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Harley Diagnostic Touble Codes
Harley Diagnostic Touble Codes
Harley Diagnostic Touble Codes
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2.1
2 3
NOTES See Figure 2-1. Key ON means that the ignition key is turned to ON and the engine stop switch is set to RUN (although the engine is not running). When the ignition switch is turned ON, the check engine lamp will illuminate for approximately four seconds and then turn off. If the check engine lamp is not illuminated at Key ON. See 2.2 INITIAL DIAGNOSTIC CHECK: SPEEDOMETER. If the check engine lamp comes on late (after 20 seconds). See 2.2 INITIAL DIAGNOSTIC CHECK: SPEEDOMETER. 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 illuminated for the rst four second period, one of three situations may occur. a. The lamp remains off. This indicates there are no current fault conditions or stored diagnostic trouble codes currently detected by the ignition control module (ICM) or electronic control module (ECM). The lamp stays off for only four seconds and then comes back on for an eight second period. This indicates an diagnostic trouble code is stored, but no current diagnostic trouble code exists. If the lamp remains on beyond the eight second period, then a current diagnostic trouble code exists. 1. 2. 3. Ignition OFF Lock position Unlock position Open switch cover Figure 2-1. Ignition Switch Accessory
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1.
b.
c. 2.
See CODE TYPES which follows for a complete description of diagnostic trouble code formats. Figure 2-2. Check Engine Lamp
NOTE 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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SECURITY LAMP
To diagnose TSM/TSSM system problems, start by observing the behavior of the security lamp. NOTES
1.
See Figure 2-3. After lamp turns off after being illuminated for the rst four second period, one of three situations may occur. a. The lamp remains off. This indicates there are no current fault conditions or stored diagnostic trouble codes currently detected by the ignition control module (ICM) or electronic control module (ECM). The lamp stays off for only four seconds and then comes back on for an eight second period. This indicates an diagnostic trouble code is stored, but no current diagnostic trouble code exists. If the lamp remains on beyond the eight second period, then a current diagnostic trouble code exists.
To provide an indication of TSM/TSSM diagnostic codes, the security lamp is enabled on all models. See Figure 2-1. Key ON means that the ignition key is turned to ON and the engine stop switch is set to RUN (although the engine is not running). When the ignition switch is turned ON, the check engine lamp will illuminate for approximately four seconds and then turn off. If the check engine lamp is not illuminated at Key ON, see 2.2 INITIAL DIAGNOSTIC CHECK: SPEEDOMETER. If the check engine lamp comes on late (after 20 seconds), see 2.2 INITIAL DIAGNOSTIC CHECK: SPEEDOMETER. If the check engine lamp fails to turn OFF after the initial four second period, see 2.2 INITIAL DIAGNOSTIC CHECK: SPEEDOMETER. 2.
b.
c.
See CODE TYPES which follows for a complete description of diagnostic trouble code formats.
NOTE Some diagnostic trouble codes can only be fully diagnosed during actuation. For example, a problem with the turn signals will be considered a current fault even after the problem is corrected, since the TSM/TSSM will not know of its resolution until after the turn signals are activated. In this manner, there may sometimes be a false indication of a diagnostic trouble code.
ON
A
OFF Key ON
4 Sec.
B
OFF Key ON
4 Sec.
Lamp OFF
C
4 Sec.
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CODE TYPES
There are two types of diagnostic trouble codes (DTCs): current and historic. If a DTC is stored, it can be read using speedometer self diagnostics. See 2.3 SPEEDOMETER SELF DIAGNOSTICS. NOTE To differentiate between current and historic diagnostic trouble codes a computer based diagnostic package called DIGITAL TECHNICIAN (Part No. HD-44750) must be employed. All DTCs reside in the memory of the ECM/ICM, TSM/TSSM or speedometer until the DTC is cleared by use of the speedometer self diagnostics. See 2.3 SPEEDOMETER SELF DIAGNOSTICS. A DTC is also cleared after a total of 50 trips has elapsed. A trip consists of a start and run cycle. After the 50 trip retention period, the DTC is automatically erased from memory providing that no subsequent faults of the same type are detected in that period.
