v-rod 2008 eletrical

2008 VRSC Models ElectricalDiagnostics Manual

©2007 H-D.ALL RIGHTS RESERVED

99499-08

Printed in the U.S.A.

VISIT THE HARLEY-DAVIDSON WEB SITEhttp://www.harley-davidson.com

CUSTOM CD CREATIONS BY REPAIRMANUALSONCD.COM

ABOUT THIS MANUAL

GENERALThis electrical diagnostic service manual has been preparedwith two purposes in mind. First, it will acquaint the user withthe construction of the Harley-Davidson product and assist inthe performance of repair. Secondly, it will introduce to theprofessional Harley-Davidson Technician the latest field-testedand factory-approved diagnostic methods.We sincerely believethat this manual will make your association with Harley-Dav-idson products more pleasant and profitable.

HOW TO USE YOUR SERVICE MANUALRefer to the table below for the content layout of this manual.

CHAPTERNO.

Starting / Charging1

Instruments2

TSM/HFSM3

Engine Management4

ABS5

Appendix A Connector RepairA

Appendix B WiringB

Appendix C ConversionsC

Appendix D GlossaryD

Appendix E TSM/TSSM (Japan/Korea)E

Use the TABLE OF CONTENTS (which follows this FORE-WORD) and the INDEX (at the back of this manual) to quicklylocate subjects. Sections and topics in this manual aresequentially numbered for easy navigation.

For example, a cross-reference shown as 2.1 SPECIFICA-TIONS refers to chapter 2 CHASSIS, heading 2.1 SPECIFIC-ATIONS.

For quick and easy reference, all pages contain a sectionnumber followed by a page number. For example, page 3-5refers to page 5 in section 3.

A number of acronyms and abbreviations are used in thisdocument. See the D.1 GLOSSARY for a list of acronyms,abbreviations and definitions.

PREPARATION FOR SERVICE

Stop the engine when refueling or servicing the fuelsystem. Do not smoke or allow open flame or sparks neargasoline. Gasoline is extremely flammable and highlyexplosive, which could result in death or serious injury.(00002a)

Good preparation is very important for efficient service work.A clean work area at the start of each job will allow you toperform the repair as easily and quickly as possible, and willreduce the incidence of misplaced tools and parts. A motorcyclethat is excessively dirty should be cleaned before work starts.Cleaning will occasionally uncover sources of trouble. Tools,instruments and any parts needed for the job should begathered before work is started. Interrupting a job to locatetools or parts is a distraction and causes needless delay.

NOTES

• To avoid unnecessary disassembly, carefully read all rel-ative service information before repair work is started.

• In figure legends, the number which follows the name ofa part indicates the quantity necessary for one completeassembly.

• When servicing a vehicle equipped with the Harley-Dav-idson Smart Security System (H-DSSS), you must firstdisarm the security system. Either keep the fob in closeproximity to the vehicle, or use Digital Technician to disablethe security system while the vehicle is being serviced andre-enable the system after service is completed.

SERVICE BULLETINSIn addition to the information presented in this Service Manual,Harley-Davidson Motor Company will periodically issue ServiceBulletins to Harley-Davidson dealers. Service Bulletins coverinterim engineering changes and supplementary information.Consult the Service Bulletins to keep your product knowledgecurrent and complete.

USE GENUINE REPLACEMENT PARTS

Do not use aftermarket parts and custom made front forkswhich can adversely affect performance and handling.Removing or altering factory installed parts can adverselyaffect performance and could result in death or seriousinjury. (00001a)

To ensure satisfactory and lasting repairs, carefully follow theService Manual instructions and use only genuine Harley-Davidson replacement parts. Behind the emblem bearing thewords GENUINE HARLEY-DAVIDSON stand more than 100years of design, research, manufacturing, testing and inspectingexperience.This is your assurance that the parts you are usingwill fit right, operate properly and last longer.

WARNINGS AND CAUTIONSStatements in this service manual preceded by the followingwords are of special significance.

WARNING indicates a potentially hazardous situationwhich, if not avoided, could result in death or seriousinjury. (00119a)

CAUTION indicates a potentially hazardous situationwhich, if not avoided, may result in minor or moderateinjury. (00139a)

CAUTION used without the safety alert symbol indicatesa potentially hazardous situation which, if not avoided,may result in property damage. (00140a)

I

FO

RE

WO

RD


NOTE

Refers to important information, and is placed in italic type. Itis recommended that you take special notice of these items.

Proper service and repair is important for the safe, reliableoperation of all mechanical products. The service proceduresrecommended and described in this service manual areeffective methods for performing service operations.

Always wear proper eye protection when using hammers,arbor or hydraulic presses, gear pullers, spring com-pressors, slide hammers and similar tools. Flying partscould result in death or serious injury. (00496b)

Some of these service operations require the use of toolsspecially designed for the purpose.These special tools shouldbe used when and as recommended. It is important to notethat some warnings against the use of specific service methods,which could damage the motorcycle or render it unsafe, arestated in this service manual. However, please remember thatthese warnings are not all-inclusive. Inadequate safety precau-tions could result in death or serious injury.

Since Harley-Davidson could not possibly know, evaluate oradvise the service trade of all possible ways in which servicemight be performed, or of the possible hazardous con-sequences of each method, we have not undertaken any suchbroad evaluation. Accordingly, anyone who uses a serviceprocedure or tool which is not recommended by Harley-Dav-idson must first thoroughly satisfy himself that neither his northe operator's safety will be jeopardized as a result. Failure todo so could result in death or serious injury.

PRODUCT REFERENCES

Read and follow warnings and directions on all products.Failure to follow warnings and directions can result indeath or serious injury. (00470b)

When reference is made in this manual to a specific brandname product, tool or instrument, an equivalent product, toolor instrument may be substituted.

Kent-Moore ProductsAll tools mentioned in this manual with an "HD", "J" or "B"preface must be ordered through SPX Kent-Moore. For ordering

information or product returns, warranty or otherwise, visitwww.spx.com.

Loctite Sealing and Threadlocking ProductsSome procedures in this manual call for the use of Loctiteproducts. If you have any questions regarding Loctite productusage or retailer/wholesaler locations, please contact LoctiteCorp. at www.loctite.com.

PRODUCT REGISTERED MARKSAllen, Amp Multilock, Bluetooth, Brembo, Delphi, Deutsch,Dunlop, Dynojet, Fluke, G.E. Versilube, Gunk, Hydroseal,Hylomar, Kevlar, Lexan, Loctite, Lubriplate, Keps, K&N, Mag-naflux, Marson Thread-Setter Tool Kit, MAXI fuse, Molex, MPZ,Mulitilock, Novus, Packard, Pirelli, Permatex, Philips, PJ1,Pozidriv, Robinair, S100, Sems, Snap-on, Teflon, Threadlocker,Torca, Torco, TORX, Tufoil, Tyco, Ultratorch, Velcro, X-Acto,and XM Satellite Radio are among the trademarks of theirrespective owners.

H-D MICHIGAN, INC.TRADEMARKINFORMATIONHarley, Harley-Davidson, H-D, Bar & Shield, Digital Tech,Digital Technician, Destroyer, Deuce, Dyna, Electra Glide,Evolution, Fat Boy, Glaze, Gloss, H-D, H-Dnet.com, HD, Harley,Heritage Softail, Heritage Springer, Low Rider, Night Rod, NightTrain, Profile, Revolution, Road Glide, Road King, Rocker,Softail, Sportster, Sun Ray, Sunwash, Tech Link, Twin Cam88, Twin Cam 88B, Twin Cam 96, Twin Cam 96B, Twin Cam103, Twin Cam 103B, Twin Cam 110, Twin Cam 110B, Tour-Pak, Screamin' Eagle, Softail, Super Guide, Super Premium,SYN3, Ultra Glide, V-Rod, VRSC, V-Rod, VRSC, Wide Glide,and Harley-Davidson Genuine Motor Parts and Genuine MotorAccessories are among the trademarks of H-D Michigan, Inc.

CONTENTSAll photographs, illustrations and procedures may not neces-sarily depict the most current model or component, but arebased on the latest production information available at the timeof publication.

Since product improvement is our continual goal, Harley-Dav-idson reserves the right to change specifications, equipmentor designs at any time without notice and without incurringobligation.

II FOREWORD


STARTING / CHARGING

1.1 STARTER TROUBLESHOOTINGGeneral...............................................................................1-1Starter Troubleshooting......................................................1-1

1.2 STARTING SYSTEM DIAGNOSISDiagnostics.........................................................................1-3

Diagnostic Notes.........................................................1-3Job/Time Code Values................................................1-3

1.3 DIAGNOSTICS/TROUBLESHOOTINGVoltage Drop.....................................................................1-12

1.4 STARTER ACTIVATION CIRCUITSStarter Activation Circuits.................................................1-13

1.5 TESTING STARTER ON MOTORCYCLEStart Relay Test................................................................1-14Starter Current Draw Test.................................................1-14

1.6 TESTING STARTER ON BENCHFree Running Current Draw Test......................................1-15

1.7 CHARGING SYSTEMGeneral.............................................................................1-16

Alternator...................................................................1-16Voltage Regulator......................................................1-16

Troubleshooting................................................................1-16Battery.......................................................................1-16Wiring........................................................................1-16Voltage Regulator Inspection....................................1-16Job/Time Code Values..............................................1-16

Testing..............................................................................1-20Milliampere Draw Test...............................................1-20Total Current Draw Test.............................................1-20Current and Voltage Output Test: Using HD-48053....1-21Current and Voltage Output Test: Using LoadTester.........................................................................1-21Stator Check..............................................................1-21AC Output Check......................................................1-22

1.8 BATTERY TESTINGGeneral.............................................................................1-23Voltmeter Test...................................................................1-23Conductance Test.............................................................1-23Load Test..........................................................................1-23

INSTRUMENTS

2.1 CHECKING FOR TROUBLE CODESCheck Engine Lamp...........................................................2-1Code Types.........................................................................2-2

Current........................................................................2-2Historic........................................................................2-2

Security Lamp....................................................................2-2Retrieving Trouble Codes...................................................2-2Multiple Trouble Codes.......................................................2-2

2.2 INSTRUMENT MODULE (IM) SELFDIAGNOSTICSGeneral...............................................................................2-3Diagnostics.........................................................................2-3

Diagnostic Tips............................................................2-3Diagnostics Notes.......................................................2-3

2.3 BREAKOUT BOX: IMGeneral...............................................................................2-5Installation..........................................................................2-5Removal.............................................................................2-5

2.4 INITIAL DIAGNOSTIC CHECK: IMGeneral...............................................................................2-6

Diagnostic Notes.........................................................2-6Circuit Diagram/Wire Harness Connector Table..........2-6Job/Time Code Values................................................2-6

Initial Diagnostics...............................................................2-6Diagnostic Tips............................................................2-6Diagnostic Notes.........................................................2-6Other Codes................................................................2-6

2.5 INSTRUMENT MODULEGeneral...............................................................................2-9

Trip Odometer Reset Switch.......................................2-9Speedometer Theory of Operation.....................................2-9Tachometer Theory of Operation......................................2-10

2.6 NO IM POWERGeneral.............................................................................2-11

Diagnostic Notes.......................................................2-11

2.7 INDICATOR LAMPSGeneral.............................................................................2-14Diagnostics.......................................................................2-14


2.8 DTC B1003General.............................................................................2-17

Internal Fault.............................................................2-17

2.9 FUEL GAUGE OPERATIONGeneral.............................................................................2-18

2.10 DTC B1004, B1005General.............................................................................2-19Diagnostics.......................................................................2-19


2.11 DTC B1006, B1007General.............................................................................2-23

Accessory or Ignition Line Overvoltage.....................2-23

2.12 DTC B1008General.............................................................................2-25

Trip Odometer Reset Switch Closed.........................2-25

2.13 DTC U1016General.............................................................................2-27

Loss of ECM Serial Data...........................................2-27Diagnostics.......................................................................2-27


2.14 DTC U1064General.............................................................................2-30

Loss of TSM/TSSM/HFSM Serial Data.....................2-30Diagnostics.......................................................................2-30


III

TAB

LE

OF

CO

NT

EN

TS


2.15 DTC U1300, U1301 OR BUS ERDiagnostics.......................................................................2-33

Diagnostic Tips..........................................................2-33Diagnostic Notes.......................................................2-33

TSM/HFSM

3.1 TURN SIGNAL OVERVIEWGeneral...............................................................................3-1Security System: Japan/Korea...........................................3-1Turn Signal Functions.........................................................3-1Manual Cancellation...........................................................3-1Automatic Cancellation.......................................................3-1Bank Angle Functions........................................................3-1Bank Angle Restart............................................................3-1Clutch/Neutral Interlock......................................................3-1Security System H-DSSS...................................................3-1

3.2 HARLEY-DAVIDSON SMART SECURITYSYSTEMComponents.......................................................................3-2Security Immobilization......................................................3-2HFSM Features..................................................................3-3

3.3 H-DSSS ACTUATIONGeneral...............................................................................3-5Sidecar Configuration.........................................................3-5Actuation............................................................................3-5Fob Assignment..................................................................3-5Power Disruption and Configuring......................................3-5

3.4 PERSONAL IDENTIFICATION NUMBER(PIN)General...............................................................................3-6Initial Pin Entry...................................................................3-6Changing the Pin................................................................3-6

Modifying an Existing Pin............................................3-6

3.5 ARMING/DISARMING SECURITYSYSTEMHands-Free Fob..................................................................3-8Security Lamp (Key Icon)...................................................3-8Arming................................................................................3-8Disarming...........................................................................3-9

Automatic Disarming...................................................3-9Disarming with a Personal Identification Number(PIN)............................................................................3-9

3.6 WARNINGS AND ALARMSWarnings..........................................................................3-10Alarm................................................................................3-10

Activation...................................................................3-10Deactivation...............................................................3-10

Siren Chirp Mode (Confirmation)......................................3-10Chirpless Mode.........................................................3-10Chirp Mode................................................................3-10Switching Modes.......................................................3-10

3.7 SERVICE/EMERGENCY FUNCTIONSTransport Mode................................................................3-11

To Enter Transport Mode...........................................3-11To Exit Transport Mode..............................................3-11

Service Mode...................................................................3-11Four-Way Flashing...........................................................3-11

To Arm the HFSM with the Hazard Warning FlashersON.............................................................................3-11To Disarm the HFSM and Turn the Hazard WarningFlashers OFF............................................................3-11

3.8 TROUBLESHOOTINGTurn Signals (TSM/HFSM)...............................................3-12Security System (HFSM)..................................................3-12Diagnostics Mode.............................................................3-12Troubleshooting................................................................3-12

3.9 CHECKING FOR DIAGNOSTIC TROUBLECODESGeneral.............................................................................3-13Security Lamp Diagnostics...............................................3-13Code Types.......................................................................3-14

Current......................................................................3-14Historic......................................................................3-14

Retrieving DTCs...............................................................3-14Multiple DTCs/Priority Order............................................3-15

3.10 INITIAL DIAGNOSTIC CHECKGeneral.............................................................................3-16

Diagnostic Notes.......................................................3-16Circuit Diagram/Wire Harness Connector Table........3-16Job/Time Codes........................................................3-16Reprogramming ECM................................................3-16

Initial Diagnostics.............................................................3-16Diagnostic Tips..........................................................3-16Diagnostic Notes.......................................................3-16Other Diagnostic Trouble Codes (DTCs)...................3-16

3.11 INSTRUMENT MODULE (IM) SELFDIAGNOSTICSGeneral.............................................................................3-19Diagnostics.......................................................................3-19


3.12 BREAKOUT BOX:TSM/HFSMGeneral.............................................................................3-21Installation........................................................................3-21Removal...........................................................................3-21

3.13 FAILS TO DISARM (HFSM ONLY)General.............................................................................3-23Job/Time Codes...............................................................3-23Diagnostics.......................................................................3-23


3.14 DTC B0563General.............................................................................3-26

DTC B0563 Battery Voltage High..............................3-26

IV TABLE OF CONTENTS

TABLE OF CONTENTS


Diagnostics.......................................................................3-26Diagnostic Tips..........................................................3-26Diagnostic Notes.......................................................3-26

3.15 TSM/HFSM:TURN SIGNAL ERRORSAND DTCSGeneral.............................................................................3-27Diagnostics.......................................................................3-28

Job/Time Codes........................................................3-28Diagnostic Tips..........................................................3-28Diagnostic Notes: All Turn Signal Flow Charts..........3-28

3.16 DTC B1131, B1132 (HFSM ONLY)General.............................................................................3-41Diagnostics.......................................................................3-41


3.17 DTC B1134 STARTER OUTPUT HIGHGeneral.............................................................................3-44Diagnostics.......................................................................3-44


3.18 DTC B1135Diagnostics.......................................................................3-47

DTC B1135 Accelerometer Fault..............................3-47

3.19 DTC B1136, B1142 (HFSM ONLY)Diagnostics.......................................................................3-48

DTC B1136 Accelerometer Tip-Over Self-TestFault..........................................................................3-48DTC B1142 Internal Fault..........................................3-48

3.20 DTC B1141 (HFSM ONLY)Diagnostics.......................................................................3-49


3.21 DTC B1143, B1144, B1145 (HFSMONLY)General.............................................................................3-54Diagnostics.......................................................................3-54


3.22 DTC B1154, B1155Diagnostics.......................................................................3-59


3.23 DTC U1016, U1255General.............................................................................3-63Diagnostics.......................................................................3-63




3.25 TSM/HFSM: PASSWORD LEARNGeneral.............................................................................3-67Password Learning...........................................................3-67

3.26 HFSM MAINTENANCEGeneral.............................................................................3-68Hands-Free Fob................................................................3-68

Schedule...................................................................3-68Battery Replacement.................................................3-68

Siren (If Installed).............................................................3-68Schedule...................................................................3-68Battery Replacement: Early Style Siren....................3-68Battery Replacement: Late Style Siren.....................3-69

ENGINE MANAGEMENT

4.1 SPECIFICATIONSSpecifications.....................................................................4-1

4.2 EFI SYSTEMGeneral...............................................................................4-2Troubleshooting..................................................................4-2

4.3 DIAGNOSTIC INTRODUCTIONSystem Problems...............................................................4-4

No Start.......................................................................4-4Poor Performance.......................................................4-4Check Engine Lamp....................................................4-4

Resolving Problems............................................................4-4

4.4 CHECKING FOR TROUBLE CODESCheck Engine Lamp...........................................................4-5Code Types.........................................................................4-6

Current........................................................................4-6Historic........................................................................4-6

Retrieving Diagnostic Trouble Codes..................................4-6Multiple Diagnostic Trouble Codes.....................................4-6


Diagnostic Tips............................................................4-7Diagnostic Notes.........................................................4-7

4.6 BREAKOUT BOX: ECMGeneral...............................................................................4-9Installation..........................................................................4-9Removal.............................................................................4-9

4.7 WIGGLE TESTGeneral.............................................................................4-10Procedure.........................................................................4-10

Using DVOM (Part No. HD-39978)..........................4-112

4.8 INITIAL DIAGNOSTIC CHECKGeneral.............................................................................4-11

Diagnostic Notes.......................................................4-11Circuit Diagram/Wire Harness Connector Table........4-11

TABLE OF CONTENTS V

TABLE OF CONTENTS


Job/Time Code Values............................................4-112Initial Diagnostics.............................................................4-11

General Information.................................................4-112Diagnostic Tips........................................................4-112Diagnostic Notes.......................................................4-11Other Codes..............................................................4-11

4.9 ENGINE CRANKS, BUT WILL NOTSTARTGeneral.............................................................................4-20Diagnostics.......................................................................4-20


4.10 NO ECM POWERGeneral.............................................................................4-28

No Spark/No Check Engine Lamp at Key On............4-28Diagnostics.......................................................................4-28


4.11 STARTS,THEN STALLSGeneral.............................................................................4-33

Diagnostic Trouble Codes U1300, U1301, or BUSER.............................................................................4-33


4.12 FUEL SYSTEM ELECTRICAL TESTGeneral.............................................................................4-37Diagnostics.......................................................................4-37


4.13 SYSTEM RELAY FAULTGeneral.............................................................................4-43

System Relay............................................................4-43Diagnostics.......................................................................4-43


4.14 FAN OPERATION CHECKGeneral.............................................................................4-48

Fan Relay..................................................................4-48Diagnostics.......................................................................4-48


4.15 FUEL PRESSURE TESTGeneral.............................................................................4-52Testing..............................................................................4-52Diagnostics.......................................................................4-53


4.16 IDLE AIR CONTROLGeneral.............................................................................4-55

IAC Operation............................................................4-55Diagnostic Trouble Code P0505: Loss of Idle SpeedControl.......................................................................4-55


4.17 MISFIRE AT IDLE OR UNDER LOADGeneral.............................................................................4-60

Misfire at Idle or Under Load.....................................4-60Diagnostics.......................................................................4-60


4.18 COMBUSTION ABSENT/INTERMITTENTGeneral.............................................................................4-66

Diagnostic Trouble Codes P1353, P1356, P1357, P1358:No Combustion..........................................................4-66

Diagnostics.......................................................................4-66Diagnostic Notes.......................................................4-66

4.19 DTC P0107, P0108General.............................................................................4-70

MAP Sensor..............................................................4-70Diagnostics.......................................................................4-70


4.20 DTC P0112, P0113General.............................................................................4-74

IAT Sensor.................................................................4-74Diagnostics.......................................................................4-74


4.21 DTC P0117, P0118General.............................................................................4-78

ECT Sensor...............................................................4-78Diagnostics.......................................................................4-78


4.22 DTC P0122, P0123General.............................................................................4-82

TP Sensor.................................................................4-82Diagnostics.......................................................................4-82


4.23 DTC P0131, P0132, P0134, P0151,P0152, P0154General.............................................................................4-86

O2 Sensor.................................................................4-86Diagnostics.......................................................................4-86


4.24 DTC P0261, P0262, P0263, P0264General.............................................................................4-91

Fuel Injectors.............................................................4-91Diagnostics.......................................................................4-91


4.25 DTC P0373, P0374General.............................................................................4-96

CKP Sensor..............................................................4-96Diagnostics.......................................................................4-96

Diagnostic Tips..........................................................4-96

VI TABLE OF CONTENTS

TABLE OF CONTENTS



4.26 DTC P0444, P0445General.............................................................................4-99

Purge Solenoid (CA Models Only)..........................4-112Diagnostics.......................................................................4-99


4.27 DTC P0501, P0502General...........................................................................4-104

Vehicle Speed Sensor.............................................4-104Diagnostics.....................................................................4-104

Diagnostic Notes.....................................................4-104

4.28 DTC P0562, P0563General...........................................................................4-108

Battery Voltage........................................................4-108Diagnostics.....................................................................4-108

Diagnostic Tips........................................................4-108Diagnostic Notes.....................................................4-108

4.29 DTC P0603, P0605General...........................................................................4-112

ECM Failure............................................................4-112Diagnostics.....................................................................4-112

DTC P0603 Test......................................................4-112DTC P0605 Test......................................................4-112

4.30 DTC P1009, P1010General...........................................................................4-113

Password Problem..................................................4-113Diagnostics.....................................................................4-113


4.31 DTC P1351, P1352, P1354, P1355General...........................................................................4-116

Ignition Coil.............................................................4-116Diagnostics.....................................................................4-116


4.32 DTC P1501, P1502General...........................................................................4-120

Jiffy Stand Sensor (HDI)..........................................4-120Diagnostics.....................................................................4-120


4.33 DTC U1064, U1255General...........................................................................4-125

Loss of TSM/TSSM/HFSM Serial Data...................4-125Diagnostics.....................................................................4-125


4.34 DTC U1096, U1255General...........................................................................4-128

Loss of IM Serial Data.............................................4-128Diagnostics.....................................................................4-128


ABS

5.1 ANTILOCK BRAKE SYSTEM (ABS)GENERAL INFORMATIONAntilock Brake System (ABS) Description..........................5-1

Antilock Brake System (ABS)......................................5-1Pressure Hold..............................................................5-2Pressure Decrease......................................................5-2Pressure Increase.......................................................5-2Initialization Self-Test...................................................5-2ABS Indicator..............................................................5-2

Code Types.........................................................................5-3Current........................................................................5-3Historic........................................................................5-3

Retrieving Diagnostic Trouble Codes..................................5-3Multiple Trouble Codes.......................................................5-3


Diagnostic Tips............................................................5-4Diagnostic Notes.........................................................5-4

5.3 BREAKOUT BOX: ABSGeneral...............................................................................5-6Installation..........................................................................5-6Removal.............................................................................5-6

5.4 INITIAL DIAGNOSTIC CHECK: ABSGeneral...............................................................................5-7

Diagnostic Notes.........................................................5-7Circuit Diagram/Wire Harness Connector Table..........5-7Job/Time Code Values................................................5-7

Initial Diagnostics...............................................................5-7Diagnostic Tips............................................................5-7Diagnostic Notes.........................................................5-7Other Diagnostic Trouble Codes (DTCs).....................5-8

5.5 ABS INDICATOR DIAGNOSTICSABS Indicator Always On Or Inoperative..........................5-11

Circuit Description.....................................................5-11Diagnostic Tips..........................................................5-11

5.6 DTC C0562DTC C0562: Device Voltage Low......................................5-15

Circuit Description.....................................................5-15Conditions for Running the DTC...............................5-15Conditions for Setting the DTC..................................5-15Action Taken When the DTC Sets.............................5-15Conditions for Clearing the DTC...............................5-15Diagnostic Tips..........................................................5-15Diagnostic Notes.......................................................5-15

5.7 DTC C0563DTC C0563: Device Voltage High.....................................5-18

Circuit Description.....................................................5-18Conditions for Running the DTC...............................5-18Conditions for Setting the DTC..................................5-18Action Taken When the DTC Sets.............................5-18

TABLE OF CONTENTS VII

TABLE OF CONTENTS


Conditions for Clearing the DTC...............................5-18Diagnostic Tips..........................................................5-18Diagnostic Notes.......................................................5-18

5.8 DTC C1017DTC C1017: Pump Motor Power Circuit Open Fault........5-21


5.9 DTC C1018DTC C1018: Pump Motor Ground High ResistanceFault..................................................................................5-24


5.10 DTC C1021, C1023DTC C1021, C1023: Wheel Speed Sensor Equals Zero (Frontor Rear)............................................................................5-27

Circuit Description.....................................................5-27Conditions for Running the DTC...............................5-27Conditions for Setting the DTC..................................5-27Action Taken When the DTC Sets.............................5-27Conditions for Clearing the DTC...............................5-27Diagnostic Tips..........................................................5-27

5.11 DTC C1025, C1027, C1206, C1208DTC C1025, C1027, C1206, C1208: Wheel Speed SignalIntermittent or Frequency Out Of Range..........................5-30


5.12 DTC C1032, C1034DTC C1032, C1034: Wheel Speed Sensor Circuit Open OrShorted (Front or Rear)....................................................5-33


5.13 DTC C1042DTC C1042: Pump Motor Open.......................................5-39

Circuit Description.....................................................5-39Conditions for Running the DTC...............................5-39

Conditions for Setting the DTC..................................5-39Action Taken When the DTC Sets.............................5-39Conditions for Clearing the DTC...............................5-39Diagnostic Tips..........................................................5-39Diagnostic Procedure................................................5-39

5.14 DTC C1043DTC C1043: Pump Motor Stalled.....................................5-40

Circuit Description.....................................................5-40Conditions for Running the DTC...............................5-40Conditions for Setting the DTC..................................5-40Action Taken When the DTC Sets.............................5-40Conditions for Clearing the DTC...............................5-40Diagnostic Tips..........................................................5-40Diagnostic Procedure................................................5-40

5.15 DTC C1094DTC C1094: Front Brake Switch Always On.....................5-41


5.16 DTC C1095DTC C1095: Front Brake Switch Open.............................5-44


5.17 DTC C1151DTC C1151: Front Wheel Release Too Long....................5-47


5.18 DTC C1153DTC C1153: Rear Wheel Release Too Long....................5-50


5.19 DTC C1158DTC C1158: Calibration Programming Required.............5-53


VIII TABLE OF CONTENTS

TABLE OF CONTENTS


5.20 DTC C1212DTC C1212: Front or Rear Brake Not Applied withDecel................................................................................5-57


5.21 DTC C1214DTC C1214: Rear Brake Switch Always On.....................5-60


5.22 DTC C1216DTC C1216: Rear Brake Switch Open.............................5-63


5.23 DTC C1014, C1055-C1066, C1118,C1121DTC C1014, C1055-C1066, C1118, C1121: ECU InternalFault..................................................................................5-66




APPENDIX A CONNECTOR REPAIR

A.1 AMP 1-PLACE CONNECTORSAMP 1-Place Connector Repair.........................................A-1

General.......................................................................A-1Separating Pin and Socket Housings.........................A-1Mating Pin and Socket Housings................................A-1Removing Socket Terminals........................................A-1Installing Socket Terminal...........................................A-1Removing Pin Terminal...............................................A-1Installing Pin Terminal.................................................A-2

A.2 AMP MULTILOCK CONNECTORSAMP Multilock Connector Repair.......................................A-3

General.......................................................................A-3Separating Pin and Socket Housings.........................A-3Mating Pin and Socket Housings................................A-3Removing Terminals from Housing.............................A-3Inserting Terminals into Housing.................................A-4Preparing Wire Leads for Crimping.............................A-4Crimping Terminals to Leads......................................A-6Inspecting Crimped Terminals.....................................A-6

A.3 DELPHI CONNECTORSDelphi Connector Repair....................................................A-8

General.......................................................................A-8Separating Pin and Socket Housings.........................A-8Mating Pin and Socket Housings................................A-8Removing Socket Terminals........................................A-8Installing Socket Terminals..........................................A-8

A.4 DEUTSCH 1-PLACE ELECTRICALCONNECTORSDeutsch 1-Place Connector Repair..................................A-10

Separating Pin and Socket Housings.......................A-10Mating Pin and Socket Housings..............................A-10Removing Socket Terminals......................................A-10Installing Socket Terminals........................................A-10

A.5 DEUSCH ELECTRICAL CONNECTORSDeutsch Connector Repair...............................................A-11

General.....................................................................A-11Separating Pin and Socket Housings.......................A-11Mating Pin and Socket Housings..............................A-11Removing Socket Terminals......................................A-11Installing Socket Terminals........................................A-11Removing Pin Terminals...........................................A-13Installing Pin Terminals.............................................A-13Crimping Terminals...................................................A-14

A.6 DEUTSCH STANDARD TERMINALSDeutsch Standard Terminal Crimps.................................A-15

Preparing Wire Leads for Crimping...........................A-15Crimping Terminal to Lead........................................A-15Inspecting Crimps.....................................................A-15

A.7 DEUTSCH MINI-TERMINAL CRIMPSDeutsch Mini Terminal Crimps.........................................A-16

Preparing Wire Leads for Crimping...........................A-16Crimping a Mini Terminal to Wire Lead.....................A-16Inspecting Crimps.....................................................A-16

A.8 DEUTSCH SOLID BARREL TERMINALSDeutsch Solid Barrel Terminal Crimps.............................A-17

Preparing Wire Leads For Crimping.........................A-17Adjusting Crimper Tool..............................................A-17Crimping a Barrel Contact To Wire Lead...................A-17Inspecting Crimps.....................................................A-17

A.9 RELAY AND FUSE BLOCKSFuse Block Repair............................................................A-19

Removing Socket Terminals......................................A-19Installing Socket Terminals........................................A-19Crimping Terminals...................................................A-19

TABLE OF CONTENTS IX

TABLE OF CONTENTS


A.10 150 METRI-PACK CONNECTORS150 Metri-Pack Connector Repair....................................A-20

General.....................................................................A-20Separating Pin and Socket Housings.......................A-20Mating Pin and Socket Housings..............................A-20Removing Socket Terminal.......................................A-20Inserting Socket Terminal..........................................A-20


General.....................................................................A-22Separating Pin and Socket Housings.......................A-22Mating Pin and Socket Housings..............................A-22Removing Socket Terminals......................................A-22Installing Socket Terminals........................................A-22Crimping Terminals...................................................A-22


General.....................................................................A-24Separating Pin and Socket Housings.......................A-24Mating Pin and Socket Housings..............................A-24Removing Socket Terminals......................................A-24Installing Socket Terminals........................................A-24


General.....................................................................A-25Separating Pin and Socket Housings.......................A-25Mating Pin and Socket Housings..............................A-25Removing Socket Terminal.......................................A-25Installing Socket Terminal.........................................A-25

A.14 800 METRI-PACK CONNECTORSDelphi Maxi-Fuse Housing Repair...................................A-26

General.....................................................................A-26Removing Maxi-Fuse................................................A-26Installing Maxi-Fuse..................................................A-26Removing Socket Terminals......................................A-26Installing Socket Terminals........................................A-26

A.15 METRI-PACK TERMINALSMetri-Pack Terminal Crimps.............................................A-28

Matching Terminal To Crimper..................................A-28Preparing Wire Lead.................................................A-28Crimping Wire Core..................................................A-28Crimping Insulation/Seal...........................................A-28Inspecting Crimps.....................................................A-29

A.16 MOLEX CONNECTORSMolex Connector Repair..................................................A-30

Separating Pin and Socket Housings.......................A-30Mating Pin and Socket Housings..............................A-30Removing Terminals.................................................A-30Installing Terminals...................................................A-30

A.17 PACKARD ECM CONNECTORPackard 100W Connector Repair.....................................A-32

General.....................................................................A-32Separating Socket Housing From ECM....................A-32Mating Socket Housing To ECM...............................A-32

Removing Socket Terminal.......................................A-32Installing Socket Terminal.........................................A-32Crimping Terminals...................................................A-32

A.18 PACKARD MICRO-64 CONNECTORSPackard Micro-64 Connector Repair................................A-34

General.....................................................................A-34Separating Pin and Socket Housings.......................A-34Mating Pin and Socket Housings..............................A-34Removing Terminal...................................................A-34Installing Terminal.....................................................A-34Preparing Wire Leads for Crimping...........................A-35Crimping Terminals...................................................A-35Inspecting Crimps.....................................................A-35

A.19 SEALED SPLICE CONNECTORSSealed Splice Connector Repair......................................A-37

General.....................................................................A-37Preparing Wire Leads...............................................A-37Splicing Wire Leads..................................................A-37Inspecting Seals.......................................................A-37

APPENDIX B WIRING

B.1 CONNECTORSConnector Locations..........................................................B-1

Function/Location.......................................................B-1Place and Color..........................................................B-1Connector Number......................................................B-1Repair Instructions......................................................B-1

B.2 WIRING DIAGRAMSWiring Diagram Information...............................................B-3

Wire Color Codes........................................................B-3Wiring Diagram Symbols............................................B-3

2008 VRSC Wiring Diagrams.............................................B-4

APPENDIX C CONVERSIONS

C.1 METRIC CONVERSIONConversion Table................................................................C-1

C.2 FLUID CONVERSIONSUnited States System........................................................C-2Metric System....................................................................C-2British Imperial System......................................................C-2

C.3 TORQUE CONVERSIONSUnited States System........................................................C-3Metric System....................................................................C-3

APPENDIX D GLOSSARY

D.1 GLOSSARYAcronyms and Abbreviations.............................................D-1

X TABLE OF CONTENTS

TABLE OF CONTENTS


APPENDIX E TSM/TSSM(JAPAN/KOREA)

E.1 TSM/TSSM (JAPAN/KOREA) OVERVIEWGeneral..............................................................................E-1

TSM............................................................................E-1TSSM..........................................................................E-1

Troubleshooting..................................................................E-1

E.2 TSM/TSSM FEATURESGeneral..............................................................................E-3Turn Signal Functions........................................................E-3

TSSM/TSSM Features................................................E-3Bank Angle Function..........................................................E-3Clutch/Neutral Interlock Functions.....................................E-3

TSM/TSSM Features..................................................E-3Security Alarm and Immobilization Functions....................E-3

TSSM Feature.............................................................E-3

E.3 TSM/TSSM VEHICLE DELIVERYGeneral..............................................................................E-5Configuring A TSSM..........................................................E-5Power Disruption and Configuring.....................................E-5Key FOB Assignment: TSSM.............................................E-5Pin Entry: TSSM.................................................................E-6Changing the Pin: TSSM....................................................E-8

E.4 TSM/TSSM TURN SIGNAL FUNCTIONSGeneral..............................................................................E-9Automatic Cancellation......................................................E-9Manual Cancellation...........................................................E-9Four-Way Flashing.............................................................E-9Diagnostics Mode..............................................................E-9

E.5 TSM/TSSM BANK ANGLE FUNCTIONGeneral............................................................................E-10Operation.........................................................................E-10

E.6 SECURITY SYSTEM FUNCTIONS:TSSMGeneral............................................................................E-11

Security System Operation.......................................E-11Security System Options: TSSM...............................E-11

Alarm Sensitivity: TSSM...................................................E-11Sensitivity..................................................................E-11Transport Mode.........................................................E-11

Auto-Arming Function: TSSM...........................................E-12Storage Mode: TSSM.......................................................E-13

E.7 ARMING/DISARMING:TSSMGeneral............................................................................E-14Security Lamp..................................................................E-14Using Key FOB: TSSM.....................................................E-14

General.....................................................................E-14Arming the System...................................................E-14Disarming the System...............................................E-14Troubleshooting.........................................................E-14

Using the Pin....................................................................E-14General.....................................................................E-14Disarming the System...............................................E-14

E.8 DIAGNOSTIC TROUBLE CODES (DTC)TSM/TSSM......................................................................E-16Code Types......................................................................E-17

Current......................................................................E-17Historic......................................................................E-17

Retrieving Diagnostic Trouble Codes...............................E-17Multiple Diagnostic Trouble Codes...................................E-18

E.9 INITIAL DIAGNOSTIC CHECK:TSM/TSSMGeneral............................................................................E-19

Diagnostic Notes.......................................................E-19Circuit Diagram/Wire Harness Connector Table.......E-19Job/Time Code Values..............................................E-19Reprogramming ECM...............................................E-19

Initial Diagnostics.............................................................E-19Diagnostic Tips.........................................................E-19Diagnostic Notes.......................................................E-19Other Diagnostic Trouble Codes (DTCs)...................E-19

E.10 INSTRUMENT MODULE (IM) SELFDIAGNOSTICSGeneral............................................................................E-22Diagnostics......................................................................E-22

Diagnostic Tips.........................................................E-22Diagnostic Notes.......................................................E-22

E.11 BREAKOUT BOX:TSM/TSSMGeneral............................................................................E-24Installation........................................................................E-24Removal...........................................................................E-24

E.12 FAILS TO DISARMGeneral............................................................................E-25

Security Equipped Vehicles Only..............................E-25Job/Time Code Values..............................................E-25

Diagnostics......................................................................E-25Diagnostic Tips.........................................................E-25Diagnostic Notes.......................................................E-25

E.13 TURN SIGNAL ERRORS: B1121, B1122,B1141General............................................................................E-28

Job/Time Code Values..............................................E-28Diagnostics......................................................................E-28

Diagnostic Tips: All....................................................E-28Diagnostic Notes: All Turn Signal Flow Charts..........E-28

E.14 DTC B0563General............................................................................E-39

Battery Voltage High.................................................E-39Diagnostics......................................................................E-39


E.15 DTC B1131, B1132General............................................................................E-40

Alarm Output Low (DTC B1131) or Alarm Output High(DTC B1132).............................................................E-40

Diagnostics......................................................................E-40

TABLE OF CONTENTS XI

TABLE OF CONTENTS



E.16 DTC B1134General............................................................................E-43

Starter Output High...................................................E-43Diagnostics......................................................................E-43

Diagnostic Notes.......................................................E-43

E.17 DTC B1135General............................................................................E-46

Accelerometer Fault: B1135......................................E-46

E.18 DTC B1154, B1155General............................................................................E-47Diagnostic Notes..............................................................E-47

E.19 DTC U1016General............................................................................E-50

Loss of ECM Serial Data..........................................E-50Diagnostics......................................................................E-50

Diagnostic Notes.......................................................E-50

E.20 DTC U1300, U1301 OR BUS ERGeneral............................................................................E-53

Serial Data Low or Serial Data Open/High...............E-53

Diagnostics......................................................................E-53Diagnostic Tips.........................................................E-53Diagnostic Notes.......................................................E-53

E.21 PASSWORD LEARNGeneral............................................................................E-54Password Learning..........................................................E-54

E.22 TSSM MAINTENANCEGeneral............................................................................E-55Key FOB...........................................................................E-55

Schedule...................................................................E-55Battery Replacement................................................E-55

Siren (If Installed).............................................................E-55Schedule...................................................................E-55Battery Replacement: Early Style Siren....................E-55Battery Replacement: Late Style Siren.....................E-56

REFERENCE MATERIAL

TOOLS...........................................................I

TORQUE VALUES........................................V

INDEX.........................................................VII

XII TABLE OF CONTENTS

TABLE OF CONTENTS


SUBJECT............................................................................................................................PAGE NO.1.1 STARTER TROUBLESHOOTING..............................................................................................1-11.2 STARTING SYSTEM DIAGNOSIS............................................................................................1-31.3 DIAGNOSTICS/TROUBLESHOOTING...................................................................................1-121.4 STARTER ACTIVATION CIRCUITS.........................................................................................1-131.5 TESTING STARTER ON MOTORCYCLE...............................................................................1-141.6 TESTING STARTER ON BENCH............................................................................................1-151.7 CHARGING SYSTEM.............................................................................................................1-161.8 BATTERY TESTING................................................................................................................1-23

STA

RT

ING

/ C

HA

RG

ING


NOTES


1.1STARTER TROUBLESHOOTING

GENERALThe troubleshooting tables contain detailed procedures to solveand correct problems. Follow 1.2 STARTING SYSTEM DIA-GNOSIS to diagnose starting system problems. The 1.3 DIA-

GNOSTICS/TROUBLESHOOTING, Voltage Drop procedurewill help you to locate poor connections or components withexcessive voltage drops.

STARTER TROUBLESHOOTING

Table 1-1. Starter Does Not Run or Runs at Very Low Speeds

SOLUTIONPROBABLE CAUSESOURCE OFPROBLEM

Charge battery.Voltage drop due to discharged battery.Battery

Replace battery.Short-circuited or open between electrodes.

Clean and retighten.Poor contact condition of battery terminal(s).

Repair or replace cable(s).Poor or no connection at either battery positive or neg-ative cable, at either end.

Wiring

Clean, tighten or replace cable(s) as needed.Cracked or corroded battery cable ends.

Tighten connections or repair or replace wire(s).Open wire(s) or poor connection at handlebar switchor start relay, especially relay ground wire (groundsthrough TSM/TSSM/HFSM).

Replace switch.Poor switch contacts or open switch.Start switch, clutchswitch, engine stopswitch or neutralswitch

Replace relay.Open coil winding.Start relay

Replace relay.Poor or no continuity at relay points.

Disarm security system.TSM/TSSM/HFSM has disabled start relay.

Replace solenoid assembly.Poor contact condition caused by burned contact.Solenoid

Replace solenoid assembly.Windings open or short-circuited.

Replace starter.Brushes worn below specification.Starter motor

Replace starter.Commutator burnt.

Replace starter.Commutator high mica.

Replace starter.Field winding grounded.

Replace starter.Armature winding grounded or short-circuited.

Replace starter.Free running current draw out of range.

Replace starter.Insufficient brush spring tension.

Replace limiter assembly.Limiter assembly failure.Limiter assembly

Replace rotor/ball clutch assembly.Ball clutch failureBall clutch

Table 1-2. Engine Cannot Be Cranked

SOLUTIONPROBABLE CAUSESOURCE OF PROBLEM

Charge battery.Voltage drop due to discharged battery.Battery

Replace battery.Short-circuited or open between electrodes.

Clean and retighten.Poor contact condition of battery terminal(s).

Replace starter.Starter gear teeth worn out.Starter motor

Replace limiter assembly.Limiter assembly malfunction.Limiter assembly

Replace limiter assembly.Limiter assembly gears damaged.

2008 VRSC Diagnostics: Starting / Charging 1-1


Table 1-2. Engine Cannot Be Cranked


Replace ball clutch gear.Excessively worn teeth.Gear teeth on ball clutch gear

Replace rotor assembly.Ball clutch failure.Ball clutch

Table 1-3. Starter Does Not Stop Running


Replace start switch or start relay.Unopened contacts.Start switch or start relay

Replace start switch or start relay.Poor return caused by sticky switch or relay contacts.

Replace solenoid.Coil shorted.Solenoid

Replace solenoid.Contact plate melted and stuck.

Replace rotor assembly.Ball clutch seizure.Ball clutch

1-2 2008 VRSC Diagnostics: Starting / Charging


1.2STARTING SYSTEM DIAGNOSIS

DIAGNOSTICS

TOOL NAMEPART NUMBER

HARNESS CONNECTOR TEST KITHD-41404-B

BREAKOUT BOXHD-42682

Diagnostic NotesEach reference number below correlates to a circled numberon the flow chart(s).

1. Test for VOLTAGE DROPS under 1.3 DIA-GNOSTICS/TROUBLESHOOTING.

2. Remove starter motor. Connect jumper wires as describedin 1.6 TESTING STARTER ON BENCH, Free RunningCurrent Draw Test.

3. Connect BREAKOUT BOX (Part No. HD-42682) toTSM/TSSM/HFSM as follows:

a. On models with a TSM/HFSM, see 3.12 BREAKOUTBOX: TSM/HFSM.

b. On models with a TSSM (Japan/Korea), seeE.11 BREAKOUT BOX: TSM/TSSM

4. Use HARNESS CONNECTOR TEST KIT (Part No. HD-41404-B) gray terminal socket probe and patch cord.

5. See 1.5 TESTING STARTER ON MOTORCYCLE, StarterCurrent Draw Test.

6. See 1.6 TESTING STARTER ON BENCH, Free RunningCurrent Draw Test.

Job/Time Code ValuesDealership technicians filing warranty claims should use thejob/time code values printed in bold text underneath theappropriate repair.

ed02916

Figure 1-1. Starter Terminal

1

2

3

ed02917

1. Solenoid stud (to battery)2. Solenoid stud (to starter)3. Connector [128B]

Figure 1-2. Starter Solenoid Terminals



BK

BK

BC

A

AB J

Sec

urity

I

15A

mp

AIg

nitio

nB

21

2115A

mp

87 30 85 86

K E S U

Neutral

BA

I

Igni

tion

Sw

itch

StartRelay

Inst

rum

entC

lust

erR

ight

Han

dC

ontr

ols

[162

]R

ight

Han

dC

ontr

ols

Left

Han

dC

ontr

ols

Turn

Sig

nal/S

ecur

ityM

odul

e(T

SM

/TS

SM

/HF

SM

)

Ele

ctro

nic

Con

trol

Mod

ule

Eng

ine

Sto

pS

witc

h

Sta

rtS

witc

hM

AX

IFU

SE

40A

mp

[33B

]

[33A

]

[39B

][2

2A]

[22B

][2

4B]

[30A

][3

0B]

[78A

][7

8B]

[39A

]

Sta

rter

Mot

or

Bat

tery

[128

A]

[128

B]

[61]

[62]

Fron

t(lo

cate

dun

der

right

side

cove

r)R

ear

(loca

ted

unde

rrig

htsi

deco

ver)

Sta

rtR

elay

[GN

D2]

[GN

D1]

[GN

D3]

Spa

re15

A

Bat

tery

11

Igni

tion

22

Ser

iald

ata

33

Neu

tral

switc

h4

4

Sta

rtre

lay

cont

rol

99

Clu

tch

switc

h10

10G

roun

d12

12

Ser

iald

ata

55

Gro

und

1010

Gro

und

2828

AC

CY

15A

15A

Sec

urity

P&

AIG

N15

AF

uelP

ump

15A

EC

M15

A

15A

Ligh

ts

Igni

tion

15A

Spa

re15

A

15A

Bat

tery

30A

AB

S

Fan

Rel

ayS

yste

mR

elay

Neu

tral

Sw

itch

[131

]

Sta

rtS

olen

oid

Con

trol

Coi

l

Sta

rtS

olen

oid

Con

tact

Pos

ts

M

10

34

6

36

78

10

GY

BK

BKGN

BK

GN

TN TNBK

GY

GY

TN

GY

RR

R

R

R

BN

/GY

BK

/GN

BK

/GN

BK/GN

LGN

/V

TN

/GN

BN

/GY BK/GN

TN

/GN

R/BK

R/B

K

R/B

K

BK

/R

BK/R

BK

/R

BK/R

BK/R

W/BK

em00071

Figure 1-3. Starting Circuit Schematic



Starter Testing 1

Check Battery using visual inspection, voltagetest, and either conductance test or load test.

Check connections at battery and starter components.Is system operational?

YES

STARTERRUNS ON.

YES YES NO

STARTER SPINS,BUT DOES NOT

ENGAGE.

STARTER STALLSOR SPINS TOO

SLOWLY.

Check for audibleclicking noise.

Disconnect starter solenoidrelay terminal from solenoid.Is 12V present on (GN) wire

with Start Switch notpressed?

See StarterTesting 5: StarterSpins But Does

Not Engage.

See StarterTesting 6: Starter

Stalls or Spins TooSlowly.

Solenoid clicks.See StarterTesting 2:

Solenoid Clicks.

YES NO

Is 12V present on start relay terminal 86 withStart Switch not pressed?

NOTEDepending on relay used, relay socket terminal

could be shown as “86” or “U”.

ReplaceStarter Solenoid.

YES NO

ReplaceStart Switch.

ReplaceStart Relay.

OR

Relay clicks. SeeStarter Testing 3:

Relay Clicks.

OR

Nothing clicks. See StarterTesting 4: Nothing Clicks

(Part 1 of 2).

5818 5832

5845

fc01401_en

5822



Starter Testing 2: Solenoid Clicks

Perform voltage drop tests between batteryand relay terminal on solenoid. Crank engine.

Is voltage drop less than 1.0 volt?

YES NO

Locate and repair poorConnection on solenoid ground.

Perform voltage drop tests frombattery positive and relay terminal on solenoid.

Crank engine.Is voltage drop less than 1.0 volt?

YES

Perform voltage drop tests frombattery positive to starter terminal.

Crank engine.Is voltage drop greater than 1.0 volt?

YES

Perform voltage drop testsbetween battery positive and

battery stud on solenoid.Crank engine.

Is voltage drop greater than1.0 volt?

NO

Perform voltage drop testsbetween battery negative and

starter studs or bolts.Is voltage drop greater than 1.0 volt?

NO

Repair connectionbetween solenoid and

starter.

YES

Clean groundconnections.

NO

5824

5840

1

1 1

1

fc01402_en

YES

Repair connection betweenbattery and solenoid.

NO

Replacesolenoid.

5824 5845

Backtrack and pinpoint poor connections orrelay contact problems using voltage drop

tests.

5823

1

5824

Perform voltage drop tests frombattery positive to starter stud on solenoid..


1

YES NO

Go to Starter Testing 3:Relay Clicks. Begin with boxmarked with bold asterisk.

1



Starter Testing 3: Relay Clicks

Test for voltage at starter solenoid relayterminal (GN) wire.

Is 12V present when Start Switch ispressed?

YES NO

Does Starterturn if jumped?

YES

Replace Solenoid.

NO

Replace Starter.

Test for voltage to Start Relay.Is 12V present on start relay socket terminal “30”?

NOTEDepending on relay used, relay socket terminal

could be shown as “30” or “E”.

YES NO

Test for voltage from Start Relay.Is 12V present on start relay socket terminal “87”

when Start Switch is pressed?NOTE

Depending on relay used, relay socket terminalcould be shown as “87” or “K”.

Repair open or poorconnections on (R/BK)

wire.

YES

Repair open or poor connections on (GN) wirebetween Start Relay and Starter Solenoid.

NO

ReplaceStart Relay.

5827 5832

5827

5860 5817

2

fc01403_en



Starter Testing 4: Nothing Clicks (Part 1 of 2)

Do turn signals work properly?

YES

Turn the Ignition Switch toIGNITION. With the Engine Stop

Switch in the RUN position,depress the start switch whilechecking for battery voltage at

start relay terminal “86”.Is battery voltage present?

NO

Is TSM/TSSM/HFSM connector[30] fully mated?

YES NO

Continuity to ground on TSM/TSSM/HFSM terminal “12”?

Mate connector [30].

YES

Continuity on TSM/TSSM/HFSMterminal “1” to battery fuse?

Repair open.

NO

YES

Continuity on TSM/TSSM/HFSMterminal “2” to IGN fuse?

NO

Repair open.

YES

Replace TSM/TSSM/HFSM. Learnpassword and perform set-up.

NO

Repair open.

6792

6805

6806

67936791

3

YES

Check for continuity to chassisground at start relay terminal “85”.

Is continuity present?

YES

Substitute goodrelay or test relay.

NO

Check for continuity from start relayterminal “85” to terminal “9” on TSM/

TSSM/HFSM connector [30].Is continuity present?

NO

Repair open.

YES

STOP

Go to Starter Testing 4:Nothing Clicks (Part 2 of 2).

5828

NO

Disconnect connector [22]. Check for continuitybetween terminal “4” (W/BK) and terminal “6”

(BK/R) of connector [22A].Continuity present with start switch pressed?

5

NO

Check for battery voltage to startswitch, at connector [22B] terminal “6”

(BK/R).Battery voltage present?

YES

NOYES

Locate and repairopen in (BK/R) wire

from connector[22B].

Repair wiring fromstarter switch to

relay.

5831 5831

Replacestart switch.

5818

fc01653_en



Starter Testing 4: Nothing Clicks (Part 2 of 2)

Continued fromStarter Testing 4: Nothing Clicks (Part 1 of 2).

Install breakout box HD-42682. Shift transmission to neutral. Measure continuityto chassis ground at breakout box terminal “4” (gray) (neutral switch).

Is continuity (less than 10 ohms) present?

YES

Disengage clutch (pull in clutch lever). Measurecontinuity to chassis ground at breakout box terminal

“10” (gray) (clutch switch) with clutch disengaged.Is continuity present?

NO

YES NO

Locate and repair open on(BK) wire between neutral

switch and ground

YES

Check for voltage on TSM/TSSM/HFSMterminal “9” with key ON.

Is voltage present?

YES

Locate and repairshort to voltage.

NO

Replace TSM/TSSM/HFSM.Learn password and

perform set-up.

5157

5862

5830 5838

5

fc01654_en

Measure continuity to ground at blackfemale terminal at neutral switch.


Replace NeutralSwitch.

YES NO

5168

Check for continuity from connector[24B] terminal “8” (BK/GN) to

chassis ground.Is continuity present?

Replace ClutchSwitch.

Locate and repair open on(BK) wire between clutch

switch and ground.

NO

4

5861



Starter Testing 5: Starter Spins, But Does Not Engage

Remove alternator (left side) cover. Rotatealternator rotor and ring gear assembly.

Ring gear should engage in one directionand slip in the other.

Does it?

YES

Replace damaged starterclutch and starter.

NO

Replace rotor and ringgear.

5825 5837

fc01406_en

Inspect for damage to starterpinion gear or starter clutch.

Is damage present?

Starter Clutch failure.Replace Starter Clutch.

5839

YES NO



Starter Testing 6: Starter Stalls or Spins Too Slowly

Perform voltage drop tests from batterypositive to starter motor terminal.


YES NO

Perform voltage drop tests betweenbattery positive to starter solenoid terminal “2”.


Perform voltage drop testsbetween battery negative and

starter studs or bolts.Is voltage drop greater than 1.0 volt?

1 1

YES

Repair connectionbetween battery and

starter.

NO

Repair or replacestarter solenoid

(contacts).

5824 5845

NOYES

Clean groundconnections.

Perform Starter Current Draw Test onmotorcycle.

Perform Starter Motor Free RunningCurrent Draw Test (on bench).

Are test results within range?

5

6

YES NO

With the spark plugs removed and thetransmission in 5th gear, rotate rear wheel.

Check for engine, primaryand/or crankshaft bind.

Replace starter.

5817

5835

1

Use appropriate code

fc01407_en

YES NO

Perform voltage droptests between batterypositive and solenoidbattery terminal “1”.

Is voltage drop greaterthan 1.0 volt?

Repair connectionbetween solenoid

and starter.

5824



1.3DIAGNOSTICS/TROUBLESHOOTING

VOLTAGE DROPCheck the integrity of all wiring, switches, fuses and connectorsbetween the source and destination.

The voltage drop test measures the difference in potential orthe actual voltage dropped between the source and destination.

1. See ITEM A in Figure 1-4. Attach your red meter lead tothe most positive part of the circuit, which in this casewould be the positive post of the battery (5).

2. See ITEM B in Figure 1-4. Attach the black meter lead tothe final destination or component in the circuit (solenoidterminal from relay).

3. Activate the starter and observe the meter reading. Themeter will read the voltage dropped or the difference inpotential between the source and destination. An idealcircuit's voltage drop would be 0 volt or no voltagedropped, meaning no difference in potential.

4. See ITEM C in Figure 1-4. An open circuit should read 12volts, displaying all the voltage dropped, and the entiredifference in potential displayed on the meter.

NOTEOpen circuits on the ground side will read zero.

5. Typically, a good circuit will drop less than 1.0 volt. If thevoltage drop is greater, back track through the connections

until the source of the potential difference is found. Thebenefits of doing it this way are speed and accuracy.

a. Readings are not as sensitive to real battery voltage.

b. Readings show the actual voltage dropped, not justthe presence of voltage.

c. This tests the system as it is actually being used. Itis more accurate and will display hard to find poorconnections.

d. This approach can be used on lighting circuits, ignitioncircuits, etc. Start from most positive and go to mostnegative (the destination or component).

6. See ITEM D in Figure 1-4. The negative or ground circuitcan be checked as well.

a. Place the negative lead on the most negative part ofthe circuit (or the negative battery post). Remember,there is nothing more negative than the negative postof the battery.

b. Place the positive lead to the ground you wish tocheck.

c. Activate the circuit. This will allow you to read thepotential difference or voltage dropped on the neg-ative or ground circuit.This technique is very effectivefor identifying poor grounds due to powdered paint.Even the slightest connection may cause an ohm-meter to give a good reading. However, when suffi-cient current is passed through, the resistance causedby the powdered paint will cause a voltage drop orpotential difference in the ground circuit.



1.4STARTER ACTIVATION CIRCUITS

STARTER ACTIVATION CIRCUITS

200A

20A

20A

0.1A

200A

0.1A

200A

20A

20A

0.1A

200A

0.1A

200A

20A

20A

0.1A

200A

0.1A

200A

20A 20A

0.1A

200A

0.1A

ITEM A

ITEM COPEN CIRCUIT

ITEM DGROUND CIRCUIT

ITEM BIDEAL CLOSEDCIRCUIT

VDC

OV

VDC

VDC

VOV21

435

6

7

8

1

2

1

2

3 4

8

7

6

5

1

3 4

2

3 45

6

7

2

1

8

7

6

5

ed02788

1. Start switch2. Relay3. Solenoid4. Starter5. Battery6. MAXIFUSE7. Ignition switch8. Ignition fuse

Figure 1-4.Typical Circuitry. Refer to wiring diagrams for more information.



1.5TESTING STARTER ON MOTORCYCLE

START RELAY TEST1. See Figure 1-5. Locate the start relay under the right side

cover.

2. See Figure 1-6. The start relay can be tested using themotorcycle's 12 volt battery and a multimeter.

a. Unplug connector from relay.

b. To energize relay, connect the negative battery ter-minal to the relay terminal "85" or "2" and relay ter-minal "86" or "1" to the positive battery terminal.

c. Check for continuity between the "30" or "3" and "87"or "5" terminals. A good relay shows continuity (con-tinuity tester lamp "on" or a zero ohm reading on theohmmeter). A malfunctioning relay will not showcontinuity and must be replaced.

3. If start relay is functioning properly, proceed to1.5 TESTING STARTER ON MOTORCYCLE, StarterCurrent Draw Test.

ed02995

Figure 1-5. Start Relay

- + 85 (2)30 (3)

87 (5)86 (1)

1

2

3ed01000

1. Ohmmeter2. Battery3. Start relay

Figure 1-6. Start Relay Test

STARTER CURRENT DRAW TEST



NOTES

• Engine temperature should be stable and at room temper-ature.

• Battery should be fully charged.

Check starter current draw with an induction ammeter beforedisconnecting battery. Proceed as follows:

1. Verify that transmission is in neutral. Verify engine stopswitch is in the OFF position.

2. Remove air cleaner cover.

3. See Figure 1-5. Remove start relay from relay/fuse block[62B].

4. See Figure 1-7. Using HARNESS CONNECTOR TESTKIT (Part No. HD-41404-B), connect purple pin probesand patch cord to relay terminals "K" and "U".

5. Clamp induction ammeter over positive starter cable tosolenoid.

NOTEIn next step with engine stop switch in OFF position and purplemale probes connected to the "K" and "U" terminals ofrelay/fuse block [62B] in place of the start relay, starter will turnbut engine will not start. This configuration also prevents dia-gnostic trouble codes from being set.

6. Turn ignition switch to IGN while reading the ammeter.Disregard initial high current reading which is normal whenengine is first turned over.

a. Typical starter current draw will range between 80-120 amperes.

b. If starter current draw exceeds 120 amperes, thenthe problem may be in the starter or starter drive.Remove starter for further tests. See 1.6 TESTINGSTARTER ON BENCH, Free Running Current DrawTest.

U S

L K

F

Spare

E

[62B]ed01344

Figure 1-7. Starter Current Draw Test



1.6TESTING STARTER ON BENCH

FREE RUNNING CURRENT DRAW TEST1. Place starter in vise, using a clean shop towel to prevent

scratches or other damage.

2. See Figure 1-8. Attach one heavy jumper cable (6 gaugeminimum).

a. Connect one end to the starter mounting flange (1).

b. Connect the other end to the negative (-) terminal ofa fully charged battery (2).

3. Connect a second heavy jumper cable (6 gauge minimum).

a. Connect one end to the positive (+) terminal of thebattery (2).

b. Connect the other end to the battery terminal (4) onthe starter. Place an induction ammeter (3) over cable.

4. Check ammeter reading.

a. Ammeter should show 30-45 amperes.

b. If reading is higher, replace starter motor. See VRSCService Manual.

c. If starter current draw on vehicle was over 120amperes and this test was within specification, theremay be a problem with engine or primary drive.

1

4

2

3

ed02985

1. Mounting flange2. Battery3. Induction ammeter4. Battery terminal

Figure 1-8. Free Running Current Draw Test



1.7CHARGING SYSTEM

GENERALThe charging system consists of the alternator and regulator.The charging system circuits are shown in Figure 1-11.

AlternatorThe alternator consists of two main components:

• The rotor which mounts to the cam drive side of thecrankshaft.

• The stator which bolts to the alternator cover.

Voltage RegulatorSee Figure 1-9. The voltage regulator is a series regulator.The circuit combines the functions of rectifying and regulating.

ed01543

Figure 1-9. Voltage Regulator

TROUBLESHOOTING


ELECTRICAL SYSTEM TESTERHD-48053

When the charging system fails to charge or does not chargeat a satisfactory rate, make the following recommended checks.

BatteryCheck for a weak or dead battery. See 1.8 BATTERY TESTINGfor battery testing procedures. Battery must be fully chargedin order to perform a load test, or starting or charging tests.However, a partially discharged battery may be tested usingthe BATTERY TEST function of the ELECTRICAL SYSTEMTESTER (Part No. HD-48053).

WiringThe stators plug and socket connections must be clean andtight.

Check for corroded or loose connections in the charging systemcircuit.

Voltage Regulator InspectionSee Figure 1-10. The voltage regulator ground must have aclean, tight connection for proper grounding. Check by usingan ohmmeter with one lead on a known good ground, such asbattery ground cable, and the other on the regulator groundlead.

Job/Time Code ValuesDealership Technicians filing warranty claims should use thejob/time code values printed in bold text underneath theappropriate repair.

ed02987

Figure 1-10. Voltage Regulator Ground Lead (typical)



BK

BKBK

BKBK

BK

VoltageRegulator

[GND2]

[77A]

[77B]

To ignitionswitch

MAXIFUSE(40 Amp)

[5B]

[47B]

[47A]

StarterSolenoid

Stator

Battery

1 2 3

1 2 3

- +

- +

A B

Contact Posts

R

R

R

R

em00072

Figure 1-11. Charging System Circuit



Charging System Test (Part 1 of 2)

Test Battery.Charge or replace as required.

Inspect Voltage Regulator.See Regulator Inspection.

PASS FAIL

Perform Milliampere Draw Test.Correct asrequired.

5306

PASS

Perform Total Current Draw Test.Record measurement.

FAIL

Isolate damaged wiring orexcessive accessories.

5310Go to Charging

System Test(Part 2 of 2).

NOTE

Whenever a charging system component fails a test andis replaced, re-test the system to be sure the problemhas been corrected.

STOP

fc01408_en

FAIL

Disconnect Regulator.Does milliampere draw drop?

5308

Isolate damagedcomponent or wiring.

Replace grounded stator.

YES NO

5312



Charging System Test (Part 2 of 2)

From Charging System Test (Part 1 of 2).

Perform CURRENT OUTPUT TEST.Record measurement and compare with TOTAL

CURRENT DRAW TEST before proceeding.

PASS FAIL

PerformVOLTAGE

OUTPUT TEST.

PerformSTATOR CHECK.

PASS FAIL

Replace voltageregulator.

System tests good up to this point.Suspect:

Accessories on for long periods whenmotorcycle is parked and not running.

Accessories on when motorcycle isridden very slowly for long periods.

Battery self-discharge and/oraccessory draw because motorcyclewas not operated for a long period.

5316

PASS FAIL

Perform ACOUTPUT TEST.

Replacestator.

5312

PASS

Replace voltageregulator.

Perform CURRENTOUTPUT TEST.

Inspect rotor.

FAIL

FAILPASS

Damaged orslipping rotor.

SystemOK.

5315

NOTE:

Whenever a charging system component fails a test andis replaced, re-test the system to be sure the problemhas been corrected.

5319

FAILPASS

Replacestator.

Replacerotor.

5314 5319

fc01409_en



TESTING



ADVANCED BATTERY CONDUCT-ANCE AND ELECTRICAL SYSTEMANALYZER

HD-48053

Milliampere Draw TestNOTES

• Be sure accessories are not wired so they stay on at alltimes. This condition could drain battery completely ifvehicle is parked for a long time. Check for this by con-necting ammeter between negative battery terminal andbattery.

• With the key off, an initial current draw of up to 200 mAwill occur directly after connecting meter.This should dropto the values shown in table in less than one minute.

• Disconnect siren during milliamperes draw test.

1. Remove right side cover. Remove MAXIFUSE.

2. See Figure 1-12. Using HARNESS CONNECTOR TESTKIT (Part No. HD-41404-B) red male socket probes andpatch cords, connect ammeter to MAXIFUSE socket ter-minals. With this arrangement, you will also pick up anyregulator drain.

3. With ignition switch turned to OFF and all lights andaccessories off, observe current reading.

a. Refer to Table 1-4. Add voltage regulator draw toappropriate value for TSM/TSSM/HFSM and ECM. Ifobserved ammeter reading is less than listed in table,draw is within limits.

b. A higher reading indicates excessive current draw.Any accessories must be considered and checkedfor excessive drain.

NOTEA battery with a surface discharge condition could suffer astatic drain. Correct by cleaning battery case.

Table 1-4. Milliampere Draw Test

MAXIMUM DRAW IN MILLI-AMPERES

ITEM

1.0Regulator

1.0TSM (non security models)

3.0TSSM (disarmed)

3.0TSSM (armed)

1.0TSSM/HFSM-Storage mode(armed or disarmed)

1.0HFSM

1.0ECM

20.0*Security Siren (optional)

* Siren will draw for 2-24 hours from time motorcycle batteryis connected and 0.05 milliamperes once siren battery ischarged. Disconnect siren during milliampere draw test.

BKBK

[GND2]

[77A]

[77B]

[5B]

[47A]1 2 3

- +

- +

A B

R

R

R

1

2

3

ed02989

1. Ammeter2. MAXIFUSE socket3. Voltage regulator

Figure 1-12. Milliampere Draw Test (Ignition Turned toOFF)

Total Current Draw TestIf battery runs down during use, the current draw of themotorcycle components and accessories may exceed outputof the charging system.

NOTE

If a load tester is unavailable, an ammeter with current probemay be used.

Turn battery load tester OFF before connecting testercables to battery terminals. Connecting tester cables withload tester ON can cause a spark and battery explosion,which could result in death or serious injury. (00252a)

1. See Figure 1-13. To check for this condition, place loadtester induction pickup or current probe pickup over batterynegative cable.

2. Disconnect stator plug from voltage regulator. Start themotorcycle and run the engine at 2000 RPM.

3. With ignition and all continuously running lights andaccessories turned on (headlamp on high beam), read thetotal current draw.

4. Compare this reading to the reading obtained after per-forming the CURRENT AND VOLTAGE OUTPUT TEST.

a. The current output should exceed current draw by3.5 amperes minimum.

b. If output does not meet specifications, there may betoo many accessories for the charging system tohandle.



5. Reconnect voltage regulator after testing.

1

2

3

ed02802

1. Load tester2. Induction pickup3. Battery

Figure 1-13. Check Current Draw (Ignition Switch On)

Current and Voltage Output Test: UsingHD-480531. Connect the ADVANCED BATTERY CONDUCTANCE

AND ELECTRICAL SYSTEM ANALYZER (Part No. HD-48053) leads to the vehicle's battery.

2. Follow the instructions in the analyzer's instruction manualto perform a Charging System Test.

3. See Figure 1-14. The test results will include a decisionon the charging system's condition and the measuredvoltage at idle and at 3000 RPM. The analyzer's printerwill provide you with a printout including one of two pos-sible test results:

CHARGING SYSTEM NORMAL - No problem found.

CHARGING SYSTEM PROBLEM - The analyzer detecteda problem and will display one of the three following res-ults:

a. LOW CHARGING VOLTS - The alternator is notsupplying sufficient current for the system's electricalloads.

b. HIGH CHARGING VOLTS - The voltage output fromthe alternator exceeds the normal regulator limits.

c. INVESTIGATE VOLT OUTPUT - The rev voltage islower than the idle voltage.

Current and Voltage Output Test: UsingLoad Tester1. Connect load tester.

a. Connect negative and positive leads to battery ter-minals.

b. Place load tester induction pickup over positive regu-lator cable.

2. Run the engine at 3000 RPM. Do not leave any load switchturned on for more than 20 seconds or overheating and

tester damage are possible. Increase the load as requiredto obtain a constant 13.0 VDC.

3. The current output should be 19-23 amperes. Make noteof measurement for use in Total Current Draw Test.

NOTE

Rider's habits may require output test at lower RPM.

ed02804

Figure 1-14. Charging System Test Results Printout

Stator Check1. Turn ignition switch OFF.

2. See Figure 1-15. Connect an ohmmeter.

a. Disconnect voltage regulator connector from alternatorstator wiring.

b. Insert one ohmmeter lead into a stator connectorsocket.

c. Attach the other lead to a suitable ground.

3. Test for continuity with ohmmeter set to the ohms scale.

a. A good stator will show no continuity (open circuit)between any stator sockets and ground.

b. Any other reading indicates a grounded stator whichmust be replaced.

4. See Figure 1-16. Remove ground lead. Check resistanceacross stator sockets 1-2, 2-3 and 3-1.

5. Test for resistance with ohmmeter set on the ohms scale.

a. Resistance across all the stator sockets should be0.1-0.3 ohms.

b. If the resistance is higher, the stator is damaged andmust be replaced.

c. If resistance is lower, the stator is may have a turn-to-turn short and should be replaced.

NOTEVerify the meter reads 0 ohms when probes are shortedtogether. If not, subtract lowest value to resistance value ofstator.



ed01435

Figure 1-15.Test for Grounded Stator (typical)

ed02806

Figure 1-16. Check for Stator Resistance (typical)

AC Output Check1. See Figure 1-17. Test AC output.

a. Disconnect voltage regulator connector from alternatorstator wiring.

b. Connect an AC voltmeter across stator connectorterminals "1" to "2".

c. Run the engine at 2000 RPM. The AC output shouldbe 32-40 volts AC (approximately 16-22 per 1000RPM).

d. Repeat test using terminals "2" to "3" and "1" to "3".

2. Compare test results to specifications.

a. If the output is below specifications, charging problemcould be a faulty rotor or stator.

b. If output is within specifications, charging problemmight be faulty voltage regulator. Replace as required.

3. Check the output again as previously described underCURRENT AND VOLTAGE OUTPUT TEST.

ed02806

Figure 1-17. Check Stator AC Voltage Output (typical)



1.8BATTERY TESTING

GENERALThree different procedures may be performed to provide agood indicator of battery condition: a voltage test, a conduct-ance test, or a load test.

A battery may be tested, whether fully charged or not, viaconductance test. In order to perform a load test, however, thebattery must be fully charged.

VOLTMETER TESTThe voltmeter test provides a general indicator of battery stateof charge or condition. Check the voltage of the battery to verifythat it is in a 100% fully charged condition. Refer to Table 1-5.

If the open circuit (disconnected) voltage reading is below12.6V, charge the battery and then recheck the voltage afterthe battery has set for one to two hours. If the voltage readingis 12.7V or above, perform the LOAD TEST described in thissection.

Table 1-5. Voltmeter Test For Battery Charge Conditions

STATE OF CHARGEVOLTAGE (OCV)

100%12.7

75%12.6

50%12.3

25%12.0

0%11.8

CONDUCTANCE TEST


ADVANCED BATTERY CONDUCT-ANCE AND ELECTRICAL SYSTEMANALYZER

HD-48053

Test the battery using the ADVANCED BATTERY CONDUCT-ANCE AND ELECTRICAL SYSTEM ANALYZER (Part No. HD-48053). Perform a battery test as follows:

1. Connect the HD-48053 analyzer leads to the vehicle bat-tery lead terminal, not to bolt or wire terminal.

NOTEConnect the tester directly to the lead terminals of the battery,and not the bolts.

2. Follow the instructions in the analyzer instruction manualto perform a battery test.

The test results will include a decision on the battery conditionand the measured state of charge.

See Figure 1-18. The analyzer printer will provide you with aprintout including one of six possible test results:

• GOOD BATTERY - Return the battery to service.

• GOOD-RECHARGE - Fully charge the battery and returnto service.

• CHARGE & RETEST - Fully charge the battery and retest.

• REPLACE BATTERY - Replace the battery.

• BAD CELL-REPLACE - Replace the battery and retest.

• BATTERY NOISE - Remove surface charge from batteryand retest.

NOTES

• A REPLACE BATTERY test result may also mean a poorconnection between the battery cables and the vehicle.After disconnecting the battery cables from the battery,retest the battery using the out-of-vehicle test beforereplacing.

• Connect the tester directly to the lead terminals of thebattery, and not the bolts.

ed02811

Figure 1-18. Battery Test Results Printout

LOAD TESTTo load test the battery, proceed as follows:

Disconnect negative (-) battery cable first. If positive (+)cable should contact ground with negative (-) cable con-nected, the resulting sparks can cause a battery explosion,which could result in death or serious injury. (00049a)

1. Remove battery from motorcycle.

2. Always fully charge the battery before testing or testreadings will be incorrect. Load testing a discharged bat-tery can also result in permanent battery damage.

3. After charging, allow battery to stand for at least one hourbefore testing.



Turn battery load tester OFF before connecting testercables to battery terminals. Connecting tester cables withload tester ON can cause a spark and battery explosion,which could result in death or serious injury. (00252a)

4. See Figure 1-19. Connect tester leads to battery postsand place induction pickup over negative (black) cable.

NOTETo avoid load tester and/or battery damage, do not leave theload tester switch turned ON for more than 20 seconds.

5. Refer to Table 1-6. Load battery at 50% of CCA ratingusing the load tester. Voltage reading after 15 secondsshould be 9.6V or more at 21° C (70° F).

Turn battery load tester OFF before disconnecting testercables to battery terminals. Disconnecting tester cableswith load tester ON can cause a spark and battery explo-sion, which could result in death or serious injury. (00253a)

Connect positive (+) battery cable first. If positive (+) cableshould contact ground with negative (-) cable connected,the resulting sparks can cause a battery explosion, whichcould result in death or serious injury. (00068a)

Do not over-tighten bolts on battery terminals. Userecommended torque values. Over-tightening battery ter-minal bolts could result in damage to battery terminals.(00216a)

6. Install the battery in the motorcycle.

VOLTS

AMPS

1

2

3

ed02812

1. Load tester2. Induction pickup3. Battery

Figure 1-19. Load Test Battery

Table 1-6. Battery Load Test

50%100%COLD CRANKINGAMPERAGE (CCA)

100200VRSC models



SUBJECT............................................................................................................................PAGE NO.2.1 CHECKING FOR TROUBLE CODES.......................................................................................2-12.2 INSTRUMENT MODULE (IM) SELF DIAGNOSTICS................................................................2-32.3 BREAKOUT BOX: IM.................................................................................................................2-52.4 INITIAL DIAGNOSTIC CHECK: IM............................................................................................2-62.5 INSTRUMENT MODULE...........................................................................................................2-92.6 NO IM POWER........................................................................................................................2-112.7 INDICATOR LAMPS................................................................................................................2-142.8 DTC B1003..............................................................................................................................2-172.9 FUEL GAUGE OPERATION....................................................................................................2-182.10 DTC B1004, B1005...............................................................................................................2-192.11 DTC B1006, B1007...............................................................................................................2-232.12 DTC B1008............................................................................................................................2-252.13 DTC U1016............................................................................................................................2-272.14 DTC U1064............................................................................................................................2-302.15 DTC U1300, U1301 OR BUS ER..........................................................................................2-33

INS

TR

UM

EN

TS


NOTES


2.1CHECKING FOR TROUBLE CODES

CHECK ENGINE LAMPTo diagnose Electronic Control Module (ECM) system prob-lems, start by observing the behavior of the check engine lamp.

NOTES

• See Figure 2-1. "Key ON" means that the Ignition Switchis turned to IGN and the Engine Stop Switch is set to RUN(although the engine is not running).

• When the Ignition Switch is turned IGN, the check enginelamp will illuminate for approximately four seconds andthen turn off.

• If the check engine lamp is not illuminated at Key ON orif it fails to turn off after the initial four-second period, thensee 2.2 INSTRUMENT MODULE (IM) SELF DIA-GNOSTICS.

1. See Figure 2-2. After the check engine lamp turns off fol-lowing the first four illumination periods, one of threeevents may occur.

a. The lamp remains off. This indicates there are nocurrent fault conditions or stored DTCs currentlydetected by the ECM.

b. The lamp stays off for only four seconds and thencomes back on for an eight second period. Thisindicates a DTC is stored, but no current DTC exists.

c. If the lamp remains on beyond the eight-secondperiod, a current DTC exists.

2. See 2.1 CHECKING FOR TROUBLE CODES, Code Typesfor a complete description of DTC formats.

NOTE

Some DTCs can only be fully diagnosed during actuation. Forexample, a problem with the ignition coil will be considered acurrent fault even after the problem is corrected, since the ECMwill not know of its resolution until after the coil is exercised bythe vehicle start sequence. In this manner, there may some-times be a false indication of the current DTC.

2

3

1

ed02991

1. Accessory (ACC) position2. OFF position3. Ignition position

Figure 2-1. Ignition Switch

ONA

B

C

ON

ON

OFF

OFF

OFF

Key On

Key On

Key On

Lamp OFF: No Current or Historic DTCs

Lamp OFF

Lamp ON 8 Seconds:Only Historic DTCs Exist

Lamp Remains ON: Current DTC*

* Historic DTCs May Also Exist

4 Sec.

4 Sec.

4 Sec.

4 Sec.

8 Sec.

4 Sec.

ed01434

Figure 2-2. Check Engine Lamp Operation

2008 VRSC Diagnostics: Instruments 2-1


CODE TYPES


DIGITAL TECHNICIANHD-44750

There are two types of DTCs: current and historic. If a DTC isstored, it can be read using either a computer-based diagnosticpackage called DIGITAL TECHNICIAN (Part No. HD-44750)or speedometer self diagnostics. See 2.2 INSTRUMENTMODULE (IM) SELF DIAGNOSTICS.

NOTES

• Speedometer self diagnostics will display both current andhistoric DTCs.To differentiate between current and historicDTCs, a computer-based diagnostic package calledDIGITAL TECHNICIAN (Part No. HD-44750) must beemployed.

• All DTCs reside in the memory of the ECM, TSM/TSSM/HFSM, speedometer or tachometer until the DTC iscleared by use of the speedometer self diagnostics.2.2 INSTRUMENT MODULE (IM) SELF DIAGNOSTICS.

• A historic DTC is also cleared after a total of 50 ignitioncycles (start and run cycle) have elapsed. After the 50ignition cycle retention period, the DTC is automaticallyerased from memory providing that no subsequent faultsof the same type are detected in that period.

CurrentCurrent DTCs are those which presently disrupt motorcycleoperation. See the appropriate flow charts for solutions.

HistoricIf a particular problem happens to resolve itself, the activestatus problem is dropped and it becomes a historic DTC ratherthan a current DTC.

Historic DTCs are stored for 50 ignition cycles after any DTCwas last set as current to assist in the diagnosis of intermittentfaults. On the 50th cycle, the DTC will clear itself. The securitylamp will only indicate the existence of historic DTCs for twoignition cycles.

It is important to note that historic DTCs will exist wheneverthe system indicates the existence of a current fault. See2.1 CHECKING FOR TROUBLE CODES, Multiple TroubleCodes if multiple DTCs are found.

Diagnostic charts are designed for use with current DTCs. Asa result, they frequently suggest part replacement. When dia-gnosing a historic DTC, the charts can be helpful but shouldnot lead to part replacement without verification that the partis faulty.

SECURITY LAMPThe security lamp functions in the same manner as the checkengine lamp, except that it is controlled by the TSSM/HFSM.The security lamp will be turned on when codes are presentin the TSSM/HFSM.

RETRIEVING TROUBLE CODES



There are two levels of diagnostics.

• The most sophisticated mode uses a computer baseddiagnostic package called the DIGITAL TECHNICIAN (PartNo. HD-44750).

• The second mode requires using the instrument module(IM) self diagnostics. IM, TSM/TSSM/HFSM, and ECMcodes can be accessed and cleared. See 2.2 INSTRU-MENT MODULE (IM) SELF DIAGNOSTICS for moreinformation..

MULTIPLE TROUBLE CODESWhile it is possible for more than one fault to occur and setmore than one trouble code, there are several conditions whichmay result in one fault setting multiple trouble codes:.

Serial data codes (DTC U1300, U1301, U1016, U1064, U1096and U1255) may be accompanied by other codes. Alwayscorrect the serial data codes before resolving the other codes.

2-2 2008 VRSC Diagnostics: Instruments


2.2INSTRUMENT MODULE (IM) SELF DIAGNOSTICS

GENERALThe Instrument Module is capable of displaying and clearingIM, TSM/TSSM/HFSM, ABS, and ECM trouble codes. SeeFigure 2-3.

MPH

010

20

RPM

1098

76

5

43

21 0

3040

5060 70 80 90

100110

120

130

140

150

ABS

3/4

F

1/2

1/4

ed01266

Figure 2-3. Instrument Module

DIAGNOSTICS

Diagnostic Tips• For a quick check of IM function, a "WOW" test can be

performed. See Figure 2-4. Turn Ignition Switch to ACC.Background lighting should illuminate, gauge needlesshould sweep their full range of motion, and indicator

lamps controlled by the serial bus (battery, security,coolant temperature and check engine) should illuminate.

• If instrument module fails "WOW" test, check for battery,ground and accessory to IM. If any feature in the instru-ment module is non-functional, see 2.6 NO IM POWER.

