2003 Dyna Starting & Charging

STARTING & CHARGING
Table Of Contents
SUBJECT PAGE NO.
1.1 Starter Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.2 Starting System Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.3 Starter Activation Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
1.4 Diagnostics/Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
1.5 Testing Starter on Motorcycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
1.6 Testing Assembled Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
1.7 Charging System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
1.8 Ignition Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
1.9 Battery Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
1
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STARTER TROUBLESHOOTING 1.1
Table 1-1. Starter Does Not Run or Runs At Very Low Speeds
SOURCE OF
PROBABLE CAUSE SOLUTION
PROBLEM
Voltage drop due to discharged battery. Charge battery.
Battery Short-circuited or open between electrodes. Replace battery.
Poor contact condition of battery terminal(s). Clean and retighten.
Poor or no connection at either battery positive or
Repair or replace cable(s).
negative cable, at either end.
Wiring Cracked or corroded battery cable ends. Clean, tighten or replace cable(s) as needed.
Open wire(s) or poor connection at handlebar
Tighten connections or repair or replace wire(s).
switch or starter relay, especially relay ground wire.
Handlebar
Poor switch contacts or open switch. Replace switch.
start switch
Open coil winding. Replace relay.
Poor or no continuity at relay points. Replace relay.
Starter relay
Check for open on wire to TSM/TSSM. Correct
TSM/TSSM has disabled starter relay.
lack of ground.
Polish contact surface or replace solenoid
Poor contact condition caused by burnt contact.
assembly.
Solenoid
Pull-in winding open or short-circuited. Repair or replace solenoid assembly.
Hold-in winding open or short-circuited. Repair or replace solenoid assembly.
Check brush spring tension. Replace field frame
Brushes worn below specification.
and holder.
Commutator burnt. Re-face or replace.
Commutator high mica. Correct by undercutting.
Field winding grounded. Replace.
Starting motor Armature winding grounded or short-circuited. Replace.
Reduction gears damaged. Replace.
Insufficient brush spring tension. Replace.
Disconnected lead wire between solenoid and field
Repair or replace lead wire.
windings.
Ball bearing sticks. Replace bearing.
2003 Dyna: Starting & Charging 1-1

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Table 1-2. Pinion Does Not Engage With Ring Gear While Starter is Cranked
or Engine Cannot Be Cranked
SOURCE OF
PROBLEM
Voltage drop due to discharged battery. Charge battery.
Battery Short-circuited or open between electrodes. Replace battery.
Poor contact condition of battery terminal(s). Clean and retighten.
Overrunning clutch malfunction (rollers or compres-
Replace overrunning clutch.
sion spring).
Pinion teeth worn out. Replace pinion.
Overrunning
Pinion does not run in overrunning direction. Replace overrunning clutch.
clutch.
Remove foreign materials, dirt or replace over-
Poor sliding condition of spline teeth.
running clutch or pinion shaft.
Reduction gears damaged. Replace overrunning clutch and idler gear.
Jackshaft
Improper jackshaft parts assembly Disassemble and assemble parts properly.
assembly
Gear teeth on Replace clutch shell.
Excessively worn teeth.
clutch shell
Table 1-3. Starter Does Not Stop Running

SOURCE OF
PROBLEM
Unopened contacts. Replace starting switch or starter relay.
Starting switch or
starter relay. Poor return caused by sticky switch
Replace starting switch or starter relay.
or relay contacts.
Gear teeth on
Excessively worn teeth. Replace clutch shell.
clutch shell
Return spring worn. Replace spring.
Solenoid. Coil layer shorted. Replace solenoid.
Contact plate melted and stuck. Replace solenoid.
1-2 2003 Dyna: Starting & Charging

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STARTING SYSTEM DIAGNOSIS 1.2
DIAGNOSTICS 1. Motor terminal

2. Battery terminal
3. Relay terminal
Diagnostic Notes
The reference numbers below correlate with the circled num-
bers on the starter system flow charts.
1. Remove starter motor. Connect jumper wires as 3
described under FREE RUNNING CURRENT DRAW
TEST under 1.6 TESTING ASSEMBLED STARTER. 1
2. See VOLTAGE DROPS under 1.4 DIAGNOSTICS/
TROUBLESHOOTING.
3. See STARTER CURRENT DRAW TEST under 1.5
2
TESTING STARTER ON MOTORCYCLE. d0361x5x
4. See FREE RUNNING CURRENT DRAW TEST under Figure 1-1. Starter Terminals
1.6 TESTING ASSEMBLED STARTER.
Starter Testing 1
Check battery using visual inspection,

voltage test and load test.
Check connections at battery and starter

components. Is system operational?
5822
YES YES YES NO
STARTER STARTER STARTER Check for audible

RUNS ON. SPINS, BUT STALLS OR clicking noise.
DOES NOT SPINS TOO
ENGAGE. SLOWLY.
Disconnect solenoid relay ter-

minal from solenoid. Is 12V
present on GN wire with starter See Starter Testing 5: Starter See Starter Testing 6: Starter Solenoid clicks. See Starter
button not pressed? Spins, But Does Not Engage. Stalls or Spins Too Slowly. Testing 2: Solenoid Clicks.
OR
YES NO
Relay clicks. See

Is 12V present on starter relay Replace Starter Testing 3: Relay Clicks.
terminal 86 with starter button solenoid.
not pressed?
5845
OR
YES NO
Nothing clicks. See Starter
Testing 4: Nothing Clicks.
Replace Replace
starter button. starter relay.
5818 5832

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Starter Testing 2: Solenoid Clicks
Perform voltage drop tests between

battery and relay terminal on solenoid.
Less than 1.0 volt?
YES NO
2 Perform voltage drop tests from 2 Backtrack to pinpoint poor

battery positive to starter motor connections or relay contact
terminal. Crank engine. Is voltage problems using voltage drop
drop greater than 1 volt? tests.
5823
YES NO
Perform voltage drop tests from Perform voltage drop tests

2 battery positive to starter battery 2 between battery negative and
terminal. Crank engine. Is voltage starter studs or bolts. Is voltage
drop greater than 1 volt? drop greater than 1 volt?
NO STOP
YES NO YES
Go to Starter Testing 3:
Relay Clicks. Begin with
box marked with bold
Repair connection Repair or replace Clean ground asterisk.
between battery and solenoid (contacts). connections.
starter.
5845 5824
5824
Starter Testing 3: Relay Clicks
Test for voltage at solenoid relay terminal

on starter. Is 12V present when
starter button is pressed?
YES NO
1 Does starter motor

turn if jumped?
* Test for voltage to relay. Is 12V
present on relay terminal 30?
YES NO YES NO
Perform solenoid Replace or repair Test for voltage from relay. Repair open on R/BK
hold-in, pull-in tests. starter motor. Is 12V present on relay wire feeding terminal 30
Solenoid OK? terminal 87 when starter on starter relay.
5817 button is pressed?
5827
YES NO
YES NO
Mechanical binding or Replace

seal binding on jackshaft solenoid. Repair open on Replace
(dirt or corrosion). GN wire between relay starter relay.
5860 and solenoid.
5832
5850
5827

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Starter Testing 4: Nothing Clicks
Do turn signals work

properly?
NO
YES Is connector [30] fully mated?
Check for battery voltage at relay YES

Terminal 86 from starter button. NO
Battery voltage present?
Continuity to ground on Mate connector [30].
pin 12?
6792
YES NO
Continuity on pin 1 on
Repair open.
security fuse?
6805
YES NO
Continuity on pin 2 on Repair open.

ignition fuse?
6806
YES
NO
Replace TSM/TSSM. Repair open.
6791 6793
YES NO
Check for ground at Check for battery voltage from

relay Terminal 85. starter button (BK/R wire at
Ground present? connector [22]). Battery voltage
present with starter button pressed?
YES NO
YES NO
Substitute good Check for continuity from relay
relay or test relay. Terminal 85 to Pin 9 on
TSM/TSSM connector [30]. Repair wiring Check for battery voltage to starter
5832 Continuity present? from starter button (W/BK wire at connector [22]).
button to relay. Battery voltage present?
5831
YES NO
Check for voltage on Repair

3 TSM/TSSM Pin 9 with open.
YES NO
key ON. Voltage
present? 5828
Replace Repair wiring to
starter button. starter button.
YES NO 5818 5831
Locate and repair

short to voltage. Replace TSM/TSSM. See
2003 Dyna Service Manual
5830 (Part Number 99481-03).
5838

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Starter Testing 5: Starter Spins, But Does Not Engage
Remove and disassemble starter jackshaft

assembly. Is jackshaft properly assembled?
YES NO
Remove starter. Disassemble drive housing Assemble jackshaft

assembly. Inspect for damage to armature properly.
gear or idler gear. Damage present?
5850
YES NO
Replace damaged idler Starter clutch failure.

gear and armature. Replace starter clutch.
5825 5837
Starter Testing 6: Starter Stalls or Spins Too Slowly
Perform voltage drop tests from battery

2 positive to starter motor terminal. Crank
engine. Is voltage drop greater than 1 volt?
YES NO
2 Perform voltage drop tests Perform voltage drop tests

between battery positive to between battery negative and
starter battery terminal. starter studs or bolts.
Crank engine. Is voltage drop Is voltage drop greater than 1
greater than 1 volt?
YES NO YES NO
Repair connection Repair or replace Clean ground Perform starter motor current
between battery and solenoid (contacts). connections. draw test (on vehicle).
3
starter.
5845 5835 Perform starter motor free draw
5824 bench test. 4
Are test results within range?
YES NO
Remove spark plugs while in Replace or repair

5th gear. Rotate rear wheel. starter motor.
Check for engine, primary
and/or crankshaft bind. 5817
Use appropriate code

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STARTER ACTIVATION CIRCUITS 1.3
b0157x5x
1 1
ITEM A ITEM B
IDEAL CLOSED
0.1A 0.1A 2 0.1A 0.1A 2 CIRCUIT
8 20A 8 20A
7 7
OV
20A 20A
6 6
VDC
3 4 3 4
5 5
150A 150A 150A 150A
1 1
ITEM C ITEM D
0.1A 0.1A 2 OPEN CIRCUIT 0.1A 0.1A 2 GROUND CIRCUIT
8 20A 8 20A 20A
VDC
7 7
12V OV
20A
6 6
VDC
3 4 5 3 4
5
150A 150A 150A 150A
1. Start switch 5. Battery

2. Relay 6. Main circuit breaker
3. Solenoid 7. Ignition switch
4. Starter 8. Ignition fuse
Figure 1-2. Typical Circuity. Refer to wiring diagrams for more information.

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DIAGNOSTICS/TROUBLESHOOTING 1.4
GENERAL 6. Typically, a good circuit will drop less than 1 volt.

7. If the voltage drop is greater, back track through the con-
The troubleshooting tables beginning on page 1-1 contain nections until the source of the potential difference is
detailed procedures to solve and correct problems. Follow the found. The benefit of doing it this way is speed and accu-
1.2 STARTING SYSTEM DIAGNOSIS diagram to diagnose racy.
starting system problems. The VOLTAGE DROPS procedure
a. Readings aren’t as sensitive to real battery voltage.
below will help you to locate poor connections or components
with excessive voltage drops. b. Readings show the actual voltage dropped, not just
the presence of voltage.
VOLTAGE DROPS c. This tests the system as it is actually being used. It

is more accurate and will display hard to find poor
Check the integrity of all wiring, switches, circuit breakers and connections.
connectors between the source and destination. d. This approach can be used on lighting circuits, igni-
The voltage drop test measures the difference in potential or tion circuits, etc. Start from most positive and go to
the actual voltage dropped between the source and destination. most negative (the destination or component).
1. See ITEM A in Figure 1-2. Attach your red meter lead to 8. See ITEM D in Figure 1-2. The negative or ground circuit
the most positive part of the circuit, which in this case can be checked as well.
would be the positive post of the battery (5). a. Place the negative lead on the most negative part of
2. See ITEM B in Figure 1-2. Attach the black meter lead to the circuit (or the negative battery post). Remember,
the final destination or component in the circuit (solenoid there is nothing more negative than the negative
terminal from relay). post of the battery.
3. Activate the starter and observe the meter reading. The b. Place the positive lead to the ground you wish to
meter will read the voltage dropped or the difference in check.
potential between the source and destination.
c. Activate the circuit. This will allow you to read the
4. An ideal circuit’s voltage drop would be 0 volts or no volt- potential difference or voltage dropped on the nega-
age dropped, meaning no difference in potential. tive or ground circuit. This technique is very effective
5. See ITEM C in Figure 1-2. An open circuit should read for identifying poor grounds due to powdered paint.
12 volts, displaying all the voltage dropped, and the Even the slightest connection may cause an ohm-
entire difference in potential displayed on the meter. meter to give a good reading. However, when suffi-
cient current is passed through, the resistance
NOTE caused by the powdered paint will cause a voltage
Open circuits on the ground side will read zero. drop or potential difference in the ground circuit.

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HAND CONTROLS,
RIGHT
[162] START
RELAY 70103-96 BK
19010-01_1starting
BATTERY
RIGHT TURN SWITCH [62A]
ENGINE STOP/RUN 858630 87a87
SWITCH
START SWITCH
BK
S U ET K
STOPLIGHT SWITCH [62B] 70102-96
STARTER
GN
BK/R
R/BK
TN/GN
GY
BK/R
[22B]
6 5 4 3 2 1
6 5 4 3 2 1
BK
[22A]
GY
BK/R
R COPPER
STUD
[64B]
[5] CIRCUIT
TURN SIGNAL/SECURITY MODULE IGN: 15A BREAKER
GH 30 AMP
GY R/BK
BATTERY 1 BN/GY
IGNITION 2 GY
VSS / SERIAL DATA LINK 3 [33A] [33B] IGNITION
SECURITY INDICATOR 4 SWITCH
LEFT TURN FEED 5 R A A R
RIGHT TURN FEED 6 B B
RIGHT TURN SWITCH INPUT 7 R/BK C C R/BK
LEFT TURN SWITCH INPUT 8 D D
START RELAY CONTROL 9 TN/GN
IGNITION ENABLE SIGNAL 10
ALARM SIGNAL 11
GROUND 12 BK
TS/TSSM i SECURITY: 15A j
BN/GY R
[30A][30B]
IGNITION SWITCH LEGEND
Figure 1-3. Starting Circuit

SWITCH RED/BLACK RED RED/GRAY
POSITION
OFF
ACC.
IGNITION
DOT INDICATES CONTINUITY WITH RED

WIRE IN SWITCH POSITION INDICATED
BK
COMPONENTS LOCATED UNDER LEFT SIDE COVER

INSTRUMENTS START RELAY
F E D C B A B A
15A
3 E C
2 SECURITY IGNITION
1
L K J I H G K I H G
15A 15A
Wire Color Code Key ACCESSORIES LIGHTS U T S R Q P
[GND1]
U S R P O M O M
PIN CONNECTOR 15A 15A
BK - Black GN - Green LT.GN - Light Green (A side)
BN - Brown BE - Blue PK - Pink TOP VIEW TOP VIEW
R - Red V - Violet TN - Tan SOCKET CONNECTOR
O - Orange GY - Gray Wire color-XX/XX-Stripe color (B side)
Y - Yellow W - White
2003 Dyna: Starting & Charging

19010-01 1 STARTING 7/12/2000
1-9
HOME
TESTING STARTER ON MOTORCYCLE 1.5
STARTER RELAY TEST 7902
1. See Figure 1-4. Locate starter relay (1) behind the elec-
1
trical panel on the motorcycle’s left side.
2. To test relay, proceed to Step 3. If installing a new starter

relay, disconnect old relay and replace.
CAUTION 2
Only connect relay terminal 85 to negative battery termi-
nal. Improper connections will damage the diode con-
nected across the relay windings. 1. Starter relay
2. Relay block
3. See Figure 1-5. The starter relay can be tested using the
motorcycle’s 12 volt battery and a multimeter. Figure 1-4. Starter Relay Block
a. Unplug connector from relay.
b. To energize relay, connect the battery leads to termi-

d0404x5x
nals 86 and 85 as shown.
c. Check for continuity between the 30 and 87 termi-

Ohmmeter
nals. A good relay shows continuity (continuity tester
lamp “on” or a zero ohm reading on the ohmmeter).
A malfunctioning relay will not show continuity and
must be replaced.
4. If starter relay is functioning properly, proceed to

STARTER CURRENT DRAW TEST. Battery
STARTER CURRENT DRAW TEST

Figure 1-5. Starter Relay Test
NOTES
● Engine temperature should be stable and at room tem-
perature.
b0160x5x
● Battery should be fully charged. Induction
ammeter
See Figure 1-6. Check starter current draw with an induction
ammeter before disconnecting battery. Proceed as follows:
1. Verify that transmission is in neutral. Disconnect spark

plug wires from spark plug terminals.
2. Clamp induction ammeter over positive battery cable

next to starter.
3. With ignition key switch ON, turn engine over by pressing

starter switch while taking a reading on the ammeter. Battery
Disregard initial high current reading which is normal
when engine is first turned over.
a. Typical starter current draw will range between 160-

Figure 1-6. Starter Draw Test
180 amperes.
b. If starter current draw exceeds 200 amperes, then NOTE

the problem may be in the starter or starter drive.
Remove starter for further tests. See the 2003 Dyna See Figure 1-6. A DC current probe may be used if an induc-
Service Manual (Part Number 99481-03). tion ammeter is not available.

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TESTING ASSEMBLED STARTER 1.6
FREE RUNNING CURRENT DRAW d0377x8x
TEST
2
1. Place starter in vise, using a clean shop towel to prevent
scratches or other damage. 3
4
2. See Figure 1-8. Attach one heavy jumper cable (6 gauge
minimum).
a. Connect to starter mounting flange (1). 1
b. Connect to negative (-) terminal of a fully charged
battery (2). 1. Nut with washer (metric)
2. Positive battery cable ring terminal
3. Connect a second heavy jumper cable (6 gauge mini- 3. Circuit breaker wire ring terminal
mum). 4. Solenoid wire
a. Connect to positive (+) terminal of the battery (2).
Figure 1-7. Starter Wires
b. Place an inductive ammeter (3) over cable. Continue
on to the battery terminal (4) on the starter solenoid.
4. Connect a smaller jumper cable (14 gauge minimum). b0439x5x
a. Connect to positive (+) terminal of the battery (2).

2
b. Connect to solenoid relay terminal (5).
5. Check ammeter reading. 1
a. Ammeter should show 90 amps maximum. 5
b. If reading is higher, disassemble starter for inspec-
tion. See the 2003 Dyna Service Manual (Part Num-
ber 99481-03).
c. If starter current draw on vehicle was over 200 amps 3
and this test was within specification, there may be a
problem with engine, primary drive or jackshaft. 4
STARTER SOLENOID 1. Mounting flange

2. Battery
3. Induction ammeter
1WARNING 4. Battery terminal
5. Relay terminal
Wear eye protection during this series of tests. These
tests may produce flying sparks which could result in Figure 1-8. Free Running Current Draw Test
death or serious injury.
NOTE
Do not disassemble solenoid. Before testing, disconnect field
wire from motor terminal as shown in Figure 1-9.
CAUTION
Each test should be performed for only 3-5 seconds to

prevent damage to solenoid.
NOTE
The solenoid Pull-in, Hold-in, and Return tests must be per-
formed together in one continuous operation. Conduct all
three tests one after the other in the sequence given without
interruption.

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SOLENOID PULL-IN TEST b0161a5x
1. See Figure 1-9. Using a 12 volt battery, connect three Motor terminal Relay terminal
separate test leads as follows:
a. Solenoid housing to negative battery post.
b. Solenoid motor terminal to negative battery post.
c. Solenoid relay terminal to positive battery post.
2. Observe starter shaft.
a. If starter shaft extends strongly, solenoid is working
properly. Battery
b. If starter shaft does not extend strongly, replace the
solenoid.
SOLENOID HOLD-IN TEST

Figure 1-9. Test 1: Pull-In Test
1. See Figure 1-10. With test leads still connected in the
manner specified in the previous SOLENOID PULL-IN
TEST, disconnect solenoid motor terminal/battery
b0162a5x
negative test lead (B) at negative battery post only;
reconnect loose end of this test lead to positive bat- Motor terminal
tery post instead. Relay terminal
2. Observe starter shaft.
a. If starter shaft remains extended, solenoid is work-
ing properly.
b. If starter shaft retracts, replace the solenoid.
SOLENOID RETURN TEST Battery

1. See Figure 1-11. With test leads still connected in the
manner specified at the end of the previous SOLENOID
HOLD-IN TEST, disconnect solenoid relay terminal/
positive battery post test lead (C) at either end.
2. Observe starter pinion. Figure 1-10. Test 2: Hold-In Test
a. If starter shaft retracts, solenoid is working properly.
b. If starter shaft does not retract, replace the solenoid.
b0163a5x
Motor terminal
Relay terminal
Battery
Figure 1-11. Test 3: Return Test

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CHARGING SYSTEM 1.7
GENERAL 7492
The charging system consists of the alternator and regulator.

Charging system circuits are shown in Figure 1-14.
Alternator
The alternator consists of two main components:
● The rotor which mounts to the engine sprocket shaft.
● The stator which bolts to the engine crankcase. 1
Voltage Regulator
See Figure 1-12. The voltage regulator is a series regulator
with shunt control. The circuit combines the functions of recti- 2
fying and regulating.
1. Voltage regulator
TROUBLESHOOTING 2. Connector
When the charging system fails to charge or does not charge Figure 1-12. Voltage Regulator
at a satisfactory rate, make the following recommended
checks.
Battery 7493
Check for a weak or dead battery. Battery must be fully

charged in order to perform any electrical tests.
Wiring
Check for corroded or loose connections in the charging cir-
cuit. See Figure 1-14.
Voltage Regulator Inspection

See Figure 1-12. The voltage regulator base must have a
clean, tight connection for proper grounding. Check by using
an ohmmeter with one lead on a known good ground, such as
battery ground cable, and the other on the regulator base.
See Figure 1-13. Connector plug at engine crankcase must
be clean and tight.
Figure 1-13. Stator Connector Plug

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Test 1.7 (Part 1 of 2)

SYMPTOM: BATTERY BECOMES DISCHARGED
Test battery.
Charge or replace as required.
Inspect regulator.
See REGULATOR INSPECTION.
PASS FAIL
Test regulator. Correct as

See REGULATOR required.
BLEED TEST.
5306
PASS FAIL
Perform MILLIAMP DRAW Replace

TEST (If applicable). regulator.
5307
PASS FAIL
Perform TOTAL CURRENT Isolate damaged

DRAW TEST. component or wiring.
Record measurement.
5308
PASS FAIL
Isolate damaged wiring or

excessive accessories.
STOP
5310
Go to Test 1.7
(Part 2 of 2).
NOTE
Whenever a charging system component fails a test and
is replaced, re-test the system to be sure the problem
has been corrected.

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SYMPTOM: BATTERY BECOMES DISCHARGED
From Test 1.7 (Part 1 of 2).
Perform CURRENT OUTPUT TEST. Record

measurement and compare with TOTAL CURRENT
DRAW TEST before proceeding.
PASS FAIL
Perform VOLTAGE Perform

OUTPUT TEST. STATOR CHECK.
PASS FAIL PASS FAIL
System tests good up to this point. Suspect: Replace Perform AC Replace

regulator. OUTPUT TEST. stator.
Accessories on for long periods when vehicle is
parked and not running. 5316 5312
Accessories on when vehicle is ridden very slowly for

long periods.
Battery self-discharge and/or accessory draw

because vehicle was not operated for a long period. PASS FAIL
Replace regulator. Inspect rotor.

Perform CURRENT
OUTPUT TEST.
5315
PASS FAIL PASS FAIL
System Damaged or Replace Replace

OK. slipping rotor. stator. rotor.
5319 5314 5319
NOTE
Whenever a charging system component fails a test and
is replaced, re-test the system to be sure the problem
has been corrected.

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d0296x8x
70097-97 BK
Stator
Battery
BK
70076-97
BK
BK
Voltage regulator
[46B]
1 2
BK
Starter
1 2
[46A]
BK
BK
Circuit breaker Copper stud

30 amp
BK
[5 ]
Figure 1-14. Charging System Circuit

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TESTING d0297x8x
Voltage Regulator Bleed Test

1. Be sure regulator is connected to battery.
Battery negative
2. Unplug voltage regulator connector at engine crankcase.
cable
3. Check regulator connector using a trouble light.
a. Touch one probe to a suitable ground.
b. Touch the other to the regulator pins, one at a time.
12 VDC
c. If light glows, replace regulator. Ignition turned
battery
to OFF
Milliampere Draw Test
NOTES Figure 1-15. Milliampere Draw Test
● Be sure accessories are not wired so they stay on at all
times. This condition could drain battery completely if
vehicle is parked for a long time. Check for this by con-
d0004x8x
necting ammeter between negative battery terminal and Load tester
battery.
● TSM/TSSM will continue to draw 16-25 mA for 30 sec-
onds after ignition is turned OFF. Any disruption and
reconnection of battery power, such as disconnecting the
battery to place a meter in series, will cause TSM/TSSM
to draw 16-25 mA for 30 seconds.
1. See Figure 1-15. Connect ammeter between negative
battery terminal and battery. With this arrangement, you
will also pick up any regulator drain.
2. With ignition key switch turned to OFF and all lights and
accessories off, observe amperage reading.
a. See Table 1-4. Add regulator draw to appropriate
value for TSM/TSSM. If sum is less than reading
observed on ammeter, draw is within limits.
b. A higher reading indicates excessive current draw.
Any accessories must be considered and checked
for excessive drain.
Figure 1-16. Check Current Draw (Ignition Switch On)
NOTE
A battery with a surface discharge condition could suffer a
static drain. Correct by cleaning battery case. Table 1-4. Milliampere Draw Test
Total Current Draw Test ITEM DRAW IN MILLIAMPERES
If battery runs down during use, the current draw of the Regulator 0.5
motorcycle components and accessories may exceed output TSM (non security models) 0.5
of the charging system. TSSM (disarmed) 0.5
TSSM (armed) 3.0
1WARNING
4. Compare this reading to the reading obtained after per-
Always turn the battery load tester OFF before connect- forming the CURRENT AND VOLTAGE OUTPUT TEST.
ing tester cables to the battery terminals. Connecting
a. The current output should exceed current draw by
tester cables with the load tester ON could cause a spark
3.5 amps minimum.
resulting in a battery explosion which could result in
death or serious injury. b. If output does not meet specifications, there may be
too many accessories for the charging system to
1. See Figure 1-16. To check for this condition, place load handle.
tester induction pickup or current probe pickup over bat-
5. Reconnect regulator after testing.
tery negative cable.
2. Disconnect regulator from stator wiring. Start the motor-
cycle and run the engine at 2000 RPM.
3. With ignition and all continuously running lights and
accessories turned on (headlamp on high beam), read
the total current draw.

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Current and Voltage Output Test d0005x8x

Load tester
1. See Figure 1-17. Connect load tester.
a. Connect negative and positive leads to battery ter-
minals.
b. Place load tester induction pickup over positive reg-
ulator cable. To circuit breaker
(DC output)
CAUTION
Do not leave any load switch turned on for more than 20

seconds or overheating and tester damage are possible.
2. Run the engine at 3000 RPM. Increase the load as
required to obtain a constant 13.0 VDC.
3. The current output should be 26-32 amps. Make note of
measurement for use in TOTAL CURRENT DRAW TEST.
NOTE
Rider’s habits may require output test at lower RPM. To stator
Voltage Output Test Figure 1-17. Current and Voltage Output Test
1. See Figure 1-17. After removing the load, read the load
tester voltage meter.
a. If voltage to the battery is not more than 15 VDC,
voltage output is within specifications. Investigate
other possible problems. See Test 1.7 (Part 1 of 2).
b. If voltage is higher, regulator is not functioning prop-
erly or connections are loose or dirty.
Stator Check
1. Turn ignition key switch OFF.
2. See Figure 1-18. Connect an ohmmeter.
a. Disconnect voltage regulator connector from alter-
nator stator wiring.
b. Insert one ohmmeter lead into either stator socket.
c. Attach the other lead to a suitable ground.
3. Test for continuity with ohmmeter set on the RX1 scale. d0527x8x
a. A good stator will show no continuity (∞ ohms)

Figure 1-18. Test for Grounded Stator (Typical)
across either stator socket.
b. Any other reading indicates a grounded stator which
must be replaced.
4. See Figure 1-19. Remove ground lead. Insert lead into
the remaining stator socket.
5. Test for resistance with ohmmeter set on the RX1 scale.
a. Resistance across the stator sockets should be 0.1-
0.2 ohms.
b. If the resistance is lower, a short is indicated. The
stator is damaged and must be replaced.
c. If resistance is higher (OL on meter), an open is indi-
cated. Stator is damaged and must be replaced.
d0528x8x
Figure 1-19. Check for Stator Resistance (Typical)

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AC Output Check
1. See Figure 1-20. Test AC output.
a. Disconnect voltage regulator connector from alter-
nator stator wiring.
b. Connect an AC voltmeter across both stator sockets.
c. Run the engine at 2000 RPM. The AC output should
be 32-40 volts AC (approximately 16-20 per 1000
RPM).
2. Compare test results to specifications.
a. If the output is below specifications, charging prob-
lem could be a faulty rotor or stator.
b. If output is good, charging problem might be faulty
regulator/rectifier. Replace as required.
3. Check the output again as previously described under
CURRENT AND VOLTAGE OUTPUT TEST. d0526x8x
Figure 1-20. Check Stator AC Voltage Output (Typical)

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IGNITION COIL 1.8
TROUBLESHOOTING s0395x8x
R F
Follow the troubleshooting procedures listed under 4.8 INI-
TIAL DIAGNOSTIC CHECK if the engine will not start, is diffi- 2 2
cult to start or runs roughly. Also check condition of spark
plug cables. Insulation on cables may be cracked or damaged
allowing high tension current to short to metal parts. This
problem is most noticeable when cables are wet. 1 1
If poor starting/running condition persists, check resistance of
ignition coil primary and secondary windings using an ohm- Terminal A Terminal B Terminal C
meter. rear coil +12 V front coil
NOTE
The ignition coil cannot be repaired. Replace the unit if it fails.
1. Primary resistance should be 0.5-0.7 ohms.
Ignition Coil Primary Circuit Test 2. Secondary resistance should be 5.5-7.5K ohms.
1. Remove ignition coil. Figure 1-21. Ignition Coil Testing

2. Set ohmmeter scale to RX1.
Ignition Coil Substitution
3. See Figure 1-21. Place multimeter wires on primary coil
windings A to B, B to C. If a coil tester is not available, use the following test.
4. Check for primary coil winding resistance. NOTE

Coil will function without being attached to frame.
a. Normal resistance range is 0.5-0.7 ohms.
1. Substitute a new ignition coil by attaching it to any con-
b. See TEST RESULTS if resistance is not within nor- venient point near the old coil. Transfer terminal wires to
mal operating range. new coil.
2. Attach new spark plug cables to coil and plugs.
Ignition Coil Secondary Circuit Test
3. Test system. If ignition trouble is eliminated by the tem-
1. Remove ignition coil. porary installation of a new coil, carefully inspect old coil
2. Set ohmmeter scale to RX1K. and cables for damage. The insulation on the cables may
be cracked or otherwise damaged allowing high tension
3. See Figure 1-21. Place multimeter wires on secondary current to short to metal parts. This is most noticeable in
coil windings B to R, B to F. wet weather or after the motorcycle has been washed.
4. Check for secondary coil winding resistance.
a. Normal resistance range is 5.5-7.5K ohms.
b. See TEST RESULTS if resistance is not within nor-
mal operating range.
Test Results
1. A low resistance value indicates a short in the coil wind-
ing. Replace coil.
2. A high resistance value might indicate that there is some
corrosion/oxidation of the coil terminals. Clean the termi-
nals and repeat resistance test. If resistance is still high
after cleaning terminals, replace coil.
3. An infinite ohms (∞ or OL) resistance value indicates an
open circuit (a break in the coil winding). Replace coil.

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BATTERY LOAD TEST 1.9
GENERAL d0428x8x
VOLTS
The load test measures battery performance under full cur- AMPS
rent load and is the best indicator of battery condition. To load
test the battery, proceed as follows: Load
tester
1. Remove battery from motorcycle.
CAUTION
Load testing a discharged battery can result in perma-

nent battery damage.
2. Always fully charge the battery before testing or test
readings will be incorrect. Load testing a discharged bat- Induction
tery can also result in permanent battery damage. pickup
3. After charging, allow battery to stand for at least one
hour before testing.
1WARNING
BATTERY
Always turn the battery load tester OFF before connect-
ing the tester cables to the battery terminals. Connecting
tester cables with the load tester ON could cause a spark
resulting in a battery explosion which could result in Figure 1-22. Load Test Battery
death or serious injury.
4. See Figure 1-22. Connect tester leads to battery posts
and place induction pickup over negative (black) cable. Table 1-5. Voltmeter Test For Battery
Charge Conditions
CAUTION
VOLTAGE (OCV) STATE OF CHARGE
To avoid load tester and/or battery damage, do not leave
the load tester switch turned ON for more than 20 sec- 12.8 100%
onds. 12.6 75%
5. See Table 1-6. Load battery at 50% of CCA rating using 12.3 50%
the load tester. Voltage reading after 15 seconds should
be 9.6V or more at 70°F. (21°C). 12.0 25%
11.8 0%
1WARNING
Always turn the battery load tester OFF before discon- Table 1-6. Battery Load Test
necting the tester cables from the battery terminals. Dis-
connecting tester cables with the load tester ON could COLD CRANKING
cause a spark resulting in a battery explosion which 100% 50%
AMPERAGE (CCA)
could result in death or serious injury.
Dyna models 270 135
6. Install the battery on the motorcycle.

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NOTES

Table Of Contents
SUBJECT PAGE NO.
2.1 Fuel Gauge Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2.2 Speedometer and Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.3 Speedometer Performance Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
2.4 Indicator Lamps: FXDWG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
INSTRUMENTS
2
HOME
FUEL GAUGE OPERATION 2.1
THEORY OF OPERATION d0315x8x
See Figure 2-1. With ignition switch ON, the fuel gauge (1) is
1
connected to +12 volts. Current flows through the gauge and
variable resistor (4) in the fuel gauge sending unit (3) to
ground. The sending unit float (2) controls the amount of 2
resistance in the variable resistor. 5
Inoperative gauges may be caused by three circumstances.
● Sender or fuel gauge not grounded.

