7

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DTC P0106, P0107, P0108 4.13

GENERAL 7351

MAP Sensor
See Figure 4-24. The manifold absolute pressure sensor
(MAP sensor) is supplied 5 volts from the ignition control
module and sends a signal back to the ignition control mod-
ule. This signal varies in accordance with engine vacuum and
atmospheric barometric pressure. Changes in barometric
pressure are influenced by weather and altitude.

Table 4-15. Code Description

DTC DESCRIPTION

P0106 MAP sensor rate-of-change error

P0107 MAP sensor failed open/low
P0108 MAP sensor failed high

Figure 4-24. MAP Sensor

DIAGNOSTICS Diagnostic Notes

The reference numbers below correlate with the circled num-
Diagnostic Tips bers on the Test 4.13 flow charts.

● DTC P0106 will set if the MAP sensor signal fluctuates 1. Connect BREAKOUT BOX (Part No. HD-42682)
faster than normal operation. between wire harness and ignition control module. See
4.6 BREAKOUT BOX: ICM.
● With the MAP sensor disconnected, the ignition control
module should recognize a low voltage. If low voltage is 2. Use HARNESS CONNECTOR TEST KIT (Part No. HD-
observed, the ignition control module and harness are 41404), gray pin probes and patch cords.
not at fault.

● Gently place a jumper wire across MAP Sensor connec-

tor [80B] Terminals B and C using HARNESS CONNEC-
TOR TEST KIT (Part No. HD-41404), gray male probes
and patch cord. With the jumper in place, the ignition
control module should recognize a high voltage.

● MAP sensor output check. Using the VACUUM PUMP

(Part No. HD-23738A), apply a vacuum to the pressure
port of the MAP sensor. The signal voltage should lower
as the vacuum is applied.

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s0587a8x

Manifold
absolute
pressure
sensor
(MAP)

[80A]
[80B]

BK/W

R/W
V/W
To vehicle
speed sensor
(VSS)

BK/W

V/W
R/W
[10B]
[10A]

Sensor power

Sensor ground

MAP signal
Ignition control module

Figure 4-25. MAP Sensor Circuit

Table 4-16. Wire Harness Connectors in Figure 4-25.

NO. DESCRIPTION TYPE LOCATION

[10] Ignition Control Module 12-Place Deutsch Under Right Side Cover
[80] Manifold Absolute Pressure Sensor (MAP) 3 - Place Packard Top of Intake Manifold

4-34 2004 Touring: Engine Management (Carbureted)

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Test 4.13 (Part 1 of 2)

MAP SENSOR: DTC P0106, P0107, P0108

With ignition ON, measure voltage

1 between Breakout Box terminal 11 (+)
and terminal 4 (-). With key ON,
engine OFF, voltage must be between
4.2 and 4.95 volts. With key ON,
engine running, voltage must be
between 1.5-3.0 volts at hot idle.
Does voltage fit specifications?

YES NO

Perform 4.7 WIGGLE TEST

to check for intermittents.
Intermittents present?
STOP

Go to Test 4.13
(Part 2 of 2).

YES NO

To identify the source of inter- Replace MAP sensor. See the Touring Ser-
mittents, start with box marked vice Manual. Clear diagnostic trouble codes.
by Bold Asterisk under Test See 4.5 SPEEDOMETER SELF DIAGNOS-
4.13 (Part 2 of 2). Wiggle har- TICS. Road test. Did check engine lamp illu-
ness while watching DVOM. minate and set Code P0106, P0107 or

YES NO

Install original MAP sensor. System

Replace ignition control module now OK.
and road test again to verify.

Clear codes using speedometer self diagnostics.

See 4.5 SPEEDOMETER SELF DIAGNOSTICS.
Confirm proper operation with no check engine
lamp.

At some point in the flow chart you

may be instructed to jump directly
to a the box with the bold asterisk.
Disregard the asterisk (but not the
instruction box) if your normal pro-
gression through the chart brings
you to this location.

2004 Touring: Engine Management (Carbureted) 4-35

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Test 4.13 (Part 2 of 2)

MAP SENSOR: DTC P0106, P0107, P0108

Continued from Test 4.13 (Part 1 of 2).

Check the 5 volt reference supply at
the MAP sensor connector [80B]. With
2 ignition ON, measure voltage between
terminal C (R/W) and terminal A (BK/W).
Is voltage approximately 5.0 volts?

YES NO. NO.

Greater Less
than 6V. than 4.5V.
Connect Breakout Box. Disconnect ignition
1 control module from Breakout Box.
OPEN CHECK: Measure resistance Locate short to 12 volts on R/W Disconnect ignition control module from
2 between MAP connector [80B] Terminal B wire in wire harness. Repair as
1 Breakout Box.
and Breakout Box connector [10] necessary. Check continuity between MAP connector
terminal 11. Is resistance less than 1 ohm?
2 [80B] Terminal C and Breakout Box
connector [10] terminal 3. Then measure
continuity between MAP connector [80B]
Terminal A and Breakout Box connector [10]
terminal 4.
Continuity present?
YES NO

SHORT CHECK: Measure Locate and repair

2 resistance between MAP con- open on V/W wire.
nector Terminal B and chassis
ground. Is resistance greater
than 1 meg ohm? YES NO

With MAP sensor connector Repair

[80] disconnected, check open wire.
resistance between Break-
YES NO out Box terminal 3 and 5
(black). Is it greater than 1
megohm?

Replace MAP sensor. See the Locate and repair

Touring Service Manual. grounded V/W wire.

YES NO

Replace ICM. Locate and repair

Reprogram and short between
learn password. R/W wire and
ground.

Clear codes using speedometer self diagnostics.

See 4.5 SPEEDOMETER SELF DIAGNOSTICS.
Confirm proper operation with no check engine
lamp.

