Harley Davidson 2011 Touring Models. Electrical Diagnostic Manual - page 3

 

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Harley Davidson 2011 Touring Models. Electrical Diagnostic Manual - page 3

 

 

Connector Information...............................................6-34

DTC P0373.......................................................................6-35

1. CKP Sensor Test...................................................6-35

DTC P0374.......................................................................6-35

1. CKP Sensor Connections Test..............................6-35
2. CKP Sensor Signal Wire Continuity Test...............6-35
3. CKP Sensor Ground Wire Continuity Test.............6-35
4. CKP Sensor Signal Wire Shorted to CKP Ground Wire
Test............................................................................6-35
5. CKP Sensor Low Shorted to Ground Test.............6-35
6. CKP Sensor Output Test........................................6-35
7. CKP Sensor Signal Wire Shorted to Ground Test..6-35

6.10 DTC P0444, P0445

Description and Operation................................................6-36

Purge Solenoid (If Equipped)....................................6-36
Connector Information...............................................6-36

DTC P0444.......................................................................6-38

1. Purge Solenoid Test...............................................6-38
2. Purge Solenoid Voltage Test..................................6-38
3. Purge Solenoid Control Wire Shorted to Ground
Test............................................................................6-38
4. Purge Solenoid Control Wire Open Test................6-38

DTC P0445.......................................................................6-38

1. Purge Solenoid Test...............................................6-38
2. Purge Solenoid Short to Voltage Test ...................6-38

6.11 DTC P0501, P0502

Description and Operation................................................6-39

Connector Information...............................................6-39

DTC P0501.......................................................................6-41

1. VSS Connections Test...........................................6-41
2. VSS Sensor Power Short to Ground Test..............6-41
3. VSS Signal Wire Short to Ground Test..................6-41
4. VSS Signal Wire Open Test...................................6-41
5. VSS Dirty or Damaged Test...................................6-41

DTC P0502.......................................................................6-41

1. VSS Sensor Power Shorted to Voltage Test..........6-41
2. VSS Signal Wire Short to Voltage Test..................6-41
3. VSS Ground Wire Open Test.................................6-41
4. VSS Signal Wire Shorted to Sensor Power Test.....6-42
5. VSS Test................................................................6-42

6.12 DTC P0505

Loss of Idle Speed Control...............................................6-43

Connector Information...............................................6-43

DTC P0505.......................................................................6-44

1. Fuel Quality Test....................................................6-44
2. Vacuum Leak Test..................................................6-44

6.13 DTC P0572

Description and Operation................................................6-45

Brake Switch.............................................................6-45
Diagnostic Tips..........................................................6-45

DTC P0572.......................................................................6-46

1. Stop Lamp Switch Validation Test..........................6-46
2. Brake Input Circuit Test..........................................6-46
3. Accessory Circuit Test...........................................6-47
4. Rear Stop Lamp Switch Circuit Test......................6-47
5. Rear Stop Lamp Switch Test.................................6-47
6. ABS Diode Pack Test.............................................6-47
7. ECM Circuit Test....................................................6-47

8. Front Stop Lamp Switch Circuit Test......................6-47
9. Front Stop Lamp Switch Test.................................6-47
10. ABS Diode Pack Test...........................................6-47
11. ECM Circuit Test..................................................6-47

6.14 DTC P0603, P0605

Description and Operation................................................6-48

DTC P0603 Test........................................................6-48
DTC P0605 Test........................................................6-48

6.15 DTC P0641, P0651

Description and Operation................................................6-49
DTC P0641.......................................................................6-50

1. Sensor Power-1 Circuit Test..................................6-50
2. Sensor Power-1 Circuit Resistance Test................6-50
3. TCA Test................................................................6-50
4. JSS Test.................................................................6-50
5. TGS Test................................................................6-50
6. VSS Test................................................................6-50

DTC P0651.......................................................................6-50

1. Sensor Power-2 Circuit Test..................................6-50
2. Sensor Power-2 Circuit Resistance Test................6-50
3. TMAP Test.............................................................6-51
4. TGS Test................................................................6-51

6.16 DTC P1001, P1002, P1003, P1004

Description and Operation................................................6-52

Connector Information...............................................6-52

DTC P1001.......................................................................6-54

1. System Relay Test.................................................6-54
2. System Relay Coil Power Circuit Test....................6-54
3. System Relay Coil Control Short to Ground Test....6-54
4. System Relay Coil Control Circuit Test..................6-54

DTC P1002.......................................................................6-54

1. System Relay Test.................................................6-54
2. System Relay Coil Short to Voltage Test...............6-54

DTC P1003.......................................................................6-54

1. System Relay Test.................................................6-54
2. System Relay Power Supply Test..........................6-54
3. System Relay Switch Side Circuit Test..................6-55
4. System Relay Power Supply Circuit Test...............6-55

DTC P1004.......................................................................6-55

1. System Relay Test.................................................6-55
2. System Relay Switch Side Short to Voltage Test....6-55
3. System Relay Coil Short to Ground Test...............6-55
4. Rear Ignition Coil Short to Voltage Test ................6-55
5. Front Ignition Coil Short to Voltage Test.................6-55

6.17 DTC P1009, P1010

Description and Operation................................................6-56

Password Problem....................................................6-56
Connector Information...............................................6-56

DTC P1009, P1010..........................................................6-57

1. Incorrect Password Test.........................................6-57
2. TSM/TSSM/HFSM Replacement Test...................6-57

6.18 DTC P1270

Description and Operation................................................6-58

TGS2 Validation.........................................................6-58
Connector Information...............................................6-58

DTC P1270.......................................................................6-60

1. ECM Connector Test..............................................6-60

TABLE OF CONTENTS  XI

TABLE OF CONTENTS

2. ECM Circuit Test....................................................6-60
3. Relay Circuit Test...................................................6-60

6.19 DTC P1351, P1352, P1354, P1355

Description and Operation................................................6-61

Connector Information...............................................6-61

DTC P1351.......................................................................6-63

1. Ignition Coil Test....................................................6-63
2. Ignition Coil Input Voltage Test...............................6-63
3. Ignition Coil Control Wire Continuity Test...............6-63
4. Ignition Coil Control Wire Shorted to Ground
Test............................................................................6-63

DTC P1352.......................................................................6-63

1. Ignition Coil Shorted to Voltage Test......................6-63
2. Ignition Coil Open Test...........................................6-63

DTC P1354.......................................................................6-64

1. Ignition Coil Test....................................................6-64
2. Ignition Coil Input Continuity Test..........................6-64
3. Ignition Coil Control Wire Continuity Test...............6-64
4. Ignition Coil Control Wire Shorted to Ground
Test............................................................................6-64

DTC P1355.......................................................................6-64

1. Ignition Coil Shorted to Voltage Test......................6-64
2. Ignition Coil Open Test...........................................6-64

6.20 DTC P1353, P1356, P1357, P1358

Description and Operation................................................6-65

Connector Information...............................................6-65

DTC P1353, P1356..........................................................6-67

1. Absence of Fuel Test.............................................6-67
2. Ignition Coil Primary Resistance Test....................6-67
3. Spark Plug Wire Test.............................................6-67
4. Ignition Coil Secondary Resistance Test ..............6-67

DTC P1357, P1358..........................................................6-67

1. Ion Sense Continuity Test......................................6-67
2. Ion Sense Resistance Test....................................6-67
3. Ion Sense Short to Voltage Test............................6-67

