2007 Harley-Davidson Touring Electrical Diagnostics Manual – PDF DOWNLOAD
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2007 Harley-Davidson Touring Electrical Diagnostics Manual – PDF DOWNLOAD
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2007 Harley-Davidson Touring Electrical Diagnostics Manual – PDF DOWNLOAD
STARTING AND CHARGING 1 ................................................................... 1 STARTER TROUBLESHOOTING 1.1............................................................ 3 STARTING SYSTEM DIAGNOSIS 1.2.......................................................... 7 DIAGNOSTICS........................................................................ 7 Diagnostic Notes............................................................... 7 Job/Time Code Values........................................................... 7 Starter Testing 1.............................................................. 7 Starter Testing 2: Solenoid Clicks............................................. 8 Starter Testing 3: Relay Clicks................................................ 8 Starter Testing 4: Nothing Clicks (Part 1 of 2)................................ 9 Starter Testing 4: Nothing Clicks (Part 2 of 2)................................ 10 Starter Testing 5: Starter Spins, But Does Not Engage.......................... 11 Starter Testing 6: Starter Stalls or Spins Too Slowly.......................... 11 STARTER ACTIVATION CIRCUITS 1.3........................................................ 12 DIAGNOSTICS/TROUBLESHOOTING 1.4........................................................ 13 GENERAL............................................................................ 13 VOLTAGE DROPS...................................................................... 13 STARTER SYSTEM TESTING 1.5............................................................. 14 GENERAL............................................................................ 14 STARTER RELAY TEST 1............................................................... 14 STARTER RELAY TEST 2............................................................... 14 STARTER CURRENT DRAW TEST.......................................................... 14 TESTING ASSEMBLED STARTER 1.6.......................................................... 16 STARTER SOLENOID................................................................... 16 SOLENOID PULL-IN TEST.............................................................. 16 SOLENOID HOLD-IN TEST.............................................................. 16 SOLENOID RETURN TEST............................................................... 17 FREE RUNNING CURRENT DRAW TEST..................................................... 17 CHARGING SYSTEM 1.7.................................................................... 18 GENERAL............................................................................ 18 Alternator..................................................................... 18 Voltage Regulator.............................................................. 18 TROUBLESHOOTING.................................................................... 18 Battery........................................................................ 18 Wiring......................................................................... 19 Voltage Regulator Inspection................................................... 19 Job/Time Code Values........................................................... 19 Test 1.7 (Part 1 of 2)......................................................... 20 Test 1.7 (Part 2 of 2)......................................................... 21 TESTING............................................................................ 22 MILLIAMP DRAW TEST............................................................. 22 TOTAL CURRENT DRAW TEST........................................................ 22 CURRENT OUTPUT TEST............................................................ 23 VOLTAGE OUTPUT TEST............................................................ 23 STATOR CHECK................................................................... 23 AC OUTPUT CHECK................................................................ 24 BATTERY TESTING 1.8.................................................................... 25 GENERAL............................................................................ 25 VOLTMETER TEST..................................................................... 25 CONDUCTANCE TEST................................................................... 25 LOAD TEST.......................................................................... 26 INSTRUMENTS 2.............................................................................. 29 CHECKING FOR DIAGNOSTIC TROUBLE CODES 2.1.............................................. 31 CHECK ENGINE LAMP.................................................................. 31 SECURITY LAMP...................................................................... 32 CODE TYPES......................................................................... 33 Current........................................................................ 33 Historic....................................................................... 33 RETRIEVING DIAGNOSTIC TROUBLE CODES................................................ 33 MULTIPLE DIAGNOSTIC TROUBLE CODES.................................................. 33 INITIAL DIAGNOSTIC CHECK: SPEEDOMETER 2.2.............................................. 34 GENERAL............................................................................ 34 Diagnostic Notes............................................................... 34 Circuit Diagram/Wire Harness Connector Table................................... 34 INITIAL DIAGNOSTICS................................................................ 35 Diagnostic Tips................................................................ 35 Diagnostic Notes............................................................... 35 Other Codes.................................................................... 35 Diagnostic Check (Part 1 of 2)................................................. 39 Diagnostic Check (Part 2 of 2)................................................. 40 SPEEDOMETER SELF DIAGNOSTICS 2.3....................................................... 41 GENERAL............................................................................ 41 DIAGNOSTICS........................................................................ 41 Diagnostic Tips................................................................ 41 Diagnostic Notes............................................................... 41 Speedometer Self Diagnostics (chart)........................................... 42 SPEEDOMETER/TACHOMETER 2.4............................................................. 43 GENERAL............................................................................ 43 Reset Switch................................................................... 43 SPEEDOMETER THEORY OF OPERATION.................................................... 44 Job/Time Code Values........................................................... 44 TACHOMETER THEORY OF OPERATION..................................................... 44 DIAGNOSTICS........................................................................ 44 Diagnostic Notes............................................................... 44 Test 2.4 (Part 1 of 2)......................................................... 45 Test 2.4 (Part 2 of 2)......................................................... 46 BREAKOUT BOX: SPEEDOMETER 2.5.......................................................... 47 GENERAL............................................................................ 47 INSTALLATION....................................................................... 47 REMOVAL............................................................................ 47 FUEL GAUGE 2.6......................................................................... 48 THEORY OF OPERATION................................................................ 48 FUEL GAUGE AND SENDER TEST......................................................... 48 OIL, AIR AND VOLTMETER GAUGES 2.7...................................................... 49 Oil Pressure Gauge and Indicator Light............................................. 49 Problem........................................................................ 49 Ambient Air Temperature Gauge...................................................... 50 Problem........................................................................ 50 Voltmeter Gauge.................................................................... 50 Problem........................................................................ 50 INDICATOR LIGHTS: FLHX, FLHT/C/U, FLTR 2.8............................................. 51 GENERAL............................................................................ 51 Job/Time Code Values........................................................... 51 DIAGNOSTICS........................................................................ 52 Oil Pressure or Neutral Indicator Will Not Function............................ 52 High Beam or R/L Turn Signal Indicator Will Not Function....................... 52 INDICATOR LIGHTS: FLHR/C/S 2.9......................................................... 53 GENERAL............................................................................ 53 Job/Time Code Values........................................................... 53 DIAGNOSTICS........................................................................ 54 Oil Pressure or Neutral Indicator Will Not Function............................ 54 High Beam or R/L Turn Signal Indicator Will Not Function....................... 54 DTC B1004, B1005 2.10.................................................................. 55 GENERAL............................................................................ 55 DIAGNOSTICS........................................................................ 