SSL LQ vy AND ELECTRICAL =|} TROUBLESHOOTING OQ ** 1993 ; & 1994 ALL MODELSELECTRICAL WIRING DIAGRAMS AND TROUBLESHOOTING MANUAL FOR 1993 & 1994 MODEL HARLEY-DAVIDSON MOTORCYCLES AND SIDECARS TABLE OF CONTENTS SUBJECT PAGE NO. 1. Connector and Wiring Changes on 1984 FLT and XLH Models... 1 2. Ignition System 4 3. Ignition Coit 10 4. Spark Plug C " 5. Charging System 12 8. Battery .... : 16 7. Tum Signal Gancelir (ail Models) 1a 8. Cruise Control Uitra Models at 9. Gruise Control Throttle Cables. 39 40. Sound System FLHTC ..... 45 11. Blown Fuse Symptom List 4 12, Voltage Drop Testing ... 50 48, Sound System ~ FLTC-ULTAA and FLHTC-ULTRA GBINTERCOMREAR SPEAKERS «...00......0000+ 60 14, TLE-Utra Sidecar Audio Troubleshooting 122 15, Deutsch Electrical Connectors - 1994 .. 126 18. Packard Electrical Connectors - 1994 159 17. Crimping Matrices .-....+....+200.0. 128 18, Wiring Hamesses, FLHTC/Uitra 1994 Model 150 19. Wiring Hamesses, FLTC Ura 1894 Models... 187 20. Sealed Wire Spices ...... anne S160 21. FLHR Road King™ Electric Speedometer 161 22. 1993 Models Wiring Diagram Index .... 165 23, 1994 Models Wiring Diagram Index .... 166CONNECTOR AND WIRING CHANGES ON 1994 FLT AND XLH MODELS ELECTRICAL CONNECTORS Identification In this publication, the connector numbers are enclosed in brackets. As an example “[10AJ"is the pin halt of the ignition module connector and ‘[108)" is the socket half of the same WIRING CHANGES To prevent electrical noise associated with poor grounds, separate ground return wires have been added to some elec trical components. For example, the turn signal/running light hamess contains three wires. Two of these wires carry cur- tent to iluminate the flaments and the third wire provides the {ground return. WIRE COLOR CODE AND CIRCUIT FUNCTION (1994 XLHs & FLTs ) ‘See the following color code legend and table. The wire color ‘codes and circuit function are listed. This information applies to 1994 XLH and FLT models only. connector. These connector numbers are the identification numbers used on the wiring diagrams at the rear of this book. Coton cove: (Fe) Ukr oneen Repair @ux @omor un muck ro @ wort = 8s One ‘Tho 1994 FLT and XLH models are equipped with sealed cen @ usw ‘electrical connectors manufactured by the Packard Electric cow Dhision/General Motors Corporation and the Deutsch Com- SQ pany. Refer to the rear of this section for instructions covering ormuomion ‘STRIPE COLOR the repair of these connectors. WIRE COLOR CODE AND CIRCUIT FUNCTION (1994 XLHs & FLTs) WIRE COLOR CIRCUIT FUNCTION BE CIRCUIT BREAKER TO RUNNING LAMPS. HDI POSITION LAMPS HEADLIGHT Hi/LO SWITCH ‘STOP LIGHT RELAY INTERNATIONAL PARK LAMP SWITCH TO FENDER TIP LAMPS RADIO TO SPEAKER SWITCH (CB PUSH-TO-TALK SWITCH REAR PASSENGER TUNING CONTROL ‘CRUISE CONTROL MODULE TO CRUISE SET/RESUME SWITCH KEY SWITCH FORK LOCK POSITION TO FUSE GROUND ‘START SWITCH TO START RELAY CALIFORNIA TRAP DOOR PULL-IN SOLENOID TIMING PLATE SENSOR TO IGNITION MODULE BATTERY GROUND TERMINAL TO RADIO, CB/POD POWER DISTRIBUTION BOX TURN SIGNAL MODULE TO RIGHT TURN SIGNALS AND RIGHT TURN SIGNAL INDICATOR RADIO FUNCTION SWITCH TO RADIO, REAR PASSENGER CONTROL PANEL RADIO TO VOLUME CONTROL SWITCH ‘START RELAY TO STARTER SOLENOID TIMING PLATE SENSOR TO IGNITION MODULE OIL PRESSURE SWITCH TO OIL PRESSURE WARNING LIGHTWIRE COLOR CODE AND CIRCUIT FUNCTION (1994 XLHs & FLTs) — Saree GNY OIL PRESSURE SENSOR TO OIL PRESSURE GAUGE J —} — a a om se Sra LT.GN/BK RADIO TO RIGHT FRONT SPEAKER (+) cone rt O/GN ‘START RELAY (POSITION 87A) TO FUSE. PKW RADIO TO VOLUME CONTROL SWITCH SWITCHES TO STOPLIGHT RELAY RO. FUSE TO RADIO, CB/POD POWER DISTRIBUTION BOX Wisk IGNITION ON/OFF SWITCH TO COIL, IGNITION MODULE, CALIFORNIA TRAP DOOR HOLD IN ULE, SPEAKER SWITCHWIRE COLOR CODE AND CIRCUIT FUNCTION (1994 XLHs & FLTs) ‘CIRCUIT FUNCTION LEFT TURN SIGNAL SWITCH TO TURN SIGNAL MODULE TEMPERATURE SENSOR CIRCUIT BREAKER TO STOP LAMP RELAY (POSITION 30) ‘CRUISE CONTROL MODULE TO CRUISE SET/RESUME SWITCH ‘WIRE COLOR WV wa WIE wo Yk Y YN RADIO TO LEFT FRONT SPEAKER (-) HORN SWITCH TO HORN HULOW BEAM SWITCH TO LOW BEAM, PASSING LAMP SWITCH ‘CB CONTROL POD TO SPEAKER SWITCHCONNECTOR AND WIRING CHANGES ON 1994 FLT AND XLH MODELS ELECTRICAL CONNECTORS Identification In this publication, the connector numbers are enclosed in brackets. As an example “[10AJ"is the pin halt of the ignition module connector and ‘[108)" is the socket half of the same WIRING CHANGES To prevent electrical noise associated with poor grounds, separate ground return wires have been added to some elec trical components. For example, the turn signal/running light hamess contains three wires. Two of these wires carry cur- tent to iluminate the flaments and the third wire provides the {ground return. WIRE COLOR CODE AND CIRCUIT FUNCTION (1994 XLHs & FLTs ) ‘See the following color code legend and table. The wire color ‘codes and circuit function are listed. This information applies to 1994 XLH and FLT models only. connector. These connector numbers are the identification numbers used on the wiring diagrams at the rear of this book. Coton cove: (Fe) Ukr oneen Repair @ux @omor un muck ro @ wort = 8s One ‘Tho 1994 FLT and XLH models are equipped with sealed cen @ usw ‘electrical connectors manufactured by the Packard Electric cow Dhision/General Motors Corporation and the Deutsch Com- SQ pany. Refer to the rear of this section for instructions covering ormuomion ‘STRIPE COLOR the repair of these connectors. WIRE COLOR CODE AND CIRCUIT FUNCTION (1994 XLHs & FLTs) WIRE COLOR CIRCUIT FUNCTION BE CIRCUIT BREAKER TO RUNNING LAMPS. HDI POSITION LAMPS HEADLIGHT Hi/LO SWITCH ‘STOP LIGHT RELAY INTERNATIONAL PARK LAMP SWITCH TO FENDER TIP LAMPS RADIO TO SPEAKER SWITCH (CB PUSH-TO-TALK SWITCH REAR PASSENGER TUNING CONTROL ‘CRUISE CONTROL MODULE TO CRUISE SET/RESUME SWITCH KEY SWITCH FORK LOCK POSITION TO FUSE GROUND ‘START SWITCH TO START RELAY CALIFORNIA TRAP DOOR PULL-IN SOLENOID TIMING PLATE SENSOR TO IGNITION MODULE BATTERY GROUND TERMINAL TO RADIO, CB/POD POWER DISTRIBUTION BOX TURN SIGNAL MODULE TO RIGHT TURN SIGNALS AND RIGHT TURN SIGNAL INDICATOR RADIO FUNCTION SWITCH TO RADIO, REAR PASSENGER CONTROL PANEL RADIO TO VOLUME CONTROL SWITCH ‘START RELAY TO STARTER SOLENOID TIMING PLATE SENSOR TO IGNITION MODULE OIL PRESSURE SWITCH TO OIL PRESSURE WARNING LIGHTWIRE COLOR CODE AND CIRCUIT FUNCTION (1994 XLHs & FLTs) — Saree GNY OIL PRESSURE SENSOR TO OIL PRESSURE GAUGE J —} — a a om se Sra LT.GN/BK RADIO TO RIGHT FRONT SPEAKER (+) cone rt O/GN ‘START RELAY (POSITION 87A) TO FUSE. PKW RADIO TO VOLUME CONTROL SWITCH SWITCHES TO STOPLIGHT RELAY RO. FUSE TO RADIO, CB/POD POWER DISTRIBUTION BOX Wisk IGNITION ON/OFF SWITCH TO COIL, IGNITION MODULE, CALIFORNIA TRAP DOOR HOLD IN ULE, SPEAKER SWITCHWIRE COLOR CODE AND CIRCUIT FUNCTION (1994 XLHs & FLTs) ‘CIRCUIT FUNCTION LEFT TURN SIGNAL SWITCH TO TURN SIGNAL MODULE TEMPERATURE SENSOR CIRCUIT BREAKER TO STOP LAMP RELAY (POSITION 30) ‘CRUISE CONTROL MODULE TO CRUISE SET/RESUME SWITCH ‘WIRE COLOR WV wa WIE wo Yk Y YN RADIO TO LEFT FRONT SPEAKER (-) HORN SWITCH TO HORN HULOW BEAM SWITCH TO LOW BEAM, PASSING LAMP SWITCH ‘CB CONTROL POD TO SPEAKER SWITCHIGNITION COIL GENERAL The ignition coil isa pulse type transformer that transforms or stops up low battery voltage to the high voltage necessary to jump the electrode at the spark plug in the cylinder