Description
This Official 2004 Harley Davidson Touring Electrical Diagnostic Manual pmotrovides electrical diagnostic information and wiring diagrams for 2004 Touring motorcycles including:
2004 Harley-Davidson FLTRI Road Glide (EFI)
2004 Harley-Davidson FLHTI Electra Glide Standard (EFI)
2004 Harley-Davidson FLHTCUI Ultra Classic Electra Glide (EFI)
2004 Harley-Davidson FLHTCSE Screamin Eagle Electra Glide
2004 Harley-Davidson FLHTCI Electra Glide Classic (EFI)
2004 Harley-Davidson FLHTC Electra Glide Classic
2004 Harley-Davidson FLHT Electra Glide Standard
2004 Harley-Davidson FLHRSI Road King (EFI)
2004 Harley-Davidson FLHRS Road King Custom
2004 Harley-Davidson FLHRI Road King (EFI)
2004 Harley-Davidson FLHRCI Road King Classic
2004 Harley-Davidson FLHR Road King
This electrical diagnostic service 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.
Each section of this manual contains sequentially numbered topics. The numbering system allows quick cross references throughout the document.
Table of Contents
SECTION 1 -STARTING & CHARGING
Starter Troubleshooting, Starting System Diagnosis (Diagnostics, Diagnostic Notes, Job/Time Code Values, Starter Testing 1, Starter Testing 2: Solenoid Clicks, Starter Testing 3: Relay Clicks, Starter Testing 4: Nothing Clicks, Starter Testing 5: Starter Spins, But Does Not, Engage, Starter Testing 6: Starter Stalls or Spins Too Slowly), Starter Activation Circuits, Diagnostics/Troubleshooting (General, Voltage Drops), Starter System Testing (General, Starter Relay Test 1, Starter Relay Test 2, Starter Current Draw Test), Testing Assembled Starter (Starter Solenoid, Solenoid Pull-in Test, Solenoid Hold-in Test, Solenoid Return Test, Free Running Current Draw Test), Charging System (General, Alternator, Voltage Regulator, Troubleshooting, Battery, Wiring, Voltage Regulator Inspection, Job/Time Code Values, Test (Part 1 of 2) (flow chart), Test (Part 2 of 2) (flow chart) Testing, Milliamp Draw Test, Total Current Draw Test, Current Output Test, Voltage Output Test, Stator Check, AC Output Check), Battery Load Test (Voltmeter Test, Load Test).
SECTION 2-INSTRUMENTS
Checking For Trouble Codes (Check Engine Lamp, Security Lamp, Code Types, Current, Historic, Retrieving Diagnostic Trouble Codes, Multiple Diagnostic Trouble Codes), Initial Diagnostic Check: Speedometer (General, Diagnostic Notes, Circuit Diagram/Wire Harness Connector Table Initial Diagnostics, Diagnostic Tips, Diagnostic Notes, Other Codes, Diagnostic Check (Part 1 of 2) (flow chart), Diagnostic Check (Part 2 of 2) (flow chart)), Speedometer Self Diagnostics (General, Diagnostics, Diagnostic Tips, Diagnostic Notes, Speedometer Self Diagnostics (chart)), Speedometer/Tachometer (General, Reset Switch, Speedometer Theory of Operation, Job/Time Code Values, Tachometer Theory of Operation, Diagnostics, Diagnostic Notes, Test (Part 1 of 2) (flow chart), Test (Part 2 of 2) (flow chart)), Breakout Box: Speedometer (General, Installation, Removal), Speedometer Performance Check (General, Testing, Speedometer Operation Test, Speedometer Needle Sweep Test, Vehicle Speed Sensor Test), Fuel Gauge Operation (Theory of Operation, Fuel Gauge and Sender Test), Indicator Lamps: FLTR, FLHT/C/U (General, Indicator Lamp Connector [20] Pins (table), Job/Time Code Values, Diagnostic Notes, Diagnostics, Oil Pressure or Neutral Indicator Will Not Function, High Beam or R/L Turn Signal Indicator Will Not Function), Indicator Lamps: FLHR/C/S (General, Indicator Lamp Connector [20] Pins (table), Job/Time Code Values, Diagnostics, Oil Pressure or Neutral Indicator Will Not Function, High Beam or R/L Turn Signal Indicator Will Not Function), DTCB1004, B1005 (General, Diagnostics, Test B1004 (flow chart), Test B1005 (flow chart)), DTC 81006,81007 (General, Accessory Or Ignition Line Overvoltage, Test (flow chart)), DTC 81008 (General, Diagnostics), DTC U1016 (General, Loss of ICM/ECM Serial Data, Diagnostics, Diagnostic Notes, Test (flow chart)), DTC U1064, U1255 (General, Loss of TSM/TSSM Serial Data, Diagnostics, Test (flow chart)), DTC U1300, U1301 or ‘BUS Er’ (General, Serial Data Low or Serial Data Open/High, Diagnostics, Diagnostic Tips, Diagnostic Notes).
