2013 HD Softail FXSBSE Supplement

2013 Harley-Davidson FXSBSE Model
Service Manual Supplement

99494-13
2012 H-D.
Harley-Davidson motorcycles conform to all applicable U.S.A. Federal Motor Vehicle Safety Standards
and U.S.A. Environmental Protection Agency regulations effective on the date of manufacture.
To maintain the safety, dependability, and emission and noise control performance, it is essential that
the procedures, specifications and service instructions in this manual are followed.
Any substitution, alteration or adjustment of emission system and noise control components outside of
factory specifications may be prohibited by law.
IMPORTANT NOTICE
Harley-Davidson Motor Company
2013 Harley-Davidson
FXSBSE Model Service
Manual Supplement
2012 H-D.
ALL RIGHTS RESERVED
99494-13
Printed in the U.S.A.
VISIT THE HARLEY-DAVIDSON WEB SITE
http://www.harley-davidson.com
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The Harley-Davidson Service Communications Department maintains a continuous effort to improve the quality
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2013 Harley-Davidson FXSBSE Model Service Manual Supplement (99494-13)
NOTES
ABOUT THIS MANUAL
GENERAL
This service manual supplement has been designed to be used
with the current service manual and has been prepared with
two purposes in mind.
It will acquaint the user with the construction of the Harley-
Davidson product and assist in the performance of basic
maintenance and repair.
It will introduce to the professional Harley-Davidson
Technician the latest field-tested and factory-approved
major repair methods.
We sincerely believe that this service manual supplement will
make your association with Harley-Davidson products more
pleasant and profitable.
NOTE
This service manual supplement provides information unique
to this model motorcycle. Any information not presented in this
supplement can be found in the appropriate service manual or
electrical diagnostic manual. Refer to Table i-1.
Table i-1. Relevant Model Year Publications
PART NUMBER PUBLICATION
99482-13 Softail Models Service Manual
99498-13 Softail Models Electrical Diagnostic
Manual
HOW TO USE YOUR SERVICE MANUAL
SUPPLEMENT
Use the TABLE OF CONTENTS (which follows this FORE-
WORD) and the INDEX (at the back of this manual) to quickly
locate subjects. Sections and topics in this manual are
sequentially numbered for easy navigation.
CHAPTER NO.
Maintenance 1
Chassis 2
Engine 3
Fuel System 4
Drive 5
Transmission 6
Electrical 7
Engine Management 8
Appendix A Wiring A
Appendix B Glossary B
For example, a cross-reference shown as 2.1
SPECIFICATIONS refers to chapter 2 CHASSIS, heading 2.1
SPECIFICATIONS.
If the subject you seek is not in this supplement, refer to the
corresponding chapter in the appropriate service manual.
Check the title page located in the front of each chapter to find
the subject.
For quick and easy reference, all pages contain a chapter
number followed by a page number. For example, page 3-5
refers to page 5 in chapter 3.
In figure legends, the number following the name of a part
indicates the quantity necessary for one complete assembly.
PREPARATION FOR SERVICE
TOOL NAME PART NUMBER
DIGITAL TECHNICIAN II HD-48650
Stop the engine when refueling or servicing the fuel
system. Do not smoke or allow open flame or sparks near
gasoline. Gasoline is extremely flammable and highly
explosive, which could result in death or serious injury.
(00002a)
Good preparation is very important for efficient service work.
Start each job with a clean work area. This will allow the repair
to proceed as smoothly as possible. It will also reduce the
incidence of misplaced tools and parts.
Clean a motorcycle that is excessively dirty before work starts.
Cleaning will occasionally uncover sources of trouble. Gather
any tools, instruments and any parts needed for the job before
work begins. Interrupting a job to locate tools or parts is a dis-
traction and causes needless delay.
NOTES
To avoid unnecessary disassembly, carefully read all
related service information before repair work begins.
In figure legends, the number which follows the name of
a part indicates the quantity necessary for one complete
assembly.
When servicing a vehicle equipped with the Harley-Dav-
idson Smart Security System (H-DSSS), first disarm the
system. Keep the fob close to the vehicle or use DIGITAL
TECHNICIAN II (Part No. HD-48650) to disable the
system. Activate the system after service is completed.
SERVICE BULLETINS
In addition to the information presented in this service manual
supplement and the appropriate service manual, Harley-Dav-
idson Motor Company will periodically issue Service Bulletins
to Harley-Davidson dealers. Service bulletins cover interim
engineering changes and supplementary information. Consult
the service bulletins to keep your product knowledge current
and complete.
USE GENUINE REPLACEMENT PARTS
Harley-Davidson parts and accessories are designed for
Harley-Davidson motorcycles. Using non-Harley-Davidson
parts or accessories can adversely affect performance,
stability or handling, which could result in death or serious
injury. (00001b)
To achieve satisfactory and lasting repairs, carefully follow the
service manual instructions and use only genuine Harley-
Davidson replacement parts. Behind the emblem bearing the
words GENUINE HARLEY-DAVIDSON stand more than 100
years of design, research, manufacturing, testing and inspecting
I
F
O
R
E
W
O
R
D
experience. This is your assurance that the parts you are using
will fit right, operate properly and last longer.
DISPOSAL AND RECYCLING
Help protect our environment! Many communities maintain
facilities for recycling used fluids, plastics and metals. Dispose
of or recycle used oil, lubricants, fuel, coolant, brake fluid and
batteries in accordance with local regulations. Many Harley-
Davidson parts and accessories are made of plastics and
metals which can also be recycled.
WARNINGS AND CAUTIONS
Statements in this manual preceded by the following words
are of special significance.
WARNING indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury. (00119a)
CAUTIONindicates a potentially hazardous situationwhich,
if not avoided, may result in minor or moderate injury.
(00139a)
NOTICE indicates a potentially hazardous situation which,
if not avoided, may result in property damage. (00140b)
NOTE
Refers to important information, and is placed in italic type. It
is recommended that you take special notice of these items.
Proper service and repair is important for the safe, reliable
operation of all mechanical products. The service procedures
recommended and described in this manual are effective
methods for performing service operations.
Always wear proper eye protection when using hammers,
arbor or hydraulic presses, gear pullers, spring com-
pressors, slide hammers and similar tools. Flying parts
could result in death or serious injury. (00496b)
Some of these service operations require the use of tools
specially designed for the purpose. These special tools should
be used when and as recommended. It is important to note
that some warnings against the use of specific service methods,
which could damage the motorcycle or render it unsafe, are
stated in this manual. However, remember that these warnings
are not all-inclusive. Inadequate safety precautions could result
in death or serious injury.
Since Harley-Davidson could not possibly know, evaluate or
advise the service trade of all possible ways in which service
might be performed, or of the possible hazardous con-
sequences of each method, we have not undertaken any such
broad evaluation. Accordingly, anyone who uses a service
procedure or tool which is not recommended by Harley-Dav-
idson must first thoroughly satisfy himself that neither his nor
the operator's safety will be jeopardized as a result. Failure to
do so could result in death or serious injury.
PRODUCT REFERENCES
Read and follow warnings and directions on all products.
Failure to follow warnings and directions can result in
death or serious injury. (00470b)
When reference is made in this manual to a specific brand
name product, tool or instrument, an equivalent product, tool
or instrument may be substituted.
Kent-Moore Products
All tools mentioned in this manual with an "HD", "J" or "B"
preface must be ordered through SPXKent-Moore. For ordering
information or product returns, warranty or otherwise, visit
www.spx.com.
LOCTITE Sealing and THREADLOCKING
Products
Some procedures in this manual call for the use of LOCTITE
products. If you have any questions regarding LOCTITEproduct
usage or retailer/wholesaler locations, contact Loctite Corp. at
www.loctite.com.
PRODUCT REGISTERED MARKS
Apple, Alcantara S.p.A., Allen, Amp Multilock, Bluetooth,
Brembo, Delphi, Deutsch, Dunlop, Dynojet, Fluke, G.E.
Versilube, Garmin, Gunk, Hydroseal, Hylomar, iPhone, iPod,
Kevlar, Lexan, Loctite, Lubriplate, Keps, K&N, Magnaflux,
Marson Thread-Setter Tool Kit, MAXI fuse, Molex, Michelin,
MPZ, Mulitilock, nano, NGK, Novus, Packard, Pirelli, Permatex,
Philips, PJ1, Pozidriv, Robinair, S100, Sems, Snap-on, Teflon,
Threadlocker, Torca, Torco, TORX, Tufoil, Tyco, Ultratorch,
Velcro, X-Acto, XM Satellite Radio, and zmo are among the
trademarks of their respective owners.
H-D MICHIGAN, INC. TRADEMARK
INFORMATION
Bar & Shield, Cross Bones, Digital Tech, Digital Technician,
Digital Technician II, Dyna, Electra Glide, Evolution, Fat Bob,
Fat Boy, Forty-Eight, Glaze, Gloss, H-D, H-Dnet.com, Harley,
Harley-Davidson, HD, Heritage Softail, Iron 883, Low Rider,
Night Rod, Nightster, Night Train, Profile, Revolution, Road
Glide, Road King, Road Tech, Rocker, Screamin' Eagle, Sev-
enty-Two, Softail, Sportster, Street Glide, Street Rod, Sun Ray,
Sunwash, Super Glide, SuperLow, Switchback, SYN3, Tech-
Link, TechLink II, Tour-Pak, Twin Cam 88, Twin Cam 88B,
Twin Cam96, Twin Cam96B, Twin Cam103, Twin Cam103B,
Twin Cam 110, Twin Cam 110B, Ultra Classic, V-Rod, VRSC,
XR1200X and Harley-Davidson Genuine Motor Parts and
Genuine Motor Accessories are among the trademarks of H-
D Michigan, Inc.
CONTENTS
All photographs, illustrations and procedures may not neces-
sarily depict the most current model or component, but are
based on the latest production information available at the time
of publication.
II FOREWORD
Since product improvement is our continual goal, Harley-Dav-
idson reserves the right to change specifications, equipment
or designs at any time without notice and without incurring
obligation.
FOREWORD III
IV FOREWORD
NOTES
MAINTENANCE
1.1 FASTENER TORQUE VALUES
Fastener Torque Values in this Chapter..............................1-1
1.2 BULB REQUIREMENTS
General...............................................................................1-2
1.3 MAINTENANCE SCHEDULE
General...............................................................................1-3
Disposal and Recycling...............................................1-3
1.4 AIR FILTER
Removal..............................................................................1-6
Cleaning..............................................................................1-6
Installation...........................................................................1-6
1.5 HYDRAULIC CLUTCH FLUID
General...............................................................................1-7
Fluid Inspection...................................................................1-7
1.6 ENGINE LUBRICATION SYSTEM
General...............................................................................1-8
1.7 TIRES AND WHEELS
Tires....................................................................................1-9
1.8 DRIVE BELT AND SPROCKETS
Checking Belt Deflection...................................................1-10
1.9 STEERING HEAD BEARINGS
Adjustment........................................................................1-11
Bearing Adjustment (Fall-away)................................1-11
1.10 SUSPENSION ADJUSTMENTS
Shock Absorbers..............................................................1-13
Calculate Number of Turns........................................1-13
Adjustment.................................................................1-13
CHASSIS
2.2 SPECIFICATIONS: CHASSIS
General...............................................................................2-3
2.3 VEHICLE IDENTIFICATION NUMBER
(VIN)
Vehicle Identification Number (VIN)....................................2-4
General........................................................................2-4
Location.......................................................................2-4
Abbreviated VIN..........................................................2-4
2.4 FRONT AXLE COVERS
Replacement.......................................................................2-6
2.5 FRONT WHEEL
Removal..............................................................................2-7
Disassembly.......................................................................2-7
Inspection...........................................................................2-8
Assembly............................................................................2-8
Installation...........................................................................2-8
2.6 REAR WHEEL
Removal..............................................................................2-9
Disassembly.......................................................................2-9
Maintenance and Cleaning.................................................2-9
Assembly..........................................................................2-11
Installation.........................................................................2-11
2.7 BRAKE PEDAL PAD
Removal............................................................................2-12
Installation.........................................................................2-12
2.8 FRONT FORKS
Removal............................................................................2-13
Disassembly.....................................................................2-13
Cleaning and Inspection...................................................2-13
Assembly..........................................................................2-15
Installation.........................................................................2-15
2.9 FOOTRESTS
Disassembly.....................................................................2-16
Assembly..........................................................................2-16
2.10 JIFFY STAND
Replacement.....................................................................2-17
2.11 HANDGRIPS AND HAND CONTROLS
General.............................................................................2-18
Switch Housings and Brackets: Removal.........................2-18
Handlebar Wiring..............................................................2-18
Pulling Wire Leads.....................................................2-18
Threading Wire Leads...............................................2-18
Throttle Grip Sensor (TGS)...............................................2-19
Handgrips.........................................................................2-19
Left Handgrip.............................................................2-19
Right Throttle Twist Grip............................................2-19
Switch Housings and Brackets: Installation......................2-20
Turn Signals and Mirrors..................................................2-20
2.12 HANDLEBARS AND RISERS
Removal............................................................................2-22
Preparation................................................................2-22
Handlebars................................................................2-22
Lower Handlebar Clamp............................................2-22
Installation.........................................................................2-23
Lower Clamp.............................................................2-23
Handlebars................................................................2-23
Return to Service.......................................................2-23
2.13 REAR FENDER
Removal............................................................................2-25
Installation.........................................................................2-26
2.14 ABS HYDRAULIC CONTROL UNIT
(HCU)
Front HCU.........................................................................2-27
Removal....................................................................2-27
Installation.................................................................2-27
2.15 CLUTCH MASTER CYLINDER AND
RESERVOIR
Removal............................................................................2-29
Disassembly.....................................................................2-29
Cleaning and Inspection...................................................2-30
V
T
A
B
L
E
O
F
C
O
N
T
E
N
T
S
Assembly..........................................................................2-31
Installation.........................................................................2-31
2.16 CLUTCH HAND LEVER
Removal............................................................................2-33
Installation.........................................................................2-33
2.17 CLUTCH FLUID LINE
Replacement.....................................................................2-34
Removal....................................................................2-34
Installation.................................................................2-34
2.18 BLEEDING CLUTCH FLUID LINE
Drain and Fill.....................................................................2-35
Drain..........................................................................2-35
Fill..............................................................................2-35
Bleed Clutch Master Cylinder...........................................2-36
Bleed Fluid Line and Secondary Clutch Actuator.............2-36
2.19 SHIFTER PEG
Disassembly.....................................................................2-38
Assembly..........................................................................2-38
2.20 REAR FORK PIVOT COVERS
Replacement.....................................................................2-39
2.21 SEAT
Replacement.....................................................................2-40
Removal....................................................................2-40
Installation.................................................................2-40
2.22 HEADLAMP NACELLE
Removal............................................................................2-41
Installation.........................................................................2-41
ENGINE
3.2 SPECIFICATIONS: ENGINE
General...............................................................................3-2
Manufacturing Tolerances..................................................3-2
3.3 SERVICE WEAR LIMITS
General...............................................................................3-4
3.4 TROUBLESHOOTING
Compression Test...............................................................3-6
Cylinder Leakdown Test......................................................3-6
3.5 INSTALLING ENGINE IN CHASSIS
Procedure...........................................................................3-8
3.6 CYLINDER HEAD
General.............................................................................3-10
Removal............................................................................3-10
Determining Service.........................................................3-10
Disassembly.....................................................................3-10
Cleaning............................................................................3-11
Inspection.........................................................................3-13
Cylinder Head............................................................3-13
Valve Guides.............................................................3-13
Valves........................................................................3-13
Valve Springs.............................................................3-13
Tapered Keepers.......................................................3-13
Valve Seats................................................................3-13
Replacing Valve Guides....................................................3-14
Removal....................................................................3-14
Installation.................................................................3-15
Assembly..........................................................................3-18
Installation.........................................................................3-20
3.7 PISTONS
Measuring Piston..............................................................3-21
3.8 BORING AND HONING CYLINDERS
Inspection.........................................................................3-22
Cylinder Bore Finished Size.............................................3-23
Piston Orientation.............................................................3-24
3.9 CRANKCASE ASSEMBLY
General.............................................................................3-25
Assembly..........................................................................3-25
3.10 OIL TANK
Removal and Disassembly...............................................3-28
Oil Tank......................................................................3-28
Oil Line Fittings/Retainers.........................................3-30
Installation.........................................................................3-31
FUEL SYSTEM
4.1 AIRCLEANERBACKPLATEASSEMBLY
Repair.................................................................................4-1
Disassembly................................................................4-1
Assembly.....................................................................4-1
4.2 CONSOLE
Removal..............................................................................4-2
Installation...........................................................................4-2
4.3 INDUCTION MODULE
Removal..............................................................................4-4
Throttle Control Actuator (TCA)..........................................4-5
Temperature Manifold Absolute Pressure (TMAP).............4-5
Removal......................................................................4-5
Installation...................................................................4-5
Installation...........................................................................4-5
4.4 EXHAUST SYSTEM
Mufflers...............................................................................4-7
Removal......................................................................4-7
Assembly.....................................................................4-7
System................................................................................4-7
Removal......................................................................4-7
Installation...................................................................4-7
VI TABLE OF CONTENTS
TABLE OF CONTENTS
DRIVE
5.2 SPECIFICATIONS: DRIVE
General...............................................................................5-2
5.3 DRIVE COMPONENTS
General...............................................................................5-3
5.4 CLUTCHRELEASEBEARINGANDPUSH
ROD
General...............................................................................5-4
Removal..............................................................................5-4
Installation...........................................................................5-4
Measure Release Plate Movement.............................5-4
Install Clutch Inspection Cover....................................5-4
5.5 CLUTCH
Clutch Pack Only................................................................5-6
Partial Disassembly.....................................................5-6
Cleaning And Inspection.............................................5-6
Assembly.....................................................................5-6
TRANSMISSION
6.2 SPECIFICATIONS: TRANSMISSION
General...............................................................................6-2
6.3 TRANSMISSON SIDE COVERS
Removal..............................................................................6-3
Installation...........................................................................6-3
Fill Transmission.................................................................6-3
6.4 SECONDARY CLUTCH ACTUATOR
Replacement.......................................................................6-4
ELECTRICAL
7.2 HEADLAMP
Headlamp Assembly Removal and Installation..................7-2
Removal......................................................................7-2
Installation...................................................................7-2
Headlamp Bulb Replacement.............................................7-2
Bulb Removal..............................................................7-2
Bulb Installation...........................................................7-3
7.3 SPEEDOMETER
Removal..............................................................................7-5
Installation...........................................................................7-5
7.4 INDICATOR LAMPS
Removal..............................................................................7-6
Installation...........................................................................7-6
7.5 WHEEL SPEED SENSOR (WSS)
Front WSS..........................................................................7-7
Removal......................................................................7-7
WSS Wire Harness Bracket........................................7-7
Installation...................................................................7-7
7.6 TURN SIGNALS
Bulb Replacement..............................................................7-9
Front Turn Signals..............................................................7-9
Rear Lamp Replacement....................................................7-9
7.7 ELECTRICAL PANEL
Removal............................................................................7-10
Installation.........................................................................7-10
7.8 ELECTRONICCONTROLMODULE(ECM)
Removal............................................................................7-11
Installation.........................................................................7-11
7.9 SECURITY SIREN
Removal............................................................................7-12
Installation.........................................................................7-12
7.10 BODY CONTROL MODULE (BCM)
Removal............................................................................7-13
Installation.........................................................................7-13
7.11 ELECTRONIC CONTROL UNIT (ECU)
Removal............................................................................7-14
Installation.........................................................................7-14
7.12 COMPONENT LOCATIONS
Component Locations.......................................................7-15
7.13 DIAGNOSTIC TOOLS
How To Use Diagnostic Tools...........................................7-18
GRX-3110 HD Battery Diagnostic Station.................7-18
HD-26792 Spark Tester.............................................7-18
HD-34730-2D Fuel Injector Test Light.......................7-18
HD-39978 Digital Multimeter (Fluke 78)....................7-19
HD-41404 Harness Connector Test Kit.....................7-19
HD-42682 Breakout Box...........................................7-19
HD-44687 Ignition Coil Circuit Test Adapter..............7-19
HD-48637 Breakout Box (ECM)................................7-20
HD-48642 Breakout Box (ABS).................................7-20
HD-48650 Digital Technician II..................................7-20
HD-50390-1 Breakout Box (BCM).............................7-20
7.14 INITIAL DIAGNOSTICS
Description and Operation................................................7-22
Retrieving Trouble Codes.................................................7-22
Odometer Self-Diagnostics...............................................7-22
Diagnostic Mode........................................................7-22
Initial Diagnostics..............................................................7-22
1. Fuse Test...............................................................7-22
2. DTC Test................................................................7-22
TABLE OF CONTENTS VII
TABLE OF CONTENTS
3. Odometer Function Test........................................7-22
4. Odometer Inoperative Test....................................7-22
5. Battery Power Test................................................7-22
6. Starter Test............................................................7-23
7. LHCM Test.............................................................7-23
Diagnostics.......................................................................7-23
Diagnostic Tips..........................................................7-23
Code Types.......................................................................7-30
Current.......................................................................7-30
Historic.......................................................................7-30
Multiple Trouble Codes.....................................................7-30
Clearing DTCs..................................................................7-30
Security Lamp...................................................................7-30
Check Engine Lamp.........................................................7-30
Symptoms.........................................................................7-31
7.15 CAN DATA COMMUNICATION
Components.....................................................................7-33
Electronic Control Module (ECM)..............................7-33
Speedometer.............................................................7-33
BCM...........................................................................7-33
ABS Module...............................................................7-33
Hand Control Modules...............................................7-33
Data Link Connector (DLC).......................................7-33
7.16 ODOMETER SELF-DIAGNOSTICS
INOPERATIVE, DTC U0001, U0011, B2274
Diagnostic Tips..........................................................7-34
Connector Information...............................................7-34
Odometer Self-Diagnostic Inoperative, DTC U0001, U0011,
B2274...............................................................................7-36
1. CAN Bus Shorted Together Test...........................7-36
2. Speedometer Test.................................................7-36
3. ECM Test...............................................................7-36
4. LHCM Test.............................................................7-36
5. RHCM Test............................................................7-36
6. BCM Test...............................................................7-36
7. ABS Test................................................................7-36
8. CAN High Circuit Short to Voltage Test.................7-36
10. ECM Test.............................................................7-36
11. LHCM Test...........................................................7-36
12. RHCM Test..........................................................7-37
13. BCM Test.............................................................7-37
14. ABS Test..............................................................7-37
15. CAN High Circuit Short to Ground Test...............7-37
16. Speedometer Test...............................................7-37
17. ECM Test.............................................................7-37
18. LHCM Test...........................................................7-37
19. RHCM Test..........................................................7-37
20. BCM Test.............................................................7-37
21. ABS Test..............................................................7-37
22. CAN Low Circuit Short to Voltage Test................7-37
24. ECM Test.............................................................7-37
25. LHCM Test...........................................................7-38
26. RHCM Test..........................................................7-38
27. BCM Test.............................................................7-38
28. ABS Test..............................................................7-38
29. CAN Low Circuit Short to Ground Test................7-38
31. ECM Test.............................................................7-38
32. LHCM Test...........................................................7-38
33. RHCM Test..........................................................7-38
34. BCM Test.............................................................7-38
35. ABS Test..............................................................7-38
36. CAN High Circuit Continuity Test.........................7-38
37. CAN Low Circuit Continuity Test.........................7-39
38. Speedometer Power Test....................................7-39
39. Speedometer Ground Test..................................7-39
40. ECM Power Test..................................................7-39
7.17 NO VEHICLE POWER, DTC U0100,
U0121, U0140, U0141, U0142, U0156
Diagnostic Tips..........................................................7-40
DTC U0100.......................................................................7-41
1. ECM Voltage Test..................................................7-41
2. System Power Test................................................7-41
3. ECM Ground Test..................................................7-41
4. CAN High Circuit Continuity Test...........................7-42
5. CAN Low Circuit Continuity Test...........................7-42
DTC U0121.......................................................................7-42
1. ABS Voltage Test...................................................7-42
2. ABS Ground Test...................................................7-42
No Vehicle Power, DTC U0140........................................7-42
1. BCM Ground Test..................................................7-42
4. RHCM Test............................................................7-43
5. BCM Voltage Test..................................................7-43
Left Hand Controls Inoperative, DTC U0141....................7-43
1. LHCM Voltage Test................................................7-43
2. LHCM Test.............................................................7-43
DTC U0142.......................................................................7-43
1. RHCM Voltage Test...............................................7-43
2. RHCM Ground Test...............................................7-43
DTC U0156.......................................................................7-44
1. Speedometer Voltage Test....................................7-44
2. Speedometer Ground Test....................................7-44
7.18 STARTING SYSTEM DIAGNOSTICS
Components.....................................................................7-45
Starter........................................................................7-45
Starter Solenoid.........................................................7-45
Engine Stop Switch...................................................7-45
Start Switch...............................................................7-45
BCM...........................................................................7-45
Battery.......................................................................7-46
Grinding Noise or Erratic Starting..............................7-46
Job/Time Code Values..............................................7-46
VIII TABLE OF CONTENTS
TABLE OF CONTENTS
Starter Troubleshooting....................................................7-48
Starter Testing...................................................................7-49
1. Starting System Operational Test..........................7-49
2. Audible Noise Test.................................................7-49
3. Starter Solenoid Test.............................................7-49
4. Checking DTCs Test..............................................7-49
Nothing Clicks...................................................................7-49
1. Battery Test............................................................7-49
2. Fuse Test...............................................................7-49
3. Ignition Circuit Test................................................7-49
4. Starter Solenoid Circuit Test..................................7-50
5. Starter Ground Test...............................................7-50
6. Neutral Switch Test................................................7-50
7. Start Solenoid Circuit Test.....................................7-50
8. BCM Test...............................................................7-50
Starter Solenoid Clicks.....................................................7-50
1. Battery Test............................................................7-50
2. Starter Voltage Drop Test......................................7-50
3. Starter Solenoid Voltage Drop Starter Side Test....7-50
4. Starter Solenoid Battery Side Voltage Drop Test....7-50
5. Starter Ground Circuit Voltage Drop Test..............7-51
6. Starter Ground Test...............................................7-51
7. Starter Draw Test...................................................7-51
8. Mechanical Binding Test........................................7-51
Starter Spins But Does Not Engage.................................7-51
1. Pinion Gear and Clutch Shell Test.........................7-51
Starter Stalls or Spins Too Slowly.....................................7-51
1. Battery Test............................................................7-51
2. Starter Stud Voltage Drop Test..............................7-51
3. Starter Ground Circuit Voltage Drop Test..............7-52
4. Starter Draw Test...................................................7-52
5. Starter Solenoid Voltage Drop Starter Side Test....7-52
6. Starter Solenoid Battery Side Voltage Drop Test....7-52
7.19 DTC P0562
Diagnostics.......................................................................7-53
Diagnostic Tips..........................................................7-53
DTC P0562.......................................................................7-55
1. Battery Test............................................................7-55
2. Charging System Test...........................................7-55
3. ECM Switched Voltage Test..................................7-55
4. ECM System Power Voltage Drop Test.................7-55
5. ECM Ground Circuit Voltage Drop Test.................7-55
6. BCM System Power Test.......................................7-55
7. BCM Power Test....................................................7-55
8. Main Fuse Voltage Test.........................................7-55
9. Fuse Block Voltage Test........................................7-55
10. Fuse Block Supply Voltage Test..........................7-55
11. Repair Validation Test..........................................7-56
7.20 DTC B1210, B1211
Fuel Range................................................................7-57
Low Fuel Warning......................................................7-57
DTC B1210.......................................................................7-58
1. Low Fuel Lamp Circuit Resistance Test................7-58
2. Fuel Pump and Sender Assembly Test.................7-58
3. Fuel Sender Resistor Assembly Test....................7-58
DTC B1211.......................................................................7-59
1. Low Fuel Lamp Circuit Voltage Test......................7-59
2. Fuel Sender Resistor Assembly Test....................7-59
3. Low Fuel Lamp Circuit Continuity Test..................7-59
4. Ground Circuit Continuity Test...............................7-59
7.21 TRIP ODOMETER FUNCTIONS
INOPERATIVE, DTC B2255
Trip Odometer Reset Switch Closed.........................7-60
Trip Odometer Functions Inoperative, DTC B2255..........7-61
1. Odometer Test.......................................................7-61
2. Speedometer "WOW" Test....................................7-61
3. LHCM Test.............................................................7-61
4. LHCM Power Test..................................................7-62
5. LHCM Ground Test................................................7-62
6. CAN Low Circuit Open Test...................................7-62
7. CAN High Circuit Open Test..................................7-62
7.22 NO INSTRUMENT POWER, DTC B1200
No Instrument Power........................................................7-64
1. Battery Circuit Test ...............................................7-64
2. Accessory Function Test.......................................7-64
3. Battery Fuse Test...................................................7-64
4. Battery Circuit to Speedometer Test......................7-65
5. Battery Circuit Short to Ground Test......................7-65
6. Ground Circuit Test................................................7-65
7.23 INDICATOR LAMPS
ABS Indicator.............................................................7-66
Security Lamp............................................................7-66
Check Engine Lamp..................................................7-66
Low Battery Lamp......................................................7-66
Low Fuel Indicator.....................................................7-66
Neutral Indicator........................................................7-67
Oil Pressure Indicator................................................7-67
Turn Signal Indicators................................................7-67
High Beam Indicator..................................................7-68
Sixth Gear Indicator...................................................7-68
Oil Pressure Lamp Always On..........................................7-69
1. Oil Pressure Lamp Function Test..........................7-69
2. Engine Running Test.............................................7-69
3. Oil Pressure Sensor Test.......................................7-69
4. Oil Pressure Circuit Test........................................7-69
5. Mechanical Test.....................................................7-69
6. Oil Pressure Switch Circuit Test............................7-69
Oil Pressure Lamp Inoperative.........................................7-69
1. Oil Pressure Lamp Function Test..........................7-69
Neutral Lamp Always On..................................................7-70
1. Neutral Lamp Function Test..................................7-70
2. DTC Test................................................................7-70
3. Indicator Harness Test...........................................7-70
Neutral Lamp Inoperative.................................................7-70
1. Neutral Lamp Function Test..................................7-70
2. BCM Message Test...............................................7-70
3. Neutral Switch Test................................................7-70
TABLE OF CONTENTS IX
TABLE OF CONTENTS
4. Ground Wire Test...................................................7-70
5. Neutral Switch Power Circuit Open Test...............7-70
High Beam Indicator Lamp Inoperative............................7-71
1. High Beam Indicator Function Test.......................7-71
2. High Beam Indicator Circuit Test ..........................7-71
Turn Signal Indicator Inoperative......................................7-71
1. Turn Signal Function Test......................................7-71
2. Turn Signal Indicator Circuit Test ..........................7-71
7.24 ACCESSORIES, DTC B2112, B2113,
B2114
Conditions for Setting................................................7-72
Diagnostic Tips..........................................................7-72
DTC B2112.......................................................................7-75
1. Accessory Power Circuit Short to Voltage Test.....7-75
2. BCM Test...............................................................7-75
DTC B2113, B2114...........................................................7-75
1. Accessory Power Circuit Short to Ground Test.....7-75
2. Accessory Circuit Test...........................................7-75
3. BCM Test...............................................................7-75
7.25 DTC B2151, B2153, B2154, B2156,
B2158, B2159
DTC B2151.......................................................................7-78
1. Bulb Test................................................................7-78
2. Ground Circuit Open Test......................................7-78
3. Power Circuit Open Test........................................7-78
DTC B2153, B2154...........................................................7-78
1. Bulb Test................................................................7-78
2. Power Circuit Short to Ground Test.......................7-78
DTC B2156.......................................................................7-79
1. Bulb Test................................................................7-79
DTC B2158, B2159...........................................................7-79
1. Bulb Test................................................................7-79
7.26 STOP LAMPS, DTC B2161, B2163,
B2164, B2223
Stop Lamp Always On, DTC B2223.................................7-82
1. Brake Switch Test..................................................7-82
2. Brake Switch Input Test.........................................7-82
3. Brake Light Power Test.........................................7-82
4. DTC Test................................................................7-82
DTC B2161.......................................................................7-82
1. Stop Lamp Test......................................................7-82
DTC B2163, B2164...........................................................7-83
1. Bulb Test................................................................7-83
2. Stop Lamp Power Circuit Short to Ground Test.....7-83
DTC B2223.......................................................................7-83
1. Stop Lamp Switch Test..........................................7-83
2. Brake Switch Short to Ground Test.......................7-83
3. DTC Test................................................................7-83
7.27 RUNNING LAMPS, DTC B2107, B2108,
B2109, B2166, B2168, B2169
Front Running Lamps Inoperative....................................7-87
1. Domestic Running Lamp Configuration Test.........7-87
2. Bulb Test................................................................7-87
3. Running Lamp Test...............................................7-87
Rear Running Lamps Inoperative.....................................7-87
1. Bulb Test................................................................7-87
DTC B2107.......................................................................7-87
1. Position Lamp Circuit Test.....................................7-87
2. DTC Test................................................................7-88
DTC B2108, B2109...........................................................7-88
1. Position Lamp Circuit Short to Ground Test..........7-88
2. Excessive Draw Test.............................................7-88
3. DTC Test................................................................7-88
DTC B2166 (Domestic Only)............................................7-88
1. Running Lamp Operation Test...............................7-88
2. Running Lamps Circuit Test..................................7-88
3. Bulb Test................................................................7-89
4. Running Lamp Open Circuit Test..........................7-89
DTC B2168, B2169: FXS and FLS...................................7-89
1. Right Rear Turn Lamp Circuit Test........................7-89
2. Left Rear Turn Lamp Circuit Test...........................7-89
3. Tail Lamp Circuit Test............................................7-89
5. BCM Test...............................................................7-89
LED Console Inoperative..................................................7-90
1. DTC Test................................................................7-90
2. LED Console Test..................................................7-90
7.28 SECURITY SYSTEM
Security Lamp...................................................................7-91
Security Immobilization.....................................................7-91
Security System Features.................................................7-91
Warnings...........................................................................7-92
Arming..............................................................................7-92
Disarming..........................................................................7-92
Automatic Disarming.................................................7-92
Disarming with a PIN.................................................7-92
Alarm................................................................................7-93
Activation...................................................................7-93
Deactivation of Alarm................................................7-93
7.29 SERVICE AND EMERGENCY
FUNCTIONS AND CONFIGURATIONS
General.............................................................................7-94
Actuation...........................................................................7-94
Selecting a PIN.................................................................7-94
Initial PIN Entry.................................................................7-94
Changing the PIN.............................................................7-94
Transport Mode................................................................7-95
X TABLE OF CONTENTS
TABLE OF CONTENTS
To Enter Transport Mode...........................................7-95
To Exit Transport Mode.............................................7-95
Service Mode....................................................................7-95
Four-Way Flashing...........................................................7-95
To Arm the Security System with the Hazard Warning
Flashers ON..............................................................7-95
To Disarm the Security System and Turn the Hazard
Warning Flashers OFF..............................................7-95
ENGINE MANAGEMENT
8.1 EFI SYSTEM
General...............................................................................8-1
EFI Operation..............................................................8-1
Heat Management System..........................................8-1
Enable/Disable Engine Idle Temperature Management
System (EITMS)..........................................................8-1
8.2 ELECTRONIC CONTROL MODULE
General...............................................................................8-3
ECM.............................................................................8-3
32-2 Flywheel..............................................................8-3
Crank Position Signal Synchronization.......................8-4
Engine Phase..............................................................8-4
Engine Run Mode........................................................8-4
Removal......................................................................8-4
Installation...................................................................8-4
8.3 SENSORS AND DRIVERS
Description and Operation..................................................8-5
Sensors...............................................................................8-5
Crank Position (CKP) Sensor......................................8-5
Twist Grip Sensor (TGS).............................................8-5
Throttle Control Actuator (TCA)...................................8-5
Jiffy Stand Sensor (JSS).............................................8-5
Accelerometer.............................................................8-5
Clutch Switch...............................................................8-5
Neutral Switch.............................................................8-5
Engine Temperature (ET) Sensor................................8-5
Temperature Manifold Absolute Pressure (TMAP)
Sensor.........................................................................8-5
Manifold Absolute Pressure (MAP) Sensor ................8-5
Intake Air Temperature (IAT) Sensor...........................8-5
Vehicle Speed Sensor (VSS)......................................8-6
HO2S: Front and Rear.................................................8-6
Drivers................................................................................8-6
Fuel Pump...................................................................8-6
Ignition Coil and Spark Plugs......................................8-6
Fuel Injectors...............................................................8-6
Purge Solenoid (If Equipped)......................................8-6
8.4 DTC B2102, B2103, B2104
Description and Operation..................................................8-8
Conditions for Setting..................................................8-8
Diagnostic Tips............................................................8-8
Connector Information.................................................8-8
DTC B2102.......................................................................8-10
1. System Power Circuit Short to Voltage Test..........8-10
DTC B2103, B2104...........................................................8-10
1. System Power Circuit Short to Ground Test..........8-10
2. Ignition Coil Test....................................................8-10
3. Rear Fuel Injector Test..........................................8-10
4. Front Fuel Injector Test..........................................8-10
5. Purge Solenoid Test..............................................8-10
6. Exhaust Actuator Test...........................................8-10
7. Rear ACR Test.......................................................8-11
8. Front ACR Test......................................................8-11
9. Front HO2 Test......................................................8-11
10. Rear HO2 Test.....................................................8-11
11. ECM Test.............................................................8-11
12. BCM Test.............................................................8-11
8.5 DTC B2116, B2117, B2118, B2119
Diagnostic Tips..........................................................8-12
DTC B2116.......................................................................8-13
1. Fuel Pump Circuit Test..........................................8-13
2. Fuel Pump Ground Circuit Open Test...................8-13
3. Fuel Pump Power Circuit Open Test.....................8-13
DTC B2117.......................................................................8-14
1. Fuel Pump Power Circuit Short to Voltage Test.....8-14
2. Code Verification Test............................................8-14
DTC B2118, B2119...........................................................8-14
1. Fuel Test................................................................8-14
2. Fuel Pump Test......................................................8-14
3. Fuel Pump Power Circuit Short to Ground Test.....8-14
8.6 DTC P0107, P0108, P0112, P0113
TMAP: MAP Signal....................................................8-15
TMAP: IAT Signal......................................................8-15
Diagnostic Tips: MAP Portion of TMAP Sensor........8-15
Diagnostic Tips: IAT Portion of TMAP Sensor...........8-15
DTC P0107.......................................................................8-16
1. MAP Sensor Test...................................................8-16
2. MAP Sensor Signal Voltage Test...........................8-16
3. MAP Sensor Signal Wire Continuity Test..............8-16
4. MAP Sensor Signal Wire Shorted to Ground
Test............................................................................8-17
5. MAP Sensor Signal Wire Shorted to Sensor Ground
Test............................................................................8-17
6. MAP Sensor 5V Reference Wire Open Test.........8-17
7. MAP Sensor 5V Reference Shorted to Signal Ground
Test............................................................................8-17
DTC P0108.......................................................................8-17
1. MAP Sensor Test...................................................8-17
2. MAP Sensor Signal Wire Short to 5V Test............8-17
3. MAP Sensor Signal Wire Short to Voltage Test.....8-17
4. MAP Sensor 5V Reference Shorted to Battery Voltage
Test............................................................................8-17
5. MAP Sensor Ground Wire Open Test...................8-17
DTC P0112.......................................................................8-18
1. IAT Sensor Test.....................................................8-18
2. IAT Sensor Signal Wire Shorted to Ground Test....8-18
3. IAT Sensor Signal Wire Shorted to Sensor Ground
Test............................................................................8-18
DTC P0113.......................................................................8-18
1. IAT Sensor Test.....................................................8-18
2. IAT Sensor Signal Wire Open Test........................8-18
TABLE OF CONTENTS XI
TABLE OF CONTENTS
3. IAT Sensor Open Ground Wire Test......................8-18
4. IAT Sensor Signal Wire Shorted to Sensor Power
Test............................................................................8-18
8.7 DTC P0117, P0118
Diagnostic Tips..........................................................8-20
DTC P0117.......................................................................8-21
1. ET Sensor Test .....................................................8-21
2. ET Sensor Signal Wire Shorted to Ground Test.....8-21
3. ET Sensor Signal Wire Shorted to Sensor Ground
Test............................................................................8-21
DTC P0118.......................................................................8-21
1. ET Sensor Test......................................................8-21
2. ET Sensor Signal Wire Open Test.........................8-22
3. ET Sensor Open Ground Wire Test.......................8-22
4. ET Sensor Signal Wire Shorted to Power Test......8-22
5. ET Sensor Resistance Test...................................8-22
8.8 DTCP0120, P0122, P0123, P0220, P0222,
P0223
DTC P0120.......................................................................8-24
1. Sensor Power-1 Circuit Test..................................8-24
2. TPS-1 Circuit Shorted Test....................................8-24
3. TPS-1 Circuit Continuity Test................................8-24
4. TPS-1 Circuit Short to Ground Test.......................8-25
5. TPS-1 Circuit Short to Voltage Test.......................8-25
6. Sensor Ground Continuity Test.............................8-25
7. TCA Test................................................................8-25
DTC P0122.......................................................................8-25
1. TCA Sensor-1 Circuit Test.....................................8-25
2. TCA Sensor-1 Circuit Short to Ground Test..........8-25
3. TCA Power-1 Circuit Open Test............................8-25
4. TCA Sensor Test...................................................8-25
5. ECM Test...............................................................8-25
DTC P0123.......................................................................8-26
1. TPS-1 Voltage Test................................................8-26
2. TPS-1 Circuit Test..................................................8-26
3. Sensor Power Circuit Test.....................................8-26
4. TCA Test................................................................8-26
5. Sensor Ground Test..............................................8-26
6. Sensor Ground Circuit Shorted Test......................8-26
7. Sensor Ground Circuit Test...................................8-26
8. TPS-1 Circuit Function Test...................................8-26
10. Ground Circuit Open Test....................................8-26
11. TPS-1 Continuity Test..........................................8-27
DTC P0220.......................................................................8-27
2. Sensor Power-2 Short to Voltage Test..................8-27
3. TPS-2 Circuit Shorted Test....................................8-27
4. TPS-2 Circuit Continuity Test................................8-27
5. TPS-1 Circuit Short to Ground Test.......................8-27
6. TPS-1 Circuit Short to Voltage Test.......................8-27
8. TCA Test................................................................8-27
DTC P0222.......................................................................8-28
1. TCA Sensor-2 Circuit Test.....................................8-28
2. TCA Sensor-2 Circuit Short to Ground Test..........8-28
3. TCA Power-1 Circuit Open Test............................8-28
4. TCA 5V Ref Circuit Short to Ground Test..............8-28
5. ECM Test...............................................................8-28
DTC P0223.......................................................................8-28
1. TPS-2 Voltage Test................................................8-28
2. TPS-2 Circuit Test..................................................8-28
5. Shorted 5V Circuit Test..........................................8-29
7. TPS-2 Circuit Test..................................................8-29
8.9 DTCP0031, P0032, P0131, P0132, P0134,
P0151, P0152, P0154
Diagnostic Tips..........................................................8-30
DTC P0031.......................................................................8-33
1. HO2S Voltage Test................................................8-33
2. HO2S Ground Test................................................8-33
3. HO2S Resistance Test..........................................8-33
DTC P0032.......................................................................8-33
1. Rear HO2S Resistance Test.................................8-33
2. Front HO2S Resistance Test.................................8-33
3. HO2S Short to Voltage Test..................................8-33
DTC P0131.......................................................................8-33
1. Front HO2S Test....................................................8-33
2. Front HO2S Signal Wire Shorted to Sensor Ground
Test............................................................................8-33
3. Front HO2S Signal Wire Shorted to Ground Test...8-34
4. Front HO2S Operation Test...................................8-34
DTC P0132.......................................................................8-34
1. Front HO2S Operation Test...................................8-34
DTC P0134.......................................................................8-34
1. Front HO2S Signal Wire Short Circuit Voltage
Test............................................................................8-34
2. Front HO2S Open Sensor Ground Test................8-34
3. Front HO2S Signal Wire Open Test......................8-34
DTC P0151.......................................................................8-35
1. Rear HO2S Test....................................................8-35
2. Rear HO2S Signal Wire Shorted to Sensor Ground
Test............................................................................8-35
3. Rear HO2S Signal Wire Shorted to Ground Test...8-35
4. Rear HO2S Operation Test...................................8-35
DTC P0152.......................................................................8-35
1. Rear HO2S Operation Test...................................8-35
DTC P0154.......................................................................8-35
1. Rear HO2S Signal Wire Short Circuit Voltage
Test............................................................................8-36
2. Rear HO2S Open Sensor Ground Test.................8-36
3. Rear HO2S Signal Wire Open Test.......................8-36
8.10 DTC P0261, P0262, P0264, P0265
DTC P0261.......................................................................8-39
1. Front Fuel Injector Test..........................................8-39
2. Front Fuel Injector Power Wire Open Circuit Test..8-39
3. Front Fuel Injector Power Wire Shorted to Ground
Test............................................................................8-39
XII TABLE OF CONTENTS
TABLE OF CONTENTS
4. Injector Resistance Test........................................8-39
5. Driver Short to Ground Test...................................8-39
DTC P0262.......................................................................8-39
1. Front Fuel Injector Control Wire Shorted to Voltage
Test............................................................................8-39
DTC P0264.......................................................................8-39
1. Rear Fuel Injector Test..........................................8-39
2. Rear Fuel Injector Power Wire Open Circuit Test...8-40
3. Rear Fuel Injector Power Wire Shorted to Ground
Test............................................................................8-40
5. Driver Short to Ground Test...................................8-40
DTC P0265.......................................................................8-40
1. Rear Fuel Injector Control Wire Shorted to Voltage
Test............................................................................8-40
8.11 DTC P0371, P0372, P0374
Diagnostic Tips..........................................................8-41
DTC P0371, P0372, P0374..............................................8-42
1. CKP Sensor Connections Test..............................8-42
2. CKP Sensor Signal Wire Continuity Test...............8-42
3. CKP Sensor Ground Wire Continuity Test.............8-42
4. CKP Sensor Signal Wire Shorted to CKP Ground Wire
Test............................................................................8-42
5. CKP Sensor Low Shorted to Ground Test.............8-42
6. CKP Sensor Output Test.......................................8-42
7. CKP Sensor Signal Wire Shorted to Ground Test..8-42
8.12 DTC P0444, P0445
Purge Solenoid (CA and Select Foreign Market Models
Only)..........................................................................8-43
DTC P0444.......................................................................8-45
2. Purge Solenoid Voltage Test.................................8-45
3. Purge Solenoid Control Wire Shorted to Ground
Test............................................................................8-45
4. Purge Solenoid Control Wire Open Test...............8-45
5. Purge Solenoid Power Wire Open Test.................8-45
DTC P0445.......................................................................8-45
2. Purge Solenoid Short to Voltage Test ...................8-45
8.13 DTC P0502, P0503
DTC P0502.......................................................................8-48
1. VSS Connections Test...........................................8-48
2. VSS Sensor Power Short to Ground Test.............8-48
3. VSS Signal Wire Short to Ground Test..................8-48
4. VSS Signal Wire Open Test..................................8-48
5. VSS Dirty or Damaged Test..................................8-48
DTC P0503.......................................................................8-48
1. VSS Sensor Power Shorted to Voltage Test.........8-48
2. VSS Signal Wire Short to Voltage Test..................8-48
3. VSS Ground Wire Open Test................................8-48
4. VSS Signal Wire Shorted to Sensor Power Test....8-49
5. VSS Test................................................................8-49
8.14 DTC P0505
Loss of Idle Speed Control...............................................8-50
DTC P0505.......................................................................8-51
1. Fuel Quality Test....................................................8-51
2. Vacuum Leak Test.................................................8-51
8.15 CRUISE CONTROL
System Operation.............................................................8-52
Troubleshooting................................................................8-53
Diagnostic Tips..........................................................8-53
Cruise Inoperative Diagnostics.........................................8-53
Cruise Control Inoperative Conditions..............................8-54
8.16 DTC P0577
Cruise Control...................................................................8-55
Diagnostic Tips..........................................................8-55
DTC P0577.......................................................................8-55
1. Switch Test............................................................8-55
8.17 DTC P0603, P0605
DTC P0603 Test........................................................8-56
DTC P0605 Test........................................................8-56
8.18 DTC P0641, P0651
DTC P0641.......................................................................8-58
2. Sensor Power-1 Circuit Resistance Test...............8-58
3. TCA Test................................................................8-58
4. JSS Test................................................................8-58
5. TGS Test................................................................8-58
6. VSS Test................................................................8-58
DTC P0651.......................................................................8-58
2. Sensor Power-2 Circuit Resistance Test...............8-58
3. TMAP Test.............................................................8-59
4. TGS Test................................................................8-59
8.19 DTC P1009
General.............................................................................8-60
Password Problem....................................................8-60
DTC P1009.......................................................................8-60
1. Incorrect Password Test........................................8-60
2. BCM Replacement Test.........................................8-60
8.20 DTC P1270
TGS2 Validation.........................................................8-61
DTC P1270.......................................................................8-63
1. ECM Connector Test.............................................8-63
2. ECM Circuit Test....................................................8-63
8.21 DTC P1353, P1356, P1357, P1358
TABLE OF CONTENTS XIII
TABLE OF CONTENTS
DTC P1353, P1356...........................................................8-66
1. Absence of Fuel Test.............................................8-66
2. Ignition Coil Primary Resistance Test....................8-66
3. Spark Plug Wire Test.............................................8-66
4. Ignition Coil Secondary Resistance Test ..............8-66
DTC P1357, P1358...........................................................8-66
1. Ion Sense Continuity Test......................................8-66
2. Ion Sense Resistance Test....................................8-66
3. Ion Sense Short to Voltage Test............................8-66
8.22 DTC P1501, P1502
DTC P1501.......................................................................8-69
1. JSS 5V Reference Open Circuit Test....................8-69
2. JSS 5V Reference Shorted to Ground Test...........8-69
3. JSS Signal Wire Shorted to Ground Test..............8-69
4. JSS Signal Wire Open Circuit Test........................8-69
DTC P1502.......................................................................8-70
1. JSS Ground Wire Test...........................................8-70
2. JSS 5V Reference Wire Short to Voltage Test......8-70
3. JSS Signal Wire Short to Voltage Test..................8-70
4. JSS 5V Reference and Signal Shorted Together
Test............................................................................8-70
Side Stand Displayed on Odometer.................................8-70
1. Starts, Then Stalls Test..........................................8-70
2. Neutral Test ..........................................................8-70
3. JSS Clearance Test...............................................8-70
8.23 DTC P1510, P1511, P1512
Throttle Actuation Control Management....................8-71
DTC P1510, P1511, P1512..............................................8-71
1. DTC Verification Test.............................................8-71
8.24 DTC P1514
Air Flow Fault.............................................................8-72
DTC P1514.......................................................................8-72
8.25 DTC P1600
DTC P1600.......................................................................8-73
8.26 DTC P1632
8.27 DTC P1655, P1656
DTC P1655.......................................................................8-77
1. Front ACR Test......................................................8-77
2. Rear ACR Test.......................................................8-77
3. Rear ACR Control Circuit Test...............................8-77
4. Front ACR Control Circuit Short to Ground Test....8-77
5. Rear ACR Control Circuit Short to Ground Test.....8-77
6. Shorted ACR Test..................................................8-77
7. ACR Supply Circuit Open Test..............................8-77
8. ACR Control Circuit Continuity Test......................8-77
DTC P1656.......................................................................8-78
1. Front ACR Test......................................................8-78
2. Rear ACR Control Circuit Test...............................8-78
3. Rear ACR Test.......................................................8-78
4. Front ACR Control Circuit Test..............................8-78
8.28 DTC P2100, P2101, P2102, P2103
DTC P2100.......................................................................8-80
1. TCA Test................................................................8-80
2. TCA High Circuit Test............................................8-80
3. TCA Low Circuit Test.............................................8-80
DTC P2101.......................................................................8-80
1. TCA Circuit Resistance Test..................................8-80
2. TCA Test................................................................8-80
DTC P2102.......................................................................8-81
2. TCA Test................................................................8-81
DTC P2103.......................................................................8-81
8.29 DTC P2105, P2107
DTC P2105.......................................................................8-84
DTC P2107.......................................................................8-84
1. ECM Connector Test.............................................8-84
2. ECM Circuit Test....................................................8-84
8.30 DTC P2119
DTC P2119.......................................................................8-85
1. Air Inlet Interference Test......................................8-85
2. Validation Test.......................................................8-85
8.31 DTC P2122, P2123, P2127, P2128
DTC P2122.......................................................................8-87
1. TGS-1 Voltage Test...............................................8-87
2. TGS-1 Circuit Open Test.......................................8-87
3. TGS-1 Short to Ground Test..................................8-87
4. Twist Grip Sensor Test..........................................8-87
5. TGS-1 Test............................................................8-87
6. TGS-1 Open Test...................................................8-87
7. Sensor Power-1 Continuity Test............................8-87
8. Sensor Power Resistance Test.............................8-87
9. TCA Test................................................................8-87
10. JSS Test..............................................................8-87
11. VSS Test..............................................................8-88
DTC P2123.......................................................................8-88
1. TGS-1 Voltage Test...............................................8-88
2. TGS-1 Short to Voltage Test..................................8-88
4. TGS Test................................................................8-88
5. TGS-1 Test............................................................8-88
6. TGS-1 Open Test...................................................8-88
XIV TABLE OF CONTENTS
TABLE OF CONTENTS
9. TCA Test................................................................8-88
DTC P2127.......................................................................8-89
1. TGS-2 Voltage Test...............................................8-89
2. TGS-2 Open Test...................................................8-89
4. TGS Test................................................................8-89
5. TGS-2 Test............................................................8-89
6. TGS-2 Open Test...................................................8-89
9. TMAP Test.............................................................8-89
DTC P2128.......................................................................8-90
1. TGS-1 Voltage Test...............................................8-90
2. TGS-1 Short to Voltage Test..................................8-90
4. TGS Test................................................................8-90
5. TGS-1 Test............................................................8-90
6. TGS-1 Open Test...................................................8-90
9. TCA Test................................................................8-90
8.32 DTC P2135, P2138
DTC P2135.......................................................................8-92
1. TPS-2 Voltage Test................................................8-92
2. TPS-2 Circuit Test..................................................8-92
7. TPS-2 Circuit Test..................................................8-92
DTC P2138.......................................................................8-93
1. TGS-2 Voltage Test...............................................8-93
2. TGS-2 Circuit Test.................................................8-93
7. Sensor Ground-2 Open Circuit Test......................8-93
8. TGS-2 Circuit Test.................................................8-93
10. Ground Circuit Open Test....................................8-93
8.33 DTC P2176
DTC P2176.......................................................................8-94
1. Air Inlet Interference Test......................................8-94
2. Validation Test.......................................................8-94
8.34 DTC P2300, P2301, P2303, P2304
Diagnostic Tips..........................................................8-95
DTC P2300.......................................................................8-97
2. Ignition Coil Input Voltage Test..............................8-97
3. Ignition Coil Control Wire Continuity Test..............8-97
4. Ignition Coil Control Wire Shorted to Ground
Test............................................................................8-97
DTC P2301.......................................................................8-97
1. Ignition Coil Shorted to Voltage Test.....................8-97
2. Ignition Coil Open Test..........................................8-97
DTC P2303.......................................................................8-97
2. Ignition Coil Input Voltage Test .............................8-98
3. Ignition Coil Control Wire Continuity Test..............8-98
4. Ignition Coil Control Wire Shorted to Ground
Test............................................................................8-98
DTC P2304.......................................................................8-98
1. Ignition Coil Shorted to Voltage Test.....................8-98
2. Ignition Coil Open Test..........................................8-98
8.35 ENGINE CRANKS, BUT WILL NOT
START
Engine Cranks But Will Not Start......................................8-99
1. Preliminary Engine Tests.......................................8-99
2. Check Engine Lamp Test......................................8-99
3. Spark Present Test................................................8-99
8.36 STARTS, THEN STALLS
Description and Operation..............................................8-101
Diagnostic Tips........................................................8-101
Connector Information.............................................8-101
Starts, Then Stalls..........................................................8-101
1. Throttle Test.........................................................8-101
2. Fuel System Test.................................................8-101
3. System Power Test..............................................8-101
8.37 MISFIRE AT IDLE OR UNDER LOAD
Description and Operation..............................................8-102
Diagnostic Tips........................................................8-102
In-line Spark Tester.........................................................8-102
Connector Information.............................................8-102
Misfire At Idle or Under Load..........................................8-104
1. Power Ground Continuity Test.............................8-104
2. Spark Test............................................................8-104
3. Spark Plug Wire Test...........................................8-104
4. Carbon Tracking Inspection Test.........................8-104
5. Ignition Coil Primary Wire Continuity Test ..........8-104
6. Battery to Main Fuse Block Voltage Drop............8-104
APPENDIX A WIRING
A.1 CONNECTORS
Connector Locations..........................................................A-1
Function/Location........................................................A-1
Place and Color...........................................................A-1
Connector Number......................................................A-1
Repair Instructions......................................................A-1
A.2 WIRING DIAGRAMS
Wiring Diagram Information................................................A-4
Wire Color Codes........................................................A-4
Wiring Diagram Symbols............................................A-4
Wiring Diagrams.................................................................A-6
TABLE OF CONTENTS XV
TABLE OF CONTENTS
APPENDIX B GLOSSARY
B.1 GLOSSARY
Acronyms and Abbreviations.............................................B-1
REFERENCE MATERIAL
TOOLS...........................................................I
TORQUE VALUES.......................................XI
INDEX.........................................................XV
XVI TABLE OF CONTENTS
TABLE OF CONTENTS
TABLE OF CONTENTS
SUBJECT............................................................................................................................PAGE NO.