The most sophisticated mode employs a computer based diagnostic package called DIGITAL TECHNICIAN (Part No. HD-44750). The second mode requires using the speedometer self diagnostics. See 2.3 SPEEDOMETER SELF DIAGNOSTICS.
Current
Current DTCs are those which presently disrupt motorcycle operation. See the appropriate ow charts for solutions.
Historic
If a particular problem happens to resolve itself, the active status problem is dropped and it becomes a historic fault rather than a current fault. Historic DTCs can only be retrieved using a computer based diagnostic package called DIGITAL TECHNICIAN (Part No. HD-44750). Historic DTCs are stored for a length of time to assist in the diagnosis of intermittent faults. The check engine lamp will not indicate the existence of only historic DTCs. It is important to note that historic DTCs may also be present whenever the system indicates the existence of a current fault. See MULTIPLE DIAGNOSTIC TROUBLE CODES if multiple DTCs are found. Diagnostic charts are designed for use with current DTCs and as a result they frequently suggest part replacement. When diagnosing a historic DTC the charts can be helpful but should not lead to part replacement without verication the part is faulty.
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7778
2.2
4
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 the diagnostic ow charts and tests in this section. For a systematic approach, always begin with INITIAL DIAGNOSTICS which follows. Read the general information and then work your way through the ow chart box by 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.
3 2
1. 2. 3. 4.
Fuse block Starter relay System relay Spare fuses Figure 2-4. Fuse Block Location
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Diagnostic Notes
1
If a numbered circle appears adjacent to a ow chart box, then more information is offered in the diagnostic notes. Many diagnostic notes contain supplemental information, descriptions of various diagnostic tools or references to other parts of the manual where information on the location and removal of components may be obtained.
4 5 6
7 8 9
9. 10. 11. 12. 13. 14.
12 10 11 13 14
Lights Start Relay System Relay (EFI) Spare 15 Amp Spare 15 Amp Empty
2 3
1. 2. 3. 4. 5. 6. 7. 8.
ECM* 15 Amp Fuel Pump* 15 Amp Headlamp P&A (2 Amp max) Battery Accessories Instruments Ignition
*EFI Fuses
Reprogramming ICM/ECM
Diagnostic charts frequently suggest ECM/ICM replacement. In the event an ignition control module (ICM) or electronic control module (ECM) needs to be replaced, it must be reprogrammed using a computer based diagnostic package called DIGITAL TECHNICIAN (Part No. HD-44750). See your dealer. Password learn procedure must also be performed. See 3.23 PASSWORD LEARN.
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INITIAL DIAGNOSTICS
Diagnostic Tips
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 connector [30B] terminal 3 or speedometer connector [39B] terminal 2. Check for an open diagnostic test terminal between diagnostic link connector [91A] terminal 3 and TSM/TSSM connector [30B] terminal 3. With ignition key turned ON, serial data 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.
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Diagnostic Notes
The reference numbers below correlate with the circled numbers on the diagnostic check ow charts. See page 2-9. 1. Connect BREAKOUT BOX (Part No. HD-42682) and INSTRUMENT HARNESS ADAPTERS (Part No. HD46601) between wire harness and speedometer. See 2.5 BREAKOUT BOX: SPEEDOMETER.
All speedometer diagnostic codes are listed on page 2-6 in Table 2-2.
Terminal 1 (IGN)
Will not wow Turn signals still functional Speedometer will indicate
Terminal 6 (ACC)
Speedometer
Terminal 7 (GRD)
Speedometer com-
pletely non-functional
Diagnostics absent
function
Will not wow
tional
Check engine lamp and
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[30B] [30A]
12V Battery
1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12
[39B] [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
TSM/TSSM Speedometer
12V instrument
2 3 4
[91A]
12V Ignition
[78B] [78A]
LtGN/R
1
Flash pin
LtGN/V
5
Serial data
ECM
BK
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[30B]
12V Battery
1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12
[39B] [39A]
[30A]
1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12
TSM/TSSM Speedometer
12V instrument
2 3 4
LtGN/V
[91A]
12V ignition
ICM [10B]
12
Serial data
[10A]
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Check for diagnostic trouble codes (DTCs). See 2.3 SPEEDOMETER SELF DIAGNOSTICS DTCs found?
