Harley Davidson Touring 2004 Service Manual fe07a

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Set/Resume

Switch

110

120

90 100

MPH

RPM

x100

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Cruise Enabled/Engaged Lamp

Tachometer

CRUISE CONTROL 7.1

GENERAL

The Cruise Control system provides automatic vehicle speed control. The electronics and stepper motor are contained in a control module mounted under the left side cover. The stepper motor actuates the cruise control cable through a gear train and ribbon reel.

SYSTEM OPERATION

To engage and disengage the cruise control system, proceed as follows:

1. While riding in fourth or ﬁfth gear, turn the Cruise ON/ OFF Switch to the ON position. See Figure 7-1. The switch is located on the fairing cap of FLHTCU models, the instrument nacelle of FLTR models, and the left handlebar lower switch housing on FLHRC models. The Cruise Enabled/Engaged lamp in the tachometer face (speedometer on FLHRC models) turns red to indicate that the system is activated. See Figure 7-3. A red lamp in the switch on both FLHTCU and FLTR models also indicates this condition to the rider.

2. Power (12 vdc) is supplied to the cruise control module through a 15 amp fuse located in the fuse block mounted under the left side cover.

3. With the motorcycle traveling at the desired “cruise” speed (30 mph/48 km/h to 85 mph/137 km/h), momentarily push the Cruise SET/RESUME switch to SET. See

Figure 7-2.

Figure 7-2. Right Handlebar Switch Assembly

(FLTR, FLHTCU)

Ignition/Light

Key Switch

Cruise ON/OFF

Switch

Figure 7-3. Instrument Panel (FLHTCU)

The cruise control module “reads” the vehicle speed sensor (VSS) output to establish the desired vehicle speed. The module then sends a signal to the stepper motor which drives the ribbon reel to take up the slack in the cruise cable. The Cruise Enabled/Engaged lamp in the tachometer face (speedometer on FLHRC models) turns from red to green to indicate that the cruising speed is

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Figure 7-1. Fairing Cap (FLHTCU)

locked in. See Figure 7-3.

4. The cruise control module monitors both the engine RPM and the VSS output speed signal. The module signals the stepper motor to open or close the throttle to keep the speedometer output speed signal constant. The engine RPM is monitored to detect engine

2004 Touring: Cruise Control 7-1

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DISENGAGE SEQUENCEENGAGE SEQUENCE

CRUISE SWITCH ON

SET/RESUME

SWITCH TO SET

READS VSS

OUTPUT SPEED SIGNAL

STEPPER MOTOR

GEAR TRAIN

& RIBBON REEL

CRUISE ENGAGED

LAMP

THROTTLE

ACTUATION

*Tachometer receives signal from ignition coil on

carbureted models, and from ECM on EFI models.

overspeed, a condition which automatically causes cruise disengagement.

5. The cruise control automatically disengages (stepper motor drives cruise cable to the full-out position) whenever the cruise control module receives one of the following inputs:

a. Front or rear brake is applied.

b. Throttle is “rolled back” or closed, thereby actuating

idle cable roll-off (disengage) switch.

ENGINE RPM MONITORED*

Figure 7-4. Cruise System Diagram

FRONT/REAR BRAKE

IDLE CABLE ROLL-OFF

(DISENGAGE) SWITCH

CRUISE

MODULE

f. Handlebar mounted Cruise SET/RESUME switch is

pushed to SET and held in that position until vehicle speed drops below 30 mph (48 km/h).

If the vehicle speed is above 30 mph (48 km/h) when the Cruise SET/RESUME Switch is released, then the cruise system automatically re-engages.

CRUISE SWITCH OFF

HANDLEBAR

ENGINE STOP

SWITCH OFF

CLUTCH DISENGAGE

(ENGINE RPM)

NOTE

c. Motorcycle clutch is disengaged (module senses too

great an increase in RPM).

d. Cruise ON/OFF Switch placed in the OFF position.

The switch is located on the fairing cap of FLHTCU models, the instrument nacelle of FLTR models, and the left handlebar lower switch housing on FLHRC models. The green Cruise Enabled/Engaged lamp in the tachometer face (speedometer on FLHRC models) is extinguished to indicate that the system is deactivated. The red lamp in the fairing cap switch of FLHTCU models and the instrument nacelle switch of FLTR models is also extinguished.

e. Handlebar mounted Engine Stop Switch placed in

the OFF position. (This removes tachometer input signal which results in module disengagement.)

7-2 2004 Touring: Cruise Control

TROUBLESHOOTING

The cruise module circuitry provides on-board diagnostics to help isolate any problems that might occur with the cruise system.

