Harley Davidson 2011 Touring Models. Electrical Diagnostic Manual - page 4

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2

4

3

ed03072

1.

HDI position lamp [29-2]

2.

HDI position lamp [29-1]

3.

Headlamp [38R]

4.

Headlamp [38L]

Figure 1-7. Headlamp: FLT Models

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2

3

4

5

6

7

8

10

9

11

ed03110

1.

Front turn signals [31]

2.

Accessories off/on switch [67]

3.

Left hand controls [24]

4.

Left cruise controls [158]

5.

Front wheel speed sensor [167]

6.

Head lamp [38]

7.

Twist grip sensor [204]

8.

Right cruise controls [159]

9.

Passing lamps off/on switch [109]

10. Right hand controls [22]
11. Passing lamps [73]

Figure 1-8. Head Lamp Nacelle: FLH Models

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3

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ed03073

1.

Ambient air temperature sensor [107]

2.

Fuel tank

3.

Front WSS [167]

Figure 1-9. Front WSS and Ambient Air Temperature

Sensor

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2

ed01799

1.

Voltage regulator [77]

2.

Stator [47]

Figure 1-10. Voltage Regulator: Left Side View

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1-6  2011 Touring Diagnostics:  General Information

ed01823

Figure 1-11. CKP Sensor [79] (from underneath)

ed03074

Figure 1-12. Horn [122]

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2

3

ed03075

1.

Front fuel injector [84]

2.

Rear fuel injector [85]

3.

ET sensor [90]

Figure 1-13. Between Cylinders Left Side

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2

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4

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6

ed03076

1.

Rear spark plug wire

2.

Front spark plug wire

3.

Ignition coil [83]

4.

Starter solenoid [128]

5.

Starter

6.

Battery to starter cable

Figure 1-14. Starter Area From Left Side

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ed03111

1.

Security siren [142]

2.

Security siren (if equipped)

3.

Fuse block

4.

Main fuse [5]

5.

DLC [91]

6.

ABS diode pack [201] (if equipped)

Figure 1-15. Under Left Side Cover: Except FLTRX, FLHX,

FLHTC

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2011 Touring Diagnostics:  General Information  1-7

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ed03125

1.

Fuse block

2.

Main fuse [5]

3.

Tour-Pak [12]

4.

Main to rear lighting interconnect harness [257]

5.

DLC [91]

6.

Security siren [142]

Figure 1-16. Under Left Side Cover: FLTRX, FLHX, FLHTC

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4

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ed03077

1.

Tour-Pak lights (rear lamp fascia on FLHX) [12]

2.

Power outlet [258]

3.

Power outlet

4.

Right marker light [12-2]

5.

CB antenna cable [104]

6.

CB antenna ground

7.

Radio antenna cable ground

8.

Left marker light [12-3]

9.

Radio antenna cable [52]

Figure 1-17. Tour-Pak Interior

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4

3

2

1

ed02694

1.

Tail lamp [93]

2.

Fender tip lamp [45]

3.

Left turn signal lamp [19]

4.

Right turn signal lamp [18]

5.

Fender lights harness [94]

Figure 1-18. Rear Fender Lights Assembly

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2

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3

ed03079

1.

Tail lamp

2.

Fascia/converter module [262]

3.

Rear fender

4.

Fascia/converter module [226]

Figure 1-19. Fascia/Converter Module

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1-8  2011 Touring Diagnostics:  General Information

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ed03080

1.

Right rear speaker [36D-1]

2.

Right rear speaker [36D-2]

3.

Right rear speaker controls [41]

Figure 1-20. Rear Speaker

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7

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ed03081

1.

Front HO2S [138]

2.

ABS module [166] (if equipped)

3.

Active exhaust [179]

4.

Rear WSS [168]

5.

Rear HO2S [137]

6.

TSM/TSSM/HFSM [30]

7.

HFSM antenna jumper harness [208]

Figure 1-21. Under Right Side Cover

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2011 Touring Diagnostics:  General Information  1-9

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2

ed01820

1.

Tail light connector [7]: except FLHX, FLTRX

2.

Console pod [53]

3.

Positive battery terminal

4.

Hands-free antenna connector [209]

5.

Fuel pump subharness connector [13]

6.

Purge solenoid [95]

7.

P&A accessory connector [4]

8.

Negative battery terminal

9.

ECM [78]

Figure 1-22. Electrical Connectors Under Seat

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1-10  2011 Touring Diagnostics:  General Information

ed01800

Figure 1-23. [95] Purge Solenoid (Under seat)

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ed03082

1.

Clutch cover

2.

Rear brake switch [121]

3.

Exhaust pipe

Figure 1-24. Rear Brake Switch

ed01275

Figure 1-25. Throttle Control Connector [211]

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2

ed03085

1.

Oil pressure [139]

2.

Front frame down tube

Figure 1-26. Oil Pressure Switch

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2011 Touring Diagnostics:  General Information  1-11

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3

ed02699

1.