55 Diagnostic Tips................................................................ 55 Diagnostic Notes............................................................... 55 Test 2.10...................................................................... 57 Test 2.10...................................................................... 58 DTC B1006, B1007 2.11.................................................................. 59 GENERAL............................................................................ 59 Accessory or Ignition Line Overvoltage......................................... 59 Test 2.11...................................................................... 60 DTC B1008 2.12......................................................................... 61 GENERAL............................................................................ 61 Reset Switch Closed............................................................ 61 DIAGNOSTICS........................................................................ 61 Diagnostic Notes............................................................... 61 Test 2.12...................................................................... 63 DTC U1016 2.13......................................................................... 64 GENERAL............................................................................ 64 Loss of ECM Serial Data........................................................ 64 DIAGNOSTICS........................................................................ 64 Diagnostic Notes............................................................... 64 Test 2.13...................................................................... 67 DTC U1064, U1255 2.14.................................................................. 68 GENERAL............................................................................ 68 Loss of TSM/TSSM/HFSM Serial Data.............................................. 68 DIAGNOSTICS........................................................................ 68 Diagnostic Notes............................................................... 68 Test 2.14...................................................................... 71 DTC U1300, U1301 or “BUS ER” 2.15...................................................... 72 GENERAL............................................................................ 72 Serial Data Low or Serial Data Open/High....................................... 72 DIAGNOSTICS........................................................................ 72 Diagnostic Tips................................................................ 72 TSM/TSSM/HFSM 3 ........................................................................... 73 TURN SIGNAL OVERVIEW 3.1............................................................... 75 GENERAL............................................................................ 75 SECURITY SYSTEM: JAPAN/KOREA....................................................... 75 TURN SIGNAL FUNCTIONS.............................................................. 75 MANUAL CANCELLATION................................................................ 75 AUTOMATIC CANCELLATION............................................................. 75 BANK ANGLE FUNCTIONS............................................................... 76 BANK ANGLE RESTART................................................................. 76 CLUTCH/NEUTRAL INTERLOCK........................................................... 76 SECURITY SYSTEM: H-DSSS............................................................ 76 HARLEY-DAVIDSON SMART SECURITY SYSTEM 3.2.............................................. 77 COMPONENTS......................................................................... 77 SECURITY IMOBILIZATION............................................................. 78 HFSM FEATURES...................................................................... 78 H-DSSS ACTUATION 3.3................................................................... 80 GENERAL............................................................................ 80 SIDECAR CONFIGURATION.............................................................. 80 ACTUATION.......................................................................... 80 FOB ASSIGNMENT..................................................................... 80 POWER DISRUPTION AND CONFIGURING................................................... 80 PERSONAL IDENTIFICATION NUMBER (PIN) 3.4............................................... 81 GENERAL............................................................................ 81 INITIAL PIN ENTRY.................................................................. 81 CHANGING THE PIN................................................................... 82 Modifying an Existing PIN...................................................... 82 ARMING/DISARMING SECURITY SYSTEM 3.5................................................... 83 HANDS-FREE FOB..................................................................... 83 SECURITY LAMP (KEY ICON)........................................................... 83 ARMING............................................................................. 84 DISARMING.......................................................................... 84 DISARMING WITH A PERSONAL IDENTIFICATION NUMBER (PIN).............................. 84 WARNINGS AND ALARM 3.6................................................................. 85 WARNINGS........................................................................... 85 ALARM.............................................................................. 85 SIREN CHIRP MODE (CONFIRMATION).................................................... 85 Chirpless Mode................................................................. 85 Chirp Mode..................................................................... 85 Switching Modes................................................................ 85 SERVICE/EMERGENCY FUNCTIONS 3.7........................................................ 86 TRANSPORT MODE..................................................................... 86 SERVICE MODE....................................................................... 86 FOUR-WAY FLASHING.................................................................. 86 TROUBLESHOOTING 3.8.................................................................... 87 TURN SIGNALS (TSM/HFSM)............................................................ 87 SECURITY SYSTEM (HFSM)............................................................. 87 DIAGNOSTICS MODE................................................................... 87 TROUBLESHOOTING.................................................................... 87 CHECKING FOR DTCS 3.9.................................................................. 88 GENERAL............................................................................ 88 SECURITY /LAMP DIAGNOSTICS......................................................... 88 CODE TYPES......................................................................... 89 Current........................................................................ 89 Historic....................................................................... 89 RETRIEVING DTCs.................................................................... 90 MULTIPLE DTCs/PRIORITY RANKING..................................................... 90 INITIAL DIAGNOSTIC CHECK 3.10.......................................................... 93 GENERAL............................................................................ 93 Diagnostic Notes............................................................... 93 Circuit Diagram/Wire Harness Connector Table................................... 93 Job/Time Codes................................................................. 93 Reprogramming ECM.............................................................. 93 INITIAL DIAGNOSTICS................................................................ 93 Diagnostic Tips................................................................ 93 Diagnostic Notes............................................................... 93 Other DTCs..................................................................... 93 Initial Diagnostic Check (Part 1 of 3)......................................... 96 Initial Diagnostic Check (Part 2 of 3)......................................... 97 Initial Diagnostic Check (Part 3 of 3)......................................... 98 SPEEDOMETER SELF DIAGNOSTICS 3.11...................................................... 99 GENERAL............................................................................ 99 DIAGNOSTICS........................................................................ 99 Diagnostic Tips................................................................ 99 Diagnostic Notes............................................................... 