Harley Davidson Touring 2004 Service Manual fe04b
7351
7
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DTC P0106, P0107, P0108 4.13
GENERAL
MAP Sensor
See Figure 4-24. The manifold absolute pressure sensor
(MAP sensor) is supplied 5 volts from the ignition control
module and sends a signal back to the ignition control module. This signal varies in accordance with engine vacuum and
atmospheric barometric pressure. Changes in barometric
pressure are influenced by weather and altitude.
Table 4-15. Code Description
DTC
P0106 MAP sensor rate-of-change error
P0107 MAP sensor failed open/low
P0108 MAP sensor failed high
DESCRIPTION
DIAGNOSTICS
Diagnostic Tips
DTC P0106 will set if the MAP sensor signal fluctuates
●
faster than normal operation.
With the MAP sensor disconnected, the ignition control
●
module should recognize a low voltage. If low voltage is
observed, the ignition control module and harness are
not at fault.
●
Gently place a jumper wire across MAP Sensor connector [80B] Terminals B and C using HARNESS CONNECTOR TEST KIT (Part No. HD-41404), gray male probes
and patch cord. With the jumper in place, the ignition
control module should recognize a high voltage.
Figure 4-24. MAP Sensor
Diagnostic Notes
The reference numbers below correlate with the circled numbers on the Test 4.13 flow charts.
1. Connect BREAKOUT BOX (Part No. HD-42682)
between wire harness and ignition control module. See
4.6 BREAKOUT BOX: ICM.
2. Use HARNESS CONNECTOR TEST KIT (Part No. HD-
41404), gray pin probes and patch cords.
MAP sensor output check. Using the VACUUM PUMP
●
(Part No. HD-23738A), apply a vacuum to the pressure
port of the MAP sensor. The signal voltage should lower
as the vacuum is applied.
2004 Touring: Engine Management (Carbureted) 4-33
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s0587a8x
To vehicle
speed sensor
(VSS)
Manifold
absolute
pressure
sensor
(MAP)
V/W
BK/W
[80A]
[80B]
R/W
R/W
BK/W
V/W
[10B]
[10A]
Ignition control module
Sensor power
Sensor ground
MAP signal
Figure 4-25. MAP Sensor Circuit
Table 4-16. Wire Harness Connectors in Figure 4-25.
NO.
[10] Ignition Control Module 12-Place Deutsch Under Right Side Cover
[80] Manifold Absolute Pressure Sensor (MAP) 3 - Place Packard Top of Intake Manifold
DESCRIPTION TYPE LOCATION
4-34 2004 Touring: Engine Management (Carbureted)
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Test 4.13 (Part 1 of 2)
MAP SENSOR: DTC P0106, P0107, P0108
1
With ignition ON, measure voltage
between Breakout Box terminal 11 (+)
and terminal 4 (-). With key ON,
engine OFF, voltage must be between
4.2 and 4.95 volts. With key ON,
engine running, voltage must be
between 1.5-3.0 volts at hot idle.
Does voltage fit specifications?
YES
Perform 4.7 WIGGLE TEST
to check for intermittents.
Intermittents present?
YES
To identify the source of inter-
mittents, start with box marked
by Bold Asterisk under Test
4.13 (Part 2 of 2). Wiggle har-
ness while watching DVOM.
YES
Install original MAP sensor.
Replace ignition control module
and road test again to verify.
NO
Replace MAP sensor. See the Touring Service Manual. Clear diagnostic trouble codes.
See 4.5 SPEEDOMETER SELF DIAGNOS-
TICS. Road test. Did check engine lamp illu-
minate and set Code P0106, P0107 or
NO
System
now OK.
NO
STOP
Go to Test 4.13
(Part 2 of 2).
Clear codes using speedometer self diagnostics.
See 4.5 SPEEDOMETER SELF DIAGNOSTICS.
Confirm proper operation with no check engine
lamp.
At some point in the flow chart you
may be instructed to jump directly
to a the box with the bold asterisk.