Ignition/light key switch [33]

2.

Indicator lights [21]

3.

Speedometer [39]

Figure 1-27. Instrument Console Connectors: FLHR, FLHRC

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2

ed03083

1.

Fuel pump [141]

2.

Fuel tank

Figure 1-28. Under Console

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ed03084

1.

Rear ACR [203R]

2.

TMAP [80]

3.

Front ACR [203F]

Figure 1-29. Between Cylinders Right Side

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1-12  2011 Touring Diagnostics:  General Information

1.2

DIAGNOSTIC TOOLS

HOW TO USE DIAGNOSTIC TOOLS

TOOL NAME

PART NUMBER

SPARK TESTER

HD-26792

FUEL INJECTOR TEST LIGHT

HD-34730-2D

DIGITAL MULTIMETER (FLUKE 78)

HD-39978

HARNESS CONNECTOR TEST KIT

HD-41404-C

BREAKOUT BOX

HD-42682

IGNITION COIL CIRCUIT TEST
ADAPTER

HD-44687

BREAKOUT BOX ADAPTERS

HD-46601

ADVANCED AUDIO SYSTEM
BREAKOUT BOX

HD-47918

ADVANCED BATTERY CONDUCT-
ANCE AND ELECTRICAL SYSTEM
ANALYZER

HD-48053

BREAKOUT BOX

HD-48637

ABS BREAKOUT BOX

HD-48642

DIGITAL TECHNICIAN II

HD-48650

HD-26792 Spark Tester

See 

Figure 1-30

. The SPARK TESTER (Part No. HD-26792)

is used to verify adequate spark at the spark plug. Attach the
tester to the spark plug wire and to ground. While cranking the
engine, a spark should jump across the gap on the tester leads.

NOTE

Engine will not spark with both spark plugs removed. When
checking for spark, use SPARK TESTER (Part No. HD-26792)
with both plugs installed.

ed02012

Figure 1-30. Spark Tester

HD-34730-2D Fuel Injector Test Light

The FUEL INJECTOR TEST LIGHT (Part No. HD-34730-2D)
and IGNITION COIL CIRCUIT TEST ADAPTER (Part No. HD-
44687) are used to test the fuel injector drivers as well as the
ignition coil drivers in the ECM.

1.

Connect the BREAKOUT BOX (Part No. HD-48637).

2.

Disconnect the fuel injector connectors.

3.

See 

Figure 1-31

 for typical setup. Connect one side of the

fuel injector test light to power and the other to the terminal
on the ECM for the circuit you are testing.

4.

Crank the engine.

5.

If the test light flashes, the circuit is working properly.

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ed01945

1.

HD-34730-2D Fuel Injector Test Light

2.

HD-44687 Ignition Coil Circuit Test Adapter

3.

HD-43876 Breakout Box

Figure 1-31. Fuel Injector Test Light

HD-39978 Digital Multimeter (Fluke 78)

The DIGITAL MULTIMETER (FLUKE 78) (Part No. HD-39978)
is used for various tests throughout this manual.

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2011 Touring Diagnostics:  General Information  1-13

4.

Is voltage between 0-1 VAC?

a.

Yes. Replace radio. See the service manual. (6103)

b.

No, battery voltage present.

Go to Test 9.

c.

No, 0V present.

Go to Test 7.

d.

No, less than battery voltage present.

Go to Test

6.

6. Receiver Audio Open Circuit Test

1.

Disconnect radio [28A] leaving breakout box connected
to harness [28B].

2.

Test for continuity between radio breakout box terminal 3
and terminal 4 of [184D], and then from radio breakout
box terminal 26 and terminal 5 of [184D].

3.

Is continuity present?

a.

Yes.

Go to Test 7.

b.

No. Repair open wire(s) (R) or (BK) between harness
[184D] and radio [28B]. (5041)

7. Receiver Audio Short to Ground Test

1.

Test for continuity between radio breakout box terminal 3
and ground. Repeat for terminal 26 and ground.

2.

Is continuity present?

a.

Yes. Repair short to ground on (R) or (BK) wire(s).
(5041)

b.

No.

Go to Test 8.

8. Receiver Audio Shorted Together Test

1.

Test for continuity between radio breakout box terminals
3 and 26.

2.

Is continuity present?

a.

Yes. Repair short circuit between (R) and (BK)
wire(s). (5041)

b.

No.

Go to Test 9.

9. Receiver Audio Harness Shorted to
Voltage Test

1.

With IGN ON, test for voltage between radio breakout box
terminal 3 to ground, and repeat for terminal 26 to ground.

2.

Is battery voltage present on either terminal to ground?

a.

Yes. Repair short to voltage on (R) or (BK) wire(s).
(5041)

b.