99 Speedometer Self Diagnostics...................................................100 BREAKOUT BOX 3.12......................................................................101 GENERAL............................................................................101 INSTALLATION.......................................................................101 REMOVAL............................................................................101 FAILS TO DISARM (HFSM ONLY) 3.13.......................................................103 GENERAL............................................................................103 JOB/TIME CODES.....................................................................103 DIAGNOSTICS........................................................................103 Diagnostic Tips................................................................103 Diagnostic Notes...............................................................103 Test 3.13......................................................................105 SYMPTOM: HFSM FAILS TO DISARM..................................................105 DTC B0563 3.14.........................................................................106 GENERAL............................................................................106 DIAGNOSTICS........................................................................106 Diagnostic Tips................................................................106 Diagnostic Notes...............................................................106 TSM/HFSM: TURN SIGNAL ERRORS AND DTCS 3.15.............................................107 GENERAL............................................................................107 DIAGNOSTICS........................................................................107 Job/Time Codes.................................................................107 Diagnostic Tips................................................................107 Diagnostic Notes: All Turn Signal Flow Charts..................................110 TSM/HFSM: Test 3.15a (Part 1 of 2).............................................111 TURN SIGNAL SYMPTOM- WILL NOT CANCEL ON TURN COMPLETION........................111 TSM/HFSM: Test 3.15b (Part 2 of 2).............................................112 TURN SIGNAL SYMPTOM- CANCELS ERRATICALLY.......................................112 TSM/HFSM: Test 3.15c...........................................................113 TSM Only: Test 3.15d (Part 1 of 4).............................................114 SYMPTOM- WILL NOT FLASH, 4-WAY FLASHERS INOPERABLE: DTC B1121, B1122, B1141....114 TSM Only: Test 3.15e (Part 2 of 4).............................................115 SYMPTOM- WILL NOT FLASH, 4-WAY FLASHERS INOPERABLE: DTC B1121, B1122, B1141....115 TSM Only: Test 3.15f (Part 3 of 4).............................................116 SYMPTOM- WILL NOT FLASH, 4-WAY FLASHERS INOPERABLE: DTC B1121, B1122, B1141....116 TSM Only: Test 3.15g (Part 4 of 4).............................................117 SYMPTOM- WILL NOT FLASH, 4-WAY FLASHERS INOPERABLE: DTC B1121, B1122, B1141....117 HFSM: Test 3.15h...............................................................118 HFSM: Test 3.15i...............................................................119 HFSM: Test 3.15j...............................................................120 DTC B1131, B1132 (HFSM ONLY) 3.16......................................................121 GENERAL............................................................................121 DIAGNOSTICS........................................................................121 Diagnostic Tips................................................................121 Diagnostic Notes...............................................................121 HFSM Only: Test 3.16...........................................................123 DTC B1134 3.17.........................................................................124 GENERAL............................................................................124 DIAGNOSTICS........................................................................124 Diagnostic Notes...............................................................124 TSM/HFSM: Test 3.17............................................................126 DTC B1135 3.18.........................................................................127 DIAGNOSTICS........................................................................127 DTC B1136, B1142 (HFSM ONLY) 3.19......................................................128 DIAGNOSTICS........................................................................128 DTC B1136 Accelerometer Tip-Over Self-Test Fault...............................128 DTC B1142 Internal Fault.......................................................128 DTC B1141 (HFSM ONLY) 3.20.............................................................129 DIAGNOSTICS........................................................................129 Diagnostic Tips................................................................129 Diagnostic Notes...............................................................129 HFSM: Test 3.20 (Part 1 of 2)..................................................130 HFSM: Test 3.20 (Part 2 of 2)..................................................131 DTC B1143, B1144, B1145 (HFSM ONLY) 3.21...............................................132 GENERAL............................................................................132 DIAGNOSTICS........................................................................132 Diagnostic Notes...............................................................132 HFSM: Test 3.21a...............................................................133 HFSM: Test 3.21b...............................................................134 HFSM: Test 3.21c...............................................................135 DTC B1151, B1152, B1153 3.22...........................................................136 GENERAL............................................................................136 Sidecar BAS....................................................................136 DIAGNOSTICS........................................................................136 Diagnostic Tips................................................................136 Diagnostic Notes...............................................................136 Test 3.22......................................................................138 DTC B1154, B1155 3.23..................................................................139 Diagnostics........................................................................139 Diagnostic Tips................................................................139 Diagnostic Notes...............................................................139 HFSM: Test 3.23a...............................................................141 HFSM: Test: 3.23b..............................................................142 DTC U1016, U1255 3.24..................................................................143 GENERAL............................................................................143 DIAGNOSTICS........................................................................143 Diagnostic Notes...............................................................143 TSM/HFSM: Test 3.24............................................................146 DTC U1300, U1301 or “BUS ER” 3.25......................................................147 DIAGNOSTICS........................................................................147 Diagnostic Tips................................................................147 Diagnostic Notes...............................................................147 HFSM: PASSWORD LEARN 3.26..............................................................148 GENERAL............................................................................148 PASSWORD LEARNING..................................................................148 HFSM: MAINTENANCE 3.27.................................................................150 GENERAL............................................................................150 HANDS-FREE FOB.....................................................................150 Schedule.......................................................................150 Battery Replacement............................................................150 SMART SIREN (IF INSTALLED).........................................................151 Schedule.......................................................................151 Battery Replacement............................................................151 ENGINE MANAGEMENT 4 .......................................................................153 SPECIFICATIONS 4.1.....................................................................155 EFI SYSTEM 4.2.........................................................................157 GENERAL............................................................................157 HEAT MANAGEMENT SYSTEM.........................................................157 TROUBLESHOOTING....................................................................157 EFI DIAGNOSTIC INTRODUCTION 4.3........................................................159 SYSTEM PROBLEMS....................................................................159 No Start.......................................................................159 Poor Performance...............................................................159 Check Engine Lamp..............................................................159 RESOLVING PROBLEMS.................................................................159 CHECKING FOR DIAGNOSTIC TROUBLE CODES: EFI 4.4.........................................160 CHECK ENGINE LAMP..................................................................160 CODE TYPES.........................................................................161 Current........................................................................161 Historic.......................................................................161 RETRIEVING DIAGNOSTIC TROUBLE CODES................................................161 MULTIPLE DIAGNOSTIC TROUBLE CODES..................................................161 INITIAL DIAGNOSTIC CHECK: EFI 4.5......................................................162 GENERAL............................................................................162 Diagnostic Notes...............................................................162 Circuit Diagram/Wire Harness Connector Table...................................162 Reprogramming ECM..............................................................162 INITIAL DIAGNOSTICS................................................................162 General Information............................................................162 Diagnostic Tips................................................................162 Diagnostic Notes...............................................................162 Other Codes....................................................................162 Diagnostic Check (Part 1 of 2).................................................169 Diagnostic Check (Part 2 of 2).................................................170 