SECTION 3-TSM/TSSM
TSM/TSSM Overview (General, Troubleshooting), TSM/TSSM Features (General, Turn Signal Functions, TSM/TSSM Features, Bank Angle Functions, TSM/TSSM Features, Security Alarm and Immobilization Functions, TSSM Only Feature), TSM/TSSM Vehicle Delivery (General, Sidecar Configuration, Power Disruption and Configuring, Key Fob Assignment, Personal Code Entry, First Time Code Entry: TSSM Only, Modifying Existing Codes: TSSM Only), TSM/TSSM Turn Signal Functions (General, Automatic Cancellation, Manual Cancellation, Four-way Flashing, Diagnostics Mode), TSM/TSSM Bank Angle Function (General, Operation), TSSM Security Functions (General, Security System Operation, Security System Options, Differences By Market Specifications, Alarm Sensitivity, Sensitivity, Transport Mode, Auto-Arming Function, Storage Mode), TSSM Arming/Disarming (General, Security Lamp, Using Key Fob, General, Arming the System, Disarming the System, Troubleshooting, Using the Personal Code, General, Disarming the System), Checking For Trouble Codes (TSM, TSSM, Code Types, Current, Historic, Retrieving Diagnostic Trouble Codes, Multiple Diagnostic Trouble Codes), Initial Diagnostic Check: TSM/TSSM (General, Diagnostic Notes, Circuit Diagram/Wire Harness Connector Table, Reprogramming ICM/ECM, Initial Diagnostics, Diagnostic Tips, Diagnostic Notes, Other Codes, Diagnostic Check (Part 1 of 2) (flow chart), Diagnostic Check (Part 1 of 2) (flow chart)), Speedometer Self Diagnostics (General, Diagnostics, Diagnostic Tips, Diagnostic Notes, Speedometer Self Diagnostics (chart)), Breakout Box (TSM/TSSM) (General, Installation, Removal), No Security Lamp at Key ON (General, No TSSM Power (Security Equipped Vehicles Only), Job/Time Code Values, Diagnostics, Diagnostic Tips, Diagnostic Notes, Test (Parti of 3) (flow chart), Test (Part 2 of 3) (flow chart), Test (Part 3 of 3) (flow chart)), Security Lamp on Continuously (General, Diagnostics, Diagnostic Notes, Test (flow chart)), Key Fob Signal To TSSM Weak or Fails (General, Security Equipped Vehicles Only, Diagnostics, Diagnostic Tips, Diagnostic Notes, Test (flow chart)), Turn Signal Errors (General, Diagnostics, Diagnostic Tips, Diagnostic Notes: All Turn Signal Flow Charts, Test 1A (flow chart):, Test 2A (flow chart), Test 2B (flow chart), Test 2C (flow chart), Test 2D (flow chart), Test 3A (flow chart)), DTC B0563 (General, Battery Voltage High, Diagnostics, Diagnostic Tips, Diagnostic Notes), DTC B1131,81132 (General, Alarm Output Low/High, Diagnostics, Diagnostic Tips, Diagnostic Notes, Test (flow chart)), DTC B1134 (General, Starter Output High, Diagnostics, Diagnostic Notes, Test (flowchart)), DTC B1135 (General, Accelerometer Fault), DTC B1151, B1152, B1153 (General, Diagnostics, Diagnostic Tips, Diagnostic Notes, Test (flow chart)), DTC U1016 (General, Loss of ICM/ECM Serial Data, Diagnostics, Diagnostic Notes, Test (flow chart)), DTC U1097, U1255 (General, Loss of Speedometer Serial Data, Diagnostics, Diagnostic Notes, Test (flow chart)), DTC U1300, U1301 or ‘BUS Er’ (General, Serial Data Low or Serial Data Open/High, Diagnostics, Diagnostic Tips, Diagnostic Notes), Password Learn (General, Password Learning), TSSM Maintenance (General, Key Fob, Schedule, Battery Replacement, Siren (If Installed), Schedule, Battery Replacement).
