Harley Davidson 2005 touring models. Service repair manual - page 39
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Test 2.4 (Part 2 of 2)
TACHOMETER INOPERATIVE
Continued from Test 2.4 (Part 1 of 2).
Check for continuity to ground on breakout box
terminal 7. Wiggle harness during continuity
check. Is continuity present?
YES
NO
Check for battery voltage
Locate and repair open
at breakout box terminal 5
on BK wire between ter-
while wiggling harness.
minal 7 of connector
Is battery voltage
[108] and ground.
continuously present?
YES
NO
Locate and repair open
Check for battery voltage at
on BN/GY wire between
breakout box terminal 6.
terminal 5 of connector
Is battery voltage present?
[108] and battery fuse.
YES
NO
Replace tachometer.
Locate and repair open on O/W
wire between terminal 6 of con-
nector [108] and accessory fuse.
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BREAKOUT BOX: SPEEDOMETER
2.5
GENERAL
10086
The BREAKOUT BOX (Part No. HD-42682) and INSTRU-
MENT HARNESS ADAPTERS (Part No. HD-46601) connect
to speedometer connector [39]. Used in conjunction with a
DVOM, it allows circuit diagnosis of wiring harness and con-
nections without having to probe with sharp objects
NOTE
See wiring diagrams for speedometer terminal functions.
INSTALLATION
1. See Figure 2-16. Bend back the external latches slightly
and remove connector [39B].
2. Connect Instrument Harness Adapters to connectors
[39A] and [39B].
3. Attach connectors from Breakout Box to Instrument Har-
Figure 2-16. Speedometer Connector [39]
ness Adapters.
REMOVAL
1. Detach connectors from Breakout Box to Instrument Har-
ness Adapters.
2. See Figure 2-15. Detach Instrument Harness Adapters
from connectors [39A] and [39B].
3. Install connector [39B] to speedometer.
f2001x8x
f1998x9x
Figure 2-17. Breakout Box (Part No. HD-42682)
Figure 2-15. Instrument Harness Adapters
(Part No. HD-46601)
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FUEL GAUGE
2.6
2.
Set MULTI-METER (Part No. HD-35500) to RXI scale to
THEORY OF OPERATION
measure the resistance of the sending unit. Place one
probe on Y/W and the other probe on a good ground.
With ignition switch ON, the fuel gauge is connected to +12
volts. Current flows through the gauge and variable resistor in
FLHT/C/U, FLTR:
the fuel gauge sending unit to ground. The sending unit float
controls the amount of resistance in the variable resistor.
If fuel tank is full, the reading should be 7-14 ohms. An
empty tank should have a 74-95 ohm resistance. A half
Inoperative gauges may be caused by three circumstances.
full tank will be approximately 30-38 ohms.
● Sender or fuel gauge not grounded.
FLHR/C/S:
● Malfunction in sender or fuel gauge.
If fuel tank is full, the reading should be 27-40 ohms. An
empty tank should have a 240-264 ohm resistance. A
● Broken or disconnected wire from ignition switch to fuel
half full tank will be approximately 97-118 ohms.
gauge.
ALL MODELS:
Use the FUEL GAUGE AND SENDER TEST to test suspect
components.
If a very high resistance or infinity is indicated on the
meter, the sender may be “open” or not grounded. Check
that sender and fuel tank are grounded by placing one
FUEL GAUGE AND SENDER TEST
probe of Multi-Meter on sender flange and the other
probe on crankcase. Meter must indicate one ohm or
less. Replace sender if one ohm or less was present. If a
NOTE
higher resistance is present, check for poor connection
on ground wire.
Always refer to the applicable wiring diagram (at the rear of
this manual) when troubleshooting instruments or gauges.
3.
Check voltage to O/W (+) and BK (-) wire of fuel gauge
1. Remove gauge. Ground Y/W wire of fuel gauge sender
connector [117] if gauge did not indicate FULL.
located at bottom of gauge. Turn ignition switch ON.
a. Fuel gauge must indicate FULL. If gauge indicated
a. Correct reading is equivalent to battery voltage.
