only GND
[38B]
[29B] BK (BK)
O/W [107B] [107A]
[22B]
BE/V 1 1
2 2 TEMP Signal
1 O/W BK 3 3 Ground
2 R/BE
3 GY Air
4 W/BK Temperature
Right Hand Controls 5 W/BN [1A]
See Indicators, 6 BK/R
Sensor
Fairing Switches, 7 BN/W
8 GY/W BE/BK 16
Handlebar Switches 9 PK/W R/GN 15
10 V/BK W/BE 14
11 W/BE LGN/V 13
12 BE/BK
W/V 11
W/BN 10 See Main
O/BE 9 Harness
[24B] BN 8 (1 Or 2 Of 5)
V 7
W/BK 6
14 O/BK O/W 5
13 V/BK O/R 4
12 BK/GN GY 3
11 GY/GN
Left Hand Controls 10 GN/BE O 1
See Indicators, 9 PK/W
Fairing Switches, 8 BN/BK [2A]
7 BK/R
Handlebar Switches 6 Y/BK
5 W/V BK/GN 12
4 W BK/R 11
3 BE TN 10
2 Y GN/Y 9
1 O/W BN/GN 8 See Main
O 7 Harness
Y/BK 6
[27B] Y/W 5
(1 Or 2 Of 5)
BN/GY 4
BE 3
1 LGN/BK BK/R 2
2 BE/Y R/BE 1
3 PK/W
4 GY/W [15A]
5 V/BK
6 BN/W
7 O/BK BK D
8 BN/BK
See Main
See BK/GN C
9 LGN/V BE B Harness
Classic/Ultra 10 R/O R/O A (1 Or 2 Of 5)
Radio Circuit 11 BK/GN

BN/GY

BK/GN

BN/GY

BK/GN
LGN/V

LGN/V
12 O/BE

O/W

O/W
Y/W
BK

BK
13 BN/O

O
15 V/GY
16 W/O On All Except FLTRX [39B] 1 2 5 6 7 8 9 11 [108B] 1 2 5 6 7
17 LGN/W
18
[39A] 1 2 5 6 7 8 9 11 [108A] 1 2 5 6 7
GY/R
19 BK/GN (BK) (GY)

Ignition
Serial Data

Battery
Accessory
Ground

Reset Switch

Ignition
Serial Data

Battery
Accessory
Ground
Tri p Sswitch
Fuel Level
Trip Odometer-
20 R/O
O/R
21 V/O
22 GY/GN
GY/BK

GY/BK
23 GN/BE BK
BN
BK
BE

BK

BE

BK

BE
V
[132B] [132A]
BK/GN

[34B] 2 1 [32A] 4 3 2 1 [31RA] 4 3 2 1 [31LA]

V/GY
BE/Y

Cigar
R/O

Right Front LGN/BK Front Fender RH Front LH Front Lighter

O/R

BK
Speaker GY/R Tip Lamp Turn Signal Turn Signal RPM x 100
[6B] 6 3 2 1
See See See
Audio Harness Front Lighting, Front Lighting, Front Lighting, 1 2 [189B]
See Console Harness, Console Harness, Console Harness, Trip Odometer
[35B] ABS ABS ABS Reset Switch Heated Grips
Classic/Ultra (If Equipped)
Radio Circuit [154A]
Left Front LGN/W
Speaker W/O

Speedometer Tachometer

Figure B-19. Fairing Harness: 2011 Touring

 Figure B-19. Figure B-19.
Fairing Harness: 2011 Touring Fairing Harness: 2011 Touring
et00390

SPOT SPKR CRUISE ACC

Right Hand
Connectors Controls
On FLT Right Hand
Models Controls
Only

GY/BK

R/GN

O
BK/GN
O/BE
Y
Except

O/V

O/R
FLHR/C

BN/O

BK/GN
V/O
BK

BK
Radio Function Switch
Right Turn Switch
Right Turn Switch
Engine Stop Switch

BK/GN
BN/O
O/BE
Engine Stop Switch

V/O
Start Switch
Cruise Set/Resume Switch Start Switch
1 2 3 4 [105D] (FLHRC Only) Cruise Set/Resume Switch
1 2 3 4 [105C] (Ultra Models Only)
(BK) [22A] Front Stop
Front Stop

BN/O
BK/GN
O/BE
V/O
Lamp Switch Lamp Switch
O/W 1
R/Y 2 O/W 1
GY 3 See Main Harness R/Y 2
GY 3
W/BK 4 (3 Or 4 of 5) W/BK 4
W/BN 5 W/BN 5
BK/R 6 BK/R 6 See Fairing Harness
BN/W 7
GY/W 8
PK/W 9
V/BK 10
(BK) [159A] W/BE 11
BE/BK 12
See Main Harness
BK/GN

GY/BK

R/GN
BN/O

2
O/BE

BE/BK
(3 Or 4 of 5)
O/R
V/O

O/V
BK

BK

[22A] (BK)
O

W/BE
Y

1 Except
(FLHRC Only)
12 1110 9 8 7 6 5 4 3 2 1 [105B] FLHR/C
Fairing Harness O/BK 14
See Fairing Harness V/BK 13
BK 12
FLHR/C GY/GN 11
GN/BE 10
PK/W 9
BN/BK 8
(GY) [24A] BK/R 7 See Fairing Harness
Y/BK 6
1 W/V 5
O/W
W 4
Y 2
BE 3
BE 3 Y 2
Fairing Harness
W 4 See Main Harness O/W 1
See Fairing Harness W/V 5 (3 Or 4 of 5)
Y/BK 6
[24A] (GY)
1 2 3 4 5 6 7 [21B] (BK) BK/R 7
Except BK 8
W
GN/Y
BN

O
BK

TN
V

FLHR/C

Indicator
Lamps Clutch Lockout Switch
(GY) [158A]
BN Right See Main Harness PTT & SQ (Push To Talk & Squelch)
BK Turn R/GN 2 (3 Or 4 of 5) (Ultra Models Only)
Clutch (FLHRC Only)
Lockout Switch Horn Switch
GN/Y Oil
O Pressure Cruise On/Off Switch Headlamp Hi/Lo Switch
(FLHRC Only)
Horn Switch Left Turn Switch
TN Lights Hi/Low Switch
Neutral
O Radio Audio Control
Left Turn Switch
W High
BK Beam
Left Hand
V Left Controls Left Hand
BK Turn Controls

Figure B-20. Indicators, Fairing Switches, Handlebar Switches: 2011 Touring

 Figure B-20. Figure B-20.
Indicators, Fairing Switches, Handlebar Switches: 2011 Indicators, Fairing Switches, Handlebar Switches: 2011
Touring Touring
et00391
[266B] [266A]

GN GN D D Start Relay Input Anti-Theft

TN/GN C C Start Relay Enable Tracking
Module
TN/GN

TN/GN
[208A] [208B]
[209B] [209A]
Receive Antenna 1 1 Y/BK
HFSM Xmit Antenna A 2 2 O/Y O/Y 1 Xmit Antenna A
Xmit Antenna B 3 3 BK BK 2 Xmit Antenna B C [267B]
C [267A]
Battery 1 1 BN/GY (Except
TSM/TSSM Ignition 2 2 GY
Anti-Theft (Anti-Theft

TN/GN

TN/GN
Serial Data 3 3 LGN/V
Neutral Switch 4 4 TN Tracking Tracking
Start Relay Control 9 9 Module) Module)
Clutch Lockout Switch 10 10 BK/R
Ground 12 12 BK/GN

[30A] [30B]

Main Fuse
[78A] [78B] 40A

BK

BK
ECM
Serial Data 69 69 LGN/V Red
Right Hand Band [5B]
Controls Engine Stop Switch 72 72 W/BK
A B

BK
Battery

R
R
R
[128A] [128B]
Engine Stop Switch
Start Switch (Black) GN
[1A] [1B]
[22A] [22B] Except
FLHR/C Starter
GY 3 3 GY

BK
W/BK 6 6 W/BK BK/GN

BK
GY 3 3 GY GY GY
W/BK 4 4 W/BK W/BK W/BK [222B] [222A] [33B] [33A]
BK/R 6 6 BK/R GY
FLHR/C W/BK
Right Left R/GY C C R/GY C ACC ACC

GND 2 GND 1 Ignition

R B B R B IGN IGN
Clean Dirty Switch
OFF
R/BK A A R/BK A B+
(Gray)
Except [2A] [2B]
FLHR/C R/GY
[24A] [24B]
R
BK/GN 12 12 BK/GN
Except
11 11 FLHR/C [64-1B] R/BK
BK 12 12 BK/GN BK/R BK/R 4G 5 87
BK/R 7 7 BK/R BK/R 2 2 BK/R
GN [33B] [33A]
TN 10 10 TN R/GY 3H 3 30 Start
BK BK/GN TN/GN 3G 1 86 Relay R/GY 1 ACC
BK/GN BK/GN ACC

BK/R 4H 2 85
BK/R
[24A] [24B] BK/R BK/R Ignition
BK/R R 2 IGN IGN

Battery 15A Switch

OFF
Clutch Lockout BK 8 8 BK/GN BK/GN R/BK 3 B+
BN/GY 2D 2C R
Switch BK/R 7 7 BK/R
BK/R BK/R
BK/R
BK/R TN
TN 13 13 TN
FLHR/C TN [64-2B]
GY
Ignition 15A
[20A] [20B] FLHR/C GY 1F 1E R/BK
TN

87 5 2G
FLHR/C Except FLHR/C Lighting 30 3 1J R
Left Hand Left GND 1 Relay 86 1 1G R/BK
Controls Dirty 85 2 2J BK
[21A] 5 [21A] 7

TN
BK
(BK) (BK)
[21B] 5 6 [21B] 7 6 B A
O

O
TN

TN

[131]
Neutral Neutral
Neutral
TN TN Switch
R R

Figure B-21. Starting Circuit: 2011 Touring

 Figure B-21. Figure B-21.
Starting Circuit: 2011 Touring Starting Circuit: 2011 Touring
et00392

(FL/TRX/HX Canada Only) (FL/TRX/HX HDI Only)

See Main Harness See Main Harness
(1 Or 2 Of 5) (1 Or 2 Of 5) Stator
[77B] [77A] [47A] [47B]
(FL/TRX/HX DOM Only)

O/W

R/Y
BN

BK

BE
O/W

R/Y
See Main Harness +

V
BN

BK

BE
V
(1 Or 2 Of 5) BK BK
1 2 3 4 5 6 BK BK
1 2 3 4 5 6 [257A]
[257A] - DC AC BK BK

BK
BK
[257B]

O/W
1 2 3 4 5 6

R/Y
[257B]

BN

BK

BE
1 2 3 4 5 6

V
O/W

R/Y
BN

BK

BE
Main Fuse

V
O/W

R/Y
BN

BK

BE
1 2 3 4 5 6

V
[257A] 40A
[257B] Charging System
1 2 3 4 5 6

BK
O/W

R/Y
BN

BK

BE
V
[5B]

R
(FLHTC Only) B A
See Main Harness

R
R
(1 Or 2 Of 5)

O/W
R/Y
BN
BK

BE
BK
O/W
R/Y

V
BN
BK

BE
BK
O/W

V
R/Y
BN

BK

BE
V

[226B] 1 3 4 5 6 7 12 [226B] 1 3 4 5 6 7 12
(Except [257A] 1 2 3 4 5 6 [226A] BK
[226A] 1 3 4 5 6 7 12

O/W
R/Y
FL/TRX/HX/HTC)

BN
BK

BE
BK
1 3 4 5 6 7 12

BK

BK
V

R
BK
See Main Harness [257B] 1 2 3 4 5 6

BK
(1 Or 2 Of 5) Facia/ [226B] 1 3 4 5 6 7 12 Red
Facia/ Converter
Converter [226A] Band
O/W

R/Y

Module
BN

BK

BE

1 3 4 5 6 7 12
V

Module
O/W

R/Y
BN

BK

BE
V

1 2 3 4 5 7 8 9 10 11
1 2 3 4 5 7 10 [262A] Facia/ Left Right
[7A] 1 2 3 5 6 7 [7A] 1 2 3 5 6 7 [262A] Converter GND 1 GND 2
[262B] 1 2 3 4 5 7 8 9 1011
Module Dirty Clean Starter
[7B] 1 2 3 5 6 7 [7B] 1 2 3 5 6 7 [262B] 1 2 3 4 5 7 10 Battery

R/W
Y/W
GN/W

GN
W/BK

BK
R

Y
BK
1 2 5 6 7 8 9 11

O/W
R/Y
BN
BE

BK
BK
V [262A]
O/W
O/W

R/Y
BN

BK

BE
V
R/Y
BN

BK

BE
V

[262B] 1 2 5 6 7 8 9 11

V/BN

BK
BK
BK
BE
BE
BK
V
Ultra Tour-Pak
Rear Marker/
Tour-Pak Right Side Stop Lights
Marker Lights (If Equipped)
O/W
R/Y
O/W

BN
O/W

R/Y

BK

BE
R/Y

BN
BK

BE
BN
BK

BE

[12-4B]
V
V

See Figures
[94B] 6 5 4 3 2 1 [94B] 6 5 4 3 2 1 [94B] 6 5 4 3 2 1 B-14, B-15
BK
3 2 1 [12A]

BE
BK
R/Y

R/Y
BK

BE
BE
[12-2A] 1 2
6 5 4 3 2 1 [94A]
Right Rear [18B] Rear Lighting [12-2B] 1 2
Turn Tail
BK

BE
BK
Lamp V/BN 1 1 Stop
BK 2 2 [18A] R/Y
BE
[19B]
Brake Light [12-5B]
Left Rear BK
V/BN 1 1 R/Y
Turn 2 [19A]
BK 2 O/W
Lamp BE/W

BE
BK
4 4 BK
BK 1 1 3 3 R/Y
2
[12-3B] 1 2
2 2 2 O/W
BK 3 3 1 1 BE/W [12-3A] 1 2
Fender Tip/License Running Light (DOM )
Running Light (HDI) Tail Lamp
Plate Lamp

BE
BK
[45B] [45A] [93A] [93B]

Tour-Pak Left Side

Marker Lights

Figure B-22. Rear Lighting, Charging System: 2011 Touring

 Figure B-22. Figure B-22.
Rear Lighting, Charging System: 2011 Touring Rear Lighting, Charging System: 2011 Touring
et00393
See Except
[166A] [166B] Main Harness FLHR/C
(3 Or 4 Of 5)
ECU/Solenoid Ground 1 1 BK
FLHR/C See
[31B] 1 2 3 4 5 6 Right
Rear Brake Input 3 3 PK/BN
Main Auxiliary
Harness

BN
BK

BE
BE

BK
V
Lamp
Rear Wheel Speed (-) 7 7 BE/V [201B] [201A] (3 Or 4 Of 5)
Right
Rear Wheel Speed (+) 8 8 BE/BN Auxiliary 2 1 [73B]
Serial Data 9 9 LGN/V 4 4
Lamp (BK)