1.1 FASTENER TORQUE VALUES.................................................................................................1-1
1.2 BULB REQUIREMENTS............................................................................................................1-2
1.3 MAINTENANCE SCHEDULE....................................................................................................1-3
1.4 AIR FILTER................................................................................................................................1-6
1.5 HYDRAULIC CLUTCH FLUID...................................................................................................1-7
1.6 ENGINE LUBRICATION SYSTEM............................................................................................1-8
1.7 TIRES AND WHEELS................................................................................................................1-9
1.8 DRIVE BELT AND SPROCKETS............................................................................................1-10
1.9 STEERING HEAD BEARINGS................................................................................................1-11
1.10 SUSPENSION ADJUSTMENTS............................................................................................1-13
M
A
I
N
T
E
N
A
N
C
E
NOTES
FASTENER TORQUE VALUES IN THIS
CHAPTER
The table below lists torque values for all fasteners presented
in this chapter.
NOTES TORQUE VALUE FASTENER
1.5 HYDRAULICCLUTCHFLUID, Fluid Inspection 1.4-1.7 Nm 12-15 in-lbs Clutch reservoir cover screws
1.9 STEERING HEAD BEARINGS, Adjustment 40.7-47.5 Nm 30-35 ft-lbs Fork bracket pinch bolt, lower
1.9 STEERING HEAD BEARINGS, Adjustment 94.9-108.4 Nm 70-80 ft-lbs Fork stem nut
1.4 AIR FILTER, Installation 5.1-6.2 Nm 45-55 in-lbs Hose clamp (air filter)
HOME
2013 FXSBSE Service Supplement: Maintenance 1-1
1.2 BULB REQUIREMENTS
GENERAL
NOTE
Speedometer and indicator lamps are illuminated with LEDs.
Table 1-1. Bulb Chart
H-D
PART NUMBER
CURRENT DRAW
(AMPERAGE)
BULBS
REQUIRED
DESCRIPTION
(ALL LAMPS 12 VOLT)
LAMP
68329-03 4.3 1 high beam/low beam Headlamp
53436-97 0.32 1 position lamp international
69331-02 0.59 2.25 2 front/running Turn signal lamp
68163-84 1.75 2 front international
68168-89A 0.59 2.25 2 rear (Domestic/Canada)
Illuminated with LEDs. Replace entire assembly upon failure. rear international
Illuminated with LEDs. Replace entire assembly upon failure. Canada Stop/tail lamp
Illuminated with LEDs. Replace entire assembly upon failure. Instrument panel and console lamps
HOME
1-2 2013 FXSBSE Service Supplement: Maintenance
1.3 MAINTENANCE SCHEDULE
GENERAL
The scheduled maintenance table in this section lists the
maintenance requirements for this CVO model. Refer to
Table 1-2. In addition to this supplement, see service manual
for service procedures.
Various lubricants, sealants and greases are recommended
in certain service operations. Refer to Table 1-3 for the appro-
priate part numbers for these items.
NOTE
This motorcycle uses SCREAMIN' EAGLE SYN3 FULL SYN-
THETIC MOTORCYCLE LUBRICANT 20W50 in the engine,
transmission and primary chaincase.
Disposal and Recycling
Help protect our environment! Many communities maintain
facilities for recycling used fluids, plastics and metals. Dispose
of or recycle used oil, lubricants, fuel, coolant, brake fluid and
batteries in accordance with local regulations. Many Harley-
Davidson parts and accessories are made of plastics and
metals which can also be recycled.
Table 1-2. Regular Service Intervals: 2013 FXSBSE
NOTES 50000
MI
80000
KM
45000
MI
72000
KM
40000
MI
64000
KM
35000
MI
56000
KM
30000
MI
48000
KM
25000
MI
40000
KM
20000
MI
32000
KM
15000
MI
24000
KM
10000
MI
16000
KM
5000 MI
8000 KM
1000 MI
1600 KM
PROCEDURE ITEM SERVICED
3, 6 X X X X X X X X X X X Replace Engine oil and filter
1, 3 X X X X X X X X X X X Inspect for leaks,
contact or abrasion
Oil lines and brake
system
6 X X X X X X X X X X Inspect, service as
required
Air cleaner
3 X X X X X X X X X X X Check pressure,
inspect tread
Tires
6 X X X X X X Replace Primary chaincase
lubricant
6 X X X X Replace Transmission lub-
ricant
1, 4, 6 X X X X X X X X X X X Check level and
condition
Clutch fluid
1 X X X X X X X X X X X Inspect, adjust belt Drive belt and
sprockets
1 X X X X X X X X X X X Check, adjust and
lubricate
Brake and clutch
controls
1 X X X X X X Inspect and lub-
ricate
Jiffy stand
contact or abrasion
Fuel lines and fit-
tings
1 Replace every 100,000 mi (160,000 km). Fuel filter element
4 X X X X X X X X X X X Inspect sight glass Brake fluid
X X X X X X X X X X X Inspect for wear Brake pads and
discs
5 X Replace Spark plugs
X X X X X X X X X X X Check operation Electrical equip-
ment and switches
1, 7 X Rebuild Front forks
1 X X X X X X Adjust Steering head
bearings
1, 2 X X X Lubricate Steering head
bearings
1 X X X X X X Check tightness Critical fasteners
Check battery and clean connections annually. Battery
cracks, and loose
or missing
fasteners or heat
shields
Exhaust system
HOME
Table 1-2. Regular Service Intervals: 2013 FXSBSE
NOTES 50000
MI
80000
KM
45000
MI
72000
KM
40000
MI
64000
KM
35000
MI
56000
KM
30000
MI
48000
KM
25000
MI
40000
KM
20000
MI
32000
KM
15000
MI
24000
KM
10000
MI
16000
KM
5000 MI
8000 KM
1000 MI
1600 KM
PROCEDURE ITEM SERVICED
X X X X X X X X X X X Verify component
and system func-
tions
Road test
1. Should be performed by an authorized Harley-Davidson dealer, unless you have the proper tools, service data and are mechanically qualified. NOTES:
2. Disassemble, lubricate and inspect every 30,000 mi (48,000 km).
3. Perform annually or at specified intervals, whichever comes first.
4. Change DOT 4 brake/clutch fluid and flush system every two years.
5. Perform every two years or at specified intervals, whichever comes first.
6. Performmaintenance more frequently in severe riding conditions (such as extreme temperatures, dusty environments, mountainous or rough
roads, long storage conditions, short runs, heavy stop/go traffic or poor fuel quality).
7. Disassemble, inspect, rebuild forks and replace fork oil every 50,000 mi (80,000 km).
Table 1-3. Lubricants, Greases, Sealants
PACKAGE PART NUMBER ITEM
5 oz tube 021200-19718 * 3M 847 Adhesive
15 oz. aerosol 3M General Purpose Adhesive Remover
1 oz squeeze tube 98960-97 Anti-Seize Lubricant
16 oz bottle 62600029 Big Piston Fork Oil (Sportster XR only)
squeeze packet (included in master cylinder
rebuild kit)
42830-05 CCI #20 Brake Grease
12 oz bottle 99953-99A DOT 4 Brake Fluid
2 cc packet 94674-99 Dow Corning Moly 44 Grease
1 oz squeeze tube 99861-02 Electrical Contact Lubricant
1 qt bottle 99851-05 Formula+ Transmission and Primary Chaincase
Lubricant
squeeze packet 42820-04 G40M Brake Grease
1 gal container 99822-02 Genuine Harley-Davidson Extended Life Antifreeze
and Coolant (V-Rod only)
1 qt bottle 99816-2050/00QT Genuine Harley-Davidson H-D 360 20W50
Motorcycle Oil
10 g tube 99839-95 Harley-Davidson Adhesive (Griplock)
1.9 oz squeeze tube 99650-02 Harley-Davidson High Performance Sealant - Gray
6 oz can 98261-91V Harley-Davidson Leather Dressing
1 oz tube 11300005 Harley-Davidson Seal Grease
1/4 oz needle dispenser 94968-09 Harley Lube
3.5 oz tube 99653-85 Hylomar Gasket and Thread Sealant
6 mL tube 99811-97 Loctite 222 Low Strength Threadlocker and Sealant (purple)
6 mL tube 99642-97 Loctite 243 Medium Strength Threadlocker and Sealant (blue)
50 mL bottle 11100005
Loctite 246 Medium Strength/High Temperature Threadlocker
(blue)
6 mL tube 94759-99 Loctite 262 High Strength Threadlocker and Sealant (red)
50 mL bottle 11100006
Loctite 411 Prism Instant Adhesive
Loctite 420 Super Bonder Adhesive
6 mL tube 99818-97 Loctite 565 Thread Sealant
Loctite 770 Prism Primer
HOME
Table 1-3. Lubricants, Greases, Sealants
PACKAGE PART NUMBER ITEM
1.75 oz bottle 98968-99 Loctite 7649 Cleaner/Primer
1.9 oz tube 99650-02 RTV Silicone Sealer
4 oz bottle 94971-09 Screamin' Eagle Assembly Lube
1 qt bottle 99824-03/00QT Screamin' Eagle SYN3 Full Synthetic Motorcycle
Lubricant 20W50
14 oz cartridge 99857-97A Special Purpose Grease
16 oz bottle 62600026 Type "E" Hydraulic Fork Oil
1 lb can 99855-89 Wheel Bearing Grease
14 oz cartridge 99856-92
* Not a Harley-Davidson part number
HOME
1.4 AIR FILTER
REMOVAL
1. See Figure 1-1. Loosen hose clamp (2). Remove air filter
(3).
NOTE
Chrome end plate on air filter is secured with an adhesive. It
is not removable.
2. Replace the filter element if damaged or if filter media
cannot be adequately cleaned.
Do not use gasoline or solvents to clean filter element.
Flammable cleaning agents can cause an intake system
fire, which could result in death or serious injury. (00101a)
CLEANING
NOTE
DO NOT over oil the air filter. Over oiling may interfere with
the proper performance of the engine and/or certain engine
components. If oil is still draining or dripping from the filter
media twenty minutes after oiling, re-clean and re-oil the filter
element.
1. Tap the air filter to dislodge any loose dirt, then gently
brush with a soft bristle brush.
2. Spray K&NAIRFILTERCLEANERliberally onto the cotton
filter media and let soak for ten minutes. Or, roll or soak
the cotton filter media in a shallow pan of air filter cleaner.
Remove immediately and let soak for ten minutes.
3. Rinse off filter media (flowing from the clean side to the
dirty side) with low-pressure tap water.
4. After rinsing, shake off all excess water, and let the filter
media air-dry naturally. DO NOT use compressed air or
a heat gun to speed drying.
5. After the filter media is completely dry, perform one of the
following:
a. Spray K&N AIR FILTER OIL along each pleat, once
only, holding the spray nozzle approximately 3 in. (76
mm) away from the media.
b. Carefully use a squeeze bottle to deposit oil along
each pleat, once only.
6. Let the oil absorb into the filter media for 20 minutes before
proceeding. After 20 minutes, inspect the filter media and
carefully apply oil to any remaining visible white spots on
the filter media and allow to absorb.
INSTALLATION
TORQUE VALUE FASTENER
5.1-6.2 Nm 45-55 in-lbs Hose clamp (air filter)
1. See Figure 1-1. Install air filter onto intake tube.
NOTE
The seam on the air filter faces the engine.
2. Position hose clamp so that the hose clamp screw is near
the bottom and just inward of the intake tube. Tighten to
45-55 in-lbs (5.1-6.2 Nm).
3. If air filter was replaced, install new front medallion on air
filter.
3
2
1
sm04811b
1. Intake tube
2. Hose clamp
3. Air filter
Figure 1-1. Air Filter
HOME
1.5 HYDRAULIC CLUTCH FLUID
GENERAL
The clutch is hydraulically actuated. The master cylinder cre-
ates pressure in the clutch fluid line. This pressure activates
the secondary clutch actuator. The secondary clutch actuator
piston extends and contacts a pushrod to disengage the clutch.
D.O.T. 4 hydraulic brake fluid is used in the hydraulic
clutch. Do not use other types of fluids as they are not
compatible and could cause equipment damage. (00353a)
D.O.T. 4 brake fluid will damage painted and body panel
surfaces it comes in contact with. Always use caution and
protect surfaces from spills whenever brake work is per-
formed. Failure to comply can result in cosmetic damage.
(00239b)
NOTE
Do not wipe any spilled brake fluid off of finished surfaces.
Always flush the affected components with clean water.
Direct contact of D.O.T. 4 brake fluid with eyes can cause
irritation. Avoid eye contact. In case of eye contact flush
with large amounts of water and get medical attention.
Swallowing large amounts of D.O.T. 4 brake fluid can cause
digestive discomfort. If swallowed, obtain medical atten-
tion. Use in well ventilated area. KEEP OUT OF REACHOF
CHILDREN. (00240a)
FLUID INSPECTION
1.4-1.7 Nm 12-15 in-lbs Clutch reservoir cover screws
Do not allow dirt or debris to enter the master cylinder
reservoir. Dirt or debris in the reservoir can cause improper
operation and equipment damage. (00205c)
1. Position vehicle on a flat, level surface. Turn handlebar
so master cylinder is level.
2. See Figure 1-2. View reservoir sight glass (3) and verify
fluid presence. Sight glass should appear dark if fluid is
present.
NOTE
Do NOT overfill clutch reservoir. Clutch fluid volume in reservoir
increases with clutch wear and can damage seals causing
damage to clutch system.
3. If sight glass is not dark:
a. Check for fluid leaks in hydraulic clutch system.
b. Remove reservoir cover and verify fluid level.
c. If fluid level is belowFILL LEVEL on ledge in reservoir,
add DOT 4 BRAKE FLUID. Do not exceed FILL
LEVEL.
d. Attach cover with screws. Tighten to 12-15 in-lbs
(1.4-1.7 Nm).
1
3
2
pd00513
1. Clutch master cylinder reservoir
2. Reservoir cover
3. Sight glass
Figure 1-2. Clutch Master Cylinder Reservoir
HOME
1.6 ENGINE LUBRICATION SYSTEM
GENERAL
Prolonged or repeated contact with used motor oil may
be harmful to skin and could cause skin cancer. Promptly
wash affected areas with soap and water. (00358b)
If swallowed, do not induce vomiting. Contact a physician
immediately. In case of contact with eyes, immediately
flush with water. Contact a physician if irritation persists.
(00357c)
Do not switch lubricant brands indiscriminately because
some lubricants interact chemically when mixed. Use of
inferior lubricants can damage the engine. (00184a)
SCREAMIN' EAGLESYN3 FULL SYNTHETICMOTORCYCLE
LUBRICANT 20W50 is provided for engine lubrication.
If necessary and SYN3 is not available, add GENUINE
HARLEY-DAVIDSON H-D 360 20W50 MOTORCYCLE OIL.
Although H-D 360 is compatible with SYN3, we suggest the
mixture of fluids be changed as soon as possible.
If H-D 360 is not available, the second choice is an oil certified
for diesel engines. Acceptable diesel engine oil designations
include: CH-4, CI-4 and CJ-4. The preferred viscosities for
diesel engine oils, in descending order are: 20W50, 15W40
and 10W40.
We again suggest the mixture of the fluids be changed as soon
as possible. At the first opportunity, see a Harley-Davidson
dealer to change back to 100 percent Harley-Davidson oil. DO
NOT add diesel engine oil to the primary chaincase or trans-
mission.
Refer to Table 1-4. To switch lubricant to H-D 360, completely
drain the SYN3 before filling with H-D 360. It is not required to
flush out any residual lubricant.
Table 1-4. Recommended Engine Oils
COLD WEATHER
STARTS BELOW
50 F (10 C)
LOWEST AMBIENT
TEMPERATURE
RATING VISCOSITY TYPE
Excellent Above 40 F (4 C) HD 360 SAE 20W50 Screamin' Eagle SYN3 Full Syn-
thetic Motorcycle Lubricant
Good Above 40 F (4 C) HD 360 SAE 20W50 Genuine H-D 360 Multi-Grade
Poor Above 60 F (16 C) HD 360 SAE 50 Genuine H-D 360 Regular Heavy
Poor Above 80 F (27 C) HD 360 SAE 60 Genuine H-D 360 Extra Heavy
Excellent Below 40 F (4 C) SH, CH-4, SAE 10W40 Multi-grade (oil certified for use in
diesel engines) CI-4, CJ-4
HOME
1.7 TIRES AND WHEELS
TIRES
Use only Harley-Davidson specified tires. See a Harley-
Davidson dealer. Using non-specified tires can adversely
affect stability, handling or braking, which could result in
death or serious injury. (00024b)
NOTES
Tubeless tires are used on all Harley-Davidson cast and
disc wheels, and tubeless profile laced wheels with MTM
designation.
Tire sizes are molded on the tire sidewall. Inner tube sizes
are printed on the tube.
Newtires should be stored on a horizontal tire rack. Avoid
stacking new tires in a vertical stack. The weight of the
stack compresses the tires and closes down the beads.
Check tire pressure and tread:
As part of the pre-ride inspection.
At every scheduled service interval.
1. Inspect each tire for punctures, cuts and breaks.
2. Inspect each tire for wear. Replace tires before they reach
the tread wear indicator bars.
Be sure tires are properly inflated, balanced, undamaged,
and have adequate tread. Inspect your tires regularly and
see a Harley-Davidson dealer for replacements. Riding
with excessively worn, unbalanced, improperly inflated,
overloaded or damaged tires can lead to tire failure and
adversely affect stability and handling, which could result
in death or serious injury. (00014b)
NOTE
Missing indicator wear bars represent less than 1/32 in. (0.8
mm) tread pattern depth remaining.
3. Check for proper front and rear tire pressures when tires
are cold. Compare results against Table 1-5.
NOTE
Harley-Davidson does not perform any testing with only
nitrogen in tires. Harley-Davidson neither recommends nor
discourages the use of pure nitrogen to inflate tires.
Table 1-5. Specified Tires
TIRE PRESSURE (COLD) SPECIFIED TIRE SIZE MOUNT
kPa PSI
248 36 Dunlop D408F 130/60B21 21 in Front
290 42 Dunlop D407 240/40R18 18 in Rear
HOME
1.8 DRIVE BELT AND SPROCKETS
CHECKING BELT DEFLECTION
BELT TENSION GAUGE HD-35381-A
NOTE
Do not rely on "feel" for the proper deflection as this typically
results in belts which are under tensioned. Always use BELT
TENSION GAUGE (Part No. HD-35381-A) to determine the
10 lbs (4.5 kg) deflection force. Loose belts will fail due to
"ratcheting" (jumping a tooth) with resultant tensile cord
crimping and breakage.
Check drive belt deflection:
As part of the pre-ride inspection.
At every scheduled service interval.
When checking belt deflection:
Set belt tension at loosest point in belt.
Perform procedure with motorcycle cold.
NOTE
Customers may purchase belt tension gauge from an author-
ized Harley-Davidson dealer.
1. See Figure 1-3. Obtain BELT TENSION GAUGE (Part
No. HD-35381-A).
2. To use the belt tension gauge:
a. Slide O-ring (4) toward 0 lbs (0 kg) mark (3).
b. See Figure 1-4. Fit belt cradle (2) against bottom of
drive belt half-way between drive pulleys.
c. Press upward on knob (6) until O-ring slides down to
10 lbs (4.5 kg) mark (5).
3. See Figure 1-4. Check drive belt deflection. Apply 10 lbs
(4.5 kg) of force upward at point 1.
4. Refer to Table 1-6. Compare drive belt deflection with
specifications listed.
Table 1-6. Drive Belt Deflection
SPECIFICATION VEHICLE
1/4-5/16 in. (6.4-7.9 mm) With motorcycle on jiffy stand
without rider or luggage
5/16-3/8 in. (7.9-9.5 mm) Vehicle upright with rear wheel
in air
10 0
3
6
1
2
4
5
sm02452
1. Belt tension gauge
2. Belt cradle
3. 0 lbs (0 kg) mark
4. O-ring
5. 10 lbs (4.5 kg) mark
6. Knob
Figure 1-3. Belt Tension Gauge
2
1
sm01833
1. 10 lbs (4.5 kg) of force
2. Amount of deflection
Figure 1-4. Checking Belt Deflection
HOME
1.9 STEERING HEAD BEARINGS
ADJUSTMENT
94.9-108.4
Nm
70-80 ft-lbs Fork stem nut
40.7-47.5 Nm 30-35 ft-lbs Fork bracket pinch bolt, lower
94.9-108.4
Nm
70-80 ft-lbs Fork stem nut
40.7-47.5 Nm 30-35 ft-lbs Fork bracket pinch bolt, lower
Bearing Adjustment (Fall-away)
1. Support motorcycle in an upright position. make sure front
end is completely suspended and the vehicle is level.
2. Remove all accessory weight, such as a windshield, that
may influence the way the front end swings.
3. ABS models: disconnect brake line from steering head.
4. Place a suitable marking material, such as masking tape,
over the fender tip.
5. Install a pointer so the base is stationary on the floor and
the pointer indicates the center of the fender. The front
end should be straight ahead, however the balance point
may be slightly off center.
6. Check steering head bearing tension.
a. Rotate the front end from steering stop to steering
stop three times and then center the front end.
b. Tap the fender on one side until the front end begins
to "fall-away" by itself. Label this point on the marking
material.
c. Repeat the previous step in the other direction.
d. Repeat until marks are consistent. If marks vary, use
the average.
e. Measure distance between marks.
7. The distance between the "fall-away" marks must be 2.0-
4.0 in. (50.8-101.6 mm). If "fall-away" is not within specific-
ations, see next steps.
8. If the distance exceeds 4.0 in. (101.6 mm).
a. Remove speedometer but do not disconnect
speedometer wiring. See 7.3 SPEEDOMETER.
b. Protect and secure speedometer.
c. See Figure 1-5. Loosen the lower pinch bolts (5).
d. Remove fork stem cap (1).
e. Loosen the fork stem nut (2).
f. Loosen the bearing adjustment nut (4) slightly.
g. Tighten the fork stem nut to 70-80 ft-lbs (94.9-108.4
Nm).
h. Tighten pinch bolts to 30-35 ft-lbs (40.7-47.5 Nm).
i. Install fork stem cap (1).
j. Install speedometer. See 7.3 SPEEDOMETER.
k. Repeat procedure to determine if fall-away is within
specifications.
9. If the distance is less than 2.0 in. (50.8 mm).
a. Remove speedometer but do not disconnect
speedometer wiring. See 7.3 SPEEDOMETER.
b. Protect and secure speedometer.
c. See Figure 1-5. Loosen lower pinch bolts (5).
d. Remove fork stem cap (1).
e. Loosen fork stem nut (2).
f. Tighten bearing adjustment nut (4) slightly.
g. Tighten fork stemnut to 70-80 ft-lbs (94.9-108.4 Nm).
h. Tighten lower pinch bolts to 30-35 ft-lbs (40.7-47.5
Nm).
i. Install fork stem cap (1).
j. Install speedometer. See 7.3 SPEEDOMETER.
k. Repeat procedure to determine if fall-away is within
specifications.
NOTE
If adjustment seems to have no impact, check to see if fork
tubes are stuck in clamps. If necessary, strike tubes with a
dead blow hammer to free. Test steering head bearing tension
after freeing forks.
HOME
2
1
3
5
6
5
3
4
sm07676
1. Fork stem cap
2. Fork stem nut
3. Upper pinch bolts
4. Adjusting nut
5. Lower pinch bolts
6. Clamp fastener
Figure 1-5. Steering Head
HOME
1.10 SUSPENSION ADJUSTMENTS
SHOCK ABSORBERS
SHOCK ADJUSTMENT SPANNER 94448-82B
Calculate Number of Turns
The rear shock spring preload is adjusted to the total load or
may be varied to suit personal comfort.
1. Identify the number of preload turns for the weight of the
rider. Refer to Table 1-7.
2. Calculate the number of turns for the intended passenger
and cargo.
3. Add the number of turns for the rider to the number of
additional turns required for the total weight of the pas-
senger and/or cargo.
Table 1-7. Shock Preload
TURNS** RIDER WEIGHT*
0 Less than 185 lb (84 kg)
1 185-235 lb (84-107 kg)
2 235-285 lb (107-129 kg)
3 285-340 lb (129-154 kg)
4 340 lb (154 kg) to maximum added weight
allowed (refer to Table 2-2)
*Passenger/Cargo: For every 35 lb (15.8 kg) increase preload
one turn.
**Turns out (counterclockwise) from minimum preload.
Adjustment
NOTES
Adjust the shocks with the motorcycle resting on the jiffy
stand.
Adjust both shocks the same number of turns.
1. See Figure 1-6. Hold the shaft with a wrench on the flats
of the shock shaft and loosen the jamnut (2).
2. Use the tangs of the SHOCK ADJUSTMENT SPANNER
(Part No. 94448-82B) in the holes in the rear shock can-
ister (1) to turn the canister clockwise until it stops. This
is the minimum preload position.
3. Mark the face of the canister for reference.
4. Turn the canister counterclockwise the number of turns
calculated for the total load.
5. Tighten the jamnut.
2
3
1
sm03080
1. Rear shock canister
2. Jamnut
3. Spring adjuster plate
Figure 1-6. Rear Shock Adjustment
HOME
NOTES
TABLE OF CONTENTS
SUBJECT............................................................................................................................PAGE NO.
2.2 SPECIFICATIONS: CHASSIS....................................................................................................2-3
2.3 VEHICLE IDENTIFICATION NUMBER (VIN)............................................................................2-4
2.4 FRONT AXLE COVERS............................................................................................................2-6
2.5 FRONT WHEEL.........................................................................................................................2-7
2.6 REAR WHEEL...........................................................................................................................2-9
2.7 BRAKE PEDAL PAD................................................................................................................2-12
2.8 FRONT FORKS.......................................................................................................................2-13
2.9 FOOTRESTS...........................................................................................................................2-16
2.10 JIFFY STAND.........................................................................................................................2-17
2.11 HANDGRIPS AND HAND CONTROLS.................................................................................2-18
2.12 HANDLEBARS AND RISERS................................................................................................2-22
2.13 REAR FENDER.....................................................................................................................2-25
2.14 ABS HYDRAULIC CONTROL UNIT (HCU)...........................................................................2-27
2.15 CLUTCH MASTER CYLINDER AND RESERVOIR..............................................................2-29
2.16 CLUTCH HAND LEVER........................................................................................................2-33
2.17 CLUTCH FLUID LINE............................................................................................................2-34
2.18 BLEEDING CLUTCH FLUID LINE.........................................................................................2-35
2.19 SHIFTER PEG.......................................................................................................................2-38
2.20 REAR FORK PIVOT COVERS..............................................................................................2-39
2.21 SEAT......................................................................................................................................2-40
2.22 HEADLAMP NACELLE..........................................................................................................2-41
C
H
A
S
S
I
S
NOTES
CHAPTER
in this chapter.
2.4 FRONT AXLE COVERS, Replacement 1.7-2.5 Nm 15-22 in-lbs Axle cover set screw, front
2.5 FRONT WHEEL, Installation 1.7-2.5 Nm 15-22 in-lbs Axle cover set screw, front
2.6 REAR WHEEL, Assembly 81.4 Nm 60 ft-lbs Belt sprocket screws, 1st torque
2.6 REAR WHEEL, Assembly 104.5-112.6 Nm 77-83 ft-lbs Belt sprocket screws, final torque
2.5 FRONT WHEEL, Installation 38.0-51.5 Nm 28-38 ft-lbs Brake caliper mounting bolt, front
2.5 FRONT WHEEL, Assembly 21.7-32.5 Nm 16-24 ft-lbs Brake disc screws, front
2.6 REAR WHEEL, Assembly 40.7-61.0 Nm 30-45 ft-lbs Brake disc screws, rear
2.7 BRAKE PEDAL PAD, Installation 3.4-4.5 Nm 30-40 in-lbs Brake pedal pad
2.17 CLUTCH FLUID LINE, Replacement 6.8-10.8 Nm 60-96 in-lbs Clutch fluid line clamp fastener
2.17 CLUTCH FLUID LINE, Replacement 10.9-16.3 Nm 96-144 in-lbs Clutch fluid line flare nut
2.17 CLUTCH FLUID LINE, Replacement 3.4-4.5 Nm 30-40 in-lbs Clutch fluid line P-clamp screw
RESERVOIR, Installation
23.0-29.8 Nm 17-22 ft-lbs Clutch master cylinder banjo bolt
2.17 CLUTCH FLUID LINE, Replacement 23.0-29.8 Nm 17.0-22.0 ft-lbs Clutch master cylinder banjo bolt
8.1-12.2 Nm 72-108 in-lbs Clutch master cylinder clamp fastener
2.18 BLEEDINGCLUTCHFLUIDLINE, Bleed Fluid
Line and Secondary Clutch Actuator
2.11 HANDGRIPSANDHANDCONTROLS, Switch
Housings and Brackets: Installation
6.8-9 Nm 60-80 in-lbs Control lever bracket clamp
2.9 FOOTRESTS, Assembly 19-25.7 Nm 14-19 ft-lbs Footpegs
2.5 FRONT WHEEL, Installation 95.0-101.8 Nm 70-75 ft-lbs Front axle nut
2.5 FRONT WHEEL, Installation 14.9-20.3 Nm 132-180 in-lbs Front axle slider cap nuts
2.8 FRONT FORKS, Assembly 40-50 Nm 29.5-36.8 ft-lbs Front fork damper tube screw
2.8 FRONT FORKS, Assembly 50-60 Nm 36.8-44.2 ft-lbs Front fork slider tube plug
2.12 HANDLEBARS AND RISERS, Installation 16.3-21.7 Nm 12-16 ft-lbs Handlebar clamp front fasteners
2.12 HANDLEBARS AND RISERS, Installation 16.3-21.7 Nm 12-16 ft-lbs Handlebar clamp rear fasteners
4.0-5.1 Nm 35-45 in-lbs Handlebar switch housing screw
(HCU), Front HCU
13.6-16.3 Nm 120-144 in-lbs HCU banjo bolts
(HCU), Front HCU
10.9-16.3 Nm 8-12 ft-lbs HCU bracket, large, front
(HCU), Front HCU
10.9-13.6 Nm 96-120 in-lbs HCU bracket, small, front
(HCU), Front HCU
2.7-4.0 Nm 24-36 in-lbs HCU fasteners, front
2.12 HANDLEBARS AND RISERS, Installation 2.3-3.4 Nm 20-30 in-lbs Indicator lamp fasteners
2.8 FRONT FORKS, Installation 40.7-47.5 Nm 30-35 ft-lbs Lower fork stem pinch bolts
HOME
2013 FXSBSE Service Supplement: Chassis 2-1
2.12 HANDLEBARS AND RISERS, Installation 40.7-54.3 Nm 30-40 ft-lbs Lower handlebar clamp fasteners
2.22 HEADLAMP NACELLE, Installation 9.0-11.3 Nm 80-100 in-lbs Nacelle bracket fasteners
2.22 HEADLAMP NACELLE, Installation 10.9-13.6 Nm 96-120 in-lbs Nacelle fasteners
11.2-13.6 Nm 100-120 in-lbs Outer transmission cover screws
2.6 REAR WHEEL, Installation/LOCTITE 243
MEDIUM STRENGTH THREADLOCKER AND
SEALANT (blue)
1.1-1.7 Nm 10-15 in-lbs Rear axle cover set screws
2.6 REAR WHEEL, Installation 128.8-142.5 Nm 95-105 ft-lbs Rear axle nut
2.13 REAR FENDER, Installation 28.5-36.6 Nm 21-27 ft-lbs Rear fender support to fender
2.13 REAR FENDER, Installation 40.7-47.5 Nm 30-35 ft-lbs Rear fender support to frame fasteners:
1st torque
final torque
2.20 REARFORK PIVOT COVERS, Replacement 6.8-9.5 Nm 60-84 in-lbs Rear fork pivot cover set screws
2.11 HANDGRIPS AND HAND CONTROLS, Turn
Signals and Mirrors
10.9-16.3 Nm 96-144 in-lbs Rear view mirror acorn nut
3.5-4.6 Nm 31-41 in-lbs Secondary clutch actuator bleeder valve
2.19 SHIFTER PEG, Assembly 16.3-19.0 Nm 12-14 ft-lbs Shifter peg screw
4-5 Nm 35-45 in-lbs Switch housings
HOME
2-2 2013 FXSBSE Service Supplement: Chassis
2.2 SPECIFICATIONS: CHASSIS
GENERAL
Table 2-1. Dimensions
MM IN ITEM
2398 94.4 Length
979 38.5 Overall width
1085 42.7 Overall height
1714 67.5 Wheelbase
109 4.3 Road clearance
630 24.8 Saddle height*
*With 180 lb (82 kg) rider on seat
NOTE
Gross Vehicle Weight Rating (GVWR) (maximum allowable
loaded vehicle weight) and corresponding Gross Axle Weight
Ratings (GAWR) are given on a decal located on the steering
head.