Diagnostics NotesEach reference number below correlates to a circled numberon the flow chart(s).

1. To exit diagnostic mode, turn Ignition Switch OFF.

2. To clear DTCs for selected module, press trip odometerreset switch for more than 5 seconds when code is dis-played. This procedure will clear all codes for selectedmodule.

2

3

1

ed02991





IM Self-Diagnostics

1

While holding Trip Odometer ResetSwitch in, turn ignition switch to ACC.Make sure Engine Stop Switch is in

RUN position.

Release Trip Odometer Reset Switch.Does “diag” appear?

YES

”P” flashing.

To display DTCs for theECM, press and holdTrip Odometer Reset

Switch for morethan 5 seconds.

To display DTCs forTSM/TSSM/HFSM,press and hold Trip

Odometer Reset Switchfor more than 5

seconds.

To choose TSM/TSSM/HFSM, press

and release TripOdometer Reset

Switch.

”S” flashing.

To chooseSpeedometer,

press and releaseTrip Odometer Reset

Switch.

”C” flashing.

To choose ABS,press and release

Trip Odometer ResetSwitch.

To display DTCs forcluster, press and

hold Trip OdometerReset Switch for more

than 5 seconds.

Press and release TripOdometer Reset Switch again

to continue to next module.

See 2.4 INITIALDIAGNOSTIC

CHECK: SPEEDOMETER.

YES

YES

NO

NO

NO

Deviceresponse?

Press andrelease

Trip OdometerReset Switch.Part number ofmodule will be

displayed.

Press andrelease

Trip OdometerReset Switch.

Are more DTCsdisplayed?

“end” displayed.To clear all DTCs for selected

module hold Trip Odometer ResetSwitch for more than 5 seconds.

If DTCs are not to be cleared,Press and release Trip Odometer

Reset Switch. Part number ofmodule will be displayed.

“no rsp” displayed. Seeapplicable code from

other modules. Modelsnot equipped with a

tachometer will display“no rsp” normally.

If “no rsp” displayed onABS equipped vehicle,

See Section 5.1ANTILOCK BRAKE

SYSTEM (ABS)GENERAL

INFORMATION.

“none”displayed.

DTCdisplayed.

Press and release Trip OdometerReset Switch. “PSCtb” appears.

2

fc01657_en

”b” flashing.

To choose ECM,press and release


To display DTCs forABS (if equipped),

press andhold Trip Odometer

Reset Switch for morethan 5 seconds.



2.3BREAKOUT BOX: IM

GENERAL



ADAPTERSHD-45325

The BREAKOUT BOX (Part No. HD-42682) andADAPTERS (Part No. HD-45325) connect to the instrumentmodule (IM) connector [39]. Used in conjunction with a DVOM,it allows circuit diagnosis of wiring harness and connectionswithout having to probe with sharp objects

NOTE

See wiring diagrams for IM terminal functions.

INSTALLATION1. Remove handlebar cover.

2. See Figure 2-5. Depress latch on connector [39B].

3. Connect Harness Adapters to connectors [39A] and [39B].

4. Attach connectors from Breakout Box to Harness Adapters.

ed02993

Figure 2-5. Instrument Module Connector [39]

REMOVAL1. Detach connectors from Breakout Box to Harness

Adapters.

2. See Figure 2-5. Detach Harness Adapters from connectors[39A] and [39B].

3. Install connector [39B] to instrument module.



2.4INITIAL DIAGNOSTIC CHECK: IM

GENERALTo locate faulty circuits or other system problems, follow thediagnostic flow charts and tests in this section. For a systematicapproach, always begin with 2.4 INITIAL DIAGNOSTICCHECK: IM, Initial Diagnostics which follows. Read the generalinformation and then work your way through the flow chart boxby box.

Diagnostic NotesIf a numbered circle appears adjacent to a flow chart box, thenmore information is offered in the diagnostic notes. Many dia-gnostic notes contain supplemental information, descriptionsof various diagnostic tools or references to other parts of themanual where information on the location and removal ofcomponents may be obtained.

Circuit Diagram/Wire Harness ConnectorTableWhen working through a flow chart, refer to the illustrations,the associated circuit diagram and the wire harness connectortable as necessary.The wire harness connector table for eachcircuit diagram identifies the connector number, description,type and general location.

In order to perform most diagnostic routines, a Breakout Boxand a DVOM are required. See 2.3 BREAKOUT BOX: IM.

To perform the circuit checks with any degree of efficiency, afamiliarity with the various wire connectors is also necessary.


INITIAL DIAGNOSTICS

Diagnostic TipsCheck for an open diagnostic test terminal between data con-nector terminal "3" and IM. With Ignition Switch turned ON,transmit data should be typically 0.6-0.8 volts. The range ofacceptable operation is 0-7.0 volts.


1. Compare engine behavior to symptoms tables in 4.8 INI-TIAL DIAGNOSTIC CHECK.

All IM diagnostic codes are listed in Table 2-1.

Table 2-1. IM Diagnostic Trouble Codes (DTC) and Fault Conditions

SOLUTIONFAULT CONDITIONRANKINGDTC

2.8 DTC B1003Internal fault1B1003

2.10 DTC B1004, B1005Fuel level sensor low8B1004

2.10 DTC B1004, B1005Fuel level sensor high/open9B1005

2.11 DTC B1006, B1007Accessory line overvoltage6B1006

2.11 DTC B1006, B1007Ignition line overvoltage5B1007

2.12 DTC B1008Trip switch inoperatble/Trip Switch closed7B1008

2.13 DTC U1016Loss of ECM serial data5U1016

2.14 DTC U1064Loss of TSM/TSSM/HFSM serial data3U1064

2.14 DTC U1064Missing response from other module (TSM//HFSM) atstartup

4U1255

2.15 DTC U1300, U1301 OR BUS ERECM serial data low3U1300

2.15 DTC U1300, U1301 OR BUS ERECM serial data high4U1301

Other CodesSee 3.10 INITIAL DIAGNOSTIC CHECK for any codes relatedto the Turn Signal Module (TSM), Turn Signal Security Module(TSSM), or Hands-Free Security Module (HFSM).

See 4.8 INITIAL DIAGNOSTIC CHECK for any codes relatedto the Electronic Control Module (ECM).



BK

/GN

BK

/GN

LGN/V

LGN/V

LGN

/VLG

N/V

LGN

/V

LGN/V

LGN

/V

GY

GY

GY

[39B][39A]

[30B]

[91A]

[166A] [166B]

[30A]

[78B][78A]

TSM/TSSM/HFSM

DataConnector

ECM

InstrumentModule

ABSModule

Batteryfuse

Ignitionfuse

Ser

iald

ata

3

9Serial data 9

1

2

4

5

5

3

3

Ser

iald

ata

Gro

und

7

7

6

6

5

5

BK

/GN

12

12

1

1

R

em00165

Figure 2-6. Diagnostic Check (typical)

Table 2-2. Wire Harness Connectors

LOCATIONTYPEDESCRIPTIONNO.

Under passenger seat12-place DeutschTSM/TSSM/HFSM[30]

Under handlebar cover12-place Mini-DeutschInstrument Module (IM)[39]

Under passenger seat36-place PackardElectronic Control Module (ECM)[78]

Under right side cover4-place DeutschData link connector[91A]

Under left side cover20-place MolexABS module[166]



Diagnostic Check

Does enginestart?

Check for diagnostic trouble codes(DTC’s). See 4.5 INSTRUMENTMODULE SELF DIAGNOSTICS.

DTC’s found?

See 4.11 STARTS, THENSTALLS.

YES.Starts and

runs.

Is IMfunctional?

“None”Displayed?

Refer to applicable DTC prioritychart. All DTC’s are listed in Table

2.1. DTC’s are listed by priority.Go to 2.6 NO IM

POWER.

No codes displayed. Forsymptoms that may notset diagnostic trouble

codes, refer to Table 2-4.Function Chart-Loss Of

Input.

Go to Trip OdometerReset SwitchInoperable /

Trip Odometer ResetSwitch Closed DTC:

B1008.

YES.Starts, then

stalls.

NO.Cranks, butwill not start.

NO.Engine will not

crank.

See 4.9 ENGINE CRANKS,BUT WILL NOT START.

See 1.2 STARTING SYSTEMDIAGNOSIS.

1

YES

NO YES

NO YES

NO

fc01597_en



2.5INSTRUMENT MODULE

GENERALThe instrument module consists of a speedometer, tachometer,fuel gauge and several icons.The icons include: check engine,ABS (if equipped), security, high beam, low battery, coolanttemp, neutral, left turn, right turn, oil pressure and low fuel.

Trip Odometer Reset SwitchSee Figure 2-7. Pressing the trip odometer reset switchprovides the following capabilities:

• Change the odometer display between mileage, trip andfuel range values (press and immediately release).

• Reset the trip odometer (press and hold 2-3 seconds).

• Gain access to the diagnostic mode and clear diagnosticcodes. See 2.2 INSTRUMENT MODULE (IM) SELF DIA-GNOSTICS.

Table 2-3. Code Description

DESCRIPTIONCODE

Internal faultB1003

Fuel level sensor lowB1004

Fuel level sensor high/openB1005

Accessory line overvoltageB1006

Ignition line overvoltageB1007

Trip switch closedB1008

Loss of ECM serial dataU1016

Loss of TSM/TSSM/HFSM serial dataU1064

Serial data lowU1300

Serial data highU1301

MPH

010

20

RPM

109

1 0

3040

5060 70 80 90

100110

120

130

140

150

ABSF

6

1 2

3 4

5

ed01267

1. Check engine lamp2. Low fuel lamp3. Low battery lamp4. Security lamp (key icon)5. ABS6. Trip odometer reset switch


SPEEDOMETER THEORY OF OPERATIONThe speedometer consists of a trip odometer reset switch andspeedometer. A speed sensor is mounted on the left side oftransmission case. The sensor circuitry is that of a Hall-Effectsensor that is triggered by the gear teeth of 5th gear on thetransmission mainshaft.

The output from the sensor is a series of pulses that are inter-preted by ECM circuitry, converted into serial data then sentto the IM. The IM converts the data to control the position ofthe speedometer needle. It also provides input to theTSM/TSSM/HFSM for turn signal cancellation.

The odometer mileage is permanently stored and will not belost when electrical power is turned off or disconnected. Thetrip odometer reset switch allows switching between the odo-meter, trip odometer and fuel range displays.

To zero the trip odometer, have the odometer display visible,press and keep the trip odometer reset switch depressed.Thetrip odometer mileage will be displayed for 2-3 seconds andthen the trip mileage will return to zero miles.

The odometer can display six numbers to indicate a maximumof 999999 miles. The trip odometer can display six numberswith a tenth of a mile accuracy for a maximum of 99999.9 miles.



TACHOMETER THEORY OF OPERATIONThe tachometer receives serial data from the ECM. The ECMreceives signal from CKP, the ECM converts signal to serialdata and sends it to the tachometer.The tachometer interprets

the serial data and converts it into tachometer needle move-ment.

Tachometer needle will turn from amber to red when RPM limitis reached.



2.6NO IM POWER

GENERAL



ADAPTERSHD-45325

Constant power is supplied to the IM through terminal "1".TheIM turns on when power is applied to terminal "6" of connector[39].The IM goes through an initialization sequence every timepower is removed and re-applied to terminal "6". The visiblepart of this sequence is the check engine lamp, security lamp,backlighting, odometer and fuel level. Upon key IGN, the checkengine lamp and security lamp will illuminate for 4 secondsand then (if parameters are normal) go out.

Loss of power on any of the three power inputs will change IMbehavior. Refer to Table 2-4.


1. Connect BREAKOUT BOX (Part No. HD-42682) andADAPTERS (Part No. HD-45325) between wire harnessand IM.

ed02995

Figure 2-8. Front Fuse Block

ed02996

Figure 2-9. Rear Fuse Block

Table 2-4. Function Chart - Loss of Input

TERMINAL 5 (GRD)TERMINAL 12 (ACC)TERMINAL 6 (IGN)

Neutral and oil pressure lamps still functionalWill not "WOW"Will "WOW"

Other features non-functional or erraticBacklighting and odometer non-functional

Needles freeze

Diagnostics absentFuel gauge, turn signals andsecurity lamp non-functional

Turn signals and fuel gauge still functional

Diagnostics absentSpeedometer, tachometer, check engine lamp,security lamp, oil pressure lamp and highbeam indicators non-functionalIf any feature is non-functional or erratic andother features are OK, replace IM (Job TimeCode 6014)

Diagnostics absent



R/O

O/W

BE/GY

BK/GN

BK/GN

BK/GN

W/BK

W/B

K

R/BKR

/GY

GY

GY

GY

GY

R

R R

R

RR

BK

[22B][22A]

[33B][33A]

[39A][39B]

Battery

IgnitionSwitch

EngineStop Switch

[GND1]

[GND1]

15 AMPECM Fuse

15 AMPBatteryFuse

15 AMPAccessory

Fuse

15 AMPIgnitionFuse

10

31

13

4

C B A

A B I

3

4 3

28

–+

[78B][78A]

Ground

Constant power

Switch power

Ground

10

31

13

28

40 AmpMAXIFUSE

InstrumentModule

1 1265

1 1265

em00166

Figure 2-10. IM Power Circuit Diagram



Under left side cover6-place MolexRight handlebar switch (black)[22]

Back of ignition switch3-place PackardIgnition switch[33]

Inside handlebar cover12-place Mini-DeutschInstrument Module (IM)[39]


Rear cylinder headRing terminalECM ground[GND 1]

Under seatFuse blockFuses-



No IM Power

YES

YES NO

NO

NOYES

YES NO

YES NO

YES NO

YES NO

YES NO

Is check engine lamp on?

Does check engine lamp turn offafter 4 seconds.

See DIAGNOSTICS under 2.2INSTRUMENT MODULE (IM)

SELF DIAGNOSTICS. Does IMpass “wow” test?

For intermittents Refer to Table2-4

IM is functioningproperly.

Replace IM. IM is functioningproperly.

Check for battery voltage at IMterminal “1”. Is battery voltage

present?

Locate and repairopen.

Check for continuity to groundon IM terminal “5”. Continuity

present?

With ignition ON, check for batteryvoltage at IM terminal “6”. Battery

voltage present?


With ignition in ACC position,check for battery voltage at IMterminal “12”. Battery voltage

present?


Replace IM.Is accessory fuse

good?

1

YES NO

Check for continuity to groundon IM terminal “12”. Continuity

present?

Inspect wiringand replace

fuse.

Locate and repair grounded(O/W) wire

Replace fuse.

Locate and repair open on(O/W) wire between accessory

fuse and IM terminal “12”.

fc01598_en



2.7INDICATOR LAMPS

GENERALVRSC models are equipped with Light Emitting Diode (LED)indicators. The indicator lamps are not serviceable. If an LEDis bad, the IM must be replaced.

See Figure 2-11 and Table 2-7 for location and names ofindicator lamps.

MPH

010

20

RPM

1098

76

5

43

21 0

3040

5060 70 80 90

100110

120

130

140

150

ABS

3/4

F

1/2

1/4

ed01266

Figure 2-11. Indicator Lamps

Table 2-6. Indicator Lamp Connector [20] Terminals

FUNCTIONWIRE COLORTERMINALON [20]

BatteryRed/Orange1

High beamWhite2

Left turnViolet3

Right turnBrown4

GroundBlack5

IgnitionGrey6

Serial dataLt. Green/Violet7

N/AN/A8

Oil pressureGreen/Yellow9

NeutralTan10

Fuel senderYellow/White11

AccessoryOrange/White12

Table 2-7. Indicator Lamp Wiring

CONNECTIONINDICATOR LAMP

Serial dataCheck engine

Serial dataSecurity

Serial dataCoolant temperature

Serial dataBattery

Ground through switchOil pressure

Ground through switchNeutral

12 volts when activeHigh beam

12 volts when activeRight/left turn

Voltage varies through sender,active at 1/4 tank or less

Low fuel

Serial dataABS

DIAGNOSTICS



ADAPTERSHD-45325



ed02993




Oil Pressure or Neutral Indicator Will Not Function

1

YES NO

YES NO

YES NO NO

Check for battery voltageat terminal

“6” of breakout box.Is battery voltage present?

Check for continuity toground on connector[39B] at terminal “10”

(neutral) and terminal “9”(oil pressure).


Check for blownIGN fuse or open

GY wire.

Replace IM. Check for continuity throughsuspect switch.


Repair open in (GN/Y)wire (oil pressure) or(TN) wire (neutral).

Replace oilpressure switch.

Replace neutralswitch.

fc01599_en

5191

50485161 5157

5048



High Beam or R/L Turn Signal Indicator Will Not Function

1

NOYES

NOYES

Check for ground at terminal “5” ofbreakout box.

Is ground present?

Check for 12 volts when circuitis active. Use terminal “3” (left

turn), terminal “4” (right turn) andterminal “2” (high beam).

Is voltage present?

Locate and repairopen in circuit.

Replace IM. Locate and repair openin suspect circuit.

fc01600_en

5048

51915048



2.8DTC B1003

GENERAL

Internal FaultThis DTC indicates a failure which requires replacement of theinstrument module.

NOTE

When DTC B1003 is set as current, the instrument module hasan internal error such as memory check sum error, EEPROMerror or Program Code Lost. This is a non-serviceable failure.Replace the instrument module.

MPH

010

20

RPM

1098

76

5

43

21 0

3040

5060 70 80 90

100110

120

130

140

150

ABS

3/4

F

1/2

1/4

ed01266




2.9FUEL GAUGE OPERATION

GENERALSee Figure 2-14. With ignition switch ON or ACC, the fuelgauge and Fuel Level Sensor (FLS) are connected to +12 volts.The FLS determines distance to fuel and then outputs a voltagefrom a table lookup for distance versus volume.

Inoperative gauges may be caused by four circumstances.

• Sensor or Instrument Module (IM) not grounded.

• Malfunction in sensor or IM.

• Loss of accessory input, blown accessory fuse.

• Broken or disconnected wire from IM to fuel pump fromharness to sensor.

[13A]123

ed03001

Figure 2-14. Fuel Level Sensor (FLS)



2.10DTC B1004, B1005

GENERALThe fuel level is monitored by the Instrument Module (IM) ter-minal "11" of connector [39] (Y/W).

• If the voltage on terminal "11" of connector [39] exceedsthe lower limit for greater than or equal to 15 seconds aDTC B1004 will be set.

• If the voltage on terminal "11" of connector [39] exceedsthe upper limit (or is open) for greater than or equal to 15seconds a DTC B1005 will set.


DESCRIPTIONDTC

Fuel level sensor or wiring shorted lowB1004

Fuel level sensor or wiring high/openB1005

DIAGNOSTICS




ADAPTERSHD-45325


1. Use HARNESS CONNECTOR TEST KIT (Part No. HD-41404-B) and brown socket terminal.

2. Use HARNESS CONNECTOR TEST KIT (Part No. HD-41404-B), grey terminal probe and patch cord.


4. If code is historic, check for intermittent wiring faults.

ed02993


4

12

3

ed03002

1. Terminal 2: ground (BK/GN)2. Terminal 3: serial data (LGN/V)3. Terminal 4: power (GY)4. Protective cap

Figure 2-16. Serial Data Connector Terminals



O/W

O/W

O/W

Y/W

Y/W

O/Y

O/W

O/WO/W

5

5

Ser

iald

ata

12

12

11

11

7

7

6

6

5

5

InstrumentModule

Toignition

fuse

ToACCfuse

Frontstoplamp

switch

Rearstoplamp

switch

[39A][39B]

[13A][13B]

[78A][78B]

[166A][166B]

Data LinkConnector

FuelLevel

Sensor

ECM

[91A]

GY

BK

GY

LGN

/V

LGN/VLGN/V

LGN

/V

BK

/GN

BK

/GN

BK/GN

3

1

2

FLS

4

3

3

2

2

1

1

ABSModule

Ser

iald

ata

9

9

em00167

Figure 2-17. Fuel Sensor Circuit



Under seat3-place MolexFuel level sensor[13]

Under handlebar cover12-place Mini-DeutschInstrument module[39]

Under left side cover36-place PackardECM[78]

Under right side cover4-place DeutschData link connector[91]

Under right side cover20-place MolexABS module[166]



Fuel Level Sensor: DTC B1004

1

NOYES

4

Remove instrument bezel andhandlebar covers. Disconnect IMconnector [39]. Check continuity

between terminal “2” ofconnector [13B] and ground.

Continuity present?

Locate and repairshort to ground.

Repair/replace fuellevel sensor.

Inspect Accy Fuse.Is fuse Good?

YES NO

Inspect for short to ground on(O/W) wire from Accy Fuse.Is wire shorted to ground?

YES NO

Repair short toground.

While testing (O/W) for ashort to ground apply the

front and then the rearStop Lamp Switches.Did the (O/W) short to

ground when the switcheswere applied?

YES NO

Repair short toGround in appropriate

stop lamp switch circuit.

Inspect wiring andreplace fuse.

fc01601_en



Fuel Level Sensor: DTC B1005

2

NOYES

NOYES

NOYES

NOYES

2

3

2

2

4

Remove instrument bezel and handlebar covers.Disconnect IM connector [39]. Disconnect fuellevel sensor connector [13]. With ignition ON,measure voltage on terminal “2” of connector

[13B] (Y/W). Should be 0 volts.Is it?

Check continuity between terminal“2” of connector [13B] (Y/W) andbreakout box terminal “11” (BK).

Continuity present?

Locate and repair shortto voltage.

Locate and repair openon (Y/W) wire.

Check continuity to ground on terminal“3” of connector [13B] (BK/GN).


Check for battery voltage onterminal “1” of connector [13B].

Battery voltage present?

Locate and repair open on(BK/GN) wire (ground circuit).

Locate and repair open on (O/W)wire between [13B] and

accessory fuse.

Repair/replace fuel levelsensor.

fc01602_en



2.11DTC B1006, B1007

GENERAL

Accessory or Ignition Line OvervoltageBattery voltage is constantly monitored by the IM (terminal "6"ignition and terminal "12" accessory). If the battery voltage failsto meet normal operating parameters, a code is set.

• Code B1006 is displayed when accessory line voltage isgreater than 16.0 volts for longer than 5 seconds.

• Code B1007 is displayed when ignition line voltage isgreater than 16.0 volts for longer than 5 seconds.

NOTE

ECM or TSSM/HFSM may also set a battery voltage diagnosticcodes.

ed02993


4

12

3

ed03002




DESCRIPTIONDTC

Accessory line overvoltageB1006

Ignition line overvoltageB1007



Accessory or Ignition Line Overvoltage: DTC B1006, B1007

YES NO

YES NO

Is battery charger connected?

Disconnect battery charger. Clear codes.

NOTEA battery charger may, at times, causean overvoltage condition which will set

codes.

Start vehicle. Run at 3000RPM for 5 seconds. Does

code reset?

Diagnose charging system.See Charging System.

Diagnose charging system.See Charging System.

System normal.

fc01603_en



2.12DTC B1008

GENERAL

Trip Odometer Reset Switch ClosedCode B1008 will be set if trip odometer reset switch terminalsare in a constant shorted state.

MPH

010

20

RPM

1098

76

5

43

21 0

3040

5060 70 80 90

100110

120

130

140

150

ABS

3/4

F

1/2

1/4

ed01353

Figure 2-20.Trip Switch


DESCRIPTIONDTC

Trip odometer reset switch closedB1008



Trip Switch Closed: DTC B1008

YES NO

YES NO

Remove riser cover.Remove rubber boot. Clearcodes. Codes still present?

Cut wires as close to trip odometer resetswitch as possible. Clear codes. Codes still

present?

Replace instrument module. Replace switch.

Replace boot.

fc01604_en



2.13DTC U1016

GENERAL

Loss of ECM Serial DataSee Figure 2-22. The serial data connector provides a meansfor the IM, ECM ABS, and TSM/TSSM/HFSM to communicatetheir current status. When all operating parameters on theserial data link are within specifications, state of health mes-sages are sent between the modules. A DTC U1016 indicatesthat the ECM is not capable of sending this state of healthmessage.


DESCRIPTIONDTC

Loss of all ECM serial data (state of health)U1016

DIAGNOSTICS





1. Connect BREAKOUT BOX (Part No. HD-43876) wireharness and ECM. See 4.6 BREAKOUT BOX: ECM.

2. Connect BREAKOUT BOX (Part No. HD-42682) betweenwire harness and TSM/TSSM/HFSM. See3.12 BREAKOUT BOX: TSM/HFSM.

ed03005

Figure 2-21. ECM Connector

4

12

3

ed03002





IgnitionSwitch

SystemRelay

FuseBlock

To righthand

controls

Battery

40 AmpMAXIFUSE

15 AMPIGN Fuse

EngineStop

Switch

10

13

28

–+

[78A] [78B]ECM

30

85

86

C

P

R

Ground

Switch power

Ground

10

5Serial data 5

13

28

4

3

4

3

[22B] [22A]

[61B]

BK/GN

LGN/V LGN/V

LGN

/V

BK

/GN

BK

/GN

BK/GN

LGN/V

BN/GY

BN

/GY

BK

/GN

BK/GN

W/BK

W/BK R/BK

W/BK W/BK

BK

GY GY

GY

GY

GY

GY

GY

R

R

87I

InstrumentModule

TSM/TSSM/HFSM

DataLinkConnector

[91A][30A][30B]

21

34

To security fuse

To batteryfuse

[39A][39B]

7

7

5

5

1

1 2 3 12

1 2 3

Bat

tery

Igni

tion

Ser

iald

ata

Gro

und

12

1

R/O

em00168

Figure 2-23. ECM,TSSM/TSSM/HFSM and IM Circuit (VRSCR)



Under left side cover6-place MolexRight hand controls[22]


Handlebar cover12-place Mini-DeutschInstrument Module (IM)[39]

Under passenger seatSpade terminalsFuse block[61B]





Loss of ECM Serial Data: DTC U1016

YES NO

2

1

YES NO

YES NO

YES NO

Install Breakout Box on IM and ECM. Checkcontinuity between terminal “7” of IM BreakoutBox and terminal “5” Of ECM Breakout Box.

Continuity present?

Perform wiggletest.

Repair open onLGN/V wire.

Locate and repairintermittent.

Check for continuity to ground onterminal “10” of ECM. Wiggle

harness during continuity check.Continuity present?

With ignition switch ON, check forbattery voltage at terminal “13” of

ECM while wiggling harness. Batteryvoltage continuously present?

Locate andrepair open.

Replace ECM.Reprogram andlearn password.


fc01605_en



2.14DTC U1064

GENERAL

Loss of TSM/TSSM/HFSM Serial DataSee Figure 2-25. The serial data connector provides a meansfor the ECM, ABS, IM and TSM/TSSM/HFSM to communicatetheir current status. When all operating parameters on theserial data link are within specifications, state of health mes-sages are sent between the modules. A DTC U1064 indicatesthat the TSM/TSSM/HFSM is not sending this state of healthmessage.

A DTC U1064 indicates that there was communication on thedata bus since power up, but was lost or interrupted duringthat key cycle.


DESCRIPTIONDTC

Loss of TSM/TSSM/HFSM serial data (state ofhealth)

U1064

DIAGNOSTICS





1. Connect BREAKOUT BOX (Part No. HD-43876) betweenwire harness and ECM. See 4.6 BREAKOUT BOX: ECM.


sm01275

Figure 2-24.TSM/TSSM/HFSM

4

12

3

ed03002





EngineStop

SwitchW/BK

GY

IgnitionSwitch

SystemRelay

FuseBlock

To righthand

controls

Battery

40 AmpMAXIFUSE

15 AMPIGN Fuse

10

13

28

–+

[78A] [78B]ECM

30

85

86

C

P

R

Ground

Switch power

Ground

10

5Serial data 5

13

28

4

3

4

3

[22B] [22A]

[68B]

BK/GN

LGN/V

LGN/V

LGN

/V

BK/GN

BK

/GN

LGN

/V

LGN

/V

BN

/GY

BK

/GN

BK/GN

W/BK

W/BK R/BK

W/BK

BK

BK

GY

GY

GY

GY

R

R

87I

InstrumentModule

TSM/TSSM/HFSM

DataLinkConnector

[91A][30A][30B]

234

1

To security fuse

To batteryfuse

[39A][39B]

7

7

5

5

1

1 2 3 12

1 2 3B

atte

ryIg

nitio

nS

eria

ldat

a

Gro

und

12

1

R/O

ABS

9 1

9 1

[166B]

[166A]

em00169

Figure 2-26.TSM/TSSM/HFSM, ECM and IM Circuit





Handlebar cover12-place Mini-DeutschInstrument module[39]


Under left side cover36-place PackardElectronic Control Module (ECM)[78]





Loss of TSM/TSSM/HFSM Serial Data: DTC U1064

YES NO

2

1

YES NO

YES NO

YES NO

Install Breakout Box on TSM/TSSM/HFSM andIM. Check continuity between terminal “3” of

TSM/TSSM/HFSM Breakout Box and terminal“7” Of IM Breakout Box. Continuity present?

Perform wiggle test.Is intermittent

present?

Repair open onLGN/V wire.


Check for continuity to groundon terminal “12” of TSM/TSSM/HFSM. Wiggle harness during

continuity check. Continuitypresent?

Check for battery voltage atterminal “1” of TSM/TSSM/

HFSM while wiggling harness.Battery voltage continuously

present?


Replace TSM/TSSM/HFSM. Reprogram

and learn


fc01606_en



2.15DTC U1300, U1301 OR BUS ER

DIAGNOSTICSThe typical serial data voltage range is 0 volts (inactive) to 7volts (active). Due to the short pulse, voltages will be muchlower on a DVOM. In analog mode, a DVOM reading serialdata will show continuous voltage when active, typically 0.6-0.8 volts. The range for acceptable operations is 0-7.0 volts.

Diagnostic Tips• If serial data is shorted, these Diagnostic Trouble Codes

(DTCs) will automatically cause the check engine lamp toilluminate. The odometer will read "BUS Er" in this condi-tion.

• DTCs P1009 and P1010 may accompany DTCs U1300and U1301.

Diagnostic NotesIf a U1300, U1301 or "BUS Er" is present, perform diagnosticprocedures listed in 4.11 STARTS, THEN STALLS.

ed03044

Figure 2-27. Data Link Connector [91A] (typical)


DESCRIPTIONDTC


Serial data open/highU1301




NOTES


SUBJECT............................................................................................................................PAGE NO.3.1 TURN SIGNAL OVERVIEW.......................................................................................................3-13.2 HARLEY-DAVIDSON SMART SECURITY SYSTEM.................................................................3-23.3 H-DSSS ACTUATION................................................................................................................3-53.4 PERSONAL IDENTIFICATION NUMBER (PIN)........................................................................3-63.5 ARMING/DISARMING SECURITY SYSTEM............................................................................3-83.6 WARNINGS AND ALARMS.....................................................................................................3-103.7 SERVICE/EMERGENCY FUNCTIONS...................................................................................3-113.8 TROUBLESHOOTING.............................................................................................................3-123.9 CHECKING FOR DIAGNOSTIC TROUBLE CODES..............................................................3-133.10 INITIAL DIAGNOSTIC CHECK..............................................................................................3-163.11 INSTRUMENT MODULE (IM) SELF DIAGNOSTICS............................................................3-193.12 BREAKOUT BOX: TSM/HFSM..............................................................................................3-213.13 FAILS TO DISARM (HFSM ONLY)........................................................................................3-233.14 DTC B0563............................................................................................................................3-263.15 TSM/HFSM: TURN SIGNAL ERRORS AND DTCS..............................................................3-273.16 DTC B1131, B1132 (HFSM ONLY)........................................................................................3-413.17 DTC B1134 STARTER OUTPUT HIGH.................................................................................3-443.18 DTC B1135............................................................................................................................3-473.19 DTC B1136, B1142 (HFSM ONLY)........................................................................................3-483.20 DTC B1141 (HFSM ONLY)....................................................................................................3-493.21 DTC B1143, B1144, B1145 (HFSM ONLY)...........................................................................3-543.22 DTC B1154, B1155...............................................................................................................3-593.23 DTC U1016, U1255...............................................................................................................3-633.24 DTC U1300, U1301 OR BUS ER..........................................................................................3-663.25 TSM/HFSM: PASSWORD LEARN.........................................................................................3-673.26 HFSM MAINTENANCE.........................................................................................................3-68

TS

M/H

FS

M


NOTES


3.1TURN SIGNAL OVERVIEW

GENERALThe Turn Signal Module (TSM) has two major functions:

• Control turn signals.

• Serve as Bank Angle Sensor (BAS).

The optional, factory-installed, Harley-Davidson Smart SecuritySystem (H-DSSS) includes a Hands-Free Security Module(HFSM) which provides the same functions as the TSM, butalso includes security and immobilization functions.

SECURITY SYSTEM: JAPAN/KOREAThe security system on motorcycles sold in Japan and Koreameet the regulatory requirements of those countries. Thesystem incorporates a Turn Signal Security Module (TSSM).Complete details on operation, troubleshooting, and diagnosticsare found in the Appendix. See E.1 TSM/TSSM(JAPAN/KOREA) OVERVIEW.

TURN SIGNAL FUNCTIONS• Manual turn signal control: Manual activation/deactiva-

tion of left and right turn signal flashing sequences.

• Automatic turn signal cancellation: Automatic cancella-tion of left and right turn signal flashing sequences basedon either vehicle speed, vehicle acceleration or turn com-pletion.

• Hazard warning 4-way flashers: Four-way left and rightturn signal flashing capability.

• Turn signal lamp diagnostics: Self-diagnostics for shortcircuit and open lamp conditions on both left and right turnsignal systems. See 3.9 CHECKING FOR DIAGNOSTICTROUBLE CODES.

NOTE

The turn signals cannot be activated or deactivated when theIgnition Switch is in the ACC position. The turn signals canonly be activated or deactivated with the Ignition Switch in theIGNITION position.

MANUAL CANCELLATIONTo stop the turn signals from flashing, briefly depress the turnsignal switch a second time.

To switch turn direction signals, depress the switch for theopposite turn signal. The first signal is cancelled and theopposite side begins flashing.

AUTOMATIC CANCELLATIONPress the left or right turn switch to activate automatic turnsignal cancellation. There is no need to hold the turn switch in

when approaching the turn. The TSM/HFSM will not cancelthe signal before the turn is actually completed.

• When the directional switch is released, the system startsa 20 count. As long as the vehicle is traveling above 11.3km/h (7 MPH) the directional will always cancel after 20flashes if the system does not recognize any other input.

• If the vehicle speed drops to 11.3 km/h (7 MPH) or less,including stopped, the directionals will continue to flash.Counting will resume when vehicle speed reaches 12.9km/h (8 MPH) and will automatically cancel when the counttotal equals 20 as stated above.

• The turn signals will cancel within two seconds upon turncompletion. A sensor inside the TSM/HFSM cancels thesignal after the vehicle has been returned to an uprightposition.

NOTE

The bank angle cancellation function has an automatic calibra-tion feature. Ride the motorcycle for 0.4 km (.25 miles) atsteady speeds (upright) to calibrate the system. Performanceof bank angle function may not be optimal until this calibrationis performed. This self-calibration is performed automaticallyevery time the vehicle is started and ridden.

BANK ANGLE FUNCTIONS• Emergency engine shutdown: Will provide engine

shutdown when vehicle is tipped over.

• Emergency outputs disable: Will disable turn signallamps and starter motor when vehicle is tipped over.

BANK ANGLE RESTARTThe engine will shut off automatically if the vehicle is tippedover.The turn signals, starter motor, Electronic Control Module(ECM), fuel pump and coil will be disabled.

The odometer displays "tIP" when a tip over condition isdetected.

To restart the motorcycle after shutdown has occurred:

1. Return the motorcycle to an upright position.

2. Cycle the Ignition Switch OFF-ON before restarting themotorcycle.

CLUTCH/NEUTRAL INTERLOCK• Disables starter: Disables starter until either the clutch

lever is pulled in or transmission neutral is selected.

• Diagnostics: Provides diagnostics for clutch and neutralswitch faults.

SECURITY SYSTEM H-DSSSSee 3.2 HARLEY-DAVIDSON SMART SECURITY SYSTEM.

2008 VRSC Diagnostics: TSM/HFSM 3-1


3.2HARLEY-DAVIDSON SMART SECURITY SYSTEM

COMPONENTSThe Harley-Davidson Smart Security System (H-DSSS) con-sists of three components:

• Hands-Free Security Module: See Figure 3-1. A elec-tronic module that functions both as the Turn SignalModule (TSM) and as the Hands-Free Security Module(HFSM).

• Hands-Free Antenna: See Figure 3-1. Mounted underthe seat of the motorcycle.

• Hands-Free Fob: See Figure 3-2. A remote control device,intended to be carried by the rider whenever the vehicleis being operated.

NOTE

Do not relocate any of the Security System components.

ed02826

Figure 3-1. HFSM and Antenna

ed02044

Figure 3-2. Hands-Free Fob w/Serial Number Label

SECURITY IMMOBILIZATIONThe Hands-Free Security Module (HFSM) provides securityand immobilization functions not found on the Turn SignalModule (TSM). The HFSM will disable the starter and ignitionsystem. Additional functions include the ability to alternatelyflash the left and right turn signals and sound a siren (ifequipped) if a theft attempt is detected.

NOTE

The siren must be in the Chirp Mode for the siren to chirp onarming or disarming. See 3.6 WARNINGS AND ALARMS,Siren Chirp Mode (Confirmation).

Conditions that activate the security system when system isarmed include:

• Detecting tampering of the ignition circuit: Turn signalsflash three times, optional siren chirps once and then turnsoff. If the tampering continues, a second warning willactivate after four seconds. Continued tampering will causethe alarm to activate for 30 seconds and then turn off.Thetwo warnings/alarm cycle is repeated for each tamperingincident.

• Detecting vehicle movement: Turn signals flash threetimes, optional siren chirps once and then turns off. If thevehicle is not returned to its original position, a secondwarning will activate after four seconds. If the vehicle isnot returned to its original position, the alarm activates for30 seconds then turns off. The two warnings/alarm cyclemay repeat a maximum of 10 times with a 10 secondpause between cycles.

• Detecting that a battery or ground disconnect hasoccurred while armed: Siren, if installed, activates itsself-alarm mode. Turn signals will not flash.

3-2 2008 VRSC Diagnostics: TSM/HFSM


See 3.5 ARMING/DISARMING SECURITY SYSTEM for moreinformation.

NOTE

Disconnect the battery to prevent the siren (if installed) fromactivating within 5 seconds of turning the Ignition Switch toOFF/FORK LOCK. If the HFSM is armed, you must turn theIgnition Switch to IGNITION with a fob within range, again turnthe Ignition Switch to OFF/FORK LOCK and remove theMAXIFUSE before the 5-second arming period expires. Withthe MAXIFUSE removed, the battery can be disconnected.

HFSM FEATURESThe following information applies only to motorcycles equippedwith the Hands Free Security System (HFSM).

• Security lamp: See Figure 3-3. A lamp (key icon) withinthe speedometer face tells the rider if the system is armedor disarmed.

• Personal code disarming: If the fob is not available, theHFSM allows the rider to disable the security alarm andimmobilization functions with a five-digit personal code.

• Arming confirmation: When the HFSM is armed, thesystem provides visual feedback (confirmation) to the riderby flashing the turn signals and an audible "chirp" ifequipped with the optional smart siren and chirp mode isenabled.

• Disarming confirmation: When the HFSM is disarmed,the system provides an audible "chirp" (confirmation) ifequipped with the optional smart siren and chirp mode isenabled.

• Transport mode: It is possible to arm the security systemwithout enabling the motion detector for one ignition cycle.This allows the vehicle to be moved in an immobilizedstate.

• Starter/ignition disable: When armed the starter andignition system are disabled.

• Security system alarm: See Figure 3-4. The system willalternately flash the left and right turn signals and soundan optional Smart Siren if a vehicle security condition isdetected while the system is armed.

• Dealer service mode: This mode allows the dealer todisable security system via DIGITAL TECHNICIAN. Dealerservice mode is exited when module detects an assignedfob in range.

MPH

010

20

RPM

109

1 0

3040

5060 70 80 90

100110

120

130

140

150

ABSF

6

1 2

3 4

5

ed01267



ed02047

Figure 3-4. Security Siren



1

3

3

Battery

+ -

SecurityFuse

IGN Fuse

ACC Fuse

421

2

1 Receive antenna

Transmit antenna A

Transmit antenna B3

2

1

2

1

2

7 712

4

7

8

2

1

3

12

4

7

8

2

1

3

22

6

5

9

10

11

6

5

9

10

11

40 AmpMAXIFUSE

FuseBlock

IgnitionSwitch

Data LinkConnector

InstrumentModule

Right TurnSwitch

ClutchSwitch

BatteryBackedSiren(Optional)

Left TurnSwitch

NeutralSwitch

Receive

HandsFree

Antenna

HFSM

TSM/HFSM

Right TurnLamps

Left TurnLamps

BK

BK

BK

BN BN

BN

BN

BN

BK BK

BK

BK

BK

BK

BK

GY

TN

R

V

V V

V V

RR

R

R/BK

R/GY

BK/R

BN/GY

LGN/V

LGN/BN

LGN

/V

LGN/V

BK

/GN

Y/BK

O/Y

O/Y

O/W

O/W

W/BN

W/V

O/W

[91A]

[39A] [39B]

[209B] [209A]

[208B] [208A]

Serial data

Serial data

5 5ECM LGN/V

LGN/V

[78A] [78B]

Serial data 9 9ABSModule

[166A] [166B]

[142B] [142A]

[30B] [30A] [30A] [30B]

Alarmsignal

Battery

Clutchswitch

Ignition

Start relaycontrol

Left turnswitch input

Right turnswitch input

Serial data

Left turnfeed

Neutralswitch

Right turnfeed

Ground

30

87

86

85

StartRelay

StarterSolenoid

EngineStop Switch

StartSwitch

Tobatterypositive

Toignitionswitch

Toignition

fuse

ToECM

GN

BK

GY

R/BK

W/BK

W/BKW/BK

BK

/R

TN/GN

BK

em01301

Figure 3-5. Simplified TSM/HFSM Wiring



3.3H-DSSS ACTUATION

GENERALSetting up a vehicle TSM/HFSM depends on whether thevehicle has a Turn Signal Module (TSM) or the optional HandsFree Security Module (HFSM) security system installed.

SIDECAR CONFIGURATION

Only Touring Harley-Davidson Motorcycles are suitablefor sidecar use. Consult a Harley-Davidson dealer. Use ofmotorcycles other than Touring models with sidecarscould result in death or serious injury. (00040a)

All motorcycles ship with the H-DSSS set for use without asidecar installed. If a motorcycle is equipped with a TSM, nofurther actuation is required.

ACTUATIONActuation consists of assigning two FOBs to the system, andentering an initial PIN (Personal Identification Number). ThePIN can be changed by the rider at any time.

1. Configure HFSM motorcycles by assigning both fobs tothe vehicle.

2. Configure HFSM motorcycles by entering a PersonalIdentification Number (PIN) picked by the owner. Thepersonal code allows the owner to operate the system ifthe fob is lost or inoperable. Record the PIN in the Owner'sManual and instruct the customer to carry a copy (use thewallet card found in the Owner's Manual). See 3.4 PER-SONAL IDENTIFICATION NUMBER (PIN).

Once the system has been activated, it will always "arm" within5 seconds of turning the Ignition Switch to OFF and no motor-cycle motion.

FOB ASSIGNMENT



Use DIGITAL TECHNICIAN (Part No. HD-44750) to assignboth fobs to the H-DSSS. Follow the menu prompts in theDigital Technician display and scan the fob serial number withthe bar code reader, or key-in the number from the keyboard.See a Harley-Davidson dealer.

NOTE

Each fob has a unique serial number. The label should beremoved from the fob and attached to a blank NOTES pagein the Owner's Manual for reference.

POWER DISRUPTION AND CONFIGURING



The HFSM will not enter PIN entry mode on the first attemptafter battery voltage has been removed from terminal "1".Thiswill occur after any of the following:

• Battery disconnect or power drain.

• Battery fuse removal.

• Connecting BREAKOUT BOX (Part No. HD-42682) toHFSM connector.

Therefore, after all battery reconnects, the configurationsequence must be modified as follows:

1. Set Engine Stop Switch to OFF, cycle Ignition SwitchIGNITION-OFF-IGNITION-OFF-IGNITION and press leftturn signal switch twice.

2. Repeat steps listed above.

3. Continue with PIN entry sequence listed.



3.4PERSONAL IDENTIFICATION NUMBER (PIN)

GENERALThe Personal Identification Number (PIN) consists of five digits.Each digit can be any number from 1-9.There can be no zeros(0) in the PIN. The PIN must be used to disarm the securitysystem in case the fob becomes unavailable.

INITIAL PIN ENTRYTo enter a PIN on a motorcycle with no PIN previously installedduring HFSM actuation, refer to Table 3-1.

Table 3-1. Entering an Initial PIN: HFSM

WAIT FOR CONFIRMATIONACTIONSTEP

Select a 5-digit (1 through 9) initial PIN and record in the Owner'sManual and on the wallet card.

1

With an assigned fob present, set Engine Stop Switch to OFF.2

Cycle Ignition Switch IGNITION-OFF-IGNITION-OFF-IGNITION.3

Turn signals will flash 3 times.Press left turn signal button 2 times.4

Five dashes will appear in the odometerwindow. The first dash will flash.

Press right turn signal button 1 time.5

Enter first digit (a) of initial PIN by pressing left turn signal button atimes.

6

The digit (a) will replace the dash in theodometer. The second dash will flash.


Enter second digit (b) of initial PIN by pressing left turn signal buttonuntil desired digit is displayed in odometer.

8

The digit (b) will replace the dash in theodometer. The third dash will flash.


Enter third digit (c) of initial PIN by pressing left turn signal button ctimes.

10

The digit (c) will replace the dash in theodometer. The fourth dash will flash.


Enter fourth digit (d) of initial PIN by pressing left turn signal button dtimes.

12

The digit (d) will replace the dash in theodometer. The fifth dash will flash.


Enter fifth digit (e) of initial PIN by pressing left turn signal button etimes.

14

The digit (e) will replace the dash in theodometer. The first digit will flash.


Turn the Ignition Switch to OFF.16

CHANGING THE PINTo change a PIN, refer to Table 3-2.

Modifying an Existing PinIf a PIN was previously entered, the odometer will display theequivalent digit. Each additional press of the left turn switchwill increment the digit.

Examples:

• To advance from 5 to 6, press and release the left turnswitch 1 time.

• To advance from 8 to 2, press and release the left turnswitch 3 times (9-1-2).



Table 3-2. Changing the PIN: HFSM

NOTESCONFIRMATIONACTIONSTEP

Select a 5-digit (1 through 9) personalcode and record in the Owner's Manualand on the wallet card.

1

With fobs present, cycle Ignition SwitchIGNITION-OFF-IGNITION-OFF-IGNITION.

2

Turn signals will flash 3 times.Press left turn signal button 2 times.3

Current PIN will appear in odometer. Thefirst digit will flash.


Enter first digit (a) of new PIN by pressingleft turn signal button until desired digit isdisplayed in odometer.

5

The new digit will replace the current inthe odometer. The second digit will flash.


Enter second digit (b) of new PIN bypressing left turn signal button until thedesired digit is displayed in the odometer.

7

The new digit will replace the current inthe odometer. The third digit will flash.


Enter third digit (c) of new PIN by pressingleft turn signal button until desired digit isdisplayed in the odometer.

9

The new digit will replace the dash in theodometer. The fourth digit will flash.


Enter fourth digit (d) of new PIN bypressing left turn signal button untildesired digit is displayed in the odometer.

11

The new digit will replace the current inthe odometer. The fifth digit will flash.


Enter fifth digit (e) of new PIN by pressingleft turn signal button until desired digit isdisplayed in the odometer.

13

The new digit will replace the current inthe odometer. The first digit will flash.


Turning the Ignition Switch toOFF stores the PIN.

Turn the Ignition Switch to OFF.15



3.5ARMING/DISARMING SECURITY SYSTEM

HANDS-FREE FOBSee Figure 3-6. The HFSM's reception range for the Hands-Free Fob signal depends on a specific receiver pattern. Therange will be an arm's length.

NOTES

• Environmental and geographic conditions may affect signalrange.

• Always have the fob present whenever the motorcycle isoperated.

• Do not place fob in metal enclosure, and do not place itcloser than 80.0 mm (3.0 in.) to cellular phones, thehandsfree antenna, PDAs, displays and other electronicdevices while operating the motorcycle.That may preventthe fob from disarming the security system.

• Fob battery should be replaced every year. See3.26 HFSM MAINTENANCE.

ed02829

Figure 3-6. Hands-Free Fob

SECURITY LAMP (KEY ICON)Refer to Table 3-3. The security lamp (key icon) in thespeedometer face provides feedback to the rider confirmingarmed or disarmed status.

Table 3-3. Security Lamp Status

MODELAMP

No security system (TSM only), securitysystem not armed.

Does not flash.

2 minute timeout after failed PIN entryattempt or a battery reconnect hasoccurred while armed.

Flashes everysecond.

Security system armed.Flashes every 2.5seconds.

PIN entry mode.Flashes 4 times asecond.

Arming is starting up. You have 5seconds before system is armed.

Stays on solid withIgnition SwitchOFF.

If solid for more than 4 seconds afterIgnition Switch ON, a current DTC ispresent.

Stays on solid withIgnition Switch ON.

MPH

010

20

RPM

109

1 0

3040

5060 70 80 90

100110

120

130

140

150

ABSF

6

1 2

3 4

5

ed01267



ARMINGThe H-DSSS automatically arms within five seconds when themotorcycle is parked and the Ignition Switch is turned to OFFand motion is not detected.

Indicator: On arming, the turn signals flash twice and the SmartSiren will "chirp" twice if chirp function is activated. While



armed, the security lamp (key icon) will flash at a rate of 2.5seconds. Refer to Table 3-3.

DISARMINGThere are two ways to disarm the H-DSSS:

• Automatic Disarming.

• Using the Personal Identification Number (PIN).

Automatic DisarmingAlways have the fob present when riding, loading, fueling,moving, parking or servicing the motorcycle. Carry the fob ina convenient pocket.The H-DSSS disarms automatically whenthe Ignition Switch is turned to ON.

On disarming, the Smart Siren will chirp once (if chirp functionis activated) and the security lamp (key icon) will turn ON solidfor four seconds then go out. Refer to Table 3-3.

Disarming with a Personal IdentificationNumber (PIN)See 3.4 PERSONAL IDENTIFICATION NUMBER (PIN) toenter an initial PIN to actuate the system.

Refer to Table 3-3. If you make an error while disarming theHFSM using the PIN, the alarm will activate for 30 secondsafter the last digit is entered. After a failed attempt, the securitylamp will flash once every second for 2 minutes. During thistime, the vehicle will not accept any attempt to enter a PIN.



3.6WARNINGS AND ALARMS

WARNINGSA warning consists of three alternate flashes of the turn signalsand chirp from the optional Smart Siren. Warnings are issuedfrom an armed HFSM in the following order:

1. First Warning: A warning is issued whenever a personwithout a fob present attempts to move the motorcycle orturns the Ignition Switch to IGNITION.

2. Second Warning: If the motion continues or the IgnitionSwitch is not turned back to OFF, a second warning isissued within four seconds of the first.

3. Alarm: If the motion continues or the Ignition Switch isnot turned to OFF past the second warning, the SmartSecurity System will go into full alarm.

ALARM

ActivationIn the full alarm state, the turn signals flash alternately, and ifequipped with the Smart Siren, the siren will sound.

After 30 seconds of alarm, if no further motorcycle motion isdetected, the alarm will stop.

NOTE

Motorcycle must be returned to original parked position withIgnition Switch turned to OFF.

If motorcycle motion continues, the alarm will start again con-tinue for another 30 seconds.

The HFSM will repeat the alarm cycles 10 times for a total offive minutes, with a 10-second pause between alarm cycles.

NOTES

• During warnings and alarms, the starter motor and theignition remain disabled.

• The alarm will also activate the LED and vibration or aud-ible modes of a Harley-Davidson Security Pager. A pager

can operate either in silent or in combination with anoptional Smart Siren. The range of the pager can be upto 0.89 km (1/2 mile).

DeactivationThe alarm cycles can be discontinued at any time by movingan assigned fob to the motorcycle. The presence of the fobwill terminate the alarm.

SIREN CHIRP MODE (CONFIRMATION)

Chirpless ModeIn the chirpless mode, the siren does not chirp on arming ordisarming.

NOTE

Even when armed in the chirpless mode, the siren still chirpswarnings on movement and will activate the alarm throughcycles.

Chirp ModeOn arming in the chirp mode, the siren responds with twochirps.When disarming, the siren responds with a single chirp.

Switching ModesCycling quickly through two armings and disarmings will switchthe system from either the chirpless mode or the chirp modeto its opposite.

1. With the fob present, the Ignition Switch ON and thesystem disarmed, turn the Ignition Switch OFF.

2. When the system arms (2 flashes of turn signals), imme-diately turn the Ignition Switch back ON.

3. Wait until the security lamp goes out, then immediatelyturn the Ignition Switch OFF.

4. When the system arms (2 flashes of turn signals), imme-diately turn the Ignition Switch ON and wait for system todisarm.



3.7SERVICE/EMERGENCY FUNCTIONS

TRANSPORT MODE

To Enter Transport ModeIt is possible to arm the security system without enabling themotion detector for one ignition cycle. This allows the vehicleto be picked up and moved in an armed state, however, anyattempt to start the engine will trigger the alarm.

1. Turn the Ignition Switch to IGNITION.

2. Set the Engine Stop Switch to OFF.

3. With an assigned fob within range, turn the Ignition Switchfrom OFF to ACCESS.

4. Simultaneously, press both the left and the right turn signalswitches.This must be done within five seconds of turningthe Ignition Switch to ACCESS.

5. After the turn signals flash once, turn the Ignition Switchto OFF and the module is armed.

6. The turn signals flash three times to confirm modulearming in transfer mode for one ignition cycle.

To Exit Transport ModeReturn the system to normal operation:

1. With the fob present, turn the Ignition Switch to IGNITIONto disarm the HFSM. To cancel the transport mode, setthe Engine Stop Switch to RUN.

SERVICE MODE



With a fob present, the HFSM can be configured for serviceby disabling the security system with DIGITAL TECHNI-CIAN (Part No. HD-44750).

Once disabled, the motorcycle can be operated without anassigned fob present. To maintain the Service Mode, theassigned fobs must be kept out of range. If the fob appears inrange, the Service Mode will be exited.

FOUR-WAY FLASHING

To Arm the HFSM with the Hazard WarningFlashers ONIf it is necessary to leave a motorcycle parked along side theroad, the hazard warning four-way flashers can be turned ONwith the Smart Security System armed.

1. Turn the Ignition Switch to IGNITION.

2. Simultaneously press both left and right turn signalswitches to turn the four-way flashers ON. The four-wayflashers will continue for two hours.

3. Turn the Ignition Switch to OFF to arm the Smart SecuritySystem.

To Disarm the HFSM and Turn the HazardWarning Flashers OFF1. With a fob present, turn the Ignition Switch to IGNITION.

2. Simultaneously press the left and right turn signal switches.



3.8TROUBLESHOOTING

TURN SIGNALS (TSM/HFSM)Verify the operation of the turn signals and the integrity of thefuse protecting the turn signals before further troubleshooting.

SECURITY SYSTEM (HFSM)If the fob is present, and the security system is issuing "warn-ings" or "Alarm" when the motorcycle is moved, the reasonmay be one of the following:

1. Strong electromagnetic interference in the area you haveparked.

a. Verify you have not placed your fob in metalenclosure, or within 80.0 mm (3.0 in.) of other elec-tronic devices.

b. Place fob next to motorcycle and turn the IgnitionSwitch ON. After the system disarms, the fob can beplaced back in its carrying location.

c. Try moving the motorcycle approximately 4.57 m (15feet) away from the current parking spot.

2. The fob battery is dead. Use PIN to disarm the vehicle.Replace fob battery.

3. Fob is damaged. Use PIN to disarm the vehicle. Replacethe fob.

NOTES

• If your Security Icon is staying solid ON while you areriding the vehicle, take your vehicle to your dealer as soonas practical.

• Always lock the fork and take the ignition key with you foradded protection.

DIAGNOSTICS MODEThe TSM/HFSM measures the current when the turn signalsare used. If there is a burned out light bulb on one side, the

remaining light and the corresponding turn signal indicator flashat double the normal rate starting with the fifth flash.

Other diagnostic conditions monitored include:

• Short circuit in the turn signal wiring.

• Open circuit in the turn signal wiring.

• Stuck turn signal switch.

NOTES

• A stuck turn signal switch will disable the automatic turnsignal cancellation feature.

• If a stuck switch is detected, you must hold the left andright turn signal switches in for more than one second toactivate the four-way flashers.

See 3.9 CHECKING FOR DIAGNOSTIC TROUBLE CODESfor more information.

TROUBLESHOOTINGTo resolve TSM/HFSM faults, follow four basic steps:

1. Retrieve Diagnostic Trouble Codes (DTCs) usingspeedometer self diagnostics. See 3.11 INSTRUMENTMODULE (IM) SELF DIAGNOSTICS.

2. Diagnose system problems. This involves using specialtools and the diagnostic flow charts in this section.

3. Correct problems through the replacement and/or repairof the affected components.

4. After repairs are performed, the work must be validated.This involves clearing the diagnostic trouble codes andconfirming proper vehicle operation as indicated by thebehavior of the turn signals.



3.9CHECKING FOR DIAGNOSTIC TROUBLE CODES

GENERALProblems fall into at least one of five categories:

• Turn signal malfunction.

• Bank angle (engine disable).

• Clutch/neutral interlock (starter enable).

• Security lamp problem.

• Security system malfunction.

SECURITY LAMP DIAGNOSTICSTo diagnose system problems, start by observing the behaviorof the security lamp.

NOTES

• See Figure 3-8. "Key ON" means that the Ignition Switchis turned to IGNITION and the Engine Stop Switch is setto RUN (although the engine is not running).

• See Figure 3-9. When the Ignition Switch is turned toIGNITION, the security lamp will illuminate for approxim-ately four seconds and then turn off.

• If the security lamp is not illuminated at IGNITION ON orif it fails to turn OFF after the initial four-second period,the speedometer may need to be replaced. See3.11 INSTRUMENT MODULE (IM) SELF DIAGNOSTICS.If "BUS Er" is displayed on the odometer, it may take upto twenty seconds for the security lamp to illuminate.

• The security lamp will also light for eight seconds after thebulb check if historic Diagnostic Trouble Codes (DTCs)are present.The security lamp will stay on if current DTCsare set. If a historic DTC is present, the security lamp willlight for 2 ignition cycles or until the DTC is clearedmanually.

1. See Figure 3-10. After the lamp turns off after being illu-minated for the first four-second period, one of threeevents may occur:

a. The lamp remains off. This indicates there are nocurrent fault conditions or stored historic DTCs cur-rently detected by the HFSM.

b. The lamp stays off for only four seconds and thencomes back on for an eight-second period. Thisindicates a historic DTC is stored, but no current DTCexists.

c. If the lamp remains on beyond the eight-secondperiod. This indicates a current DTC exists.

NOTE

See 3.9 CHECKING FOR DIAGNOSTIC TROUBLE CODES,Code Types for a complete description of DTC formats.

2

3

1

ed02991



MPH

010

20

RPM

109

1 0

3040

5060 70 80 90

100110

120

130

140

150

ABSF

6

1 2

3 4

5

ed01267





ONA

B

C

ON

ON

OFF

OFF

OFF

Key On

Key On

Key On


Lamp OFF




4 Sec.

4 Sec.

4 Sec.

4 Sec.

8 Sec.

4 Sec.

ed01434

Figure 3-10. Security Lamp Operation

CODE TYPES



There are two types of DTCs:

• Current

• Historic

If a DTC is stored, it can be read using either a computer-baseddiagnostic package called DIGITAL TECHNICIAN (Part No. HD-44750) or speedometer self diagnostics. See 3.11 INSTRU-MENT MODULE (IM) SELF DIAGNOSTICS.

NOTES

• Speedometer self diagnostics will display both current andhistoric DTCs.To differentiate between current and historicDTCs, a computer-based diagnostic package calledDIGITAL TECHNICIAN (Part No. HD-44750) must beemployed.

• All DTCs reside in the memory of the Electronic ControlModule (ECM), TSM/HFSM, speedometer or tachometeruntil the DTC is cleared by use of the speedometer selfdiagnostics. See 3.11 INSTRUMENT MODULE (IM) SELFDIAGNOSTICS.

• A historic DTC is also cleared after a total of 50 ignitioncycles has elapsed. After the 50 ignition cycle retentionperiod, the DTC is automatically erased from memoryproviding that no subsequent faults of the same type aredetected in that period.

CurrentCurrent DTCs are those which are present during the currentignition cycle. See the appropriate flow charts for solutions.

HistoricIf a particular problem happens to resolve itself, the activestatus problem is dropped and it becomes a historic DTC ratherthan a current DTC. For example, intermittent output shortscan become typical historic DTCs.

Historic DTCs can only be retrieved using a computer-baseddiagnostic package called DIGITAL TECHNICIAN (Part No.HD-44750).

Historic DTCs are stored for 50 ignition cycles after any DTCwas last set as current to assist in the diagnosis of intermittentfaults. On the 50th cycle, the DTC will clear itself. The securitylamp will only indicate the existence of historic DTCs for twoignition cycles.

It is important to note that historic DTCs will exist wheneverthe system indicates the existence of a current fault. See3.9 CHECKING FOR DIAGNOSTIC TROUBLE CODES, Mul-tiple DTCs/Priority Order if multiple DTCs are found.

Diagnostic charts are designed for use with current DTCs andas a result they frequently suggest part replacement. Whendiagnosing a historic DTC the charts can be helpful but shouldnot lead to part replacement without verification the part isfaulty.

RETRIEVING DTCS



The TSM/HFSM supports two levels of diagnostics.

• The most sophisticated mode employs a computer-baseddiagnostic package called DIGITAL TECHNICIAN (PartNo. HD-44750).

• The second mode requires using the speedometer selfdiagnostics. Speedometer, tachometer, TSM/HFSM, ECM



and ABS (if equipped) DTCs can be accessed and cleared.See 3.11 INSTRUMENT MODULE (IM) SELF DIA-GNOSTICS.

MULTIPLE DTCS/PRIORITY ORDERWhile it is possible for more than one fault to occur and setmore than one DTC, there are several conditions which mayresult in one fault setting multiple DTCs:

Serial data DTCs (U1016, U1255, U1300 and U1301) may beaccompanied by other DTCs. Always correct the serial dataDTCs before resolving the other DTCs.

Refer to Table 3-4. This table lists the DTCs in priority order.Correct DTCs in priority order.

Table 3-4.TSM/HFSM DTCs and Fault Conditions

DIAGNOSTICSFAULT CONDITIONDTCPRIORITY

3.24 DTC U1300, U1301 OR BUS ERJ1850 Short-to-groundU13001

3.24 DTC U1300, U1301 OR BUS ERJ1850 Short-to-batteryU13012

3.23 DTC U1016, U1255Loss of serial communications - ECMU10163

3.23 DTC U1016, U1255Loss of serial communications - Gen-eral

U12554

3.19 DTC B1136, B1142 (HFSM ONLY)HFSM2 Internal faultB11425

3.18 DTC B1135Accelerometer periodic test faultB11356

3.19 DTC B1136, B1142 (HFSM ONLY)Accelerometer tip-over self-test faultB1136 (HFSM)7

3.22 DTC B1154, B1155Clutch switch input short-to-groundB11548

3.22 DTC B1154, B1155Neutral switch input short-to-batteryB11559

3.17 DTC B1134 STARTER OUTPUT HIGHStarter relay output short-to-batteryB113410

3.15 TSM/HFSM: TURN SIGNAL ERRORS ANDDTCS

Left turn lamp output open circuitB1121 (TSM)11


Left turn lamp output open circuitB1121 (HFSM)


Right turn lamp output open circuitB1122 (TSM)12


Right turn lamp output open circuitB1122 (HFSM)


Left turn lamp output short-to-groundB1123 (HFSM)13


Right turn lamp output short-to-groundB1124 (HFSM)14


Left turn lamp output short-to-batteryB1125 (HFSM)15


Right turn lamp output short-to-batteryB1126 (HFSM)16

3.21 DTC B1143, B1144, B1145 (HFSM ONLY)Security antenna short-to-groundB1143 (HFSM)17

3.21 DTC B1143, B1144, B1145 (HFSM ONLY)Security antenna short-to-batteryB1144 (HFSM)18

3.21 DTC B1143, B1144, B1145 (HFSM ONLY)Security antenna openB1145 (HFSM)19

3.14 DTC B0563Battery voltage highB056320

3.16 DTC B1131, B1132 (HFSM ONLY)Alarm output short-to-groundB1131 (HFSM)21

3.16 DTC B1131, B1132 (HFSM ONLY)Alarm output short-to-batteryB1132 (HFSM)22


Ignition switch open/lowB1141 (TSM)23

3.20 DTC B1141 (HFSM ONLY)Ignition switch open/lowB1141 (HFSM)



3.10INITIAL DIAGNOSTIC CHECK

GENERAL



To locate faulty circuits or other system problems, follow thediagnostic flow charts in this section. For a systematicapproach, always begin with 3.10 INITIAL DIAGNOSTICCHECK, Initial Diagnostics which follows. Read the generalinformation and then work your way through the flow chart boxby box.



In order to perform most diagnostic routines, a Breakout Boxand a digital volt/ohmmeter (DVOM) are required. See3.12 BREAKOUT BOX: TSM/HFSM.


Job/Time CodesSome charts may contain warranty job/time codes. Dealershiptechnicians filing warranty claims should use the job/time codevalues printed in bold text underneath the appropriate repair.

Reprogramming ECMDiagnostic charts frequently suggest Electronic Control Module(ECM) replacement. In the event an ECM needs to be replaced,it must be reprogrammed using a computer-based diagnosticpackage called DIGITAL TECHNICIAN (Part No. HD-44750).See your dealer. Password learn procedure must also be per-formed. See 3.25 TSM/HFSM: PASSWORD LEARN.

INITIAL DIAGNOSTICS

Diagnostic Tips• If odometer reads "BUS Er" with the Ignition Switch turned

to IGNITION (Engine Stop Switch at RUN with the engineoff), check data bus for an open or short to groundbetween data link connector [91A] terminal "3" and ECMconnector [78B] terminal "5", HFSM connector [30B] ter-minal "3", speedometer connector [39B] terminal "2" ortachometer (if equipped) connector [108B] terminal "2".

• Check for an open diagnostic test terminal between datalink connector [91A] terminal "3" and TSM/HFSM con-nector [30B] terminal "3". With Ignition Switch turned toIGNITION, serial data bus voltage should be typically 0.6-0.8 volts. The range of acceptable voltage is 0-7.0 volts.

• To identify intermittents, wiggle wire harness while per-forming steps in the diagnostic check charts.


1. Compare TSM/HFSM system behavior to symptoms inTable 3-5.

Table 3-5. Symptoms That May Not Set Diagnostic Trouble Codes

SOLUTIONSYMPTOM

HFSM Fails to DisarmHFSM: Fails to disarm

Turn Signal Error 1A (Part 1 of 2) Will Not Cancel Upon TurnCompletion

TSM/HFSM: Turn signal will not cancel

Turn Signal Error 1A (Part 2 of 2) Cancels ErraticallyTSM/HFSM: Turn signal cancels erratically

Turn Signal Error 2A Flash at Double Normal Rate, All BulbsWork

TSM/HFSM: Turn signal flashes double normal rate, all bulbsgood

Turn Signal Error 3A Will Not Flash, 4-Way Flashers Inoperable:DTC B1121, B1122, B1141

TSM: Turn signals will not flash

Will Not Flash, No Codes: DTC B1141HFSM: Symptom will not flash. No codes or DTC B1141

Other Diagnostic Trouble Codes (DTCs)See 2.3 BREAKOUT BOX: IM for any DTCs related to thespeedometer.

See 4.8 INITIAL DIAGNOSTIC CHECK for any DTCs relatedto the Electronic Control Module (ECM).



3

99

7

7

Ser

iald

ata

5

Ser

iald

ata

Serial data

Gro

und

Gro

und

10 28

5 10 28

4

3

2

1

12

3

Ser

iald

ata

12

Gro

und

TSM/HFSM

ECM

Data LinkConnector

[78B]

[166A] [166B]

[91A]

[78A]

[39B]

[39A]

[30B]

[30A]

InstrumentModule(Typical)

ABS Module

LGN

/V

LGN/V

LGN

/V

LGN

/V

LGN/V

BK

/GN

BK/GN

BK

/GN

BK

/GN

GY

Toignition

fuse

em00063

Figure 3-11. Initial Diagnostic Check



Under passenger seat12-place DeutschTSM/HFSM[30]



Behind left side cover4-place DeutschData link connector[91]

Behind right side cover20-place MolexABS module[166]



Initial Diagnostic Check

Does enginestart?


DTC’s found?


YES.Starts and

runs.

Is IMfunctional?


Refer to applicable DTC prioritychart. All DTC’s are listed in Table3-5. DTC’s are listed by priority.

Go to 2.6 NO IMPOWER.


codes, refer to Table 2-4.Function Chart-Loss Of

Input.



B1008.

YES.Starts, then

stalls.


NO.Engine will not

crank.



1

YES NO

YES

NOYES

NO

fc01658_en




GENERALThe Instrument Module (IM) is capable of displaying andclearing speedometer, tachometer, TSM/HFSM, ABS, andElectronic Control Module (ECM) Diagnostic Trouble Codes(DTCs) (diagnostic mode).

DIAGNOSTICS

Diagnostic Tips• For a quick check of speedometer function, a "WOW" test

can be performed. Press and hold trip odometer resetswitch then turn Ignition Switch to ACC. Release tripodometer reset switch. See Figure 3-12. Backgroundlighting should illuminate, gauge needles should sweeptheir full range of motion, and indicator lamps (battery,security, low fuel and check engine) should illuminate. Alllamps should illuminate, even those not used in normalvehicle operations.

• If speedometer fails "WOW" test, check for battery, ground,ignition, trip odometer reset switch, and accessory wiringto speedometer. If any feature in the Instrument Moduleis non-functional, see 3.10 INITIAL DIAGNOSTIC CHECK.



2. To clear DTCs for the selected module, press the tripodometer reset switch for more than 5 seconds when aDTC is displayed. This procedure will clear all DTCs forthe selected module.

MPH

010

20

RPM

109

1 0

3040

5060 70 80 90

100110

120

130

140

150

ABSF

6

1 2

3 4

5

ed01267

1. Check engine lamp2. Low fuel lamp3. Battery lamp4. Security lamp (key icon)5. ABS6. Trip odometer reset switch

Figure 3-12. Speedometer



Instrument Module Self-Diagnostics

1


RUN position.


YES

”P” flashing.





seconds.



Switch.

”S” flashing.



Switch.

”C” flashing.





than 5 seconds.




CHECK: SPEEDOMETER.

YES

YES

NO

NO

NO

Deviceresponse?

Press andrelease


displayed.

Press andrelease












SYSTEM (ABS)GENERAL

INFORMATION.


DTCdisplayed.


2

fc01657_en

”b” flashing.








3.12BREAKOUT BOX:TSM/HFSM

GENERAL



The BREAKOUT BOX (Part No. HD-42682) splices into themain harness. Used in conjunction with a Digital Volt/Ohmmeter(DVOM), it allows circuit diagnosis of wiring harness and con-nections without having to probe with sharp objects.

INSTALLATIONNOTE

For HFSM: Disarm security system, then remove MAXIFUSEwhile the system remains disarmed.

1. Access TSM/HFSM. See Service Manual.

2. Disconnect harness connector(s) from TSM/HFSM:

a. For HFSM: Depress latches on antenna connector[208B] and remove from antenna connector [208A](4).

b. Depress latches on main harness connector [30B]and remove from main connector [30A] (1).

3. See Figure 3-13. Attach Breakout Box to connectors.

a. Mate gray socket housing on Breakout Box withTSM/HFSM connector [30A].

b. Mate gray pin housing on Breakout Box with vehicleharness connector [30B].

4. For HFSM: Mate antenna connector [208B] to HFSM.

ed02823

Figure 3-13. Breakout Box Connection Point at TSM/HFSM

REMOVAL1. See Figure 3-14. For HFSM: Depress latches on antenna

connector [208B] and disconnect from HFSM antennaconnector [208A].

2. Disconnect Breakout Box from vehicle:

a. Depress latches and detach gray Breakout Box socketconnector from TSM/HFSM main harness connector[30A] (1).

b. Detach gray Breakout Box connector from TSM/HFSMmain harness connector [30B] (3).

3. For HFSM: Mate the antenna connector [208B] beforemain harness connector [30B].

4. Mate main harness connector [30B] to TSM/ HFSM.

5. Reinstall TSM/HFSM. See the Service Manual.

6. Install parts removed for access.

NOTE

Vehicle will not start with TSM/HFSM disconnected or incor-rectly mounted.

2

1 3

4

ed02050

1. Connector [208A] terminal 12. Connector [208A] terminal 43. Connector [30A] terminal 124. Connector [30A] terminal 1

Figure 3-14.TSM/HFSM Terminal Cavity Numbers

Table 3-7.TSM/HFSM Connector [30B]

FUNCTIONTERMINALFUNCTIONTERMINAL

Right turn switch input7Battery 12V1

Left turn switch input8Battery 12V switched2

Start relay ground9Serial data3

Clutch switch input10Neutral switch input4



Table 3-7.TSM/HFSM Connector [30B]


Alarm signal output11Left turn feed output5

Chassis ground12Right turn feed output6



3.13FAILS TO DISARM (HFSM ONLY)

GENERALIf the HFSM does not respond or responds weakly (limitedrange - will not consistently disarm with fob within normalrange), follow the flow chart.

JOB/TIME CODESDealership technicians filing warranty claims should use thejob/time codes printed in bold text underneath the appropriaterepair.

DIAGNOSTICS

Diagnostic Tips• Verify that cell phone is not within 80.0 mm (3.0 in.) of

key fob.

• Interference from physical surroundings may affect RFtransmission. Place fob next to motorcycle or movemotorcycle to a new location and retest.

• See Figure 3-15.Verify that antenna is in OE location andthat seat has not been replaced with a metal base seat.

• Check for damage to antenna wire.

• See Figure 3-16. Verify fob battery (1) voltage is at least2.9 volts. See 3.26 HFSM MAINTENANCE.

• Fob serial number (2) is located inside fob. Open fob bytwisting a thin blade in the thumbnail slot between fobhalves.


1. After a battery disconnect, the HFSM will not enter theconfiguration mode on the first attempt. All attempts toassign a fob or enter the configuration mode will requireat least two attempts.

ed02826

Figure 3-15. HFSM and Antenna

1

2

ed02051

1. Battery2. Fob serial number

Figure 3-16. Open Fob: HFSM



HFSM

TransmitAntenna

15 AmpSecurity

Fuse

40 AmpMAXIFUSEBattery

BK

BK

R

BN

/GY

BK

/GN

[30A]

[30B]

[208A]

[208B]

[209B]

[209A]

1 12

1

1

1

Rec

ieve

ante

nna

Gro

und

Bat

tery

Tran

smit

ante

nna

ATr

ansm

itan

tenn

aB

2

2

1

1

2

2

3

312

R

– +

O/Y

BK

O/Y

Y/B

K

ReceiveAntenna

em00064

Figure 3-17. Antenna Circuit: HFSM



Under passenger seat12-place DeutschHFSM[30]


Under passenger seat2-place MolexSecurity antenna[209]



HFSM Fails to Disarm

Does any assignedFob work?

YES

Check battery on non-functional Fob.Is battery voltage greater than 2.9 volts?

Replace Fob. Replace Battery.

YES NO

NO

Check for continuity betweenconnector [208B] terminal “1"

and end of (Y/BK) wire (pull backconduit to expose unterminated

end of wire).Continuity present?

YES

Check for continuity between connector[208B] terminal “1” and Ground.

Continuity present?

NO

Locate and repair open wirebetween connector [208B]

and end of (Y/BK) wire.

YES

Locate and repairshort to Ground.

NO

Replace HFSM.Learn password and

perform set-up.

6757

6879

67556756

6879

1

fc01102_en

NOTEThe fob for the HFSM must be assigned using DIGITALTECHNICIAN (Part No. HD-44750). DIGITAL TECHNICIANcan also validate fob operation when connected to the motorcycle.

Replace the security antenna with aknown good security antenna.

Does the security system now disarm?

YES NO

Replace thesecurity antenna.

6879



3.14DTC B0563

GENERAL

DTC B0563 Battery Voltage HighThe TSM/HFSM continually checks the battery voltage duringIGN/OFF and IGN/RUN power modes. If the voltage exceeds16.0 volts for more than 5.0 ±0.5 seconds, the TSM/HFSMsets Diagnostic Trouble Code (DTC) B0563.

DIAGNOSTICS

Diagnostic Tips• This DTC may set when the vehicle is placed on a battery

charger, on fast charge, for a long period of time.

• The HFSM does not illuminate the security lamp when thisDTC is set.

Diagnostic NotesSee 1.7 CHARGING SYSTEM tests to correct. Problem maybe faulty voltage regulator.



3.15TSM/HFSM:TURN SIGNAL ERRORS AND DTCS

GENERALThe turn signals will automatically cancel either based on thespeed/acceleration of the vehicle or based upon turn comple-tion. See 3.1 TURN SIGNAL OVERVIEW.

TSM/HFSM: For turn signal diagnostics based on symptoms,refer to Table 3-9.

TSM DTCs Only: Refer to Table 3-10.

HFSM DTCs Only: Refer to Table 3-11.

Table 3-9.Turn Signal Symptoms:TSM/HFSM

START WITH FLOW CHARTSYMPTOMDTC

Turn Signal Error 1A. (Part 1 of 2) Will Not CancelUpon Turn Completion

Will not cancel on turn completionN/A

Turn Signal Error 1A. (Part 2 of 2) Cancels Erratic-ally

Cancels erraticallyN/A

Turn Signal Error 2A. Flash at Double Normal Rate,All Bulbs Work

Flash at double normal rate while all bulbs areworking

N/A

Table 3-10.Turn Signal DTCs:TSM Only


Turn Signal Error 3A. Will Not Flash, 4-WayFlashers Inoperable: DTC B1121, B1122, B1141

Turn signals will not flash, 4-way flashers inoper-able

B1121


B1122


B1141

Table 3-11.Turn Signal DTCs: HFSM Only


Turn Signal Error 4A. Turn Signal Lamp Open Cir-cuit DTC: B1121 Left/ B1122 Right

Left turn signal openB1121

Turn Signal Error 4A. Turn Signal Lamp Open Cir-cuit DTC: B1121 Left/ B1122 Right

Right turn signal openB1122

Turn Signal Error 5A. Turn Signal Lamp Short-to-Ground DTC: B1123 Left/B1124 Right

Left turn signal short-to-groundB1123

Turn Signal Error 5A. Turn Signal Lamp Short-to-Ground DTC: B1123 Left/B1124 Right

Right turn signal short-to-groundB1124

Turn Signal Error 6A. Turn Signal Lamp Short-to-Voltage DTC: B1125 Left/B1126 Right

Left turn signal short-to-voltageB1125

Turn Signal Error 6A. Turn Signal Lamp Short-to-Voltage DTC: B1125 Left/B1126 Right

Right turn signal short-to-voltageB1126



DIAGNOSTICS



Job/Time CodesDealership technicians filing warranty claims should use thejob/time code printed in bold text underneath the appropriaterepair in the diagnostic flow charts.

Diagnostic Tips• TSM Only:DTC B1121 and B1122 will illuminate the

security lamp. DTC B1141 will not illuminate the securitylamp.

• HFSM Only: DTC B1121, B1122, B1123, B1124, B1125,and B1126 will illuminate the security lamp.

• TSM/HFSM: When an over current or short-to-groundcondition is detected, it will turn off the turn lamp outputs.

Diagnostic Notes: All Turn Signal FlowChartsEach reference number below correlates to a circled numberon the flow chart(s).

1. Gain access to vehicle's TSM/HFSM. Perform the followingprocedure:

a. See Figure 3-18. Position TSM/HFSM in same orient-ation it is mounted on vehicle.Turn on ignition switch.Turn on 4-way flashers by depressing both left andright turn signal switches simultaneously.Turn ignitionswitch off; 4-way flashers should continue to flash.

b. Tilt module greater than 45 degrees to the left.

c. Repeat step a.

d. Tilt module greater than 45 degrees to the right.

2. To enable diagnostic mode, see 3.9 CHECKING FORDIAGNOSTIC TROUBLE CODES.

3. Connect BREAKOUT BOX (Part No. HD-42682) , gray,between TSM/HFSM connector [30A] and wiring harnessconnector [30B]. See 3.12 BREAKOUT BOX:TSM/HFSM.

4. Closely inspect handlebar controls for pinched wiring.

5. Connect gray HARNESS CONNECTORS AND PATCHCORDS (Part No. HD-41404-B) to connector [22] (right)or connector [24] (left).

6. Replace HFSM if DTC is current (lamp ON continuously,cleared codes return during operation). If DTC is historic,check for intermittents.

ed02900

Figure 3-18.Tilting TSM/TSSM



[22B

]

Sec

urity

15A

[24B

]

[91A

]D

ata

Link

Con

nect

or

LK

Igni

tion

15A

Rig

htH

and

Con

trol

s

Left

Han

dC

ontr

ols

BN

/GY

40A

mp

MA

XIF

US

E

[5B

]

Fron

tTu

rnS

igna

ls [31A

]

Turn

Sig

nal

&LP

Lam

p [94A

][3

9A]

AB

[30A

][3

0B]

[39B

]

55

GN

D1

GN

D3

3

RturnLturn

IgnitionSerialdata

Inst

rum

entM

odul

e

AB

25

53

34

67

34

67

Igni

tion

Sw

itch

Vol

tage

Reg

ulat

or

[33B

][3

3A]

I

BB

A

[778

]

[61B

]

[62B

]

-+

Left

Fron

tTu

rnS

igna

l

Rig

htFr

ont

Turn

Sig

nal

Mai

nH

arne

ss

[31B

]6521

Left

Rea

rTu

rnS

igna

l

Rig

htR

ear

Turn

Sig

nal

[94B

]

3 4 5 6

BK

/GN

BN

W/V

R

R

R

V

R

V

BN

V

V

BN

GY

GY

GY

BN

BN

BK

BK

VBN

BK

BK

V

BK

/GN

BK

/GN

BK

/GN

BN

/GY

LGN

/V

LGN/V

LGN

/V

LGN/V

W/BN

W/V

W/B

N

R/BK

R/B

K

BK

Bat

tery

Igni

tion

VS

S/S

eria

ldat

alin

k

Left

turn

feed

Rig

httu

rnfe

edR

ight

turn

switc

hin

put

Left

turn

switc

hin

put

Ser

iald

ata

link

Pow

ergr

ound

Pow

ergr

ound

Gro

und

1212

55

1010

2828

88

77

66

55

33

22

11

ElectronicControlModuleTurnSignal/SecurityModule(TSM/HFSM)

[78A

][7

8B]

99

Ser

iald

ata

[166

A]

[166

B]

AB

SM

odul

eLG

N/V

em00080

Figure 3-19.Turn Signal Circuit





Under right side coverSpade terminalsMAXIFUSE[5]

Under left side cover6-place MolexRight hand controls[22B]

Under left side cover8-place MolexLeft hand controls[24B]


Under handlebar cover6-place MultilockFront turn signals[31]

Back of instrument module12-place Mini-DeutschInstrument Module (IM)[39]


Under right side coverSpade terminalsFuse block (Start relay, Fan relay)[62B]


Behind radiator cover2-place DeutschVoltage regulator[77]


Under left side cover4-place DeutschData link connector[91A]

Inside tail lamp lens6-place MultilockRear turn signals[94]

Behind right side cover20-place MolexABS module (if equipped)[166]



Turn Signal Error 1A (Part 1 of 2) Will Not Cancel Upon Turn Completion

Is TSM/HFSM mounted properly?