At some point in the flow chart you

may be instructed to jump directly
to a the box with the bold asterisk.
Disregard the asterisk (but not the
instruction box) if your normal pro-
gression through the chart brings
you to this location.

4-36 2004 Touring: Engine Management (Carbureted)

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DTC P0562, P0563 4.14

GENERAL DIAGNOSTICS

Battery Voltage Diagnostic Notes

The ignition control module monitors battery positive voltage. The reference numbers below correlate with the circled num-
The normal operating range is between 8-16 volts while bers on the Test 4.14 flow charts.
engine is running.
1. Was battery allowed to discharge? Was battery drawn
NOTE down by a starting problem?
When either a diagnostic trouble code P0562 or P0563 is set, a. Yes. Charge battery.
the battery icon in the speedometer will illuminate.
b. No. See charging system troubleshooting.
● A DTC P0562 is set if the ignition module detects battery
positive voltage less than 8 volts while the engine is run- 2. Connect BREAKOUT BOX (Part No. HD-42682)
ning. between wire harness and ignition control module. See
4.6 BREAKOUT BOX: ICM.
● A DTC P0563 is set if the ignition module detects battery
positive voltage greater than 16 volts. 3. The ignition control module is monitoring voltage at igni-
tion control module connector [10] (black) Pin 1.
● Low voltage generally indicates a loose wire, corroded
4. This checks for voltage drops in the ignition control mod-
connections and/or a charging system problem.
ule circuit.
● A high voltage condition may be caused by a faulty volt-
a. Place (+) probe to battery positive terminal.
age regulator.
b. Place (-) probe to terminal 1 on Breakout Box.

Table 4-17. Code Description 5. Remove Breakout Box at ICM, reconnect ICM. Insert
Breakout Box at connector [22] (BK). On FLHR/S models
DTC DESCRIPTION (6-place connector), install Breakout Box adapters (HD-
42962).
P0562 battery voltage low
P0563 battery voltage high

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R/BK To Ignition Switch Ignition Control Module

[83B]

7
A Y \ BE Rear Coil
B
6
C BE \ O Front Coil
5
15 Amp BK Ground
Ignition Fuse W
Ignition \
B
Coil K
GY

1
W \ BK Key ON Power

To TSM/TSSM
[10B] [10A]
[8A] To
1 2 3 4 5 6 7 8 9 10 11 12 [8B] Data Link

Ground Stud
[1B]
1 2 3 4 5 6 7 8 9 10 11 12
[1A]

FLHT/C Only
GY

Engine Stop Switch W \ BK

6-Place on FLHR/S
[22B]
1 2 3 4 5 6 7 8 9 10 11 12
[22A]

Figure 4-26. Battery Voltage Circuit

Table 4-18. Wire Harness Connectors in Figure 4-26.

NO. DESCRIPTION MODEL TYPE LOCATION

[1] Main to Interconnect Harness FLHT/C 12-Place Deutsch Inner Fairing- Right Fairing Bracket
[8] Ignition Harness All 12-Place Deutsch Under Right Side Cover
[10] Ignition Control Module All 12-Place Deutsch (Black) Under Right Side Cover
Inner Fairing-
Interconnect to Right FLHT/C 12-Place Deutsch
[22] Right Fairing Support Brace
Handlebar Switch Controls
FLHR/S 6-Place Deutsch Inside Headlamp Nacelle
[83] Ignition Coil All 3 - Place Packard Below Fuel Tank (Left Side)

4-38 2004 Touring: Engine Management (Carbureted)

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Test 4.14 (Part 1 of 2)

BATTERY VOLTAGE: DTC P0562, P0563

Perform charging system tests.

1 Charging system OK?

YES NO

2
With ignition ON, measure voltage drop Repair
between battery positive (+) terminal charging system.
3 and Breakout Box connector [10] (black)
Pin 1 (-). Is voltage drop greater
than 0.5 volt?
4

YES NO

With ignition ON, measure voltage drop Check for voltage drop between battery
5 between battery positive (+) terminal negative (-) terminal and Pin 5 (+) on
and connector [22A] Pin 4 (-). Is voltage connector [10B] (black) on Breakout Box.
drop greater than 0.5 volt? Is voltage drop greater than 0.5 volt?

YES NO YES NO

With ignition ON, measure voltage drop Repair or replace Locate and repair Problem is intermittent.
between battery positive (+) terminal W/BK wire or bad connection. Perform 4.7 WIGGLE
and connector [22A] Pin 3 (-). Is voltage terminals. TEST.
drop greater than 0.5 volt?

YES NO

Inspect connector [22] for

corrosion or loose wires. If
STOP above conditions are not
present, replace engine stop
switch.
Go to Test 4.14
(Part 2 of 2).

Clear codes using speedometer self diagnostics.

See 4.5 SPEEDOMETER SELF DIAGNOSTICS.
Confirm proper operation with no check engine
lamp.

2004 Touring: Engine Management (Carbureted) 4-39

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Test 4.14 (Part 2 of 2)

BATTERY VOLTAGE: DTC P0562, P0563

Continued from Test 4.14 (Part 1 of 2). With

ignition ON, measure voltage drop between
battery positive (+) terminal and GY terminal
on 15 amp ignition fuse (-). Is voltage
drop greater than 0.5 volt?

YES NO

With ignition ON, measure voltage drop Repair or replace GY

between battery positive (+) terminal and wire or terminals.
R/BK terminal on 15 amp ignition fuse. Is
voltage drop greater than 0.5 volt?

YES NO

With ignition ON, measure voltage drop Replace fuse or

between battery positive (+) terminal and fuse terminals.
terminal A of maxi fuse (-).
Is voltage drop greater than 0.5 volt?

