Harley Davidson Touring 2004 Service Manual fe05a

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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

HOME

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

HOME

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

HOME

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)

HOME

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

HOME

INTAKE LEAK TESTING

1. Start engine.

2. Warm engine to operating temperature.

3. See Figure 5-14. Turn knob (5) counterclockwise to open propane bottle (6).

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.

NOTE

Do not direct propane stream toward front of engine. If propane enters air cleaner, a false reading will be obtained.

4. See Figure 5-15. Aim nozzle toward possible sources of leak such as fuel injectors and intake tract.

5. See Figure 5-14. Push valve (4) to release propane. To ne of engine will change when propane enters source of leak.

10054

Figure 5-15. Checking for Leaks

5-22 2004 Touring: Engine Management (EFI)

HOME

d0273x8x

7863

ENGINE CRANKS, BUT WILL NOT START 5.10

GENERAL

If the starter will not crank the engine, the problem is not EFI related. Refer to SECTION 1-STARTING & CHARGING or SECTION 3-TSM & TSSM.

DIAGNOSTICS

Diagnostic Notes

The reference numbers below correlate with the circled numbers on the Test 5.10 ﬂow charts.

1. Check for trouble codes. See RETRIEVING DIAGNOS-

TIC TROUBLE CODES under 5.4 CHECKING FOR DIAGNOSTIC TROUBLE CODES: EFI.

2. Check the condition of the battery. Perform a voltage test and recharge if below 12.60V. Check battery connections and perform load test. Replace the battery if necessary. See BATTERY in the Touring Service Manual.

3. Connect BREAKOUT BOX (Part No. HD-43876). See 5.7

BREAKOUT BOX: EFI.

4. Remove spark plug cable from spark plug.

a. Visually check condition of plug.

b. See Figure 5-16. Attach cable to SPARK TESTER

(Part No. HD-26792). Clip tester to cylinder head bolt.

c. While cranking engine, look for spark. Repeat pro-

cedure on other spark plug cables.

NOTE

Engine will not spark with both spark plugs removed. When checking for spark, use SPARK TESTER (Part No. HD-

26792) with both plugs installed.

Diagnostic Tips

Figure 5-16. Spark Tester

Figure 5-17. Ignition Coil Circuit Test

5. Use HARNESS CONNECTOR TEST KIT (Part No. HD-

41404), gray pin probe and patch cord.

6. Typically, when IAC is not functioning, the engine will not start unless throttle is opened and the engine will stall when throttle is closed.

7. See Figure 5-17. Plug IGNITION COIL CIRCUIT TEST ADAPTER (Part No. HD-44687) and FUEL INJECTOR TEST LAMP (Part No. HD-34730-2C) into Breakout Box Te r minals 13 and 11. Start engine. If lamp ﬂashes, no problem is found. Repeat for Breakout Box Terminals 13 and 29.

8. Use HARNESS CONNECTOR TEST KIT (Part No. HD-

41404), brown socket probe and patch cord.

Check TP sensor value with DVOM. If TP sensor is equal to or greater than 3.8 volts, system is in “clear ﬂood” mode and engine will not start. While spark is present, fuel is shut off. Problem can be mechanical, such as throttle cables stuck.

2004 Touring: Engine Management (EFI) 5-23

HOME

Intake air

control

[79A]

[79B]

[87A]

CKP

System relay

Ion sense

Coil R Coil F

Constant

[87B]

Switch power

Inj. F

Inj. R

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]

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 5-18. EFI System Circuit - Simpliﬁed

5-24 2004 Touring: Engine Management (EFI)

HOME

Table 5-8. Wire Harness Connectors in Figure 5-18.

NO.

[22]

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

[65] Vehicle Speed Sensor All 3 - Place Deutsch

[78] Electronic Control Module All 36-Place Packard Under Right Side Cover [79] Crankshaft Position Sensor All 2 - Place Mini-Deutsch Bottom of Voltage Regulator

[80]

[83] Ignition Coil All 4 - Place Packard Below Fuel Tank (Left Side) [84] Front Injector All 2 - Place Packard Below Fuel Tank (Left Side) [85] Rear Injector All 2 - Place Packard Below Fuel Tank (Left Side) [87] Idle Air Control All 4 - Place Packard Below Fuel Tank (Right Side) [88] Throttle Position Sensor All 3 - Place Packard Below Fuel Tank (Right Side) [89] Intake Air Temperature Sensor All 2 - Place Packard Below Fuel Tank (Right Side) [90] Engine Temperature Sensor All 2 - Place Packard Back of Front Cylinder (Left Side) [91] Data Link All 4 - Place Deutsch Under Right Side Cover

DESCRIPTION MODEL TYPE LOCATION

Right Handlebar Switch Controls

Manifold Absolute Pressure Sensor

FLHT/C/U

FLTR

FLHR/C/S 6 - Place Deutsch

All 3 - Place Packard Top of Induction Module

12-Place Deutsch

(Black)

12-Place Deutsch

(Black)

Inner Fairing - Fork Stem Nut Lock Plate

Inner Fairing - Right Side of Radio Bracket

Inside Headlamp Nacelle - Fork Stem

Nut Lock Plate (Right Side)

Cavity in Crossmember at Rear of

Battery Box (Under Seat)

Under Right Side Cover

(Behind Electrical Bracket)

(Left Side)

2004 Touring: Engine Management (EFI) 5-25

HOME

Test 5.10 (Part 1 of 4)

ENGINE CRANKS, BUT WILL NOT START

Fresh fuel in tank?

Refer to IGNITION COIL in the Tour-

ing Service Manual for proper coil ter-

connected to proper coil terminals?

NOTE

minal location.

Spark plug wires ﬁrmly

Check for trouble

codes.

Codes found?

Refer to Table 5-5.

Start with

the lowest ranking

code.

YES

Add fuel /connect

Is TSM/TSSM mounted in

proper orientation?

Check battery connections

and voltage. Is voltage

above 12.60?

Does battery pass

spark plugs.

YES

load test?

Install TSM/TSSM properly.

Was battery allowed to dis-

charge? Was battery drawn

down by starting problem?

Recharge battery.

Turn ignition key ON and engine stop switch to RUN. Did fuel pump run for 2 seconds and check engine lamp illumi-

YES

Connect breakout box to ECM [78]. Measure

voltage to breakout box with DVOM at terminal

13 (+) and terminal 4 (-). Crank engine for

greater than 2 seconds to insure proper system

operation. 6-12 volts present continuously?

YES

STOP

Go to Test 5.10

(Part 2 of 4).

5-26 2004 Touring: Engine Management (EFI)

YES

nate for 4 seconds?

No pump,

light OK.

See

5.13 FUEL SYSTEM

ELECTRICAL TEST.

Go to bold asterisk in

Test 5.10 (Part 4 of 4).

Replace battery.

No light or pump

See 5.11 NO ECM POWER.

HOME

Test 5.10 (Part 2 of 4)

ENGINE CRANKS, BUT WILL NOT START

Install fuel pressure gauge (Part No. HD-41182).

cranking engine (for more than 2 seconds to

ensure proper system operation), verify that

fuel pressure rises to 55-62 PSI (380-427 kPa).

Continued from Test 5.10 (Part 1 of 4).

See 5.15 FUEL PRESSURE TEST. While

Adequate fuel pressure present?

NOYES

Check spark plug condition, replace if fouled. Reinstall spark plugs before checking spark.

Check spark at both plugs while cranking.

Spark present?

YES

Ver ify connector is securely attached to each injector. If so, disconnect fuel

injector connector and attach fuel

injector test lamp (HD-34730-2C).

Crank engine. Does lamp flash?

YES

Monitor IAC pintle for 10 seconds

after turning ignition OFF. Does pin-

tle extend and then retract during

10 second key OFF

reset procedure?

YES

Check for plugged fuel

injectors. Injectors

plugged?

Correct problems with

fuel injectors. See 5.23

DTC P0261, P0262,

P0263, P0264.

See 5.16 IDLE

AIR CONTROL.

Check battery voltage at

Terminal A (+) of coil connector

[83B] using DVOM. Battery

voltage present for 2 seconds

after key ON?

YES

STOP

Go to Test 5.10

(Part 3 of 4).

Incorrect pressure. See 5.15

FUEL PRESSURE TEST.

Open in Y/GN wire between splice for fuel pump wire and ignition

coil. Repair open

YES

Replace plugged

injector(s).

Check engine compression.

Clear codes using speedometer self diagnostics.

See 5.6 SPEEDOMETER SELF DIAGNOSTICS. Conﬁrm proper operation with no check engine

lamp.

2004 Touring: Engine Management (EFI) 5-27

HOME

Test 5.10 (Part 3 of 4)

ENGINE CRANKS, BUT WILL NOT START

YES

Check coil connections.

Connections OK?

YES

Test spark plug cable resis-

tance. See 5.17 MISFIRE AT

IDLE OR UNDER LOAD.

Resistance OK?

YES

Replace

coil.

Continued from Test 5.10 (Part 2 of 4).

Perform coil circuit test. Does lamp ﬂash?

Repair.

Replace spark

plug cables.

Disconnect ECM connector [78]. Inspect

for damaged terminals, terminals backed

out or corroded. Terminal problems

YES

Repair terminal

damage.