GY/BK
GY/BK
R/BE Except

BK
ECU/Solenoid Power 10 10 R/V
Motor Ground 11 11 BK R/BE 3 3 FLTRX [73RB]
Front Brake Input 13 13 R/BN R/BN 2 2 [73RB] GY/BK [31RB]
PK/BN 1 1 GY/BK GY/BK 4
Front Wheel Speed (+) 17 17 BK/BE
Right BK BK 3 See Fairing
Front Wheel Speed (-) 18 18 BK/V GND Turn BN 2
Ignition Wake-Up 19 19 GY BK
BN Harness
ABS Diode Pack Right And DOM BE BE 1
Motor Power 20 20 R/V
Turn Turn
BN Running Lamp
And DOM BE
Running Lamp
ABS Control [32B]
Module Running Fender Tip Lamp
DOM Only (DOM only) Front Fender

BE/BN
BK/BE
Front Fender Tip Lamp

BK/V

BE/V
O/W 1
See O/W 1 1 O/W 1
Tip Lamp Main Harness BK 2 2 BK 2
(Except FLHRX)
(DOM only) BK 2 See Fairing
(3 Or 4 Of 5)
(BK) [32B] Harness
[167B] A B A B [168B] [31LB]
[167A] A B A B [166A] GND
BK GY/BK 4
Left Turn Left
Turn V BK BK 3 See Fairing
BE Turn V Harness

PK/BN

LGN/V
And DOM V 2

R/BN

R/BE
And DOM BE BE 1

R/V
Running Lamp

GY
BK
Running Lamp
Running

GY/BK
DOM Only
See Main Harness [73LB] GY/BK
Front Wheel Rear Wheel (2 Or 4 Of 5)
Speed Sensor Speed Sensor [73LB]
BK
Left
Auxiliary Left
Lamp Auxiliary Except
Console Harness FLTRX
FLHR/C Lamp
Fuel
A BC D [141A]
Pump A BC D [141B]

Y/W
O/GY
BK/GN
BK
[39A] [39B] Fuel Pump
Speedometer Assembly Intank
Trip Switch 11 11 BK

Fuel Level 9 9 Y/W

Trip Odometer Reset Switch 8 8 BK
Ground 7 7 BK/GN
Accessory 6 6 O/W
Battery 5 5 BN/GY
FLHR/C

Serial Data 2 2 LGN/V

Ignition 1 1 O
See
Main Harness
Trip Odometer [109B] (3 Or 4 Of 5)
Reset Switch BK and/or 1 2 3 4
BK [67B]

BK
BK
BK
BK
BK 7 7 BK/GN
O 6 6 O
TN 5 Rear View Of
5 TN
BN 4
Toggle Switch
4 BN
GN/Y 3 3 GN/Y
With Keyway Down
W 2 2 W On
V 1 1 V Normally Closed BK
Common
GN/Y

Normally Open BK
BN
BK

BK

TN

BK

[21B] [21A]
W
V

BN/GY

BK/GN
LGN/V

Off
O/GY

Keyway Down
GN/Y
O/W

Y/W

Accessory/Auxiliary
BN
TN

BK
W
O

Lamp Switch
[20A] 1 2 3 4 5 6 9 10 11 121314 15
Left High Neutral Oil Right
Turn Beam Console Harness
Pressure Turn See Main Harness
(3 Or 4 Of 5)

Figure B-23. Front Lighting, Console Harness, ABS: 2011 Touring

 Figure B-23. Figure B-23.
Front Lighting, Console Harness, ABS: 2011 Touring Front Lighting, Console Harness, ABS: 2011 Touring
et00402 See Indicators, See Indicators, See See Ignition
Fairing Switches, Fairing Switches, Fairing Fairing Switch
Handlebar Switches Handlebar Switches Harness Harness
[142A] [142B] 1 5 7 8 [24B] 1 3 4 5 6 [22B] 3 5 6 10 11 [1B] 2 12 11 [2B] ACC
IGN

O/W

O/W

O/W
W/BN

W/BN
W/V

W/BK

W/BK

W/V
BK/GN

BK/GN
GY

GY
BK/R

BK/R

BK/R

BK/R
Security TN OFF

Siren Power A 1 BN/GY BK B+ ACC IGN [33A]

(Optional) Signal B 2 LGN/BN B A
Ground C 3 BK

2 1 3 [33B] B C A [33B]
Neutral

R/GY

R/GY
R/BK

R/BK
R

R
Switch
[131]

[30A] [30B] B C A [222A]

TSM/HFSM
B C A [222B]
Battery 1 1 BN/GY

BK/GN

BK/GN
Ignition 2 2 GY

R/GY
W/BN

W/BN
W/BK

W/BK

R/BK
R/GY
BK/R

BK/R

BK/R

BK/R

R/BK
O/W

O/W
W/V

W/V
GY

GY

R
3 3

R
Serial Data LGN/V
Neutral Switch 4 4 TN
Left Turn Feed 5 5 V FLHR/C All Except All Except FLHR/C

O/W

W/BN
FLHR/C FLHR/C

W/BK

W/V

R/GY
BK/GN

R/BK
GY

BK/R

BK/R

R
Right Turn Feed 6 6 BN
Right Turn Switch Input 7 7 W/BN
Main Fuse
40A
Left Turn Switch Input 8 8 W/V
Start Relay Control 9 9 TN/GN [64-1B]
[5B]
Clutch Switch 10 10 BK/R
Accessory 15A A B
Alarm Signal 11 11 LGN/BN O/W 1D 1C R/GY

R
R
Ground 12 12 BK/GN Battery 15A
BN/GY 2D 2C R

ECM PWR 15A

BE/GY 2F 2E R

Receive Antenna 1 1 Y/BK

Transmit Antenna A 2 2 O/Y 4C 5 87
Transmit Antenna B 3 3 BK System
BE/GY 3D 3 30
GN/O 3G 1 85 Relay
[208A] [208B] W/BK 4D 2 86

GN 4G 5 87

R/GY 3H 3 30
Start
Relay
TN/GN 3G 1 85
[209B] [209A] Hands Free Antenna BK/R 4H 2 86

O/Y 1 1 Antenna ’A’

BK 2 2 Antenna ’B’
Ignition 15A
GY 1F 1E R/BK

R
[64-2B]

ECM
See
System Relay 4 4 GN/O Rear Lighting,
Serial Data 5 5 LGN/V Charging Circuit
Ground 28 28 BK/GN

Ground 10 10 BK/GN

Switched Power 13 13 W/BK

Battery 31 31 BE/GY
Red
Band

BK

BK
[78A] [78B]

BK/GN

BK
BK

BK
R
[128]
BN

BK
V

GN
GND 2 GND 1
See Rear Lighting, Battery Starter
Charging Circuit Right Stud Left Stud
Clean Dirty

Figure B-24. Security Circuit: 2011 Touring

 Figure B-24. Figure B-24.
Security Circuit: 2011 Touring Security Circuit: 2011 Touring
et00403 See Indicators, See Indicators, See See Ignition
Anti-Theft Fairing Switches, Fairing Switches, Fairing Fairing Switch
Tracking Module Handlebar Switches Handlebar Switches Harness Harness
1 5 7 8 [24B] 1 3 4 5 6 [22B] 3 5 6 10 11 [1B] 2 12 11 [2B] ACC
IGN

O/W

O/W

O/W
W/BN

W/BN
W/V

W/BK

W/BK

W/V
BK/GN

BK/GN
GY

GY
BK/R

BK/R

BK/R

BK/R
OFF

[142A] [142B] B+ ACC IGN [33A]

Power A A BN/GY
Signal B B LGN/BN 2 1 3 [33B] B C A [33B]
Ground C C BK

R/GY

R/GY
R/BK

R/BK
R

R
TN
BK

Right A A W/BN W/BN A A W/BN B A

Left B B W/V W/V B B W/V
B C A [222A]
Start Enable C C TN/GN TN/GN C C TN/GN B C A [222B]
Start Input D D GN
Neutral

BK/GN

BK/GN
[267A] [267B] Switch

R/GY
W/BN

W/BN
W/BK

W/BK

R/BK
R/GY
BK/R

BK/R

BK/R

BK/R

R/BK
O/W

O/W
W/V

W/V
[131]

GY

GY
[266A] [266B]

R
R
[30A] [30B]
TSM/HFSM FLHR/C All Except All Except FLHR/C

O/W

W/BN
FLHR/C FLHR/C

W/BK

W/V

R/GY
BK/GN

R/BK
GY

BK/R

BK/R

R
Battery 1 1 BN/GY
Ignition 2 2 GY Main Fuse
Serial Data 3 3 LGN/V
40A
Neutral Switch 4 4 TN
[64-1B]
Left Turn Feed 5 5 V [5B]
Right Turn Feed 6 6
Accessory 15A A B
BN
O/W 1D 1C R/GY

R
R
Right Turn Switch Input 7 7 W/BN

Left Turn Switch Input 8 8 W/V

Battery 15A
BN/GY 2D 2C R
Start Relay Control 9 9 GN

Clutch Switch 10 10 BK/R ECM PWR 15A

Alarm Signal 11 11 LGN/BN BE/GY 2F 2E R

Ground 12 12 BK/GN
4C 5 87

BE/GY 3D 3 30 System
Y/BK GN/O 3G 1 85 Relay
Receive Antenna 1 1
Transmit Antenna A 2 2 O/Y W/BK 4D 2 86
Transmit Antenna B 3 3 BK

GN 4G 5 87
[208A] [208B]
R/GY 3H 3 30
Start
Relay
TN/GN 3G 1 85
BK/R 4H 2 86

[209B] [209A] Hands Free Antenna

Ignition 15A
GY 1F 1E R/BK
O/Y 1 1 Antenna ’A’
BK 2 2 Antenna ’B’

R
[64-2B]
ECM
See
System Relay 4 4 GN/O Rear Lighting,
Serial Data 5 5 LGN/V Charging Circuit
Ground 28 28 BK/GN

Ground 10 10 BK/GN

Switched Power 13 13 W/BK

Battery 31 31 BE/GY
Red
Band

BK

BK
[78A] [78B]

BK/GN

BK
BK

BK
R
[128]
BN

BK
V

GN
GND 2 GND 1
See Rear Lighting, Battery Starter
Charging Circuit Right Stud Left Stud
Clean Dirty

Figure B-25. Security Circuit: 2011 Touring With Anti-Theft Tracking Module
 Figure B-25. Figure B-25.
Security Circuit: 2011 Touring With Anti-Theft Tracking Security Circuit: 2011 Touring With Anti-Theft Tracking
Module Module
et00281

Mounting Stud AM/FM

On Rear Of Antenna Mast
Tour-Pak FLHX, FLHTC/CU, FLTRX
(FLHTCU, FLHTK Models Only
Only)
Ground Plane
In Tour-Pak
[50D]
[184A] Mounting Stud
[185A] [50C] On Left
XM/SIRIUS CB Radio Connector
Radio Connector Saddle Bag
RT Rear Speaker (+) 1 Bracket
1 N/C LFT Rear Speaker (+) 2
2 N/C CB/GMRS Audio (+) 3 (FLHX,
3 N/C HFM Audio (+) 4 FLTRX Only)
4 N/C LFT Rear HDSET SPKR (+) 5
5 N/C LFT FRT HDSET SPKR (+) 6 Mounting Stud
6 XM SDAR Right LFT XM 7 On Rear Of
7 XM SDAR Left [104B] [104A] N/C 8 Tour Pak
8 XM SDAR Shield FRT MIC (+) 9
9 Battery Rear MIC (+) 10
(FLHTC/CU,
10 Ground RR2 (RR CNTL Matrix) 11 FLHTK Only)
11 CAN (+) C.B. Antenna RC4 (RR CNTL Matrix) 12
12 CAN (-) Back Of
Used with optional [50A] C.B. Module Antenna Cable Part Of
XM module Main Harness And
(Violet) Present On All Models
XM C.B. To Radio Antenna
Antenna XM Ground For
Connector
[185C] [193B] (FLHX, FLHTC/CU, Standard
FLTRX/FLHTK Installations
GPS [185D] XM Antenna [50B] C.B. Antenna [51B]
Antenna AM/FM Models Only) [52B]
Antenna [51A]
GPS
Antenna
[193A]

[27A] [28A]
Ground Wire On
1 RT FRT Speaker (-) RT Rear Speaker (+) 1 Ground Plane Tour-Pak Only
2 Push To Talk (MIC) LFT Rear Speaker (+) 2 In Tour-Pak
3 R0 (Handlebar Matrix) CB/GMRS Audio (+) 3
4 R1 (Handlebar Matrix) HFM Audio (+) 4
5 R2 (Handlebar Matrix) LFT Rear HDSET SPKR (+) 5
6 C4 (Handlebar Matrix) LFT FRT HDSET SPKR (+) 6
7 C3 (Handlebar Matrix) LFT XM 7
8 C2 (Handlebar Matrix) N/C 8
9 Serial Bus FRT MIC (+) 9
Classic Radio 10 Battery Rear MIC (+) 10
11 Ground RR2 (RR CNTL Matrix) 11
Connector 12 Accessory Enable RC4 (RR CNTL Matrix) 12
13 Headset Speakers B CAN (+) 13
14 N/C CAN (-) 14
15 DSCAR Switch Matrix In LFT SDCAR HDSET SPKR (+) 15
16 LFT FRT Speaker (+) Ul tra Radio RT SDCAR HDSET SPKR (+) 16
17 LFT FRT Speaker (-) Connector HDSET SPKR Shared (-) 17
18 RT FRT Speaker (+) XM (-) 18
19 Ground N/C 19
20 Battery MIC Shared (-) 20
21 Headset Speakers A MIC Shared Shield 21
22 C1 (Handlebar Matrix) MIC SUM OUT (-) 22
23 C0 (Handlebar Matrix) RR1 (RR CNTL Matrix) 23
RT Rear SPKR (-) 24
LFT Rear SPKR (-) 25
CB/GMRS Audio (-) 26
HFM Audio (-) 27
RT REAR HDSET SPKR (+) 28
RT FRT HDSET SPKR (+) 29
RT XM 30
N/C 31
SDCAR MIC IN (+) 32
MIC SUM OUT (+) 33
RR0 (RR CNTL Matrix) 34
RC3 (RR CNTL Matrix) 35

Figure B-26. Ultra Radio RF Interconnect Circuit: 2011 Touring

 Figure B-26. Figure B-26.
Ultra Radio RF Interconnect Circuit: 2011 Touring Ultra Radio RF Interconnect Circuit: 2011 Touring
et00394

(BK) [41A] [41D] [41C] [41B]

Twisted Twisted
Pair Pair
PK/W 1 1 1 1 PK/W PK/W +VOL Right Rear
[28A] [28B] GY/W 2 2 2 2 GY/W GY/W Speaker &
PTT
Radio V/BK 3 3 3 3 V/BK V/BK Controls
-VOL
O/BK 4 4 4 4 O/BK O/BK
RT Rear Speaker (+) 1 1 GN GN 5 5 5 5 GN
LFT Rear Speaker (+) 2 2 BN LGN/BN 6 6 6 6 LGN/BN