YES NO

With ignition ON, measure voltage drop Replace ignition

between battery positive (+) terminal and switch or terminals.
terminal B of maxi fuse (-).
Is voltage drop greater than 0.5 volt?

YES NO

High resistance between maxi Replace maxi fuse.

fuse and battery. Replace wire or
terminals.

Clear codes using speedometer self diagnostics.

See 4.5 SPEEDOMETER SELF DIAGNOSTICS.
Confirm proper operation with no check engine
lamp.

4-40 2004 Touring: Engine Management (Carbureted)

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DTC P1009, P1010 4.15

GENERAL

Password Problem
The ICM and TSM/TSSM exchange passwords during opera-
tion. An incorrect password or missing password will set a
diagnostic code.

NOTE
If the TSM/TSSM is not connected to the wiring harness, the
vehicle will not start.

Table 4-19. Code Description

DTC DESCRIPTION

P1009 Incorrect password

P1010 Missing password Figure 4-27. TSM/TSSM

DIAGNOSTICS 6924

Diagnostic Notes 3
4
The reference numbers below correlate with the circled num-
bers on the Test 4.15 flow charts.
2
1. DTC P1009 may be set if a recent ICM or TSM/TSSM
replacement did not follow the correct password assign-
1
ment procedure. See 3.24 PASSWORD LEARN for
details.
2. Use HARNESS CONNECTOR TEST KIT (Part No. HD-
1. Terminal 2: ground (BK)
41404), black socket probes and patch cord.
2. Terminal 3: serial data (Lt GN/V)
3. Connect BREAKOUT BOX (Part No. HD-42682) 3. Terminal 4: power (GY)
between wire harness and ICM. See 4.6 BREAKOUT 4. Protective cap
BOX: ICM.
4. See the Touring Service Manual for TSM/TSSM replace- Figure 4-28. Data Link Connector
ment. See PASSWORD LEARNING under 3.24 PASS-
WORD LEARN for the password learning procedure.

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f2208z8x
[156B] [156A]
Main to Interconnect
6 6 Harness
5 5
4 4
3 3 GY
BK
2 2 BK
LtGN/V 1 1 LtGN/V
O
1 2 3 4 5 6 7 8 9 10 11 12 [30B]
BN/GY 1 2 3 4 5 6 7 8 9 10 11 12 [30A]
BN/GY
TSM/TSSM

[39B] GY BK
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12 [39A]
1 2 3 4 5 6 7 8 9 10 11 12 [8B]
Speedometer 1 2 3 4 5 6 7 8 9 10 11 12
[108B] 1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12 [8A] Ignition
[108A] Tachometer Harness

15A [1B] [1A]

Accessory
Fuse 1

12 11 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 6 5 4 3 2 1
2
Main to Interconnect 3
[2A] 1 2 3 4 5 6 7 8 9 10 11 12 Harness 4
[2B] 1 2 3 4 5 6 7 8 9 10 11 12
Data Link
[91A]
Main to Interconnect 15A
Harness Ignition
Fuse

LtGN/V
12
15A [10B]
Battery 12
Fuse
[10A] Ignition Control Module

Serial data
Figure 4-29. Serial Data Circuit (FLHT/C)

Table 4-20. Wire Harness Connectors in Figure 4-29.

NO. DESCRIPTION TYPE LOCATION

[1] Main to Interconnect Harness 12-Place Deutsch (Black) Inner Fairing - Right Radio Support Bracket
[2] Main to Interconnect Harness 12-Place Deutsch (Gray) Inner Fairing - Right Fairing Support Brace
[8] Ignition Harness 12-Place Deutsch Under Right Side Cover
[10] Ignition Control Module 12-Place Deutsch Under Right Side Cover
Cavity in Crossmember at Rear of
[30] Turn Signal/Security Module 12-Place Deutsch
Battery Box (Under Seat)
[39] Speedometer 12-Place Packard Inner Fairing (Back of Speedometer)
[91] Data Link 4-Place Deutsch Under Right Side Cover
[108] Tachometer 12-Place Packard Inner Fairing (Back of Tachometer)
[156] Main to Interconnect Harness 6-Place Deutsch Inner Fairing - Right Fairing Support Brace

4-42 2004 Touring: Engine Management (Carbureted)

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f2208y8x

BK GY
LtGN/V LtGN/V BK

BN/GY
O 1 2 3 4 5 6 7 8 9 10 11 12 [30B]
1 2 3 4 5 6 7 8 9 10 11 12 [30A]
BN/GY TSM/TSSM

1 2 3 4 5 6 7 8 9 10 11 12 BK
[39B]
1 2 3 4 5 6 7 8 9 10 11 12 [39A] GY
Speedometer
1 2 3 4 5 6 7 8 9 10 11 12 [8B] Ignition
1 2 3 4 5 6 7 8 9 10 11 12 [8A] Harness

15A
Battery
Fuse 15A
Accessory
Fuse 1
2
3
4
Data Link
[91A]

15A

LtGN/V
Ignition
Fuse

12
[10B]
[10A] Ignition Control Module 12

Serial data
Figure 4-30. Serial Data Circuit (FLHR/S)

Table 4-21. Wire Harness Connectors in Figure 4-30.

NO. DESCRIPTION TYPE LOCATION

[8] Ignition Harness 12-Place Deutsch Under Right Side Cover

[10] Ignition Control Module 12-Place Deutsch Under Right Side Cover
Cavity in Crossmember at Rear of
[30] Turn Signal/Security Module 12-Place Deutsch
Battery Box (Under Seat)
[39] Speedometer 12-Place Packard Under Console (Back of Speedometer)
[91] Data Link 4-Place Deutsch Under Right Side Cover

2004 Touring: Engine Management (Carbureted) 4-43

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Test 4.15
PASSWORD PROBLEM: DTC P1009, P1010

Which diagnostic trouble

code was set?