YES NO

Mount correctly.Check if TSM/HFSM is configuredcorrectly. See 3.3 H-DSSS

ACTUATION.Proper configuration?

YES NO

Select propervehicle configuration.

Do 4-way flashers cancel inboth directions?

YES NO

Operate motorcycle at a speedgreater than 7 MPH (11.2 km/h) in a

straight line. Activate either turnsignal. Turn signals should cancel

after 20 flashes.Do turn signals cancel?

Replace TSM/HFSM.Perform setup and

password learn.

6773

YES NO

Does speedometerregister vehicle

speed?

YES

Replace TSM/HFSM.Perform password learn

and setup.

NO

Refer to 3.10 INITIALDIAGNOSTIC CHECK:

INSTRUMENT MODULE.

6773

1

2

STOP

Go to Turn Signal Error1A: Cancels Erratically.

fc01415_en



Turn Signal Error 1A (Part 2 of 2) Cancels Erratically

Continued from Turn Signal Error 1A (Part 1 of 2)Will Not Cancel Upon Turn Completion.

Check for voltage between Breakout Box terminal “8” (Gray) and ground atBreakout Box terminal “12” (Gray): with left turn signal switch depressed, wiggle

harness between TSM/HFSM and left handlebar switches whilemonitoring for voltage fluctuations or changes in turn signal flash pattern.

Check for voltage between Breakout Box terminal “7” (Gray) and ground atBreakout Box terminal “12” (Gray): with right turn signal switch depressed,wiggle harness between TSM/HFSM and right handlebar switches whilemonitoring for voltage fluctuations or changes in turn signal flash pattern.

Are voltage fluctuations present?

YES

Locate and repairintermittentcondition.

NO

Check for voltage between Breakout Box terminal “8” (Gray) and ground atBreakout Box terminal “12” (Gray): with left turn signal switch NOT depressed,

wiggle harness between TSM/HFSM and left handlebar switches whilemonitoring for voltage fluctuations or turn signal activation.

Check for voltage between Breakout Box terminal “7” (Gray) and ground atBreakout Box terminal “12” (Gray): with right turn signal switch depressed,wiggle harness between TSM/HFSM and right handlebar switches while

monitoring for voltage fluctuations or turn signal flash pattern.


YES

Locate and repairintermittent short to

voltage.

Turn ignition switch OFF.

Check for continuity between Breakout Box terminal “8” (gray) and groundat Breakout Box terminal “12” (gray): with left turn signal switch

depressed, wiggle harness between TSM/HFSM and left handlebarswitches.

Check for continuity between Breakout Box terminal “7” (gray) and groundat Breakout Box terminal “12” (gray): with right turn signal switch

depressed, wiggle harness between TSM/HFSM and right handlebarswitches.

Is continuity present at any time?

NO

YES NO

Locate and repairintermittent short

to ground.

System OK. Review turn signalcancellation function with customer. See

AUTOMATIC CANCELLATION under3.1 TURN SIGNAL OVERVIEW.

4

4

3

fc01416_en

6855

6856

6857



Turn Signal Error 2A Flash at Double Normal Rate, All Bulbs Work

YES NO

YES NO

YES NO

YES NO

YES NO YES NO

Determine correct part number forall installed Turn Signal Bulbs and verify

against parts installed on motorcycle.Correct parts installed?

Check for corrosionon bulbs and/or sockets.

Corrosion present?

Check for corrosion on all lampconnection terminals.Corrosion present?

Remove corrosion with a wirebrush. Install ELECTRICAL

CONTACT LUBRICANT (PartNo. 99861-02) in bulb sockets.Do lamps flash at normal rate?

Clean corrosion fromwires and terminals.

Do lamps flash atnormal rate?

Replace Turn Signal Module/HandsFree Security Module (TSM/HFSM).

Learn password (if needed) andperform setup.

Clean or replace Bulb.Do lamps flash at

normal rate?

SystemOK.

SystemOK.

Replace LampAssembly.

SystemOK.

Replace TSM/HFSM.Learn password (if needed)

and perform setup.

Replace withcorrect Bulbs.

6821

6822 6823 6822

6824

6824

6820

fc01104_en

NOTE:Before troubleshooting this issue you should verifythat the lamp loads have been learned by:

1) Turn ignition switch Off-On.2) Activate left turn lamps for 4 or more flashes.3) Activate right turn lamps for 4 or more flashes.



Turn Signal Error 3A (Part 1 of 4) Will Not Flash, 4-Way Flashers Inoperable: DTC B1121,B1122, B1141

Turn ignition switch to IGN.Are turn signal lamps on continuously?

YES NO

Check for voltage on Breakout Box terminal “5” (Gray)(left turn signals) or terminal “6" (Gray) (right turn

signals) with TSM disconnected from Breakout Box.Is battery voltage present?

YES NO


Replace TSM. Learnpassword andperform setup.

Activate 4-way flashers.Do any lamps illuminate?

YES NO

Connector [30]mated fully?STOP

Go to Turn Signal Error3A (Part 2 of 4) Will NotFlash, 4-way Flashers

Inoperable: DTC B1121,B1122, B1141.

NOYES

Place red meter lead at terminal “1”(Gray) and black meter lead at terminal

“12” (Gray) of Breakout Box.Is battery voltage present?

Mateconnector.

NOYES

Move red meter lead toBreakout Box terminal “2”.Battery voltage present?

STOP



NO

Check for voltage atIgnition Fuse. Battery

voltage present on bothterminals?

NO

YES

STOP

Go to 4.10 NO ECMPOWER.

3

67906791

3

6792

STOP



YES

Locate and repairopen on (GY) wire

between Ignition Fuseand TSM.

6793

fc01418_en




Continued from Turn Signal Error 3A (Part 1 of 4)Will Not Flash, 4-way Flashers Inoperable:

DTC B1121, B1122, B1141.

Inspect lamps on side that will not flash.Are the lamps OK?

YES NO

Place jumper wire betweenterminals “1” and “6” of Breakout Box.

Do the right turn signals (front andrear) illuminate?

Replace lampsas necessary.

6796

YES

Place a jumper wire betweenterminals “1” and “5” of Breakout Box.

Do the left turn signals (front andrear) illuminate?

NO

Check for continuity betweenterminal “6” of Breakout Box and

lamps (front and rear).Continuity present?

YES

Repair openground circuit.

6797

NO

Repair open betweenlamps and TSMconnector [30].

6798

YES NO

Check for continuitybetween terminal “5” of

Breakout Box andlamps (front and rear).

Continuity present?

YES NO


Repair open betweenlamps and TSMconnector [30].

6799 6800

STOP

Go to Turn SignalError 2A Flash at

Double Normal Rate,All Bulbs Work.

fc01419_en





DTC B1121, B1122, B1141.

Check resistance to ground on Breakout Boxterminal “12” (Gray).

Is resistance less than 1 ohm?

YES

Check for 12 volts at bothterminals of 15 amp Battery Fuse.

Proper voltage present atboth terminals?

YES

Repair open in wire(BN/GY) between Battery Fuse

and TSM/HFSM.

6806

NO

NO

1 Terminal?

Repair poorground.

6805

Neither terminal?

Replacefuse.

6807

Repair open between 40 AmpMAXIFUSE and fuse block.

6808

fc01420_en





DTC B1121, B1122, B1141.

Check for battery voltage at breakout boxterminal “7” (Gray) with right turn signal

depressed and terminal “8” (Gray) with left turnsignal depressed.

Is battery voltage present?

YES

Replace TSM.Learn password and

perform set-up.

NO

6791

3

Check for battery voltage on terminal“1” connector [22B] (right), or

connector [24B] (left).Battery voltage present?

5

YES NO

With turn signal switch depressedon side under test, check for continuity

between terminal “1” and terminal“5” on connector [22A] (right), or

connector [24A] (left).Is continuity present?

Locate and repair open (O/W)wire between terminal “1” on connector

[22B] (right), or connector[24B] (left) and Accessory Fuse.

6814 - right

6812 - left

YES NO

Locate and repair open wirebetween terminal “5” on connector

[22B] (right), or connector [24B](left) and TSM connector [30].

Replace Turn SignalSwitch or repair wiring to

Turn Signal Switch?

6813 - right

6810 - left

6811

fc01421_en



Turn Signal Error 4A Turn Signal Lamp Open Circuit Inoperable: DTC B1121 Left/B1122Right

Inspect lamps on side that will notflash. Are the lamps O.K?

YES NO

Replace failedlamps as

necessary.

Place jumper wire between terminals“1” and “6” (right, B1122) or “1” and“5” (left, B1121) on Breakout Box

(Gray).Do the respective turn signals illuminate?

YES NO

Replace HFSM.Learn password and

perform set-up.

3

6807

Check for continuity between BreakoutBox terminal “5" (left) or terminal “6”

(right) and front or rear lamps.Is continuity present?

YES NO


Repair wire betweenconnector [30B] and

turn signal lamp.6808

6805

fc01422_en

6790



Turn Signal Error 5A Turn Signal Lamp Short-to-Ground: DTC B1123 Left/B1124 Right

Remove turn signal lamps. Disconnect instrument connector[20]. Check for continuity between terminals “12” and “6” (right,B1124) or terminals “12” and “5” (left, B1123) on Breakout Box

(Gray).Is continuity present?

YES NO

Locate and repairshort-to-ground.

Replace HFSM. Learn passwordand perform set-up.

3

6

6810 6791

fc01423_en



Turn Signal Error 6A Turn Signal Lamp Short-to-Voltage: DTC B1125 Left/B1126 Right

With ignition ON, check for voltage between terminals “12”and “6" (right, B1126) or “12" and “5" (left, B1125) on

Breakout Box (Gray) with [30] disconnected from HFSM.Voltage present?

YES NO

Locate and repairshort-to-voltage.

.


3

6

6790 6791

fc01424_en



3.16DTC B1131, B1132 (HFSM ONLY)

GENERALNOTE

This section applies only to those vehicles equipped with theoptional security system.

See Figure 3-20. An alarm cycle is activated when the HFSMis connected, the siren has been armed by the HFSM and asecurity event occurs. See 3.6 WARNINGS AND ALARMS.Under normal armed operation, the siren input (terminal B) isdriven low by the HFSM to trigger the audible alarm.When thesiren input is driven high by the HFSM the audible alarmstops.the audible alarm. When the siren input is driven highby the HFSM the audible alarm stops.

ed02047

Figure 3-20. Security Siren

DIAGNOSTICS



Diagnostic Tips• If the siren is armed and the internal siren battery is dead,

shorted, disconnected, or has been charging for a period

longer than 24 hours, the siren will respond with threechirps on arming instead of two.

• The internal siren battery may not charge if the vehicle'sbattery is less than 12.5 volts.

• If the siren does not chirp two or three times on a validarming command from the HFSM, the chirp function hasbeen disabled, the siren is either not connected, notworking, or the siren wiring was opened or shorted whilethe siren was disarmed.

• If the siren enters the self-driven mode where it is poweredfrom the siren internal nine-volt battery, the turn-signallamps will not alternately flash. If the HFSM activates thesiren, the turn-signal lamps will flash. If the siren has beenarmed and a security event occurs, and the siren is in self-driven mode, the siren will alarm for 20 to 30 seconds andthen turn off for 5 to 10 seconds. This alarm cycle will berepeated ten times if the siren is in the self-driven mode.

• If the siren does not stop alarming after it has been armed,then either the HFSM output or siren input may be shortedto ground, or the siren vehicle battery connection is openor shorted to ground, or the siren vehicle ground connec-tion is open, or a security event has occurred. See3.6 WARNINGS AND ALARMSfor a description of alarmfunctions.


1. Use BREAKOUT BOX (Part No. HD-42682) and HAR-NESS CONNECTOR TEST KIT (Part No. HD-41404-B),gray pin probe and patch cord. See 3.12 BREAKOUTBOX: TSM/HFSM.

2. Use HARNESS CONNECTOR TEST KIT (Part No. HD-41404-B), gray socket probe and patch cord.

3. Having the correct multimeter ohm scale is important forthis test. Some meters may read infinity for high ohmvalues. If this is the case, check your ohm scale and retest.

Table 3-13. Siren Alarm Output DTCs


Alarm Output Low: DTC B1131, Alarm Output High: DTC B1132Alarm output lowB1131

Alarm Output Low: DTC B1131, Alarm Output High: DTC B1132Alarm output highB1132



BK

RR

BN

/GY

BN/GY

BK/GN

BK

/GN

LGN/BN

LGN

/BN

– +

[30A][30B]

[142A] [142B]

HFSM

15 AmpSecurity

Fuse


SecuritySiren

(Optional)

1

1

Bat

tery

Ala

rmsi

gnal

Gro

und

1211

1211

1

2

3

1

2

3

em00066

Figure 3-21. Smart Siren Circuit




Under passenger seat3-place PackardSecurity siren[142]



Alarm Output Low: DTC B1131; Alarm Output High: DTC B1132

YES

NO

1

YES

2

YES NO

3

NO

NO

NO

NO

YES

YES

YES

Check for battery voltage at security sirenconnector [142B]. With ignition ON,

measure voltage between terminal “3” (BK/GN) and terminal “1” (BN/GY).


With ignition OFF, check continuity betweensecurity siren connector [142B] terminal “3” and

Breakout Box terminal “12”. Then measurecontinuity between security siren connector

[142B] terminal “1” and Breakout Box terminal “1”.Is continuity present?

With ignition OFF, measure resistance betweensecurity siren connector [142B] terminal “2” and

Breakout Box terminal “11” (Gray).Is resistance less than 1 ohm?

Measure resistance between BreakoutBox terminal “11” and chassis ground.


Disconnect security Siren from BreakoutBox.

Measure resistance between security sirenconnector [142A] terminal “2” and “3”.

Is resistance between 120,000-200,000ohms with security Siren disconnected?

Connect security Siren to a knowngood motorcycle. Arm and activatesecurity Siren to verify operation.

Disarm security Siren.Did security Siren operate

correctly?

Replace HFSM. Learnpassword and perform setup.

Locate and repairshort between (BN/GY)

and (BK/GN) wires.

Locate and repairgrounded (LGN/BN)

wire.

Locate and repairopen on (LGN/BN) wire.

ReplacesecuritySiren.

ReplacesecuritySiren.

Repairopen wire.

Clear DTCs using speedometer self diagnostics.See 3.11 SPEEDOMETER SELF DIAGNOSTICS.Confirm proper operation with no check enginelamp.

1

fc01112_en

Disconnect HFSM from breakoutbox. Check for voltage on HFSM

connector [30A] pin “11”.Voltage present?

NOYES

Locate and repairShort to voltage on

(LGN/BN) wire.

2

3



3.17DTC B1134 STARTER OUTPUT HIGH

GENERALWith the HFSM (if equipped) disarmed, Ignition Switch turnedto IGNITION, Engine Stop Switch set to RUN and the transmis-sion in neutral or clutch lever pulled in, the start relay isgrounded. Battery voltage is applied to the start relay and coilwhich are grounded through the TSM/HFSM.

DTC B1134: Starter Output High is set when that ground is notestablished through the TSM/HFSM.

DIAGNOSTICS




1. Connect BREAKOUT BOX (Part No. HD-42682) (gray) towire harness connector [30] leaving TSM/HFSM discon-nected. See 3.12 BREAKOUT BOX: TSM/HFSM.

ed02833

Figure 3-22. Start Relay Location



1 12

1

9

9 12

TSM/HFSM

[30B]

[62B]

A B I

C B A

[30A]

[33A]

[33B]

BK

/GN

Battery

40 AmpMAXIFUSE 15 Amp

SecurityFuse

+–

Start Relay

3085

86

KL

S

IgnitionSwitch

To right handlebarswitch [22]

TN/GN

TN

/GN

BN

/GY

BK/R

R/BK

R/B

K

R R

R

BK

IBat

tery

Sta

rtre

lay

cont

rol

Gro

und

em00067

Figure 3-23. Starter TSM/HFSM Circuit






Under passenger seat5-place AmpStart relay[62]



Starter Output High: DTC B1134

Remove Start Relay.Check for voltage on

Breakout Box terminal “9” (Gray).Voltage present?

YES

Locate and repairshort to voltage

on (TN/GN) wire.

NO

Install Start Relay.Is voltage present on

Breakout Boxterminal “9” (Gray)?

YES

Replace Start Relay.

NO

Replace TSM/HFSM.Learn password and

perform setup.

1

Clear DTCs using speedometer self-diagnostics. See3.11 SPEEDOMETER SELF-DIAGNOSTICS. Confirmproper operation with no check engine lamp illumination.

fc01426_en



3.18DTC B1135

DIAGNOSTICS

DTC B1135 Accelerometer FaultDTC B1135 indicates a failure which requires replacement ofthe TSM/HFSM.

NOTE

When DTC B1135 is set, the tip-over engine shutdown, HFSMtamper alarm and bank angle sensors are disabled. Thesecurity lamp will also illuminate when this code is set.



3.19DTC B1136, B1142 (HFSM ONLY)

DIAGNOSTICS

DTC B1136 Accelerometer Tip-OverSelf-Test FaultDTC B1136 indicates a failure which requires replacement ofthe HFSM.

DTC B1142 Internal FaultDTC B1142 indicates a failure which requires replacement ofthe HFSM.



3.20DTC B1141 (HFSM ONLY)

DIAGNOSTICS



Diagnostic TipsDTC B1141: Ignition Switch Open/Low or a symptom of WillNot Flash can be diagnosed using the flow charts.


1. Connect BREAKOUT BOX (Part No. HD-42682) (gray)between TSM/HFSM connector [30A] and wiring harnessconnector [30B]. See 3.12 BREAKOUT BOX:TSM/HFSM.

2. Use HARNESS CONNECTOR TEST KIT (Part No. HD-41404-B), gray terminal probe and patch cord.



[22B

]

Sec

urity

15A

[24B

]

[91A

]D

ata

Link

Con

nect

or

LK

Igni

tion

15A

Rig

htH

and

Con

trol

s

Left

Han

dC

ontr

ols

BN

/GY

40A

mp

MA

XIF

US

E

[5B

]

Fron

tTu

rnS

igna

ls [31A

]

Turn

Sig

nal

&LP

Lam

p [94A

][3

9A]

AB

[30A

][3

0B]

[39B

]

55

GN

D1

GN

D3

3

RturnLturn

IgnitionSerialdata

Inst

rum

entM

odul

e

AB

25

53

34

67

34

67

Igni

tion

Sw

itch

Vol

tage

Reg

ulat

or

[33B

][3

3A]

I

BB

A

[778

]

[61B

]

[62B

]

-+

Left

Fron

tTu

rnS

igna

l

Rig

htFr

ont

Turn

Sig

nal

Mai

nH

arne

ss

[31B

]6521

Left

Rea

rTu

rnS

igna

l

Rig

htR

ear

Turn

Sig

nal

[94B

]

3 4 5 6

BK

/GN

BN

W/V

R

R

R

V

R

V

BN

V

V

BN

GY

GY

GY

BN

BN

BK

BK

VBN

BK

BK

V

BK

/GN

BK

/GN

BK

/GN

BN

/GY

LGN

/V

LGN/V

LGN

/V

LGN/V

W/BN

W/V

W/B

N

R/BK

R/B

K

BK

Bat

tery

Igni

tion

VS

S/S

eria

ldat

alin

k

Left

turn

feed

Rig

httu

rnfe

edR

ight

turn

switc

hin

put

Left

turn

switc

hin

put

Ser

iald

ata

link

Pow

ergr

ound

Pow

ergr

ound

Gro

und

1212

55

1010

2828

88

77

66

55

33

22

11

ElectronicControlModuleTurnSignal/SecurityModule(TSM/HFSM)

[78A

][7

8B]

99

Ser

iald

ata

[166

A]

[166

B]

AB

SM

odul

eLG

N/V

em00080

Figure 3-24.Turn Signal Circuit






Under left side cover6-place MolexRight hand controls[22B]

Under left side cover8-place MolexLeft hand controls[24B]





Under right side coverSpade terminalsFuse block (Start relay, Fan relay)[62B]





Inside tail lamp lens6-place MultilockRear turn signals[94]

Behind right side cover20-place MolexABS module (if equipped)[166]



Will Not Flash, No Codes: DTC B1141 (Part 1 of 2)

Turn ignition switch to IGN.Activate 4-way flashers.

Do any turn signals illuminate?

YES NO

Connector [30]fully mated?

YES NO

Place red meter lead at terminal “1"(Gray) and black meter lead at terminal


YES

Place red meter lead at terminal“2” (Gray) of Breakout Box.Is battery voltage present?

NO

Check resistance to ground onbreakout box terminal “12” (Gray).Is resistance less than one ohm?

YES NO

Check for battery voltageat both terminals of Ignition Fuse.Is ignition voltage present at both

terminals?

YES NO

Locate and repairopen on (GY) wire

between Ignition Fuseand HFSM.


STOP

Go to Will Not Flash,No Codes: DTC

B1141 (Part 2 of 2).

Mate connector.

YES NO

Check for battery voltage atboth terminals of BatteryFuse. Is battery voltage

present at both terminals?

Locate and repair openor poor ground circuit.

STOP

Go to Will Not Flash,No Codes: DTC

B1141 (Part 2 of 2).

1

6805

6793

YES

Repair open on (BN/GY) wire betweenBattery Fuse and

HFSM.

NO

Oneterminal?

Replacefuse.

Neitherterminal?

Repair openbetween MAXIFUSE

and fuse block.

6806

6807

6808

fc01427_en



Will Not Flash, No Codes: DTC B1141 (Part 2 of 2)

Continued from Will Not Flash,No Codes: DTC B1141 (Part 1 of 2).

Check for battery voltage at BreakoutBox terminal “7” (Gray) with right

turn signal depressed and terminal “8”(Gray) with left turn signal depressed.


YES


NO

Check for battery voltage on terminal “1”connector [22B] (right), or connector

[24B] (left).Battery voltage present?

YES NO

With turn signal switch depressed on sideunder test, check for continuity between

terminal “1" and terminal “5” on connector[22A] (right), or connector [24A] (left).

Continuity present?

Locate and repair open (O/W) wirebetween terminal “1" on connector

[22B] (right), or connector [24B}(left) and Accessory Fuse.

YES NO


[22B] (right), or connector [24B](left) and HFSM connector [30].


Turn Signal Switch.

68116813 - right

6810 - left

6814 - right6812 - left

6791

1

2

fc01428_en



3.21DTC B1143, B1144, B1145 (HFSM ONLY)

GENERALDiagnostic Trouble Codes (DTCs) B1143, B1144 and B1145will set when faults occur to the security antenna circuit usedto transmit to the fob. Refer to Table 3-17.

Table 3-17. Security Antenna DTCs

START WITH FLOWCHARTCONDITIONDTC

Security Antenna Short-to-Ground: DTC B1143Security antenna short-to-groundB1143

Security Antenna Short-to-Voltage: DTC B1144Security antenna short-to-batteryB1144

Security Antenna Open: DTC B1145Security antenna openB1145

DIAGNOSTICS




1. Use black male HARNESS CONNECTOR TEST KIT (PartNo. HD-41404-B) adapters and patch cords to connector[208B].

2. Connect light blue male HARNESS CONNECTOR TESTKIT (Part No. HD-41404-B) adapters and patch cords toconnector [209B] and black male HARNESS CON-NECTOR TEST KIT (Part No. HD-41404-B) adapters andpatch cords to connector [208B].

3. If DTC is current (lamp on continuously, cleared codesreturn during operation), replace HFSM. If DTC is historic,check for intermittents.

HFSM

TransmitAntenna

15 AmpSecurity

Fuse


BK

BK

R

BN

/GY

BK

/GN

[30A]

[30B]

[208A]

[208B]

[209B]

[209A]

1 12

1

1

1

Rec

ieve

ante

nna

Gro

und

Bat

tery

Tran

smit

ante

nna

ATr

ansm

itan

tenn

aB

2

2

1

1

2

2

3

312

R

– +

O/Y

BK

O/Y

Y/B

K

ReceiveAntenna

em00064

Figure 3-25. Security Antenna Circuit





Electrical panel behind fender extension12-place DeutschHFSM[30]

Electrical panel behind fender extension4-place DeutschHFSM[208]

Under seat2-place MolexSecurity antenna[209]



Security Antenna Short-to-Ground: DTC B1143

Disconnect antenna connector [208] fromHFSM. Check for continuity between [208B]

terminal “2” and “3” and ground.Is continuity (less than 1 ohm) present?

YES NO

Locate and repairshort-to-ground.


1

3

6879 6791

fc01429_en



Security Antenna Short-to-Voltage: DTC B1144

With the ignition switch turned to IGN, check forvoltage between [208B] terminal “2” and “3” and

ground. Voltage present?

YES NO

Locate and repairshort-to-voltage.


1

3

6879 6791

fc01430_en



Security Antenna Open: DTC B1145

Check for resistance between connector [208B]terminals “2” and “3”.

Is resistance between 3.7K ohms and 5.7 K ohms?

YES NO


Check for continuity between [208B] terminal “3”and [209B] terminal “2", and also between [208B]

terminal “2” and [209B] terminal “1”.Is continuity present?

1

2

6791

3

YES NO

Replace Security Antenna. Locate and repair open wirebetween connectors [208B]

and [209B].6878

6879

fc01431_en



3.22DTC B1154, B1155

DIAGNOSTICS



Diagnostic TipsDiagnostic Trouble Codes (DTCs) B1154 and B1155 will setwhen either the clutch switch circuit or neutral switch circuit is

shorted to ground at speeds greater than 16 km/h (10 MPH)for more than 60 seconds. Refer to Table 3-19.

Table 3-19. Clutch/Neutral Switch DTCs


Clutch Switch Short-to-Ground: DTC B1154Clutch switch short-to-groundB1154

Neutral Switch Short-to-Ground: DTC B1155Neutral switch short-to-groundB1155


1. Connect BREAKOUT BOX (Part No. HD-42682) to HFSM.3.12 BREAKOUT BOX: TSM/HFSM

2. If DTC is current (lamp on continuously, clear codesreturned during operation), replace HFSM. If DTC is his-toric, check for intermittents.

3. A reading of several hundred ohms is normal due to theneutral indicator lamp (LED).

Instrument Module

4

10

4

10

Turn Signal/Security Module(TSM/TSSM)

[39A]

[30A] [30B]

[39B]

[131]

NeutralSwitch

GND 1 GND 2GND 3

Neu

tral

Neutral switch

Clutch switch

10

10

[163]

Left HandControls

Clutch Switch

BK

BK

TN

TN

TN

BK/GN

BK

/GN

BK/R

BK/RBK/GNBK/R

Left HandControls

87

87

[24B] [24A]em00083

Figure 3-26. Clutch and Neutral Interlock Circuit





Under left side cover8-place MolexLeft hand controls[24]

Electrical panel behind fender exten-sion

12-place DeutschHFSM[30]

Under handlebar cover12-place Mini-DeutschInstrument module[39]

Bottom rear of crankcasePost terminalsNeutral switch[131]



Clutch Switch Short-to-Ground: DTC B1154

Connect Breakout Box HD-42682 to the main harness, leavingconnector [30] disconnected. Measure continuity between

terminal “10” (Gray) and terminal “12” (Gray).Is continuity present?

YES NO

Disconnect connector [24]. Measurecontinuity between terminal “10” (Gray) and

terminal “12” (Gray) on Breakout Box.Is continuity present?


1

2

6791

YES NO

Locate and repair short-to-ground on (BK/R) wire in mainwiring harness between [30B]

and [24B).

Locate and repairshort-to-ground in

left handlebar switchwiring.

5861 5861

NOTE;This DTC may occur if the vehicle is ridden with clutch disengaged(pulled in) at speeds greater than 10 MPH (16 km/h)for more than 60 seconds (coasting down a long mountain road).

fc01432_en



Neutral Switch Short-to-Ground: DTC B1155

WIth the transmission in 1st or 2nd gear, connectBreakout Box HD-42682 to the main harness, leavingthe HFSM disconnected. Measure continuity between

terminal “4” (Gray) and terminal “12” (Gray).Is continuity (less than 10 ohms) present?

YES NO

Disconnect neutral switch [131]. Measurecontinuity between terminal “4” (Gray) and

terminal “12" (Gray) on Breakout Box.Is continuity (less than 10 ohms) present?


1

2

6791

3

3

YES NO

Locate and repair short-to-ground on (TN) wire in main

wiring harness.

Replace Neutral Switch.

5862

5157

NOTEThis DTC may occur if the vehicle is ridden with transmission inneutral at speeds greater than 10 MPH (16 km/h) for more than60 seconds (coasting down a long mountain road).

fc01433_en



3.23DTC U1016, U1255

GENERALThe serial data connector provides a means for the ElectronicControl Module (ECM), TSM/HFSM and the speedometer tocommunicate their current status. When all operating para-meters on the serial data bus are within specifications, a stateof health message is sent between the components.

A Diagnostic Trouble Code (DTC) U1016 indicates that theECM is not capable of sending this state of health message.A DTC U1255 indicates that no messages were present duringpower up of the current key cycle. A DTC U1016 also indicatesthat there was communication on the data bus since powerup, but communication was lost or interrupted during that keycycle.



Loss of ECM Serial Data: DTC U1016Loss of all ECM serial data (state of health)U1016

Serial Data Error/Missing Message: DTC U1255Serial data error/missing messageU1255

DIAGNOSTICS





1. Connect BREAKOUT BOX (Part No. HD-42682) (gray)between TSM/HFSM connector [30A] and wire harnessconnector [30B]. See 3.12 BREAKOUT BOX:TSM/HFSM.


ed03005

Figure 3-27. ECM Location



5

5

Ser

iald

ata

10

10

28

28

Sys

tem

grou

nd

Sys

tem

grou

nd

3 12

3

Ser

iald

ata

Gro

und

12

7

7

Ser

iald

ata


[39A][39B]

[30A][30B]

[78A][78B]

TSM/TSSM/HFSM

To ignitionfuse

ECM

[91A]

BK

/GN

BK

/GN

GY

LGN

/V

LGN/V

LGN

/V

LGN

/V

Data LinkConnector

BK/GN

3

1

2

4[166B]

(ABS is optional)

[166A]

1

11

ABS

Power ground

Power ground

1

9Serial data 9

11

LGN/V

BK

BK

em00138

Figure 3-28. Serial Data Circuit



Under passenger seat12-place DeutschTSM/TSSM[30]







Serial Data Error/Missing Message: DTC U1255, Loss of ECM Serial Data: DTC U1016

Can you read ECM hardware part number?See 3.11 SPEEDOMETER SELF-

DIAGNOSTICS.

YES NO or “No Rsp”

While wiggling harness, check continuitybetween terminal “3” (Gray) of

TSM/HFSM Breakout Box and terminal“5" of ECM Breakout Box.


Check continuity between terminal “3”(Gray) of TSM/HFSM Breakout Box and

terminal “5” of ECM Breakout Box.Is continuity present?

1

2

Clear DTCs using speedometer selfdiagnostics. See 3.11 SPEEDOMETER SELFDIAGNOSTICS. Confirm proper operationwith no check engine lamp illuminated.

1

2

YES

Clear codes. Test ride.Did DTC U1016 return?

YES

Replace ECM.Reprogram and learn

password.

NO

Repair intermittenton (LGN/V) wire.

NO

No trouble found.

YES


password.

NO

Repair open on(LGN/V) wire.

fc01434_en









ed02995

Figure 3-29. Data Link Connector [91A] (typical)


DESCRIPTIONDTC


Serial data highU1301



3.25TSM/HFSM: PASSWORD LEARN

GENERALIf the ECM or TSM/HFSM is faulty, follow the instructions inthe Service Manual for ECM or TSM/HFSM replacement.Then,to determine if password learn is necessary, refer to Table 3-24.

Table 3-24. Password Learn

IS PASSWORD LEARNNECESSARY?

DEVICE REPLACED

YesECM

No *TSM

YesTSM/HFSM

* If a TSM has been replaced by a HFSM, or a HFSM hasbeen replaced by a TSM, password learn is necessary.

PASSWORD LEARNINGTo perform password learning procedure, refer to Table 3-24.When finished, continue with all instructions under 3.3 H-DSSSACTUATION.

Always perform all appropriate instructions under 3.3 H-DSSSACTUATION after TSM/HFSM replacement or removal.

NOTE

Fob assignment must be performed at an authorized Harley-Davidson dealer using Digital Technician.

Table 3-25. Setting TSM/HFSM and ECM Password

NOTESCONFIRMATIONACTIONNO.

With Ignition Switch turned off,Check Engine Lamp andSecurity Lamp will be off.

Ignition must be turned off for at least 15 seconds.

Install new TSM/HFSM or ECM. Perform all steps under3.3 H-DSSS ACTUATION.

1

Set Engine Stop Switch to RUN.2

TSM/HFSM enables start rely.Verify Check Engine Lampand Security Lamp illuminateand then turn off.

Turn Ignition Switch to IGNITION.3

Password has not beenlearned. ECM sets DTCP1009.

Engine starts and stalls.Check Engine Lamp illumin-ates and stays on.

Attempt normal start one time.4

ECM enters PasswordLearning mode for tenminutes. Do not cycle IgnitionSwitch or interrupt vehiclepower or Password Learn willbe unsuccessful.

Security Lamp illuminates.Wait ten seconds. Security Lamp will illuminate and stayon.

5

This takes ten minutes.Wait until Security Lamp turns off.6

ECM must not be allowed toshutdown.

Quickly (within two seconds) turn Ignition SwitchOFF-ON.

7




9




11

Turn Ignition Switch OFF. Wait 15 seconds beforeturning Ignition Switch on. Turn Ignition Switch ONand start engine to confirm successful Password Learnprocedure. Clear diagnostic trouble codes.

12

Perform all steps under 3.3 H-DSSS ACTUATION.13



3.26HFSM MAINTENANCE

GENERALThe HFSM uses a battery in the fob and siren. These are theonly parts requiring periodic maintenance.

HANDS-FREE FOB

ScheduleReplace the fob battery every year.

Battery Replacement1. See Figure 3-30. Open the fob case.

a. Place a thin blade in the thumbnail slot (1) betweenthe 2 halves of the case.

b. Slowly twist the blade.

2. Replace battery (2).

a. Remove the original battery.

b. Install a new battery with the positive (+) side down.Use a Panasonic® 2032 or equivalent.

3. With O-ring (3) in place, align case halves and snap casehalves together.

1

2

3

1

ed02055

1. Thumbnail slot2. Battery (Panasonic 2032)3. O-ring

Figure 3-30. Open Fob: HFSM

SIREN (IF INSTALLED)

ScheduleThe siren's internal 9 volt battery is rechargeable and does notneed to be replaced on a regular basis. Battery life undernormal conditions is approximately three to six years.

NOTE

The internal siren battery may not charge if the vehicle's batteryis less than 12.5 volts.

Battery Replacement: Early Style Siren1. Disarm system and remove siren.

2. See Figure 3-31. Remove battery cover (1).

a. Place the siren module on a flat and sturdy table withthe potted section (area with epoxy covering circuitboard) (4) facing up and towards you.

b. Position a knife blade at a 45 degree angle to the longside of the siren case. Insert the knife blade betweenthe siren case and battery cover at one of the twoaccessible corners of the battery cover. Keep theblade slightly higher towards the battery cover as thishelps keep the blade away from the battery seal.

c. Slowly twist the blade towards the battery cover andthe cover will pop off.

NOTES• For protection against corrosion, battery terminals and

battery clip are covered with a special grease. Do not wipeaway this substance. Apply all available existing greaseto terminals on new battery.

• Only a 9 volt nickel metal hydride battery should be usedin the siren.

3. Replace battery (2) by removing old battery from polarizedbattery clip. Install a new 9 volt nickel metal hydride bat-tery. See Parts Catalog for correct part number.

4. Reinstall battery cover.

a. Carefully replace the rubber seal.

b. Align battery cover with case placing round cornerson cover away from connector [142A] (3). Snap coverinto place.

5. Install siren and check operation. If siren is working prop-erly, it will respond with two chirps after receiving the armcommand.



4

3

1

2

ed02056

1. Cover2. 9 volt battery3. Connector [142A]4. Potted section

Figure 3-31. Siren Battery Compartment (Early Siren)

Battery Replacement: Late Style Siren1. Disarm system and remove siren.

2. See Figure 3-32. With a small screwdriver or pick, pushthe catches (1) in through the two slots (2) in the end ofthe siren to release the battery cover (3).




3. Replace battery (4) by removing old battery from polarizedbattery clip.

4. Recharge and re-install, or install a new 9 volt nickel metalhydride battery.

5. Reinstall battery cover (3).

a. Carefully replace the rubber seal (5) on the cover.

b. Align battery cover with case placing round cornerson cover away from connector [142A] (6).

c. Snap cover into place.


3 4

5 2

6

1

ed02057

1. Catch (2)2. Slot (2)3. Cover4. 9 volt battery5. Rubber seal6. Connector [142A]

Figure 3-32. Siren Battery Compartment (Late Style Siren)




NOTES


SUBJECT............................................................................................................................PAGE NO.4.1 SPECIFICATIONS.....................................................................................................................4-14.2 EFI SYSTEM.............................................................................................................................4-24.3 DIAGNOSTIC INTRODUCTION................................................................................................4-44.4 CHECKING FOR TROUBLE CODES.......................................................................................4-54.5 INSTRUMENT MODULE (IM) SELF DIAGNOSTICS................................................................4-74.6 BREAKOUT BOX: ECM.............................................................................................................4-94.7 WIGGLE TEST........................................................................................................................4-104.8 INITIAL DIAGNOSTIC CHECK................................................................................................4-114.9 ENGINE CRANKS, BUT WILL NOT START............................................................................4-204.10 NO ECM POWER..................................................................................................................4-284.11 STARTS, THEN STALLS.......................................................................................................4-334.12 FUEL SYSTEM ELECTRICAL TEST....................................................................................4-374.13 SYSTEM RELAY FAULT........................................................................................................4-434.14 FAN OPERATION CHECK....................................................................................................4-484.15 FUEL PRESSURE TEST.......................................................................................................4-524.16 IDLE AIR CONTROL.............................................................................................................4-554.17 MISFIRE AT IDLE OR UNDER LOAD...................................................................................4-604.18 COMBUSTION ABSENT/INTERMITTENT...........................................................................4-664.19 DTC P0107, P0108...............................................................................................................4-704.20 DTC P0112, P0113...............................................................................................................4-744.21 DTC P0117, P0118...............................................................................................................4-784.22 DTC P0122, P0123...............................................................................................................4-824.23 DTC P0131, P0132, P0134, P0151, P0152, P0154..............................................................4-864.24 DTC P0261, P0262, P0263, P0264.......................................................................................4-914.25 DTC P0373, P0374...............................................................................................................4-964.26 DTC P0444, P0445...............................................................................................................4-994.27 DTC P0501, P0502.............................................................................................................4-1044.28 DTC P0562, P0563.............................................................................................................4-1084.29 DTC P0603, P0605.............................................................................................................4-1124.30 DTC P1009, P1010.............................................................................................................4-1134.31 DTC P1351, P1352, P1354, P1355.....................................................................................4-1164.32 DTC P1501, P1502.............................................................................................................4-1204.33 DTC U1064, U1255.............................................................................................................4-1254.34 DTC U1096, U1255.............................................................................................................4-128

EN

GIN

E M

AN

AG

EM

EN

T


NOTES


4.1SPECIFICATIONS

SPECIFICATIONS

Table 4-1. Spark Specifications

DATAIGNITION

1150-1250 RPMIdle speed

12 mmSpark plug size

0.89 mm (0.035 in.)Spark plug gap

Harley-DavidsonNo. 10R12A (no substitute)

Spark plug type

0.3-0.5 ohmsIgnition coil primary res-istance at room temper-ature

3500-4500 ohmsIgnition coil secondaryresistance at room tem-perature

Table 4-2. Circuit Breaker/Fuse Specifications

RATING (AMPERES)ITEM

40MAXIFUSE

15Ignition fuse

15Lighting fuse

15Accessory fuse

15Battery fuse

15Security fuse

15ECM power fuse

15Fuel pump fuse

NOTE

The fuse labeled Security provides basic turn signal function-ality on vehicles without a factory-installed security system. Donot remove this fuse or use it as a replacement fuse on othersystems.

Table 4-3. Charging Specifications

DATAITEM

12 amp hour/200 CCABattery

16-22 VAC per 1000 RPMAlternator AC voltage output

0.1-0.3 ohmsAlternator stator coil resist-ance

14.4-14.6 voltsRegulator voltage output @3600 RPM

30-35 ampsRegulator amperes @ 3600RPM

2008 VRSC Diagnostics: Engine Management 4-1


4.2EFI SYSTEM

GENERALSee Figure 4-1. The engine management system consists ofthe following components:

• Electronic Control Module (ECM).

• Crankshaft Position (CKP) Sensor.

• Manifold Absolute Pressure (MAP) Sensor.

• Intake Air Temperature (IAT) Sensor.

• Engine Coolant Temperature (ECT) Sensor.

• Idle Air Control (IAC).

• Throttle Position (TP) Sensor.

• Vehicle Speed Sensor (VSS).

• Oxygen (O2) Sensor

• Turn Signal Module (TSM) or optional, factory-installedTurn Signal Security Module (TSSM Japan/Korea only)or Hands-Free Security Module (HFSM).This includes anintegrated Bank Angle Sensor (BAS).

• Fan relay.

• Jiffy Stand Sensor (HDI).

• System relay.

• Ignition (plug top) coils.

• Purge solenoid (California models only).

The ECM is mounted ahead of the battery behind the left sidecover. It computes the spark advance for proper ignition timingand fuel control based on sensor inputs (from CKP, MAP, IATand TP sensor) and controls the low-voltage circuits for theignition coils and injectors.

The ECM contains all of the solid state components used inthe ignition system. The dwell time for the ignition coil is alsocalculated in the microprocessor and is dependent upon batteryvoltage. The programmed dwell is an added feature to giveadequate spark at all speeds. (The ECM has added protectionagainst transient voltages, continuous reverse voltage protec-tion, and damage due to jump starts.) The ECM is fullyenclosed to protect it from vibration, dust, water or oil.This unitis a non-repairable item. If it fails, it must be replaced.

The CKP is located on the left front of the lower crankcase half.The CKP generates an AC signal which is sent to the ECMwhere it is used to reference engine position (TDC) and speed.It functions by taking readings off the 22 teeth on the alternatorrotor (two teeth are missing to establish a reference point).

The MAP sensor is located at the rear intake port. The MAPsensor monitors the intake manifold pressure (vacuum) andsends the information to the ECM where the module adjuststhe spark and fuel timing advance curves for optimum perform-ance.

The BAS is within the TSM/TSSM/HFSM. TheTSM/TSSM/HFSM will shut the engine down if the vehicle istipped over. Once the sensor is tripped, the motorcycle mustbe uprighted, turned off and then on again before the enginecan be restarted. This is communicated across the data bus.

Front and rear coils fire each spark plug independently (onecylinder at a time - no wasted spark).The coil also has an extraterminal to monitor current on the coil secondary circuit. Thisis used for knock detection and combustion diagnostics.

The ignition system gives a spark near top dead center forstarting. At RPM and loads above this, the system gives aspark advance that varies between 0 and 50 degreesadvanced.

The IAT, ECT, O2, and TP sensors are used to provideinformation to the ECM to fine tune spark and fuel delivery.The ECT sensor also controls the cooling fan relay to provide12VDC to the fans. The VSS is used as an input for idle speedcontrol.

The O2 sensor Diagnostic Trouble Codes (DTCs) may be seenduring the vehicle break-in period. The O2 sensor DTCs willnot illuminate the check engine lamp for current or historiccodes and will only be indicated by Digital Technician orspeedometer self diagnostics. If the DTCs are reported duringthe break-in period, clear or ignore the codes until the break-in period is completed.

The purge solenoid (California models only) allows vapors fromthe charcoal canister to flow to the throttle body. The timingand amount of solenoid opening depends on engine speed,vehicle speed, engine temperature and throttle position.

TROUBLESHOOTINGSee the diagnostic charts for troubleshooting information.

4-2 2008 VRSC Diagnostics: Engine Management


10

24

11

29

33

30

12

31

26

7

6

28

8

–+

35

36

18

17

1

2

3

A

B

C

D

A

B

C

D

5

3

3

BD

BD

[79A]

CKP

[78]

[87B]

[90B] [90A]

Instrument Module

Fan Relay

CoolingFan

(Bottom)

CoolingFan

(Top)

To batteryfuse

TP Sensor

IATSensor

EngineCoolantTemperatureSensor

MAPSensor

Battery

IgnitionSwitch

EngineStop

Switch

40 AmpMAXIFUSE

15 AmpECM Fuse

RightHand

Controls

15 AmpFuel Pump

Fuse

15 AmpIGN Fuse

TSM/TSSM/HFSM

[88B] [88A]

[80B] [80A]

[89B] [89A]

[30B][30A]

[87A]

[133B]

JiffyStand

Sensor

[61A]SystemRelay

PurgeSolenoid

FuelPump

Plug TopCoil (Rear)

Plug TopCoil (Front)

[61B]

[79B]

VehicleSpeedSensor

7

7

A A

AB

C CA

B

21

21

AB

C CA

B

B B

8730

8586

KE

SU

12

12

[86B] [86A]

11

11

8730

8586

IQ

CP

R

1

1

27

2

22

25

4

13

[65A][65A]

BC A

BC A

[95A][95B]B

A

BA

[39B][39A]

[97B T] [97A T]

AB

AB

[97A B]

AB

AB

[97B B]

[62A][62B]

CB

A

CB

A

CB

A

CB

A

[83R B] [83R A]

[83F B] [83F A]

19

14

23

33

30

12

8

35

36

18

17

13

23

9 9 21

AB

AB

AB

AB

13

13

2 2

7 7

8 8

6 6

13

10

24

11

29

31

26

7

6

28

5

TP

Serial data

27

2

22

25

4

19

14

21

13

Coil R

Coil F

Constantpower

5V sensorGND

IAT

ECT

Ion

Fan output

Solenoid ctrl.

MAP

System relay

Rear Inj.

5V sensor pwr

Front Inj.

Switch power

[145B][145A]

[84B] [84A]

[85B] [85A]

6

6

5

5

43

43

[22B]

5 5

[22A]

[138A]

[138B]

[137A]

[137B]

FrontO2

Sensor

RearO2

Sensor

1 2

1 2

1 2

1 2

PK/GN

PK/O

BK/W

BK

/BE

BE/GN

BK/PK

GN/BN

BK

RB

K

BE

GY

GY

BK

GY

BK

/R

BN/R

BK/O

R/O

W/R

R/O

Y/BN

Y/BN

Y/BN

GY/BE

Y/GN

BE/O

GY/BE

BE/GY

Y/GN

Y/BE

BK/W

BK/W

BK/W

PK/Y

BK/W

GY/VR/W

LGN/Y

GY

/BE

BE

GY

/BE

V/WR/W

R

R

R

GN/O

GY/Y

GY/Y

W/BK R/BK

W/BK

Y/GN

W/BK

GN/O

Y/GN

Y/GN

Y/GN O/GY

BE/GY

GN/GY

BK/GN

LGN/V

LGN/V

LGN

/V

BK/GN

W/Y

R/W

V/W

[91A]

21

34

Data LinkConnector

em00121

Figure 4-1. EFI System Circuit



4.3DIAGNOSTIC INTRODUCTION

SYSTEM PROBLEMSAll system problems fall into at least one of three general cat-egories.

No StartThe engine cranks over freely, but will not start. This does notinclude situations where the engine will not crank, such as asecurity disabled starter, dead battery, etc. This conditionassumes that all obvious checks (fuel in tank, etc.) have beenmade.

Poor PerformanceThe engine starts but there are performance problems. Theseproblems may include poor fuel economy, rough idle, enginemisfire, engine hesitation, severe spark knock, etc.

Check Engine LampSee Figure 4-2.The check engine lamp indicates the ElectronicControl Module (ECM) has determined a fault condition exists.There may also be starting or performance problems.

MPH

010

20

RPM

109

1 0

3040

5060 70 80 90

100110

120

130

140

150

ABSF

ed01507

Figure 4-2. Check Engine Lamp

RESOLVING PROBLEMSTo resolve system problems, four basic steps are involved. Inorder of occurrence, they are:

1. Check for Diagnostic Trouble Codes (DTCs) by observingcheck engine lamp. See 4.4 CHECKING FOR TROUBLECODES.

2. Diagnose system problems. This involves using specialtools and the diagnostic flow charts.


4. After repairs are performed, the work must be validated.This involves clearing the trouble codes and confirmingproper vehicle operation as indicated by the behavior ofthe check engine lamp.



4.4CHECKING FOR TROUBLE CODES

CHECK ENGINE LAMPTo diagnose system problems, start by observing the behaviorof the check engine lamp.

NOTES

• See Figure 4-3. "Key ON" means that the Ignition Switchis turned to IGN and the Engine Stop Switch is set to RUN(although the engine is not running).

• When the Ignition Switch is turned ON, the check enginelamp will illuminate for approximately four seconds andthen turn off.

• If the check engine lamp is not illuminated at Key ON orif it fails to turn off after the initial four-second period, thenthe instrument module may need to be replaced. See4.5 INSTRUMENT MODULE (IM) SELF DIAGNOSTICS.

1. See Figure 4-4. After lamp turns off after being illuminatedfor the first four-second period, one of three situations mayoccur.

a. The lamp remains off. This indicates there are nocurrent fault conditions or stored DTCs currentlydetected by the Electronic Control Module (ECM).

b. The lamp stays off for only four seconds and thencomes back on for an eight-second period. Thisindicates a code is stored, but no current DTC exists.

c. The lamp remains on beyond the eight-second period.This indicates a current DTC exists.

2. See 4.4 CHECKING FOR TROUBLE CODES, Code Typesfor a complete description of DTC formats.

NOTE

Some DTCs can only be fully diagnosed during actuation. Forexample, a problem with the ignition coil will be considered acurrent fault even after the problem is corrected, since the ECMwill not know of its resolution until after the coil is exercised byvehicle start sequence. In this manner, there may sometimesbe a false indication of the current DTC.

2

3

1

ed02991



ONA

B

C

ON

ON

OFF

OFF

OFF

Key On

Key On

Key On


Lamp OFF




4 Sec.

4 Sec.

4 Sec.

4 Sec.

8 Sec.

4 Sec.

ed01434

Figure 4-4. Check Engine Lamp Operation



CODE TYPES



There are two types of Diagnostic Trouble Codes (DTCs):current and historic. If a DTC is stored, it can be read usingeither a computer-based diagnostic package called DIGITALTECHNICIAN (Part No. HD-44750) or speedometer self dia-gnostics. See 4.5 INSTRUMENT MODULE (IM) SELF DIA-GNOSTICS.

NOTES

• To differentiate between current and historic DTCs, acomputer-based diagnostic package called DIGITALTECHNICIAN (Part No. HD-44750) must be employed.

• All DTCs reside in the memory of the ECM, TSM/TSSM/HFSM, speedometer or tachometer until the DTC iscleared by use of the speedometer self diagnostics. See4.5 INSTRUMENT MODULE (IM) SELF DIAGNOSTICS.

• A historic DTC is also cleared after a total of 50 trips haselapsed. A trip consists of a start and run cycle. After the50 trip retention period, the DTC is automatically erasedfrom memory providing that no subsequent faults of thesame type are detected in that period.



Historic DTCs can only be retrieved using a computer-baseddiagnostic package called DIGITAL TECHNICIAN (Part No. HD-44750).

Historic DTCs are stored for 50 ignition cycles after any DTCwas last set as current to assist in the diagnosis of intermittentfaults. On the 50th cycle, the DTC will clear itself. The checkengine lamp will not indicate the existence of only historicDTCs.

It is important to note that historic DTCs will exist wheneverthe system indicates the existence of a current fault. See4.4 CHECKING FOR TROUBLE CODES, Multiple DiagnosticTrouble Codes if multiple DTCs are found.

Diagnostic charts are designed for use with current DTCs andas a result they frequently suggest part replacement. Whendiagnosing a historic DTC the charts can be helpful but shouldnot lead to part replacement without verification the part isfaulty.

RETRIEVING DIAGNOSTIC TROUBLECODES



The engine management system provides two levels of dia-gnostics.


• The second mode requires using the instrument module(IM) self-diagnostics. IM, TSM/TSSM/HFSM and ECMDTCs can be accessed and cleared. See 4.5 INSTRU-MENT MODULE (IM) SELF DIAGNOSTICS for moreinformation.

MULTIPLE DIAGNOSTIC TROUBLE CODESWhile it is possible for more than one fault to occur and setmore than one DTC, there are several conditions which mayresult in one fault setting multiple DTCs:

• The MAP and TP sensors are connected to the same ref-erence line (+5V Vref). If the reference line goes to groundor open, multiple codes will be set (DTC P0107, P0122and P0501).

• Serial data DTCs (U1300, U1301, U1016, U1064, U1096and U1255, ) may be accompanied by other DTCs.Always correct the serial data DTCs before resolving theother DTCs.

Refer to Table 4-8. This table gives most ECM DTCs a priorityranking.




GENERALThe Instrument Module (IM) is capable of displaying andclearing IM, TSM/TSSM/HFSM, ABS and ECM DiagnosticTrouble Codes (DTCs).

DIAGNOSTICS


performed. See Figure 4-6. Turn Ignition Switch to ACC.Background lighting should illuminate, gauge needlesshould sweep their full range of motion, and indicatorlamps controlled by the serial bus (battery, security,coolant temperature, ABS and check engine) should illu-minate.

• If IM fails "WOW" test, check for battery, ground andaccessory to IM. If any feature in the IM is non-functional,see 2.6 NO IM POWER.



2. To clear DTCs for selected module, press IM reset switchfor more than 5 seconds when code is displayed. Thisprocedure will clear all codes for selected module.

MPH

010

20

RPM

1098

76

5

43

21 0

3040

5060 70 80 90

100110

120

130

140

150

ABS

3/4

F

1/2

1/4

ed01266


2

3

1

ed02991





IM Self-Diagnostics

1


RUN position.


YES

”P” flashing.





seconds.



Switch.

”S” flashing.



Switch.

”C” flashing.





than 5 seconds.




CHECK: SPEEDOMETER.

YES

YES

NO

NO

NO

Deviceresponse?

Press andrelease


displayed.

Press andrelease












SYSTEM (ABS)GENERAL

INFORMATION.


DTCdisplayed.


2

fc01596_en

”b” flashing.








4.6BREAKOUT BOX: ECM

GENERAL



The BREAKOUT BOX (Part No. HD-43876) splices into themain harness. Used in conjunction with a digital volt/ohmmeterDVOM, it allows circuit diagnosis of wiring harness and connec-tions without having to probe with sharp objects.

NOTE

See wiring diagrams for ECM terminal functions. ECM is loc-ated under passenger seat.

INSTALLATION1. Remove passenger seat.

2. Depress latch on connector [78B] and disconnect fromECM. See Figure 4-7.

3. See Figure 4-8. Attach Breakout Box (1) by connectingECM connector (2) to ECM and wiring harness connector(3) to ECM connector removed in previous step.

ed03005

Figure 4-7. ECM

1

23

ed02007

1. Breakout Box2. ECM connector3. Wiring harness connector

Figure 4-8. Breakout Box

REMOVAL1. See Figure 4-8. Depress latch on ECM connection.

2. Detach Breakout Box connector from ECM connector.

3. Detach Breakout Box connector from wiring harness.

4. Reattach ECM connector to wiring harness.

5. Install passenger seat.



4.7WIGGLE TEST

GENERALThe wiggle test indicates the presence of intermittents in awiring harness. Depending on the availability of diagnostictools, either version of this test may be used.

PROCEDURE


FLUKE 78 MULTIMETER (DVOM)HD-39978


Using DVOM (Part No. HD-39978)1. See Figure 4-9. Connect FLUKE 78 MULTIMETER

(DVOM) (Part No. HD-39978) to wiring harness betweenthe suspect connections. When diagnosing ECM connec-tions, use a BREAKOUT BOX (Part No. HD-43876) tosimplify the procedure. See 4.6 BREAKOUT BOX: ECM.

2. Set DVOM to read voltage changes.

3. Start motorcycle engine and run at idle.

4. Shake or wiggle harness to detect intermittents. If intermit-tents are present, radical voltage changes will register onthe DVOM.

ed02008

Figure 4-9. Fluke 78 Multimeter (DVOM) (Part No. HD-39978)



4.8INITIAL DIAGNOSTIC CHECK

GENERALTo locate faulty circuits or other system problems, follow thediagnostic flow charts in this section. For a systematicapproach, always begin with 2.4 INITIAL DIAGNOSTICCHECK: IM, Initial Diagnostics. Read the general informationand then work your way through the flow chart box by box.



In order to perform most diagnostic routines, a Breakout Boxand a digital volt/ohmmeter (DVOM) are required. See4.6 BREAKOUT BOX: ECM.


Job/Time Code ValuesDealership technicians filing warranty claims should use thejob/time code values printed in bold text beneath the appro-priate repair.

INITIAL DIAGNOSTICS

General InformationThe diagnostic check is an organized approach to identifyinga problem caused by an electronic control system malfunction.

Diagnostic Tips• If Instrument Module (IM) reads "No Response" with the

Ignition Switch turned ON (Engine Stop Switch at RUNwith the engine off), check data link for an open or shortto ground between data link connector [91A] terminal "3"and ECM, IM or TSM/TSSM/HFSM. See 4.5 INSTRU-MENT MODULE (IM) SELF DIAGNOSTICS.

• Check for an open diagnostic test terminal between dataterminal "3" and ECM. With Ignition Switch turned ON,transmit data should be typically 0.6-0.8 volts. The rangeof acceptable operation is 0-7.0 volts.

• If IM reads "BUS ER" (serial date bus error), refer to flowcharts in 4.11 STARTS, THEN STALLS.


1. Compare engine behavior to symptoms tables.

a. Starts hard. Refer to Table 4-5.

b. Hesitates, stumbles, surges, misfires and/or sluggishperformance. Refer to Table 4-6.

c. Engine exhaust emits black smoke or fouls plugs.Refer to Table 4-7.

All EFI diagnostic codes are listed in Table 4-8.

Other CodesSee 3.10 INITIAL DIAGNOSTIC CHECK for any codes relatedto the Turn Signal Module (TSM), Turn Signal Security Module(TSSM), or Hands-Free Security Module (HFSM).

See 2.4 INITIAL DIAGNOSTIC CHECK: IM for any codesrelated to the IM.

Table 4-4.Typical Scan Values for Engine Data

HOTIDLE

MAX.VALUE

MIN.VALUE

ITEM

31-36 kPa (9.1-10.6 in. Hg)104 kPa10 kPaMAP sensor

1.1-1.4 volts5.1 volts0 volts

0%1000TP sensor

0.2-0.8 volts4.8 volts0.2 volts

20-50 steps1500IAC pintle

120090000RPM (non-adjustable)

98-103° C (208-217° F)150° C (302° F)AmbientETC sensor


20-49° C (68-120° F)120° C (248° F)AmbientIAT sensor


1.6-2.3 mS50 mS0INJ PW front

1.6-2.3 mS50 mS0INJ PW rear



Table 4-4.Typical Scan Values for Engine Data

HOTIDLE

MAX.VALUE

MIN.VALUE

ITEM

8-10°50°0Advance front

8-10°50°0Advance rear

0 MPH136/140**0VSS

13.4-14.5 volts15 volts10 voltsBattery voltage

RunRunOffENG RUN

120016001200Idle RPM

0%100%0%Purge solenoid

Depends on coolant temper-ature

On103° C (217° F)

Off98° C (208° F)

Fan relay

and higherand lower

0.45 V0.60 V0 voltsOxygen sensor

n/a4.0 to 4.5 volts1.5 to 2.0 voltsJiffy Stand Sensor

** 218.8 km/h (136 MPH) for domestic models using 28-tooth sprocket. 225.3 km/h (140 MPH) for HDI models using 30-toothsprocket.

NOTE

Hot idle specifications are with stock exhaust, the engineoperating at 1200 RPM and an engine temperature of approx-

imately 100° C (212° F). Idle settings are controlled by theECM and cannot be changed.

Table 4-5. Engine Starts Hard

SOLUTIONCAUSE

1.7 CHARGING SYSTEM, TroubleshootingBattery discharged

4.17 MISFIRE AT IDLE OR UNDER LOADSpark plugs

4.17 MISFIRE AT IDLE OR UNDER LOADSpark plug boots

4.17 MISFIRE AT IDLE OR UNDER LOADIgnition coil

See Section 3 in the Service Manual.Valve sticking

Drain and refill with fresh fuel.Water or dirt in fuel system

4.10 NO ECM POWERLoss of battery power to ECM terminal 31*

* Codes will not clear (although they appear to).

Table 4-6. Engine Performance Problems

SOLUTIONCAUSE

See Intake Leak Test in the Service Manual .Manifold leakA low IAC count may also indicate an air leak.(When manifold leak is large enough, IAC will close to 0 and

DTC P0505 will set.)

4.19 DTC P0107, P0108MAP sensor plugged or not operating properly

Drain and refill with fresh fuel.Water or dirt in fuel system

4.17 MISFIRE AT IDLE OR UNDER LOADSpark plugs

See Throttle Cable Adjustment in the Service Manual.Throttle plate not opening fully

4.15 FUEL PRESSURE TEST.Low fuel pressure

4.14 FAN OPERATION CHECKCooling system fan(s) inoperative



Table 4-7. Engine Exhaust Emits Black Smoke or Fouls Plugs

SOLUTIONCAUSE

See Air Cleaner Filter in the Service Manual.Clogged air filter

4.19 DTC P0107, P0108MAP sensor plugged or not operating properly

Table 4-8. Diagnostic Trouble Codes (DTCs) and Fault Conditions

SOLUTIONFAULT CONDITIONSTATUSDTCRANKING

4.29 DTC P0603, P0605ECM flash errorCurrentP06051

4.29 DTC P0603, P0605ECM flash errorHistoricP06052

4.29 DTC P0603, P0605ECM EEPROM errorCurrentP06033

4.29 DTC P0603, P0605ECM EEPROM errorHistoricP06034

4.11 STARTS, THEN STALLSECM serial data lowCurrentU13005

4.11 STARTS, THEN STALLSECM serial data open/highCurrentU13016

4.11 STARTS, THEN STALLSTSM/TSSM/HFSM serialdata low

CurrentU13007

4.11 STARTS, THEN STALLSTSM/TSSM/HFSM serialdata open/high

CurrentU13018

4.11 STARTS, THEN STALLSIM serial data lowCurrentU13009

4.11 STARTS, THEN STALLSIM serial data open/highCurrentU130110

4.33 DTC U1064, U1255Loss of TSM/TSSM/HFSMserial data at ECM

CurrentU106411

3.19 DTC B1136, B1142 (HFSM ONLY)Loss of all ECM serial dataat TSSM/HFSM

CurrentU101612

3.20 DTC B1141 (HFSM ONLY)Loss of IM serial data atTSSM/HFSM

CurrentU109613

4.33 DTC U1064, U1255Missing response atTSSM/HFSM

CurrentU125514

2.14 DTC U1064Loss of TSM/TSSM/HFSMserial data at IM

CurrentU106415

2.13 DTC U1016Loss of all ECM serial dataat IM

CurrentU101616

4.34 DTC U1096, U1255Missing response at IMCurrentU125517

4.13 SYSTEM RELAY FAULTSystem relay contacts openCurrentP100318

4.13 SYSTEM RELAY FAULTSystem relay coi lhigh/shorted

CurrentP100219

4.13 SYSTEM RELAY FAULTSystem relay coil open/lowCurrentP100120

4.13 SYSTEM RELAY FAULTSystem relay contactsclosed

CurrentP100421

4.30 DTC P1009, P1010Incorrect passwordCurrentP100922

4.30 DTC P1009, P1010Missing passwordCurrentP101023

4.25 DTC P0373, P0374CKP sensor intermittentCurrentP037324

4.25 DTC P0373, P0374CKP sensor synch errorCurrentP037425

4.32 DTC P1501, P1502Jiffy Stand Sensor lowCurrentP150126

4.32 DTC P1501, P1502Jiffy Stand Sensor highCurrentP150227

4.22 DTC P0122, P0123TP sensor open/lowCurrentP012228

4.22 DTC P0122, P0123TP sensor highCurrentP012329

4.19 DTC P0107, P0108MAP sensor open/lowCurrentP010730





4.19 DTC P0107, P0108MAP sensor highCurrentP010831

4.21 DTC P0117, P0118ET sensor voltage lowCurrentP011732

4.21 DTC P0117, P0118ET sensor open/highCurrentP011833

4.20 DTC P0112, P0113IAT sensor voltage lowCurrentP011234

4.20 DTC P0112, P0113IAT sensor open/highCurrentP011335

4.31 DTC P1351, P1352, P1354, P1355Front ignition coil open/lowCurrentP135136

4.31 DTC P1351, P1352, P1354, P1355Rear ignition coil open/lowCurrentP135437

4.31 DTC P1351, P1352, P1354, P1355Front ignit ion coilhigh/shorted

CurrentP135238

4.31 DTC P1351, P1352, P1354, P1355Rear ignit ion coi lhigh/shorted

CurrentP135539

4.18 COMBUSTION ABSENT/INTERMITTENTFront cylinder combustionintermittent

CurrentP135740

4.18 COMBUSTION ABSENT/INTERMITTENTRear cylinder combustionintermittent

CurrentP135841

4.24 DTC P0261, P0262, P0263, P0264Front injector open/lowCurrentP026142

4.24 DTC P0261, P0262, P0263, P0264Rear injector open/lowCurrentP026343

4.24 DTC P0261, P0262, P0263, P0264Front injector highCurrentP026244

4.24 DTC P0261, P0262, P0263, P0264Rear injector highCurrentP026445

4.28 DTC P0562, P0563Battery voltage lowCurrentP056246

4.28 DTC P0562, P0563Battery voltage highCurrentP056347

4.27 DTC P0501, P0502VSS sensor lowCurrentP050148

4.27 DTC P0501, P0502VSS sensor highCurrentP050249

4.5 INSTRUMENT MODULE (IM) SELF DIAGNOSTICSCheck engine light open/lowCurrentP165150

4.5 INSTRUMENT MODULE (IM) SELF DIAGNOSTICSCheck engine light highCurrentP165251

4.5 INSTRUMENT MODULE (IM) SELF DIAGNOSTICSTachometer lowCurrentP165352

4.5 INSTRUMENT MODULE (IM) SELF DIAGNOSTICSTachometer highCurrentP165453

4.18 COMBUSTION ABSENT/INTERMITTENTRear cylinder no combus-tion

CurrentP135654

4.18 COMBUSTION ABSENT/INTERMITTENTFront cylinder no combus-tion

CurrentP135355

4.26 DTC P0444, P0445Purge control open/lowCurrentP044456

4.26 DTC P0444, P0445Purge control highCurrentP044557

4.14 FAN OPERATION CHECKFan output open/lowCurrentP148158

4.14 FAN OPERATION CHECKFan output highCurrentP148259

4.16 IDLE AIR CONTROLLoss of idle speed controlCurrentP050560

4.23 DTC P0131, P0132, P0134, P0151, P0152, P0154Front O2 sensor low (lean)CurrentP013161

4.23 DTC P0131, P0132, P0134, P0151, P0152, P0154Rear O2 sensor low (lean)CurrentP015162

4.23 DTC P0131, P0132, P0134, P0151, P0152, P0154Front O2 sensor high (rich)CurrentP013263

4.23 DTC P0131, P0132, P0134, P0151, P0152, P0154Rear O2 sensor high (rich)CurrentP015264

4.23 DTC P0131, P0132, P0134, P0151, P0152, P0154Front O2 sensor open/notresponding

CurrentP013465

4.23 DTC P0131, P0132, P0134, P0151, P0152, P0154Rear O2 sensor open/notresponding

CurrentP015466

3.18 DTC B1135Accelerometer faultCurrentB113567

3.17 DTC B1134 STARTER OUTPUT HIGHStarter output highCurrentB113468

3.15 TSM/HFSM: TURN SIGNAL ERRORS AND DTCSLeft turn output faultCurrentB112169





3.15 TSM/HFSM: TURN SIGNAL ERRORS AND DTCSRight turn output faultCurrentB112270

3.14 DTC B0563Battery voltage highCurrentB056371

3.16 DTC B1131, B1132 (HFSM ONLY)Alarm output lowCurrentB113172

3.16 DTC B1131, B1132 (HFSM ONLY)Alarm output highCurrentB113273

3.15 TSM/HFSM: TURN SIGNAL ERRORS AND DTCSIgnition switch open/lowCurrentB114174

2.8 DTC B1003IM internal faultCurrentB100375

2.10 DTC B1004, B1005Fuel sender lowCurrentB100476

2.10 DTC B1004, B1005Fuel sender open/highCurrentB100577

2.11 DTC B1006, B1007Accessory line overvoltageCurrentB100678

2.11 DTC B1006, B1007Ignition line overvoltageCurrentB100779

2.12 DTC B1008Trip odometer rest switchclosed

CurrentB100880

4.11 STARTS, THEN STALLSECM serial data lowHistoricU130081

4.11 STARTS, THEN STALLSECM serial data open/highHistoricU130182

4.11 STARTS, THEN STALLSTSM/TSSM/HFSM serialdata low

HistoricU130083

4.11 STARTS, THEN STALLSTSM/TSSM/HFSM serialdata open/high

HistoricU130184

4.11 STARTS, THEN STALLSIM serial data lowHistoricU130085

4.11 STARTS, THEN STALLSIM serial data open/highHistoricU130186

4.33 DTC U1064, U1255Loss of TSM/TSSM/HFSMserial data at ECM

HistoricU106487

3.23 DTC U1016, U1255Loss of all ECM serial data-at TSSM/HFSM

HistoricU101688

4.34 DTC U1096, U1255Loss of IM serial data-atTSSM/HFSM

HistoricU109689

4.33 DTC U1064, U1255Missing response-atTSSM/HFSM

HistoricU125590

4.33 DTC U1064, U1255Loss of TSM/TSSM/HFSMserial data at IM

HistoricU106491

3.23 DTC U1016, U1255Loss of all ECM serial dataat IM

HistoricU101692

4.34 DTC U1096, U1255Missing response at IMHistoricU125593

4.32 DTC P1501, P1502Jiffy Stand Sensor lowHistoricP150194

4.32 DTC P1501, P1502Jiffy Stand Sensor highHistoricP150295

4.13 SYSTEM RELAY FAULTSystem relay contacts openHistoricP100396

4.13 SYSTEM RELAY FAULTSystem relay coi lhigh/shorted

HistoricP100297

4.13 SYSTEM RELAY FAULTSystem relay coil open/lowHistoricP100198

4.13 SYSTEM RELAY FAULTSystem relay contactsclosed

HistoricP100499

4.30 DTC P1009, P1010Incorrect passwordHistoricP1009100

4.30 DTC P1009, P1010Missing passwordHistoricP1010101

4.25 DTC P0373, P0374CKP sensor intermittentHistoricP0373102

4.25 DTC P0373, P0374CKP sensor synch errorHistoricP0374103

4.32 DTC P1501, P1502Jiffy Stand Sensor lowHistoricP1501104

4.32 DTC P1501, P1502Jiffy Stand Sensor highHistoricP1502105





4.22 DTC P0122, P0123TP sensor open/lowHistoricP0122106

4.22 DTC P0122, P0123TP sensor highHistoricP0123107

4.19 DTC P0107, P0108MAP sensor open/lowHistoricP0107108

4.19 DTC P0107, P0108MAP sensor highHistoricP0108109

4.21 DTC P0117, P0118ET sensor voltage lowHistoricP0117110

4.21 DTC P0117, P0118ET sensor open/highHistoricP0118111

4.20 DTC P0112, P0113IAT sensor voltage lowHistoricP0112112

4.20 DTC P0112, P0113IAT sensor open/highHistoricP0113113

4.31 DTC P1351, P1352, P1354, P1355Front ignition coil open/lowHistoricP1351114

4.31 DTC P1351, P1352, P1354, P1355Rear ignition coil open/lowHistoricP1354115

4.31 DTC P1351, P1352, P1354, P1355Front ignit ion coilhigh/shorted

HistoricP1352116

4.31 DTC P1351, P1352, P1354, P1355Rear ignit ion coi lhigh/shorted

HistoricP1355117

4.18 COMBUSTION ABSENT/INTERMITTENTFront cylinder combustionintermittent

HistoricP1357118

4.18 COMBUSTION ABSENT/INTERMITTENTRear cylinder combustionintermittent

HistoricP1358119

4.24 DTC P0261, P0262, P0263, P0264Front injector open/lowHistoricP0261120

4.24 DTC P0261, P0262, P0263, P0264Rear injector open/lowHistoricP0263121

4.24 DTC P0261, P0262, P0263, P0264Front injector highHistoricP0262122

4.24 DTC P0261, P0262, P0263, P0264Rear injector highHistoricP0264123

4.28 DTC P0562, P0563Battery voltage lowHistoricP0562124

4.28 DTC P0562, P0563Battery voltage highHistoricP0563125

4.27 DTC P0501, P0502VSS sensor lowHistoricP0501126

4.27 DTC P0501, P0502VSS sensor highHistoricP0502127

4.5 INSTRUMENT MODULE (IM) SELF DIAGNOSTICSCheck engine light open/lowHistoricP1651128

4.5 INSTRUMENT MODULE (IM) SELF DIAGNOSTICSCheck engine light highHistoricP1652129

4.5 INSTRUMENT MODULE (IM) SELF DIAGNOSTICSTachometer lowHistoricP1653130

4.5 INSTRUMENT MODULE (IM) SELF DIAGNOSTICSTachometer highHistoricP1654131

4.18 COMBUSTION ABSENT/INTERMITTENTRear cylinder no combus-tion

HistoricP1356132

4.18 COMBUSTION ABSENT/INTERMITTENTFront cylinder no combus-tion

HistoricP1353133

4.26 DTC P0444, P0445Purge control open/lowHistoricP0444134

4.26 DTC P0444, P0445Purge control highHistoricP0445135

4.14 FAN OPERATION CHECKFan output open/lowHistoricP1481136

4.14 FAN OPERATION CHECKFan output highHistoricP1482137

4.16 IDLE AIR CONTROLLoss of idle speed controlHistoricP0505138

4.23 DTC P0131, P0132, P0134, P0151, P0152, P0154Front O2 sensor low (lean)HistoricP0131139

4.23 DTC P0131, P0132, P0134, P0151, P0152, P0154Rear O2 sensor low (lean)HistoricP0151140

4.23 DTC P0131, P0132, P0134, P0151, P0152, P0154Front O2 sensor high (rich)HistoricP0132141

4.23 DTC P0131, P0132, P0134, P0151, P0152, P0154Rear O2 sensor high (rich)HistoricP0152142

4.23 DTC P0131, P0132, P0134, P0151, P0152, P0154Front O2 sensor open/notresponding

HistoricP0134143

4.23 DTC P0131, P0132, P0134, P0151, P0152, P0154Rear O2 sensor open/notresponding

HistoricP0154144





3.18 DTC B1135Accelerometer faultHistoricB1135145

3.17 DTC B1134 STARTER OUTPUT HIGHStarter output highHistoricB1134146

3.15 TSM/HFSM: TURN SIGNAL ERRORS AND DTCSLeft turn output faultHistoricB1121147

3.15 TSM/HFSM: TURN SIGNAL ERRORS AND DTCSRight turn output faultHistoricB1122148

3.14 DTC B0563Battery voltage highHistoricB0563149

3.16 DTC B1131, B1132 (HFSM ONLY)Alarm output lowHistoricB1131150

3.16 DTC B1131, B1132 (HFSM ONLY)Alarm output highHistoricB1132151

3.15 TSM/HFSM: TURN SIGNAL ERRORS AND DTCSIgnition switch open/lowHistoricB1141152

2.8 DTC B1003IM internal faultHistoricB1003153

2.10 DTC B1004, B1005Fuel sender lowHistoricB1004154

2.10 DTC B1004, B1005Fuel sender open/highHistoricB1005155

2.11 DTC B1006, B1007Accessory line overvoltageHistoricB1006156

2.11 DTC B1006, B1007Ignition line overvoltageHistoricB1007157

2.12 DTC B1008Trip odometer reset switchclosed

HistoricB1008158



BK

/GN

BK/GN

LGN

/V

LGN/V

LGN

/V

LGN

/V

BK

/GN

BK

/GN

BK

/GN

GY

GY

[39B][39A] [30B]

[91A] [91B]

[30A]

[78B][78A]

TSM/TSSM/HFSM

DataConnector

ECM


Tobattery

fuse

Toignition

fuse

Ser

iald

ata

3

1

2

4

5

5

Gro

und

28

28

Gro

und

10

10

3

3

7

7

6

6

5

5

1

1

Bat

tery

Gro

und

Igni

tion

Ser

iald

ata

Ser

iald

ata

12

12

Gro

und

R/O

[166B]

(ABS is optional)

[166A]

1

11

ABS

Power ground

Power ground

1

9Serial data 9

11

LGN/V

BK

BK

em00122

Figure 4-10. Diagnostic Check




Under handlebar cover12-place MolexInstrument Module (IM)[39]



Under right side cover20-place MolexABS module (If equipped)[166]



Diagnostic Check

Does enginestart?

YES.Starts and runs.

Check for diagnostic troublecodes (DTC’s). See 4.5

INSTRUMENT MODULESELF-DIAGNOSTICS.

DTCs found?

YES

Refer to applicable DTC prioritychart. All DTCs are listed in Table

4-8. DTCs are listed by priority.

YES.Starts, then stalls.

See 4.11 STARTS,THEN STALLS.


NO.Engine willnot crank.


See 1.2 STARTINGSYSTEM DIAGNOSIS.

NO

Go to 2.6 NO IM POWER. fc01469_en



4.9ENGINE CRANKS, BUT WILL NOT START

GENERALIf the starter will not crank the engine, the problem is not EFIrelated. Refer to CHAPTER 1 - STARTING / CHARGING orCHAPTER 3 - TSM/HFSM.

Instrument Module (IM) self-diagnostics can be used to retrievetrouble codes. See 4.5 INSTRUMENT MODULE (IM) SELFDIAGNOSTICS.

DIAGNOSTICS


SPARK TESTERHD-26792

FUEL INJECTOR TEST LAMPHD-34730-2C





IGNITION COIL CIRCUIT TESTADAPTER

HD-44687

ELECTRICAL SYSTEM ANALYZERMCR-101 HD


1. Check for DTCs. See 4.4 CHECKING FOR TROUBLECODES, Retrieving Diagnostic Trouble Codes.

2. Check the condition of the battery. Perform a voltage testand recharge if below 12.60V. Check battery connectionsand perform either a conductance test (using ELEC-TRICAL SYSTEM ANALYZER (Part No. MCR-101 HD) )or load test. Replace the battery if necessary. See Batteryin the Service Manual.

3. Typically, when IAC is not functioning, the engine will notstart unless throttle is opened and the engine will stallwhen throttle is closed.

4. See Figure 4-12. Plug IGNITION COIL CIRCUIT TESTADAPTER (Part No. HD-44687) and FUEL INJECTORTEST LAMP (Part No. HD-34730-2C) into Breakout Boxterminals "13" and "11". Start engine. If lamp flashes, noproblem is found. Repeat for Breakout Box terminals "13"and "29".


6. Connect BREAKOUT BOX (Part No. HD-43876). See4.6 BREAKOUT BOX: ECM.

7. Use HARNESS CONNECTOR TEST KIT (Part No. HD-41404-B), gray terminal probes and patch cords.

Wipe up spilled fuel and dispose of rags in a suitablemanner. An open spark around gasoline could cause afire or explosion, resulting in death or serious injury.(00518b)

NOTEEngine will not spark with both spark plugs removed. Whenchecking for spark, use SPARK TESTER (Part No. HD-26792)with both plugs installed.

8. Remove both plug top coils and spark plugs.

a. Visually check condition of plugs.

b. Reinstall spark plugs.

c. See Figure 4-13. Attach plug top coil to SPARKTESTER (Part No. HD-26792). Clip tester to ground.

d. While cranking engine, look for spark. Repeat pro-cedure on other cylinder.

9. Use HARNESS CONNECTOR TEST KIT (Part No. HD-41404-B), brown socket probe and patch cord.

ed02012

Figure 4-11. Spark Tester

ed02013

Figure 4-12. Ignition Coil Circuit Test



32

1

ed03031

1. Terminal "A"2. Terminal "B"3. Terminal "C"

Figure 4-13. Plug Top Coil



10

24

11

29

33

30

12

31

26

7

6

28

8

–+

35

36

18

17

1

2

3

A

B

C

D

A

B

C

D

5

3

3

BD

BD

[79A]

CKP

[78]

[87B]

[90B] [90A]

Instrument Module

Fan Relay

CoolingFan

(Bottom)

CoolingFan

(Top)

To batteryfuse

TP Sensor

IATSensor

EngineCoolantTemperatureSensor

MAPSensor

Battery

IgnitionSwitch

EngineStop

Switch

40 AmpMAXIFUSE

15 AmpECM Fuse

RightHand

Controls

15 AmpFuel Pump

Fuse

15 AmpIGN Fuse

TSM/TSSM/HFSM

[88B] [88A]

[80B] [80A]

[89B] [89A]

[30B][30A]

[87A]

[133B]

JiffyStand

Sensor

[61A]SystemRelay

PurgeSolenoid

FuelPump

Plug TopCoil (Rear)

Plug TopCoil (Front)

[61B]

[79B]

VehicleSpeedSensor

7

7

A A

AB

C CA

B

21

21

AB

C CA

B

B B

8730

8586

KE

SU

12

12

[86B] [86A]

11

11

8730

8586

IQ

CP

R

1

1

27

2

22

25

4

13

[65A][65A]

BC A

BC A

[95A][95B]

BA

BA

[39B][39A]

[97B T] [97A T]

AB

AB

[97A B]

AB

AB

[97B B]

[62A][62B]

CB

A

CB

A

CB

A

CB

A

[83R B] [83R A]

[83F B] [83F A]

19

14

23

33

30

12

8

35

36

18

17

13

23

9 9 21

AB

AB

AB

AB

13

13

2 2

7 7

8 8

6 613

10

24

11

29

31

26

7

6

28

5

TP

Serial data

27

2

22

25

4

19

14

21

13

Coil R

Coil F

Constantpower

5V sensorGND

IAT

ECT

Ion

Fan output

Solenoid ctrl.

MAP

System relay

Rear Inj.

5V sensor pwr

Front Inj.