If [36B] [36A] O/BE 9 9 O/BE 9 9 O/BE

Equipped V/O 10 10 V/O 10 10 V/O
With LGN/BN
SPKR
P&A Kit GN

RR2 (RR CNTL Matrix) 11 11 V/BK BN/O 11 11 BN/O 11 11 BN/O

RC4 (RR CNTL Matrix) 12 12 BN/W BK/GN 12 12 BK/GN 12 12 BK/GN

[105A] [105D] [105C] [105B] Connectors

On FLTRX
Only

RR1 (RR CNTL Matrix) 23 23 GY/W

RT Rear SPKR 24 24 LGN/BN
LFT Rear SPKR 25 25 W/BN

(BK)
[42A] [42D] [42C] [42B]
O/BE 9 Radio Power
See
RR0 (RR CNTL Matrix) 34 34 PK/W PK/W 1 1 1 1 PK/W PK/W UP Left Rear Main Harness
RC3 (RR CNTL Matrix) 35 35 O/BK GY/W 2 2 2 2 GY/W GY/W MODE Speaker & (1 Or 2 Of 5)
V/BK 3 3 3 3 V/BK V/BK LGN/V 13 Serial Data
BN/W 4 4 4 4 O/BK O/BK DOWN Controls
BN 5 5 5 5 BN
W/BN 6 6 6 6 W/BN
[1A]
If [37B] [37A]
Equipped
With
P&A Kit W/BN
BN

R/O A Radio Memory See

RT FRT Speaker (-) 1 1 LGN/BK Main Harness
Push To Talk (MIC) 2 2 BE/Y BK/GN C
(1 Or 2 Of 5)
R0 (Handlebar Matrix) 3 3 GND 2
PK/W
R1 (Handlebar Matrix) 4 4 GY/W
R2 (Handlebar Matrix) 5 5 V/BK
C4 (Handlebar Matrix) 6 6 BN/W [15A]
C2 (Handlebar Matrix) 8 8 BN/BK
Serial Bus 9 9 LGN/V
Battery 10 10 R/O
Ground 11 11 BK/GN
Accessory Enable 12 12 O/BE
Headset Speakers B 13 13 BN/O
N/C 14
DSCAR Switch Matrix 15 15 V/GY
LFT FRT Speaker (+) 16 16 W/O
LFT FRT Speaker (-) 17 17 LGN/W
RT FRT Speaker (+) 18 18 V/GY 1
GY/R
Ground 19 19 BK/GN BE/Y 2 To Audio
Battery 20 20 R/O R/O 3 Harness See Fairing
Headset Speakers A 21 21 V/O Harness
C1 (Handlebar Matrix) 22 22 GY/GN
C0 (Handlebar Matrix) 23 23 GN/BE BK/GN 6

[27A] [27B] [34A] [34B] [6A]

Right Front LGN/BK

Speaker GY/R

[35A] [35B]
GY/GN
GN/BE
BN/BK

Left Front
GY/W
BN/W
PK/W

PK/W
V/BK

LGN/W
Speaker W/O

[24B] 8 9 10 11 10 9 8 7 [22B]
See Fairing See Fairing
Harness Harness

Figure B-27. Classic Radio Circuit: 2011 Touring

 Figure B-27. Figure B-27.
Classic Radio Circuit: 2011 Touring Classic Radio Circuit: 2011 Touring
et00410
(BK) [41A] [41B]

PK/W 1 1 PK/W +VOL Right Rear

Twisted Twisted GY/W 2 2 GY/W
PTT Speaker &
V/BK 3 3 V/BK Controls
Pair Pair O/BK 4 4 O/BK
-VOL
GN 5 5 GN
[28A] [28B] LGN/BN 6 6 LGN/BN
Radio
[36B]
RT Rear Speaker (+) 1 1 GN
LFT Rear Speaker (+) 2 2 BN
LGN/BN To
Sidecar
GN Speaker
[36A]
LGN/BN
GN
RR2 (RR CNTL Matrix) 11 11 V/BK With Amplifier And No Sidecar
RC4 (RR CNTL Matrix) 12 12 BN/W These Leads Are Not Active [36D]
CAN (+) 13 13 Y/O
CAN (-) 14 14
From The Radio And Should
Y/V [37A]
Be Secured Inside The Speaker
Pods With No Connection
W/BN
BN

[37D]
RR1 (RR CNTL Matrix) 23 23 GY/W
RT Rear SPKR 24 24 LGN/BN BN To
LFT Rear SPKR 25 25 W/BN
W/BN
Sidecar
(BK) Speaker
[42A] [42B] [37B]

PK/W 1 1 PK/W UP Left Rear

GY/W 2 2 GY/W MODE Speaker &
V/BK 3 3 V/BK
RR0 (RR CNTL Matrix) 34 34 PK/W BN/W 4 4 O/BK DOWN Controls
RC3 (RR CNTL Matrix) 35 35 O/BK 5 BN
BN 5
W/BN 6 6 W/BN

RT FRT Speaker (-) 1 1 LGN/BK

Y/O 4 4 Y/O
Y/V 5 5 Y/V

LFT FRT Speaker (+) 16 16 W/O

LFT FRT Speaker (-) 17 17 LGN/W
[6A] [6B]
RT FRT Speaker (+) 18 18 GY/R

[149B] [149A]
[27A] [27B] Amplifier
Y/O 1 1 CAN (+)
Y/V 2 2 CAN (-)
R 3 3 Battery
Battery (+) R 30A R 4 4 Battery

GY/R 6 6 Right Front Out (+)

W/O 7 7 Left Front Out (+)
BN 8 8 Left Rear Out (+)
[34A] [34D]
LGN/W 11 11 Left Front In (-)
Right LGN/BK 12 12 Right Front In (-)
Front LGN/BK LGN/BK 13 13 Right Front Out (-)
Speaker GY/R LGN/W 14 14 Left Front Out (-)
[35B] [35C] W/BN 15 15 Left Rear Out (-)

LGN/W LGN/W
W/O 18 18 Left Front In (+)
W/O W/O GY/R
GY/R 19 19 Right Front In (+)
BK 20 20 Ground
LGN/BK LGN/BK BK BK 21 21 Ground
[35A] [35D] GN 22 22 Right Rear Out (+)
GY/R GY/R
Right GND 2 LGN/BN 23 23 Right Rear Out (-)
Left [34B] [34C] Stud
LGN/W
Front W/O Clean
Speaker Twisted Twisted
Pair Pair

Figure B-28. Ultra Radio Circuit: 2011 Touring

 Figure B-28. Figure B-28.
Ultra Radio Circuit: 2011 Touring Ultra Radio Circuit: 2011 Touring
et00411 Twisted
Shielded
Pair
Ultra Radio (BK) [28A] [28B]

LFT FRT HDSET SPKR (+) 5 5 GY/O

LFT FRT HDSET SPKR (+) 6 6 Y/W

FRT MIC (+) 9 9 ++R DIN on ULTRA

Rear MIC (+) 10 10 R
[76B]

BK 1 Passenger
LFT SDCAR HDSET SPKR (+) 15 15 GN/V Y/BK 2 Headset
RT SDCAR HDSET SPKR (+) 16 16 GY/BK GY/Y 3
HDSET SPKR Shared 17 17 Y/BK R 4
GY/O 5
6
MIC Shared (-) 20 20 BK 7
SHIELD 8/
MIC Shared Shield 21 21 BK TAB

Twisted
Shielded
Pair
RT Rear HDSET SPKR (+) 28 28 GY/Y
RT FRT HDSET SPKR (+) 29 29 Y/R

SDCAR Mic In (+) 32 32 ++W

Push To Talk (MIC) 2 2 BE/Y

R0 (Handlebar Matrix) 3 3 PK/W

R2 (Handlebar Matrix) 5 5 V/BK

C3 (Handlebar Matrix) 7 7 O/BK

C2 (Handlebar Matrix) 8 8 BN/BK

Ground 11 11 BK/GN BK/GN 6 6 BK/GN

BE/Y 2 2 BE/Y
DSCAR Switch Matrix 15 15 V/GY V/GY 1 1 V/GY

[6B] [6A]
Ground 19 19 BK/GN

C1 (Handlebar Matrix) 22 22 GY/GN

C0 (Handlebar Matrix) 23 23 GN/BE
++Twisted
Shielded
GY/GN
GN/BE

BN/BK
PK/W

Triad
O/BK
V/BK

[53A] [53B]
[27A] [27B]
[24B]
14 14
13 13

10 10
11 11

9
8

++SHIELD 12 12 SHIELD
++BK 11 11 BK
[24A]
9
8

++R 10 10 R
Y/R 9 9 Y/R
GY/GN

PK/W
GN/BE
O/BK

BN/BK
V/BK

Y/W 8 8 Y/W
Y/BK 7 7 Y/BK
BE/Y 6 6 BE/Y
V/GY 5
BK/GN 4
GY/BK 3
GN/V 2
++W 1 Driver
Headset

Left
Hand Radio PTT & SQ
Controls Audio
Control

Figure B-29. 2-Place Intercom and Headset Audio: 2011 Touring

 Figure B-29. Figure B-29.
2-Place Intercom and Headset Audio: 2011 Touring 2-Place Intercom and Headset Audio: 2011 Touring
et00412

Ultra Radio (BK) [28A] [28B]

Twisted
Triad
CB/GRMS Audio (+) 3 3 R

Left XM 7 7 W

R 6
CAN (+) 13 13 Y/O W 7
CAN (-) 14 14 Y/V BK 8 XM
R/O 9
BK/GN 10 [185B]
Y/O 11
XM (-) 18 18 BK Y/V 12

++R 1
MIC Sum Out (-) 22 22 ++BK ++BK 2
++Twisted
Pair R 4 Future
CB/GRMS Audio (-) 26 26 BK
BK 5 ACC
[186B]
R/O 9
Right XM (-) 30 30 R BK/GN 10
Y/O 11
Y/V 12
MIC Sum Out (+) 32 32 ++R

++R 1 1 ++R 1
++BK 2 2 ++BK 2
3 3
R 4 4 R 4
BK 5 5 BK 5 C.B.
R 6 6
W 7 7 [184D]
BK 8 8
R/O 9 9 R/O 9
BK/GN 10 10 BK/GN 10
Y/O 11 11 Y/O 11
Y/V 12 12 Y/V 12
Battery 10 R/O
Ground 11 BK/GN
C.B. [184B] [184C]
P&A ULTRA
(If Equipped) Overlay Harness
BK/GN 6 6 BK/GN For FL/HTCU/HTK/TRU
Y/V 5 5 Y/V Only

BK/GN

BK/GN
Y/O

++BK
4 4 Y/O

++R
R/O

R/O
Y/O

Y/O
Y/V

Y/V
Ground 19 R/O 3 3 R/O
BK/GN
Battery 20
Future ACC
R/O
[175B] 1 2 3 4 1 2 5 6 7 8 [187B]
[6A] [6B] 1 2 5 6 7 8 [187A]

++BK

R/O
BK/GN
Y/O
[149B] [149A]

Y/V
++R
[27A] Bluetooth
Amplifier Antenna
Y/O 1 1 CAN (+)
Y/V 2 2 CAN (-)
[194B]
(Beige)
R/O 1 Differential Mic Out (+)
BK/GN 2 Differential Mic Out (-)

Hands
Free
Module
Y/O 17 Audio Out (+)
Y/V 18 Audio Out (-)

++R 45 CAN (+)

++BK 46 CAN (-)

Figure B-30. CAN and Module Audio Inputs to Ultra Radio: 2011 Touring
 Figure B-30. Figure B-30.
CAN and Module Audio Inputs to Ultra Radio: 2011 Touring CAN and Module Audio Inputs to Ultra Radio: 2011 Touring
TABLE OF CONTENTS

SUBJECT............................................................................................................................PAGE NO.
C.1 METRIC CONVERSION...........................................................................................................C-1
C.2 FLUID CONVERSIONS............................................................................................................C-2
C.3 TORQUE CONVERSIONS.......................................................................................................C-3

APPENDIX C CONVERSIONS
NOTES
HOME

METRIC CONVERSION C.1

CONVERSION TABLE
Table C-1. Metric Conversions
MILLIMETERS to INCHES INCHES to MILLIMETERS
(MM x 0.03937 = IN) (IN x 25.40 = MM)
mm in mm in mm in mm in in mm in mm in mm in mm

.1 .0039 25 .9842 58 2.283 91 3.582 .001 .025 .6 15.240 1-15/16 49.21 3-5/16 84.14
.2 .0078 26 1.024 59 2.323 92 3.622 .002 .051 5/8 15.875 2 50.80 3-3/8 85.72
.3 .0118 27 1.063 60 2.362 93 3.661 .003 .076 11/16 17.462 2-1/16 52.39 3.4 86.36
.4 .0157 28 1.102 61 2.401 94 3.701 .004 .102 .7 17.780 2.1 53.34 3-7/16 87.31
.5 .0197 29 1.142 62 2.441 95 3.740 .005 .127 3/4 19.050 2-1/8 53.97 3-1/2 88.90
.6 .0236 30 1.181 63 2.480 96 3.779 .006 .152 .8 20.320 2-3/16 55.56 3-9/16 90.49
.7 .0275 31 1.220 64 2.519 97 3.819 .007 .178 13/16 20.638 2.2 55.88 3.6 91.44
.8 .0315 32 1.260 65 2.559 98 3.858 .008 .203 7/8 22.225 2-1/4 57.15 3-5/8 92.07
.9 .0354 33 1.299 66 2.598 99 3.897 .009 .229 .9 22.860 2.3 58.42 3-11/16 93.66
1 .0394 34 1.338 67 2.638 100 3.937 .010 .254 15/16 23.812 2-5/16 58.74 3.7 93.98
2 .0787 35 1.378 68 2.677 101 3.976 1/64 .397 1 25.40 2-3/8 60.32 3-3/4 95.25
3 .1181 36 1.417 69 2.716 102 4.016 .020 .508 1-1/16 26.99 2.4 60.96 3.8 96.52
4 .1575 37 1.456 70 2.756 103 4.055 .030 .762 1.1 27.94 2-7/16 61.91 3-13/16 96.84
5 .1968 38 1.496 71 2.795 104 4.094 1/32 .794 1-1/8 28.57 2-1/2 63.50 3-7/8 98.42
6 .2362 39 1.535 72 2.834 105 4.134 .040 1.016 1-3/16 30.16 2-9/16 65.09 3.9 99.06
7 .2756 40 1.575 73 2.874 106 4.173 .050 1.270 1.2 30.48 2.6 66.04 3-15/16 100.01
8 .3149 41 1.614 74 2.913 107 4.212 .060 1.524 1-1/4 31.75 2-5/8 66.67 4 101.6
9 .3543 42 1.653 75 2.953 108 4.252 1/16 1.588 1.3 33.02 2-11/16 68.26 4-1/16 102.19
10 .3937 43 1.693 76 2.992 109 4.291 .070 1.778 1-5/16 33.34 2.7 68.58 4.1 104.14
11 .4331 44 1.732 77 3.031 110 4.331 .080 2.032 1-3/8 34.92 2-3/4 69.85 4-1/8 104.77
12 .4724 45 1.772 78 3.071 111 4.370 .090 2.286 1.4 35.56 2.8 71.12 4-3/16 106.36
13 .5118 46 1.811 79 3.110 112 4.409 .1 2.540 1-7/16 36.51 2-13/16 71.44 4.2 106.68
14 .5512 47 1.850 80 3.149 113 4.449 1/8 3.175 1-1/2 38.10 2-7/8 73.02 4-1/4 107.95
15 .5905 48 1.890 81 3.189 114 4.488 3/16 4.762 1-9/16 39.69 2.9 73.66 4.3 109.22
16 .6299 49 1.929 82 3.228 115 4.527 .2 5.080 1.6 40.64 2-15/16 74.61 4-5/16 109.54
17 .6693 50 1.968 83 3.268 116 4.567 1/4 6.350 1-5/8 41.27 3 76.20 4-3/8 111.12
18 .7086 51 2.008 84 3.307 117 4.606 .3 7.620 1-11/16 42.86 3-1/16 77.79 4.4 111.76
19 .7480 52 2.047 85 3.346 118 4.645 5/16 7.938 1.7 43.18 3.1 78.74 4-7/16 112.71
20 .7874 53 2.086 86 3.386 119 4.685 3/8 9.525 1-3/4 44.45 3-1/8 79.37 4-1/2 114.30
21 .8268 54 2.126 87 3.425 120 4.724 .4 10.160 1.8 45.72 3-3/16 80.96 4-9/16 115.89
22 .8661 55 2.165 88 3.464 121 4.764 7/16 11.112 1-13/16 46.04 3.2 81.28 4.6 116.84
23 .9055 56 2.205 89 3.504 122 4.803 1/2 12.700 1-7/8 47.62 3-1/4 82.55 4-5/8 117.47
24 .9449 57 2.244 90 3.543 123 4.842 9/16 14.288 1.9 48.26 3.3 83.82 4-11/16 119.06

