Page 1
7351
7
HOME
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
Page 2
HOME
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)
Page 3
HOME
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
Page 4
HOME
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.
Page 5
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
Page 6
HOME
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)
Page 7
HOME
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
Page 8
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.
Page 9
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
Page 10
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[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)
Page 11
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f2208y8x
BN/GY
BK
321654987121110
321654987121110
15A
Battery
Fuse
Speedometer
LtGN/V
BN/GY
O
15A
Accessory
Fuse
[39B]
[39A]
15A
Ignition
Fuse
LtGN/V
GY
21
21
GY
BK
321654987121110
321654987121110
[30B]
[30A]
TSM/TSSM
BK
[8B]
[8A]
[91A]
Ignition
Harness
1
2
3
4
Data Link
987
6
54
3
98
7
654
3
121110
121110
LtGN/V
[10B]
[10A]
Ignition Control Module
12
12
Serial data
Figure 4-30. Serial Data Circuit (FLHR/S)
Table 4-21. Wire Harness Connectors in Figure 4-30.
NO.
[8] Ignition Harness 12-Place Deutsch Under Right Side Cover
[10] Ignition Control Module 12-Place Deutsch Under Right Side Cover
[30] Turn Signal/Security Module 12-Place Deutsch
[39] Speedometer 12-Place Packard Under Console (Back of Speedometer)
[91] Data Link 4-Place Deutsch Under Right Side Cover
DESCRIPTION TYPE LOCATION
Cavity in Crossmember at Rear of
Battery Box (Under Seat)
2004 Touring: Engine Management (Carbureted) 4-43
Page 12
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Test 4.15
PASSWORD PROBLEM: DTC P1009, P1010
Which diagnostic trouble
code was set?
1
4
4
DTC P1009.
Bad password.
Reprogram password.
See 3.24 PASSWORD
DTC P1009 still exist?
Replace TSSM and
relearn password.
System OK?
LEARN.
YES
YES
System
OK.
6702
NO
System
OK.
NO
Reinstall original TSSM.
5
Replace ICM.
Reprogram and relearn
password.
6701
6703
Troubleshoot
lowest U-code.
Repair short
to ground.
Repair short
to voltage.
6704
6705
DTC P1010.
No password.
Are there any
U-codes set?
NOYES
Remove ICM connector [10]. Check
for continuity to ground at data
connector [91A] Terminal 3.
Continuity present?
NOYES
Check for battery voltage on Pin 3.
Battery voltage present?
NOYES
Test data connector [91A]
Terminal 3 against Breakout Box Pin
12 for continuity. Continuity present?
2
2
3
YES
Replace TSM/TSSM and relearn
4
Clear codes using speedometer self diagnostics.
See 4.5 SPEEDOMETER SELF DIAGNOSTICS.
Confirm proper operation with no check engine
lamp.
password. System OK?
YES
System
OK.
6707
4-44 2004 Touring: Engine Management (Carbureted)
Inspect terminals
for damage or repair
opens as necessary.
2
Reinstall original TSSM.
4
Replace ICM.
Reprogram and relearn
NO
6706
NO
password.
6708
Page 13
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7863
s0592x8x
A
B
C
Coil tower
DTC P1351, P1352, P1354, P1355 4.16
GENERAL
Ignition Coil
Ignition coil codes will set if the ignition coil primary voltage is
out of range. This could occur if there is an open coil or loss of
power to the coil. If front and rear codes are set simultaneously, it is likely a coil power failure or a coil failure.
The coil receives power from the engine run/stop switch. The
ignition control module is responsible for turning on the coils
by providing the ground to activate the coils, which in turn
powers the coils.
Table 4-22. Code Description
DTC
P1351 Front ignition coil open/low
P1352 Front ignition coil high/shorted
P1354 Rear ignition coil open/low
P1355 Rear ignition coil high/shorted
DESCRIPTION
Figure 4-31. Ignition Coil Circuit Test
DIAGNOSTICS
Diagnostic Notes
The reference numbers below correlate with the circled numbers on the Test 4.16 flow charts.
1. Use HARNESS CONNECTOR TEST KIT (Part No. HD-
41404), gray pin probes and patch cord.
CAUTION
Gently connect test lamp to connector [83B]. Forcefully
inserting test lamp will result in ignition connector terminal damage.