FULL, gauge is functioning correctly. Proceed to
b. If battery voltage is not present check for broken or
step 2.
disconnected wire. Replace gauge if wiring problem
b. If gauge did not indicate FULL, proceed to step 3.
is not found.
FLT0294C
BK
BK
Light
O
O
Light
Oil
Voltmeter
Pressure
O
BN/GN
To Sender
O
To +12 vdc
BK
BK
Color Code:
NOTE
BK- Black
All gauges are shown
BN/GN-Brown/Green
as viewed from rear.
O-Orange
Figure 2-18. Connections for Gauges
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OIL, AIR AND VOLTMETER GAUGES
2.7
OIL PRESSURE GAUGE
AND INDICATOR LIGHT
Problem
Low oil pressure light remains on with engine running above
idle and/or oil pressure gauge does not work.
Cause
Solution
No oil pressure due to lack of oil or
CAUTION
faulty oil pump.
Running engine when OIL pressure light remains on and gauge indicates
low pressure will result in engine damage.
1. Check oil level. Add oil if low.
2. Restart engine and verify that oil pressure light goes off and gauge indicates
pressure. If problem still exists, refer to OIL PUMP in the Dyna Service Manual.
Contacts in pressure sending unit
1. Locate the oil pressure sending unit on the front right side of the crankcase.
not opening to shut off light.
2. Verify that the electrical connector is properly connected to the sending unit.
Variable resistor in sender is
shorted to ground.
3. If the oil pressure gauge indicates pressure but the low oil pressure light remains
on, proceed as follows:
a. Remove electrical connector from oil pressure sending unit. Place one
ohmmeter probe on indicator lamp terminal (closest to latch), place the other
probe on the crankcase. Meter must read zero ohms.
b. Start the engine and run at a fast idle. The ohmmeter must read infinity.
c. Replace the sending unit if the above meter readings are not obtained.
4. If the low oil pressure light functions correctly, but the pressure gauge does not,
then proceed as follows:
a. Remove electrical connector from oil pressure sending unit. Turn the Ignition/
Light Key Switch to IGNITION. The gauge must read zero.
b. Ground BN/GN wire terminal to crankcase. The gauge must read full scale 70
PSI.
c. Replace the sending unit if the above gauge readings are obtained. If the
gauge readings are not obtained, then replace the pressure gauge.
No power to gauge.
See Voltmeter.
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AMBIENT AIR
TEMPERATURE GAUGE
Problem
Gauge inoperative.
Cause
Solution
Sensor not grounded or open
Test for continuity between pin 1 and ground and pin 3 and gauge. Repair if open.
between sensor and gauge.
Check for 12 vdc between pins 1 and 3 at connector [115A]. Replace gauge if voltage
Broken or disconnected power or
is present. Use voltage drop tests and continuity checks to isolate if voltage is not
ground wire to gauge.
present.
Measure resistance between pins 1 and 3 at 65˚ to 85˚ F. Resistance should be 43-31
Malfunction in gauge or sensor.
ohms. Replace sensor if out of range, replace gauge if within range.
VOLTMETER GAUGE
Problem
Meter inoperative.
Cause
Solution
Broken or disconnected leads to meter
1. With Ignition/Light Key Switch turned to IGNITION, verify that 12 vdc is
or open meter winding.
present at “±” terminal on voltmeter. With switch turned to OFF, check
ground terminal for continuity to ground.
2. Replace the voltmeter if 12 vdc is present and ground terminal is grounded.
3. If 12 vdc is not present, trace wiring until disconnected or broken wire is
found and repair as necessary. If ground terminal is not grounded, refer to
wiring diagram and repeat procedure given for 12 vdc lead.
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INDICATOR LAMPS: FLTR, FLHT/C/U
2.8
GENERAL
Indicator Lamp
See Figure 2-19. All models except FLHR/C/S are equipped
Connector [21]
with incandescent indicator lamps which may be replaced
individually. See the Touring Models Service Manual for lamp
replacement procedure. See DIAGNOSTICS which follows
for troubleshooting procedures.