YES

present?

Reconnect. Problem

STOP

still exist?

Problem

fixed.

Clear codes using speedometer self diagnostics.

See 5.6 SPEEDOMETER SELF DIAGNOSTICS. Conﬁrm proper operation with no check engine

lamp.

Go to Test 5.10

(Part 4 of 4).

5-28 2004 Touring: Engine Management (EFI)

HOME

Test 5.10 (Part 4 of 4)

ENGINE CRANKS, BUT WILL NOT START

Continued from Test 5.10 (Part 3 of 4).

Check connectors for moisture and cor-

rosion. Check wires for chaﬁng. Connect DVOM to ECM terminals 12 and

30 on Breakout Box and set it for AC

volts. Crank engine. Does DVOM read

1 VAC minimum?

Reprogram and learn password.

At some point in the ﬂow chart you may be instructed to jump directly to a the box with the bold asterisk. Disregard the asterisk (but not the instruction box) if your normal progression through the chart brings you to this location.

YES NO

Check for continuity between

terminal 30 on Breakout Box

and Terminal 1 of connector

[79B].

Continuity present?

YES

Replace ECM.

Disconnect CKP connector

[79]. Check connectors for

moisture and corrosion. Check

wires for chaﬁng. Is connector

or wire damage present?

YES NO

Repair damage.

Connect DVOM to Terminals

engine. Does DVOM read 1

1 and 2 of [79A]. Crank

VAC minimum?

YES

With meter still connected,

check for resistance.

Is resistance 600-1200 ohms?

Locate and repair open on

BK wire between Terminal 2 of

connector [79B] and terminal

12 on Breakout Box.

Locate and repair open on R wire between Terminal 1 of connector [79B] and terminal

30 on Breakout Box.

Loosen sensor at crankcase.

Check for contamination or

damage. Tighten sensor.

Clear codes using speedometer self diagnostics.

See 5.6 SPEEDOMETER SELF DIAGNOSTICS. Conﬁrm proper operation with no check engine

lamp.

Replace crank position sensor.

2004 Touring: Engine Management (EFI) 5-29

HOME

NO ECM POWER 5.11

GENERAL

No Spark/No Check Engine Lamp at Key ON

Constant power is supplied to the ECM through terminal 31. The ECM turns on when power is applied to terminal 13 of connector [78]. The ECM goes through an initialization sequence every time power is removed and re-applied to terminal 13. The only visible part of this sequence is the check engine lamp. Upon starting, the check engine lamp will illuminate for 4 seconds and then (if parameters are normal) go out.

If battery power is absent at ECM terminal 31:

DTCs cannot be cleared. Tool will show them as cleared

●

but will be present next time ignition key is cycled. ECM cannot be re-ﬂashed.

●

Vehicle will start but IAC pintle will not reset at key OFF.

●

Eventually pintle will be out of position causing performance problems.

NOTE

The key ON sequence also activates the idle air control motor. If power from terminal 31 is disrupted (blown fuse, etc.) always turn the key OFF wait 10 seconds then turn the key ON to reset the motor to the default position.

System Fuse Block (Under Left Side Cover)

FLHR/C/S

f2210x8x

FLTR, FLHT/C/U

DIAGNOSTICS

Diagnostic Notes

The reference numbers below correlate with the circled numbers on the Test 5.11 ﬂow charts.

1. Connect BREAKOUT BOX (Part No. HD-43876). See 5.7

BREAKOUT BOX: EFI.

NOTE

Adapters are not used on FLTR and FLHT/C/U models.

2. Connect BREAKOUT BOX (Part No. HD-42682) between connectors [22A] and [22B] using Adapters (HD-42962) on FLHR/C/S models.

f2204x8x

1. Headlamp

2. Ignition

3. Lighting

4. Instruments

5. Brakes/Cruise

6. Radio Memory

EFI Fuse Block (Under Right Side Cover)

Fuel Pump

ECM Power

Spare

Figure 5-19. Fuse Locations

7. Radio Power

8. Accessory

9. Battery

10. Brake Light Relay

11. P&A

12. Starter Relay

EFI System

Relay

f2223x9x

5-30 2004 Touring: Engine Management (EFI)

HOME

[78A] [78B]

ECM

BE/GY

W/BK

12 11 10 9 8 7 6 5 4 3 2 1

[8A] [8B]

15 Amp

ECM Fuse

R/BK

DCB

40 Amp

Maxi Fuse

[33A] [33B]

f2208f8x

–+

Battery

15 Amp

Ignition Fuse

Ignition

Switch

10 28

12 11 10 9 8 7 6 5 4 3 2 1

Engine Stop

Switch

[1A] [1B]

[22A] [22B]

Figure 5-20. ECM Power Circuit (FLTR, FLHT/C/U)

Table 5-9. Wire Harness Connectors in Figure 5-20.

NO.

[1] Main to Interconnect Harness 12-Place Deutsch (Black) Inner Fairing (Right Fairing Bracket) [8] Main to EFI Harness 12-Place Deutsch (Gray) Under Right Side Cover

[22] Right Handlebar Switches 12-Place Deutsch (Black) Inner Fairing (Right Fairing Support Brace)

[33] Ignition/Light Key Switch 4-Place Packard

[78] ECM 36-Place Packard Under Right Side Cover

DESCRIPTION TYPE LOCATION

Inner Fairing

(Front of Top Fork Bracket -Below Radio)

2004 Touring: Engine Management (EFI) 5-31

HOME

[78A] [78B]

ECM

BE/GY

W/BK

12 11 10 9 8 7 6 5 4 3 2 1

[8A] [8B]

15 Amp

ECM Fuse

R/BK

40 Amp

Maxi Fuse

[33A] [33B]

f2208e8x

–+

Battery

15 Amp

Ignition Fuse

Ignition

Switch

10 28

12-Place on FLHP

12 11 10 9 8 7 6 5 4 3 2 1

Engine Stop

Switch

[22A] [22B]

Figure 5-21. ECM Power Circuit (FLHR/C/S)

Table 5-10. Wire Harness Connectors in Figure 5-21.

NO. DESCRIPTION TYPE LOCATION

[8] Main to EFI Harness 12-Place Deutsch (Gray) Under Right Side Cover [22] Right Handlebar Switches 6-Place Deutsch (Black) Inside Headlamp Nacelle [33] Ignition/Light Key Switch 3-Place Packard Under Console [78] ECM 36-Place Packard Under Right Side Cover

5-32 2004 Touring: Engine Management (EFI)

HOME

Test 5.11 (Part 1 of 2)

NO ECM POWER

Check ECM and ignition fuse.

Are fuses OK?

YES

Disconnect ECM connector [78]. Inspect

for damaged terminals, terminals backed

out or corrosion. Terminal problems

With ignition ON, probe ECM Terminal 13 on

Breakout Box with a circuit test lamp con-

nected to ground. Does test lamp illuminate?

connected to ground. Does test

present?

YES

Repair terminal

damage.

YES

Probe ECM Terminal 31 on Breakout Box with test lamp

lamp illuminate?

STOP

Go to Test 5.11

(Part 2 of 2).

Reconnect. Problem

still exist?

Problem

fixed.

Locate and repair short

to ground. Replace 15

amp fuse.

YES

Probe ECM Terminal 10 and 28 on Breakout Box with test

lamp connected to +12V (bat-

tery positive terminal). Does

test lamp illuminate?

YES

Replace ECM.

Reprogram and learn

password.

Repair open in

BK wire between

connector [78B] and

ground 1.

Probe red wire terminal in

15 amp ECM fuse holder with test lamp connected

to ground. Does test lamp

illuminate?

YES

Repair open in BE/GY

wire between fuse

holder and ECM con-

nector [78].

Repair open in

red wire between 40

amp maxi fuse and 15

amp fuse holder.

2004 Touring: Engine Management (EFI) 5-33

HOME

Test 5.11 (Part 2 of 2)

NO ECM POWER

Continued from Test 5.11 (Part 1 of 2).

Measure voltage at terminal 3 (BK) of

breakout box. Battery voltage present?

Clear codes using speedometer self diagnostics.

See 5.6 SPEEDOMETER SELF DIAGNOSTICS. Conﬁrm proper operation with no check engine

lamp.

YES

With ignition ON, Measure voltage at terminal A (BK).

Battery voltage present?

YES

Repair open circuit on W/BK wire

between ECM and connector [22A].

Repair open (GY) wire between

connector [22] and fuse.

Repair/Replace engine stop

switch or wiring.

5-34 2004 Touring: Engine Management (EFI)

HOME

f1917x9x

Data Link

Connector [91]

STARTS, THEN STALLS 5.12

GENERAL

Diagnostic Trouble Codes U1300, U1301 or “BUS Er”

See Figure 5-22. The typical serial data voltage range is 0 volts (inactive) to 7 volts (active). Due to the short pulse, voltages will be much lower on a DVOM. In analog mode, a DVOM reading serial data will show continuous voltage when active, typically 0.6-0.8 volts. The range for acceptable operations is greater than 0 and less than 7.0 volts.

NOTE

Problems in the fuel system or idle air control system may also create this symptom.