Switch power

[145B][145A]

[84B] [84A]

[85B] [85A]

6

6

5

5

43

43

[22B]

5 5

[22A]

[138A]

[138B]

[137A]

[137B]

FrontO2

Sensor

RearO2

Sensor

1 2

1 2

1 2

1 2

PK/GN

PK/O

BK/W

BK

/BE

BE/GN

BK/PK

GN/BN

BK

R

BK

BE

GY

GY

BK

GY

BK

/R

BN/R

BK/O

R/O

W/R

R/O

Y/BN

Y/BN

Y/BN

GY/BE

Y/GN

BE/O

GY/BE

BE/GY

Y/GN

Y/BE

BK/W

BK/W

BK/W

PK/Y

BK/W

GY/VR/W

LGN/Y

GY

/BE

BE

GY

/BE

V/WR/W

R

R

R

GN/O

GY/Y

GY/Y

W/BK R/BK

W/BK

Y/GN

W/BK

GN/O

Y/GN

Y/GN

Y/GN O/GY

BE/GY

GN/GY

BK/GN

LGN/V

LGN/V

LGN

/V

BK/GN

W/Y

R/W

V/W

[91A]

21

34

Data LinkConnector

em00121

Figure 4-14. EFI System Circuit







Under crankcase2-place Mini-DeutschCrankshaft Position (CKP) sensor[79]

On top of front rocker box3-place PackardFront plug top coil[83F]

On top of rear rocker box3-place PackardRear plug top coil[83R]

Under left side cover4-place DeutschData link connector[91]

Under air cleaner12-place DeutschEngine harness[145]



Engine Cranks, But Will Not Start (Part 1 of 4)

Is there fresh fuel in tank?Are spark plug wires firmly

connected to coil terminals?

YES

Check for DTCs.Any DTCs found?

YES

Refer to prioritylisting in Table 4-8.

1

NO

Add fuel and/ orconnect spark plugs.

Check batteryconnections and voltage.Is voltage above 12.60?

NO

YES NO

Does battery pass conductancetest or load test?

Recharge battery.

YES NO

Replace battery.

Check spark plug condition,replace if fouled. Check spark at

both plugs while cranking.Is spark present?

3

YES

Check compression. See the VRSCService Manual. If compression is good,

check fuel system.

NO

Turn ignition ON and engine stopswitch to RUN.

Does check engine lamp illuminate for4 seconds immediately after Key ON?

NOYES

Check battery voltage at wire (W/BK) connector [83B] using DVOM.


See 4.10 NO ECMPOWER.

YES NO

Locate and repair openon wire (W/BK) to coil.

4

2

STOP

Go to EngineCranks but Will

Not Start(Part 2 of 4)

fc01470_en




YES

Continued from Engine Cranks but Will Not Start(Part 1 of 4).

Install fuel pressure gauge (Part No. HD-41182).See 4.15 FUEL PRESSURE TEST. While

cranking engine (for more than 2 seconds toensure proper system operation), verify that

fuel pressure rises to 55-62 PSI (380-427 kPa).Adequate fuel pressure present?

NO

Verify connector is securelyattached to each injector. If so,

disconnect fuel injector connectorand attach fuel injector test lamp.

Crank engine.Does lamp flash?

YES

Does IAC function? Seefirst box of 4.16 IDLE AIR

CONTROL flow chart.

YES NO

See 4.16 IDLEAIR CONTROL.

Correct problems withfuel injectors. See 4.24

DTC P0261, P0262,P0263, P0264.

NO

Incorrect pressure. See4.15 FUEL PRESSURE

TEST.

3

fc01471_en

STOP






Continued from Engine Cranks butWill Not Start (Part 2 of 4).

Perform coil circuit test.Does lamp flash?

YES NO

Check coil connections.Connections OK?

YES NO

Repair.

Check battery voltage at terminal“B” of both coil connectors [83B]

using DVOM.Battery voltage present for 2

seconds after key ON?

YES

Open in wire (Y/GN)between splice for fuelpump wire and ignition

coil. Repair open.

Connect Breakout Box. Measure resistancebetween ignition coil terminal “C”

[83F B] and ECM terminal “29" on BreakoutBox and resistance between ignition coil

terminal “C” of connector [83R B] andECM terminal “11” on Breakout Box.

Is resistance less than 0.5 ohm?

NO

YES NO

Check spark plug condition, replaceif fouled. Reinstall plugs and checkspark at both plugs while cranking.

Spark present?

Poor connection atconnector [78] or open inharness between coil and

ECM. Repair open.

YES NO

Check engine compression. See VRSCService Manual. Engine compression100 psi (690 kPa) or more (front) and200 psi (1379 kPa) or more (rear)?

YES

Replace coil.

Replace sparkplug boot.

NO

Repair engine compressionproblem. See VRSC Service

Manual.

Disconnect ECM connector [78].Inspect for damaged terminals,

terminals backed out or corrosion.Terminal problems present?

YES NO

Repair terminaldamage.

Reconnect.Problem still exist?

NO

Problem fixed.

YES

8

5

4

6

7

fc01472_en

STOP






Continued from Engine Cranks but Will NotStart (Part 3 of 4).

Check connectors for moisture and corrosion.Check wires for chafing. Connect DVOM to

ECM terminals “12” and “30” on Breakout Boxand set it for AC volts. Crank engine.Does DVOM read 1 VAC minimum?

YES


NO

Disconnect CKP connector [79]. Checkconnectors for moisture and corrosion.

Check wires for chafing.Is connector or wire damage present?

YES

Repair damage.

NO

Connect DVOM to terminals “1”and “2” of [79A]. Crank engine.

Does DVOM read 1 VACminimum?

NO

With meter still connected,check for resistance.

Is resistance 600-1200 ohms?

NO

Replace crank positionsensor. See VRSC

Service Manual.

YES

Loose or contaminated sensorat crankcase. Check for

contamination or damage.Tighten sensor.

YES

Check for continuity betweenterminal “30” on Breakout Box and

terminal “1” of connector [79B].Continuity present?

YES

Locate and repair open onwire (R) between terminal “2”

of connector [79B] and terminal“12” on Breakout Box.

NO

Locate and repair open onwire (BK) between terminal 1 ofconnector [79B] and cavity 30

on Breakout Box.

9

At some point in the flow chart youmay be instructed to jump directlyto the box with the bold asterisk .Disregard the asterisk (but not theinstruction box ) if your normal pro -gression through the chart bringsyou to this location.

fc01473_en



4.10NO ECM POWER

GENERAL

No Spark/No Check Engine Lamp at Key OnConstant power is supplied to the ECM through terminal "31".The ECM turns on when power is applied to terminal "13" ofconnector [78]. The ECM goes through an initializationsequence every time power is removed and re-applied to ter-minal "13". The only visible part of this sequence is the checkengine lamp. Upon starting, the check engine lamp will illu-minate for 4 seconds and then (if parameters are normal) goout.

If battery power is absent at ECM terminal "31":

• DTCs cannot be cleared. Tool will show them as clearedbut will be present next time ignition key is cycled.

• ECM cannot be re-flashed.

• Vehicle will start but IAC pintle will not reset at key OFF.Eventually pintle will be out of position causing perform-ance problems.

NOTE

The key ON sequence also activates the idle air control motor.If power from terminal "31" is disrupted (blown fuse, etc.)always turn the key OFF wait 10 seconds then turn the keyON to reset the motor to the default position.

DIAGNOSTICS






2. Use HARNESS CONNECTOR TEST KIT (Part No. HD-41404-B), purple pin probe and patch cord.

ed03020

Figure 4-15. Ignition Fuse Location

ed02842

Figure 4-16. ECM Fuse Location

ed03019

Figure 4-17. Right Hand Control Connector [22] Under LeftSide Cover (typical)



IgnitionSwitch

SystemRelay

EngineStop Switch

[22A]

[61A][61B]

[22B]

Battery

40 AmpMAXIFUSE

StartSolenoid

15 AMPECM Fuse

15 AMPIGN Fuse

10

31

13

28

–+

[78]

3085

86

ES

U

4

Power ground

Constant power

Switch power

Power ground

System relay

10

31

13

28

4

34

34

BE/GY

BE/GY BE/GY

BK/GN

BK/GN

BE

/GY

GN/O

GN/O

W/BK

W/BK R/BK

W/B

K

W/B

K

GY

BK

GY

R

RR

em00123

Figure 4-18. ECM Power Circuit





Under seat and right side coverFuse blockFuse block[61]



No ECM Power (Part 1 of 3)

Check ECM Fuse.Is fuse OK?

NOYES

Check Ignition Fuse.Is fuse OK?

YES NO

Disconnect ECM connector [78]. Inspectfor damaged terminals, terminals backed

out, or corrosion.Terminal problems present?

Locate and repair shortto ground. Replace

Ignition Fuse.

YES NO

Repair terminaldamage.

Reconnect.Problem still exist?

NO

Problemfixed.

YES

With ignition ON, probe ECM terminal “13”on Breakout Box with a circuit test lamp

connected to ground.Does test lamp illuminate?

YESNO

Probe ECM terminal “31” on BreakoutBox with test lamp connected to ground.

Does test lamp illuminate?

YES

Probe ECM terminals “10” and “28” onBreakout Box with test lamp connected

to +12V (battery positive terminal).Does test lamp illuminate?

YES


NO

Repair open inwire (BK/GN)

between connector[78B] and ground 1.

NO

Probe red wire terminal in 15 ampECM fuse holder with test lamp

connected to ground.Does test lamp illuminate?

YES

Repair open in wire(BE/GY) between

fuse holder and ECMconnector [78].

NO

Repair open in red wirebetween 40 amp

MAXIFUSE and 15 ampfuse holder.

fc01474_en

1

STOP

Go to No ECMPower

(Part 3 of 3)

STOP

Go to No ECMPower

(Part 2 of 3)




Continued from No ECM Power (Part 1 of 3).

Remove left side cover. With ignition ON,measure voltage at connector [22B] terminal “3”.


YES NO

With ignition OFF, Engine StopSwitch to RUN, measure resistancebetween terminals “3” and “4” [22A].


YES

Repair open circuit on wire(W/BK) between ECM and

connector [22B].

NO

Repair/replace enginestop switch or wiring.

Repair open wire (GY)between [22] and fuse.

fc01475_en

2

2




Continued from No ECM Power (Part 1 of 3).

Check for intermittent continuity to ground onterminal “1" of [13B] Continuity to ground present?

YES

Repair short to ground on wire(Y/GN) and replace fuse.

NO

Reconnect fuel pump connector [13] and Install fuel pressure gauge.See 4.15 FUEL PRESSURE TEST.

With fuel system intact and battery fully charged, remove ECM fuse.Connect DVOM across ECM fuse terminals using probe. Place positive male probe in

H slot. Turn key ON. With pump running, check current and fuel pressure.Is current draw under 4.5 amps and fuel pressure between 55-62 PSI (380-425 kPA)?

NOYES

Substitute known good relay for SystemRelay. Test for current draw across ECM Fuse.

Is current draw less than 4.5 amps?

NO

Repair short to ground onwire (Y/GN) and replace fuse.

Replace fuse.

YES

Current draw now in range.Replace System Relay and fuse.

fc01476_en



4.11STARTS,THEN STALLS

GENERAL

Diagnostic Trouble Codes U1300, U1301, orBUS ERSee Figure 4-19.The typical serial data voltage range is 0 volts(inactive) to 7 volts (active). Due to the short pulse, voltageswill be much lower on a DVOM. In analog mode, a DVOMreading serial data will show continuous voltage when active,typically 0.6-0.8 volts. The range for acceptable operations is0-7.0 volts.

NOTE

Problems in the fuel system or idle air control system may alsocreate this symptom.


DESCRIPTIONDTC



1

2

ed03021

1. Data link connector [91A]2. Protective rubber plug

Figure 4-19. Serial Data Connector [91A]

ed03022


DIAGNOSTICS


(DTCs) will automatically trip the check engine light.



1. Check for DTCs. See 4.5 INSTRUMENT MODULE (IM)SELF DIAGNOSTICS.



5

5

Ser

iald

ata

10

10

28

28

Sys

tem

grou

nd

Sys

tem

grou

nd

3 12

3 12

7

7

Ser

iald

ata

Ser

iald

ata

Gro

und


[39A][39B]

[30A][30B]

[78A][78B]

TSM/TSSMData LinkConnector

Toignition

fuse

ECM

[91A] [91B]

BK

/GN

BK

/GN

BK

/GN

GY

LGN

/V

LGN/V

LGN

/V

LGN

/V

BK/GN

3

1

2

4[166B]

(ABS is optional)

[166A]

1

11

ABS

Power ground

Power ground

1

9Serial data 9

11

LGN/V

BK

BK

em00124

Figure 4-21. Serial Data Circuit







Under right side cover20-place MolexABS module (if equipped)[166]



Starts,Then Stalls: DTC U1300, U1301 (Part 1 of 2)

Fresh fuel in tank?

YES NO

Check for trouble codes using 4.5INSTRUMENT MODULE SELF-

DIAGNOSTICS.1 Add fuel.

YES.DTC P1009, P1010

found. See 4.30 DTCP1009, P1010.

YES.Historic DTC U1300or U1301 are found.

NO.No codes found.

YES.“bus er” present.

IM will not communicatewith other modules.

Will engine start withthrottle opened partiallyand stall when throttle

closed?

YES

See 4.16IDLE AIR

CONTROL.

NO

Check fuel pressure whilecranking engine. See 4.15FUEL PRESSURE TEST.

Is fuel pressure OK?

NO

Fuel pressure problem.See flow chart under 4.15FUEL PRESSURE TEST.

YES

Tap lightly on fuel injectors.Problem still exist?

YES NO

SystemOK.

Replace fuel injectors.Problem still exist?

YES


password.

NO

SystemOK.

fc01477_en

STOP

Go to Starts,Then Stalls(Part 2 of 2)

STOP

Go to Starts,Then Stalls(Part 2 of 2)

(Shake and wiggleharness (4.7

WIGGLE TEST)while performingresistance tests.)

With ignition switch turned to IGN, EngineStop Switch in the Run position and the

Jiffy Stand down.Does the odometer display “SIdE StAnd”?

YES

Turn the Ignition Switch OFF. Raise the JiffyStand. Turn the ignition switch to IGN with the

Enigine Stop Switch in the RUN position.Does the odometer display “SIdE StAnd”?

YES

YES NO

Inspect the Jiffy Stand Sensor forcorrect mounting and clearance to

Jiffy Stand tab (4.5mm) max.Is switch mounted correctly?

Replace JiffyStand Sensor.

Install JiffyStand Sensor

correctly.

NO

NO

YES

YES

NO

NO

Check for an open in theneutral switch circuits.

Is there an open?

Test Neutral switch.Is Neutral Switch

operating properly?

Correct openin circuit.

Replace TSM/TSSM.

ReplaceNeutral Switch.



Starts,Then Stalls: DTC U1300, U1301 (Part 2 of 2)

Continued from Starts, Then Stops (Part 1 of 2).

Set engine stop switch to RUN. Turn ignition switch ON.Is BUS Er present?

YES NO

Turn ignition switch OFF.Disconnect ECM at connector[78]. Turn ignition switch ON.

Is BUS Er present?

Turn ignition switch OFF. While wigglingharness, check for continuity to ground at

terminal “3" of connector [91A].Is continuity to ground present at any time?

YES

Turn ignition switch OFF.Disconnect TSM/TSSM/HFSM at connector

[30]. Turn ignition switch ON.Is BUS Er present?

NO

Replace ECM.Reprogram and perform

password learn.

YES NO

Replace TSM/TSSM/HFSM.Perform password learn.

Turn ignition switch OFF. DisconnectIM at connector [39].Check for continuity toground at terminal “3" of connector [91A].

Is continuity to ground present?

YES

Locate and repair shortto ground.

NO

Turn ignition switch ON.Check for voltage at terminal

“3" of connector [91A].Is voltage present?

YES NO


Replacespeedometer.

YES NO

Turn ignition switch ON.While wiggling harness,

check for voltage at terminal“3" of connector [91A].Is voltage present at

any time?


to ground.

NOYES


to voltage.

No problemfound.

Clear DTCs using instrument module self-diagnostics.See 4.5 INSTRUMENT MODULE SELF-DIAGNOSTICS.Confirm proper operation with no check engine lamp.

fc01478_en

Is vehicle equippedwith ABS?

YES NO

Turn ignition switch OFF.Disconnect ABS Module

at connector [166].Is BUS ER present?

YES NO

Replace ABSModule.



4.12FUEL SYSTEM ELECTRICAL TEST

GENERALWith the Ignition Switch turned to ON and the Engine StopSwitch at RUN, the ECM will energize the system relay tocomplete the circuit to the in-tank fuel pump. It will remain onas long as the engine is cranking or running, and the ECM isreceiving ignition reference pulses from the CKP sensor. Ifthere are no reference pulses, the ECM will de-energize thesystem relay within 2 seconds after ignition is turned on or theengine has stalled, or immediately after the ignition is shut off.

The fuel pump delivers fuel to the injectors then to the pressureregulator.The regulator controls system pressure. Excess fuelflow is returned to the fuel tank through the pressure regulator.

See Figure 4-22. When the engine is stopped, the pump canbe turned on by applying battery voltage to terminal "1" andground to terminal "3" of the fuel pump connector [141A]. Thefuel pump connector is located on top of the fuel tank.

Improper fuel system pressure may contribute to one or all ofthe following symptoms:

• Engine cranks, but will not run.

• Engine cuts out (may feel like ignition problems).

• Hesitation, loss of power and poor fuel economy.

NOTE

After turning ignition off, you must wait 10 seconds beforeturning the ignition back on to get the fuel pump to reprime.This time-out period is necessary for the fuel pump and IACto reset.

ed03000

Figure 4-22. Fuel Pump Connector [86]

DIAGNOSTICS





1. Turns on fuel pump if wiring is OK. If pump runs, problemis in basic fuel delivery.

2. Use HARNESS CONNECTOR TEST KIT (Part No. HD-41404-B), brown terminal probe and patch cord.

3. See Fuel Injectors or Ignition Coil in the Service Manual.

4. See Relays in the Service Manual. This test checks for ashort to ground in the system relay harness circuit.

5. Use HARNESS CONNECTOR TEST KIT (Part No. HD-41404-B), purple terminal probe and patch cord.


ed03024

Figure 4-23. System Relay



EngineStop Switch

[22A][22B]

34

34

W/BK

W/B

K

GY

IgnitionSwitch

SystemRelay

[145A] [145B][85A]

Front Injector

Rear Injector

[85B]

[84A][84B]

[86B] [86A]

BatteryStarter

Solenoid

40 AmpMAXIFUSE

15 AMPECM Fuse

15 AMPFuel Pump

Fuse

15 AMPIGN Fuse

10

31

13

28

–+

[78A] [78B] 3085

86

ES

U

4

Power ground

Constant power

Switch power

Power ground

System relay

10

31

13

28

4

BE/GY

BE/GY

BK/GN

BK/GN

GN/OGN/O

W/BK

Y/GN

Y/GN

Y/GN O/GY

R/BK

BK

R

R

R

19

21

19

21

Rear INJ

Front INJ

87K

AB

AB

AB

AB

13

13

2 2 W/Y

GN/GY

W/Y

GN/GY

AB

CD

AB

CD

FuelPump

[61B] [61A]em00125

Figure 4-24. Fuel Pump Circuit




Under passenger seatSpade terminalsFuse block[61]


Throttle body2-place DelphiFront injector[84]

Throttle body2-place DelphiRear injector[85]

Under seat4-place DelphiFuel pump[86]




Fuel System Electrical Test (Part 1 of 4)

Is ECM Fuse OK?

YES NO

Is Fuel Pump Fuse OK? See 4.10 NO ECM POWER.

YES NO

Check for 12 volts at terminal B(+) andterminal D (-) of fuel pump connector [86B]

during first 2-3 seconds after key ON.Voltage present?

1

2

YES NO

Check for corroded connections orloose connectors between fuel pump

and pump connector [86B].Poor connections?

Check for continuityto ground on [86B]

terminal “D”.Continuity present?

2

NO

Locate and repairopen on wire (BK)between [86B] and

ground.

YESNO

With key OFF, check for openpump circuit. Connect ohmmeter

between connector [86A] terminal “B”and connector [86A] terminal “D”.

Continuity present?

NO

2

YES

Repair asnecessary.

YES

Check pump connections andrepair as required. If good,

replace fuel Pump.

Remove Fuel Pump. Check forcontinuity across fuel pump terminals.

Does meter read continuity?2

NO

ReplaceFuel Pump.

YES

Check for openingin wiring.

fc01479_en

STOP

Go to FuelSystem

Electrical Test(Part 4 of 4)

STOP

Go to FuelSystem





Continued from Fuel System ElectricalTest (Part 1 of 4).

Is 12 volts present at terminal “87" ofSystem Relay (with relay in place) during

first two seconds after key is on?

YES

Locate and repair open betweenterminal “B” of [86B] and terminal

“87” of System Relay.

NO

Is 12 volts present atterminal “30” ofSystem Relay?

YES

With ignition and engine stopswitch on, is 12 Volts present

at terminal “86" of SystemRelay?

YES

NO

Locate and repair open onwire (BE/GY) between ECM

fuse and terminal “30” ofSystem Relay.

NO

Locate and repair open onwire (W/BK) to system relay.

3

3

3

fc01480_en

STOP

Go to FuelSystem





Continued from Fuel System Electrical Test (Part 2 of 4).

Probe system relay connector terminal “85” with a test light to12 volts.

Does test light illuminate for 2 seconds after key ON?

YES

Replace SystemRelay.

Probe Breakout Box terminal “4” with a test lightconnected to 12 volts.

Does test light illuminate for 2 seconds after key ON?

YES

Locate and repairopen on wire (GN/O).

Replace ECM. Reprogramand learn password.

5

NO

NO

fc01481_en

4

6




Continued from Fuel System ElectricalTest (Part 1 of 4).

Check for intermittent short to ground onterminal “B” of connector [86B].

Short to ground present?

YES

Repair short toground on wire (O/GY)

and replace Fuse.

NO

Reconnect fuel pump connector [86] and Install Fuel PressureGauge. See 4.15 FUEL PRESSURE TEST.

With fuel system intact and Battery fully charged, remove FuelPump Fuse.

Connect DVOM across fuel pump fuse terminals using probe.Place positive male probe in “A” slot. Turn key ON. With pump

running, check current and fuel pressure.Is current draw under 4.5 amps and fuel pressure between 55-

62 PSI (380-425 kPA)?

YES

ReplaceFuse.

NO

Substitute known good relay for System Relay.Test for current draw across Fuel Pump Fuse

terminals.Is current draw less than 4.5 amps?

YES

Current draw nowin range.

Replace SystemRelay and replace

Fuse.

Replace FuelPump and

Replace Fuse.

3

fc01482_en

NO



4.13SYSTEM RELAY FAULT

GENERAL

System RelaySee Figure 4-25. With the ignition switch ON and the enginestop switch at RUN, the ECM will energize the system relay tocomplete the circuit to the in-tank fuel pump, ignition coil, andfuel injectors. They will remain powered as long as the engineis cranking or running, and the ECM is receiving ignition refer-ence pulses from the CKP sensor. If there are no referencepulses, the ECM will de-energize the system relay within 2seconds after ignition is ON or engine has stalled, or immedi-ately after the ignition is shut OFF.


DESCRIPTIONDTC

System relay coil open/lowP1001

System relay coil high/shortedP1002

System relay contacts openP1003

System relay contacts closedP1004

ed03024


DIAGNOSTICS





1. Use HARNESS CONNECTOR TEST KIT (Part No. HD-41404-B), purple terminal probe and patch cord to relayand gray terminal probe and patch cord to the coil con-nectors [83B]


3. Connect BREAKOUT BOX (Part No. HD-43876) to ECM.See 4.6 BREAKOUT BOX: ECM.



EngineStop Switch

[22A][22B]

34

34

W/BK

W/B

K

GY

FuelPump

IgnitionSwitch

SystemRelay

[145A] [145B]

[85A][85B]

[84A][84B]

[61B] [61A]

[86B]

[83R B] [83R A]RearCoil

FrontCoil

[83F B] [83F A]

Battery

40 AmpMAXIFUSE

StarterSolenoid

15 AmpECM Fuse

15 AMPFuel Pump

Fuse

Front Injector

Rear Injector

15 AmpIGN Fuse

10

31

13

28

–+

[78A] [78B]

3085

86

ES

U

4

Power ground

Constant power

Switch power

Power ground

System relay

10

31

13

28

4

BE/GY

GY/BE

GY/BE

BE/GY

BK/GN

BK/GN

GN/OGN/O

W/BK

Y/GN

Y/GN

Y/G

N

Y/GN

Y/GN

Y/GN

Y/BE

BE/O

GY/BE

Y/BE

BE/O

O/GY

R/BK

BK

RR

R

19

21

19

21

Rear INJ

2727Ion sense

1111Rear coil

2929Front coil

Front INJ

87K

AB

AB

AB

AB

13

13

2 2 W/Y

GN/GY

W/Y

GN/GY

BD

C C

B B

A A

C C

B B

A A

em00126

Figure 4-26. System Relay Circuit






On top of front rocker box3-place PackardFront plug top coil[83F]

On top of rear rocker box3-place PackardRear plug top coil[83R]



Top of fuel tank4-place DelphiFuel pump[86]




System Relay: DTC P1001, P1003

With relay in, check for battery voltage atterminal “87” of System Relay during first 2-3

seconds after Ignition switch ON.Battery voltage (10-13 volts) present for 2-3

seconds after key ON?

YES

System Relay OK. With relay out, measureresistance between terminal “87” of the

System Relay and coil connector [83B] ofboth coils.

Is resistance less than 0.5 ohm?

YES NO

Recheck connections.Wiggle harness whilerepeating test. Repair

intermittent.

Find and repairconnection or open

on (Y/GN) wire.

Check for 10-13 volts at terminal“30” of the system relay.

Voltage present?

NO

Check for continuity toground on (BE/GY) wire.

Continuity present?

NO

Find and repairopen betweenfuse and relay.

YES

Repair short toground and replace

ECM fuse.

YES

With ignition ON, check for10-13 volts at terminal “86” of

the System Relay.Voltage present?

NO

Was IgnitionFuse good?

YES

Measure resistance betweenterminal “85” of system relay and

terminal “4” on Breakout Box.Is resistance less than 0.5 ohm?

YES NO


Check for continuity to groundon terminal “4” on Breakout Box.

Continuity present?

YES

Repair shortto ground.

NO

NO

Repair short to groundand replace Ignition

Fuse.

YES

Find and repairopen on wire (W/BK)between connector

[22] and relay.

Replace System Relay.Does fuel pump run for the first

2 seconds after key ON?

YES

SystemOK.

NO


1 2

2

2

3

NO

fc01483_en



System Relay: DTC P1002

Remove System Relay. Check forvoltage on terminal “4" of Breakout Box.

Voltage present?

YES NO

Remove Breakout Box connector from ECM.Is voltage still present on terminal “4"?

ReplaceSystem Relay.

YES NO

Repair shortto voltage onwire (GN/O).


password.

fc01484_en



System Relay: DTC P1004

Check for poor connections, damaged terminals,poor ground or wires reversed at Fuel Pump.

Do any of these conditions exist?

YES NO

Repair.

Condition: Fuel Pump continues torun with Ignition Switch OFF.

Remove System Relay.Does pump continue to run?

YES NO

Replace short tovoltage on wire (Y/GN).

ReplaceSystem Relay.

fc01485_en



4.14FAN OPERATION CHECK

GENERAL

Fan RelaySee Figure 4-27. The ECM will energize the fan relay whencoolant temperature rises to 103° C (217° F) and shut off whencoolant temperature falls to 98° C (208° F). The ECM maycontinue this function for up to one minute when engine is offif engine temperature is above 98° C (208° F).


DESCRIPTIONDTC

Fan relay coil open/lowP1481

Fan relay coil highP1482

ed03033

Figure 4-27. Fan Relay

DIAGNOSTICS






2. Use HARNESS CONNECTOR TEST KIT (Part No. HD-41404-B) , purple terminal probe and patch cord.




Fan Relay

TopCooling

Fan

BottomCooling

Fan


Data LinkConnector

Battery

40 AmpMAXIFUSE

15 AmpBattery

Fuse

Ignitionswitch

[62A][62B]

[97A T][97B T] [39B]

[39A]

[78B][78A]

[91A]Toignition

fuse

ECM

[97A B][97B B]

3

1

2

4

5

1 2

1 2

1 2

1 2

2

Fan

outp

ut

Ser

iald

ata

52

7

7

Ser

iald

ata

Bat

tery

1

1

R C IP

85 863087a

87

–+

R/O

R/O

Y/BN

BK

BK

LGN/V

R/O

R/O

W/R

BK

GY

LGN/V

LGN

/V

R

em00127

Figure 4-28. Fan Relay Circuit



Inside handlebar cover12-place Mini-DeutschInstrument module[39]

Right-side coverFuse blockFan relay[62]


Under left side cover4-place DeutschData link connector[91A}

Behind radiator2-place MultilockTop cooling fan[97T]

Behind radiator2-place MultilockBottom cooling fan[97B]



Fan Operation Check: DTC P1481 or No Codes

Connect Breakout Box. Using purple terminal probe and patchcord, groundterminal “2” on Breakout Box. With relay in, turn fan relay on. Check for battery

voltage at terminal “87” of fan relay during first 2 seconds after ignition switch ON.Battery voltage (10-13 volts) present?

YES

Fan Relay OK. With relay out, measureresistance between terminal “87” of the

fan relay and fan connectors terminal “A”[97B T] and Terminal “A” [97B B].Is resistance less than 0.5 ohm?

YES NO

Recheck connections.Wiggle harness whilerepeating test. Repair

intermittent.

Find and repairconnection or open on

wire (Y/BN).

No voltage or voltage is alwayspresent, check for 10-13 voltsat terminal “30” and “86” of the

Fan Relay.Voltage present?

NO

Check for continuity toground on wire (R/O).Continuity present?

YES NO

Repair short to groundand replace Battery

Fuse.

Find and repairopen between fuse

and relay.

2

3

2

1

2

YES

Measure resistance between terminal“85” of Fan Relay and terminal “2” on

Breakout Box.Is resistance less than 0.5 ohm?

2

3

YES NO

Check for continuity to groundon terminal “2” on Breakout Box.

Continuity present?

Locate and repairopen on wire (W/R).

YES NO

Repair short toground on wire (W/R).

Replace Fan Relay.Does fan run when turnedon with active diagnostics?

YES

SystemOK.

NO


password.

NO

fc01486_en



Fan Operation Check: DTC P1482 or No Codes

Remove Fan Relay. Check forvoltage on terminal “2" of Breakout Box.

Voltage present?

YES NO

Remove Breakout Box connector from ECM.Is voltage still present on terminal “2"?

ReplaceFan Relay.

YES NO

Repair short tovoltage on wire (W/R).


password.

3

fc01487_en



4.15FUEL PRESSURE TEST

GENERALThe fuel pump is located in the fuel tank. It delivers fuel to thefuel metering assembly. The fuel metering assembly containsthe fuel injectors and the pressure regulator, where the systempressure is controlled. Excess fuel pressure is returned to thefuel tank by a return line. The ECM controls the system relaysupplying 12V to the fuel pump.

When the engine is stopped, the pump can be turned on byapplying battery voltage to terminal "B" and ground to terminal"D" of the fuel pump connector [86A].

Improper fuel system pressure may contribute to one of thefollowing conditions:

• Cranks, but won't run.

• Cuts out (may feel like ignition problem).

• Hesitation, loss of power, or poor fuel economy.

TESTING


1/8 IN. PIPE THREAD 90° DEGREE(RIGHT ANGLE) ELBOW

26338-68

FUEL PRESSURE GAUGEHD-41182

The fuel pressure gauge allows for fuel injector and fuel systempressure diagnosis.

1. See Figure 4-29. Disconnect fuel pump connector [86]from top of fuel tank.

2. Start the engine and allow the vehicle to run.

3. When engine stalls, operate the starter for 3 seconds toremove any remaining fuel from the fuel lines.Turn ignitionswitch off.

4. See Figure 4-30. Insert a 1/8 IN. PIPE THREAD 90°DEGREE (RIGHT ANGLE) ELBOW (Part No. 26338-68)(1) between the fuel valve (2) and the Schrader valveadapter (3).

5. See Figure 4-31. Remove protective cap from Schradervalve in fuel metering assembly.

6. Verify that the fuel valve and air bleed petcock on theFUEL PRESSURE GAUGE (Part No. HD-41182) areclosed.

7. Connect fuel pressure gauge to Schrader valve. Reconnectconnector [86].

8. Start and idle engine to pressurize the fuel system. Openthe fuel valve to allow the flow of fuel down the hose ofthe pressure gauge.

9. Position the clear air bleed tube in a suitable containerand open and close the air bleed petcock to purge thegauge and hose of air. Repeat this step several times untilonly solid fuel (without bubbles) flows from the air bleedtube. Close the petcock.

10. Open and close throttle to change engine speed. Note thereading of the pressure gauge. Fuel pressure shouldremain steady at 55-62 psi (380-425 kPa).

11. Turn the engine off. Open the air bleed petcock to relievethe fuel system pressure and purge the pressure gaugeof gasoline.

Gasoline can drain from quick-connect fitting whenremoving fuel line. Gasoline is extremely flammable andhighly explosive, which could result in death or seriousinjury. Wipe up spilled fuel immediately and dispose ofrags in a suitable manner. (00267a)

12. Remove fuel pressure gauge from the Schrader valve infuel metering assembly. Install protective cap overSchrader valve.

ed03000

Figure 4-29. Fuel Pump Connector [86]

21

3ed03027

1. 1/8 in. pipe thread 90 degree elbow2. Fuel valve3. Schrader valve adapter

Figure 4-30. Fuel Pressure Gauge Valves



ed03028

Figure 4-31. Schrader Valve Location

ed03029

Figure 4-32. Fuel Pressure Gauge Installed

DIAGNOSTICS


1. If the regulator is faulty, see the Service Manual.

2. If fuel system has pressure, but it is less than specification,check for the following conditions.

a. If fuel system has pressure, but it is less than specific-ation, check for the following conditions.

b. Restricted fuel flow causing pressure drop. However,if pressure drop occurs only when driving, engine maysurge and lose power as pressure begins to droprapidly.

3. This condition may be identified when the fuel level is lowand the fuel pump turned on for the first 2 seconds afterkey ON. A ringing sound can be heard as the high pres-sure fuel is sprayed against the inside wall of the fuel tank.



Fuel Pressure Test

Install Fuel Pressure Gauge. See TESTINGunder 4.15 FUEL PRESSURE TEST.

Start and idle engine.Open and close throttle to change engine speed.Does fuel pressure remain steady at 55-62 PSI

(380-425 kPa)?

Steady pressure. Low pressure. High pressure.

No trouble found.Review symptoms.

Check for restricted Fuel Filter orPump Inlet Screen.

Are Filter and Screen OK?

Inspect return line to fuel tank for damage orobstructions.

If OK, replace Faulty Fuel Pressure Regulator.

YES NO

Check for restricted pressure line or flex hose betweenSchrader valve and test gauge. If lines are OK, check for:

Faulty Fuel Pump.Leak inside tank caused by faulty coupling hose

or connection, such as hose at filter or pump.Faulty Fuel Pressure Regulator.

Replace Filter or cleanPump Inlet Screen.

Retest.

1

3

2 1

fc01488_en

YES NO NO



4.16IDLE AIR CONTROL

GENERAL



IAC OperationThe ECM controls engine idle speed by moving the IACto openor close a passage around the throttle plates. It does this bysending voltage pulses to the proper motor winding of the IAC.This causes the pintle to move in or out of the IAC a givendistance for each pulse received.

• To increase idle speed, the ECM retracts the pintle,allowing more air to flow through the throttle body.

• To decrease idle speed, the ECM extends the pintle,allowing less air to flow through the throttle body.

The IAC position can be measured in steps. This can only bedone by using DIGITAL TECHNICIAN (Part No. HD-44750).

• A high number of steps represents a fully retracted pintleand open passage around throttle plate. This correlateswith an increase in the amount of air flowing through thethrottle body.

• Zero steps represents a fully extended pintle. A zeroreading indicates an abnormal condition in which the pintlehas been fully extended and has consequently closed thepassage around throttle plate.

Each time the ignition is turned off, the ECM resets the IAC bysending enough pulses to extend the pintle and effectivelyclose the throttle body. The fully extended value is the ECMreference point. A given number of steps are then calculatedby the ECM for use in setting the proper idle speed and IACposition.

NOTE

Idle speed is controlled by the ECM and cannot be adjusted.

Diagnostic Trouble Code P0505: Loss ofIdle Speed ControlLoss of idle speed control will result if the idle RPM is ±200from preset idle speed and IAC motor is at zero or maximumfor greater than 5 seconds. This DTC may occur with others

for a multiple code situation. Resolve the other codes first tocorrect.


DESCRIPTIONDTC

Loss of idle speed controlP0505

DIAGNOSTICS




Diagnostic TipsEngine idle speed can be adversely affected by the following:

• A loss of idle speed control does not necessarily imply theIAC actuator or wiring has failed. It can be caused by anumber of conditions such as an intake air leak, improperlyadjusted throttle linkage or a misfiring cylinder.

• Leaking injectors will cause fuel imbalance and poor idlequality due to different air/fuel ratios in each cylinder. Tocheck for leaky injectors, first remove the airbox and airfilter. See Airbox and Filter in the Service Manual. Then,with the throttle wide open, turn key ON for 2 seconds andthen OFF for 2 seconds five consecutive times. Replacethe fuel injector if there is any evidence of raw fuel in thebores. See Fuel Injectors in the Service Manual.

• Vacuum leaks. To check for vacuum leaks, spray wateraround the throttle body seals while idling the engine. IfRPM changes, replace seals.

• Contaminated fuel.

• TPS reading of greater than 1% (possible throttle cablemisadjustment) or battery voltage reading of less than 9volts or a Vehicle Speed Sensor (VSS) greater than 0 willdisable idle speed control.

• If there is a loss of battery power at ECM terminal "31",vehicle will start but IAC pintle will not reset at key OFF.Eventually pintle will be out of position causing perform-ance problems.


1. When the engine is stopped, the IAC pintle extends andthen retracts to a fixed "Park" position for increased airflowand idle speed during the next engine start sequence.Thiskey OFF reset procedure takes 10 seconds to perform.

2. Test lamp behavior may follow two patterns. The color ofthe lights is not relevant to IAC operation.

a. Normal behavior: At key ON, test lights will alternatelyflash and then remain steady on to confirm ECM sig-nals. At key OFF lights alternately flash and go outafter 10 second reset procedure.

b. Problem indicated: One or more lights fail to illuminateduring key ON/key OFF cycle.



NOTEThere is a remote possibility that one of the circuits is shortedto voltage which would have been indicated by a steady light.Disconnect ECM and turn the ignition ON. Probe terminals tocheck for this condition.

3. Connect BREAKOUT BOX (Part No. HD-43876) to EFIwire harness only, leaving ECM disconnected. See4.6 BREAKOUT BOX: ECM.

4. Use HARNESS CONNECTOR TEST KIT (Part No. HD-41404-B) , purple terminal probe and patch cord.

5. Repair faulty ECM connection or replace ECM. If ECMrequires replacement, see ECM in the Service Manual.

ed02020

Figure 4-33. IAC Test Lamp (Part No. HD-41199-3)

ed03030

Figure 4-34. IAC



[87A][87B]

[78B][78A]

ECM

IACMotor

BE

/GN

BE

/GN

BK

/PK

BK

/PK

BN

/R

BN

/R

BK

/O

BK

/O

A

17 18 35 36

17

Idle

air

cont

rol(

A)

Hi

Idle

air

cont

rol(

B)

Low

Idle

air

cont

rol(

A)

Low

Idle

air

cont

rol(

B)

Hi

18 35 36

B C D

A B C D

em00128

Figure 4-35. IAC Circuit




Below air cleaner assembly4-place PackardIdle Air Control (IAC)[87]



Idle Air Control: DTC P0505 (Part 1 of 2)

Remove air cleaner cover and element.Are throttle valves completely closed?

YES NO

Lubricate andadjust throttle

cables.

Remove air cleaner cover and element.Monitor IAC pintle for 10 seconds after turning

ignition OFF. Does pintle extend and thenretract during 10 second key OFF

reset procedure?

YES NO

Check intake manifold for leaks. Remove airbox. Disconnect IAC and connecttest lamp. See Figure 4-34.

Turn ignition switch ON for 2 seconds,then turn ignition switch OFF for 10 seconds.NO

Check fuel pressure.See 4.15 FUEL

PRESSURE TEST.

Repair intakeleak.

Problemindicated.

Normalbehavior.

Repair faulty IACconnection or IAC

assembly.

Remove test lamp.Connect Breakout Box to connector[78B] leaving ECM disconnected.

Check terminal 31 for battery voltage.Battery voltage present?

YES NO

Go to 4.10 NO

ECM POWER.

YES

YES NO

Turn ignition ON. With ECM stilldisconnected, check voltage on allfour terminals at connector [87B].

Is voltage present?

Repair poor connection atconnectors [87B] or [78B] orrepair open wire in harness.

YES

Repair shortto voltage.

No

Using DVOM, measure resistance between IACconnector [87B] and Breakout Box.

Does each wire measure 0.5 ohms or less?

4

3

4

2

1

IAC

A

B

C

D

WIRE COLOR

BE/GN

BN/R

BK/PK

BK/O

ECM

to 35

to 36

to 18

to 17

fc01489_enSTOP

Go to Idle Air ControlDTC P0505(Part 2 of 2)



Idle Air Control: DTC P0505 (Part 2 of 2)

Continued from Idle Air Control DTC P0505 (Part 1 of 2).

Turn ignition OFF. Measure resistance betweeneach terminal on connector [87B] and ground.

Is resistance greater than 1 megohm for all terminals?

YES NO

Inspect ECMconnections.

Connections OK?


NO

Repair ECMconnections.

YES


5

4

fc01490_en



4.17MISFIRE AT IDLE OR UNDER LOAD

GENERAL

Misfire at Idle or Under Load• Battery condition and connections may also cause misfires.

See Battery in the Service Manual for more information.

• Fuel system problems may also cause misfires. Consult4.15 FUEL PRESSURE TEST and then see symptomtables under 4.8 INITIAL DIAGNOSTIC CHECK.

• Mechanical problems with the engine may cause misfires.See Service Manual for more information.

• Vehicle modifications including intake and exhaust maycause misfires.

DIAGNOSTICS






Wipe up spilled fuel and dispose of rags in a suitablemanner. An open spark around gasoline could cause afire or explosion, resulting in death or serious injury.(00518b)


NOTEEngine will not spark with both spark plugs removed. Whenchecking for spark, use SPARK TESTER (Part No. HD-26792)with both plugs installed.

2. See Figure Figure 4-36. A SPARK TESTER (Part No. HD-26792) must be used to verify adequate secondary voltage(25,000 volts) at the spark plug.

a. Turn ignition switch OFF.

b. See Figure 4-36 and Figure 4-37. Attach plug top coilto SPARK TESTER (Part No. HD-26792). Clip testerto ground.

c. While cranking engine, watch for spark to jump testergap on leads.

d. Reinstall and repeat procedure on other coil.

3. See Figure 4-37. Perform plug top coil resistance test.

a. Remove plug top coil.

b. Using an ohmmeter, touch probes to coil terminalsreferred to in Table 4-21.

c. If coil primary is out of range or coil secondary isbelow range, replace coil.

d. If coil secondary is above specified range, removeboot and recheck coil. If coil readings are within spe-cifications, replace boot. If coil secondary readingsare still above specifications, replace coil.

e. Reinstall and repeat procedure on other coil.

4. This test can also be performed by substituting a knowngood coil for one causing the no spark condition. The coildoes not require full installation to be functional. Verifyfaulty coil by performing resistance test. See Ignition Coilin the Service Manual.

5. Use HARNESS CONNECTOR TEST KIT (Part No. HD-41404-B), red terminal probe and patch cord to relay andgray terminal probe and patch cord to the coil connector[83B].

6. See 3.8 TROUBLESHOOTING for more information onvoltage drop testing.

ed02012

Figure 4-36. Spark Tester



32

1

ed03031



Table 4-21. Plug Top Coil

SPECIFICATIONCOIL

0.3-0.5 ohmsPrimaryTerminal "B" to Terminal "C"

3500-4500 ohmsSecondaryTerminal "A" to plug end ofboot

less than 5 ohmsPlug top coil boot

SystemRelay


FrontCoil

[83F B] [83F A]

[61B] [61A]

[78A] [78B]

Battery

40 AmpMAXIFUSE

StartSolenoid

IgnitionSwitch

15 AMPECM Fuse

15 AMPIGN Fuse

10

31

13

28

–+

3085

86

ES

U

4

Power ground

Constant power

Switch power

Power ground

System relay

10

31

13

28

4

BE/GY

GY/BE

GY/BEGY/BE

BE/GY

BK/GN

BK/GN

GN/OGN/O

W/BK

Y/GN

Y/GN

BE/O

BE/O Y/BE

Y/BE

Y/GN

W/BK

W/B

K

R/BK

GY

W/B

K

GY

BK

RR

R

87K

11

29

27

11

29

27

Rear coil

Front coil

Ion

CB

AC

BA

CB

AC

BA

Engine StopSwitch

[22A]

[22B]

4 3

4 3

em00129

Figure 4-38. Ignition Coil Circuit










On top of front cam cover3-place PackardFront plug top coil[83F]

On top of rear cam cover3-place PackardRear plug top coil[83R]



Misfire at Idle or Under Load (Part 1 of 3)

Is Fuel contaminated?

YES NO

Drain and flushtank. Refill with

fresh Fuel.

Connect Breakout Box. Check for continuitybetween terminal “10” of ECM and Battery

Negative and terminal “28” of ECM andBattery Negative.

Resistance should be less than 1 ohm. Is it?

YES NO

Locate and repair poorground connection.

Use spark tester to check cables.Did spark jump gap on both leads?

NOYES

Check for:• Faulty, worn or cracked spark plug(s).• Plug fouling due to engine mechanical fault.• Faulty or poor connection at plug or coils.

Check resistance of each spark plug boot that did notfire the spark tester.

Also, check for faulty plug boots and carbon tracking.Are boots OK?

NOYES

Plug top coils should befree of carbon tracking.

Are they?

Replacefaulty boots.

YES

Switch coil with unit known to begood. Perform spark test.

Did spark jump gap during enginecranking?

YES

Original plug top coilis faulty. Replace.

NO

Replaceignition coil.

2

4

NO

3

2

1

fc01491_en

STOP

Go to Misfire atIdle or Under

Load(Part 2 of 3)




Continued from Misfire at Idle or Under Load (Part 1 of 3).

Measure resistance between relay terminal “87” of fuseblock (relay removed) and coil connectors [83B] front and

rear at terminal “A” wire (Y/GN). Wiggle harness.Is resistance continuously less than 0.5 ohms?

YES NO

Find source ofintermittent and

repair.

Reassemble plug top coil. Measure voltagedrop between battery (positive lead) and

terminal “87” (negative lead) from underneathon system relay with engine running.

Is voltage drop less than 1.0 volt?

YES NO

Problem fuel related. See symptomcharts under 4.8 INITIALDIAGNOSTIC CHECK.

Repeat voltage drop test after moving negative lead toterminal “30”.

With engine running, is voltage drop less than 1.0 volt?

YES

Replace SystemRelay.

NO

Repeat voltage drop test after moving negative lead to15 amp ECM Fuse (BE/GY wire).


Repair wire(BE/GY).

NO

Repeat voltage drop test after moving negative lead to15 amp ECM Fuse (R wire).


YES NO

YES

Check terminal orReplace 15 amp

ECM Fuse.

5

6

fc01492_en

STOP

Go to Misfire atIdle or Under

Load(Part 3 of 3)




Continued from Misfire at Idle or Under Load (Part 2 of 3).

Repeat voltage drop test after moving negative lead to 40amp MAXIFUSE (output side).


YES

Check terminalor repair wire.

NO

Repeat voltage drop test after movingnegative lead to 40 amp MAXIFUSE

(input side).With engine running, is voltage drop

less than 1.0 volt?

NO

Repeat voltage drop test aftermoving negative lead to wire between

Maxifuse and Starter Solenoid.With engine running, is voltage drop

less than 1.0 volt?

NO

Repair or replaceBattery Cable.

YES

Check terminalor replace

MAXIFUSE.

YES

Repair wire betweenMAXIFUSE and Starter Motor.

fc01493_en



4.18COMBUSTION ABSENT/INTERMITTENT

GENERAL

Diagnostic Trouble Codes P1353, P1356,P1357, P1358: No CombustionSee Figure 4-39. A feedback voltage signal in the secondaryignition circuit (terminal A) detects the presence of combustioneach time a cylinder fires on ECM terminal "27". For diagnosticpurposes, this signal is only analyzed at high speed and loadwhere it may be easily measured. Failure to detect combustionat high speed and load means one of following conditions istrue:

• Cylinder is truly misfiring.

• There is a lack of continuity in the ignition coil secondarycircuit.


DESCRIPTIONDTC

Front cylinder no combustionP1353

Rear cylinder no combustionP1356

Front cylinder combustion intermittentP1357

Rear cylinder combustion intermittentP1358

Table 4-24. Plug Top Coil

SPECIFICATIONCOIL

0.3-0.5 ohmsPrimaryTerminal "B" to Terminal "C"

3500-4500 ohmsSecondaryTerminal "A" to plug end ofboot

less than 5 ohmsPlug top coil boot

DIAGNOSTICS




1. Perform plug top coil resistance test.

a. Remove plug top coil.

b. Using an ohmmeter, touch probes to coil terminalsreferred to in Table 4-24.

c. If coil primary is out of range or coil secondary isbelow range, replace coil.

d. If coil secondary is above specified range, removeboot and recheck coil. If coil readings are within spe-cifications, replace boot. If coil secondary readingsare still above specifications, clean the coil terminalsand repeat resistance test. If resistance is still highafter cleaning terminals, replace plug top coil.

e. An infinite ohms (or no continuity) resistance valueindicates an open circuit (a break in the coil winding).Replace plug top coil.

f. Reinstall and repeat procedure on other coil.


32

1

ed03031





SystemRelay


FrontCoil

[83F B] [83F A]

[61B] [61A]

[78A] [78B]

Battery

40 AmpMAXIFUSE

StartSolenoid

IgnitionSwitch

15 AMPECM Fuse

15 AMPIGN Fuse

10

31

13

28

–+

3085

86

ES

U

4

Power ground

Constant power

Switch power

Power ground

System relay

10

31

13

28

4

BE/GY

GY/BE

GY/BEGY/BE

BE/GY

BK/GN

BK/GN

GN/OGN/O

W/BK

Y/GN

Y/GN

BE/O

BE/O Y/BE

Y/BE

Y/GN

W/BK

W/B

K

R/BK

GY

W/B

K

GY

BK

RR

R

87K

11

29

27

11

29

27

Rear coil

Front coil

Ion

CB

AC

BA

CB

AC

BA

Engine StopSwitch

[22A]

[22B]

4 3

4 3

em00129











Combustion Absent/Intermittent: DTC P1353, P1356, P1357, P1358 (Part 1 of 2)

Is vehicle running properly?

YES NO

Has vehicle run outof fuel recently?

Check fuel pressure. See 4.15 FUELPRESSURE TEST.

Is fuel pressure 55-62 PSI (380-425 kPA)?

NOYES

See 4.15 FUELPRESSURE TEST.

See 4.12 FUEL SYSTEMELECTRICAL TEST.

YES NO

Clear codes, refill withfresh fuel and restart.

Does code return?

YES NO

SystemOK.

Perform coilresistance test.

Pass?

NO

Replace FaultyCoil.

YES

1

fc01494_enSTOP

Go to CombustionAbsent/IntermittentDTC P1353, P1356,

P1357, P1358(Part 2 of 2)



Combustion Absent/Intermittent: DTC P1353, P1356, P1357, P1358 (Part 2 of 2)

Continued from Combustion Absent/Intermittent DTC P1353,P1356, P1357, P1358 (Part 1 of 2).

Using Breakout Box, check continuity between connector [83B]terminal “A” of affected cylinder and Breakout Box terminal “27”.


YES NO

Replace Spark Plug.Condition still present?

YES NO

Measure resistance betweenterminal “A” and “B” at coil.

Resistance should begreater than 100k ohms.

Is it?

YES


password.

NO

Replace Coil and ECM.Reprogram and learn

password.

SystemOK.

Repair open onwire (GY/BE).

2

fc01495_en



4.19DTC P0107, P0108

GENERAL

MAP SensorSee Figure 4-41.The Manifold Absolute Pressure (MAP) sensoris supplied 5 volts from the ECM terminal "14" and sends asignal back to the ECM terminal "25". This signal varies inaccordance with engine vacuum and atmospheric barometricpressure. Changes in barometric pressure are influenced byweather and altitude.


DESCRIPTIONDTC

MAP sensor open/lowP0107

MAP sensor highP0108

DIAGNOSTICS


VACUUM PUMPHD-23738



Diagnostic TipsThese codes will set if the MAP sensor signal is out of range.Code P0108 can only be detected with the engine running.

NOTE

Do not over-pump vacuum pump during MAP sensor outputcheck as sensor damage may result.

• MAP sensor output check. Using the VACUUMPUMP (Part No. HD-23738), apply a vacuum to the pres-

sure port of the MAP sensor. The signal voltage shouldlower as the vacuum is applied.

• The MAP, Jiffy Stand and TP sensors are connected tothe same reference line (+5V Vref). If the reference linegoes to ground or open, multiple codes will be set (DTCP0107, P0108, P0122, P0123, P1501, P1502).



2. Use HARNESS CONNECTOR TEST KIT (Part No. HD-41404-B), purple terminal probes and patch cords.

3

12

ed03034

1. Front intake2. Rear intake3. MAP sensor

Figure 4-41. MAP Sensor (throttle body removed)



[80A][80B]

[78B][78A]

[145B][145A]

To TP, ECT &IAT sensors

To TPsensor& VSS

ECM

14 25 26

14

5Vse

nsor

pow

er

Map

inpu

t

5Vse

nsor

grou

nd

25 26

V/W

R/W

BK

/W

V/W

R/W

BK

/W

V/W

R/W

BK

/W

A B C

A B C

6 7 8

6 7 8

MAPSensor

em00130

Figure 4-42. MAP Sensor Circuit




Front intake passage3-place PackardManifold Absolute Pressure (MAP)sensor

[80]

Under air cleaner12-place DeutschEngine[145]



MAP Sensor: DTC P0107, P0108 (Part 1 of 2)

1

YES NO

YES

YES

NO

NO

Connect Breakout Box. With ignition ON,measure voltage between terminal “25”

and terminal “26” on Breakout Box.

With ignition ON, engine OFF, voltage mustbe between 3.5 and 5.0 volts.

With ignition ON, engine running, voltagemust be between 1.5-3.0 volts at hot idle.

Does voltage fit specifications?

Perform 4.7 WIGGLE TESTto check for intermittents.

Intermittents present?

To identify the source ofintermittents, start with boxmarked by Bold Asteriskunder MAP Sensor: DTC

P0107, P0108 (Part 2 of 2).

Wiggle harness whilewatching DVOM.

Replace MAP sensor. Clear codes using IM.Perform road test. Did check engine lampilluminate and set DTC P0107 or P0108?

Install original MAP sensor.Replace ECM (reprogram,

relearn) and road test againto verify.

Systemnow OK.

At some point in the flow chart youmay be instructed to jump directlyto the box with the bold asterisk.Disregard the asterisk (but not theinstruction box) if your normal pro-gression through the chart bringsyou to this location.

fc01496_en

*

STOP

Go to MAP SensorDTC P0107, P0108

(Part 2 of 2)



MAP Sensor: DTC P0107, P0108 (Part 2 of 2)

YES NO


2

2

2

YES NO

NO

NO

YES

YES

YESNO.

Greater than6V.

NO.Less

than 4.5V.

Locate and repairopen on (V/W) wire.

Locate short to 12 volts on(R/W) wire in wire harness.

Repair as necessary.

Continued from MAP Sensor DTC P0107,P0108 (Part 1 of 2).

Check the 5 volt reference supply atthe MAP sensor connector [80B]. Withignition ON, measure voltage between

terminal “C” (R/W) and terminal “A” (BK/W).Voltage approximately 5.0 volts?

2

Connect Breakout Box to [78B] leavingECM disconnected.

OPEN CHECK: Measure resistancebetween MAP connector [80B]

terminal “B” and Breakout Box terminal ‘25".Resistance less than 1 ohm?

SHORT CHECK: Measureresistance between MAP connector

terminal “B” and chassis ground.Resistance greater than 1 megohm?

Connect Breakout Box to [78B] leavingECM disconnected. Check continuity between

MAP connector [80B] terminal “C” andBreakout Box terminal “14”. Then measurecontinuity between MAP connector [80B]

terminal “A” and Breakout Box terminal “26”.Less than 1 ohm present?

Replace MAP sensor.See VRSC Service

Manual.

Locate and repairgrounded V/W wire.

Check resistance betweenMAP connector [80B]

terminal “C” andBreakout Box terminal “26”.

Resistance greater than1 megohm?


password.

Locate and repair shortbetween (R/W) and

(BK/W) wires.

Repairopen wire.

fc01497_en

*

*



4.20DTC P0112, P0113

GENERAL

IAT SensorThe ECM supplies and monitors a voltage signal terminal "7"to one side of the Intake Air Temperature (IAT) sensor. Theother side of the IAT sensor is connected to a common sensorground, which is also connected to the ECM terminal "26".

The IAT sensor is a thermistor device, meaning that at a spe-cific temperature, it will have a specific resistance across itsterminals. As this resistance varies, so does the voltage atterminal "7".

• At high temperatures, the resistance of the sensor is verylow, which effectively lowers the signal voltage on terminal"7".

• At low temperatures, the resistance is very high, allowingthe voltage to rise close to 5 volts.

The ECM monitors this voltage to compensate for variousoperating conditions.


DESCRIPTIONDTC

IAT sensor voltage lowP0112

IAT sensor open/highP0113

Table 4-29. IAT Sensor Table

TEMP °FVOLTAGERESISTANCETEMP°C

-44.815701-20

144.69539-10

324.359590

504382010

683.6250920

773.4205125

863.2168630

1042.7115740

1222.381050

1401.957860

1581.541970

1761.230980

194123190

2120.8176100

ed03035

Figure 4-43. IAT Sensor

DIAGNOSTICS




Diagnostic TipsAn intermittent may be caused by a poor connection, rubbedthrough wire insulation or a wire broken inside the insulation.

Check the following conditions:

• Poor connection: Inspect ECM and harness connector[78] for backed out terminals, improper mating, brokenlocks, improperly formed or damaged terminals, poor ter-minal- to-wire connection and damaged harness.

• Perform 4.7 WIGGLE TEST to locate intermittents: Ifconnections and harness check out OK, use a DVOM tocheck the intake air temperature sensor voltage whilemoving related connectors and wiring harness. If the failureis induced, the intake air temperature display will change.

• Shifted sensor: Refer to Table 4-29. This table may beused to test the intake air temperature sensor at varioustemperature levels in order to evaluate the possibility of ashifted (out-of-calibration) sensor which may result indriveability problems.

NOTE

All voltage and resistance values are approximate (±20%).Measure IAT sensor resistance between ECM terminal "7" andsystem ground (ECM terminal "26").


1. Connect BREAKOUT BOX (Part No. HD-43876) to EFIwire harness only (leave ECM disconnected). See4.6 BREAKOUT BOX: ECM.



2. If the engine has not been operated for 1 hour, the meas-ured resistance should be very close to the measuredresistance across the ECT sensor which is terminals "6"and "26" on the Breakout Box.

3. Use HARNESS CONNECTOR TEST KIT (Part No. HD-41404-B) , gray terminal probes and patch cords.

4. Use HARNESS CONNECTOR TEST KIT (Part No. HD-41404-B), purple socket probes and patch cords.

5. Replace IAT sensor. See the Service Manual.

To TP, ECT &MAP sensors

IATSensor

[89A][89B]

[78B]

ECM

[78A]LG

N/Y

BK

/W

BK

/W

1 2

1 2

7

IAT

5Vse

nsor

grou

nd

26

7 26

em00131

Figure 4-44. IAT Sensor Circuit




Under airbox cover2-place PackardIntake Air Temperature (IAT) sensor[89]



IAT Sensor: DTC P0112, P0113 (Part 1 of 2)

YES NO


YES YESNO NO

NO

NO

YES

YES

YES

11

1

2

Connect Breakout Box to connector [78B] leavingECM disconnected. With engine at room temperature

60-90°F (16-32°C), use a DVOM to measureresistance across terminals “7” and “26” on Breakout

Box. If engine is warm, refer to Table 4-29.Resistance between 1.0k ohms and 2.8k ohms?

Connect ECM to Breakout Box.Perform 4.7 WIGGLE TEST to

check for intermittents.Intermittents present?

While wiggling harness, performsteps marked by BOLD ASTERISKS

under IAT Sensor: DTC P0112, P0113(Part 2 of 2).


Disconnect IAT sensor connector [89]. Turnignition ON. Using a DVOM, measure the

voltage between ECM terminal “7” (positive)and terminal “26” (negative) on Breakout Box.

Voltage approximately 5 volts?

Replace IAT sensor, clear codesusing IM. Perform road test. Did

check engine lamp illuminate and setDTC P0112 or P0113?

With IAT sensor disconnected,disconnect ECM from Breakout box.

Measure resistance betweenBreakout Box terminal “7” and terminals

“10” or “28”.Resistance less than 1 megohm?

Unplug ECM leaving Breakout Boxconnected at vehicle harness.

Measure voltage betweenBreakout Box terminal “7” and

terminals “10” or “28”.Voltage 0 volts?

NO.Less than4.7 volts.

NO.Greater than

5.3 volts.

Examine IAT signalwire (LGN/Y) forshort to voltage

and repair.



Repair short toground on

LGN/Y wire.

SystemOK.

Install original IATsensor, replace ECM.

Perform Passwordlearning and road test.

fc01498_en

*

STOP

Go to IAT SensorDTC P0112, P0113

(Part 2 of 2)



IAT Sensor: DTC P0112, P0113 (Part 2 of 2)

YES NO


3

3

4

5

YES NO

YES NO

YES

YES

YES

NO

NO

NO

Continued from IAT Sensor DTCP0112, P0113 (Part 1 of 2).

Disconnect IAT sensor connector[89B] and examine for damage.

Connector OK?

Using a DVOM, measure the resistancebetween IAT sensor connector [89B]terminal “1" and ECM terminal “7” on

Breakout Box.Resistance less than 1.0 ohm?

Using a DVOM, measure the resistancebetween IAT sensor connector [89B]

terminal “2” and ECM terminal “26” onBreakout Box.

Resistance less than 1.0 ohm?

Using a DVOM, measure the resistancebetween ECM terminal “7” and terminal “26”

on Breakout Box.Resistance greater than 1.0 megohm?

Using a DVOM, measure the resistancebetween ECM terminal “7” on Breakout

Box and ground.Resistance greater than 1.0 megohm?

Remove IAT sensor and measure resistance acrossthe terminals of the IAT sensor directly. Again, with

sensor at room temperature 60-90F (16-32C).If engine is warm, refer to Table 4-29.

is resistance between 1.0k ohms and 2.1k ohms?

Perform 4.7 WIGGLE TEST on stepsmarked with a BOLD ASTERISK above tolocate intermittents. Repair as necessary.

Examine harness forshort to ground and

repair.

Examine (LGN/Y) and(BK/W) wires in harnessfor short between thesetwo circuits and repair.

Examine (BK/W) wire inharness for open circuit

and repair.

Examine (LGN/Y) wire inharness for open circuit

and repair.

Repairconnector.

ReplaceIAT sensor.

fc01499_en

*

*

*

*

*



4.21DTC P0117, P0118

GENERAL

ECT SensorThe ECM supplies and monitors a voltage signal terminal "6"to one side of the Engine Coolant Temperature (ECT) sensor.The other side of the ECT sensor is connected to a commonsensor ground, which is also connected to the ECM terminal"26".

The ECT sensor is a thermistor device, which means that at aspecific temperature it will have a specific resistance acrossits terminals. As this resistance varies, so does the voltage onterminal "6".

• At high temperatures, the resistance of the sensor is verylow, which effectively lowers the signal voltage on terminal"6".

• At low temperatures, the resistance is very high, allowingthe voltage to rise close to 5 volts.

The ECM monitors this voltage to compensate for variousoperating conditions. The ECM also uses the sensor input asa reference for determining IAC pintle position.


DESCRIPTIONDTC

ECT sensor voltage lowP0117

ECT sensor open/highP0118

DIAGNOSTICS




Diagnostic TipsOnce the engine is started, the temperature should rise steadily.

An intermittent may be caused by a poor connection, rubbedthrough wire insulation or a wire broken inside the insulation.

Check the following conditions:

• Poor connection: Inspect ECM harness connector [78]for backed out terminals, improper mating, broken locks,improperly formed or damaged terminals, poor terminal-to-wire connection and damaged harness.

• Perform 4.7 WIGGLE TEST to locate intermittents: Ifconnections and harness check out OK, use a DVOM tocheck the engine temperature reading while moving relatedconnectors and wiring harness. If the failure is induced,the engine coolant temperature display will change.

• Shifted sensor: Refer to Table 4-32. This table may beused to test the Engine Temperature (ET) sensor at

various temperature levels in order to evaluate the possib-ility of a shifted (out-of-calibration) sensor which may resultin driveability problems.

NOTE

All voltage and resistance values are approximate (±20%).Measure ECT sensor resistance between ECM terminal "6"and system ground ECM terminal "26".


1. Connect BREAKOUT BOX (Part No. HD-43876) to EFIwire harness only (leave ECM disconnected). See4.6 BREAKOUT BOX: ECM.

2. If engine has not been operated for 1 hour, the measuredresistance should be very close to the measured resist-ance across the IAT sensor which is terminals "7" and"26" on the Breakout Box.


4. Use HARNESS CONNECTOR TEST KIT (Part No. HD-41404-B), gray socket probes and patch cords.

5. Replace ECT sensor. See the Service Manual.

Table 4-32. ECT Sensor Table

TEMP °FVOLTAGERESISTANCETEMP°C

-44.428582-20

144.116120-10

323.693990

503565810

682.4351120

772.1280025

861.8224030

1041.4 or 4.1*146540

1221.0 or 3.7*98050

1403.367160

1582.946970

1762.533480

1942.124290

2121.7178100

* Between 40-50° C (104-122° F) the ECM changes scaling.Voltages for ECT sensor will shift scales in that range. Thisprovides proper sensor resolution for all temperatures.



To TP, IAT &MAP sensors

ECTSensor

[90A][90B]

[78B]

ECM

[78A]

[145B][145A]

BK

/W

BK

/W

A B

5 6

5 6

A B

6

EC

T

5Vse

nsor

grou

nd

26

6 26

PK

/Y

BK

/W

PK

/Y

PK

/Y

em00132

Figure 4-45. ECT Sensor Circuit




Water pump housing2-place PackardEngine Coolant Temperature (ECT)sensor

[90]




ECT Sensor: DTC P0117, P0118 (Part 1 of 2)


1

11

2

YES NO

YES

YES

NO

NONONOYES YES YES

Connect Breakout Box to connector [78B] leaving ECMdisconnected. With engine at room temperature 60-90F(16-32C), use a DVOM to measure resistance across

terminals “6” and “26" on Breakout Box. If engine is warm,refer to Table 4-32.

Resistance between 2k ohms and 4k ohms?

Connect ECM to Breakout Box.Perform 4.7 WIGGLE TEST to check for

intermittents.Intermittents present?

While wiggling harness, performsteps marked by BOLD ASTERISKS

under Test 4.21 (Part 2 of 2).Repair as necessary.

Disconnect ECT sensor connector[90]. Turn ignition ON. Using a

DVOM, measure the voltage betweenterminals “6” (positive) and “26”

(negative) on Breakout Box.Voltage approximately 5 volts?

With ECT sensor disconnected,disconnect ECM from Breakout box.

Measure resistance between terminal“6" and terminals “10” or “28”.

Resistance less than 1 megohm?

Replace ECT sensor, clear codesusing IM. Perform road test. Did

check engine lamp illuminate and setDTC P0117 or P0118?

Unplug ECM leaving Breakout Boxconnected at vehicle harness.

Measure voltage between terminal“6” and terminals “10” or “28”.

Voltage 0 volts?

NO.Less than4.7 volts.

NO.Greater than

5.3 volts.

Examine ECT signalwire (PK/Y) for shortto voltage and repair.



Repair short toground on

(PK/Y) wire.

Install original ECTsensor, replaceECM. Perform

password learningand road test.

SystemOK.

fc01500_en

*

STOP

Go to ECT SensorDTC P0117, P0118

(Part 2 of 2)



ECT Sensor: DTC P0117, P0118 (Part 2 of 2)

YES NO


3

3

4

5

YES NO

YES NO

YES

YES

YES

NO

NO

NO

Continued from ECT Sensor DTC P0117,P0118 (Part 1 of 2).

Disconnect ECT sensor connector [90B]and examine for damage.

Connector OK?

Using a DVOM, measure the resistancebetween ECT sensor connector [90B]terminal “A” and ECM terminal “6” on


Using a DVOM, measure the resistancebetween ECT sensor connector [90B]terminal “B” and ECM terminal “26” on


Using a DVOM, measure the resistancebetween ECM terminals “6” and “26” on

Breakout Box.Resistance greater than 1.0 megohm?

Using a DVOM, measure the resistancebetween ECM terminal “6” on Breakout

Box and ground.Resistance greater than 1.0 megohm?

Remove ECT sensor and measure resistanceacross the terminals of the ECT sensor directly.

Measure again, with sensor at roomtemperature 60-90F (16-32C).

If engine is warm, refer to Table 4-29.Resistance between 2k ohms and 4k ohms?

Perform 4.7 WIGGLE TEST on stepsmarked with a BOLD ASTERISK above tolocate intermittents. Repair as necessary.

Examine harness forshort to ground and

repair.

Examine (PK/Y) and(BK/W) wires in harnessfor short between thesetwo circuits and repair.

Examine (BK/W) wire inharness for open circuit

and repair.

Examine (PK/Y) wire inharness for open circuit

and repair.

Repairconnector.

ReplaceECT sensor.

*

*

*

*

*

fc01501_en



4.22DTC P0122, P0123

GENERAL

TP SensorThe ECM supplies a 5 volt signal terminal "14" to the ThrottlePosition (TP) sensor. The TP sensor sends a signal back tothe ECM terminal "24". The returned signal varies in voltageaccording to throttle position.

• At idle (closed throttle), the signal is typically in the rangeof 0.20-0.80 volts.

• At wide open throttle, the signal is normally 4.0-4.9 volts.

DTC P0122 or P0123 will set if the TP sensor voltage signaldoes not fall within the acceptable range.


DESCRIPTIONDTC

TP sensor open/lowP0122

TP sensor highP0123

DIAGNOSTICS




Diagnostic TipsThe DVOM reads throttle position in volts. Voltage shouldincrease at a steady rate as the throttle is moved from idle towide open. A short to ground or open on the (GY/V) or (R/W)wires also will result in a DTC P0122. A short to ground or openon the (R/W) wire (+5V REF) sets multiple codes as describedbelow.

NOTE

The MAP and TP sensors are both connected to the samereference line (+5V Vref). If the line goes to ground or open,

multiple trouble codes will be set (DTCs P0107, P0108 andP0122, P0123, P1501, or P1502.) Start with the DTC havingthe lowest ranking value.

Check for the following conditions:

• Poor Connection: Inspect ECM harness connector [78B]for backed out terminals, improper mating, broken locks,improperly formed or damaged terminals, poor terminal-to-wire connection and damaged harness.

• Perform 4.7 WIGGLE TEST to locate intermittents: Ifconnections and harness check out OK, monitor TP sensorvoltage using a DVOM while moving related connectorsand wiring harness. If the failure is induced, the TP sensorvoltage will change.

• TP sensor scaling: Observe the TP sensor voltage dis-play while opening the throttle with engine stopped andignition switch ON. Display should vary from closed throttleTP sensor voltage (when throttle is closed) to greater than4.0 volts (when throttle is held wide open). As the throttleis slowly moved, the voltage should change graduallywithout spikes or low voltages being observed.


1. Connect a BREAKOUT BOX (Part No. HD-43876) betweenEFI wire harness and ECM before measuring voltage. See4.6 BREAKOUT BOX: ECM. If using a DVOM to measurevoltage, take reading across terminals "24" (positive lead)and "26" (negative lead) on Breakout Box.

2. Replace TP sensor. See the Service Manual.




[88A][88B]

[78B]

To MAPsensor& VSS

To MAP, ECT &IAT sensors

TPSensors

[78A] 14 24 26

14 24 26

ECM

TP

5Vse

nsor

grou

nd

5Vse

nsor

pow

er

BK

/W

GY

/V

R/W

BK

/W

GY

/V

R/W

A B C

A B C

em00133

Figure 4-46.TP Sensor Circuit




Front of throttle body3-place PackardThrottle Position (TP) sensor[88]



TP Sensor: DTC P0122, P0123 (Part 1 of 2)

YES NO


2

2

1

YES NO

YES

YES

YES

YES YES

NO

NO

NO

NO NO

With ignition switch ON, measure TP sensor voltage whilegradually opening throttle.

Does voltage increase steadily (without spikes or low voltages)from 0.2-0.8 volts at idle to 4.0-4.9 volts at wide open throttle?

Check engine lamp ONcontinuously and

DTC P0122 or P0123the only codes set?

Voltage isgreater than4.95 volts.

Low voltageor spikesobserved.

Unplug TP sensor connector [88B]and measure voltage between

terminal “B” (+) and terminal “A”(-) with ignition ON.

Is reading 4.8-5.0 volts?

Measure resistanceBetween TP sensor

connector [88B] terminal“B” to ECM terminal “14”

on Breakout Box.Less than 1.0 ohm?



Disconnect ECM fromBreakout Box. Check

resistance between ECMterminal “24” on Breakout

Box to chassis ground.Greater than 1 megohm?

Replace TP sensor, clear codesusing IM. Perform road test.

Did check engine lampilluminate and set DTC P0122

or P0123?

While wiggling harness,start with the first step ofTest 4.22 (Part 2 of 2)

(marked by BOLDASTERISK).



ReplaceTP sensor.

Find short toground on (GY/V)

signal wire.Install original TP sensor,replace ECM (reprogramand learn password) and

road test.

Repair openin (BK/W) wire.

Repair openin (R/W) wire.

SystemOK.

*

fc01502_en

STOP

Go to TP SensorDTC P0122, P0123

(Part 2 of 2)



TP Sensor: DTC P0122, P0123 (Part 2 of 2)

YES NO

At some point in the flow chart youmay be instructed to jump directlyto the box with the bold asterisk.Disregard the asterisk (but not theinstruction box) if your normalprogression through the chart bringsyou to this location.

YES

YES

NO

NO

3

3

2

Continued from TP Sensor DTC P0122, P0123 (Part 1 of 2).

With ignition switch OFF, disconnect ECM connector [78B].Turn ignition switch ON.

Voltage greater than 0 volts across terminals “24” (+) and “26”(-) on Breakout Box?

Measure resistance between ECMterminal “24” on Breakout Box and TPsensor connector [88B] terminal “C”.

Less than 0.5 ohm?

Repair short between(GY/V) signal wire and

12 volts.

Measure resistance from TPsensor connector [88B]

terminal “C” to terminal “B”.Less than 1.0 megohm?

Repair open (GY/V)signal wire.

Repair shortbetween (R/W) and(GY/V) signal wire.

ReplaceTP sensor.

*

*

fc01503_en



4.23DTC P0131, P0132, P0134, P0151, P0152, P0154

GENERAL

O2 SensorSee Figure 4-47. The Oxygen (O2) Sensor provides a signalto the ECM which indicates whether the engine is running richor lean.

• A P0131 (front) or P0151 (rear) is set when the ECMdetects an excessively lean condition for a specified lengthof time. DTCs may also set if O2 Sensor fails.

• A P0132 (front) or P0152 (rear) is set when the ECMdetects an excessively rich condition for a specified lengthof time. DTCs may also set if O2 Sensor fails.

• A P0134 is set when the front O2 Sensor circuit is openor sensor is too cold to respond. A P0154 is set when therear O2 Sensor circuit is open or sensor is too cold torespond.

When the air/fuel mixture is ideal, approximately 14.6 parts airto 1 part fuel, the voltage will be approximately 0.45 V.


DESCRIPTIONDTC

Front O2 sensor low or engine running leanP0131

Engine running richP0132

Front O2 sensor open/not responding/highP0134

Rear O2 sensor low or engine running leanP0151

Engine running richP0152

Rear O2 sensor open/not responding/highP0154

ed02059

Figure 4-47. O2 Sensor

DIAGNOSTICS




Diagnostic TipsO2 Sensor diagnostic codes may be seen during the vehiclebreak-in period. The O2 Sensor DTCs will not illuminate thecheck engine lamp for current or historic codes and will onlybe indicated by DIGITAL TECHNICIAN (Part No. HD-44750)or IM self-diagnostics. If the DTCs are reported during thebreak-in period, clear or ignore the codes until the break-inperiod is completed. All historic O2 Sensor DTCs are to beignored and cleared.

The DVOM displays the signal from the O2 Sensor in volts.This voltage will have an average value tending towards lean,rich or ideal value depending on operating temperature of theengine, engine speed and throttle position. An open/short tovoltage or short to ground in the (PK/O) wire (front) and(PK/GN) wire (rear) will cause the engine to run rich (short toground) or lean (short to voltage) until fault is detected. Oncefault is detected, vehicle will run in open loop.

Check for the following conditions:

• Poor Connection: Inspect the ECM [78], fuel injector [84,85] and O2 Sensor connectors for backed out terminals,improper mating, broken locks, improperly formed ordamaged terminals, poor terminal-to-wire connection anddamaged harnesses.

• Dirty/stuck open injectors: The vehicle may run lean(dirty/clogged injectors) or rich (stuck open injectors) ifthere are injector problems. This could also cause poorfuel economy and performance.

• Loose O2Sensor: If an O2 Sensor is loose, engine per-formance may be affected. This could also show up as aslow changing O2 Sensor voltage.

• Loose/leaking exhaust: This can cause a poor groundconnection for the sensor or allow fresh air into the exhaustsystem. If fresh air enters exhaust system, the O2 Sensorwill read a lean condition, causing the system to go rich.

• Engine misfire: See 4.6 BREAKOUT BOX: ECM


1. Connect a BREAKOUT BOX (Part No. HD-48637) betweenwire harness and ECM before measuring voltage. See4.6 BREAKOUT BOX: ECM

2. 5 volts is typical for a cold engine. Once the O2 Sensorsare up to operating temperature, typical voltage is 0.45volt.



Front O2 Sensor Rear O2 Sensor

[138A][138B]

[78B][78A]

ECM

[137A][137B]

1 2

1 2

1 2

1 2

26238

26238

Fron

tO2

sens

orin

put

Rea

rO

2se

nsor

inpu

t

Sen

sor

grou

nd

BE

GY

/BE

BE

GY

/BE

PK

/GN

PK

/O

BK

/W

em00116

Figure 4-48. O2 Sensor Circuit



Under seat36-place terminal PackardElectronic Control Module (ECM)[78]

Under seat2-place terminal Amp (Tyco)Oxygen (O2) Sensor rear exhaustheader

[137]

Under left trim cover2-place terminal Amp (Tyco)Oxygen (O2) Sensor front exhaustheader

[138]



Oxygen Sensor: DTC P0131, P0132, P0134, P0151, P0152, P0154 (Part 1 of 3)

Disconnect O2 Sensor from harness. Connect DVOM to terminal “8” (front, +)and terminal “26” (-), terminal “23” (rear, +) and terminal “26” (-) of connector [78B].

Turn Ignition Switch to IGNITION position. Observe O2 voltage.Is it approximately 5.0 volts?

YES

2

NO.0.0 volt.

NO.Greater than

5.0 volts.

Install Breakout Box (HD-43876) leavingECM [78B] disconnected from the Breakout

Box. Measure continuity to ground onterminal “8” (front) or terminal “23” (rear).


Install Breakout Box (HD-43876)leaving ECM [78B] disconnected

from the Breakout Box.Is voltage present?

1

YES NO

Locate and repairshort to ground on

(PK/O) (front) and/or(PK/GN) (rear) wire.

NOYES

Inspect (PK/O) (front)and/or (PK/GN) (rear)

wire for short tovoltage and repair.

Replace ECM.

1

STOP

Go to O2 SensorDTC P0131,

P0132, P0134,P0151, P0152,

P0154(Part 2 of 3).

Replace ECM.

1

Clear DTCs using instrument module self-diagnostics.See 4.5 INSTRUMENT MODULE SELF-DIAGNOSTICSConfirm proper operation with no check engine lamp.

fc01521_en




Continued from O2 Sensor DTC P0131, P0132, P0134, P0151, P0152, P0154 (Part 1 of 3).

Turn Ignition Switch OFF and reconnect O2 sensor. Turn Ignition Switch to IGNITION positionand start engine. Allow engine to reach operating temperature.

With engine idling, does voltage at terminal “8” (+) and terminal “26” (-) (front) and terminal“23” (+) and terminal “26” (-) (rear) quickly fluctuate between 0.0 and 1.0 volt?

NO.0.6-1.0 volt.

NO.Slow or no change.

Perform fuel pressure test.See 4.15 FUEL

PRESSURE TEST.Pressure too high?

Check continuity betweenterminal “8” [78] (front) andterminal “1” [138] (front) or

terminal “23” [78] (rear) andterminal “1” [137] (rear).

Continuity present?

YES NO

Replace FuelPressure Regulator.

NOYES

Replace O2

sensor

Repair openon (PK/O) (front)and/or (PK/GN)

(rear) wire.

Check for injectorsstuck open. See4.22 DTC P0261,P0262, P0263,P0264. Retest.

YES

STOP

NO.0.0-0.4 volt.

Perform fuel pressure test.See 4.15 FUEL

PRESSURE TEST.Pressure too low?

YES NO

Repair low pressureproblem. See

4.15 FUELPRESSURE TEST.

Check for restrictedFuel Filter or Fuel

Line.Restriction present?

Go to O2 SensorDTC P0131, P0132,

P0134, P0151,P0152, P0154 (Part

3 of 3).

NOYES

Replace FuelLine or Fuel

Filter.

Check for air leaksat induction

module.Air leak present?

NOYES

RepairFuel Injectors may

be dirty.

fc01522_en


3




Continued from O2 Sensor DTC P0131, P0132, P0134,P0151, P0152, P0154 (Part 2 of 3).

Check for intermittents by performing wiggle test.See 4.7 WIGGLE TEST.


YES NO

Repairas necessary.

Replace O2 Sensor.Clear codes and road test.

Check for DTCs.

Did O2 Sensor set a P0131, P0132,P0134, P0151, P0152 or P0154?

NOYES

Install original O2 Sensorand replace ECM.

Road test again to verify.

Systemnow OK.

fc01523_enClear DTCs using instrument module self-diagnostics.See 4.5 INSTRUMENT MODULE SELF-DIAGNOSTICSConfirm proper operation with no check engine lamp.



4.24DTC P0261, P0262, P0263, P0264

GENERAL

Fuel InjectorsThe fuel injectors are solenoids that allow pressurized fuel intothe intake tract.The injectors are timed to the engine cycle andtriggered sequentially. The power for the injectors comes fromthe system relay. The system relay also provides power forthe fuel pump and the ignition coil.The ECM provides the pathto ground to trigger the injectors.

NOTE

ECM fuse and system relay failures or wiring harness problemswill cause 12 volt power to be lost to both injectors, ignitioncoils and fuel pump.