For carbureted models, see 4.10 STARTS, THEN STALLS. For EFI models, see 5.12 STARTS, THEN STALLS.
For carbureted models, see 4.9 ENGINE CRANKS, BUT WILL NOT START. For EFI models, see 5.10 ENGINE CRANKS, BUT WILL NOT START.
NO YES With ignition switch OFF, press and release odometer reset switch. Does odometer display appear?
Refer to applicable DTC priority chart. All DTCs are listed on page 2-6 in Table 2-2. DTCs are listed by priority.
YES NO
STOP
Go to Diagnostic Check (Part 2 of 3).
Check for continuity to ground on terminal 7 of speedometer. Wiggle harness during continuity check. Continuity present?
YES
NO
Check for battery voltage at terminal 5 of speedometer while wiggling harness. Battery voltage continuously present?
YES
NO
With connector [39] disconnected from speedometer, check continuity (with ignition switch OFF) between terminals 8 and 11 on Breakout Box. Continuity present when speedometer reset switch is depressed and infinity when released?
YES
NO
Replace speedometer.
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Continued from Diagnostic Check (Part 1 of 3).Turn ignition switch ON, is odometer backlight present?
YES 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) LEDs that should illuminate: check engine battery security (all models) 4) LEDs that may illuminate: low fuel (EFI models) cruise (although not cruise equipped) Are all features functional?
NO
Replace Speedometer.
NO With ignition switch turned to IGN, check for battery voltage at terminal 1 of Breakout Box. Battery voltage present?
Check for battery voltage at Breakout Box terminal 6. Battery voltage present?
YES
YES
NO Locate and repair open between terminal 1 of connector [39] and instrument fuse.
Replace speedometer.
YES YES NO Locate and repair open on O/W wire between terminal 6 of connector [39] and accessory fuse.
STOP
Go to Diagnostic Check (Part 2 of 3).
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YES
NO
YES Remove debris. Reinstall vehicle speed sensor. NO Check for damaged wiring/loose connection between vehicle speed sensor and ECM/ICM. Is wiring damage/loose connection present?
No trouble found.
NO
Replace Speedometer.
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2.3
DIAGNOSTICS
Diagnostic Tips
2 1
4 5
For a quick check of speedometer function, a wow test can be performed. See Figure 2-8. Press and hold odometer reset switch then turn ignition switch ON. Release reset switch. See Figure 2-8. Background lighting should illuminate, speedometer needle should sweep its full range of motion, and indicator lamps [battery, security, low fuel (EFI models) check engine and cruise] should illuminate. Some lamps may illuminate even though they do not apply to the vehicle. For example, the cruise lamp may illuminate although this feature does not apply to Softail models. If instrument module fails wow test, check for battery, ground, ignition, speedometer reset switch and accessory wiring to speedometer. If any feature in the speedometer is non-functional, see 2.2 INITIAL DIAGNOSTIC CHECK: SPEEDOMETER.
1. 2. 3. 4. 5.
Cruise (not used) Check engine Low fuel Battery Security Figure 2-8. Speedometer
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2 3
Diagnostic Notes
Use of speedometer self diagnostics assumes that the DIGITAL TECHNICIAN (Part No. HD-44750) is not available. The reference numbers below correlate with the circled numbers in the Speedometer Self Diagnostics (chart) 1. 2. To exit diagnostic mode, turn ignition switch OFF. On Softail models with an accessory tachometer, no rsp will be displayed during speedometer self diagnostics if tachometer module is chosen because accessory tachometer does not utilize the serial bus. To clear DTCs for selected module, press instrument module reset switch for more than 5 seconds when code is displayed. This procedure will clear all DTCs for selected module. Ignition OFF 1. 2. 3. Lock position Unlock position Open switch cover Figure 2-9. Ignition Switch
Accessory
3.
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While holding odometer reset switch in, turn ignition switch to IGN. Make sure Run/Stop switch is in RUN position.
YES Press and release reset switch. PSSPT appears. To display DTCs for the ECM/ICM, press and hold reset switch for more than 5 seconds.
NO
P flashing.