6.21 DTC P1475, P1477, P1478

Description and Operation................................................6-68

Connector Information...............................................6-68

DTC P1475.......................................................................6-70

1. Exhaust Actuator Test............................................6-70
2. Exhaust Actuator Voltage Test...............................6-70
3. Exhaust Actuator Motor Ground Wire Continuity
Test............................................................................6-70
4. Exhaust Actuator Motor Power Wire Continuity
Test............................................................................6-70
5. Exhaust Actuator Feedback Voltage Test..............6-70
6. Exhaust Actuator Feedback Continuity Test..........6-70
7. Exhaust Actuator Feedback Control Test...............6-70
8. Exhaust Actuator Feedback Run Test....................6-70
9. Exhaust Actuator Feedback Short to Voltage
Test............................................................................6-70
10. Exhaust Actuator Feedback Short to Ground
Test............................................................................6-71

DTC P1477.......................................................................6-71

1. Exhaust Actuator Motor Open Test........................6-71
2. Exhaust Actuator Motor Shorted to Ground Test....6-71
3. Exhaust Actuator Feedback Shorted to Ground
Test............................................................................6-71

DTC P1478.......................................................................6-71

1. Exhaust Actuator Motor High Test.........................6-71
2. Exhaust Actuator Motor Shorted to Voltage Test....6-71

6.22 DTC P1501, P1502

Description and Operation................................................6-72

Connector Information...............................................6-72

DTC P1501.......................................................................6-73

1. JSS 5V Reference Open Circuit Test.....................6-73
2. JSS 5V Reference Shorted to Ground Test...........6-73
3. JSS Signal Wire Shorted to Ground Test...............6-73
4. JSS Signal Wire Open Circuit Test........................6-74

DTC P1502.......................................................................6-74

1. JSS Ground Wire Test...........................................6-74
2. JSS 5V Reference Wire Short to Voltage Test.......6-74
3. JSS Signal Wire Short to Voltage Test...................6-74
4. JSS 5V Reference and Signal Shorted Together
Test............................................................................6-74

Side Stand Displayed on Odometer.................................6-74

1. Starts, Then Stalls Test..........................................6-74
2. Neutral Test ...........................................................6-74
3. JSS Clearance Test...............................................6-74

6.23 DTC P1510, P1511, P1512

Description and Operation................................................6-75

Throttle Actuation Control Management....................6-75

DTC P1510, P1511, P1512..............................................6-75

1. DTC Verification Test.............................................6-75

6.24 DTC P1514

Description and Operation................................................6-76

Air Flow Fault.............................................................6-76

DTC P1514.......................................................................6-76

1. DTC Verification Test.............................................6-76

6.25 DTC P1600

Description and Operation................................................6-77
DTC P1600.......................................................................6-77

1. DTC Verification Test.............................................6-77

6.26 DTC P1655, P1656

Description and Operation................................................6-78

Connector Information...............................................6-78

DTC P1655.......................................................................6-80

1. Front ACR Test......................................................6-80
2. Rear ACR Test.......................................................6-80
3. Rear ACR Control Circuit Test...............................6-80
4. Front ACR Control Circuit Short to Ground Test.....6-80
5. Rear ACR Control Circuit Short to Ground Test.....6-80
6. Shorted ACR Test..................................................6-80
7. ACR Supply Circuit Open Test...............................6-80
8. ACR Control Circuit Continuity Test.......................6-80

DTC P1656.......................................................................6-81

1. Front ACR Test......................................................6-81
2. Rear ACR Control Circuit Test...............................6-81
3. Rear ACR Test.......................................................6-81
4. Front ACR Control Circuit Test...............................6-81

6.27 DTC P2100, P2101, P2102, P2103

Description and Operation................................................6-82

Connector Information...............................................6-82

DTC P2100.......................................................................6-83

XII TABLE OF CONTENTS

TABLE OF CONTENTS

1. TCA Test................................................................6-83
2. TCA High Circuit Test.............................................6-83
3. TCA Low Circuit Test.............................................6-83

DTC P2101.......................................................................6-84

1. TCA Circuit Resistance Test..................................6-84
2. TCA Test................................................................6-84
3. TCA High Circuit Test.............................................6-84
4. TCA Low Circuit Test.............................................6-84

DTC P2102.......................................................................6-84

1. TCA High Circuit Test.............................................6-84
2. TCA Test................................................................6-84

DTC P2103.......................................................................6-84

1. TCA High Circuit Test.............................................6-84
2. TCA Low Circuit Test.............................................6-85

6.28 DTC P2105, P2107

Description and Operation................................................6-86
DTC P2105.......................................................................6-88

1. DTC Verification Test.............................................6-88

DTC P2107.......................................................................6-88

1. ECM Connector Test..............................................6-88
2. ECM Circuit Test....................................................6-88
3. Relay Circuit Test...................................................6-88

6.29 DTC P2119

Description and Operation................................................6-89
DTC P2119.......................................................................6-89

1. Air Inlet Interference Test.......................................6-89
2. Validation Test........................................................6-89

6.30 DTC P2122, P2123, P2127, P2128

Description and Operation................................................6-90
DTC P2122.......................................................................6-90

1. TGS-1 Voltage Test................................................6-90
2. TGS-1 Circuit Open Test........................................6-90
3. TGS-1 Short to Ground Test..................................6-90
4. Twist Grip Sensor Test...........................................6-90
5. TGS-1 Test.............................................................6-90
6. TGS-1 Open Test...................................................6-90
7. Sensor Power-1 Continuity Test.............................6-90
8. Sensor Power Resistance Test..............................6-91
9. TCA Test................................................................6-91
10. JSS Test...............................................................6-91
11. VSS Test..............................................................6-91

DTC P2123.......................................................................6-91

1. TGS-1 Voltage Test................................................6-91
2. TGS-1 Short to Voltage Test..................................6-91
3. TGS-1 Short to Ground Test..................................6-91
4. TGS Test................................................................6-91
5. TGS-1 Test.............................................................6-92
6. TGS-1 Open Test...................................................6-92
7. Sensor Power-1 Continuity Test.............................6-92
8. Sensor Power Resistance Test..............................6-92
9. TCA Test................................................................6-92

DTC P2127.......................................................................6-92

1. TGS-2 Voltage Test................................................6-92
2. TGS-2 Open Test...................................................6-92
3. TGS-2 Short to Ground Test..................................6-92
4. TGS Test................................................................6-92
5. TGS-2 Test.............................................................6-93
6. TGS-2 Open Test...................................................6-93
7. Sensor Power-2 Continuity Test.............................6-93

8. Sensor Power Resistance Test..............................6-93
9. TMAP Test.............................................................6-93

DTC P2128.......................................................................6-93

1. TGS-1 Voltage Test................................................6-93
2. TGS-1 Short to Voltage Test..................................6-93
3. TGS-1 Short to Ground Test..................................6-93
4. TGS Test................................................................6-93
5. TGS-1 Test.............................................................6-94
6. TGS-1 Open Test...................................................6-94
7. Sensor Power-1 Continuity Test.............................6-94
8. Sensor Power Resistance Test..............................6-94
9. TCA Test................................................................6-94

6.31 DTC P2135, P2138

Description and Operation................................................6-95
DTC P2135.......................................................................6-95

1. TPS-2 Voltage Test................................................6-95
2. TPS-2 Circuit Test..................................................6-95
3. Sensor Power Circuit Test......................................6-95
4. Sensor Ground Test...............................................6-95
5. Shorted 5V Circuit Test..........................................6-95
6. Sensor Ground Circuit Test....................................6-95
7. TPS-2 Circuit Test..................................................6-95
8. Sensor Ground Continuity Test..............................6-95
9. Ground Circuit Open Test......................................6-96