2. See Figure 4-31. Plug IGNITION COIL CIRCUIT TEST
ADAPTER (Part No. HD-44687) and FUEL INJECTOR
TEST LAMP (Part No. HD-34730-2C) into Breakout Box.
Note that cranking the engine with test lamp in place of
the ignition coil can sometimes cause a DTC P1351,
P1352, P1354 or P1355. This condition is normal and
does not by itself indicate a malfunction. Codes must be
cleared if this condition occurs.
3. Connect BREAKOUT BOX (Part No. HD-42682)
between wire harness and ICM. See 4.6 BREAKOUT
BOX: ICM.
Figure 4-32. Ignition Coil Connector Terminals
4. Use HARNESS CONNECTOR TEST KIT (Part No. HD-
41404), gray socket probes and patch cord.
Table 4-23. Coil Terminal Description
TERMINAL
A Rear coil Y/BE
BPowerW/BK
CFront coil BE/O
DESCRIPTION WIRE COLOR
2004 Touring: Engine Management (Carbureted) 4-45
Page 14
HOME
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 4-33. Battery Voltage Circuit
Table 4-24. Wire Harness Connectors in Figure 4-33.
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-
4-46 2004 Touring: Engine Management (Carbureted)
Page 15
HOME
Test 4.16 (Part 1 of 2)
IGNITION COIL: DTC P1351, P1352, P1354, P1355
Disconnect connector [83].
Measure voltage on Terminal B
of coil. Equal to battery voltage
1
after key ON?
YES
Use Breakout Box and test light for the
2
Front coil codes: Check between ICM Pin
3
Rear coil codes: Check between ICM Pin
Does test lamp flash when engine is
YES
4
YES
Measure coil resistance.
Front coil codes: Check between
coil Terminal B and Terminal C.
Rear coil codes: Check between
coil Terminal B and Terminal A.
Resistance 0.5-0.7 ohms?
NO
next inspection.
6 and ICM Pin 1.
7 and ICM Pin 1.
cranked?
connection on W/BK wire.
Replace ICM.
Reprogram and
perform password learn.
NO
Repair open wire or
NO
STOP
Go to Test 4.16
(Part 2 of 2).
Replace coil.
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) 4-47
Page 16
HOME
Test 4.16 (Part 2 of 2)
IGNITION COIL: DTC P1351, P1352, P1354, P1355
Continued from Test 4.16 (Part 1 of 2).
Using Breakout Box, measure resistance between
ICM and coil terminals as follows.
YES NO
Perform 5.8 WIGGLE TEST
to check for intermittents.
Intermittents present?
YES NO
Repair
intermittent.
DTC COIL
P1351/
P1352C(BE/O wire)
1
P1353/
P1354A(Y/BE wire)
3
TERMINAL
Resistance less than 0.5 ohms?
Check for continuity to ground.
Front coil codes: Check
Breakout Box Pin 6.
Rear coil codes: Check
Breakout Box Pin 7.
Continuity present?
BREAK-
OUT BOX
TERMINAL
6
7
Repair open wire
or connection.
YES NO
Repair short
to ground.
YES
Repair short
to voltage.
Check for voltage.
Front coil codes: Check
Breakout Box Pin 6.
Rear coil codes: Check
Breakout Box Pin 7.
Voltage present?
Reprogram and
learn password.
4-48 2004 Touring: Engine Management (Carbureted)
NO
Replace ICM.
Clear codes using speedometer self diagnostics.
See 4.5 SPEEDOMETER SELF DIAGNOSTICS.
Confirm proper operation with no check engine
lamp.
Page 17
HOME
f2256x8x
Crankshaft
Position Sensor
Connector [79]
Under Voltage Regulator
Stator
Connector [46]
DTC P0373, P0374 4.17
GENERAL
Crank Position Sensor
See Figure 4-34. A DTC P0373, P0374 will set if the crankshaft position sensor (CKP) signal is weak or absent.
Table 4-25. Code Description
DTC
P0373 Crankshaft position sensor intermittent
P0374
Crankshaft position sensor not detected or
cannot synchronize
DESCRIPTION
DIAGNOSTICS
Diagnostic Notes
1. Connect BREAKOUT BOX (Part No. HD-42682) to ignition control module wire harness only, leaving ignition
control module disconnected. See 4.6 BREAKOUT BOX:
ICM.