2011 Touring Diagnostics: Appendix C Conversions C-1

HOME
FLUID CONVERSIONS
UNITED STATES SYSTEM
Unless otherwise specified, all fluid volume measurements in
this service manual are expressed in United States (U.S.) units-
of-measure. See below:
• 1 pint (U.S.) = 16 fluid ounces (U.S.)
• 1 quart (U.S.) = 2 pints (U.S.) = 32 fl. oz. (U.S.)
• 1 gallon (U.S.) = 4 quarts (U.S.) = 128 fl. oz. (U.S.)
METRIC SYSTEM
Fluid volume measurements in this service manual include the
metric system equivalents. In the metric system, 1 liter (L) =
1,000 milliliters (mL). Should you need to convert between U.S.
units-of-measure and metric units-of-measure, refer to the fol-
lowing:
• fluid ounces (U.S.) x 29.574 = milliliters
• pints (U.S.) x 0.473 = liters
• quarts (U.S.) x 0.946 = liters
• gallons (U.S.) x 3.785 = liters
• milliliters x 0.0338 = fluid ounces (U.S.)
• liters x 2.114 = pints (U.S.)
• liters x 1.057 = quarts (U.S.)
• liters x 0.264 = gallons (U.S.)
C-2 2011 Touring Diagnostics: Appendix C Conversions
C.2
BRITISH IMPERIAL SYSTEM
Fluid volume measurements in this service manual do not
include the British Imperial (Imp.) system equivalents. The fol-
lowing conversions exist in the British Imperial system:
• 1 pint (Imp.) = 20 fluid ounces (Imp.)
• 1 quart (Imp.) = 2 pints (Imp.)
• 1 gallon (Imp.) = 4 quarts (Imp.)
Although the same unit-of-measure terminology as the U.S.
system is used in the British Imperial (Imp.) system, the actual
volume of each British Imperial unit-of-measure differs from its
U.S. counterpart. The U.S. fluid ounce is larger than the British
Imperial fluid ounce. However, the U.S. pint, quart, and gallon
are smaller than the British Imperial pint, quart, and gallon,
respectively. Should you need to convert between U.S. units
and British Imperial units, refer to the following:
• fluid ounces (U.S.) x 1.042 = fluid ounces (Imp.)
• pints (U.S.) x 0.833 = pints (Imp.)
• quarts (U.S.) x 0.833 = quarts (Imp.)
• gallons (U.S.) x 0.833 = gallons (Imp.)
• fluid ounces (Imp.) x 0.960 = fluid ounces (U.S.)
• pints (Imp.) x 1.201 = pints (U.S.)
• quarts (Imp.) x 1.201 = quarts (U.S.)
• gallons (Imp.) x 1.201 = gallons (U.S.)
HOME
TORQUE CONVERSIONS
UNITED STATES SYSTEM
The U.S. units of torque, foot pounds and inch pounds, are
used in this service manual. To convert units, use the following
equations:
• foot pounds (ft-lbs) X 12.00000 = inch pounds (in-lbs).
• inch pounds (in-lbs) X 0.08333 = foot pounds (ft-lbs).
C.3
METRIC SYSTEM
All metric torque specifications are written in Newton-meters
(Nm). To convert metric to United States units and United
States to metric, use the following equations:
• Newton meters (Nm) X 0.737563 = foot pounds (ft-lbs).
• Newton meters (Nm) X 8.85085 = inch pounds (in-lbs).
• foot pounds (ft-lbs) X 1.35582 = Newton meters (Nm).
• inch pounds (in-lbs) X 0.112985 = Newton meters (Nm).
2011 Touring Diagnostics: Appendix C Conversions C-3
NOTES

C-4 2011 Touring Diagnostics: Appendix C Conversions

TABLE OF CONTENTS

SUBJECT............................................................................................................................PAGE NO.
D.1 GLOSSARY..............................................................................................................................D-1

APPENDIX D GLOSSARY
NOTES
HOME

GLOSSARY D.1
ACRONYMS AND ABBREVIATIONS
Table D-1. Acronyms and Abbreviations

ACRONYM OR ABBREVIATION DESCRIPTION

A Amperes
ABS Anti-lock braking system
Ah Ampere-hour
AC Alternating current
ACC Accessory position on ignition switch
ACR Automatic compression release
AIS Active Intake Solenoid
AGM Absorbed glass mat (battery)
AWG American wire gauge
B+ Battery voltage
bar Bar
BAS Bank angle sensor
BTDC Before top dead center
°C Celsius (Centigrade)
CA California
CAL Calibration
CAN Controller area network
cc Cubic centimeters
cm Centimeters
cm3 Cubic centimeters
CCA Cold cranking amps
CKP Crankshaft position
cm Centimeter
CCW Counterclockwise
CW Clockwise
DC Direct current
DLC Data link connector
DOM Domestic
DTC Diagnostic trouble code
DOT Department of Transportation
DVOM Digital volt ohm meter
ECM Electronic control module
ECT Engine coolant temperature
ECU Electronic Control Unit
EEPROM Electrically erasable programmable read only memory
EFI Electronic fuel injection
ET Engine temperature
EVAP Evaporative emissions control system
°F Fahrenheit
FPS Fuel pressure sensor

2011 Touring Diagnostics: Appendix D Glossary D-1

HOME

Table D-1. Acronyms and Abbreviations

ACRONYM OR ABBREVIATION DESCRIPTION

ft Foot
ft-lbs Foot pounds
fl oz Fluid ounce
g Gram
gal Gallon
GAWR Gross axle weight rating
GPS Global positioning system
GND Ground (electrical)
GVWR Gross vehicle weight rating
HCU Hydraulic control unit
HDI Harley-Davidson International
H-DSSS Harley-Davidson smart security system
HFSM Hands-free security module
Hg Mercury
H02S Heated oxygen sensor
hp Horsepower
hr Hour
IAC Idle air control
IAT Intake air temperature
IC Instrument cluster
ID Inside diameter
IGN Ignition light/key switch position
in Inch
in3 Cubic inch
INJ PW Injector pulse width
in-lbs Inch pounds
JSS Jiffy stand sensor
kg Kilogram
km Kilometer
kPa Kilopascal
km/h Kilometers per hour
kW Kilowatt
L Liter
lb Pounds
LCD Liquid crystal display
LED Light emitting diode
mA Milliampere
MAP Manifold absolute pressure
max Maximum
mi Mile
min Minimum
mL Milliliter
mm Millimeter

D-2 2011 Touring Diagnostics: Appendix D Glossary

HOME

Table D-1. Acronyms and Abbreviations

ACRONYM OR ABBREVIATION DESCRIPTION

mph Miles per hour
ms millisecond
Nm Newton-meter
NiMH Nickel metal hydride
N/A Not applicable
O2 Oxygen
OD Outside diameter
OEM Original equipment manufacturer
oz Ounce
P&A Parts and Accessories
Part No. Part number
PIN Personal identification number
psi Pounds per square inch
PWM signal Pulse width modulated signal
qt Quart
RCM Reverse control module
RES Reserve mark on fuel supply valve
rpm Revolutions per minute
s seconds
SCFH Cubic feet per hour at standard conditions
TCA Throttle control actuator
TDC Top dead center
TGS Twist grip sensor
TMAP Intake air temperature/manifold absolute pressure
TPS Throttle position sensor
TSM Turn signal module
TSSM Turn signal/security module
V Volt
VAC Volts of alternating current
VDC Volts of direct current
VIN Vehicle identification number
VSS Vehicle speed sensor
W Watt
WSS Wheel speed sensor

2011 Touring Diagnostics: Appendix D Glossary D-3

NOTES

D-4 2011 Touring Diagnostics: Appendix D Glossary

 Tools Used in This Manual
PART NUMBER TOOL NAME NOTES
99861-02 ELECTRICAL CONTACT LUBRICANT 5.6 TURN SIGNALS, Flash at Double Normal Rate, All
Bulbs Work, No DTCs
B-50085 TERMINAL EXTRACTOR A.16 JAE MX19 SEALED CONNECTORS, JAE MX19
Sealed Connectors
GA500A SNAP-ON TERMINAL PICK A.1 AUTOFUSE UNSEALED ELECTRICAL CON-
NECTORS, Autofuse Unsealed Connector Repair
HD-23738 VACUUM PUMP 6.4 DTC P0107, P0108, P0112, P0113, Diagnostics
HD-25070 HEAT GUN A.20 SEALED SPLICE CONNECTORS, Sealed Splice
Connector Repair
HD-26792 SPARK TESTER 1.2 DIAGNOSTIC TOOLS, How To Use Diagnostic Tools
HD-26792 SPARK TESTER 6.33 ENGINE CRANKS, BUT WILL NOT START, Engine
Cranks But Will Not Start
HD-34730-2D FUEL INJECTOR TEST LIGHT 1.2 DIAGNOSTIC TOOLS, How To Use Diagnostic Tools
HD-34730-2D FUEL INJECTOR TEST LIGHT 1.2 DIAGNOSTIC TOOLS, How To Use Diagnostic Tools
HD-34730-2D FUEL INJECTOR TEST LIGHT 6.8 DTC P0261, P0262, P0263, P0264, DTC P0261
HD-34730-2D FUEL INJECTOR TEST LIGHT 6.8 DTC P0261, P0262, P0263, P0264, DTC P0263
HD-34730-2D FUEL INJECTOR TEST LIGHT 6.19 DTC P1351, P1352, P1354, P1355, DTC P1351
HD-34730-2D FUEL INJECTOR TEST LIGHT 6.19 DTC P1351, P1352, P1354, P1355, DTC P1354
HD-34730-2D FUEL INJECTOR TEST LIGHT 6.26 DTC P1655, P1656, DTC P1655
HD-34730-2D FUEL INJECTOR TEST LIGHT 6.26 DTC P1655, P1656, DTC P1656
HD-35500 MULTI-METER 4.6 GAUGES, Fuel Gauge and Sender Test
HD-38125-6 PACKARD TERMINAL CRIMP TOOL A.8 DELPHI METRI-PACK TERMINAL REPAIR, Metri-

TOOLS
Pack Terminal Crimps
HD-38125-7 PACKARD TERMINAL CRIMPER A.8 DELPHI METRI-PACK TERMINAL REPAIR, Metri-
Pack Terminal Crimps
HD-38125-7 PACKARD TERMINAL CRIMPER A.14 DEUTSCH DTM SEALED MINI TERMINAL
REPAIR, Deutsch DTM Sealed Mini Terminal Crimps
HD-38125-8 PACKARD CRIMPING TOOL A.8 DELPHI METRI-PACK TERMINAL REPAIR, Metri-
Pack Terminal Crimps
HD-38125-8 PACKARD CRIMPING TOOL A.20 SEALED SPLICE CONNECTORS, Sealed Splice
Connector Repair
HD-39448 CB MICROPHONE LOAD DEVICE 8.5 ADVANCED AUDIO SYSTEM SYMPTOMS, Symptom
4: CB Transmitter Inoperative
HD-39965-A DEUTSCH TERMINAL CRIMP TOOL A.13 DEUTSCH DT SEALED TERMINAL
REPAIR, Deutsch DT Sealed Terminal Crimps
HD-39969 ULTRA TORCH A.20 SEALED SPLICE CONNECTORS, Sealed Splice
Connector Repair
HD-39978 DIGITAL MULTIMETER (FLUKE 78) 1.2 DIAGNOSTIC TOOLS, How To Use Diagnostic Tools
HD-39978 DIGITAL MULTIMETER (FLUKE 78) 1.3 DIAGNOSTICS AND TROUBLESHOOTING, Wiggle
Test
HD-41183 HEAT SHIELD ATTACHMENT A.20 SEALED SPLICE CONNECTORS, Sealed Splice
Connector Repair
HD-41404-C HARNESS CONNECTOR TEST KIT 1.2 DIAGNOSTIC TOOLS, How To Use Diagnostic Tools
HD-41404-C HARNESS CONNECTOR TEST KIT 2.3 DTC U1016, U1040, U1064, U1097, U1255, DTC
U1016
HD-41404-C HARNESS CONNECTOR TEST KIT 2.3 DTC U1016, U1040, U1064, U1097, U1255, DTC
U1016
HD-41404-C HARNESS CONNECTOR TEST KIT 2.3 DTC U1016, U1040, U1064, U1097, U1255, DTC
U1064, U1255
HD-41404-C HARNESS CONNECTOR TEST KIT 2.3 DTC U1016, U1040, U1064, U1097, U1255, DTC
U1064, U1255

