Harley Davidson Touring 2004 Service Manual fe05a

HOME

Spare

ECM Power

f2223x9x

EFI System

Relay

System Fuse Block (Under Left Side Cover)

EFI Fuse Block (Under Right Side Cover)

FLHR/C/S

FLTR, FLHT/C/U

1. Headlamp

2. Ignition

3. Lighting

4. Instruments

5. Brakes/Cruise

6. Radio Memory

7. Radio Power

8. Accessory

9. Battery

10. Brake Light Relay

11. P&A

12. Starter Relay

f2210x8x

f2204x8x

Fuel Pump

SPECIFICATIONS 5.1

IGNITION

Spark timing advance

Idle speed 990 ± 50 RPM

Spark plug size 12 mm

Spark plug gap

Spark plug type

Ignition coil primary resistance

Ignition coil secondary resistance

System Fuses

Maxi-Fuse 40 Orange

Headlamp 15 Blue

Ignition 15 Blue

Lighting 15 Blue

Instruments 15 Blue

Brakes/Cruise 15 Blue

Radio Memory 15 Blue

Radio Power 10 Red

Accessory 15 Blue

Battery 15 Blue

P & A 15 Blue

EFI Fuses

Fuel Pump 15 Blue

ECM Power 15 Blue

Circuit

DATA

0°-45° BTDC (range)

12° BTDC@1000 RPM

0.038-0.043 in

0.97-1.09 mm

Harley-Davidson

No. 6R12 (no substitute)

0.3-0.5 ohms

2500-3500 ohms

Rating

(Amperes)

Color

Figure 5-1. Fuse Locations

2004 Touring: Engine Management (EFI) 5-1

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NOTES

5-2 2004 Touring: Engine Management (EFI)

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EFI SYSTEM 5.2

GENERAL

The engine management system consists of the following components:

Electronic control module (ECM).

●

Crank position sensor (CKP).

●

Manifold absolute pressure sensor (MAP).

Intake air temperature sensor (IAT).

●

Engine temperature sensor (ET).

Idle air control (IAC).

●

Throttle position sensor (TP).

●

Vehicle speed sensor (VSS).

Tu rn signal module (TSM) or optional, factory-installed

●

turn signal security module (TSSM). This includes an integrated bank angle sensor (BAS).

Ignition coil.

●

The ECM is mounted under the electrical caddie cover (left side of vehicle). It computes the spark advance for proper ignition timing based on sensor inputs (from CKP, MAP and TP sensor) and regulates the low-voltage circuits between battery and ignition coil.

The bank angle sensor is within the TSM/TSSM. If the vehicle lean angle exceeds 45 degrees for one second, the fuel pump is shut off. Once the sensor is tripped, the motorcycle must be uprighted, turned off and then on again before the engine can be restarted. This is communicated across the data bus.

Front and rear coils ﬁre each spark plug independently (one cylinder at a time - no wasted spark). The coil also has an extra terminal to monitor current on the coil secondary circuit. This is used for knock detection and combustion diagnostics.

The ignition system gives a spark near top dead center for starting. At RPM and loads above this, the system gives a spark advance that varies between 0° and 50°.

The IAT, ET and TP sensors are used to provide information to the ECM to ﬁne tune spark and fuel delivery. The VSS is used as an input for idle speed control.

TROUBLESHOOTING

See the diagnostic charts that follow for troubleshooting information.

The ECM contains all of the solid state components used in the ignition system. The dwell time for the ignition coil is also calculated in the microprocessor and is dependent upon battery voltage. The programmed dwell is an added feature to give adequate spark at all speeds. (The ECM has added protection against transient voltages, continuous reverse voltage protection, and damage due to jump starts.) The ECM is fully enclosed to protect it from vibration, dust, water or oil. This unit is a non-repairable item. If it fails, it must be replaced.

The crank position sensor (CKP) is located in the front left side of the crankcase. The CKP generates an AC signal which is sent to the ECM where it is used to reference engine position (TDC) and speed. It functions by taking readings off the 30 teeth on the left side ﬂywheel (two teeth are missing to establish a reference point).

The MAP sensor is located on top of the intake manifold. The MAP sensor monitors the intake manifold pressure (vacuum) and sends the information to the ECM where the module adjusts the spark and fuel timing advance curve for optimum performance.

