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Harley Davidson FLHRC 2006. Maintenance & Repair Manual - page 37

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SPEEDOMETER/TACHOMETER

2.4

GENERAL

NOTE

60

40

Some icons may illuminate during “wow” test though the icon

50

70

30

50

has no functionality on that vehicle.

40

80

30

90

20

MPH

RPM x100

The speedometer consists of a speedometer display and sev-

20

100

eral icons. The icons include: check engine, security, battery,

10

10

110

and low fuel (EFI only).

0

120

0

TI

-D

-D

Reset Switch

1

See Figure 2-14. Pressing the odometer reset switch pro-

vides the following capabilities:

2

3

5

4

● Change the odometer display between mileage, trip A

f2160x8x

and trip B values (press and immediately release).

1.

Check Engine

2.

Low Fuel

● Reset an individual trip odometer (press and hold 2-3

3.

Battery

seconds).

4.

Security

● Gain access to the diagnostic mode, clear DTC’s and

5.

Cruise (Where Applicable)

exit diagnostic mode. See Section 2.3 SPEEDOMETER

SELF DIAGNOSTICS.

Figure 2-14. Icons (FLHX, FLHT/C/U)

● Display odometer while key is OFF. Press and hold reset

switch while key is OFF and odometer mileage will be

displayed.

● On models with dual scale speedometers, toggle

between miles/kilometers on odometer and trip odome-

ter display. To toggle display, turn key ON. Press and

hold reset switch while odometer is displayed. Release

switch when change is noted. (If reset switch is held

while trip odometer is displayed, trip odometer will reset.)

2006 Touring: Instruments

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Test 2.4 (Part 1 of 2)

TACHOMETER INOPERATIVE

Perform “wow” test. See Section 2.3 SPEEDOME-

1

TER SELF DIAGNOSTICS.

The following features should be functional

1) backlight should illuminate

2) needle should sweep its full range of motion

3) LED’s may illuminate: cruise (although not

cruise equipped on some models) pursuit

(although may not be a police vehicle)

Are all features functional?

YES

NO

Is problem intermittent?

Check for battery voltage at

2

terminal 1 of breakout box. Is

battery voltage present?

YES

NO

Repeat Diagnostic

No trouble found.

NO

Check while wiggling

harnesses.

Is instrument

fuse blown?

YES

NO

Locate and repair

Locate and repair

source of fault.

open in orange wire

Replace fuse.

between terminal 1 of

connector [108] and

YES

instrument fuse.

Check for continuity between

3

breakout box terminal 2 and

terminal 1 of connector [156B].

Is continuity present?

YES

NO

Locate and repair open

STOP

on LGN/V wire.

Go to Test 2.4 (Part

2 of 2).

2006 Touring: Instruments

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Test 2.4 (Part 2 of 2)

TACHOMETER INOPERATIVE

Continued from Test 2.4 (Part 1 of 2).

Check for continuity to ground on breakout box

terminal 7. Wiggle harness during continuity

check. Is continuity present?

YES

NO

Check for battery voltage

Locate and repair open

at breakout box terminal 5

on BK wire between ter-

while wiggling harness.

minal 7 of connector

Is battery voltage

[108] and ground.

continuously present?

YES

NO

Locate and repair open

Check for battery voltage at

on BN/GY wire between

breakout box terminal 6.

terminal 5 of connector

Is battery voltage present?

[108] and battery fuse.

YES

NO

Replace tachometer.

Locate and repair open on O/W

wire between terminal 6 of con-

nector [108] and accessory fuse.

2-18

2006 Touring: Instruments

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BREAKOUT BOX: SPEEDOMETER

2.5

GENERAL

10086

The BREAKOUT BOX (Part No. HD-42682) and INSTRU-

MENT HARNESS ADAPTERS (Part No. HD-46601) connect

to speedometer connector [39]. Used in conjunction with a

DVOM, it allows circuit diagnosis of wiring harness and con-

nections without having to probe with sharp objects

NOTE

See wiring diagrams for speedometer terminal functions.

