Harley Davidson 2008 Touring Models. Electrical Diagnostics Manual - page 29
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Table 6-5. FLHX, FLHT/C/U Connector Locations
NO.
DESCRIPTION
TYPE
LOCATION
[5]
MAXIFUSE
2-place Packard
Under left side cover
[20]
Console harness
16-place Molex
Under seat
[33]
Ignition Switch
3-place Packard
Inner fairing
- under radio
(front of
Ignition Switch housing)
[64-2]
Fuse block
Packard
Under left side cover
[77]
Voltage regulator
2-place Lyall
Bottom of voltage regulator (right side)
[108]
T
achometer
12-place Packard
Inner fairing (back of tachometer)
[166]
ABS module
20-place Molex
Under right side cover
2008 Touring Diagnostics: ABS 6-21
HOME
Device Voltage High: DTC C0563
Install Breakout Box (HD-48642). Start and run the engine at
approximately 2000 RPM. Using a DVOM test for voltage at the Battery
circuits at terminals “10” and “20” and the ignition circuit at terminal “19”
Is the voltage above 18.0V?
YES
NO
Clear the DTC. Operate the system
Test and repair charging
within Conditions for Running the DTC.
system. Refer to Section 1.
Does the DTC reset?
YES
NO
Replace the ABS
Refer to Diagnostic Tips.
Module.
Clear DTCs using speedometer self diagnostics.
fc01559_en
See 2.3 SPEEDOMETER SELF DIAGNOSTICS.
Confirm proper operation with no check engine
lamp.
6-22 2008 Touring Diagnostics: ABS
HOME
DTC C1017
6.8
DTC C1017: PUMP MOTOR POWER CIRCUIT
OPEN FAULT
PART NUMBER
TOOL NAME
HD-48642
BREAKOUT BOX
Circuit Description
See Figure 6-14. The ABS module monitors the internal relay
for the pump motor along with the power circuit going to it.
ed01285
2
4
3
1
5
1. Pump motor connector (ECU)
2. Solenoids
3. Pump motor
4. Valves
5. Pump motor connector (HCU)
Figure 6-14. ECU and HCU Pump Motor Connectors
Conditions for Running the DTC
Action Taken When the DTC Sets
•
The system is enabled and the system voltage is above
•
ABS is disabled.
10.5V.
•
The ABS indicator is illuminated.
•
The ignition voltage is between 8.7V and 18.0V.
Conditions for Clearing the DTC
Conditions for Setting the DTC
The condition for the DTC is no longer present and the DTC
The DTC will set if any of the following conditions exist:
has been cleared with either a "WOW" test or Digital Techni-
cian.
•
The voltage across the pump is below 8.0V for 0.2
seconds.
The ABS module automatically clears the historic DTC when
a current DTC is not detected in 50 consecutive drive cycles.
•
The battery voltage to the pump is less than 8.84V.
•
The pump relay coil is NOT shorted to battery or open.
2008 Touring Diagnostics: ABS 6-23
HOME
Diagnostic Tips
Diagnostic Notes
The following conditions are possible causes for this fault:
Each reference number below correlates to a circled number
on the flow chart(s).
•
High resistance or open pump motor battery circuit.
1.
Connect BREAKOUT BOX (Part No. HD-48642) between
•
Internal ECU pump relay fault.
wire harness connector [166B] and ABS connector [166A].
•
Battery or charging malfunction.
em00159
MAXIFUSE
Voltage
40 Amp
Regulator
BK
1
1
BK
[5B]
[77B] [77A]
Electronic
B A
Hydraulic
Control Unit (ECU)
BK
Control Unit
R
R
(HCU)
1
1
Pump motor supply
Pump
M
Motor
2
2
Pump motor ground
Battery
IGN
I
A
R/BK
OFF
B
B
R
A
C
1E
4A
[64-2]
ACC
Ignition
ABS Motor
Ignition
Fuse
Fuse
Switch
[33A]
[33B]
15 Amp
30 Amp
1F
4B
R/V
R/V
20
20
Battery (Motor)
See appendix B
main harness
GY
R/V
10
10
Battery
page 1 of 3
GY
19
19
Ignition
See appendix B
main harness
LGN/V
page 1 of 3
Tachometer
Serial data
2
2
LGN/V
2
2
LGN/V
LGN/V
9
9
Serial data
[20A] [20B]
[108A]
[108B]
BK
1
1
Ground
See appendix B
main harness
BK
11
11
Ground (Motor)
page 1 of 3
[GND 1A]
[166B] [166A]
Figure 6-15. ABS Power and Ground Schematic
Table 6-6. FLHX, FLHT/C/U Connector Locations
NO.