head. Internally the coil consists of primary and secondary windings with a laminated iron core and sealed in waterproof insulating compound. The ignition coll cannot be taken apart or repaired. Ifthe ignition coils faulty it must be replaced. Ignition Coil Primary Circuit Ignition Coil Secondary Circuit Figure 3. Test ignition Coil 10 TROUBLESHOOTING ‘When engine will not start or when hard starting or missing indicates a faulty ignition system, follow the procedure listed ‘under ignition system TROUBLESHOOTING. If condition persists, check primary and secondary resistance of ignition coil with an ohmmeter. See Figure 3. Resistances should be Within the following limits: Primary resistance 2.5-3.1 ohms, secondary resistance 10,000-12,500 ohms. Check ignition coil with a col tester. It a coil tester is not avaliable, temporarily substitute a new ignition coll by attaching it at any convenient point near old oil (coil wil function without being securely grounded). ‘Transter terminal wires to new coil. See Wiring Diagram. CAUTION Connect ignition coll wires as shown in Figure 1. Reversing polarity to the ignition control module will Permanently damage the control module. ‘Attach new spark plug cables to coil and plugs. If ignition trouble is eliminated by the temporary installation of new coil, carefully inspect old coil for damaged cables and insulation The insulation on cables may be cracked or otherwise dam- aged allowing high tension current to short to metal parts. This is most noticeable in wet weather or when motorcycle has been washed.SPARK PLUG CABLES GENERAL Resistor-type high-tension cables have a carbon-impreg- nated fabric core (instead of solid wire) for radio noise sup- pression and improved reliablity of electronic components, Use the exact replacement cable for best results. REMOVAL WARNING Never disconnect a spark plug cable with the engine running, If you disconnect a spark plug cable with the ‘engine running, you may recelve a potentially fatal ‘electric shock from the ignition system. CAUTION When disconnecting each spark plug cable from its ‘spark plug terminal, always grasp and pull on the rubber boot at the end of the cable assembly (as close as possible to the spark plug terminal). Do not pull on the cable portion Itself. Pulling on the cable will damage the cable's carbon core. Disconnect spark plug cables from ignition coil and spark plug terminals. INSPECTION CChack cables for cracks or loose terminals. ‘Check spark plug cable resistance with an ohmmeter. Resis~ tance must be 250-583 ohms per in. (25.4 mm) of spark plug cable. Replace cables that are worn or damaged, or that do not meet resistance specifications. Check cable boots/caps for cracks or tears; also check for loose fit on ignition coil and ‘spark plugs. Replace boots/caps if you find any of the detri- mental conditions mentioned above. INSTALLATION Connect spark plug cables to ignition coil and spark plugs. Make sure boots/caps are secured propery; this will provide the necessary moisture-proof environment forthe ignition coil and spark plug terminals, "CHARGING SYSTEM GENERAL Alternator ‘The alternator consists of two main components: the rotor which is mounted on the engine sprocket shaft, and the sta- tor, which is bolted to the engine crankcase, Regulator ‘The regulator is a series regulator with shunt control. The cit- cuit combines the functions of rectifying and regulating. TROUBLESHOOTING i co Preliminary Checks When the charging system fails or does not charge at a satis- factory rate, itis recommended that the following checks be made: BATTERY Check for a weak or dead battery. See the BATTERY section. Battery must be fully charged in order to perform any electri- cal tests. WIRING ‘Check for corroded or loose connections in the charging cir- cuit. Regulator Inspection ‘The 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. Connector plug at engine crankcase must be clean and tight. Regulator Bleed Test Be sure regulator is connected to battery. Unplug regulator ‘connector at engine crankcase. Use a trouble light and touch ‘one probe to a known good ground and the other to the regu: lator pins, one at a time. If ight glows, replace regulator, 2 MILLIAMP DRAW TEST NOTE Be sure accessories are not wired so they stay on at all times. Check for this by connecting ammeter between nega- tive battery terminal and battery. ‘See Figure 4. Connect ammeter between negative battery terminal and battery. With this arrangement, you will also pick Up any regulator drain. Figure 4. Milllampere Draw Test ‘The limits for these drains are listed in the tabulation below: Any accessories must be considered and checked for excessive drain ‘This condition could drain battery completely if vehicle is parked for a long time. NOTE AA battery with surface discharge condition or over full could ‘cause a static drain. Correct by lowering levels in cells and ‘leaning battery case. METER READING MODEL (milliamperes) FLHTC Lees than 10 (radio memory) FLTC Ura Less than 15 & (radio & CB memory) FLHTC Ultra | All models Less than 3 without radio (regulator leakage) NOTE Any reading that exceeds the above “Meter reading” values indicates excessive current draw. Check for bad radio, CB, regulator or a short in the interconnecting wiring. Isolate prob- fem by disconnecting suspect components and observe ‘change in meter reading.CHARGING SYSTEM TROUBLESHOOTING NOTE Whenever @ charging system component fails atest and is replaced, the system must be re-tested to be sure problem hhas been corrected. ‘SYMPTOM: BATTERY BECOMES DISCHARGED Test battery. ‘Charge or replace as required. See BATTERY section. Pass, 5 Inspect regulator. Correct as required. kk Fail REGULATOR INSPECTION. Pass, Test regulator. Replace regulator. kk Fal ‘See REGULATOR BLEED TEST. Pass. tT tpolate damaged Fall Perform MILLIAMP DRAW TEST (I applicable). ‘component or wiring, ; Pass. q eotate damaged wirng or ral Perform TOTAL CURRENT DRAW TEST. lexcessive accessories. at Record measurement. Pass Perform ¥ Replace stator ef Fall }—] STATOR le{ Fail form CURRENT OUTPUT TEST. CHECK. Record measurement and compare with TOTAL CURRENT DRAW TEST before proceeding bel aa Perform ng HW i i Perfo PUT TEST. Fail Fa mee el Fal AS 1m VOLTAGE OUTPU qT Test. we Replace Pass Pass regul roto. T is point. Foss ‘System tests good up to tris pot stator. Replace regulator. Suspect 1. Accessories on for ong periods when vehicle ls parked and not running. 2. Accessories on when vehicle is ridden Damaged or |, Fay ]__[Pertorm CURRENT OUTPUT very slowly for long periods. sipping rotor/ TEST. 3. Battery self-discharge andlor acces- sory draw because vehicle was not ‘operated for a long period. 8Total Current Draw Test See Figure 5. If battery runs down during use, the current draw of the motoreycle components and accessories may ‘exceed output of the charging system. To check for this con- dition, place load tester induction pickup or current probe pickup, over battery negative cable as shown below. Figure 5. Check Current Draw (Ignition Switch On) With ignition and all continuously running lights and acoesso- ries turned on (headiamp on high beam), wait 10 seconds, ‘and then read the total current draw. Compare this reading 10 the reading obtained in CURRENT OUTPUT TEST. The cur- rent output should exceed current draw by 6.5 amps, mit mum (3 amps for ignition and 3.5 amps for battery maintenance). If not, there may be too many accessories for the charging system to handle. Noe Rider's habits may require output test at lower RPM. Current and Voltage Output Test 1. Connect load tester negative and positive leads to bat: tery terminals and place load tester induction pickup ‘over positive regulator cable as shown in Figure 6. 