2004 Touring: Engine Management (EFI) 5-3

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[79A]

[79B]

Intake air

control

[87A]

CKP

System relay

Ion sense

Constant

[87B]

Switch power

Inj. F

Inj. R

Coil R Coil F

BE/GN

BN/R

BK/PK

BK/O

power

[78]

30 12

11 29

35 36

[62B]

To Ta chometer

(FLHR/C/S Optional)

Y/GN

BE/GY

IQCPR

87A

30 85 86

System

relay

GN/O

15 Amp

fuel pump

fuse

W/BK

[13A] [13B]

123

O/GY

123

Fuel

pump

GN/O

Y/GN

W/Y

[141B][141A]

All Except

FLHR/C/S

GN/GY

GY/BE

[84B] [84A]

[85B] [85A]

Y/GN

[83B] [83A]

AB CD

Coil

Y/BE

BE/O

40 Amp

Maxi fuse

Battery

–+

BE/GY

W/BK

Engine stop switch

15 Amp

ECM fuse

15 Amp

IGN fuse

GY R/BK

Ignition switch

Vehicle speed sensor

f2208g8x

TP sensor

ET sensor

IAT sensor

5v sensor gnd.

MAP sensor

5v sensor pwr.

Serial data

Flash pin

Power gnd. Power gnd.

BK/W

GY/V

PK/Y

LT GN/Y

BK/W

V/W

R/W

W/GN

LT GN/V

LT GN/R

10 28

[65B] [65A]

A B C

BK/W

A B C

[90B] [90A]

[89B] [89A]

[91A]

R/W

GY/V

BK/W

V/W R/W

Vehicle speed sensor

Data link connector

AB B C

[88B] [88A]

ET sensor

IAT sensor

[80B] [80A]

[30B] [30A]

MAP sensor

TP sensor

hand controls

W/BK W/BN

To speedometer

and tachometer

7 7

To right

3 4 5

[22A]

TSM/ TSSM

Figure 5-2. EFI System Circuit - Simpliﬁed

5-4 2004 Touring: Engine Management (EFI)

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110

120

90 100

MPH

RPM

x100

f2160x8x

Check Engine Lamp

EFI DIAGNOSTIC INTRODUCTION 5.3

SYSTEM PROBLEMS

All system problems fall into at least one of three general categories.

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 security disabled 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

See Figure 5-3. The check engine lamp indicates the ECM has determined a fault condition exists. There may also be starting or performance problems.

RESOLVING PROBLEMS

To resolve system problems, ﬁve basic steps are involved. In order of occurrence, they are:

1. Check for diagnostic trouble codes by using speedometer self diagnostics. See 5.4 CHECKING FOR DIAG-

NOSTIC TROUBLE CODES: EFI.

2. Retrieve diagnostic trouble codes by using speedometer self diagnostics. See 5.6 SPEEDOMETER SELF DIAG-

NOSTICS.

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 lack of trouble codes.

Figure 5-3. Speedometer

2004 Touring: Engine Management (EFI) 5-5

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CHECKING FOR DIAGNOSTIC TROUBLE CODES: EFI 5.4

CHECK ENGINE LAMP

To diagnose system problems, start by observing the behavior of the check engine lamp.

NOTES

See Figure 5-4. “Key ON” means that the ignition key is

●

turned to IGN and the engine stop switch is set to RUN (although the engine is

When the ignition key is turned ON, the check engine

●

lamp will illuminate for approximately four seconds and then turn off.

●

If the check engine lamp is not illuminated at Key ON or if it fails to turn OFF after the initial four second period, then the speedometer may need to be replaced. See 5.5

INITIAL DIAGNOSTIC CHECK: EFI.

not

running).

f1240x2x

Figure 5-4. Ignition Switch (FLTR, FLHT/C/U)

1. When the lamp turns off after being illuminated for the ﬁrst four second period, it will:

a. Remain off if there are no fault conditions or trouble

codes currently detected by the ignition control module. See A of Figure 5-5.

b. Come back on for an 8 second period if only historic

codes exist. See B of Figure 5-5.

c. Come back on, and remain on, if a current trouble

code exists. See C of Figure 5-5.

4 Sec.

OFF

Key On

Lamp ON 8 Seconds:

Only Historic Trouble Codes Exist

4 Sec.

OFF

Key On

4 Sec.

2. See CODE TYPES which follows for a complete descrip- tion of trouble code formats.

NOTE Some trouble codes can only be fully diagnosed during actuation. For example, a problem with the ignition coil will be considered a current fault even after the problem is corrected, since the ECM will not know of its resolution until after the coil is exercised by vehicle start sequence. In this manner, there may sometimes be a false indication of the current trouble code.

Lamp OFF: No Current or Historic Trouble Codes

8 Sec.

Lamp OFF

4 Sec.

OFF

Key On

Figure 5-5. Check Engine Lamp Operation

5-6 2004 Touring: Engine Management (EFI)

4 Sec.

Lamp Remains ON: Current Trouble Code *

Historic Trouble Codes May Also Exist

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CODE TYPES

There are two types of diagnostic trouble codes (DTCs): current and historic. If a diagnostic trouble code is stored, it can be read using speedometer self diagnostics. See 5.6

SPEEDOMETER SELF DIAGNOSTICS.