S flashing.
To display DTCs for TSM/TSSM, press and hold reset switch for more than 5 seconds.
Device response? NO YES no rsp displayed.* Tachometer malfunction. See 2.4 SPEEDOMETER.
SP flashing.
To display DTCs for speedometer, press and hold reset switch for more than 5 seconds.
*
none displayed.
2
T flashing. To display DTCs for tachometer, press and hold reset switch for more than 5 seconds. Press and release reset switch. Part number of module will be displayed.
DTC displayed. Press and release reset switch. Are more DTCs displayed?
NO
YES end displayed. To clear all DTCs for selected module hold reset switch for more than 5 seconds. If DTCs are not to be cleared, Press and release reset switch. Part number of module will be displayed.
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SPEEDOMETER
GENERAL
NOTE Some icons may illuminate during wow test though the icon has no functionality on that vehicle. The speedometer consists of a speedometer display and several icons. The icons include: check engine, security, battery, and low fuel (EFI only).
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2.4
Reset Switch
See Figure 2-12. Pressing the odometer reset switch provides the following capabilities:
Change the odometer display between mileage, trip A and trip B values (press and immediately release). Reset an individual trip odometer (press and hold 2-3 seconds). Gain access to the diagnostic mode, clear diagnostic codes and exit diagnostic mode. See 2.3 SPEEDOMETER SELF DIAGNOSTICS. 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 odometer 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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7495
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2.5
INSTALLATION
1. 2. 3. See Figure 2-13. Depress latch on connector [39B]. Connect Harness Adapters (HD-46601) to connectors [39A] and [39B]. Attach connectors from Breakout Box to Harness Adapters.
REMOVAL
Figure 2-13. Speedometer Connector [39] 1. 2. 3. Detach connectors from Breakout Box to Harness Adapters. See Figure 2-13. Detach Harness Adapters from connectors [39A] and [39B]. Install connector [39B] to speedometer.
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2.6
Checking speedometer operation. Testing speedometer needle sweeping action. Verifying serial data message to speedometer.
The tester generates a simulated vehicle speed sensor signal which is sent to the ICM/ECM. The ICM/ECM interprets the signal then sends a message to the speedometer. This signal aids in determining whether speedometer replacement is necessary.
NOTES Use the following procedures in conjunction with the manual supplied with the speedometer tester. Test results may be inaccurate if tester battery is low.
TESTING
NOTE The SPEEDOMETER TESTER (Part No. HD-41354) cannot be used to verify the calibration of a speedometer and it will not verify the speedometers function to support legal proceedings. Its purpose is to verify speedometer function when performing service diagnosis or repair. It can also assist in determining if speedometer replacement is necessary.
5087
2. 3. 4.
1. 2.
Tester connector Vehicle speed sensor (VSS) connector [65] Figure 2-15. Speedometer Sensor Connector
c.
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2. 3. 4.
5.
After selecting a range, use the corresponding arrow keys to accelerate through the range. As you move through the speed range, check for smooth needle movement. a. b. c. If testing LO range, press 1 or 3. If testing CEN range, press 4 or 6. If testing HI range, press 7 or 9.
Table 2-5. Speedometer Test Frequency in Hertz (Hz): All But FXSTD
MARKET Domestic (mile) Canada (kilo) HDI (kilo) Great Britain (mile/kilo) Japan (kilo) 20 MPH 451 451 40 MPH 903 903 60 MPH 1354 1354 80 MPH 1806 1806 30 KPH 421 421 421 450 60 KPH 842 842 842 901 100 KPH 1403 1403 1403 1501 130 KPH 1824 1824 1824 1952
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1. 2.
Two Deutsch 3-place socket housings (Part No. 7211394BK) and six socket terminals (Part No. 72191-94). Deutsch 3-place pin housing (Part No. 72103-94BK) and three pin terminals (Part No. 72190-94). Six lengths of 18 gauge wire, each 6.0 in. (15 cm) long.
2 1 1
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Before attempting the actual speedometer sensor check, two system checks must be made. Install the test harness at the speedometer sensor connector.
