Harley Davidson Touring 2004 Service Manual fe06a
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DIAGNOSTIC INTRODUCTION 6.1
GENERAL
The radio diagnostics for the Premium Sound System is
symptom based
Simply locate the apparent problem from the list of 15 symptoms listed in Ta bl e 6-1. Tak e note of the section number and
turn to the flow chart that addresses the problem.
If the problem is not listed or is intermittent, locate the most
relative symptom and inspect connectors for moisture or corrosion. Also look for backed out terminals, improper mating,
broken locks, improperly formed or damaged terminals, poor
terminal-to-wire connection and damaged harness.
At the beginning of the section, follow the SETUP instructions
and then review the FUNCTIONALITY description to determine whether the system is operating as intended. If it
appears that the system is not working correctly, validate the
problem by performing the flow chart under SOFTWARE
DIAGNOSIS. (See Section 6.2 DIAGNOSTIC MODE OVER-
VIEW to gain a general understanding of how the on-board
diagnostics work.)
If the Diagnostic Mode indicates that a malfunction exists,
refer to the flow chart under HARDWARE DIAGNOSIS for
correction of the problem.
Work your way through each flow chart box by box. If a numbered circle appears adjacent to a box, then more information
is offered in the
contain supplemental information, helpful tips or references
to other parts of the manual.
When working through a flow chart, refer to the illustrations,
and the
Wire Harness Connector
wire harness connector table identifies the connector number, description, type and general location.
.
NOTE
Diagnostic Notes
. Many Diagnostic Notes
table as necessary. The
Table 6-1. Symptom Table
SYMPTOM
Audio Control Inoperative
Mode Control Inoperative 6.5 RADIO SYMPTOM 2
No Sound in One or More
Speakers (External)
Automatic Volume Control
(AVC) Inoperative
Poor Stereo Reception 6.8 RADIO SYMPTOM 5
No Power 6.9 RADIO SYMPTOM 6
CD Will Not Eject 6.10 RADIO SYMPTOM 7
No Sound in One or More
Headsets/Microphone
Inoperative
Rear Headset Volume/PTT
Inoperative
Intercom Inoperative 6.13 RADIO SYMPTOM 10
CB Receiver Inoperative 6.14 RADIO SYMPTOM 11
CB Transmitter Inoperative
(With CB Antenna Test and
SWR Adjustment)
PTT/Squelch Control
Inoperative
Handheld Microphone PTT
Inoperative
No CB Audio in Headset in
Center Position
SOLUTION
6.4 RADIO SYMPTOM 1
6.6 RADIO SYMPTOM 3
6.7 RADIO SYMPTOM 4
6.11 RADIO SYMPTOM 8
6.12 RADIO SYMPTOM 9
6.15 RADIO SYMPTOM 12
6.16 RADIO SYMPTOM 13
6.17 RADIO SYMPTOM 14
6.18 RADIO SYMPTOM 15
After correction of the problem, refer back to SETUP and
FUNCTIONALITY to verify proper operation.
Not Applicable to Classic/Road Glide Models
2004 Touring: Sound System 6-1
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DIAGNOSTIC MODE OVERVIEW 6.2
GENERAL
Push any two of four Preset buttons on the front panel of the
radio. See Figure 6-1. With the buttons depressed, turn the
Ignition/Light Key Switch to IGNITION. Diagnostic Group 1,
the first of five diagnostic screens, appears on the LCD display, as indicated by the “d1” in the lower portion. Figure 6-2.
The upper portion of the display shows a line of input bits
which correlate to a particular set of switch functions.
Whether the display shows a “0,” a “1” or is able to toggle
between “0” and “1” indicates whether or not the switch is
working.
Push the LO/DX button on the front panel to sequence from
Diagnostic Group 1 to Diagnostic Group 2. Figure 6-3. Press
the button again to advance to Diagnostic Group 3. After all
modes have been accessed, the final push of the LO/DX button will cause the system to revert back to normal radio operation. The Diagnostic Mode can also be exited at any time by
simply turning the Ignition/Light Key Switch to OFF.
NOTE
Diagnostic Groups 3, 4 and 5 are for factory use only, while
the last display, which follows Diagnostic Group 5, allows the
user to adjust the rate of volume change for the Automatic
Volume Control (AVC). See Automatic Volume Control (AVC)
Adjustment under Section 6.7 RADIO SYMPTOM 4 for addi-
tional information.
Push any two Preset buttons and turn
the Ignition/Light Key Switch to IGNITION.
f2125x8x
Figure 6-1. Access Radio Diagnostic Mode
Input Bits
6-2 2004 Touring: Sound System
f2123x8x
f2122x8x
Diagnostic Mode Group 1
Figure 6-2. Front Panel LCD Display
Figure 6-3. LO/DX Button
HOME
MODE UP
FF
REAR
VOLUME
UP
AUDIOINAUDIO-AUDIO
+
MODE DN
RW
REAR
VOLUME
DOWN
EJECT LO/DX
RADIO
POWER
MODE
IN
PTT
SQUELCH
DOWN
SQUELCHUPSEEK
SCAN
NOT
USED
PRESET 4PRESET 3PRESET 2PRESET
1
C4
(BN/W)C3(O/BK)C2(BN/BK)C1(GY/GN)CO(GN/BE)
RO
(PK/W)
R1
(GY/W)
R2
(V/BK)
R3
(INT)
● If Cx and Rx are normal, input bit on LCD display toggles
between “1” and “0” at a one second rate while button is
depressed.
● If Cx is shorted to ground, input bit on LCD display
appears as “0” whether switch is open or closed. See Figure A below.