DESCRIPTIONDTC

Front injector open/lowP0261

Front injector highP0262

Rear injector open/lowP0263

Rear injector highP0264

DIAGNOSTICS





1. See the Service Manual for all service information.


3. Connect a BREAKOUT BOX (Part No. HD-43876) betweenEFI wire harness and ECM. See 4.6 BREAKOUT BOX:ECM.

ed03036

Figure 4-49. Fuel Injector Connector

ed02060

Figure 4-50. Fuel Injector Test Lamp (Part No. HD-34730-2C)

ed02800

Figure 4-51. Relay Terminals



EngineStop Switch

[22A][22B]

34

34

W/BK

W/B

K

GY

IgnitionSwitch

SystemRelay

[145A] [145B][85A]

Front Injector

Rear Injector

[85B]

[84A][84B]

[86B] [86A]

BatteryStarter

Solenoid

40 AmpMAXIFUSE

15 AMPECM Fuse

15 AMPFuel Pump

Fuse

15 AMPIGN Fuse

10

31

13

28

–+

[78A] [78B] 3085

86

ES

U

4

Power ground

Constant power

Switch power

Power ground

System relay

10

31

13

28

4

BE/GY

BE/GY

BK/GN

BK/GN

GN/OGN/O

W/BK

Y/GN

Y/GN

Y/GN O/GY

R/BK

BK

R

R

R

19

21

19

21

Rear INJ

Front INJ

87K

AB

AB

AB

AB

13

13

2 2 W/Y

GN/GY

W/Y

GN/GY

AB

CD

AB

CD

FuelPump

[61B] [61A]em00125

Figure 4-52. Fuel Injectors Circuit






Throttle body2-place PackardFront injector[84]

Throttle body2-place PackardRear injector[85]

Top of fuel tank4-place PackardFuel pump[86]

Under air cleaner12-place DeutschEngine harness145]



Fuel Injectors: DTC P0261, P0262, P0263, P0264 (Part 1 of 3)

1

YES NO

2

2

2

1

YES

YES

YES

YES

YES

YES

NO

NO

NO

NO

NO

NO

Is wire bail on connector securelyattached to the fuel injector?

With the Fuel Injector TestLamp installed, crank

engine.Does lamp flash?

Recheck connections.Perform 4.7 WIGGLE TEST

to check for intermittents.Intermittents present?

Reconnect.

Check terminal “A” (Y/GN wire)on injector connector to ground.

Voltage equivalent to battery voltagefor 2 seconds after key ON?

Check for 12 volts at terminal “87” ofsystem relay during first 2 seconds after

key ON. Correct voltage present?

Measure resistance ofsuspect injector across

injector terminals.Resistance

10.0-25.0 ohms?

System relay OK. Measureresistance between terminal “87” of

system relay and terminal “A”(Y/GN wire) at injector connector.Resistance less than 0.5 ohm?

Repairintermittent.

Replaceinjector.

Check for looseor corroded terminals

in harness.



Find and repairbad connectionor open wire.

fc01504_en

STOP

Go to Fuel InjectorsDTC P0261, P0262,

P0263, P0264(Part 3 of 3).

STOP

Go to Fuel InjectorsDTC P0261, P0262,

P0263, P0264(Part 2 of 3).




2

YES NO

2

33

3

NO

NO

YES

YES

Continued from Fuel Injectors DTC P0261, P0262, P0263,P0264 (Part 1 of 3).

FRONT INJECTOR: DTC P0261 or P0262.

Measure resistance between Breakout Box terminal “21”(W/Ywire) and terminal “B” of front injector connector [84B].

Continued from Fuel Injectors DTC P0261, P0262, P0263,P0264 (Part 1 of 3).

REAR INJECTOR: DTC P0263 or P0264.

Measure resistance between Breakout Box terminal “19” (GN/GY wire) and terminal “B” of rear injector connector [85B].

Resistanceless than 0.5 ohm?

Repair open orpoor connection.

Check for continuity between terminal“10” and ground.

Front injector codes: Check continuitybetween terminals “21” and “10”,

orRear injector codes: Check continuity

between terminals “19” and “10”.Continuity present?

Check for voltage with Ignition Switch ON.Front injector codes: Check betweenBreakout box terminals “10” and “21”,

orRear injector codes: Check betweenBreakout box terminals “10” and “19”.

Voltage present after 2 seconds?




fc01505_en




2

YES NO

2

2

2

3

3

YES

YES

YES

YES

NO

NO

NO

NO

Continued from Fuel Injectors DTC P0261, P0262, P0263, P0264(Part 1 of 3)

Check for 12 volts at terminal “30” of the system relay.Correct voltage present?

Check for 12 volts at terminal“86” of the system relay.Correct voltage present?

Find and repairopen on (BE/GY) between

fuse and relay.

Measure resistance betweenterminal “86” of the system

relay and ECM terminal “13” onBreakout Box.


Measure resistance betweenterminal “85” of the system relay

and ECM terminal “4” onBreakout Box.


Install known good relay.Does fuel pump run for first2 seconds after key ON?


Find and repairopen on (W/BK) wire.

Find and repairopen on (GN/O) wire.

Reinstall original relayReplace ECM.

Reprogram and learn password.

Replacerelay.

fc01506_en



4.25DTC P0373, P0374

GENERAL

CKP SensorIf the Crankshaft Position (CKP) sensor signal is weak orabsent, DTCs P0373 or P0374 will be set.

NOTE

If signal is not detected or cannot synchronize (DTC P0374),engine will not start.


DESCRIPTIONDTC

CKP sensor intermittentP0373

CKP sensor synch errorP0374

DIAGNOSTICS



Diagnostic TipsEngine must be cranked for more than five seconds withoutCKP signal to set code.


1. Connect BREAKOUT BOX (Part No. HD-43876) to ECMwire harness only (leave ECM disconnected). See4.6 BREAKOUT BOX: ECM.

2. One megohm is very high resistance. Some meters mayread infinity.

3. Use HARNESS CONNECTOR TEST KIT (Part No. HD-41404-B), brown socket probes and patch cords.

4. For testing purposes, install sensor without running wiringalong normal path. Disconnect and route wiring properlyif system is now OK.

ed03037

Figure 4-53. CKP Sensor (typical)

ed03038

Figure 4-54. CKP Sensor Connector Location (typical)



CKPSensor

[79A][79B]

[78B][78A]

ECM

1

1210 28 30

1210

Pow

ergr

ound

Cra

nksh

aft

posi

tion

sens

or

Pow

ergr

ound

Cra

nksh

aft

posi

tion

sens

or

28 30

2

1 2

BK

BK

R

R

BK

/GN

BK

/GN

em00134

Figure 4-55. CKP Sensor Circuit




Under left trim cover2-place Mini-DeutschCrankshaft Position (CKP) sensor[79]



CKP Sensor: DTC P0373, P0374

1

YES NO

2

3

4

YES

YES

YES

YES

YES

YES

YES

NO

NO

NO

NO

NO

NO

NO

Connect Breakout Box to harness only,leaving ECM disconnected. Measure resistance

between terminals “30” and “28”and betweenterminals “12” and “28” on Breakout Box.

Resistance more than 1 megohm?

Disconnect connector [79]. LeavingECM disconnected, measure resistance

between terminals “12” and “28” andterminals “30” and “28” on Breakout Box.

Continuity to ground(less than 1 megohm resistance)?

Check for intermittent connection, pinched ordamaged wires, and loose CKP sensor fasteners.

Conditions found?

Connect DVOM to terminals “12” and“30” on Breakout Box. Set DVOM to AC

volts and crank engine.Does DVOM read 1 VAC minimum

during cranking?

With DVOM still connected, check for intermittentsusing 4.7 WIGGLE TEST.


Connect DVOM at terminals “1”and “2” of connector [79A].Does DVOM read 1 VACminimum while cranking?

Check for continuity betweenterminal “1” of connector [79B]

and terminal “30” on Breakout Box.Continuity present?

Repair open on wire (BK)between terminal “2” of

connector [79B] andterminal “12” of Breakout Box.

Repair open on wire (R)between terminal “1” of

connector [79B] andtermnal “30” of Breakout

Box.

Repair short toground on wires(R) or (BK) wire

betweenconnectors [78B]

and [79B].

ReplaceCKP sensor.

See VRSC ServiceManual.

Install knowngood CKP sensor.Clear codes and

retest. DTC P0373 orP0374 set?

Repair asnecessary.

Reinstall originalCKP. Reprogram

and learn password.

ReplaceCKP sensor.

Repair asnecessary.

Replace CKPsensor.

See VRSC ServiceManual.

fc01507_en



4.26DTC P0444, P0445

GENERAL

Purge Solenoid (CA Models Only)See Figure 4-56. The purge solenoid allows vapors to escapeback into the throttle body. The purge solenoid is timed to thethrottle position but is disabled at startup, low engine temper-ature, low engine speed or low vehicle speed. The power forthe purge solenoid comes from the system relay. The systemrelay also provides power for the injectors, fuel pump and theignition coil. The ECM provides the path to ground to triggerthe purge solenoid.

NOTE

System fuse and system relay failures or wiring harness prob-lems will cause 12 volt power to be lost to both injectors, ignitioncoils, fuel pump and purge solenoid.


DESCRIPTIONDTC

Purge solenoid open/lowP0444

Purge solenoid highP0445

ed01278

Figure 4-56. Purge Solenoid

DIAGNOSTICS






1. See the Service Manual for all service information.

2. Use HARNESS CONNECTOR TEST KIT (Part No. HD-41404-B), purple terminal probes and patch cord toBreakout Box and gray socket probes and patch cord toFUEL INJECTOR TEST LAMP (Part No. HD-34730-2C).See Figure 4-57.


4. Connect a BREAKOUT BOX (Part No. HD-43876) betweenEFI wire harness and ECM. See 4.6 BREAKOUT BOX:ECM.

ed02060

Figure 4-57. Fuel Injector Test Lamp (Part No. HD-34730-2C)



PurgeSolenoid

[95A][95B]

[78B][78A]

40 AmpMAXIFUSE

15 AmpECM Fuse

15 AmpIGN Fuse

*California models only

BatteryIgnitionSwitch

SystemRelay

BK

10

31

13

28

–+

ECM

22

BA

BA

8730

8586

KE

SU

4

10

31

13

28

22

4

Power ground

Constant power

Switch power

Power ground

Solenoid CTRL

System relay

BE/GY

Y/GN

GN/O

GN/O

W/BK

GY/YGY/Y

Y/GN

BE/GY

BK/GN

BK/GN

W/BK R/BK

R

RR

W/B

K

GY

W/B

K

GY

Engine StopSwitch

[22A]

[22B]

4 3

4 3

em00135

Figure 4-58. Purge Solenoid Circuit





Below seat2-place PackardPurge Solenoid[95]



Purge Solenoid: DTC P0444, P0445 (Part 1 of 3)

1

2

3

3

3

3

YES

YES

YES

YES

YES

YES

YES

NO

NO

NONONO

NO

NO

NO

NO

Is connector securely attached to thepurge solenoid?

See Figure 4-57. Using Purge Solenoid TestLamp, turn purge solenoid on by grounding terminal

“22” using purple terminal probe and patch cord.Does test amp illuminate for 2 seconds after key ON?

Recheck connections.Perform 4.7 WIGGLE TEST

to check for intermittents.Intermittents present?

Check terminal “A” (Y/GN wire) onpurge solenoid connector [95B] to

ground. Voltage equivalent to batteryvoltage for 2 seconds after key ON?

Reconnect.

Check for 12 volts at terminal “87” ofsystem relay during first 2 seconds after

key ON. Correct voltage present?

Measure resistance ofpurge solenoid across

solenoid terminals.Resistance 22-29 ohms?

Repairintermittent.

Check for looseor corroded terminals

in harness.

System relay OK. Measureresistance between terminal 87of system relay and terminal “A”(Y/GN wire) at purge solenoid

connector [95B].Resistance less than 0.5 ohm?

Find and repairbad connection

or open on wire (Y/GN).



ReplacePurge solenoid.

fc01508_en

STOP

Go to PurgeSolenoid DTCP0444, P0445(Part 3 of 3).

STOP

Go to PurgeSolenoid DTCP0444, P0445(Part 2 of 3).




Continued from Purge Solenoid DTC P0444,P0445 (Part 1 of 3)

Measure resistance between Breakout Boxterminal “22” (GY/Y wire) and terminal “B” of

purge solenoid connector [95B].

3

NOYES

2

4

YES

YES

NO

NO

Resistanceless than 0.5 ohm?

Repair open orpoor connection.

Disconnect test light.Check for continuity to ground on

Breakout Box terminal “22”.Continuity present?

Check for voltage within 2 seconds ofkey ON.

Breakout Box terminal “22”.Voltage present?

Repair shortto ground onwire (GY/Y).

Repair shortto voltage onwire (GY/Y).


fc01509_en




3

NOYES

3

3

YES

YES

YES

YES

NO

NO

NO

NO

Continued from Purge Solenoid DTC P0444, P0445(Part 1 of 3).

Check for battery voltage at terminal “30” of the systemrelay.

Correct voltage present?

Check for battery voltage atterminal “86” of the system

relay.Correct voltage present?

Find and repair openbetween ECM

Fuse and relay.

Measure resistance betweenterminal “86” of the system

relay and ECM terminal “13” onBreakout Box.


Measure resistance betweenterminal “85” of the system relay

and ECM terminal “4” onBreakout Box.


Install known good relay.Does fuel pump run for first2 seconds after key ON?

Find and repairopen on wire (GN/O).

Reinstall original relay andreplace ECM. Reprogram and

learn password.

Find and repairopen on wire (W/BK).


Replacerelay.

fc01510_en



4.27DTC P0501, P0502

GENERAL

Vehicle Speed SensorSee Figure 4-59.The Vehicle Speed Sensor (VSS) is poweredand monitored by the ECM. The ECM processes the vehiclespeed signal and transmits this signal to the TSM/TSSM/HFSM,ABS Module (if equipped) and IM through serial data.

NOTES

Vehicle speed is input to the idle air control system. Thereforeproblems with the vehicle speed signal can lead to improperoperation of the idle air control.

The MAP, TP, Jiffy Stand, and VSS sensors are connected tothe same reference line (+5V Vref). If the reference line goesto ground or open, multiple codes will be set (DTC P0107,P0108, P0122, P0123, P0501, P0502, P1501, P1502). Startwith the trouble code having the lowest ranking value.


DESCRIPTIONDTC

VSS lowP0501

VSS high/openP0502

ed03040

Figure 4-59. Vehicle Speed Sensor (typical)

DIAGNOSTICS





1. The Instrument Module (IM) has a built-in diagnostic mode.See 4.5 INSTRUMENT MODULE (IM) SELF DIA-GNOSTICS.





[39B]


VehicleSpeedSensor

To MAP & TPSsensor

[39A]

[78B][78A]

[65A] [65B]

7

7

Ser

iald

ata

33

A

B

C

14155

33 1415

ECM

5

Ser

iald

ata

Dig

italg

roun

d

VS

Sin

put

Sen

sor

pow

er

A

B

C

LGN

/V

R/W

BK/BE

BK/R

BK

em00136

Figure 4-60. VSS Circuit




At vehicle speed sensor3-place PackardVehicle Speed Sensor (VSS)[65]




Vehicle Speed Sensor: DTC P0501, P0502 (Part 1 of 2)

NOYES

2

1

2

3

YES

YES

YES

YES

NO

NO

NO

NO

Remove and inspect speedometer sensor. Inspect fordebris and clean if necessary. Place speedometer into

diagnostic mode and clear fault codes. Connect all circuitsand ride motorcycle for approximately 1.0 mile (1.6

km). Check for newly logged codes.Are new codes present?

Inspect connector [65].Mated properly?

Mate connector.

System OK.Check for continuity between terminal “A” of

connector [65B] wire (BK/R) and ground.Continuity present?

Check for continuity between terminal Aof connector [65B] wire (BK/R) and

terminal “14” of breakout box.Continuity present?

Repair short to ground.

Repair open on wire (BK/R)between [78B] and [65B].

Check for continuity between terminal “C”of connector [65B] wire (BK/GN) and

terminal “15” of breakout box.Continuity present?

Repair open on wire (BK/GN)between [78B] and [65B].

fc01512_en

STOP

Go to VehicleSpeed Sensor

DTC P0501,P0502

(Part 2 of 2).



Vehicle Speed Sensor: DTC P0501, P0502 (Part 2 of 2)

2

YES NO

3

YES

YES

NO NO NO

NO

Continued Vehicle Speed Sensor DTC P0501, P0502(Part 1 of 2).

Check for continuity between terminal “B” of connector[65B] and terminal “33” of breakout box.

Continuity present?

Check for voltage at terminal “33” on breakoutbox. Meter should read 4-6 volts when gear toothabsent and 0-1 volts when gear tooth is present.

Does voltage fall within specifications?

Repair open on wire (BK/BE) between [78B] and

[65B].

No voltage fluctuation fromhigh (4-6 volts) to low (0-1

volts).

Measure continuity toground from terminal (33) on

breakout box.Is resistance less than 100 ohms?

Locate and repair short tovoltage on wire (W/GN)

between [78B] and [65B].

Voltage fluctuates from high(4.6 Volts) to low (0-1 volts).


Battery voltagepresent.

No voltage present.

Replace Vehicle SpeedSensor.


Locate and repair short toground on wire (W/GN)

between [78B] and [65B].

fc01513_en



4.28DTC P0562, P0563

GENERAL

Battery VoltageBattery voltage is monitored by the ECM (terminal "13"). If thebattery voltage fails to meet normal operating parameters, aDTC is set.

• DTC P0562 is displayed when battery positive voltage isless than 12.2 volts at idle and voltage does not increasewhen engine speed is greater than 2000 RPM.

• DTC P0563 is displayed when battery positive voltage isgreater than 15.0 volts for more than 4 seconds.

NOTES

• Warm idle speed will be automatically increased if batteryvoltage is low at idle.

• IM or TSSM/HFSM problems may also set a batteryvoltage DTC P0563.


DESCRIPTIONDTC

Battery voltage lowP0562

Battery voltage highP0563

ed03024


DIAGNOSTICS



Diagnostic Tips• Low voltage generally indicates a loose wire, corroded

connections, battery and/or a charging system problem.

• A high voltage condition may be caused by a faulty voltageregulator.


1. Was battery allowed to discharge? Was battery drawndown by a starting problem?

a. Yes. Charge battery.

b. No. See 1.7 CHARGING SYSTEM, Troubleshooting.


3. This checks for voltage drops in the ignition module circuit.

a. Place (+) probe to battery positive terminal.

b. Place (-) probe to (W/BK) terminal on Breakout Box.

4. Use HARNESS CONNECTOR TEST KIT (Part No. HD-41404-B) purple terminals and patch cords.

5. Problem is most likely the ground connection at the frame.



SystemRelay

[61B]Tofuel pump fuse

injector coil

[22B][22A]

[33B][33A]

[61A]

[78A] [78B]

Battery

IgnitionSwitchEngine

Stop Switch

15 AMPECM Fuse

15 AMPIGN Fuse

10

31

13

4

C B A

A B I

3

4 3

28

–+

3085

86

ES

U

4

Power ground

Constant power

Switch power

Power ground

System relay

10

31

13

28

4

BE/GY

BE/GY

BK/GN

BK/GN

BE

/GY

GN/OGN/O

W/BK

Y/GN

W/BK R/BK

W/B

K

GY

BK

RR

R

87K

StarterSolenoid

40 AmpMAXIFUSE

em00137

Figure 4-62. Battery Voltage Circuit





Under left passenger seatSpade terminalsFuse block[61]




Battery Voltage: DTC P0562, P0563 (Part 1 of 2)

2

YES NO

13

4

5

Perform charging system tests.Charging system OK?

YES

YES

YES

YES

YES

Connect Breakout Box. Measure voltage onBreakout Box between terminals “13” and “10”

and again between terminals “13” and “28”with engine running at 2000 RPM or higher for

10 seconds or longer.Is voltage above 11.0 volts?

Repair charging system.See Section 1.

SystemOK.

With ignition ON, measure voltage dropbetween battery positive (+) terminaland Breakout Box terminal “13” (-).

Is voltage drop greater than 0.5 volt?

Check for voltage drop between batterynegative (-) terminal and terminal “10” (+)on Breakout Box connector and betweenbattery negative (-) terminal and terminal

“28” on Breakout Box.Is voltage drop greater than 0.5 volt?

NO

NO

NO

NO

NO

With ignition OFF, measure resistancebetween breakout box terminal “13”

and connector [22B] terminal “4” (-) (BK).Is resistance greater than 1 ohm?

With ignition OFF, measureresistance

between ignition fuse terminal andconnector [22B] terminal “3”.

Is resistance greater than 1 ohm?

Repair wire (W/BK)wire or terminals

between connectors[22B] and [78B].

Locate and repairbad connection.

Problem is intermittent.Perform 4.7 WIGGLE

TEST. Locate andrepair bad connection.

Inspect [22] for corrosion orloose wires. If above conditionsare not present, replace engine

stop switch.

1

fc01514_en

STOP

Go to BatteryVoltage DTCP0562, P0563(Part 2 of 2).



Battery Voltage: DTC P0562, P0563 (Part 2 of 2)

YES NO

YES NO

YES NO

YES NO

Continued from Battery Voltage DTC P0562, P0563 (Part 1 of 2).

With ignition ON, measure voltage drop between batterypositive (+) terminal and (GY) terminal at 15 amp ignition fuse (-).


With ignition ON, measure voltage dropbetween battery positive (+) terminal and(R/BK) terminal at 15 amp Ignition Fuse.


With ignition ON, measure voltage dropbetween battery positive (+) terminal and

both fused terminals (-).Is voltage drop greater than 0.5 volt?

With ignition ON, measure voltage dropbetween battery positive (+) terminal and

one fuse terminal (-).Is voltage drop greater than 0.5 volt?

High resistance between 40 ampMAXIFUSE and battery. Replace

wire or terminals.

ReplaceFuse.

Replace IgnitionSwitch or terminals.

Replace fuse orfuse terminals.

Repair wire (GY)or terminals.

fc01515_em



4.29DTC P0603, P0605

GENERAL

ECM FailureRefer to Table 4-48. The Diagnostic Trouble Codes (DTCs)listed indicate a failure which requires replacement of the ECM.See the Service Manual for replacement information.

NOTE

After replacing ECM, perform password learning procedureand clear codes.


DESCRIPTIONDTC

ECM EEPROM errorP0603

ECM flash errorP0605

DIAGNOSTICS

DTC P0603 Test1. Turn IGN switch to OFF position.

2. Clear DTCs using IM self-diagnostics. See 4.5 INSTRU-MENT MODULE (IM) SELF DIAGNOSTICS.

3. Replace ECM if DTCs reappear.

DTC P0605 Test1. Turn IGN switch to OFF position.

2. Clear DTCs using IM self-diagnostics. See 4.5 INSTRU-MENT MODULE (IM) SELF DIAGNOSTICS.

3. Attempt to reprogram ECM using correct calibration.

4. Restart vehicle. If DTC reappears, replace ECM.



4.30DTC P1009, P1010

GENERAL

Password ProblemThe ECM and TSM/TSSM/HFSM exchange passwords duringoperation. An incorrect password or missing password will seta Diagnostic Trouble Code (DTC).

NOTE

If the TSM/TSSM/HFSM is not connected to the wiring harness,the vehicle will not start.


DESCRIPTIONDTC

Incorrect passwordP1009

Missing passwordP1010

DIAGNOSTICS





1. DTC P1009 may be set if a recent ECM or TSM/TSSM/HFSM replacement did not follow the correct passwordassignment procedure. See 3.25 TSM/HFSM: PASS-WORD LEARN.

2. See Service Manual for TSM/TSSM/HFSM replacement.See 3.25 TSM/HFSM: PASSWORD LEARN for the pass-word learning routine.

3. Use HARNESS CONNECTOR TEST KIT (Part No. HD-41404-B), black socket probes and patch cord.


1

2

ed03021

1. Data link connector [91A]2. Protective rubber plug

Figure 4-63. Serial Data Connector [91A]

ed03022




5

5

Ser

iald

ata

10

10

28

28

Sys

tem

grou

nd

Sys

tem

grou

nd

3 12

3

Ser

iald

ata

Gro

und

12

7

7

Ser

iald

ata


[39A][39B]

[30A][30B]

[78A][78B]

TSM/TSSM/HFSM

To ignitionfuse

ECM

[91A]

BK

/GN

BK

/GN

GY

LGN

/V

LGN/V

LGN

/V

LGN

/V

Data LinkConnector

BK/GN

3

1

2

4[166B]

(ABS is optional)

[166A]

1

11

ABS

Power ground

Power ground

1

9Serial data 9

11

LGN/V

BK

BK

em00138

Figure 4-65. ECM and TSM/TSSM/HFSM Circuit






Under left side cover4-place DeutschData Link Connector[91]

Under right side cover20-place MolexABS Module (if equipped)[166]



Password Problem: DTC P1009, P1010

2

YES NO

1

2 3

2

3

4

2

YES YES

YES

YES

YES

YES

NO

NO

NO

NO

NO

NO

Which Diagnostic TroubleCode (DTC) was set?

DTC P1009.Bad password.

Reprogram password.DTC P1009 still exist?

DTC P1010.No password.

Are there any U-codes set?

Remove ECM connector [78]. Checkfor continuity to ground at dataconnector [91A] terminal “3”.

Continuity present?

Troubleshootlowest U-code.

Replace TSSM/HFSMand relearn password.

System OK?

SystemOK.

Reinstall original TSM/TSSM/HFSM. Replace

ECM.Reprogram and relearn

password.

SystemOK.


Check for battery voltageon terminal “3”.



Test data connector [91A]terminal “3” against Breakout Box

terminal “5” for continuity.Continuity present?

Inspect terminalsfor damage or repairopens as necessary.

Replace TSM/TSSM/HFSM andrelearn password.

System OK?

SystemOK.

Reinstall original TSM/TSSM/HFSM.Replace ECM.

Reprogram and relearn password.

fc01516_en



4.31DTC P1351, P1352, P1354, P1355

GENERAL

Ignition CoilIgnition coil DTCs will set if the ignition coil primary voltage isout of range. This could occur if there is an open coil or lossof power to the coil. If front and rear DTCs are set simultan-eously, it is likely a coil power failure or a coil failure.

The coil receives power from the system relay at the sametime that the fuel pump and injectors are activated.The systemrelay is active for the first 2 seconds after the ignition switch isturned ON and then shuts off until RPM is detected from theCKP sensor, at which time it is reactivated. The ECM isresponsible for turning on the system relay by providing theground to activate the relay, which in turn powers the coil.


DESCRIPTIONDTC

Front ignition coil open/lowP1351

Front ignition coil high/shortedP1352

Rear ignition coil open/lowP1354

Rear ignition coil high/shortedP1355

DIAGNOSTICS






IGNITION COIL CIRCUIT TESTADAPTER

HD-44687


1. Use HARNESS CONNECTOR TEST KIT (Part No. HD-41404-B), gray terminal probes and patch cord.

NOTEGently connect test lamp to connector [83B]. Forcefully insertingtest lamp will result in ignition connector terminal damage.

2. See Figure 4-66. Plug IGNITION COIL CIRCUIT TESTADAPTER (Part No. HD-44687) and FUEL INJECTORTEST LAMP (Part No. HD-34730-2C) into Breakout Box.Note that cranking the engine with test lamp in place ofthe ignition coil can sometimes cause a DTC P1351,P1352, P1354 or P1355. This condition is normal anddoes not by itself indicate a malfunction.

3. Connect BREAKOUT BOX (Part No. HD-43876) betweenEFI wire harness and ECM. See 4.6 BREAKOUT BOX:ECM.

4. Use HARNESS CONNECTOR TEST KIT (Part No. HD-41404-B), purple probes and patch cords.

ed02013

Figure 4-66. Ignition Coil Circuit Test

1

34 5

2

ed03041

1. Plug top coil2. Boot3. Feedback signal terminal (ion sense)4. Power5. Coil driver




SystemRelay


FrontCoil

[83F B] [83F A]

[61B] [61A]

[78A] [78B]

Battery

40 AmpMAXIFUSE

StartSolenoid

IgnitionSwitch

15 AMPECM Fuse

15 AMPIGN Fuse

10

31

13

28

–+

3085

86

ES

U

4

Power ground

Constant power

Switch power

Power ground

System relay

10

31

13

28

4

BE/GY

GY/BE

GY/BEGY/BE

BE/GY

BK/GN

BK/GN

GN/OGN/O

W/BK

Y/GN

Y/GN

BE/O

BE/O Y/BE

Y/BE

Y/GN

W/BK

W/B

K

R/BK

GY

W/B

K

GY

BK

RR

R

87K

11

29

27

11

29

27

Rear coil

Front coil

Ion

CB

AC

BA

CB

AC

BA

Engine StopSwitch

[22A]

[22B]

4 3

4 3

em00129











Ignition Coil: DTC P1351, P1352, P1354, P1355 (Part 1 of 2)

2

NO

4

Disconnect coil connector [83]. Measure voltageon terminal “B” of coil [83B] front or rear.Is voltage equal to battery voltage during

first 2 seconds after key ON?

Use Breakout Box and test light for the next inspection.Front coil codes: Check between ECM terminal “29” and

ECM terminal “13”.Rear coil codes: Check between ECM terminal “11” and

ECM terminal “13”.Does test lamp flash when engine is cranked?

Measure coil resistance.Front coil codes: Check betweencoil terminal “B” and terminal “C”.Rear coil codes: Check betweencoil terminal “B” and terminal “C’.

Is resistance 0.3-0.5 ohms?

Measure voltage at systemrelay terminal “30” during first 2

seconds after key ON?Is voltage equivalent to battery

voltage?

Repair open wire orconnection on wire (Y/GN).

Replace Coil.See VRSC Service

Manual.

Check for multiple codes.See MULTIPLE TROUBLE

CODES under 4.4CHECKING FOR

TROUBLE CODES.

YES

YES

YES YES

NO

NONO

1

3

1

fc01517_en

STOP

Go to IgnitionCoil DTC P1351,P1352, P1354,

P1355(Part 2 of 2).

STOP

Go to IgnitionCoil DTC P1351,P1352, P1354,

P1355(Part 2 of 2).



Ignition Coil: DTC P1351, P1352, P1354, P1355 (Part 2 of 2)

YES NO

NOYES

YES

YES

NO

NO

1

3



Repair open wireor connection.

Repairintermittent.

Check for continuity to ground.

Front coil codes:Check Breakout Box terminal “29”.

Rear coil codes:Check Breakout Box terminal “11".

Continuity present?

Check for voltage.

Front coil codes:Check Breakout Box terminal “29”.

Rear coil codes:Check Breakout Box terminal “11”.

Voltage present?




Continued from Ignition Coil DTC P1351, P1352,P1354, P1355 (Part 1 of 2).

Using Breakout Box, measure resistance betweenECM and coil terminals as follows.

Resistance less than 0.5 ohms?

DTC

P1351/P1352

P1353/P1354

COILTERMINAL

C(BE/O wire)

C(Y/BE wire)

COILTERMINAL

29

11

fc01518_en



4.32DTC P1501, P1502

GENERAL

Jiffy Stand Sensor (HDI)The Jiffy Stand Sensor utilizes a Hall-effect sensor to monitorJiffy Stand position. When the Jiffy Stand is fully retracted thesensor picks up the presence of the metal tab mounted to theJiffy Stand. The metal tab is moved away from the sensor asthe Jiffy Stand is extended. When the Jiffy Stand is extendedthe engine will only start and run if the TSM/TSSM/HFSMdetermines the transmission is in neutral. Otherwise the enginewill start and stall.This is done by monitoring the neutral switchinput to the TSM/TSSM/HFSM and communicating that inputover the serial data circuit to the Electronic Control Module(ECM).

See Figure 4-69. The Jiffy Stand Sensor is powered andmonitored by the ECM. The ECM terminal "14" supplies the5V reference to the Jiffy Stand Sensor connector [133] terminal"1". The Jiffy Stand Sensor terminal "2" sends a signal backto the ECM terminal "9". This signal is used by the ECM todetermine when the Jiffy Stand is retracted or extended. TheJiffy Stand Sensor terminal "3" is grounded through the ECMterminal "28".

The Jiffy Stand Sensor also has a Fail Enable Mode.This modeallows the engine to start and run if the system recognizes aproblem with the Jiffy Stand Sensor circuit. When a problemexists or if the transmission is put in gear with the Jiffy Standextended the odometer will display "SIdE Stand." DTC P1501or P1502 will set if the Jiffy Stand Sensor circuits are out ofrange.


DESCRIPTIONDTC

Jiffy Stand Sensor lowP1501

Jiffy Stand Sensor highP1502

DIAGNOSTICS





1. See the Service Manual for TSM/TSSM/HFSM replace-ment. See 3.25 TSM/HFSM: PASSWORD LEARN,Password Learning for the password learning procedure.

2. Unplug the Neutral Switch connector [131]. Using a DVOMtest for continuity between terminals "A" and "B" of theNeutral Switch. When the transmission is in NEUTRAL,continuity should exist. When the transmission is in gear,there should not be continuity through the Neutral Switch.

3. When the Jiffy Stand is retracted, voltage on terminal "9"should be approximately 1.65-2.47 volts. When the JiffyStand is extended, the voltage on terminal "9" should beapproximately 2.94-4.41 volts.

4. Connect BREAKOUT BOX (Part No. HD-43876) to theECM and ECM harness.

5. Use HARNESS CONNECTOR TEST KIT (Part No. HD-41404-B), gray pin probes, socket probes and patch cords.

6. Replace defective mechanical components in accordancewith the Service Manual. Follow the flow chart stepsprovided until component replacement directs you to theservice manual.



[78B][78B]

ECM

[133B]

Jiffy StandSensor

9

14

28

9

14

28

1 2 3

Jiffy stand sensor (HDI only)

5V sensor power

Ground

R/W

BK/GN

GN/BN

R/W

BK

/GN

GN

/BN

em00117

Figure 4-69. Jiffy Stand Sensor Circuit



Under seat36-place PackardElectronic Control Module (ECM)[78]

Lower left side of chassis (toward frontof engine)

3-place MolexJiffy Stand Sensor (HDI)[133]



Jiffy Stand Sensor: DTC P1501, P1502

NOYES

Clear DTCs using instrument module self diagnostics. See4.5 INSTRUMENT MODULE SELF-DIAGNOSTICS. Confirmproper operation with no check engine lamp.

2

Is the transmission in neutral?

Check for DTCs Areany DTCs present?

See 4.12 STARTS,THEN STALLS

Diagnostics.


Test Neutral Switch.Is Neutral Switch operating

correctly?

Is Neutral Lamp ON?Go to appropriate DTC

Diagnostics.

YES

YES

YES

NO

NO

NO

1

Doses the enginestart then stall?

Place transmission inNeutral.

Check for an open in theneutral switch circuit.Is there and open?

Inspect the Jiffy Stand Sensor and the Jiffy Standfor correct mounting and clearance to Jiffy Stand

tab (4.5mm max.).Is switch and stand mounted correctly?

YES NO YES

YES

NO

NO

Install Jiffy StandSensor or Jiffy Stand

correctly.

Correct openin circuit.

ReplaceTSM/TSSM/HFSM.

Replace NeutralSwitch.

fc01526_en




NOYES

Clear DTCs using instrument module self diagnostics. See4.5 INSTRUMENT MODULE SELF-DIAGNOSTICS. Confirmproper operation with no check engine lamp.

If DTC P1501 is displayed, disconnect Jiffy Stand Sensorconnector. Turn Ignition Switch to IGNITION position and make

sure the Engine Stop Switch is in the RUN position. Test terminal“1” of connector [133B] for voltage.

Is voltage present?

Locate and repair open in5V reference circuit.


Disconnect connector [78] Engine Control Module (ECM). Testcircuit terminal “9” connector [78B] for continuity to ground.


Replace Engine ControlModule (ECM).

Locate and repairshort to ground.

YES

YES

NO

NO

Check for DTC’s. Did DTCP1501 clear or go to history and

P1502 set as a current DTC?

fc01525_en




NOYES

If DTC P1502 is displayed, then disconnect JiffyStand Sensor connector. Test for continuity

between connector [133B] terminal “3” and Ground.Continuity present?


Is voltageapproximately 5V?

Turn Ignition Switch OFF. Test for continuityfrom connector [133B] terminal “1” to ground.

Continuity present?

Test for continuity from connector[133B] terminal “1” to connector

[78B] terminal “14”.Continuity present?

Locate andrepair shortto ground.

YES

YES

NO

NO

Turn Ignition Switch on withEngine Stop Switch in RUN. Test

for voltage on terminal “1”connector [133B]

Is voltage present?

YES NO


Replace EngineControl Module

(ECM).

YES NO

Measure voltage at terminal“9” (+) on Breakout Box to

ground.Voltage present?

NOYES

Locate andrepair short to

voltage.

Replace EngineControl Module (ECM).

Turn off Ignition Switch. ConnectECM Breakout Box (Part No. HD-

43876) to wiring harness connector[78B] leaving ECM connector [78A]

disconnected. Test for continuityfrom connector [78B] terminal “9” to

connector [133B] terminal “2”Is continuity present?

NOYES

YES NO


Connect ECM Breakout Box (Part No.HD-43876) to ECM connector [78A].

Connect Jiffy Stand Sensor connector[133]. Test terminal “9” of the Breakout

Box for voltage with the Jiffy Standretracted and extended.

Are the voltages within the specification?

3

Replace EngineControl Module (ECM).

Replace Jiffy StandSensor.

fc01524_en




4.33DTC U1064, U1255

GENERAL

Loss of TSM/TSSM/HFSM Serial DataThe serial data connector provides a means for the ECM, IMand TSM/TSSM/HFSM to communicate their current status.When all operating parameters on the serial data link are withinspecifications, a state of health message is sent between thecomponents. DTC U1064 indicates that the TSM/TSSM/HFSMis not receiving this state of health message.


DESCRIPTIONDTC

Loss of TSM/TSSM/HFSM serial dataU1064

Serial data error/missing messageU1255

DIAGNOSTICS







sm01275


4

12

3

ed03002


Figure 4-71. Data Connector Terminals



IgnitionSwitch

SystemRelay

Battery

[61B] [61A]

[166B]

(ABS is optional)

[166A]

[78A] [78B]

40 AmpMAXIFUSE

15 AMPIGN Fuse

EngineStop

Switch

1

13

11

–+

ECM

ABS

3085

86

CP

R

Power ground

Switch power

Power ground

1

9Serial data 9

13

11

LGN/V

BK/GN

BK/GN

BK/GN

BK

/GN

BK

/GN

LGN

/V

LGN/V

LGN

/V

LGN/V

BN

/GY

W/BK

W/BK R/BK

GYBK

BK

BK

10

28

Power

Ground

10

5Serial data 5

28

GY

GY

R

87I


TSM/TSSM/HFSM

[91A]

To security fuse

To battery fuse

[39A][39B]

[30A][30B]

6

6

7

7

5

5

21

34

1

1 2 3 12

1 2 3 12

1

Bat

tery

Gro

und

Igni

tion

Ser

iald

ata

Bat

tery

Gro

und

Igni

tion

Ser

iald

ata

R/O

Data LinkConnector

em00139

Figure 4-72.TSM/TSSM/HFSM, ABS, ECM, and IM Circuit











Loss of TSM/TSSM/HFSM Serial Data: DTC U1064, U1255

2

YES NO

1

YES

YES

YES

NO

NO

NO

Install Breakout Box on TSM/TSSM/HFSM andECM. Check continuity between terminal “3” ofTSM/TSSM/HFSM Breakout Box and terminal

“5” of ECM Breakout Box.Continuity present?

Intermittentpresent?

Repair open onwire (LGN/V).

Locate and repairIntermittent.

Check for continuity to groundon terminal “12” of TSM/TSSM/HFSM. Wiggle harness during

continuity check.Continuity present?

Check for battery voltage atterminal “1” of TSM/TSSM/

HFSM while wiggling harness.Battery voltage continuously

present?



ReplaceTSM/TSSM/

HFSM.

fc01519_en



4.34DTC U1096, U1255

GENERAL

Loss of IM Serial DataThe serial data connector provides a means for the ECM, IM,ABS module (if equipped) and TSM/TSSM/HFSM to commu-nicate their current status. When all operating parameters onthe serial data link are within specifications, a state of healthmessage is sent between the components. A DTC U1096indicates that the IM is not capable of sending this state ofhealth message.


DESCRIPTIONDTC

Loss of IM serial data (state of health)U1096

Missing message at IMU1255

DIAGNOSTICS




SPEEDOMETER MODULE HARNESSADAPTER

HD-46601



2. Connect BREAKOUT BOX (Part No. HD-42682) (black)to wire harness connector [39B] using SPEEDOMETERMODULE HARNESS ADAPTER (Part No. HD-46601).Leave speedometer [39A] disconnected. See2.3 BREAKOUT BOX: IM.

ed03005

Figure 4-73. ECM Connector

4

12

3

ed03002


Figure 4-74. Data Connector Terminals



IgnitionSwitch

SystemRelay

Battery

[61B] [61A]

[166B]

(ABS is optional)

[166A]

[78A] [78B]

40 AmpMAXIFUSE

15 AMPIGN Fuse

EngineStop

Switch

1

13

11

–+

ECM

ABS

3085

86

CP

R

Power ground

Switch power

Power ground

1

9Serial data 9

13

11

LGN/V

BK/GN

BK/GN

BK/GN

BK

/GN

BK

/GN

LGN

/V

LGN/V

LGN

/V

LGN/V

BN

/GY

W/BK

W/BK R/BK

GYBK

BK

BK

10

28

Power

Ground

10

5Serial data 5

28

GY

GY

R

87I


TSM/TSSM/HFSM

[91A]

To security fuse

To battery fuse

[39A][39B]

[30A][30B]

6

6

7

7

5

5

21

34

1

1 2 3 12

1 2 3 12

1

Bat

tery

Gro

und

Igni

tion

Ser

iald

ata

Bat

tery

Gro

und

Igni

tion

Ser

iald

ata

R/O

Data LinkConnector

em00139

Figure 4-75.TSM/TSSM/HFSM, ABS, ECM, and IM Circuit











Loss of IM Serial Data: DTC U1096, U1255

YES NO

2

1

YES NO

YES NO

NOYES

IMPORTANT! Always start from4.8 INITIAL DIAGNOSTIC CHECK

Install Breakout Box on IM and ECM. Checkcontinuity between terminal “7” of IM Breakout Box

and terminal “5” of ECM Breakout Box.Continuity present?

Intermittentpresent?

Repair open onwire (LGN/V).


Check for continuity to groundon terminal “5” of IM. Wiggle harness

during continuity check.Continuity present?

Check for battery voltage atterminal “1” of IM while wiggling harness.

Battery voltage continuously present?



Replace IM.

fc01520_en



SUBJECT............................................................................................................................PAGE NO.5.1 ANTILOCK BRAKE SYSTEM (ABS) GENERAL INFORMATION.............................................5-15.2 INSTRUMENT MODULE (IM) SELF DIAGNOSTICS................................................................5-45.3 BREAKOUT BOX: ABS..............................................................................................................5-65.4 INITIAL DIAGNOSTIC CHECK: ABS........................................................................................5-75.5 ABS INDICATOR DIAGNOSTICS...........................................................................................5-115.6 DTC C0562..............................................................................................................................5-155.7 DTC C0563..............................................................................................................................5-185.8 DTC C1017..............................................................................................................................5-215.9 DTC C1018..............................................................................................................................5-245.10 DTC C1021, C1023...............................................................................................................5-275.11 DTC C1025, C1027, C1206, C1208......................................................................................5-305.12 DTC C1032, C1034...............................................................................................................5-335.13 DTC C1042............................................................................................................................5-395.14 DTC C1043............................................................................................................................5-405.15 DTC C1094............................................................................................................................5-415.16 DTC C1095............................................................................................................................5-445.17 DTC C1151............................................................................................................................5-475.18 DTC C1153............................................................................................................................5-505.19 DTC C1158............................................................................................................................5-535.20 DTC C1212............................................................................................................................5-575.21 DTC C1214............................................................................................................................5-605.22 DTC C1216............................................................................................................................5-635.23 DTC C1014, C1055-C1066, C1118, C1121..........................................................................5-665.24 DTC U1300, U1301 OR BUS ER..........................................................................................5-70

AB

S


NOTES


5.1ANTILOCK BRAKE SYSTEM (ABS) GENERALINFORMATION

ANTILOCK BRAKE SYSTEM (ABS)DESCRIPTION

Antilock Brake System (ABS)The Antilock Brake System (ABS) module controls brakeapplication under extreme stopping conditions in order to keepthe wheels from slipping. When wheel slip is detected duringa brake application, an ABS event occurs. The hydraulicpressure to the individual wheel is controlled to prevent slippingon that wheel. Specific valves and individual hydraulic linesare provided for each wheel. The ABS can decrease, hold, orincrease fluid pressure to each brake. However, the ABScannot increase hydraulic pressure above the pressure beingtransmitted by the master cylinder.

During an ABS event, a series of rapid pulsations may be feltin either the front brake lever or rear brake pedal. Thesepulsations are caused by the rapid changes in position of theindividual solenoid valves as the ABS responds to wheel speedsensor inputs and attempts to prevent wheel slip. Thesepulsations are present only during initialization and antilockbraking. The pulsations stop when normal braking is resumedor when the vehicle comes to a stop. A ticking or popping noisemay also be heard as the solenoid valves cycle rapidly. Duringantilock braking on dry pavement intermittent chirping noisesmay be heard as the tires approach slipping.These noises andpulsations are considered normal during antilock operation.

Vehicles equipped with ABS may be stopped by applyingnormal force to the brake pedal or lever. Brake operation duringnormal braking is no different then that of previous non-ABSsystems. Maintaining a constant force on the brake pedal orlever provides the shortest stopping distance while maintainingvehicle stability.

In addition to the normal brake system, the Antilock BrakeSystem consists of the following components.

• See Figure 5-1. Electronic Control Unit (ECU): The ECUcontains the motor relay, valve relay, system enable relay,and the solenoids.

• See Figure 5-1. Hydraulic Control Unit (HCU): The HCUcontains the four valves (an apply valve and release valvefor each wheel), two pumps, pump motor, and accumu-lators.

• See Figure 5-2. Front Wheel Speed Sensor.

• See Figure 5-3. Rear Wheel Speed Sensor.

• See Figure 5-4. ABS Diode Pack.

When referencing the ECU and the HCU as a unit they arereferred to as the Antilock Brake System (ABS) module.

12

3

ed01289

1. Rear stop lamp switch2. Electronic Control Unit (ECU)3. Hydraulic Control Unit (HCU)

Figure 5-1. ECU, HCU and Rear Brake Switch

ed01287

Figure 5-2. Front Wheel Speed Sensor

2008 VRSC Diagnostics: ABS 5-1


ed01288

Figure 5-3. Rear Wheel Speed Sensor

ed01284

Figure 5-4. ABS Diode Pack

Pressure HoldThe ECU closes the apply valve and keeps the release valveclosed in order to isolate the slipping wheel when wheel slipoccurs. This holds the pressure steady on the brake so thatthe hydraulic pressure does not increase or decrease.

Pressure DecreaseIf a pressure hold does not correct the wheel slip condition, apressure decrease occurs. The apply valve is closed and therelease valve is opened. The excess fluid is stored in the

accumulator until the pump can return the fluid to the mastercylinder or fluid reservoir.

Pressure IncreaseAfter the wheel slip is corrected, a pressure increase occurs.The ECU increases the pressure to individual wheels duringdeceleration in order to reduce the speed of the wheel. Theapply valve is opened and the release valve is closed. Theincreased pressure is delivered from the master cylinder andwill not exceed the pressure from the master cylinder.

Initialization Self-TestThe ABS module performs one initialization test each ignitioncycle.The ABS module verifies internal circuitry and the wheelspeed sensor circuits.

As part of the initialization self test the ABS module also doesa modular test. This test consists of energizing the actuators,and commanding the motor and solenoids on and off.The ABSmodule will run this test the first time the vehicle speed exceeds16 km/h (10 MPH) in an ignition cycle or when all the followingconditions are met for the first time in an ignition cycle:

• Brake switch is not applied.

• Engine is above 500 RPM.

• No ABS event present.

• The system ECU is enabled.

• The ABS system is not communicating with Digital Tech-nician.

ABS IndicatorSee Figure 5-5. The Instrument Module (IM) illuminates theABS indicator when the following occurs.

• The ECU detects an ABS disabling malfunction.The ECUsends a serial data message to the instrument requestingillumination.

• The IM performs a bulb check.

• The IM detects a loss of communication with the ECU.

The ECU sends a message to the instrument when a malfunc-tion that disables ABS operation is detected. Depending onthe fault the ABS Indicator may stay on even after the malfunc-tion is corrected. The indicator will not go off until the vehicleis operated at speeds greater than 16 km/h (10 MPH). It isimportant to verify that this is not the cause of an ABS indicatorwhich is illuminated when no DTCs are set, before attemptingto diagnose other possible causes.

5-2 2008 VRSC Diagnostics: ABS


MPH

010

20

RPM

109

1 0

3040

5060 70 80 90

100110

120

130

140

150

ABSF

6

1 2

3 4

5

ed01267



CODE TYPES



There are two types of DTCs: current and historic. If a DTC isstored, it can be read using either a computer based diagnosticpackage called DIGITAL TECHNICIAN (Part No. HD-44750)or IM Self Diagnostics. See 5.2 INSTRUMENT MODULE (IM)SELF DIAGNOSTICS.

Trouble codes reside in the memory of the IM, ECM,TSM/TSSM/HFSM, or ABS (if equipped) until the code iscleared by use of the Instrument Module or a total of 50 tripshas elapsed. A trip consists of a start and run cycle, the runcycle lasting at least 5 seconds. After the 50 trip retentionperiod, the trouble code is automatically erased from memoryproviding that no subsequent faults of the same type aredetected in that period.



Historic DTCs are stored for 50 ignition cycles after any DTCwas last set as current to assist in the diagnosis of intermittentfaults. On TSM models, the check engine lamp will also indicatethe existence of historic codes for one ignition cycle.

It is important to note that historic DTCs may also be presentwhenever the system indicates the existence of a current fault.See 5.1 ANTILOCK BRAKE SYSTEM (ABS) GENERALINFORMATION, Multiple Trouble Codes if multiple DTCs arefound.

Diagnostic charts are designed for use with current DTCs andas a result they frequently suggest wire repair or part replace-ment.When diagnosing a historic DTC the charts can be helpfulbut should not lead to part replacement without verification thepart is faulty.




There are two levels of diagnostics.

• The most sophisticated mode uses a computer-baseddiagnostic package called the DIGITAL TECHNICIAN (PartNo. HD-44750)

• The second mode requires using Instrument Module (IM)Self Diagnostics. IM, TSM/TSSM/HFSM, ABS, and ECMcodes can be accessed and cleared. See 5.2 INSTRU-MENT MODULE (IM) SELF DIAGNOSTICS for moreinformation.

MULTIPLE TROUBLE CODESWhile it is possible for more than one fault to occur and setmore than one DTC, there are several conditions which mayresult in one fault setting multipleDTCs:

Serial data codes (DTC U1300, U1301, U1016, U1097 andU1098) may be accompanied by other codes. Always correctthe serial data codes before resolving the other codes.




GENERALThe Instrument Module (IM) is capable of displaying andclearing IM, TSM/TSSM/HFSM, ABS, and Electronic ControlModule (ECM) Diagnostic Trouble Codes (DTCs) (diagnosticmode).

DIAGNOSTICS


performed. See Figure 5-6. While pressing the Trip Odo-meter Reset Switch, turn Ignition Switch to ACC. SeeFigure 5-7. Background lighting should illuminate, gaugeneedles should sweep their full range of motion andindicator lamps controlled by the serial data bus (battery,coolant temperature, ABS, and check engine) should illu-minate.

• If IM fails "WOW" test, check for battery, ground andaccessory to IM. If any feature in the IM is non-functional,see 5.4 INITIAL DIAGNOSTIC CHECK: ABS.

MPH

010

20

RPM

1098

76

5

43

21 0

3040

5060 70 80 90

100110

120

130

140

150

ABS

3/4

F

1/2

1/4

ed01266


2

3

1

ed02991




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

2. To clear DTCs for selected module, press IM Trip Odo-meter Reset Switch for more than 5 seconds when codeis displayed.This procedure will clear all codes for selectedmodule.



IM Self-Diagnostics

1


RUN position.


YES

”P” flashing.





seconds.



Switch.

”S” flashing.

To choose Cluster,press and release


”C” flashing.





than 5 seconds.



See 2.4 INITIALDIAGNOSTICCHECK: IM.

YES

YES

NO

NO

NO

Deviceresponse?

Press andrelease


displayed.

Press andrelease








other modules. Modelsnot equipped with ABS

will display “no rsp”normally.



SYSTEM (ABS)GENERAL

INFORMATION.


DTCdisplayed.

Press and release Trip OdometerReset Switch. “PSCb” appears.

2

fc01551_en

”b” flashing.








5.3BREAKOUT BOX: ABS

GENERAL



The BREAKOUT BOX (Part No. HD-48642) connects to theAntilock Brake System (ABS) module connector [166]. Usedin conjunction with a DVOM, it allows circuit diagnosis of wiringharness and connections without having to probe with sharpobjects.

NOTE

See wiring diagrams for ABS terminal functions.

INSTALLATION1. Depress latch on connector [166B].

2. Connect Harness Adapters to connectors [166A] and[166B].

3. Attach Breakout Box to connector(s).

4. Attach connectors from Breakout Box to Harness Adapters.

ed01281

Figure 5-8. Electronic Control Unit (ECU) Location

ed01282

Figure 5-9. Electronic Control Unit (ECU) Connector (EndView)

REMOVAL1. Detach connectors from Breakout Box to Harness

Adapters.

2. Detach Harness Adapters from connectors [166A] and[166B].

3. Install connector [166B] to ABS Module.



5.4INITIAL DIAGNOSTIC CHECK: ABS

GENERALTo locate faulty circuits or other system problems, follow thediagnostic flow charts and tests in this section. For a systematicapproach, always begin with 5.4 INITIAL DIAGNOSTICCHECK: ABS, Initial Diagnostics. Read the general informationand then work your way through the flow chart box by box.



In order to perform most diagnostic routines, a Breakout Boxand a DVOM are required. See 5.3 BREAKOUT BOX: ABS.



INITIAL DIAGNOSTICS

Diagnostic Tips• If Instrument Module (IM) reads "No Response" with the

Ignition Switch turned to ACC (Engine Stop Switch at RUNwith the engine off), check data link for an open or shortto ground between data link connector [91A] terminal "3"and ECM, TSM/TSSM/HFSM, IM, tachometer, or ABSModule (if equipped) connector. See 3.10 INITIAL DIA-GNOSTIC CHECK.

• Check for an open data test terminal between data linkconnector [91A] terminal "3" and ECM.With Ignition Switchturned to ACC, serial data bus voltage should be typically0.6-0.8 volts. The range of acceptable operation is 0-7.0volts.

• If IM reads "BUS Er" (serial data bus error), refer to flowcharts in 4.2 EFI SYSTEM.


1. Compare engine behavior to symptoms tables in 4.8 INI-TIAL DIAGNOSTIC CHECK.

All ABS Diagnostic Trouble Codes (DTCs) are listed inTable 5-1.

Table 5-1. ABS Diagnostic Trouble Codes (DTCs) and Fault Conditions


5.6 DTC C0562Device voltage low18C0562

5.7 DTC C0563System voltage high19C0563

5.23 DTC C1014, C1055-C1066, C1118, C1121ECU internal fault10C1014

5.8 DTC C1017Pump motor power circuit open fault17C1017

5.9 DTC C1018Pump motor ground high resistancefault

16C1018

5.10 DTC C1021, C1023Wheel speed sensor equals 0 (front)22C1021

5.10 DTC C1021, C1023Wheel speed sensor equals 0 (rear)23C1023

5.11 DTC C1025, C1027, C1206, C1208Wheel speed signal intermittent(front)

24C1025

5.11 DTC C1025, C1027, C1206, C1208Wheel speed signal intermittent(rear)

25C1027

5.12 DTC C1032, C1034Wheel speed sensor circuit open orshorted (front or rear)

20C1032

5.12 DTC C1032, C1034Wheel speed sensor circuit open orshorted (front or rear)

21C1034

5.13 DTC C1042Pump motor open11C1042

5.14 DTC C1043Pump motor stalled12C1043





Table 5-1. ABS Diagnostic Trouble Codes (DTCs) and Fault Conditions







5.15 DTC C1094Front brake switch always on28C1094

5.16 DTC C1095Front brake switch open29C1095



5.17 DTC C1151Front wheel release too long33C1151

5.18 DTC C1153Rear wheel release too long34C1153

5.19 DTC C1158Calibration programming required15C1158

5.11 DTC C1025, C1027, C1206, C1208Wheel speed signal frequency out ofrange (front)

26C1206

5.11 DTC C1025, C1027, C1206, C1208Wheel speed signal frequency out ofrange (rear)

27C1208

5.20 DTC C1212Front or rear brake not applied withdecel

32C1212

5.21 DTC C1214Rear brake switch always on30C1214

5.22 DTC C1216Rear brake switch open31C1216

5.24 DTC U1300, U1301 OR BUS ERSerial data low13U1300

5.24 DTC U1300, U1301 OR BUS ERSerial data open/high14U1301

Other Diagnostic Trouble Codes (DTCs)See 3.10 INITIAL DIAGNOSTIC CHECK for any DTCs relatedto the Turn Signal Module (TSM), Turn Signal Security Module(TSSM) or Hands-Free Security Module (HFSM).

See 4.2 EFI SYSTEM for any DTCs related to the ElectronicControl Module (ECM).



ABS Module

Tobattery

fuse

Toignition

fuse

InstrumentModule

[166A][166B][39A]

[39B]

[78A]

ECM

[78B]

9

9

Ser

iald

ata

5

7651

7651

5

Ser

iald

ata

GY

GY

LGN/V

BK/GN

LGN

/V

LGN

/V

LGN

/V

BK

/GN

Data LinkConnector3

2

1

4

[91A]

R/O

em00155

Figure 5-10. Diagnostic Check





Under right side cover4-place DeutschData link connector[91]

Behind side cover20-place MolexABS module[166]



Diagnostic Check

Does enginestart?

Check for diagnostic trouble codes(DTC’s).

DTC’s found?

See 4.11 STARTS,THEN STALLS.

YES.Starts and

runs.

Is IMfunctional?


Refer to applicable DTC prioritychart. DTC’s are listed by priority.


No codes displayed. For symptomsthat may not set diagnostic

trouble codes, refer to Table 2-4.Function Chart-Loss Of Input.

Go to Trip Switch Inoperable /Trip Switch Closed DTC:

B1008.

YES.Starts, then

stalls.


NO.Engine will not

crank.


See 1.2 STARTINGSYSTEM DIAGNOSIS.

1

YES NO

YES

NOYES

NO

fc01527_en



5.5ABS INDICATOR DIAGNOSTICS

ABS INDICATOR ALWAYS ON ORINOPERATIVE

Circuit DescriptionThe Instrument Module (IM) illuminates the ABS indicator bysupplying ground to the lamp. The ABS Module sends a serialdata message to the IM in order to command the indicator ONor OFF. See Figure 5-11. MPH

010

20

RPM

109

1 0

3040

5060 70 80 90

100110

120

130

140

150

ABSF

6

1 2

3 4

5

ed01267



Diagnostic TipsThe malfunction must be present during diagnosis in order toprevent unnecessary parts replacement.



-+

-+

R/Y

BK

R/BN

BK/V

BE/V

PK/BN

BK/BEBE/BN

R/Y

R/Y

R/Y

R/Y

ABSDiodePack

InstrumentModule

[201B]

[201A]

4 3 2 1

4 3 2 1

Battery

ACCYFuse15 Amp

FrontStopLampSwitch

Serialdata

IgnitionFuse

15 Amp

ABSFuse30 Amp

20

19

9

181787

1

11

13

3

Battery (motor)

Ignition

Serial data

Front wheel speed sensor lowFront wheel speed sensor highRear wheel speed sensor highRear wheel speed sensor low

Ground

Ground (motor)

Front brake input

Rear brake input

20

1

2

10 Battery

HydraulicControl

Unit(HCU)

10

19

9

181787

1

11

13

3

See appendix Bmain harness

page 1 of 2


page 1 of 2

[33A]

[61B]

[22A][22B]

[39B]

[GND2]

ElectronicControl Unit (ECU)

[39A]

[33B]

GY

GY

GY

O/W

O/W

O/W

O/W

PK/BN

PK

/BN

R/BN

R/B

N

O/W

R/V

R/V R/V

LGN/V

LGN/V

LGN

/V

Tail/StopLamp

[93A]3 4

3 4 [93B]

BK

BK

BK

BK

BK

RearStopLampSwitch

[121AA]

[121AB]

[121BA]

[121BB]

PressureSwitch

1 1

1 1

[62B]OFF

IGN I

BA

A

B A

BCACC

RR/BK

R/GY

MAXIFUSE40 Amp

[5B] [166B] [166A]

BK

RR R

1

2

1

2

77

M

Pump motor supply

Pump motor ground

BK R

RearWheelSpeedSensor

[168B]

[168A]

[167B]

[167A]

FrontWheelSpeedSensor

B A

B A

BKR

A B

A B

PumpMotor

See appendix Bmain harnesspage 1 of 2

VoltageRegulator

BK

[77B] [77A]

em00112

Figure 5-12. ABS Schematic







Back of ignition switch3-place PackardIgnition key switch[33]

Under handlebar cover12-place PackardInstrument module[39]

Under the passenger seat18-placeFuse block[61]

Under the right side cover18-placeFuse block[62]


Under rear fender4-place MultilockTail/stop/lamp[93]

Right side of ABS ModuleSpade terminalsRear stoplight switch[121]


Under left radiator shroud2-place PackardFront wheel speed sensor[167]

Right side below swingarm pivot2-place PackardRear wheel speed sensor[168]

Behind right side cover4-place DeutschABS diode pack[201]



ABS Indicator Always On or Inoperative

Inspect (LGN/V) between terminal “9” ofconnector [166B] and terminal “7” of

connector [39B] for an open.Open condition present?

Perform a WOW test. Refer to 2.2 INSTRUMENTMODULE (IM) SELF DIAGNOSTICS.

Does the ABS lamp function properly during theWOW test?

Verify that the bike is equipped withABS and has the appropriate

Instrument Module. Check for DTCs.Any ABS DTCs present?

NOYES

YES

Repair open in (LGN/V) betweenterminal “9” of connector [166B] and

terminal “7” of connector [39B].

NO

Replace ABSModule.

Refer to appropriateDiagnostic table.

YES NO

Replace theInstrument Module.

fc01528_en



5.6DTC C0562

DTC C0562: DEVICE VOLTAGE LOW

Circuit DescriptionThe ABS module monitors the voltage level available for systemoperation. A low voltage condition prevents the system fromoperating properly.

Conditions for Running the DTCIgnition voltage is greater than 6.5V and the vehicle speed isabove 8 km/h (5 MPH).

Conditions for Setting the DTCOne of the following conditions exists for at least 0.72 seconds:

• During initialization or when the system is active thesystem voltage is below 9.0V.

• The system voltage drops below 10.5V with the systemenabled and the pump not running.

• The ignition voltage is below 8.7V.

• Battery voltage is below 8.7V with vehicle speed above8 km/h (5 MPH) and engine speed above 500 RPM.

Action Taken When the DTC Sets• ABS is disabled.

• The ABS indicator is illuminated.

Conditions for Clearing the DTCThe condition for the DTC is no longer present and the DTChas been cleared with either a "WOW" test or Digital Techni-cian.

The ABS module automatically clears the historic DTC whena current DTC is not detected in 50 consecutive drive cycles.

Diagnostic TipsThe following conditions are possible causes for this fault:

• Charging system malfunction.

• Excessive battery draw and/or extended idling in heavytraffic.

• A weak battery.

• A faulty system ground.


1. The ignition circuit between wire harness connector [166B]and ABS connector [166A] consists of all the circuitry backto and including the Ignition Switch.



-+

-+

InstrumentModule

Battery

Serialdata

IgnitionFuse

15 AmpIgnitionSwitch

ABSFuse30 Amp

20

19

9

Battery (motor)

Ignition

Serial data

20

1

2

10 Battery

HydraulicControl

Unit (HCU)

Pump motor supply

Pump motor ground

10

19

9

1 Ground1

11 Ground11

[33A]

[39B]

[GND2]


[39A]

[33B]

GY

GY

GY

R/V

R/V R/V

LGN/V LGN/V

LGN

/V

OFF

IGN I

BA

A

B A

BCACC

RR/BK

VoltageRegulator

MAXIFUSE40 Amp

[5B]

[62B]

BK

BK

BK

BKBK

BK

R RR

77

M

[166B] [166A]

PumpMotor


page 1 of 2


page 1 of 2


page 1 of 2

[77B] [77A]

em00115

Figure 5-13. ABS Power and Ground Schematic






Under right side cover18-placeFuse block[62]





Device Voltage Low: DTC C0562

NOYES

Clear DTCs using speedometer self diagnostics.See 2.2 INSTRUMENT MODULE (IM) SELF DIAGNOSTICS.Confirm proper operation with no check engine lamp.

Install Breakout Box (HD-48642). Turn the IgnitionSwitch to the IGN position. Using a DVOM test for

voltage at the Battery circuits at terminals “20” and “10”.Is the voltage above 10.5V?

Repair highresistance in

ignition circuit.

Test the ground circuits atterminals “1” and “11” for

high resistance or an open.Is high resistance or open

present?

Clear the DTC. Operate the systemwithin Conditions for Running the DTC.

Does the DTC reset?

Repair high resistance oropen condition on ground

circuits.

YES

YES

YES

NO

NO

Test the ignition circuitterminal “19” for voltage.Is voltage above 10.5V?

Test battery circuit terminals “10”and “20” for high resistance.

High resistance present?

Refer toDiagnostic Tips.

Replace ABSModule.

YES NO

Repair circuit.

Repair Battery andcharging system.

Refer to section 1.7CHARGINGSYSTEM.

NO

fc01529_en

1



5.7DTC C0563

DTC C0563: DEVICE VOLTAGE HIGH



Circuit DescriptionThe ABS module monitors the system voltage level. If thevoltage level is too high, damage may result to the system.When the ABS module detects a high voltage condition, it dis-ables the ABS.

Conditions for Running the DTCIgnition voltage is greater than 6.5V.

Conditions for Setting the DTCOne of the following conditions exists for at least 0.72 seconds:

• When the system is active the system voltage is above18.0V.

• The ignition voltage is above 18.0V.





Diagnostic TipsThis fault could be caused by an overcharging condition witheither the vehicle's charging system or an external chargingsystem.


1. Connect BREAKOUT BOX (Part No. HD-48642) betweenwire harness connector [166B] and ABS connector [166A].



-+

-+

InstrumentModule

Battery

Serialdata

IgnitionFuse


ABSFuse30 Amp

20

19

9

Battery (motor)

Ignition

Serial data

20

1

2

10 Battery

HydraulicControl

Unit (HCU)

Pump motor supply

Pump motor ground

10

19

9

1 Ground1

11 Ground11

[33A]

[39B]

[GND2]


[39A]

[33B]

GY

GY

GY

R/V

R/V R/V

LGN/V LGN/V

LGN

/V

OFF

IGN I

BA

A

B A

BCACC

RR/BK

VoltageRegulator

MAXIFUSE40 Amp

[5B]

[62B]

BK

BK

BK

BKBKB

K

R RR

77

M

[166B] [166A]

PumpMotor


page 1 of 2


page 1 of 2


page 1 of 2

[77B] [77A]

em00115












Device Voltage High: DTC C0563

NOYES


Install Breakout Box (HD-48642). Start and run the engine atapproximately 2000 RPM. Using a DVOM test for voltage at the Batterycircuits at terminals “10” and “20” and the ignition circuit at terminal “19”.

Is the voltage above 18.0V?

Test and repair chargingsystem. Refer to 1.7

CHARGING SYSTEM.

Clear the DTC. Operate the systemwithin Conditions for Running the DTC.

Does the DTC reset?


YES NO

Replace ABSModule.

fc01530_en

1



5.8DTC C1017

DTC C1017: PUMP MOTOR POWER CIRCUITOPEN FAULT



Circuit DescriptionSee Figure 5-15. The ABS module monitors the internal relayfor the pump motor along with the power circuit going to it.

3

1

2

5

4ed01285

1. Pump motor connector (ECU)2. Solenoids3. Pump motor4. Valves5. Pump motor connector (HCU)

Figure 5-15. ECU and HCU Pump Motor Connectors

Conditions for Running the DTC• The system is enabled and the system voltage is above

10.5V.

• The ignition voltage is between 8.7V and 18.0V.

Conditions for Setting the DTCThe DTC will set if any of the following conditions exist:

• The voltage across the pump is below 8.0V for 0.2seconds.

• The battery voltage to the pump is less than 8.84V.

• The pump relay coil is NOT shorted to battery or open.






• High resistance or open pump motor battery circuit.

• Internal ECU pump relay fault.

• Battery or charging malfunction.



Diagnostic NotesEach reference number below correlates to a circled number

on the flow chart(s).


-+

-+

InstrumentModule

Battery

Serialdata

IgnitionFuse


ABSFuse30 Amp

20

19

9

Battery (motor)

Ignition

Serial data

20

1

2

10 Battery

HydraulicControl

Unit (HCU)

Pump motor supply

Pump motor ground

10

19

9

1 Ground1

11 Ground11

[33A]

[39B]

[GND2]


[39A]

[33B]

GY

GY

GY

R/V

R/V R/V

LGN/V LGN/V

LGN

/V

OFF

IGN I

BA

A

B A

BCACC

RR/BK

VoltageRegulator

MAXIFUSE40 Amp

[5B]

[62B]

BK

BK

BK

BKBK

BK

R RR

77

M

[166B] [166A]

PumpMotor


page 1 of 2


page 1 of 2


page 1 of 2

[77B] [77A]

em00115












Pump Motor Power Circuit Open Fault: DTC C1017

NOYES

Install Breakout Box (HD-48642). Using aDVOM test the Battery circuit at terminal “20”.

Is Battery voltage present?

Replace ABSModule.

Repair open in batterycircuit terminal “20”.

Inspect for short to ground inbattery circuit terminal “20”.Did you find and correct the

condition?

Inspect the ABS Motor 30 Amp fuse.Is the fuse good?

NOYES

NOYES

Replace the 30 AmpABS Motor fuse.

Replace ABS Module and30 Amp ABS Motor fuse.

fc01531_en

1



5.9DTC C1018

DTC C1018: PUMP MOTOR GROUND HIGHRESISTANCE FAULT



Circuit DescriptionSee Figure 5-17.The ABS module monitors the internal pumpmotor and the circuit supplying ground to the pump motor.

3

1

2

5

4ed01285



Conditions for Running the DTC• The ignition voltage is between 8.7V and 18.0V.

• The system is enabled.

Conditions for Setting the DTCThe DTC will set if the following conditions exist when the pumpmotor is commanded off.

• The system voltage is between 8.0V and 18.0V.

• The voltage at the low side of the pump is greater than1.7V.

The DTC will set if the following conditions exist when the pumpis commanded on.

• The system voltage is between 10.0V and 18.0V.

• The voltage across the pump motor is less than 8.4V.

• The voltage at the high side of the pump motor is greaterthan 8.84V.








• Pump motor ground circuit has high resistance or open.

• Battery or charging malfunction.



-+

-+

InstrumentModule

Battery

Serialdata

IgnitionFuse


ABSFuse30 Amp

20

19

9

Battery (motor)

Ignition

Serial data

20

1

2

10 Battery

HydraulicControl

Unit (HCU)

Pump motor supply

Pump motor ground

10

19

9

1 Ground1

11 Ground11

[33A]

[39B]

[GND2]


[39A]

[33B]

GYG

Y

GY

R/V

R/V R/V

LGN/V LGN/V

LGN

/V

OFF

IGN I

BA

A

B A

BCACC

RR/BK

VoltageRegulator

MAXIFUSE40 Amp

[5B]

[62B]

BK

BK

BK

BKBK

BK

R RR

77

M

[166B] [166A]

PumpMotor


page 1 of 2


page 1 of 2


page 1 of 2

[77B] [77A]

em00115












Pump Motor Ground High Resistance Fault: DTC C1018

NOYES

Install Breakout Box (HD-48642). Using aDVOM test the Battery circuit at terminal “20”.

Is Battery voltage present?

Replace ABSModule.

Repair open in batterycircuit terminal “20”.

Inspect for short to ground inbattery circuit terminal “20”.Did you find and correct the

condition?

Inspect the ABS Motor 30 Amp fuse.Is the fuse good?

NOYES

NOYES

Replace the 30 AmpABS Motor fuse.

Replace ABS Module and30 Amp ABS Motor fuse.

fc01531_en

1



5.10DTC C1021, C1023

DTC C1021, C1023:WHEEL SPEED SENSOREQUALS ZERO (FRONT OR REAR)

Circuit DescriptionThe active wheel speed sensor is supplied system voltage fromthe ABS module. The sensor then returns a 7 milliamp to 14milliamp signal back to the ABS module.

Conditions for Running the DTC• Ignition voltage is greater than 6.5V.

• The ABS is inactive.

• The brake is not depressed.

• There are no wheel speed sensor circuit malfunctions.

• Vehicle must be driven above 16 km/h (10 MPH) for 20seconds without a brake input.

Conditions for Setting the DTCDTC C1021 will set if the following conditions exist for over 20seconds:

• The front wheel speed equals 0 km/h (0 MPH).

• The rear wheel speed is greater than 16 km/h (10 MPH).

• The difference between the two wheel speeds is greaterthan 18 km/h (11 MPH).

DTC C1023 will set if the following conditions exist for over 20seconds.

• The rear wheel speed equals 0 km/h (0 MPH).

• The front wheel speed is greater than 16 km/h (10 MPH).

• The difference between the two wheel speeds is greaterthan 18 km/h (11 MPH).

Action Taken When the DTC Sets• The ABS module disables the ABS.





• Internal sensor fault.

• Spinning up the rear wheel over 16 km/h (10 MPH) withthe vehicle in a stationary position for an extended periodof time (dynamometer).



BE

/BN

BK

/BE

Fron

twhe

elsp

eed

sens

orlo

wFr

ontw

heel

spee

dse

nsor

high

Rea

rw

heel

spee

dse

nsor

high

Rea

rw

heel

spee

dse

nsor

low

[166A]

[166B]

ElectronicControlUnit(ECU)

BE

/V

BK

/V

7

7

8

8

17

17

18

18

BK R


[167B]

[167A]

[168B]

[168A]


B A

B A

BKR

A B

A B

em00114

Figure 5-19. Wheel Speed Sensor Schematic








Wheel Speed Sensor Equals Zero: DTC C1021, C1023

Refer to highest priorityDTC diagnostics and

repair it first.

Clear the DTC. Operate the system inthe Conditions for Running the DTC.

Did the DTC reset?

Are any other wheel speedDTCs present?

NOYES

NOYES


Replace appropriatebearing assembly andwheel speed sensor.

fc01533_en

Clear DTCs using Instrument Module self diagnostics.See 2.2 INSTRUMENT MODULE (IM) SELF DIAGNOSTICS.Confirm proper operation with no ABS lamp.

NOTEThis code may occur if the vehicle experiences an abnormal amount ofwheel slippage due to slippery conditions under launch or intentional front orrear wheel spin (dynamometer testing).



5.11DTC C1025, C1027, C1206, C1208

DTC C1025, C1027, C1206, C1208: WHEELSPEED SIGNAL INTERMITTENT ORFREQUENCY OUT OF RANGE



Circuit DescriptionThe active wheel speed sensor is supplied system voltage fromthe ABS module. The sensor then returns a 7 milliamp or 14milliamp signal back to the ABS module.


• The brake is not depressed.

• There are no front or rear wheel speed sensor circuitmalfunctions.

Conditions for Setting the DTCThe DTC will set if the following conditions exist.

• The ABS module detects a rapid variation in the wheelspeed. The wheel speed changes by 20 km/h (12 MPH)or more in 0.01 second. The change must occur 3 timeswith no more than 0.2 seconds between occurrences.

• The frequency of the wheel speed input goes above2.5kHz for 20 milliseconds.






• External or internal wheel speed circuit intermittent open.

• Mismatched or improperly sized tires.

• Electrical noise on the wheel speed wires.

• Worn suspension components.

• Rough terrain.

If the fault only occurs in moist conditions (rain, snow, vehiclewash, etc.) inspect the wheel speed sensor and wiring for signsof water intrusion.


1. A possible cause of the DTC is electrical noise on thewheel speed sensor harness wiring. Electrical noise couldresult from the wheel speed sensor wires being routed toclose to high energy ignition system components, suchas spark plug wires.




BE

/BN

BK

/BE

Fron

twhe

elsp

eed

sens

orlo

wFr

ontw

heel

spee

dse

nsor

high

Rea

rw

heel

spee

dse

nsor

high

Rea

rw

heel

spee

dse

nsor

low

[166A]

[166B]


BE

/V

BK

/V

7

7

8

8

17

17

18

18

BK R


[167B]

[167A]

[168B]

[168A]


B A

B A

BKR

A B

A B

em00114









Wheel Speed Signal Intermittent or Frequency Out of Range: DTC C1025, C1027, C1206,C1208


Remove or relocateinterference.

Inspect for loose or damaged connections onwheel speed sensor circuits.Were poor connections found?

Inspect vehicle for accessories that may causeelectrical interference with the wheel speed sensors.

Electrical interference present?

NOYES

NOYES

Repair connectionsand circuits.

Clear DTC. Operate vehicleunder conditions for running DTC.

Does DTC reset?

YES NO


Inspect for worn or damagedsuspension components.

Were damaged or worn componentsfound?

YES NO

Replace the appropriatebearing assembly andwheel speed sensor.

Repair openin circuits.

Connect ABS breakout box (HD-48642). Turn IgnitionSwitch on. Start engine and wait 10 seconds for ABS to

complete initialization test. While wiggling harness checkfor voltage at connector [166B] terminal “18” to ground

(front wheel) or terminal “7” to ground (rear wheel).Does voltage drop out intermittently?

NOYES

Replace neededcomponents.

fc01535_en

2

1



5.12DTC C1032, C1034

DTC C1032, C1034:WHEEL SPEED SENSORCIRCUIT OPEN OR SHORTED (FRONT ORREAR)




Circuit DescriptionThe active wheel speed sensor is supplied system voltage fromthe ABS module. The sensor then returns a 7 milliamp to 14milliamp signal back to the ABS module.


• There are no front or rear wheel speed sensor circuitmalfunctions.

Conditions for Setting the DTCThe DTC will set if the following conditions exist:

• Short to ground on either the high or low side circuits ofthe front wheel speed sensor.

• Open on either the high or low side circuits of the frontwheel speed sensor.

• Short to voltage on the low side causing the voltage to goabove 0.79V.

• Wheel speed sensor open.






• Open in either of the front wheel speed sensor circuits.

• Short to ground in either of the front wheel speed sensorwires.

• Front wheel speed sensor open.

• Front wheel speed circuit low shorted to battery.

If the fault only occurs in moist conditions (rain, snow, vehiclewash, etc.) inspect the wheel speed sensor and wiring for signsof water intrusion.


1. Use HARNESS CONNECTOR TEST KIT (Part No. HD-41404-B) with gray male probes and patch cords.




BE

/BN

BK

/BE

Fron

twhe

elsp

eed

sens

orlo

wFr

ontw

heel

spee

dse

nsor

high

Rea

rw

heel

spee

dse

nsor

high

Rea

rw

heel

spee

dse

nsor

low

[166A]

[166B]


BE

/V

BK

/V

7

7

8

8

17

17

18

18

BK R


[167B]

[167A]

[168B]

[168A]


B A

B A

BKR

A B

A B

em00114









Wheel Speed Sensor Circuit Open or Shorted: DTC C1032, C1034 (Part 1 of 4)

Disconnect front wheelspeed sensor. Test

connector [166B] terminals“17” and “18” at BreakoutBox for short to ground.

Short to ground present?

Disconnect front wheel speedsensor. Test for an openbetween connector [166B]

terminal “17” and connector[167B] terminal “A”Is an open present?

Disconnect ABS Module [166] from theBreakout Box. Test connector [166B] terminal“17” for short to ground and terminal “18” for

short to ground at Breakout Box.Short to ground present?

NOYES

NO

YES

Repair short toground in

appropriatecircuit.

Test for an open betweenconnector [166B] terminal“18” and connector [167B]

terminal “B”Is an open present?

YES NO

Replace FrontWheel Speed

Sensor.

Repair open infront wheel speedsensor low circuit.

NO


Sensor.

YES

Repair open infront wheel speedsensor high circuit.


fc01534_en

Clear the DTC. Operate the system inthe Conditions for Running the DTC.

Did the DTC reset?

NO


YES

Did DTC C1032reset?

NO, C1034 setYES, C1032 set

STOP

Go to Wheel Speed SensorCircuit Open or Shorted: DTC

C1032, C1034 (Part 3 of 4).

Connect ABS Breakout Box (HD-48642). Turn ignition switch on with theengine stop switch in the RUN position. Start engine and wait 10

seconds for ABS Module to complete initialization test. Measure voltageat connector [166B] terminals “18” at Breakout Box

Is voltage below 0.5V?

NOYES

STOP


C1032, C1034 (Part 2 of 4).

2

1




fc01537_en


connector [166B] terminals“7” and “8” at Breakout Box

for short to ground.Short to ground present?

Disconnect front wheel speedsensor. Test for an openbetween connector [166B]terminal “8” and connector

[167B] terminal “A”Is an open present?

Disconnect ABS Module from the BreakoutBox. Test connector [166B] terminals “7” and

“8” at Breakout Box for short to ground.Short to ground present?

NOYES

NO

YES

Repair short toground in

appropriatecircuit.

Test for an open betweenconnector [166B] terminal“7” and connector [167B]

terminal “B”Is an open present?

YES NO


Sensor.

Repair open infront wheel speedsensor low circuit.

NO


Sensor.

YES

Repair open infront wheel speedsensor high circuit.

Continued from Wheel Speed Sensor Circuit Open or Shorted:DTC C1032, C1034 (Part 1 of 4).

Connect ABS Breakout Box (HD-48642). Turn ignition switch onwith the engine stop switch in the RUN position. Wait 10 secondsfor ABS Module to complete initialization test. Measure voltage at

connector [166B] terminals “7” at Breakout BoxIs voltage below 0.5V?

NOYES

STOP


C1032, C1034 (Part 4 of 4).




fc01536_en

Continued from Wheel Speed Sensor Circuit Open or Shorted: DTCC1032, C1034 (Part 1 of 4).

Disconnect ABS Module from the Breakout Box. Test connector [166B]terminals “17” and “18” at Breakout Box for short to voltage.

Short to voltage present?


connector [166B] terminals“17” and “18” at BreakoutBox for short to voltage.

Short to voltage present?

Disconnect front wheel speedsensor. Test connector [166B]

terminals “17” and “18” atBreakout Box for continuity.

Continuity present?

NOYES

YES

Repair short tovoltage in

appropriatecircuit.

NO


Sensor.

YES

Repair short infront wheel speed

sensor wires.

NO

Test for continuity acrossterminals “A” and “B” at

connector [167A].Is continuity present?

YES


Sensor.

NO

Replace ABSModule.

1




fc01538_en

Continued from Wheel Speed Sensor Circuit Openor Shorted: DTC C1032, C1034 (Part 2 of 4).

Disconnect ABS Module from the Breakout Box. Testconnector [166B] terminals “7” and “8” at Breakout Box

for short to voltage.Short to voltage present?

Disconnect rear wheelspeed sensor. Test

connector [166B] terminals“7” and “8” at Breakout Box

for short to voltage.Short to voltage present?

Disconnect rear wheel speedsensor. Test connector [166B]

terminals “7” and “8” atBreakout Box for continuity.

Continuity present?

NOYES

YES

Repair short tovoltage in

appropriatecircuit.

NO

Replace RearWheel Speed

Sensor.

YES

Repair short inrear wheel speed

sensor wires.

NO

Test for continuity acrossterminals “A” and “B” at

connector [168A].Is continuity present?