SECTION 4-ENGINE MANAGEMENT (CARB)
Specifications, Diagnostic Introduction (System Problems, No Start, Poor Performance, Check Engine Lamp, Resolving Problems), Checking For Trouble Codes (Check Engine Lamp, Code Types, Current, Historic, Retrieving Diagnostic Trouble Codes, Multiple Diagnostic Trouble Codes), Initial Diagnostic Check: ICM (General, Diagnostic Notes, Circuit Diagram/Wire Harness Connector Table, Reprogramming ICM, Initial Diagnostics, General Information, Diagnostic Tips, Diagnostic Notes, Diagnostic Check (Part 1 of 2) (flow chart), Diagnostic Check (Part 2 of 2) (flow chart)), Speedometer Self Diagnostics (General, Diagnostics, Diagnostic Tips, Diagnostic Notes), Breakout Box (General, Installation, Removal), Wiggle Test (General, Procedure), Intake Leak Test (General, Leak Tester, Parts List, Tester Assembly, Intake Leak Testing), Engine Cranks, But Will Not Start (General, Diagnostics, Diagnostic Notes, Test (Part 1 of 3) (flow chart), Test (Part 2 of 3) (flow chart), Test (Part 3 of 3) (flow chart)), Starts and Then Stalls (General, Diagnostics, Diagnostic Tips, Diagnostic Notes, Test (Part 1 of 2) (flow chart), Test (Part 2 of 2) (flow chart)), No Spark/No ICM Power (General, Diagnostics, Diagnostic Notes, Test (flow chart)), Misfire (General, Misfire at Idle or Under Load, Diagnostics, Diagnostic Notes, Test (flow chart)), DTC P0106, P0107, P0108 (General, MAP Sensor, Diagnostics, Diagnostic Tips, Diagnostic Notes, Test (Part 1 of 2) (flow chart), Test (Part 2 of 2) (flow chart)), DTCP0562, P0563 (General, Battery Voltage, Diagnostics, Diagnostic Notes, Test (Part 1 of 2) (flow chart), Test (Part 2 of 2) (flow chart)), DTC P1009, P1010 (General, Password Problem, Diagnostics, Diagnostic Notes, Test (flow chart)), DTC P1351, P1352, P1354, P1355 (General, Ignition Coil, Diagnostics, Diagnostic Notes, Test (Part 1 of 2) (flow chart), Test (Part 2 of 2) (flow chart)), DTCP0373, P0374 (General, Crank Position Sensor, Diagnostics, Diagnostic Notes, Test (flowchart)), DTCP0501,P0502 (General, Vehicle Speed Sensor, Diagnostics, Test (Part 1 of 2) (flow chart), Test (Part 2 of 2) (flow chart)), DTC P0602, P0603, P0604, P0605, P0607 (General, ICM Failure, Diagnostics, DTC P0607 Test, DTC P0602, P0603, P0604, P0605 Test), DTC U1064 (General, Loss of TSM/TSSM Serial Data, Diagnostics, Diagnostic Notes, Test (flow chart)), DTC U1097 (General, Loss of Speedometer Serial Data, Diagnostics, Diagnostic Notes, Test (flow chart)).