● If Cx is shorted to +12 volts, input bit on LCD display
appears as “1” whether switch is open or closed. See Figure B below.
● If Rx is shorted to ground, input bit on LCD display
appears as “1” when switch is open and “0” when switch is
closed (depressed), but does not toggle at a one second
rate as occurs when switch is normal. See Figure C below.
● If Rx is shorted to +12 volts, input bit on LCD display
appears as “1” whether switch is open or closed. See Figure D below.
● If all other switch functions on the Cx and Rx lines toggle
between “1” and “0,” then an open is indicated. See Figure
E and Figure F below.
A. B.
C. D.
Not Applicable to Classic/Road Glide Models
0
0
0
0
C3 is shorted to ground. C3 is shorted to +12 volts.
R0 is shorted to ground. R0 is shorted to +12 volts.
E. F.
1
1
1
1
[1/0] [1/0] [1/0] [1/0] [1/0] 1 1 1 1 1
(1/0) 1 (1/0) (1/0) (1/0) 1
(1/0)
(1/0)
(1/0)
C3 is open. R0 is open.
[1/0] = Displays “1” when open, “0” when button is depressed.
(1/0) = Toggles between “1” and “0” while button is depressed.
Cx = C0 thru C4. Rx = R0 thru R3.
DIAGNOSTIC MODE GROUP 1
GENERAL
When the Diagnostic Mode is first accessed, a line of five
input bits appears in the upper portion of the front panel LCD
display. See Figure 6-2.
SAMPLE DIAGNOSTIC
For explanatory purposes, assume that the REAR VOLUME
UP control is inoperative. Referencing the matrix at the top of
Figure 6-4, note that this switch function is found at the intersection of the C3 and R0 lines. The matrix indicates that the
problem either involves the O/BK or the PK/W wires.
Operate the switch while observing the input bit. The input bit
to watch correlates with the position of the switch in the
matrix. Therefore, the REAR VOLUME UP control is the second bit from the left hand side. If the input bit toggles between
“1” and “0” at a one second rate while the switch is
depressed, then the switch is functioning normally. However,
if the switch is locked on “1” or “0” and fails to toggle, then a
problem exists.
Now assume that the input bit of the REAR VOLUME UP control is locked on “1.” Review the text below the matrix in Figure
6-4. From this information, we see that when the input bit is
locked on “1,” then either the O/BK or the PK/W wires are
shorted to +12 volts.
To further pinpoint the problem, exercise the MODE UP or
FAST FORWARD functions, or any other switch function on
the R0 line, which also utilize the PK/W wire. If the input bit
toggles, then one can conclude that the PK/W wire is alright
and the problem involves the O/BK lead. Now operate the
REAR VOLUME DOWN switch to verify the conclusion. As
seen from the matrix, this switch function also utilizes the O/
BK wire. If the input bit is still locked on “1” then the O/BK wire
is confirmed as the source of the problem. Operation of the
PTT and PRESET 4 buttons (the remaining switch functions
on the C3 line) would serve to confirm the same conclusion.
On the other hand, if all other switch functions on the C3 line
toggle between “1” and “0” at a one second rate, indicating
that the switch is functioning normally, then an open exists on
the R0 line. Conversely, if all other switch functions on the R0
line toggle between “1” and “0” at a one second rate, then an
open exists on the C3 line.
Therefore, a continuous “0” is a short to ground, while a continuous “1” is a short to +12 volts, but ONLY if all other switch
functions on that respective Cx or Rx line are also locked on
“0” or “1,” respectively. If all other switch functions on the Cx
and Rx lines toggle between “1” and “0,” then an open is indicated.
Figure 6-4. Diagnostic Mode Group 1 Matrix
2004 Touring: Sound System 6-3
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DIAGNOSTIC MODE GROUP 2
GENERAL
When the radio Diagnostic Mode is first accessed, Diagnostic
Group 1 appears on the LCD display, as indicated by the “d1”
in the lower portion. Push the LO/DX button on the front panel
to sequence to Diagnostic Group 2. See Figure 6-5.
The upper portion of the Diagnostic Group 2 display shows a
line of eight input bits each of which correlates to a particular
switch function. The characters “d2” appear in the lower portion.
Input Bits
SAMPLE DIAGNOSTIC
Operate the switch while observing the input bit. The input bit
to watch correlates with the position of the switch in the line.
For example, the INTERCOM OFF/ON SWITCH is the fifth
input bit from the left hand side. If the input bit toggles
between “1” and “0” as the console mounted rocker switch is
turned ON and then OFF, respectively, then the switch is
functioning normally. However, if the switch is locked on “1” or
“0,” then a problem exists.
Not Applicable to Classic/Road Glide Models
0=PTT 0 or 1 1=ON 1=ON
HAND-
HELD MIC.
PTT
7
(BE/Y)
Diagnostic Mode 2, which displays the logic states of various
signals, functions as follows (left to right):
● Handheld Microphone PTT: input bit on LCD appears as
“1” when PTT button is not depressed, “0” when button is
depressed. (This should not be confused with the handlebar mounted PTT Switch.)
● AVC Vehicle Speed Signal: Input bit normally toggles
between “1” and “0” as the rear wheel is rotated greater
than 3 mph. The rate at which it toggles is proportional to
the speed of the wheel.
● * VOX Break: When the microphone signal is strong
enough to exceed threshold (set in Intercom Set Up
Mode), input bit on LCD appears as “1.” When VOX is not
broken, display appears as “0.”