SPEEDOMETER SELF DIAGNOSTICS 4.6.......................................................171 GENERAL............................................................................171 DIAGNOSTICS........................................................................171 Diagnostic Tips................................................................171 Diagnostic Notes...............................................................171 Speedometer Self Diagnostics (chart)...........................................172 BREAKOUT BOX: EFI 4.7..................................................................173 GENERAL............................................................................173 INSTALLATION.......................................................................173 REMOVAL............................................................................173 WIGGLE TEST 4.8........................................................................174 GENERAL............................................................................174 PROCEDURE..........................................................................174 INTAKE LEAK TEST 4.9...................................................................175 GENERAL............................................................................175 LEAK TESTER........................................................................175 Parts List.....................................................................175 Tester Assembly................................................................175 INTAKE LEAK TESTING................................................................176 ENGINE CRANKS, BUT WILL NOT START 4.10.................................................177 GENERAL............................................................................177 DIAGNOSTICS........................................................................177 Diagnostic Notes...............................................................177 Diagnostic Tips................................................................177 Test 4.10 (Part 1 of 4)........................................................180 Test 4.10 (Part 2 of 4)........................................................181 Test 4.10 (Part 3 of 4)........................................................182 Test 4.10 (Part 4 of 4)........................................................183 NO ECM POWER 4.11......................................................................184 GENERAL............................................................................184 No Spark/No Check Engine Lamp at Key ON........................................184 DIAGNOSTICS........................................................................184 Diagnostic Notes...............................................................184 Test 4.11 (Part 1 of 2)........................................................187 Test 4.11 (Part 2 of 2)........................................................188 STARTS, THEN STALLS 4.12...............................................................189 GENERAL............................................................................189 Diagnostic Trouble Codes U1300, U1301 or “BUS Er”..............................189 DIAGNOSTICS........................................................................189 Diagnostic Tips................................................................189 Diagnostic Notes...............................................................189 Test 4.12 (Part 1 of 2)........................................................192 Test 4.12 (Part 2 of 2)........................................................193 FUEL SYSTEM ELECTRICAL TEST 4.13.......................................................194 GENERAL............................................................................194 DIAGNOSTICS........................................................................194 Diagnostic Notes...............................................................194 Test 4.13 (Part 1 of 4)........................................................196 Test 4.13 (Part 2 of 4)........................................................197 Test 4.13 (Part 3 of 4)........................................................198 Test 4.13 (Part 4 of 4)........................................................198 SYSTEM RELAY CHECK 4.14................................................................199 GENERAL............................................................................199 System Relay...................................................................199 DIAGNOSTICS........................................................................199 Diagnostic Notes...............................................................199 Test 4.14 (Part 1 of 3)........................................................202 Test 4.14 (Part 2 of 3)........................................................203 Test 4.14 (Part 3 of 3)........................................................203 FUEL PRESSURE TEST 4.15................................................................204 GENERAL............................................................................204 TESTING............................................................................204 DIAGNOSTICS........................................................................206 Diagnostic Notes...............................................................206 Test 4.15......................................................................207 IDLE AIR CONTROL, DTC P0505 4.16.......................................................208 GENERAL............................................................................208 IAC Operation..................................................................208 Diagnostic Trouble Code P0505: Loss of Idle Speed Control......................208 DIAGNOSTICS........................................................................208 Diagnostic Tips................................................................208 Diagnostic Notes...............................................................209 Test 4.16 (Part 1 of 2)........................................................211 Test 4.16 (Part 2 of 2)........................................................212 MISFIRE AT IDLE OR UNDER LOAD 4.17.....................................................213 GENERAL............................................................................213 Misfire at Idle or Under Load..................................................213 DIAGNOSTICS........................................................................213 Diagnostic Notes...............................................................213 Test 4.17 (Part 1 of 3)........................................................215 Test 4.17 (Part 2 of 3)........................................................216 Test 4.17 (Part 3 of 3)........................................................217 COMBUSTION ABSENT/INTERMITTENT 4.18....................................................218 GENERAL............................................................................218 Diagnostic Trouble Codes P1353, P1356, P1357, P1358: No Combustion.............218 DIAGNOSTICS........................................................................218 Diagnostic Notes...............................................................218 Test 4.18 (Part 1 of 2)........................................................221 Test 4.18 (Part 2 of 2)........................................................222 DTC P0107, P0108 4.19..................................................................223 GENERAL............................................................................223 MAP Sensor.....................................................................223 DIAGNOSTICS........................................................................223 Diagnostic Tips................................................................223 Diagnostic Notes...............................................................223 Test 4.19 (Part 1 of 2)........................................................225 Test 4.19 (Part 2 of 2)........................................................226 DTC P0112, P0113 4.20..................................................................227 GENERAL............................................................................227 IAT Sensor.....................................................................227 DIAGNOSTICS........................................................................227 Diagnostic Tips................................................................227 Diagnostic Notes...............................................................227 Test 4.20 (Part 1 of 2)........................................................229 Test 4.20 (Part 2 of 2)........................................................230 DTC P0117, P0118 4.21..................................................................231 GENERAL............................................................................231 ET Sensor......................................................................231 DIAGNOSTICS........................................................................231 Diagnostic Tips................................................................231 Diagnostic Notes...............................................................231 Test 4.21 (Part 1 of 2)........................................................233 Test 4.21 (Part 2 of 2)........................................................234 DTC P0122, P0123 4.22..................................................................235 GENERAL............................................................................235 TP Sensor......................................................................235 DIAGNOSTICS........................................................................235 Diagnostic Tips................................................................235 Diagnostic Notes...............................................................235 Test 4.22 (Part 1 of 2)........................................................237 