Table 5-11. Code Description

DTC DESCRIPTION

U1300 Serial data low U1301 Serial data open/high

DIAGNOSTICS

Diagnostic Tips

● If serial data is shorted, these codes will automatically

trip the check engine light.

● DTCs P1009 and P1010 may accompany DTCs U1300

and U1301.

Diagnostic Notes

The reference numbers below correlate with the circled numbers on the Test 5.12 ﬂow charts.

1. Check for trouble codes. See RETRIEVING DIAGNOS-

TIC TROUBLE CODES under 5.4 CHECKING FOR DIAGNOSTIC TROUBLE CODES: EFI.

2. Use HARNESS CONNECTOR TEST KIT (Part No. HD-

41404), black socket probes and patch cord.

Figure 5-22. Electrical Bracket (Under Right Side Cover)

2004 Touring: Engine Management (EFI) 5-35

HOME

f2208u8x

321654987121110 321654987121110

Speedometer

LtGN/V

BN/GY

[39B] [39A]

[108B] [108A]

BN/GY

321654987121110 321654987121110

Tachometer

[156B] [156A]

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 5-23. Serial Data Circuit (FLTR, FLHT/C/U)

Table 5-12. Wire Harness Connectors in Figure 5-23.

NO. DESCRIPTION MODEL TYPE LOCATION

Main to Interconnect

[1]

Harness

Main to Interconnect

[2]

Harness

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

Tu rn Signal/Security

[30]

Module

[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]

Main to Interconnect Harness

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)

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

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

5-36 2004 Touring: Engine Management (EFI)

HOME

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]

EFI

[8A]

Harness

121110

1 2 3

Data Link

[91A]

LtGN/V

LtGN/R

[78B] [78A]

Flash pin

Serial data

ECM

Figure 5-24. Serial Data Circuit (FLHR/C/S)

Table 5-13. Wire Harness Connectors in Figure 5-24.

NO. DESCRIPTION TYPE LOCATION

[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

Cavity in Crossmember at Rear of

Battery Box (Under Seat)

2004 Touring: Engine Management (EFI) 5-37

HOME

Test 5.12 (Part 1 of 2)

STARTS, THEN STALLS: DTC U1300, U1301 or “BUS Er”

Fresh gasoline

in tank?

NOYES

YES.

DTC P1009,

P1010 found. See

5.28 DTC P1009, P1010.

YES.

U1300 or U1301

codes found.

STOP

Go to Test 5.12

(Part 2 of 2).

YES

Tap lightly on fuel injectors.

Problem still exist?

Check for trouble codes using.5.6

SPEEDOMETER SELF DIAG-

NOSTICS. Codes found?

NO.

No codes

found.

Will engine start with throttle

opened partially and stall when

throttle closed?

YES. NO.

See 5.16 IDLE AIR

CONTROL.

Add gasoline.

YES.

BUS Er present.

speedometer will not

communicate with other

modules.

STOP

Check fuel pressure while

cranking engine. See 5.15

FUEL PRESSURE TEST. Is

fuel pressure OK?

Fuel pressure problem. See ﬂow chart under 5.15 FUEL

PRESSURE TEST.

Go to Test 5.12

(Part 2 of 2).

YES

Replace fuel injectors.

Problem still exist?

YES NO

Replace ECM.

Reprogram and learn

password.

5-38 2004 Touring: Engine Management (EFI)

System

OK.

System

OK.

Clear codes using speedometer self diagnostics.

See 5.6 SPEEDOMETER SELF DIAGNOSTICS. Conﬁrm proper operation with no check engine

lamp.

HOME

Test 5.12 (Part 2 of 2)

STARTS, THEN STALLS: DTC U1300, U1301 or “BUS Er”

Continued from Test 5.12 (Part 1 of 2)

Set run/stop switch to RUN. Turn ignition key ON.

Is BUS Er present?

YES

Tu rn ignition key OFF.

Disconnect ECM at connector

[78]. Turn ignition key ON.

Is BUS Er present?

Tu rn ignition key OFF.

Disconnect TSM/TSSM at connector

[30]. Turn ignition key ON.

Is BUS Er present?

YES

Is vehicle equipped with a tachometer?

NO YES

Tu rn ignition key OFF. Disconnect tachometer

at connector [108]. Turn ignition key ON.

Is BUS Er present?

NOYES

Replace ECM.

Reprogram and perform

password learn.

Replace TSM/TSSM. Per-

form password learn.

Tu rn ignition key OFF. While wiggling

harness, check for continuity to ground at

terminal 3 of connector [91A].

Is continuity to ground present at any time?

YES

Locate and repair

intermittent short

to ground.

YES

Locate and repair

intermittent short

to voltage.

Tu rn ignition switch ON. While wiggling harness,

check for voltage at terminal

3 of connector [91A]. Is voltage present at

any time?

No problem

found.

YES

Tu rn ignition key OFF. Disconnect

speedometer at connector [39].

Check for continuity to ground at

terminal 3 of connector [91A].

Is continuity to ground present?

YES

Locate and repair short

to ground.

Clear codes using speedometer self diagnostics.

See 5.6 SPEEDOMETER SELF DIAGNOSTICS. Conﬁrm proper operation with no check engine

lamp.

Replace tachometer.

Tu rn ignition switch ON.

Check for voltage at terminal

3 of connector [91A].

Is voltage present?

YES

Locate and repair short

to voltage.

2004 Touring: Engine Management (EFI) 5-39

Replace

speedometer.

HOME

FUEL SYSTEM ELECTRICAL TEST 5.13

GENERAL

With ignition switch turned to IGNITION and the engine stop switch at RUN, the ECM will energize the system relay to complete the circuit to the in-tank fuel pump. It will remain on as long as the engine is cranking or running, and the ECM is receiving ignition reference pulses from the CKP. If there are no reference pulses, the ECM will de-energize the system relay within 2 seconds after ignition is ON or engine has stalled, or immediately after the ignition is shut OFF.

The fuel pump delivers fuel to the injectors. The pressure regulator is where the system pressure is controlled. Excess fuel ﬂow is bypassed into the fuel tank through the pressure regulator. When the engine is stopped, the pump can be turned on by applying battery voltage and ground to the fuel pump connector [141A]. The fuel pump connector is located on the canopy at the top of the fuel tank. Improper fuel system pressure may contribute to one or all of the following symptoms.

● Engine cranks, but won’t run.

● Engine cuts out (may feel like ignition problems).

● Hesitation, loss of power and poor fuel economy.

NOTE

After turning ignition OFF, you must wait 10 seconds before turning the ignition back ON to get the fuel pump to reprime. This time out period is necessary for the ECM and IAC to reset.

f1924x8x

Fuel Tank

Fuel Tank Harness

Connector [13]

Not Present on FLHR/C/S

Figure 5-25. Fuel Pump/Fuel Level Sender Connector

(FLTR, FLHT/C/U)

EFI System Relay

Spare

DIAGNOSTICS

Diagnostic Notes

The reference numbers below correlate with the circled numbers on the Test 5.15 ﬂow charts.

1. Turns on fuel pump if wiring is OK. If pump runs, problem is in basic fuel delivery.

2. Use HARNESS CONNECTOR TEST KIT (Part No. HD-

41404), brown pin probe and patch cord.

3. Connect BREAKOUT BOX (Part No. HD-43876). See Section 5.7 BREAKOUT BOX: EFI.

4. Use HARNESS CONNECTOR TEST KIT (Part No. HD-

41404), purple pin probe and patch cord.

Fuel

Pump

f2223x9x

ECM Power

Figure 5-26. EFI Fuse Block

5-40 2004 Touring: Engine Management (EFI)

HOME

Idle air

control

System relay

Inj. F

Inj. R

[87B][87A]

BE/GN

BN/R

BK/PK

BK/O

Constant power

Switch power

[78]

35 36

GN/O

W/Y

GN/GY

BE/GY

W/BK

[84B] [84A]

[85B] [85A]

Engine stop switch

Y/GN

15 Amp

ECM fuse

15 Amp

IGN fuse

GY R/BK

fuel pump

Y/GN

15 Amp

fuse

40 Amp

Maxi Fuse

Ignition switch

Y/GN

BE/GY

GN/O W/BK

[13A] [13B]

123

IQCPR

87A

30 85 86

123

O/GY

[141B][141A]

All Except FLHR/C/S

Battery

[62B]

123

–+

System

relay

Fuel

pump

MAIN FUSE BLOCK COVER

Power gnd. Power gnd.

10A 15A 15A

SPARE FUSES

HEADLAMPS

BRAKE RELAY

15A

10 28

BK BK

15A

MAIN FUSE BLOCK

BRAKE RELAY

P&A

IGN

15A 15A 15A

P&A

IGN

RADIO PWR

BATTERY

RADIO MEM

ACCESS.

CRUISE/BRK

INSTRUMENTS

LIGHTS

10A

15A

f2208d8x

Figure 5-27. Fuel Pump Circuit

Table 5-14. Wire Harness Connectors in Figure 5-27.

