Harley Davidson 2011 Touring Models. Electrical Diagnostic Manual - page 5

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Figure 1-32. Digital Multimeter (Fluke 78) (Part No.

HD-39978)

HD-41404-C Harness Connector Test Kit

The HARNESS CONNECTOR TEST KIT (Part No. HD-41404-
C) contains pin and socket terminals and stackable banana
jack patch cords used to test circuits. The pin and socket ter-
minals are used to connect to various connectors used on the
vehicle. See the tool instruction sheet for specific terminal
usage.

NOTE

To prevent terminal damage while using the probe tips, insert
the probe tip straight into the cavity and keep it stable during
the test. Do not wiggle or move the probe tip once it has been
inserted into the terminal. Do not use more than one probe per
terminal or cavity at any one time.

HD-42682 Breakout Box (Instruments)

The BREAKOUT BOX (Part No. HD-42682) and BREAKOUT
BOX ADAPTERS (Part No. HD-46601) connect to the
speedometer [39]. Used in conjunction with a multimeter, it
allows circuit diagnosis of wiring harness and connections
without having to probe with sharp objects. Install breakout
box in series using the black connectors as follows:

Access the speedometer [39]. See the service manual.

See

Figure 1-33

. Press latch and disconnect speedometer

[39B].

Connect BREAKOUT BOX ADAPTERS (Part No. HD-
46601) to [39A] and [39B] (speedometer) or [108A] and
[108B] (tachometer).

Attach black connectors from BREAKOUT BOX (Part
No. HD-42682) to BREAKOUT BOX ADAPTERS (Part
No. HD-46601). All tests will be performed using the black
side of the breakout box.

When testing is completed, remove the breakout box and
jumper harness, and restore connections.

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Breakout box HD-42682

Breakout box adapter HD-46601

Speedometer [39]

Breakout box adapter HD-46601

Speedometer [39]

Figure 1-33. Breakout Box Connection

HD-42682 Breakout Box (TSM/TSSM/HFSM)

The BREAKOUT BOX (Part No. HD-42682) splices into the
main harness. Used in conjunction with a multimeter, it allows
circuit diagnosis of wiring harness and connections without
having to probe with sharp objects. Install breakout box in
series as follows:

NOTE

For HFSM: Disarm security system, then remove main fuse
while the system remains disarmed.

Access TSM/TSSM/HFSM. See the service manual.

Disconnect HFSM antenna jumper [208] and
TSM/TSSM/HFSM [30].

For HFSM: Press latches and disconnect [208].

Press latches and disconnect [30].

See

Figure 1-34

. Connect BREAKOUT BOX (Part No. HD-

42682) to connectors.

For HFSM: Mate antenna [208B] to HFSM.

When testing is completed remove the breakout box and
restore connections.

NOTE

Vehicle will not start with TSM/TSSM/HFSM disconnected or
incorrectly mounted.

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1-14 2011 Touring Diagnostics: General Information

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Breakout box

Breakout box to TSM/TSSM/HFSM connection

Breakout box to harness connection

Figure 1-34. Breakout Box Connection Point at

TSM/TSSM/HFSM (Typical)

HD-48637 Breakout Box (ECM)

The BREAKOUT BOX (Part No. HD-48637) splices into the
main harness. Used in conjunction with a multimeter, it allows
circuit diagnosis of wiring harness and connections without
having to probe with sharp objects. Install breakout box in
series as follows:

NOTE

See wiring diagrams for ECM terminal functions. ECM is loc-
ated under passenger seat.

Access the ECM. See the service manual.

Press latch and disconnect ECM [78].

See

Figure 1-35

. Connect BREAKOUT BOX (Part No. HD-

48637) to connectors.

When testing is completed, remove the breakout box and
restore connections.