Bulb
Housing
Table 2-7. Indicator Lamp Connector [21]
WIRE
TERMINAL
FUNCTION
COLOR
1
Brown
Right Turn Power
Rubber
2
Green/Yellow
Oil Pressure Lamp To Switch
Boot
3
White
High Beam Power
Paddle
4
Violet
Left Turn Power
Lense
f1346x2x
5
Black
Right Turn Ground
6
Orange
Oil Pressure Power
Figure 2-19. Indicator Lamp Assembly
7
Tan
Neutral Lamp To Switch
(FLTR, FLHT/C/U)
8
Orange
Neutral Power
9
Black
High Beam Ground
10
Black
Left Turn Ground
Job/Time Code Values
Dealership technicians filing warranty claims should use the
Table 2-8. Indicator Lamp Wiring
job/time code values printed in bold text underneath the
appropriate repair.
INDICATOR LAMP
CONNECTION
Oil pressure
Ground Through Switch
Neutral
Ground Through Switch
High beam
12 VDC When Active
Right/left turn
12 VDC When Active
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DIAGNOSTICS
Oil Pressure or Neutral Indicator Will Not Function
Turn on ignition switch. Check for 12
VDC at connector [21A], terminal 6
(oil) and/or terminal 8 (neutral). Turn
off ignition switch.
Was 12 VDC present?
YES
NO
Check for continuity to
Check for blown fuses
ground at connector [21A],
or locate open.
terminal 7 (neutral) and/or
5048
terminal 2 (oil pressure).
Is continuity present?
YES
NO
Check each terminal for continuity
Replace indicator lamp.
to ground through switch.
5191
Is continuity present?
YES
NO
NO
Repair open in GN/Y
Replace oil
Replace neutral
wire (oil pressure) or
pressure switch.
switch.
TN wire (neutral).
5161
5157
5048
High Beam or R/L Turn Signal Indicator Will Not Function
Check for ground at
connector [21A], terminal 5 (right turn),
9 (high beam) and/or 10 (left turn).
Is continuity to ground present?
YES
NO
Check for 12 VDC when circuit is active:
Locate and repair
connector [21A], terminal 4 (left turn), terminal
open in circuit.
1 (right turn) or terminal 3 (high beam).
5048
Is voltage present?
YES
NO
Replace indicator lamp.
Locate and repair
open in circuit.
5191
5048
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INDICATOR LAMPS: FLHR/C/S
2.9
GENERAL
f2095x8x
Paddles
FLHR/C/S models are equipped with Light Emitting Diode
(LED) indicators. The indicator lamp assembly is not service-
able. If one LED is bad, the entire assembly must be
replaced.
See DIAGNOSTICS which follows for troubleshooting proce-
dures.
Table 2-9. Indicator Lamp Connector [21]
TERMINAL
WIRE COLOR
FUNCTION
1
Violet
Left Turn
2
White
High Beam
3
Green/yellow
Oil Pressure
4
Brown
Right Turn
5
Tan
Neutral
6
Orange
Neutral/Oil Pressure
7
Black
Left Turn/high Beam
Figure 2-20. Release Paddles to Free
8
Not used
N/A
Indicator Lights Assembly (FLHR/C/S)
Table 2-10. LED Assembly Wiring
Job/Time Code Values
INDICATOR LAMP
CONNECTION
Oil pressure
Ground Through Switch
Dealership technicians filing warranty claims should use the
job/time code values printed in bold text underneath the
Neutral
Ground Through Switch
appropriate repair.
High beam
12 VDC When Active
Right/left turn
12 VDC When Active
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DIAGNOSTICS
Oil Pressure or Neutral Indicator Will Not Function
Check for 12 VDC at terminal 6
of connector [21A].
Is 12 VDC present?
YES
NO
Check for continuity to
Check for blown
ground on connector [21] at
fuses or find open.
terminal 5 (neutral) and ter-
minal 3 (oil pressure). Is
5048
continuity present?
YES
NO
Replace indicator
Check each terminal for continuity
lamp assembly.
to ground through switch.