2. Run the engine at 2,000 rpm's for Sportster models or 3000 rpm's for 1340cc models. Increase the load as required to obtain a constant 13.0 volts. 3. The current output should be 19-23 amps for Sportster models or 26-32 amperes for 1340cc models. Make nate of measurement. 4 Voltage Output Test See Figure 6. After removing the load, read the load tester voltage meter. Voltage to the battery must not be more than 15 volts. If voltage is higher, regulator is not functioning prop- erly or connections are loose or dirty. CAUTION Do not leave any load switch tuned on for more than 20 ‘seconds or overheating and tester damage are possible. Figure 6. Current and Voltage Output Test, Stator Check 1. To check for a grounded stator, turn off ignition and dls- Connect the regulator from the stator at the terminal in the crankcase. 2. See Figure 7. Connect an ohmmeter on the AX1 scale between crankcase and either stator socket. There ‘should be no continuity (-= ohms) across either test point. ‘Any other reading indicates a grounded stator which ‘must be replaced 3. See Figure 8. Check the resistance using an ohmmeter set on the AX1 scale. Resistance across the stator socket or pins should be 0.1-0.2 ohms on 1340ee mod- els or 0.2-0.4 ohms on Sportster models. If the resis- tance is lower, the stator is damaged and must be replaced,Figure 7. Teet for Grounded Stator AC Output Check 1. See Figure 9. To test AC output, disconnect the regulator land connect an AC voltmeter across both stator sockets. un the engine at 2000 rpm's. The AC output should be 38-52 volts ac for Sportster models or 32-40 volts ac for '1340cc models. 2. If the output is below spectfcations, charging problem ‘could be a faulty rotor or stator. Replace the rotor or sta- tor as described in the appropriate Service Manual. 3, Check the output again as described under CURRENT AND VOLTAGE OUTPUT TEST. Figure 9. Check AC Output 8BATTERY GENERAL Harley-Davidson batteries are of the lead plate/sulturic acid electrolyte type.The battery stores electrical energy for the Purposes of starting the motorcycle, operating accessories: When the engine is not running, and providing additional cur- rent (above that generated by the alternator) when required. ‘The battery will remain in good condition ifthe current drave is balanced by the current input. WARNING Lead-acid motorcycle batteries contain sulfuric acid, which is highly corrosive and can cause severe chemical burns. Avoid contact with skin, eyes, and clothing. Always wear protective face shield, rubberized gloves, and protective clothing when working near batteries or electrolyte. Warning label (shown below) is located on top or back panel of all batteries. Never remove warning label from battery. DANGER - EXPLOSIVE GASES Cigarettes, flames, or sparks could cause battery to explode. Always shield eyes and face from battery. Do not charge without proper instruction and training. Securely Connect cables to the proper terminals. Check vent tube to Avoid any crimping or obstruction of the tube. KEEP FILLING PLUGS TIGHT AND LEVEL POISON - CAUSES SEVERE BURNS Contains sulfuric acid. Avoid contact with skin, eyes, and Clothing. In event of accident, flush with water and call a physician immediately. KEEP OUT OF REACH OF CHILDREN ANTIDOTE, EXTERNAL - Flush with water. INTERNAL ~ Drink large quantities of milk or water, fol towed by milk of magnesia, vegetable cil, or beaten eggs. Call doctor immediately. EYES - Flush eyes with water, and get immediate medi- cal attention. TESTING 1. Remove battery from motorcycle; see applicable Service ‘Manual for instructions. Place battery on a level surface. 2. Remove six battery cell filler caps. 16 WARNING Electrolyte is sulfuric acid solution. Avoid spillage and Fully charge battery (see BATTERY, MAINTENANCE AND CHARGING in this section), and allow battery to stand at east one hour before testing. 3. electrolyte level in any battery coll is below upper level ‘mark on battery case, add distilled water as required to bring electrolyte level up to that mark. 4. Fully charge battery, and allow battery to stand at least tone hour before testing. WARNING Charge battery in a well ventilated area. Explosive hydro- gen gas escapes from battery during charging. Keep ‘open flames, electrical sparks, and smoking materials away from battery at all times. 5. Check SPECIFIC GRAVITY of electrolyte in each battery cell using a HYDROMETER (Part No. HD-96910-35); it ‘electrolyte temperature is not 80"F (27°C), adjust specific ‘gravity readings for temperature differences - see NOTE. below. NOTE When using a syringe hydrometer, read electrolyte level at bottom of meniscus (curved upper surface of fluid). ‘Speaitic gravity changes with temperature differences. When the temperature increases, specific gravity of a typical fluid decreases, and vice versa. If electrolyte temperature in bat- tery is not 80°F (27'C), use the following formula to compute temperature-corrected specific gravity: — For each 10°F (5.5°C) above 80°F (27°C), add 0.004 to actual specific gravity reading. = For each 10°F (5.5°C) below 80°F (27°C), subtract 0.004 trom actual specific gravity reading. For example: Electrolyte temperature 100°F (38 °0) Hydrometer reading 1272 Adjustment for temperature +$0.008 Corrected speciic gravity 1.280 ‘The difference in temperature-corrected specific gravity vvalues between the cell with the highest value and the cell with the lowest value must be lass than 0.050 sp. gr. In addition, a temperature-corrected specific gravity of at least 1.220 must exist in each cell of the fully charged battery f battery does not meet both of these conditions, it should be repiaced. 6. Install six battery cel filer caps.WARNING ‘Always turn battery load tester OFF before connecting or disconnecting tester cables at battery terminals. Con- necting or disconnecting tester cables with load tester ON could cause a spark and a possible battery explo- sion. A battery explosion may rupture the battery case, spraying sulfuric acid onto the surrounding area and personnel; this may result in serious injury. CAUTION © Never load test a discharged battery; otherwise, bat- tery might sustaln permanent damage. © Do not leave load tester switch turned ON for more than 20 seconds; otherwise, load tester and battery might overheat and sustain permanent damage. Load battery to three times amp hour rating using a load tester, Connect tester leads to battery posts and place induction pickup over negative (black) cable. The Harley- Davidson 19 amperes hour battery should be loaded to 57 amperes. The Harley-Davidson 20 amperes hour FLT battery should be loaded to 60 amperes. Voltage reading alter fitteen seconds should be 9.6 volts or more. If volt- age is lower, replace the battery. Install fuly charged battery onto motorcycle. Connect battery cables (POSITIVE GABLE FIRST) to battery. 