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.

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Figure 6-1. Access Radio Diagnostic Mode

Input Bits

6-2 2004 Touring: Sound System

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Diagnostic Mode Group 1

Figure 6-2. Front Panel LCD Display

Figure 6-3. LO/DX Button

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MODE UP

REAR

VOLUME

AUDIOINAUDIO-AUDIO

MODE DN

REAR

VOLUME

DOWN

EJECT LO/DX

RADIO

POWER

MODE

PTT

SQUELCH

DOWN

SQUELCHUPSEEK

SCAN

NOT

USED

PRESET 4PRESET 3PRESET 2PRESET

(BN/W)C3(O/BK)C2(BN/BK)C1(GY/GN)CO(GN/BE)

(PK/W)

(GY/W)

(V/BK)

(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

C3 is shorted to ground. C3 is shorted to +12 volts.

R0 is shorted to ground. R0 is shorted to +12 volts.

E. F.

[1/0] [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)

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

(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

(W/GN)

1=Break

VOX

BREAK

543

Internal Internal

SQUELCH

BREAK

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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.

OFF/ON

SWITCH

Internal

SPEAKER

SWITCH

“B”

(BN/O)

SPEAKER

SWITCH

“A”

(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-

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

N/C 19 N/C 20

RR MIC 21

FRT MIC 22

ULTRA RADIO

CONNECTOR

HANDLEBAR MATRIX

C0 C1 C2 C3 C4

VOL UP

[

28A]

SQUELCH UP

VOL DWN

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

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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?

(BN/W)C3(O/BK)C2(BN/BK)C1(GY/GN)CO(GN/BE)

(PK/W)

(GY/W)

(V/BK)

(INT)

MODE UP

MODE DN

MODE

NOT

USED

REAR

VOLUME

REAR

VOLUME

DOWN

PTT

PRESET 4PRESET 3PRESET 2PRESET

AUDIOINAUDIO-AUDIO

EJECT LO/DX

SQUELCH

DOWN

SQUELCHUPSEEK

RADIO

POWER

SCAN

Figure 6-10. Diagnostic Mode Group 1 Switch Matrix

f2123x8x

Figure 6-11. Audio Control Switch Input Bits

●

Yes -

System is OK. See Section 6.6 RADIO SYMPTOM

●

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.

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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

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

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.

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

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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

(-)

Terminal

(+)

3 (PK/W)

Ground

8 (BN/BK)

22 (GY/GN)

23 (GN/BE)

YES

Disconnect [24]. With Key

ON, Check for Power at

Connector [24B]. Is Voltage

Present?.

From

(-)

Terminal

(+)

8 (BN/BK)

Ground

9 (PK/W)

10 (GN/BE)

11 (GY/GN)

YES

Locate and Repair Short in Handlebar

Harness.

6551

Locate and

Repair Short

in Interconnect

Harness.

6531

What Did Test 6.4 (Part 1 of 2)

Indicate?

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

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?

From

Terminal

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

9 (PK/W) 10 (GN/BE) 11 (GY/GN)

YES

Locate and

Repair Short in

Handlebar

Harness.

SHORT to GROUND

Terminal

Connector [27B].

From

3 (PK/W)

Ground

8 (BN/BK) 22 (GY/GN) 23 (GN/BE)

Any Continuity Present?

(+)

Locate and

Repair Short

in Interconnect

Harness.

6551

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.

Replace Audio

Switch or

Repair Switch

Wiring.

5186

HOME

MODE UP

REAR

VOLUME

AUDIOINAUDIO-AUDIO

MODE DN

REAR

VOLUME

DOWN

EJECT LO/DX

RADIO

POWER

MODE

PTT

SQUELCH

DOWN

SQUELCHUPSEEK

SCAN

NOT

USED

PRESET 4PRESET 3PRESET 2PRESET

(BN/W)C3(O/BK)C2(BN/BK)C1(GY/GN)CO(GN/BE)

(PK/W)

(GY/W)

(V/BK)

(INT)

Not Applicable to Classic/Road Glide Models

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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

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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)

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

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.

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

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?

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

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

Terminal

(+)

7 (BN/W) 8 (GY/W) 9 (PK/W)

10 (V/BK)

Locate and

Repair Repair

in Interconnect

Harness.

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

Replace

Radio.

OPEN

From

TerminalToTerminal

With Switch Depressed, Check for

Continuity at Connector [22B].

6601

Switch

Position

TerminalToTerminal

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

Switch is Open. Is It?

YES

With Key OFF, Check for

Check for Continuity to

Ground at Connector [22B].

From

(-)

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

Replace

Radio.

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

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

Terminal

(+)

13 (PK/W) 6 (GY/W) 14 (V/BK) 5 (BN/W)

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.

From

TerminalToTerminal

Is It?

Indicate?

Remove Outer Fairing. Connect Breakout Box

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

Terminal

(+)

13 (PK/W) 6 (GY/W) 14 (V/BK) 5 (BN/W)

Replace

Radio.

6601

6-12 2004 Touring: Sound System

YES

Replace

Radio.

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?

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

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)

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?

OPEN

From

TerminalToTerminal

Disconnect Connector [42B] and [42C].

With Key OFF, Check for Continuity to

Ground at Connector [42C].

6940

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.

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.

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

Replace

Sidecar

Ampliﬁer.

15 23 2 (GY/W) 22 3 (V/BK) 17 4 (BN/W)

Continuity Present?

6949

[42C]

1 (PK/W)

Locate and

Repair Open or

Replace Sidecar

Audio Harness.

6940

2004 Touring: Sound System 6-13

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.

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

(BE/Y)

6-14 2004 Touring: Sound System

AVC

VEHICLE

SPEED

SIGNAL

(W/GN)

Internal

VOX

BREAK

Figure 6-14. Diagnostic Mode Group 2 Matrix

SQUELCH

BREAK

Internal

INTERCOM

OFF/ON

SWITCH

Internal

OFF/ON SWITCH

Internal

10=Headset 11=Speaker 01=Center

SPEAKER

SWITCH

“B”

(BN/O)

SPEAKER

SWITCH

“A”

(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?

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.

Go to Test 6.6

(Part 2 of 3).

Test 6.6 (Part 2 of 3).

Go to

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

and Speaker Switch B Dis-

played in LCD as “1?”

YES

Is Handheld Micro-

phone PTT Displayed

in LCD as “1?”

YES

Is Intercom ON/OFF

Switch Displayed in

LCD as “0?”

YES

Is CB ON/OFF

Switch Displayed

in LCD as “0?”

Go to Test 6.6

(Part 2 of 3).

Go to Test 6.17

(Part 2 of 2).

Replace

Radio.

6601

Speaker

Switch B

Speaker

Switch A

Figure 6-15. Speaker Switch B and

Speaker Switch A Input Bits

f2122x8x

Test 6.6 (Part 2 of 3).

YES

Go to

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.

YES

Replace

Radio.

Front

Speaker.

YES

Individual Speakers Inoperative Speaker Switch Malfunction

Is 5-7 volts DC

Present?

YES

Perform Speaker Test. Speaker OK?

Replace

Speaker.

6601

Rear

Speaker.

6605 6606

Connect Breakout Box to Harness Only, Leaving Radio Disconnected. Check for

Continuity as Follows:

Speaker

Each Wire Should be Less than 0.5 Ohms.

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

Locate and

Repair Open

in Wire.

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

Replace

Radio.

6601

Replace

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

Disconnect Connec-

tor [27B]. Measure

Continuity to Ground

on BN/O Wire in

Connector [105A].

Continuity Present?

6531

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)

HOME

Test 6.6 (Part 3 of 3)

NO SOUND IN ONE OR MORE SIDECAR SPEAKERS: HARDWARE DIAGNOSIS

Do Any Sidecar

Speakers Work?

YES

Check for Continuity Between Each Speaker Terminal

and Connector [149B] as Follows:

FROM TO

Speaker

Ampliﬁer

input/Output

Speaker/

Connector

Terminal Terminal Connector

Left + OUT Speaker Lt. BE/W 9 Left - OUT Speaker Lt. BE/BK 1 Right + OUT Speaker Lt. GN/W 7 Right - OUT Speaker Lt. GN/BK 8 Left + IN [42D] 5 BN 3 Left - IN [42D] 6 W/BN 2 Right + IN [41D] 5 GN 5 Right - IN [41D] 6 Lt. G/BN 4

Continuity Present?

Locate and

Repair Open or

Replace Sidecar

Audio Harness.

6943

6940

Test Speakers. Speakers OK?

YES

Replace

Sidecar

Ampliﬁer.

6949

YES

Replace

Sidecar

Speaker.

[149B]

Check for Power on [149B] at Te r minal 21 (+) and Terminal

20 (-). With Ignition Switch ON,

Measure Voltage. Is Battery

Voltage Present?

YES

Check for Continuity Between Connector [149B] and

Rear Speaker Connectors [41] and [42] as Follows:

FROM TO

Speaker Connector Terminal Terminal Connector

Left + Left - 6 W/BN 2 Right + Right - 6 Lt. G/BN 4

[42D]

[41D]

YES

Replace

Sidecar

Ampliﬁer.