DTC P2138.......................................................................6-96

1. TGS-2 Voltage Test................................................6-96
2. TGS-2 Circuit Test..................................................6-96
3. Sensor Power Circuit Test......................................6-96
4. Sensor Ground Test...............................................6-96
5. Shorted 5V Circuit Test..........................................6-96
6. Sensor Ground Circuit Test....................................6-96
7. Sensor Ground-2 Open Circuit Test.......................6-96
8. TGS-2 Circuit Test..................................................6-96
9. Sensor Ground Continuity Test..............................6-96
10. Ground Circuit Open Test....................................6-97

6.32 DTC P2176

Description and Operation................................................6-98
DTC P2176.......................................................................6-98

1. Air Inlet Interference Test.......................................6-98
2. Validation Test........................................................6-98

6.33 ENGINE CRANKS, BUT WILL NOT
START

Description and Operation................................................6-99

Connector Information...............................................6-99

Engine Cranks But Will Not Start....................................6-101

1. Preliminary Engine Tests.....................................6-101
2. Check Engine Lamp Test.....................................6-101
3. Spark Present Test..............................................6-101

6.34 NO ECM POWER

Description and Operation..............................................6-102

Connector Information.............................................6-102

No ECM Power...............................................................6-103

1. ECM Fuse Test....................................................6-103
2. IGN Fuse Test......................................................6-103
3. ECM Connector Test............................................6-103
4. ECM Battery Wire Test........................................6-103
5. ECM Switched Voltage Test.................................6-104

TABLE OF CONTENTS  XIII

TABLE OF CONTENTS

6. ECM Ground Wires Test......................................6-104
7. Engine Stop Switch Battery Voltage Test.............6-104
8. Engine Stop Switch Test......................................6-104

6.35 STARTS, THEN STALLS

Description and Operation..............................................6-105

Diagnostic Tips........................................................6-105
Connector Information.............................................6-105

Starts, Then Stalls..........................................................6-105

1. Throttle Test.........................................................6-105
2. Jiffy Stand Test....................................................6-105
3. Neutral Switch Test..............................................6-105
4. Fuel System Test.................................................6-105

6.36 FUEL SYSTEM ELECTRICAL TEST

Description and Operation..............................................6-106

Connector Information.............................................6-106

Fuel System Electrical Test............................................6-108

1. ECM Fuse Test....................................................6-108
2. Fuel Pump Voltage Test.......................................6-108
3. Fuel Pump Open Circuit Test...............................6-108

6.37 MISFIRE AT IDLE OR UNDER LOAD

Description and Operation..............................................6-109

Diagnostic Tips........................................................6-109

In-line Spark Tester.........................................................6-109

Connector Information.............................................6-109

Misfire At Idle or Under Load..........................................6-111

1. Power Ground Continuity Test.............................6-111
2. Spark Test............................................................6-111
3. Spark Plug Wire Test...........................................6-111
4. Carbon Tracking Inspection Test..........................6-111
5. Ignition Coil Primary Wire Continuity Test ...........6-111
6. Battery to System Relay Voltage Drop Test.........6-111
7. System Relay Test ..............................................6-111
8. Battery to ECM Fuse Voltage Drop Test..............6-111
9. Battery to Fuse Block Voltage Drop Test.............6-111
10. Battery to Main Fuse Voltage Drop Test ...........6-112
11. Battery to Main Fuse Block Voltage Drop Test....6-112

ABS

7.1 ANTI-LOCK BRAKE SYSTEM (ABS)
GENERAL INFORMATION

Description and Operation..................................................7-1

Pressure Hold..............................................................7-2
Pressure Decrease......................................................7-2
Pressure Increase.......................................................7-2
Initialization Self-Test...................................................7-2
ABS Indicator..............................................................7-3

7.2 DTC C1017, C1018

Description and Operation..................................................7-4

Conditions for Setting the DTC....................................7-4
Action Taken When the DTC Sets...............................7-4
Conditions for Clearing the DTC.................................7-4
Diagnostic Tips............................................................7-4
Connector Information.................................................7-4

DTC C1017........................................................................7-5

1. ABS Fuse Test.........................................................7-5
2. Battery Circuit Short to Ground Test........................7-5

3. Battery Voltage Circuit Test......................................7-5
4. Ground Circuit Open Test........................................7-6

DTC C1018........................................................................7-6

1. Ground Circuit Open Test........................................7-6

7.3 DTC C1021, C1023

Description and Operation..................................................7-7

Conditions for Setting the DTC....................................7-7
Action Taken When the DTC Sets...............................7-7
Conditions for Clearing the DTC.................................7-7
Diagnostic Tips............................................................7-7
Connector Information.................................................7-7

DTC C1021, C1023............................................................7-8

1. DTC Verification Test...............................................7-8
2. Validation of Current DTC Test................................7-8

7.4 DTC C1025, C1027, C1206, C1208

Description and Operation..................................................7-9

Conditions for Setting the DTC....................................7-9
Action Taken When the DTC Sets...............................7-9
Conditions for Clearing the DTC.................................7-9
Diagnostic Tips............................................................7-9
Connector Information.................................................7-9

DTC C1025 (Front), C1027 (Rear), C1206, C1208..........7-10

1. Electrical Interference Test....................................7-10
2. Loose or Damaged Connections Test....................7-10
3. Validation of Current DTC Test..............................7-10
4. WSS Circuit Open Test..........................................7-10
5. Worn or Damaged Components Test.....................7-10

7.5 DTC C1032, C1034

Description and Operation................................................7-11

Conditions for Setting the DTC..................................7-11
Action Taken When the DTC Sets.............................7-11
Conditions for Clearing the DTC...............................7-11
Diagnostic Tips..........................................................7-11
Connector Information...............................................7-11

DTC C1032......................................................................7-12

1. Validation of Current DTC Test..............................7-12
2. Front WSS Low Circuit Test...................................7-12
3. Front WSS Circuits Short to Ground Test..............7-12
4. Front WSS High Circuit Test..................................7-12
5. Front WSS Low Circuit Open Test.........................7-12
6. Front WSS Short to Ground Test...........................7-12
7. Front WSS Circuits Short to Voltage Test..............7-12
8. Front WSS Circuits Shorted Together Test............7-12
9. Front WSS Continuity Test.....................................7-12
10. Front WSS Short to Voltage Test.........................7-12

DTC C1034......................................................................7-13

1. Validation of Current DTC Test..............................7-13
2. Rear WSS Low Circuit Test....................................7-13
3. Rear WSS Circuits Short to Ground Test...............7-13
4. Rear WSS High Circuit Test...................................7-13
5. Rear WSS Low Circuit Open Test..........................7-13
6. Rear WSS Circuits Short to Ground Test...............7-13
7. Rear WSS Circuits Short to Voltage Test...............7-13
8. Rear WSS Circuits Shorted Together Test.............7-13
9. Rear WSS Continuity Test.....................................7-13
10. Rear WSS Short to Voltage Test..........................7-13

7.6 DTC C1042, C1043

Description and Operation................................................7-14

XIV TABLE OF CONTENTS

TABLE OF CONTENTS

Conditions for Setting the DTC..................................7-14
Action Taken When the DTC Sets.............................7-14
Conditions for Clearing the DTC...............................7-14
Diagnostic Tips..........................................................7-14

DTC C1042......................................................................7-14

1. Ground Circuit Open Test......................................7-14
2. Pump Motor Test....................................................7-14

