Harley Davidson Touring 2008 Electrical Diagnostics Manual

2008 Touring Models Electrical Diagnostics Manual

99497-08

©2007 H-D.

Harley-Davidson motorcycles conform to all applicable U.S.A. Federal Motor Vehicle Safety Standards
and U.S.A. Environmental Protection Agency regulations effective on the date of manufacture.

To maintain the safety, dependability, and emission and noise control performance, it is essential that
the procedures, specifications and service instructions in this manual are followed.

Any substitution, alteration or adjustment of emission system and noise control components outside of
factory specifications may be prohibited by law.

IMPORTANT NOTICE

Harley-Davidson Motor Company

2008 T ouring Models Electrical

Diagnostics Manual

©2007 H-D.

ALL RIGHTS RESERVED

99497-08

Printed in the U.S.A.

VISIT THE HARLEY-DAVIDSON WEB SITE

http://www.harley-davidson.com

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READER COMMENTS

Please comment on the completeness, accuracy, organization, usability, and readability of this manual.

Please list the page, item, and part number(s) of any errors you find in this manual.

Please tell us how we can improve this manual.

Occupation:

Name: Dealership:

Street: Department:

City: State: Zip:

Please clip out and mail to:
Service Communications Department
Harley-Davidson Motor Company
P.O. Box 653
Milwaukee, WI USA 53201

The Harley-Davidson Service Communications Department maintains a continuous effort to improve the quality
and usefulness of its publications. To do this effectively, we need user feedback - your critical evaluation of
this manual.

2008 Touring Models Electrical Diagnostics Manual (99497-08)

NOTES

ABOUT THIS MANUAL

GENERAL

This electrical diagnostic service manual has been prepared
with two purposes in mind. First, it will acquaint the user with
the construction of the Harley-Davidson product and assist in
the performance of repair. Secondly, it will introduce to the
professional Harley-Davidson Technician the latest field-tested
and factory-approved diagnostic methods.We sincerely believe
that this manual will make your association with Harley-Dav­idson products more pleasant and profitable.

HOW TO USE YOUR SERVICE MANUAL

Refer to the table below for the content layout of this manual.

CHAPTERNO.

Starting / Charging1
Instruments2
TSM/HFSM3
Engine Management4
Audio System5
ABS6
Appendix A Connector RepairA
Appendix B WiringB
Appendix C ConversionsC
Appendix D GlossaryD
Appendix E TSM/TSSM (Japan/Korea)E

Use the TABLE OF CONTENTS (which follows this FORE­WORD) and the INDEX (at the back of this manual) to quickly
locate subjects. Sections and topics in this manual are
sequentially numbered for easy navigation.

For example, a cross-reference shown as 2.1 SPECIFICA-
TIONS refers to chapter 2 CHASSIS, heading 2.1 SPECIFIC­ATIONS.

For quick and easy reference, all pages contain a section
number followed by a page number. For example, page 3-5
refers to page 5 in section 3.

A number of acronyms and abbreviations are used in this
document. See the D.1 GLOSSARY for a list of acronyms,
abbreviations and definitions.

PREPARATION FOR SERVICE

NOTES

• To avoid unnecessary disassembly, carefully read all rel­ative service information before repair work is started.

• In figure legends, the number which follows the name of
a part indicates the quantity necessary for one complete
assembly.

• When servicing a vehicle equipped with the Harley-Dav­idson Smart Security System (H-DSSS), you must first
disarm the security system. Either keep the fob in close
proximity to the vehicle, or use Digital Technician to disable
the security system while the vehicle is being serviced and
re-enable the system after service is completed.

SERVICE BULLETINS

In addition to the information presented in this Service Manual,
Harley-Davidson Motor Company will periodically issue Service
Bulletins to Harley-Davidson dealers. Service Bulletins cover
interim engineering changes and supplementary information.
Consult the Service Bulletins to keep your product knowledge
current and complete.

USE GENUINE REPLACEMENT PARTS

Do not use aftermarket parts and custom made front forks
which can adversely affect performance and handling.
Removing or altering factory installed parts can adversely
affect performance and could result in death or serious
injury. (00001a)

To ensure satisfactory and lasting repairs, carefully follow the
Service Manual instructions and use only genuine Harley­Davidson replacement parts. Behind the emblem bearing the
words GENUINE HARLEY-DAVIDSON stand more than 100
years of design, research, manufacturing, testing and inspecting
experience.This is your assurance that the parts you are using
will fit right, operate properly and last longer.

WARNINGS AND CAUTIONS

Statements in this service manual preceded by the following
words are of special significance.

WARNING indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury. (00119a)

FOREWORD

Stop the engine when refueling or servicing the fuel
system. Do not smoke or allow open flame or sparks near
gasoline. Gasoline is extremely flammable and highly
explosive, which could result in death or serious injury.
(00002a)

Good preparation is very important for efficient service work.
A clean work area at the start of each job will allow you to
perform the repair as easily and quickly as possible, and will
reduce the incidence of misplaced tools and parts. A motorcycle
that is excessively dirty should be cleaned before work starts.
Cleaning will occasionally uncover sources of trouble. Tools,
instruments and any parts needed for the job should be
gathered before work is started. Interrupting a job to locate
tools or parts is a distraction and causes needless delay.

CAUTION indicates a potentially hazardous situation
which, if not avoided, may result in minor or moderate
injury. (00139a)

CAUTION used without the safety alert symbol indicates
a potentially hazardous situation which, if not avoided,
may result in property damage. (00140a)

I

NOTE

Refers to important information, and is placed in italic type. It
is recommended that you take special notice of these items.

Proper service and repair is important for the safe, reliable
operation of all mechanical products.The service procedures
recommended and described in this service manual are
effective methods for performing service operations.

information or product returns, warranty or otherwise, visit
www.spx.com.

Loctite Sealing and Threadlocking Pr oducts

Some procedures in this manual call for the use of Loctite
products. If you have any questions regarding Loctite product
usage or retailer/wholesaler locations, please contact Loctite
Corp. at www.loctite.com.

PRODUCT REGISTERED MARKS

Always wear proper ey e protection when using hammer s,
arbor or hydraulic presses, gear pullers, spring com­pressors, slide hammers and similar tools. Flying parts
could result in death or serious injury. (00496b)

Some of these service operations require the use of tools
specially designed for the purpose.These special tools should
be used when and as recommended. It is important to note
that some warnings against the use of specific service methods,
which could damage the motorcycle or render it unsafe, are
stated in this service manual. Howe v er, please remember that
these warnings are not all-inclusive. Inadequate safety precau­tions could result in death or serious injury.

Since Harley-Davidson could not possibly know, evaluate or
advise the service trade of all possible ways in which service
might be performed, or of the possible hazardous con­sequences of each method, we have not undertaken any such
broad evaluation. Accordingly, anyone who uses a service
procedure or tool which is not recommended by Harley-Dav­idson must first thoroughly satisfy himself that neither his nor
the operator's safety will be jeopardized as a result. Failure to
do so could result in death or serious injury.

PRODUCT REFERENCES

Allen, Amp Multilock, Bluetooth, Brembo, Delphi, Deutsch,
Dunlop, Dynojet, Fluke, G.E. Versilube, Gunk, Hydroseal,
Hylomar, Kevlar, Lexan, Loctite, Lubriplate, Keps, K&N, Mag­naflux, Marson Thread-Setter Tool Kit, MAXI fuse, Molex, MPZ,
Mulitilock, Novus, Packard, Pirelli, Permatex, Philips, PJ1,
Pozidriv , Robinair , S100, Sems, Snap-on, Teflon, Threadlocker ,
Torca, Torco, TORX, Tufoil, Tyco, Ultratorch, Velcro, X-Acto,
and XM Satellite Radio are among the trademarks of their
respective owners.

H-D MICHIGAN, INC.TRADEMARK
INFORMATION

Harley, Harley-Davidson, H-D, Bar & Shield, Digital Tech,
Digital Technician, Destroyer, Deuce, Dyna, Electra Glide,
Evolution, F at Boy, Glaze, Gloss, H-D, H-Dnet.com, HD , Harley,
Heritage Softail, Heritage Springer, Low Rider, Night Rod, Night
Train, Profile, Revolution, Road Glide, Road King, Rocker,
Softail, Sportster, Sun Ray, Sunwash, Tech Link, Twin Cam
88, Twin Cam 88B, Twin Cam 96, Twin Cam 96B, Twin Cam
103, Twin Cam 103B, Twin Cam 110, Twin Cam 110B, Tour­Pak, Screamin' Eagle, Softail, Super Guide, Super Premium,
SYN3, Ultra Glide, V-Rod, VRSC, Wide Glide, and Harley­Davidson Genuine Motor Parts and Genuine Motor Accessories
are among the trademarks of H-D Michigan, Inc.

CONTENTS

Read and follow warnings and directions on all products.
Failure to follow warnings and directions can result in
death or serious injury. (00470b)

When reference is made in this manual to a specific brand
name product, tool or instrument, an equivalent product, tool
or instrument may be substituted.

Kent-Moore Products

All tools mentioned in this manual with an "HD", "J" or "B"
preface must be ordered through SPX K ent-Moore. For ordering

All photographs, illustrations and procedures may not neces­sarily depict the most current model or component, but are
based on the latest production information available at the time
of publication.

Since product improvement is our continual goal, Harley-Da v­idson reserves the right to change specifications, equipment
or designs at any time without notice and without incurring
obligation.

II FOREWORD

STARTING / CHARGING

1.1 STARTER TROUBLESHOOTING

General...............................................................................1-1

Starter Troubleshooting......................................................1-1

1.2 STARTING SYSTEM DIAGNOSIS

Diagnostics.........................................................................1-3

Diagnostic Notes.........................................................1-3

Job/Time Code Values................................................1-3

1.3 DIAGNOSTICS/TROUBLESHOOTING

Voltage Drop.....................................................................1-13

1.4 STARTER ACTIVATION CIRCUITS

Starter Activation Circuits.................................................1-14

1.5 TESTING STARTER ON MOTORCYCLE

Start Relay Test................................................................1-15

Starter Current Draw Test.................................................1-15

1.6 TESTING STARTER ON BENCH

Free Running Current Draw Test......................................1-16

Starter Solenoid................................................................1-16

Solenoid Pull-In Test.........................................................1-16

Solenoid Hold-In Test........................................................1-16

Solenoid Return Test........................................................1-17

1.7 CHARGING SYSTEM

General.............................................................................1-18

Alternator...................................................................1-18

Voltage Regulator......................................................1-18

Troubleshooting................................................................1-18

Battery.......................................................................1-18

Wiring........................................................................1-18

Voltage Regulator Inspection....................................1-18

Job/Time Code Values..............................................1-18

Testing..............................................................................1-22

Milliampere Draw Test...............................................1-22

Total Current Draw Test.............................................1-22

Current and Voltage Output Test: Using HD-48053....1-23

Current and Voltage Output Test: Using Load

Tester.........................................................................1-23

Stator Check..............................................................1-24

AC Output Check......................................................1-25

1.8 BATTERY TESTING

General.............................................................................1-26

Voltmeter Test...................................................................1-26

Conductance Test.............................................................1-26

Load Test..........................................................................1-26

INSTRUMENTS

2.1 CHECKING FOR DIAGNOSTIC TROUBLE
CODES

Check Engine Lamp...........................................................2-1

Security Lamp....................................................................2-2

Code Types.........................................................................2-3

Current........................................................................2-3

Historic........................................................................2-3

Retrieving Diagnostic Trouble Codes..................................2-3

Multiple Diagnostic Trouble Codes.....................................2-3

2.2 INITIAL DIAGNOSTIC CHECK:
SPEEDOMETER

General...............................................................................2-4

Diagnostic Notes.........................................................2-4

Circuit Diagram/Wire Harness Connector Table..........2-4

Initial Diagnostics...............................................................2-4

Diagnostic Tips............................................................2-4

Diagnostic Notes.........................................................2-4

Other Diagnostic Trouble Codes..................................2-5

2.3 SPEEDOMETER SELF DIAGNOSTICS

General.............................................................................2-11

Diagnostics.......................................................................2-11

Diagnostic Tips..........................................................2-11

Diagnostic Notes.......................................................2-11

2.4 SPEEDOMETER/TACHOMETER

General.............................................................................2-13

Trip Odometer Reset Switch.....................................2-13

Speedometer Theory of Operation...................................2-13

Odometer Theory of Operation.........................................2-13

Job/Time Code Values..............................................2-13

Tachometer Theory of Operation......................................2-13

Diagnostics.......................................................................2-13

Diagnostic Notes.......................................................2-13

2.5 BREAKOUT BOX:
SPEEDOMETER/TACHOMETER

General.............................................................................2-16

Installation........................................................................2-16

Removal...........................................................................2-16

2.6 FUEL GAUGE

Theory of Operation.........................................................2-17

Fuel Gauge and Sender Test............................................2-17

2.7 OIL, AIR AND VOLTMETER GAUGES

Oil Pressure Gauge and Indicator Light...........................2-18

Problem.....................................................................2-18

Cause 1.....................................................................2-18

Solution 1..................................................................2-18

Cause 2.....................................................................2-18

Solution 2..................................................................2-18

Cause 3.....................................................................2-18

Solution 3..................................................................2-18

Ambient Air Temperature Gauge......................................2-18

Problem.....................................................................2-18

Cause 1.....................................................................2-18

Solution 1..................................................................2-18

Cause 2.....................................................................2-18

Solution 2..................................................................2-18

Cause 3.....................................................................2-18

Solution 3..................................................................2-18

Voltmeter Gauge...............................................................2-18

Problem.....................................................................2-18

Cause........................................................................2-18

Solution.....................................................................2-18

2.8 INDICATOR LIGHTS: ALL

General.............................................................................2-20

Job/Time Code Values..............................................2-21

Diagnostics.......................................................................2-21

2.9 DTC B1004, B1005

General.............................................................................2-24

TABLE OF CONTENTS

III

TABLE OF CONTENTS

Diagnostics.......................................................................2-24

Diagnostic Tips..........................................................2-24

Diagnostic Notes.......................................................2-24

2.10 DTC B1006, B1007

General.............................................................................2-28

Accessory or Ignition Line Overvoltage.....................2-28

2.11 DTC B1008

General.............................................................................2-30

Trip Odometer Reset Switch Closed.........................2-30

Diagnostics.......................................................................2-30

Diagnostic Notes.......................................................2-30

2.12 DTC U1016

General.............................................................................2-32

Loss of ECM Serial Data...........................................2-32

Diagnostics.......................................................................2-32

Diagnostic Notes.......................................................2-32

2.13 DTC U1064, U1255

General.............................................................................2-37

Loss of TSM/TSSM/HFSM Serial Data.....................2-37

Diagnostics.......................................................................2-37

Diagnostic Notes.......................................................2-37

2.14 DTC U1300, U1301 OR BUS ER

General.............................................................................2-42

Serial Data Low or Serial Data Open/High................2-42

Diagnostics.......................................................................2-42

Diagnostic Tips..........................................................2-42

TSM/HFSM

3.1 TURN SIGNAL OVERVIEW

General...............................................................................3-1

Security System: Japan/Korea...........................................3-1

Turn Signal Functions.........................................................3-1

Manual Cancellation...........................................................3-1

Automatic Cancellation.......................................................3-1

Bank Angle Functions........................................................3-1

Bank Angle Restart............................................................3-1

Clutch/Neutral Interlock......................................................3-1

Security System H-DSSS...................................................3-1

3.2 HARLEY-DAVIDSON SMART SECURITY
SYSTEM

Components.......................................................................3-2

Security Immobilization......................................................3-2

HFSM Features..................................................................3-3

3.3 H-DSSS ACTUATION

General...............................................................................3-5

Sidecar Configuration.........................................................3-5

Actuation............................................................................3-5

Fob Assignment..................................................................3-5

Power Disruption and Configuring......................................3-5

3.4 PERSONAL IDENTIFICATION NUMBER
(PIN)

General...............................................................................3-6

Initial Pin Entry...................................................................3-6

Changing the PIN...............................................................3-6

Modifying an Existing Pin............................................3-6

3.5 ARMING/DISARMING SECURITY
SYSTEM

Hands-Free Fob..................................................................3-8

Security Lamp (Key Icon)...................................................3-8

Arming................................................................................3-8

Disarming...........................................................................3-8

Automatic Disarming...................................................3-8

Disarming with a Personal Identification Number

(PIN)............................................................................3-9

3.6 WARNINGS AND ALARMS

Warnings..........................................................................3-10

Alarm................................................................................3-10

Activation...................................................................3-10

Deactivation...............................................................3-10

Siren Chirp Mode (Confirmation)......................................3-10

Chirpless Mode.........................................................3-10

Chirp Mode................................................................3-10

Switching Modes.......................................................3-10

3.7 SERVICE/EMERGENCY FUNCTIONS

Transport Mode................................................................3-11

To Enter Transpor t Mode:..........................................3-11

To Exit Transport Mode: ............................................3-11

Service Mode...................................................................3-11

Four-Way Flashing...........................................................3-11

To Arm the HFSM with the Hazard Warning Flashers

ON.............................................................................3-11

To Disarm the HFSM and Turn the Hazard Warning

Flashers OFF............................................................3-11

3.8 TROUBLESHOOTING

Turn Signals (TSM/HFSM)...............................................3-12

Security System (HFSM)..................................................3-12

Diagnostics Mode.............................................................3-12

Troubleshooting................................................................3-12

3.9 CHECKING FOR DIAGNOSTIC TROUBLE
CODES

General.............................................................................3-13

Security Lamp Diagnostics...............................................3-13

Code Types.......................................................................3-14

Current......................................................................3-14

Historic......................................................................3-15

Retrieving DTCs...............................................................3-15

Multiple DTCs/Priority Order............................................3-15

3.10 INITIAL DIAGNOSTIC CHECK:
TSM/HFSM

General.............................................................................3-17

Diagnostic Notes.......................................................3-17

Circuit Diagram/Wire Harness Connector Table........3-17

Job/Time Codes........................................................3-17

IV TABLE OF CONTENTS

TABLE OF CONTENTS

Reprogramming ECM................................................3-17

Initial Diagnostics.............................................................3-17

Diagnostic Tips..........................................................3-17

Diagnostic Notes.......................................................3-17

Other Diagnostic Trouble Codes (DTCs)...................3-18

3.11 SPEEDOMETER SELF-DIAGNOSTICS

General.............................................................................3-24

Diagnostics.......................................................................3-24

Diagnostic Tips..........................................................3-24

Diagnostic Notes.......................................................3-24

3.12 BREAKOUT BOX:TSM/HFSM

General.............................................................................3-26

Installation........................................................................3-26

Removal...........................................................................3-26

3.13 FAILS TO DISARM (HFSM ONLY)

General.............................................................................3-27

Job/Time Codes...............................................................3-27

Diagnostics.......................................................................3-27

Diagnostic Tips..........................................................3-27

Diagnostic Notes.......................................................3-27

3.14 DTC B0563

General.............................................................................3-30

Diagnostics.......................................................................3-30

Diagnostic Tips..........................................................3-30

Diagnostic Notes.......................................................3-30

3.15 TSM/HFSM:TURN SIGNAL ERRORS
AND DTCS

General.............................................................................3-31

Diagnostics.......................................................................3-32

Job/Time Codes........................................................3-32

Diagnostic Tips..........................................................3-32

Diagnostic Notes: All Tur n Signal Flow Char ts..........3-35

3.20 DTC B1141 (HFSM ONLY)

Diagnostics.......................................................................3-55

DTC B1141 Ignition Switch Open/Low......................3-55

Diagnostic Notes.......................................................3-55

3.21 DTC B1143, B1144, B1145 (HFSM
ONLY)

General.............................................................................3-61

Diagnostics.......................................................................3-61

Diagnostic Notes.......................................................3-61

3.22 DTC B1151, B1152, B1153

General.............................................................................3-66

Sidecar Bank Angle Sensor (BAS)............................3-66

Diagnostics.......................................................................3-66

Diagnostic Tips..........................................................3-66

Diagnostic Notes.......................................................3-66

3.23 DTC B1154, B1155

Diagnostics.......................................................................3-69

Diagnostic Tips..........................................................3-69

Diagnostic Notes.......................................................3-69

3.24 DTC U1016, U1255

General.............................................................................3-75

Diagnostics.......................................................................3-75

Diagnostic Notes.......................................................3-75

3.25 DTC U1300, U1301 OR BUS ER

Diagnostics.......................................................................3-80

Diagnostic Tips..........................................................3-80

Diagnostic Notes.......................................................3-80

3.26 TSM/HFSM: PASSWORD LEARN

General.............................................................................3-81

Password Learning...........................................................3-81

3.16 DTC B1131, B1132 (HFSM ONLY)

General.............................................................................3-47

Diagnostics.......................................................................3-47

Diagnostic Tips..........................................................3-47

Diagnostic Notes.......................................................3-47

3.17 DTC B1134

General.............................................................................3-50

DTC B1134 Starter Output High...............................3-50

Diagnostics.......................................................................3-50

Diagnostic Notes.......................................................3-50

3.18 DTC B1135

Diagnostics.......................................................................3-53

DTC B1135 Accelerometer Fault..............................3-53

3.19 DTC B1136, B1142 (HFSM ONLY)

Diagnostics.......................................................................3-54

DTC B1136 Accelerometer Tip-Over Self-Test

Fault..........................................................................3-54

DTC B1142 Internal Fault..........................................3-54

3.27 HFSM MAINTENANCE

General.............................................................................3-82

Hands-Free Fob................................................................3-82

Schedule...................................................................3-82

Battery Replacement.................................................3-82

Smart Siren (If Installed)...................................................3-82

Schedule...................................................................3-82

Battery Replacement: Early Style Siren....................3-82

Battery Replacement: Late Style Siren.....................3-82

ENGINE MANAGEMENT

4.1 SPECIFICATIONS

Specifications.....................................................................4-1

General........................................................................4-1

4.2 EFI SYSTEM

General...............................................................................4-3

Heat Management System..........................................4-4

Troubleshooting..................................................................4-4

TABLE OF CONTENTS V

TABLE OF CONTENTS

4.3 EFI DIAGNOSTIC INTRODUCTION

System Problems...............................................................4-7

No Start.......................................................................4-7

Poor Performance.......................................................4-7

Check Engine Lamp....................................................4-7

Resolving Problems............................................................4-7

4.4 CHECKING FOR DIAGNOSTIC TROUBLE
CODES: EFI

Check Engine Lamp...........................................................4-8

Code Types.........................................................................4-9