5 BN 3

5 GN 5

Continuity Present?

Locate and

Repair Open or

Replace Sidecar

6949

Audio Harness.

[149B]

Check for Continu-

6940

ity to Ground on BK

Wire of Connector

Between Connector [149B]

Te r minal 21 and Connector [53D] O/V Wire. Also Check for Continuity Between Con-

nector [149B] Terminal 20

and Connector [53D] BK

Wire. Continuity Present on

YES

[53A]. Continuity

Present?

Check for Continuity

Both Wires?

Locate and

Repair Open or

Replace Sidecar

Audio Harness.

6940

After correction of problem, refer to SETUP and

FUNCTIONALITY to verify proper operation.

YES

Do Brake

Lights Work?

YES

Locate and Repair Open on O/V Wire.

Locate and Repair Open in Ground Circuit.

6561

Check for

Blown Fuse.

Replace if Nec-

6561

essary.

5145

2004 Touring: Sound System 6-17

HOME

RADIO SYMPTOM 4 6.7

GENERAL

Problem

Automatic volume control (AVC) 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 (red lamp illuminated).

●

Set radio frequency to known strong station. Set Volume and Fader to Middle position on horizontal

●

bar graph display.

Functionality

To compensate for higher background noise, volume should increase with increasing motorcycle speed (most evident above 40 MPH). Does it?

Yes -

●

Since AVC function is not as obtrusive as that seen in previous model years, providing a very smooth transition from no AVC effect up to full AVC effect, it may be most easily observed in the headsets (Ultra models only). To ramp the AVC up or down, that is, to change the rate of volume increase, see Automatic Volume Control (AVC) Adjustment below.

System is OK.

No -

See Test 6.7 (Part 1 of 2).

NOTE

DIAGNOSTICS

Automatic Volume Control (AVC) Adjustment

Active in CB, INTERCOM and music, Automatic Volume Control (AVC) automatically adjusts volume level to compensate for ambient noise associated with motorcycle speed. Since wind and road noise is less of a factor with headset speakers, headset and external speakers are provided with separate AVC schedules.

AVC Adjustment Mode

f2124x8x

Figure 6-16. Adjust Automatic Volume Control

If the AVC does not adequately compensate for ambient noise (or if it overcompensates), adjust as follows:

1. Push any two Preset buttons on the front panel of the radio. With the buttons depressed, turn the Ignition/Light Key Switch to IGNITION. Diagnostic Group 1 appears on the LCD display, as indicated by the “d1” in the lower portion.

2. Push the LO/DX button on the front panel of the radio three times to sequence to the model year conﬁguration screen. “Press 1 for bikes before MY2004, press 2 for MY2004 and later” is displayed in the upper portion of the LCD display, while the current selection is displayed in the lower portion. If the number displayed is not correct, simply change the display by pressing the appropriate preset button. Entering the wrong digit will adversely affect AVC operation.

3. Push the LO/DX button two more times to sequence to the AVC adjustment screen. The letters “AVC” are displayed in the upper portion of the LCD display, while the automatic volume level number appears in the lower portion. See Figure 6-16.

4. To ramp the AVC up, press the Mode Select Switch on the right handlebar in an upward direction (UP). To ramp the AVC down, press the switch in a downward direction (DN). Although the factory presets the volume level at number “2,” it is adjustable from “0” (AVC least aggressive) to “4” (AVC most aggressive). Any adjustment affects the AVC schedules of both headset and external speakers.

5. After making the desired change, continue pushing the LO/DX button until the system reverts back to normal radio operation. The Diagnostic Mode also can be exited by simply turning the Ignition/Light Key Switch to OFF.

Automatic Volume Level

6-18 2004 Touring: Sound System

HOME

Enter Diagnostic Mode 2.

Does AVC Bit in LCD Display Alternate Between “0” and “1” When Rear Wheel

is Rotated.

YES

Go to Test 6.7

(Part 2 of 2)

Replace

Radio.

6601

Test Ride Above

40 MPH. Does

Volume Increase

With Speed?

No Problem. See Auto-

matic Volume Control

(AVC) Adjustment to

Change Rate of Volume

Increase.

YES

Change selection to number 2. See step 2 under Automatic Vol-

ume Control (AVC)

Adjustment.

Does Model Year

Conﬁguration

Screen Display 1

or 2?

1 2

AVC Vehicle

Speed Signal

f2122x8x

Diagnostic Notes

Test 6.7 (Part 1 of 2)

The reference numbers below correlate with the circled numbers in the Test 6.7 ﬂow charts.

1. The circuit that recognizes the vehicle speed signal is the same one that controls the AVC. If the bit alternates between “0” and “1,” then the AVC is functioning as designed.

2. Connect Speedometer Tester (HD-41354) to speedometer sensor connector [65] located under the seat (3-place Deutsch). Enter a speed greater than 40 MPH (see table 2-7), and observe speedometer needle and radio volume. Volume should begin to increase around 40 MPH and further increase as indicated speed rises above 40 MPH.

3. To enable Diagnostic Mode, see 2.3 SPEEDOMETER

SELF DIAGNOSTICS.

4. Install BREAKOUT BOX (Part No. HD-44608). See Section 6.3 BREAKOUT BOX, INSTALLATION.

5. Use HARNESS CONNECTOR KIT (Part No. HD-41404), black pin probe and patch cord.

AUTOMATIC VOLUME CONTROL (AVC) INOPERATIVE: SOFTWARE DIAGNOSIS

Figure 6-17. LCD Input Bit Display

2004 Touring: Sound System 6-19

HOME

Test 6.7 (Part 2 of 2)

AUTOMATIC VOLUME CONTROL (AVC) INOPERATIVE: HARDWARE DIAGNOSIS

Perform speedometer selfdiagnostics in Section 2.3. Is P0501 or P0502 set?

YES

See P0501/P0502.

After correction of problem, refer to SETUP and

FUNCTIONALITY to verify proper operation.

Disconnect ECM connector [78B].

Disconnect connector [27]. Connect Breakout Box. Measure voltage at Terminal 9. Is voltage present?

Locate and repair

short to voltage on

W/GN wire.

YES

Measure continuity to ground from Te rminal 9 on Breakout Box. Is continuity present?

6531

Locate and repair

short to ground on

W/GN wire.

YES

6531

Check continuity between Terminal 9 on Breakout Box and connector [65B], terminal B. Is continuity present?

YES

Replace

radio.

6601

Locate and

repair open

on W/GN

wire.

6532

Table 6-5. FLHTC/U Wire Harness Connectors

NO.

[27] Radio 23-Place Amp (Black) Inner Fairing- Back of Radio (Right Side)

[65] Speedometer Speed Sensor 3-Place Deutsch

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

6-20 2004 Touring: Sound System

DESCRIPTION TYPE LOCATION

Under Right Side Cover

(Behind Electrical Bracket)

HOME

Less than 1 ohm

on X1 scale

Less than 1 ohm

on X1 scale

Infinite on

X1000

scale

f1859xed

Antenna

OK?

YES

Repair/Replace

Antenna.

Replace

Radio.

Replace

Mast.

Replace Antenna

Cable.

6601

6617

6609

RADIO SYMPTOM 5 6.8

GENERAL

Problem

Poor stereo reception.

Setup

●

Press the POWER button to turn the radio ON. Select AM mode.

●

Set LO/DX Switch to LO(CAL).

●

Select SEEK function and use MODE CONTROL SWITCH to select station with strong signal.

Functionality

Radio should lock onto strong station. Does it?

●

Yes -

System is OK.

No -

●

See Radio Antenna Test below. If antenna passes

test, continue with the Test 6.8 ﬂow chart.

Test 6.8

POOR STEREO RECEPTION

Figure 6-18. Antenna Test Hookup

DIAGNOSTICS

Radio Antenna Test

A faulty antenna can cause poor reception. Check it in three steps after cleaning the mast.

1. See Figure 6-18. Set your ohmmeter to the X 1 scale and

2. Using the same scale, connect the leads as shown. If the

3. Set the meter to the X 1,000 scale and connect the leads

connect the leads as shown. If the reading is more than 1 ohm, replace the antenna or cable. If less than 1 ohm, proceed to Step 2.

reading is greater than 1 ohm, replace the antenna or cable. If less than 1 ohm, proceed to Step 3.

as shown. If the reading is not inﬁnite, replace the antenna or cable. If replacement parts are necessary, retest after installation of new parts.

2004 Touring: Sound System 6-21

HOME

RADIO SYMPTOM 6 6.9

GENERAL

Problem

No power.

Setup

Tu rn the Ignition/Light Key Switch to IGNITION.

●

Functionality

The radio LCD should illuminate. The LCD should display the time or an operational mode (radio, CD, etc.), depending on the last state of the POWER button on the radio front panel. The radio should toggle between the time display and an operational mode when the POWER button is repeatedly pushed. Does it?

●

Yes -

System is OK.

●

No -

See Test 6.9 (Part 1 of 2).

DIAGNOSTICS

Diagnostic Notes

f2203x8x

Figure 8-19. Fuse Block (FLTR, FLHTC/U)

3. Install BREAKOUT BOX (Part No. HD-44608). See Section 6.3 BREAKOUT BOX, INSTALLATION.

4. Revalidate failure. Reconnect all connectors. If problem still exists, replace radio. If problem is gone, look for intermittents.