NO. DESCRIPTION TYPE LOCATION

[13] Fuel Tank Harness 3-Place Multilock Behind Fuel Tank (Under Seat) [78] ECM 36-Place Packard Under Right Side Cover

[141] Fuel Pump/Fuel Level Sender 3-Place Mini-Deutsch Top of Canopy (Under Console)

2004 Touring: Engine Management (EFI) 5-41

HOME

Test 5.13 (Part 1 of 4)

FUEL SYSTEM ELECTRICAL TEST

Is ECM fuse OK?

YES

Repair as

necessary.

YES

Is fuel pump fuse OK?

YES

Check for 12 volts at terminals 1 (+) and 3 (-) of fuel

pump connector [141B] during ﬁrst 2-3 seconds

between connector Pin 1 of [141A] and

after key ON.

Voltage present?

YES

Check for corroded

connections or loose

connectors between fuel pump

and pump connector [141B].

Poor connections?

With key OFF, check for open

pump circuit. Connect ohmmeter

Pin 3 of connector [141A].

Continuity present?

STOP

Check for continuity to

ground on [141B] terminal 3.

Continuity present?

YES

Go to 5.11 NO

ECM POWER.

Go to Test 5.13

(Part 4 of 4).

STOP

Go to Test 5.13

(Part 2 of 4).

Locate and repair open on

BK wire between [141B]

and ground.

YES

Check pump

connections and repair

as required. If good,

replace fuel pump.

YES

Check for opening

in wiring.

Remove fuel pump. Check for continuity

across fuel pump

terminals.

Does meter read

continuity?

Replace

fuel pump.

5-42 2004 Touring: Engine Management (EFI)

HOME

Test 5.13 (Part 2 of 4)

FUEL SYSTEM ELECTRICAL TEST

Continued from Test 5.13 (Part 1 of 4).

Is 12 volts present at terminal 87 of system

relay (with relay in place) during first two sec-

onds after key on?

YES

Locate and repair open between

terminal 1 of [141B] and terminal 87

of system relay.

Is 12 volts present at terminal

30 of system relay?

YES

With ignition and Run/Stop

switch on, is 12 volts present at

terminal 86 of system relay.

YES

STOP

Go to Test 5.13

(Part 3 of 4).

Locate and repair open on BE/GY wire

between ECM fuse and terminal 30 of

system relay.

Locate and repair open on

W/BK wire to system relay.

2004 Touring: Engine Management (EFI) 5-43

HOME

Test 5.13 (Part 3 of 4)

FUEL SYSTEM ELECTRICAL TEST

Continued from Test 5.13 (Part 2 of 4).

Probe system relay connector Terminal 85 with a test light to 12 volts. Does test light illuminate

for 2 seconds after key ON?

YES

Replace system

relay.

Test 5.13 (Part 4 of 4)

FUEL SYSTEM ELECTRICAL TEST

YES

Locate and repair open

on GN/O wire.

Continued from Test 5.13 (Part 1 of 4) or

Test 5.13 (Part 2 of 4).

Check for intermittent short to ground on

terminal 1 of connector [141B]. Short to

ground present?

Probe Breakout Box Terminal 4 with a test light connected to 12 volts. Does test light illuminate

for 2 seconds after key ON?

Replace ECM. Reprogram

and learn password.

Repair short to

ground on O/GY wire

and replace fuse.

5-44 2004 Touring: Engine Management (EFI)

YES

Replace fuse.

YES

Current draw now in range. Replace

system relay and replace fuse.

Reconnect fuel pump connector [141]

and Install fuel pressure gauge.

See 5.15 FUEL PRESSURE TEST.

With fuel system intact and battery fully charged,

Connect DVOM across fuel pump fuse terminals using probe.

Place male positive probe in H slot. Turn key ON. With pump run-

ning, check current and fuel pressure. Is current draw under 4.5

amps and fuel pressure between 55-62 PSI (380-425 kPA)?

Substitute known good relay for system relay. Test

for current draw across fuel pump fuse. terminals.

remove fuel pump fuse.

Is current draw less than 4.5 amps?

Replace fuel

pump and replace fuse.

HOME

f2223x9x

EFI System Relay

ECM Power

Spare

Fuel

Pump

SYSTEM RELAY CHECK 5.14

GENERAL

System Relay

See Figure 5-28. With ignition switch turned to IGNITION and the engine stop/run switch at RUN, the ECM energizes the system relay to complete the circuit to the in-tank fuel pump, ignition coil and fuel injectors. They will remain powered as long as the engine is cranking or running, and the ECM is receiving ignition reference pulses from the CKP. If there are no reference pulses, the ECM will de-energize the system relay within 2 seconds after ignition is ON or engine has stalled, or immediately after the ignition is shut OFF.

Table 5-15. Code Description

DTC DESCRIPTION

P1001 System relay coil open/low P1002 System relay coil high/shorted P1003 System relay contacts open P1004 System relay contacts closed

Figure 5-28. EFI Fuse Block

DIAGNOSTICS

Diagnostic Notes

The reference numbers below correlate with the circled numbers on the Test 5.16 ﬂow charts.

1. Use HARNESS CONNECTOR TEST KIT (Part No. HD-

41404), gray pin probe and patch cord.

2. Connect BREAKOUT BOX (Part No. HD-43876) to ECM. See Section 5.7 BREAKOUT BOX: EFI.

2004 Touring: Engine Management (EFI) 5-45

HOME

f2208h8x

System relay

Power gnd.

Switch power

ECM

Ion sense

Power gnd.

Constant power

Coil R

Inj. R

Inj. F

Coil F

[78A] [78B]

4 5

10 11 12

13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36

GN/O

GN/GY

Y/BE

W/Y

BE/GY

BE/O

W/BK

W/Y

[84B] [84A]

[85B] [85A]

ECM fuse

GY/BE

W/BK

[8B] [8A]

15 amp

Y/GN

GY/BE

Y/BE

BE/O

W/BK

BE/GY

IGN fuse

W/BK

15 amp

Y/GN

[83B] [83A]

R/BK

DCBA

15 amp

fuel pump

fuse

AB CD

[33B] [33A]

Ignition

switch

12345

678

12345

678

[62B]

Y/GN

BE/GY

GN/O W/BK

[13A] [13B]

123

Ignition

coil

40 Amp

Maxi Fuse

[1B] [1A]

System relay

IQCPR

87A

30 85 86

Fuel pump

123

O/GY

[141B][141A]

Battery

123

–+

BK BK

12345

678

[22A] [22B]

12345

Engine stop

switch

Figure 5-29. System Relay Circuit (FLTR, FLHT/C/U)

Table 5-16. Wire Harness Connectors in Figure 5-29.

NO. DESCRIPTION TYPE LOCATION

[1] Main to Interconnect Harness 12-Place Deutsch (Black) Inner Fairing (Right Fairing Bracket)

[8] Main to EFI Harness 12-Place Deutsch (Gray) Under Right Side Cover [22] Right Handlebar Switches 12-Place Deutsch (Black) Inner Fairing (Right Fairing Support Brace) [33] Ignition/Light Key Switch 4-Place Packard Inner Fairing (Top Fork Bracket) [78] ECM 36-Place Packard Under Right Side Cover [83] Ignition Coil 4-Place Packard Below Fuel Tank (Left Side) [84] Front Injector 2-Place Packard Below Fuel Tank (Left Side) [85] Rear Injector 2-Place Packard Below Fuel Tank (Left Side)

5-46 2004 Touring: Engine Management (EFI)

HOME

f2208m8x

System relay

Power gnd.

Switch power

ECM

Ion sense

Power gnd.

Constant power

Coil R

Inj. R

Inj. F

Coil F

[78A] [78B]

10 11 12

13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36

GN/O

GN/GY

Y/BE

W/Y

BE/GY

W/BK

BE/O

W/Y

BK BK

[84B] [84A]

[85B] [85A]

15 amp

ECM fuse

GY/BE

W/BK

[8B] [8A]

12 11

[62B]

Y/GN

BE/GY

System relay

[62B]

IQCPR

87A

30 85 86

GN/O

W/BK

Fuel pump

123

Y/GN

15 amp

fuel pump

fuse

Y/GN

123

[141B][141A]

Y/GN

AB CD

GY/BE

Y/BE

Ignition

coil

BE/O

W/BK

[83B] [83A]

BE/GY

–+

Battery

11 10

15 amp

IGN fuse

W/BK

12-Place on

FLHP Only

R/BK

I B A

678

40 Amp

Maxi Fuse

[33B] [33A]

Ignition

switch

12345

Engine stop

switch

[22A] [22B]

Figure 5-30. System Relay Circuit (FLHR/C/S)

Table 5-17. Wire Harness Connectors in Figure 5-30.

NO. DESCRIPTION TYPE LOCATION

[8] Main to EFI Harness 12-Place Deutsch (Gray) Under Right Side Cover [22] Right Handlebar Switches 12-Place Deutsch (Black) Inside Headlamp Nacelle [33] Ignition/Light Key Switch 3-Place Packard Under Console [78] ECM 36-Place Packard Under Right Side Cover [83] Ignition Coil 4-Place Packard Below Fuel Tank (Left Side) [84] Front Injector 2-Place Packard Below Fuel Tank (Left Side) [85] Rear Injector 2-Place Packard Below Fuel Tank (Left Side)

2004 Touring: Engine Management (EFI) 5-47

HOME

Test 5.14 (Part 1 of 3)

SYSTEM RELAY: DTC P1001, P1003

With relay in, check for battery voltage at Termi-

nal 87 of system relay during first 2-3 seconds

after key ON. Battery voltage (10-13 volts)

present for 2-3 seconds after key ON?

