Harley Davidson FLHRC 2006. Maintenance & Repair Manual - page 43
Table Of Contents
ENGINE MANAGEMENT (EFI)
5
SUBJECT
PAGE NO.
5.1 Specifications
5-1
5.2 EFI System
5-3
5.3 EFI Diagnostic Introduction
5-5
5.4 Checking For Diagnostic Trouble Codes: EFI
5-6
5.5 Initial Diagnostic Check: EFI
5-8
5.6 Speedometer Self Diagnostics
5-17
5.7 Breakout Box
5-19
5.8 Wiggle Test
5-20
5.9 Intake Leak Test
5-21
5.10 Engine Cranks, But Will Not Start
5-23
5.11 No ECM Power
5-30
5.12 Starts, Then Stalls
5-35
5.13 Fuel System Electrical Test
5-40
5.14 System Relay Check
5-45
5.15 Fuel Pressure Test
5-50
5.16 Idle Air Control, DTC P0505
5-54
5.17 Misfire at Idle or Under Load
5-59
5.18 Combustion Absent/Intermittent, DTC P1353, P1356, P1357, P1358
5-64
5.19 DTC P0107, P0108
5-69
5.20 DTC P0112, P0113
5-73
5.21 DTC P0117, P0118
5-77
5.22 DTC P0122, P0123
5-81
5.23 DTC P0261, P0262, P0263, P0264
5-85
5.24 DTC P0373, P0374
5-91
5.25 DTC P0501, P0502
5-94
5.26 DTC P0562, P0563
5-98
5.27 DTC P0603, P0605
5-103
5.28 DTC P1009, P1010
5-104
5.29 DTC P1351, P1352, P1354, P1355
5-108
5.30 DTC U1064, U1255
5-113
5.31 DTC U1097, U1255
5-117
HOME
SPECIFICATIONS
5.1
System Fuse Block (Under Left Side Cover)
IGNITION
DATA
8
0°-45° BTDC (range)
FLHR/C/S
Spark timing advance
12° BTDC@1000 RPM
9
10
Idle speed
975 ± 50 RPM
5
Spark plug size
12 mm
11
0.038-0.043 in
Spark plug gap
0.97-1.09 mm
Harley-Davidson
4
Spark plug type
No. 6R12 (no substitute)
12
Ignition coil primary
0.3-0.5 ohms
resistance
f2210x8x
3
1
2
Ignition coil secondary
2500-3500 ohms
resistance
8
7
FLHX, FLHT/C/U, FLTR
9
6
Rating
10
Circuit
Color
(Amperes)
5
11
System Fuses
Maxi-Fuse
40
Orange
Headlamp
15
Blue
4
Ignition
15
Blue
Lighting
15
Blue
f2204x8x
2
3
Instruments
15
Blue
1
Brakes/Cruise
15
Blue
1.
Headlamp
7.
Radio Power
2.
Ignition
8.
Accessory
Radio Memory
15
Blue
3.
Lighting
9.
Battery
Radio Power
10
Red
4.
Instruments
10.
Brake Light Relay
5.
Brakes/Cruise
11.
P&A
Accessory
15
Blue
6.
Radio Memory
12.
Starter Relay
Battery
15
Blue
EFI Fuse Block (Under Right Side Cover)
P & A
15
Blue
EFI Fuses
EFI System
Relay
Fuel Pump
15
Blue
Spare
ECM Power
15
Blue
Fuel Pump
ECM Power
f2223x9x
Figure 5-1. Fuse Locations
2006 Touring: Engine Management (EFI)
5-1
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NOTES
5-2
2006 Touring: Engine Management (EFI)
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EFI SYSTEM
5.2
The bank angle sensor is within the TSM/TSSM. If the vehicle
GENERAL
lean angle exceeds 45 degrees for one second, the fuel injec-
tors are shut off. Once the sensor is tripped, the motorcycle
The engine management system consists of the following
must be uprighted, turned off and then on again before the
components:
engine can be restarted. This is communicated across the
data bus.
● ECM
Front and rear coils fire each spark plug independently (one
● CKP sensor
cylinder at a time - no wasted spark). The coil also has an
extra terminal to monitor current on the coil secondary circuit.
● MAP sensor
This is used for knock detection and combustion diagnostics.
● IAT sensor
The ignition system gives a spark near top dead center for
● ET sensor
starting. At RPM and loads above this, the system gives a
spark advance that varies between 0° and 50°.
● IAC
The IAT, ET and TP sensors are used to provide information
● TP sensor
to the ECM to fine tune spark and fuel delivery. The VSS is
used as an input for idle speed control.
● VSS
● Turn signal module (TSM) or optional, factory-installed
EFI ENGINE HEAT MANAGEMENT
turn signal security module (TSSM). This includes an
integrated bank angle sensor (BAS).
● Ignition coil.