All diagnostic trouble codes reside in the memory of the ECM/ICM, TSM/TSSM, speedometer or tachometer until the code is cleared by use of the speedometer self diagnostics. See 5.6 SPEEDOMETER SELF DIAGNOSTICS.

A historic diagnostic trouble code is also cleared after a total of 50 trips has elapsed. A trip consists of a start and run cycle. After the 50 trip retention period, the diagnostic trouble code is automatically erased from memory providing that no subsequent faults of the same type are detected in that period.

Current

Current trouble codes are those which occur during the present ignition cycle. See the appropriate ﬂow charts for solutions.

Historic

If a particular problem happens to resolve itself, the active status problem is dropped and it becomes a historic code rather current code.

Historic codes are stored for a length of time to assist in the diagnosis of intermittent faults. See Figure 5-5. The check engine lamp will come back on for 8 seconds to indicate the existence of only historic codes.

It is important to note that historic codes may also be present whenever the system indicates the existence of a current code. See MULTIPLE DIAGNOSTIC 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 replacement. When diagnosing a historic code the charts can be helpful but should not lead to part replacement without veriﬁcation the part is faulty.

RETRIEVING DIAGNOSTIC TROUBLE CODES

The engine management system provides two levels of diagnostics.

The most sophisticated mode uses a computer based

●

diagnostic package called the DIGITAL TECHNICIAN (Part No. HD-44750).

The second mode requires using the speedometer self

●

diagnostics. Speedometer, tachometer (if equipped), TSM/TSSM and ECM codes can be accessed and cleared. See 5.6 SPEEDOMETER SELF DIAGNOSTICS for more information.

MULTIPLE DIAGNOSTIC TROUBLE CODES

While it is possible for more than one fault to occur and set more than one trouble code, there are several conditions which may result in

The MAP and TP and vehicle speed sensors are con-

●

nected to the same reference line (+5V Vref). If the reference line goes to ground or open, multiple codes will be set (DTC P0107, P0122 and P0501).

Serial data codes (DTC U1300, U1301, U1016, U1064,

●

U1097 and U1255) may be accompanied by other codes. resolving the other codes.

Refer to Ta bl e 5-5. This table gives most ECM DTCs a priority ranking.

one

fault setting

Always

correct the serial data codes before

multiple

trouble codes:

2004 Touring: Engine Management (EFI) 5-7

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INITIAL DIAGNOSTIC CHECK: EFI 5.5

GENERAL

To locate faulty circuits or other system problems, follow the diagnostic ﬂow charts in this section. For a systematic approach, always begin with INITIAL DIAGNOSTICS which follows. Read the general information and then work your way through the ﬂow chart box by box.

Diagnostic Notes

If a numbered circle appears adjacent to a ﬂow chart box, then more information is offered in the diagnostic notes. Many diagnostic notes contain supplemental information, descriptions of various diagnostic tools or references to other parts of the manual where information on the location and removal of components may be obtained.

Circuit Diagram/Wire Harness Connector Table

When working through a ﬂow chart, refer to the illustrations, the associated circuit diagram and the wire harness connector table as necessary. The wire harness connector table for each circuit diagram identiﬁes the connector number, description, type and general location.

In order to perform most diagnostic routines, a Breakout Box and a DVOM are required. See 5.7 BREAKOUT BOX: EFI.

To perform the circuit checks with any degree of efﬁciency, a familiarity with the various wire connectors is also necessary.

Reprogramming ECM

Diagnostic charts frequently suggest ECM replacement. In the event an electronic control module (ECM) needs to be replaced, it must be reprogrammed using a computer based diagnostic package called DIGITAL TECHNICIAN (Part No. HD-44750). See your dealer. Password learn procedure must also be performed. See 3.24 PASSWORD LEARN.

Diagnostic Tips

If speedometer reads “No Rsp” (no response) while in

●

diagnostic mode, check data bus for an open or short to ground between data connector [91A] Terminal 3 and ECM, TSM/TSSM, tachometer (if equipped) or speedometer. For more information on speedometer diagnostic mode see 5.6 SPEEDOMETER SELF DIAGNOSTICS.

●

Check for an open diagnostic test terminal between data Te rminal 3 and ECM Terminal 5. With ignition key turned ON, transmit data should be typically 0.6-0.8 volts. The range of acceptable voltage is greater than 0 and less than 7.0 volts.