If the cruise is inoperative or fails to set, begin troubleshooting with 7.2 CRUISE INOPERATIVE DIAGNOSTICS. If the cruise seems to disengage or drop out for no apparent reason, then see 7.3 CRUISE DROPOUT DIAGNOSTICS.

In the diagnostic mode, the Cruise Enabled/Engaged lamp is employed as a test indicator. The lamp is in the tachometer face (speedometer on FLHRC models). See Figure 7-3.

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CRUISE INOPERATIVE DIAGNOSTICS 7.2

GENERAL

Perform the following diagnostic procedures in the order presented. If the test sequence is not followed precisely, the diagnostic mode may not be exited at conclusion of the diagnostic routine and the test indicator (Cruise Engaged Lamp) may continue to ﬂash while the engine is running.

INOPERATIVE DIAGNOSTICS

See Ta b l e 7-2. All diagnostic steps are listed in table format. Follow the numbered steps to test the system. Compare the system behavior to CORRECT FUNCTION or INCORRECT FUNCTION columns and advance to the next step listed.

Diagnostic Notes

The diagnostic notes below provides supplementary information for Ta ble 7-2.

1. If the cruise engaged lamp does not illuminate at all, check for one or more of the following conditions:

a. SET/RESUME switch faulty or not wired correctly.

b. Broken or pinched wire to SET switch or cruise mod-

ule.

c. Cruise engaged lamp burned out or miswired. Lamp

is turned on by module supplied ground.

d. Main 10-place connector not plugged into cruise

module.

e. Faulty cruise main switch and associated wiring.

f. No module ground at Terminal E of 10-place module

connector.

Table 7-1. Cruise Module Connector [17A]

TERMINAL

A Red/Green ON/OFF switch enable

BBlue/Black

C White/Blue

DViolet/Yellow

EBlack Cruise module ground

FOrange/Violet 12 vdc power from 15 amp fuse

G Red/Blue

HBlue/Orange Tachometer input

JGreen/Red

KWhite/Green Vehicle speed signal input

WIRE

COLOR

SET input from SET/RESUME switch

RESUME input from SET/RESUME switch

Idle cable disengage switch (12 vdc from 15 amp fuse)

Disengage from brake relay (12 vdc)

12 vdc from “CRUISE” indicator in instrument panel (module provides ground)

g. Brake light on constantly.

h. Throttle cables too tight.

i. Bad cruise control fuse.

2. Repeat Steps 1 and 2. If the cruise engaged lamp still does not illuminate, see 7.4 CRUISE CHART A: INITIAL

DIAGNOSTICS. For cruise module connector wire color

locations and functions, see Ta bl e 7-1. Repair any problems and recheck by repeating Steps 1 and 2.

FUNCTION AND

CONNECTION

2004 Touring: Cruise Control 7-3

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Table 7-2. Cruise Inoperative Diagnostics

NO.

Tu rn the Ignition/Light Key Switch to OFF. Connect Speedometer Tester

(HD-41354).

Enter the diagnostic mode: With the fairing cap Cruise ON/OFF Switch at ON, and the handlebar mounted

Cruise SET/RESUME Switch at SET, turn the Ignition/Light Key Switch to IGNITION.

Push the handlebar mounted Cruise SET/RESUME Switch to RES(UME)

and hold in this position.

Next, turn the throttle grip tightly closed to check the throttle grip

switch.

ACTION CORRECT FUNCTION INCORRECT FUNCTION

The cruise engaged lamp will illuminate and remain on as long as the Cruise SET/ RESUME switch is held in the SET position.

held

Continue with Step 3.

The cruise engaged lamp will illuminate and remain on as long as the SET/RESUME Switch is held in the RES(UME) position.

Continue with Step 4.

The cruise engaged lamp will illuminate when the switch is closed, and then be extinguished when the throttle grip returns to its free position.

Continue with Step 5.

If the cruise engaged lamp remains illuminated after the switch is released, then either the switch or related wiring is shorted. See Diagnostic Note 1 for possible causes.

Continue with steps listed under Diagnostic Note 2.

If the cruise engaged lamp does not illuminate at all, check for one or more of the following conditions:

RES(UME) switch not wired correctly.

●

Broken or pinched wire to RES(UME)

●

switch or cruise module.

Continue with 7.5 CRUISE CHART B:

RESUME SWITCH.

If the cruise engaged lamp does not illuminate at all, check for one or more of the following conditions:

Throttle grip switch not wired correctly.

●

Broken or pinched wire to throttle grip

●

switch or cruise module. Throttle grip switch not working correctly.

●

Continue with 7.11 CRUISE CHART G:

THROTTLE SWITCH.