6
● Malfunction in sender or fuel gauge.
● Broken or disconnected wire from ignition switch to fuel

X
4 3
gauge.
1. Fuel gauge
Use the FUEL GAUGE AND SENDER TEST to test suspect
2. Float
components.
3. Sending unit
4. Resistance value (varies on fuel present)
5. Gauge winding
FUEL GAUGE AND SENDER TEST 6. +12 volts wire
Figure 2-1. Fuel Gauge Schematic

CAUTION
Always refer to the applicable wiring diagram (at the rear

of this manual) when troubleshooting instruments or 7494
gauges.
1. See Figure 2-2. Remove gauge. Ground Y/W wire of fuel

gauge sender located at bottom of gauge. Turn ignition
switch ON.
a. Fuel gauge must indicate FULL. If gauge indicated

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 a good ground.
Figure 2-2. Fuel Gauge Connector
a. If fuel tank is full, the reading should be 40 ohms. An
empty tank should have a 240 ohm resistance. A 3. Check voltage to O/W (+) and BK (-) wire of fuel gauge
half full tank will be approximately 97-118 ohms. connector [117] if gauge did not indicate FULL.
b. If a very high resistance or infinity is indicated on the a. Correct reading is equivalent to battery voltage.
meter, the sender may be “open” or not grounded. b. If battery voltage is not present check for broken or
Check that sender and fuel tank are grounded by disconnected wire. Replace gauge if wiring problem
placing one probe of Multi-Meter on sender flange is not found.
and the other probe on crankcase. Meter must indi-
cate one ohm or less. Replace sender if one ohm or
less was present. If a higher resistance is present,
check for poor connection on ground wire.
2003 Dyna: Instruments 2-1

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SPEEDOMETER AND TACHOMETER 2.2
GENERAL 7495
Reset Switch
See Figure 2-3. Pressing the odometer reset switch provides
the following capabilities:
● Change the odometer display between mileage and trip

values (press and immediately release).
● Reset the trip odometer (press and hold 2-3 seconds).
● Identify the speedometer calibration (see below).
● Gain access to the diagnostic mode, clear diagnostic
codes and exit diagnostic mode (see below).
Diagnostic Mode
The diagnostic mode is entered by turning the ignition from Figure 2-3. Reset Switch: FXDWG
OFF to ON while holding the reset switch in. The normal (All Other Models On Back of Speedometer)
power-up sequence will occur before entering the diagnostic
mode. Diagnostic codes set during this power-up sequence
will be stored as well.
Table 2-1. Speedometer Trouble Codes
IMPORTANT NOTE
Be sure no diagnostic codes are indicated before reset is held WIRE
CODE TROUBLE
in for more than 5 seconds or diagnostic information will be COLOR
lost. Speed sensor power output
d01 Red
shorted low
When in the diagnostic mode the odometer will display the
first diagnostic code. When the trip switch is pressed again Speed sensor power output
d02 Red
the next code will be shown. If the trip switch is pressed for shorted high or open
more than 5 seconds at any time while in the diagnostic d03 Not used
mode, all of the diagnostic codes will be erased whether
they have been displayed or not. d04 Not used
d05 Speed sensor return shorted high White
See Table 2-1. There are 7 different diagnostic codes avail-
able. When in the diagnostic mode, all codes are displayed in d06 Speed sensor return shorted low White
sequence from d01 to d10. d07 Not used
As a code appears in the display (for instance d02), it will d08 Speedometer power overvoltage Orange/White
read “d02SEt” if set or “d02CLr” if clear. d09 Speed output shorted high White/Green
The diagnostic mode is exited either by turning ignition from Speed output shorted low or
d10 White/Green
ON to OFF to ON again without depressing the reset switch open
or if a speed signal greater than 5 MPH is detected. 5 digit Speedometer pulses per unit
Diagnostics cannot be performed if system voltage is less number
than 9 VDC or greater than 16 VDC. The only exception is
d08 which is set when system voltage is greater than
16 VDC.
After all the diagnostic codes are displayed, the speedome-

ter’s pulses per unit setting is displayed. This number will vary
depending on speedometer part number.
2-2 2003 Dyna: Instruments

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THEORY OF OPERATION DIAGNOSTICS

The electronic speedometer consists of a speed sensor,
odometer reset switch and the speedometer. The speed sen- Diagnostic Notes
sor is mounted on the right side of transmission case below
The reference numbers below correlate with circled numbers
the starter. The sensor circuitry is that of a Hall-Effect sensor
on the speedometer diagnostic flow charts.
that is triggered by the gear teeth of 4th gear on the transmis-
sion mainshaft. 1. To enable diagnostic mode: depress odometer reset
switch and turn ignition/key switch to ON.
The output from the sensor is a series of pulses that are inter-
preted by speedometer circuitry to control the position of the 2. To clear codes: turn ignition switch from OFF to ON while
speedometer needle and the liquid crystal (LCD) odometer holding reset switch in. Press and release the reset
display. switch to cycle through the codes. Set codes will display
as Code d0xSet; holding the reset switch in will result in
The odometer mileage is permanently stored and will not be Code d0xClr being displayed. This indicates the code
lost when electrical power is turned off or disconnected. The has been cleared.
odometer reset switch allows switching between the odome-
3. To return speedometer to normal operating state: cycle
ter and trip odometer displays.
ignition/key switch.
To zero the trip odometer, have the odometer display visible, 4. Remove seat.
press and keep the function switch depressed. The trip odom-
eter mileage will be displayed for 2-3 seconds and then the 5. Test results may be inaccurate if tester battery is low.
trip mileage will return to zero miles. 6. See 2.3 SPEEDOMETER PERFORMANCE CHECK.
The odometer can display six numbers to indicate a maxi- 7. Sensor can also be tested with SPEEDOMETER
mum of 999999 miles. The trip odometer can display six num- TESTER (Part No. HD-41354) and test harness. See 2.3
bers with a tenth of a mile accuracy for a maximum of SPEEDOMETER PERFORMANCE CHECK.
99999.9 miles. 8. Remove sensor and check for accumulation of debris on
sensor; if debris is not present, replace sensor. If debris
Circuitry in the speedometer also uses the sensor input to
is present, clean sensor and repeat test. Replace if nec-
provide an input to the turn signal canceler. This turn signal
essary. See the 2003 Dyna Service Manual (Part Num-
canceler input was previously supplied by the reed switch in
ber 99481-03).
mechanical speedometers.
9. Sweep tool has frequency jumps in full scale sweeps.
Perform sweep in 3 stages as described in speedometer
tester manual.
10. Disconnecting speed sensor or installing speedometer
tester will cause code d02 to set.
Speedometer Trouble Codes

Numbers in bold text beginning with d0x refer to the start
point for troubleshooting speedometer codes. For codes d09
to d10, see Turn Signal Error 1C under 3.15 TURN SIGNAL
ERRORS.

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Speedometer Test 1
ODOMETER, TRIP ODOMETER AND RESET SWITCH
Turn ignition ON. Does odometer display

consist of correct numbers?
YES NO
Press trip reset switch. Does Replace

LCD display toggle between speedometer.
trip and odometer modes?
6020
YES NO
Does trip display consist Loosen reset switch boot

of correct numbers? and then tighten again until
snug. Toggle switch again
and verify operation.
Does LCD display toggle
between trip and
YES NO odometer modes?
Replace
STOP speedometer.
YES NO
6020
Go to Speedometer
Test 2A. Unit OK. Return Remove boot over trip
to customer. reset switch. Toggle trip
reset switch without boot.
6002 Does LCD display toggle
between trip and
odometer modes?
YES NO
Replace Place jump wire across

boot. leads to reset switch on
speedometer connector
6002 [39B]. Does LCD display
toggle between trip and
odometer modes?
YES NO
Replace Replace
reset switch. speedometer.
6001 6020

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Speedometer Test 2A
SPEEDOMETER INOPERATIVE, READS HIGH/LOW, NEEDLE STICKS, INTERMITTENT/ERRATIC, OUTPUT

SPEED SIGNAL INOPERATIVE
Turn ignition ON.

Is speedometer backlighting on?
YES NO
If speedometer backlighting is
1 Enable diagnostic mode and
clear codes. Recheck for
not on, check for 9-12 VDC
on the O/W wire at connector
codes. Any codes present? [39B]. Proper voltage present?
2
YES NO
YES NO
Check continuity to Check continuity between O/W

Go to applicable Return speedometer to normal ground on BK wire at wire at connector [39B] and
code in Speed-
3 state. Turn ignition ON. Spin connector [39B]. accessory fuse terminals.
ometer Test 2B back tire. Enable diagnostic Is continuity present? Is continuity present?
(d0x). 1 mode and check for codes.
Codes present?
YES NO
YES NO
Check continuity to ground
on Pin 12 connector [39B]. Locate and repair
Is continuity present? open in O/W wire.
Go to applicable Hook up speedometer tester.
code in Speed-
4 Verify that tester battery is OK.
6008
ometer Test 2B Perform speed sweep function

(d0x). 5 and specified speed inputs with YES NO
tester and observe output speed
and odometer/trip meter change
6 on speedometer. Does speedometer Locate and repair Replace
appear to function normally grounded O/W wire.
and follow sweeping fuse.
Replace fuse.
9 frequency input?
6032
6031
10
YES NO
Replace Locate and repair

speedometer. open in BK wire.
6014 6008
YES
NO
Program steady input
frequency on tester and
observe output speed on Check 3-pin vehicle speed
speedometer while moving/ connector and wires for
shaking vehicle harness damage. Connector or wire
connections. Output erratic? damage found?
YES NO
YES NO
Bad connection
found. Repair STOP Repair as Replace
connector necessary. speedometer.
or harness.
Go to Speedometer 6004 6006
6008
Test 2B.

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Speedometer Test 2B
SPEEDOMETER INOPERATIVE, READS HIGH/LOW, NEEDLE STICKS, INTERMITTENT/ERRATIC, OUTPUT
SPEED SIGNAL INOPERATIVE
d01, d02
Continued from Speedometer Test 2A.
Check for 6-12 VDC on R wire in
connector [65B]. Proper voltage present?
10
YES NO
Check for continuity to ground Check for open/

on BK wire in connector [65B]. grounded wires. OK?
Is continuity present?
YES NO
YES NO
d05, d06 Repair Replace

Check for voltage on W wire in Check for open wires. speedometer.
connector [65B] while connected. Meter wires. OK? 6013 6022
should read 6-12 VDC when gear tooth
absent and 0-1 VDC when gear tooth is
present. Does it?
YES NO
7
Replace Repair
speedometer. wires.
6022 6013
NO
YES 6-12 VDC 6-12 VDC

not present. present, but no
d08 flunctuation
to 0-1 VDC.
Check speedometer power (O/W wire)
and ground terminal (BK wire) voltage on
connector [39B] at back of speedometer. Replace
Replace speed
Test voltage while shaking harness. speedometer. 8 sensor.
Does voltage flunctuate?
6022
6010
YES NO
Repair as Start vehicle and run at

necessary. 2,500 RPM. Is battery
voltage over 15 volts?
6008
NO
NO
Check for spark plug wire terminals properly Check speedometer sensor.
seated onto spark plugs and secondary coil Clean or replace sensor
terminals/standoffs. Also check for wear as required. Retest. 8
points on spark plug wires where insulation Problem solved?
may be damaged. Insulation damaged?
YES
YES
YES NO
See 1.7 CHARG- Repair as
ING SYSTEM. necessary.
System Replace
6016
ok. speedometer.
6029 6024

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d0535x8x
ELECTRONIC [20B]
SPEEDOMETER
TACHOMETER
[108] O/W 1
SOLID STATE
SWITCH W/GN 2
SPEED SIGNAL OUT

\
INPUT BN 3
POWER GND
GROUND W
CHECK ENGINE
TACH 4
SIGNAL V 5 TO MAIN
POWER SPEED
SIGNAL O 6 HARNESS
NOT PK 7 [20A]
INPUT
USED
TN 8
[136A] [39A]
1 2 3 4 5 6 12 11 10 9 8 7 6 4 1 GN/Y 9
BK/Y 10
1 2 3 4 5 6 12 11 10 9 8 7 6 4 1 [39B] BK 11
[136B]
BK 12
FUNCTION/
W/GN
BK/Y
O/W
PK
BK
BK
BK
W
R
O
TRIPMETER
RESET
SWITCH
[154]
[21A] 1 2 3 4 5 6 7 8 9 10
SPEED SENSOR
P/N 74420-94
CONNECTOR USED [21B] 1 2 3 4 5 6 7 8 9 10
+12VDC SENSOR ON FXDL ONLY
OUTPUT
R A A R
W B B W
BK C C BK
GROUND
[65A] [65B]
LT - HB - N + OP + - RT
V BK W BK TN O GN/Y O BK BN
[155] [156] [157] [158] [159]

LEFT HIGH NEUTRAL OIL RIGHT
INDICATOR BEAM INDICATOR
Figure 2-4. Electronic Speedometer Connectors: All But FXDWG
d0534x8x
ELECTRONIC
SPEEDOMETER
SOLID STATE
SWITCH
SPEED SIGNAL OUT
\
INPUT
POWER GND
CHECK ENGINE
SPEED
SIGNAL
INPUT
O/W
[39A]
12 11 10 9 8 7 6 4 1 W/GN
BN
12 11 10 9 8 7 6 4 1 [39B] W
V
O
FUNCTION/
W/GN
BK/Y
O/W
TO MAIN
BK
BK
BK
BK
W
R
TRIPMETER
TN HARNESS
RESET
SWITCH GN/Y [20A]
BK/Y
[154] BK
BK
[21A] 1 2 3 4 5 6 7 8
SPEED SENSOR [21B] 1 2 3 4 5 6 7 8

P/N 74420-94
GN/Y
BN
TN
BK
+12VDC SENSOR
W
O
V
OUTPUT
R A A R
W B B W
BK C C BK
GROUND
[65A] [65B]
LT - HB - N + OP + - RT
V BK W BK TN O GN/Y O BK BN
[155] [156] [157] [158] [159]

Figure 2-5. Electronic Speedometer Connectors: FXDWG

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SPEEDOMETER PERFORMANCE CHECK 2.3
GENERAL hd41354
See Figure 2-6. Use the SPEEDOMETER TESTER (Part No.

HD-41354) for speedometer diagnostics. These diagnostics
may include:
● Checking speedometer operation.

● Testing speedometer needle sweeping action.
The tester generates a simulated speedometer sensor signal.
This signal aids in determining whether speedometer
replacement is necessary.
NOTES
● Use the following procedures in conjunction with the
manual supplied with the speedometer tester.
● Test results may be inaccurate if tester battery is low.

Figure 2-6. Speedometer Tester
TESTING
5087
NOTE
1 2
The SPEEDOMETER TESTER (Part No. HD-41354) cannot
be used to verify the calibration of a speedometer and it will
not verify the speedometer’s function to support legal pro-
ceedings. It’s purpose is to verify speedometer function when
performing service diagnosis or repair. It can also assist in
determining if speedometer replacement is necessary.
Speedometer Operation Test

1. See Figure 2-7. Locate the 3-place speedometer con-
nector [65] under the seat and disconnect. Attach speed-
ometer tester connector.
2. Place speedometer tester power switch in the ON posi- 1. Tester connector
tion. Place signal switch in the OUT position. 2. Speedometer sensor connector [65]
3. Turn vehicle ignition switch ON. Figure 2-7. Speedometer Sensor Connector
4. When speedometer tester displays “P_ _ _ _1”:
a. Press 1 and ENTER on the tester keypad.
Table 2-2. Speedometer Test
b. Enter a frequency from Table 2-2. Note that different Frequency in Hertz (Hz)
markets use different frequencies.
c. Verify that speedometer display reads the corre- 20 MPH 40 MPH 60 MPH 80 MPH
MARKET
sponding speed. To change the test frequency, (30 KPH) (60 KPH) (100 KPH) (130 KPH)
press CLEAR to cancel and enter the new fre-
Domestic
quency. Press ENTER to begin and reverify. 471 939 1403 1861
(mile)
NOTE
Great
The speedometer should be accurate within -0 to +4 MPH (0 Britain 471 939 1403 1861
to +6.5 KPH). (mile/kilo)
HDI (kilo)
includes
440 877 1453 1880
Japan &
Canada

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Speedometer Needle Sweep Test

1. Deutsch socket housing (2)
The tester’s sweep function moves the speedometer needle 2. Deutsch pin housing
through the full range of movement. This allows for testing the
smoothness of operation and checking for hesitancy or a
stuck needle.
1. See Figure 2-7. Disconnect speedometer sensor con-
nector. Attach speedometer tester connector to speed- 2
ometer sensor connector.
2. Place speedometer tester power switch in the ON posi- 1
tion. Place signal switch in the OUT position.
1
3. Turn vehicle ignition switch ON.
4. Begin test by pressing 0 on the tester keypad and then
pressing ENTER. The tester will scan for two seconds, d0318x8x
then the tester will put out a 1 Hz signal.

Figure 2-8. Test Harness
5. Select a test range.
a. Press 2 to select LO range (1-20 Hz). Before attempting the actual speedometer sensor check, two
b. Press 5 to select CEN range (21-999 Hz). system checks must be made. Install the test harness at the
speedometer sensor connector.
c. Press 8 to select HI range (1000-20,000 Hz).
● Test for voltage to sensor by checking for 8-12 VDC on
6. After selecting a range, use the corresponding arrow
keys to accelerate through the range. As you move red wire in connector [65B].
through the speed range, check for smooth needle ● Then check for continuity to ground on black wire in con-
movement. nector [65B].
a. If testing LO range, press 1 or 3. 1. Raise rear wheel off floor.
b. If testing CEN range, press 4 or 6. 2. Install the test harness between the speedometer sensor
c. If testing HI range, press 7 or 9. connectors.
3. Place speedometer tester power switch in the ON posi-
Speedometer Sensor Test tion. Place signal switch in the IN position.
If the speedometer is inoperative, but backlighting and odom- 4. Plug the speedometer tester into the test harness. Turn
eter work, the speedometer sensor may not be working. vehicle ignition switch ON.
See Figure 2-8. Fabricate a test harness using the following 5. Press ENTER on the tester keypad.
parts. 6. Rotate the motorcycle’s rear wheel.
● Two Deutsch 3-place socket housings (Part No. 72113- a. If reading on speedometer tester changes as wheel
94BK) and six socket terminals (Part No. 72191-94). is rotated, speedometer sensor is OK.
● Deutsch 3-place pin housing (Part No. 72103-94BK) and b. If reading does not change, speedometer sensor is
three pin terminals (Part No. 72190-94). suspect. Install a known, good speedometer sensor
and test again.
● Six lengths of 18 gauge wire, each 6.0 in. (15 cm) long.
Tachometer Testing
Use the SCANALYZER (Part No. HD-41325) to test the
tachometer. See 4.4 SCANALYZER and the Active Test Menu
under Figure 4-7.

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INDICATOR LAMPS: FXDWG 2.4
GENERAL d0321x8x
Dyna Wide Glides are equipped with Light Emitting Diode 2

(LED) indicators. The indicator lamp assembly is not service-
1
able. If one LED is bad, the entire assembly must be
replaced.
See DIAGNOSTICS which follows for troubleshooting proce-
dures.
Table 2-3. FXDWG Connector [21] Pins

PIN ON [21] WIRE COLOR FUNCTION
1 Violet left turn
2 White high beam
3
3 Green/yellow oil pressure
4 Brown right turn
5 Tan neutral
6 Orange neutral/oil pressure
7 Black left turn/high beam 1. Nut @ 80-100 in-lbs (9.0-11.3 Nm)
2. Console
8 Not used n/a 3. LED assembly
Figure 2-9. Indicator Lamp Assembly: FXDWG

Table 2-4. LED Assembly Wiring
INDICATOR LAMP CONNECTION
7357
Oil pressure ground through switch
Neutral ground through switch 3
High beam 12 VDC when active
Right/left turn 12 VDC when active 2
1. LED assembly
2. Clips (2 pair)
3. Connector [21]
Figure 2-10. FXDWG Connector [21]

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DIAGNOSTICS
Oil Pressure or Neutral Indicator Will Not Function
Check for 12 VDC at Pin 6 of

connector [21A].
Is 12 VDC present?
YES NO
Check for continuity to Check for blown

ground on connector fuses or find open.
[21] at Pin 5 (neutral)
and Pin 3 (oil pressure). 5048
YES NO
Replace indicator Check each pin for continuity

lamp assembly. to ground through switch.
5191
YES NO NO
Repair open in GN/Y Replace oil Replace neutral

wire (oil pressure) or pressure switch. switch.
TN wire (neutral).
5161 5157
5048
High Beam or R/L Turn Signal Indicator Will Not Function
Check for ground at Pin 2 of

connector [21A].
Is ground present?
YES NO
Check for 12 VDC when circuit Locate and repair

is active. Use Pin 1 (left turn), open in circuit.
Pin 4 (right turn) and Pin 2
(high beam). Voltage present? 5048
YES NO
Replace indicator Locate and repair

lamp assembly. open in circuit.
5191 5048

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NOTES

Table Of Contents
TSM/TSSM
SUBJECT PAGE NO.
3.1 TSM/TSSM Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.2 TSM/TSSM Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.3 TSM/TSSM Vehicle Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.4 TSM/TSSM Turn Signal Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
3.5 TSM/TSSM Bank Angle Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
3.6 Security System (TSSM) Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3.7 Arming/Disarming Security System (TSSM) . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
3.8 Checking For Trouble Codes: TSM/TSSM . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
3.9 Checking For Trouble Codes: TSSM Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
3.10 Breakout Box: TSM/TSSM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
3.11 Initial Diagnostic Check: TSM/TSSM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
3.12 No Security Lamp at Key ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
3.13 Security Lamp on Continuously . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
3.14 Key Fob Signal To TSSM Weak or Fails . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
3.15 Turn Signal Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
3.16 DTC 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47
3.17 DTC 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
3.18 DTC 31, 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51
3.19 DTC 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54
3.20 DTC 35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57
3.21 TSM/TSSM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58
3.22 TSSM Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59
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TSM/TSSM OVERVIEW 3.1
GENERAL 7844
See Figure 3-1. The turn signal module (TSM) has two major
functions:
● Control turn signals.
● Serve as bank angle sensor.
The optional, factory-installed, security system (turn signal
security module or TSSM) provides the same functionality as
the TSM, but also includes:
● Security and immobilization functions.
See 3.2 TSM/TSSM FEATURES for complete details.
TROUBLESHOOTING
Problems fall into at least one of four categories:
● Turn signal malfunction.
Figure 3-1. TSM/TSSM
● Bank angle (engine disable).
● Security lamp problem (TSSM only).
● Security system malfunction (TSSM only). s0457xtm
To resolve TSM/TSSM problems, five basic steps are

involved. In order of occurrence, they are:
1. Check for trouble codes by observing the turn signals.
See 3.8 CHECKING FOR TROUBLE CODES: TSM/
TSSM or 3.9 CHECKING FOR TROUBLE CODES:
TSSM ONLY.
2. Retrieve trouble codes using TSM/TSSM diagnostics.
See 3.8 CHECKING FOR TROUBLE CODES: TSM/
TSSM.
3. Diagnose system problems. This involves using special
tools and the diagnostic flow charts in this section.
4. Correct problems through the replacement and/or repair
of the affected components.
5. After repairs are performed, the work must be validated.
This involves clearing the trouble codes and confirming
proper vehicle operation as indicated by the behavior of
the turn signals.
Figure 3-2. Key Fob
2003 Dyna: TSM & TSSM 3-1

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3-2
d0636x9x
Battery
Battery
+ – backed siren
(optional)
TSM/
TSSM NOTE
Main
circuit Fuse Pin 4 (security lamp) and Pin 11 (siren) not
breaker Ignition module
block 11 used on TSM.
1
Security
fuse 10
2003 Dyna: TSM & TSSM

Start
IGN fuse switch
2 Ignition
Run/stop
switch
Left Ignition
ACC fuse turn
Ignition switch
switch 9 Battery
8
Starter
relay
Starter
7
Right
turn
switch Left turn lamps
5
Vehicle speed sensor
3
12
Speedometer
GND
6
4
Right turn lamps
Speedometer
security lamp
Figure 3-3. Simplified TSM/TSSM Wiring: See Diagrams For Wire Colors
HOME
TSM/TSSM FEATURES 3.2
GENERAL s0457xtm
The TSM/TSSM provides the following capabilities. Note that

some hardware options and software settings are dependent
upon vehicle market specifications.
TURN SIGNAL FUNCTIONS
TSM/TSSM Features
See 3.4 TSM/TSSM TURN SIGNAL FUNCTIONS for com-
plete details.
● Manual turn signal control: Manual activation/deactiva-
tion of left and right turn signal flashing sequences.
● Automatic turn signal cancellation: Automatic cancel-
lation of left and right turn signal flashing sequences
based on either vehicle speed, vehicle acceleration or Figure 3-4. Key Fob
turn completion.
● Emergency flashers: Four-way left and right turn signal
flashing capability.
d0571x8x
● Turn signal lamp diagnostics: Self-diagnostics for
short circuit and open lamp conditions on both left and
right turn signal systems.
BANK ANGLE FUNCTIONS
TSM/TSSM Features
See 3.5 TSM/TSSM BANK ANGLE FUNCTION for complete
details.
● Emergency engine shutdown: Monitors vehicle lean
and will provide engine shutdown when lean exceeds
45° from vertical for more than one second.
● Emergency outputs disable: Monitors vehicle lean and
will disable turn signal lamps and starter motor when
lean exceeds 45° from vertical for more than one sec-
ond. Figure 3-5. TSSM Lamp
● Security status lamp: See Figure 3-5. A lamp within the

SECURITY ALARM AND speedometer face tells the rider if the system is armed or
IMMOBILIZATION FUNCTIONS disarmed.
● Personal code disarming: If a key fob is not available,
the TSSM allows the rider to disable the security alarm
TSSM Only Feature and immobilization functions if the rider knows the previ-
The following information applies only to vehicles with the ously entered personal code.
security option (TSSM). See 3.6 SECURITY SYSTEM ● Security command confirmation: When the system is
(TSSM) FUNCTIONS for more information. armed or disarmed, the system provides visual feedback
to the rider by flashing the turn signals and sounding the
● Remote arming/disarming: See Figure 3-4. Owners
optional siren.
may enable and disable security alarm and immobiliza-
tion functions with a remote, personally carried transmit-
ter. This transmitter is referred to as a key fob within this
document.

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● Auto-arming: Automatically enables the security alarm o0236xox
and immobilization functions when the ignition key is
switched OFF.
NOTE
Default auto-arming behavior depends upon vehicle market.
All HDI vehicles have auto-arming by default. Motorcycles
sold in other markets have auto-arming disabled, but it may
be activated. See 3.3 TSM/TSSM VEHICLE DELIVERY.
● Transport mode: It is possible to arm the security sys-
tem without enabling the motion detector for one ignition
cycle. This allows the vehicle to be moved in an immobi-
lized state.
● Starter/ignition disable: Should the security alarm and
immobilization functions be triggered by a vehicle secu-
rity condition, the starter and ignition system will be dis- Figure 3-6. Siren
abled.
● Security system alarm: See Figure 3-6. The system will
alternately flash the left and right turn signals and sound
an optional siren if a vehicle security condition is
detected while the system is armed.
3-4 2003 Dyna: TSM & TSSM

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TSM/TSSM VEHICLE DELIVERY 3.3
GENERAL 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
1WARNING to the next step. Important information pertaining to certain
actions will be found in the NOTES column.
ONLY FLT Harley-Davidson Motorcycles are suitable for
sidecar use. Consult your Harley-Davidson Dealer. Use of
vehicles other than FLT models for this purpose could
SIDECAR CONFIGURATION
result in death or serious injury.
Setting up a vehicle TSM/TSSM depends on two factors: 1WARNING
● Does the vehicle have a sidecar attached?
ONLY FLT Harley-Davidson Motorcycles are suitable for
● Does the vehicle have a turn signal module (TSM) or the sidecar use. Consult your Harley-Davidson Dealer. Use of
optional security system (TSSM) installed? vehicles other than FLT models for this purpose could
All motorcycles ship with the TSM/TSSM set for use without result in death or serious injury.
a sidecar installed. If a motorcycle is equipped with a TSM, no On motorcycles equipped with a sidecar, the TSM/TSSM
further configuration is required. However, if a motorcycle has must be switched from the factory solo vehicle setting to the
a sidecar or an optional security system (TSSM) installed, sidecar setting using Digital Technician. If the sidecar is then
perform the following steps as necessary. removed, the TSM/TSSM must be reconfigured back to the
solo setting. To verify whether the TSM/TSSM is configured
CAUTION for solo or sidecar usage. See Table 3-1.
If the vehicle is being operated with a sidecar, the setting

MUST be switched from solo vehicle operation to sidecar POWER DISRUPTION AND
operation or the TSM/TSSM will not function properly. CONFIGURING
1. Configure the TSM/TSSM for sidecar or solo configura-
tion. If no sidecar is installed, skip this step. The TSM/TSSM will not enter configuration mode on the first
2. Configure TSSM motorcycles by assigning both key fobs attempt after battery voltage has been removed from Pin 1.
to the vehicle. This will occur after any of the following situations:
3. Configure TSSM motorcycles by entering a personal ● Battery disconnect or power drain.
code picked by the owner. The personal code allows the ● Security fuse removal.
owner to operate the system if the key fob is lost or inop-
erable. Record this code in the owner’s manual and ● Connecting Breakout Box to TSM/TSSM connector.
instruct the customer to carry a copy. Therefore, after all battery reconnects, the configuration
sequence must be modified as follows.
IMPORTANT NOTE
Do not forget to enter a personal code for TSSM vehicles. 1. Set run switch to OFF, cycle ignition key ON-OFF-ON-
If a code is not assigned and the key fob is lost or dam- OFF-ON and press left turn signal switch twice.
aged while the vehicle is armed, the TSSM must be 2. Repeat step listed above.
replaced.
3. Continue with configuration sequence listed.
Changes to TSM/TSSM settings are made by a series of pro-
gramming operations involving the ignition key, left/right turn
signal switches and key fob (security systems).
At certain steps in the programming sequence, the motorcy-
cle may provide confirmation of settings by flashing the turn
signals, turn signal indicators and/or security lamp.

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KEY FOB ASSIGNMENT NOTE

For better security, do not use 3-1-3-1-3 as a personal code.
It is shown as an example only.
The key fob on TSSM motorcycles must be set so it will oper-
ate the alarm system on the vehicle. This assignment must Decide what five digit code the owner would like to use. The
be completed with no pauses between steps greater than 10 code will be programmed using the turn signal switches and
seconds. Turn the ignition OFF after all key fobs have been key fob. Keep a record of the code in a secure place such as
assigned. The programming mode will also exit after 60 sec- your wallet or the owner’s manual.
onds has elapsed without detecting any fob signup messages
● When programming the personal code, the security lamp
or turn signal switch activity.
flashes to provide feedback when entering each digit.
Two key fobs may be assigned to the TSSM. The first suc- ● The number of security lamp flashes corresponds to the
cessful attempt to program a fob will disable all previously number currently selected for a given digit. Therefore, the
assigned fobs. If a second fob is to be programmed, it must lamp may flash 1-9 times depending on the number
be done in the same programming sequence as the initial fob. entered.
To assign a key fob to a motorcycle, see Table 3-2. ● Press the left turn switch one time to increment each
digit of the code.
PERSONAL CODE ENTRY ● Quickly press the key fob button twice to advance to the
next digit of the code.
NOTE
First Time Code Entry: TSSM Only The programming mode exits upon turning the key switch to
IMPORTANT NOTE OFF or if no turn signal switch/key fob button activity occurs
Do not forget to enter a personal code for TSSM vehicles. for 60 seconds. No data is saved for partial configuration
If a code is not assigned and the key fob is lost or dam- attempts.
aged while the vehicle is armed, the TSSM must be
replaced. Modifying Existing Codes: TSSM Only
The TSSM personal code consists of five digits. Each digit If a code was previously entered, the lamp will flash the
can be any number from 1-9. The personal code must be equivalent digit. Each additional press of the left turn switch
used to disarm the security system in case the key fob will increment the digit.
becomes unavailable. ● To advance from 5 to 6, press and release the left turn
To set a personal code on a motorcycle with no code previ- switch 1 time.
ously installed, see Table 3-3. The procedure listed uses 3-1- ● To advance from 8 to 2, press and release the left turn
3-1-3 as the desired personal code. switch 3 times (9-1-2).
Table 3-1. Verifying Whether TSM/TSSM is Configured for Solo/Sidecar* Use

NO. ACTION WAIT FOR CONFIRMATION NOTES
Verify that security lamp is
1 Set RUN/OFF switch to OFF not blinking (vehicle is dis-
armed)
2 Turn IGN key ON-OFF-ON-OFF-ON
1 flash-Worldwide TSM, no
1-3 flashes turn signals & indicators security
depending on vehicle configuration 2 flashes-North American/
Press left turn switch 2 times and
3 (See section under 3.3 TSM/TSSM Domestic configuration
release
VEHICLE DELIVERY regarding battery TSSM
disconnects.) 3 flashes-European/HDI con-
figuration TSSM
Press right turn switch 1 time and
4 1 flash turn signals & indicators
release
5 2 flashes turn signals & indicators
release
1-2 flashes turn signals & indicators 1 flash-Solo
6 Press left turn switch 1 time and release
depending on vehicle configuration 2 flashes-Sidecar
7 Turn IGN key OFF
* Only Touring models can be configured for sidecar usage and then access to Digital Technician is required.

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Table 3-2. TSSM Key Fob Assignment

not blinking (vehicle is dis-
armed)
1 Set RUN/OFF switch to OFF This assignment procedure
must be completed with no
pauses between steps
greater than 10 seconds
release
figuration TSSM
release
5 Press left turn switch 1 time and release 2 flashes turn signals & indicators
Press and hold key fob button until
6 2 flashes turn signals & indicators This may take 10-25 seconds
confirmation is received
If you have two key fobs, press and hold
7 button on second key fob until 2 flashes turn signals & indicators optional step
8 Turn IGN key OFF

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Table 3-3. Programming A TSSM Personal Code (Example: 3-1-3-1-3)

With No Code Previously Installed
armed)
release
disconnects) 3 flashes-European/HDI con-
figuration TSSM
Quickly press key fob button 2 times Vehicle is in personal code
and release entry mode
None if no code entered A lack of confirmation flashes
1 - 9 flashes if code previously entered indicates no digit is entered
Press and release left turn switch to security lamp flashes to indicate each
advance through the digits digit selected You’ve selected 3 as a num-
6
In this example, you will press and In this example, the lamp will flash 3 ber for the first digit
release three times times
You’ve confirmed 3 as a num-
Quickly press key fob button 2 times ber for the first digit and have
and release advanced to entering the
second digit
A lack of confirmation flashes
8 Press left turn switch 1 time and release none
indicates no digit is entered
Press and release left turn switch to
security lamp flashes to indicate each
advance through the digits You’ve selected 1 as a num-
9 digit selected
In this example, you will perform this step ber for the second digit
In this example, the lamp will flash 1 time
one time
Quickly press key fob button 2 times ber for the second digit and
and release have advanced to entering
the third digit
12
In this example, you will repeat this step In this example, the lamp will flash 3 ber for the third digit
three times times
Quickly press key fob button 2 times ber for the third digit and
the fourth digit
Press and release left turn switch to
security lamp flashes to indicate each
advance through the digits You’ve selected 1 as a num-
15 digit selected
In this example, you will perform this step ber for the fourth digit
In this example, the lamp will flash 1 time
one time

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Table 3-3. Programming A TSSM Personal Code (Example: 3-1-3-1-3)

With No Code Previously Installed
Quickly press key fob button 2 times ber for the fourth digit and
the fifth digit
18
In this example, you will repeat this step In this example, the lamp will flash 3 ber for the fifth digit
three times times
Quickly press key fob button 2 times
19 1 flash turn signals & indicators ber for the fifth digit and have
and release
gone back to the first digit
20 Turn IGN key OFF
21 Write down code in owner’s manual
Arm the security system and attempt to
22 disarm using personal code entry. See
Table 3-9.