AVC
VEHICLE
SPEED
SIGNAL
6
(W/GN)
1=Break
VOX
BREAK
543
Internal Internal
CB
SQUELCH
BREAK
f2122x8x
Diagnostic Mode Group 2
Figure 6-5. Front Panel LCD Display
Unlike the Diagnostic Group 1 input bits, whether the problem
is a short to ground, a short to +12 volts or an open is not so
readily apparent. See Figure 6-6 for further explanation of the
Diagnostic Group 2 input bits and then refer to the appropriate flow chart under SOFTWARE DIAGNOSIS.
10=Headset
11=Speaker
01=Center
INTERCOM
OFF/ON
SWITCH
Internal
● * CB Squelch Break: When CB receives signal strong
enough to exceed threshold (set by squelch level setting),
input bit on LCD appears as “1.” When CB Squelch is not
broken, display appears as “0.”
● Intercom OFF/ON: When switch is ON, input bit on LCD
display appears as “1.” When switch is OFF, display
appears as “0.”
● CB OFF/ON: When switch is ON, input bit on LCD
appears as “1.” When switch is OFF, display appears as
“0.”
● Speaker Switch A, Speaker Switch B: When fairing cap
rocker switch is in the HEADSET position, input bits on
LCD display appears as “10.” Display is “11” in the
SPEAKER position and “01” in the Center position.
CB
OFF/ON
SWITCH
2
Internal
SPEAKER
SWITCH
“B”
1
(BN/O)
SPEAKER
SWITCH
“A”
0
(V/O)
* CB or Intercom must be turned on and VOX or Squelch settings must be established before entering diagnostic mode.
Figure 6-6. Diagnostic Mode Group 2
6-4 2004 Touring: Sound System
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hd44608
f2238x8x
Radio [27]
Radio [28]
Ultra Only
BREAKOUT BOX 6.3
GENERAL
The RADIO BREAKOUT BOX (Part No. HD-44608), used in
conjunction with a DVOM, allows circuit diagnosis without
having to probe connectors with sharp objects. See Figure 6-
7.
INSTALLATION
1. Remove the outer fairing. See 2004Touring Service Manual (Part Number 99483-04).
2. Remove black connector [27] from back of radio to
release interconnect harness. See Figure 6-8.
3. Remove gray connector [28] from back of radio to
release audio harness (Ultra models only).
4. Install black connectors on Breakout Box to black radio
and interconnect harness connectors.
5. Install gray connectors on Breakout Box to gray radio and
audio harness connectors.
REMOVAL
1. Remove Breakout Box between radio and wiring harness
connectors.
2. Install black connector [27] at back of radio to connect
interconnect harness. See Figure 6-8.
3. Install gray connector [28] at back of radio to connect
audio harness (Ultra models only).
4. Install the outer fairing. See 2004Touring Service Manual
(Part Number 99483-04).
Figure 6-7. Radio Breakout Box (HD-44608)
Figure 6-8. Radio Connections - FLHTCU
RT FRONT HEADSET(+) 1
FRT HEADSET COMMON 2
LFT RR SPEAKER () 3
RT RR SPEAKER() 4
C4 (RR CNTL MATRIX)
R1 (RR CNTL MATRIX) 6
RR MIC SHIELD 7
RR MIC COMMON 8
LFT FRT HEADSET
LFT RR SPEAKER (+) 10
RT RR SPEAKER (+) 11
C3 (RR CNTL MATRIX) 12
R0 (RR CNTL MATRIX) 13
R2 (RR CNTL MATRIX) 14
FRT MIC SHIELD 15
RT RR HEADSET (+) 16
LFT RR HEADSET (+) 17
RR HEADSET COMMON 18
FRT MIC COMMON 23
5
9
N/C 19
N/C 20
RR MIC 21
FRT MIC 22
R0
R1
R2
ULTRA RADIO
CONNECTOR
HANDLEBAR MATRIX
C0 C1 C2 C3 C4
VOL UP
[
28A]
SQUELCH UP
R0
R1
R2
VOL DWN
MENU
SQUELCH DWN
RR CONTROL MATRIX
C3 C4
RR VOL UP
RR VOL DWN
PUSH TO TALK
DWN TUNE / REWIND
PUSH TO TALK
UP TUNE / FF
DWN TUNE / REWIND
BAND
Figure 6-9. Radio Pinouts
1 RT FRT SPEAKER (+)
2 PUSH TO TALK (MIC)
3 R0 (HANDLEBAR MATRIX)
UP TUNE / FF
BAND
BASE RADIO
CONNECTOR
[
27A]
4 R1 (HANDLEBAR MATRIX)
5 R2 (HANDLEBAR MATRIX)
6 C4 (HANDLEBAR MATRIX)
7 C3 (HANDLEBAR MATRIX)
8 C2 (HANDLEBAR MATRIX)
9 VEHICLE SPEED SIGNAL
10 BATTERY
11 GROUND
12 IGNITION
13 HEADSET SPEAKERS B
14 N/C
15 N/C
16 LFT FRT SPEAKER (+)
17 LFT FRT SPEAKER ( )
18 RT FRT SPEAKER (+)
19 GROUND
20 BATTERY
21 HEADSET SPEAKERS A
22 C1 (HANDLEBAR MATRIX)
23 C0 (HANDLEBAR MATRIX)
2004 Touring: Sound System 6-5
HOME
RADIO SYMPTOM 1 6.4
GENERAL
Not Applicable to Classic/Road Glide Models
Problem
Audio control inoperative.
Setup
●
Press the POWER button to turn the radio ON.
●
Press and hold the CB button to turn the Citizen Band
radio OFF. Press and hold the INT button to turn the
Intercom OFF.
Set fairing mounted Headset/Speaker Switch to
●
SPEAKER.