Test for voltage to sensor by checking for 8-12 volts on red wire in connector [65B]. Then check for continuity to ground on black wire in connector [65B]. Raise rear wheel off oor. Install the test harness between the speedometer sensor connectors. Place speedometer tester power switch in the ON position. Place signal switch in the IN position. Plug the speedometer tester into the test harness. Turn vehicle ignition switch ON. Press ENTER on the tester keypad. Rotate the motorcycles rear wheel. a. b. If reading on speedometer tester changes as wheel is rotated, speedometer sensor is OK. If reading does not change on carbureted models, see 4.15 DTC P0501, P0502. If reading does not change on EFI models, see 5.25 DTC P0501, P0502.
1. 2. 3. 4. 5. 6.
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2.7
To speedometer
Sender or fuel gauge not grounded. Malfunction in sender or fuel gauge. Broken or disconnected wire from ignition switch to fuel gauge.
6 X 4
1. 2. 3. 4. 5. 6. Fuel gauge Float Sending unit Variable resistor Gauge winding +12 volts wire Figure 2-17. Fuel Gauge Schematic
Use the FUEL GAUGE AND SENDER TEST to test suspect components.
b. 2.
Set MULTI-METER (Part No. HD-35500) to RXI scale to measure the resistance of the sending unit. Place one probe on Y/W and the other probe on a good ground. a. If fuel tank is full, the reading should be 27-40 ohms. An empty tank should have a 240-264 ohm resistance. A half full tank will be approximately 97-118 ohms. If a very high resistance or innity is indicated on the meter, the sender may be open or not grounded. Check that sender and fuel tank are grounded by placing one probe of Multi-Meter on sender ange and the other probe on crankcase. Meter must indicate one ohm or less. Replace sender if one ohm or less was present. If a higher resistance is present, check for poor connection on ground wire.
Figure 2-18. Fuel Gauge Connector 3. Check voltage to O/W (+) and BK (-) wire of fuel gauge connector [117] if gauge did not indicate FULL. a. b. Correct reading is equivalent to battery voltage. If battery voltage is not present check for broken or disconnected wire. Replace gauge if wiring problem is not found.
b.
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INDICATOR LAMPS
GENERAL
Softails are equipped with Light Emitting Diode (LED) indicators. The indicator lamp assembly is not serviceable. If one LED is bad, the entire assembly must be replaced. See DIAGNOSTICS which follows for troubleshooting procedures.
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2.8
3 2 2
1. 2. 3.
LED assembly Clips (2 pair) Connector [21] Figure 2-20. Connector [21]
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DIAGNOSTICS
Oil Pressure or Neutral Indicator Will Not Function
YES
NO
Check for continuity to ground on connector [21] at Terminal 5 (neutral) and Terminal 3 (oil pressure). Is continuity present?
YES
NO
Check each terminal for continuity to ground through switch. Is continuity present?
YES
NO
NO
YES
NO
Check for 12 volts when circuit is active. Use Terminal 1 (left turn), Terminal 4 (right turn) and Terminal 2 (high beam). Voltage present?
YES
NO
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10086
2.9
If the voltage on terminal 9 of connector [39] exceeds the lower limit for greater than or equal to 15 seconds a DTC B1004 will set. If the voltage on terminal 9 of connector [39] exceeds the upper limit (or is open) for greater than or equal to 15 seconds a DTC B1005 will set.
DIAGNOSTICS
Diagnostic Tips
If fuel gauge is performing erratically (possible false codes), inspect for unobstructed movement of sending unit arm. Repair or align as necessary.
Diagnostic Notes
The reference numbers below correlate with the circled numbers on the test 2.9 ow chart. 1. 2. Use HARNESS CONNECTOR TEST KIT (Part No. HD41404), brown pin probe and patch cord. Connect BREAKOUT BOX (Part No. HD-42682) and ADAPTERS (Part No. HD-41606) between wire harness and speedometer.
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Y/W BK
O/W BN/GY
To system relay
Y/GN BK
[86B] [86A]
LtGN/V
1 1
2 2
3 3
[39B] [39A]
12 12
56 7 567
9 9
O Y/W BK
LtGN/R BK LtGN/V GY
1 2 3 4
Speedometer
12V
[91A]
LtGN/R
[78B] [78A]
1 5
LtGN/V
ECM
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Disconnect speedometer connector [39]. Check continuity between Terminal 2 of connector [86B] and ground. Continuity present?