5. Use HARNESS CONNECTOR KIT (Part No. HD-41404), black pin probes and patch cord.

Radio Power

O/BE

Radio Memory

R/O

The reference numbers below correlate with the circled numbers in the Test 6.9 ﬂow charts.

1. See Test 6.9 (Part 1 of 2).

2. Perform tests to ensure that battery is fully charged.

6-22 2004 Touring: Sound System

HOME

Test 6.9 (Part 1 of 2)

NO POWER: SOFTWARE DIAGNOSIS

Does LCD Lighting

Illuminate?

YES

Does Time Display

Appear in LCD?

YES

Push Power Button on

Radio Front Panel.

Did Radio Display

Change to Operational

Mode (i.e., Radio,

CD, Etc.)?

YES

Power

OK.

Access Radio

Diagnostic Mode

1. Were You Successful?

With No Switches

Active, Are All Five

Input Bits in LCD

Displayed as “1?”

YES

Does Opera-

tional Mode

Appear in LCD?

YES

Power

OK.

Replace

Radio.

6601

Replace

Radio.

6601

Do Other Lights

Illuminate?

YES

Go to Test 6.9

(Part 2 of 2).

Check Battery.

Charge or

Replace.

Push Each of the Switches in the Left Hand Column While Observing

the LCD Display. Match Your Observations to the Table Below.

Push

Switch

Mode Up OK R0 R0 or C4 Rear Vol. - OK R1 R1 or C3 SQ - OK R2 R2 or C2 Audio - OK R0 R0 or C1 Audio + OK R0 R0 or C0

(1/0) = OK

to Ground

Do the Switches Work OK?

YES

Replace

Radio.

LCD Display

0 = Short

6601

(or Open Circuit Between Lines

When Switch Closed Equals “0”)

Go to Corresponding

Hardware Diagnosis for

Switch That is Inoperative.

After correction of problem, refer to SETUP and

1 = Short to Voltage

FUNCTIONALITY to verify proper operation.

Input Bit on Cx Line Displaying “0” in LCD is Grounded.

See Short to Ground in Associated Hardware Chart.

Cx Line Hardware Chart

C0, C1, C2 Audio Control Inoperative C3 Rear Headset Volume/PTT Inoperative

Mode Control Inoperative (if Front Mode Control OK, See Rear)

2004 Touring: Sound System 6-23

HOME

Test 6.9 (Part 2 of 2)

NO POWER: HARDWARE DIAGNOSIS

Check Fuses.

Are Fuses OK?

YES

Remove Outer Fairing. Connect

Breakout Box leaving [27B] disconnected from Radio. Check for Resistance to Battery Ground at Te r minals 11 and 19 (BK/GN) of Connector [27B]. Is Continuity to

Ground 1 Ohm or Less?

YES

With Key ON or OFF,

Check for Voltage at Te rminals 10 and 20

(R/O) of Connector

[27B]. Battery Voltage

Present?

YES

With Key ON, Check for

Power at Terminal 12

(O/BE) of Connector

[27B]. Battery Voltage

Present?

YES

Replace

Radio.

6601

Check for Voltage

(O/BE) of Connec-

Voltage Present?

With Key ON,

at Terminal 9

tor [1B]. Battery

With Key ON or

OFF, Check for Volt-

age at Terminal A (R/O) of Connector [15B]. Battery Volt-

age Present?

YES

Locate and

Repair Open in

Interconnect

Harness.

6532

Locate and

Repair Open

in Main Har-

ness.

5028

Replace Fuse. Did Fuse Blow

Again?

YES

Replace Fuse.

Disconnect Connector

[27]. Turn ignition ON.

Did Fuse Blow Again?

YES

Replace Fuse.

Disconnect Connector

[1]. Turn ignition ON.

Did Fuse Blow Again?

YES

Locate and

Repair Short to

Ground

Between

Fuse and Con-

nector.

5028

System

OK.

Replace

Radio.

6601

Locate and

Repair Short to

Ground Between

Connectors [1]

and [27].

6531

YES

Locate and

Repair Open in

Interconnect

Harness.

6532

After correction of problem, refer to SETUP and

FUNCTIONALITY to verify proper operation.

Locate and

Repair Open in

Main Harness.

5028

Check for Resistance

at Terminal on Top of

Fork Bracket. Is Conti-

nuity to Battery Ground

1 Ohm or Less?

YES

Locate and

Repair Open

in Intercon-

nect Harness.

6532

Locate and

Repair Open in

Ground Circuit

Between Top Fork Bracket

and Frame.

5038

Table 6-6. Wire Harness Connectors

NO. DESCRIPTION MODEL TYPE LOCATION

Main to Interconnect

[1]

Harness

[27] Radio All 23-Place Amp (Black) Inner Fairing- Back of Radio (Right Side)

6-24 2004 Touring: Sound System

FLHTC/U 12-Place Deutsch (Black) Inner Fairing - Right Radio Support Bracket

FLTR 12-Place Deutsch (Black) Inner Fairing - Below Radio (Left Side)

HOME

CAUTION

RADIO SYMPTOM 7 6.10

GENERAL

Problem

CD will not eject.

Setup

● Press the POWER button to turn the radio ON.

Functionality

CD should eject when EJECT button is pushed while radio is in either CD or radio mode. Does it?

● Yes - System is OK.

● No - See Test 6.10 (Part 1 of 2).

DIAGNOSTICS

Diagnostic Notes

The reference number below correlates with the circled numbers in the Test 6.10 ﬂow charts.

Do not force mechanism or radio damage will occur.

1. If ejection does not work, contact your Radio Sound representative.

2004 Touring: Sound System 6-25

HOME

Test 6.10 (Part 1 of 2)

CD WILL NOT EJECT: SOFTWARE DIAGNOSIS

Does EJECT Button Have

Any Effect? In Other Words,

Does EJECT Button Cause

CD to Move or LCD to

Change?

YES

Go to

Test 6.10 (Part 2 of 2).

If CD Successfully

Removed, Will CD Unit

Now Operate Correctly?

YES

System

OK.

Replace

Radio.

Test 6.10 (Part 2 of 2).

If CD Successfully

Removed, Will CD Unit

Now Operate Correctly?

YES

System

OK.

6601

Mode “d1.” Are All

Input Bits Displayed

Does Input Bit C2

Toggle Between “1”

and “0” When EJECT

Button is Pushed?

YES

Go to

Replace

Radio.

Enter Diagnostic

in LCD as “1?”

YES

6601

Check Other C2 Functions (Preset 3, Audio In, Squelch -).

Did They Work?

YES

Go to

Test 6.10 (Part 2 of 2).

If CD Successfully

Removed, Will CD Unit

Now Operate Correctly?

Other Symptoms

Present?

YES

Diagnose

Other

Symptoms.

Go to Hardware

Diagnosis for

That Function.

Go to

Test 6.10 (Part 2 of 2).

If CD Successfully

Removed, Will CD Unit

Now Operate Correctly?

YES

System

OK.

Replace

Radio.

6601

After correction of problem, refer to SETUP and

FUNCTIONALITY to verify proper operation.

6-26 2004 Touring: Sound System

YES

System

OK.

Replace

Radio.

6601

HOME

Test 6.10 (Part 2 of 2)

CD WILL NOT EJECT: HARDWARE DIAGNOSIS

Does Eject Button Function Per

Test 6.10 (Part 1 of 2)?

Refer Customer to

Owner’s Manual for

Proper Operation.

YES

Replace Radio. See

2004Touring Service Manual

(Part Number 99483-04).

After correction of problem, refer to SETUP and

FUNCTIONALITY to verify proper operation.

6601

2004 Touring: Sound System 6-27

HOME

RADIO SYMPTOM 8 6.11

GENERAL

Problem

No sound in one or more headsets/microphone inoperative.

Setup

● Press the POWER button to turn the radio ON.

● Set fairing mounted Headset/Speaker Switch to HEAD-

SET.

● 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 Front and Rear Volume Control to Middle position on

horizontal bar graph display.

● Set radio frequency to known strong station.

Functionality

Sound should be audible in all headsets. Is it?

● Yes - System is OK.

● No - See Test 6.11 (Part 1 of 2).

DIAGNOSTICS

Diagnostic Notes

The reference numbers below correlate with the circled numbers in the Test 6.11 ﬂow charts.

1. Install BREAKOUT BOX (Part No. HD-44608). See Section 6.3 BREAKOUT BOX, INSTALLATION.

2. BE/Y Wire for Handheld PTT is also part of front Interconnect Harness.

1. Microphone input

2. Speaker ground

3. Right speaker positive

4. Microphone ground

5. Left speaker positive

6. Shield (ground)

7. Handheld PTT

f1355x8x

Figure 6-20. 7-place DIN Connector: Socket Side

Index

groove

Not Applicable to Classic/Road Glide Models

0=PTT 0 or 1 1=Break 1=ON 1=ON

HAND-

HELD MIC.