INSTALLATION

1.

See Figure 2-16. Bend back the external latches slightly

and remove connector [39B].

2.

Connect Instrument Harness Adapters to connectors

[39A] and [39B].

3.

Attach connectors from Breakout Box to Instrument Har-

Figure 2-16. Speedometer Connector [39]

ness Adapters.

REMOVAL

1.

Detach connectors from Breakout Box to Instrument Har-

ness Adapters.

2.

See Figure 2-15. Detach Instrument Harness Adapters

from connectors [39A] and [39B].

3.

Install connector [39B] to speedometer.

f2001x8x

f1998x9x

Figure 2-17. Breakout Box (Part No. HD-42682)

Figure 2-15. Instrument Harness Adapters

(Part No. HD-46601)

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FUEL GAUGE

2.6

2.

Set MULTI-METER (Part No. HD-35500) to RXI scale to

THEORY OF OPERATION

measure the resistance of the sending unit. Place one

probe on Y/W and the other probe on a good ground.

With ignition switch ON, the fuel gauge is connected to +12

volts. Current flows through the gauge and variable resistor in

FLHX, FLHT/C/U, FLTR:

the fuel gauge sending unit to ground. The sending unit float

controls the amount of resistance in the variable resistor.

If fuel tank is full, the reading should be 7-14 ohms. An

empty tank should have a 74-95 ohm resistance. A half

Inoperative gauges may be caused by three circumstances.

full tank will be approximately 30-38 ohms.

● Sender or fuel gauge not grounded.

FLHR/C/S:

● Malfunction in sender or fuel gauge.

If fuel tank is full, the reading should be 27-40 ohms. An

empty tank should have a 240-264 ohm resistance. A

● Broken or disconnected wire from ignition switch to fuel

half full tank will be approximately 97-118 ohms.

gauge.

ALL MODELS:

Use the FUEL GAUGE AND SENDER TEST to test suspect

components.

If a very high resistance or infinity is indicated on the

meter, the sender may be “open” or not grounded. Check

that sender and fuel tank are grounded by placing one

FUEL GAUGE AND SENDER TEST

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

NOTE

higher resistance is present, check for poor connection

on ground wire.

Always refer to the applicable wiring diagram (at the rear of

this manual) when troubleshooting instruments or gauges.

3.

Check voltage to O/W (+) and BK (-) wire of fuel gauge

1.

Remove gauge. Ground Y/W wire of fuel gauge sender

connector [117] if gauge did not indicate FULL.

located at bottom of gauge. Turn ignition switch ON.

a. Fuel gauge must indicate FULL. If gauge indicated

a. Correct reading is equivalent to battery voltage.

FULL, gauge is functioning correctly. Proceed to

b. If battery voltage is not present check for broken or

step 2.

disconnected wire. Replace gauge if wiring problem

b. If gauge did not indicate FULL, proceed to step 3.

is not found.

FLT0294C

BK

BK

Light

O

O

Light

Oil

Voltmeter

Pressure

O

BN/GN

To Sender

O

To +12 vdc

BK

BK

Color Code:

NOTE

BK- Black

All gauges are shown

BN/GN-Brown/Green

as viewed from rear.

O-Orange

Figure 2-18. Connections for Gauges

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OIL, AIR AND VOLTMETER GAUGES

2.7

OIL PRESSURE GAUGE

AND INDICATOR LIGHT

Problem

Low oil pressure light remains on with engine running above

idle and/or oil pressure gauge does not work.

Cause

Solution

No oil pressure due to lack of oil or

faulty oil pump.

CAUTION

Running engine when OIL pressure light remains on and gauge indicates

low pressure will result in engine damage.

1.

Check oil level. Add oil if low.

2.

Restart engine and verify that oil pressure light goes off and gauge indicates

pressure. If problem still exists, refer to OIL PUMP in the Touring Service Manual.

Contacts in pressure sending unit

1.

Locate the oil pressure sending unit on the front right side of the crankcase.

not opening to shut off light.