DTC P1009. DTC P1010.

1 Bad password. No password.
Reprogram password. Are there any
See 3.24 PASSWORD U-codes set?
4 LEARN.
DTC P1009 still exist?

YES NO YES NO

Replace TSSM and System Troubleshoot Remove ICM connector [10]. Check
4 relearn password. OK. lowest U-code. for continuity to ground at data
System OK? connector [91A] Terminal 3. 2
6701 Continuity present?

YES NO YES NO

System Repair short Check for battery voltage on Pin 3.

Reinstall original TSSM.
OK. to ground. Battery voltage present?
Replace ICM.
5 Reprogram and relearn
6702 6704
password.
6703

YES NO

Repair short Test data connector [91A] 2

to voltage. Terminal 3 against Breakout Box Pin
12 for continuity. Continuity present?
6705 3

YES NO

Inspect terminals
for damage or repair
Replace TSM/TSSM and relearn
4 password. System OK? 2 opens as necessary.
6706

YES NO

System Reinstall original TSSM.

OK. Replace ICM.
4 Reprogram and relearn
6707
password.

6708

Clear codes using speedometer self diagnostics.

See 4.5 SPEEDOMETER SELF DIAGNOSTICS.
Confirm proper operation with no check engine
lamp.

4-44 2004 Touring: Engine Management (Carbureted)

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DTC P1351, P1352, P1354, P1355 4.16

GENERAL 7863

Ignition Coil
Ignition coil codes 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 codes are set simulta-
neously, it is likely a coil power failure or a coil failure.

The coil receives power from the engine run/stop switch. The
ignition control module is responsible for turning on the coils
by providing the ground to activate the coils, which in turn
powers the coils.

Table 4-22. Code Description

DTC DESCRIPTION Figure 4-31. Ignition Coil Circuit Test

P1351 Front ignition coil open/low

s0592x8x
P1352 Front ignition coil high/shorted Coil tower
P1354 Rear ignition coil open/low
P1355 Rear ignition coil high/shorted

DIAGNOSTICS
C

Diagnostic Notes B
The reference numbers below correlate with the circled num-
bers on the Test 4.16 flow charts. A

1. Use HARNESS CONNECTOR TEST KIT (Part No. HD-

41404), gray pin probes and patch cord.

CAUTION Figure 4-32. Ignition Coil Connector Terminals

Gently connect test lamp to connector [83B]. Forcefully
inserting test lamp will result in ignition connector termi-
nal damage. 4. Use HARNESS CONNECTOR TEST KIT (Part No. HD-
41404), gray socket probes and patch cord.
2. See Figure 4-31. Plug IGNITION COIL CIRCUIT TEST
ADAPTER (Part No. HD-44687) and FUEL INJECTOR
TEST LAMP (Part No. HD-34730-2C) into Breakout Box. Table 4-23. Coil Terminal Description
Note that cranking the engine with test lamp in place of
the ignition coil can sometimes cause a DTC P1351, TERMINAL DESCRIPTION WIRE COLOR
P1352, P1354 or P1355. This condition is normal and
does not by itself indicate a malfunction. Codes must be A Rear coil Y/BE
cleared if this condition occurs.
B Power W/BK
3. Connect BREAKOUT BOX (Part No. HD-42682)
between wire harness and ICM. See 4.6 BREAKOUT C Front coil BE/O
BOX: ICM.

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R/BK To Ignition Switch Ignition Control Module

[83B]

7
A Y \ BE Rear Coil
B
6
C BE \ O Front Coil
5
15 Amp BK Ground
Ignition Fuse W
Ignition \
B
Coil K
GY

1
W \ BK Key ON Power

To TSM/TSSM
[10B] [10A]
[8A] To
1 2 3 4 5 6 7 8 9 10 11 12 [8B] Data Link

Ground Stud
[1B]
1 2 3 4 5 6 7 8 9 10 11 12
[1A]

FLHT/C Only
GY

Engine Stop Switch W \ BK

6-Place on FLHR/S
[22B]
1 2 3 4 5 6 7 8 9 10 11 12
[22A]

Figure 4-33. Battery Voltage Circuit

Table 4-24. Wire Harness Connectors in Figure 4-33.

NO. DESCRIPTION MODEL TYPE LOCATION

[1] Main to Interconnect Harness FLHT/C 12-Place Deutsch Inner Fairing- Right Fairing Bracket
[8] Ignition Harness All 12-Place Deutsch Under Right Side Cover
[10] Ignition Control Module All 12-Place Deutsch (Black) Under Right Side Cover
Inner Fairing-
Interconnect to Right FLHT/C 12-Place Deutsch
[22] Right Fairing Support Brace
Handlebar Switch Controls
FLHR/S 6-Place Deutsch Inside Headlamp Nacelle
[83] Ignition Coil All 3 - Place Packard Below Fuel Tank (Left Side)

4-46 2004 Touring: Engine Management (Carbureted)

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Test 4.16 (Part 1 of 2)

IGNITION COIL: DTC P1351, P1352, P1354, P1355

Disconnect connector [83].

Measure voltage on Terminal B
of coil. Equal to battery voltage
1 after key ON?

YES NO

Use Breakout Box and test light for the

2 next inspection.
Repair open wire or
Front coil codes: Check between ICM Pin connection on W/BK wire.
3 6 and ICM Pin 1.

Rear coil codes: Check between ICM Pin

7 and ICM Pin 1.

Does test lamp flash when engine is

cranked?

YES NO

Measure coil resistance. Replace ICM.

4 Reprogram and
Front coil codes: Check between perform password learn.
coil Terminal B and Terminal C.

Rear coil codes: Check between

coil Terminal B and Terminal A.

Resistance 0.5-0.7 ohms?