Current........................................................................4-9

Historic........................................................................4-9

Retrieving Diagnostic Trouble Codes..................................4-9

Multiple Diagnostic Trouble Codes.....................................4-9

4.5 INITIAL DIAGNOSTIC CHECK: EFI

General.............................................................................4-11

Diagnostic Notes.......................................................4-11

Circuit Diagram/Wire Harness Connector Table........4-11

Reprogramming ECM................................................4-11

Initial Diagnostics.............................................................4-11

General Information...................................................4-11

Diagnostic Tips..........................................................4-11

Diagnostic Notes.......................................................4-11

Other Diagnostic Trouble Codes (DTCs)...................4-11

4.6 SPEEDOMETER SELF-DIAGNOSTICS

General.............................................................................4-20

Diagnostics.......................................................................4-20

Diagnostic Tips..........................................................4-20

Diagnostic Notes.......................................................4-20

4.7 BREAKOUT BOX: EFI

General.............................................................................4-22

Installation........................................................................4-22

Removal...........................................................................4-22

4.12 STARTS,THEN STALLS

General.............................................................................4-38

Diagnostic Trouble Codes U1300, U1301, or BUS

ER.............................................................................4-38

Diagnostics.......................................................................4-38

Diagnostic Tips..........................................................4-38

Diagnostic Notes.......................................................4-38

4.13 FUEL SYSTEM ELECTRICAL TEST

General.............................................................................4-44

Diagnostics.......................................................................4-44

Diagnostic Notes.......................................................4-44

4.14 SYSTEM RELAY FAULT

General.............................................................................4-52

System Relay............................................................4-52

Diagnostics.......................................................................4-53

Diagnostic Notes.......................................................4-53

4.15 FUEL PRESSURE TEST

General.............................................................................4-61

Testing..............................................................................4-62

Diagnostics.......................................................................4-64

Diagnostic Notes.......................................................4-64

4.16 MISFIRE AT IDLE OR UNDER LOAD

General.............................................................................4-66

Misfire at Idle or Under Load.....................................4-66

Diagnostics.......................................................................4-66

Diagnostic Notes.......................................................4-66

4.17 COMBUSTION ABSENT/INTERMITTENT

General.............................................................................4-72

Diagnostic Trouble Codes P1353, P1356, P1357, P1358:

No Combustion..........................................................4-72

Diagnostics.......................................................................4-72

Diagnostic Notes.......................................................4-72

4.8 WIGGLE TEST

General.............................................................................4-23

Procedure.........................................................................4-23

4.9 INTAKE LEAK TEST

General.............................................................................4-24

Leak Tester.......................................................................4-24

Parts List...................................................................4-24

Tester Assembly........................................................4-24

Intake Leak Testing...........................................................4-24

4.10 ENGINE CRANKS, BUT WILL NOT
START

General.............................................................................4-26

Diagnostics.......................................................................4-26

Diagnostic Notes.......................................................4-26

4.11 NO ECM POWER

General.............................................................................4-33

No Spark/No Check Engine Lamp at IGNITION.......4-33

Diagnostics.......................................................................4-34

Diagnostic Notes.......................................................4-34

VI TABLE OF CONTENTS

4.18 DTC P0107, P0108, P0112, P0113

General.............................................................................4-77

TMAP: MAP Signal....................................................4-77

TMAP: IAT Signal......................................................4-77

Diagnostics.......................................................................4-78

Diagnostic Tips: MAP Portion of TMAP Sensor.........4-78

Diagnostic Tips: IAT Portion of TMAP Sensor...........4-78

Diagnostic Notes: TMAP Sensor...............................4-78

4.19 DTC P0117, P0118

General.............................................................................4-85

ET Sensor.................................................................4-85

Diagnostics.......................................................................4-85

Diagnostic Tips..........................................................4-85

Diagnostic Notes: ET Sensor....................................4-85

4.20 DTC P0120, P0122, P0123, P0220,
P0222, P0223

General.............................................................................4-89

Diagnostics.......................................................................4-89

Diagnostic Tips..........................................................4-89

Diagnostic Notes.......................................................4-89

TABLE OF CONTENTS

4.21 DTC P0131, P0132, P0134, P0151,
P0152, P0154

General.............................................................................4-96

Oxygen Sensor.........................................................4-96

Diagnostics.......................................................................4-96

Diagnostic Tips..........................................................4-96

Diagnostic Notes.......................................................4-96

4.22 DTC P0261, P0262, P0263, P0264

General...........................................................................4-102

Fuel Injectors...........................................................4-102

Diagnostics.....................................................................4-102

Diagnostic Notes.....................................................4-102

4.23 DTC P0373, P0374

General...........................................................................4-108

CKP Sensor............................................................4-108

Diagnostics.....................................................................4-108

Diagnostic Tips........................................................4-108

Diagnostic Notes.....................................................4-108

4.24 DTC P0444, P0445

General...........................................................................4-111

Purge Solenoid (CA and Select Foreign Market Models

Only)........................................................................4-111

Diagnostics.....................................................................4-112

Diagnostic Notes.....................................................4-112

Diagnostic Procedure..............................................4-112

4.25 DTC P0501, P0502

General...........................................................................4-119

Vehicle Speed Sensor (VSS)..................................4-119

Diagnostics.....................................................................4-119

Diagnostic Notes.....................................................4-119

4.26 DTC P0562, P0563

General...........................................................................4-123

Battery Voltage........................................................4-123

Diagnostics.....................................................................4-125

Diagnostic Tips........................................................4-125

Diagnostic Notes.....................................................4-125

4.27 DTC P0572

General...........................................................................4-130

Brake Switch...........................................................4-130

Diagnostics.....................................................................4-130

Diagnostic Tips........................................................4-130

Diagnostic Notes.....................................................4-130

4.28 DTC P0577

General...........................................................................4-136

System Operation...........................................................4-136

Troubleshooting..............................................................4-138

Diagnostics.....................................................................4-138

Diagnostic Tips........................................................4-138

Diagnostic Notes.....................................................4-138

Cruise Inoperative Diagnostics.......................................4-143

Cruise Disengage Causes..............................................4-144

OFF Request...........................................................4-144

DISENGAGE Request.............................................4-144

4.29 DTC P0603, P0605

General...........................................................................4-145

ECM Failure............................................................4-145

Diagnostics.....................................................................4-145

DTC P0603.............................................................4-145

DTC P0605.............................................................4-145

4.30 DTC P0641, P0651

General...........................................................................4-146

Diagnostics.....................................................................4-146

Diagnostic Tips........................................................4-146

Diagnostic Notes.....................................................4-146

4.31 DTC P1009, P1010

General...........................................................................4-152

Password Problem..................................................4-152

Diagnostics.....................................................................4-152

Diagnostic Notes.....................................................4-152

4.32 DTC P1270

General...........................................................................4-158

TGS Validation.........................................................4-158

Diagnostics.....................................................................4-158

Diagnostic Tips........................................................4-158

4.33 DTC P1351, P1352, P1354, P1355

General...........................................................................4-160

Ignition Coil.............................................................4-160

Diagnostics.....................................................................4-160

Diagnostic Notes.....................................................4-160

4.34 DTC P1475, P1477, P1478

General...........................................................................4-165

Active Exhaust Actuator (HDI Models)....................4-165

Diagnostics.....................................................................4-166

Diagnostic Notes.....................................................4-166

4.35 DTC P1501, P1502

General...........................................................................4-172

Jiffy Stand Sensor (HDI and FLHTP)......................4-172

Diagnostics.....................................................................4-172

Diagnostic Notes.....................................................4-172

4.36 DTC P1510, P1511, P1512

General...........................................................................4-177

Throttle Actuation Control Management..................4-177

Diagnostics.....................................................................4-177

Diagnostic Notes.....................................................4-177

Diagnostic Tips........................................................4-177

4.37 DTC P1514

General...........................................................................4-179

Air Flow Fault...........................................................4-179

Diagnostics.....................................................................4-179

Diagnostic Notes.....................................................4-179

4.38 DTC P1600

General...........................................................................4-181

Diagnostics.....................................................................4-181

Diagnostic Tips........................................................4-181

TABLE OF CONTENTS VII

TABLE OF CONTENTS

4.39 DTC P2100, P2101, P2102, P2103

General...........................................................................4-183

Diagnostics.....................................................................4-183

Diagnostic Tips........................................................4-183

Diagnostic Notes.....................................................4-183

4.40 DTC P2105

General...........................................................................4-187

Diagnostics.....................................................................4-187

Diagnostic Notes.....................................................4-187

4.41 DTC P2107

General...........................................................................4-189

Diagnostics.....................................................................4-190

Diagnostic Tips........................................................4-190

Diagnostic Notes.....................................................4-191

4.42 DTC P2119

General...........................................................................4-193

Diagnostics.....................................................................4-193

Diagnostic Notes.....................................................4-193

4.43 DTC P2122, P2123, P2127, P2128

General...........................................................................4-195

Diagnostics.....................................................................4-195

Diagnostic Tips........................................................4-195

Diagnostic Notes.....................................................4-195

4.44 DTC P2135, P2138

General...........................................................................4-199

Diagnostics.....................................................................4-199

Diagnostic Tips........................................................4-199

Diagnostic Notes.....................................................4-199

4.45 DTC P2176

General...........................................................................4-203

Diagnostics.....................................................................4-203

4.46 DTC U1064

General...........................................................................4-205

Loss of TSM/TSSM/HFSM Serial Data...................4-205

Diagnostics.....................................................................4-205

Diagnostic Notes.....................................................4-205

4.47 DTC U1097

General...........................................................................4-210

Loss of Speedometer Serial Data...........................4-210

Diagnostics.....................................................................4-210

Diagnostic Notes.....................................................4-210

AUDIO SYSTEM

5.2 RADIO SWITCH DIAGNOSTICS: DTC
B2006-B2015

General...............................................................................5-6

Diagnostics.........................................................................5-6

Diagnostic Notes.........................................................5-6

5.3 RADIO SPEAKER DIAGNOSTICS: DTC
B2016-B2027

General.............................................................................5-44

Diagnostics.......................................................................5-44

Diagnostic Notes.......................................................5-44

5.4 SERIAL DATA BUS DIAGNOSTICS

General.............................................................................5-61

LOSS OF SERIAL DATA: DTC U1016.......................5-61

STARTS THEN STALLS: DTC U1300, U1301...........5-61

Diagnostic Tips..........................................................5-61

Diagnostics.......................................................................5-61

Diagnostic Notes.......................................................5-61

5.5 ADV ANCED A UDIO SYSTEM SYMPTOMS

General.............................................................................5-82

Factory Defaults...............................................................5-82

Diagnostics.......................................................................5-83

Diagnostic Notes.......................................................5-83

CB Transmitter Inoperative: Symptom 7: SWR Adjustment

(Part 3 of 4)...............................................................5-95

ABS

6.1 ANTILOCK BRAKE SYSTEM (ABS)
GENERAL INFORMATION

Antilock Brake System (ABS) Description..........................6-1

Antilock Brake System (ABS)......................................6-1

Pressure Hold..............................................................6-2

Pressure Decrease......................................................6-2

Pressure Increase.......................................................6-2

Initialization Self-Test...................................................6-2

ABS Indicator..............................................................6-2

Code Types.........................................................................6-3

Current........................................................................6-3

Historic........................................................................6-3

Retrieving Diagnostic Trouble Codes..................................6-3

Multiple Trouble Codes.......................................................6-3

6.2 SPEEDOMETER SELF DIAGNOSTICS

General...............................................................................6-4

Diagnostics.........................................................................6-4

Diagnostic Tips............................................................6-4

Diagnostic Notes.........................................................6-5

5.1 RADIO DIAGNOSTICS

System Description............................................................5-1

Onboard Diagnostics..........................................................5-1

General........................................................................5-1

Radio Diagnostic Display............................................5-1

VIII TABLE OF CONTENTS

6.3 BREAKOUT BOX: ABS

General...............................................................................6-7

Installation..........................................................................6-7

Removal.............................................................................6-7

6.4 INITIAL DIAGNOSTIC CHECK: ABS

General...............................................................................6-8

Diagnostic Notes.........................................................6-8

TABLE OF CONTENTS

Circuit Diagram/Wire Harness Connector Table..........6-8

Job/Time Code Values................................................6-8

Initial Diagnostics...............................................................6-8

Diagnostic Tips............................................................6-8

Diagnostic Notes.........................................................6-8

Other Diagnostic Trouble Codes (DTCs).....................6-9

6.5 ABS INDICATOR DIAGNOSTICS

ABS Indicator Always On or Inoperative...........................6-13

Circuit Description.....................................................6-13

Diagnostic Tips..........................................................6-13

6.6 DTC C0562

DTC C0562: Device Voltage Low......................................6-17

Circuit Description.....................................................6-17

Conditions for Running the DTC...............................6-17

Conditions for Setting the DTC..................................6-17

Action Taken When the DTC Sets.............................6-17

Conditions for Clearing the DTC...............................6-17

Diagnostic Tips..........................................................6-17

Diagnostic Notes.......................................................6-17

6.7 DTC C0563

DTC C0563: Device Voltage High.....................................6-20

Circuit Description.....................................................6-20

Conditions for Running the DTC...............................6-20

Conditions for Setting the DTC..................................6-20

Action Taken When the DTC Sets.............................6-20

Conditions for Clearing the DTC...............................6-20

Diagnostic Tips..........................................................6-20

6.8 DTC C1017

DTC C1017: Pump Motor Power Circuit Open Fault........6-23

Circuit Description.....................................................6-23

Conditions for Running the DTC...............................6-23

Conditions for Setting the DTC..................................6-23

Action Taken When the DTC Sets.............................6-23

Conditions for Clearing the DTC...............................6-23

Diagnostic Tips..........................................................6-24

Diagnostic Notes.......................................................6-24

6.9 DTC C1018

DTC C1018: Pump Motor Ground High Resistance

Fault..................................................................................6-27

Circuit Description.....................................................6-27

Conditions for Running the DTC...............................6-27

Conditions for Setting the DTC..................................6-27

Action Taken When the DTC Sets.............................6-27

Conditions for Clearing the DTC...............................6-27

Diagnostic Tips..........................................................6-28

Diagnostic Notes.......................................................6-28

6.10 DTC C1021, C1023

DTC C1021, C1023:Wheel Speed Sensor Equals Zero (Front

or Rear)............................................................................6-31

Circuit Description.....................................................6-31

Conditions for Running the DTC...............................6-31

Conditions for Setting the DTC..................................6-31

Action Taken When the DTC Sets.............................6-31

Conditions for Clearing the DTC...............................6-31

Diagnostic Tips..........................................................6-31

6.11 DTC C1025, C1027, C1206, C1208

DTC C1025, C1027, C1206, C1208:Wheel Speed Signal

Intermittent or Frequency Out Of Range..........................6-34

Circuit Description.....................................................6-34

Conditions for Running the DTC...............................6-34

Conditions for Setting the DTC..................................6-34

Action Taken When the DTC Sets.............................6-34

Conditions for Clearing the DTC...............................6-34

Diagnostic Tips..........................................................6-34

Diagnostic Notes.......................................................6-34

6.12 DTC C1032, C1034

DTC C1032, C1034:Wheel Speed Sensor Circuit Open Or

Shorted (Front or Rear)....................................................6-37

Circuit Description.....................................................6-37

Conditions for Running the DTC...............................6-37

Conditions for Setting the DTC..................................6-37

Action Taken When the DTC Sets.............................6-37

Conditions for Clearing the DTC...............................6-37

Diagnostic Tips..........................................................6-37

Diagnostic Notes.......................................................6-37

6.13 DTC C1042

DTC C1042: Pump Motor Open.......................................6-43

Circuit Description.....................................................6-43

Conditions for Running the DTC...............................6-43

Conditions for Setting the DTC..................................6-43

Action Taken When the DTC Sets.............................6-43

Conditions for Clearing the DTC...............................6-43

Diagnostic Tips..........................................................6-43

Diagnostic Procedure................................................6-43

6.14 DTC C1043

DTC C1043: Pump Motor Stalled.....................................6-44

Circuit Description.....................................................6-44

Conditions for Running the DTC...............................6-44

Conditions for Setting the DTC..................................6-44

Action Taken When the DTC Sets.............................6-44

Conditions for Clearing the DTC...............................6-44

Diagnostic Tips..........................................................6-44

Diagnostic Procedure................................................6-44

6.15 DTC C1094

DTC C1094: Front Brake Switch Always On.....................6-45

Circuit Description.....................................................6-45

Conditions for Running the DTC...............................6-45

Conditions for Setting the DTC..................................6-45

Action Taken When the DTC Sets.............................6-45

Conditions for Clearing the DTC...............................6-45

Diagnostic Tips..........................................................6-45

Diagnostic Notes.......................................................6-45

6.16 DTC C1095

DTC C1095: Front Brake Switch Open.............................6-49

Circuit Description.....................................................6-49

Conditions for Running the DTC...............................6-49

Conditions for Setting the DTC..................................6-49

Action Taken When the DTC Sets.............................6-49

Conditions for Clearing the DTC...............................6-49

Diagnostic Tips..........................................................6-49

TABLE OF CONTENTS IX

TABLE OF CONTENTS

6.17 DTC C1151

DTC C1151: Front Wheel Release Too Long....................6-53

Circuit Description.....................................................6-53

Conditions for Running the DTC...............................6-53

Conditions for Setting the DTC..................................6-53

Action Taken When the DTC Sets.............................6-53

Conditions for Clearing the DTC...............................6-53

Diagnostic Tips..........................................................6-53

6.18 DTC C1153

DTC C1153: Rear Wheel Release Too Long....................6-56

Circuit Description.....................................................6-56

Conditions for Running the DTC...............................6-56

Conditions for Setting the DTC..................................6-56

Action Taken When the DTC Sets.............................6-56

Conditions for Clearing the DTC...............................6-56

Diagnostic Tips..........................................................6-56

6.19 DTC C1158

DTC C1158: Calibration Programming Required.............6-59

Circuit Description.....................................................6-59

Conditions for Running the DTC...............................6-59

Conditions for Setting the DTC..................................6-59

Action Taken When the DTC Sets.............................6-59

Conditions for Clearing the DTC...............................6-59

Diagnostic Tips..........................................................6-59

6.20 DTC C1212

DTC C1212: Front or Rear Brake Not Applied with

Decel................................................................................6-63

Circuit Description.....................................................6-63

Conditions for Running the DTC...............................6-63

Conditions for Setting the DTC..................................6-63

Action Taken When the DTC Sets.............................6-63

Conditions for Clearing the DTC...............................6-63

Diagnostic Tips..........................................................6-63

Diagnostic Notes.......................................................6-63

6.21 DTC C1214

DTC C1214: Rear Brake Switch Always On.....................6-67

Circuit Description.....................................................6-67

Conditions for Running the DTC...............................6-67

Conditions for Setting the DTC..................................6-67

Action Taken When the DTC Sets.............................6-67

Conditions for Clearing the DTC...............................6-67

Diagnostic Tips..........................................................6-67

6.22 DTC C1216

DTC C1216: Rear Brake Switch Open.............................6-71

Circuit Description.....................................................6-71

Conditions for Running the DTC...............................6-71

Conditions for Setting the DTC..................................6-71

Action Taken When the DTC Sets.............................6-71

Conditions for Clearing the DTC...............................6-71

Diagnostic Tips..........................................................6-71

6.23 DTC C1014, C1055-C1066, C1118,
C1121

DTC C1014, C1055-C1066, C1118, C1121: ECU Internal

Fault..................................................................................6-75

Circuit Description.....................................................6-75

Conditions for Running the DTC...............................6-75

Conditions for Setting the DTC..................................6-75

Action Taken When the DTC Sets.............................6-75

Conditions for Clearing the DTC...............................6-75

Diagnostic Tips..........................................................6-75

Diagnostic Notes.......................................................6-75

6.24 DTC U1300, U1301 OR BUS ER

Diagnostics.......................................................................6-79

Diagnostic Tips..........................................................6-79

Diagnostic Notes.......................................................6-79

APPENDIX A CONNECTOR REPAIR

A.1 AMP 1-PLACE CONNECTORS

AMP 1-Place Connector Repair.........................................A-1

General.......................................................................A-1

Separating Pin and Socket Housings.........................A-1

Mating Pin and Socket Housings................................A-1

Removing Socket Ter minals........................................A-1

Installing Socket Ter minal...........................................A-1

Removing Pin Terminal...............................................A-1

Installing Pin Terminal.................................................A-2

A.2 AMP MULTILOCK CONNECTORS

AMP Multilock Connector Repair.......................................A-3

General.......................................................................A-3

Separating Pin and Socket Housings.........................A-3

Mating Pin and Socket Housings................................A-3

Removing Terminals from Housing.............................A-3

Inserting Terminals into Housing.................................A-4

Preparing Wire Leads for Crimping.............................A-4

Crimping Terminals to Leads......................................A-6

Inspecting Crimped Terminals.....................................A-6

A.3 DELPHI CONNECTORS

Delphi Connector Repair....................................................A-8

General.......................................................................A-8

Separating Pin and Socket Housings.........................A-8

Mating Pin and Socket Housings................................A-8

Removing Socket Ter minals........................................A-8

Installing Socket Terminals..........................................A-8

A.4 DEUTSCH 1-PLACE ELECTRICAL
CONNECTORS

Deutsch 1-Place Connector Repair..................................A-10

Separating Pin and Socket Housings.......................A-10

Mating Pin and Socket Housings..............................A-10

Removing Socket Ter minals......................................A-10

Installing Socket Terminals........................................A-10

A.5 DEUSCH ELECTRICAL CONNECTORS

Deutsch Connector Repair...............................................A-11

General.....................................................................A-11

Separating Pin and Socket Housings.......................A-11

Mating Pin and Socket Housings..............................A-11

Removing Socket Ter minals......................................A-11

Installing Socket Terminals........................................A-11

Removing Pin Terminals...........................................A-13

Installing Pin Terminals.............................................A-13

X TABLE OF CONTENTS

TABLE OF CONTENTS

Crimping Terminals...................................................A-14

A.6 DEUTSCH STANDARD TERMINALS

Deutsch Standard Terminal Crimps.................................A-15

Preparing Wire Leads for Crimping...........................A-15

Crimping Terminal to Lead........................................A-15

Inspecting Crimps.....................................................A-15

A.7 DEUTSCH MINI-TERMINAL CRIMPS

Deutsch Mini Terminal Crimps.........................................A-16

Preparing Wire Leads for Crimping...........................A-16

Crimping a Mini Terminal to Wire Lead.....................A-16

Inspecting Crimps.....................................................A-16

A.8 DEUTSCH SOLID BARREL TERMINALS

Deutsch Solid Barrel Terminal Crimps.............................A-17

Preparing Wire Leads For Crimping.........................A-17

Adjusting Crimper Tool..............................................A-17

Crimping a Barrel Contact To Wire Lead...................A-17

Inspecting Crimps.....................................................A-17

A.9 RELAY AND FUSE BLOCKS

Fuse Block Repair............................................................A-19