Injected Twin Cam High Temperature Idle
The ECM is mounted to the electrical bracket under the right
NOTE
side cover. It computes the spark advance for proper ignition
Fuel injected Twin Cam engines use a three phase heat man-
timing based on sensor inputs (from CKP, MAP and TP sen-
agement system to reduce engine temperature under
sor) and regulates the low-voltage circuits between battery
extreme conditions. A rider with a very hot engine may notice
and ignition coil.
the effects of this three phase heat management system and
incorrectly assume an idle problem exists.
The ECM contains all of the solid state components used in
the ignition system. The dwell time for the ignition coil is also
Phase 1
calculated in the microprocessor and is dependent upon bat-
tery voltage. The programmed dwell is an added feature to
When the ET sensor signals that the cylinder head has
give adequate spark at all speeds. (The ECM has added pro-
reached approximately 291°F (144°C) the ECM will gradually
tection against transient voltages, continuous reverse voltage
reduce engine idle speed until the engine temperature drops
protection, and damage due to jump starts.) The ECM is fully
or the engine reaches 800 rpm.
enclosed to protect it from vibration, dust, water or oil. This
unit is a non-repairable item. If it fails, it must be replaced.
Phase 2
The CKP sensor is located in the front left side of the crank-
If engine temperature reaches 320°F (160°C), the ECM rich-
case. The CKP generates an AC signal which is sent to the
ens the air/fuel ratio to provide additional cooling.
ECM where it is used to reference engine position (TDC) and
speed. It functions by taking readings off the 30 teeth on the
Phase 3
left side flywheel (two teeth are missing to establish a refer-
ence point).
If the engine temperature reaches 329° F (165° C), fuel injec-
tor pulses are interrupted. The air drawn in and expelled
The MAP sensor is located on top of the intake manifold. The
helps cool the engine further. Since there is no combustion it
MAP sensor monitors the intake manifold pressure (vacuum)
would be perceived as a misfire. This third stage will only hap-
and sends the information to the ECM where the module
pen when the motorcycle is stationary.
adjusts the spark and fuel timing advance curve for optimum
performance.
TROUBLESHOOTING
See the diagnostic charts that follow for troubleshooting infor-
mation.
2006 Touring: Engine Management (EFI)
5-3
HOME
[62B]
CKP
To Tachometer
Y/GN
[78]
(FLHR/C/S Optional)
System
relay
BE/GY
[79A]
1
2
GN/O
[79B]
1
2
3
W/BK
R
30
15 Amp
[13A] [13B]
BK
12
fuel pump
fuse
System relay
4
GN/O
Fuel
O/GY
pump
Y/GN
Inj. F
21
W/Y
[84B]
[84A]
BK
[141B] [141A]
Y/GN
All Except
FLHR/C/S
[83B]
[83A]
Inj. R
19
GN/GY
[85B]
[85A]
Coil
Ion sense
27
GY/BE
Coil R
Y/BE
11
Coil F
29
BE/O
A
A
BK/PK
18
40 Amp
B
B
BN/R
36
Maxi fuse
C
C
BE/GN
35
D
D
BK/O
17
15 Amp
Battery
ECM fuse
R
[87A]
[87B]
Constant
31
BE/GY
Intake air
power
BK
control
15 Amp
IGN fuse
Switch power
13
W/BK
GY
R/BK
Ignition switch
R/W
TP
BK/W
sensor
TP sensor
24
GY/V
GY/V
To right
[90B] [90A]
hand controls
[88B] [88A]
ET sensor
6
PK/Y
ET sensor
BK/W
Engine
IAT sensor
7
LT GN/Y
stop
IAT sensor
5v sensor gnd.
26
BK/W
BK/W
[22A]
switch
[89B] [89A]
[80B] [80A]
BK/W
MAP
MAP sensor
25
V/W
V/W
sensor
5v sensor pwr.
14
R/W
R/W
Vehicle
Vehicle speed sensor
speed
33
W/GN
sensor
[65B] [65A]
To speedometer
Serial data
5
LT GN/V
and tachometer
[91A]
3
Data link
2
connector
4
[30B]
2
3
7
TSM/
Power gnd.
10
BK
TSSM
[30A]
2
3
7
Power gnd.
28
BK
f2436a8x
Figure 5-2. Simplified EFI System Circuit
5-4
2006 Touring: Engine Management (EFI)
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EFI DIAGNOSTIC INTRODUCTION
5.3
SYSTEM PROBLEMS
All system problems fall into at least one of three general cat-
egories.
60
40
50
70
30
50
40
80
No Start
30
90
20
MPH
RPM x100
20
100
The engine cranks over freely, but will not start. This does not
10
10
110
include situations where the engine will not crank, such as a
0
0
security disabled starter, dead battery, etc. This condition
120
assumes that all obvious checks (fuel in tank, etc.) have been
made.
