Harley Davidson 2005 touring models. Service repair manual

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10.

Insert bolt through battery positive cable

(red) into

1WARNING

threaded hole of battery positive (+) terminal. Tighten

bolt to 60-96 in-lbs (6.8-10.9 Nm).

Always turn the battery load tester OFF before discon-

necting the tester cables from the battery terminals. Dis-

11.

Insert bolt through battery negative cable (black) into

connecting tester cables with the load tester ON could

threaded hole of battery negative (-) terminal. Tighten

cause a spark resulting in a battery explosion. A battery

bolt to 60-96 in-lbs (6.8-10.9 Nm).

explosion may rupture the battery case causing a dis-

12.

Apply a light coat of petroleum jelly or corrosion retardant

charge or spray of sulfuric acid which could result in

material to both battery terminals.

death or serious injury.

13.

Rotate the hold-down clamp so that the lip (with rubber

9. Place the fully charged battery into the battery box, ter-

pad) rests on the edge of the battery. Using a T-40 TORX

minal side forward.

drive head, tighten the clamp bolt to 15-20 ft-lbs (20-27

Nm).

CAUTION

14.

Install seat.

Connect the cables to the correct battery terminals or

damage to the motorcycle electrical system will occur.

1WARNING

Always connect the positive battery cable first. If the pos-

itive cable should contact ground with the negative cable

installed, the resulting sparks may cause a battery explo-

sion which could result in death or serious injury.

CAUTION

Overtightening bolts can damage battery terminals.

1-20

2005 Touring: Starting & Charging

INSTRUMENTS

Table Of Contents

SUBJECT

PAGE NO.

2.1 Checking For Diagnostic Trouble Codes

2-1

2.2 Initial Diagnostic Check: Speedometer

2-4

2.3 Speedometer Self Diagnostics

2-13

2.4 Speedometer/Tachometer

2-15

2.5 Breakout Box: Speedometer

2-19

2.6 Fuel Gauge

2-20

2.7 Oil, Air and Voltmeter Gauges

2-21

2.8 Indicator Lamps: FLTR, FLHT/C/U

2-23

2.9 Indicator Lamps: FLHR/C/S

2-25

2.10 DTC B1004, B1005

2-27

2.11 DTC B1006, B1007

2-31

2.12 DTC B1008

2-33

2.13 DTC U1016

2-36

2.14 DTC U1064, U1255

2-42

2.15 DTC U1300, U1301 or "BUS Er"

2-48

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CHECKING FOR DIAGNOSTIC TROUBLE CODES

2.1

CHECK ENGINE LAMP

To diagnose electronic control module (ECM) or ignition con-

trol module (ICM) system problems, start by observing the

behavior of the check engine lamp.

NOTES

MPH

RPM x100

100

●

See Figure 2-2. “Key ON” means that the ignition key is

turned to ON and the engine stop switch is set to RUN

110

(although the engine is not running).

120

●

When the ignition switch is turned ON, the check engine

lamp will illuminate for approximately four seconds and

-D

then turn off.

●

If the check engine lamp is not illuminated at Key ON.

See 2.2 INITIAL DIAGNOSTIC CHECK: SPEEDOME-

TER.

Check Engine Lamp

f2160x8x

●

If the check engine lamp comes on late (after 20 sec-

onds). See 2.2 INITIAL DIAGNOSTIC CHECK: SPEED-

Figure 2-1. Speedometer

OMETER.

●

If the check engine lamp fails to turn OFF after the initial

four second period. See

2.2 INITIAL DIAGNOSTIC

CHECK: SPEEDOMETER.

See Figure 2-3. After lamp turns off after being illumi-

nated for the first four second period, one of three situa-

tions may occur.

a. The lamp remains off. This indicates there are no

current fault conditions or stored diagnostic trouble

codes (DTC) currently detected by the ignition con-

trol module

(ICM) or electronic control module

(ECM).

b. The lamp stays off for only four seconds and then

comes back on for an eight second period. This indi-

f1240x2x

cates an diagnostic trouble code is stored, but no

current diagnostic trouble code exists.

Figure 2-2. Ignition Switch (FLTR, FLHT/C/U)

c. If the lamp remains on beyond the eight second

period, then a current diagnostic trouble code exists.

See CODE TYPES which follows for a complete descrip-

tion of diagnostic trouble code formats.