YES NO

Replace coil.
STOP

Go to Test 4.16
(Part 2 of 2).
Clear codes using speedometer self diagnostics.
See 4.5 SPEEDOMETER SELF DIAGNOSTICS.
Confirm proper operation with no check engine
lamp.

2004 Touring: Engine Management (Carbureted) 4-47

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Test 4.16 (Part 2 of 2)

IGNITION COIL: DTC P1351, P1352, P1354, P1355

Continued from Test 4.16 (Part 1 of 2).

Using Breakout Box, measure resistance between

ICM and coil terminals as follows.

DTC COIL BREAK-

TERMINAL OUT BOX
TERMINAL

P1351/ C
6
P1352 (BE/O wire)

P1353/ A
1 P1354 (Y/BE wire)
7

3 Resistance less than 0.5 ohms?

YES NO

Perform 5.8 WIGGLE TEST Repair open wire

to check for intermittents. or connection.
Intermittents present?

YES NO

Repair Check for continuity to ground.

intermittent.
Front coil codes: Check
Breakout Box Pin 6.

Rear coil codes: Check

Breakout Box Pin 7.

Continuity present?

YES NO

Repair short Check for voltage.

to ground.
Front coil codes: Check
Breakout Box Pin 6.

Rear coil codes: Check

Breakout Box Pin 7.

Voltage present?

YES NO

Repair short Replace ICM.

to voltage. Reprogram and
learn password.

Clear codes using speedometer self diagnostics.

See 4.5 SPEEDOMETER SELF DIAGNOSTICS.
Confirm proper operation with no check engine
lamp.

4-48 2004 Touring: Engine Management (Carbureted)

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DTC P0373, P0374 4.17

GENERAL
f2256x8x

Crank Position Sensor

See Figure 4-34. A DTC P0373, P0374 will set if the crank-
shaft position sensor (CKP) signal is weak or absent.

Table 4-25. Code Description

DTC DESCRIPTION
P0373 Crankshaft position sensor intermittent
Crankshaft position sensor not detected or
P0374
cannot synchronize Stator
Connector [46]

Crankshaft
DIAGNOSTICS Position Sensor
Connector [79]
Under Voltage Regulator

Diagnostic Notes
Figure 4-34. Voltage Regulator (Left Side View)
1. Connect BREAKOUT BOX (Part No. HD-42682) to igni-
tion control module wire harness only, leaving ignition
control module disconnected. See 4.6 BREAKOUT BOX:
ICM.

2. One megohm is very high resistance. Some meters will

read infinity, OL, etc.

3. Use HARNESS CONNECTOR TEST KIT (Part No. D-

41404), brown socket probes and patch cords.

4. For testing purposes, install sensor without running wir-

ing along normal path. Disconnect and route wiring prop-
erly if system is now OK.

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f2208w8x

Crankshaft
Position
Sensor

BK
R
[79A]
[79B] 1 2

BK

BK
R
[10B]
[10A]

Crank Sensor (+)

Module Ground

Crank Sensor (-)

Ignition Control Module

Figure 4-35. Ignition Circuit

Table 4-26. Wire Harness Connectors in Figure 4-35.

NO. DESCRIPTION TYPE LOCATION

[10] Ignition Control Module 12-Place Deutsch Under Right Side Cover
[79] Crankshaft Position Sensor 2 - Place Mini-Deutsch Bottom of Voltage Regulator

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Test 4.17
CRANK POSITION SENSOR: DTC P0373, P0374

Leaving ICM disconnected, connect Breakout

1 Box to harness only. Measure resistance
between Pins 8 and 5, and between Pins 9 and 5
on connector [10]. Is resistance more than 1
2 megohm?

YES NO

Check for intermittent connection, pinched Disconnect connector [79]. Leaving ICM
or damaged wires, and loose CKP sensor disconnected, use Breakout Box to measure
fastener. Conditions found? resistance between Pins 8 and 5 on connector
[10]. Also measure resistance between Pins 9
and 5 on connector [10]. Is there still continuity to
ground (less than 1 megohm resistance)?

YES NO

Repair as Connect DVOM to Terminals 8 and 9 at YES NO

necessary. connector [10] on Breakout Box.
Set DVOM to AC volts and crank engine.
Does DVOM read 1 VAC minimum Repair short to Replace CKP
during cranking? ground on R or sensor.
BK wire between
connectors [10B]
and [79B].

YES NO

With DVOM still connected, check for Connect DVOM at Terminals 1

intermittents using 4.7 WIGGLE TEST. 3 and 2 of connector [79A].
Intermittents present? DVOM should read 1 VAC
minimum while cranking.
Does it?

YES NO

YES NO
Repair as Replace CKP
necessary. sensor. Clear
codes and retest. Check for continuity between Replace CKP
Code P0373, Pin 8 [10B] and Pin 1 [79B]. Is sensor.
P0374 set? continuity present?

4
YES NO
YES NO

Repair open on BK wire Repair open on R wire

Reinstall CKP System between Pin 2 [79B] and Pin 9 between Pin 1 [79B] and Pin 8
sensor. Replace OK. on connector [10B]. on connector [10B].
ICM. Reprogram
and perform pass-
word learn.

Clear codes using speedometer self diagnostics.

See 4.5 SPEEDOMETER SELF DIAGNOSTICS.
Confirm proper operation with no check engine
lamp.

2004 Touring: Engine Management (Carbureted) 4-51

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DTC P0501, P0502 4.18

GENERAL
7951

Vehicle Speed Sensor

See Figure 4-36. The vehicle speed sensor is powered and
Speed
monitored by the ICM. The ICM processes the vehicle speed Sensor
signal and transmits this signal to the TSM/TSSM and speed-
ometer through serial data.

NOTE
When the vehicle speed signal is greater than 0, the closed
loop idle speed control is inhibited.