TI
-D
-D
Poor Performance
The engine starts but there are performance problems. These
problems may include poor fuel economy, rough idle, engine
Check Engine Lamp
misfire, engine hesitation, severe spark knock, etc.
f2160x8x
Figure 5-3. Speedometer
Check Engine Lamp
See Figure 5-3. The check engine lamp indicates the ECM
has determined a fault condition exists. There may also be
starting or performance problems.
RESOLVING PROBLEMS
To resolve system problems, five basic steps are involved. In
order of occurrence, they are:
1.
Check for DTC’s by using speedometer self diagnostics.
See Section 5.4 CHECKING FOR DIAGNOSTIC TROU-
BLE CODES: EFI.
2.
Retrieve DTC’s by using speedometer self diagnostics.
See Section
5.6 SPEEDOMETER SELF DIAGNOS-
TICS.
3.
Diagnose system problems. This involves using special
tools and the diagnostic flow charts in this section.
4.
Correct problems through the replacement and/or repair
of the affected components.
5.
After repairs are performed, the work must be validated.
This involves clearing the trouble codes and confirming
proper vehicle operation as indicated by the lack of trou-
ble codes.
2006 Touring: Engine Management (EFI)
5-5
HOME
CHECKING FOR DIAGNOSTIC TROUBLE CODES: EFI
5.4
CHECK ENGINE LAMP
To diagnose system problems, start by observing the behav-
ior of the check engine lamp.
NOTES
● See Figure 5-4. “Key ON” means that the ignition key is
turned to IGN and the engine stop switch is set to RUN
(although the engine is not running).
● When the ignition key is turned ON, the check engine
lamp will illuminate for approximately four seconds and
then turn off.
● If the check engine lamp is not illuminated at Key ON or if
f2080x8x
it fails to turn OFF after the initial four second period,
then the speedometer may need to be replaced. See
Figure 5-4. Ignition Switch (FLHX, FLHT/C/U, FLTR)
Section 5.5 INITIAL DIAGNOSTIC CHECK: EFI.
1.
When the lamp turns off after being illuminated for the
2.
See CODE TYPES which follows for a complete descrip-
first four second period, it will:
tion of trouble code formats.
a. Remain off if there are no fault conditions or trouble
NOTE
codes currently detected by the ignition control mod-
Some trouble codes can only be fully diagnosed during actu-
ule. See A of Figure 5-5.
ation. For example, a problem with the ignition coil will be
b. Come back on for an 8 second period if only historic
considered a current fault even after the problem is corrected,
codes exist. See B of Figure 5-5.
since the ECM will not know of its resolution until after the coil
is exercised by vehicle start sequence. In this manner, there
c. Come back on, and remain on, if a current trouble
may sometimes be a false indication of the current trouble
code exists. See C of Figure 5-5.
code.
ON
4 Sec.
A
Lamp OFF: No Current or Historic Trouble Codes
OFF
Key On
Lamp ON 8 Seconds:
Only Historic Trouble Codes Exist
ON
4 Sec.
8 Sec.
B
Lamp OFF
OFF
4 Sec.
Key On
Lamp Remains ON: Current Trouble Code *
ON
4 Sec.
C
OFF
4 Sec.
Key On
* Historic Trouble Codes May Also Exist
Figure 5-5. Check Engine Lamp Operation
5-6
2006 Touring: Engine Management (EFI)
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CODE TYPES
RETRIEVING DIAGNOSTIC
TROUBLE CODES
There are two types of DTC’s: current and historic. If a DTC is
stored, it can be read using speedometer self diagnostics.
The engine management system provides two levels of diag-
See Section 5.6 SPEEDOMETER SELF DIAGNOSTICS.
nostics.
All DTC’s reside in the memory of the ECM/ICM, TSM/TSSM,
speedometer or tachometer until the code is cleared by use
● The most sophisticated mode uses a computer based
of the speedometer self diagnostics. See Section
5.6
diagnostic package called the DIGITAL TECHNICIAN
SPEEDOMETER SELF DIAGNOSTICS.
(Part No. HD-44750).
A historic DTC is also cleared after a total of 50 trips has
● The second mode requires using the speedometer self
elapsed. A trip consists of a start and run cycle. After the 50
diagnostics. Speedometer, tachometer
(if equipped),
trip retention period, the DTC is automatically erased from
TSM/TSSM and ECM codes can be accessed and
memory providing that no subsequent faults of the same type
cleared. See Section 5.6 SPEEDOMETER SELF DIAG-
are detected in that period.
NOSTICS for more information.
Current
MULTIPLE DIAGNOSTIC TROUBLE
Current trouble codes are those which occur during the
CODES
present ignition cycle. See the appropriate flow charts for
solutions.
