Harley Davidson Touring 2004 Service Manual fe01a

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STARTER TROUBLESHOOTING 1.1

Table 1-1. Starter Does Not Run or Runs At Very Low Speeds

SOURCE OF

PROBLEM

Battery

Wiring

Handlebar start switch

Starter relay

Solenoid

Starting motor

PROBABLE CAUSE SOLUTION

Voltage drop due to discharged battery. Charge battery. Short-circuited or open between electrodes. Replace battery. Poor contact condition of battery terminal(s). Clean and retighten. Poor or no connection at either battery positive or

negative cable, at either end. Cracked or corroded battery cable ends. Clean, tighten or replace cable(s) as needed. Open wire(s) or poor connection at handlebar

switch or starter relay, especially relay ground wire.

Poor switch contacts or open switch. Replace switch.

Open coil winding. Replace relay. Poor or no continuity at relay points. Replace relay.

TSM/TSSM has disabled starter relay.

Poor contact condition caused by burnt contact.

Pull-in winding open or short-circuited. Repair or replace solenoid assembly. Hold-in winding open or short-circuited. Repair or replace solenoid assembly.

Brushes worn below speciﬁcation.

Commutator burnt. Re-face or replace. Commutator high mica. Correct by undercutting. Field winding grounded. Replace. Armature winding grounded or short-circuited. Replace. Reduction gears damaged. Replace. Insufﬁcient brush spring tension. Replace. Disconnected lead wire between solenoid and ﬁeld

windings. Ball bearing sticks. Replace bearing.

Repair or replace cable(s).

Tighten connections or repair or replace wire(s).

Check for open on wire to TSM/TSSM. Correct lack of ground.

Polish contact surface or replace solenoid assembly.

Check brush spring tension. Replace ﬁeld frame and holder.

Repair or replace lead wire.

2004 Touring: Starting & Charging 1-1

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Table 1-2. Pinion Does Not Engage With Ring Gear

While Starter is Cranked or Engine Cannot Be Cranked

SOURCE OF

PROBLEM

Battery

Overrunning clutch.

Jackshaft assembly

Gear teeth on clutch shell

SOURCE OF

PROBLEM

PROBABLE CAUSE SOLUTION

Voltage drop due to discharged battery. Charge battery. Short-circuited or open between electrodes. Replace battery. Poor contact condition of battery terminal(s). Clean and retighten. Overrunning clutch malfunction (rollers or compres-

sion spring). Pinion teeth worn out. Replace pinion. Pinion does not run in overrunning direction. Replace overrunning clutch.

Poor sliding condition of spline teeth.

Reduction gears damaged. Replace overrunning clutch and idler gear.

Improper jackshaft parts assembly. Disassemble and assemble parts properly.

Excessively worn teeth. Replace clutch shell.

Replace overrunning clutch.

Remove foreign materials, dirt or replace overrunning clutch or pinion shaft.

Table 1-3. Starter Does Not Stop Running

PROBABLE CAUSE SOLUTION

Starting switch or starter relay.

Gear teeth on clutch shell

Solenoid.

Unopened contacts. Replace starting switch or starter relay. Poor return caused by sticky switch

or relay contacts.

Excessively worn teeth. Replace clutch shell.

Return spring worn. Replace spring. Coil layer shorted. Replace solenoid. Contact plate melted and stuck. Replace solenoid.

Replace starting switch or starter relay.

1-2 2004 Touring: Starting & Charging

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STARTING SYSTEM DIAGNOSIS 1.2

DIAGNOSTICS

Diagnostic Notes

The reference numbers below correlate with the circled numbers on the starter system ﬂow charts.

1. See Section 1.4 DIAGNOSTICS/TROUBLESHOOTING,

VOLTAGE DROPS.

2. Remove starter motor. Connect jumper wires as described under Section 1.6 TESTING ASSEMBLED

STARTER, FREE RUNNING CURRENT DRAW TEST.

3. Remove TSSM and use HARNESS CONNECTOR TEST KIT (Part No. HD-41404) to short Pin 9 on connector [30] to ground. If starter motor cranks, replace TSSM.

Starter Testing 1

Check battery using visual inspection,

voltage test and load test.

Check connections at battery and starter

components. Is system operational?

4. See Section 1.5 STARTER SYSTEM TESTING,

STARTER CURRENT DRAW TEST.

5. See Section 1.6 TESTING ASSEMBLED STARTER, FREE RUNNING CURRENT DRAW TEST.

6. Connect BREAKOUT BOX (Part No. HD-42682) to TSM/ TSSM. See BREAKOUT BOX, TSM/TSSM.

7. Connect BREAKOUT BOX (Part No. HD-42682) (black) and 6-pin Harness Adapters (Part no. HD-42962) between wiring harness connector [22A] and Right Hand Control harness connector [22B] (adapters not used on FLHR/C/S models).

Job/Time Code Values

Dealership technicians ﬁling warranty claims should use the job/time code values printed in appropriate repair.

5822

bold text

underneath the

YES

STARTER RUNS ON.

Disconnect solenoid relay ter-

minal from solenoid. Is 12V

present on GN wire with starter

button not pressed?

YES

Is 12V present on starter relay

Terminal 86 with starter button

not pressed?

YES

Replace

starter button.