YES

System relay OK. With relay out,

measure resistance between

Terminal 87 of the system relay and

Socket A of Connector [83B].

Is resistance less than 0.5 ohm?

YES

Recheck connections.

Wiggle harness while repeating test. Repair

intermittent.

YES

Measure resistance

between Terminal 85 of

system relay and Terminal 4

on Breakout Box.

Is resistance less than

0.5 ohm?

Locate and repair

connection or

open on Y/GN

wire.

No voltage or voltage always

YES

With ignition ON, check for

10-13 volts at Terminal 86 of

the system relay. Voltage present?

YES

Was Ignition

fuse blown?

Locate and repair short

to ground and replace

ECM fuse.

Terminal 30 of the system relay.

NO.

present.

Check for 10-13 volts at

Voltage present?

Check for continuity to

ground on BE/GY wire.

Continuity present?

Locate and repair

open between fuse

and relay.

YES

Check for continuity to ground

on Terminal 4 of Breakout

Box. Continuity present?

YES

Locate and repair short

to ground.

Clear codes using speedometer self diagnostics.

See 5.6 SPEEDOMETER SELF DIAGNOSTICS. Conﬁrm proper operation with no check engine

lamp.

repair open on

5-48 2004 Touring: Engine Management (EFI)

Locate and

GN/O wire.

Replace system relay. Does

fuel pump run for the first 2

seconds after key ON?

YES

System

OK.

Locate and repair short

to ground and replace

Ignition fuse.

Replace ECM. Reprogram

and learn password.

Locate and repair

open on W/BK wire

between Connector [22]

and system relay.

NOYES

HOME

Test 5.14 (Part 2 of 3)

SYSTEM RELAY: DTC P1002

Remove system relay.

Check for voltage on

Terminal 4 of Breakout Box.

Voltage present?

Remove Breakout Box

connector from ECM.

Is voltage still present on

Terminal 4?

YES

Locate and repair

short to voltage

on GN/O wire.

Test 5.14 (Part 3 of 3)

SYSTEM RELAY: DTC P1004

YES

Replace ECM.

Reprogram and learn

password.

Replace

system relay.

Clear codes using speedometer self diagnostics. See 5.6 SPEEDOMETER SELF DIAGNOSTICS. Conﬁrm proper operation with no check engine

lamp.

Check connectors [13] (except FLHR/C/S) and [141] for

corrosion, damaged terminals, improper wire location, or

poor ground. Do any of these conditions exist?

YES

Repair.

Clear codes using speedometer self diagnostics.

See 5.6 SPEEDOMETER SELF DIAGNOSTICS. Conﬁrm proper operation with no check engine

lamp.

Condition: Fuel pump continues to run

YES NO

Locate and repair short

to voltage on Y/GN wire.

with key OFF.

Remove system relay.

Does pump continue to run?

2004 Touring: Engine Management (EFI) 5-49

Replace

system relay.

HOME

FUEL PRESSURE TEST 5.15

GENERAL

EFI System Relay

The fuel pump delivers fuel to the fuel line, to a cavity in the induction module that supplies the fuel injectors and to the pressure regulator, where the system pressure is controlled. Excess fuel pressure is bypassed to the fuel tank through the pressure regulator.

Spare

See Figure 5-31. The fuel pump fuse is located in the fuse block under the right side cover. The fuel pump can be turned on with the Scanalyzer or by applying battery voltage to the fuel pump fuse.

Improper fuel system pressure may contribute to one of the following conditions:

● Cranks, but won’t run.

● Cuts out (may feel like ignition problem).

● Hesitation, loss of power or poor fuel economy.

TESTING

The fuel pressure gauge (0-100 PSI) allows for fuel injector and fuel system pressure diagnosis. Special adapters allow the gauge to be attached to the external fuel supply line.

PART NO. SPECIALTY TOOL

HD-41182 Fuel pressure gauge

HD-44061 Fuel pressure gauge adapters (2)

1. Remove right side saddlebag and side cover.

Fuel

Pump

f2223x9x

ECM Power

Figure 5-31. EFI Fuse Block

1WARNING1WARNING

A small amount of gasoline may drain from the quickconnect ﬁtting when the fuel supply line is removed. Thoroughly wipe up any spilt fuel immediately. Dispose of rags in a suitable manner. Gasoline is extremely ﬂammable and highly explosive. Inadequate safety precautions could result in death or serious injury.

3. Locate quick-connect ﬁtting on left side of fuel tank. Pull up on chrome sleeve, and then pull down on fuel supply line to disconnect.

CAUTION

1WARNING1WARNING

The gasoline in the fuel supply line downstream of the fuel pump is under high pressure (58 psi). To avoid an uncontrolled discharge or spray of gasoline, always purge the system of high pressure gas before removing the fuel supply line from the fuel tank. Gasoline is extremely ﬂammable and highly explosive. Inadequate safety precautions could result in death or serious injury.

2. Purge the fuel supply line of high pressure gas.

a. See Figure 5-31. Pull the fuel pump fuse from the

EFI fuse block.

b. Start the engine and allow the vehicle to run.

c. When the engine stalls, operate the starter for 3 sec-

onds to remove any remaining fuel from the fuel lines.

5-50 2004 Touring: Engine Management (EFI)

The next step requires two fuel pressure gauge adapters. Failure to use two adapters will cause the fuel line to twist. This may result in a broken fuel line or fuel line ﬁtting.

4. Attach fuel line to gauge assembly.

a. See Figure 5-32. Install a second adapter in series

with the ﬁrst.

b. See Figure 5-33. Pull up on chrome sleeve of quick-

connect ﬁtting and insert neck of FUEL PRESSURE GAUGE ADAPTER (Part No. HD-44061) into fuel supply line.

c. While pushing up on bottom of adapter, pull down on

chrome sleeve until it “clicks” into the locked position. Tug on adapter to be sure that it will not come free.

HOME

7822

7833

1. Fuel supply line

2. Adapter to fuel line

3. Adapter to fuel tank

4. Pressure adapter/Schroeder valve union

5. Fuel valve (closed position)

7834

d. See Figure 5-34. In the same manner, install neck of

second fuel supply line ﬁtting into quick-connect ﬁtting on fuel tank. Tug on fuel supply line to be sure that it will not come free.

1WARNING1WARNING

To avoid an uncontrolled discharge or spray of gasoline, always be sure the quick-connect ﬁttings are properly mated. A slight tug on the fuel pressure gauge adapter and fuel supply line will verify this condition. Gasoline is extremely ﬂammable and highly explosive. Inadequate safety precautions could result in death or serious injury.

5. Verify that the fuel valve and air bleed petcock on the FUEL PRESSURE GAUGE (Part No. HD-41182) are closed.

6. See Figure 5-32. Remove protective cap from free end of fuel pressure gauge adapter. Connect fuel pressure gauge to Schroeder valve.

7. See Figure 5-31. Install fuel pump fuse.

8. Start and idle engine to pressurize the fuel system. Open the fuel valve to allow the ﬂow of fuel down the hose of the pressure gauge.

9. Position the clear air bleed tube in a suitable container and open and close the air bleed petcock to purge the gauge and hose of air. Repeat this step several times until only solid fuel (without bubbles) ﬂows from the air bleed tube. Close the petcock.

10. Open and close throttle to change engine speed. Note the reading of the pressure gauge. Fuel pressure should remain steady at 55-62 psi (380-425 kPa).

11. Turn the engine off. Position the air bleed tube in a suitable container. Open the air bleed petcock to relieve the fuel system pressure and purge the pressure gauge of gasoline.

Figure 5-32. Fuel Pressure Gauge Adapters

Figure 5-33. Fuel Line

1WARNING1WARNING

A small amount of gasoline may drain from the adapter when the gauge is removed. Thoroughly wipe up any spilt fuel immediately. Dispose of rags in a suitable manner. Gasoline is extremely ﬂammable and highly explosive. Inadequate safety precautions could result in death or serious injury.

12. Remove fuel pressure gauge from the adapter. Install protective cap over Schroeder valve.

1WARNING1WARNING

A small amount of gasoline may drain from the fuel supply line and adapter when these items are removed. Thoroughly wipe up any spilt fuel immediately. Dispose of rags in a suitable manner. Gasoline is extremely ﬂammable and highly explosive. Inadequate safety precautions could result in death or serious injury.

Figure 5-34. Fuel Pressure Gauge Installed (Typical)

2004 Touring: Engine Management (EFI) 5-51

HOME

DIAGNOSTICS

Diagnostic Notes

The reference numbers below correlate with the circled numbers on the Test 5.17 ﬂow chart.

Fuel Pressure

Regulator

f1940x9x

Figure 5-35. Underside of Canopy

13. Pull up on sleeve of quick-connect ﬁtting and remove fuel supply line from fuel pressure gauge adapter. Release adapter from fuel tank in the same manner.

1WARNING1WARNING

To avoid an uncontrolled discharge or spray of gasoline, always be sure the quick-connect ﬁtting is properly mated. A slight tug on the fuel supply line will verify this condition. Gasoline is extremely ﬂammable and highly explosive. Inadequate safety precautions could result in death or serious injury.