Is continuity present?
5191
YES
NO
NO
Repair open in GN/Y
Replace oil
Replace neutral
wire (oil pressure) or
pressure switch.
switch.
TN wire (neutral).
5161
5157
5048
High Beam or R/L Turn Signal Indicator Will Not Function
Check for ground at terminal 2
of connector [21A].
Is ground present?
YES
NO
Check for 12 VDC when circuit is
Locate and repair
active. Use terminal 1 (left turn), ter-
open in circuit.
minal 4 (right turn) and terminal 2
(high beam). Voltage present?
5048
YES
NO
Replace indicator
Locate and repair
lamp assembly.
open in circuit.
5191
5048
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DTC B1004, B1005
2.10
GENERAL
10086
The fuel level is monitored by the speedometer pin 9 of con-
nector [39] (Y/W).
● If the voltage on pin 9 of connector [39] exceeds the
lower limit for greater than or equall to 15 seconds a DTC
B1004 will set.
● If the voltage on pin 9 of connector [39] exceeds the
upper limit (or is open) for greater than or equall to 15
seconds a DTC B1005 will set.
Table 2-11. Code Description
DTC
DESCRIPTION
B1004
Fuel level sending unit low.
B1005
Fuel level sending unit high/open.
DIAGNOSTICS
Figure 2-22. Speedometer Connector [39]
Diagnostic Tips
If fuel gauge is performing erratically (possible false diagnos-
tic trouble codes), inspect for unobstructed movement of
sending unit arm. Repair or align as necessary.
Diagnostic Notes
The reference numbers below correlate with the circled num-
bers on the 2.10 flow chart.
1. Use HARNESS CONNECTOR TEST KIT (Part No. HD-
41404A), brown pin probe and patch cord.
2. Connect BREAKOUT BOX (Part No. HD-42682) and
f2001x8x
INSTRUMENT HARNESS ADAPTERS (Part No. HD-
46601) between wire harness and speedometer.
f1998x9x
Figure 2-23. Breakout Box (Part No. HD-42682)
Figure 2-21. Instrument Harness Adapters
(Part No. HD-46601)
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f2332c8x
Fuel Gauge:
All except
Fuel Gauge
BK
FLHR/C/S
FLHR/C/S
[117B]
1
3
To accessory fuse
O/W
2
[117B]
1
2
3
4
To battery fuse
BN/GY
To Instrument
1
2
3
[141A]
O
fuse
Fuel Level
1
2
3
[141B]
Sender
Y/W
5
5
LGN/V
1
2
3
[13B]
1
2
3
[13A]
[39B]
12
5
6
7
9
[39A]
1
2
5
6
7
9
Y/W
[2A] [2B]
FLTR, FLHT/C/U Only
1
BK
2
Data Link
Lt GN/V
3
Connector
GY
4
Speedometer
[91A]
12V
[78B]
5
ECM
[78A]
Figure 2-24. Fuel Sender Circuit
Table 2-12. Wire Harness Connectors in Figure 2-24.
NO.
DESCRIPTION
MODEL
TYPE
LOCATION
Inner Fairing - Right Fairing Support
FLHT/C
12-Place Deutsch (Gray)
[2]
Main to Interconnect Harness
Brace
FLTR
12-Place Deutsch (Gray)
Inner Fairing - Below Radio (Right Side)
FLHT/C
3-Place Multilock
Behind Fuel Tank (Under Seat)
[13]
Fuel Tank Harness
FLTR
3-Place Multilock
Behind Fuel Tank (Under Seat)
FLHT/C
12-Place Packard
Inner Fairing (Back of Speedometer)
[39]
Speedometer
FLTR
12-Place Packard
Under Bezel (Back of Speedometer)
[78]
Electronic Control Module
All
36-Place Packard
Under Right Side Cover
[91]
Data Link
All
4-Place Deutsch
Under Right Side Cover
FLHT/C
3-Place Mini-Deutsch
Top of Canopy (Under Console)
[141]
Fuel Level Sender
FLTR
3-Place Mini-Deutsch
Top of Canopy (Under Console)
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Test 2.10: DTC B1004
FUEL LEVEL SENDING UNIT
Disconnect speedometer con-
nector [39]. Check continuity
between terminal 2 of connec-
tor [141B] and ground.