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Breakout box

Wiring harness connector

ECM connector

Figure 1-35. Breakout Box

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Breakout box

Breakout box to ECM connector disconnected

Breakout box to harness connection

ECM [78A]

Figure 1-36. ECM Breakout Box Disconnected

HD-48642 Breakout Box (ABS)

The ABS BREAKOUT BOX (Part No. HD-48642) connects to
the ABS module [166]. Used in conjunction with a multimeter,
it allows circuit diagnosis of wiring harness and connections
without having to probe with sharp objects. Install breakout
box in series as follows:

Remove the right side cover. See the service manual.

Press latch and disconnect ABS module [166B].

See

Figure 1-37

. Connect ABS BREAKOUT BOX (Part

No. HD-48642) to connectors.

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2011 Touring Diagnostics: General Information 1-15

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Breakout box to ABS unit connection

HD-48642 breakout box

Breakout box to harness connection

Figure 1-37. Typical HD-48642 Connection

See

Figure 1-38

. In some cases it is necessary to leave

the ABS module disconnected.

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ABS [166A]

HD-48642 breakout box

Breakout box harness disconnected

Breakout box harness connection

Figure 1-38. Typical HD-48642 With ABS Module

Disconnected

When testing is completed remove the breakout box and
restore connections.

Install the right side cover. See the service manual.

HD-47918 Advanced Audio System Breakout
Box

The ADVANCED AUDIO SYSTEM BREAKOUT BOX (Part
No. HD-47918) connects to the radio at [27] and [28]. Used in
conjunction with a multimeter, it allows circuit diagnosis of
wiring harness and connections without having to probe with
sharp objects. Install breakout box in series as follows:

Remove the upper fairing and windshield. See the service
manual.

Press the latch and disconnect radio [27] and radio [28].

See

Figure 1-39

. Connect BREAKOUT BOX (Part No. HD-

47918) to connectors.

When testing is completed remove the breakout box and
restore connections.

Install the upper fairing and windshield. See the service
manual.

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HD-47918 breakout box

Breakout box to radio connection

Breakout box to harness connection

Breakout box to radio connection

Figure 1-39. Typical HD-47918 Connection

HD-44687 Ignition Coil Circuit Test Adapter

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

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

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1-16 2011 Touring Diagnostics: General Information

Disconnect the fuel injector connectors.

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.

Crank the engine.

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

HD-48053 Advanced Battery Conductance
and Electrical System Analyzer

Follow the instructions in the ADVANCED BATTERY CON-
DUCTANCE AND ELECTRICAL SYSTEM ANALYZER (Part
No. HD-48053) instruction manual to perform a battery test.
The test results include a decision on the battery condition and
the measured state of charge.

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Figure 1-40. HD-48053 Advanced Battery Conductance

and Electrical System Analyzer Kit

HD-48650 Digital Technician II

DIGITAL TECHNICIAN II (Part No. HD-48650) is a computer
based diagnostic device used to communicate/diagnose and
program systems/modules.

Diagnostics in this manual are developed under the assumption
that DTII is not available.

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2011 Touring Diagnostics: General Information 1-17

[76B]

[28B]

Ultra Radio

LFT Rear HDSET SPKR (+)

LFT FRT HDSET SPKR (+)

RT Rear HDSET SPKR (+)

RT FRT HDSET SPKR (+)

RT SDCAR HDSET SPKR (+)

HDSET SPKR Shared (-)

LFT SDCAR HDSET SPKR (+)

(BK)

[28A]

DIN On Ultra

(BK)

5
6

15
16
17

28
29

Passenger

Headset

2
3

1
2
3
4

5
6
7

MIC IN SHARED (-)

Y/BK

HDSET SPKR SHARED (-)

GY/Y

RT REAR HDSET SPKR (+)

REAR MIC (+)

GY/O

LFT REAR HDSET SPKR (+)

TAB

SHIELD

MIC SHARED SHIELD

Driver

Headset

(BK)