DESCRIPTION
TYPE
LOCATION
[5]
MAXIFUSE
2-place Packard
Under left side cover
[20]
Console harness
16-place Molex
Under seat
[33]
Ignition Switch
3-place Packard
Inner fairing
- under radio
(front of
Ignition Switch housing)
[64-2]
Fuse block
Packard
Under left side cover
[77]
Voltage regulator
2-place Lyall
Bottom of voltage regulator (right side)
6-24 2008 Touring Diagnostics: ABS
HOME
Table 6-6. FLHX, FLHT/C/U Connector Locations
NO.
DESCRIPTION
TYPE
LOCATION
[108]
T
achometer
12-place Packard
Inner fairing (back of tachometer)
[166]
ABS module
20-place Molex
Under right side cover
2008 Touring Diagnostics: ABS 6-25
HOME
Pump Motor Power Circuit Open Fault: DTC C1017
Test the charging system for proper
operation. Refer to Charging System.
Inspect the ABS Motor 30 Amp fuse.
Is the fuse good?
YES
NO
Inspect for short to ground in
Install Breakout Box (HD-48642). Using a
battery circuit terminal “20”.
1
DVOM test the Battery circuit at terminal “20”.
Did you find and correct the
Is Battery voltage present?
condition?
YES
NO
YES
NO
Replace the ABS
Repair open in battery circuit
Replace the 30 Amp
Replace ABS Module.
Module.
terminal “20”.
ABS Motor fuse.
fc01560_en
6-26 2008 Touring Diagnostics: ABS
HOME
DTC C1018
6.9
DTC C1018: PUMP MOTOR GROUND HIGH
RESISTANCE FAULT
PART NUMBER
TOOL NAME
HD-48642
BREAKOUT BOX
Circuit Description
See Figure 6-16. The ABS module monitors the internal pump
motor and the circuit supplying ground to the pump motor.
ed01285
2
4
3
1
5
1. Pump motor connector (ECU)
2. Solenoids
3. Pump motor
4. Valves
5. Pump motor connector (HCU)
Figure 6-16. ECU and HCU Pump Motor Connectors
Conditions for Running the DTC
The DTC will set if the following conditions exist when the pump
is commanded on.
•
The ignition voltage is between 8.7V and 18.0V.
•
The system voltage is between 10.0V and 18.0V.
•
The system is enabled.
•
The voltage across the pump motor is less than 8.4V.
Conditions for Setting the DTC
•
The voltage at the high side of the pump motor is greater
The DTC will set if the following conditions exist when the pump
than 8.84V.
motor is commanded off.
Action Taken When the DTC Sets
•
The system voltage is between 8.0V and 18.0V.
•
ABS is disabled.
•
The voltage at the low side of the pump is greater than
1.7V.
•
The ABS indicator is illuminated.
Conditions for Clearing the DTC
The condition for the DTC is no longer present and the DTC
has been cleared with either a "WOW" test or Digital Techni-
cian.
2008 Touring Diagnostics: ABS 6-27
HOME
The ABS module automatically clears the historic DTC when
Diagnostic Notes
a current DTC is not detected in 50 consecutive drive cycles.
Each reference number below correlates to a circled number
Diagnostic Tips
on the flow chart(s).
The following conditions are possible causes for this fault:
1.
Connect BREAKOUT BOX (Part No. HD-48642) between
wire harness connector [166B] and ABS connector [166A].
•
Pump motor ground circuit has high resistance or open.