●

If speedometer reads “BUS er” (serial data bus error), refer to ﬂow charts in 5.12 STARTS, THEN STALLS.

Diagnostic Notes

The reference numbers below correlate with the circled numbers on the diagnostic check ﬂow charts. See page 5-15.

1. Compare engine behavior to symptoms tables.

a. Starts hard. Refer to Ta bl e 5-2.

b. Hesitates, stumbles, surges, misﬁres and/or slug-

gish performance. Refer to Ta ble 5-3.

c. Engine exhaust emits black smoke or fouls plugs.

Refer to Ta ble 5-4.

2. Connect BREAKOUT BOX (Part No. HD-43682) to

speedometer using HD-46601 adapters.

All EFI diagnostic codes are listed on page 5-11 in Ta ble 5-5.

Other Codes

See 3.9 INITIAL DIAGNOSTIC CHECK: TSM/TSSM for any codes related to the turn signal module (TSM) or turn signal security module (TSSM).

See 2.2 INITIAL DIAGNOSTIC CHECK: SPEEDOMETER for any codes related to the speedometer or tachometer.

INITIAL DIAGNOSTICS

General Information

The diagnostic check (see page 5-15) is an organized approach to identifying a problem caused by an electronic control system malfunction.

5-8 2004 Touring: Engine Management (EFI)

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Table 5-1. Typical Scan Values for

Engine Data

ITEM

MAP sensor

TP sensor

IAC pintle 0 155 30-45 steps

RPM 800 5600 990

ET sensor

IAT sensor

INJ PW front 0 50 mS 2-4 mSec

INJ PW rear 0 50 mS 2-4 mSec

Advance front 0 45° 10-15°

Advance rear 0 45° 10-15°

VSS 0 120 0 MPH

Battery voltage 10 15 14.5 volts

ENG RUN off Run Run

Idle RPM 800 1250 990

MIN.

VALUE

10 kPa 104 kPa

0 volts 5.1 volts

0100 0%

0.2 volts 4.5 volts 0.2-1.0 volts

3° F

(-16° C)

0.0 volts 5.0 volts 0.5-3.23 volts

3° F

(-16° C)

0.0 volts 5.0 volts 2.0-3.5 volts

MAX.

VALUE

464° F

(240° C)

248° F

(120° C)

HOT

IDLE

10.3-13.3 in. Hg 35-45 kPa

230-300° F

(110-150° C)

104-140° F

(40-60° C)

Table 5-2. Engine Starts Hard

SYMPTOM

Battery discharged

Spark plugs

Spark plug wires

Ignition coil

Valve sticking

Water or dirt in fuel system Drain and reﬁll with fresh fuel.

Loss of battery power to ECM terminal 31*

* Codes will not clear (although they appear to).

See charging system troubleshooting in this section.

5.17 MISFIRE AT IDLE OR UNDER LOAD.

See Section 3 in the Touring Service Manual.

5.11 NO ECM POWER

SOLUTION

NOTE

Hot idle speciﬁcations are with stock exhaust, the engine operating at 990 RPM and an engine temperature of approximately 260° F (127° C). Idle settings may be changed with the idle set procedure. See the Touring Service Manual.

2004 Touring: Engine Management (EFI) 5-9

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Table 5-3. Engine Performance Problems

SYMPTOM

Manifold leak

NOTE- When manifold leak is large enough, IAC will close to 0 and code P0505 will set

MAP sensor plugged or not operating properly

Water or dirt in fuel system

Spark plugs

Throttle plate not opening fully

Low fuel pressure

See 5.9 INTAKE LEAK

TEST.

A low IAC count may also indicate an air leak.

5.19 DTC P0107, P0108.

Drain and reﬁll with fresh fuel.

5.17 MISFIRE AT IDLE OR UNDER LOAD.

See throttle cable adjustment in the Touring Service Manual.

5.15 FUEL PRESSURE TEST.

SOLUTION

Table 5-4. Engine Exhaust Emits

Black Smoke or Fouls Plugs

SYMPTOM

See AIR CLEANER FILTER

Clogged air ﬁlter

MAP sensor plugged or not operating properly

in the Touring Service Manual.