While it is possible for more than one fault to occur and set
Historic
more than one trouble code, there are several conditions
which may result in one fault setting multiple trouble codes:
If a particular problem happens to resolve itself, the active
status problem is dropped and it becomes a historic code
● The MAP sensor, TP sensor and VSS are connected to
rather current code.
the same reference line (+5V Vref). If the reference line
goes to ground or open, multiple codes will be set (DTC
Historic codes are stored for a length of time to assist in the
P0107, P0122 and P0501).
diagnosis of intermittent faults. See Figure 5-5. The check
engine lamp will come back on for 8 seconds to indicate the
● Serial data codes (DTC U1300, U1301, U1016, U1064,
existence of only historic codes.
U1097 and U1255) may be accompanied by other
codes. Always correct the serial data codes before
It is important to note that historic codes may also be present
resolving the other codes.
whenever the system indicates the existence of a current
code. See MULTIPLE DIAGNOSTIC TROUBLE CODES if
Refer to Table 5-5. This table gives most ECM DTC’s a prior-
multiple trouble codes are found.
ity ranking.
Diagnostic charts are designed for use with current trouble
codes and as a result they frequently suggest part replace-
ment. When diagnosing a historic code the charts can be
helpful but should not lead to part replacement without verifi-
cation the part is faulty.
2006 Touring: Engine Management (EFI)
5-7
HOME
INITIAL DIAGNOSTIC CHECK: EFI
5.5
GENERAL
Diagnostic Tips
● If speedometer reads “No Rsp” (no response) while in
To locate faulty circuits or other system problems, follow the
diagnostic mode, check data bus for an open or short to
diagnostic flow charts in this section. For a systematic
ground between data connector [91A] Terminal 3 and
approach, always begin with INITIAL DIAGNOSTICS which
ECM, TSM/TSSM, tachometer (if equipped) or speedom-
follows. Read the general information and then work your way
eter. For more information on speedometer diagnostic
through the flow chart box by box.
mode See Section 5.6 SPEEDOMETER SELF DIAG-
NOSTICS.
Diagnostic Notes
● Check for an open diagnostic test terminal between data
If a numbered circle appears adjacent to a flow chart box,
Terminal 3 and ECM Terminal 5. With ignition key turned
then more information is offered in the diagnostic notes. Many
ON, transmit data should be typically 0.6-0.8 volts. The
diagnostic notes contain supplemental information, descrip-
range of acceptable voltage is greater than 0 and less
tions of various diagnostic tools or references to other parts
than 7.0 volts.
of the manual where information on the location and removal
● If speedometer reads “BUS er” (serial data bus error),
of components may be obtained.
refer to flow charts in Section
5.12 STARTS, THEN
STALLS.
Circuit Diagram/Wire Harness
Connector Table
Diagnostic Notes
When working through a flow chart, refer to the illustrations,
The reference numbers below correlate with the circled num-
the associated circuit diagram and the wire harness connec-
bers on the diagnostic check flow charts. See page 5-15.
tor table as necessary. The wire harness connector table for
1.
Compare engine behavior to symptoms tables.
each circuit diagram identifies the connector number, descrip-
tion, type and general location.
a. Starts hard. Refer to Table 5-2.
b. Hesitates, stumbles, surges, misfires and/or slug-
In order to perform most diagnostic routines, a Breakout Box
gish performance. Refer to Table 5-3.
and a DVOM are required. See Section 5.7 BREAKOUT BOX:
EFI.
c. Engine exhaust emits black smoke or fouls plugs.
Refer to Table 5-4.
To perform the circuit checks with any degree of efficiency, a
2.
Connect BREAKOUT BOX (Part No. HD-43682) to
familiarity with the various wire connectors is also necessary.
speedometer using HD-46601 adapters.
Reprogramming ECM
All EFI diagnostic codes are listed on page 5-11 in Table 5-5.
Diagnostic charts frequently suggest ECM replacement. In
Other Codes
the event an ECM needs to be replaced, it must be repro-
grammed using a computer based diagnostic package called
See Section 3.9 INITIAL DIAGNOSTIC CHECK: TSM/TSSM
DIGITAL TECHNICIAN
(Part No. HD-44750). See your
for any codes related to the turn signal module (TSM) or turn
dealer. Password learn procedure must also be performed.
signal security module (TSSM).
See Section 3.24 PASSWORD LEARN.
See Section 2.2 INITIAL DIAGNOSTIC CHECK: SPEEDOM-
ETER for any codes related to the speedometer or tachome-
ter.
INITIAL DIAGNOSTICS
General Information
The diagnostic check
(see page
5-15) is an organized
approach to identifying a problem caused by an electronic
control system malfunction.
5-8
2006 Touring: Engine Management (EFI)
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Table 5-1. Typical Scan Values for
Table 5-2. Engine Starts Hard
Engine Data
SYMPTOM
SOLUTION
MIN.
MAX.
HOT
ITEM
See charging system trouble-
VALUE
VALUE
IDLE
Battery discharged
shooting in this section.