•
Battery or charging malfunction.
em00159
MAXIFUSE
Voltage
40 Amp
Regulator
BK
1
1
BK
[5B]
[77B] [77A]
Electronic
B A
Hydraulic
Control Unit (ECU)
BK
Control Unit
R
R
(HCU)
1
1
Pump motor supply
Pump
M
Motor
2
2
Pump motor ground
Battery
IGN
I
A
R/BK
OFF
B
B
R
A
C
1E
4A
[64-2]
ACC
Ignition
ABS Motor
Ignition
[33A]
[33B]
Fuse
Fuse
Switch
15 Amp
30 Amp
1F
4B
R/V
R/V
20
20
Battery (Motor)
See appendix B
main harness
GY
R/V
10
10
Battery
page 1 of 3
GY
19
19
Ignition
See appendix B
main harness
LGN/V
page 1 of 3
Tachometer
Serial data
2
2
LGN/V
2
2
LGN/V
LGN/V
9
9
Serial data
[20A] [20B]
[108A]
[108B]
BK
1
1
Ground
See appendix B
main harness
BK
11
11
Ground (Motor)
page 1 of 3
[GND 1A]
[166B] [166A]
Figure 6-17. ABS Power and Ground Schematic
Table 6-7. FLHX, FLHT/C/U Connector Locations
NO.
DESCRIPTION
TYPE
LOCATION
[5]
MAXIFUSE
2-place Packard
Under left side cover
[20]
Console harness
16-place Molex
Under seat
[33]
Ignition Switch
3-place Packard
Inner fairing
- under radio
(front of
Ignition Switch housing)
[64-2]
Fuse block
Packard
Under left side cover
[77]
Voltage regulator
2-place Lyall
Bottom of voltage regulator (right side)
6-28 2008 Touring Diagnostics: ABS
HOME
Table 6-7. FLHX, FLHT/C/U Connector Locations
NO.
DESCRIPTION
TYPE
LOCATION
[108]
T
achometer
12-place Packard
Inner fairing (back of tachometer)
[166]
ABS module
20-place Molex
Under right side cover
2008 Touring Diagnostics: ABS 6-29
HOME
Pump Motor Ground High Resistance Fault: DTC C1018
Disconnect ECU connector. Connect Breakout
Box (HD-48642). Test ground circuit terminal
1
“11” for continuity to ground.
Continuity present?
YES
NO
Replace the ABS
Locate and repair open in
Module.
ground circuit terminal “11”.
fc01561_en
6-30 2008 Touring Diagnostics: ABS
HOME
DTC C1021,
C1023
6.10
DTC C1023 will set if the following conditions exist for over 20
DTC C1021, C1023:WHEEL SPEED SENSOR
seconds.
EQUALS ZERO (FRONT OR REAR)
•
The rear wheel speed equals 0 MPH (0 km/h).
Circuit Description
•
The front wheel speed is greater than 10 MPH (16 km/h).
The active wheel speed sensor is supplied system voltage from
•
The difference between the two wheel speeds is greater
the ABS module. The sensor then returns a 7 milliamp to 14
than 11 MPH (18 km/h).
milliamp signal back to the ABS module.
Action Taken When the DTC Sets
Conditions for Running the DTC
•
The ABS module disables the ABS.
•
Ignition voltage is greater than 6.5V.
•
The ABS indicator is illuminated.
•
The ABS is inactive.
•
The brake is not depressed.
Conditions for Clearing the DTC
•
There are no wheel speed sensor circuit malfunctions.
The condition for the DTC is no longer present and the DTC
has been cleared with either a "WOW" test or Digital Techni-
•
Vehicle must be driven above
10 MPH (16 km/h) for 20
cian.
seconds without a brake input.
The ABS module automatically clears the historic DTC when
Conditions for Setting the DTC
a current DTC is not detected in 50 consecutive drive cycles.
DTC C1021 will set if the following conditions exist for over 20
Diagnostic Tips
seconds:
The following conditions are possible causes for this fault:
•
The front wheel speed equals 0 MPH (0 km/h).
•
Internal sensor fault.
•
The rear wheel speed is greater than 10 MPH (16 km/h).
•
Spinning up the rear wheel over 10 MPH (16 km/h) with
•
The difference between the two wheel speeds is greater
the vehicle in a stationary position for an extended period
than 11 MPH (18 km/h).
of time (dynamometer).
