2018 HARLEY-DAVIDSON® ELECTRICAL DIAGNOSTIC

MANUAL: HARLEY-DAVIDSON STREET™ MODELS

Foreword
Foreword
General
How To Use Your Manual
Preparation For Service
Service Bulletins
Use Genuine Replacement Parts
Warnings and Cautions
Product References
Product Registered Marks
H-D U.S.A., LLC Trademark Information
Contents
Initial Diagnostics
Specifications
Specifications
Initial Diagnostics
Description and Operation
Initial Diagnostics
Diagnostics
Retrieving Trouble Codes
Odometer Self-Diagnostics
Code Types
Multiple Trouble Codes
Clearing DTCs
Security Lamp
Check Engine Lamp
Symptoms
DIAGNOSTIC TOOLS
How To Use Diagnostic Tools
DIAGNOSTICS AND TROUBLESHOOTING
Voltage Drop
Wiggle Test
Relay Diagnostics
Serial Data
CAN DATA COMMUNICATION
Description and Operation
Components
Communication DTCs and Error Messages
DTC U0001
Description and Operation
DTC U0001
NO VEHICLE POWER OR LOST COMMUNICATION DTCS
Description and Operation
DTC U0100
DTC U0121
DTC U0002
SCM Inoperative: DTC U0168
Speedometer Inoperative: DTC U0156
DTC U0300
Starting and Charging
BATTERY TESTING
 General
Voltmeter Test
Battery Diagnostic Test
Load Test
STARTING SYSTEM
Description and Operation
Components
Starter Testing
Nothing Clicks
Start Relay Clicks
Starter Solenoid Clicks
Starter Spins, But Does Not Engage
Starter Stalls or Spins Too Slowly
TESTING STARTER ON MOTORCYCLE
Starter Current Draw Test
STARTER CIRCUIT DIAGNOSTICS
Description and Operation
DTC P0512
DTC P0616
DTC P0617
TESTING STARTER ON BENCH
Free Running Current Draw Test
CLUTCH SWITCH DIAGNOSTICS
Description and Operation
DTC P0704
CHARGING SYSTEM
Description and Operation
Troubleshooting
Low or No Charging
Overcharging
Low Battery After Extended IGN OFF
Battery Runs Down During Use
Battery Charging Tests
ECM VOLTAGE DIAGNOSTICS
Description and Operation
DTC P0562, P0563
BATTERY AND SYSTEM VOLTAGE DIAGNOSTICS
Description and Operation
DTC P0562
DTC P0563
DTC B2272
Instruments
SPEEDOMETER
Description and Operation
Speedometer Theory of Operation
Instrument Diagnostics
FUEL LEVEL DIAGNOSTICS
Description and Operation
DTC B1210
DTC B1211
Trip Odometer Functions Inoperative: DTC B2255
Description and Operation
Trip Odometer Functions Inoperative: DTC B2255
NEUTRAL SWITCH DIAGNOSTICS
Description and Operation
 DTC P0851 Neutral Switch Input Circuit Low
NO SPEEDOMETER POWER DIAGNOSTICS
Description and Operation
No Instrument Power
DTC B1200
INDICATOR LAMPS
Description and Operation
Oil Pressure Lamp Always On
Oil Pressure Lamp Inoperative
Neutral Lamp Always On
Neutral Lamp Inoperative
High Beam Indicator Always On
High Beam Indicator Inoperative
Low Fuel Lamp Inoperative
Turn Signal Indicator Inoperative
Turn Signal Indicator Always On
Horn, Lighting and Turn Signals
HORN DIAGNOSTICS
Description and Operation
Components
Symptoms
Horn Always On
Horn Inoperative
HEADLAMP DIAGNOSTICS
Description and Operation
Headlamp Inoperative
STOP LAMP DIAGNOSTICS
Description and Operation
Stop Lamp Always On
Stop Lamp Inoperative
TURN SIGNAL DIAGNOSTICS
Description and Operation
All Turn Signals Inoperative +[2018 STREET 750 (XG750)]
Any Front Turn Signal Inoperative
Any Rear Turn Signal Inoperative
Left Turn Signals Inoperative
Right Turn Signals Inoperative
RUNNING LAMP DIAGNOSTICS
Description and Operation
Position Lamp Inoperative: If Equipped
Front Running Lamps Inoperative
Tail Lamp Inoperative
LP Lamp Inoperative
SECURITY SYSTEM
Security Lamp
Security Immobilization
Security System Features
Security System Warnings
Arming
Disarming
DTC B2400
Alarm
KEY FOB
Description and Operation
Fob Assignment
 SIREN
Description and Operation
Siren Chirp Mode Confirmation
SERVICE AND EMERGENCY FUNCTIONS AND CONFIGURATIONS
Actuation
Selecting a PIN
Initial PIN Entry
Changing the PIN
Transport Mode
Service Mode
ALARM DIAGNOSTICS
Description and Operation
SECURITY ANTENNA DIAGNOSTICS
Description and Operation
DTC B2176
DTC B2177
DTC B2178
Fails to Disarm
Engine Management
EFI SYSTEM
General
Electronic Control Module
General
SENSORS AND DRIVERS
Description and Operation
Sensors
Drivers
TMAP SENSOR DIAGNOSTICS
Description and Operation
DTC P0107
DTC P0108
DTC P0112
DTC P0113
TPS DIAGNOSTICS
Description and Operation
DTC P0122
DTC P0123
HO2S DIAGNOSTICS
Description and Operation
DTC P0031
DTC P0032
DTC P0051
DTC P0052
DTC P0131
DTC P0132
DTC P0134
DTC P0151
DTC P0152
DTC P0154
FUEL INJECTOR DIAGNOSTICS
Description and Operation
DTC P0261
DTC P0262
DTC P0264
DTC P0265
CKP SENSOR DIAGNOSTICS
Description and Operation
DTC P0371, P0374
PURGE SOLENOID DIAGNOSTICS
Description and Operation
DTC P0444
DTC P0445
VSS DIAGNOSTICS
Description and Operation
DTC P0502
DTC P0503
IDLE SPEED CONTROL DIAGNOSTICS
Description and Operation
DTC P0506, P0507
ECT SENSOR DIAGNOSTICS
Description and Operation
DTC P0117
DTC P0118
SYSTEM RELAY DIAGNOSTICS
Description and Operation
DTC P1001
DTC P1002
ECM INTERNAL DIAGNOSTICS
Description and Operation
DTC P0603
DTC P0605
DTC U0300
DTC P0641
Description and Operation
DTC P0641
BANK ANGLE SENSOR DIAGNOSTICS
Description and Operation
DTC P1151
DTC P1152
DTC P1009
General
DTC P1009
COMBUSTION EFFICIENCY DIAGNOSTICS
Description and Operation
DTC P1353, P1356
COOLING FAN DIAGNOSTICS
Description and Operation
DTC P0691
DTC P0692
Fan Inoperative, No DTCs
Fan Runs Continually, No DTCs
JSS DIAGNOSTICS
Description and Operation
DTC P1501
DTC P1502
Will Only Crank in Neutral
Description and Operation
Will Only Crank in Neutral
ENGINE PERFORMANCE DIAGNOSTICS
Description and Operation
 DTC P1505
Hesitation or Loss of Power Test
Starts Hard or Emits Black Smoke
STARTS, THEN STALLS
Description and Operation
STARTS, THEN STALLS
IGN COIL DRIVER DIAGNOSTICS
Description and Operation
DTC P2300
DTC P2301
DTC P2303
DTC P2304
Engine Cranks But Will Not Start
Description and Operation
Engine Cranks But Will Not Start
Misfire at Idle or Under Load
Description and Operation
Inline Spark Tester
Misfire at Idle or Under Load
ABS
ANTI-LOCK BRAKE SYSTEM (ABS) GENERAL INFORMATION
Description and Operation
INTERNAL FAULT DIAGNOSTICS
Description and Operation
DTC C1014, C1040, C1055, C1061, C1062, C1065, C1066
WSS DIAGNOSTICS
Description and Operation
DTC C1021, C1023, C1025, C1027, C1029
DTC C1032
DTC C1034
BRAKE INPUT DIAGNOSTICS
Description and Operation
DTC C1094
DTC C1212
INVALID VIN DIAGNOSTICS
Description and Operation
DTC C1159, C1178, C1184
ABS INDICATOR ALWAYS ON, FLASHING OR INOPERATIVE
Description and Operation
ABS Indicator Continuously Flashing, No DTCs
ABS Indicator Always On or Inoperative
Wiring
Wiring Diagrams
General
Wiring Diagrams
Wire Harness Connectors
General
Connector End Views
Connector Locations
Connector Repair
BOSCH COMPACT 1.1M SEALED CONNECTORS
Repair
DELPHI GT SEALED CONNECTORS
Repair
DELPHI METRI-PACK SEALED CONNECTORS
 Repair
DELPHI MICRO 64 SEALED CONNECTORS
Repair
DEUTSCH DT AND DTM SEALED CONNECTORS
Repair
FURUKAWA QLW SEALED CONNECTORS
Repair
JAE MX19 SEALED CONNECTOR
Repair
MOLEX MX SEALED CONNECTORS
Repair
SEALED SPLICE CONNECTORS
Repair
SUMITOMO DL SEALED AND MT CONNECTORS
Repair
SUMITOMO MTW AND MTL UNSEALED CONNECTORS
Repair
TYCO GET 64 SEALED CONNECTORS
Repair
TYCO JUNIOR POWER TIMER SEALED CONNECTORS
Repair
TYCO JUNIOR POWER TIMER UNSEALED CONNECTORS
Repair
TYCO MCP SEALED CONNECTORS
Repair
TYCO MULTILOCK UNSEALED CONNECTOR
Repair
TYCO SUPERSEAL 1.5 SEALED CONNECTORS
Repair
YAZAKI SSD SEALED CONNECTORS
Repair
Reference
GLOSSARY
Acronyms and Abbreviations
METRIC CONVERSION
Conversion Table
FLUID CONVERSIONS
United States System
Metric System
British Imperial System
TORQUE CONVERSION
United States System
Metric System
Backmatter
Backmatter
Backmatter
Backmatter
 WARNING

The rider's safety depends upon proper motorcycle service and maintenance. If a procedure in this manual is not
within your capabilities or you do not have the correct tools, have a Harley-Davidson dealer perform the procedure.
Improper service or maintenance could result in death or serious injury. (00627b)

This electrical diagnostic manual has been prepared with two purposes in mind. First, it will acquaint the user with the
construction of the Harley-Davidson product and assist in the performance of repair. Secondly, it will introduce to the
professional Harley-Davidson Technician the latest field-tested and factory-approved diagnostic methods. We sincerely
believe that this manual will make your association with Harley-Davidson products more pleasant and profitable.
Refer to the table below for the content layout of this manual.

Generated list of chapters

Use the TABLE OF CONTENTS (which follows this FOREWORD) and the INDEX (at the back of this manual) to quickly
locate subjects. Chapters and topics in this manual are sequentially numbered for easy navigation.

For example, a cross-reference shown as 2.2 SPECIFICATIONS refers to chapter 2 CHASSIS, heading 2.2
SPECIFICATIONS.

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

A number of acronyms and abbreviations are used in this document. See the Acronyms and Abbreviations for a list of
acronyms, abbreviations and definitions.
Special Tools

Description Part Number Qty.

DIGITAL TECHNICIAN II HD-48650 1

WARNING

Stop the engine when refueling or servicing the fuel system. Do not smoke or allow open flame or sparks near
gasoline. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00002a)

Good preparation is very important for efficient service work. Start each job with a clean work area. This will allow the
repair to proceed as smoothly as possible. It will also reduce the incidence of misplaced tools and parts.

Clean a motorcycle that is excessively dirty before work starts. Cleaning will occasionally uncover sources of trouble.
Gather any tools, instruments and any parts needed for the job before work begins. Interrupting a job to locate tools or
parts is a distraction and causes needless delay.

NOTE

To avoid unnecessary disassembly, carefully read all related service information before repair work begins.

In figure legends, the number which follows the name of a part indicates the quantity necessary for one complete
assembly.

When servicing a vehicle equipped with the Harley-Davidson Smart Security System (H-DSSS), first disarm the
system. Keep the fob close to the vehicle or use DIGITAL TECHNICIAN II (Part Number:HD-48650) to disable
the system. Activate the system after service is completed.
In addition to the information presented in this manual, Harley-Davidson Motor Company will periodically issue service
bulletins to Harley-Davidson dealers. Service bulletins cover interim engineering changes and supplementary information.
Consult the service bulletins to keep your product knowledge current and complete.
 WARNING

Harley-Davidson parts and accessories are designed for Harley-Davidson motorcycles. Using non-Harley-Davidson
parts or accessories can adversely affect performance, stability or handling, which could result in death or serious
injury. (00001b)

To achieve satisfactory and lasting repairs, carefully follow the service manual instructions and use only genuine Harley-
Davidson replacement parts. Behind the emblem bearing the words GENUINE HARLEY-DAVIDSON stand more than 100
years of design, research, manufacturing, testing and inspecting experience. This is your assurance that the parts you are
using will fit right, operate properly and last longer.
Statements in this manual preceded by the following words are of special significance.

WARNING

WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
(00119a)

CAUTION

CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.
(00139a)

NOTICE

NOTICE indicates a potentially hazardous situation which, if not avoided, may result in property damage. (00140b)

NOTE

Refers to important information. It is recommended that you take special notice of these items.

Proper service and repair are important for the safe, reliable operation of all mechanical products. The service procedures
recommended and described in this manual are effective methods for performing service operations.

WARNING

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

Some of these service operations require the use of tools specially designed for the purpose. These special tools should
be used when and as recommended. It is important to note that some warnings against the use of specific service
methods, which could damage the motorcycle or render it unsafe, are stated in this manual. However, remember that
these warnings are not all-inclusive. Inadequate safety precautions could result in death or serious injury.

Since Harley-Davidson could not possibly know, evaluate or advise the service trade of all possible ways in which service
might be performed, or of the possible hazardous consequences of each method, we have not undertaken any such broad
evaluation. Accordingly, anyone who uses a service procedure or tool which is not recommended by Harley-Davidson
must first thoroughly satisfy himself that neither his nor the operator's safety will be jeopardized as a result. Failure to do
so could result in death or serious injury.
 WARNING

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

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

Special Tools

All tools mentioned in this manual with a part number beginning with "HD", "J" or "B" must be ordered through your
local Harley-Davidson dealer. Special tools may only be purchased, serviced or warrantied through a Harley-Davidson
dealer.

Specific use of special tools is not discussed in this manual.

Refer to the tool instruction sheet for instructions. If the
tool
instructions are misplaced, a copy can be obtained online at
[Link] > My Toolbox > Edit > Bosch Tool Site.

LOCTITE Sealing and Threadlocking Products

Some procedures in this manual call for the use of LOCTITE products. If you have any questions regarding LOCTITE
product usage or retailer/wholesaler locations, contact Loctite Corp. at [Link].
Apple, Alcantara S.p.A., Allen, Amp Multilock, Bluetooth, Brembo, City Navigator, Delphi, Deutsch, Dunlop, Dynojet, Fluke,
G.E. Versilube, Garmin, Gunk, Hydroseal, Hylomar, iPhone, iPod, Kevlar, Lexan, Loctite, Lubriplate, Keps, K&N,
Magnaflux, Marson Thread-Setter Tool Kit, MAXI fuse, Molex, Michelin, MPZ, Mulitilock, nano, NGK, Novus, Packard,
Pirelli, Permatex, Philips, PJ1, Pozidriv, Road Tech, Robinair, S100, Sems, SiriusXM, Snap-on, Teflon, Threadlocker,
Torca, Torco, TORX, Tufoil, Tyco, Ultratorch, Velcro, X-Acto and XM Satellite Radio are among the trademarks of their
respective owners.
Bar & Shield, Boom!, Cross Bones, Cruise Drive, CVO, Digital Tech, Digital Technician, Digital Technician II, Dyna, Electra
Glide, Evolution, Fat Bob, Fat Boy, Forty-Eight, Glaze, Gloss, H-D, [Link], Harley, Harley-Davidson, HD, Heritage
Softail, Iron 883, Low Rider, Milwaukee-Eight, Night Rod, Nightster, Night Train, Profile, Reflex, Revolution, Road Glide,
Road King, Road Tech, Rocker, Screamin' Eagle, Seventy-Two, Softail, Sportster, Street Glide, Street Rod, Sun Ray,
Sunwash, Super Glide, SuperLow, Supersmart, Switchback, SYN3, TechLink, TechLink II, Tour-Pak, Tri Glide, Twin Cam
88, Twin Cam 88B, Twin Cam 96, Twin Cam 96B, Twin Cam 103, Twin Cam 103B, Twin Cam 110, Twin Cam 110B, Twin-
Cooled, Ultra Classic, V-Rod, VRSC and Harley-Davidson Genuine Motor Parts and Genuine Motor Accessories are
among the trademarks of H-D U.S.A., LLC.
All photographs, illustrations and procedures may not necessarily depict the most current model or component, but are
based on the latest production information available at the time of publication.

Since product improvement is our continual goal, Harley-Davidson reserves the right to change specifications, equipment
or designs at any time without notice and without incurring obligation.
Table 1. Fuel System Specifications

FUEL SYSTEM TYPE

Intake Side draft throttle body

Recommended fuel 87 Octane or higher

Table 2. Fuel Pump Specifications

MEASUREMENT VALUE

Pressure 359–441 kPa (52–64 psi)

Current draw 6A or less

Table 3. Idle Speed Specifications

ADJUSTMENT RPM

Normal idle speed 1350 Nominal, non-adjustable

Table 4. Battery Specifications

BATTERY SPECIFICATIONS

Size 12V/12 AH/225CCA

Type Sealed, AGM

Table 5. Spark Plug Specifications

SPARK PLUG SPECIFICATIONS

Gap 0.8-0.9 mm 0.031-0.035 in

Table 6. Spark Plug Cable Specifications

SPECIFICATION FRONT REAR

Length (in) 10.6 18.5

Length (mm) 268 470

Resistance (ohms) 3000-8000 4625-12340

Table 7. Starter Specifications

STARTER SPECIFICATIONS

Cranking current 160A

Free speed 8800 rpm (MIN)

Free current 27A

Table 8. Alternator Specifications

ALTERNATOR VALUE

AC voltage output 16-20 VAC per 1000 rpm

Stator coil resistance 0.1-0.3 ohms

Three phase 35 amp system

Table 9. Regulator Specifications

REGULATOR VALUE

Amperes @ 3600 rpm 30-35A

Voltage @ 3600 rpm 14.4-14.6V @ 24 °C (75 °F)

Overheat protection Approximately 105 °C (221 °F)

Table 10. Fuse Specifications

ITEM RATING (AMPERES)

Battery 5

Fuel pump 10

Fan 15

ACC 5

Lights 10

Lights/instruments 10

Ignition 15

Security 10

P&A accessory (if equipped) 5

Table 11. Ignition Coil Specifications

WINDING RESISTANCE

Ignition coil primary resistance at room temperature 0.3-0.7 ohms

Ignition coil secondary resistance at room temperature 1500-2400 ohms

Table 12. JSS Specifications

JSS SPECIFICATIONS

Gap 0.5–2.5 mm (0.02–0.09 in)

Use initial diagnostics as a starting point to efficiently troubleshoot concerns. A basic understanding of electronics and a
general knowledge of the vehicle are necessary to effectively use this manual.

NOTE

Certain diagnostic procedures require part removal. See the service manual for details.

Before diagnosing a concern, perform a general functional test of the vehicle to verify the concern. This will also identify
any other issues that may affect diagnostics. Use the procedures in this chapter for initial diagnostics.

NOTE

Follow the steps in the order listed in the diagnostic procedures. Never jump to a test in another procedure. All "Go to
Test" statements refer to a test in that procedure.
1. Fuse Test

1. Verify all fuses are good.

2. Are all fuses good?
a. Yes. Go to Test 2.
b. No. Replace fuse.

2. Security System Test

1. Verify security indicator is not flashing.

2. Is security indicator flashing?
a. Yes. Disarm security system then continue.
b. No. Go to Test 3.

3. Odometer Function Test

1. Enter odometer self-diagnostics. See Odometer Self-Diagnostics.

2. Does odometer self-diagnostics mode function properly?
a. Yes. Go to Test 4.
b. No. Go to Test 5.

4. DTC Test

1. Check DTCs. See Retrieving Trouble Codes.

NOTE

Historic DTCs are not to be diagnosed unless the condition is reoccurring and intermittent.

2. Are any current DTCs present?

a. Yes. Refer to Diagnostic Trouble Codes (DTCs) and Fault Conditions.
b. No. Refer to Symptom Table.

5. BUS Err Test

1. Turn IGN ON.

2. Does the odometer display BUS Err?
a. Yes. See Description and Operation.
b. No. Go to Test 6.

6. Odometer Inoperative Test

 1. Turn IGN ON.
2. Does the odometer display illuminate?
a. Yes. See Description and Operation.
b. No. Go to Test 7.

7. Battery Power Test

1. Turn IGN ON.

2. Does the headlamp and/or tail lamp illuminate?
a. Yes. Go to Test 8.
b. No. Verify battery condition and connections. If all are good, see Description and Operation.

8. Starter Test

1. Attempt to start vehicle.

2. Does the starter crank?
a. Yes. See Description and Operation.
b. No. See Description and Operation.
Diagnostic Tips

For a quick check of instrument function, turn the ignition ON. Background lighting will illuminate, gauge needle will
sweep its full range of motion and indicator lamps will illuminate.

Table 1. Diagnostic Trouble Codes (DTCs) and Fault Conditions

DTC PRIORITY FAULT CONDITION SOLUTION

ORDER

B1200 37 Internal fault Description and

Operation

B1210 173 Fuel level sender shorted low/open Description and

Operation

B1211 179 Fuel level sender shorted high Description and

Operation

B2176 236 Security antenna output open Description and

Operation

B2177 237 Security antenna output shorted high Description and

Operation

B2178 238 Security antenna output shorted low Description and

Operation

B2255 243 Trip switch stuck Description and

Operation

B2272 33 Voltage high Description and

Operation

B2400 30 SCM internal fault Security Lamp

C0562 38 ABS voltage low Description and

Operation

C0563 40 ABS voltage high Description and

Operation

C1014 180 ABS ECU relay error Description and

Operation

C1021 188 ABS front WSS always zero Description and

Operation

C1023 189 ABS rear WSS always zero Description and

Operation

C1025 191 ABS front wheel speed intermittent Description and

Operation
C1027 192 ABS rear wheel speed intermittent Description and
Operation

C1029 190 ABS wheel speed difference too high Description and
Operation

C1032 186 ABS front wheel speed circuit open/shorted Description and
Operation

C1034 187 ABS rear wheel speed circuit open/shorted Description and
Operation

C1040 181 ABS pump/motor error Description and

Operation

C1055 39 ABS ECU internal error Description and

Operation

C1061 182 ABS front apply solenoid circuit open/high resistance Description and
Operation

C1062 184 ABS front release solenoid circuit open/high Description and
resistance Operation

C1065 183 ABS rear apply solenoid circuit open/high resistance Description and
Operation

C1066 185 ABS rear release solenoid circuit open/high Description and
resistance Operation

C1094 297 Front/rear brake applied without decel Description and

Operation

C1159 43 ABS invalid stored VIN Description and

Operation

C1178 41 ABS no VIN received from ECM Description and

Operation

C1184 42 ABS invalid VIN from ECM Description and

Operation

C1212 298 Front/rear brake not applied with decel Description and
Operation

P0031 127 Front HO2S low/open Description and

Operation

P0032 130 Front HO2S shorted high Description and

Operation

P0051 128 Rear HO2S low/open Description and

Operation

P0052 129 Rear HO2S shorted high Description and

Operation
P0107 89 MAP sensor failed low/open Description and
Operation

P0108 90 MAP sensor failed high/open port Description and

Operation

P0112 105 IAT sensor shorted low Description and

Operation

P0113 107 IAT sensor high/open Description and

Operation

P0117 91 ECT sensor shorted low Description and

Operation

P0118 94 ECT sensor high/open Description and

Operation

P0122 63 TPS 1 low/open Description and

Operation

P0123 64 TPS 1 high Description and

Operation

P0131 131 O2 sensor low/engine lean (front) Description and

Operation

P0132 133 Engine running rich (front) Description and

Operation

P0134 135 O2 sensor high/open (front) Description and

Operation

P0151 132 O2 sensor low/engine lean (rear) Description and

Operation

P0152 134 Engine running rich (rear) Description and

Operation

P0154 136 O2 sensor high/open (rear) Description and

Operation

P0261 85 Fuel injector low/open (front) Description and

Operation

P0262 86 Fuel injector shorted high (front) Description and

Operation

P0264 87 Fuel injector low/open (rear) Description and

Operation

P0265 88 Fuel injector shorted high (rear) Description and

Operation

P0371 53 CKP sensor wrong number of pulses Description and

Operation
P0374 52 CKP sensor no pulses Description and
Operation

P0444 121 Purge solenoid low/open Description and

Operation

P0445 122 Purge solenoid shorted high Description and

Operation

P0502 117 VSS failed low Description and

Operation

P0503 118 VSS failed high Description and

Operation

P0506 106 Idle speed control - rpm too low Description and
Operation

P0507 108 Idle speed control - rpm too high Description and
Operation

P0512 108 Starter request circuit Description and

Operation

P0562 109 ECM voltage low Description and

Operation

P0563 18 ECM voltage high Description and

Operation

P0603 15 ECM EEPROM memory error Description and

Operation

P0605 14 ECM FLASH memory error Description and

Operation

P0616 109 Starter relay circuit low Description and

Operation

P0617 110 Starter relay circuit high Description and

Operation

P0641 50 5 Volt reference out of range Description and

Operation

P0691 95 Fan/cooling relay output low/open Description and

Operation

P0692 98 Fan/cooling relay output high Description and

Operation

P0704 128 Clutch switch input circuit Description and

Operation

P0851 129 Park/neutral switch input circuit low Description and

Operation
P1001 19 System relay coil low/open Description and
Operation

P1002 20 System relay coil shorted high Description and

Operation

P1151 219 Bank angle sensor low Description and

Operation

P1152 220 Bank angle sensor high/open Description and

Operation

P1501 143 JSS low Description and

Operation

P1502 144 JSS high/open Description and

Operation

P1505 442 Power limit violation Description and

Operation

P2300 77 Ignition coil driver low/open (front) Description and

Operation

P2301 78 Ignition coil driver shorted high (front) Description and

Operation

P2303 79 Ignition coil driver low/open (rear) Description and

Operation

P2304 80 Ignition coil driver shorted high (rear) Description and

Operation

U0001 1 CAN bus error Description and

Operation

U0002 16 CAN comm bus perf error Description and

Operation

U0100 7 Lost comm w/ECM Description and

Operation

U0121 11 Lost comm w/ABS Description and

Operation

U0156 10 Lost comm w/speedo Description and

Operation

U0168 12 Lost comm w/SCM Description and

Operation

U0300 13 Internal control module software incompatibility Description and

Operation
Special Tools

Description Part Number Qty.

DIGITAL TECHNICIAN II HD-48650 1

There are two levels of diagnostics.

The most sophisticated mode uses a computer-based diagnostic package called DIGITAL TECHNICIAN II (Part
Number:HD-48650).
The second mode requires using odometer self-diagnostics. Speedometer, ECM, SCM (if equipped) and ABS (if
equipped) DTCs can be accessed and cleared.
Diagnostic Mode

1. Press and hold the trip odometer reset switch located on the speedometer, while turning the IGN ON.
2. Release the trip odometer reset switch. "diag" will appear on the odometer display.
3. Press and release the trip odometer reset switch. "ECM" will appear on the odometer display. It will have either
a "Y" or an "N" after it, depending if there are any ECM codes.
4. Quickly press and release the trip odometer reset switch to cycle through the modules. The modules include
the ECM, SPDO, Sec, and ABS.
5. When the desired module is displayed, press and hold the trip odometer reset switch.
6. If any DTCs are stored in the module, the odometer will display the DTC. Quickly pressing and releasing the
trip odometer reset switch will cycle through the stored DTCs.
7. When all the DTCs have been cycled the odometer will display "end".
8. Pressing and holding the trip odometer reset switch with a DTC displayed clears all the DTCs in that module. If
DTCs are not to be cleared quickly press and release the trip odometer reset switch. The part number of the
module will be displayed.
9. Press and release the trip odometer reset switch again to continue to the next module.
10. Make note of all DTCs. Clear all the DTCs and operate the vehicle to verify DTCs set and are current. Historic
DTCs are not to be diagnosed unless the condition is recurring and intermittent.
11. Turn the IGN OFF to exit diagnostic mode. If IGN is not turned off, vehicle will exit diagnostics mode when
vehicle starts moving.
Special Tools

Description Part Number Qty.

DIGITAL TECHNICIAN II HD-48650 1

There are two types of DTCs: current and historic. If a DTC is stored, it can be read using a computer-based diagnostic
package called DIGITAL TECHNICIAN II (Part Number:HD-48650).

NOTE

Current DTCs reside in the memory of the ECM, SCM, ABS and speedometer until the DTC is resolved.

A historic DTC will be cleared after a total of 40 error free ignition cycles (start and run cycle) have elapsed.

Current

Current DTCs failed the last time the module ran the parameters to set them. Therefore, the fault that caused them is
normally present.

Historic

If a particular problem happens to resolve itself, the active status problem is dropped and it becomes a historic DTC
rather than a current DTC. DTCs will also lose their current status when the ignition is turned off. If the problem still
exists when the ignition is turned on, the code will show as current.

Historic DTCs are stored for 40 ignition cycles to assist in the diagnosis of intermittent faults. On the 40th error free
cycle, the DTC will clear itself.

It is important to note that historic DTCs will exist whenever the system indicates the existence of a current fault. See
Multiple Trouble Codes if multiple DTCs are found.

Diagnostic procedures are designed for use with current DTCs. As a result, they frequently suggest part replacement.
When diagnosing a historic DTC, the procedures can be helpful but should not lead to part replacement without
verification that the part is faulty.
All DTCs are assigned a priority number to determine the order in which they should be diagnosed. If there are multiple
DTCs present, always diagnose the highest priority first. Refer to Diagnostics.

1. Complete the repair.

2. Restore connections.
3. Clear DTCs.
4. Start vehicle.
5. Perform odometer self-diagnostics test to verify repair and DTCs have been cleared. If any DTCs are still present,
refer to Diagnostics.
Clear DTCs after any diagnostic or repair procedure. The odometer is capable of displaying and clearing ECM,
speedometer, SCM and ABS DTCs. Once the DTCs are cleared perform a road test to verify DTCs do not return. It is
important to perform a road test and not simply start the motorcycle since some DTCs may require vehicle speed or other
inputs in order to validate repair.
See Figure 1. The security lamp turns on when:

current DTCs are present in the SCM.

non emission related DTCs are present in the ECM.

When the IGN is turned ON, the security lamp will illuminate for approximately four seconds and then turn off. The ECM
and SCM controls the security lamp by sending a CAN message to the speedometer. After the security lamp turns off
following the first four second illumination period, one of two events may occur.

The lamp remains off. This indicates there are no current fault conditions or stored DTCs currently detected by the
SCM or ECM.
If the lamp illuminates again and remains lit, a current DTC exists.

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Figure 1. Security Lamp Operation

To diagnose ECM system problems, start by observing the behavior of the check engine lamp.

NOTE

"IGN ON" means that the engine stop switch is set to RUN (although the engine is not running).

When the IGN is turned ON, check engine lamp will illuminate.

Start engine, if it fails to turn off after start up, DTC exists.

Emissions related DTCs illuminate the check engine lamp for three warm up cycles after the DTC has transitioned
from current to historic.

1. See Figure 1. After engine startup, one of two events may occur.
a. The lamp turns off, which indicates there are no current fault conditions or stored DTCs currently detected
by the ECM.
b. If the lamp continues to illuminate and remains illuminated, a current or historic DTC exists.
2. See Code Types for a complete description of DTC formats.

NOTE

Some DTCs can only be fully diagnosed during actuation. For example, a problem with the ignition coil will be
considered a current fault even after the problem is corrected. The ECM will not know of its resolution until after the
coil is exercised by the vehicle start sequence. In this manner, there may sometimes be a false indication of the
current DTC.

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Figure 1. Check Engine Lamp

If no DTCs are present, address any symptoms indicating a malfunction. Refer to Table 1.

Table 1. Symptom Table

CHAPTER SYMPTOM DIAGNOSTIC PROCEDURE

Serial Data Loss of communication Description and Operation

Starting and Charging Battery runs down during use Description and Operation

Low battery after extended IGN OFF Description and Operation

Low or no charging Description and Operation

Nothing clicks Description and Operation

Overcharging Description and Operation

Start relay clicks Description and Operation

Starter solenoid clicks Description and Operation

Starter spins, but does not engage Description and Operation

Starter stalls or spins too slowly Description and Operation

Instruments Coolant lamp always on Description and Operation

Coolant lamp inoperative Description and Operation

High beam indicator always on Description and Operation

High beam indicator inoperative Description and Operation

Low fuel lamp inoperative Description and Operation

Neutral lamp always on Description and Operation

Neutral lamp inoperative Description and Operation

Oil pressure lamp always on Description and Operation

Oil pressure lamp inoperative Description and Operation

Speedometer inoperative Description and Operation

Trip odometer functions inoperative Description and Operation

Turn signal indicator always on Description and Operation

Turn signal indicator inoperative Description and Operation

Horn, Lighting and Turn Signals All turn signals inoperative Description and Operation

Any front turn signal inoperative Description and Operation

 Any rear turn signal inoperative Description and Operation

Front running lamp inoperative Description and Operation

Headlamp inoperative Description and Operation

Horn always on Description and Operation

Horn inoperative Description and Operation

Left turn signals inoperative Description and Operation

LP lamp inoperative Description and Operation

Position lamp inoperative Description and Operation

Right turn signals inoperative Description and Operation

Stop lamp always on Description and Operation

Stop lamp inoperative Description and Operation

Tail lamp inoperative Description and Operation

Engine Management Engine cranks but will not start Description and Operation

Fan inoperative, no DTCs Description and Operation

Fan runs continually, no DTCs Description and Operation

Fuel pump inoperative Description and Operation

Hesitation or loss of power Description and Operation

Misfire at idle or under load Description and Operation

Starts hard or emits black smoke Description and Operation

Starts, then stalls Description and Operation

Will only crank in neutral Description and Operation

Special Tools

Description Part Number Qty.

HD BATTERY DIAGNOSTIC GRX-3110HD 1

STATION

FLUKE AC/DC CURRENT PROBE HD-39617 1

DIGITAL MULTIMETER (FLUKE 78) HD-39978 1

IAC TEST LIGHT HD-41199-3 1

TEST CONNECTOR KIT HD-41404 1

BREAKOUT BOX HD-42682 1

BREAKOUT BOX ADAPTERS HD-46601 1

DIGITAL TECHNICIAN II HD-48650 1

BREAKOUT BOX HD-50390-1 1

ECM CABLE HD-50390-4 1

ECM OVERLAY HD-50390-4-P 1

ABS CABLE HD-50390-6 1

INLINE SPARK TESTER KIT HD-51724 1

GRX-3110 HD Battery Diagnostic Station

See Figure 1. Read the HD BATTERY DIAGNOSTIC STATION (Part Number:GRX-3110HD) instruction manual to
perform a battery test. The test results dictate battery condition.

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Figure 1. GRX-3110 HD Battery Diagnostic Station

HD-51724 Inline Spark Tester Kit

See Figure 2. The INLINE SPARK TESTER KIT (Part Number:HD-51724) is used to verify adequate spark at the
spark plug.

1. Install the inline spark tester between front ignition coil cable and spark plug.
2. Start engine and inspect tester light. The light will flash on each spark event if power is transmitted to the plug.
3. Remove inline spark tester and install cable on plug. Repeat procedure for rear cylinder.

NOTE

The coil will not produce spark voltage with both spark plugs removed. When checking for spark, use the inline
spark tester with both plugs installed.

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Figure 2. Spark Tester

HD-39978 Digital Multimeter (Fluke 78)

See Figure 3. The DIGITAL MULTIMETER (FLUKE 78) (Part Number:HD-39978) is used for various tests
throughout this manual.

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Figure 3. Digital Multimeter (Fluke 78)

HD-39617 Fluke AC/DC Current Probe

See Figure 4. The FLUKE AC/DC CURRENT PROBE (Part Number:HD-39617) is used to measure current draw.
Use in conjunction with DIGITAL MULTIMETER (FLUKE 78) (Part Number:HD-39978).

1. Connect the current probe to positive and negative input terminals on the multimeter.
2. Position the rotary switch to mV dc (millivolt direct current).
3. Push the ON/OFF button and the ON indicator will illuminate.
4. With the inductive jaws empty, turn the zero adjust so the multimeter reads 0.000 mV.
5. Clamp the inductive jaws around the conductor being tested.
6. With the circuit activated, read the multimeter display (1 mV=1 A).

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Figure 4. Fluke AC/DC Current Probe

HD-41199-3 IAC Test Light

The IAC TEST LIGHT (Part Number:HD-41199-3) is used to verify that the electrical circuit from the ECM to the IAC
is operating correctly.

1. See Figure 5. Disconnect IAC [87B] and connect test light.

2. Turn IGN ON for 2 seconds, then turn IGN OFF for 10 seconds. Test light behavior may follow two patterns.
The color of the lights is not relevant to IAC operation.
a. Normal behavior: At IGN ON, test lights will alternately flash and then remain on to confirm ECM
signals. At IGN OFF, lights alternately flash and go out after 10 second reset procedure.
b. Problem indicated: One or more lights fail to illuminate during IGN ON/IGN OFF cycle.

NOTE

There is a remote possibility that one of the circuits is shorted to voltage which would have been indicated
by a steady light. Disconnect ECM and turn ignition ON. Probe terminals to check for this condition.

3. Disconnect test light and connect IAC [87B].

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1 IAC test light

2 IAC [87]

Figure 5. IAC Test Light

HD-41404 Harness Connector Test Kit

The TEST CONNECTOR KIT (Part Number:HD-41404) contains pin and socket terminals and stackable banana jack
patch cords used to test circuits. The pin and socket terminals are used to connect to various connectors. See the tool
instruction sheet for specific terminal usage.

NOTE

To prevent terminal damage while using the probe tips, insert the probe tip straight into the cavity. Hold it steady
during the test. Do not wiggle or move the probe tip once it has been inserted into the terminal. Do not use more
than one probe per terminal or cavity at any one time.

HD-50390-1 Breakout Box (ECM)

The BREAKOUT BOX (Part Number:HD-50390-1) and ECM CABLE (Part Number:HD-50390-4) splice into the main
harness. Used in conjunction with a multimeter, it allows circuit diagnosis of wiring harness and connections without
having to probe with sharp objects. Install breakout box in series as follows:

NOTE

See wiring diagrams for ECM terminal functions. ECM is located under seat.

1. Access the ECM.

2. Press latch and disconnect ECM connectors [78B-1] and [78B-2].
3. See Figure 6. Connect BREAKOUT BOX (Part Number:HD-50390-1) and ECM CABLE (Part Number:HD-
50390-4) to connectors.
4. Verify ECM OVERLAY (Part Number:HD-50390-4-P) is in position on BOB.
5. When testing is complete, remove the BOB and restore connections.
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1 Breakout box

2 ECM overlay

3 Wiring harness [78-B]

4 ECM

5 ECM [78-A]

Figure 6. ECM Breakout Box Connection

HD-42682 Breakout Box (Instruments)

The BREAKOUT BOX (Part Number:HD-42682) and BREAKOUT BOX ADAPTERS (Part Number:HD-46601)
connect to the speedometer [39]. Used in conjunction with a multimeter, it allows circuit diagnosis of wiring harness
and connections without having to probe with sharp objects. Install BOB in series using the black connectors:

1. Access the speedometer [39].

2. See Figure 7. Press latch and disconnect [39B].
3. Connect BREAKOUT BOX ADAPTERS (Part Number:HD-46601) to [39A] and [39B].
4. Attach black connectors from BREAKOUT BOX (Part Number:HD-42682) to BREAKOUT BOX ADAPTERS
(Part Number:HD-46601). All tests will be performed using the black side of BOB.
5. Remove BOB and jumper harness and restore connections when testing is completed.

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 1 Breakout box adapter to harness connector

2 Speedometer [39]

3 Breakout box adapter HD-46601 to speedometer [39]

4 Breakout box harness connector

5 Breakout box HD-42682

Figure 7. Instrument Breakout Box Connection

HD-50390-1 Breakout Box (ABS)

The BREAKOUT BOX (Part Number:HD-50390-1) and ABS CABLE (Part Number:HD-50390-6) splice to the ABS
harness. Used in conjunction with a multimeter, allows circuit diagnosis of wiring harness and connections without
having to probe with sharp objects. Install BOB in series:

NOTE

See wiring diagrams for ABS module terminal functions.

1. Access the ABS module.

2. See Figure 8. Remove the ABS module bracket screws.
3. Press latch and disconnect ABS module [166B]. Route the connector below the ABS module.
4. Connect BREAKOUT BOX (Part Number:HD-50390-1) and ABS CABLE (Part Number:HD-50390-6) to
[166].
5. In some cases it is necessary to leave the ABS module disconnected.
6. When testing is completed remove BOB, restore connections and install the ABS module bracket screws.

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1 ABS module [166A]

2 ABS module

3 Breakout box

4 ABS overlay
 5 Breakout box cable

6 Wiring harness [166B]

Figure 8. ABS Breakout Box Installation

HD-42682 Breakout Box (SCM)

The BREAKOUT BOX (Part Number:HD-42682) and BREAKOUT BOX ADAPTERS (Part Number:HD-46601)
connect to the SCM [326]. Used in conjunction with a multimeter, it allows circuit diagnosis of wiring harness and
connections without having to probe with sharp objects. Install BOB in series using the black connectors:

1. Access the SCM [326].

2. See Figure 9. Press latch and disconnect [326B].
3. Connect BREAKOUT BOX ADAPTERS (Part Number:HD-46601) to [326A] and [326B].
4. Attach black connectors from BREAKOUT BOX (Part Number:HD-42682) to BREAKOUT BOX ADAPTERS
(Part Number:HD-46601). All tests will be performed using the black side of BOB.
5. Remove BOB and jumper harness and restore connections when testing is completed.

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1 Breakout box HD-42682

2 Breakout box harness connector

3 Breakout box adapter HD-46601 to SCM [326]

4 Breakout box adapter to harness connector

5 SCM [326]

6 SCM

Figure 9. SCM Breakout Box Connection

HD-48650 Digital Technician II

DIGITAL TECHNICIAN II (Part Number:HD-48650) is a computer based diagnostic device used to

communicate/diagnose and program systems/modules.
Diagnostics in this manual are developed under the assumption that DIGITAL TECHNICIAN II (Part Number:HD-
48650) is not available.
Voltage Drop Test

The voltage drop test:

Helps locate poor connections or components with excessive voltage drops.

Measures the difference in potential or the actual voltage dropped between the source and destination.
Checks the integrity of the wiring, switches, fuses, connectors and contacts between the source and destination.
Identifies poor grounds.
A voltage drop test measures the difference in voltage between two points in a circuit. The amount of voltage dropped
over any part of a circuit is directly related to the amount of resistance in that part of the circuit. A poor connection may
cause an ohmmeter to give a good reading, but voltage drop test will locate the problem.

Components such as wires, switches and connectors are designed to have very little resistance and therefore very
little voltage drop. A possible fault is indicated when a voltage drop is greater than 1.0V across components. This
could indicate a high resistance in that circuit.

The benefits of testing this way are:

Readings are not as sensitive to real battery voltage.

Readings show the actual voltage dropped not just the presence of voltage.
The system is tested as it is actually being used.
Testing is more accurate and displays hard-to-find poor connections.
Starting circuits, lighting circuits or ignition circuits can be tested with this approach. (Start from the most positive
and go to the most negative destination or component.)
When testing a typical power circuit, place the positive (red) meter lead on the most positive part of the circuit (or the
positive battery post). Remember, there is nothing more positive than the positive post of the battery. Place the
negative (black) meter lead at the positive side of the connector in question. Activate the circuit. Move the negative
meter lead through the circuit until the high voltage drop is found.

When testing a typical ground circuit, place the negative lead on the most negative part of the circuit (or the negative
battery post). Remember, there is nothing more negative than the negative post of the battery. Place the positive
meter lead at the negative side of the connector in question. Activate the circuit. Move the positive meter lead through
the circuit until the high voltage drop is found.

The following steps demonstrate a typical starter circuit voltage drop test:

1. See Figure 1. Disconnect the fuel pump connector [86] to prevent the engine from starting.
a. Connect the red meter lead to the positive battery post.
b. Connect the black meter lead to the battery power starter post on the starter and observe the meter
reading.
c. Crank the starter and observe the meter reading. The difference in the voltage is the voltage drop.

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 1 Battery

2 Starter solenoid

3 Starter motor

Figure 1. To Starter Terminal

2. See Figure 2. Move the black meter lead to the starter side post of the starter solenoid. Crank the starter.

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1 Battery

2 Starter solenoid

3 Starter motor

Figure 2. To Starter Solenoid Starter Terminal

3. See Figure 3. Move the black meter lead to the battery side post on the starter solenoid. Crank the starter.

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1 Battery

2 Starter solenoid
 3 Starter motor

Figure 3. To Starter Solenoid Battery Terminal

4. See Figure 4. Finally move the black meter lead to the negative battery post and the red meter lead to the
starter case. Crank the starter.

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1 Battery

2 Starter solenoid

3 Starter motor

Figure 4. Starter Ground Circuit

When testing a typical ground circuit, place the black meter lead on the negative battery post. Place the red meter lead
at the negative side of the connector in question. Move the red meter lead through the circuit until the high voltage
drop is found.
Special Tools

Description Part Number Qty.

DIGITAL MULTIMETER (FLUKE 78) HD-39978 1

DIGITAL TECHNICIAN II HD-48650 1

BREAKOUT BOX HD-50390-1 1

ECM CABLE HD-50390-4 1

ECM OVERLAY HD-50390-4-P 1

Wiggle test checks for the presence of intermittents in a wiring harness. If available, use DIGITAL TECHNICIAN II (Part
Number:HD-48650) to perform wiggle test.

1. See Figure 1. Connect DIGITAL MULTIMETER (FLUKE 78) (Part Number:HD-39978) to wiring harness between
suspect connections. When diagnosing ECM connections, use BREAKOUT BOX (Part Number:HD-50390-1),
ECM CABLE (Part Number:HD-50390-4) and ECM OVERLAY (Part Number:HD-50390-4-P) to simplify the
procedure. See How To Use Diagnostic Tools.
2. Set the multimeter to read voltage changes.
3. Start motorcycle engine and run at idle.
4. Shake or wiggle harness to detect intermittents. If intermittents are present, radical voltage changes register on
multimeter.

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Figure 1. Digital Multimeter (Fluke 78)

Relay Variation

See Figure 1. Relays normally have four or five terminals. Circuitry inside relays are very similar with the exception of
normally closed contact being eliminated in four terminal relays. Some relays have five terminals at the base, even
though internally 4 or 87A are not connected.

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1 Standard 5 terminal relay

2 Standard 4 terminal relay

Figure 1. Standard Relays

Relay Test

A relay can be tested using the motorcycle's 12V battery and a multimeter.

1. Unplug relay from relay block.

2. See Figure 2 and Figure 3 to energize the relay. Connect relay terminal 85 to negative battery terminal and
relay terminal 86 to positive battery terminal.

NOTE

Some relays contain internal diodes. If the applied voltage is not the correct polarity, the diode could be damaged.

3. Test for continuity between terminals 30 and 87.

a. A good relay shows continuity (continuity tester lamp on or a zero ohm reading on the ohmmeter).
b. A malfunctioning relay will not show continuity and must be replaced.

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 View interactive image

1 Ohmmeter

2 Battery

3 Start relay

Figure 2. Four Terminal Relay Test

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1 Battery

2 Start relay

3 Ohmmeter

Figure 3. Five Terminal Relay Test

Special Tools

Description Part Number Qty.

DIGITAL TECHNICIAN II HD-48650 1

CAN bus circuits are used by modules and diagnostic tools to share information.

The instruments, ECM, SCM and ABS (if equipped) all communicate on the CAN bus. The CAN communication uses a
(W/BK) and (W/R) wire in a twisted pair that runs to all the modules. It is used to transfer data from one module to the
other. It also runs to the DLC [91] and is used to communicate with the modules using DIGITAL TECHNICIAN II (Part
Number:HD-48650).

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1 Main fuse [5]

2 DLC [91]

3 Fuse block [64]

4 Relay block [62B-2]

5 Relay block [62B-1]

6 Diode pack [201]

7 Purge solenoid [95]

8 VSS [65]

9 Ground

10 Rear WSS [168]

Figure 1. Under Right Side Cover

Special Tools

Description Part Number Qty.

DIGITAL TECHNICIAN II HD-48650 1

Electronic Control Module (ECM)

See Figure 1. The ECM is located under the seat. The ECM monitors the engine sensors to enhance performance and
driveability. This is done by adjusting the fuel and spark delivery based on the information provided by the sensors.

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1 Security module [326]

2 ECM [78-2]

3 Rear lighting [7]

4 Flasher [69]

5 BAS [134]

6 Engine harness [145]

7 Starter solenoid [128]

8 ECM [78-1]

9 Security antenna [142]

10 Terminating resistor [319]

Figure 1. Under Seat: Except 750A

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1 Terminating resistor [319]

2 Left turn lamp [19]

3 LP lamp [40]

4 Right turn lamp [18]

5 Stop/tail lamp [93]

6 ECM [78-2]

7 Flasher [69]

8 BAS [134]

9 Engine harness [145]

10 P&A connector

11 Starter solenoid [128]

12 ECM [78-1]

13 Security antenna [142]

14 Security module [326]

Figure 2. Under Seat: 750A

Security Control Module (SCM)

See Figure 1. The SCM is located in the rear fender behind the passenger seat. The SCM controls the security
functions on the motorcycle including sounding an alarm (if equipped). It is disarmed with either an assigned fob or by
entering a PIN using the trip switch. It sends information to the ECM over the CAN BUS circuit letting the ECM know if
the security parameters are met for the vehicle to start. The SCM is also connected to the turn signal circuits enabling
it to flash the turn signals.

Terminating Resistor

See Figure 1. The terminating resistor is located in the rear fender behind the passenger seat. This is one of two
terminating resistors in the CAN circuit the other is internal to the ECM.

Instruments

The speedometer contains the indicator and warning lamps for the motorcycle. It uses the CAN communication to
receive information from the other modules to know which lamps to illuminate at any given time. Vehicle speed is also
sent to the speedometer over the CAN bus.

ABS Module

See Figure 3. The ABS ECU is located under the radiator inside the left frame rail. The ECU receives input from the
brake switches and the front and rear WSS. These inputs are used by the ECU to control the HCU. The ABS ECU
communicates over the CAN bus to the speedometer to control the ABS indicator.

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1 Neutral switch [131]

2 JSS [133]

3 CKP [79]

4 Cooling fan [97]

5 Horn [122-1]

6 Horn [122-2]

7 Front WSS [167]

 8 Starter

9 VSS [65]

10 Voltage regulator [77]

11 ABS ECU [166]

12 Oil pressure switch [120]

Figure 3. Front of Engine

Data Link Connector (DLC)

See Under Right Side Cover. The DLC is located under the right side cover. The DLC is used to connect the
DIGITAL TECHNICIAN II (Part Number:HD-48650) to the motorcycle.
There are several DTCs that may set due to an issue with the CAN bus communication. Different DTCs are set by different
modules. If a module loses communication with the rest of the system it will set DTC U0001, but the DTC cannot be
retrieved until the CAN lines to that module are restored. If a module goes offline due to loss of PWR or GND or a loss of
communication to that module, the module will not set a code, but the other modules will set DTCs indicating they are not
able to communicate with it. When the speedometer recognizes a problem on the CAN bus it may display "BUS Err" on
the odometer.

"VINERR" may also be displayed in the odometer if the speedometer and ECM are not seeing the same VIN in both
modules. This will usually occur after replacing one of the two modules. The two modules must have the VINs match
before they can share odometer mileage.

Both the ECM and speedometer retain the odometer value. If the speedometer is replaced, it will display the odometer
value stored in the ECM. The replacement speedometer will become locked to the ECM after 50 km (31.1 mi) have been
accumulated. The trip B odometer will display the countdown mileage. Once the countdown reaches zero, the
speedometer is locked to the ECM. If installed on another vehicle, the odometer will display "VINERR". If the speedometer
is removed from the vehicle before the countdown reaches zero, it has not been locked to the ECM. This mileage
countdown allows for a road test to verify that speedometer replacement was the proper repair.

Diagnostic Tips

Modules must have power and be grounded in order to communicate. Therefore, when checking any communication
DTC be sure to check the power and ground connections on the suspected module. BUS Err may show on the
odometer if the following are present:

CAN wires shorted together.

CAN wire shorted to PWR or GND.
CAN transceiver on some module failed shorted.
Non-compliant module connected to the CAN bus.
Special Tools

Description Part Number Qty.

DIGITAL TECHNICIAN II HD-48650 1

CAN communication uses a set of wires in a twisted pair. These two wires are designated as CAN low and CAN high
circuits. Both circuits are connected to the ECM, instruments, SCM and the ABS module (if equipped). The ECM contains
a 120 ohm terminating resistor and a second terminating resistor located in the harness under the seat. Typical resistance
between the two circuits is approximately 60 ohms.

DTC U0001 indicates there is a fault on the CAN bus circuits. This code can be set by the ECM, SCM, instruments and
ABS module (if equipped). This code is usually accompanied by other "U" codes because it causes a loss of
communication between the modules on the CAN bus.

NOTE

Always start from Description and Operation before proceeding.

Table 1. Code Description

DTC DESCRIPTION

U0001 CAN bus error

NOTE

If DIGITAL TECHNICIAN II (Part Number:HD-48650) is connected to the DLC [91] and communicating with the
vehicle, the odometer self-diagnostics will not function properly. Disconnect DIGITAL TECHNICIAN II (Part
Number:HD-48650) before entering odometer self-diagnostics.

Connector Information

For additional information about the connectors in the following diagram(s) and diagnostic procedure(s), see
Connector Locations.
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Figure 1. CAN Bus Circuit

Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

BREAKOUT BOX HD-42682 1

BREAKOUT BOX ADAPTERS HD-46601 1

BREAKOUT BOX HD-50390-1 1

ECM CABLE HD-50390-4 1

ECM OVERLAY HD-50390-4-P 1

ABS CABLE HD-50390-6 1

Table 1. DTC U0001

POSSIBLE CAUSES

Short between CAN low and high circuits

Open in CAN high circuit

Open in CAN low circuit

Short to ground on CAN high circuit

Short to ground on CAN low circuit

Short to voltage on CAN high circuit

Short to voltage on CAN low circuit

1. Battery Fuse Test

1. Turn IGN OFF.

2. Check battery fuse in fuse block [64].
3. Is fuse good?
a. Yes. Go to Test 2.
b. No. Replace battery fuse.

2. Speedometer System Voltage Test

1. Disconnect speedometer [39].

2. Connect BREAKOUT BOX ADAPTERS (Part Number:HD-46601) to [39]. Attach connectors from
BREAKOUT BOX (Part Number:HD-42682) to harness adapters, leaving [39A] disconnected.
 3. Turn IGN ON.
4. Measure voltage between BOB terminal 5 and ground.
5. Is battery voltage present?
a. Yes. Connect [39]. Go to Test 3.
b. No. Repair open in (R/O) wire.

3. CAN Bus Test

1. Turn IGN OFF.

2. Remove the main fuse.
3. Using TEST CONNECTOR KIT (Part Number:HD-41404), test resistance between DLC [91A] terminals 1 and
3.
4. Is resistance between 50-70 ohms?
a. Yes. Go to Test 14.
b. No. Resistance is less than 50 ohms. Go to Test 4.
c. No. Resistance is more than 70 ohms. Go to Test 9.

4. Speedometer Test

1. Disconnect speedometer [39].

2. Is resistance between [91A] terminals 1 and 3 between 50-70 ohms?
a. Yes. Replace speedometer.
b. No. With ABS. Go to Test 5.
c. No. Without ABS but with SCM. Go to Test 6.
d. No. Without ABS and SCM. Go to Test 7.

5. ABS Test

1. Disconnect ABS module [166].

2. Is resistance between [91A] terminals 1 and 3 between 50-70 ohms?
a. Yes. Replace ABS module.
b. No. With SCM. Go to Test 6.
c. No. Without SCM. Go to Test 7.

6. SCM Test

1. Disconnect SCM [326].

2. Is resistance between [91A] terminals 1 and 3 between 50-70 ohms?
a. Yes. Replace SCM.
b. No. Go to Test 7.

7. ECM Test

1. Disconnect ECM [78B-1].

2. Is resistance between [91A] terminals 1 and 3 between 100-130 ohms?
a. Yes. Replace ECM.
 b. No. Go to Test 8.

8. Terminating Resistor Test

1. Disconnect terminating resistor [319].

2. Is resistance between [91A] terminals 1 and 3 greater than 500 ohms?
a. Yes. Replace terminating resistor [319].
b. No. Repair short between (W/R) and (W/BK) wires.