Test 4.22 (Part 2 of 2)........................................................238 DTC P0131, P0132, P0134, P0151, P0152, P0154 4.23......................................239 GENERAL............................................................................239 O2 Sensor......................................................................239 DIAGNOSTICS........................................................................239 Diagnostic Tips................................................................239 Diagnostic Notes...............................................................239 Test 4.23 (Part 1 of 3)........................................................241 Test 4.23 (Part 2 of 3)........................................................242 Test 4.23 (Part 3 of 3)........................................................243 DTC P0261, P0262, P0263, P0264 4.24....................................................244 GENERAL............................................................................244 Fuel Injectors.................................................................244 DIAGNOSTICS........................................................................244 Diagnostic Notes...............................................................244 Test 4.24 (Part 1 of 3)........................................................247 Test 4.24 (Part 2 of 3)........................................................248 Test 4.24 (Part 3 of 3)........................................................249 DTC P0373, P0374 4.25..................................................................250 GENERAL............................................................................250 CKP Sensor.....................................................................250 DIAGNOSTICS........................................................................250 Diagnostic Tips................................................................250 Diagnostic Notes...............................................................250 Test 4.25......................................................................252 DTC P0501, P0502 4.26..................................................................253 GENERAL............................................................................253 Vehicle Speed Sensor...........................................................253 DIAGNOSTICS........................................................................253 Diagnostic Notes...............................................................253 Test 4.26 (Part 1 of 2)........................................................255 Test 4.26 (Part 2 of 2)........................................................256 DTC P0562, P0563 4.27..................................................................257 GENERAL............................................................................257 Battery Voltage................................................................257 DIAGNOSTICS........................................................................257 Diagnostic Tips................................................................257 Diagnostic Notes...............................................................257 Test 4.27 (Part 1 of 2)........................................................260 Test 4.27 (Part 2 of 2)........................................................261 DTC P0603, P0605 4.28..................................................................262 GENERAL............................................................................262 ECM Failure....................................................................262 DIAGNOSTICS........................................................................262 DTC P0603......................................................................262 DTC P0605......................................................................262 DTC P0661, P0662 4.29..................................................................263 GENERAL............................................................................263 Active Intake Solenoid (HDI Models Only).......................................263 DIAGNOSTICS........................................................................263 Diagnostic Notes...............................................................263 Test 4.29 (Part 1 of 2)........................................................265 Test 4.29 (Part 2 of 2)........................................................266 DTC P1009, P1010 4.30..................................................................267 GENERAL............................................................................267 Password Problem...............................................................267 DIAGNOSTICS........................................................................267 Diagnostic Notes...............................................................267 Test 4.30......................................................................270 DTC P1351, P1352, P1354, P1355 4.31....................................................271 GENERAL............................................................................271 Ignition Coil..................................................................271 DIAGNOSTICS........................................................................271 Diagnostic Notes...............................................................271 Test 4.31 (Part 1 of 2)........................................................274 Test 4.31 (Part 2 of 2)........................................................275 DTC P1475, P1477, P1478 4.32...........................................................276 GENERAL............................................................................276 Active Exhaust Actuator (HDI Models)...........................................276 DIAGNOSTICS........................................................................276 Diagnostic Notes...............................................................276 Test 4.32 (Part 1 of 4)........................................................278 Test 4.32 (Part 2 of 4)........................................................279 Test 4.32 (Part 3 of 4)........................................................280 Test 4.32 (Part 4 of 4)........................................................281 DTC U1064, U1255 4.33..................................................................282 GENERAL............................................................................282 Loss of TSM/TSSM/HFSM Serial Data..............................................282 DIAGNOSTICS........................................................................282 Diagnostic Notes...............................................................282 Test 4.33......................................................................285 DTC U1097, U1255 4.34..................................................................286 GENERAL............................................................................286 Loss of Speedometer Serial Data................................................286 DIAGNOSTICS........................................................................286 Diagnostic Notes...............................................................286 Test 4.34......................................................................289 ADVANCED AUDIO SYSTEM 5 ...................................................................291 RADIO DIAGNOSTICS 5.1..................................................................293 SYSTEM DESCRIPTION.................................................................293 ONBOARD DIAGNOSTICS................................................................293 General........................................................................293 Radio Diagnostic Display.......................................................293 RADIO SWITCH DIAGNOSTICS: DTC B2006-B2015 5.2..........................................298 GENERAL............................................................................298 DIAGNOSTICS........................................................................298 Diagnostic Notes...............................................................298 Test 5.2a......................................................................299 Test 5.2b (Part 1 of 3)........................................................300 Test 5.2b (Part 2 of 3)........................................................301 Test 5.2b (Part 3 of 3)........................................................302 Test 5.2c (Part 1 of 3)........................................................303 Test 5.2c (Part 2 of 3)........................................................304 Test 5.2c (Part 3 of 3)........................................................305 Test 5.2d (Part 1 of 3)........................................................306 Test 5.2d (Part 2 of 3)........................................................307 Test 5.2d (Part 3 of 3)........................................................308 Test 5.2e (Part 1 of 2)........................................................309 Test 5.2e (Part 2 of 2)........................................................310 Test 5.2f (Part 1 of 2)........................................................311 Test 5.2f (Part 2 of 2)........................................................312 Test 5.2g (Part 1 of 2)........................................................313 Test 5.2g (Part 2 of 2)........................................................314 Test 5.2h......................................................................315 Test 5.2i......................................................................316 Test 5.2j......................................................................317 RADIO SPEAKER DIAGNOSTICS: DTC B2016-B2027 5.3.........................................318 GENERAL............................................................................318 DIAGNOSTICS........................................................................318 Diagnostic Notes...............................................................318 Test 