YES

Replace RearWheel Speed

Sensor.

NO

Replace ABSModule.

1



5.13DTC C1042

DTC C1042: PUMP MOTOR OPEN

Circuit DescriptionSee Figure 5-22.The pump motor is located in the HCU portionof the ABS module. Power is supplied through an internal pump

motor relay when the ignition is turned on. The ECU monitorspump motor feedback voltage after activation to detect a stalledor binding pump motor.

3

1

2

5

4ed01285



Conditions for Running the DTC• Ignition voltage is between 8.7V and 18.0V.

• System voltage is between 8.0V and 18.0V.

• System is enabled.

• The pump motor has been commanded off for 2.4seconds.

Conditions for Setting the DTCThe DTC will set if the following condition exists:

• Current did not exceed 15.6A within 0.1 seconds ofswitching the pump motor on.




The ECU automatically clears the historic DTC when a currentDTC is not detected in 50 consecutive drive cycles.


• Open or high resistance at the pump motor connector.

• Open or high resistance in the pump motor windings.

Diagnostic ProcedureIf this code exists clear the code. Operate the system underconditions for running the DTC and if it resets replace the ABSModule.



5.14DTC C1043

DTC C1043: PUMP MOTOR STALLED

Circuit DescriptionSee Figure 5-23.The pump motor is located in the HCU portionof the ABS module. Power is supplied through an internal pump

motor relay when the ignition is turned on. The ECU monitorspump motor feedback voltage after activation to detect a stalledor binding pump motor.

3

1

2

5

4ed01285




• System voltage is between 8.0V and 18.0V.

• System is enabled.

• The pump motor has been commanded on for 0.3seconds.

Conditions for Setting the DTCThe DTC will set if the following conditions exist:

• The pump takes less than 0.03 seconds to spin down.

• The current exceeds 15.6A within 0.33 millisecond ofswitching the pump motor on.






• High side of the pump motor is shorted to ground.

• High or low resistance in the pump motor windings.

• The pump motor is seized or requires excessive torqueto spin.

Diagnostic ProcedureIf this code exists clear the code. Operate the system underconditions for running the code and if it resets replace the ABSmodule.



5.15DTC C1094

DTC C1094: FRONT BRAKE SWITCHALWAYS ON



Circuit DescriptionThe ABS module monitors the front brake switch input. Whenthe brake lever is applied the ABS Module receives voltage onthe front brake switch circuit.The ABS module uses this signalto enhance ABS operation.


Conditions for Setting the DTCThe DTC will set if all of the following conditions exist for 2seconds:

• The ECU sees a front brake input.

• The vehicle speed exceeds 40 km/h (25 MPH).

• The vehicle acceleration exceeds 8 km/h/second (5MPH/second).

Action Taken When the DTC SetsNo action is taken when this code is set. The ABS indicatordoes not illuminate and the ABS is still active.




• Short to voltage between the front brake switch and theECU.

• Front brake switch stuck closed or applied during acceler-ation.

• Internal front brake sensing malfunction.


1. Use HARNESS CONNECTOR TEST KIT (Part No. HD-41404-B) wit gray male probes and patch cords.



ACCYFuse15 Amp

Front StopLampSwitch

RearStop LampSwitch

ABSDiodePack

Tail/StopLamp

[GND2]

PressureSwitch

Electronic ControlUnit (ECU)

13 Front brake input13

3 Rear brake input3

[61B]

[121AA]

[121AB]

[121BA]

[121BB]

[201B][201A]

[93A][93B]

1

1

4 3 2 1

4 3

3 4

3 4

2 1

1

1 1

2

1 2

[166B]

[22B]

[22A]

[166A]R

/Y

R/Y

R/Y

R/Y

R/Y

R/BN

R/B

N

R/B

N

PK/BN

PK/BN

PK

/BN

O/W O/W

O/W

O/W

O/W

BK

BK


em00113

Figure 5-24. Brake Switches Schematic





Under rear fender4-place MultilockTail/stop lamp[93]






Front Brake Switch Always On: DTC C1094

Disconnect connector [22]. Test for voltageon terminal “2” of connector [22B].

Voltage present?


Clear the DTC. Operate the system inthe conditions for running the DTC.

Did the DTC reset?

NOYES

YES

Repair short tovoltage.

NO

Replace frontbrake switch.


Voltage present?

YES NO

Replace ABSModule.

fc01541_en


1



5.16DTC C1095

DTC C1095: FRONT BRAKE SWITCH OPEN

Circuit DescriptionThe ABS module monitors the front brake switch input. Whenthe brake lever is applied the ABS module receives voltage onthe front brake switch circuit.The ABS module uses this signalto enhance ABS operation.


• The rear brake switch is not closed (brake applied).


• The ABS module detects an open in the front brake inputcircuit.

• The ABS module detects an open in the ground circuit tothe front brake switch.

Action Taken When the DTC SetsNo action is taken when this code is set. The ABS indicatorDOES NOT illuminate and the ABS is still active.




• An open in the front brake input circuit.

• Open coil in the brake lamp relay.

• The ground path to the brake lamp is open.

• Internal ABS module problem in the front brake circuitry.



ACCYFuse15 Amp


RearStop LampSwitch

ABSDiodePack

Tail/StopLamp

[GND2]

PressureSwitch



3 Rear brake input3

[61B]

[121AA]

[121AB]

[121BA]

[121BB]

[201B][201A]

[93A][93B]

1

1

4 3 2 1

4 3

3 4

3 4

2 1

1

1 1

2

1 2

[166B]

[22B]

[22A]

[166A]

R/Y

R/Y

R/Y

R/Y

R/Y

R/BN

R/B

N

R/B

N

PK/BN

PK/BN

PK

/BN

O/W O/W

O/W

O/W

O/W

BK

BK


em00113












Front Brake Switch Open: DTC C1095

Disconnect front stop lamp switchconnector [22]. Measure voltage at

terminal “13” of Breakout Box.Is voltage greater then 2.0V?


Clear the DTC. Operate the system underthe conditions for running the DTC.

Did the DTC reset?

NOYES

YES

Disconnect ABSdiode pack connector

[201]. Measurevoltage at terminal

“13" of Breakout Box.Is voltage greater

then 2.0V?

NO

Replace Front StopLamp Switch.

Connect ABS Breakout Box (HD-48642). Turn theIgnition switch to the IGNITION position.

Measure voltage at terminal “13” of Breakout Box.Is voltage greater then 2.0V?

YES NO

Apply front brake switch. Measurevoltage drop from terminal “10” toterminal “13” of the breakout box.Is voltage drop greater then 2.0V?

YES NO

Disconnect front stop lamp switchconnector [22]. Jumper terminal “1” and

terminal “2” of connector [22B]. Measurevoltage drop from terminal “10” toterminal “13” of the Breakout Box.Is voltage drop greater then 2.0V?

YES

NO

NO

While performing wiggle testmeasure voltage drop from

terminal “10” to terminal “13”of the breakout box.

Is voltage drop greater then2.0V.

Replace ABSModule.

Locate and repair short tovoltage on (R/BN) front

brake input circuit.

Replace ABSDiode Pack.

fc01542_enClear DTCs using speedometer self diagnostics.See 2.2 INSTRUMENT MODULE (IM) SELF DIAGNOSTICS.Confirm proper operation with no check engine lamp.

YES

Disconnect ABS diode packconnector [201]. Measure voltagedrop from terminal “10” to terminal

“13” of Breakout Box. Is voltage dropgreater then 1.0V?

NO

Replace Front StopLamp Switch.

YESNO

Locate and repair highresistance short to ground on

(R/BN) front brake inputcircuit.


YES


(R/BN) front brake inputcircuit.



5.17DTC C1151

DTC C1151: FRONT WHEEL RELEASE TOOLONG

Circuit DescriptionThe ABS module activates the valve relay to supply voltage tothe valve solenoids. This voltage is referred to as the systemvoltage. The ABS module microprocessor activates individualvalve solenoids by grounding the valve solenoid control circuits.

ed01287

Figure 5-26. Front Wheel Speed Sensor


Conditions for Setting the DTCThe DTC will set if all of the following conditions exist.

• The ABS is commanding a pressure release from the frontwheel release valve.

• The front wheel speed is below 5 km/h (3 MPH) for morethan 1 second.






• An intermittent wheel speed sensor.

• Wheel speed sensor equals 0 km/h (0 MPH).

• Internal ECU problem in the release solenoid.

• Internal problem in the HCU.

• Brake lines reversed on the HCU inlet and outlet ports.

• A stuck or seized caliper or bald tires could contribute tothis code setting.



BE

/BN

BK

/BE

Fron

twhe

elsp

eed

sens

orlo

wFr

ontw

heel

spee

dse

nsor

high

Rea

rw

heel

spee

dse

nsor

high

Rea

rw

heel

spee

dse

nsor

low

[166A]

[166B]


BE

/V

BK

/V

7

7

8

8

17

17

18

18

BK R


[167B]

[167A]

[168B]

[168A]


B A

B A

BKR

A B

A B

em00114









Front Wheel Release Too Long: DTC C1152

Go to appropriateDTC chart.

Inspect brake lines at the ABSmodule for proper installation.

Are the lines installed properly?

Check for DTCs.Are any front wheel speedsensor DTCs currently set?

NOYES

YES

Replace ABSModule.

NO

Correctly installbrake lines.

Clear DTCs using speedometer self diagnostics.See 2.2 INSTRUMENT MODULE (IM) SELF DIAGNOSTICS.Confirm proper operation with no check engine lamp. fc01543_en



5.18DTC C1153

DTC C1153: REAR WHEEL RELEASE TOOLONG

Circuit DescriptionThe ABS module activates the valve relay to supply voltage tothe valve solenoids. This voltage is referred to as the systemvoltage. The ABS module microprocessor activates individualvalve solenoids by grounding the valve solenoid control circuits.

ed01288

Figure 5-28. Rear Wheel Speed Sensor


Conditions for Setting the DTCThe DTC will set if all of the following conditions exist:

• The ABS is commanding a pressure release from the rearwheel release valve.

• The rear wheel speed is below 5 km/h (3 MPH) for morethan 1 second.






• An intermittent wheel speed sensor.

• Wheel speed sensor equals 0 km/h (0 MPH).

• Internal ECU problem in the release solenoid.

• Internal problem in the HCU.

• Brake lines reversed on the HCU inlet and outlet ports.

• A stuck or seized caliper or bald tires.



BE

/BN

BK

/BE

Fron

twhe

elsp

eed

sens

orlo

wFr

ontw

heel

spee

dse

nsor

high

Rea

rw

heel

spee

dse

nsor

high

Rea

rw

heel

spee

dse

nsor

low

[166A]

[166B]


BE

/V

BK

/V

7

7

8

8

17

17

18

18

BK R


[167B]

[167A]

[168B]

[168A]


B A

B A

BKR

A B

A B

em00114









Rear Wheel Release too Long: DTC C1153

Go to appropriateDTC chart.

Inspect brake lines at the ABSmodule for proper installation.

Are the lines installed properly?

Check for DTCs.Are any rear wheel speed

sensor DTCs currently set?

NOYES

YES

Replace ABSMdule.

NO

Correctly installbrake lines.

fc01544_en




5.19DTC C1158

DTC C1158: CALIBRATION PROGRAMMINGREQUIRED

Circuit DescriptionThe ECU is calibrated to maximize ABS performance. If thecorrect calibration is not in the module the ABS may not performcorrectly.


Conditions for Setting the DTCThe ABS module determines final calibration is not completed.



Conditions for Clearing the DTCThe condition for the DTC is no longer present and the DTChas been cleared with Digital Technician. This code may beset whenever an ABS module is replaced. The code on thenew module will have to be cleared using Digital Technician.



• An ECU that is not calibrated correctly or has an internalfault.

• All replacement ABS modules will have this DTC set.



-+

-+

R/Y

BK

R/BN

BK/V

BE/V

PK/BN

BK/BEBE/BN

R/Y

R/Y

R/Y

R/Y

ABSDiodePack

InstrumentModule

[201B]

[201A]

4 3 2 1

4 3 2 1

Battery

ACCYFuse15 Amp

FrontStopLampSwitch

Serialdata

IgnitionFuse

15 Amp

ABSFuse30 Amp

20

19

9

181787

1

11

13

3

Battery (motor)

Ignition

Serial data


Ground

Ground (motor)

Front brake input

Rear brake input

20

1

2

10 Battery

HydraulicControl

Unit(HCU)

10

19

9

181787

1

11

13

3


page 1 of 2


page 1 of 2

[33A]

[61B]

[22A][22B]

[39B]

[GND2]


[39A]

[33B]

GY

GY

GY

O/W

O/W

O/W

O/W

PK/BN

PK

/BN

R/BN

R/B

N

O/W

R/V

R/V R/V

LGN/V

LGN/V

LGN

/V

Tail/StopLamp

[93A]3 4

3 4 [93B]

BK

BK

BK

BK

BK

RearStopLampSwitch

[121AA]

[121AB]

[121BA]

[121BB]

PressureSwitch

1 1

1 1

[62B]OFF

IGN I

BA

A

B A

BCACC

RR/BK

R/GY

MAXIFUSE40 Amp

[5B] [166B] [166A]

BK

RR R

1

2

1

2

77

M

Pump motor supply

Pump motor ground

BK R


[168B]

[168A]

[167B]

[167A]


B A

B A

BKR

A B

A B

PumpMotor


VoltageRegulator

BK

[77B] [77A]

em00112




Calibration Programming Required: DTC C1158

Using Digital Technician (See yourdealer) attempt to calibrate the

ECU. Clear the DTC.Does the DTC reset?


Clear the DTC. Operate the ABS underthe conditions for running the DTC.

Does the DTC reset?

NOYES

YES NO

Calibration complete.Replace ABS

Module.

Clear DTCs using speedometer self diagnostics.See 2.2 INSTRUMENT MODULE (IM) SELF DIAGNOSTICS.Confirm proper operation with no check engine lamp. fc01545_en



5.20DTC C1212

DTC C1212: FRONT OR REAR BRAKE NOTAPPLIED WITH DECEL



Circuit DescriptionThe ABS module monitors the front and rear brake switchinputs through terminal "13" and terminal "3". This allows theABS to determine if the brake is being applied or not when awheel is decelerating.


Conditions for Setting the DTCThe DTC will set if the following conditions exist. The first fourconditions have to occur twice.

• The front or rear brake is not applied.

• There is no current ABS event in progress.

• Vehicle speed exceeds 24 km/h (15 MPH).

• Vehicle decelerates at a rate greater than 8 km/h (5 MPH)per second for more than two seconds.

• Vehicle speed drops below 24 km/h (15 MPH).





• A short or open on the brake switch input circuits to theABS module.

• Downshifting up a steep hill without using the brakesconsecutive times could cause this code.


1. Use HARNESS CONNECTOR TEST KIT (Part No. HD-41404-B) with gray male probes and patch cords.



ACCYFuse15 Amp


RearStop LampSwitch

ABSDiodePack

Tail/StopLamp

[GND2]

PressureSwitch



3 Rear brake input3

[61B]

[121AA]

[121AB]

[121BA]

[121BB]

[201B][201A]

[93A][93B]

1

1

4 3 2 1

4 3

3 4

3 4

2 1

1

1 1

2

1 2

[166B]

[22B]

[22A]

[166A]R

/Y

R/Y

R/Y

R/Y

R/Y

R/BN

R/B

N

R/B

N

PK/BN

PK/BN

PK

/BN

O/W O/W

O/W

O/W

O/W

BK

BK


em00113












Front or Rear Brake Not Applied With Decel: DTC C1212



Did the DTC reset?

NOYES

Disconnect connector [166]. Apply Front and Rear Stop LampSwitch. Test for voltage on terminal “13” to ground and

terminal “3” to ground of connector [166B].Voltage present at both terminals?

YES NO

Is voltage present on terminal “3”?

YES NO

YES

YES

NO

NO

Apply the rear brake pedal.Does the stop lamp

illuminate?

Repair open inRear Brake inputcircuit terminal

“3” of connector[166B].

Disconnect Rear Stop LampSwitch. Apply rear brake pedaland test for continuity between

terminals “1” and “2” ofconnector [121A].

Continuity present?

NO

Replace RearStop Lamp

Switch.

YES

Turn the Ignition Switch ON.Test terminal “1” of connector

[121B] for voltage.Voltage present?

Disconnect connector[22]. Test terminal “1”

connector [22B] forvoltage.

Voltage present?

YES NO

Repair open in(O/W) wire.

Connect jumper wire from terminal“1” to terminal “2” of connector [22B].

Does the stop lamp illuminate?

YES NO

Replace FrontStop Lamp

Switch.

Repair open in(R/BN) wire.

Replace ABSModule.

fc01547_en

Clear DTCs using speedometer self diagnostics.See2.2 INSTRUMENT MODULE (IM) SELF DIAGNOSTICS.Confirm proper operation with no check engine lamp. Repair open in

(O/W) wire.Repair open in(PK/BN) wire.

1



5.21DTC C1214

DTC C1214: REAR BRAKE SWITCHALWAYS ON

Circuit DescriptionThe ABS module monitors the rear brake switch input. Whenthe brake pedal is applied the ABS module receives voltageon the rear brake switch circuit. The ABS module uses thissignal to enhance ABS operation.



• The ABS module sees a rear brake input.

• The vehicle speed exceeds 40 km/h (25 MPH).

• The vehicle acceleration exceeds 8 km/h/second (5MPH/second).

Action Taken When the DTC SetsNo action is taken when this code is set. The ABS indicatordoes not illuminate and the ABS is still active.




• Short to voltage between the rear brake switch and theABS module.

• Rear brake switch stuck closed or applied during acceler-ation.

• Internal rear brake sensing malfunction.



ACCYFuse15 Amp


RearStop LampSwitch

ABSDiodePack

Tail/StopLamp

[GND2]

PressureSwitch



3 Rear brake input3

[61B]

[121AA]

[121AB]

[121BA]

[121BB]

[201B][201A]

[93A][93B]

1

1

4 3 2 1

4 3

3 4

3 4

2 1

1

1 1

2

1 2

[166B]

[22B]

[22A]

[166A]

R/Y

R/Y

R/Y

R/Y

R/Y

R/BN

R/B

N

R/B

N

PK/BN

PK/BN

PK

/BN

O/W O/W

O/W

O/W

O/W

BK

BK


em00113












Rear Brake Switch Always On: DTC C1214

Disconnect connector [121-1]. Test forvoltage on terminal “1” of connector [121-1B].

Voltage present?


Clear the DTC. Operate the system inthe conditions for running the DTC.

Did the DTC reset?

NOYES

YES

Repair short tovoltage.

NO

Replace rearbrake switch.


Voltage present?

YES NO

Replace ABSModule.

fc01548_en




5.22DTC C1216

DTC C1216: REAR BRAKE SWITCH OPEN

Circuit DescriptionThe ABS module monitors the rear brake switch input. Whenthe brake pedal is applied the ABS module receives voltageon the rear brake switch circuit. The ABS module uses thissignal to enhance ABS operation.


• The front brake switch is not closed (brake applied).


• The ABS module detects an open in the rear brake inputcircuit.

• The ABS module detects an open in the ground circuit tothe rear brake switch.





• An open or loose connection in the rear brake input circuit.

• All brake lamps are open or burned out.

• The ground path to the brake lamps is open.

• Internal ABS module problem in the rear brake input cir-cuitry.



ACCYFuse15 Amp


RearStop LampSwitch

ABSDiodePack

Tail/StopLamp

[GND2]

PressureSwitch



3 Rear brake input3

[61B]

[121AA]

[121AB]

[121BA]

[121BB]

[201B][201A]

[93A][93B]

1

1

4 3 2 1

4 3

3 4

3 4

2 1

1

1 1

2

1 2

[166B]

[22B]

[22A]

[166A]R

/Y

R/Y

R/Y

R/Y

R/Y

R/BN

R/B

N

R/B

N

PK/BN

PK/BN

PK

/BN

O/W O/W

O/W

O/W

O/W

BK

BK


em00113












Rear Brake Switch Open: DTC C1216

Disconnect rear stop lamp switchconnector [22]. Measure voltage at

terminal “3” of Breakout Box.Is voltage greater then 2.0V?



Did the DTC reset?

NOYES

YES

Disconnect ABS diode packconnector [201]. Measurevoltage at terminal “3" of

Breakout Box.Is voltage greater then 2.0V?

NO

Replace Rear StopLamp Switch.

Connect ABS Breakout Box (HD-48642). Turn theIgnition switch to the IGNITION position.

Measure voltage at terminal “3” of Breakout Box.Is voltage greater then 2.0V?

YES NO

Apply rear brake switch. Measurevoltage drop from terminal “10” toterminal “3” of the breakout box.

Is voltage drop greater then 2.0V?

YES NO

Disconnect rear stop lamp switch connector[121-1] and connector [121-2]. Jumper thetwo connectors together. Measure voltage

drop from terminal “10” to terminal “3” of theBreakout Box.

Is voltage drop greater then 2.0V?

YES

NO

NO

While performing wiggle testmeasure voltage drop from

terminal “10” to terminal “3” ofthe breakout box.

Is voltage drop greater then2.0V?

Replace ABSModule.

Locate and repair short tovoltage on (PK/BN) rear

brake input circuit.


fc01549_en


YES

Disconnect ABS diode packconnector [201]. Measure voltagedrop from terminal “10” to terminal

“3” of Breakout Box.Is voltage drop greater then 1.0V?

NO

Replace Reart StopLamp Switch.

YESNO


(PK/BN) rear brake inputcircuit.


YES


(PK/BN) rear brake inputcircuit.



5.23DTC C1014, C1055-C1066, C1118, C1121

DTC C1014, C1055-C1066, C1118, C1121:ECU INTERNAL FAULT

Circuit DescriptionThe ABS module monitors the voltage level available for systemoperation. A low voltage condition prevents the system fromoperating properly. The ABS module also performs severalself-tests for internal problems which may affect proper opera-tion.


Conditions for Setting the DTCThe ABS module detects an internal malfunction.



Conditions for Clearing the DTCCertain conditions that may cause this DTC to set cannot becleared. Other conditions that may cause this DTC to set maybe cleared, at least temporarily, with either a "WOW" test orDigital Technician.


• Internal system malfunction.

• A faulty system voltage supply to the module.

• A faulty system ground.


1. The ignition circuit consists of all the circuitry back to andincluding the ignition switch.



-+

-+

R/Y

BK

R/BN

BK/V

BE/V

PK/BN

BK/BEBE/BN

R/Y

R/Y

R/Y

R/Y

ABSDiodePack

InstrumentModule

[201B]

[201A]

4 3 2 1

4 3 2 1

Battery

ACCYFuse15 Amp

FrontStopLampSwitch

Serialdata

IgnitionFuse

15 Amp

ABSFuse30 Amp

20

19

9

181787

1

11

13

3

Battery (motor)

Ignition

Serial data


Ground

Ground (motor)

Front brake input

Rear brake input

20

1

2

10 Battery

HydraulicControl

Unit(HCU)

10

19

9

181787

1

11

13

3


page 1 of 2


page 1 of 2

[33A]

[61B]

[22A][22B]

[39B]

[GND2]


[39A]

[33B]

GY

GY

GY

O/W

O/W

O/W

O/W

PK/BN

PK

/BN

R/BN

R/B

N

O/W

R/V

R/V R/V

LGN/V

LGN/V

LGN

/V

Tail/StopLamp

[93A]3 4

3 4 [93B]

BK

BK

BK

BK

BK

RearStopLampSwitch

[121AA]

[121AB]

[121BA]

[121BB]

PressureSwitch

1 1

1 1

[62B]OFF

IGN I

BA

A

B A

BCACC

RR/BK

R/GY

MAXIFUSE40 Amp

[5B] [166B] [166A]

BK

RR R

1

2

1

2

77

M

Pump motor supply

Pump motor ground

BK R


[168B]

[168A]

[167B]

[167A]


B A

B A

BKR

A B

A B

PumpMotor


VoltageRegulator

BK

[77B] [77A]

em00112




ECU Internal Fault: DTC C1014, C1055-C1066, C1118, C1121

NOYES

Install Breakout Box (HD-48642). Turn the IgnitionSwitch to the IGNITION position. Using a DVOM test forvoltage at the Battery circuits at terminals “20” and “10”

Is the voltage above 10.5V?

Repair high resistancein ignition circuit.

Test the ground circuits atterminals “1” and “11” for

high resistance or an open.Is high resistance or open

present?

Replace ABSModule.

Repair high resistance oropen condition on ground

circuits.

YES

YES

NO

NO

Test the ignition circuitterminal “19” for voltage.Is voltage above 10.5V?

Test battery circuit terminals “10”and “20” for high resistance.

High resistance present?

YES NO

Repair circuit.Repair Battery andcharging system.

Refer to section 1.7CHARGINGSYSTEM.

1

fc01550_en






ed01355

Figure 5-35. Serial Data Connector [91A] (Typical)







SUBJECT............................................................................................................................PAGE NO.A.1 AMP 1-PLACE CONNECTORS................................................................................................A-1A.2 AMP MULTILOCK CONNECTORS..........................................................................................A-3A.3 DELPHI CONNECTORS..........................................................................................................A-8A.4 DEUTSCH 1-PLACE ELECTRICAL CONNECTORS.............................................................A-10A.5 DEUSCH ELECTRICAL CONNECTORS...............................................................................A-11A.6 DEUTSCH STANDARD TERMINALS.....................................................................................A-15A.7 DEUTSCH MINI-TERMINAL CRIMPS...................................................................................A-16A.8 DEUTSCH SOLID BARREL TERMINALS..............................................................................A-17A.9 RELAY AND FUSE BLOCKS..................................................................................................A-19A.10 150 METRI-PACK CONNECTORS.......................................................................................A-20A.11 280 METRI-PACK CONNECTORS.......................................................................................A-22A.12 480 METRI-PACK CONNECTORS.......................................................................................A-24A.13 630 METRI-PACK CONNECTORS.......................................................................................A-25A.14 800 METRI-PACK CONNECTORS.......................................................................................A-26A.15 METRI-PACK TERMINALS...................................................................................................A-28A.16 MOLEX CONNECTORS.......................................................................................................A-30A.17 PACKARD ECM CONNECTOR............................................................................................A-32A.18 PACKARD MICRO-64 CONNECTORS................................................................................A-34A.19 SEALED SPLICE CONNECTORS.......................................................................................A-37

AP

PE

ND

IX A

CO

NN

EC

TOR

RE

PAIR


NOTES


A.1AMP 1-PLACE CONNECTORS

AMP 1-PLACE CONNECTOR REPAIR


PACKARD TERMINAL CRIMPERHD-38125-7

SOCKET TERMINAL TOOLHD-39621-27

PIN TERMINAL REMOVERHD-39621-28

GeneralObtain the necessary tools to repair the connector or terminals.

For terminal crimping, use the PACKARD TERMINALCRIMPER (Part No. HD-38125-7).

Separating Pin and Socket HousingsBend back the ears on the pin housing slightly and separatethe pin and socket halves of the connector.

Mating Pin and Socket HousingsPush the pin and socket halves of the connector together untilthe latches click.

Removing Socket Terminals1. See Figure A-1. Grasp the lead on the wire end of the

socket housing (1) and push the terminal forward towardthe mating end of the connector until it stops. This willdisengage the locking tang from the groove in the con-nector.

2. Fit the barrel (2) of the SOCKET TERMINAL TOOL (PartNo. HD-39621-27) over the socket.

3. While rotating the tool slightly, push until it bottoms (3) inthe socket housing.

4. Allow the plunger (4) to "back out" of the handle.

5. Holding the socket housing while keeping the tool firmlybottomed (5), depress the plunger (6). The terminal (7)pops out the wire end of the connector.

NOTE

If the terminal is not released from the socket housing, thenthe terminal was not pushed forward far enough before place-ment of the tool or the tool was not bottomed in the connectorhousing.

Installing Socket Terminal1. Note the lip at the middle of the socket housing. One side

of the lip is flat while the other side is tapered. Insert thewire terminal into the socket housing on the flat (lip) side.

2. Push the lead into the socket housing until it stops. A clickis heard when the terminal is properly seated.

3. Gently tug on the lead to verify that the terminal is lockedin place.

1

8

2

3

7

6

4

5

sm00011

1. Socket housing2. Barrel3. Barrel bottomed in connector4. Plunger "backed out"5. Hold barrel bottomed6. Plunger pressed7. Socket terminal8. Connector lip

Figure A-1. Socket Terminal Tool (HD-39621-27)

Removing Pin Terminal1. Grasp the lead on the wire end of the pin housing and

push the terminal forward toward the mating end of theconnector until it stops. This will disengage the lockingtang from the groove in the connector.

2008 VRSC Diagnostics: Appendix A Connector Repair A-1


2. See Figure A-2.

a. Fit the barrel of the PIN TERMINAL REMOVER (PartNo. HD-39621-28) over the pin, and while rotatingthe tool slightly, push until it bottoms in the housing.Allow the plunger to "back out" of the handle.

b. Holding the pin housing while keeping the tool firmlybottomed, depress the plunger. The terminal popsout the wire end of the connector.

NOTE

If the terminal is not released from the pin housing, then theterminal was not pushed forward far enough before placementof the tool or the tool was not bottomed in the connectorhousing.

Installing Pin Terminal1. Push the lead into the pin housing until it stops. A click is

heard when the terminal is properly seated.

2. Gently tug on the lead to verify that the terminal is lockedin place.

1

3

4

5

6

2

sm00012

1. Pin housing2. Barrel3. Barrel bottomed in connector4. Plunger backed out of the handle5. Depressed plunger6. Pin terminal

Figure A-2. AMP Pin Terminal Remover (HD-39621-28)

A-2 2008 VRSC Diagnostics: Appendix A Connector Repair


A.2AMP MULTILOCK CONNECTORS

AMP MULTILOCK CONNECTOR REPAIR


AMP MULTILOCK CRIMPERHD-41609

GeneralAMP Multilock connectors are found between wire harnessesand component wiring and may be either floating or anchoredto the frame with attachment clips.

See Figure A-3. Attachment clips (1) on the pin housings arefitted to T-studs on the motorcycle frame. The T-studs identifyOE connector locations. To maintain serviceability, alwaysreturn connectors to OE locations after service.

Obtain the necessary tools to repair the connector and ter-minals.

NOTE

For terminal crimping use the AMP MULTILOCKCRIMPER (Part No. HD-41609).

Separating Pin and Socket Housings1. If necessary, slide connector attachment clip T-stud to the

large end of the opening.

2. See Figure A-3. Depress the release button (2) on thesocket terminal side of the connector and pull the sockethousing (3) out of the pin housing (4).

Mating Pin and Socket Housings1. Hold the housings to match wire color to wire color.

2. Insert the socket housing into the pin housing until it snapsin place.

3. If OE location is a T-stud, fit large opening end of attach-ment clip over T-stud and slide connector to engage T-stud to small end of opening.

23

1

4

sm00002

1. Attachment clip2. Release button3. Socket housing4. Pin housing

Figure A-3. AMP Multilock Connector

Removing Terminals from Housing1. See Figure A-4. Bend back the latch (1) to free one end

of secondary lock (2) then repeat on the opposite end.Hinge the secondary lock outward.

2. Look in the terminal side of the connector (opposite thesecondary lock) and note the cavity next to each terminal.

3. Insert a pick or pin into the terminal cavity until it stops.

NOTEIf socket/pin terminal tool is not available, a push pin/safety pinor a Snap-on pick (Part No. TT600-3) may be used.

4. Press the tang in the housing to release the terminal.

a. Socket: Lift the socket tang (8) up.

b. Pin: Press the pin tang (7) down.

NOTEA "click" is heard if the tang is released.

5. Gently tug on wire to pull wire and terminal from cavity.



5

2

7

1

3

61

24

8

sm00013

1. Latch2. Secondary lock open3. Pin housing4. Socket housing5. Pin terminal6. Socket terminal7. Tang (pin)8. Tang (socket)

Figure A-4. AMP Multilock Connector: Socket and PinHousings

Inserting Terminals into HousingNOTE

See Figure A-5. Cavity numbers are stamped into the sec-ondary locks of both the socket and pin housings. Match thewire color to the cavity number found on the wiring diagram.

1. Hold the terminal so the catch faces the tang in thechamber. Insert the terminal into its numbered cavity untilit snaps in place.

NOTES• Up and down can be determined by the position of the

release button, the button is the top of the connector.

• On the pin side of the connector, tangs are positioned atthe bottom of each cavity, so the slot in the pin terminal(on the side opposite the crimp tails) must face downward.

• On the socket side, tangs are at the top of each cavity, sothe socket terminal slot (on the same side as the crimptails) must face upward.

2. Gently tug on wire end to verify that the terminal is lockedin place.

3. Rotate the hinged secondary lock inward until tabs fullyengage latches on both sides of connector.

– AMP

1 2 3

– AMP

1 2 3 4 5 6

5 6 7 8 9 10

4321

1

2

3

sm00005

1. 3-place housing2. 6-place housing3. 10-place housing

Figure A-5. AMP Multilock Connector: Cavity Numbers onSecondary Locks (Socket Housings Shown)

Preparing Wire Leads for Crimping1. Strip 4.0 mm (5/32 in.) of insulation from the wire lead.



2. See Figure A-4 and Figure A-7. Select the pin/socket ter-minals from the parts catalog and identify the insulationcrimp tails (1) and the wire crimp tails (2) and the groovefor the crimp tool locking bar (3).

3. Identify the wire lead gauge and the corresponding crimpertool and nesting die. Refer to Table A-1.

Table A-1. AMP Multilock Connector: Crimp Tool WireGauge/Nest

NESTWIRE GAUGE

Front20

Middle16

Rear18

5

2

7

1

3

61

24

8

sm00013

1. Latch2. Secondary lock open3. Pin housing4. Socket housing5. Pin terminal6. Socket terminal7. Tang (pin)8. Tang (socket)

Figure A-6. AMP Multilock Connector: Socket and PinHousings



2

3

1sm00001

1. Insulation crimp tail2. Wire crimp tail3. Locking bar groove

Figure A-7. AMP Multilock Connector: Socket Terminal

Crimping Terminals to LeadsNOTE

Crimping with an Amp Multilock tool is a one step operation.One squeeze crimps both the wire core and the insulation tails.

1. See Figure A-8. Squeeze the handles to cycle the AMPMULTILOCK CRIMPER (Part No. HD-41609) to the fullyopen position (1).

2. Raise locking bar by pushing up on bottom flange (2).

NOTESee Figure A-4 and Figure A-7. Hold the terminal with theinsulation crimp tail (1) facing up.The tool will hold the terminalby the locking bar groove (3) and crimp the wire crimp tail (2)around the bare wire of the stripped lead and the insulationcrimp tail around the insulation.

3. See Figure A-8. With the insulation crimp tail facingupward, insert terminal (pin or socket) (3) through thelocking bar, so that the closed side of the terminal restson the nest of the crimp tool.

4. Release locking bar to lock position of contact (4). Whencorrectly positioned, the locking bar fits snugly in the spaceat the front of the core crimp tails.

5. Insert stripped end of lead (5) until ends make contact withlocking bar.

6. Verify that wire is positioned so that wire crimp tailssqueeze bare wire strands, while insulation crimp tails foldover the wire lead insulation.

7. Squeeze handle of crimp tool until tightly closed. Toolautomatically opens when the crimping sequence is com-plete.

8. Raise up locking bar (8) and remove crimped terminal.

4

6

7

3

1

2

5

8

sm00007

1. Open position2. Locking bar flange3. Insert contact4. Release locking bar5. Insert lead6. Squeeze7. Raise locking bar8. Remove crimped terminal

Figure A-8. AMP Multilock Connector:Terminal CrimpingProcedure

Inspecting Crimped TerminalsSee Figure A-9. Inspect the wire core crimp (2) and insulationcrimp (1). Distortion should be minimal.



1

2

sm00008

1. Insulation crimp2. Wire core crimp

Figure A-9. AMP Multilock Connector:Terminal Crimp



A.3DELPHI CONNECTORS

DELPHI CONNECTOR REPAIR

GeneralDelphi connectors are embossed with the brand name, Delphi,on the housing latch.

Separating Pin and Socket HousingsSee Figure A-10. Bend back the external latch(es) slightly andseparate pin and socket halves of connector.

Mating Pin and Socket HousingsPush pin and socket halves of connector together until externallatch(es) engage.

Removing Socket TerminalsNOTE

Although the parts of the different Delphi connectors vary inappearance, the instructions which follow will work for all. Theonly exception is the oil pressure sender connector [139B], theterminals of which are removed like the Packard push-to-seatconnectors. Therefore, see A.10 150 METRI-PACK CON-NECTORS to remove/install terminals in this connector.

1. See Figure A-11. If present, free one side of wire lock (1)from ear on wire end of socket housing, then release theother side. Release wires from channels in wire lock andremove from socket housing.

2. Use a fingernail to pry colored terminal lock (2) loose andthen remove from mating end of socket housing.

3. Using a thin flat blade, like the unsharpened edge of ahobby knife, gently pry tang (3) outward away from ter-minal, and then tug on wire to back terminal out wire endof chamber. Do not pull on wire until tang is released orterminal will be difficult to remove.

Installing Socket TerminalsNOTE

For wire location purposes, alpha or numeric characters arestamped into the wire end of each socket housing.

1. Gently push tang on socket housing inward towardchamber. With the open side of the terminal facing thetang, push terminal into chamber at wire end of sockethousing.

2. Gently tug on wire to verify that terminal is locked and willnot back out of chamber. If necessary, use fingernail topush tang into engagement with terminal.

3. Install colored terminal lock onto mating end of sockethousing.

4. If present, seat wires in separate channels of wire lockand then push channels inside chambers at wire end ofsocket housing. Fully installed, slot on each side of wirelock engages ear on socket housing.

sm00014

Figure A-10. Delphi Connector: Socket Housing Latch



2

3

1

sm00015

1. Remove wire lock2. Remove terminal lock3. Pry tang outward

Figure A-11. Delphi Connector: Removing SocketTerminals



A.4DEUTSCH 1-PLACE ELECTRICAL CONNECTORS

DEUTSCH 1-PLACE CONNECTOR REPAIR

Separating Pin and Socket HousingsDepress external latch and separate the pin and socket hous-ings of the Deutsch one place connector found on voltageregulators.

Mating Pin and Socket HousingsOrient the housings so the latch faces the catch and push thehousings together until it clicks.

Removing Socket TerminalsNOTE

Rough handling or careless storage can result in tool damage.Exercise care to avoid cracking or breaking the thin plasticconstruction.

1. Pull rear wire seal from back of housing and slide downvoltage regulator cable to move out of the way.

2. See Figure A-12. Using terminal pick tool (Deutsch®114008) (1), install tool onto voltage regulator cable sothat the tapered end is in the wire end of the housing (2).

3. Push tool into wire end of housing until it bottoms. Gentlytug on housing to pull from terminal (3).

4. Remove tool from voltage regulator cable.

Installing Socket Terminals1. Insert terminal into wire end of housing until it "clicks" in

place. Verify that terminal will not back out of housing. Aslight tug on the voltage regulator cable will confirm thatit is properly locked in place.

2. Fit rear wire seal into back of housing.

1

2

3

sm00016

1. Deutsch terminal pick tool (114008)2. Tool installed in housing3. Terminal removed from housing

Figure A-12. Deutsch 1-Place Connector: RemoveSocket/Pin Housing



A.5DEUSCH ELECTRICAL CONNECTORS

DEUTSCH CONNECTOR REPAIR


DEUTSCH CONNECTOR SERVICEKIT

HD-41475

FLAT BLADE L-HOOKHD-41475-100

GeneralDeutsch connectors are colored coded for location purposes.Those connectors associated with left side accessories, suchas the front and rear left turn signals, are gray. All other con-nectors, including those associated with right side accessories,are black.

NOTE

A DEUTSCH CONNECTOR SERVICE KIT (Part No. HD-41475) contains a selection of wire seals, internal seals, sealplugs, secondary locking wedges, attachment clips andsocket/pin terminals. Also included is a compartmented storagebox, carrying case and a FLAT BLADE L-HOOK (Part No. HD-41475-100) is used for the removal of all types of lockingwedges.

Separating Pin and Socket HousingsSee Figure A-12. To separate the connector halves, depressthe external latch(es) (1) on the socket housing (2) whilerocking the pin (3) and socket housings.

NOTES

• Generally, the socket housing is found on the accessoryside, while the pin housing is plumbed to the wiring har-ness.

• Two-, three-, four- and six-place Deutsch connectors haveone latch on the connector.

• Eight- and twelve-place connectors have a latch on eachside. Simultaneously press both latches to separate theconnector.

Mating Pin and Socket Housings1. Align the connectors to match the wire lead colors.

a. For One External Latch: Two-, three-, four- and six-place Deutsch connectors have one external latch onthe socket half of the connector. To fit the halves ofthe connector together, the latch on the socket sidemust be aligned with the latch cover on the pin side.

b. For Two External Latches: (8-place and 12-place)Align the tabs on the socket housing with the grooveson the pin housing.

2. Insert socket housing into pin housing until it snaps orclicks into place.

For Two External Latches: (8-place and 12-place) Iflatches do not click (latch), press on one side of the con-nector until that latch engages, then press on the oppositeside to engage the other latch.

3. If necessary, fit the attachment clip to the pin housing.

4. Place large end of slot on attachment clip over T-stud onframe. Push assembly forward to engage small end ofslot.

2

3

1

1

sm00017

1. External latch2. Socket housing3. Pin housing

Figure A-13. Deutsch Connector

Removing Socket Terminals1. See Figure A-14. Insert a small screwdriver between the

socket housing and locking wedge in-line with the groove(in-line with the pin holes if the groove is absent).Turn thescrewdriver 90 degrees to pop the wedge up and removethe secondary locking wedge.

2. See Figure A-17. Use a pick or small screwdriver todepress terminal latches inside socket housing and backout sockets through holes in rear wire seal.

NOTE

If wire leads require new terminals, see the instructions forcrimping terminals.

Installing Socket Terminals1. Match wire lead color to connector cavity.

2. See Figure A-16. Fit rear wire seal (1) into back of sockethousing (2), if removed.

3. Grasp wire lead (3) approximately 25.4 mm (1.0 in.)behind the socket terminal. Gently push socket throughhole in wire seal into its chambers until it "clicks" in place.

4. A tug on the wire will confirm that it is properly locked inplace.

NOTESeal plugs (6) are installed through the wire seals of unusedchambers. If removed, seal plugs must be replaced to seal theconnector.



5. Install internal seal (4) on lip of socket housing, if removed.

6. Insert tapered end of secondary locking wedge (5) intosocket housing and press down until it snaps in place.Thewedge fits into the center groove within the socket housingand holds the terminal latches tightly closed.

NOTES• See Figure A-15.While rectangular wedges do not require

a special orientation, the conical secondary locking wedgeof the 3-place connector must be installed with the arrow(1) pointing toward the external latch.

• If the secondary locking wedge does not slide into theinstalled position easily, verify that all terminals are fullyinstalled in the socket housing. The lock indicates whenterminals are not properly installed by not entering its fullyinstalled position.

sm00009

Figure A-14. Deutsch Connector: Remove SecondaryLocking Wedge

2

1

sm00018

1. Arrow on socket locking wedge2. Arrow on pin locking wedge

Figure A-15. Deutsch Connector: 3-Place Locking Wedges



DEU

TSC

H

6

1

2

3

4

5

sm00010

1. Wire seal2. Socket housing3. Wire lead4. Internal seal5. Secondary locking wedge6. Seal plug

Figure A-16. Deutsch Connector: 2, 3, 4 and 12-PlaceSocket Housings

Removing Pin Terminals1. Use the hooked end of a stiff piece of mechanics wire, a

needle nose pliers or the FLAT BLADE L-HOOK (PartNo. HD-41475-100) to remove the secondary lockingwedge.

2. Gently depress terminal latches inside pin housing andback out pins through holes in wire seal.

NOTES

• If wire leads require new terminals, see the instructionsfor crimping terminals.

• If it should become necessary to replace a pin or sockethousing, please note that the 8-place and 12-place grayand black connectors are not interchangeable. Since loc-ation of the alignment tabs differ between the black and

gray connectors, plugs or receptacles must be replacedby those of the same color.

• When replacing both socket and pin housings, then theblack may be substituted for the gray, and vice versa. Thesocket and pin housings of all other connectors are inter-changeable, that is, the black may be mated with the gray,since the alignment tabs are absent and the orientationof the external latch is the same.

sm00019

Figure A-17. Deutsch Connector: Depress Terminal Latchand Back Out Pin

Installing Pin Terminals1. See Figure A-18. Fit wire seal (1) into back of pin housing

(2).

2. Grasp wire lead approximately 25.4 mm (1.0 in.) behindthe pin terminal (3). Gently push pin through holes in wireseal into its respective numbered chamber until it "clicks"in place.

NOTEA tug on the wire lead will confirm that a pin is locked in place.

3. Insert tapered end of secondary locking wedge (4) intopin housing and press down until it snaps in place.

NOTES

• The wedge fits in the center groove of the pin housing andholds the terminal latches tightly closed.

• See Figure A-15.While rectangular wedges do not requirea special orientation, the conical secondary locking wedgeof the 3-place connector must be installed with the arrow(2) pointing toward the external latch.

• If the secondary locking wedge does not slide into theinstalled position easily, verify that all terminals are fullyinstalled in the pin housing. The lock indicates when ter-minals are not properly installed by not entering its fullyinstalled position.



DEU

TSC

H

1

2

3

4

sm00020

1. Wire seal2. Pin housing3. Pin terminal4. Locking wedge

Figure A-18. Deutsch Connector: 2, 3, 4 and 12-Place PinHousings

Crimping TerminalsIdentify which of the types of Deutsch terminals are used withthe connector and follow the corresponding crimping instruc-tions. Refer to Table A-2.

Table A-2. Deutsch Connector:Terminal Crimping Instructions

CRIMPING INSTRUCTIONSTYPE

A.6 DEUTSCH STANDARD TERMINALSStandard (with crimp tails)

A.8 DEUTSCH SOLID BARREL TERMINALSMini Terminal (solid barrel)

A.7 DEUTSCH MINI-TERMINAL CRIMPSMini Terminal (with crimp tails)



A.6DEUTSCH STANDARD TERMINALS

DEUTSCH STANDARD TERMINAL CRIMPS


DEUTSCH TERMINAL CRIMP TOOLHD-39965-A

Preparing Wire Leads for Crimping1. Use a shop gauge to determine gauge of wire lead.

2. Strip lead removing 4.0 mm (5/32 in.) of insulation.

Crimping Terminal to Lead1. See Figure A-19. Squeeze the handles of the DEUTSCH

TERMINAL CRIMP TOOL (Part No. HD-39965-A) to openthe jaws. Push the locking bar (1) up.

2. Insert (2) terminal (socket/pin) through hole of the lockingbar, so that the rounded side of the contact barrel rests inthe nest (concave split level area) with the crimp tailsfacing upward. To match the wire gauge to the crimp tooldie, refer to Table A-3.

3. Release locking bar to lock terminal in die.

NOTEIf the crimp tails are slightly out of vertical alignment, the crimptool automatically rotates the terminal so that the tails face

straight upward. When positioned, the locking bar fits snuglyin the space between the contact band and the core crimp tails.

4. Insert stripped wire core between crimp tails until endsmake contact with locking bar.Verify that wire is positionedso that short pair of crimp tails squeeze bare wire strands,while long pair folds over the insulation.

5. Squeeze handle of crimp tool until tightly closed. Toolautomatically opens after the terminal is crimped.

6. Raise locking bar up and remove wire lead and terminal.

Inspecting CrimpsInspect the wire core and insulation crimps. Distortion shouldbe minimal.

Table A-3. Deutsch Standard Terminal Crimp:Wire GaugeTo Die

CRIMP TOOL DIEWIRE GAUGE (AWG)

Front20

Middle16-18

2

5

4

6

1

3

sm00021

4.1. Insert stripped leadOpen jaws and raise locking bar2. 5.Insert terminal in locking bar Squeeze crimper

6.3. Raise locking bar and remove terminalRelease locking bar to lock terminal in die

Figure A-19. Crimping a Deutsch Standard Terminal



A.7DEUTSCH MINI-TERMINAL CRIMPS

DEUTSCH MINI TERMINAL CRIMPS



Preparing Wire Leads for CrimpingStrip wire lead removing 4.0 mm (5/32 in.) of insulation.

Crimping a Mini Terminal to Wire Lead1. See Figure A-20. Compress the handles of PACKARD

TERMINAL CRIMPER (Part No. HD-38125-7) until theratchet (2) automatically opens.

NOTEAlways perform core crimp before insulation crimp.

2. Position the core crimp on die E (1) of the crimper. Besure the core crimp tails are facing the forming jaws.

3. Gently apply pressure to handles of tool until crimpers justsecure the core crimp tails.

4. Insert stripped wire core stands between crimp tails. Pos-ition wire so that short pair of crimp tails squeeze barewire strands, while long pair squeeze over the insulation.

5. Squeeze handle of crimper until tightly closed. Tool auto-matically opens when the crimping sequence is complete.

NOTEIf the crimper does not open, it can be opened by squeezingthe ratchet trigger (2).

6. Position the insulation crimp on nest C of the crimper. Besure the insulation crimp tails are facing the forming jaws.

7. Squeeze handle of crimp tool until tightly closed. Toolautomatically opens when the crimping sequence is com-plete.

Inspecting CrimpsInspect the core and insulation crimps. Distortion should beminimal.

2

1

sm00022

1. E die2. Crimper ratchet trigger

Figure A-20. Packard Terminal Crimper (HD-38125-7)



A.8DEUTSCH SOLID BARREL TERMINALS

DEUTSCH SOLID BARREL TERMINALCRIMPS


ELECTRICAL CRIMPER TOOLHD-42879

Preparing Wire Leads For CrimpingFor size 20, 16 and 12 contacts, wire ranges 26-12 AWG.

Strip wire lead removing 6.4 mm (1/4 in.) of insulation.

Adjusting Crimper Tool1. See Figure A-21. Squeeze the ELECTRICAL CRIMPER

TOOL (Part No. HD-42879) handles to cycle the crimptool to open.

2. Remove locking pin (1) from selector knob (2).

3. Raise selector knob and rotate until selected wire sizestamped on wheel is aligned with "SEL. NO." arrow (3).

4. Loosen knurled locknut (4) and turn adjusting screw (5)clockwise (in) until it stops.

Crimping a Barrel Contact To Wire Lead1. See Figure A-22. Turn tool over and drop contact barrel

(1) into indentor cover (2) hole with the wire end out.

2. Turn adjusting screw counterclockwise (out) until contactis flush with bottom of depression in indentor cover.Tighten knurled locknut.

3. Slowly squeeze handles of crimp tool until contact iscentered between the four indentor points (3).

4. Insert bare wire core strands of stripped wire lead (4) intocontact barrel. Squeeze handle of crimp tool until tightlyclosed. Tool automatically opens when the crimpingsequence is complete.

5. Remove wire lead with crimped contact from indentor.

NOTETool must be readjusted when changing contact size/type.

6. Install pin to lock selector knob.

Inspecting CrimpsInspect the crimp. All core wire strands are to be crimped inthe barrel.

This

HA

ND

toolm

ustnot

be

used

inany

pow

ere

d

"PR

ES

S''

as

defin

ed

by

OS

HA

CFR

1910.2

11

(46)

2

4

5

1

3

sm00023

1. Locking pin2. Selector knob3. SEL. NO. arrow4. Knurled locknut5. Adjusting screw

Figure A-21. Electrical Crimper Tool (HD-42879)



HDT - 48 - 00JDG360-1

HEMET RYAN AIRPORT, P.O. BOX 878

HEMET, CA. 92343-0161 (714) 929-1200

INDUSTRIAL PRODUCTS DIVISION

HDT - 48 - 00JDG360-1

HEMET RYAN AIRPORT, P.O. BOX 878

HEMET, CA. 92343-0161 (714) 929-1200

INDUSTRIAL PRODUCTS DIVISION

2

1

3

4

3

sm00024

1. Contact barrel2. Indentor cover3. Indentor point4. Stripped wire lead

Figure A-22. Deutsch Solid Barrel



A.9RELAY AND FUSE BLOCKS

FUSE BLOCK REPAIR

Removing Socket Terminals1. See Figure A-23. To remove secondary locks, insert end

of small flat blade screwdriver (1) under lip of lockingwedge (2) and gently pry up secondary lock.

NOTEFor best results, start with locking wedge on outboard side ofsecondary lock.

2. Looking into chamber at top of fuse block, note the tangnext to each socket terminal.

3. Using a thin flat blade, like that on a hobby knife, gentlypush tang away from terminal, and then tug on wire toback terminal out.

Installing Socket Terminals1. Match the wire lead color to the fuse block terminal cavity.

NOTES• Refer to the main harness wiring diagram for wire lead

color codes.

• See Figure A-24. The main fuse block terminal cavity isidentified as alpha (1) and numeric (2) coordinates. Referto the main harness wiring diagram for fuse block terminalcavity coordinates.

2. With the open side of the socket terminal facing the tang,push lead into chamber at the wire end of the fuse block.A click is heard when the terminal is properly engaged.

3. Gently tug on the wire to verify that the terminal is lockedin place and will not back out of the chamber.

4. Install the secondary locks. With the locking wedgespositioned above the tangs in each chamber, slide flatside of secondary lock into slot (between rows), and pushdown until it bottoms.

Crimping TerminalsTerminals are crimped twice; once over the wire core and asecond time over the insulation/seal.

A correctly crimped terminal may require different crimpingdies found on separate crimpers.

NOTE

The wiring diagram indicates when one socket terminal is becrimped to two wire leads.

1

2

sm00025

1. Pry up secondary lock2. Lip of locking wedge

Figure A-23. Fuse Block: Remove Secondary Locks

3

A C

D

E

F

G

H

J1

2

4B

1

2

sm00026

1. Alpha2. Numeric

Figure A-24. Fuse Block: Coordinates (typical)



A.10150 METRI-PACK CONNECTORS

150 METRI-PACK CONNECTOR REPAIR

GeneralMetri-Pack connectors are embossed with the initials (P.E.D.).

There are two types of connectors in this series:

• Pull-to-Seat

• Push-to-Seat

Separating Pin and Socket HousingsBend back the external latch slightly and separate the pin andsocket halves of the connector.

Mating Pin and Socket HousingsAlign the wire colors and push the pin and socket halves of theconnector together.

Removing Socket Terminal1. See Figure A-25 for pull-to-seat connector or Figure A-26

for push to seat connector. Remove wire lock (1) from wireend of socket housing on push-to-seat type connectors.

NOTEFor best results, free one side of wire lock first and then releasethe other side.

2. Find the locking tang in the mating end of the connector.

NOTEThe tangs are always positioned in the middle of the chamberand are on the same side as the external latch.

3. Gently insert a safety pin into the chamber about 3.2mm (1/8 in.).

a. For pull-to-seat: Stay between the terminal and thechamber wall and pivot the end of the pin toward theterminal body.

b. For push-to-seat: There is a small opening for thepin.

4. When a click is heard, remove the pin and repeat theprocedure.

NOTEThe click is the sound of the tang returning to the locked posi-tion as it slips from the point of the pin.

5. Pick at the tang until the clicking stops and the pin seemsto slide in deeper than it had previously. This is an indica-tion that the tang has been depressed.

NOTEOn those terminals that have been extracted on multipleoccasions, the click may not be heard, but pivot the pin as ifthe click was heard at least 3 times.

6. Remove the pin.

a. For pull-to-seat: Push on the lead to extract the ter-minal from the mating end of the connector.

b. For push-to-seat: Pull on the lead to draw the ter-minal out the wire end.

Inserting Socket TerminalNOTE

For wire location purposes, alpha characters are stamped intothe socket housings.

1. See Figure A-25 for pull-to-seat connector or Figure A-26for push to seat connector. Using a thin flat blade, like thaton a hobby knife, carefully bend the tang outward awayfrom the terminal body.

2. Gently pull or push on the lead to install the terminal backinto the chamber. A click is heard when the terminal isproperly seated.

3. Gently pull or push on the lead to verify that the terminalis locked in place.

For push-to-seat: See Figure A-26. Seat wires in separatechannels of wire lock and then push channels insidechambers at wire end of socket housing. Fully installed,slot on each side of wire lock engages ear on sockethousing.



4

2

3

1

sm00027

1. Locate tang in chamber2. Pivot pin to depress tang3. Push to remove4. Raise tang to install

Figure A-25. 150 Metri-Pack Connector: Pull-to-Seat

3

4

2

1

sm00028

1. Remove wire lock2. Pivot pin to depress tang3. Pull to remove4. Raise tang to install

Figure A-26. 150 Metri-Pack Connector: Push-to-Seat





GeneralSee Figure A-27. Called Packard connectors, Metri-Pack seriesconnectors are embossed with the initials (P.E.D.)

Separating Pin and Socket HousingsDepress the wireform and use a rocking motion to detach thesocket connector half.

Mating Pin and Socket HousingsAlign the groove in the socket housing with the tab in the pinhousing. Push the pin and socket halves of the connectortogether until the latch clicks.

Removing Socket Terminals1. See Figure A-28. Pry rubber seal from wire end of con-

nector and move seal down wires (1) toward conduit. Holdthe connector so that the wireform is facing down.

2. Looking into the wire end of the connector, insert the pointof a safety pin (2) between the top of the terminal and theinside chamber wall.

3. Push safety pin completely into chamber while watchingterminal on mating end of connector. When terminal isobserved moving forward slightly, tang is depressed.Remove safety pin.

NOTERepeat as necessary until the terminal can be pushed out ofthe connector.

4. Push on wire end of the lead to extract the terminal fromthe mating end of the connector.

5. If necessary, crimp new terminals on wires. SeeA.15 METRI-PACK TERMINALS, Metri-Pack TerminalCrimps.

Installing Socket TerminalsNOTE

Terminal cavities are lettered on the socket housing. To matchthe wire lead colors to the terminal cavity, refer to the wiringdiagram.

1. See Figure A-28. Using a thin flat blade, like an X-Actoknife (4), carefully bend the tang outward away from theterminal body.

2. Gently pull on the wire lead (5) to draw the terminal backinto the chamber. The tang faces opposite the wireformas it enters the chamber.

NOTEA "click" is heard when the terminal is properly seated.

3. Push on lead to verify that terminal is locked in place.

4. Fit rubber wire seal back into wire end of connector.

Crimping TerminalsIf necessary, crimp new terminals on the wire leads. Refer toA.15 METRI-PACK TERMINALS, Metri-Pack Terminal Crimps.

sm00029

Figure A-27. 280 Metri-Pack Connector (P.E.D.)



3

5

2

4

1

sm00030

1. Pry rubber seal from connector2. Insert safety pin to depress tang3. Push on lead to remove terminal4. Raise tang with X-Acto knife5. Pull on lead to draw terminal into chamber

Figure A-28. 280 Metri-Pack Connector: Remove/InstallSocket Terminal





GeneralA 480 Metri-Pack (P.E.D.) connector is frequently used for theB+ (battery voltage) connector to power P&A accessories.

Referred to as Packard connectors, Metri-Pack connectors areembossed with the initials P.E.D.

Separating Pin and Socket HousingsNOTE

Cut any cable strap anchoring the wire conduits of the pin(accessory connector housing) and the socket (B+) housing.

See Figure A-29. Using small flat blade screwdriver, depressbutton (1) on pin housing (red wire) side of the connector andpull apart the pin and socket housings.

Mating Pin and Socket HousingsOrient the latch on the socket housing to the button catch onthe pin housing and press the housings together.

Removing Socket Terminals1. See Figure A-29. Bend back the latch (2) slightly and free

one side of secondary lock, then repeat to release theopposite side. Rotate the secondary lock outward on hingeto access terminal in chamber of connector housing.

2. On the mating end of the connector, note the tang in thesquare shaped opening centered next to the terminal.Gently insert the point of a stick pin or large safety pin intothe opening (3) between the tang and the chamber walluntil it stops.

3. Pivot the end of the pin toward the terminal body todepress the tang.

4. Remove the pin and then pull terminal out of the wire endof connector housing.

5. If necessary, crimp new terminals on wires. SeeA.15 METRI-PACK TERMINALS.

Installing Socket Terminals1. Carefully bend the tang outward away from the terminal

body.

2. With the tang on the same side as the square shapedopening in the mating end of the connector housing, feedterminal into wire end of connector housing until it "clicks"in place.

3. Verify that terminal will not back out of the chamber. Aslight tug on the cable will confirm that it is locked.

4. Rotate the hinged secondary lock inward until latches fullyengage tabs on both sides of connector housing.

NOTE

If removed, install new anchored cable strap in O.E. location.Tighten cable strap to capture conduit of both accessory con-nector and B+ connector approximately 25.4 mm (1.0 in.) fromhousings.

1

2

3

sm00031

1. Button on pin housing2. Secondary lock latch3. Opening between tang and chamber wall

Figure A-29. 480 Metri-Pack Connector: Remove SocketTerminal






SNAP-ON PICKTT600-3

GeneralReferred to as Packard connectors, Metri-Pack 630 seriesconnectors are embossed with the initials P.E.D.

Separating Pin and Socket HousingsNOTE

If necessary, remove connector from barbed anchor or otherretaining device.

Bend back the external latch slightly and separate pin andsocket halves of the connector.

Mating Pin and Socket HousingsOrient the latch to the catch and push the pin and socket halvesof the connector together until the latch "clicks".

NOTE

If removed, install connector on barbed anchor or other OEretaining device.

Removing Socket Terminal1. Bend back the latch slightly and free one side of the sec-

ondary lock. Repeat the step to unlatch the other side.

2. Rotate the secondary lock outward on hinge to view theterminals in the chambers of the connector housing. Thelocking tang is on the side opposite the crimp tails and

engages a rib in the chamber wall to lock the terminal inplace.

3. Moving to the mating end of the connector, take note ofthe small opening on the chamber wall side of each ter-minal.

4. Insert SNAP-ON PICK (Part No. TT600-3) into openinguntil it stops. Pivot the end of the pick toward the terminalto depress the locking tang.

5. Remove the pick and gently tug on the wire to pull theterminal from the wire end of the connector. Repeat stepsif the terminal is still locked in place.

6. If necessary, crimp new terminals on wires. Refer toA.15 METRI-PACK TERMINALS.

Installing Socket TerminalNOTE

Refer to the wiring diagrams to match wire lead colors to alphacharacters molded into the secondary locks of each connectorhousing.

1. Using a thin flat blade, like that of a hobby knife, carefullybend the tang outward away from the terminal body.

2. With the tang facing the chamber wall, push the lead intothe chamber at the wire end of the connector. A click isheard when the terminal is properly seated.

3. Gently tug on the wire end to verify that the terminal islocked in place and will not back out of the chamber.

4. Rotate the hinged secondary lock inward until tabs fullyengage latches on both sides of connector.




DELPHI MAXI-FUSE HOUSING REPAIR

GeneralA Delphi Maxi-fuse connector completes the circuit throughthe main fuse (Maxi-fuse).

Removing Maxi-Fuse1. See Figure A-30. Depress latches on Maxi-fuse cover (1)

and then slide cover off of connector (2).

2. Holding the connector (fuse holder), pull the Maxi-fuse outof the connector.

Installing Maxi-Fuse1. Insert the blade terminals of the Maxi-fuse into the sockets

of the connector and press the Maxi-fuse into the con-nector.

2. Slide the cover over the fuse until the cover clicks intoplace.

NOTE

If removed from an OE attachment such as a grooved fuseblock cover, engage cover and slide into place.

Removing Socket Terminals1. See Figure A-31. Gently pull socket housing to disengage

slots (1) on secondary lock (2) from tabs (3) on sockethousing. Free secondary lock from cables and set aside.

2. Take note of the opening on one side of the socket ter-minal. Gently insert flat blade of pick (Snap-On TT600-5)or small screwdriver into opening (4) until it stops. Pivotthe pick toward the terminal body and hold in position.

3. Tug on cable to pull socket from wire end of sockethousing. A firm tug is necessary to overcome the resist-ance of the rubber seal.

4. Repeat to remove remaining socket terminal.

Installing Socket Terminals1. See Figure A-32. Carefully bend tang outward away from

the terminal body.

2. Feed socket into wire end of socket housing until it clicksin place. Verify that socket will not back out of chamber.A slight tug on the cable will confirm that it is locked.

3. Push rubber seal into wire end of socket housing.

4. Repeat to install remaining socket terminal.

5. Install secondary lock onto cables and then push onto wireend of socket housing until slots engage tabs on sides ofsocket housing.

1

2

sm00032

1. Maxi-fuse cover2. Delphi Maxi-fuse housing

Figure A-30. Delphi Connector Housing: Maxi-Fuse

3

4

12

sm00033

1. Secondary lock slot2. Secondary lock3. Tab4. Insert flat blade into opening

Figure A-31. Delphi Maxi-Fuse Housing: Remove SocketTerminals



sm00034

Figure A-32. Delphi Maxi-Fuse Housing: Bend Tang



A.15METRI-PACK TERMINALS

METRI-PACK TERMINAL CRIMPS


PACKARD TERMINAL CRIMP TOOLHD-38125-6


PACKARD CRIMPING TOOLHD-38125-8

Matching Terminal To CrimperMetri-Pack connectors embossed with the initials P.E.D. requirePackard crimp tools to crimp terminals to wire leads.

Terminals are crimped twice to a wire lead, once over the wirecore and a second time over the insulation/seal.

See Figure A-33. A completed crimp may require two differentcrimping dies found on PACKARD TERMINAL CRIMPTOOL (Part No. HD-38125-6) and/or PACKARD TERMINALCRIMPER (Part No. HD-38125-7).The terminal (pin or socket)and the wire lead gauge will determine the core crimp die andthe insulator/seal die.

NOTE

The PACKARD CRIMPING TOOL (Part No. HD-38125-8) willalso crimp sealed splice connectors in wire gauge sizes 18-20,14-16 and 10-12.

Preparing Wire LeadUse a wire striper to strip off the insulation and expose 4.0mm (5/32 in.) of wire core.

Crimping Wire CoreNOTE

Metri-Pack terminal crimps require two steps. Always performCrimping Wire Core before Crimping Insulation/Seal.

1. Squeeze and release handles until ratchet automaticallyopens.

2. Identify the corresponding sized nest for the core crimp.

3. Position the core crimp in the die. Be Sure the core crimptails are facing the forming jaws.

4. Gently squeeze the handles until crimpers just secure thecore crimp tails.

5. Insert stripped wire between crimp tails. Verify that wireis positioned so that short pair of crimp tails squeeze corewire strands, while long pair is positioned over the insula-tion or seal material.

6. Squeeze handles tightly closed. Release grip and the toolwill automatically open.

1

2

3

sm00035

1. HD-38125-6 sealed terminals2. HD-38125-7 non-sealed terminals3. HD-38125-8 non-sealed terminals

Figure A-33. Metri-Pack Terminal Crimp Tools

Crimping Insulation/SealNOTE

Always perform Crimping Wire Core before Crimping Insu-lation/Seal.

1. See Figure A-34. Identify the correct die for the insula-tion/seal crimp (2).



2. Position the insulation/seal crimp in the nest. Be sure theinsulation/seal crimp tails are facing the forming jaws.

3. Squeeze handle of crimp tool until tightly closed. Toolautomatically opens when the crimp is complete.

Inspecting Crimps1. See Figure A-34. Inspect the wire core crimp (1).The tails

should be folded in on the wire core without any distortionor excess wire strands.

2. Inspect the insulation (2) or seal (3) crimp.The tails of theterminal should be wrapped around the insulation withoutdistortion.

3

2 1

sm00036

1. Wire core crimp2. Insulation crimp3. Seal crimp

Figure A-34. Metri-Pack Connector: Inspect Core andInsulation/Seal Crimps



A.16MOLEX CONNECTORS

MOLEX CONNECTOR REPAIR


MOLEX ELECTRICAL CONNECTORTERMINAL REMOVER

HD-48114

Separating Pin and Socket HousingsSee Figure A-35. Depress the latch while pulling the pin andsocket housings apart.

Mating Pin and Socket Housings1. Orient the latch on the pin housing to the latch pocket on

the socket housing so the rails on the outside of the pinhousings lines up with the tunnels on the socket housing.

2. Press the housings together until the latch clicks.

Removing Terminals1. Pull the secondary lock up, approximately 4.8 mm (3/16

in.), until it stops.

a. Socket Housing: See Figure A-36. Use a smallscrewdriver in the pry slot. The slot next to theexternal latch provides a pivot point.

b. Pin Housing: See Figure A-37. Use needle nosepliers to engage the D-holes in the center of the sec-ondary lock.

NOTEDo not remove the secondary lock from the connector housing.

2. See Figure A-38. Insert MOLEX ELECTRICAL CON-NECTOR TERMINAL REMOVER (Part No. HD-48114)into the pin hole next to the terminal until the tool bottoms.

a. Socket Housing: The pin holes are inside the ter-minal openings.

b. Pin Housing: The pin holes are outside the pins.

3. Pressing the terminal remover to the bottom of the pinhole, gently pull on the wire to remove wire terminal fromits cavity.

Installing Terminals1. See Figure A-39. From the wiring diagram, match the wire

color to its numbered terminal cavity.

NOTECavity numbers (1) are stamped on the housing at the endsof the cavity rows. The cavity number can be determined bycounting the cavities up or down along the row from eachstamped number.

2. Orient the terminal so that the tang (2) opposite the opencrimp engages the slot (3) in the cavity.

3. Push the terminal into the cavity.

4. Gently tug on wire to verify that the terminal is capturedby the secondary lock.

5. With all terminals installed, push the secondary lock intothe socket housing to lock the wire terminals into thehousing.

sm00040

Figure A-35. Molex Connector: Latch

sm00041

Figure A-36. Molex Connector: Secondary Lock Pry Slot(Socket Housing)



sm00042

Figure A-37. Molex Connector: Secondary Lock D-Holes(Pin Housing)

sm00043

Figure A-38. Molex Connector:Terminal Remover(HD-48114)

13

2

sm00044

1. Cavity number2. Tang3. Cavity slot

Figure A-39. Molex Connector: Pin Cavities and WireTerminal



A.17PACKARD ECM CONNECTOR

PACKARD 100W CONNECTOR REPAIR

GeneralA Packard 100W connector connects the the electronic controlmodule (ECM) to the main harness.

NOTE

For vehicles with 73-pin connectors, see A.18 PACKARDMICRO-64 CONNECTORS and A.15 METRI-PACK TER-MINALS.

Separating Socket Housing From ECMSee Figure A-40. While pressing the connector into the ECM,press the thumb lever (1) against the connector until the latch(2) pops out of the catch (3) on the ECM.

Mating Socket Housing To ECMPush the connector into the ECM until the latch is captured bythe catch on the ECM.

Removing Socket Terminal1. See Figure A-41. Gently depress latch (1) on each side

of the clear plastic secondary lock (2) and remove. Forbest results, release one side at a time.

2. Carefully cut cable strap (3) to free strain relief collar (4)from conduit (5).

3. See Figure A-42. Using a thin blade, gently pry at seamat back of socket housing to release three plastic pins (1)from slots in housing. Separate and spread halves ofsocket housing.

4. Push on wire lead to free terminal from chamber.

Installing Socket Terminal1. From inside socket housing, gently pull on wire to draw

terminal into chamber.

2. Exercising caution to avoid pinching wires, press halvesof socket housing together until three plastic pins fullyengage slots in housing.

3. Install new cable strap in groove of strain relief collarcapturing cable conduit.

4. With the two ribs on the secondary lock on the same sideas the external latch, install over terminals until latcheslock in place.

Crimping TerminalsIf necessary, crimp new terminals on wire leads. SeeA.15 METRI-PACK TERMINALS.

2

3

1

sm00037

1. Thumb lever2. Latch3. Catch (ECM)

Figure A-40. Packard 100W to ECM (Typical)



1

3

5 1

4

2

sm00038

1. Latch2. Secondary lock3. Cable strap4. Strain relief collar5. Conduit

Figure A-41. Packard 100W Connector 2

1

1

1

sm00039

1. Pins2. Socket terminal

Figure A-42. Packard 100W Connector: Separate Halvesof Socket Housing



A.18PACKARD MICRO-64 CONNECTORS

PACKARD MICRO-64 CONNECTOR REPAIR


PACKARD MICRO-64 TERMINALREMOVER

HD-45928

PACKARD MICRO-64 TERMINALCRIMPER

HD-45929

GeneralPackard Micro-64 connectors are frequently found onspeedometers, tachometers and the ECM of Touring Models.For pin 73 of these ECMs, see A.10 150 METRI-PACK CON-NECTORS.

Separating Pin and Socket HousingsBend back the external latches slightly and separate the pinand socket housings.

Mating Pin and Socket HousingsOrient the wire lead colors and push the pin and socket hous-ings of the connector together until the latches click.

Removing Terminal1. See Figure A-45. Locate the head of the secondary lock

(1) on one side of the connector housing.

2. Insert the blade of a small screwdriver between the centerear of the lock and the connector housing and gently pryout lock.When partially removed, pull lock from connectorhousing.

3. Locate pin hole (2) between terminals on mating end ofconnector.

4. See Figure A-46. Obtain the PACKARD MICRO-64 TER-MINAL REMOVER (Part No. HD-45928).

5. See Figure A-44. Push the adjacent terminals all the wayinto the connector housing and then insert tool into holeuntil it bottoms.

6. Leaving the tool installed, gently tug on wires to pull eitherone or both terminals from wire end of connector. Removetool.

sm00046

Figure A-43. Packard Micro 64 Terminal Remover(HD-45928)

sm00048

Figure A-44. Packard Micro 64 Connector: Insert Tool andRemove Terminal

Installing Terminal1. Insert terminal into its respective numbered chamber on

wire end of connector. No special orientation of the ter-minal is necessary.

NOTESee Figure A-45. For wire location purposes, the corners ofthe socket housing are stamped (3) with the numbers 1, 6, 7and 12, representing terminals 1-6 on one side, and 7-12 onthe other.

2. Bottom the terminal in the chamber and then gently tugon the wire to verify that it is locked in place.

NOTEOnce the terminal is removed it may not lock in place whenfirst reinstalled. Until the lock engages, move the terminal backand forth slightly while wiggling the lead.

3. Since the terminal remover tool releases two terminalssimultaneously, repeat step 2 on the adjacent terminaleven if it was not pulled from the connector housing.



4. With the center ear on the head of the secondary lockpinfacing the mating end of the connector, push secondarylock in until head is flush with the connector housing.

Preparing Wire Leads for CrimpingStrip lead removing 3.0 mm (1/8 in.) of insulation.

Crimping Terminals1. Inspect new socket terminal for bent or deformed contact

and crimp tails. Replace as necessary.

2. See Figure A-47. Squeeze the handles of the PACKARDMICRO-64 TERMINAL CRIMPER (Part No. HD-45929)to cycle the tool to the fully open position (1).

3. Raise locking bar and barrel holder by pushing up onbottom tab with index finger (2).

4. With the crimp tails facing upward, insert terminal throughlocking bar into front hole in barrel holder (20-22 gaugewire) (3).

5. Release locking bar to lock position of contact. Whencorrectly positioned, the locking bar fits snugly in the spaceat the front of the core crimp tails and the closed side ofthe terminal rests on the outer nest of the crimp tool.

6. Insert wires between crimp tails until ends make contactwith locking bar. Verify that wire is positioned so that widepair of crimp tails squeeze bare wire strands, while thenarrow pair folds over the insulation material.

7. Squeeze handle of crimp tool until tightly closed (4). Toolautomatically opens when the crimping sequence is com-plete.

8. Raise locking bar and barrel holder to remove contact.

Inspecting CrimpsInspect the quality of the core and insulation crimps. Distortionshould be minimal.

1 2 3 4 5 6

7 8 9 10 11 12

1 6

7 12

1

23

sm00047

1. Secondary lock2. Pin hole3. Stamped number

Figure A-45. Packard Micro 64 Connector: Housing

sm00045

Figure A-46. Packard Micro 64 Terminal Crimper (HD-45929)



3

1

2

4

sm00049

1. Open position2. Raising locking bar3. Insert terminal4. Crimp terminal

Figure A-47. Packard Micro 64 Connector:Terminal inCrimper



A.19SEALED SPLICE CONNECTORS

SEALED SPLICE CONNECTOR REPAIR


ROBINAIR HEAT GUNHD-25070


ULTRA-TORCH UT-100HD-39969

HEAT SHIELD ATTACHMENTHD-41183

GeneralSplice connectors and several OE ring terminal connectorsuse heat shrink covering to seal the connection.

Preparing Wire LeadsNOTE

If adjacent wires are to be spliced, stagger the splices so thatthe sealed splice connectors will not touch each other but arelocated at different positions along the length of the wires.

1. Using a shop gauge, identify the gauge of the wire.

2. Match the wire gauge to a sealed splice connector by colorand part number. Refer to Table A-4.

3. Using a wire stripper, cut and strip a length of insulationoff the wire ends. Refer to Table A-4 for the strip length.

Table A-4. Sealed Splice Connectors

STRIPLENGTH

CONNECTORPART NO.

CONNECTORCOLOR

WIRE GAUGE

9.5 mm (3/8in.)

70585-93Red18-20(0.5-0.8 mm)

9.5 mm (3/8in.)

70586-93Blue14-16(1.0-2.0 mm)

9.5 mm (3/8in.)

70587-93Yellow10-12(3.0-5.0 mm)

NOTE

If any copper wire strands are cut off of the wire core, trim theend and strip the wire again in a larger gauge stripper.

Splicing Wire LeadsNOTE

See Figure A-49. The connector is crimped twice - one sideand then the other.

1. See Figure A-48. Open the PACKARD CRIMPINGTOOL (Part No. HD-38125-8) ratchet by squeezing thehandles closed.

2. Match the connector color to the wire gauge crimp die inthe jaws and insert one end of the sealed connector.

3. Gently squeeze the handles until the connector is held inthe jaws.

4. See Figure A-49. Feed the stripped end of a wire into theconnector until the wire stops inside the metal insert (1).

5. Squeeze the handles tightly closed to crimp the lead inthe insert (2). The tool automatically opens when thecrimping is complete.

6. Slide the connector to the other half of the metal insert.Insert the stripped wire lead (1) until it stops, and crimpthe lead in the insert (2).

Be sure to follow manufacturer's instructions when usingthe UltraTorch UT-100 or any other radiant heating device.Failure to follow manufacturer's instructions can cause afire, which could result in death or serious injury. (00335a)

• Avoid directing heat toward any fuel system component.Extreme heat can cause fuel ignition/explosion resultingin death or serious injury.

• Avoid directing heat toward any electrical system com-ponent other than the connectors on which heat shrinkwork is being performed.

• Always keep hands away from tool tip area and heat shrinkattachment.

7. Use an ULTRA-TORCH UT-100 (Part No. HD-39969), ora ROBINAIR HEAT GUN (Part No. HD-25070) with aHEAT SHIELD ATTACHMENT (Part No. HD-41183), toheat the connector from the center of the crimp (3) out toeach end.

NOTE

It is acceptable for the splice to rest against the heat shrinktool attachment.

Inspecting SealsSee Figure A-49. Allow the splice to cool and inspect the seal.The insulation should appear smooth and cylindrical. Meltedsealant will have extruded out the ends (4) of the insulation.



1

2

3

sm00050

1. Red connector die2. Blue connector die3. Yellow connector die

Figure A-48. Packard Crimping Tool (HD-38125-8)

1

1

4

2

2

4

3

sm00051

1. Wire lead in metal insert2. Crimp metal insert3. Center of crimp4. Melted sealant

Figure A-49. Sealed Splice Connector



SUBJECT............................................................................................................................PAGE NO.B.1 CONNECTORS........................................................................................................................B-1B.2 WIRING DIAGRAMS.................................................................................................................B-3

AP

PE

ND

IX B

WIR

ING


NOTES


B.1CONNECTORS

CONNECTOR LOCATIONS

Function/LocationRefer to Table B-1. On the motorcycle, a connector can beidentified by its function and location.

Place and ColorThe place (number of wire cavities of a connector housing)and color of the connector can also aid identification.

Connector NumberOn wiring diagrams and in service/repair instructions, con-nectors are identified by a number in brackets.

Repair InstructionsThe repair instructions in this Service Manual are by connectortype. Refer to Table B-1.

Table B-1. VRSC Connector Locations



Below seat3-place MolexFuel level sensor[13]


Under left side cover8-place MolexLeft hand controls and horn[24]

Under left side cover2-place Mini-DeutschPosition lamp (HDI)[29]


Under left side cover6-place MultilockFront turn signals[31]


Back of headlamp4-place MultilockHeadlamp[38]


Back of voltage regulator3-place PackardVoltage regulator to stator[47]


Under right side coverSpade terminalsFuse block (start relay, fan relay)[62]

Rear of transmission case3-place DelphiVehicle Speed Sensor (VSS)[65]



Under left side cover2-place Mini-DeutschCrankshaft Position (CKP) sensor[79]

Front intake passage3-place PackardManifold Air Pressure (MAP) sensor[80]

On top of front cam cover3-place PackardFront plug-top ignition coil[83F]

On top of rear cam cover3-place PackardRear plug-top ignition coil[83R]



Top of fuel tank4-place PackardFuel pump[86]

Below air cleaner assembly4-place DelphiIdle Air Control (IAC)[87]

Front of throttle body3-place DelphiThrottle Position (TP) sensor[88]

Under airbox2-place DelphiIntake Air Temperature (IAT) sensor[89]

Water pump housing2-place DelphiEngine Coolant Temperature (ECT) sensor[90]



Under rear fender6-place MultilockRear turn signal lamp[94]

Below seat2-place PackardPurge solenoid[95]

Under left side cover2-place MultilockCooling fan (top)[97T]

Under left side cover2-place MultilockCooling fan (bottom)[97B]

Back of tachometer12-place PackardTachometer[108]

2008 VRSC Diagnostics: Appendix B Wiring B-1


Table B-1. VRSC Connector Locations


On oil pressure switch, front of rightcrankcase

Post terminalOil pressure switch[120]

Behind transmission (without ABS)Spade terminalsRear stop lamp switch[121]Right side of ABS module (with ABS)

Between cylinders, left sideSpade terminalsHorn[122]

Under left side cover2-place AmpStarter solenoid[128]

Bottom rear of crankcasePost terminalsNeutral switch[131]

Under left side cover3-place MolexJiffy Stand Sensor (HDI)[133]

Along left side of frame, behind rear cyl-inder

2-place DelphiRear oxygen sensor[137]

Under left side cover2-place DelphiFront oxygen sensor[138]

Under passenger seat3-place DelphiSecurity siren (optional)[142]

Along frame8-placeEngine sensor harness connector[145]


Behind radiator cover2-place DelphiFront wheel speed sensor[167]

Along right side of frame, behind transmis-sion

2-place DelphiRear wheel speed sensor[168]

Under right side cover4-place DeutschABS diode pack[201]

Under passenger seat4-place DeutschHands-Free Security Module (HFSM)antenna harness

[208]

Under passenger seat2-place MolexHands-Free Security Module (HFSM)antenna

[209]

Front and rear cam coversRing terminalsHarness ground (3)[GND 1][GND 2][GND 3]

B-2 2008 VRSC Diagnostics: Appendix B Wiring


B.2WIRING DIAGRAMS

WIRING DIAGRAM INFORMATION

Wire Color CodesWire traces on wiring diagrams are labeled with alpha codes.Refer to Table B-2.

For Solid Color Wires: See Figure B-1. The alpha codeidentifies wire color (3).

For Striped Wires: The code is written with a slash (/) betweenthe solid color code and the stripe code (4). For example, atrace labeled GN / Y is a green wire with a yellow stripe.