2008 Touring Diagnostics: ABS 6-31
HOME
em00158
ABS
Module
7
8
17
18
[166A]
7
8
17
18
[166B]
[168B]
B A
A B
[167B]
[168A]
B A
A
B
[167A]
Rear
Front
Wheel
Wheel
Speed
Speed
Sensor
Sensor
Figure 6-18. Wheel Speed Sensor Schematic
Table 6-8. FLHX, FLHT/C/U Connector Locations
NO.
DESCRIPTION
TYPE
LOCATION
[166]
ABS module
20-place Molex
Under right side cover
[167]
Front wheel speed sensor
2-place Packard
Below upper fork bracket (left side)
[168]
Rear wheel speed sensor
2-place Packard
Lower right side behind exhaust
6-32 2008 Touring Diagnostics: ABS
HOME
Wheel Speed Sensor Equals Zero: DTC C1021 (Front), DTC C1023 (Rear)
NOTE
This code may occur if the vehicle experiences an abnormal amount of
wheel slippage due to slippery conditions under launch or intentional front or
rear wheel spin (dynamometer testing).
Are any other wheel speed
DTCs present?
YES
NO
Refer to highest priority
Clear the DTC. Operate the system in
DTC diagnostics and
the Conditions for Running the DTC.
repair it first.
Did the DTC reset?
YES
NO
Replace appropriate
Refer to
bearing assembly and
Diagnostic Tips.
wheel speed sensor.
Clear DTCs using speedometer self diagnostics.
See 2.3 SPEEDOMETER SELF DIAGNOSTICS.
Confirm proper operation with no ABS lamp.
fc01562_en
2008 Touring Diagnostics: ABS 6-33
HOME
DTC C1025,
C1027, C1206, C1208
6.11
DTC C1025, C1027, C1206, C1208: WHEEL
Conditions for Clearing the DTC
SPEED SIGNAL INTERMITTENT OR
The condition for the DTC is no longer present and the DTC
FREQUENCY OUT OF RANGE
has been cleared with either a "WOW" test or Digital Techni-
cian.
PART NUMBER
TOOL NAME
The ABS module automatically clears the historic DTC when
HD-48642
BREAKOUT BOX
a current DTC is not detected in 50 consecutive drive cycles.
Circuit Description
Diagnostic Tips
The active wheel speed sensor is supplied system voltage from
The following conditions are possible causes for this fault:
the ABS module. The sensor then returns a 7 milliamp or 14
•
External or internal wheel speed circuit intermittent open.
milliamp signal back to the ABS module.
•
Mismatched or improperly sized tires.
Conditions for Running the DTC
•
Electrical noise on the wheel speed wires.
•
Ignition voltage is greater than 6.5V.
•
Worn suspension components.
•
The brake is not depressed.
•
Rough terrain.
•
There are no front or rear wheel speed sensor circuit
malfunctions.
If the fault only occurs in moist conditions (rain, snow, vehicle
wash, etc.) inspect the wheel speed sensor and wiring for signs
Conditions for Setting the DTC
of water intrusion.
The DTC will set if the following conditions exist.
Diagnostic Notes
•
The ABS module detects a rapid variation in the wheel
Each reference number below correlates to a circled number
speed. The wheel speed changes by 12 MPH (20 km/h)
on the flow chart(s).
or more in 0.01 second. The change must occur 3 times
1. A possible cause of the DTC is electrical noise on the
with no more than 0.2 seconds between occurrences.
wheel speed sensor harness wiring. Electrical noise could
•
The frequency of the wheel speed input goes above
result from the wheel speed sensor wires being routed to
2.5kHz for 20 milliseconds.
close to high energy ignition system components, such
as spark plug wires.
Action Taken When the DTC Sets
2. Connect BREAKOUT BOX (Part No. HD-48642) between
•
The ABS module disables the ABS.
wire harness connector [166B] and ABS connector [166A].
•
The ABS indicator is illuminated.