Removing Socket Ter minals......................................A-19

Installing Socket Terminals........................................A-19

Crimping Terminals...................................................A-19

A.10 150 METRI-PACK CONNECTORS

150 Metri-Pack Connector Repair....................................A-20

General.....................................................................A-20

Separating Pin and Socket Housings.......................A-20

Mating Pin and Socket Housings..............................A-20

Removing Socket Ter minal.......................................A-20

Inserting Socket Terminal..........................................A-20

A.11 280 METRI-PACK CONNECTORS

280 Metri-Pack Connector Repair....................................A-22

General.....................................................................A-22

Separating Pin and Socket Housings.......................A-22

Mating Pin and Socket Housings..............................A-22

Removing Socket Ter minals......................................A-22

Installing Socket Terminals........................................A-22

Crimping Terminals...................................................A-22

A.12 480 METRI-PACK CONNECTORS

480 Metri-Pack Connector Repair....................................A-24

General.....................................................................A-24

Separating Pin and Socket Housings.......................A-24

Mating Pin and Socket Housings..............................A-24

Removing Socket Ter minals......................................A-24

Installing Socket Terminals........................................A-24

A.14 800 METRI-PACK CONNECTORS

Delphi Maxi-Fuse Housing Repair...................................A-26

General.....................................................................A-26

Removing Maxi-Fuse................................................A-26

Installing Maxi-Fuse..................................................A-26

Removing Socket Ter minals......................................A-26

Installing Socket Terminals........................................A-26

A.15 METRI-PACK TERMINALS

Metri-Pack Ter minal Crimps.............................................A-28

Matching Terminal To Crimper..................................A-28

Preparing Wire Lead.................................................A-28

Crimping Wire Core..................................................A-28

Crimping Insulation/Seal...........................................A-28

Inspecting Crimps.....................................................A-29

A.16 MOLEX CONNECTORS

Molex Connector Repair..................................................A-30

Separating Pin and Socket Housings.......................A-30

Mating Pin and Socket Housings..............................A-30

Removing Terminals.................................................A-30

Installing Terminals...................................................A-30

A.17 PACKARD ECM CONNECTOR

Packard 100W Connector Repair.....................................A-32

General.....................................................................A-32

Separating Socket Housing From ECM....................A-32

Mating Socket Housing To ECM...............................A-32

Removing Socket Ter minal.......................................A-32

Installing Socket Ter minal.........................................A-32

Crimping Terminals...................................................A-32

A.18 PACKARD MICRO-64 CONNECTORS

Packard Micro-64 Connector Repair................................A-34

General.....................................................................A-34

Separating Pin and Socket Housings.......................A-34

Mating Pin and Socket Housings..............................A-34

Removing Terminal...................................................A-34

Installing Terminal.....................................................A-35

Preparing Wire Leads for Crimping...........................A-35

Crimping Terminals...................................................A-35

Inspecting Crimps.....................................................A-35

A.19 SEALED SPLICE CONNECTORS

Sealed Splice Connector Repair......................................A-37

General.....................................................................A-37

Preparing Wire Leads...............................................A-37

Splicing Wire Leads..................................................A-37

Inspecting Seals.......................................................A-37

APPENDIX B WIRING

A.13 630 METRI-PACK CONNECTORS

630 Metri-Pack Connector Repair....................................A-25

General.....................................................................A-25

Separating Pin and Socket Housings.......................A-25

Mating Pin and Socket Housings..............................A-25

Removing Socket Ter minal.......................................A-25

Installing Socket Ter minal.........................................A-25

B.1 CONNECTORS

Connector Locations..........................................................B-1

Function/Location.......................................................B-1

Place and Color..........................................................B-1

Connector Number......................................................B-1

Repair Instructions......................................................B-1

TABLE OF CONTENTS XI

TABLE OF CONTENTS

B.2 WIRING DIAGRAMS

Wiring Diagram Information.............................................B-18

Wire Color Codes......................................................B-18

Wiring Diagram Symbols..........................................B-18

2008 Touring Wiring Diagrams.........................................B-19

APPENDIX C CONVERSIONS

C.1 METRIC CONVERSION

Conversion Table................................................................C-1

C.2 FLUID CONVERSIONS

United States System........................................................C-2

Metric System....................................................................C-2

British Imperial System......................................................C-2

C.3 TORQUE CONVERSIONS

United States System........................................................C-3

Metric System....................................................................C-3

APPENDIX D GLOSSARY

D.1 GLOSSARY

Acronyms and Abbreviations.............................................D-1

APPENDIX E TSM/TSSM
(JAPAN/KOREA)

E.1 TSM/TSSM (JAPAN/KOREA) O VERVIEW

General..............................................................................E-1

TSM............................................................................E-1

TSSM..........................................................................E-1

Troubleshooting..................................................................E-1

E.2 TSM/TSSM FEATURES

General..............................................................................E-3

Turn Signal Functions........................................................E-3

TSM/TSSM Features..................................................E-3

Bank Angle Function..........................................................E-3

Clutch/Neutral Interlock Functions.....................................E-3

TSM/TSSM Features..................................................E-3

Security Alarm and Immobilization Functions....................E-3

TSSM Feature.............................................................E-3

E.3 TSM/TSSM VEHICLE DELIVERY

General..............................................................................E-5

Configuring A TSSM..........................................................E-5

Sidecar Configuration.........................................................E-5

Power Disruption and Configuring.....................................E-5

Key Fob Assignment:TSSM...............................................E-5

Pin Entry: TSSM.................................................................E-6

Changing the Pin:TSSM....................................................E-8

Diagnostics Mode..............................................................E-9

E.5 TSM/TSSM BANK ANGLE FUNCTION

General............................................................................E-10

Operation.........................................................................E-10

E.6 SECURITY SYSTEM FUNCTIONS (TSSM
ONLY)

General............................................................................E-11

Security System Operation.......................................E-11

Security System Options: TSSM...............................E-11

Alarm Sensitivity: TSSM...................................................E-11

Sensitivity..................................................................E-11

Transport Mode.........................................................E-12

Auto-Arming Function:TSSM...........................................E-12

Storage Mode: TSSM.......................................................E-13

E.7 ARMING/DISARMING (TSSM ONLY)

General............................................................................E-14

Security Lamp..................................................................E-14

Using Key FOB:TSSM.....................................................E-14

General.....................................................................E-14

Arming the System...................................................E-14

Disarming the System...............................................E-14

Troubleshooting.........................................................E-14

Using the Pin....................................................................E-14

General.....................................................................E-14

Disarming the System...............................................E-14

E.8 DIAGNOSTIC TROUBLE CODES (DTC)

TSM/TSSM......................................................................E-16

Code Types......................................................................E-17

Current......................................................................E-17

Historic......................................................................E-17

Retrieving Diagnostic Trouble Codes...............................E-17

Multiple Diagnostic Trouble Codes...................................E-18

E.9 INITIAL DIAGNOSTIC CHECK:
TSM/TSSM

General............................................................................E-19

Diagnostic Notes.......................................................E-19

Circuit Diagram/Wire Harness Connector Table.......E-19

Job/Time Code Values..............................................E-19

Reprogramming ECM...............................................E-19

Initial Diagnostics.............................................................E-19

Diagnostic Tips.........................................................E-19

Diagnostic Notes.......................................................E-19

Other Diagnostic Trouble Codes (DTCs)...................E-19

E.10 SPEEDOMETER SELF DIAGNOSTICS

General............................................................................E-26

Diagnostics......................................................................E-26

Diagnostic Tips.........................................................E-26

Diagnostic Notes.......................................................E-26

E.4 TSM/TSSM TURN SIGNAL FUNCTIONS

General..............................................................................E-9

Automatic Cancellation......................................................E-9

Manual Cancellation...........................................................E-9

Four-Way Flashing.............................................................E-9

XII TABLE OF CONTENTS

E.11 BREAKOUT BOX:TSM/TSSM

General............................................................................E-28

Installation........................................................................E-28

Removal...........................................................................E-28

TABLE OF CONTENTS

E.12 FAILS TO DISARM (TSSM ONLY)

General............................................................................E-29

Security Equipped Vehicles Only..............................E-29

Job/Time Code Values..............................................E-29

Diagnostics......................................................................E-29

Diagnostic Tips.........................................................E-29

Diagnostic Notes.......................................................E-29

E.13 TSM/TSSM TURN SIGNAL ERRORS:
B1121, B1122, B1141

General............................................................................E-32

Job/Time Code Values..............................................E-32

Diagnostics......................................................................E-32

Diagnostic Tips: All....................................................E-32

Diagnostic Notes: All Turn Signal Flow Charts..........E-35

E.14 DTC B0563

General............................................................................E-44

Battery Voltage High.................................................E-44

Diagnostics......................................................................E-44

Diagnostic Tips.........................................................E-44

Diagnostic Notes.......................................................E-44

E.15 DTC B1131, B1132

General............................................................................E-45

Alarm Output Low (DTC B1131) or Alarm Output High

(DTC B1132).............................................................E-45

Diagnostics......................................................................E-45

Diagnostic Tips.........................................................E-45

Diagnostic Notes.......................................................E-45

E.16 DTC B1134

General............................................................................E-48

Starter Output High...................................................E-48

Diagnostics......................................................................E-48

Diagnostic Notes.......................................................E-48

Sidecar Bank Angle Sensor (BAS)...........................E-52

Diagnostics......................................................................E-52

Diagnostic Tips.........................................................E-52

Diagnostic Notes.......................................................E-53

E.19 DTC B1154, B1155

General............................................................................E-56

Diagnostic Notes..............................................................E-56

E.20 DTC U1016

General............................................................................E-61

Loss of ECM Serial Data..........................................E-61

Diagnostics......................................................................E-61

Diagnostic Notes.......................................................E-61

E.21 DTC U1300, U1301 OR BUS ER

General............................................................................E-66

Serial Data Low or Serial Data Open/High...............E-66

Diagnostics......................................................................E-66

Diagnostic Tips.........................................................E-66

Diagnostic Notes.......................................................E-66

E.22 TSM/TSSM: PASSWORD LEARN

General............................................................................E-67

Password Learning..........................................................E-67

E.23 TSSM MAINTENANCE

General............................................................................E-69

Key FOB...........................................................................E-69

Schedule...................................................................E-69

Battery Replacement................................................E-69

Siren (If Installed).............................................................E-69

Schedule...................................................................E-69

Battery Replacement: Early Style Siren....................E-69

Battery Replacement: Late Style Siren.....................E-70

REFERENCE MATERIAL

E.17 DTC B1135

General............................................................................E-51

Accelerometer Fault: B1135......................................E-51

E.18 DTC B1151, B1152, B1153

General............................................................................E-52

TOOLS...........................................................I

TORQUE VALUES......................................VII

INDEX..........................................................IX

TABLE OF CONTENTS XIII

NOTES

XIV TABLE OF CONTENTS

TABLE OF CONTENTS

SUBJECT............................................................................................................................PAGE NO.

1.1 STARTER TROUBLESHOOTING..............................................................................................1-1

1.2 STARTING SYSTEM DIAGNOSIS............................................................................................1-3

1.3 DIAGNOSTICS/TROUBLESHOOTING...................................................................................1-13

1.4 STARTER ACTIVATION CIRCUITS.........................................................................................1-14

1.5 TESTING STARTER ON MOTORCYCLE...............................................................................1-15

1.6 TESTING STARTER ON BENCH............................................................................................1-16

1.7 CHARGING SYSTEM.............................................................................................................1-18

1.8 BATTERY TESTING................................................................................................................1-26

STARTING / CHARGING

NOTES

HOME

1.1STARTER TROUBLESHOOTING

GENERAL

The troubleshooting tables contain detailed procedures to solve
and correct problems. Follow 1.2 STARTING SYSTEM DIA-

GNOSIS to diagnose starting system problems.The 1.3 DIA-

Table 1-1. Starter Does Not Run or Runs at Very Low Speeds

PROBLEM

Wiring

negative cable, at either end.

or start relay, especially relay ground wire (grounds
through TSM/TSSM/HFSM).

switch, engine stop
switch or neutral
switch

Poor contact condition caused by burned contact.Solenoid

Brushes worn below specification.Starting motor

windings.

Incorrect oil for low temperature.Temperature

GNOSTICS/TROUBLESHOOTING, Voltage Drop procedure

will help you to locate poor connections or components with
excessive voltage drops.

STARTER TROUBLESHOOTING

SOLUTIONPROBABLE CAUSESOURCE OF

Charge battery.Voltage drop due to discharged battery.Battery
Replace battery.Short-circuited or open between electrodes.
Clean and retighten.Poor contact condition of battery terminal(s).
Repair or replace cable(s).Poor or no connection at either battery positive or

Clean, tighten or replace cable(s) as needed.Cracked or corroded battery cable ends.
Tighten connections or repair or replace wire(s).Open wire(s) or poor connection at handlebar switch

Replace switch.Poor switch contacts or open switch.Start switch, clutch

Replace relay.Open coil winding.Start relay
Replace relay.Poor or no continuity at relay points.
Disarm security system.TSM/TSSM/HFSM has disabled starter relay.
Polish contact surface or replace solenoid

assembly.
Repair or replace solenoid assembly.Pull-in winding open or short-circuited.
Repair or replace solenoid assembly.Hold-in winding open or short-circuited.
Check brush spring tension. Replace field frame

and holder.
Re-face or replace.Commutator burned.
Correct by undercutting.Commutator high mica.
Replace starter.Field winding grounded.
Replace armature.Armature winding grounded or short-circuited.
Replace starter.Free running current draw out of range.
Replace starter.Reduction gears damaged.
Replace starter.Insufficient brush spring tension.
Repair or replace lead wire.Disconnected lead wire between solenoid and field

Replace bearing.Ball bearing sticks.
Use recommended viscosity oil for temperature

range. Consult owner's manual.

2008 Touring Diagnostics: Starting / Charging 1-1

HOME

Table 1-2. Pinion Does Not Engage With Ring Gear While Starter is Cranked or Engine Cannot Be Cranked

SOLUTIONPROBABLE CAUSESOURCE OF PROBLEM

Charge battery.Voltage drop due to discharged battery.Battery
Replace battery.Short-circuited or open between electrodes.
Clean and retighten.Poor contact condition of battery terminal(s).

Overrunning clutch

compression spring).

Poor sliding condition of spline teeth.

Table 1-3. Starter Does Not Stop Running

Replace overrunning clutch.Overrunning clutch malfunction (rollers or

Replace starter clutch sub-assembly.Pinion teeth worn out.
Replace overrunning clutch.Pinion does not run in overrunning direction.
Remove foreign materials, dirt or replace

overrunning clutch or pinion shaft.
Replace overrunning clutch and idler gear.Reduction gears damaged.
Replace clutch shell.Excessively worn teeth.Gear teeth on clutch shell

SOLUTIONPROBABLE CAUSESOURCE OF PROBLEM

Replace start switch or start relay.Unopened contacts.Start switch or start relay
Replace start switch or start relay.Poor return caused by sticky switch or relay contacts.
Replace clutch shell.Excessively worn teeth.Gear teeth on clutch shell
Replace spring.Return spring worn.Solenoid
Replace solenoid.Coil layer shorted.
Replace solenoid.Contact plate melted and stuck.

1-2 2008 Touring Diagnostics: Starting / Charging

HOME

1.2STARTING SYSTEM DIAGNOSIS

DIAGNOSTICS

TOOL NAMEPART NUMBER

HARNESS CONNECTOR TEST KITHD-41404-B
BREAKOUT BOXHD-42682

Diagnostic Notes

Each reference number below correlates to a circled number
on the flow chart(s).

1. See 1.3 DIAGNOSTICS/TROUBLESHOOTING, Voltage

Drop.

2. Remove starter motor. Connect jumper wires as described
in 1.6 TESTING STARTER ON BENCH, Free Running

Current Draw Test.

3. Connect BREAKOUT BOX (Part No. HD-42682) to TSM/
TSSM/HFSM as follows:

a. On models with a TSM/HFSM, see 3.12 BREAK OUT

BOX:TSM/HFSM.

b. On models with a TSSM (Japan/Korea),

E.11 BREAKOUT BOX:TSM/TSSM.

4. Use HARNESS CONNECTOR TEST KIT (Part No. HD­41404-B) purple terminal pin probe and patch cord.

5. See 1.5 TESTING STARTER ON MOT ORCYCLE, Starter

Current Draw Test.

6. See 1.6 TESTING STARTER ON BENCH, Free Running

Current Draw Test.

7. Closely inspect handlebar controls for pinched wiring.

Job/Time Code Values

Dealership technicians filing warranty claims should use the
job/time code values printed in bold text underneath the
appropriate repair.

2008 Touring Diagnostics: Starting / Charging 1-3

1E

GY

GY GY

GN

GY

BK

BK

BK

BK

GN

BK

TN

TN

TN
BK

BK

BK

TN

BN/GY

TN/GN

BK/GN

TN/GN

BN/GY

BK/GN

BK/GN

LGN/V

LGN/V

BK/R

BK/R BK/R

BK/R BK/R

BK/R

W/BK

W/BK W/BK

TSM/

TSSM/

HFSM

[30A] [30B]

[22A] [22B]

Rear

GND2

(Clear)

Front
GND1
(Dirty)

[24A] [24B]

[21A]

[131]

[33B] [33A]

[5B]

[128B]

[128A]

B A

[21B]

[20A]
[20B]

(BK)

Neutral

[GND1A]

Front GND

Stud

(Dirty)

Start
Relay

To ignition

Relay

To instrument fuse

Ignition

Switch

Starting System

Battery

Starter

40A

MAXIFUSE

Red
Band

Neutral
Switch

[78A]

Right Hand
Controls

Engine Stop
Switch

Starter Switch

[78B]

Electronic

Control

Module (ECM)

Battery 1

Ignition

2

Serial data link

3

Neutral switch

4

Start relay control

9

Clutch switch

10

Ground

Serial data link

Engine stop switch

12

69 69

72 72

3 3
4 4

6 6

7 7

2D 2C

Battery - 15A

Ignition - 15A

1F

A

IGNITION SWITCH LEGEND

RED

RED/

GRAY

RED/

BLACK

“X” INDICATESCONTINUITY

BETWEEN LEAD WIRES

IN POSITION INDICATED

SWITCH

POSITION

LOCK X

X
X
X

X X
X

OFF
IGN
ACC

B

[64-2B]

[64-1B]

4H

3H

3G

4G

30
87
86
85

3

A

B

C

I

B

A

5
1
2

8 8

1
2
3
4

9

10
12

Left Hand
Controls

Clutch
Switch

R

R

R

R

R

R/BK

R/BK

R/GY

R/BK

R/GY

O

TN

O

556

6

13131

1

em01116

HOME

1-4 2008 Touring Diagnostics: Starting / Charging

Figure 1-1. Starting Circuit (FLHR/C/S)

1E

GY

GY GY

GY GY

GN

GY

BK

BK

BK

GN

BK

TN

TN

TN

BK

BK

BK

TN

TN

BN/GY

TN/GN

BK/GN

BK/GN BK/GN

TN/GN

BN/GY

BK/GN

BK/GN

LGN/V

LGN/V

BK/R

BK/R BK/R

BK/R

BK/R

BK/R BK/R

BK/R

BK/R

BK/R

W/BK

W/BK W/BK

W/BK W/BK

TSM/

TSSM/

HFSM

[30A] [30B]

[22A] [22B]

(Black)

[1A] [1B]

(Black)

[2A] [2B]

Rear

GND2

(Clean)

Front
GND1
(Dirty)

(Gray)

[24A] [24B]

(Gray)

[21A]

[131]

[33B]

[5B]

[128B]

[128A]

B A

[21B]

(BK)

Neutral

[GND1A]

Front GND

Stud

(Dirty)

Start
Relay

To ignition

relay

Ignition
Switch

Starting System

Battery

Starter

40A

MAXIFUSE

Red
Band

Neutral
Switch

16-way on all except FLHTP
12-way on FLHTP

[78A]

Right Hand
Controls

Engine Stop Switch
Starter Switch

[78B]

Electronic

Control

Module (ECM)

Battery 1
Ignition

2

Serial data link

3

Neutral switch

4

Start relay control

9

Clutch switch

10

Ground

Serial data link

Engine stop switch

12

69 69

72 72

3 3
4 4

6 6

636

3

2

7 7

2D 2C

Battery - 15A

Ignition - 15A

1F

A

IGNITION SWITCH LEGEND

RED

RED/

GRAY

RED/

BLACK

“X” INDICATESCONTINUITY

BETWEEN LEAD WIRES

IN POSITION INDICATED

SWITCH

POSITION

LOCK X

X
X
X

X X
X

OFF
IGN
ACC

B

[64-2B]

[64-1B]

4H

4G

3H

3G

30
87
86
85

3

3

2

1

5
1
2

12 12
13 13

14

14

15 15
16 16

2

11 11

12 12

1
2
3
4

9

10
12

Left Hand
Controls

Clutch
Switch

R

R

R

R

R

R/BK

R/BK

R/GY

R/BK

R/GY

7

7

To instrument fuse

O

6

6

em01117

HOME

Figure 1-2. Starting Circuit (FLHX, FLHT/C/U, FLTR)

2008 Touring Diagnostics: Starting / Charging 1-5

Check Battery using visual inspection,

VoltageTest, and either Conductance Test or

Load Test.

Check connections at Battery and Starter

components.

Is system operational?

Starter Runs On.

Starter

Spins, But

Does Not

Engage.

Starter

Stalls or

Spins Too

Slowly.

Check for audible

clicking noise.

Disconnect solenoid relay terminal

from Solenoid.

Is 12V present on (GN) wire with

Starter Button not pressed?

See Starter Testing 5: Starter
Spins, But Does Not Engage.

See Starter Testing 6: Starter

Stalls or Spins Too Slowly.

Solenoid clicks. See Starter

Testing 2: Solenoid Clicks.

Relay clicks. See

Starter Testing 3: Relay Clicks.