Wiring Diagram SymbolsSee Figure B-1. On wiring diagrams and in service/repairinstructions, connectors are identified by a number in brackets(1). The letter (2) inside the brackets identifies whether thehousing is a socket or pin housing.

A=Pin: The letter A after a connector number and the pinsymbol (6) identifies a pin housing.

B=Socket: The letter B after a connector number and thesocket symbol (5) identifies a socket housing.

Other symbols found on the wiring diagrams include the symbolfor a diode (7), a symbol for a wire-to-wire connection (8), asymbol that verifies that no connection (9) between two wiretraces exists and a symbol identifying two wires that are twistedtogether (10).

910

1 2

1 2

8

7

6

5

3 4

TN

TN

WW

GN

/YG

N/Y

1 2 4

1 2 4

[21A]

[21B]

ed01269

1. Connector number2. Terminal code (A=pin, B=socket)3. Solid wire color4. Striped wire color5. Socket symbol6. Pin symbol7. Diode8. Connection9. No connection10. Twisted pair

Figure B-1. Connector/Wiring Diagram Symbols (typical)

Table B-2. Wire Color Codes

WIRE COLORALPHA CODE

BlueBE

BlackBK

BrownBN

GreenGN

GreyGY

Light GreenLGN

OrangeO

PinkPK

RedR

TanTN

VioletV

WhiteW

YellowY

2008 VRSC Diagnostics: Appendix B Wiring B-3


2008 VRSC WIRING DIAGRAMS Refer to the table below for wiring diagram information.

Wiring Diagram ListLOCATIONDIAGRAM

Figure B-22008 ALL VRSC DOM. and INT. MODELS WITH ABS, MAIN HARNESS 1 of 2

Figure B-32008 ALL VRSC DOM. and INT. MODELS WITH ABS, MAIN HARNESS and CHARGING CIRCUIT 2 of 2

Figure B-42008 ALL VRSC DOM. and INT. MODELS WITHOUT ABS, MAIN HARNESS 1 of 2

Figure B-52008 ALL VRSC DOM. and INT. MODELS WITHOUT ABS, MAIN HARNESS and CHARGING CIRCUIT 2of 2

Figure B-62008 ALL VRSC DOM. and INT. MODELS, IGNITION CIRCUIT

Figure B-72008 ALL VRSC DOM. and INT. MODELS, STARTING CIRCUIT

Figure B-82008 ALL VRSC DOM. and INT. MODELS WITH ABS, ABS CIRCUIT

Figure B-92008 ALL VRSC DOM. and INT. MODELS WITH ABS, LIGHTING CIRCUIT

Figure B-102008 ALL VRSC DOM. and INT. MODELS WITHOUT ABS, LIGHTING CIRCUIT

Figure B-112008 ALL VRSC DOM. and INT. MODELS WITH ABS, HORN AND INSTRUMENT CIRCUIT

Figure B-122008 ALL VRSC DOM. and INT. MODELS WITHOUT ABS, HORN AND INSTRUMENT CIRCUIT

Figure B-132008 ALL VRSC DOM. and INT. MODELS, SECURITY CIRCUIT

B-4 2008 VRSC Diagnostics: Appendix B Wiring


BA

Intake AirTemp Sensor

[30B]

OptionalSecurity Siren

See security circuit forHFSM antenna

Turn

Sig

nal/S

ecur

ityM

odul

e(T

SM

/TS

SM

/HF

SM

)

[142A]

[30A]

[78A] [78B]

[87A]

Idle AirControlMotor

CrankPositionSensor

ThrottlePositionSensor

PurgeSolenoid

[87B]

[79A] [79B]

[88A] [88B]

[95A]FrontCoilsee

sheet2

[95B]

[83F B]

RearCoilsee

sheet2

DataLink

Connector[91A]

FuelLevel

Sensorsee

sheet2

[83R B]

[13B]

RearOxygenSensor

seesheet

2[137B] [138B]

[133B]

Battery 1 1Ignition 2 2

Serial data 3 3Neutral switch 4 4Left turn feed 5 5

Right turn feed 6 6Right turn switch input 7 7

Left turn switch input 8 8Start relay control 9 9

Clutch switch 10 10Alarm signal 11 11

Ground 12 12

Fan output 2 2

System relay 4 4Serial data 5 5

Coolant temperature 6 6Intake air temperature 7 7

Oxygen sensor A 8 8Jiffy stand sensor (HDI) 9 9

Ground 10 10Coil rear 11 11

Crank POS sensor (-) 12 12Switched power 13 13

5V sensor power 14 14

Idle air control (A) Hi 17 17Idle air control (B) Low 18 18

Injector rear 19 19

Injector front 21Solenoid control 22 22

Oxygen sensor B 23 23Throttle POS sensor input 24 24

MAP sensor input 25 255V sensor ground 26 26

ION sense 27 27Ground 28 28

Coil front 29 29Crank POS sensor (+) 30 30

Battery 31 31

Vehicle speed sensor input 33 33

Idle air control (A) Low 35 35Idle air control (B) Hi 36 36

D

21

21

CBA

DCBA

CBA

B BA A

CBA

C B A C B A 4 3 2 1 1 2 3

3 2 1 A B

FrontOxygenSensor

seesheet

2[168B]


seesheet 2

[167B]


seesheet 2

FuelPumpsee

sheet 2[86B]

[89A]

StarterSolenoid

Control Coilsee sheet 2

EngineSensorHarness

see sheet 2[145A] Rear

StopLampSwitch[121]

[97T A]

[97T B]

[97B A]

[62B]

[61B]

C ABS 30A D

Fan

Rel

ayS

tart

Rel

ay

[160B]

[GND1][GND3]

[GND2]

[77B]

[39B]

[39A]

[31A]

[93A][201B]

[94A]

[166B][22B]ABS Diode Pack

see sheet 2

Turn Signal& LP Lamp

ABS Modulesee sheet 2

RightHand Controls

see sheet 2

[38A]

HeadlampInterconnectsee sheet 2

[24B]

Left HandControls

see sheet 2 Tail/StopLamp

Front TurnSignals

Instrument Module

40 AmpMAXIFUSE

IgnitionSwitch

see sheet 2

VoltageRegulator

[5B]

[33B]

A

- +

NOTE:See sheet 2charging system forfurther MAXIFUSEconnections

1

6 5 4 3 2 1

4

6 5 4 3 2 1

A B

1 2 3 47 8 9 10 11 13 17181920316 5 4 3 2 11 2 3 456 4 3 2 178

3 2 1

Bat

tery

2

Hib

eam

3 4

Left

turn

5

Rig

httu

rn

6

Gro

und

Igni

tion

7

Ser

iald

ata

9

Oil

pres

sure

10

Neu

tral

11

Fuel

leve

l

12

1 2 3 4 5 6 7 9 101112

Acc

esso

ry

C B A

B

Sys

tem

Rel

ay

A Ignition 15A B

I Battery 15A J

B Fuel Pump 15A A

P ECM 15A R

U ACCY 15A S

J Lights 15A I

L Security 15A K

D P & A IGN 2A C

E Spare 15A F

P & ABattery

E Spare 15A F

[97B B]

NeutralSwitch[131]

TopCooling

Fan

BottomCooling

Fan

VehicleSpeedSensor

[89B]

[65B]

[128A]

Jiffy StandSensor

(HDI only)see sheet 2

A B B A A

D

C B A

12

1

1 2

2 1

87

87

8530

86

U

LK

S

87

8530

86

O

HG

M

308586

O

GHM

2 1

2 1

2 1

2

B

8 7 6 5 4 3 2 1B

21

[142B]

PowerSignal

Ground

123

123

BK

BK

GY

GN

BK

BK

BK

BK

BK TN

GN

GY

BK BK

BN

BK

R/W

R/W

V/W

W/Y

O/W

R/O

R/O

R/OR/V

W/R

Y/W

O/W

W/R

W/Y

V/W

R/W

R/W

W/V

R

R R

V

LGN

/Y

LGN

/V

BN/GY

BK/GN

BK/GN

BK/GN

BK/GN

BK/BE

BK/PK

BK/PK

GN/GY

GY/BE

GY

/BE

BK

/GN

GY

/BE

BK

/GN

BK

/GN

BE

/BN

BK

/BE

GN

/GY

BK

/GN

PK

/BNBK

/BE

GN

/BN

PK

/GN

BE/GY

BE/GN

BE/GN

PK/GN

GN/BN

LGN/BN

LGN/BN

GY

TN

BN/GY

TN/GN

LGN/V

LGN/Y

LGN/V

O/G

Y

BE

/V

BK

/V

BK

/W

BK

/W

BK

/R

Y/B

N

Y/BN

R/BK

R/BK

GN/O

BK/R

Y/GN

O/GYY/GN

R/BK

R/BK

R/GY

R/G

Y

R/B

K

W/BK

Y/BN

PK

/YG

N/Y

Y/G

N

BK

/W

BK

/W

PK

/O

BE

/OY

/GN

Y/G

NY

/BE

PK/Y

Y/BE

W/BK

GN/O

PK/O

GY/V

GY/V

GY/YY/GN

BN/R

BK/W

BN/R

BK/O

BK/O

BE/O

BK/W

GY/Y

W/BN

BK/R

TN

GY

BN

BE

BK

BK

BK

BK

BK

BK

OW

GYBK

GY

BK

BK

BK

BK

BK

BE

BE

BN

BK

BK

BN

BE

BE

O/W

R/Y

R/Y

R/V

R/V

R/O

Y/W

R/Y

O/W

O/W

O/W

OWBE

W/V Y

YW

W

V

VW

V

R

R

R

R

R

R

R

R

BK

/GN

BK

/BE

LGN

/V

PK

/BN

BE

/BN

PK

/BN

LGN

/V

BK

/GN

TN/GN

BE/GY

BE/GY

BN/GY

GN

/Y

R/B

N

Y/B

K

BK

/V

R/B

N

R/B

N

BE

/V

W/B

KW

/BN

BK

/R

BK

/RY

/BK

Ele

ctro

nic

Con

trol

Mod

ule

Horn[122]

BK

BK/GN BK

/GN

et00024

Figure B-2. 2008 ALL VRSC DOM. and INT. MODELS WITH ABS, MAIN HARNESS 1 of 2


Figure B-2.Figure B-2.2008 ALL VRSC DOM. and INT. MODELS WITH ABS, MAIN

HARNESS 1 of 22008 ALL VRSC DOM. and INT. MODELS WITH ABS, MAIN

HARNESS 1 of 2


FrontCoil

RearCoil

BE

BK R BKR

GY

/BE

GY

/BE

BE

BE

/BN

GY

/BE

BK

/W

PK

/O

PK

/GN

BE

/V

Y/G

N

BE

/O

BK

/BE

BK

/V

O/W

R/YGY

W/B

K

W/B

NB

K/R

O/W Y BE W

W/V

Y/B

KHorn SwitchHeadlamp Hi/Lo Switch

Left Turn Switch

Right Turn SwitchEngine Stop Switch

Start Switch

Front Stop Lamp Switch

[22A]

[24A]

FrontInjector

RearInjector

CoolantTemp

Sensor

W/YGN/GY

GN

/Y

Y/GN

Y/G

N

PK/YBK/W

BK

/WV/WR/W

BK

/W

V/W

R/W

PK

/Y

Y/G

NW

/Y

GN

/GY

GN/Y

Tomain wiringHarness

(70116−01)

Engine Harness70155−07

(70147−01)

(70149−01)

[84B]

[84A]

[85B]

[85A]

[90B]

[90A]

[163]

Left HandControls

[162]

Right HandControls

Antilock Braking System Module

123456

[120]

OilPressureSending

Unit

A B C

A B C

ManifoldAbsolutePressureSensor

RearOxygenSensor



FrontOxygenSensor

[80A]

[80B]

BA BA

BA BA

BA

BA

[145B]

12345678

Ignition Switch

[86A]

MTR

O/G

Y

BK

Fuel Pump

D C B A

D C B A

[86B]

R

R/B

K

R/G

Y

[33B]

[33A]A B I

C B A

BK

/R BK

Clutch Switch

654321 7 8

[13A] 3 2

3 2

1

1

O/WY/W

BK

/GN

Fuel Level Sensor

[13B]

O/Y

[208B]

To HFSM [208A]1 2 3

Y/B

K

BK

[209B]

1 2

O/Y

BK

Hands Free Antenna

[137B]

[137A]

[138B] [133B]

[133A]

[138A]

[168B]

[168A]

[83F B]

[83F A]

BA

[201B]

[201A]

ABSDiodePack

PK

/BN

R/Y

R/Y

R/B

N

1 2 3 4

1 2 3 4

BA

BA

AB

AB

BA

[167B]

[167A]

BA

BA

C B A

C B A

C B A

C B A

GY

/BE

Y/G

N

Y/B

E

[83R B]

[83R A]

Ignition

SystemRelay

15A15A

15A15A

15A 15A

FanRelay

15AStartRelay

15A2A MaxSpare

Battery30A

ABSSpare

Security

Accy

P&a Ign

Lights

Ecm

15AFuel Pump

All VRSC with ABS

[61] [62]FrontRear

(located under passenger seat) (located under right side cover)

1 2 3

1 2 3

R/W

GN

/BN

BK

/GN

R W BK

HDI Only

Jiffy Stand Sensor

1 3 7 8 9 10 11 13 17 18 19 20

1 3 7 8 9 10 11 13 17 18 19 20

EC

U/S

olen

oid

grou

nd

EC

U/S

olen

oid

pow

er

Rea

rbr

ake

inpu

t

Rea

rw

heel

spee

d(-

)R

ear

whe

elsp

eed

(+)

Fron

twhe

elsp

eed

(+)

Fron

twhe

elsp

eed

(-)

Dat

alin

k

Mot

orgr

ound

Fron

tbra

kein

put

Igni

tion

wak

e-up

Mot

orpo

wer

BK

BK GY

R/V

R/V

BK

/BE

PK

/BN

BE

/BN

LGN

/V

BK

/V

R/B

N

BE

/V

[166B]

[166A]

BK

/W

BK

Charging System

BKBK

BK

BK

VoltageRegulator

BK

[GND2]

[77A]

[77B]

R

R

Note: See sheet1 for furtherMAXIFUSE& regulatorconnections

MAXIFUSE(40 AMP)

[5B]

[47B]

[47A]

StarterSolenoid

StarterMotor

BK

GN

BK

Tomain

harness

[128B]

Stator

Battery

1 2 3

1 2 3

- +

- +

A B

Contact Posts

M

12

R

R

et00025

Figure B-3. 2008 ALL VRSC DOM. and INT. MODELS WITH ABS, MAIN HARNESS and CHARGING CIRCUIT 2 of 2


Figure B-3.Figure B-3.2008 ALL VRSC DOM. and INT. MODELS WITH ABS, MAIN

HARNESS and CHARGING CIRCUIT 2 of 22008 ALL VRSC DOM. and INT. MODELS WITH ABS, MAIN

HARNESS and CHARGING CIRCUIT 2 of 2


[122]

[77B]

VoltageRegulator

- +

BK

BK


[30B]

OptionalSecurity Siren


Turn

Sig

nal/S

ecur

ityM

odul

e(T

SM

/TS

SM

/HF

SM

)

[142A]

[30A]

[78A] [78B]

[87A]

Idle AirControlMotor

CrankPositionSensor


PurgeSolenoid

[87B]

[79A] [79B]

[88A] [88B]

[95A]FrontCoilsee

sheet2

[95B]

[83F B]

RearCoilsee

sheet2

DataLink

Connector

FuelLevel

Sensorsee

sheet2

[83R B]

[13B]

RearOxygenSensor

seesheet

2[137B] [138B]

[133B]


Serial data 3 3Neutral switch 4 4Left turn feed 5 5

Right turn feed 6 6Right turn switch input 7 7

Left turn switch input 8 8Start relay control 9 9

Clutch switch 10 10Alarm signal 11 11

Ground 12 12

Fan output 2 2






5V sensor power 14 14


Injector rear 19 19


Oxygen sensor B 23 23Throttle POS sensor input 24 24




Battery 31 31



D

21

21

CBA

DCBA

CBA

B BA A

CBA

C B A C B A 4 3 2 1 1 2 3

3 2 1 A B

FrontOxygenSensor

seesheet

2

FuelPumpsee

sheet 2

[89A]

StarterSolenoid

Control Coilsee sheet 2

EngineSensorHarness

see sheet 2

RearStopLampSwitch

[97T A]

[97T B]

[97B A]

[62B]

[61B]

Fan

Rel

ayS

tart

Rel

ay

[160B]

[GND1][GND3]

[GND2]

[39B]

[39A]

[31A]

[93A][94A][22B]

Turn Signal& LP Lamp

RightHand Controls

see sheet 2[38A]

HeadlampInterconnectsee sheet 2

[24B]

Left HandControls

see sheet 2 Tail/StopLamp

Front TurnSignals

Instrument Module40 Amp

MAXIFUSE

IgnitionSwitch

see sheet 2

[5B]

[33B]

A

NOTE:See sheet 2charging systemfor furtherMAXIFUSEconnections

1

6 5 4 3 2 1

46 5 4 3 2 16 5 4 3 2 11 2 3 456 4 3 2 178

3 2 1

Bat

tery

2

Hib

eam

3

Left

turn

4 5 6

Igni

tion

Rig

httu

rnG

roun

d

7

Ser

iald

ata

9

Oil

pres

sure

10

Neu

tral

11

Fuel

leve

l

12

1 2 3 4 5 6 7 9 101112

Acc

esso

ry

C B A

B

Sys

tem

Rel

ay

A Ignition 15A B

I Battery 15A J

B Fuel Pump 15A A

P ECM 15A R

U ACCY 15A S

J Lights 15A I

L Security 15A K

D P & A IGN 2A C

E Spare 15A F

P & ABattery

E Spare 15A F

[97B B]

NeutralSwitch Top

CoolingFan

BottomCooling

Fan

VehicleSpeedSensor

[89B]

[65B]

[128A]

Jiffy StandSensor


A B

D

C B A

12

1

1 2

2 1

87

87

8530

86

U

LK

S

87

8530

86

O

HG

M

308586

O

GHM

2 1

2 1

2 1

2

B

8 7 6 5 4 3 2 1

21

[142B]

PowerSignal

Ground

123

123

BK

BK

GY

GN

BK

BK

BK

BK

BK TN

GN

GY

BK BK

BN

BK

R/W

R/W

V/W

W/Y

O/W

R/Y

R/O

R/O

R/OW/R

Y/W

O/W

W/R

W/Y

V/W

R/W

R/W

W/V

R

R R

V

LGN

/Y

LGN

/V

BN/GY

BK/GN

BK/GN

BK/GN

BK/GN

BK/BE

BK/PK

BK/PK

GN/GY

GY/BE

GY

/BE

BK

/GN

GY

/BE

BK

/GN

BK

/GN

GN

/GY

BK

/GN

BK

/BE

GN

/BN

PK

/GN

BE/GY

BE/GN

BE/GN

PK/GN

GN/BN

LGN/BN

LGN/BN

GY

TN

BN/GY

TN/GN

LGN/V

LGN/Y

LGN/V

O/G

Y

BK

/W

BK

/W

BK

/R

Y/B

N

Y/BN

R/BK

R/BK

GN/O

BK/R

Y/GN

O/GYY/GN

R/BK

R/BK

R/GY

R/G

Y

R/B

K

W/BK

Y/B

N

PK

/YG

N/Y

Y/G

N

BK

/W

BK

/W

PK

/O

BE

/OY

/GN

Y/G

NY

/BE

PK/Y

Y/BE

W/BK

GN/O

PK/O

GY/V

GY/V

GY/YY/GN

BN/R

BK/W

BN/R

BK/O

BK/O

BE/O

BK/W

GY/Y

W/BN

BK/R

TN

GY

BN

BE

BK BK

OW

GYBK

BK

BK

BK

BK

BE

BE

BN

BK

BK

BN

BE

BE

O/W

R/O

Y/W

R/Y

R/Y

O/W

O/W

O/W

OWBE

W/V Y

YW

W V

VW

V

R

R

R

RR

R

R

R

BK

/GN

LGN

/V

BK

/GN

TN/GN

BE/GY

BE/GY

BN/GY

GN

/Y

W/B

KW

/BN

BK

/R

BK

/RY

/BK

Y/B

K

Ele

ctro

nic

Con

trol

Mod

ule

2 1

2 1

[121]

[131]

[145A]

[86B][91A]

BK

A B

Horn

BK

BK/GN

BK

/GN

et00026

Figure B-4. 2008 ALL VRSC DOM. and INT. MODELS WITHOUT ABS, MAIN HARNESS 1 of 2


Figure B-4.Figure B-4.2008 ALL VRSC DOM. and INT. MODELS WITHOUT ABS, MAIN

HARNESS 1 of 22008 ALL VRSC DOM. and INT. MODELS WITHOUT ABS, MAIN

HARNESS 1 of 2


FrontCoil

RearCoil

BE

GY

/BE

GY

/BE

BE

GY

/BE

BK

/W

PK

/O

PK

/GN

Y/G

N

BK

/GN

BE

/O

O/W

R/YGY

W/B

K

W/B

NB

K/R

O/W Y BE W

W/V

Y/B

K

Horn SwitchHeadlamp Hi/Lo Switch

Left Turn Switch

Right Turn SwitchEngine Stop Switch

Start Switch


[22A]

[24A]

FrontInjector

RearInjector

CoolantTemp

Sensor

W/YGN/GY

GN

/Y

Y/GN

Y/G

N

PK/YBK/W

BK

/W

V/WR/W

BK

/W

V/W

R/W

PK

/Y

Y/G

NW

/Y

GN

/GY

GN/Y

Main WiringHarness

(70116−01)

Engine Harness70155−07

(70147−01)

(70149−01)

[84B]

[84A]

[85B]

[85A]

[90B]

[90A]

[163]

Left HandControls

[162]

Right HandControls

123456

[120]

OilPressureSending

Unit A B C

A B C

ManifoldAbsolutePressureSensor

RearOxygenSensor

FrontOxygenSensor

[80A]

[80B]

BA BA

BA BA

BA

BA

[145B]

12345678

Ignition Switch

[86A]

MTR

Fuel Pump

D C B A

D C B A

[86B]

[33B]

[33A]A B I

C B A

BK

/R BK

Clutch Switch

654321 7 8

[13A]

3 2 1

3 2 1

Fuel Level Sensor

[13B]

O/Y

[208B]

To HFSM [208A]

1 2 3

Y/B

K

BK

[209B] 1 2

O/Y

BK

Hands Free Antenna

[137A]

[137B]

[138A]

[133B]

[133A]

[138B]

[83F B]

[83F A]

BA

BA

BA

BA

C B A

C B A

C B A

C B A

GY

/BE

Y/G

N

Y/B

E

O/G

Y

R/G

Y

R/B

K

[83R B]

[83R A]

Ignition

SystemRelay

15A15A

15A15A

15A 15A

FanRelay

15AStartRelay

15A2A MaxSpare

Battery

Spare

Security

Accy

P&a Ign

Lights

Ecm

15AFuel Pump

All VRSC without ABS

[61] [62]

FrontRear(located under passenger seat) (located under right side cover)

1 2 3

1 2 3

R/W

GN

/BN

BK

/GN

R W BK

HDI Only

Jiffy Stand Sensor

R

Y/W

O/W B

K

BK

/W

BK

Charging System

BKBK

BK

BK

VoltageRegulator

BK

[GND2]

[77A]

[77B]

R

R

Note: See sheet1 for furtherMAXIFUSE& regulatorconnections

MAXIFUSE(40 AMP)

[5B]

[47B]

[47A]

StarterSolenoid

StarterMotor

BK

GN

BK

Tomain

harness

[128B]

Stator

Battery

1 2 3

1 2 3

- +

- +

A B

Contact Posts

M

12

R

R

et00027

Figure B-5. 2008 ALL VRSC DOM. and INT. MODELS WITHOUT ABS, MAIN HARNESS and CHARGING CIRCUIT 2 of 2


Figure B-5.Figure B-5.2008 ALL VRSC DOM. and INT. MODELS WITHOUT ABS, MAIN

HARNESS and CHARGING CIRCUIT 2 of 22008 ALL VRSC DOM. and INT. MODELS WITHOUT ABS, MAIN

HARNESS and CHARGING CIRCUIT 2 of 2


[30B]

RightHand Control

Instrument Module

1

Bat

tery

5

Gro

und

6

Igni

tion

9

1 5 6 9

Oil

pres

sure

Right HandControls


Turn

Sig

nal/S

ecur

ityM

odul

e(T

SM

/TS

SM

/HF

SM

)

[30A]

[22B]


Start Switch

Engine Stop Switch

Right Turn Switch

[22A]

[78A] [78B]

[87A]

IdleAir

ControlMotor

CrankPositionSensor


PurgeSolenoid

[87B]

[79A] [79B]

[88B][88A]

[95A] [95B]

Battery 1

5

6 5 4 3 2 1

4 3

1Ignition 2 2

Serial data 3 3

Right turn switch input 7 7

Ground 12 12

Fan output 2 2






5V power 14 14


Injector rear 19 19


Oxygen sensor B 23 23Throttle POS. sensor input 24 24




Battery 31 31



D

21

21

CBA

DCBA

CBA

B BA A

CBA

21

[160B]

[39B]

[39A]

P & ABattery

IgnitionSwitch

see sheet 2

[33B]

Rear(located under

passenger seat)

Front(located under

right side cover)

Rear(located under

passenger seat)

Front(located under

right side cover)

All VRSC with ABS

All VRSC without ABS

C B A

[GND1][GND3]

[GND2][62B]

[61B]

Fan

Rel

ayS

yste

mR

elay

A Ignition 15A B

Q ECM 15A R

I Battery 15A J

B Fuel Pump 15A A

L Security 15A K

87

308586

O

GHM

87

308586

O

GHM

[97T A]

[97 T B]

[97B A] [97B B]

Oil PressureSending

Unit

CoolantTemp

Sensor

ManifoldAbsolutePressure

Sensor

Front Injector

Rear Injector

[84A] [84B]

[85A] [85B]

[90A] [90B]

[80A] [80B]

[120]

TopCooling

Fan

BottomCooling

Fan

To main wiringharness

2 1

2 1

21

2

1 2

AB

AB

AB

AB

AB

AB

ABC

ABC

3 4 5 6 7 8

EngineHarness70155-07

1


FuelPumpsee

sheet 2

[89A]

EngineSensorHarness

VehicleSpeedSensor

[89B]

[65B]

D

C B A

12

12

B

8 7 6 5 4 3 2 1

RearOxygenSensor

seesheet

2[138B] [133B]

A B

FrontOxygenSensor

seesheet

2

Jiffy StandSensor

(HDIonly)see

sheet 2

A B 1 2 3

[137B]

FrontCoilsee

sheet 2[83F B]

RearCoilsee

sheet 2

DataLink

[83R B]

C B A C B A 4 3 2 1

Spare P&A IGN Fuel Pump15A

SystemRelay

StartRelay

FanRelay

Security Lights

ACCY ECM

15A 2A MAXSpare Ignition

15A15A

Battery15A15A 15A

15A 15A


SystemRelay

StartRelay

FanRelay

Security Lights

ACCY ECM


15A15AABS30A

Battery15A15A 15A

15A 15A

BK/GN

GYBN/GY

LGN/V

W/BN

BK

W/R

W/Y

V/W

R/W

R

BK/GN

BK/GN

BK/BE

BK/PKGN/GY

GY/BE

BE/GY

BE/GN

PK/GN

GN/BN

LGN/Y

LGN/VPK/Y

Y/BE

W/BK

GN/O

PK/O

GY/V

BN/R

BK/O

BE/O

BK/W

GY/Y

BK BK

R/W

R R

BK/PK

BE/GN

GY/V

BK/W

BN/R

BK/O

GY

/BE

GY

/BE

BE

/OY

/GN

Y/G

NY

/BE

GY/YY/GN

BK

R/W

V/W

W/Y

GN

/GY

BK

/GN

BK

/BE

O/G

Y

BK

/W

BK

/RPK

/YG

N/Y

GN

/Y

Y/G

N

PK

/GN

BK

/W

BK

/W

PK

/O

R/W

BK

/GN

GN

/BN

GY

LGN

/VB

K/G

N

BK

BK

LGN/YBK/W

Y/B

N

Y/BN

GY

R/O

R/O

R/W

W/Y

V/W

R/W

V/W

R/OW/R

Y/BN

R/BK

BK/W

PK/Y

Y/G

N

BK

/W

GN

/YP

K/Y

GN/Y

BK/W

R/B

K

GN/O

O/GY

W/BK

BE/GY

BE/GY

BN/GY

Y/GN

R

R

R

R

R

GN

/GY

(70147-01)[162]

[86B][91A]

GY

R/O

O/W

R/Y

BK

/GN

BK

/RW

/BN

W/B

K

GY

GY

W/B

KW

/BN

Ele

ctro

nic

Con

trol

Mod

ule

40 AmpMAXIFUSE

[5B]A

NOTE:See sheet 2charging systemfor furtherMAXIFUSEconnections

B

R

RR

[77B]

VoltageRegulator

- +

BK

BK

[62][61]

[62][61]

[145A]

BK

BK/GN

BK

/GN

et00028

Figure B-6. 2008 ALL VRSC DOM. and INT. MODELS, IGNITION CIRCUIT


Figure B-6.Figure B-6.2008 ALL VRSC DOM. and INT. MODELS, IGNITION CIRCUIT2008 ALL VRSC DOM. and INT. MODELS, IGNITION CIRCUIT


Rear(located underpassenger seat)

Front(located under

right side cover)


Front(located under

right side cover)

All VRSC with ABS

All VRSC without ABSSpare P&A IGN Fuel Pump

15A

SystemRelay

StartRelay

FanRelay

Security Lights

ACCY ECM


15A15A

Battery15A15A 15A

15A 15A


SystemRelay

StartRelay

FanRelay

Security Lights

ACCY ECM


15A15AABS30A

Battery15A15A 15A

15A 15A


Serial data 3 3Neutral switch 4 4

Start relay control 9 9Clutch switch 10 10

Ground 12 12

Serial data 5 5

Ground 10 10

Switched power 13 13

Ground 28 28

[30B]


Turn

Sig

nal/S

ecur

ityM

odul

e(T

SM

/TS

SM

/HF

SM

)

Ele

ctro

nic

Con

trol

Mod

ule

[30A]

[78A] [78B]

LeftHand Controls

see sheet 2

RightHand Controls

[24B][22B]

[22A]

[GND1][GND3]

[GND2]

[39A]

[39B]

86 34

6 4 3

1

2

1

2

7

Instrument Module

10

10

Neu

tral

Right HandControls

Start Switch

Engine StopSwitch

[162]

40 AmpMAXIFUSE

[33B]

Sta

rtR

elay

[5B]

[33A]

A

U

KLS

87

308586

B

BC A

BC 1

IgnitionSwitch

L Security 15A K

A Ignition 15A B

[62B]

M

[61B]

Battery

NeutralSwitch

StarterMotor

Contactposts

[131]

BK/GN

BK

/GN

BK/GN

BK/GN

TN/GN

GYBN/GY

LGN/V

LGN/V

BK

/R

BK/R

W/BK

BK

/R

W/B

K

W/B

K

BK

/R

GY

GY

BK

BK

BK

BK

GY

GN

TN

GN

BK

GN

TN

TN

R

R

R R

R

R

R/BK

R/BK

R/B

K

BK/R

BN/GY

TN/GN

[128A] [128B]

[61] [62]

[61] [62]

BKBK/GN

et00029

Figure B-7. 2008 ALL VRSC DOM. and INT. MODELS, STARTING CIRCUIT


Figure B-7.Figure B-7.2008 ALL VRSC DOM. and INT. MODELS, STARTING CIRCUIT2008 ALL VRSC DOM. and INT. MODELS, STARTING CIRCUIT


BA

DataLink[91A]

4 3 2 1

RearStopLampSwitch

[62B]

[61B]

C ABS 30A D

[GND1][GND3]

[GND2]

[39B]

[39A]

[93B]

[93A]

[22B]

[22A]

Tail/StopLamp

Instrument Module

40 AmpMAXIFUSE

[5B]A

NOTE:See sheet 2chargingsystem forfurtherMAXIFUSEconnections

1

41 2 3 4

1 2 3 4

7 8 9 10 11 13 17 1819203

7 8 9 10 11 13 17 1819203

1

1

2 1

2 1 3

4 3

Bat

tery

5

Gro

und

6

Ingi

tion

7

Ser

iald

ata

12

Acc

esso

ry

B

I Battery 15A J

U ACCY 15A S

GY

GY

O/W

R/O

R/V

LGN

/VB

K/G

N

BK

/BE

PK

/BN

BK

/V

BE

/VB

E/B

N

R/BK

R/GY

R/G

Y

R/B

K

GY

BK

BK

O/W

GY

BK

BK

R/Y

R/Y

R/VR/V

R/O

R/Y

O/W

O/W

R

R

R

R

BK

/BE

LGN

/V PK

/BN

BE

/BN

PK

/BN

LGN

/V

BK

/GN

BK/GN

BK

/GN

R/B

N

BK

/V

R/B

N

R/B

NO

/WR

/Y

BE

/V

A Ignition 15A B

BK R


[168B]

[168A]

AB

AB

BKR


[167B]

[167A]

BA

BA

Ignition

SystemRelay

15A15A

15A15A

15A 15A

FanRelay

15AStartRelay

15A2A MaxSpare

Battery30A

ABSSpare

Security

Accy

P&a Ign

Lights

Ecm

15AFuel Pump

All VRSC with ABS

[61] [62]Rear

(located under passenger seat)Front

(located under right side cover)

[121]

Ignition Switch

[33B]

[33A]A B I

C B A

R

[201A]

[201B][166A]

[166B]

ABSDiode Pack

AntilockBrakingSystemModule

EC

U/S

olen

oid

grou

ndR

ear

brak

ein

put

Rea

rw

heel

spee

d(-

)R

ear

whe

elsp

eed

(+)

Dat

alin

kE

CU

/sol

enoi

dpo

wer

Mot

orgr

ound

Fron

tbra

kein

put

Fron

twhe

elsp

eed

(+)

Fron

twhe

elsp

eed

(-)

Igni

tion

wak

e-up

Mot

orpo

wer

Right HandControls


(70147-01)[162]

BKR/Y

et00030

Figure B-8. 2008 ALL VRSC DOM. and INT. MODELS WITH ABS, ABS CIRCUIT


Figure B-8.Figure B-8.2008 ALL VRSC DOM. and INT. MODELS WITH ABS, ABS

CIRCUIT2008 ALL VRSC DOM. and INT. MODELS WITH ABS, ABS

CIRCUIT


R/BK

R/BK

R/B

K

R/GY

R/G

Y

Rear(located under

passenger seat)

[31B]

[38B]

[38B]

[29]

[38H]

[38L]

Left FrontTurn Signal

VRSCR Headlamp

HighBeam

PositionLamp

LowBeam

VRSCA Headlamp

Front Turn Lighting

MainHarness

Right FrontTurn Signal

Hi Beam

BK

1

2

A

B

1

2

2

1234

34

W

YLow Beam

Black connector

Front(located under

right side cover)

All VRSC with ABSSpare P&A IGN Fuel Pump

15A

SystemRelay

StartRelay

FanRelay

Security Lights

ACCY ECM


15A15AABS30A

Battery15A15A 15A

15A 15A


Serial data 3 3

8 56 4 3 2 11

1

2 3 4 4 3 2 1

6

2

Hib

eam

2

3

Ltu

rn

3

4

Rtu

rn

4

5

Gro

und

5

6

Igni

tion

6

7

Ser

iald

ata

7

12

Acc

esso

ry

12

5 4 3 2 15 4 3 2 1

5 3 2 1

Left turn feed 5 5Right turn feed 6 6

Right turn switch input 7 7Left turn switch input 8 8

Ground 12 12

Serial data 5 5

Ground 10 10

Ground 28 28

[30B]

[24B]

Left HandControls

Right HandControls

HeadlampInterconnect

see

shee

t2

Tail/StopLamp

FrontTurn Signals

InstrumentModule

TurnSignal& LPLamp

[22B]

[38A]

[94A]

[93A]

[31A][39A]

[39B]


Turn

Sig

nal/S

ecur

ityM

odul

e(T

SM

/TS

SM

/HF

SM

)

Ele

ctro

nic

Con

trol

Mod

ule

[30A]

[78A] [78B]

40 AmpMAXIFUSE

IgnitionSwitch

[5B]

[33B]

[22A]

[24B

[24A]

[33A]

A

NOTE:See sheet 2chargingsystem for furtherMAXIFUSEconnections

B

[160B]

P & ABattery

A Ignition 15A B

U ACCY 15A S

J Lights 15A I

L Security 15A K

C B A

A B I

[62B]

[61B]

B

123

54

6

A

RearStopLampSwitch

Right HandControls


Clutch Switch

Horn SwitchHeadlamp Hi/Lo SwitchLeft Turn Switch

Start SwitchEngine Stop SwitchRight Turn Switch

6 5 4 3 2 1

1

4

123456

321

2 3 4 5 6 7 8

1 2 3 4 5 6 7 8

(70147-01)[162]

Left HandControls

Tail/StopLamp

LicenseLamp

RightRRTurn

LeftRRTurn

Rear Stop/Turn Lighting

[93B](BK)

[94B]

O/W

O/W

R/Y

W/V

BK

/RW

/BN

Y/B

K

BK

/R

W/B

KG

Y

BE

BK

[GND1][GND3]

[GND2]

BK/GN

GY

BN

BKBK

BE

BNBK

BK

BE

BK

BK

BK

GY

BE

BEBN

BE

BK

BK

BN/GY

LGN/V

W/BN

R/B

N

R/B

N

W/B

N

BK/GN

BK/GN

LGN/V

BE G

Y

BK

V

W

WY

Y

W

WY

Y

V

V

Y W

O/W O

/W

O/W

O/W

W/V

W/V

O/W

O/W

R/YO/W

O/W

O/W

PK

/BN

BK/GN

BK

/GN

BK

/GN

BN/GY

R

R

R

R

R R

BK

BK

BK

BN

BK

BK

BE

BE

BN

BN

GY

R/Y

R/Y

R/Y

V

V

V

W

PK

/BN

BK

/GN

LGN

/V

BE

1 2 3 4

2 3 4

[201A]

[201B] [77B]

VoltageRegulator

- +

BK

BK

ABSDiode Pack

[61] [62]

[121]

(70149-01)[163]

BE

BK

BK

BK

W

Y

O/W

et00031

Figure B-9. 2008 ALL VRSC DOM. and INT. MODELS WITH ABS, LIGHTING CIRCUIT


Figure B-9.Figure B-9.2008 ALL VRSC DOM. and INT. MODELS WITH ABS, LIGHTING

CIRCUIT2008 ALL VRSC DOM. and INT. MODELS WITH ABS, LIGHTING

CIRCUIT


R/BK

R/BK

R/B

K

R/GY

R/G

Y


[31B]

[38B]

[38B]

[29]

[38H]

[38L]


VRSCR Headlamp

Front Turn Lighting

HighBeam

PositionLamp

LowBeam

VRSCA Headlamp

MainHarness


Hi Beam

BK

1

2

A

B

1

2

2

1234

34

W

YLow Beam

Black connector

Front(located under

right side cover)


15A

SystemRelay

StartRelay

FanRelay

Security Lights

ACCY ECM


15A15A

Battery15A15A 15A

15A 15A


Serial data 3 3

8 5 4 3 2 11 2 3 4 4 3 2 1

6

2

Hib

eam

2

3

Ltu

rn

3

4

Rtu

rn

4

5

Gro

und

5

6

Igni

tion

6

7

Ser

iald

ata

7

12

Acc

esso

ry

12

5 4 3 2 15 4 3 2 1

5 3 2 1



Ground 12 12

Serial data 5 5

Ground 10 10

Ground 28 28

[30B]

[24B]

Left HandControl

Right HandControl

HeadlampInterconnect

Tail/StopLamp

FrontTurn Signals

InstrumentModule

Turn Signal& LPLamp

[22B][38A]

[94A]

[93A]

[31A] [39A]

[39B]


Turn

Sig

nal/S

ecur

ityM

odul

e(T

SM

/TS

SM

/HF

SM

)

Ele

ctro

nic

Con

trol

Mod

ule

[30A]

[78A] [78B]

40 AmpMAXIFUSE

IgnitionSwitch

[5B]

[33B]

[22A]

[24B

[24A]

[33A]

A


B

[160B]

P & ABattery

A Ignition 15A B

U ACCY 15A S

J Lights 15A I

L Security 15A K

C B A

A B I

[62B]

[61B]

123

54

6

RearStopLampSwitch

Right HandControls


Clutch Switch


Start SwitchEngine Stop SwitchRight Turn Switch

6 5 4 3 2 1

1

4

123456

321

2 3 4 5 6 7 8

1 2 3 4 5 6 7 8

(70147-01)[162]

Left HandControls

Tail/StopLamp

LicenseLamp

RightRRTurn

LeftRRTurn

Rear Stop/Turn Lighting

(70149-01)[163]

[93B](BK)

[94B]

O/W

O/W

R/Y

W/V

BK

/RW

/BN

Y/B

K

BK

/R

W/B

KG

Y

BE

BK

[GND1][GND3]

[GND2]

BK/GN

GY

BN

BKBK

BE

BNBK

BK

BE

BK

BK

BK

GY

BE

BEBN

BE

BK

BK

BK

BK

BK

BN/GY

LGN/V

W/BN

W/B

N

BK/GN

BK/GN

LGN/V

BE G

Y

BK

V

W

WY

Y

W

W WY

Y

Y

V

V

Y W

O/W O

/W

O/W

O/W

W/V

W/V

O/W

O/W

O/W

R/YO/W

O/W

O/W

BK/GN

BK

/GN

BK

/GN

BN/GY

R

R

R

R

R

BK

BK

BK

BE

BN

BK

BK

BE

BE

BN

GY

R/Y

R/Y

V

V

V

W

BK

/GN

LGN

/V

BE

R/Y

BN

[77B]

VoltageRegulator

- +

BK

BK

2 1

2 1

[121]

[61] [62]

et00032

Figure B-10. 2008 ALL VRSC DOM. and INT. MODELS WITHOUT ABS, LIGHTING CIRCUIT


Figure B-10.Figure B-10.2008 ALL VRSC DOM. and INT. MODELS WITHOUT ABS,

LIGHTING CIRCUIT2008 ALL VRSC DOM. and INT. MODELS WITHOUT ABS,

LIGHTING CIRCUIT


ACCY 15ALGN/V

R/W

Battery 15A

ECM 15A

TN

EngineSensorHarness

see sheet 2

FuelLevel

Sensorsee sheet 2

LGN

/V

40 AmpMAXIFUSE

[5B]

R

R/GY

R

R

R

R

R/G

Y

Ele

ctro

nic

Con

trol

Mod

ule

VehicleSpeedSensor

BK/BER/O

BE/GY

R/O

O/W

O/W

Y/W

BK

/GN

GN

/Y

GN

/Y

BK

[39A]

TN

BK

/BE

BK

/GN

[78A] [78B]

[145A]

[65B]

Note:see sheet 2charging systemfor furtherMAXIFUSEconnections

BK/GN

BK

/GN

[39B]

[131]

NeutralSwitch

[GND1][GND3]

[GND2]

5

10

99

14

31

33

5

10

14

31

33

Bat

tery

Gro

und

Ser

iald

ata

Oil

pres

s.N

eutr

alF

uell

evel

Acc

esso

ry

Instrument Module

4

C B A

BK

/GN

Y/W

O/W

123

P&A Battery

[160B]

[61B]

[62B]

R

BE/GY

BK/GN

Ignition

SystemRelay

15A15A

15A15A

15A 15A

FanRelay

15AStartRelay

15A 30A2A MaxSpare

Battery

Spare

Security

Accy

P&A IGN

Lights

Ecm

15AFuel Pump

All VRSC With ABS

[61] [62]Rear

(Located under passenger seat)Front

(Located under right side cover)

1

A

B

5 7 9 10 11 12

1 5 7 9 10 11 12

LGN/V

BN/GY1

3

12

1

3

12 BK/GN

Turn

Sig

nal/S

ecur

ityM

odul

e(T

SM

/TS

SM

/HF

SM

)

[30A] [30B]

Battery

Serial data

Ground

Ground

Jiffy stand sensor (HDI)

Battery

2828Ground

Serial data link

5V Sensor power

Vehicle speed sensor input

SecurityBN/GY

O/W

Y/B

K


[24A]

Y/BK[24B]

[163]Left Hand Controls

61

61

BK

Horn[122] Ignition Switch

see sheet 2

[33B]A B

ABC

[13B]

P R

U S

L K

I J

ABS 30AC D

ABS

1 9 10 11 20

BK

BK R/V

R/V

R/V

[166B]

LGN

/V

ABS Modulesee sheet 2

BK

[77B]

VoltageRegulator

BK

BK

- +

RR

BK

/R

1 2 3

Jiffy StandSensor


GN

/BN

R/W

R/W

R/W BK/R

GN/BN

BK

/GN

[133B]

et00033

Figure B-11. 2008 ALL VRSC DOM. and INT. MODELS WITH ABS, HORN AND INSTRUMENT CIRCUIT


Figure B-11.Figure B-11.2008 ALL VRSC DOM. and INT. MODELS WITH ABS, HORN AND

INSTRUMENT CIRCUIT2008 ALL VRSC DOM. and INT. MODELS WITH ABS, HORN AND

INSTRUMENT CIRCUIT


ACCY 15ALGN/V

Battery 15A

ECM 15A

TN

EngineSensorHarness

see sheet 2

LGN

/V

40 AmpMAXIFUSE

[5B]

R

R/GY

R

R

R

R

R/G

Y

Ele

ctro

nic

Con

trol

Mod

ule

VehicleSpeedSensor

BK/BER/O

BE/GY

R/O

O/W

O/W

Y/W

BK

/GN

GN

/Y

GN

/Y

BK

[39A]

TN

BK

/BE

BK

/GN

[78A] [78B]

[145A] [65B]

Note:see sheet 2charging systemfor furtherMAXIFUSEconnections

BK/GN

BK

/GN

[39B]

[131]

NeutralSwitch

[GND1][GND3]

[GND2]

5

10

14

31

33

5

10

14

31

33

Bat

tery

Gro

und

Ser

iald

ata

Oil

pres

s.N

eutr

alF

uell

evel

Acc

esso

ry

Instrument Module

4 C B A

BK

/GN

Y/W

O/W

123

P&A Battery[160B]

[61B]

[62B]

R

BE/GY

BK/GN

Ignition

SystemRelay

15A15A

15A15A

15A 15A

FanRelay

15AStartRelay

15A2A MaxSpare

Battery

Spare

Security

Accy

P&A IGN

Lights

Ecm

15AFuel Pump

All VRSC Without ABS

[61] [62]FrontRear

(Located under passenger seat) (Located under right side cover)

1 5

A

B

7 9 10 11 12

1 5 7 9 10 11 12

LGN/V

BN/GY1

3

12

1

3

12 BK/GN

Turn

Sig

nal/s

ecur

ityM

odul

e(T

SM

/TS

SM

/HF

SM

)

[30A] [30B]

Battery

Serial data

Ground

Ground

Battery

2828Ground

Serial data link

5V Sensor power

Vehicle speed sensor input

SecurityBN/GY

O/W

Y/B

K


[24A]

Y/BK[24B]

[163]Left Hand Controls

61

61

[122]

BK

Horn

Ignition Switch

[33B]

[33A]A B I

C B A

FuelLevel

Sensorsee sheet 2

[13B]

P R

U S

L K

I J

A B

BK

RR[77B]

VoltageRegulator

BK

BK

- +

BK/GN

R/W

99Jiffy stand sensor (HDI)

BK

/R

1 2 3

Jiffy StandSensor


GN

/BN

R/W

R/W

R/W BK/R

BK

/GN

[133B]

et00034

Figure B-12. 2008 ALL VRSC DOM. and INT. MODELS WITHOUT ABS, HORN AND INSTRUMENT CIRCUIT


Figure B-12.Figure B-12.2008 ALL VRSC DOM. and INT. MODELS WITHOUT ABS, HORN

AND INSTRUMENT CIRCUIT2008 ALL VRSC DOM. and INT. MODELS WITHOUT ABS, HORN

AND INSTRUMENT CIRCUIT


[31B]


Front Turn Lighting

MainHarness


123

54

6

BK

BEBN

BE

BKV

LicenseLamp

RightRRTurn

LeftRRTurn

Rear Turn Lighting

[94B]

BE

BNBK

BK

BKV

123456

[62B]

Sta

rtR

elayU

KLS

87

308586

[61B]

Optional Security Siren

[142A] [142B]

1PowerSignal

Ground23

123

Battery 1 1

Serial data 3 3



Start relay control 9 9

Ground 12 12

Receive antenna 1 1Transmit antenna A 2 2

Transmit antenna B 3 3

Alarm signal 11 11

[30B]

Turn

Sig

nal/S

ecur

ityM

odul

e(T

SM

/TS

SM

/HF

SM

)

Ele

ctro

nic

Con

trol

Mod

ule

[30A]

[78A] [78B]

[208A] [208B]

Serial data 5 5

Ground 1010

Switched power 1313

Ground 2828

Battery 3131

Antenna A1Antenna B2

12

[22A]

[22B]

[24A]

[24B]

RightHandControls

LeftHand

Controls

Left Hand ControlsRight Hand Controls


Start SwitchEngine Stop SwitchRight Turn SwitchLeft Turn Switch

Headlamp Hi/Lo SwitchHorn Switch

Clutch Switch

51

5 3 18

5 384 3 1

5 4 3 1

[162][163]

6 5 2 16 5 4 3

FrontTurn Signals

Instrument Cluster

Turn Signal& LPLamp

[94A]

[31A]1

Bat

tery

1

3

Ltu

rn

3

4

Rtu

rn

4

5

Gro

und

5

7

Ser

iald

ata

7

12

Acc

esso

ry

12

[39A]

[39B]

40 AmpMAXIFUSE

[5B]

A


B

[160B]

P & ABattery

IgnitionSwitch

[33B]

[33A]

C B A

A B I

P ECM 15A R

Battery 15AI J

A BIgnition 15A

U ACCY 15A S

J Lights 15A I

L Security 15A K

[GND1][GND3]

Hands Free Antenna

[209A][209B]

[GND2]

BKBK/GN

BK

/GN

BK

/GN

BN/GY

BE/GY

TN/GN

BE

GY

BK

BK

BE G

Y

BE

BK

BN

R/O

O/W

O/W

R/O

O/Y

O/Y

O/W

O/W O

/W

W/V

W/V

W/V

V

V V

V

R

R

R

R

R

BN/GY

BN/GY

LGN/V

LGN/V

LGN

/V

TN/GN

LGN/BN

LGN/BN

BK/GN

BK/GNB

K/G

N

BK/GN

BK/GN

BE/GY

R/BK

R/B

K

R/BK

R/GY

R/G

Y

Y/BK

W/BK

W/BN

W/B

NW

/BK

GY

BK

BK

BK

BK

BN

BN

BN

O/W

W/B

NW

/BK

RR

[77B]

VoltageRegulator

BK

BK

- +


Front(located under

right side cover)


Front(located under

right side cover)

All VRSC with ABS


15A

SystemRelay

StartRelay

FanRelay

Security Lights

ACCY ECM


15A15A

Battery15A15A 15A

15A 15A


SystemRelay

StartRelay

FanRelay

Security Lights

ACCY ECM


15A15AABS30A

Battery15A15A 15A

15A 15A

[61] [62]

[62][61]

et00035

Figure B-13. 2008 ALL VRSC DOM. and INT. MODELS, SECURITY CIRCUIT


Figure B-13.Figure B-13.2008 ALL VRSC DOM. and INT. MODELS, SECURITY CIRCUIT2008 ALL VRSC DOM. and INT. MODELS, SECURITY CIRCUIT


SUBJECT............................................................................................................................PAGE NO.C.1 METRIC CONVERSION...........................................................................................................C-1C.2 FLUID CONVERSIONS............................................................................................................C-2C.3 TORQUE CONVERSIONS.......................................................................................................C-3

AP

PE

ND

IX C

CO

NV

ER

SIO

NS


NOTES


C.1METRIC CONVERSION

CONVERSION TABLE

Table C-1. Metric Conversions

INCHES to MILLIMETERS(IN. x 25.40 = MM)

MILLIMETERS to INCHES(MM x 0.03937 = IN.)

MMIN.MMIN.MMIN.MMIN.IN..MMIN.MMIN.MMIN.MM

84.143-5/1649.211-15/1615.240.6.025.0013.582912.28358.984225.0039.1

85.723-3/850.80215.8755/8.051.0023.622922.323591.02426.0078.2

86.363.452.392-1/1617.46211/16.076.0033.661932.362601.06327.0118.3

87.313-7/1653.342.117.780.7.102.0043.701942.401611.10228.0157.4

88.903-1/253.972-1/819.0503/4.127.0053.740952.441621.14229.0197.5

90.493-9/1655.562-3/1620.320.8.152.0063.779962.480631.18130.0236.6

91.443.655.882.220.63813/16.178.0073.819972.519641.22031.0275.7

92.073-5/857.152-1/422.2257/8.203.0083.858982.559651.26032.0315.8

93.663-11/1658.422.322.860.9.229.0093.897992.598661.29933.0354.9

93.983.758.742-5/1623.81215/16.254.0103.9371002.638671.33834.03941

95.253-3/460.322-3/825.401.3971/643.9761012.677681.37835.07872

96.523.860.962.426.991-1/16.508.0204.0161022.716691.41736.11813

96.843-13/1661.912-7/1627.941.1.762.0304.0551032.756701.45637.15754

98.423-7/863.502-1/228.571-1/8.7941/324.0941042.795711.49638.19685

99.063.965.092-9/1630.161-3/161.016.0404.1341052.834721.53539.23626

100.013-15/1666.042.630.481.21.270.0504.1731062.874731.57540.27567

101.6466.672-5/831.751-1/41.524.0604.2121072.913741.61441.31498

102.194-1/1668.262-11/1633.021.31.5881/164.2521082.953751.65342.35439

104.144.168.582.733.341-5/161.778.0704.2911092.992761.69343.393710

104.774-1/869.852-3/434.921-3/82.032.0804.3311103.031771.73244.433111

106.364-3/1671.122.835.561.42.286.0904.3701113.071781.77245.472412

106.684.271.442-13/1636.511-7/162.540.14.4091123.110791.81146.511813

107.954-1/473.022-7/838.101-1/23.1751/84.4491133.149801.85047.551214

109.224.373.662.939.691-9/164.7623/164.4881143.189811.89048.590515

109.544-5/1674.612-15/1640.641.65.080.24.5271153.228821.92949.629916

111.124-3/876.20341.271-5/86.3501/44.5671163.268831.96850.669317

111.764.477.793-1/1642.861-11/167.620.34.6061173.307842.00851.708618

112.714-7/1678.743.143.181.77.9385/164.6451183.346852.04752.748019

114.304-1/279.373-1/844.451-3/49.5253/84.6851193.386862.08653.787420

115.894-9/1680.963-3/1645.721.810.160.44.7241203.425872.12654.826821

116.844.681.283.246.041-13/1611.1127/164.7641213.464882.16555.866122

117.474-5/882.553-1/447.621-7/812.7001/24.8031223.504892.20556.905523

119.064-11/1683.823.348.261.914.2889/164.8421233.543902.24457.944924

2008 VRSC Diagnostics: Appendix C Conversions C-1


C.2FLUID CONVERSIONS

UNITED STATES SYSTEMUnless otherwise specified, all fluid volume measurements inthis Service Manual are expressed in United States (U.S.)units-of-measure. See below:

• 1 pint (U.S.) = 16 fluid ounces (U.S.)

• 1 quart (U.S.) = 2 pints (U.S.) = 32 fl. oz. (U.S.)

• 1 gallon (U.S.) = 4 quarts (U.S.) = 128 fl. oz. (U.S.)

METRIC SYSTEMFluid volume measurements in this Service Manual includethe metric system equivalents. In the metric system, 1 liter (L)= 1,000 milliliters (mL). Should you need to convert from U.S.units-of-measure to metric units-of-measure (or vice versa),refer to the following:

• fluid ounces (U.S.) x 29.574 = milliliters

• pints (U.S.) x 0.473 = liters

• quarts (U.S.) x 0.946 = liters

• gallons (U.S.) x 3.785 = liters

• milliliters x 0.0338 = fluid ounces (U.S.)

• liters x 2.114 = pints (U.S.)

• liters x 1.057 = quarts (U.S.)

• liters x 0.264 = gallons (U.S.)

BRITISH IMPERIAL SYSTEMFluid volume measurements in this Service Manual do notinclude the British Imperial (Imp.) system equivalents. The fol-lowing conversions exist in the British Imperial system:

• 1 pint (Imp.) = 20 fluid ounces (Imp.)

• 1 quart (Imp.) = 2 pints (Imp.)

• 1 gallon (Imp.) = 4 quarts (Imp.)

Although the same unit-of-measure terminology as the U.S.system is used in the British Imperial (Imp.) system, the actualvolume of each British Imperial unit-of-measure differs from itsU.S. counterpart.The U.S. fluid ounce is larger than the BritishImperial fluid ounce. However, the U.S. pint, quart, and gallonare smaller than the British Imperial pint, quart, and gallon,respectively. Should you need to convert from U.S. units toBritish Imperial units (or vice versa), refer to the following:

• fluid ounces (U.S.) x 1.042 = fluid ounces (Imp.)

• pints (U.S.) x 0.833 = pints (Imp.)

• quarts (U.S.) x 0.833 = quarts (Imp.)

• gallons (U.S.) x 0.833 = gallons (Imp.)

• fluid ounces (Imp.) x 0.960 = fluid ounces (U.S.)

• pints (Imp.) x 1.201 = pints (U.S.)

• quarts (Imp.) x 1.201 = quarts (U.S.)

• gallons (Imp.) x 1.201 = gallons (U.S.)

C-2 2008 VRSC Diagnostics: Appendix C Conversions


C.3TORQUE CONVERSIONS

UNITED STATES SYSTEMThe U.S. units of torque, foot pounds and inch pounds, areused in this service manual.To convert units, use the followingequations:

• foot pounds (ft-lbs) X 12.00000 = inch pounds (in-lbs).

• inch pounds (in-lbs) X 0.08333 = foot pounds (ft-lbs).

METRIC SYSTEMAll metric torque specifications are written in Newton-meters(Nm). To convert metric to United States units and UnitedStates to metric, use the following equations:

• Newton meters (Nm) X 0.737563 = foot pounds (ft-lbs).

• Newton meters (Nm) X 8.85085 = inch pounds (in-lbs).

• foot pounds (ft-lbs) X 1.35582 = Newton meters (Nm).

• inch pounds (in-lbs) X 0.112985 = Newton meters (Nm).

2008 VRSC Diagnostics: Appendix C Conversions C-3


C-4 2008 VRSC Diagnostics: Appendix C Conversions

NOTES


SUBJECT............................................................................................................................PAGE NO.D.1 GLOSSARY..............................................................................................................................D-1

AP

PE

ND

IX D

GL

OS

SA

RY


NOTES


D.1GLOSSARY

ACRONYMS AND ABBREVIATIONS

Table D-1. Acronyms and Abbreviations

DESCRIPTIONACRONYM OR ABBREVIATION

AmperesA

Alternating CurrentAC

AccessoryACC

Automatic Compression ReleaseACR

Absorbed Glass Mat (battery)AGM

AmpereAMP

American Wire GaugeAWG

Battery VoltageB+

Bank angle sensorBAS

Before Top Dead CenterBTDC

Celsius (Centigrade)C

CaliforniaCA

CalibrationCAL

Cubic CentimetersCC

Cold Cranking AmpsCCA

Crankshaft PositionCKP

Centimetercm

Direct CurrentDC

Data Link ConnectorDLC

DomesticDOM

Diagnostic Trouble CodeDTC

Digital Volt Ohm MeterDVOM

Electronic Control ModuleECM

Engine Coolant TemperatureECT

Electrically Erasable Programmable Read Only MemoryEEPROM

Electronic Fuel InjectionEFI

Engine TemperatureET

Evaporative Emissions Control SystemEVAP

FahrenheitF

Foot-Poundsft-lbs

Fluid Ouncefl oz.

Gramg

GallonGAL

Gross Axle Weight RatingGAWR

Ground (electrical)GND

Gross Vehicle Weight RatingGVWR

Harley-Davidson InternationalHDI

Harley-Davidson Smart Security SystemH-DSSS

Hands Free Security ModuleHFSM

MercuryHg

Idle Air ControlIAC

2008 VRSC Diagnostics: Appendix D Glossary D-1


Table D-1. Acronyms and Abbreviations

DESCRIPTIONACRONYM OR ABBREVIATION

Intake Air TemperatureIAT

Inside DiameterID

Ignition Light/Key SwitchIGN

Instrument ModuleIM

InchIn.

Injector Pulse WidthINJ PW

Inch-Poundsin-lbs

KilogramKg

KilometerKm

KilopascalkPa

Kilometers Per Hourkm/hr

LiterL

Liquid Crystal DisplayLCD

Light Emitting DiodeLED

MilliamperemA

Manifold Absolute PressureMAP

milliliterml

millimetermm

Miles Per HourMPH

millisecondms

Newton-MeterNm

Not ApplicableN/A

Numberno.

OxygenO2

Outside DiameterOD

Original Equipment ManufacturerOEM

Ounceoz

Parts and AccessoriesP&A

Part NumberPN

Pounds per Square InchPSI

ReserveRES

Revolutions Per MinuteRPM

Cubic Feet per Hour at Standard ConditionsSCFH

Top Dead CenterTDC

Twist Grip SensorTGS

Throttle PositionTP

Intake Air Temperature/Manifold Absolute PressureTMAP

Turn Signal ModuleTSM

Turn Signal/Security ModuleTSSM

VoltV

Volts of Alternating CurrentVAC

Volts of Direct CurrentVDC

Vehicle Identification NumberVIN

Vehicle Speed SensorVSS

D-2 2008 VRSC Diagnostics: Appendix D Glossary


SUBJECT............................................................................................................................PAGE NO.E.1 TSM/TSSM (JAPAN/KOREA) OVERVIEW...............................................................................E-1E.2 TSM/TSSM FEATURES............................................................................................................E-3E.3 TSM/TSSM VEHICLE DELIVERY.............................................................................................E-5E.4 TSM/TSSM TURN SIGNAL FUNCTIONS................................................................................E-9E.5 TSM/TSSM BANK ANGLE FUNCTION..................................................................................E-10E.6 SECURITY SYSTEM FUNCTIONS: TSSM............................................................................E-11E.7 ARMING/DISARMING: TSSM................................................................................................E-14E.8 DIAGNOSTIC TROUBLE CODES (DTC)...............................................................................E-16E.9 INITIAL DIAGNOSTIC CHECK: TSM/TSSM..........................................................................E-19E.10 INSTRUMENT MODULE (IM) SELF DIAGNOSTICS...........................................................E-22E.11 BREAKOUT BOX: TSM/TSSM..............................................................................................E-24E.12 FAILS TO DISARM...............................................................................................................E-25E.13 TURN SIGNAL ERRORS: B1121, B1122, B1141................................................................E-28E.14 DTC B0563...........................................................................................................................E-39E.15 DTC B1131, B1132...............................................................................................................E-40E.16 DTC B1134...........................................................................................................................E-43E.17 DTC B1135...........................................................................................................................E-46E.18 DTC B1154, B1155...............................................................................................................E-47E.19 DTC U1016...........................................................................................................................E-50E.20 DTC U1300, U1301 OR BUS ER.........................................................................................E-53E.21 PASSWORD LEARN............................................................................................................E-54E.22 TSSM MAINTENANCE.........................................................................................................E-55

AP

PE

ND

IX E

TS

M/T

SS

M (

JAPA

N/K

OR

EA

)


NOTES


E.1TSM/TSSM (JAPAN/KOREA) OVERVIEW

GENERAL

TSMThe Turn Signal Module (TSM) has two major functions:

• Control turn signals.

• Serve as Bank Angle Sensor (BAS).

TSSMSee Figure E-1.The optional, factory-installed, Harley-DavidsonFactory Security System (H-DFSS) includes a Turn SignalSecurity Module (TSSM) which provides the same functionsas the TSM, but also includes security and immobilizationfunctions.

sm01275

Figure E-1.TSSM (Japan/Korea)

ed03023

Figure E-2.TSM/TSSM Location

TROUBLESHOOTINGProblems fall into at least one of five categories:

• Turn signal malfunction.

• Bank angle (engine disable).

• Clutch/neutral interlock (starter enable).

• Security lamp problem.

• Security system malfunction.

To resolve TSM/TSSM problems, four basic steps are involved.In order of occurrence, they are:

1. Retrieve Diagnostic Trouble Codes (DTCs) using instru-ment module self-diagnostics. See E.10 INSTRUMENTMODULE (IM) SELF DIAGNOSTICS.

2. Diagnose system problems. This involves using specialtools and the diagnostic flow charts in this section.


4. After repairs are performed, the work must be validated.This involves clearing the DTCs and confirming propervehicle operation as indicated by the behavior of the turnsignals.

2008 VRSC Diagnostics: Appendix E TSM/TSSM (Japan/Korea) E-1


Battery

+ -

SecurityFuse

IGN Fuse

ACC Fuse

1 2 3 4

12

4

7

8

2

1

3

12

4 Neutral switch

Serial data

Right turn switchinput

Left turn switchinput

Ignition

Battery

Alarm signal

Clutch switch

Start relay control

Left turn feed

Right turn feed

Ground

7

8

2

1

3

22

6

5

9

30

87

86

85

10

11

6

5

9

10

11

40 AmpMAXIFUSE

[30B] [30A]

[142B] [142A]

[78A]

[166A][166B]

[78B]

[39A][39B]

[30A] [30B]

FuseBlock

IgnitionSwitch

Data LinkConnector

InstrumentModule

Right TurnSwitch

StartRelay

StarterSolenoid

EngineStop Switch

StartSwitch

ClutchSwitch

Smart Siren(Optional)

Tobatterypositive

Toignitionswitch

Toignition

fuse

ToECM

Left TurnSwitch

NeutralSwitch

TSM/TSSM

Right TurnLamps

Left TurnLamps

BK

BN

BN

BN

BN BN

BK BK

BK

BK

BK

GN

BK

GY

BK

BK

BK

BK

GY

TN

R

V

V V

V V

RR

R

R/BK

R/GY

W/BN

R/BK

W/BK

BK

/R

BK/R

BN/GY

LGN/V

TN/GN

BK/GN

LGN/BNLG

N/V

LGN

/V

LGN

/V

LGN

/V

5

5

Ser

iald

ata

9

9

Ser

iald

ata

7

7

Ser

iald

ata

ECM

W/V

O/W

O/W

BK

/GN

ABSModule

em00077

Figure E-3. Simplified TSM/TSSM Wiring

E-2 2008 VRSC Diagnostics: Appendix E TSM/TSSM (Japan/Korea)


E.2TSM/TSSM FEATURES

GENERALThe Turn Signal Module (TSM) and the Turn Signal SecurityModule (TSSM) provide the following capabilities.

TURN SIGNAL FUNCTIONS

TSSM/TSSM FeaturesSee E.4 TSM/TSSM TURN SIGNAL FUNCTIONS for completedetails.

• Manual turn signal control: Manual activation/deactiva-tion of left and right turn signal flashing sequences.

• Automatic turn signal cancellation: Automatic cancella-tion of left and right turn signal flashing sequences basedon either vehicle speed, vehicle acceleration or turn com-pletion.

• Emergency flashers: Four-way left and right turn signalflashing capability.

• Turn signal lamp diagnostics: Self-diagnostics for shortcircuit and open lamp conditions on both left and right turnsignal systems.

BANK ANGLE FUNCTIONSee E.5 TSM/TSSM BANK ANGLE FUNCTION for completedetails.

• Emergency engine shutdown: Will provide engineshutdown when vehicle is tipped over.

• Emergency outputs disable: Will disable turn signallamps and starter motor when vehicle is tipped over.

CLUTCH/NEUTRAL INTERLOCKFUNCTIONS

TSM/TSSM Features• Disables starter: Disables starter until either the clutch

lever is pulled in or transmission neutral is selected.

• Diagnostics: Provides diagnostics for clutch and neutralswitch faults.

SECURITY ALARM AND IMMOBILIZATIONFUNCTIONS

TSSM FeatureThe following information applies only to motorcycles with thesecurity option (TSSM). See E.6 SECURITY SYSTEMFUNCTIONS: TSSM for more information.

• Remote arming/disarming: See Figure E-4. Owners mayenable and disable security alarm and immobilizationfunctions with a personally carried transmitter. This trans-mitter is referred to as a key fob. Remote arming/dis-arming is a function of the TSSM (Japan/Korea) only.

• Security lamp (key icon): See Figure E-5. A lamp withinthe speedometer face tells the rider if the system is armedor disarmed.

• PIN disarming: If a key fob is not available, the TSSMallows the rider to disable the security alarm and immobil-

ization functions if the rider knows the previously enteredpersonal identification number (PIN).

• Arming/disarming confirmation: When the TSSM isarmed, the system provides visual feedback to the riderby flashing the turn signals and sounding the optionalSmart Siren.

• Auto-arming: Automatically enables the security alarmand immobilization functions within 30 seconds after theIgnition Switch is switched OFF.

NOTE

Motorcycles sold with a TSSM have auto-arming disabled, butit can be activated. See E.3 TSM/TSSM VEHICLE DELIVERY.

• Transport mode: It is possible to arm the security systemwithout enabling the motion detector for one ignition cycle.This allows the vehicle to be moved in an immobilizedstate.

• Starter/ignition disable: If the security alarm andimmobilization functions be triggered by a vehicle securitycondition, the starter and ignition system will be disabled.

• Security system alarm: See Figure E-6. The system willalternately flash the left and right turn signals and soundan optional Security Siren if a vehicle security conditionis detected while the system is armed.

ed03007

Figure E-4. Key Fob:TSSM



MPH

010

20

RPM

109

1 0

3040

5060 70 80 90

100110

120

130

140

150

ABSF

ed01354

Figure E-5. Security Lamp (Key Icon): VRSC Models

ed02047

Figure E-6. Security Siren



E.3TSM/TSSM VEHICLE DELIVERY

GENERALSetting up a vehicle TSM/TSSM depends on whether thevehicle has a Turn Signal Module (TSM) or the optional securitysystem (TSSM) installed. If a motorcycle is equipped with aTSM, no further configuration is required.

However, if a motorcycle has an optional security system(TSSM) installed, perform the following steps as necessary.

1. Configure TSSM motorcycles by assigning both key fobsto the vehicle. See E.3 TSM/TSSM VEHICLE DELIVERY,Key FOB Assignment: TSSM

2. Configure TSSM motorcycles by entering a PersonalIdentification Number (PIN) picked by the customer. ThePIN allows the customer to operate the system if the keyfob is lost or inoperable. Record this PIN in the Owner'sManual and instruct the customer to carry a copy.

CONFIGURING A TSSMNOTE

Do not forget to enter a Personal Identification Number (PIN)for TSSM motorcycles. If a PIN is not assigned and both keyfobs are lost or damaged while the motorcycle is armed, theTSSM must be replaced.

Changes to TSSM settings are made by a series of program-ming operations involving the ignition key, left/right turn signalswitches and key fob (security systems).

At certain steps in the programming sequence, the motorcyclemay provide confirmation of settings by flashing the turn sig-nals, turn signal indicators and/or security lamp. In addition,when programming a PIN into a TSSM system, the odometerdisplays the PIN to the user and dynamically updates it as thecode is entered or changed.

All programming operations are listed in table format. Followthe numbered steps to configure the system. If a confirmation

response is listed, wait for the confirmation before continuingto the next step. Important information pertaining to certainactions will be found in the NOTES column.

POWER DISRUPTION AND CONFIGURINGThe TSM/TSSM will not enter configuration mode on the firstattempt after battery voltage has been removed from terminal"1". This will occur after any of the following situations:

• Battery disconnect or power drain.

• Battery fuse removal.

• Connecting Breakout Box to TSM/TSSM connector.

Therefore, after all battery reconnects, the configurationsequence must be modified as follows.

1. Set run switch to OFF, cycle ignition/headlamp switchON-OFF-ON-OFF-ON and press left turn signal switchtwice.

2. Repeat step listed above.

3. Continue with configuration sequence listed.

KEY FOB ASSIGNMENT:TSSMRefer to Table E-1 to assign a key fob to a motorcycle equippedwith a TSSM.

The key fob on TSSM motorcycles must be set so it will operatethe alarm system on the vehicle. This assignment must becompleted with no pauses between steps greater than 10seconds. Turn the ignition OFF after all key fobs have beenassigned. The programming mode will also exit after 60seconds has elapsed without detecting any fob sign-up mes-sages or turn signal switch activity.

Two key fobs may be assigned to the TSSM. The first suc-cessful attempt to program a fob will disable all previouslyassigned fobs. If a second fob is to be programmed, it mustbe done in the same programming sequence as the initial fob.

Table E-1. Key FOB Assignment:TSSM

NOTESWAIT FOR CONFIRMATIONACTIONNO.

Verify the security lamp is notflashing (vehicle is disarmed)

Set RUN/OFF to OFF1

This assignment proceduremust be completed with nopauses between stepsgreater than 10 seconds

Turn ignition/headlamp switchON-OFF-ON-OFF-ON

2

One flash - Worldwide TSM,no security

One to four flashes turn signals andindicators depending on vehicle config-uration

Press left turn switch 2 times andrelease

3

Two flashes - Japan/Koreaconfiguration TSSM(See E.3 TSM/TSSM VEHICLE

DELIVERY regarding battery discon-nects.)

One flash turn signals and indicatorsPress right turn switch 1 time andrelease

4

Two flashes turn signals and indicatorsPress left turn switch 1 time andrelease

5



Table E-1. Key FOB Assignment:TSSM


This may take 10-25seconds.

Two flashes turn signals and indicatorsPress and hold key fob button untilconfirmation is received

6

Optional stepTwo flashes turn signals and indicatorsIf you have two key fobs, press andhold button on second key fob untilconfirmation is received

7

Turn ignition/headlamp switch OFF8

PIN ENTRY:TSSMNOTE

Do not forget to enter a Personal Identification Number (PIN)for TSSM vehicles. If a PIN is not assigned and the key fob islost or damaged while the vehicle is armed, the TSSM mustbe replaced.

The TSSM PIN consists of five digits. Each digit can be anynumber from 1-9. There can be no zeros (0) in the PIN. ThePIN must be used to disarm the security system in case thekey fob becomes unavailable.

Refer to Table E-2 to enter an initial PIN with no PIN previouslyinstalled. The procedure listed uses 3-1-3-1-3 as the desiredPIN.

NOTE

For better security, do not use 3-1-3-1-3 as a PIN. It is shownas an example only.

Decide what five-digit PIN the owner would like to use. Thecode will be programmed using the turn signal switches and

key fob. Keep a record of the PIN in a secure place such asyour wallet or the Owner's Manual.

• When programming the PIN, the security lamp flashes toprovide feedback when entering each digit.The odometeralso displays the PIN and the change dynamically.

• The number of security lamp flashes corresponds to thenumber currently selected for a given digit. Therefore, thelamp may flash 1-9 times depending on the numberentered. The five-digit PIN will change in the odometerwindow and the active digit will blink.

• Press the left turn switch one time to increment each digit.

• Quickly press the key fob button twice to advance to thenext digit.

NOTE

The programming mode exits upon turning the ignition switchto OFF, or if no turn signal switch/key fob button activity occursfor 60 seconds. No data is saved for partial configurationattempts if entering a PIN for the first time. If a PIN has previ-ously been entered, the user can change any digit or group ofdigits.

Table E-2. Entering an Initial TSSM PIN (Example: 3-1-3-1-3) with No PIN Previously Entered


Verify thet security lamp is notflashing (vehicle is disarmed)

Set RUN/OFF switch to OFF1

This assignment proceduremust becompleted with no pauses betweensteps greater than 10 seconds

Turn IGN key ON-OFF-ON-OFF-ON2

One flash - Worldwide TSM, nosecurity

One to four flashes turn signals andindicators depending on vehicleconfiguration


3

Two flashes - Japan/Korea configur-ation TSSM(See E.3 TSM/TSSM VEHICLE

DELIVERY regarding battery discon-nects)

Vehicle is in PIN entry mode readyto enter or modify first digit

One flash turn signals and indicatorsOdometer displays current five-digitPIN (five dashes if no code entered),first digit flashes

Quickly press key fob button 2times and release

4

A lack of confirmation flashes indic-ates no digit entered

Security lamp flashes 1 - 9 times ifcode was previously entered

Press left turn switch 1 time andrelease

5





You have selected 3 as a numberfor the first digit

Blinking digit in odometer displayincrements, security lamp flashes toindicate each digit selected

Press and release left turn switchto advance through the digitsIn this example, you will press andrelease three times

6

In this example, the blinking digitdisplayed is 3 and the security lampwill flash three times

You have confirmed 3 as a numberfor the first digit and have advancedto entering the second digit

Two flashes turn signals and indic-ators second digit in odometer dis-play blinks


7


NonePress left turn switch 1 time andrelease

8

You have selected 1 as a numberfor the second digit


Press and release left turn switchto advance through the digitsIn this example, you will perform thisstep one time

9

In this example, the blinking digitdisplayed is 1 and the security lampwill flash one time

You have confirmed 1 as a numberfor the second digit and haveadvanced to entering the third digit

Three flashes turn signals andindicators third digit in odometerdisplay blinks


10



11

You have selected 3 as a numberfor the third digit


Press and release left turn switchto advance through the digitsIn this example, you will repeat thisstep three times

12


You have confirmed 3 as a numberfor the third digit and have advancedto entering the fourth digit

Four flashes turn signals and indic-ators fourth digit in odometer displayblinks


13



14

You have selected 1 as a numberfor the fourth digit


Press and release left turn switchto advance through the digitsIn this example, you will perform thisstep one time

15

In this example, the blinking digitdisplayed is 1 and the security lampwill flash one time

You have confirmed 1 as a numberfor the fourth digit and haveadvanced to entering the fifth digit

Five flashes turn signals and indic-ators fifth digit in odometer displayblinks


16



17

You have selected 3 as a numberfor the fifth digit


Press and release left turn switchto advance through the digitsIn this example, you will repeat thisstep three times

18


You have confirmed 3 as a numberfor the fifth digit and have gone backto the first digit

One flash turn signals and indicatorsfirst digit in odometer display blinks


19

Turn IGN key OFF20





Write down code in Owner's Manual21

Arm the security system and attemptto disarm using PIN entry. Refer toTable E-8.

22

CHANGING THE PIN:TSSMIf a PIN has been previously entered, the security lamp willflash the equivalent digit, and the odometer will display the

existing PIN with the active digit blinking. Each additional pressof the left turn switch will increment the digit.

• To advance from 5 to 6, press and release the left turnswitch 1 time.

• To advance from 8 to 2, press and release the left turnswitch 3 times (9-1-2).



E.4TSM/TSSM TURN SIGNAL FUNCTIONS

GENERALThe TSM/TSSM turn signal feature has several modes:

• Automatic cancellation.

• Manual cancellation.

• Four-way flashing.

• Diagnostics mode.

The turn signals cannot be activated or deactivated when theIgnition Switch is in the ACC position. The turn signals canonly be activated or deactivated with the Ignition Switch in theIGNITION position.

AUTOMATIC CANCELLATIONPress the left or right turn switch to activate automatic turnsignal cancellation. There is no need to hold the turn switch inwhen approaching the turn. The TSM/TSSM will not cancelthe signal before the turn is actually completed.

• When the directional switch is released, the system startsa 20 count. As long as the vehicle is traveling above 11km/h (7 MPH) he directional will always cancel after 20flashes if the system does not recognize any other input.

• If the vehicle speed drops to 11 km/h (7 MPH) or less,including stopped, the directionals will continue to flash.Counting will resume when vehicle speed reaches 12.9km/h (8 MPH) and will automatically cancel when the counttotal equals 20 as stated above.

• The turn signals will cancel within two seconds upon turncompletion. A sensor inside the TSM/TSSM cancels thesignal after the vehicle has been returned to an uprightposition.

NOTE

The bank angle cancellation function has an automatic calibra-tion feature. Ride the motorcycle for 0.4 km (0.25 mile) atsteady speeds (upright) to calibrate the system. Performanceof bank angle function may not be optimal until this calibrationis performed. This self-calibration is performed automaticallyevery time the vehicle is started and ridden.

MANUAL CANCELLATIONIf you want to stop the turn signals from flashing, briefly depressthe turn signal switch a second time.

If you are signalling to turn in one direction and you depressthe switch for the opposite turn signal, the first signal is can-celled and the opposite side begins flashing.

FOUR-WAY FLASHINGUse the following method to activate the four-way flashers:

1. With the Ignition Switch ON and the security system dis-armed (models with security only), press the left and rightturn signal switches at the same time.

2. Turn the Ignition Switch OFF and arm the security systemif present and desired.The four-way flashers will continuefor two hours.

3. To cancel four-way flashing, disarm the security systemif necessary, turn the Ignition Switch ON and press theleft and right turn signal switches at the same time.

This system allows a stranded vehicle to be left in the four-wayflashing mode and secured until help is found.

If the security system is disarmed while the four-way flashersare active, the lights will flash as follows:

1. TSSM stops four-way flashing mode. Motorcycle sits for1 second with turn signals off.

2. TSSM performs disarming confirmation (1 flash).

3. Motorcycle sits for 1 second with turn signals off.

4. Motorcycle restarts four-way flashing mode.

DIAGNOSTICS MODEThe TSM/TSSM measures the current when the turn signalsare used. If there is a burned out light bulb on one side, theremaining light and the corresponding turn signal indicator flashat double the normal rate starting with the fifth flash.

Other diagnostic conditions monitored include:

• Short circuit in the turn signal wiring.

• Open circuit in the turn signal wiring.

• Stuck turn signal switch.

NOTES

• A stuck turn signal switch will disable the automatic turnsignal cancellation feature.

• If a stuck switch is detected, you must hold the left andright turn signal switches in for more than one second toactivate the four-way flashers.

See E.8 DIAGNOSTIC TROUBLE CODES (DTC) for moreinformation.



E.5TSM/TSSM BANK ANGLE FUNCTION

GENERALThe turn signals, starter motor, Electronic Control Module(ECM), fuel pump, and coil will be disabled in the event thevehicle is tipped over.

OPERATIONThe engine will shut off automatically if the vehicle is tippedover. The odometer displays "tIP" when a tip-over condition isdetected.

To restart the motorcycle after shutdown has occurred:

1. Return the motorcycle to an upright position.

2. Cycle the Ignition Switch OFF-ON before restarting.

3. Restart the vehicle.



E.6SECURITY SYSTEM FUNCTIONS:TSSM

GENERAL

Security System OperationThe TSSM provides security and immobilization functions notfound on the TSM. The TSSM will disable the starter and igni-tion system. Additional functions include the ability to alternatelyflash the left and right turn signals and sound a siren (ifequipped) if a theft attempt is detected.

Conditions that activate the security system when system isarmed include:

• Detecting tampering of the ignition circuit: Turn signalsflash three times, optional siren chirps once and then turnsoff. If the tampering continues, a second warning willactivate after four seconds. Continued tampering will causethe alarm to activate for 30 seconds and then turn off.Thetwo warnings/alarm cycle is repeated for each tamperingincident.

• Detecting vehicle movement: Turn signals flash threetimes, optional siren chirps once and then turns off. If thevehicle is not returned to its original position, a secondwarning will activate after four seconds. If the vehicle isnot returned to its original position, the alarm activates for30 seconds then turns off. The two warnings/alarm cyclemay repeat a maximum of 10 times with a 10 secondpause between alarm cycles.