PTT

(BE/Y)

AVC

VEHICLE

SPEED

SIGNAL

(W/GN)

VOX

BREAK

Internal

Figure 6-21. Diagnostic Mode Group 2

SQUELCH

BREAK

Internal

INTERCOM

OFF/ON SWITCH

Internal

OFF/ON

SWITCH

Internal

10=Headset 11=Speaker 01=Center

SPEAKER

SWITCH

“B”

(BN/O)

SPEAKER

SWITCH

“A”

(V/O)

6-28 2004 Touring: Sound System

HOME

Test 6.11 (Part 1 of 2)

NO SOUND IN ONE OR MORE HEADSETS/MICROPHONE INOPERATIVE: SOFTWARE DIAGNOSIS

Does Any

Headset Work?

Replace Inoperative

Headset With Known

Working Headset.

Does It Work?

YES

Replace

Headset.

YES

Go to

Test 6.11 (Part 2 of 2)

Enter Diagnostic Mode 2 by Holding Any

Tw o Preset Buttons and Turning Ignition Switch to ON. Then Push LO/DX Button

Once to Obtain “d2” in LCD.

Are Speaker Switch B and Speaker

Switch A Displayed in LCD as “10?”

YES

Is Handheld Micro-

phone PTT Displayed

in LCD as “1?”

YES

Is Intercom ON/OFF

Switch Displayed in

LCD as “0?”

YES

Is CB ON/OFF

Switch Displayed

in LCD as “0?”

Go to Test 6.11

(Part 2 of 2)

Go to Test 6.17

(Part 2 of 2).

Replace

Radio.

6601

Replace

Radio.

6601

Go to Test 6.11

(Part 2 of 2).

After correction of problem, refer to SETUP and

FUNCTIONALITY to verify proper operation.

YES

Replace Inoperative

Headset With Known

Working Headset.

Does It Work?

YES

Replace

Headset.

Table 6-7. FLHTCU Wire Harness Connectors

NO. DESCRIPTION TYPE LOCATION

[15] Main to Interconnect Harness 4-Place Packard Inner Fairing - Right Fairing Bracket [27] Radio 23-Place Amp (Black) Inner Fairing- Back of Radio (Right Side) [28] Radio 23-Place Amp (Gray) Inner Fairing- Back of Radio (Left Side)

[105] Fairing Cap Switches 12-Place Multilock Inner Fairing- Beneath Radio (Right Side)

2004 Touring: Sound System 6-29

HOME

Test 6.11 (Part 2 of 2)

NO SOUND IN ONE OR MORE HEADSETS/MICROPHONE INOPERATIVE: HARDWARE DIAGNOSIS

FRONT HEADSET or

HANDHELD MICROPHONE

Remove Outer Fairing. Connect

Breakout Box leaving Connector [27] and Connector [28] Disconnected from Radio. Check for Continuity as Follows:

FROM TO

Connector Terminal

13 22 26

[28B]

[27B] 2 7

YES

Replace

Radio.

2 Tab (Shield)

95 22 1 23 4

Is Continuity Present?

Check for Continuity as Follows:

6601

Connector Terminal

Front

Headset DIN

FROM TO

22 11

[28B]

[27B] 2 6

Is Continuity Present?

23 10

Connector

[53B]

Speaker Switch Malfunction

BOTH HEADSETS

Remove Outer Fairing. Connect Breakout Box leaving Connector [27]

Disconnected from Radio.

Check Continuity Between

Te rminal 13 of Connector

[27B] and Ground.

Continuity Present?

YES

Replace

Radio.

6601

YES

With Connector

[105] Connected,

Check for Continu-

ity to Ground on

BK/GN Wire of

Connector [105].

Continuity Present?

REAR HEADSET

Remove Outer Fairing. Connect

Breakout Box leaving Connector [28]

Disconnected from Radio. Check for

Continuity as Follows:

FROM TO

Connector Terminal

[28B]

Is Continuity Present?

YES

Replace

Radio.

6601

Headset DIN

21 1 18 2 16 3

17 5

Repair Open in

Audio Harness.

Rear

Locate and

6561

YES

Replace Head-

set Harness.

6616

After correction of problem, refer to SETUP and

FUNCTIONALITY to verify proper operation.

Locate and Repair Open in Audio Harness.

6561

Check Continuity

Between Terminal

13 of Connector [27B] and BN/O Wire of Connector [105A].

Continuity Present?

YES

Replace Speaker

Switch.

Repair

Open in

BN/O Wire.

65325192

Check for Continu-

ity to Ground on

BK/GN Wire of

Connector [15B].

Continuity Present?

YES

Locate and Repair

Open in BK/GN

Wire Between Con-

nector [105A] and

Connector [15A].

6532

Inspect BK/GN

Ground Terminal in

Front of Battery.

Tighten and/or

Repair as Necessary.

If Ground Connector is Good, Locate and

Repair Open in BK/

GN Wire Between

Connector [15B] and

Ground Terminal in

Main Wire Harness.

5038

6-30 2004 Touring: Sound System

HOME

MODE UP

REAR

VOLUME

AUDIOINAUDIO-AUDIO

MODE DN

REAR

VOLUME

DOWN

EJECT LO/DX

RADIO

POWER

MODE

PTT

SQUELCH

DOWN

SQUELCHUPSEEK

SCAN

NOT

USED

PRESET 4PRESET 3PRESET 2PRESET

(BN/W)C3(O/BK)C2(BN/BK)C1(GY/GN)CO(GN/BE)

(PK/W)

(GY/W)

(V/BK)

(INT)

Not Applicable to Classic/Road Glide Models

Cx = C0 thru C4. Rx = R0 thru R3.

f2123x8x

RADIO SYMPTOM 9 6.12

GENERAL

Problem

Rear headset volume/PTT inoperative.

Setup

● Press the POWER button to turn the radio ON.

● Set fairing mounted Headset/Speaker Switch to HEAD-

SET.

● 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 radio frequency to known strong station.

Functionality

Figure 6-22. Diagnostic Mode Group 1 Switch Matrix

Adjust the volume with the Audio Control Switch on the rear right speaker box. Stereo audio should be present in the headset. Push the switch upward (+) to raise the volume, downward (-) to lower the volume. The front panel LCD annunciates rear volume level through a horizontal bar graph display. The display reverts to the time of day approximately two seconds after the switch is released. Pressing PTT while CB is OFF activates Intercom microphone. Pressing PTT while CB is ON activates CB transmitter.

Are these your observations?

● Yes - System is OK.

● No - See Test 6.12 (Part 1 of 3).

DIAGNOSTICS

Diagnostic Notes

The reference numbers below correlate with the circled numbers in the Test 6.12 ﬂow charts.

1. Install BREAKOUT BOX (Part No. HD-44608). See Section 6.3 BREAKOUT BOX, INSTALLATION.

Figure 6-23. Rear Headset Volume/PTT Switch Input Bit

2. Revalidate failure. Reconnect all connectors. If problem still exists, replace radio. If problem is gone, look for intermittents.

3. Use HARNESS CONNECTOR KIT (Part No. HD-41404), black pin probes and patch cord.

4. Use HARNESS CONNECTOR KIT (Part No. HD-41404), black socket probes and patch cord.

2004 Touring: Sound System 6-31

HOME

Test 6.12 (Part 1 of 3)

REAR HEADSET VOLUME/PTT INOPERATIVE OR SIDECAR PTT INOPERATIVE: SOFTWARE DIAGNOSIS

Enter Diagnostic Mode by Pressing Any Two Preset Buttons While Turning

Ignition Switch to On.

Look at Input Bit C3 in LCD

Display. See Figure 6-23. Does the Input Bit Display

“0” With the Switches Open?

YES

Move to Hardware Chart to Find Short to Ground on Wire Where

Corresponding Input Bit Displays “0”

(With No Switches Depressed).

Rear Headset Volume/PTT

Switch

Position

Vol +

PTT

Switch

Position

PTT C3 O/BK

Input

Bit

C3 O/BKVol -

Sidecar PTT

Input

Bit

Wire

Color

Wire

Color

Exercise All Three Posi-

tions of REAR VOLUME/

PTT SWITCH or Single Position of SIDECAR PTT SWITCH. Does the Corre-

sponding Input Bit Toggle

Between “1” and “0” For

Each Switch Position?

HARDWARE CHART CONTINUE WITH

Rear Headset Volume/PTT Test 6.12 (Part 2 of 3) Sidecar PTT Test 6.12 (Part 3 of 3)

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.”

Rear Headset Volume/PTT

Switch

Position

Vol +

Vol - GY/W

PTT V/BK

Switch

Position

PTT C3 V/BK

Input

Bit

Sidecar PTT

Input

Bit

Is it a “0” or a “1”

While Switch Posi-

tion is Activated?

Wire

Color

PK/W

Wire

Color

Does the Preset

4 Button Work?

YES

Move to

Hardware Chart

to Find Open at

Bold Asterisk.

Move to Hardware Chart to Find

Short to Voltage on Wire Where

Corresponding Input Bit Displays “1.”