Is 12V present on connector [64-1]

start relay socket terminal “86” with

starter button not pressed?

NOTE:

Depending on relay used relay

socket terminal could be shown as

“1” or “4H”.

Replace

Start Solenoid.

Replace

Starter Button.

Nothing clicks. See Starter Testing

4: Nothing Clicks (Part 1 of 2).

Replace

Start Relay.

5845

5818

5832

YES NOYES YES

YES

YES

NO NO

NO

NO

fc01074_en

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Starter Testing 1

1-6 2008 Touring Diagnostics: Starting / Charging

NO

YES

NO

NOYES

NO

YES

YES

Perform voltage drop test between battery

negative and relay terminal on Solenoid.

Is voltage drop less than 1.0 volt?

Perform voltage drop test from

battery positive to starter motor

terminal. Crank Engine.

Voltagegreater than 1.0 volt?

Pinpoint poor connections or
relay contact problems using

voltage drop test.

Perform voltage drop test

between battery negative and

starter studs or bolts.

Is voltage drop greater than 1.0

volt?

Perform voltage drop test from

battery positive to starter battery

terminal. Crank Engine.

Is voltage drop greater than 1.0 volt?

Repair connection

between Battery and

Starter.

Repair or replace

Solenoid (contacts).

Clean ground

connections.

1

1

1

1

5824

5845

5824

YES

Does Starter Motor

turn if jumped?

5860

Replace

Solenoid.

NO

Replace or repair

Starter Motor.

5817

fc01075_en

5823

1

HOME

Starter Testing 2: Solenoid Clicks

2008 Touring Diagnostics: Starting / Charging 1-7

YES NO

Test for voltage at starter solenoid

terminal connector [128B] (GN).

Is 12V present when Starter Button is

pressed?

YES

YES

YES

NO

NO

NO

Replace Starter

Solenoid.

Replace or repair

Starter Motor.

Test for voltage from Start Relay.

Is 12V present on connector [64-1] relay socket

terminal “87” when Starter Button is pressed?

NOTE:

Depending on relay used relay socket terminal

could be shown as “5” or “4G”.

Replace

Start Relay.

Repair open on (R/BK)

wire feeding connector [64-1]

relay socket terminal “30”.

NOTE:

Depending on relay used

relay socket terminal could

be shown as “3” or “3H”.

Repair open on (GN)

wire between Start Relay

and Starter Solenoid.

Does Starter Motor

turn if jumped?

Test for voltage to Start Relay.

Is 12V present on connector

[64-1] relay socket terminal “30”?

NOTE:

Depending on relay used relay

socket terminal could be shown

as “3” or “3H”.

5860

5817

5832

5827

5827

fc01076_en

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Starter Testing 3: Relay Clicks

1-8 2008 Touring Diagnostics: Starting / Charging

Do turn signals work properly?

YES

Turn the Ignition Switch to

IGNITION. With the Engine Stop

Switch in the RUN position,
depress the start switch while
checking for battery voltage at

start relay terminal “86”.

Is battery voltage present?

NOTE:

Depending on relay used relay

socket terminal could be shown

as “1” or “4H”.

NO

Is TSM/TSSM/HFSM connector

[30] fully mated?

YES NO

Continuity to ground on TSM/

TSSM/HFSM terminal “12”?

Mate connector [30].

YES

Continuity on TSM/TSSM/HFSM

terminal “1” to battery fuse?

Repair open.

NO

YES

Continuity on TSM/TSSM/HFSM

terminal “2” to IGN fuse?

NO

Repair open.

YES

Replace TSM/TSSM/HFSM. Learn

password and perform set-up.

NO

Repair open.

6792

6805

6806

6793

6791

3

YES

Check for continuity to chassis ground at start relay terminal “85”.

Is continuity present?

NOTE:

Depending on relay used relay socket terminal could be shown as

“2” or “3G”.

YES

Substitute good

relay or test relay.

NO

Check for continuity from start relay

terminal “85” to terminal “9” on TSM/

TSSM/HFSM connector [30].

Is continuity present?

NOTE:

Depending on relay used relay

socket terminal could be shown as

“2” or “3G”.

NO

Repair open.

YES

STOP

Go to Starter Testing 4:

Nothing Clicks (Part 2 of 2).

5828

NO

Disconnect connector [22]. Check for continuity

between terminal “4” (W/BK) and terminal “6”

(BK/R) of connector [22A].

Continuity present with start switch pressed?

4

NO

Turn the Ignition Switch to IGNITION.

Check for voltage to start switch, at

connector [22B] terminal “3” (GY).

Battery voltage present?

YES

NOYES

Locate and repair
open in (GY) wire

from connector [22B]

to IGN fuse.

Locate and repair

open in (BK/R) wire

from connector [22B]

to start relay.

5831

5831

Replace

start switch.

5818

7

fc01077_en

HOME

Starter Testing 4: Nothing Clicks (Part 1 of 2)

2008 Touring Diagnostics: Starting / Charging 1-9

Continued from

Starter Testing 4: Nothing Clicks (Part 1 of 2).

Install breakout box HD-42682. Shift transmission to neutral. Measure continuity

to chassis ground at breakout box terminal “4” (Gray) (neutral switch).

Is continuity (less than 10 ohms) present?

YES

Disengage clutch (pull in clutch lever). Measure

continuity to chassis ground at breakout box terminal

“10” (Gray) (clutch switch) with clutch disengaged.

Is continuity present?

NO

YES NO

Locate and repair open on
(TN) wire between neutral

switch and TSM/TSSM/

HFSM.

YES

Turn Ignition Switch to IGNITION. Check for
voltage on breakout box terminal “9” (Gray).

Is voltage present?

YES

Locate and repair

short to voltage on

(TN/GN).

NO

Replace TSM/TSSM/HFSM.

Learn password and

perform set-up.

5157

5862

5830

5838

6

fc01648_en

Disconnect neutral switch connector [131]. Check

for continuity between breakout box terminal “4”

(Gray) and connector [131] terminal “B” (TN).

Is continuity present?

Replace Neutral

Switch.

Check for continuity from

connector [131] terminal “A”

(BK) to chassis ground.

Is continuity present?

Locate and repair open on
(BK) wire between neutral

switch and ground.

5861

YES NO

Locate and repair open on

(BK/R) wire between clutch

switch and TSM/TSSM/

HFSM.

5168

Disconnect left hand controls connector [24]. Check

for continuity between breakout box terminal “10”

(Gray) and connector [24B] terminal “7” (BK/R).

Is continuity present?

Replace Clutch

Switch.

Check for continuity from
connector [24B] terminal “8”
(BK/GN) to chassis ground.

Is continuity present?

Locate and repair open on

(BK/GN) wire between clutch

switch and ground.

NO

YES NO

YES NO

HOME

Starter Testing 4: Nothing Clicks (Part 2 of 2)

1-10 2008 Touring Diagnostics: Starting / Charging

Replace damaged Idler

Gear and Armature.

Remove Starter. Disassemble Drive Housing

Assembly. Inspect for damage to Armature

Gear or Idler Gear.

Damage present?

Starter Clutch failure.

Replace Starter Clutch.

YES NO

5825 5837

fc01079_en

HOME

Starter Testing 5: Starter Spins, But Does Not Engage

2008 Touring Diagnostics: Starting / Charging 1-11

Perform voltage drop test from battery positive to

starter motor terminal. Crank Engine.

Voltagegreater than 1.0 volt?

Perform voltage drop test

between battery negative and

starter studs or bolts.

Is voltage drop greater than 1.0

volt?

Perform voltage drop test

between battery positive to

starter battery terminal.

Crank Engine.

Is voltage drop greater than 1.0

volt?

Perform starter motor current

draw test (on vehicle).

Perform starter motor free running

current draw bench test.

Are test results within range?

Clean Ground

connections.

Replace or repair

Starter Motor.

Repair or replace

Solenoid (contacts).

Repair connection

between Battery and

Starter.

Remove Spark Plugs. While in

5th gear, rotate rear wheel.

Check for Engine, Primary

and/or Crankshaft bind.

YES NO

NO

NO

NOYES

YES

YES

1

1

5

6

5817

Use appropriate code

5835

5845

5824

fc01080_en

HOME

Starter Testing 6: Starter Stalls or Spins Too Slowly

1-12 2008 Touring Diagnostics: Starting / Charging

HOME

1.3DIAGNOSTICS/TROUBLESHOOTING

VOLTAGE DROP

Check the integrity of all wiring, switches, fuses and connectors
between the source and destination.

The voltage drop test measures the difference in potential or
the actual voltage dropped between the source and destination.

1. See ITEM A in Figure 1-3. Attach your red meter lead to
the most positive part of the circuit, which in this case
would be the positive post of the battery (5).

2. See ITEM B in Figure 1-3. Attach the black meter lead to
the final destination or component in the circuit (solenoid
terminal from relay).

3. Activate the starter and observe the meter reading. The
meter will read the voltage dropped or the difference in
potential between the source and destination. An ideal
circuit's voltage drop would be 0 volt or no voltage
dropped, meaning no difference in potential.

4. See ITEM C in Figure 1-3. An open circuit should read 12
volts, displaying all the voltage dropped, and the entire
difference in potential displayed on the meter.

NOTE

Open circuits on the ground side will read zero.

5. Typically, a good circuit will drop less than 1.0 volt. If the
voltage drop is greater , back track through the connections

until the source of the potential difference is found.The
benefits of doing it this way are speed and accuracy.

a. Readings are not as sensitive to real battery voltage.
b. Readings show the actual voltage dropped, not just

the presence of voltage.

c. This tests the system as it is actually being used. It

is more accurate and will display hard to find poor
connections.

d. This approach can be used on lighting circuits, ignition

circuits, etc. Start from most positive and go to most
negative (the destination or component).

6. See ITEM D in Figure 1-3.The negative or ground circuit
can be checked as well.

a. Place the negative lead on the most negative part of

the circuit (or the negative battery post). Remember,
there is nothing more negative than the negative post
of the battery.

b. Place the positive lead to the ground you wish to

check.

c. Activate the circuit. This will allow you to read the

potential difference or voltage dropped on the neg­ative or ground circuit.This technique is very effective
for identifying poor grounds due to powdered paint.
Even the slightest connection may cause an ohm­meter to give a good reading. However, when suffi­cient current is passed through, the resistance caused
by the powdered paint will cause a voltage drop or
potential difference in the ground circuit.

2008 Touring Diagnostics: Starting / Charging 1-13

200A

20A

20A

0.1A

200A

0.1A

200A

20A

20A

0.1A

200A

0.1A

200A

20A

20A

0.1A

200A

0.1A

200A

20A 20A

0.1A

200A

0.1A

ITEM A

ITEM C

OPEN CIRCUIT

ITEM D

GROUND CIRCUIT

ITEM B

IDEAL CLOSED
CIRCUIT

VDC

OV

VDC

VDC

VOV21

4

3

5

6

7

8

1

2

1

2

3

4

8

7

6

5

1

3

4

2

3

4

5

6

7

2

1

8

7

6

5

ed02788

HOME

STARTER ACTIVATION CIRCUITS

1.4STARTER ACTIVATION CIRCUITS

Figure 1-3.Typical Circuitry. Refer to wiring diagrams for more information.

1. Start switch

2. Relay

3. Solenoid

4. Starter

5. Battery

6. MAXIFUSE

7. Ignition switch

8. Ignition fuse

1-14 2008 Touring Diagnostics: Starting / Charging

HD

15A

85

1
2
3

4

1
2
3

4

87

30

86

15A
15A

15A

15A
15A

15A 15A

64-1B

64-2B

15A

30A 30A15A

15A 15A
15A15A 15A

15A

A

B F

B D F H

C E G J

A C E G J

85

87

30

86

85

87

30

86

ed01343

- +

85 (2)

30 (3)

87 (5)

86 (1)

1

2

3

ed01000

1

2

3

ed02864

HOME

1.5TESTING STARTER ON MOTORCYCLE

START RELAY TEST

1. See Figure 1-4. Locate the start relay behind the left side
cover.

2. See Figure 1-5. The start relay can be tested using the
motorcycle's 12 volt battery and a multimeter.

a. Unplug connector from relay.
b. To energize relay, connect the "85"(2) and relay ter-

minal "86"(1) to the positive battery terminal.

c. Check for continuity between the 30 (3) and 87 (5)

terminals. A good relay shows continuity (continuity
tester lamp "on" or a zero ohm reading on the ohm­meter). A malfunctioning rela y will not show continuity
and must be replaced.

3. If start relay is functioning properly, proceed to

1.5 TESTING STARTER ON MOTORCYCLE, Starter
Current Draw Test.

STARTER CURRENT DRAW TEST

NOTES

• Engine temperature should be stable and at room temper­ature.

• Battery should be fully charged.

See Figure 1-6. Check starter current draw with an induction
ammeter before disconnecting battery. Proceed as follows:

1. Verify that transmission is in neutral. Disconnect spark
plug wires from spark plug terminals.

2. Clamp induction ammeter over positive battery cable ne xt
to starter.

3. With ignition switch to IGNITION, turn engine over by
pressing starter switch while reading the ammeter. Dis­regard initial high current reading which is normal when
engine is first turned over.

a. Typical starter current draw will range between 160

to 200 amperes.

b. If starter current draw exceeds 250 amperes, then

the problem may be in the starter or starter drive.
Remove starter for further tests. See 1.6 TESTING

STARTER ON BENCH, Free Running Current Draw
Test.

1. Ohmmeter

2. Battery

3. Start relay
Figure 1-5. Start Relay Test

Figure 1-4. Start Relay

NOTE

A DC current probe may be used if an induction ammeter is
not available.

1. Starter

2. Induction Ammeter

3. Battery
Figure 1-6. Starter Current Draw Test

2008 Touring Diagnostics: Starting / Charging 1-15

2

3

4

5

1

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B

C

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1.6TESTING STARTER ON BENCH

FREE RUNNING CURRENT DRAW TEST

1. Place starter in vise, using a clean shop towel to prevent
scratches or other damage.

2. See Figure 1-7. Attach one heavy jumper cable (6 gauge
minimum).

a. Connect one end to the starter mounting flange (1).
b. Connect the other end to the negative (-) terminal of

a fully charged battery (2).

3. Connect a second heavy jumper cable (6 gauge minimum).
a. Connect one end to the positive (+) terminal of the

battery (2).

b. Connect the other end to the battery terminal (4) on

the starter solenoid. Place an inductive ammeter (3)
over cable.

4. Connect a smaller jumper cable (14 gauge minimum).
a. Connect one end to the positive (+) terminal of the

battery (2).

b. Connect the other end to the solenoid relay terminal

(5).

5. Check ammeter reading.
a. Ammeter should show 90 amps maximum.

b. If reading is higher, disassemble starter for inspection.

See the Service Manual.

c. If starter current draw on vehicle was over 200 amps

and this test was within specification, there may be a
problem with engine or primary drive.

STARTER SOLENOID

Do not disassemble solenoid. Before testing, disconnect field
wire from motor terminal as shown in Figure 1-8.

Each test should be performed for only 3-5 seconds to prev ent
damage to solenoid.

The solenoid Pull-in, Hold-in, and Return tests must be per­formed together in one continuous operation. Conduct all three
tests one after the other in the sequence given without interrup­tion.

SOLENOID PULL-IN TEST

1. See Figure 1-8. Using a 12 volt battery, connect three
separate test leads as follows:

a. Solenoid housing to negative battery post.
b. Solenoid motor terminal to negative battery post.
c. Solenoid relay terminal to positive battery post.

2. Observe starter shaft.
a. If starter shaft extends strongly, solenoid is working

properly.

b. If starter shaft does not extend strongly, replace the

solenoid.

1. Mounting flange

2. Battery

3. Induction ammeter

4. Battery terminal

5. Relay terminal
Figure 1-7. Free Running Current Draw Test

1-16 2008 Touring Diagnostics: Starting / Charging

1. Motor terminal

2. Relay terminal

3. Battery
Figure 1-8. Pull-In Test

SOLENOID HOLD-IN TEST

1. See Figure 1-9. With test leads still connected in the
manner specified in the previous 1.6 TESTING STARTER

ON BENCH, Solenoid Pull-In Test, disconnect solenoid

motor terminal/battery negative test lead at negative bat­tery post only; reconnect loose end of this test lead to
positive battery post instead.

1

3

2

A

B

C

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2. Observe starter shaft.
a. If starter shaft remains extended, solenoid is working

properly.

b. If starter shaft retracts, replace the solenoid.

1. Motor terminal

2. Relay terminal

3. Battery
Figure 1-9. Hold-In Test

SOLENOID RETURN TEST

ST AR TER ON BENCH, Solenoid Hold-In Test, disconnect

solenoid relay terminal/positive battery post test lead at
either end.

2. Observe starter pinion.
a. If starter shaft retracts, solenoid is working properly.

b. If starter shaft does not retract, replace the solenoid.

1. Motor terminal

2. Relay terminal

3. Battery
Figure 1-10. Return Test

1. See Figure 1-10. With test leads still connected in the
manner specified at the end of the previous 1.6 TESTING

2008 Touring Diagnostics: Starting / Charging 1-17

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1.7CHARGING SYSTEM

GENERAL

The charging system consists of the alternator and voltage
regulator. Charging system circuits are shown in Figure 1-12.

Alternator

The alternator consists of two main components:

• The rotor which mounts to the engine sprocket shaft.

• The stator which bolts to the engine crankcase.

Voltage Regulator

See Figure 1-11. The voltage regulator is a series regulator.
The circuit combines the functions of rectifying and regulating.

1. Stator (AC) Connector [47A]

2. Voltage Regulator (DC) Connector [77A]

Figure 1-11.Voltage Regulator (Bottom View) AC and DC

Connectors

TROUBLESHOOTING

TOOL NAMEPART NUMBER

HD-48053

When the charging system fails to charge or does not charge
at a satisfactory rate, make the f ollowing recommended checks.

ADVANCED BATTERY CONDUCT­ANCE AND ELECTRICAL SYSTEM
ANALYZER

Battery

Check for a weak or dead battery . See 1.8 BATTERY TESTING
for battery testing procedures. Battery must be fully charged
in order to perform a load test, or starting or charging tests.
However, a partially discharged battery may be tested using
the BATTERY TEST function of the ADVANCED BATTERY
CONDUCTANCE AND ELECTRICAL SYSTEM ANA­LYZER (Part No. HD-48053).

Wiring

The stator and battery plug and socket connections must be
clean and tight.

See Figure 1-12. Check for corroded or loose connections in
the charging circuit.

Voltage Regulator Inspection

The voltage regulator must have a clean, tight connection for
proper operation. Check by using an ohmmeter with one lead
on chassis ground, such as battery ground cable, and the other
on the voltage regulator ground lead.

Job/Time Code Values

Dealership technicians filing warranty claims should use the
job/time code values printed in bold text underneath the
appropriate repair.

1-18 2008 Touring Diagnostics: Starting / Charging

[47A] [47B]

Stator

40 A

MAXIFUSE

Starter

Battery

Red

Band

Powertrain

Grounds

Front

Dirty GND

[77B] [77A]

1

2

DC AC

B A

+

-

BK

BK

BK

BK

BK BK

BK

R

R

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Figure 1-12. Charging System Circuit (Typical)

2008 Touring Diagnostics: Starting / Charging 1-19

Test Battery.

Charge or replace as required.

Inspect Voltage Regulator.

See Voltage Regulator Inspection.

Perform MILLIAMPERE DRAW

TEST.

Correct as

required.

Isolate damaged

component or wiring.

Perform TOTAL CURRENT

DRAW TEST.

Record measurement.

Isolate damaged wiring or

excessive accessories.

PASS FAIL

STOP

PASS

PASS

NO

FAIL

5306

5308

5310

Go to Charging

System (Part 2 of 2).

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Disconnect Regulator.

Does milliamp draw drop?

YES

Replace grounded

Stator.

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Charging System Test (Part 1 of 2)

1-20 2008 Touring Diagnostics: Starting / Charging

PASS FAIL

FAIL

FAIL

FAIL

NO

FAIL

YES

PASS

PASS PASS

PASS

From Charging System (Part 1 of 2).

Perform CURRENT and VOLTAGEOUTPUT TEST.

Record measurement and compare with TOTAL CURRENT

DRAW TEST before proceeding.

System tests good up to this point. Suspect:
Accessories on for long periods when vehicle is

parked and not running.
Accessories on when vehicle is ridden very slowly

for long periods.
Battery self-discharge and/or accessory draw

because vehicle was not operated for a long
period.

Is voltage less than 15.0V?

Perform

STATOR CHECK.

Perform

AC OUTPUT CHECK.

Replace

Stator.

Replace Voltage Regulator.

Perform CURRENT and

VOLTAGE OUTPUT TEST.

Inspect Rotor.

Replace Voltage

Regulator.

System OK. Damaged Rotor. Replace Stator.

Replace

Rotor.

5316

5312

5319

5319

5314

5315

NOTE:
Whenever a charging system component fails a test and
is replaced, retest the system to be sure the problem has
been corrected.

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Charging System Test (Part 2 of 2)

2008 Touring Diagnostics: Starting / Charging 1-21

BK

BK

[GND2]

[77A]

[77B]

[5B]

[47A]

1 2 3

-

+

- +

A B

R

R

R

1

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TESTING

TOOL NAMEPART NUMBER

HARNESS CONNECTOR TEST KITHD-41404-B

HD-48053

ADVANCED BATTERY CONDUCT­ANCE AND ELECTRICAL SYSTEM
ANALYZER

Milliampere Draw Test

NOTES

• Be sure accessories are not wired so they stay on at all
times. This condition could drain battery completely if
vehicle is parked for a long time. Check for this by con­necting ammeter between negative battery terminal and
battery.

• TSM/TSSM/HFSM will continue to draw 16-25 mA for 30
seconds after ignition is turned OFF. Any disruption and
reconnection of battery power, such as disconnecting the
battery to place a meter in series, will cause TSM/TSSM/
HFSM to draw 16-25 mA for 30 seconds.

Disconnect siren during milliamperes draw test. (Siren may
draw up to 20 mA.)

1. Remove left side cover. Remove MAXIFUSE.

2. See Figure 1-13. Using HARNESS CONNECTOR TEST
KIT (Part No. HD-41404-B) red male socket probes and
patch cords, connect ammeter to MAXIFUSE socket ter­minals. With this arrangement, you will also pick up any
regulator drain.