Apply the brake hand lever.

Press and hold the brake foot pedal

for at least 5 seconds.

The cruise engaged lamp will illuminate and remain on until the brake lever is released.

Continue with Step 6.

The cruise engaged lamp will illuminate. After depressing and holding the brake foot pedal for 5 seconds, the lamp will be extinguished.

Release the brake pedal and the cruise module will momentarily pull the throttle open slightly and then release.

Continue with Step 7.

If the cruise engaged lamp does not illuminate at all, check for one or more of the following conditions:

●

Front brake switch not wired correctly.

●

Broken or pinched wire to front brake switch or cruise module.

●

Front brake switch not working properly.

See 7.9 CRUISE CHART F-1: BRAKE

LIGHTS ON (constant brake light input) or

7.10 CRUISE CHART F-2: BRAKE LIGHTS OFF (no front and/or rear brake lights).

The cruise engaged lamp will not illuminate if any of the following conditions exist:

●

Rear brake switch not wired correctly.

●

Broken or pinched wire to rear brake switch or cruise control module.

●

Rear brake switch not working properly.

The throttle will not open if the following conditions exist:

●

Cables not adjusted properly.

●

Faulty cruise control module.

See 7.9 CRUISE CHART F-1: BRAKE

LIGHTS ON (constant brake light input) or

7.10 CRUISE CHART F-2: BRAKE LIGHTS OFF (no front and/or rear brake lights).

7-4 2004 Touring: Cruise Control

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Table 7-2. Cruise Inoperative Diagnostics

NO.

Rotate rear wheel.

Tu rn the fairing cap Cruise ON/OFF Switch and the Ignition/Light Key

Switch to OFF. Disconnect spark plug wires.

Press SET/RESUME Switch to

RES(UME), and hold.

While holding SET/RESUME Switch at RES(UME), turn Ignition/Light Key Switch to ON and crank engine. (If

weak battery or poor connections result in low system voltage, Diagnostic Mode may be aborted.)

ACTION CORRECT FUNCTION INCORRECT FUNCTION

The cruise engaged lamp will ﬂash on and off indicating that the vehicle speed signal is wired properly and working correctly.

Continue with Step 8.

Continue with Step 9.

Continue with Step 10.

The cruise engaged lamp ﬂashes with RPM input.

Continue with Step 11.

The cruise engaged lamp will not illuminate if any of the following conditions exist:

Vehicle speed signal not wired correctly.

●

Broken or pinched wire to speedometer.

●

Speedometer not working properly.

●

Vehicle speed signal wiring discon-

●

nected.

See 7.12 CRUISE CHART H: SPEEDOME-

TER INPUT.

The cruise engaged lamp does not ﬂash with RPM input.

See 7.13 CRUISE CHART I: TACHOMETER

INPUT.

While continuing to hold SET/ RESUME Switch at RES(UME), turn

fairing cap Cruise ON/OFF Switch to ON. Release SET/RESUME Switch.

To restart or repeat the diagnostic

sequence, return to Step 1.

Cruise engaged lamp blinks twice. NOTE: Lamp may go on for three seconds if

RPM signal was above cranking speed.

DIAGNOSTIC ROUTINE EXITED

2004 Touring: Cruise Control 7-5

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CRUISE DROPOUT DIAGNOSTICS 7.3

GENERAL

To check for diagnostic codes, see DROPOUT DIAGNOS-

TICS below. If other problems are experienced, such as

harsh cruise engagement or speed loss, see Ta ble 7-4.

DROPOUT DIAGNOSTICS

The last eight diagnostic codes for cruise disengagement are stored in memory.

1. To enter the diagnostic mode, turn the engine off and proceed as follows:

a. Turn the fairing cap Cruise ON/OFF switch to OFF.

The light in the rocker switch is extinguished to indicate this condition to the operator.

b. Push the Cruise SET/RESUME Switch on the right

handlebar to SET and hold

c. Turn the Ignition/Light Key Switch to IGNITION, but

do not start the engine.

d. Release the Cruise SET/RESUME Switch from the

SET position while observing the behavior of the Cruise Enabled/Engaged Lamp on the tachometer gauge (speedometer on FLHRC models).

2. The system transmits the most recent cruise dropout code. Each dropout code consists of 3 digits and is sent out as a series of ﬂashes.

3. The lamp will begin by ﬂashing one or more times to indicate the ﬁrst digit of the dropout code. The length of time the lamp is illuminated and the length of time in which it is off are each about 1/4 second in duration. Simply

count the number of times the lamp ﬂashes in order to retrieve the ﬁrst digit of the dropout code.