9. CAN Circuit Open Test

1. While watching the resistance between DLC [91A] terminals 1 and 3, disconnect ECM [78-1].
2. Did the resistance change?
a. Yes. Go to Test 10.
b. No. Go to Test 12.

10. CAN High Circuit Resistance to Terminating Resistor Test

1. Disconnect terminating resistor [319].

2. Test resistance between [91A] terminal 1 (W/R) wire and [319B] terminal A.
3. Is resistance less than 0.5 ohm?
a. Yes. Go to Test 11.
b. No. Repair (W/R) wire.

11. CAN Low Circuit Resistance to Terminating Resistor Test

1. Test resistance between [91A] terminal 3 (W/BK) wire and [319B] terminal B.
2. Is resistance less than 0.5 ohm?
a. Yes. Replace terminating resistor.
b. No. Repair (W/BK) wire.

12. CAN Low Circuit Resistance to ECM Test

1. Connect BREAKOUT BOX (Part Number:HD-50390-1) and ECM CABLE (Part Number:HD-50390-4) to
wiring harness [78B-1], leaving [78A-1] disconnected.
2. Verify ECM OVERLAY (Part Number:HD-50390-4-P) is in position on BOB.
3. Test resistance between [91A] terminal 3 (W/BK) wire and BOB [78-1] terminal 13.

NOTE

When measuring resistance (ohms), compensate for test lead resistance before performing the measurement.
Select the ohms position and touch the test leads together. Refer to the multimeter user's manual to either zero
the display or manually subtract the test lead resistance from the measured circuits value.

4. Is resistance less than 0.5 ohm?

a. Yes. Go to Test 13.
 b. No. Repair (W/BK) wire.

13. CAN High Circuit Resistance to ECM Test

1. Test resistance between [91A] terminal 1 (W/R) wire and BOB terminal 14.
2. Is resistance less than 0.5 ohm?
a. Yes. Replace ECM.
b. No. Repair (W/R) wire.

14. CAN High Circuit Short to Ground Test

1. Turn IGN OFF.

2. Test resistance between [91A] terminal 1 and ground.
3. Is resistance less than 1000 ohms?
a. Yes. Go to Test 15.
b. No. Go to Test 21.

15. Speedometer Test

1. Disconnect speedometer [39].

2. Is resistance between [91A] terminal 1 and ground less than 1000 ohms?
a. Yes. Go to Test 16.
b. No. Replace speedometer.

16. ECM Test

1. Disconnect ECM [78B-1].

2. Is resistance between [91A] terminal 1 and ground less than 1000 ohms?
a. Yes. With ABS. Go to Test 17.
b. Yes. Without ABS but with SCM. Go to Test 18.
c. Yes. Without ABS and SCM. Go to Test 19.
d. No. Replace ECM.

17. ABS Test

1. Disconnect ABS module [166].

2. Is resistance between [91A] terminal 1 and ground less than 1000 ohms?
a. Yes. With SCM. Go to Test 18.
b. Yes. Without SCM. Go to Test 19.
c. No. Replace ABS module.

18. SCM Test

1. Disconnect SCM [326].

 2. Is resistance between [91A] terminal 1 and ground less than 1000 ohms?
a. Yes. Go to Test 19.
b. No. Replace SCM.

19. Terminating Resistor Test

1. Disconnect terminating resistor [319].

2. Is resistance between [91A] terminal 1 and ground less than 1000 ohms?
a. Yes. Repair short to ground in (W/R) wire.
b. No. Go to Test 20.

20. CAN Low Circuit Short to Ground Test

1. Test resistance between [91A] terminal 3 and ground.

2. Is resistance less than 1000 ohms?
a. Yes. Repair short to ground in (W/BK) wire.
b. No. Replace terminating resistor [319].

21. CAN High Circuit Short to Voltage Test

1. Install the main fuse.

2. Turn IGN ON.
3. Test voltage between [91A] terminal 1 and ground.
4. Is voltage greater than 4V?
a. Yes. Go to Test 22.
b. No. With SCM. Go to Test 28.
c. No. Without SCM but with ABS. Go to Test 30.
d. No. Without ABS and SCM. Go to Test 32.

22. Speedometer Test

1. Turn IGN OFF.

2. Disconnect speedometer [39].
3. Turn IGN ON.
4. Is voltage between [91A] terminal 1 and ground greater than 4V?
a. Yes. Go to Test 23.
b. No. Replace speedometer.

23. ECM Test

1. Turn IGN OFF.

2. Disconnect ECM [78B-1].
3. Turn IGN ON.
4. Is voltage between [91A] terminal 1 and ground greater than 4V?
a. Yes. With ABS. Go to Test 24.
b. Yes. Without ABS but with SCM. Go to Test 25.
 c. Yes. Without ABS and SCM. Go to Test 26.
d. No. Replace ECM.

24. ABS Test

1. Turn IGN OFF.

2. Disconnect ABS module [166].
3. Turn IGN ON.
4. Is voltage between [91A] terminal 1 and ground greater than 4V?
a. Yes. With SCM. Go to Test 25.
b. Yes. Without SCM. Go to Test 26.
c. No. Replace ABS module.

25. SCM Test

1. Turn IGN OFF.

2. Disconnect SCM [326].
3. Turn IGN ON.
4. Is voltage between [91A] terminal 1 and ground greater than 4V?
a. Yes. Go to Test 26.
b. No. Replace SCM.

26. Terminating Resistor Test

1. Turn IGN OFF.

2. Disconnect terminating resistor [319].
3. Turn IGN ON.
4. Is voltage between [91A] terminal 1 and ground greater than 4V?
a. Yes. Repair short to voltage in (W/R) wire.
b. No. Go to Test 27.

27. CAN Low Circuit Short to Voltage Test

1. Test voltage between [91A] terminal 3 and ground.

2. Is voltage present?
a. Yes. Repair short to voltage in (W/BK) wire.
b. No. Replace terminating resistor.

28. CAN Low Circuit Resistance to SCM Test

1. Turn IGN OFF.

2. Remove cables and ECM BOB, connect ECM.
3. Disconnect SCM [326].
4. Connect BREAKOUT BOX ADAPTERS (Part Number:HD-46601) to [326B].
5. Attach connectors from BREAKOUT BOX (Part Number:HD-42682) to harness adapters, leaving [326A]
disconnected. See How To Use Diagnostic Tools.
 6. Test resistance between [91A] terminal 3 (W/BK) wire and BOB terminal 7.
7. Is resistance less than 0.5 ohm?
a. Yes. Go to Test 29.
b. No. Repair (W/BK) wire between [91A] terminal 3 and [326B] terminal 7.

29. CAN High Circuit Resistance to SCM Test

1. Test resistance between [91A] terminal 1 (W/R) wire and BOB terminal 8.
2. Is resistance less than 0.5 ohm?
a. Yes, with ABS. Go to Test 30.
b. Yes, without ABS. Go to Test 32.
c. No. Repair (W/R) wire between [91A] terminal 1 and [326B] terminal 8.

30. CAN Low Circuit Resistance to ABS Module Test

1. Remove cables and SCM BOB.

2. Connect SCM.
3. Disconnect ABS [166].
4. Connect BREAKOUT BOX (Part Number:HD-50390-1) and ABS CABLE (Part Number:HD-50390-6) to
wiring harness connector [166B].
5. Leaving [166A] disconnected, test resistance between [91A] terminal 3 (W/BK) wire and BOB terminal 11.
6. Is resistance less than 0.5 ohm?
a. Yes. Go to Test 31.
b. No. Repair (W/BK) wire between [91A] terminal 3 and [166B] terminal 11.

31. CAN High Circuit Resistance to ABS Module Test

1. Test resistance between [91A] terminal 1 (W/R) wire and BOB terminal 2.
2. Is resistance less than 0.5 ohm?
a. Yes. Go to Test 32.
b. No. Repair (W/R) wire between [91A] terminal 1 and [166B] terminal 2.

32. CAN Low Circuit Resistance to Speedometer Test

1. Remove cables and ABS BOB.

2. Connect ABS module.
3. Disconnect speedometer [39].
4. Connect BREAKOUT BOX (Part Number:HD-42682) and BREAKOUT BOX ADAPTERS (Part Number:HD-
46601) to wiring harness connectors [39B].
5. Leaving [39A] disconnected, test resistance between [91A] terminal 3 (W/BK) wire and BOB terminal 8.
6. Is resistance less than 0.5 ohm?
a. Yes. Go to Test 33.
b. No. Repair (W/BK) wire between [91A] terminal 3 and [39B] terminal 8.

33. CAN High Circuit Resistance to Speedometer Test

1. Test resistance between [91A] terminal 1 (W/R) wire and BOB terminal 2.
2. Is resistance less than 0.5 ohm?
a. Yes. Concern is intermittent. Perform wiggle test and verify all connectors are properly connected. See
Wiggle Test.
b. No. Repair (W/R) wire between [91A] terminal 1 and [39B] terminal 2.
Special Tools

Description Part Number Qty.

DIGITAL TECHNICIAN II HD-48650 1

The CAN bus circuit provides a means for the ECM, SCM, speedometer and the ABS ECU (if equipped) to communicate
their current status. When all operating parameters on the CAN bus are within specifications, a state of health message is
sent between the components.

The CAN bus is made up of two circuits. The (W/R) is the CAN bus high circuit and the (W/BK) is the CAN bus low circuit.
Both of these circuits show approximately 2.5V when measured between each of the circuits and ground with the IGN ON.
These circuits are connected to each module on the CAN bus network. A fault on either one of these circuits will cause
several modules to set "U" codes and may cause a complete loss of communication between all modules.

Table 1. Code Description

DTC DESCRIPTION

U0002 CAN comm bus perf error

U0100 Lost comm with ECM

U0121 Lost comm with ABS

U0156 Lost comm with speedo

U0168 Lost comm with SCM

U0300 Internal control module software incompatibility

Diagnostic Tips

Modules must have power in order to communicate on the CAN bus. It is important to check for good power and
ground on any module that is not communicating effectively on the CAN bus network.

At least two modules will set a DTC when one module loses the ability to communicate on the CAN bus.
When two or more modules set the same U code it indicates a problem with the device or wiring at the device the
codes are set against.
Two or more modules setting the same U code intermittently indicates an intermittent problem with the device or
wiring.
See Wiggle Test to test wiring to the component.

Historic U codes may be found if battery power has been lost for any reason or if the main or battery fuses have been
disconnected and reconnected. This may also happen when using DIGITAL TECHNICIAN II (Part Number:HD-
48650), and the diagnostics connector has been disconnected before vehicle has been powered down. This is not an
indication of a problem and does not cause any loss of functionality.

Connector Information

For additional information about the connectors in the following diagram(s) and diagnostic procedure(s), see
Connector Locations.
 View interactive
View interactive image
image

Figure 1. CAN Bus Circuit

Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

BREAKOUT BOX HD-50390-1 1

ECM CABLE HD-50390-4 1

ECM OVERLAY HD-50390-4-P 1

Table 1. DTC U0100 Diagnostic Faults

POSSIBLE CAUSES

Open in CAN high circuit to the ECM

Open in CAN low circuit to the ECM

Open in ECM system power circuit

Open in ECM ground circuit

1. System Power Test

1. Turn IGN OFF.

2. Connect BREAKOUT BOX (Part Number:HD-50390-1) and ECM CABLE (Part Number:HD-50390-4) to
wiring harness connectors [78B-1] and [78B-2], leaving [78A] disconnected. See How To Use Diagnostic
Tools.
3. Verify ECM OVERLAY (Part Number:HD-50390-4-P) is in position on BOB.
4. Turn IGN ON.
5. Using TEST CONNECTOR KIT (Part Number:HD-41404), test voltage between BOB [78-2] terminal 16 and
ground.
6. Is battery voltage present?
a. Yes. Go to Test 2.
b. No. Repair open in (W/GY) wire.

2. ECM [78-1] Ground Test

1. Turn IGN OFF.

2. Test resistance between BOB [78-1] terminal 10 and ground.
3. Is resistance less than 0.5 ohm?
a. Yes. Go to Test 3.
b. No. Repair open in (BK/GN) wire.

3. ECM [78-2] Ground Test

 1. Test resistance between BOB [78-2] terminal 10 and ground.
2. Is resistance less than 0.5 ohm?
a. Yes. Go to Test 4.
b. No. Repair open in (BK/GN) wire.

4. CAN High Circuit Continuity Test

1. Test resistance between BOB [78-1] terminal 14 and DLC [91A] terminal 1.
2. Is resistance less than 0.5 ohm?
a. Yes. Go to Test 5.
b. No. Repair open in (W/R) wire.

5. CAN Low Circuit Continuity Test

1. Test resistance between BOB [78-1] terminal 13 and [91A] terminal 3.

2. Is resistance less than 0.5 ohm?
a. Yes. Go to Test 6.
b. No. Repair open in (W/BK) wire.

6. Module Test

1. Check DTCs.
2. Is only speedometer setting DTC?
a. Yes. Go to Test 8.
b. No, ABS module only. Go to Test 7.
c. No, SCM module only. Go to Test 9.
d. No, multiple modules. Replace ECM.

7. Verify ABS Module Test

1. Turn IGN OFF.

2. Replace ABS module with a known good ABS module.
3. Turn IGN ON.
4. Attempt to start vehicle.
5. Check DTC.
6. Did DTC U0100 reset?
a. Yes. Check vehicle for any accessories connected to the CAN bus.
b. No. Replace ABS module.

8. Verify Speedometer Test

1. Turn IGN OFF.

2. Replace speedometer with a known good speedometer.
3. Turn IGN ON.
4. Attempt to start vehicle.
 5. Check DTC.
6. Did DTC U0100 reset?
a. Yes. Check vehicle for any accessories connected to the CAN bus.
b. No. Replace speedometer.

9. Verify SCM Test

1. Replace SCM with a known good SCM.

2. Turn IGN ON.
3. Attempt to start vehicle.
4. Check DTC.
5. Did DTC U0100 reset?
a. Yes. Check vehicle for any accessories connected to the CAN bus.
b. No. Replace SCM.
Special Tools

Description Part Number Qty.

BREAKOUT BOX HD-50390-1 1

ABS OVERLAY HD-50390-1-P1 1

ABS CABLE HD-50390-6 1

Table 1. DTC U0121 Diagnostic Faults

POSSIBLE CAUSES

Open in CAN high circuit to the ABS ECU

Open in CAN low circuit to the ABS ECU

Open in ABS system power circuit

Open in ABS ground circuit

1. ABS Voltage Test

1. Turn IGN OFF.

2. Connect BREAKOUT BOX (Part Number:HD-50390-1) and ABS CABLE (Part Number:HD-50390-6) to
wiring harness [166B], leaving [166A] disconnected. See How To Use Diagnostic Tools.
3. Verify ABS OVERLAY (Part Number:HD-50390-1-P1) is in position on BOB.
4. Test voltage between BOB terminal 9 and ground.
5. Is battery voltage present?
a. Yes. Go to Test 2.
b. No. Repair open in (R) wire.

2. ABS Ground Test

1. Test voltage between BOB terminals 9 and 10.

2. Is battery voltage present?
a. Yes. Go to Test 3.
b. No. Repair open in (BK) wire.

3. Switched Power Test

1. Turn IGN ON.

2. Test voltage between BOB terminal 4 and ground.
3. Is battery voltage present?
a. Yes. Go to Test 4.
b. No. Go to Test 6.
4. CAN High Circuit Continuity Test

1. Turn IGN OFF.

2. Test resistance between ABS [166B] terminal 2 and DLC [91A] terminal 1.
3. Is resistance less than 0.5 ohm?
a. Yes. Go to Test 5.
b. No. Repair open in (W/R) wire.

5. CAN Low Circuit Continuity Test

1. Turn IGN OFF.

2. Test resistance between [166B] terminal 11 and [91A] terminal 3.
3. Is resistance less than 0.5 ohm?
a. Yes. Replace ABS module.
b. No. Repair open in (W/BK) wire.

6. Switched Power Ground Test

1. Turn IGN OFF.

2. Test continuity between BOB terminal 4 and ground.
3. Is continuity present?
a. Yes. Repair short to ground in (V/GY) wire.
b. No. Repair open in (V/GY) wire.

7. Switched Power Voltage Test

1. Turn IGN ON.

2. Test voltage between BOB terminal 4 and ground.
3. Is battery voltage present?
a. Yes. Repair open in (V/GY) wire.
b. No. Replace ABS module.
Table 1. DTC U0002 Diagnostic Faults

POSSIBLE CAUSES

ABS ECU malfunction

1. ABS ECU DTC Test

1. Clear DTCs.
2. Turn IGN OFF.
3. Check DTCs.
4. Did DTC U0002 reset?
a. Yes. Replace ABS module.
b. No. ABS system working properly.
Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

BREAKOUT BOX HD-42682 1

BREAKOUT BOX ADAPTERS HD-46601 1

Table 1. SCM Inoperative: DTC U0168 Diagnostic Faults

POSSIBLE CAUSES

Open in CAN high circuit to the SCM

Open in CAN low circuit to the SCM

Open in SCM battery power circuit

Open in SCM ground circuit

NOTE

If the security fuse keeps opening due to a shorted circuit check the turn signal circuits for a short to ground. A shorted
turn signal circuit will cause the security fuse to open when the security module flashes the turn signals.

1. SCM Voltage Test

1. Turn IGN OFF.

2. Connect BREAKOUT BOX (Part Number:HD-42682) and BREAKOUT BOX ADAPTERS (Part Number:HD-
46601) to the wiring harness [326B], leaving [326A] disconnected. See How To Use Diagnostic Tools.
3. Using TEST CONNECTOR KIT (Part Number:HD-41404), test voltage between BOB terminal 1 and ground.
4. Is battery voltage present?
a. Yes. Go to Test 2.
b. No. Repair open in (R) wire.

2. SCM Ground Test

1. Test voltage between BOB terminals 1 and 6.

2. Is battery voltage present?
a. Yes. Go to Test 3.
b. No. Repair open in (BK/GN) wire.

3. CAN High Circuit Continuity Test

 1. Test resistance between BOB terminal 8 and DLC [91A] terminal 1.
2. Is resistance less than 0.5 ohm?
a. Yes. Go to Test 4.
b. No. Repair open in (W/R) wire.

4. CAN Low Circuit Continuity Test

1. Test resistance between BOB terminal 7 and [91A] terminal 3.

2. Is resistance less than 0.5 ohm?
a. Yes. Replace SCM.
b. No. Repair open in (W/BK) wire.
Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

BREAKOUT BOX HD-42682 1

BREAKOUT BOX ADAPTERS HD-46601 1

Table 1. Speedometer Inoperative: DTC U0156 Diagnostic

Faults

POSSIBLE CAUSES

Open in CAN high circuit to the speedometer

Open in CAN low circuit to the speedometer

Open in speedometer battery power circuit

Open in speedometer ground circuit

1. Speedometer Voltage Test

1. Turn IGN OFF.

2. Connect BREAKOUT BOX (Part Number:HD-42682) and BREAKOUT BOX ADAPTERS (Part Number:HD-
46601) to the wiring harness [39B], leaving [39A] disconnected.
3. Using TEST CONNECTOR KIT (Part Number:HD-41404), test voltage between BOB terminal 5 and ground.
4. Is battery voltage present?
a. Yes. Go to Test 2.
b. No. Repair open in (R/O) wire.

2. Speedometer Ground Test

1. Test voltage between BOB terminals 5 and 7.

2. Is battery voltage present?
a. Yes. Go to Test 3.
b. No. Repair open in (BK/GN) wire.

3. CAN High Circuit Continuity Test

1. Test resistance between BOB terminal 2 and DLC [91A] terminal 1.

2. Is resistance less than 0.5 ohm?
a. Yes. Go to Test 4.
b. No. Repair open in (W/R) wire.
4. CAN Low Circuit Continuity Test

1. Test resistance between BOB terminal 8 and [91A] terminal 3.

2. Is resistance less than 0.5 ohm?
a. Yes. Replace speedometer.
b. No. Repair open in (W/BK) wire.
Special Tools

Description Part Number Qty.

DIGITAL TECHNICIAN II HD-48650 1

Table 1. DTC U0300 Diagnostic Faults

POSSIBLE CAUSES

ECM software error

1. Verify DTC

1. Clear DTC.
2. Turn IGN OFF for 30 seconds.
3. Check DTCs.
4. Did DTC reset?
a. Yes. Go to Test 2.
b. No. System working properly.

2. Reflash ECM

1. Using DIGITAL TECHNICIAN II (Part Number:HD-48650) reflash ECM.

2. Clear DTCs.
3. Turn IGN OFF for 30 seconds.
4. Check DTCs.
5. Did DTC reset?
a. Yes. Replace ECM.
b. No. System working properly.
Test battery condition by using a voltage, charging or load test.

Always fully charge battery prior to load testing.

NOTE

An automatic, constant monitoring battery charger/tender with a charging rate of 5 amps or less at less than 14.6V is
recommended. The use of constant current chargers (including trickle chargers) to charge sealed AGM batteries is not
recommended. Any overcharge will cause dry-out and premature battery failure.
The voltmeter test provides a general indication of battery state of charge or condition. Check the voltage of the battery to
verify that it is in a 100% fully charged condition. Refer to Table 1.

If the open circuit (disconnected) voltage reading is below 12.6V, charge battery and then check voltage after battery has
set for 1-2 hours. If voltage reading is 12.7V or above, perform a load test. See Load Test.

Table 1. Voltmeter Test For Battery Charge Conditions

VOLTAGE STATE OF CHARGE

12.7 100%

12.6 75%

12.3 50%

12.0 25%

11.8 0%
Special Tools

Description Part Number Qty.

HD BATTERY DIAGNOSTIC GRX-3110HD 1

STATION

Test battery using the HD BATTERY DIAGNOSTIC STATION (Part Number:GRX-3110HD).

WARNING

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

1. Disconnect and remove battery.

2. Read GRX instruction manual before performing a battery test.
3. Connect HD BATTERY DIAGNOSTIC STATION (Part Number:GRX-3110HD) leads to the battery terminals.
4. Test results will include a decision on battery condition and measured state of charge. See Figure 1. The GRX
printer will provide a printout including test results:
a. GOOD BATTERY - Return battery to service.
b. REPLACE BATTERY - Replace battery.

View interactive
View interactive image
image

Figure 1. Battery Test Results Printout (Typical)

 WARNING

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

1. With vehicle battery on a bench, charge battery using an

automatic, constant monitoring battery charger approved
for AGM batteries.

NOTE

Always fully charge battery before testing or test

readings will be incorrect. Load testing a discharged
battery can also result in permanent battery damage.

WARNING

Turn battery load tester OFF before connecting

tester cables to battery terminals. Connecting tester
cables with load tester ON can cause a spark and
battery explosion, which could result in death or
serious injury. (00252a)

2. See Figure 1. Connect tester leads to battery posts and

place induction pickup over negative (black) cable.

NOTE

To avoid load tester and/or battery damage, do not

leave load tester switch turned ON for more than 20
seconds.

WARNING

Turn battery load tester OFF before disconnecting

tester cables to battery terminals. Disconnecting
tester cables with load tester ON can cause a spark
and battery explosion, which could result in death
or serious injury. (00253a)

WARNING

Connect positive (+) battery cable first. If positive (+)

cable should contact ground with negative (-) cable
connected, the resulting sparks can cause a battery
explosion, which could result in death or serious
 injury. (00068a)

NOTICE

Do not over-tighten bolts on battery terminals. Use

recommended torque values. Over-tightening
battery terminal bolts could result in damage to
battery terminals. (00216a)

3. Load battery at 50 percent of CCA rating using load tester.

Voltage reading after 15 seconds should be 9.6V or more
at 21 °C (70 °F). Refer to Table 1.

View interactive
View interactive image
image

1 Load tester

2 Induction pickup

3 Battery

Figure 1. Load Test Battery

Table 1. Battery Load Test

COLD CRANKING 100% 50%

AMPERAGE (CCA)

Street models 225 110

With IGN ON, battery voltage is supplied to the ignition relay and ignition fuse. The ignition fuse supplies battery voltage to
the engine stop switch and start switch.

With engine stop switch to RUN, battery voltage is supplied to the ECM.

When the start switch is pressed, power flows to the coil side of the start relay. The ground is controlled by the ECM. The
ECM monitors several inputs to determine if the vehicle is ready to start.
Starter

See Figure 1. The starter receives power from the battery through the starter solenoid and is grounded through the
starter case.

The starter output gear transfers rotation to the idler gear.

The idler gear transfers rotation to the starter clutch gear.
The starter clutch gear drives the alternator rotor assembly on the end of the crankshaft.
When the engine starts, the sprag clutch on the backside of the alternator rotor disengages the starter gear and the
rotor. This allows the starter gear and the rotor to rotate independently of each other.

View interactive
View interactive image
image

1 Neutral switch [131]

2 JSS [133]

3 CKP [79]

4 Cooling fan [97]

5 Horn [122-1]

6 Horn [122-2]

7 Front WSS [167]

8 Starter

9 VSS [65]

10 Voltage regulator [77]

11 ABS ECU [166]

12 Oil pressure switch [120]

Figure 1. Front of Engine

Starter Solenoid

See Figure 2. The starter solenoid provides power to the starter. The solenoid is a means of controlling a high
amperage device with a low amperage switch. The low amperage switch in this circuit is the start relay. When the start
relay is activated, it sends voltage to the starter solenoid. This makes a magnetic field that pulls a larger circuit closed,
allowing voltage to the starter.

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1 Security module [326]

2 ECM [78-2]

3 Rear lighting [7]

4 Flasher [69]

5 BAS [134]

6 Engine harness [145]

7 Starter solenoid [128]

8 ECM [78-1]

9 Security antenna [142]

10 Terminating resistor [319]

Figure 2. Under Seat: Except 750A

 View interactive
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image

1 Terminating resistor [319]

2 Left turn lamp [19]

3 LP lamp [40]

4 Right turn lamp [18]

5 Stop/tail lamp [93]

6 ECM [78-2]

7 Flasher [69]

8 BAS [134]

9 Engine harness [145]

10 P&A connector

11 Starter solenoid [128]

12 ECM [78-1]

13 Security antenna [142]

14 Security module [326]

Figure 3. Under Seat: 750A

Engine Stop Switch

The engine stop switch is located on the right hand controls. With the engine stop switch in the RUN position, battery
voltage is supplied to the ECM.

Start Switch

The start switch is a push button switch located in the right hand controls. When the start switch is pressed, power
flows to the coil side of the start relay.

Start Relay

See Figure 4. The start relay is located in the relay block under the right side cover. With the IGN ON, battery voltage
is supplied to the start relay through the ignition fuse. The ignition fuse supplies battery voltage to the engine stop
switch and the start switch. With the engine stop switch in the RUN position, battery voltage is supplied to the ECM.
When the start switch is pressed, power flows to the coil side of the start relay.

The ECM supplies the ground to the start relay, energizing the start relay. This allows battery voltage from the ignition
fuse to flow through the start relay to the starter solenoid.

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1 Main fuse [5]

2 DLC [91]

3 Fuse block [64]

4 Relay block [62B-2]

5 Relay block [62B-1]

6 Diode pack [201]

7 Purge solenoid [95]

8 VSS [65]

9 Ground

10 Rear WSS [168]

Figure 4. Under Right Side Cover

Ignition Switch

The ignition switch turns the electrical power to the vehicle on and/or off. The ignition switch has three positions.

OFF: The ignition switch turns off all power to the vehicle except for the components powered directly by the
battery.
ACC: The ignition switch allows power to flow through the ACC and lights/instrument fuses and supplies power to
only certain parts of the vehicle such as the lights and indicator lamps.
ON/IGN: The ignition switch supplies power for all the systems on the vehicle.

Battery

WARNING

Batteries contain sulfuric acid, which could cause severe burns to eyes and skin. Wear a protective face shield,
rubberized gloves and protective clothing when working with batteries. KEEP BATTERIES AWAY FROM
CHILDREN. (00063a)

WARNING

Never remove warning label attached to top of battery. Failure to read and understand all precautions contained in
warning, could result in death or serious injury. (00064a)

WARNING

Explosive hydrogen gas, which escapes during charging, could cause death or serious injury. Charge battery in a
well-ventilated area. Keep open flames, electrical sparks and smoking materials away from battery at all times.
KEEP BATTERIES AWAY FROM CHILDREN. (00065a)

WARNING

If battery becomes hot, gassing or spewing of electrolyte can occur, which could cause death or serious injury.
Unplug or turn OFF the charger until battery cools. (00412b)

WARNING

Batteries, battery posts, terminals and related accessories contain lead and lead compounds, and other chemicals
known to the State of California to cause cancer, and birth defects or other reproductive harm. Wash hands after
handling. (00019e)

NOTICE

If battery releases an excessive amount of gas during charging, decrease the charging rate. Overheating can
result in plate distortion, internal shorting, drying out or damage. (00413b)

The AGM batteries are permanently sealed, maintenance-free, valve-regulated, lead/calcium and sulfuric acid
batteries.

The battery is recharged by the alternator and kept from overcharging by the regulator during use.

See General. Battery condition can be determined by a voltage test, a conductance test or a load test.

A battery may be tested, whether fully charged or not, using the conductance test. However, the battery must be fully
charged to perform a load test.

Diagnostic Tips

The Voltage Drop procedure will help you to locate poor connections or components with excessive voltage drops.

Connector Information

For additional information about the connectors in the following diagram(s) and diagnostic procedure(s), see
Connector Locations.
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image

Figure 5. Starting Circuit

Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

Table 1. Starter Testing Diagnostic Faults

POSSIBLE CAUSES

Short to voltage at starter solenoid

Start switch malfunction

Short to voltage on start relay supply circuit

Start relay malfunction

1. Starting System Operational Test

1. Attempt to start vehicle.

2. Does starter spin?
a. Yes. Starter spins, but does not engage. See Starter Spins, But Does Not Engage.
b. Yes. Starter stalls or spins too slowly. See Starter Stalls or Spins Too Slowly.
c. Yes. Starter runs on after switch is released. Go to Test 3.
d. No. Go to Test 2.

2. Audible Noise Test

1. While listening for audible clicking noises from start relay and starter solenoid, press start switch.
2. Is there a click?
a. Yes. Start solenoid clicks. See Starter Solenoid Clicks.
b. Yes. Start relay clicks. See Start Relay Clicks.
c. No. See Nothing Clicks.

3. Starter Solenoid Test

1. Disconnect starter solenoid [128].

2. Does starter stop?
a. Yes. Go to Test 4.
b. No. Repair short to voltage between [128B] terminal 1 and starter solenoid (GN) wire, run test again. If
run on is present replace starter solenoid.

4. Start Switch Circuit Test

 1. Turn IGN OFF, remove start relay.
2. Turn IGN ON. Using TEST CONNECTOR KIT (Part Number:HD-41404), test voltage between relay block
[62B-1] socket terminal 3 (W/BN) and ground.
3. Is battery voltage present?
a. Yes. Go to Test 5.
b. No. Go to Test 7.

5. Start Switch Circuit Short to Voltage Test

1. Turn IGN OFF.

2. Disconnect right hand controls [22].
3. Turn IGN ON.
4. Test voltage between [22B] terminal 4 (W/BN) and ground.
5. Is voltage present?
a. Yes. Repair short to voltage between [22B] terminal 4 and [62B-1] socket terminal 3 (W/BN) wire.
b. No. Go to Test 6.

6. Start Switch Test

1. Test continuity between [22A] terminal 4 (W/BN) wire and terminal 3 (V/GY) wire.
2. Is continuity present?
a. Yes. Replace right hand control assembly.
b. No. Repair short to voltage on [22A] terminal 4 (W/BN) wire.

7. Start Relay Test

1. Perform relay test. See Relay Diagnostics.

2. Is the start relay good?
a. Yes. Perform wiggle test to locate short to voltage between relay block [62B-1] socket terminals 5
(TN/GY) wire or 4 (V/GY) wire. See Wiggle Test.
b. No. Replace start relay.
Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

BREAKOUT BOX HD-42682 1

BREAKOUT BOX ADAPTERS HD-46601 1

BREAKOUT BOX HD-50390-1 1

ECM CABLE HD-50390-4 1

ECM OVERLAY HD-50390-4-P 1

Table 1. Nothing Clicks Diagnostic Faults

POSSIBLE CAUSES

Low battery

Open ignition switch feed circuit

Start switch malfunction

Start relay malfunction

Ignition switch malfunction

Open ignition circuit

Open start switch circuit

Neutral switch malfunction

Open neutral circuit

Short to voltage on coil control circuit

Open ignition circuit

NOTE

Confirm the security system disarms either through PIN entry or fob. The security lamp turns off when security is
disarmed.

1. Battery Test

1. Perform battery test. See General.

 2. Did battery pass test?
a. Yes. Go to Test 2.
b. No. Replace battery, attempt to start engine, if nothing clicks, then continue with tests. Go to Test 2.

2. Relay Test

1. Perform relay test on system, ignition and start relays. See Relay Diagnostics.
2. Are relays good?
a. Yes. Install relays. Go to Test 3.
b. No. Replace bad relay. If problem is still present, continue with tests. Go to Test 3.

3. Ignition Circuit Test

1. Turn IGN ON.

2. Do right or left turn signals work?
a. Yes. Go to Test 9.
b. No. Go to Test 4.

4. Ignition Switch Supply Voltage Test

1. Turn IGN OFF.

2. Disconnect ignition switch [33].
3. Using TEST CONNECTOR KIT (Part Number:HD-41404), test voltage between [33B] terminal 1 (R) wire and
ground.
4. Is battery voltage present?
a. Yes. Go to Test 5.
b. No. Repair open between ignition switch [33B] terminal 1 and main fuse [5A] terminal 2 (R) wire.

5. Ignition Switch Test

1. Turn IGN ON.

2. Test resistance between [33A] terminals 1 and 2.
3. Is resistance less than 0.5 ohm?
a. Yes. Go to Test 6.
b. No. Replace ignition switch.

6. Ignition Switch IGN Circuit Test

1. Remove ignition relay [62B-2].

2. Test resistance between [33B] terminal 2 and relay block [62B-2] socket terminal 6.
3. Is resistance less than 0.5 ohm?
a. Yes. Go to Test 7.
b. No. Repair open between [33B] terminal 2 and [62B-2] socket terminal 6 (R/BK).

7. Ignition Relay Ground Test

 1. Test resistance between [62B-2] socket terminal 8 and ground.
2. Is resistance less than 0.5 ohm?
a. Yes. Go to Test 8.
b. No. Repair open between [62B-2] socket terminal 8 (BK) and ground.

8. Ignition Relay Battery Power Test

1. Test voltage between [62B-2] socket terminal 10 and ground.

2. Is battery voltage present?
a. Yes. Repair open between [62B-2] terminal 9 and [64B] terminal B (R/BN).
b. No. Repair open between main fuse [5A] terminal 2 and [62B-2] socket terminal 10 (R).

9. Start Switch Circuit Voltage Test

1. Remove start relay.

2. Turn IGN ON.
3. While pressing start switch, test voltage between [62B-1] socket terminal 3 (W/BN) wire and ground.
4. Is battery voltage present?
a. Yes. Go to Test 13.
b. No. Go to Test 10.

10. Start Switch Test

1. Turn IGN OFF.

2. Disconnect right hand controls [22].
3. With start switch pressed, test continuity between [22A] terminals 3 (V/GY) wire and 4 (W/BN) wire.
4. Is continuity present?
a. Yes. Go to Test 11.
b. No. Replace right hand control assembly.

11. Start Switch Circuit Continuity Test

1. Test resistance between [22B] terminal 3 and [64B] socket terminal A (V/GY) wire.
2. Is resistance less than 0.5 ohm?
a. Yes. Go to Test 12.
b. No. Repair open between [22B] terminal 3 and [64B] socket terminal A (V/GY) wire.

12. Start Relay Switch Circuit Test

1. Test resistance between [64B] socket terminal A and [62B-1] socket terminal 4 (V/GY) wire.
2. Is resistance less than 0.5 ohm?
a. Yes. Repair open between [22B] terminal 4 and [62B-1] socket terminal 3 (W/BN) wire.
b. No. Repair open between [64B] socket terminal A and [62B-1] socket terminal 4 (V/GY) wire.
13. Starter Solenoid Voltage Test

1. Install start relay.

2. Install ignition fuse.
3. Disconnect starter solenoid [128].
4. Turn IGN ON.
5. While pressing start switch, test voltage between [128B] terminal 1 (TN/GY) and ground.
6. Is battery voltage present?
a. Yes. Go to Test 14.
b. No. Go to Test 15.

14. Starter Solenoid Ground Test

1. While pressing start switch, test voltage between [128B] terminal 1 and 2.
2. Is battery voltage present?
a. Yes. Replace starter solenoid.
b. No. Repair open between [128B] terminal 2 and ground (BK).

15. Starter Solenoid Circuit Test

1. Turn IGN OFF.

2. Remove start relay.
3. Test resistance between [62B-1] terminal 5 and [128B] terminal 1 (TN/GY) wire.
4. Is resistance less than 0.5 ohm?
a. Yes. Go to Test 16.
b. No. Repair open between [128B] terminal 1 and [62B-1] terminal 5 (TN/GY).

16. Neutral Lamp Test

1. Turn IGN OFF.

2. Connect start relay.
3. Verify vehicle is in neutral.
4. Turn IGN ON.
5. Is neutral lamp illuminated?
a. Yes. Go to Test 19.
b. No. Go to Test 17.

17. Neutral Switch Ground Test

1. Turn IGN OFF.

2. Disconnect neutral switch [131].
3. Jumper [131] to ground.
4. Turn IGN ON.
5. Is neutral lamp illuminated?
a. Yes. Replace neutral switch.
b. No. Go to Test 18.
18. Neutral Switch Circuit Continuity Test

1. Turn IGN OFF.

2. Connect BREAKOUT BOX ADAPTERS (Part Number:HD-46601) to [39]. Attach connectors from
BREAKOUT BOX (Part Number:HD-42682) to harness adapters leaving [39A] disconnected. See How To
Use Diagnostic Tools.
3. Using TEST CONNECTOR KIT (Part Number:HD-41404), test resistance between BOB terminal 6 and
[131B].
4. Is resistance less than 0.5 ohm?
a. Yes. Replace speedometer.
b. No. Repair open in (W) wire.

19. Start Enable Test

1. Turn IGN OFF.

2. Connect BREAKOUT BOX (Part Number:HD-50390-1) and ECM CABLE (Part Number:HD-50390-4) to
wiring harness [78B-1] and [78B-2] and ECM [78A-1] and [78A-2]. See How To Use Diagnostic Tools.
3. Verify ECM OVERLAY (Part Number:HD-50390-4-P) is in position on BOB.
4. Turn IGN ON.
5. Test voltage between BOB [78-2] terminal 4 and BOB [78-2] terminal 18.
6. Is voltage greater than 5V?
a. Yes. Verify security system is functioning properly. If security system functions, then continue with tests.
Go to Test 20.
b. No. Go to Test 20.

20. System Relay Control Circuit Test

1. Test voltage between BOB [78-2] terminal 3 and ground.

2. Is battery voltage present?
a. Yes. Go to Test 21.
b. No. Go to Test 22.

21. Start Enable Circuit Test

1. Turn IGN OFF.

2. Remove start relay.
3. Test resistance between BOB [78-2] terminal 4 and [62B-1] terminal 1 (TN/GN) wire.
4. Is resistance less than 0.5 ohm?
a. Yes. Replace ECM.
b. No. Repair open between [78-2] terminal 4 and [62B-1] terminal 1 (TN/GN) wire.

22. Engine Stop Switch Circuit Test

1. Remove system relay.

2. Test voltage between [62B-2] terminal 3 and ground.
3. Is battery voltage present?
 a. Yes. Repair open in (V/GN) wire.
b. No. Go to Test 23.

23. Engine Stop Switch Test

1. Disconnect right hand controls [22].

2. With engine stop switch ON, test continuity between [22A] terminals 1 (V/GY) wire and 2 (W/GY) wire.
3. Is continuity present?
a. Yes. Go to Test 24.
b. No. Replace right hand control assembly.

24. Engine Stop Switch Open Circuit Test

1. Test resistance between [62B-2] terminal 3 and [22B] terminal 2.

2. Is resistance less than 0.5 ohm?
a. Yes. Repair open in (V/GY) wire.
b. No. Repair open in (W/GY) wire.
Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

Table 1. Start Relay Clicks Diagnostic Faults

POSSIBLE CAUSES

Low battery

Starter solenoid malfunction

Open starter solenoid control circuit

Open starter solenoid ground circuit

Start relay malfunction

1. Battery Test

1. Perform battery test. See General.

2. Did battery pass test?
a. Yes. Go to Test 2.
b. No. Replace battery.

2. Start Relay Test

1. Turn IGN OFF.

2. Remove start relay [62B-1].
3. Perform relay test. See Relay Diagnostics.
4. Is relay good?
a. Yes. Go to Test 3.
b. No. Replace start relay.

3. Starter Solenoid Control Coil Voltage Test

1. Install start relay.

2. Disconnect starter solenoid [128].
3. Turn IGN ON.
4. Using TEST CONNECTOR KIT (Part Number:HD-41404), test voltage between [128B] terminal 1 (TN/GY)
wire and ground.
5. Is battery voltage present when start switch is pressed?
a. Yes. Go to Test 4.
b. No. Go to Test 5.
4. Starter Solenoid Control Coil Ground Circuit Test

1. Test resistance between [128B] terminal 2 (BK) wire and ground.

2. Is resistance less than 0.5 ohm?
a. Yes. Go to Test 6.
b. No. Repair open between [128A] terminal 2 (BK) wire and ground.

5. Ignition Circuit Test

1. Turn IGN OFF.

2. Remove ignition fuse [64B].
3. Test continuity between [64B] socket terminal A and [62B-1] socket terminal 4 (V/GY).
4. Is continuity present?
a. Yes. Repair open between [128B] terminal 1 and [62B-1] socket terminal 5 (TN/GY).
b. No. Repair open between [64B] socket terminal A and [62B-1] socket terminal 4 (V/GY).

6. Start Solenoid Wiring Inspection Test

1. Inspect for corrosion or damage to the wiring from [128A] to starter solenoid.
2. Are there any problems?
a. Yes. Repair damage or replace starter solenoid.
b. No. Go to Test 7.

7. Starter Solenoid Test

1. With IGN ON, press the start switch.

2. Does starter solenoid click?
a. Yes. See Starter Solenoid Clicks.
b. No. Replace starter solenoid.
Table 1. Starter Solenoid Clicks Diagnostic Faults

POSSIBLE CAUSES

Low battery

Starter malfunction

Starter solenoid malfunction

Open starter cable

Mechanical binding

1. Battery Test

1. Perform battery test. See General.

2. Did battery pass test?
a. Yes. Go to Test 2.
b. No. Replace battery. Attempt to start engine. If starter solenoid continues to click and starter does not
engage, then continue with tests. Go to Test 2.

2. Starter Voltage Test

1. While start switch is pressed, test voltage at starter stud #1 on starter (R) wire.
2. Is battery voltage present?
a. Yes. Go to Test 3.
b. No. Go to Test 4.

3. Starter Ground Test

1. Remove starter attaching bolts.

2. Clean bolts and starter base, install starter bolts.
3. Does engine crank?
a. Yes, engine cranks at normal speed. Repair complete.
b. Yes, engine cranks, but at a slower speed. See Starter Current Draw Test.
c. No. Go to Test 6.

4. Starter Solenoid Voltage Drop Starter Side Test

1. While start switch is pressed, perform voltage drop test from battery (+) terminal to starter solenoid terminal 2
(R) wire.
2. Is voltage drop greater than 1.0V?
a. Yes. Go to Test 5.
b. No. Repair open between starter terminal 1 and starter solenoid terminal 2 (R) wire.
5. Starter Solenoid Battery Side Voltage Drop Test

1. Perform voltage drop test from battery (+) terminal to starter solenoid terminal 1 (R) and (R/W) wires.
2. Is voltage drop greater than 1.0V?
a. Yes. Repair or replace (R) wire from starter solenoid terminal 1 to battery (+) terminal.
b. No. Replace starter solenoid.

6. Starter Ground Circuit Voltage Drop Test

1. Perform voltage drop test from battery (-) terminal to starter attaching bolts.
2. Is voltage drop greater than 1.0V?
a. Yes. Repair or replace (BK) wire from battery (-) terminal or ground 1 connections.
b. No. Go to Test 7.

7. Starter Draw Test

1. Perform Starter Current Draw Test on motorcycle. See Starter Current Draw Test.
2. Perform Starter Motor Free Running Current Draw Test (on bench). See Free Running Current Draw Test.
3. Are test results within range?
a. Yes. Go to Test 8.
b. No. Replace starter.

8. Mechanical Binding Test

1. Remove spark plugs and place transmission in 6th gear.

2. Raise vehicle.
3. Rotate rear wheel.
4. Check for engine binding in the primary and/or crankshaft or starter limiter assembly.
5. Is engine binding?
a. Yes. Repair as needed.
b. No. Replace starter solenoid.
Table 1. Starter Spins, But Does Not Engage Diagnostic
Faults

POSSIBLE CAUSES

Rotor wear

Starter clutch gear wear

Ball clutch wear

Starter malfunction

1. Starter Gear Test

1. Remove main fuse.

2. Disconnect solenoid cable from starter terminal 1.
3. Remove and inspect starter output gear.
4. Is gear damaged?
a. Yes. Replace starter.
b. No. Go to Test 2.

2. Starter Clutch Gear Test

1. Remove alternator (left side) cover.

2. Rotate starter clutch gear.
3. Does ball clutch gear engage in one direction and slip in the other?
a. Yes. Go to Test 3.
b. No. Remove and inspect the rotor assembly, starter clutch gear and needle bearings for damage.
Replace as needed.

3. Idler Gear Test

1. Rotate and inspect idler gear for damage.

2. Is damage present?
a. Yes. Replace idler gear.
b. No. Replace starter.
Table 1. Starter Stalls or Spins Too Slowly Diagnostic
Faults

POSSIBLE CAUSES

Low battery

Starter malfunction

Starter solenoid malfunction

Poor connections at starter ground

Poor battery cable connections

1. Battery Test

1. Perform battery test. See General.

2. Did battery pass test?
a. Yes. Go to Test 2.
b. No. Replace battery. If symptom is still present, continue with tests. Go to Test 2.

2. Starter Stud Voltage Drop Test

1. Perform voltage drop test from battery (+) terminal to starter stud on starter terminal 1 (R) wire. See Voltage
Drop.
2. Is voltage drop greater than 1.0V?
a. Yes. Go to Test 5.
b. No. Go to Test 3.

3. Starter Ground Circuit Voltage Drop Test

1. Perform voltage drop test between battery (-) terminal and starter attaching bolts.
2. Is voltage drop greater than 1.0V?
a. Yes. Clean ground connections.
b. No. Go to Test 4.

4. Starter Draw Test

1. Perform Starter Current Draw Test on motorcycle. See Starter Current Draw Test.
2. Perform Starter Motor Free Running Current Draw Test (on bench). See Free Running Current Draw Test.
3. Are test results within range?
a. Yes. With the spark plugs removed and the transmission in 6th gear, rotate rear wheel. Check for
engine, primary and/or crankshaft bind.
b. No. Replace starter.

5. Starter Solenoid Voltage Drop Starter Side Test

 1. Perform voltage drop test between battery (+) terminal to starter solenoid terminal 2.
2. Is voltage drop greater than 1.0V?
a. Yes. Go to Test 6.
b. No. Repair connection or (R) wire between starter solenoid and starter.

6. Starter Solenoid Battery Side Voltage Drop Test

1. Perform voltage drop test between battery (+) terminal and starter solenoid terminal 1 (R) wire.
2. Is voltage drop greater than 1.0V?
a. Yes. Repair or replace connection between battery (+) terminal and starter solenoid terminal 1 (R) wire.
b. No. Replace starter solenoid.
 NOTE

Engine temperature should be stable and at room temperature.

Battery should be fully charged.

Check starter current draw with an induction ammeter before disconnecting battery.

1. Verify transmission is in neutral.

2. Turn engine stop switch OFF.
3. Clamp induction ammeter over positive starter cable to starter solenoid.
4. Turn IGN ON. Read ammeter and zero meter or note current amperage reading.
5. Press start switch and read ammeter. Disregard initial high current reading which is normal when engine is first
turned over.
a. Typical starter current draw will range between 60-100A.
b. If starter current draw exceeds 160A, then problem may be in the starter. See Free Running Current Draw
Test.
When the ECM has determined the vehicle is in a safe state to start, it will ground the coil side of the start relay. When the
start switch is pushed, the start relay will energize and send battery voltage to the starter solenoid.

DTC P0512 sets if the start switch is stuck closed.

DTC P0616 sets when the ECM [78-2] terminal 4 is shorted to ground.
DTC P0617 sets when the ECM [78-2] terminal 4 is shorted to voltage.

Table 1. Code Description

DTC DESCRIPTION

P0512 Starter request circuit

P0616 Starter relay circuit low

P0617 Starter relay circuit high

View interactive
View interactive image
image

1 Rear injector [85]

2 TPS [88]

3 TMAP [80]

4 IAC [87]

5 Headlamp [38]

6 Ignition switch [33]

7 LH controls [24]

8 RH controls [22]

9 Fuel pump [141]

10 Front injector [84]

11 ECT [90]
 12 Ignition coil [83]

Figure 1. Under Fuel Tank Right Side

View interactive
View interactive image
image

1 Main fuse [5]

2 DLC [91]

3 Fuse block [64]

4 Relay block [62B-2]

5 Relay block [62B-1]

6 Diode pack [201]

7 Purge solenoid [95]

8 VSS [65]

9 Ground

10 Rear WSS [168]

Figure 2. Under Right Side Cover

Connector Information

For additional information about the connectors in the following diagram(s) and diagnostic procedure(s), see
Connector Locations.
 View interactive
View interactive image
image

Figure 3. Starting Circuit

Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

Table 1. DTC P0512 Diagnostic Faults

POSSIBLE CAUSES

Malfunctioning start relay

Malfunctioning start switch

Short to voltage start relay circuit

1. Start Relay Test

1. Turn IGN OFF.

2. Remove start relay.
3. Turn IGN ON.
4. Using TEST CONNECTOR KIT (Part Number:HD-41404), test voltage between start relay [62B-1] terminal 3
(W/BN) wire and ground.
5. Is voltage greater than 6V?
a. Yes. Go to Test 2.
b. No. Go to Test 3.

2. Start Button Test

1. Turn IGN OFF.

2. Disconnect right hand control [22].
3. Turn IGN ON.
4. Test voltage between start relay [62B-1] terminal 3 and ground.
5. Is voltage greater than 6V?
a. Yes. Repair short to voltage in (W/BN) wire.
b. No. Replace start switch.

3. Start Enable Circuit Test

1. Turn IGN OFF.

2. Disconnect ECM [78-2].
3. Turn IGN ON.
4. Test voltage between start relay [62B-1] terminal 1 (TN/GN) wire and ground.
5. Is voltage greater than 6V?
a. Yes. Repair short to voltage in (TN/GN) wire.
b. No. Replace start relay.
Special Tools

Description Part Number Qty.

BREAKOUT BOX HD-50390-1 1

ECM CABLE HD-50390-4 1

ECM OVERLAY HD-50390-4-P 1

Table 1. DTC P0616 Diagnostic Faults

POSSIBLE CAUSES

Malfunctioning start relay

Short to ground start relay circuit

1. Start Relay Test

1. Turn IGN OFF.

2. Connect BREAKOUT BOX (Part Number:HD-50390-1) and ECM CABLE (Part Number:HD-50390-4) to
wiring harness [78B-1] and [78B-2], leaving ECM [78A-1] and [78A-2] disconnected. See How To Use
Diagnostic Tools.
3. Verify ECM OVERLAY (Part Number:HD-50390-4-P) is in position on BOB.
4. Test resistance between BOB [78-2] terminal 4 and ground.
5. Is resistance less than 0.5 ohm?
a. Yes. Go to Test 2.
b. No. Replace ECM.

2. Start Enable Circuit Test

1. Remove start relay.

2. Test resistance between BOB [78-2] terminal 4 and ground.
3. Is resistance less than 0.5 ohm?
a. Yes. Repair short to ground in (TN/GN) wire.
b. No. Replace start relay.
Special Tools

Description Part Number Qty.

BREAKOUT BOX HD-50390-1 1

ECM CABLE HD-50390-4 1

ECM OVERLAY HD-50390-4-P 1

Table 1. DTC P0617 Diagnostic Faults

POSSIBLE CAUSES

Malfunctioning start relay

Short to ground start relay circuit

1. Start Relay Test

1. Turn IGN OFF.

2. Connect BREAKOUT BOX (Part Number:HD-50390-1) and ECM CABLE (Part Number:HD-50390-4) to
wiring harness [78B-1] and [78B-2], leaving ECM [78A-1] and [78A-2] disconnected. See How To Use
Diagnostic Tools.
3. Verify ECM OVERLAY (Part Number:HD-50390-4-P) is in position on BOB.
4. Turn IGN ON.
5. Test voltage between BOB [78-2] terminal 4 and ground.
6. Is voltage greater than 6V?
a. Yes. Go to Test 2.
b. No. Replace ECM.

2. Start Enable Circuit Test

1. Remove start relay.

2. Test voltage between BOB [78-2] terminal 4 and ground.
3. Is voltage greater than 6V?
a. Yes. Repair short to voltage in (TN/GN) wire.
b. No. Replace start relay.
Special Tools

Description Part Number Qty.

FLUKE AC/DC CURRENT PROBE HD-39617 1

1. Place starter in vise. Use a clean shop towel to prevent

scratches or other damage.
2. See Figure 1. Attach one heavy jumper cable (6 gauge
minimum).
a. Connect one end to the starter mounting flange.
b. Connect the other end to the battery (-) terminal of a
fully charged battery.
3. Connect a second heavy jumper cable (6 gauge
minimum).
a. Connect one end to the battery (+) terminal of the
battery.
b. Connect the other end to the battery terminal on the
starter. Clamp the FLUKE AC/DC CURRENT
PROBE (Part Number:HD-39617) around the cable.

CAUTION

Keep fingers and clothing away from starter gear to

prevent personal injury. (00613b)

4. Connect a smaller jumper cable (14 gauge minimum).

a. Connect one end to positive (+) terminal of battery.
b. Connect other end to solenoid relay terminal.
5. Check ammeter reading.
a. Ammeter should show 27A maximum.
b. If reading is higher, replace starter.
c. If starter current draw on vehicle was over 27A and
this test was within specification, there may be a
problem with engine or primary drive.

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 View interactive image

1 Mounting flange

2 Battery

3 Induction ammeter

4 Battery terminal

Figure 1. Free Running Current Draw Test

DTC P0704 sets if the clutch switch is stuck in the "pulled in" (closed) position for more than 30 seconds above 30 km/h
(19 mph).

Table 1. Code Description

DTC DESCRIPTION

P0704 Clutch switch input circuit

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1 Clutch switch [314]

2 Front stop lamp switch [170]

Figure 1. Hand Controls

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1 Security module [326]

2 ECM [78-2]

3 Rear lighting [7]

4 Flasher [69]
 5 BAS [134]

6 Engine harness [145]

7 Starter solenoid [128]

8 ECM [78-1]

9 Security antenna [142]

10 Terminating resistor [319]

Figure 2. Under Seat: Except 750A

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1 Terminating resistor [319]

2 Left turn lamp [19]

3 LP lamp [40]

4 Right turn lamp [18]

5 Stop/tail lamp [93]

6 ECM [78-2]

7 Flasher [69]

8 BAS [134]
 9 Engine harness [145]

10 P&A connector

11 Starter solenoid [128]

12 ECM [78-1]

13 Security antenna [142]

14 Security module [326]

Figure 3. Under Seat: 750A

Connector Information

For additional information about the connectors in the following diagram(s) and diagnostic procedure(s), see
Connector Locations.
 View interactive
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Figure 4. Starting Circuit

Special Tools

Description Part Number Qty.

BREAKOUT BOX HD-50390-1 1

ECM CABLE HD-50390-4 1

ECM OVERLAY HD-50390-4-P 1

Table 1. DTC P0512 Diagnostic Faults

POSSIBLE CAUSES

Malfunctioning clutch switch

Short to voltage start relay circuit

1. Clutch Switch Test

1. Turn IGN OFF.

2. Connect BREAKOUT BOX (Part Number:HD-50390-1) and ECM CABLE (Part Number:HD-50390-4) to
wiring harness [78B-1] and [78B-2], leaving ECM [78A-1] and [78A-2] disconnected. See How To Use
Diagnostic Tools.
3. Verify ECM OVERLAY (Part Number:HD-50390-4-P) is in position on BOB.
4. Test resistance between BOB [78-1] terminal 12 and ground.
5. Is resistance less than 0.5 ohm?
a. Yes. Go to Test 2.
b. No. Replace ECM.