14. Pull up on chrome sleeve of quick-connect ﬁtting and insert neck of fuel supply line ﬁtting. While pushing up on bottom of fuel supply line ﬁtting, pull down on chrome sleeve until it “clicks” into the locked position. Tug on fuel supply line to be sure that it will not come free.

1. See FUEL PRESSURE REGULATOR, REMOVAL/INSTALLATION, in the Touring Service Manual.

2. If fuel system has pressure, but it is less than speciﬁcation, check for the following conditions.

a. The amount of fuel to the injectors is within limits,

but pressure is too low. Also, hard starting cold and overall poor performance condition may exist.

b. Restricted fuel ﬂow causing pressure drop. How-

ever, if pressure drop occurs only when driving, engine may surge and lose power as pressure begins to drop rapidly.

3. This condition may be identiﬁed when the fuel level is low and the fuel pump is turned on for the ﬁrst 2 seconds after key ON. A metallic ringing sound can be heard as the high pressure fuel is sprayed against the inside wall of the fuel tank.

15. Install right side cover and saddlebag.

5-52 2004 Touring: Engine Management (EFI)

HOME

Test 5.15

FUEL PRESSURE TEST

Install fuel pressure gauge. See TESTING

under Section 5.15 FUEL PRESSURE TEST.

Start and idle engine.

Open and close throttle to change engine speed. Does fuel pressure remain steady

at 55-62 PSI (380-425 kPa)?

YES

Steady pressure.

No trouble found.

Review symptoms.

Check for restricted pressure line or flex hose between

Leak inside tank caused by faulty coupling hose

Check for restricted fuel filter

or pump inlet screen. Are filter

YES

tank and test gauge. If lines are OK, check for:

Faulty fuel pump.

Restricted check valve fitting assembly.

or connection, such as hose at filter or pump.

Faulty fuel pressure regulator.

Low pressure.

and screen OK?

assembly and fuel tank. If OK,

replace faulty fuel pressure

Replace filter or clean pump

inlet screen. Retest.

High pressure.

Inspect check valve fitting

regulator.

2004 Touring: Engine Management (EFI) 5-53

HOME

IDLE AIR CONTROL 5.16

GENERAL

IAC Operation

The ECM controls engine idle speed by moving the idle air control (IAC) to open or close a passage around the throttle plate. It does this by sending voltage pulses to the proper motor winding of the IAC. This causes the pintle to move in or out of the IAC a given distance for each pulse received.

● To increase idle speed, the ECM retracts the pintle,

allowing more air to ﬂow through the throttle body.

● To decrease idle speed, the ECM extends the pintle,

allowing less air to ﬂow through the throttle body.

The IAC position is measured in steps. This can only be done by using a computer based diagnostic package called DIGITAL TECHNICIAN (Part No. HD-44750).

● A high number of steps represents a fully retracted pintle

and open passage around throttle plate. This correlates with an increase in the amount of air ﬂowing through the throttle body.

● Zero steps represents a fully extended pintle. A zero

reading indicates that the pintle has been fully extended and has consequently closed the passage around throttle plate, which is an abnormal condition.

Each time the ignition is turned off, the ECM resets the IAC by sending enough pulses to extend the pintle and effectively close the throttle body. The fully extended value is the ECM reference point. A given number of counts are then calculated by the ECM for use in setting the proper idle speed and IAC position.

DIAGNOSTICS

Diagnostic Tips

Engine idle speed can be adversely affected by the following:

● A loss of idle speed control does not necessarily imply

the IAC actuator or wiring has failed. It can be caused by a number of conditions such as an intake air leak, improperly adjusted throttle stop or a misﬁring cylinder.

● Leaking injectors will cause fuel imbalance and poor idle

quality due to different air/fuel ratios in each cylinder. To check for leaky injectors, ﬁrst remove the air cleaner. With the throttle wide open, turn key ON for 2 seconds and then OFF for 2 seconds ﬁve consecutive times. Replace the fuel injector if there is any evidence of raw fuel in the bores. See FUEL INJECTORS, REMOVAL/INSTALLATION, in the Touring Service Manual.

● Vacuum leaks. To check for vacuum, see 5.9 INTAKE

LEAK TEST.

● Contaminated fuel.

● Excessive oil in the crankcase (oil sumping).

● TPS reading greater than 1% (possible throttle cable

misadjustment) or battery voltage reading of less than 9 volts or a vehicle speed sensor (VSS) greater than 0 will disable idle speed control.

● Loss of battery power to ECM pin 31.

NOTE

Warm idle speed is controlled by the ECM and can only be adjusted by using a computer based diagnostic package called DIGITAL TECHNICIAN (Part No. HD-44750).

Diagnostic Trouble Code P0505: Loss of Idle Speed Control

Loss of idle speed control will result if the idle RPM is ±200 from preset idle speed and IAC motor is at zero or maximum for greater than 5 seconds. This code may occur with others for a multiple code situation. Resolve the other codes ﬁrst to correct.

Table 5-18. Code Description

DTC DESCRIPTION

P0505 Loss of idle speed control

5-54 2004 Touring: Engine Management (EFI)

HOME

b0426x9x

f1939x9x

Idle Air Control

7837

Diagnostic Notes

The reference numbers below correlate with the circled numbers on the Test 5.18 ﬂow charts.

1. When the engine is stopped, the IAC pintle extends and then retracts to a ﬁxed “Park” position for increased airﬂow and idle speed during the next engine start sequence. This key OFF reset procedure takes 10 seconds to perform.

2. Test lamp behavior may follow two patterns. The color of the lights is not relevant to IAC operation.

a. Normal behavior: At key ON, test lights will alter-

nately ﬂash and then remain steady on to conﬁrm ECM signals. At key OFF lights alternately ﬂash and go out after 10 second reset procedure.

b. Problem indicated: One or more lights fail to illumi-

nate during key ON/key OFF cycle.

NOTE

There is a remote possibility that one of the circuits is shorted to voltage which would have been indicated by a steady light. Disconnect ECM and turn the ignition ON. Probe terminals to check for this condition.

3. Connect BREAKOUT BOX (Part No. HD-43876) to EFI wire harness only, leaving ECM disconnected. See Section 5.7 BREAKOUT BOX: EFI.

4. Use HARNESS CONNECTOR TEST KIT (Part No. HD-

41404), gray pin probe and patch cord.

5. Repair faulty ECM connection or replace ECM.

Figure 5-36. IAC Test Lamp (Part No. HD-41199-3)

Figure 5-37. Induction Module (Top View)

Figure 5-38. IAC Pintle

2004 Touring: Engine Management (EFI) 5-55

HOME

s0448x9x

IAC

motor

[78B] [78A]

[87A] [87B]

BCD

BE/GN

BN/R

BK/PK

BK/O

ECM

BK/O

BK/PK

BE/GN

17 18 35 36

BN/R

Figure 5-39. IAC Circuit

Table 5-19. Wire Harness Connectors in Figure 5-39.

NO. DESCRIPTION TYPE LOCATION

[78] ECM 36-Place Packard Under Right Side Cover [87] IAC 4-Place Packard Below Fuel Tank (Right Side)

5-56 2004 Touring: Engine Management (EFI)

HOME

Test 5.16 (Part 1 of 2)

IDLE AIR CONTROL: DTC P0505

Remove air cleaner cover

and element. Is throttle

valve completely closed?

YES NO

YES

Repair intake

leak.

Lubricate and adjust

throttle cables.

YES

Check intake manifold for leaks. See

5.9 INTAKE LEAK TEST. Leaks

found?

Check fuel pressure.

See Section 5.15 FUEL

PRESSURE TEST.

Monitor IAC pintle for 10 seconds after turning

ignition OFF. Does pintle extend and then retract

during 10 second key OFF reset procedure?

Problem

indicated.

Remove test lamp.

Connect Breakout Box to Connector [78B]

leaving ECM disconnected. Check Terminal 31

for 12 volts. Battery voltage present?

YES NO

Using DVOM, measure resistance

between IAC connector [87B]

and Breakout Box.

IAC WIRE COLOR ECM

A BE/GN to 35 B BN/R to 36

C BK/PK to 18 D BK/O to 17

Does each wire measure 0.5 ohms or less?

Disconnect IAC and connect test lamp.

Turn ignition switch to IGNITION for 2 seconds,

Check test lamp during key ON/OFF cycle.

See Figure 5-36.

and then OFF for 10 seconds.

Normal

behavior.

Repair faulty IAC

connection or IAC assembly.

Go to Test 5.13. No ECM Power.

Clear codes using speedometer self diagnostics.

See 5.6 SPEEDOMETER SELF DIAGNOSTICS. Conﬁrm proper operation with no check engine

lamp.

YES

Turn ignition ON. With ECM still

disconnected, check voltage on all

four sockets of Connector [87B].

Is voltage present?

YES NO

Locate and repair

short to voltage.

2004 Touring: Engine Management (EFI) 5-57

Repair poor connection

at Connectors [87B] or

[78B], or repair open

wire in harness.

STOP

Go to Test 5.16

(Part 2 of 2).