Rear Headset Volume/PTT

Switch

Position

Vol +

Vol - GY/W PTT V/BK

All Positions O/BK

Switch

Position

PTT C3 V/BK

Input

Bit

Sidecar PTT

Input

Bit

Wire

Color

PK/W

Wire

Color

After correction of problem, refer to SETUP and

FUNCTIONALITY to verify proper operation.

Table 6-8. FLHTCU Wire Harness Connectors

NO. DESCRIPTION TYPE LOCATION

[28] Radio 23-Place Amp (Gray) Inner Fairing- Back of Radio (Left Side)

[41]

Rear Right Speaker/Passenger Controls

6-32 2004 Touring: Sound System

6-Place Mini-Deutsch (Black) Inside Rear Right Speaker Box

HOME

Test 6.12 (Part 2 of 3)

REAR HEADSET VOLUME/PTT INOPERATIVE: HARDWARE DIAGNOSIS

What Did Test 6.12 (Part 1 of 3)

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

Locate and

Repair Short in

Harness.

Connector [28B].

From (-) To Terminal (+)

Ground

YES

Audio

13 (PK/W) 6 (GY/W) 14 (V/BK) 12 (O/BK)

Is Voltage Present?

With Switch Depressed, Check for

6560

Continuity at Connector [28B].

Switch

Position

Vol. Up 12 (O/BK) 13 (PK/W) Vol. Dn 12 (O/BK) 6 (GY/W)

PTT 12 (O/BK) 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?

TerminalToTerminal

Indicate?

OPEN

From

Remove Outer Fairing. Connect Breakout

Box leaving Connector [28B] Disconnected

from Radio. With Key OFF, Check for Continu-

ity to Ground at Connector [28B].

From (-) To Terminal (+)

Ground

Any Continuity Present?

13 (PK/W) 6 (GY/W) 14 (V/BK) 12 (O/BK)

YES

Locate and

Repair Short in

Audio

Harness.

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

6560

Replace

Radio.

6601

YES

Replace

Radio.

6601

Disconnect Connector [41]. With

Switch Depressed, Check for

Continuity at Connector [41B].

Switch

Position

Vol. Up 4 (O/BK) 1 (PK/W) Vol. Dn 4 (O/BK) 2 (GY/W)

PTT 4 (O/BK) 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?

YES

Locate and

Repair Open or

Replace Audio

Harness.

From

TerminalToTerminal

Replace Rear

Volume/PTT

Switch or Repair

Switch Wiring.

6561

6627

After correction of problem, refer to SETUP and

FUNCTIONALITY to verify proper operation.

2004 Touring: Sound System 6-33

HOME

Test 6.12 (Part 3 of 3)

SIDECAR PTT INOPERATIVE: HARDWARE DIAGNOSIS

What Did Test 6.12 (Part 1 of 3)

SHORT to VOLTAGE SHORT to GROUND

Disconnect Connector [41B] and

[41C]. With Key ON, Check for Power

at Connector [41C].

YES

6561

Terminal

(+)

3 (V/BK) 4 (O/BK)

Replace

Radio.

From

(-)

Ground

Is Voltage Present?

Reconnect Connector [41].

Remove Outer Fairing. Connect

Breakout Box leaving Connector

[28B] Disconnected from Radio. Check for Voltage at Terminals 12 (O/BK) and 14 (V/BK) of Connec-

tor [28B]. Is Voltage Present?

YES

Locate and

Repair Short To

Voltage or

Replace Audio

Harness.

4 4

With Sidecar PTT Switch Depressed,

Check for Continuity at Connector [41C].

Switch

Position

PTT 4 (O/BK) 3 (V/BK)

Resistance Should be Less than 0.5

Ohms While Switch is Depressed and

Inﬁnity While Switch is Open. Is It?

6601

Indicate?

OPEN

From

TerminalToTerminal

YES

Replace

Radio.

6601

Disconnect Connector [41B] and

[41C]. With Key OFF, Check for Con-

tinuity to Ground at Connector [41C].

From

(-)

Ground

Any Continuity Present?

Repair Short to

Sidecar Audio

Remove Sidecar Speaker Console. Disconnect

Connector [149] from Sidecar Speaker Ampliﬁer.

Check Continuity as Follows:

FROM TO

Connector Terminal Terminal Connector

[149B]

16 4 (O/BK) 22 3 (V/BK)

Continuity Present?

Terminal

3 (V/BK) 4 (O/BK)

YES

Replace or Locate and

Ground in

Harness.

(+)

Go to Test 6.12

(Part 2 of 3).

6940

[42C]

After correction of problem, refer to SETUP and

FUNCTIONALITY to verify proper operation.

6-34 2004 Touring: Sound System

YES

Replace

Sidecar

Ampliﬁer.

6949

Locate and

Repair Open or

Replace Sidecar

Audio Harness.

6940

HOME

NOTES

2004 Touring: Sound System 6-35

HOME

RADIO SYMPTOM 10 6.13

GENERAL

Functionality

Problem

Intercom inoperative.

Setup

● Press the POWER button to turn the radio ON.

● Set fairing mounted Headset/Speaker Switch to HEAD-

SET.

● Press and hold the CB button to turn the Citizen Band

radio OFF.

● Press and hold the INT button to turn the Intercom ON

(Setup Mode).

● Use Mode Select Switch to adjust VOX sensitivity to a

value greater than “10.”

● Set Front and Rear Volume Control to Middle position on

horizontal bar graph display.

Not Applicable to Classic/Road Glide Models

Speak into Intercom. Voice should be heard in all headsets. Is it?

● Yes - System is OK.

● No - See Test 6.13.

DIAGNOSTICS

See Test 6.13 on the next page.

0=PTT 0 or 1 1=Break 1=ON 1=ON

HAND-

HELD MIC.

PTT

(BE/Y)

AVC

VEHICLE

SPEED

SIGNAL

(W/GN)

VOX

BREAK

Internal

Figure 6-24. Diagnostic Mode Group 2 Matrix

SQUELCH

BREAK

Internal

INTERCOM

OFF/ON

SWITCH

Internal

OFF/ON

SWITCH

Internal

10=Headset 11=Speaker 01=Center

SPEAKER

SWITCH

“B”

(BN/O)

SPEAKER

SWITCH

“A”

(V/O)

6-36 2004 Touring: Sound System

HOME

Test 6.13

INTERCOM INOPERATIVE: SOFTWARE DIAGNOSIS

Did Radio Enter Intercom Setup

Mode as Indicated

by LCD When Inter-

com Switch Turned

On?

Adjust VOX Level

to 11. Then Test

for Audio When Speaking Loudly Into Microphone.

Audio Present?

YES

Intercom

OK.

YES

Press Mode Up Switch So That VOX

Level is at Maximum Value (13).

Set Front Volume to Middle Position

in Horizontal Bar Graph Display. Set

Rear Volume to Middle Position.

Is Intercom Audio Present When

Speaking Into Microphone

(Both Directions)?

YES

Replace

Radio.

6601

Intercom

Is Communication Possible In

Either Direction?

YES

Replace

“Dead” Head-

set. Intercom

OK?

YES

OK.

Replace

“Dead” Micro-

phone. Inter-

com OK?

Replace

Radio.

6601

Ver ify Headset Operation

on Another Vehicle.

Do the Speakers and

Microphone Work?

YES

Replace

Radio.

6601

Replace

Headset.

After correction of problem, refer to SETUP and

FUNCTIONALITY to verify proper operation.

YES

Intercom

OK.

Replace

Radio.

6601

2004 Touring: Sound System 6-37

HOME

RADIO SYMPTOM 11 6.14

GENERAL

CB OFF/ON

Switch

Problem

CB receiver inoperative.

Setup

● Press the POWER button to turn the radio ON.

● Press and hold the INT button to turn the Intercom OFF.

● Set fairing mounted Headset/Speaker Switch to

SPEAKER.

● Set Volume Control to Middle position on horizontal bar

graph display.

● Press and hold the CB button to turn the Citizen Band

radio ON.

Functionality

See Test 6.14.

Not Applicable to Classic/Road Glide Models

0=PTT 0 or 1 1=Break 1=ON 1=ON

HAND-

HELD MIC.

PTT

AVC

VEHICLE

SPEED

SIGNAL

VOX

BREAK

SQUELCH

BREAK

f2122x8x

Figure 6-25. LCD Input Bit Display

DIAGNOSTICS

Diagnostic Notes

The reference number below correlates with the circled number in the Test 6.14 ﬂow chart.

1. See Section 6.15 RADIO SYMPTOM 12.

10=Headset 11=Speaker 01=Center

INTERCOM

OFF/ON SWITCH

OFF/ON

SWITCH

SPEAKER

SWITCH

“B”

SPEAKER

SWITCH

“A”

(BE/Y)

6-38 2004 Touring: Sound System

(W/GN)

Internal

Figure 6-26. Diagnostic Mode Group 2

Internal

(BN/O)

(V/O)

HOME

Test 6.14

CB RECEIVER INOPERATIVE: SOFTWARE DIAGNOSIS

Did Radio Enter

CB Setup Mode?

YES

Press SQ- Until Bar Graph

Moves to Left Most Position.

This Forces Squelch Open

Independent of CB Signal

Strength. Is CB Audio Present?