5.19 DTC P0107, P0108.

SOLUTION

5-10 2004 Touring: Engine Management (EFI)

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

PRIORITY RANKING

1 P0605 ECM ﬂash error 5.27 DTC P0603, P0605 2 P0603 ECM EEPROM error 5.27 DTC P0603, P0605 3“BUS Er” Serial data bus shorted low/open/high 5.12 STARTS, THEN STALLS 4U1300 ECM serial data low 5.12 STARTS, THEN STALLS 5U1301 ECM serial data open/high 5.12 STARTS, THEN STALLS 6U1300 TSSM serial data low 5.12 STARTS, THEN STALLS 7U1301 TSSM serial data open/high 5.12 STARTS, THEN STALLS 8U1300 Speedometer/tachometer serial data low 5.12 STARTS, THEN STALLS

9U1301

10 U1064 Loss of TSM/TSSM serial data at ECM 5.30 DTC U1064, U1255

11 U1064

12 U1016

13 U1097 Loss of speedometer serial data at TSSM 5.31 DTC U1097, U1255 14 U1255 Missing response at TSSM 3.21 DTC U1016, U1255 15 U1255 Missing response at speedometer 5.31 DTC U1097, U1255 16 P1003 System relay contacts open 5.14 SYSTEM RELAY CHECK 17 P1002 System relay coil high/shorted 5.14 SYSTEM RELAY CHECK 18 P1001 System relay coil open/low 5.14 SYSTEM RELAY CHECK 19 P1004 System relay contacts closed 5.14 SYSTEM RELAY CHECK 20 P1009 Incorrect password 5.28 DTC P1009, P1010 21 P1010 Missing password (starts then stalls) 5.28 DTC P1009, P1010 22 P0373 CKP sensor intermittent 5.24 DTC P0373, P0374 23 P0374 CKP sensor synch error 5.24 DTC P0373, P0374 24 P0122 TP sensor open/low 5.22 DTC P0122, P0123 25 P0123 TP sensor high 5.22 DTC P0122, P0123 26 P0107 MAP sensor open/low 5.19 DTC P0107, P0108 27 P0108 MAP sensor high 5.19 DTC P0107, P0108 28 P0117 ET sensor voltage low 5.21 DTC P0117, P0118 29 P0118 ET sensor open/high 5.21 DTC P0117, P0118 30 P0112 IAT sensor voltage low 5.20 DTC P0112, P0113 31 P0113 IAT sensor open/high 5.20 DTC P0112, P0113 32 P1351 Front ignition coil open/low 5.29 DTC P1351, P1352, P1354, P1355 33 P1354 Rear ignition coil open/low 5.29 DTC P1351, P1352, P1354, P1355 34 P1352 Front ignition coil high/shorted 5.29 DTC P1351, P1352, P1354, P1355 35 P1355 Rear ignition coil high/shorted 5.29 DTC P1351, P1352, P1354, P1355 36 P1357 Front cylinder combustion intermittent 5.18 COMBUSTION ABSENT/INTERMITTENT 37 P1358 Rear cylinder combustion intermittent 5.18 COMBUSTION ABSENT/INTERMITTENT 38 P0261 Front injector open/low 5.23 DTC P0261, P0262, P0263, P0264 39 P0263 Rear injector open/low 5.23 DTC P0261, P0262, P0263, P0264 40 P0262 Front injector high 5.23 DTC P0261, P0262, P0263, P0264

DTC NO. FAULT CONDITION SOLUTION

Speedometer/tachometer serial data open/ high

Loss of TSM/TSSM serial data at speedometer

Loss of all ECM serial data (state of health) at TSSM

Loss of all ECM serial data (state of health) at speedometer

Loss of vehicle speed 3.21 DTC U1016, U1255 Loss of vehicle inhibit motion 3.21 DTC U1016, U1255 Loss of powertrain security status 3.21 DTC U1016, U1255

5.12 STARTS, THEN STALLS

5.30 DTC U1064, U1255

3.21 DTC U1016, U1255

2004 Touring: Engine Management (EFI) 5-11

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

PRIORITY RANKING

41 P0264 Rear injector high 5.23 DTC P0261, P0262, P0263, P0264 42 P0562 Battery voltage low 5.26 DTC P0562, P0563 43 P0563 Battery voltage high 5.26 DTC P0562, P0563 44 P0501 VSS sensor low 5.25 DTC P0501, P0502 45 P0502 VSS sensor high 5.25 DTC P0501, P0502 46 P1356 Rear cylinder no combustion 5.18 COMBUSTION ABSENT/INTERMITTENT 47 P1353 Front cylinder no combustion 5.18 COMBUSTION ABSENT/INTERMITTENT 48 P0505 Loss of idle speed control 5.16 IDLE AIR CONTROL 49 B1135 Accelerometer fault 3.19 DTC B1135 51 B1134 Starter output high 3.18 DTC B1134 52 B1121 Left turn output fault 3.15 TURN SIGNAL ERRORS 53 B1122 Right turn output fault 3.15 TURN SIGNAL ERRORS 54 B0563 Battery voltage high 3.16 DTC B0563 55 B1131 Alarm output low 3.17 DTC B1131, B1132 56 B1132 Alarm output high 3.17 DTC B1131, B1132 57 B1141 Ignition switch open/low 3.15 TURN SIGNAL ERRORS