2 3

7 8 9

2 3

7 8 9

Y/W

Y/R

GY/BK

GY/O

GY/Y

GN/V

Y/BK

GY/O

GY/Y

Y/BK

Y/W

Y/R

GY/BK

GN/V

Y/BK

Y/W

Y/R

Y/BK

CAV

CIR

DESCRIPTION

1
2
3
4

5
6

MIC IN SHARED (-)

Y/BK

HDSET SPKR SHARED (-)

Y/R

RT HDSET SPKR (+)

FRT MIC (+)

Y/W

LFT HDSET SPKR (+)

BE/Y

PUSH-TO-TALK

TAB

SHIELD

MIC SHARED SHIELD

CAV

CIR

DESCRIPTION

[53A]

[53B]

em00866

Figure 8-16. Headset Speaker Circuit

Table 8-47. Symptom 9: Headset Speakers Inoperative

Diagnostic Faults

POSSIBLE CAUSES

Headset speaker malfunction

Radio malfunction

1. Headset Speaker Operational Test

Connect headsets to the appropriate DIN connectors.

Turn radio ON, tune to a station and place speaker switch
to HEADSET.

Do both helmet speakers work?

Yes. System okay.

No. Both helmet speakers inoperative. Substitute
or swap headsets and coil cords. If the problem clears
in the suspect unit, replace that component.

No. Rider headset.

Go to Test 2.

No. Passenger headset.

Go to Test 6.

2. Rider Headset Speaker Continuity Test

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

Table 8-48

Test for continuity between breakout box [28] and rider
DIN, using HARNESS CONNECTOR TEST KIT (Part
No. HD-41404-C).

Is continuity present?

Yes.

Go to Test 3.

No. Repair open wire between radio harness [28B]
and [53A], or [53B] and rider DIN. (5041)

Table 8-48. Rider Headset Speaker Terminations and Wire

Colors

WIRE COLOR

DIN CONNECTOR

TERMINAL

RADIO HARNESS

[28B] TERMINAL

(Y/W)

(Y/BK)

(Y/R)

3. Rider Headset Speaker Shorted Wires
Test

Test for continuity between breakout box [28] terminals 6,
17 and 29.

Is continuity present between any two terminals?

Yes. Repair shorted wires between radio harness
[28B] and [53A], or [53B] and rider DIN. (5041)

No.

Go to Test 4.

4. Rider Headset Speaker Short to Voltage
Test

Connect radio breakout box to radio [28A], and turn radio
ON.

Measure voltage between breakout box [28] terminals 6
(left) or 29 (right), to ground.

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8-42 2011 Touring Diagnostics: Audio System

Is voltage greater than 9V?

Yes. Repair short to voltage between radio harness
[28B] and [53A], or [53B] and rider DIN. (5041)

No.

Go to Test 5.

5. Rider Headset Speaker Short to Ground
Test

Turn radio off and disconnect radio breakout box from
radio [28A].

Test for continuity between breakout box [28] terminals 6
(left), 17 or 29 (right) to ground.

Is continuity present on any terminals?

Yes. Repair short to ground between radio harness
[28B] and [53A], or [53B] and rider DIN. (5041)

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

6. Passenger Headset Speaker Continuity
Test

Install ADVANCED AUDIO SYSTEM BREAKOUT
BOX (Part No. HD-47918) harness [27B] and harness
[28B] leaving radio disconnected.

Test for continuity between breakout box [28] and rider
DIN, using HARNESS CONNECTOR TEST KIT (Part
No. HD-41404-C). Refer to

Table 8-49

Is continuity present?

Yes.

Go to Test 7.

No. Repair open wire between radio harness [28B]
and [76A], or [76B] and passenger DIN. (5041)

Table 8-49. Passenger Headset Speaker Terminations and

Wire Colors

WIRE COLOR

DIN CONNECTOR

TERMINAL

RADIO HARNESS

[28B] TERMINAL

(GY/O)

(Y/BK)

(GY/Y)

7. Passenger Headset Speaker Shorted
Wires Test

Test for continuity between breakout box [28] terminals 5,
17 and 28.