Functionality
Locate the Audio Control Switch on the left handlebar. Push
the switch in to sequence to Bass, Treble, Fader and then
back to Volume. The front panel LCD display indicates the
function selected.
Momentarily push the switch upward (+) to raise the volume,
downward (-) to lower the volume. The front panel LCD
annunciates volume level through a horizontal bar graph display and stereo audio should be present in all four speakers
(front speakers on non-Ultra). The display reverts to the time
of day approximately two seconds after the switch is
released.
Are these your observations?
C4
(BN/W)C3(O/BK)C2(BN/BK)C1(GY/GN)CO(GN/BE)
RO
(PK/W)
R1
(GY/W)
R2
(V/BK)
R3
(INT)
MODE UP
FF
MODE DN
RW
MODE
IN
NOT
USED
REAR
VOLUME
UP
REAR
VOLUME
DOWN
PTT
PRESET 4PRESET 3PRESET 2PRESET
AUDIOINAUDIO-AUDIO
EJECT LO/DX
SQUELCH
DOWN
SQUELCHUPSEEK
RADIO
POWER
+
SCAN
1
Figure 6-10. Diagnostic Mode Group 1 Switch Matrix
f2123x8x
C2
C0
C1
Figure 6-11. Audio Control Switch Input Bits
●
Yes -
System is OK. See Section 6.6 RADIO SYMPTOM
3.
●
No -
See Test 6.4 (Part 1 of 2).
DIAGNOSTICS
Diagnostic Notes
The reference numbers below correlate with the circled numbers in the Test 6.4 flow charts.
1. This also may be an open. First go to SHORT TO VOLTAGE in Te st 6.4 (Part 2 of 2).
6-6 2004 Touring: Sound System
2. Install BREAKOUT BOX (Part No. HD-44608). See Section 6.3 BREAKOUT BOX, INSTALLATION.
3. Revalidate failure. Reconnect all connectors. If problem
still exists, replace radio. If problem is gone, look for
intermittents.
4. Use HARNESS CONNECTOR KIT (Part No. HD-41404),
black pin probes and patch cord.
HOME
Test 6.4 (Part 1 of 2)
AUDIO CONTROL INOPERATIVE: SOFTWARE DIAGNOSIS
Enter Diagnostic Mode
by Pressing Any Two Preset Buttons While Turning
Ignition Switch to On.
Look at Input Bits C0,
C1 and C2 in LCD
Display. See Figure 6-
11. Do Any of the
Input Bits Display “0?”
YES
Move to Test 6.4 (Part 2 of 2). Find
Short to Ground on Any Wire Where
Corresponding Input Bit Displays “0”
(With No Switches Depressed).
Switch
Position
Audio + C0 GN/BE
Audio - C1 GY/GN
Audio In C2 BN/BK
Input
Bit
Wire
Color
NO
Exercise All Three Posi-
tions of AUDIO CON-
TROL SWITCH. Do All of
the Corresponding Input
Bits Toggle Between “1”
and “0?”
YES
Switch and
Wiring are OK.
Replace Radio.
6601
NO
Activate Switch Where
Corresponding Input Bit
Does Not Toggle
Between “1” and “0?” Is it
a “0” or a “1” While Switch
is Activated?
0 1
Move to Test 6.4
(Part 2 of 2).
Find Short to
Ground on R0
(PK/W) Wire.
1
Move to Test 6.4 (Part 2 of 2). Find
Short to Voltage on Wire Where
Corresponding Input Bit Displays “1.”
Switch
Position
Audio + C0 GN/BE
Audio - C1 GY/GN
Audio In C2 BN/BK
All Positions All PK/W
Input
Bit
Wire
Color
Table 6-2. Wire Harness Connectors
NO.
[24]
[27] Radio All 23-Place Amp (Black) Inner Fairing- Back of Radio (Right Side)
DESCRIPTION MODEL TYPE LOCATION
Interconnect Harness to Left
Handlebar Switch Controls
FLHTC/U 12-Place Deutsch (Gray) Inner Fairing- Left Fairing Support Brace
FLTR 12-Place Deutsch (Gray) Inner Fairing- Left Side of Radio Bracket
2004 Touring: Sound System 6-7
HOME
Test 6.4 (Part 2 of 2)
AUDIO CONTROL INOPERATIVE: HARDWARE DIAGNOSIS
SHORT to VOLTAGE
Remove Outer Fairing. Connect Breakout Box
leaving Connector [27B] disconnected from
Radio. With Key ON, Check for Power at Con-
nector [27B]. Is Voltage Present?.
From
(-)
To
Terminal
(+)
3 (PK/W)
Ground
8 (BN/BK)
22 (GY/GN)
23 (GN/BE)
YES
4
Disconnect [24]. With Key
ON, Check for Power at
Connector [24B]. Is Voltage
Present?.
From
(-)
To
Terminal
(+)
8 (BN/BK)
Ground
9 (PK/W)
10 (GN/BE)
11 (GY/GN)
YES
Locate and
Repair Short
in Handlebar
Harness.
6551
NO
Locate and
Repair Short
in Interconnect
Harness.
6531
What Did Test 6.4 (Part 1 of 2)
Indicate?
2
NO
OPEN
Disconnect Connector [27]. from radio
With Switch Depressed, Check for
Continuity at Connector [27B].
Switch
Position
From
TerminalToTerminal
Audio + 3 (PK/W) 23 (GN/BE)
Audio - 3 (PK/W) 22 (GY/GN)
Audio In 3 (PK/W) 8 (BN/BK)
Each Wire Pair Should be Less than 0.5
Ohms While Switch is Depressed and
Infinity While Switch is Open. Is It?