Disregard the asterisk (but not the
instruction box) if your normal progression through the chart brings
you to this location.
2004 Touring: Engine Management (Carbureted) 4-35
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Test 4.13 (Part 2 of 2)
MAP SENSOR: DTC P0106, P0107, P0108
2
Continued from Test 4.13 (Part 1 of 2).
Check the 5 volt reference supply at
the MAP sensor connector [80B]. With
ignition ON, measure voltage between
terminal C (R/W) and terminal A (BK/W).
Is voltage approximately 5.0 volts?
YES
Connect Breakout Box. Disconnect ignition
1
control module from Breakout Box.
OPEN CHECK: Measure resistance
between MAP connector [80B] Terminal B
2
and Breakout Box connector [10]
terminal 11. Is resistance less than 1 ohm?
YES
SHORT CHECK: Measure
2
resistance between MAP connector Terminal B and chassis
ground. Is resistance greater
than 1 meg ohm?
YES
Replace MAP sensor. See the
Touring Service Manual.
NO.
Greater
than 6V.
Locate short to 12 volts on R/W
wire in wire harness. Repair as
necessary.
NO
Locate and repair
open on V/W wire.
With MAP sensor connector
NO
Locate and repair
grounded V/W wire.
Disconnect ignition control module from
1
Check continuity between MAP connector
2
connector [10] terminal 3. Then measure
continuity between MAP connector [80B]
Te r minal A and Breakout Box connector [10]
YES
[80] disconnected, check
resistance between Break-
out Box terminal 3 and 5
(black). Is it greater than 1
megohm?
YES
NO.
Less
than 4.5V.
Breakout Box.
[80B] Terminal C and Breakout Box
terminal 4.
Continuity present?
NO
Repair
open wire.
NO
Clear codes using speedometer self diagnostics.
See 4.5 SPEEDOMETER SELF DIAGNOSTICS.
Confirm proper operation with no check engine
lamp.
At some point in the flow chart you
may be instructed to jump directly
to a the box with the bold asterisk.
Disregard the asterisk (but not the
instruction box) if your normal progression through the chart brings
you to this location.
4-36 2004 Touring: Engine Management (Carbureted)
Replace ICM.
Reprogram and
learn password.
Locate and repair
short between
R/W wire and
ground.
HOME
DTC P0562, P0563 4.14
GENERAL
Battery Voltage
The ignition control module monitors battery positive voltage.
The normal operating range is between 8-16 volts while
engine is running.
NOTE
When either a diagnostic trouble code P0562 or P0563 is set,
the battery icon in the speedometer will illuminate.
A DTC P0562 is set if the ignition module detects battery
●
positive voltage less than 8 volts while the engine is running.
A DTC P0563 is set if the ignition module detects battery
●
positive voltage greater than 16 volts.
Low voltage generally indicates a loose wire, corroded
●
connections and/or a charging system problem.
●
A high voltage condition may be caused by a faulty voltage regulator.
Table 4-17. Code Description
DTC
P0562 battery voltage low
P0563 battery voltage high
DESCRIPTION
DIAGNOSTICS
Diagnostic Notes
The reference numbers below correlate with the circled numbers on the Test 4.14 flow charts.
1. Was battery allowed to discharge? Was battery drawn
down by a starting problem?
a.
Yes.
Charge battery.
b.
No.
See charging system troubleshooting.
2. Connect BREAKOUT BOX (Part No. HD-42682)
between wire harness and ignition control module. See
4.6 BREAKOUT BOX: ICM.
3. The ignition control module is monitoring voltage at ignition control module connector [10] (black) Pin 1.
4. This checks for voltage drops in the ignition control module circuit.
a. Place (+) probe to battery positive terminal.
b. Place (-) probe to terminal 1 on Breakout Box.
5. Remove Breakout Box at ICM, reconnect ICM. Insert
Breakout Box at connector [22] (BK). On FLHR/S models
(6-place connector), install Breakout Box adapters (HD-
42962).