2. One megohm is very high resistance. Some meters will
read infinity, OL, etc.
3. Use HARNESS CONNECTOR TEST KIT (Part No. D-
41404), brown socket probes and patch cords.
4. For testing purposes, install sensor without running wiring along normal path. Disconnect and route wiring properly if system is now OK.
Figure 4-34. Voltage Regulator (Left Side View)
2004 Touring: Engine Management (Carbureted) 4-49
Page 18
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Crankshaft
Position
Sensor
R
BK
f2208w8x
[10B]
[10A]
[79A]
[79B]
BK
Module Ground
12
R
BK
Crank Sensor (-)
Crank Sensor (+)
Ignition Control Module
Figure 4-35. Ignition Circuit
Table 4-26. Wire Harness Connectors in Figure 4-35.
NO.
[10] Ignition Control Module 12-Place Deutsch Under Right Side Cover
[79] Crankshaft Position Sensor 2 - Place Mini-Deutsch Bottom of Voltage Regulator
4-50 2004 Touring: Engine Management (Carbureted)
DESCRIPTION TYPE LOCATION
Page 19
HOME
Test 4.17
CRANK POSITION SENSOR: DTC P0373, P0374
Leaving ICM disconnected, connect Breakout
1
2
Box to harness only. Measure resistance
between Pins 8 and 5, and between Pins 9 and 5
on connector [10]. Is resistance more than 1
megohm?
YES
Check for intermittent connection, pinched
or damaged wires, and loose CKP sensor
fastener. Conditions found?
YES
Repair as
necessary.
YES
With DVOM still connected, check for
intermittents using 4.7 WIGGLE TEST.
Intermittents present?
YES
Repair as
necessary.
codes and retest.
NO
Replace CKP
sensor. Clear
Code P0373,
P0374 set?
NO
Connect DVOM to Terminals 8 and 9 at
connector [10] on Breakout Box.
Set DVOM to AC volts and crank engine.
Does DVOM read 1 VAC minimum
during cranking?
NO
Connect DVOM at Terminals 1
3
and 2 of connector [79A].
DVOM should read 1 VAC
minimum while cranking.
Does it?
YES
Check for continuity between
Pin 8 [10B] and Pin 1 [79B]. Is
continuity present?
4
NO
Disconnect connector [79]. Leaving ICM
disconnected, use Breakout Box to measure
resistance between Pins 8 and 5 on connector
[10]. Also measure resistance between Pins 9
and 5 on connector [10]. Is there still continuity to
ground (less than 1 megohm resistance)?
YES
Repair short to
ground on R or
BK wire between
connectors [10B]
and [79B].
NO
Replace CKP
sensor.
Replace CKP
sensor.
NO
YES
Reinstall CKP
sensor. Replace
ICM. Reprogram
and perform pass-
word learn.
NO
System
OK.
YES
Repair open on BK wire
between Pin 2 [79B] and Pin 9
on connector [10B].
Clear codes using speedometer self diagnostics.
See 4.5 SPEEDOMETER SELF DIAGNOSTICS.
Confirm proper operation with no check engine
lamp.
between Pin 1 [79B] and Pin 8
2004 Touring: Engine Management (Carbureted) 4-51
NO
Repair open on R wire
on connector [10B].
Page 20
HOME
DTC P0501, P0502 4.18
GENERAL
Vehicle Speed Sensor
See Figure 4-36. The vehicle speed sensor is powered and
monitored by the ICM. The ICM processes the vehicle speed
signal and transmits this signal to the TSM/TSSM and speedometer through serial data.
NOTE
When the vehicle speed signal is greater than 0, the closed
loop idle speed control is inhibited.
Table 4-27. Code Description
DTC
P0501 VSS sensor low
P0502 VSS sensor high/open
DESCRIPTION
DIAGNOSTICS
Diagnostic Notes
7951
Speed
Sensor
Engine Oil Fill
Plug/Dipstick
Figure 4-36. Vehicle Speed Sensor Location
f2183x8x
The reference numbers below correlate with the circled numbers on the Test 4.18 flow charts.