7TURN SIGNAL CANCELLER (ALL MODELS) HOW-IT-WORKS The tum signals and 4-way flashers are controlled by an electronic module. See the following table for the module location on all models. The electronic module contains cir- cuitry to generate pulses for “lashing” the appropriate lamps ‘and eliminates both the directional and hazard flashers. See Figure 10. To explain the canceller operation, the following steps identify what happens when a rider signals for a left turn, Turn Signal Module Location LOCATION Upper righ fork tube Behind right side cover | Softai_| Beneath fuel tank console on frame top tube Beneath seat on inner side of ignition module bracket Beneath seal on frame crssmember Under headlamp 1. Pressing and releasing the left turn signal switch causes ‘a momentary 12 vdc to be applied to pin 10 or 7 (04 FLTs & XLHs). The module sends a series of 12 vd pulses (pin 6 oF 5 on 94 FLTS & XLHs) to flash left front and rear signal lights. 2. The module monitors the number of speedometer reed switch closures at pin 3. These switch closures indicate the speed and the distance traveled. When the number of switch closures equals the quantity preset in module for the given speed, the left signal is cancelled, 3. Pressing and releasing the right turn signal switch ‘causes a momentary 12 vde to be applied to pin 8 or 6 (@4 FLTs & XLHs) and an output at pin 4 identical to that described fora left tur. NOTE {If turn signal switch is pressed and held, the turn signal will flash indefinitely. “Counting” of reed switch closures begins ‘upon release of turn signal switch. Manual or Rider Control ‘Tum signals may be cancelled by pressing the turn signal ‘switch a second time. Also, pressing the left turn signal ‘switch, while the right turn signal lights are flashing will can- cel the right turn lights and turn on left turn lights or vice- versa. Hazard Flasher (4-Way) To activate the hazard flashers, press and hold in both right, ‘and lett turn signal switches for 1-1/2 seconds. To cancel haz- ard flashers, press and release right and left tum signal switches simultaneously. 18 All $3 & $4 Models; except 94 FLTs & XLHs Pin Module pin connector LerrTuRN. ‘SIGNALUGHT Rie TURN SIGNAL LIGHT TURN SIGNAL SWITCH + acer Tuan SIGNAL SwiTCH Cole Ww w/ | we code | GN an |v 1994 FLT & XLH Models Connector (30A] PINNO. ‘All 938 94 | except 94 | FLT, XLH 1994 | DESCRIPTIONFUNCTION FLT, XLH 7 [Module ground to matoraycle ‘2vde input from accessory circuit breaker [Speedometer reed switch input Pulsed 2vdc for flashing right signal lights = Not usec Pulsed 2vde for fasting ie signal lights = Not used FTavde from right Switch (when pressed) = [Not uses T2vde from Te signal Switch (when pressed) Not used Figure 10. Turn Signal CancelerPERFORMANCE CHECK If turn signals are not functioning, perform the following six tests. 1. See Figure 10. Check for 12 vde at pin 2 2. Check for ground at pin 1. 3 Place jumper wire between pins 2 and 4. The right turn lamps (front and rear) should illuminate. 4, Place jumper wire between pins 2 and 6 (93 models) or 2 and 5 (94 FLT & XLH). The left turn lamps (front and rear) should iluminate. 5. Place jumper wire between pins 4 and 8 (83 models) or 4 and 6 (94 FLT & XLH), With the right turn button depressed, both right lamps should illuminate. 6. Place jumper wire between pins 6 and 10 (83 models) or 5 and 7 (94 FLT & XLH). With the left turn button depressed, both left lamps should illuminate. 7. If all six tests were passed, the module must be replaced. If turn signals stil do not function, proceed to ‘TROUBLESHOOTING. DISTANCE TEST ‘As described earlier, the turn signals cancel after the front wheel travels a certain distance. The tum signal module ‘begins counting the distance the instant the turn signal button is released. The distances traveled (with turn signals flash- Ing) at four speed ranges are as folows: Speed range 1 0-30 mph 220 ft. (0.04 mi.) (0-48 krvh 7m Speed range 231-45 mph 339 f. (0.08 50-72 km/h 103 m Speed range 3 46-60 mph 754A (0.14 74.97 kmih 230 m ‘Speed range 4 60+ mph 1056 ft. (0.20 mi.) 97+ kmh 322m To verity proper operation, perform the following: 1. Operate the motorcycle at the midpoint of speed range 1 (18 mph) (24 kmh). 2. Press and release the right turn button and closely moni- tor the vehicle speed and odometer reading at the time the button is released and at the time the turn signal cancels. NOTE Because the odometer's lowest indication is 1/10 of a mile, (0.04 mi. is 4/10 the distance between numbers on the tenth of a mile odometer wheel. 3. Repeat Steps 1 and 2 for left turn and for right and left ‘tums at midpoint of speed ranges 2 through 4 4, I the distances observed in Steps 1 through 3 are not ‘correct, check the following: ‘a. Tum signal module ground and module pin connec- tions. b. Lamp grounds and lamp connections, ©. Reed switch operation, connections, and grounds. ‘Check for incorrect bulbs in lamps. (Module is designed to operate with stock bulbs. Bulbs with more or less wattage may affect operation.) e. Replace module with known good module and repeat DISTANCE TEST. NOTE It is very important that the turn signal module and the turn ‘signal lamps are at the same ground potential that is, the ‘grounds for both the module and the lamps must have good ‘continuity to one another. TIME TEST (ALTERNATE) ‘An alternate method of checking the module for correct oper- ation is to measure the turn signal *ON" time at a constant ‘speed. The approximate "ON" times at four constant speeds are as follows: constant sreeo | TURNSIGNAL-OW" 2 mph Om a mph (6 A) BT SE mph (6 ih att 6 ph 1S eh i072 RIDER PREFERENCE AND CONTROL If the rider prefers a longer distance (with turn signals “ON"), the button can be held in longer and released cioser to the intersection. For a shorter distance (with turn signals *ON’), the button can be pressed a second time to cancel the turn signal. TROUBLESHOOTING ‘See the following chart for troubleshooting procedure. CAUTION ‘Do net apply 12 vdc to module with pin 1 not connected to ground. Module burnout will occur. 19TROUBLESHOOTING Problem ‘Cause Solution 1. Right or left tum signals do not flash ~ front or rear lamp on inopera- tive side is lit, ut does not flash. (Other side signals operate normally.) 11 Burned out bulb. 1.2 Broken lamp wire. 1.3 Loose lamp socket (where staked at housing). 1.4 Poor ground. 1.5 _Corroded contacts. 1.1.1 Replace bulb that does not light and check for normal operation 1.2.1 Repair broken wire. 1.3.1 Replace lamp. 1.4.1 Scrape paint or replace ground wires. 1.5.1 Clean bulb/socket. Apply grease to bulb contacts. 2. Turn signals on one side operate — other side inoperative. 2.1 Handlebar directional ‘switch on inoperative side Not functioning, 22 Broken or discon- nected wire in directional switch circuit. 23° Apossible combina- tion of causes found in Prob- lem 1 2.4 Module maifunction- ing. 2.1.1 With ignition switch ON, press directional switch and measure voltage at Pin 8 or 10 (83 models) or Pin 6 or 7 on 94 FLTs & XLHs. (See Figure 10 for applicable pin.) With ‘switch pressed and held, 12 vdc must be present at pin, Measure with positive probe at pin and negative probe con- ected to ground. If voltage is present go to 2.4.1 2.2.1 Ino voltage is present, refer to Wiring Diagram and determine (using voltage or continuity checks) whether ‘switch or wiring is faulty. Replace switch (See HANDLEBAR ‘SWITCHES in Section 2) or repair wiring as needed. 2.9.1 See Probiem 1. Solutions. 