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TSM/TSSM TURN SIGNAL FUNCTIONS 3.4
GENERAL FOUR-WAY FLASHING

The TSM/TSSM’s turn signal feature has several modes: Use the following method to activate the four-way flashers.
● Automatic cancellation. 1. With the ignition key ON and security system disarmed
(models with security only), press the left and right turn
● Manual cancellation. signal switches at the same time.
● Four-way flashing. 2. Turn the ignition key OFF and arm the security system if
● Diagnostics mode. present and desired. The four-way flashers will continue
for two hours.
The turn signals cannot be activated or deactivated when the
ignition key is in the ACC position. The turn signals can only 3. To cancel four-way flashing, disarm the security system if
be activated or deactivated with the ignition key in the IGN necessary, turn the ignition key ON and press the left
position. and right turn signal switches at the same time.
NOTE
CAUTION Auto-arming (always active on HDI bikes, user selectable on
other vehicles) requires that the four-way flashers be acti-
If the vehicle is being operated with a sidecar, the setting vated within 30 seconds of key OFF or after the vehicle has
MUST be switched from solo vehicle operation to sidecar been disarmed.
operation or the TSM/TSSM will not function properly.
This system allows a stranded vehicle to be left in the four-
If a sidecar is installed, reconfigure the TSM/TSSM using the way flashing mode and secured until help is found.
method under 3.3 TSM/TSSM VEHICLE DELIVERY.
If the security system is disarmed while the four-way flashers
are active, the lights will flash as follows:
AUTOMATIC CANCELLATION 1. TSSM stops four-way flashing mode. Motorcycle sits for
1 second with turn signals off.
Press the left or right turn switch to activate automatic turn 2. TSSM performs disarming confirmation (1 flash).
signal cancellation. There is no need to hold the turn switch in
when approaching the turn. The TSM/TSSM will not cancel 3. Motorcycle sits for 1 second with turn signals off.
the signal before the turn is actually completed. 4. Motorcycle restarts four-way flashing mode.
● When the directional switch is released, the system
starts a 20 count. As long as the vehicle is traveling DIAGNOSTICS MODE
above 7 MPH the directional will always cancel after 20
flashes if the system does not recognize any other input.
The TSM/TSSM measures the current when the turn signals
● If the vehicle speed drops to 7 MPH or less, including are used. If there is a burned out light bulb on one side, the
stopped, the directionals will continue to flash. Counting remaining light and the corresponding turn signal indicator
will resume when vehicle speed reaches 8 MPH and will flash at double the normal rate starting with the fifth flash.
automatically cancel when the count total equals 20 as
stated above. Other diagnostic conditions monitored include:
● The turn signals will cancel within two seconds upon turn ● Short circuit in the turn signal wiring.
completion if the turn is greater than 45 degrees. A sen- ● Open circuit in the turn signal wiring.
sor inside the TSM/TSSM cancels the signal after the
vehicle has been returned to an upright position. ● Stuck turn signal switch.
NOTE NOTE
● A stuck turn signal switch will disable the automatic turn
The bank angle cancellation function has a calibration fea-
signal cancellation feature.
ture. Ride the motorcycle for 1/4 mile (0.4 KM) at steady
speeds (upright) to calibrate the system. ● If a stuck switch is detected, you must hold the left and
right turn signal switches in for more than one second to
activate the four-way flashers.
MANUAL CANCELLATION
See 3.8 CHECKING FOR TROUBLE CODES: TSM/TSSM for
If you want to stop the turn signals from flashing, briefly more information.
depress the turn signal switch a second time.
If you are signalling to turn in one direction and you depress
the switch for the opposite turn signal, the first signal is can-
celled and the opposite side begins flashing.

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TSM/TSSM BANK ANGLE FUNCTION 3.5
GENERAL OPERATION
The turn signals, starter motor, ignition controller (ECM) and The engine will shut off automatically if the vehicle tilts more
coil will be disabled in the event the vehicle tilts more than 45 than 45 degrees from vertical for longer than one second. The
degrees from vertical for longer than one second. engine will automatically shut off even if the tilt occurs at a
very slow speed.
CAUTION To restart the motorcycle after shutdown has occurred:
If the vehicle is being operated with a sidecar, the setting 1. Return the motorcycle to an upright position.
MUST be switched from solo vehicle operation to sidecar 2. Cycle the ignition key OFF-ON before restarting the vehi-
operation or the TSM/TSSM will not function properly. cle.
If a sidecar is installed, reconfigure the TSM/TSSM using the
method under 3.3 TSM/TSSM VEHICLE DELIVERY.

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SECURITY SYSTEM (TSSM) FUNCTIONS 3.6
GENERAL Differences By Market Specifications

The HDI version of the TSSM differs from the domestic TSSM
in the following ways:
Security System Operation
● The HDI version always auto-arms itself within 30 sec-
The TSSM provides security and immobilization functions not onds after the ignition key is turned OFF.
found on the TSM. The TSSM will disable the starter and igni- ● The HDI version does not have the remote arming only
tion system. Additional functions include the ability to alter- option.
nately flash the left and right turn signals and sound a siren (if
purchased as an option) if a theft attempt is detected.
Conditions that activate the security system when system is
ALARM SENSITIVITY
armed include:
● Detecting small vehicle movement: Turn signals flash Sensitivity
3 times and optional siren chirps once and then turns off.
If the vehicle is not returned to its original position the The TSSM has four sensitivity settings: extremely low, low,
warning will reactivate after 4 seconds. This cycle may medium or high. The selection picked controls the sensitivity
repeat a maximum of 255 times. of the security system in regards to motion detection.
To set alarm sensitivity, see Table 3-4.
● Detecting large vehicle movement: System activates
for 30 seconds and turn off. If the vehicle is not returned
to its original position the alarm will reactivate after 10
Transport Mode
seconds. This cycle may repeat a maximum of 10 times. It is possible to arm the security system without enabling the
motion detector for one ignition cycle. This allows the vehicle
● Detecting tampering of the security lamp circuit:
to be picked up and moved in an armed state. In this mode,
System activates for 30 seconds. This cycle repeats
any attempt to hot-wire the vehicle will trigger the security
once for each tampering incident.
system.
● Detecting that a battery or ground disconnect has
● To enter the transport mode, see Table 3-5.
occurred while armed. Siren, if installed, activates its
self-alarm mode. Turn signals will not flash. ● To exit from transport mode and return the system to nor-
mal operation/functions, disarm the system using either
See 3.7 ARMING/DISARMING SECURITY SYSTEM (TSSM)
the key fob or personal code.
for more information.
NOTE
NOTE Transport mode is especially useful when working on HDI
Always disarm the TSSM before removing or disconnecting vehicles. If it is not used, then the alarm will activate under
the battery to prevent the siren (if installed) from activating. If many typical service activities.
the TSSM is in auto-arming mode, you must disarm the sys-
tem using two clicks of the key fob and disconnect the battery
or remove the TSSM fuse before the 30 second arming
period expires.
Security System Options

The following customization 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 (sidecar not installed).
● Medium motion sensitivity on alarm sensitivity.
● Auto-arming standard on HDI vehicles and disabled on
domestic motorcycles.
● Storage mode set to 60 days.

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AUTO-ARMING FUNCTION STORAGE MODE

Auto-arming causes the system to automatically arm itself The TSSM has a special mode for long term storage. This
(no key fob needed) within 30 seconds after the ignition key is mode prevents the security system from draining the battery
turned OFF. During this period, the security lamp stays on after a period of days (30, 60, 90 or infinite) without any igni-
solid to indicate auto-arming is starting up. tion key switch activity.
The vehicle may be moved during these 30 seconds without ● If the TSSM is set to infinite, the system will not go into
triggering the alarm. However, any motion after that period storage mode.
will trigger the security alarm. Upon expiration of the auto-
arming period, the turn signals flash twice, the security lamp ● Vehicles will enter storage mode whether the security
begins to flash and the siren (if installed) chirps twice. system is armed or disarmed.
The TSSM allows remote arming via the key fob at anytime. ● If set to infinite or 90 days, the customer must use a
However, if the system is remotely disarmed (with the key trickle charger to keep the battery from discharging.
fob) but the ignition key is not turned ON within 30 seconds, In storage mode, all alarm functions are suspended and the
the system will rearm itself when auto-arming is enabled. receiver is shut down and will not respond to the key fob. The
The auto-arming setting depends upon vehicle market speci- vehicle is immobilized because the starter motor and ignition
fications. module are disabled. When the storage mode is entered, the
security lamp stops flashing to conserve power.
● Motorcycles sold in North America have auto-arming
disabled by default. However, the feature may be To wake up the TSSM from storage mode, the ignition key
enabled if the customer desires. must be turned ON. This will trigger the alarm if the system
was previously armed. You must use the key fob or personal
● Vehicles sold elsewhere have auto-arming enabled and
code to disarm the system and stop the alarm.
this setting cannot be changed.
When auto-arming is disabled, the key fob must be used to To set the storage mode preferences, see Table 3-7.
arm the security system.
To set the auto-arming function, if it is available on your vehi-
cle, see Table 3-6.
Table 3-4. TSSM Alarm Sensitivity

armed)
2 or 3 flashes turn signals & indicators 2 flashes-North American/
depending on vehicle configuration Domestic configuration
Press left turn switch 2 times and TSSM
3 (See section under 3.3 TSM/TSSM
release
VEHICLE DELIVERY regarding battery 3 flashes-European/HDI con-
disconnects.) figuration TSSM
1 flash-extremely low
turn signals & indicators flash to indicate 2 flashes-low sensitivity

option selected 3 flashes-medium sensitivity
4 flashes-high sensitivity
1 flash-extremely low
Press and release left turn switch to turn signals & indicators flash to indi- 2 flashes-low sensitivity
6
advance through options cate option selected 3 flashes-medium sensitivity
4 flashes-high sensitivity
7 Turn IGN key OFF

HOME
Table 3-5. TSSM Transport Mode

armed)
2 Turn IGN key ON
4 Turn IGN key OFF
Press and hold key fob button until The vehicle can be moved
confirmation is received without tripping the alarm
Table 3-6. Selecting TSSM Auto-arming Function (Not Available on HDI Vehicles)
armed)
release
1 flash-
turn signals & indicators flash to indicate auto-arming disabled
option selected 2 flashes-
auto-arming enabled
Press and release left turn switch to turn signals & indicators flash to indicate
7
advance through options option selected
8 Turn IGN key OFF

HOME
Table 3-7. TSSM Storage Mode Preferences

armed)
release
Release and then hold key fob button
until confirmation is received
Release and then hold key fob button
until confirmation is received
1 flash-30 days
turn signals & indicators flash to indicate 2 flashes-60 days
option selected 3 flashes-90 days
4 flashes-Infinite
1 flash-30 days
Press left turn switch to advance through turn signals & indicators flash to indicate 2 flashes-60 days
8
options option selected 3 flashes-90 days
4 flashes-Infinite
9 Turn IGN key OFF

HOME
ARMING/DISARMING SECURITY SYSTEM (TSSM) 3.7
GENERAL USING KEY FOB

There are two methods to arm the security system:
● Using the key fob.
General
● Using auto-arming. See 3.6 SECURITY SYSTEM The TSSM’s reception range for the key fob signal depends
(TSSM) FUNCTIONS. on a specific receiver pattern.
NOTE NOTE
The vehicle cannot be armed with the engine running or the Environmental and geographic conditions may affect signal
ignition ON. range.
There are two ways to disarm the system: Arming the System
● Using the key fob. This method works in all situations 1. Hold key fob horizontal at waist level.
except before turning ignition key ON when TSSM stor-
2. Point key fob at the front of the vehicle.
age mode is activated.
3. Hold down the key fob button until the system responds
● Using the personal code. with two turn signal flashes.
SECURITY LAMP Disarming the System

1. Hold key fob horizontal at waist level.
See Table 3-8. The security lamp within the speedometer pro- 2. Point key fob at the front of the vehicle.
vides feedback to the rider confirming armed or disarmed sta-
3. Quickly press the key fob button twice. The system will
tus.
respond with one turn signal flash.
NOTE
Table 3-8. Security Lamp Status Disarming function may require practice. The key fob button
must be pressed twice within 1.5 seconds to send the disarm
LAMP MODE command. The action is very similar to double-clicking a com-
No security system (TSM), security puter mouse. Light quick taps work best; very hard or very
slow taps are less likely to work.
Does not flash system not armed or storage mode
active Troubleshooting
10 minute timeout after failed
If the key fob button has been pressed numerous times while
Flashes every personal code entry attempt or a bat-
away from the vehicle, the fob may fall out of synchronization
second tery reconnect has occurred while with the TSSM. If this happens, the TSSM might fail to recog-
armed nize the key fob’s commands.
Flashes every To solve this problem, press and hold the key fob button for
Security system armed
2 seconds 10-15 seconds until the security system responds with two
Flashes 3 times turn signal flashes. After confirmation, you may resume nor-
Personal code entry mode mal fob operation.
a second
Stays on solid with Auto-arming is starting up. You have
ignition key OFF 30 seconds before system is armed.
If solid for more than 4 seconds after
Stays on solid with
key ON, a current trouble code is
ignition key ON
present

HOME
USING THE PERSONAL CODE Disarming the System

See Table 3-9. If you make an error while disarming the
General TSSM using the personal code, the alarm will activate for 30
seconds after the last digit is entered. After a failed attempt,
The personal code consists of five digits entered using the left the security lamp will flash once every second for 10 minutes.
and right turn signal switches. Each digit can be any number
During this time, the vehicle will not accept any attempt
from 1-9. The personal code is intended to be used to disarm
to enter a personal code.
the vehicle in case the key fob becomes unavailable or inop-
erable.
See 3.3 TSM/TSSM VEHICLE DELIVERY to set a personal
code.
Table 3-9. Entering A Personal Code To Disarm TSSM (Example: 3-1-3-1-3)

1 Set RUN/OFF switch to OFF
2 Turn IGN key to ACC
Hold both turn switches in until System is ready for personal
3 security lamp blinks at fast rate
confirmation code entry
Enter first digit of code (3) by pressing
4
left turn switch 3 times
Serves as “enter” key for first
5 Press right turn switch 1 time
digit
Enter second digit of code (1) by press-
6
ing left turn switch 1 time
Serves as “enter” key for sec-
ond digit
Enter third digit of code (3) by pressing
8
Serves as “enter” key for third
digit
Enter fourth digit of code (1) by pressing
10
left turn switch 1 time
Serves as “enter” key for
fourth digit
Enter fifth digit of code (3) by pressing
12
System is disarmed. You may
13 Press right turn switch 1 time security lamp stops blinking use the vehicle or program
another key fob

HOME
CHECKING FOR TROUBLE CODES: TSM/TSSM 3.8
GENERAL TURN SIGNAL DIAGNOSTICS

To diagnose the TSM/TSSM, observe the behavior of the turn To determine which error code (either current and/or historic)
signals. If the turn signals flash six fast four-way flashes is logged:
shortly after key ON, then an error code is logged. See TURN 1. Activate TSM/TSSM diagnostic mode using instructions
SIGNAL DIAGNOSTICS which follow. in Table 3-10.
2. Observe the turn signals. All codes are flashed in
CODE TYPES numeric order.
a. The flashes will pause for 4 seconds.
There are two types of trouble codes: current and historic. If a b. Watch for four-way flashers to cycle a number of
trouble code is stored, it can be read using TSM/TSSM diag- times equal to the first digit of the first DTC.
nostics. c. The flashes will pause for 1.5 seconds.
d. Watch for four-way flashers to cycle a number of
Current times equal to the second digit of the first DTC.
Current trouble codes are those which are present during the e. If multiple codes are present, the system will restart
current ignition cycle. See the appropriate flow charts for with Step A.
solutions. 3. To determine the meaning of a code, see 3.11 INITIAL
DIAGNOSTIC CHECK: TSM/TSSM and Table 3-12.
Historic NOTES
If a particular problem happens to resolve itself, the active ● If the turn signals flash six four-way flashes shortly after
status problem is dropped and it becomes a historic code key ON, it indicates an error code has been logged
rather than a current code. For example, intermittent output sometime in the last 3 ignition cycles.
shorts can become typical historic codes. ● On vehicles with a TSSM, the security lamp will also light
Historic codes are stored for 50 ignition cycles after any code for 8 seconds after the bulb check if historic codes are
was last set as current to assist in the diagnosis of intermit- present. The security lamp will stay on if current codes
tent faults. On the 50th cycle, the code will clear itself. are set. If a historic code is present, the security lamp will
light for 50 ignition cycles or until the code is cleared
It is important to note that historic codes will exist whenever manually.
the system indicates the existence of a current fault.
Diagnostic charts are designed for use with current trouble

codes and as a result they frequently suggest part replace-
ment. When diagnosing a historic code the charts can be
helpful but should not lead to part replacement without verifi-
cation the part is faulty.

HOME
Table 3-10. Invoking TSM/TSSM Code Diagnostics

1 Set RUN/OFF switch to OFF
release
figuration TSSM
release
release
release
turn signals & indicators flash to indicate
7 Press left turn switch 1 time and release See Table 3-12.
trouble codes
To clear codes, press and hold left turn
8 switch for 4-5 seconds until confirmation 2 flashes turn signals & indicators
is received
9 Turn IGN key OFF

HOME
CHECKING FOR TROUBLE CODES: TSSM ONLY 3.9
SECURITY LAMP 7501
To diagnose system problems, start by observing the behav- 3

ior of the security lamp. 2
NOTE
● See Figure 3-7. “Key ON” means that the ignition key is 1
turned to ON and the engine stop switch is set to RUN
(although the engine is not running).
● If the security lamp is not illuminated at Key ON or if it
fails to turn OFF after the initial four second period, then
a problem exists in the lamp circuit. See 3.12 NO SECU-
RITY LAMP AT KEY ON or 3.13 SECURITY LAMP ON
CONTINUOUSLY for more information.
1. See Figure 3-8. When the ignition key is turned ON, the
security lamp will illuminate for approximately four sec-
onds and then turn off. 1. Ignition OFF
2. See Figure 3-9. After the lamp turns off after being illumi- 2. Marker lights ON
nated for the first four second period, one of three situa- 3. Ignition ON
tions may occur. Figure 3-7. Ignition Switch
a. The lamp remains off. This indicates there are no
current fault conditions or stored historic trouble
codes currently detected by the TSSM.
d0571x8x
b. The lamp stays off for only four seconds and then
comes back on for an eight second period. This indi-
cates a historic code is stored, but no current trouble
code exists.
c. If the lamp remains on beyond the eight second
period, then a current trouble code exists.
3. See CODE TYPES under 3.8 CHECKING FOR TROU-
BLE CODES: TSM/TSSM for a complete description of
trouble code formats.
Figure 3-8. Security Lamp

HOME
ON 4 Sec.
A Lamp OFF: no current OR historic trouble codes
OFF
Key ON
Lamp ON 8 seconds:
historic code
ON 4 Sec. 8 Sec.
B Lamp OFF
OFF 4 Sec.
Key ON
Lamp remains ON: current trouble code

ON 4 Sec.
C
OFF 4 Sec.
Key ON
Figure 3-9. Security Lamp Operation

HOME
BREAKOUT BOX: TSM/TSSM 3.10
GENERAL s0474x9x
The BREAKOUT BOX (Part No. HD-42682) splices into the

main harness. Used in conjunction with a DVOM, it allows cir-
cuit diagnosis of wiring harness and connections without hav-
ing to probe with sharp objects.
2
INSTALLATION
1. Gain access to TSM/TSSM. See 2003 Dyna Service
Manual (Part Number 99481-03).
2. See Figure 3-10. Depress latches on connector [30B]. 1
3. See Figure 3-11. Attach Breakout Box to connector. 1. Pin 1
a. Attach gray connector from Breakout Box to TSM/ 2. Pin 12
TSSM connector.
Figure 3-10. TSM/TSSM Connector Pins
b. Attach connector from the wiring harness to gray
connector on Breakout Box.
hd42682
REMOVAL
1. See Figure 3-10. Depress latches on connector [30B].
2. Detach gray Breakout Box connector from TSM/TSSM
connector.
3. Detach gray Breakout Box connector from wiring har-
ness.
4. Reattach TSM/TSSM connector to wiring harness.
5. Install parts removed for access.
NOTE
Vehicle will not start with TSM/TSSM disconnected or incor-
rectly mounted.
Figure 3-11. Breakout Box
Table 3-11. TSM/TSSM Connector [30B]

PIN FUNCTION PIN FUNCTION
1 Battery 7 Right turn switch input

2 Ignition 8 Left turn switch input
3 Vehicle speed sensor 9 Start relay control
4 Security indicator 10 Ignition enable signal
5 Left turn feed 11 Alarm signal
6 Right turn feed 12 Ground

HOME
INITIAL DIAGNOSTIC CHECK: TSM/TSSM 3.11
GENERAL Circuit Diagram/Wire Harness

Connector Table
To locate faulty circuits or other system problems, follow the
When working through a flow chart, refer to the illustrations,
diagnostic flow charts in this section. For a systematic
the associated circuit diagram and the wire harness connec-
approach, always begin with the Diagnostic Check which fol-
tor table as necessary. The wire harness connector table for
lows. Read the general information and then work your way
each circuit diagram identifies the connector number, descrip-
through the flow chart box by box.
tion, type and general location.
Diagnostic Notes In order to perform most diagnostic routines, a Breakout Box
and a DVOM are required. See 3.10 BREAKOUT BOX: TSM/
If a numbered circle appears adjacent to a flow chart box,
TSSM.
then more information is offered in the diagnostic notes. Many
diagnostic notes contain supplemental information, descrip- To perform the circuit checks with any degree of efficiency, a
tions of various diagnostic tools or references to other parts familiarity with the various wire connectors is also necessary.
of the manual where information on the location and removal See the appendix or electrical section of your service manual.
of components may be obtained.
Job/Time Code Values
Multiple Trouble Codes Dealership technicians filing warranty claims should use the
DTCs that have a current fault status take priority over historic job/time code values printed in bold text underneath the
status codes. appropriate repair.
Table 3-12. TSM/TSSM Diagnostic Trouble Codes (DTC) and Fault Conditions
TURN
SIGNAL LAMP FAULT CONDITION SOLUTION
CODE
N/A No security lamp at key ON 3.12 NO SECURITY LAMP AT KEY ON
N/A Security lamp on continuously 3.13 SECURITY LAMP ON CONTINUOUSLY
N/A Fob signal to TSSM weak or fails 3.14 KEY FOB SIGNAL TO TSSM WEAK OR FAILS
11 Battery voltage high 3.16 DTC 11
21 Left turn output fault 3.15 TURN SIGNAL ERRORS
22 Right turn output fault 3.15 TURN SIGNAL ERRORS
25 Ignition enable output high 3.17 DTC 25
31 Alarm output low 3.18 DTC 31, 32
32 Alarm output high 3.18 DTC 31, 32
34 Starter output high 3.19 DTC 34
35 Accelerometer fault 3.20 DTC 35
Ignition switch open/low
N/A 3.15 TURN SIGNAL ERRORS
(may show Code 41 if historic)

HOME
Diagnostic Check
Does the vehicle have a

security system (TSSM)
installed?
YES NO
Does security lamp go off Enter diagnostic code

after 4 seconds? YES flashout mode. See Table 3-10.
Codes present?
NO NO
Light does not illuminate at all. Light stays on continuously.
YES NO
See Table 3-12. Review symptoms under

See 3.12 NO SECURITY LAMP See 3.13 SECURITY LAMP ON
Follow applicable 3.15 TURN SIGNAL
AT KEY ON. CONTINUOUSLY.
flow chart. ERRORS and Table 3-19.
IMPORTANT NOTE
For the first three ignition cycles after a
fault has occurred, the turn signals flash
six fast four-way flashes shortly after key
ON.

7
HOME
NO SECURITY LAMP AT KEY ON 3.12
GENERAL d0571x8x
No TSSM Power
See Figure 3-12. When the ignition key is turned ON, the
security lamp should illuminate for 4 seconds. Following the
initial illumination period, the lamp should go off for 4 sec-
onds. It may come back on for an 8 second period (for a
stored historic error) or remain on continuously (current
error).
Ground is supplied to the lamp bulb. Battery voltage is sup-
plied by the TSSM through the BN/V wire. A lack of power to
the TSSM will cause the security lamp to be inoperative and
will also create a no start situation.
Table 3-13. Models Affected Figure 3-12. Security Lamp
VEHICLE SECURITY NO SECURITY
Dyna Yes No 7900
DIAGNOSTICS
Diagnostic Tips
● Check for open in BN/V wire.
● See Figure 3-13. Check security fuse.
Diagnostic Notes
bers on the Test 3.12 flow charts.
1. Connect BREAKOUT BOX (Part No. HD-42682) Figure 3-13. Security Fuse
between wire harness and TSSM. See 3.10 BREAKOUT
BOX: TSM/TSSM.
2. Connector [39B] is on the back of the speedometer.
Leave connector halves mated to test. Insert probe into
wire end of connector [39B] until contact is made with
backside of terminal. If necessary, use a fine paper clip
to avoid damage.
3. Use HARNESS CONNECTOR TEST KIT (Part No. HD-
41404), purple pin probe and patch cord between break-
out Breakout Box and ground. Align blade with slot in ter-
minal of Breakout Box.
4. Security lamp failure requires speedometer replacement.
See the 2003 Dyna Service Manual (Part Number
99481-03).

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d0639x9x
FXDWG uses Terminals 5 and
10 on connector [39]. All
other models use 2 and 12.
BK
Security lamp inside

speedometer
[39A] [39B]
R R 15 Amp
– + 30 Amp main security fuse
circuit breaker
Battery
BK
BN/GY
BN/V
BK
[30B] 1 2 3 4 5 6 7 8 9 10 11 12
[30A] 1 2 3 4 5 6 7 8 9 10 11 12
TSSM
Figure 3-14. Security Lamp Circuit
Table 3-14. Wire Harness Connectors in Figure 3-14.

NO. DESCRIPTION TYPE LOCATION
[30] TSSM 12-place Deutsch behind electrical panel
[39] Speedometer: FXDWG 12-place Mini-Deutsch back of speedometer
[39] Speedometer: All but FXDWG 12-place Packard back of speedometer

HOME

NO SECURITY LAMP AT KEY ON
Turn ignition key ON. Set engine stop switch

to RUN. Does engine crank?
YES NO
Turn ignition key OFF. Disconnect connector

1 [30] (gray) and connect Breakout Box. Check
for continuity between Terminal 5 (FXDWG
STOP
only) or Terminal 2 (all except FXDWG) of
2 connector [39B] and Pin 4 on
connector [30] (gray) on Breakout Box. Go to Test 3.12
Continuity present? (Part 2 of 3).
YES NO
Check for continuity to ground Repair open on BN/V wire

on Pin 4 of Breakout Box. between connectors [30B]
Continuity present? and [39B].
6735
YES NO
Locate and repair short to Reconnect connector [39].

ground on BN/V wire. 3 Place jumper between
Pin 4 of connector [30]
6736 (gray) on Breakout Box to
battery positive. Does
security lamp illuminate?
YES NO
Replace TSSM. Replace

Perform setup. 4 speedometer.
6737 6738
Clear codes and confirm proper

operation with no security lamp.

HOME

Continued from Test 3.12 (Part 1 of 3).
Connector [30] mated fully?
YES NO
Place red meter lead at Pin 1 Mate

and black meter lead at Pin 12 connector.
of connector [30]. Battery
voltage present? 6739
YES NO
Move red meter lead to Pin 2 of

connector [30]. Battery voltage
present? STOP
Go to Test 3.12
YES NO (Part 3 of 3).
Replace TSSM. Check for voltage at

Perform setup. ignition fuse. Battery
voltage present on both
6740
terminals?
YES NO
Locate and repair open

on gray wire between
ignition fuse and TSSM. STOP
6741
Go to 4.12 NO IGNITION
MODULE POWER.


HOME

Continued from
Test 3.12 (Part 2 of 3).
Check resistance to ground on

Pin 12. Resistance less than
1 ohm?
YES NO
Check for 12 volts at both Repair poor

terminals of 15 amp security fuse. ground.
Proper voltage present at
both terminals? 6742
YES NO
Repair open in BN/GY wire

between security fuse and TSSM.
1 Terminal. Neither Terminal.
6743
Replace Repair open between main

fuse. circuit breaker and fuse block.
6744 6745


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SECURITY LAMP ON CONTINUOUSLY 3.13
GENERAL d0571x8x
See Figure 3-15. When the ignition key is turned ON, the
security lamp should illuminate for 4 seconds. Following the
initial illumination period, the lamp should go off for 4 sec-
onds. It may come back on for an 8 second period (for a
stored historic error) or remain on continuously (current
error).
Table 3-15. Models Affected

Dyna Yes No
DIAGNOSTICS Figure 3-15. Security Lamp
Diagnostic Notes
1. Connector [39B] is on the back of the speedometer. Use
HARNESS CONNECTOR TEST KIT (Part No. HD-
41404), black pin probe and patch cord.

HOME
d0639x9x
FXDWG uses Terminals 5 and
10 on connector [39]. All
other models use 2 and 12.
BK
Security lamp inside

speedometer
[39A] [39B]
R R 15 Amp
– + 30 Amp main security fuse
circuit breaker
Battery
BK
BN/GY
BN/V
[30B] 1 2 3 4 5 6 7 8 9 10 11 12 BK
[30A] 1 2 3 4 5 6 7 8 9 10 11 12
TSSM
Figure 3-16. Security Lamp Circuit

[39] Speedometer: FXDWG 12-place Mini-Deutsch back of speedometer
[39] Speedometer: All but FXDWG 12-place Packard back of speedometer

HOME
Test 3.13
SECURITY LAMP ON CONTINUOUSLY
Turn ignition key ON. Does security lamp turn

ON for 4 seconds and then turn OFF
for 4 seconds?
YES NO
Security lamp function OK. Turn ignition key OFF.

Check for trouble codes. See Disconnect connector [30] (gray).
3.9 CHECKING FOR TROUBLE Turn ignition ON.
CODES: TSSM ONLY. Does security lamp illuminate?
YES NO
Disconnect connector [39]. Replace TSSM.

1 Check for voltage on Perform setup.
Pin 4 (BN/V wire) of
connector [30]. 6750
Voltage present?
YES NO
Repair short to battery Replace

on BN/V wire between speedometer.
connector [30A] and [39B].
6752
6751


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KEY FOB SIGNAL TO TSSM WEAK OR FAILS 3.14
GENERAL o0235xox
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.
See Figure 3-17. 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 confirmation at arming/disarming system) or
responds weakly (limited range, won’t consistently arm/dis-
arm or synchronize), follow the Test 3.14 flow chart.
Figure 3-17. Key Fob Battery
Table 3-17. Models Affected Diagnostic Notes

VEHICLE SECURITY NO SECURITY bers on the Test 3.14 flow charts.
Dyna Yes No 1. After a battery disconnect, the TSSM will not enter the
configuration mode on the first attempt. All attempts to
assign a fob or enter the configuration mode will require
DIAGNOSTICS at least two attempts.
Diagnostic Tips
● Verify key fob battery voltage is approximately 3 volts.
See 3.22 TSSM MAINTENANCE.
● Interference from physical surroundings may affect RF
transmission. Place fob next to left handgrip and disarm
with two clicks or move motorcycle to a new location and
retest.
● Check for damage to antenna wire. Does left turn signal
work?
NOTE
See 3.7 ARMING/DISARMING SECURITY SYSTEM
(TSSM). Use only the proper key fob for your market and
TSSM package.

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s0466x9x
W/V
Left turn signal [24B] [24A]

switch
30 Amp main
circuit breaker
R R
– +
15 Amp
security
fuse
Battery
BK
BN/GY
W/V
BK
[30B] 1 2 3 4 5 6 7 8 9 10 11 12
[30A] 1 2 3 4 5 6 7 8 9 10 11 12
TSSM
Figure 3-18. Starter/TSSM Circuit

[24] Left handlebar switch 6-place Deutsch left handlebar

HOME
Test 3.14
FOB SIGNAL TO TSSM WEAK OR FAILS
Correct key fob for vehicle?
YES NO
Does left turn Obtain correct fob or replace

signal function? fob. Verify fob is synchronized
to vehicle’s TSSM.
YES NO
Replace fob battery and See 3.15 TURN SIGNAL

retest. See 3.22 TSSM ERRORS.
MAINTENANCE.
Does fob work?
YES NO
System Attempt to assign new fob

OK.
1 to TSSM and retest.
Does fob work?
6755
YES NO
System Replace TSSM.

OK. Perform setup.
6756 6757

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TURN SIGNAL ERRORS 3.15
GENERAL 7844
The turn signals will automatically cancel either based on the

speed/acceleration of the vehicle or based upon turn comple-
tion. See 3.4 TSM/TSSM TURN SIGNAL FUNCTIONS.
For turn signal diagnostics, see Table 3-19.
DIAGNOSTICS
Diagnostic Tips
● On vehicles with a security system, DTC 21 and 22 will
illuminate the security lamp.
● On vehicles with a security system, DTC 41 will not illu-
minate the security lamp.
● When the TSM/TSSM is in four-way flasher mode, a fault
on either the left or right turn lamp output will not cause Figure 3-19. TSM/TSSM
either DTC 21 and DTC 22 to be set as current. If fault
occurs on both left and right outputs, then both DTC 21
and DTC 22 will be set as current.
● When the TSM/TSSM detects an over current (or short to
ground) condition, it will turn off the turn lamp outputs.
The outputs will be automatically reactivated once the
fault is removed.
Table 3-19. Turn Signal Errors

START WITH
SYMPTOM MODELS DTC(S)
FLOW CHART
Turn signals will not cancel
Carbureted Turn Signal Error 1A N/A
or cancel erratically
Turn signals will not flash,
All Turn Signal Error 2A 21, 22, 41
4-way flashers inoperable
Left or right turn signals flash at double the
All Turn Signal Error 3A N/A
normal rate while all bulbs are working

[10] Ignition module (black) 12-place Deutsch under left sidecover
[11] Ignition module (gray) 12-place Deutsch under left sidecover
[18] Left rear turn signal 2-place Multi-lock inside tail lamp lens
[19] Right rear turn signal 2-place Multi-lock inside tail lamp lens
[22] Right hand controls 6-place Deutsch inside frame backbone
[24] Left hand controls and horn 6-place Deutsch inside frame backbone
[30] TSM/TSSM 12-place Deutsch behind electrical panel
[31] Front turn signals 6-place Multi-lock inside frame backbone

HAND CONTROLS,
HOME
RIGHT COMPONENTS LOCATED UNDER LEFT SIDE COVER START

[162 ]
d0676xtm
RELAY 70103-96 BK
F E D C B A B A
TO 15A BATTERY
RIGHT TURN SWITCH E C [62A]
FRONT SECURITY IGNITION
ENGINE STOP/RUN 85 86 30 87a 87
L K J I H G K I H G
TURN SIGNALS SWITCH 15A 15A
PAGE 2 START SWITCH ACCESSORIES LIGHTS U T S R Q P
BK
S UE T K
6 5 4 3 2 1 U S R P O M O M
STOPLIGHT SWITCH 15A 15A 70102-96
[31A] [62B]
TOP VIEW TOP VIEW
V
BK
BN
BK
STARTER
TN/GN
GN
BK/R
R/BK
GY
O/W
[46B]
BK/R
W/BN
W/BK
Wire Color Code Key
[22B]
6 5 4 3 2 1 BK - Black GN - Green LT.GN - Light Green PIN CONNECTOR
(A side)
BN - Brown BE - Blue PK - Pink
6 5 4 3 2 1 R - Red V - Violet TN - Tan SOCKET CONNECTOR
BK
[128A] [128B]
[22A] O - Orange GY - Gray Wire color-XX/XX-Stripe color (B side)
[46A]
GN
O/W
GY
BK/R
W/BN
R COPPER
[64B] STUD
[5 ]
CIRCUIT
G IGN: 15A H BREAKER
TURN SIGNAL/SECURITY MODULE
GY R/BK 30 AMP
BATTERY 1 BN/GY
IGNITION 2 GY
VSS / SERIAL DATA LINK 3 W/GN [33A] [33B] IGNITION
SECURITY INDICATOR 4 BN/V SWITCH
LEFT TURN FEED 5 V R A A R,
RIGHT TURN FEED 6 BN R/GY B B R/GY
RIGHT TURN SWITCH INPUT 7 W/BN R/BK C C R/BK
LEFT TURN SWITCH INPUT 8 W/V D D
IGNITION ENABLE SIGNAL 10 LGN/GY P ACCY: 15A R
ALARM SIGNAL 11 LGN/BN O/W R/GY
GROUND 12 BK
BN/GY R
[30A] [30B]
1
2 W/GN
3 BN
4
TO 5 V
SPEEDO 6
7
[20A]
8
9
10
11 BN/V
12 BK
BK
BN/GY
LGN/BN
[142B]
Figure 3-20. Turn Signal Circuit (FXDWG Similar)

A B C
BK
BK
BK
LGN/GY
V
BN
BK
BK
[11B] [7A]
GND
[142A]
ALARM
[10B]
POWER
1 2 3 4 5 6 7 8
W/V
1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 3
O/W
1 2
1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12
TO
[24A] REAR LIGHTING
GRAY BLACK [10A] [GND1]
1 2 3 4 5 6 [11A] PAGE 2 OPTIONAL
SECURITY
IGNITION MODULE SIREN
1 2 3 4 5 6
[24B]
O/W
W/V
SWITCH RED/BLACK RED RED/GRAY HORN SWITCH
POSITION
OFF
HEADLAMP HI/LO
ACC.
SWITCH
IGNITION
LEFT TURN SWITCH

WIRE IN SWITCH POSITION INDICATED HAND CONTROLS,
2003 Dyna: TSM & TSSM

LEFT
[163 ]
3-37
HOME
Diagnostic Notes: hd41354

All Turn Signal Flow Charts
bers on the turn signal flow charts.
1. The turn signals will automatically cancel either based on
the speed/acceleration of the vehicle or based upon turn
completion. See 3.4 TSM/TSSM TURN SIGNAL FUNC-
TIONS.
2. See Figure 3-21. Use SPEEDOMETER TESTER (Part
No. HD-41354) to input a signal which duplicates 3 MPH.
Enter 70 into tester and watch for voltage drop on W/GN
wire. If tester is not available, elevate rear wheel and spin
briskly while looking for voltage drop on W/GN wire.
3. Connect BREAKOUT BOX (Part No. HD-42682) to TSM/
TSSM. See 3.10 BREAKOUT BOX: TSM/TSSM.
4. Use the following steps to enable diagnostic mode.
a. See Figure 3-22. Depress odometer reset switch
and turn ignition key ON. Figure 3-21. Speedometer Tester
b. To clear codes, turn ignition key from OFF to ON

while holding reset switch in.
c. Press and release the reset switch to cycle through 7495
the codes. Set codes will display as Code d0xSet;
holding the reset switch in will result in Code d0xClr
being displayed. This indicates the code has been
cleared.
d. To return speedometer to normal operating state,
cycle ignition key.
5. Check for corrosion at rear lighting harness connector
[7], front lighting harness connector [31] and TSSM [30].
Figure 3-22. Odometer Reset Switch: FXDWG Shown

HOME
Turn Signal Error 1A

WILL NOT CANCEL OR CANCEL ERRATICALLY
Verify type
1 of cancellation error.
Flash will not cancel Flash will not cancel.

by turn completion.
Is TSM/TSSM Check for battery Voltage between

mounted properly? Pin 7 and Pin 12 of Connector [30B]
and Pin 8 and Pin 12 of Connector
[30B]. Is battery Voltage present?
YES NO
Check TSM/TSSM setting for solo Mount YES NO

or side car operation. correctly.
See 3.3 TSM/TSSM VEHICLE
DELIVERY. Proper configuration?
Repair switch or
short to voltage. STOP
5173
Go to Turn Signal
YES NO Error 1B.
Connect all wiring. Perform TSM/TSSM auto- Select proper

calibration by riding vehicle in a straight line vehicle
at a constant speed between 10-40 MPH configuration.
(16-64 KPH) for 1/4 mile (0.4 KM). At end of
ride, perform left or right turn.
Do turn signals cancel properly?
YES NO
System OK. Review Gain access to TSM/TSSM on

cancellation function vehicle. Verify engine shutdown by
with customer. tilting module both left and right while
engine is running. Does shutdown
occur in both directions?
YES NO
System OK. Review Replace TSM/TSSM.

cancellation function Perform setup.
with customer.
6773

HOME
Turn Signal Error 1B

Check for speedometer

trouble codes. Codes
present?
YES NO
Continued from Turn Signal Error 1A.