HOME

Test 5.16 (Part 2 of 2)

IDLE AIR CONTROL: DTC P0505

Replace ECM.

Reprogram and learn

password.

YES

Continued from Test 5.16 (Part 1 of 2).

Turn ignition OFF. Measure resistance

between each socket of Connector [87B]

Is resistance greater than 1 megohm

Clear codes using speedometer self diagnostics.

See 5.6 SPEEDOMETER SELF DIAGNOSTICS. Conﬁrm proper operation with no check engine

lamp.

and ground.

for all sockets?

YES

Inspect ECM

connections.

Connections OK?

Repair ECM connections.

Locate and

repair short to

ground.

5-58 2004 Touring: Engine Management (EFI)

HOME

d0273x8x

MISFIRE AT IDLE OR UNDER LOAD 5.17

GENERAL

Misﬁre at Idle or Under Load

● Battery condition and connections may also cause mis-

ﬁres. See BATTERY in the Touring Service Manual for more information.

● Fuel system problems may also cause misﬁres. Consult

5.15 FUEL PRESSURE TEST and then see symptom

tables under 5.5 INITIAL DIAGNOSTIC CHECK: EFI.

● Mechanical problems with the engine may cause mis-

ﬁres. See Section 3 of the Touring Service Manual for more information.

● Vehicle modiﬁcations including intake and exhaust may

cause misﬁres.

Figure 5-40. Spark Tester

Table 5-20. Spark Plug Cables

DIAGNOSTICS

Diagnostic Notes

The reference numbers below correlate with the circled numbers on the Test 5.17 ﬂow charts.

1WARNING1WARNING

Any open spark around gasoline or other combustibles may result in ﬁre or explosion. Thoroughly wipe up any spilt fuel and dispose of rags in a suitable manner. Gasoline is extremely ﬂammable and highly explosive. Inadequate safety precautions could result in death or serious injury.

1. Connect BREAKOUT BOX (Part No. HD-43876) between wire harness and ECM. See 5.7 BREAKOUT

BOX: EFI.

2. See Figure 5-40. A SPARK TESTER (Part No. HD-

26792) must be used to verify adequate secondary voltage (25,000 volts) at the spark plug.

NOTE Engine will not spark with both spark plugs removed. When checking for spark, use SPARK TESTER (Part No. HD-

26792) with both plugs installed.

a. Turn ignition key OFF. b. Remove spark plug cable from spark plug. Visually

check plug condition.

c. Attach cable to SPARK TESTER. Clip tester to cylin-

der head bolt.

d. While cranking engine, watch for spark to jump

tester gap on leads.

e. Reinstall and repeat procedure on other spark plug

cable.

LOCATION LENGTH RESISTANCE

Front/Rear 20.2 inch (513 mm) 4975-11960

3. Perform spark plug cable resistance test.

a. Remove spark plug cable from spark plug and igni-

tion coil. For best results, use a needle nose pliers for removal/installation on coil. Gently grasp cable as close to terminals as possible.

b. Using an ohmmeter, touch probes to terminals on

each end plug cable.

c. Compare resistance values to Ta b le 5-20. Replace

cables not meeting speciﬁcations. Reinstall and repeat procedure on other spark plug cable.

4. If carbon tracking is evident on outside of coil towers, replace ignition coil and inspect spark plug cables. Cables must be clean and tight. Excessive cable resistance or faulty connections can cause coil damage.

5. This test can also be performed by substituting a known good coil for one causing the no spark condition. The coil does not require full installation to be functional. Verify faulty coil by performing resistance test. See IGNITION COIL in the Touring Service Manual.

6. Use HARNESS CONNECTOR TEST KIT (Part No. HD-

41404), red pin probe and patch cord to relay and gray pin probe and patch cord to the coil connector [83B].

2004 Touring: Engine Management (EFI) 5-59

HOME

f2208n8x

System relay

Inj. F

Inj. R

Ion sense

Coil R Coil F

Constant power

[78]

11 29

[62B]

IQCPR

Y/GN

BE/GY

87A

30 85 86

System

relay

GN/O W/BK

[13A] [13B]

GN/O

W/Y

[84B] [84A]

Y/GN

15 Amp

fuel pump

fuse

Y/GN

GN/GY

GY/BE

[85B] [85A]

[83B] [83A]

AB CD

Coil

123

O/GY

All Except FLHR/C/S

123

[141B][141A]

Fuel

pump

Y/BE

BE/O

40 Amp

Maxi Fuse

–+

Battery

BE/GY

15 Amp

ECM fuse

Starter

Motor

Switch power

Power gnd. Power gnd.

Table 5-21. Wire Harness Connectors in Figure 5-41.

W/BK

Engine

stop

switch

10 28

BK BK

GY R/BK

15 Amp

IGN fuse

Ignition switch

Figure 5-41. Ignition Coil Circuit

NO. DESCRIPTION TYPE LOCATION

[78] ECM 36-Place Packard Under Right Side Cover [83] Ignition Coil 4-Place Packard Below Fuel Tank (Left Side)

5-60 2004 Touring: Engine Management (EFI)

HOME

Test 5.17 (Part 1 of 3)

MISFIRE AT IDLE OR UNDER LOAD

Is fuel contaminated?

YES

Drain and flush tank. Refill with

fresh fuel.

YES

• Faulty, worn or cracked spark plug(s).

• Plug fouling due to engine mechanical fault.

• Faulty or poor connection at plug or coil.

Check for:

YES

Connect breakout box. Check for continuity

between terminal 10 of ECM and battery neg-

ative and terminal 28 of ECM and battery neg-

ative. Resistance should be less than 1 ohm.

YES

Use spark tester to check cables.

Did spark jump tester lead gap?

Check resistance of each spark plug

cable that did not fire the spark tester.

Also, check for faulty plug cable connections

and wires for carbon tracking.

Are spark plug cables OK?

Did it?

Is it?

Locate and repair poor

ground connection.

Coils should be free

of carbon tracking.

Are they?

Switch coil with unit

known to be good.

Re-perform spark test.

Did spark jump gap

during engine cranking?

Original ignition coil

is faulty. Replace.

YES

STOP

Replace

faulty spark plug cables.

Replace

ignition coil.

Go to Test 5.17

(Part 2 of 3).

2004 Touring: Engine Management (EFI) 5-61

HOME

Test 5.17 (Part 2 of 3)

MISFIRE AT IDLE OR UNDER LOAD

YES NO

Reassemble coil and fuel tank. Measure

voltage drop between battery (positive

lead) and Terminal 87 (negative lead) on

system relay with engine running. Is voltage drop less than 1.0 volt?

YES

Problem is fuel related.

See symptoms under

Table 5-3. Engine Performance

Problems.

Continued from Test 5.17 (Part 1 of 3).

Measure resistance between relay

Terminal 87 and Socket A (Y/GN wire)

of Connector [83B]. Wiggle harness.

Is resistance continuously less than 0.5 ohms?

Repeat voltage drop test after moving

negative lead to Terminal 30. With

engine running, is voltage drop less

than 1.0 volt?

YES

Replace

system relay.

Find source of

intermittent and repair.

Repeat voltage drop test after

moving negative lead to 15 amp

ECM fuse (BE/GY wire). With

engine running, is voltage drop less

than 1.0 volt?

5-62 2004 Touring: Engine Management (EFI)

YES

Repair.

BE/GY wire.

YES

Replace 15 amp

ECM fuse.

Repeat voltage drop test after

moving negative lead to 15 amp

ECM fuse (R wire). With engine

running, is voltage drop less than

1.0 volt?

STOP

Go to Test 5.17

(Part 3 of 3).

HOME

Test 5.17 (Part 3 of 3)

MISFIRE AT IDLE OR UNDER LOAD

YES NO

Continued from Test 5.17 (Part 2 of 3).

Repeat voltage drop test after

moving negative lead to 40 amp maxi-fuse, ter-

minal B. With engine running, is voltage drop

less than 1.0 volt?

Check terminal

or repair wire.

Check terminal

or replace

maxi-fuse or

terminals.

Repeat voltage drop test after

moving negative lead to 40 amp maxi-fuse,

terminal A. With engine running, is voltage

drop less than 1.0 volt?

NOYES

Repair wire between

maxi-fuse and battery.

2004 Touring: Engine Management (EFI) 5-63

HOME

COMBUSTION ABSENT/INTERMITTENT 5.18

GENERAL

s0475x9x

Diagnostic Trouble Codes P1353, P1356, P1357, P1358: No Combustion

See Figure 5-42. A feedback voltage signal in the secondary ignition circuit detects the presence of combustion each time a cylinder ﬁres on ECM Pin 27. For diagnostic purposes, this signal is only analyzed under load above 2000 rpm where it may be easily measured. Failure to detect combustion at high speed and load means one of following conditions exist.

● Cylinder is truly misﬁring.

● There is a lack of continuity in the ignition coil secondary

circuit.

Pin B

Table 5-22. Code Description

DTC DESCRIPTION

P1353 Front cylinder no combustion P1356 Rear cylinder no combustion P1357 Intermittent secondary front P1358 Intermittent secondary rear

DIAGNOSTICS

Diagnostic Notes

The reference number below correlates with the circled numbers on the Test 5.20 ﬂow charts.