2.4.1 If voltage was present in 2.1.1 and lamps and wires are good, but module does not generate pulses, module is bad and must be replaced,Problem Cause Solution 3. Tumsignals andhazard | 3.1 No power (12 vdc) at | 3.1.1 Refer to Wiring Diagram and check for 12 vde on load flashers are inoperative, pin 2 of module due side of accessory circuit breaker. Use voltage or conti- to “bad!” accessory cir- nuity checks. Isolate the “bad” component or broken cuit breaker, starter wire, Replace bad component or repair broken wire. relay (vehicles with radio only), ignition switch, oF main circuit breaker or the con- necting wiring, 3.2 Pin1 of module not_—_| 3.2.1 Check for ground with ohmmeter. Clean and tighten ‘connected to ground. {ground connections or repair broken ground wires. CAUTION ‘Operating modulle without pin 1 grounded will cause module to burn out. “Turn signals do not can- | 4.1 No reed switch signal | 4.1.1 Check for speedometer reed switch input at Pin 3 of cel, all models, except at Pin 3 of module. module. Connect ohmmeter to WIGN lead and FLHR. See 5 below for ground. Spin front wheel or turn speedometer cable. FLHR procedure. ‘Ohmmeter must alternate between ‘0’ ohms and infin- ity. Check for broken wire or “bad” reed switch it above ohmmeter reading is not obtained. Ifreed switch signal is present, module is bad. NOTE Reed switch signal is also used to control ‘Sound System volume and cruise control speed (on Ultra models. 42 _Bad module. 4.2.1 Replace module. %. Tum signals do not can- | 5.1 Open in wiring to turn | 5.1.1 Check for vollage on WIGN wire in connector [208] cel on FLHR. ‘signal module while connected. Meter should alternate between 412VDC (from tum signal module) and 0-0.5VDC when rear wheel is rotated. If no voltage is present, trace wiring to find open connection and correct it. 52 No voltage from tum | 6.2.1 Check for voltage on WIGN wire in connector [208] signal module while connected. Meter should alternate between 12VDC (from tur signal module) and 0-0.5VDC when rear wheel is rotated. If no voltage is present, replace turn signal module. 53 Speedometer is not | 5.3.1 Check for voltage on WIGN wire in connector [208] creating signal to while connected. Meter should alternate between ‘ground 42VDC (from turn signal module) and 0-0.5VDC when rear wheel is rotated. If no voltage is present, replace speedometer. REMOVAL/INSTALLATION Refer to the applicable Service Manual for removalinstala tion instructions. aCRUISE CONTROL - ULTRA MODELS HOW-IT-WORKS ‘The Cruise Control System is an electronic system that pro- vides automatic vehicle speed control. See Figure 11 ‘The new control electronics and stepper motor are contained in one control module. The control module is mounted under the left side cover. The stepper motor actuates the cruise control cable through a gear train and ribbon reel. A 15 amp circuit breaker supplies 12 vdc to the module. The circuit breaker is located ahead of the steering head on all FLHTCU and 93 FLTCU models, and on the left instrument housing support on 1994 FLTCU models. System Diagram and Operation 1. See Figure 12. To illustrate how the system works, the following steps explain how to engage, allow the cruise ‘control to control speed and disengage the system. 2. While riding in fourth or fifth gear, turn CRUISE switch “ON”. Power is supplied through a 15 ampere (amp) ci- cuit breaker to the electronics module. 3. With motorcycle traveling at the desired “cruise” speed (30 mph or greater) momentarily press the “RESUME/ SET switch on right handlebar contro! downward. NOTE Final design refinements have allowed the cruise “SET” speed to be reduced to 30 mph (48 km/h). 4. The electronics module responds to the SET switch input by “reading” the speedometer reed switch input. ‘The reed switch signal becomes the desired speed. 5. The electronics module sends a signal to the stepper ‘motor. The stepper motor drives the ribbon reel to take up the slack in the cruise cable, NOTE The cruise cable is connected directly to the carburetor. 6. The electronics module monitors the engine rpm and the speedometer reed switch signal. The module signals the stepper motor to open or close the throttle to keep the speedometer reed switch signal constant. The engine pm ig monitored to detect engine ~ over speed which will cause cruise disengagement. (See next paragraph.) 7. The cruise contro! will disengage (stepper motor drives cruise cable to full out position) when the electronics ‘module receives any ofthe following inputs: a. Front or rear brake is applied. b. Throttle is “rolled back” (closed) actuating cable switch ©. Motoreycle clutch disengaged, module senses 100 (reat an increase in rpm. d. Cruise ON/OFF switch turned OFF. fe. Engine STOP switch tumed OFF. (This removes tachometer input signal and module disengages.) 1. The “RESUME/SET switch is pressed and held for more than 6 seconds (93 models) 9g The “RESUME/SET” switch is pressed down “SET ‘and held until speed drops below 30 mph (48 kmh). It switch is released with motorcycle speed above 30 mph (48 krv/h), the system will -engage, Figure 11. Cruise Control Module (Left Side Cover Removed)FRONT & REAR BRAKE LIGHT ‘SPEEDOMETER REED ‘SWITCHES (RELAY) ‘SWITCH IDLE THROTTLE CRUISE CABLE SWITCH SET LAMP L_SABLE swiren J i readeasdee yf Srebecnioton [Tacnoweren |»! ELECTRONS L_4! Gearman 4 uc | AND RIBBON REEL 3 CRUISE ON/OFF SWITCH | | THROTTLE ACTUATION ‘SET SWITCH RESUME Figure 12. Cruise Control System Diagram24 NOTESTROUBLESHOOTING It the cruise is inoperative, perform the following switch diag Nostic sequence to isolate the problem. Also refer to TROU- BLESHOOTING CHARTS following the “Switch Diagnostic ‘Sequence”. Switch Diagnostic Sequence The following steps provide a diagnostic procedure that uses cruise system switches and the vehicle ignition switch to ‘enable a diagnostic mode in the cruise module circuitry. The diagnostic mode or builtin test circuitry uses the green “CRUISE” indicator, below speedometer, as a test indicator. GENERAL TEST CONDITIONS Perform the following procedures (steps) in the sequence sven and actuate switches in the order specified in the pro- cedure, NOTE ‘The diagnostic mode may be aborted and/or incorrect indica- tions may be given if the sequence of testing is not followed or if the engine is started. 