STOP
2
With ignition ON and RUN/STOP set to RUN, check for volt-
age on W/GN wire in connector [30B] while connected. Volt-
Go to DIAGNOSTICS age will be 9-11 volts with rear wheel stationary and 3-6 volts
under 2.2 SPEEDOMETER when rear wheel is rotated faster than 3 MPH (speedo con-
AND TACHOMETER. nected and ignition key ON). Is it?
YES No flunctuation. No voltage.
Replace TSM/TSSM. Remove speedometer

Disconnect connector [30] and remove speedometer
Perform setup. sensor. Debris on
harness connector [39] at back of speedometer.
sensor?
6777 Check for continuity to ground on W/GN wire (Pin 3).
Measure with connector [30]
disconnected from TSM/TSSM.
3 Continuity present?
YES NO
Remove debris.
Retest. Does YES NO
voltage
STOP
flunctuate?
Go to Turn Signal Replace short Replace TSM/TSSM.
Error 1C. to ground on Perform setup.
W/GN wire..
6780
6779
YES NO
System
OK. STOP
6778
Go to Turn Signal
Error 1C.

HOME
Turn Signal Error 1C

Continued from Turn Signal Error 1A.
Install Breakout Box leaving TSM/TSSM disconnected. Remove

speedometer harness connector [39] at back of speedometer.
Check for continuity on W/GN wire (Pin 12) speedometer harness
connector [39B] and Pin 3 on Breakout Box. d09,
d10
YES NO
Check for continuity to ground at Pin 3 Locate and

of Breakout Box with TSM/TSSM dis- repair open
connected. Continuity present? in W/GN wire.
6784
YES NO
Locate and Does

repair short to speedometer
ground in appear to be
in W/GN wire. functional?
6785
YES NO
Connect all wiring. Place See Speedometer Test 2A

speedometer into under 2.2 SPEEDOME-
diagnostic mode and clear TER AND TACHOMETER
codes. Connect all circuits and in this manual.
run vehicle approximately
1 mile (1.6 KM). Check for new
4 logged codes. Codes present?
YES NO
See codes on Speedometer Replace

Test 2A under 2.2 SPEEDOM- speedometer.
ETER AND TACHOMETER in
this manual. 6786

HOME

WILL NOT FLASH, 4-WAY FLASHERS INOPERABLE (ALL MODELS): DTC 21, 22, 41
Set RUN/OFF switch to OFF. Turn key ON. Turn

signal lamps on continuously?
YES NO
Check for voltage on Pin 5 (left) Does turn signal indicator

or Pin 6 (right) of connector illuminate on side that will
[30] with TSM/TSSM discon- not flash?
3 nected from Breakout Box.
YES NO
YES NO
Connector [30]
mated fully?
Locate and repair Replace TSM/TSSM. STOP
short to voltage. Perform setup.
6790 6791 Go to Turn Signal

Error 2B.
YES NO
Place red meter lead at Pin 1 Mate

and black meter lead at Pin 12 connector.
of Breakout Box. Battery
3 voltage present? 6792
YES NO
Move red meter lead to

Pin 2 of connector [30].
STOP
Go to Turn Signal
Error 2C.
YES NO
Check for voltage at

ignition fuse. Battery
STOP voltage present on both
terminals?
Go to Turn Signal
Error 2D.
YES NO
Locate and repair

open on gray wire
between ignition fuse STOP
and TSM/TSSM.
6793 Go to 4.12 NO IGNITION

MODULE POWER.

HOME
Turn Signal Error 2B

Continued from Turn Signal Error 2A or

Turn Signal Error 2D.
Inspect bulbs on side that will not flash.

Are the bulbs OK?
YES NO
Place jumper wire between Replace bulbs

Pins 1 and 6 of Breakout Box. Do as necessary.
the right turn signals (front and
6796
3 rear) illuminate?
YES NO
Place a jumper wire between Check for continuity

Pins 1and 5. Do the left turn between Pin 6 of Breakout
signals (front and rear) illuminate? Box and lamps (front and
rear). Continuity present?
YES NO YES NO
Check for continuity Repair open Repair open between

STOP between Pin 5 of con- ground circuit. lamps and TSM/TSSM
nector [30] and lamps connector [30].
(front and rear). 6797
Continuity present? 6798
Go to Turn Signal
Error 3A.
YES NO
Repair open Repair open between

ground circuit. lamps and TSM/TSSM
connector [30].
6799
6800

HOME
Turn Signal Error 2C

Continued from
Turn Signal Error 2A.
Check resistance to ground on

Pin 12 of connector [30]. Resis-
tance less than 1 ohm?
YES NO
Check for 12 volts at both Repair poor

terminals of 15 amp security fuse. ground.
Proper voltage present at
both terminals? 6805
YES NO
Repair open in BN/GY wire

between security fuse and TSSM.
6806
1 Terminal. Neither terminal.
Replace Repair open between main

fuse. circuit breaker and fuse block.
6807 6808

HOME
Turn Signal Error 2D

Continued from
Turn Signal Error 2A.
Check for 12 volts at Pin 7 of connec-

tor [30] with right turn button pressed.
Proper voltage present?
YES NO
Check for 12 volts at Pin 8 of con- Is 12 volts present at W/BN wire

nector [30] with left turn button in connector [22] with right turn
pressed. Proper voltage present? button pressed?
YES NO YES NO
Is 12 volts present at Repair open Check for continuity to

STOP W/V wire in connector between connector ground on W/BN wire
[24] with left turn [22] and TSSM. in connector [22].
button pressed? Continuity present?
Go to Turn Signal 6813
Error 2B.
YES NO
YES NO
Repair short Is 12 volts present
to ground. at O/W wire in
Repair open Check for continuity to connector [22]?
6814
between connector ground on W/V wire in
[24] and TSSM. connector [24].
Continuity present?
6810
YES NO
Replace turn Repair open between

signal switch. connector [22] and
YES NO fuse block.
6815
6816
Repair short Is 12 volts present

to ground. at O/W wire in
connector [24]?
6814
YES NO
Replace turn Repair open between

signal switch. connector [24] and
fuse block.
6811
6812

HOME

FLASH AT DOUBLE NORMAL RATE, ALL BULBS WORKING (ALL MODELS)
Determine correct part number for

all installed turn signal bulbs and verify
against parts installed on motorcycle.
Correct parts installed?
YES NO
Check for corrosion Replace with

on bulbs and/or sockets. correct bulbs.
Corrosion present?
6820
YES NO
Remove corrosion with a wire Check for corrosion

brush. Install DIELECTRIC on all lamp connection
5
GREASE (Part No. 99861-90) terminals. Corrosion present?
in bulb sockets. Do lamps flash at
normal rate?
YES NO
YES NO
Clean corrosion from Replace TSM/TSSM.
wires and terminals. Perform setup.
Do lamps flash at
System Clean or replace bulb. normal rate? 6824
OK. Do lamps flash
at normal rate?
6821
YES NO
YES NO
System Replace TSM/TSSM.

System Replace lamp OK. Perform setup.
OK. assembly.
6822 6824
6822 6823

HOME
DTC 11 3.16
GENERAL DIAGNOSTICS
Battery Voltage High Diagnostic Tips

The TSM/TSSM continually checks the battery voltage during ● This DTC may set when the vehicle is placed on a a bat-
IGN/OFF and IGN/RUN power modes. If the voltage exceeds tery charger, on fast charge, for a long period of time.
16.0 volts for more than 5.0±0.5 seconds, the TSM/TSSM ● The TSSM does not illuminate the security lamp when
sets DTC 11. this code is set as current.
Diagnostic Notes
See charging system tests in Section 1 to correct. Problem
VEHICLE SECURITY NO SECURITY may be faulty voltage regulator.
Dyna Yes Yes

HOME
DTC 25 3.17
GENERAL DIAGNOSTICS
Ignition Enable Output High Diagnostic Tips

During vehicle operation, the TSM/TSSM checks the ignition The TSSM does not illuminate the security lamp when this
enable output (Pin 10) for a short to battery condition. This code is set as current.
test occurs when the vehicle’s key is turned to IGN and the
RUN/OFF switch is in the RUN position. Diagnostic Notes
bers on the Test 3.17 flow chart.
1. Attach BREAKOUT BOX (Part No. HD-42682). See 3.10
VEHICLE SECURITY NO SECURITY BREAKOUT BOX: TSM/TSSM.
Dyna Yes Yes

HOME
s0467x9x
Lt GN/GY
[10B]
10
[10A]
Ignition module
R R 15 Amp
– + 30 Amp main security
circuit breaker fuse
Battery
Lt GN/GY
BK
BN/GY
BK
[30B] 1 2 3 4 5 6 7 8 9 10 11 12
[30A] 1 2 3 4 5 6 7 8 9 10 11 12
TSM/TSSM
Figure 3-23. Ignition Circuit

[10] Ignition module (gray) 12-place Deutsch behind electrical panel


HOME
Test 3.17
IGNITION ENABLE OUTPUT HIGH: DTC 25
Attach Breakout Box to harness leaving

TSM/TSSM disconnected. Check for voltage 1
on TSM/TSSM Pin 10 of Breakout Box with
RUN/OFF switch in OFF position and ignition
ON. Voltage present?
YES NO
Repair short to voltage Replace TSM/TSSM.

on Lt GN/GY wire. Perform setup.
6827 6828

HOME
DTC 31, 32 3.18
GENERAL o0236xox
Alarm Output Low (DTC 31) or

Alarm Output High (DTC 32)
See Figure 3-24. An alarm cycle is activated when the TSSM
is connected, the siren has been armed by the TSSM and a
security event occurs. See 3.6 SECURITY SYSTEM (TSSM)
FUNCTIONS. Under normal armed operation, the siren input
(Pin B) is driven low by the TSSM to trigger the audible alarm.
When the siren input is driven high by the TSSM the audible
alarm stops.
Figure 3-24. Siren
● If the siren does not stop alarming after it has been

armed, then either the TSSM output or siren input may
VEHICLE SECURITY NO SECURITY be shorted to ground, or the siren vehicle battery con-
nection is open or shorted to ground, or the siren vehicle
Dyna Yes No ground connection is open, or a security event has
occurred. See 3.6 SECURITY SYSTEM (TSSM) FUNC-
TIONS for a description of alarm functions.
DIAGNOSTICS Diagnostic Notes
Diagnostic Tips bers on the Test 3.18 flow chart.
● If the siren is armed and the internal siren battery is 1. Use BREAKOUT BOX (Part No. HD-42682) and HAR-
dead, shorted, disconnected, or has been charging for a NESS CONNECTOR TEST KIT (Part No. HD-41404),
period longer than 24 hours, the siren will respond with gray pin probe and patch cord. See 3.10 BREAKOUT
three chirps on arming instead of two. BOX: TSM/TSSM.
● The internal siren battery may not charge if the vehicle’s
41404), gray socket probe and patch cord.
battery is less than 12.5 volts.
3. Having the correct multimeter ohm scale is important for
● If the siren does not chirp, two or three times, on a valid this test. Some meters may read infinity for high ohm val-
arming command from the TSSM, the siren is either not ues. If this is the case, check your ohm scale and retest.
connected, not working, or the siren wiring was opened
or shorted while the siren was disarmed.
● If the siren enters the self-driven mode where it is pow-
ered from the siren internal nine-volt battery, the turn-sig-
nal lamps will not alternately flash. If the TSSM activates
the siren, 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 to 30 sec-
onds and then turn off for 5 to 10 seconds. This alarm
cycle will be repeated ten times if the siren is in the self-
driven mode.

HOME
s0468x9x
[142A] [142B]
Security A BN/GY
siren Lt GN/BN
B
(optional)
C BK
R R
– + 30 Amp main 15 Amp
circuit breaker security
fuse
Battery
BK
Lt GN/BN
BN/GY
BK
1 2 3 4 5 6 7 8 9 10 11 12
[30B] 1 2 3 4 5 6 7 8 9 10 11 12
[30A]
TSSM
Figure 3-25. Siren Circuit

[30] TSSM 12-place Deutsch behind splash panel

[142] Siren 3-place Packard behind splash panel

HOME
Test 3.18
ALARM OUTPUT: DTC 31, 32
Check for battery voltage at

siren sensor connector [142B]. With
ignition ON, measure voltage between
Pin C (BK) and Pin A (BN/GY).
YES NO
With ignition OFF, connect Breakout Box to With ignition OFF, connect Breakout Box to
TSSM. Measure resistance between TSSM. Check continuity between siren con-
siren connector [142B] nector [142B] Terminal C and Breakout Box
Terminal B and Breakout Box Pin 11. Pin 12. Then measure continuity between
1 Resistance less than 1 ohm? siren connector [142B] Terminal A
1 and Breakout Box Pin 1.
Continuity present?
YES NO
YES NO
Measure resistance between Locate and repair
Breakout Box Pin 11 open on Lt GN/BN wire.
and chassis ground.
Resistance less than 1 ohm? 6830 Locate and repair short Repair
between BN/GY and open wire.
BK wires.
6835
6834
YES NO
Locate and repair Disconnect siren from Breakout

grounded Lt GN/BN wire. Box.Measure resistance between
siren connector [142A] Terminal B
6831 2 and C.
Resistance between 120,000-
3 200,000 ohms with siren
disconnected?
YES NO
Connect siren to a known good Replace

motorcycle. Arm and activate siren siren.
to verify operation. Disarm siren.
Did siren operate correctly? 6832
YES NO
Replace TSSM. Replace

Perform setup. siren.
6833 6832


HOME
DTC 34 3.19
GENERAL 7902
Starter Output High

With the TSM/TSSM disarmed, ignition ON and RUN/STOP
switch set to RUN the starter relay is grounded. Battery volt-
age is applied to the starter relay and coil which are grounded
through the TSM/TSSM. This code is set when that ground is
not established through the TSM/TSSM.

Figure 3-26. Starter Relay
Dyna Yes Yes
DIAGNOSTICS
Diagnostic Notes
1. Connect BREAKOUT BOX (Part No. HD-42682) to wire
harness leaving TSM/TSSM disconnected. See 3.10
BREAKOUT BOX: TSM/TSSM.

HOME
s0473x9x
Ignition
switch
[33A]
[33B]
R/BK
R
Starter relay
BK/R
30 85 86
K T E S U
TN/GN
R/BK
87A
87
[62B] To right handlebar

switch [22]
R R
– + 30 Amp main 15 Amp
circuit breaker security
fuse
Battery
BK
TN/GN
BN/GY
BK
1 2 3 4 5 6 7 8 9 10 11 12
[30B] 1 2 3 4 5 6 7 8 9 10 11 12
[30A]
TSSM
Figure 3-27. Starter/TSSM Circuit: FXDWG Shown


[62] Starter relay relay behind electrical panel

HOME
Test 3.19
STARTER OUTPUT HIGH: DTC 34
Remove starter relay.

1 Check for voltage on
Breakout Box Pin 9 (gray).
Voltage present?
YES NO
Locate and repair Install starter relay.

short to voltage Is voltage present on
on TN/GN wire. Breakout Box
Pin 9 (gray)?
6840
YES NO
Replace Replace TSM/TSSM.

starter relay. Perform setup.
6841 6842


HOME
DTC 35 3.20
GENERAL
Accelerometer Fault
This DTC indicates a failure which requires replacement of
the TSM/TSSM (Job Time Code 6845).
NOTE
When DTC 35 is set as current, the tip-over engine shut-
down, TSSM tamper alarm and bank angle sensors are dis-
abled. The security lamp will also illuminate on vehicles with
security systems.

Dyna Yes Yes

HOME
TSM/TSSM 3.21
REMOVAL/INSTALLATION
Follow the instructions in the 2003 Dyna Service Manual
(Part Number 99481-03) for TSM/TSSM replacement.
After replacing TSM/TSSM, perform all appropriate instruc-
tions under 3.3 TSM/TSSM VEHICLE DELIVERY.
IMPORTANT NOTE
Do not forget to enter a personal code for TSSM vehicles.
If a code is not assigned and the key fob is lost or dam-
aged while the vehicle is armed, the TSSM must be
replaced.

HOME
TSSM MAINTENANCE 3.22
GENERAL o0235xox
1 2
The TSSM system uses batteries in the key fob and siren.
These are the only parts requiring periodic maintenance.
KEY FOB
Schedule
Replace the key fob battery every 2 years. 3
Battery Replacement
1. Battery
1. Open the key fob case. 2. Battery contact
a. Place a thin blade between the 2 halves of the case. 3. Circuit board
b. Slowly twist the blade. Figure 3-28. Open Key Fob Case
2. See Figure 3-28. Replace battery (1).
a. Remove the original battery.
b. Install a new battery with the positive (+) side down. o0234xox
Use a Panasonic® 2032 or equivalent.
3. See Figure 3-29. Align case and circuit board as shown.
Snap case halves together.
4. While standing next to the motorcycle, press and hold
the key fob button for 10-15 seconds until the security
system responds with two turn signal flashes/siren
chirps.
Figure 3-29. Key Fob Assembly

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SIREN (IF INSTALLED) 7867
Schedule
The siren’s internal 9 volt battery is rechargeable and does
not need to be replaced on a regular basis. Battery life under
normal conditions is approximately three to six years.
NOTE
The internal siren battery may not charge if the vehicle’s bat-
tery is less than 12.5 volts. 1 2
3
Battery Replacement
1. Cover
1. Disarm system and remove siren. 2. Battery
2. See Figure 3-30. Remove battery cover (1). 3. Connector [142A]
a. Place the siren module on a flat and sturdy table Figure 3-30. Siren Battery Compartment
with the potted section (area with epoxy covering
circuit board) facing up and towards you.
b. Position a knife blade at a 45 degree angle to the 7866
long side of the siren case. Insert the knife blade
between the siren case and battery cover at one of
the two accessible corners of the battery cover.
Keep the blade slightly higher towards the battery
cover as this helps keep the blade away from the
battery seal.
c. Slowly twist the blade towards the battery cover and
the cover will pop off.
NOTE
For protection against corrosion, battery terminals and bat-
tery clip are covered with a special grease. Do not wipe away
this substance. Apply all available existing grease to termi-
nals on new battery.
3. See Figure 3-31. Replace battery by removing old bat-

tery from polarized battery clip. Install a new 9 volt nickel
metal hydride battery (Part No. 68959-00).
NOTE Figure 3-31. Siren Battery

Only a nickel metal hydride nine-volt battery should be used
in the siren.
4. See Figure 3-30. Reinstall battery cover (1).

a. Carefully replace the rubber seal.
b. Align battery cover (1) with case placing round cor-
ners on cover away from connector [142A]. Snap
cover into place.
5. Install siren and check operation. If siren is working prop-
erly, it will respond with two chirps after receiving the arm
command.

Table Of Contents
SUBJECT PAGE NO.
4.1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.2 Diagnostic Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.3 Checking For Trouble Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.4 Scanalyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.5 Check Engine Lamp Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4.6 Breakout Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
4.7 Wiggle Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4.8 Initial Diagnostic Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
4.9 No Check Engine Lamp at Key ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
4.10 Check Engine Lamp on Continuously . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
4.11 Engine Cranks, But Will Not Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
4.12 No Ignition Module Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
4.13 Misfire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
4.14 DTC 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
4.15 DTC 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
4.16 DTC 24, 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42
4.17 DTC 35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45
4.18 DTC 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47
4.19 DTC 44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50
4.20 DTC 52, 53, 54, 55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54
ENGINE MANAGEMENT
7
HOME
SPECIFICATIONS 4.1
IGNITION DATA CHARGING SYSTEM DATA
0°-50° BTDC (range) Battery 19 amp hour/270 CCA

Spark timing advance
30° BTDC@1000 RPM
Alternator AC voltage output 16-20 VAC per 1000 RPM
Idle speed 1000 ± 50 RPM
Alternator stator coil
0.1-0.2 ohms
Spark plug size 12 mm resistance
0.038-0.043 in Regulator voltage 14.3-14.7 @
Spark plug gap 75° F (24° C)
0.97-1.09 mm output @ 3600 RPM
Harley-Davidson Regulator amperes

Spark plug type 32 amps
No. 6R12 (no substitute) @ 3600 RPM
Ignition coil primary

0.5-0.7 ohms
resistance
Ignition coil secondary
5500-7500 ohms
resistance
CIRCUIT BREAKER/FUSES RATING (AMPERES)
Main circuit breaker 30

Ignition fuse 15
Lighting fuse 15
Accessory fuse 15
Instruments fuse 15
Security fuse 15
NOTE
The fuse labeled Security provides basic turn signal function-
ality on vehicles without a factory-installed security system.
Do not remove this fuse or use it as a replacement fuse for
other systems.
2003 Dyna: Engine Management 4-1

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DIAGNOSTIC INTRODUCTION 4.2
SYSTEM PROBLEMS d0571x8x
All system problems fall into at least one of three general cat-
egories.
No Start
The engine cranks over freely, but will not start. This does not
include situations where the engine will not crank, such as a
bad starter, dead battery, etc. This condition assumes that all
obvious checks (fuel in tank, etc.) have been made.
Poor Performance
The engine starts but there are performance problems. These
problems may include poor fuel economy, rough idle, engine
misfire, engine hesitation, severe spark knock, etc.
Check Engine Lamp Figure 4-1. Check Engine Lamp

See Figure 4-1. The check engine lamp indicates the ignition
module has determined a fault condition exists. There may
also be starting or performance problems. d0543x8x
RESOLVING PROBLEMS
To resolve system problems, five basic steps are involved. In
order of occurrence, they are:
1. Check for trouble codes by observing check engine

lamp. See 4.3 CHECKING FOR TROUBLE CODES.
2. Retrieve trouble codes using SCANALYZER (Part No.
HD-41325) or check engine lamp diagnostics. See 4.4
SCANALYZER, 4.5 CHECK ENGINE LAMP DIAGNOS-
TICS and Figure 4-2.
3. Diagnose system problems. This involves using special
tools and the diagnostic flow charts in this section.
4. Correct problems through the replacement and/or repair
of the affected components.
5. After repairs are performed, the work must be validated.
This involves clearing the trouble codes and confirming
proper vehicle operation as indicated by the behavior of
the check engine lamp.
Figure 4-2. Scanalyzer
4-2 2003 Dyna: Engine Management

HOME
CHECKING FOR TROUBLE CODES 4.3
CHECK ENGINE LAMP 7501 3

2
To diagnose system problems, start by observing the behav-
ior of the check engine lamp.
1
NOTE
● See Figure 4-3. “Key ON” means that the ignition key is
turned to ON and the engine stop switch is set to RUN
(although the engine is not running).
● If the check engine lamp is not illuminated at Key ON or if
it fails to turn OFF after the initial four second period,
then a problem exists in the lamp circuit. See 4.9 NO
CHECK ENGINE LAMP AT KEY ON or 4.10 CHECK
ENGINE LAMP ON CONTINUOUSLY for more informa-
tion.
1. Ignition OFF
1. When the ignition switch is turned ON, the check engine 2. Marker lights ON
lamp will illuminate for approximately four seconds and 3. Ignition ON
then turn off.
2. See Figure 4-4. After lamp turns off after being illumi- Figure 4-3. Ignition Switch (U.S. Models, Except FXDWG)
nated for the first four second period, one of three situa-
tions may occur. 3. See CODE TYPES which follows for a complete descrip-
tion of trouble code formats.
a. The lamp remains off. This indicates there are no
current fault conditions or stored functional trouble NOTE
codes currently detected by the ignition module. Trouble codes relating to the ignition coil can only be fully
b. The lamp stays off for only four seconds and then diagnosed during actuation. For example, a problem with the
comes back on for an eight second period. This indi- ignition coil will be considered a current fault even after the
cates a functional error code is stored, but no cur- problem is corrected, since the ignition module will not know
rent trouble code exists. of its resolution until after the coil is exercised by vehicle start
c. If the lamp remains on beyond the eight second sequence. In this manner, there may sometimes be a false
period, then a current trouble code exists. indication of the current trouble code.
ON 4 Sec.
A Lamp OFF: no current trouble code*
OFF
Key ON
Lamp ON 8 seconds:
functional error*
ON 4 Sec. 8 Sec.
B Lamp OFF
OFF 4 Sec.
Key ON
Lamp remains ON: current trouble code**

ON 4 Sec.
C
OFF 4 Sec. * Historic trouble code may exist
Key ON ** Trouble codes 52-55, ignition module
failure
Figure 4-4. Check Engine Lamp Operation

HOME
CODE TYPES RETRIEVING TROUBLE

There are three types of diagnostic trouble codes (DTCs):
CODES
current, historic or functional. If a trouble code is stored, it can
be read using either a Scanalyzer or check engine lamp diag- The engine management system provides two levels of diag-
nostics. nostics.
● The most sophisticated mode employs a portable diag-
All trouble codes reside in the memory of the ignition module
until the code is cleared by use of the Scanalyzer or a total of nostic tool called a Scanalyzer. This device plugs into the
50 trips has elasped. A trip consists of a start and run cycle, motorcycle wiring harness. It facilitates the diagnosis of
the run cycle lasting at least 30 seconds. After the 50 trip system problems through a direct interface with the igni-
retention period, the trouble code is automatically erased tion module. See 4.4 SCANALYZER.
from memory providing that no subsequent faults of the same ● The second mode requires using the check engine lamp.
type are detected in that period. See 4.5 CHECK ENGINE LAMP DIAGNOSTICS for
more information.
Current
Current trouble codes are those which presently disrupt MULTIPLE TROUBLE CODES
motorcycle operation. See the appropriate flow charts for
solutions. While it is possible for more than one fault to occur and set
more than one trouble code, there are several conditions
Historic which may result in one fault setting multiple trouble codes:
If a particular problem happens to resolve itself, the active If one of the primary side coil lines becomes grounded it
status problem is dropped and it becomes a historic fault will also ground the Bank Angle Sensor resulting in multiple
rather current fault. trouble codes being set (Trouble Codes 24 and/or 25 and 44).
Historic trouble codes are stored for a length of time to assist
Always start with the trouble code having the lowest numeri-
in the diagnosis of intermittent faults. The check engine lamp
cal value. In the case of the above multiple trouble codes, the
will not indicate the existence of only historic trouble codes.
second code should be resolved when the first code is cor-
It is important to note that historic trouble codes may also be rected. See list of fault conditions on page 4-14 (Table 4-5.)
present whenever the system indicates the existence of a
current fault. See MULTIPLE TROUBLE CODES if multiple
trouble codes are found.
Diagnostic charts are designed for use with current trouble
codes and as a result they frequently suggest part replace-
ment. When diagnosing a historic code the charts can be
helpful but should not lead to part replacement without verifi-
cation the part is faulty.
Functional
A functional trouble code indicates an internal problem with
the ignition module (trouble codes 52 through 55).

HOME
SCANALYZER 4.4
SCANALYZER DIAGNOSTICS 7487
Data Link Connector

2
See Figure 4-5. Using the Scanalyzer requires access to the
data link connector (1). See below for instructions on reach-
ing the data link.
Scanalyzer Cartridge
See Figure 4-6. Through a special programmable application
cartridge, the Scanalyzer offers data displays and menu 1
selections that allow for quick and easy retrieval of data. The
device enables the user to perform a variety of diagnostic
tests while monitoring inputs and outputs.
Sample Scanalyzer menu selections are shown in Figure 4-7. 1. Data link connector [91A]
2. Protective rubber plug
INSTALLATION Figure 4-5. Data Link Connector
PART NO. SPECIALTY TOOL d0279x8x
HD-41325 Scanalyzer
1
HD-41325-95C Scanalyzer cartridge
HD-42921A Cable
The behavior of the check engine lamp (as described under

4.3 CHECKING FOR TROUBLE CODES) indicates the pres-
ence of trouble codes.
1. Turn ignition key switch OFF.

2. Gain access to the electrical panel by detaching cover.
3. See Figure 4-5. Remove rubber protective plug (2) from
2
data link connector (1). Plug Scanalyzer into connector.
1. Scanalyzer (Part No. HD-41325)
4. Turn ignition key switch ON. Set engine stop switch to 2. Cartridge (Part No. HD-41325-95C)
RUN, but do not start engine.
Figure 4-6. Scanalyzer and Cartridge
5. See Figure 4-6. Insert the diagnostic application car-
tridge (2) into the Scanalyzer (1). During the next few
seconds, the Scanalyzer sequences through a series of
screens that reflect a power-on self test, the system
copyright, and then an attempt at communications with
the ignition module. Once communications is established
with the ignition module, the diagnostic menu appears.
See Figure 4-7.
6. Continue with the instructions listed under USAGE which
follows.

HOME
DIAGNOSTIC MENU
1- System ID
2- Trouble Codes
Main Menu 3- Data Monitor
4- Active Diagnostic
5- Special Tests
6- Tool Setup
1 2 3 4 5 6
TOOL SETUP MENU

1- General Setup
2- Save Setup
3- Restore Setup
MODE
SPECIAL TEST MENU

1- Wiggle Test
2- Data Capture
3- File Manager MODE
ACTIVE TEST MENU

1- Front Coil
2- Rear Coil
3- Tachometer
MODE
Secondary
Menus
DATA MONITOR MENU
RPM = 1000
MAP = 14.5 in. Hg
MAP = 2.10 V
ADVANCE = 20 DEG
B+ = 13.20 V
DWELL = 1800 uSec
BAS MODE = RUN MODE
BAS = 0.65 V
CHECK ENG = LAMP ON
MODE
TROUBLE CODE MENU

1- Display Current
2- Display Historic
3- Clear Historic MODE
SYSTEM ID
P/N 32479-99
CAL MODE
H32EV110
Figure 4-7. Scanalyzer Menus

HOME
USAGE d0543x8x
See Figure 4-7. The diagnostic menu is the primary system

menu (main menu) through which all other secondary menus
and displays are accessed. Since the screen may not be
large enough to display all line items at any given time, use
the up and down arrow keys to scroll through the list.
Checking Codes
1. See Figure 4-8. From the diagnostic menu, press num-
ber “2” to access the trouble codes menu. At this point,
the unit allows the operator to:
a. Press number “1” to display current trouble codes.
b. Press number “2” to display historic trouble codes.
c. Press number “3” to clear trouble codes. See Clear-
ing Codes below.
2. When examining trouble codes, write down all codes on
a piece of paper. If a current trouble code exists, place it
at the top of the list.
a. If trouble codes are present, see Table 4-5. Follow
the applicable flow charts for each code.
b. If trouble codes are NOT present, but starting or
driveability problems are evident, see symptoms
charts under 4.8 INITIAL DIAGNOSTIC CHECK.
c. After reading current/historic trouble codes, simply
press the mode key to return to the trouble codes
menu.
3. Press the mode key again to return to the diagnostic Figure 4-8. Scanalyzer Diagnostic Menu
menu. In this manner, regardless of where the operator
is in the program, the mode key need only be pressed REMOVAL
once or twice to return to the main menu.
4. After correcting system problems, clear trouble codes 1. Turn ignition key switch OFF. Set engine stop switch to
using the trouble codes menu of the scanalyzer. the OFF position.
2. Unplug Scanalyzer from data link connector. Install pro-
Clearing Codes tective plug connector.
Unlike the check engine lamp diagnostics, note that the Scan- 3. Attach electrical panel cover to frame.
alyzer does allow the operator to clear trouble codes from 4. Road test vehicle and observe check engine lamp. Con-
memory as well as differentiate between current and historic firm proper operation without the reoccurrence of trouble
codes. codes. See 4.3 CHECKING FOR TROUBLE CODES.
Trouble codes cannot be cleared while the engine is running.
Turn the engine off by setting handlebar stop switch to the
OFF position, but leaving the ignition key switch ON. Return
the handlebar engine stop switch to the RUN position and
restart motorcycle.
NOTE
For more detailed instructions, refer to the literature provided
with the Scanalyzer.