2. Clutch Start Interlock Test

1. Disconnect clutch switch [314].

2. Test resistance between BOB [78-1] terminal 12 and ground.
3. Is resistance less than 0.5 ohm?
a. Yes. Repair short to ground in (TN/GN) wire.
b. No. Replace clutch switch.
The charging system is the source of electric current that supplies power to run the ignition, lights, accessories and charge
the battery. AC voltage is generated by an alternator assembly driven by the crankshaft. A rotor supplied with a magnetic
field spins around a stator. A rectifier (located in the regulator) converts the voltage from AC to DC. A regulator ensures
that the output voltage is properly matched to the battery voltage as engine speed varies. Even though the alternator
provides additional voltage at all engine speeds, it is not recommended to idle the vehicle for long periods of time.

Alternator

See Charging System Circuit. The alternator consists of two main components:

The rotor which mounts to the cam drive side of the crankshaft.
The stator which bolts to the alternator cover.

Voltage Regulator

See Charging System Circuit. The voltage regulator is a series regulator. The circuit combines the functions of
rectifying and regulating.
Battery

Test for a weak or dead battery. Battery must be fully charged in order to perform a load test or starting or charging
tests. See General.

Wiring

The stator connections must be clean and tight.

Check for corroded or loose connections in the charging system circuit.

Voltage Regulator Inspection

The voltage regulator must have clean, tight connections for proper operation. Verify both AC and DC connectors are
fully inserted and locked with the regulator latch.

Overheat Protection

Overheat protection is built into the regulator to protect the regulator circuits against extreme heat conditions. At
approximately 105 °C (221 °F), the overheat protection will limit the current output of the regulator. This allows the
regulator to cool down and resume normal operation.

Connector Information

For additional information about the connectors in the following diagram(s) and diagnostic procedure(s), see
Connector Locations.

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Figure 1. Charging System Circuit
Table 1. Low or No Charging Diagnostic Faults

POSSIBLE CAUSES

Battery

Stator malfunction

Rotor malfunction

Voltage regulator malfunction

Open voltage regulator circuit

Stator shorted to ground

AC wire shorted to ground

1. Battery Test

1. Perform battery test. See General.

2. Did battery pass test?
a. Yes. Go to Test 2.
b. No. Replace battery. If symptom is still present, continue with tests. Go to Test 2.

NOTE

A discharged battery may show a reading under 13V even though the charging system is working properly.

2. Off Idle Voltage Test

1. With vehicle in neutral, start engine and run at 3000 rpm.

2. Test battery voltage.
3. Is voltage above 13V?
a. Yes. Charging system working properly.
b. No. Go to Test 3.

3. AC Output Test

1. Perform AC output test. See Battery Charging Tests.

2. Did the output test pass?
a. Yes. Go to Test 6.
b. No. Go to Test 4.

4. Stator Test
 1. Perform stator test. See Battery Charging Tests.
2. Is the stator good?
a. Yes. Go to Test 5.
b. No. Replace stator.

5. Rotor Inspection Test

1. Inspect rotor for damage.

2. Verify that rotor bolt is not loose and inspect for crankshaft damage.
3. Verify that stator bolts have not backed out and contacted the rotor.
4. Is rotor in good condition?
a. Yes. Go to Test 6.
b. No. Replace rotor.

6. Voltage Regulator Power Circuit Test

1. With IGN OFF, disconnect voltage regulator [77].

2. Test resistance between [77B] terminal 3 and main fuse [5A] terminal 2 (R).
3. Is resistance less than 0.5 ohm?
a. Yes. Go to Test 7.
b. No. Repair or replace (R) wire between [77B] terminal 3 and [5A] terminal 2.

7. Voltage Regulator Ground Circuit Test

NOTE

The voltage regulator ground must have a clean, tight connection for proper grounding.

1. Test resistance between voltage regulator [77B] terminal 1 and ground.

2. Is resistance less than 0.5 ohms?
a. Yes. Replace voltage regulator.
b. No. Repair or replace wire between voltage regulator [77B] terminal 1 and GND 2 (BK) wire.
Table 1. Overcharging Diagnostic Faults

POSSIBLE CAUSES

Voltage regulator malfunction

Open in GND 2 circuit

1. Battery Voltage Test

1. With vehicle in neutral, start engine and run at 3000 rpm.

2. Test battery voltage.
3. Is voltage above 15.5V?
a. Yes. Go to Test 2.
b. No. Charging system working properly.

2. Voltage Regulator Ground Circuit Test

NOTE

The voltage regulator ground must have a clean, tight connection for proper grounding.

1. With IGN OFF, disconnect voltage regulator [77].

2. Test resistance between [77B] terminal 1 and ground.
3. Is resistance less than 0.5 ohms?
a. Yes. Replace voltage regulator.
b. No. Repair or replace wire between voltage regulator [77B] terminal 1 and GND 2 (BK) wire.
Table 1. Low Battery After Extended IGN OFF Diagnostic
Faults

POSSIBLE CAUSES

Battery

Accessories improperly wired to stay on at all times

Excessive draw from electrical component with IGN OFF

Battery discharged because motorcycle was not operated for a

long period

1. Battery Test

1. Perform battery test. See General.

2. Did battery pass test?
a. Yes. Go to Test 2.
b. No. Replace battery.

2. Amp Draw Test

1. Perform milliampere draw test. See Battery Charging Tests.

2. Did test exceed maximum draw?
a. Yes. Repair excessive draw and run test again.
b. No. System is working properly.
Table 1. Battery Runs Down During Use Diagnostic Faults

POSSIBLE CAUSES

Battery

Excessive accessory draw

Accessories on when idling or low rpm riding for extended period

1. Battery Test

1. Perform battery test. See General.

2. Did battery pass test?
a. Yes. Go to Test 2.
b. No. Replace battery.

2. Total Current Draw Test

1. Perform total current draw and output test. See Battery Charging Tests.
2. Does charging system exceed current draw by 3.5A?
a. Yes. System is working properly.
b. No. System accessory power requirements exceed charging system capability.
Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

Milliampere Draw Test

NOTE

Be sure accessories are not wired so they stay on at all times. This condition could drain battery completely if
vehicle is parked for a long time. Test for this by connecting ammeter between negative battery terminal and
battery.

1. Remove main fuse.

NOTE

With IGN OFF, an initial current draw of up to 30 mA will occur directly after connecting meter. This should drop to
the values shown in Table 1 in less than one minute.

2. See Figure 1. Using TEST CONNECTOR KIT (Part Number:HD-41404), connect ammeter to main fuse
socket terminals. With this arrangement, you will pick up any drain.
3. With IGN OFF and all lights and accessories off, observe current reading.
a. Add the maximum draw values found in table for the components equipped on the vehicle being tested.
If the reading observed on the ammeter is less than the sum of the maximum draw for the components,
the draw is within specification. Refer to Table 1.
b. A higher ammeter reading indicates excessive current draw. Locate the component or accessory with
high draw by unplugging one at a time while observing the meter reading.

Table 1. Milliampere Draw Test

ITEM MAXIMUM DRAW IN MILLIAMPERES

Regulator 0.5

ECM 1.0

Speedometer 0.5

ABS (if equipped) 0.5

SCM (if equipped) 0.5

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1 Ammeter

2 MAIN FUSE socket

3 Voltage regulator

Figure 1. Milliampere Draw Test (Ignition Turned to OFF)

Total Current Draw and Output Test

If battery runs down during use, the current draw of the motorcycle components and accessories may exceed output of
the charging system.

NOTE

If a load tester is unavailable, use an ammeter with current probe.

WARNING

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

1. See Figure 2. Connect load tester.

a. Connect negative and positive leads to battery terminals.
b. Place load tester induction pickup over battery negative cable.
2. With IGN OFF, disconnect voltage regulator [77].
3. Start engine.
4. Turn all continuously running lights and accessories turned ON (headlamp on high beam).
5. Run at 3000 rpm and make note of the current draw.
6. Turn engine OFF.
7. With IGN OFF, connect voltage regulator [77].
8. Remove the induction pickup from the battery negative cable.
 9. Place induction pickup over positive regulator cable.
10. Start engine and run at 3000 rpm.

NOTE

Do not leave any load switch turned on for more than 20 seconds or overheating and tester damage are possible.

11. Increase the load as required to obtain a constant 13.0V.

12. Current output should be 30-35A. Make note of current output.

NOTE

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

13. Compare both of these readings.

a. The current output should exceed current draw by 3.5A minimum.
b. If output does not meet specifications, there may be too many accessories for the charging system to
handle.

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1 Load tester

2 Induction pickup

3 Battery

Figure 2. Check Current Draw (Ignition On)

Stator Test

1. Turn IGN OFF.

2. See Figure 3. Connect an ohmmeter.
a. Disconnect voltage regulator [47] from stator wiring.
b. Insert one ohmmeter lead into a stator connector socket.
c. Attach the other lead to a suitable ground.
3. Test for continuity.
a. A good stator will show no continuity (open circuit) between all stator sockets and ground.
b. Any other reading indicates a grounded stator which must be replaced.
 4. See Figure 4. Remove ground lead. Measure resistance across stator [47B] terminals 1-2, 2-3 and 3-1.
a. Resistance across all the stator terminals should be 0.1-0.3 ohm.
b. If the resistance is higher, the stator is damaged and must be replaced.
c. If resistance is lower, the stator may have a turn-to-turn short and should be replaced.

NOTE

When measuring resistance (ohms), compensate for test lead resistance before performing the measurement.
Select the ohms position and touch the test leads together. Refer to the multimeter user's manual to either zero
the display or manually subtract the test lead resistance from the measured circuit's value.

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Figure 3. Test for Grounded Stator (Typical)

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Figure 4. Check for Stator Resistance (Typical)

AC Output Test

1. See Figure 5. Test AC output.

a. Disconnect voltage regulator [47] from alternator stator wiring.
 b. Test VAC across stator [47B] terminals 1 to 2.
c. Run engine at 2000 rpm. The VAC output should be 32-40 VAC (approximately 16-20 VAC per 1000
rpm).
d. Repeat test using terminals 2 to 3 and 1 to 3.
2. Compare test results to specifications. If the output is below specifications, charging problem could be a faulty
rotor or stator.
3. Check the output again as previously described under Total Current Draw and Output Test.

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Figure 5. Check Stator AC Voltage Output (Typical)

Battery voltage is monitored by the ECM on terminal 16 of [78-2]. Power is supplied to this terminal through the ignition
fuse.

DTC P0562 sets when run/stop switch power is less than 12.2V at idle and voltage does not increase when engine
speed is greater than 2000 rpm.
DTC P0563 sets when battery voltage is greater than 15.0V for more than 4 seconds.

Table 1. Code Description

DTC DESCRIPTION

P0562 ECM voltage low

P0563 ECM voltage high

Diagnostic Tips

Any of the following conditions could cause this DTC to set:

The charging system is malfunctioning.

There is excessive battery draw and/or extended idling in heavy traffic.
A faulty system ground is present. Low voltage generally indicates a loose wire, corroded connections, battery
and/or a charging system problem.
Table 1. DTC P0562, P0563 Diagnostic Faults

POSSIBLE CAUSES

Low battery

Charging system malfunction

1. Battery Test

1. Perform battery test. See General.

2. Did battery pass test?
a. Yes. Go to Test 2.
b. No. Replace battery.

2. Charging System Test

1. Perform charging system test. See Low or No Charging.

2. Is charging system working properly?
a. Yes. Go to Test 3.
b. No. Repair charging system.

3. Repair Validation Test

1. Clear DTCs.
2. Start vehicle.
3. Run at 3000 rpm for 5 seconds.
4. Did DTC reset?
a. Yes. Replace ECM.
b. No. System working properly.
Battery voltage is monitored by the ECM on terminal 16 of [78-2]. The ignition power is supplied to the ECM from the
ignition fuse.

DTC B2272 sets when battery power is greater than 16.8V at idle and voltage does not decrease.
DTC P0562 sets when ignition power is less than 12.2V at idle and voltage does not increase when engine speed is
greater than 2000 rpm.
DTC P0563 sets when ignition power is greater than 16.8V at idle and voltage does not decrease.

Table 1. Code Description

DTC DESCRIPTION

B2272 Voltage high

P0562 ABS voltage low

P0563 ABS voltage high

Diagnostic Tips

Any of the following conditions could cause these DTCs to set:

The charging system is malfunctioning.

There is excessive battery draw.
Extended idling in heavy traffic.
A faulty system ground is present.
Low voltage generally indicates a loose wire, corroded connections, battery or a charging system problem. High
voltage DTC may set when the vehicle is placed on an unapproved constant current battery charger for a long period
of time.

Connector Information

For additional information about the connectors in the following diagram(s) and diagnostic procedure(s), see
Connector Locations.
 View interactive
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Figure 1. Starting Circuit

Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

BREAKOUT BOX HD-50390-1 1

ECM CABLE HD-50390-4 1

ECM OVERLAY HD-50390-4-P 1

Table 1. DTC P0562 Diagnostic Faults

POSSIBLE CAUSES

Low battery

Open ECM ground circuit

Open ECM system power circuit

1. Battery Test

1. Perform battery test. See General.

2. Did battery pass test?
a. Yes. Go to Test 2.
b. No. Replace battery.

2. Charging System Test

1. Perform charging system test. See Low or No Charging.

2. Is charging system working properly?
a. Yes. Go to Test 3.
b. No. Repair charging system.

3. ECM Switched Voltage Test

1. Turn IGN OFF.

2. Connect BREAKOUT BOX (Part Number:HD-50390-1) and ECM CABLE (Part Number:HD-50390-4)
between wiring harness [78B-1] and [78B-2] and ECM [78A-1] and [78A-2]. See How To Use Diagnostic
Tools.
3. Verify ECM OVERLAY (Part Number:HD-50390-4-P) is in position on BOB.
4. Start vehicle.
5. Using TEST CONNECTOR KIT (Part Number:HD-41404), test voltage between BOB [78-2] terminals 16 and
10.
6. Is voltage greater than 12.2V?
 a. Yes. Go to Test 11.
b. No. Go to Test 4.

4. ECM System Power Test

1. Test voltage between BOB [78-2] terminal 16 and ground.

2. Is voltage greater than 12.2V?
a. Yes. Go to Test 5.
b. No. Go to Test 7.

5. ECM Ground [78-1] Circuit Test

1. Turn IGN OFF.

2. Test resistance between BOB terminal 10 of [78-1] and ground.
3. Is resistance less than 0.5 ohm?
a. Yes. Go to Test 6.
b. No. Repair wiring between ECM [78B-1] terminal 10 and ground.

6. ECM Ground [78-2] Circuit Test

1. Test resistance between BOB [78-2] terminal 10 and ground.

2. Is resistance greater than 1 ohm?
a. Yes. Repair wiring between ECM [78B-2] terminal 10 and ground.
b. No. Problem may be intermittent. Locate and repair bad connection. Perform Voltage Drop. If no
problem is found, then continue with tests.

7. Ignition Power Test

1. Turn IGN OFF.

2. Remove BOB from ECM.
3. Connect [78A] to [78B].
4. Start vehicle.
5. Test voltage between fuse block [64B] terminal A (V/GY) wire and ground.
6. Is voltage greater than 12.2V?
a. Yes. Repair wire between [64B] terminal A and [78B-2] terminal 16.
b. No. Go to Test 8.

8. Main Fuse Voltage Test

1. Turn IGN ON.

2. Leaving main fuse in place, perform a voltage drop test between main fuse [5B] socket terminal 2 and battery
(+).
3. Is voltage drop greater than 0.5V?
a. Yes. Go to Test 9.
b. No. Repair or replace (R) wire between main fuse and [64B].
9. Main Fuse Voltage Drop Test

1. Perform a voltage drop test between [5B] socket terminal 1 and battery (+).
2. Is voltage drop greater than 0.5V?
a. Yes. Go to Test 10.
b. No. Repair or replace [5B] socket terminals 1 and 2.

10. Main Fuse Supply Voltage Drop Test

1. Perform a voltage drop test between starter terminal 1 and battery (+).
2. Is voltage drop greater than 0.5V?
a. Yes. Repair or replace (R) wire between starter terminal 1 and battery (+).
b. No. Repair or replace (R/W) wire between starter terminal 1 and main fuse [5B] socket terminal 1.

11. Repair Validation Test

1. Clear DTCs.
2. Start vehicle.
3. Run at 3000 rpm for 5 seconds.
4. Did code reset?
a. Yes. Replace ECM.
b. No. System working properly.
Table 1. DTC P0563 Diagnostic Faults

POSSIBLE CAUSES

Charging system malfunction

1. Charging System Test

1. Perform charging system tests. See Description and Operation.

2. Is charging system good?
a. Yes. Go to Test 2.
b. No. Repair charging system.

2. Repair Validation Test

1. Clear DTCs.
2. Start vehicle.
3. Run at 3000 rpm for 5 seconds.
4. Did DTC reset?
a. Yes. Replace ECM.
b. No. System working properly.
Table 1. DTC B2272 Diagnostic Faults

POSSIBLE CAUSES

Charging system malfunction

1. Charging System Test

1. Perform charging system tests. See Description and Operation.

2. Is charging system good?
a. Yes. Go to Test 2.
b. No. Repair charging system.

2. Repair Validation Test

1. Clear DTCs.
2. Start vehicle.
3. Run at 3000 rpm for 5 seconds.
4. Did DTC reset?
a. Yes. Replace speedometer.
b. No. System working properly.
See Figure 1. The speedometer contains several indicators. These indicators include the check engine, security, neutral,
turn signals, low oil pressure, coolant temperature, low fuel, high beam and ABS.

Trip Odometer Reset Switch Operation

Pressing the trip odometer reset switch, located on the left hand controls, provides the following functions:

Change the odometer display between total mileage, trip odometer A and B, 12/24 hour clock and tachometer with
gear indication. A low fuel trip odometer is also visible when the fuel lamp is illuminated.
Reset the trip odometer (press and hold 2-3 seconds).
Gain access to self-diagnostic mode and clear diagnostic codes. See Odometer Self-Diagnostics.

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1 Left turn indicator

2 Neutral indicator

3 Security indicator

4 Coolant temperature

5 High beam indicator

6 Right turn indicator

7 Check engine indicator

8 Low fuel indicator

9 Trip odometer reset switch

10 Odometer

11 ABS icon indicator

12 Oil pressure indicator

Figure 1. Speedometer
The odometer mileage is permanently stored and will not be lost when electrical power is turned off or disconnected.
The trip odometer reset switch allows switching between the odometer and trip odometer displays.

To zero the trip odometer, have the trip odometer display visible, press and keep the trip odometer reset switch
depressed. The trip odometer mileage will be displayed for 2-3 seconds and then the trip mileage will return to zero.
The vehicle speed sensor is mounted at the back of the transmission case. The VSS is a Hall-Effect sensor that is
triggered by the gear teeth of fifth gear on the transmission mainshaft.

The output from the sensor is a series of pulses that are interpreted by the ECM, converted into CAN bus data then sent to
the speedometer. The speedometer uses the data to control the position of the speedometer needle.
The speedometer monitors direct inputs from sensors and switches, along with receiving information from the other
modules over the CAN bus lines. It sets codes when the parameters for the inputs are out of range.

Table 1. Code Description

DTC DESCRIPTION

B1200 Internal fault

B1210 Fuel level sender shorted low/open

B1211 Fuel level sender shorted high

B2255 Trip switch stuck

The fuel level is monitored by the speedometer [39] at terminal 9 (W/Y) wire. The low fuel warning lamp serves two
functions. It is used to indicate a low fuel condition and to communicate a circuit problem with the fuel sender circuit. The
speedometer will flash the low fuel warning lamp on and off at a steady rate when a current fuel level sender DTC is set.

If the voltage on terminal 9 exceeds the lower limit for greater than or equal to 15 seconds, a DTC B1210 will be set.
If the voltage on terminal 9 exceeds the upper limit (or is open) for greater than or equal to 15 seconds, a DTC B1211
will set.

Table 1. Code Description

DTC DESCRIPTION

B1210 Fuel level sender shorted low

B1211 Fuel level sender shorted high/open

NOTE

For the DTCs to set, the fuel in the tank must be above the level required to turn on the low fuel indicator.

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1 Speedometer [39]

2 Speedometer

Figure 1. Behind Speedometer

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Figure 2. Speedometer Circuit Diagram

Connector Information

For additional information about the connectors in the following diagram(s) and diagnostic procedure(s), see
Connector Locations.
Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

Table 1. DTC B1210 Diagnostic Faults

POSSIBLE CAUSES

Short to ground in fuel level sender circuit

Fuel level sender assembly malfunction

1. Fuel Level Circuit Short to Ground Test

1. Disconnect the fuel pump [141] and speedometer [39].

2. Using TEST CONNECTOR KIT (Part Number:HD-41404), test for continuity between [141B] terminal 1 and
ground.
3. Is continuity present?
a. Yes. Repair short to ground in the (W/Y) wire.
b. No. Go to Test 2.

2. Fuel Level Sender Resistance Test

1. Measure the resistance between [141A] terminals 1 and 3.

2. Is the resistance between 850-1450 ohms?
a. Yes. Replace speedometer.
b. No. Replace the fuel pump assembly.
Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

BREAKOUT BOX HD-42682 1

BREAKOUT BOX ADAPTERS HD-46601 1

Table 1. DTC B1211 Diagnostic Faults

POSSIBLE CAUSES

Short to voltage in fuel level sensor circuit

Fuel level sender malfunction

Open fuel level sensor circuit

1. Fuel Level Circuit Short to Voltage Test

1. Connect BREAKOUT BOX ADAPTERS (Part Number:HD-46601) to [39B] leaving speedometer [39A]
disconnected. Attach connectors from BREAKOUT BOX (Part Number:HD-42682) to harness adapters.
2. Using TEST CONNECTOR KIT (Part Number:HD-41404), test for voltage between [141B] terminal 1 and
ground.
3. Turn IGN ON.
4. Is voltage present?
a. Yes. Repair short to voltage in (W/Y) wire.
b. No. Go to Test 2.

2. Fuel Level Circuit Open Test

1. Measure resistance between [39B] terminal 9 and [141B] terminal 1.

2. Is resistance less than 0.5 ohms?
a. Yes. Go to Test 3.
b. No. Repair open in (W/Y) wire.

3. Fuel Level Sender Resistance Test

1. Measure the resistance between [141A] terminals 1 and 3.

2. Is the resistance between 850-1450 Ohms?
a. Yes. Replace speedometer.
b. No. Replace fuel pump assembly.
Special Tools

Description Part Number Qty.

DIGITAL TECHNICIAN II HD-48650 1

Trip Odometer Reset Switch Closed

DTC B2255 will set if trip odometer reset switch is closed for more than 2 minutes. Odometer self-diagnostics will not
function if the switch is stuck. It will not be possible to toggle the switch to navigate through the different diagnostic
steps in the odometer.

A stuck trip odometer reset switch disables odometer self-diagnostics.

If DIGITAL TECHNICIAN II (Part Number:HD-48650) is connected to the DLC [91] and communicating with the
vehicle then the odometer self-diagnostics will not function properly.
Disconnect DIGITAL TECHNICIAN II (Part Number:HD-48650) before entering odometer self-diagnostics.

Table 1. Code Description

DTC DESCRIPTION

B2255 Trip switch stuck

Table 1. Trip Odometer Functions Inoperative Diagnostic
Faults: DTC B2255

POSSIBLE CAUSES

Instrument malfunction

1. Odometer Test

1. Turn IGN ON.

2. Press and release trip odometer reset switch.
3. Does odometer cycle through different odometer counters?
a. Yes. Go to Test 2.
b. No. Go to Test 3.

2. Speedometer "WOW" Test

1. Turn IGN OFF.

2. Turn IGN ON while pressing trip odometer reset switch.
3. Does speedometer needle sweep its full range of motion?
a. Yes. System functioning properly. Test for intermittent condition. See Wiggle Test.
b. No. Replace speedometer.

3. ECM Ignition Test

1. Turn IGN OFF for 1 minute.

2. Turn IGN ON.
3. Did the fuel pump turn ON?
a. Yes. Replace the speedometer.
b. No. Repair open in (W/GY) wire at [78B-2] terminal 16.
The neutral switch [131] is connected to the (W) wire at speedometer [39] terminal 6. When the vehicle is in neutral, the
switch is closed, grounding the circuit and illuminating the neutral indicator. The speedometer communicates to the ECM
using CAN when the vehicle is in neutral. When this code is set, the ECM requires a clutch switch input to start the bike.

Table 1. Code Description

DTC DESCRIPTION

P0851 Neutral switch input circuit low

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1 Neutral switch [131]

2 JSS [133]

3 CKP [79]

4 Cooling fan [97]

5 Horn [122-1]

6 Horn [122-2]

7 Front WSS [167]

8 Starter

9 VSS [65]

10 Voltage regulator [77]

11 ABS ECU [166]

12 Oil pressure switch [120]

Figure 1. Front of Engine

Connector Information

For additional information about the connectors in the following diagram(s) and diagnostic procedure(s), see
Connector Locations.

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image

Figure 2. Speedometer Circuit Diagram

Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

BREAKOUT BOX HD-42682 1

BREAKOUT BOX ADAPTERS HD-46601 1

Table 1. DTC P0851 Neutral Switch Input Circuit Low

Diagnostic Faults

POSSIBLE CAUSES

Neutral switch malfunction

Short to ground in neutral switch circuit

1. Transmission Operation Test

1. Shift transmission out of neutral.

2. Does neutral lamp turn OFF and stay off?
a. Yes. Neutral lamp is operating properly. Test for intermittent. See Wiggle Test.
b. No. Go to Test 2.

2. Neutral Switch Test

1. Disconnect neutral switch [131].

2. Does neutral lamp turn OFF?
a. Yes. Replace neutral switch.
b. No. Go to Test 3.

3. Neutral Switch Circuit Test

1. Disconnect speedometer [39].

2. Connect BREAKOUT BOX ADAPTERS (Part Number:HD-46601) to [39]. Attach connectors from
BREAKOUT BOX (Part Number:HD-42682) to harness adapters leaving [39A] disconnected. See How To
Use Diagnostic Tools.
3. Using TEST CONNECTOR KIT (Part Number:HD-41404), test resistance between BOB terminal 6 and
ground.
4. Is resistance less than 5 ohms?
a. Yes. Repair short to ground in (W) wire.
b. No. Replace speedometer.
See Figure 1. The speedometer receives battery power at terminal 5. This is supplied through the battery fuse located in
fuse block [64]. The speedometer receives a message from the ECM over the CAN bus which communicates if the ignition
switch is in the IGN position. When the ignition switch is in the ACC or IGN position, the speedometer illuminates the
backlighting, the odometer and the indicators.

Table 1. Code Description

DTC DESCRIPTION

B1200 Internal fault

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1 Speedometer [39]

2 Speedometer

Figure 1. Behind Speedometer

Connector Information

For additional information about the connectors in the following diagram(s) and diagnostic procedure(s), see
Connector Locations.
 View interactive
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image

Figure 2. Speedometer Circuit Diagram

Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

BREAKOUT BOX HD-42682 1

BREAKOUT BOX ADAPTERS HD-46601 1

Table 1. No Instrument Power Diagnostic Faults

POSSIBLE CAUSES

Open battery circuit

Open ground circuit

Open in CAN bus circuit to speedometer

Open in ACC circuit

1. Speedometer Battery Voltage Test

1. Turn IGN ON.

2. Does the speedometer illuminate?
a. Yes. Go to Test 2.
b. No. Go to Test 3.

2. Speedometer ACC Voltage Test

1. Turn IGN to ACC.

2. Does the speedometer illuminate?
a. Yes. System functioning properly. Test for intermittent condition. See Wiggle Test.
b. No. Repair open in (R/Y) wire.

3. Speedometer Voltage Test

1. Turn IGN OFF.

2. Connect BREAKOUT BOX (Part Number:HD-42682) and BREAKOUT BOX ADAPTERS (Part Number:HD-
46601) to the wiring harness [39B], leaving [39A] disconnected.
3. Using TEST CONNECTOR KIT (Part Number:HD-41404), test voltage between BOB terminal 5 and ground.
4. Is battery voltage present?
a. Yes. Go to Test 4.
b. No. Repair open in (R/O) wire.
4. Speedometer Ground Test

1. Test voltage between BOB terminals 5 and 7.

2. Is battery voltage present?
a. Yes. Go to Test 5.
b. No. Repair open in (BK/GN) wire.

5. CAN High Circuit Continuity Test

1. Test resistance between BOB terminal 2 and DLC [91A] terminal 1.

2. Is resistance less than 0.5 ohm?
a. Yes. Go to Test 6.
b. No. Repair open in (W/R) wire.

6. CAN Low Circuit Continuity Test

1. Test resistance between BOB terminal 8 and [91A] terminal 3.

2. Is resistance less than 0.5 ohm?
a. Yes. Replace speedometer.
b. No. Repair open in (W/BK) wire.
Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

BREAKOUT BOX HD-42682 1

BREAKOUT BOX ADAPTERS HD-46601 1

Table 1. DTC B1200 Diagnostic Faults

POSSIBLE CAUSES

Open in speedometer battery power circuit

Open in speedometer ground circuit

1. Speedometer Voltage Test

1. Turn IGN OFF.

2. Connect BREAKOUT BOX (Part Number:HD-42682) and BREAKOUT BOX ADAPTERS (Part Number:HD-
46601) to wiring harness [39B], leaving [39A] disconnected. See How To Use Diagnostic Tools.
3. Using TEST CONNECTOR KIT (Part Number:HD-41404), test voltage between BOB terminal 5 and ground.
4. Is battery voltage present?
a. Yes. Go to Test 2.
b. No. Repair open in (R/O) wire.

2. Speedometer Ground Test

1. Test voltage between BOB terminals 5 and 7.

2. Is battery voltage present?
a. Yes. Replace speedometer.
b. No. Repair open in ground circuit.
See Figure 1. Indicators inside speedometer are not serviceable.

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1 Left turn indicator

2 Neutral indicator

3 Security indicator

4 Coolant temperature

5 High beam indicator

6 Right turn indicator

7 Check engine indicator

8 Low fuel indicator

9 Trip odometer reset switch

10 Odometer

11 ABS icon indicator

12 Oil pressure indicator

Figure 1. Speedometer

Table 1. Indicator Lamp Wiring

INDICATOR LAMP CONNECTION

Check engine Signal from ECM

Oil pressure Ground through switch

Neutral Ground through switch

High beam 12V when active

Right/left turn 12V when active

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

Coolant temperature Signal from ECM

ABS Signal from ABS module

Security Signal from SCM

High Beam Indicator

The high beam indicator is connected to the (BE/W) wire at [39] terminal 4. This circuit is powered when the headlamp
switch is placed in the high beam position. When voltage is applied to [39] terminal 4, the high beam indicator
illuminates.

Low Fuel Indicator

See Figure 2. The low fuel indicator lamp is controlled through [39] terminal 3. The low fuel indicator will illuminate
when the fuel level in the tank drops below 3.8 L (1.0 USgal). It will also flash due to a malfunction in the fuel level
sensor circuit or if the system voltage drops below 11.0V.

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1 Rear injector [85]

2 TPS [88]

3 TMAP [80]

4 IAC [87]

5 Headlamp [38]

6 Ignition switch [33]

 7 LH controls [24]

8 RH controls [22]

9 Fuel pump [141]

10 Front injector [84]

11 ECT [90]

12 Ignition coil [83]

Figure 2. Under Fuel Tank Right Side

Neutral Indicator

The neutral switch [131] is connected to the (W) wire at speedometer [39] terminal 6. When the vehicle is in neutral,
the switch is closed grounding the circuit and illuminating the neutral indicator.

Oil Pressure Indicator

See Figure 3. The oil pressure indicator is connected to the (W/O) wire at [39] terminal 1. This circuit is connected to
the oil pressure switch. The switch closes when oil pressure is low and illuminates the oil pressure indicator. This is
why the oil pressure indicator is illuminated with the IGN ON and the engine OFF.

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1 Neutral switch [131]

2 JSS [133]

3 CKP [79]

4 Cooling fan [97]

5 Horn [122-1]

6 Horn [122-2]

7 Front WSS [167]

 8 Starter

9 VSS [65]

10 Voltage regulator [77]

11 ABS ECU [166]

12 Oil pressure switch [120]

Figure 3. Front of Engine

Turn Signal Indicators

The turn signal indicators are connected at [39] terminals 10 (left) and 12 (right). The turn signal indicators are
controlled by the flasher and turn signal switch. The turn signal switch supplies power from the flasher to the correct
turn signal indicator, causing it to flash.

When the left turn signal switch is pressed, voltage is supplied on the (BE/V) wire to the left turn signals and the
turn signal indicator.
When the right turn signal is pressed, voltage is supplied on the (BE/BN) wire to the right turn signals and the
indicator.

Connector Information

For additional information about the connectors in the following diagram(s) and diagnostic procedure(s), see
Connector Locations.
 View interactive
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image

Figure 4. Speedometer Circuit Diagram

Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

BREAKOUT BOX HD-42682 1

BREAKOUT BOX ADAPTERS HD-46601 1

Table 1. Oil Pressure Lamp Always On Diagnostic Faults

POSSIBLE CAUSES

Short to ground in oil pressure circuit

Mechanical issue

Oil pressure switch malfunction

1. Oil Pressure Lamp Function Test

1. Turn IGN ON.

2. Does oil pressure lamp illuminate?
a. Yes. Go to Test 2.
b. No. See Oil Pressure Lamp Inoperative.

2. Engine Running Test

1. Start engine.
2. Does oil pressure lamp turn OFF and stay off?
a. Yes. Oil pressure lamp is operating properly. Test for intermittent. See Wiggle Test.
b. No. Go to Test 3.

3. Oil Pressure Sensor Test

1. Disconnect oil pressure sensor [120].

2. Does oil pressure lamp turn OFF?
a. Yes. Go to Test 5.
b. No. Go to Test 4.

4. Oil Pressure Circuit Test

1. Turn IGN OFF.

 2. Connect BREAKOUT BOX ADAPTERS (Part Number:HD-46601) to [39]. Attach connectors from
BREAKOUT BOX (Part Number:HD-42682) to harness adapters leaving [39A] disconnected. See How To
Use Diagnostic Tools.
3. Using TEST CONNECTOR KIT (Part Number:HD-41404), test resistance between BOB terminal 1 and
ground.
4. Is resistance less than 0.5 ohms?
a. Yes. Repair short to ground in (W/O) wire.
b. No. Replace speedometer.

5. Mechanical Test

1. Inspect engine for issues that may affect oil pressure.

2. Was the problem found?
a. Yes. Repair as needed.
b. No. Replace oil pressure switch.
Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

BREAKOUT BOX HD-42682 1

BREAKOUT BOX ADAPTERS HD-46601 1

Table 1. Oil Pressure Lamp Inoperative Diagnostic Faults

POSSIBLE CAUSES

Oil pressure switch malfunction

Open in ground circuit

Open oil pressure circuit

1. Oil Pressure Lamp Function Test

1. Turn IGN ON.

2. Does oil pressure lamp illuminate?
a. Yes. Test for intermittent. See Wiggle Test.
b. No. Go to Test 2.

2. Oil Pressure Switch Test

1. Disconnect oil pressure sensor [120].

2. Using TEST CONNECTOR KIT (Part Number:HD-41404), jumper between [120B] terminal 1 to ground.
3. Does oil pressure lamp turn ON?
a. Yes. Go to Test 4.
b. No. Go to Test 3.

3. Oil Pressure Circuit Test

1. Turn IGN OFF.

2. Connect BREAKOUT BOX ADAPTERS (Part Number:HD-46601) to [39]. Attach connectors from
BREAKOUT BOX (Part Number:HD-42682) to harness adapters leaving [39A] disconnected. See How To
Use Diagnostic Tools.
3. Using TEST CONNECTOR KIT (Part Number:HD-41404), test resistance between BOB terminal 1 and [120B]
terminal 1.
4. Is resistance less than 0.5 ohm?
a. Yes. Replace speedometer.
b. No. Repair open in (W/O) wire.
4. Ground Circuit Test

1. Test resistance between [120B] terminal 2 and ground.

2. Is resistance less than 0.5 ohms?
a. Yes. Replace pressure switch.
b. No. Repair open in (BK/GN) wire.
Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

BREAKOUT BOX HD-42682 1

BREAKOUT BOX ADAPTERS HD-46601 1

Table 1. Neutral Lamp Always On Diagnostic Faults

POSSIBLE CAUSES

Neutral switch malfunction

Short to ground in neutral circuit

1. Neutral Lamp Function Test

1. Verify transmission is in neutral.

2. Is neutral lamp illuminated?
a. Yes. Go to Test 2.
b. No. See Neutral Lamp Inoperative.

2. Transmission Operation Test

1. Shift transmission out of neutral.

2. Does neutral lamp turn OFF and stay off?
a. Yes. Neutral lamp is operating properly. Test for intermittent. See Wiggle Test.
b. No. Go to Test 3.

3. Neutral Switch Test

1. Disconnect neutral switch [131].

2. Does neutral lamp turn OFF?
a. Yes. Replace neutral switch.
b. No. Go to Test 4.

4. Neutral Switch Circuit Test

1. Disconnect speedometer [39].

2. Connect BREAKOUT BOX ADAPTERS (Part Number:HD-46601) to [39]. Attach connectors from
BREAKOUT BOX (Part Number:HD-42682) to harness adapters leaving [39A] disconnected. See How To
 Use Diagnostic Tools.
3. Using TEST CONNECTOR KIT (Part Number:HD-41404), test resistance between BOB terminal 6 and
ground.
4. Is resistance less than 5 ohms?
a. Yes. Repair short to ground in (W) wire.
b. No. Replace speedometer.
Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

BREAKOUT BOX HD-42682 1

BREAKOUT BOX ADAPTERS HD-46601 1

Table 1. Neutral Lamp Inoperative Diagnostic Faults

POSSIBLE CAUSES

Neutral switch malfunction

Open ground circuit

Open neutral switch circuit

1. Neutral Lamp Function Test

1. Verify transmission is in neutral.

2. Does neutral lamp illuminate?
a. Yes. Test for intermittent. See Wiggle Test.
b. No. Go to Test 2.

2. Neutral Switch Test

1. Disconnect neutral switch [131].

2. Using TEST CONNECTOR KIT (Part Number:HD-41404), jumper [131B] terminal 1 to ground.
3. Does neutral lamp turn ON?
a. Yes. Replace neutral switch.
b. No. Go to Test 3.

3. Neutral Switch Power Circuit Open Test

1. Turn IGN OFF.

2. Connect BREAKOUT BOX ADAPTERS (Part Number:HD-46601) to [39]. Attach connectors from
BREAKOUT BOX (Part Number:HD-42682) to harness adapters leaving [39A] disconnected. See How To
Use Diagnostic Tools.
3. Using TEST CONNECTOR KIT (Part Number:HD-41404), test resistance between BOB terminal 6 and
ground.
4. Is resistance less than 0.5 ohm?
a. Yes. Replace speedometer.
b. No. Repair open in (W) wire.
Table 1. High Beam Indicator Always On Diagnostic Faults

POSSIBLE CAUSES

Speedometer malfunction

1. High Beam Indicator Function Test

1. Verify headlamp.
2. Is high beam headlamp always on or inoperative?
a. Yes. See Description and Operation.
b. No. Replace speedometer.
Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

BREAKOUT BOX HD-42682 1

BREAKOUT BOX ADAPTERS HD-46601 1

Table 1. High Beam Indicator Inoperative Diagnostic

Faults

POSSIBLE CAUSES

Open high beam indicator circuit

1. High Beam Indicator Function Test

1. Operate headlamp switch from low beam to high beam.

2. Do high and low beam headlamps function correctly?
a. Yes. Go to Test 2.
b. No. See Description and Operation.

2. High Beam Indicator Circuit Test

1. Turn IGN OFF.

2. Connect BREAKOUT BOX ADAPTERS (Part Number:HD-46601) to [39]. Attach connectors from
BREAKOUT BOX (Part Number:HD-42682) to harness adapters leaving [39A] disconnected. See How To
Use Diagnostic Tools.
3. Turn IGN ON.
4. Place headlamp switch in high position.
5. Using TEST CONNECTOR KIT (Part Number:HD-41404), test voltage between BOB terminal 4 and ground.
6. Is battery voltage present?
a. Yes. Replace speedometer.
b. No. Repair open in (BE/W) wire.
Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

BREAKOUT BOX HD-42682 1

BREAKOUT BOX ADAPTERS HD-46601 1

Table 1. Low Fuel Lamp Inoperative Diagnostic Faults

POSSIBLE CAUSES

Open in low fuel circuit

Short to voltage in low fuel circuit

1. Fuel Level Circuit Open Test

1. Connect BREAKOUT BOX ADAPTERS (Part Number:HD-46601) to [39B] leaving speedometer [39A]
disconnected. Attach connectors from BREAKOUT BOX (Part Number:HD-42682) to harness adapters.
2. Using TEST CONNECTOR KIT (Part Number:HD-41404), test for continuity between [141B] terminal 1 and
[39B] terminal 9.
3. Is continuity present?
a. Yes. Replace speedometer.
b. No. Repair open in (W/Y) wire.
Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

BREAKOUT BOX HD-42682 1

BREAKOUT BOX ADAPTERS HD-46601 1

Table 1. Turn Signal Indicator Inoperative Diagnostic

Faults

POSSIBLE CAUSES

Open turn signal circuit

1. Turn Signal Function Test

1. Operate turn signals.

2. Do turn signals operate?
a. Yes. Go to Test 2.
b. No. See Description and Operation.

2. Turn Signal Indicator Circuit Test

1. Turn IGN OFF.

2. Connect BREAKOUT BOX ADAPTERS (Part Number:HD-46601) to [39]. Attach connectors from
BREAKOUT BOX (Part Number:HD-42682) to harness adapters leaving [39A] disconnected. See How To
Use Diagnostic Tools.
3. Turn IGN ON.
4. Turn inoperative turn signal on.
5. Using TEST CONNECTOR KIT (Part Number:HD-41404), test voltage between BOB terminal 10 (left) and 12
(right) and ground.
6. Is voltage cycling on and off?
a. Yes. Replace speedometer.
b. No. Repair open in (BE/V) left or (BE/BN) right wire.
Table 1. Turn Signal Indicator Always On Diagnostic
Faults

POSSIBLE CAUSES

Speedometer malfunction

1. Turn Signal Function Test

1. Operate turn signals.

2. Do turn signals operate and turn off correctly?
a. Yes. Replace speedometer.
b. No. See Description and Operation.
The horn is powered through the horn switch from the ACC fuse. The horn is grounded through GND 2. When the horn
switch is pressed, battery voltage is applied to [122-1] terminal 1, causing the horn to sound.
Horn Switch

The horn switch is a push button switch on the left handlebar controls.

Horn

See Figure 1. The horn is located on the left side of the vehicle beside the front cylinder.

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1 Horn [122-1]

2 Horn [122-2]

3 Cooling fan [97]

4 JSS [133]

5 Oil pressure [120]

6 CKP [79]

7 Neutral switch [131]

Figure 1. Lower Left Front of Engine

The horn circuit does not set DTCs when there is a malfunction. Refer to Table 1 for troubleshooting.

Table 1. Horn Symptoms

SYMPTOM COMMON CAUSE

Horn always on Short to voltage or a stuck switch

Horn inoperative Open circuit, faulty horn or horn switch

Diagnostic Tips

If the ACC fuse is open, check the circuit between the horn switch and the horn for a short to ground. This would cause
the fuse to open only when the horn switch is pressed.

Connector Information

For additional information about the connectors in the following diagram(s) and diagnostic procedure(s), see
Connector Locations.

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Figure 1. Horn
Table 1. Horn Always On Diagnostic Faults

POSSIBLE CAUSES

Short to voltage in horn power circuit

Horn switch malfunction

1. Horn Switch Test

1. Turn IGN OFF.

2. Disconnect left hand controls [24].
3. Turn IGN ON.
4. Did horn turn off?
a. Yes. Replace left hand control assembly.
b. No. Repair short to voltage in the (R/V) wire between horn and left hand controls.
Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

Table 1. Horn Inoperative Diagnostic Faults

POSSIBLE CAUSES

Open accessory circuit

Shorted accessory circuit

Horn malfunction

Open ground circuit

Horn switch malfunction

Open horn power circuit

1. Accessory Circuit Open or Shorted Test

1. Turn IGN to ACC.

2. Check speedometer lighting.
3. Does speedometer illuminate?
a. Yes. Go to Test 2.
b. No. Repair open in (R/Y) wire.

2. Horn Test

1. Disconnect horn [122-1] and [122-2].

2. Using TEST CONNECTOR KIT (Part Number:HD-41404), test voltage between [122B-1] and [122B-2].
3. Press horn switch.
4. Is battery voltage present?
a. Yes. Replace horn.
b. No. Go to Test 3.

3. Ground Circuit Open Test

1. Test resistance between [122B-2] and ground.

2. Is resistance less than 0.5 ohm?
a. Yes. Go to Test 4.
b. No. Repair open in the ground circuit.
4. Horn Switch Malfunction Test

1. Connect horn [122-1] and [122-2].

2. Disconnect left hand controls [24].
3. Turn IGN ON.
4. Using TEST CONNECTOR KIT (Part Number:HD-41404) jumper [24A] terminals 2 and 7.
5. Did horn sound?
a. Yes. Replace left hand control assembly.
b. No. Go to Test 5.

5. Horn Power Circuit Open Test

1. Test voltage between [24A] terminal 2 (R/Y) to ground.

2. Is battery voltage present?
a. Yes. Repair open in (R/V) wire.
b. No. Repair open in (R/Y) wire.
See Figure 1. The headlamp switch is used to select either the high beam or the low beam headlamps. When the ignition
is turned ON the headlamp switch receives power through the lights/instrument fuse.

In the low position, the headlamp switch directs voltage to illuminate the low beam headlamp.
In the high position, the headlamp switch directs voltage to illuminate the high beam headlamp and the high beam
indicator.

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1 Left front turn lamp [31L]

2 Right front turn lamp [31R]

3 Clutch switch [314]

Figure 1. Under Fuel Tank Left Side

Diagnostic Tips

If the lights fuse is open:

Test for short to ground on (BE) wire from the fuse to the headlamp switch.
Check for a short to ground on the (BE/W) and (BE/Y) wires from the headlamp switch. If these circuits are
grounded, it will open the fuse when the headlamp switch is in that position.

Connector Information

For additional information about the connectors in the following diagram(s) and diagnostic procedure(s), see
Connector Locations.
 View interactive
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image

Figure 2. Headlamp and Running Lamps

Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

Table 1. Headlamp Inoperative Diagnostic Faults

POSSIBLE CAUSES

Open fuse

Open power to switch circuit

Headlamp Hi/Lo switch malfunction

Open ground circuit

Open high beam power circuit

Open low beam power circuit

Headlamp malfunction

1. Operational Test

1. Operate headlamp switch between high and low positions.

2. Do headlamps work in both positions?
a. Yes. Concern is intermittent. Perform wiggle test. See Wiggle Test.
b. No, high beam headlamp inoperative. Go to Test 2.
c. No, low beam headlamp inoperative. Go to Test 5.
d. No, both headlamps inoperative. Go to Test 7.

2. High Beam Indicator Test

1. With headlamp Hi/Lo switch in high position, observe high beam indicator lamp.
2. Does high beam indicator illuminate?
a. Yes. Go to Test 4.
b. No. Go to Test 3.

3. Headlamp Hi/Lo Switch Test

1. Turn IGN OFF.

2. Disconnect left hand controls [24].
3. Using TEST CONNECTOR KIT (Part Number:HD-41404), jumper [24A] terminals 4 and 6.
4. Turn IGN ON.
5. Does high beam headlamp operate?
 a. Yes. Replace left hand control assembly.
b. No. Repair open in (BE/W) wire between [24A] and speedometer.

4. High Beam Headlamp Test

1. Turn IGN OFF.

2. Disconnect headlamp [38-2].
3. Turn IGN ON.
4. Position headlamp Hi/Lo switch in high position.
5. Using TEST CONNECTOR KIT (Part Number:HD-41404), test voltage between [38B-2] terminals HI and
GND.
6. Is battery voltage present?
a. Yes. Replace headlamp.
b. No. Repair open in (BE/GN) or (BE/W) wire to headlamp.

5. Headlamp Hi/Lo Switch Test

1. Turn IGN OFF.

2. Disconnect left hand controls [24].
3. Using TEST CONNECTOR KIT (Part Number:HD-41404), jumper [24A] terminals 4 and 5.
4. Turn IGN ON.
5. Does low beam headlamp operate?
a. Yes. Replace left hand control assembly.
b. No. Go to Test 6.

6. Low Beam Headlamp Test

1. Turn IGN OFF.

2. Connect [24].
3. Disconnect headlamp [38B-2].
4. Turn IGN ON.
5. Position Hi/Lo switch in low position.
6. Using TEST CONNECTOR KIT (Part Number:HD-41404), test voltage between [38B-2] terminals LO and
GND.
7. Is battery voltage present?
a. Yes. Replace headlamp.
b. No. Repair open in (BE/O) or (BE/Y) wire to headlamp.

7. High Beam Indicator Test

1. With headlamp Hi/Lo switch in high position, observe high beam indicator lamp.
2. Does high beam indicator illuminate?
a. Yes. Go to Test 9.
b. No. Go to Test 8.

8. Ignition Power Circuit Test

 1. Turn IGN OFF.
2. Disconnect left hand controls [24].
3. Using TEST CONNECTOR KIT (Part Number:HD-41404), jumper [24A] terminals 4 and 5.
4. Turn IGN ON.
5. Does low beam headlamp operate?
a. Yes. Replace left hand control assembly.
b. No. Repair open in (BE/O) or (BE) wire to LH control.

9. Headlamp Ground Test

1. Turn IGN OFF.

2. Disconnect headlamp [38B-2].
3. Using TEST CONNECTOR KIT (Part Number:HD-41404), test resistance between [38B-2] terminal GND and
ground.
4. Is resistance less than 0.5 ohms?
a. Yes. Replace headlamp.
b. No. Repair open in (GY/W) or (BK) ground circuit from headlamp.
See Figure 1. The front and rear stop lamp switches control the stop lamp portion of the tail/stop lamp. The front stop lamp
switch is a mechanical switch. Squeezing the front brake lever closes the switch contacts.

See Figure 2. The rear stop lamp switch is a pressure switch. Pressing the rear brake pedal generates brake fluid
pressure, closing the switch contacts. The lights/instrument fuse supplies power to the stop lamp switches.

When the front stop lamp switch closes (front brake lever pulled in), power flows through the switch to the tail/stop
lamp.
When the rear stop lamp switch is applied (rear brake pedal pressed), power flows through the switch to the tail/stop
lamp.

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1 Front brake switch

2 Front brake switch [170-2]

3 Front brake switch [170-1]

Figure 1. Right Front Hand Controls

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1 Rear stop lamp [121-1]

2 Rear stop lamp [121-2]

3 Front HO2S [138]

Figure 2. Rear of Transmission Right Side

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1 LP lamp [40]

2 Left rear turn signal [19]

3 Right rear turn signal [18]

4 Rear lighting jumper [7]

5 Stop/tail lamp [93]

Figure 3. Under Passenger Seat: Except 750A

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 1 Terminating resistor [319]

2 Left turn lamp [19]

3 LP lamp [40]

4 Right turn lamp [18]

5 Stop/tail lamp [93]

6 ECM [78-2]

7 Flasher [69]

8 BAS [134]

9 Engine harness [145]

10 P&A connector

11 Starter solenoid [128]

12 ECM [78-1]

13 Security antenna [142]

14 Security module [326]

Figure 4. Under Seat: 750A

Diagnostic Tips

When testing for a short to ground due to an open lights/instrument fuse, check the (BE/R) wire between the brake
switches and the stop lamp. A short to ground on these wires causes the fuse to open only when the brake switches
are closed.

Connector Information

For additional information about the connectors in the following diagram(s) and diagnostic procedure(s), see
Connector Locations.
 View interactive
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image

Figure 5. Tail/Stop Lamp Circuit

Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

Table 1. Stop Lamp Always On Diagnostic Faults

POSSIBLE CAUSES

Short to voltage in stop lamp power circuit

Front stop lamp switch malfunction

Rear stop lamp switch malfunction

1. Front Stop Lamp Switch Test

1. Disconnect front stop lamp switch [170-2].

2. Does stop lamp turn off?
a. Yes. Replace front stop lamp switch.
b. No. Go to Test 2.

2. Rear Stop Lamp Switch Test

1. Disconnect rear stop lamp switch [121-2].

2. Does stop lamp turn off?
a. Yes. Replace rear stop lamp switch.
b. No. Go to Test 3.

3. Stop Lamp Test

1. Disconnect stop lamp [93].

2. Using TEST CONNECTOR KIT (Part Number:HD-41404), test voltage between [93A] terminals 2 and 3.
3. Is battery voltage present?
a. Yes. Repair short to voltage in the (BE/R) wire.
b. No. Replace stop lamp.
Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

Table 1. Stop Lamp Inoperative Diagnostic Faults

POSSIBLE CAUSES

Open fuse

Short in stop lamp circuit

Open power to switch circuit

Open ground circuit

Open stop lamp circuit

Stop lamp malfunction

Rear stop lamp switch malfunction

Front stop lamp switch malfunction

1. Lights Circuit Test

1. Observe tail lamp.

2. Is tail lamp illuminated?
a. Yes. Go to Test 3.
b. No. Go to Test 2.

2. Tail Stop Lamp Test

1. Disconnect tail lamp [93].

2. Using TEST CONNECTOR KIT (Part Number:HD-41404), test voltage between [93A] terminals 1 and 3.
3. Is battery voltage present?
a. Yes. Replace stop/tail lamp.
b. No. Go to Test 6.

3. Stop Lamp Switch Test

1. Apply front brake lever while observing stop lamp.

2. Apply rear brake pedal while observing stop lamp.
3. Does stop lamp illuminate?
a. Yes. Stop lamp illuminates only with front brake
lever applied. Go to Test 7.
 b. Yes. Stop lamp illuminates only with rear brake
pedal applied. Go to Test 9.
c. No. Go to Test 4.

4. Tail Stop Lamp Test

1. Disconnect rear lighting [93].

2. With one stop lamp switch closed, test voltage between [93A] terminals 2 and 3.
3. Is battery voltage present?
a. Yes. Replace tail/stop lamp.
b. No. Go to Test 5.

5. Diode Pack Test

1. Disconnect diode pack [201].

2. Using TEST CONNECTOR KIT (Part Number:HD-41404), jumper terminals 1 and 3 of diode pack [201B].
3. Apply rear brake pedal and test voltage between [93B] terminals 2 and 3.
4. Is battery voltage present?
a. Yes. Replace diode pack.
b. No. Repair open in (BE/R) wire.

6. Stop Lamp Ground Test

1. Test voltage between [93B] terminal 1 and ground.

2. Is battery voltage present?
a. Yes. Repair open in (BK) wire.
b. No. Repair open in (R/BE) wire at fuse block.

7. Rear Stop Lamp Switch Test

1. Disconnect rear stop lamp switch [121].

2. Jumper [121B-1] terminal 1 and [121B-2] terminal 1.
3. Turn IGN ON.
4. Does brake lamp illuminate?
a. Yes. Replace rear stop lamp switch.
b. No. Go to Test 8.

8. Rear Stop Lamp Switch Circuit Test

1. Test voltage between [121B-2] and ground.

2. Is battery voltage present?
a. Yes. Repair open in (BE/R) wire.
b. No. Repair open in (BE) wire.

9. Front Stop Lamp Switch Test

 1. Disconnect front stop lamp switch [170].
2. Using TEST CONNECTOR KIT (Part Number:HD-41404) jumper [170B-1] terminal 1 and [170B-2] terminal 1.
3. Turn IGN ON.
4. Does brake lamp illuminate?
a. Yes. Replace front stop lamp switch.
b. No. Go to Test 10.

10. Front Stop Lamp Switch Circuit Test

1. Test voltage between [170B-1] terminal 1 and ground.

2. Is battery voltage present?
a. Yes. Repair open in (BE/R) wire.
b. No. Repair open in (BE) wire.
See Figure 1 and Figure 3. The flasher receives battery power through the lights fuse. When the turn signal switch is
pressed the switch closes and power flows from the flasher to the turn lamps and indicators.

If you want to stop the turn signals from flashing, briefly press the turn signal release switch. If you are signaling to turn in
one direction and you press the switch for the opposite turn signal, the first signal is cancelled and the opposite side
begins flashing.