DTC C1043......................................................................7-15

1. Ground Circuit Open Test......................................7-15

7.7 DTC C1094

Description and Operation................................................7-16

Conditions for Setting the DTC..................................7-16
Action Taken When the DTC Sets.............................7-16
Conditions for Clearing the DTC...............................7-16
Diagnostic Tips..........................................................7-16
Connector Information...............................................7-16

DTC C1094......................................................................7-17

1. Validation of Current DTC Test..............................7-17
2. Front Brake Input Short to Voltage Test.................7-17
3. Front Stop Lamp Switch Test.................................7-18

7.8 DTC C1095

Description and Operation................................................7-19

Conditions for Setting the DTC..................................7-19
Action Taken When the DTC Sets.............................7-19
Conditions for Clearing the DTC...............................7-19
Connector Information...............................................7-19

DTC C1095......................................................................7-20

1. Validation of Current DTC Test..............................7-20
2. DTC Verification Test.............................................7-20
3. Tail/Stop Lamp Test................................................7-21
4. Ground Circuit Open Test......................................7-21
5. Front Stop Lamp Switch Test.................................7-21
6. Front Stop Lamp Switch Input Circuit Open Test....7-21
7. ABS Diode Pack Test.............................................7-21
8. Tail/Stop Lamp Circuit Open Test...........................7-21
9. Front Stop Lamp Switch Test.................................7-21
10. Accessory Circuit Test.........................................7-21

7.9 DTC C1151

Description and Operation................................................7-22

Conditions for Setting the DTC..................................7-22
Action Taken When the DTC Sets.............................7-22
Conditions for Clearing the DTC...............................7-22
Diagnostic Tips..........................................................7-22
Connector Information...............................................7-22

DTC C1151......................................................................7-23

1. Validation of Current DTC Test..............................7-23
2. Brake Lines Installation Test..................................7-23
3. ECU Test................................................................7-23

7.10 DTC C1153

Description and Operation................................................7-24

Conditions for Setting the DTC..................................7-24
Action Taken When the DTC Sets.............................7-24
Conditions for Clearing the DTC...............................7-24
Diagnostic Tips..........................................................7-24
Connector Information...............................................7-24

DTC C1153......................................................................7-25

1. Validation of Current DTC Test..............................7-25
2. Brake Lines Installation Test..................................7-25

3. ECU Test................................................................7-25

7.11 DTC C1158

Description and Operation................................................7-26

Conditions for Setting the DTC..................................7-26
Action Taken When the DTC Sets.............................7-26
Conditions for Clearing the DTC...............................7-26

DTC C1158......................................................................7-26

1. Validation of Current DTC Test..............................7-26
2. Successful Calibration Test....................................7-26

7.12 DTC C1212

Description and Operation................................................7-27

Conditions for Setting the DTC..................................7-27
Action Taken When the DTC Sets.............................7-27
Conditions for Clearing the DTC...............................7-27
Diagnostic Tips..........................................................7-27
Connector Information...............................................7-27

DTC C1212......................................................................7-28

1. Validation of Current DTC Test..............................7-28
2. Stop Lamp Switch Input Circuits Voltage Test.......7-28
3. Rear Stop Lamp Switch Input Test........................7-29
4. Rear Stop Lamp Circuit Test..................................7-29
5. Rear Stop Lamp Switch Test.................................7-29
6. Rear Stop Lamp Switch Accessory Circuit Open
Test............................................................................7-29
7. Front Stop Lamp Switch Accessory Circuit Open
Test............................................................................7-29
8. Front Stop Lamp Switch Test.................................7-29

7.13 DTC C1214

Description and Operation................................................7-30

Conditions for Setting the DTC..................................7-30
Action Taken When the DTC Sets.............................7-30
Conditions for Clearing the DTC...............................7-30
Diagnostic Tips..........................................................7-30
Connector Information...............................................7-30

DTC C1214......................................................................7-31

1. Validation of Current DTC Test..............................7-31
2. Rear Stop Lamp Switch Input Voltage Test............7-31
3. Rear Stop Lamp Switch Test.................................7-32

7.14 DTC C1216

Description and Operation................................................7-33

Conditions for Setting the DTC..................................7-33
Action Taken When the DTC Sets.............................7-33
Conditions for Clearing the DTC...............................7-33
Diagnostic Tips..........................................................7-33
Connector Information...............................................7-33

DTC C1216......................................................................7-34

1. Validation of Current DTC Test..............................7-34
2. DTC Verification Test.............................................7-34
3. Tail/Stop Lamp Test................................................7-34
4. Rear Stop Lamp Switch Input Circuit Open Test....7-35
5. ABS Diode Pack Test ............................................7-35
6. Tail/Stop Lamp Circuit Open Test...........................7-35
7. Rear Stop Lamp Switch Test.................................7-35
8. Accessory Circuit Test ..........................................7-35

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TABLE OF CONTENTS

7.15 DTC C1014, C1055-C1066, C1118,
C1121

Description and Operation................................................7-36

Circuit Description.....................................................7-36
Conditions for Setting the DTC..................................7-36
Action Taken When the DTC Sets.............................7-36
Conditions for Clearing the DTC...............................7-36
Connector Information...............................................7-36

DTC C1014, C1055-C1066, C1118, C1121.....................7-38

1. Battery Circuit Voltage Test....................................7-38
2. Battery Power Circuit Resistance Test...................7-38
3. Ignition Circuit Test................................................7-38
4. Ground Circuit Resistance Test.............................7-38

7.16 ABS INDICATOR ALWAYS ON OR
INOPERATIVE

Description and Operation................................................7-39

Diagnostic Tips..........................................................7-39
Connector Information...............................................7-39

ABS Indicator Always On or Inoperative...........................7-41

1. DTC Test................................................................7-41
2. ABS Lamp Function Test.......................................7-41
3. Serial Data Circuit Test..........................................7-41
4. ABS Fuse Test.......................................................7-41
5. ABS Power Circuit Test..........................................7-41
6. ABS Ground Circuit Test........................................7-41
7. ABS Power Circuit Short to Ground Test...............7-41

AUDIO SYSTEM

8.1 RADIO DIAGNOSTICS

Description and Operation..................................................8-1
Diagnostics.........................................................................8-1

Diagnostic Tips............................................................8-1
Radio Diagnostic Display............................................8-1

8.2 DTC B2006-B2015, RADIO SWITCH
DIAGNOSTICS

Description and Operation..................................................8-6
Diagnostics.........................................................................8-6

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

Radio Switch Diagnostics...................................................8-8

1. Checking for Diagnostic Trouble Codes (DTCs)
Test..............................................................................8-8
2. Switch Function Test ...............................................8-9
3. DTC B2007, Handlebar Audio Switch Shorted High
(Part A) Test.................................................................8-9
4. DTC B2007, Handlebar Audio Switch Shorted High
(Part B) Test.................................................................8-9
5. DTC B2007, Handlebar Mode Switch Shorted High (Part
A) Test.........................................................................8-9
6. DTC B2007, Handlebar Mode Switch Shorted High (Part
B) Test.........................................................................8-9
7. DTC B2007, Handlebar PTT/Squelch Switch Shorted
High (Part A) Test........................................................8-9
8. DTC B2007, Handlebar PTT/Squelch Switch Shorted
High (Part B) Test......................................................8-10
9. DTC B2008, Handlebar Audio Switch Shorted Low (Part
A) Test.......................................................................8-10