2.

Verify that the electrical connector is properly connected to the sending unit.

Variable resistor in sender is

shorted to ground.

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 Connector Test Kit (HD-41404A), 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/

Light Key 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.

No power to gauge.

See Voltmeter.

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AMBIENT AIR

TEMPERATURE GAUGE

Problem

Gauge inoperative.

Cause

Solution

Sensor not grounded or open

Test for continuity between pin 1 and ground and pin 3 and gauge. Repair if open.

between sensor and gauge.

Check for 12 vdc between pins 1 and 3 at connector [115A]. Replace gauge if voltage

Broken or disconnected power or

is present. Use voltage drop tests and continuity checks to isolate if voltage is not

ground wire to gauge.

present.

Measure resistance between pins 1 and 3 at 65˚ to 85˚ F. Resistance should be 43-31

Malfunction in gauge or sensor.

ohms. Replace sensor if out of range, replace gauge if within range.

VOLTMETER GAUGE

Problem

Meter inoperative.

Cause

Solution

Broken or disconnected leads to meter

1.

With Ignition/Light Key Switch turned to IGNITION, verify that 12 vdc is

or open meter winding.

present at “±” terminal on voltmeter. With switch turned to OFF, check

ground terminal for continuity to ground.

2.

Replace the voltmeter if 12 vdc is present and ground terminal is grounded.

3.

If

12 vdc 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 12 vdc lead.

2-22

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INDICATOR LAMPS: FLHX, FLHT/C/U, FLTR

2.8

GENERAL

Indicator Lamp

See Figure 2-19. All models except FLHR/C/S are equipped

Connector [21]

with incandescent indicator lamps which may be replaced

individually. See the Touring Models Service Manual for lamp

replacement procedure. See DIAGNOSTICS which follows

for troubleshooting procedures.

Bulb

Housing

Table 2-7. Indicator Lamp Connector [21]

WIRE

TERMINAL

FUNCTION

COLOR

1

Brown

Right Turn Power

Rubber

2

Green/Yellow

Oil Pressure Lamp To Switch

Boot

3

White

High Beam Power

Paddle

4

Violet

Left Turn Power

Lense

f1346x2x

5

Black

Right Turn Ground

6

Orange

Oil Pressure Power

Figure 2-19. Indicator Lamp Assembly

7

Tan

Neutral Lamp To Switch

(FLHX, FLHT/C/U, FLTR)

8

Orange

Neutral Power

9

Black

High Beam Ground

10

Black

Left Turn Ground

Job/Time Code Values

Dealership technicians filing warranty claims should use the

Table 2-8. Indicator Lamp Wiring

job/time code values printed in bold text underneath the

appropriate repair.

INDICATOR LAMP

CONNECTION

Oil pressure

Ground Through Switch

Neutral

Ground Through Harness

High beam

12 VDC When Active

Right/left turn

12 VDC When Active

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DIAGNOSTICS

Oil Pressure or Neutral Indicator Will Not Function

Turn on ignition switch. Check for

battery voltage at connector [21A],

terminal 6 (oil) and/or terminal 8

(neutral). Turn off ignition switch.

Was battery voltage present?

YES

NO

With transmission in neutral, check

Check for blown fuses

for continuity to ground at connector

or locate open.

[21A], terminal 7 (neutral) and/or

5048

terminal 2 (oil pressure).

Is continuity present?

YES

NO

Check each terminal for continuity

Replace indicator lamp.

to ground through switch.

5191

Is continuity present?

YES

NO

NO

Repair open in GN/Y

Replace oil

Replace neutral

wire (oil pressure) or

pressure switch.

switch.

TN wire (neutral).

5161

5157

5048

High Beam or R/L Turn Signal Indicator Will Not Function

Check for ground at connector [21A],

terminal 5 (right turn), 9 (high beam)

and/or 10 (left turn). Is continuity to

ground present?

YES

NO

Check for 12 VDC when circuit is active:

Locate and repair

connector [21A], terminal 4 (left turn), termi-

open in circuit.

nal 1 (right turn) or terminal 3 (high beam).