Continuity present?
YES
NO
Locate and repair short to
Repair/replace fuel level
ground.
sending unit.
Clear codes using speedometer self diagnostics.
See 2.3 SPEEDOMETER SELF DIAGNOSTICS.
Confirm proper operation with no check engine
lamp.
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Test 2.10: DTC B1005
FUEL LEVEL SENDING UNIT
Disconnect Speedometer connector [39].
1
Measure voltage on terminal 2 of connector
[141B] (Y/W). Should be 0 volts. Is it?
YES
NO
Locate and repair short
Check continuity between terminal
to voltage.
1
2 of connector [141B] (Y/W) and
breakout box terminal 11 (BK).
Continuity present?
2
YES
NO
Check continuity to ground on ter-
Locate and repair open
1
minal 3 of connector [141B] (BK).
on Y/W wire.
Is continuity present?
YES
NO
Repair/replace fuel level
Locate and repair open on BK
sending unit.
wire (ground circuit).
Clear diagnostic trouble codes using speedometer
self diagnostics. See 2.3 SPEEDOMETER SELF
DIAGNOSTICS. Confirm proper operation with no
check engine lamp.
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DTC B1006, B1007
2.11
GENERAL
Accessory Or Ignition Line Overvoltage
Ignition and accessory voltage is constantly monitored by the
speedometer (terminal 1-ignition and terminal 6-accessory).
If the battery voltage fails to meet normal operating parame-
ters, a diagnostic trouble code is set.
● DTC B1006 is displayed when accessory line voltage is
greater than 16.0 volts for longer than 5 seconds.
● DTC B1007 is displayed when ignition line voltage is
greater than 16.0 volts for longer than 5 seconds.
NOTE
ICM/ECM or TSM/TSSM may also set a battery voltage diag-
nostic trouble codes.
Table 2-13. Code Description
DTC
DESCRIPTION
B1006
Accessory line overvoltage
B1007
Ignition line overvoltage
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Test 2.11
ACCESSORY OR IGNITION LINE OVERVOLTAGE:
DTC B1006/B1007
Is battery charger connected?
YES
NO
Disconnect battery charger. Clear codes.
Diagnose charging system. See 1.7
CHARGING SYSTEM.
NOTE
Sometimes battery charger may cause
overvoltage condition which will set codes.
Start vehicle. Run at 3000
RPM for 5 seconds. Does
code reset?
YES
NO
Clear codes using speedometer self diagnostics.
See 2.3 SPEEDOMETER SELF DIAGNOSTICS.
Confirm proper operation with no check engine
System normal.
lamp.
Diagnose charging system.
See Charging System.
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DTC B1008
2.12
GENERAL
Reset Switch Closed
DTC B1008 will be set if switch terminals are in a constant
shorted state.
Table 2-14. Code Description
DTC
DESCRIPTION
B1008
Reset switch closed
DIAGNOSTICS
Diagnostic Notes
The reference numbers below correlate with the circled num-
bers on the 2.12 flow chart.
1. Connect BREAKOUT BOX (Part No. HD-42682) and
INSTRUMENT HARNESS ADAPTERS (Part No. HD-
46601) between wire harness and speedometer, leaving
speedometer disconnected.
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d0723x2x
[39A]
[39B]
Speedometer
1
2
3
4
5
6
7
BK
8
9
10
BK
11
12
Reset
Switch
Figure 2-25. Reset Switch Circuit
Table 2-15. Wire Harness Connectors in Figure 2-25.
NO.
DESCRIPTION
MODEL
TYPE
LOCATION
FLHT/C
12-Place Packard
Inner Fairing (Back of Speedometer)
[39]
Speedometer
FLTR
12-Place Packard
Under Bezel (Back of Speedometer)
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Test 2.12
RESET SWITCH CLOSED: DTC B1008
Remove reset switch rubber boot.