Is continuity present between any two terminals?

Yes. Repair shorted wires between radio harness
[28B] and [76A], or [76B] and passenger DIN. (5041)

No.

Go to Test 8.

8. Passenger Headset Speaker Short to
Voltage Test

Connect radio breakout box to radio [28A], and turn radio
ON.

Measure voltage between breakout box [28] terminals 5
(left) or 28 (right), to ground.

Is voltage greater than 9V?

Yes. Repair short to voltage between radio harness
[28B] and [76A], or [76B] and passenger DIN. (5041)

No.

Go to Test 9.

9. Passenger Headset Speaker Short to
Ground Test

Turn radio off and disconnect radio breakout box from
radio [28A].

Test for continuity between breakout box [28] terminals 5
(left), 17 or 28 (right) to ground.

Is continuity present on any terminals?

Yes. Repair short to ground between radio harness
[28B] and [76A], or [76B] and passenger DIN. (5041)

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

SYMPTOM 10: NO OR LOW AUDIO FROM
MICROPHONES

TOOL NAME

PART NUMBER

HARNESS CONNECTOR TEST KIT

HD-41404-C

ADVANCED AUDIO SYSTEM
BREAKOUT BOX

HD-47918

Table 8-50. Symptom 10: No or Low Audio from

Microphones Diagnostic Faults

POSSIBLE CAUSES

Headset malfunction

Microphone malfunction

NOTE

Use PTT switch if intercom is not installed.

1. Headset Microphone Set-Up Test

Plug a known good headset in rider DIN connector.

Turn intercom ON, set VOX threshold to OPEN, intercom
volume to mid-level.

Speak into the microphone.

Can the audio be heard in the headset?

Yes. Replace coil cord on faulty headset and retest.
If fault persists, then continue with tests.

Go to Test

No. Perform test for each microphone driven source
installed. If no issues are found then continue with
testing.

Go to Test 2.

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2011 Touring Diagnostics: Audio System 8-43

1.3

DIAGNOSTICS AND TROUBLESHOOTING

VOLTAGE DROP

Voltage Drop Test

The voltage drop test:

•

Helps locate poor connections or components with
excessive voltage drops.

•

Measures the difference in potential or the actual voltage
dropped between the source and destination.

•

Checks the integrity of the wiring, switches, fuses, con-
nectors and contacts between the source and destination.

•

Identifies poor grounds.

A voltage drop test measures the difference in voltage between
two points in a circuit. The amount of voltage dropped over
any part of a circuit is directly related to the amount of resist-
ance in that part of the circuit.

Components such as wires, switches and connectors are
designed to have very little resistance and therefore very little
voltage drop. A voltage drop greater than 1.0V across these
components indicates a high resistance and possible fault.

The benefits of doing it this way are:

•

Readings are not as sensitive to real battery voltage.

•

Readings show the actual voltage dropped not just the
presence of voltage.

•

The system is tested as it is actually being used.

•

Testing is more accurate and displays hard-to-find poor
connections.

•

Starting circuits, lighting circuits or ignition circuits can be
tested with this approach. (Start from the most positive
and go to the most negative destination or component.)

When testing a typical power circuit, place the positive (red)
meter lead on the most positive part of the circuit (or the pos-
itive battery post). Remember, there is nothing more positive
than the positive post of the battery. Place the negative (black)
meter lead at the positive side of the connector in question.
Activate the circuit. Move the negative meter lead through the
circuit until the high voltage drop is found.

When testing a typical ground circuit, place the negative lead
on the most negative part of the circuit (or the negative battery
post). Remember, there is nothing more negative than the
negative post of the battery. Place the positive meter lead at
the negative side of the connector in question. Activate the
circuit. Move the positive meter lead through the circuit until
the high voltage drop is found.

The following steps demonstrate a typical starter circuit voltage
drop test:

Disconnect the fuel pump connector [86] to prevent the
engine from starting.

Connect the red meter lead to the positive battery
post.