3. With ignition switch turned to OFF and all lights and
accessories off, observe current reading.

a. Refer to Table 1-4. Add regulator draw ammeter

reading to appropriate value for TSM/TSSM/HFSM/
ECM. If observed ammeter reading is less than listed
in table, draw is within limits.

b. A higher reading indicates excessive current draw.

Any accessories must be considered and checked
for excessive drain.

NOTE

A battery with a surface discharge condition could suffer a
static drain. Correct by cleaning battery case.

1-22 2008 Touring Diagnostics: Starting / Charging

1. Ammeter

2. MAXIFUSE socket

3. Voltage regulator

Figure 1-13. Milliampere Draw Test (Ignition Turned to

OFF)

Table 1-4. Milliampere Draw Test

ITEM

MAXIMUM DRAW

IN MILLIAMPERES

1.0ECM

1.0Speedometer

1.0Tachometer

1.0TSM (no security)

3.0TSSM (armed)

3.0TSSM (disarmed)

1.0TSSM (storage mode)

1.0HFSM

20.0*Security Siren (optional)

2.0Voltage Regulator

2.0Radio

1.0High Output Amplifier

1.0CB Module

1.0XM Module

* Siren will draw for 2-24 hours from time motorcycle battery
is connected and 0.05 milliamperes once siren battery is
charged. Disconnect siren during milliampere draw test.

Total Current Draw Test

If battery runs down during use, the current draw of the
motorcycle components and accessories may exceed output
of the charging system.

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NOTE

If a load tester is unavailable, an ammeter with current probe
may be used.

Turn battery load tester OFF before connecting tester
cables to battery terminals. Connecting tester cables with
load tester ON can cause a spark and battery explosion,
which could result in death or serious injury. (00252a)

1. See Figure 1-14. To check for this condition, place load
tester induction pickup or current probe pickup ov er battery
negative cable.

2. Disconnect stator plug from voltage regulator. Start the
motorcycle and run the engine at 2000 RPM.

3. With ignition and all continuously running lights and
accessories turned on (headlamp on high beam), read the
total current draw.

4. Compare this reading to the reading obtained after per­forming the CURRENT AND VOLTAGE OUTPUT TEST.

a. The current output should exceed current draw by

3.5 amps minimum.

b. If output does not meet specifications, there may be

too many accessories for the charging system to
handle.

5. Reconnect voltage regulator after testing.

Follow the instructions in the analyzer's instruction manual to
perform a Charging System Test.

See Figure 1-15.The test results will include a decision on the
charging system's condition and the measured system voltage
at idle and at 3000 RPM. The analyzer's printer will provide
you with a printout including one of two possible test results:

1. CHARGING SYSTEM NORMAL - No problem found.

2. CHARGING SYSTEM PROBLEM - The analyz er detected
a problem and will display one of the three following res­ults:

a. LOW CHARGING VOLTS - The alternator is not

supplying sufficient current for the system's electrical
loads.

b. HIGH CHARGING VOLTS - The voltage output from

the alternator exceeds the normal regulator limits.

c. INVESTIGATE VOLT OUTPUT - The rev voltage is

lower than the idle voltage.

Current and Voltage Output Test: Using
Load Tester

1. See Figure 1-14. Connect load tester.
a. Connect negative and positive leads to battery ter-

minals.

b. Place load tester induction pickup over positiv e regu-

lator cable.

2. Run the engine at 3000 RPM. Increase the load as
required to obtain a constant 13.0VDC. Do not leave any
load switch turned on for more than 20 seconds or over­heating and tester damage are possible.

3. The current output should be 35-50 amps. Make note of
measurement for use in TOTAL CURRENT DRAW TEST.

NOTE

Rider's habits may require output test at lower RPM.

4. See Figure 1-14. After removing the load, read the load
tester voltage meter.

a. If voltage to the battery is not more than 15V, voltage

output is within specifications. Investigate other pos­sible problems. See Charging System Test.

b. If voltage is higher , voltage regulator is not functioning

properly.

Figure 1-14. Check Durrent Draw (Ignition Switch On)

Current and Voltage Output Test: Using
HD-48053

Connect ADVANCED BATTERY CONDUCTANCE AND
ELECTRICAL SYSTEM ANALYZER (Part No. HD-48053) to
the vehicle's battery.

2008 Touring Diagnostics: Starting / Charging 1-23

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Figure 1-15. Charging System Test Results Printout

Stator Check

1. Turn ignition switch OFF.

2. See Figure 1-16. Connect an ohmmeter.
a. Disconnect voltage regulator connector from alternator

stator wiring.

b. Insert one ohmmeter lead into a stator connector

socket.

c. Attach the other lead to a suitable ground.

Figure 1-16.Test for Grounded Stator (Typical)

3. Test for continuity with ohmmeter set to the ohms scale.
a. A good stator will show no continuity (open circuit)

between any stator sockets and ground.

b. Any other reading indicates a grounded stator which

must be replaced.

4. See Figure 1-17. Remo ve ground lead. Check resistance
across stator sockets 1-2, 2-3 and 3-1.

5. Test for resistance with ohmmeter set on the ohms scale .
a. Resistance across all the stator sockets should be

0.1-0.2 ohms.

b. If the resistance is higher, the stator is damaged and

must be replaced.

c. If the resistance is lower, it could indicate turn to turn

short.

NOTE
Verify that meter reads 0 ohms when probes are shorted
together. If not, subtract lowest value to resistance value of
stator.

Figure 1-17. Check for Stator Resistance (Typical)

1-24 2008 Touring Diagnostics: Starting / Charging

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AC Output Check

1. See Figure 1-18.Test AC output.
a. Disconnect voltage regulator connector from alternator

stator wiring.

b. Connect an AC voltmeter across stator connector

sockets 1-2.

c. Run the engine at 2000 RPM. The AC output should

be 32-46 volts AC (approximately 16-23 per 1000
RPM).

d. Repeat test across stator sockets 2-3 and 3-1.

2. Compare test results to specifications.
a. If the output is below specifications, charging problem

could be a faulty rotor or stator.

b. If output is within spec, charging problem might be

faulty regulator. Replace as required.

3. Check the output again as previously described under
Current and Voltage Output Test.

Figure 1-18. Check Stator AC Voltage Output (Typical)

2008 Touring Diagnostics: Starting / Charging 1-25

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1.8BATTERY TESTING

GENERAL

Three different procedures may be performed to provide a
good indicator of battery condition: a voltage test, a conduct­ance test, or a load test.

A battery may be tested, whether fully charged or not, via
conductance test. In order to perf orm a load test, howe ver, the
battery must be fully charged.

VOLTMETER TEST

The voltmeter test provides a general indicator of battery state
of charge or condition. Chec k the voltage of the battery to verify
that it is in a 100% fully charged condition. Refer to Table 1-5.

If the open circuit (disconnected) voltage reading is below

12.6V, charge the battery and then recheck the voltage after
the battery has set for one to two hours. If the voltage reading
is 12.7V or above, perform the LOAD TEST described in this
section.

Table 1-5.Voltmeter Test For Battery Charge Conditions

STATE OF CHARGEVOLTAGE (OCV)

100%12.7

75%12.6
50%12.3
25%12.0

0%11.8

See Figure 1-19. The analyzer printer will provide you with a
printout including one of six possible test results:

• GOOD BATTERY - Return the battery to service.

• GOOD-RECHARGE - Fully charge the battery and return

to service.

• CHARGE & RETEST - Fully charge the battery and retest.

• REPLACE BATTERY - Replace the battery.

• BAD CELL-REPLACE - Replace the battery and retest.

• BATTERY NOISE - Remove surface charge from battery

and retest.

NOTES

• A REPLACE BATTERY test result may also mean a poor
connection between the battery cables and the vehicle.
After disconnecting the battery cables from the battery,
retest the battery using the out-of-vehicle test before
replacing.

• Connect the tester directly to the lead terminals of the
battery, and not the bolts.

CONDUCTANCE TEST

TOOL NAMEPART NUMBER

HD-48053

Test the battery using the AD VANCED BATTERY CONDUCT­ANCE AND ELECTRICAL SYSTEM ANAL YZER (P art No. HD-

48053). Perform a battery test as follows:

1. Connect the HD-48053 analyzer leads to the vehicle bat­tery lead terminal, not to bolt or wire terminal.

Connect the tester directly to the lead terminals of the battery,
and not the bolts.

2. Follow the instructions in the analyzer instruction manual
to perform a battery test.

The test results will include a decision on the battery condition
and the measured state of charge.

ADVANCED BATTERY CONDUCT­ANCE AND ELECTRICAL SYSTEM
ANALYZER

NOTE

Figure 1-19. Battery Test Results Printout

LOAD TEST

To load test the battery, proceed as follows:

Disconnect negative (-) battery cable first. If positive (+)
cable should contact ground with negative (-) cable con­nected, the resulting sparks can cause a battery explosion,
which could result in death or serious injury. (00049a)

1. Remove battery from motorcycle.

2. Always fully charge the battery before testing or test
readings will be incorrect. Load testing a discharged bat­tery can also result in permanent battery damage.

3. After charging, allow battery to stand for at least one hour
before testing.

1-26 2008 Touring Diagnostics: Starting / Charging

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3

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Turn battery load tester OFF before connecting tester
cables to battery terminals. Connecting tester cables with
load tester ON can cause a spark and battery explosion,
which could result in death or serious injury. (00252a)

4. See Figure 1-20. Connect tester leads to battery posts
and place induction pickup over negative (black) cable.

NOTE
To avoid load tester and/or battery damage, do not leave the
load tester switch turned ON for more than 20 seconds.

5. Refer to Table 1-6. Load battery at 50% of CCA rating

using the load tester. Voltage reading after 15 seconds
should be 9.6V or more at 70° F (21° C).

Turn battery load tester OFF before disconnecting tester
cables to battery terminals. Disconnecting tester cables
with load tester ON can cause a spark and battery explo­sion, which could result in death or serious injury . (00253a)

6. Install the battery in the motorcycle.

Connect positive (+) battery cable first. If positive (+) cable
should contact ground with negative (-) cable connected,
the resulting sparks can cause a battery explosion, which
could result in death or serious injury. (00068a)

Do not over-tighten bolts on battery terminals. Use
recommended torque values. Over-tightening battery ter­minal bolts could result in damage to battery terminals.
(00216a)

1. Load tester

2. Induction pickup

3. Battery
Figure 1-20. Load Test Battery

Table 1-6. Battery Load Test

50%100%COLD CRANKING

AMPERAGE (CCA)

150300Touring models

2008 Touring Diagnostics: Starting / Charging 1-27

NOTES

1-28 2008 Touring Diagnostics: Starting / Charging

TABLE OF CONTENTS

SUBJECT............................................................................................................................PAGE NO.

2.1 CHECKING FOR DIAGNOSTIC TROUBLE CODES................................................................2-1

2.2 INITIAL DIAGNOSTIC CHECK: SPEEDOMETER....................................................................2-4

2.3 SPEEDOMETER SELF DIAGNOSTICS.................................................................................2-11

2.4 SPEEDOMETER/TACHOMETER...........................................................................................2-13

2.5 BREAKOUT BOX: SPEEDOMETER/TACHOMETER..............................................................2-16

2.6 FUEL GAUGE..........................................................................................................................2-17

2.7 OIL, AIR AND VOLTMETER GAUGES....................................................................................2-18

2.8 INDICATOR LIGHTS: ALL.......................................................................................................2-20

2.9 DTC B1004, B1005.................................................................................................................2-24

2.10 DTC B1006, B1007...............................................................................................................2-28

2.11 DTC B1008............................................................................................................................2-30

2.12 DTC U1016............................................................................................................................2-32

2.13 DTC U1064, U1255...............................................................................................................2-37

2.14 DTC U1300, U1301 OR BUS ER..........................................................................................2-42

INSTRUMENTS

NOTES

0

10

30

20

50

40

110

120

60

70

80

90
100

0

20

30

70

80

40

50

60

10

MPH

H

A

R

L

E

Y

-

D

A

V

I

D

S

O

N

C

E

R

T

I

F

I

E

D

RPM

x100

H

A

R

L

E

Y

-

D

A

V

I

D

S

O

N

1

1

2

2

3

4

10

4

5

5

6

6

7

7

9

9

8

11

11

8

10

FLHT, FLTR & FLHX FLHR

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2.1CHECKING FOR DIAGNOSTIC TROUBLE CODES

CHECK ENGINE LAMP

See Figure 2-1.To diagnose Electronic Control Module (ECM)
system problems, begin by observing the behavior of the check
engine lamp (1).

NOTES

• See Figure 2-2. "Key ON" means that the Ignition Switch
is turned to IGNITION and the Engine Stop Switch is set
to RUN (although the engine is not running).

• When the Ignition Switch is turned to IGNITION, the check
engine lamp will illuminate for approximately f our seconds
and then turn off.

• If the check engine lamp is not illuminated at Ignition ON,
the problem is likely to be an instrument failure. See

2.2 INITIAL DIAGNOSTIC CHECK: SPEEDOMETER.

• If the check engine lamp illuminates late (after 20
seconds), the problem is most likely a serial data bus
failure. Test for Diagnostic Trouble Codes (DTCs) using
speedometer self diagnostics. See 2.2 INITIAL DIA-

GNOSTIC CHECK: SPEEDOMETER.

• If the check engine lamp fails to turn off after the initial
four-second period, see 2.2 INITIAL DIAGNOSTIC

CHECK: SPEEDOMETER.

1. See Figure 2-3. After the check engine lamp turns off fol­lowing the first four-second illumination period, one of
three events may occur:

a. The lamp remains off. This indicates there are no

current fault conditions or stored DTCs currently
detected by the ECM.

b. The lamp remains off for only four seconds and then

illuminates for an eight-second period.This indicates
a DTC is stored, but no current DTC exists.

c. The lamp remains on beyond the eight-second period.

This indicates a current DTC exists.

2. See 2.1 CHECKING FOR DIAGNOSTIC TROUBLE

CODES, Code Types which follows for a complete

description of DTC formats.

NOTE

Some DTCs can only be fully diagnosed during actuation. F or
example, a problem with the ignition coil will be considered a
current fault ev en after the problem is corrected, since the ECM
will not know of its resolution until after the coil is ex ercised by
the vehicle start sequence. In this manner, there may some­times be a false indication of the current DTC.

Figure 2-1. Speedometer

7.1. Check engine lampSpeedometer

9.3. Sixth gear lampTachometer

11.5. Pursuit lampOdometer/trip odometer/clock

2008 Touring Diagnostics: Instruments 2-1

2. 8.Security lamp (key icon) Battery discharge lamp

4. 10.Cruise lamp ABS lamp

6. Low fuel warning lamp

1 2 3

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1. All except FLHR models

2. All FLHR models (cover shown closed)

3. All FLHR models (cover shown open)
Figure 2-2. Ignition Switch (FLHX, FLHT/C/U, FLTR)

SECURITY LAMP

T o diagnose TSM/HFSM system problems , begin by observing
the behavior of the security lamp.

NOTES

• T o provide an indication of HFSM DTCs , the security lamp
is enabled on HFSM models.

• See Figure 2-2. "Key ON" means that the ignition switch
is turned to IGNITION and the engine stop switch is set
to RUN (although the engine is not running).

• When the ignition switch is turned to IGNITION, the check
engine lamp will illuminate for approximately f our seconds
and then turn off.

• If the check engine lamp is not illuminated at IGNITION
ON, the problem is likely to be an instrument failure. See

2.2 INITIAL DIAGNOSTIC CHECK: SPEEDOMETER.

• If the check engine lamp illuminates late (after 20
seconds), See 2.2 INITIAL DIAGNOSTIC CHECK:

SPEEDOMETER.

• If the security lamp fails to turn OFF after the initial four­second period, a problem exists in the instrumentation.
See 2.2 INITIAL DIAGNOSTIC CHECK: SPEEDOMETER.

1. See Figure 2-3. After the security lamp turns off following
the first four-second illumination period, one of three
events may occur:

a. The lamp remains off. This indicates there are no

current fault conditions or stored DTCs currently
detected by the HFSM.

b. The lamp stays off for only four seconds and then

comes back on for an eight-second period. This
indicates a DTC is stored, but no current DTC exists.

c. The lamp remains on beyond the eight-second period.

This indicates a current DTC exists.

2. See 2.1 CHECKING FOR DIAGNOSTIC TROUBLE

CODES, Code Types which follows for a complete

description of DTC formats.

NOTE

Some DTCs can only be fully diagnosed during actuation. F or
example, a problem with the turn signals will be considered a
current fault even after the problem is corrected, since the
TSM/HFSM will not know of its resolution until after the turn
signals are activated. In this manner , there ma y sometimes be
a false indication of the current DTC.

2-2 2008 Touring Diagnostics: Instruments

ON

A

B

C

ON

ON

OFF

OFF

OFF

Key On

Key On

Key On

Lamp OFF: No Current or Historic DTCs

Lamp OFF

Lamp ON 8 Seconds:

Only Historic DTCs Exist

Lamp Remains ON: Current DTC*

* Historic DTCs May Also Exist

4 Sec.

4 Sec.

4 Sec.

4 Sec.

8 Sec.

4 Sec.

ed01046

HOME

Figure 2-3. Check Engine and Security Lamp Operation

CODE TYPES

TOOL NAMEPART NUMBER

DIGITAL TECHNICIANHD-44750

There are two types of DTCs: current and historic. If a DTC is
stored, it can be read using DIGITAL TECHNICIAN (Part
No. HD-44750) or speedometer self diagnostics. See

2.3 SPEEDOMETER SELF DIAGNOSTICS.

All DTCs reside in the memory of the ECM, TSM/TSSM/HFSM,
speedometer or tachometer until the code is cleared.

Current

Current DTCs are those which presently disrupt motorcycle
operation. See the appropriate flow charts for solutions.

Historic

If a particular problem happens to resolve itself, the active
status problem is dropped and it becomes a historic fault rather
than a current fault. Historic DTCs are stored for a length of
time to assist in the diagnosis of intermittent faults.

Historic DTCs are cleared after a total of 50 trips has elapsed.
A trip consists of a start and run cycle. After the 50 trip retention
period, the historic DTC is automatically erased from memory
providing no subsequent faults of the same type are detected
in that period.

DTCs can only be identified as historic using DIGITAL TECH­NICIAN (Part No. HD-44750), a computer-based diagnostic
package.

It is important to note that historic DTCs may also be present
whenever the system indicates the e xistence of a current fault.
See 2.1 CHECKING FOR DIAGNOSTIC TROUBLE CODES,

Multiple Diagnostic Trouble Codes if multiple DTCs are found.

Diagnostic charts are designed for use with current DTCs and
as a result they frequently suggest wire repair or part replace­ment.

RETRIEVING DIAGNOSTIC TROUBLE CODES

TOOL NAMEPART NUMBER

DIGITAL TECHNICIANHD-44750

The engine management system provides two levels of dia­gnostics.

• The most sophisticated mode employs DIGITAL TECHNI­CIAN (Part No. HD-44750), a computer-based diagnostic
package.

• The second mode requires using the speedometer self
diagnostics. See 2.3 SPEEDOMETER SELF DIA-

GNOSTICS.

MULTIPLE DIAGNOSTIC TROUBLE CODES

While it is possible for more than one fault to occur and set
more than one DTC, there are several conditions which may
result in one fault setting multiple DTCs. For example, serial
data DTCs (DTC U1016, U1064, U1097, U1300 and U1301)
may be accompanied by other DTCs.Always correct the serial
data DTCs before resolving other DTCs.

For proper resolution of multiple DTCs, refer to Table 2-2.

2008 Touring Diagnostics: Instruments 2-3

HOME

2.2INITIAL DIAGNOSTIC CHECK: SPEEDOMETER

GENERAL

• Constant power is supplied to the speedometer through
terminal "5" of connector [39].The speedometer turns on
when power is applied to terminal "1".The speedometer
proceeds through an initialization sequence every time
power is removed and re-applied to terminal "6".The vis­ible part of this sequence is the check engine lamp (in
"run" mode), security lamp, backlighting, odometer and
fuel level. Upon IGNITION ON, the check engine lamp

Table 2-1. Speedometer Function Chart - Loss of Input

(Constant)

• Security lamp
glows dimly
during 4-second
bulb check.

• Will not "WOW".

• Turn signals still functional.

• Speedometer will indicate

vehicle speed (zero).

• Security lamp still functions.

• Check engine lamp and battery

lamp non-functional.

• Diagnostics absent.

• Display will be

• Security lamp

and security lamp will illuminate for four seconds and then
(if parameters are normal) will go out.

• To locate faulty circuits or other system problems, follow
the diagnostic flow charts and tests in this section. For a
systematic approach, always begin with 2.2 INITIAL DIA-

GNOSTIC CHECK: SPEEDOMETER, Initial Diagnostics

which follows. Read the general inf ormation and then work
your way through the flow chart box by box.

• Loss of power on any of the four po wer inputs will change
speedometer behavior. Refer to Table 2-1.

Terminal 8 and 11

(Trip Odometer

Reset Switch)

• No trip odometer
reset switch func­tion.

• Will not "WOW".

non-functional in
accessory and
ignition modes.

still performs 4­second bulb
check in ignition
mode.

Terminal 7 (GRD)Terminal 6 (ACC)Terminal 1 (IGN)Terminal 5

• Display completely
non-functional.

• Diagnostic absent.

Diagnostic Notes

If a numbered circle appears adjacent to a flow chart box, more
information is offered in the diagnostic notes. Many diagnostic
notes contain supplemental information, descriptions of various
diagnostic tools or references to other parts of the manual
where information on the location and removal of components
may be obtained.

Circuit Diagram/Wire Harness Connector
Table

When working through a flow chart, refer to the illustrations,
the associated circuit diagram and the wire harness connector
table as necessary .The wire harness connector table for each
circuit diagram identifies the connector number, description,
type and general location.

In order to perform most diagnostic routines, a Breakout Box
and a DVOM are required. See 2.5 BREAKOUT BOX:

SPEEDOMETER/TACHOMETER.

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

INITIAL DIAGNOSTICS

TOOL NAMEPART NUMBER

BREAKOUT BOXHD-42682
INSTRUMENT HARNESS AD APTERSHD-46601

Diagnostic Tips

• If Speedometer reads "BUS Er" with the ignition switch
turned to IGNITION (engine stop switch at RUN with the
engine off), check data bus for an open or short to ground
between data link connector [91A] terminal "3" and ECM
connector [78B] terminal "69", TSM/TSSM/HFSM con­nector [30B] terminal "3", speedometer connector [39B]
terminal "2" or tachometer (if equipped) connector [108B]
terminal "2".