YES
3
Replace
Radio.
Disconnect [24]. With Switch Depressed,
Check for Continuity at Connector [24B].
6601
Switch
Position
Audio + 9 (PK/W) 10 (GN/BE)
Audio - 9 (PK/W) 11 (GY/GN)
Audio In 9 (PK/W) 8 (BN/BK)
Each Wire Pair Should be Less than 0.5
Ohms While Switch is Depressed and
Infinity While Switch is Open. Is It?
4
NO
From
Terminal
To
Terminal
2
Remove Outer Fairing. Connect
Breakout Box leaving Connector
[27B] disconnected from Radio. With
Key OFF, Check for Continuity
to Ground on Breakout Box at
YES
Disconnect [24]. With Key
OFF, Check for Continuity
to Ground at Connector
[24B]. Any Continuity
Present?
From
Terminal
(-)
8 (BN/BK)
Ground
4
9 (PK/W)
10 (GN/BE)
11 (GY/GN)
YES
Locate and
Repair Short in
Handlebar
Harness.
SHORT to GROUND
To
Terminal
Connector [27B].
From
3 (PK/W)
Ground
8 (BN/BK)
22 (GY/GN)
23 (GN/BE)
Any Continuity Present?
3
To
(+)
NO
Locate and
Repair Short
in Interconnect
Harness.
6551
NO
Replace
Radio.
6531
6601
6-8 2004 Touring: Sound System
YES
Locate and Repair
Open or Replace
Interconnect
Harness.
6532
After correction of problem, refer to SETUP and
FUNCTIONALITY to verify proper operation.
NO
Replace Audio
Switch or
Repair Switch
Wiring.
5186
HOME
MODE UP
FF
REAR
VOLUME
UP
AUDIOINAUDIO-AUDIO
+
MODE DN
RW
REAR
VOLUME
DOWN
EJECT LO/DX
RADIO
POWER
MODE
IN
PTT
SQUELCH
DOWN
SQUELCHUPSEEK
SCAN
NOT
USED
PRESET 4PRESET 3PRESET 2PRESET
1
C4
(BN/W)C3(O/BK)C2(BN/BK)C1(GY/GN)CO(GN/BE)
RO
(PK/W)
R1
(GY/W)
R2
(V/BK)
R3
(INT)
Not Applicable to Classic/Road Glide Models
C4
f2123x8x
RADIO SYMPTOM 2 6.5
GENERAL
Problem
Mode control inoperative.
Setup
Press the POWER button to turn the radio ON.
●
●
Press and hold the CB button to turn the Citizen Band
radio OFF. Press and hold the INT button to turn the
Intercom OFF.
Functionality
Locate the Mode Select Switch on the right handlebar.
Momentarily push the switch in to sequence between the AM,
FM and WB bands. The LCD display indicates the band
selected.
Momentarily push the Mode Select Switch in an upward
direction (UP) to cause the receiver to increment one step on
the frequency scale. Similarly, push the Mode Select Switch
in a downward direction (DN) to cause the receiver to decrement one step on the frequency scale.
NOTE
In Intercom Setup Mode (Ultra models only), the UP and DN
functions adjust the VOX sensitivity level. Press UP to
increase microphone sensitivity, press DN to decrease sensitivity. In CB Setup Mode, UP and DN allow for channel selection.
Are these your observations?
Yes -
●
●
System is OK. See Owner’s Manual.
No -
See Test 6.5 (Part 1 of 4).
DIAGNOSTICS
Figure 6-12. Diagnostic Mode Group 1 Switch Matrix
Figure 6-13. Mode Control Switch Input Bit
3. Revalidate failure. Reconnect all connectors. If problem
still exists, replace radio. If problem is gone, look for
intermittents.
4. Mode Control switch is integral part of sidecar amplifier.
Replace sidecar amplifier if switch fails.
5. Use HARNESS CONNECTOR KIT (Part No. HD-41404),
black pin probes and patch cord.
Diagnostic Notes
The reference numbers below correlate with the circled numbers in the Test 6.5 flow charts.
1. To eliminate Rear Mode Control Switch from diagnosis,
disconnect Connector [28]. If problem is eliminated, see
REAR MODE CONTROL INOPERATIVE. If problem remains, continue with present flow chart.
2. Install BREAKOUT BOX (Part No. HD-44608). See Section 6.3 BREAKOUT BOX, INSTALLATION.
6. Use HARNESS CONNECTOR KIT (Part No. HD-41404),
black socket probes and patch cord.
2004 Touring: Sound System 6-9
HOME
Test 6.5 (Part 1 of 4)
MODE CONTROL INOPERATIVE: SOFTWARE DIAGNOSIS
Enter Diagnostic Mode
by Pressing Any Two Preset Buttons While Turning
Ignition Switch to On.
Look at Input Bit C4 in
LCD Display. See Fig-
ure 6-13. Does the
Input Bit Display “0?”
YES
Move to Hardware Chart to Find
Short to Ground on Wire Where
Corresponding Input Bit Displays “0”
(With No Switches Depressed).
Switch
Position
Mode Up
Mode In
Input
Bit
C4 BN/WMode Dn
Wire
Color
HARDWARE CHART CONTINUE WITH
Front Mode Control Test 6.5 (Part 2 of 4)
Rear Mode Control Test 6.5 (Part 3 of 4)
Sidecar Mode Control Test 6.5 (Part 4 of 4)
NO
Exercise All Three Positions of MODE CONTROL
SWITCH. Does the Corre-
sponding Input Bit Toggle
Between “1” and “0” For
Each Switch Position?
YES
Switch and
Wiring are OK.