SECTION 5-ENGINE MANAGEMENT (EFI)
Specifications, EFI System (General, Troubleshooting), EFI Diagnostic Introduction (System Problems, No Start, Poor Performance, Check Engine Lamp, Resolving Problems), Checking For Trouble Codes (Check Engine Lamp, Code Types, Retrieving Diagnostic Trouble Codes, Multiple Diagnostic Trouble Codes), Initial Diagnostic Check: EFI (General, Diagnostic Notes, Circuit Diagram/Wire Harness Connector Table, Reprogramming ECM, Initial Diagnostics, Diagnostic Tips, Diagnostic Notes, Other Codes, Diagnostic Check (Part 1 of 2) (flow chart), Diagnostic Check (Part 2 of 2) (flow chart)), Speedometer Self Diagnostics (General, Diagnostics, Diagnostic Tips, Diagnostic Notes, Speedometer Self Diagnostics (chart)), Breakout Box (General, Installation, Removal), Wiggle Test (General, Procedure), Intake Leak Test (General, Leak Tester, Parts List, Tester Assembly, Intake Leak Testing), Engine Cranks, But Will Not Start (General, Diagnostics, Diagnostic Notes, Diagnostic Tips, Test (Part 1 of 4) (flow chart), Test (Part 2 of 4) (flow chart), Test (Part 3 of 4) (flow chart), Test (Part 4 of 4) (flow chart)), No ECM Power (General, No Spark/No Check Engine Lamp at Key ON, Diagnostics, Diagnostic Notes, Test (Part 1 of 2) (flow chart), Test (Part 2 of 2) (flow chart)), Starts, Then Stalls (General, Diagnostics, Diagnostic Tips, Diagnostic Notes, Test (Part 1 of 2) (flow chart), Test (Part 2 of 2) (flow chart)), Fuel System Electrical Test (General, Diagnostics, Diagnostic Notes, Test (Part 1 of 4) (flow chart), Test (Part 2 of 4) (flow chart), Test (Part 3 of 4) (flow chart), Test (Part 4 of 4) (flow chart)), System Relay Check (General, System Relay, Diagnostics, Diagnostic Notes), Test (Part 1 of 3) (flow chart), Test (Part 2 of 3) (flow chart), Test (Part 3 of 3) (flow chart)), Fuel Pressure Test (General, Testing, Diagnostics, Diagnostic Notes, Test (flow chart)), Idle Air Control (General, IAC Operation, Diagnostic Trouble Code P0505: Loss of Idle, Speed Control, Diagnostics, Diagnostic Tips, Diagnostic Notes, Test (Part 1 of 2) (flow chart), Test (Part 2 of 2) (flow chart)), Misfire at Idle or Under Load (General, Misfire at Idle or Under Load, Diagnostics, Diagnostic Notes, Test (Part 1 of 3) (flow chart), Test (Part 2 of 3) (flow chart), Test (Part 3 of 3) (flow chart)), Combustion Absent/Intermittent (General, Diagnostic Trouble Codes P1353, P1356: No Combustion, Diagnostics, Diagnostic Notes, Test (Part 1 of 2) (flow chart), Test (Part 2 of 2) (flow chart)), DTCP0107, P0108 (General, MAP Sensor, Diagnostics, Diagnostic Tips, Diagnostic Notes, Test (Part 1 of 2) (flow chart), Test (Part 2 of 2) (flow chart)), DTCP0112, P0113 (General, IAT Sensor, Diagnostics, Diagnostic Tips, Diagnostic Notes, Test (Part 1 of 2) (flow chart), Test (Part 2 of 2) (flow chart)), DTCP0117, P0118 (General, ET Sensor, Diagnostics, Diagnostic Tips, Diagnostic Notes, Test (Part 1 of 2) (flow chart), Test (Part 2 of 2) (flow chart)), DTCP0122, P0123 (General, TP Sensor, Diagnostics, Diagnostic Tips, Diagnostic Notes, Test (Part 1 of 2) (flow chart), Test (Part 2 of 2) (flow chart)), DTC P0261, P0262, P0263, P0264 (General, Fuel Injectors, Diagnostics, Diagnostic Notes, Test (Part 1 of 3) (flow chart), Test (Part 2 of 3) (flow chart), Test (Part 3 of 3) (flow chart)), DTC P0373, P0374 (General, CKP Sensor, Diagnostics, Diagnostic Tips, Diagnostic Notes, Test (flowchart)), DTC P0501,P0502 (General, Vehicle Speed Sensor, Diagnostics, Diagnostic Notes, Test (Part 1 of 2) (flow chart), Test (Part 2 of 2) (flow chart)), DTC P0562, P0563 (General, Battery Voltage, Diagnostics, Diagnostic Tips, Diagnostic Notes, Test (Part 1 of 2) (flow chart), Test (Part 2 of 2) (flow chart)), DTC P0603, P0605 (General, ECM Failure, Diagnostics, DTC P0603 Test, DTC P0605 Test), DTC P1009, P1010 (General, Password Problem, Diagnostics, Diagnostic Notes, Test (flowchart)), DTC P1351, P1352, P1354, P1355 (General, Ignition Coil, Diagnostics, Diagnostic Notes, Test (Parti of 2) (flow chart), Test (Part 2 of 2) (flow chart)), DTCU1064, U1255 (General, Loss of TSMfTSSM Serial Data, Diagnostics, Diagnostic Notes, Test (flow chart)), DTCU1097, U1255 (General, Loss of Speedometer Serial Data, Diagnostics, Test (flow chart)).