10.3-13.3 in. Hg
10 kPa
104 kPa
5.17 MISFIRE AT IDLE OR
35-45 kPa
Spark plugs
MAP sensor
UNDER LOAD.
0 volts
5.1 volts
5.17 MISFIRE AT IDLE OR
Spark plug wires
0
100
0%
UNDER LOAD.
TP sensor
0.2 volts
4.5 volts
0.2-1.0 volts
5.17 MISFIRE AT IDLE OR
Ignition coil
UNDER LOAD.
IAC pintle
0
155
30-45 steps
See Section 3 in the Touring
RPM
800
5600
975
Valve sticking
Service Manual.
3° F
464° F
230-300° F
Water or dirt in fuel system
Drain and refill with fresh fuel.
(-16° C)
(240° C)
(110-150° C)
ET sensor
Loss of battery power to
0.0 volts
5.0 volts
0.5-3.23 volts
5.11 NO ECM POWER
ECM terminal 31*
3° F
248° F
104-140° F
(-16° C)
(120° C)
(40-60° C)
IAT sensor
* Codes will not clear (although they appear to).
0.0 volts
5.0 volts
2.0-3.5 volts
INJ PW front
0
50 mS
2-4 mSec
INJ PW rear
0
50 mS
2-4 mSec
Advance front
0
45°
10-15°
Advance rear
0
45°
10-15°
VSS
0
120
0 MPH
Battery voltage
10
15
14.5 volts
ENG RUN
off
Run
Run
Idle RPM
800
1300
940-975
NOTE
Hot idle specifications are with stock exhaust, the engine
operating at 975 RPM and an engine temperature of approxi-
mately 260° F (127° C). Idle settings may be changed with
the idle set procedure. See the Touring Service Manual.
2006 Touring: Engine Management (EFI)
5-9
HOME
Table 5-3. Engine Performance Problems
Table 5-4. Engine Exhaust Emits
Black Smoke or Fouls Plugs
SYMPTOM
SOLUTION
SYMPTOM
SOLUTION
Manifold leak
See
5.9 INTAKE LEAK
See AIR CLEANER FILTER
TEST.
Clogged air filter
in the Touring Service Man-
NOTE- When manifold leak
is large enough, IAC will
A low IAC count may also
ual.
close to 0 and code P0505
indicate an air leak.
MAP sensor plugged or not
5.19 DTC P0107, P0108.
will set
operating properly
MAP sensor plugged or not
5.19 DTC P0107, P0108.
operating properly
Drain and refill with fresh
Water or dirt in fuel system
fuel.
5.17 MISFIRE AT IDLE OR
Spark plugs
UNDER LOAD.
See throttle cable adjust-
Throttle plate not opening
ment in the Touring Service
fully
Manual.
5.15 FUEL PRESSURE
Low fuel pressure
TEST.
5-10
2006 Touring: Engine Management (EFI)
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Table 5-5. EFI Diagnostic Trouble Codes (DTC) and Fault Conditions
PRIORITY
DTC NO.
FAULT CONDITION
SOLUTION
RANKING
1
P0605
ECM flash error
5.27 DTC P0603, P0605
2
P0603
ECM EEPROM error
5.27 DTC P0603, P0605
3
“BUS Er”
Serial data bus shorted low/open/high
5.12 STARTS, THEN STALLS
4
U1300
ECM serial data low
5.12 STARTS, THEN STALLS
5
U1301
ECM serial data open/high
5.12 STARTS, THEN STALLS
6
U1300
TSSM serial data low
5.12 STARTS, THEN STALLS
7
U1301
TSSM serial data open/high
5.12 STARTS, THEN STALLS
8
U1300
Speedometer/tachometer serial data low
5.12 STARTS, THEN STALLS
Speedometer/tachometer serial data open/
9
U1301
5.12 STARTS, THEN STALLS
high
10
U1064
Loss of TSM/TSSM serial data at ECM
5.30 DTC U1064, U1255
Loss of TSM/TSSM serial data at speedome-
11
U1064
5.30 DTC U1064, U1255
ter
Loss of all ECM serial data (state of health) at
3.21 DTC U1016, U1255
TSSM
12
U1016
Loss of all ECM serial data (state of health) at
3.21 DTC U1016, U1255
speedometer
13
U1097
Loss of speedometer serial data at TSSM
5.31 DTC U1097, U1255
14
U1255
Missing response at TSSM
3.21 DTC U1016, U1255
15
U1255
Missing response at speedometer
5.31 DTC U1097, U1255
16
P1003
System relay contacts open
5.14 SYSTEM RELAY CHECK
17
P1002
System relay coil high/shorted
5.14 SYSTEM RELAY CHECK
18
P1001
System relay coil open/low
5.14 SYSTEM RELAY CHECK
19
P1004
System relay contacts closed
5.14 SYSTEM RELAY CHECK
20
P1009
Incorrect password
5.28 DTC P1009, P1010
21
P1010
Missing password (starts then stalls)
5.28 DTC P1009, P1010
22
P0373
CKP sensor intermittent
5.24 DTC P0373, P0374
23
P0374
CKP sensor synch error
5.24 DTC P0373, P0374
B1151
Sidecar BAS low
Sidecar DTC’s apply only to Touring models
B1152
Sidecar BAS high
equipped with sidecars. If these DTC’s are present
24
on non sidecar equipped motorcycles,
B1153
Sidecar BAS out of range
the TSM/TSSM is not properly configured.