HOME
CHECK ENGINE LAMP DIAGNOSTICS 4.5
ACTIVATION d0278x8x
Use of check engine lamp diagnostics assumes that the

1 2 1
SCANALYZER (Part No. HD-41325) is not available.
1. Gain access to the electrical panel by detaching cover.
Detach data link connector [91A] from electrical panel
and remove protective cover.
2. To activate the diagnostic feature of the check engine
lamp, proceed as follows:
a. See Figure 4-9. Create diagnostic test wire from
parts shown. 1. Part number 72191-94 (2)
b. See Figure 4-10. Install diagnostic test wire across 2. 2.0 in. (51 mm) 18 gauge wire
Terminal 1 and Terminal 2 on the data link connector Figure 4-9. Diagnostic Test Wire
[91A].
c. Turn the ignition key switch ON and wait approxi-
mately eight seconds for the check engine lamp to
start flashing. 6924
3. See Figure 4-11. All trouble codes are sent out as a

series of flashes. To retrieve the first digit of the trouble
code simply observe the number of times the lamp
flashes. 1
4
a. The transmission of a trouble code is always pre- 5
ceded by six rapid flashes (about 3 per second).
b. This “intermission” is followed by a 2 second pause
3
in which the lamp is off.
2
c. The lamp will then flash one or more times to indi-
cate the first digit of the trouble code. For example,
three blinks equals 3. The length of time the lamp
is illuminated and the length of time in which it is off
are each about 1 second in duration.
4. The second digit follows:
1. Terminal 1: receive data line (Lt GN/R)
a. Following transmission of the first digit, there is 2. Terminal 2: ground (BK)
another 2 second pause in which the lamp is off. 3. Terminal 3: transmit data line (V/R)
b. The lamp will then flash one or more times to indi- 4. Terminal 4: power (W/BK)
cate the second digit of the trouble code. Count the 5. Protective cap
number of times the lamp flashes to retrieve the sec- Figure 4-10. Installing Diagnostic Test Wire
ond digit. For example, an additional five blinks
would equal 5. If you take the 3 blinks from the
first digit and combine it with the second 5 6. Once all codes have been sent, the data string is
blinks, the numbers represent trouble code 35 repeated. When you have recorded the same trouble
(tachometer). code twice, it is an indication that the transmission has
been restarted and that all trouble codes have been
5. If more than one trouble code is sent:
retrieved.
a. Following transmission of the second digit of the first
code, there is a third 2 second pause in which the
lamp is off.
b. After the pause comes the intermission, which is fol-
lowed by transmission of the next recorded trouble
code.
c. All subsequent codes are sent in the same manner,
each separated from the next by the intermission.

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d0264x8x Start of
Intermission 1st digit 2nd digit intermission
ON 1 1 1
Sec. Sec. Sec.
OFF 2 Sec. 2 Sec. 1 2 Sec.

Sec.
3 flashes Pause Pause
per second before before
1st digit 2nd digit
NOTE
Looking at the above transmission, we can see that the trouble
code is 12. The source of the fault condition is identified as the
MAP sensor according to Table 4-5.
Figure 4-11. Check Engine Lamp Diagnostics

NOTE IMPORTANT NOTE
If the lamp flashes at a rate faster than normal, then you are If diagnostic test wire is installed across Pins 1 and 2 on
observing the “Intermission” only, which means that no trou- connector [91A] in lieu of a Scanalyzer, the ignition mod-
ble codes are present. ule is placed in a diagnostic test mode and the engine
will start. The test wire must be removed from the data
7. When examining trouble codes, write down all codes on
link connector and the ignition switch turned OFF or the
a piece of paper. If a current trouble code exists, place it
check engine lamp will continue to flash codes.
at the top of the list.
a. If trouble codes are present, see Table 4-5. Follow
the applicable flow charts for each code. CLEARING CODES
b. If trouble codes are NOT present, but starting or
driveability problems are evident, see symptoms After correcting system problems, clear trouble codes. If the
charts under 4.8 INITIAL DIAGNOSTIC CHECK. Scanalyzer is not available, perform 50 start and run cycles.
To execute one run cycle:
8. Turn the ignition key switch OFF.
9. Remove diagnostic test wire from connector. Install pro- 1. Start the vehicle.
tective cover over data link connector. 2. Let it run for at least 30 seconds.
10. Attach electrical panel cover to frame. 3. Turn the engine off.

HOME
BREAKOUT BOX 4.6
GENERAL 7503
The BREAKOUT BOX (Part No. HD-42682) splices into the

main harness. Used in conjunction with a DVOM, it allows cir-
cuit diagnosis of wiring harness and connections without hav- 3
ing to probe with sharp objects. 3
INSTALLATION 1
2
1. See Figure 4-12. Completely remove the electrical panel
to gain access to the ignition module. See the 2003 Dyna
Service Manual (Part Number 99481-03) for complete
1. Ignition module connector [10] (black)
details.
2. Ignition module connector [11] (gray)
2. Depress latches on each side of connectors [10] (black) 3. Screw (2)
and [11] (gray).
Figure 4-12. Ignition Module Connectors
3. See Figure 4-13. Attach Breakout Box (1) to black con-
nector [10].
a. Attach black connector from Breakout Box to corre- 7504

sponding black ignition module connector. 2
b. Attach black connector from the wiring harness to
black connector on Breakout Box.
3
4. Attach Breakout Box to gray connector [11].
a. Attach gray connector from Breakout Box to corre-

sponding gray ignition module connector. 1
b. Attach gray connector from the wiring harness to

gray connector on Breakout Box.
REMOVAL
1. See Figure 4-13. Depress latches on each side of con-

nectors [10] (black) and [11] (gray).
2. Detach Breakout Box connectors from ignition module

connectors.
1. Breakout Box
3. Detach Breakout Box connectors from wiring harness. 2. Ignition module connection
3. Wiring harness connection
4. Reattach ignition module connectors to wiring harness.
Figure 4-13. Installed Breakout Box
5. Attach electrical panel to frame.

HOME
WIGGLE TEST 4.7
GENERAL d0544x8x
The wiggle test indicates the presence of intermittents in a

wiring harness. Depending upon the availability of diagnostic
tools, either version of this test may be used.
PROCEDURE 1
Using Scanalyzer (Part No. HD-41325)

1. Connect Scanalyzer to vehicle. See 4.4 SCANALYZER.
2 2
2. Start motorcycle engine and run at idle.
3. Enter wiggle test mode.
a. Press “5” from the DIAGNOSTIC MENU to enter the
SPECIAL TESTS menu.
1. Minus sign
b. Press “1” from the SPECIAL TESTS menu to enter 2. Corner LED (4)
the WIGGLE TEST.
Figure 4-14. Wiggle Test Indicators
4. Shake or wiggle harness to detect intermittents. If inter-
mittents are present the Scanalyzer will beep, light the
four corner LEDs and display a minus sign when a cur-
rent trouble code is detected. See Figure 4-14. hd39978
NOTE
If a current trouble code is present when the wiggle test is
entered, the Scanalyzer will respond as described immedi-
ately upon entering the wiggle test mode. With key ON and
engine off, clear trouble codes and then perform wiggle test
with vehicle running.
Using DVOM (Part No. HD-39978)

1. See Figure 4-15. Connect DVOM to wiring harness
between the suspect connections. When diagnosing igni-
tion module connections, a BREAKOUT BOX (Part No. Figure 4-15. Fluke 78 Multimeter (DVOM)
HD-42682) may be used to simplify the procedure. See (Part No. HD-39978)
4.6 BREAKOUT BOX.
2. Set DVOM to read voltage changes.
3. Start motorcycle engine and run at idle.
4. Shake or wiggle harness to detect intermittents. If inter-
mittents are present, radical voltage changes will register
on the DVOM.

HOME
INITIAL DIAGNOSTIC CHECK 4.8
GENERAL Diagnostic Tips
To locate faulty circuits or other system problems, follow the ● If the Scanalyzer is not working properly, check operation
diagnostic flow charts in this section. For a systematic on another vehicle.
approach, always begin with INITIAL DIAGNOSTICS which
follows. Read the general information and then work your way
● If proper Scanalyzer function is verified, check data link
through the flow chart box by box.
connector [91A] for 12 volts (Terminal 4) and proper
ground (Terminal 2). See Figure 4-16.
Diagnostic Notes
If a numbered circle appears adjacent to a flow chart box, ● See Figure 4-10. If Scanalyzer reads “No Response”
then more information is offered in the diagnostic notes. Many with the ignition key switch turned ON (engine stop
diagnostic notes contain supplemental information, descrip- switch at RUN with the engine off), check serial receive
tions of various diagnostic tools or references to other parts data wire for an open or short to ground between data
of the manual where information on the location and removal link Terminal 1 and ignition module.
of components may be obtained.
● Check for an open diagnostic test terminal between data
Scanalyzer Icon link Terminal 3 and ignition module. With ignition key
The Scanalyzer icon appears at those points in the flow chart switch turned ON, transmit data line and receive data
where the Scanalyzer may be used. If a number is printed line should have 5 volts.
next to the icon, then refer to the Scanalyzer notes, which are
similar to the diagnostic notes, but are restricted to informa- IMPORTANT NOTE
tion on the use of the Scanalyzer. All Scanalyzer notes may
be found at the end of the respective flow chart. If diagnostic test wire is installed across Pins 1 and 2 on
connector [91A] in lieu of a Scanalyzer, the ignition mod-
Circuit Diagram/Wire Harness ule is placed in a diagnostic test mode and the engine
Connector Table will start. The test wire must be removed from the data
link connector and the ignition switch turned OFF or the
When working through a flow chart, refer to the illustrations, check engine lamp will continue to flash codes.
the associated circuit diagram and the wire harness connec-
tor table as necessary. The wire harness connector table for
each circuit diagram identifies the connector number, descrip- Diagnostic Notes
tion, type and general location.
In order to perform most diagnostic routines, a Breakout Box The reference numbers below correlate with the circled num-
and a DVOM are required. See 4.6 BREAKOUT BOX. bers on the diagnostic check flow charts. See page 4-16.
To perform the circuit checks with any degree of efficiency, a
familiarity with the various wire connectors is also necessary. 1. Compare engine behavior to symptoms tables.
Job/Time Code Values a. Starts hard. See Table 4-2.

Dealership technicians filing warranty claims should use the
job/time code values printed in bold text underneath the b. Hesitates, stumbles, surges, misfires and/or slug-
appropriate repair. gish performance. See Table 4-3.
c. Engine exhaust emits black smoke or fouls plugs.

INITIAL DIAGNOSTICS See Table 4-4.

General Information 41404), black socket probes and patch cord.
The diagnostic check (see page 4-16) is an organized
approach to identifying a problem caused by an electronic 3. Connect BREAKOUT BOX (Part No. HD-42682) to igni-
control system malfunction. If no problems are found after tion module. See 4.6 BREAKOUT BOX.
completion of the diagnostic check, a comparison of Scana-
lyzer parameters may be used to help locate intermittents All diagnostic codes are listed on page 4-14 in Table 4-5.
and out-of-specification sensors. See Table 4-1.

HOME
Table 4-1. Typical Scan Values Table 4-3. Engine Performance Problems
MIN. MAX. HOT SYMPTOM SOLUTION
ITEM
VALUE VALUE IDLE
Manifold leak Spray water around induc-
4.96 V tion module seals with
0.1 V
(atmo- engine idling. If RPM
MAP sensor (high 1.5-3.0 V
spheric changes, change seals.
vacuum)
pressure)
MAP sensor plugged or not
Spark advance 4.14 DTC 12.
0° 50° 20-30° operating properly
while running
Water or dirt in fuel system Drain and refill with fresh
RPM 0 5600 1000 fuel.
Bank angle Run mode Disable Run mode Spark plugs 4.13 MISFIRE.
sensor 0.45-1.1 V 1.8-3.2 V 0.45-1.1 V
EVAP hose disconnected Connect.
Dwell 1600-2400 from induction module (CA)
960 uSec 8100 uSec
uSec
Throttle plates not opening See throttle cable adjust-
fully ment in 2003 Dyna Service
Table 4-2. Engine Starts Hard Manual (Part Number
99481-03).
SYMPTOM SOLUTION
Battery discharged See charging system trouble-

shooting in this section. Table 4-4. Engine Exhaust Emits
Spark plugs 4.13 MISFIRE. Black Smoke or Fouls Plugs
Spark plug wires 4.13 MISFIRE SYMPTOM SOLUTION
Ignition coil 4.13 MISFIRE. Clogged air filter See Section 1 in 2003 Dyna
Valve sticking See Section 3 in 2003 Dyna Service Manual (Part Num-
Service Manual (Part Number ber 99481-03).
99481-03). MAP sensor plugged or not
4.14 DTC 12.
Water or dirt in fuel system Drain and refill with fresh fuel. operating properly

HOME
Table 4-5. Diagnostic Trouble Codes (DTC) and Fault Conditions

DTC NO. FAULT CONDITION RELEVANT TOPIC
12 MAP sensor 4.14 DTC 12

16 Battery voltage 4.15 DTC 16
24 Front ignition coil 4.16 DTC 24, 25
25 Rear ignition coil 4.16 DTC 24, 25
35 Tachometer 4.17 DTC 35
41 Crank sensor 4.18 DTC 41
Bank angle sensor (within TSM/TSSM) 4.19 DTC 44
44
detects possible theft attempt
52 RAM failure 4.20 DTC 52, 53, 54, 55
53 ROM failure 4.20 DTC 52, 53, 54, 55
54 EEPROM failure 4.20 DTC 52, 53, 54, 55
55 Ignition module failure 4.20 DTC 52, 53, 54, 55

HOME
d0271x8x
Data
link Power wire
[91A]
Lt GN/R
V/R
W/BK
BK
Lt GN/R
V/R
[11B]
[11A]
Connector [10] Connector [11]
Ignition module
Figure 4-16. Diagnostic Check

[10] Ignition module (black) 12-place Deutsch behind electrical panel
[91A] Data link 4-place Deutsch behind electrical panel

HOME
Diagnostic Check (Part 1 of 2)
Turn ignition key switch ON. Set engine stop

switch to RUN. Do not start engine. Does
check engine lamp illuminate?
YES NO
Does light go off after See 4.9 NO CHECK ENGINE

four seconds? LAMP AT KEY ON.
YES NO
Does engine See 4.10 CHECK ENGINE

start? LAMP ON CONTINUOUSLY.
YES NO
Does Scanalyzer or check See 4.11 ENGINE CRANKS,

engine lamp display ignition BUT WILL NOT START.
module data? See 4.3 CHECK-
ING FOR TROUBLE CODES.
YES NO
Are any trouble

codes displayed? Go to Diagnostic
STOP Check (Part 2 of 2).
YES NO
Refer to applicable trouble code flow chart. Compare scan data with Table 4-1.
Start with lowest trouble code. All diagnostic Are values normal or within
codes are listed on page 4-14 in Table 4-5. typical ranges?
YES NO
See 4.7 WIGGLE TEST.

If Wiggle Test does not
Refer to diagnostic
tips in related trouble
1
recreate condition, refer code chart (even if
to symptoms tables. no code is set).
7110

HOME
Diagnostic Check (Part 2 of 2)
Continued from Diagnostic Check (Part 1 of 2).

2
Remove ignition module connectors [10B] (BK)
and [11B] (GY). Check for continuity to ground
at data link connector [91A] Terminals 1 and 3.
Continuity to ground?
YES NO
Repair short Test the four data link connector terminals against
to ground. 2 their ignition module connector pins for continuity.
7115
DATA LINK TERMINAL IGNITION MODULE
3 TERMINAL
Pin Wire Color Pin Connector
1 Lt. GN/R 11 [11B]

2 BK 11 [10B]
3 V/R 12 [11B]
4 W/BK 1 [10B]
Continuity present in all four circumstances?
YES NO
Check Scanalyzer on Inspect terminals

another vehicle. for damage or repair
Scanalyzer OK? opens as necessary.
7120
YES NO
Replace ignition Scanalyzer

module. malfunction.
7125

HOME
NO CHECK ENGINE LAMP AT KEY ON 4.9
GENERAL d0571x8x
If the engine stop switch is set to RUN with the engine off, and
the ignition key switch is turned ON, the check engine lamp
should illuminate for four seconds. See Figure 4-17.
Battery voltage is supplied to the lamp bulb. The lamp bulb is
grounded by the ignition module through the BK/Y wire. A
lack of power to the ignition module will cause the check
engine lamp to be inoperative and also create a no start situ-
ation.
DIAGNOSTICS
Diagnostic Tips
Check for the following conditions:
Figure 4-17. Check Engine Lamp
● Check for open in BK/Y wire.
● See Figure 4-18. Check accessory fuse.
d0675xtm
Diagnostic Notes
1. Connect BREAKOUT BOX (Part No. HD-42682). See 4.6
BREAKOUT BOX.
41404), purple pin probe and patch cord between Break-
out Box and ground. Align blade with slot on Breakout
Box terminal.
3. Assumes speedometer is functioning. If speedometer is
not functioning, see 2.2 SPEEDOMETER AND
TACHOMETER.
41404), brown pin probe and patch cord.
Figure 4-18. Fuse Block: Accessory Fuse, Top View
5. Check continuity.
a. If continuity is present, then problem is most likely
short to voltage.
b. If no continuity, then open.
6. LED failure requires speedometer replacement.
7. Move connector [20] to left side to disconnect. Remove
cable straps if necessary.

HOME
d0269x8x
15 amp
accessory fuse
From ignition
R/GY
switch
O/W
O/W wire is
Pin 1 on
FXDWG and
Pin 12 on all
other models
BK/Y
BK/Y
Check engine lamp O/W

inside speedometer
[39A] [39B] [20B] [20A]
(Not present
on FXDWG)
BK/Y
[10B]
[10A]
Ignition module
Figure 4-19. Check Engine Lamp Circuit

[20] Main harness to instruments 12-place Mini-Deutsch behind headlamp
[39] Speedometer: FXDWG 12-place Mini-Deutsch on speedometer
Speedometer: FXD, FXDX, FXDL,
[39] 12-place Packard on speedometer
FXDS-CONV

HOME
Test 4.9
NO CHECK ENGINE LAMP AT KEY ON
Turn ignition key switch ON.

Set engine stop switch to RUN.
Does engine start?
YES NO
Turn ignition key switch OFF. Did check engine lamp

Disconnect ignition module connector and no start condition
[10B] (black). Check continuity between occur simultaneously?
Pin 4 on connector [10B] (black) on
Breakout Box and Pin 4 connector [39B].
Continuity present?
1
YES NO
YES NO No ignition module power. See See 4.11 ENGINE CRANKS,

4.12 NO IGNITION MODULE BUT WILL NOT START for no
POWER. start condition and return to 4.9
NO CHECK ENGINE LAMP AT
Reconnect connector [39]. KEY ON to resolve no check
Place jumper between engine lamp.
Breakout Box (black) and
ground. Does check engine
lamp illuminate?
All FXDWG
models but only.
2 FXDWG.
YES NO
Replace Replace Disconnect connector [20]. Repair open on

ignition module. speedometer. Check continuity of BK/Y wire BK/Y wire between
between Pin 4 connector [20B] connector [39B] and
7130 7143 and [39B]. Continuity present? connector [10B].
6
7146
3 3
4
7
YES NO
Repair open on Repair open on

BK/Y wire between BK/Y wire between
connector [20A] and connector [20B] and
connector [10B]. connector [39B].
7135 7145
5

HOME
CHECK ENGINE LAMP ON CONTINUOUSLY 4.10
GENERAL d0571x8x
If the engine stop switch is set to RUN with the engine off, and
the ignition key switch is turned ON, the check engine lamp
should illuminate for four seconds. See Figure 4-20.
Following the initial period of illumination, the lamp should go
off for four seconds. It may then come back on for an eight
second period (for a stored error) or remain on continuously.
Battery voltage is supplied to the lamp bulb. The lamp bulb is
grounded by the ignition module through the BK/Y wire. A
steady light may indicate a short to ground on the black wire.
DIAGNOSTICS
Diagnostic Notes
The reference numbers below correlate with the circled num- Figure 4-20. Check Engine Lamp
1. If the lamp goes OFF when ignition module connector is
unplugged, BK/Y wire is shorted to ground.
2. Check for trouble codes. See RETRIEVING TROUBLE
CODES under 4.3 CHECKING FOR TROUBLE CODES.

HOME
d0269x8x
15 amp
accessory fuse
From ignition
R/GY
switch
O/W
O/W wire is
Pin 1 on
FXDWG and
Pin 12 on all
other models
BK/Y
BK/Y
O/W
Check engine lamp
inside speedometer
[39A] [39B] [20B] [20A]
(Not present
on FXDWG)
BK/Y
[10B]
[10A]
Ignition module
Figure 4-21. Check Engine Lamp Circuit

[20] Main harness to instruments 12-place Mini-Deutsch behind headlamp
[39] Speedometer: FXDWG 12-place Mini-Deutsch on speedometer
Speedometer: FXD, FXDX, FXDL,
[39] 12-place Packard on speedometer
FXDS-CONV

HOME
Test 4.10
CHECK ENGINE LAMP ON CONTINUOUSLY
With ignition key switch ON, verify that

there is NOT a 4 second lamp OFF period.
Is there a lamp OFF period?
YES NO
Check engine lamp function Turn ignition key switch OFF. Disconnect
2 OK? Check for trouble codes.
1 ignition module connector [10] (black).
Turn ignition key switch ON.
Is the check engine lamp OFF?
YES NO
Replace Disconnect connector [39].

ignition module.
3 Check for continuity to
ground on Pin 4 BK/Y wire
7150 in connector [10] (black).
Continuity present?
YES
All FXDWG NO
models but only.
FXDWG.
Replace
speedometer.
Disconnect connector [20]. Repair short to ground on
Remove BK/Y wire, Pin 10, BK/Y wire between 7148
[20A]. Reconnect. Does check connector [39B] and
engine light illuminate? connector [10] (black).
7155
YES NO
Repair short to ground Repair short to ground

on BK/Y wire between on BK/Y wire between
connector [20B] and connector [20A] and
connector [39B]. connector [10B].
7160 7165

HOME
ENGINE CRANKS, BUT WILL NOT START 4.11
GENERAL d0273x8x
If starter will not crank engine, the problem is not ignition

related. Refer to SECTION 1-STARTING & CHARGING.
Engine can be started with diagnostics test wire installed or if
the receive data line is grounded. Ignition key switch must be
turned OFF after test wire is removed or check engine lamp
will continue to flash stored codes.
DIAGNOSTICS
Diagnostic Notes
The reference numbers below correlate with the circled num- Figure 4-22. Spark Tester
1. Check for trouble codes. See RETRIEVING TROUBLE
CODES under 4.3 CHECKING FOR TROUBLE CODES.
d0275x8x
2. Check the condition of the battery. Perform a voltage test
and recharge if below 12.60V. Check battery connections A
and perform load test. Replace the battery if necessary.
3. Remove spark plug cable from spark plug.
a. Visually check condition of plug.
C B
b. See Figure 4-22. Attach cable to SPARK TESTER
(Part No. HD-26792). Clip tester to cylinder head
bolt.
c. While cranking engine, look for spark. Repeat pro-
cedure on other spark plug cables.
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.
4. Use HARNESS CONNECTOR TEST KIT (Part No. HD- Battery
41404) gray pin probes and patch cords.
5. Gently use test lamp as shown in Figure 4-23. Inserting
the test lamp forcefully into the connector will damage
the terminal and require its replacement.
6. Connect BREAKOUT BOX (Part No. HD-42682). See 4.6 Figure 4-23. Ignition Coil Test
BREAKOUT BOX.
41404), gray pin probe and patch cord.
41404), brown socket probe and patch cord.

HOME
s0481x8x
Engine stop
Wire switch
to TSM/TSSM
1 2 3 4 5 6 [22B]
15 amp [22A]
ignition fuse
R/BK wire
to ignition GY
switch
Crank
position
Ignition sensor
coil (CKP)
A B C
BK
[83A]
R
[83B]
W/BK
BE/O
Y/BE
[79A] 1 2
[79B]
W/BK
BE/O
Y/BE
BK
[10B] R [11B]
[10A] [11A]
Ignition module
Figure 4-24. Ignition Circuit Diagram

[83] Ignition coil 3-place Packard front of left side cover
[79] CKP sensor 2-place Mini-Deutsch under seat

HOME

ENGINE CRANKS, BUT WILL NOT START
Fresh fuel in tank?

Spark plug wires firmly
connected to proper coil
terminals? (Rear cylinder
connects to upper terminal.)
Add fuel /
connect
NO spark
plugs. Place Scanalyzer in
data monitor mode.
Does BAS MODE=RUN?
YES
Check for trouble

1 codes.
Codes found? YES NO
NO Check battery connections Go to

and voltage. Is voltage 4.19 DTC 44.
YES above 12.60?
2
See Table 4-5.
Start with
the lowest code. YES NO
Does battery pass Recharge battery.

load test?
7180
YES NO
Check spark plug condition, Replace battery.

3 replace if fouled. Check
spark at both plugs while 7185
cranking. Spark present?
YES NO
Check compression. See the 2003 Dyna Turn ignition ON and engine
Service Manual (Part Number 99481-03). stop switch to RUN.
If compression is good, Does check engine lamp
check fuel system. illuminate for 4 seconds?
7210
YES NO
Check battery voltage at See

4 Terminal B of coil connector 4.12 NO IGNITION MODULE
[83B] using DVOM. Battery POWER.
voltage present?
YES NO
Go to Test 4.11 Open in W/BK wire to coil.

STOP (Part 2 of 3). Repair open.
7215

HOME


5 Disconnect coil connector [83B]. Gently
connect test lamp to connector [83B]
Terminal C (front cylinder) or Terminal A
(rear cylinder). Crank engine.
Does test lamp flash?
YES NO
Check coil connections. Connect Breakout Box. Check continuity

Connections OK?
6 between ignition coil Terminal A of connec-
tor [83B] and Breakout Box Pin 7 (black).
7 Measure resistance between ignition coil
Terminal C of connector [83B] and ignition
module Pin 6 [10B] on Breakout Box.
Is resistance less than 1.0 ohm?
YES NO
Test spark plug cable resis- Repair.

tance. See 4.13 MISFIRE.
YES NO
Resistance OK? 7226
Connect DVOM to ignition Poor connection at connector

module Pins 5 and 6 on con- [10B] or open in harness
nector [11] (gray) on Breakout between coil and ignition
YES NO Box and set it for AC volts. module. Repair open.
Crank engine. Does DVOM
read 1 VAC minimum? 7225
Plug wires in correct Replace spark
coil towers? plug cables.
7227
YES NO
YES NO
Disconnect connector [79].
8 Check connectors for moisture
STOP and corrosion. Check wires for
Replace Route
coil. correctly. chafing. Connect DVOM to
Go to Test 4.11 Terminals 1 and 2 of [79A].
(Part 3 of 3). Crank engine. Does DVOM
7228
read 1 VAC minimum?
YES NO
Check for continuity between With meter still connected,

Terminal 1 of Connector [79B] check for resistance.
and Pin 5 of Connector [11] Is resistance 600-1200 ohms?
(gray) on Breakout Box.
Continuity present?
YES NO YES NO
Locate and repair open on Locate and repair open on Loose sensor at crankcase. Replace crank
BK wire between Terminal 2 R wire between Terminal 1 of Tighten sensor. position sensor.
[79B] and Pin 6 [11B] (gray). [79B] and Pin 5 of [11B] (gray).
7235 7230
7231 7231

HOME

Replace ignition module. Does vehicle start?
YES NO
System OK. Mechanical failure. Inspect for

sprocket gear, timing chain or
7250 other mechanical failure.
7255

HOME
NO IGNITION MODULE POWER 4.12
GENERAL DIAGNOSTICS
No Spark/No Check Engine Diagnostic Notes

Lamp At Key ON The reference numbers below correlate with the circled num-
The ignition module turns on when power is applied to Pin 1
of [10], the black connector. The ignition module goes through 1. See FUSES in the 2003 Dyna Service Manual (Part
an initialization sequence every time power is removed and Number 99481-03).
re-applied to Pin 1. The only visible part of this sequence is 2. Connect BREAKOUT BOX (Part No. HD-42682). See 4.6
the check engine lamp. Upon starting, the check engine lamp BREAKOUT BOX.
will illuminate for 4 seconds and then (if parameters are nor-
mal) go out.
d0276x8x
Engine stop
switch
Wire
to TSM/TSSM [22B]
[22A]
R/BK wire
to ignition GY
switch 15 amp
ignition fuse
W/BK
BK
BK
[10B]
[10A]
Ignition module
Figure 4-25. Ignition Module Power Circuit Diagram

[22] Right handlebar switch (black) 6-place Deutsch in frame backbone

HOME
Test 4.12
NO IGNITION MODULE POWER
Check ignition fuse.

1 Is ignition fuse OK?
YES NO
Connect Breakout Box. With ignition ON, Replace fuse.

2 place multimeter red wire to Pin 1 terminal Find source of fault.
on [10] and black wire to Pin 2 and Pin 11 on
3 connector [10B] (black) on Breakout Box. 7270
Is voltage 11-13 V?
YES NO
Replace ignition Check continuity between

module.
3 Pin 2 and Pin 11 on connector [10B]
(black) on Breakout Box and ground.
YES NO
Check continuity between Pin 1 Repair open in BK wire

3 on connector [10B] (black) on (Pin 2 or Pin 11)
Breakout Box and right handle- to ground.
bar connector [22A] Pin 4.
Continuity present? 7310
YES NO
Check continuity between Pin 3 Repair open

3 on connector [11B] (gray) on in W/BK wire.
Breakout Box and Pin 4 (W/
BK) on connector [22B]. 7285
Continuity present?
YES NO
Repair open in GY wire Replace engine

between [22A] and stop switch.
fuse block.
7295
7291

HOME
MISFIRE 4.13
GENERAL d0273x8x
Misfire at Idle or Under Load

● Battery condition and connections may also cause mis-
fires.
● Fuel system problems may also cause misfires. See
Table 4-3.
DIAGNOSTICS
Diagnostic Notes
The reference numbers below correlate with the circled num- Figure 4-26. Spark Tester
1WARNING Table 4-11. Spark Plug Cables

Any open spark around gasoline or other combustibles SPECIFICATION REAR FRONT
may result in fire or explosion. Thoroughly wipe up any
spilt fuel and dispose of rags in a suitable manner. Inade- Length in. 19.0-19.25 7.25-7.50
quate safety precautions could result in death or serious
injury. Length mm 482.6-489.0 184.2-190.5
NOTE Resistance-ohms 4750-11,230 1812-4375

Engine will not spark with both spark plugs removed. When
checking for spark, use SPARK TESTER (Part No. HD- 3. If carbon tracking is evident, replace ignition coil and
26792) with both plugs installed. inspect spark plug wires. Wires must be clean and tight.
1. See Figure 4-26. A SPARK TESTER (Part No. HD- Excessive wire resistance or faulty connections can
26792) must be used to verify adequate secondary volt- cause coil damage.
age (25,000 volts) at the spark plug. 4. This test can also be performed by substituting a known
a. Turn ignition switch OFF. good coil for one causing the no spark condition. The coil
b. Remove spark plug cable from spark plug. Visually does not require full installation to be functional. Verify
check plug condition. faulty coil by performing resistance test.
c. Attach cable to SPARK TESTER. Clip tester to cylin- 5. Use HARNESS CONNECTOR TEST KIT (Part No. HD-
der head bolt. 41404), gray pin probe and patch cord to the coil connec-
d. While cranking engine, watch for spark to jump tor [83B].
tester gap on leads.
6. Inspect for corrosion at battery terminals, main circuit
e. Reinstall and repeat procedure on other spark plug breakers, ignition fuse terminals (GY and R/BK), right
cable. handlebar connector [22] and coil connector.
2. Perform spark plug cable resistance test.
a. Remove spark plug cable from spark plug and igni-
tion coil. For best results, use a needle nose pliers
for removal/installation on coil. Gently grasp cable
as close to terminals as possible.
b. Using an ohmmeter, touch probes to terminals on
each end plug wire.
c. Compare resistance values to Table 4-11. Replace
cables not meeting specifications. Reinstall and
repeat procedure on other spark plug cable.

HOME
d0277x8x
Engine stop
Wire switch
to TSM/TSSM [22B]
15 amp [22A]
ignition fuse
R/BK wire
to ignition GY
switch
Ignition
coil
[83A]
[83B]
W/BK
BE/O
Y/BE
W/BK
BE/O
Y/BE
[10B]
[10A]
Ignition module
Figure 4-27. Ignition Coil Circuit Diagram

[83] Coil 3-place Packard in front of left side cover

HOME
Test 4.13
MISFIRE AT IDLE OR UNDER LOAD
Is fuel contaminated?
YES NO
Use spark tester to check cables.

Drain and flush
tank. Refill with 1 Did spark jump gap on both leads?
fresh fuel.
YES NO
Check for: Check resistance of each spark plug

• Faulty, worn or cracked spark plug(s). 2 cable that did not fire the spark tester.
• Plug fouling due to engine
mechanical fault. Also, check for faulty plug wire connections
• Faulty or poor connection at plug. and wire boots for carbon tracking.
7520 Are wires OK?
YES NO
3 Coils should be free Replace

of carbon tracking. faulty wires.
Are they?
7525
YES NO
Switch coil with unit Replace

4 known to be good. ignition coil.
Perform spark test.
7535
Did spark jump gap
during engine cranking?
Remove test coil. Disconnect negative bat-

tery cable. Measure resistance between bat-
NO tery positive and coil connector [83B]
Terminal B (W/BK). Wiggle harness. Is
resistance continuously less than 1.0 ohm?
YES
5
Original ignition coil YES NO
is faulty. Replace.
6
7535
Replace ignition Find source of
module. intermittent and repair.
7541 7540

HOME
NOTES

7
HOME
DTC 12 4.14
GENERAL 7351
MAP Sensor
See Figure 4-28. The manifold absolute pressure sensor
(MAP sensor) is supplied 5 volts from the ignition module and
sends a signal back to the ignition module. This signal varies
in accordance with engine vacuum and atmospheric baro-
metric pressure. Changes in barometric pressure are influ-
enced by weather and altitude.
DIAGNOSTICS
Diagnostic Tips
● DTC 12 will set if the MAP sensor signal is out of range
or fluctuates faster than normal operation.
● With the MAP sensor disconnected, the ignition module
and Scanalyzer should recognize a low voltage. If low
voltage is observed, the ignition module and harness are Figure 4-28. MAP Sensor
not at fault.
NOTE
Diagnostic Notes
Engine must be running for Scanalyzer to work properly.
● Gently place a jumper wire across MAP Sensor connec- bers on the Test 4.14 flow charts.
tor [80B] Terminals B and C using HARNESS CONNEC-
TOR TEST KIT (Part No. HD-41404), gray male probes 1. Connect BREAKOUT BOX (Part No. HD-42682)
and patch cord. With the jumper in place, the ignition between wire harness and ignition module. See 4.6
module and Scanalyzer should recognize a high voltage. BREAKOUT BOX.
● MAP sensor output check. Using the VACUUM PUMP 2. Use HARNESS CONNECTOR TEST KIT (Part No. HD-
(Part No. HD-23738A), apply a vacuum to the pressure 41404), gray pin probes and patch cords.
port of the MAP sensor. The signal voltage should lower
as the vacuum is applied. Scanalyzer Notes
● Historic codes may be set if rider operates motorcycle
The Scanalyzer icon appears at those points in the flow chart
with extreme high RPM downshifting.
where the Scanalyzer can be used.