1. Connect BREAKOUT BOX (Part No. HD-43876) between wire harness and ECM. See Section 5.7 BREA-

KOUT BOX: EFI.

2. Spark plugs must be correct Harley-Davidson resistor type speciﬁed for this model.

3. Use HARNESS CONNECTOR TEST KIT (Part No. HD-

41404), gray pin probes and patch cords.

4. Perform spark plug cable resistance test. a. Remove spark plug cable from spark plug and igni-

tion coil. For best results, use a needle nose pliers for removal/installation on coil. Gently grasp cable as close to terminals as possible.

Figure 5-42. Ignition Coil

b. Using an ohmmeter, touch probes to terminals on

each end plug wire.

c. Compare resistance values to Ta b le 5-20. Replace

cables not meeting speciﬁcations. Reinstall and repeat procedure on other spark plug cable.

Table 5-23. Spark Plug Cables

LOCATION LENGTH RESISTANCE

Front/Rear 20.2 inch (513 mm) 4975-11960

5-64 2004 Touring: Engine Management (EFI)

HOME

f2208h8x

System relay

Power gnd.

Switch power

ECM

Ion sense

Power gnd.

Constant power

Coil R

Inj. R

Inj. F

Coil F

[78A] [78B]

2 3

4 5

10 11 12

13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36

GN/O

GN/GY

Y/BE

W/Y

BE/GY

BE/O

W/BK

W/Y

GY/BE

[84B] [84A]

[85B] [85A]

15 amp

ECM fuse

12 11 10

9 8

7 6 5

W/BK

4 3 2 1

[8B] [8A]

Y/GN

GY/BE

Y/BE

BE/O

W/BK

BE/GY

15 amp

fuel pump

fuse

Y/GN

AB CD

[83B] [83A]

[62B]

Y/GN

BE/GY

GN/O W/BK

[13A] [13B]

AB CD

Ignition

coil

123

System relay

IQCPR

87A

30 85 86

Fuel pump

123

O/GY

[141B][141A]

123

–+

Battery

12 11 10

9 8 7 6 5 4 3 2 1

W/BK

R/BK

15 amp

IGN fuse

DCBA

678

[33B] [33A]

Ignition

switch

12345

40 Amp

Maxi Fuse

[1B] [1A]

BK BK

12345

678

[22A] [22B]

12345

Engine stop

switch

Figure 5-43. Battery Voltage Circuit (FLTR, FLHT/C/U)

Table 5-24. Wire Harness Connectors in Figure 5-43.

NO. DESCRIPTION TYPE LOCATION

[1] Main to Interconnect Harness 12-Place Deutsch (Black) Inner Fairing (Right Fairing Bracket)

2004 Touring: Engine Management (EFI) 5-65

HOME

f2208m8x

System relay

Power gnd.

Switch power

ECM

Ion sense

Power gnd.

Constant power

Coil R

Inj. R

Inj. F

Coil F

[78A] [78B]

10 11 12

13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36

GN/O

GN/GY

Y/BE

W/Y

BE/GY

BE/O

W/BK

W/Y

BK BK

[84B] [84A]

[85B] [85A]

15 amp

ECM fuse

GY/BE

W/BK

[8B] [8A]

12 11 10

9 8 7 6 5 4 3 2 1

[62B]

Y/GN

BE/GY

System relay

IQCPR

87A

30 85 86

[62B]

GN/O

W/BK

Fuel pump

123

Y/GN

15 amp

fuel pump

fuse

Y/GN

123

[141B][141A]

Y/GN

AB CD

GY/BE

Y/BE

Ignition

coil

BE/O

W/BK

[83B] [83A]

BE/GY

–+

Battery

11 10

9 8 7 6 5 4 3 2 1

W/BK

R/BK

15 amp

IGN fuse

12-Place on

FLHP Only

I B A

678

40 Amp

Maxi Fuse

[33B] [33A]

Ignition

switch

12345

Engine stop

switch

[22A] [22B]

Figure 5-44. Battery Voltage Circuit (FLHR/C/S)

Table 5-25. Wire Harness Connectors in Figure 5-44.

NO. DESCRIPTION TYPE LOCATION

5-66 2004 Touring: Engine Management (EFI)

HOME

Test 5.18 (Part 1 of 2)

COMBUSTION ABSENT: DTC P1353, P1356, P1357, P1358

YES NO

Is vehicle

running properly?

YES

Clear codes, refill with fresh

fuel and restart. Does code

return?

YES NO

Has vehicle run out

of fuel recently?

System

OK.

Check if spark plug terminal is fully

connected on spark plug.

YES

See Section 5.17

MISFIRE AT IDLE

OR UNDER LOAD.

Check fuel pressure. See

Section 5.15 FUEL PRESSURE

TEST. Is fuel pressure 55-62

PSI (380-425 kPA)?

See Section

5.13 FUEL SYSTEM

ELECTRICAL TEST.

Crimp spark plug terminal

slightly to improve connection

or replace spark plug cable.

Remove spark plug terminal from spark plug. Inspect cable and spark plug terminals for carbon tracking or evidence of a loose terminal. Loose

terminal present?

NOYES

STOP

Go to Test 5.18

(Part 2 of 2).

Seat terminal

on spark plug.

Clear codes using speedometer self diagnostics.

See 5.6 SPEEDOMETER SELF DIAGNOSTICS. Conﬁrm proper operation with no check engine

lamp.

2004 Touring: Engine Management (EFI) 5-67

HOME

Test 5.18 (Part 2 of 2)

COMBUSTION ABSENT: DTC P1353, P1356, P1357, P1358

Continued from Test 5.18 (Part 1 of 2).

Using Breakout Box, measure resistance between

spark plug center electrode and Breakout Box Terminal

27. Is resistance less than 60,000 ohms?

YES

Replace spark plug.

Condition still present?

Replace spark plug cable. Condition still

present?

YES

Measure resistance between

Te rminal A and B at coil.

Resistance should be greater

than 100k ohms.

Is it?

Replace ECM.

Reprogram and learn

password.

NOYES

System

OK.

System

OK.

NOYES

Replace coil and ECM.

Reprogram and learn

password.

Check continuity between coil Terminal B and Breakout Box

Terminal 27. Continuity present?

Replace

coil.

Replace spark

plug.

NOYES

Check spark plug cable resistance.

Resistance meet specifications?

NOYES

Replace spark

plug cable.

5-68 2004 Touring: Engine Management (EFI)

Clear codes using speedometer self diagnostics. See 5.6 SPEEDOMETER SELF DIAGNOSTICS. Conﬁrm proper operation with no check engine

lamp.

Harley Davidson Touring 2004 Service Manual fe05a

Specifications and Main Features

Frequently Asked Questions

User Manual

SPECIFICATIONS 5.1

EFI SYSTEM 5.2

GENERAL

TROUBLESHOOTING

Check Engine Lamp

EFI DIAGNOSTIC INTRODUCTION 5.3

SYSTEM PROBLEMS

No Start

Poor Performance

RESOLVING PROBLEMS

CHECKING FOR DIAGNOSTIC TROUBLE CODES: EFI 5.4

CHECK ENGINE LAMP

CODE TYPES

Current

Historic

RETRIEVING DIAGNOSTIC TROUBLE CODES

MULTIPLE DIAGNOSTIC TROUBLE CODES

INITIAL DIAGNOSTIC CHECK: EFI 5.5

GENERAL

Diagnostic Notes

Circuit Diagram/Wire Harness Connector Table

Reprogramming ECM

Diagnostic Tips

Diagnostic Notes

Other Codes

INITIAL DIAGNOSTICS

General Information

Diagnostic Check (Part 1 of 2)

Diagnostic Check (Part 2 of 2)

SPEEDOMETER SELF DIAGNOSTICS 5.6

GENERAL

DIAGNOSTICS

Diagnostic Tips

Diagnostic Notes

Speedometer Self Diagnostics (chart)

BREAKOUT BOX: EFI 5.7

GENERAL

INSTALLATION

REMOVAL

WIGGLE TEST 5.8

GENERAL

PROCEDURE

INTAKE LEAK TEST 5.9

GENERAL

LEAK TESTER

Parts List

Tester Assembly

INTAKE LEAK TESTING

ENGINE CRANKS, BUT WILL NOT START 5.10

GENERAL

DIAGNOSTICS

Diagnostic Notes

Diagnostic Tips

Test 5.10 (Part 1 of 4)

Test 5.10 (Part 2 of 4)

Test 5.10 (Part 3 of 4)

Test 5.10 (Part 4 of 4)

NO ECM POWER 5.11

GENERAL

No Spark/No Check Engine Lamp at Key ON

DIAGNOSTICS

Diagnostic Notes

Test 5.11 (Part 1 of 2)

Test 5.11 (Part 2 of 2)

STARTS, THEN STALLS 5.12

GENERAL

Diagnostic Trouble Codes U1300, U1301 or “BUS Er”

DIAGNOSTICS

Diagnostic Tips

Diagnostic Notes

Test 5.12 (Part 1 of 2)

Test 5.12 (Part 2 of 2)

FUEL SYSTEM ELECTRICAL TEST 5.13

GENERAL

DIAGNOSTICS

Diagnostic Notes