25
P0122
TP sensor open/low
5.22 DTC P0122, P0123
26
P0123
TP sensor high
5.22 DTC P0122, P0123
27
P0107
MAP sensor open/low
5.19 DTC P0107, P0108
28
P0108
MAP sensor high
5.19 DTC P0107, P0108
29
P0117
ET sensor voltage low
5.21 DTC P0117, P0118
30
P0118
ET sensor open/high
5.21 DTC P0117, P0118
31
P0112
IAT sensor voltage low
5.20 DTC P0112, P0113
32
P0113
IAT sensor open/high
5.20 DTC P0112, P0113
33
P1351
Front ignition coil open/low
5.29 DTC P1351, P1352, P1354, P1355
34
P1354
Rear ignition coil open/low
5.29 DTC P1351, P1352, P1354, P1355
35
P1352
Front ignition coil high/shorted
5.29 DTC P1351, P1352, P1354, P1355
36
P1355
Rear ignition coil high/shorted
5.29 DTC P1351, P1352, P1354, P1355
37
P1357
Front cylinder combustion intermittent
5.18 COMBUSTION ABSENT/INTERMITTENT
38
P1358
Rear cylinder combustion intermittent
5.18 COMBUSTION ABSENT/INTERMITTENT
39
P0261
Front injector open/low
5.23 DTC P0261, P0262, P0263, P0264
40
P0263
Rear injector open/low
5.23 DTC P0261, P0262, P0263, P0264
2006 Touring: Engine Management (EFI)
5-11
HOME
Table 5-5. EFI Diagnostic Trouble Codes (DTC) and Fault Conditions
PRIORITY
DTC NO.
FAULT CONDITION
SOLUTION
RANKING
41
P0262
Front injector high
5.23 DTC P0261, P0262, P0263, P0264
42
P0264
Rear injector high
5.23 DTC P0261, P0262, P0263, P0264
43
P0562
Battery voltage low
5.26 DTC P0562, P0563
44
P0563
Battery voltage high
5.26 DTC P0562, P0563
45
P0501
VSS sensor low
5.25 DTC P0501, P0502
46
P0502
VSS sensor high
5.25 DTC P0501, P0502
47
P1356
Rear cylinder no combustion
5.18 COMBUSTION ABSENT/INTERMITTENT
48
P1353
Front cylinder no combustion
5.18 COMBUSTION ABSENT/INTERMITTENT
49
P0505
Loss of idle speed control
5.16 IDLE AIR CONTROL, DTC P0505
50
B1135
Accelerometer fault
3.19 DTC B1135
51
B1134
Starter output high
3.18 DTC B1134
52
B1121
Left turn output fault
3.15 TURN SIGNAL ERRORS
53
B1122
Right turn output fault
3.15 TURN SIGNAL ERRORS
54
B0563
Battery voltage high
3.16 DTC B0563
55
B1131
Alarm output low
3.17 DTC B1131, B1132
56
B1132
Alarm output high
3.17 DTC B1131, B1132
57
B1141
Ignition switch open/low
3.15 TURN SIGNAL ERRORS
5-12
2006 Touring: Engine Management (EFI)
HOME
f2353n8x
[156B] [156A]
Radio
[27A]
Main to Interconnect
6
6
[27B]
5
5
Harness
9
4
4
BK
3
3
GY
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
BK
[39B]
1
2
3
4 5 6 7 8 9 10 11 12
GY
1
2
3
4 5 6 7 8 9 10 11 12
[39A]
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
[108A]
Tachometer
To
Ignition
15A
Keyswitch
Instruments
[1B] [1A]
Relay
Fuse
1
2
Main to Interconnect
3
Harness
1
2
3
4 5 6 7 8 9 10 11 12
4
Data Link
[2B]
1
2
3
4 5 6 7 8 9 10 11 12
15A
[2A]
Ignition
Main to Interconnect
Fuse
[91A]
Harness
[78B]
15A
5
ECM
Battery
[78A]
Fuse
Figure 5-6. Diagnostic Check (FLHX, FLHT/C/U, FLTR)
Table 5-6. Wire Harness Connectors in Figure 5-6.
NO.