1. The speedometer has a built-in diagnostic mode. See
4.5 SPEEDOMETER SELF DIAGNOSTICS.
2. Use HARNESS CONNECTOR TEST KIT (Part No. HD-
41404), black pin probe and patch cord.
3. Connect BREAKOUT BOX (Part No. HD-42682)
between wire harness and ICM. See 4.6 BREAKOUT
BOX: ICM.
4. Jack up motorcycle and rotate rear wheel with transmission in neutral.
1
2
1. Vehicle Speed Sensor Connector [65]
2. P&A Security Siren Connector [142]
Figure 4-37. Electrical Bracket (Inboard Side)
4-52 2004 Touring: Engine Management (Carbureted)
Page 21
HOME
Vehicle Speed
Sensor
R
W
BK
A
B
C
[65A]
A
B
C
[65B]
R/W
W/GN
BK/W
R/W
BK/W
f2208x8x
W/GN
[10B]
[10A]
Ignition
Control
Module
3
10
VSS
5v Power
Sensor Ground
Figure 4-38. Vehicle Speed Sensor Circuit
Table 4-28. Wire Harness Connectors in Figure 4-38.
NO.
[10] Ignition Control Module 12-Place Deutsch Under Right Side Cover
[65] Vehicle Speed Sensor 3 - Place Deutsch Under Right Side Cover (Behind Electrical Bracket)
DESCRIPTION TYPE LOCATION
2004 Touring: Engine Management (Carbureted) 4-53
Page 22
HOME
Test 4.18 (Part 1 of 2)
VEHICLE SPEED SENSOR: DTC P0501, P0502
Remove and inspect vehicle speed sensor. Inspect
for debris and clean if necessary. Place speedometer
into diagnostic mode and clear ICM trouble codes.
Connect all circuits and ride motorcycle for
approximately 1.0 mile (1.6 km). Check for newly
1
logged codes. Codes present?
Check for continuity between socket
2
A of connector [65B] (R/W wire) and
YES
Repair short to ground.
Check for continuity between socket C
YES
YES
ground. Continuity present?
Check for continuity between socket A
2
of connector [65B] (R/W wire) and pin 3
[10] of breakout box. Continuity
3
YES
of connector [65B] (BK wire) and
ground. Continuity present?
NO
present?
NO
NO
System OK.
NO
Repair open on R/W wire
between connectors [10B]
and [65B].
Repair open on BK wire
STOP
Go to. Test 4.18
(Part 2 of 2)
between connector [65B]
4-54 2004 Touring: Engine Management (Carbureted)
and ground.
Clear codes using speedometer self diagnostics.
See 4.5 SPEEDOMETER SELF DIAGNOSTICS.
Confirm proper operation with no check engine
lamp.
Page 23
HOME
Test 4.18 (Part 2 of 2)
VEHICLE SPEED SENSOR: DTC P0501, P0502
YES
Check for voltage on W/GN wire of connector
[65B] while connected. Meter should read 4-6
volts when gear tooth absent and 0-1 volts
4
when gear tooth is present. Does it?
YES NO
Replace ICM. Reprogram
and learn password.
2
3
Replace ICM. Reprogram
and learn password.
Continued from Test 4.18 (Part 1 of 2).
Check for continuity between socket B of connector
[65B] and Pin 10 [10] of breakout box. Continuity
4-6 volts present. 4-6 volts present but no
present?
fluctuation from 0-1 volts
Replace vehicle
speed sensor.
NO
Repair open on W/GN
wire between connectors
[10B] and [65B].
2004 Touring: Engine Management (Carbureted) 4-55
Page 24
HOME
DTC P0602, P0603, P0604, P0605, P0607 4.19
GENERAL
ICM Failure
All of the following codes indicate an internal failure which
requires replacement of the ignition control module. See the
To uring Service Manual for replacement procedures.