• Check for an open data test terminal between data link
connector [91A] terminal "3" and TSM/TSSM/HFSM con­nector [30B] terminal "3". With ignition switch turned to
IGNITION, serial data bus voltage should be typically 0.6-

0.8 volts.The range of acceptable voltage is greater than
0 and less than 7.0 volts.

• To identify intermittents, wiggle instrument and/or vehicle
harness while performing steps in the Diagnostic Check
charts.

2-4 2008 Touring Diagnostics: Instruments

Diagnostic Notes

The reference number below correlates with the circled number
on the initial diagnostic check flow charts.

HOME

1. Connect BREAKOUT BOX (Part No. HD-42682) and
INSTRUMENT HARNESS ADAPTERS (Part No. HD-

46601) between wire harness and speedometer.

Table 2-2. Speedometer/Tachometer Diagnostic Trouble Codes (DTC) Priority Chart

DTC

ORITY

6U1255

(TSM/TSSM/HFSM and/or ECM) at startup

All Speedometer diagnostic trouble codes are listed in

Table 2-2.

MODULESOLUTIONFAULT CONDITIONPRI-

2.14 DTC U1300, U1301 OR BUS ERSerial data bus shorted low/open/high1"BUS Er"

2.14 DTC U1300, U1301 OR BUS ERSerial data low2U1300

2.14 DTC U1300, U1301 OR BUS ERSerial data high3U1301

2.12 DTC U1016Loss of ECM serial data4U1016

2.13 DTC U1064, U1255Loss of TSM/TSSM/HFSM serial data.5U1064

2.13 DTC U1064, U1255Missing response from other module

2.10 DTC B1006, B1007Ignition line overvoltage7B1007

2.10 DTC B1006, B1007Accessory line overvoltage8B1006

Speedometer/tacho­meter

Speedometer/tacho­meter

Speedometer/tacho­meter

Speedometer/tacho­meter

Speedometer/tacho­meter

Speedometer/tacho­meter

Speedometer/tacho­meter

Speedometer/tacho­meter

Speedometer2.11 DTC B1008Reset switch closed9B1008
Speedometer2.9 DTC B1004, B1005Fuel level sending unit low10B1004
Speedometer2.9 DTC B1004, B1005Fuel level sending unit high/open11B1005

Other Diagnostic Trouble Codes

See 3.10 INITIAL DIAGNOSTIC CHECK:TSM/HFSM for any
diagnostic trouble codes related to the Turn Signal Module

(TSM), Turn Signal Security Module (TSSM) or Hands-Free
Security Module (HFSM).

See 4.5 INITIAL DIAGNOSTIC CHECK: EFI for any diagnostic
trouble codes related to the Electronic Control Module (ECM).

2008 Touring Diagnostics: Instruments 2-5

ECM

Serial data

GY

GY

GY

O

O O

O

69
69

321 12
3

TSM/TSSM/HSFM

21 12

21 5 7
21 5 7

21 5 7
21 5 7

4412

12

3

1
2

4

1131

13

9

9

Radio

Speedometer

Tachometer

Main to

interconnect

harness

15A

Instruments

Fuse

To

ignition

switch

Main to interconnect

harness

To

battery

fuse

[27A]
[27B]

[2B]
[2A]

[166B]
[166A]

[78B]
[78A]

[30B]
[30A]

[1B][1A]

[91A]

Data Link

Connector

[39B]
[39A]

[108B]
[108A]

BK/GN

BK/GN

BK/GN BK/GN

BN/GY

BN/GY

BN/GY

BN/GY

BN/GY

LGN/V

LGN/V

LGN/V

LGN/V

LGN/V

LGN/V

LGN/V

R/BK

LGN/V

LGN/V

BK/GN

BK/GN

To

ignition

fuse

9
9

ABS

(Optional)

em01170

HOME

[1]

ness

[2]

ness

[78]

(ECM)

2-6 2008 Touring Diagnostics: Instruments

Figure 2-4. Diagnostic Check: FLHX, FLHT/C/U, FLTR

Table 2-3.Wire Harness Connectors

12-place DeutschAllTSM/HFSM[30]

Inner fairing - right radio support bracket16-place Molex (Black)FLHT/CMain to interconnect har­Inner fairing - below radio (right side)16-place Molex (Black)FLTR
Inner fairing - left fairing support bracket12-place Molex (Gray)FLHT/CMain to interconnect har­Inner fairing - below radio (right side)12-place Molex (Gray)FLTR
Inner fairing - back of radio (right side)23-place Amp (Tyco)AllRadio[27]
Cavity in crossmember at rear of battery

box (under seat)
Inner fairing (back of speedometer)12-place PackardFLHT/CSpeedometer[39]
Under bezel (back of speedometer)12-place PackardFLTR
Under seat73-place PackardAllElectronic Control Module

Under left side cover4-place DeutschAllData link connector[91]

LOCATIONTYPEMODELDESCRIPTIONNO.

69
69

2
3

1

4

ECM

Serial data

To

ignition

fuse

15A

Instruments

Fuse

To

ignition

relay

To

battery

fuse

[78B]
[78A]

[30B]
[30A]

[91A]

Data Link

Connector

[39B]
[39A]

BK/GN

GY

GY

GY

O

O O

21 5 7
21 5 7

Speedometer

321 12
3

TSM/TSSM/HSFM

21 12

BK/GN

LGN/V

LGN/V

LGN/V

LGN/V

LGN/V

BN/GY

BN/GY

LGN/V

BN/GY

BK/GN

9
9

ABS

(Optional)

O

21 3 5

[20B]

BN/GY

LGN/V

BK/GN

[166B]
[166A]

em01171

HOME

Table 2-3.Wire Harness Connectors

LOCATIONTYPEMODELDESCRIPTIONNO.

Inner fairing (back of tachometer)12-place PackardFLHT/CTachometer[108]
Under bezel (back of tachometer)12-place PackardFLTR
Under right side cover20-place MolexAllABS module[166]

Figure 2-5. Diagnostic Check: FLHR/C/S

2008 Touring Diagnostics: Instruments 2-7

HOME

Table 2-4.Wire Harness Connectors

12-place DeutschTSM/TSSM/HFSM[30]

LOCATIONTYPEDESCRIPTIONNO.

Under seat16-place MolexConsole harness[20]
Cavity in crossmember at rear of bat-

tery box (under seat)
Under console (back of speedometer)12-place Mini-DeutschSpeedometer[39]
Under seat73-place PackardElectronic Control Module (ECM)[78]
Under left side cover4-place DeutschData link connector[91]
Under right side cover20-place MolexABS module[166]

2-8 2008 Touring Diagnostics: Instruments

YES NO

STOP

YES

YES

YES

NO

NO

NO

YES

NO

Does Engine

start?

See Section 4.10 ENGINE
CRANKS, BUT WILL NOT

START.

See Section 1.2 STARTING

SYSTEM DIAGNOSIS.

See Section 4.12 STARTS,

THEN STALLS.

Check for DTCs. See

Section 2.3

SPEEDOMETER

SELF DIAGNOSTICS

Codes found?

Refer to applicable DTC priority chart.

Codes are listed by priority.

Unable to enter diagnostic mode.

With Ignition Switch OFF, press and

release Trip Odometer Reset Switch.

Does odometer display appear with

display backlighting?

Check for continuity to Ground on terminal “7” of

Speedometer. Wiggle harness during continuity check.

Continuity present?

Check for battery voltage at

terminal “5” of Speedometer

while wiggling harness.

Battery voltage continuously

present?

With connector [39] disconnected from
Speedometer, check continuity (with ignition
switch OFF) between terminals “8” and “11”

on Breakout Box.

Continuity present when Trip Odometer Reset

Switch is depressed and infinity when

released?

Locate and repair open

between terminal “7”

and Ground.

Locate and repair open

between terminal “5” and

Battery Fuse.

Replace Trip Odometer

Reset Switch.

Replace Speedometer.

NO

Engine will not crank.

NO

Cranks, but will not start.

YES

Starts, then stalls.

YES

Starts and runs.

Go to Diagnostic

Check (Part 2 of 2).

1

fc01085_en

HOME

Diagnostic Check (Part 1 of 2)

2008 Touring Diagnostics: Instruments 2-9

YES NO

YES

YES

YES

YES

NO

YES

YES

YES

YES

NO

NO

NO

YES

NO

NO

NO

NO

Continued from Diagnostic Check (Part 1 of 2).

Perform “WOW” test. See Section 2.3 SPEEDOMETER SELF

DIAGNOSTICS.

The following features should be functional:

1) backlight should illuminate

2) needle should sweep its full range of motion

3) LED’s that should illuminate:

• check engine

• battery

• security

• low fuel

• sixth gear

Are all features functional?

Turn Ignition Switch

to ACCESS.

Is backlight present?

With Ignition Switch turned to

IGNITION, check for battery voltage

at terminal “1” of Breakout Box.

Battery voltage present?

Check for battery voltage at

Breakout Box terminal “6”.

Battery voltage present?

Is problem intermittent?

Replace Speedometer.

Is Instrument

Fuse good?

Locate and repair

source of fault.

Replace Instrument

Fuse.

Locate and repair open

on (O) wire between

terminal “1” of connector

[39] and Instrument Fuse.

NO

Locate and repair open on (O/W)

wire between terminal “6” of

connector [39] and Accessory Fuse.

Tachometer Inoperative

(no engine speed).

Repeat Diagnostic Check

while wiggling harnesses.

Intermittent present?

Intermittent vehicle speed

indication.

Remove and inspect Vehicle

Speed Sensor (VSS).

Debris present?

Remove debris.

Reinstall VSS.

Locate and repair

intermittent.

No trouble found.

Locate and repair

source of fault.

Replace Speedometer.

Is Accessory Fuse

good?

Replace Speedometer.

Check for damaged wiring/

loose connection between

VSS and Electronic Control

Module (ECM).

Is wiring damage/loose

connection present?

See Tachometer

Inoperative (Part 1 of 2).

YES

fc01086_en

Locate and repair source

of fault.

Replace Accessory Fuse.

HOME

Diagnostic Check (Part 2 of 2)

2-10 2008 Touring Diagnostics: Instruments

HOME

2.3SPEEDOMETER SELF DIAGNOSTICS

GENERAL

The speedometer is capable of displaying and clearing
speedometer, tachometer, TSM/TSSM/HFSM, and ECM Dia­gnostic Trouble Codes (DTCs) (diagnostic mode).

DIAGNOSTICS
Diagnostic Tips

• For a quick check of speedometer function, a "W O W" test
can be performed. Press and hold trip odometer reset
switch (Figure 2-1), then turn Ignition Switch ON. Release
trip odometer reset switch. Background lighting should
illuminate, gauge needle should sweep its full range of
motion, and indicator lamps (check engine, low fuel, bat­tery and security) should illuminate.

• If instrument module fails "WOW" test, check for battery,
ground, ignition, trip odometer reset switch and accessory
wiring to speedometer. If any feature in the speedometer

is non-functional, see 2.2 INITIAL DIAGNOSTIC CHECK:

SPEEDOMETER.

Diagnostic Notes

Each reference number below correlates to a circled number
on the flow chart(s).

1. To exit diagnostic mode, turn ignition switch OFF.

2. To clear DTCs for the selected module:
a. Press and hold the trip odometer reset switch for more

than 5 seconds to display av ailable modules, release.

b. Press the trip odometer reset switch to choose the

module.

c. Press and hold the trip odometer reset switch for more

than 5 seconds to display the DTC, release.

d. Press and hold the trip odometer reset switch for more

than 5 seconds to clear the DTCs for the selected
module.

2008 Touring Diagnostics: Instruments 2-11

1

While holding Trip Odometer Reset Switch in, turn

Ignition Switch to IGNITION.

Make sure Engine Stop Switch is in RUN position.

Release Trip Odometer

Reset Switch.

Does “diag” appear?

YES

”P” flashing.

To display DTCs for

the Electronic Control

Module (ECM), press

and hold Trip

Odometer Reset

Switch for more than 5

seconds.

To display DTCs for

TSM/TSSM/HFSM,

press and Trip

Odometer Reset

Switch for more than

5 seconds.

To choose Turn Signal

Module/Turn Signal

Security Module/
Hands Free Security
Module (TSM/TSSM/

HFSM), press and

release trip odometer

reset switch.

”S” flashing.

To choose

Speedometer,

press and release the

Trip Odometer Reset

Switch.

”SP” flashing.

To choose Tachometer,

press and release Trip

Odometer Reset Switch.

To choose ECM, press

and release Trip Odometer

Reset Switch.

To exit, turn Ignition Switch

to OFF.

”t” flashing.

To display DTCs for

Speedometer, press

and hold Trip

Odometer Reset

Switch for more than

5 seconds.

To display DTCs for

Tachometer, press

and hold Trip

Odometer Reset

Switch for more than

5 seconds.

Press and release Trip Odometer
Reset Switch again to continue to

next module.

See 2.2 INITIAL

DIAGNOSTIC CHECK:

SPEEDOMETER.

YES

YES

NO

NO

NO

Device

response?

Press and release

Trip Odometer

Reset Switch.
Part number of
module will be

displayed.

Press and release

Trip Odometer

Reset Switch.

Are more DTCs

displayed?

“end” displayed.

To clear all DTCs for selected

module press and hold Trip

Odometer Reset Switch for more

than 5 seconds.

If DTCs are not to be cleared,

Press and release Trip Odometer

Reset Switch. Part number of

module will be displayed.

“no rsp” displayed.
See applicable code from other
modules. Models not equipped

with a Tachometer or ABS will

display “no rsp” normally.

If “no rsp” displayed on
Odometer on Tachometer
equipped vehicle, see 2.4

SPEEDOMETER/

TACHOMETER.

If “no rsp” displayed on

Odometer on ABS equipped

vehicle, see 6.1 ANTILOCK

BRAKE SYSTEM (ABS)

GENERAL INFORMATION.

“none” displayed.

DTC

displayed.

Press and release

Trip Odometer

Reset Switch.

“PSSPtb” appears?

fc01087_en

”b” flashing.

To display DTCs for

ABS (if equipped),

press and hold Trip

Odometer Reset

Switch for more than

5 seconds.

To choose Anti-Lock
Brake System (ABS),

press and release Trip

Odometer Reset

Switch.

2

HOME

Speedometer Self Diagnostics

2-12 2008 Touring Diagnostics: Instruments

HOME

2.4SPEEDOMETER/TACHOMETER

GENERAL

NOTE

Some icons may illuminate during "WOW" test though the icon
has no functionality on that vehicle.

The speedometer consists of a speedometer display and sev­eral icons. The icons include the sixth gear indicator, check
engine, low fuel, battery, security and cruise enabled lamps.

Trip Odometer Reset Switch

Pressing the trip odometer reset switch provides the follo wing
capabilities:

• Change the odometer display between mileage, trip A and
trip B values (press and immediately release).

• Reset an individual trip odometer (press and hold 2-3
seconds).

• Gain access to the diagnostic mode, clear DTCs, and exit
diagnostic mode. See 2.3 SPEEDOMETER SELF DIA-

GNOSTICS.

• Display odometer while ignition switch is OFF. Press and
hold trip odometer reset switch while ignition switch is OFF
and odometer mileage will be displayed.

• On models with dual scale speedometers, toggle between
miles/kilometers on odometer and trip odometer display.
To toggle display, turn ignition switch ON. Press and hold
trip odometer reset switch while odometer is displayed.
Release trip odometer reset switch when change is noted.
(If trip odometer reset switch is held while trip odometer
is displayed, trip odometer will reset.)

• The trip odometer reset switch is also used to set or select
the clock located in the odometer.The clock function for
the odometer is not present on vehicles equipped with the
Advanced Audio System. Detailed instructions for setting
the clock are located in the Owner's Manual.

The vehicle speed serial data is also transmitted to the
TSM/TSSM/HFSM for turn signal cancellation.

ODOMETER THEORY OF OPERATION

The odometer mileage is permanently stored and will not be
lost when electrical power is turned off or disconnected. The
trip odometer reset switch allows switching between the odo­meter, trip odometer A and trip odometer B displays.

To zero the trip odometer, have the desired trip odometer dis­play visible and press and hold the trip odometer reset switch.
The trip odometer mileage will be displayed for 2-3 seconds
and then the trip mileage will return to zero miles.

The odometer can display six numbers to indicate a maximum
of 999999 miles/kilometers.The trip odometers can display six
numbers with a tenth of a mile accuracy for a maximum of

99999.9 miles/kilometers.
The speedometer indicates when vehicle is in sixth gear.

Selection of sixth gear is inferred as the system identifies when
correct RPM and vehicle speed coincide.

Job/Time Code Values

Dealership technicians filing warranty claims should use the
job/time code values in Digital Technician.

TACHOMETER THEORY OF OPERATION

The tachometer receives serial data from the ECM. The
tachometer interprets the serial data and converts it into
tachometer needle movement.

DIAGNOSTICS

TOOL NAMEPART NUMBER

HARNESS CONNECTOR TEST KITHD-41404-B
BREAKOUT BOXHD-42682
INSTRUMENT HARNESS AD APTERSHD-46601

SPEEDOMETER THEORY OF OPERATION

The speedometer circuit consists of a vehicle speed sensor,
the ECM, trip odometer reset switch and the speedometer.
The vehicle speed sensor is mounted on the rear of the trans­mission case below the starter motor assembly. The sensor
circuitry is that of a Hall-effect sensor triggered by the gear
teeth of 5th gear on the transmission mainshaft.

The output from the sensor is a series of pulses that are inter­preted by the ECM circuitry, converted into serial data then
sent to the speedometer to control the position of the speedo­meter needle and the odometer liquid crystal display (LCD).

Diagnostic Notes

Each reference number below correlates to a circled number
on the flow chart(s).

1. If problems are intermittent, wiggle harness while per­forming tests.

2. Connect BREAKOUT BOX (Part No. HD-42682) and
INSTRUMENT HARNESS ADAPTERS (Part No. HD-

46601) between wire harness and tachometer.

3. Use HARNESS CONNECTOR TEST KIT (Part No. HD­41404-B), black pin probe and patch cord.

2008 Touring Diagnostics: Instruments 2-13

YES NO

STOP

1

2

3

YES

NO

YES NO

YES

NO

Perform “WOW” test. See 2.3 SPEEDOMETER

SELF DIAGNOSTICS.

The following features should be functional:

1) backlight should illuminate

2) needle should sweep its full range of motion

3) LED’s should illuminate:

• cruise (although not cruise equipped on some models)

• abs (although not abs equipped on some models)

• pursuit (although may not be a police vehicle)

Are all features functional?

Is problem intermittent?

Repeat Diagnostic

Check while wiggling

harnesses.

No trouble

found.

Is Instrument

Fuse good?

Locate and repair

source of fault.

Replace

Instrument Fuse.

Locate and repair

open in (O) wire

between terminal “1”

of connector [108] and

Instrument Fuse.

Check for continuity between

Breakout Box terminal “2” and

terminal “13" of connector [1A].

Is continuity present?

Locate and repair open

on (LGN/V) wire.

Check for battery voltage at

terminal “1” of Breakout Box.

Is battery voltage present?

NO

YES

Go to Tachometer

Inoperative (Part 2 of 2).

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Tachometer Inoperative (Part 1 of 2)

2-14 2008 Touring Diagnostics: Instruments

YES NO

YES

YES

NO

NO

Continued from Tachometer Inoperative (Part 1 of 2).

Check for continuity to ground on Breakout Box

terminal “7". Wiggle harness during continuity check.

Is continuity present?

Check for battery voltage

at Breakout Box terminal “5”

while wiggling harness.

Is battery voltage

continuously present?

Locate and repair open on

(BK/GN) wire between

terminal “7" of connector [108]

and Ground.

Locate and repair open

on (BN/GY) wire

between terminal “5” of

connector [108] and

Battery Fuse.

Check for battery voltage at

Breakout Box terminal “6.”

Is battery voltage present?

Locate and repair open on (O/W)

wire between terminal “6” of connector

[108] and Accessory Fuse.

Replace Tachometer.

fc01089_en

HOME

Tachometer Inoperative (Part 2 of 2)

2008 Touring Diagnostics: Instruments 2-15

ed02036

ed02037

ed02039

HOME

BREAKOUT BOX: SPEEDOMETER/TACHOMETER

GENERAL

TOOL NAMEPART NUMBER

BREAKOUT BOXHD-42682
INSTRUMENT HARNESS AD APTERSHD-46601

The BREAKOUT BO X (P art No. HD-42682) and INSTR UMENT
HARNESS ADAPTERS (Part No. HD-46601) connect to
speedometer connector [39]. Used in conjunction with a D V OM,
it allows circuit diagnosis of wiring harness and connections
without having to probe with sharp objects.

NOTE

See wiring diagrams for speedometer terminal functions.

INSTALLATION

1. See Figure 2-6. Release the e xternal latches and remov e
connector [39B].

2. See Figure 2-8. Connect instrument harness adapters to
connectors [39A] and [39B].

3. See Figure 2-7. Attach connectors from Breakout Box to
instrument harness adapters.

2.5

Figure 2-7. Breakout Box (Part No. HD-42682)

Figure 2-8. Instrument Harness Adapters (Part No.

HD-46601)

REMOVAL

1. Detach connectors from Breakout Box to instrument har­ness adapters.

2. Detach instrument harness adapters from connectors [39A]
and [39B].

3. Install connector [39B] to speedometer.

Figure 2-6. Speedometer Connector [39]

2-16 2008 Touring Diagnostics: Instruments

To +12V

To Sender

NOTE

All gauges are shown

as viewed from rear.

Color Code:
BK-Black
BN/GN-Brown/Green
O-Orange

Oil

Pressure

Voltmeter

GND

+

BK

O

BK

BK

O

O

BK

O

BN/GN

Light

Light

em01174

HOME

2.6FUEL GAUGE

THEORY OF OPERATION

With ignition switch turned to IGNITION, the fuel gauge is
connected to +12 volts. Current flows through the gauge and
variable resistor in the fuel gauge sending unit to ground.The
sending unit float controls the amount of resistance in the
variable resistor.

Inoperative gauges may be caused b y se v er al circumstances.

• Sender or fuel gauge not grounded.

• Malfunction in sender or fuel gauge.

• Broken or disconnected wire from ignition switch to fuel

gauge.

• Corroded connections at fuel gauge.
Use the 2.6 FUEL GAUGE, Fuel Gauge and Sender Test to

test suspect components.