SECTION 6-PREMIUM SOUND
Diagnostic Introduction (General Information), Diagnostic Mode Overview (General, Diagnostic Group 1, General, Sample Diagnostic, Diagnostic Group 2, General, Sample Diagnostic), Breakout Box (General, Installation, Removal), Radio Symptom 1: Audio Control Inoperative (General, Problem, Setup, Functionality, Diagnostics, Diagnostic Notes, Test (Part 1 of 2) (flow chart), Test (Part 2 of 2) (flow chart)), Radio Symptom 2: Mode Control Inoperative (General, Problem, Setup, Functionality, Diagnostics, Diagnostic Notes, Test (Parti of 4) (flow chart), Test (Part 2 of 4) (flow chart), Test (Part 3 of 4) (flow chart), Test (Part 4 of 4) (flow chart)), Radio Symptom 3: No Sound In External Speakers (General, Problem, Setup, Functionality, Diagnostics, Diagnostic Notes, Test (Part 1 of 3) (flow chart), Test (Part 2 of 3) (flow chart), Test (Part 3 of 3) (flow chart)), Radio Symptom 4: AVC Inoperative (General, Problem, Setup, Functionality, Diagnostics, Automatic Volume Control (AVC) Adjustment, Diagnostic Notes, Test (Part 1 of 2) (flow chart), Test (Part 2 of 2) (flow chart)), Radio Symptom 5: Poor Stereo Reception (General, Problem, Setup, Functionality, Diagnostics, Radio Antenna Test, Test (flowchart)), Radio Symptom 6: No Power (General, Problem, Setup, Functionality, Diagnostics, Diagnostic Notes, Test (Part 1 of 2) (flow chart), Test (Part 2 of 2) (flow chart)), Radio Symptom 7: CD Will Not Eject (General, Problem, Setup, Functionality, Diagnostics, Diagnostic Notes, Test (Part 1 of 2) (flow chart), Test (Part 2 of 2) (flow chart)), Radio Symptom 8: Headset/Microphone Inoperative (General, Problem, Setup, Functionality, Diagnostics, Diagnostic Notes, Test (Part 1 of 2) (flow chart), Test (Part 2 of 2) (flow chart)), Radio Symptom 9: Headset Volume/ PTT Inoperative (General, Problem, Setup, Functionality, Diagnostics, Diagnostic Notes, Test (Part 1 of 3) (flow chart), Test (Part 2 of 3) (flow chart), Test (Part 3 of 3) (flow chart)), Radio Symptom 10: Intercom Inoperative (General, Problem, Setup, Functionality, Diagnostics, Test (Part 1 of 1) (flow chart)), Radio Symptom 11: CB Receiver Inoperative (General, Problem, Setup, Functionality, Diagnostics, Diagnostic Notes, Test (Part 1 of 1) (flow chart)), Radio Symptom 12: CB Transmitter Inoperative (General, Problem, Setup, Functionality, Diagnostics, Diagnostic Notes, Test (Part 1 of 2) (flow chart), Test (Part 2 of 2) (flow chart), CB Antenna Test, SWR Adjustment), Radio Symptom 13: PTT/Squelch Inoperative (General, Problem, Setup, Functionality, Diagnostics, Diagnostic Notes, Test (Part 1 of 2) (flow chart), Test (Part 2 of 2) (flow chart)), Radio Symptom 14: Handheld Microphone PTT Inoperative (General, Problem, Setup, Functionality, Diagnostics, Diagnostic Notes, Test (Part 1 of 2) (flow chart), Test (Part 2 of 2) (flow chart)), Radio Symptom 15: No CB Audio in Headset (General, Problem, Setup, Functionality, Diagnostics, Diagnostic Notes, Test (flowchart)).