6-34 2008 Touring Diagnostics: ABS
HOME
em00158
ABS
Module
7
8
17
18
[166A]
7
8
17
18
[166B]
[168B]
B A
A B
[167B]
[168A]
B A
A
B
[167A]
Rear
Front
Wheel
Wheel
Speed
Speed
Sensor
Sensor
Figure 6-19. Wheel Speed Sensor Schematic
Table 6-9. FLHX, FLHT/C/U Connector Locations
NO.
DESCRIPTION
TYPE
LOCATION
[166]
ABS module
20-place Molex
Under right side cover
[167]
Front wheel speed sensor
2-place Packard
Below upper fork bracket (left side)
[168]
Rear wheel speed sensor
2-place Packard
Lower right side behind exhaust
2008 Touring Diagnostics: ABS 6-35
HOME
Wheel Speed Signal Intermittent or Frequency Out of Range: DTC C1025 (front), C1027
(rear), C1206, C1208
Inspect vehicle for accessories that may cause
1
electrical interference with the wheel speed sensors.
Electrical interference present?
YES
NO
Inspect for loose or damaged connections on
Remove or relocate
wheel speed sensor circuits.
interference.
Were poor connections found?
YES
NO
Clear DTC. Operate vehicle under
Repair connections
conditions for running DTC.
and circuits.
Does DTC reset?
YES
NO
Connect ABS Breakout Box (HD-48642). Turn Ignition
Switch on. Start engine and wait 10 seconds for ABS
to complete initialization test. While wiggling harness
Refer to
2
check for voltage at connector [166B] terminal “18” to
Diagnostic Tips.
ground (front wheel) or terminal “7” to ground (rear
wheel).
Does voltage drop out intermittently?
YES
NO
Inspect for worn or damaged
Repair open
suspension components.
in circuits.
Were damaged or worn components
found?
YES
NO
Replace the appropriate
Replace needed
bearing assembly and
components.
wheel speed sensor.
Clear DTCs using speedometer self diagnostics.
See 2.3 SPEEDOMETER SELF DIAGNOSTICS.
Confirm proper operation with no ABS lamp.
fc01564_en
6-36 2008 Touring Diagnostics: ABS
HOME
DTC C1032,
C1034
6.12
DTC C1032, C1034:WHEEL SPEED SENSOR
Action Taken When the DTC Sets
CIRCUIT OPEN OR SHORTED (FRONT OR
•
The ABS module disables the ABS.
REAR)
•
The ABS indicator is illuminated.
PART NUMBER
TOOL NAME
Conditions for Clearing the DTC
HD-41404-B
HARNESS CONNECTOR TEST KIT
The condition for the DTC is no longer present and the DTC
HD-48642
BREAKOUT BOX
has been cleared with either a "WOW" test or Digital Techni-
cian.
Circuit Description
The ABS module automatically clears the historic DTC when
The active wheel speed sensor is supplied system voltage from
a current DTC is not detected in 50 consecutive drive cycles.
the ABS module. The sensor then returns a 7 milliamp to 14
milliamp signal back to the ABS module.
Diagnostic Tips
The following conditions are possible causes for this fault:
Conditions for Running the DTC
•
Open in either of the front wheel speed sensor circuits.
•
Ignition voltage is greater than 6.5V.
•
Short to ground in either of the front wheel speed sensor
•
There are no front or rear wheel speed sensor circuit
wires.
malfunctions.
•
Front wheel speed sensor open.
Conditions for Setting the DTC
•
Front wheel speed circuit low shorted to battery.
The DTC will set if the following conditions exist:
If the fault only occurs in moist conditions (rain, snow, vehicle
•
Short to ground on either the high or low side circuits of
wash, etc.) inspect the wheel speed sensor and wiring for signs
the front wheel speed sensor.
of water intrusion.
•
Open on either the high or low side circuits of the front
Diagnostic Notes
wheel speed sensor.
Each reference number below correlates to a circled number
•
Short to voltage on the low side causing the voltage to go
on the flow chart(s).
above 0.79V.
1. Use HARNESS CONNECTOR TEST KIT (Part No. HD-
•
Wheel speed sensor open.
41404-B) with gray male probes and patch cords.