5.3a......................................................................319 Test 5.3b......................................................................321 Test 5.3c......................................................................322 Test 5.3d......................................................................323 Test 5.3e......................................................................324 Test 5.3f......................................................................326 Test 5.3g......................................................................327 Test 5.3h......................................................................328 Test 5.3i......................................................................329 Test 5.3j......................................................................331 Test 5.3k......................................................................332 Test 5.3l......................................................................333 SERIAL DATA BUS DIAGNOSTICS 5.4........................................................335 GENERAL............................................................................335 LOSS OF SERIAL DATA: DTC U1016.................................................335 STARTS, THEN STALLS: DTC U1300, U1301..........................................335 DIAGNOSTICS........................................................................335 Diagnostic Notes...............................................................335 Test 5.4a......................................................................336 Test 5.4b......................................................................338 Test 5.4c (Part 1 of 3)........................................................339 Test 5.4c (Part 2 of 3)........................................................341 Test 5.4c (Part 3 of 3)........................................................342 Test 5.4d......................................................................343 Test 5.4e......................................................................345 Test 5.4f......................................................................347 Test 5.4g......................................................................349 Test 5.4h......................................................................350 ADVANCED AUDIO SYSTEM SYMPTOMS 5.5.....................................................352 GENERAL............................................................................352 FACTORY DEFAULTS...................................................................352 DIAGNOSTICS........................................................................353 Diagnostic Notes...............................................................353 Test 5.5a......................................................................354 Test 5.5b......................................................................356 Test 5.5c......................................................................357 Test 5.5d......................................................................357 Test 5.5e......................................................................358 Test 5.5f......................................................................359 Test 5.5g (Part 1 of 4)........................................................360 Test 5.5g (Part 2 of 4)........................................................361 Test 5.5g (Part 3 of 4)........................................................362 Test 5.5g (Part 4 of 4)........................................................363 Test 5.5h (Part 1 of 3)........................................................364 Test 5.5h (Part 2 of 3)........................................................366 Test 5.5h (Part 3 of 3)........................................................367 Test 5.5i......................................................................368 Test 5.5j (Part 1 of 2)........................................................369 Test 5.5j (Part 2 of 2)........................................................370 Test 5.5k......................................................................372 Test 5.5l (Part 1 of 5)........................................................374 Test 5.5l (Part 2 of 5)........................................................375 Test 5.5l (Part 3 of 5)........................................................376 Test 5.5l (Part 4 of 5)........................................................377 Test 5.5l (Part 5 of 5)........................................................378 Test 5.5m (Part 1 of 4)........................................................380 Test 5.5m (Part 2 of 4)........................................................381 Test 5.5m (Part 3 of 4)........................................................382 Test 5.5m (Part 4 of 4)........................................................383 Test 5.5n (Part 1 of 2)........................................................385 Test 5.5n (Part 2 of 2)........................................................387 Test 5.5o (Part 1 of 2)........................................................388 Test 5.5o (Part 2 of 2)........................................................389 Test 5.5p......................................................................391 Test 5.5q (Part 1 of 2)........................................................392 Test 5.5q (Part 2 of 2)........................................................393 Test 5.5r......................................................................394 Test 5.5s (Part 1 of 4)........................................................395 Test 5.5s (Part 2 of 4)........................................................396 Test 5.5s (Part 3 of 4)........................................................398 Test 5.5s (Part 4 of 4)........................................................400 Test 5.5t......................................................................401 Test 5.5u (Part 1 of 5)........................................................402 Test 5.5u (Part 2 of 5)........................................................403 Test 5.5u (Part 3 of 5)........................................................405 Test 5.5u (Part 4 of 5)........................................................407 Test 5.5u (Part 5 of 5)........................................................408 CRUISE CONTROL 6 ..........................................................................409 CRUISE CONTROL 6.1.....................................................................411 GENERAL............................................................................411 SYSTEM OPERATION...................................................................411 TROUBLESHOOTING....................................................................412 CRUISE INOPERATIVE DIAGNOSTICS 6.2.....................................................413 GENERAL............................................................................413 INOPERATIVE DIAGNOSTICS............................................................413 Diagnostic Notes...............................................................413 CRUISE DROPOUT DIAGNOSTICS 6.3.........................................................416 GENERAL............................................................................416 DROPOUT DIAGNOSTICS................................................................416 CRUISE CHART A: INITIAL DIAGNOSTICS 6.4................................................419 DIAGNOSTICS........................................................................419 Test 6.4 (Part 1 of 2).........................................................419 Test 6.4 (Part 2 of 2).........................................................420 CRUISE CHART B: RESUME SWITCH 6.5......................................................421 DIAGNOSTICS........................................................................421 Test 6.5.......................................................................421 CRUISE CHART C: CRUISE ENGAGED LAMP 6.6................................................422 DIAGNOSTICS........................................................................422 Test 6.6.......................................................................422 CRUISE CHART D: CRUISE POWER 6.7.......................................................423 DIAGNOSTICS........................................................................423 Test 6.7.......................................................................423 CRUISE CHART E: CRUISE ENABLE 6.8......................................................425 DIAGNOSTICS........................................................................425 Test 6.8.......................................................................425 Diagnostic Notes...............................................................425 CRUISE CHART F-1: BRAKE LIGHTS ON 6.9..................................................426 DIAGNOSTICS........................................................................426 Test 6.9.......................................................................426 CRUISE CHART F-2: BRAKE LIGHTS OFF 6.10................................................427 DIAGNOSTICS........................................................................427 Test 6.10 (Part 1 of 2)........................................................427 Test 6.10 (Part 2 of 2)........................................................428 Diagnostic Notes...............................................................428 CRUISE CHART G: THROTTLE SWITCH 6.11...................................................429 DIAGNOSTICS........................................................................429 Test 6.11......................................................................429 CRUISE CHART H: SPEEDOMETER INPUT 6.12.................................................430 DIAGNOSTICS........................................................................430 Diagnostic Notes...............................................................430 Test 6.12......................................................................430 