Table 2-2. Weights
KG LB ITEM
328.5 724 Running weight*
204.4 451 Maximum added weight
allowed**
532.9 1175 GVWR
188.2 415 GAWR front
344.7 760 GAWR rear
*The total weight of the motorcycle as delivered with oil/fluids
and approximately 90% of fuel.
**The total weight of accessories, cargo, riding gear, pas-
senger and rider cannot exceed this weight.
Table 2-3. Specified Tires
TIRE PRESSURE (COLD) SPECIFIED TIRE SIZE MOUNT
kPa PSI
248 36 Dunlop D408F 130/60B21 21 in Front
290 42 Dunlop D407 240/40R18 18 in Rear
Table 2-4. Capacities
LITERS U.S. ITEM
18.9 5.0 gal Fuel tank (total)
3.79 1.0 gal Low fuel warning light on
3.3 3.5 qt Oil tank with filter
0.95 1.0 qt Transmission
(approximate)
0.95 1.0 qt Primary chaincase
(approximate)
HOME
2.3 VEHICLE IDENTIFICATION NUMBER (VIN)
VEHICLE IDENTIFICATION NUMBER (VIN)
General
See Figure 2-2. A unique 17-digit serial or Vehicle Identification
Number (VIN) is assigned to each motorcycle. For a description
of each item in the VIN, refer to Table 2-5.
Location
See Figure 2-1. The full 17-digit VIN(1) is stamped on the right
side of the frame near the steering head. In some destinations,
a printed VIN label (2) is also attached to the front downtube.
Abbreviated VIN
An abbreviated VIN showing the vehicle model, engine type,
model year, and sequential number is stamped on the left side
of the crankcase between the engine cylinders.
NOTE
Always give the full 17-digit Vehicle Identification Number when
ordering parts or making any inquiry about your motorcycle.
1
2
om01393
1. Stamped VIN
2. VIN label
Figure 2-1. VIN Locations
HOME
1HD 1 TD 9 1 3 D B 111000
1 2 3 4 5 6 7 8 9
om01026
Figure 2-2. Typical Harley-Davidson VIN: 2013 FXSBSE Models
Table 2-5. Harley-Davidson VIN Breakdown: 2013 FXSBSE Models
POSSIBLE VALUES DESCRIPTION POSITION
1HD=Originally manufactured for sale within the United States World manufacturer identifier 1
5HD=Originally manufactured for sale outside of the United States
932=Originally manufactured in and for sale only in Brazil market
MEG=Originally manufactured in and for sale only in India market
1=Heavyweight motorcycle (901 cm
3
or larger) Motorcycle type 2
TD=FXSBSE CVO Breakout
Model 3
9=Twin Cam 110B
(1802 cm
3
) air-cooled, fuel-injected, balanced Engine type 4
Mid-year or Special Introduction Normal Introduction Calibration/configuration, introduc-
tion
5
2, 4=Domestic (DOM) 1=Domestic (DOM)
5, 6=California (CAL) 3=California (CAL)
B=Canada (CAN) A=Canada (CAN)
D=HDI C=HDI
F=Japan (JPN) E=Japan (JPN)
H=Australia (AUS) G=Australia (AUS)
K=Brazil (BRZ) J=Brazil (BRZ)
M=Asia Pacific (APC) L=Asia Pacific (APC)
P=India (IND) N=India (IND)
Can be 0-9 or X V.I.N. check digit 6
D=2013 Model year 7
B=York, PA U.S.A. Assembly plant 8
D=H-D Brazil-Manaus, Brazil (CKD)
N=Haryana India (Bawal District Rewari)
Varies Sequential number 9
HOME
2.4 FRONT AXLE COVERS
REPLACEMENT
1.7-2.5 Nm 15-22 in-lbs Axle cover set screw, front
1. See Figure 2-3. Loosen but do not remove set screws
from covers.
2. Remove covers and remove set screws from covers.
3. Liberally apply LOCTITE 262 HIGH STRENGTH
THREADLOCKERANDSEALANT (Red) to threads of set
screw. Loosely install in cover.
4. Place cover over axle end with set screw facing down.
5. Tighten set screws to 15-22 in-lbs (1.7-2.5 Nm).
sm04815c
Figure 2-3. Front Axle Cover
HOME
2.5 FRONT WHEEL
REMOVAL
1. Raise the front wheel off the ground.
NOTE
Do not operate front brake lever or the caliper piston may be
forced out of piston bore. Reseating the piston requires disas-
sembly of the caliper.
2. Remove the brake caliper. Support caliper using a rubber
bungee cord. See the service manual.
3. Inspect the wheel bearings and measure end play. See
the service manual.
4. See Figure 2-4. Loosen the set screw (2) to remove the
axle covers (1).
5. Remove the axle nut (12) and washer (11).
NOTE
The WSS wire harness is attached to the WSS bracket with
adhesive.
6. Remove the WSS cover (10) and the WSS (9).
7. Loosen the slider cap fasteners from bottom of right fork
and pull the axle (3) free.
8. Remove the wheel.
DISASSEMBLY
1. See Figure 2-4. Remove the spacer (4).
2. If necessary, remove brake disc (8). Discard screws.
3. To replace the wheel bearings (5), see the service manual.
2
5
1
8
9
1
5
6
3
4
2
12
11
10
7
sm04593d
9. 5. 1. WSS Bearing Axle cover
2. 10. 6. Set screw Cover Sleeve
7. 3. 11. Wheel Axle Washer
12. 8. 4. Nut Brake disc Spacer
Figure 2-4. Front Wheel
HOME
INSPECTION
1. Inspect all parts for damage or excessive wear.
Always replace brake pads in complete sets for correct
and safe brake operation. Improper brake operation could
result in death or serious injury. (00111a)
2. Inspect the brake disc.
a. Minimumbrake disc thickness is stamped on the side
of the disc. Replace disc if badly scored.
b. Maximum brake disc lateral runout and warpage is
0.008 in. (0.2 mm).
ASSEMBLY
21.7-32.5 Nm 16-24 ft-lbs Brake disc screws, front
Be sure that brake fluid or other lubricants do not contact
brake pads or discs. Such contact can adversely affect
braking ability, which could cause loss of control, resulting
in death or serious injury. (00290a)
1. Verify that the runout of the wheel and tire are within spe-
cification. See the service manual.
Do not re-use brake disc/rotor screws. Re-using these
screws can result in torque loss and damage to brake
components. (00319c)
2. See Figure 2-4. Install brake disc (8) with newscrews and
tighten to 16-24 ft-lbs (21.7-32.5 Nm).
3. Install spacer (4).
INSTALLATION
95.0-101.8
Nm
70-75 ft-lbs Front axle nut
14.9-20.3 Nm 132-180
in-lbs
Front axle slider cap nuts
38.0-51.5 Nm 28-38 ft-lbs Brake caliper mounting bolt,
front
1.7-2.5 Nm 15-22 in-lbs Axle cover set screw, front
1. Apply a light coat of ANTI-SEIZE LUBRICANT to the ID
of the right side bearing only.
2. See Figure 2-4. Place wheel into front fork.
3. Install the axle (3) through right side fork, the wheel (7),
the WSS (9) and the WSS cover (10) into the left fork.
4. Verify that the WSS index pin contacts the shoulder on
the left fork slider.
5. Install the washer (11) and axle nut (12).
6. Hold the axle stationary with a steel rod through the hole
in the right side of the axle. Tighten axle nut to 70-75 ft-
lbs (95.0-101.8 Nm).
NOTE
Make sure front and rear gaps between slider cap and slider
are even.
7. Tighten the slider cap nuts on the lower right fork to 132-
180 in-lbs (14.9-20.3 Nm).
NOTES
Fit the WSS harness behind the WSS front bracket on the
caliper.
There is a yellow mark on the WSS harness that should
just be covered with the bottom of the WSS front bracket.
8. Install brake caliper. See the service manual.
9. Tighten brake caliper fasteners to 28-38 ft-lbs (38.0-51.5
Nm).
Whenever a wheel is installed and before moving the
motorcycle, pump brakes to build brake systempressure.
Insufficient pressure can adversely affect brake perform-
ance, which could result in death or serious injury. (00284a)
10. Pump brake hand lever to move pistons out until they
contact both brake pads. Verify piston location against
pads.
11. Verify that the WSS harness is secured to the brake fluid
line with three retainer clips.
12. Align the axle covers so that the set screw is out of sight
and aligned with the flat on the axle nut hex. Tighten the
set screw to 15-22 in-lbs (1.7-2.5 Nm).
Be sure that all lights and switches operate properly before
operating motorcycle. Low visibility of rider can result in
death or serious injury. (00316a)
13. Test ride the motorcycle.
HOME
2.6 REAR WHEEL
REMOVAL
1. Block motorcycle under frame so weight of motorcycle is
off rear wheel.
2. Inspect drive belt for wear conditions and belt sprocket for
tooth damage or loss of chrome. See the service manual.
3. Inspect brake disc and pads for wear. Measure brake disc
thickness. See the service manual.
4. Rotate the wheel several times to check for rough or
uneven bearing rotation.
5. Remove rear muffler. See 4.4 EXHAUST SYSTEM.
6. Remove belt guard and debris deflector from rear fork.
See the service manual.
7. Remove rear brake caliper. See the service manual.
8. See Figure 2-5. Remove right axle cover (8).
9. Remove axle nut (6) with retainer (7), and washer (5).
10. Loosen axle adjusters.
NOTE
Support rear wheel from underneath during removal.
11. Remove axle (18), washer (5), axle adjuster spacer (17),
brake caliper bracket (14), wheel speed sensor (16), and
wheel spacer (10).
NOTE
Do not operate rear brake pedal with the rear wheel removed
or the caliper piston may be forced out of the piston bores.
Reseating the piston requires disassembly of the caliper.
12. Move wheel forward and slip belt off belt sprocket (2).
13. Pull wheel (1) with belt sprocket (2) from rear fork.
DISASSEMBLY
1. See Figure 2-5. If necessary, remove brake disc screws
(15) and brake disc (13).
2. If necessary, remove covers (4), belt sprocket fasteners
(3), and belt sprocket (2).
3. Inspect wheel bearing end play. Service bearings if
necessary. See the service manual.
4. Inspect all parts for wear or damage.
MAINTENANCE AND CLEANING
Chrome parts must be maintained regularly to make sure that
they keep their original shine and luster.
1. Clean heavily-soiled wheel surfaces using HARLEY
WHEEL AND TIRE CLEANER applied with HARLEY
WHEEL AND SPOKE BRUSH.
2. Thoroughly clean chrome with a good quality chrome
cleaner.
3. After cleaning and polishing, seal the finish with HARLEY
GLAZE POLISH AND SEALANT.
HOME
1
19
2
3
4
8
9
10
13
14
15
16
17
5
18
9
8
11
12
5
6
7
sm04592c
15. 8. 1. Screw (5) Axle cover (2) Wheel
2. 16. 9. Belt sprocket Wheel speed sensor Set screw (2)
10. 3. 17. Wheel spacer Screw with washer (5) Axle adjuster spacer
18. 11. 4. Axle Bearing Cover (5)
5. 19. 12. Washer (2) ABS decoder bearing Sleeve
13. 6. Brake disc Nut
7. 14. Retainer Brake caliper bracket
Figure 2-5. Rear Wheel Components
HOME
ASSEMBLY
81.4 Nm 60 ft-lbs Belt sprocket screws, 1st
torque
104.5-112.6
Nm
77-83 ft-lbs Belt sprocket screws, final
torque
40.7-61.0 Nm 30-45 ft-lbs Brake disc screws, rear
Do not re-use brake disc/rotor screws. Re-using these
screws can result in torque loss and damage to brake
components. (00319c)
Do not re-use sprocket mounting screws. Re-using
sprocket mounting screws can result in torque loss and
damage to the sprocket and/or belt assembly. (00480b)
1. See Figure 2-5. If removed, install wheel bearings (11,
19). See the service manual.
NOTE
If fastener covers (4) were removed in order to remove
fasteners (3), install after fasteners have been installed.
2. Using newscrews (3), install belt sprocket (2), if removed.
Tighten screws using the following sequence:
a. Tighten screws (3) to an initial torque of 60 ft-lbs (81.4
Nm).
b. Back screws off 1/2 turn (180 degrees).
c. Tighten screws (3) to a final torque of 77-83 ft-lbs
(104.5-112.6 Nm).
3. Using new screws (15), install brake disc (13). Tighten
screws to 30-45 ft-lbs (40.7-61.0 Nm).
INSTALLATION
128.8-142.5
Nm
95-105 ft-lbs Rear axle nut
1. See Figure 2-5. Apply a light coat of ANTI-SEIZE LUB-
RICANT to axle (18), bearing bores, and bore of inner
sleeve (12).
a. Carefully slide axle (18) with washer (5) through right
side of rear fork and install axle adjuster spacer (17)
and brake caliper bracket (14).
b. Install wheel spacer (10) on left side of wheel and roll
wheel into rear fork.
c. Pull drive belt over drive sprocket.
d. Install wheel speed sensor (16).
e. Continue sliding axle (18) through wheel speed sensor
(16), wheel (1), left side spacer (10) and left rear fork.
Do not exceed specified torque when tightening axle nut.
Exceedingtorque can cause wheel bearings to seize during
vehicle operation, which could result in death or serious
injury. (00408e)
2. Install washer (5) and axle nut (6) with new retainer (7).
3. Verify correct axle alignment and belt deflection. See the
service manual.
4. Tighten axle nut (6) to 95-105 ft-lbs (128.8-142.5 Nm).
5. Apply LOCTITE 243 MEDIUM STRENGTH THREAD-
LOCKER AND SEALANT (blue) to screws (9).
6. Install axle covers (8) with screws (9). Tighten screws to
10-15 in-lbs (1.1-1.7 Nm).
7. Install debris deflector and belt guard. See the service
manual.
8. Install rear caliper. See the service manual.
Whenever a wheel is installed and before moving the
motorcycle, pump brakes to build brake systempressure.
Insufficient pressure can adversely affect brake perform-
ance, which could result in death or serious injury. (00284a)
9. Pump brake pedal to move pistons out until they contact
both brake pads. Verify piston location against pads.
10. Install mufflers. See 4.4 EXHAUST SYSTEM.
HOME
2.7 BRAKE PEDAL PAD
REMOVAL
See Figure 2-6. Remove screw and washer (4, 3) and remove
pad (1).
INSTALLATION
3.4-4.5 Nm 30-40 in-lbs Brake pedal pad
1. See Figure 2-6. Place brake pedal pad (1) over brake
pedal (2).
2. Insert screw with washer (3, 4) through brake pedal (2)
and into the brake pedal pad.
3. Tighten to 30-40 in-lbs (3.4-4.5 Nm).
4
2
1
3
sm04594b
1. Brake pad
2. Brake pedal
3. Washer
4. Screw
Figure 2-6. Brake Pedal Pad
HOME
2.8 FRONT FORKS
REMOVAL
1. Support the vehicle so the front end is off floor and the
forks are fully extended.
2. Remove front wheel and brake caliper. See 2.5 FRONT
WHEEL.
3. Remove front fender. See service manual.
4. Loosen upper pinch bolts (1).
5. Loosen lower pinch bolt (14) and pull the fork side from
the brackets.
6. Repeat two previous steps for the other fork side.
DISASSEMBLY
Wear safety glasses or goggles when servicing fork
assembly. Do not remove slider tube caps without relieving
spring preload or caps and springs can fly out, which could
result in death or serious injury. (00297a)
1. See Figure 2-7. Remove the slider tube plug (1) and O-
ring (2) from the top of one fork side.
2. Remove case cover (15) and dust seal (16).
3. Remove stopper ring (17).
NOTE
Since there is little resistance to rotation when removing screw
(32), use an air impact wrench.
4. Remove screw (32) with washer (31) from the bottomend
of fork slider (30). This will free damper tube (21) and fork
slider tube (28) so that they can be removed from slider.
5. The upper slider tube bushing (20) is a slight interference
fit in slider (30). The upper bushing together with seal
spacer (19) and slider oil seal (18) are removed by lightly
hitting the upper bushing with the lower slider tube bushing
(29) as the slider tube is pulled free of the fork slider in a
quick continuous stroke. Continue this slide hammer action
until the components are freed.
6. Drain the slider (30) and allow the lower stop (27) to fall
free.
7. Push the damper tube (25) and damper tube spring (26)
free of slider tube (28) by inserting a small diameter rod
through the opening in the bottom of tube.
8. Damper tube ring (24) can now be removed from the
grooves at the top end of damper tube (25).
NOTES
Lower slider tube bushing (29) should not be removed
unless it is to be replaced.
9. If replacing lower slider bushing (29), expand the newsplit
bushing diameter only enough to fit over slider tube (28)
and slide bushing into the bushing groove.
CLEANING AND INSPECTION
Thoroughly clean and inspect each part. Replace parts as
necessary.
1. See Figure 2-7. Inspect damper tube ring (24) on damper
tube (25) and replace if worn excessively or damaged.
2. Replace either of the springs (23 or 26) if damaged.
3. Inspect small hole(s) in lower end of slider tube (28) and
be sure it is not obstructed.
4. Be sure fork tube plug O-ring (2) is in good condition,
without irregularities, and that it provides proper sealing
when in place.
5. Install new screw (32) and washer (31).
6. Replace bent or damaged slider tube (28).
HOME
4
5
3
2
1
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
25
24
26
27
36
37
35
34
33
32
31
30
29
28
sm07687
27. 14. 1. Lower stop Lower pinch bolt (2) Upper pinch bolt (2)
2. 28. 15. O-ring Slider tube Case cover
16. 3. 29. Dust seal Slider tube plug Lower slider tube bushing
30. 17. 4. Slider Stopper ring Fork stem cap
5. 31. 18. Fork stem nut Washer Oil seal
19. 6. 32. Seal spacer Washer Screw
33. 20. 7. Axle cap Upper slider tube bushing Adjusting nut
8. 34. 21. Upper dust shield Washer (2) Spring collar
22. 9. 35. Washer Upper roller bearing Screw (2)
36. 23. 10. Fork slider and tube
assembly, left
Spring Upper bearing race
11. 24. Lower bearing race Damper tube ring
37. 25. 12. Fork slider and tube
assembly, right
Damper tube Lower roller bearing
13. 26. Lower dust shield Damper tube spring
Figure 2-7. Front Forks
HOME
ASSEMBLY
FORK SEAL DRIVER HD-45305
40-50 Nm 29.5-36.8 ft-
lbs
Front fork damper tube screw
50-60 Nm 36.8-44.2 ft-
lbs
Front fork slider tube plug
1. Install damper tube ring (24). Place damper tube spring
(26) on damper tube (25). Insert damper tube into slider
tube (28).
2. Insert spring (23) into slider tube (28), tapered side toward
damper tube (25), and push bottom of damper tube
through the opening at the bottom end of the fork tube.
Place lower stop (27) over end of damper tube (25).
3. Insert washer (22) and spring collar (21).
4. Position slider tube (28) and damper tube (25) in slider
(30). Hold the assembly in place by exerting pressure on
the spring and install screw (32) with washer (31).
5. Tighten screw (32) to 29.5-36.8 ft-lbs (40-50 Nm).
6. Place upper slider tube bushing (20), seal spacer (19) and
a new slider oil seal (18) (in that order) over fork slider
(30). Be sure that the lettered side of the seal is facing
upward.
7. Place FORK SEAL DRIVER (Part No. HD-45305) over
fork slider (30). Seat upper slide tube bushing (16), seal
spacer (17), and slider oil seal (18) into the slider bore by
lightly tapping the components into place with the installa-
tion tool.
8. Install oil seal retaining ring (17).
9. Install dust seal (16) and case cover (15).
10. Fill forks with Harley-Davidson TYPE "E" HYDRAULIC
FORK OIL. Refer to Table 2-6.
11. Install newO-ring (2) and slider tube plug (3). Tighten plug
to 36.8-44.2 ft-lbs (50-60 Nm).
Table 2-6. TYPE "E" HYDRAULIC FORK OIL Amounts
MM IN CC OZ MODEL
85.0 3.35 790 26.7 FXSBSE
INSTALLATION
40.7-47.5 Nm 30-35 ft-lbs Lower fork stem pinch bolts
1. Insert both fork side assemblies up through the lower and
upper fork stem brackets.
2. Tighten pinch bolts (1, 14) to 30-35 ft-lbs (40.7-47.5 Nm).
3. Install front fender. See service manual.
4. Install front wheel and brake caliper. See 2.5 FRONT
WHEEL.
5. Check steering head bearing adjustment if fork stem was
removed. See 1.9 STEERING HEAD BEARINGS.
HOME
2.9 FOOTRESTS
DISASSEMBLY
1. See Figure 2-8. Remove fastener (4).
2. Slide footpeg assembly off footpeg mount (2 or 3) and
separate if needed.
ASSEMBLY
19-25.7 Nm 14-19 ft-lbs Footpegs
1. See Figure 2-8. Assemble footpeg, if needed. Slide onto
footpeg mount (2 or 3).
2. Install fastener (4). Tighten to 14-19 ft-lbs (19-25.7 Nm).
1
4
3
2
sm07075a
1. Mount extension
2. Front mount
3. Rear mount
4. Fastener
Figure 2-8. Front and Rear Footpegs
HOME
2.10 JIFFY STAND
REPLACEMENT
See Figure 2-9. When replacing spring (3), make sure hook
that attaches to jiffy stand leg faces upward.
After installing pin (1), secure with cotter pin (2).
1
2
3
sm07689
1. Pin
2. Cotter pin
3. Spring
Figure 2-9. Jiffy Stand
HOME
2.11 HANDGRIPS AND HAND CONTROLS
GENERAL
Install the clutch lever/reservoir bracket, the left handgrip, and
the switch housing before the right hand controls. Install the
throttle twist grip to match the clutch handgrip decorative pat-
tern.
SWITCH HOUSINGS AND BRACKETS:
REMOVAL
1. Remove the acorn nut, lockwasher, turn signal bracket,
washer and the rear view mirror.
2. Support the turn signal lamp(s).
3. Loosen but do not remove fasteners securing the control
lever clamp(s) to the control lever bracket(s).
4. Remove the upper and lower switch housing fasteners.
5. Remove the handgrip(s) from the handlebar.
6. Remove fasteners securing the control lever clamp(s) to
the control lever bracket(s).
7. Support the control lever bracket and fluid reservoir away
from chrome and paint finishes.
HANDLEBAR WIRING
Pulling Wire Leads
NOTE
To replace individual switches (brake or clutch) or hand control
modules in the housings, see the service manual.
1. Remove the fuel tank fasteners, vent, fuel supply fitting,
and slide the fuel tank back. See the service manual.
NOTES
Note the conduit routing and location of cable straps for
assembly.
Pull the right switch housing wire leads and the TGS
sensor wire leads together.
2. See Figure 2-10. Separate the connector housings.
a. Right control connector [22-1] (1)
b. OFF/RUN connector [22-2] (2)
c. TGS connector [204] (3)
d. Left switch housing connector [24] (4)
3. Remove the terminals fromthe connector socket housings.
4. Bundle the terminals and wire leads. Secure a length of
mechanics or safety wire long enough to pull conduits and
leads though through the handlebars. Wrap with electrical
tape.
NOTES
Support the turn signal lamp(s) to prevent pulling the relief
grommet or the turn signal wires out of the switch
housing(s).
Support the control lever bracket(s) and reservoirs to
relieve tension on the fluid line(s).
5. Remove the hand control bracket(s) and fluid reservoir(s).
6. Remove the switch housing fasteners.
NOTE
To access the TGS sensor, remove the throttle twist grip.
7. Lubricate the conduits and wire leads with glass cleaner.
Push the wire leads up through the opening in the bottom
of the handlebars while pulling the wire leads fromthe top.
8. Unwrap the mechanics wire and leave the wire in the
handlebar.
2
3
1
4
sm07092
1. RH switch housing [22-1]
2. OFF/RUN switch [22-2]
3. TGS [204]
4. LH switch housing [24]
Figure 2-10. Handlebar Wiring Connector Housings
Threading Wire Leads
NOTE
Thread the right switch housing wire leads and the TGS sensor
wire leads at the same time.
1. If necessary, replace the grommet(s) on the handlebar
wire openings.
HOME
2. Tie the bundled terminals, wire leads and conduits to the
mechanics wire(s) left in the handlebars.
3. Wrap socket wires with electrical tape and wrap open ends
of conduit.
Grommets in each of the wiring holes in the handlebar
must remain in position after routing the wiring through
the handlebar. Operation without the grommets in place
can damage wires, causing a short circuit which could
result in death or serious injury. (00416d)
4. Lubricate wire conduits with glass cleaner and pull the
wire bundles through the handlebar grommet(s) to the
handlebar center hole.
a. Pull the switch housing wire leads through the
handlebar grommet(s).
b. Pull the TGS wire leads through the end of the
handlebar
5. Install the hand lever bracket(s) and the switch housing(s).
6. Pull the mechanics wire leader and unwrap the tape and
wire.
7. Install the socket terminals into the socket housing(s).
8. Tug on the wire to confirm that the sockets will not back
out of the terminal chambers and install the connector
locking wedges.
9. As required, join the connector housings:
a. Right switch housing connector [22-1]
b. OFF/RUN switch connector [22-2]
c. TGS connector [204]
d. Left switch housing connector [24]
10. Install cable straps and install wire conduits into frame
clips.
11. Slide fuel tank into position and install fuel tank fasteners,
vent, fuel supply fitting. See the service manual.
12. Test control switches and stop light lamp.
THROTTLE GRIP SENSOR (TGS)
See Figure 2-11. When installing TGS, tab (4) on TGS (2) must
engage notch (3) in handlebar (1).
1 2
4
3
sm07098
1. Handlebar
2. TGS
3. Notch
4. Tab
Figure 2-11. Throttle Grip Sensor (TGS)
HANDGRIPS
Left Handgrip
See Figure 2-12. Slide the handgrip onto the handlebar with
the 1/2 round (1) down so the Harley-Davidson logo (2) faces
the rider and snap the grip cap (3) into place.
Right Throttle Twist Grip
See Figure 2-12. Match the orientation of the logo (2) on the
left handgrip and fit the splines in the bottomof the throttle twist
grip (5) to the splines on the TGS sensor. Snap the grip cap
(3) into place.
3
1
2
3
4
2
5
sm07036
1. Half-round
2. H-D logo
3. Cap
4. LH handgrip
5. RH throttle twist grip
Figure 2-12. Handgrips
HOME
SWITCH HOUSINGS AND BRACKETS:
INSTALLATION
1. Verify that the wire harness grommet is snapped in place
in the handlebar.
2. Slide the handgrip on the handlebar:
a. LH Handgrip: Orient with the half-round on the
bottom.
b. RHTwist Grip: Engage the splines to match the logo
to the LH handgrip.
NOTES
LH Clutch Lever/Reservoir Bracket:A lip in the control
lever bracket will fit tightly against the neck on the
handlebars.
RHBrake Lever/Reservoir Bracket: Position the control
lever bracket against the scribed line on the smaller dia-
meter handlebar.
3. See Figure 2-13. Orient the control lever bracket and the
clamp to align the mating joint (1) between the dimples
(2) on the handlebar.
4. Install the fasteners and finger tighten.
5. Fit the switch housings to the control lever bracket and
the handgrip. Loosely install the fasteners.
6. Adjust the fit of the switch housings and the control lever
bracket:
a. LHHandgrip: Fit groove in lower housing to handgrip
half-round.
RH Twist Grip: Fit the groove in the housing to the
groove around the twist grip.
b. Verify that the wires will not be pinched when
fasteners are tightened.
c. Engage lower switch housing tab with notch (3) in the
control lever bracket.
d. Alternately tighten the fasteners until the housing is
snug to the bracket.
e. Test the TGS for 0.02-0.04 in (0.5-0.6 mm) freeplay
and return to stop.
7. Tighten the fasteners:
a. Tighten control lever bracket clamp beginning with
the top fastener to 60-80 in-lbs (6.8-9 Nm). The top
gap, if any, should be tighter.
b. Tighten switch housing beginning with the bottom
fastener to 35-45 in-lbs (4-5 Nm). The rear gap, if
any, should be tighter.
8. Test clutch lever for pressure and operation.
9. Test the switch housing functions.
2
3
1
sm07016b
1. Clamp joint
2. Dimple
3. Notch
Figure 2-13. LH Controls/Handlebar (bottom view)
TURN SIGNALS AND MIRRORS
1. See Figure 2-14. Slide small washer (1) on mirror stem
and install rear view mirror stem through clutch lever
bracket. Install lockwasher (2) and acorn nut (3).
2. Hold the mirror parallel to hand grip. Tighten the acorn nut
to 96-144 in-lbs (10.9-16.3 Nm).
HOME
2
3
1
sm07077b
1. Washer
2. Lockwasher
3. Acorn nut
Figure 2-14. Mirror
HOME
2.12 HANDLEBARS AND RISERS
REMOVAL
Preparation
To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before pro-
ceeding. (00251b)
1. Remove seat.
death or serious injury, disconnect negative (-) battery
cable before proceeding. (00048a)
2. Disconnect negative battery cable.
3. Remove fuel tank fasteners, vent, fuel supply fitting and
slide the fuel tank back. See the service manual.
Handlebars
NOTE
Note conduit routing and the location of cable straps for
assembly.
1. Cut the cable strap.
2. See Figure 2-15 and Figure 2-16. Separate the handlebar
connector housings.
a. TGS [204]
b. Right hand switch housing [22-1]
c. OFF/RUN [22-2]
d. Left hand switch housing [24]
NOTE
Support turn signal bullets to prevent turn signal wire grommet
or wire leads from pulling out of the housing.
3. Remove acorn nuts, lockwashers, left and right rear view
mirror and small washers and turn signal brackets. See
2.11 HANDGRIPSANDHANDCONTROLS, Turn Signals
and Mirrors.
4. Separate left and right hand switch housings and remove
clutch lever bracket and brake lever bracket. Support
brackets to prevent strain on fluid lines. See 2.11 HAND-
GRIPS AND HAND CONTROLS, Switch Housings and
Brackets: Removal.
NOTE
If necessary, pull switch housing and TGS wire leads through
handlebars. See 2.11 HANDGRIPS AND HAND CONTROLS,
Handlebar Wiring.
5. See Figure 2-17. Remove upper handlebar clamp
fasteners (2).
6. Remove the handlebar and pull the connectors through
the opening in the fork clamp.
2
1
3
sm07033
1. RH switch housing [22-1]
2. OFF/RUN switch [22-2]
3. TGS [204]
Figure 2-15. Right Hand Handlebar Connectors
sm07032
Figure 2-16. Left Hand Switch Housing Connector [24]
Lower Handlebar Clamp
1. Separate indicator lamp assembly from upper handlebar
clamp.
2. Remove speedometer. See 7.3 SPEEDOMETER.
3. Remove headlamp horizontal adjusting bolt. See the ser-
vice manual.
4. Pull headlamp nacelle away from forks.
5. See Figure 2-17. Remove lower handlebar clamp:
a. Remove two lower handlebar clamp fasteners (10),
washers (9), cup washers (8) and lower bushings (7).
b. Remove the lower handlebar clamp (3).
c. Remove upper spacers (6), bushings (5) and upper
cup washers (4).
HOME
INSTALLATION
2.3-3.4 Nm 20-30 in-lbs Indicator lamp fasteners
16.3-21.7 Nm 12-16 ft-lbs Handlebar clamp front
fasteners
16.3-21.7 Nm 12-16 ft-lbs Handlebar clamp rear
fasteners
40.7-54.3 Nm 30-40 ft-lbs Lower handlebar clamp
fasteners
Lower Clamp
1. See Figure 2-17. Install lower bushings (7), spacers (6),
upper bushings (5) and upper cup washers (4) in upper
fork bracket.
2. Install washers (9) and lower cup washers (8) on lower
handlebar clamp fasteners (10).
3. Install lower handlebar clamp and finger tighten lower
handlebar clamp fasteners.
Handlebars
1. Route indicator lamp assembly through lower handlebar
clamp and attach to upper handlebar clamp. Tighten
fasteners to 20-30 in-lbs (2.3-3.4 Nm).
2. Guide connectors from handlebar through the opening in
the upper fork bracket.
3. See Figure 2-17. Place handlebars on lower handlebar
clamp. Install upper handlebar clamp (1). Install but do
not tighten clamp fasteners (2).
4. Using knurled areas of handlebar as a guide, center
handlebars between lower handlebar clamps.
5. Rotate handlebar so that:
a. the top of the handgrip is 9.4 in. (23.9 cm) above the
bottom of the lower handlebar clamp.
b. the rear of the hand grip is 10.7 in. (27.2 cm) from
the front of the lower handlebar clamp.
6. Tighten the clamp fasteners:
a. Front upper clamp screws to 12-16 ft-lbs (16.3-21.7
Nm)
NOTE
The slight gap between upper and lower clamps should
face the rider.
b. Rear upper clamp fasteners to 12-16 ft-lbs (16.3-21.7
Nm)
c. Lower handlebar clamp fasteners to 30-40 ft-lbs (40.7-
54.3 Nm)
7. Install the left hand and right hand handgrips and hand
controls. See 2.11 HANDGRIPSANDHANDCONTROLS,
Switch Housings and Brackets: Installation.
8. Replace left and right rear view mirror with turn signal
brackets. See 2.11 HANDGRIPSANDHANDCONTROLS,
Turn Signals and Mirrors.
Improperly aligned handlebars or components can contact
the fuel tank when turned to the left or right. Contact with
the fuel tank can cause cosmetic damage. (00372b)
9. Connect handlebar connector housings:
a. Right hand switch housing [22-1]
b. OFF/RUN switch [22-2]
c. TGS [204]
d. Left hand switch housing [24]
10. Replace wire conduits in frame clips and install cable strap.
10
3
4
9
1
8
5
7
6
2
sm04599c
1. Handlebar clamp
2. Fastener (4)
3. Lower handlebar clamp
4. Upper cup washer (2)
5. Bushing (2)
6. Spacer (2)
7. Lower bushing (2)
8. Lower cup washer (2)
9. Washer (2)
10. Lower handlebar clamp fastener (2)
Figure 2-17. Handlebar Assembly
Return to Service
1. Slide fuel tank forward and replace fuel tank fasteners,
vent, fuel supply fitting. See the service manual.
HOME
2. Install negative battery cable to battery.
After installing seat, pull upward on seat to be sure it is
locked in position. While riding, a loose seat can shift
causing loss of control, which could result in death or
serious injury. (00070b)
3. Install seat.
After servicing brakes and before moving motorcycle,
pump brakes to build brake system pressure. Insufficient
pressure can adversely affect brake performance, which
could result in death or serious injury. (00279a)
4. Test front brake lever and clutch lever for pressure and
operation.
5. Test ride motorcycle.
HOME
2.13 REAR FENDER
REMOVAL
1. Remove seat.
ceeding. (00251b)
2. Remove main fuse.
3. Disconnect rear lighting harness connector housings:
a. Right turn signal [18]
b. License plate/running lamp [40]
c. Left turn signal [19]
4. See Figure 2-18. Remove fasteners (6). Lift fender from
frame.
5. If replacing fender, perform the following steps:
a. Remove rear lighting. See 7.6 TURN SIGNALS.
b. Remove fasteners (1), fender supports (2) and
brackets (4).
4
5
3
2
1
6
sm06794c
4. 1. Bracket (4) Fastener (8)
2. 5. Fender support (2) Retainer bracket (HDI, Canada) (1)
6. 3. Fastener (4) Retention pad (8)
Figure 2-18. Rear Fender
HOME
INSTALLATION
28.5-36.6 Nm 21-27 ft-lbs Rear fender support to fender
40.7-47.5 Nm 30-35 ft-lbs Rear fender support to frame
fasteners: 1st torque
51.6-57.0 Nm 38-42 ft-lbs Rear fender support to frame
fasteners: final torque
1. If fender was replaced, perform the following steps.
a. Install rear lighting. See 7.6 TURN SIGNALS.
NOTE
HDI and Canada Markets: install retainer bracket (5)
between front left bracket (4) and fender.
b. Install fender supports (2) with brackets (4) and
fasteners (1). Tighten outer fasteners first then inner
fasteners last to 21-27 ft-lbs (28.5-36.6 Nm).
2. Install rear fender using fasteners (6). Tighten fasteners
to 30-35 ft-lbs (40.7-47.5 Nm) then loosen.
3. Final tighten fasteners (6) to 38-42 ft-lbs (51.6-57.0 Nm).
4. Connect rear lighting harness connector housings:
a. Right turn signal [18]
b. License plate/running lamp [40]
c. Left turn signal [19]
5. Install main fuse.
6. Install seat.
7. Check turn signal and tail lamp operation.
HOME
2.14 ABS HYDRAULIC CONTROL UNIT (HCU)
FRONT HCU
13.6-16.3 Nm 120-144
in-lbs
HCU banjo bolts
Removal
1. Remove the nacelle. See 2.22 HEADLAMP NACELLE.
2. Drain the front brake fluid lines. See the service manual.
NOTE
Plug open HCUports and seal banjo fittings to prevent leakage
and contamination.
3. See Figure 2-19. Remove the banjo bolts (1, 3) from the
HCU. Discard the sealing washers (2, 4).
4. Disconnect the HCU connector [254] housing from the
HCU.
5. See Figure 2-20. Remove fasteners (4) and front HCU
(2).
2
1
2
4
4
3
sm07059b
1. Banjo bolt (small)
2. Sealing washer (small ID)
3. Banjo bolt (large)
4. Sealing washer (large ID)
Figure 2-19. Front ABS Lines
4
1
2
3
6
5
sm07677
1. Fastener (2)
2. Front HCU
3. Bracket
4. Fastener (2)
5. Fastener (2)
6. Bracket
Figure 2-20. Front HCU Brackets
Installation
1. See Figure 2-20. If removed, install HCU bracket (6) with
fasteners (1). Tighten to 8-12 ft-lbs (10.9-16.3 Nm).
2. If removed, install HCU bracket (3) with fasteners (5).
Tighten to 96-120 in-lbs (10.9-13.6 Nm).
3. Install HCU (2) with the fasteners (4). Tighten to 24-36
in-lbs (2.7-4.0 Nm).
4. Connect HCU connector [254] housing to HCU.
NOTE
The MCand CAL banjo bolts and sealing washers are different
sizes.
5. See Figure 2-19. Install large master cylinder brake fluid
line banjo bolt (3) with new large ID sealing washers (4)
to HCU port marked MC.
6. Install the small caliper brake fluid line banjo bolt (1) with
newsmall ID sealing washers (2) to the HCU port marked
CAL.
7. Tighten banjo bolts to 120-144 in-lbs (13.6-16.3 Nm).
8. Install the nacelle. See 2.22 HEADLAMP NACELLE.
HOME
When any hydraulic brake component, line or connection
is loosened or replaced on an ABS motorcycle, Digital
Technician II must be used during the brake bleeding
procedure to verify all air is removed from the system.
Failure to properly bleed the brake systemcould adversely
affect braking, which could result in death or serious injury.
(00585c)
9. Fill and bleed the front brake fluid lines. See the service
manual.
10. To confirm that the brakes are connected and the air is
completely purged, install the master cylinder reservoir
covers, connect the motorcycle to DIGITAL TECHNICIAN
II (Part No. hd-48650) and perform the "ABS Service"
procedure.
After servicing brakes and before moving motorcycle,
pump brakes to build brake system pressure. Insufficient
pressure can adversely affect brake performance, which
After repairing the brake system, test brakes at lowspeed.
If brakes are not operating properly, testing at high speeds
can cause loss of control, which could result in death or
serious injury. (00289a)
HOME
2.15 CLUTCHMASTERCYLINDERANDRESERVOIR
REMOVAL
1. Loosen left handlebar switch housing fasteners. See ser-
vice manual.
2. See Figure 2-21. Loosen, but do not remove, fasteners
(11) that secure handlebar clamp (10) to clutch master
cylinder (4).
3. Loosen both cover screws (13) to relieve pressure in
master cylinder/reservoir.
CHILDREN. (00240a)
Be sure no clutch fluid gets on tires, wheels or brakes
when draining fluid. Traction can be adversely affected,
which could result in loss of control and death or serious
injury. (00295a)
(00239b)
Do not wipe any spilled brake fluid off of finished surfaces.
Always flush the affected components with clean water.
NOTE
Place a cup under the banjo fitting. Hydraulic fluid will begin
draining from the reservoir as the banjo bolt is removed.
4. Slowly loosen banjo bolt (7) and allow clutch fluid from
reservoir to drain into cup.
5. Remove banjo bolt. Discard two steel/rubber washers (6).
NOTE
To prevent the rest of the clutch fluid from draining from the
clutch line and secondary clutch actuator, support the banjo
fitting and clutch fluid line upright.
6. Remove master cylinder clamp screws and remove clutch
master cylinder/reservoir assembly.
11
9
8
12
14
13
16
15
2
1
4
3
5
7
6
10
sm07697
1. Clutch hand lever
2. Bushing
3. Retaining ring
4. Master cylinder
5. Clutch fluid line
6. Steel/rubber washers
7. Banjo bolt
8. Sight glass
9. Washer
10. Clamp
11. Clamp screw
12. Gasket
13. Cover screw
14. Cover
15. Pivot pin
16. Rebuild kit
Figure 2-21. Clutch Master Cylinder Assembly
DISASSEMBLY
NOTE
Thoroughly clean cover before removal. This prevents system
contamination.
1. Remove cover and gasket. Turn housing upside down to
remove remaining clutch fluid from reservoir.
Wear safety glasses or goggles when removing or
installing retaining rings. Retaining rings can slip fromthe
pliers and could be propelled with enough force to cause
serious eye injury. (00312a)
HOME
2. Remove clutch hand lever. See 2.16 CLUTCH HAND
LEVER.
3. See Figure 2-22. Using a toothpick or small screwdriver,
gently pry outer edge of piston boot (1) out of piston bore.
4. Remove piston (2) and spring (4).
CHILDREN. (00240a)
D.O.T. 4 hydraulic brake fluid is used in the hydraulic
clutch. Do not use other types of fluids as they are not
compatible and could cause equipment damage. (00353a)
(00239b)
1
7
5
4
2
3
8
6
sm04960
1. Boot
2. Piston
3. Shoulder
4. Spring
5. Primary cup
6. Groove - primary cup
7. Secondary cup
8. Groove - secondary cup
Figure 2-22. Clutch Master Cylinder Components
CLEANING AND INSPECTION
Use denatured alcohol to clean brake systemcomponents.
Do not use mineral-based solvents (such as gasoline or
paint thinner), which will deteriorate rubber parts even
after assembly. Deterioration of these components can
cause brake failure, which could result in death or serious
injury. (00291a)
Compressed air can pierce the skin and flying debris from
compressed air could cause serious eye injury. Wear
safety glasses when working with compressed air. Never
use your hand to check for air leaks or to determine air
flow rates. (00061a)
HOME
1. Clean all parts with denatured alcohol. Wipe dry with a
clean, lint free cloth.
2. Inspect banjo seating surface for scratches or nicks.
3. Verify that reservoir is completely free of dust, dirt or
residue.
4. Using a clean air supply, blow out piston bore and other
drilled passages. Do not use a wire or similar instrument.
5. Inspect piston bore for scratches, nicks, scoring, pitting,
corrosion or other damage.
6. Inspect retaining ring for wear or distortion. Inspect
retaining ring groove for damage.
7. Inspect piston seals, dust boot and reservoir cover gasket
for damage.
ASSEMBLY
To rebuild clutch master cylinder, use the components found
in the service parts kit.
1. See Figure 2-22. Using lubricant in the service parts kit,
lightly lubricate inside of primary cup (5) and fit over lip on
spring end of piston (2) so the closed end (small ID) con-
tacts evenly with the shoulder (3) in primary cup groove
(6).