• Detecting that a battery or ground disconnect hasoccurred while armed: Siren, if installed, activates itsself-alarm mode. Turn signals will not flash.

See E.7 ARMING/DISARMING: TSSM for more information.

NOTE

Always disarm the TSSM before removing or disconnectingthe battery to prevent the siren (if installed) from activating. Ifthe TSSM is in auto-arming mode, you must disarm the systemand disconnect the battery or remove the battery fuse beforethe 30 second arming period expires.

Security System Options:TSSMThe following options are only available on the TSSM unit:alarm sensitivity, auto-arming feature, and storage mode.

Default settings for the TSSM include:

• Solo vehicle configuration.

• Medium motion sensitivity on alarm sensitivity.

• All vehicles are shipped with auto-arming disabled.

• Storage mode set to 10 days.

ALARM SENSITIVITY:TSSM

SensitivityThe TSSM has four sensitivity settings: extremely low, low,medium or high. The selection chosen controls the sensitivityof the security system regarding motion detection.

To set alarm sensitivity, refer to Table E-3.

Transport ModeIt is possible to arm the security system without enabling themotion detector for one ignition cycle. This allows the vehicleto be picked up and moved in an armed state. In this mode,any attempt to hot-wire the vehicle will trigger the securitysystem.

• To enter the transport mode, refer to Table E-4.

• To exit from transport mode and return the system tonormal operation/functions, disarm the system using eitherthe key fob or Personal Identification Number (PIN).

NOTE

Transport mode is especially useful when working on themotorcycle. If it is not used, the alarm will activate under manytypical service activities.

Table E-3.TSSM Alarm Sensitivity





Two flashes - Japan/Korea configur-ation TSSM

Two flashes turn signals and indic-ators depending on vehicle configur-ation


3

(See E.3 TSM/TSSM VEHICLEDELIVERY regarding battery discon-nects.)

One flash turn signals and indicatorsPress and hold key fob button untilconfirmation is received

4

One flash - extremely lowTurn signals and indicators flash toindicate option selected


5Two flashes - low sensitivityThree flashes - medium sensitivityFour flashes - high sensitivity



Table E-3.TSSM Alarm Sensitivity


One flash - extremely lowTurn signals and indicators flash toindicate option selected

Press and release left turn switchto advance through options

6Two flashes - low sensitivityThree flashes - medium sensitivityFour flashes - high sensitivity

Turn IGN key OFF7

Table E-4.Transport Mode:TSSM



Set OFF/RUN switch to OFF1

Turn IGN key ON2

Three flashes turn signals andindicators

Press and hold key fob button untilconfirmation is received

3

Turn IGN key OFF4

The vehicle can be moved withouttripping the alarm



5

AUTO-ARMING FUNCTION:TSSMAuto-arming causes the system to automatically arm itself (nokey fob needed) within 30 seconds after the Ignition Switch isturned OFF. During this period, the security lamp stays illumin-ated to indicate auto-arming is starting up.

The vehicle may be moved during these 30 seconds withouttriggering the alarm. However, any motion after that period willtrigger the security alarm. Upon expiration of the auto-armingperiod, the turn signals flash twice, the security lamp beginsto flash and the siren (if equipped) chirps twice.

The TSSM allows remote arming via the key fob at any time.However, if the system is remotely disarmed (with the key fob)but the Ignition Switch is not turned ON within 30 seconds, thesystem will rearm itself when auto-arming is enabled.

Japan and Korea motorcycles have auto-arming disabled bydefault. However, the feature may be enabled if the customerdesires.

When auto-arming is disabled, the key fob must be used toarm the security system.To set the auto-arming function, referto Table E-5.

Table E-5. Selecting TSSM Auto-Arming Function






Two flashes turn signals and indic-ators (See E.3 TSM/TSSMVEHICLE DELIVERY regardingbattery disconnects.)


3


4

Two flashes turn signals and indic-ators


5

One flash - auto-arming disabledTurn signals and indicators flash toindicate option selected


6Two flashes - auto-arming enabled

Turn signals and indicators flash toindicate option selected

Press and release left turn switchto advance through options

7

Turn IGN key OFF8



STORAGE MODE:TSSMThe TSSM has a special mode for long term storage. Thismode prevents the security system from draining the batteryafter a period of days (10, 20, 60 or infinite) without any IgnitionSwitch activity.

• If the TSSM is set to infinite, the system will not go intostorage mode.

• Vehicles will enter storage mode whether the securitysystem is armed or disarmed.

• If set to 20 days or greater, the customer must use anapproved trickle charger to keep the battery from dischar-ging.

In storage mode, all alarm functions remain active but thereceiver is shut down and will not respond to the key fob. Thevehicle is immobilized because the starter motor and ElectronicControl Module (ECM) are disabled. When the storage modeis entered, the security lamp stops flashing to conserve power.

To wake up the TSSM from storage mode, the Ignition Switchmust be turned ON. This will trigger a warning/alarm if thesystem was previously armed. You must use the key fob orPIN to disarm the system and stop the alarm.

To set the storage mode preferences, refer to Table E-6.

Table E-6. Storage Mode Preferences:TSSM






Two flashes turn signals and indic-ators depending on vehicle configur-ation


3

(See E.3 TSM/TSSM VEHICLEDELIVERY regarding battery discon-nects.)


4

Two flashes turn signals and indic-ators

Release and then hold key fobbutton until confirmation is received

5


Release and then hold key fobbutton until confirmation is received

6

One flash - 10 daysTurn signals and indicators flash toindicate option selected


7Two flashes - 20 daysThree flashes - 60 daysFour flashes - Infinite

One flash - 10 daysTurn signals and indicators flash toindicate option selected

Press left turn switch to advancethrough options

8Two flashes - 20 daysThree flashes - 60 daysFour flashes - Infinite

Turn IGN key OFF9



E.7ARMING/DISARMING:TSSM

GENERALThere are two methods to arm the security system:

• Using the key fob.

• Using auto-arming. See E.6 SECURITY SYSTEMFUNCTIONS: TSSM.

NOTE

The vehicle cannot be armed with the ignition ON.

There are two ways to disarm the system:

• Using the key fob. This method works in all situationsexcept before turning Ignition Switch ON when TSSMstorage mode is activated.

• Using a Personal Identification Number (PIN).

SECURITY LAMPRefer to Table E-7. The security lamp within the speedometerprovides feedback to the rider confirming armed or disarmedstatus.

Table E-7. Security Lamp Status:TSSM

MODELAMP

No security system (TSM),security system not armed orstorage mode active

Does not flash

10 minute timeout after failedPIN entry attempt or a batteryreconnect has occurred whilearmed

Flashes every second

Security system armedFlashes every 2 seconds

PIN entry modeFlashes 4 times a second

Auto-arming is starting up.You have 30 seconds beforesystem is armed

Stays illuminated with Ignitionkey OFF

If solid for more than 4seconds after key ON, a cur-rent DTC is present

Stays illuminated with Ignitionkey ON

USING KEY FOB:TSSM

GeneralThe TSSM reception range for the key fob signal depends ona specific receiver pattern.

NOTE

Environmental and geographic conditions may affect signalrange.

Arming the System1. Hold key fob horizontal at waist level.

2. Point key fob at the front of the vehicle.

3. Hold down the key fob button until the system respondswith two turn signal flashes.

Disarming the System1. Hold key fob horizontal at waist level.

2. Point key fob at the front of the vehicle.

3. Quickly press the key fob button twice. The system willrespond with one turn signal flash.

NOTE

Disarming function may require practice. The key fob buttonmust be pressed twice within 1.5 seconds to send the disarmcommand. The action is very similar to double-clicking a com-puter mouse. Light quick taps work best; very hard or very slowtaps are less likely to work.

TroubleshootingIf the key fob button has been pressed numerous times whileaway from the vehicle, the fob may fall out of synchronizationwith the TSSM. If this happens, the TSSM might fail to recog-nize the key fob's commands.

To solve this problem, press and hold the key fob button for10-15 seconds until the security system responds with two turnsignal flashes. After confirmation, you may resume normal foboperation.

USING THE PIN

GeneralThe Personal Identification Number (PIN) consists of five digitsentered using the left and right turn signal switches. Each digitcan be any number from 1-9. The PIN is intended to be usedto disarm the motorcycle in case the key fob becomesunavailable or inoperable.

See E.3 TSM/TSSM VEHICLE DELIVERY to set a PIN.

Disarming the SystemRefer to Table E-8. If you make an error while disarming theTSSM using a PIN, the alarm will activate for 30 seconds afterthe last digit is entered. After a failed attempt, the security lampwill flash once every second for 10 minutes. During this time,the vehicle will not accept any attempt to enter a PIN.

Table E-8. Disarming TSSM with the PIN (Example: 3-1-3-1-3)



Turn IGN key to ACC2

System is ready for PIN entrySecurity lamp flashes at fast rateHold both turn switches in until confirm-ation

3



Table E-8. Disarming TSSM with the PIN (Example: 3-1-3-1-3)


Enter first digit of code (3) by pressingleft turn switch 3 times

4

Serves as "enter" key for firstdigit

Press right turn switch 1 time5

Enter second digit of code (1) bypressing left turn switch 1 time

6

Serves as "enter" key forsecond digit


Enter third digit of code (3) by pressingleft turn switch 3 times

8

Serves as "enter" key forthird digit


Serves as "enter" key forfourth digit

Enter fourth digit of code (1) bypressing left turn switch 1 time

10


System is disarmed. Youmay use the vehicle or pro-gram another key fob

Enter fifth digit of code (3) by pressingleft turn switch 3 times

12

Security lamps stop flashingPress right turn switch 1 time13



E.8DIAGNOSTIC TROUBLE CODES (DTC)

TSM/TSSMTo diagnose system problems, start by observing the behaviorof the security lamp.

NOTES

• See Figure E-7. "Key ON" means that the Ignition Switchis turned to IGNITION and the Engine Stop Switch is setto RUN (although the engine is not running).

• See Figure E-8. When the Ignition Switch is turned ON,the security lamp will illuminate for approximately fourseconds and then turn off.

• If the security lamp is not illuminated at Key ON or if it failsto turn OFF after the initial four second period, thespeedometer may need to be replaced. SeeE.10 INSTRUMENT MODULE (IM) SELF DIAGNOSTICS.If "BUS Er" is displayed on the odometer, it may take upto twenty seconds for the security lamp to illuminate.

• The security lamp will also light for eight seconds after thebulb check if historic diagnostic trouble codes (DTCs) arepresent. The security lamp will stay illuminated if currentDTCs are set. If a historic DTC is present, the securitylamp will light for 2 ignition cycles or until the DTC iscleared manually.

2

3

1

ed02991


Figure E-7. Ignition Switch

MPH

010

20

RPM

109

1 0

3040

5060 70 80 90

100110

120

130

140

150

ABSF

6

1 2

3 4

5

ed01267

4.1. Security lamp (keyicon)

Check engine lamp2. Low fuel lamp

5.3. ABSBattery lamp6. Trip odometer

reset switch

Figure E-8. Instrument Module

1. See Figure E-9. After the lamp turns off after being illumin-ated for the first four-second period, one of three eventsmay occur:

a. The lamp remains off. This indicates there are nocurrent fault conditions or stored historic DTCs cur-rently detected by the TSSM.

b. The lamp stays off for only four seconds and thenilluminates for an eight-second period. This indicatesa historic DTC is stored, but no current DTC exists.

c. If the lamp remains illuminated beyond the eight-second period, a current DTC exists.

2. See E.8 DIAGNOSTIC TROUBLE CODES (DTC), CodeTypes for a complete description of DTC formats.



ONA

B

C

ON

ON

OFF

OFF

OFF

Key On

Key On

Key On


Lamp OFF




4 Sec.

4 Sec.

4 Sec.

4 Sec.

8 Sec.

4 Sec.

ed01434

Figure E-9. Security Lamp Operation

CODE TYPES



There are two types of Diagnostic Trouble Codes (DTCs):current and historic. If a DTC is stored, it can be read usingeither a computer based diagnostic package called DIGITALTECHNICIAN (Part No. HD-44750) or instrument module self-diagnostics. See E.10 INSTRUMENT MODULE (IM) SELFDIAGNOSTICS.

NOTES

• To differentiate between current and historic diagnostictrouble codes a computer based diagnostic package calledDIGITAL TECHNICIAN (Part No. HD-44750) must beused.

• All DTCs reside in the memory of the ECM, TSM/TSSM,speedometer or tachometer until the DTC is cleared byuse of the instrument module self-diagnostics. SeeE.10 INSTRUMENT MODULE (IM) SELF DIAGNOSTICS.

• A historic DTC is also cleared after a total of 50 ignitioncycles has elapsed. After the 50 ignition cycles retentionperiod, the DTC is automatically erased from memoryproviding no subsequent faults of the same type aredetected in that period.

CurrentCurrent DTCs are those present during the current ignitioncycle. See the appropriate flow charts for solutions.

HistoricIf a particular problem happens to resolve itself, the activestatus problem is dropped and it becomes a historic DTC ratherthan a current DTC. For example, intermittent output shortscan become typical historic DTCs.

Historic DTCs can only be retrieved using a computer baseddiagnostic package called DIGITAL TECHNICIAN (Part No. HD-44750).

Historic DTCs are stored for 50 ignition cycles after any DTCwas last set as current to assist in diagnosing intermittent faults.On the 50th cycle, the DTC will clear itself. The security lampwill indicate the existence of only historic DTCs for just twoignition cycles.

It is important to note that historic DTCs will exist wheneverthe system indicates the existence of a current fault. SeeE.8 DIAGNOSTIC TROUBLE CODES (DTC), Multiple Dia-gnostic Trouble Codes if multiple DTCs are found.

Diagnostic charts are designed for use with current DTCs andas a result they frequently suggest part replacement. Whendiagnosing a historic DTC the charts can be helpful but shouldnot lead to part replacement without verifying the part is faulty.




The TSM/TSSM provides two levels of diagnostics.


• The second mode requires using the instrument moduleself-diagnostics. Speedometer, tachometer (if equipped),TSM/TSSM and ECM DTCs can be accessed and cleared.See E.10 INSTRUMENT MODULE (IM) SELF DIA-GNOSTICS.



MULTIPLE DIAGNOSTIC TROUBLE CODESWhile it is possible for more than one fault to occur and setmore than one DTC, there are several conditions which mayresult in one fault setting multiple DTCs:

Serial data DTCs (U1016, U1300 and U1301) may be accom-panied by other DTCs. Always correct the serial data DTCsbefore resolving the other DTCs.

Refer to Table E-9. This table gives most TSM/TSSM DTCs apriority ranking.

Table E-9.TSM/TSSM Diagnostic Trouble Codes (DTC) and Fault Conditions

SOLUTIONFAULT CONDITIONDTCRANKING

E.20 DTC U1300, U1301 OR BUS ERJ1850 short-to-groundU13001

E.20 DTC U1300, U1301 OR BUS ERJ1850 short-to-batteryU13012

E.19 DTC U1016Loss of serial communications - ECMU10163

E.19 DTC U1016Loss of serial communication - generalU12554

E.17 DTC B1135Accelerometer faultB11355

E.18 DTC B1154, B1155Clutch switch input short-to-groundB11546

E.18 DTC B1154, B1155Neutral switch input short-to-groundB11557

E.16 DTC B1134Start relay output short-to-groundB11348

E.13 TURN SIGNAL ERRORS: B1121, B1122, B1141Left turn lamp output faultB11219

E.13 TURN SIGNAL ERRORS: B1121, B1122, B1141Right turn lamp output faultB112210

E.14 DTC B0563Battery voltage highB056311

E.15 DTC B1131, B1132Alarm output short-to-groundB113112

E.15 DTC B1131, B1132Alarm output short-to-groundB113213

E.13 TURN SIGNAL ERRORS: B1121, B1122, B1141Ignition switch input short-to-ground oropen

B114114



E.9INITIAL DIAGNOSTIC CHECK:TSM/TSSM

GENERAL



To locate faulty circuits or other system problems, follow thediagnostic flow charts. For a systematic approach, always beginwith E.9 INITIAL DIAGNOSTIC CHECK: TSM/TSSM, InitialDiagnostics. Read the general information and then work yourway through the flow chart box by box.



In order to perform most diagnostic routines, a Breakout Boxand a digital volt/ohmmeter (DVOM) are required. SeeE.11 BREAKOUT BOX: TSM/TSSM.


Job/Time Code ValuesSome charts may contain warranty job/time codes. Dealershiptechnicians filing warranty claims should use the job/time codevalues printed in bold text underneath the appropriate repair.

Reprogramming ECMDiagnostic charts frequently suggest Electronic Control Module(ECM) replacement. In the event an ECM needs to be replaced,it must be reprogrammed using a computer-based diagnosticpackage called DIGITAL TECHNICIAN (Part No. HD-44750).See your dealer. Password learn procedure must also be per-formed. See 3.25 TSM/HFSM: PASSWORD LEARN.

INITIAL DIAGNOSTICS

Diagnostic Tips• If odometer reads "BUS Er" with the Ignition Switch turned

ON (Engine Stop Switch at RUN with the engine off), checkdata bus for an open or short to ground between data linkconnector [91A] terminal "3" and ECM connector [78B]terminal "5", TSSM connector [30B] terminal "3", speedo-meter connector [39B] terminal "2" or tachometer (ifequipped) connector [108B] terminal "2".

• Check for an open diagnostic test terminal between datalink connector [91A] terminal "3" and TSM/TSSM connector[30B] terminal "3". With Ignition Switch turned ON, serialdata bus voltage should be typically 0.6-0.8 volt.The rangeof acceptable voltage is 0-7.0 volts.

• To identify intermittents, wiggle vehicle harness whileperforming steps in the Diagnostic Check charts.


1. Compare TSM/TSSM system behavior to symptoms inTable E-10.

All TSM/TSSM diagnostic trouble codes (DTCs) are listed inTable E-9.

Table E-10. Symptoms That May Not Set Diagnostic Trouble Codes

SOLUTIONSYMPTOM

E.12 FAILS TO DISARMFails to disarm

E.13 TURN SIGNAL ERRORS: B1121, B1122, B1141Turn signal will not cancel or cancelserratically

E.13 TURN SIGNAL ERRORS: B1121, B1122, B1141Turn signal flashes double normal rate, allbulbs good

Other Diagnostic Trouble Codes (DTCs)See 2.4 INITIAL DIAGNOSTIC CHECK: IM for any DTCsrelated to the speedometer.

See 4.8 INITIAL DIAGNOSTIC CHECK for any DTCs relatedto the Electronic Control Module (ECM).



3

2

1

4

5

5

Ser

iald

ata

32 12

32

Igni

tion

Ser

iald

ata

Gro

und

12

7

7

6

6

5

5

1

1B

atte

ry

Rig

httu

rnG

roun

dS

eria

ldat

a

Tobattery

fuse


[39A][39B]

[30A][30B]

[78A][78B]

TSM/TSSM

Data LinkConnector

Toignition

fuse

ECM

[91A]

BK

/GN

BK

/GN

BK/GN

GY

GY

LGN

/V

LGN/V

GY

LGN

/V

LGN

/V

99Serial data

[166A] [166B]

ABS Module

LGN/V

R/O

em00078

Figure E-10. Diagnostic Check

Table E-11. Wire Harness Connectors





Under left side cover4-place DeutschData Link Connector[91A]

Under right side cover20-place MolexABS Module (If equipped)[166]



Initial Diagnostic Check

Does enginestart?


DTC’s found?


YES.Starts and

runs.

Is IMfunctional?


Refer to applicable DTC prioritychart. All DTC’s are listed in TableE-9. DTC’s are listed by priority.



codes, refer to Table E-10.Function Chart-Loss Of

Input.



B1008.

YES.Starts, then

stalls.


NO.Engine will not

crank.



1

YES NO

YES

NOYES

NO

fc01659_en



E.10INSTRUMENT MODULE (IM) SELF DIAGNOSTICS

GENERALThe Instrument Module (IM) is capable of displaying andclearing speedometer, tachometer, TSM/TSSM, and ECMDiagnostic Trouble Codes (DTCs) (diagnostic mode).

DIAGNOSTICS

Diagnostic Tips• For a quick check of speedometer function, a "WOW" test

can be performed. Press and hold trip odometer resetswitch then turn Ignition Switch to ACC. Release tripodometer reset switch. See Figure E-11. Backgroundlighting should illuminate, gauge needles should sweeptheir full range of motion, and indicator lamps (battery,security, low fuel, check engine and sixth gear) shouldilluminate. Some lamps may illuminate even though theydo not apply to the vehicle.

• If speedometer fails "WOW" test, check for battery, ground,ignition, odometer reset switch and accessory wiring tospeedometer. If any feature in the speedometer is non-functional, see 2.4 INITIAL DIAGNOSTIC CHECK: IM.

MPH

010

20

RPM

109

1 0

3040

5060 70 80 90

100110

120

130

140

150

ABSF

6

1 2

3 4

5

ed01267

4.1. Security lamp (keyicon)

Check engine lamp2. Low fuel lamp

5.3. ABSBattery lamp6. Trip odometer

reset switch

Figure E-11. Instrument Module



2. To clear DTCs for the selected module, press the tripodometer reset switch for more than 5 seconds when aDTC is displayed. This procedure will clear all DTCs forthe selected module.

2

3

1

ed02991


Figure E-12. Ignition Switch



Instrument Module Self-Diagnostics

1


RUN position.


YES

”P” flashing.





seconds.



Switch.

”S” flashing.



Switch.

”C” flashing.





than 5 seconds.




CHECK: SPEEDOMETER.

YES

YES

NO

NO

NO

Deviceresponse?

Press andrelease


displayed.

Press andrelease












SYSTEM (ABS)GENERAL

INFORMATION.


DTCdisplayed.


2

fc01596_en

”b” flashing.








E.11BREAKOUT BOX:TSM/TSSM

GENERAL



The BREAKOUT BOX (Part No. HD-42682) splices into themain harness. Used in conjunction with a digital volt/ohmmeter(DVOM), it allows circuit diagnosis of wiring harness and con-nections without having to probe with sharp objects.

INSTALLATION1. Disarm security.

2. Gain access to TSM/TSSM. See Service Manual.

3. Depress latches on connector [30B].

4. Attach Breakout Box to connector.

a. Mate gray socket housing on Breakout Box withTSM/TSSM connector [30A].

b. Mate gray pin housing on Breakout Box with harnessconnector [30B].

1

2

ed03008

1. Terminal 12. Terminal 12

Figure E-13.TSM/TSSM Connector Pins

ed03042

Figure E-14.TSM/TSSM Connector [30B] Location (typical)

REMOVAL1. Depress latches on connector [30B].

2. Detach gray Breakout Box connector from TSM/TSSMconnector [30A].

3. Detach gray Breakout Box connector from wire harnessconnector [30B].

4. Reinstall TSM/TSSM. See the Service Manual.

5. Install parts removed for access.

NOTE

Vehicle will not start with TSM/TSSM disconnected or incor-rectly mounted.

Table E-12.TSM/TSSM Connector [30B]


Right Turn Switch Input7Battery1

Left Turn Switch Input8Ignition2

Start Relay Control9Serial data3

Clutch Switch Interlock10Neutral switch interlock4

Alarm Signal11Left turn feed5

Ground12Right turn feed6



E.12FAILS TO DISARM

GENERAL

Security Equipped Vehicles OnlyThis section applies only to those vehicles equipped with theoptional security system (TSSM).

NOTE

Disarming function may require practice. The key fob buttonmust be pressed twice within 1.5 seconds to send the disarmcommand. The action is very similar to double-clicking a com-puter mouse. Light quick taps work best; very hard or very slowtaps are less likely to work.

The key fob sends a RF signal to activate all remote TSSMfunctions. The left front turn signal switch wire serves as thevehicle's antenna. If the TSSM does not respond (no confirm-ation at arming/disarming system) or responds weakly (limitedrange, won't consistently arm/disarm or synchronize), followthe flow chart.


ed03009

Figure E-15. Key Fob Battery:TSSM

DIAGNOSTICS

Diagnostic Tips• Verify key fob battery voltage is at least 2.9 volts. See

E.22 TSSM MAINTENANCE.

• Interference from physical surroundings may affect RFtransmission. Place fob next to left handgrip and disarmwith two clicks or move motorcycle to a new location andretest.

• Check for damage to antenna wire. Does left turn signalwork?

NOTE

See E.7 ARMING/DISARMING: TSSM. Use only the properkey fob for your market and TSSM package.


After a battery disconnect, the TSSM will not enter the config-uration mode on the first attempt. All attempts to assign a fobor enter the configuration mode will require at least twoattempts.



[24A]

[30B][30A]

[24B]

Key Fob Antenna(TSSM Only)

Left TurnSignalSwitch

Battery

40 AmpMAXIFUSE

15 AmpSecurity

Fuse

TSSM

5 5

1 8 12

1

Bat

tery

Left

turn

inpu

t

GN

D

8 12

W/V

W/V

BK

/GN

BN

/GY

RR

BK

– +

em00079

Figure E-16. Antenna Circuit



Under left side cover8-place MolexLeft hand controls and horn[24]

Under passenger seat12-place DeutschTSSM[30]



Fails to Disarm

Is the key fob correct for the vehicle?

YES NO

Obtain correct fob or replacefob. Verify fob is

synchronized to vehicle’sTSSM.

Does left turn signal function?

YES NO

See E.13 TURN SIGNALERRORS: B1121, B1122,

and B1141.

Replace fob battery and retest.See E.22 TSSM MAINTENANCE.

Does fob work?

YES NO

System OK.Attempt to assign new fob

to TSSM and retest.Does fob work?

YES NO

6757

fc01445_en

6755

Replace TSM/TSSM.Perform password learn

and setup.

System OK.

6756



E.13TURN SIGNAL ERRORS: B1121, B1122, B1141

GENERALThe turn signals will automatically cancel either based on thespeed/acceleration of the vehicle or based upon turn comple-tion. See E.4 TSM/TSSM TURN SIGNAL FUNCTIONS.

For turn signal diagnostics, refer to Table E-14.


Table E-14.Turn Signal Errors:TSM/TSSM


Turn Signal Error 1A (Part 2 of 2), Cancels Erratic-ally

Turn signals cancel erraticallyN/A

Turn Signal Error 2A, Will Not Flash, 4-WayFlashers Inoperable

Turn signals will not flash, 4-way flashers inoper-able

B1121, B1122, B1141

Turn Signal Error 1A (Part 1 of 2), Will Not CancelUpon Turn Completion

Turn signals will not cancel upon turn completionN/A

Turn Signal Error 3A, Flash at Double Rate, AllBulbs Working

Left or right turn signals flash at double the normalrate while all lamps are working

N/A

sm01275

Figure E-17.TSM/TSSM

DIAGNOSTICS



Diagnostic Tips: All• Diagnostic Trouble Codes (DTCs) B1121 and B1122 will

illuminate the security lamp.

• DTC B1141 will not illuminate the security lamp.

• When the TSM/TSSM is in 4-way flasher mode, a fault oneither the left or right turn lamp output will not cause eitherDTC B1121 and DTC B1122 to be set. If fault occurs on

both left and right outputs, then both DTC B1121 and DTCB1122 will be set.

• When the TSM/TSSM detects an over-current or short toground condition, it will turn off the turn lamp outputs.Theoutputs will be automatically reactivated once the fault isremoved.

Diagnostic Notes: All Turn Signal FlowChartsEach reference number below correlates to a circled numberon the flow chart(s).

1. Gain access to vehicle's TSM/TSSM. Perform the followingprocedure:

a. See Figure E-18. Position TSM/TSSM in the sameorientation it is mounted on vehicle. Turn on ignitionswitch. Turn on 4-way flashers by depressing bothleft and right turn signal switches simultaneously.Turnignition off; 4-way flashers should continue to flash.

b. Tilt module greater than 45 degrees to the left.

c. Repeat step a.

d. Tilt module greater than 45 degrees to the right.

2. To enable diagnostic mode, see E.8 DIAGNOSTICTROUBLE CODES (DTC).

3. Connect BREAKOUT BOX (Part No. HD-42682) (gray)between TSM/TSSM connector [30A] and wiring harnessconnector [30B]. See E.11 BREAKOUT BOX:TSM/TSSM.

4. Closely inspect handlebar controls for pinched wiring.

5. Connect gray HARNESS CONNECTOR TEST KIT (PartNo. HD-41404-B) to connector [22] (right) or connector[24] (left).



ed02900

Figure E-18.Tilting TSM/TSSM



Left

Han

dC

ontr

olR

ight

Han

dC

ontr

ol

Turn

Sig

nal

&LP

Lam

pFr

ontT

urn

Sig

nals

Inst

rum

entM

odul

e

Igni

tion

Sw

itch

Vol

tage

Reg

ulat

or

Sec

urity

NO

TE

See

shee

t2ch

argi

ngsy

stem

sfo

rfu

rthe

rM

AX

IFU

SE

conn

ectio

ns3

55

5

32

14

1 2 5 6

3 4 5 6

5

32

3

LowbeamLeftturn

GroundSerialdata

44

66

77

L15

A

AB

C

IB

A

BA

K

Igni

tion

Rig

htR

ear

Turn

Sig

nal

Left

Rea

rTu

rnS

igna

l

Left

Fron

tTu

rnS

igna

l

See

shee

t3fo

rH

FS

Man

tenn

a

Bat

tery

Igni

tion

VS

S/S

eria

ldat

alin

k

Left

turn

feed

Rig

httu

rnfe

edR

ight

turn

switc

hin

put

Left

turn

switc

hin

put

Ser

iald

ata

link

Pow

ergr

ound

Pow

ergr

ound

Gro

und

1212 5

5

1010

2828

88

77

66

55

33

22

11

ElectronicControlModuleTurnSignal/SecurityModule

(TSM/HFSM)

Mai

nH

arne

ss

Dat

aLi

nkC

onne

ctor

Rig

htFr

ont

Turn

Sig

nal

[94B

][3

1B]

[5B

]

[77A

]

[91A

]

[GN

D1]

[GN

D3]

[22B

][2

4B]

[30A

]

[31A

]

[39]

[94A

]

[30B

]

[78A

][7

8B]

[33A

]

[33B

]

A15

AB40

Am

pM

AX

IFU

SE

BK

BK

BN

BN

BN

BN

GY

GY

GY

VB

K

BK

BN V

V

V

BN

V

V

R

R

R

LGN/V

LGN

/V

LGN

/V

LGN/V

BN

/GY

BK

/GN

BK

/GN

BK

/GN

BK

/GN

BK

/GN

R/B

K

R/BK

W/B

N

W/BN

W/Y

W/Y

99

Ser

iald

ata

[166

A]

[166

B]

AB

SM

odul

e

LGN

/V

em00065

Figure E-19.Turn Signal Circuit







Under left side cover8-place MolexLeft hand controls[24]








Inside tail lamp lens6-place MultilockRear turn signals[94B]

Under right side cover20-place MolexABS Module[166]



Turn Signal Error 1A (Part 1 of 2), Will Not Cancel Upon Turn Completion

Is TSM/TSSM mounted properly?

YES NO

Mount correctly.Check if TSM/TSSM is configuredcorrectly. See E.3 TSM/TSSM

VEHICLE DELIVERYProper configuration?

YES NO

Select propervehicle configuration.

Do 4-way flashers cancel inboth directions?

YES NO

Operate motorcycle at a speedgreater than 7 MPH (11.2km/h) in a

straight line. Activate either turnsignal. Turn signals should cancel

after 20 flashes.Do turn signals cancel?

Replace TSM/TSSM.Perform setup and

password learn.

6773

YES NO

Does speedometerregister vehicle

speed?

YES

Replace TSM/TSSM.Perform password learn

and setup.

NO

Refer to E.9 INITIALDIAGNOSTIC CHECK:

INSTRUMENT MODULE.

6773

1

2

STOP

Go to Turn Signal Error1A: Cancels Erratically.

fc01446_en



Turn Signal Error 1A (Part 2 of 2), Cancels Erratically

Continued from Turn Signal Error 1A: Will Not Cancel Upon Turn Completion.

Check for voltage between Breakout Box terminal “8” (Gray) and ground atBreakout Box terminal “12” (Gray): with left turn signal switch depressed, wiggle

harness between TSM/TSSM and left handlebar switches whilemonitoring for voltage fluctuations or changes in turn signal flash pattern.

Check for voltage between Breakout Box terminal “7” (Gray) and ground atBreakout Box terminal “12” (Gray): with right turn signal switch depressed,wiggle harness between TSM/TSSM and right handlebar switches whilemonitoring for voltage fluctuations or changes in turn signal flash pattern.


YES

Locate and repairintermittentcondition.

NO

Check for voltage between Breakout Box terminal “8” (Gray) and ground atBreakout Box terminal “12” (Gray): with left turn signal switch NOT depressed,

wiggle harness between TSM/TSSM and left handlebar switches whilemonitoring for voltage fluctuations or turn signal activation.

Check for voltage between Breakout Box terminal “7” (Gray) and ground atBreakout Box terminal “12” (Gray): with right turn signal switch depressed,wiggle harness between TSM/TSSM and right handlebar switches while

monitoring for voltage fluctuations or turn signal flash pattern.


YES

Locate and repairintermittent short to

voltage.

Turn ignition switch OFF.

Check for continuity between Breakout Box terminal “8” (gray) and groundat Breakout Box terminal “12” (gray): with left turn signal switch

depressed, wiggle harness between TSM/TSSM and left handlebarswitches.

Check for continuity between Breakout Box terminal “7” (gray) and groundat Breakout Box terminal “12” (gray): with right turn signal switch

depressed, wiggle harness between TSM/TSSM and right handlebarswitches.

Is continuity present at any time?

NO

YES NO


to ground.

System OK. Review turn signalcancellation function with customer. See

AUTOMATIC CANCELLATION underE.4 TSM/TSSM TURN SIGNAL

FUNCTION.

4

4

3

fc01447_en



Turn Signal Error 2A,Will Not Flash, 4-Way Flashers Inoperable: DTC B1121, B1122, B1141

Turn ignition switch to IGN.Are turn signal lamps on continuously?

YES NO

Check for voltage on Breakout Box terminal “5” (Gray)(left turn signals) or terminal “6” (Gray) (right turn

signals) with TSM disconnected from Breakout Box.Is battery voltage present?

YES NO


Replace TSM/TSSM.Learn password and

perform setup.

Activate 4-way flashers.Do any lamps illuminate?

YES NO

Connector [30]mated fully?STOP

Go to Turn Signal Error2B: Will Not Flash, 4-wayFlashers Inoperable: DTC

B1121, B1122, B1141.

NOYES

Place red meter lead at terminal “1”(Gray) and black meter lead at terminal


Mateconnector.

NOYES

Move red meter lead toBreakout Box terminal “2”.Battery voltage present?

STOP

Go to Turn Signal Error2C: Will Not Flash, 4-wayFlashers Inoperable: DTC

B1121, B1122, B1141.NO

Check for voltage atIgnition Fuse.

Battery voltage presenton both terminals?

NO

YES

STOP


3

67906791

3

6792

STOP

Go to Turn Signal Error2D: Will Not Flash, 4-wayFlashers Inoperable: DTC

B1121, B1122, B1141. YES

Locate and repair openon (GY) wire between

Ignition Fuse and TSM.

6793

fc01448_en



Turn Signal Error 2B,Will Not Flash, 4-Way Flashers Inoperable: DTC B1121, B1122, B1141

Continued from Turn Signal Error 2A: Will Not Flash, 4-wayFlashers Inoperable: DTC B1121, B1122, B1141

orTurn Signal Error 2D: Will Not Flash, 4-way Flashers

Inoperable: DTC B1121, B1122, B1141.

Inspect lamps on side that will not flash.Are the lamps OK?

YES NO

Place jumper wire betweenterminals “1” and “6' of Breakout Box.

Do the right turn signals (front andrear) illuminate?

Replace lampsas necessary.

6796

YES

Place a jumper wire betweenterminals “1” and “5” of Breakout Box.

Do the left turn signals (front andrear) illuminate?

NO

Check for continuity betweenterminal “6” of Breakout Box and

lamps (front and rear).Continuity present?

YES


6797

NO

Repair open betweenlamps and TSM/

TSSM connector [30].

6798

YES NO

Check for continuitybetween terminal “5” of

Breakout Box andlamps (front and rear).

Continuity present?

YES NO

Repair openground circuit. Repair open between

lamps and TSM/TSSMconnector [30].6799

6800

STOP

Go to Turn Signal Error3A: Flash at Double Rate,

All Lamps Working.

fc01449_en



Turn Signal Error 2C,Will Not Flash, 4-Way Flashers Inoperable: DTC B1121, B1122, B1141

Continued from Turn Signal Error 2A: Will NotFlash, 4-way Flashers Inoperable: DTC B1121,

B1122, B1141.

Check resistance to ground on Breakout Boxterminal “12” (Gray).


YES

Check for 12 volts at bothterminals of 15 Amp Battery Fuse.

Proper voltage present at bothterminals?

YES

Repair open in wire (BN/GY)between Battery Fuse and TSM/

TSSM.

6806

NO

NO

1 terminal?

Repair poorground.

6805

Neither terminal?

Replacefuse.

6807

Repair open between 40 AmpMAXIFUSE and fuse block.

6808

fc01450_en



Turn Signal Error 2D,Will Not Flash, 4-Way Flashers Inoperable: DTC B1121, B1122, B1141

Check for battery voltage at breakout boxterminal “7” (Gray) with right turn signal

depressed and terminal “8” (Gray) with leftturn signal depressed.


YES


perform set-up.

NO

6791

3

Check for battery voltage on terminal“1” connector [22B] (right), or

connector [24B] (left).Battery voltage present?

5

YES NO

With turn signal switch depressedon side under test, check for continuity

between terminal “1” and terminal“5” on connector [22A] (right), or

connector [24A] (left).Is continuity present?

Locate and repair open (O/W)wire between terminal “1” on connector

[22B] (right), or connector[24B] (left) and Accessory Fuse.

6814 - right

6812 - left

YES NO


[22B] (right), or connector [24B](left) and TSM/TSSM connector [30].


Turn Signal Switch.

6813 - right6810 - left

6811

fc01451_en



Turn Signal Error 3A, Flash at Double Rate, All Lamps Working

YES NO

YES NO

YES NO

YES NO

YES NOYES NO

Determine correct part number forall installed Turn Signal Lamps and verify

against parts installed on motorcycle.Correct parts installed?

Check for corrosionon lamps and/or sockets.

Corrosion present?

Check for corrosion on all lampconnection terminals.Corrosion present?

Remove corrosion with a wirebrush. Install ELECTRICAL

CONTACT LUBRICANT (PartNo. 99861-02) in lamp sockets.Do lamps flash at normal rate?

Clean corrosion fromwires and terminals.

Do lamps flash atnormal rate?

Replace TSM/TSSM.Learn password (if needed)

and perform setup.Clean or replace lamp.Do lamps flash at

normal rate?

SystemOK.

SystemOK.Replace Lamp

Assembly.System

OK.

Replace TSM/TSSM.Learn password (if needed)

and perform setup.

Replace withcorrect lamps.

6821

6822 68236822

6824

6824

6820

fc01452_en

NOTE:Before troubleshooting this issue you should verifythat the lamp loads have been learned by:

1) Turn ignition switch Off-On.2) Activate left turn lamps for 4 or more flashes.3) Activate right turn lamps for 4 or more flashes.



E.14DTC B0563

GENERAL

Battery Voltage HighThe TSM/TSSM continually checks the battery voltage duringIGN/OFF and IGN/RUN power modes. If the voltage exceeds16.0 volts for more than 5.0 ± 0.5 seconds, the TSM/TSSMsets diagnostic trouble code (DTC) B0563.

DIAGNOSTICS

Diagnostic Tips• This DTC may set when the vehicle is placed on a battery

charger, on fast charge, for a long period of time.

• The TSSM does not illuminate the security lamp when thisDTC is set.

Diagnostic NotesSee 1.7 CHARGING SYSTEM tests to correct. Problem maybe faulty voltage regulator.



E.15DTC B1131, B1132

GENERALNOTE

This section applies only to those vehicles equipped with theoptional security system.

Alarm Output Low (DTC B1131) or AlarmOutput High (DTC B1132)See Figure E-20. An alarm cycle is activated when the TSSMis connected, the siren has been armed by the TSSM and asecurity event occurs. See E.6 SECURITY SYSTEM FUNC-TIONS: TSSM. Under normal armed operation, the siren input(terminal "2") is driven low by the TSSM to trigger the audiblealarm. When the siren input is driven high by the TSSM theaudible alarm stops.

ed02047

Figure E-20. Security Siren

DIAGNOSTICS




Diagnostic Tips• If the siren is armed and the internal siren battery is dead,

shorted, disconnected, or has been charging for a period

longer than 24 hours, the siren will respond with threechirps on arming instead of two.


• If the siren does not chirp two or three times on a validarming command from the TSSM, the siren is either notconnected, not working, or the siren wiring was openedor shorted while the siren was disarmed.

• If the siren enters the self-driven mode where it is poweredfrom the siren internal nine-volt battery, the turn-signallamps will not alternately flash. If the TSSM activates thesiren, the turn-signal lamps will flash. If the siren has beenarmed and a security event occurs, and the siren is in self-driven mode, the siren will alarm for 20 to 30 seconds andthen turn off for 5 to 10 seconds. This alarm cycle will berepeated ten times if the siren is in the self-driven mode.

• If the siren does not stop alarming after it has been armed,then either the TSSM output or siren input may be shortedto ground, or the siren vehicle battery connection is openor shorted to ground, or the siren vehicle ground connec-tion is open, or a security event has occurred. SeeE.6 SECURITY SYSTEM FUNCTIONS: TSSM for adescription of alarm functions.


1. Use BREAKOUT BOX (Part No. HD-42682) and HAR-NESS CONNECTOR TEST KIT (Part No. HD-41404-B),gray pin probe and patch cord. See E.11 BREAKOUTBOX: TSM/TSSM.

2. Use HARNESS CONNECTOR TEST KIT (Part No. HD-41404-B), gray socket probe and patch cord.

3. Having the correct multimeter ohm scale is important forthis test. Some meters may read infinity for high ohmvalues. If this is the case, check your ohm scale and retest.



SecuritySiren

(Optional)

TSSM

[142A]

[30A][30B]

15 AmpSecurity

Fuse

40 AmpMAXIFUSE

Battery

[142B]

BN/GY

BN

/GY

BK/GN

BK

/GN

LGN/BN

LGN

/BN

BK

RR

1

1

2

3

1

2

3

1211

1 1211

- +

Bat

tery

Ala

rmsi

gnal

Gro

und

em00081

Figure E-21. Siren Circuit



Under passenger seat12-place DeutschTurn Signal Security Module (TSSM)[30]

Electrical panel behind fender exten-sion

3-place PackardSecurity siren (optional)[142]



Alarm Output: DTC B1131, B1132

Check for battery voltage at siren sensorconnector [142B]. With ignition switch turnedto IGN, measure voltage between terminal

“3” (BK) and terminal “1” (BN/GY).Is battery voltage present?

YES NO

With ignition OFF, measure resistancebetween siren connector [142B] terminal

“2" and Breakout Box terminal “11”(Gray).


With ignition OFF, check continuity between sirenconnector [142B] terminal 3 and Breakout Box terminal“12”. Then measure continuity between siren connector

[142B] Terminal 1 and Breakout Box terminal “1”.Is continuity present?

1 1

YES NO

Measure resistance between BreakoutBox terminal “11” and chassis ground.


Locate and repairopen on (LGN/BN)

wire.

YES NO

Locate and repairshort between (BN/GY)

and (BK) wires.

Repairopen wire.

YES NO

Locate and repairgrounded (LGN/BN)

wire.

Disconnect siren from Breakout Box.Measure resistance between siren

connector [142A] terminals “2” and “3”.Is resistance between 120,000-200,000

ohms with siren disconnected?

YES

Connect siren to a known goodmotorcycle. Arm and activate sirento verify operation. Disarm siren.

Did siren operate correctly?

YES

Replace TSSM. Learnpassword and perform

setup.

NO

ReplaceSiren.

NO

ReplaceSiren.

Clear DTCs using instrument module self-diagnostics. SeeE.10 INSTRUMENT MODULE SELF-DIAGNOSTICS. Confirmproper operation with no check engine lamp illuminated.

2

3

fc01453_en



E.16DTC B1134

GENERAL

Starter Output HighWith the TSM/TSSM disarmed, Ignition Switch turned toIGNITION, Engine Stop Switch set to RUN and the transmissionin neutral or clutch lever pulled in, the start relay is grounded.Battery voltage is applied to the start relay and coil which aregrounded through the TSM/TSSM.

ed02833

Figure E-22. Start Relay Location

DIAGNOSTICS




1. Connect BREAKOUT BOX (Part No. HD-42682) (gray) towire harness connector [30] leaving TSM/TSSM discon-nected. See E.11 BREAKOUT BOX: TSM/TSSM.



TSM/TSSM

[30A][30B]

[33B]

[62B]

[33A]

IgnitionSwitch

To right handlebarswitch [22]

Start Relay

15 AmpSecurity

Fuse40 AmpMAXIFUSE

Battery

BN

/GY

TN/GN

BK

/GN

TN

/GN

BK

R

R

R

R/B

K

R/BK

BK/R

1 12

1 12

- +

9

9

8787

A30

8586

KT

ES

U

C B A

A B I

Bat

tery

Sta

rtre

lay

cont

rol

Gro

und

em00082

Figure E-23. Starter TSM/TSSM Circuit




Under passenger seat12-place DeutschTurn Signal Security Module (TSSM)[30]


Under airbox cover, in fuse block5-place AmpStart relay[62]



Starter Output High: DTC B1134

Remove Start Relay.Check for voltage on

Breakout Box terminal “9” (Gray).Voltage present?

YES

Locate and repairshort to voltage

on (TN/GN) wire.

NO

Install Start Relay.Is voltage present on

Breakout Boxterminal “9" (Gray)?

YES

Replace Start Relay.

NO


perform setup.

1

Clear DTCs using instrument module self-diagnostics.See E.10 INSTRUMENT MODULE SELF-DIAGNOSTICS.Confirm proper operation with no check engine lampillumination.

fc01454_en



E.17DTC B1135

GENERAL

Accelerometer Fault: B1135Diagnostic Trouble Code (DTC) B1135 indicates a failure whichrequires replacement of the TSM/TSSM.

NOTE

When DTC B1135 is set, the tip-over engine shutdown, TSSMtamper alarm and bank angle sensors are disabled and thesecurity lamp will illuminate.

Instrument Module

4

10

4

10

Turn Signal/Security Module(TSM/TSSM)

[39A]

[30A] [30B]

[39B]

[131]

NeutralSwitch

GND 1 GND 2GND 3

Neu

tral

Neutral switch

Clutch switch

10

10

[163]

Left HandControls

Clutch Switch

BK

BK

TN

TN

TN

BK/GN

BK

/GN

BK/R

BK/RBK/GNBK/R

Left HandControls

87

87

[24B] [24A]em00083

Figure E-24. Clutch and Neutral Interlock Circuit



E.18DTC B1154, B1155

GENERALDTC B1154 may occur if the motorcycle is ridden with theclutch pulled at speeds greater than 16 km/h (10 MPH) formore than 60 seconds (as in coasting down a long mountainroad).

DIAGNOSTIC NOTES



Each reference number below correlates to a circled numberon the flow chart(s).

1. Connect BREAKOUT BOX (Part No. HD-42682) to TSSM.See E.11 BREAKOUT BOX: TSM/TSSM.

2. If DTC is current (lamp on continuously, clear codes returnduring operation), replace TSSM. If DTC is historic, checkfor intermittents.

3. A reading of several hundred ohms is normal due to theneutral indicator lamp (LED).



Clutch Switch Short-to-Ground: DTC B1154

Connect Breakout Box HD-42682 to the main harness, leavingconnector [30] disconnected. Measure continuity between

terminal “10”; (Gray) and terminal “12” (Gray).Is continuity present?

YES NO

Disconnect connector [24]. Measurecontinuity between terminal “10” (Gray) and

terminal “12” (Gray) on Breakout Box.Is continuity present?

Replace TSSM. Learn passwordand perform set-up.

1

2

6791

YES NO

Locate and repair short-to-ground on (BK/R) wire in mainwiring harness between [30B]

and [24B).

Locate and repairshort-to-ground in

left handlebar switchwiring.

5861 5861

NOTEThis DTC may occur if the vehicle is ridden with clutch disengaged(pulled in) at speeds greater than 10 MPH (16km/h)for more than 60 seconds (coasting down a long mountain road).

fc01455_en



Neutral Switch Short-to-Ground: B1155

WIth the transmission in 1st or 2nd gear, connectBreakout Box HD-42682 to the main harness, leavingthe TSSM disconnected. Measure continuity between

terminal 4 (Gray) and terminal “12” (Gray).Is continuity (less than 10 ohms) present?

YES NO

Disconnect neutral switch [131]. Measurecontinuity between terminal “4" (Gray) and

terminal “12” (Gray) on Breakout Box.Is continuity (less than 10 ohms) present?

Replace TSSM. Learn passwordand perform set-up.

1

6791

YES NO

Locate and repair short-to-ground on (TN) wire in main

wiring harness.

Replace Neutral Switch.

5862

5157

NOTEThis DTC may occur if the vehicle is ridden with transmission inneutral at speeds greater than 10 MPH (16km/h) for more than 60seconds (coasting down a long mountain road).

fc01456_en

3 2



E.19DTC U1016

GENERAL

Loss of ECM Serial DataThe serial data connector provides a means for the ElectronicControl Module (ECM), TSM/TSSM, and speedometer tocommunicate their current status. When all operating para-meters on the serial data bus are within specifications, a stateof health message is sent between the components. A dia-gnostic trouble code DTC U1016 indicates that the ECM is notcapable of sending this state of health message. A DTC U1016indicates there was communication on the data bus since powerup, but was lost or interrupted during that key cycle.

Table E-18. Code Description

DESCRIPTIONDTC

Loss of all ECM serial data (state ofhealth)

U1016

ed03005

Figure E-25. ECM Location

DIAGNOSTICS





1. Connect BREAKOUT BOX (Part No. HD-42682) (gray)between TSM/TSSM connector [30A] and wire harnessconnector [30B]. See E.11 BREAKOUT BOX:TSM/TSSM.




3

2

1

4

5

99

5

Ser

iald

ata

Serial data

10

10

Gro

und

28

28

Gro

und

3 12

3 12

Ser

iald

ata

Gro

und

7

7

Ser

iald

ata


ABSModule

(If equipped)

[39A][39B]

[30A][30B]

[78A][78B]

[166A] [166B]

TSM/TSSMData LinkConnector

ToIgnitionFuse

ECM

[91A]

BK

/GN

BK/GN

BK

/GN

BK

/GN

GY

LGN/V

LGN/V

LGN

/V

LGN

/V

LGN/V

em00084

Figure E-26. Serial Data Circuit







Under left side cover20-place MolexABS Module (if equipped)[166]



Loss of ECM Serial Data: DTC U1016

Can you read ECM hardware part number?

See E.10 INSTRUMENT MODULE SELF-DIAGNOSTICS.

YES NO or “No Rsp”

While wiggling harness, check continuitybetween terminal “3” (Gray) of

TSM/TSSM Breakout Box and terminal“5” of ECM Breakout Box.


Check continuity between terminal “3”(Gray) of TSM/TSSM Breakout Boxand terminal “5” of ECM Breakout

Box.Is continuity present?

1

2

Clear DTCs using instrument module self-diagnostics. See E.10 INSTRUMENT MODULESELF-DIAGNOSTICS. Confirm proper operationwith no check engine lamp illuminated.

1

2

YES

Clear codes. Test ride.Did DTC U1016 return?

YES


password.

NO

Repair intermittenton (LGN/V) wire.

NO

No trouble found.

YES


password.

NO

Repair open on(LGN/V) wire.

fc01457_en



E.20DTC U1300, U1301 OR BUS ER

GENERAL

Serial Data Low or Serial Data Open/HighThe typical serial data voltage range is 0 volts (inactive) to 7volts (active). Due to the short pulse, voltages will be muchlower on a digital/voltmeter (DVOM). In analog mode, a DVOMreading serial data will show continuous voltage when active,typically 0.6-0.8 volts. The range for acceptable operations is0-7.0 volts.

Table E-20. Code Description

DESCRIPTIONDTC



ed01355

Figure E-27. Data Link Connector [91A]

DIAGNOSTICS

Diagnostic Tips• If serial data is shorted, these diagnostic trouble codes

(DTCs) will automatically cause the check engine lamp toilluminate. The odometer will read "Bus Er" in this condi-tion.


Diagnostic Notes• If a U1300, U1301 or "BUS Er" is present, perform dia-

gnostic procedures listed in 4.11 STARTS, THEN STALLS.



E.21PASSWORD LEARN

GENERALIf the ECM or TSM/TSSM is faulty, follow the instructions inthe Service manual for ECM or TSM/TSSM replacement.Then,to determine if password learn is necessary, refer toTable E-21.

Table E-21. Password Learn

IS PASSWORD LEARNNECESSARY?

DEVICE REPLACED

YesECM

No *TSM

YesTSSM

* If a TSM has been replaced by a TSSM, or a TSSM hasbeen replaced by a TSM, password learn is necessary.

PASSWORD LEARNINGTo perform password learning procedure, refer to Table E-21.When finished, continue with all instructions underE.3 TSM/TSSM VEHICLE DELIVERY.

Always perform all appropriate instructions underE.3 TSM/TSSM VEHICLE DELIVERY after TSM/TSSMreplacement or removal.

NOTE

Do not forget to enter a Personal Identification Number (PIN)for TSSM vehicles. If a code is not assigned and the key fobis lost or damaged while the vehicle is armed, the TSSM mustbe replaced.

Table E-22. Setting TSM/TSSM and ECM Password

NOTESCONFIRMATIONACTIONNO.

With ignition turned off, Check EngineLamp and Security Lamp will be off.

Ignition must be turned off for at least15 seconds.

Install new TSM/TSSM or ECM. Per-form all steps under E.3 TSM/TSSMVEHICLE DELIVERY.

1

Set RUN/OFF switch to RUN.2

TSM/TSSM enables starterrelay.

Verify Check Engine Lamp andSecurity Lamp illuminate and stays on.

Turn IGN key ON.3

Password has not beenlearned. ECM sets DTCP1009

Engine starts and stalls. Check EngineLamp illuminates and stays on.

Attempt normal start one time.4

ECM enters PasswordLearning mode for tenminutes. Do not cycle IgnitionSwitch or interrupt vehiclepower or Password Learn willbe unsuccessful.

Security Lamp illuminates.Wait ten seconds. Security lamp willilluminate and stay on.

5


ECM must not be allowed toshutdown

Quickly (within two seconds) turn IGNkey OFF-ON.

7




9




11

Turn IGN key OFF. Wait 15 secondsbefore turning IGN on. . Turn IGNswitch ON and start engine to confirmsuccessful Password Learn procedure.Clear diagnostic trouble codes.

12

Perform all steps under E.3 TSM/TSSMVEHICLE DELIVERY.

13



E.22TSSM MAINTENANCE

GENERALThe TSSM system uses batteries in the key fob and siren.These are the only parts requiring periodic maintenance.

KEY FOB

ScheduleReplace the key fob battery every 2 years.

Battery Replacement1. See Figure E-28. Open the key fob case.

a. Place a thin blade between the 2 halves of the case.

b. Slowly twist the blade.

2. Replace battery (1).

a. Remove the original battery.

b. Install a new battery with the positive (+) side down.Use a Panasonic® 2032 or equivalent.

3. Align case and circuit board (3) as shown. Snap casehalves together.

4. While standing next to the motorcycle, press and hold thekey fob button for 10-15 seconds until the security systemresponds with two turn signal flashes/siren chirps.

1 2

3

ed030114

1. Battery2. Battery Contact3. Circuit Board

Figure E-28. Open Key Fob:TSSM

ed03015

Figure E-29. Key Fob Assembly:TSSM

SIREN (IF INSTALLED)

ScheduleThe siren's internal 9 volt battery is rechargeable and does notneed to be replaced on a regular basis. Battery life undernormal conditions is approximately three to six years.

NOTES

• See Figure E-30 and Figure E-31. Early style siren willwork with both TSSM and HFSM. Late style siren will onlywork with HFSM.


Battery Replacement: Early Style Siren1. Disarm system and remove siren.

2. See Figure E-30. Remove battery cover.

a. Place the siren module on a flat and sturdy table withthe potted section (area with epoxy covering circuitboard) facing up and towards you.

b. Position a knife blade at a 45 degree angle to the longside of the siren case. Insert the knife blade betweenthe siren case and battery cover at one of the twoaccessible corners of the battery cover. Keep theblade slightly higher towards the battery cover as thishelps keep the blade away from the battery seal.

c. Slowly twist the blade towards the battery cover andthe cover will pop off.






3. Replace battery by removing old battery from polarizedbattery clip. Install a new 9 volt nickel metal hydride bat-tery.

4. Reinstall battery cover.

a. Carefully replace the rubber seal.

b. Align battery cover with case placing round cornerson cover away from connector [142A]. Snap coverinto place.


Battery Replacement: Late Style Siren1. Disarm system and remove siren.

2. See Figure E-31. With a small screwdriver or pick, pushthe catches (1) in through the two slots (2) in the end ofthe siren to release the battery cover (3).




3. Replace battery (4) by removing old battery from polarizedbattery clip.

4. Recharge and re-install or install a new 9 volt nickel metalhydride battery.

5. Reinstall battery cover (3).

a. Carefully replace the rubber seal (5) on the cover.

b. Align battery cover with case placing round cornerson cover away from connector [142A] (6).

c. Snap cover into place.


1 23

ed03016

1. Cover2. Battery3. Connector [142A]

Figure E-30. Battery Compartment (Early Style Siren)

4

5

6

3

1

2

ed02958

1. Catch2. Slot3. Cover4. 9 volt battery5. Rubber seal6. Connector [142A]

Figure E-31. Siren Battery Compartment (Late Style Siren)



Tools Used in This ManualNOTESTOOL NAMEPART NUMBER

4.15 FUEL PRESSURE TEST, Testing 1/8 IN. PIPE THREAD 90° DEGREE (RIGHTANGLE) ELBOW

26338-68

4.19 DTC P0107, P0108, Diagnostics VACUUM PUMPHD-23738

A.19 SEALED SPLICE CONNECTORS, Sealed SpliceConnector Repair

ROBINAIR HEAT GUNHD-25070

4.9 ENGINE CRANKS, BUT WILL NOT START, Dia-gnostics


4.17 MISFIRE AT IDLE OR UNDER LOAD, Diagnostics SPARK TESTERHD-26792



4.26 DTC P0444, P0445, Diagnostics FUEL INJECTOR TEST LAMPHD-34730-2C

4.31 DTC P1351, P1352, P1354, P1355, Diagnostics FUEL INJECTOR TEST LAMPHD-34730-2C

A.15 METRI-PACK TERMINALS, Metri-Pack TerminalCrimps

PACKARD TERMINAL CRIMP TOOLHD-38125-6

A.1 AMP 1-PLACE CONNECTORS, AMP 1-Place Con-nector Repair


A.7 DEUTSCH MINI-TERMINAL CRIMPS, Deutsch MiniTerminal Crimps









SOCKET TERMINAL TOOLHD-39621-27


PIN TERMINAL REMOVERHD-39621-28

A.6 DEUTSCH STANDARD TERMINALS, DeutschStandard Terminal Crimps

DEUTSCH TERMINAL CRIMP TOOLHD-39965-A


ULTRA-TORCH UT-100HD-39969

4.7 WIGGLE TEST, Procedure FLUKE 78 MULTIMETER (DVOM)HD-39978

4.15 FUEL PRESSURE TEST, Testing FUEL PRESSURE GAUGEHD-41182


HEAT SHIELD ATTACHMENTHD-41183

1.2 STARTING SYSTEM DIAGNOSIS, Diagnostics HARNESS CONNECTOR TEST KITHD-41404-B

1.7 CHARGING SYSTEM, Testing HARNESS CONNECTOR TEST KITHD-41404-B

2.10 DTC B1004, B1005, Diagnostics HARNESS CONNECTOR TEST KITHD-41404-B

3.16 DTC B1131, B1132 (HFSM ONLY), Diagnostics HARNESS CONNECTOR TEST KITHD-41404-B

3.20 DTC B1141 (HFSM ONLY), Diagnostics HARNESS CONNECTOR TEST KITHD-41404-B







4.10 NO ECM POWER, Diagnostics HARNESS CONNECTOR TEST KITHD-41404-B

4.13 SYSTEM RELAY FAULT, Diagnostics HARNESS CONNECTOR TEST KITHD-41404-B

4.14 FAN OPERATION CHECK, Diagnostics HARNESS CONNECTOR TEST KITHD-41404-B

4.16 IDLE AIR CONTROL, Diagnostics HARNESS CONNECTOR TEST KITHD-41404-B

I

TOO

LS



4.17 MISFIRE AT IDLE OR UNDER LOAD, Diagnostics HARNESS CONNECTOR TEST KITHD-41404-B

4.19 DTC P0107, P0108, Diagnostics HARNESS CONNECTOR TEST KITHD-41404-B




4.24 DTC P0261, P0262, P0263, P0264, Diagnostics HARNESS CONNECTOR TEST KITHD-41404-B








5.12 DTC C1032, C1034, DTC C1032, C1034: WheelSpeed Sensor Circuit Open Or Shorted (Front or Rear)


5.15 DTC C1094, DTC C1094: Front Brake Switch AlwaysOn


E.13 TURN SIGNAL ERRORS: B1121, B1122,B1141, Diagnostics


E.15 DTC B1131, B1132, Diagnostics HARNESS CONNECTOR TEST KITHD-41404-B

A.5 DEUSCH ELECTRICAL CONNECTORS, DeutschConnector Repair

DEUTSCH CONNECTOR SERVICE KITHD-41475

A.5 DEUSCH ELECTRICAL CONNECTORS, DeutschConnector Repair

FLAT BLADE L-HOOKHD-41475-100

A.2 AMP MULTILOCK CONNECTORS, AMP MultilockConnector Repair

AMP MULTILOCK CRIMPERHD-41609

1.2 STARTING SYSTEM DIAGNOSIS, Diagnostics BREAKOUT BOXHD-42682

2.3 BREAKOUT BOX: IM, General BREAKOUT BOXHD-42682

2.6 NO IM POWER, General BREAKOUT BOXHD-42682

2.7 INDICATOR LAMPS, Diagnostics BREAKOUT BOXHD-42682

2.10 DTC B1004, B1005, Diagnostics BREAKOUT BOXHD-42682

2.13 DTC U1016, Diagnostics BREAKOUT BOXHD-42682


3.3 H-DSSS ACTUATION, Power Disruption and Config-uring


3.12 BREAKOUT BOX: TSM/HFSM, General BREAKOUT BOXHD-42682

3.17 DTC B1134 STARTER OUTPUT HIGH, Diagnostics BREAKOUT BOXHD-42682

3.22 DTC B1154, B1155, Diagnostics BREAKOUT BOXHD-42682

4.33 DTC U1064, U1255, Diagnostics BREAKOUT BOXHD-42682


E.11 BREAKOUT BOX: TSM/TSSM, General BREAKOUT BOXHD-42682

E.15 DTC B1131, B1132, Diagnostics BREAKOUT BOXHD-42682

E.16 DTC B1134, Diagnostics BREAKOUT BOXHD-42682

II TOOLS



A.8 DEUTSCH SOLID BARREL TERMINALS, DeutschSolid Barrel Terminal Crimps

ELECTRICAL CRIMPER TOOLHD-42879




4.6 BREAKOUT BOX: ECM, General BREAKOUT BOXHD-43876

4.7 WIGGLE TEST, Procedure BREAKOUT BOXHD-43876



4.10 NO ECM POWER, Diagnostics BREAKOUT BOXHD-43876

4.12 FUEL SYSTEM ELECTRICAL TEST, Diagnostics BREAKOUT BOXHD-43876

4.13 SYSTEM RELAY FAULT, Diagnostics BREAKOUT BOXHD-43876

4.14 FAN OPERATION CHECK, Diagnostics BREAKOUT BOXHD-43876

4.16 IDLE AIR CONTROL, Diagnostics BREAKOUT BOXHD-43876

4.17 MISFIRE AT IDLE OR UNDER LOAD, Diagnostics BREAKOUT BOXHD-43876

4.18 COMBUSTION ABSENT/INTERMITTENT, Dia-gnostics


4.19 DTC P0107, P0108, Diagnostics BREAKOUT BOXHD-43876




4.24 DTC P0261, P0262, P0263, P0264, Diagnostics BREAKOUT BOXHD-43876




4.31 DTC P1351, P1352, P1354, P1355, Diagnostics BREAKOUT BOXHD-43876




E.19 DTC U1016, Diagnostics BREAKOUT BOXHD-43876


IGNITION COIL CIRCUIT TEST ADAPTERHD-44687

4.31 DTC P1351, P1352, P1354, P1355, Diagnostics IGNITION COIL CIRCUIT TEST ADAPTERHD-44687

2.1 CHECKING FOR TROUBLE CODES, Code Types DIGITAL TECHNICIANHD-44750

3.3 H-DSSS ACTUATION, Fob Assignment DIGITAL TECHNICIANHD-44750

3.7 SERVICE/EMERGENCY FUNCTIONS, Service Mode DIGITAL TECHNICIANHD-44750

4.4 CHECKING FOR TROUBLE CODES, Code Types DIGITAL TECHNICIANHD-44750

4.16 IDLE AIR CONTROL, General DIGITAL TECHNICIANHD-44750

4.23 DTC P0131, P0132, P0134, P0151, P0152,P0154, Diagnostics


5.1 ANTILOCK BRAKE SYSTEM (ABS) GENERALINFORMATION, Code Types


E.8 DIAGNOSTIC TROUBLE CODES (DTC), CodeTypes


TOOLS III



2.3 BREAKOUT BOX: IM, General ADAPTERSHD-45325

2.6 NO IM POWER, General ADAPTERSHD-45325

2.7 INDICATOR LAMPS, Diagnostics ADAPTERSHD-45325

2.10 DTC B1004, B1005, Diagnostics ADAPTERSHD-45325

A.18 PACKARD MICRO-64 CONNECTORS, PackardMicro-64 Connector Repair

PACKARD MICRO-64 TERMINALREMOVER

HD-45928

A.18 PACKARD MICRO-64 CONNECTORS, PackardMicro-64 Connector Repair

PACKARD MICRO-64 TERMINALCRIMPER

HD-45929

4.34 DTC U1096, U1255, Diagnostics SPEEDOMETER MODULE HARNESSADAPTER

HD-46601

1.7 CHARGING SYSTEM, Troubleshooting ELECTRICAL SYSTEM TESTERHD-48053

1.7 CHARGING SYSTEM, Testing ADVANCED BATTERY CONDUCTANCEAND ELECTRICAL SYSTEM ANALYZER

HD-48053

A.16 MOLEX CONNECTORS, Molex Connector Repair MOLEX ELECTRICAL CONNECTOR TER-MINAL REMOVER

HD-48114

4.23 DTC P0131, P0132, P0134, P0151, P0152,P0154, Diagnostics


5.3 BREAKOUT BOX: ABS, General BREAKOUT BOXHD-48642

5.12 DTC C1032, C1034, DTC C1032, C1034: WheelSpeed Sensor Circuit Open Or Shorted (Front or Rear)



ELECTRICAL SYSTEM ANALYZERMCR-101 HD

A.13 630 METRI-PACK CONNECTORS, 630 Metri-PackConnector Repair

SNAP-ON PICKTT600-3

IV TOOLS


2008 VRSC Models Electrical Diagnostics ManualNOTESTORQUE VALUEFASTENER

No torque values were found in this manual.

V

TOR

QU

E V

AL

UE

S


VI TORQUE VALUES

NOTES


1150 Metri-Pack Connector

Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-20


Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-22


Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-24


Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-25

AABS Diode Pack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1ABS Indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2ABS Indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11Alternator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16AMP 1-Place Connector

Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1AMP Multilock Connector

Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3Antilock Brake System (ABS) Description. . . . . . . . . . . . . 5-1

BBank Angle Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1Bank Angle Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2Battery Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23

Conductance Test. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23Load Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23Voltmeter Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23

Bus ER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33

CChanging the Pin

Modifying an Existing Pin. . . . . . . . . . . . . . . . . . . . . . 3-6Charging System Testing. . . . . . . . . . . . . . . . . . . . . . . . . 1-20

Current and Voltage Output Test: Using HD-48053. . 1-21Current and Voltage Output Test: Using LoadTester. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21Milliampere Draw Test. . . . . . . . . . . . . . . . . . . . . . . 1-20Total Current Draw Test. . . . . . . . . . . . . . . . . . . . . . 1-20

Check Engine Lamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1Check Engine Lamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4CKP Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-96Code Types

Current. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14Historic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Connector Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1Conversions

Fluid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2Length. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3

Crank Position (CKP) Sensor. . . . . . . . . . . . . . . . . . . . . . 4-2

DDelphi Connector

Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-8Deutsch 1-Place Connector

Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-10Deutsch Connector

Crimping Mini Terminals. . . . . . . . . . . . . . . . . . . . . . A-16Crimping Solid Barrel Terminals. . . . . . . . . . . . . . . . A-17Crimping Standard Terminals. . . . . . . . . . . . . . . . . . A-15Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-11

Diagnostic Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6Diagnostic Trouble Code Types. . . . . . . . . . . . . . . . . . . . . 2-2

Current. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2Historic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2Retrieving Diagnostic Trouble Codes. . . . . . . . . . . . . 2-2

DTC B0563 Battery Voltage High. . . . . . . . . . . . . . . . . . 3-26DTC B0563 Battery Voltage High. . . . . . . . . . . . . . . . . . E-39DTC B1003 Internal Fault. . . . . . . . . . . . . . . . . . . . . . . . 2-17DTC B1004 Fuel Level Sending unit low. . . . . . . . . . . . . 2-19DTC B1005 Fuel Level Sending unit High/Open. . . . . . . 2-19DTC B1006 Accessory line Overvoltage. . . . . . . . . . . . . 2-23DTC B1007 Ignition line Overvoltage. . . . . . . . . . . . . . . 2-23DTC B1008 Trip Odometer Reset Switch Closed. . . . . . 2-25DTC B1121, B1122, B1141 Turn Signals will not flash, 4wayFlashers Inoperable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27DTC B1123 Left Turn Signal short-to-ground. . . . . . . . . 3-27DTC B1124 Right Turn Signal short-to-ground. . . . . . . . 3-27DTC B1125 Left Turn Signal short-to-voltage. . . . . . . . . 3-27DTC B1126 Right Turn Signal short-to-voltage. . . . . . . . 3-27DTC B1131 Alarm output low. . . . . . . . . . . . . . . . . . . . . 3-41DTC B1131 Alarm Output Low. . . . . . . . . . . . . . . . . . . . E-40DTC B1132 Alarm output high. . . . . . . . . . . . . . . . . . . . 3-41DTC B1132 Alarm Output High. . . . . . . . . . . . . . . . . . . . E-40DTC B1134 Starter Output High. . . . . . . . . . . . . . . . . . . 3-44DTC B1134 Starter Output High. . . . . . . . . . . . . . . . . . . E-43DTC B1135 Accelerometer Fault. . . . . . . . . . . . . . . . . . . 3-47DTC B1135 Accelerometer Fault. . . . . . . . . . . . . . . . . . E-46DTC B1136 Accelerometer Tip-Over Self-Test Fault. . . . 3-48DTC B1141 Ignition Switch Open/Low. . . . . . . . . . . . . . 3-49DTC B1142 Internal Fault. . . . . . . . . . . . . . . . . . . . . . . . 3-48DTC B1143 Security antenna short-to-ground. . . . . . . . 3-54DTC B1144 Security antenna short-to-battery. . . . . . . . 3-54DTC B1145 Security antenna open. . . . . . . . . . . . . . . . . 3-54DTC B1154 Clutch switch short-to-ground. . . . . . . . . . . 3-59DTC B1155 Neutral switch short-to-ground. . . . . . . . . . . 3-59DTC C0562: Device Voltage Low. . . . . . . . . . . . . . . . . . . 5-15DTC C0563: Device Voltage High. . . . . . . . . . . . . . . . . . 5-18DTC C1014, C1055-C1066, C1118, C1121: ECU InternalFault. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-66DTC C1017: Pump Motor Power Circuit Open Fault. . . . 5-21DTC C1018: Pump Motor Ground High Resistance Fault. 5-24DTC C1021, C1023: Wheel Speed Sensor Equals Zero (Frontor Rear). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27DTC C1025, C1027, C1206, C1208: Wheel Speed SignalIntermittent or Frequency Out Of Range. . . . . . . . . . . . . 5-30DTC C1032, C1034: Wheel Speed Sensor Circuit Open OrShorted (Front or Rear). . . . . . . . . . . . . . . . . . . . . . . . . . 5-33DTC C1042: Pump Motor Open. . . . . . . . . . . . . . . . . . . 5-39DTC C1043: Pump Motor Stalled. . . . . . . . . . . . . . . . . . 5-40DTC C1094: Front Brake Switch Always On. . . . . . . . . . 5-41DTC C1095: Front Brake Switch Open. . . . . . . . . . . . . . 5-44DTC C1151: Front Wheel Release Too Long. . . . . . . . . . 5-47DTC C1153: Rear Wheel Release Too Long. . . . . . . . . . 5-50DTC C1158: Calibration Programming Required. . . . . . 5-53DTC C1212: Front or Rear Brake Not Applied with Decel. 5-57DTC C1214: Rear Brake Switch Always On. . . . . . . . . . 5-60DTC C1216: Rear Brake Switch Open. . . . . . . . . . . . . . 5-63DTC P0107 MAP sensor open/low. . . . . . . . . . . . . . . . . 4-70DTC P0108 MAP sensor high. . . . . . . . . . . . . . . . . . . . . 4-70DTC P0112 IAT sensor voltage low. . . . . . . . . . . . . . . . . 4-74DTC P0113 IAT sensor open/high. . . . . . . . . . . . . . . . . . 4-74DTC P0117 ECT sensor voltage low. . . . . . . . . . . . . . . . 4-78DTC P0118 ECT sensor open/high. . . . . . . . . . . . . . . . . 4-78DTC P0122 TP sensor open/low. . . . . . . . . . . . . . . . . . . 4-82DTC P0123 TP sensor high. . . . . . . . . . . . . . . . . . . . . . . 4-82DTC P0131 Front O2 sensor low or engine running lean. 4-86DTC P0132 Engine running rich. . . . . . . . . . . . . . . . . . . 4-86

VII

IND

EX


DTC P0134 Front O2 sensor open/not responding/high. . 4-86DTC P0151 Rear O2 sensor low or engine running lean. 4-86DTC P0152 Engine running rich. . . . . . . . . . . . . . . . . . . 4-86DTC P0154 Rear O2 sensor open/not responding/high. . 4-86DTC P0261 Front Injector Open/Low. . . . . . . . . . . . . . . 4-91DTC P0262 Front Injector High. . . . . . . . . . . . . . . . . . . . 4-91DTC P0263 Rear Injector Open/Low. . . . . . . . . . . . . . . . 4-91DTC P0264 Rear Injector High. . . . . . . . . . . . . . . . . . . . 4-91DTC P0373 CKP sensor intermittent. . . . . . . . . . . . . . . . 4-96DTC P0374 CKP sensor synch error. . . . . . . . . . . . . . . . 4-96DTC P0444 Purge solenoid open/low. . . . . . . . . . . . . . . 4-99DTC P0445 Purge solenoid high. . . . . . . . . . . . . . . . . . . 4-99DTC P0501 VSS sensor low. . . . . . . . . . . . . . . . . . . . . 4-104DTC P0502 VSS sensor high/open. . . . . . . . . . . . . . . . 4-104DTC P0505 Loss of Idle Speed Control. . . . . . . . . . . . . 4-55DTC P0562 Battery voltage low. . . . . . . . . . . . . . . . . . 4-108DTC P0563 Battery voltage high. . . . . . . . . . . . . . . . . . 4-108DTC P0603 ECM EEPROM error. . . . . . . . . . . . . . . . . 4-112DTC P0605 ECM flash error. . . . . . . . . . . . . . . . . . . . . 4-112DTC P1001 Ssytem Relay Coil Open/Low. . . . . . . . . . . 4-43DTC P1002 System Relay Coil High/Shorted. . . . . . . . . 4-43DTC P1003 System Relay Contacts Open. . . . . . . . . . . 4-43DTC P1004 System Relay Contacts Closed. . . . . . . . . . 4-43DTC P1353 Front cylinder no combustion. . . . . . . . . . . . 4-66DTC P1356 Rear cylinder no combustion. . . . . . . . . . . . 4-66DTC P1357 Front cylinder combustion intermittent. . . . . 4-66DTC P1358 Rear cylinder combustion intermittent. . . . . 4-66DTC P1501 Jiffy Stand Sensor Low. . . . . . . . . . . . . . . 4-120DTC P1502 Jiffy Stand Sensor High. . . . . . . . . . . . . . . 4-120DTC U1016 Loss of all ECM serial data. . . . . . . . . . . . . 2-27DTC U1064 Loss of TSM/TSSM/HFSM serial data. . . . . 2-30DTC U1064 Loss of TSM/TSSM/HFSM serial data. . . . 4-125DTC U1096 Loss of IM serial data (state of health). . . 4-128DTC U1255 Missing message at IM. . . . . . . . . . . . . . . 4-128DTC U1255 Serial data error/missing message. . . . . . 4-125DTC U1300 serial data low. . . . . . . . . . . . . . . . . . . . . . . 2-33DTC U1300 Serial Data Low. . . . . . . . . . . . . . . . . . . . . . 4-33DTC U1300 Serial Data Low. . . . . . . . . . . . . . . . . . . . . . E-53DTC U1301 serial data open/high. . . . . . . . . . . . . . . . . . 2-33DTC U1301 Serial Data Open/High. . . . . . . . . . . . . . . . 4-33DTC U1301 Serial Data Open/High. . . . . . . . . . . . . . . . E-53DTC U1616 Loss of ECM Serial Data. . . . . . . . . . . . . . . E-50

EECT Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-78Electronic Control Module (ECM). . . . . . . . . . . . . . . . . . . 4-2Electronic Control Unit (ECU). . . . . . . . . . . . . . . . . . . . . . 5-1Electronic Fuel Injection (EFI). . . . . . . . . . . . . . . . . . . . . . 4-2Engine Coolant Temperature (ECT) Sensor. . . . . . . . . . . 4-2

FFan Operation Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-48Fan relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2Fluid Conversions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2Front Wheel Speed Sensor. . . . . . . . . . . . . . . . . . . . . . . . 5-1Fuel Gauge Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18Fuel Injectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-91Fuel Pressure Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-52Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37Fuse Block Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-19

GGlossary

Acronyms and Abbreviations. . . . . . . . . . . . . . . . . . . D-1

HHands-Free FOB

Battery Replacement. . . . . . . . . . . . . . . . . . . . . . . . 3-68Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68

Hands-Free FOB battery. . . . . . . . . . . . . . . . . . . . . . . . . 3-68Hands-Free Security Module (HFSM). . . . . . . . . . . . . . . . 3-2Hydraulic Control Unit (HCU). . . . . . . . . . . . . . . . . . . . . . 5-1

IIAT Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-74Idle Air Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-55Idle Air Control (IAC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2Ignition (plug top) coils. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2Ignition Coil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-116Indicator Lamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14Instrument Module (IM) Self Diagnostics. . . . . . . . . . . . . 2-3Instrument Module Functions. . . . . . . . . . . . . . . . . . . . . . 2-6Intake Air Temperature (IAT) Sensor. . . . . . . . . . . . . . . . . 4-2

JJiffy Stand Sensor (HDI). . . . . . . . . . . . . . . . . . . . . . . . . . 4-2Jiffy Stand Sensor (HDI). . . . . . . . . . . . . . . . . . . . . . . . 4-120

KKey FOB Assignment: TSSM. . . . . . . . . . . . . . . . . . . . . . E-5Key Fob Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-55

LLoctite. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-II

MManifold Absolute Pressure (MAP) Sensor. . . . . . . . . . . . 4-2Maxi-Fuse Housing

Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-26Metric System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2Metri-Pack Terminals

Crimping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-28Molex Connector

Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-30

OO2 Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-86Oxygen (O2) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

PPackard 100W Connector

Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-32Packard Micro-64 Connector

Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-34Persnal Identification Number (PIN). . . . . . . . . . . . . . . . . 3-6Pin Entry: TSSM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-6Purge solenoid (California models only). . . . . . . . . . . . . . 4-2Purge Solenoid (CA Models Only). . . . . . . . . . . . . . . . . . 4-99

RRear Wheel Speed Sensor. . . . . . . . . . . . . . . . . . . . . . . . 5-1Reprogramming ECM. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

SSealed Splice. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-37

VIII INDEX


Security Lamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2Security Lamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3Security Lamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-14

Retrieving Trouble Codes. . . . . . . . . . . . . . . . . . . . . . 2-2Security Lamp (Key Icon). . . . . . . . . . . . . . . . . . . . . . . . . 3-8Security Lamp Diagnostics. . . . . . . . . . . . . . . . . . . . . . . 3-13Security System Functions: TSSM. . . . . . . . . . . . . . . . . E-11Service Bulletins. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-IService Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-ISidecar Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5Siren. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10Siren (If Installed)

Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68Siren Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68Siren Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-55Siren Chirp Mode (Confirmation)

Chirpless Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10Chirp Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10Switching Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Smart Security SystemTransport Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Speedometer Theory of Operation. . . . . . . . . . . . . . . . . . 2-9SPX Kent-Moore. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-IIStarter Activation Circuits. . . . . . . . . . . . . . . . . . . . . . . . 1-13Starter Free Running Current Draw Test. . . . . . . . . . . . . 1-15Starter Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1Starting System Diagnosis. . . . . . . . . . . . . . . . . . . . . . . . 1-3Start Relay Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14Stator Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21System relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2System Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43

TTachometer Theory of Operation. . . . . . . . . . . . . . . . . . . 2-10Throttle Position (TP) Sensor. . . . . . . . . . . . . . . . . . . . . . 4-2Torque Conversion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3TP Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-82Trademarks

Harley-Davidson. . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-IIReferenced Products. . . . . . . . . . . . . . . . . . . . . . . . . . I-II

Trip Odometer Reset Switch. . . . . . . . . . . . . . . . . . . . . . . 2-9Troubleshooting

Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16TSM/HFSM: Password Learn. . . . . . . . . . . . . . . . . . . . . 3-67TSM/TSSM Password Learn. . . . . . . . . . . . . . . . . . . . . . E-54TSM/TSSM Turn Signal Functions. . . . . . . . . . . . . . . . . . E-9

Automatic Cancellation. . . . . . . . . . . . . . . . . . . . . . . E-9Four-Way Flashing. . . . . . . . . . . . . . . . . . . . . . . . . . . E-9Manual Cancellation. . . . . . . . . . . . . . . . . . . . . . . . . E-9

Turn Signal Errors: B1121, B1122, B1141. . . . . . . . . . . E-28Turn Signal Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1Turn Signal Module (TSM). . . . . . . . . . . . . . . . . . . . . . . . . 4-2Turn Signal Security Module. . . . . . . . . . . . . . . . . . . . . . . E-3

VVehicle Speed Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . 4-104Vehicle Speed Sensor (VSS). . . . . . . . . . . . . . . . . . . . . . . 4-2Voltage Regulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

WWiggle Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10Wiring Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3WOW Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-22

INDEX IX


X INDEX

NOTES


INSIDE BACK COVER GOES HERE


OUTSIDE BACK COVER GOES HERE


v-rod 2008 eletrical

Documents

efficient service work

service manualrefer

repair work

service bulletinsin

relative service information

page number

disablethe security

harleydavidson product