HOME
s0480x8x
Manifold
absolute
pressure
sensor
(MAP)
[80A]
[80B]
BK/W
R/W
V/W
BK/W
R/W
V/W
[11B]
[11A]
Ignition module
Figure 4-29. MAP Sensor Circuit Diagram

[80] MAP sensor 3-place Packard under fuel tank

HOME

MAP SENSOR: DTC 12
USING BREAKOUT BOX USING SCANALYZER

1
Connect Breakout Box. With ignition ON, With engine running, observe
measure voltage between Pin 2 on Scanalyzer MAP voltage values.
Breakout Box and Pin 8.
With key ON, engine OFF, voltage must be

between 4.2 and 4.95 volts.
With key ON, engine running, voltage must
be between 1.5-3.0 volts at hot idle.
Does voltage fit specifications?
YES NO
Perform 4.7 WIGGLE TEST

to check for intermittents.
Intermittents present?
STOP
Go to Test 4.14
(Part 2 of 2).
YES NO
To identify the source of inter- Replace MAP sensor. See the 2003 Dyna
mittents, start with box marked Service Manual (Part Number 99481-03).
by Bold Asterisk under Test Clear codes if a Scanalyzer is available and
4.14 (Part 2 of 2). Wiggle har- road test. Did check engine lamp illuminate
ness while watching DVOM. and set Code 12?
7620
YES NO
Install original MAP sensor. System

Replace ignition module and now OK.
road test again to verify.
7630
7625

operation with no check engine
lamp.
At some point in the flow chart you

may be instructed to jump directly
to a the box with the bold asterisk.
Disregard the asterisk (but not the
instruction box) if your normal pro-
gression through the chart brings
you to this location.

HOME

MAP SENSOR: DTC 12

Check the 5 volt reference supply at
the MAP sensor connector [80B]. With
2 ignition ON, measure voltage between
Pin C (R/W) and Pin A (BK/W).
Is voltage approximately 5.0 volts?
YES NO. NO.

Greater Less
than 6V. than 4.5V.
Connect Breakout Box. Disconnect ignition
1 module from Breakout Box.
OPEN CHECK: Measure resistance Locate short to 12 volts on R/W Connect Breakout Box. Disconnect
2 between MAP connector [80B] Terminal B wire in wire harness. Repair as
1 ignition module from Breakout Box.
and Breakout Box connector [11] (gray) necessary. Check continuity between MAP connector
Pin 2. Is resistance less than 1 ohm?
2 [80B] Terminal C and Breakout Box
7635 connector [11] (gray) Pin 1. Then measure
continuity between MAP connector [80B]
Terminal A and Breakout Box
connector [11] (gray) Pin 8.
Continuity present?
YES NO
SHORT CHECK: Measure Locate and repair

2 resistance between MAP con- open on V/W wire.
nector Terminal B and chassis
ground. Is resistance greater 7645
than 1 meg ohm? YES NO
Disconnect ignition Repair

module.Check resistance open wire.
between MAP connector
YES NO [80B] Terminal C and 7640
Breakout Box [11] (gray)
Pin 1. Is it greater than
1 megohm?
Replace MAP sensor. See the Locate and repair
2003 Dyna Service Manual grounded V/W wire.
(Part Number 99481-03).
7655
7650
YES NO
Replace ignition Locate and repair

module. short between
R/W and BK/W
7641 wires.
7642

lamp.
At some point in the flow chart you

may be instructed to jump directly
to a the box with the bold asterisk.
Disregard the asterisk (but not the
instruction box) if your normal pro-
gression through the chart brings
you to this location.

HOME
DTC 16 4.15
GENERAL Diagnostic Notes

Battery Voltage
1. Was battery allowed to discharge? Was battery drawn
A DTC 16 is set if the ignition module sees battery positive down by a starting problem?
voltage less than 8 or greater than 16 volts.
a. Yes. Charge battery.
● Low voltage generally indicates a loose wire, corroded b. No. See charging system troubleshooting.
connections and/or a charging system problem.
2. Connect BREAKOUT BOX (Part No. HD-42682)
● A high voltage condition may be caused by a faulty volt- between wire harness and ignition module. See 4.6
age regulator. BREAKOUT BOX.
3. The ignition module is monitoring voltage at ignition
module connector [10] (black) Pin 1.
DIAGNOSTICS
4. This checks for voltage drops in the ignition module cir-
cuit.
Scanalyzer Notes a. Place (+) probe to battery positive terminal.
The Scanalyzer icon appears at those points in the flow chart b. Place (-) probe to W/BK terminal on Breakout Box.
d0283x3x
Engine stop
switch
30 amp
main circuit
breaker
(silver post) Ignition [22B]
switch 15 amp [22A]
ignition fuse
R R/BK GY
W/BK
BK
BK
[10B]
Battery
[10A]
Connector [10]
Ignition module
Figure 4-30. Battery Voltage Circuit Diagram



HOME

BATTERY VOLTAGE: DTC 16
Perform charging system tests.

1 Charging system OK?
YES NO
Remove spark plug cables. Connect Break- Repair

2 out Box. Measure voltage on Breakout Box charging system.
(black) between Pin 1 and Pin 11 and again
3 between Pin 1 and Pin 2 while cranking
engine. Disregard reading during first
2 seconds of cranking. Is voltage above
8 volts? Reconnect spark plug cables.
YES NO
System With ignition ON, measure voltage drop

1 OK.
4 between battery positive (+) terminal
and Breakout Box connector [10] (black)
7770 Pin 1 (-). Is voltage drop greater
than 0.5 volt?
YES YES
With ignition ON, measure voltage drop Check for voltage drop between battery
between battery positive (+) terminal negative (-) terminal and Pin 2 (+) on
and connector [22A] Pin 4 (-). Is voltage connector [10B] (black) on Breakout Box
drop greater than 0.5 volt? connector (black) and between battery
negative (-) terminal and Pin 11 on
connector [11B] (gray) on Breakout Box.
Is voltage drop greater than 0.5 volt?
YES NO
With ignition ON, measure voltage drop Replace W/BK YES NO

between battery positive (+) terminal wire or
and connector [22A] Pin 3 (-). Is voltage terminals.
drop greater than 0.5 volt?
Locate and repair Problem is intermittent.
7776
bad connection. Perform 4.7 WIGGLE
TEST.
7775
7775
YES NO
Inspect [22] for corrosion or

loose wires. If above conditions
STOP are not present, replace engine
stop switch.
Go to Test 4.15 7781
lamp.
(Part 2 of 2).

HOME

BATTERY VOLTAGE: DTC 16
Continued from Test 4.15 (Part 1 of 2). With

ignition ON, measure voltage drop between
battery positive (+) terminal and GY terminal
on 15 amp fuse (-). Is voltage
drop greater than 0.5 volt?
YES NO
With ignition ON, measure voltage drop Replace GY wire

between battery positive (+) terminal and or terminals.
R/BK terminal on 15 amp ignition module
fuse. Is voltage drop greater than 0.5 volt? 7780
YES NO
With ignition ON, measure voltage drop Replace fuse or

between battery positive (+) terminal and fuse terminals.
silver post on main circuit breaker (-).
Is voltage drop greater than 0.5 volt? 7782
YES NO
With ignition ON, measure voltage drop Replace ignition

between battery positive (+) terminal and switch or terminals.
copper post on main circuit breaker (-).
Is voltage drop greater than 0.5 volt? 7783
YES NO
High resistance between 30 amp Replace circuit

circuit breaker and battery. Replace breaker.
wire or terminals.
7779
7784

lamp.

HOME
DTC 24, 25 4.16
GENERAL d0275x8x
A
Front Ignition Coil (DTC 24) and
Rear Ignition Coil (DTC 25)
A DTC 24 or 25 will set if the ignition coil voltage is out of
range. This could occur if there is an open coil or loss of
C B
power to the coil. If both codes are set, it is likely a coil power
failure or a coil failure.
The coil receives power from the engine run/stop switch. The
ignition module is responsible for turning on the coils by pro-
viding the ground to activate the coils, which in turn powers
the coils.
DIAGNOSTICS
Battery
Diagnostic Notes
1. Gently use test lamp as shown in Figure 4-31. Inserting Figure 4-31. Ignition Coil Test
the test lamp forcefully into the connector will damage
the terminal and require its replacement.
41404), gray pin probes and patch cord.
3. Connect BREAKOUT BOX (Part No. HD-42682)
between wire harness and ignition module. See 4.6
BREAKOUT BOX.
Scanalyzer Notes
The Scanalyzer icon appears at those points in the flow chart
NOTE
With the engine OFF, the Scanalyzer (Active Diagnostic Test
Mode) can be used to energize either the front or rear coil
once each second for a total of five seconds.

HOME
d0277x8x
Engine stop
Wire switch
to TSM/TSSM [22B]
15 amp [22A]
ignition fuse
R/BK wire
to ignition GY
switch
Ignition
coil
[83A]
[83B]
W/BK
BE/O
Y/BE
W/BK
BE/O
Y/BE
[10B]
[10A]
Ignition module
Figure 4-32. Ignition Coil Circuit Diagram

[83] Coil 3-place Packard in front of left side cover

HOME
Test 4.16
IGNITION COIL: DTC 24, 25
Disconnect coil connector [83B]. Gently connect

1 test lamp to connector [83B] Terminal C (front)
or Terminal A (rear). Crank engine.
Do test lamp lights flash when cranked?
YES
Perform 4.7 WIGGLE

TEST. Intermittents
found?
YES NO NO
2 With ignition ON, measure voltage between

Repair as Replace
Terminal B connector [83B] and ground. Is it
necessary. ignition coil.
equal to battery voltage?
7855 7856
YES NO
Using Breakout Box, measure resistance Locate and repair open

2 between ignition module and coil terminals wire or connection on
as follows: W/BK wire.
3 7875
Trouble Coil Breakout
Code Terminal Box (BK)
24 C
6
(Front) (BE/O)
25 A
7
(Rear) (Y/BE)
Resistance should be less than 0.5 ohms. Is it?
YES NO
Perform 4.7 WIGGLE Repair open wire

TEST. Intermittents or connection.
found?
7860
YES NO
Repair as Replace ignition

necessary. module.
7865 7870

lamp.

HOME
DTC 35 4.17
GENERAL DIAGNOSTICS
Tachometer: All Except FXDWG Diagnostic Notes

A DTC 35 will set if the PK wire is shorted to ground. The reference numbers below correlate with the circled num-
BREAKOUT BOX.
d0284x8x
R/BK O
[108A] [108B]
[20B] [20A]
BK
BK
PK
[10B]
[10A]
Ignition module
Figure 4-33. Tachometer Circuit Diagram

[20] Instruments 12-place Deutsch behind headlamp
[108] Tachometer 6-place Packard back of tachometer

HOME
Test 4.17
TACHOMETER: DTC 35
Install Breakout Box but leave connector [10]

1 (black) unplugged at ignition module.
Disconnect connector [108]. With ignition ON,
measure voltage across Pin 12 (+) and Pin 11 (-) of
Breakout Box connector [10] (black).
Is battery voltage present?
YES NO
Disconnect connector [20]. Check for continuity between Pin 12 [10B]

Check for continuity between (black) and Pin 11 [10B] (black) on Breakout
Pin 6 and Pin 7 in [20]. Box. Also check between Pin 12 [10B]
Continuity present? (black) and Pin 2 [10B] (black) on Breakout
Box. Is continuity present?
YES NO NO
Locate and repair Reconnect [10]. Start Reconnect connector

short to voltage. bike. Does voltage [108]. Check resistance
change? between Pin 12 [10B]
7884 (black) and Pin 11 [10B]
(black) on Breakout Box.
Is resistance less than
5,000 ohms?
YES NO YES
Use 4.7 WIGGLE TEST Replace ignition Disconnect connector

to locate intermittents. module. [20]. Is continuity YES NO
present on Breakout
7881 7882 Box between Terminal
11 [10B] (black) and Replace Replace ignition
Terminal 12 [10B] tachometer. module.
(black)?
7883 7882
YES NO
Repair short to ground Repair short to ground

on PK wire between on PK wire between
connector [10B] and connector [20B] and
connector [20A]. connector [108B].
7886 7886

lamp.

HOME
DTC 41 4.18
GENERAL d0541x8x
Crank Position Sensor 1 2

See Figure 4-34. A DTC 41 will set if the crankshaft position
sensor (CKP) signal is weak or absent.
DIAGNOSTICS
Diagnostic Notes 3
1. Connect BREAKOUT BOX (Part No. HD-42682) to igni-
tion module wire harness only, leaving ignition module
disconnected. See 4.6 BREAKOUT BOX.
2. One megohm is very high resistance. Some meters will
read infinity, OL, etc.
3. Use HARNESS CONNECTOR TEST KIT (Part No. D-
41404), brown socket probes and patch cords. 1. CKP sensor and O-ring
4. For testing purposes, install sensor without running wir- 2. Screw and captive washer
ing along normal path. Disconnect and route wiring prop- 3. CKP connector [79A]
erly if system is now OK.
Figure 4-34. CKP Sensor
7939
Figure 4-35. CKP Sensor Location

HOME
d0564x8x
Crank
position
sensor
BK
R
[79A]
[79B] 1 2
BK
BK
BK
R
[10B]
[10A]
Ignition module
Figure 4-36. Ignition Circuit Diagram


[79] CKP sensor 2-place Mini-Deutsch under seat

HOME
Test 4.18
CRANK POSITION SENSOR: DTC 41
Connect Breakout Box to harness only,

1 leaving ignition module disconnected.
Measure resistance between Pin 5 [11B] (gray)
and Pin 2 [10B] (black) on Breakout Box and
2 Pin 6 [11] (gray) and Pin 2 of [10] (black)
on Breakout Box. Is resistance more than 1
megohm?
YES NO
Check for intermittent connection, pinched Disconnect connector [79]. Leaving ignition module
or damaged wires, and loose CKP sensor disconnected, measure resistance between Pin 5 [11B]
fasteners. Conditions found? (gray) and Pin 2 [10B] (black) on Breakout Box. Also
measure resistance between Pin 6 [11B] (gray) and
Pin 2 [10B] (black) on Breakout Box. Is there still
continuity to ground (less than 1 megohm resistance)?
YES NO
Repair as Connect DVOM to Terminals 5 and 6 at

necessary. connector [11B] (gray) on Breakout Box.
Set DVOM to AC volts and crank engine.
7980
YES NO
Does DVOM read 1 VAC minimum
during cranking?
Repair short to Replace CKP
ground on R or sensor.
BK wire between
7981
YES NO connectors [11B]
and [79B].
With DVOM or Scanalyzer still connected, Connect DVOM. At connector 7980

check for intermittents using 4.7 WIGGLE [79] Terminals 1 and 2, DVOM
TEST. Intermittents present? should read 1 VAC
minimum while cranking.
Does it?
YES NO
YES NO
Repair as Replace CKP
necessary. sensor. Clear
codes and retest. Check for continuity between Replace CKP
7982 Code 41 set? Pin 5 [11B] (gray) and Pin 1 sensor.
[79B]. Is continuity present?
7985
4
YES NO
Replace ignition System

module. OK. YES NO
7983 7984
Repair open on BK wire Repair open on R wire
between Pin 2 [79B] and Pin 6 between Pin 1 [79B] and Pin 5
on connector [11B] (gray). on connector [11B] (gray).
7986 7987

lamp.

HOME
DTC 44 4.19
GENERAL DIAGNOSTICS
TSM/TSSM Diagnostic Notes

DTC 44 occurs when the TSM/TSSM detects a fault in the Lt
GN/GY wire. If the fault occurs with the ignition OFF, this DTC
represents a possible theft attempt. 1. Use HARNESS CONNECTOR TEST KIT (Part No. HD-
41404), black pin probes and patch cord.
If this code occurs, the engine may stop running. The engine
may still be started and ridden to a dealership for repair.
BREAKOUT BOX.


HOME
HAND CONTROLS,
RIGHT
[162 ] 70103-96 BK
BATTERY
RIGHT TURN SWITCH
ENGINE STOP/RUN
SWITCH
START SWITCH
BK
STOPLIGHT SWITCH 70102-96
STARTER
GY
W/BK
[22B]
6 5 4 3 2 1
6 5 4 3 2 1
BK
[22A]
GY
W/BK
R COPPER
STUD
[64B]
[5 ]
CIRCUIT
TURN SIGNAL/SECURITY MODULE G IGN: 15A H BREAKER
GY R/BK 30 AMP
BATTERY 1
IGNITION 2 GY
VSS / SERIAL DATA LINK 3 [33A] [33B]
SECURITY INDICATOR 4
START RELAY CONTROL 9
IGNITION ENABLE SIGNAL 10 LGN/GY
ALARM SIGNAL 11
GROUND 12 BK IGNITION
TS/TSSM SWITCH
[30A] [30B]
Figure 4-37. Bank Angle Sensor Circuit

BK
BK
LGN/GY
BK
Y/BE
BK
W/BK
V/R

V/R
W/BK
BE/O
Y/BE
BE/O
W/BK
[83B]
LGN/R
LTGN/R
[11B] [10B]
INSTRUMENTS START RELAY [91A]
F E D C B A B A C B A 4 3 2 1
1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 3
15A 1 2
E C
SECURITY IGNITION
1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 C B A DATA LINK
L K J I H G K I H G
15A 15A GRAY BLACK [ GND1] [83A]
ACCESSORIES LIGHTS
[11A] [10A] IGNITION
U T S R Q P
COIL
U S R P O M O M IGNITION MODULE
15A 15A
TOP VIEW TOP VIEW
2003 Dyna: Engine Management

4-51
HOME

TSM/TSSM: DTC 44
Is TSM/TSSM
connected?
YES NO
1 Disconnect connector [30]. Measure Reconnect. Clear

voltage on [30] between codes and cycle
Socket 10 (Lt GN/GY) and Socket 12 (BK). ignition key.
What is the voltage? Recheck for codes.
7971
4.0-6.0 volts 11.0-13.0 volts 0 volts
Measure voltage between Socket 2 (GY) Repair short to

and Socket 12 (BK) on connector [30B]. voltage on
Voltage 11.0-13.0 volts? Lt GN/GY wire. STOP
7972
Go to Test 4.19
(Part 2 of 2).
YES NO
Is TSM/TSSM Repair open in

correctly installed? GY wire between
[30] and
ignition fuse.
7975
YES NO
Replace TSM/TSSM. Install

properly.
7976

lamp.

HOME

TSM/TSSM: DTC 44
1 Continued from Test 4.19 (Part 1 of 2).
Disconnect connectors [10] (BK) and [11] (GY) from

2 ignition module and plug into Breakout Box. Check
continuity between Socket 10 (Lt GN/GY) on connector [30]
and Pin 10 on connector [10B] (BK) on Breakout Box.
YES NO
Check continuity to ground on Repair open in

1 Socket 12 (BK) on connector [30B]. Lt GN/GY wire.
7975
YES NO
Check continuity to ground on Repair open in

1 Socket 10 (Lt GN/GY) and connector [30B]. ground wire.
7975
YES NO
Repair short to ground Replace ignition module.

on Lt GN/GY wire. Check for codes.
7973 7974

lamp.

HOME
DTC 52, 53, 54, 55 4.20
GENERAL
Ignition Module Failure

All of the following codes indicate an internal failure which
requires replacement of the ignition module. See the 2003
Dyna Service Manual (Part Number 99481-03) for replace-
ment procedures.
● Code 52 - RAM failure
● Code 53 - ROM failure
● Code 54 - EE PROM failure
● Code 55 - Module microprocessor malfunction.
NOTE
Dealership technicians filing warranty claims should use job/
time code 7913 for all Code 52, 53, 54 and 55 ignition module
replacements.

Table Of Contents
SUBJECT PAGE NO.
5.1 Connector Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.2 Amp Multilock Electrical Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.3 Deutsch Electrical Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.4 Mini-Deutsch Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
5.5 Sealed Butt Splice Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
5.6 Packard Electrical Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
5.7 Index to Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
WIRING
2
HOME
CONNECTOR LOCATIONS 5.1
Table 5-1. Dyna Connector Locations

CONNECTOR
DESCRIPTION TYPE LOCATION
NO.
[7] tail lamp harness to main harness 8-place Multilock under seat
[10] ignition module (black) 12-place Deutsch under seat, behind electrical panel
[11] ignition module (gray) 12-place Deutsch under seat, behind electrical panel
[18] left rear turn signal 2-place Multilock inside tail lamp lens
[19] right rear turn signal 2-place Multilock inside tail lamp lens
FXD, FXDX, FXDXT: under
[20] console gauges 12-place Multilock headlight bracket
FXDL: under console
indicator lamps 8-place Multilock FXDWG: under console
[21]
console gauges 10-place Multilock FXDL: under console
[22] right hand controls 6-place Deutsch frame backbone
[24] left hand controls and horn 6-place Deutsch frame backbone
[30] TSM/TSSM 12-place Deutsch electrical panel
[31] front turn signals 6-place Multilock frame backbone
ignition key switch - all except FXDWG 4-place Packard under seat
[33]
ignition key switch - FXDWG only 3-place Packard FXDWG: under console
[38] headlamp 4-place Multilock frame backbone
speedometer - all except FXDWG 12-place Packard
[39] back of speedometer
speedometer - FXDWG only 12-place Mini-Deutsch
[46] voltage regulator to stator 2-place Facon front of engine crankcase
[65] speedometer sensor 3-place Deutsch under seat
[79] crank position sensor (CKP) 2-place Mini-Deutsch under seat
[80] manifold air pressure sensor 3-place Packard top of manifold
[83] ignition coil 3-place Packard on back of coil
[91] data link connector 4-place Deutsch t-stud on back of electrical panel
[93] tail lamp 4-place Multilock behind tail lamp
[94] tail lamp power in 6-place Multilock behind tail lamp
[108] tachometer 6-place Packard back of tachometer
[117] fuel gauge and fuel level sending unit 2-place Multilock left front side of fuel tank
[120] oil pressure sending unit 2-place Mini-Deutsch under seat
spade terminals
[123] starter relay electrical panel
fuse/relay block
- fuse block spade terminals electrical panel
- rear stoplight switch spade terminals behind rear master cylinder
- main circuit breaker ring terminals electrical panel
- starter solenoid spade terminals top of starter
- neutral switch post terminals top of transmission
- harness grounds (2) ring terminals under seat
- oil pressure switch post terminal on oil pressure switch
2003 Dyna: Wiring 5-1

HOME
AMP MULTILOCK ELECTRICAL CONNECTORS 5.2
REMOVING SOCKET/PIN inadvertently released. Repeat the step without releasing

the tang.
TERMINALS
NOTE
● If pick tool is not available, a a push pin/safety pin may be
1. Remove connector from the retaining device, either
used instead.
attachment or rosebud clip.
2. Depress the button on the socket terminal side of the ● An ELECTRICAL TERMINAL CRIMP TOOL (Part No.
connector (plug) and pull apart the pin and socket HD-41609) is used to install Amp Multi lock pin and
halves. socket terminals on wires. If new terminals must be
installed, see Crimping Instructions on the next page.
3. Bend back the latch slightly and free one side of second-
ary lock, then repeat the step to release the other side.
Rotate the secondary lock outward on hinge to access INSTALLING SOCKET/PIN
terminals in chambers of connector housing.
4. Looking in the terminal side of the connector (opposite
TERMINALS
the secondary lock), take note of the cavity next to each
terminal. NOTE
5. See Figure 5-1. With the flat edge against the terminal, For wire location purposes, numbers are stamped into the
insert the pick tool (Snap-On TT600-3) into the cavity secondary locks of both the socket and pin housings. See
until it stops. Pivot the end of the pick away from the ter- Figure 5-2.
minal (locktab is inside housing) and gently tug on wire to 1. From the secondary lock side of the connector, insert the
pull terminal from chamber. Do not tug on the wire until terminal into its respective numbered chamber until it
the tang is released or the terminal will be difficult to snaps in place. For proper fit, the slot in the terminal
remove. A “click” is heard if the tang is engaged but then must face the tang in the chamber.
d0242x3x
Pin terminal
Secondary lock open
Pin housing
Socket housing
Latch
Secondary lock open
Button
Latch
Secondary lock open
Socket terminal
Figure 5-1. 10-Place Amp Multilock Connector
5-2 2003 Dyna: Wiring

HOME
d0243x8x
Socket terminal
Secondary lock open

4
Socket housing
2 Pick tool
1
Pin terminal 3
Secondary lock open

4
Pin housing
1
2 Pick tool
1. Open secondary lock. 3

2. Insert pick into cavity on inboard side
of connector.
3. Pivot end of pick to release tang.
4. Gently tug on wire to remove terminal
from housing.
Figure 5-2. Release Tang and Back Out Terminals

NOTES
● See Figure 5-3. The tang in the chamber engages the
Pin housing Socket housing
slot to lock the terminal in position.
● On the pin side of the connector, tangs are positioned at Button
the bottom of each chamber, so the slot in the pin termi-
nal (on the side opposite the crimp tails) must face down- Tang
ward.
● On the socket side, tangs are at the top of each chamber,
so the socket terminal slot (on the same side as the
crimp tails) must face upward.
● Up and down can be determined by the position of the
release button (used to separate the pin and socket
halves). Consider the button to always be on top of the
connector. Tang
2. Gently tug on wire end to verify that the terminal is
locked in place and will not back out of chamber. d0244x8x
3. Rotate the hinged secondary lock inward until tabs fully Figure 5-3. Multilock Connector Cutaway View
engage latches on both sides of connector.
4. Insert the socket housing (plug) into the pin housing
(receptacle) until it snaps in place.
5. Install connector on retaining device, either attachment
or rosebud clip.

HOME
Secondary locks open (socket housings shown)

1 2 3 4
Stamped numbers on secondary locks indicate wire color locations
– AMP – AMP
1 2 3 1 2 3 4 5 6 5 6 7 8 9 10
3-place 6-place 12-place
Secondary lock
Pin terminal
Socket housing
Button
Pin housing
Secondary lock
Pin terminal
Secondary lock
Socket terminal
Latch
Button
Pin housing Latch
Socket housing
Secondary lock
Socket terminal
d0245x2x
Figure 5-4. 3-Place and 6-Place Amp Multilock Connectors

HOME
CRIMPING INSTRUCTIONS 4. Strip lead removing 5/32 in. (4 mm) of insulation. Insert
wires between crimp tails until ends make contact with
locking bar. Verify that wire is positioned so that short
1. Squeeze the handles to cycle the crimp tool (Part No. pair of crimp tails squeeze bare wire strands, while long
HD-41609) to the fully open position. pair folds over insulation material.
2. Raise locking bar by pushing up on bottom flange. With 5. Squeeze handle of crimp tool until tightly closed. Tool
automatically opens when the crimping sequence is
the crimp tails facing upward, insert contact (socket/pin)
complete. Raise up locking bar and remove contact.
through locking bar, so that the closed side of the contact
rests on the front nest (concave split level area of the 6. Inspect the quality of the core and insulation crimps. Dis-
crimp tool). See Figure 5-3. tortion should be minimal.
3. 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.
1. Insulating crimp tail

2. Core crimp tail
1 1
2 3 2
3. Locking bar groove
4. Tang slot 3 4
1. Raise locking bar and seat contact 2. Insert stripped lead until it
on front nest of crimp tool. Release contacts locking bar.
locking bar
GAUGE CRIMP TOOL

WIRE NEST
20 Front
16 Middle
18 Rear
3. Close and squeeze crimp tool. 4. Raise locking bar and remove contact.
d0246x8x
Figure 5-5. Amp Multilock Crimping Procedure

HOME
DEUTSCH ELECTRICAL CONNECTORS 5.3
GENERAL 4566
Deutsch Connectors feature a superior seal to protect electri-

cal contacts from dirt and moisture in harsh environments.
The connector also provides superior pin retention.
See Figure 5-8. This 12-pin connector illustrates the various

parts of the Deutsch connector. The following instructions
may be followed for all 2-pin through 12-pin Deutsch connec-
tors.
Socket housing: alignment tabs and/or external latch, sec-

ondary locking wedge, internal seal, wire seal, seal pin.
NOTE
Seal pins or plugs are installed in the wire seals of unused pin
and socket locations. If removed, seal pins must be replaced
to maintain the integrity of the environmental seal.
Pin housing: alignment grooves and/or external latch cover, Figure 5-6. Remove Secondary Locking Wedge
attachment clip, secondary locking wedge, wire seal, seal pin.
s0545x8x
REMOVING/DISASSEMBLING
Attachment clips are attached to the pin housings of most
connectors. The clips are then attached to T-studs on the
motorcycle frame. T-studs give positive location to electrical
connectors and wire harness. Consistent location reduces
electrical problems and improves serviceability.
1. Push the connector to disengage small end of slot on

attachment clip from T-stud. Lift connector off T-stud.
2. Depress the external latch(es) on the socket housing
side and use a rocking motion to separate the pin and
socket halves. Two-, three-, four- and six-pin Deutsch
connectors have one external latch, while eight- and
twelve-pin connectors have two, both of which must be
pressed simultaneously to separate the connector
halves.
NOTE
Figure 5-7. Depress Terminal Latches/Back Out Pins
With few exceptions, the socket housing can always be found
on the accessory side, while the pin side of the connector is
connected to the wiring harness. NOTE
An ELECTRICAL TERMINAL CRIMP TOOL (Part No. HD-
REMOVING/INSTALLING SOCKETS 39965) is used to install Deutsch pin and socket terminals on
wires. If new terminals must be installed, follow the instruc-
tions included with the crimping tool or see Crimping Instruc-
1. See Figure 5-7. Remove the secondary locking wedge. tions in this section.
Insert the blade of a small screwdriver between the
socket housing and locking wedge inline with the groove Fit rear wire seal into back of socket housing, if removed.
(inline with the pin holes if the groove is absent). Turn the Grasp socket approximately 1.0 in. (25.4 mm) behind the
screwdriver 90 degrees to pop the wedge up. contact barrel. Gently push sockets through holes in wire seal
2. See Figure 5-8. Gently depress terminal latches inside into their respective chambers. Feed socket into chamber
socket housing and back out sockets through holes in until it “clicks” in place. Verify that socket will not back out of
rear wire seal. chamber; a slight tug on the wire will confirm that it is properly
locked in place.

HOME
d0248x8x
Wire seal
Pin housing
Pin
terminal
Locking wedge
Locking wedge
Internal seal
Latch cover
Alignment grooves
Socket housing
Wire seal
Alignment tabs Seal pin
External latch
Socket terminal
Figure 5-8. 12-pin Deutsch Connector (Exploded View)
3. Install internal seal on lip of socket housing, if removed.

d0249x3x
Insert tapered end of secondary locking wedge 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. Pin
NOTES housing
● While rectangular wedges do not require a special orien-
tation, the conical secondary locking wedge of the 3-pin
connector must be installed with the arrow pointing
Arrow points to
toward the external latch. See Figure 5-9.
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.
REMOVING/INSTALLING PINS Socket

housing
1. Remove the secondary locking wedge. Use the hooked
end of a stiff piece of mechanics wire a needle nose pli-
ers, or a suitable pick tool (Part No. HD-41475-100). See
Figure 5-10.
Figure 5-9. Depress Terminal Latches/Back Out Pins
2. Gently depress terminal latches inside pin housing and
back out pins through holes in wire seal.

HOME
NOTE
h41475-100
An ELECTRICAL TERMINAL CRIMP TOOL (Part No. HD-
39965) is used to install Deutsch pin and socket terminals on
wires. If new terminals must be installed, see Crimping
Instructions in this section.
3. Fit wire seal into back of pin housing. Grasp crimped pin
approximately 1.0 in. (25.4 mm) behind the contact bar-
rel. Gently push pins through holes in wire seal into their Figure 5-10. Deutsch Connector Pick Tool
respective numbered locations. Feed pin into chamber (Part No. HD-41475-100)
until it “clicks” in place. Verify that pin will not back out of
chamber; a slight tug on the wire will confirm that it is
properly locked in place.
4. Insert tapered end of secondary locking wedge into pin
housing and press down until it snaps in place. The 5893
Lock tab
wedge fits in the center groove within the pin housing
and holds the terminal latches tightly closed.
NOTES
● While rectangular wedges do not require a special orien-
tation, the conical secondary locking wedge of the 3-pin Lock bar
connector must be installed with the arrow pointing
toward the external latch. See Figure 5-9.
● 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
5892
installed position.
Pin housing
ASSEMBLING/INSTALLING
1. Insert socket housing into pin housing until it snaps in
place. Two-, three-, four- and six-pin Deutsch connectors
have one external latch on the socket half of the connec-
tor. To fit the halves of the connector together, the latch
on the socket side must be aligned with the latch cover
Attachment clip
on the pin side.
For those connectors with two external latches (8-pin
and 12-pin), a different system is used to prevent
5891
improper assembly. Align the tabs on the socket housing
with the grooves on the pin housing. Push the connector
halves together until the latches “click.” If latches do not
click (latch), press on one side of the connector until that
latch engages, then press on the opposite side to
engage the other latch.
NOTE
Deutsch connectors are color coded for location purposes.
Those connectors associated with left side accessories, such
Attachment clip installed
as the front and rear left turn signals, are gray. All other con-
nectors, including those associated with right side accesso-
ries, are black.
Figure 5-11. Attachment Clip Installation
If it should become necessary to replace a plug or receptacle,
please note that the 8-pin and 12-pin gray and black connec-
tors are not interchangeable. Since location of the alignment 2. See Figure 5-11. Fit the attachment clip to the pin hous-
tabs differ between the black and gray connectors, plugs or ing, if removed. Place large end of slot on attachment
receptacles must be replaced by those of the same color. If clip over T-stud on frame. Push assembly forward to
replacing both the socket and pin halves, then the black may engage small end of slot.
be substituted for the gray, and vice versa. The socket and pin
halves of all other connectors are interchangeable, that is, the
black may be mated with the gray, since the alignment tabs
are absent and the orientation of the external latch is the
same.

HOME
d0250x8x
Locking bar
1. Insert contact through middle 2. Insert stripped lead until it

hole in locking bar. contacts locking bar.
3. Close and squeeze crimp tool 4. Raise locking bar and remove
contact.
Insulation crimp Core crimp
Figure 5-12. Deutsch Crimping Procedure
CRIMPING INSTRUCTIONS 4. Strip lead removing 5/32 in. (4 mm) of insulation. Insert
wires between crimp tails until ends make contact with
locking bar. Verify that wire is positioned so that short
1. See Figure 5-12. Squeeze the handles to cycle the crimp pair of crimp tails squeeze bare wire strands, while long
tool to the fully open position. pair folds over insulation material.
2. Raise locking bar by pushing up on bottom flange. With 5. Squeeze handle of crimp tool until tightly closed. Tool
the crimp tails facing upward and the rounded side of the automatically opens when the crimping sequence is
contact barrel resting on the concave split level area of complete. Raise up locking bar and remove contact.
the crimp tool, insert contact (socket/pin) through middle 6. Inspect the quality of the core and insulation crimps. Dis-
hole of locking bar. tortion should be minimal.
3. Release locking bar to lock position of contact. If the
crimp tails are slightly out of vertical alignment, the crimp
tool automatically rotates the contact so that the tails
face straight upward. When correctly positioned, the
locking bar fits snugly in the space between the contact
band and the core crimp tails.