CRUISE CHART I: TACHOMETER INPUT 6.13..................................................431 DIAGNOSTICS........................................................................431 Test 6.13......................................................................431 WIRING 7 ..................................................................................433 DEUTSCH ELECTRICAL CONNECTORS 7.1......................................................435 GENERAL............................................................................435 REMOVING/DISASSEMBLING.............................................................435 REMOVING/INSTALLING SOCKETS........................................................435 REMOVING/INSTALLING PINS...........................................................436 ASSEMBLING/INSTALLING..............................................................438 CRIMPING INSTRUCTIONS..............................................................438 STANDARD TERMINALS.............................................................438 MINI TERMINALS.................................................................440 SOLID BARREL CONTACTS..........................................................440 MULTILOCK ELECTRICAL CONNECTORS 7.2....................................................442 REMOVING SOCKET/PIN TERMINALS......................................................442 INSTALLING SOCKET/PIN TERMINALS....................................................442 CRIMPING INSTRUCTIONS..............................................................446 DELPHI ELECTRICAL CONNECTORS 7.3.......................................................447 GENERAL............................................................................447 REMOVING SOCKET TERMINALS..........................................................447 INSTALLING SOCKET TERMINALS........................................................447 PACKARD ELECTRICAL CONNECTORS 7.4......................................................449 150 METRI-PACK SERIES..............................................................449 General........................................................................449 Disassembly....................................................................449 Assembly.......................................................................449 280 METRI-PACK SERIES..............................................................449 General........................................................................449 System Fuse Block..............................................................449 480 METRI-PACK SERIES..............................................................451 General........................................................................451 Disassembly....................................................................451 Assembly.......................................................................452 630 METRI-PACK SERIES..............................................................453 General........................................................................453 Disassembly....................................................................453 Assembly.......................................................................453 800 METRI-PACK SERIES..............................................................453 General........................................................................453 Disassembly....................................................................453 Assembly.......................................................................453 PACKARD MICRO 64...................................................................454 General........................................................................454 Disassembly....................................................................454 Assembly.......................................................................455 Crimping Instructions..........................................................455 PACKARD 100W.......................................................................456 General........................................................................456 Disassembly....................................................................456 Assembly.......................................................................457 Crimping Instructions..........................................................457 AUTOFUSE ELECTRICAL CONNECTOR 7.5......................................................459 GENERAL............................................................................459 DISASSEMBLY........................................................................459 ASSEMBLY...........................................................................459 SEALED BUTT SPLICE CONNECTORS 7.6......................................................460 PROCEDURE..........................................................................460 MOLEX ELECTRICAL CONNECTORS 7.7........................................................462 REMOVING TERMINALS.................................................................462 INSTALLING TERMINALS...............................................................462 ELECTRICAL CONNECTOR LOCATIONS 7.8.....................................................464 FLHX, FLHT/C/U.....................................................................464 FLHX, FLHT/C/U (Continued).....................................................466 FLTR...............................................................................470 FLTR (Continued)...............................................................471 FLTR (Continued)...............................................................472 FLHR/C/S...........................................................................473 FLHR/C/S (Continued)...........................................................474 FLHR/C/S (Continued)...........................................................475 WIRING DIAGRAMS 7.9....................................................................477 APPENDICES ................................................................................503 ACRONYMS AND ABBREVIATIONS A.1.........................................................505 TSM/TSSM (JAPAN/KOREA) OVERVIEW B.1....................................................507 GENERAL............................................................................507 TROUBLESHOOTING....................................................................507 TSM/TSSM FEATURES B.2..................................................................509 GENERAL............................................................................509 TURN SIGNAL FUNCTIONS..............................................................509 TSM/TSSM Features..............................................................509 BANK ANGLE FUNCTION................................................................509 CLUTCH/NEUTRAL INTERLOCK FUNCTIONS.................................................509 TSM/TSSM Features..............................................................509 SECURITY ALARM AND IMMOBILIZATION FUNCTIONS........................................510 TSSM Feature...................................................................510 TSM/TSSM VEHICLE DELIVERY B.3..........................................................511 GENERAL............................................................................511 CONFIGURING A TSSM.................................................................511 SIDECAR CONFIGURATION..............................................................511 POWER DISRUPTION AND CONFIGURING...................................................511 KEY FOB ASSIGNMENT: TSSM...........................................................512 PIN ENTRY: TSSM....................................................................512 CHANGING THE PIN: TSSM.............................................................512 TSM/TSSM TURN SIGNAL FUNCTIONS B.4.....................................................516 GENERAL............................................................................516 AUTOMATIC CANCELLATION.............................................................516 MANUAL CANCELLATION................................................................516 FOUR-WAY FLASHING..................................................................517 DIAGNOSTICS MODE...................................................................517 TSM/TSSM BANK ANGLE FUNCTION B.5.......................................................518 GENERAL............................................................................518 OPERATION..........................................................................518 SECURITY SYSTEM FUNCTIONS: TSSM B.6....................................................519 GENERAL............................................................................519 Security System Operation......................................................519 Security System Options: TSSM..................................................519 ALARM SENSITIVITY: TSSM............................................................520 Sensitivity....................................................................520 Transport Mode.................................................................520 AUTO-ARMING FUNCTION: TSSM.........................................................520 STORAGE MODE: TSSM.................................................................520 ARMING/DISARMING: TSSM B.7.............................................................523 GENERAL............................................................................523 SECURITY LAMP......................................................................523 USING KEY FOB: TSSM................................................................523 General........................................................................523 Arming the System..............................................................523 Disarming the System...........................................................523 Troubleshooting................................................................523 