Replace Radio.
6601
0 1
Move to Hardware Chart to Find
Short to Ground on Wire Where
Corresponding Input Bit Displays “0.”
Switch
Position
Mode Up
Mode Dn GY/W
Mode In V/BK
Input
Bit
C4
Is it a “0” or a “1”
While Switch Posi-
tion is Activated?
Wire
Color
PK/W
After correction of problem, refer to SETUP and
FUNCTIONALITY to verify proper operation.
NO
Move to Hardware Chart to Find
Short to Voltage on Wire Where
Corresponding Input Bit Displays “1.”
Switch
Position
Mode Up
Mode Dn GY/W
Mode In V/BK
All Positions BN/W
Input
Bit
C4
Wire
Color
PK/W
Table 6-3. Wire Harness Connectors
NO.
[22]
[27] Radio All 23-Place Amp (Black) Inner Fairing- Back of Radio (Right Side)
[28] Radio FLHTCU 23-Place Amp (Gray) Inner Fairing- Back of Radio (Left Side)
[42]
6-10 2004 Touring: Sound System
DESCRIPTION MODEL TYPE LOCATION
Interconnect Harness to Right
Handlebar Switch Controls
Rear Left Speaker/Passenger
Controls
FLHTC/U 12-Place Deutsch (Black)
FLTR 12-Place Deutsch (Black) Inner Fairing- Right Side of Radio Bracket
FLHTCU
6-Place Mini-Deutsch
(Black)
Inner Fairing - Fork Stem Nut
Inside Rear Left Speaker Box
Lock Plate (Left Side)
HOME
Test 6.5 (Part 2 of 4)
FRONT MODE CONTROL INOPERATIVE: HARDWARE DIAGNOSIS
What Did Test 6.5
(Part 1 of 4)
Indicate?
SHORT to VOLTAGE SHORT to GROUND
Remove Outer Fairing. Connect Breakout Box
1 1
leaving [27B] disconnected from Radio. With
2 2
Key ON, Check for Power at Connector [27B].
From
(-)
Ground
Is Voltage Present?
To
Terminal
(+)
3 (PK/W)
4 (GY/W)
5 (V/BK)
6 (BN/W)
Remove Outer Fairing. Connect Breakout Box
leaving [27B] disconnected from Radio. With
Key OFF, Check for Continuity to Ground at
Connector [27B].
From
Terminal
To
3 (PK/W)
Ground
4 (GY/W)
5 (V/BK)
6 (BN/W)
Any Continuity Present?
YES
5 5
With Key ON, Check for
Power at Connector [22B].
From
(-)
Ground
Is Voltage Present?
YES
Locate and
Repair Short in
Handlebar
Harness.
6551
To
Terminal
(+)
7 (BN/W)
8 (GY/W)
9 (PK/W)
10 (V/BK)
Locate and
Repair Repair
in Interconnect
Harness.
NO
Short
6531
With Switch Depressed, Check for
Continuity at Connector [27B].
Switch
Position
Mode Up 6 (BN/W) 3 (PK/W)
Mode Dn 6 (BN/W) 4 (GY/W)
Mode In 6 (BN/W) 5 (V/BK)
Each Wire Pair Should be Less than
0.5 Ohms While Switch is Depressed
and Infinity While Switch is Open. Is It?
YES
3
Replace
Radio.
NO
OPEN
From
TerminalToTerminal
With Switch Depressed, Check for
Continuity at Connector [22B].
6601
Switch
Position
TerminalToTerminal
NO
From
Mode Up 7 (BN/W) 9 (PK/W)
Mode Dn 7 (BN/W) 8 (GY/W)
Mode In 7 (BN/W) 10 (V/BK)
Each Wire Pair Should be Less
than 0.5 Ohms While Switch is
Depressed and Infinity While
5
Switch is Open. Is It?
YES
With Key OFF, Check for
Check for Continuity to
Ground at Connector [22B].
From
(-)
To
Terminal
(+)
7 (BN/W)
Ground
8 (GY/W)
9 (PK/W)
10 (V/BK)
Any Continuity Present?
YES
Locate and
Repair Short in
Handlebar
Harness.
6551
NO
3
Replace
Radio.
NO
Locate and
Repair Short
in Interconnect
Harness.
6601
6531
After correction of problem, refer to SETUP and
FUNCTIONALITY to verify proper operation.
YES
Locate and
Repair or Replace
Interconnect
Harness.
6532
NO
Replace Mode
Switch or Repair
Switch Wiring.
5183
2004 Touring: Sound System 6-11
HOME
Test 6.5 (Part 3 of 4)
REAR MODE CONTROL INOPERATIVE: HARDWARE DIAGNOSIS
What Did Test 6.5 (Part 1 of 4)
SHORT to VOLTAGE SHORT to GROUND
Remove Outer Fairing. Connect Breakout Box leaving
Connector [28B] disconnected from Radio.
With Key ON, Check for Power at Connector [28B].
From
(-)
Ground
Is Voltage Present?
YES
Locate and
Repair Short in
Audio
Harness.
6560
To
Terminal
(+)
13 (PK/W)
6 (GY/W)
14 (V/BK)
5 (BN/W)
NO
OPEN
With Switch Depressed, Check for
Continuity at Connector [28B].
Switch
Position
Mode Up 5 (BN/W) 13 (PK/W)
Mode Dn 5 (BN/W) 6 (GY/W)
Mode In 5 (BN/W) 14 (V/BK)
Each Wire Pair Should be Less than
0.5 Ohms While Switch is Depressed
and Infinity While Switch is Open.
5
From
TerminalToTerminal
Is It?
Indicate?