NOTES

Some diagnostic trouble codes can only be fully diagnosed

during actuation. For example, a problem with the ignition coil

will be considered a current fault even after the problem is

corrected, since the ECM/ICM will not know of its resolution

until after the coil is exercised by vehicle start sequence. In

this manner, there may sometimes be a false indication of the

current diagnostic trouble code.

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2-1

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1. See Figure 2-3. After lamp turns off after being illumi-

SECURITY LAMP

nated for the first four second period, one of three situa-

tions may occur.

To diagnose TSM/TSSM system problems, start by observing

the behavior of the security lamp.

a. The lamp remains off. This indicates there are no

current fault conditions or stored diagnostic trouble

NOTES

codes currently detected by the ignition control mod-

● To provide an indication of TSSM diagnostic trouble

ule (ICM) or electronic control module (ECM).

codes, the security lamp is enabled on TSSM models.

b. The lamp stays off for only four seconds and then

● See Figure 2-2. “Key ON” means that the ignition key is

comes back on for an eight second period. This indi-

turned to ON and the engine stop switch is set to RUN

cates an diagnostic trouble code is stored, but no

(although the engine is not running).

current diagnostic trouble code exists.

● When the ignition switch is turned ON, the check engine

c. If the lamp remains on beyond the eight second

lamp will illuminate for approximately four seconds and

period, then a current diagnostic trouble code exists.

then turn off.

2. See CODE TYPES which follows for a complete descrip-

● If the check engine lamp is not illuminated at Key ON,

tion of diagnostic trouble code formats.

see 2.2 INITIAL DIAGNOSTIC CHECK: SPEEDOME-

TER.

NOTE

Some diagnostic trouble codes can only be fully diagnosed

● If the check engine lamp comes on late (after 20 sec-

during actuation. For example, a problem with the turn signals

onds), see 2.2 INITIAL DIAGNOSTIC CHECK: SPEED-

will be considered a current fault even after the problem is

OMETER.

corrected, since the TSM/TSSM will not know of its resolution

● If the check engine lamp fails to turn OFF after the initial

until after the turn signals are activated. In this manner, there

four second period, see

2.2 INITIAL DIAGNOSTIC

may sometimes be a false indication of a diagnostic trouble

CHECK: SPEEDOMETER.

code.

4 Sec.

Lamp OFF: No Current or Historic DTCs

OFF

Key ON

Lamp ON 8 Seconds:

Only Historic DTCs Exist

4 Sec.

8 Sec.

Lamp OFF

OFF

4 Sec.

Key ON

Lamp Remains ON: Current DTC *

4 Sec.

OFF

4 Sec.

Key ON

* Historic DTCs May Also Exist

Figure 2-3. Check Engine and Security Lamp Operation

2-2

2005 Touring: Instruments

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CODE TYPES

RETRIEVING DIAGNOSTIC

TROUBLE CODES

There are two types of diagnostic trouble codes (DTCs): cur-

rent and historic. If a diagnostic trouble code is stored, it can

be read using speedometer self diagnostics. See

2.3

The engine management system provides two levels of diag-

SPEEDOMETER SELF DIAGNOSTICS.

nostics.

All diagnostic trouble codes reside in the memory of the

● The most sophisticated mode employs a computer

ECM/ICM, TSM/TSSM, speedometer or tachometer until the

based diagnostic package called DIGITAL TECHNICIAN

code is cleared by use of the speedometer self diagnostics.

(Part No. HD-44750).

See 2.3 SPEEDOMETER SELF DIAGNOSTICS.

● The second mode requires using the speedometer self

A historic diagnostic trouble code is also cleared after a total

diagnostics. Speedometer, tachometer

(if equipped),

of 50 trips has elapsed. A trip consists of a start and run

TSM/TSSM and ECM/ICM diagnostic trouble codes can

cycle. After the 50 trip retention period, the diagnostic trouble

be accessed and cleared. See 2.3 SPEEDOMETER

code is automatically erased from memory providing that no

SELF DIAGNOSTICS.

subsequent faults of the same type are detected in that

period.

Current

MULTIPLE DIAGNOSTIC TROUBLE

Current diagnostic trouble codes are those which presently

disrupt motorcycle operation. See the appropriate flow charts

CODES

for solutions.

While it is possible for more than one fault to occur and set

Historic

more than one diagnostic trouble code, there are several con-

ditions which may result in one fault setting multiple diagnos-

If a particular problem happens to resolve itself, the active

tic trouble codes:

status is dropped and it becomes a historic fault rather than a

current fault.