YES
NO
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Disconnect Speedometer connector [39]. Measure voltage on terminal 2 of connector [86B] (Y/W). Should be 0 volts. Is it?
YES
NO
1 2
Check continuity between terminal 2 of connector [86B] (Y/W) and Breakout Box terminal 11 (BK). Continuity present?
YES
NO
Clear codes using speedometer self diagnostics. See 2.3 SPEEDOMETER SELF DIAGNOSTICS. Conrm proper operation with no check engine lamp.
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2.10
Code B1006 is displayed when accessory line voltage is greater than 16.0 volts for longer than 5 seconds. Code 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 diagnostic codes.
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Test 2.10
ACCESSORY OR IGNITION LINE OVERVOLTAGE: DTC B1006/B1007
YES.
NO
Disconnect battery charger. Clear codes. NOTE Sometimes battery charger may cause overvoltage condition which will set codes. Start vehicle. Run at 3000 RPM for 5 seconds. Does code reset? Diagnose charging system. See Charging System.
YES
NO Clear codes using speedometer self diagnostics. See 2.3 SPEEDOMETER SELF DIAGNOSTICS. Conrm proper operation with no check engine lamp.
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DTC B1008
GENERAL
Reset Switch Closed
Code B1008 will be set if switch terminals are in a constant shorted state.
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2.11
DIAGNOSTICS
Diagnostic Notes
The reference numbers below correlate with the circled numbers on the 2.11 ow chart. 1. Connect BREAKOUT BOX (Part No. HD-42682) and ADAPTERS (Part No. HD-41606) between wire harness and speedometer, leaving speedometer disconnected. Figure 2-23. Reset Switch
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[39A] Speedometer
[39B]
1 2 3 4 5 6 7 8 9 10 11 12
BK
BK
Reset Switch
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Test 2.11
RESET SWITCH CLOSED: DTC B1008
Remove reset switch rubber boot. Clear codes using 2.3 SPEEDOMETER SELF DIAGNOSTICS. Codes still present?
YES
NO
With speedometer disconnected, measure resistance between terminals 8 and 11 (black) on Breakout Box. Resistance should be less than 1 ohm with switch depressed and innity ohms when released. Is it?
Replace boot.
YES
NO
Replace speedometer.
Replace switch.
Clear codes using speedometer self diagnostics. See 2.3 SPEEDOMETER SELF DIAGNOSTICS. Conrm proper operation with no check engine lamp.
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2.12
1 5
3 2
DIAGNOSTICS
Diagnostic Notes
The reference numbers below correlate with the circled numbers on the Test 2.12 ow 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. Connect BREAKOUT BOX (Part No. HD-42682) (black) between ICM connector [10A] and wiring harness connector [10B]. See 4.6 BREAKOUT BOX: ICM Connect BREAKOUT BOX (Part No. HD-43876) between wire harness and ECM. See 5.7 BREAKOUT BOX: EFI. 1. 2. 3. 4. 5. Terminal 1: ash pin-EFI models (Lt GN/R) Terminal 2: ground (BK) Terminal 3: serial data (Lt GN/V) Terminal 4: power (GY) Protective cap Figure 2-26. Data Link Connector
2.
3.
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[30B] [30A]
12V Battery
1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12
[39B] [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
TSM/TSSM Speedometer
12V instrument
2 3 4
[91A]
12V Ignition
[78B] [78A]
LtGN/R
1
Flash pin
LtGN/V
5
Serial data
ECM
BK
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[30B]
12V Battery
1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12
[39B] [39A]
[30A]
1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12
TSM/TSSM Speedometer
12V instrument
2 3 4
LtGN/V
[91A]
12V ignition
ICM [10B]
12
Serial data
[10A]
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Test 2.12
LOSS OF ECM SERIAL DATA: DTC U1016
Can you read ECM/ICM hardware P/N? See 2.3 SPEEDOMETER SELF DIAGNOSTICS.
NO or No Rsp YES
1 1
Install Breakout Box on TSM/TSSM.