Remove Outer Fairing. Connect Breakout Box
22
leaving Connector [28B] disconnected from
Radio. With Key OFF, Check for Continuity to
Ground at Connector [28B].
From
(-)
Ground
Any Continuity Present?
YES
Locate and
Repair Short in
Audio
Harness.
6560
To
Terminal
(+)
13 (PK/W)
6 (GY/W)
14 (V/BK)
5 (BN/W)
3
NO
Replace
Radio.
6601
3
6-12 2004 Touring: Sound System
YES
Replace
Radio.
NO
Disconnect Connector [42]. With
Switch Depressed, Check for
6601
Continuity at Connector [42B].
Switch
Position
Mode Up 4 (BN/W) 1 (PK/W)
Mode Dn 4 (BN/W) 2 (GY/W)
Mode In 4 (BN/W) 3 (V/BK)
Each Wire Pair Should be Less than
0.5 Ohms While Switch is Depressed
and Infinity While Switch is Open. Is It?
5
Locate and
Repair open
or Replace
Harness.
After correction of problem, refer to SETUP and
FUNCTIONALITY to verify proper operation.
From
TerminalToTerminal
YES
Audio
6561
NO
Replace
Mode Switch
or Repair
Switch Wiring.
6627
HOME
Test 6.5 (Part 4 of 4)
SIDECAR MODE CONTROL INOPERATIVE: HARDWARE DIAGNOSIS
SHORT to VOLTAGE SHORT to GROUND
Disconnect Connectors [42B]
and [42C]. With Key ON, Check
for Power at Connector [42B].
From
(-)
Ground
Is Voltage Present?
YES
Replace Sidecar
Audio Harness or
Locate and
Repair Short to
Voltage.
6940
What Did Test 6.5 (Part 1 of 4)
To
Terminal
(+)
1 (PK/W)
2 (GY/W)
3 (V/BK)
4 (BN/W)
Disconnect Connector [42]. With
Sidecar Mode Switch Depressed, Check
for Continuity at Connector [42C].
Switch
Position
Mode Up 4 (BN/W) 1 (PK/W)
Mode Dn 4 (BN/W) 2 (GY/W)
Mode In 4 (BN/W) 3 (V/BK)
Each Wire Pair Should be Less than 0.5
Ohms While Switch is Depressed and
Infinity While Switch is Open. Is It?
Indicate?
NO
OPEN
From
TerminalToTerminal
Disconnect Connector [42B] and [42C].
65
With Key OFF, Check for Continuity to
Ground at Connector [42C].
6940
To
Terminal
1 (PK/W)
2 (GY/W)
3 (V/BK)
4 (BN/W)
From
Ground
Any Continuity Present?
YES
Replace Sidecar
Audio Harness or
Locate and Repair
Short to Ground.
NO
Go to Test 6.5
(Part 3 of 4).”
YES
2 5
Reconnect Connector [42]. Remove
Outer Fairing and Disconnect Connector
[28]. With Switch Depressed, Check for
Continuity at Connector [28B].
Switch
Position
Mode Up 5 (BN/W) 13 (PK/W)
Mode Dn 5 (BN/W) 6 (GY/W)
Mode In 5 (BN/W) 14 (V/BK)
Each Wire Pair Should be Less than 0.5
Ohms While Switch is Depressed and
Infinity While Switch is Open. Is It?
From
TerminalToTerminal
YES
Replace
Radio.
6601
After correction of problem, refer to SETUP and
FUNCTIONALITY to verify proper operation.
NO
Locate and
Repair Open in
Audio Harness.
6561
Remove Sidecar Speaker Console. Disconnect
Connector [149] From Sidecar Speaker Amplifier.
Check Continuity as Follows:
FROM TO
Connector Terminal Connector Terminal
[149B]
YES
4
Replace
Sidecar
Amplifier.
NO
15
23 2 (GY/W)
22 3 (V/BK)
17 4 (BN/W)
Continuity Present?
6949
[42C]
1 (PK/W)
NO
Locate and
Repair Open or
Replace Sidecar
Audio Harness.
6940
2004 Touring: Sound System 6-13
6
HOME
RADIO SYMPTOM 3 6.6
GENERAL
Problem
No sound in one or more speakers (external).
Setup
●
Press the POWER button to turn the radio ON.
●
Press and hold the CB button to turn the Citizen Band
radio OFF. Press and hold the INT button to turn the
Intercom OFF.
Set fairing mounted Headset/Speaker Switch to
●
SPEAKER (red lamp illuminated).
Set radio frequency to known strong station.
●
Set Volume and Fader to Middle position on horizontal
●
bar graph display.
If performing sidecar diagnosis, rotate sidecar volume
●
control clockwise to middle or full volume position.
Functionality
Sound should be audible in all speakers. Is it?
●
Yes -
System is OK.
●
No -
See Test 6.6 (Part 1 of 3).
DIAGNOSTICS
Diagnostic Notes
The reference numbers below correlate with the circled numbers in the Test 6.6 flow charts.
1. For input bit location see illustration inside flow chart.
2. If both motorcycle speakers and sidecar speakers are
inoperative, first go to Te st 6.6 (Part 2 of 3).
3. Perform following:
a.
Impedance Check:
measure impedance or resistance of the speaker
voice coil. Place probes of ohmmeter on the speaker
terminals and observe the reading. Reading must
be 6-10 ohms. Replace the speaker if any other
reading is observed.
b.
Cone Inspection:
damage. Replace the speaker if torn or warped.
Check for binding voice coil. Remove speaker and
place four fingers evenly across the face of the
speaker cone. Very gently press inward evenly on
the cone. The cone must move smoothly without
binding. Release finger pressure. Cone must move
outward smoothly. Replace the speaker if the cone
does not move without binding.