Serial data diagnostic trouble codes (DTC U1016, U1064,

U1097, U1255, U1300 and U1301) may be accompanied by

Historic trouble codes can only be retrieved using a computer

other codes. Always correct the serial data diagnostic trouble

based diagnostic package called DIGITAL TECHNICIAN

codes before resolving the other codes.

(Part No. HD-44750).

Historic trouble codes are stored for a length of time to assist

For proper resolution to multiple diagnostic trouble codes

in the diagnosis of intermittent faults.

refer to diagnostic trouble code priority chart page 2-6,Table

2-2.

It is important to note that historic trouble codes may also be

present whenever the system indicates the existence of a

current fault. See MULTIPLE DIAGNOSTIC TROUBLE

CODES if multiple diagnostic trouble codes are found.

Diagnostic charts are designed for use with current trouble

codes and as a result they frequently suggest wire repair or

part replacement.

2005 Touring: Instruments

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INITIAL DIAGNOSTIC CHECK: SPEEDOMETER

2.2

GENERAL

● Constant power is supplied to the speedometer through

terminal 5 of connector [39]. The speedometer turns on

when power is applied to terminal 1 of connector [39].

The speedometer goes through an initialization

sequence every time power is removed and re-applied to

terminal 6. The visible part of this sequence is the check

engine lamp (in “run” mode), security lamp (models with

security only), backlighting, odometer and fuel level (EFI

only). Upon key ON, the check engine lamp and security

lamp will illuminate for 4 seconds and then (if parameters

are normal) go out.

● To locate faulty circuits or other system problems, follow

Fuse

Block

Maxi-Fuse

the diagnostic flow charts and tests in this section. For a

Cover

systematic approach, always begin with INITIAL DIAG-

f2206x8x

NOSTICS which follows. Read the general information

and then work your way through the flow chart box by

Figure 2-4. Remove Left Side Cover

box.

● Loss of power on any of the four power inputs will

change speedometer behavior. Refer to Table

2-1.

Speedometer Function Chart-Loss Of Input.

Diagnostic Notes

If a numbered circle appears adjacent to a flow chart box,

then more information is offered in the diagnostic notes. Many

diagnostic notes contain supplemental information, descrip-

tions of various diagnostic tools or references to other parts

of the manual where information on the location and removal

of components may be obtained.

Maxi-Fuse

f2207x8x

Circuit Diagram/Wire Harness

Figure 2-5. Remove Maxi-Fuse Cover

Connector Table

When working through a flow chart, refer to the illustrations,

the associated circuit diagram and the wire harness connec-

tor table as necessary. The wire harness connector table for

each circuit diagram identifies the connector number, descrip-

tion, type and general location.

In order to perform most diagnostic routines, a Breakout Box

and a digital volt/ohm meter (DVOM) are required. See 2.5

BREAKOUT BOX: SPEEDOMETER.

To perform the circuit checks with any degree of efficiency, a

familiarity with the various wire connectors is also necessary.

2-4

2005 Touring: Instruments

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INITIAL DIAGNOSTICS

Spare Fuse

Holder

Fuse Block

Diagnostic Tips

Cover

● If Speedometer reads “BUS Er” with the ignition key

turned ON (engine stop switch at RUN with the engine

off), check data bus for an open or short to ground.

between data link connector [91A] terminal 3 and ICM

connector [10B] terminal 12 (carbureted models), ECM

connector [78B] terminal 5 (EFI models), TSSM connec-

tor [30B] terminal 3, Speedometer connector [39B] termi-

nal

2 or tachometer

(if equipped) connector

[108B]

terminal 2.

● Check for an open data test terminal between data link

f2209x8x

connector [91A] terminal 3 and TSM/TSSM connector

[30B] terminal 3. With ignition key turned ON, serial data

f2203x8x

bus voltage should be typically 0.6-0.8 volts. The range

of acceptable voltage is greater than 0 and less than 7.0

volts.

● To identify intermittents, wiggle instrument and/or vehicle

harness while performing steps in the Diagnostic Check

charts.

Diagnostic Notes

The reference numbers below correlate with the circled num-

bers on the diagnostic check flow charts. See page 2-11.

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

INSTRUMENT HARNESS ADAPTERS (Part No. HD-

46601) between wire harness and speedometer.