HOME
d0251x3x
11
10
9
8
7
6 2-pin connector
5
1
11 3
10
9
8
7
6
5 3-pin connector
1
11 3
10
9
8
7
6
5 4-pin connector
2
SOCKET SIDE PIN SIDE
1. Socket terminal 7. Locking wedge
2. Wire seal 8. Latch cover 1
3. Socket housing 9. Pin housing
4. External latch 10. Wire seal
3
5. Internal seal 11. Pin terminal
6. Locking wedge
Figure 5-13. 2-Pin, 3-pin and 4-pin Deutsch Connectors

HOME
MINI-DEUTSCH CONNECTORS 5.4
GENERAL d0253x8x
For Size 20, 16 and 12 Contacts

Wire Range 26-12 AWG
t not
D tool mus
This HAN
Mini-Deutsch connectors make use of a solid barrel contact be used in
"PRESS''
any powered
as defined
by
(46)
1910.211
OSHA CFR
without crimp tails. As a result, a special TERMINAL CRIMP
TOOL (Part No. HD-42879) is needed to install pin and
socket terminals on wires.
d0252x8x
1 3
not
tool must
This HAND d
any powere
be used in by
as defined
"PRESS'' (46)
1910.211
OSHA CFR
2 Figure 5-15. Selector Knob
4 1. Indentor cover
2. Contact
3. Indentor points
1. Adjusting screw
2. Locknut 1
3. Locking pin
4. Selector knob 2
Figure 5-14. Deutsch Solid Barrel Contact Crimp Tool
(Part No. HD-42879)
HE
CRIMPING INSTRUCTIONS HE MET
ME R
T, C YAN
A. A IN
92 IRPO USTRIA
D
34
3-0 RT, L
1. Squeeze the handles to cycle the crimp tool to the fully 16 P.O
PR
OD
UC
open position.
HD 1
(71 . BOX DIV
4)
TS
T- 92 878
9-1
2. See Figure 5-14. Remove locking pin (3) from selector 3 48 20
-0
knob (4). J 0 DG
3. See Figure 5-15. Raise selector knob and rotate until 36
0-1
selected wire size stamped on wheel is aligned with d0254x8x
“SEL. NO.” arrow.
4. Loosen knurled locknut and turn adjusting screw clock- Figure 5-16. Indentor Points
wise (in) until it stops.
5. Turn tool over and drop contact into indentor cover hole
with the wire end out.
6. Turn adjusting screw counterclockwise (out) until contact
is flush with bottom of depression in indentor cover.
Tighten knurled locknut.
7. See Figure 5-16. Slowly squeeze handles of crimp tool
until contact (2) is centered between indentor points (3).

HOME
8. Strip wire lead removing 1/4 in. (6.3 mm) of insulation.
9. See Figure 5-17. Insert bare wire strands into contact
barrel.
10. Squeeze handle of crimp tool until tightly closed. Tool
complete.
11. Remove crimped contact from indentor.
HE
HE MET
12. Inspect the quality of the crimp. Verify that all wire ME R
T, C YAN
A. A
strands are in crimp barrel. IN
92 IRPO USTRIA
34
D
3-0 RT, L
PR
OD
16 P.O UC
NOTE HD 1
(71 . BOX DIVISIO
4)
TS
T- 92 878
9-1
N
Tool must be readjusted when changing contact size/type. 48 20

0
-0
13. Install pin to lock position of selector knob. J 0 DG
36
0-1
d0255x8x
Figure 5-17. Contact Barrel

HOME
SEALED BUTT SPLICE CONNECTORS 5.5
INSTALLATION
Red
Blue
Butt splicing may be a necessary procedure for the replace-
ment of some components.
1. Strip 3/8 in. (9.5 mm) of insulation off the ends of the
wires.
Yellow
2. Compress the handles of the Packard Crimp Tool (HD-
38125-8) until the ratchet automatically opens.
3. See Table 5-2. Since the size of the connectors varies

with the gauge of the wire, always used the correct com-
ponents when creating sealed splices. d0256x8x
4. See Figure 5-18. Determine the correct dye or nest for Figure 5-18. Packard Crimp Tool
the crimping operation. Match the color or gauge wire (Part No. HD-38125-8)
marked on the butt splice connector with the correspond-
ing crimp cavity on the crimp tool.
5. Gently apply pressure to the handles until the crimper d0257x8x
lightly secures one side of the metal insert inside the butt
splice connector. The connector must be crimped in two
stages; one side then the other.
6. See Figure 5-19. Feed the wire into the butt splice con- Metal insert
nector until the stripped end contacts the wire stop inside
the metal insert.
Crimp wire ends
7. Squeeze the handles of the crimp tool until tightly closed.
The tool automatically opens when the crimping
sequence is complete.
8. Repeat steps 5, 6, and 7 on the other side of the butt

splice connector.
NOTE Melted sealant after heating/cooling

If adjacent wires are being spliced, stagger the splices so that
the butt splice connectors are spaced at different positions
along the length of the wires.
1WARNING Figure 5-19. Installing Sealed Butt Splice Connectors
Use caution when operating the UltraTorch UT-100 or any

other radiant heating device. Read the manufacturers
instructions carefully before use. Always keep hands Table 5-2. Common Sealed Splices
away from tool tip area and heat shrink attachment.
CONNECTOR
Avoid directing the heat toward any fuel system compo- GAUGE WIRE PART NO.
COLOR
nent. Extreme heat can cause fuel ignition or explosion.
Avoid directing heat toward any electrical system com- 18-20 Red 70585-93
ponent other than the connectors on which heat shrink
14-16 Blue 70586-93
work is being performed. Be sure to turn the “ON/OFF”
switch to the “OFF” position after use. Improper handling 10-12 Yellow 70587-93
could result in death or serious injury.
NOTE
9. Using the UltraTorch UT-100 (Part No. HD-39969), Robi-
nair Heat Gun (Part No. HD-25070) with heat shrink It is acceptable for the splice to rest against the heat shrink
attachment (Part No. HD-41183) or other suitable radiant tool attachment.
heating device, heat the crimped splice to encapsulate
the butt splice connection. Apply heat from the center of 10. Heat the center of the splice until the crimp indentations
the crimp out to each end until the meltable sealant disappear and the tubing assumes a smooth cylindrical
exudes out both ends of the connector. appearance.

HOME
PACKARD ELECTRICAL CONNECTORS 5.6
GENERAL Unlike most connectors, where the terminals are pulled out
the wire end of the connector, to remove the terminals from
From a servicing standpoint, there are two basic types of the pull-to-seat connectors, the terminal is pushed out the
Packard electrical connectors, those with pull-to-seat termi- mating end of the connector. Once a new terminal is crimped
nals and those with push-to-seat terminals. onto the end of the wire, the wire is pulled to draw the termi-
nal back inside the chamber of the connector housing.
Look into the mating end of the connector. If it appears that
the terminal can be extracted from this side, then it is proba-
bly the pull-to-seat type. Two types of Packard pull-to-seat electrical connectors are
used. One type has an external latch to lock the pin and
At least one Packard pull-to-seat terminal can be easily rec-
socket halves together, while the other makes use of a wire-
ognized by the presence of a locking ear. The ear engages a
form. See Figure 5-20. The manner in which the terminals are
slot in the connector housing and prevents the terminal from
being removed from the wire end side of the connector. The picked differs between these two types of connectors, as fur-
ear also acts as a strain relief in the event that the wires are ther described below.
pulled and further inhibits movement of the terminal inside
the chamber.
d0258x8x
A C
Locate tang on latch side of chamber. Push on wire end of lead to
remove terminal.
B D
Pivot end of pin to depress tang.
Raise tang and re-install terminal.
Figure 5-20. Packard Connectors

HOME
PULL-TO-SEAT TERMINALS Installing External Latch Type

NOTE
For wire location purposes, alpha characters are stamped
Removing External Latch Type into the socket housings.
To remove a pull-to-seat terminal from connectors with exter-
1. To install a terminal back into the chamber of the connec-
nal latches, proceed as follows:
tor housing, use a thin flat blade, like that on an X-Acto
1. Remove the connector from the retaining device, if knife, and carefully bend the tang outward away from the
present. terminal body. See D in Figure 5-20.
2. Bend back the external latch(es) slightly and separate 2. Gently pull on the lead at the wire end of the connector to
the pin and socket halves of the connector. draw the terminal back into the chamber. A click is heard
3. To free a pull-to-seat terminal from the connector hous- when the terminal is properly seated.
ing, first look into the mating end of the connector to find 3. Push on the lead to verify that the terminal is locked in
the locking tang. See A in Figure 5-20. The tangs are place.
always positioned in the middle of the chamber and are 4. Push the pin and socket halves of the connector together
on the same side as the external latch. On those connec- until the latches “click.”
tors with locking ears, the tang is on the side opposite
the ear.
4. At a slight angle, gently insert the point of a one inch PUSH-TO-SEAT TERMINALS
safety pin down the middle of the chamber (about 1/8
inch) and pivot the end of the pin toward the terminal
body. When a click is heard, remove the pin and repeat Removing Push-to-Seat Terminals
the procedure. See B in Figure 5-20. The click is the Like most connectors, Packard push-to-seat terminals are
sound of the tang returning to the locked position as it pulled out the wire end of the connector. To remove a push-
slips from the point of the pin. Pick at the tang in this to-seat terminal, proceed as follows:
manner until the clicking stops and the pin seems to slide
in at a slightly greater depth than it had previously. This is 1. Remove the connector from the retaining device, if
an indication that the tang has been depressed. present.
2. Bend back the external latch(es) slightly and separate
NOTES
the pin and socket halves of the connector.
● On those terminals that have been extracted on a previ-
ous occasion, no clicking sound may be heard when the NOTE
pin is pivoted to depress the tang, but proceed as if the Both the Ignition Light/Key Switch and the Main Power con-
clicking is audible and then push on the wire end of the nectors are provided with secondary locks. The secondary
lead to check if the terminal is free. lock, which may be molded onto the connector or exist as a
separate piece, aids in terminal retention. Secondary locks
● When picking multiple terminals, the end of the pin may must be opened (or removed) before the terminals can be
become malleable. For best results, continue the proce- extracted from the connector housing.
dure with a new safety pin.
5. Remove the pin and push on the wire end of the lead to
extract the terminal from the mating end of the connec-
tor. See C in Figure 5-20. If necessary, pull back the con-
duit and remove the wire seal at the back of the
connector to introduce some slack in the wires.
NOTE
A series of Packard Electrical Terminal Crimp Tools are avail-
able to install Packard pin and socket terminals on wires. If
new terminals must be installed, see Crimping Instructions.

HOME
3. Open or remove the secondary lock. Ignition Switch:
d0259x8x
Bend back the latch slightly and free one side of the sec- Tool tip
ondary lock, then repeat the step to release the other
side. Rotate the secondary lock outward on hinge to
access the terminals in the chambers of the connector
housing.
4. Looking in the mating end or terminal side of the connec-
tor (opposite the secondary lock), take note of the larger
cavity next to each terminal.
5. Insert the pick (Snap-On TT600-3) into the cavity until it
stops. Pivot the end of the pick toward the terminal to
depress the locking tang. Remove the pick and gently
tug on the wire to pull the terminal from the wire end of
the connector. Repeat the step if the terminal is still
locked in place.
NOTE
A series of Packard Electrical Terminal Crimp Tools are avail- Packard 115 Packard 271
able to install Packard pin and socket terminals on wires. If
new terminals must be installed, see Crimping Instructions.
Installing Push-to-Seat Terminals Figure 5-21. Packard Terminal Crimp Tools
NOTE
For wire location purposes, alpha characters are stamped
onto the secondary locks or onto the wire end of the connec- Table 5-3. Packard Terminal Crimp Tools
tor housing.
SPECIFICATION PACKARD 115 PACKARD 271
1. To install a terminal back into the chamber of the connec-
tor housing, use a thin flat blade, like that on an X-Acto Part No. HD-38125-8 HD-38125-7
knife, and carefully bend the tang outward away from the Non-sealed
terminal body. Non-sealed
Type of Crimp terminals,
terminals
2. Push the lead into the chamber at the wire end of the butt splices
connector. A click is heard when the terminal is properly Dye/nests F-G A-E
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. Close or install the secondary lock. Ignition Switch:
Rotate the hinged secondary lock inward until tabs fully
engage latches on both sides of connector.
5. Push the pin and socket halves of the connector together
until the latches “click.”
6. Install connector on retaining device, if present.
CRIMPING INSTRUCTIONS
1. Strip wire lead removing 5/32 in. (4 mm) of insulation.
2. Compress handles until ratchet automatically opens.
NOTE
Always perform core crimp before insulation/seal crimp.
3. Determine the correct dye or nest for the core crimp by
checking with the appropriate crimp table.
NOTE
When the word “TIP” appears in the Crimp Table, use the tip
of the tool specified to perform the core crimp procedure. See
Figure 5-21.

HOME
4. Lay the back of the core crimp tails on the appropriate
d0259x8x
nest. Be sure the core crimp tails are pointing towards
the forming jaws.
5. Gently apply pressure to handles of tool until crimpers 1 2
slightly secure the core crimp tails.
3
6. Insert stripped wire between crimp tails. Verify that wire
is positioned so that short pair of crimp tails squeeze
bare wire strands, while long pair folds over insulation or
seal material.
complete.
8. Determine the correct dye or nest for the insulation/seal
crimp. 1. Insulation
9. Lay the back of the insulation/seal crimp tails on the 2. Insulation crimp
appropriate nest. Be sure the insulation/seal crimp tails 3. Core crimp
are pointing towards the forming jaws.
Figure 5-22. Inspect Core and Insulation/Seal Crimps
complete.
11. See Figure 5-22. Inspect the quality of the core (3) and
insulation/seal (2) crimps. Distortion should be minimal.

HOME
INDEX TO WIRING DIAGRAMS 5.7
Table 5-4. Wiring Diagrams
DIAGRAM PAGE
2003 ALL DYNA DOM. and INT. MODELS (Except FXDWG), MAIN HARNESS 5-19
2003 ALL DYNA DOM. and INT. MODELS (Except FXDWG), LIGHTS, INST. & IND. 5-20
2003 ALL DYNA DOM. and INT. MODELS (Except FXDWG), LIGHTS, PAGE 1 OF 2 5-21
2003 ALL DYNA DOM. and INT. MODELS (Except FXDWG), LIGHTS, PAGE 2 OF 2 5-22
2003 ALL DYNA DOM. and INT. MODELS (Except FXDWG), HORN & INSTRUMENTS CIRCUIT, PAGE 1
5-23
OF 2
2003 ALL DYNA DOM. and INT. MODELS (Except FXDWG), HORN & INSTRUMENTS CIRCUIT, PAGE
5-24
2 OF 2
2003 ALL DYNA DOM. and INT. MODELS (Except FXDWG), CHARGING CIRCUIT 5-25
2003 ALL DYNA DOM. and INT. MODELS (Except FXDWG), STARTING CIRCUIT 5-26
2003 ALL DYNA DOM. and INT. MODELS (Except FXDWG), IGNITION CIRCUIT 5-27
2003 ALL DYNA DOM. and INT. MODELS (Except FXDWG), SECURITY, PAGE 1 OF 2 5-28
2003 ALL DYNA DOM. and INT. MODELS (Except FXDWG), SECURITY, PAGE 2 OF 2 5-29
2003 ALL FXDWG DOM. and INT. MODELS, MAIN HARNESS 5-30
2003 ALL FXDWG DOM. and INT. MODELS, LIGHTS, SPEEDO. & INDICATORS 5-31
2003 ALL FXDWG DOM. and INT. MODELS, HORN & INSTRUMENTS, PAGE 1 OF 2 5-32
2003 ALL FXDWG DOM. and INT. MODELS, HORN & INSTRUMENTS, PAGE 2 OF 2 & CHARGING 5-33
2003 ALL FXDWG DOM. and INT. MODELS, IGNITION CIRCUIT 5-34
2003 ALL FXDWG DOM. and INT. MODELS, LIGHTS, PAGE 1 OF 2 5-35
2003 ALL FXDWG DOM. and INT. MODELS, LIGHTS, PAGE 2 OF 2 5-36
2003 ALL FXDWG DOM. and INT. MODELS, STARTING CIRCUIT 5-37
2003 ALL FXDWG DOM. and INT. MODELS, SECURITY CIRCUIT, PAGE 1 OF 2 5-38
2003 ALL FXDWG DOM. and INT. MODELS, SECURITY CIRCUIT, PAGE 2 OF 2 5-39

HOME
CRANK POSITION
SENSOR
HAND CONTROLS,
RIGHT START
[ 162 ] RELAY 70103-96 BK
FUEL GAUGE OIL STATOR
GN/Y
PRESSURE
MANIFOLD SENDING
TO FUEL LEVEL AIR BATTERY
FRONT TURN SENDING UNIT [120] UNIT [62A]
RIGHT TURN SWITCH PRESSURE
SENSOR 85 86 30 87a 87
SIGNALS ENGINE STOP/RUN
R BK
SWITCH
PAGE 2
BK
START SWITCH BK Y/W S UE TK
6 5 4 3 2 1 BK
STOPLIGHT SWITCH
O [62B] 70102-96
[31A]
BK/R
R/BK
BK
BN
TN/GN
BK
BE
BE
GN
V
[140A] STARTER
[80A] [79A] TO
W/BN
W/BK
BK
BK
1 2
BK/R
O/W
A B C
GY
R/Y
2 1 HEADLAMP VOLTAGE
PAGE 2 REGULATOR
[22B] 2 1 1 2
[117A] [46B]
A B C 4 3 2 1
6 5 4 3 2 1 [79B] [140B] 1 2
1 2 [80B] [38A]
FULL:39.5/27.5 OHMS
GN/Y
O/W
BK
6 5 4 3 2 1 1/2: 118.0/97.0 OHMS
W
Y
1 2
BK
BK/W
1 2
V/W
[128B]
R/W
EMPTY: 260.0/240.0 OHMS [128A]
BK
[22A]
R
O/W
W/BN
GN
[46A]
W/BK
BK/R
BK
[117B]
O
R/Y
GY
BK
BK
COPPER
STUD
R
[64B] BK
[5 ]
CIRCUIT
GY R/BK 30 AMP
BATTERY 1 BN/GY
IGNITION 2 GY A INSTR: 15A B IGNITION
VSS / SERIAL DATA LINK 3 W/GN O R/BK [33A] [33B] SWITCH
SECURITY INDICATOR 4 BN/V
LEFT TURN FEED 5 V R A A R
RIGHT TURN FEED 6 BN M LIGHTS: 15A O R/GY B B R/GY
RIGHT TURN SWITCH INPUT 7 W/BN BE R/BK R/BK C C R/BK
GROUND 12 BK
BN/GY R
[30A] [30B]
1 O/W
2 W/GN
3 BN
4 W
TO 5 V
SPEEDO 6 O
PAGE 2 7 PK
8 TN
9 GN/Y
10 BK/Y
11 BN/V
12 BK
LGN/BN
BN/GY
BK
[20A]
TN
BK
LGN/GY
[142B]
LTGN/R
LTGN/R
W/BK
W/BK
A B C
Y/BE
BK/W
W/BK
BE/O
BE/O
V/W
BK/Y
Y/BE
BK
BK
R/W
BK
BK
O/W
BK
V/R
PK
BK
BK
BK
V/R
R/Y
BN
BK
BK
BE
BK
[7A]
POWER
ALARM
GND
[83B]
[11B] [10B] [91A]
O/W
Y/BK
W/V
CB A
BE
W
4 3 2 1 1 2 3 4 5 6 7 8
O/W
3
Y
1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 [142A]
R/Y
NEUTRAL 1 2
SWITCH
C B A
Y/BK
[131] 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 DATA LINK TO REAR LIGHTING

[24A] PAGE 2
HORN 1 2 3 4 5 6 [11A] IGNITION
[83A] OPTIONAL
COIL SECURITY
REAR IGNITION MODULE
1 2 3 4 5 6
STOPLIGHT
[24B] SWITCH
BK [121]
O/W
Y/BK
W/V
BE
W
[122 ]
Y
Wire Color Code Key

BK - Black GN - Green LT.GN - Light Green PIN CONNECTOR
HORN SWITCH (A side)
COMPONENTS LOCATED UNDER LEFT SIDE COVER BN - Brown BE - Blue PK - Pink
IGNITION SWITCH LEGEND HEADLAMP HI/LO INSTRUMENTS R - Red V - Violet TN - Tan SOCKET CONNECTOR
START RELAY
SWITCH (B side)
SWITCH RED/BLACK RED RED/GRAY F E D C B A B A O - Orange GY - Gray Wire color-XX/XX-Stripe color
POSITION LEFT TURN SWITCH 15A
HORN GROUND WIRE SECURITY
E C Y - Yellow W - White
OFF IGNITION
ACC. P/N 70392-99 L K J I H G K I H G
IGNITION
HAND CONTROLS, 15A 15A
LEFT ACCESSORIES LIGHTS R Q P
U T S
DOT INDICATES CONTINUITY WITH RED [163] U S R P O M O M
WIRE IN SWITCH POSITION INDICATED 15A 15A 19010-01 1 All 7/10/2000
TOP VIEW TOP VIEW
2003 ALL DYNA DOM. and INT. MODELS (Except FXDWG), MAIN HARNESS
5-19
HOME
SPEEDOMETER
POSITION LAMP
HDI ONLY
RIGHT
[38B]
TURN [190]
SPEED SENSOR GROUND

VEHICLE SPEED SIGNAL
O/W 1
TRIP SWITCH RETURN

TO MAIN
SPEED SENSOR PWR

W 2
[212] HARNESS
CHECK ENGINE LP
Y 3
OUTPUT SPEED
[38A]
PURSUIT LAMP
BK 4 V/BN RIGHT
SECURITY LP
TRIP SWITCH
ACCESSORY
BK TURN
DATA BUS
HEADLAMP
GROUND
[39A]
FUNCTION/
TRIPOMETER
RESET SWITCH [154]
1 2 3 4 5 6 7 8 9 101112 [31B]
[39B]
BK 1
GY
BN 2
BN/V
BE 3 TO MAIN TO MAIN HARNESS [7A]
GY
W/GN
HARNESS
BK
W
BK/Y
R
BE 4
O/W
BK
[38 ] DOM ONLY V 5 [31A] 1 2 3 4 5 6 7 8
BK 6 P/N 68762-99
[7B]
LEFT
TURN
[214]
O/W
R/Y
BN
BK
BE
V
BRAKE LIGHT
[94B] TAIL LAMP
[ 20B]
6 5 4 3 2 1 [198 ]
TACHOMETER O/W 1
[108] W/GN 2 6 5 4 3 2 1
BN 3 [19B] [94A]
GROUND TACH W 4 [19A]
SIGNAL V 5 1 1
POWER TO MAIN
O 6 2 2
NOT PK HARNESS
7
USED
TN [20A]
[108A] 8
1 2 3 4 5 6 GN/Y 9 [18B]
BK/Y 10 RUNNING LIGHT (HDI)
1 2 3 4 5 6 BN/V 11 1 1 [18A]
BK 12 2 2 RUNNING LIGHT (DOM)
[108B]
4 4 BK
1 3 3 R/Y
BK
PK
O
2 2 2 O/W
3 1 1 BE
[ 194]
[93A] [93B]
V/BN LEFT
BK
GN/Y
CONNECTOR USED TURN

BN
TN
BK
W
ON FXDL ONLY
BK
O
O
BK
V
SPEED SENSOR
P/N 74420-94 [21A]
+12VDC
1 2 3 4 5 6 7 8 9 10
SENSOR
OUTPUT
R A A R 1 2 3 4 5 6 7 8 9 10
W B B W
BK C C BK [21B]
[65A] [65B]
GROUND
LT HB N + OP + RT
V BK w BK TN O GN/Y O BK BN

INDICATOR BEAM [157] [158 ] INDICATOR
[155] [156] [159]
19010-01 2 ALL 7/12/2000
2003 ALL DYNA DOM. and INT. MODELS (Except FXDWG), LIGHTS, INST. & IND.
5-20
HOME
HAND CONTROLS,
RIGHT
[162]
70103-96 BK
BATTERY
RIGHT TURN SWITCH
TO FRONT
ENGINE STOP/RUN
TURN SIGNALS SWITCH
PAGE 2
BK
START SWITCH
6 5 4 3 2 1 STOPLIGHT SWITCH 70102-96
[31A]
BK
BN
BK
BE
BE
STARTER
V
TO
W/BN
O/W
R/Y
HEADLAMP
PAGE 2
[22B]
4 3 2 1
6 5 4 3 2 1
[38A]
O/W
W
BK
6 5 4 3 2 1
BK
[22A]
O/W
W/BN
R/Y
COPPER
R STUD
[64B]
[5 ] CIRCUIT
GY R/BK 30 AMP
BATTERY 1 BN/GY
IGNITION 2 GY A INSTR: 15A B IGNITION
VSS / SERIAL DATA LINK 3 W/GN R/BK [33A] [33B]
SWITCH
SECURITY INDICATOR 4
LEFT TURN FEED 5 V R A A R
RIGHT TURN FEED 6 BN M LIGHTS: 15A O R/GY B B R/GY
RIGHT TURN SWITCH INPUT 7 W/BN BE R/BK R/BK C C R/BK
IGNITION ENABLE SIGNAL 10 P ACCY: 15A R
ALARM SIGNAL 11 O/W R/GY
GROUND 12 BK
BN/GY R
[30A] [30B]
1 O/W
2 W/GN
3 BN
4 W
TO 5 V
SPEEDO 6
PAGE 2 7
8
9
10
11
12 BK
[20A]
BK
BK
BK
O/W
R/Y
BN
BK
BK
BE
BK
V
[7A]
O/W
W/V
BE
W
1 2 3 4 5 6 7 8
O/W
3
Y
R/Y
1 2
[24A] TO REAR LIGHTING

[GND1] PAGE 2
1 2 3 4 5 6
REAR
STOPLIGHT
1 2 3 4 5 6 SWITCH
[24B]
[121]
O/W
W/V
BE
W
Y
HORN SWITCH
HEADLAMP HI/LO
SWITCH
LEFT TURN SWITCH COMPONENTS LOCATED UNDER LEFT SIDE COVER
Wire Color Code Key IGNITION SWITCH LEGEND INSTRUMENTS START RELAY
F E D C B A B A
BK - Black GN - Green LT.GN - Light Green PIN CONNECTOR HAND CONTROLS, SWITCH RED/BLACK RED RED/GRAY
(A side) 15A
POSITION E C
BN - Brown BE - Blue PK - Pink LEFT OFF
SECURITY IGNITION
R - Red V - Violet TN - Tan SOCKET CONNECTOR [163] ACC.

L K J I H G K I H G
15A 15A
O - Orange GY - Gray Wire color-XX/XX-Stripe color (B side) IGNITION ACCESSORIES LIGHTS U T S R Q P
Y - Yellow W - White DOT INDICATES CONTINUITY WITH RED U S R P O M O M
15A 15A
TOP VIEW
19010-01 1 lighting 7/12/2000
TOP VIEW
2003 ALL DYNA DOM. and INT. MODELS (Except FXDWG), LIGHTS, PAGE 1 OF 2
5-21
HOME
POSITION LAMP
HDI ONLY
SPEED SENSOR GROUND

TRIP SWITCH RETURN
SPEED SENSOR PWR

CHECK ENGINE LP
OUTPUT SPEED
PURSUIT LAMP
SECURITY LP
TRIP SWITCH
ACCESSORY
RIGHT [38B]
DATA BUS
[39A]
GROUND
TURN
[190]
O/W
W TO MAIN
[ 212] Y HARNESS
BK [38A] V/BN
BK
HEADLAMP
1 2 3 4 5 6 7 8 9 10 11 12
[39B]
[31B]
W/GN
BK 1
O/W
BK
BN 2 TO MAIN
BE 3 TO MAIN HARNESS [7A]
HARNESS
BE 4
[38 ] [31A]
DOM ONLY V 5 1 2 3 4 5 6 7 8
BK 6 P/N 68762-99
[7B]
LEFT
TURN
RIGHT
TURN
[214]
O/W
R/Y
BN
BK
BE
V
BRAKE LIGHT
[94B] TAIL LAMP
6 5 4 3 2 1 [198 ]
[20B]
O/W 1 6 5 4 3 2 1
[19B] [94A]
W/GN 2
BN 3 TO MAIN 1 1 [19A]
W 4 HARNESS 2 2
V 5 [20A]
6
[18B]
7 RUNNING LIGHT (HDI)
[18A]
8 1 1
9 2 2 RUNNING LIGHT (DOM)
10
4 4 BK
11 1 3 3 R/Y
BK 12 2 2 2 O/W
3 1 1 BE
[194]
[93B]
[93A]
V/BN LEFT
BK TURN
CONNECTOR USED
BN
BK
W
BK
BK
ON FXDL ONLY
V
[21A ]
1 2 3 4 5 6 7 8 9 10
1 2 3 4 5 6 7 8 9 10
[21B]
LT HB RT
V BK w BK BK BN
LEFT HIGH RIGHT

[155] [156] [159]
19010-01 2 lighting 7/12/2000
2003 ALL DYNA DOM. and INT. MODELS (Except FXDWG), LIGHTS, PAGE 2 OF 2
5-22
HOME
FUEL GAUGE OIL 70103-96 BK
GN/Y
PRESSURE
SENDING
FUEL LEVEL UNIT
SENDING UNIT [120 ]
BATTERY
BK Y/W
BK
BK
70102-96
O
[140A] STARTER
1 2
FULL:39.5/27.5 OHMS
1/2: 118.0/97.0 OHMS 1 2
EMPTY: 260.0/240.0 OHMS [140B]
[117A] 1 2
GN/Y
1 2
BK
[117B]
BK
O
R COPPER
[64B] STUD
[5 ]
CIRCUIT
TURN SIGNAL/SECURITY MODULE BREAKER
30 AMP
BATTERY 1
IGNITION 2 A INSTR: 15A B
VSS / SERIAL DATA LINK 3 W/GN [33A] [33B] IGNITION
RIGHT TURN FEED 6 R/GY B B R/GY
IGNITION ENABLE SIGNAL 10 P ACCY: 15A R
ALARM SIGNAL 11 R/GY
GROUND 12
TS/TSSM
[30A] [30B]
1 O/W
2 W/GN
3
TO 4
SPEEDO 5
PAGE 2 6 O
7 PK
8 TN
9 GN/Y
10
11 Wire Color Code Key
12 BK
(A side)
TN
[20A] BN - Brown BE - Blue PK - Pink

BK

BK
BK
PK
[11B] [10B]
O/W
Y/BK
NEUTRAL 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 3
1 2
SWITCH
Y/BK
[24A] [131] 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12
GRAY BLACK [GND1] COMPONENTS LOCATED UNDER LEFT SIDE COVER
HORN 1 2 3 4 5 6 [11A] [10A]
IGNITION MODULE
1 2 3 4 5 6 F E D C B A B A
15A
E C
[24B] SECURITY IGNITION
BK L K J I H G H G
O/W
Y/BK
K I
15A 15A
ACCESSORIES LIGHTS U T S R Q P
[122 ]
U S R P O M O M
IGNITION SWITCH LEGEND 15A 15A
HORN SWITCH
SWITCH RED/BLACK RED RED/GRAY TOP VIEW TOP VIEW
HEADLAMP HI/LO POSITION
SWITCH OFF
HORN GROUND WIRE LEFT TURN SWITCH ACC.
P/N 70392-99 IGNITION

HAND CONTROLS, WIRE IN SWITCH POSITION INDICATED
19010-01 1 horn/inst 7/11/2000
LEFT
[163 ]
2003 ALL DYNA DOM. and INT. MODELS (Except FXDWG), HORN & INSTRUMENTS CIRCUIT, PAGE 1 OF 2
5-23
HOME
SPEEDOMETER
SPEED SENSOR GROUND

TRIP SWITCH RETURN
SPEED SENSOR PWR

CHECK ENGINE LP
OUTPUT SPEED
PURSUIT LAMP
SECURITY LP
TRIP SWITCH
ACCESSORY
[39A]
DATA BUS
GROUND
FUNCTION/
TRIPOMETER
RESET
SWITCH
1 2 3 4 5 6 7 8 9 101112
[39B]
[154 ]
GY
W/GN
GY
R
BK
[ 20B ]
TACHOMETER
O/W 1
[108] W/GN 2
3
GROUND TACH 4
SIGNAL 5
POWER
O 6 TO MAIN
NOT PK 7 HARNESS
USED
TN 8 [20A]
1 2 3 4 5 6 GN/Y 9
[108A] 10
1 2 3 4 5 6 11
[108B] BK 12
BK
PK
O
GN/Y
CONNECTOR USED
SPEED SENSOR
TN
ON FXDL ONLY
O
O
P/N 74420-94
+12VDC [ 21A]
SENSOR 1 2 3 4 5 6 7 8 9 10
OUTPUT
R A A R 1 2 3 4 5 6 7 8 9 10
W B B W
BK C C BK [ 21B]
[65A] [65B]
GROUND
N + OP +
TN O GN/Y O
NEUTRAL OIL
[157] [158]
19010-01 2 horn / inst 7/12/2000
2003 ALL DYNA DOM. and INT. MODELS (Except FXDWG), HORN & INSTRUMENTS CIRCUIT, PAGE 2 OF 2
5-24
HOME
70103-96 BK
STATOR
BATTERY
BK
70102-96
STARTER
BK
BK
VOLTAGE
REGULATOR
[46B]
1 2
BK
1 2
[46A]
BK
BK
COPPER
STUD
BK
[5 ]
CIRCUIT
BREAKER
30 AMP
Wire Color Code Key F E D C B A B A
15A
E C
PIN CONNECTOR SECURITY IGNITION
BK - Black GN - Green LT.GN - Light Green (A side) L K J I H G K I H G
BN - Brown BE - Blue PK - Pink 15A 15A
R - Red V - Violet TN - Tan SOCKET CONNECTOR ACCESSORIES LIGHTS U T S R Q P
O - Orange GY - Gray Wire color-XX/XX-Stripe color (B side) U S R P O M O M

15A 15A
TOP VIEW TOP VIEW
19010-01a 1 charge 7/13/2000
2003 ALL DYNA DOM. and INT. MODELS (Except FXDWG), CHARGING CIRCUIT
5-25
HOME
HAND CONTROLS,
RIGHT
[162] START
RELAY 70103-96 BK
BATTERY
RIGHT TURN SWITCH [62A]
ENGINE STOP/RUN 858630 87a87
SWITCH
BK
START SWITCH S U ET K
TN/GN
BK/R
R/BK
GN
STARTER
BK/R
GY
[22B]
6 5 4 3 2 1
6 5 4 3 2 1
BK
[22A]
BK/R
GY
R COPPER
STUD
[64B]
[5] CIRCUIT
TURN SIGNAL/SECURITY MODULE IGN: 15A BREAKER
GH 30 AMP
GY R/BK
BATTERY 1 BN/GY
IGNITION 2 GY
ALARM SIGNAL 11
GROUND 12 BK
BN/GY R
[30A][30B]
SWITCH RED/BLACK RED RED/GRAY
POSITION
OFF
ACC.
IGNITION

BK
F E D C B A B A
15A
3 E C
1 2 SECURITY IGNITION
L K J I H G K I H G
15A 15A
Wire Color Code Key [GND1] ACCESSORIES LIGHTS U T S R Q P
U S R P O M O M
BK - Black GN - Green LT.GN - Light Green PIN CONNECTOR 15A 15A

(A side)
BN - Brown BE - Blue PK - Pink TOP VIEW TOP VIEW
19010-01 1 STARTING 7/12/2000
2003 ALL DYNA DOM. and INT. MODELS (Except FXDWG), STARTING CIRCUIT
5-26
HOME
CRANK POSITION
SENSOR
HAND CONTROLS,
RIGHT
[162 ] 70103-96 BK
MANIFOLD
AIR BATTERY
ENGINE STOP/RUN SENSOR
SWITCH R BK
SPEEDOMETER
BK
START SWITCH
STARTER
[80A] [79A]
W/BK
A B C
GY
2 1
[22B] 2 1
A B C
6 5 4 3 2 1 [79B]
[80B]
SPEED SENSOR GROUND