DESCRIPTION
MODEL
TYPE
LOCATION
Main to Interconnect
FLHT/C
12-Place Deutsch (Black)
Inner Fairing - Right Radio Support Bracket
[1]
Harness
FLTR
12-Place Deutsch (Black)
Inner Fairing - Below Radio (Right Side)
FLHT/C
12-Place Deutsch (Gray)
Inner Fairing - Right Fairing Support Brace
Main to Interconnect
[2]
Harness
FLTR
12-Place Deutsch (Gray)
Inner Fairing - Below Radio (Right Side)
[27]
Radio
All
23-Place Amp
Inner Fairing - Back of Radio (Right Side)
Cavity in Crossmember at Rear of
[30]
TSM/TSSM
All
12-Place Deutsch
Battery Box (Under Seat)
FLHT/C
12-Place Packard
Inner Fairing (Back of Speedometer)
[39]
Speedometer
FLTR
12-Place Packard
Under Bezel (Back of Speedometer)
[78]
ECM
All
36-Place Packard
Under Right Side Cover
[91]
Data Link
All
4-Place Deutsch
Under Right Side Cover
FLHT/C
12-Place Packard
Inner Fairing (Back of Tachometer)
[108]
Tachometer
FLTR
12-Place Packard
Under Bezel (Back of Tachometer)
Main to Interconnect
FLHT/C
6-Place Deutsch
Inner Fairing - Right Fairing Support Brace
[156]
Harness
FLTR
6-Place Deutsch
Inner Fairing - Below Radio (Right Side)
2006 Touring: Engine Management (EFI)
5-13
HOME
f2353o8x
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
BK
1
2
3
4 5 6 7 8 9 10
11
12
[39B]
1
2
3
4 5 6 7 8 9 10
11
12
[39A]
GY
Speedometer
15A
Instruments
To
Fuse
15A
Ignition
Battery
Keyswitch
Fuse
Relay
1
15A
2
Ignition
3
Fuse
4
Data Link
[91A]
[78B]
5
ECM
[78A]
Figure 5-7. Diagnostic Check (FLHR/C/S)
Table 5-7. Wire Harness Connectors in Figure 5-7.
NO.
DESCRIPTION
TYPE
LOCATION
Cavity in Crossmember at Rear of
[30]
TSM/TSSM
12-Place Deutsch
Battery Box (Under Seat)
[39]
Speedometer
12-Place Packard
Under Console (Back of Speedometer)
[78]
ECM
36-Place Packard
Under Right Side Cover
[91]
Data Link
4-Place Deutsch
Under Right Side Cover
5-14
2006 Touring: Engine Management (EFI)
HOME
Diagnostic Check (Part 1 of 2)
Does engine
start?
YES.
YES.
NO.
NO.
Starts and
Starts, then
Cranks, but
Engine will not
runs.
stalls.
will not start.
crank.
Check for trouble
See Section 5.12 STARTS,
See Section 5.10 ENGINE
See Section 1.2 STARTING
codes. See Section
THEN STALLS.
CRANKS, BUT WILL NOT
SYSTEM DIAGNOSIS.
5.6 SPEEDOMETER
START.
SELF DIAGNOSTICS
Codes found?
NO
YES
NO
1
Unable to enter diagnostic mode.
No codes displayed. For
Refer to applicable trouble code priority chart.
With ignition switch OFF, press and
symptoms that may not set
All diagnostic codes are listed on page 5-11
release odometer reset switch.
DTC’s, refer to table 5-2,
in Table 5-5. Codes are listed by priority.
Does odometer display appear with
Table 5-3 and Table 5-4.
display backlighting?
YES
NO
STOP
Check for continuity to ground on terminal 7
of speedometer. Wiggle harness during con-
tinuity check. Continuity present?
Go to Diagnostic
Check (Part 2 of 2).
YES
NO
Check for battery voltage at
terminal 5 of speedometer
Locate and repair open
while wiggling harness. Bat-
between terminal 7
tery voltage continuously
and ground.
present?
YES
NO
Check continuity (with ignition
Locate and repair open
switch OFF) between terminals
between terminal 5 and
8 and 11 on breakout box. Con-
battery fuse.
tinuity present when speedome-
ter reset switch is depressed?
Replace speedometer.
Replace speedometer
reset switch.
2006 Touring: Engine Management (EFI)
5-15
HOME
Diagnostic Check (Part 2 of 2)
Continued from Diagnostic Check (Part 1 of 2).
Perform “wow” test. See Section 5.6 SPEEDOMETER SELF DIAGNOSTICS.
The following features should be functional
1) backlight should illuminate
2) needle should sweep its full range of motion
3) LED’s that should illuminate:
• check engine
• battery
• security (all models)
4) LED’s that may illuminate:
• low fuel (EFI models)
• cruise (even though not cruise equipped)
Are all features functional?
YES
NO
Turn key to ACC. Is
backlight present?
Check for battery voltage at
terminal 1 of breakout box.