2. Lightly lubricate inside of secondary cup (7) (steep taper
from center to outside diameter) and fit over the lip on
outboard end of piston so that flared end is open toward
the shoulder of the secondary cup groove (8).
3. Install boot (1), large sealing ID first, on piston until seal
on smaller ID fits snugly into thin groove in piston.
4. Using lubricant in service parts kit, thoroughly coat outside
diameters of primary and secondary cups. Coat master
cylinder piston bore.
5. See Figure 2-23. With tapered end out, install spring into
opening on inboard side of piston assembly.
6. Align and install piston assembly into bore. Firmly press
on flat end of piston, compressing spring, until the entire
assembly slides into cylinder bore.
NOTE
Do not damage piston sealing boot during installation.
7. Compress piston until it is even with the end of bore. Using
a small dull bladed screwdriver or similar tool, gently work
around sealing edges of boot until entire circumference
of boot is seated in cylinder bore groove.
8. Replace cover gasket if necessary.
a. Pull rubber gasket from cover.
b. Fit nipple of new gasket into hole of cover aligning
gasket and cover thru holes.
9. Replace sight glass gasket if necessary.
a. From inboard side, push sight glass toward the out-
side of the reservoir until free.
b. Pull rubber gasket from sight glass.
c. Fit sight glass into new gasket.
d. Push flat end of sight glass through reservoir until top
of glass is flush with top of gasket. Verify that glass
is square in bore. If lubrication is necessary, use clean
DOT 4 BRAKE FLUID.
10. Install cover with gasket on master cylinder reservoir.
Install two screws to fasten the cover to reservoir, but do
not tighten.
11. Install clutch hand lever. See 2.16 CLUTCH HAND
LEVER.
2
3
1
sm02046
1. Boot in piston groove
2. Secondary cup flare
3. Primary cup
Figure 2-23. Assembled Cups and Piston
INSTALLATION
8.1-12.2 Nm 72-108 in-lbs Clutch master cylinder clamp
fastener
4.0-5.1 Nm 35-45 in-lbs Handlebar switch housing
screw
23.0-29.8 Nm 17-22 ft-lbs Clutch master cylinder banjo
bolt
1. See Figure 2-24. Attach master cylinder/reservoir to
handlebar.
a. Orient lever to rider position.
b. Verify clamping surface joint (1) is within range marks
(2) in handlebar.
c. Tighten clamp fasteners to 72-108 in-lbs (8.1-12.2
Nm).
HOME
2. Tighten handlebar switch housing screws to 35-45 in-lbs
(4.0-5.1 Nm).
Avoid leakage. Be sure gaskets, banjo bolt(s) and clutch
line are clean and undamaged before assembly. (00329a)
3. Attach banjo fitting to master cylinder using new
steel/rubber washers. Tighten banjo bolt. Refer to
Table 2-7.
Table 2-7. Banjo Bolt Torque Specification
TORQUE MODEL
17-22 ft-lbs (23.0-29.8 Nm). Softail CVO
4. Fill and bleed clutch system. See 2.18 BLEEDING
CLUTCH FLUID LINE.
5. Verify operation by squeezing clutch hand lever.
6. Tighten reservoir cover screws to 12-15 in-lbs (1.4-1.7
Nm).
1
2
2
sm04496a
1. Clamping surface
2. Range marks
Figure 2-24. Right Hand Control Assembly to Handlebar
Alignment
HOME
2.16 CLUTCH HAND LEVER
REMOVAL
ceeding. (00251b)
1. Remove the main fuse.
2. See Figure 2-25. Remove the retaining ring (1) from the
pivot pin (2).
3. Remove pivot pin and lever.
4. Disassemble roller pin (3) and bushing cups (4).
5. Remove pivot bushing (5).
3
5
1
4
2
sm03994
1. Retaining ring
2. Pivot pin
3. Roller pin
4. Bushing cups
5. Pivot bushing
Figure 2-25. Clutch Hand Lever
INSTALLATION
1. See Figure 2-25. Slide bushing cups onto pins of roller
(3).
NOTE
Be careful when handling the bushing cups. The bushing cups
are hard plastic and easily damaged.
2. With connector bow portion of the bushing cups parallel
with groove in clutch handle, snap roller pin and bushing
cups into clutch lever roller groove. Roller/bushing
assembly will install with a snap and will be held securely.
3. Lightly grease pivot bushing (5) and install into clutch hand
lever pivot hole. Position bushing until it is flush with both
sides of lever.
NOTE
If the clutch master cylinder/reservoir is full of clutch fluid under
pressure, it may be necessary to apply force to the hydraulic
piston in order to align the clutch hand lever and to allow the
pivot pin to be inserted.
4. Orient clutch lever in lever mounting bracket. Insert pivot
pin from top.
5. Install new retaining ring on pivot pin.
7. Verify clutch lever operation.
HOME
2.17 CLUTCH FLUID LINE
REPLACEMENT
6.8-10.8 Nm 60-96 in-lbs Clutch fluid line clamp fastener
3.4-4.5 Nm 30-40 in-lbs Clutch fluid line P-clamp screw
23.0-29.8 Nm 17.0-22.0 ft-
lbs
Clutch master cylinder banjo
bolt
10.9-16.3 Nm 96-144 in-lbs Clutch fluid line flare nut
Removal
when adding fluid. Traction can be adversely affected,
injury. (00294a)
(00239b)
Do not wipe any spilled brake fluid off of finished
surfaces. Always flush the affected components with
plenty of clear water without soap.
NOTE
Dispose of clutch fluid in accordance with local regulations.
1. Disconnect and drain clutch fluid line. See 2.18 BLEEDING
CLUTCH FLUID LINE.
NOTE
Clutch fluid line O-ring may stick to inside of secondary clutch
actuator. Use a non-metallic pick to remove.
2. See Figure 2-26. Remove and discard fluid line O-ring.
3. Disconnect banjo fitting from clutch reservoir and master
cylinder. Discard washers.
4. Remove two clamps along frame down tubes.
5. Remove fluid line from P-clamp.
6. Remove clutch fluid line.
Installation
1. Loosely secure line to clutch master cylinder using banjo
bolt and new washers.
2. See Figure 2-27. Route clutch fluid line through clamps
(1, 2) to secondary clutch actuator. Tighten clamp (1)
fastener to 60-96 in-lbs (6.8-10.8 Nm).
3. Install newO-ring on end of clutch fluid line. Loosely install
flare nut to secondary clutch actuator.
4. Secure line in P-clamp (3). Tighten to 30-40 in-lbs (3.4-
4.5 Nm).
5. Tighten banjo bolt to 17.0-22.0 ft-lbs (23.0-29.8 Nm).
6. Tighten flare nut to 96-144 in-lbs (10.9-16.3 Nm).
7. Fill and bleed clutch fluid system. See 6.3 TRANSMISSON
SIDE COVERS.
3
5
4
1
2
6
sm07667
1. Bleeder valve and cap
3. O-ring
4. Screw
5. Secondary clutch actuator
6. O-ring
Figure 2-26. Secondary Clutch Actuator
1
2
3
sm07668
1. Upper clamp
2. Lower clamp
3. P Clamp
Figure 2-27. Clamp Locations
HOME
2.18 BLEEDING CLUTCH FLUID LINE
DRAIN AND FILL
SNAP-ON BASIC VACUUM BRAKE
BLEEDER
BB200A
when adding fluid. Traction can be adversely affected,
injury. (00294a)
CHILDREN. (00240a)
(00239b)
Never wipe spilled brake fluid off of finished surfaces.
Always flush the affected components with clean
water.
Drain
1. See Figure 2-28. Remove outer transmission side cover
(7).
2. Place a pan under the secondary clutch actuator (6) to
catch excess clutch fluid.
3. Remove plastic cap (9) and loosen bleeder valve (8).
4. Run hose from bleeder valve to pan.
5. Loosen the clutch master cylinder/reservoir cover (1).
6. Allow clutch fluid to drain into pan.
7. Hand-tighten bleeder valve and replace cap.
Fill
NOTE
When filling an empty clutch fluid line, a SNAP-ON BASIC
VACUUM BRAKE BLEEDER (Part No. BB200A) connected
to the bleeder valve can be used for initial bleeding.
1. Fill clutch master cylinder/reservoir with DOT 4 BRAKE
FLUID. Initial fluid level should not exceed FILL LEVEL
with reservoir in a level position.
NOTE
The shelf life of an unopened bottle of DOT 4 BRAKE FLUID
is one year. Discard any opened bottle after one week.
2. Bleed clutch fluid line and secondary clutch actuator. See
2.18 BLEEDING CLUTCH FLUID LINE, Bleed Fluid Line
and Secondary Clutch Actuator.
HOME
10
5
1
8 2
4
3
7
9
6
sm07698
6. 1. Secondary clutch actuator Cover
2. 7. Clutch master cylinder Outer transmission side cover
8. 3. Bleeder valve Clutch hand lever
4. 9. Clutch fluid line Bleeder cap
10. 5. Banjo bolt Clutch line fitting w/O-ring
Figure 2-28. Clutch Hydraulics
BLEED CLUTCH MASTER CYLINDER
NOTE
Do NOT overfill clutch reservoir. Clutch fluid volume in reservoir
increases with clutch wear. Overfilling can lead to damaged
seals resulting in damage to clutch system.
1. Stand motorcycle upright. Turn handlebar to level reser-
voir.
2. See Figure 2-28. Add DOT 4 BRAKE FLUID to clutch
master cylinder/reservoir (2). Initial fluid level should not
exceed FILL LEVEL with reservoir in a level position.
NOTE
The shelf life of an unopened bottle of DOT 4 BRAKE FLUID
is one year. Discard any opened bottle after one week.
(00239b)
Never wipe spilled brake fluid off of finished surfaces.
Always flush the affected components with clean
water.
NOTE
Loosen banjo bolt only enough to allow air bubbles to escape.
Clutch fluid under pressure can squirt a steady stream several
feet.
3. While holding reservoir cover (1) in place:
a. Pump clutch hand lever (3) 5 times.
b. Hold clutch hand lever against handlebar.
c. Hold shop towel under fitting and loosen master cyl-
inder banjo bolt (10).
d. Watch banjo fitting for air bubbles.
e. Tighten banjo fitting.
f. Release hand lever.
4. With reservoir level, fill reservoir to FILL LEVEL.
5. Repeat bleed procedure three times or more until only a
steady flow of clutch fluid escapes banjo fitting.
6. Verify reservoir is at FILL LEVEL with reservoir level. Fill
as necessary.
BLEED FLUID LINE AND SECONDARY
CLUTCH ACTUATOR
3.5-4.6 Nm 31-41 in-lbs Secondary clutch actuator
bleeder valve
11.2-13.6 Nm 100-120
in-lbs
Outer transmission cover
screws
1. Stand motorcycle upright. Turn handlebar to level reser-
voir.
2. See Figure 2-28. Add DOT 4 BRAKE FLUID to clutch
master cylinder/reservoir (2). Initial fluid level should not
exceed FILL LEVEL with reservoir in a level position.
HOME
3. While holding reservoir cover (1) in place:
a. Pump clutch hand lever (3) 5 times.
b. Hold clutch hand lever against handlebar.
c. Remove bleeder cap (9) and run hose from bleeder
valve (8) to suitable container.
d. Loosen bleeder valve.
e. Watch bleeder valve for air bubbles.
f. Tighten bleeder valve.
g. Release clutch hand lever.
NOTE
Clutch fluid volume in reservoir actually increases with clutch
wear. Do NOT overfill clutch reservoir.
4. With reservoir level, fill reservoir to FILL LEVEL.
5. Repeat bleed procedure three times or more until only a
steady flow of clutch fluid escapes bleeder valve.
6. Tighten bleeder valve to 31-41 in-lbs (3.5-4.6 Nm).
7. Verify reservoir is at FILL LEVEL with reservoir level. Fill
as necessary.
8. Tighten reservoir cover screws to 12-15 in-lbs (1.4-1.7
Nm).
9. Measure release plate movement. See 5.4 CLUTCH
RELEASE BEARING AND PUSH ROD.
10. Install outer transmission side cover. Tighten to 100-120
in-lbs (11.2-13.6 Nm).
11. Test ride motorcycle. Incorrect pressure or fluid level can
cause a dragging clutch or hard shifting.
HOME
2.19 SHIFTER PEG
DISASSEMBLY
See Figure 2-29. Remove screw(1), shifter peg assembly, and
washer (4).
ASSEMBLY
16.3-19.0 Nm 12-14 ft-lbs Shifter peg screw
See Figure 2-29. Install washer (4) and shifter peg assembly
with screw (1). Tighten screw to 12-14 ft-lbs (16.3-19.0 Nm).
2
1
3
4
5
sm04603b
1. Screw
2. Shifter peg
3. Spacer
4. Lockwasher
5. Shifter lever
Figure 2-29. Shifter Peg
HOME
2.20 REAR FORK PIVOT COVERS
REPLACEMENT
6.8-9.5 Nm 60-84 in-lbs Rear fork pivot cover set
screws
1. See Figure 2-30. Loosen but do not remove set screw
under cover. Remove cover.
2. Remove set screw from cover.
3. Liberally apply LOCTITE 262 HIGH STRENGTH
THREADLOCKERANDSEALANT (Red) to threads of set
screw. Loosely install in cover.
4. Install cover with set screw facing down.
5. Tighten set screw to 60-84 in-lbs (6.8-9.5 Nm).
6. Repeat for opposite side.
sm04606b
Figure 2-30. Pivot Cover
HOME
2.21 SEAT
REPLACEMENT
Removal
1. See Figure 2-31. Remove thumbscrew(1) at rear of pillion.
2. Slide pillion rearward to remove.
3. Remove two fasteners (4).
4. Lift rear of seat up and slide rearward to remove.
5. If necessary, remove grabstrap (5).
Installation
1. See Figure 2-31. Insert tang at front of seat into the
channel in the frame.
2. If removed, replace grab strap (5), then install rear of seat
over mounting studs. Install seat fasteners (4) and tighten.
3. Slide notches in front of seat pillion into grooves of
fasteners.
4. Secure pillion with thumbscrew (1).
3
2
1
5
4
sm04610d
1. Thumbscrew
2. Emblem
3. Washer
4. Fastener
5. Fastener and washer
6. Grabstrap
Figure 2-31. Seat
HOME
2.22 HEADLAMP NACELLE
REMOVAL
1. See Figure 2-32. Remove fasteners (1), clamp (2) and left
and right nacelles (3, 6).
2. Remove headlamp. See 7.2 HEADLAMP.
3. Pull front nacelle (4) away from forks.
INSTALLATION
9.0-11.3 Nm 80-100 in-lbs Nacelle bracket fasteners
10.9-13.6 Nm 96-120 in-lbs Nacelle fasteners
1. See Figure 2-32. If nacelle brackets were removed, install
brackets and fasteners (5). Tighten to 80-100 in-lbs (9.0-
11.3 Nm).
2. Attach front nacelle (4) to nacelle brackets.
3. Install headlamp. See 7.2 HEADLAMP.
4. Install left and right nacelles (3, 6), clamp (2) and fasteners
(1). Tighten to 96-120 in-lbs (10.9-13.6 Nm).
6
5
1 2
4
3
sm07043b
1. Fastener (2)
2. Clamp
3. Left nacelle
4. Center nacelle
5. Nacelle bracket fasteners (2)
6. Right nacelle
Figure 2-32. Nacelle Assembly
HOME
NOTES
TABLE OF CONTENTS
SUBJECT............................................................................................................................PAGE NO.
3.2 SPECIFICATIONS: ENGINE......................................................................................................3-2
3.3 SERVICE WEAR LIMITS...........................................................................................................3-4
3.4 TROUBLESHOOTING...............................................................................................................3-6
3.5 INSTALLING ENGINE IN CHASSIS..........................................................................................3-8
3.6 CYLINDER HEAD....................................................................................................................3-10
3.7 PISTONS.................................................................................................................................3-21
3.8 BORING AND HONING CYLINDERS.....................................................................................3-22
3.9 CRANKCASE ASSEMBLY......................................................................................................3-25
3.10 OIL TANK...............................................................................................................................3-28
E
N
G
I
N
E
NOTES
CHAPTER
in this chapter.
3.6 CYLINDER HEAD, Assembly/Apply three
equally spaced dots of LOCTITE 243 MEDIUM
STRENGTH THREADLOCKER AND SEALANT
(blue) around lower third of threads
14.9-20.3 Nm 131-180 in-lbs Automatic compression release (ACR)
3.9 CRANKCASE ASSEMBLY, Assembly 13.6 Nm 120 in-lbs Crankcase bolts, 1st torque
3.9 CRANKCASE ASSEMBLY, Assembly 20.3-25.8 Nm 15-19 ft-lbs Crankcase bolts, final torque
3.8 BORING AND HONING CYLINDERS, Inspec-
tion
13.6-16.3 Nm 120-144 in-lbs Cylinder bolts, 1st torque
tion/See procedure for properly marking bolts
before turning 90 degrees.
20.3-23.1 Nm
plus 90 degrees
15-17 ft-lbs plus
90 degrees
Cylinder bolts, final torque
3.5 INSTALLINGENGINEINCHASSIS, Procedure 47.5-54.2 Nm 35-40 ft-lbs Cylinder head bracket bolts
3.10 OIL TANK, Installation 4.1-6.8 Nm 36-60 in-lbs Electrical panel fastener
3.5 INSTALLINGENGINEINCHASSIS, Procedure 40.7-47.5 Nm 30-35 ft-lbs Engine/transmission bracket bolts
3.5 INSTALLINGENGINEINCHASSIS, Procedure 61.0-67.8 Nm 45-50 ft-lbs Engine mount bolt, top
3.5 INSTALLINGENGINEINCHASSIS, Procedure 27.1-33.9 Nm 20-25 ft-lbs Engine mount bracket nuts, top
3.5 INSTALLINGENGINEINCHASSIS, Procedure 94.9-108.5 Nm 70-80 ft-lbs Engine mounting bolts, front
3.10 OIL TANK, Installation 16.3-20.3 Nm 12-15 ft-lbs Oil tank bolts
3.5 INSTALLINGENGINEINCHASSIS, Procedure 122-149.1 Nm 90-110 ft-lbs Pivot shaft nut
3.10 OIL TANK, Installation 4.1-6.8 Nm 36-60 in-lbs Splash guard fasteners
3.5 INSTALLINGENGINEINCHASSIS, Procedure 20.3 Nm 15 ft-lbs Transmission mounting bolts, 1st torque
3.5 INSTALLINGENGINEINCHASSIS, Procedure 46.1-52.9 Nm 34-39 ft-lbs Transmission mounting bolts, final torque
HOME
2013 FXSBSE Service Supplement: Engine 3-1
3.2 SPECIFICATIONS: ENGINE
GENERAL
NOTE
This chapter provides unique information for models equipped
with Twin-Cam 110 engines.
Table 3-1. Engine: Twin-Cam 110
SPECIFICATION ITEM
2 Number of cylinders
4-cycle, 45 degree
V-Type, air cooled
Type
4.000 in. (101.60 mm) Bore
4.375 in. (111.13 mm) Stroke
110 cu. in. (1800 cc) Piston displacement (approx.)
9.15:1 Compression ratio
Twin cams, chain driven with
hydraulic tensioners
Cam system
5500 RPM Max. sustained engine speed
1000 RPM 50 Idle speed
Table 3-2. Oiling System
SPECIFICATION ITEM
3.5 qt (3.3 L) Oil tank capacity
with filter
SYN3 20W50 Preferred oil
Twin gerotor, dual scavenge, crank
mounted and driven, internal oil pump,
dry sump
Pump
30-38 psi (207-262 kN/m
2
) at 2000 RPM
and normal operating temperature of 230
F (110 C)
Pressure
5 micron media, filtered between pump
and engine
Filtration
MANUFACTURING TOLERANCES
See the service manual for any specification not shown in the
following tables.
Table 3-3. Rocker Arms Specifications
MM IN ROCKER ARMS
0.013-0.051 0.0005-0.0020 Shaft fit in bushing (loose)
0.08-0.33 0.003-0.013 End clearance
0.051-0.102 0.002-0.004 Bushing fit in rocker arm(tight)
Table 3-4. Rocker Arm Shaft Specifications
MM IN ROCKER ARM SHAFTS
0.018-0.056 0.0007-0.0022 Shaft fit in rocker arm support
plate (loose)
Table 3-5. Hydraulic Lifter Specifications
MM IN HYDRAULIC
LIFTERS
0.002-0.066 0.0009-0.0026 Fit in crankcase
(loose)
Table 3-6. Cylinder Heads
MM IN ITEM
0.051-0.084 0.0020-0.0033 Valve guide in head
(tight)
0.102-0.140 0.004-0.0055 Intake valve seat in
head (tight)
0.102-0.140 0.004-0.0055 Exhaust valve seat
in head (tight)
0.0-0.0152 0.0-0.006 Head gasket sur-
face (flatness)
Table 3-7. Valves
MM IN ITEM
0.028-0.074 0.0011-0.0029 Fit in guide (intake
and exhaust)
0.86-1.57 0.034-0.062 Seat width
50.55-51.41 1.990-2.024 Stem protrusion
from cylinder head
boss
Table 3-8. Valve Springs Specifications
DIMENSION PRESSURE ITEM
1.800 in (45.7 mm) 175 lbs (79 kg) Closed
1.250 in (31.8 mm) 432 lbs (196 kg) Open
2.210 in (56.1 mm) n/a Free length
HOME
3-2 2013 FXSBSE Service Supplement: Engine
Table 3-9. Piston: Twin Cam 110
MM IN ITEM
0.046-0.069 0.0018-0.0027 Fit in cylinder
0.013-0.023 0.0005-0.0009 Piston pin fit (loose)
Ring end gap:
0.406-0.610 0.016-0.024 Top compression ring
0.356-0.559 0.014-0.022 2nd compression ring
0.254-0.762 0.010-0.030 Oil control ring
Ring side clearance:
0.025-0.061 0.00098-0.0024 Top compression ring
0.025-0.061 0.00098-0.0024 2nd compression ring
0.051-0.102 0.002-0.004 Oil control ring
Table 3-10. Connecting Rods
MM IN ITEM
0.015-0.030 0.0006-0.0012 Piston pin fit (loose)
0.13-0.38 0.005-0.015 Side play between fly-
wheels
0.0102-0.0432 0.0004-0.0017 Connecting rod to
crankpin (loose)
Table 3-11. Flywheel Specifications
MM IN FLYWHEELS
0.0-0.254 0.000-0.010 Runout (shaft measured
in case)
0.0-0.102 0.000-0.004 Runout (measured in
truing stand)
0.076-0.330 0.003-0.013 End play
Table 3-12. Crankshaft/Sprocket Shaft Bearing
Specifications
MM IN CRANK-
SHAFT/SPROCKET
SHAFT BEARINGS
0.005-0.038 0.0002-0.0015 Roller bearing fit (loose)
0.097-0.137 0.0038-0.0054 Bearing fit in crankcase
(tight)
0.010-0.036 0.0004-0.0014 Bearing inner race on
crankshaft (tight)
HOME
3.3 SERVICE WEAR LIMITS
GENERAL
Wear limits can be used as a guide when deciding whether to
reuse engine parts. Replace used parts whenever the following
wear limits are exceeded.
NOTE
See the service manual for any specification not shown in the
following tables.
Table 3-13. Rocker Arm/Rocker Arm Shaft
REPLACE IF WEAR EXCEEDS ROCKERARM/ROCKER
ARM SHAFT
MM IN
0.089 0.0035 Shaft fit in bushing (loose)
0.635 0.025 End clearance
0.089 0.0035 Shaft fit in rocker arm
support (loose)
Table 3-14. Hydraulic Lifters
REPLACE IF WEAR EXCEEDS ITEM
MM IN
0.08 0.003 Fit in crankcase
0.038 0.0015 Roller fit
0.38 0.015 Roller end clearance
Table 3-15. Cylinder Heads
REPLACE IF ITEM
MM IN
Less than 0.051 Less than 0.002 Valve guide (tight)
(intake and
exhaust)
Less than 0.102 Less than 0.004 Intake seat (tight)
Less than 0.102 Less than 0.004 Exhaust seat (tight)
Greater than 0.152 Greater than 0.006 Head warpage
Table 3-16. Cylinder
REPLACE IF WEAR EXCEEDS CYLINDER
MM IN
0.051 0.002 Taper
0.051 0.002 Out of round
0.152 0.006 Warpage of gasket sur-
faces: top
0.102 0.004 Warpage of gasket or O-
ring surfaces: base
Table 3-17. Cylinder Bore
REPLACE IF WEAR EXCEEDS ITEM
MM IN
101.65 4.002 Standard
101.78 4.007 0.005 in. oversize
101.90 4.012 0.010 in. oversize
Table 3-18. Pistons
REPLACE IF
WEAR EXCEEDS
ITEM
MM IN
0.076 0.003 Fit in cylinder (loose)
0.023 0.0009 Piston pin fit (loose)
0.864 0.034 Top compression Ring end gap
0.813 0.032 2nd compression
0.762 0.030 Oil control ring rails
0.081 0.0032 Top compression Ring side clearance
0.081 0.0032 2nd compression
0.102 0.004 Oil control ring rails
Table 3-19. Flywheel
REPLACE IF WEAR EXCEEDS FLYWHEEL
MM IN
0.305 0.012 Runout (shaft measured
in case)
0.127 0.005 Runout (measured in
truing stand)
0.330 0.013 End play
Table 3-20. Crankshaft Roller Bearing
REPLACE IF ITEM
MM IN
More than
0.038
More than
0.0015
Roller bearing fit (loose)
More than
0.076
More than
0.003
Crankshaft runout
Less than
0.097
Less than
0.0038
Bearing fit in crankcase (tight)
Less than
0.010
Less than
0.0004
Inner race on crankshaft (tight)
HOME
Table 3-21. Breather Assembly
REPLACE IF WEAR
EXCEEDS
BREATHER ASSEMBLY
MM IN
0.13 0.005 Breather cover warpage
0.13 0.005 Breather baffle warpage
HOME
3.4 TROUBLESHOOTING
COMPRESSION TEST
CYLINDER COMPRESSION GAUGE HD-33223-1
A compression test can determine the source of cylinder
leakage. Use CYLINDER COMPRESSION GAUGE (Part
No. HD-33223-1) with a screw-in type adapter.
NOTE
The Twin Cam 110 Engine uses a 12 mm adapter with the
compression gauge.
1. Operate engine to normal operating temperature.
2. Disconnect spark plug wires, clean around plug base and
remove plugs.
3. Remove air cleaner cover and filter. See 1.4 AIR FILTER.
4. Connect compression tester to front cylinder per manufac-
turer's instructions.
5. Make sure transmission is in neutral. Crank engine con-
tinuously through 5 to 7 full compression strokes.
6. Note gauge readings at the end of the first and last com-
pression strokes. Record test results.
7. Disconnect the ACR and repeat test.
8. Repeat tests on rear cylinder with and without the ACR
connected.
9. Disconnection of the ACR may set diagnostic trouble
codes. Clear codes when test is complete.
10. Refer to Table 3-22. If the final readings are within specific-
ations and do not indicate more than a 10% variance
between cylinders, compression is considered normal. If
compression does not meet specifications, refer to
Table 3-23.
11. Install air cleaner cover and filter. See 1.4 AIR FILTER.
12. Install spark plugs and connect spark plug wires.
Table 3-22. Compression Specifications
kPa PSI ACR STATUS
896-1173 130-170 ACR connected
1379-1517 200-220 ACR disconnected
Table 3-23. Compression Test Results
DIAGNOSIS TEST RESULTS
-Readings that are con-
siderably higher during
the test after oil was
injected, indicates worn
piston rings.
Compression low on first stroke,
tends to build on the following
strokes, but does not reach specific-
ation. Readings improve consider-
ably when oil is added to cylinder.
Results are similar with ACRdiscon-
nected. Inject approximately 1/2 oz
(15 mL) engine oil into cylinder and
repeat the compression tests.
-Damaged intake or
exhaust valve
-Leaky cylinder head
gasket
-ACR valve stuck open
-Incorrect pushrod
length
Compression low on first stroke,
does not build up much on following
strokes. Does not improve consider-
ably with the addition of oil. Results
are similar with ACR disconnected.
-Faulty ACRsolenoid or
circuit
Compression builds quickly to near
maximum specification. Similar
reading with ACR disconnected.
CYLINDER LEAKDOWN TEST
CYLINDER LEAKDOWN TESTER HD-35667-A
NOTE
On vehicles with automatic compression release (ACR), verify
the ACRs are closed for this test. Perform the test with the
ignition/light switch in the OFF position.
The cylinder leakdown test will help pinpoint leaking valves,
worn, damaged or stuck piston rings and blown head gaskets.
The cylinder leakage tester applies compressed air to the cyl-
inder at a controlled pressure and volume. It then measures
the percent of leakage from the cylinder.
Use the CYLINDER LEAKDOWN TESTER (Part No. HD-
35667-A). Follow the specific instructions supplied with the
tester.
The following are some general instructions that apply to
Harley-Davidson V-twin engines:
1. Run engine until it reaches normal operating temperature.
2. Stop engine. Clean dirt fromaround spark plugs. Remove
the spark plugs.
3. Rotate crankshaft until piston in the cylinder being tested
is at top dead center of compression stroke (both valves
closed) during the test.
4. To keep the engine from turning over when air pressure
is applied to the cylinder, engage transmission in highest
gear and lock the rear brake.
NOTE
Before performing the cylinder leakdown test, verify the tester
itself is free from leakage. Apply a soap solution around all
HOME
tester fittings. Connect cylinder leakdown tester to compressed
air source. Look for any bubbles that indicate leakage fromthe
tester.
5. Following the manufacturer's instructions, perform a cyl-
inder leakdown test on the front cylinder. Make a note of
the percent of leakage. Leakage greater than 10% indic-
ates internal engine problems.
6. Listen for air leaks at throttle body, exhaust pipe and head
gasket. Air escaping through the throttle body indicates a
leaking intake valve. Air escaping through the exhaust
pipe indicates a leaking exhaust valve.
NOTE
If air is escaping through valves, verify that piston is still at TDC
or check for correct pushrod length.
7. Repeat procedure on rear cylinder.
HOME
3.5 INSTALLING ENGINE IN CHASSIS
PROCEDURE
20.3 Nm 15 ft-lbs Transmission mounting bolts,
1st torque
46.1-52.9 Nm 34-39 ft-lbs Transmission mounting bolts,
final torque
122-149.1 Nm 90-110 ft-lbs Pivot shaft nut
94.9-108.5
Nm
70-80 ft-lbs Engine mounting bolts, front
40.7-47.5 Nm 30-35 ft-lbs Engine/transmission bracket
bolts
47.5-54.2 Nm 35-40 ft-lbs Cylinder head bracket bolts
61.0-67.8 Nm 45-50 ft-lbs Engine mount bolt, top
27.1-33.9 Nm 20-25 ft-lbs Engine mount bracket nuts,
top
1. Using a suitable hoist, position engine in chassis from the
right side.
2. Loosely install the front two mounting bolts and spacers
from the right side.
a. The shorter top bolt has a spacer installed on the right
side between the frame and the engine.
b. The longer lower bolt has a spacer on both sides.
Loosely install corresponding washers and nuts.
3. Attach induction module connectors and horn wire.
3
3
2
1
sm07691
1. Nut (3)
2. Upper engine to frame mounting bolt with
washer
3. Cylinder head bracket bolt with washer (2)
Figure 3-1. Top Engine Mount
4. See Figure 3-1. Loosen nuts (1).
5. Loosely install upper engine to frame mounting bolt with
washer (2). Loosely install both cylinder head bracket bolts
with washers (3).
6. If equipped with ACRs, attach ACR connectors.
NOTE
Use newtransmission mounting bolts when installing transmis-
sion case. Do not reuse old bolts.
7. See Figure 3-2. Install transmission case from the right
side. Align all four transmission mounting holes verifying
that the two lower locating dowels engage their holes in
crankcase.
8. Tighten the four transmission mounting bolts in a crosswise
pattern:
a. Tighten finger-tight.
b. Tighten to 15 ft-lbs (20.3 Nm).
c. Tighten to 34-39 ft-lbs (46.1-52.9 Nm).
9. Apply ANTI-SEIZE LUBRICANT to pivot shaft. From the
right side, install pivot shaft and spacers with spacer collars
facing transmission case.
10. Apply LOCTITE262 HIGHSTRENGTHTHREADLOCKER
and SEALANT (red) to pivot shaft nut.
11. Install pivot shaft nut. tighten to 90-110 ft-lbs (122-149.1
Nm).
HOME
12. Apply LOCTITE262 HIGHSTRENGTHTHREADLOCKER
and SEALANT (red) to both front mounting bolts. Tighten
to 70-80 ft-lbs (94.9-108.5 Nm).
13. Install lower bracket (right side). Apply LOCTITE262 HIGH
STRENGTH THREADLOCKER and SEALANT (red).
Tighten bracket bolts to 30-35 ft-lbs (40.7-47.5 Nm).
NOTE
Always tighten the top engine mount hardware in the order
listed below to alleviate stress on the engine mount.
14. Final tighten upper engine mount hardware in the order
below.
a. Tighten two cylinder head bracket bolts to 35-40 ft-
lbs (47.5-54.2 Nm).
b. Tighten the upper engine to frame mounting bolt to
45-50 ft-lbs (61.0-67.8 Nm).
c. Tighten the upper bracket to lower bracket nuts to 20-
25 ft-lbs (27.1-33.9 Nm).
15. Attach throttle cables. Adjust throttle cables. Connect fuel
hose to fuel tank.
16. Install air cleaner backplate and cover. See 4.1 AIR
CLEANER BACKPLATE ASSEMBLY.
17. Install regulator bracket. See service manual.
18. Move the panel into position and tighten the two upper
bolts. Verify that all wiring is in place and not twisted or
kinked.
4
2
1
3
sm02789
Figure 3-2. Transmission Case Hardware
19. Install rear electrical panel. See 7.7 ELECTRICAL PANEL.
NOTE
Replace the gasket between the primary chaincase cover and
chaincase each time the cover is removed. Failure to replace
this gasket could cause primary chaincase leaks.
20. Install primary chaincase. See service manual.
21. Install secondary clutch actuator with fluid line. See
6.4 SECONDARY CLUTCH ACTUATOR.
22. Install the left foot peg.
23. Install the seat post. Connect the coil connector and the
neutral switch wires.
24. Connect VSS to transmission.
25. Install starter. See service manual.
26. Install oil tank and connect all oil lines. See 3.10 OIL
TANK.
27. Install belt guard.
28. Tighten axle nut.
29. Install heat shields, exhaust and right foot peg. See
4.4 EXHAUST SYSTEM.
30. Install instrument console, fuel tank, fuel gauge connector
and fuel tank crossover tube. See service manual.
Connect positive (+) battery cable first. If positive (+) cable
should contact ground with negative (-) cable connected,
the resulting sparks can cause a battery explosion, which
31. Install battery and connect battery cables, positive cable
first.
32. Install seat.
33. Install new oil filter and fill oil tank to proper level. See
service manual.
34. Remove motorcycle from lift.
35. Verify vehicle alignment. See service manual.
36. Check drive belt deflection and alignment. See 1.8 DRIVE
BELT AND SPROCKETS.
37. Check rear brakes, clutch and throttle for proper operation.
38. Check oil level after running motorcycle on sidestand. See
service manual.
HOME
3.6 CYLINDER HEAD
GENERAL
For service wear limits, refer to Table 3-15.
REMOVAL
See service manual for removal of cylinder heads.
NOTE
Separate ACRconnectors fromthe rear [203R] and front [203F]
cylinder heads when removing the heads from the cylinders.
DETERMINING SERVICE
1. With valves installed, raise cylinder head to strong light
source. If light is visible around edges of seats, proceed
to 3.6 CYLINDER HEAD, Disassembly to recondition cyl-
inder head.
2. One at a time, fill each port with solvent. Wait ten seconds
and check for leakage past the valve seats. If solvent
leaks, proceed to 3.6 CYLINDER HEAD, Disassembly to
recondition cylinder head.
sm04036
Figure 3-3. Combustion Chamber
sm04037
Figure 3-4. Spring/Valve Stack and ACR
DISASSEMBLY
VALVE SPRING COMPRESSOR HD-34736-B
CYLINDERHEADHOLDINGFIXTURE HD-39786
ACR SOLENOID SOCKET HD-48498-A
1. Use the ACR SOLENOID SOCKET (Part No. HD-48498-
A) to remove the ACR. See the service manual.
2. See Figure 3-5. Obtain the CYLINDER HEAD HOLDING
FIXTURE (Part No. HD-39786) and proceed as follows:
a. Thread the 12 mm end of the tool into the spark plug
hole of the cylinder head.
b. See Figure 3-6. Clamp tool in vise at a 45 degree
angle (or one that offers a comfortable working posi-
tion).
3. See Figure 3-7. Obtain the VALVE SPRING COM-
PRESSOR(Part No. HD-34736-B) and proceed as follows:
a. Place tool over cylinder head so that the blunt end is
centered on the valve head and adapter at end of
forcing screw is seated on the valve spring retainer.
b. Rotate forcing screw to compress valve springs.
c. If spring retainer has not separated from tapered
keepers, give head of tool a sharp tap with a soft
mallet. Using magnetic rod or small screwdriver,
remove the keepers from the valve stem groove.
d. Rotate forcing screw to release the valve spring
compression.
HOME
4. Remove the spring retainer and inner and outer valve
springs.
5. Slide the valve from the valve guide.
6. Using pliers, twist and remove the valve guide seal from
the top of the valve guide. Discard the valve guide seal.
7. Remove the spring seat from the cylinder head.
8. Mark the bottom of the valve "F(ront)" or "R(ear)" to
indicate the cylinder head from which it was removed.
Also, separate and tag tapered keepers, valve springs,
spring retainers, retaining rings and spring seats so that
they are installed on the same valve at time of assembly.
9. Repeat to remove the other valve.
10. Release the cylinder head holding fixture from the vise
and then remove the tool from the spark plug hole.
2
1
sm04038
1. 14 mm end
2. 12 mm end
Figure 3-5. Cylinder Head Holding Fixture
sm04039
Figure 3-6. Install Cylinder Head Holding Fixture in Vise
2
2
1
sm02495
1. Holding fixture
2. Compressor
Figure 3-7. Valve Spring Compressor
CLEANING
1. Remove old gasket material from cylinder head. Gasket
material left on sealing surfaces will cause leaks.
NOTE
To soften stubborn deposits, soak the cylinder head in a
chemical solution, such as GUNK HYDRO-SEAL or other
carbon and gum dissolving agent.
2. Remove all carbon deposits from combustion chamber
and machined surfaces of cylinder head. For best results,
use an air tool with a worn wire brush. Scraping may result
in scratches or nicks. Avoid removing any metal material.
3. Thoroughly clean all components in a non-volatile cleaning
solution or solvent. Follow up with a thorough wash in hot
soapy water. Blow dry with compressed air.
Do not use glass or sand to bead blast surfaces exposed
to engine oil. Blasting materials can lodge in pores of the
casting. Heat expansion releases this material which can
contaminate oil resulting in engine damage. (00534b)
HOME
NOTES
Use only walnut shells or other soft cleaning materials for
bead blasting.
Cover all threaded holes if bead blasting is used.
5 1
8
9
20
6
27
18
25
19
22
11
3
2
21
26
10
4
14
13
12
7
16
17
15
23
24
24
21
sm04040
15. 1. Cylinder Automatic compression release (ACR)
2. 16. Tapered keepers Ring dowel
17. 3. O-ring seal Spring retainer
4. 18. Outer spring Cylinder stud
19. 5. Piston Inner spring
6. 20. Valve guide seal Piston pin
21. 7. Circlip (2) Spring seat
8. 22. Valve guide Top compression ring
23. 9. Second compression ring Cylinder head bolt, short (2)
10. 24. Cylinder head bolt, long (2) Oil rail
25. 11. Oil rail spacer Cylinder head
12. 26. Valve seat Nameplate
27. 13. Retaining ring Valve
14. Cylinder head gasket
Figure 3-8. Cylinder Head, Cylinder and Piston Assemblies
HOME
INSPECTION
VALVE GUIDE HONE HD-34723
VALVE GUIDE CLEANING BRUSH HD-34751
CYLINDER TORQUE PLATES HD-48627
VALVE SPRING TESTER HD-96796-47
Cylinder Head
1. Check for scratches and nicks on all gasket sealing sur-
faces.
2. Check head for warpage. Discard the head if warpage is
0.006 in. (0.15 mm) or greater.
a. Set a straightedge diagonally across the cylinder head
intersecting the upper and lower corners of the gasket
surface.
b. Slide a feeler gauge beneath the straightedge to
check the head for warpage.
c. Repeat the procedure to check the opposite diagonal.
NOTE
One of the CYLINDERTORQUEPLATES(Part No. HD-48627)
can be used in lieu of the straightedge. Lay the upper plate flat
on the machined surface of the head. As a preliminary check,
see if the plate rocks from side to side. A head on which the
plate rocks is immediately suspect. Insert a feeler gauge
between the plate and head at various locations to see if
warpage exceeds above specification.
3. Verify that oil passageways are open and clean.
Valve Guides
1. Inspect external surfaces for cracks (particularly the com-
bustion chamber side). Replace the guide if any cracks
are found.
2. Lightly hone the guides using the VALVE GUIDE HONE
(Part No. HD-34723). Then scrub with the VALVE GUIDE
CLEANING BRUSH (Part No. HD-34751) to remove any
dust or debris. Polish the valve stem with fine emery cloth
or steel wool to remove carbon buildup. Then check valve
stem to guide clearance as follows:
a. Carefully measure the inside diameter of the valve
guide using an inside ball micrometer.
b. Measure the outside diameter of the valve stem with
an outside micrometer.
c. The clearance is the difference between the two
measurements. The valve stem and/or guide are
excessively worn if the clearance exceeds the limits
shown in Table 3-24. To determine if the guide is
excessively worn and must be replaced, repeat
measurements using a new valve.
Table 3-24. Service Wear Limits
VALVESTEMTOGUIDECLEARANCE VALVE
0.0038 in. (0.0965 mm) Intake
0.0038 in. (0.0965 mm) Exhaust
Valves
1. Replace cracked or burned valves.
2. Inspect the end of the valve stem for pitting or uneven
wear. Replace the valve if either of these conditions are
found.
3. Inspect for burrs around the valve stem keeper groove.
Remove burrs with a fine tooth file if found.
4. To determine if the valve stem is excessively worn, see
VALVE GUIDES above.
Valve Springs
1. Replace springs with cracked or discolored coils.
2. Set the intake and exhaust valve springs on a level sur-
face. Use a straightedge to check for proper squareness
and height.
3. Check free length of inner and outer springs using a dial
vernier caliper or load test with the VALVE SPRING
TESTER (Part No. HD-96796-47). Replace springs if free
length or compression force do not meet specifications.
See 3.2 SPECIFICATIONS: ENGINE.
Tapered Keepers
1. Inspect parts for damage or rust pits. Replace as neces-
sary.
2. Inspect inboard side of tapered keepers for excessive
wear. Upraised center must be pronounced and fit snugly
in valve stemgroove. Place keepers into groove and verify
that they grip tightly without sliding.
Valve Seats
1. Replace cracked, chipped or burned valve seats.
2. Check seats for recession by measuring valve stem pro-
trusion.
HOME
REPLACING VALVE GUIDES
8 MM VALVE GUIDE FLEX HONE HD-34723
VALVE GUIDE AND VALVE GUIDE
SEAL HANDLE
HD-34740
CYLINDER HEAD SUPPORT STAND HD-39782-A
RATCHETING TAP HANDLE HD-39847
VALVE GUIDE REAMER HD-39932
REAMER LUBRICANT HD-39964
VALVE GUIDE INSTALLER HD-46583
Removal
NOTE
The support stand ensures that valve guide and seat are per-
pendicular. If perpendicularity is not achieved, the cylinder
head valve guide bore will be damaged during the press pro-
cedure.
1. See Figure 3-9. Obtain the CYLINDER HEAD SUPPORT
STAND (Part No. HD-39782-A) and proceed as follows:
a. Insert sleeve of intake or exhaust seat adapter into
tube at top of support stand.
b. Position cylinder head so that valve seat is centered
on seat adapter.
NOTE
Do not press out the valve guide fromthe bottomof the cylinder
head. Carbon buildup on the combustion chamber side of the
guide can deeply gouge the bore. This can cause an improper
interference fit with the replacement guide and possibly require
cylinder head replacement.
2. See Figure 3-10. At the top of the cylinder head, insert
VALVE GUIDE AND VALVE GUIDE SEAL HANDLE (Part
No. HD-34740) into valve guide bore.
3. See Figure 3-11. Using valve guide driver, press until valve
guide drops free of cylinder head. Discard the valve guide.