Table 4-27. Code Description

DTC DESCRIPTION
Engine Oil Fill
P0501 VSS sensor low Plug/Dipstick
P0502 VSS sensor high/open

Figure 4-36. Vehicle Speed Sensor Location

DIAGNOSTICS
f2183x8x

Diagnostic Notes
The reference numbers below correlate with the circled num-
bers on the Test 4.18 flow charts.

1. The speedometer has a built-in diagnostic mode. See 1

4.5 SPEEDOMETER SELF DIAGNOSTICS.

2. Use HARNESS CONNECTOR TEST KIT (Part No. HD-

41404), black pin probe and patch cord.

3. Connect BREAKOUT BOX (Part No. HD-42682)

between wire harness and ICM. See 4.6 BREAKOUT
BOX: ICM.

4. Jack up motorcycle and rotate rear wheel with transmis- 2

sion in neutral.

1. Vehicle Speed Sensor Connector [65]

2. P&A Security Siren Connector [142]

Figure 4-37. Electrical Bracket (Inboard Side)

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f2208x8x
Vehicle Speed
Sensor

R A A R/W
W B B W/GN
BK C C BK/W

[65A] [65B]

W/GN
BK/W
R/W
[10B] 3 10
[10A]

Sensor Ground
5v Power

VSS
Ignition
Control
Module

Figure 4-38. Vehicle Speed Sensor Circuit

Table 4-28. Wire Harness Connectors in Figure 4-38.

NO. DESCRIPTION TYPE LOCATION

[10] Ignition Control Module 12-Place Deutsch Under Right Side Cover
[65] Vehicle Speed Sensor 3 - Place Deutsch Under Right Side Cover (Behind Electrical Bracket)

2004 Touring: Engine Management (Carbureted) 4-53

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Test 4.18 (Part 1 of 2)

VEHICLE SPEED SENSOR: DTC P0501, P0502

Remove and inspect vehicle speed sensor. Inspect

for debris and clean if necessary. Place speedometer
into diagnostic mode and clear ICM trouble codes.
Connect all circuits and ride motorcycle for
1 approximately 1.0 mile (1.6 km). Check for newly
logged codes. Codes present?

YES
NO

Check for continuity between socket System OK.

2 A of connector [65B] (R/W wire) and
ground. Continuity present?

YES NO

Repair short to ground. 2 Check for continuity between socket A

of connector [65B] (R/W wire) and pin 3
[10] of breakout box. Continuity
3 present?

YES NO

Check for continuity between socket C Repair open on R/W wire

of connector [65B] (BK wire) and between connectors [10B]
ground. Continuity present? and [65B].

YES NO

Repair open on BK wire

STOP between connector [65B]
and ground.

Go to. Test 4.18

(Part 2 of 2)
Clear codes using speedometer self diagnostics.
See 4.5 SPEEDOMETER SELF DIAGNOSTICS.
Confirm proper operation with no check engine
lamp.

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Test 4.18 (Part 2 of 2)

VEHICLE SPEED SENSOR: DTC P0501, P0502

Continued from Test 4.18 (Part 1 of 2).

2
Check for continuity between socket B of connector
3 [65B] and Pin 10 [10] of breakout box. Continuity
present?

YES NO

Check for voltage on W/GN wire of connector

[65B] while connected. Meter should read 4-6 Repair open on W/GN
wire between connectors
4 volts when gear tooth absent and 0-1 volts
[10B] and [65B].
when gear tooth is present. Does it?

YES NO

Replace ICM. Reprogram

and learn password.
4-6 volts present. 4-6 volts present but no
fluctuation from 0-1 volts

Replace ICM. Reprogram Replace vehicle

and learn password. speed sensor.

2004 Touring: Engine Management (Carbureted) 4-55

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DTC P0602, P0603, P0604, P0605, P0607 4.19

GENERAL DIAGNOSTICS

ICM Failure DTC P0607 Test

All of the following codes indicate an internal failure which 1. Power down the vehicle.
requires replacement of the ignition control module. See the
Touring Service Manual for replacement procedures. 2. Clear codes using speedometer self-diagnostics.

3. Replace ICM if codes reappear.

● DTC P0602 - Calibration memory error

● DTC P0603 - EE PROM failure

● DTC P0604 - RAM failure DTC P0602, P0603, P0604, P0605 Test
● DTC P0605 - Program memory error 1. Power down the vehicle.
● DTC P0607 - A to D converter error 2. Clear codes.

3. Using Digital Technician, reprogram ICM using the cor-

rect calibration. See your dealer.

4. Restart vehicle. If code reappears, replace ICM. Repro-

gram and perform password learn.

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DTC U1064 4.20

GENERAL

Loss of TSM/TSSM Serial Data

The serial data connector provides a means for the ICM and
TSM/TSSM to communicate their current status. When all
operating parameters on the serial data link are within specifi-
cations, a state of health message is sent between the com-
ponents. A DTC U1064 indicates that the TSM/TSSM is not
receiving this state of health message.

Table 4-29. Code Description

DTC DESCRIPTION

U1064 Loss of TSM/TSSM serial data

Figure 4-39. TSM/TSSM

DIAGNOSTICS 6924

Diagnostic Notes 3
4
The reference numbers below correlate with the circled num-
bers on the Test 4.20 flow chart.
1. Connect BREAKOUT BOX (Part No. HD-42682) as fol- 2
lows: 1
a. Mate black socket housing on Breakout Box with
speedometer connector [39] using SPEEDOMETER
HARNESS ADAPTER (Part No. HD-46601).
1. Terminal 2: ground (BK)
b. Mate black pin housing on Breakout Box with speed- 2. Terminal 3: serial data (Lt GN/V)
ometer harness connector [39B] using SPEEDOM- 3. Terminal 4: power (GY)
ETER HARNESS ADAPTER (Part No. HD-46601). 4. Protective cap
c. Mate gray socket housing on Breakout Box with
TSM/TSSM connector [30A]. Figure 4-40. Data Link Connector
d. Mate gray pin housing on Breakout Box with har-
ness connector [30B].