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1 Security module [326]

2 ECM [78-2]

3 Rear lighting [7]

4 Flasher [69]

5 BAS [134]

6 Engine harness [145]

7 Starter solenoid [128]

8 ECM [78-1]

9 Security antenna [142]

10 Terminating resistor [319]

Figure 1. Under Seat: Except 750A

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1 Terminating resistor [319]

2 Left turn lamp [19]

3 LP lamp [40]

4 Right turn lamp [18]

5 Stop/tail lamp [93]

6 ECM [78-2]

7 Flasher [69]

8 BAS [134]

9 Engine harness [145]

10 P&A connector

11 Starter solenoid [128]

12 ECM [78-1]

13 Security antenna [142]

14 Security module [326]

Figure 2. Under Seat: 750A

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1 Left front turn lamp [31L]

2 Right front turn lamp [31R]

3 Clutch switch [314]

Figure 3. Under Fuel Tank Left Side

Connector Information

For additional information about the connectors in the following diagram(s) and diagnostic procedure(s), see
Connector Locations.
 View interactive
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image

Figure 4. Turn Signals

Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

Table 1. All Turn Signals Inoperative Diagnostic Faults

POSSIBLE CAUSES

Turn signal flasher malfunction

Turn signal switch malfunction

Open in ground circuit

Open in power circuit

1. Turn Signal Test

1. Operate turn signals.

2. Do turn signals illuminate without flashing?
a. Yes. Go to Test 2.
b. No. Go to Test 3.

2. Turn Signal Flasher Test

1. Remove turn signal flasher.

2. Operate turn signals.
3. Do turn signals still illuminate?
a. Yes. Repair short to voltage in (BE/O) wire.
b. No. Replace turn signal flasher.

3. Turn Signal Flasher Open Test

1. Turn IGN OFF.

2. Remove turn signal flasher.
3. Using TEST CONNECTOR KIT (Part Number:HD-41404), jumper [69B] terminals 1 and 2.
4. Turn IGN ON.
5. Do turn signals illuminate?
a. Yes. Replace turn signal flasher.
b. No. Go to Test 4.

4. Open Power Circuit Test

 1. Test voltage between [69B] terminal 2 and ground.
2. Is battery voltage present?
a. Yes. Go to Test 5.
b. No. Repair open in (BE) wire.

5. Switch Power Test

1. Disconnect LH control [24].

2. Test resistance between [24A] terminal 3 and [69B] terminal 1.
3. Is resistance less than 0.5 ohm?
a. Yes. Go to Test 6.
b. No. Repair open in (BE/O) wire.

6. Turn Signal Switch Test

1. Disconnect rear lighting [7].

2. Test resistance between [7B] terminal 6 and ground.
3. Is resistance less than 0.5 ohms?
a. Yes. Replace left hand control assembly.
b. No. Repair open in (BK) wire.
Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

Table 1. Any Front Turn Signal Inoperative Diagnostic

Faults

POSSIBLE CAUSES

Open bulb

Light assembly malfunction

Open in ground circuit

Open in power circuit

1. Turn Signal Inspection Test

1. Inspect turn signal.

2. Is the turn signal LED?
a. Yes. Go to Test 3.
b. No. Go to Test 2.

2. Bulb Test

1. Inspect inoperative turn signal bulb.

2. Is bulb good?
a. Yes. Go to Test 3.
b. No. Replace bulb.

3. Power Circuit Test

1. Disconnect inoperative turn signal [31L] or [31R].

2. Operate turn signals.
3. Using TEST CONNECTOR KIT (Part Number:HD-41404), test voltage between [31LA] or [31RA] terminals 1
and 3 of inoperative turn signal.
4. Does battery voltage cycle on and off?
a. Yes. Replace turn signal.
b. No. Go to Test 4.

4. Ground Circuit Test

1. Operate turn signals.

2. Test voltage between [31LA] or [31RA] terminal 3 and ground of inoperative turn signal.
3. Does battery voltage cycle on and off?
a. Yes. Repair open in (BK) wire.
b. No. Repair open in (BE/V) left or (BE/BN) right wire.
Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

Table 1. Any Rear Turn Signal Inoperative Diagnostic

Faults

POSSIBLE CAUSES

Open bulb

Light assembly malfunction

Open in ground circuit

Open in power circuit

1. Turn Signal Inspection Test

1. Inspect turn signal.

2. Is the turn signal LED?
a. Yes. Go to Test 3.
b. No. Go to Test 2.

2. Bulb Test

1. Inspect inoperative turn signal bulb.

2. Is bulb good?
a. Yes. Go to Test 3.
b. No. Replace bulb.

3. Power Circuit Test

1. Disconnect inoperative turn signal [18] right or [19] left.

2. Operate turn signals.
3. Using TEST CONNECTOR KIT (Part Number:HD-41404), test voltage between [18B] or [19B] terminals 1 and
2 of inoperative turn signal.
4. Does battery voltage cycle on and off?
a. Yes. Replace turn signal.
b. No. Go to Test 4.

4. Ground Circuit Test

1. Test voltage between [18B] or [19B] terminal 1 and ground of inoperative turn signal.
2. Does battery voltage cycle on and off?
a. Yes. Repair open in (BK) wire.
b. No. Repair open in (BE/V) left or (BE/BN) right wire.
Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

Table 1. Left Turn Signals Inoperative Diagnostic Faults

POSSIBLE CAUSES

Turn signal switch malfunction

Open in power circuit from switch

1. Power Circuit Test

1. Turn IGN OFF.

2. Disconnect LH control [24].
3. Using TEST CONNECTOR KIT (Part Number:HD-41404), jumper [24A] terminals 3 and 8.
4. Turn IGN ON.
5. Do turn signals flash?
a. Yes. Replace left hand control assembly.
b. No. Repair open in (BE/V) wire.
Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

Table 1. Right Turn Signals Inoperative Diagnostic Faults

POSSIBLE CAUSES

Turn signal switch malfunction

Open in power circuit from switch

1. Power Circuit Test

1. Turn IGN OFF.

2. Disconnect LH control [24].
3. Using TEST CONNECTOR KIT (Part Number:HD-41404), jumper [24A] terminals 3 and 9.
4. Turn IGN ON.
5. Do turn signals flash?
a. Yes. Replace left hand control assembly.
b. No. Repair open in (BE/BN) wire.
See Figure 1 and Figure 2. The headlamp connector is located on the right side under the fuel tank.

The rear tail/stop lamp, rear turn signals and license plate lamp connectors are located in the rear fender behind the seat.

The running lamps consist of the front running lamps, the position lamp (if equipped), the license plate lamp and the tail
lamp. The running lamps are powered in the ACC and the ON position.

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1 Left front turn lamp [31L]

2 Right front turn lamp [31R]

3 Clutch switch [314]

Figure 1. Under Fuel Tank Left Side

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1 LP lamp [40]

2 Left rear turn signal [19]

3 Right rear turn signal [18]

4 Rear lighting jumper [7]

5 Stop/tail lamp [93]

Figure 2. Under Passenger Seat: Except 750A

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1 Terminating resistor [319]

2 Left turn lamp [19]

3 LP lamp [40]

4 Right turn lamp [18]

5 Stop/tail lamp [93]

6 ECM [78-2]

7 Flasher [69]

8 BAS [134]

9 Engine harness [145]

10 P&A connector

11 Starter solenoid [128]

12 ECM [78-1]

13 Security antenna [142]

14 Security module [326]

Figure 3. Under Seat: 750A

Connector Information

For additional information about the connectors in the following diagram(s) and diagnostic procedure(s), see
Connector Locations.

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Figure 4. Running Lamps Circuit

Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

Table 1. Position Lamp Inoperative Diagnostic Faults:

If Equipped

POSSIBLE CAUSES

Open lights circuit

Lamp malfunction

Open ground

1. Position Lamp Test

1. Turn IGN OFF.

2. Disconnect headlamp [38].
3. Turn IGN ON.
4. Using TEST CONNECTOR KIT (Part Number:HD-41404), test voltage between [38B] terminals 1 and 2.
5. Is battery voltage present?
a. Yes. Replace position lamp.
b. No. Go to Test 2.

2. Ground Circuit Test

1. Test voltage between [38B] terminal 1 and ground.

2. Is battery voltage present?
a. Yes. Repair open in (BK) wire.
b. No. Repair open in (BE) wire.
Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

Table 1. Front Running Lamps Inoperative Diagnostic

Faults

POSSIBLE CAUSES

Open lights circuit

Lamp malfunction

Open ground

1. Running Lamp Test

1. Turn IGN OFF.

2. Disconnect running lamp [31L] or [31R].
3. Turn IGN ON.
4. Using TEST CONNECTOR KIT (Part Number:HD-41404), test voltage between [31LA] or [31RA] terminals 1
and 2.
5. Is battery voltage present?
a. Yes. Replace inoperative running lamp.
b. No. Go to Test 2.

2. Ground Circuit Test

1. Test voltage between [31LA] or [31RA] terminal 2 and ground.

2. Is battery voltage present?
a. Yes. Repair open in (BK) wire.
b. No. Repair open in (BE) wire.
Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

Table 1. Tail Lamp Inoperative Diagnostic Faults

POSSIBLE CAUSES

Open in ground circuit

Open in power circuit

Tail/stop lamp malfunction

1. Tail Lamp Test

1. Turn IGN OFF.

2. Disconnect stop/tail lamp [93].
3. Turn IGN ON.
4. Using TEST CONNECTOR KIT (Part Number:HD-41404), test voltage between [93B] terminals 1 and 3.
5. Is battery voltage present?
a. Yes. Replace tail/stop lamp.
b. No. Go to Test 2.

2. Ground Circuit Test

1. Test voltage between [93B] terminal 1 and ground.

2. Is battery voltage present?
a. Yes. Repair open in (BK) wire.
b. No. Repair open in (BE) wire.
Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

Table 1. LP Lamp Inoperative Diagnostic Faults

POSSIBLE CAUSES

Open in ground circuit

Open in power circuit

LP lamp malfunction

1. LP Lamp Test

1. Turn IGN OFF.

2. Disconnect LP lamp [40].
3. Turn IGN ON.
4. Using TEST CONNECTOR KIT (Part Number:HD-41404), test voltage between [40B] terminals 1 and 2.
5. Is battery voltage present?
a. Yes. Replace the LP lamp.
b. No. Go to Test 2.

2. Ground Circuit Test

1. Test voltage between [40B] terminal 2 and ground.

2. Is battery voltage present?
a. Yes. Repair open in (BK) wire.
b. No. Repair open in (BE) wire.
See Figure 1. The security lamp indicates system status. Refer to Table 1.

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1 Left turn indicator

2 Neutral indicator

3 Security indicator

4 Coolant temperature

5 High beam indicator

6 Right turn indicator

7 Check engine indicator

8 Low fuel indicator

9 Trip odometer reset switch

10 Odometer

11 ABS icon indicator

12 Oil pressure indicator

Figure 1. Speedometer

Table 1. Security Lamp Status

LAMP MODE

Does not flash. Security system not armed.

Stays on solid. After failed PIN entry attempt or a battery reconnect has occurred
while armed.

Flashes every 2.5 seconds. Security system armed.

Flashes four times a second. PIN entry mode.

Stays on solid with IGN OFF. Arming is starting up. You have five seconds before system is
armed.

Stays on solid with IGN ON. If solid for more than four seconds after IGN ON, a current
DTC is present.
 NOTE

Always disarm the vehicle by turning the IGN ON with the fob present before removing or disconnecting the battery.
This prevents the siren (if installed) from activating.

If the vehicle is equipped with the security system, the functionality is provided by a SCM. The SCM will disable the starter
and ignition system. Additional functions include the ability to alternately flash the left and right turn signals and sound a
siren (if equipped) if a theft attempt is detected.

NOTE

The siren must be in the chirp mode for the siren to chirp on arming or disarming. See Siren Chirp Mode
Confirmation.

Conditions that trigger a security event when system is armed include:

Detecting tampering of the ignition

circuit: Turn signals flash three times, optional siren chirps once and then turns
off. If the tampering continues, a second warning will activate after four seconds. Continued tampering will cause the
alarm to activate for 30 seconds and then turn off. The two warnings/alarm cycle is repeated for each tampering
incident. The system will remain armed and the vehicle will be immobilized.
Detecting vehicle movement: Turn signals flash three times, optional siren chirps once and then turns off. If the
vehicle is not returned to its original position, a second warning will activate after four seconds. If the vehicle is not
returned to its original position, the alarm activates for 30 seconds then turns off. The two warnings/alarm cycle may
repeat a maximum of 10 times with a 10 second pause between cycles.
Detecting that a battery or ground
disconnect has occurred while armed: The optional siren activates its self-
alarm mode. Turn signals will not flash.
Special Tools

Description Part Number Qty.

DIGITAL TECHNICIAN II HD-48650 1

The following information applies only to vehicles equipped with the security.

Personal code
disarming: If the fob is not available or inoperative, the SCM allows the rider to disable the security
alarm and immobilization functions with a five-digit personal code.
Arming confirmation: When the security system is armed, the system provides visual feedback (confirmation) to the
rider by flashing the turn signals and an audible "chirp" if equipped with the optional smart siren and chirp mode is
enabled.
Disarming confirmation: When the security system is disarmed, the system provides an audible "chirp" (confirmation)
if equipped with the optional smart siren and chirp mode is enabled.
Transport mode: It is possible to arm the security system without enabling the motion detector for one ignition cycle.
This allows the vehicle to be moved in an immobilized state.
Starter/ignition
disable: When armed the starter and fuel system are disabled.
Security system
alarm: See Description and Operation. The system will alternately flash the left and right turn
signals and sound an optional Smart Siren if a vehicle security condition is detected while the system is armed.
Dealer service
mode: This mode allows the dealer to disable security system via DIGITAL TECHNICIAN II (Part
Number:HD-48650). Dealer service mode is exited when the IGN is turned ON with the assigned fob in range.
A warning consists of three alternate flashes of the turn signals and chirp from the optional smart siren.

1. First Warning: A warning is issued whenever a person without a fob present or with the system armed attempts to
move the vehicle.
2. Second Warning: If the motion continues, a second warning is issued within four seconds of the first.
3. Alarm: If the motion continues past the second warning, the smart security system will go into full alarm.
The security system automatically arms within 5 seconds when the vehicle is parked and the ignition switch is turned to
OFF or ACC and motion is not detected.

On arming, the turn signals flash twice and the smart siren will chirp twice if chirp function is activated. While armed, the
security lamp will flash once every 2.5 seconds. Refer to Security Lamp Status
.
There are two ways to disarm the security:

Automatic disarming.
Using the PIN.

Automatic Disarming

Always have the fob present when riding, loading, fueling, moving, parking or servicing the vehicle. The vehicle can be
moved in an armed state with the fob present without triggering the alarm. The security disarms automatically when
the ignition switch is turned to ON.

On disarming, the smart siren will chirp once (if chirp function is activated) and the security lamp will turn ON solid for 4
seconds then go out. Refer to Security Lamp Status.

Disarming with a PIN

See Actuation to enter an initial PIN to enable the system.

If you make an error while disarming the security system using the PIN, the alarm will activate for 30 seconds after the
last digit is entered. Refer to Table 1.

Table 1. Entering a PIN to Disarm Harley-Davidson Smart

Security System

STEP ACTION WAIT FOR CONFIRMATION NOTES

NO.

1 If necessary, verify the current 5-digit PIN. Should be

recorded
on wallet
card.

2 Turn ignition to IGN. If armed, the odometer window display will

read: ENTER PIN and
the security lamp
will be flashing at a fast
rate.

3 Press and release the trip switch. In the odometer window, a flashing 1
followed by 4 dashes will
appear.

4 Increment the digit by pressing and releasing The first digit in the odometer will be the
the trip switch
until the odometer window first digit in the
PIN.
displays the first digit of the PIN.

5 Press and hold the trip switch until the The first digit is stored and the next digit Serves as
second digit appears. will flash. enter key.

6 Increment the second digit using the trip The second digit in the odometer will be
switch until the digit
reaches the second the second digit in
the PIN.
digit of the PIN.

7 Press and hold the trip switch until the third The second digit is stored and the next Serves as
digit appears. digit will flash. enter key.

8 Increment the third digit using the trip switch The third digit in the odometer will be the
until it reaches
the third digit of the PIN. third digit in the PIN.
9 Press and hold the trip switch until the fourth The third digit is stored and the next digit Serves as
digit appears. will flash. enter key.

10 Increment the fourth digit using the trip The fourth digit in the odometer will be the
switch until it reaches
the fourth digit of the fourth digit in the PIN.
PIN.

11 Press and hold the trip switch until the fifth The fourth digit is stored and the next digit Serves as
digit appears. will flash. enter key.

12 Increment the fifth digit using the trip switch The fifth digit in the odometer will be the
until it reaches
the fifth digit of the PIN. fifth digit in the PIN.

13 Press and hold the trip switch. The fifth digit is stored. The security Security
system indicator lamp
stops blinking. system is
disarmed.
Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

BREAKOUT BOX HD-42682 1

BREAKOUT BOX ADAPTERS HD-46601 1

Table 1. DTC B2400 Diagnostic Faults

POSSIBLE CAUSES

Open in SCM battery power circuit

Open in SCM ground circuit

1. DTC Test

1. Clear DTCs.
2. Turn IGN ON.
3. Check DTCs.
4. Did DTC reset?
a. Yes. Go to Test 2.
b. No. System operating properly.

2. SCM Voltage Test

1. Turn IGN OFF.

2. Connect BREAKOUT BOX (Part Number:HD-42682) and BREAKOUT BOX ADAPTERS (Part Number:HD-
46601) to wiring harness [39B], leaving [39A] disconnected. See How To Use Diagnostic Tools.
3. Using TEST CONNECTOR KIT (Part Number:HD-41404), test voltage between BOB terminal 1 and ground.
4. Is battery voltage present?
a. Yes. Go to Test 3.
b. No. Repair open in (R) wire.

3. SCM Ground Test

1. Test voltage between BOB terminals 1 and 6.

2. Is battery voltage present?
a. Yes. Replace SCM.
b. No. Repair open in ground circuit.
Activation

When the alarm system is activated:

Turn signals alternately flash.

Smart siren, if equipped, sounds.
After 30 seconds of alarm, if no further vehicle motion is detected, the alarm will stop.

NOTE

Vehicle must be returned to original parked position.

If vehicle motion continues, the alarm will start again and continue for another 30 seconds.

The security system will repeat the alarm cycles 10 times for a total of 5 minutes, with a 10-second pause between
alarm cycles.

Deactivation

Stop the alarm at any time by moving an assigned fob to the vehicle. The presence of the fob will terminate the alarm.

Connector Information

For additional information about the connectors in the following diagram(s) and diagnostic procedure(s), see
Connector Locations.

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Figure 1. SCM Circuit

See Figure 1. The fob's reception range for the signal depends on a specific receiver pattern. The typical range will be an
arm's length. Replace the fob battery every year.

NOTE

Environmental and geographic conditions impact signal range.

Always have the fob present whenever the vehicle is operated.

Do not place fob in metal enclosure. Do not place it closer than 80 mm (3.0 in) to cellular phones, the hands-free
antenna, PDAs, displays and other electronic devices while operating the vehicle. That may prevent the fob from
disarming the security system.

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1 Battery

2 Fob serial number

Figure 1. Open Fob

Special Tools

Description Part Number Qty.

DIGITAL TECHNICIAN II HD-48650 1

Use DIGITAL TECHNICIAN II (Part Number:HD-48650) to assign both fobs to the security system. Follow the menu
prompts in the DIGITAL TECHNICIAN II (Part Number:HD-48650) display and scan the fob serial number with the bar
code reader, or key-in the number from the keyboard.

NOTE

Each fob has a unique serial number. Attach fob label to a blank NOTES page in the owner's manual for reference.
See Figure 1. If equipped, the siren is attached at [142] and is located behind the left side cover. Through this connector it
shares the battery circuit, the ground circuit and the alarm signal circuit with the SCM. The siren adds an audible warning
to the visual warnings that are a standard function of the security system.

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1 Rear HO2S [137]

2 Security siren [142]

3 Battery tender [280]

Figure 1. Under Left Side Cover

Chirpless Mode

In the chirpless mode, the siren does not chirp on arming or disarming.

NOTE

When armed in the chirpless mode, the siren still chirps warnings on movement and will activate the alarm through
the normal cycles.

Chirp Mode

On arming in the chirp mode, the siren responds with two chirps. When disarming, the siren responds with a single
chirp.

Switching Modes

Cycling quickly through three armings and disarmings will switch chirp mode.

1. With the fob present, the IGN and engine stop switch ON and the system disarmed, turn the IGN OFF.
2. When the security lamp turns off, immediately turn the IGN ON. If the turn signals flash twice before the IGN is
turned ON, the system will drop out of the switching mode sequence and will have to be started over from the
beginning.
3. Wait until the security lamp goes out, then immediately turn the IGN OFF.
4. When the security lamp turns off, immediately turn the IGN ON. If the turn signals flash twice before the IGN is
turned ON, the system will drop out of the switching mode sequence and will have to be started over from the
beginning.
5. Wait until the security lamp goes out, then immediately turn the IGN OFF.
6. When the security lamp turns off, immediately turn the IGN ON. If the turn signals flash twice before the IGN is
turned ON, the system will drop out of the switching mode sequence and will have to be started over from the
beginning.
Actuation consists of assigning two fobs to the system and entering an initial PIN. The PIN can be changed by the owner at
any time.

1. Configure vehicles by assigning both fobs to the vehicle.

2. Configure vehicles by entering a PIN picked by the owner. The personal code allows the owner to operate the
system if the fob is lost or inoperable. Record the PIN in the owner's manual wallet card. Instruct the customer to
always carry this card when riding the motorcycle.

Once the system has been activated, it will always arm within 5 seconds of turning the ignition switch to OFF or ACC and
no vehicle motion.
The 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 security system in case the fob becomes unavailable.
Special Tools

Description Part Number Qty.

DIGITAL TECHNICIAN II HD-48650 1

The initial PIN entry should be performed using DIGITAL TECHNICIAN II (Part Number:HD-48650) in conjunction with fob
assignment.
To change a PIN, refer to Table 1.

If a PIN was previously entered, the odometer will display the equivalent digit. To increment the digits, press the trip switch.
The first press selects the same value and then each additional press of the trip switch will increment the digit by one.

Examples:

To advance from 5 to 6, press and release the trip switch twice.

To advance from 8 to 2, press and release the trip switch four times.

Table 1. Changing the PIN

STEP ACTION WAIT FOR CONFIRMATION NOTES

NO.

1 Select a 5-digit (1 thru 9) PIN and

record on the wallet card
from owner's
manual.

2 With an assigned fob present, turn the This will reset the SCM
ignition switch to OFF. allowing for entrance into
the change
PIN function.

3 With an assigned FOB present, the Steps 4 and 5 must be

ignition switch will be set
to the ON completed within 10
position. seconds.

4 Cycle the ignition switch twice: IGN -

OFF
- IGN - OFF - IGN.

5 Press and release the trip switch two ENTER PIN will scroll through the
times. odometer window.

6 The trip switch shall be pressed and Turn signals will flash three times.
held for at least 1.5 seconds. Current PIN will appear
in
odometer. The first digit will be
flashing.

7 Enter first digit of new PIN by pressing

and releasing the trip
switch until the
selected digit appears.

8 Press and hold the trip switch until the The new digit will replace the current
second digit appears. in odometer window.

9 Enter second digit of selected PIN by

pressing and releasing
the trip switch
until the selected digit is present.

10 Press and hold the trip switch until the The new digit will replace the current
third digit appears. in odometer window.

11 Enter third digit of the selected PIN by

pressing and releasing
the trip switch
until the selected digit is present.
12 Press and hold the trip switch until the The new digit will replace the current
fourth digit appears. in odometer window.

13 Enter fourth digit of new PIN by

pressing and releasing the
trip switch
until the selected digit is present.

14 Press and hold the trip switch until the The new digit will replace the current
fifth digit appears. in odometer window.

15 Enter fifth digit of the new PIN by

pressing and releasing the
trip switch
until the selected digit is present.

16 Press and hold the trip switch for 1.5 The new digit will replace the current
seconds. in odometer window.

17 Turn the ignition switch to OFF. Turn the ignition switch to

OFF stores
the new PIN
in the module.
Put the system in transport mode to transport the motorcycle. Otherwise, the alarm activated by motion detection can
discharge the battery.

In the transport mode, the security system is armed without enabling the motion detector for one ignition cycle. This allows
the vehicle to be picked up and moved in an armed state. Any attempt to start the engine when the fob is not within range
will trigger the alarm.

To Enter Transport Mode

1. With an assigned fob within range, turn the ignition ON.

2. Quickly turn the ignition OFF.
3. Within 3 seconds, the trip switch should be pressed and held for 1.5 seconds on the speedometer.
4. After the turn signals flash once, the system enters the transport mode. With the fob removed, the motorcycle
can be moved without setting off the alarm.

To Exit Transport Mode

With the fob present, turn the ignition ON to disarm the system.
Special Tools

Description Part Number Qty.

DIGITAL TECHNICIAN II HD-48650 1

With a fob present, the security system can be configured for service by disabling the security system with DIGITAL
TECHNICIAN II (Part Number:HD-48650).

Once disabled, the vehicle can be operated without an assigned fob present. To maintain the service mode, the assigned
fobs must be kept out of range. If the fob appears in range, the service mode is cancelled.
 NOTE

This section applies only to those vehicles equipped with the optional security system.

See Figure 1. An alarm cycle is activated when the SCM is connected, the siren has been armed by the SCM and a
security event occurs. See Security Lamp. Under normal armed operation, the siren input (terminal 2) is driven low by the
SCM to trigger the audible alarm. When the siren input is driven high by the SCM the audible alarm stops.

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1 Rear HO2S [137]

2 Security siren [142]

3 Battery tender [280]

Figure 1. Under Left Side Cover

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 three chirps on arming instead of two.
The internal siren battery may not charge if the vehicle battery is less than 12.5V.
If the siren does not chirp two or three times on a valid arming command from the SCM, the chirp function has
been disabled, the siren is either not connected, not working or the siren wiring was opened or shorted while the
siren was disarmed.
If the siren enters the self-driven mode where it is powered from the siren internal 9V battery, the turn signal lamps
will not alternately flash. If the SCM activates the siren, the turn signal lamps will flash. If the siren has been armed
and a security event occurs, and the siren is in self-driven mode, the siren will alarm for 20-30 seconds and then
turn off for 5-10 seconds. This alarm cycle will be repeated 10 times if the siren is in the self-driven mode.
If the siren does not stop sounding after it has been armed, then either the SCM output or siren input may be
shorted to ground, the siren vehicle battery connection is open or the siren vehicle ground connection is open or a
security event has occurred. See Security Lamp for a description of alarm functions.
See Figure 1 , Figure 2 and Figure 3. DTC B2176, B2177 or B2178 will set when a fault occurs to the security antenna
circuit used to transmit to the fob. Refer to Table 1.

If the security system does not respond, responds with limited range or will not consistently disarm with fob within normal
range, see Fails to Disarm.

Table 1. Code Description

DTC DESCRIPTION

B2176 Security antenna output open

B2177 Security antenna output shorted high

B2178 Security antenna output shorted low

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1 Security module [326]

2 ECM [78-2]

3 Rear lighting [7]

4 Flasher [69]

5 BAS [134]

6 Engine harness [145]

7 Starter solenoid [128]

8 ECM [78-1]

9 Security antenna [142]

10 Terminating resistor [319]

Figure 1. Under Seat: Except 750A

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1 Terminating resistor [319]

2 Left turn lamp [19]

3 LP lamp [40]

4 Right turn lamp [18]

5 Stop/tail lamp [93]

6 ECM [78-2]

7 Flasher [69]

8 BAS [134]

9 Engine harness [145]

10 P&A connector

11 Starter solenoid [128]

12 ECM [78-1]

13 Security antenna [142]

14 Security module [326]

Figure 2. Under Seat: 750A

 View interactive
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1 Battery

2 Fob serial number

Figure 3. Open Fob

Conditions for Setting

The SCM will recognize the faults with IGN ON.

Diagnostic Tips

Verify that cell phone is not within 80 mm (3.0 in) of key fob.
Interference from physical surroundings impacts RF transmission. Place fob next to vehicle or move vehicle to a
new location and retest.
Verify that antenna is in OE location. Make sure that seat has not been replaced with a metal base seat.
Check for damage to antenna wire.
Verify fob battery voltage is at least 2.9V.
Fob serial number is located inside fob. Twist thin blade in thumbnail slot to open.

Connector Information

For additional information about the connectors in the following diagram(s) and diagnostic procedure(s), see
Connector Locations.
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Figure 4. SCM Circuit

Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

BREAKOUT BOX HD-42682 1

BREAKOUT BOX ADAPTERS HD-46601 1

Table 1. DTC B2176 Diagnostic Faults

POSSIBLE CAUSES

Security antenna malfunction

Open antenna circuit

NOTE

Always inspect connectors for backed out terminals, improper mating, inoperative locks, improperly formed or
damaged terminals, poor terminal-to-wire connection and damaged harnesses when disconnecting any connector.

1. Fob Test

1. Turn IGN OFF.

2. With fob present, turn IGN ON.
3. Does odometer read ENTER PIN?
a. Yes. Go to Test 2.
b. No. Go to Test 6.

2. Security Antenna Visual Test

1. Inspect security antenna for damage.

2. Is security antenna damaged?
a. Yes. Repair or replace security antenna as needed.
b. No. Go to Test 3.

3. Visual Water Test

1. Turn IGN OFF.

2. Disconnect antenna [209].
3. Inspect for water or contamination.
4. Is water or contamination present?
a. Yes. Replace antenna.
 b. No. Go to Test 4.

4. Security Antenna Resistance Test

1. Using TEST CONNECTOR KIT (Part Number:HD-41404), test resistance between [209A] terminals A and C.
2. Is resistance greater than 5700 ohms?
a. Yes. Replace security antenna.
b. No. Go to Test 5.

5. Antenna B Circuit Open Test

1. Connect BREAKOUT BOX ADAPTERS (Part Number:HD-46601) to [326]. Attach connectors from
BREAKOUT BOX (Part Number:HD-42682) to harness adapters, leaving [326A] disconnected. See How To
Use Diagnostic Tools.
2. Test resistance between BOB terminal 9 and [209B] terminal C.
3. Is resistance less than 0.5 ohm?
a. Yes. Go to Test 6.
b. No. Repair open in (BK) wire.

6. Antenna A Circuit Open Test

1. Test resistance between BOB terminal 10 and [209B] terminal A.

2. Is resistance less than 0.5 ohm?
a. Yes. Go to Test 7.
b. No. Repair open in (R) wire.

7. DTC Test

1. Connect [326] and [209].

2. Clear DTCs.
3. Turn IGN ON.
4. Check DTCs.
5. Did DTC reset?
a. Yes. Replace SCM.
b. No. Concern is intermittent. See Wiggle Test.
Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

BREAKOUT BOX HD-42682 1

BREAKOUT BOX ADAPTERS HD-46601 1

Table 1. DTC B2177 Diagnostic Faults

POSSIBLE CAUSES

Security antenna malfunction

Short to voltage in antenna circuit

NOTE

Always inspect connectors for backed out terminals, improper mating, inoperative locks, improperly formed or
damaged terminals, poor terminal-to-wire connection and damaged harnesses when disconnecting any connector.

1. Security Antenna Visual Test

1. Inspect security antenna for damage.

2. Is security antenna damaged?
a. Yes. Repair or replace security antenna as needed.
b. No. Go to Test 2.

2. Visual Water Test

1. Turn IGN OFF.

2. Disconnect antenna [209].
3. Inspect for water or contamination.
4. Is water or contamination present?
a. Yes. Replace antenna.
b. No. Connect [209]. Go to Test 3.

3. Security Antenna High Circuit Short to Voltage Test

1. Connect BREAKOUT BOX ADAPTERS (Part Number:HD-46601) to [326]. Attach connectors from
BREAKOUT BOX (Part Number:HD-42682) to harness adapters, leaving [326A] disconnected. See How To
Use Diagnostic Tools.
2. Turn IGN ON.
 3. Using TEST CONNECTOR KIT (Part Number:HD-41404), test voltage between BOB terminal 10 and ground.
4. Is voltage greater than 0.6V?
a. Yes. Repair short to voltage in (R) wire.
b. No. Go to Test 4.

4. Security Antenna Low Circuit Short to Voltage Test

1. Test voltage between BOB terminal 9 and ground.

2. Is voltage greater than 0.6V?
a. Yes. Repair short to voltage on (BK) wire.
b. No. Go to Test 5.

5. DTC Test

1. Clear DTCs.
2. Turn IGN ON.
3. Check DTCs.
4. Did DTC reset?
a. Yes. Replace SCM.
b. No. Concern is intermittent. See Wiggle Test.
Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

Table 1. DTC B2178 Diagnostic Faults

POSSIBLE CAUSES

Security antenna malfunction

Short to ground in antenna circuit

NOTE

Always inspect connectors for backed out terminals, improper mating, inoperative locks, improperly formed or
damaged terminals, poor terminal-to-wire connection and damaged harnesses when disconnecting any connector.

1. Security Antenna Visual Test

1. Inspect security antenna for damage.

2. Is security antenna damaged?
a. Yes. Repair or replace security antenna as needed.
b. No. Go to Test 2.

2. Visual Water Test

1. Turn IGN OFF.

2. Disconnect antenna [209].
3. Inspect for water or contamination.
4. Is water or contamination present?
a. Yes. Replace antenna.
b. No. Go to Test 3.

3. Security Antenna High Circuit Short to Ground Test

1. Disconnect SCM [326].

2. Using TEST CONNECTOR KIT (Part Number:HD-41404), test continuity between [209B] terminal A and
ground.
3. Is continuity present?
a. Yes. Repair short to ground in (R) wire.
b. No. Go to Test 4.
4. Security Antenna Low Circuit Short to Ground Test

1. Test continuity between [209B] terminal C and ground.

2. Is continuity present?
a. Yes. Repair short to ground in (BK) wire.
b. No. Go to Test 5.

5. DTC Test

1. Connect SCM [326] and [209].

2. Clear DTC.
3. Turn IGN ON.
4. Did DTC reset?
a. Yes. Replace SCM.
b. No. Concern is intermittent. See Wiggle Test.
Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

BREAKOUT BOX HD-42682 1

BREAKOUT BOX ADAPTERS HD-46601 1

DIGITAL TECHNICIAN II HD-48650 1

Table 1. Fails to Disarm Diagnostic Faults

POSSIBLE CAUSES

Open antenna circuit

Short to ground in antenna circuit

RF interference

Antenna malfunction

Fob malfunction or dead battery

1. Battery Test

1. Check battery on non-functional fob.

2. Is battery voltage greater than 2.9V?
a. Yes. Go to Test 2.
b. No. Replace battery.

2. Interference Test

1. Move vehicle away from any possible interference sources.

2. Place fob on seat.
3. Will security system disarm?
a. Yes. Inspect for electrical accessories or an aftermarket seat that may be causing interference.
b. No. Go to Test 3.

3. Antenna Connection Test

1. Inspect antenna location and connection.

2. Is antenna properly located and connected?
a. Yes. Go to Test 4.
 b. No. Repair connection.

4. Antenna Circuit Short to Ground Test

1. Turn IGN OFF.

2. Connect BREAKOUT BOX ADAPTERS (Part Number:HD-46601) to [326B]. Attach connectors from
BREAKOUT BOX (Part Number:HD-42682) to harness adapters, leaving [326A] disconnected. See How To
Use Diagnostic Tools.
3. Using TEST CONNECTOR KIT (Part Number:HD-41404), test continuity between BOB terminal 4 and ground.
4. Is continuity present?
a. Yes. Repair short to ground.
b. No. Go to Test 5.

5. Antenna Circuits Shorted Together Test

1. Disconnect security antenna [209].

2. Test continuity between BOB terminals 9 and 10.
3. Is continuity present?
a. Yes. Repair short between antenna circuits.
b. No. Go to Test 6.

6. Antenna Circuit Open Test

1. Test resistance between BOB terminal 4 and end of (BK) wire. Pull back conduit to expose unterminated end of
wire.
2. Is resistance less than 0.5 ohm?
a. Yes. Go to Test 7.
b. No. Repair open on (BK) wire.

7. Security System Antenna Test

1. Replace security antenna with a known good security antenna.

2. Does security system now disarm?
a. Yes. Replace security antenna.
b. No. Go to Test 8.

8. Non-Functional Fob Test

1. Replace non-functional fob with a known good fob.

2. Using DIGITAL TECHNICIAN II (Part Number:HD-48650), program known good fob to SCM.
3. Turn IGN ON.
4. Push TEST button on DT unit.
5. Did DT unit see fob?
a. Yes. Replace original fob.
b. No. Verify fob serial number is correct. If so, replace SCM.
This chapter describes the operation of the EFI system. A good working knowledge of motorcycle components is required
for troubleshooting engine and EFI problems. See General and Description and Operation for the operation of the ECM
and function of the various sensors and drivers. See How To Use Diagnostic Tools for instructions on using the test
equipment called out in the diagnostic test procedures in this chapter.

The EFI system provides microprocessor-based electronic engine management for the engine. The EFI system has the
following features:

Independently mapped spark and fuel control.

Compensated fuel delivery through engine temperature, intake air temperature and manifold air pressure.
Engine load measurement via throttle position sensing.
Single point spark delivery.
Sequential port indirect (manifold) fuel injection.
Open/closed loop air/fuel control.
Automatic enrichment at start-up.
Engine speed and position determined by using a single CKP sensor.
Engine idle speed electronically managed with an IAC system.

The ECM makes decisions for enabling ignition, starting, spark and fuel delivery. Sensors include:

CKP sensor
TPS
JSS
Clutch switch
Neutral switch
BAS
ECT sensor
VSS
HO2 sensor
TMAP

EFI Operation

The EFI system operates as an open or closed loop system, allowing it to adjust for all possible operating conditions.

During open loop operation, the system uses programmed fuel and spark maps in the ECM providing easy cold
starting and maximum power at Wide Open Throttle (WOT). The adaptive fuel value, learned during closed loop
operation, is applied to open loop operation to adjust fuel and spark maps for optimal performance.
During closed loop operation, the HO2 sensors provide input for an optimal air/fuel mixture resulting in reduced
emissions, good fuel economy and smooth power. HO2 sensors must be at the normal operating temperature of
the engine.
By using both open and closed loop systems, engine performance is continually adjusted. This compensates for
change in conditions and provides maximum performance. A schematic for the EFI system is shown in Figure 1.

Symptom Diagnostics

These sections contain diagnostic test procedures for DTCs listed in Description and Operation. For symptoms of
engine malfunctions not specifically covered by DTCs, refer to Symptom Table.
 View interactive
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Figure 1. ECM Circuit

See Figure 1 and Figure 2. The ECM receives and processes signals from the sensors and applies output signals to the
drivers to crank, start, idle and run the engine. This section describes the configuration of the ECM.

ECM

The ECM is mounted under the seat. It computes the spark advance for proper ignition timing and fuel control based
on sensor inputs (from CKP, TMAP and TPS sensors). The ECM controls the circuits for the ignition coils and
injectors.

The ECM contains all of the components used in the ignition system. The dwell time for the ignition coil is also
calculated in the microprocessor and is dependent upon battery voltage. The programmed dwell provides adequate
spark at all speeds. The ECM is fully enclosed to protect it from vibration, dust, water or oil. This unit is a non-
repairable item. If it fails, it must be replaced.

24-2 Crankshaft

The left flywheel has 24 teeth evenly spaced around its circumference with two consecutive teeth missing (sync gap).
In this configuration, the ECM determines engine position, engine phase and engine speed from the CKP sensor
input. Phase (TDC compression) is determined by the ECM during startup and, when necessary, while running. No
engine ignition events can occur until the ECM determines the relationship of piston position to crankshaft position.
These continual ECM adjustments allow smooth engine operation at all speeds.

Crank Position Signal Synchronization

In the 24-2 crank configuration, crankshaft position is determined by the ECM finding the two-tooth (sync gap) in the
CKP sensor signal. This is usually accomplished the first time the sync gap is encountered. The ECM monitors the
CKP signal status every engine revolution. If the ECM determines synchronization is lost, it immediately terminates
ignition events and synchronizes on the next occurrence of the sync gap.

Engine Phase

Phasing is accomplished by the ECM identifying a widening in the CKP signal caused by the deceleration of the
crankshaft, as a piston approaches TDC on its compression stroke. Since the rear cylinder approaches TDC earlier
than the front cylinder, engine phase can be readily discriminated. Phasing is normally accomplished on the first TDC
cycle after engine synchronization. Once phased, the ECM can begin normal ignition events. If the ECM experiences
a system reset or loss of synchronization while the engine is running it also loses phase.

When phase is lost one of the following occurs:

If an engine-not-running (crank mode) rpm is detected, the ECM executes the normal start-up phasing process.
If engine run mode is detected, the ECM executes a running re-phase sequence.
The front cylinder is fired every engine revolution. The ECM monitors the power stroke after the fire event to determine
if sufficient acceleration occurred to indicate the ECM fired on the compression stroke. When two valid power strokes
are detected, the ECM locks phase and resumes normal ignition events.

Engine Run Mode

Many functions of the EFI system require an engine run mode determination. Engine run is determined by the level of
engine rpm. Generally, the engine is considered to be running when engine rpm exceeds a minimum of 750 rpm.
 View interactive
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1 Security module [326]

2 ECM [78-2]

3 Rear lighting [7]

4 Flasher [69]

5 BAS [134]

6 Engine harness [145]

7 Starter solenoid [128]

8 ECM [78-1]

9 Security antenna [142]

10 Terminating resistor [319]

Figure 1. Under Seat: Except 750A

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1 Terminating resistor [319]

2 Left turn lamp [19]

3 LP lamp [40]

4 Right turn lamp [18]

5 Stop/tail lamp [93]

6 ECM [78-2]

7 Flasher [69]

8 BAS [134]

9 Engine harness [145]

10 P&A connector

11 Starter solenoid [128]

12 ECM [78-1]

13 Security antenna [142]

14 Security module [326]

Figure 2. Under Seat: 750A

Sensors and drivers play an important part in the ECM's ability to provide the proper operational parameters for engine
efficiency, emissions control and fuel economy. When a failure occurs, a DTC is generated by, and stored in, the ECM.
These codes help the technician diagnose engine trouble to the proper sensor or driver. See Description and Operation.
A failed CKP sensor completely disables the engine. Other sensor problems may cause engine performance issues or
complete engine shutdowns. The following are brief explanations of sensor types and their functions within the EFI
system.

Crank Position (CKP) Sensor

The CKP sensor, located under the left side outer cover, is a variable reluctance device that generates AC voltage as
the teeth on the crankshaft pass by the sensor. The signal is routed to the ECM where it is used to determine
crankshaft position, engine speed (rpm) and engine phase (TDC compression). Without the presence of the CKP
signal, the ECM will not allow the ignition and fuel injection drivers to operate, and thus the engine will not run. The
ECM uses crankshaft compression slow down events to determine engine phase. Therefore, the spark plugs must be
installed when checking for spark.

Throttle Position Sensor (TPS)

The TPS is a variable resistor (potentiometer) having a linear resistance range. It is mounted on the throttle plate. The
output of the sensor is a voltage dependent on the position of the throttle plate. The output is used by the ECM to
determine ignition timing and fuel required at any given rpm and engine load.

Jiffy Stand Sensor (JSS)

The JSS uses a Hall-effect device to monitor jiffy stand position. When the jiffy stand is fully retracted, the sensor picks
up the presence of a metal tab mounted to the jiffy stand. When extended, the engine only starts and runs if the ECM
receives a signal from the neutral switch indicating the transmission is in neutral.

Bank Angle Sensor (BAS)

The Bank Angle Sensor (BAS) is located under seat. It operates from a 5V sensor reference voltage and sensor
ground provided by the ECM. The BAS sends a signal to the ECM ranging from 3.5-4.79V under normal operating
conditions. A BAS signal between 0.24-3.4V indicates to the ECM that the vehicle has tipped over and will turn off the
engine. When the vehicle is righted, turn the ignition OFF, wait 10 seconds and turn ON again to restart the engine. If
the signal from the BAS is below 0.24V or above 4.79V, the ECM sets a code. Refer to Code Description. A BAS
code will not disable the vehicle and the engine will continue to run. A tipped vehicle will not set a DTC.

Clutch Switch

The clutch switch is located on the left handlebar under the clutch lever. It is one of the components used to energize
the start relay.

Neutral Switch

The speedometer provides voltage to the neutral switch, which is open when the transmission is in gear. With the
transmission in neutral, the switch is closed, allowing current flow to ground. The ECM will not allow the engine to start
unless the transmission is in neutral or the clutch is pulled in.

Engine Coolant Temperature (ECT) Sensor

The ECT sensor is a thermistor device. At a specific temperature it has a specific resistance across its terminals. As
this resistance varies, so does the voltage.
 At high temperatures, the resistance of the sensor is very low. This effectively lowers the signal voltage on ECM
[78-2] terminal 8.
At low temperatures, the resistance is very high, allowing the voltage to rise close to 5V. The ECM monitors this
voltage to compensate for various operating conditions. The ECM also uses the sensor input as a reference for
determining Idle Air Control (IAC) pintle position.

Temperature Manifold Absolute Pressure (TMAP) Sensor

The TMAP sensor combines the MAP and IAT in a single component. The functions of each are described in the
following paragraphs. During diagnostics the two parts of the TMAP are tested as separate units.

Manifold Absolute Pressure (MAP) Sensor

The MAP sensor is supplied 5V from the ECM and sends a signal back to the ECM. This signal changes with engine
vacuum, intake air temperature and atmospheric barometric pressure. The MAP sensor monitors the intake manifold
pressure (vacuum) and sends the information to the ECM. The ECM then adjusts the spark and fuel timing advance
curves for optimum performance. The sensor output determines if the engine is rotating when a fault with the CKP
sensor is present.

Intake Air Temperature (IAT) Sensor

The IAT sensor is a thermistor device. At a specific temperature it has a specific resistance across its terminals. As the
temperature varies, the thermistor resistance varies and so does the voltage on ECM [78-2] terminal 6.

At high temperatures, the resistance of the sensor is very low. This effectively lowers the signal voltage on ECM
[78-2] terminal 6.
At low temperatures, the resistance is very high, allowing the voltage to rise close to 5V. The ECM monitors this
voltage to compensate for various operating conditions.

Vehicle Speed Sensor (VSS)

The VSS is a Hall-effect device mounted close to the teeth of the 5th gear in the transmission. The output signal
frequency varies with vehicle speed. The VSS signal is sent to the ECM and the speedometer.

HO2S: Front and Rear

The HO2S detects unburned oxygen in the engine exhaust. The output of the sensor is a voltage having a range of
about 0-1.0V.

The normal output is 0.5V which represents a balance between a lean (not enough fuel) and rich (too much fuel)
air/fuel mixture.
An output less than 0.5V represents a lean mixture; greater than 0.5V represents a rich mixture.
The change in output level signals the ECM to modify the air/fuel ratio.
The HO2S does not operate efficiently until the engine is at operating temperature. Always warm-up the vehicle prior
to troubleshooting the HO2S. The heater elements on the HO2S help bring the HO2S up to operating temperature
quicker. Leaks in the exhaust system, leaky exhaust valves, misfires or any engine problem allowing unburned
oxygen into the exhaust stream could create a DTC indicating a bad sensor. Look for problems related to an improper
air/fuel mixture before replacing the sensor.
The ECM drivers are the output devices or system outputs of the EFI system. Drivers are provided ground by the ECM to
pump, inject and ignite the air/fuel mixture in the engine and to activate relays.

Fuel Pump

The system relay provides battery voltage to the fuel pump which is inside the fuel tank.

Ignition Coils and Spark Plugs

The ignition coils create the energy to fire the spark plugs and ignite the air/fuel mixture in the cylinders. Advancing or
retarding the spark is controlled by the ECM to suit load and speed conditions of the engine.

Fuel Injectors

The system relay provides battery power to the fuel injectors. The ECM provides the path to ground to trigger the
injectors. The fuel injectors are pulse-width modulated solenoids for metering fuel into the intake tract. The pulse-width
of the ground path to the injectors is varied by the ECM in response to inputs from the various sensors, thus varying
the length of time the injector is open.

Idle Air Control (IAC)

The IAC motor is a stepper-motor used to regulate the amount of air entering the intake manifold during idle. The ECM
controls engine idle speed by moving the IAC pintle to open or close a passage around the throttle plate. It does this
by sending voltage pulses to the proper motor winding of the IAC. This causes the pintle to move in or out of the IAC a
given distance 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.
Special Tools

Description Part Number Qty.

VACUUM PUMP HD-23738 1

See Figure 1. The TMAP sensor provides the functions of both an IAT sensor and a MAP sensor in one unit. The TMAP
sensor is supplied 5V from ECM [78-2] terminal 9 and sends MAP and IAT signals back to ECM [78-1] terminal 7 and [78-
2] terminal 6 respectively. Refer to Table 1.

Table 1. Code Description

DTC DESCRIPTION

P0107 MAP sensor open/low

P0108 MAP sensor high

P0112 IAT sensor voltage low

P0113 IAT sensor open/high

View interactive
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image

1 Rear injector [85]

2 TPS [88]

3 TMAP [80]

4 IAC [87]

5 Headlamp [38]

6 Ignition switch [33]

7 LH controls [24]

8 RH controls [22]
 9 Fuel pump [141]

10 Front injector [84]

11 ECT [90]

12 Ignition coil [83]

Figure 1. Under Fuel Tank Right Side

TMAP: MAP Signal

The MAP signal varies in accordance with engine vacuum and atmospheric pressure. Changes in atmospheric
pressure are influenced by weather and altitude.

TMAP: IAT Signal

The IAT portion of the TMAP sensor is a thermistor device. At a specific temperature, it will have a specific resistance
across its terminals. As this resistance varies, so does the voltage on [78-2] terminal 6 of the ECM.

At high temperatures, the resistance of the IAT sensor is very low, which effectively lowers the signal voltage on
[78-2] terminal 6.
At low temperatures, the resistance is very high, allowing the voltage to rise close to 5V. The ECM monitors this
voltage to compensate for various operating conditions.

Diagnostic Tips: MAP Portion of TMAP Sensor

DTCs P0107 or P0108 will set if the MAP sensor signal is out of range. DTC P0108 can only be detected with the
engine running.
Using the VACUUM PUMP (Part Number:HD-23738), apply a vacuum to the pressure port of the TMAP sensor.
The MAP signal voltage should lower as the vacuum is applied.
The TMAP and TGS are connected to the same reference line (5V reference). If the reference line goes to ground
or open, multiple codes will be set (DTCs P0107, P0108, P0122, P0123, P1501 and P1502).

Diagnostic Tips: IAT Portion of TMAP Sensor

An intermittent may be caused by a poor connection, rubbed through wire insulation or an open wire inside the
insulation. Check the following conditions:

Poor connection: Inspect ECM and harness connector [78-1] and [78-2] for backed out terminals, improper
mating, inoperative locks, improperly formed or damaged terminals, poor terminal-to-wire connection and
damaged harness.
Perform Wiggle Test to locate intermittents: If connections and harness check out OK, use a multimeter to
check the IAT sensor voltage while moving related connectors and wiring harness. If the failure is induced, the IAT
voltage will change.
Shifted sensor resistance value: Measure ECT and IAT sensor temperatures with a cool engine. The sensor
temperatures should be within 5.6 °C (10 °F) of each other. If the two sensors are not within the specified range,
replace the inaccurate sensor.
A faulty sensor can negatively affect the signal voltage of the other sensors sharing the same 5V reference. If the
wiring passes the following tests, disconnect one sensor at a time on the 5V reference and verify the DTC is still
present. Additional DTCs will be set as each sensor is disconnected, clear DTCs after this test. Be sure to perform
 this test before replacing a component.

Connector Information

For additional information about the connectors in the following diagram(s) and diagnostic procedure(s), see
Connector Locations.

View interactive
View interactive image
image

Figure 2. Sensor Circuit

Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

BREAKOUT BOX HD-50390-1 1

ECM CABLE HD-50390-4 1

ECM OVERLAY HD-50390-4-P 1

Table 1. DTC P0107 Diagnostic Faults

POSSIBLE CAUSES

Open or shorted to ground signal wire

Open or shorted to ground 5V reference circuit

1. MAP Sensor Test

1. Turn IGN OFF.

2. Disconnect TMAP sensor [80].
3. Using TEST CONNECTOR KIT (Part Number:HD-41404), jumper between [80B] terminals 4 (GY) wire and 3
(R/W) wire.
4. Clear DTCs.
5. Start engine.
6. Turn IGN OFF.
7. Check DTCs.
8. Did DTC reset?
a. Yes. Go to Test 2.
b. No. Replace TMAP sensor.

2. Signal Voltage Test

1. Turn IGN OFF.

2. Remove jumper.
3. Turn IGN ON.
4. Test voltage between [80B] terminal 3 (R/W) wire to ground.
5. Is voltage approximately 5V?
a. Yes. Go to Test 3.
b. No. Go to Test 6.

3. Signal Wire Continuity Test

1. Turn IGN OFF.

 2. Connect BREAKOUT BOX (Part Number:HD-50390-1) and ECM CABLE (Part Number:HD-50390-4) to
wiring harness [78B-1] and [78B-2], leaving ECM [78A-1] and [78A-2] disconnected. See How To Use
Diagnostic Tools.
3. Verify ECM OVERLAY (Part Number:HD-50390-4-P) is in position on BOB.
4. Test continuity between [80B] terminal 4 (GY) wire and BOB [78-1] terminal 7.
5. Is continuity present?
a. Yes. Go to Test 4.
b. No. Repair open in (GY) wire.

4. Signal Wire Shorted to Ground Test

1. Test continuity between BOB [78-1] terminal 7 and ground.

2. Is continuity present?
a. Yes. Repair short to ground in (GY) wire.
b. No. Go to Test 5.

5. Signal Wire Shorted to Sensor Ground Test

1. Test continuity between BOB [78-1] terminal 7 and [78-2] terminal 7.

2. Is continuity present?
a. Yes. Repair short between (GY) and (BK/W) wires.
b. No. Replace ECM.

6. 5V Reference Wire Open Test

1. Turn IGN OFF.

2. Connect BREAKOUT BOX (Part Number:HD-50390-1) and ECM CABLE (Part Number:HD-50390-4) to
wiring harness [78B-1] and [78B-2], leaving ECM [78A-1] and [78A-2] disconnected. See How To Use
Diagnostic Tools.
3. Verify ECM OVERLAY (Part Number:HD-50390-4-P) is in position on BOB.
4. Test resistance between [80B] terminal 3 (R/W) wire and BOB [78-2] terminal 9.
5. Is resistance less than 0.5 ohm?
a. Yes. Go to Test 7.
b. No. Repair open in (R/W) wire.

7. 5V Reference Shorted to Signal Ground Test

1. Test resistance between BOB [78-2] terminals 9 and 7.

2. Is resistance less than 1.0 ohm?
a. Yes. Repair short between the (R/W) and (BK/W) wires.
b. No. See diagnostic tips before replacement. Replace ECM.
Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

BREAKOUT BOX HD-50390-1 1

ECM CABLE HD-50390-4 1

ECM OVERLAY HD-50390-4-P 1

Table 1. DTC P0108 Diagnostic Faults

POSSIBLE CAUSES

Short to voltage

Open ground circuit

1. MAP Sensor Test

1. Turn IGN OFF.

2. Disconnect TMAP sensor [80].
3. Clear DTC.
4. Start engine.
5. Turn IGN OFF.
6. Check DTCs.
7. Did DTC reset?
a. Yes. Go to Test 2.
b. No. Replace TMAP sensor.

2. Signal Wire Short to 5V Test

1. Turn IGN OFF.

2. Connect BREAKOUT BOX (Part Number:HD-50390-1) and ECM CABLE (Part Number:HD-50390-4)to wire
harness [78B-1] and [78B-2], leaving ECM [78A-1] and [78A-2] disconnected. See How To Use Diagnostic
Tools.
3. Verify ECM OVERLAY (Part Number:HD-50390-4-P) is in position on BOB.
4. Using TEST CONNECTOR KIT (Part Number:HD-41404), test continuity between BOB [78-1] terminal 7 and
[78-2] terminal 9.
5. Is continuity present?
a. Yes. Repair short between (R/W) and (GY) wires.
b. No. Go to Test 3.

3. Signal Wire Short to Voltage Test

 1. Turn IGN ON.
2. Test voltage between BOB [78-1] terminal 7 and ground.
3. Is voltage present?
a. Yes. Repair short to voltage in (GY) wire.
b. No. Go to Test 4.

4. Ground Wire Open Test

1. Turn IGN OFF.

2. Test resistance between [80B] terminal 1 and BOB [78-2] terminal 7.
3. Is resistance less than 0.5 ohms?
a. Yes. Go to Test 5.
b. No. Repair open in (BK/W) wire.

5. 5V Reference Shorted to Battery Voltage Test

1. Connect [78A-1] and [78A-2].

2. Turn IGN ON.
3. Test voltage between BOB [78-2] terminal 9 and ground.
4. Is voltage greater than 5.25V?
a. Yes. Repair short to voltage in (R/W) wire.
b. No. Replace TMAP sensor.
Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

BREAKOUT BOX HD-50390-1 1

ECM CABLE HD-50390-4 1

ECM OVERLAY HD-50390-4-P 1

Table 1. DTC P0112 Diagnostic Faults

POSSIBLE CAUSES

Short to ground in 5V reference circuit

NOTE

Vehicle and sensor must be at ambient room temperature before starting diagnostic test.

1. IAT Sensor Test

1. Turn IGN OFF.

2. Disconnect TMAP sensor [80].
3. Using TEST CONNECTOR KIT (Part Number:HD-41404), test resistance between [80A] terminals 1 and 2.
4. Is resistance between 500-5000 ohms?
a. Yes. Go to Test 2.
b. No. Replace TMAP sensor.