I
 Tools Used in This Manual
PART NUMBER TOOL NAME NOTES
HD-41404-C HARNESS CONNECTOR TEST KIT 2.3 DTC U1016, U1040, U1064, U1097, U1255, DTC
U1097, U1255
HD-41404-C HARNESS CONNECTOR TEST KIT 2.3 DTC U1016, U1040, U1064, U1097, U1255, DTC
U1097, U1255
HD-41404-C HARNESS CONNECTOR TEST KIT 2.3 DTC U1016, U1040, U1064, U1097, U1255, DTC
U1097, U1255
HD-41404-C HARNESS CONNECTOR TEST KIT 2.4 DTC U1300, U1301 OR BUS ER, DTC U1301
HD-41404-C HARNESS CONNECTOR TEST KIT 3.2 STARTING SYSTEM, Starter Testing
HD-41404-C HARNESS CONNECTOR TEST KIT 3.2 STARTING SYSTEM, Start Relay Clicks
HD-41404-C HARNESS CONNECTOR TEST KIT 3.6 DTC B0563, P0562, P0563, DTC P0562
HD-41404-C HARNESS CONNECTOR TEST KIT 4.2 DTC B1004, B1005, DTC B1004
HD-41404-C HARNESS CONNECTOR TEST KIT 4.2 DTC B1004, B1005, DTC B1005
HD-41404-C HARNESS CONNECTOR TEST KIT 4.4 NO INSTRUMENT POWER, Speedometer Inoper-
ative
HD-41404-C HARNESS CONNECTOR TEST KIT 4.4 NO INSTRUMENT POWER, Speedometer Inoper-
ative
HD-41404-C HARNESS CONNECTOR TEST KIT 4.6 GAUGES, Oil Pressure Gauge and Indicator Light
HD-41404-C HARNESS CONNECTOR TEST KIT 5.5 HORN, Horn Inoperative
HD-41404-C HARNESS CONNECTOR TEST KIT 5.6 TURN SIGNALS, One Turn Signal Lamp Inoperative,
No DTCs
HD-41404-C HARNESS CONNECTOR TEST KIT 5.16 FAILS TO DISARM, Fails to Disarm: HFSM
HD-41404-C HARNESS CONNECTOR TEST KIT 5.17 DTC B1131, B1132, DTC B1131
HD-41404-C HARNESS CONNECTOR TEST KIT 5.19 DTC B1143, B1144, B1145, DTC B1143
HD-41404-C HARNESS CONNECTOR TEST KIT 6.4 DTC P0107, P0108, P0112, P0113, DTC P0107
HD-41404-C HARNESS CONNECTOR TEST KIT 6.4 DTC P0107, P0108, P0112, P0113, DTC P0112
HD-41404-C HARNESS CONNECTOR TEST KIT 6.4 DTC P0107, P0108, P0112, P0113, DTC P0113
HD-41404-C HARNESS CONNECTOR TEST KIT 6.5 DTC P0117, P0118, DTC P0117
HD-41404-C HARNESS CONNECTOR TEST KIT 6.5 DTC P0117, P0118, DTC P0118
HD-41404-C HARNESS CONNECTOR TEST KIT 6.5 DTC P0117, P0118, DTC P0118
HD-41404-C HARNESS CONNECTOR TEST KIT 6.6 DTC P0120, P0122, P0123, P0220, P0222,
P0223, DTC P0120
HD-41404-C HARNESS CONNECTOR TEST KIT 6.6 DTC P0120, P0122, P0123, P0220, P0222,
P0223, DTC P0122
HD-41404-C HARNESS CONNECTOR TEST KIT 6.6 DTC P0120, P0122, P0123, P0220, P0222,
P0223, DTC P0123
HD-41404-C HARNESS CONNECTOR TEST KIT 6.6 DTC P0120, P0122, P0123, P0220, P0222,
P0223, DTC P0220
HD-41404-C HARNESS CONNECTOR TEST KIT 6.6 DTC P0120, P0122, P0123, P0220, P0222,
P0223, DTC P0222
HD-41404-C HARNESS CONNECTOR TEST KIT 6.6 DTC P0120, P0122, P0123, P0220, P0222,
P0223, DTC P0223
HD-41404-C HARNESS CONNECTOR TEST KIT 6.7 DTC P0031, P0032, P0131, P0132, P0134, P0151,
P0152, P0154, DTC P0031
HD-41404-C HARNESS CONNECTOR TEST KIT 6.7 DTC P0031, P0032, P0131, P0132, P0134, P0151,
P0152, P0154, DTC P0031

II TOOLS
 Tools Used in This Manual
PART NUMBER TOOL NAME NOTES
HD-41404-C HARNESS CONNECTOR TEST KIT 6.7 DTC P0031, P0032, P0131, P0132, P0134, P0151,
P0152, P0154, DTC P0134
HD-41404-C HARNESS CONNECTOR TEST KIT 6.7 DTC P0031, P0032, P0131, P0132, P0134, P0151,
P0152, P0154, DTC P0151
HD-41404-C HARNESS CONNECTOR TEST KIT 6.9 DTC P0373, P0374, DTC P0374
HD-41404-C HARNESS CONNECTOR TEST KIT 6.10 DTC P0444, P0445, DTC P0445
HD-41404-C HARNESS CONNECTOR TEST KIT 6.11 DTC P0501, P0502, DTC P0502
HD-41404-C HARNESS CONNECTOR TEST KIT 6.13 DTC P0572, DTC P0572
HD-41404-C HARNESS CONNECTOR TEST KIT 6.13 DTC P0572, DTC P0572
HD-41404-C HARNESS CONNECTOR TEST KIT 6.16 DTC P1001, P1002, P1003, P1004, DTC P1003
HD-41404-C HARNESS CONNECTOR TEST KIT 6.19 DTC P1351, P1352, P1354, P1355, DTC P1351
HD-41404-C HARNESS CONNECTOR TEST KIT 6.19 DTC P1351, P1352, P1354, P1355, DTC P1352
HD-41404-C HARNESS CONNECTOR TEST KIT 6.19 DTC P1351, P1352, P1354, P1355, DTC P1355
HD-41404-C HARNESS CONNECTOR TEST KIT 6.20 DTC P1353, P1356, P1357, P1358, DTC P1357,
P1358
HD-41404-C HARNESS CONNECTOR TEST KIT 6.21 DTC P1475, P1477, P1478, DTC P1475
HD-41404-C HARNESS CONNECTOR TEST KIT 6.21 DTC P1475, P1477, P1478, DTC P1477
HD-41404-C HARNESS CONNECTOR TEST KIT 6.22 DTC P1501, P1502, DTC P1501
HD-41404-C HARNESS CONNECTOR TEST KIT 6.26 DTC P1655, P1656, DTC P1655
HD-41404-C HARNESS CONNECTOR TEST KIT 6.26 DTC P1655, P1656, DTC P1656
HD-41404-C HARNESS CONNECTOR TEST KIT 6.27 DTC P2100, P2101, P2102, P2103, DTC P2100
HD-41404-C HARNESS CONNECTOR TEST KIT 6.27 DTC P2100, P2101, P2102, P2103, DTC P2101
HD-41404-C HARNESS CONNECTOR TEST KIT 6.30 DTC P2122, P2123, P2127, P2128, DTC P2122
HD-41404-C HARNESS CONNECTOR TEST KIT 6.30 DTC P2122, P2123, P2127, P2128, DTC P2123
HD-41404-C HARNESS CONNECTOR TEST KIT 6.30 DTC P2122, P2123, P2127, P2128, DTC P2127
HD-41404-C HARNESS CONNECTOR TEST KIT 6.30 DTC P2122, P2123, P2127, P2128, DTC P2128
HD-41404-C HARNESS CONNECTOR TEST KIT 6.31 DTC P2135, P2138, DTC P2135
HD-41404-C HARNESS CONNECTOR TEST KIT 6.31 DTC P2135, P2138, DTC P2138
HD-41404-C HARNESS CONNECTOR TEST KIT 6.36 FUEL SYSTEM ELECTRICAL TEST, Fuel System
Electrical Test
HD-41404-C HARNESS CONNECTOR TEST KIT 6.37 MISFIRE AT IDLE OR UNDER LOAD, Misfire At
Idle or Under Load
HD-41404-C HARNESS CONNECTOR TEST KIT 7.2 DTC C1017, C1018, DTC C1017
HD-41404-C HARNESS CONNECTOR TEST KIT 7.2 DTC C1017, C1018, DTC C1017
HD-41404-C HARNESS CONNECTOR TEST KIT 7.2 DTC C1017, C1018, DTC C1018
HD-41404-C HARNESS CONNECTOR TEST KIT 7.4 DTC C1025, C1027, C1206, C1208, DTC C1025
(Front), C1027 (Rear), C1206, C1208
HD-41404-C HARNESS CONNECTOR TEST KIT 7.5 DTC C1032, C1034, DTC C1032
HD-41404-C HARNESS CONNECTOR TEST KIT 7.5 DTC C1032, C1034, DTC C1034
HD-41404-C HARNESS CONNECTOR TEST KIT 7.6 DTC C1042, C1043, DTC C1042
HD-41404-C HARNESS CONNECTOR TEST KIT 7.6 DTC C1042, C1043, DTC C1043
HD-41404-C HARNESS CONNECTOR TEST KIT 7.7 DTC C1094, DTC C1094
HD-41404-C HARNESS CONNECTOR TEST KIT 7.8 DTC C1095, DTC C1095
HD-41404-C HARNESS CONNECTOR TEST KIT 7.8 DTC C1095, DTC C1095

TOOLS III
 Tools Used in This Manual
PART NUMBER TOOL NAME NOTES
HD-41404-C HARNESS CONNECTOR TEST KIT 7.12 DTC C1212, DTC C1212
HD-41404-C HARNESS CONNECTOR TEST KIT 7.13 DTC C1214, DTC C1214
HD-41404-C HARNESS CONNECTOR TEST KIT 7.14 DTC C1216, DTC C1216
HD-41404-C HARNESS CONNECTOR TEST KIT 7.15 DTC C1014, C1055-C1066, C1118, C1121, DTC
C1014, C1055-C1066, C1118, C1121
HD-41404-C HARNESS CONNECTOR TEST KIT 7.16 ABS INDICATOR ALWAYS ON OR INOPER-
ATIVE, ABS Indicator Always On or Inoperative
HD-41404-C HARNESS CONNECTOR TEST KIT 8.2 DTC B2006-B2015, RADIO SWITCH DIA-
GNOSTICS, Radio Switch Diagnostics
HD-41404-C HARNESS CONNECTOR TEST KIT 8.2 DTC B2006-B2015, RADIO SWITCH DIA-
GNOSTICS, Radio Switch Diagnostics
HD-41404-C HARNESS CONNECTOR TEST KIT 8.2 DTC B2006-B2015, RADIO SWITCH DIA-
GNOSTICS, Radio Switch Diagnostics
HD-41404-C HARNESS CONNECTOR TEST KIT 8.2 DTC B2006-B2015, RADIO SWITCH DIA-
GNOSTICS, Radio Switch Diagnostics
HD-41404-C HARNESS CONNECTOR TEST KIT 8.2 DTC B2006-B2015, RADIO SWITCH DIA-
GNOSTICS, Radio Switch Diagnostics
HD-41404-C HARNESS CONNECTOR TEST KIT 8.2 DTC B2006-B2015, RADIO SWITCH DIA-
GNOSTICS, Radio Switch Diagnostics
HD-41404-C HARNESS CONNECTOR TEST KIT 8.2 DTC B2006-B2015, RADIO SWITCH DIA-
GNOSTICS, Radio Switch Diagnostics
HD-41404-C HARNESS CONNECTOR TEST KIT 8.2 DTC B2006-B2015, RADIO SWITCH DIA-
GNOSTICS, Radio Switch Diagnostics
HD-41404-C HARNESS CONNECTOR TEST KIT 8.2 DTC B2006-B2015, RADIO SWITCH DIA-
GNOSTICS, Radio Switch Diagnostics
HD-41404-C HARNESS CONNECTOR TEST KIT 8.2 DTC B2006-B2015, RADIO SWITCH DIA-
GNOSTICS, Radio Switch Diagnostics
HD-41404-C HARNESS CONNECTOR TEST KIT 8.2 DTC B2006-B2015, RADIO SWITCH DIA-
GNOSTICS, Radio Switch Diagnostics
HD-41404-C HARNESS CONNECTOR TEST KIT 8.2 DTC B2006-B2015, RADIO SWITCH DIA-
GNOSTICS, Radio Switch Diagnostics
HD-41404-C HARNESS CONNECTOR TEST KIT 8.2 DTC B2006-B2015, RADIO SWITCH DIA-
GNOSTICS, Radio Switch Diagnostics
HD-41404-C HARNESS CONNECTOR TEST KIT 8.2 DTC B2006-B2015, RADIO SWITCH DIA-
GNOSTICS, Radio Switch Diagnostics
HD-41404-C HARNESS CONNECTOR TEST KIT 8.2 DTC B2006-B2015, RADIO SWITCH DIA-
GNOSTICS, Radio Switch Diagnostics
HD-41404-C HARNESS CONNECTOR TEST KIT 8.4 SERIAL DATA BUS DIAGNOSTICS, DTC U1302
Infotainment Bus Off Error
HD-41404-C HARNESS CONNECTOR TEST KIT 8.4 SERIAL DATA BUS DIAGNOSTICS, DTC U1317
Infotainment Bus Lost Communication with High Output
Amplifier
HD-41404-C HARNESS CONNECTOR TEST KIT 8.5 ADVANCED AUDIO SYSTEM SYMPTOMS, Symptom
7: Handheld Microphone/PTT Inoperative
HD-41404-C HARNESS CONNECTOR TEST KIT 8.5 ADVANCED AUDIO SYSTEM SYMPTOMS, Symptom
8: Fairing Mounted Speaker Switch Malfunction
HD-41404-C HARNESS CONNECTOR TEST KIT 8.5 ADVANCED AUDIO SYSTEM SYMPTOMS, Symptom
8: Fairing Mounted Speaker Switch Malfunction

IV TOOLS
 Tools Used in This Manual
PART NUMBER TOOL NAME NOTES
HD-41404-C HARNESS CONNECTOR TEST KIT 8.5 ADVANCED AUDIO SYSTEM SYMPTOMS, Symptom
9: Headset Speakers Inoperative
HD-41404-C HARNESS CONNECTOR TEST KIT 8.5 ADVANCED AUDIO SYSTEM SYMPTOMS, Symptom
9: Headset Speakers Inoperative
HD-41404-C HARNESS CONNECTOR TEST KIT 8.5 ADVANCED AUDIO SYSTEM SYMPTOMS, Symptom
10: No or Low Audio from Microphones
HD-41404-C HARNESS CONNECTOR TEST KIT 8.5 ADVANCED AUDIO SYSTEM SYMPTOMS, Symptom
12: No or Low Audio from XM or XM Inoperative
HD-41404-C HARNESS CONNECTOR TEST KIT 8.5 ADVANCED AUDIO SYSTEM SYMPTOMS, Symptom
13: No or Intermittent Reception on XM Module
HD-41404-C HARNESS CONNECTOR TEST KIT 8.5 ADVANCED AUDIO SYSTEM SYMPTOMS, Symptom
18: Hands-Free Phone Module Initial Diagnostics
HD-41475 DEUTSCH TERMINAL REPAIR KIT A.12 DEUTSCH DT SEALED CONNECTORS, Deutsch
DT Sealed Connector Repair
HD-41475-100 FLAT BLADE L-HOOK A.12 DEUTSCH DT SEALED CONNECTORS, Deutsch
DT Sealed Connector Repair
HD-41609 AMP MULTI-LOCK CRIMPER A.19 TYCO 070 MULTILOCK UNSEALED CON-
NECTOR, Tyco 070 Multilock Unsealed Connector Repair
HD-41609 AMP MULTI-LOCK CRIMPER A.19 TYCO 070 MULTILOCK UNSEALED CON-
NECTOR, Tyco 070 Multilock Unsealed Connector Repair
HD-42662 BREAKOUT BOX 8.5 ADVANCED AUDIO SYSTEM SYMPTOMS, Symptom
5: CB Receiver Inoperative
HD-42682 BREAKOUT BOX 1.2 DIAGNOSTIC TOOLS, How To Use Diagnostic Tools
HD-42682 BREAKOUT BOX 1.2 DIAGNOSTIC TOOLS, How To Use Diagnostic Tools
HD-42682 BREAKOUT BOX 1.2 DIAGNOSTIC TOOLS, How To Use Diagnostic Tools
HD-42682 BREAKOUT BOX 2.3 DTC U1016, U1040, U1064, U1097, U1255, DTC
U1016
HD-42682 BREAKOUT BOX 2.3 DTC U1016, U1040, U1064, U1097, U1255, DTC
U1016
HD-42682 BREAKOUT BOX 2.3 DTC U1016, U1040, U1064, U1097, U1255, DTC
U1016
HD-42682 BREAKOUT BOX 2.3 DTC U1016, U1040, U1064, U1097, U1255, DTC
U1040, U1255
HD-42682 BREAKOUT BOX 2.3 DTC U1016, U1040, U1064, U1097, U1255, DTC
U1064, U1255
HD-42682 BREAKOUT BOX 2.3 DTC U1016, U1040, U1064, U1097, U1255, DTC
U1064, U1255
HD-42682 BREAKOUT BOX 2.3 DTC U1016, U1040, U1064, U1097, U1255, DTC
U1097, U1255
HD-42682 BREAKOUT BOX 2.3 DTC U1016, U1040, U1064, U1097, U1255, DTC
U1097, U1255
HD-42682 BREAKOUT BOX 2.4 DTC U1300, U1301 OR BUS ER, DTC U1300
HD-42682 BREAKOUT BOX 2.4 DTC U1300, U1301 OR BUS ER, DTC U1301
HD-42682 BREAKOUT BOX 3.2 STARTING SYSTEM, Nothing Clicks
HD-42682 BREAKOUT BOX 4.2 DTC B1004, B1005, DTC B1004
HD-42682 BREAKOUT BOX 4.2 DTC B1004, B1005, DTC B1005
HD-42682 BREAKOUT BOX 4.4 NO INSTRUMENT POWER, Speedometer Inoper-
ative