5048

Is voltage present?

YES

NO

Replace indicator lamp.

Locate and repair

open in circuit.

5191

5048

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INDICATOR LAMPS: FLHR/C/S

2.9

GENERAL

f2095x8x

Paddles

FLHR/C/S models are equipped with Light Emitting Diode

(LED) indicators. The indicator lamp assembly is not service-

able. If one LED is bad, the entire assembly must be

replaced.

See DIAGNOSTICS which follows for troubleshooting proce-

dures.

Table 2-9. Indicator Lamp Connector [21]

TERMINAL

WIRE COLOR

FUNCTION

1

Violet

Left Turn

2

White

High Beam

3

Green/yellow

Oil Pressure

4

Brown

Right Turn

5

Tan

Neutral

6

Orange

Neutral/Oil Pressure

7

Black

Left Turn/high Beam

Figure 2-20. Release Paddles to Free

8

Not used

N/A

Indicator Lights Assembly (FLHR/C/S)

Table 2-10. LED Assembly Wiring

Job/Time Code Values

INDICATOR LAMP

CONNECTION

Oil pressure

Ground Through Switch

Dealership technicians filing warranty claims should use the

job/time code values printed in bold text underneath the

Neutral

Ground Through Harness

appropriate repair.

High beam

12 VDC When Active

Right/left turn

12 VDC When Active

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DIAGNOSTICS

Oil Pressure or Neutral Indicator Will Not Function

Check for battery voltage at ter-

minal 6 of connector [21A].

Is battery voltage present?

YES

NO

With transmission in neutral,

Check for blown

check for continuity to ground on

fuses or find open.

connector [21] at terminal 5 (neu-

tral) and terminal 3 (oil pressure).

5048

Is continuity present?

YES

NO

Replace indicator

Check each terminal for continuity

lamp assembly.

to ground through switch.

Is continuity present?

5191

YES

NO

NO

Repair open in GN/Y

Replace oil

Replace neutral

wire (oil pressure) or

pressure switch.

switch.

TN wire (neutral).

5161

5157

5048

High Beam or R/L Turn Signal Indicator Will Not Function

Check for ground at terminal 2

of connector [21A].

Is ground present?

YES

NO

Check for 12 VDC when circuit is

Locate and repair

active. Use terminal 1 (left turn), ter-

open in circuit.

minal 4 (right turn) and terminal 2

(high beam). Voltage present?

5048

YES

NO

Replace indicator

Locate and repair

lamp assembly.

open in circuit.

5191

5048

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DTC B1004, B1005

2.10

GENERAL

10086

The fuel level is monitored by the speedometer pin 9 of con-

nector [39] (Y/W).

● If the voltage on pin 9 of connector [39] exceeds the

lower limit for greater than or equal to 15 seconds, DTC

B1004 will set.

● If the voltage on pin 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 2-11. Code Description

DTC

DESCRIPTION

B1004

Fuel level sending unit low.

B1005

Fuel level sending unit high/open.

DIAGNOSTICS

Figure 2-22. Speedometer Connector [39]

Diagnostic Tips

If fuel gauge is performing erratically (possible false DTC’s),

inspect for unobstructed movement of sending unit arm.

Repair or align as necessary.

Diagnostic Notes

The reference numbers below correlate with the circled num-

bers on the 2.10 flow chart.

1.

Use HARNESS CONNECTOR TEST KIT (Part No. HD-

41404A), brown pin probe and patch cord.

2.