1. Begin the diagnostic mode with the vehicle ignition ‘switched off and the cruise main switch turned on. 2. While holding the SET switch on, turn the vehicte ignition to the ON position. CORRECT FUNCTION ~The green cruise lamp will light land remain on as long as the operator holds down the ‘SET switch. If the lamp continues to light after switch released, either the switch or related wiring is shorted. Continue at Step 3 if function is correct. INCORRECT FUNCTION ~ The green cruise lamp will ‘not light for any ofthe following reasons: (a) SETIRES switch not wired correctly or bad switch. (b) Broken or pinched wire to SET switch or cruise module. (©) Green cruise lamp burned out or miswired. Cruise lamp Is turned on by module supplied ground. (6) Main 10-place connector not plugged into cruise module. (@) On 1993 models, cruise power wire hooked up to constant 12.volt circuit breaker rather than ignition switched 15 amp circuit breaker. () Bad cruise main switch and associated wiring (g) No module ground at Terminal E of 10-place module connector. (h)_ Brake light on constantly () Throttle cables too tight. NOTE Before proceeding to CHART A, repeat Stops 1 and 2. It cruise lamp still does not light, proceed to “CHART A CRUISE TROUBLESHOOTING”. See Table 1 for module connector wires and function. Repair any problems and recheck by repeating Steps 1 and 2. Connector references such as “BA” refer to the connector ‘centication used in the wiring diagrams at the rear of this ‘manual.To Identity the model year of a connector a dash and the year have been used as shown in this example: “(8A}-93". ‘TABLE 1. MODULE CONNECTOR [8A-93, 17A -94) TERMINAL Leer’ FUNCTION aja. | WIRECOLOR AND. (eal CONNECTION (17a) ar) a ted) | red) | ON/OFF switch enable green | bive 8 blue’ | blue ‘SET input from black SETIRESUME switch © | white? | white [~ RESUME input from blue SET/RESUME switch D | violet | black’ | ide cable disengage yellow | ted | switch (12 vae from 15 amp circuit breaker) E lack | black | Cruise module ground F | orange | black” | 12 vde power from 15 ‘Wiolet | orange | _ amp circuit breaker G red! | red’ | Disengage from brake yellow | white relay (12 vde) H ink | pink | Tachometer input (12 vd) J | green’ | green |” 12 vde trom “CRUISE” red indicator in instrument panel (Module provides ground) «| white’ | white? [~~ Speedometer reed ‘green | green ‘switch ‘Letters are on sides of connector next to wires. 3. Press the RES switch upward. CORRECT FUNCTION — The green cruise lamp will light land remain on as long as the operator holds the RES ‘switch upward. Continue at Step 4 if function is correct. INCORRECT FUNCTION — The green cruise lamp will ‘not light for any of the following reasons: (@) RES switch not wired correctly. (©) Broken of pinched wire to RES switch or cruise module. 25NOTE ‘Conditions (a) through (i) in Step 2 should not apply if Step 2 was completed successfully. Proceed to “CHART 8 CRUISE TROUBLESHOOTING” 4. Next, to check the throttle grip switch, turn the throttle ‘tip tightly closed, CORRECT FUNCTION — The green cruise lamp should ‘come on when the switch is closed and should go off when the throttle grip returns to its free position. Con- tinue at Step 5 if function is correct. INCORRECT FUNCTION ~ The green cruise lamp will ‘ot light for any of the following reasons: (2) Throttle grip switch not wired correctly. (b) Broken or pinched wire to throttle grip switch or cruise module. (c) Throttle grip switch not working correctly. Proceed to “CHART G CRUISE TROUBLESHOOTING” 5. Apply the hand brake lever. CORRECT FUNCTION - The green cruise lamp should remain on until the brake is released. If correction func- tion is obtained, continue at Step 6. INCORRECT FUNCTION - The green cruise lamp will ‘not light for any of the folowing reasons: (@) Front brake switch or brake relay not wired correctly. (0) Broken or pinched wire to front brake switch or cruise model. (©) Front brake switch or brake relay not working prop- only. (@) All brake light bulbs are burned out or disconnected. Proceed to “CHART FI or F2 CRUISE. TROUBLESHOOTING” 6. Press the foot brake pedal and keep it applied for at least 5 seconds, CORRECT FUNCTION - The green cruise lamp should ‘come on. After holding the foot brake for § seconds, the amp will go off. Release the brake switch, and the cruise ‘module will momentarily pull the throttle open, approxi- ‘mately 20%. This throttle stroke is immediately aborted it the brake is applied. Continue at Step 7. INCORRECT FUNCTION ~ The green cruise lamp will ‘ot light if reasons (a) through (c) exist. The throttle will ‘not open if reasons (d) and (e) exist (a) Rear brake switch or relay not wired correctly. (©) Broken or pinched wire to rear brake switch, brake relay or circuit model. (c)_ Rear brake switch not working propery. NOTE 1f cruise lamp lights, but throtle fils to open approximately 20%, refer to (d) and (e). (6) Cables not properly adjusted. (e) Bad cruise control module. Proceed to“CHART FI or F2 CRUISE TROUBLESHOOTING” 26 7. Roll the vehicle forward and backward to activate the reed switch in the speedometer. CORRECT FUNCTION ~ The green cruise lamp will flash on and off indicating that the reed switch is wired properly and working correctly. Continue at Step 8. INCORRECT FUNCTION - The green cruise lamp will ‘ot light for any of the following reasons: (@) Broken speedometer cableidrive. (b) Reed switch not wired correctly. (©) Broken or pinched wire to reed switch, (@) Reed switch not working properly (€) Reed switch ground wire disconnected. Proceed to “CHART H CRUISE TROUBLESHOOTING” 8. If the cruise main switch is turned off, the lamp will lash in response to the ignition sensor plate input. Since start ing the engine will abort diagnostic mode, simulate the sensor plate input as follows: (1) Turn main cruise switch off {@) Disconnect 3-piace connector that connects ignition ‘sensor to ignition module. (2) Momentariy place screwdriver blade across black/ white and green wire terminals of connector half connected to ignition module. Repeat this step 6-10 times. The ignition module ignores the first four sen- sor inputs. ‘The cruise lamp must flash on the fifth and sub- ‘sequent sensor inputs. Proceed to “CHART | CRUISE TROUBLESHOOTING” 8. The switch diagnostic sequence may be repeated at any time by going to Step 1 oF pross SET switch twice to restart diagnostic sequence. 10. The cruise switch diagnostic sequence is designed to abort for any of the following reasons: (a) Engine is started, (b) Incorrect switching sequence is used. 11. Quit diagnostic mode by turing off ignition switch.Other Malfunctions HARSH ENGAGEMENT If cruise control opens throttle abruptly or harshly, check for a cruise cable that is too tight. Refer to cruise cable adjustment ven later in this section. ‘SPEED VARIATION Loses Speed Check for 1. Cruise cable too loose. 2. Set switch held too long. Gains Speed Cruise cable too tight. Cruise Disengagos with RES Switch “ON” If RES switch is held “ON* for longer than 6 seconds, cruise will disengage. This is normal operation for 1983 models. ‘Speed Surges If speed surges occur, check for the folowing: 1. Defective reed switch. 2. Poor ground at cruise module or reed switch 3. Defective cruise module. NOTE (Check for surging with cruise control turned "OFF". if surging is stil present, a lean fuel mixture may be the cause of surg- ing. arCHART A CRUISE TROUBLESHOOTING ——— Remove left saddlebag and sidecover. Is 10-pin connector (85]-3 | models or [17A]-94 models plugged into cruise module? Plug in connector and perform Switch Diagnostic Sequence to verify problem is repaired. Unplug connector (88)-93 or [17A}-98 from See cruise module. a Chart. SET SWITCH (Check continuity between the BK/O terminal (F) and the BE terminal (B) of connector (88)- 99 of O/V terminal (F)) and BE terminal (B) of connector [17A}-94. Resistance should be between 250-300 ohms. Pressing the set button should give a reading of jess than 0.5 ohms. and 17B]-93 or [16A and 168}-94 for cruise set switch. Measure between the BKIO and the BE terminals on 93 ‘models or O/V and BE/BK on 94 models, at the connector. Resistance should be 250-300 ohms. Pressing the SET button should give a reading of less than 0.5 ohms. Remove headlanp asserély on FLATCU or the nse (v0) mont duster on FLICU. Loca the Spin connector [17A Repair or replace cruise hamess, Replace SET/RESUME switch Connect a jumper from the GN terminal (J) on 93 models