4. Following transmission of the ﬁrst digit, there is a one second pause in which the lamp is off. The lamp will then ﬂash one or more times to indicate the second digit of the dropout code. Count the number of times the lamp ﬂashes to retrieve the second digit. See Figure 7-5.

5. Following transmission of the second digit, there is a another one second pause in which the lamp is off. The lamp will then ﬂash one or more times to indicate the third digit of the dropout code. Again, count the number of times the lamp ﬂashes to retrieve the third digit.

6. Write down the dropout code on a piece of paper. To identify the reason for cruise disengagement see Ta bl e

7-3. The last column of the table suggests the appropri-

ate corrective action.

7. To verify the dropout code, toggle the Cruise SET/ RESUME Switch to RESUME. The transmission of the most recent dropout code is repeated. To continue with the next code, simply toggle the Cruise Switch to SET. All subsequent codes are sent in the same manner as the ﬁrst, after which the operator may repeat the code or move on to the next in the series.

8. After the eighth (or oldest) dropout code is ﬂashed, the Cruise Engaged Lamp remains illuminated to indicate that the end of the dropout code buffer has been reached.

9. To start the sequence at the beginning, that is, with transmission of the most recent dropout code, momentarily push the Cruise SET/RESUME Switch to SET.

10. To exit the diagnostic mode, turn the Ignition/Light Key Switch to OFF.

1st Digit 2nd Digit

OFF

Cruise

Engaged

Lamp

1/4

Sec.

Pause After

1 Sec. 1 Sec.

1st Digit

Figure 7-5. Cruise Engaged Lamp Dropout Code Timing Diagram

7-6 2004 Touring: Cruise Control

1/4

Sec.

1/4

Sec.

3rd Digit

1/4

Sec.

Pause After

1/4

Sec.

1/4

Sec.

1/4

Sec.

Tog gle Cruise Switch to RESUME to Verify Code.

Tog gle Cruise Switch to SET to Continue With Next Code.

2nd Digit

NOTE

Looking at the above transmission, we can see that the dropout code is 122. See Ta b le 7-3. The reason for cruise disengagement is identiﬁed as application of front or rear brakes.

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Table 7-3. Cruise Dropout Code Key

ACTION

CODE

111 Initial State or Cleared Memory (No Codes Recorded) 112 Throttle Roll Off 7.11 CRUISE CHART G: THROTTLE SWITCH 113 Fairing Cap Cruise Switch Turned OFF 7.8 CRUISE CHART E: CRUISE ENABLE

121 Short in Wiring Between Set/Resume

Application of Front or Rear Brakes

122

211 Coast (S/C Button Engaged) Interval Longer than 6 Seconds 7.4 CRUISE CHART A: INITIAL DIAGNOSTICS

212

213 Speed Drops Below 26 MPH or Exceeds 90 MPH 7.12 CRUISE CHART H: SPEEDOMETER INPUT

221

222 Speed Decreases Greater than 20 MPH per Second 7.12 CRUISE CHART H: SPEEDOMETER INPUT 223 Vehicle Speed Sensor Input 7.12 CRUISE CHART H: SPEEDOMETER INPUT 231 Over 5000 RPM 7.13 CRUISE CHART I: TACHOMETER INPUT 232 Loss of Tachometer Signal 7.13 CRUISE CHART I: TACHOMETER INPUT

242

311 312 313 321 323 331 332 333 341 Low Voltage 7.7 CRUISE CHART D: CRUISE POWER 342 343 351 352 353 361 362 363 371 423 432 777

May require inspection of brake levers

or front brake light switch mounting.

Speed Drops Below 30 MPH While in Coast

Speed Drops 15 MPH Below Set Speed

(Such as When Climbing a Steep Hill)

High Rate of Change of RPM Detected

(Such as When Clutch is Pulled In or Contact is Made

With Ice Patch or Slippery Surface)

CONDITION

NOTE

(S/C Button Engaged)

Internal Failure

While performing instructions under applicable ﬂow chart, wiggle connectors and wires to identify intermittents.

7.4 CRUISE CHART A: INITIAL DIAGNOSTICS or 7.5 CRUISE CHART B: RESUME SWITCH

7.9 CRUISE CHART F-1: BRAKE LIGHTS ON

7.4 CRUISE CHART A: INITIAL DIAGNOSTICS or 7.12 CRUISE CHART H: SPEEDOMETER INPUT

7.12 CRUISE CHART H: SPEEDOMETER INPUT

7.13 CRUISE CHART I: TACHOMETER INPUT

Replace cruise module. See the 2004 Touring Models Service

Manual (Part Number 99483-04).

NOTE

2004 Touring: Cruise Control 7-7

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