Connect BREAKOUT BOX (Part No. HD-42682) and

f2001x8x

INSTRUMENT HARNESS ADAPTERS (Part No. HD-

46601) between wire harness and speedometer.

f1998x9x

Figure 2-23. Breakout Box (Part No. HD-42682)

Figure 2-21. Instrument Harness Adapters

(Part No. HD-46601)

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f2332c8b

Fuel Gauge:

All except

Fuel Gauge

BK

FLHR/C/S

FLHR/C/S

[117B]

1

3

To accessory fuse

O/W

2

[117B]

1

2

3

4

To battery fuse

BN/GY

To Instrument

A B C D

[141A]

O

fuse

Fuel Level

A B C D

[141B]

Sender

Y/W

5

5

LGN/V

1

2

3

4

[13B]

[13A]

1

2

3

4

[39B]

12

5

6

7

9

[39A]

Y/W

1

2

5

6

7

9

[2A] [2B]

FLHX, FLHT/C/U, FLTR

1

BK

2

Data Link

Lt GN/V

3

Connector

GY

4

Speedometer

[91A]

12V

[78B]

5

ECM

[78A]

Figure 2-24. Fuel Sender Circuit

Table 2-12. Wire Harness Connectors in Figure 2-24.

NO.

DESCRIPTION

MODEL

TYPE

LOCATION

Inner Fairing - Right Fairing

FLHT/C

12-Place Deutsch (Gray)

[2]

Main to Interconnect Harness

Support Brace

FLTR

12-Place Deutsch (Gray)

Inner Fairing - Below Radio (Right Side)

FLHT/C

4-Place Multilock

Behind Fuel Tank (Under Seat)

[13]

Fuel Tank Harness

FLTR

4-Place Multilock

Behind Fuel Tank (Under Seat)

FLHT/C

12-Place Packard

Inner Fairing (Back of Speedometer)

[39]

Speedometer

FLTR

12-Place Packard

Under Bezel (Back of Speedometer)

[78]

ECM

All

36-Place Packard

Under Right Side Cover

[91]

Data Link

All

4-Place Deutsch

Under Right Side Cover

FLHT/C

4-Place Packard

Top of Canopy (Under Console)

[141]

Fuel Level Sender

FLTR

4-Place Packard

Top of Canopy (Under Console)

2-28

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Test 2.10: DTC B1005

FUEL LEVEL SENDING UNIT

Disconnect Speedometer connector

1

[39]. Measure voltage on terminal 2 of

connector [141B] (Y/W). Should be 0

volts. Is it?

YES

NO

Check continuity between termi-

Locate and repair short

1

nal 2 of connector [141B] (Y/W)

to voltage.

and breakout box terminal 11

2

(BK). Continuity present?

YES

NO

Check continuity to ground on

Locate and repair open

1

terminal 3 of connector [141B]

on Y/W wire.

(BK). Is continuity present?

YES

NO

Repair/replace fuel

Locate and repair open on

level sending unit.

BK wire (ground circuit).

Clear diagnostic trouble codes using speedometer

self diagnostics. See Section 2.3 SPEEDOMETER

SELF DIAGNOSTICS. Confirm proper operation

with no check engine lamp.

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Test 2.11

ACCESSORY OR IGNITION LINE OVERVOLTAGE:

DTC B1006/B1007

Is battery charger connected?

YES

NO

Disconnect battery charger. Clear codes.

Diagnose charging system.

See Section 1.7 CHARGING

NOTE

SYSTEM.

Sometimes battery charger may cause

overvoltage condition which will set

codes.

Start vehicle. Run at 3000

RPM for 5 seconds. Does

code reset?

YES

NO

Clear codes using speedometer self diagnostics.

See Section 2.3 SPEEDOMETER SELF DIAGNOS-

TICS. Confirm proper operation with no check

engine lamp.

Diagnose charging system.

System normal.

See Section 1.7 CHARGING

SYSTEM.

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d0723x2x

[39A]

[39B]

Speedometer

1

2

3

4

5

6

7

BK

8

9

10

11

BK

12

Reset

Switch

Figure 2-25. Reset Switch Circuit

Table 2-15. Wire Harness Connectors in Figure 2-25.

NO.

DESCRIPTION

MODEL

TYPE

LOCATION

FLHT/C

12-Place Packard

Inner Fairing (Back of Speedometer)

[39]

Speedometer

FLTR

12-Place Packard

Under Bezel (Back of Speedometer)

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