DTC NO. FAULT CONDITION SOLUTION

5-12 2004 Touring: Engine Management (EFI)

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f2208u8x

321654987121110 321654987121110

Speedometer

LtGN/V

BN/GY

[39B]

[108B]

[108A]

[39A]

321654987121110 321654987121110

Tachometer

[156B] [156A]

BN/GY

Main to Interconnect

Harness

LtGN/V

1 1

987 987

321654987121110 321654987121110

TSM/TSSM

[8B]

121110 121110

[8A]

Harness

[30B] [30A]

EFI

[1B] [1A]

123

Main to Interconnect

Harness

15A

Ignition

Fuse

1 2 3 4

Data Link

[91A]

[2B] [2A]

15A

Accessory

Fuse

321654987121110 321654987121110

Main to Interconnect

Harness

101112 78945

LtGN/V

15A

Battery

Fuse

LtGN/R

Flash pin

ECM

Serial data

[78B] [78A]

Figure 5-6. Diagnostic Check (FLTR, FLHT/C/U)

Table 5-6. Wire Harness Connectors in Figure 5-6.

NO.

[1]

[2]

[8] Main to EFI Harness All 12-Place Deutsch (Gray) Under Right Side Cover

[30]

[39] Speedometer

[78] Electronic Control Module All 36-Place Packard Under Right Side Cover [91] Data Link All 4-Place Deutsch Under Right Side Cover

[108] Tachometer

[156]

DESCRIPTION MODEL TYPE LOCATION

Main to Interconnect Harness

Tu rn Signal/Security Module

FLHT/C 12-Place Deutsch (Black) Inner Fairing - Right Radio Support Bracket

FLTR 12-Place Deutsch (Black) Inner Fairing - Below Radio (Left Side)

FLHT/C 12-Place Deutsch (Gray) Inner Fairing - Right Fairing Support Brace

FLTR 12-Place Deutsch (Gray) Inner Fairing - Below Radio (Left Side)

All 12-Place Deutsch

Cavity in Crossmember at Rear of

Battery Box (Under Seat)

FLHT/C 12-Place Packard Inner Fairing (Back of Speedometer)

FLTR 12-Place Packard Under Bezel (Back of Speedometer)

FLHT/C 12-Place Packard Inner Fairing (Back of Tachometer)

FLTR 12-Place Packard Under Bezel (Back of Tachometer)

Main to Interconnect Harness

FLHT/C 6-Place Deutsch Inner Fairing - Right Fairing Support Brace

FLTR 6-Place Deutsch Inner Fairing - Front of Right Fairing Bracket

2004 Touring: Engine Management (EFI) 5-13

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f2208t8x

BN/GY

321654987121110 321654987121110

Speedometer

15A

Battery

Fuse

15A

Accessory

Fuse

LtGN/V

BN/GY

[39B]

[39A]

15A

Ignition

Fuse

LtGN/V

321

321654987121110 321654987121110

[30B] [30A]

TSM/TSSM

121110

[8B]

121110

[8A]

EFI

Harness

1 2 3

Data Link

[91A]

LtGN/V

LtGN/R

[78B] [78A]

Flash pin

Serial data

ECM

Figure 5-7. Diagnostic Check (FLHR/C/S)

Table 5-7. Wire Harness Connectors in Figure 5-7.

NO.

[8] Main to EFI Harness 12-Place Deutsch Under Right Side Cover

[30] Turn Signal/Security Module 12-Place Deutsch

[39] Speedometer 12-Place Packard Under Console (Back of Speedometer) [78] Electronic Control Module 36-Place Packard Under Right Side Cover [91] Data Link 4-Place Deutsch Under Right Side Cover

DESCRIPTION TYPE LOCATION

Cavity in Crossmember at Rear of

Battery Box (Under Seat)

5-14 2004 Touring: Engine Management (EFI)

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Diagnostic Check (Part 1 of 2)

Does engine

start?

YES.

Starts and

runs.

Check for trouble

codes. See 5.6

SPEEDOMETER

SELF DIAGNOSTICS

Codes found?

YES

Refer to applicable trouble code priority chart.

All diagnostic codes are listed on page 5-11

in Table 5-5. Codes are listed by priority.

YES.

Starts, then

stalls.

See 5.12 STARTS, THEN

STALLS.

YES

STOP

Go to Diagnostic

Check (Part 2 of 2).

NO.

Cranks, but

will not start.