1. Headlamp

Radio Power

All Speedometer diagnostic trouble codes are listed on page

2. Ignition

Accessory

2-6 in Table 2-2.

3. Lighting

Battery

4. Instruments

10. Brake Light Relay

5. Brakes/Cruise

11. P&A

6. Radio Memory

Other Codes

Figure 2-6. Fuse Block (FLTR, FLHTC/U)

See 3.9 INITIAL DIAGNOSTIC CHECK: TSM/TSSM for any

diagnostic trouble codes related to the turn signal module

(TSM) or turn signal security module (TSSM).

See 4.4 INITIAL DIAGNOSTIC CHECK: ICM for any diagnos-

tic trouble codes related to the ignition control module (ICM).

See 5.5 INITIAL DIAGNOSTIC CHECK: EFI for any diagnos-

tic trouble codes related to the electronic control module

(ECM).

2005 Touring: Instruments

2-5

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Table 2-1. Speedometer Function Chart-Loss Of Input

Terminal 5

Terminal 8 and 11

Terminal 1 (IGN)

Terminal 6 (ACC)

Terminal 7 (GRD)

(Constant)

(Reset Switch)

● Security lamp

● Will not “wow”

● Speedometer will

● Speedometer com-

● No reset switch

glows dimly dur-

be non-functional

pletely non-functional

function

● Turn signals still functional

ing 4-second

in accessory and

● Diagnostics absent

● Will not “wow”

● Speedometer will indicate

bulb check

ignition modes

vehicle speed (zero)

● Security lamp still

● Tachometer unaffected

performs 4-sec-

● Security lamp still func-

ond bulb check in

tional

ignition mode

● Check engine lamp and

battery lamp non-func-

tional

● Diagnostics absent

Table 2-2. Speedometer/Tachometer Diagnostic Trouble Codes (DTC) Priority Chart

DTC

PRIORITY

FAULT CONDITION

SOLUTION

MODULE

2.15 DTC U1300, U1301

“BUS Er”

Serial data bus shorted low/open/high

Speedometer/tachometer

or “BUS ER”

2.15 DTC U1300, U1301

U1300

Serial data bus shorted low

Speedometer/tachometer

or “BUS ER”

2.15 DTC U1300, U1301

U1301

Serial data bus shorted open/high

Speedometer/tachometer

or “BUS ER”

U1016

Loss of ECM serial data

2.13 DTC U1016

Speedometer/tachometer

U1064

Loss of TSM/TSSM serial data

2.14 DTC U1064, U1255

Speedometer/tachometer

Missing response from other module

U1255

2.14 DTC U1064, U1255

Speedometer/tachometer

(TSM/TSSM and/or ICM/ECM) at startup

B1007

Ignition line overvoltage

2.11 DTC B1006, B1007

Speedometer/tachometer

B1006

Accessory line overvoltage

2.11 DTC B1006, B1007

Speedometer/tachometer

B1008

Reset switch closed

2.12 DTC B1008

Speedometer

B1004

Fuel level sending unit low

2.10 DTC B1004, B1005

Speedometer

B1005

Fuel level sending unit high/open

2.10 DTC B1004, B1005

Speedometer

2-6

2005 Touring: Instruments

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f2332e8x

[156B] [156A]

Main to Interconnect

Harness

LtGN/V

4 5 6 7 8 9 10 11 12

[30B]

BN/GY

4 5 6 7 8 9 10 11 12

[30A]

TSM/TSSM

BN/GY

[39B]

4 5 6 7 8 9 10 11 12

[39A]

4 5 6 7 8 9 10 11 12

[8B]

Speedometer

4 5 6 7 8 9 10 11 12

[8A]

[108B]

4 5 6 7 8 9 10 11 12

Ignition

[108A]

Harness

Ignition

Tachometer

Keyswitch

Relay

15A

Instruments

[1B] [1A]

Fuse

Main to Interconnect

[2A]

4 5 6 7 8 9 10 11 12

Harness

[2B]

4 5 6 7 8 9 10 11 12

Data Link

[91A]

Main to Interconnect

15A

Harness

Ignition

Fuse

15A

[10B]

Battery

[10A]

Ignition Control Module

Fuse

Figure 2-7. Diagnostic Check: FLHT/C (Carbureted)

Table 2-3. Wire Harness Connectors in Figure 2-7.

NO.