or GN/R termi- nal (J) on 94 models to ground. The cruise lamp should glow when the ignition is on. Continued on next pageYes L_,) (64) terminal (A) and the negative probe on the BK © @ {>} (F) withthe ignition switch off. The meter should read (= )}-G0o} 4 aaeoae L_,} has never iluminated. If the eruise light will not ilumi- Refer to Chart C. Place the positive probe on the BK/O (93) or O/V (94) terminal (F) and the negative probe on the BK terminal (E). With the ignition on, the meter should read battery votage Le Refer to Chart D. @ Place the positive probe on the R/BE (93) or R/GN. terminal (E). With the ignition and cruise switches on, the meter should read battery voltage. Refer to Chart E. Piace the positive probe on the RAW (83) or PUY (94) | terminal (G) and the negative probe on the BK termi- rl (E). Meter should read between 11-13 volts only Ls} when the brake is applied and the ignition is on. If voltage is present and lamps don't light, check for ‘opens in wiring to lamps or for burnt out lamps (all 3 lamps must have failed to make cruise inoperative), Refer to Chart F-1 or F:2. ? ‘Check continuity between the BK/R (93) or V/V (94) terminal (D) and the BK/O (93) or O/V (94) terminal infty when the throttle switch is in the relaxed pos'- tion, and continuity when the throttle grip is rolled for- ward, Restart Switch Diagnostic test sequence if cruise light nate when the first step is performed now, replace the ‘cruise module.CHART B CRUISE TROUBLESHOOTING | RESUME SWITCH less than 0.5 ohms. | Check continuity between the BK/O (93) or Orv (94) terminal (F) and the W (83) or W/BE (84) terminal (C). Resistance should be between 250-300 ohms. Pressing the SET button should give a reading of Repeat Switch Diagnostic ‘Sequence. Remove headlamp assembly on FLHTCU or the instrument ‘luster on FLTCU. Locate the 3-pin connector [17A and 178}. 93 or [16A and 168]-94 for cruise set switch. Measure between the BK/O and W terminals on 93 models or ON and \WIBE on 94 models, at the connector. Resistance should be 250-300 ohms. Pressing the SET button should give a read- ing of less than 0.5 ohms. | Repair or replace cruise hamess. ‘switch, i J CHART C CRUISE TROUBLESHOOTING CRUISE LAMP the ignition is on. Connect a jumper from the GN (93) or GN/R (84) termi- nal (J) to ground. The cruise lamp should glow when Repeat Switch Diagnostic, ‘Sequence. Remove headlamp assembly on FLHTCU or remove two screws from the instrument cluster and raise cluster on FLTCU (do not disconnect all connectors from cluster). On {93 models disconnect the GN wire (64B) that connects to the Instrument housing.On 94 models remove GN/R wire from ‘connector [21B}. Connect a jumper wire to ground from the GN (83) or GN/R (94) wire that feeds the instrument cluster. The cruise lamp should glow when the ignition is on. Replace SET/RESUME Repair or replace cruise Replace bulb. harness. Replace Cruise Module.CHART D CRUISE TROUBLESHOOTING CRUISE POWER voltage. Place the positive probe on the BK/O(93) or O/V (94) terminal (F) and the negative probe on the BK terminal (€). With the ignition on, the meter should read battery Sequence. Repeat Switch Diagnostic ) ‘Check continuity between the BK terminal (E) and ground. wire. Correct open in ground Replace Cruise Module. Remove headlamp assembly on FLHTCU or the instrument cluster on $3 FLTCU. Check for cont- nity between BK/O (93) or O/V (24) terminal (F) and the 15 amp cruise circuit breaker. Repair or replace cruise hares. check for power at RIGY wire in circuit breaker block. NO + Replace 15 amp circuit breaker. (On 93 models repair open between the accessory cit- ‘out breaker and the cruise circuit breaker. On 94 mod- ‘ls repair open between cruise circuit breaker and RY GY ignition switch wire. a1CHART E CRUISE TROUBLESHOOTING CRUISE ENABLE (CRUISE SWITCH) Place positive probe on RUBE (93) or RIGN (94) termi- | nal (A) and the negative probe on the BK terminal (E) | With the ignition and cruise switches on, the meter should read battery voltage. Remove the instrument cluster on FLTCU or carefully pry the ‘cruise switch out ofthe inner fairing on the FLHTCU, With the ignition and cruise switches on, the meter should read battery voltage on the FUBE (93) or RIGN (94) terminal of the cruise switch. Repeat Switch Diagnostic ‘Sequence. Repair or replace cruise harness. Measure voltage at O/BK (93) or O/V (94) termi- nal on switch. Meter should read battery voltage. eLe ¥ ©) Replace Cruise Module. f l Replace main cruise | | Repair open between switch, cruise circuit breaker and main cruise switch.CHART F-1 CRUISE TROUBLESHOOTING CONSTANT BRAKE LIGHT INPUT Check front brake handlever for excessive clearance between the handlebar clamp and the right switch housing ‘Adjust master cylinder handlebar clamp to obtain ‘minimum clearance. (On 83 models remove seat. Measure voltage at R/W wire termin (on the brake light relay. Meter should read battery voltage only when brakes are applied. On 94 models remove headlamp assembly. Measure voltage at A/BE wire terminal (86) on the brake light relay. Meter should read battery voltage only when brakes are applied. (06) —9 Replace brake light relay. + Perform Switch Diagnostic | Sequence to verify prob- paired, | ee Remove one of the spade terminals from the rear brake light switch. Are brake lights stil lit?” @- | Replace front brake | switch. Replace rear brake light switch. [oTCHART F-2 CRUISE TROUBLESHOOTING NO FRONT AND/OR REAR BRAKE LIGHTS (On 93 madels, remove seat. Make sure connectors (48A) and (488) are connected. On 93 and 94 models, turn on, ignition. Does relay cick when brakes are applied? Rornove headlamp on 84 model, Check or pow ‘on RW (83) or R/BE (94) wire at terminal (86) on the: brake ft rly wth gnton on and brake apptod. | Nor sei ta bar) wage, | Check for grounds at BK | ‘Check for power at brake light switches or for wire on relay terminal (85). ‘opens (continuity) in the wiring from the switches. C ) Perform Switch Diagnostic Sequence to verity prob- ¥ lems repaired. Replace relay Correct open in ground circuit. ‘Check for power on WIR (83) or OFV (84) wire at terminal (20) with ignition on. Meter should read battery vottage. (Check for power on R (83) or FUY (94) wire at terminal (87) on the brake light relay with ignition on and brakes applied. Meter should read battery voltage. Remove headlamp assembly on 93 and 94 FLHTCU or the instrument panel on 93 FLTCU. On 94 FLTCU the circuit breaker block is located under the left side of the instrument panel support bracket. Check for open in wiring | (Continuity) from cruise circuit breaker to termi | nal (30) (WIR (83) or O/V (94) wire) on the | brake ight retay. ' a Check for opens in wiring to || Replace brake light Perform Switch Diagnostic. lamps or for burnt out lamps (all || relay. Sequence to very prob. three must fail for cruise to be een ae inoperative) > —CHART G CRUISE TROUBLESHOOTING THROTTLE SWITCH Check continuity between the BK/R (83) or V/Y (94) terminal (D) and the BK/O (23) oF O/V (04) terminal (F) with the ignition switch off The meter should read infinity when the throttle switch is in the relaxed position, and continuity when the throttle grip is rolled forward, ©! ©) aaa Restart test sequence. If the cruise light will not illuminate when this step is performed now, replace the cruise module. Check for continuity directly at throtte switch. Continuity should only be present when the throttle is rolled forward under pressure. Repair or replace the cruise harness. 