2. Connect BREAKOUT BOX (Part No. HD-48642) between
wire harness connector [166B] and ABS connector [166A].
2008 Touring Diagnostics: ABS 6-37
HOME
em00158
ABS
Module
7
8
17
18
[166A]
7
8
17
18
[166B]
[168B]
B A
A B
[167B]
[168A]
B A
A
B
[167A]
Rear
Front
Wheel
Wheel
Speed
Speed
Sensor
Sensor
Figure 6-20. Wheel Speed Sensor Schematic
Table 6-10. FLHX, FLHT/C/U Connector Locations
NO.
DESCRIPTION
TYPE
LOCATION
[166]
ABS module
20-place Molex
Under right side cover
[167]
Front wheel speed sensor
2-place Packard
Below upper fork bracket (left side)
[168]
Rear wheel speed sensor
2-place Packard
Lower right side behind exhaust
6-38 2008 Touring Diagnostics: ABS
HOME
Wheel Speed Sensor Circuit Open or Shorted: DTC C1032, C1034 (1 of 4)
Clear the DTC. Operate the system in
the Conditions for Running the DTC.
Did the DTC reset?
YES
NO
Did DTC C1032
Refer to
reset?
Diagnostic Tips.
YES, C1032 set.
NO, C1034 set.
Connect ABS Breakout Box (HD-48642). Turn ignition switch on with the
engine stop switch in the RUN position. Start engine and wait 10
1
seconds for ABS Module to complete initialization test. Measure voltage
STOP
at connector [166B] terminals “18” at Breakout Box
Is voltage below 0.5V?
Go to Wheel Speed
Sensor Circuit Open or
Shorted: DTC C1032,
YES
NO
C1034 (Part 3 of 4).
Disconnect ABS Module [166] from the
Breakout Box. Test connector [166B] terminal
STOP
“17” for short to ground and terminal “18” for
short to ground at Breakout Box.
Short to ground present?
Go to Wheel Speed Sensor
Circuit Open or Shorted: DTC
C1032, C1034 (Part 2 of 4).
YES
NO
Disconnect front wheel
Disconnect front wheel speed
speed sensor. Test
sensor. Test for an open
connector [166B] terminals
between connector [166B]
“17” and “18” at Breakout
terminal “17” and connector
Box for short to ground.
[167B] terminal “A”
Short to ground present?
Is an open present?
YES
NO
YES
NO
Test for an open between
Repair short to
Replace Front
Repair open in
connector [166B] terminal
ground in
Wheel Speed
front wheel speed
“18” and connector [167B]
appropriate
Sensor.
sensor high circuit.
terminal “B”
circuit.
Is an open present?
Clear DTCs using speedometer self diagnostics.
YES
NO
See 2.3 SPEEDOMETER SELF DIAGNOSTICS.
Confirm proper operation with no ABS lamp.
Repair open in
Replace Front
front wheel speed
Wheel Speed
sensor low circuit.
Sensor.
fc01563_en
2008 Touring Diagnostics: ABS 6-39
HOME
Wheel Speed Sensor Circuit Open or Shorted: DTC C1032, C1034 (2 of 4)
Continued from Wheel Speed Sensor Circuit Open
or Shorted: DTC C1032, C1034 (Part 1 of 4).
Disconnect ABS Module from the Breakout Box. Test
connector [166B] terminals “17” and “18” at Breakout
Box for short to voltage.
Short to voltage present?
YES
NO
Disconnect front wheel speed sensor.
Disconnect front wheel speed
Test for short to voltage at connector
sensor. Test connector [166B]
[166B] terminal “17” and at terminal
terminals “17” and “18” at
“18” at Breakout Box.
Breakout Box for continuity.
Short to voltage present?
Continuity present?
NO
YES
NO
YES
Repair short to
voltage in
appropriate
Replace Front
Test for continuity from
circuit.
Repair short in
Wheel Speed
terminals “A” to terminal “B” at
front wheel speed
Sensor.
connector [167A].
sensor wires.
Is continuity present?
YES
NO
Replace Front
Replace ABS
Wheel Speed
Module.
Sensor.
fc01565_en
6-40 2008 Touring Diagnostics: ABS