DTC P0602 - Calibration memory error
●
●
DTC P0603 - EE PROM failure
●
DTC P0604 - RAM failure
●
DTC P0605 - Program memory error
●
DTC P0607 - A to D converter error
DIAGNOSTICS
DTC P0607 Test
1. Power down the vehicle.
2. Clear codes using speedometer self-diagnostics.
3. Replace ICM if codes reappear.
DTC P0602, P0603, P0604, P0605 Test
1. Power down the vehicle.
2. Clear codes.
3. Using Digital Technician, reprogram ICM using the correct calibration. See your dealer.
4. Restart vehicle. If code reappears, replace ICM. Reprogram and perform password learn.
4-56 2004 Touring: Engine Management (Carbureted)
Page 25
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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 U1064 4.20
GENERAL
Loss of TSM/TSSM Serial Data
The serial data connector provides a means for the ICM and
TSM/TSSM to communicate their current status. When all
operating parameters on the serial data link are within specifications, a state of health message is sent between the components. A DTC U1064 indicates that the TSM/TSSM is not
receiving this state of health message.
Table 4-29. Code Description
DTC
U1064 Loss of TSM/TSSM serial data
DESCRIPTION
DIAGNOSTICS
Diagnostic Notes
The reference numbers below correlate with the circled numbers on the Test 4.20 flow chart.
1. Connect BREAKOUT BOX (Part No. HD-42682) as follows:
a. Mate black socket housing on Breakout Box with
speedometer connector [39] using SPEEDOMETER
HARNESS ADAPTER (Part No. HD-46601).
b. Mate black pin housing on Breakout Box with speed-
ometer harness connector [39B] using SPEEDOMETER HARNESS ADAPTER (Part No. HD-46601).
c. Mate gray socket housing on Breakout Box with
TSM/TSSM connector [30A].
d. Mate gray pin housing on Breakout Box with har-
ness connector [30B].
Figure 4-39. TSM/TSSM
Figure 4-40. Data Link Connector
2004 Touring: Engine Management (Carbureted) 4-57
Page 26
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 4-41. Serial Data Circuit (FLHT/C)
Table 4-30. Wire Harness Connectors in Figure 4-41.
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)
4-58 2004 Touring: Engine Management (Carbureted)
Page 27
HOME
f2208y8x
BN/GY
BK
321654987121110
321654987121110
15A
Battery
Fuse
Speedometer
LtGN/V
BN/GY
O
15A
Accessory
Fuse
[39B]
[39A]
15A
Ignition
Fuse
LtGN/V
GY
21
21
GY
BK
321654987121110
321654987121110
[30B]
[30A]
TSM/TSSM
BK
[8B]
[8A]
[91A]
Ignition
Harness
1
2
3
4
Data Link
987
6
54
3
98
7
654
3
121110
121110
LtGN/V
[10B]
[10A]
Ignition Control Module
12
12
Serial data
Figure 4-42. Serial Data Circuit (FLHR/S)
Table 4-31. Wire Harness Connectors in Figure 4-42.
NO.
[8] Ignition Harness 12-Place Deutsch Under Right Side Cover
[10] Ignition Control Module 12-Place Deutsch Under Right Side Cover
[30] Turn Signal/Security Module 12-Place Deutsch
[39] Speedometer 12-Place Packard Under Console (Back of Speedometer)
[91] Data Link 4-Place Deutsch Under Right Side Cover
DESCRIPTION TYPE LOCATION
Cavity in Crossmember at Rear of
Battery Box (Under Seat)
2004 Touring: Engine Management (Carbureted) 4-59
Page 28
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Test 4.20
LOSS OF TSM/TSSM SERIAL DATA: DTC U1064
Can you read TSM/TSSM hardware P/N?
See 4.5 SPEEDOMETER SELF DIAGNOSTICS.
YES
Install Breakout Box on speedometer.
1
While wiggling harness, check for continuity
between terminal 3 (gray) and terminal 2
(black) of Breakout Box
Continuity present?
YES
Clear trouble codes.
Test Ride. Does U1064
return?
YES NO
Perform password learn
procedure.
NO
Repair intermittent
on LtGN/V wire.
No trouble found.Replace TSM/TSSM.
NO or “No Rsp”
Install Breakout Box on speedometer.
1
Check for continuity between terminal 3
(gray) and terminal 2 (black) of Breakout
YES
Replace TSM/TSSM.
Learn password.
Box
Continuity present?
NO
Repair open on
LtGN/V wire.
Clear codes using speedometer self diagnostics.
See 4.5 SPEEDOMETER SELF DIAGNOSTICS.
Confirm proper operation with no check engine
lamp.