Clear codes using 2.3 SPEEDOM-
ETER SELF DIAGNOSTICS.
Codes still present?
YES
NO
1
With speedometer disconnected, measure
resistance between terminals 8 and 11
(black) on Breakout Box. Resistance should
Replace boot.
be less than 1 ohm with switch depressed
and infinity ohms when released. Is it?
YES
NO
Replace speedometer.
Replace switch.
Clear codes using speedometer self diagnostics.
See 2.3 SPEEDOMETER SELF DIAGNOSTICS.
Confirm proper operation with no check engine
lamp.
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DTC U1016
2.13
GENERAL
Loss of ICM/ECM Serial Data
The serial data connector provides a means for the ignition
control module (ICM) or electronic control module (ECM),
TSM/TSSM and speedometer to communicate their current
status. When all operating parameters on the serial data bus
are within specifications, a state of health message is sent
between the components. A DTC U1016 indicates that the
ICM/ECM is not capable of sending this state of health mes-
sage.
Table 2-16. Code Description
f2191x8x
DTC
DESCRIPTION
Ignition Control Module
Loss of all ICM/ECM serial data
Connector [10]
Carbureted
(state of health)
U1016
Loss of vehicle speed
Loss of vehicle inhibit motion
f1917x9x
Loss of powertrain security status
DIAGNOSTICS
Diagnostic Notes
The reference numbers below correlate with the circled num-
bers on the Test 2.13 flow chart.
1.
Connect BREAKOUT BOX (Part No. HD-42682) (gray)
between TSM/TSSM connector [30A] and wire harness
connector
[30B]. See
3.11 BREAKOUT BOX: TSM/
TSSM.
Electronic Control
Fuel Injected
Module Connector [78]
6924c
3
Figure 2-27. Electrical Bracket (Under Right Side Cover)
2
2. Connect BREAKOUT BOX (Part No. HD-42682) (black)
1
between ICM connector [10A] and wiring harness con-
nector [10B]. See 4.6 BREAKOUT BOX: ICM
3. Connect BREAKOUT BOX
(Part No. HD-43876)
1. Terminal 2: ground (BK)
between wire harness and ICM/ECM. See 5.7 BREAK-
2.
Terminal 3: serial data (Lt GN/V)
OUT BOX: EFI.
3.
Terminal 4: power (GY)
Figure 2-26. Data Link Connector
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f2332e8x
[156B] [156A]
Main to Interconnect
6
6
Harness
5
5
4
4
3
3
GY
BK
2
2
BK
LtGN/V
1
1
LtGN/V
O
1
2
3
4 5 6 7 8 9 10 11 12
[30B]
BN/GY
1
2
3
4 5 6 7 8 9 10 11 12
[30A]
TSM/TSSM
BN/GY
[39B]
GY
BK
1
2
3
4 5 6 7 8 9 10 11 12
[39A]
1
2
3
4 5 6 7 8 9 10 11 12
1
2
3
4 5 6 7 8 9 10 11 12
[8B]
Speedometer
1
2
3
4 5 6 7 8 9 10 11 12
1
2
3
4 5 6 7 8 9 10 11 12
[8A]
[108B]
1
2
3
4 5 6 7 8 9 10 11 12
Ignition
To
[108A]
Harness
Ignition
Tachometer
Keyswitch
Relay
15A
Instruments
[1B] [1A]
Fuse
1
2
Main to Interconnect
3
[2A]
1
2
3
4 5 6 7 8 9 10 11 12
Harness
4
[2B]
1
2
3
4 5 6 7 8 9 10 11 12
Data Link
[91A]
Main to Interconnect
15A
Harness
Ignition
Fuse
12
15A
[10B]
Battery
12
[10A]
Ignition Control Module
Fuse
Figure 2-28. Serial Data Circuit: FLHT/C (Carbureted)
Table 2-17. Wire Harness Connectors in Figure 2-28.
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
[30]
Turn Signal/Security Module
12-Place Deutsch
Battery Box (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
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