Harley Davidson Touring 2004 Service Manual fe04a

System Fuse Block (Under Left Side Cover)

FLHR/S

FLHT/C

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

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SPECIFICATIONS 4.1

IGNITION

Spark timing advance

Idle speed 1000 ± 50 RPM

Spark plug size 12 mm

Spark plug gap

Spark plug type

Ignition coil primary resistance

Ignition coil secondary resistance

CIRCUIT

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

DATA

0°-50° BTDC (range)

30° BTDC@1000 RPM

0.038-0.043 in

0.97-1.09 mm

Harley-Davidson

No. 6R12 (no substitute)

0.5-0.7 ohms

5500-7500 ohms

RATING

(AMPERES)

COLOR

Figure 4-1. Fuse Locations

2004 Touring: Engine Management (Carbureted) 4-1

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DIAGNOSTIC INTRODUCTION 4.2

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 bad 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 4-2. The check engine lamp indicates the ignition control module (ICM) has determined a fault condition exists. There may also be starting or performance problems.

MPH

Check Engine Lamp

Figure 4-2. Speedometer

90 100

110

120

RPM

x100

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RESOLVING PROBLEMS

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

1. Check for diagnostic trouble codes (DTCs) by observing check engine lamp. See 4.3 CHECKING FOR TROUBLE

CODES.

2. Retrieve DTCs using speedometer self diagnostics. See

4.5 SPEEDOMETER SELF DIAGNOSTICS.

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 DTCs and conﬁrming proper vehicle operation as indicated by the behavior of the check engine lamp.

4-2 2004 Touring: Engine Management (Carbureted)

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CHECKING FOR TROUBLE CODES 4.3

CHECK ENGINE LAMP

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

NOTE

●

See Figure 4-3. “Key ON” means that the ignition key is turned to ON and the engine stop switch is set to RUN (although the engine is

●

When the ignition switch 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 ititial four second period, then see 4.5 SPEEDOMETER SELF DIAGNOSTICS.

●

If the check engine lamp comes on late (after 20 seconds), the problem is likely a serial data bus failure. Test for codes using speedometer self diagnostics. See 4.5

SPEEDOMETER SELF DIAGNOSTICS.

●

If the check engine lamp fails to turn OFF after the initial four second period, then a problem exists in the instrumentation. See 4.5 SPEEDOMETER SELF DIAGNOS-

TICS.

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 4-4.

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

codes exist. See B of Figure 4-4.

not

running).

Figure 4-3. Ignition Switch (FLHT/C)

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

code exists. See C of Figure 4-4.

2. See CODE TYPES which follows for a complete description of trouble code formats.

NOTE Tr ouble codes relating to the ignition coil 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 ignition control module 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.

OFF

Key On

4 Sec.

Lamp OFF: No Current or Historic Trouble Codes

Lamp ON 8 Seconds:

Only Historic Trouble Codes Exist

4 Sec.

8 Sec.

Lamp Remains ON: Current Trouble Code *

4 Sec.

Figure 4-4. Check Engine Lamp Operation

Historic Trouble Codes May Also Exist

2004 Touring: Engine Management (Carbureted) 4-3

Lamp OFF

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CODE TYPES

There are two types of current and historic. If a trouble code is stored, it can be read using the speedometer self diagnostics. See 4.5 SPEEDOM-

ETER SELF DIAGNOSTICS.

All trouble codes reside in the memory of the ignition control module (ICM) until cleared using the speedometer self diagnostics. See 4.5 SPEEDOMETER SELF DIAGNOSTICS.

A trouble code is also cleared after a total of 50 trips has elasped. A trip consists of a start and run cycle, the run cycle lasting at least 30 seconds. After the 50 trip retention period, the 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 presently disrupt motorcycle operation. See the appropriate ﬂow charts for solutions.

Historic

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

Historic trouble codes can only be retrieved using a computer based diagnostic package called DIGITAL TECHNICIAN (Part No. HD-44750).

Historic trouble codes are stored for a length of time to assist in the diagnosis of intermittent faults.

diagnostic trouble codes (DTCs):

RETRIEVING DIAGNOSTIC TROUBLE CODES

The engine management system provides two levels of diagnostics.

●

The most sophisticated mode employs a computer based diagnostic package called 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 4.5 SPEEDOMETER SELF DIAGNOS-

TICS.

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

Serial data codes (DTC U1016, U1064, U1097, U1255,

●

U1300 and U1301) may be accompanied by other codes. resolving the other codes.

For proper resolution to multiple trouble codes refer to diagnostic code priority chart (Table 4-5.)

one

fault setting

Always

correct the serial data codes before

multiple

trouble codes:

It is important to note that historic trouble codes may also be present whenever the system indicates the existence of a current fault. 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.

4-4 2004 Touring: Engine Management (Carbureted)

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INITIAL DIAGNOSTIC CHECK: ICM 4.4

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.

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 4.6 BREAKOUT BOX: ICM.

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

Reprogramming ICM

Diagnostic charts frequently suggest ICM replacement. In the event an ignition control module (ICM) 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.