TOOLS V
 Tools Used in This Manual
PART NUMBER TOOL NAME NOTES
HD-42682 BREAKOUT BOX 4.4 NO INSTRUMENT POWER, Speedometer Inoper-
ative
HD-42682 BREAKOUT BOX 4.4 NO INSTRUMENT POWER, Speedometer Inoper-
ative
HD-42682 BREAKOUT BOX 4.4 NO INSTRUMENT POWER, Speedometer Inoper-
ative
HD-42682 BREAKOUT BOX 5.6 TURN SIGNALS, Both Turn Signal Lamps on One
Side Inoperative, No DTCs
HD-42682 BREAKOUT BOX 5.10 DTC B1121, B1122, B1123, B1124, B1125,
B1126, DTC B1121: HFSM
HD-42682 BREAKOUT BOX 5.15 SERVICE AND EMERGENCY FUNCTIONS AND
CONFIGURATIONS, Power Disruption and Configuring:
HFSM
HD-42682 BREAKOUT BOX 5.17 DTC B1131, B1132, DTC B1131
HD-42682 BREAKOUT BOX 5.17 DTC B1131, B1132, DTC B1131
HD-42682 BREAKOUT BOX 5.20 DTC B1154, B1155, DTC B1154
HD-42682 BREAKOUT BOX 7.16 ABS INDICATOR ALWAYS ON OR INOPER-
ATIVE, ABS Indicator Always On or Inoperative
HD-42682 BREAKOUT BOX 8.5 ADVANCED AUDIO SYSTEM SYMPTOMS, Symptom
12: No or Low Audio from XM or XM Inoperative
HD-42879 ELECTRICAL CRIMPER TOOL A.15 DEUTSCH DTM SEALED SOLID BARREL MINI
TERMINAL REPAIR, Deutsch DTM Sealed Solid Barrel
Terminal Crimps
HD-44608 RADIO BREAKOUT BOX 8.4 SERIAL DATA BUS DIAGNOSTICS, DTC U1317
Infotainment Bus Lost Communication with High Output
Amplifier
HD-44608 RADIO BREAKOUT BOX 8.5 ADVANCED AUDIO SYSTEM SYMPTOMS, Symptom
11: No or Low Audio with High Output Amplifier
HD-44687 IGNITION COIL CIRCUIT TEST ADAPTER 1.2 DIAGNOSTIC TOOLS, How To Use Diagnostic Tools
HD-44687 IGNITION COIL CIRCUIT TEST ADAPTER 1.2 DIAGNOSTIC TOOLS, How To Use Diagnostic Tools
HD-45325 JUMPER HARNESS 2.4 DTC U1300, U1301 OR BUS ER, DTC U1300
HD-45325 JUMPER HARNESS 2.4 DTC U1300, U1301 OR BUS ER, DTC U1301
HD-45325 JUMPER HARNESS 7.16 ABS INDICATOR ALWAYS ON OR INOPER-
ATIVE, ABS Indicator Always On or Inoperative
HD-45325 JUMPER HARNESS 8.5 ADVANCED AUDIO SYSTEM SYMPTOMS, Symptom
5: CB Receiver Inoperative
HD-45325 JUMPER HARNESS 8.5 ADVANCED AUDIO SYSTEM SYMPTOMS, Symptom
12: No or Low Audio from XM or XM Inoperative
HD-45928 TERMINAL REMOVER A.9 DELPHI MICRO 64 SEALED CONNECTORS, Delphi
Micro 64 Sealed Connector Repair
HD-45929 TERMINAL CRIMPER A.9 DELPHI MICRO 64 SEALED CONNECTORS, Delphi
Micro 64 Sealed Connector Repair
HD-46601 BREAKOUT BOX ADAPTERS 1.2 DIAGNOSTIC TOOLS, How To Use Diagnostic Tools
HD-46601 BREAKOUT BOX ADAPTERS 1.2 DIAGNOSTIC TOOLS, How To Use Diagnostic Tools
HD-46601 BREAKOUT BOX ADAPTERS 2.3 DTC U1016, U1040, U1064, U1097, U1255, DTC
U1016
HD-46601 BREAKOUT BOX ADAPTERS 2.3 DTC U1016, U1040, U1064, U1097, U1255, DTC
U1016

VI TOOLS
 Tools Used in This Manual
PART NUMBER TOOL NAME NOTES
HD-46601 BREAKOUT BOX ADAPTERS 2.3 DTC U1016, U1040, U1064, U1097, U1255, DTC
U1040, U1255
HD-46601 BREAKOUT BOX ADAPTERS 2.3 DTC U1016, U1040, U1064, U1097, U1255, DTC
U1064, U1255
HD-46601 BREAKOUT BOX ADAPTERS 2.3 DTC U1016, U1040, U1064, U1097, U1255, DTC
U1064, U1255
HD-46601 BREAKOUT BOX ADAPTERS 2.3 DTC U1016, U1040, U1064, U1097, U1255, DTC
U1097, U1255
HD-46601 BREAKOUT BOX ADAPTERS 2.3 DTC U1016, U1040, U1064, U1097, U1255, DTC
U1097, U1255
HD-46601 BREAKOUT BOX ADAPTERS 4.2 DTC B1004, B1005, DTC B1004
HD-46601 BREAKOUT BOX ADAPTERS 4.2 DTC B1004, B1005, DTC B1005
HD-46601 BREAKOUT BOX ADAPTERS 4.4 NO INSTRUMENT POWER, Speedometer Inoper-
ative
HD-46601 BREAKOUT BOX ADAPTERS 4.4 NO INSTRUMENT POWER, Speedometer Inoper-
ative
HD-46601 BREAKOUT BOX ADAPTERS 4.4 NO INSTRUMENT POWER, Speedometer Inoper-
ative
HD-46601 BREAKOUT BOX ADAPTERS 4.4 NO INSTRUMENT POWER, Speedometer Inoper-
ative
HD-47918 ADVANCED AUDIO SYSTEM BREAKOUT 1.2 DIAGNOSTIC TOOLS, How To Use Diagnostic Tools
BOX
HD-47918 ADVANCED AUDIO SYSTEM BREAKOUT 8.2 DTC B2006-B2015, RADIO SWITCH DIA-
BOX GNOSTICS, Diagnostics
HD-47918 ADVANCED AUDIO SYSTEM BREAKOUT 8.2 DTC B2006-B2015, RADIO SWITCH DIA-
BOX GNOSTICS, Radio Switch Diagnostics
HD-47918 ADVANCED AUDIO SYSTEM BREAKOUT 8.2 DTC B2006-B2015, RADIO SWITCH DIA-
BOX GNOSTICS, Radio Switch Diagnostics
HD-47918 ADVANCED AUDIO SYSTEM BREAKOUT 8.2 DTC B2006-B2015, RADIO SWITCH DIA-
BOX GNOSTICS, Radio Switch Diagnostics
HD-47918 ADVANCED AUDIO SYSTEM BREAKOUT 8.2 DTC B2006-B2015, RADIO SWITCH DIA-
BOX GNOSTICS, Radio Switch Diagnostics
HD-47918 ADVANCED AUDIO SYSTEM BREAKOUT 8.2 DTC B2006-B2015, RADIO SWITCH DIA-
BOX GNOSTICS, Radio Switch Diagnostics
HD-47918 ADVANCED AUDIO SYSTEM BREAKOUT 8.2 DTC B2006-B2015, RADIO SWITCH DIA-
BOX GNOSTICS, Radio Switch Diagnostics
HD-47918 ADVANCED AUDIO SYSTEM BREAKOUT 8.2 DTC B2006-B2015, RADIO SWITCH DIA-
BOX GNOSTICS, Radio Switch Diagnostics
HD-47918 ADVANCED AUDIO SYSTEM BREAKOUT 8.2 DTC B2006-B2015, RADIO SWITCH DIA-
BOX GNOSTICS, Radio Switch Diagnostics
HD-47918 ADVANCED AUDIO SYSTEM BREAKOUT 8.2 DTC B2006-B2015, RADIO SWITCH DIA-
BOX GNOSTICS, Radio Switch Diagnostics
HD-47918 ADVANCED AUDIO SYSTEM BREAKOUT 8.2 DTC B2006-B2015, RADIO SWITCH DIA-
BOX GNOSTICS, Radio Switch Diagnostics
HD-47918 ADVANCED AUDIO SYSTEM BREAKOUT 8.2 DTC B2006-B2015, RADIO SWITCH DIA-
BOX GNOSTICS, Radio Switch Diagnostics
HD-47918 ADVANCED AUDIO SYSTEM BREAKOUT 8.2 DTC B2006-B2015, RADIO SWITCH DIA-
BOX GNOSTICS, Radio Switch Diagnostics

TOOLS VII
 Tools Used in This Manual
PART NUMBER TOOL NAME NOTES
HD-47918 ADVANCED AUDIO SYSTEM BREAKOUT 8.2 DTC B2006-B2015, RADIO SWITCH DIA-
BOX GNOSTICS, Radio Switch Diagnostics
HD-47918 ADVANCED AUDIO SYSTEM BREAKOUT 8.2 DTC B2006-B2015, RADIO SWITCH DIA-
BOX GNOSTICS, Radio Switch Diagnostics
HD-47918 ADVANCED AUDIO SYSTEM BREAKOUT 8.3 DTC B2016-B2027, RADIO SPEAKER DIA-
BOX GNOSTICS, Description and Operation
HD-47918 ADVANCED AUDIO SYSTEM BREAKOUT 8.4 SERIAL DATA BUS DIAGNOSTICS, DTC U1302
BOX Infotainment Bus Off Error
HD-47918 ADVANCED AUDIO SYSTEM BREAKOUT 8.4 SERIAL DATA BUS DIAGNOSTICS, DTC U1317
BOX Infotainment Bus Lost Communication with High Output
Amplifier
HD-47918 ADVANCED AUDIO SYSTEM BREAKOUT 8.5 ADVANCED AUDIO SYSTEM SYMPTOMS, Symptom
BOX 1: Radio Inoperative
HD-47918 ADVANCED AUDIO SYSTEM BREAKOUT 8.5 ADVANCED AUDIO SYSTEM SYMPTOMS, Symptom
BOX 5: CB Receiver Inoperative
HD-47918 ADVANCED AUDIO SYSTEM BREAKOUT 8.5 ADVANCED AUDIO SYSTEM SYMPTOMS, Symptom
BOX 8: Fairing Mounted Speaker Switch Malfunction
HD-47918 ADVANCED AUDIO SYSTEM BREAKOUT 8.5 ADVANCED AUDIO SYSTEM SYMPTOMS, Symptom
BOX 8: Fairing Mounted Speaker Switch Malfunction
HD-47918 ADVANCED AUDIO SYSTEM BREAKOUT 8.5 ADVANCED AUDIO SYSTEM SYMPTOMS, Symptom
BOX 9: Headset Speakers Inoperative
HD-47918 ADVANCED AUDIO SYSTEM BREAKOUT 8.5 ADVANCED AUDIO SYSTEM SYMPTOMS, Symptom
BOX 9: Headset Speakers Inoperative
HD-47918 ADVANCED AUDIO SYSTEM BREAKOUT 8.5 ADVANCED AUDIO SYSTEM SYMPTOMS, Symptom
BOX 10: No or Low Audio from Microphones
HD-47918 ADVANCED AUDIO SYSTEM BREAKOUT 8.5 ADVANCED AUDIO SYSTEM SYMPTOMS, Symptom
BOX 12: No or Low Audio from XM or XM Inoperative
HD-47918 ADVANCED AUDIO SYSTEM BREAKOUT 8.5 ADVANCED AUDIO SYSTEM SYMPTOMS, Symptom
BOX 12: No or Low Audio from XM or XM Inoperative
HD-47918 ADVANCED AUDIO SYSTEM BREAKOUT 8.5 ADVANCED AUDIO SYSTEM SYMPTOMS, Symptom
BOX 17: CD Skipping
HD-47918 ADVANCED AUDIO SYSTEM BREAKOUT 8.5 ADVANCED AUDIO SYSTEM SYMPTOMS, Symptom
BOX 18: Hands-Free Phone Module Initial Diagnostics
HD-48037 SWR METER ADAPTERS 8.5 ADVANCED AUDIO SYSTEM SYMPTOMS, Dia-
gnostics
HD-48053 ADVANCED BATTERY CONDUCTANCE 1.2 DIAGNOSTIC TOOLS, How To Use Diagnostic Tools
AND ELECTRICAL SYSTEM ANALYZER
HD-48053 ADVANCED BATTERY CONDUCTANCE 3.1 BATTERY TESTING, Conductance Test
AND ELECTRICAL SYSTEM ANALYZER
HD-48114 TERMINAL REMOVER A.18 MOLEX MX 150 SEALED CONNECTORS, Molex
MX 150 Sealed Connector Repair
HD-48119 TERMINAL CRIMPER A.18 MOLEX MX 150 SEALED CONNECTORS, Crimp
Terminal to Lead
HD-48637 BREAKOUT BOX 1.2 DIAGNOSTIC TOOLS, How To Use Diagnostic Tools
HD-48637 BREAKOUT BOX 1.2 DIAGNOSTIC TOOLS, How To Use Diagnostic Tools
HD-48637 BREAKOUT BOX 1.2 DIAGNOSTIC TOOLS, How To Use Diagnostic Tools
HD-48637 BREAKOUT BOX 1.3 DIAGNOSTICS AND TROUBLESHOOTING, Wiggle
Test