DESCRIPTION

TYPE

LOCATION

[1]

Main to Interconnect Harness

12-Place Deutsch (Black)

Inner Fairing - Right Radio Support Bracket

[2]

Main to Interconnect Harness

12-Place Deutsch (Gray)

Inner Fairing - Right Fairing Support Brace

[8]

Ignition Harness

12-Place Deutsch

Under Right Side Cover

[10]

Ignition Control Module

12-Place Deutsch

Under Right Side Cover

Cavity in Crossmember at Rear of Battery Box

[30]

Turn Signal/Security Module

12-Place Deutsch

(Under Seat)

[39]

Speedometer

12-Place Packard

Inner Fairing (Back of Speedometer)

[91]

Data Link

4-Place Deutsch

Under Right Side Cover

[108]

Tachometer

12-Place Packard

Inner Fairing (Back of Tachometer)

[156]

Main to Interconnect Harness

6-Place Deutsch

Inner Fairing - Right Fairing Support Brace

2005 Touring: Instruments

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f2332d8x

LtGN/V

BN/GY

5 6 7 8 9 10 11 12

[30B]

5 6 7 8 9 10 11 12

[30A]

BN/GY

TSM/TSSM

4 5 6 7 8 9 10 11 12

[39B]

4 5 6 7 8 9 10 11 12

[39A]

Speedometer

4 5

10 11 12

[8B] Ignition

15A

4 5

10 11 12

[8A] Harness

Instruments

Fuse

15A

Battery

Fuse

Ignition

Keyswitch

Relay

Data Link

[91A]

15A

Ignition

Fuse

[10B]

[10A]

Ignition Control Module

Figure 2-8. Diagnostic Check: FLHR/S (Carbureted)

Table 2-4. Wire Harness Connectors in Figure 2-8.

NO.

DESCRIPTION

TYPE

LOCATION

[8]

Ignition Harness

12-Place Deutsch

Under Right Side Cover

[10]

Ignition Control Module

12-Place Deutsch

Under Right Side Cover

Cavity in Crossmember at Rear of

[30]

Turn Signal/Security Module

12-Place Deutsch

Battery Box (Under Seat)

[39]

Speedometer

12-Place Packard

Under Console (Back of Speedometer)

[91]

Data Link

4-Place Deutsch

Under Right Side Cover

2-8

2005 Touring: Instruments

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[156B] [156A]

f2332a8x

Main to Interconnect

Harness

LtGN/V

4 5 6 7 8 9 10 11 12

[30B]

BN/GY

4 5 6 7 8 9 10 11 12

[30A]

BN/GY

TSM/TSSM

[39B]

4 5 6 7 8 9 10 11 12

[39A]

Speedometer

4 5 6 7 8 9 10 11 12

[8B]

Ignition

[108B]

4 5 6 7 8 9 10 11 12

[8A]

Harness

[108A]

Tachometer

Ignition

15A

Keyswitch

Instruments

[1B] [1A]

Relay

Fuse

Main to Interconnect

Harness

4 5 6 7 8 9 10 11 12

Data Link

[2B]

[2A]

4 5 6 7 8 9 10 11 12

15A

Ignition

Main to Interconnect

Fuse

[91A]

Harness

[78B]

15A

ECM

Battery

[78A]

Fuse

Figure 2-9. Diagnostic Check: FLTR, FLHT/C/U (Fuel Injected)

Table 2-5. Wire Harness Connectors in Figure 2-9.

NO.

DESCRIPTION

MODEL

TYPE

LOCATION

Main to Interconnect

FLHT/C

12-Place Deutsch (Black)

Inner Fairing - Right Radio Support Bracket

[1]

Harness

FLTR

12-Place Deutsch (Black)

Inner Fairing - Below Radio (Right Side)

Main to Interconnect

FLHT/C

12-Place Deutsch (Gray)

Inner Fairing - Right Fairing Support Brace

[2]

Harness

FLTR

12-Place Deutsch (Gray)

Inner Fairing - Below Radio (Right Side)

[8]

Ignition Harness

All

12-Place Deutsch

Under Right Side Cover

[10]

Ignition Control Module

All

12-Place Deutsch

Under Right Side Cover

Turn Signal/Security

Cavity in Crossmember at Rear of

[30]

All

12-Place Deutsch

Module

Battery Box (Under Seat)

FLHT/C

12-Place Packard

Inner Fairing (Back of Speedometer)

[39]