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f2208z8x
[156B] [156A]
Main to Interconnect
6 6 Harness
5 5
4 4
3 3 GY
BK
2 2 BK
LtGN/V 1 1 LtGN/V
O
1 2 3 4 5 6 7 8 9 10 11 12 [30B]
BN/GY 1 2 3 4 5 6 7 8 9 10 11 12 [30A]
BN/GY
TSM/TSSM

[39B] GY BK
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12 [39A]
1 2 3 4 5 6 7 8 9 10 11 12 [8B]
Speedometer 1 2 3 4 5 6 7 8 9 10 11 12
[108B] 1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12 [8A] Ignition
[108A] Tachometer Harness

15A [1B] [1A]

Accessory
Fuse 1

12 11 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 6 5 4 3 2 1
2
Main to Interconnect 3
[2A] 1 2 3 4 5 6 7 8 9 10 11 12 Harness 4
[2B] 1 2 3 4 5 6 7 8 9 10 11 12
Data Link
[91A]
Main to Interconnect 15A
Harness Ignition
Fuse

LtGN/V
12
15A [10B]
Battery 12
Fuse
[10A] Ignition Control Module

Serial data
Figure 4-41. Serial Data Circuit (FLHT/C)

Table 4-30. Wire Harness Connectors in Figure 4-41.

NO. DESCRIPTION TYPE LOCATION

[1] Main to Interconnect Harness 12-Place Deutsch (Black) Inner Fairing - Right Radio Support Bracket
[2] Main to Interconnect Harness 12-Place Deutsch (Gray) Inner Fairing - Right Fairing Support Brace
[8] Ignition Harness 12-Place Deutsch Under Right Side Cover
[10] Ignition Control Module 12-Place Deutsch Under Right Side Cover
Cavity in Crossmember at Rear of
[30] Turn Signal/Security Module 12-Place Deutsch
Battery Box (Under Seat)
[39] Speedometer 12-Place Packard Inner Fairing (Back of Speedometer)
[91] Data Link 4-Place Deutsch Under Right Side Cover
[108] Tachometer 12-Place Packard Inner Fairing (Back of Tachometer)
[156] Main to Interconnect Harness 6-Place Deutsch Inner Fairing - Right Fairing Support Brace

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f2208y8x

BK GY
LtGN/V LtGN/V BK

BN/GY
O 1 2 3 4 5 6 7 8 9 10 11 12 [30B]
1 2 3 4 5 6 7 8 9 10 11 12 [30A]
BN/GY TSM/TSSM

1 2 3 4 5 6 7 8 9 10 11 12 BK
[39B]
1 2 3 4 5 6 7 8 9 10 11 12 [39A] GY
Speedometer
1 2 3 4 5 6 7 8 9 10 11 12 [8B] Ignition
1 2 3 4 5 6 7 8 9 10 11 12 [8A] Harness

15A
Battery
Fuse 15A
Accessory
Fuse 1
2
3
4
Data Link
[91A]

15A

LtGN/V
Ignition
Fuse

12
[10B]
[10A] Ignition Control Module 12

Serial data
Figure 4-42. Serial Data Circuit (FLHR/S)

Table 4-31. Wire Harness Connectors in Figure 4-42.

NO. DESCRIPTION TYPE LOCATION

[8] Ignition Harness 12-Place Deutsch Under Right Side Cover

[10] Ignition Control Module 12-Place Deutsch Under Right Side Cover
Cavity in Crossmember at Rear of
[30] Turn Signal/Security Module 12-Place Deutsch
Battery Box (Under Seat)
[39] Speedometer 12-Place Packard Under Console (Back of Speedometer)
[91] Data Link 4-Place Deutsch Under Right Side Cover

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Test 4.20
LOSS OF TSM/TSSM SERIAL DATA: DTC U1064

Can you read TSM/TSSM hardware P/N?

See 4.5 SPEEDOMETER SELF DIAGNOSTICS.

NO or “No Rsp”
YES

Install Breakout Box on speedometer.

1 Install Breakout Box on speedometer. 1 Check for continuity between terminal 3
While wiggling harness, check for continuity (gray) and terminal 2 (black) of Breakout
between terminal 3 (gray) and terminal 2 Box
(black) of Breakout Box Continuity present?
Continuity present?

YES
YES NO NO

Clear trouble codes. Repair intermittent Replace TSM/TSSM. Repair open on

Test Ride. Does U1064 on LtGN/V wire. Learn password. LtGN/V wire.
return?

YES NO

Replace TSM/TSSM. No trouble found.

Perform password learn
procedure.

Clear codes using speedometer self diagnostics.

See 4.5 SPEEDOMETER SELF DIAGNOSTICS.
Confirm proper operation with no check engine
lamp.

4-60 2004 Touring: Engine Management (Carbureted)

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DTC U1097 4.21

GENERAL f2191x8x

Loss of Speedometer Serial Data

The serial data connector provides a means for the speedom-
eter, ICM and TSM/TSSM to communicate their current sta-
tus. When all operating parameters on the serial data link are
within specifications, a state of health message is sent
between the components. A DTC U1097 indicates that the
speedometer is not capable of sending this state of health
message.