2
1
3
sm04193
1. Intake seat adapter
2. Exhaust seat adapter
3. Cylinder head support stand
Figure 3-9. Cylinder Head Support Stand (HD-39782-A)
sm04041
Figure 3-10. Valve Guide & Valve Guide Seal Handle
(HD-34740)
1
2
sm02498
1. Valve guide driver
2. Cylinder head stand
Figure 3-11. Remove Valve Guide
HOME
Installation
NOTE
Since some material is typically removed when the guide is
pressed out, it is not uncommon to need the next larger valve
guide for the proper interference fit.
1. Check valve guide to valve bore clearance.
a. Measure the cylinder head valve guide bore.
b. Measure the outside diameter of a new valve guide.
Select a valve guide 0.0020-0.0033 in. (0.051-0.084
mm) larger than the bore.
NOTE
Always back off the ram to allow the valve guide to find center.
Do not press the guide into the cylinder head in one stroke.
This can result in a bent driver, broken guide, distorted cylinder
head casting and/or damaged valve guide bore.
2. See Figure 3-9 and Figure 3-12. Obtain the CYLINDER
HEADSUPPORT STAND(Part No. HD-39782-A), VALVE
GUIDEANDVALVEGUIDESEAL HANDLE(Part No. HD-
34740) and VALVE GUIDE INSTALLER (Part No. HD-
46583). Proceed as follows:
a. See Figure 3-12. Insert sleeve of intake or exhaust
seat adapter into tube at top of support stand. Position
cylinder head so that valve seat is centered on seat
adapter.
NOTE
The support stand ensures that valve guide and seat are
perpendicular. If perpendicularity is not achieved, cylinder
head valve guide bore will be damaged during the press
procedure.
b. Lightly lubricate entire external surface of valve guide
with petroleum jelly.
c. Start valve guide into bore.
d. Place installer sleeve over valve guide and insert
tapered end of valve guide driver into installer sleeve.
e. Apply pressure only until valve guide is started in bore
and then back off ram slightly to allow guide to center
itself.
f. Verify that support stand and driver are square. Press
valve guide further into bore, then back off ram again
to allow valve guide to find center.
g. Repeat previous step and then press until installer
sleeve contacts machined area of cylinder head.
1
3
2
2
1
sm02299
1. Valve guide driver
2. Valve guide installer sleeve
3. Cylinder head stand
Figure 3-12. Install Valve Guide
3. See Figure 3-5. Obtain the CYLINDER HEAD HOLDING
FIXTURE (Part No. HD-39786) and proceed as follows:
b. Clamp tool in vise at a comfortable working angle.
NOTES
Valve guides must be reamed to within 0.0005-0.0001 in.
(0.013-0.0025 mm) under finished size.
Do not push excessively on reamer or apply pressure to
the reamer handle. Excessive pressure results in a rough
cut and bore will be tapered if pressure is not centrally
applied.
Never pull reamer up out of valve guide or bore will be
damaged.
4. See Figure 3-13. Obtain the VALVE GUIDE REAMER
(Part No. HD-39932), RATCHETING TAP HANDLE (Part
HOME
No. HD-39847) and REAMERLUBRICANT (Part No. HD-
39964). Proceed as follows:
a. Install tap handle (2) on reamer (1).
b. Apply a liberal amount of reamer lubricant to valve
guide bore and reamer. Start bit of reamer into bore
at top of cylinder head.
c. See Figure 3-14. Placing thumb on drive socket of
RATCHETING TAP HANDLE (Part No. HD-39847),
apply slight pressure on reamer while rotating clock-
wise. Squirt additional lubricant onto reamer and into
guide as necessary.
d. Continue rotating RATCHETING TAP HANDLE (Part
No. HD-39847) until entire bit has passed through
valve guide bore and shank of reamer rotates freely.
e. Remove tap handle from reamer and carefully draw
shaft of reamer out combustion chamber side of valve
guide.
5. Use low pressure compressed air to remove metal shav-
ings from bore.
1
2
sm04042
1. Valve guide reamer
2. Ratcheting tap handle
Figure 3-13. Valve Guide Reamer and Ratcheting Tap
Handle
sm04043
Figure 3-14. Ream Valve Guide Bore
6. See Figure 3-15. Clean valve guide bore with the VALVE
GUIDE CLEANING BRUSH (Part No. HD-34751).
7. See Figure 3-16. Obtain the 8 MM VALVE GUIDE FLEX
HONE (Part No. HD-34723) and REAMER LUBRICANT
(Part No. HD-39964). Proceed as follows:
a. Install hone in a high speed electric drill.
b. Apply reamer lubricant to finishing stones of hone and
valve guide bore.
c. Start finishing stones of hone into bore.
d. See Figure 3-17. Activate the drill and move the fin-
ishing stones through the bore for 10 to 12 complete
strokes. Work for a crosshatch pattern of approxim-
ately 60 degrees.
NOTE
Abrasive particles can damage machined surfaces and plug
oil passageways.
8. See Figure 3-15. Clear debris with low pressure com-
pressed air and then clean with the VALVE GUIDE
CLEANING BRUSH (Part No. HD-34751).
NOTE
Always verify valve stemto valve guide clearance after honing.
9. Measure the inside diameter of the valve guide with an
inside ball micrometer. Measure the outside diameter of
the valve stemwith an outside micrometer. The clearance
should be within the limits (low end preferable) shown in
Table 3-25.
HOME
10. Using cleaning solvent and VALVE GUIDE CLEANING
BRUSH(Part No. HD-34751), thoroughly clean valve guide
bore.
Table 3-25. New Parts Limits
VALVESTEMTOGUIDECLEARANCE VALVE
0.0011-0.0029 in. (0.028-0.074 mm) Intake
0.0011-0.0029 in. (0.028-0.074 mm) Exhaust
NOTE
After solvent cleaning, use gun cleaning swabs or patches
soaked with thin engine oil to final clean valve guide bore.
Continue to wipe bore until clean cloth shows no evidence of
dirt or debris.
11. Clean valves, cylinder head and valve seats in solvent.
Follow up with a thorough wash in hot soapy water. Dry
with low pressure compressed air.
sm04044
Figure 3-15. Valve Guide Cleaning Brush
sm04045
Figure 3-16. 8mm Valve Guide Flex Hone
sm04046
Figure 3-17. Hone Valve Guide Bore
sm04047
Figure 3-18. Scrub Valve Guide Bore
HOME
ASSEMBLY
VALVE SPRING COMPRESSOR HD-34736-B
VALVE GUIDE AND VALVE GUIDE
SEAL HANDLE
HD-34740
VALVE GUIDE SEAL INSTALLER HD-48644
14.9-20.3 Nm 131-180
in-lbs
Automatic compression
release (ACR)
1. Obtain the CYLINDER HEAD HOLDING FIXTURE (Part
No. HD-39786) and proceed as follows:
b. Clamp tool in vise at a 45 degree angle (or one that
offers a comfortable working position).
2. Slide spring seat over valve guide until it contacts the
machined area on the cylinder head casting. Use a little
grease to hold the spring seat in position, if necessary.
NOTE
At the time of disassembly, all parts should have been marked
or tagged so that they are installed on the same valve (and in
the same head).
3. Run the VALVEGUIDECLEANINGBRUSH(Part No. HD-
34751) through the valve guide bore to verify cleanliness.
4. Apply a liberal amount of SCREAMIN' EAGLEASSEMBLY
LUBE to valve stem.
5. Fromthe bottomof the cylinder head, insert the valve stem
into the valve guide.
6. To distribute the assembly lube evenly around the valve
stemand guide, hand spin the valve as it is installed. Work
the valve back and forth in the bore to verify that it slides
smoothly and seats properly.
7. Remove the valve and apply a second coat of assembly
lube to the valve stem. Install the valve in the valve guide.
8. Retract the valve so that the stem is not visible above the
top of the valve guide.
9. Using isopropyl alcohol or other suitable degreaser, thor-
oughly clean external surface of valve guide until com-
pletely free of grease and oil.
Failure to install plastic capsule can cause the valve stem
seal to catch the edge of the valve stem keeper groove.
The resulting damage can cause leakage around the valve
stem, excessive oil consumption and valve sticking.
(00535b)
10. See Figure 3-19. Push on head of valve until it contacts
the valve seat. Placing finger at head of valve to keep
valve seated, slide plastic capsule over valve stemtip and
keeper groove.
11. See Figure 3-20. Apply a very thin film of SCREAMIN'
EAGLE ASSEMBLY LUBE to capsule. Slide new valve
guide seal over capsule and down valve stemuntil contact
is made with top of valve guide. Remove capsule from
valve stem tip.
1
2
sm04048
1. Plastic capsule
2. Spring seat
Figure 3-19. Install Plastic Capsule on Valve Stem
1
2
sm04049
1. Plastic capsule
2. Valve guide seal
Figure 3-20. Install Valve Guide Seal
HOME
12. See Figure 3-21. Obtain the VALVE GUIDE SEAL
INSTALLER(Part No. HD-48644) and proceed as follows:
a. Slide the installer tool over the valve guide seal using
valve stem as pilot. The tool bore allows insertion of
the valve stem, while the counterbore fits over the
valve guide seal.
b. See Figure 3-22. Using a small hammer, gently tap
the end of the tool until it lightly bottoms on the
installed spring seat. For best results, brace the cyl-
inder head to prevent movement during seal installa-
tion.
NOTES
Repeated blows on installer after seal is in place will cause
seal distortion resulting in leakage around the valve stem,
excessive oil consumption and valve sticking.
See Figure 3-23. If an arbor press is the preferred method
of valve guide seal installation, use the VALVE GUIDE
SEAL INSTALLER (Part No. HD-48644) with the VALVE
GUIDEANDVALVEGUIDESEAL HANDLE(Part No. HD-
34740).
Do NOT remove valve after seal is installed. Removing
the valve after seal installation will cause the valve guide
seal to catch the edge of the valve stem keeper groove.
The resulting damage will lead to leakage around the valve
stem, excessive oil consumption and valve sticking.
sm04051
Figure 3-21. Valve Guide Seal Installer
sm04052
Figure 3-22. Seat Valve Guide Seal
5
2
1
4
6
3
sm04052
1. Valve guide & valve guide seal handle
2. Valve guide seal installer
3. Valve guide seal
4. Valve
5. Valve guide
6. Valve seat
Figure 3-23. Using Arbor Press to Install Valve Guide Seal
LUBE to valve stem tip and keeper groove.
14. Install the inner and outer valve springs over the valve
guide. Fit the spring retainer on top of the inner and outer
valves springs. Like the spring seat, the smaller diameter
flange fits inside the inner valve spring. The larger diameter
flange separates the inner and outer springs.
15. Obtain the VALVESPRINGCOMPRESSOR(Part No. HD-
34736-B) and proceed as follows:
a. Place tool over cylinder head so that the blunt end is
centered on the valve head and adapter at end of
forcing screw is seated on the valve spring retainer.
b. Rotate forcing screw to compress valve springs.
c. With the tapered side down, fit the keepers into the
valve stem groove. For best results, apply a dab of
grease to the inboard side of the keepers before
installation and use a magnetic rod for easy place-
ment.
d. Arranging tapered keepers so that the gaps are evenly
spaced, turn forcing screw to release valve spring
compression.
HOME
NOTE
Over-compressing the valve spring can damage the valve guide
seal resulting in leakage around the valve stem, excessive oil
consumption and valve sticking.
16. Tap the end of the valve stem once or twice with a soft
mallet to make sure that tapered keepers are tightly seated
in the valve stem groove.
17. Repeat all previous steps to install the other valve compon-
ents.
18. Verify that the copper seal washer is in place on the ACR.
19. Apply three equally spaced dots of LOCTITE243 MEDIUM
STRENGTH THREADLOCKER AND SEALANT (blue)
around the lower third of the threads. Tighten to 131-180
in-lbs (14.9-20.3 Nm). See the service manual.
20. Release the cylinder head holding fixture from the vise
and then remove the tool from the spark plug hole.
21. Cover the cylinder head to protect it from dust and dirt
until time of installation.
INSTALLATION
See service manual for cylinder head installation procedure.
HOME
3.7 PISTONS
MEASURING PISTON
NOTE
Piston service procedures are the same for all Twin Cam pis-
tons except for nominal diameter specifications. See service
manual. For service wear limits, refer to Table 3-18.
1. Allow the piston to cool to room temperature.
2. See Figure 3-24. With a pencil or marker, mark the piston
on each side of the skirt across the thrust faces (perpen-
dicular to the piston pin bore) 0.394 in. (10 mm) from the
bottom edge.
NOTE
Set the piston skirt down on a level table. Use a rule to measure
0.394 in. (10 mm) high on the skirt.
3. Using a micrometer at the marks, measure the nominal
diameter of the piston.
4. Use a dial bore gauge to measure the piston ring travel
zone in the cylinder bore. See service manual.
5. Replace piston and/or cylinder if running clearance
exceeds 0.003 in. (0.076 mm).
sm04056
Figure 3-24. 0.394 in. (10 mm)
HOME
3.8 BORING AND HONING CYLINDERS
INSPECTION
CYLINDER TORQUE PLATES HD-48627
SNAP-ON TORQUE ANGLE GAUGE TA360
13.6-16.3 Nm 120-144
in-lbs
Cylinder bolts, 1st torque
20.3-23.1 Nm
plus 90
degrees
15-17 ft-lbs
plus 90
degrees
NOTE
Always use cylinder torque plates to simulate an assembled
cylinder for accurately measuring, boring, honing or deglazing.
Failure to use torque plates can produce measurements that
vary by as much as 0.001 in. (0.025 mm).
1. See Figure 3-25. Install CYLINDER TORQUE PLATES
(Part No. HD-48627) as follows:
a. Remove O-ring seal from cylinder sleeve.
b. Clamp stepped side of lower plate in a soft-jawed vise
with the simulated split line (machined strip) facing
away.
c. See Figure 3-26. Lightly oil threads and shoulders of
four bolts (1) with clean H-D 20W50 engine oil. Slide
four bolts all the way through holes of lower plate (2)
until washers contact outboard side.
d. Slide cylinder onto bolts with the indent in the cooling
fins facing upward.
e. With two dowel pins and used head gasket in place,
place upper plate on cylinder so blind holes align with
dowel pins. Finger-tighten bolts.
f. See Figure 3-27. Tighten the bolts to 120-144 in-lbs
(13.6-16.3 Nm) in the sequence shown.
g. Following the same sequence, tighten each bolt to
15-17 ft-lbs plus 90 degrees (20.3-23.1 Nm plus 90
degrees).
h. Using either marks as a guide or SNAP-ONTORQUE
ANGLE GAUGE (Part No. TA360), turn each bolt an
additional 90 degrees in the sequence shown.
2
4
1
3
sm02506
1. Bolts
2. Lower plate
3. Upper plate
4. Vise grip step
Figure 3-25. Cylinder Torque Plates
NOTE
Maximum cylinder wear occurs at the top of top ring travel.
Minimum wear occurs below ring travel. Failure to measure
the cylinder at these points may result in inaccurate wear
measurements.
2. See Figure 3-28. Using an inside micrometer or dial bore
gauge, check cylinder bore for out-of-round and taper.
Record the readings:
a. At the top of the piston ring travel zone, measure the
cylinder diameter at two locations; parallel and per-
pendicular to the crankshaft.
b. Repeat the two measurements at the center of the
piston ring travel zone.
c. Repeat the measurements at the bottom of the bore
at a point below the piston ring travel zone.
3. Results:
a. If cylinders are not scuffed or scored and are within
the service limits, deglaze the cylinders and inspect
for wear. See service manual.
b. If measurements at any one of the three locations
vary more than 0.002 in. (0.051 mm), the cylinder is
out-of-round.
c. If measurements between any of the three locations
vary more than 0.002 in. (0.051 mm), the cylinder has
excessive taper.
d. If cylinders are worn beyond the service limits, they
must be rebored and/or honed to the next standard
oversize piston. See 3.8 BORING AND HONING
CYLINDERS, Cylinder Bore Finished Size.
HOME
3
2
1
sm02530
1. Bolt (4)
2. Lower plate
3. Vise
Figure 3-26. Attaching Cylinder Torque Plates
3
1
2
4
sm02531
Figure 3-27. Cylinder Torque Plate Bolt Sequence
sm02532
Figure 3-28. Measure for Out-of-Round and Taper
CYLINDER BORE FINISHED SIZE
1. For cylinder removal, cleaning, inspection, boring and
honing and installation, see service manual.
2. Refer to Table 3-26. Bore the cylinder to 0.003 in. (0.08
mm) under the desired finished size. See service manual.
An incorrect crosshatch pattern or too fine a hone will
result in insufficient oil retention and possible piston
seizure and/or high oil consumption. (00538c)
3. Hone the cylinder to its finished size using a 280 grit rigid
hone. Followwith a 240 grit flexible ball hone. Honing must
be done with the torque plates attached. All honing must
be done from the bottom (crankcase end) of the cylinder.
Work for a 60 degree crosshatch pattern.
4. Stop frequently to examine the cylinder bore and/or take
measurements. Remember, a precise 60 degree
crosshatch pattern in the piston travel area is important.
5. Thoroughly wash the cylinder bore with liquid dish soap
and warm water to remove all abrasive particles and
residual grit. Continue cleaning until a clean cloth wiped
on the cylinder wall shows no evidence or dirt or debris.
6. Immediately apply a thin film of clean engine oil to a clean
white paper towel and thoroughly wipe the inside of the
cylinder to prevent the cylinder bore from rusting.
NOTE
Wipe cylinder with a clean, oiled paper towel. Repeat wiping
process until a new towel remains white.
7. With the cylinder at room temperature, check the piston
clearance in the cylinder in which the piston will run. See
service manual.
HOME
8. For cylinder installation, see service manual.
PISTON ORIENTATION
See Figure 3-29. When replacing a piston, orient the piston so
that the etched arrow on the top of the piston faces forward.
sm04057
Figure 3-29. Piston Orientation Arrow(arrowpoints to front
of engine)
Table 3-26. Oversize Pistons and Cylinder Bores, Twin Cam 110
CYLINDER BORE FINISHED SIZE PISTON
MAXIMUM MINIMUM SIZE TYPE
4.0005 in. (101.613 mm) 4.0000 in. (101.6 mm) STD Standard
4.0055 in. (101.740 mm) 4.0050 in. (101.727 mm) 0.005 in. (0.13 mm) Oversize
4.0105 in. (101.867 mm) 4.0100 in. (101.854 mm) 0.010 in. (0.25 mm)
HOME
3.9 CRANKCASE ASSEMBLY
GENERAL
With the exception of the top center crankcase bolt, crankcase
service is identical to original equipment engines. See service
manual.
ASSEMBLY
SPROCKET SHAFT OIL SEAL
INSTALLER
HD-39361-B
CRANKSHAFT GUIDE HD-42326-B
SPROCKET SHAFT BEARING
INSTALLER
HD-97225-55C
13.6 Nm 120 in-lbs Crankcase bolts, 1st torque
20.3-25.8 Nm 15-19 ft-lbs Crankcase bolts, final torque
1. Install left crankcase half in engine stand so that the split
line face is vertical.
2. See Figure 3-30. To prevent damage to the sprocket shaft
(roller) bearing, slide CRANKSHAFT GUIDE(Part No. HD-
42326-B) over end of sprocket shaft.
3. Slide flywheel assembly into left case half and remove
tool.
4. Tip crankcase in engine stand so that flywheel pinion shaft
is pointing straight up.
5. Apply a bead of HARLEY-DAVIDSON HIGH PERFORM-
ANCE SEALANT - GRAY approximately 0.056 in. (1.4
mm) wide to the split line face.
6. To prevent damage to the crankshaft (roller) bearing, slide
CRANKSHAFT GUIDE (Part No. HD-42326-B) over end
of crankshaft until it contacts shoulder on shaft.
7. See Figure 3-31. Slide right crankcase half over end of
crankshaft and mate case halves. Remove tool.
sm04058
Figure 3-30. Crankshaft Guide
4
1
2
3
1
2
5
sm04059
1. Water pipe insulation
2. Crankshaft guide
3. Left crankcase
4. Crankshaft bearing
5. Right crankcase
Figure 3-31. Crankshaft Guide
NOTE
See Figure 3-32. The center upper bolt (1) is longest.
8. See Figure 3-32. Install nine crankcase bolts:
a. Finger-tighten each crankcase bolt.
b. In sequence shown, tighten the crankcase bolts to
120 in-lbs (13.6 Nm).
c. In sequence shown, final-tighten each bolt to 15-19
ft-lbs (20.3-25.8 Nm).
9. Rotate crankcase in the engine stand so that the stator
mount flange is facing upward.
HOME
LUBE into main bearing and rotate flywheel assembly to
distribute.
11. Slide thrust washer over sprocket shaft with "THIS SIDE
OUT" facing out (and the chamfer inboard), or if using OE
part without markings, orient as required to preserve
existing wear pattern.
12. To install new oil seal into bearing bore, obtain pilot,
bearing, large flat washer and handle from SPROCKET
SHAFT BEARINGINSTALLER (Part No. HD-97225-55C)
and proceed as follows:
a. Verify that seal lip garter springs are in place on both
sides of new seal.
b. With the lettering facing out, slide oil seal onto
sprocket shaft until it contacts bearing bore.
c. Thread pilot onto sprocket shaft until contact is made
with shoulder.
d. See Figure 3-33. Slide SPROCKET SHAFT OIL SEAL
INSTALLER (Part No. HD-39361-B) over pilot until it
contacts oil seal.
e. Slide bearing and large flat washer over pilot until
contact is made with seal installer.
f. Thread handle onto pilot shaft.
g. See Figure 3-34. Rotate handle until oil seal installer
makes firm contact with crankcase.
h. Remove seal installer tools from sprocket shaft.
13. Slide sprocket shaft spacer over end of sprocket shaft and
push into oil seal until seated against bearing race.
14. Rotate crankcase in engine stand so cam cover flange is
facing upward.
LUBE into main bearing. Rotate crankshaft to distribute.
16. See CAMCOMPARTMENT in service manual to complete
the assembly.
1
4
8
2
6
9
3
7
5
sm04060
Figure 3-32. Crankcase Torque Sequence (left side)
sm04061
Figure 3-33. Sprocket Shaft Oil Seal Installer
HOME
sm02348
Figure 3-34. Sprocket Shaft Oil Seal Installer
HOME
3.10 OIL TANK
REMOVAL AND DISASSEMBLY
OIL LINE REMOVING TOOL HD-44455
Oil Tank
1. Remove seat.
Disconnect negative (-) battery cable first. If positive (+)
cable should contact ground with negative (-) cable con-
nected, the resulting sparks can cause a battery explosion,
which could result in death or serious injury. (00049a)
2. Remove battery. See service manual.
3. Remove battery caddy. See service manual.
4. Remove rear exhaust pipe. See 4.4 EXHAUST SYSTEM.
5. Drain oil tank. See service manual.
6. Remove rear fender assembly. See 2.13 REARFENDER.
7. Remove rear wheel. See 2.6 REAR WHEEL.
8. Remove two fasteners securing wire shield to frame.
9. Remove splash guard. See service manual.
10. Remove fasteners securing top of electrical panel to oil
tank.
11. See Figure 3-36. Remove two bolts (21) securing rear of
oil tank.
12. Remove two bolts with washers (18) on top front of oil
tank.
13. Cut lower drain hose clamp (2) from frame.
14. See Figure 3-35. Detach feed line to engine (1), return
line to oil tank (2), and vent line (3) using OIL LINE
REMOVING TOOL (Part No. HD-44455).
a. Insert oil line removing tool (4) inside retainer (5).
b. Pull oil line straight out, leaving oil line retainer inside
tank.
15. Remove oil tank from right side of vehicle.
1
2
3
4
5
sm03891a
1. Feed line to engine
2. Return line to oil tank
3. Vent line
4. Oil line removing tool
5. Retainer
Figure 3-35. Oil Lines
HOME
1
21
16
15
20
19
18
17
16
15
14
12
8
12
7
9
10
11
11
10
9
9
9
5
3
2
4
6
13
11
sm03920a
15. 8. 1. Spacer (3) Vent line Drain plug and O-ring
2. 16. 9. Clamp Grommet (3) Oil line retainer (large) (4)
10. 3. 17. Oil line fiitting (large) (2) Drain hose Top bracket
18. 11. 4. Bolt (2) O-ring (3) Clamp
5. 19. 12. Dipstick Bolt Oil line retainer (small) (2)
13. 6. 20. Oil line fitting (small) Feed line Cap
21. 14. 7. Bolt (2) Oil tank Return line
Figure 3-36. Oil Tank
HOME
Oil Line Fittings/Retainers
NOTES
There are two sizes of oil line retainers and fittings. Use the
appropriate sized oil line tool for all service procedures. See
Figure 3-37.
See Figure 3-38. Small retainers connect the vent line (3)
to the oil tank and to the engine.
Large retainers connect the feel line to engine (1) and
return line to oil tank (2) to the oil tank and to the engine.
See Figure 3-39. Do not remove oil line retainers from
engine fittings or oil tank unless retainers, O-rings, and/or
spacers are damaged.
See Figure 3-40. O-rings (1) and spacer (2) are not sold
separately. If either O-rings or spacer are damaged, oil
line retainer assembly must be replaced.
1. Insert OIL LINE O-RING TOOL (Part No. HD-44455) (4)
inside retainer (3).
2. Squeeze tabs on retainer and withdrawtool, retainer, both
O-rings and spacer. Discard retainer, O-rings and spacer.
3. Insert tool (4) through new retainer (3).
4. Insert tool, retainer, spacer and O-rings into engine fitting
or oil tank until tabs on retainer lock into place. Do not
damage O-rings during installation.
5. Carefully withdrawtool leaving retainer assembly in place.
2
1
sm03324
1. O-ring tool (2 sizes)
2. Oil line tool (2 sizes)
Figure 3-37. Oil Line Tools
1
2
3
sm03896a
1. Feed line to engine
2. Return line to oil tank
3. Vent line
Figure 3-38. Oil Line Fittings/Retainers
4
2
3
1
5
sm03326
1. O-ring tool
2. Engine fitting and retainer
3. Tool, retainer, O-rings and spacer
4. Engine fitting without retainer
5. Tabs
Figure 3-39. Oil Line Retainers (Parts Removed From
Engine for Clarity)
HOME
1
2
3
4
sm03327
1. O-rings (2)
2. Spacer
3. Retainer
4. Tool
Figure 3-40. O-rings and Spacer
INSTALLATION
HOSE CLAMP PLIERS HD-97087-65B
16.3-20.3 Nm 12-15 ft-lbs Oil tank bolts
4.1-6.8 Nm 36-60 in-lbs Electrical panel fastener
4.1-6.8 Nm 36-60 in-lbs Splash guard fasteners
1. See Figure 3-36. Slide oil tank into position within frame.
2. Install bolts (18, 21). Tighten to 12-15 ft-lbs (16.3-20.3
Nm).
3. Attach drain hose and install new clamp (2) to frame.
Crimp clamp using HOSE CLAMP PLIERS (Part No. HD-
97087-65B).
4. Secure wire harness and rear brake line to drain at frame
with a cable strap.
5. Secure wire shield to frame with both fasteners.
6. See Figure 3-35. Connect vent line, return line to oil tank,
and feed line to engine.
7. Install fasteners securing top of electrical panel to oil tank.
8. Install splash guard. Tighten to 36-60 in-lbs (4.1-6.8 Nm).
9. Install rear fender. See 2.13 REAR FENDER.
10. Install exhaust system. See 4.4 EXHAUST SYSTEM.
11. Install battery caddy. See service manual.
Connect positive (+) battery cable first. If positive (+) cable
should contact ground with negative (-) cable connected,
the resulting sparks can cause a battery explosion, which
12. Install battery and connect cables, positive cable first.
13. Install seat.
14. Fill oil tank and check oil level after running motorcycle on
side stand. See service manual.
HOME
NOTES
TABLE OF CONTENTS
SUBJECT............................................................................................................................PAGE NO.
4.1 AIR CLEANER BACKPLATE ASSEMBLY.................................................................................4-1
4.2 CONSOLE.................................................................................................................................4-2
4.3 INDUCTION MODULE...............................................................................................................4-4
4.4 EXHAUST SYSTEM..................................................................................................................4-7
F
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S
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S
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NOTES
4.1 AIR CLEANER BACKPLATE ASSEMBLY
REPAIR
6.2-6.8 Nm 55-60 in-lbs Air cleaner backplate screws
29.8-32.5 Nm 22-24 ft-lbs Breather bolts
6.2-6.8 Nm 55-60 in-lbs Intake tube screws
Disassembly
1. See Figure 4-1. Remove screws (1).
2. Remove filter and intake tube as an assembly. If disas-
sembly is required, refer to 1.4 AIR FILTER.
3. Remove plugs (4).
4. Remove breather screws (6).
5. Remove adapter (12) from the backplate.
6. Remove three screws (11). Remove cover (10) and
backplate (7).
Assembly
NOTE
Replace O-rings if necessary.
1. See Figure 4-1. Install cover and backplate with new
gaskets (9). Tighten screws (11) to 55-60 in-lbs (6.2-6.8
Nm). Tighten breather bolts (6) to 22-24 ft-lbs (29.8-32.5
Nm).
2. Install plugs (4) and insert adapter (12) in backplate.
3. Secure air cleaner/intake tube assembly with screws (1).
1
2
3
4
5
6
7
8
9
9
10
11
12
sm07688
9. 5. 1. Gasket (2) O-ring, plug Screw (3)
2. 10. 6. Mounting ring Cover Breather bolt (2)
7. 3. 11. Backplate Gasket Screw (3)
12. 8. 4. Adapter O-ring (2) Plug (2)
Figure 4-1. Air Cleaner and Backplate
HOME
2013 FXSBSE Service Supplement: Fuel System 4-1
4.2 CONSOLE
REMOVAL
1. Remove seat.
ceeding. (00251b)
2. See Figure 4-2. Remove fasteners (1, 3).
3. Disconnect hose (5) and vent line (6).
4. Remove console (2) and seal (4).
INSTALLATION
4.5-6.8 Nm 40-60 in-lbs Fuel tank console fasteners
0.6-1.1 Nm 5-10 in-lbs Fuel tank console rear
fastener
1. See Figure 4-2. Place seal (4) on console (2).
2. Attach vent line (6) and hose (5) to console.
3. Place electrical wiring in clips on underside of console.
4. Place console (2) on fuel tank.
5. Install fasteners (3). Tighten to 40-60 in-lbs (4.5-6.8 Nm).
6. Install fastener (1). Tighten to 5-10 in-lbs (0.6-1.1 Nm).
7. Install seat.
HOME
4-2 2013 FXSBSE Service Supplement: Fuel System
1
2
3
4
6
5
sm07678
1. Fastener
2. Console
3. Fastener (2)
4. Seal
5. Hose
6. Vent line
Figure 4-2. Console
HOME
4.3 INDUCTION MODULE
REMOVAL
INTAKE MANIFOLD WRENCH HD-47250
1. Remove fuel tank. See the service manual.
2. Remove air cleaner and backplate. See 4.1 AIRCLEANER
BACKPLATE ASSEMBLY.
3. See Figure 4-3. Remove the ACRconnectors and retainer
from the mounting bracket (3).
4. CA/APC Models: Pull the purge tube from fitting (2) at
top of induction module.
5. Remove the TMAP sensor connector [80] (5).
6. Remove front fuel injector connector [84] (1) and rear fuel
injector connector [85] (6).
7. Remove TCA connector [211] (4). Cut anchored cable
strap to release connector conduit from front right side of
induction module.
8. Use the INTAKE MANIFOLD WRENCH (Part No. HD-
47250) to remove right side screws from front and rear
cylinder head flange adapters.
9. Loosen left side screws from flange adapters. Slots in
flanges make removal of screws unnecessary.
10. Slide induction module out right side of motorcycle.
11. Remove seals from flange adapters. Discard seals.
Remove flange adapters from outlet ports of induction
module.
8
1
2
3
4
5
6
7
sm04089
5. 1. TMAP sensor [80] Front fuel injector [84]
2. 6. Purge tube fitting/cap Rear fuel injector [85]
7. 3. Fuel rail Mounting bracket
4. 8. TCA [211] Fuel supply tube
Figure 4-3. Induction Module Assembly
HOME
THROTTLE CONTROL ACTUATOR (TCA)
See Figure 4-4. The TCA is not sold separately. Damage or
failure requires complete replacement of the induction module.
Also note that tampering or removing TCA cover voids war-
ranty.
sm04034
Figure 4-4. TCA
TEMPERATURE MANIFOLD ABSOLUTE
PRESSURE (TMAP)
9.5-12.2 Nm 84-108 in-lbs TMAP hex screw
Removal
1. Remove fuel tank. See the service manual.
2. Remove hex screw to release TMAP sensor bracket from
induction module. Discard screw.
3. See Figure 4-5. While rotating TMAP sensor [80] slightly,
pull straight up to release pressure port from hole in
induction module.
Installation
1. Inspect O-ring on pressure port for cuts, tears or signs of
deterioration. Install new O-ring if necessary.
2. With the electrical connector facing toward the rear of the
induction module, insert pressure port on TMAP sensor
[80] into hole in induction module.
3. Align hole in TMAP sensor bracket with threaded hole in
induction module.
4. Install new hex screw and tighten to 84-108 in-lbs (9.5-
12.2 Nm).
5. Install fuel tank. See the service manual.
sm04080
Figure 4-5. TMAP Sensor
INSTALLATION
INTAKE MANIFOLD WRENCH HD-47250
10.9-16.3 Nm 96-144 in-lbs Induction module flange
adapter screws
10.9-16.3 Nm 96-144 in-lbs Induction module flange
adapter screws
1. With the counterbore facing outward, slide flange adapters
onto the induction module.
2. Place a new seal in each flange adapter with the beveled
side against the counterbore.
3. Slide induction module into position until slots engage
screws on left side.
4. Use the INTAKE MANIFOLD WRENCH (Part No. HD-
47250) to start the right side screws.
5. Loosely install two breather bolts to temporarily fasten
mounting bracket to cylinder heads.
6. Tighten right side flange adapter screws until snug. Tighten
left side screws to 96-144 in-lbs (10.9-16.3 Nm).
7. Tighten right side screws to 96-144 in-lbs (10.9-16.3 Nm).
8. Install the rear fuel injector connector [85] and the front
fuel injector connector [84].
9. Install TMAP sensor connector [80].
10. Route TCA connector and conduit straight down between
induction module and front cylinder staying inboard of
mounting bracket. Install newanchored cable strap in hole
at front right side of induction module and loosely capture
TCA conduit.
11. Route conduit rearward under induction module and install
TCA connector [211]. Tighten cable strap and cut any
excess cable strap material.
12. CA/APC Models: Connect purge tube to fitting.
All other Models: Inspect rubber cap for tears, cracks or
signs of deterioration. Replace cap if damaged or missing.
HOME
13. Install ACR connector retainer on mounting bracket and
secure connectors to it.
14. Install fuel tank. See the service manual.
15. Install backplate and air cleaner. See 4.1 AIR CLEANER
BACKPLATE ASSEMBLY.
HOME
4.4 EXHAUST SYSTEM
MUFFLERS
10.9-13.6 Nm 96-120 in-lbs Muffler fasteners
51.6-58.4 Nm 38-43 ft-lbs Muffler clamps
2.3-4.5 Nm 20-40 in-lbs Muffler shield clamps
Removal
1. See Figure 4-6. Apply penetrating oil to seams of mufflers
and exhaust pipes (5, 8).
2. Remove muffler shield clamps (2) to detach muffler shields
(1, 17) from mufflers.
3. Remove fasteners (18).
4. Remove and discard muffler clamps (4).
5. Remove mufflers.
Assembly
1. Install mufflers and fasteners (18). Tighten to 96-120 in-lbs
(10.9-13.6 Nm).
2. Install new clamps (4). Tighten to 38-43 ft-lbs (51.6-58.4
Nm).
3. Install muffler shields (1, 17) with clamps (2). tighten to
20-40 in-lbs (2.3-4.5 Nm).
SYSTEM
20.4-27.1 Nm 15-19 ft-lbs Exhaust interconnect clamp
1.0-2.0 Nm 9-18 in-lbs Exhaust manifold clamp lower
nut, 1st torque
11.3-13.6 Nm 100-120
in-lbs
Exhaust manifold clamp upper
nut
11.3-13.6 Nm 100-120
in-lbs
Exhaust manifold clamp lower
nut final torque
27.1-33.9 Nm 20-25 ft-lbs Exhaust system interconnect
tube fasteners
2.3-4.5 Nm 20-40 in-lbs Exhaust shield clamps
Removal
1. Disconnect O2 sensor wiring.
2. See Figure 4-6. Remove exhaust shields (7, 15).
3. Remove locknuts (9).
4. Remove locknuts (19).
5. Remove exhaust systemas an assembly. Disengage rear
pipe from port, then front pipe. Replace interconnect gas-
kets (21) and clamps (22) anytime the connections are
disassembled.
Installation
NOTE
Replacement cylinder head exhaust port gaskets (10) are
tapered internally. Be sure the tapered side is facing exhaust
pipes. Also check condition of retaining ring (11) before
installation.
1. If either exhaust tube was removed from the interconnect
tube, replace exhaust interconnect gasket (21) and
exhaust interconnect clamp (22). Tighten new clamp to
15-19 ft-lbs (20.4-27.1 Nm).
2. Install new gaskets in both the front and rear cylinder
heads with the tapered side facing exhaust pipes.
3. Position ends of exhaust pipes into front, then rear cylinder
head exhaust ports placing holes in exhaust manifold
clamp (12) over cylinder head exhaust studs. Loosely
thread on locknuts (9).
4. Loosely install locknuts (19) to attach interconnect tube
assembly (23) to frame.
5. Tighten nuts (9) at cylinder studs as follows:
a. Install upper nut and tighten finger tight.
b. Install lower nut and tighten to 9-18 in-lbs (1.0-2.0
Nm).
c. Tighten upper nut to 100-120 in-lbs (11.3-13.6 Nm).
d. Tighten lower nut to 100-120 in-lbs (11.3-13.6 Nm).
6. Tighten locknuts (19) to 20-25 ft-lbs (27.1-33.9 Nm).
7. Install front and rear exhaust shields (7, 15) with clamps
(14). Tighten to 20-40 in-lbs (2.3-4.5 Nm).
8. Connect O2 sensor wiring.
HOME
23
21
16
22
17
18
8
15
14
20
13
12
11
10
9
7
6
5
4
3
19
1
2
sm07695
13. 1. Front oxygen sensor Rear muffler shield
2. 14. Clamp (4) Clamp (5)
15. 3. Front exhaust shield Rear muffler
4. 16. Clamp (2) Front muffler
17. 5. Front muffler shield Rear exhaust pipe
6. 18. Rear oxygen sensor Fastener (4)
19. 7. Locknut (2) Rear exhaust shield
8. 20. Front exhaust pipe Stud (2)
21. 9. Exhaust interconnect gasket (2) Locknut (4)
10. 22. Exhaust port gasket (2) Clamp (2)
23. 11. Interconnect tube assembly Exhaust gasket retaining ring (2)
12. Exhaust manifold clamp (2)
Figure 4-6. Exhaust System
HOME
TABLE OF CONTENTS
SUBJECT............................................................................................................................PAGE NO.
5.2 SPECIFICATIONS: DRIVE........................................................................................................5-2
5.3 DRIVE COMPONENTS.............................................................................................................5-3
5.4 CLUTCH RELEASE BEARING AND PUSH ROD.....................................................................5-4
5.5 CLUTCH....................................................................................................................................5-6
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NOTES
CHAPTER
in this chapter.
5.5 CLUTCH, Clutch Pack Only 7.9-11.3 Nm 70-100 in-lbs Clutch diaphragm spring retainer bolts
5.4 CLUTCH RELEASE BEARING AND PUSH
ROD, Installation
9.5-12.2 Nm 84-108 in-lbs Clutch inspection cover
HOME
2013 FXSBSE Service Supplement: Drive 5-1
5.2 SPECIFICATIONS: DRIVE
GENERAL
Table 5-1. Primary Chaincase Lubricant
WET FILL DRY FILL ITEM
L oz L oz
1.12 38 1.32 45 Amount
SCREAMIN' EAGLE SYN3 FULL SYNTHETIC
MOTORCYCLE LUBRICANT 20W50
Lubricant
NOTES
A dry fill is required any time the primary cover has been
removed and replaced.
A wet fill is required when the primary chain case lubricant
has only been drained through the primary drain plug.
HOME
5-2 2013 FXSBSE Service Supplement: Drive
5.3 DRIVE COMPONENTS
GENERAL
See the service manual for drive component information.
HOME
5.4 CLUTCH RELEASE BEARING AND PUSH ROD
GENERAL
The following procedure is unique to this motorcycle. For all
other clutch service procedures see the service manual.
REMOVAL
1. Remove seat.
2. Remove negative cable from battery.
3. See Figure 5-1. To access clutch release bearing, remove
clutch inspection cover.
4. See Figure 5-2. Remove bearing plate retaining ring (1).
5. Pull out release bearing plate (3) with release bearing (4)
and push rod (5).
6. Remove push rod retainer (2).
7. Press release bearing out of bearing plate.
INSTALLATION
1. See Figure 5-2. Pressing on the outer race, press a new
release bearing (4) into bearing plate (3).
2. Assemble push rod (5) to bearing.
3. Snap in push rod retainer (2).
4. Slide push rod and clutch release bearing assembly
through clutch pack to secondary clutch actuator.
5. Snap in bearing plate retaining ring (1).
NOTE
Before installing clutch inspection cover check push rod and
release plate movement.
sm07664
Figure 5-1. Clutch Release Bearing
5
2
4
1
3
sm04072
1. Bearing plate retaining ring
2. Push rod retainer
3. Release bearing plate
4. Release bearing
5. Push rod
Figure 5-2. Push Rod and Release Bearing
Measure Release Plate Movement
1. Attach a dial indicator to measure push rod axial move-
ment.
Insufficient clutch-release plate movement can lead to
difficulty or inability to shift, causing loss of control, which
2. Actuate the clutch lever to measure the axial movement
of the push rod and the clutch-release plate assembly.
The minimumaxial movement must be as specified. Refer
to Table 5-2.
NOTE
Proper bleeding of the system will typically yield plate move-
ment greater than specification. If clutch release plate move-
ment is less than specification, bleed system and measure
plate movement again.
Table 5-2. Release Plate Movement Specification
MM IN.
1.78 0.070
Install Clutch Inspection Cover
1. Thoroughly clean all gasket material fromclutch inspection
cover and mating surface on primary cover.
HOME
2. See Figure 5-3. Install clutch inspection cover with new
gasket. Make sure the correct side of the gasket faces the
clutch inspection cover. In sequence shown, tighten
fasteners to 84-108 in-lbs (9.5-12.2 Nm).
3. Connect negative battery cable to battery.
4. Install seat.
4
5
2
3
1
sm02844
Figure 5-3. Clutch Cover Torque Sequence
HOME
5.5 CLUTCH
CLUTCH PACK ONLY
7.9-11.3 Nm 70-100 in-lbs Clutch diaphragm spring
retainer bolts
Partial Disassembly
This procedure can be performed on the motorcycle without
removing the clutch shell or hub. For replacement of the shell
or hub, see service manual.
1. Remove primary chaincase cover. See service manual.
2. See Figure 5-4. Remove three bolts (1) to release stopper
plate (2) from clutch hub (6). Loosen each bolt gradually
and in a sequence around the hub.
NOTE
Do not lose the coil spring seats (5).
3. Remove stopper plate, three coil springs (4), coil spring
seats and pressure plate (11) from clutch hub.
4. Remove the three spring seats from the clutch pressure
plate.
5. Remove friction plates (12,14), steel plates (13) fromclutch
hub.
Cleaning And Inspection
1. Wash all parts in cleaning solvent, except for friction plates
and bearing, if removed. Dry parts with low pressure
compressed air.
NOTE
Replace any damaged spring seats.
2. Check friction plates:
a. Use compressed air to remove all lubricant from the
friction plates. Do not wipe off with a rag.
b. Measure the thickness of each plate.
c. If the thickness of any plate is less than 0.143 in. (3.62
mm), replace with an entirely new set.
d. Look for worn or damaged fiber surface material (both
sides).
NOTE
Friction and steel plates are only sold as a kit.
3. Check the steel plates:
a. Discard any plate that is grooved or bluish in color.
Blue plates are likely warped or distorted.
b. Check each plate for distortion. Lay the plate on a
precision flat surface. Insert a feeler gauge between
the plate and the flat surface in several places.
Replace any steel plate that is warped more than
0.006 in. (0.15 mm).
4. Hold the clutch hub and rotate the clutch shell to check
bearing for smooth operation. Replace the bearing if it
runs rough, binds or has any end play. See service
manual.
5. Replace clutch shell if primary chain sprocket or starter
ring gear are worn or damaged.
6. Replace clutch hub and shell if slots for clutch plates are
worn or damaged.