No. Replace the CB Module. See the service manual.
(6625)

SYMPTOM 6: INTERCOM INOPERATIVE

Table 8-43. Symptom 6: Intercom Inoperative Diagnostic

Faults

POSSIBLE CAUSES

Intercom not installed

Radio malfunction

1. Set-Up Mode Test

1.

Perform the following:

a.

Press POWER button to turn radio ON.

b.

Set Headset/Speaker switch on fairing to HEADSET.

c.

Press COM button. Press softkey 1 to turn CB radio
OFF.

d.

Press INT button. Press softkey 1 to turn intercom
ON (Setup Mode).

2.

Does intercom enter setup mode?

a.

Yes.

Go to Test 2.

b.

No.  If intercom will not enter setup mode, the
intercom is not installed. See your dealer for assist-
ance.

2. Intercom Speech Test

1.

Speak into any microphone.

2.

Is voice heard in all headsets?

a.

Yes. Intercom okay.

b.

No.

Go to Test 3.

3. VOX Maximum (Open) Test

1.

Press softkey 4 to adjust VOX sensitivity to greater than
10 bars. Set front intercom volume control to middle posi-
tion on horizontal bar graph display. Set rear volume to
middle position.

2.

Is intercom audio present both ways when speaking?

a.

Yes.

Go to Test 4.

b.

No.

Go to Test 5.

4. VOX Adjustment Test

1.

Adjust VOX level down one step at a time using softkey
6 until VOX is no longer open.

2.

Speak loudly into any microphone.

3.

Is audio present?

a.

Yes. Intercom okay.

b.

No.  Replace radio. See the service manual. (6103)

5. Headset Test

1.

Determine which headset is faulty by swapping headset
positions, or by substituting a known good headset for one
of the suspect units.

2.

Does the problem follow the suspect unit or does the
known good headset solve the problem?

a.

Yes. Replace suspect headset.

b.

No.  Replace radio. See the service manual. (6101)

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8-38  2011 Touring Diagnostics:  Audio System

SYMPTOM 7: HANDHELD
MICROPHONE/PTT INOPERATIVE

TOOL NAME

PART NUMBER

HARNESS CONNECTOR TEST KIT

HD-41404-C

RADIO BREAKOUT BOX

HD-47918

Table 8-44. Symptom 7: Handheld Microphone/PTT

Inoperative Diagnostic Faults

POSSIBLE CAUSES

PTT switch malfunction

Radio malfunction

1. Set-Up Test

1.

Perform the following:

a.

Press POWER button to turn radio ON.

b.

Press INT button. Press softkey 1 to turn intercom
OFF.

c.

Press COM button. Press softkey 1 to turn CB radio
ON.

d.

Set Headset/Speaker switch on fairing to SPEAKER.

2.

Press the handheld PTT switch. The following should
occur:

a.

Radio display shows CB mode.

b.

CB transmitter operates.

c.

CB channel number inverts.

3.

Do these changes take place?

a.

Yes. System okay.

b.

No.

Go to Test 2.

2. Switch Diagnostic Test

1.

Enter switch diagnostics mode.

2.

With handheld microphone disconnected, does display
show "Handheld PTT"?

a.

Yes.

Go to Test 3.

b.

No. Substitute microphone with a known good unit.
If display continues to show "Handheld PTT", then
continue with tests.

Go to Test 4.

Driver

Headset

[28A]

To

Ultra

Radio

(BK)

17

2

2

2

6

7

6

7

8

9

10

11

12

1
2

3

4

5
6
7

CAV

CIR

DESCRIPTION

BK

MIC IN SHARED (-)

Y/BK

HDSET SPKR SHARED (-)

Y/R

RT FRT HDSET SPKR (+)

R

FRT MIC (+)

Y/W

LFT FRT HDSET SPKR (+)

BE/Y

PUSH-TO-TALK

TAB

SHIELD

MIC SHARED SHIELD

To

Radio

[27A]

(BK)

Y/BK

BE/Y

BK

Y/R

Y/W

R

SHEILD

BE/Y

BE/Y

Y/BK
BE/Y

Y/BK
BE/Y

[28B]

[6A]

[6B]

[27B]

[53B]

[53A]

em00723

Figure 8-14. Handheld Microphone PTT Circuit

3. PTT Open Circuit Test

1.

Install RADIO BREAKOUT BOX (Part No. HD-47918) to
radio harness [27B] and [28B], leaving radio disconnected.

2.

Test for continuity between breakout box [27] terminal 2
to breakout box [28] terminal 17 using HARNESS CON-
NECTOR TEST KIT (Part No. HD-41404-C), and press
handheld PTT switch.

3.

Is continuity present?

a.

Yes. Replace radio. See the service manual. (6103)

b.

No. Substitute microphone with a known good unit
and perform step 2 again. If open still exists, repair
open wire between [27B] terminal 2 (BE/Y), or
between [28B] terminal 17 (Y/BK). (5041)

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2011 Touring Diagnostics:  Audio System  8-39