2004 Touring: Engine Management (Carbureted) 4-37
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R/BK To Ignition Switch
15 Amp
Ignition Fuse
To TSM/TSSM
[22B]
[22A]
Ignition
GY
[1B]
[1A]
GY
Engine Stop Switch
Coil
[83B]
A
B
C
W
\
B
K
56784321 9101112
56784321 9101112
FLHT/C Only
W \ BK
6-Place on FLHR/S
56784321 9101112
Y \BE
BE \ O
[8A]
[8B]
Ground Stud
Ignition Control Module
BK
W \ BK
[10B]
To
Data Link
7
6
5
1
[10A]
Rear Coil
Front Coil
Ground
Key ON Power
Figure 4-26. Battery Voltage Circuit
Table 4-18. Wire Harness Connectors in Figure 4-26.
NO.
[1] Main to Interconnect Harness FLHT/C 12-Place Deutsch Inner Fairing- Right Fairing Bracket
[8] Ignition Harness All 12-Place Deutsch Under Right Side Cover
[10] Ignition Control Module All 12-Place Deutsch (Black) Under Right Side Cover
[22]
[83] Ignition Coil All 3 - Place Packard Below Fuel Tank (Left Side)
DESCRIPTION MODEL TYPE LOCATION
Interconnect to Right
Handlebar Switch Controls
FLHT/C 12-Place Deutsch
Right Fairing Support Brace
FLHR/S 6-Place Deutsch Inside Headlamp Nacelle
Inner Fairing-
4-38 2004 Touring: Engine Management (Carbureted)
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Test 4.14 (Part 1 of 2)
BATTERY VOLTAGE: DTC P0562, P0563
Perform charging system tests.
1
Charging system OK?
YES
With ignition ON, measure voltage drop
between battery positive (+) terminal
and connector [22A] Pin 3 (-). Is voltage
drop greater than 0.5 volt?
YES
2
With ignition ON, measure voltage drop
between battery positive (+) terminal
3
and Breakout Box connector [10] (black)
Pin 1 (-). Is voltage drop greater
4
With ignition ON, measure voltage drop
5
between battery positive (+) terminal
and connector [22A] Pin 4 (-). Is voltage
than 0.5 volt?
YES
drop greater than 0.5 volt?
NO
Repair or replace
W/BK wire or
terminals.
YES
Locate and repair
bad connection.
NO
Repair
charging system.
NO
Check for voltage drop between battery
negative (-) terminal and Pin 5 (+) on
connector [10B] (black) on Breakout Box.
Is voltage drop greater than 0.5 volt?
NO
Problem is intermittent.
Perform 4.7 WIGGLE
TEST.
YES
STOP
Go to Test 4.14
(Part 2 of 2).
NO
Inspect connector [22] for
corrosion or loose wires. If
above conditions are not
present, replace engine stop
switch.
Clear codes using speedometer self diagnostics.
See 4.5 SPEEDOMETER SELF DIAGNOSTICS.
Confirm proper operation with no check engine
lamp.
2004 Touring: Engine Management (Carbureted) 4-39
HOME
Test 4.14 (Part 2 of 2)
BATTERY VOLTAGE: DTC P0562, P0563
Continued from Test 4.14 (Part 1 of 2). With
ignition ON, measure voltage drop between
battery positive (+) terminal and GY terminal
on 15 amp ignition fuse (-). Is voltage
drop greater than 0.5 volt?
YES
With ignition ON, measure voltage drop
between battery positive (+) terminal and
R/BK terminal on 15 amp ignition fuse. Is
voltage drop greater than 0.5 volt?
YES
With ignition ON, measure voltage drop
between battery positive (+) terminal and
terminal A of maxi fuse (-).
Is voltage drop greater than 0.5 volt?
YES
With ignition ON, measure voltage drop
between battery positive (+) terminal and
terminal B of maxi fuse (-).
Is voltage drop greater than 0.5 volt?
NO
Repair or replace GY
wire or terminals.
NO
Replace fuse or
fuse terminals.