INITIAL DIAGNOSTICS

General Information

The diagnostic check is an organized approach to identifying a problem caused by an electronic control system malfunction. If no problems are found after completion of the diagnostic check, a comparison of running parameters may be used to help locate intermittents and out-of-speciﬁcation sensors. See Ta ble 4-1.

Diagnostic Tips

If Speedometer reads “BUS Er” with the ignition key

●

turned ON (engine stop switch at RUN with the engine off), check data bus for an open or short to ground between data connector [91A] terminal 3 and ICM connector [10B] terminal 12, TSSM connector [30B] terminal 3, Speedometer connector [39B] terminal 2 or tachometer (if equipped) connector [108B] terminal 2.

Check for an open diagnostic test terminal between data

●

link connector [91A] terminal 3 and TSM/TSSM connector [30B] terminal 3. With ignition key turned ON, serial data bus voltage should be typically 0.6-0.8 volts. The range of acceptable voltage is 0-7.0 volts.

Diagnostic Notes

The reference numbers below correlate with the circled numbers on the diagnostic check ﬂow charts. See page 4-10.

1. Compare engine behavior to symptoms tables in this

section. a. Starts hard. See Ta ble 4-2. b. Hesitates, stumbles, surges, misﬁres and/or slug-

gish performance. See Ta bl e 4-3.

c. Engine exhaust emits black smoke or fouls plugs.

See Ta bl e 4-4.

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

41404), black socket probes and patch cord.

3. Connect BREAKOUT BOX (Part No. HD-42682) to igni-

tion control module. See 4.6 BREAKOUT BOX: ICM.

All diagnostic codes are listed in Ta bl e 4-5.

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 2.5 BREAKOUT BOX: SPEEDOMETER for any codes related to the speedometer.

2004 Touring: Engine Management (Carbureted) 4-5

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Table 4-1. Typical Running Values

ITEM

MAP sensor

RPM 0 5600 1000

Bank angle sensor

MIN.

VALUE

0.1 V (high

vacuum)

Run mode

0.45-1.1 V

MAX.

VALUE

4.96 V (atmo-

spheric

pressure)

Disable

1.8-3.2 V

HOT

IDLE

1.5-3.0 V

Run mode

0.45-1.1 V

Table 4-2. Engine Starts Hard

SYMPTOM

Battery discharged

Spark plugs 4.12 MISFIRE.

Spark plug wires 4.12 MISFIRE

Ignition coil 4.12 MISFIRE.

Valve sticking

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

See charging system troubleshooting in this section.

See Section 3 in Touring Service Manual.

SOLUTION

Table 4-3. Engine Performance Problems

SYMPTOM

Perform intake leak test.

Manifold leak

MAP sensor plugged or not operating properly

Water or dirt in fuel system

Spark plugs 4.12 MISFIRE.

EVAP hose disconnected from induction module (CA)

Throttle plates not opening fully

See 4.8 INTAKE LEAK

TEST.

4.13 DTC P0106, P0107, P0108

Drain and reﬁll with fresh fuel.

Connect.

See throttle cable adjustment in Touring Service Manual.

SOLUTION

Table 4-4. Engine Exhaust Emits

Black Smoke or Fouls Plugs

SYMPTOM

Clogged air ﬁlter

See Section 1 in Touring Service Manual.

SOLUTION

4-6 2004 Touring: Engine Management (Carbureted)

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Table 4-5. Diagnostic Trouble Codes (DTC) and Fault Conditions

PRIORITY RANKING

1 P0605 ﬂash memory error 4.19 DTC P0602, P0603, P0604, P0605, P0607

2 P0603 EEProm memory error 4.19 DTC P0602, P0603, P0604, P0605, P0607

3 P0602 Flash memory error 4.19 DTC P0602, P0603, P0604, P0605, P0607

4 P0604 RAM memory error 4.19 DTC P0602, P0603, P0604, P0605, P0607

5 P0607 A to D error 4.19 DTC P0602, P0603, P0604, P0605, P0607

6“BUS Er” Serial data bus shorted low/open/high 4.10 STARTS, THEN STALLS

7U1300 serial data shorted low 4.10 STARTS, THEN STALLS

8U1301 serial data shorted high 4.10 STARTS, THEN STALLS

9U1064 lost TSM/TSSM communication 4.20 DTC U1064

10 U1097 lost speedometer communication 4.21 DTC U1097

11 U1255 Missing response at TSSM 4.20 DTC U1064

12 U1255 Missing response at speedometer 4.21 DTC U1097

13 P1009

14 P1010

15 P0373 crankshaft position sensor intermittent 4.17 DTC P0373, P0374

16 P0374

17 P0106 MAP sensor rate-of-change error 4.13 DTC P0106, P0107, P0108

18 P0107 MAP sensor failed open/low 4.13 DTC P0106, P0107, P0108

19 P0108 MAP sensor failed high 4.13 DTC P0106, P0107, P0108

21 P1351 Ignition coil driver front low/open 4.16 DTC P1351, P1352, P1354, P1355

20 P1354 Ignition coil driver rear low/open 4.16 DTC P1351, P1352, P1354, P1355

22 P1352 Ignition coil driver front high 4.16 DTC P1351, P1352, P1354, P1355

23 P1355 Ignition coil driver rear high 4.16 DTC P1351, P1352, P1354, P1355

24 P0562 system voltage low 4.14 DTC P0562, P0563

25 P0563 system voltage high 4.14 DTC P0562, P0563

26 P0501 VSS failed low 4.18 DTC P0501, P0502

27 P0502 VSS failed high/open 4.18 DTC P0501, P0502

DTC NO. FAULT CONDITION SOLUTION

TSM/TSSM disabled fuel due to bad password

TSM/TSSM disabled fuel due to no password (starts then stalls)