Speedometer

FLTR

12-Place Packard

Under Bezel (Back of Speedometer)

[91]

Data Link

All

4-Place Deutsch

Under Right Side Cover

FLHT/C

12-Place Packard

Inner Fairing (Back of Tachometer)

[108]

Tachometer

FLTR

12-Place Packard

Under Bezel (Back of Tachometer)

Main to Interconnect

FLHT/C

6-Place Deutsch

Inner Fairing - Right Fairing Support Brace

[156]

Harness

FLTR

6-Place Deutsch

Inner Fairing - Below Radio (Right Side)

2005 Touring: Instruments

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f2332b8x

LtGN/V

BN/GY

4 5 6 7 8 9 10 11 12

[30B]

4 5 6 7 8 9 10 11 12

[30A]

BN/GY

TSM/TSSM

4 5 6 7 8 9 10

[39B]

4 5 6 7 8 9 10

[39A]

Speedometer

8 9 10 11 12

[8B] Ignition

8 9 10 11 12

[8A] Harness

15A

Instruments

Fuse

15A

Ignition

Battery

Keyswitch

Fuse

Relay

15A

Ignition

Fuse

Data Link

[91A]

[78B]

ECM

[78A]

Figure 2-10. Diagnostic Check: FLHR/C/S (Fuel Injected)

Table 2-6. Wire Harness Connectors in Figure 2-10.

NO.

DESCRIPTION

TYPE

LOCATION

[8]

Ignition Harness

12-Place Deutsch

Under Right Side Cover

[10]

Ignition Control Module

12-Place Deutsch

Under Right Side Cover

Cavity in Crossmember at Rear of

[30]

Turn Signal/Security Module

12-Place Deutsch

Battery Box (Under Seat)

[39]

Speedometer

12-Place Mini-Deutsch

Under Console (Back of Speedometer)

[78]

Electronic Control Module

36-Place Packard

Under Right Side Cover

[91]

Data Link

4-Place Deutsch

Under Right Side Cover

2-10

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Diagnostic Check (Part 1 of 2)

Does engine

start?

YES.

NO.

Starts and

Starts, then

Cranks, but

Engine will not

runs.

stalls.

will not start.

crank.

Check for diagnostic

For carbureted models, see

For carbureted models, see 4.9

See 1.2 STARTING SYSTEM

trouble codes. See 2.3

4.10 STARTS, THEN STALLS.

ENGINE CRANKS, BUT WILL

DIAGNOSIS.

SPEEDOMETER SELF

For EFI models, see 5.12

NOT START. For EFI models,

DIAGNOSTICS

STARTS, THEN STALLS.

see 5.10 ENGINE CRANKS,

Codes found?

BUT WILL NOT START.

YES

Refer to applicable diagnostic trouble

Unable to enter diagnostic mode.

code priority chart. All diagnostic codes

With ignition switch OFF, press and

are listed on page 2-6 in Table 2-2.

release odometer reset switch.

Codes are listed by priority.

Does odometer display appear with

display backlighting?

YES

STOP

Check for continuity to ground on terminal 7

of speedometer. Wiggle harness during con-

tinuity check. Continuity present?

Go to Diagnostic

Check (Part 2 of 2).

YES

Check for battery voltage at

terminal 5 of speedometer

Locate and repair open

while wiggling harness. Bat-

between terminal 7

tery voltage continuously

and ground.

present?

YES

With connector [39] disconnected from

Locate and repair open

speedometer, check continuity (with ignition

between terminal 5 and

switch OFF) between terminals 8 and 11 on

battery fuse.

Breakout Box. Continuity present when

speedometer reset switch is depressed and

infinity when released?

YES

Replace speedometer.

Replace speedometer

reset switch.

2005 Touring: Instruments

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Diagnostic Check (Part 2 of 2)

Continued from Diagnostic Check (Part 1 of 2).

Perform “wow” test. See 2.3 SPEEDOMETER SELF DIAGNOSTICS.

The following features should be functional

1) backlight should illuminate

2) needle should sweep its full range of motion

3) LED’s that should illuminate:

• check engine

• battery

• security (all models)

4) LED’s that may illuminate:

• low fuel (EFI models)

• cruise (although not cruise equipped on some models)

Are all features functional?

YES

Turn key to ACC. Is

With ignition switch turned to

backlight present?

IGN, check for battery voltage

at terminal 1 of Breakout Box.

Battery voltage present?