YES

Press SQ+ So Bar Graph

Moves One Bar to the

Right. Is Audio Still Present

(With Test Signal From External Transmitter)?

YES

Receiver

OK.

Perform Antenna Check and SWR

Adjustment Proce-

dures. Antenna OK?

YES

Bad Squelch

Circuit Internal

to Radio.

Replace Radio.

Replace

CB Mast.

6601

6613

Receiver

OK. Repair

or Adjust Antenna.

Replace

CB Load

Coil.

Using Mode Control

Switch Press Mode Up or

Mode Dn to Change CB Channel. Does Channel

Number Change on LCD?

YES

Using External Transmitter

for Test Signal, Can CB Audio be Heard When Set to Same Channel as Receiver?

YES

Press SQ+ So Bar Graph

Moves One Bar to the

Right. Is Audio Still Present

(With Test Signal From

External Transmitter)?

YES

Receiver

6618

OK.

Perform Antenna

Check and SWR

Adjustment Proce-

dures. Antenna OK?

Enter Diagnostics Mode 2.

Does Handheld Microphone

PTT Display “0” (i.e., is PTT

Line Shorted to Ground)?

YES

Go to Test 6.17

(Part 2 of 2).

Go to Test 6.5

(Part 2 of 4).

Replace

Radio.

Perform Antenna Check and SWR

Adjustment Proce-

dures. Antenna OK?

YES

Bad Squelch

Circuit Internal

to Radio.

Replace Radio.

6601

Receiver

OK. Repair

or Adjust Antenna.

After correction of problem, refer to SETUP and

FUNCTIONALITY to verify proper operation.

YES

Bad Squelch

Circuit Internal

to Radio.

Replace Radio.

6601

Receiver OK.

Repair or Adjust

Antenna.

Replace

Mast.

6613 6618

Replace

CB Load

Coil.

Replace

CB Mast.

6613

Replace

CB Load

Coil.

6618

2004 Touring: Sound System 6-39

HOME

NOTES

6-40 2004 Touring: Sound System

HOME

RADIO SYMPTOM 12 6.15

GENERAL

Problem

CB transmitter inoperative.

Setup

● Press the POWER button to turn the radio ON.

● Press and hold the INT button to turn the Intercom OFF.

● Set fairing mounted Headset/Speaker Switch to

SPEAKER.

● Set Volume Control to Middle position on horizontal bar

graph display.

● Press and hold the CB button to turn the Citizen Band

radio ON.

Functionality

Depressing any PTT switch will change the radio display to reﬂect CB mode and cause the transmitter to transmit. To verify transmission, use another CB receiver tuned to the same channel. In CB Setup mode, the squelch display will disappear when PTT is depressed. Are these your observations?

● Yes - System is OK.

● No - See Tes t 6.15 (Part 1 of 2).

DIAGNOSTICS

Diagnostic Notes

The reference numbers below correlate with the circled numbers in the Test 6.15 ﬂow charts.

1. Remove outer fairing. Disconnect antenna connector from CB and replace it with a dummy load, that is, the lamp included with tool HD-39448.

NOTE

The lamp acts as a load that allows the CB to be operated and provides a means of checking relative power output and modulation.

2. To use the load, screw the dummy load onto the antenna jack of the CB. Depress the PTT switch. If the CB is transmitting a carrier wave, the lamp should illuminate. Speaking into the microphone should cause the lamp to ﬂicker. It should get brighter and dimmer depending on how loud your voice is. A change in lamp brilliance means the CB is modulating.

Not Applicable to Classic/Road Glide Models

0=PTT 0 or 1 1=Break 1=ON 1=ON

HAND-

HELD MIC.

PTT

(BE/Y)

AVC

VEHICLE

SPEED

SIGNAL

(W/GN)

VOX

BREAK

Internal

Figure 6-27. Diagnostic Mode Group 2

SQUELCH

BREAK

Internal

INTERCOM

OFF/ON

SWITCH

Internal

OFF/ON

SWITCH

Internal

10=Headset 11=Speaker 01=Center

SPEAKER

SWITCH

“B”

(BN/O)

SPEAKER

SWITCH

“A”

(V/O)

2004 Touring: Sound System 6-41

HOME

Test 6.15 (Part 1 of 2)

CB TRANSMITTER INOPERATIVE: SOFTWARE DIAGNOSIS

Did Radio Enter

CB Setup Mode?

Perform Antenna Check and SWR

Adjustment Proce-

Replace

CB Mast.

6613

YES

Tune Known Good

Receiver to Same

Channel Number as Tr ansmitter. Test Transmitter. Transmitter OK?

YES

dures.

Replace

CB Load

Coil.

6618

Go to Test 6.15

(Part 2 of 2).

Does Unit Under

Test Receiver

Does Display

Change When

Depressed?

YES

Enter Diagnostic Mode 2. Does CB OFF/ON Switch

Display “1” in LCD?

YES

Work OK?

YES

PTT is

Replace

Radio.

6601

Go to the Appropriate

PTT Inoperative Chart.

PTT INOPERATIVE

CHART

Rear Headset Volume PTT 6.12 RADIO SYMPTOM 9 Sidecar PTT 6.12 RADIO SYMPTOM 9 PTT/Squelch 6.16 RADIO SYMPTOM 13 Handheld Microphone/PTT 6.17 RADIO SYMPTOM 14

Does Handheld

Microphone Dis-

play “0” in LCD

With PTT Switch

Not Pushed In?

YES

Go to Test 6.17

(Part 1 of 2).

CONTINUE WITH

Go to Test 6.15

(Part 2 of 2).

Work Normally

Except for CB

Tr ansmitter?

YES

Replace

Radio.

6601

Does Radio

Diagnose

Symptom.

Other

After correction of problem, refer to SETUP and

FUNCTIONALITY to verify proper operation.

6-42 2004 Touring: Sound System

HOME

CAUTION

Test 6.15 (Part 2 of 2)

CB TRANSMITTER INOPERATIVE: HARDWARE DIAGNOSIS

Does Lamp Glow When

Tr ansmitting?

Lamp Glows and

Changes in Brilliance

While Speaking.

Perform Antenna Check

and SWR Adjustment

Procedures.

Replace

Mast.

6613 6618

Replace

CB Load

Coil.

Substitute Known Good

YES

Replace Microphone or Headset.

CB Antenna Test

A faulty CB antenna can cause poor reception and transmitting range. Check the antenna system as follows:

Lamp Glows But No Change in Brilliance

While Speaking.

Microphone. Repeat

Test. Does Lamp Glow

and Change in Bril-

liance While Speaking.

Go to Test 6.11

(Part 2 of 2).

After correction of problem, refer to SETUP and

SWR Adjustment

Lamp Does

Not Glow.

Replace

Radio.

6601

FUNCTIONALITY to verify proper operation.

1. Remove outer fairing. Remove antenna cable from back of radio. Using clip-on test leads, connect one lead of ohmmeter to center pin in antenna lead and other lead to antenna mast. Meter must read 1 ohm or less. Wiggle or ﬂex mast while observing meter. If resistance is more than 1 ohm or varies when mast is wiggled, replace mast. Inspect connections at base of loading coil and at mounting bracket.

NOTE

It is normal to observe a reading of less than one ohm between the center conductor and ground due to the conﬁguration of the loading coil.

2. Check SWR adjustment.

3. To replace the CB antenna, see the 2004Touring Service Manual (Part Number 99483-04).

Do not press PTT switches with antenna and SWR meter disconnected. Transceiver damage could result.

Standing wave ratio (SWR) is a technical term for the procedure that checks how well the CB transmitter and antenna are matched. The SWR should be 2:1 or below on channel 20. A SWR of 1:1 is optimum.

To check SWR, a SWR meter or bridge is required. Your Harley-Davidson dealer will either have a SWR meter or direct you to a CB repair shop for a SWR check. Since the operating procedures for SWR meters vary, be sure you carefully follow the operating instructions for the SWR meter being used.

1. Locate motorcycle outdoors or in a building with a ceiling of 11 ft. (3.4 m) minimum above ﬂoor. Also, there must be 8 ft. (2.4 m) of radial clearance around motorcycle. Adjusting the SWR in an area with a lower ceiling and/or less radial clearance may result in an inaccurate adjustment.

2004 Touring: Sound System 6-43

HOME

2. Remove the outer fairing. Remove the antenna cable and connect the SWR meter to the radio. Connect the antenna cable to the SWR meter. The SWR meter is connected in series with the antenna cable so the antenna will be connected to the SWR meter.

3. Check that the antenna loading coil bracket in Tour-Pak is tight and that antenna cable is tightly connected to loading coil.

4. Check that antenna mast is threaded securely on to base and set screw is tight.

5. Before measuring the SWR, the SWR meter must be calibrated. Follow the instructions for the meter being used. The following procedure is the general calibration most meter instructions specify.

CAUTION

Do not touch the antenna or meter during calibration or SWR measurement. Move CAL knob and then move your hand away from meter while calibrating.

6. With ignition and CB switches ON, the SWR meter set on “FWD”, Channel 20 selected, press either PTT switches. Hold the PTT switch and rotate the calibration (CAL) control until the meter needle aligns with the “CAL” mark.