CARBURETED MODELS
EFI MODELS
CARBURETED MODELS
EFI MODELS
Check continuity between Breakout Box terminal 3 (gray) and Breakout Box terminal 12 (black). Continuity present?
Check continuity between terminalnal 3 (gray) 2 (black) of TSM/TSSM of speedometer Breakout Breakout Box and Box terminal and terminal 5 of ECM 5 of ECM Breakout Breakout Box. Box. Continuity present?
While wiggling harness, check continuity between Breakout Box terminal 3 (gray) and Breakout Box terminal 12 (black). Continuity present?
While wiggling harness, check continuity between terminal 3 (gray) of TSM/TSSM Breakout Box and terminal 5 of ECM Breakout Box. Continuity present?
YES NO Clear codes. Test ride. Does DTC U1016 return? Repair intermittent on Lt GN/V wire.
YES
NO
NO No trouble found.
No trouble found.
Clear codes using speedometer self diagnostics. See 2.3 SPEEDOMETER SELF DIAGNOSTICS. Conrm proper operation with no check engine lamp.
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2.13
DIAGNOSTICS
Diagnostic Notes
The reference numbers below correlate with the circled numbers on the Test 2.13 ow chart. 1. Connect BREAKOUT BOX (Part No. HD-42682) as follows: a. Mate black socket housing on Breakout Box with speedometer connector [39] using SPEEDOMETER HARNESS ADAPTER (Part No. HD-46601). Mate black pin housing on Breakout Box with speedometer harness connector [39B] using SPEEDOMETER HARNESS ADAPTER (Part No. HD-46601. Mate gray socket housing on Breakout Box with TSM/TSSM connector [30A]. Mate gray pin housing on Breakout Box with harness connector [30B].
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1 5
3 2
b.
c. d.
1. 2. 3. 4. 5.
Terminal 1: ash pin-EFI models (Lt GN/R) Terminal 2: ground (BK) Terminal 3: serial data (Lt GN/V) Terminal 4: power (GY) Protective cap Figure 2-30. Data Link Connector
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d0700c8x
[30B] [30A]
12V Battery
1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12
[39B] [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
TSM/TSSM Speedometer
12V instrument
2 3 4
[91A]
12V Ignition
[78B] [78A]
LtGN/R
1
Flash pin
LtGN/V
5
Serial data
ECM
BK
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d0721c8x
[30B]
12V Battery
1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12
[39B] [39A]
[30A]
1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12
TSM/TSSM Speedometer
12V instrument
2 3 4
LtGN/V
[91A]
12V ignition
ICM [10B]
12
Serial data
[10A]
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Test 2.13
LOSS OF TSM/TSSM SERIAL DATA: DTC U1064, U1255
Can you read TSM/TSSM hardware P/N? See 2.3 SPEEDOMETER SELF DIAGNOSTICS.
NO or No Rsp YES
Install Breakout Box on speedometer. While wiggling harness, check for continuity between terminal 3 (gray) and terminal 2 (black) of Breakout Box. Continuity present?
Install Breakout Box on speedometer. Check for continuity between terminal 3 (gray) and terminal 2 (black) of Breakout Box Continuity present?
YES
NO
YES
NO
Repair intermittent on Lt GN/V wire. Clear DTCs. Test ride. Does DTC U1064 return?
Clear codes using speedometer self diagnostics. See 2.3 SPEEDOMETER SELF DIAGNOSTICS. Conrm proper operation with no check engine lamp. YES Replace TSM/TSSM. Learn password. NO No trouble found.
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2.14
DIAGNOSTICS
Diagnostic Tips
If serial data is shorted, these codes will automatically cause the check engine lamp to illuminate. The odometer will read Bus Er in this condition. Diagnostic trouble codes (DTCs) P1009 and P1010 may accompany DTCs U1300 and U1301.
Diagnostic Notes
If a U1300, U1301 or BUS Er is present on carbureted models, perform diagnostic procedures listed in 4.10 STARTS, THEN STALLS. If a U1300, U1301 or BUS Er is present on EFI models, perform diagnostic procedures listed in 5.12 STARTS, THEN STALLS.
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