YES

Is problem intermittent?

Check for battery voltage at

Replace Speedometer.

Is instrument

breakout box terminal 6.

fuse blown?

Battery voltage present?

YES

Replace speedometer.

Is accessory fuse

Locate and repair

Locate and repair open

blown?

source of fault.

between terminal 1 of

Replace fuse.

connector [39] and

instrument fuse.

YES

Locate and repair

Locate and repair open on O/W

source of fault.

wire between termin al 6 of con-

Replace fuse.

nector [39] and accessory fuse.

YES

Intermittent vehicle speed

indication.

Repeat Diagnostic Check

Tachometer Inoperative

while wiggling harnesses.

(no engine speed).

Intermittent present?

Remove and inspect vehi-

cle speed sensor. Debris

present?

See Test 2.4 (Part 1 of 2).

YES

Locate and repair

No trouble found.

intermittent.

Remove debris. Reinstall

Check for damaged wiring/

vehicle speed sensor.

loose connection between

vehicle speed sensor and ICM/

ECM. Is wiring damage/loose

connection present?

YES

Locate and repair

Replace Speedometer.

source of fault.

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SPEEDOMETER SELF DIAGNOSTICS

2.3

GENERAL

The speedometer is capable of displaying and clearing

speedometer, tachometer, TSM/TSSM, and ICM/ECM diag-

nostic trouble codes (diagnostic mode).

MPH

RPM x100

100

DIAGNOSTICS

110

120

Diagnostic Tips

-D

● For a quick check of speedometer function, a “wow” test

can be performed. Press and hold odometer reset switch

then turn ignition switch ON. Release reset switch. Back-

ground lighting should illuminate, speedometer needle

should sweep its full range of motion, and indicator

f2160x8x

Check Engine

lamps [battery, security, low fuel

(EFI models) check

Low Fuel

engine and cruise should illuminate. Some lamps may

Battery

illuminate even though they do not apply to the vehicle.

Security

For example, the cruise lamp may illuminate although

Cruise (Where Applicable)

this feature does not apply to some models.

● If instrument module fails “wow” test, check for battery,

Figure 2-11. Icons

ground, ignition, speedometer reset switch and acces-

sory to speedometer. If any feature in the speedometer is

non-functional, see 2.2 INITIAL DIAGNOSTIC CHECK:

SPEEDOMETER.

Diagnostic Notes

Use of speedometer self diagnostics assumes that DIGITAL

TECHNICIAN (Part No. HD-44750) is not available.

The reference numbers below correlate with the circled num-

bers in the Speedometer Self Diagnostics (chart)

1. To exit diagnostic mode, turn ignition switch OFF.

2. To clear diagnostic trouble codes (DTCs) for selected

module, press speedometer reset switch for more than 5

f1240x2x

seconds when code is displayed. This procedure will

clear all diagnostic trouble codes for selected module.

Figure 2-12. Ignition Switch (FLTR, FLHT/C/U)

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Speedometer Self Diagnostics (chart)

While holding odometer reset switch in,

turn ignition switch to IGN. Make sure

Run/Stop switch is in RUN position.

Release reset switch.

Does “diag” appear?

YES

Press and release reset

See 2.2 INITIAL DIAGNOSTIC

switch.

CHECK: SPEEDOMETER.

“PSSPT” appears.

To display DTCs for the

ECM/ICM, press and

”P” flashing.

hold reset switch for

more than 5 seconds.

To choose TSM/

TSSM, press and

release reset switch.

To display DTCs for

”S” flashing.

TSM/TSSM, press and

hold reset switch for

more than 5 seconds.

To choose Speedometer,

Device

response?

press and release reset

switch.

YES

“no rsp” displayed.

To display DTCs for

See applicable code from

”SP” flashing.

speedometer, press and

other modules. Models not

hold reset switch for more

equipped with a tachometer

than 5 seconds.

will display “no rsp” normally.

If “no rsp” displayed on odom-

eter on tachometer equipped

To choose Tachometer,

vehicle, see 2.4 SPEEDOME-

“none” displayed.

press and release reset

TER/TACHOMETER.

switch.

DTC

displayed.

To display DTCs for

tachometer, press and

Press and release

”T” flashing.

hold reset switch for more

reset switch. Part num-

reset switch.

than 5 seconds.

ber of module will be

Are more DTCs

displayed.

displayed?

To choose ICM, press and

YES

release reset switch.