4-60 2004 Touring: Engine Management (Carbureted)
Page 29
HOME
f2191x8x
Ignition Control Module
Connector [10]
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 U1097 4.21
GENERAL
Loss of Speedometer Serial Data
The serial data connector provides a means for the speedometer, ICM and TSM/TSSM to communicate their current status. When all operating parameters on the serial data link are
within specifications, a state of health message is sent
between the components. A DTC U1097 indicates that the
speedometer is not capable of sending this state of health
message.
Table 4-32. Code Description
DTC
U1097
Loss of all speedometer serial data
(state of health)
DESCRIPTION
DIAGNOSTICS
Diagnostic Notes
The reference numbers below correlate with the circled numbers on the 4.21 flow chart.
1. Connect BREAKOUT BOX (Part No. HD-42682)
between wire harness and speedometer using SPEEDOMETER HARNESS ADAPTER (Part No. HD-46601).
See 2.5 BREAKOUT BOX: SPEEDOMETER.
2. Connect BREAKOUT BOX (Part No. HD-42682) (black)
as follows:
a. Mate black socket housing on Breakout Box with
speedometer connector [39A] (at the back of the
speedometer) using INSTRUMENT HARNESS
ADAPTERS (Part No. HD-46601).
b. Mate black pin housing on Breakout Box with wire
harness connector [39B] using INSTRUMENT HARNESS ADAPTERS (Part No. HD-46601).
Figure 4-43. Electrical Bracket (Under Right Side Cover)
Figure 4-44. Data Link Connector
2004 Touring: Engine Management (Carbureted) 4-61
Page 30
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[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 4-45. Serial Data Circuit (FLHT/C)
Table 4-33. Wire Harness Connectors in Figure 4-45.
NO.
[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
DESCRIPTION TYPE LOCATION
Cavity in Crossmember at Rear of
Battery Box (Under Seat)
4-62 2004 Touring: Engine Management (Carbureted)
Page 31
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f2208y8x
BN/GY
BK
321654987121110
321654987121110
15A
Battery
Fuse
Speedometer
LtGN/V
BN/GY
O
15A
Accessory
Fuse
[39B]
[39A]
15A
Ignition
Fuse
LtGN/V
GY
21
21
GY
BK
321654987121110
321654987121110
[30B]
[30A]
TSM/TSSM
BK
[8B]
[8A]
[91A]
Ignition
Harness
1
2
3
4
Data Link
987
6
54
3
98
7
654
3
121110
121110
LtGN/V
[10B]
[10A]
Ignition Control Module
12
12
Serial data
Figure 4-46. Serial Data Circuit (FLHR/S)
Table 4-34. Wire Harness Connectors in Figure 4-46.
NO. DESCRIPTION TYPE LOCATION
[8] Ignition Harness 12-Place Deutsch Under Right Side Cover
[10] Ignition Control Module 12-Place Deutsch Under Right Side Cover
[30] Turn Signal/Security Module 12-Place Deutsch
[39] Speedometer 12-Place Packard Under Console (Back of Speedometer)
[91] Data Link 4-Place Deutsch Under Right Side Cover
Cavity in Crossmember at Rear of
Battery Box (Under Seat)
2004 Touring: Engine Management (Carbureted) 4-63
Page 32
HOME
Test 4.21
LOSS OF SPEEDOMETER SERIAL DATA:
DTC U1097
Can you read ECM/ICM hardware part number?
See 4.5 SPEEDOMETER SELF DIAGNOSTICS.
Install Breakout Box on speedometer.
While wiggling harness, check continuity
1
between terminal 2 (black) of Breakout
Box and terminal 12 of connector [10B].
2
YES
Clear codes. Test ride.
Does DTC U1097
return?
YES
Replace ICM.
Reprogram and learn
password.
YES
Continuity present?
NO
No trouble found.
NO
Repair intermittent
on LtGN/V wire.
NO or “No Rsp”
Install Breakout Box on speedometer. Check conti-
1
nuity between terminal 2 (black) of Breakout Box
and terminal 12 of connector [10B].
2
Replace speedometer.
Clear codes using speedometer self diagnostics.
See 4.5 SPEEDOMETER SELF DIAGNOSTICS.
Confirm proper operation with no check engine
lamp.
Continuity present?
YES
NO
Repair open on
Lt GN/V wire.
4-64 2004 Touring: Engine Management (Carbureted)
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