10. DTC B2008, Handlebar Audio Switch Shorted Low
(Part B) Test...............................................................8-10
11. DTC B2008, Handlebar Mode Switch Shorted Low
(Part A) Test...............................................................8-10
12. DTC B2008, Handlebar Mode Switch Shorted Low
(Part B) Test...............................................................8-10
13. DTC B2008, Handlebar PTT/Squelch Switch Shorted
Low (Part A) Test.......................................................8-10
14. DTC B2008, Handlebar PTT/Squelch Switch Shorted
Low (Part B) Test.......................................................8-10
15. DTC B2009, Handlebar Audio Switch Stuck or Open
(Part A) Test...............................................................8-10
16. DTC B2009, Handlebar Audio Switch Stuck or Open
(Part B) Test...............................................................8-11
17. DTC B2009, Handlebar Mode Switch Stuck or Open
(Part A) Test...............................................................8-11
18. DTC B2009, Handlebar Mode Switch Stuck or Open
(Part B) Test...............................................................8-11
19. DTC B2009, Handlebar PTT/Squelch Switch Stuck or
Open (Part A) Test.....................................................8-11
20. DTC B2009, Handlebar PTT/Squelch Switch Stuck or
Open (Part B) Test.....................................................8-11
21. DTC B2010, Passenger Audio/PTT Switch Shorted
High (Part A) Test......................................................8-12
22. DTC B2010, Passenger Audio/PTT Switch Shorted
High (Part B) Test......................................................8-12
23. DTC B2010, Passenger Mode Switch Shorted High
(Part A) Test...............................................................8-12
24. DTC B2010, Passenger Mode Switch Shorted High
(Part B) Test...............................................................8-12
25. DTC B2011, Passenger Audio/PTT Switch Shorted
Low (Part A) Test.......................................................8-13
26. DTC B2011, Passenger Audio/PTT Switch Shorted
Low (Part B) Test.......................................................8-13
27. DTC B2011, Passenger Mode Switch Shorted Low
(Part A) Test...............................................................8-13
28. DTC B2011, Passenger Mode Switch Shorted Low
(Part B) Test...............................................................8-13
29. DTC B2012, Passenger Audio/PTT Switch Stuck or
Open (Part A) Test.....................................................8-13
30. DTC B2012, Passenger Audio/PTT Switch Stuck or
Open (Part B) Test.....................................................8-13
31. DTC B2012, Passenger Mode Switch Stuck or Open
(Part A) Test...............................................................8-14
32. DTC B2012, Passenger Mode Switch Stuck or Open
(Part B) Test...............................................................8-14

8.3 DTC B2016-B2027, RADIO SPEAKER
DIAGNOSTICS

Description and Operation................................................8-15

Diagnostic Tips..........................................................8-15

B2016 Front Speakers Shorted: Without Amplifier...........8-15

1. Front Speakers Shorted (Part A) Test....................8-15
2. Front Speakers Shorted (Part B) Test....................8-15

B2016 Front Speakers Shorted: With Amplifier................8-15

1. Front Speakers Shorted (Part A) Test....................8-15
2. Front Speakers Shorted (Part B) Test....................8-15

B2017 Front Speakers Open: Without Amplifier...............8-16

1. Front Speakers Open (Part A) Test........................8-16
2. Front Speakers Open (Part B) Test........................8-16

B2017 Front Speakers Open: With Amplifier....................8-17

1. Front Speakers Open (Part A) Test........................8-17

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2. Front Speakers Open (Part B) Test........................8-17

B2018 Front Speakers Shorted to Ground: Without
Amplifier...........................................................................8-17

1. Front Speakers Shorted to Ground Test................8-17

B2018 Front Speakers Shorted to Ground: With
Amplifier...........................................................................8-17

1. Front Speakers Shorted to Ground.......................8-17

B2019 Front Speakers Shorted to Battery: Without
Amplifier...........................................................................8-18

1. Front Speakers Shorted to Battery Test.................8-18

B2019 Front Speakers Shorted to Battery: With
Amplifier...........................................................................8-18

1. Front Speakers Shorted to Battery Test.................8-18

B2020 Rear Speakers Shorted: Without Amplifier............8-18

1. Rear Speakers Shorted (Part A) Test....................8-19
2. Rear Speakers Shorted (Part B) Test....................8-19

B2020 Rear Speakers Shorted: With Amplifier.................8-20

1. Rear Speakers Shorted (Part A) Test....................8-20
2. Rear Speakers Shorted (Part B) Test....................8-20

B2021 Rear Speakers Open: Without Amplifier................8-20

1. Rear Speakers Open (Part A) Test........................8-20
2. Rear Speakers Open (Part B) Test........................8-20

B2021 Rear Speakers Open: With Amplifier.....................8-20

1. Rear Speakers Open (Part A) Test........................8-20
2. Rear Speakers Open (Part B) Test........................8-20

B2022 Rear Speakers Shorted to Ground: Without
Amplifier...........................................................................8-21

1. Rear Speakers Shorted to Ground Test................8-21

B2022 Rear Speakers Shorted to Ground: With
Amplifier...........................................................................8-21

1. Rear Speakers Shorted to Ground Test................8-21

B2023 Rear Speakers Shorted to Battery: Without
Amplifier...........................................................................8-21

1. Rear Speakers Shorted to Battery Test.................8-21

B2023 Rear Speakers Shorted to Battery: With
Amplifier...........................................................................8-21

1. Rear Speakers Shorted to Battery Test.................8-21

8.4 SERIAL DATA BUS DIAGNOSTICS

Description and Operation................................................8-22

Loss of Serial Data: DTC U1016...............................8-22
Starts then Stalls: DTC U1300, U1301......................8-22
Diagnostic Tips..........................................................8-22

DTC U1016 J1850 Loss of Communication with ECM.....8-22

1. Speed Pulse Availability Test.................................8-23
2. Serial Data Continuity Test....................................8-23

DTC U1302 Infotainment Bus Off Error............................8-24

1. Infotainment Bus Voltage Test................................8-24
2. Infotaintment Bus Shorted to Ground Test............8-24
3. Infotainment Bus Wires Shorted Together Test......8-24
4. Infotainment Bus Shorted to Voltage Test..............8-25

DTC U1306 Infotainment Bus Lost Communication with
Hands-Free Phone Module..............................................8-25

1. Hands-Free Phone Module Voltage Test...............8-27
2. Hands-Free Phone Module Jumper Harness Voltage
Test............................................................................8-27
3. Hands-Free Phone Module CAN Test....................8-27
4. Hands-Free Phone Module Jumper Harness CAN
Test............................................................................8-27

DTC U1307 Infotainment Bus Lost Communication with CB
Module..............................................................................8-27

1. CB Module Voltage Test.........................................8-27

2. CB Module CAN Test.............................................8-27

DTC U1308 Infotainment Bus Lost Communication with Future
Accessory Module (4-Pin)................................................8-27

1. Future Accessory Voltage Test..............................8-27
2. Future Accessory CAN Test..................................8-27

DTC U1310 Infotainment Bus Lost Communication with
iPod..................................................................................8-28

1. iPod Voltage Test...................................................8-28
2. iPod CAN Test........................................................8-28

DTC U1312 Infotainment Bus Lost Communication with Future
Accessory Module (12-Pin)..............................................8-28

1. Future Accessory Voltage Test..............................8-28
2. Future Accessory CAN Test..................................8-28

DTC U1313 Infotainment Bus Lost Communication with XM
Module..............................................................................8-28

1. XM Module Voltage Test........................................8-28
2. XM Module CAN Test............................................8-28

DTC U1314 Infotainment Bus Lost Communications with
Navigation Module............................................................8-28