7. Release the PTT switch and move the FWD/REF switch to “REF” (reﬂected).

CAUTION

Do not touch the antenna or meter during calibration or SWR measurement. Move CAL knob and then move your hand away from meter while calibrating. Do not press PTT switches with antenna and SWR meter disconnected. Transceiver damage could result.

9. If SWR is more than 3:1, remove antenna cable from transceiver under Tour-Pak. Using clip-on test leads, connect one lead of ohmmeter to center pin in antenna lead and other lead to antenna mast. Meter must read 1 ohm or less. Wiggle or ﬂex mast while observing meter. If resistance is more than 1 ohm or varies when mast is wiggled, replace mast. Inspect connections at base of loading coil and at mounting bracket. If the SWR is less than 3:1, loosen antenna set screw and change mast length.

NOTE

It is normal to observe a reading of less than one ohm between the center conductor and ground due to the conﬁguration of the loading coil.

10. Repeat Step 8. If SWR became higher, adjust antenna mast in opposite direction. Continue adjusting antenna until the minimum SWR is achieved. If you cannot obtain an SWR of 2:1 or less by adjusting the antenna length, make the mast shorter to improve the SWR. Remove mast and use grinder to shorten mast (grind in small increments).

11. After SWR is adjusted on channel 20, check SWR on channels 1 and 40. Adjust the mast length to obtain a balance between channels 1 and 40.

NOTE

Check the SWR if a luggage rack is installed on the Tour-Pak cover. Be sure that the Tour-Pak cover is closed when the check is performed. Accessories mounted on the Tour Pak may affect the SWR reading and broadcast range, so the luggage rack should be mounted as far forward as possible. The Ultra Tour-Pak chrome accent rail also can adversely affect SWR.

8. Press and hold either PTT switch. The meter reading is the SWR.

6-44 2004 Touring: Sound System

HOME

MODE UP

REAR

VOLUME

AUDIOINAUDIO-AUDIO

MODE DN

REAR

VOLUME

DOWN

EJECT LO/DX

RADIO

POWER

MODE

PTT

SQUELCH

DOWN

SQUELCHUPSEEK

SCAN

NOT

USED

PRESET 4PRESET 3PRESET 2PRESET

(BN/W)C3(O/BK)C2(BN/BK)C1(GY/GN)CO(GN/BE)

(PK/W)

(GY/W)

(V/BK)

(INT)

Not Applicable to Classic/Road Glide Models

f2123x8x

RADIO SYMPTOM 13 6.16

GENERAL

Problem

PTT/Squelch control inoperative.

Setup

● Press the POWER button to turn the radio ON.

● Press and hold the INT button to turn the Intercom OFF.

● Press and hold the CB button to turn the Citizen Band

radio ON.

● Set fairing mounted Headset/Speaker Switch to

SPEAKER.

Functionality

Depressing any PTT switch will change the radio display to reﬂect CB mode and cause the transmitter to transmit. Pressing the Squelch Control in either direction will cause the horizontal bar graph display to change. Are these your observations?

Figure 6-28. Diagnostic Mode Group 1 Switch Matrix

● Yes - System is OK.

● No - See Test 6.16 (Part 1 of 2).

DIAGNOSTICS

Diagnostic Notes

The reference numbers below correlate with the circled numbers in the Test 6.16 ﬂow charts.

1. This also may be an open. First go to SHORT TO VOLTAGE in Te st 6.16 (Part 2 of 2).

2. Install BREAKOUT BOX (Part No. HD-44608). See Section 6.3 BREAKOUT BOX, INSTALLATION.

Figure 6-29. PTT/Squelch Control Switch Input Bits

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.

2004 Touring: Sound System 6-45

HOME

Test 6.16 (Part 1 of 2)

PTT/SQUELCH CONTROL INOPERATIVE: SOFTWARE DIAGNOSIS

Enter Diagnostic Mode by Pressing Any Two Preset Buttons While Turning

Ignition Switch to On.

Look at Input Bits C1,

C2 and C3 in LCD Dis-

play. See Figure 6-29.

Do Any of the Input Bits

Display “0?”

YES

Move to Test 6.16 (Part 2 of 2) to Find Short to Ground on Any Wire Where

Corresponding Input Bit Displays “0.”

Switch

Position

Squelch + C1 GY/GN Squelch - C2 BN/BK

PTT C3 O/BK

Input

Bit

Wire

Color

Exercise All Three Positions of PTT/SQUELCH

CONTROL SWITCH. Do

All of the Corresponding

Input Bits Toggle

Between “1” and “0?”

YES

Switch and

Wiring are OK.

Replace Radio.

6601

0 1

Move to Test 6.16

(Part 2 of 2) to

Find Short to

Ground on R2

(V/BK) Wire.

Activate Switch Where

Corresponding Input Bit

Does Not Toggle

Between “1” and “0?” Is it a “0” or a “1” While Switch

is Activated?

Move to Test 6.16 (Part 2 of 2) to

Find Short to Voltage on Wire

Where Corresponding Input Bit Dis-

plays “1” (With No Switches

Switch

Position

Squelch + C1 GY/GN Squelch - C2 BN/BK

PTT C3 O/BK

All Positions All V/BK

Depressed).

Input

Bit

Wire

Color

After correction of problem, refer to SETUP and

FUNCTIONALITY to verify proper operation.

Table 6-9. FLHTCU Wire Harness Connectors

NO. DESCRIPTION TYPE LOCATION

[24]

Interconnect Harness to Left Handlebar Switch Controls

[27] Radio 23-Place Amp (Black) Inner Fairing- Back of Radio (Right Side)

6-46 2004 Touring: Sound System

12-Place Deutsch (Gray) Inner Fairing- Left Fairing Support Brace

HOME

Test 6.16 (Part 2 of 2)

PTT/SQUELCH CONTROL INOPERATIVE: HARDWARE DIAGNOSIS

Test 6.16 (Part 1 of 2) Indicate?

SHORT to VOLTAGE

Remove Outer Fairing. Connect Breakout Box

leaving Connector [27B] Disconnected from

Radio. With Key ON, Check for Power at

Connector [27B].

From (-) To Terminal (+)

5 (V/BK)

Ground

7 (O/BK)

8 (BN/BK)

22 (GY/GN)

Is Voltage Present?

YES

With Key ON, Check for Power

at Connector [24B].

From

(-)

Terminal

(+)

7 (V/BK)

Ground

8 (BN/BK)

11 (GY/GN)

12 (O/BK)

Is Voltage Present?

YES

Locate

and

Repair

Short in Handlebar Har-

ness.

6551

Locate and

Repair Short

in Interconnect

Harness.

6531

What Did

OPEN

Disconnect Connector [27B]. With

Switch Depressed, Check for

Continuity at Connector [27B].

Switch

Position

From

TerminalToTerminal

Squelch + 5 (V/BK) 22 (GY/GN) Squelch - 5 (V/BK) 8 (BN/BK)

PTT 5 (V/BK) 7 (O/BK)

Each Wire Pair Should be Less than 0.5

Ohms While Switch is Depressed and

Inﬁnity While Switch is Open. Is It?

YES

Replace

Radio.

6601

With Switch Depressed, Check for

Continuity at Connector [24B].

Switch

Position

From

Terminal

Squelch + 7 (V/BK) 11 (GY/GN) Squelch - 7 (V/BK) 8 (BN/BK)

PTT 7 (V/BK) 12 (O/BK)

Each Wire Pair Should be Less than 0.5

Ohms While Switch is Depressed and

Inﬁnity While Switch is Open. Is It?

Terminal

Remove Outer Fairing. Connect Breakout

Box leaving Connector [27B] Discon-

nected from Radio. With Key OFF, Check

for Continuity to Ground at Connector

With Key OFF, Check for

Continuity to Ground at

Connector [24B].

From

(-)

Ground

Any Continuity Present?

Locate and

Repair Short in

Handlebar

Harness.

SHORT to GROUND

[27B].

From To Terminal

5 (V/BK)

Ground

7 (O/BK)

8 (BN/BK)

22 (GY/GN)

Any Continuity Present?

YES

Terminal

(+)

7 (V/BK)

8 (BN/BK)

11 (GY/GN)

12 (O/BK)

YES

6551

Replace

Radio.

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

Open or Replace

Interconnect

Harness.

6532

Replace PTT/

Squelch Control

Switch or Repair

Switch Wiring.

5184

2004 Touring: Sound System 6-47

HOME

RADIO SYMPTOM 14 6.17

GENERAL

Problem

Handheld microphone PTT inoperative.

Setup

● Press the POWER button to turn the radio ON.

● Press and hold the INT button to turn the Intercom OFF.

● Press and hold the CB button to turn the Citizen Band

radio ON.

● Set fairing mounted Headset/Speaker Switch to

SPEAKER.

Functionality

Depressing handheld PTT switch will change the radio display to reﬂect CB mode and cause the transmitter to transmit. In CB Setup mode, the squelch display will disappear when PTT is depressed. Are these your observations?

● Yes - System is OK.

● No - See Test 6.17 (Part 1 of 2).

DIAGNOSTICS

Diagnostic Notes

The reference numbers below correlate with the circled numbers in the Test 6.17 ﬂow charts.