4. Assumes Speaker Switch B input bit displays “0.”
5. Revalidate failure. Reconnect all connectors. If problem
still exists, replace radio. If problem is gone, look for
intermittents.
6. Use HARNESS CONNECTOR KIT (Part No. HD-41404),
black pin probes and patch cord.
7. Use HARNESS CONNECTOR KIT (Part No. HD-41404),
black socket probes and patch cord.
With ohmmeter set on R x 1,
Inspect the speaker cone for
Not Applicable to Classic/Road Glide Models
0=PTT 0 or 1 1=Break 1=ON 1=ON
HAND-
HELD MIC.
PTT
7
(BE/Y)
6-14 2004 Touring: Sound System
AVC
VEHICLE
SPEED
SIGNAL
6
(W/GN)
Internal
VOX
BREAK
5
Figure 6-14. Diagnostic Mode Group 2 Matrix
CB
SQUELCH
BREAK
4
Internal
INTERCOM
OFF/ON
SWITCH
3
Internal
OFF/ON
SWITCH
Internal
CB
2
10=Headset
11=Speaker
01=Center
SPEAKER
SWITCH
“B”
1
(BN/O)
SPEAKER
SWITCH
“A”
0
(V/O)
HOME
Test 6.6 (Part 1 of 3)
NO SOUND IN ONE OR MORE SPEAKERS/SIDECAR SPEAKERS: SOFTWARE DIAGNOSIS
Is Vehicle Ultra or
Classic/Road Glide?
2
Classic/Road GlideUltra
Does Any
Speaker Work?
YES
Optional Side-
car Speakers
Inoperative?
YES
Go to Test 6.6
(Part 3 of 3).
After correction of problem, refer to SETUP and
FUNCTIONALITY to verify proper operation.
NO
Go to Test 6.6
(Part 2 of 3).
Test 6.6 (Part 2 of 3).
Go to
NO
Enter Diagnostic Mode 2 by
Holding Any Two Preset
Buttons and Turning Igni-
tion Switch to ON. Then
Push LO/DX Button Once
to Obtain “d2” in LCD.
Are Both Speaker Switch A
1
and Speaker Switch B Dis-
played in LCD as “1?”
YES
1
Is Handheld Micro-
phone PTT Displayed
in LCD as “1?”
YES
1
Is Intercom ON/OFF
Switch Displayed in
LCD as “0?”
YES
1
Is CB ON/OFF
Switch Displayed
in LCD as “0?”
NO
Go to Test 6.6
(Part 2 of 3).
NO
Go to Test 6.17
(Part 2 of 2).
NO
Replace
Radio.
6601
Speaker
Switch B
Speaker
Switch A
Figure 6-15. Speaker Switch B and
Speaker Switch A Input Bits
f2122x8x
1
Test 6.6 (Part 2 of 3).
YES
Go to
NO
Replace
Radio.
6601
2004 Touring: Sound System 6-15
HOME
Test 6.6 (Part 2 of 3)
NO SOUND IN ONE OR MORE SPEAKERS: HARDWARE DIAGNOSIS
Do Any
Speakers
Work?
Measure Voltage at
Speaker Leads With
Reference to Ground.
3
YES
5
Replace
Radio.
Front
Speaker.
YES
Individual Speakers Inoperative Speaker Switch Malfunction
Is 5-7 volts DC
Present?
YES
Perform
Speaker Test.
Speaker OK?
NO
Replace
Speaker.
6601
Rear
Speaker.
6605 6606
4
NO
Connect Breakout Box to Harness Only,
Leaving Radio Disconnected. Check for
Continuity as Follows:
Speaker
Each Wire Should be Less than 0.5 Ohms.
5
Wire
Color
GY/R [27B] 18
Front
Right
L.GN/BK [27B] 1
Front
Left
Rear
Right
Rear
Left
W/O [27B] 16
L.GN/W [27B] 17
GN [28B] 11
L.GN/BN [28B] 4
W/BN [28B] 3
BN [28B] 10
Is It?
YES
Replace
Radio.
6601
Connector Terminal
NO
Locate and
Repair Open
in Wire.
NO
With Ignition Switch ON,
Measure Voltage Between
BN/O Wire on Connector [105]
(While Connected) and
Ground. Voltage Must Approximate Battery Voltage. Does It?
YES
5
Replace
Radio.
6601
Replace
NO
Disconnect Connector [105].
Repeat Voltage Test on BN/O
Wire in Connector [105A].
Voltage Must Approximate
Battery Voltage. Does It?
YES
Switch.
5192
Locate and Repair
Grounded BN/O
Wire Between
Connectors [105A]
and [27B].
YES
NO
Disconnect Connec-
tor [27B]. Measure
Continuity to Ground
on BN/O Wire in
Connector [105A].
Continuity Present?
6531
5
NO
Replace
Radio.
6601
Front
Speaker.
6532
Rear
Speaker.
6561
After correction of problem, refer to SETUP and
FUNCTIONALITY to verify proper operation.
Table 6-4. Wire Harness Connectors
NO.
[27] Radio All 23-Place Amp (Black) Inner Fairing- Back of Radio (Right Side)
[105]
6-16 2004 Touring: Sound System
DESCRIPTION MODEL TYPE LOCATION
Fairing Cap Switches FLHTC/U 12 - Place Multilock
Inner Fairing - Below Upper Fork Bracket
(Right Side)
Instrument Nacelle Switches FLTR 12 - Place Multilock Inside Instrument Nacelle (Under Bezel)
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