VIII TOOLS
 Tools Used in This Manual
PART NUMBER TOOL NAME NOTES
HD-48637 BREAKOUT BOX 2.3 DTC U1016, U1040, U1064, U1097, U1255, DTC
U1016
HD-48637 BREAKOUT BOX 2.3 DTC U1016, U1040, U1064, U1097, U1255, DTC
U1064, U1255
HD-48637 BREAKOUT BOX 2.3 DTC U1016, U1040, U1064, U1097, U1255, DTC
U1097, U1255
HD-48637 BREAKOUT BOX 3.6 DTC B0563, P0562, P0563, DTC P0562
HD-48637 BREAKOUT BOX 5.4 DTC P0577, DTC P0577
HD-48637 BREAKOUT BOX 6.4 DTC P0107, P0108, P0112, P0113, DTC P0107
HD-48637 BREAKOUT BOX 6.4 DTC P0107, P0108, P0112, P0113, DTC P0112
HD-48637 BREAKOUT BOX 6.4 DTC P0107, P0108, P0112, P0113, DTC P0113
HD-48637 BREAKOUT BOX 6.5 DTC P0117, P0118, DTC P0117
HD-48637 BREAKOUT BOX 6.5 DTC P0117, P0118, DTC P0118
HD-48637 BREAKOUT BOX 6.6 DTC P0120, P0122, P0123, P0220, P0222,
P0223, DTC P0120
HD-48637 BREAKOUT BOX 6.6 DTC P0120, P0122, P0123, P0220, P0222,
P0223, DTC P0122
HD-48637 BREAKOUT BOX 6.6 DTC P0120, P0122, P0123, P0220, P0222,
P0223, DTC P0123
HD-48637 BREAKOUT BOX 6.6 DTC P0120, P0122, P0123, P0220, P0222,
P0223, DTC P0220
HD-48637 BREAKOUT BOX 6.6 DTC P0120, P0122, P0123, P0220, P0222,
P0223, DTC P0222
HD-48637 BREAKOUT BOX 6.6 DTC P0120, P0122, P0123, P0220, P0222,
P0223, DTC P0223
HD-48637 BREAKOUT BOX 6.7 DTC P0031, P0032, P0131, P0132, P0134, P0151,
P0152, P0154, DTC P0031
HD-48637 BREAKOUT BOX 6.7 DTC P0031, P0032, P0131, P0132, P0134, P0151,
P0152, P0154, DTC P0131
HD-48637 BREAKOUT BOX 6.7 DTC P0031, P0032, P0131, P0132, P0134, P0151,
P0152, P0154, DTC P0134
HD-48637 BREAKOUT BOX 6.7 DTC P0031, P0032, P0131, P0132, P0134, P0151,
P0152, P0154, DTC P0151
HD-48637 BREAKOUT BOX 6.8 DTC P0261, P0262, P0263, P0264, DTC P0261
HD-48637 BREAKOUT BOX 6.8 DTC P0261, P0262, P0263, P0264, DTC P0263
HD-48637 BREAKOUT BOX 6.10 DTC P0444, P0445, DTC P0444
HD-48637 BREAKOUT BOX 6.11 DTC P0501, P0502, DTC P0501
HD-48637 BREAKOUT BOX 6.11 DTC P0501, P0502, DTC P0502
HD-48637 BREAKOUT BOX 6.13 DTC P0572, DTC P0572
HD-48637 BREAKOUT BOX 6.13 DTC P0572, DTC P0572
HD-48637 BREAKOUT BOX 6.16 DTC P1001, P1002, P1003, P1004, DTC P1004
HD-48637 BREAKOUT BOX 6.19 DTC P1351, P1352, P1354, P1355, DTC P1351
HD-48637 BREAKOUT BOX 6.19 DTC P1351, P1352, P1354, P1355, DTC P1354
HD-48637 BREAKOUT BOX 6.20 DTC P1353, P1356, P1357, P1358, DTC P1357,
P1358

TOOLS IX
 Tools Used in This Manual
PART NUMBER TOOL NAME NOTES
HD-48637 BREAKOUT BOX 6.20 DTC P1353, P1356, P1357, P1358, DTC P1357,
P1358
HD-48637 BREAKOUT BOX 6.21 DTC P1475, P1477, P1478, DTC P1477
HD-48637 BREAKOUT BOX 6.21 DTC P1475, P1477, P1478, DTC P1478
HD-48637 BREAKOUT BOX 6.26 DTC P1655, P1656, DTC P1655
HD-48637 BREAKOUT BOX 6.27 DTC P2100, P2101, P2102, P2103, DTC P2100
HD-48637 BREAKOUT BOX 6.27 DTC P2100, P2101, P2102, P2103, DTC P2101
HD-48637 BREAKOUT BOX 6.27 DTC P2100, P2101, P2102, P2103, DTC P2103
HD-48637 BREAKOUT BOX 6.30 DTC P2122, P2123, P2127, P2128, DTC P2123
HD-48637 BREAKOUT BOX 6.30 DTC P2122, P2123, P2127, P2128, DTC P2127
HD-48637 BREAKOUT BOX 6.30 DTC P2122, P2123, P2127, P2128, DTC P2128
HD-48637 BREAKOUT BOX 6.31 DTC P2135, P2138, DTC P2135
HD-48637 BREAKOUT BOX 6.31 DTC P2135, P2138, DTC P2138
HD-48637 BREAKOUT BOX 6.34 NO ECM POWER, No ECM Power
HD-48637 BREAKOUT BOX 6.37 MISFIRE AT IDLE OR UNDER LOAD, Misfire At
Idle or Under Load
HD-48637 BREAKOUT BOX 8.4 SERIAL DATA BUS DIAGNOSTICS, DTC U1016
J1850 Loss of Communication with ECM
HD-48642 ABS BREAKOUT BOX 1.2 DIAGNOSTIC TOOLS, How To Use Diagnostic Tools
HD-48642 ABS BREAKOUT BOX 2.3 DTC U1016, U1040, U1064, U1097, U1255, DTC
U1040, U1255
HD-48642 ABS BREAKOUT BOX 2.3 DTC U1016, U1040, U1064, U1097, U1255, DTC
U1040, U1255
HD-48642 ABS BREAKOUT BOX 7.2 DTC C1017, C1018, DTC C1017
HD-48642 ABS BREAKOUT BOX 7.2 DTC C1017, C1018, DTC C1017
HD-48642 ABS BREAKOUT BOX 7.2 DTC C1017, C1018, DTC C1018
HD-48642 ABS BREAKOUT BOX 7.4 DTC C1025, C1027, C1206, C1208, DTC C1025
(Front), C1027 (Rear), C1206, C1208
HD-48642 ABS BREAKOUT BOX 7.5 DTC C1032, C1034, DTC C1032
HD-48642 ABS BREAKOUT BOX 7.5 DTC C1032, C1034, DTC C1034
HD-48642 ABS BREAKOUT BOX 7.6 DTC C1042, C1043, DTC C1042
HD-48642 ABS BREAKOUT BOX 7.6 DTC C1042, C1043, DTC C1043
HD-48642 ABS BREAKOUT BOX 7.7 DTC C1094, DTC C1094
HD-48642 ABS BREAKOUT BOX 7.8 DTC C1095, DTC C1095
HD-48642 ABS BREAKOUT BOX 7.12 DTC C1212, DTC C1212
HD-48642 ABS BREAKOUT BOX 7.13 DTC C1214, DTC C1214
HD-48642 ABS BREAKOUT BOX 7.14 DTC C1216, DTC C1216
HD-48642 ABS BREAKOUT BOX 7.15 DTC C1014, C1055-C1066, C1118, C1121, DTC
C1014, C1055-C1066, C1118, C1121
HD-48642 ABS BREAKOUT BOX 7.16 ABS INDICATOR ALWAYS ON OR INOPER-
ATIVE, ABS Indicator Always On or Inoperative
HD-48650 DIGITAL TECHNICIAN II 1.2 DIAGNOSTIC TOOLS, How To Use Diagnostic Tools
HD-48650 DIGITAL TECHNICIAN II 1.3 DIAGNOSTICS AND TROUBLESHOOTING, Job/Time
Codes Values
HD-48650 DIGITAL TECHNICIAN II 5.12 SECURITY SYSTEM, TSSM/HFSM Features

X TOOLS
 Tools Used in This Manual
PART NUMBER TOOL NAME NOTES
HD-48650 DIGITAL TECHNICIAN II 6.1 EFI SYSTEM, General
HD-48650 DIGITAL TECHNICIAN II 6.7 DTC P0031, P0032, P0131, P0132, P0134, P0151,
P0152, P0154, Description and Operation
HD-48650 DIGITAL TECHNICIAN II 7.1 ANTI-LOCK BRAKE SYSTEM (ABS) GENERAL
INFORMATION, Description and Operation
HD-48650 DIGITAL TECHNICIAN II 7.3 DTC C1021, C1023, Description and Operation
HD-48650 DIGITAL TECHNICIAN II 7.5 DTC C1032, C1034, Description and Operation
HD-48650 DIGITAL TECHNICIAN II 7.6 DTC C1042, C1043, Description and Operation
HD-48650 DIGITAL TECHNICIAN II 7.7 DTC C1094, Description and Operation
HD-48650 DIGITAL TECHNICIAN II 7.8 DTC C1095, Description and Operation
HD-48650 DIGITAL TECHNICIAN II 7.9 DTC C1151, Description and Operation
HD-48650 DIGITAL TECHNICIAN II 7.13 DTC C1214, Description and Operation
HD-48650 DIGITAL TECHNICIAN II 7.14 DTC C1216, Description and Operation
HD-48650 DIGITAL TECHNICIAN II 7.15 DTC C1014, C1055-C1066, C1118,
C1121, Description and Operation
HD-48650 DIGITAL TECHNICIAN II 8.1 RADIO DIAGNOSTICS, Diagnostics
SNAP-ON TT600-3 SNAP-ON PICK A.6 DELPHI 630 METRI-PACK UNSEALED CON-
NECTORS, Delphi 630 Metri-Pack Unsealed Connector
Repair
SNAP-ON TT600-3 SNAP-ON PICK A.19 TYCO 070 MULTILOCK UNSEALED CON-
NECTOR, Tyco 070 Multilock Unsealed Connector Repair
YA840 SNAP-ON IN-LINE SPARK TESTER 6.37 MISFIRE AT IDLE OR UNDER LOAD, In-line Spark
Tester
YA840 SNAP-ON IN-LINE SPARK TESTER 6.37 MISFIRE AT IDLE OR UNDER LOAD, Misfire At
Idle or Under Load

TOOLS XI
NOTES

XII TOOLS
 2011 Touring Models Electrical Diagnostic Manual
FASTENER TORQUE VALUE NOTES
No torque values were found in this manual.