Battery voltage present?
YES
NO
YES
NO
Check for battery voltage at
Is problem intermittent?
Replace speedometer.
Is instrument
breakout box terminal 6.
fuse blown?
Battery voltage present?
YES
YES
NO
NO
Replace speedometer.
Locate and repair open on O/W
Locate and repair
Locate and repair
wire between terminal 6 of con-
source of fault.
open between terminal
nector [39] and accessory fuse.
Replace fuse.
1 of connector [39]
and instrument fuse.
YES
NO
YES
Intermittent vehicle speed
Repeat Diagnostic
indication.
Check while wiggling
Tachometer Inoperative
harnesses. Intermittent
(no engine speed).
present?
Remove and inspect VSS.
Debris present?
See Test 2.4 (Part 1 of 2)
under Section 2.4 SPEED-
YES
NO
OMETER/TACHOMETER.
YES
NO
Locate and repair
intermittent.
No trouble found.
Remove debris.
Check for damaged wiring/
Reinstall VSS.
loose connection between
VSS and ECM. Is wiring
damage/loose
connection present?
YES
NO
Locate and repair
Replace Speedometer.
source of fault.
5-16
2006 Touring: Engine Management (EFI)
HOME
SPEEDOMETER SELF DIAGNOSTICS
5.6
GENERAL
d0715x8x
The speedometer is capable of displaying and clearing
speedometer, tachometer, TSM/TSSM, and ICM/ECM trouble
codes (diagnostic mode).
DIAGNOSTICS
Diagnostic Tips
● For a quick check of speedometer function, a “wow” test
can be performed. See Figure 5-8. Press and hold
odometer reset switch then turn ignition switch ON.
Release reset switch. Background lighting should illumi-
nate, speedometer needle should sweep its full range of
motion, and indicator lamps [battery, security, low fuel
(EFI models) check engine and cruise] should illuminate.
1
5
Some lamps may illuminate even though they do not
2
4
apply to the vehicle. For example, the cruise lamp may
3
illuminate even though the motorcycle may not be
equipped with cruise control.
1.
Cruise On/Engaged
4.
Battery
● If instrument module fails “wow” test, check for battery,
2.
Check Engine
5.
Security
ground, ignition, speedometer reset switch and acces-
3.
Low Fuel
sory to speedometer. If any feature in the speedometer is
non-functional, See Section 2.2 INITIAL DIAGNOSTIC
Figure 5-8. Speedometer (FLHR/C/S)
CHECK: SPEEDOMETER.
Diagnostic Notes
Use of speedometer self diagnostics assumes that DIGITAL
TECHNICIAN (Part No. HD-44750) is not available.
The reference numbers below correlate with the circled num-
bers in the Speedometer Self Diagnostics (chart)
1.
To exit diagnostic mode, turn ignition switch OFF.
2.
To clear DTC’s for selected module, press speedometer
reset switch for more than 5 seconds when code is dis-
played. This procedure will clear all codes for selected
module.
2006 Touring: Engine Management (EFI)
5-17
HOME
Speedometer Self Diagnostics (chart)
1
While holding odometer reset switch in,
turn ignition switch to IGN. Make sure
Run/Stop switch is in RUN position.
Release reset switch.
Does “diag” appear?
YES
NO
See Section 2.2 INITIAL
To display DTC’s for the
DIAGNOSTIC CHECK:
ECM, press and hold
”P” flashing.
SPEEDOMETER.
reset switch for more
than 5 seconds.
To choose TSM/
TSSM, press and
release reset switch.
To display DTC’s for
”S” flashing.
TSM/TSSM, press and
hold reset switch for
more than 5 seconds.
To
choose Speedometer,
Device
response?
press and release reset
switch.
NO
YES
“no rsp” displayed.
To display DTC’s for
See applicable code from
”SP” flashing.
speedometer, press and
other modules. Models not
hold reset switch for more
equipped with a tachometer
than 5 seconds.
will display “no rsp” normally.
If “no rsp” displayed on odom-
eter on tachometer equipped
To choose Tachometer,
“none” displayed.
vehicle, See Section 2.4
press and release reset
SPEEDOMETER/TACHOMETER.
switch.
DTC
2
displayed.
To display DTC’s for
tachometer, press and
Press and release
Press and release
”T” flashing.
hold reset switch for more
reset switch. Part num-
reset switch.
than 5 seconds.
ber of module will be
Are more DTC’s
displayed.
displayed?
NO
To choose ECM, press
YES
and release reset switch.
“end” displayed.
To clear all DTC’s for
selected module hold reset
switch for more than 5 sec-
onds. If DTC’s are not to be
cleared, Press and release
reset switch. Part number of
module will be displayed.
Press and release reset
switch again to continue to
next module.
Figure 5-9. Speedometer Self Diagnostics
5-18
2006 Touring: Engine Management (EFI)