SECTION 7-CRUISE CONTROL
Cruise Control (General, System Operation, Troubleshooting), Cruise Inoperative Diagnostics (General, Inoperative Diagnostics, Diagnostic Notes), Cruise Dropout Diagnostics (General, Dropout Diagnostics), Cruise Chart A: Initial Diagnostics (Diagnostics, Test: Initial Diagnostics (flowchart)), Cruise Chart B: Resume Switch (Diagnostics, Test: Resume Switch (flowchart)), Cruise Chart C: Cruise Engaged Lamp (Diagnostics, Test: Cruise Engaged Lamp (flow chart)), Cruise Chart D: Cruise Power (Diagnostics, Test: Cruise Power (flow chart)), Cruise Chart E: Cruise Enable (Diagnostics, Test: Cruise Enable (flowchart), Diagnostic Notes), Cruise Chart F-1: Brake Lights ON (Diagnostics, Test: Constant Brake Light Input (flow chart)), Cruise Chart F-2: Brake Lights OFF (Diagnostics, Test: No Front and/or Rear Brake Lights (flow chart), Diagnostic Notes), Diagnostics, Test: No Front and/or Rear Brake Lights (flow chart), Diagnostic Notes (Diagnostics, Test: Throttle Switch (flow chart)), Cruise Chart H: Speedometer Input (Diagnostics, Diagnostic Notes, Test: Speedometer Input (flow chart)), Cruise Chart I: Tachometer Input (Diagnostics, Test: Tachometer Input (flow chart)).
SECTION 8-WIRING
Electrical Connector Locations (FLHT/C/U, FLHR/C/S, FLTR), Deutsch Electrical Connectors (General, Removing/Disassembling, Removing/Installing Sockets, Removing/Installing Pins, Assembling/Installing, Crimping Instructions, Standard Terminals, Mini Terminals, Solid Barrel Contacts, 1-Place Cable Connector, General, Removal, Installation), Amp Multilock Electrical Connectors (Removing Socket/Pin Terminals, Installing Socket/Pin Terminals, Crimping Instructions), Packard Electrical Connectors (150 Metri-Pack Series, General, Disassembly, Assembly, 280 Metri-Pack Series, General, Fuel Injectors, System Fuse Block, 480 Metri-Pack Series, General, Disassembly, Assembly, 630 Metri-Pack Series, General, Disassembly, Assembly, 800 Metri-Pack Series, General, Disassembly, Assembly, Packard Micro 64, General, Disassembly, Assembly, Crimping Instructions, Packard 100W, General, Disassembly, Assembly, Crimping Instructions), Autofuse Electrical Connector (General, Disassembly, Assembly), Sealed Butt Splice Connectors (Procedure), Amp Electrical Connectors (1-Place Connector, Socket Terminal, Pin Terminal).
WIRING DIAGRAMS
FLHT, FLHTC, FLHTCU (Main Harness, Interconnect Harness, Ignition Harness (Carbureted), Electronic Fuel Injection (EFI) Harness, Ignition Switch, Tail Lamp, Passing Lamps, Fender Tip Lamps, Directional Lamps and Tour-Pak Lights, Starting and Charging, Handlebar Controls and Indicator Lamps, Fairing Cap Switches, Radio, CB/lntercom and Rear Speakers), FLTR (Main Harness, Interconnect Harness, Ignition Harness (Carbureted), Electronic Fuel Injection (EFI) Harness, Ignition Switch, Tail Lamp and Directional Lamps, Starting and Charging, Handlebar Controls and Indicator Lamps, Instrument Nacelle Switches, Radio), FLHR, FLHRC, FLHRS (Main Harness, Ignition Harness (Carbureted), Electronic Fuel Injection (EFI) Harness, Starting and Charging, Handlebar Controls, Speedometer, Indicator Lamps, Tail Lamp, Passing Lamps, Directional Lamps, Fender Tip Lamps and Spot/Accessory Switches), TLE Sidecar, TLE Ultra Sidecar (Chassis, Audio Harness).