crankshaft position sensor not detected/ cannot synchronize

4.15 DTC P1009, P1010

4.17 DTC P0373, P0374

2004 Touring: Engine Management (Carbureted) 4-7

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[2A] [2B]

f2208z8x

321654987121110 321654987121110

Speedometer

15A

Accessory

Fuse

321654987121110 321654987121110

Main to Interconnect

Harness

LtGN/V

BN/GY

[39B] [39A]

[108B] [108A]

321654987121110 321654987121110

Tachometer

[1B] [1A]

123

Main to Interconnect

Harness

101112 78945

[156B] [156A]

BN/GY

Main to Interconnect

Harness

LtGN/V

1 1

15A

Ignition

Fuse

987 987

321654987121110 321654987121110

TSM/TSSM

[8B]

121110 121110

[8A]

Ignition

Harness

1 2 3 4

Data Link

[91A]

[30B] [30A]

LtGN/V

15A

Battery

Fuse

[10B] [10A]

Ignition Control Module

12 12

Serial data

Figure 4-5. Diagnostic Check (FLHT/C)

Table 4-6. Wire Harness Connectors in Figure 4-5.

NO. DESCRIPTION TYPE LOCATION

[1] Main to Interconnect Harness 12-Place Deutsch (Black) Inner Fairing - Right Radio Support Bracket [2] Main to Interconnect Harness 12-Place Deutsch (Gray) Inner Fairing - Right Fairing Support Brace [8] Ignition Harness 12-Place Deutsch Under Right Side Cover

[10] Ignition Control Module 12-Place Deutsch Under Right Side Cover

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

[39] Speedometer 12-Place Packard Inner Fairing (Back of Speedometer)

[91] Data Link 4-Place Deutsch Under Right Side Cover [108] Tachometer 12-Place Packard Inner Fairing (Back of Tachometer) [156] Main to Interconnect Harness 6-Place Deutsch Inner Fairing - Right Fairing Support Brace

Cavity in Crossmember at Rear of

Battery Box (Under Seat)

4-8 2004 Touring: Engine Management (Carbureted)

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f2208y8x

BN/GY

321654987121110 321654987121110

15A

Battery

Fuse

Speedometer

LtGN/V

BN/GY

15A

Accessory

Fuse

[39B] [39A]

15A

Ignition

Fuse

LtGN/V

21 21

321654987121110 321654987121110

[30B] [30A]

TSM/TSSM

[8B] [8A]

[91A]

Ignition

Harness

1 2 3

Data Link

987

654

121110 121110

LtGN/V

[10B] [10A]

Ignition Control Module

12 12

Serial data

Figure 4-6. Diagnostic Check (FLHR/S)

Table 4-7. Wire Harness Connectors in Figure 4-6.

NO.

[8] Ignition Harness 12-Place Deutsch Under Right Side Cover

[10] Ignition Control Module 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) [91] Data Link 4-Place Deutsch Under Right Side Cover

DESCRIPTION TYPE LOCATION

Cavity in Crossmember at Rear of

Battery Box (Under Seat)

2004 Touring: Engine Management (Carbureted) 4-9

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Initial Diagnostic Check (Part 1 of 2)

Does engine

start?

YES.

Starts and

runs.

Check for trouble

codes. See 4.5

SPEEDOMETER

SELF DIAGNOSTICS

Codes found?

YES

Refer to applicable trouble code priority chart. All diagnostic codes are listed on page 4-7 in

Table 4-5. Codes are listed by priority.

YES.

Starts, then

stalls.

See 4.10 STARTS, THEN

STALLS.

YES

STOP

Go to Initial Diagnostic

Check (Part 2 of 2).

NO.

Cranks, but

will not start.

See 4.9 ENGINE CRANKS,

BUT WILL NOT START.

With ignition switch OFF, press and

release odometer reset switch. Does

odometer display appear?

Check for continuity to ground on terminal 7

of speedometer. Wiggle harness during con-

tinuity check. Continuity present?

YES NO

Check for battery voltage at

terminal 5 of speedometer

while wiggling harness. Bat-

tery voltage continuously

present?

NO.

Engine will not

crank.

See 1.2 STARTING SYSTEM

DIAGNOSIS.

Locate and

repair open.

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.

4-10 2004 Touring: Engine Management (Carbureted)

YES

Replace speedometer

reset switch.

Locate and

repair open.

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