USING THE PIN......................................................................524 General........................................................................524 Disarming the System...........................................................524 DIAGNOSTIC TROUBLE CODES (DTC) B.8.....................................................525 TSM/TSSM...........................................................................525 CODE TYPES.........................................................................526 Current........................................................................526 Historic.......................................................................526 RETRIEVING DIAGNOSTIC TROUBLE CODES................................................527 MULTIPLE DIAGNOSTIC TROUBLE CODES..................................................527 INITIAL DIAGNOSTIC CHECK: TSM/TSSM B.9.................................................528 GENERAL............................................................................528 Diagnostic Notes...............................................................528 Circuit Diagram/Wire Harness Connector Table...................................528 Job/Time Code Values...........................................................528 Reprogramming ECM..............................................................528 INITIAL DIAGNOSTICS................................................................528 Diagnostic Tips................................................................528 Diagnostic Notes...............................................................528 Other Diagnostic Trouble Codes (DTCs)..........................................528 Initial Diagnostic Check (Part 1 of 3).........................................532 Initial Diagnostic Check (Part 2 of 3).........................................533 Initial Diagnostic Check (Part 3 of 3).........................................534 SPEEDOMETER SELF DIAGNOSTICS B.10......................................................535 GENERAL............................................................................535 DIAGNOSTICS........................................................................535 Diagnostic Tips................................................................535 Diagnostic Notes...............................................................536 Speedometer Self Diagnostics...................................................537 BREAKOUT BOX: TSM/TSSM B.11............................................................538 GENERAL............................................................................538 INSTALLATION.......................................................................538 REMOVAL............................................................................538 FAILS TO DISARM B.12...................................................................539 GENERAL............................................................................539 Security Equipped Vehicles Only................................................539 Job/Time Code Values...........................................................539 DIAGNOSTICS........................................................................539 Diagnostic Tips................................................................539 Diagnostic Notes...............................................................539 Test B.12......................................................................541 TURN SIGNAL ERRORS: B1121, B1122, B1141 B.13...........................................542 GENERAL............................................................................542 Job/Time Code Values...........................................................542 DIAGNOSTICS........................................................................542 Diagnostic Tips: All...........................................................542 Diagnostic Notes: All Turn Signal Flow Charts..................................545 Test B.13a (Part 1 of 2).......................................................546 Turn Signal Error 1A (Part 1 of 2).............................................546 Test B.13a (Part 2 of 2).......................................................547 Turn Signal Error 1A (Part 2 of 2).............................................547 Test B.13b.....................................................................548 Turn Signal Error 2A...........................................................548 Test B.13c.....................................................................549 Turn Signal Error 2B...........................................................549 Test B.13d.....................................................................550 Turn Signal Error 2C...........................................................550 Test B.13e.....................................................................551 Turn Signal Error 2D...........................................................551 Test B.13f.....................................................................552 Turn Signal Error 3A...........................................................552 DTC B0563 B.14.........................................................................553 GENERAL............................................................................553 Battery Voltage High...........................................................553 DIAGNOSTICS........................................................................553 Diagnostic Tips................................................................553 Diagnostic Notes...............................................................553 DTC B1131, B1132 B.15..................................................................554 GENERAL............................................................................554 Alarm Output Low (DTC B1131) or Alarm Output High (DTC B1132)..................554 DIAGNOSTICS........................................................................554 Diagnostic Tips................................................................554 Diagnostic Notes...............................................................554 Test B.15......................................................................556 DTC B1134 B.16.........................................................................557 GENERAL............................................................................557 Starter Output High............................................................557 DIAGNOSTICS........................................................................557 Diagnostic Notes...............................................................557 Test B.16a.....................................................................559 DTC B1151, B1152, B1153 B.17...........................................................560 GENERAL............................................................................560 Sidecar BAS....................................................................560 DIAGNOSTICS........................................................................560 Diagnostic Tips................................................................560 Diagnostic Notes...............................................................560 Test B.17......................................................................562 DTC B1135 B.18.........................................................................563 GENERAL............................................................................563 Accelerometer Fault: B1135.....................................................563 DTC B1154, B1155 B.19..................................................................565 GENERAL............................................................................565 DIAGNOSTIC NOTES...................................................................565 Test B.19a.....................................................................566 CLUTCH SWITCH SHORT TO GROUND: DTC B1154.......................................566 Test B.19b.....................................................................567 DTC U1016, U1255 B.20..................................................................568 GENERAL............................................................................568 Loss of ECM Serial Data........................................................568 DIAGNOSTICS........................................................................568 Diagnostic Notes...............................................................568 Test B.20a.....................................................................571 DTC U1300, U1301 or “BUS ER” B.21......................................................572 GENERAL............................................................................572 Serial Data Low or Serial Data Open/High.......................................572 DIAGNOSTICS........................................................................572 Diagnostic Tips................................................................572 Diagnostic Notes...............................................................572 PASSWORD LEARN B.22....................................................................573 GENERAL............................................................................573 PASSWORD LEARNING..................................................................573 TSSM MAINTENANCE B.23..................................................................575 GENERAL............................................................................575 KEY FOB............................................................................575 Schedule.......................................................................575 Battery Replacement............................................................575 SIREN (IF INSTALLED)...............................................................576 Schedule.......................................................................576 Battery Replacement............................................................576
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