2. Signal Wire Shorted to Ground Test

1. Test resistance between [80B] terminal 2 (GN/GY) and ground.

2. Is resistance less than 1 ohm?
a. Yes. Repair short to ground on (GN/GY) wire.
b. No. Go to Test 3.

3. Signal Grounded Test

1. Connect BREAKOUT BOX (Part Number:HD-50390-1) and ECM CABLE (Part Number:HD-50390-4) to
wiring harness [78B-1] and [78B-2], leaving ECM [78A-1] and [78A-2] disconnected. See How To Use
Diagnostic Tools.
2. Verify ECM OVERLAY (Part Number:HD-50390-4-P) is in position on BOB.
3. Test continuity between BOB [78-2] terminals 6 and 10.
 4. Is continuity present?
a. Yes. Repair short to ground on (GN/GY) wire.
b. No. Go to Test 4.

4. Signal Wire Shorted to Sensor Ground Test

1. Test continuity between BOB [78-2] terminals 6 and 7.

2. Is continuity present?
a. Yes. Repair short between [80B] terminals 1 and 2 (GN/GY and BK/W) wires.
b. No. Replace ECM.
Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

BREAKOUT BOX HD-50390-1 1

ECM CABLE HD-50390-4 1

ECM OVERLAY HD-50390-4-P 1

Table 1. DTC P0113 Diagnostic Faults

POSSIBLE CAUSES

Open or short to voltage in 5V reference circuit

1. IAT Sensor Shorted High Test

1. Turn IGN OFF.

2. Disconnect TMAP sensor [80].
3. Turn IGN ON.
4. Using TEST CONNECTOR KIT (Part Number:HD-41404), test voltage between [80B] terminal 2 (GN/GY) and
ground.
5. Is voltage greater than 6V?
a. Yes. Repair short to voltage on (GN/GY) wire.
b. No. Go to Test 2.

2. Signal Wire Open Test

1. Turn IGN OFF.

2. Connect BREAKOUT BOX (Part Number:HD-50390-1) and ECM CABLE (Part Number:HD-50390-4) to
wiring harness [78B-1] and [78B-2] leaving ECM [78A-1] and [78A-2] disconnected. See How To Use
Diagnostic Tools.
3. Verify ECM OVERLAY (Part Number:HD-50390-4-P) is in position on BOB.
4. Test resistance between [80B] terminal 2 (GN/GY) and BOB [78-2] terminal 6.
5. Is resistance less than 0.5 ohms?
a. Yes. Go to Test 3.
b. No. Repair open circuit in (GN/GY) wire.

3. Open Ground Wire Test

1. Test resistance between BOB [78-2] terminal 7 and [80B] terminal 1 (BK/W).
2. Is resistance less than 0.5 ohms?
a. Yes. Go to Test 4.
b. No. Repair open in (BK/GY) wire.
4. Signal Wire Shorted to Sensor Power Test

1. Test continuity between BOB [78-2] terminal 6 and [78-2] terminal 9.

2. Is continuity present?
a. Yes. Repair short between (GN/GY) and (R/W) wires. Verify IAT sensor resistance value and if
incorrect replace TMAP sensor.
b. No. Replace ECM.
See Figure 1. The ECM supplies a 5V signal on [78-2] terminal 9 to terminal 2 of the TPS. The TPS sends a signal back to
the ECM on [78-2] terminal 15. The returned signal varies in voltage according to throttle position.

At idle (closed throttle), the signal is low voltage.

At wide open throttle, the signal is high voltage.

DTC P0122 or P0123 will set if the TPS voltage signal does not fall within the acceptable range.

Table 1. Code Description

DTC DESCRIPTION

P0122 TPS 1 low/open

P0123 TPS 1 high

View interactive
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image

1 Rear injector [85]

2 TPS [88]

3 TMAP [80]

4 IAC [87]

5 Headlamp [38]

6 Ignition switch [33]

7 LH controls [24]

8 RH controls [22]

9 Fuel pump [141]

10 Front injector [84]

11 ECT [90]

12 Ignition coil [83]

Figure 1. Under Fuel Tank Right Side

Diagnostic Tips

The multimeter reads throttle position in Volts. Voltage should increase at a steady rate as the throttle is moved from
idle to wide open. A short to ground or open on the (GN/V) or (R/W) wires also will result in a DTC P0122. A short to
ground or open on the (R/W) wire (5V reference) sets multiple codes.

NOTE

The TMAP, JSS, VSS, BAS, and TPSs are connected to the same reference line (5V reference). If the line goes to
ground or open, multiple trouble codes will be set (DTCs P0107, P0108 and P0122, P0123, P1501 or P1502).
Start with the DTC having the highest priority ranking.

Check for the following conditions:

Poor connection: Inspect ECM harness connector [78B-1] and [78B-2] for backed out terminals, improper mating,
inoperative locks, improperly formed or damaged terminals, poor terminal-to-wire connection and damaged
harness.
Perform Wiggle Test to locate intermittents: If connections and harness check out OK, monitor TPS voltage
using a multimeter while moving related connectors and wiring harness. A TPS voltage change when a part is
moved indicates an intermittent.
TPS scaling: Observe the TPS voltage display while opening the throttle with engine stopped and ignition switch
ON. Display should vary from closed throttle TPS voltage (when throttle is closed) to greater than 4.0V (when
throttle is held wide open). As the throttle is slowly moved, the voltage should change gradually without spikes or
low voltages being observed.

Connector Information

For additional information about the connectors in the following diagram(s) and diagnostic procedure(s), see
Connector Locations.
 View interactive
View interactive image
image

Figure 2. Sensor Circuit

Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

BREAKOUT BOX HD-50390-1 1

ECM CABLE HD-50390-4 1

ECM OVERLAY HD-50390-4-P 1

Table 1. DTC P0122 Diagnostic Faults

POSSIBLE CAUSES

TPS malfunction

Open or short to ground in 5V reference circuit

Open or short to ground in signal circuit

1. TPS Circuit Test

1. Turn IGN OFF.

2. Disconnect TPS [88].
3. Using TEST CONNECTOR KIT (Part Number:HD-41404), jumper between [88B] terminals 2 (R/W) wire and 3
(GN/V) wire.
4. Clear DTCs.
5. Turn IGN OFF and ON.
6. Check DTCs.
7. Did DTC reset?
a. Yes. Go to Test 2.
b. No. Replace induction module.

2. Signal Voltage Test

1. Turn IGN OFF.

2. Remove jumper.
3. Turn IGN ON.
4. Test voltage between [88B] terminal 2 (R/W) wire and ground.
5. Is voltage approximately 5V?
a. Yes. Go to Test 3.
b. No. Go to Test 6.

3. Signal Wire Continuity Test

 1. Turn IGN OFF.
2. Connect BREAKOUT BOX (Part Number:HD-50390-1) and ECM CABLE (Part Number:HD-50390-4) to
wiring harness [78B-1] and [78B-2], leaving ECM [78A-1] and [78A-2] disconnected. See How To Use
Diagnostic Tools.
3. Verify ECM OVERLAY (Part Number:HD-50390-4-P) is in position on BOB.
4. Test resistance between [88B] terminal 3 (GN/V) wire and BOB [78-2] terminal 15.
5. Is resistance less than 0.5 ohm?
a. Yes. Go to Test 4.
b. No. Repair open in (GN/V) wire.

4. Signal Wire Shorted to Ground Test

1. Test continuity between BOB [78-2] terminal 15 and ground.

2. Is continuity present?
a. Yes. Repair short to ground in (GN/V) wire.
b. No. Go to Test 5.

5. Signal Wire Shorted to Sensor Ground Test

1. Test continuity between BOB [78-2] terminals 15 and 7.

2. Is continuity present?
a. Yes. Repair short between (GN/V) and (BK/W) wires.
b. No. Replace ECM.

6. 5V Sensor Power Open Wire Test

1. Turn IGN OFF.

2. Connect BREAKOUT BOX (Part Number:HD-50390-1) and ECM CABLE (Part Number:HD-50390-4) to
wiring harness [78B-1] and [78B-2], leaving ECM [78A-1] and [78A-2] disconnected. See How To Use
Diagnostic Tools.
3. Verify ECM OVERLAY (Part Number:HD-50390-4-P) is in position on BOB.
4. Test resistance between [88B] terminal 2 (R/W) wire and BOB [78-2] terminal 9.
5. Is resistance less than 0.5 ohm?
a. Yes. Go to Test 7.
b. No. Repair open in (R/W) wire.

7. Sensor Power Shorted To Ground Test

1. Test resistance between BOB [78-2] terminal 9 and ground.

2. Is resistance less than 0.5 ohms?
a. Yes. Repair short to ground on (R/W) wire.
b. No. Replace ECM.
Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

BREAKOUT BOX HD-50390-1 1

ECM CABLE HD-50390-4 1

ECM OVERLAY HD-50390-4-P 1

Table 1. DTC P0123 Diagnostic Faults

POSSIBLE CAUSES

Short to voltage in 5V reference circuit

Open sensor ground

Short to voltage on signal circuit

1. TPS Test

1. Turn IGN OFF.

2. Disconnect TPS [88].
3. Clear DTCs.
4. Turn IGN OFF and ON.
5. Check DTCs.
6. Did DTC reset?
a. Yes. Go to Test 2.
b. No. Go to Test 4.

2. Signal Wire Short to 5V Test

1. Turn IGN OFF.

2. Disconnect ECM [78-1] and [78-2].
3. Using TEST CONNECTOR KIT (Part Number:HD-41404), test continuity between [88B] terminals 2 and 3.
4. Is continuity present?
a. Yes. Repair short between (R/W) and (GN/V) wires.
b. No. Go to Test 3.

3. Signal Wire Short to Voltage Test

1. Connect [78-1] and [78-2].

2. Turn IGN ON.
3. Test voltage between [88B] terminal 3 (GN/V) wire and ground.
 4. Is voltage present?
a. Yes. Repair short to voltage in (GN/V) wire.
b. No. Replace ECM.

4. 5V Shorted to Battery Voltage Test

1. Using TEST CONNECTOR KIT (Part Number:HD-41404), test voltage between [88B] terminal 2 (R/W) wire
and ground.
2. Is voltage greater than 5.25V?
a. Yes. Repair short to voltage in (R/W) wire.
b. No. Go to Test 5.

5. Ground Wire Open Test

1. Turn IGN OFF.

2. Connect BREAKOUT BOX (Part Number:HD-50390-1) and ECM CABLE (Part Number:HD-50390-4) to
wiring harness [78B-1] and [78B-2], leaving ECM [78A-1] and [78A-2] disconnected. See How To Use
Diagnostic Tools.
3. Verify ECM OVERLAY (Part Number:HD-50390-4-P) is in position on BOB.
4. Test resistance between [88B] terminal 1 (BK/W) wire and BOB [78-2] terminal 7.
5. Is resistance less than 0.5 ohm?
a. Yes. Replace induction module.
b. No. Repair open in (BK/W) wire.
 NOTE

The ECM requires a fault for three drive cycles to set DTC P0131, P0132, P0151 and P0152.

The HO2S provides a signal to the ECM which indicates whether the engine is running rich or lean.

A P0131 (front) or P0151 (rear) is set when the ECM detects an excessively lean condition for a specified length of
time. DTCs may also set if HO2S fails.
A P0132 (front) or P0152 (rear) is set when the ECM detects an excessively rich condition for a specified length of
time. This can be caused by oil contamination or fuel injector malfunctions. DTCs may also set if HO2S fails.
A P0134 (front) or a P0154 (rear) is set when the sensor circuit is open or too cold to respond.
When the air/fuel mixture is ideal, approximately 14.6 parts air to 1 part fuel, the voltage will be approximately 0.45V
when measuring across the sensor.

The heater portion of the HO2S is powered by the system relay. The front and rear HO2S heaters have separate control
circuits monitored by the ECM.

Table 1. Code Description

DTC DESCRIPTION

P0031 Front HO2S low/open

P0032 Front HO2S shorted high

P0051 Rear HO2S low/open

P0052 Rear HO2S shorted high

P0131 O2 sensor low/engine lean (front)

P0132 Engine running rich (front)

P0134 O2 sensor high/open (front)

P0151 O2 sensor low/engine lean (rear)

P0152 Engine running rich (rear)

P0154 O2 sensor high/open (rear)

Diagnostic Tips

The ECM requires a HO2S fault be present for three drive cycles before it sets a code. After clearing codes, operate
the vehicle for three drive cycles before checking for codes.

The multimeter displays the signal from the HO2S in Volts. This voltage will have an average value tending towards
lean, rich or ideal value depending on operating temperature of the engine, engine speed and throttle position. An
open/short to voltage or short to ground in the (GN/BN) wire (front) and (GY/BN) wire (rear) will cause the engine to
run rich (short to ground) or lean (short to voltage) until the fault is detected. Once fault is detected, vehicle will run in
open loop.
Check for the following conditions:

Poor connection: Inspect the ECM [78-1] and [78-2], fuel injector [84, 85] and HO2S [137, 138] connectors for
backed out terminals, improper mating, inoperative locks, improperly formed or damaged terminals, poor terminal-
to-wire connection and damaged harnesses.
Dirty/stuck open injectors: The vehicle may run lean (dirty/clogged injectors) or rich (stuck open injectors) if there
are injector problems. This could also cause poor fuel economy and performance.
Loose HO2S: If an HO2S is loose, engine performance may be affected. This could also show up as a slow
changing HO2S voltage.
Loose/leaking exhaust: This can cause a poor ground connection for the sensor or allow fresh air into the
exhaust system. If fresh air enters exhaust system, the HO2S will read a lean condition, causing the system to go
rich.
Engine misfire: See Description and Operation.
Leaking injectors: This causes fuel imbalance and poor idle quality due to different air/fuel ratios in each cylinder.
To check for leaky injectors, first remove the air box and air filter. Then, with the throttle wide open, turn IGN ON
for 2 seconds and then OFF for 2 seconds five consecutive times. Replace the fuel injector if there is any evidence
of raw fuel in the bores. See Fuel Injectors in the service manual.
Intake leaks: This may cause a lean sensor reading.

Connector Information

For additional information about the connectors in the following diagram(s) and diagnostic procedure(s), see
Connector Locations.

View interactive
View interactive image
image

Figure 1. Sensor Circuit

Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

BREAKOUT BOX HD-50390-1 1

ECM CABLE HD-50390-4 1

ECM OVERLAY HD-50390-4-P 1

Table 1. DTC P0031 Diagnostic Faults

POSSIBLE CAUSES

Open or short to ground on front HO2S circuit

Open in sensor power circuit

1. Front HO2S Voltage Test

1. Turn IGN OFF.

2. Disconnect front HO2S [138].
3. Turn IGN ON.
4. Using TEST CONNECTOR KIT (Part Number:HD-41404), test voltage between [138A] terminal 1 (R/GN) wire
and ground.
5. Is battery voltage present?
a. Yes. Go to Test 2.
b. No. Repair open in (R/GN) wire.

2. Open Ground Test

1. Turn IGN OFF.

2. Connect BREAKOUT BOX (Part Number:HD-50390-1) and ECM CABLE (Part Number:HD-50390-4) to
wiring harness [78B-1] and [78B-2], leaving ECM [78A-1] and [78A-2] disconnected. See How To Use
Diagnostic Tools.
3. Verify ECM OVERLAY (Part Number:HD-50390-4-P) is in position on BOB.
4. Test resistance between BOB [78-1] terminal 3 and [138A] terminal 2 (BK/O) wire.
5. Is resistance less than 0.5 ohm?
a. Yes. Go to Test 3.
b. No. Repair open in (BK/O) wire.

3. Short to Ground Test

1. Test continuity between BOB [78-1] terminal 3 and ground.

2. Is continuity present?
 a. Yes. Repair short to ground in (BK/O) wire.
b. No. Go to Test 4.

4. Resistance Test

1. Test resistance between [138B] terminals 1 (V) wire and 2 (W) wire.
2. Is resistance between 13.5-35 ohms?
a. Yes. Replace ECM.
b. No. Replace front HO2S.
Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

BREAKOUT BOX HD-50390-1 1

ECM CABLE HD-50390-4 1

ECM OVERLAY HD-50390-4-P 1

Table 1. DTC P0032 Diagnostic Faults

POSSIBLE CAUSES

Front HO2S circuit shorted to 12V

1. Front HO2S Shorted to Voltage Test

1. Turn IGN OFF.

2. Connect BREAKOUT BOX (Part Number:HD-50390-1) and ECM CABLE (Part Number:HD-50390-4) to
wiring harness [78B-1] and [78B-2], leaving ECM [78A-1] and [78A-2] disconnected. See How To Use
Diagnostic Tools.
3. Verify ECM OVERLAY (Part Number:HD-50390-4-P) is in position on BOB.
4. Turn IGN ON.
5. Using TEST CONNECTOR KIT (Part Number:HD-41404), test voltage between BOB [78-1] terminal 3 and
ground.
6. Is voltage present?
a. Yes. Repair short to voltage on (BK/O) wire.
b. No. Go to Test 2.

2. Resistance Test

1. Turn IGN OFF.

2. Disconnect front HO2S [138].
3. Test resistance between [138B] terminals 1 (V) wire and 2 (W) wire.
4. Is resistance between 13.5-35 ohms?
a. Yes. Replace ECM.
b. No. Replace front HO2S.
Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

BREAKOUT BOX HD-50390-1 1

ECM CABLE HD-50390-4 1

ECM OVERLAY HD-50390-4-P 1

Table 1. DTC P0051 Diagnostic Faults

POSSIBLE CAUSES

Open or short to ground on rear HO2S circuit

Open in sensor power circuit

1. Rear HO2S Voltage Test

1. Turn IGN OFF.

2. Disconnect rear HO2S [137].
3. Turn IGN ON.
4. Using TEST CONNECTOR KIT (Part Number:HD-41404), test voltage between [137A] terminal 1 (R/GN) wire
and ground.
5. Is battery voltage present?
a. Yes. Go to Test 2.
b. No. Repair open in (R/GN) wire.

2. Open Ground Test

1. Turn IGN OFF.

2. Connect BREAKOUT BOX (Part Number:HD-50390-1) and ECM CABLE (Part Number:HD-50390-4) to
wiring harness [78B-1] and [78B-2], leaving ECM [78A-1] and [78A-2] disconnected. See How To Use
Diagnostic Tools.
3. Verify ECM OVERLAY (Part Number:HD-50390-4-P) is in position on BOB.
4. Test resistance between BOB [78-1] terminal 15 and [137A] terminal 2 (BK/PK) wire.
5. Is resistance less than 0.5 ohm?
a. Yes. Go to Test 3.
b. No. Repair open in (BK/PK) wire.

3. Short to Ground Test

1. Test continuity between BOB [78-1] terminal 15 and ground.

2. Is continuity present?
 a. Yes. Repair short to ground in (BK/PK) wire.
b. No. Go to Test 4.

4. Resistance Test

1. Test resistance between [137B] terminals 1 (V) wire and 2 (W) wire.
2. Is resistance between 13.5-35 ohms?
a. Yes. Replace ECM.
b. No. Replace rear HO2S.
Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

BREAKOUT BOX HD-50390-1 1

ECM CABLE HD-50390-4 1

ECM OVERLAY HD-50390-4-P 1

Table 1. DTC P0052 Diagnostic Faults

POSSIBLE CAUSES

Rear HO2S circuit shorted to voltage

1. Rear HO2S Shorted to Voltage Test

1. Turn IGN OFF.

2. Connect BREAKOUT BOX (Part Number:HD-50390-1) and ECM CABLE (Part Number:HD-50390-4) to
wiring harness [78B-1] and [78B-2], leaving ECM [78A-1] and [78A-2] disconnected. See How To Use
Diagnostic Tools.
3. Verify ECM OVERLAY (Part Number:HD-50390-4-P) is in position on BOB.
4. Turn IGN ON.
5. Using TEST CONNECTOR KIT (Part Number:HD-41404), test voltage between BOB [78-1] terminal 15 and
ground.
6. Is voltage present?
a. Yes. Repair short to voltage on (BK/PK) wire.
b. No. Go to Test 2.

2. Resistance Test

1. Turn IGN OFF.

2. Disconnect rear HO2S [137].
3. Test resistance between [137B] terminals 1 (V) wire and 2 (W) wire.
4. Is resistance between 13.5-35 ohms?
a. Yes. Replace ECM.
b. No. Replace rear HO2S.
Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

BREAKOUT BOX HD-50390-1 1

ECM CABLE HD-50390-4 1

ECM OVERLAY HD-50390-4-P 1

Table 1. DTC P0131 Diagnostic Faults

POSSIBLE CAUSES

Short to ground in signal circuit

Fuel system malfunction

NOTE

Vehicle and sensor must be at ambient temperature before starting diagnostic test.

1. Front HO2S Voltage Test

1. Turn IGN OFF.

2. Disconnect front HO2S [138].
3. Turn IGN ON.
4. Using TEST CONNECTOR KIT (Part Number:HD-41404), test voltage between [138A] terminal 3 (GN/BN)
wire, to ground.
5. Is voltage approximately 5V?
a. Yes. Go to Test 5.
b. No. Go to Test 2.

2. HO2S Test

1. Turn IGN OFF.

2. Test continuity between [138B] terminal 3 (GY) wire and ground.
3. Is continuity present?
a. Yes. Replace HO2S.
b. No. Go to Test 3.

3. Signal Wire Shorted to Sensor Ground Test

 1. Turn IGN OFF.
2. Disconnect ECM [78-1] and [78-2].
3. Test continuity between [138A] terminals 3 (GN/BN) wire and 4 (BK/W) wire.
4. Is continuity present?
a. Yes. Repair short between (GN/BN) and (BK/W) wires.
b. No. Go to Test 4.

4. Signal Wire Shorted to Ground Test

1. Test continuity between [138A] terminal 3 (GN/BN) wire and ground.

2. Is continuity present?
a. Yes. Repair short between (GN/BN) wire and ground.
b. No. Replace ECM.

5. Operation Test

1. Connect BREAKOUT BOX (Part Number:HD-50390-1) and ECM CABLE (Part Number:HD-50390-4)
between wiring harness [78B-1] and [78B-2] and ECM [78A-1] and [78A-2]. See How To Use Diagnostic
Tools.
2. Verify ECM OVERLAY (Part Number:HD-50390-4-P) is in position on BOB.
3. Connect [138].
4. Start engine and allow it to reach operating temperature.
5. With engine speed at a steady rpm, test voltage between BOB [78-1] terminal 17 and [78-2] terminal 7.
6. Is voltage approximately 0.45V?
a. Yes. Replace ECM.
b. No. (0.0-0.4V). Perform fuel pressure test. Look for incorrect ECM calibration, low fuel pressure, air
leaks and dirty injectors. If no issues are found, replace HO2S.
Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

BREAKOUT BOX HD-50390-1 1

ECM CABLE HD-50390-4 1

ECM OVERLAY HD-50390-4-P 1

Table 1. DTC P0132 Diagnostic Faults

POSSIBLE CAUSES

Fuel system malfunction

1. Front HO2S Operation Test

1. Turn IGN OFF.

2. Connect BREAKOUT BOX (Part Number:HD-50390-1) and ECM CABLE (Part Number:HD-50390-4)
between wiring harness [78B-1] and [78B-2] and ECM [78A-1] and [78A-2]. See How To Use Diagnostic
Tools.
3. Verify ECM OVERLAY (Part Number:HD-50390-4-P) is in position on BOB.
4. Start engine and allow it to reach operating temperature.
5. With engine speed at a steady rpm, using TEST CONNECTOR KIT (Part Number:HD-41404), test voltage
between BOB [78-1] terminal 17 and [78-2] terminal 7.
6. Is voltage approximately 0.45V?
a. Yes. Replace ECM.
b. No. (0.6-1.0V) Perform fuel pressure test. Look for incorrect ECM calibration, high fuel pressure, stuck
open or leaking injectors. If no issues are found, replace the HO2S.
Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

BREAKOUT BOX HD-50390-1 1

ECM CABLE HD-50390-4 1

ECM OVERLAY HD-50390-4-P 1

Table 1. DTC P0134 Diagnostic Faults

POSSIBLE CAUSES

Open or short to voltage in signal circuit

Open sensor ground

1. Front HO2S Signal Wire Short Circuit Voltage Test

1. Turn IGN OFF.

2. Disconnect front HO2S [138].
3. Turn IGN ON.
4. Using TEST CONNECTOR KIT (Part Number:HD-41404), test voltage between [138A] terminal 3 (GN/BN)
wire to ground.
5. Is voltage greater than 5V?
a. Yes. Repair short to voltage on (GN/BN) wire.
b. No. Greater than 4V. Go to Test 2.
c. No. Less than 4V. Go to Test 3.

2. Open Sensor Ground Test

1. Turn IGN OFF.

2. Connect BREAKOUT BOX (Part Number:HD-50390-1) and ECM CABLE (Part Number:HD-50390-4) to
wiring harness [78B-1] and [78B-2], leaving ECM [78A-1] and [78A-2] disconnected. See How To Use
Diagnostic Tools.
3. Verify ECM OVERLAY (Part Number:HD-50390-4-P) is in position on BOB.
4. Test resistance between [138A] terminal 4 (BK/W) wire and BOB [78-2] terminal 7.
5. Is resistance less than 0.5 ohm?
a. Yes. Replace front O2 sensor.
b. No. Repair open on (BK/W) wire.

3. Signal Wire Open Test

1. Test resistance between [138A] terminal 3 (GN/BN) wire and BOB [78-1] terminal 17.
2. Is resistance less than 0.5 ohm?
a. Yes. Replace ECM.
b. No. Repair open in (GN/BN) wire.
Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

BREAKOUT BOX HD-50390-1 1

ECM CABLE HD-50390-4 1

ECM OVERLAY HD-50390-4-P 1

Table 1. DTC P0151 Diagnostic Faults

POSSIBLE CAUSES

Short to ground in signal circuit

Fuel system malfunction

NOTE

Vehicle and sensor must be at ambient temperature before starting diagnostic test.

1. Rear HO2S Test

1. Turn IGN OFF.

2. Disconnect rear HO2S [137].
3. Turn IGN ON.
4. Using TEST CONNECTOR KIT (Part Number:HD-41404), test voltage between [137A] terminal 3 (GY/BN)
wire to ground.
5. Is voltage approximately 5V?
a. Yes. Go to Test 5.
b. No. Go to Test 2.

2. HO2S Test

1. Test continuity between [137B] terminal 3 (GY) wire and ground.

2. Is continuity present?
a. Yes. Replace HO2S.
b. No. Go to Test 3.

3. Signal Wire Shorted to Sensor Ground Test

1. Turn IGN OFF.

 2. Disconnect ECM [78-1] and [78-2].
3. Test continuity between [137A] terminals 3 (GY/BN) wire and 4 (BK/W) wire.
4. Is continuity present?
a. Yes. Repair short between (GY/BN) and (BK/W) wires.
b. No. Go to Test 4.

4. Signal Wire Shorted to Ground Test

1. Test continuity between [137A] terminal 3 (GY/BN) wire and ground.

2. Is continuity present?
a. Yes. Repair short between (GY/BN) wire and ground.
b. No. Replace ECM.

5. Operation Test

1. Connect BREAKOUT BOX (Part Number:HD-50390-1) and ECM CABLE (Part Number:HD-50390-4)
between wiring harness [78B-1] and [78B-2] and ECM [78A-1] and [78A-2]. See How To Use Diagnostic
Tools.
2. Verify ECM OVERLAY (Part Number:HD-50390-4-P) is in position on BOB.
3. Start engine and allow it to reach operating temperature.
4. With engine speed at a steady rpm, test voltage between BOB [78-2] terminal 17 and [78-2] terminal 7.
5. Is voltage approximately 0.45V?
a. Yes. Replace ECM.
b. No. (0.0-0.4V). Perform fuel pressure test. Look for incorrect ECM calibration, low fuel pressure, air
leaks and dirty injectors. If no issues are found, replace HO2S.
Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

BREAKOUT BOX HD-50390-1 1

ECM CABLE HD-50390-4 1

ECM OVERLAY HD-50390-4-P 1

Table 1. DTC P0152 Diagnostic Faults

POSSIBLE CAUSES

Fuel system malfunction

1. Rear HO2S Operation Test

1. Turn IGN OFF.

2. Connect BREAKOUT BOX (Part Number:HD-50390-1) and ECM CABLE (Part Number:HD-50390-4)
between wiring harness [78B-1] and [78B-2] and ECM [78A-1] and [78A-2]. See How To Use Diagnostic
Tools.
3. Verify ECM OVERLAY (Part Number:HD-50390-4-P) is in position on BOB.
4. Start engine and allow it to reach operating temperature.
5. Using TEST CONNECTOR KIT (Part Number:HD-41404), with engine speed at a steady rpm, test voltage
between BOB [78-2] terminal 17 and [78-2] terminal 7.
6. Is voltage approximately 0.45V?
a. Yes. Replace ECM.
b. No. (0.6-1.0V). Perform fuel pressure test. Look for incorrect ECM calibration, high fuel pressure, stuck
open or leaking injectors. If no issues are found, replace the HO2S.
Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

BREAKOUT BOX HD-50390-1 1

ECM CABLE HD-50390-4 1

ECM OVERLAY HD-50390-4-P 1

Table 1. DTC P0154 Diagnostic Faults

POSSIBLE CAUSES

Open or short voltage in signal circuit

Open sensor ground

1. Rear HO2S Signal Wire Short Circuit Voltage Test

1. Turn IGN OFF.

2. Disconnect rear HO2S [137].
3. Turn IGN ON.
4. Using TEST CONNECTOR KIT (Part Number:HD-41404), test voltage between [137A] terminal 3 (GY/BN)
wire to ground.
5. Is voltage greater than 5V?
a. Yes. Repair short to voltage on (GY/BN) wire.
b. No, greater than 4V. Go to Test 2.
c. No, less than 4V. Go to Test 3.

2. Open Sensor Ground Test

1. Turn IGN OFF.

2. Connect BREAKOUT BOX (Part Number:HD-50390-1) and ECM CABLE (Part Number:HD-50390-4) to
wiring harness [78B-1] and [78B-2], leaving ECM [78A-1] and [78A-2] disconnected. See How To Use
Diagnostic Tools.
3. Verify ECM OVERLAY (Part Number:HD-50390-4-P) is in position on BOB.
4. Test resistance between [137A] terminal 4 (BK/W) wire and BOB [78-2] terminal 7.
5. Is resistance less than 0.5 ohms?
a. Yes. Replace rear HO2S.
b. No. Repair open on (BK/W) wire.

3. Signal Wire Open Test

1. Test resistance between [137A] terminal 3 (GY/BN) wire and BOB [78-2] terminal 17.
2. Is resistance less than 0.5 ohms?
a. Yes. Replace ECM.
b. No. Repair open in (GY/BN) wire.
See Figure 1. The fuel injectors are solenoids that allow pressurized fuel into the intake tract. The injectors are timed to the
engine cycle and triggered sequentially. The power for the injectors comes from the system relay. The ECM provides the
path to ground to trigger the injectors.

NOTE

System power failures or wiring harness problems will cause 12V power to be lost to both injectors and the ignition
coils.

Table 1. Code Description

DTC DESCRIPTION

P0261 Fuel injector low/open (front)

P0262 Fuel injector shorted high (front)

P0264 Fuel injector low/open (rear)

P0265 Fuel injector shorted high (rear)

View interactive
View interactive image
image

1 Rear injector [85]

2 TPS [88]

3 TMAP [80]

4 IAC [87]

5 Headlamp [38]

6 Ignition switch [33]

7 LH controls [24]

8 RH controls [22]
 9 Fuel pump [141]

10 Front injector [84]

11 ECT [90]

12 Ignition coil [83]

Figure 1. Under Fuel Tank Right Side

Diagnostic Tips

When disconnecting any connectors always inspect connector for corrosion or backed out terminals and repair as
required.

Connector Information

For additional information about the connectors in the following diagram(s) and diagnostic procedure(s), see
Connector Locations.

View interactive
View interactive image
image

Figure 2. System Power Circuit

Special Tools

Description Part Number Qty.

FUEL INJECTOR TEST LIGHT HD-34730-2E 1

TEST CONNECTOR KIT HD-41404 1

BREAKOUT BOX HD-50390-1 1

ECM CABLE HD-50390-4 1

ECM OVERLAY HD-50390-4-P 1

Table 1. DTC P0261 Diagnostic Faults

POSSIBLE CAUSES

Front fuel injector malfunction

Open signal circuit

Open power circuit

1. Front Fuel Injector Test

1. Turn IGN OFF.

2. Disconnect front fuel injector [84].
3. Connect FUEL INJECTOR TEST LIGHT (Part Number:HD-34730-2E) to [84B].
4. Crank engine.
5. Does light flash when engine is cranking (or running)?
a. Yes. Go to Test 4.
b. No, lamp does not illuminate. Go to Test 2.
c. No, lamp is on steady. Go to Test 5.

2. Power Circuit Open Test

1. Turn IGN OFF.

2. Remove fuel injector test light.
3. Using TEST CONNECTOR KIT (Part Number:HD-41404), test resistance between relay block [61B] socket
terminal 4 and [84B] terminal A (R/GN) wire.
4. Is resistance less than 0.5 ohm?
a. Yes. Go to Test 3.
b. No. Repair open in (R/GN) wire.

3. Control Circuit Open Test

 1. Connect BREAKOUT BOX (Part Number:HD-50390-1) and ECM CABLE (Part Number:HD-50390-4) to
wiring harness [78B-1] and [78B-2], leaving ECM [78A-1] and [78A-2] disconnected. See How To Use
Diagnostic Tools.
2. Verify ECM OVERLAY (Part Number:HD-50390-4-P) is in position on BOB.
3. Test resistance between BOB [78-1] terminal 5 and [84B] terminal B (GN/Y) wire.
4. Is resistance less than 0.5 ohm?
a. Yes. Go to Test 4.
b. No. Repair open in (GN/Y) wire.

4. Injector Resistance Test

1. Using TEST CONNECTOR KIT (Part Number:HD-41404), test resistance between [84A] terminals A and B.
2. Is resistance between 10-20 ohms?
a. Yes. Replace ECM.
b. No. Replace front injector.

5. Driver Short to Ground Test

1. Turn IGN OFF.

2. Remove fuel injector test light.
3. Using TEST CONNECTOR KIT (Part Number:HD-41404), test continuity between [84B] terminal B and
ground.
4. Is continuity present?
a. Yes. Repair short to ground on (GN/Y) wire.
b. No. Replace ECM.
Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

Table 1. DTC P0262 Diagnostic Faults

POSSIBLE CAUSES

Short to ground in signal circuit

1. Front Fuel Injector Control Circuit Shorted to Voltage Test

1. Turn IGN OFF.

2. Disconnect front injector [84].
3. Turn IGN ON.
4. Using TEST CONNECTOR KIT (Part Number:HD-41404), test voltage between [84B] terminal B (GN/Y) wire
and ground.
5. Is voltage less than 5.0V?
a. Yes. Go to Test 3.
b. No. Go to Test 2.

2. Control Circuit Shorted to System Test

1. Turn IGN OFF.

2. Test continuity between [84B] terminals A (R/GN) wire and B (GN/Y) wire.
3. Is continuity present?
a. Yes. Repair short between (R/GN) and (GN/Y) wires.
b. No. Repair short to voltage on (GN/Y) wire.

3. Injector Resistance Test

1. Test resistance between [84A] terminals A and B.

2. Is resistance between 10-20 ohms?
a. Yes. Replace ECM.
b. No. Replace front injector.
Special Tools

Description Part Number Qty.

FUEL INJECTOR TEST LIGHT HD-34730-2E 1

TEST CONNECTOR KIT HD-41404 1

BREAKOUT BOX HD-50390-1 1

ECM CABLE HD-50390-4 1

ECM OVERLAY HD-50390-4-P 1

Table 1. DTC P0264 Diagnostic Faults

POSSIBLE CAUSES

Open signal circuit

Open power circuit

1. Rear Fuel Injector Test

1. Turn IGN OFF.

2. Disconnect rear fuel injector [85].
3. Connect FUEL INJECTOR TEST LIGHT (Part Number:HD-34730-2E) to [85B].
4. Crank engine.
5. Does lamp flash when engine is cranking (or running)?
a. Yes. Go to Test 4.
b. No, lamp does not illuminate. Go to Test 2.
c. No, lamp is on steady. Go to Test 5.

2. Power Circuit Open Test

1. Turn IGN OFF.

2. Remove fuel injector test light.
3. Using TEST CONNECTOR KIT (Part Number:HD-41404), test resistance between relay block [61B] socket
terminal 4 and [85B] terminal A (R/GN) wire.
4. Is resistance less than 0.5 ohm?
a. Yes. Go to Test 3.
b. No. Repair open in (R/GN) wire.

3. Control Circuit Open Test

1. Connect BREAKOUT BOX (Part Number:HD-50390-1) and ECM CABLE (Part Number:HD-50390-4) to
wiring harness [78B-1] and [78B-2], leaving ECM [78A-1] and [78A-2] disconnected. See How To Use
 Diagnostic Tools.
2. Verify ECM OVERLAY (Part Number:HD-50390-4-P) is in position on BOB.
3. Test resistance between BOB [78-1] terminal 6 and [85B] terminal B (GY/Y) wire.
4. Is resistance less than 0.5 ohm?
a. Yes. Go to Test 4.
b. No. Repair open in (GY/Y) wire.

4. Injector Resistance Test

1. Using TEST CONNECTOR KIT (Part Number:HD-41404), test resistance between [85A] terminals A and B.
2. Is resistance between 10-20 ohms?
a. Yes. Replace ECM.
b. No. Replace rear injector.

5. Driver Short to Ground Test

1. Turn IGN OFF.

2. Remove fuel injector test light.
3. Using TEST CONNECTOR KIT (Part Number:HD-41404), test continuity between BOB [85B] terminal B and
ground.
4. Is continuity present?
a. Yes. Repair short to ground on (GY/Y) wire.
b. No. Replace ECM.
Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

Table 1. DTC P0265 Diagnostic Faults

POSSIBLE CAUSES

Short to ground in signal circuit

1. Rear Fuel Injector Control Circuit Shorted to Voltage Test

1. Turn IGN OFF.

2. Disconnect rear injector [85].
3. Turn IGN ON.
4. Using TEST CONNECTOR KIT (Part Number:HD-41404), test voltage between [85B] terminal B (GY/Y) wire
and ground.
5. Is voltage less than 5.0V?
a. Yes. Go to Test 2.
b. No. Go to Test 3.

2. Injector Resistance Test

1. Test resistance between [85A] terminals A and B.

2. Is resistance between 10-20 ohms?
a. Yes. Replace ECM.
b. No. Replace rear injector.

3. Control Circuit Shorted to System Test

1. Turn IGN OFF.

2. Test continuity between [85B] terminals A (R/GN) wire and B (GY/Y) wire.
3. Is continuity present?
a. Yes. Repair short between (R/GN) and (GY/Y) wires.
b. No. Repair short to voltage on (GY/Y) wire.
See Figure 1. If the CKP sensor signal is weak or absent, DTCs P0371 or P0374 will be set. DTC P0371 is usually set
when several attempts to crank the engine have failed.

NOTE

If signal is not detected or cannot synchronize (DTC P0374), engine will not start.

Table 1. Code Description

DTC DESCRIPTION

P0371 CKP sensor wrong number of pulses

P0374 CKP sensor no pulses

Diagnostic Tips

Engine must be cranked for more than 5 seconds without CKP signal to set P0374 code. Intermittent TMAP wiring or
sensor issues may cause these codes to set prior to setting TMAP codes. Verify TMAP wiring and sensor prior to
replacing the ECM.

When disconnecting any connectors always inspect connector for corrosion or backed out terminals and repair as
required.

View interactive
View interactive image
image

1 Neutral switch [131]

2 JSS [133]

3 CKP [79]

4 Cooling fan [97]

5 Horn [122-1]

6 Horn [122-2]

7 Front WSS [167]

 8 Starter

9 VSS [65]

10 Voltage regulator [77]

11 ABS ECU [166]

12 Oil pressure switch [120]

Figure 1. Front of Engine

Connector Information

For additional information about the connectors in the following diagram(s) and diagnostic procedure(s), see
Connector Locations.

View interactive
View interactive image
image

Figure 2. CKP Circuit

Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

BREAKOUT BOX HD-50390-1 1

ECM CABLE HD-50390-4 1

ECM OVERLAY HD-50390-4-P 1

Table 1. DTC P0371, P0374 Diagnostic Faults

POSSIBLE CAUSES

CKP sensor malfunction

Open or short to ground in signal circuit

May be set if there are incorrect fluctuations from TMAP that

does not set TMAP codes (examples - intermittent sensor
or wiring
issue)

1. CKP Sensor Connections Test

1. Turn IGN OFF.

2. Disconnect ECM [78-1] and [78-2].
3. Are terminal problems present?
a. Yes. Repair terminals as required.
b. No. Go to Test 2.

2. Signal Wire Continuity Test

1. Disconnect CKP sensor [79].

2. Connect BREAKOUT BOX (Part Number:HD-50390-1) and ECM CABLE (Part Number:HD-50390-4) to
wiring harness [78B-1] and [78B-2], leaving ECM [78A-1] and [78A-2] disconnected. See How To Use
Diagnostic Tools.
3. Verify ECM OVERLAY (Part Number:HD-50390-4-P) is in position on BOB.
4. Using TEST CONNECTOR KIT (Part Number:HD-41404), test resistance between BOB [78-1] terminal 16
and [79B] terminal 1 (R) wire.
5. Is resistance less than 0.5 ohm?
a. Yes. Go to Test 3.
b. No. Repair open on (R) wire.

3. Ground Wire Continuity Test

1. Test resistance between BOB [78-1] terminal 18 and [79B] terminal 2 (BK) wire.
 2. Is resistance less than 0.5 ohm?
a. Yes. Go to Test 4.
b. No. Repair open on (BK) wire.

4. Signal Wire Shorted to CKP Ground Wire Test

1. Test continuity between BOB [78-1] terminals 16 and 18.

2. Is continuity present?
a. Yes. Repair short between [79B] terminals 1 (R) and 2 (BK).
b. No. Go to Test 5.

5. Output Test

1. Connect CKP sensor [79].

2. Test AC voltage between BOB [78-1] terminals 16 and 18.
3. Crank engine for 5 seconds while observing multimeter.
4. Is AC voltage greater than 2V?
a. Yes. See diagnostic tips. If TMAP sensor is good, replace ECM.
b. No. Replace CKP sensor.
Purge Solenoid (If Equipped)

See Figure 1. The purge solenoid is mounted under the right side cover. The solenoid connects to a fuel tank vent line
and a vent canister.

A return line from the canister connects to the air intake manifold. This allows vented fumes to be recirculated, for
emission efficiency. The purge solenoid is timed to the throttle position and is disabled during startup, low engine
temperature, low engine speed or low vehicle speed.

Power for the purge solenoid is supplied by the system relay. The system relay also provides power for the HO2S, fuel
injectors, ECM and the ignition coil.

The ECM provides a path to ground to trigger the purge solenoid.

NOTE

System relay or wiring harness problems will cause 12V power to be lost to the HO2S, fuel injectors, ECM,
ignition coil and purge solenoid.

Purge solenoid is not installed on non-emission vehicles and DTCs P0444 and P0445 are not available. If
these DTCs appear, program the ECM again.

View interactive
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image

1 Main fuse [5]

2 DLC [91]

3 Fuse block [64]

4 Relay block [62B-2]

5 Relay block [62B-1]

6 Diode pack [201]

7 Purge solenoid [95]

8 VSS [65]

9 Ground
 10 Rear WSS [168]

Figure 1. Under Right Side Cover

Table 1. Code Description

DTC DESCRIPTION

P0444 Purge solenoid low/open

P0445 Purge solenoid shorted high

Diagnostic Tips

The purge solenoid is powered from the system power circuit. This circuit voltage is supplied by the system relay
through the ignition fuse and ignition relay.

When disconnecting any connectors always inspect connector for corrosion or backed out terminals and repair as
required.

Connector Information

For additional information about the connectors in the following diagram(s) and diagnostic procedure(s), see
Connector Locations.

View interactive image

 View interactive image

Figure 2. System Power Circuit

Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

BREAKOUT BOX HD-50390-1 1

ECM CABLE HD-50390-4 1

ECM OVERLAY HD-50390-4-P 1

Table 1. DTC P0444 Diagnostic Faults

POSSIBLE CAUSES

Short to ground in signal circuit

System power open

1. Purge Solenoid Test

1. Turn IGN OFF.

2. Disconnect purge solenoid [95].
3. Using TEST CONNECTOR KIT (Part Number:HD-41404), test resistance between [95A] terminals A and B.
4. Is resistance between 4-21 ohms?
a. Yes.
b. No. Replace purge solenoid.

2. Purge Solenoid Voltage Test

1. Test voltage between [95B] terminal A (R/GN) wire and ground.

2. Turn IGN ON.
3. Is battery voltage present?
a. Yes.
b. No.

3. Control Wire Shorted to Ground Test

1. Turn IGN OFF.

2. Disconnect ECM [78-1] and [78-2].
3. Test continuity between [95B] terminal B (LGN/BK) wire and ground.
4. Is continuity present?
a. Yes. Repair short to ground on (LGN/BK) wire.
b. No.
4. Control Wire Open Test

1. Connect BREAKOUT BOX (Part Number:HD-50390-1) and ECM CABLE (Part Number:HD-50390-4) to
wiring harness [78B-1] and [78B-2], leaving ECM [78A-1] and [78A-2] disconnected. See How To Use
Diagnostic Tools.
2. Verify ECM OVERLAY (Part Number:HD-50390-4-P) is in position on BOB.
3. Test resistance between [95B] terminal B (LGN/BK) wire and BOB [78-2] terminal 5.
4. Is resistance less than 0.5 ohms?
a. Yes. Replace ECM.
b. No. Repair open in (LGN/BK) wire.

5. Power Wire Open Test

1. Test resistance between [95B] terminal A and relay block [61B] socket terminal 4 (R/GN).
2. Is resistance less than 0.5 ohms?
a. Yes. Replace ECM.
b. No. Repair open in (R/GN) wire.
Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

Table 1. DTC P0445 Diagnostic Faults

POSSIBLE CAUSES

Short to voltage in signal circuit

1. Purge Solenoid Test

1. Turn IGN OFF.

2. Disconnect purge solenoid [95].
3. Using TEST CONNECTOR KIT (Part Number:HD-41404), test resistance between [95A] terminals A and B.
4. Is resistance between 4-21 ohms?
a. Yes. Go to Test 2.
b. No. Replace purge solenoid.

2. Purge Solenoid Short to Voltage Test

1. Turn IGN ON.

2. Test voltage between [95B] terminal B (LGN/BK) wire and ground.
3. Is voltage greater than 5.0V?
a. Yes. Repair short to voltage on (LGN/BK) wire.
b. No. Replace ECM.
See Figure 1. The VSS is powered and monitored by the ECM. The ECM and speedometer process the vehicle speed
sensor signal.

NOTE

The ECM uses VSS input to calculate idle air control position. Therefore problems with the vehicle speed signal
can lead to improper operation of the idle air control.

The TMAP, JSS, TPS, BAS and VSS sensors are connected to the same reference line (5V reference). If the
reference line goes to ground or open, multiple codes will be set (DTC P0107, P0108, P0122, P0123, P0502,
P0503, P1501, P1502). Start with the trouble code having the highest priority ranking. Refer to Diagnostic
Trouble Codes (DTCs) and Fault Conditions.

A faulty sensor can negatively affect the signal voltage of the other sensors sharing the same 5V reference. If the
wiring passes the following tests, disconnect one sensor at a time on the 5V reference and verify the DTC is still
present. Additional DTCs will be set as each sensor is disconnected, clear DTCs after this test. Be sure to
perform this test before replacing a component.

Table 1. Code Description

DTC DESCRIPTION

P0502 VSS failed low

P0503 VSS failed high

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image

1 VSS [65]

2 GND 2A

Figure 1. Right Side Above Transmission

Diagnostic Tips

When disconnecting any connectors always inspect connector for corrosion or backed out terminals and repair as
required.
Connector Information

For additional information about the connectors in the following diagram(s) and diagnostic procedure(s), see
Connector Locations.

View interactive
View interactive image
image

Figure 2. VSS Circuit

Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

BREAKOUT BOX HD-50390-1 1

ECM CABLE HD-50390-4 1

ECM OVERLAY HD-50390-4-P 1

Table 1. DTC P0502 Diagnostic Faults

POSSIBLE CAUSES

VSS malfunction

Open or short to ground in signal circuit

Open or short to ground in 5V reference circuit

1. VSS Connections Test

1. Turn IGN OFF.

2. Disconnect VSS [65].
3. Turn IGN ON.
4. Using TEST CONNECTOR KIT (Part Number:HD-41404), test voltage between [65B] terminal 2 (R/W) wire
and ground.
5. Is voltage approximately 5.0V?
a. Yes. Go to Test 2.
b. No. Repair open on (R/W) wire.

2. Signal Wire Short to Ground Test

1. Turn IGN OFF.

2. Connect BREAKOUT BOX (Part Number:HD-50390-1) and ECM CABLE (Part Number:HD-50390-4) to
wiring harness [78B-1] and [78B-2], leaving ECM [78A-1] and [78A-2] disconnected. See How To Use
Diagnostic Tools.
3. Verify ECM OVERLAY (Part Number:HD-50390-4-P) is in position on BOB.
4. Test continuity between BOB [78-1] terminals 4 and 10.
5. Is continuity present?
a. Yes. Repair short to ground on (LGN/Y) wire.
b. No. Go to Test 3.

3. Signal Wire Open Test

 1. Test resistance between BOB [78-1] terminal 4 and [65B] terminal 3 (LGN/Y) wire.
2. Is resistance less than 0.5 ohm?
a. Yes. Go to Test 4.
b. No. Repair open on (LGN/Y) wire.

4. Dirty or Damaged Test

1. Remove VSS.
2. Check for debris on sensor tip.
3. Is debris present?
a. Yes. Clean debris from VSS and install.
b. No. Replace VSS.
Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

BREAKOUT BOX HD-50390-1 1

ECM CABLE HD-50390-4 1

ECM OVERLAY HD-50390-4-P 1

Table 1. DTC P0503 Diagnostic Faults

POSSIBLE CAUSES

Short to voltage in signal circuit

Open ground

5V reference shorted to battery voltage

1. VSS Power Shorted to Voltage Test

1. Turn IGN OFF.

2. Disconnect VSS [65].
3. Turn IGN ON.
4. Using TEST CONNECTOR KIT (Part Number:HD-41404), test voltage between [65B] terminals 2 (R/W) wire
and 1 (BK/GN) wire.
5. Is voltage greater than 6.0V?
a. Yes. Repair short to voltage on (R/W) wire.
b. No. Go to Test 2.

2. Signal Wire Short to Voltage Test

1. Test voltage between [65B] terminal 3 (LGN/Y) wire and ground.

2. Is voltage above 6.0V?
a. Yes. Repair short to voltage on (LGN/Y) wire.
b. No. Go to Test 3.

3. Ground Wire Open Test

1. Turn IGN OFF.

2. Connect BREAKOUT BOX (Part Number:HD-50390-1) and ECM CABLE (Part Number:HD-50390-4) to
wiring harness [78B-1] and [78B-2], leaving ECM [78A-1] and [78A-2] disconnected. See How To Use
Diagnostic Tools.
3. Verify ECM OVERLAY (Part Number:HD-50390-4-P) is in position on BOB.
 4. Test resistance between BOB [78-1] terminal 10 and [65B] terminal 1 (BK/GN) wire.
5. Is resistance less than 0.5 ohm?
a. Yes. Go to Test 4.
b. No. Repair open on (BK/GN) wire.

4. Signal Wire Shorted to Sensor Power Test

1. Test continuity between BOB [78-1] terminal 4 and [78-2] terminal 9.

2. Is continuity present?
a. Yes. Repair short between (LGN/Y) and (R/W) wires.
b. No. Go to Test 5.

5. VSS Test

1. Connect [78A-1] and [78A-2].

2. Clear DTC.
3. Did DTC reset?
a. Yes. Replace ECM.
b. No. Replace VSS.
Special Tools

Description Part Number Qty.

DIGITAL TECHNICIAN II HD-48650 1

See Figure 1. The ECM controls engine idle speed by moving the IAC to open or close a passage around the throttle
plates. It does this by sending voltage pulses to the proper motor winding of the IAC. This causes the pintle to move in or
out of the IAC a given distance 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 be done with DIGITAL TECHNICIAN II (Part Number:HD-48650).
A high number of steps represents a fully retracted pintle and open passage around throttle plate. This correlates with
an increase in the amount of air flowing through the throttle body.
Zero steps represents a fully extended pintle. A zero reading indicates an abnormal condition in which the pintle has
been fully extended and has consequently closed the passage around throttle plate. Each time the ignition is turned
OFF, the ECM resets the IAC by sending enough pulses to extend the pintle and effectively close the throttle body.
The fully extended value is the ECM reference point. A given number of steps are then calculated by the ECM for use
in setting the proper idle speed and IAC position for the next start event.

NOTE

Idle speed is controlled by the ECM and cannot be adjusted.

Loss of idle speed control will result if the idle rpm is ±200 from preset idle speed and IAC motor is at zero or maximum for
greater than 5 seconds. These DTCs may occur with others for a multiple code situation. Resolve the other codes first to
correct. A misfire condition or similar symptom affecting idle can cause P0506 to set. Inspect for these conditions before
diagnosing DTCs.

Table 1. Code Description

DTC DESCRIPTION

P0506 Idle speed control - rpm too low

P0507 Idle speed control - rpm too high

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 View interactive image

1 Rear injector [85]

2 TPS [88]

3 TMAP [80]

4 IAC [87]

5 Headlamp [38]

6 Ignition switch [33]

7 LH controls [24]

8 RH controls [22]

9 Fuel pump [141]

10 Front injector [84]

11 ECT [90]

12 Ignition coil [83]

Figure 1. Under Fuel Tank Right Side

Diagnostic Tips

The following items may impact engine idle speed:

A loss of idle speed control does not necessarily imply the IAC actuator or wiring has failed. It can be caused by a
number of conditions such as an intake air leak, improperly adjusted throttle stop or a misfiring cylinder.
A non-OE engine configuration can lead to idle instability and could generate a DTC.
Leaking injectors will cause fuel imbalance and poor idle quality due to different air/fuel ratios in each cylinder. To
check for leaky injectors, first remove the air box and air filter. Then, with the throttle wide open, turn IGN ON for 2
seconds and then OFF for 2 seconds five consecutive times. Replace the fuel injector if there is any evidence of
raw fuel in the bores.
Intake leaks.
Contaminated fuel.
TPS reading of greater than 1% (possible throttle cable misadjustment) or battery voltage reading of less than 9V
or a VSS greater than 0 will disable idle speed control.
When disconnecting any connectors always inspect connector for corrosion or backed out terminals and repair as
required.

Connector Information

For additional information about the connectors in the following diagram(s) and diagnostic procedure(s), see
Connector Locations.
 View interactive
View interactive image
image

Figure 2. IAC Circuit

Special Tools

Description Part Number Qty.

IAC TEST LIGHT HD-41199-3 1

TEST CONNECTOR KIT HD-41404 1

BREAKOUT BOX HD-50390-1 1

ECM CABLE HD-50390-4 1

ECM OVERLAY HD-50390-4-P 1

Table 1. DTC P0506, P0507 Diagnostic Faults

POSSIBLE CAUSES

Short to voltage in circuits

Short to ground in circuits

Open in system power circuit

Short between IAC circuits

Open circuits

Vacuum/air leaks

Fuel system problems

1. IAC Operational Test

1. While watching the IAC pintle for movement turn IGN OFF, ON, then OFF.
2. Did pintle move?
a. Yes. IAC system operating properly. Check for improperly adjusted throttle stop, vacuum leaks, cylinder
misfire, contaminated fuel, leaking injectors and engine mechanical failure.
b. No. Go to Test 2.

2. Connector Test

1. Disconnect IAC [87].

2. Connect IAC TEST LIGHT (Part Number:HD-41199-3) to [87B].
3. Turn IGN ON.
4. While observing test light, turn IGN OFF.
5. Did both IAC test lights flash alternately?
a. Yes. Replace IAC.
b. No. Go to Test 3.
Table 2. IAC, Wire Color, ECM

IAC [87B] WIRE COLOR ECM [78-2]

A GY/O 11

B GN/W 12

C GY/W 13

D GN/O 1

3. Circuits Open Test

1. Turn IGN OFF.

2. Remove test light.
3. Connect BREAKOUT BOX (Part Number:HD-50390-1) and ECM CABLE (Part Number:HD-50390-4) to
wiring harness [78B-1] and [78B-2], leaving ECM [78A-1] and [78A-2] disconnected. See How To Use
Diagnostic Tools.
4. Verify ECM OVERLAY (Part Number:HD-50390-4-P) is in position on BOB.
5. Using TEST CONNECTOR KIT (Part Number:HD-41404), test resistance on each IAC wire between BOB and
[87B]. Refer to Table 2.
6. Is resistance less than 0.5 ohm on all circuits?
a. Yes. Go to Test 4.
b. No. Repair open in appropriate circuit.