1. Navigation Module Test.........................................8-28

DTC U1317 Infotainment Bus Lost Communication with High
Output Amplifier................................................................8-29

1. Amplifier Module Voltage Test................................8-29
2. Amplifier Module CAN Test....................................8-29
3. CAN Short to Voltage Test.....................................8-29
4. CAN Short to Ground Test.....................................8-29
5. CAN Open Test......................................................8-29

8.5 ADVANCED AUDIO SYSTEM SYMPTOMS

General.............................................................................8-30
Factory Defaults...............................................................8-30
Diagnostics.......................................................................8-31

Diagnostic Tips..........................................................8-31

Symptom 1: Radio Inoperative.........................................8-32

1. Radio Power Test...................................................8-32
2. Radio Power Continuity Test..................................8-32
3. Radio Memory Continuity Test...............................8-33

Symptom 2: Poor or No Reception...................................8-33

1. Low-Band Radio Operation Test............................8-33
2. FM-Band Radio Operation Test.............................8-33
3. Antenna Cable Test...............................................8-34
4. Antenna Cable Open Circuit Test..........................8-34
5. Antenna Cable Short Circuit Test..........................8-34
6. Antenna Base Shorted to Ground Test..................8-34
7. Antenna Base Open to Ground Plate Test.............8-34

Symptom 3: Static Present with Engine Running.............8-36

1. Static Observation Test..........................................8-36
2. Regulator Test........................................................8-36
3. Regulator Connectors Test....................................8-36
4. Ignition System Test...............................................8-36

Symptom 4: CB Transmitter Inoperative...........................8-36

1. Set-Up Test............................................................8-36
2. Push-to-Talk (PTT) Test.........................................8-36
3. CB Transmission Test............................................8-36
4. CB Reception Test.................................................8-36
5. CB Modulation Test................................................8-36
6. Microphone Test....................................................8-36
7. CB Antenna Cable Open Circuit Test....................8-37
8. CB Antenna Cable Shield Open Circuit Test.........8-37
9. CB Antenna Cable Shorted Test............................8-37

Symptom 5: CB Receiver Inoperative...............................8-37

1. Set-Up Test............................................................8-37

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TABLE OF CONTENTS

2. Receiver Audio Test...............................................8-37
3. Squelch Operation Test.........................................8-37
4. Receiver Operation Test........................................8-37
5. Receiver Audio Voltage Test..................................8-37
6. Receiver Audio Open Circuit Test..........................8-38
7. Receiver Audio Short to Ground Test....................8-38
8. Receiver Audio Shorted Together Test..................8-38
9. Receiver Audio Harness Shorted to Voltage Test...8-38

Symptom 6: Intercom Inoperative.....................................8-38

1. Set-Up Mode Test..................................................8-38
2. Intercom Speech Test............................................8-38
3. VOX Maximum (Open) Test...................................8-38
4. VOX Adjustment Test.............................................8-38
5. Headset Test..........................................................8-38

Symptom 7: Handheld Microphone/PTT Inoperative........8-39

1. Set-Up Test............................................................8-39
2. Switch Diagnostic Test...........................................8-39
3. PTT Open Circuit Test...........................................8-39
4. PTT Short Circuit to Ground Test..........................8-40

Symptom 8: Fairing Mounted Speaker Switch
Malfunction.......................................................................8-40

1. Speaker Switch Headset Mode Test......................8-40
2. Speaker Switch Speaker and Headset Mode
Test............................................................................8-40
3. Speaker Switch Mode Test....................................8-40
4. Headset SpkA Voltage Test...................................8-41
5. Headset SpkA Continuity Test...............................8-41
6. Headset SpkA Short to Ground Test.....................8-41
7. Headset SpkA Short to Voltage Test......................8-41
8. Headset SpkB Voltage Test...................................8-41
9. Headset SpkB Continuity Test...............................8-41
10. Headset SpkB Short to Voltage Test....................8-41
11. Headset SpkB Short to Ground Test...................8-41

Symptom 9: Headset Speakers Inoperative.....................8-41

1. Headset Speaker Operational Test........................8-42
2. Rider Headset Speaker Continuity Test.................8-42
3. Rider Headset Speaker Shorted Wires Test..........8-42
4. Rider Headset Speaker Short to Voltage Test.......8-42
5. Rider Headset Speaker Short to Ground Test.......8-43
6. Passenger Headset Speaker Continuity Test........8-43
7. Passenger Headset Speaker Shorted Wires Test...8-43
8. Passenger Headset Speaker Short to Voltage
Test............................................................................8-43
9. Passenger Headset Speaker Short to Ground
Test............................................................................8-43

Symptom 10: No or Low Audio from Microphones...........8-43

1. Headset Microphone Set-Up Test..........................8-43
2. Headset Microphone Voltage Test.........................8-44
3. Microphone Sum Out Voltage Test........................8-44
4. Headset Microphone Circuit Continuity Test..........8-44
5. Headset Microphone Circuit Short to Ground
Test............................................................................8-45
6. Headset Microphone Circuit Wires Shorted Together
Test............................................................................8-45
7. Headset Microphone Circuit Short to Voltage
Test............................................................................8-45

Symptom 11: No or Low Audio with High Output
Amplifier...........................................................................8-45

1. Amplifier Power Voltage Test.................................8-45
2. Amplifier CAN Test.................................................8-45
3. Amplifier Power Open Ground Test.......................8-45
4. Amplifier Power Open to Battery Test....................8-45

Symptom 12: No or Low Audio from XM or XM
Inoperative........................................................................8-46

1. XM Radio Operation Test.......................................8-46
2. XM Audio Voltage Output Test...............................8-48
3. XM Audio Output Continuity Test...........................8-48
4. XM Audio Output Short to Ground Test.................8-48
5. XM Audio Output Wires Shorted Together Test.....8-48
6. XM Audio Output Shorted to Voltage Test.............8-48
7. XM Module Power Test..........................................8-48
8. XM Module CAN Voltage Test................................8-48
9. XM Module CAN Continuity Test...........................8-48
10. XM Module Power/Ground Bus Continuity Test....8-49

Symptom 13: No or Intermittent Reception on XM
Module..............................................................................8-49

1. XM Antenna Power Test .......................................8-49
2. XM Antenna Resistance Test.................................8-49

Symptom 14: Navigation Inoperative................................8-49

1. Navigation Module Activation Test.........................8-49
2. GPS Antenna Error Test........................................8-49
3. GPS Antenna Resistance Test..............................8-49
4. GPS Module Error Test..........................................8-50
5. Screen Speed Test................................................8-50
6. Navigation CD Operation Test...............................8-50

Symptom 15: AVC Inoperative..........................................8-50

1. AVC Speed Test.....................................................8-50
2. Screen Speed Test................................................8-50

Symptom 16: Handlebar, Passenger or Sidecar Switches
Inoperative........................................................................8-50
Symptom 17: CD Skipping...............................................8-50

1. CD Player to CB/Intercom Interactivity Test...........8-50
2. Radio Input (Power) Positive Voltage Drop Test.....8-50
3. Radio Input (Power) Negative Voltage Drop Test....8-51
4. Front Motor Mount Inspection Test........................8-51
5. Exhaust System Mounts Inspection Test...............8-51

Symptom 18: Hands-Free Phone Module Initial
Diagnostics.......................................................................8-51