See 5.10 ENGINE CRANKS,

BUT WILL NOT START.

Unable to enter diagnostic mode.

With ignition switch OFF, press and

release odometer reset switch.

Does odometer display appear with

display backlighting?

Check for continuity to ground on terminal 7 of speedometer. Wiggle harness during con-

tinuity check. Continuity present?

YES NO

See 1.2 STARTING SYSTEM

No codes displayed. For

symptoms that may not set

diagnostic trouble codes,

refer to table 5-2, Table 5-3

and Table 5-4.

NO.

Engine will not

crank.

DIAGNOSIS.

Check continuity (with ignition

switch OFF) between terminals

8 and 11 on breakout box. Con-

tinuity present when speedome-

ter reset switch is depressed?

Replace speedometer.

Check for battery voltage at

terminal 5 of speedometer

while wiggling harness. Bat-

tery voltage continuously

YES

Replace speedometer

reset switch.

Locate and repair open

between terminal 7

present?

Locate and repair open between terminal 5 and

battery fuse.

and ground.

2004 Touring: Engine Management (EFI) 5-15

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Diagnostic Check (Part 2 of 2)

YES

Turn key to ACC. Is

backlight present?

YES

Is problem intermittent?

Perform “wow” test. See 5.6 SPEEDOMETER SELF DIAGNOSTICS.

1) backlight should illuminate

2) needle should sweep its full range of motion

3) LED’s that should illuminate:

• check engine

• battery

• security (all models)

4) LED’s that may illuminate:

• low fuel (EFI models)

• cruise (even though not cruise equipped)

Continued from Diagnostic Check (Part 1 of 2).

The following features should be functional

Are all features functional?

Check for battery voltage at

breakout box terminal 6. Battery voltage present?

YES

Replace speedometer.

Check for battery voltage at

terminal 1 of breakout box.

Battery voltage present?

Is instrument

fuse blown?

Replace speedometer.

YES

Repeat Diagnostic

Check while wiggling

harnesses. Intermittent

present?

YES

Locate and repair

intermittent.

YES

No trouble found.

Locate and repair open on O/W wire between terminal 6 of connector [39] and accessory fuse.

Intermittent vehicle speed

Remove and inspect vehi-

cle speed sensor. Debris

Remove debris. Reinstall

YES

indication.

present?

YES

vehicle speed sensor.

YES

Locate and repair

source of fault.

Replace fuse.

Check for damaged wiring/

loose connection between

vehicle speed sensor and

ECM. Is wiring damage/loose

connection present?

YES

Locate and repair

open between terminal

1 of connector [39]

and instrument fuse.

Tachometer Inoperative

(no engine speed).

See Test 2.4 (Part 1 of 2)

under 2.4 SPEEDOMETER/

TACHOMETER.

5-16 2004 Touring: Engine Management (EFI)

Locate and repair

source of fault.

Replace Speedometer.

HOME

d0715x8x

1. Cruise On/Engaged

2. Check Engine

3. Low Fuel

4. Battery

5. Security

SPEEDOMETER SELF DIAGNOSTICS 5.6

GENERAL

The speedometer is capable of displaying and clearing speedometer, tachometer, TSM/TSSM, and ICM/ECM trouble codes (diagnostic mode).

DIAGNOSTICS

Diagnostic Tips

●

For a quick check of speedometer function, a “wow” test can be performed. See Figure 5-8. Press and hold odometer reset switch then turn ignition switch ON. Release reset switch. Background lighting should illuminate, speedometer needle should sweep its full range of motion, and indicator lamps [battery, security, low fuel (EFI models) check engine and cruise] should illuminate. Some lamps may illuminate even though they do not apply to the vehicle. For example, the cruise lamp may illuminate even though the motorcycle may not be equipped with cruise control.

●

If instrument module fails “wow” test, check for battery, ground, ignition, speedometer reset switch and accessory to speedometer. If any feature in the speedometer is non-functional, see 2.2 INITIAL DIAGNOSTIC CHECK:

SPEEDOMETER.

Diagnostic Notes

Use of speedometer self diagnostics assumes that DIGITAL TECHNICIAN (Part No. HD-44750) is

The reference numbers below correlate with the circled numbers in the Speedometer Self Diagnostics (chart)

1. To exit diagnostic mode, turn ignition switch OFF.

2. To clear DTCs for selected module, press speedometer reset switch for more than 5 seconds when code is displayed. This procedure will clear all codes for selected module.

not

available.

Figure 5-8. Speedometer (FLHR/C/S)

2004 Touring: Engine Management (EFI) 5-17

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Speedometer Self Diagnostics (chart)

While holding odometer reset switch in,

turn ignition switch to IGN. Make sure

Run/Stop switch is in RUN position.