4. Circuits Shorted to Ground Test

1. Test continuity on each IAC wire between BOB and ground. Refer to Table 2.
2. Is continuity present on any circuits?
a. Yes. Repair short to ground on appropriate circuit.
b. No. Go to Test 5.

5. Circuits Short to Voltage Test

1. Turn IGN ON.

2. Test voltage between BOB and ground on each IAC wire. Refer to Table 2.
3. Is voltage present on any circuit?
a. Yes. Repair short to voltage in appropriate circuit.
b. No. Go to Test 6.

6. Short Between Circuits Test

1. Turn IGN OFF.

2. Test continuity between each IAC circuit and the other IAC circuits. Refer to Table 2.
3. Is continuity present between any two IAC circuits?
a. Yes. Repair short between IAC circuits.
b. No. Replace ECM.
See Figure 1. The ECM supplies and monitors a voltage signal from [78-2] terminal 8 to one side of the ECT sensor. The
other side of the ECT sensor is connected to a common sensor ground. The ground is also connected to the ECM [78-2]
terminal 7.

The ECT sensor is a thermistor device. At a specific temperature it will have a specific resistance across its terminals. As
this resistance varies, so does the voltage on ECM [78-2] terminal 8.

At high temperatures, the resistance of the sensor is very low. This lowers the signal voltage on ECM [78-2] terminal 8.
At low temperatures, the resistance is very high. This allows the voltage to rise close to 5V.

The ECM monitors this voltage to compensate for various operating conditions. The ECM also uses the sensor input as a
reference for determining IAC pintle position.

Table 1. Code Description

DTC DESCRIPTION

P0117 ECT sensor shorted low

P0118 ECT sensor high/open

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image

1 Rear injector [85]

2 TPS [88]

3 TMAP [80]

4 IAC [87]

5 Headlamp [38]

6 Ignition switch [33]

7 LH controls [24]

8 RH controls [22]

9 Fuel pump [141]

 10 Front injector [84]

11 ECT [90]

12 Ignition coil [83]

Figure 1. Under Fuel Tank Right Side

Diagnostic Tips

Once the engine is started, the temperature should rise steadily to operating temperature.

An intermittent may be caused by a poor connection, rubbed through wire insulation or an inoperative wire inside the
insulation.

Check the following conditions:

Poor connection: Inspect ECM harness connector [78-1] and [78-2] for backed out terminals, improper mating,
inoperative locks, improperly formed or damaged terminals, poor terminal-to-wire connection and damaged
harness.
Perform Wiggle Test to locate intermittents: If connections and harness check out OK, use a multimeter to
check the engine temperature reading while moving related connectors and wiring harness. If the failure is
induced, the engine temperature display will change.
Shifted sensor resistance value: Measure ECT and IAT sensor temperatures with a cool engine. The sensor
temperatures should be within 5.6 °C (10 °F) of each other. If the two sensors are not within the specified range
replace the inaccurate sensor.

Connector Information

For additional information about the connectors in the following diagram(s) and diagnostic procedure(s), see
Connector Locations.
 View interactive
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image

Figure 2. Sensor Circuit

Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

BREAKOUT BOX HD-50390-1 1

ECM CABLE HD-50390-4 1

ECM OVERLAY HD-50390-4-P 1

Table 1. DTC P0117 Diagnostic Faults

POSSIBLE CAUSES

Short to ground in 5V reference circuit

1. ECT Sensor Test

NOTE

Vehicle and sensor must be at ambient temperature before starting diagnostic test.

1. Turn IGN OFF.

2. Disconnect ECT sensor [90].
3. Using TEST CONNECTOR KIT (Part Number:HD-41404), test resistance between [90A] terminals 1 and 2.
4. Is resistance between 900-10,000 ohms?
a. Yes. Go to Test 2.
b. No. Replace ET sensor.

2. Signal Wire Shorted to Ground Test

1. Test resistance between [90B] terminal 1 (GY/GN) wire and ground.

2. Is resistance less than 1 ohm?
a. Yes. Repair short to ground in (GY/GN) wire.
b. No. Go to Test 3.

3. Signal Wire Shorted to Sensor Ground Test

1. Connect BREAKOUT BOX (Part Number:HD-50390-1) and ECM CABLE (Part Number:HD-50390-4) to
wiring harness [78B-1] and [78B-2], leaving ECM [78A-1] and [78A-2] disconnected. See How To Use
Diagnostic Tools.
2. Verify ECM OVERLAY (Part Number:HD-50390-4-P) is in position on BOB.
3. Test continuity between BOB [78-2] terminals 8 and 7.
4. Is continuity present?
a. Yes. Repair short between [90B] terminals 1 (GY/GN) wire and 2 (BK/W) wire.
b. No. Replace ECM.
Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

BREAKOUT BOX HD-50390-1 1

ECM CABLE HD-50390-4 1

ECM OVERLAY HD-50390-4-P 1

Table 1. DTC P0118 Diagnostic Faults

POSSIBLE CAUSES

Open or short to voltage in 5V reference circuit

1. ECT Signal Voltage Test

1. Turn IGN OFF.

2. Disconnect ECT sensor [90].
3. Using TEST CONNECTOR KIT (Part Number:HD-41404), test voltage between [90B] terminal 1 (GY/GN) wire
and ground.
4. Turn IGN ON.
5. Is voltage greater than 6V?
a. Yes. Repair short to voltage on (GY/GN) wire.
b. No. Go to Test 2.

2. Signal Wire Open Test

1. Turn IGN OFF.

2. Connect BREAKOUT BOX (Part Number:HD-50390-1) and ECM CABLE (Part Number:HD-50390-4) to
wiring harness [78B-1] and [78B-2], leaving ECM [78A-1] and [78A-2] disconnected. See How To Use
Diagnostic Tools.
3. Verify ECM OVERLAY (Part Number:HD-50390-4-P) is in position on BOB.
4. Test resistance between [90B] terminal 1 (GY/GN) wire and BOB [78-2] terminal 8.
5. Is resistance less than 0.5 ohm?
a. Yes. Go to Test 3.
b. No. Repair open in (GY/GN) wire.

3. Open Ground Wire Test

1. Test resistance between [90B] terminal 2 (BK/W) wire and BOB [78-2] terminal 7.
2. Is resistance less than 0.5 ohm?
a. Yes. Go to Test 4.
b. No. Repair open in (BK/W) wire.
4. Signal Wire Shorted to Sensor Power Test

1. Test continuity between BOB [78-2] terminals 8 and 9.

2. Is continuity present?
a. Yes. Repair short between (GY/GN) and (R/W) wires.
b. No. Replace ECM.
See Figure 1. With IGN ON and the engine stop switch at RUN, the ECM will energize the system relay to complete the
circuit to the in-tank fuel pump, ignition coils and fuel injectors. They will remain powered as long as the engine is cranking
or running, and the ECM is receiving ignition reference pulses from the CKP sensor. If there are no reference pulses, the
ECM will de-energize the system relay within 2 seconds after ignition is ON or engine has stalled, or immediately after the
ignition is shut OFF.

Table 1. Code Description

DTC DESCRIPTION

P1001 System relay coil open/low

P1002 System relay coil high

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image

1 Main fuse [5]

2 DLC [91]

3 Fuse block [64]

4 Relay block [62B-2]

5 Relay block [62B-1]

6 Diode pack [201]

7 Purge solenoid [95]

8 VSS [65]

9 Ground

10 Rear WSS [168]

Figure 1. Under Right Side Cover

Connector Information

For additional information about the connectors in the following diagram(s) and diagnostic procedure(s), see
Connector Locations.

View interactive
View interactive image
image

Figure 2. System Power Circuit

Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

BREAKOUT BOX HD-50390-1 1

ECM CABLE HD-50390-4 1

ECM OVERLAY HD-50390-4-P 1

Table 1. DTC P1001 Diagnostic Faults

POSSIBLE CAUSES

Relay malfunction

Open in coil supply circuit

Short to ground in coil control circuit

Open in coil control circuit

1. System Relay Test

1. Turn IGN OFF.

2. Remove system relay [61].
3. Test system relay. See Relay Diagnostics.
4. Is relay good?
a. Yes. Go to Test 2.
b. No. Replace system relay.

2. Coil Power Circuit Test

1. Turn IGN ON.

2. Verify engine stop switch is in RUN.
3. Using TEST CONNECTOR KIT (Part Number:HD-41404), test voltage between relay block [61B] socket
terminal 3 and ground.
4. Is battery voltage present?
a. Yes. Go to Test 3.
b. No. Repair open in (W/GY) wire.

3. Relay Power Circuit Test

1. Test voltage between relay block [61B] socket terminal 4 and ground.
2. Is battery voltage present?
 a. Yes. Go to Test 4.
b. No. Repair short to voltage in (R/GN) wire.

4. Coil Control Short to Ground Test

1. Turn IGN OFF.

2. Connect BREAKOUT BOX (Part Number:HD-50390-1) and ECM CABLE (Part Number:HD-50390-4) to wire
harness [78B-1] and [78B-2], leaving ECM [78A-1] and [78A-2] disconnected. See How To Use Diagnostic
Tools.
3. Verify ECM OVERLAY (Part Number:HD-50390-4-P) is in position on BOB.
4. Using TEST CONNECTOR KIT (Part Number:HD-41404), test continuity between BOB [78-2] terminal 3 and
ground.
5. Is continuity present?
a. Yes. Repair short to ground on (V/GN) wire.
b. No. Go to Test 5.

5. Coil Control Circuit Test

1. Test resistance between [61B] socket terminal 1 and BOB [72-2] terminal 3.
2. Is resistance less than 0.5 ohm?
a. Yes. Replace ECM.
b. No. Repair open in (V/GN) wire.
Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

Table 1. DTC P1002 Diagnostic Faults

POSSIBLE CAUSES

Short to voltage in coil control circuit

1. System Relay Test

1. Turn IGN OFF.

2. Remove system relay [61].
3. Test system relay. See Relay Diagnostics.
4. Is relay good?
a. Yes. Go to Test 2.
b. No. Replace system relay.

2. Coil Short to Voltage Test

1. Using TEST CONNECTOR KIT (Part Number:HD-41404), test voltage between [61B] socket terminal 1 and
ground.
2. Is voltage present?
a. Yes. Repair short to voltage in (V/GN) wire.
b. No. Replace ECM.
See Figure 1 and Figure 2. The DTCs listed indicate a failure which could require replacement of the ECM. Refer to Table
1.

Table 1. Code Description

DTC DESCRIPTION

P0603 ECM EEPROM memory error

P0605 ECM flash memory error

U0300 Internal control module software incompatibility

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image

1 Security module [326]

2 ECM [78-2]

3 Rear lighting [7]

4 Flasher [69]

5 BAS [134]

6 Engine harness [145]

7 Starter solenoid [128]

8 ECM [78-1]

9 Security antenna [142]

10 Terminating resistor [319]

Figure 1. Under Seat: Except 750A

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image

1 Terminating resistor [319]

2 Left turn lamp [19]

3 LP lamp [40]

4 Right turn lamp [18]

5 Stop/tail lamp [93]

6 ECM [78-2]

7 Flasher [69]

8 BAS [134]

9 Engine harness [145]

10 P&A connector

11 Starter solenoid [128]

12 ECM [78-1]

13 Security antenna [142]

14 Security module [326]

Figure 2. Under Seat: 750A

Table 1. DTC P0603 Diagnostic Faults

POSSIBLE CAUSES

ECM memory error

DTC P0603 Test

1. Clear DTCs.
2. Turn IGN ON.
3. Check DTCs.
4. Did DTC reset?
a. Yes. Replace ECM.
b. No. System operating properly.
Special Tools

Description Part Number Qty.

DIGITAL TECHNICIAN II HD-48650 1

Table 1. DTC P0605 Diagnostic Faults

POSSIBLE CAUSES

ECM memory error

DTC P0605 Test

1. Clear DTCs.
2. Using DIGITAL TECHNICIAN II (Part Number:HD-48650) reflash ECM
3. Start engine.
4. Check DTCs.
5. Did DTC reset?
a. Yes. Replace ECM.
b. No. System operating properly.
Special Tools

Description Part Number Qty.

DIGITAL TECHNICIAN II HD-48650 1

Table 1. DTC U0300 Diagnostic Faults

POSSIBLE CAUSES

ECM software error

1. Verify DTC

1. Clear DTC.
2. Turn IGN OFF for 30 seconds.
3. Check DTCs.
4. Did DTC reset?
a. Yes. Go to Test 2.
b. No. System working properly.

2. Reflash ECM

1. Using DIGITAL TECHNICIAN II (Part Number:HD-48650) reflash ECM.

2. Clear DTCs.
3. Turn IGN OFF for 30 seconds.
4. Check DTCs.
5. Did DTC reset?
a. Yes. Replace ECM.
b. No. System working properly.
See Figure 1 and Figure 2. The ECM supplies 5V to the VSS, TMAP, TPS, BAS and JSS from [78-2] terminal 9. These
sensors may have individual codes along with this code since they all share the 5V reference circuit. If the ECM sees a
voltage of less than 4V or greater than 6V on the 5V reference circuit, P0641 will be set.

Table 1. Code Description

DTC DESCRIPTION

P0641 5V Vref out of range

Any of these conditions will set a DTC P0641:

Short to ground on the 5V sensor power circuit.

Short to voltage on the 5V sensor power circuit.
VSS fault or malfunction.
TMAP sensor fault or malfunction.
TPS fault or malfunction.
JSS (HDI) fault or malfunction.
ECM fault or malfunction.
BAS fault or malfunction.

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1 Front injector [84]

2 IAC [87]

3 TPS [88]

4 Rear injector [85]

5 TMAP [80]

6 ECT [90]

7 Ignition coil [83]

Figure 1. Between Cylinders Left Side

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1 VSS [65]

2 GND 2A

Figure 2. Right Side Above Transmission

Connector Information

For additional information about the connectors in the following diagram(s) and diagnostic procedure(s), see
Connector Locations.

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image
Figure 3. Sensor Circuit
Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

BREAKOUT BOX HD-50390-1 1

ECM CABLE HD-50390-4 1

ECM OVERLAY HD-50390-4-P 1

Table 1. DTC P0641 Diagnostic Faults

POSSIBLE CAUSES

Short to ground on the 5V sensor power circuit

Short to voltage on the 5V sensor power circuit

VSS fault or malfunction

TMAP sensor fault or malfunction

TPS fault or malfunction

JSS (HDI) fault or malfunction

BAS fault or malfunction

1. 5V Sensor Short to Voltage Test

1. Turn IGN OFF.

2. Connect BREAKOUT BOX (Part Number:HD-50390-1) and ECM CABLE (Part Number:HD-50390-4)
between wiring harness [78B-1] and [78B-2] and ECM [78A-1] and [78A-2]. See How To Use Diagnostic
Tools.
3. Verify ECM OVERLAY (Part Number:HD-50390-4-P) is in position on BOB.
4. Turn IGN ON.
5. Using TEST CONNECTOR KIT (Part Number:HD-41404), test voltage between BOB [78-2] terminal 9 and
ground.
6. Is voltage between 4-6V?
a. Yes. Concern is intermittent. See Wiggle Test.
b. No. Greater than 6V. Repair short to voltage on (R/W) wire.
c. No. Less than 4V. Go to Test 2.

2. TPS Circuit Below Range Test

1. Turn IGN OFF.

2. Disconnect TPS [88].
 3. Turn IGN ON.
4. Test voltage between BOB [78-2] terminals 9 and 10.
5. Is voltage less than 4V?
a. Yes. Go to Test 3.
b. No. Replace TPS.

3. TMAP Power Circuit Below Range Test

1. Turn IGN OFF.

2. Disconnect TMAP sensor [80].
3. Turn IGN ON.
4. Test voltage between BOB [78-2] terminals 9 and 10.
5. Is voltage less than 4V?
a. Yes. Go to Test 4.
b. No. Replace TMAP sensor.

4. VSS Circuit Below Range Test

1. Turn IGN OFF.

2. Disconnect VSS [65].
3. Turn IGN ON.
4. Test voltage between BOB [78-2] terminals 9 and 10.
5. Is voltage less than 4V?
a. Yes, with JSS. Go to Test 5.
b. Yes, without JSS. Go to Test 6.
c. No. Replace VSS.

5. JSS Circuit Below Range Test

1. Turn IGN OFF.

2. Disconnect JSS [133].
3. Turn IGN ON.
4. Test voltage between BOB [78-2] terminals 9 and 10.
5. Is voltage less than 4V?
a. Yes. Go to Test 6.
b. No. Replace JSS.

6. BAS Circuit Below Range Test

1. Turn IGN OFF.

2. Disconnect BAS [134].
3. Turn IGN ON.
4. Test voltage between BOB [78-2] terminals 9 and 10.
5. Is voltage less than 4V?
a. Yes. Go to Test 7.
b. No. Replace BAS.
7. Circuit Short to Ground Test

1. Disconnect [78A-1] and [78A-2].

2. Test continuity between BOB [78-2] terminal 9 and ground.
3. Is continuity present?
a. Yes. Repair short to ground in (R/W) wire.
b. No. Go to Test 8.

8. Circuit Shorted to Sensor Ground Circuit Test

1. Test continuity between BOB [78-2] terminals 9 and 7.

2. Is continuity present?
a. Yes. Repair short between (R/W) and (BK/W) wires.
b. No. Replace ECM.
See Figure 1 and Figure 2. The Bank Angle Sensor (BAS) is located under seat. The BAS operates from a 5V sensor
reference voltage and sensor ground provided by the ECM.

The BAS sends a signal to the ECM ranging from 3.5-4.79V under normal operating conditions. A BAS signal between
0.24-3.4V indicates to the ECM that the vehicle has tipped over and will turn off the engine. When the vehicle is righted,
turn the ignition OFF, wait 10 seconds, and turn ON again to restart the engine.

If the signal from the BAS is below 0.24V or above 4.79V, the ECM sets a code. Refer to Table 1. A BAS code will not
disable the vehicle and the engine will continue to run. A tipped vehicle will not set a DTC.

Table 1. Code Description

DTC DESCRIPTION

P1151 Bank angle sensor low

P1152 Bank angle sensor high

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1 Security module [326]

2 ECM [78-2]

3 Rear lighting [7]

4 Flasher [69]

5 BAS [134]

6 Engine harness [145]

7 Starter solenoid [128]

8 ECM [78-1]

9 Security antenna [142]

10 Terminating resistor [319]

Figure 1. Under Seat: Except 750A

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1 Terminating resistor [319]

2 Left turn lamp [19]

3 LP lamp [40]

4 Right turn lamp [18]

5 Stop/tail lamp [93]

6 ECM [78-2]

7 Flasher [69]

8 BAS [134]

9 Engine harness [145]

10 P&A connector

11 Starter solenoid [128]

12 ECM [78-1]

13 Security antenna [142]

14 Security module [326]

Figure 2. Under Seat: 750A

Connector Information

For additional information about the connectors in the following diagram(s) and diagnostic procedure(s), see
Connector Locations.

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image

Figure 3. Sensor Circuit

Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

BREAKOUT BOX HD-50390-1 1

ECM CABLE HD-50390-4 1

ECM OVERLAY HD-50390-4-P 1

Table 1. DTC P1151 Diagnostic Faults

POSSIBLE CAUSES

Sensor signal short to ground

Sensor stuck in tip mode

1. BAS Circuit Short to Ground Test

1. Turn IGN OFF.

2. Disconnect BAS [134].
3. Connect BREAKOUT BOX (Part Number:HD-50390-1) and ECM CABLE (Part Number:HD-50390-4) to
wiring harness [78B-1] [78B-2], leaving ECM [78A-1] and [78A-2] disconnected. See How To Use Diagnostic
Tools.
4. Verify ECM OVERLAY (Part Number:HD-50390-4-P) is in position on BOB.
5. Using TEST CONNECTOR KIT (Part Number:HD-41404), test continuity between [134B] terminal 3 and
ground.
6. Is continuity present?
a. Yes. Repair short to ground in (TN/BK) wire.
b. No. Go to Test 2.

2. Short to Sensor Ground Test

1. Test continuity between [134] terminals 1 and 3.

2. Is continuity present?
a. Yes. Repair short between (TN/BK) and (BK/W) wires.
b. No. Go to Test 3.

3. BAS Test

1. Connect [78A-1] and [78A-2].

2. Connect [134].
3. Turn IGN ON.
4. Test voltage between BOB [78-2] terminals 7 and 14.
5. Is voltage between 3.5-4.79V?
a. Yes. Replace ECM.
b. No. Replace BAS.
Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

BREAKOUT BOX HD-50390-1 1

ECM CABLE HD-50390-4 1

ECM OVERLAY HD-50390-4-P 1

Table 1. DTC P1152 Diagnostic Faults

POSSIBLE CAUSES

Short to voltage in signal circuit

Open in ground circuit

Open in signal circuit

1. BAS Circuit Short to Voltage Test

1. Turn IGN OFF.

2. Connect BREAKOUT BOX (Part Number:HD-50390-1) and ECM CABLE (Part Number:HD-50390-4) to
wiring harness [78B-1] [78B-2], leaving ECM [78A-1] and [78A-2] disconnected. See How To Use Diagnostic
Tools.
3. Verify ECM OVERLAY (Part Number:HD-50390-4-P) is in position on BOB.
4. Using TEST CONNECTOR KIT (Part Number:HD-41404)
5. Turn IGN ON.
6. Test voltage between BOB [78-2] terminals 7 and 14.
7. Is voltage greater than 5.25V?
a. Yes. Go to Test 2.
b. No. Go to Test 3.

2. BAS Test

1. Turn IGN OFF.

2. Disconnect BAS [134].
3. Turn IGN ON.
4. Test voltage between BOB [78-2] terminals 7 and 14.
5. Is voltage greater than 5.25V?
a. Yes. Repair short to voltage in (TN/BK) wire.
b. No. Replace BAS.

3. Sensor Ground Continuity Test

 1. Turn IGN OFF.
2. Disconnect BAS [134].
3. Test resistance between BOB [78-2] terminal 7 and [134B] terminal 1.
4. Is resistance less than 0.5 ohm?
a. Yes. Go to Test 4.
b. No. Repair open in (BK/W) wire.

4. Circuit Continuity Test

1. Test resistance between BOB [78-2] terminal 14 and [134B] terminal 3.

2. Is resistance less than 0.5 ohm?
a. Yes. Go to Test 5.
b. No. Repair open in (TN/BK) wire.

5. Short to 5V Circuit Test

1. Test continuity between BOB [78-2] terminals 14 and 9.

2. Is continuity present?
a. Yes. Go to Test 6.
b. No. Repair short between (TN/BK) and (R/W) wires.

6. BAS Circuit Test

1. Connect [78A-1] and [78A-2].

2. Connect [134].
3. Turn IGN ON.
4. Test voltage between BOB [78-2] terminals 7 and 14.
5. Is voltage between 3.5-4.79V?
a. Yes. Replace ECM.
b. No. Replace BAS.
Special Tools

Description Part Number Qty.

DIGITAL TECHNICIAN II HD-48650 1

Password Problem

The ECM and SCM exchange passwords during operation. An incorrect password will not allow the vehicle to start and
will set a DTC. If any U-codes exist, troubleshoot the higher priority codes prior to performing the tests in this section.
Refer to Diagnostic Trouble Codes (DTCs) and Fault Conditions.

Table 1. Code Description

DTC DESCRIPTION

P1009 VTD disabled fuel due to bad password

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1 Security module [326]

2 ECM [78-2]

3 Rear lighting [7]

4 Flasher [69]

5 BAS [134]

6 Engine harness [145]

7 Starter solenoid [128]

8 ECM [78-1]

9 Security antenna [142]

 10 Terminating resistor [319]

Figure 1. Under Seat: Except 750A

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1 Terminating resistor [319]

2 Left turn lamp [19]

3 LP lamp [40]

4 Right turn lamp [18]

5 Stop/tail lamp [93]

6 ECM [78-2]

7 Flasher [69]

8 BAS [134]

9 Engine harness [145]

10 P&A connector

11 Starter solenoid [128]

12 ECM [78-1]

13 Security antenna [142]

14 Security module [326]

Figure 2. Under Seat: 750A

Diagnostic Tips

This code will usually appear after replacing the ECM or SCM. New modules must be programmed using DIGITAL
TECHNICIAN II (Part Number:HD-48650). After parts are programmed and matched correctly for specific vehicle,
clear codes.
Special Tools

Description Part Number Qty.

DIGITAL TECHNICIAN II HD-48650 1

Table 1. DTC P1009 Diagnostic Faults

POSSIBLE CAUSES

ECM malfunction

SCM malfunction

1. Incorrect Password Test

1. Using DIGITAL TECHNICIAN II (Part Number:HD-48650), attempt to calibrate the ECM using the module
replace feature found in vehicle set up.
2. Clear DTCs.
3. Turn IGN OFF.
4. Check DTCs.
5. Did DTC reset?
a. Yes. Go to Test 2.
b. No. System operating properly.

NOTE

If equipped with a siren, removing the SCM with IGN OFF will cause the siren to sound.

2. SCM Replacement Test

1. Turn IGN OFF.

2. Replace SCM.
3. Attempt to calibrate the ECM (to learn new password) using the module replace feature found in vehicle set-up.
4. Clear DTCs.
5. Turn IGN OFF.
6. Check DTCs.
7. Did DTC reset?
a. Yes. Install original SCM and replace ECM.
b. No. System operating properly.
See Figure 1. A feedback voltage signal in the secondary ignition circuit (terminal B) detects the presence of combustion
each time a cylinder fires on ECM [78-1] terminal 9. For diagnostic purposes, this signal is only analyzed at high speed
and load conditions where it may be easily measured. Failure to detect combustion at high speed and load means one of
following conditions is true:

Cylinder is truly misfiring.

There is a lack of continuity in the ignition coil secondary circuit.

NOTE

Check for non-OE spark plugs and cables before testing. The incorrect resistance values of non-OE components
will set these DTCs.

Make sure vehicle is running properly before performing the tests in this section. Perform fuel pressure tests if
required.

Table 1. Code Description

DTC DESCRIPTION

P1353 No combustion detected (front)

P1356 No combustion detected (rear)

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1 Terminal A: power

2 Terminal B: ion sense

3 Terminal C: rear coil

4 Terminal D: front coil

Figure 1. Ignition Coil: Typical

Connector Information
For additional information about the connectors in the following diagram(s) and diagnostic procedure(s), see
Connector Locations.

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image

Figure 2. System Power Circuit

Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

BREAKOUT BOX HD-50390-1 1

ECM CABLE HD-50390-4 1

ECM OVERLAY HD-50390-4-P 1

Table 1. DTC P1353, P1356 Diagnostic Faults

POSSIBLE CAUSES

Fuel system problems

Open or short to voltage in signal circuit

Spark plug wire connections faulty

Spark plug cables

Spark plug

1. Absence of Fuel Test

1. Verify vehicle has fuel.

2. Has vehicle run out of fuel recently?
a. Yes. Clear DTCs. Fill with fresh fuel and restart. If code returns, then continue with tests.
b. No.

2. Ion Sense Continuity Test

1. Turn IGN OFF.

2. Connect BREAKOUT BOX (Part Number:HD-50390-1) and ECM CABLE (Part Number:HD-50390-4) to
wiring harness [78B-1] and [78B-2], leaving ECM [78A-1] and [78A-2] disconnected. See How To Use
Diagnostic Tools.
3. Verify ECM OVERLAY (Part Number:HD-50390-4-P) is in position on BOB.
4. Disconnect ignition coil [83].
5. Using TEST CONNECTOR KIT (Part Number:HD-41404), test resistance between [83B] terminal B (LGN/BN)
wire and BOB [78-1] terminal 9.
6. Is resistance less than 0.5 ohm?
a. Yes.
b. No. Repair open in (LGN/BN) wire.
3. Ion Sense Short to Voltage Test

1. Connect [78A-1] and [78A-2].

2. Turn IGN ON.
3. Test voltage between [83B] terminal B (LGN/BN) wire and BOB [78-1] terminal 10.
4. Is voltage present?
a. Yes. Repair short to voltage on (LGN/BN) wire.
b. No.

4. Spark Plug Cable Test

1. Disconnect spark plug cables.

2. Inspect spark plug cables for carbon tracking or loose connections.
3. Test resistance of spark plug cables.
4. Is front and rear spark plug cable resistance within specified range? Refer to Spark Plug Specifications
.
a. Yes.
b. No. Replace out of range spark plug cable.

5. Ignition Rear Coil Primary Resistance Test

1. Test resistance between [83A] terminals A and C.

2. Is resistance 0.3-1.5 ohms?
a. Yes.
b. No. Replace ignition coil.

6. Ignition Front Coil Primary Resistance Test

1. Test resistance between [83A] terminals A and D.

2. Is resistance 0.3-1.5 ohms?
a. Yes.
b. No. Replace ignition coil.

7. Ion Sense Coil Resistance Test

1. Test resistance between [83A] terminal B to front coil secondary output tower. Repeat test for rear output
tower.
2. Is resistance 1500-2400 ohms?
a. Yes.
b. No. Replace ignition coil.

8. Ignition Coil Secondary Resistance Test

1. Test resistance across ignition coil front and rear secondary output towers.
2. Is resistance within specifications? Refer to Ignition Coil Specifications
.
a. Yes.
 b. No. Replace ignition coil.

9. Coil Internal Short Test

1. Test continuity between [83A] terminals A and B.

2. Is continuity present?
a. Yes. Replace ignition coil.
b. No. Replace spark plugs and spark plug cables.
See Figure 1 and Figure 2. The ECM controls the ground side of fan relay. Voltage is provided to the relay on the R/PK
wire from the fan fuse. The ECM turns the fan relay on and off based on engine temperature. The ECM may continue fan
operation for approximately one minute after engine is turned off.

Table 1. Code Description

DTC DESCRIPTION

P0691 Fan relay coil open/low

P0692 Fan relay coil high

The fan relay is located in the relay block under the right side cover. Power is supplied from the battery to the coil and
switch sides of the fan relay. The ECM controls the ground for the coil side of the relay. When the fan relay energizes
battery power is supplied to the cooling fan.

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1 Neutral switch [131]

2 JSS [133]

3 CKP [79]

4 Cooling fan [97]

5 Horn [122-1]

6 Horn [122-2]

7 Front WSS [167]

8 Starter

9 VSS [65]

10 Voltage regulator [77]

11 ABS ECU [166]

12 Oil pressure switch [120]

Figure 1. Front of Engine

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1 Main fuse [5]

2 DLC [91]

3 Fuse block [64]

4 Relay block [62B-2]

5 Relay block [62B-1]

6 Diode pack [201]

7 Purge solenoid [95]

8 VSS [65]

9 Ground

10 Rear WSS [168]

Figure 2. Under Right Side Cover

Diagnostic Tips

DTCs P0691 and P0692 can only set when engine is at normal operating temperature.

Connector Information

For additional information about the connectors in the following diagram(s) and diagnostic procedure(s), see
Connector Locations.
 View interactive
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image

Figure 3. Fan Relay Circuit

Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

BREAKOUT BOX HD-50390-1 1

ECM CABLE HD-50390-4 1

ECM OVERLAY HD-50390-4-P 1

Table 1. DTC P0691 Diagnostic Faults

POSSIBLE CAUSES

Short to ground in fan relay control circuit

Open in fan relay supply circuit

1. Relay Test

1. Turn IGN OFF.

2. Remove fan relay [62].
3. Perform relay test. See Relay Diagnostics.
4. Is relay good?
a. Yes. Go to Test 2.
b. No. Replace relay.

2. Relay Coil Power Test

1. Using TEST CONNECTOR KIT (Part Number:HD-41404), test voltage between [62B] socket terminal 6 and
ground.
2. Is battery voltage present?
a. Yes. Go to Test 4.
b. No. Go to Test 3.

3. Power Continuity Test

1. Remove fan fuse [64B].

2. Test resistance between [62B] socket terminal 6 and [64B] socket terminal D.
3. Is resistance less than 0.5 ohm?
a. Yes. Repair open between [64B] socket terminal C and main fuse [5A] socket terminal B (R).
b. No. Repair open between [62B] socket terminal 6 and [64B] socket terminal D (R/PK).
4. Ground Continuity Test

1. Connect BREAKOUT BOX (Part Number:HD-50390-1) and ECM CABLE (Part Number:HD-50390-4)
between wiring harness [78B-1] and [78B-2], leaving ECM [78A-1] and [78A-2] disconnected. See How To
Use Diagnostic Tools.
2. Verify ECM OVERLAY (Part Number:HD-50390-4-P) is in position on BOB.
3. Test resistance between BOB [78-2] terminal 2 and [62B] socket terminal 8.
4. Is resistance less than 0.5 ohm?
a. Yes. Go to Test 5.
b. No. Repair open between [62B] socket terminal 8 and [78B-2] terminal 2 (GN/BK).

5. Ground Shorted Test

1. Test continuity between BOB [78-2] terminal 2 and ground.

2. Is continuity present?
a. Yes. Repair short to ground between [62B] socket terminal 8 and [78B-2] terminal 2 (GN/BK).
b. No. Go to Test 6.

6. Repair Validation Test

1. Install fan relay.

2. Connect [78A-1] and [78A-2].
3. Clear DTCs.
4. Start vehicle.
5. Run until engine is at normal operating temperature.
6. Does DTC set?
a. Yes. Replace ECM.
b. No. System working properly.
Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

Table 1. DTC P0692 Diagnostic Faults

POSSIBLE CAUSES

Short to voltage in fan relay control circuit

1. Relay Test

1. Turn IGN OFF.

2. Remove fan relay [62].
3. Perform relay test. See Relay Diagnostics.
4. Is relay good?
a. Yes. Go to Test 2.
b. No. Replace relay.

2. Ground Continuity Test

1. Disconnect [78A-1] and [78A-2].

2. Turn IGN ON.
3. Using TEST CONNECTOR KIT (Part Number:HD-41404), test voltage between [62B] socket terminal 8 and
ground.
4. Is battery voltage present?
a. Yes. Repair short to voltage on (GN/BK).
b. No. Go to Test 3.

3. Repair Validation Test

1. Install fan relay.

2. Connect [78A-1] and [78A-2].
3. Clear DTCs.
4. Start vehicle.
5. Run until engine is at normal operating temperature.
6. Does code set?
a. Yes. Replace ECM.
b. No. System working properly.
Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

BREAKOUT BOX HD-50390-1 1

ECM CABLE HD-50390-4 1

ECM OVERLAY HD-50390-4-P 1

Table 1. Fan Inoperative, No DTCs Diagnostic Faults

POSSIBLE CAUSES

Open power circuit

Shorted power circuit

Open ground circuit

1. Fan Relay Ground Test

1. Turn IGN OFF.

2. Connect BREAKOUT BOX (Part Number:HD-50390-1) and ECM CABLE (Part Number:HD-50390-4)
between wiring harness [78B-1] and [78B-2] and ECM [78A-1] and [78A-2]. See How To Use Diagnostic
Tools.
3. Verify ECM OVERLAY (Part Number:HD-50390-4-P) is in position on BOB.
4. Turn IGN ON.
5. Using TEST CONNECTOR KIT (Part Number:HD-41404), jumper between BOB [78-2] terminals 2 and 10.
6. Is fan running?
a. Yes. Replace ECM.
b. No. Go to Test 2.

2. Relay Test

1. Turn IGN OFF.

2. Remove fan relay [62B].
3. Perform relay test. See Relay Diagnostics.
4. Is relay good?
a. Yes. Go to Test 3.
b. No. Replace relay.

3. Relay Switched Power Test

1. Test voltage between [62B] socket terminal 10 and ground.

 2. Is battery voltage present?
a. Yes. Go to Test 3.
b. No. Repair open between [62B] socket terminal 10 and fuse block [64B] socket terminal D.

4. Cooling Fan Power Continuity Test

1. Disconnect cooling fan [97].

2. Test resistance between [97A] terminal 2 (GY/BK) and [62B] socket terminal 9.
3. Is resistance greater than 0.5 ohm?
a. Yes. Repair open or high resistance in (GY/BK).
b. No. Go to Test 5.

5. Cooling Fan Short to Ground Test

1. Test continuity between [97A] terminal 2 (GY/BK) and ground.

2. Is continuity present?
a. Yes. Repair short to ground in (GY/BK).
b. No. Go to Test 6.

6. Ground Test

1. Test continuity between [97A] terminal 1 (BK) and ground.

2. Is continuity present?
a. Yes. Replace cooling fan.
b. No. Repair open in (BK).
Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

Table 1. Fan Runs Continually, No DTCs Diagnostic Faults

POSSIBLE CAUSES

Shorted fan power circuit

1. Relay Test

1. Turn IGN OFF.

2. Remove fan relay [62].
3. Perform relay test. See Relay Diagnostics.
4. Is relay good?
a. Yes. Go to Test 2.
b. No. Replace relay.

2. Power Test

1. Turn IGN ON.

2. Using TEST CONNECTOR KIT (Part Number:HD-41404), test voltage between [62B] terminal 9 and ground.
3. Is voltage present?
a. Yes. Repair short to voltage on (GY/BK).
b. No. Repair short to ground on (GN/BK).
See Figure 1. The Jiffy Stand Sensor (JSS) uses a Hall-effect sensor to monitor jiffy stand position.

When the jiffy stand is fully retracted the sensor picks up the presence of the metal tab mounted to the jiffy stand. The
metal tab is moved away from the sensor as the jiffy stand is extended.
When the jiffy stand is extended the engine will only start and run if the ECM determines the transmission is in neutral.
This is done by monitoring the neutral switch input to the ECM.

The JSS is powered and monitored by the ECM. The ECM supplies the 5V reference to the JSS. The JSS sends a signal
back to the ECM. This signal is used by the ECM to determine when the jiffy stand is retracted or extended. The JSS is
grounded through the ECM.

The JSS also has a Fail Enable Mode. This mode allows the engine to start and run if the system recognizes a problem
with the JSS circuit. DTC P1501 or P1502 will set if the JSS circuits are out of range.

NOTE

The ECM supplies 5V reference voltage to the VSS, TPS, BAS and TMAP sensors in addition to the JSS. Problems on
the 5V reference will cause other DTCs.

Table 1. Code Description

DTC DESCRIPTION

P1501 JSS low

P1502 JSS high/open

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1 Neutral switch [131]

2 JSS [133]

3 CKP [79]

4 Cooling fan [97]

5 Horn [122-1]

6 Horn [122-2]
 7 Front WSS [167]

8 Starter

9 VSS [65]

10 Voltage regulator [77]

11 ABS ECU [166]

12 Oil pressure switch [120]

Figure 1. Front of Engine

Diagnostic Tips

When disconnecting any connectors always inspect connector for corrosion or backed out terminals and repair as
required.

Connector Information

For additional information about the connectors in the following diagram(s) and diagnostic procedure(s), see
Connector Locations.

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Figure 2. Sensor Circuit
Table 1. DTC P1501 Diagnostic Faults

POSSIBLE CAUSES

Short to ground in signal circuit

1. Signal Wire Shorted to Ground Test

1. Turn IGN OFF.

2. Disconnect JSS [133].
3. Test continuity between [133B] terminal 2 (LGN/GY) wire and ground.
4. Is continuity present?
a. Yes. Repair short to ground on (LGN/GY) wire.
b. No. Replace JSS.
Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

BREAKOUT BOX HD-50390-1 1

ECM CABLE HD-50390-4 1

ECM OVERLAY HD-50390-4-P 1

Table 1. DTC P1502 Diagnostic Faults

POSSIBLE CAUSES

Short to voltage in signal circuit

Open ground

Short between 5V reference circuit and signal circuit

Open in signal circuit

1. JSS Ground Wire Test

1. Turn IGN OFF.

2. Disconnect JSS [133].
3. Using TEST CONNECTOR KIT (Part Number:HD-41404), test resistance between [133B] terminal 3 and
ground.
4. Is resistance less than 0.5 ohm?
a. Yes. Go to Test 2.
b. No. Repair open in (BK/GN) wire.

2. Signal Wire Short to Voltage Test

1. Turn IGN ON.

2. Test voltage between [133B] terminal 2 (LGN/GY) wire and ground.
3. Is voltage greater than 5V?
a. Yes. Repair short to voltage in (LGN/GY) wire.
b. No. Go to Test 3.

3. 5V Reference and Signal Shorted Together Test

1. Turn IGN OFF.

2. Disconnect ECM [78-1] and [78-2].
3. Test continuity between [133B] terminals 1 (R/W) wire and 2 (LGN/GY) wire.
 4. Is continuity present?
a. Yes. Repair short between (R/W) and (LGN/GY) wires.
b. No. Go to Test 4.

4. Signal Wire Open Circuit Test

1. Connect BREAKOUT BOX (Part Number:HD-50390-1) and ECM CABLE (Part Number:HD-50390-4) to
wiring harness [78B-1] and [78B-2], leaving ECM [78A-1] and [78A-2] disconnected. See How To Use
Diagnostic Tools.
2. Verify ECM OVERLAY (Part Number:HD-50390-4-P) is in position on BOB.
3. Test resistance between BOB [78-1] terminal 8 and [133B] terminal 2 (LGN/GY) wire.
4. Is resistance less than 0.5 ohm?
a. Yes. Replace JSS.
b. No. Repair open on (LGN/GY) wire.
The only crank in neutral conditions may be caused by an open in the clutch switch circuit. When the clutch lever is pulled
in, the clutch switch is released and provides continuity to ground. This allows current flow through the coil side of the start
relay.

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1 Clutch switch [314]

2 Front stop lamp switch [170]

Figure 1. Hand Controls

Connector Information

For additional information about the connectors in the following diagram(s) and diagnostic procedure(s), see
Connector Locations.
 View interactive
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image

Figure 2. Starting Circuit

Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

BREAKOUT BOX HD-50390-1 1

ECM CABLE HD-50390-4 1

ECM OVERLAY HD-50390-4-P 1

Table 1. Will Only Crank In Neutral Diagnostic Faults

POSSIBLE CAUSES

Clutch switch circuit open

Clutch switch malfunction

1. Validation Test

1. Pull in clutch.
2. Shift transmission into first gear.
3. Start the vehicle.
4. Does the engine crank?
a. Yes. System operating properly. Concern is intermittent. See Wiggle Test.
b. No. Go to Test 2.

2. Clutch Switch Test

1. Turn IGN OFF.

2. Disconnect clutch switch [314].
3. Using TEST CONNECTOR KIT (Part Number:HD-41404), short [314A] terminals 1 and 2.
4. Start the vehicle.
5. Does the engine crank?
a. Yes. Replace clutch switch.
b. No. Go to Test 3.

3. Clutch Switch Ground Test

1. Test resistance between clutch switch [314A] terminal 2 and ground.

2. Is resistance less than 0.5 ohm?
a. Yes. Go to Test 4.
b. No. Repair open in (BK/GN) wire.
4. Clutch Switch Circuit Test

1. Connect BREAKOUT BOX (Part Number:HD-50390-1) and ECM CABLE (Part Number:HD-50390-4)
between wiring harness [78B-1] and [78B-2], leaving ECM [78A-1] and [78A- 2] disconnected. See How To
Use Diagnostic Tools.
2. Verify ECM OVERLAY (Part Number:HD-50390-4-P) is in position on BOB.
3. Test resistance between BOB [78-1] terminal 12 clutch switch [314A] terminal 1.
4. Is resistance less than 0.5 ohm?
a. Yes. Replace ECM.
b. No. Repair open in (TN/GN) wire.
See Figure 1 and Figure 2. Improper fuel system pressure may contribute to hesitation or loss of power.

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1 Security module [326]

2 ECM [78-2]

3 Rear lighting [7]

4 Flasher [69]

5 BAS [134]

6 Engine harness [145]

7 Starter solenoid [128]

8 ECM [78-1]

9 Security antenna [142]

10 Terminating resistor [319]

Figure 1. Under Seat: Except 750A

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1 Terminating resistor [319]

2 Left turn lamp [19]

3 LP lamp [40]

4 Right turn lamp [18]

5 Stop/tail lamp [93]

6 ECM [78-2]

7 Flasher [69]

8 BAS [134]

9 Engine harness [145]

10 P&A connector

11 Starter solenoid [128]

12 ECM [78-1]

13 Security antenna [142]

14 Security module [326]

Figure 2. Under Seat: 750A

Table 1. Code Description

DTC DESCRIPTION

P1505 Power limit violation

Table 1. DTC P1505 Diagnostic Faults

POSSIBLE CAUSES

Restrictor plate missing or modified

Intake leak

1. DTC Validation Test

1. Verify no other engine sensor DTCs are present.

2. Are any other DTCs present?
a. Yes. Diagnose other DTCs first.
b. No. Go to Test 2.

2. Vacuum Leak Test

1. Start engine.
2. Check for vacuum leaks.
3. Were any leaks found?
a. Yes. Repair vacuum leak.
b. No. Go to Test 3.

3. Restrictor Plate Test

1. Inspect restrictor plate.

2. Has the restrictor plate been modified or removed?
a. Yes. Repair or replace restrictor plate.
b. No. Go to Test 4.

4. DTC Confirmation Test

1. Clear DTCs.
2. Did DTC return?
a. Yes. Replace ECM.
b. No. Repair complete.
Special Tools

Description Part Number Qty.

SPARK PLUG TESTER HD-26792 1

Table 1. Hesitation or Loss of Power Test Diagnostic

Faults

POSSIBLE CAUSES

Loss of engine compression

Fuel system issues

Battery condition and connections

Spark plug condition

Air filter condition

Poor chassis ground connections

Performance modifications

Electrical modifications

Throttle valve malfunction

1. Preliminary Engine Tests

1. Verify battery connections are in good condition.

2. Verify fuel in the tank is fresh and not contaminated.
3. Verify spark plug wires are firmly connected the coil and plugs.
4. Verify fuel injectors are not clogged.
5. Verify battery condition. See General.
6. Does battery pass tests?
a. Yes. Go to Test 2.
b. No. Charge or replace battery.

2. Vacuum Leak Test

1. Start engine. Check for vacuum leaks.

2. Were any leaks found?
a. Yes. Repair vacuum leak.
b. No. Go to Test 3.

3. Spark Present Test

 1. Check spark plug condition. Replace if fouled.
2. Using SPARK PLUG TESTER (Part Number:HD-26792), check spark at both plugs while cranking engine.
3. Is spark present?
a. Yes. Go to Test 5.
b. No. Go to Test [Link] spark plugs will not spark if there is low or no compression. If spark is not
present, test compression before troubleshooting ignition circuit. Once good compression is confirmed,
check condition of ignition coils, coil primary wiring and spark plug boots. See Description and
Operation or Description and Operation.

4. Compression Test

1. Perform compression test.

2. Does engine pass compression test?
a. Yes. Check condition of ignition coils, coil primary wiring and spark plug boots. See Description and
Operation or Description and Operation. If good, continue with tests. Go to Test 5.
b. No. Repair engine loss of compression.

5. Fuel System Test

1. Check fuel system and perform fuel pressure test. See Specifications.
2. Does fuel pressure meet specification?
a. Yes. Inspect and clean throttle body and repair as needed.
b. No. Inspect fuel inlet sock and fuel filter for obstruction. Inspect internal fuel hose for leaks. If no issues
are found, replace fuel pump assembly.
Table 1. Starts Hard or Emits Black Smoke Diagnostic
Faults

POSSIBLE CAUSES

Clogged air filter

Poor compression

Leaking injectors

Manifold leak

1. Air Filter Inspection

1. Inspect air filter.

2. Is air filter clean and in good condition?
a. Yes. Go to Test 2.
b. No. Replace air filter.

2. Compression Test

1. Perform compression test.

2. Is compression within normal specifications?
a. Yes. Go to Test 3.
b. No. Repair as needed.

3. Intake Leak Test

1. Perform intake leak test.

2. Did leak test pass?
a. Yes. Go to Test 4.
b. No. Repair as needed.

4. Fuel Injector Test

1. Inspect fuel injectors for mechanical failure.

2. Were any issues found?
a. Yes. Repair as needed.
b. No. Go to Test 5.

5. Throttle Cable Adjustment

1. Inspect throttle cable for correct adjustment.

2. Is throttle cable properly adjusted?
a. Yes. California models. Go to Test 6.
 b. Yes. Except California models. Perform misfire diagnostics.
c. No. Repair as needed.

6. EVAP Test

1. Inspect EVAP hose for leak.

2. Is EVAP hose in good condition?
a. Yes. Perform misfire diagnostics.
b. No. Repair as needed.
See Figure 1 and Figure 2. The starts, then stalls condition may be created by the fuel system, the idle air control system
or an ECM failure.

There may be DTCs set causing this condition. Solve the problems with the DTCs before performing the tests in this
section. The DTCs that may be involved with starts, then stalls are:

Fuel injectors: DTCs P0261, P0262 and P0264

TPS1: DTCs P0122 and P0123
ECM errors: DTCs P0603 and P0605
IAC errors: DTCs P0506 and P0507

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1 Security module [326]

2 ECM [78-2]

3 Rear lighting [7]

4 Flasher [69]

5 BAS [134]

6 Engine harness [145]

7 Starter solenoid [128]

8 ECM [78-1]

9 Security antenna [142]

10 Terminating resistor [319]

Figure 1. Under Seat: Except 750A

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1 Terminating resistor [319]

2 Left turn lamp [19]

3 LP lamp [40]

4 Right turn lamp [18]

5 Stop/tail lamp [93]

6 ECM [78-2]

7 Flasher [69]

8 BAS [134]

9 Engine harness [145]

10 P&A connector

11 Starter solenoid [128]

12 ECM [78-1]

13 Security antenna [142]

14 Security module [326]

Figure 2. Under Seat: 750A

Diagnostic Tips

The vehicle will stall if the jiffy stand is extended when the transmission is in gear.
If this condition is fuel related, perform fuel pressure test.
If vehicle stalls when shifted into gear with the jiffy stand up check JSS gap. See JSS Specifications.

Connector Information

For additional information about the connectors in the following diagram(s) and diagnostic procedure(s), see
Connector Locations.

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Figure 3. Starting Circuit
Table 1. Starts, Then Stalls Diagnostic Faults

POSSIBLE CAUSES

Fuel system malfunction

Idle air control system malfunction

1. Throttle Test

1. Will engine start with the throttle partially opened and then stall when closed?
a. Yes. See Description and Operation and perform IAC diagnostic procedure.
b. No. Go to Test 2.

2. Fuel System Test

1. Perform fuel pressure test. See Specifications.

2. Is fuel pressure normal?
a. Yes. If fuel injectors are okay, then continue with tests. Go to Test 3.
b. No. Repair fuel pressure problem.

3. ECM Connector Test

1. Turn IGN OFF.

2. Disconnect ECM [78-1] and [78-2].
3. Inspect [78-1] and [78-2].
4. Are both A and B sides of connectors good?
a. Yes. Without JSS. Perform a wiggle test. Issue may be intermittent. If no intermittent is found, replace
ECM.
b. Yes. With JSS. Go to Test 4.
c. No. Repair connectors.

4. Neutral Lamp Test

1. Verify vehicle is in neutral.

2. Turn IGN ON.
3. Is neutral lamp illuminated?
a. Yes. Go to Test 5.
b. No. See Neutral Lamp Inoperative.

5. JSS Signal Open Test

1. Disconnect JSS [133].

2. Test resistance between [201B] terminal 2 and [133B] terminal 2 (LGN/GY) wire.
3. Is resistance less than 0.5 ohm?
 a. Yes. Go to Test 6.
b. No. Repair open in (LGN/GY) wire.

6. JSS Signal Shorted High Test

1. Connect [133].
2. Connect [78-2].
3. Turn IGN ON.
4. Test voltage between [201B] terminal 1 and ground.
5. Is voltage greater than 2.5V?
a. Yes. Repair short to voltage on (LGN/GY) wire.
b. No. Replace ECM.
See Figure 1 and Figure 2. Ignition coil DTCs will set if the ignition coil primary voltage is out of range. This could occur if
there is an open coil or loss of power to the coil. If front and rear DTCs are set simultaneously, it is likely a coil power
failure or a coil failure. The coil receives power from the system relay at the same time the HO2S, purge solenoid and
injectors are activated.

Table 1. Code Description

DTC DESCRIPTION

P2300 Ignition coil driver low/open (front)

P2301 Ignition coil driver shorted high (front)

P2303 Ignition coil driver low/open (rear)

P2304 Ignition coil driver shorted high (rear)

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1 Rear injector [85]

2 TPS [88]

3 TMAP [80]

4 IAC [87]

5 Headlamp [38]

6 Ignition switch [33]

7 LH controls [24]

8 RH controls [22]

9 Fuel pump [141]

10 Front injector [84]

11 ECT [90]
 12 Ignition coil [83]

Figure 1. Under Fuel Tank Right Side

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1 Terminal A: power

2 Terminal B: ion sense

3 Terminal C: rear coil

4 Terminal D: front coil

Figure 2. Ignition Coil: Typical

Diagnostic Tips

When disconnecting any connectors always inspect connector for corrosion or backed out terminals and repair as
required.

Connector Information

For additional information about the connectors in the following diagram(s) and diagnostic procedure(s), see
Connector Locations.
 View interactive
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image

Figure 3. System Power Circuit

Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

BREAKOUT BOX HD-50390-1 1

ECM CABLE HD-50390-4 1

ECM OVERLAY HD-50390-4-P 1

Table 1. DTC P2300 Diagnostic Faults

POSSIBLE CAUSES

Ignition coil malfunction

Open or short to ground in signal circuit

Open power circuit

1. Ignition Coil Test

1. Turn IGN OFF.

2. Disconnect ignition coil [83].
3. Using TEST CONNECTOR KIT (Part Number:HD-41404), test resistance between [83A] terminals A and D.
4. Is resistance greater than 2 ohms?
a. Yes. Replace ignition coil.
b. No. Go to Test 2.

2. Input Voltage Test

1. Turn IGN ON.

2. Test voltage between [83B] terminal A (R/GN) wire and ground.
3. Is battery voltage present?
a. Yes. Go to Test 3.
b. No. Repair open on (R/GN) wire.

3. Control Wire Continuity Test

1. Turn IGN OFF.

2. Connect BREAKOUT BOX (Part Number:HD-50390-1) and ECM CABLE (Part Number:HD-50390-4)
between wiring harness [78B-1] and [78B-2] and ECM [78A-1] and [78A-2]. See How To Use Diagnostic
Tools.
3. Verify ECM OVERLAY (Part Number:HD-50390-4-P) is in position on BOB.
4. Test resistance between BOB [78-1] terminal 2 and [83B] terminal D (GN/BE) wire.
 5. Is resistance less than 0.5 ohm?
a. Yes. Go to Test 4.
b. No. Repair open in (GN/BE) wire.

4. Control Wire Shorted to Ground Test

1. Disconnect [78A-1] and [78A-2].

2. Test continuity between BOB [78-1] terminal 2 and ground.
3. Is continuity present?
a. Yes. Repair short to ground in (GN/BE) wire.
b. No. Replace ECM.
Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

Table 1. DTC P2301 Diagnostic Faults

POSSIBLE CAUSES

Short to voltage in signal circuit

1. Ignition Coil Shorted to Voltage Test

1. Turn IGN OFF.

2. Disconnect ignition coil [83].
3. Turn IGN ON.
4. Using TEST CONNECTOR KIT (Part Number:HD-41404), test voltage between [83B] terminal D (GN/BE) wire
and ground.
5. Is voltage greater than 5.0V?
a. Yes. Repair short to voltage in (GN/BE) wire.
b. No. Go to Test 2.

2. Open Test

1. Test resistance between [83A] terminals B and D.

2. Is resistance greater than 0.4 ohms?
a. Yes. Replace ECM.
b. No. Replace ignition coil.
Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

BREAKOUT BOX HD-50390-1 1

ECM CABLE HD-50390-4 1

ECM OVERLAY HD-50390-4-P 1

Table 1. DTC P2303 Diagnostic Faults

POSSIBLE CAUSES

Open or short to ground in signal circuit

Open power circuit

1. Ignition Coil Test

1. Turn IGN OFF.

2. Disconnect ignition coil [83].
3. Using TEST CONNECTOR KIT (Part Number:HD-41404), test resistance between [83A] terminals A and C.
4. Is resistance greater than 2 ohms?
a. Yes. Replace ignition coil.
b. No. Go to Test 2.

2. Input Voltage Test

1. Turn IGN ON.

2. Test voltage between [83B] terminal A (R/GN) wire and ground.
3. Is battery voltage present?
a. Yes. Go to Test 3.
b. No. Repair open in (R/GN) wire.

3. Control Wire Continuity Test

1. Turn IGN OFF.

2. Connect BREAKOUT BOX (Part Number:HD-50390-1) and ECM CABLE (Part Number:HD-50390-4)
between wiring harness [78B-1] and [78B-2] and to ECM [78A-1] and [78A-2]. See How To Use Diagnostic
Tools.
3. Verify ECM OVERLAY (Part Number:HD-50390-4-P) is in position on BOB.
4. Test resistance between BOB [78-1] terminal 1 and [83B] terminal C (GY/BE) wire.
5. Is resistance less than 0.5 ohm?
a. Yes. Go to Test 4.
 b. No. Repair open in (GY/BE) wire.