1. Phone Mode Enable Test.......................................8-51
2. Phone Pairing Test.................................................8-51
3. Phone Communication Test...................................8-51
4. Phonebook Download Test....................................8-51
5. Signal Strength Test...............................................8-51
6. Phone Module Power Test.....................................8-53
7. CAN Communication Test......................................8-53
8. Phone Module Continuity Test...............................8-53
9. Phone Module Open Ground Test.........................8-53
10. Phone Mode Entry Test.......................................8-53
11. Phone Module Output Test..................................8-53
12. Phone Module Continuity Test.............................8-53
13. Phone Module Audio Short to Low Test...............8-53
14. Phone Module Audio Short to Ground Test.........8-53
15. Phone Module Audio Short to Voltage Test.........8-53
16. Phone Module Antenna Test................................8-53

APPENDIX A CONNECTOR REPAIR

A.1 AUTOFUSE UNSEALED ELECTRICAL
CONNECTORS

Autofuse Unsealed Connector Repair................................A-1

General.......................................................................A-1
Disassembly................................................................A-1
Assembly....................................................................A-1

XVIII TABLE OF CONTENTS

TABLE OF CONTENTS

A.2 DELPHI 100W MICRO-PACK SEALED
CONNECTOR

Delphi 100W Micro-Pack Sealed Connector Repair..........A-2

General.......................................................................A-2
Separating Socket Housing From ECM......................A-2
Mating Socket Housing To ECM.................................A-2
Removing Socket Terminal.........................................A-2
Installing Socket Terminal...........................................A-2
Crimping Terminals.....................................................A-2

A.3 DELPHI 150 METRI-PACK SEALED
CONNECTORS

Delphi 150 Metri-Pack Sealed Connector Repair..............A-4

General.......................................................................A-4
Separating Pin and Socket Housings.........................A-4
Mating Pin and Socket Housings................................A-4
Removing Socket Terminal.........................................A-4
Inserting Socket Terminal............................................A-4

A.4 DELPHI 280 METRI-PACK UNSEALED
CONNECTORS

Fuse Block Repair..............................................................A-6

Removing Socket Terminals........................................A-6
Installing Socket Terminals..........................................A-6
Crimping Terminals.....................................................A-6

A.5 DELPHI 480 METRI-PACK UNSEALED
CONNECTORS

Delphi 480 Metri-Pack Unsealed Connector Repair..........A-7

General.......................................................................A-7
Separating Pin and Socket Housings.........................A-7
Mating Pin and Socket Housings................................A-7
Removing Socket Terminals........................................A-7
Installing Socket Terminals..........................................A-7

A.6 DELPHI 630 METRI-PACK UNSEALED
CONNECTORS

Delphi 630 Metri-Pack Unsealed Connector Repair..........A-8

Separating Pin and Socket Housings.........................A-8
Mating Pin and Socket Housings................................A-8
Removing Socket Terminal.........................................A-8
Installing Socket Terminal...........................................A-8

A.7 DELPHI 800 METRI-PACK SEALED MAIN
FUSE HOUSING

Delphi 800 Metri-Pack Sealed Main Fuse Housing
Repair................................................................................A-9

Removing Socket Terminals........................................A-9
Installing Socket Terminals..........................................A-9

A.8 DELPHI METRI-PACK TERMINAL
REPAIR

Metri-Pack Terminal Crimps.............................................A-11

Matching Terminal To Crimper..................................A-11
Preparing Wire Lead.................................................A-11
Crimping Wire Core..................................................A-11
Crimping Insulation/Seal...........................................A-11
Inspecting Crimps.....................................................A-12

A.9 DELPHI MICRO 64 SEALED
CONNECTORS

Delphi Micro 64 Sealed Connector Repair.......................A-13

General.....................................................................A-13
Separating Pin and Socket Housings.......................A-13
Mating Pin and Socket Housings..............................A-13
Removing Terminal...................................................A-13
Installing Terminal.....................................................A-14
Preparing Wire Leads for Crimping...........................A-14
Crimping Terminals...................................................A-14
Inspecting Crimps.....................................................A-14

A.10 DELPHI GT 150 SEALED
CONNECTORS

Delphi GT 150 Sealed Connector Repair.........................A-16

General.....................................................................A-16
Separating Pin and Socket Housings.......................A-16
Mating Pin and Socket Housings..............................A-16
Removing Socket Terminals......................................A-16
Installing Socket Terminals........................................A-16

A.11 DELPHI GT 280 SEALED 73-TERMINAL
ECM CONNECTOR

Delphi GT 280 Sealed 73-Terminal ECM Connector.......A-18

Separating Socket Housing From ECM....................A-18
Mating Socket Housing To ECM...............................A-18
Socket Terminal.........................................................A-18
ECM Ground Terminal..............................................A-18

A.12 DEUTSCH DT SEALED CONNECTORS

Deutsch DT Sealed Connector Repair.............................A-20

General.....................................................................A-20
Separating Pin and Socket Housings.......................A-20
Mating Pin and Socket Housings..............................A-20
Removing Socket Terminals......................................A-20
Installing Socket Terminals........................................A-20
Removing Pin Terminals...........................................A-22
Installing Pin Terminals.............................................A-22
Crimping Terminals...................................................A-23

A.13 DEUTSCH DT SEALED TERMINAL
REPAIR

Deutsch DT Sealed Terminal Crimps...............................A-24

Preparing Wire Leads for Crimping...........................A-24
Crimping Terminal to Lead........................................A-24
Inspecting Crimps.....................................................A-24

A.14 DEUTSCH DTM SEALED MINI
TERMINAL REPAIR

Deutsch DTM Sealed Mini Terminal Crimps....................A-25

Preparing Wire Leads for Crimping...........................A-25
Crimping a Mini Terminal to Wire Lead.....................A-25
Inspecting Crimps.....................................................A-25

A.15 DEUTSCH DTM SEALED SOLID
BARREL MINI TERMINAL REPAIR

Deutsch DTM Sealed Solid Barrel Terminal Crimps........A-26

Preparing Wire Leads For Crimping.........................A-26
Adjusting Crimper Tool..............................................A-26

TABLE OF CONTENTS  XIX

TABLE OF CONTENTS

Crimping a Barrel Contact To Wire Lead...................A-26
Inspecting Crimps.....................................................A-26

A.16 JAE MX19 SEALED CONNECTORS

JAE MX19 Sealed Connectors.........................................A-28

Connector Housings.................................................A-28
Removing Terminals.................................................A-28
Installing Terminals...................................................A-28

A.17 MOLEX CMC SEALED CONNECTORS

Molex CMC Sealed Connectors.......................................A-29

Separating the Connector.........................................A-29
Removing Terminals.................................................A-29
Installing Terminals...................................................A-29

A.18 MOLEX MX 150 SEALED
CONNECTORS

Molex MX 150 Sealed Connector Repair.........................A-31

Separating Pin and Socket Housings.......................A-31
Mating Pin and Socket Housings..............................A-31
Removing Terminals.................................................A-31
Installing Terminals...................................................A-31

Crimp Terminal to Lead....................................................A-32

Prepare Lead............................................................A-32
Prepare Tool..............................................................A-32
Position Terminal in the Punch/Die...........................A-33
Insert Stripped Lead.................................................A-33
Crimp Terminal to Lead.............................................A-34
Inspect Crimp............................................................A-34

A.19 TYCO 070 MULTILOCK UNSEALED
CONNECTOR

Tyco 070 Multilock Unsealed Connector Repair..............A-35

General.....................................................................A-35
Separating Pin and Socket Housings.......................A-35
Mating Pin and Socket Housings..............................A-35
Removing Terminals from Housing...........................A-35
Inserting Terminals into Housing...............................A-36
Preparing Wire Leads for Crimping...........................A-36
Crimping Terminals to Leads....................................A-37
Inspecting Crimped Terminals...................................A-38