TORQUE VALUES

XIII
NOTES

XIV TORQUE VALUES


A Molex CMC Sealed. . . . . . . . . . . . . . . . . . . . . . . . . A-29
ABS Diode Pack Location. . . . . . . . . . . . . . . . . . . . . . . . . 1-7
ABS Indicator Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . 7-39
ABS Indicator Operation. . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
ABS Module Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
AC Output Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Active Exhaust. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Active Exhaust Location. . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Alarm
Activation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48
Deactivation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48
Alarm Sensitivity (TSSM). . . . . . . . . . . . . . . . . . . . . . . . 5-48
Alternator Description. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Alternator Rotor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Ambient Air Temperature Gauge
Problem. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Ambient Air Temperature Sensor Location. . . . . . . . . . . . 1-4
Antenna Cable Location. . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Anti-lock Brake System (ABS) Description. . . . . . . . . . . . 7-1
Initialization Self-Test. . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Pressure Decrease. . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Pressure Hold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Pressure Increase. . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Autofuse Electrical Connector. . . . . . . . . . . . . . . . . . . . . . A-1
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Automatic Compression Release (ACR)
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-78
Auxiliary Lamps Diagnostics. . . . . . . . . . . . . . . . . . . . . . 5-27
B Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-13
BAS Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Battery Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Battery Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Bus ER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
C Deutsch DTM Sealed Solid Barrel Connector
CB Antenna Cable Location. . . . . . . . . . . . . . . . . . . . . . . 1-2
Changing the Pin
Modifying an Existing Pin. . . . . . . . . . . . . . . . . . . . . 5-56
Charging System Description. . . . . . . . . . . . . . . . . . . . . 3-16
Charging System Diagnostics. . . . . . . . . . . . . . . . . . . . . 3-17
Charging System Output Test. . . . . . . . . . . . . . . . . . . . . 3-19
Check Engine Lamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Cigar Lighter Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
CKP Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
CKP Sensor Description. . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
CKP Sensor Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
CKP Synchronization. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Clearing DTCs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Clutch Switch Description. . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Conductance Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Connector Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Connectors
Autofuse Unsealed. . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Delphi 100W Micro-Pack Sealed. . . . . . . . . . . . . . . . A-2
Delphi 150 Metri-Pack Sealed. . . . . . . . . . . . . . . . . . A-4
Delphi 280 Metri-Pack Unsealed. . . . . . . . . . . . . . . . A-6
Delphi 480 Metri-Pack Unsealed. . . . . . . . . . . . . . . . A-7
Delphi 630 Metri-Pack Unsealed. . . . . . . . . . . . . . . . A-8
Delphi 800 Metri-Pack Sealed. . . . . . . . . . . . . . . . . . A-9
Delphi GT 280 Sealed. . . . . . . . . . . . . . . . . . . . . . . A-18
Delphi Micro 64 Sealed. . . . . . . . . . . . . . . . . . . . . . A-13
Deutsch DTM Sealed Mini. . . . . . . . . . . . . . . . . . . . A-25
Deutsch DTM Sealed Solid Barrel. . . . . . . . . . . . . . A-26
Deutsch DT Sealed. . . . . . . . . . . . . . . . . . . . . . . . . A-20
JAE MX19 Sealed. . . . . . . . . . . . . . . . . . . . . . . . . . A-28
Metri-Pack Terminal Crimps. . . . . . . . . . . . . . . . . . . A-11
Molex MX 150 Sealed. . . . . . . . . . . . . . . . . . . . . . . A-31
Sealed Splice. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-39
Tyco 070 Multilock Unsealed. . . . . . . . . . . . . . . . . . A-35
Conversions
Fluid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
Length. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
Cruise Control
Description and Operation. . . . . . . . . . . . . . . . . . . . . 5-7
Cruise Control Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . 5-8
Current Draw Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Current DTCs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
D
Data Link Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Delphi 100W Sealed Connector
Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Delphi 150 Metri-Pack Connector
Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
Delphi 280 Metri-Pack Unsealed Connectors. . . . . . . . . . A-6
Delphi 480 Metri-Pack Unsealed Connector
Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7
Delphi 630 Metri-Pack Unsealed Connector. . . . . . . . . . . A-8
Delphi 800 Metri-Pack Sealed Connectors
Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9
Delphi Connector
Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-16
Delphi GT 280 Sealed Connector. . . . . . . . . . . . . . . . . . A-18
Delphi Micro-64 Sealed Connector
Deutsch Connector
INDEX
Crimping Standard Terminals. . . . . . . . . . . . . . . . . . A-24
Deutsch DTM Sealed Mini Connector
Crimping Terminals. . . . . . . . . . . . . . . . . . . . . . . . . A-25
Crimping Terminals. . . . . . . . . . . . . . . . . . . . . . . . . A-26
Deutsch DT Sealed Connector
Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-20
Diagnostic Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
DLC Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
DTC Priority Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
DTC B0563. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
DTC B1004. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
DTC B1005. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
DTC B1006. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
DTC B1007. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
DTC B1008. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
DTC B1121. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37
DTC B1122. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37
DTC B1123. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37
DTC B1124. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37
DTC B1125. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37
DTC B1126. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37
DTC B1131. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-63
DTC B1132. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-63
DTC B1134. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-66
DTC B1135. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44
DTC B1136. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44
DTC B1141. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44
DTC B1142. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44
DTC B1143. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68
DTC B1144. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68
DTC B1145. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68
DTC B1154. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-70
DTC B1155. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-70
DTC B2006. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
XV
 DTC B2007. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
DTC B2008. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
DTC B2009. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
DTC B2010. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
DTC B2011. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
DTC B2012. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
DTC B2013. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
DTC B2014. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
DTC B2015. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
DTC B2016. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
DTC B2017. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
DTC B2018. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
DTC B2019. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
DTC B2020. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
DTC B2021. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
DTC B2022. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
DTC B2023. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
DTC B2024. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
DTC B2025. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
DTC B2026. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
DTC B2027. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
DTC C1014. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36
DTC C1017. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
DTC C1018. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
DTC C1021. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
DTC C1023. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
DTC C1025. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
DTC C1027. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
DTC C1032. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
DTC C1034. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
DTC C1042. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
DTC C1043. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
DTC C1055. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36
DTC C1056. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36
DTC C1057. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36
DTC C1061. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36
DTC C1062. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36
DTC C1065. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36
DTC C1066. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36
DTC C1094. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
DTC C1095. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
DTC C1118. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36
DTC C1121. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36
DTC C1151. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
DTC C1153. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24
DTC C1158. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
DTC C1206. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
DTC C1208. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
DTC C1212. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27
DTC C1214. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30
DTC C1216. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33
DTC P0031. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
DTC P0032. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
DTC P0107. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
DTC P0108. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
DTC P0112. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
DTC P0113. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
DTC P0117. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
DTC P0118. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
DTC P0120. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
DTC P0122. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
DTC P0123. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
DTC P0131. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
XVI INDEX
DTC P0132. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
DTC P0134. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
DTC P0151. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
DTC P0152. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
DTC P0154. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
DTC P0220. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
DTC P0222. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
DTC P0223. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
DTC P0261. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30
DTC P0262. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30
DTC P0263. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30
DTC P0264. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30
DTC P0373. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
DTC P0374. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
DTC P0444. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36
DTC P0445. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36
DTC P0501. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39
DTC P0502. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39
DTC P0505. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43
DTC P0562. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
DTC P0563. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
DTC P0572. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45
DTC P0577. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
DTC P0603. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-48
DTC P0605. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-48
DTC P0641. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-49
DTC P0651. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-49
DTC P1001. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-52
DTC P1002. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-52
DTC P1003. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-52
DTC P1004. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-52
DTC P1009. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-56
DTC P1010. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-56
DTC P1270. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-58
DTC P1351. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-61
DTC P1352. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-61
DTC P1353. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-65
DTC P1354. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-61
DTC P1355. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-61
DTC P1356. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-65
DTC P1357. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-65
DTC P1358. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-65
DTC P1475. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-68
DTC P1477. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-68
DTC P1478. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-68
DTC P1501. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-72
DTC P1502. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-72
DTC P1510. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-75
DTC P1511. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-75
DTC P1512. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-75
DTC P1514. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-76
DTC P1600. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-77
DTC P1655. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-78
DTC P1656. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-78
DTC P2100. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-82
DTC P2101. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-82
DTC P2102. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-82
DTC P2103. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-82
DTC P2105. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-86
DTC P2107. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-86
DTC P2119. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-89
DTC P2122. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-90
DTC P2123. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-90
 DTC P2127. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-90
DTC P2128. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-90
DTC P2135. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-95
DTC P2138. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-95
DTC P2176. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-98
DTC U1016. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
DTC U1040. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
DTC U1064. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
DTC U1097. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
DTC U1255. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
DTC U1300. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
DTC U1301. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
E HD-48650 Digital Technician II. . . . . . . . . . . . . . . . . . . . 1-17
ECM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
ECM Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
ECM Drivers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Fuel Injectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Fuel Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Ignition Coils. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Purge Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Start Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
ECM Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
EFI System Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Engine Phase. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Engine Run Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Engine Stop Switch Description. . . . . . . . . . . . . . . . . . . . 3-3
Engine Symptoms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
ET Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
ET Sensor Description. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
ET Sensor Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
F Ignition Coil Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Fails to Disarm: HFSM Diagnostic. . . . . . . . . . . . . . . . . . 5-62
Fails to Disarm: TSSM Diagnostic. . . . . . . . . . . . . . . . . . 5-62
Fairing Cap Switches Location Oil Pressure Gauge
Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Fluid Conversions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
Free Running Current Draw Test. . . . . . . . . . . . . . . . . . . 3-14
Front ACR Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Front Fuel Injector Location. . . . . . . . . . . . . . . . . . . . . . . . 1-7
Front HO2S Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Front WSS Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Fuel Gauge
Fuel Gauge and Sender Test. . . . . . . . . . . . . . . . . . 4-20
Fuel Gauge Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Fuel Gauge Location Position Lamp Location: HDI. . . . . . 1-4
Fuel Gauge Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Fuel Injectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Fuel Injectors Description. . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Fuel Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Fuel Pump Description. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Fuel Pump Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Fuel System Electrical Test. . . . . . . . . . . . . . . . . . . . . . 6-106
Fuse Block Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Fuse Block Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6
G L
Glossary
Acronyms and Abbreviations. . . . . . . . . . . . . . . . . . . D-1
GND3 Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
GPS Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
H
HD-26792 Spark Tester. . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
HD-34730-2D Fuel Injector Test Light. . . . . . . . . . . . . . . 1-13
HD-39978 Digital Multimeter (Fluke 78). . . . . . . . . . . . . 1-13
HD-41404-C Harness Connector Test Kit. . . . . . . . . . . . 1-14
HD-42682 Breakout Box. . . . . . . . . . . . . . . . . . . . . . . . . 1-14
HD-42682 Breakout Box (TSM/TSSM/HFSM). . . . . . . . . 1-14
HD-44687 Ignition Coil Circuit Test Adapter. . . . . . . . . . 1-16
HD-47918 Advanced Audio System Breakout Box. . . . . 1-16
HD-48053 Advanced Battery Conductance and Electrical
System Analyzer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
HD-48637 Breakout Box (ECM). . . . . . . . . . . . . . . . . . . 1-15
Headlamp Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
Headlamp Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
Heated Grips Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Heated Handgrips
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Heat Management System. . . . . . . . . . . . . . . . . . . . . . . . 6-2
HFSM Antenna Location. . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
HFSM Fails to Disarm. . . . . . . . . . . . . . . . . . . . . . . . . . . 5-60
High Beam. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
High Beam Indicator Lamp Diagnostics. . . . . . . . . . . . . 4-19
History DTCs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
HO2S Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Horn Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Horn Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Horn Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Horn Switch Description. . . . . . . . . . . . . . . . . . . . . . . . . 5-14
I
Ignition Coils. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Ignition Switch Description. . . . . . . . . . . . . . . . . . . . . . . . 3-3
IM Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Indicator Lamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Indicator Lamps Location. . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Initial Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Diagnostic Procedure. . . . . . . . . . . . . . . . . . . . . . . . 2-21
J
JAE MX19 Sealed Connector
Connector Housings. . . . . . . . . . . . . . . . . . . . . . . . A-28
JAE MX19 Sealed Connectors
Installing Terminals. . . . . . . . . . . . . . . . . . . . . . . . . A-28
Removing Terminals. . . . . . . . . . . . . . . . . . . . . . . . . A-28
Job/Time Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
JSS Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
K
Key Fob
Fob Assignment (HFSM). . . . . . . . . . . . . . . . . . . . . 5-50
Fob Assignment (TSSM). . . . . . . . . . . . . . . . . . . . . 5-50
HFSM Fob. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50
TSSM Fob. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50
Left Front Speaker Location. . . . . . . . . . . . . . . . . . . . . . . 1-2
Load Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Loctite. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-II
Low Fuel Indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
INDEX XVII

M
Main Fuse Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Metric System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
Metri-Pack Terminal Crimps. . . . . . . . . . . . . . . . . . . . . . A-11
Milliampere Draw Test. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Molex CMC Sealed Connectors
Housings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-29
Installing Terminals. . . . . . . . . . . . . . . . . . . . . . . . . A-29
Removing Terminals. . . . . . . . . . . . . . . . . . . . . . . . . A-29
Molex MX 150 Sealed Connector
Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-31
Terminal Crimps. . . . . . . . . . . . . . . . . . . . . . . . . . . . A-32
Multiple DTCs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
N Power Disruption and Configuration: TSSM. . . . . . . 5-59
Nacelle Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Neutral Indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Neutral Lamp Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . 4-18
Neutral Switch Description. . . . . . . . . . . . . . . . . . . . . . . . 6-6
O CKP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
O2 Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Odometer Self-Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . 2-1
Oil Pressure Gauge and Indicator
Problem. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Oil Pressure Indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Oil Pressure Lamp Diagnostics. . . . . . . . . . . . . . . . . . . . 4-17
Oil Pressure Sensor Location. . . . . . . . . . . . . . . . . . . . . 1-11
P Serial Data
P&A Accessory Connector Location. . . . . . . . . . . . . . . . . 1-9
PIN Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-53
Changing the PIN. . . . . . . . . . . . . . . . . . . . . . . . . . . 5-56
Initial PIN Entry (HFSM). . . . . . . . . . . . . . . . . . . . . . 5-53
Initial PIN Entry (TSSM). . . . . . . . . . . . . . . . . . . . . . 5-54
Position Lamp Diagnostics (HDI). . . . . . . . . . . . . . . . . . . 5-36
Position Lamp Location: HDI Headlamp Location. . . . . . . 1-6
Position Lamp Location (HDI). . . . . . . . . . . . . . . . . . . . . . 1-2
Power Outlet Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Purge Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Purge Solenoid Description. . . . . . . . . . . . . . . . . . . . . . . . 6-7
Purge Solenoid Location. . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
R Specifications
Radio
Audio Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . 8-30
Factory Defaults. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-30
Serial Data Errors. . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22
Radio Description and Operation. . . . . . . . . . . . . . . . . . . 8-1
Radio Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Radio DTCs and Symptoms. . . . . . . . . . . . . . . . . . . . . . . 8-2
Radio Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Radio Symptom Diagnostics. . . . . . . . . . . . . . . . . . . . . . 8-30
Rear ACR Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Rear Brake Switch Location. . . . . . . . . . . . . . . . . . . . . . 1-11
Rear Fuel Injector Location. . . . . . . . . . . . . . . . . . . . . . . . 1-7
Rear HO2S Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Rear WSS Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Relay Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
Retrieving Trouble Codes. . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Right Front Speaker Location. . . . . . . . . . . . . . . . . . . . . . 1-2
Right Rear Speaker Location. . . . . . . . . . . . . . . . . . . . . . 1-9
Running Lamps Description. . . . . . . . . . . . . . . . . . . . . . 5-34
XVIII INDEX
Running Lamps Diagnostics. . . . . . . . . . . . . . . . . . . . . . 5-36
S
Sealed Splice Connectors. . . . . . . . . . . . . . . . . . . . . . . . A-39
Security Immobilization. . . . . . . . . . . . . . . . . . . . . . . . . . 5-45
Security Lamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Security Lamp Description. . . . . . . . . . . . . . . . . . . . . . . 5-45
Security Siren Location. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Security System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45
Arming (HFSM). . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46
Arming (TSSM). . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46
Auto-arming (TSSM). . . . . . . . . . . . . . . . . . . . . . . . 5-46
Disarming (HFSM). . . . . . . . . . . . . . . . . . . . . . . . . . 5-47
Disarming (TSSM). . . . . . . . . . . . . . . . . . . . . . . . . . 5-47
Power Disruption and Configuration: HFSM. . . . . . . 5-58
Security System Options (TSSM). . . . . . . . . . . . . . . . . . 5-46
Security System Warnings. . . . . . . . . . . . . . . . . . . . . . . 5-46
Sensors and Drivers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
BAS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Clutch Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
ET. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
IAT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
JSS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
MAP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Neutral Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
O2 Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
VSS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Serial Data Communication. . . . . . . . . . . . . . . . . . . . . . . 2-22
Service and Emergency Functions. . . . . . . . . . . . . . . . . 5-53
Actuation (HFSM). . . . . . . . . . . . . . . . . . . . . . . . . . . 5-53
Configuring TSSM. . . . . . . . . . . . . . . . . . . . . . . . . . 5-53
Service Bulletins. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-I
Service Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-57
Service Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-I
Siren Chirp Mode (HFSM). . . . . . . . . . . . . . . . . . . . . . . . 5-52
Siren Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-52
Sixth Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Smart Security System
Transport Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-57
Alternator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Fuel Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Fuse Rating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Idle Speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Ignition Coil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Regulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Spark Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Starter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Speedometer Location. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Speedometer Operation. . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
SPX Kent-Moore. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-II
Starter Current Draw Test. . . . . . . . . . . . . . . . . . . . . . . . 3-13
Starter Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Starter Solenoid
Solenoid Hold-In Test. . . . . . . . . . . . . . . . . . . . . . . . 3-14
Solenoid Pull-In Test. . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Solenoid Return Test. . . . . . . . . . . . . . . . . . . . . . . . 3-15
Starter Solenoid Description. . . . . . . . . . . . . . . . . . . . . . . 3-3
Starter Solenoid Location. . . . . . . . . . . . . . . . . . . . . . . . . 1-7
W
Starter Symptoms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Wiggle Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
Starter Testing Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . 3-7 Wiring Diagram Symbols. . . . . . . . . . . . . . . . . . . . . . . . . . B-7
Starter Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 WOW Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Starting System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Start Relay Description. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Start Switch Description. . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Stator Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Stop Lamp Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . 5-31
Stop Lamps Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
Storage Mode (TSSM). . . . . . . . . . . . . . . . . . . . . . . . . . . 5-57
Symptoms
Symptom Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
T
Tachometer Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Tachometer Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Tail Lamp Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
TCA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
TCA Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
TGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
TMAP Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
TMAP Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
TMAP Sensor Description. . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Torque Conversion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
Trademarks
Harley-Davidson. . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-II
Referenced Products. . . . . . . . . . . . . . . . . . . . . . . . . . I-II
Transport Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-57
Trip Odometer Reset Switch Operation. . . . . . . . . . . . . . . 4-1
TSM/TSSM/HFSM Location. . . . . . . . . . . . . . . . . . . . . . . 1-9
TSSM/HFSM Features
Arming Confirmation. . . . . . . . . . . . . . . . . . . . . . . . 5-46
Auto-arming (TSSM Only). . . . . . . . . . . . . . . . . . . . 5-46
Dealer Service Mode (HFSM Only). . . . . . . . . . . . . 5-46
Disarming Confirmation. . . . . . . . . . . . . . . . . . . . . . 5-46
Personal Code Disarming. . . . . . . . . . . . . . . . . . . . 5-46
Remote Arming/Disarming (TSSM Only). . . . . . . . . 5-46
Security Lamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46
Security System Alarm. . . . . . . . . . . . . . . . . . . . . . . 5-46
Starter/Ignition Disable. . . . . . . . . . . . . . . . . . . . . . . 5-46
Transport Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46
TSSM Fails to Disarm. . . . . . . . . . . . . . . . . . . . . . . . . . . 5-60
Turn Signal
Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Turn Signal Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Turn Signal Indicators Diagnostics. . . . . . . . . . . . . . . . . 4-19
Tyco 070 Multilock Unsealed Connector
Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-35
V
Voltage Drop Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
Voltage Regulator Description. . . . . . . . . . . . . . . . . . . . . 3-16
Voltage Regulator Inspection. . . . . . . . . . . . . . . . . . . . . . 3-16
Voltage Regulator Stator. . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Voltmeter Gauge
Problem. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Voltmeter Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Voltmeter Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
VSS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
VSS Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

INDEX XIX
NOTES

XX INDEX