4. Control Wire Shorted to Ground Test

1. Disconnect [78A-1] and [78A-2].

2. Test continuity between BOB [78-1] terminal 1 and ground.
3. Is continuity present?
a. Yes. Repair short to ground in (GY/BE) wire.
b. No. Replace ECM.
Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

Table 1. DTC P2304 Diagnostic Faults

POSSIBLE CAUSES

Short to voltage in signal circuit

1. Ignition Coil Shorted to Voltage Test

1. Turn IGN OFF.

2. Disconnect ignition coil [83].
3. Turn IGN ON.
4. Using TEST CONNECTOR KIT (Part Number:HD-41404), test voltage between [83B] terminal C (GY/BE) wire
and ground.
5. Is voltage more than 5.0V?
a. Yes. Repair short to voltage in (GY/BE) wire.
b. No. Go to Test 2.

2. Open Test

1. Test resistance between [83A] terminals A and C.

2. Is resistance greater than 0.4 ohms?
a. Yes. Replace ECM.
b. No. Replace ignition coil.
If the starter will not crank the engine, the problem is not EFI related. See Description and Operation.

There may be DTCs associated with this problem. Check for DTCs and clear them before proceeding with this test.

NOTE

To set a CKP DTC, a start attempt must last at least five seconds.

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Figure 1. Spark Tester

Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

INLINE SPARK TESTER KIT HD-51724 1

Table 1. Engine Cranks but Will Not Start Diagnostic

Faults

POSSIBLE CAUSES

Battery voltage too low

Ignition system issues

Fuel system issues

Electrical system issues

No or low compression

Open ground circuit

1. Preliminary Engine Tests

1. Verify battery connections are in good condition.

2. Verify fuel in the tank is fresh and not contaminated.
3. Verify spark plug wires are firmly connected to the coil and plugs.
4. Verify fuel injectors are not clogged.
5. Verify BAS is not stuck in tipped position.
6. Verify battery condition. See General.
7. Does battery pass tests?
a. Yes. Go to Test 2.
b. No. Charge or replace battery.

2. Check Engine Lamp Test

1. Turn IGN ON and engine stop switch to RUN.

2. Does check engine lamp illuminate for 4 seconds immediately after key ON?
a. Yes. Go to Test 3.
b. No. See Initial Diagnostics.

3. Spark Present Test

1. Check spark plug condition. Replace if fouled.

2. Using INLINE SPARK TESTER KIT (Part Number:HD-51724), check spark at both plugs while cranking
 engine.
3. Is spark present?
a. Yes. Go to Test 5.
b. No. Go to Test 4.

4. Compression Test

1. Perform compression test.

2. Does engine pass compression test?
a. Yes. Check condition of ignition coils, coil primary wiring and spark plug boots. See Description and
Operation or Description and Operation. If good, continue with tests. Go to Test 5.
b. No. Repair engine loss of compression.

5. Fuel Pump Voltage Test

1. Disconnect fuel pump connector [141].

2. Using TEST CONNECTOR KIT (Part Number:HD-41404), test voltage between [141B] terminals 2 and 4
during the first 2-3 seconds after IGN ON.
3. Is battery voltage present?
a. Yes. Go to Test 6.
b. No. Go to Test 7.

6. Fuel System Test

1. Check fuel system and perform fuel pressure test.

2. Does fuel pressure meet specification?
a. Yes. Inspect and clean throttle body and repair as needed.
b. No. Inspect fuel inlet sock and fuel filter for obstruction. Inspect internal fuel hose for leaks. If no issues
are found, replace fuel pump assembly.

7. Fuel Pump Open Circuit Test

1. Turn IGN OFF.

2. Remove system relay.
3. Using TEST CONNECTOR KIT (Part Number:HD-41404), test resistance between [141B] terminal 4 and
[61B] terminal 4.
4. Is resistance less than 0.5 ohms?
a. Yes. Repair open in (BK) wire to ground.
b. No. Repair open in (R/GN) wire.
Misfire conditions may be caused by:

Battery condition and connections.

Fuel system problems. See Description and Operation.
Ignition system faults.

Diagnostic Tips

WARNING

Wipe up spilled fuel and dispose of rags in a suitable manner. An open spark around gasoline could cause a fire or
explosion, resulting in death or serious injury. (00518b)

When performing the steps in the diagnostic tests, use a known good part to verify whether a suspected part is
faulty.
The ignition coil does not require full installation to be functional.
Verify faulty ignition coil by performing resistance test.
Special Tools

Description Part Number Qty.

INLINE SPARK TESTER KIT HD-51724 1

See Figure 1. Using a INLINE SPARK TESTER KIT (Part Number:HD-51724) can help determine whether a problem
exists in the ignition or fuel systems.

If the test light flashes without interruption on both cylinders during the misfire event, verify spark plug condition and
gap and inspect the fuel system for proper operation.
If the test light does not flash or the flash is interrupted during the misfire event, the problem is ignition related.

1. Turn IGN OFF.

2. Remove front spark plug wire.
3. Install inline spark tester between spark plug wire and spark plug.
4. Start engine and inspect tester light. The light will flash on each spark event if power is transmitted to the plug.
5. Install and repeat procedure on rear cylinder.

NOTE

Use an inline spark tester and a load applying dynamometer to diagnose misfire under load.

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image

Figure 1. Spark Tester

Connector Information

For additional information about the connectors in the following diagram(s) and diagnostic procedure(s), see
Connector Locations.
 View interactive
View interactive image
image

Figure 2. System Power Circuit

Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

BREAKOUT BOX HD-50390-1 1

ECM CABLE HD-50390-4 1

ECM OVERLAY HD-50390-4-P 1

INLINE SPARK TESTER KIT HD-51724 1

Table 1. Misfire at Idle or Under Load Diagnostic Faults

POSSIBLE CAUSES

Loss of engine compression

Fuel system issues

Battery condition and connections

Spark plug condition

Air filter condition

Poor chassis ground connections

Performance modifications

Electrical modifications

Throttle valve malfunction

1. Power Ground Continuity Test

1. Turn IGN OFF.

2. Connect BREAKOUT BOX (Part Number:HD-50390-1) and ECM CABLE (Part Number:HD-50390-4)
between wiring harness [78B-1], [78B-2] and to ECM [78A-1] and [78A-2]. See How To Use Diagnostic
Tools.
3. Verify ECM OVERLAY (Part Number:HD-50390-4-P) is in position on BOB.
4. Using TEST CONNECTOR KIT (Part Number:HD-41404), test resistance between BOB [78-1] terminal 10
and then [78-2] terminal 10 to ground.
5. Is resistance less than 0.5 ohm on both circuits?
a. Yes. Go to Test 2.
b. No. Repair open on (BK/GN) wire.
2. Spark Test

1. Connect INLINE SPARK TESTER KIT (Part Number:HD-51724) between front spark plug cable and ground.
See How To Use Diagnostic Tools.
2. Crank engine for a few seconds.
3. Remove tester from front spark plug cable. Connect rear spark plug cable and ground.
4. Did spark jump gap on both cables?
a. Yes. Check for faulty, worn or cracked spark plugs, plug fouling due to mechanical problems or faulty
connection at plug or coils. Repair as required.
b. No. Go to Test 3.

3. Spark Plug Wire Test

1. Turn IGN OFF.

2. Disconnect spark plug cables.
3. Test resistance of both spark plug cables.
4. Is resistance within specifications? Refer to Spark Plug Specifications.
a. Yes. Go to Test 4.
b. No. Replace out of range spark plug cable.

4. Carbon Tracking Inspection Test

1. Inspect top of ignition coils for carbon tracking.

2. Is carbon tracking present?
a. Yes. Replace ignition coil.
b. No. Switch ignition coil with known good unit and perform previous test. If spark jumps gap, replace
ignition coil. If not, then continue with tests. Go to Test 5.

5. Ignition Coil Primary Wire Continuity Test

1. Disconnect ignition coil [83].

2. Disconnect system relay [61].
3. Test resistance between [61B] terminal 4 and [83B] terminal A (R/GN) wire. Wiggle connectors while
measuring.
4. Is resistance continuously less than 0.5 ohms?
a. Yes. Go to Test 6.
b. No. Repair intermittent on (R/GN) wire.

6. Battery to Main Fuse Block Voltage Drop Test

1. Start engine.
2. Test voltage drop between battery (+) and main fuse [5A] terminal 1 (R/W) wire.
3. Is voltage drop more than 1.0V?
a. Yes. Repair (R/W) wire between terminal 1 of [5A] and connection at battery including connections at
starter.
b. No. Check for corrosion or damage at system relay [61B].
Special Tools

Description Part Number Qty.

DIGITAL TECHNICIAN II HD-48650 1

The ABS module consists of an electro-hydraulic control unit (EHCU) which controls brake application under extreme
stopping conditions. The ABS only activates when wheel slip is detected.

The ABS includes the:

See Figure 1. The EHCU.

See Figure 2. Front WSS.
See Figure 2. Rear WSS.

The EHCU responds to WSS inputs. When the EHCU is activated, the solenoid valves decrease, hold or increase
hydraulic fluid pressure to control the individual calipers of each wheel to prevent wheel slipping. However, the EHCU
cannot increase hydraulic pressure beyond the pressure or force being applied to the brake pedal or lever by the rider.

View interactive
View interactive image
image

1 Neutral switch [131]

2 JSS [133]

3 CKP [79]

4 Cooling fan [97]

5 Horn [122-1]

6 Horn [122-2]

7 Front WSS [167]

8 Starter

9 VSS [65]

10 Voltage regulator [77]

 11 ABS ECU [166]

12 Oil pressure switch [120]

Figure 1. Front of Engine

ABS Brake Input Signals

The front brake switch supplies a signal to the EHCU to indicate that the front brake is applied. The rear brake switch
supplies a signal to the EHCU to indicate that the rear brake is applied.

During normal ABS operation:

A series of rapid solenoid valve pulsations may be felt in either the front brake lever or rear brake pedal but only
during initialization and anti-lock braking.
A ticking or popping noise may be heard as the solenoid valves cycle rapidly.
During anti-lock braking on dry pavement, intermittent chirping noises may be heard as the tires approach slipping.
When the EHCU is replaced, use DIGITAL TECHNICIAN II (Part Number:HD-48650) to program and bleed the
EHCU.

View interactive
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image

1 Main fuse [5]

2 DLC [91]

3 Fuse block [64]

4 Relay block [62B-2]

5 Relay block [62B-1]

6 Diode pack [201]

7 Purge solenoid [95]

8 VSS [65]

9 Ground

10 Rear WSS [168]

Figure 2. Under Right Side Cover

Pressure Hold

The EHCU controls the release and apply valves. This holds the same constant pressure on the appropriate caliper.
The EHCU will release the pressure hold in the event of wheel slip.

Pressure Decrease

Sometimes the pressure being applied to the caliper is high enough for the EHCU to detect wheel slip. To control the
wheel slip, the EHCU closes the apply valve and opens the release valve. This releases pressure on the appropriate
caliper until wheel slip is no longer detected. The excess fluid is stored in the accumulator until the pump can return
the fluid to the master cylinder or fluid reservoir.

Pressure Increase

After the wheel slip is corrected during an ABS event, a pressure increase occurs. The EHCU closes the release valve
and opens the apply valve. This increases the pressure applied to the caliper during deceleration in order to reduce
the speed of the wheel. The increased pressure will not exceed the pressure being applied to the master cylinder by
the rider.

Initialization Self-Test

The ABS module performs one initialization test each ignition cycle. As part of the initialization self-test, the ABS
module energizes the actuators and commands the motor and solenoids on and off. The ABS ECU will run this test
the first time the vehicle speed exceeds 5 km/h (3 mph) in an ignition cycle.

ABS Indicator

See Figure 3. The speedometer illuminates the ABS indicator if:

The EHCU detects an ABS disabling malfunction. The EHCU sends a message to the speedometer requesting
illumination.
The speedometer performs a lamp check.
The speedometer detects a loss of communication with the EHCU.
The ABS indicator may flash when the IGN is turned on. This will continue until the vehicle is driven to verify WSS
operation.
The EHCU sends a message to the instrument when a malfunction that disables ABS operation is detected.
Depending on the fault, the ABS indicator may stay on even after the malfunction is corrected. The indicator will not
go off until the vehicle is operated at speeds greater than 5 km/h (3 mph). It is important to verify that this is not the
cause of an ABS indicator illumination when no DTCs are set, before attempting to diagnose other possible causes.
 View interactive
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image

1 Left turn indicator

2 Neutral indicator

3 Security indicator

4 Coolant temperature

5 High beam indicator

6 Right turn indicator

7 Check engine indicator

8 Low fuel indicator

9 Trip odometer reset switch

10 Odometer

11 ABS icon indicator

12 Oil pressure indicator

Figure 3. Speedometer
See Figure 1. The EHCU is replaced as a unit. It contains the pump, valves and solenoids along with all the controlling
circuitry.

The ABS module monitors the voltage level available for system operation. A low voltage condition prevents the system
from operating properly. The ABS module also performs several self-tests for internal problems.

Table 1. Code Description

DTC DESCRIPTION

C1014 ABS ECU relay error

C1040 ABS pump/motor error

C1055 ABS ECU internal error

C1061 ABS front apply solenoid circuit open/high resistance

C1062 ABS front release solenoid circuit open/high resistance

C1065 ABS rear apply solenoid circuit open/high resistance

C1066 ABS rear release solenoid circuit open/high resistance

Conditions for Setting the DTC

These DTCs will set if one of the following conditions exists in the EHCU:

Low battery voltage.

High resistance in the ABS power or ground circuits.
EHCU malfunction.

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image

1 Neutral switch [131]

2 JSS [133]

3 CKP [79]

4 Cooling fan [97]

 5 Horn [122-1]

6 Horn [122-2]

7 Front WSS [167]

8 Starter

9 VSS [65]

10 Voltage regulator [77]

11 ABS ECU [166]

12 Oil pressure switch [120]

Figure 1. Front of Engine

Action Taken When the DTC Sets

ABS is disabled.
The ABS indicator is illuminated.

Diagnostic Tips

If improper voltage is supplied to the EHCU, these codes may set. Using an improper or high voltage charger may
cause these codes to inadvertently set when there is nothing wrong with the ABS system.

Connector Information

For additional information about the connectors in the following diagram(s) and diagnostic procedure(s), see
Connector Locations.
 View interactive
View interactive image
image

Figure 2. ABS Schematic

Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

BREAKOUT BOX HD-50390-1 1

ABS OVERLAY HD-50390-1-P1 1

ABS CABLE HD-50390-6 1

Table 1. DTC C1014, C1040, C1055, C1061, C1062, C1065,

C1066 Diagnostic Faults

POSSIBLE CAUSES

High resistance in the ABS power or ground circuits

Low battery voltage

1. Battery Voltage Test

1. Turn IGN OFF.

2. Verify battery terminals are properly connected, tightened and clean.
3. Connect BREAKOUT BOX (Part Number:HD-50390-1) and ABS CABLE (Part Number:HD-50390-6) to
wiring harness [166B], leaving EHCU [166A] disconnected. See How To Use Diagnostic Tools.
4. Verify ABS OVERLAY (Part Number:HD-50390-1-P1) is in position on BOB.
5. Turn IGN ON.
6. Using TEST CONNECTOR KIT (Part Number:HD-41404), test voltage between BOB terminal 9 and ground.
7. Test voltage between BOB terminal 18 and ground.
8. Is voltage between 10.5-16.0V on both circuits?
a. Yes. Go to Test 2.
b. No. Go to Test 4.

2. Ground Circuit Resistance Test

1. Turn IGN OFF.

2. Test resistance between BOB terminal 1 and ground.
3. Test resistance between BOB terminal 10 and ground.
4. Is resistance less than 0.5 ohms on both circuits?
a. Yes. Go to Test 3.
b. No. Repair high resistance or open condition on ground circuit.

3. ABS ECU DTC Test

1. Connect EHCU [166].

2. Clear DTCs.
 3. Turn IGN ON.
4. Check DTCs.
5. Do any of the following DTCs reset: C1014, C1040, C1055, C1061, C1062, C1065, C1066?
a. Yes. Replace EHCU.
b. No. System working properly.

4. Battery Power Open Test

1. Turn IGN OFF.

2. Remove main fuse [5B].
3. Test resistance between BOB terminal 9 and [5B] socket terminal 2 (R) wire.
4. Test resistance between BOB terminal 18 and [5B] socket terminal 2 (R) wire.
5. Is resistance less than 0.5 ohms on both circuits?
a. Yes. Inspect battery and charging system. See Description and Operation.
b. No. Repair open in (R) wire.
See Figure 1 and Figure 2. The active WSS is supplied system voltage from the EHCU. The sensor returns a 7mA or
14mA signal back to the EHCU.

Front WSS high circuit: The EHCU monitors ignition voltage from terminal 12 of the EHCU through terminal 1 of the
front WSS.
Front WSS low circuit: The EHCU monitors the signal from terminal 2 of the front WSS through terminal 3 of the ABS
ECU.
Rear WSS high circuit: The EHCU monitors ignition voltage from terminal 13 of the EHCU through terminal 1 of the
rear WSS.
Rear WSS low circuit: The EHCU monitors the frequency signal from terminal 2 of the rear WSS through terminal 14
of the EHCU.

Table 1. Code Description

DTC DESCRIPTION

C1021 ABS front WSS always zero

C1023 ABS rear WSS always zero

C1025 ABS front wheel speed intermittent

C1027 ABS rear wheel speed intermittent

C1029 ABS wheel speed difference too high

C1032 ABS front wheel speed circuit open/shorted

C1034 ABS rear wheel speed circuit open/shorted

View interactive
View interactive image
image

1 Neutral switch [131]

2 JSS [133]

3 CKP [79]

4 Cooling fan [97]

 5 Horn [122-1]

6 Horn [122-2]

7 Front WSS [167]

8 Starter

9 VSS [65]

10 Voltage regulator [77]

11 ABS ECU [166]

12 Oil pressure switch [120]

Figure 1. Front of Engine

View interactive
View interactive image
image

1 Main fuse [5]

2 DLC [91]

3 Fuse block [64]

4 Relay block [62B-2]

5 Relay block [62B-1]

6 Diode pack [201]

7 Purge solenoid [95]

8 VSS [65]

9 Ground

10 Rear WSS [168]

Figure 2. Under Right Side Cover

Conditions for Setting the DTC

DTC C1021, C1023, C1025, C1027 or C1029 can set if the following conditions exist in the WSS circuit:

Interference on the WSS circuit.

Dynamometer testing.
WSS malfunction.
ABS ECU malfunction.
Incorrect or worn bearing assembly.
Mismatched or improperly sized tires.
Worn suspension components.
Riding over rough terrain.
External or internal wheel speed circuit intermittent open.
Electrical noise on the WSS wires.
DTC C1032 can set if one of the following conditions exist in the front high or low WSS circuit:

Short to ground, short to battery, open or high resistance in the front high or low WSS circuits.
WSS malfunction.
ABS ECU malfunction.
DTC C1034 can set if one of the following conditions exist in the rear high or low WSS circuit:

Short to ground, short to battery, open or high resistance in the rear high or low WSS circuits.
WSS malfunction.
ABS ECU malfunction.

Action Taken When the DTC Sets

ABS is disabled.
The ABS indicator is illuminated.

Diagnostic Tips

All the DTCs that set in this diagnostic are related to terminals 1 and 2 of the WSS, either internally in the EHCU or
WSS, or externally in the wire or connectors. If a DTC is intermittent, it may be a connection problem from terminal 1
or 2 of the WSS to the harness wiring.

Check for these issues prior to part replacement:

A correctly installed ABS wheel bearing will have a tan seal facing outward.
If the red seal is showing, the bearing is installed backward.
If the seal is black, it is a non-ABS bearing and should be replaced with the correct bearing.
Open in WSS circuit.
WSS circuit short to voltage.
Short to ground in WSS circuit.
Short between WSS circuits.
External or internal wheel speed circuit intermittent open.
ABS module malfunction.

Connector Information

For additional information about the connectors in the following diagram(s) and diagnostic procedure(s), see
Connector Locations.
 View interactive
View interactive image
image

Figure 3. Wheel Speed Sensor Circuits

Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

BREAKOUT BOX HD-50390-1 1

ABS OVERLAY HD-50390-1-P1 1

ABS CABLE HD-50390-6 1

Table 1. DTC C1021, C1023, C1025, C1027, C1029 Diagnostic

Faults

POSSIBLE CAUSES

Electrical interference

Poor connections

WSS malfunction

Worn bearing assembly

1. Electrical Interference Test

1. Inspect vehicle for accessories that may cause electrical interference with the wheel speed sensors.
2. Electrical interference present?
a. Yes. Remove or relocate interference.
b. No.

2. Validation of Current DTC Test

1. Clear DTC.
2. Operate vehicle above 5 km/h (3 mph) for at least 90 seconds.
3. Check DTCs.
4. Did DTC reset?
a. Yes.
b. No. See diagnostic tips.

3. Worn or Damaged Components Test

1. Inspect for worn, damaged or incorrect bearing assembly.

NOTE

A correctly installed ABS wheel bearing will have a tan seal facing outward.
 If the seal is red, the bearing is installed backward.

If the seal is black, it is a non-ABS bearing and should be replaced with the correct bearing.

2. Were worn, damaged or incorrect components found?

a. Yes. Repair as needed.
b. No.

4. Front Short to Voltage Test

1. Turn IGN OFF.

2. Disconnect front WSS [167].
3. Connect BREAKOUT BOX (Part Number:HD-50390-1) and ABS CABLE (Part Number:HD-50390-6) to
wiring harness [166B], leaving EHCU [166A] disconnected. See How To Use Diagnostic Tools.
4. Verify ABS OVERLAY (Part Number:HD-50390-1-P1) is in position on BOB.
5. Turn IGN ON.
6. Using TEST CONNECTOR KIT (Part Number:HD-41404), test voltage between BOB terminal 12 and ground.
7. Is voltage greater than 1.0V?
a. Yes. Repair short to voltage on (O/BE) wire.
b. No.

5. Rear Short to Voltage Test

1. Turn IGN OFF.

2. Disconnect rear WSS [168].
3. Turn IGN ON.
4. Test voltage between BOB terminal 13 and ground.
5. Is voltage greater than 1.0V?
a. Yes. Repair short to voltage on (O/PK) wire.
b. No.

6. Circuit Test

1. Inspect WSS connector for proper fit and damage.

2. Is WSS connector secure and in good condition?
a. Yes. Replace with appropriate bearing assembly and WSS and retest. If code comes back during retest
replace ABS module.
b. No. Repair or replace WSS connector.
Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

WHEEL SPEED SENSOR TEST HD-50341 1

LEAD

BREAKOUT BOX HD-50390-1 1

ABS OVERLAY HD-50390-1-P1 1

ABS CABLE HD-50390-6 1

Table 1. DTC C1032 Diagnostic Faults

POSSIBLE CAUSES

WSS malfunction

Intermittent open in the front high or low WSS circuits

Short to ground, short to battery, open or high resistance in

the front WSS circuits

1. Electrical Interference Test

1. Inspect vehicle for accessories that may cause electrical interference with the WSS.
2. Inspect front wheel bearing.
3. Is electrical interference or wheel bearing malfunction present?
a. Yes. Remove or relocate interference or correct wheel bearing issues.
b. No. Go to Test 2.

2. Loose or Damaged Connections Test

1. Turn IGN OFF.

2. Inspect for loose or damaged connections on front WSS circuits.
3. Were poor connections found?
a. Yes. Repair connections and circuits.
b. No. Go to Test 3.

3. Front WSS Test

1. Turn IGN OFF.

2. Disconnect front WSS [167].
3. Connect WHEEL SPEED SENSOR TEST LEAD (Part Number:HD-50341) between [167B] terminals 1 and 2.
See How To Use Diagnostic Tools.
 4. Clear DTCs.
5. Cycle IGN OFF, ON, wait 10 seconds for ABS to complete initialization test.
6. Check DTCs.
7. Did DTC reset?
a. Yes. Go to Test 4.
b. No. Replace front WSS.

4. (O/BK) Open Test

1. Turn IGN OFF.

2. Connect BREAKOUT BOX (Part Number:HD-50390-1) and ABS CABLE (Part Number:HD-50390-6)
between wire harness [166B], leaving ABS module [166A] disconnected. See How To Use Diagnostic Tools.
3. Verify ABS OVERLAY (Part Number:HD-50390-1-P1) is in position on BOB.
4. Remove sensor test lead.
5. Using TEST CONNECTOR KIT (Part Number:HD-41404), test resistance between BOB terminal 3 and [167B]
terminal 2 (O/BK) wire.
6. Is resistance less than 0.5 ohm?
a. Yes. Go to Test 5.
b. No. Repair open in (O/BK) wire.

5. (O/BE) Open Test

1. Test resistance between BOB terminal 12 and [167B] terminal 1 (O/BE) wire.
2. Is resistance less than 0.5 ohm?
a. Yes. Go to Test 6.
b. No. Repair open in (O/BE) wire.

6. Shorted Wires Test

1. Test continuity between BOB terminals 3 and 12.

2. Is continuity present?
a. Yes. Repair short between (O/BE) and (O/BK) wires.
b. No. Go to Test 7.

7. (O/BK) Ground Test

1. Test continuity between BOB terminal 3 and ground.

2. Is continuity present?
a. Yes. Repair short to ground on (O/BK) wire.
b. No. Go to Test 8.

8. (O/BE) Ground Test

1. Test continuity between BOB terminal 12 and ground.

2. Is continuity present?
a. Yes. Repair short to ground on (O/BE) wire.
 b. No. Go to Test 9.

9. (O/BK) Voltage Test

1. Turn IGN ON.

2. Test voltage between BOB terminal 3 and ground.
3. Is voltage present?
a. Yes. Repair short to voltage on (O/BK) wire.
b. No. Replace ABS module.
Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

WHEEL SPEED SENSOR TEST HD-50341 1

LEAD

BREAKOUT BOX HD-50390-1 1

ABS OVERLAY HD-50390-1-P1 1

ABS CABLE HD-50390-6 1

Table 1. DTC C1034 Diagnostic Faults

POSSIBLE CAUSES

WSS malfunction

Intermittent open in the rear high or low WSS circuits

Short to ground, short to battery, open or high resistance in

the rear WSS circuits

1. Electrical Interference Test

1. Inspect vehicle for accessories that may cause electrical interference with the WSS.
2. Inspect rear wheel bearing.
3. Is electrical interference or wheel bearing malfunction present?
a. Yes. Remove or relocate interference or correct wheel bearing issues.
b. No. Go to Test 2.

2. Loose or Damaged Connections Test

1. Inspect for loose or damaged connections on rear WSS circuits.

2. Were poor connections found?
a. Yes. Repair connections and circuits.
b. No. Go to Test 3.

3. Rear WSS Test

1. Turn IGN OFF.

2. Disconnect rear WSS [168].
3. Connect WHEEL SPEED SENSOR TEST LEAD (Part Number:HD-50341) between [168B] terminals 1 and 2.
See How To Use Diagnostic Tools.
4. Clear DTCs.
 5. Cycle IGN OFF, ON, wait 10 seconds for ABS to complete initialization test.
6. Check DTCs.
7. Did DTC reset?
a. Yes. Go to Test 4.
b. No. Replace rear WSS.

4. (O/BN) Open Test

1. Turn IGN OFF.

2. Connect BREAKOUT BOX (Part Number:HD-50390-1) and ABS CABLE (Part Number:HD-50390-6)
between wire harness [166B], leaving ABS module [166A] disconnected. See How To Use Diagnostic Tools.
3. Verify ABS OVERLAY (Part Number:HD-50390-1-P1) is in position on BOB.
4. Remove sensor test lead.
5. Using TEST CONNECTOR KIT (Part Number:HD-41404), test resistance between BOB terminal 14 and
[168B] terminal 2 (O/BN) wire.
6. Is resistance less than .5 ohm?
a. Yes. Go to Test 5.
b. No. Repair open in (O/BN) wire.

5. (O/PK) Open Test

1. Test resistance between BOB terminal 13 and [168B] terminal 1 (O/PK) wire.
2. Is resistance less than .5 ohm?
a. Yes. Go to Test 6.
b. No. Repair open in (O/PK) wire.

6. Shorted Wires Test

1. Test continuity between BOB terminals 14 and 13.

2. Is continuity present?
a. Yes. Repair short between (O/BN) and (O/PK) wires.
b. No. Go to Test 7.

7. (O/BN) Ground Test

1. Test continuity between BOB terminal 14 and ground.

2. Is continuity present?
a. Yes. Repair short to ground on (O/BN) wire.
b. No. Go to Test 8.

8. (O/PK) Ground Test

1. Test continuity between BOB terminal 13 and ground.

2. Is continuity present?
a. Yes. Repair short to ground on (O/PK) wire.
b. No. Go to Test 9.
9. (O/BN) Voltage Test

1. Turn IGN ON.

2. Test voltage between BOB terminal 14 and ground.
3. Is voltage present?
a. Yes. Repair short to voltage on (O/BN) wire.
b. No. Replace ABS module.
See Figure 1 , Figure 2 and Figure 3. The ABS module monitors the front and rear brake switch inputs through terminal 6
and terminal 7. This allows the ABS to determine if the brake is being applied or not when a wheel is decelerating.

When the brake lever or pedal is applied, the ABS module receives voltage on the front or rear brake switch circuit. The
ABS module uses this signal to enhance ABS operation.

Table 1. Code Description

DTC DESCRIPTION

C1094 Front/rear brake applied without decel

C1212 Front/rear brake not applied with decel

View interactive
View interactive image
image

1 Neutral switch [131]

2 JSS [133]

3 CKP [79]

4 Cooling fan [97]

5 Horn [122-1]

6 Horn [122-2]

7 Front WSS [167]

8 Starter

9 VSS [65]

10 Voltage regulator [77]

11 ABS ECU [166]

12 Oil pressure switch [120]

Figure 1. Front of Engine

View interactive
View interactive image
image

1 Clutch switch [314]

2 Front stop lamp switch [170]

Figure 2. Hand Controls

View interactive
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image

1 Rear lighting [7]

2 Behind right cover

3 Under fuel tank

4 Clutch switch [314]

5 Front stop lamp switch [170]

6 Speedometer [39]

7 Front of engine

8 Front HO2S [138]

9 Rear stop lamp switch [121-1]

 10 Rear stop lamp switch [121-2]

Figure 3. Frame Right Side

Conditions for Setting the DTC

DTC C1094 can set if the following conditions exist:

The front or rear brake is applied.

Vehicle speed faster than 40 km/h (25 mph).
The vehicle acceleration exceeds 8 km/h (5 mph) per second
DTC C1212 can set if the following conditions exist:

The front or rear brake is not applied.

Vehicle speed faster than 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).

Action Taken When the DTC Sets

No action is taken when these codes are set. The ABS indicator does not illuminate and the ABS is still active.

Connector Information

For additional information about the connectors in the following diagram(s) and diagnostic procedure(s), see
Connector Locations.
 View interactive
View interactive image
image

Figure 4. ABS Schematic

Table 1. DTC C1094 Diagnostic Faults

POSSIBLE CAUSES

Front/rear brake lamp switch input shorted to voltage

Front/rear brake lamp switch malfunction

1. Validation Test

1. Clear DTCs.
2. Operate the vehicle at speed faster than 40 km/h (25 mph).
3. Check for DTCs.
4. Did the DTC set?
a. Yes. Go to Test 2.
b. No. System operating properly.

2. Stop Lamp Test

1. Turn IGN ON.

2. Observe stop lamp.
3. Is stop lamp illuminated?
a. Yes. See Stop Lamp Always On.
b. No. Replace ABS EHCU.
Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

BREAKOUT BOX HD-50390-1 1

ABS OVERLAY HD-50390-1-P1 1

ABS CABLE HD-50390-6 1

Table 1. DTC C1212 Diagnostic Faults

POSSIBLE CAUSES

Front/rear brake lamp switch input open

Front/rear brake lamp switch malfunction

1. Stop Lamp Test

1. Turn IGN ON.

2. Observe stop lamp.
3. Apply front and rear brakes.
4. Is stop lamp illuminated?
a. Yes. Go to Test 2.
b. No. See Stop Lamp Inoperative.

2. Rear Brake Switch Input Test

1. Turn IGN OFF.

2. Connect BREAKOUT BOX (Part Number:HD-50390-1) and ABS CABLE (Part Number:HD-50390-6) to
wiring harness [166B], leaving EHCU [166A] disconnected. See How To Use Diagnostic Tools.
3. Verify ABS OVERLAY (Part Number:HD-50390-1-P1) is in position on BOB.
4. Disconnect rear stop lamp switch [121B-1].
5. Using TEST CONNECTOR KIT (Part Number:HD-41404), test resistance between BOB terminal 7 and [121B-
1].
6. Is resistance less than 0.5 ohm?
a. Yes. Go to Test 2.
b. No. Repair open in (BE/R) wire.

3. Front Brake Switch Input Test

1. Disconnect front stop lamp switch [170B-2].

2. Test resistance between BOB terminal 6 and [170B-2].
3. Is resistance less than 0.5 ohm?
a. Yes. Replace ABS EHCU.
b. No. Repair open in (BE/R) wire.
Special Tools

Description Part Number Qty.

DIGITAL TECHNICIAN II HD-48650 1

The EHCU is calibrated to maximize ABS performance. If the correct calibration is not in the module the ABS may not
perform correctly. The ECM and ABS modules also compare VINs to verify the correct ABS module is installed. These
VINs must match before the ABS will operate properly.

Table 1. Code Description

DTC DESCRIPTION

C1159 ABS invalid stored VIN

C1178 ABS no VIN received from ECM

C1184 ABS invalid VIN from ECM

Conditions for Setting the DTC

The ABS module determines final calibration is not completed or that the VIN does not match calibration.

Action Taken When the DTC Sets

ABS is disabled.
The ABS indicator is illuminated.

Diagnostic Tips

These codes will usually appear after replacing the ECM or the EHCU. The new modules must be programmed using
DIGITAL TECHNICIAN II (Part Number:HD-48650). After the parts are programmed and matched correctly for the
specific vehicle, clear the codes.
Special Tools

Description Part Number Qty.

DIGITAL TECHNICIAN II HD-48650 1

Table 1. DTC C1159, C1178, C1184 Diagnostic Faults

POSSIBLE CAUSES

An EHCU that is not calibrated correctly or has an internal

fault

ECM VIN does not match ABS

1. Validation of Current DTC Test

1. Clear DTC.
2. Start engine, wait 10 seconds for ABS to complete initialization test.
3. Turn engine off.

NOTE

If more than one DTC resets, make sure to diagnose the DTC with the higher priority first. Refer to Diagnostics.

4. Check DTCs.
5. Did DTC reset?
a. Yes. Go to Test 2.
b. No. See diagnostic tips.

2. Successful Calibration Test

1. Using DIGITAL TECHNICIAN II (Part Number:HD-48650), attempt to calibrate the EHCU using the ABS
service feature found in Vehicle Set Up.
2. Clear DTCs.
3. Turn IGN ON.
4. Check DTCs.
5. Did DTC reset?
a. Yes. Go to Test 3.
b. No. Calibration complete.

3. Speedometer Test

1. Cycle IGN OFF and ON.

2. Does speedometer display "VINERR"?
a. Yes. Replace ECM.
b. No. Replace EHCU.
See Figure 1. The ABS module sends a message on the CAN bus to the speedometer in order to command the indicator
ON or OFF.

The ABS indicator will normally come on and then begin to flash when the vehicle is turned ON. It will continue to flash until
the EHCU sees at least 5 km/h (3 mph) from both WSS to verify proper operation.

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1 Left turn indicator

2 Neutral indicator

3 Security indicator

4 Coolant temperature

5 High beam indicator

6 Right turn indicator

7 Check engine indicator

8 Low fuel indicator

9 Trip odometer reset switch

10 Odometer

11 ABS icon indicator

12 Oil pressure indicator

Figure 1. Speedometer

Diagnostic Tips
The malfunction must be present during diagnosis in order to prevent unnecessary parts replacement.

Connector Information

For additional information about the connectors in the following diagram(s) and diagnostic procedure(s), see
Connector Locations.

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Figure 2. ABS Schematic

Table 1. ABS Indicator Continuously Flashing, No DTCs
Diagnostic Faults

POSSIBLE CAUSES

Incorrect wheel bearing

Bearing not properly installed

Damaged wheel bearing

1. DTC Test

1. Verify vehicle is equipped with ABS and has appropriate speedometer.

2. Clear DTCs.
3. Turn IGN OFF.
4. Check DTCs.
5. Did DTCs set?
a. Yes. See appropriate diagnostic procedure.
b. No. Go to Test 2.

2. Wheel Bearing Inspection Test

1. Inspect for worn, damaged or incorrect bearing assembly on the front wheel.

NOTE

A correctly installed ABS wheel bearing will have a tan seal facing outward.
If the seal is red, the bearing is installed backward.

If the seal is black, it is a non-ABS bearing and should be replaced with the correct bearing.

2. Inspect for worn, damaged or incorrect bearing assembly on both wheels.

3. Were worn, damaged or incorrect components found on either wheel?
a. Yes. Repair wheel bearing as needed.
b. No. System working properly.
Special Tools

Description Part Number Qty.

TEST CONNECTOR KIT HD-41404 1

BREAKOUT BOX HD-42682 1

JUMPER HARNESS HD-45325 1

BREAKOUT BOX HD-50390-1 1

ABS OVERLAY HD-50390-1-P1 1

ABS CABLE HD-50390-6 1

Table 1. ABS Indicator Always On or Inoperative Diagnostic

Faults

POSSIBLE CAUSES

Open battery circuit

Open ground circuit

Short to ground in battery circuit

1. DTC Test

1. Verify vehicle is equipped with ABS and has appropriate speedometer.

2. Clear DTCs.
3. Turn IGN OFF.
4. Check DTCs.
5. Did DTCs set?
a. Yes. See appropriate diagnostic procedure.
b. No. Go to Test 2.

2. ABS Lamp Function Test

1. Perform a "WOW" test. See Description and Operation.

2. Does ABS lamp function properly during the "WOW" test?
a. Yes. Go to Test 3.
b. No. Replace speedometer.

3. CAN High Circuit Continuity Test

1. Turn IGN OFF.

2. Connect BREAKOUT BOX (Part Number:HD-50390-1) and ABS CABLE (Part Number:HD-50390-6) to
 wiring harness [166B], leaving ABS module [166A] disconnected. See How To Use Diagnostic Tools.
3. Verify ABS OVERLAY (Part Number:HD-50390-1-P1) is in position on BOB.
4. Connect BREAKOUT BOX (Part Number:HD-42682) and JUMPER HARNESS (Part Number:HD-45325)
between wire harness [39B] and speedometer [39A]. See How To Use Diagnostic Tools.
5. Using TEST CONNECTOR KIT (Part Number:HD-41404), test resistance between ABS BOB terminal 2 and
speedometer BOB terminal 2.
6. Is resistance less than 0.5 ohm?
a. Yes. Go to Test 4.
b. No. Repair open in (W/R) wire.

4. CAN Low Circuit Continuity Test

1. Turn IGN OFF.

2. Test resistance between ABS BOB terminal 11 and speedometer BOB terminal 8.
3. Is resistance less than 0.5 ohm?
a. Yes. Go to Test 5.
b. No. Repair open in (W/BK) wire.

5. ABS Power Circuit Test

1. Turn IGN ON.

2. Test voltage between ABS BOB terminal 9 and ground.
3. Test voltage between ABS BOB terminal 18 and ground.
4. Is battery voltage present on both circuits?
a. Yes. Go to Test 6.
b. No. Repair open in ABS module battery circuit.

6. ABS Ground Circuit Test

1. Turn IGN OFF.

2. Test resistance between ABS BOB terminal 1 and ground.
3. Is resistance less than 0.5 ohm?
a. Yes. Go to Test 7.
b. No. Repair open in (BK) wire.

7. ABS Switched Power Circuit Test

1. Turn IGN ON.

2. Test voltage between ABS BOB terminal 4 to ground.
3. Is battery voltage present?
a. Yes. Go to Test 8.
b. No. Repair open in (V/GY) wire.

8. ABS ECU Test

1. Remove ABS BOB and connect [166].

2. Remove speedometer BOB and connect [39].
3. Clear DTCs.
4. Start vehicle. Operate in the parameters for initialization self-test.
5. Turn IGN OFF.
6. Check DTCs.
7. Did DTC reset?
a. Yes. Replace EHCU.
b. No. Concern is intermittent. See Wiggle Test.
Wire Color Codes

Wire traces on wiring diagrams are labeled with alpha codes. Refer to Table 1.

For Solid Color Wires: See Figure 1. The alpha code identifies wire color.

For Striped Wires: The code is written with a slash (/) between the solid color code and the stripe code. For example,
a trace labeled GN/Y is a green wire with a yellow stripe.

Wiring Diagram Symbols

See Figure 1. On wiring diagrams and in service/repair instructions, connectors are identified by a number in brackets
[ ]. The letter inside the brackets identifies whether the housing is a socket or pin housing.

A=Pin: The letter A and the pin symbol after a connector number identifies the pin side of the terminal connectors.

B=Socket: The letter B and the socket symbol after a connector number identifies the socket side of the terminal
connectors. Other symbols found on the wiring diagrams include the following:

Diode: The diode allows current flow in one direction only in a circuit.

Wire break: The wire breaks are used to show option variances or page breaks.

No Connection: Two wires crossing over each other in a wiring diagram that are shown with no splice indicating they
are not connected together.

Circuit to/from: This symbol indicates a more complete circuit diagram on another page. The symbol is also
identifying the direction of current flow.

Splice: Splices are where two or more wires are connected together along a wiring diagram. The indication of a splice
only indicates that wires are spliced to that circuit. It is not the true location of the splice in the wiring harness.

Ground: Grounds can be classified as either clean or dirty grounds. Clean grounds are identified by a (BK/GN) wire
and are normally used for sensors or modules.

NOTE

Clean grounds usually do not have electric motors, coils or anything that may cause electrical interference on the
ground circuit.

Dirty grounds are identified by a (BK) wire and are used for components that are not as sensitive to electrical
interference.

Twisted pair: This symbol indicates the two wires are twisted together in the harness. This minimizes the circuit's
electromagnetic interference from external sources. If repairs are necessary to these wires they should remain as
twisted wires.
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1 Connector number

2 Terminal code (A=pin, B=socket)

3 Solid wire color

4 Striped wire color

5 Socket symbol

6 Pin symbol

7 Diode

8 Wire break

9 No connection

10 Circuit to/from

11 Splice

12 Ground

13 Twisted pair

Figure 1. Connector/Wiring Diagram Symbols

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1 Fuse block [64]

2 Accessory fuse

3 Fan fuse

4 Ignition fuse

5 Lights/instrument fuse

6 Lights fuse

7 Fuel pump fuse

8 P&A ACC fuse [750A]

9 Security fuse

10 Battery fuse

11 Relay block [61]

12 Start relay

13 Fan relay

14 System relay

15 Ignition relay

16 Relay block [62]

Figure 2. Fuse Block and Socket Terminals

Table 1. Wire Color Codes

ALPHA CODE WIRE COLOR

BE Blue

BK Black

BN Brown

GN Green

GY Gray

LBE Light Blue

LGN Light Green

O Orange

PK Pink

R Red

TN Tan

V Violet

W White

Y Yellow
Refer to the table below for wiring diagram information.

WIRING DIAGRAM LIST

FIGURE   NUMBER

IGN and ACC Figure 1.

Grounds Figure 2.

Lighting and Hand Controls: 2018 Street Figure 3.

Main Harness (1 of 3): 2018 Street Figure 4.

Main Harness (2 of 3): 2018 Street Figure 5.

Main Harness (3 of 3) (750A): 2018 Street Figure 6.

Main Harness (3 of 3) (except 750A): 2018 Street Figure 7.

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Figure 1. IGN and ACC

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Figure 2. Grounds
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Figure 3. Lighting and Hand Controls: 2018 Street

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Figure 4. Main Harness (1 of 3): 2018 Street

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Figure 5. Main Harness (2 of 3): 2018 Street

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Figure 6. Main Harness (3 of 3) (750A): 2018 Street

Main Harness (3 of 3) (except 750A): 2018 Street
Function/Location

All vehicle connectors are identified by their function and location. Refer to Table 1.

Place and Color

The place (number of wire cavities of a connector housing) and color of the connector can also aid identification.

Connector Number

On wiring diagrams and in service instructions, connectors are identified by a number in brackets.

Repair Instructions

The repair instructions in Appendix B of the electrical diagnostic manual (EDM) are by connector type. Refer to Table
1.

Table 1. Connector Locations

NO. DESCRIPTION TYPE TERMINAL LOCATION

PROBE
COLOR

[5] Main fuse 2-place Sumitomo Housing, Gray Under right side cover
Unsealed (Y)

[7] Rear lighting 6-Place Sumitomo MT series, Purple Under seat

Unsealed (W)

[18] Right rear turn 2-Place Sumitomo MTW Purple Under passenger seat
lamp series, Unsealed (W) (750) Yellow
2-place JAE MX19 (750A)

[19] Left rear turn lamp 2-Place Sumitomo MTW Purple Under passenger seat
series, Unsealed (R) (750) Yellow
2-place JAE MX19 (750A)

[22] Right hand 4-Place Sumitomo MTL series, Purple Right side under fuel tank
controls Unsealed (BK)

[24] Left hand controls 9-Place Sumitomo MTL series, Purple Right side under fuel tank
Unsealed (BK)

[31L] Left front turn 3-Place Sumitomo MTW Purple Right side under fuel tank
signals series, Unsealed (BK)

[31R] Right front turn 3-Place Sumitomo MTW Purple Right side under fuel tank
signals series, Unsealed (BK)

[33] Ignition switch 4-Place Sumitomo MTW Purple Right side under fuel tank
series, Unsealed (BK)
 [38] Headlamp 4-Place Sumitomo MT series, Purple [38A] Right side under fuel tank
Unsealed (BK) Gray [38B]

[38-2] Headlamp 3-Place Tyco Positive Lock Purple Inside headlamp nacelle

[39] Speedometer 12-place Delphi Micro 64 BOB Back of speedometer

Sealed (GY)

[40] LP lamp 2-Place Sumitomo MTW Purple Under passenger seat

series, Unsealed (BK) (750) Yellow
2-place JAE MX19 (750A)

[47] Voltage regulator 3-Place Furukawa QLW series, Red Back of voltage regulator
to stator Sealed (GY)

[61] Relay block 1 10-place Sumitomo Housing, Blue Under right side cover
Unsealed (BK)

[62] Relay block 2 10-place Sumitomo Housing, Blue Under right side cover
Unsealed (BK)

[64] Fuse block 18-place Tyco JPT Power Purple Under right side cover
Timer series, Unsealed (BK)

[65] VSS 3-Place Sumitomo MT series Gray Left rear of transmission

(BK) case

[69] Flasher 2-Place Sumitomo .250, Red Under seat

Unsealed (BK) (750) Purple
3-place Sumitomo MTW 110
Unsealed (750A)

[77] Voltage regulator 3-Place Furukawa QLW series, Red Back of voltage regulator
Sealed (BK)

[78-1] ECM GET 64 sealed Breakout Box Under passenger seat

[78-2] ECM GET 64 sealed Breakout Box Under passenger seat

[79] CKP sensor 2-Place Sumitomo MT series Purple [79A] Under left crankcase
Unsealed (W) Gray [79B] cover

[80] TMAP sensor 4-Place MTA Compact 1.1M Gray Induction module
Sealed (BK)

[83] Ignition coil 4-Place Delphi GT 150 series, Gray Left side of engine
Sealed (BK)

[84] Front fuel injector 2-place Delphi GT150 Sealed Gray Between cylinders
(BK)

[85] Rear fuel injector 2-place Delphi GT150 Sealed Gray Between cylinders
(BK)

[87] IAC 4-place Delphi GT 150 Sealed Gray Between cylinders right
(BK) side
 [88] TPS SSD series, Sealed Gray Between cylinders right
side

[90] ECT sensor 2-Place Sumitomo MT Series, Gray Between cylinders left
Sealed (BE) side

[91] DLC 6-Place Deutsch DT Sealed Black Under right side cover
(GY)

[93] Stop/tail lamp 3-Place Sumitomo MTW Purple Under passenger seat
series, Unsealed (BK) (750) Yellow
4-place JAE MX19 (750A)

[95] Purge solenoid 2-place Delphi 150 Metri-Pack Gray In front of battery
Sealed (R)

[97] Cooling fan 2-place Tyco 070 Multilock Gray Right frame tube below
(BK) fan

[120] Oil pressure switch 2-place Tyco Timer series Purple Bottom front crankcase
Sealed (BK) left side

[121] Rear stop lamp Tyco Insulated Spade Red Right side next to rear
switch terminals (BK) fork pivot

[122] Horn Flag terminals (BK) Red Left side by front cylinder

[128] Start solenoid 2-place Sumitomo MTL series, Gray Under seat
Unsealed (BK)

[131] Neutral switch Right angle push on molded Red Bottom front of engine
terminal Yazaki (BK) next to left frame tube

[133] JSS (HDI) 3-Place Molex MX150 series Gray Front lower left frame
Sealed (GY) tube

[134] BAS 3-Place Sumitomo MT series Purple [134A] Under seat

(W) Gray [134B]

[137] Rear HO2S 4-place Molex MX 150 Sealed Gray Under left side cover
(BK)

[138] Front HO2S 4-place Molex MX 150 Sealed Gray Rear of engine right side
(GY)

[141] Fuel pump 4-Place Tyco Superseal Gray Under left side of fuel tank
Sealed (BK)

[142B] Security siren 3-way Delphi GT 150 3.5 Gray Under left side cover
behind coolant reservoir

[145] Engine harness 16-Place Sumitomo DL series Gray Under seat

Sealed (GY)

[166] ABS 18-place Tyco MCP Sealed Breakout Box Under radiator inside left
(BK) frame tube
 [167] FWSS 2-place Deutch DTM Brown Inside left frame tube
midway up radiator

[168] RWSS 2-place Deutch DTM Brown Under right side cover

[170] Front stop lamp 1-place Spade, Unsealed Purple Right side of handlebars
switch

[201] Diode pack 4-Place Deutsch DT series Black Under right side cover
(GY)

[209B] Security antenna 3-way Delphi GT 150 3.5 Gray Under seat

[281B] Battery tender 2-way overmold (BK) Under seat

[314] Clutch switch 3-Place Sumitomo MT series Purple Handlebar left side
(BK)

[319B] Terminating 2-way Delphi GT 150 Gray In rear fender behind seat
resistor

[325B] P&A connector 3-way Molex MX150 Gray Under seat

[326B] Security module 12-way Delphi Micro 64 BOB In rear fender behind seat
(SCM)

Battery Negative battery Ring terminal Under left side cover

ground cable connection

[GND 1] Harness ground Ring terminal Center of frame above

transmission

[GND 2] Harness ground Ring terminal Under left side cover

[GND2A] Engine ground Ring terminal Top of transmission

Table 1. Main Fuse [5]

TERMINAL WIRE COLOR CIRCUIT DESCRIPTION

1 R/W Battery

2 R Fused battery

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Figure 1. Main Fuse [5]

Table 2. Rear Lighting [7]

TERMINAL WIRE COLOR CIRCUIT DESCRIPTION

1 BE/V Left turn signal

2 BE/BN Right turn signal

3 BE Lights

4 BE/R Stop lamp

5 BE Lights

6 BK Ground

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Figure 2. Rear Lighting [7]

Table 3. Right Rear Turn [18]

TERMINAL WIRE COLOR CIRCUIT DESCRIPTION

1 BE/BN Right turn signal

 2 BK GND

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Figure 3. Right Rear Turn [18]: Except 750A

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Figure 4. Right Rear Turn [18]: 750A

Table 4. Left Rear Turn [19]

TERMINAL WIRE COLOR CIRCUIT DESCRIPTION

1 BE/V Left turn signal

2 BK GND

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Figure 5. Left Rear Turn [19]: Except 750A

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Figure 6. Left Rear Turn [19]: 750A

Table 5. RH Control [22]

TERMINAL WIRE COLOR CIRCUIT DESCRIPTION

1 V/GY IGN

2 W/GY Engine stop switch

3 V/GY IGN

4 W/BN Start switch

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Figure 7. RH Control [22]

Table 6. LH Control [24]

TERMINAL WIRE COLOR CIRCUIT DESCRIPTION

1 - N/C

2 R/Y ACC

3 BE/O Flasher in

4 BE Lights

5 BE/Y Low beam

6 BE/W High beam

7 R/V Horn

8 BE/V Left turn

9 BE/BN Right turn

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Figure 8. LH Control [24]

Table 7. Left Front Turn Lamp [31L]

TERMINAL WIRE COLOR CIRCUIT DESCRIPTION

1 BK GND

2 BE Running lights

3 BE/V Left turn lamp

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Figure 9. Left Front Turn Lamp [31L]

Table 8. Right Front Turn Lamp [31R]

TERMINAL WIRE COLOR CIRCUIT DESCRIPTION

1 BK GND

2 BE Running lights

3 BE/BN Right turn lamp

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Figure 10. Right Front Turn Lamp [31R]

Table 9. Ignition Switch [33]

TERMINAL WIRE COLOR CIRCUIT DESCRIPTION

1 R Battery

2 R/BK IGN

3 R/GY ACC

4 - N/C

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Figure 11. Ignition Switch [33]

Table 10. Headlamp [38]

TERMINAL WIRE COLOR CIRCUIT DESCRIPTION

1 BE Running lights

2 BK GND

3 BE/W High beam headlamp

4 BE/Y Low beam headlamp

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Figure 12. Headlamp [38]

Table 11. Single Headlamp [38B-2]

TERMINAL WIRE COLOR CIRCUIT DESCRIPTION

1 BE/GN High beam power

 2 BE/O Low beam power

3 GY/W Ground

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Figure 13. Headlamp [38B-2]

Table 12. Speedometer [39]

TERMINAL WIRE COLOR CIRCUIT DESCRIPTION

1 W/O Oil pressure

2 W/R CAN high

3 R/Y Accessory power

4 BE/W High beam

5 R/O Battery power

6 W Neutral

7 BK/GN Ground

8 W/BK CAN low

9 W/Y Fuel level

10 BE/V Left turn

11 - N/C

12 BE/BN Right turn

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Figure 14. Speedometer [39]

Table 13. LP Lamp [40]

TERMINAL WIRE COLOR CIRCUIT DESCRIPTION

1 BK GND

2 BE Running lamps

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Figure 15. LP Lamp [40]: Except 750A

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Figure 16. LP Lamp [40]: 750A

Table 14. Stator [47]

TERMINAL WIRE COLOR CIRCUIT DESCRIPTION

1 BK Stator

2 BK Stator

3 BK Stator

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Figure 17. Stator [47]

Table 15. VSS [65]

TERMINAL WIRE COLOR CIRCUIT DESCRIPTION

1 BK/GN GND

2 R/W 5V sensor power

3 LGN/Y VSS

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Figure 18. VSS [65]

Table 16. Flasher [69]: Except 750A

TERMINAL WIRE COLOR CIRCUIT DESCRIPTION

1 BE/O Flasher output

2 BE Lights fuse

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Figure 19. Flasher [69]: Except 750A

Table 17. Flasher [69]: 750A

TERMINAL WIRE COLOR CIRCUIT DESCRIPTION

1 BE Lights fuse

2 BK/GN Ground

3 BE/O Flasher output

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Figure 20. Flasher [69]: 750A

Table 18. Voltage Regulator [77]

TERMINAL WIRE COLOR CIRCUIT DESCRIPTION

1 BK GND

2 - N/C

3 R Battery Power

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Figure 21. Voltage Regulator [77]

Table 19. [78B-1] ECM

TERMINAL WIRE COLOR CIRCUIT DESCRIPTION

1 GY/BE Rear ignition coil

2 GN/BE Front ignition coil

3 BK/O Front HO2 heater ground

4 LGN/Y VSS input

5 GN/Y Front fuel injector

6 GY/Y Rear fuel injector

7 GY Map input

8 LGN/GY JSS signal

9 LGN/BN ION sense

 10 BK/GN Ground

11 - N/C

12 TN/GN Clutch start interlock

13 W/BK CAN low

14 W/R CAN high

15 BK/PK Rear HO2 heater ground

16 R CKP high

17 GN/BN Front HO2S

18 BK CKP low

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Figure 22. ECM [78-1]

Table 20. [78B-2] ECM

TERMINAL WIRE COLOR CIRCUIT DESCRIPTION

1 GN/O IAC A high

2 GN/BK Fan relay

3 V/GN System relay

4 TN/GN Start enable

5 LGN/BK Purge solenoid

6 GN/GY IAT

7 BK/W 5V sensor ground

8 GY/GN ECT

9 R/W 5V sensor power

10 BK/GN Ground

11 GY/O IAC A low

 12 GN/W IAC B high

13 GY/W IAC B low

14 TN/BK TIP sensor

15 GN/V TPS

16 W/GY Run/stop switch

17 GY/BN Rear HO2S

18 R/O Battery fuse

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Figure 23. ECM [78-2]