FUEL GAUGE AND SENDER TEST

TOOL NAMEPART NUMBER

MULTI-METERHD-35500

NOTE

Always refer to the applicable wiring diagram when
troubleshooting instruments or gauges.

1. Remove gauge. Ground (Y/W) wire of fuel gauge sender
located at bottom of gauge. Turn ignition switch to IGNI­TION.

a. Fuel gauge must indicate FULL. If gauge indicated

FULL, gauge is functioning correctly . Proceed to step

2.

b. If gauge did not indicate FULL, proceed to step 3.

2. Set MULTI-METER (Part No. HD-35500) to RXI scale to
measure the resistance of the sending unit. Place one
probe on (Y/W) and the other probe on chassis ground.

If fuel tank is full, the reading should be 30-50 ohms. An
empty tank should have a 240-260 ohm resistance. A half
full tank will be approximately 125-165 ohms.

If a very high resistance or infinity is indicated on the
meter, the sender ma y be "open" or not grounded. Check
that sender and fuel tank are grounded by placing one
probe of Multi-Meter on sender flange and the other probe
on crankcase. Meter must indicate one ohm or less.
Replace sender if one ohm or less was present. If a higher
resistance is present, check for poor connection on ground
wire.

3. Check voltage to (O/W) (+) and (BK) (-) wire of fuel gauge
connector [117] if gauge did not indicate FULL.

a. Correct reading is equivalent to battery voltage.
b. If battery voltage is not present check for broken or

disconnected wire. Replace gauge if wiring problem
is not found.

Figure 2-9. Connections for Gauges

2008 Touring Diagnostics: Instruments 2-17

HOME

2.7OIL, AIR AND VOLTMETER GAUGES

OIL PRESSURE GAUGE AND INDICATOR LIGHT

TOOL NAMEPART NUMBER

HARNESS CONNECTOR TEST KITHD-41404-B

Problem

Low oil pressure light remains on with engine running above
idle and/or oil pressure gauge does not work.

Do not operate the engine when the oil level is below the
add mark on the dipstick at operating temperature. Engine
damage will result. (00187b)

Cause 1

No oil pressure due to lack of oil or faulty oil pump.

Solution 1

1. Check oil level. Add oil if low.

2. Restart engine and verify that oil pressure light goes off
and gauge indicates pressure. If prob lem still exists, refer
to OIL PUMP in the Service Manual.

Cause 2

Contacts in pressure sending unit not opening to shut off light.
Variable resistor in sender is shorted to ground.

Solution 2

1. Locate the oil pressure sending unit on the front right side
of the crankcase.

2. Verify that the electrical connector is properly connected
to the sending unit.

3. If the oil pressure gauge indicates pressure but the low oil
pressure light remains on proceed as follows:

a. Remove electrical connector from oil pressure sending

unit. Using ohmmeter and HARNESS CONNECT OR
TEST KIT (Part No. HD-41404-B) gray socket probe
and patch cord, place one probe on indicator lamp
terminal (closest to latch on sending unit), place the
other probe on the crankcase. Ohmmeter must read
less than one ohm.

b. Start the engine and run at a fast idle.The ohmmeter

must read infinity.

c. Replace the sending unit if the above meter readings

are not obtained.

4. If the low oil pressure light functions correctly, but the
pressure gauge does not, Then proceed as follows:

a. Remove electrical connector from oil pressure sending

unit.Turn the ignition switch to IGNITION.The gauge
must read zero.

b. Ground (BN/GN) wire terminal to crankcase. The

gauge must read full scale 60 PSI.

c. Replace the sending unit if the above gauge readings

are obtained. If the gauge readings are not obtained,
then replace the pressure gauge.

Cause 3

No power to gauge.

Solution 3

See Voltmeter Gauge.

AMBIENT AIR TEMPERATURE GAUGE
Problem

Gauge inoperative.

Cause 1

Sensor not grounded or open between sensor and gauge.

Solution 1

Test for continuity between terminal "1" and ground and ter­minal "3" and gauge. Repair if open.

Cause 2

Broken or disconnected power or ground wire to gauge.

Solution 2

Check for 12V between terminals "1" and "3" at connector
[115A]. Replace gauge if voltage is present. Use voltage drop
tests and continuity checks to isolate if voltage is not present.

Cause 3

Malfunction in gauge or sensor.

Solution 3

Measure resistance between terminals "1" and "3" at 65­85°F (18.3-29.4°C). Resistance should be 43-31 ohms . Replace
sensor if out of range, replace gauge if within range.

VOLTMETER GAUGE
Problem

Meter inoperative.

2-18 2008 Touring Diagnostics: Instruments

Cause

Broken or disconnected leads to meter or open meter winding.

Solution

1. With ignition switch turned to IGNITION, verify that 12V
is present at "±" terminal on voltmeter.With ignition switch
turned to OFF, check ground terminal for continuity to
ground.

HOME

2. Replace the voltmeter if 12V is present and ground ter­minal is grounded.

3. If 12V is not present, trace wiring until disconnected or
broken wire is found and repair as necessary. If ground
terminal is not grounded, refer to wiring diagram and
repeat procedure given for 12V lead.

2008 Touring Diagnostics: Instruments 2-19

HOME

2.8INDICATOR LIGHTS: ALL

GENERAL

See Figure 2-10. All models are equipped with Light Emitting
Diode (LED) indicators. The indicator lights assembly is not

Table 2-5. Indicator Lamp Connector [21] (All But FLHR/C/S)

Table 2-6. Indicator Lamp Connector [21] (FLHR/C/S)

serviceable. If one LED is bad, the entire assembly must be
replaced.

See 2.8 INDICATOR LIGHTS: ALL, Diagnostics for
troubleshooting procedures.

FUNCTIONWIRE COLORTERMINAL

Right Turn PowerBrown1

Oil Pressure Lamp To SwitchGreen/Yellow2

High Beam PowerWhite3

Left Turn PowerViolet4

GroundBlack5

Neutral/Oil Pressure PowerOrange6

Neutral Lamp To SwitchTan7

N/ANot Used8
N/ANot Used9
N/ANot Used10

Table 2-7. Indicator Lamp Wiring

CONNECTIONINDICATOR LAMP

Ground through switchOil pressure
Ground through harnessNeutral
12V when activeHigh beam
12V when activeRight/left turn

FUNCTIONWIRE COLORTERMINAL

Left Turn PowerViolet1

High Beam PowerWhite2

Oil Pressure Lamp To SwitchGreen/Yellow3

Right Turn PowerBrown4

Neutral Lamp To SwitchTan5

Neutral/Oil Pressure PowerOrange6

GroundBlack7

N/ANot Used8

2-20 2008 Touring Diagnostics: Instruments

5

6

1

2

4

3

ed02040

ed02041

HOME

1. Indicator Lights Connector

2. Indicator Lights Assembly

3. Lens

4. Paddles

5. Index Tabs

6. Orientation Stamp

Figure 2-10. Indicator Lights Assembly (FLHS, FLHT/C/U,

FLTR)

Figure 2-11. Release Paddles to Free Indicator Light

Assembly (FLHR/C)

Job/Time Code Values

Dealership technicians filing warranty claims should use the
job/time code values printed in bold text underneath the
appropriate repair.

DIAGNOSTICS

2008 Touring Diagnostics: Instruments 2-21

YES NO

NO

NO NO

YES

YES

Turn the Ignition Switch to IGNITION.

Check for battery voltage at connector

[21A], terminal “6”.

Turn OFF Ignition Switch.

Was battery voltage present?

With transmission in neutral, check

for continuity to Ground at connector

[21A], terminal “7” (terminal “5” on FLHR

models) and/or terminal “2” (terminal “3” on

FLHR models).

Is continuity present?

Replace Indicator Lights

Assembly.

Check for continuity through

switch.

Is continuity present?

Repair open in (GN/Y)

wire (oil pressure) or

(TN) wire (neutral).

Check for bad fuses

or locate open.

Replace Oil

Pressure Switch.

Replace Neutral

Switch.

5157

5161

5048

5191

5048

fc01090_en

HOME

Oil Pressure or Neutral Indicator Will Not Function

2-22 2008 Touring Diagnostics: Instruments

Check for Ground at connector [21A],

terminal “1”, terminal “3” (terminal “2” on FLHR

models) and/or terminal “4”.

Is continuity to Ground present?

Check for 12V when circuit is active:

connector [21A], terminal “4”, terminal “1” or

terminal “3” (terminal “2” on FLHR models).

Is voltage present?

YES NO

NOYES

Replace Indicator

Lights Assembly.

Locate and repair

open in circuit.

Locate and repair

open in circuit.

5191

5048

5048

fc01091_en

HOME

High Beam or R/L Turn Signal Indicator Will Not Function

2008 Touring Diagnostics: Instruments 2-23

ed02036

ed02037

ed02039

HOME

2.9DTC B1004, B1005

GENERAL

See Figure 2-12. The fuel level is monitored by the speedo­meter terminal "9" of connector [39] (Y/W).

• If the voltage on terminal "9" of connector [39] exceeds
the lower limit for greater than or equal to 15 seconds a
DTC B1004 will set.

• If the voltage on terminal "9" of connector [39] exceeds
the upper limit (or is open) for greater than or equal to 15
seconds a DTC B1005 will set.

Table 2-8. Code Description

DESCRIPTIONDTC

Fuel level sending unit lowB1004
Fuel level sending unit high/openB1005

Diagnostic Notes

Each reference number below correlates to a circled number
on the flow chart(s).

1. See Figure 2-14. Use HARNESS CONNECTOR TEST
KIT (Part No. HD-41404-B), brown pin probe and patch
cord.

2. See Figure 2-13. Connect BREAK OUT BO X (P art No. HD-

42682) and INSTRUMENT HARNESS ADAPTERS (Part
No. HD-46601) between wire harness and speedometer.

3. Use HARNESS CONNECTOR TEST KIT (Part No. HD­41404-B), gray pin probe and patch cord.

Figure 2-12. Speedometer Connector [39]

DIAGNOSTICS

TOOL NAMEPART NUMBER

HARNESS CONNECTOR TEST KITHD-41404-B
BREAKOUT BOXHD-42682
INSTRUMENT HARNESS AD APTERSHD-46601

Diagnostic Tips

If fuel gauge is performing erratically (possible false DTCs),
inspect for unobstructed movement of sending unit arm. Repair
or align as necessary.

Figure 2-13. Breakout Box (Part No. HD-42682)

Figure 2-14. Instrument Harness Adapters (Part No.

HD-46601)

2-24 2008 Touring Diagnostics: Instruments

To accessory fuse

To battery fuse

To instrument fuse

Fuel Gauge

All Except

FLHR/C/S

[117B]

[117B]

Fuel Gauge

FLHR/C/S

Fuel Level

Sender

FLHX, FLHT/C/U, FLTR

FLHR Only

Data Link

Connector

[141A]
[141B]

[39B]
[39A]

[20A]

[91A]

[78B]

Speedometer

[78A]

11225

1

2

1 2 4

C
C

1 2 3 4 8 14 15

A
A B D

B D

2

69
69

Serial data

ECM

3

1

4

3

566

9 12

12977

GY

BK/GN
LGN/V

R/GN

R/GN

O/GY

O/GY

LGN/V

BK

BK

BK

BK

Y/W

Y/W

Y/W

Y/W

O/W

O/W

BN/GY

BN/GY

BK/GN

[13B]
[13A]

[2A] [2B]

2 3
2

5125

12

3

Y/W Y/W

Y/W

Y/WY/W

BK/GN BK/GNBK/GN

BK/GNBK/GN

BK/GN

LGN/V

LGN/V

O

O

O

O

To ignition

fuse

em01047

HOME

[2]

[78]

ness

(ECM)

Figure 2-15. Fuel Sender Circuit

Table 2-9.Wire Harness Connectors

Inner fairing - left fairing support bracket12-place Molex (Gray)FLHT/CMain to interconnect har­Inner fairing - below radio (right side)12-place Molex (Gray)FLTR
Behind fuel tank (under seat)4-place MultilockFLHT/CFuel tank harness[13]
Behind fuel tank (under seat)4-place MultilockFLTR
Under seat16-place MolexFLHRConsole harness[20]
Inner fairing (back of speedometer)12-place PackardFLHT/CSpeedometer[39]
Under bezel (back of speedometer)12-place PackardFLTR
Under seat73-place PackardAllElectronic Control Module

Under left side cover4-place DeutschAllData link connector[91]
Inner fairing - back of fuel gaugeSpade terminalsAllFuel gauge[117]
Top of canopy (under console)4-place PackardAllFuel level sender[141]

LOCATIONTYPEMODELDESCRIPTIONNO.

2008 Touring Diagnostics: Instruments 2-25

Disconnect the fuel gauge connector [117B]. Turn the

Ignition Switch to the IGNITION position. Check for voltage

at terminal “1” of connector [117B].

Is voltage present?

NO

YES

Repair open.

Check for continuity to Ground in

(Y/W) wire connector [39B].

Is continuity less then 10 ohms?

NO

Replace the Fuel

Gauge.

YES

Replace the Fuel Level

Sending Unit.

Replace

Speedometer.

Disconnect the speedometer connector [39B]. Check
for continuity between terminal “9” of connector [39B]

and terminal “3” (terminal "2" on FLHR models) of

connector [117B].

Is Continuity present?

YES

NO

Repair open.

YES

Locate and repair

short to ground.

Disconnect the fuel level sending unit

connector [141B]. Check for continuity

between terminal “A” of connector

[141B] and ground.

Is continuity present?

Connect the fuel gauge connector [117B].

Turn the Ignition Switch to the IGNITION

position. Check for voltage on terminal “9” of

connector [39B].

Is voltage present?

NO

YES

NO

fc01092_en

2

3

1

HOME

Fuel Level Sending Unit: DTC B1004

2-26 2008 Touring Diagnostics: Instruments

YES NO

1

Clear codes using speedometer self diagnostics.
See Section 4.6 SPEEDOMETER SELF DIAGNOSTICS.
Confirm proper operation with no check engine lamp.

YES

YES

NO

NO

1

1

2

Disconnect speedometer connector [39].

Measure voltage on terminal “A” of

connector [141B] (Y/W). Should be 0 volts.

Is it?

Check continuity between terminal
“A" of connector [141B] (Y/W) and

Breakout Box terminal “9”.

Continuity present?

Check continuity to ground on

terminal “C” of connector [141B]

(BK/GN).

Is continuity present?

Locate and repair short

to voltage.

Locate and repair open

on (Y/W) wire.

Locate and repair open on

(BK/GN) wire (ground

circuit).

Repair/replace Fuel

Level Sending Unit.

fc01093_en

HOME

Fuel Level Sending Unit: DTC B1005

2008 Touring Diagnostics: Instruments 2-27

HOME

2.10DTC B1006, B1007

GENERAL
Accessory or Ignition Line Overvoltage

Ignition and accessory voltage is constantly monitored by the
speedometer (terminal "1" ignition and terminal "6" accessory).
If the battery voltage fails to meet normal operating parameters,
a Diagnostic Trouble Code (DTC) is set.

• DTC B1006 is displayed when accessory line voltage is
greater than 16.0 volts for longer than 5 seconds.

• DTC B1007 is displayed when ignition line voltage is
greater than 16.0 volts for longer than 5 seconds.

NOTE

ECM or TSM/TSSM/HFSM ma y also set a battery voltage DTC.

Table 2-10. Code Description

DESCRIPTIONDTC

Accessory line overvoltageB1006
Ignition line overvoltageB1007

2-28 2008 Touring Diagnostics: Instruments

YES NO

Clear codes using speedometer self diagnostics.
See Section 4.6 SPEEDOMETER SELF DIAGNOSTICS.
Confirm proper operation with no Check Engine Lamp.

NOYES

Has battery charger been recently connected?

Start vehicle. Run at 3000

RPM for 5 seconds.

Does code reset?

Diagnose charging system.

See 1.7 CHARGING SYSTEM.

Diagnose charging system.

See 1.7 CHARGING SYSTEM.

System normal.

NOTE: Sometimes battery charger may cause

over voltage condition which will set codes.

Clear codes.

fc01094_en

HOME

Accessory or Ignition Line Overvoltage: DTC B1006, B1007

2008 Touring Diagnostics: Instruments 2-29

[39B][39A]

Speedometer

Trip

Odometer

Reset
Switch

8118

11

BK

BK

em01048

HOME

2.11DTC B1008

GENERAL
Trip Odometer Reset Switch Closed

Diagnostic Trouble Code (DTC) B1008 will be set if trip odo­meter reset switch terminals are in a constant shorted state.

Table 2-11. Code Description

DESCRIPTIONDTC

Trip odometer reset switch closedB1008

DIAGNOSTICS

TOOL NAMEPART NUMBER

BREAKOUT BOXHD-42682
INSTRUMENT HARNESS AD APTERSHD-46601

Diagnostic Notes

Each reference number below correlates to a circled number
on the flow chart(s).

1. Disconnect speedometer connector [39] (at the back of
the speedometer). See 2.5 BREAKOUT BOX: SPEEDO-

METER/TACHOMETER.

Table 2-12.Wire Harness Connectors

2. Connect BREAKOUT BOX (Part No. HD-42682) (black)
to wire harness connector [39B] using INSTRUMENT
HARNESS ADAPTERS (Part No. HD-46601), leaving

speedometer disconnected.

Figure 2-16.Trip Odometer Reset Switch Circuit

LOCATIONTYPEMODELDESCRIPTIONNO.

Inner fairing (back of speedometer)12-place PackardFLHT/CSpeedometer[39]
Under bezel (back of speedometer)12-place PackardFLTR

2-30 2008 Touring Diagnostics: Instruments

YES

NO

Clear codes using speedometer self diagnostics.
See Section 4.6 SPEEDOMETER SELF DIAGNOSTICS.
Confirm proper operation with no check engine lamp.

YES NO

Remove TripOdometer Reset Switch Rubber Boot.

Clear codes using 2.3 SPEEDOMETER SELF

DIAGNOSTICS.

Codes still present?

With speedometer connector [39B]

disconnected, measure resistance between

terminals “8” and “11” on Breakout Box.

Resistance should be less than 1 ohm with

Trip Odometer Reset Switch depressed and

infinity ohms when released.

Is it?

Replace Trip

Odometer Reset

Switch Rubber

Boot.

Replace Trip Odometer

Reset Switch.

Replace Speedometer.

1

fc01095_en

2

HOME

Trip Odometer Reset Switch Closed: DTC B1008

2008 Touring Diagnostics: Instruments 2-31

3

2

1

ed02982

HOME

2.12DTC U1016

GENERAL
Loss of ECM Serial Data

See Figure 2-17. The data link connector provides a means
for the ECM, TSM/TSSM/HFSM and speedometer to commu­nicate their current status.When all operating parameters on
the serial data bus are within specifications, a state of health
message is sent between the components. A DTC U1016
indicates that the ECM is not capable of sending this state of
health message.

1. Terminal 2: ground (BK/GN)

2. Terminal 3: serial data (LGN/V)

3. Terminal 4: power (GY)
Figure 2-17. Data Link Connector

Table 2-13. Code Description

DESCRIPTIONDTC

U1016

Loss of all ECM serial data (state of
health)

Loss of vehicle speed
Loss of vehicle inhibit motion
Loss of powertrain security status

DIAGNOSTICS

TOOL NAMEPART NUMBER

BREAKOUT BOXHD-42682
BREAKOUT BOXHD-43876

Diagnostic Notes

Each reference number below correlates to a circled number
on the flow chart(s).

1. Connect BREAKOUT BOX (Part No. HD-42682) (gray)
between TSM/TSSM/HFSM connector [30A] and wire
harness connector [30B]. See 4.7 BREAK OUT BOX: EFI.

2. Connect BREAKOUT BOX (Part No. HD-43876) between
wire harness and ECM. See 4.7 BREAKOUT BOX: EFI.

2-32 2008 Touring Diagnostics: Instruments

R/BK

ECM

Serial data

GY

BK

GY

GY

O

O

O

O

O

69
69

321 12
3

TSM/TSSM/HSFM

21 12

21 5 7
21 5 7

21 5 7

21 3 5

21 5 7

3

1
2

4

1131

13

9

9

Radio

Speedometer

Tachometer

Main to

interconnect

harness

To ignition fuse

To

battery

fuse

15A

Instruments

Fuse

To

ignition

switch

Main to interconnect

harness

[27A]
[27B]

[2B]
[2A]

[78B]
[78A]

[30B]
[30A]

[1B][1A]

[91A]

Data Link

Connector

[39B]
[39A]

[20B]

[108B]

BK/GN

BK/GN

BK/GNBK/GN

BN/GY

BN/GY

BN/GY

BN/GY

BN/GY

BN/GY

LGN/V

LGN/V

LGN/V

LGN/V

LGN/V

LGN/V

LGN/V

LGN/V

LGN/V

LGN/V

BK/GN

BK/GN

BK/GN

4412

12

ABS

9 1
9 1

[166B]

[166A]

em01111

HOME

[1]

[2]

[78]

ness

ness

(ECM)

Figure 2-18. Serial Data Circuit: FLHX, FLHT/C/U, FLTR

Table 2-14.Wire Harness Connectors

12-place DeutschAllTSM/TSSM/HFSM[30]

2008 Touring Diagnostics: Instruments 2-33

LOCATIONTYPEMODELDESCRIPTIONNO.

Inner fairing - right radio support bracket16-place Molex (Black)FLHT/CMain to interconnect har­Inner fairing - below radio (right side)16-place Molex (Black)FLTR
Inner fairing - left fairing support bracket12-place Molex (Gray)FLHT/CMain to interconnect har­Inner fairing - below radio (right side)12-place Molex (Gray)FLTR
Under seat16-place MolexAllConsole harness[20]
Inner fairing - back of radio (right side)23-place Amp (Tyco)AllRadio[27]
Cavity in crossmember at rear of battery

box (under seat)
Inner fairing (back of speedometer)12-place PackardFLHT/CSpeedometer[39]
Under bezel (back of speedometer)12-place PackardFLTR
Under seat73-place PackardAllElectronic Control Module

R/BK

69
69

2
3

1

4

ECM

Serial data

To

ignition

fuse

15A

Instruments

Fuse

To

battery

fuse

[78B]
[78A]

[30B]
[30A]

[91A]

Data Link

Connector

[39B]
[39A]

BK/GN

GY

GY

GY

O

O

21 5 7
21 5 7

Speedometer

321 12
3

TSM/TSSM/HSFM

ABS

21

9 1
9 1

12

BK/GN

BK

LGN/V

LGN/V

LGN/V

LGN/V

BN/GY

BN/GY

BN/GY

LGN/V

BK/GN

To

ignition

switch

O

21 3 5

[20B]

BN/GY

LGN/V

BK/GN

[166B]
[166A]

em01112

HOME

Table 2-14.Wire Harness Connectors

LOCATIONTYPEMODELDESCRIPTIONNO.