95CHART H (1993 MODELS ONLY) CRUISE TROUBLESHOOTING rotated. ‘SPEEDOMETER INPUT (REED SWITCH) Check for continuity between the WIGN terminal (K) ‘and BK terminal (E). The meter should alternate between continuity and infinity as the front wheel is Remove headlamp assembly on FLHTCU or the instrument cluster on FLTCU. Locate the W/GN wire wrapped with the White tape (connector 20). Check continuity between WIGN ter- minal (K) and connector 20A (the male side of the WIGN con- | nector with white tape in the fairing). Repeat Switch Diagnostic Sequence. It the cruise light will not illuminate when this step is per formed now, replace the Repair or replace cise hares, cruise module. Check continuity between the single pin connector to ground on the BK wire of the reed switch, Check continuity between 208 and ground. The meter should altemate between continuity and infinity as the front whee! is rotated, Replace reed switch on back of speedometer. Repair open or loose connection to ground.CHART H (1994 MODELS) ONLY CRUISE TROUBLESHOOTING ‘SPEEDOMETER INPUT (REED SWITCH) Check for continuity between the WIGN terminal (k) and BK terminal (E). The meter should alternate }$-—£ between continuity and infinity as the front wheel is. rotated. Remove headlamp assembly on FLHTCU or the instrument cluster on FLTCU: Locate the WIGN wire in connector (21A]. Check continuity between W/GN terminal (K) and connector 21a) Repeat Switch Diagnostic Sequence. if the cruise light will not iluminate when this step is per- formed now, replace the cruise module ~ s Repair or replace Check continuity between the cruise harness or inter- black wire in connector [214] and connect hamess. ‘ground, ‘Check continuity between W/GN wire in Repair open or loose connector [21] and ground. The meter connection to ground. {> should alternate between continuity and Infinity as the front wheel is rotated. (4 Replace reed switch on back of speedometer. 37CHART | CRUISE TROUBLESHOOTING ‘TACHOMETER INPUT Place the postive probe on the PK terminal (H) and the negative probe ‘on the BK terminal (E). The meter should read battory voltage. If voltage 'is not present, “bump” the starter unt the voltage is present. The meter should read a voltage fluctuation during cranking. Remove headlamp assembly on FLHTCU or the instrument cluster on FLTGU. On $3 models check for continuity between the PK terminal (H) land the single pin connector [33A]. On 94 models check for continuity between the PK terminal (H) and the PK wire in connector [20A] ‘Repeat Switch Diagnostic No ‘Sequence. + Repair open betwoen connector pair of replace cruise har- [83A] and connector [38] on 83 ‘ess or interconnect harness models or between connector 00 94 models. {20A] and the instrument pane! (on 94 mode's. Replace Cruise Module.CRUISE CONTROL - THROTTLE CABLES GENERAL See Figure 13. The cruise control cable (1) is connected irectly to the carburetor. The throttle cable (2) is identical to the throttle cables used on all FLT models. The idle cable (3) is similar to non-cruise con- trol models; except it has the cruise disengage switch (4), Figure 14. CABLE ADJUSTMENT NOTE ‘See Figure 13. The throttle cable (2) must be adjusted with the idle cable (3) completely loosened (slack). Therefore, adjust the cables in the sequence given in the procedure. These procedures cover adjustment only. you must remove and install any of the cables refer to the REMOVAL AND INSTALLATION procedure that follows. THROTTLE CABLE ADJUSTMENT 1. With handlebar in straight ahead position, idle cable adjusted to full slack and throttle grip turned to wide ‘open throttle (W.O.T}), adjust pull open cable to obtain full throttle opening at carburetor. 2. ‘Twist throttle grip to full closed position. Check that idle stop-serew is touching idle stop with handlebar in straight ahead position, and while turning handlebar from “lock-to-iock’. NOTE It idle stop-screw is not touching carburetor, adjust (loosen) pull-open cable just enough so that idle stop-screw is touching idle stop through full lock-to-fock handlebar ‘movement. Also check that cruise cable has slack and is not ‘opening throttle. Loosen cruise cable if required. 3. Rotate throtle grip to W.O-T. and release, throttle must return to idle position freely. If it does not, check for incorrect cable routing, damaged cables or binding in the throttle grip. IDLE CABLE ADJUSTMENT (Connects throttle grip to carburetor). 1. See Table 1. With idle cable stil adjusted to full slack position, remove left side cover. 2. Connect ohmmeter to black/red and black/orange leads ‘on 10-pin connector [88] on 98 models. On 94 models, connect ohmmeter to violetyellow and orange /Violet leads on connector [17A]. 3. Ohmmeter must indicate infinity (switch contacts open). {f ohmmeter indicates continuity, the roll-off switch may be shorted and entire cable must be replaced. 4, With handlebar in straight ahead position, adjust idle cable until approximately 0.08 in. (1.5 mm) of freeplay ‘xists at the outside diameter (OD) of the throttle grip. 5. Rotate the throttle grip, with light force, toward the closed position, The ohmmeter must indicate continuity. If It does not, decrease freeplay at throttle grip by adjusting the idle cable to obtain continuity while maintaining some freeplay at the throttle grip. 6 While holding the throttle grip (with light force) in the ‘closed position, tun handlebar from “lock-to-lock’. ‘Ohmmeter must indicate continuity throughout handlebar movement. 7. With handlebar in straight ahead position, rotate throttie Gfip to W.OT. and release. Throttle must return to idle Position reely. 8 Repeat Step 7 with handlebar at full left and right positions. If throttle does nat return to idle position freely, oosen idle cable slightly and repeat Steps 5-8. CRUISE CABLE (Connects stepper motor to carburetor) NOTE Cruise cable must be adjusted last; that is, after throttle and idle cables have been adjusted. Cruise cable will only require adjustment if cruise module or cable are being replaced. The ribbon that actuates the cruise cable must be in the ful-out position. 1. See Figure 1. Route cruise cable (2) through the T-stud mount (5), then forward and over the top engine stabilizer and down between cylinder heads to the carburetor. 2. See Figures 8-13 and 8-18, With cruise cable attached to cruise module, adjust cable length by depressing locking button (2) and moving the upper cruise cable housing in or out $0 eyelet on cable may be slipped on pin at carburetor as shown in Figure 13. 3, See Figure 13. Check slack in cruise cable as shown. ‘Shorten or lengthen cable as required. 4. Place eyelet end of cable on carburetor pin. '5. Install cxing (6) to secure cruise cable to cable bracket. Install washer (8) and another crring (5) to secure cable ‘eyelet to carburetor pin.1 2. Throttle cable 3. Idle cable 4. Idle adjusting screw Cruise cable stack must be such that hole in eyelet extends beyond pin on carburetor ‘a distance equal to 1/3 the hole diameter. Hole in eyelet Carburetor pin 5. C-Ring (2) 6. Throttle stop VIEW FROM END OF CARBURETOR PIN 7. Moveable throttle stop oe 8 Washer Figure 13. Carburetor Cables 1. Idle cable ‘Switch terminals. 2. Disengage switch Cable bracket Figure 14. Throttle Cable Routing