YES

STARTER

SPINS, BUT

DOES NOT

ENGAGE.

See Starter Testing 5: Starter

Spins, But Does Not Engage.

Replace

solenoid.

5845

Replace

starter relay.

58325818

YES

STARTER STALLS OR SPINS TOO

SLOWLY.

See Starter Testing 6: Starter

Stalls or Spins Too Slowly.

Check for audible

clicking noise.

Solenoid clicks. See Starter

Testing 2: Solenoid Clicks.

Relay clicks. See

Starter Testing 3: Relay Clicks.

Nothing clicks. See Starter

Testing 4: Nothing Clicks.

2004 Touring: Starting & Charging 1-3

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Starter Testing 2: Solenoid Clicks

Perform voltage drop tests between

battery and relay terminal on solenoid.

Less than 1.0 volt?

YES

Perform voltage drop tests from

battery positive to starter motor

terminal. Crank engine. Voltage

greater than 1 volt?

YES

Perform voltage drop tests from

battery positive to starter battery

terminal. Crank engine. Voltage

greater than 1 volt?

YES

Repair connection

between battery and

starter.

5824

Starter Testing 3: Relay Clicks

Repair or replace

solenoid (contacts).

Perform voltage drop tests

between battery negative and starter studs or bolts. Voltage

greater than 1 volt?

5845

YES

Clean ground

connections.

5824

Backtrack to pinpoint poor

connections or relay contact problems using voltage drop

STOP

Go to Starter Testing 3:

Relay Clicks. Begin with

box marked with bold

asterisk.

tests.

5823

Does starter motor

turn if jumped?

Perform solenoid

hold-in, pull-in tests. See

1.6 TESTING ASSEMBLED STARTER.

Solenoid OK?

Mechanical binding or

seal binding on jackshaft

(dirt or corrosion).

YES

5850

Test for voltage at solenoid relay terminal

on starter. Is 12V present when

starter button is pressed?

Replace or repair

starter motor.

Replace

solenoid.

5860

5817

Test for voltage from relay.

Is 12V present on relay

Terminal 87 when starter

button is pressed?

GN wire between relay

YES

Repair open on

and solenoid.

Test for voltage to relay. Is 12V

present on relay terminal 30?

Repair open on R/BK

wire feeding Terminal 30

on starter relay.

Replace

starter relay.

5827

5832

1-4 2004 Touring: Starting & Charging

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Starter Testing 4: Nothing Clicks

Do turn signals work properly?

NOYES

With ignition switch ON and

starter button depressed, check

for battery voltage from starter

button to relay Terminal 86.

Battery voltage present?

Is Connector [30] fully mated?

YES

Continuity to ground on

Pin 12 of TSM/TSSM?

YES

Continuity on Pin 1 to

battery fuse?

YES NO

Continuity on Pin 2 to

Ignition fuse?

YES

Sidecar BAS installed?

YES NO

B1152, B1153.

Mate Connector [30].

6792

Repair open.

6805

Repair open.

6806

Repair open.

6793

Replace TSM/TSSM.See 3.20 DTC B1151,

6791

YES

Check for ground at relay Terminal

85. Ground present?

YES

Substitute good

relay or test relay.

5832

YES

Check for voltage on

TSM/TSSM Pin 9 with

key ON. Voltage

present?

YES

Locate and repair

short to voltage.

5830

Check for continuity from relay

Te rminal 85 to Pin 9 on

TSSM connector [30].

Continuity present?

Repair

open.

5828

Replace TSM/TSSM. See 2004 Touring Models Service Manual

(Part Number 99483-04).

5838

YES

Repair wiring

from starter

button to relay.

YES

Replace

starter button.

5831

5818 5831

Check for battery voltage from

starter button, terminal 6 (black). Bat-

tery voltage present with starter but-

Check for battery voltage to starter

button, terminal 4 (black). Battery volt-

ton pressed?

age present?

Repair wiring to

starter button.

2004 Touring: Starting & Charging 1-5

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Starter Testing 5: Starter Spins, But Does Not Engage

Remove and disassemble starter jackshaft

assembly. Is jackshaft properly assembled?

YES

Remove starter. Disassemble drive housing

assembly. Inspect for damage to armature

gear or idler gear. Damage present?

YES

Replace damaged idler

gear and armature.

5825

Starter Testing 6: Starter Stalls or Spins Too Slowly

Perform voltage drop tests from battery

positive to starter motor terminal. Crank

engine. Voltage greater than 1 volt?

YES

Assemble jackshaft

properly.

Starter clutch failure.

Replace starter clutch.

5850

5837

Perform voltage drop tests

between battery positive to

starter battery terminal.

Crank engine.

Voltage greater than 1 volt?

Repair connection

between battery and

YES

starter.

5824

Repair or replace

solenoid (contacts).

5845

Remove spark plugs while in

5th gear. Rotate rear wheel.

Check for engine, primary

and/or crankshaft bind.

YES

Clean ground

connections.

5835

YES

Use appropriate code

Perform voltage drop tests

between battery negative and

starter studs or bolts.

Voltage greater than 1 volt?

Perform starter motor current

draw test (on vehicle).

Perform starter motor free draw

bench test.

Are test results within range?

Replace or repair

starter motor.

5817

1-6 2004 Touring: Starting & Charging

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