7. Replace coil springs and stopper plate if either are cracked
or bent.
Assembly
NOTE
Submerge and soak all friction plates in primary chaincase
lubricant for at least five minutes.
1. Install the three spring seats in the clutch pressure plate.
NOTE
Verify that there are two narrow friction discs with a narrow
steel between them on the clutch pressure plate during
assembly.
2. See Figure 5-4. Install one of the narrow friction plates
(14) first, along with a narrow steel plate (13) on the on
the pressure plate (11).
3. Install a narrow friction plate (14) and then a steel plate
(13) on the clutch hub. Install seven remaining sets in the
same manner, alternating between steel plates and friction
plates.
4. Engage tabs on friction plates with slots in clutch shell.
NOTES
If the pressure plate is installed properly, the bolts in the
stopper plate will have excess protruding and be able to
thread into the clutch hub without distorting the stopper
plate.
Alternately tighten the three bolts 1-2 turns to prevent
damage to the stopper plate.
5. Install pressure plate (11) on clutch hub aligning holes in
plate with threaded bosses on hub.
6. Install three coil springs (4) in pressure plate.
7. Align holes in stopper plate (2) with threaded bosses on
clutch hub and install.
8. Install three bolts (1) (metric) to secure stopper plate and
coil springs to clutch hub. Alternately tighten to 70-100
in-lbs (7.9-11.3 Nm).
HOME
NOTE
Always install a newgasket between primary chaincase cover
and chaincase. Failure to replace this gasket may cause
primary chaincase leaks.
9. Install primary chaincase cover. Fill primary chaincase
with lubricant. See service manual.
1
11
7
16
15
10
6
8
9
4
5
2
3
14
13
12
sm02704c
9. 1. Retaining ring Bolt (3)
2. 10. Stopper plate Retaining ring
11. 3. Pressure plate Mainshaft nut
4. 12. Coil spring Friction plate, wide (6)
13. 5. Steel plate, wide (7), narrow (1) Seat (3)
6. 14. Clutch hub Narrow friction plate (3)
15. 7. Damper spring Clutch shell
8. 16. Bearing Damper spring seat
Figure 5-4. Clutch Shell Assembly
HOME
NOTES
TABLE OF CONTENTS
SUBJECT............................................................................................................................PAGE NO.
6.2 SPECIFICATIONS: TRANSMISSION........................................................................................6-2
6.3 TRANSMISSON SIDE COVERS...............................................................................................6-3
6.4 SECONDARY CLUTCH ACTUATOR........................................................................................6-4
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CHAPTER
in this chapter.
6.3 TRANSMISSONSIDECOVERS, Fill Transmis-
sion
2.8-8.5 Nm 25-75 in-lbs Filler plug and dipstick
6.4 SECONDARYCLUTCHACTUATOR, Replace-
ment
sion
19.0-28.5 Nm 14-21 ft-lbs Transmission drain plug
6.3 TRANSMISSON SIDE COVERS, Installation 11.2-13.6 Nm 100-120 in-lbs Transmission inner side cover screw
6.3 TRANSMISSON SIDE COVERS, Installation 11.2-13.6 Nm 100-120 in-lbs Transmission outer side cover screw
HOME
2013 FXSBSE Service Supplement: Transmission 6-1
6.2 SPECIFICATIONS: TRANSMISSION
GENERAL
Table 6-1. Transmission Specficationa
DATA ITEM
6-speed constant mesh Cruise Drive Type
SCREAMIN' EAGLE SYN3 FULL SYN-
THETIC MOTORCYCLE LUBRICANT
20W50
Lubricant
32 oz (946 mL) Capacity
NOTE
See the service manual for all other transmission specifications.
HOME
6-2 2013 FXSBSE Service Supplement: Transmission
6.3 TRANSMISSON SIDE COVERS
REMOVAL
1. Remove seat.
2. Remove negative battery cable.
3. Remove filler plug and dipstick.
4. Drain transmission lubricant into a suitable container. See
service manual.
5. Remove components as necessary to access side covers.
See service manual.
6. See Figure 6-1. Remove outer side cover (5).
7. If necessary, remove secondary clutch actuator (3). See
8. Remove inner side cover (1) and discard gasket (2).
9. Clean and inspect inner side cover. Clean with denatured
alcohol only.
NOTE
If required, replace locating dowels in inner transmission side
cover.
1
2
3
4
5
6
sm07666
1. Inner side cover
2. Gasket
4. Outer side cover screw
5. Outer side cover
6. Inner side cover screw
Figure 6-1. Transmission Side Covers
INSTALLATION
11.2-13.6 Nm 100-120
in-lbs
Transmission inner side cover
screw
11.2-13.6 Nm 100-120
in-lbs
Transmission outer side cover
screw
1. See Figure 6-1. Place a new clutch release gasket (2) on
locating dowels and position inner side cover on transmis-
sion.
2. Tighten inner side cover fasteners to 100-120 in-lbs (11.2-
13.6 Nm).
3. If removed, install secondary clutch actuator (3). See
4. Install outer transmission side cover. Tighten to 100-120
in-lbs (11.2-13.6 Nm).
5. Fill transmission with lubricant. See 6.3 TRANSMISSON
SIDE COVERS, Fill Transmission.
FILL TRANSMISSION
1. Verify clutch operation.
2. Inspect O-ring on transmission lubricant drain plug and
replace as necessary. Install drain plug. Tighten to 14-21
ft-lbs (19.0-28.5 Nm).
3. Position the motorcycle level and upright.
4. Fill the transmission with approximately 32 oz. (946 ml)
of SCREAMIN' EAGLE SYN3 FULL SYNTHETIC
MOTORCYCLE LUBRICANT 20W50. Check level. Fill
until level is at the F (FULL) mark with the filler plug resting
on the threads.
5. Inspect the filler plug O-ring and install filler plug/dipstick.
6. Install components removed to access side covers. See
service manual.
7. Install negative battery cable.
8. Install seat.
9. Test ride motorcycle. Incorrect clutch fluid pressure or fluid
level can cause a dragging clutch or hard shifting.
HOME
2013 FXSBSE Service Supplement: Transmission 6-3
6.4 SECONDARY CLUTCH ACTUATOR
REPLACEMENT
11.2-13.6 Nm 100-120
in-lbs
Secondary clutch actuator
1. Remove the transmission outer side cover. See
6.3 TRANSMISSON SIDE COVERS.
2. See Figure 6-2. Loosen clutch fluid line (2) and allowclutch
fluid to drain.
NOTE
Clutch fluid line O-ring may remain inside the secondary clutch
actuator. Use a non-metallic pick to remove old O-ring and
other debris.
3. Remove and discard O-ring (3) from clutch fluid line.
NOTE
A small amount of transmission lubricant will drain when sec-
ondary clutch actuator is removed.
4. Remove three screws (4) and secondary clutch actuator
(5).
5. Remove and discard O-ring (6) from secondary clutch
actuator.
NOTES
The secondary clutch actuator is not serviceable. Replace
as needed.
Secondary clutch actuator and O-ring must be seated in
cover before tightening screws to specification.
6. Lubricate new O-ring with transmission lubricant prior to
installing. Install newO-ring on secondary clutch actuator.
7. Install three screws (4) attaching secondary clutch actuator
(5) to transmission inner side cover. Tighten to 100-120
in-lbs (11.2-13.6 Nm).
8. Bleed clutch. See 2.18 BLEEDINGCLUTCHFLUIDLINE.
3
5
4
1
2
6
sm07667
1. Bleeder valve and cap
3. O-ring
4. Screw
6. O-ring
Figure 6-2. Secondary Clutch Actuator
HOME
6-4 2013 FXSBSE Service Supplement: Transmission
TABLE OF CONTENTS
SUBJECT............................................................................................................................PAGE NO.
7.2 HEADLAMP...............................................................................................................................7-2
7.3 SPEEDOMETER.......................................................................................................................7-5
7.4 INDICATOR LAMPS..................................................................................................................7-6
7.5 WHEEL SPEED SENSOR (WSS).............................................................................................7-7
7.6 TURN SIGNALS........................................................................................................................7-9
7.7 ELECTRICAL PANEL..............................................................................................................7-10
7.8 ELECTRONIC CONTROL MODULE (ECM)...........................................................................7-11
7.9 SECURITY SIREN...................................................................................................................7-12
7.10 BODY CONTROL MODULE (BCM)......................................................................................7-13
7.11 ELECTRONIC CONTROL UNIT (ECU).................................................................................7-14
7.12 COMPONENT LOCATIONS..................................................................................................7-15
7.13 DIAGNOSTIC TOOLS............................................................................................................7-18
7.14 INITIAL DIAGNOSTICS.........................................................................................................7-22
7.15 CAN DATA COMMUNICATION.............................................................................................7-33
7.16 ODOMETER SELF-DIAGNOSTICS INOPERATIVE, DTC U0001, U0011, B2274...............7-34
7.17 NO VEHICLE POWER, DTC U0100, U0121, U0140, U0141, U0142, U0156......................7-40
7.18 STARTING SYSTEM DIAGNOSTICS....................................................................................7-45
7.19 DTC P0562............................................................................................................................7-53
7.20 DTC B1210, B1211................................................................................................................7-57
7.21 TRIP ODOMETER FUNCTIONS INOPERATIVE, DTC B2255.............................................7-60
7.22 NO INSTRUMENT POWER, DTC B1200..............................................................................7-63
7.23 INDICATOR LAMPS..............................................................................................................7-66
7.24 ACCESSORIES, DTC B2112, B2113, B2114........................................................................7-72
7.25 DTC B2151, B2153, B2154, B2156, B2158, B2159..............................................................7-76
7.26 STOP LAMPS, DTC B2161, B2163, B2164, B2223..............................................................7-80
7.27 RUNNING LAMPS, DTC B2107, B2108, B2109, B2166, B2168, B2169..............................7-84
7.28 SECURITY SYSTEM.............................................................................................................7-91
7.29 SERVICE AND EMERGENCY FUNCTIONS AND CONFIGURATIONS..............................7-94
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CHAPTER
in this chapter.
7.5 WHEEL SPEED SENSOR (WSS), Front WSS 38-52 Nm 28-38 ft-lbs Brake caliper/WSS bracket mounting
bolts
7.4 INDICATOR LAMPS, Installation 2.3-3.4 Nm 20-30 in-lbs Indicator lamp fasteners
7.7 ELECTRICAL PANEL, Installation 4.1-6.8 Nm 36-60 in-lbs Rear electrical panel fasteners
7.6 TURN SIGNALS, Rear Lamp Replacement 16.3-21.7 Nm 12-16 ft-lbs Rear turn signal housing fastener
7.3 SPEEDOMETER, Installation 1.4-1.9 Nm 12-17 in-lbs Speedometer fasteners
7.4 INDICATOR LAMPS, Installation 16.3-21.7 Nm 12-16 ft-lbs Upper handlebar clamp fasteners
HOME
2013 FXSBSE Service Supplement: Electrical 7-1
7.2 HEADLAMP
HEADLAMP ASSEMBLY REMOVAL AND
INSTALLATION
Removal
NOTE
Fuel tank crossover hose does not need to be disconnected.
Fuel tank can be slid back enough to remove required con-
nectors.
1. Slide fuel tank rearward. See service manual.
2. See Figure 7-1. Disconnect headlamp connector (5).
3. See Figure 7-2. Remove horizontal adjusting bolt (2) and
headlamp assembly.
Installation
1. See Figure 7-2. Install headlamp assembly with horizontal
adjusting bolt (2).
2. See Figure 7-1. Connect headlamp connector (5).
3. Install fuel tank. See service manual.
4. Adjust headlamp alignment. See service manual.
5
4
1
2
3
6
sm07179a
1. Instruments [20]
2. Left hand control [24]
3. Fuel gauge [117]
4. Front wheel speed sensor [167]
5. Headlamp [38]
6. Front fender tip lamp [32]: FLSTC
Figure 7-1. Under Fuel Tank Left Side
2 1
om01642
1. Vertical adjustment fastener
2. Horizontal adjustment fastener
Figure 7-2. Headlamp Adjustment
HEADLAMP BULB REPLACEMENT
Handle bulb carefully and wear eye protection. Bulb con-
tains gas under pressure, which, if not handled carefully,
could cause serious eye injury. (00062b)
When replacement is required, use only the specified
sealed beamunit or bulb, available froma Harley-Davidson
dealer. An improper wattage sealed beam or bulb, can
cause charging system problems. (00209a)
If a headlamp bulb filament burns out, the bulb must be dis-
carded and a new bulb installed. Refer to Table 1-1 for bulbs.
Bulb Removal
ceeding. (00251b)
NOTE
Make note of components during disassembly to aid in correct
assembly.
2. See Figure 7-3. Remove screw (1) and trim ring (2).
3. Remove rubber boot (8) from back of headlamp lens (3).
4. Disconnect headlamp connector from bulb (5).
HOME
7-2 2013 FXSBSE Service Supplement: Electrical
5. See Figure 7-4. Remove wire retaining clip (6) from
headlamp base.
6. Remove bulb from headlamp assembly.
7. For International Models Only: Rotate position lamp
boot one-quarter turn and remove bulb assembly from
housing. Pull position bulb (7) to remove from boot.
Bulb Installation
Never touch the quartz bulb. Fingerprints will etch the
glass and decrease bulb life. Handle the bulb with paper
or a clean, dry cloth. Failure to do so could result in bulb
damage. (00210b)
NOTE
When installing a new bulb, be sure connector contacts are
clean for good electrical contact.
1. Install newbulb and assemble the headlamp components.
2. For International Models Only: Install new bulb in boot.
Install boot in housing and rotate one-quarter turn.
3. Verify slots and tabs in headlamp and trimring are aligned.
4. Install rubber boot with word TOP at the top of the head-
lamp lens assembly.
5. Connect the headlamp connector.
6. Install trim ring and screw.
8. Turn ignition on and test for proper operation.
9. If necessary, align headlamp assembly. See service
manual.
2
3
4
6
7
8
9
10
5
1
om01641
9. 5. 1. Mounting ring Bulb Screw
2. 10. 6. Trim ring Shell assembly Wire retaining clip
7. 3. Bulb, position (international
models)
Headlamp lens
4. Gasket
8. Boot
Figure 7-3. Headlamp Bulbs
HOME
1
2
sm05135
1. Wire retaining clip
2. Retainer
Figure 7-4. Wire Retaining Clip (Typical)
HOME
7.3 SPEEDOMETER
REMOVAL
1. See Figure 7-5. Remove fasteners (3).
2. Disconnect speedometer wire connector.
3. Remove speedometer.
INSTALLATION
1.4-1.9 Nm 12-17 in-lbs Speedometer fasteners
1. See Figure 7-5. Install speedometer (1) with seal (2).
2. Connect speedometer wire connector.
3. Install fasteners (3). Tighten to 12-17 in-lbs (1.4-1.9 Nm).
1
2
3
3
sm07680
1. Speedometer
2. Seal
3. Fastener (2)
Figure 7-5. Speedometer
HOME
7.4 INDICATOR LAMPS
REMOVAL
1. Slide fuel tank back to access instrumentation connector.
See service manual.
2. Disconnect instrumentation connector.
3. Disconnect speedometer connector.
NOTE
Support handlebar in position.
4. Remove upper handlebar clamp.
5. Remove both fasteners securing indicator lamp to upper
handlebar clamp.
6. Remove indicator lamp.
INSTALLATION
2.3-3.4 Nm 20-30 in-lbs Indicator lamp fasteners
16.3-21.7 Nm 12-16 ft-lbs Upper handlebar clamp
fasteners
1. Route indicator lamp wiring to instrumentation and
speedometer connectors. Connect connectors.
2. See Figure 7-6. Attach indicator lamp to upper handlebar
clamp with fasteners. Tighten to 20-30 in-lbs (2.3-3.4 Nm).
NOTE
The slight gap between upper and lower handlebar clamps
should face the rider.
3. Install upper handlebar clamp. Tighten forward fasteners
then rear fasteners to 12-16 ft-lbs (16.3-21.7 Nm).
4. Install fuel tank. See service manual.
sm04599c
3
1
2
sm07681
1. Handlebar clamp
2. Fastener (4)
3. Lower handlebar clamp
Figure 7-6. Indicator Lamp
HOME
7.5 WHEEL SPEED SENSOR (WSS)
FRONT WSS
38-52 Nm 28-38 ft-lbs Brake caliper/WSS bracket
mounting bolts
Removal
NOTES
Never pull the wheel speed sensor harness or use the
harness to support the wheel or other components.
The left side wheel bearing is an encoded bearing that
works with the WSS to identify the wheel speed for the
ABS ECU.
Keep both the WSS and the ABS encoded bearing away
from magnetic parts and tools.
1. Remove the nacelle. See 2.22 HEADLAMP NACELLE.
2. Remove and pull the fuel tank to access the electrical
connectors on the left side of the frame. See the service
manual.
3. See Figure 7-7. Separate the front WSS connector [167]
housings.
4. To access the WSS, remove the front wheel. See
2.5 FRONT WHEEL.
5. Visually inspect the left side wheel bearing. Replace if
necessary.
6. Remove the clips holding the WSS wire harness to the
brake fluid line.
sm07066
Figure 7-7. Front WSS Connector [167]
WSS Wire Harness Bracket
See Figure 7-8. The bracket for the WSS wire harness mounts
with the caliper. If replacing the bracket, tighten both the long
and the short mounting bolts to 28-38 ft-lbs (38-52 Nm).
sm07696
Figure 7-8. WSS Wire Harness Chrome Bracket
Installation
1. Route the wire harness through the fork clamps and along
side the frame. Connect the WSS connector [167] hous-
ings
NOTE
Be sure wiring is routed inside the notch in the bracket.
2. See Figure 7-9. Route the WSS harness behind the
bracket on the caliper and along side the brake fluid line
with plastic clips.
3. Install the wheel with the WSS and the cover. See
2.5 FRONT WHEEL.
4. Install the fuel tank. See the service manual.
5. Install the nacelle. See 2.22 HEADLAMP NACELLE.
HOME
sm07061b
Figure 7-9. WSS Harness Clips
HOME
7.6 TURN SIGNALS
BULB REPLACEMENT
NOTE
Rear turn signals for all markets except domestic and Canada
use LEDs. Replace the entire turn signal housing.
1. Locate latch slot on circumference of turn signal lamp
smoked lens. Press in with small screw driver or coin and
turn to remove lens.
2. Push bulb in and rotate 1/4 turn counterclockwise to
remove.
3. Inspect contacts in socket. If necessary, clean contacts
with a small wire brush and electrical contact cleaner.
4. Evenly apply dielectric grease to the contacts and bottom
of the new bulb.
5. Push and rotate new bulb clockwise into socket.
6. Snap-in and rotate smoked lens to position latch slot on
bottom.
FRONT TURN SIGNALS
For replacing the front turn signals, see the service manual.
REAR LAMP REPLACEMENT
16.3-21.7 Nm 12-16 ft-lbs Rear turn signal housing
fastener
1. Remove and disassemble rear fender. See 2.13 REAR
FENDER.
2. Disconnect pins from 4-Pin connector [18, 19] as needed.
Refer to Table 7-1 or Table 7-2. See DEUTSCH DTM
SEALED SOLID BARREL MINI TERMINAL REPAIR in
the service manual.
3. Carefully remove wire from retainer clips along fender
support.
4. Remove fastener and washer securing lamp assembly to
fender support.
5. If equipped with side mount license plate bracket, separate
turn signal from license plate bracket.
6. Canada and HDI models: See Figure 7-10. If needed,
remove haness retainer (4) and tail lamp (1) or license
plate lamp (2).
7. Canada and HDI models: If installing tail lamp (1) or
license plate lamp (2), secure harness with a newhaness
retainer (4).
8. When installing new turn signal lamp assembly, install
side mount license plate bracket if equipped.
9. Install fastener and washer securing lamp assembly to
fender support. Tighten to 12-16 ft-lbs (16.3-21.7 Nm).
NOTE
Make sure retainer clips are securely fastened to fender. if
installing new retainer clips, clean affected surface with isop-
ropyl alcohol. Remove protective paper and press on surface
for 1-3 minutes.
10. Route wires of lamp along fender support. Make sure wires
are properly positioned in the retaining clips.
11. Refer to Table 7-1 or Table 7-2. Attach wires to 4-pin
connector [18, 19]. See DEUTSCH DTM SEALED SOLID
BARREL MINI TERMINAL REPAIRin the service manual.
12. Assemble and install rear fender. See 2.13 REAR
FENDER.
Table 7-1. Turn Signal Lighting Connector Pin Location
(Domestic and Canada)
FUNCTION COLOR PIN
Tail BE 1
Brake/Turn V 2
Not used - 3
Ground BK 4
Table 7-2. Turn Signal Lighting Connectors Pin Location
(HDI)
FUNCTION COLOR PIN
Tail W 1
Turn GN 2
Brake R 3
Ground BK 4
1
4
2
3
sm07692
1. Tail lamp (Canada)
2. License plate lamp (HDI)
3. Reflector (U.S.)
4. Harness retainer (Canada, HDI)
Figure 7-10. Rear Lighting
HOME
7.7 ELECTRICAL PANEL
REMOVAL
3. Remove splash guard.
4. See Figure 7-11. Press in on tab and pull ECMpanel away
from latch.
5. See Figure 7-12. Remove security siren (2), BCM(3), ECU
(4) and ECM with panel (5).
6. Detach purge solenoid (1) from rear electrical panel.
7. See Figure 7-13. Remove three fasteners securing rear
electrical panel to frame.
8. Remove rear electrical panel.
INSTALLATION
4.1-6.8 Nm 36-60 in-lbs Rear electrical panel fasteners
1. Install rear electrical panel.
2. See Figure 7-13. Install three fasteners securing rear
electrical panel to frame. Tighten to 36-60 in-lbs (4.1-6.8
Nm).
3. Attach purge solenoid (1) to rear electrical panel.
4. See Figure 7-12. Install BCM (3), security siren (2), ECU
(4) and ECM (5) with panel.
5. See Figure 7-11. Push ECM panel forward and engage
latch.
6. Install splash guard.
7. Install rear wheel. See 2.6 REAR WHEEL.
sm07682
Figure 7-11. ECM
2
3
4
1
5
sm07686
1. Purge solenoid
2. Security siren
3. BCM
4. ECU
5. ECM
Figure 7-12. Rear Electrical Panel
sm07693
Figure 7-13. Rear Electrical Panel Fasteners
HOME
7.8 ELECTRONIC CONTROL MODULE (ECM)
REMOVAL
from latch.
5. Disconnect ECM connector.
6. Remove ECM from panel.
INSTALLATION
1. Install ECM onto panel.
2. Connect ECM connector.
latch.
sm07682
Figure 7-14. ECM
HOME
7.9 SECURITY SIREN
REMOVAL
from latch.
5. See Figure 7-16. Disconnect electrical connector.
6. Remove security siren.
INSTALLATION
1. See Figure 7-16. Install security siren.
2. Connect electrical connector.
latch.
sm07682
Figure 7-15. ECM
sm07683
Figure 7-16. Security Siren
HOME
7.10 BODY CONTROL MODULE (BCM)
REMOVAL
from latch.
5. See Figure 7-18. Move security siren (1) out of the way.
6. Remove BCM (2).
INSTALLATION
1. See Figure 7-18. Install BCM (2).
2. See Figure 7-19. Install BCM connectors with harness
routed as shown.
3. Install security siren (1).
latch.
sm07682
Figure 7-17. ECM
1
2
sm07684
1. Security siren
2. BCM
Figure 7-18. BCM
sm07694
Figure 7-19. BCM Wire Routing
HOME
7.11 ELECTRONIC CONTROL UNIT (ECU)
REMOVAL
4. See Figure 7-20. Disconnect ECU connector.
5. Remove ECU from panel.
INSTALLATION
1. See Figure 7-20. Install ECU.
2. Connect ECU connector.
sm07685
Figure 7-20. ECU
HOME
7.12 COMPONENT LOCATIONS
COMPONENT LOCATIONS
Some components and connectors are not easily located on
the motorcycle. The following figures show locations for these
components and connectors. The figures are generally ordered
from front to back around the motorcycle.
1
2
ed03190
1. Front HCU connector [254]
2. Front HCU
Figure 7-21. Front HCU
1
3
2
ed03194
1. TGS connector [204]
2. Redundant engine stop switch connector [22-2]
3. RHCM connector [22-1]
Figure 7-22. Under Fuel Tank Right Side
sm07088
Figure 7-23. Interconnect Harness Connector [20]
1
2
ed03413
1. Fuel pump connector [141]
2. Console
Figure 7-24. Under Console
HOME
5
6
1
2
3
4
ed03192
1. Rear fuel injector connector [85]
2. Front ACR connector [203F]
3. Front fuel injector connector [84]
4. Rear ACR connector [203R]
5. TCA connector [211]
6. TMAP connector [80]
Figure 7-25. Between Cylinders Right Side
1 2
3
ed03195
1. Ignition coil connector [83]
2. Rear spark plug cable
3. Front spark plug cable
Figure 7-26. Ignition Coil
HOME
2
3
5
6
7
8
9
10
11
4
1
ed03415
7. 1. Fuel pump/sender [13] GND 1
2. 8. GND 2 Fuse block connector [64]
9. 3. DLC [91] Resistor pack [200] (behind battery)
4. 10. Security antenna connector [209] Left rear lighting [19]
11. 5. Rear HO2S [137] Right rear lighting [18]
6. Tail/LP lamp [45]
Figure 7-27. Under Seat
HOME
7.13 DIAGNOSTIC TOOLS
HOW TO USE DIAGNOSTIC TOOLS
BATTERY DIAGNOSTIC STATION GRX-3110 HD
SPARK TESTER HD-26792
FUEL INJECTOR TEST LIGHT HD-34730-2D
DIGITAL MULTIMETER (FLUKE 78) HD-39978
HARNESS CONNECTOR TEST KIT HD-41404
BREAKOUT BOX HD-42682
IGNITION COIL CIRCUIT TEST
ADAPTER
HD-44687
BREAKOUT BOX ADAPTERS HD-46601
ABS BREAKOUT BOX HD-48642
BREAKOUT BOX HD-50390-1
BCM CABLE HD-50390-2
BCM OVERLAY HD-50390-2-P
GRX-3110 HD Battery Diagnostic Station
Follow the instructions in the BATTERY DIAGNOSTIC STA-
TION (Part No. GRX-3110 HD) instruction manual to perform
a battery test. The test results include a decision on the battery
condition.
ed03407
Figure 7-28. Advanced Battery Conductance and Electrical
System Analyzer Kit
HD-26792 Spark Tester
See Figure 7-29. The SPARK TESTER (Part No. HD-26792)
is used to verify adequate spark at the spark plug. Attach the
tester to the coil top plug and to ground, while cranking the
engine a spark should jump across the gap on the tester leads.
NOTE
Engine will not spark with both spark plugs removed. When
checking for spark, use SPARK TESTER(Part No. HD-26792)
with both plugs installed.
ed02012
Figure 7-29. Spark Tester
HD-34730-2D Fuel Injector Test Light
The FUEL INJECTOR TEST LIGHT (Part No. HD-34730-2D)
and IGNITIONCOIL CIRCUIT TEST ADAPTER(Part No. HD-
44687) are used to test the fuel injector drivers as well as the
ignition coil drivers in the ECM.
1. Connect the BREAKOUT BOX (Part No. HD-43876).
2. Disconnect the fuel injector connectors.
3. See Figure 7-30 for typical setup. Connect one side of the
fuel injector test light to power and the other to the terminal
on the ECM for the circuit you are testing.
4. Crank the engine.
5. If the test light flashes, the circuit is working properly.
HOME
1
3
2
ed01945
1. Fuel injector test light
2. Ignition coil circuit test adapter
3. Breakout box
Figure 7-30. Fuel Injector Test Light
HD-39978 Digital Multimeter (Fluke 78)
The DIGITAL MULTIMETER(FLUKE 78) (Part No. HD-39978)
is used for various tests throughout this manual.
ed02008
Figure 7-31. Digital Multimeter (Fluke 78)
HD-41404 Harness Connector Test Kit
The HARNESSCONNECTORTEST KIT (Part No. HD-41404)
contains pin and socket terminals, and stackable banana jack
patch cords used to test circuits. The pin and socket terminals
are used to connect to various connectors used on the vehicle.
See the tool instruction sheet for specific terminal usage.
NOTE
To prevent terminal damage while using the probe tips, insert
the probe tip straight into the cavity and hold it steady during
the test. Do not wiggle or move the probe tip once it has been
inserted into the terminal. Do not use more than one probe per
terminal or cavity at any one time.
HD-42682 Breakout Box
The BREAKOUT BOX (Part No. HD-42682) and BREAKOUT
BOX ADAPTERS (Part No. HD-46601) connect to the
speedometer [39]. Used in conjunction with a multimeter, it
allows circuit diagnosis of wiring harness and connections
without having to probe with sharp objects. Install breakout
box in series using the black connectors as follows:
1. Access the speedometer [39]. See 7.3 SPEEDOMETER.
2. See Figure 7-32. Press latch and disconnect [39B].
3. Connect BREAKOUT BOX ADAPTERS (Part No. HD-
46601) to [39A] and [39B].
4. Attach black connectors from BREAKOUT BOX (Part
No. HD-42682) to BREAKOUT BOX ADAPTERS (Part
No. HD-46601). All tests will be performed using the black
side of the breakout box.
5. When testing is complete, remove the breakout box and
jumper harness and restore connections.
4
1
2
3
ed03412
1. Breakout box
2. Breakout box adapter
3. Speedometer [39]
4. Indicator lamps
Figure 7-32. Breakout Box Connection
HD-44687 Ignition Coil Circuit Test Adapter
The IGNITIONCOIL CIRCUIT TEST ADAPTER(Part No. HD-
44687) and FUEL INJECTOR TEST LIGHT (Part No. HD-
34730-2D) are used to test the fuel injector drivers as well as
the ignition coil drivers in the ECM.
1. Connect the BREAKOUT BOX (Part No. HD-48637).
2. Disconnect the fuel injector connectors.
3. See Figure 7-30 for typical setup. Connect one side of the
fuel injector test light to power and the other to the ECM
terminal for the circuit you are testing.
4. Crank the engine.
5. If the test light flashes, the circuit is working properly.
HOME
HD-48637 Breakout Box (ECM)
The BREAKOUT BOX (Part No. HD-48637) splices into the
main harness. Used in conjunction with a multimeter, it allows
circuit diagnosis of wiring harness and connections without
having to probe with sharp objects. Install breakout box in
series as follows:
NOTE
See wiring diagrams for ECM terminal functions. ECM is loc-
ated under passenger seat.
1. Access the ECM. See 8.2 ELECTRONIC CONTROL
MODULE.
2. Press latch and disconnect ECM [78].
3. See Figure 7-33. Connect BREAKOUT BOX(Part No. HD-
48637) to connectors.
restore connections.
2
1
3
ed03411
1. Breakout box (Part No. HD-48637)
2. ECM connection
3. Wiring harness connection
Figure 7-33. Installed Breakout Box (Part No. HD-48637)
HD-48642 Breakout Box (ABS)
The ABS BREAKOUT BOX (Part No. HD-48642) connects to
the ABS module [166]. Used in conjunction with a multimeter,
it allows circuit diagnosis of wiring harness and connections
without having to probe with sharp objects. Install breakout
box in series as follows:
1. Remove the splash guard and position the BCM aside.
2. Press latch and disconnect ABS module [166B].
3. See Figure 7-34. Connect ABS BREAKOUT BOX (Part
No. HD-48642) to connectors.
4. In some cases it is necessary to leave the ABS module
disconnected.
6. Position the BCM and install the splash guard.
2
3
1
ed03409
1. ECU harness [266B]
2. ECU [266A]
3. Breakout box
Figure 7-34. Typical Breakout Box Installation with ABS
Module Disconnected
HD-48650 Digital Technician II
DIGITAL TECHNICIAN II (Part No. HD-48650) is a computer
based diagnostic device used to communicate/diagnose and
program systems/modules.
Diagnostics in this manual are developed under the assumption
that DTII is not available.
HD-50390-1 Breakout Box (BCM)
The BREAKOUTBOX(Part No. HD-50390-1) and BCMCABLE
(Part No. HD-50390-2) splice into the main harness. Used in
conjunction with a multimeter, it allows circuit diagnosis of
wiring harness and connections without having to probe with
sharp objects. Install breakout box in series as follows:
NOTE
See wiring diagrams for BCM terminal functions. BCM is loc-
ated in front of the rear tire.
1. Access the BCM. See the service manual.
2. Press latch and disconnect BCM [242B].
3. See Figure 7-35. Connect BREAKOUT BOX(Part No. HD-
50390-1) and BCM CABLE (Part No. HD-50390-2) to
connectors.
4. Verify BCM OVERLAY (Part No. HD-50390-2-P) is in
position on breakout box.
HOME
6
4
5
1
2
3
ed03410
1. Breakout box
2. BCM cable
3. BCM
4. Wiring harness [242B]
5. BCM [242A]
6. BCM overlay
Figure 7-35. BCM Breakout Box Connection
HOME
7.14 INITIAL DIAGNOSTICS
DESCRIPTION AND OPERATION
Use initial diagnostics as a starting point to efficiently
troubleshoot concerns. A basic understanding of electronics
and a general knowledge of the vehicle are necessary to
effectively use this manual.
NOTE
Certain diagnostic procedures require part removal. See the
service manual for details.
Before diagnosing a concern, performa general functional test
of the vehicle to verify the concern. This will also identify any
other issues that may affect diagnostics. Use the procedures
in this chapter for initial diagnostics.
NOTE
When working through a diagnostic procedure followthe steps
in the order instructed. Never jump to a test in another pro-
cedure. All "Go to test" statements refer to a test in that pro-
cedure.
RETRIEVING TROUBLE CODES
There are two levels of diagnostics.
The most sophisticated mode uses a computer-based
diagnostic package called DIGITAL TECHNICIAN II (Part
No. HD-48650).
The second mode requires using the odometer self-dia-
gnostics. Speedometer, BCM, ECMand ABS (if equipped)
DTCs can be accessed and cleared.
ODOMETER SELF-DIAGNOSTICS
Diagnostic Mode
1. To enter diagnostic mode, press and hold the trip odometer
reset switch located on the left handlebar controls, while
turning the engine stop switch ON.
NOTE
The trip odometer reset switch is located in the left hand control
module. The switch signal is sent to the speedometer over the
CAN bus. Therefore, if there is a problem with the CAN bus,
the odometer self-diagnostic mode may not function.
2. Release the trip odometer reset switch. "diag" will appear
on the odometer display.
3. Press and release the trip odometer reset switch. "ECM"
will appear on the odometer display. It will have either a
"Y" or an "N" after it, depending if there are any ECM
codes or not.
4. Quickly press and release the trip odometer reset switch
to cycle through the modules. The modules include the
BCM, SPDO and ABS.
5. Once the desired module is displayed, press and hold the
trip odometer reset switch.
6. If any DTCs are stored in the module, the odometer will
display the DTC. Quickly pressing and releasing the trip
odometer reset switch will cycle through the stored DTCs.
7. When all the DTCs have been cycled the odometer will
display "end".
8. To clear all the DTCs in that module press and hold the
trip odometer reset switch, while a DTC is displayed. If
DTCs are not to be cleared quickly press and release the
trip odometer reset switch. The part number of the module
will be displayed.
9. Press and release the trip odometer reset switch again to
continue to the next module.
10. Make note of all DTCs. Clear all the DTCs and operate
the vehicle to verify DTCs set and are current. Historic
DTCs are not to be diagnosed unless the condition is
recurring and intermittent.
11. Turn the engine stop switch OFF to exit diagnostic mode.
If the engine stop switch is not turned off, vehicle will exit
diagnostics mode when vehicle starts moving.
INITIAL DIAGNOSTICS
1. Fuse Test
1. Verify all fuses a good.
2. Are all fuses good?
a. Yes. Go to Test 2.
b. No. Replace fuse.
2. DTC Test
1. Check for DTCs. See 7.14 INITIAL DIAGNOSTICS, Odo-
meter Self-Diagnostics.
2. Are DTCs present?
a. Yes. Refer to Table 7-3.
b. No. Go to Test 3.
3. Odometer Function Test
1. Enter odometer self-diagnostics. See 7.14 INITIAL DIA-
GNOSTICS, Odometer Self-Diagnostics.
2. Did odometer self-diagnostics mode function properly?
4. Odometer Inoperative Test
1. Turn the engine stop switch ON.
2. Does the odometer display illuminate?
5. Battery Power Test
HOME
2. Do headlamp and/or tail lamp illuminate?
b. No. Verify battery condition, connections and fuses.
See 7.17 NOVEHICLEPOWER, DTCU0100, U0121,
U0140, U0141, U0142, U0156, No Vehicle Power,
DTC U0140.
6. Starter Test
1. Attempt to start vehicle. Does the starter crank?
a. Yes. See the electrical diagnostic manual.
b. No. See 7.16 ODOMETER SELF-DIAGNOSTICS
INOPERATIVE, DTC U0001, U0011, B2274.
7. LHCM Test
1. With the engine stop switch ON, operate all left hand
control functions.
2. Do any left hand controls function properly?
a. Yes. All controls are operational except the trip switch.
See 7.21 TRIP ODOMETER FUNCTIONS INOPER-
ATIVE, DTC B2255.
b. No. All left hand control functions are inoperative. See
7.17 NO VEHICLE POWER, DTC U0100, U0121,
U0140, U0141, U0142, U0156, Left Hand Controls
Inoperative, DTC U0141.
DIAGNOSTICS
Diagnostic Tips
For a quick check of instrument function, performa "WOW"
test by entering odometer self-diagnostics. Background
lighting will illuminate, gauge needles will sweep their full
range of motion and indicator lamps controlled by the CAN
circuit (battery, security and check engine) will illuminate.
If the instrument fails "WOW" test, check for battery power
and ground to the instrument. If any feature in the
speedometer is non-functional, see the electrical diagnostic
manual.