Table 4-32. Code Description

DTC DESCRIPTION
Loss of all speedometer serial data
U1097 Ignition Control Module
(state of health)
Connector [10]

Figure 4-43. Electrical Bracket (Under Right Side Cover)

DIAGNOSTICS 6924

3
Diagnostic Notes 4

The reference numbers below correlate with the circled num-

bers on the 4.21 flow chart. 2
1
1. Connect BREAKOUT BOX (Part No. HD-42682)
between wire harness and speedometer using SPEED-
OMETER HARNESS ADAPTER (Part No. HD-46601).
See 2.5 BREAKOUT BOX: SPEEDOMETER. 1. Terminal 2: ground (BK)
2. Terminal 3: serial data (Lt GN/V)
2. Connect BREAKOUT BOX (Part No. HD-42682) (black) 3. Terminal 4: power (GY)
as follows: 4. Protective cap

a. Mate black socket housing on Breakout Box with

speedometer connector [39A] (at the back of the Figure 4-44. Data Link Connector
speedometer) using INSTRUMENT HARNESS
ADAPTERS (Part No. HD-46601).

b. Mate black pin housing on Breakout Box with wire

harness connector [39B] using INSTRUMENT HAR-
NESS ADAPTERS (Part No. HD-46601).

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f2208z8x
[156B] [156A]
Main to Interconnect
6 6 Harness
5 5
4 4
3 3 GY
BK
2 2 BK
LtGN/V 1 1 LtGN/V
O
1 2 3 4 5 6 7 8 9 10 11 12 [30B]
BN/GY 1 2 3 4 5 6 7 8 9 10 11 12 [30A]
BN/GY
TSM/TSSM

[39B] GY BK
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12 [39A]
1 2 3 4 5 6 7 8 9 10 11 12 [8B]
Speedometer 1 2 3 4 5 6 7 8 9 10 11 12
[108B] 1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12 [8A] Ignition
[108A] Tachometer Harness

15A [1B] [1A]

Accessory
Fuse 1

12 11 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 6 5 4 3 2 1
2
Main to Interconnect 3
[2A] 1 2 3 4 5 6 7 8 9 10 11 12 Harness 4
[2B] 1 2 3 4 5 6 7 8 9 10 11 12
Data Link
[91A]
Main to Interconnect 15A
Harness Ignition
Fuse

LtGN/V
12
15A [10B]
Battery 12
Fuse
[10A] Ignition Control Module

Serial data
Figure 4-45. Serial Data Circuit (FLHT/C)

Table 4-33. Wire Harness Connectors in Figure 4-45.

NO. DESCRIPTION TYPE LOCATION

[1] Main to Interconnect Harness 12-Place Deutsch (Black) Inner Fairing - Right Radio Support Bracket
[2] Main to Interconnect Harness 12-Place Deutsch (Gray) Inner Fairing - Right Fairing Support Brace
[8] Ignition Harness 12-Place Deutsch Under Right Side Cover
[10] Ignition Control Module 12-Place Deutsch Under Right Side Cover
Cavity in Crossmember at Rear of
[30] Turn Signal/Security Module 12-Place Deutsch
Battery Box (Under Seat)
[39] Speedometer 12-Place Packard Inner Fairing (Back of Speedometer)
[91] Data Link 4-Place Deutsch Under Right Side Cover
[108] Tachometer 12-Place Packard Inner Fairing (Back of Tachometer)
[156] Main to Interconnect Harness 6-Place Deutsch Inner Fairing - Right Fairing Support Brace

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f2208y8x

BK GY
LtGN/V LtGN/V BK

BN/GY
O 1 2 3 4 5 6 7 8 9 10 11 12 [30B]
1 2 3 4 5 6 7 8 9 10 11 12 [30A]
BN/GY TSM/TSSM

1 2 3 4 5 6 7 8 9 10 11 12 BK
[39B]
1 2 3 4 5 6 7 8 9 10 11 12 [39A] GY
Speedometer
1 2 3 4 5 6 7 8 9 10 11 12 [8B] Ignition
1 2 3 4 5 6 7 8 9 10 11 12 [8A] Harness

15A
Battery
Fuse 15A
Accessory
Fuse 1
2
3
4
Data Link
[91A]

15A

LtGN/V
Ignition
Fuse

12
[10B]
[10A] Ignition Control Module 12

Serial data
Figure 4-46. Serial Data Circuit (FLHR/S)

Table 4-34. Wire Harness Connectors in Figure 4-46.

NO. DESCRIPTION TYPE LOCATION

[8] Ignition Harness 12-Place Deutsch Under Right Side Cover

[10] Ignition Control Module 12-Place Deutsch Under Right Side Cover
Cavity in Crossmember at Rear of
[30] Turn Signal/Security Module 12-Place Deutsch
Battery Box (Under Seat)
[39] Speedometer 12-Place Packard Under Console (Back of Speedometer)
[91] Data Link 4-Place Deutsch Under Right Side Cover

2004 Touring: Engine Management (Carbureted) 4-63

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Test 4.21
LOSS OF SPEEDOMETER SERIAL DATA:
DTC U1097

Can you read ECM/ICM hardware part number?

See 4.5 SPEEDOMETER SELF DIAGNOSTICS.

YES NO or “No Rsp”

Install Breakout Box on speedometer. Install Breakout Box on speedometer. Check conti-
1 While wiggling harness, check continuity
1 nuity between terminal 2 (black) of Breakout Box
between terminal 2 (black) of Breakout and terminal 12 of connector [10B].
Box and terminal 12 of connector [10B]. Continuity present?
2 Continuity present?
2

YES NO
YES NO
Repair open on
Repair intermittent Replace speedometer. Lt GN/V wire.
Clear codes. Test ride. on LtGN/V wire.
Does DTC U1097
return?

Clear codes using speedometer self diagnostics.

YES NO See 4.5 SPEEDOMETER SELF DIAGNOSTICS.
Confirm proper operation with no check engine
lamp.
Replace ICM. No trouble found.
Reprogram and learn
password.

4-64 2004 Touring: Engine Management (Carbureted)