NO
Replace ignition
switch or terminals.
High resistance between maxi
fuse and battery. Replace wire or
Clear codes using speedometer self diagnostics.
See 4.5 SPEEDOMETER SELF DIAGNOSTICS.
Confirm proper operation with no check engine
lamp.
4-40 2004 Touring: Engine Management (Carbureted)
YES
terminals.
NO
Replace maxi fuse.
HOME
6924
3
2
1
4
1. Terminal 2: ground (BK)
2. Terminal 3: serial data (Lt GN/V)
3. Terminal 4: power (GY)
4. Protective cap
DTC P1009, P1010 4.15
GENERAL
Password Problem
The ICM and TSM/TSSM exchange passwords during operation. An incorrect password or missing password will set a
diagnostic code.
NOTE
If the TSM/TSSM is not connected to the wiring harness, the
vehicle will not start.
Table 4-19. Code Description
DTC
P1009 Incorrect password
P1010 Missing password
DESCRIPTION
DIAGNOSTICS
Diagnostic Notes
The reference numbers below correlate with the circled numbers on the Test 4.15 flow charts.
1. DTC P1009 may be set if a recent ICM or TSM/TSSM
replacement did not follow the correct password assignment procedure. See 3.24 PASSWORD LEARN for
details.
2. Use HARNESS CONNECTOR TEST KIT (Part No. HD-
41404), black socket probes and patch cord.
3. Connect BREAKOUT BOX (Part No. HD-42682)
between wire harness and ICM. See 4.6 BREAKOUT
BOX: ICM.
4. See the Touring Service Manual for TSM/TSSM replacement. See PASSWORD LEARNING under 3.24 PASS-
WORD LEARN for the password learning procedure.
Figure 4-27. TSM/TSSM
Figure 4-28. Data Link Connector
2004 Touring: Engine Management (Carbureted) 4-41
HOME
[2A]
[2B]
f2208z8x
321654987121110
321654987121110
Speedometer
15A
Accessory
Fuse
321654987121110
321654987121110
Main to Interconnect
Harness
BK
LtGN/V
O
BN/GY
[39B]
[39A]
[108B]
[108A]
321654987121110
321654987121110
Tachometer
[1B] [1A]
123
123
Main to Interconnect
Harness
6
6
101112 78945
101112 78945
[156B] [156A]
6
6
5
5
4
4
3
3
2
2
1
1
BN/GY
Main to Interconnect
Harness
LtGN/V
GY
65
4
32
1
1
15A
Ignition
Fuse
6
5
4
32
GY
987
987
321654987121110
321654987121110
TSM/TSSM
BK
[8B]
121110
121110
[8A]
Ignition
Harness
1
2
3
4
Data Link
[91A]
BK
[30B]
[30A]
LtGN/V
15A
Battery
Fuse
[10B]
[10A]
Ignition Control Module
12
12
Serial data
Figure 4-29. Serial Data Circuit (FLHT/C)
Table 4-20. Wire Harness Connectors in Figure 4-29.
NO. DESCRIPTION TYPE LOCATION
[1] Main to Interconnect Harness 12-Place Deutsch (Black) Inner Fairing - Right Radio Support Bracket
[2] Main to Interconnect Harness 12-Place Deutsch (Gray) Inner Fairing - Right Fairing Support Brace
[8] Ignition Harness 12-Place Deutsch Under Right Side Cover
[10] Ignition Control Module 12-Place Deutsch Under Right Side Cover
[30] Turn Signal/Security Module 12-Place Deutsch
[39] Speedometer 12-Place Packard Inner Fairing (Back of Speedometer)
[91] Data Link 4-Place Deutsch Under Right Side Cover
[108] Tachometer 12-Place Packard Inner Fairing (Back of Tachometer)
[156] Main to Interconnect Harness 6-Place Deutsch Inner Fairing - Right Fairing Support Brace
Cavity in Crossmember at Rear of
Battery Box (Under Seat)
4-42 2004 Touring: Engine Management (Carbureted)
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