Table 7-3. Diagnostic Trouble Codes (DTCs) and Fault Conditions Priority Table
SOLUTION FAULT CONDITION PRIORITY
ORDER
DTC
See the electrical diagnostic manual. LHCM internal fault 27 B1103
See the electrical diagnostic manual. RHCM internal fault 25 B1153
7.22 NO INSTRUMENT POWER, DTC B1200 Instrument internal fault 15 B1200
7.20 DTC B1210, B1211 Fuel sender shorted low/fuel
gauge circuit open
124 B1210
7.20 DTC B1210, B1211 Fuel sender shorted high 125 B1211
8.4 DTC B2102, B2103, B2104 System power output shorted
high
26 B2102
8.4 DTC B2102, B2103, B2104 System power output shorted
low
28 B2103
8.4 DTC B2102, B2103, B2104 System power output over-
loaded
29 B2104
See the electrical diagnostic manual. Front position/running power
output shorted high
178 B2107
output shorted low
179 B2108
output overloaded
180 B2109
7.24 ACCESSORIES, DTC B2112, B2113, B2114 Accessory output shorted high 91 B2112
7.24 ACCESSORIES, DTC B2112, B2113, B2114 Accessory output shorted low 92 B2113
7.24 ACCESSORIES, DTC B2112, B2113, B2114 Accessory output overloaded 93 B2114
See the electrical diagnostic manual. Fuel pump output open 69 B2116
See the electrical diagnostic manual. Fuel pump output shorted
high
71 B2117
See the electrical diagnostic manual. Fuel pump output shorted low 73 B2118
See the electrical diagnostic manual. Fuel pump output overloaded 75 B2119
See the electrical diagnostic manual. Starter output open 43 B2121
See the electrical diagnostic manual. Starter output shorted high 45 B2122
See the electrical diagnostic manual. Starter output shorted low 47 B2123
HOME
ORDER
DTC
See the electrical diagnostic manual. Starter output overloaded 49 B2124
See the electrical diagnostic manual. Horn output open 197 B2126
See the electrical diagnostic manual. Horn output shorted high 198 B2127
See the electrical diagnostic manual. Horn output shorted low 199 B2128
See the electrical diagnostic manual. Horn output overloaded 200 B2129
See the electrical diagnostic manual. High beam output open 187 B2131
See the electrical diagnostic manual. High beam output shorted
high
188 B2132
See the electrical diagnostic manual. High beamoutput shorted low 189 B2133
See the electrical diagnostic manual. High beamoutput overloaded 190 B2134
See the electrical diagnostic manual. Low beam output open 183 B2136
See the electrical diagnostic manual. Lowbeamoutput shorted high 184 B2137
See the electrical diagnostic manual. Low beam output shorted low 185 B2138
See the electrical diagnostic manual. Low beam output overloaded 186 B2139
See the electrical diagnostic manual. Left front turn signal output
open
166 B2141
shorted low
167 B2143
overloaded
168 B2144
See the electrical diagnostic manual. Right front turn signal output
open
169 B2146
shorted low
170 B2148
overloaded
171 B2149
See the electrical diagnostic manual. Left rear turn signal output
open
172 B2151
shorted low
173 B2153
overloaded
174 B2154
See the electrical diagnostic manual. Right rear turn signal output
open
175 B2156
shorted low
176 B2158
overloaded
177 B2159
See the electrical diagnostic manual. Brake lamp output open 160 B2161
See the electrical diagnostic manual. Brake lamp output shorted low 161 B2163
See the electrical diagnostic manual. Brake lamp output overloaded 162 B2164
See the electrical diagnostic manual. Running lights output open 121 B2166
7.27 RUNNING LAMPS, DTC B2107, B2108, B2109, B2166, B2168,
B2169
Running lights output shorted
low
122 B2168
7.27 RUNNING LAMPS, DTC B2107, B2108, B2109, B2166, B2168,
B2169
Running lights output over-
loaded
123 B2169
HOME
ORDER
DTC
See the electrical diagnostic manual. Security siren output shorted
high
191 B2172
See the electrical diagnostic manual. Security siren output shorted
low
192 B2173
See the electrical diagnostic manual. Security antenna output open 193 B2176
See the electrical diagnostic manual. Security antenna output
shorted high
194 B2177
See the electrical diagnostic manual. Security antenna output
shorted low
195 B2178
See the electrical diagnostic manual. High side drive output #1
shorted low
203 B2183
shorted low
204 B2188
shorted low
205 B2193
shorted low
206 B2198
No ignition switch present. Verify BCM is properly calibrated. Ignition switch input shorted
low
31 B2203
See the electrical diagnostic manual. Engine stop switch input open 33 B2206
See the electrical diagnostic manual. Run stop switch input shorted
low
35 B2208
See the electrical diagnostic manual. Run and stop inputs both
open
37 B2210
See the electrical diagnostic manual. Run and stop inputs both
closed
39 B2212
See the electrical diagnostic manual. Neutral switch shorted low 90 B2218
See the electrical diagnostic manual. Rear brake switch shorted low 159 B2223
BAS input open 207 B2226
BAS input shorted low 208 B2228
See the electrical diagnostic manual. Clutch switch stuck 88 B2250
See the electrical diagnostic manual. Horn switch stuck 196 B2251
See the electrical diagnostic manual. High beam switch stuck 182 B2252
See the electrical diagnostic manual. Low beam switch stuck 181 B2253
See the electrical diagnostic manual. Left turn switch stuck 164 B2254
7.21 TRIP ODOMETER FUNCTIONS INOPERATIVE, DTC B2255 Trip switch stuck 201 B2255
See the electrical diagnostic manual. Start switch stuck 41 B2260
See the electrical diagnostic manual. Right turn switch stuck 165 B2261
See the electrical diagnostic manual. Front brake switch stuck 158 B2262
See the electrical diagnostic manual. Hazard switch stuck 163 B2263
See the electrical diagnostic manual. BCM internal fault 10 B2270
See the electrical diagnostic manual. BCM voltage low 9 B2271
See the electrical diagnostic manual. BCM or speedometer voltage
high
14 B2272
7.16 ODOMETERSELF-DIAGNOSTICSINOPERATIVE, DTCU0001,
U0011, B2274
Constant battery line fault 30 B2274
See the electrical diagnostic manual. ABS voltage low 19 C0562
HOME
ORDER
DTC
See the electrical diagnostic manual. ABS voltage high 20 C0563
See the electrical diagnostic manual. Front actuator circuit low/open 132 C1018
See the electrical diagnostic manual. Front wheel speed sensor
always equals 0
152 C1021
See the electrical diagnostic manual. Rear wheel speed sensor
always equals 0
153 C1023
See the electrical diagnostic manual. Front wheel speed signal
intermittent
156 C1025
See the electrical diagnostic manual. Rear wheel speed signal
intermittent
157 C1027
See the electrical diagnostic manual. Front wheel speed sensor cir-
cuit open or shorted
150 C1032
See the electrical diagnostic manual. Rear wheel speed sensor cir-
cuit open or shorted
151 C1034
See the electrical diagnostic manual. Rear actuator lowcurrent fault 133 C1041
See the electrical diagnostic manual. Front actuator motor circuit
open
128 C1042
See the electrical diagnostic manual. Rear actuator motor circuit
open
129 C1044
See the electrical diagnostic manual. Rear actuator high current
fault
135 C1052
See the electrical diagnostic manual. ECU internal fault 21 C1055
See the electrical diagnostic manual. Front or rear brake switch
always on
146 C1094
See the electrical diagnostic manual. Rear actuator motor stalled 127 C1102
See the electrical diagnostic manual. Front wheel release too long 148 C1151
See the electrical diagnostic manual. Rear wheel release too long 149 C1153
See the electrical diagnostic manual. Calibration not programmed 22 C1158
See the electrical diagnostic manual. No VIN received from ECM 23 C1178
See the electrical diagnostic manual. VIN does not match ECU cal-
ibration
24 C1184
See the electrical diagnostic manual. Front actuator high current
fault
134 C1192
See the electrical diagnostic manual. Front actuator motor stalled 126 C1193
See the electrical diagnostic manual. Front wheel speed sensor
frequency out of range
154 C1206
See the electrical diagnostic manual. Rear wheel speed sensor fre-
quency out of range
155 C1208
See the electrical diagnostic manual. Front or rear brake not applied
on decel
147 C1212
See the electrical diagnostic manual. Battery 1 voltage low 16 C1222
See the electrical diagnostic manual. Battery 2 voltage low 17 C1223
See the electrical diagnostic manual. Front actuator power shorted 130 C1224
See the electrical diagnostic manual. Rear actuator power shorted 131 C1225
See the electrical diagnostic manual. Front apply solenoid circuit
open
136 C1561
See the electrical diagnostic manual. Front apply solenoid circuit
shorted low
138 C1562
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ORDER
DTC
See the electrical diagnostic manual. Front solenoid circuit shorted
high
140 C1563
See the electrical diagnostic manual. Front release solenoid circuit
open
142 C1564
See the electrical diagnostic manual. Front release solenoid circuit
shorted low
144 C1565
See the electrical diagnostic manual. Rear apply solenoid open 137 C1567
See the electrical diagnostic manual. Rear apply solenoid circuit
shorted low
139 C1568
See the electrical diagnostic manual. Rear solenoid circuit shorted
high
141 C1571
See the electrical diagnostic manual. Rear release solenoid circuit
open
143 C1572
See the electrical diagnostic manual. Rear release solenoid circuit
shorted low
145 C1573
8.9 DTCP0031, P0032, P0131, P0132, P0134, P0151, P0152, P0154 Front HO2 heaters low/open 106 P0031
8.9 DTCP0031, P0032, P0131, P0132, P0134, P0151, P0152, P0154 Front HO2 heaters
shorted/high
107 P0032
8.6 DTC P0107, P0108, P0112, P0113 MAP sensor failed low/open 80 P0107
8.6 DTC P0107, P0108, P0112, P0113 MAP sensor failed high/open
port
81 P0108
8.6 DTC P0107, P0108, P0112, P0113 Intake air temp sensor
low/shorted
85 P0112
8.6 DTC P0107, P0108, P0112, P0113 Intake air temp sensor
high/open
86 P0113
8.7 DTC P0117, P0118 Engine temp sensor
low/shorted
82 P0117
8.7 DTC P0117, P0118 Engine temp sensor
high/open
83 P0118
8.8 DTC P0120, P0122, P0123, P0220, P0222, P0223 Throttle position sensor 1
range error
48 P0120
8.8 DTC P0120, P0122, P0123, P0220, P0222, P0223 TP sensor open/low 51 P0122
8.8 DTC P0120, P0122, P0123, P0220, P0222, P0223 Throttle position sensor high 59 P0123
8.9 DTCP0031, P0032, P0131, P0132, P0134, P0151, P0152, P0154 Oxygen sensor low/engine
lean (front)
108 P0131
8.9 DTCP0031, P0032, P0131, P0132, P0134, P0151, P0152, P0154 Engine running rich (front) 110 P0132
8.9 DTCP0031, P0032, P0131, P0132, P0134, P0151, P0152, P0154 Oxygen sensor high/open
(front)
112 P0134
8.9 DTCP0031, P0032, P0131, P0132, P0134, P0151, P0152, P0154 Oxygen sensor low/engine
lean (rear)
109 P0151
8.9 DTCP0031, P0032, P0131, P0132, P0134, P0151, P0152, P0154 Engine running rich (rear) 111 P0152
8.9 DTCP0031, P0032, P0131, P0132, P0134, P0151, P0152, P0154 Oxygen sensor high/open
(rear)
114 P0154
range error
50 P0220
low/open
54 P0222
8.8 DTC P0120, P0122, P0123, P0220, P0222, P0223 Throttle position sensor 2 high 56 P0223
HOME
ORDER
DTC
8.10 DTC P0261, P0262, P0264, P0265 Fuel injector low/open (front) 76 P0261
8.10 DTC P0261, P0262, P0264, P0265 Fuel injector high/shorted
(front)
77 P0262
8.10 DTC P0261, P0262, P0264, P0265 Fuel injector low/open (rear) 78 P0264
8.10 DTC P0261, P0262, P0264, P0265 Fuel injector high/shorted
(rear)
79 P0265
8.11 DTC P0371, P0372, P0374 Crank position sensor too
many pulses
55 P0371
8.11 DTC P0371, P0372, P0374 Crank position sensor too few
pulses
57 P0372
8.11 DTC P0371, P0372, P0374 Crank position sensor no
pulses
53 P0374
8.12 DTC P0444, P0445 Purge solenoid low/open 100 P0444
8.12 DTC P0444, P0445 Purge solenoid shorted/high 101 P0445
8.13 DTC P0502, P0503 Vehicle speed failed low 94 P0502
8.13 DTC P0502, P0503 Vehicle speed failed high 96 P0503
8.14 DTC P0505 Loss of idle speed control 102 P0505
7.19 DTC P0562 Battery voltage low 95 P0562
8.16 DTC P0577 Battery voltage high 97 P0577
8.17 DTC P0603, P0605 ECMEEPROMmemory error 12 P0603
8.17 DTC P0603, P0605 ECM FLASH memory error 11 P0605
8.18 DTC P0641, P0651 5V Vref out of range 52 P0641
8.18 DTC P0641, P0651 5V reference 2 out of range 18 P0651
8.19 DTC P1009 Incorrect password 13 P1009
MAP sensor failed low/open 84 P1107
8.20 DTC P1270 Twistgrip position sensor 2
A/D validation error
34 P1270
8.21 DTC P1353, P1356, P1357, P1358 No combustion detected
(front)
98 P1353
8.21 DTC P1353, P1356, P1357, P1358 No combustion detected (rear) 99 P1356
8.21 DTC P1353, P1356, P1357, P1358 Front ignition coil intermittent
secondary detected
87 P1357
8.21 DTC P1353, P1356, P1357, P1358 Rear ignition coil intermittent
secondary detected
89 P1358
8.22 DTC P1501, P1502 JSS sensor low 116 P1501
8.22 DTC P1501, P1502 JSS sensor high/open 118 P1502
8.23 DTC P1510, P1511, P1512 Throttle actuator control lim-
ited performance
113 P1510
8.23 DTC P1510, P1511, P1512 Throttle actuator limited power
management mode
115 P1511
8.23 DTC P1510, P1511, P1512 Throttle actuator control
forced idle mode
117 P1512
8.24 DTC P1514 Throttle actuator control
system airflow fault
72 P1514
8.25 DTC P1600 TAC module - internal fault 32 P1600
8.26 DTC P1632 Odometer learned up 202 P1632
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ORDER
DTC
8.27 DTC P1655, P1656 ACR solenoid low/open 119 P1655
8.27 DTC P1655, P1656 ACR solenoid shorted/high 120 P1656
8.28 DTC P2100, P2101, P2102, P2103 Throttle actuator control motor
circuit/open
61 P2100
circuit range error
63 P2101
circuit low
65 P2102
circuit high
67 P2103
8.29 DTC P2105, P2107 Throttle actuator control
system forced engine shut-
down
74 P2105
8.29 DTC P2105, P2107 Throttle actuator control
module processor
36 P2107
system throttle return error
60 P2119
8.31 DTC P2122, P2123, P2127, P2128 Twistgrip position sensor 1
low/open
38 P2122
high
40 P2123
low/open
42 P2127
high
44 P2128
8.32 DTC P2135, P2138 Throttle position sensor correl-
ation error
58 P2135
8.32 DTC P2135, P2138 Twistgrip position sensor cor-
relation error
46 P2138
system - closed position not
learned
70 P2176
8.34 DTC P2300, P2301, P2303, P2304 Ignition coil driver low/open
(front)
62 P2300
8.34 DTC P2300, P2301, P2303, P2304 Ignition coil driver
high/shorted (front)
64 P2301
8.34 DTC P2300, P2301, P2303, P2304 Ignition coil driver low/open
(rear)
66 P2303
8.34 DTC P2300, P2301, P2303, P2304 Ignition coil driver
high/shorted (rear)
68 P2304
U0011, B2274
CAN BUS fault 1 U0001
U0011, B2274
CANBUSlowshorted to CAN
BUS high
2 U0011
7.17 NO VEHICLE POWER, DTC U0100, U0121, U0140, U0141,
U0142, U0156
Lost communication with ECM 4 U0100
U0142, U0156
Lost communication with ABS 8 U0121
U0142, U0156
Lost communication with BCM 3 U0140
HOME
ORDER
DTC
U0142, U0156
Lost communication with
LHCM
6 U0141
U0142, U0156
RHCM
5 U0142
U0142, U0156
instrument 1
7 U0156
CODE TYPES
There are two types of DTCs: current and historic. If a DTC is
stored, it can be read using either a computer-based diagnostic
package called DIGITAL TECHNICIANII (Part No. HD-48650)
or odometer self-diagnostics.
NOTES
Odometer self-diagnostics will display both current and
historic DTCs. To differentiate between current and historic
DTCs, a computer-based diagnostic package called
DIGITAL TECHNICIAN II (Part No. HD-48650) must be
employed.
Current DTCs reside in the memory of the ECM, BCM,
speedometer or ABS module (if equipped) until the DTC
is resolved.
DTCs are designated by a P, C, B or U depending on the
type of code and what module sets them. The ECM sets
"P" codes to indicate issues monitored by the ECM. The
ABS module sets "C" codes indicating an issue with the
ABS on the vehicle. The speedometer or BCM can both
set "B" codes. All the modules set "U" codes when there
is an issue causing the modules not to communicate
properly.
A historic DTCcan be cleared by use of the odometer self-
diagnostics or after a total of 20 error free ignition cycles
(start and run cycle) have elapsed.
Current
Current DTCs are those which presently disrupt motorcycle
operation and are set during the current ignition cycle. Verify
DTCs are current by clearing the DTC and then operating the
vehicle under the conditions for setting the DTC. To determine
current DTCs are present, clear the DTCs and operate the
vehicle within the parameters for setting the DTC. See the
appropriate diagnostic procedures for solutions.
Historic
If a particular problem happens to resolve itself, the active
status problemis dropped and it becomes a historic DTCrather
than a current DTC. DTCs will also lose their current status
when the engine stop switch is turned off. If the problem still
exists when the engine stop switch is turned on the code will
show as current.
Historic DTCs are stored for 20 ignition cycles after any DTC
was last set as current to assist in the diagnosis of intermittent
faults. On the 20th error free cycle, the DTC will clear itself.
It is important to note that historic DTCs will exist whenever
the system indicates the existence of a current fault. See
7.14 INITIAL DIAGNOSTICS, Multiple Trouble Codes if multiple
DTCs are found.
Diagnostic procedures are designed for use with current DTCs.
As a result, they frequently suggest part replacement. When
diagnosing a historic DTC, the procedures can be helpful but
should not lead to part replacement without verification that
the part is faulty.
MULTIPLE TROUBLE CODES
All DTCs are assigned a priority number to determine the order
in which they should be diagnosed. In the event there are
multiple DTCs present, always diagnose the highest priority
first. Refer to Table 7-3.
After a repair is completed, restore connections, clear DTCs
and start vehicle. Perform the odometer self-diagnostics test
to verify repair and that all DTCs have been cleared. If any
DTCs are still present, refer to Table 7-3.
CLEARING DTCS
DTCs should be cleared after any diagnostic or repair pro-
cedure is performed. The odometer is capable of displaying
and clearing ECM, BCM, speedometer and ABS DTCs. Once
the DTCs are cleared perform a road test to verify DTCs do
not return. It is important to perform a road test and not simply
start the motorcycle since some DTCs may require vehicle
speed or other inputs in order to validate repair.
SECURITY LAMP
The security lamp functions in the same manner as the check
engine lamp, except that it is controlled by the BCM. The
security lamp will be turned on when current codes are present
in the BCM.
CHECK ENGINE LAMP
To diagnose ECM system problems, start by observing the
behavior of the check engine lamp.
HOME
NOTES
"IGNON" means that the engine stop switch is set to RUN
(although the engine is not running).
When the engine stop switch 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 IGN ON or
if it fails to turn off after the initial four-second period, then
refer to Table 7-3.
1. See Figure 7-36. After the check engine lamp turns off
following the first four second illumination period, one of
two events may occur.
a. The lamp remains off. This indicates there are no
current fault conditions or stored DTCs currently
detected by the ECM.
b. If the lamp remains on beyond the four-second period,
a current DTC exists.
2. See 7.14 INITIAL DIAGNOSTICS, Code Types for a
complete description of DTC formats.
NOTE
Some DTCs can only be fully diagnosed during actuation. For
example, a problem with the ignition coil will be considered a
current fault even after the problemis corrected, since the ECM
will not know of its resolution until after the coil is exercised by
the vehicle start sequence. In this manner, there may some-
times be a false indication of the current DTC.
ON O
O ON
OFF
OFF
Ignition ON
ON
OFF
Ignition ON
ON
OFF
Ignition ON
Ignition ON
Lamp OFF: No Current DTCs
Lamp OFF: No Current DTCs
10 mph (16 km/h)
Lamp Remains ON: Current DTC*
Lamp Remains ON: Current DTC*
* Historic DTCs May Also Exist
4 Sec.
4 Sec.
4 Sec.
ed03174
Figure 7-36. Check Engine Lamp and Security Lamp Operation
SYMPTOMS
If no DTCs are present but there is a symptom or concern
indicating a malfunction, address and repair the symptom if it
is not a normal characteristic of the system. Refer to Table 7-4
for a list of symptoms.
Table 7-4. Symptom Table
DIAGNOSTIC PROCEDURE SYMPTOM
See the electrical diagnostic manual. ABS indicator always on or inoperative
See the electrical diagnostic manual. Any hand control switch inoperative
See the electrical diagnostic manual. Auxiliary lamps/running lamps inoperative
See the electrical diagnostic manual. Battery runs down during use
See the electrical diagnostic manual. Charging system inoperative
8.35 ENGINE CRANKS, BUT WILL NOT START Engine cranks, but will not start
See the electrical diagnostic manual. Fuel gauge inaccurate, no DTCs
HOME
Table 7-4. Symptom Table
DIAGNOSTIC PROCEDURE SYMPTOM
See the electrical diagnostic manual. Hand control switch inoperative
7.23 INDICATOR LAMPS High beam indicator inoperative
7.17 NO VEHICLE POWER, DTC U0100, U0121, U0140, U0141, U0142, U0156 Left hand controls inoperative
See the electrical diagnostic manual. Low battery after extended IGN OFF
7.23 INDICATOR LAMPS Low fuel lamp always on
See the electrical diagnostic manual. Low fuel lamp flashes at steady rate fuel
sender DTC set
7.23 INDICATOR LAMPS Low fuel lamp inoperative
See the electrical diagnostic manual. Low or no charging
7.23 INDICATOR LAMPS Neutral lamp inoperative
8.37 MISFIRE AT IDLE OR UNDER LOAD Misfire at idle or under load
7.21 TRIP ODOMETER FUNCTIONS INOPERATIVE, DTC B2255 Odometer displays "DIAG" at IGN ON
7.14 INITIAL DIAGNOSTICS, Odometer Self-Diagnostics Odometer self-diagnostics inoperative
7.23 INDICATOR LAMPS Oil pressure lamp always on
7.23 INDICATOR LAMPS Oil pressure lamp inoperative
See the electrical diagnostic manual. Overcharging
7.24 ACCESSORIES, DTC B2112, B2113, B2114 P&A battery power inoperative
7.27 RUNNING LAMPS, DTC B2107, B2108, B2109, B2166, B2168, B2169 Running lamps inoperative
7.28 SECURITY SYSTEM Security lamp inoperative
See the electrical diagnostic manual. Speedometer inoperative
Replace the console interconnect wire harness with the LED indicator lamp bar Speedometer inoperative and LEDflashes
continuously
7.18 STARTING SYSTEM DIAGNOSTICS Starter does not spin
7.18 STARTING SYSTEM DIAGNOSTICS Starter solenoid clicks
7.18 STARTING SYSTEM DIAGNOSTICS Starter spins, but does not engage
7.18 STARTING SYSTEM DIAGNOSTICS Starter stalls or spins too slowly
8.36 STARTS, THEN STALLS Starts, then stalls
7.21 TRIP ODOMETER FUNCTIONS INOPERATIVE, DTC B2255 Trip odometer reset switch inoperative
7.17 NO VEHICLE POWER, DTC U0100, U0121, U0140, U0141, U0142, U0156 Trip switch functions will not enter self-
diagnostics
7.23 INDICATOR LAMPS Turn signal indicator inoperative
7.17 NO VEHICLE POWER, DTC U0100, U0121, U0140, U0141, U0142, U0156 Vehicle power inoperative
HOME
7.15 CAN DATA COMMUNICATION
CAN bus circuits are used by modules and diagnostic tools to
share information.
1
2 4 3
5
6
7
10 9
8
ed03414
1. ECM
2. ECM [78]
3. Purge solenoid [95] (back side of purge solenoid)
4. Security siren
5. BCM
6. BCM [242] (back side of BCM)
7. Security siren [142]
8. Rear WSS [168]
9. ABS [166]
10. ABS ECU
Figure 7-37. ABS [166]
The speedometer, ECM, BCM, hand controls and ABS (if
equipped) all communicate on the CANbus. The CANcommu-
nication uses a (W/BK) and (W/R) wire in a twisted pair that
runs to all the modules and is used to transfer data from one
module to the other. This also runs to the DLC [91] and is used
to communicate with the modules using DIGITAL TECHNICIAN
II (Part No. HD-48650).
COMPONENTS
Electronic Control Module (ECM)
The ECM is located under the seat. The ECM monitors the
sensors from the engine and fuel system in order to manage
the fuel and spark delivery to the motorcycle which enhances
performance and driveability.
Speedometer
The speedometer contains part of the indicator and warning
lamps for the motorcycle. It uses the CAN communication to
receive information from the other modules to know which
lamps to illuminate at any given time. Vehicle speed is also
sent to the speedometer over the CAN bus. The LEDs in the
indicator bar are directly wired to the speedometer. The
speedometer turns the indicators on and off based off com-
mands from the BCM over the CAN bus.
BCM
See Figure 7-37. The BCM is located in front of the rear tire.
The BCMsupplies ignition and accessory power to most of the
vehicle and controls the power mode of the electrical system.
It controls the lighting along with other functions on the vehicle
by using the switches as inputs, and the power circuits for the
lights as outputs. The BCM is also connected to the CAN bus
and shares information with the other modules on the vehicle.
ABS Module
See Figure 7-37. The ABS ECU is located in front of the rear
tire. The ECU receives input from the front and rear WSS, and
controls the front and rear HCUs accordingly. The ABS ECU
communicates over the CANbus to the speedometer to control
the ABS indicator.
Hand Control Modules
The left and right hand control modules control all the switches
and controls on the handlebars. The engine stop switch has a
redundant wire directly to the BCM. In the event of a commu-
nication malfunction, this redundant circuit is used to keep the
engine from shutting off until the switch is turned off.
Data Link Connector (DLC)
The DLCis located under the seat. The DLCis used to connect
the DIGITAL TECHNICIAN II (Part No. HD-48650) to the
motorcycle.
HOME
7.16
ODOMETERSELF-DIAGNOSTICSINOPERATIVE,
DTC U0001, U0011, B2274
CANcommunication uses a set of wires in a twisted pair. These
two wires are designated as CAN low and CAN high circuits.
Both circuits are connected to the ECM, BCM, speedometer,
both hand control modules and the ABS module (if equipped).
The ECM and the right hand control module contain 120 Ohm
terminating resistors. Therefore, when checking the resistance
between the two circuits, approximately 60 Ohms will be dis-
played.
DTC U0001 indicates there is a fault on the CAN bus cir-
cuits. This code can be set by the ECM, BCM, instruments
and ABS module (if equipped). This code is usually
accompanied by other "U" codes, due to it usually causing
a loss of communication between the modules on the CAN
bus.
DTC U0011 indicates the high and low CAN circuits are
shorted together. This fault will be accompanied by other
"U" codes and may cause the odometer display not to
function.
DTC B2274 indicates there is a fault with the battery fuse
or the (R/O) wire.
NOTE
It is important to always start from7.14 INITIAL DIAGNOSTICS
before proceeding with this test.
Table 7-5. Code Description
DESCRIPTION DTC
CAN bus fault U0001
CAN bus low shorted to CAN bus high U0011
Constant battery line fault B2274
Diagnostic Tips
The speedometer does not have an ignition input. Instead, it
receives a message over the CAN bus, indicating the engine
stop switch is ON. Also, the trip odometer reset switch is a
CAN communication to the speedometer. Therefore, CAN bus
errors can cause the odometer self-diagnostics to be completely
inoperative or to only partially function. The speedometer
backlighting may not function along with the hand control
switches and the indicators.
The odometer may read "BUS Err" in this condition, prior to
the odometer becoming inoperative.
The BCM supplies power to several systems on the vehicle.
When testing for a short to voltage, perform all tests before
disconnecting the BCM to keep from powering down systems
on the vehicle. If the short to voltage goes away when the BCM
is disconnected, test for continuity between circuit in question
and BCM [242B] terminals F4, J3, L3, L4 and M2 to verify the
tested circuit is not shorted to one of these circuits. If continuity
is present, repair short to circuit instead of replacing the BCM.
Connector Information
For additional information about the connectors in the following
diagram(s) and diagnostic procedure(s), including the color of
the harness test kit terminal probes, see A.1 CONNECTORS.
HOME
Right
Hand
Controls
BCM
DLC
GND 2
Main
Wiring
GND 1
Battery
Power
Indicator
Lamps
Battery
Fuse
ECM
Left
Hand
Controls
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
BK
B
K
BK/GN BK/GN
W/BK
R/O
W/R
W/BK
W/R
BK/GN BK/GN
BK/GN BK/GN
W/BK
W/BK
R/GN
W/BK
R/GN
R/GN
W/BK
R/O R/O R/O
R/O
W/R
W/BK
W/R
W/R W/R
W/R
R
R
R
[24A] [24B]
[91A]
[22B-1] [22A-1]
E2
D2
G4
1
E2
D2
G4
L3 L3
1
42
41
73
71 71
52 52
42
41
73
ABS
1
3
Speedometer
2
8
7
5
2
8
7
5
1
3
2
6
1
3
2
6
18
19
20
6 6
18
19
20
R 11 11
[242A] [242B]
[39A] [39B] [20A] [20B]
[78B] [78A]
[166B] [166A]
W/BK
W/R
R/O
R
/
O
R
/
O
BK/GN
W/BK
W/R
R/O
BK/GN
B
K
/
G
N
W/BK
W/R
[259A] [259B]
em01459
Figure 7-38. CAN Bus Circuit
HOME
ODOMETER SELF-DIAGNOSTIC
INOPERATIVE, DTC U0001, U0011, B2274
Table 7-6. Odometer Self-Diagnostic Inoperative, DTC
U0001, U0011, B2274 Diagnostic Faults
POSSIBLE CAUSES
Blown battery fuse
Open battery power circuit
Short between CAN low and high circuits
Open in CAN high circuit
Open in CAN low circuit
Short to ground on CAN high circuit
Short to ground on CAN low circuit
Short to voltage on CAN high circuit
Short to voltage on CAN low circuit
1. CAN Bus Shorted Together Test
1. Measure the resistance between DLC [91A] terminals 1
and 3.
2. Is resistance less than 50 Ohms?
2. Speedometer Test
1. Disconnect the speedometer [39].
2. Is resistance between DLC [91A] terminals 1 and 3 less
than 50 Ohms?
b. No. Replace the speedometer. See 7.3 SPEEDO-
METER.
3. ECM Test
1. Disconnect the ECM [78].
than 50 Ohms?
b. No. Replace the ECM. See 8.2 ELECTRONIC CON-
TROL MODULE.
4. LHCM Test
1. Disconnect the left hand control module [24].
than 50 Ohms?
b. No. Replace the LHCM. See the service manual.
5. RHCM Test
1. Disconnect the right hand control module [22-1].
than 50 Ohms?
b. No. Replace the RHCM. See the service manual.
6. BCM Test
1. Disconnect the BCM [242].
than 50 Ohms?
a. Yes, with ABS. Go to Test 6.
b. Yes, without ABS. Repair short between high and
low speed CAN circuits.
c. No. Replace the BCM. See the service manual.
7. ABS Test
1. Disconnect the ABS module [166].
than 50 Ohms?
a. Yes. Repair short between high and low speed CAN
circuits.
b. No. Replace the ABS module. See the service
manual.
8. CAN High Circuit Short to Voltage Test
1. With the engine stop switch ON, measure voltage between
DLC [91A] terminal 1 and ground.
2. Is voltage greater than 4V?
9. Speedometer Test
2. Is voltage between DLC [91A] terminal 1 and ground
greater than 4V?
METER.
10. ECM Test
greater than 4V?
TROL MODULE.
11. LHCM Test
HOME
greater than 4V?
12. RHCM Test
13. BCM Test
greater than 4V?
b. Yes, without ABS. Repair short to voltage in (W/R)
wire.
14. ABS Test
greater than 4V?
a. Yes. Repair short to voltage in (W/R) wire.
manual.
15. CAN High Circuit Short to Ground Test
1. With the engine stop switch OFF, measure resistance
between DLC [91A] terminal 1 and ground.
16. Speedometer Test
2. Is resistance between DLC [91A] terminal 1 and ground
less than 1000 Ohms?
METER.
17. ECM Test
TROL MODULE.
18. LHCM Test
19. RHCM Test
20. BCM Test
b. Yes, without ABS. Repair short to ground in (W/R)
wire.
21. ABS Test
a. Yes. Repair short to ground in (W/R) wire.
manual.
22. CAN Low Circuit Short to Voltage Test
1. With the engine stop switch OFF, measure voltage
greater than 4V?
METER.
24. ECM Test
HOME
greater than 4V?
b. Yes, without ABS. Go to Test 28.
c. No. Replace the ECM. See 8.2 ELECTRONIC CON-
TROL MODULE.
25. LHCM Test
greater than 4V?
26. RHCM Test
greater than 4V?
27. BCM Test
greater than 4V?
b. Yes, without ABS. Repair short to voltage in (W/BK)
wire.
28. ABS Test
greater than 4V?
a. Yes. Repair short to voltage in (W/BK) wire.
manual.
29. CAN Low Circuit Short to Ground Test
1. With the engine stop switch OFF, measure resistance
METER.
31. ECM Test
TROL MODULE.
32. LHCM Test
33. RHCM Test
34. BCM Test
b. Yes, without ABS. Repair short to ground in (W/BK)
wire.
35. ABS Test
a. Yes. Repair short to ground in (W/BK) wire.
manual.
36. CAN High Circuit Continuity Test
46601) to [39]. Attach connectors from BREAKOUT BOX
(Part No. HD-42682) to harness adapters, leaving [39A]
disconnected.
HOME
2. With the engine stop switch OFF, test for continuity
between breakout box terminal 2 and DLC [91A] terminal
1.
3. Is continuity present?
b. No. Repair open in (W/R) wire.
37. CAN Low Circuit Continuity Test
between breakout box terminal 8 and DLC [91A] terminal
3.
b. No. Repair open in (W/BK) wire.
38. Speedometer Power Test
1. Test for voltage between breakout box terminal 5 and
ground.
2. Is battery voltage present?
b. No. Repair open in (R/O) wire.
39. Speedometer Ground Test
1. Test for voltage between breakout box terminals 5 and 7.
b. No. Repair open in (BK/GN) wire.
40. ECM Power Test
1. Turn the engine stop switch OFF.
2. Connect BREAKOUT BOX (Part No. HD-43876) to wiring
harness [78B], leaving ECM [78A] disconnected. See
7.13 DIAGNOSTIC TOOLS.
ground.
4. Is voltage present?
a. Yes, speedometer is setting the code. Replace the
speedometer. See 7.3 SPEEDOMETER.
b. Yes, ECM is setting the code. Replace the ECM.
See 8.2 ELECTRONIC CONTROL MODULE.
c. No. Repair open in (R/O) wire.
HOME
7.17
NOVEHICLEPOWER, DTCU0100, U0121, U0140,
U0141, U0142, U0156
The CAN bus circuit provides a means for the ECM, speedo-
meter, BCM, hand control modules and the ABS module (if
equipped) to communicate their current status. When all
operating parameters on the CANbus are within specifications,
a state of health message is sent between the components.
The CAN bus is made up of two circuits. The (W/R) is the CAN
bus high circuit and the (W/BK) is the CANbus lowcircuit. Both
of these circuits show around 2.5V when measured between
each of the circuits and ground with the engine stop switch
ON. These circuits are connected to each module on the CAN
bus network. A fault on either one of these circuits will cause
several modules to set "U" codes and may cause a complete
loss of communication between all modules.
DESCRIPTION DTC
Lost communication with ECM, set by BCM or
speedometer
U0100
Lost communication with ABS, set by BCM or
speedometer
U0121
Lost communication with BCM, set by speedo-
meter, ECM or ABS (if equipped)
U0140
Lost communication with LHCM, set by BCM,
speedometer or ECM
U0141
Lost communication from RHCM, set by BCM,
ECM or ABS (if equipped)
U0142
Lost communication from speedometer, set by
BCM or ECM
U0156
Diagnostic Tips
Modules must have power in order to communicate on the
CAN bus. It is important to check for good power and ground
on any module that is not communicating effectively on the
CAN bus network. At least two modules will set a lost commu-
nication DTC when one module has lost the ability to commu-
nicate on the CANbus. When two or more modules are setting
the same U-code this indicates a problem with the device the
code is set against. If two or more modules are intermittently
setting the same U-code, it indicates an intermittent problem
with the device the code is set against or intermittent CAN,
power or ground wires to the device. See the electrical dia-
gnostic manual for procedure to perform a wiggle test.
The BCM supplies power to several systems on the vehicle.
When testing for a short to voltage, perform all tests before
disconnecting the BCM to keep from powering down systems
on the vehicle. If the short to voltage goes away when the BCM
is disconnected, test for continuity between the circuit in
question and BCM [242B] terminals F4, J3, L3, L4 and M2 to
verify the tested circuit is not shorted to one of these circuits.
If continuity is present, repair shorted circuit instead of replacing
the BCM.
Historic U-codes may be found if battery power has been lost
for any reason or if the main or battery fuse have been discon-
nected and reconnected. This may also happen if during dia-
gnostics using DIGITAL TECHNICIAN II (Part No. HD-48650).
The diagnostics connector has been disconnected before
vehicle has been powered down. This is not an indication of a
problem and does not cause any loss of functionality.
HOME
Right
Hand
Controls
BCM
DLC
GND 2
Main
Wiring
GND 1
Battery
Power
Indicator
Lamps
Battery
Fuse
ECM
Left
Hand
Controls
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
BK
B
K
BK/GN BK/GN
W/BK
R/O
W/R
W/BK
W/R
BK/GN BK/GN
BK/GN BK/GN
W/BK
W/BK
R/GN
W/BK
R/GN
R/GN
W/BK
R/O R/O R/O
R/O
W/R
W/BK
W/R
W/R W/R
W/R
R
R
R
[24A] [24B]
[91A]
[22B-1] [22A-1]
E2
D2
G4
1
E2
D2
G4
L3 L3
1
42
41
73
71 71
52 52
42
41
73
ABS
1
3
Speedometer
2
8
7
5
2
8
7
5
1
3
2
6
1
3
2
6
18
19
20
6 6
18
19
20
R 11 11
[242A] [242B]
[39A] [39B] [20A] [20B]
[78B] [78A]
[166B] [166A]
W/BK
W/R
R/O
R
/
O
R
/
O
BK/GN
W/BK
W/R
R/O
BK/GN
B
K
/
G
N
W/BK
W/R
[259A] [259B]
em01459
DTC U0100
Table 7-8. DTC U0100 Diagnostic Faults
POSSIBLE CAUSES
Open in CAN high circuit to the ECM
Open in CAN low circuit to the ECM
Open in ECM system power circuit
Open in ECM ground circuit
1. ECM Voltage Test
1. Connect BREAKOUT BOX (Part No. HD-48637) to the
wiring harness [78B], leaving the ECMdisconnected. See
ground.
2. System Power Test
ground.
b. No. Repair open in (R/GN) wire.
3. ECM Ground Test
1. Test for voltage between breakout box terminals 71 and
73.
HOME
between breakout box terminal 41 and DLC[91A] terminal
1.
between breakout box terminal 42 and DLC[91A] terminal
3.
a. Yes. See diagnostic tips. Replace BCM. See the
service manual.
DTC U0121
POSSIBLE CAUSES
Open in CAN high circuit to the ABS module
Open in CAN low circuit to the ABS module
Open in ABS system power circuit
Open in ABS ground circuit
1. ABS Voltage Test
1. Connect ABS BREAKOUT BOX (Part No. HD-48642) to
the wiring harness [166B], leaving the ABSmodule discon-
nected. See 7.13 DIAGNOSTIC TOOLS.
ground.
b. No. Repair open in (R) wire.
2. ABS Ground Test
1. Test for voltage between breakout box terminals 20 and
6.
b. No. Repair open in (BK) wire.
between ABS [166B] terminal 18 and DLC [91A] terminal
1.
between ABS [166] terminal 19 and DLC [91A] terminal
3.
a. Yes. Replace the ABS module. See the service
manual.
NO VEHICLE POWER, DTC U0140
Table 7-10. No Vehicle Power, DTC U0140 Diagnostic
Faults
POSSIBLE CAUSES
Open in CAN high circuit to the BCM
Open in CAN low circuit to the BCM
Open in BCM battery power circuit
Open in BCM ground circuit
BCM malfunction
RHCM malfunction
NOTE
The BCM will turn off power to the vehicle if the engine stop
switch has been ON for 15 minutes with no inputs from any of
the modules or switches.
1. BCM Ground Test
1. Connect the BREAKOUT BOX(Part No. HD-50390-1) and
BCM CABLE (Part No. HD-50390-2) to wire harness
[242B], leaving BCM [242A] disconnected. See 7.13 DIA-
GNOSTIC TOOLS.
3. Using the HARNESS CONNECTOR TEST KIT (Part
No. HD-41404) and a multimeter, test for voltage between
BCM [259B] terminal 1 and breakout box terminal G4.
HOME
between BCM[242B] terminal D2 and DLC [91A] terminal
1.
between BCM [242B] terminal E2 and DLC [91A] terminal
3.
4. RHCM Test
1. Disconnect RHCM connector [22-1] and [22-2].
2. Test a known good RHCM without installing it on the
vehicle.
3. Connect [22B-1] and [22B-2] fromthe newRHCMto [22A-
1] and [22A-2] of the main harness.
4. Push the engine stop switch to RUN.
5. Does the vehicle power up?
a. Yes. Replace the RHCM. See the service manual.
b. No. Replace the BCM. See the service manual.
5. BCM Voltage Test
1. Test for voltage between BCM [259B] terminal 1 and
ground.
a. Yes. Repair open in (BK/GN) wire.
b. No. Repair open in (R) wire.
LEFTHANDCONTROLSINOPERATIVE, DTC
U0141
Table 7-11. Left Hand Controls Inoperative, DTC U0141
Diagnostic Faults
POSSIBLE CAUSES
Open in CAN high circuit to the LHCM
Open in CAN low circuit to the LHCM
Open in LHCM battery power circuit
Open in LHCM ground circuit
1. LHCM Voltage Test
1. Test for voltage between LHCM [24A] terminal 1 and
ground.
2. LHCM Test
1. Test for voltage between [24A] terminals 1 and 2.
between [24A] terminal 3 and DLC [91A] terminal 1.
between [24A] terminal 4 and DLC [91A] terminal 3.
a. Yes. Replace the LHCM. See the service manual.
DTC U0142
POSSIBLE CAUSES
Open in CAN high circuit to the RHCM
Open in CAN low circuit to the RHCM
Open in RHCM battery power circuit
Open in RHCM ground circuit
1. RHCM Voltage Test
1. Test for voltage between RHCM [22A-1] terminal 1 and
ground.
2. RHCM Ground Test
1. Test for voltage between RHCM [22A-1] terminals 1 and
2.
HOME
between [22A-1] terminal 3 and DLC [91A] terminal 1.
between [22A-1] terminal 4 and DLC [91A] terminal 3.
DTC U0156
POSSIBLE CAUSES
Open in CAN high circuit to the speedometer
Open in CAN low circuit to the speedometer
Open in speedometer battery power circuit
Open in speedometer ground circuit
1. Speedometer Voltage Test
1. Connect BREAKOUT BOX (Part No. HD-42682) and
BREAKOUT BOX ADAPTERS (Part No. HD-46601) to
the wiring harness [39B], leaving the speedometer discon-
nected. See 7.14 INITIAL DIAGNOSTICS.
ground.
2. Speedometer Ground Test
1. Test for voltage between breakout box terminals 5 and 7.
between speedometer [39B] terminal 2 and DLC [91A]
terminal 1.
between speedometer [39B] terminal 8 and DLC [91A]
terminal 3.
a. Yes. Replace the speedometer. See 7.3 SPEEDO-
METER.
HOME
7.18 STARTING SYSTEM DIAGNOSTICS
Battery voltage is supplied to the BCM at all times through the
main fuse.
When the engine stop switch is in the RUN position, a CAN
message is sent, signaling the BCM that the switch is in the
RUNposition. If CANcommunication is interrupted while engine
is running, a redundant engine stop switch circuit allows com-
munication with the BCM. The engine stop switch also functions
as the ignition switch. The BCM will not supply any ignition or
accessory power to the vehicle unless the engine stop switch
is in the RUN position.
When the start switch is pressed, a CAN message is sent to
the BCM. The BCM provides power to the starter solenoid.
This energizes the solenoid and full battery power is sent to
the starter. The BCM disables the starter solenoid if the start
switch is pressed for more than 10 seconds.
COMPONENTS
Starter
The starter receives power fromthe battery through the starter
solenoid and is grounded through the starter case. When the
starter solenoid is energized, two actions occur:
The plunger pulls inward which allows current to flow to
the starter motor.
The pinion gear engages with the ring gear on the clutch
shell.
With the starter motor turning, the rotation is transferred to the
following:
The starter armature gear transfers rotation to the idler
gear.
The idler gear transfers rotation to the starter clutch.
The starter clutch transfers rotation through a spline gear
to the starter drive shaft which also drives the pinion gear.
The pinion gear transfers its rotation to the ring gear on
the clutch shell.
The primary chain drives the alternator rotor sprocket on
the end of the crankshaft.
The starter clutch is equipped with a one way clutch so when
the engine starts, it allows the clutch shell and sprocket to spin
freely without causing any damage to the starter motor. After
the engine starts and the start switch is released, the plunger
returns to its normal position, disengaging the pinion gear from
the clutch shell and sprocket.
1
2
3
2
4
5
6
sm04239
1. Starter
2. Starter mounting fasteners
3. Positive battery cable post
4. Solenoid wire
5. Neutral switch
6. Vehicle speed sensor
Figure 7-40. Starter
Starter Solenoid
See Figure 7-40. The starter solenoid provides power to the
starter. The solenoid is a means of controlling a high amperage
device with a low amperage switch. The low amperage switch
in this circuit is the BCM. The BCMsends voltage to the starter
solenoid making a magnetic field that pulls a larger circuit
closed, allowing voltage to the starter.
Engine Stop Switch
The engine stop switch is located on the right hand controls.
With the engine stop switch in the RUN position, a CAN mes-
sage is sent, signaling the BCM that the switch is in the RUN
position. If CAN communication is interrupted while engine is
running, a redundant engine stop switch circuit allows commu-
nication to the BCM. The engine stop switch also functions as
the ignition switch. The BCM will not supply any ignition or
accessory power to the vehicle unless the engine stop switch
is in the RUN position.
Start Switch
The start switch is a push button switch located in the right
hand controls. When the start switch is pressed, a CAN mes-
sage is sent to the BCM.
BCM
The BCMsupplies ignition and accessory power to most of the
vehicle. It controls the lighting along with other functions on
HOME
the vehicle by using the switches as inputs, and the power
circuits for the lights and other electrical loads as outputs.
Battery
Batteries contain sulfuric acid, which could cause severe
burns to eyes and skin. Wear a protective face shield,
rubberized gloves and protective clothing when working
with batteries. KEEPBATTERIESAWAYFROMCHILDREN.
(00063a)
Never remove warning label attached to top of battery.
Failure to read and understand all precautions contained
in warning, could result in death or serious injury. (00064a)
Explosive hydrogen gas, which escapes during charging,
could cause death or serious injury. Charge battery in a
well-ventilated area. Keep open flames, electrical sparks
and smoking materials away from battery at all times.
KEEP BATTERIES AWAY FROM CHILDREN. (00065a)
If battery becomes hot, gassing or spewing of electrolyte
can occur, which could cause death or serious injury.
Unplug or turn OFF the charger until battery cools.
(00412b)
Batteries, battery posts, terminals and related accessories
contain lead and lead compounds, and other chemicals
known to the State of California to cause cancer, and birth
defects or other reproductive harm. Wash hands after
handling. (00019e)
If battery releases an excessive amount of gas during
charging, decrease the charging rate. Overheating can
result in plate distortion, internal shorting, drying out or
damage. (00413b)
The AGMbatteries are permanently sealed, maintenance-free,
valve-regulated, lead/calcium and sulfuric acid batteries.
The battery is recharged by the alternator and kept from over-
charging by the regulator during use.
Battery condition can be determined by a voltage test, a con-
ductance test or a load test. See the electrical diagnostic
manual.
A battery may be tested, whether fully charged or not, using
the conductance test. However, the battery must be fully
charged to perform a load test.
Grinding Noise or Erratic Starting
1. Remove starter. See the service manual.
2. Inspect the starter mounting surface and mating area on
inner primary for arcing and pitting. This condition is
caused by insufficient ground and or clamp load.
3. Clean mating surfaces.
4. Inspect starter pinion gear. Replace starter clutch
assembly if damaged (cracked or missing teeth). Rounding
of pinion gear teeth is considered normal. If pinion gear
needs to be replaced, inspect ring gear on clutch. Replace
clutch ring gear if damaged. See the service manual.
5. Install starter. See the service manual.
Job/Time Code Values
Dealership Technicians filing warranty claims should use the
job/time code values printed in (bold text) beside the appro-
priate repair.
HOME
BK/GN BK/GN
BK/GN
BK/GN
BK/GN
B
K
/
G
N
R/BK
R/BK
R/GN
R/GN
W/BK
W/BK
W/BK
W/GY
W/GY W/GY
BK
BK
BK
BK
R
/
O
R/O
R/O
W/R
W/BK
W/BK
R/O
R/O
W/R
W/R W/R
W/R
R
R
W
W
R
R
R
R
R
[259A] [259B]
2
1
B
A
[131B-2] [131A-2]
[22B-2] [22A-2]
[131B-1] [131A-1]
[78B] [78A]
[22B-1] [22A-1]
[128B]
C4
D2
D3
E2
G4
L2
Engine Stop Switch Input
Engine Stop Switch
CAN High
CAN High
CAN High
Neutral Switch Input
CAN Low
CAN Low
CAN Low
Ground
Ground
Ground
Battery
Battery
Starter Solenoid Power
System Power
Battery Power
BCM
Fuse
Block
GND 1
B
K
GND 2 GND 1
Battery
Starter
Right
Hand
Controls
Left
Hand
Controls
Main
40A
Battery
15A
[64B]
1
C4
D2
D3
E2
G4
L2
L3 L3
1
BCM Input
Ground
Neutral
Switch
ECM
1 1
1 1
10
13
28
Ground
System Power
Ground
10
13
28
1
2
3
4
1
1 1
2
3
4
[24B] [24A]
4
3
2
1
4
3
2
1
[242A] [242B]
2
1
em00911
Figure 7-41. Starting Circuit
HOME
STARTER TROUBLESHOOTING
The troubleshooting tables contain detailed procedures to solve
and correct problems. Follow 7.18 STARTING SYSTEM DIA-
GNOSTICSto diagnose starting systemproblems. The voltage
drop test procedure will help you to locate poor connections
or components with excessive voltage drops.