A.20 SEALED SPLICE CONNECTORS

Sealed Splice Connector Repair......................................A-39

General.....................................................................A-39
Preparing Wire Leads...............................................A-39

Splicing Wire Leads..................................................A-39
Inspecting Seals.......................................................A-39

APPENDIX B WIRING

B.1 CONNECTORS

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

Function/Location.......................................................B-1
Place and Color..........................................................B-1
Connector Number......................................................B-1
Repair Instructions......................................................B-1

B.2 WIRING DIAGRAMS

Wiring Diagram Information...............................................B-7

Wire Color Codes........................................................B-7
Wiring Diagram Symbols............................................B-7

2011 Touring Wiring Diagrams...........................................B-9

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

REFERENCE MATERIAL

TOOLS...........................................................I

TORQUE VALUES.....................................XIII

INDEX.........................................................XV

XX TABLE OF CONTENTS

TABLE OF CONTENTS

1.1

SPECIFICATIONS AND COMPONENT
LOCATIONS

SPECIFICATIONS

Table 1-1. Fuel System Specifications

TYPE

FUEL SYSTEM

Side draft throttle body

Intake

91 Octane

Recommended fuel

Table 1-2. Idle Speed Specifications

RPM

ADJUSTMENT

950-1050 Nominal, non-

adjustable

Normal idle speed

Table 1-3. Battery Specifications

SPECIFICATIONS

BATTERY

12V/28 AH/405CCA

Size

Sealed, AGM

Type

Table 1-4. Spark Plug Specifications

SPECIFICATIONS

SPARK PLUG

0.97-1.09 mm

0.038-0.043 in.

Gap

16.3-24.4 Nm

12-18 ft-lbs

Torque with anti-seize
applied to threads

Harley-Davidson No. 6R12

Type

Table 1-5. Spark Plug Cables

REAR

FRONT

SPECIFICA-

TION

16.5-17

34.5-35

Length in.

419-431

876-889

Length mm

4125-11,334

8625-23,334

Resistance-
ohms

Table 1-6. Ignition Coil Specifications

RESISTANCE

WINDING

0.5-0.7 Ohm

Ignition coil primary resistance
at room temperature

5500-7500 Ohms

Ignition coil secondary resist-
ance at room temperature

Table 1-7. Starter Specifications

SPECIFICATIONS

STARTER

200A

Cranking current

3000 rpm (min)

Free speed

90A

Free current

8.0 ft-lbs (10.8 Nm)

Stall torque

Table 1-8. Fuel Pump Pressure Specifications

VALUE

RANGE

55-62 psi (380-425 kPA)

Normal

Table 1-9. Alternator Specifications

VALUE

MEASUREMENT

16-23 VAC per 1000 rpm

AC voltage output

0.1-0.2 Ohm

Stator coil resistance

Table 1-10. Regulator Specifications

VALUE

MEASUREMENT

35-50A

Amperes @ 3000 rpm

14.3-14.7V @ 75 °F (24 °C)

Voltage @ 3600 rpm

Table 1-11. Fuse Specifications

RATING (AMPERES)

ITEM

15

Instruments fuse

15

Accessory fuse

15

Battery fuse

15

ECM PWR fuse

15

Fuel pump fuse

15

Ignition fuse

15

Lights fuse

40

Main fuse

2

P&A IGN fuse

15

Exhaust control

15

Brake fuse

15

P&A fuse

15

Radio power/siren fuse

15

Headlamp fuse

30

ABS fuse

15

Radio memory fuse

15

Power outlet fuse

HOME

2011 Touring Diagnostics:  General Information  1-1

COMPONENT LOCATIONS

Some components and connectors are not easily located on

the motorcycle. The following graphics show locations for these
components and connectors. The graphics are generally
ordered from front to back around the motorcycle.

1

2

5

7

12

9

10

13

14

15

16

8

11

6

3

4

ed03066

9.

1.

Radio [28]

Right front speaker [34+]

2.

10.

Right front speaker [34-]

Radio [27]

11.

3.

GPS [193]

Voltmeter [111]

4.

12.

Voltmeter lamp [110]

Main to interconnect harness [1]

13.

5.

Main to interconnect harness [15]

Tachometer [108]

6.

14.

Speedometer [39]

TGS harness [204]

15.

7.

Interconnect to right handle bar switches [22]

Indicator lamps [21]

8.

16.

CB antenna cable [50]

Right front turn signal/auxiliary lamp [31R]

Figure 1-1. Right Side Behind Upper Fairing

HOME

1-2  2011 Touring Diagnostics:  General Information

7

8

13

9

14

15

16

1

11

12

2

3

4

10

5

18

17

6

ed03067

10.

1.

Audio to interconnect harness [6]

Indicator lamps [21]

2.

11.

Tachometer [108]

Main to interconnect harness [2]

12.

3.

Heated grips [189]

Speedometer [39]

4.

13.

Fuel gauge lamp [116]

Cigar lighter [132]

14.

5.

CB module [184]

Left front speaker [35+]

6.

15.

Left front speaker [35-]

Radio [28]

16.

7.

Radio [27]

Left front turn signal/auxiliary lamp [31L]

8.

17.

Fuel gauge [117]

GPS [193]

18.

9.

CB antenna cable [50]

Interconnect to left handlebar switches [24]

Figure 1-2. Left Side Inner Fairing: Except FLT models

HOME

2011 Touring Diagnostics:  General Information  1-3

1

2

ed03068

1.

Steering head

2.

Ground to upper triple clamp [GND3]

Figure 1-3. Steering Head Ground

1

6

2

3

4

5

ed03069

1.

Indicator lamps [21]

2.

Instrument nacelle switches [105 A/B]

3.

Ambient air temperature sensor [107]

4.

Tachometer [108]

5.

Speedometer [39]

6.

Speaker switches [105 C/D]

Figure 1-4. FLTR Instruments

1

2

3

5

9

10

11

6

7

8

12

13

4

ed03070

8.

1.

Fairing cap switches [105]

Voltmeter lamp [110]

2.

9.

Voltmeter [111]

Right front turn signal [31RA]

10.

3.

Right front speaker [34B-2]

Main to interconnect harness [1]

4.

11.

Radio [27]

Right front speaker [34B-1]

12.

5.

Oil pressure gauge [113]

Audio to interconnect harness [6]

6.

13.

Main to interconnect harness [15]

Oil pressure gauge lamp [112]

7.

Interconnect to right handlebar switches [22]

Figure 1-5. FLTR Right Side Behind Upper Fairing

HOME

1-4  2011 Touring Diagnostics:  General Information

1

10

3

2

12

13

15

4

14

16

6

7

8

9

11

5

ed03071

9.

1.

Ambient air temperature gauge [115]

Radio [27]

2.

10.

CB antenna cable [50]

Left front speaker [35B-]

11.

3.

Left front speaker [35B+]

CB module [184]

4.

12.

Ground to upper triple clamp [GND3]

Cigar lighter [132]

13.

5.

Left front turn signal [31L]

Interconnect to left handlebar switches [24]

6.

14.

Fuel gauge lamp [116]

Main to interconnect harness [2]

15.

7.

HDI position lamps [29]

Fuel gauge [117]

8.

16.

Ambient air temperature gauge lamp [114]

Radio [28]

Figure 1-6. Left Side Inner Fairing: FLT models

HOME

2011 Touring Diagnostics:  General Information  1-5

 

 

 

 

 

 

 

 

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