Table 21. CKP [79]

TERMINAL WIRE COLOR CIRCUIT DESCRIPTION

1 R CKP high

2 BK CKP low

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Figure 24. CKP [79]

Table 22. TMAP [80]

TERMINAL WIRE COLOR CIRCUIT DESCRIPTION

1 BK/W 5V sensor ground

2 GN/GY IAT
 3 R/W 5V sensor power

4 GY MAP sensor

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Figure 25. TMAP [80]

Table 23. Ignition Coil [83]

TERMINAL WIRE COLOR CIRCUIT DESCRIPTION

A R/GN System power

B LGN/BN Ion sense

C GY/BE Rear IGN coil

D GN/BE Front IGN coil

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Figure 26. Ignition Coil [83]

Table 24. Front Injector [84]

TERMINAL WIRE COLOR CIRCUIT DESCRIPTION

A R/GN System power

B GN/Y Front fuel injector

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Figure 27. Front Injector [84]

Table 25. Rear Injector [85]

TERMINAL WIRE COLOR CIRCUIT DESCRIPTION

A R/GN System power

B GY/Y Rear fuel injector

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Figure 28. Rear Injector [85]

Table 26. IAC [87]

TERMINAL WIRE COLOR CIRCUIT DESCRIPTION

A GY/O IAC A low

B GN/W IAC B high

C GY/W IAC B low

D GN/O IAC A high

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Figure 29. IAC [87]

Table 27. TPS [88]

TERMINAL WIRE COLOR CIRCUIT DESCRIPTION

1 BK/W 5V sensor ground

2 R/W 5V sensor power

3 GN/V TPS

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Figure 30. TPS [88]

Table 28. ECT [90]

TERMINAL WIRE COLOR CIRCUIT DESCRIPTION

1 GY/GN ECT

2 BK/W 5V sensor ground

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Figure 31. ECT Sensor [90]

Table 29. DLC [91]

TERMINAL WIRE COLOR CIRCUIT DESCRIPTION

1 W/R CAN high

2 BK/GN GND

3 W/BK CAN low

4 - N/C
 5 R/Y ACC

6 - N/C

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Figure 32. DLC [91]

Table 30. Stop/Tail Lamp [93]

TERMINAL WIRE COLOR CIRCUIT DESCRIPTION

1 BE Running lights

2 BE/R Stop lamp

3 BK GND

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Figure 33. Stop/Tail Lamp [93]: Except 750A

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Figure 34. Stop/Tail Lamp [93]: 750A

Table 31. Purge Solenoid [95]

TERMINAL WIRE COLOR CIRCUIT DESCRIPTION

 A R/GN System power

B LGN/BK Purge solenoid

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Figure 35. Purge Solenoid [95]

Table 32. Cooling Fan [97]

TERMINAL WIRE COLOR CIRCUIT DESCRIPTION

1 BK GND

2 GY/BK Fan relay

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Figure 36. Cooling Fan [97]

Table 33. Oil Pressure Switch [120]

TERMINAL WIRE COLOR CIRCUIT DESCRIPTION

1 W/O Oil pressure

2 BK/GN GND

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Figure 37. Oil Pressure Switch [120]

Table 34. Rear Stop Lamp Switch [121]

TERMINAL WIRE COLOR CIRCUIT DESCRIPTION

1 BE/R Stop lamp

2 BE Running lights

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Figure 38. Rear Stop Lamp Switch [121]

Table 35. Horn [122]

TERMINAL WIRE COLOR CIRCUIT DESCRIPTION

1 R/V Stop lamp

2 BK GND

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Figure 39. Horn [122-1] and [122-2]

Table 36. Starter Solenoid [128]

TERMINAL WIRE COLOR CIRCUIT DESCRIPTION

1 TN/GY Starter solenoid

2 BK GND
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image

Figure 40. Starter Solenoid [128]

Table 37. Neutral Switch [131]

TERMINAL WIRE COLOR CIRCUIT DESCRIPTION

1 W Neutral switch

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image

Figure 41. Neutral Switch [131]

Table 38. JSS [133]

TERMINAL WIRE COLOR CIRCUIT DESCRIPTION

1 R/W 5V sensor power

2 LGN/GY JSS

3 BK/GN GND

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image

Figure 42. JSS [133]

Table 39. BAS [134]

 TERMINAL WIRE COLOR CIRCUIT DESCRIPTION

1 BK/W 5V sensor ground

2 R/W 5V sensor power

3 TN/BK TIP

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Figure 43. BAS [134]

Table 40. Rear HO2S [137]

TERMINAL WIRE COLOR CIRCUIT DESCRIPTION

1 R/GN System power

2 BK/PK Rear HO2S heater GND

3 GY/BN Rear HO2S

4 BK/W 5V sensor gnd

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Figure 44. Rear HO2S [137]

Table 41. Front HO2S [138]

TERMINAL WIRE COLOR CIRCUIT DESCRIPTION

1 R/GN System power

2 BK/O Front HO2S heater GND

3 GN/BN Front HO2S

 4 BK/W 5V sensor gnd

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Figure 45. Front HO2S [138]

Table 42. Fuel Pump [141]

TERMINAL WIRE COLOR CIRCUIT DESCRIPTION

1 W/Y Low fuel

2 BK GND

3 BK/GN GND

4 R/GN System power

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Figure 46. Fuel Pump [141]

Table 43. Security Siren [142]

TERMINAL WIRE COLOR CIRCUIT DESCRIPTION

A R Battery

B W/GN Security siren

C BK GND
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Figure 47. Security Siren [142]

Table 44. Engine Harness [145]

TERMINAL WIRE COLOR CIRCUIT DESCRIPTION

1 GY/W IAC B low

2 GN/O IAC A high

3 BK/W 5V sensor ground

4 GN/W IAC B high

5 R/W 5V sensor power

6 LGN/BN ION sense

7 R/GN System power

8 GY/Y Rear fuel injector

9 GY/O IAC A low

10 GY/BE Rear ignition coil

11 GY MAP input

12 GN/V TPS

13 GN/Y Front fuel injector

14 GN/GY IAT

15 GN/BE Front ignition coil

16 GY/GN ECT

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 View interactive image

Figure 48. Engine Harness [145]

Table 45. ABS [166]

TERMINAL WIRE COLOR CIRCUIT DESCRIPTION

1 BK Ground

2 W/R CAN high

3 O/BK Front WSS low

4 V/GY Switched aux lamp PWR

5 - N/C

6 BE/R Front brake switch input

7 BE/R Rear brake switch input

8 - N/C

9 R Battery power

10 BK Ground

11 W/BK CAN low

12 O/BE Front WSS high

13 O/PK Rear WSS high

14 O/BN Rear WSS low

15 - N/C

16 - N/C

17 - N/C

18 R Battery power

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Figure 49. ABS [166]

Table 46. Front WSS [167]

TERMINAL WIRE COLOR CIRCUIT DESCRIPTION

1 O/BE Front WSS high

2 O/BK Front WSS low

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image

Figure 50. Front WSS [167]

Table 47. Rear WSS [168]

TERMINAL WIRE COLOR CIRCUIT DESCRIPTION

1 O/PK Rear WSS high

2 O/BN Rear WSS low

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Figure 51. Rear WSS [168]

Table 48. Front Stop Lamp Switch [170]

TERMINAL WIRE COLOR CIRCUIT DESCRIPTION

1 BE/R Stop lamp

2 BE Running lights
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image

Figure 52. Front Stop Lamp Switch [170]

Table 49. Diode Pack [201]

TERMINAL WIRE COLOR CIRCUIT DESCRIPTION

1 BE/R Rear brake switch

2 BE/R Front brake switch

3 BE/R Stop/tail lamp

4 BE/R Stop/tail lamp

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Figure 53. Diode Pack [201]

Table 50. Security Antenna [209]

TERMINAL WIRE COLOR CIRCUIT DESCRIPTION

A R LO frequency antenna +

B - N/C

C BK LO frequency antenna -

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Figure 54. Security Antenna [209]

Table 51. Battery Tender [281]

TERMINAL WIRE COLOR CIRCUIT DESCRIPTION

1 R Battery power

2 BK Ground

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Figure 55. Battery Tender [281]

Table 52. Clutch Switch [314]

TERMINAL WIRE COLOR CIRCUIT DESCRIPTION

1 TN/GN Clutch switch

2 BK/GN GND

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image

Figure 56. Clutch Switch [314]

Table 53. Terminating Resistor [319]

TERMINAL WIRE COLOR CIRCUIT DESCRIPTION

A W/R CAN high

B W/BK CAN low

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Figure 57. Terminating Resistor [319]

Table 54. P&A Accessory [325]

TERMINAL WIRE COLOR CIRCUIT DESCRIPTION

1 V/BE P&A relay power

2 BK Ground

3 - N/C

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Figure 58. P&A Accessory [325]

Table 55. SCM [326]

TERMINAL WIRE COLOR CIRCUIT DESCRIPTION

1 R Battery

2 V/GYK Ignition in

3 - N/C

4 BK RF Antenna

5 W/GN Security siren

6 BK GND

7 W/BK CAN low

8 W/R CAN high

9 BK Lo frequency antenna -
 10 R Lo frequency antenna +

11 BE/BN Right turn

12 BE/V Left turn

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Figure 59. SCM [326]

Some components and connectors are not easily located on the motorcycle. The following graphics show locations for
these components and connectors. The graphics are generally ordered from front to back around the motorcycle.

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1 Clutch switch [314]

2 Front stop lamp switch [170]

Figure 1. Hand Controls

 View interactive
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1 Front stop lamp switch [170]

2 Front HO2S [138]

3 Under seat

4 Under fuel tank

5 Clutch switch [314]

6 Cooling fan [97]

Figure 2. Frame Top View

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1 Rear lighting [7]

2 Behind right cover

3 Under fuel tank

4 Clutch switch [314]

5 Front stop lamp switch [170]

6 Speedometer [39]

7 Front of engine

8 Front HO2S [138]

9 Rear stop lamp switch [121-1]

10 Rear stop lamp switch [121-2]

Figure 3. Frame Right Side

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1 Rear injector [85]

2 TPS [88]

3 TMAP [80]

4 IAC [87]

5 Headlamp [38]

6 Ignition switch [33]

7 LH controls [24]

8 RH controls [22]

9 Fuel pump [141]

10 Front injector [84]

11 ECT [90]

12 Ignition coil [83]

Figure 4. Under Fuel Tank Right Side

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1 Neutral switch [131]

2 JSS [133]

3 CKP [79]

4 Cooling fan [97]

5 Horn [122-1]

6 Horn [122-2]

7 Front WSS [167]

8 Starter

9 VSS [65]

10 Voltage regulator [77]

11 ABS ECU [166]

12 Oil pressure switch [120]

Figure 5. Front of Engine

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1 Main fuse [5]

2 DLC [91]

3 Fuse block [64]

4 Relay block [62B-2]

5 Relay block [62B-1]

 6 Diode pack [201]

7 Purge solenoid [95]

8 VSS [65]

9 Ground

10 Rear WSS [168]

Figure 6. Under Right Side Cover

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1 Rear HO2S [137]

2 Security siren [142]

3 Battery tender [280]

Figure 7. Under Left Side Cover

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1 Security module [326]

2 ECM [78-2]
 3 Rear lighting [7]

4 Flasher [69]

5 BAS [134]

6 Engine harness [145]

7 Starter solenoid [128]

8 ECM [78-1]

9 Security antenna [142]

10 Terminating resistor [319]

Figure 8. Under Seat: Except 750A

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1 Terminating resistor [319]

2 Left turn lamp [19]

3 LP lamp [40]

4 Right turn lamp [18]

5 Stop/tail lamp [93]

6 ECM [78-2]

7 Flasher [69]
 8 BAS [134]

9 Engine harness [145]

10 P&A connector

11 Starter solenoid [128]

12 ECM [78-1]

13 Security antenna [142]

14 Security module [326]

Figure 9. Under Seat: 750A

Special Tools

Description Part Number Qty.

SNAP-ON TERMINAL PICK GA500A 1

See Figure 1. The Bosch Compact 1.1M connector is found on MAP and TMAP sensors.

Separating Connector

See Figure 1. Snap back the secondary lock. Press on the latch while pulling the connector from the sensor.

Mating Connector

1. Align the connector housings.

2. Press the housings together until the locking tab snaps into place.

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Figure 1. Bosch Compact 1.1M Connector

Terminal Removal

1. See Figure 2. Slide the locking bar off the terminal housing.
2. Insert the smallest pins of the SNAP-ON TERMINAL PICK (Part Number:GA500A) into the gaps on each side
of the terminal to compress the tangs on each side of the terminal.
3. Gently pull on the wire to remove the terminal.
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Figure 2. Terminal Removal: Bosch Compact 1.1M Connector

Installing Terminal

1. See Figure 3. Use a hobby knife to bend the tangs on each side of the terminal outward.
2. Align terminal to connector. Press terminal into connector until it snaps.

NOTE

The teeth on the locking bar face down.

3. Slide the locking bar onto the connector.

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Figure 3. Tangs: Bosch Compact 1.1M Terminal

Replacement and Repair

The terminals and connector assemblies are not repairable. Discard and replace any defective or damaged terminals
or connector assemblies. DO NOT re-use a terminal by removing the wire.
Special Tools

Description Part Number Qty.

TERMINAL EXTRACTOR B-50085 1

PACKARD TERMINAL CRIMP HD-38125-6 1

TOOL

Delphi GT 150 connectors are typically used on fuel injectors, ignition coil and VSS. The GT 280 sealed connectors are
used to connect to the fuel pump and sender.

See Figure 1. The plug assembly consists of housing with connector cavities, terminals, secondary lock, wire seals, safety
lock, mating seal and primary lock.

NOTE

Use PACKARD TERMINAL CRIMP TOOL (Part Number:HD-38125-6) for Delphi GT sealed terminal crimping. Refer
to Bosch tool instruction sheet for crimping instructions.

Separating Connector

See Figure 2. Press connector release (A), separate the two halves (B).

Mating Connector

Push the halves of connector together until external latch(es) engage.

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1 Secondary lock

2 GT 280 female terminals

 3 Connector housing 2-way

4 Seal

5 Primary lock

Figure 1. Exploded View

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1 Connector housing

2 Connector release

Figure 2. Disconnect

Terminal Removal

1. See Figure 3. Using TERMINAL EXTRACTOR (Part Number:B-50085), completely remove the primary lock.
2. Release the two locks and remove the secondary lock.
3. From the front of the cavity, locate the terminal lock. Insert the removal tool straight into the cavity, deflect the
terminal lock and release the terminal. Gently pull on the wire to remove terminal from the connector.
 View interactive
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1 Primary lock

2 Removing secondary lock

3 Removal tool

4 Terminal lock

5 Terminal

6 Connector housing

Figure 3. Terminal Removal

Installing Terminals

1. See Figure 4. Insert the primary lock into the outer most position on the connector.

NOTE
 Proper orientation of terminal required.

2. Insert terminals into connector housing.

3. Insert secondary lock onto cavity until locked.
4. Install primary lock until it is locked in position.

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1 Primary lock

2 Terminal

3 Secondary lock

4 Primary lock

Figure 4. Terminal Installation

Replacement and Repair

The terminals and connector assemblies are not repairable. Discard and replace any defective or damaged terminals
or connector assemblies. Do not re-use a terminal by removing the wire.
Special Tools

Description Part Number Qty.

PACKARD TERMINAL CRIMP HD-38125-6 1

TOOL

PACKARD TERMINAL CRIMPER HD-38125-7 1

There are two types of connectors in this series:

Pull-to-Seat
Push-to-Seat

NOTE

Use PACKARD TERMINAL CRIMP TOOL (Part Number:HD-38125-6) for push-to-seat Delphi Metri-Pack
terminal crimping.

Use PACKARD TERMINAL CRIMPER (Part Number:HD-38125-7) for pull-to-seat Delphi Metri-Pack terminal
crimping.
Refer to Bosch tool instruction sheet for crimping instructions.

Separating Connector

Pry up on the external latch slightly and separate the connector.

Mating Connector

Push the halves of the connector together.

Terminal Removal Push-to-Seat

NOTE

The same process is followed for both the male and female ends of the push to seat connectors.

For best results, free one side of the secondary lock first and then release the other side.

1. See Figure 1. Remove secondary lock from wire end of connector.

2. Find the locking tang in the mating end of the connector.

NOTE

The tangs are always positioned in the middle of the cavity on the same side as the external latch.

There is a small opening for the pin.

3. Gently insert a small diameter straight pin into the cavity about 3.2 mm (⅛ in).

NOTE
 The click is the sound of the tang returning to the locked position as it slips from the point of the pin.

4. Pick at the tang until the clicking stops and the pin seems to slide in deeper. This indicates the tang is pressed
in.
5. Pull on the lead to draw the terminal out the wire end.

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1 Remove wire lock

2 Pivot pin to release tang

3 Pull to remove

4 Raise tang to install

Figure 1. Removing Delphi Metri-Pack Sealed Connector: Push-to-Seat

Terminal Removal Pull-to-Seat

NOTE

The tangs are always positioned in the middle of the cavity. The tangs are on the same side as the external latch.
 1. See Figure 2. Find the locking tang in the mating end of the connector.

NOTE

Stay between the terminal and the cavity wall and pivot the end of the pin toward the terminal body.

2. Gently insert a small diameter straight pin into the cavity about 3.2 mm (⅛ in).

NOTE

The click is the sound of the tang returning to the locked position as it slips from the point of the pin.

3. When a click is heard, remove the pin and repeat the procedure.

NOTE

After repeated terminal extractions, the click may not be heard, but pivot the pin as if the click was heard at least
three times.

4. Pick at the tang until the clicking stops and the pin seems to slide in deeper. This indicates the tang is pressed
in.
5. Push on the lead to extract the terminal from the mating end of the connector.

View interactive image

 View interactive image

1 Locate tang in cavity

2 Pivot pin to release tang

3 Push to remove

4 Raise tang to install

Figure 2. Delphi 150.2 Metri-Pack Sealed Connector: Pull-to-Seat

Installing Terminal Push-to-Seat

1. See Figure 3. Plug terminals into connector assembly.

2. After all leads are plugged, install secondary lock to connector.
a. Hold connector as shown and install secondary lock.
b. Position secondary locks with corresponding grooves and verify one lead per cavity. Apply pressure
with fingers until secondary lock snaps into place.

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1 Insert terminals into connector

2 Install secondary lock

3 Locked
Figure 3. Insert Terminals Push-to-Seat

Installing Terminal Pull-to-Seat

NOTE

Leads must be blunt cut for this operation.

1. See Figure 4. Push wire leads through cable seal at least 203 mm (8 in).
2. Strip each wire lead to the required length for the terminal being applied.
3. Crimp terminals on wire ends
4. Align the terminals with the locating tabs in the cavity and pull wires back through connector to install the
terminal.
5. Verify terminal is fully seated in the terminal cavity.

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1 Push wire leads through cable seal

2 Strip each wire lead

 3 Crimp terminals on wire ends

4 Pull wires back through connector

5 Verify terminal is fully seated

Figure 4. Inserting Terminal Pull-to-Seat

Replacement and Repair

The terminals and connector assemblies are not repairable. Discard and replace any defective or damaged terminals
or connector assemblies. Do not re-use a terminal by removing the wire.
Special Tools

Description Part Number Qty.

PACKARD MICRO-64 TERMINAL HD-45928 1

REMOVER

PACKARD MICRO-64 TERMINAL HD-45929 1

CRIMPER

Delphi Micro 64 Sealed connectors are frequently found on speedometers and tachometers.

NOTE

Use PACKARD MICRO-64 TERMINAL CRIMPER (Part Number:HD-45929) for Delphi Micro 64 terminal crimping.
Refer to Bosch tool instruction sheet for crimping instructions.

Separating Connector

Bend back the external latches slightly and separate the connector.

Mating Connector

Align the terminals and press the connector together until the latch snaps.

Terminal Removal

1. See Figure 1. Locate the head of the secondary lock on one side of the connector housing.
2. Insert the blade of a small screwdriver between the center ear of the lock and the connector housing and gently
pry out lock. When partially removed, pull lock from connector housing.
3. Locate pin hole between terminals on mating end of connector.
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1 Stamped number

2 Pin hole

3 Secondary lock

4 Insert terminal remover

5 Remove terminal

Figure 1. Terminal Removal

4. Obtain the PACKARD MICRO-64 TERMINAL REMOVER (Part Number:HD-45928).

5. Push the adjacent terminals all the way into the connector housing and then insert tool into hole until it bottoms.
6. Leaving the tool installed, gently tug on wires to pull either one or both terminals from wire end of connector.
Remove tool.

Installing Terminal
 1. Insert terminal into its respective numbered cavity on wire end of connector. No special orientation of the
terminal is necessary.

NOTE

For wire location purposes, the corners of the connector are stamped with the numbers 1, 6, 7 and 12,
representing terminals 1-6 on one side, and 7-12 on the other.

2. Bottom the terminal in the cavity and then gently tug on the wire to verify that it is locked in place.

NOTE

Once removed, the terminal may not lock in place when first installed. Until the lock engages, move the terminal
back and forth slightly while wiggling the lead.

3. Since the terminal remover tool releases two terminals simultaneously, repeat step 2 on the adjacent terminal
even if it was not pulled from the connector housing.
4. With the center ear on the head of the secondary lock facing the mating end of the connector, push secondary
lock in until head is flush with the connector housing.

Replacement and Repair

The terminals and connector assemblies are not repairable. Discard and replace any defective or damaged terminals
or connector assemblies. Do not re-use a terminal by removing the wire.
Special Tools

Description Part Number Qty.

DEUTSCH CRIMPER HD-39965-a 1

DEUTSCH CONNECTOR SERVICE HD-41475 1

KIT

FLAT BLADE L-HOOK HD-41475-100 1

ELECTRICAL CRIMPER TOOL HD-42879 1

A DEUTSCH CONNECTOR SERVICE KIT (Part Number:HD-41475) contains a selection of seals and seal plugs, locking
wedges, attachment clips and terminals. Also included is a FLAT BLADE L-HOOK (Part Number:HD-41475-100) used to
remove locking wedges, compartmented storage box and carrying case.

NOTE

Use the DEUTSCH CRIMPER (Part Number:HD-39965-a) for non-solid barrel terminal crimping.

Use the ELECTRICAL CRIMPER TOOL (Part Number:HD-42879) for solid barrel terminal crimping.
Refer to Bosch tool instruction sheet for crimping instructions.

Separating Connector

See Figure 1. To separate the connector halves, press the external latch(es) on the connector while rocking the
connector halves, and pull.

NOTE

Six-place and smaller Deutsch connectors have one latch on the connector.

Eight- and twelve-place connectors have a latch on each side. Simultaneously press both latches to separate
the connector.

Mating Connector

1. Align the connectors to match the wire lead colors.

a. For One External Latch: To join the halves, align the latch on the socket side with the latch cover on
the pin side.
b. For Two External Latches: Align the tabs on the connector halves.

NOTE

For Two External Latches: If latches do not click (latch), press on one side of the connector until that latch
engages then press on the opposite side to engage the other latch.

2. Insert the two halves together until it locks into place.

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1 External latch

2 Socket housing

3 Pin housing

Figure 1. Deutsch DT Sealed Connector

Terminal Removal

1. See Figure 2. Remove wedgelock using needlenose pliers or removal tool.

2. To remove the terminals, gently pull wire backwards, while at the same time releasing the locking finger by
moving it away from the terminal with a screwdriver.
3. Hold the rear seal in place when pulling terminal/wire out, as removing the terminal may displace the seal.
 View interactive
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1 Remove wedgelock

2 Releasing locking finger

3 Locking finger

4 Remove terminal

Figure 2. Terminal Removal

Installing Terminal

NOTE

The receptacle is shown. Use the same procedure for plug.

1. See Figure 3. Grasp terminal approximately 25.4 mm (1 in) behind the terminal barrel.
2. Push terminal straight into connector grommet until a click is felt.
3. Gently pull on the wire to confirm that it is properly locked in place.
4. Once all terminals are in place, insert wedgelock. The wedgelock will snap into place.
 View interactive
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1 Grasp terminal

2 Hold connector

3 Insert terminal

4 Insert wedgelock

Figure 3. Inserting Terminals

Replacement and Repair

The terminals and connector assemblies are not repairable. Discard and replace any defective or damaged terminals
or connector assemblies. Do not re-use a terminal by removing the wire.
Special Tools

Description Part Number Qty.

TERMINAL EXTRACTOR B-50085 1

Separating Connector

1. Press the release button.

2. Pull the connector apart.

Mating Connector

1. Align the connector housings.

2. Press the housings together until the locking tab snaps into place.

Terminal Removal

1. File the edge of a TERMINAL EXTRACTOR (Part Number:B-50085) to a 45 degree angle.

2. See Figure 1. Remove secondary lock from connector.
3. Insert the extractor into the cavity next to the terminal. Press the tang away from the terminal.
4. Gently pull the wire to remove the terminal from the connector.

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1 Terminal

2 Connector
 3 Secondary lock

4 Tang

Figure 1. Furukawa QLW Sealed Connector

Installing Terminal

1. Align terminal to the connector.

2. Install the terminal into the connector. Terminal snaps into place.
3. Gently pull wire to verify terminal is locked.
4. Install secondary lock into connector.

Replacement and Repair

The terminals and connector assemblies are not repairable. Discard and replace any defective or damaged terminals
or connector assemblies. Do not re-use a terminal by removing the wire.
Special Tools

Description Part Number Qty.

TERMINAL EXTRACTOR B-50085 1

HAND CRIMP FRAME HD-50120-2 1

JAE DIE HD-50120-6 1

The plug assembly consists of a wire seal (part of housing), housing and two terminals.

NOTE

Use HAND CRIMP FRAME (Part Number:HD-50120-2) with JAE DIE (Part Number:HD-50120-6) for JAE MX19
series terminal crimping. Refer to Bosch tool instruction sheet for crimping instructions.

Separating Connector

See Figure 1. Press the latch while pulling the connector halves apart.

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Figure 1. Release Button

Mating Connector

Align the terminals and press the connectors together until the latch snaps.

Terminal Removal

1. Modify a TERMINAL EXTRACTOR (Part Number:B-50085) by filing the front edge to 45 degrees.
2. See Figure 2. Insert the extractor into the opening above the terminal and press the plastic molding up and out
of the way.
3. Pull the wire lead and terminal out of the back of the connector.
 View interactive
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1 Terminal extractor

2 Connector

Figure 2. Terminal Removal

Installing Terminal

1. Inspect the connector housing and replace if necessary.

2. Orient the terminal to the housing. Push terminal into housing until it clicks into place.

Replacement and Repair

The terminals and connector assemblies are not repairable. Discard and replace any defective or damaged terminals
or connector assemblies. Do not re-use a terminal by removing the wire.
Special Tools

Description Part Number Qty.

MOLEX ELECTRICAL HD-48114 1

CONNECTOR TERMINAL
REMOVER

ELECTRICAL CRIMP TOOL HD-48119 1

DIE SET HD-50120-11 1

HAND CRIMP FRAME HD-50120-2 1

NOTE

Use ELECTRICAL CRIMP TOOL (Part Number:HD-48119) for Molex MX150 terminal crimping.

Use HAND CRIMP FRAME (Part Number:HD-50120-2) with DIE SET (Part Number:HD-50120-11) for Molex
MX64 series terminal crimping.
Refer to Bosch tool instruction sheet for crimping instructions.

Separating Connector

See Figure 1. Press the latch while pulling the connector halves apart.

Mating Connector

1. Align the connectors so the latches line up.

2. Press together until locked.

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Figure 1. Molex MX 150 Sealed Connector Latch

Terminal Removal (Male Terminals)

NOTE

The secondary lock should never be fully removed from the connector. Excessive force may damage the
secondary lock.

Do not apply any lateral force. This may damage the tool or the locking finger.

Excessive force can damage the lock finger.

Do not insert the service tool at an angle. This may cause damage to the terminal.

Do not insert the removal tool into the terminal opening.

1. See Figure 2. Insert a small pair of needle nose pliers in the removal holes.
2. Pull back gently 5 mm (0 in) until the secondary lock is unlocked.
3. Using the MOLEX ELECTRICAL CONNECTOR TERMINAL REMOVER (Part Number:HD-48114), insert the
tip into the terminal service ports adjacent to the terminal cavity to be removed.
4. Apply downward pressure to release the lock and remove the wire. If the terminal resists, the removal tool may
not be fully engaged. Verify that it has fully disengaged the lock.

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1 Pull up secondary lock

 2 Service ports

3 Insert removal tool

Figure 2. Terminal Removal: Male

Terminal Removal (Female Terminals) MX150 Series

NOTE

The secondary lock should never be fully removed from the connector housing. Excessive force may damage
the secondary lock.

Do not apply any lateral force. This may damage the tool or the locking finger.

Excessive force can damage the lock finger.

Do not insert the service tool at an angle. This may cause damage to the terminal.

Do not insert the removal tool into the terminal opening.

1. See Figure 3. Insert a small screwdriver into the secondary lock release.
2. Using the housing as a pivot point gently pry out on the secondary lock to unlock.
3. Using the MOLEX ELECTRICAL CONNECTOR TERMINAL REMOVER (Part Number:HD-48114), insert the
tip into the terminal service ports adjacent to the terminal cavity to be removed.
4. Apply downward pressure to release the lock and remove the wire. If the terminal resists, the removal tool may
not be fully engaged. Verify that it has fully disengaged the lock.
 View interactive
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1 Pry up secondary lock

2 Service ports

3 Insert removal tool

Figure 3. Terminal Removal: Female

Terminal Removal (Female Terminals) MX64 Series

1. See Figure 4. Using a small blade screwdriver pry up on the secondary lock and remove.

NOTE

Do not use excessive force. Excessive force can damage the lock finger.

2. Using a small blade screwdriver, release the terminal lock. Gently pull on the wire to remove the terminal.
 View interactive
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1 Remove secondary lock

2 1 mm pry tool

3 Pry point for terminal lock

4 Primary lock

Figure 4. Removing Terminals in MX64 Series Connector

Installing Terminal

1. See Figure 5. With secondary lock unlocked, align the terminal to rear of connector.
2. Insert the terminal until it stops and locks on the lock finger with an audible click.
3. See Figure 5.
a. On the MX64, install and lock the secondary lock.
b. On the MX150, push to lock the secondary lock.
 View interactive
View interactive image
image

1 MX 64 series

2 MX 150 series

Figure 5. Terminal Installation

Replacement and Repair

The terminals and connector assemblies are not repairable. Discard and replace any defective or damaged terminals
or connector assemblies. Do not re-use a terminal by removing the wire.
Special Tools

Description Part Number Qty.

ROBINAIR HEAT GUN HD-25070 1

PACKARD CRIMPING TOOL HD-38125-8 1

ULTRA TORCH UT-100 HD-39969 1

HEAT SHIELD ATTACHMENT HD-41183 1

NOTE

Refer to Bosch tool instruction sheet for crimping instructions.

Splice connectors and several OEM ring terminal connectors use heat shrink covering to seal the connection.

Preparing Wire Leads

NOTE

When splicing adjacent wires, stagger the splices so the sealed splice connectors will not touch each other.

1. Using a shop gauge, identify the gauge of the wire.

2. Match the wire gauge to a sealed splice connector by color and part number. Refer to Table 1.
3. Strip insulation off the wire lead. Refer to Table 1.

Table 1. Sealed Splice Connectors

WIRE GAUGE COLOR PART NO. STRIP LENGTH

IN MM

18-20 (0.5-0.8 mm) Red 70585-93 3/8 9.5

14-16 (1.0-2.0 mm) Blue 70586-93 3/8 9.5

10-12 (3.0-5.0 mm) Yellow 70587-93 3/8 9.5

NOTE

If any copper wire strands are cut off of the wire core, trim the end and strip the wire again in a larger gauge
stripper.

Splicing Wire Leads

 NOTE

The connector is crimped on one side and then the other.

1. See Figure 1. Open the PACKARD CRIMPING TOOL (Part Number:HD-38125-8) ratchet by squeezing the
handles closed.
2. Match the connector color to the wire gauge crimp die in the jaws. Insert one end of the sealed connector.
3. Gently squeeze the handles until the connector is held in the jaws.
4. See Figure 2. Feed the stripped end of a wire into the connector until the wire stops inside the metal insert.
5. Squeeze the handles tightly closed to crimp the lead in the insert. The tool automatically opens when the
crimping is complete.
6. Slide the connector to the other half of the metal insert. Insert the stripped wire lead until it stops. Crimp the
lead in the insert.

WARNING

Be sure to follow manufacturer's instructions when using the UltraTorch UT-100 or any other radiant heating
device. Failure to follow manufacturer's instructions can cause a fire, which could result in death or serious injury.
(00335a)

Avoid directing heat toward any electrical system component that is not being serviced.
Always keep hands away from tool tip area and heat shrink attachment.

NOTE

It is acceptable for the splice to rest against the heat shrink tool attachment.

7. Use an ULTRA TORCH UT-100 (Part Number:HD-39969), or a ROBINAIR HEAT GUN (Part Number:HD-
25070) with a HEAT SHIELD ATTACHMENT (Part Number:HD-41183), to heat the connector from the center
of the crimp out to each end.

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image

1 Red connector die

2 Blue connector die

3 Yellow connector die

Figure 1. Packard Crimping Tool (HD-38125-8)

Inspecting Seals

See Figure 2. Allow the splice to cool and inspect the seal. The insulation should appear smooth and cylindrical.
Melted sealant will have extruded out the ends of the insulation.

View interactive
View interactive image
image

1 Wire lead in metal insert

2 Crimp metal insert

3 Center of crimp

4 Melted SEALANT

Figure 2. Sealed Splice Connector

Special Tools

Description Part Number Qty.

TERMINAL EXTRACTOR B-50085 1

Separating Connector

1. Press the release button.

2. Pull the connector apart.

Mating Connector

1. Align the connector housings.

2. Press the housings together until the lock clicks into place.

Terminal Removal

1. File the edge of a TERMINAL EXTRACTOR (Part Number:B-50085) to a 45 degree angle.

2. Sumitomo DL sealed connectors: Pry secondary lock away from connector.
3. See Figure 1. Remove terminal from connector.
a. Insert the extractor into the cavity next to the terminal.
b. Press and hold the tang away from the terminal.
c. Gently pull the wire to remove the terminal from the connector housing.

View interactive
View interactive image
image

1 Tang

2 Connector housing

3 Terminal
Figure 1. Sumitomo MT Unsealed Connector

Installing Terminal

1. Align terminal to the connector. Install the terminal into the connector. Terminal snaps into place.
2. Gently pull wire to verify terminal is locked.
3. Sumitomo DL sealed connectors: Install secondary lock into connector.

Replacement and Repair

The terminals and connector assemblies are not repairable. Discard and replace any defective or damaged terminals
or connector assemblies. Do not re-use a terminal by removing the wire.
Special Tools

Description Part Number Qty.

TERMINAL EXTRACTOR B-50085 1

Separating Connector

1. Press the locking tab.

2. Pull the connector apart.

Mating Connector

1. Align the connector housings.

2. Press the housings together until the lock clicks into place.

Terminal Removal

1. File the edge of a TERMINAL EXTRACTOR (Part Number:B-50085) to a 45 degree angle.

2. See Figure 1. Insert the extractor into the cavity next to the terminal. Bend the metal tang of the terminal flush
with the terminal body.
3. Gently pull the wire to remove the terminal from the connector.

Installing Terminal

1. See Figure 1. Bend metal tang of terminal up.

2. Align terminal to the connector. Install the terminal into the connector. Terminal will snap into place.
3. Gently pull wire to verify terminals are locked.

View interactive
View interactive image
image

1 Terminal
 2 Connector

3 Cavity

4 Tang

Figure 1. Sumitomo MTW and MTL Unsealed Connector

Replacement and Repair

The terminals and connector assemblies are not repairable. Discard and replace any defective or damaged terminals
or connector assemblies. Do not re-use a terminal by removing the wire.
Special Tools

Description Part Number Qty.

TERMINAL EXTRACTOR B-50085 1

HAND CRIMP FRAME HD-50120-2 1

TYCO GET 64 DIE HD-50120-7 1

NOTE

Use HAND CRIMP FRAME (Part Number:HD-50120-2) with TYCO GET 64 DIE (Part Number:HD-50120-7) for Tyco
GET 64 series terminal crimping. Refer to Bosch tool instruction sheet for crimping instructions.

Separating Connector

1. See Figure 1. Pull the latch lock open.

2. While pressing the connector latch, pull the connector apart.

Mating Connector

1. Align the connector housings.

2. Press the housings together.
3. Push the latch lock closed.
 View interactive
View interactive image
image

1 Latch lock (open)

2 Latch lock (closed)

3 Connector latch

Figure 1. Tyco GET 64 Sealed Connector Latch and Lock

Terminal Removal

1. See Figure 2. Remove secondary lock from the connector.

2. Insert TERMINAL EXTRACTOR (Part Number:B-50085) into the cavity next to the terminal.
3. Pry and hold the tang away from the terminal.
4. Pull on the wire lead to remove the terminal.
 View interactive
View interactive image
image

1 Secondary lock

2 Terminal extractor

3 Retention beam

Figure 2. Terminal Removal

Installing Terminal

1. See Figure 3. Align the open side of the crimp to the tang side of the connector cavity.
2. Install the terminal into the connector. Terminal will snap into place.
3. Install secondary lock into the connector.
 View interactive
View interactive image
image

Figure 3. Socket Terminal Orientation: Crimp Open Side

Replacement and Repair

The terminals and connector assemblies are not repairable. Discard and replace any defective or damaged terminals
or connector assemblies. Do not re-use a terminal by removing the wire.
Special Tools

Description Part Number Qty.

SNAP-ON TERMINAL PICK GA500A 1

Separating Connector

1. See Figure 1. Remove wire clip.

2. Pull the connector from the sensor.

View interactive
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image

1 Wire clip

2 Sealing boot

3 Cavity (2)

4 Terminal

5 Housing

6 Tang

Figure 1. Tyco Sealed Timer Connector

Mating Connector

1. Align the terminals and press the connectors together.

 2. Install wire locking clip.

Terminal Removal

1. See Figure 1. Remove sealing boot from housing.

2. Insert the smallest pins of the SNAP-ON TERMINAL PICK (Part Number:GA500A) into the cavities on each
side of the terminal to compress the tangs on each side of the terminal.
3. Gently pull on the wire to remove the terminal.

Installing Terminal

1. See Figure 1. Bend the tangs on each side of the terminal outward.
2. Align terminal to the housing. Install the terminal into housing. Terminal will snap into place.

Replacement and Repair

The terminals and connector assemblies are not repairable. Discard and replace any defective or damaged terminals
or connector assemblies. Do not re-use a terminal by removing the wire.
Special Tools

Description Part Number Qty.

SNAP-ON TERMINAL PICK GA500A 1

Separating Connector

Remove fuses to access the terminals, as necessary.

Mating Connector

Install fuses back to their original location.

Terminal Removal

1. See Figure 1. Insert smallest pair of pins on the SNAP-ON TERMINAL PICK (Part Number:GA500A) into
cavity on either side of terminal to press tangs on each side of terminal simultaneously.
2. Gently pull on wire to remove terminal from housing.

Installing Terminal

1. Bend tang on each side of terminal away from terminal body.

2. Install terminal into connector.
a. Align terminal to the connector. The open side of the terminal should face the wire lead connected to
the other side of the fuse.
b. Install the terminal into connector until the terminal snaps into place.

Replacement and Repair

The terminals and connector assemblies are not repairable. Discard and replace any defective or damaged terminals
or connector assemblies. Do not re-use a terminal by removing the wire.

View interactive
View interactive image
image
Figure 1. Removing Autofuse Unsealed Terminal from Fuse Block
Special Tools

Description Part Number Qty.

TERMINAL EXTRACTOR B-50085 1

SNAP-ON TERMINAL PICK GA500A 1

HAND CRIMP FRAME HD-50120-2 1

TYCO MCP DIE HD-50120-8 1

The Tyco MCP sealed connector is used on certain ABS modules.

NOTE

Use HAND CRIMP FRAME (Part Number:HD-50120-2) with TYCO MCP DIE (Part Number:HD-50120-8) for Tyco
MCP series terminal crimping. Refer to Bosch tool instruction sheet for crimping instructions.

Separating Connector

See Figure 1. Press and hold the lock tab. Pulling on both ends of the lever, open the lever.

View interactive
View interactive image
image

Figure 1. Tyco MCP Connector Release Bar

Mating Connector

Gently mate the pins to the socket. Press and hold the lock tab. Pressing on both ends of the lever, close the lever.

Terminal Removal (Large Terminals)

1. Snap the wire harness cover off of the back of the connector

NOTE
 Insert a thin flat bladed screwdriver all the way to the bottom behind the tab of the secondary lock.

2. See Figure 2. Gently slide the secondary lock out of the connector with a screwdriver.
3. Insert the smallest pins of the SNAP-ON TERMINAL PICK (Part Number:GA500A) into the gaps on each side
of the terminal to compress the tangs on each side of the terminal.
4. Gently pull on the wire to remove the terminal.

View interactive
View interactive image
image

1 Secondary lock

2 Terminal pick

Figure 2. Removing Small Socket Terminals

Terminal Removal (Small Terminals)

1. Snap the wire harness cover off of the back of the connector

NOTE

Insert a thin flat bladed screwdriver all the way to the bottom behind the tab of the secondary lock.

2. Gently slide the secondary lock out of the connector with a screwdriver.
3. See Figure 3. Insert the TERMINAL EXTRACTOR (Part Number:B-50085) into the cavity on the outside of
 the terminal.
4. Tilt extractor to lift the latch and release the terminal.
5. Gently pull on the wire to remove the terminal.

View interactive
View interactive image
image

1 Secondary lock

2 Terminal extractor

Figure 3. Removing Small Socket Terminals

Installing Terminals

1. Locate the wire lead cavity by number.

2. Use a hobby knife to bend the tangs on each side of the terminal outward.
3. Align the terminal.
4. Push the terminal in until it clicks.
5. Press the secondary lock back into the connector.
6. Snap the wire cover in place.

Replacement and Repair

The terminals and connector assemblies are not repairable. Discard and replace any defective or damaged terminals
or connector assemblies. Do not re-use a terminal by removing the wire.
Special Tools

Description Part Number Qty.

TERMINAL EXTRACTOR B-50085 1

AMP MULTILOCK CRIMPER HD-41609 1

MULTI-LOCK CRIMPER HD-44695-A 1

Tyco Multilock Unsealed connectors are found between wire harnesses and component wiring. They are either floating or
anchored to the frame with attachment clips. To maintain serviceability, always return connectors to OEM locations after
service.

NOTE

Use the AMP MULTILOCK CRIMPER (Part Number:HD-41609) for 070 Multilock terminal crimping.

Use the MULTI-LOCK CRIMPER (Part Number:HD-44695-A) for 040 Multilock terminal crimping.
Refer to Bosch tool instruction sheet for crimping instructions.

Separating Connector

1. If necessary, slide connector attachment clip so T-stud is in the large end of the clip opening. Remove
connector from T-stud.
2. See Figure 1. Press the release button and pull the connector halves apart.

Mating Connector

1. Hold the connectors to match wire color to wire color.

2. Align the terminals and press the connectors together until they click in place.
3. If OEM location is a T-stud, fit large opening end of attachment clip over T-stud. Slide connector to engage T-
stud to small end of opening in clip.
 View interactive
View interactive image
image

1 Socket housing

2 Release button

3 Pin housing

4 Attachment clip

Figure 1. Tyco Multilock Unsealed Connector

Terminal Removal

1. See Figure 2. Bend back the latch to free one end of secondary lock then repeat on the opposite end. Hinge
the secondary lock outward.
2. Look in the terminal side of the connector (opposite the secondary lock) and note the cavity next to each
terminal.
3. Using TERMINAL EXTRACTOR (Part Number:B-50085), press the tang in the housing to release the
terminal.
a. Socket: Lift the socket tang up.
b. Pin: Press the pin tang down.

NOTE

If the tang is released, a click is heard.

4. Gently pull on wire to remove terminal from cavity.

 View interactive
View interactive image
image

1 Latch

2 Secondary lock open

3 Pin housing

4 Socket housing

5 Pin terminal

6 Socket terminal

7 Tang (pin)

8 Tang (socket)

Figure 2. Tyco 070 Multilock Unsealed Connector: Socket and Pin

Housings

Installing Terminals

NOTE

Match the wire color to the cavity number found on the wiring diagram.
 The release button is always on the top of the connector.

On the pin side of the connector, tangs are positioned at the bottom of each cavity. Therefore, 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. Therefore, the socket terminal slot (on the same side
as the crimp tails) must face upward.

1. Hold the terminal so the catch faces the tang in the cavity. Insert the terminal into its numbered cavity until it
snaps in place.
2. Gently tug on wire ends to verify that all terminals are locked.
3. Rotate the hinged secondary lock inward until tabs are fully engaged on both sides of connector.

Replacement and Repair

The terminals and connector assemblies are not repairable. Discard and replace any defective or damaged terminals
or connector assemblies. Do not re-use a terminal by removing the wire.
Special Tools

Description Part Number Qty.

TERMINAL EXTRACTOR B-50085 1

Separating Connector

1. Lift locking tab.

2. Pull the connector apart.

Mating Connector

1. Align the connector housings.

2. Press the housings together until the locking tab snaps into place.

Terminal Removal

1. File the edge of a TERMINAL EXTRACTOR (Part Number:B-50085) to a 45 degree angle.

2. See Figure 1. Remove seal from connector.
3. Lift locking tab on either side of connector and remove secondary lock.
4. Insert the extractor into the cavity next to the terminal. Press the retainer away from the terminal.
5. Gently pull the wire to remove the terminal from the connector.

Installing Terminal

1. Align terminal to the connector.

2. Install the terminal into the connector until it snaps into place.
3. Gently pull wire to verify terminal is locked.
4. See Figure 1. Install secondary lock into connector.
5. Install seal.
 View interactive
View interactive image
image

1 Terminal

2 Connector

3 Secondary lock

4 Seal

Figure 1. Tyco SuperSeal 1.5 Sealed Connector

Replacement and Repair

The terminals and connector assemblies are not repairable. Discard and replace any defective or damaged terminals
or connector assemblies. Do not re-use a terminal by removing the wire.
Special Tools

Description Part Number Qty.

TERMINAL EXTRACTOR B-50085 1

Separating Connector

1. Press the release button.

2. Pull the connector apart.

Mating Connector

1. Align the connector housings.

2. Press the housings together until the lock clicks into place.

Terminal Removal

1. File the edge of a TERMINAL EXTRACTOR (Part Number:B-50085) to a 45 degree angle.

2. See Figure 1. Pry secondary lock from connector.
3. Insert the extractor into the cavity next to the terminal. Press the tang away from the terminal.
4. Gently pull the wire to remove the terminal from the connector.

Installing Terminal

1. Align terminal to the connector.

2. Install the terminal into the connector until it snaps into place.
3. Gently pull wire to verify terminal is locked.
4. See Figure 1. Install secondary lock into connector.
 View interactive
View interactive image
image

1 Secondary lock

2 Terminal

3 Connector

4 Cavity

Figure 1. Yazaki SSD Sealed Connector

Replacement and Repair

The terminals and connector assemblies are not repairable. Discard and replace any defective or damaged terminals
or connector assemblies. Do not re-use a terminal by removing the wire.
Refer to the table below for a list of common acronyms and abbreviations.

Table 1. Acronyms and Abbreviations

ACRONYM OR ABBREVIATION DESCRIPTION

A Amperes

AAT Ambient air temperature

ABS Anti-lock braking system

AC Alternating current

ACC Accessory position on ignition switch

ACR Automatic compression release

AGM Absorbed glass mat (battery)

Ah Ampere-hour

AIS Active intake solenoid

AWG American wire gauge

B+ Battery voltage

bar Bar

BAS Bank angle sensor

BCM Body control module

BOB Breakout box

BTDC Before top dead center

°C Celsius (Centigrade)

CA California

CAL Calibration

CAN Controller area network

CB Tx CB send transmission

CB Rx CB receive transmission

cc Cubic centimeters

CCA Cold cranking amps

CCW Counterclockwise
CKP Crankshaft position

cm Centimeters

cm3 Cubic centimeters

CW Clockwise

DC Direct current

DLC Data link connector

DOM Domestic

DOT Department of Transportation

DTC Diagnostic trouble code

DVOM Digital volt ohm meter

ECM Electronic control module

ECT Engine coolant temperature

ECU Electronic control unit

EEPROM Electrically erasable programmable read only memory

EFI Electronic fuel injection

EHCU Electro hydraulic control unit

ET Engine temperature

ETC Electronic throttle control

EVAP Evaporative emissions control system

°F Fahrenheit

fl oz Fluid ounce

FPS Fuel pressure sensor

ft Feet

ft-lbs Foot pounds

FTP Flash to pass

g Gram

gal Gallon

GAWR Gross axle weight rating

GND Ground (electrical)

GPS Global positioning system

GVWR Gross vehicle weight rating

HCU Hydraulic control unit

HDI Harley-Davidson International

HD-Link Networking system

H-DSSS Harley-Davidson smart security system

HFM Hands-free mode

HFSM Hands-free security module

Hg Mercury

H02S Heated oxygen sensor

hp Horsepower

hr Hour

IAC Idle air control

IAT Intake air temperature

IC Instrument cluster

ID Inside diameter

IGN Ignition light/key switch position

IM Instrument module

in inch

in3 Cubic inch

INJ PW Injector pulse width

INTCM Intercom

in-lbs Inch pounds

JSS Jiffy stand sensor

kg Kilogram

km Kilometer

km/h Kilometers per hour

kPa Kilopascal
kW Kilowatt

KS Knock sensor

L Liter

lb Pounds

LCD Liquid crystal display

LED Light emitting diode

LH Left hand

LHCM Left hand control module

LP License plate

LT Left

mA Milliampere

MAP Manifold absolute pressure

max Maximum

mi Mile

min Minimum

mL Milliliter

mm Millimeter

mph Miles per hour

ms Millisecond

Nm Newton-meter

NIM Navigation interface module

NiMH Nickel metal hydride

N/A Not applicable

O2 Oxygen

OD Outside diameter

OEM Original equipment manufacturer

oz Ounce

P&A Parts and Accessories

Part No. Part number

PIN Personal identification number

PND Personal navigation device

psi Pounds per square inch

PWM signal Pulse width modulated signal

qt Quart

RAD Radio

RCM Reverse control module

RDS Radio data system

RES Reserve mark on fuel supply valve

RH Right hand

RHCM Right hand control module

rpm Revolutions per minute

RT Right

s Seconds

SCFH Cubic feet per hour at standard conditions

SDARS Satellite digital audio radio service

SPDO Speedometer

SPKR Speaker

STT Stop/tail/turn

TA Traffic announcement

TCA Throttle control actuator

TDC Top dead center

TGS Twist grip sensor

TPMS Tire pressure monitoring system

TPS Throttle position sensor

TSM Turn signal module

TSSM Turn signal/security module

TT Telltale
USB Universal serial bus

V Volt

VAC Volts of alternating current

VDC Volts of direct current

VIN Vehicle identification number

VR Voice recognition

VSS Vehicle speed sensor

W Watt

WA Weather alert

WHIM Wireless headset interface module

WSS Wheel speed sensor

Table 1. Metric Conversions

MILLIMETERS TO INCHES INCHES TO MILLIMETERS

(MM X 0.03937 = IN) (IN X 25.40 = MM)

MM IN MM IN MM IN MM IN IN MM IN MM IN MM IN

.1 .0039 25 .9842 58 2.283 91 3.582 .001 .025 .6 15.240 1- 49.21 3-

15/16 5/16

.2 .0078 26 1.024 59 2.323 92 3.622 .002 .051 5/8 15.875 2 50.80 3-3/8

.3 .0118 27 1.063 60 2.362 93 3.661 .003 .076 11/16 17.462 2- 52.39 3.4
1/16

.4 .0157 28 1.102 61 2.401 94 3.701 .004 .102 .7 17.780 2.1 53.34 3-

7/16

.5 .0197 29 1.142 62 2.441 95 3.740 .005 .127 3/4 19.050 2-1/8 53.97 3-1/2

.6 .0236 30 1.181 63 2.480 96 3.779 .006 .152 .8 20.320 2- 55.56 3-

3/16 9/16

.7 .0275 31 1.220 64 2.519 97 3.819 .007 .178 13/16 20.638 2.2 55.88 3.6

.8 .0315 32 1.260 65 2.559 98 3.858 .008 .203 7/8 22.225 2-1/4 57.15 3-5/8

.9 .0354 33 1.299 66 2.598 99 3.897 .009 .229 .9 22.860 2.3 58.42 3-

11/16

1 .0394 34 1.338 67 2.638 100 3.937 .010 .254 15/16 23.812 2- 58.74 3.7
5/16

2 .0787 35 1.378 68 2.677 101 3.976 1/64 .397 1 25.40 2-3/8 60.32 3-3/4

3 .1181 36 1.417 69 2.716 102 4.016 .020 .508 1- 26.99 2.4 60.96 3.8
1/16

4 .1575 37 1.456 70 2.756 103 4.055 .030 .762 1.1 27.94 2- 61.91 3-
7/16 13/16

5 .1968 38 1.496 71 2.795 104 4.094 1/32 .794 1-1/8 28.57 2-1/2 63.50 3-7/8

6 .2362 39 1.535 72 2.834 105 4.134 .040 1.016 1- 30.16 2- 65.09 3.9
3/16 9/16

7 .2756 40 1.575 73 2.874 106 4.173 .050 1.270 1.2 30.48 2.6 66.04 3-
15/16

8 .3149 41 1.614 74 2.913 107 4.212 .060 1.524 1-1/4 31.75 2-5/8 66.67 4

9 .3543 42 1.653 75 2.953 108 4.252 1/16 1.588 1.3 33.02 2- 68.26 4-
11/16 1/16
10 .3937 43 1.693 76 2.992 109 4.291 .070 1.778 1- 33.34 2.7 68.58 4.1
5/16

11 .4331 44 1.732 77 3.031 110 4.331 .080 2.032 1-3/8 34.92 2-3/4 69.85 4-1/8

12 .4724 45 1.772 78 3.071 111 4.370 .090 2.286 1.4 35.56 2.8 71.12 4-
3/16

13 .5118 46 1.811 79 3.110 112 4.409 .1 2.540 1- 36.51 2- 71.44 4.2

7/16 13/16

14 .5512 47 1.850 80 3.149 113 4.449 1/8 3.175 1-1/2 38.10 2-7/8 73.02 4-1/4

15 .5905 48 1.890 81 3.189 114 4.488 3/16 4.762 1- 39.69 2.9 73.66 4.3
9/16

16 .6299 49 1.929 82 3.228 115 4.527 .2 5.080 1.6 40.64 2- 74.61 4-

15/16 5/16

17 .6693 50 1.968 83 3.268 116 4.567 1/4 6.350 1-5/8 41.27 3 76.20 4-3/8

18 .7086 51 2.008 84 3.307 117 4.606 .3 7.620 1- 42.86 3- 77.79 4.4

11/16 1/16

19 .7480 52 2.047 85 3.346 118 4.645 5/16 7.938 1.7 43.18 3.1 78.74 4-
7/16

20 .7874 53 2.086 86 3.386 119 4.685 3/8 9.525 1-3/4 44.45 3-1/8 79.37 4-1/2

21 .8268 54 2.126 87 3.425 120 4.724 .4 10.160 1.8 45.72 3- 80.96 4-

3/16 9/16

22 .8661 55 2.165 88 3.464 121 4.764 7/16 11.112 1- 46.04 3.2 81.28 4.6
13/16

23 .9055 56 2.205 89 3.504 122 4.803 1/2 12.700 1-7/8 47.62 3-1/4 82.55 4-5/8

24 .9449 57 2.244 90 3.543 123 4.842 9/16 14.288 1.9 48.26 3.3 83.82 4-
11/16
Unless otherwise specified, all fluid volume measurements in this 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.)
Fluid volume measurements in this manual include the metric system equivalents. In the metric system, 1 liter (L) = 1,000
milliliters (mL). To convert between U.S. units-of-measure and metric units-of-measure, 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.)
Fluid volume measurements in this manual do not include the British Imperial (Imp.) system equivalents. The following
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 actual
volume of each British Imperial unit-of-measure differs from its U.S. counterpart. The U.S. fluid ounce is larger than the
British Imperial fluid ounce. However, the U.S. pint, quart, and gallon are smaller than the British Imperial pint, quart, and
gallon, respectively. To convert between U.S. units and British Imperial units, 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.)
The U.S. units of torque, foot pounds and inch pounds, are used in this manual. To convert units, use the following
equations:

foot pounds (ft-lbs) X 12.00000 = inch pounds (in-lbs)

inch pounds (in-lbs) X 0.08333 = foot pounds (ft-lbs)
All metric torque specifications are written in Newton-meters (Nm). To convert metric to United States units and United
States 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)
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Figure 1.
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Figure 1.