1. Install BREAKOUT BOX (Part No. HD-44608). See Section 6.3 BREAKOUT BOX, INSTALLATION.

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

41404), black pin probes and patch cords.

3. Use HARNESS CONNECTOR KIT (Part No. HD-41404), black socket probes and patch cord.

6-48 2004 Touring: Sound System

HOME

Test 6.17 (Part 1 of 2)

HANDHELD MICROPHONE PTT INOPERATIVE: SOFTWARE DIAGNOSIS

Which PTT Switch

Does Not Work?

Rider/Passenger

Enter Diagnostic Mode

1. Is Input Bit C3 Displayed in LCD as “1?”

YES

Press Rider/Passen-

ger PTT Switch. Does

Input Bit C3 Displayed

in LCD Toggle

Between “1” and “0”

While PTT Switch is

Depressed?

YES

Rider/Pas-

senger PTT

Switch OK.

Which PTT

Switch is

Inoperative?

Go to Test 6.17

(Part 2 of 2).

Handheld Micro-

phone PTT Circuit

Go to Test 6.17

(Part 2 of 2).

Replace Microphone

With Unit Known To Be

Good. Does New

Microphone Work?

YES

is OK.

Handheld Microphone

Enter Diagnostic Mode

2. With Microphone Disconnected, Is PTT Input Bit Displayed in

LCD as “0?”

YES

Go to Test 6.17

(Part 2 of 2).

Plug In Handheld

Microphone. Is PTT

Input Bit Displayed in

LCD as “0” While PTT

IS NOT Depressed on

Microphone.

PTT Circuit is

Depress Microphone

PTT Switch. Does

PTT Input Bit Dis-

played in LCD

Change From “1” to

“0” When Button is

YES

Handheld

Microphone

OK.

Depressed?

Replace Microphone

With Unit Known To Be

Good. Does New

Microphone Work?

Rider Rear Passenger Sidecar

Go to Test 6.16

(Part 2 of 2).

Go to Test 6.12

(Part 2 of 3).

After correction of problem, refer to SETUP and

FUNCTIONALITY to verify proper operation.

Go to Test 6.12

(Part 3 of 3).

YES

Handheld Microphone PTT Circuit

is OK.

Go to

Test 6.17

(Part 2 of 2).

Table 6-10. FLHTCU Wire Harness Connectors

NO. DESCRIPTION TYPE LOCATION

[27] Radio 23-Place Amp (Black) Inner Fairing- Back of Radio (Right Side) [28] Radio 23-Place Amp (Gray) Inner Fairing- Back of Radio (Left Side) [53] Console Pod 12-Place Mini-Deutsch (Black) Rear of Battery Box (Under Seat)

2004 Touring: Sound System 6-49

HOME

Test 6.17 (Part 2 of 2)

HANDHELD MICROPHONE PTT INOPERATIVE: HARDWARE DIAGNOSIS

Use Microphone

Known to be Good.

Problem Still Exists?

YES

Place in Diagnostic Mode. What did Test 6.17 (Part 1

of 2) Indicate?

OPEN

Connect Breakout Box to Harness Only.

1 1

Check for Continuity as Follows:

FROM TO

Connector Terminal Connector Terminal

[27B] 2 (BE/Y)

[28B] 2 (Y/BK)

Each Wire Should be Less than 0.5 Ohms. Is It?

Headset DIN

YES

Replace

Radio.

Front

6601

Each Wire Should be Less than 0.5 Ohms. Is It?

Replace

Microphone.

Check for Continuity as Follows:

FROM TO

Connector Terminal Connector Terminal

[27B] 2 (BE/Y) [53B] 6 [28B] 2 (Y/BK) [53B] 7

SHORT

Check for Continuity as Follows:

FROM TO

Connector Terminal

[27B] 2 (BE/Y)

Should Read Inﬁnity. Does It?

YES

Replace

Radio.

Ground

Disconnect Connector [53]. Check

for Continuity as Follows:

6601

FROM TO

Connector Terminal

[27B] 2 (BE/Y)

Should Read Inﬁnity. Does It?

YES

Ground

YES

Replace Pod

Headset

Harness.

6616 6561

After correction of problem, refer to SETUP and

FUNCTIONALITY to verify proper operation.

Y/BK

Repair

Audio

Harness.

BE/Y

Check for Continuity as Follows:

FROM TO

Connector Terminal Connector Terminal

[27B] 2 (BE/Y) [6A] 4 (BE/Y)

Continuity Present?

YES

Replace Pod

Headset

Harness.

6616

Repair

Audio

Harness.

Replace Pod

Headset Harness.

6561

Repair

Audio

Harness.

6616 6560

6-50 2004 Touring: Sound System

HOME

RADIO SYMPTOM 15 6.18

GENERAL

Functionality

Problem

No CB audio in headset in center position.

Setup

● Press the POWER button to turn the radio ON.

● Press and hold the INT button to turn the Intercom OFF.

● Press and hold the CB button to turn the Citizen Band

radio ON.

● Set fairing mounted Headset/Speaker Switch to CEN-

TER position.

● Set Volume Control to Middle position on horizontal bar

graph display.

● Set Squelch Control to receive incoming CB signals.

CB audio should be heard in headset and stereo audio should be heard in fairing speakers. Is it?

● Ye s - System is OK.

● No - See Test 6.18.

DIAGNOSTICS

Diagnostic Notes

The reference number below correlates with the circled number in the Test 6.18 ﬂow chart.

1. If the lamp is missing or the ﬁlament is broken, Speaker B, Speaker A input bits are displayed in LCD as “11” with the Headset/Speaker Switch in the center position. In other words, the system functions as though the switch is in the SPEAKER position.

Test 6.18

NO CB AUDIO IN HEADSET IN CENTER POSITION: SOFTWARE DIAGNOSIS

Enter Diagnostic Mode “d2.”

Set Fairing Mounted Headset/ Speaker Switch to SPEAKER.

Is Red Lamp Illuminated?

YES

Are Speaker B, Speaker

A Input Bits Displayed in

LCD as “11?”

YES

Set Fairing Mounted

Headset/Speaker Switch

to CENTER Position.

Are Speaker B, Speaker A

Input Bits Displayed in

LCD as “01?”

Go to Test 6.6 (Part 2 of 3)

(speakers) or Test 6.11

(Part 2 of 2) (headsets).

(speakers) or Test 6.11

(Part 2 of 2) (headsets).

YES

Set Fairing Mounted

Headset/Speaker Switch

to HEADSET.

Are Speaker B, Speaker A Input Bits Displayed in

LCD as “10?”

YES

Headset/ Speaker Switch and Wiring OK.

Go to Test 6.6 (Part 2 of 3)

(speakers) or Test 6.11

(Part 2 of 2) (headsets).

Go to Test 6.6 (Part 2 of 3)

(speakers) or Test 6.11

(Part 2 of 2) (headsets).

2004 Touring: Sound System 6-51

HOME

NOTES

6-52 2004 Touring: Sound System

Harley Davidson Touring 2004 Service Manual fe06a

Specifications and Main Features

Frequently Asked Questions

User Manual

DIAGNOSTIC INTRODUCTION 6.1

GENERAL

DIAGNOSTIC MODE OVERVIEW 6.2

GENERAL

DIAGNOSTIC MODE GROUP 1

GENERAL

SAMPLE DIAGNOSTIC

DIAGNOSTIC MODE GROUP 2

GENERAL

SAMPLE DIAGNOSTIC

BREAKOUT BOX 6.3

GENERAL

INSTALLATION

REMOVAL

RADIO SYMPTOM 1 6.4

GENERAL

Problem

Setup

Functionality

DIAGNOSTICS

Diagnostic Notes

Test 6.4 (Part 1 of 2)

Test 6.4 (Part 2 of 2)

RADIO SYMPTOM 2 6.5

GENERAL

Problem

Setup

Functionality

DIAGNOSTICS

Diagnostic Notes

Test 6.5 (Part 1 of 4)

Test 6.5 (Part 2 of 4)

Test 6.5 (Part 3 of 4)

Test 6.5 (Part 4 of 4)

RADIO SYMPTOM 3 6.6

GENERAL

Problem

Setup

Functionality

DIAGNOSTICS

Diagnostic Notes

Test 6.6 (Part 1 of 3)

Test 6.6 (Part 2 of 3)

Test 6.6 (Part 3 of 3)

RADIO SYMPTOM 4 6.7

GENERAL

Problem

Setup

Functionality

DIAGNOSTICS

Automatic Volume Control (AVC) Adjustment

Diagnostic Notes

Test 6.7 (Part 1 of 2)

Test 6.7 (Part 2 of 2)

RADIO SYMPTOM 5 6.8

GENERAL

Problem

Setup

Functionality

Test 6.8

DIAGNOSTICS

Radio Antenna Test

RADIO SYMPTOM 6 6.9

GENERAL

Problem

Setup

Functionality

DIAGNOSTICS

Diagnostic Notes

Test 6.9 (Part 1 of 2)

Test 6.9 (Part 2 of 2)

RADIO SYMPTOM 7 6.10

GENERAL

Problem

Setup

Functionality