“end” displayed.

To clear all DTCs for

selected module hold reset

switch for more than 5 sec-

onds. If DTCs are not to be

cleared, Press and release

reset switch. Part number of

module will be displayed.

Press and release reset

switch again to continue to

next module.

Figure 2-13. Speedometer Self Diagnostics

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SPEEDOMETER/TACHOMETER

2.4

GENERAL

NOTE

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

has no functionality on that vehicle.

MPH

RPM x100

The speedometer consists of a speedometer display and sev-

100

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

110

and low fuel (EFI only).

120

-D

Reset Switch

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

vides the following capabilities:

● Change the odometer display between mileage, trip A

f2160x8x

and trip B values (press and immediately release).

Check Engine

Low Fuel

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

Battery

seconds).

Security

● Gain access to the diagnostic mode, clear diagnostic

Cruise (Where Applicable)

trouble codes and exit diagnostic mode. See

2.3

SPEEDOMETER SELF DIAGNOSTICS.

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

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

switch while key is OFF and odometer mileage will be

displayed.

● On models with dual scale speedometers, toggle

between miles/kilometers on odometer and trip odome-

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

hold reset switch while odometer is displayed. Release

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

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

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SPEEDOMETER THEORY

TACHOMETER THEORY

OF OPERATION

The speedometer consists of a vehicle speed sensor, ICM/

The tachometer receives serial data from the ICM/ECM. The

ECM, odometer reset switch and the speedometer. The vehi-

tachometer interprets the serial data and converts it into

cle speed sensor is mounted on the right side of transmission

tachometer needle movement.

case below the starter. The sensor circuitry is that of a Hall-

Effect sensor that is triggered by the gear teeth of 4th gear on

the transmission mainshaft.

DIAGNOSTICS

The output from the sensor is a series of pulses that are inter-

preted by ICM/ECM circuitry, converted into serial data inside

the ICM/ECM then sent to the speedometer to control the

Diagnostic Notes

position of the speedometer needle and the liquid crystal

(LCD) odometer display. The vehicle speed serial data is also

The reference numbers below correlate with circled numbers

transmitted to the TSM/TSSM for turn signal cancellation,

on the tachometer diagnostic flow chart.

sound system for automatic volume control (AVC), and cruise

control (for vehicle speed control).

1. If problems are intermittent, wiggle harness while per-

forming tests.

The odometer mileage is permanently stored and will not be

lost when electrical power is turned off or disconnected. The

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

odometer reset switch allows switching between the odome-

INSTRUMENT HARNESS ADAPTERS (Part No. HD-

ter, trip odometer A and trip odometer B displays.

46601) between wire harness and tachometer.

To zero the trip odometer, have the desired trip odometer dis-

3. Use HARNESS CONNECTOR TEST KIT (Part No. HD-

play visible, press and keep the reset switch depressed. The

41404A), black pin probe and patch cord.

trip odometer mileage will be displayed for 2-3 seconds and

then the trip mileage will return to zero miles.

The odometer can display six numbers to indicate a maxi-

mum of 999999 miles/kilometers. The trip odometers can dis-

play six numbers with a tenth of a mile accuracy for a

maximum of 99999.9 miles/kilometers.

Job/Time Code Values

Dealership technicians filing warranty claims should use the

job/time code values in Digital Technician.

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Test 2.4 (Part 1 of 2)

TACHOMETER INOPERATIVE

Perform “wow” test. See 2.3 SPEEDOMETER SELF

DIAGNOSTICS.

The following features should be functional

1) backlight should illuminate

2) needle should sweep its full range of motion

3) LED’s may illuminate:

cruise (although not cruise equipped on some

models)

pursuit (although may not be a police vehicle)

Are all features functional?

YES

Is problem intermittent?

Check for battery voltage at terminal 1

of breakout box. Is battery voltage

present?

YES

Repeat Diagnostic

No trouble found.

Check while wiggling

harnesses.

Is instrument

fuse blown?

YES

Locate and repair

source of fault.

open in orange wire

Replace fuse.

between terminal 1 of

connector [108] and

YES

instrument fuse.

Check for continuity between

breakout box terminal 2 and

terminal 1 of connector [156B].

Is continuity present?

YES

Locate and repair open

STOP

on LGN/V wire.

Go to Test 2.4 (Part

2 of 2).

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Harley Davidson 2005 touring models. Service repair manual - page 38