Release reset switch.

Does “diag” appear?

YES

”P” flashing.

To choose TSM/

TSSM, press and

release reset switch.

”S” flashing.

To choose Speedometer,

press and release reset

switch.

”SP” flashing.

To choose Tachometer, press and release reset

switch.

”T” flashing.

To choose ECM, press

and release reset switch.

To display DTCs for the

ECM, press and hold

reset switch for more

than 5 seconds.

To display DTCs for

TSM/TSSM, press and

hold reset switch for

more than 5 seconds.

To display DTCs for

speedometer, press and

hold reset switch for more

than 5 seconds.

To display DTCs for

tachometer, press and

hold reset switch for more

than 5 seconds.

See 2.2 INITIAL DIAGNOSTIC

CHECK: SPEEDOMETER.

Device

response?

YES

“none” displayed.

Press and release

reset switch. Part num-

ber of module will be

displayed.

DTC

displayed.

Press and release

reset switch.

Are more DTCs

displayed?

YES

“no rsp” displayed.*

Tachometer malfunction.

2.4 SPEEDOMETER/

See

TACHOMETER.

* Models not equipped

with a tachometer will display “no rsp” normally.

“end” displayed.

To clear all DTCs for selected module hold reset switch for more than 5 seconds. If DTCs are not to be cleared, Press and release

reset switch. Part number of

module will be displayed.

Press and release reset

switch again to continue to

next module.

Figure 5-9. Speedometer Self Diagnostics

5-18 2004 Touring: Engine Management (EFI)

HOME

f1917x9x

Electronic Control

Module Connector [78]

BREAKOUT BOX: EFI 5.7

GENERAL

The BREAKOUT BOX (Part No. HD-43876) splices into the main harness. Used in conjunction with a DVOM, it allows circuit diagnosis of wiring harness and connections without having to probe with sharp objects.

NOTE

See wiring diagrams for ECM terminal functions.

INSTALLATION

1. Remove right saddlebag and side cover. See Figure 5-

10.

2. Depress latch and remove connector [78B] to release EFI harness from ECM.

3. Install connectors on Breakout Box to ECM and EFI harness connectors.

REMOVAL

1. Separate connectors to remove Breakout Box between ECM and EFI harness.

2. Install connector [78B] to connect EFI harness to ECM.

3. Install right side cover and saddlebag.

Figure 5-10. Electrical Bracket (Under Right Side Cover)

Figure 5-11. Breakout Box (Part No. HD-43876)

2004 Touring: Engine Management (EFI) 5-19

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WIGGLE TEST 5.8

GENERAL

The wiggle test indicates the presence of intermittents in a wiring harness.

PROCEDURE

1. See Figure 5-12. Connect DVOM (Part No. HD-39978) to wiring harness between the suspect connections. When diagnosing ECM connections, use a BREAKOUT BOX (Part No. HD-43876) to simplify the procedure. See 5.7

BREAKOUT BOX: EFI.

2. Set DVOM to read voltage changes.

3. Start motorcycle engine and run at idle.

4. Shake or wiggle harness to detect intermittents. If intermittents are present, radical voltage changes will register on the DVOM.

hd39978

Figure 5-12. Fluke 78 Multimeter (DVOM)

(Part No. HD-39978)

5-20 2004 Touring: Engine Management (EFI)

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9648

9649

1. Nozzle

2. Copper tube

3. Hose

4. Valve

5. Knob

6. Propane bottle

INTAKE LEAK TEST 5.9

GENERAL

1DANGER

Propane is an extremely ﬂammable liquid and vapor. Vapor may cause ﬂash ﬁre. Keep away from heat, sparks and ﬂame. Keep container closed. Use only with adequate ventilation.

1WARNING1WARNING

Read all directions and warnings on propane bottle. Failure to follow all directions and warnings on bottle could result in death or serious injury.

●

To prevent false readings, keep airbox cover installed when performing test.

Do not direct propane into air cleaner, false readings will

●

result.

Figure 5-13. Nozzle

LEAK TESTER

Parts List

●

Standard 14 oz. propane cylinder.

Snap-on YA7148 Propane Enrichment Kit.

●

12 in. (304 mm) long-1/4 in. (6 mm) diameter copper tub-

●

ing.

Tester Assembly

1. Cut rubber hose from kit to 18 in. (457 mm) in length.

2. See Figure 5-13. Flatten one end of copper tube to form a nozzle.

3. Insert round side of copper tube into end of tubing.

Figure 5-14. Leak Tester

2004 Touring: Engine Management (EFI) 5-21

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