6 5 4 3 2 1
BK
TRIP SWITCH RETURN
BK/W
SPEED SENSOR PWR
V/W
R/W
BK
[22A]
R
CHECK ENGINE LP
W/BK
OUTPUT SPEED
PURSUIT LAMP
GY
SECURITY LP
TRIP SWITCH
ACCESSORY
[39A]
DATA BUS
GROUND
R COPPER
STUD
1 2 3 4 5 6 7 8 9 101112 [64B]
[39B] [5 ]
CIRCUIT
GY R/BK 30 AMP
BK/Y
,
BATTERY 1
IGNITION 2 GY
ALARM SIGNAL 11
GROUND 12
TS/TSSM
[30A] [30B]
[20B ] [20A]
TACHOMETER 1 1
2 2
[108] 3
3
GROUND TACH 4 4
SIGNAL 5
POWER 5
6 6
NOT 7 PK
USED PK 7
8 8
1 2 3 4 5 6 [108A] 9 9
BK/Y 10 10 BK/Y
1 2 3 4 5 6 [108B] 11 11
12 12
PK
LGN/GY
LTGN/R
W/BK
LGN/R
W/BK
Y/BE
BK/W
W/BK
BE/O
BE/O
V/W
BK/Y
Y/BE
BK
BK
R/W
V/R
PK
BK
BK
V/R
BK
R
[11B] [83B]
[10B] [91A]
CB A 4 3 2 1
1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 3
1 2
1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 C B A DATA LINK
GRAY BLACK [GND1] [83A]
[11A] [10A] IGNITION
COIL
IGNITION MODULE

Wire Color Code Key IGNITION SWITCH LEGEND INSTRUMENTS START RELAY
F E D C B A B A
BK - Black GN - Green LT.GN - Light Green PIN CONNECTOR SWITCH RED/BLACK RED RED/GRAY
(A side) POSITION 15A
E C
BN - Brown BE - Blue PK - Pink OFF
SECURITY IGNITION
R - Red V - Violet TN - Tan SOCKET CONNECTOR ACC. L K J I H G K I H G

15A 15A
O - Orange GY - Gray Wire color-XX/XX-Stripe color (B side) IGNITION
ACCESSORIES LIGHTS U T S R Q P
Y - Yellow W - White DOT INDICATES CONTINUITY WITH RED U S R P O M O M
15A 15A
TOP VIEW TOP VIEW
19010-01 1+2 ignition 7/11/2000
2003 ALL DYNA DOM. and INT. MODELS (Except FXDWG), IGNITION CIRCUIT
5-27
HOME
HAND CONTROLS,
RIGHT START
[162 ] RELAY 70103-96 BK
TO RIGHT TURN SWITCH [62A] BATTERY

FRONT ENGINE STOP/RUN 85 86 30 87a 87
TURN SIGNALS SWITCH
PAGE 2
BK
START SWITCH S UE T K
6 5 4 3 2 1
[31A]
TN/GN
BK
BN
BK
BK/R
R/BK
V
STARTER
GN
W/BN
W/BK
BK/R
O/W
GY
[46B]
[22B]
6 5 4 3 2 1
6 5 4 3 2 1
BK
[128A] [128B]
[22A]
O/W
GN
[46A]
BK/R
W/BN
GY
R COPPER
[64B] STUD
[5 ]
CIRCUIT
GY R/BK 30 AMP
BATTERY 1 BN/GY
IGNITION 2 GY
SECURITY INDICATOR 4 BN/V SWITCH
LEFT TURN FEED 5 V R A A R,
RIGHT TURN FEED 6 BN R/GY B B R/GY
RIGHT TURN SWITCH INPUT 7 W/BN R/BK C C R/BK
GROUND 12 BK
BN/GY R
[30A] [30B]
1
2
3 BN
4
TO 5 V
SPEEDO 6
PAGE 2 7
[20A] 8
9
10
11 BN/V
12 BK
LGN/BN
BN/GY
BK
[142B]
LGN/GY
A B C
BK
BK
BK
BN
BK
BK
V
GND
ALARM
POWER
[11B] [7A]
W/V
O/W
[10B] [142A]
1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 3 1 2 3 4 5 6 7 8
1 2
1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12
TO
[24A] REAR LIGHTING
1 2 3 4 5 6 [11A] PAGE 2 OPTIONAL
SECURITY
IGNITION MODULE SIREN
1 2 3 4 5 6
[24B]
O/W
W/V

SWITCH RED/BLACK RED RED/GRAY HORN SWITCH INSTRUMENTS START RELAY
POSITION
HEADLAMP HI/LO Wire Color Code Key F E D C B A B A
OFF
SWITCH 15A
E C
ACC.
BK - Black GN - Green LT.GN - Light Green PIN CONNECTOR SECURITY IGNITION
IGNITION
LEFT TURN SWITCH (A side) L K J I H G K I H G
BN - Brown BE - Blue PK - Pink 15A 15A
DOT INDICATES CONTINUITY WITH RED R - Red V - Violet TN - Tan SOCKET CONNECTOR ACCESSORIES LIGHTS U T S R Q P
WIRE IN SWITCH POSITION INDICATED HAND CONTROLS, O - Orange GY - Gray Wire color-XX/XX-Stripe color (B side) U S R P O M O M
LEFT 15A 15A
[163 ]
TOP VIEW TOP VIEW
19010-01 1 security 7/12/2000
2003 ALL DYNA DOM. and INT. MODELS (Except FXDWG), SECURITY, PAGE 1 OF 2
5-28
HOME
SPEEDOMETER
RIGHT
TURN
SPEED SENSOR GROUND

TRIP SWITCH RETURN
SPEED SENSOR PWR

[190]
CHECK ENGINE LP
[ 212]
OUTPUT SPEED
PURSUIT LAMP
V/BN
SECURITY LP
TRIP SWITCH
ACCESSORY
[39A] BK
DATA BUS
GROUND
1 2 3 4 5 6 7 8 9 101112 [31B]
[39B] BK 1
BN 2
BN/V
3 TO MAIN
TO MAIN HARNESS [7A]
4 HARNESS
V 5 [31A]
1 2 3 4 5 6 7 8
BK 6 P/N 68762-99
[7B]
LEFT
TURN
[ 214]
BN
BK
V
[94B]
[20B] 6 5 4 3 2 1
1
2 6 5 4 3 2 1
BN 3 [94A]
[19B]
4
V 5 TO MAIN 1 [19A]
1
6 HARNESS 2 2
7 [20A]
8
9 [18B]
10
BN/V 1 [18A]
11 1
BK 12 2 2
4
1 3
2 2
3 1
[194]
[93A] [93B]
LEFT
TURN
V/BN
BK
BN
BK
BK
V
[21A ]
1 2 3 4 5 6 7 8 9 10
1 2 3 4 5 6 7 8 9 10
[ 21B]
LT RT
V BK BK BN
LEFT RIGHT
INDICATOR INDICATOR
[155] [159]
19010-01 2 security 7/13/2000
2003 ALL DYNA DOM. and INT. MODELS (Except FXDWG), SECURITY, PAGE 2 OF 2
5-29
HOME
FUEL GAUGE CRANK POSITION

HAND CONTROLS, FUEL LEVEL SENSOR
RIGHT SENDING UNIT
[162] ALARM SIREN 70103-96 BK,W310
STATOR
OPTIONAL
MANIFOLD
BK Y/W AIR
RIGHT TURN SWITCH BK
FULL:39.5/27.5 OHMS
PRESSURE [142A]
1/2: 118.0/97.0 OHMS
BK,W309
GROUND
ENGINE STOP/RUN SENSOR BATTERY
POWER
O
SIGNAL
EMPTY: 260.0/240.0 OHMS
SWITCH
START SWITCH R BK
A B C START
STOPLIGHT SWITCH RELAY 70102-96
[142B]
LGN/BN
STARTER
[79A]
BK
BN/GY
[117a] [80A]
TO [61A]
W/BN
W/BK
BK
BK
BK/R
O/W
A B C
GY
R/Y
1 2 1 2 HEADLAMP 85 86 30 87a 87
VOLTAGE
PAGE 2 [38A] REGULATOR
[22B] 1 2
A B C 1 2 1 2 3 4 [46B]
6 5 4 3 2 1 S UE T K
[117B] 1 2
[80B] [79B]
BK
O/W
[61B ]
TN/GN
BK
W
R/BK
Y
6 5 4 3 2 1
GN
BK/W
BK/R
[128A] 1 2
V/W
[128B]
R/W
GN
BK
BK
O
[22A]
R
[46A]
W/BN
W/BK
BK/R
O/W
BK
R/Y
GY
BK
R COPPER
[31A] STUD
[5 ] BK
1 BK CIRCUIT
TO 2 BN BREAKER
FRONT 3 BE 30 AMP
TURN 4 BE
SIGNALS
5 V G IGN 15A H
PAGE 2
6 BK GY R/BK
TURN SIGNAL/SECURITY MODULE A INSTR 15A B

O R/BK [ 33 ]
[30A] [30B] (REAR VIEW)
TSM/TSSM M LIGHTS 15A O
BATTERY 1 BN/GY BE R/BK
IGNITION 2 GY R/GY
ACCY 15A A IGNITION
VSS / SERIAL DATA LINK 3 W/GN P R R
SECURITY INDICATOR 4 BN/V O/W R/GY B SWITCH
R/BK
LEFT TURN FEED 5 V I
RIGHT TURN FEED 6 BN J SECURITY15A I
RIGHT TURN SWITCH INPUT 7 W/BN BN/GY R
LEFT TURN SWITCH INPUT 8 W/V
9 TN/GN [33B] [33A]
START RELAY CONTROL [64B]
ALARM SIGNAL 11 LGN/BN
GROUND 12 BK
BN
W
V
O/W
TO W/GN
SPEEDO TN
PAGE 2 GN/Y
BK/Y
BK
BK GN/Y
O
BN/V
TN
BK
[140A]
1 2
LTGN/R
BK
LGN/GY
LTGN/R
W/BK
W/BK
BK
BK
BE/O
Y/BE
V/R
BK
BK
BN
W/BK
O/W
BK/W
BE/O
1 2
V/W
BK/Y
Y/BE
R/Y
BK
R/W
BE
V/R
BK
BK
BK
BK
BK
PK
V
[11B] [83B]
R
[10B] [140B]
NEUTRAL
O/W
CB A [7A]
GN/Y
[91A]
BEW
SWITCH
Y/BK
W/V
Y
1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 3
R/Y
O/W
,
PK
1
W
[131] 4 3 2 1 1 2 3 4 5 6 7 8
C B A
Y/BK
1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12
[24A] DATA LINK TO REAR LIGHTING
BLACK [GND1]
1 2 3 4 5 6 GRAY [10A] [83A] PAGE 2
HORN [11A] IGNITION
REAR COIL
STOPLIGHT IGNITION MODULE OIL
1 2 3 4 5 6 PINK WIRE LOCATED AT
SWITCH SPEEDOMETER CONNECTOR AND PRESSURE
[24B] IS TAPED BACK TO THE SENDING
[121] WIRE HARNESS. UNIT
BK
O/W
Y/BK
[120]
W/V
BE
W
Y
[122]
HORN SWITCH COMPONENTS LOCATED UNDER LEFT SIDE COVER

HEADLAMP HI/LO
SWITCH INSTRUMENTS START RELAY
Wire Color Code Key
IGNITION SWITCH LEGEND LEFT TURN SWITCH
F E D C B A B A
HORN GROUND WIRE 15A
SWITCH RED/BLACK RED RED/GRAY P/N 70392-99 E C BK - Black GN - Green LT.GN - Light Green PIN CONNECTOR
SECURITY IGNITION
POSITION (A side)
OFF
L K J I H G K I H G BN - Brown BE - Blue PK - Pink
15A 15A
ACC. HAND CONTROLS, R - Red V - Violet TN - Tan SOCKET CONNECTOR
ACCESSORIES LIGHTS
IGNITION LEFT U T S R Q P O - Orange GY - Gray Wire color-XX/XX-Stripe color (B side)
U S R P O M O M
[163] 15A 15A Y - Yellow W - White
TOP VIEW TOP VIEW 19082-01 1 all 7/14/2000
2003 ALL FXDWG DOM. and INT. MODELS, MAIN HARNESS

5-30
HOME
POSITION LAMP
HDI ONLY
O/W
BK
SPEEDOMETER
RIGHT
TURN [38B]
O/W 1
TO MAIN
[212] W 2
HARNESS
Y 3
[38A]
BK 4
HEADLAMP TO MAIN HARNESS [7A]
W
[31B] 1 2 3 4 5 6 7 8
Y
BK
BK 1 [7B]
BN 2
SPEED SENSOR GROUND

TO MAIN

BE 3
O/W
R/Y
BN
BK
BE
TRIP SWITCH RETURN
HARNESS
V
SPEED SENSOR PWR
BE 4
5 [31A]
V
CHECK ENGINE LP
BK 6
OUTPUT SPEED
PURSUIT LAMP
[38] DOM ONLY

SECURITY LP
TRIP SWITCH
ACCESSORY
P/N 68764-99
DATA BUS
GROUND
LEFT [190]
[39A] TURN
RIGHT
[214] V/BN TURN
1 2 3 4 5 6 7 8 9101112 [39B] BK
TAIL LAMP
O/W
R/Y
BN
BK
BE
V
,
W/GN
BN/V
BK/Y
O/W
GY
GY
BK
BK
W
R
6 5 4 3 2 1 [94B]
6 5 4 3 2 1 [94A]
BN/V [19B]
O/W 1 1 [19A]
W/GN 2 2
W
V [198]
[18B]
O MAIN BRAKE LIGHT
BN HARNESS 1 1 [18A]
TN 2 2
GN/Y
BK/Y 4 4 BK
FUNCTION/ BK 1 3 3 R/Y
TRIPOMETER BK 2 2 2 O/W
RESET 3 1 1 BE
SWITCH
[154]
[93A] [93B]
[21A] 1 2 3 4 5 6 7 8
RUNNING LIGHT (HDI) RUNNING LIGHT (DOM)
[21B] 1 2 3 4 5 6 7 8
SPEED SENSOR
P/N 74420-94
GN/Y
BN
TN
BK
W
O
V
+12VDC [194]
SENSOR OUTPUT
R A A R LEFT
W B B W V/BN
BK C C BK TURN
BK
[65A] [65B]
GROUND
LT - HB - N + OP + - RT
V BK W BK TN O GN Y O BK BN
[155] [156] [157] [158] [159]

19082-01_2all 7/13/2000
2003 ALL FXDWG DOM. and INT. MODELS, LIGHTS, SPEEDO. & INDICATORS
5-31
HOME
FUEL GAUGE
FUEL LEVEL
SENDING UNIT 70103-96 BK
BK Y/W BATTERY
BK
O
BK
70102-96
FULL:39.5/27.5 OHMS
1/2: 118.0/97.0 OHMS STARTER
[117A]
EMPTY: 260.0/240.0 OHMS
1 2
1 2
[117B]
BK
BK
O
R COPPER
STUD
[5 ] CIRCUIT
BREAKER
30 AMP

A INSTR 15A B
[30A] [30B] O R/BK [ 33 ]
(REAR VIEW)
TSM/TSSM
BATTERY 1
IGNITION 2 R/GY
VSS / SERIAL DATA LINK 3 W/GN P ACCY 15A R A IGNITION
R
SECURITY INDICATOR 4 O/W R/GY B SWITCH
R/BK
LEFT TURN FEED 5 I
RIGHT TURN FEED 6
RIGHT TURN SWITCH INPUT 7
LEFT TURN SWITCH INPUT 8
START RELAY CONTROL 9 [64B] [33B] [33A]
ALARM SIGNAL 11
GROUND 12
O/W
W/GN
TN
TO GN/Y
SPEEDO
PAGE 2 BK
GN/Y
O
TN
BK
[140A]
1 2
BK
BK
1 2
PK
[10B]
[11B] [140B]
O/W
NEUTRAL
GN/Y
1 2 3 4 5 6 7 8 9 101112 1 2 3 4 5 6 7 8 9 101112 3
Y/BK
SWITCH 1 2
[ 131 ]
Y/BK
1 2 3 4 5 6 7 8 9 101112 1 2 3 4 5 6 7 8 9 101112
[24A] GRAY BLACK [GND1]
HORN [11A]
1 2 3 4 5 6 [10A]
OIL
IGNITION MODULE PINK WIRE LOCATED AT
1 2 3 4 5 6 PRESSURE
SPEEDOMETER CONNECTOR AND SENDING
[24B] IS TAPED BACK TO THE UNIT
BK [120 ]
O/W
Y/BK
WIRE HARNESS.
[122 ]

HORN SWITCH
HEADLAMP HI/LO
SWITCH Wire Color Code Key
F E D C B A B A
HORN GROUND WIRE LEFT TURN SWITCH 15A
P/N 70392-99 E C
SECURITY IGNITION
L K J I H G K I H G (A side)
15A 15A
IGNITION SWITCH LEGEND HAND CONTROLS ACCESSORIES LIGHTS R - Red V - Violet TN - Tan SOCKET CONNECTOR
LEFT U T S R Q P
U S R P O M O M O - Orange GY - Gray Wire color-XX/XX-Stripe color (B side)
SWITCH RED/BLACK RED RED/GRAY [163 15A 15A
POSITION Y - Yellow W - White
OFF
TOP VIEW TOP VIEW
ACC.
IGNITION
19082-01 1 horn/inst 7/13/2000
2003 ALL FXDWG DOM. and INT. MODELS, HORN & INSTRUMENTS, PAGE 1 OF 2
5-32
HOME
082-01-2horn_inst&chg.
SPEEDOMETER BATTERY
BK
SPEED SENSOR GROUND
TRIP SWITCH RETURN

SPEED SENSOR PWR
70102-96
CHECK ENGINE LP
OUTPUT SPEED
PURSUIT LAMP
SECURITY LP
TRIP SWITCH
ACCESSORY
DATA BUS
GROUND
[39A]
STARTER
BK
BK
1 2 3 4 5 6 7 8 9101112
[39B]
VOLTAGE
W/GN
O/W
GY
GY
BK
BK
W
R
REGULATOR
[46B]
O/W 1 2
BK
W/GN
O MAIN
TN
GN/Y
HARNESS
1 2
FUNCTION/
TRIPOMETER
BK
BK [46A]
RESET
SWITCH
[154]
BK
[21A] 1 2 3 4 5 6 7 8 BK
SPEED SENSOR
P/N 74420-94
[21B] 1 2 3 4 5 6 7 8
COPPER
STUD
GN/Y
TN
O
+12VDC
SENSOR OUTPUT
R A A R [5 ] BK
W B B W
BK BK
[65A]
GROUND
C C
[65B] CIRCUIT
BREAKER
N + OP +
30 AMP
TN O GN Y O
[157]
NEUTRAL
[158]
OIL
CHARGING CIRCUIT
HORN & INSTRUMENTS
2003 ALL FXDWG DOM. and INT. MODELS, HORN & INSTRUMENTS, PAGE 2 OF 2 & CHARGING
5-33
HOME
HAND CONTROLS, CRANK POSITION

RIGHT SENSOR
[ 162 ]
MANIFOLD BATTERY
AIR
ENGINE STOP/RUN SENSOR
SWITCH
BK
START SWITCH R BK
STARTER
, W139
[79A]
GY,W138
W/BK
[80A] A B C
1 2
[22B]
A B C 1 2
[80B]
BK
6 5 4 3 2 1
SPEEDOMETER
, W358
R/W,W356
BK, W395
V/W, W57
R, W396
6 5 4 3 2 1 [79B]
BK/W
, W61
GY,W25
[22A]
W/BK
R COPPER
STUD
[5 ]
CIRCUIT
BREAKER
30 AMP
G IGN 15A H
GY R/BK
SPEED SENSOR GROUND
TRIP SWITCH RETURN

SPEED SENSOR PWR

CHECK ENGINE LP
[ 33 ]
OUTPUT SPEED
PURSUIT LAMP
[30A] [30B] (REAR VIEW)

SECURITY LP
TRIP SWITCH
ACCESSORY
DATA BUS
GROUND
[39A] TSM/TSSM
BATTERY 1
A IGNITION
IGNITION 2 GY R
VSS / SERIAL DATA LINK 3 B SWITCH
R/BK
SECURITY INDICATOR 4 I
1 2 3 4 5 6 7 8 9 101112 LEFT TURN FEED 5
[39B]
RIGHT TURN FEED 6
RIGHT TURN SWITCH INPUT 7 [33B] [33A]
BK/Y
LEFT TURN SWITCH INPUT 8 [64B]

ALARM SIGNAL 11
GROUND 12
BK/Y
LTGN/R
LTGN/R
LGN/GY
B A
W/BK
F E D C B A
W/BK
BE/O
BK
BK
V/R
Y/BE
BK
15A
E
W/BK
C
BE/O
BK/Y
Y/BE
BK/W
BK
IGNITION
V/W
SECURITY
R/W
BK
PK
V/R
BK
[83B]
R
L K J I H G K I H G [11B] [10B]
15A 15A
ACCESSORIES LIGHTS C B A [91A]
U T S R Q P 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 3
2
PK
U S R P O M O M 1 4 3 2 1
15A 15A
1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12
C B A
DATA LINK
TOP VIEW TOP VIEW GRAY BLACK [ GND1]
[11A] [10A] [83A]
IGNITION IGNITION SWITCH LEGEND
IGNITION MODULE COIL
PINK WIRE LOCATED AT SWITCH RED/BLACK RED RED/GRAY
SPEEDOMETER CONNECTOR AND POSITION
Wire Color Code Key IS TAPED BACK TO THE OFF
WIRE HARNESS. ACC.
(A side) IGNITION
R - Red V - Violet TN - Tan SOCKET CONNECTOR DOT INDICATES CONTINUITY WITH RED
O - Orange GY - Gray Wire color-XX/XX-Stripe color (B side) WIRE IN SWITCH POSITION INDICATED
19082-01 1+2 IGNITION 7/13/2000
2003 ALL FXDWG DOM. and INT. MODELS, IGNITION CIRCUIT

5-34
HOME
HAND CONTROLS,
RIGHT
[162]
70103-96 BK
BATTERY
RIGHT TURN SWITCH
ENGINE STOP/RUN
SWITCH
BK
START SWITCH
STARTER
TO
W/BN
O/W
R/Y
HEADLAMP
[38A] PAGE 2
[22B]
1 2 3 4
6 5 4 3 2 1
BK
O/W
BK
W
6 5 4 3 2 1
Y
[22A]
W/BN
O/W
R/Y
COPPER
R STUD
[31A]
[5 ] CIRCUIT
1 BK
TO 2 BN BREAKER
FRONT 3 BE 30 AMP
TURN 4 BE
SIGNALS 5 V G IGN 15A H
PAGE 2 6 BK GY R/BK

[30A] [ 33 ]
[30B] (REAR VIEW)
M LIGHTS 15A O
TSM/TSSM BATTERY 1 BN/GY BE R/BK
IGNITION 2 GY R/GY
VSS / SERIAL DATA LINK 3 W/GN P ACCY 15A R A IGNITION
R
SECURITY INDICATOR 4 O/W R/GY R/BK B SWITCH
RIGHT TURN FEED 6 BN J SECURITY15A I
LEFT TURN SWITCH INPUT 8 W/V
START RELAY CONTROL 9 [64B] [33B] [33A]
ALARM SIGNAL 11
GROUND 12 BK
BN
TO W
SPEEDO V
PAGE 2 O/W
W/GN
BK
BK
BK
BK
BN
O/W
R/Y
BE
BK
BK
BK
V
O/W
[7A]
W/V
Y
3
R/Y
BE
O/W
W
1 2 1 2 3 4 5 6 7 8
[24A]
[GND1] TO REAR LIGHTING
1 2 3 4 5 6
REAR PAGE 2
STOPLIGHT
1 2 3 4 5 6 SWITCH COMPONENTS LOCATED UNDER LEFT SIDE COVER
[24B]
[121] Wire Color Code Key
O/W

W/V
BE
W
Y
F E D C B A B A
15A
E C BK - Black GN - Green LT.GN - Light Green PIN CONNECTOR
SECURITY IGNITION (A side)
L K J I H G K I H G
IGNITION SWITCH LEGEND HORN SWITCH 15A 15A R - Red V - Violet TN - Tan SOCKET CONNECTOR
ACCESSORIES LIGHTS
U T S R Q P O - Orange GY - Gray Wire color-XX/XX-Stripe color (B side)
SWITCH RED/BLACK RED RED/GRAY HEADLAMP HI/LO O M
POSITION SWITCH U S R P O M Y - Yellow W - White
15A 15A
OFF LEFT TURN SWITCH
ACC.
TOP VIEW TOP VIEW
IGNITION
19082-01 1 lighting 7/14/2000
HAND CONTROLS,
DOT INDICATES CONTINUITY WITH RED LEFT
WIRE IN SWITCH POSITION INDICATED [163 ]
2003 ALL FXDWG DOM. and INT. MODELS, LIGHTS, PAGE 1 OF 2

5-35
HOME
POSITION LAMP
HDI ONLY
O/W
BK
SPEEDOMETER
RIGHT
TURN [38B]
O/W 1
TO MAIN
[212] W 2
HARNESS
Y 3
[38A]
BK 4
HEADLAMP TO MAIN HARNESS [7A]
W
[31B] 1 2 3 4 5 6 7 8
Y
BK
BK 1 [7B]
BN 2
SPEED SENSOR GROUND

TO MAIN

BE 3
O/W
R/Y
BN
BK
BE
TRIP SWITCH RETURN
HARNESS
V
SPEED SENSOR PWR
BE 4
5 [31A]
V
CHECK ENGINE LP
BK 6
OUTPUT SPEED
PURSUIT LAMP
[38] DOM ONLY

SECURITY LP
TRIP SWITCH
ACCESSORY
P/N 68764-99
DATA BUS
GROUND
LEFT [190]
[39A] TURN
RIGHT
[214] V/BN TURN
1 2 3 4 5 6 7 8 9101112 [39B] BK
TAIL LAMP
O/W
R/Y
BN
BK
BE
V
,
W/GN
O/W
BK
6 5 4 3 2 1 [94B]
6 5 4 3 2 1 [94A]
[19B]
O/W 1 1 [19A]
W/GN 2 2
W
V [198]
[18B]
MAIN BRAKE LIGHT
2 2
4 4 BK
BK 1 3 3 R/Y
BK 2 2 2 O/W
3 1 1 BE
[93A] [93B]
[21A] 1 2 3 4 5 6 7 8
RUNNING LIGHT (HDI) RUNNING LIGHT (DOM)
[21B] 1 2 3 4 5 6 7 8
BN
BK
W
V
[194]
LEFT
V/BN TURN
BK
LT - HB - - RT
V BK W BK BK BN
[155] [156] [159]
LEFT HIGH RIGHT 19082-01_2lighting 7/13/2000

2003 ALL FXDWG DOM. and INT. MODELS, LIGHTS, PAGE 2 OF 2

5-36
HOME
70103-96 BK
HAND
CONTROLS,
RIGHT
[162]
BATTERY
BK
RIGHT TURN SWITCH
ENGINE STOP/RUN START
SWITCH RELAY 70102-96
START SWITCH
STOPLIGHT SWITCH STARTER
85 86 30 87a 87 [61A]
BK/R
GY
S UE T K [61B]
BK
6 5 4 3 2 1 [22B]
TN/GN
BK/R
R/BK
GN
[128A] [128B]
6 5 4 3 2 1 [22A]
BK/R
R COPPER
GY
STUD
[5]
CIRCUIT
BREAKER
30 AMP
G IGN 15A H
GY R/BK
[30A] [30B]
[ 33 ]
TSM/TSSM (REAR VIEW)
BATTERY 1 BN/GY
IGNITION 2 GY
VSS / SERIAL DATA LINK 3
A IGNITION
SECURITY INDICATOR 4 R
LEFT TURN FEED 5 B SWITCH
R/BK
RIGHT TURN FEED 6 J SECURITY 15A I I
RIGHT TURN SWITCH INPUT 7 BN/GY R
LEFT TURN SWITCH INPUT 8
[64B]
START RELAY CONTROL 9 TN/GN [33B] [33A]
ALARM SIGNAL 11
GROUND 12 BK
BK
3
1 2
19082-01_1starting 7/13/2000
[GND1]
2003 ALL FXDWG DOM. and INT. MODELS, STARTING CIRCUIT

5-37
HOME
OPTIONAL
70103-96 BK
HAND ALARM SIREN
CONTROLS,
RIGHT
[162]
POWER BATTERY
SIGNAL
BK
RIGHT TURN SWITCH [142A] GROUND
ENGINE STOP/RUN START
SWITCH RELAY 70102-96
START SWITCH
A B C
STOPLIGHT SWITCH STARTER
[142B]
LGN/BN
[61A]
BN/GY
85 86 30 87a 87 [46B]
BK
W/BN
O/W
S UE T K [61B]
BK
GN
6 5 4 3 2 1 [22B]
TN/GN
R/BK
GN
[128A] [128B] [46A]
6 5 4 3 2 1 [22A]
R COPPER
W/BN
O/W
[31A] STUD
TO 1 BK [5]
FRONT 2 BN CIRCUIT
TURN 3 BREAKER
SIGNALS 4 30 AMP
PAGE 2 5 V G IGN 15A H
6 BK GY R/BK
[30A] [30B] [ 33 ]
(REAR VIEW)
TSM/TSSM
BATTERY 1 BN/GY
IGNITION 2 GY R/GY
ACCY 15A A IGNITION
VSS / SERIAL DATA LINK 3 P R R
SECURITY INDICATOR 4 BN/V O/W R/GY B SWITCH
R/BK
RIGHT TURN FEED 6 BN J SECURITY 15A I
LEFT TURN SWITCH INPUT 8 W/V [33B] [33A]
START RELAY CONTROL 9 TN/GN [64B]
ALARM SIGNAL 11 LGN/BN
GROUND 12 BK
TO BN
SPEEDO
PAGE 2 V
BK
BK
BN/V
BK
LGN/GY
BK
BK
BN
BK
BK
V
3
O/W
W/V
[11B] 1 2 3 4 5 6 7 8 9101112 1 2 3 4 5 6 7 8 9101112 [10B]

1 2 [7A] 1 2 3 4 5 6 7 8
[24A] 1 2 3 4 5 6 7 8 9101112 1 2 3 4 5 6 7 8 9101112
1 2 3 4 5 6 [11A] [10A] TO REAR
GRAY BLACK [GND1]
LIGHTING
[24B] 1 2 3 4 5 6 PAGE 2
IGNITION MODULE
O/W
W/V
COMPONENTS LOCATED UNDER LEFT SIDE COVER START RELAY Wire Color Code Key
HORN SWITCH INSTRUMENTS
F E D C B A B A BK - Black GN - Green LT.GN - Light Green PIN CONNECTOR
SWITCH RED/BLACK RED RED/GRAY HEADLAMP HI/LO (A side)
POSITION SWITCH 15A BE - Blue
E C BN - Brown PK - Pink
OFF SECURITY IGNITION
LEFT TURN SWITCH R - Red V - Violet TN - Tan SOCKET CONNECTOR
ACC. J I H G H G
L K K I O - Orange GY - Gray (B side)
IGNITION 15A 15A Wire color-XX/XX-Stripe color
HAND ACCESSORIES LIGHTS U T S R Q P Y - Yellow W - White
DOT INDICATES CONTINUITY WITH RED CONTROLS, U S R P O M O M
WIRE IN SWITCH POSITION INDICATED LEFT 15A 15A
[163]
TOP VIEW TOP VIEW
19082-01_1security 7/13/2000
2003 ALL FXDWG DOM. and INT. MODELS, SECURITY CIRCUIT, PAGE 1 OF 2
5-38
HOME
SPEEDOMETER
RIGHT
TURN
[212]
TO MAIN HARNESS [7A]
[31B] 1 2 3 4 5 6 7 8
BK 1 [7B]
BN 2
SPEED SENSOR GROUND

TO MAIN

3
BN
BK
TRIP SWITCH RETURN
HARNESS
V
SPEED SENSOR PWR
4
5 [31A]
V
CHECK ENGINE LP
BK 6
OUTPUT SPEED
PURSUIT LAMP
SECURITY LP
TRIP SWITCH
ACCESSORY
DATA BUS
GROUND
LEFT [190]
[39A] TURN
RIGHT
[214] V/BN TURN
1 2 3 4 5 6 7 8 9101112 [39B] BK
TAIL LAMP
BN
BK
V
BN/V
BK
6 5 4 3 2 1 [94B]
6 5 4 3 2 1 [94A]
BN/V [19B]
1 1 [19A]
2 2
V [18B]
MAIN
2 2
4 4
BK 1 3 3
BK 2 2 2
3 1 1
[93A] [93B]
[21A] 1 2 3 4 5 6 7 8
[21B] 1 2 3 4 5 6 7 8
BN
BK
V
[194]
LEFT
V/BN TURN
BK
LT - - RT
V BK BK BN
[155] [159]
LEFT RIGHT 19082-01_2security 7/13/2000

INDICATOR INDICATOR
2003 ALL FXDWG DOM. and INT. MODELS, SECURITY CIRCUIT, PAGE 2 OF 2
5-39

2003 Dyna Starting &amp; Charging

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STARTING & CHARGING

SUBJECT PAGE NO.

1.1 Starter Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

STARTER TROUBLESHOOTING 1.1

2003 Dyna: Starting & Charging 1-1

Table 1-3. Starter Does Not Stop Running

1-2 2003 Dyna: Starting & Charging

STARTING SYSTEM DIAGNOSIS 1.2

DIAGNOSTICS 1. Motor terminal

Check battery using visual inspection,

Check connections at battery and starter

YES YES YES NO

STARTER STARTER STARTER Check for audible

Disconnect solenoid relay ter-

Relay clicks. See

2003 Dyna: Starting & Charging 1-3

Starter Testing 2: Solenoid Clicks

Perform voltage drop tests between

2 Perform voltage drop tests from 2 Backtrack to pinpoint poor

Perform voltage drop tests from Perform voltage drop tests

Starter Testing 3: Relay Clicks

Test for voltage at solenoid relay terminal

1 Does starter motor

Mechanical binding or Replace

1-4 2003 Dyna: Starting & Charging

Starter Testing 4: Nothing Clicks

Do turn signals work

YES Is connector [30] fully mated?

Check for battery voltage at relay YES

Continuity on pin 2 on Repair open.

Replace TSM/TSSM. Repair open.

Check for ground at Check for battery voltage from

Check for voltage on Repair

Locate and repair

2003 Dyna: Starting & Charging 1-5

Starter Testing 5: Starter Spins, But Does Not Engage

Remove and disassemble starter jackshaft

Remove starter. Disassemble drive housing Assemble jackshaft

Replace damaged idler Starter clutch failure.

Starter Testing 6: Starter Stalls or Spins Too Slowly

Perform voltage drop tests from battery

2 Perform voltage drop tests Perform voltage drop tests

Remove spark plugs while in Replace or repair

Use appropriate code

1-6 2003 Dyna: Starting & Charging

STARTER ACTIVATION CIRCUITS 1.3

8 20A 8 20A 20A

1. Start switch 5. Battery

2003 Dyna: Starting & Charging 1-7

GENERAL 6. Typically, a good circuit will drop less than 1 volt.

VOLTAGE DROPS c. This tests the system as it is actually being used. It

1-8 2003 Dyna: Starting & Charging

Figure 1-3. Starting Circuit

DOT INDICATES CONTINUITY WITH RED

COMPONENTS LOCATED UNDER LEFT SIDE COVER

2003 Dyna: Starting & Charging

TESTING STARTER ON MOTORCYCLE 1.5

STARTER RELAY TEST 7902

2. To test relay, proceed to Step 3. If installing a new starter

b. To energize relay, connect the battery leads to termi-

c. Check for continuity between the 30 and 87 termi-

4. If starter relay is functioning properly, proceed to

STARTER CURRENT DRAW TEST

2003 Dyna Starting & Charging

2003 Dyna Starting & Charging