Connect the black meter lead to the battery power
starter post on the starter and observe the meter
reading.

Crank the starter and observe the meter reading. The
difference in the voltage is the voltage drop.

See

Figure 1-41

. Move the black meter lead to the starter

side post of the starter solenoid. Crank the starter.

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Battery

Starter solenoid

Starter motor

Figure 1-41. To Starter Solenoid Starter Terminal

See

Figure 1-42

. Move the black meter lead to the battery

side post on the starter solenoid. Crank the starter.

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Battery

Starter solenoid

Starter motor

Figure 1-42. To Starter Solenoid Battery Terminal

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1-18 2011 Touring Diagnostics: General Information

See

Figure 1-43

. Finally move the black meter lead to the

negative battery post and the red meter lead to the starter
case. Crank the starter.

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Battery

Starter solenoid

Starter motor

Figure 1-43. Starter Ground Circuit

WIGGLE TEST

TOOL NAME

PART NUMBER

DIGITAL MULTIMETER (FLUKE 78)

HD-39978

BREAKOUT BOX

HD-48637

DIGITAL TECHNICIAN II

HD-48650

The wiggle test checks for the presence of intermittents in a
wiring harness. The DIGITAL TECHNICIAN II (Part No. HD-
48650) can be used to perform the wiggle test.

See

Figure 1-44

. Connect DIGITAL MULTIMETER (FLUKE

78) (Part No. HD-39978) to wiring harness between the
suspect connections. When diagnosing ECM connections,
use BREAKOUT BOX (Part No. HD-48637) to simplify the
procedure. See

1.2 DIAGNOSTIC TOOLS

Set the multimeter to read voltage changes.

Start the motorcycle engine and run at idle.

Shake or wiggle the harness to detect intermittents. If
intermittents are present, radical voltage changes register
on the multimeter.

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Figure 1-44. Digital Multimeter (Fluke 78) (Part No.

HD-39978)

RELAY DIAGNOSTICS

Relay Variation

See

Figure 1-45

. Relays normally have four or five terminals.

The circuitry inside the relays are very similar with the exception
of the normally closed contact being eliminated in the four ter-
minal relay. Some relays have five terminals at the base, even
though internally 4 or 87A are not connected. See this topic
whenever a relay terminal is referenced in this manual to make
sure the proper terminal is being accessed.

87A

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Standard 5 terminal relay

Standard 4 terminal relay

Figure 1-45. Standard Relays

Relay Test

A relay can be tested using the motorcycle's 12V battery and
a multimeter.

Unplug the relay from relay block.

to energize the relay.

Connect relay terminal 85 to the negative battery terminal
and relay terminal 86 to the positive battery terminal.

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2011 Touring Diagnostics: General Information 1-19

NOTE

Some relays contain internal diodes. If the applied voltage is
not the correct polarity, the diode could be damaged.

Test for continuity between terminals 30 and 87.

A good relay shows continuity (continuity tester lamp
on or a zero Ohm reading on the ohmmeter).

A malfunctioning relay will not show continuity and
must be replaced.

86 (1)

30 (3)

87 (5)

85 (2)

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Ohmmeter

Battery

Start relay

Figure 1-46. Four Terminal Relay Test

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Battery

Start relay

Ohmmeter

Figure 1-47. Five Terminal Relay Test

JOB/TIME CODES VALUES

TOOL NAME

PART NUMBER

DIGITAL TECHNICIAN II

HD-48650

Dealership technicians filing warranty claims should use the
job/time code values printed in bold text at the end of the
appropriate repair. When using DIGITAL TECHNICIAN II (Part
No. HD-48650), dealership technicians filling out warranty
claims should use the job/time code given by the computer.

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1-20 2011 Touring Diagnostics: General Information

TABLE OF CONTENTS

SUBJECT

............................................................................................................................

PAGE NO.

INITIAL DIA

GNOSTICS AND SERIAL D

Content .. 3 4 5 6 ..