Under left side cover4-place DeutschAllData link connector[91]
Inner fairing (back of tachometer)12-place PackardFLHT/CTachometer[108]
Under bezel (back of tachometer)12-place PackardFLTR
Under right side cover20-place MolexAllABS module[166]

Figure 2-19. Serial Data Circuit: FLHR/C/S

2-34 2008 Touring Diagnostics: Instruments

HOME

Table 2-15. FLHR Wire Harness Connectors

12-place DeutschTSM/TSSM/HFSM[30]

LOCATIONTYPEDESCRIPTIONNO.

Under seat16-place MolexConsole harness[20]
Cavity in crossmember at rear of bat-

tery box (under seat)
Under console (back of speedometer)12-place Mini-DeutschSpeedometer[39]
Under seat73-place PackardElectronic Control Module (ECM)[78]
Under left side cover4-place DeutschData link connector[91]
Under right side cover20-place MolexABS module[166]

2008 Touring Diagnostics: Instruments 2-35

YES

NO

YES

YES

NO

YES

NO

Can you read Electronic Control Module (ECM)

hardware part number (P/N)?

See 2.3 SPEEDOMETER SELF DIAGNOSTICS.

While wiggling harness, check

continuity between terminal “3” (Gray) of

TSM/TSSM/HFSM Breakout Box and

terminal “5” of ECM Breakout Box.

Continuity present?

Check continuity between terminal

“3" (Gray) of TSM/TSSM/HFSM
breakout box and terminal “5” of

ECM breakout box.

Continuity present?

Clear codes. Test ride.

Did DTC U1016 return?

Repair intermittent

on (LGN/V) wire.

Repair open on

(LGN/V) wire.

Replace ECM.

Reprogram and learn

password.

Replace ECM.

Reprogram and learn

password.

Install Breakout Box on Turn Signal Module/

Turn Signal Security Module/Hands Free

Security Module (TSM/TSSM/HFSM).

Install Breakout Box on Turn Signal Module/

Turn Signal Security Module/Hands Free

Security Module (TSM/TSSM/HFSM).

No trouble found.

NO or “No Rsp”

1

2

1

2

Clear codes using speedometer self diagnostics.
See Section 4.6 SPEEDOMETER SELF DIAGNOSTICS.
Confirm proper operation with no check engine lamp.

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Loss of ECM Serial Data: DTC U1016

2-36 2008 Touring Diagnostics: Instruments

3

1

2

ed02043

3

2

1

ed02982

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GENERAL
Loss of TSM/TSSM/HFSM Serial Data

See Figure 2-21. The data link connector provides a means
for the ECM, TSM/TSSM/HFSM and speedometer to commu­nicate their current status.When all operating parameters on
the serial data bus are within specifications, a state of health
message is sent between the components. A DTC U1255 (only
reported by the TSM/TSSM/HFSM or speedometer) indicates
that no messages were present during power up of the current
key cycle. A DTC U1064 indicates that there was communica­tion on the data bus since power up , but was lost or interrupted
during that key cycle.

2.13DTC U1064, U1255

1. Terminal 2: ground (BK/GN)

2. Terminal 3: serial data (LGN/V)

3. Terminal 4: power (GY)
Figure 2-21. Data Link Connector

1. HFSM Antenna connector [209]

2. HFSM Antenna Jumper Harness connector [208]

3. TSM/TSSM/HFSM connector [30]
Figure 2-20. Frame Crossmember (Under Seat)

Table 2-16. Code Description

DESCRIPTIONDTC

Loss of TSM/TSSM/HFSM serial dataU1064
Serial data error/missing messageU1255

DIAGNOSTICS

TOOL NAMEPART NUMBER

BREAKOUT BOXHD-42682
INSTRUMENT HARNESS AD APTERSHD-46601

Diagnostic Notes

Each reference number below correlates to a circled number
on the flow chart(s).

1. Connect BREAKOUT BOX (Part No. HD-42682) as fol­lows:

a. Mate black socket housing on Breakout Box with

speedometer connector [39] using INSTRUMENT
HARNESS ADAPTERS (Part No. HD-46601).

b. Mate black pin housing on Breakout Box with

speedometer harness connector [39B] using
INSTRUMENT HARNESS AD APTERS (Part No. HD-

46601).

c. Mate gray socket housing on Breakout Box with

TSM/TSSM/HFSM connector [30A].

d. Mate gray pin housing on Breakout Bo x with harness

connector [30B].

2008 Touring Diagnostics: Instruments 2-37

R/BK

ECM

Serial data

GY

BK

GY

GY

O

O

O

O

O

69
69

321 12
3

TSM/TSSM/HSFM

21 12

21 5 7
21 5 7

21 5 7

21 3 5

21 5 7

3

1
2

4

1131

13

9

9

Radio

Speedometer

Tachometer

Main to

interconnect

harness

To ignition fuse

To

battery

fuse

15A

Instruments

Fuse

To

ignition

switch

Main to interconnect

harness

[27A]
[27B]

[2B]
[2A]

[78B]
[78A]

[30B]
[30A]

[1B][1A]

[91A]

Data Link

Connector

[39B]
[39A]

[20B]

[108B]

BK/GN

BK/GN

BK/GNBK/GN

BN/GY

BN/GY

BN/GY

BN/GY

BN/GY

BN/GY

LGN/V

LGN/V

LGN/V

LGN/V

LGN/V

LGN/V

LGN/V

LGN/V

LGN/V

LGN/V

BK/GN

BK/GN

BK/GN

4412

12

ABS

9 1
9 1

[166B]

[166A]

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Figure 2-22. Serial Data Circuit: FLHX, FLHT/C/U, FLTR

2-38 2008 Touring Diagnostics: Instruments

[1]

[2]

[78]

ness

ness

(ECM)

Table 2-17.Wire Harness Connectors

12-place DeutschAllTSM/TSSM/HFSM[30]

Inner fairing - right radio support bracket16-place Molex (Black)FLHT/CMain to interconnect har-

LOCATIONTYPEMODELDESCRIPTIONNO.

Inner fairing - below radio (right side)16-place Molex (Black)FLTR
Inner fairing - left fairing support bracket12-place Molex (Gray)FLHT/CMain to interconnect har­Inner fairing - below radio (right side)12-place Molex (Gray)FLTR
Under seat16-place MolexAllConsole harness[20]
Inner fairing - back of radio (right side)23-place Amp (Tyco)AllRadio[27]
Cavity in crossmember at rear of battery

box (under seat)
Inner fairing (back of speedometer)12-place PackardFLHT/CSpeedometer[39]
Under bezel (back of speedometer)12-place PackardFLTR
Under seat73-place PackardAllElectronic Control Module

R/BK

69
69

2
3

1

4

ECM

Serial data

To

ignition

fuse

15A

Instruments

Fuse

To

battery

fuse

[78B]
[78A]

[30B]
[30A]

[91A]

Data Link

Connector

[39B]
[39A]

BK/GN

GY

GY

GY

O

O

21 5 7
21 5 7

Speedometer

321 12
3

TSM/TSSM/HSFM

ABS

21

9 1
9 1

12

BK/GN

BK

LGN/V

LGN/V

LGN/V

LGN/V

BN/GY

BN/GY

BN/GY

LGN/V

BK/GN

To

ignition

switch

O

21 3 5

[20B]

BN/GY

LGN/V

BK/GN

[166B]
[166A]

em01112

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Table 2-17.Wire Harness Connectors

LOCATIONTYPEMODELDESCRIPTIONNO.

Under left side cover4-place DeutschAllData link connector[91]
Inner fairing (back of tachometer)12-place PackardFLHT/CTachometer[108]
Under bezel (back of tachometer)12-place PackardFLTR
Under right side cover20-place MolexAllABS module[166]

Figure 2-23. Serial Data Circuit: FLHR/C/S

2008 Touring Diagnostics: Instruments 2-39

HOME

Table 2-18. FLHR Wire Harness Connectors

12-place DeutschTSM/TSSM/HFSM[30]

LOCATIONTYPEDESCRIPTIONNO.

Under seat16-place MolexConsole harness[20]
Cavity in crossmember at rear of bat-

tery box (under seat)
Under console (back of speedometer)12-place Mini-DeutschSpeedometer[39]
Under seat73-place PackardElectronic Control Module (ECM)[78]
Under left side cover4-place DeutschData link connector[91]
Under right side cover20-place MolexABS module[166]

2-40 2008 Touring Diagnostics: Instruments

YES

NO

1

NOYES

YES NO

YES

1

Can you read Turn Signal Module/ Turn Signal Security

Module/Hands Free Security Module (TSM/TSSM/

HFSM) hardware part number (P/N)?

See 2.3 SPEEDOMETER SELF DIAGNOSTICS.

Install Breakout Box on Speedometer.

Check for continuity between terminal “3”

(Gray) and terminal “2” (Black) of Breakout

Box.

Continuity present?

Install Breakout Box on Speedometer.

While wiggling harness, check for

continuity between terminal “3” (Gray) and

terminal “2' (Black) of Breakout Box.

Continuity present?

Clear codes. Test ride.

Does DTC U1064

return?

Repair intermittent

on (LGN/V) wire.

Replace TSM/TSSM/HFSM.

Learn password.

Replace TSM/TSSM/HFSM.

Learn password.

No trouble found.

Repair open on

(LGN/V) wire.

NO or “No Rsp”

Clear codes using speedometer self diagnostics.
See Section 4.6 SPEEDOMETER SELF DIAGNOSTICS.
Confirm proper operation with no check engine lamp.

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Loss of TSM/TSSM/HFSM Serial Data: DTC U1064, U1255

2008 Touring Diagnostics: Instruments 2-41

ed01569

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GENERAL
Serial Data Low or Serial Data Open/High

See Figure 2-24.The typical serial data voltage range is 0 volts
(inactive) to 7 volts (active). Due to the short pulse, voltages
will be much lower on a DVOM. In analog mode, a DVOM
reading serial data will show continuous voltage when active,
typically 0.6-0.8 volts.The range for acceptable operations is
0-7.0 volts.

Table 2-19. Code Description

DESCRIPTIONDTC

Serial data lowU1300
Serial data open/highU1301

2.14DTC U1300, U1301 OR BUS ER

Figure 2-24. Electronic Control Module (ECM)

DIAGNOSTICS
Diagnostic Tips

• If serial data is shorted, these DTCs will automatically
cause the check engine lamp to illuminate.The odometer
will read "BUS Er" in this condition.

• DTCs P1009 and P1010 may accompany DTCs U1300
and U1301.

• If a U1300, U1301 or "BUS Er" is present, perform dia­gnostic procedures listed in 4.12 ST AR TS, THEN STALLS.

2-42 2008 Touring Diagnostics: Instruments

TABLE OF CONTENTS

SUBJECT............................................................................................................................PAGE NO.

3.1 TURN SIGNAL OVERVIEW.......................................................................................................3-1

3.2 HARLEY-DAVIDSON SMART SECURITY SYSTEM.................................................................3-2

3.3 H-DSSS ACTUATION................................................................................................................3-5

3.4 PERSONAL IDENTIFICATION NUMBER (PIN)........................................................................3-6

3.5 ARMING/DISARMING SECURITY SYSTEM............................................................................3-8

3.6 WARNINGS AND ALARMS.....................................................................................................3-10

3.7 SERVICE/EMERGENCY FUNCTIONS...................................................................................3-11

3.8 TROUBLESHOOTING.............................................................................................................3-12

3.9 CHECKING FOR DIAGNOSTIC TROUBLE CODES..............................................................3-13

3.10 INITIAL DIAGNOSTIC CHECK:TSM/HFSM.........................................................................3-17

3.11 SPEEDOMETER SELF-DIAGNOSTICS...............................................................................3-24

3.12 BREAKOUT BOX:TSM/HFSM..............................................................................................3-26

3.13 FAILS TO DISARM (HFSM ONLY)........................................................................................3-27

3.14 DTC B0563............................................................................................................................3-30

3.15 TSM/HFSM:TURN SIGNAL ERRORS AND DTCS..............................................................3-31

3.16 DTC B1131, B1132 (HFSM ONLY)........................................................................................3-47

3.17 DTC B1134............................................................................................................................3-50

3.18 DTC B1135............................................................................................................................3-53

3.19 DTC B1136, B1142 (HFSM ONLY)........................................................................................3-54

3.20 DTC B1141 (HFSM ONLY)....................................................................................................3-55

3.21 DTC B1143, B1144, B1145 (HFSM ONLY)...........................................................................3-61

3.22 DTC B1151, B1152, B1153...................................................................................................3-66

3.23 DTC B1154, B1155...............................................................................................................3-69

3.24 DTC U1016, U1255...............................................................................................................3-75

3.25 DTC U1300, U1301 OR BUS ER..........................................................................................3-80

3.26 TSM/HFSM: PASSWORD LEARN.........................................................................................3-81

3.27 HFSM MAINTENANCE.........................................................................................................3-82

TSM/HFSM

NOTES

HOME

3.1TURN SIGNAL OVERVIEW

GENERAL

The Turn Signal Module (TSM) has two major functions:

• Control turn signals.

• Serve as Bank Angle Sensor (BAS).

The optional, factory-installed, Harley-Davidson Smart Security
System (H-DSSS) includes a Hands-Free Security Module
(HFSM) which provides the same functions as the TSM, but
also includes security and immobilization functions.

SECURITY SYSTEM: JAPAN/KOREA

The security system on motorcycles sold in Japan and Korea
meet the regulatory requirements for those countries. The
system incorporates a Tur n Signal Security Module (TSSM).
Complete details on operation, troubleshooting, and diagnostics
are found in E.1 TSM/TSSM (JAPAN/KOREA) OVERVIEW.

TURN SIGNAL FUNCTIONS

• Manual turn signal control: Manual activation/deactiv a-
tion of left and right turn signal flashing sequences.

• Automatic turn signal cancellation: Automatic cancella-
tion of left and right turn signal flashing sequences based
on either vehicle speed, vehicle acceleration or turn com­pletion.

• Hazard warning 4-way flashers: Four-way left and right
turn signal flashing capability.

• T urn signal lamp diagnostics: Self-diagnostics for short
circuit and open lamp conditions on both left and right turn
signal systems. See 3.9 CHECKING FOR DIAGNOSTIC

TROUBLE CODES.

NOTE

The turn signals cannot be activated or deactivated when the
Ignition Switch is in the ACC position. The turn signals can
only be activated or deactivated with the Ignition Switch in the
IGNITION position.

MANUAL CANCELLATION

To stop the turn signals from flashing, briefly depress the turn
signal switch a second time.

To switch turn direction signals, depress the switch for the
opposite turn signal. The first signal is cancelled and the
opposite side begins flashing.

AUTOMATIC CANCELLATION

Press the left or right turn switch to activate automatic turn
signal cancellation.There is no need to hold the turn switch in
when approaching the turn. The TSM/HFSM will not cancel
the signal before the turn is actually completed.

• When the directional switch is released, the system starts
a 20 count. As long as the vehicle is traveling above 7

MPH (11.3 km/h) the directional will always cancel after
20 flashes if the system does not recognize any other
input.

• If the vehicle speed drops to 7 MPH (11.3 km/h) or less,
including stopped, the directionals will continue to flash.
Counting will resume when vehicle speed reaches 8
MPH (12.9 km/h) and will automatically cancel when the
count total equals 20 as stated above.

• The turn signals will cancel within two seconds upon turn
completion. A sensor inside the TSM/HFSM cancels the
signal after the vehicle has been returned to an upright
position.

NOTE

The bank angle cancellation function has an automatic calibra­tion feature. Ride the motorcycle for 0.25 miles (0.4 km) at
steady speeds (upright) to calibrate the system. Performance
of bank angle function may not be optimal until this calibration
is performed. This self-calibration is performed automatically
every time the vehicle is started and ridden.

BANK ANGLE FUNCTIONS

• Emergency engine shutdown: Will provide engine
shutdown when vehicle is tipped over.

• Emergency outputs disable: Will disable turn signal
lamps and starter motor when vehicle is tipped over.

BANK ANGLE RESTART

The engine will shut off automatically if the vehicle is tipped
over .The turn signals, starter motor, Electronic Control Module
(ECM), fuel pump and coil will be disabled.

The odometer displays "tIP" when a tip over condition is
detected.

To restart the motorcycle after shutdown has occurred:

1. Return the motorcycle to an upright position.

2. Cycle the Ignition Switch OFF-ON before restarting the
motorcycle.

CLUTCH/NEUTRAL INTERLOCK

• Disables starter: Disables starter until either the clutch
lever is pulled in or transmission neutral is selected.

• Diagnostics: Provides diagnostics for clutch and neutral
switch faults.

SECURITY SYSTEM H-DSSS

See 3.2 HARLEY-DAVIDSON SMART SECURITY SYSTEM.

2008 Touring Diagnostics: TSM/HFSM 3-1

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COMPONENTS

The Harley-Davidson Smart Security System (H-DSSS) con­sists of three components:

• Hands-Free Security Module: See Figure 3-1. A elec-
tronic module that functions both as the Turn Signal
Module (TSM) and as the Hands-Free Security Module
(HFSM).

• Hands-Free Antenna: See Figure 3-1. Mounted under
the seat of the motorcycle.

• Hands-Free Fob: See Figure 3-2. A remote control de vice,
intended to be carried by the rider whenever the vehicle
is being operated.

NOTE

Do not relocate any of the Security System components.

3.2HARLEY-DA VIDSON SMART SECURITY SYSTEM

Figure 3-1. HFSM and Antenna

Figure 3-2. Hands-Free Fob w/Serial Number Label

SECURITY IMMOBILIZATION

The Hands-Free Security System (HFSM) provides security
and immobilization functions not found on the Turn Signal
Module (TSM).The HFSM will disable the starter and ignition
system. Additional functions include the ability to alternately
flash the left and right turn signals and sound a siren (if
equipped) if a theft attempt is detected.

NOTE

The siren must be in the Chirp Mode for the siren to chirp on
arming or disarming. See 3.6 WARNINGS AND ALARMS,

Siren Chirp Mode (Confirmation).

Conditions that activate the security system when system is
armed include:

• Detecting tampering of the ignition circuit:Turn signals
flash three times, optional siren chirps once and then turns
off. If the tampering continues, a second warning will
activate after four seconds. Contin ued tampering will cause
the alarm to activate for 30 seconds and then turn off.The
two warnings/alarm cycle is repeated for each tampering
incident.

• Detecting vehicle movement: Turn signals flash three
times, optional siren chirps once and then turns off. If the
vehicle is not returned to its original position, a second
warning will activate after four seconds. If the vehicle is
not returned to its original position, the alarm activates for
30 seconds then turns off.The two warnings/alarm cycle

3-2 2008 Touring Diagnostics: TSM/HFSM

0

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may repeat a maximum of 10 times with a 10 second
pause between cycles.

• Detecting that a battery or ground disconnect has
occurred while armed: Siren, if installed, activates its

self-alarm mode.Turn signals will not flash.

See 3.5 ARMING/DISARMING SECURITY SYSTEM for more
information.

NOTE

Disconnect the battery to prevent the siren (if installed) from
activating within 5 seconds of turning the Ignition Switch to
OFF/FORK LOCK. If the HFSM is armed, you must turn the
Ignition Switch to IGNITION with a fob within range, again turn
the Ignition Switch to OFF/FORK LOCK and remove the
MAXIFUSE before the 5-second arming period expires.With
the MAXIFUSE removed, the battery can be disconnected.

HFSM FEATURES

The following inf ormation applies only to motorcycles equipped
with the Hands Free Security System (HFSM).

• Security lamp: See Figure 3-3. A lamp (key icon) within
the speedometer face tells the rider if the system is armed
or disarmed.

• Personal code disarming: If the f ob is not available, the
HFSM allows the rider to disable the security alarm and
immobilization functions with a five-digit personal code.

• Arming confirmation: When the HFSM is armed, the
system provides visual feedback (confirmation) to the rider
by flashing the turn signals and an audible "chirp" if
equipped with the optional smart siren and chirp mode is
enabled.

• Disarming confirmation: When the HFSM is disarmed,
the system provides an audible "chirp" (confirmation) if
equipped with the optional smart siren and chirp mode is
enabled.

• T ransport mode: It is possible to arm the security system
without enabling the motion detector for one ignition cycle.
This allows the vehicle to be moved in an immobilized
state.

• Starter/ignition disable: When armed the starter and
ignition system are disabled.

• Security system alarm: See Figure 3-4.The system will
alternately flash the left and right turn signals and sound

an optional Smart Siren if a vehicle security condition is
detected while the system is armed.

• Dealer service mode: This mode allows the dealer to
disable security system via DIGIT AL TECHNICIAN. Dealer
service mode is exited when module detects an assigned
fob in range.

Figure 3-3. Security Lamp (Key Icon)

Figure 3-4. Security Siren

2008 Touring Diagnostics: TSM/HFSM 3-3

1

3

Battery

+ -

Battery

Fuse

IGN Fuse

ACC Fuse

2

1

3
2

212

1

69

2

12

4

7

8

2

1

3

12

4

7

8

2

1

3

22

6

5

9

10

11

6

5

9

10

11

40 Amp

MAXIFUSE

Fuse

Block

Ignition

Switch

ECM

Speedometer

Security Lamp

Right Turn

Switch

Start
Relay

Starter

Engine

Stop Switch

Start

Switch

Clutch

Switch

Battery
Backed Siren
(Optional)

To battery

To ignition
fuse

To ignition
fuse

To ECM

Left Turn

Switch

Neutral

Switch

Receive

Hands-Free Antenna

Transmit

HFSM

TSM/HFSM

[30]

Right Turn
Lamps

Left Turn
Lamps

BK

BK

BN BN BN

BK

BK

BK

BK

GN

BK

GY

BK

GY

TN

R

V V V

RR

R/BK

R/BK

R/BK

W/BK

BK/R

BK/R

BN/GY

LGN/V

LGN/V

BK/GN

TN/GN

LGN/BN

LGN/V

Y/BK

O/Y

GND

em01175

HOME

3-4 2008 Touring Diagnostics: TSM/HFSM

Figure 3-5. Simplified TSM/HFSM Wiring