Table 7-14. Starter Does Not Run or Runs at Very Low Speeds
SOLUTION POSSIBLE CAUSE SOURCE OF PROBLEM
Charge battery. Voltage drop due to discharged battery. Battery
Replace battery. Short-circuit or open between electrodes.
Clean and retighten. Poor contact condition of battery ter-
minal(s).
Repair or replace cable(s). Poor or no connection at either end of the
battery positive or negative cable.
Wiring
Clean, tighten or replace cable(s) as
needed.
Cracked or corroded battery cable ends.
Tighten connections or repair or replace
wire(s).
Open wire(s) or poor connection at
handlebar switch or BCM ground wire.
Replace RHCM. Stuck switch or open switch. Start switch or engine stop switch
Replace neutral switch or repair open. Switch or wiring from neutral switch to
BCM failed open.
Neutral switch
Replace clutch switch. Clutch switch always open. Clutch switch
Replace solenoid assembly. Poor contact condition caused by burned
contacts.
Starter solenoid
Replace solenoid assembly. Windings open or short-circuited.
Replace starter. Brushes worn below specification. Starter motor
Replace starter. Commutator burnt.
Replace starter. Commutator high mica.
Replace starter. Field winding grounded.
Replace starter. Armature winding grounded or short-cir-
cuited.
Replace starter. Free running current draw out of range.
Replace starter. Insufficient brush spring tension.
Replace ACR. ACR failure. ACR (if equipped)
Replace starter clutch assembly. Starter clutch failure. Starter clutch
Table 7-15. Starter Spins But Does Not Engage
Charge battery. Voltage drop due to discharged battery. Battery
Replace battery. Short-circuit or open between electrodes.
Clean and retighten. Poor contact condition of battery ter-
minal(s).
Replace starter clutch assembly. Pinion gear teeth worn out. Starter motor
Replace clutch shell and sprocket. Excessively worn teeth. Gear teeth on clutch shell and sprocket.
Replace starter clutch assembly. Starter clutch failure. Starter clutch
HOME
Table 7-16. Starter Does Not Stop Running
Replace starter solenoid assembly. Coil shorted. Starter solenoid
Replace starter solenoid assembly. Contact plate melted and stuck.
STARTER TESTING
Table 7-17. Starter Testing Diagnostic Faults
POSSIBLE CAUSES
Short to voltage at starter solenoid
Start switch malfunction
Short to voltage on BCM supply circuit
1. Starting System Operational Test
1. With the transmission in neutral and the engine stop switch
in the RUN position, press the start switch.
2. Does the starter spin?
a. Yes, starter spins but does not engage. See
7.18 STARTING SYSTEM DIAGNOSTICS, Starter
Spins But Does Not Engage.
b. Yes, starter stalls or spins too slowly. See
7.18 STARTING SYSTEM DIAGNOSTICS, Starter
Stalls or Spins Too Slowly.
c. Yes, starter runs on. Go to Test 3.
d. No. Go to Test 2.
2. Audible Noise Test
1. While listening for audible clicking noise from the starter
solenoid, press the start switch.
2. Does the starter solenoid click?
a. Yes, starter solenoid clicks. See 7.18 STARTING
SYSTEM DIAGNOSTICS, Starter Solenoid Clicks.
b. No. See 7.18 STARTING SYSTEM DIAGNOSTICS,
Nothing Clicks.
3. Starter Solenoid Test
1. Disconnect starter solenoid [128].
2. Does starter stop?
b. No. Replace starter solenoid assembly. See the ser-
vice manual. (5845)
4. Checking DTCs Test
1. Check for DTCs.
2. Is DTC B2122 present?
a. Yes. See the electrical diagnostics manual.
b. No. Replace BCM. (5838)
NOTHING CLICKS
Table 7-18. Nothing Clicks Diagnostic Faults
POSSIBLE CAUSES
Low battery
Open fuse
RHCM malfunction
BCM malfunction
Neutral switch malfunction
Open neutral circuit
NOTE
Verify that vehicle is in neutral and that the key fob is present
and in working order (if security equipped) and that the engine
stop switch is in RUN position.
1. Battery Test
1. Verify battery condition. See the electrical diagnostic
manual.
2. Is battery condition good?
b. No. Charge or replace battery as needed, attempt to
start engine, if nothing clicks, then continue tests. Go
to Test 2.
2. Fuse Test
1. Verify that all fuses, including main fuse, are good.
2. Are all fuses good?
b. No. Replace fuse and repair circuit accordingly. If
problem is still present, then continue tests. Go to
Test 3.
3. Ignition Circuit Test
HOME
2. Do the odometer, headlamp and tail lamps illuminate?
b. No. Odometer is inoperative, but headlamp and
tail lamps illuminate. See 7.16 ODOMETER SELF-
DIAGNOSTICSINOPERATIVE, DTCU0001, U0011,
B2274.
c. No. Odometer, headlamp and tail lamps
inoperative. See 7.17 NO VEHICLE POWER, DTC
U0100, U0121, U0140, U0141, U0142, U0156, No
Vehicle Power, DTC U0140.
4. Starter Solenoid Circuit Test
1. Disconnect start solenoid [128].
2. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
41404), test for battery voltage at [128B] (R/BK) wire
during the first 4-5 seconds, while start button is pressed.
5. Starter Ground Test
1. Remove starter attaching bolts. See the service manual.
2. Clean bolts and starter base, install starter bolts.
3. Does engine crank?
a. Yes. Engine cranks at normal speed. Repair com-
plete. (5817)
b. Yes. Engine cranks, but at a slower speed. See
the electrical diagnostic manual.
c. No. Replace start solenoid. See the service manual.
(5845)
6. Neutral Switch Test
1. With the engine stop switch ON and the transmission in
neutral, observe the neutral lamp.
2. Is the neutral lamp illuminated?
b. No. See 7.23 INDICATOR LAMPS, Neutral Lamp
Inoperative.
7. Start Solenoid Circuit Test
BCMCABLE(Part No. HD-50390-2) between wire harness
[242B] and BCM[242A]. See 7.13 DIAGNOSTICTOOLS.
4. Test for continuity between breakout box terminal L2 and
[128B].
b. No. Repair open in (R/BK) wire. (5041)
8. BCM Test
1. Turn engine stop switch to OFF.
2. Disconnect the BCMand replace with a known good BCM.
3. Turn engine stop switch to RUN, attempt to start vehicle.
a. Yes. Replace BCM. See the service manual. (5838)
b. No. Replace RHCM. See the service manual. (6166)
STARTER SOLENOID CLICKS
Table 7-19. Starter Solenoid Clicks Diagnostic Faults
POSSIBLE CAUSES
Low battery
Starter malfunction
Starter solenoid malfunction
Open battery cable
Open starter cable
Mechanical binding
1. Battery Test
manual.
b. No. Charge or replace battery as needed. Attempt to
start engine. If starter solenoid continues to click and
starter does not engage, then continue with tests. Go
to Test 2.
2. Starter Voltage Drop Test
1. Perform voltage drop tests from battery (+) to starter stud
on starter (BK) wire. See the electrical diagnostic manual.
2. Is voltage drop greater than 1.0V?
3. Starter Solenoid Voltage Drop Starter Side
Test
1. Perform voltage drop test from battery (+) terminal to
starter solenoid terminal 2 (BK) wire.
vice manual. (5845)
4. Starter Solenoid Battery Side Voltage
Drop Test
starter solenoid terminal 1 (BK) wire.
HOME
a. Yes. Repair or replace (BK) wire fromstarter solenoid
terminal 1 to battery (+) terminal. (5041)
vice manual. (5845)
5. Starter Ground Circuit Voltage Drop Test
1. Perform voltage drop test from battery (-) terminal to
ground.
a. Yes. Inspect (BK) wire for damage from battery (-)
terminal to chassis ground, repair or replace if
necessary. Go to Test 6.
6. Starter Ground Test
1. Remove starter attaching bolts. See the service manual.
2. Clean bolts and starter base, install starter bolts.
a. Yes. Engine cranks at normal speed. Repair com-
plete.
b. Yes. Engine cranks, but at a slower speed. See
c. No. Replace starter. See the service manual. (5817)
7. Starter Draw Test
1. Perform Starter Current Draw Test on motorcycle. See
2. Perform Starter Motor Free Running Current Draw Test
(on bench). See the electrical diagnostic manual.
3. Are test results within range?
b. No. Replace starter. See the service manual. (5817)
8. Mechanical Binding Test
1. Remove spark plugs and place transmission in 5th gear.
2. Raise vehicle.
3. Rotate rear wheel.
4. Check for engine binding in the primary and/or crankshaft
or starter clutch.
5. Is engine binding? See the service manual.
a. Yes. Repair as needed. (Use appropriate code).
vice manual. (5845)
STARTER SPINS BUT DOES NOT ENGAGE
Table 7-20. Starter Spins But Does Not Engage Diagnostic
Faults
POSSIBLE CAUSES
Clutch assembly
Clutch shell and sprocket
1. Pinion Gear and Clutch Shell Test
1. Remove primary cover.
2. Inspect for damage to starter pinion gear and clutch shell
and sprocket.
NOTE
Inspect ACR operation (if equipped) before installation of new
starter clutch assembly.
3. Is damage present?
a. Yes. Replace the clutch assembly or clutch shell and
sprocket. (5825)
b. No. Replace the clutch assembly. (5837)
STARTERSTALLSORSPINSTOOSLOWLY
Table 7-21. Starter Stalls or Spins Too Slowly Diagnostic
Faults
POSSIBLE CAUSES
Low battery
Starter malfunction
Starter solenoid malfunction
Poor connections at starter ground
Open battery cable
Open starter cable
ACR malfunction (if equipped)
1. Battery Test
manual.
b. No. Charge or replace battery as needed. If symptom
is still present, then continue with tests. Go to Test
2.
2. Starter Stud Voltage Drop Test
starter stud on starter (BK) wire. See the electrical dia-
gnostic manual.
HOME
3. Starter Ground Circuit Voltage Drop Test
1. Performvoltage drop test between battery (-) terminal and
starter attaching bolts.
a. Yes. Clean ground connections. (5041)
4. Starter Draw Test
1. Perform Starter Current Draw Test on motorcycle. See
2. Perform Starter Motor Free Running Current Draw Test
(on bench). See the electrical diagnostic manual.
3. Are test results within range?
a. Yes. With the spark plugs removed and the transmis-
sion in 5th gear, rotate rear wheel. Check for engine,
primary and/or crankshaft bind. (Use appropriate
code)
b. No. Replace starter. See the service manual. (5817)
5. Starter Solenoid Voltage Drop Starter Side
Test
1. Perform voltage drop test between battery (+) terminal to
starter solenoid terminal 2.
b. No. Repair connection or (BK) wire between starter
solenoid and starter. (5041)
6. Starter Solenoid Battery Side Voltage
Drop Test
1. Perform voltage drop test between battery (+) terminal
and starter solenoid terminal 1 (R) wire.
a. Yes. Repair or replace connection between battery
(+) terminal and starter solenoid terminal 1 (R) wire.
(5041)
b. No. Repair or replace starter solenoid assembly. See
the service manual. (5845)
HOME
7.19 DTC P0562
Battery voltage is monitored by the ECM on the system power
terminal 52 of [78]. The system power is supplied to the ECM
from the BCM system power terminal L3.
DTC P0562 is displayed when battery voltage is less than
12.2V at idle and voltage does not increase when engine speed
is greater than 2000 rpm.
DESCRIPTION DTC
ECM voltage low P0562
DIAGNOSTICS
Diagnostic Tips
Any of the following conditions could cause these DTCs to set:
The charging system is malfunctioning.
There is excessive battery draw and/or extended idling in
heavy traffic.
A faulty system ground is present.
Lowvoltage generally indicates a loose wire, corroded connec-
tions, battery and/or a charging system problem.
HOME
BK/GN BK/GN
BK/GN
BK/GN
BK/GN
B
K
/
G
N
R/BK
R/BK
R/GN
R/GN
W/BK
W/BK
W/BK
W/GY
W/GY W/GY
BK
BK
BK
BK
R
/
O
R/O
R/O
W/R
W/BK
W/BK
R/O
R/O
W/R
W/R W/R
W/R
R
R
W
W
R
R
R
R
R
[259A] [259B]
2
1
B
A
[131B-2] [131A-2]
[22B-2] [22A-2]
[131B-1] [131A-1]
[78B] [78A]
[22B-1] [22A-1]
[128B]
C4
D2
D3
E2
G4
L2
Engine Stop Switch Input
Engine Stop Switch
CAN High
CAN High
CAN High
Neutral Switch Input
CAN Low
CAN Low
CAN Low
Ground
Ground
Ground
Battery
Battery
Starter Solenoid Power
System Power
Battery Power
BCM
Fuse
Block
GND 1
B
K
GND 2 GND 1
Battery
Starter
Right
Hand
Controls
Left
Hand
Controls
Main
40A
Battery
15A
[64B]
1
C4
D2
D3
E2
G4
L2
L3 L3
1
BCM Input
Ground
Neutral
Switch
ECM
1 1
1 1
10
13
28
Ground
System Power
Ground
10
13
28
1
2
3
4
1
1 1
2
3
4
[24B] [24A]
4
3
2
1
4
3
2
1
[242A] [242B]
2
1
em00911
Figure 7-42. Starting Circuit
HOME
DTC P0562
Table 7-23. DTC P0562 Diagnostic Faults
POSSIBLE CAUSES
Low battery
Open ECM ground circuit
Open ECM system power circuit
1. Battery Test
manual.
b. No. Charge or replace battery as needed. Verify
repair.
2. Charging System Test
1. Performcharging systemtest. See the electrical diagnostic
manual.
2. Is charging system working properly?
b. No. Repair charging system.
3. ECM Switched Voltage Test
1. With the engine stop switch OFF, connect BREAKOUT
BOX (Part No. HD-43876) between wire harness [78A]
and ECM [78B]. See 7.13 DIAGNOSTIC TOOLS.
2. With the transmission in neutral, turn the engine stop
switch ON.
3. Test for voltage on breakout box between terminals 52
and 73.
a. Yes. System is working properly.
4. ECM System Power Voltage Drop Test
1. Perform a voltage drop test between battery (+) terminal
and breakout box terminal 13. See the electrical diagnostic
manual.
5. ECM Ground Circuit Voltage Drop Test
1. Performa voltage drop test between breakout box terminal
73 and battery (-) terminal.
a. Yes. Repair wiring between ECM [78B] terminal 73
and GND 1.
b. No. Problem may be intermittent. Locate and repair
bad connection. See the electrical diagnostic manual
for wiggle test procedure. If no problemis found, then
continue with tests. Go to Test 11.
6. BCM System Power Test
1. Turn the engine stop switch OFF, disconnect BCM [242].
4. Perform a voltage drop test between BCM breakout box
terminal L3 and ECM breakout box terminal 52.
a. Yes. Repair (R/GN) wire between [242B] terminal L3
and [78B] terminal 52. (5041)
7. BCM Power Test
1. Disconnect BCM power [259].
2. Perform a voltage drop test between [259B] and battery
(+).
b. No. Replace BCM.
8. Main Fuse Voltage Test
1. Perform a voltage drop test between fuse block [64B]
socket terminal A and battery (+).
b. No. Repair or replace (R) wire between fuse block
[64B] socket terminal A and [259B].
9. Fuse Block Voltage Test
1. Perform a voltage drop test between fuse block [64B]
socket terminal B and battery (+).
b. No. Repair or replace fuse block [64B] socket ter-
minals A and B.
10. Fuse Block Supply Voltage Test
1. Performa voltage drop test between starter terminal 1 and
battery (+).
HOME
a. Yes. Repair or replace (R) wire between starter ter-
minal 1 and battery (+).
b. No. Repair or replace (R) wire between starter ter-
minal 1 and fuse block [64B] socket terminal B.
11. Repair Validation Test
1. Clear DTCs using odometer self-diagnostics. See
7.14 INITIAL DIAGNOSTICS, Odometer Self-Diagnostics.
2. Start vehicle.
3. Run at 3000 rpm for 5 seconds.
4. Does code set?
a. Yes. Replace ECM. See 8.2 ELECTRONIC CON-
TROL MODULE.
b. No. System working properly.
HOME
7.20 DTC B1210, B1211
The fuel level is monitored by the speedometer [39] at terminal
9 (W/Y) wire. The low fuel warning lamp serves two functions.
It is used to indicate a low fuel condition and to communicate
a circuit problemwith the fuel sender circuit. The speedometer
will flash the low fuel warning lamp on and off at a steady rate
when a current fuel level sender DTC is set.
If the voltage on terminal 9 exceeds the lower limit for
greater than or equal to 15 seconds a DTC B1210 will be
set and the low fuel warning lamp will flash on and off at
a steady rate.
If the voltage on terminal 9 exceeds the upper limit (or is
open) for greater than or equal to 15 seconds a DTC
B1211 will set and the low fuel warning lamp will flash on
and off at a steady rate.
DESCRIPTION DTC
Fuel sender shorted low/fuel gauge circuit
open
B1210
Fuel sender shorted high/open B1211
Voltage is supplied to the fuel level sender on the (W/Y) wire
from the fuel gauge. As the fuel level changes the resistance
of the sender changes. The fuel gauge and the low fuel lamp
are controlled through the (W/Y) wire based off the change in
the resistance of the fuel level sender.
1
2
ed03413
2. Console
Fuel Range
The fuel range display shows the approximate mileage avail-
able with the amount of fuel left in the fuel tank.
With the OFF/RUN switch in the RUN position, press the TRIP
switch until fuel range is displayed, as indicated by the letter
"R" in the left side of the display. The calculated remaining
distance (miles or kilometers) to empty is displayed, based on
the amount of fuel in tank. Range can be accessed at any time
using the TRIP switch.
NOTE
The fuel range and low fuel warning features are not active on
early production vehicles. See an authorized Harley-Davidson
dealer to have the latest calibration installed to activate these
features.
Low Fuel Warning
When the low fuel warning lamp illuminates, the fuel range
feature will automatically be displayed in the odometer window.
The rider can press the TRIP switch to return to the cycle of
odometer displays. The fuel range warning will not be repeated
until the OFF/RUN is cycled to OFF and back to RUN.
After the fuel range drops to 10 mi (16 km) remaining, the fuel
range display will scroll "Range Lo" to indicate that the motor-
cycle will shortly run out of fuel.
HOME
[141A]
[141B]
[20A]
[20B]
[242B] [242A]
[200B] [200A]
[39B] [39A]
Fuel
Pump
R/O Battery Fuse
Ground
Fuel Level
Speedometer
5
7
9
5
7
9
6 4 2
6 4 2
BE
BE
BE
B
K
B
K
B
K
BK/GN
W/Y
R
/
O
B
K
/
G
N
B
K
/
G
N
B
K
/
G
N
W
/
Y
R
/
O
B
K
/
G
N
B
K
/
G
N
BK/GN
W
/
Y
W/Y
W
/
Y
W
/
Y
Battery
15A
Main
Harness
R
/
O
1
2 [64B]
R
R
A
F
u
e
l
P
u
m
p
P
o
w
e
r
A
B
F
u
e
l
L
e
v
e
l
S
e
n
s
o
r
B
C
S
e
n
d
e
r
G
r
o
u
n
d
C
D
P
u
m
p
G
r
o
u
n
d
D
[13A]
[13B]
1
1
2
2
3
3
4
4
R
/
B
N
R
/
B
N
R/BN
J3
1
2
3
1
2
3
F4 Fuel Pump Power
Running Light Power
BCM
Main
Harness
GND 1 GND 2
J3
F4
36
36 200
3
6
em01461
Figure 7-44. Fuel Sensor Circuit
DTC B1210
Table 7-25. DTC B1210 Diagnostic Faults
POSSIBLE CAUSES
Instrument malfunction
Short to ground in fuel level sender circuit
Fuel level sender assembly malfunction
Open fuel level sender circuit
Short to ground in accessory power circuit
1. Low Fuel Lamp Circuit Resistance Test
46601) to [39]. Connect BREAKOUT BOX (Part No. HD-
42682) leaving the speedometer [39A] disconnected. See
3. Measure resistance between breakout box terminal 9 and
ground.
4. Is resistance greater than 50 Ohms?
a. Yes. Replace the speedometer.
2. Fuel Pump and Sender Assembly Test
1. Disconnect the fuel pump [141].
ground.
a. Yes. Replace the fuel pump.
3. Fuel Sender Resistor Assembly Test
1. Disconnect the fuel sender resistor assembly [200].
ground.
a. Yes. Replace the fuel sender resistor assembly.
b. No. Repair short to ground in (Y/W) wire.
HOME
DTC B1211
POSSIBLE CAUSES
Open ground circuit
Short to voltage in fuel level sensor circuit
Open fuel level sensor circuit
Fuel sender resistor assembly malfunction
1. Low Fuel Lamp Circuit Voltage Test
46601) to [39]. Connect BREAKOUT BOX (Part No. HD-
42682) leaving [39A] disconnected.
3. With IGN ON, test for voltage between breakout box ter-
minal 9 and ground
a. Yes. Repair short to voltage in (Y/W) wire.
2. Fuel Sender Resistor Assembly Test
1. Disconnect the fuel level sender resistor assembly [200].
41404), measure resistance at [200A] between terminals
1 and 3.
3. Is resistance between 9600-10,400 Ohms?
b. No. Replace the fuel sender resistor assembly.
3. Low Fuel Lamp Circuit Continuity Test
1. Test for continuity between breakout box terminal 9 and
fuel level sender resistor [200B] terminal 2.
b. No. Repair open in (Y/W) wire.
4. Ground Circuit Continuity Test
1. Test for continuity between fuel level sender resistor [200B]
terminal 3 and ground.
a. Yes. Replace speedometer.
b. No. Repair open in (BK/GN) wire between terminal 3
and ground.
HOME
7.21
TRIP ODOMETER FUNCTIONS INOPERATIVE,
DTC B2255
Trip Odometer Reset Switch Closed
DTC B2255 will be set if trip odometer reset switch is closed
for more than two minutes. This code can be set by the
speedometer or the BCM. It will normally be set by both if there
is a concern with the trip odometer reset switch.
Odometer self-diagnostics will not function if the switch is stuck
since it won't be possible to toggle the switch to navigate
through the different diagnostic steps in the odometer.
A stuck trip odometer reset switch disables odometer self-
diagnostics.
If DIGITAL TECHNICIAN II (Part No. HD-48650) is con-
nected to the DLC[91] and communicating with the vehicle
then the odometer self-diagnostics will not function prop-
erly.
Disconnect DIGITAL TECHNICIANII (Part No. HD-48650)
before entering odometer self-diagnostics.
DESCRIPTION DTC
Trip switch stuck B2255
HOME
Right
Hand
Controls
BCM
DLC
GND 2
Main
Wiring
GND 1
Battery
Power
Indicator
Lamps
Battery
Fuse
ECM
Left
Hand
Controls
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
BK
B
K
BK/GN BK/GN
W/BK
R/O
W/R
W/BK
W/R
BK/GN BK/GN
BK/GN BK/GN
W/BK
W/BK
R/GN
W/BK
R/GN
R/GN
W/BK
R/O R/O R/O
R/O
W/R
W/BK
W/R
W/R W/R
W/R
R
R
R
[24A] [24B]
[91A]
[22B-1] [22A-1]
E2
D2
G4
1
E2
D2
G4
L3 L3
1
42
41
73
71 71
52 52
42
41
73
ABS
1
3
Speedometer
2
8
7
5
2
8
7
5
1
3
2
6
1
3
2
6
18
19
20
6 6
18
19
20
R 11 11
[242A] [242B]
[39A] [39B] [20A] [20B]
[78B] [78A]
[166B] [166A]
W/BK
W/R
R/O
R
/
O
R
/
O
BK/GN
W/BK
W/R
R/O
BK/GN
B
K
/
G
N
W/BK
W/R
[259A] [259B]
em01459
TRIP ODOMETER FUNCTIONS
INOPERATIVE, DTC B2255
Table 7-28. Trip Odometer Functions Inoperative, DTC
B2255 Diagnostic Faults
POSSIBLE CAUSES
Trip odometer reset switch malfunction
1. Odometer Test
2. Press and release the trip odometer reset switch.
3. Does the odometer cycle through the different odometer
functions?
2. Speedometer "WOW" Test
2. Turn the engine stop switch ON, while pressing the trip
odometer reset switch.
3. Does the speedometer needle sweep its full range of
motion?
a. Yes. Systemfunctioning properly. Test for intermittent
condition. See the electrical diagnostic manual for
wiggle test procedure.
b. No. Replace speedometer. See 7.3 SPEEDOMETER.
3. LHCM Test
1. Operate the other switches on the LHCM.
HOME
2. Do any of the switches operate?
a. Yes. Replace the LHCM. See the service manual.
4. LHCM Power Test
1. With the engine stop switch OFF, disconnect the LHCM
[24].
No. HD-41404), test for voltage between [24A] terminal 1
and ground.
5. LHCM Ground Test
1. Test for continuity between [24A] terminal 2 and ground.
6. CAN Low Circuit Open Test
1. Test for continuity between [24A] terminal 4 and DLC[91A]
terminal 3.
7. CAN High Circuit Open Test
1. Test for continuity between [24A] terminal 3 and [91A]
terminal 1.
a. Yes. Replace LHCM. See the service manual.
HOME
7.22 NO INSTRUMENT POWER, DTC B1200
See Figure 7-46. The speedometer receives battery power at
terminal 5. This is supplied through the battery fuse located in
fuse block [64]. The speedometer receives a message from
the BCM over the CAN bus to know if the engine stop switch
is ON.
2
3
5
6
7
8
9
10
11
4
1
ed03415
With the engine stop switch ON, the speedometer illuminates
several of the warning lamps along with the backlighting.
The speedometer has an internal fault code DTC B1200. The
speedometer will set this code if it detects a malfunction inside
the speedometer. The BCM will turn off power to the vehicle
if the engine stop switch has been ON for 15 minutes with no
inputs from any of the modules or switches.
DESCRIPTION DTC
Instrument internal fault B1200
HOME
Right
Hand
Controls
BCM
DLC
GND 2
Main
Wiring
GND 1
Battery
Power
Indicator
Lamps
Battery
Fuse
ECM
Left
Hand
Controls
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
BK
B
K
BK/GN BK/GN
W/BK
R/O
W/R
W/BK
W/R
BK/GN BK/GN
BK/GN BK/GN
W/BK
W/BK
R/GN
W/BK
R/GN
R/GN
W/BK
R/O R/O R/O
R/O
W/R
W/BK
W/R
W/R W/R
W/R
R
R
R
[24A] [24B]
[91A]
[22B-1] [22A-1]
E2
D2
G4
1
E2
D2
G4
L3 L3
1
42
41
73
71 71
52 52
42
41
73
ABS
1
3
Speedometer
2
8
7
5
2
8
7
5
1
3
2
6
1
3
2
6
18
19
20
6 6
18
19
20
R 11 11
[242A] [242B]
[39A] [39B] [20A] [20B]
[78B] [78A]
[166B] [166A]
W/BK
W/R
R/O
R
/
O
R
/
O
BK/GN
W/BK
W/R
R/O
BK/GN
B
K
/
G
N
W/BK
W/R
[259A] [259B]
em01459
NO INSTRUMENT POWER
Table 7-30. No Instrument Power Diagnostic Faults
POSSIBLE CAUSES
Open battery circuit
Open ground circuit
Open in CAN bus circuit to speedometer
1. Battery Circuit Test
2. Does the headlamp or tail lamp come on?
b. No. See 7.17 NO VEHICLE POWER, DTC U0100,
U0121, U0140, U0141, U0142, U0156, No Vehicle
Power, DTC U0140.
2. Accessory Function Test
1. Attempt to start the vehicle.
2. Does the engine crank?
b. No. See 7.16 ODOMETER SELF-DIAGNOSTICS
INOPERATIVE, DTC U0001, U0011, B2274.
3. Battery Fuse Test
1. Inspect the battery fuse.
HOME
2. Is the fuse good?
4. Battery Circuit to Speedometer Test
BOX ADAPTERS (Part No. HD-46601) to [39]. Attach
connectors from BREAKOUT BOX (Part No. HD-42682)
to harness adapters leaving [39A] disconnected. See
2. Install battery fuse in fuse block.
ground.
b. No. Repair open between [39B] terminal 5 and [64B]
socket terminal 2 (R/O) wire. (5041)
5. Battery Circuit Short to Ground Test
to harness adapters leaving [39A] disconnected. See
ground.
a. Yes. Repair short to ground in (R/O) wire. (5041)
b. No. Concern is intermittent, perform a wiggle test to
test for intermittent. See the electrical diagnostic
manual for wiggle test procedure. Replace the battery
fuse.
6. Ground Circuit Test
No. HD-41404) and a multimeter, test for continuity
between breakout box terminal 7 and ground.
METER. (6020)
b. No. Repair open in (BK/GN) wire. (5041)
HOME
7.23 INDICATOR LAMPS
See Figure 7-48. The battery, check engine, security, sixth
gear, cruise control, ABS and low fuel indicators are located
in the speedometer. The other indicators are located separately
from the speedometer.
ABS
E
F
4
3
2
1
5
6
7
8
9
ed03408
1. Speedometer/odometer
2. Low fuel lamp
3. Cruise enabled lamp
4. Tachometer
5. Security lamp
6. Low fuel lamp
7. ABS lamp
8. Battery lamp
9. Gear indicator
Figure 7-48. Indicator Lamps
ABS Indicator
The speedometer illuminates the ABS indicator when the fol-
lowing occurs:
The ECUdetects an ABS disabling malfunction. The ECU
sends a serial data message to the instrument requesting
illumination.
The speedometer performs a bulb check.
The speedometer detects a loss of communication with
the ECU.
The ABS light may flash when the engine stop switch is
turned on. This will continue until the vehicle is driven to
verify WSS operation.
The ECU sends a message to the instrument when a malfunc-
tion that disables ABS operation is detected. Depending on
the fault, the ABS indicator may stay on even after the malfunc-
tion is corrected. The indicator will not go off until the vehicle
is operated at speeds greater than 10 mph (16 km/h). It is
important to verify that this is not the cause of an ABS indicator,
which is illuminated when no DTCs are set, before attempting
to diagnose other possible causes.
Security Lamp
When the engine stop switch is turned ON, the security lamp
will illuminate for approximately four seconds and then turn off.
The BCM controls the security lamp by sending a CAN mes-
sage to the speedometer. After the security lamp turns off fol-
lowing the first four second illumination period, one of two
events may occur.
The lamp remains off. This indicates there are no current
fault conditions or stored DTCs currently detected by the
BCM.
If the lamp remains on beyond the four-second period, a
current DTC exists.
Check Engine Lamp
When the engine stop switch is ON, the check engine lamp
will illuminate for approximately four seconds and then turn off.
The ECM controls the check engine lamp by sending a CAN
message to the speedometer. After the check engine lamp
turns off following the first four second illumination period, one
of two events may occur.
The lamp remains off. This indicates there are no current
fault conditions or stored DTCs currently detected by the
ECM.
If the lamp remains on beyond the four-second period, a
current DTC exists.
Low Battery Lamp
The BCM sends a message to the speedometer to control the
low battery lamp. The speedometer will turn the lamp on if the
BCM identifies a low voltage condition on [259] terminal 1.
Low Fuel Indicator
See Figure 7-52. The lowfuel indicator is controlled at terminal
9 (W/Y) of the speedometer. The fuel gauge sends voltage on
the (W/Y) wire to the lowfuel lamp and fuel level sender. When
the fuel drops below 1.0 gal (3.8 L), the resistance in the fuel
level sender reaches a point that causes enough of a change
in the voltage on the (W/Y) wire it signals the speedometer to
activate the low fuel lamp. The low fuel lamp will also flash on
and off at a steady rate if there is a problem with the circuit.
HOME
1
3
2
ed03194
1
2
ed03413
2. Console
1
2
3
4
ed01990
1. Starter
2. Starter solenoid [128]
3. Neutral switch [131]
4. Oil tank
Figure 7-51. Under Oil Tank Right Side
Neutral Indicator
See Figure 7-51. The neutral indicator is controlled through
the (W) wire connected to the speedometer. When the trans-
mission is in neutral, the neutral switch closes and supplies a
ground to the BCM on terminal D3. The BCM then sends a
message to the speedometer over the CAN bus indicating the
transmission is in neutral. The speedometer supplies ground
to the neutral indicator causing it to illuminate.
ed03335
Figure 7-52. Oil Pressure Switch [120]
Oil Pressure Indicator
See Figure 7-52. The oil pressure indicator is connected to the
speedometer. The switch closes when oil pressure is low and
supplies ground to the BCM at terminal E3. The BCM then
sends a message to the speedometer over the CAN bus
indicating the oil pressure is low. The speedometer supplies
ground to the oil pressure indicator causing it to illuminate. This
is why the oil pressure indicator is illuminated with the engine
stop switch ON and the engine OFF.
Turn Signal Indicators
The turn signal indicators are controlled by the speedometer.
When the BCM receives a CAN bus message from the left or
HOME
right turn signal switch it flashes the correct turn signals. At the
same time the BCM sends a message to the speedometer
over the CAN bus indicating which turn signal to operate. The
speedometer supplies ground to the corresponding turn signal
indicator causing it to illuminate.
High Beam Indicator
This circuit is grounded by the speedometer when the head-
lamp switch is placed in the high beam position. In the high
position, a message is sent over the CAN bus to the speedo-
meter and the BCM. The speedometer controls the indicator
and the BCM controls the headlamp.
Sixth Gear Indicator
The sixth gear indicator illuminates indicating the vehicle is in
sixth gear. This is done by the ECM. The ECM monitors the
vehicle speed and engine rpm with the clutch released. It then
sends a signal over the CAN bus to illuminate the indicator
when the parameters are correct for sixth gear operation.
Therefore, there may be a delay in the indicator illuminating
when shifting to sixth gear. The ECM receives clutch switch
status over the CAN bus. Pulling in the clutch lever will cause
the sixth gear indicator to turn off.
If the sixth gear indicator is inoperative or always on check for
any DTCs. If no DTCs are present, verify the clutch switch is
operating properly. If the clutch lever is not pulled in enough
to engage the clutch switch or the clutch is slipping, it is pos-
sible that the sixth gear indicator may illuminate briefly when
the vehicle is not in sixth gear. If none of these conditions exist
and the sixth gear indicator is malfunctioning replace the
speedometer.
B
E
/
W
BE/W
BE/O
W/BK W/BK
B
E
/
O
Indicators
W
W
[39B] [39A]
[20B] [20A]
Speedometer
12
6 Neutral Indicator
10 Left Turn Indicator
Right Turn Indicator
5
8 CAN Low
4 High Beam Indicator
1 Oil Pressure Indicator
2
12
6
10
5
8
4
1
2 CAN High
BCM
Battery
Fuse
D2 CAN High
E2
D2
E2 CAN Low
Battery Fuse
B
E
/
P
K
BE/PK
W
/
O
R
/
O
R
/
O
R
/
O
R
/
O
R
/
O
R/O R/O R/O
R
/
O
W/R W/R
W/BK
W/R
W/BK
W/R
W/O
[242A] [242B]
1
3
1
3
6 6
em01460
HOME
OIL PRESSURE LAMP ALWAYS ON
OIL PRESSURE GAUGE SET HD-96921-52D
Table 7-31. Oil Pressure Lamp Always On Diagnostic
Faults
POSSIBLE CAUSES
Short to ground in oil pressure circuit
Indicator malfunction
Mechanical issue
Oil pressure switch malfunction
1. Oil Pressure Lamp Function Test
1. Turn the engine stop switch ON with the engine OFF.
2. Does the oil pressure lamp illuminate?
b. No. See 7.23 INDICATORLAMPS, Oil Pressure Lamp
Inoperative.
2. Engine Running Test
1. Start the engine.
2. Does the oil pressure lamp turn OFF and stay off?
a. Yes. Oil pressure lamp is operating properly. Test for
intermittent. See the electrical diagnostic manual for
performing a wiggle test procedure.
3. Oil Pressure Sensor Test
1. Disconnect the oil pressure switch [120].
2. Does the oil pressure lamp turn OFF when the engine is
running?
4. Oil Pressure Circuit Test
3. With the engine stop switch ON, test for voltage between
terminal E3 and ground.
b. No. Replace the BCM. See the service manual. (5863)
5. Mechanical Test
1. Inspect the engine for any issues that may affect oil pres-
sure. See the service manual.
2. Using OIL PRESSUREGAUGESET (Part No. HD-96921-
52D), verify engine oil pressure. See the service manual.
3. Is oil pressure within specification?
a. Yes. Replace the oil pressure switch. See the service
manual. (5161)
b. No. Repair as needed.
6. Oil Pressure Switch Circuit Test
2. Test for continuity from [242B] E3 to ground.
a. Yes. Repair short to ground. (5041)
7. Speedometer Test
to harness adapters, leaving [39A] disconnected. See
ground.
a. Yes. Repair short to ground in (W/O) wire. (5041)
METER. (6020)
OIL PRESSURE LAMP INOPERATIVE
Table 7-32. Oil Pressure Lamp Inoperative Diagnostic
Faults
POSSIBLE CAUSES
Open oil pressure circuit
1. Oil Pressure Lamp Function Test
1. Turn the engine stop switch ON with the engine OFF.
2. Does the oil pressure lamp illuminate?
a. Yes. Test for intermittent. See the electrical diagnostic
manual for performing a wiggle test procedure.
HOME
2. Speedometer Test
No. HD-41404), connect [39B] terminal 1 to ground.
4. Does the oil pressure lamp turn ON?
METER. (6020)
b. No. Repair or replace the indicator harness. See
7.3 SPEEDOMETER. (5191)
NEUTRAL LAMP ALWAYS ON
Table 7-33. Neutral Lamp Always On Diagnostic Faults
POSSIBLE CAUSES
Short to ground in neutral switch circuit
Short to ground in neutral indicator circuit
1. Neutral Lamp Function Test
1. With the vehicle in neutral, turn the engine stop switch ON
with the engine OFF.
2. Does the neutral lamp illuminate?
b. No. See 7.23 INDICATOR LAMPS, Neutral Lamp
Inoperative.
2. DTC Test
2. Is DTC B2218 present?
a. Yes. See 7.14 INITIAL DIAGNOSTICS.
3. Indicator Harness Test
2. Did the neutral lamp turn OFF?
METER. (6020)
b. No. Repair short to ground in (W) wire between
neutral indicator and speedometer. (5041)
NEUTRAL LAMP INOPERATIVE
Table 7-34. Neutral Lamp Inoperative Diagnostic Faults
POSSIBLE CAUSES
Neutral switch malfunction
Open ground circuit
Open neutral switch circuit
1. Neutral Lamp Function Test
1. With the vehicle in neutral, turn the engine stop switch ON
with the engine OFF.
a. Yes. Test for intermittent. See the electrical diagnostic
manual for performing a wiggle test procedure.
2. BCM Message Test
1. Verify the transmission is in neutral.
2. With the clutch lever released, start the engine.
3. Does the engine start?
3. Neutral Switch Test
1. Disconnect the neutral switch [131].
No. HD-41404), jump the (W) wire to the (BK) ground wire.
3. Does the neutral lamp turn ON?
a. Yes. Replace the neutral switch. See the service
manual. (5157)
4. Ground Wire Test
41404), jump the (W) wire of the neutral switch to ground.
2. Does the neutral lamp turn on?
a. Yes. Repair open in (BK) ground wire. (5041)
5. Neutral Switch Power Circuit Open Test
HOME
No. HD-41404) and a multimeter, test for continuity on the
(W) wire between [242B] terminal D3 and [131B-1].
a. Yes. Replace the BCM. See the service manual.
(5863)
b. No. Repair open in (W) wire between indicators and
neutral switch. (5041)
6. Speedometer Test
2. Connect [39B] terminal 6 to ground.
METER. (6020)
b. No. Replace the indicator harness. See
HIGH BEAM INDICATOR LAMP
INOPERATIVE
Table 7-35. High Beam Indicator Lamp Inoperative
Diagnostic Faults
POSSIBLE CAUSES
Open high beam indicator circuit
1. High Beam Indicator Function Test
1. With the engine stop switch ON, operate the headlamp
switch.
2. Do the high and low beam headlamps function correctly?
b. No. See the electrical diagnostic manual.
2. High Beam Indicator Circuit Test
1. With the engine stop switch OFF, disconnect speedometer
[39].
3. Connect [39B] terminal 4 to ground.
4. Does high beam indicator illuminate?
METER. (6020)
TURN SIGNAL INDICATOR INOPERATIVE
Table 7-36. Turn Signal Indicator Inoperative Diagnostic
Faults
POSSIBLE CAUSES
Open turn signal circuit
1. Turn Signal Function Test
1. With the engine stop switch ON, operate the turn signals.
2. Do the turn signals operate?
b. No. See 7.6 TURN SIGNALS.
2. Turn Signal Indicator Circuit Test
1. With the engine stop switch OFF, disconnect speedometer
[39].
3. Connect [39B] terminal 10 (left) or terminal 12 (right) to
ground.
4. Does the turn signal indicator illuminate?
METER. (6020)
HOME
7.24 ACCESSORIES, DTC B2112, B2113, B2114
The P&A battery circuit is connected to battery power through
the P&A fuse. This circuit can be used to supply power to
additional systems on the vehicle. The P&A circuit runs from
the fuse to the DLC connector terminal 6.
There is also an accessory power circuit fromthe BCMterminal
M2 that runs to the rear lighting and DLC connectors. This cir-
cuit is energized by the BCM when the engine stop switch is
in the ON position.
DESCRIPTION DTC
Accessory output shorted high B2112
Accessory output shorted low B2113
Accessory output overloaded B2114
Conditions for Setting
The accessory circuit normally has power when the engine
stop switch is ON. If the accessory circuit has power when the
engine stop switch is OFF, then DTC B2112 will set.
DTC B2114 will set if the accessory circuit draws more than
15 Amps.
The other accessory circuit DTCs will set if the BCM identifies
them with the engine stop switch ON.
Diagnostic Tips
This circuit may be used for aftermarket accessories or systems
for the vehicle. If a code is set and cannot be duplicated, verify
that an aftermarket device did not cause the concern.
2
3
5
6
7
8
9
10
11
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HOME
HOME
R
R
W
W
W
[120B] [120A]
E3 J3 L3 M2 F4
O
i
l
P
r
e
s
s
u
r
e
S
w
i
t
c
h
I
n
p
u
t
F
u
e
l
P
u
m
p
P
o
w
e
r
R
u
n
n
i
n
g
L
i
g
h
t
P
o
w
e
r
S
y
s
t
e
m
P
o
w
e
r
F
r
o
n
t
R
u
n
n
i
n
g
/
F
o
g
L
i
g
h
t
P
o
w
e
r
A
c
c
e
s
s
o
r
y
P
o
w
e
r
B
a
t
t
e
r
y
P
o
w
e
r
BCM
Battery
Power
Distribution
1
E3 J3 L3
L4
L4 M2 F4 1
B
E
B
E
/
B
K
BE/BK
R
/
B
N
R
/
G
N
R
/
G
N
R/GN
R/GN
R/GN
R/GN
R/GN
R/GN
R
/
Y
R/Y R/Y
R/Y
O/W O/W
W
/
O
R/BN R/BN
W/O
[259A]
[259B]
[242A]
[242B]
1 1
Oil
Pressure
Switch
[141B] [141A]
1 1
Fuel
Pump
[200B] [200A]
1 1
Resistor
Assembly
[84B] [84A]
[38B] [38A]
[91A]
A A
Front Fuel
Injector
[85B] [85A]
A
A
A
A
Rear Fuel
Injector
R/GN
R/GN
1 1
Front HO2S
1 1
Rear HO2S
Ignition
Coil
DOM
Canada
HDI
BE
BE
BE
[83B]
[83A]
[95A] [95B]
[18A]
A A
Purge
Solenoid
1 1
Position
Lamp
DLC
[78A] [78B]
R/GN 52 52
72 72
ECM
[203AF] [203BF]
1 1
Front
ACR
[203AR] [203BR]
[138A] [138B]
[137A] [137B]
1 1
Rear
ACR
1 1
[20B] [20A]
6 6
5
[19A]
1
1
[19A]
1
Left
Tail
Lamp
Right
Tail
Lamp
LP
Lamp
BK
B
K
B
K
BK
B
E
B
E
BE
BE
[19B]
1
[40B]
1
[18B]
1
Left
Tail
Lamp
Right
Tail
Lamp
LP/
Stop/Tail
B
E
B
E
B
E
BE
BE
BE
[19B]
1
[40B]
1
[18B]
1
Left
Tail
Lamp
Right
Tail
Lamp
LP
Lamp
B
E
[19B]
1
[40B]
1
[18B]
1
BK
BK
em01465
Figure 7-55. Ignition and Accessory Power Distribution
HOME
DTC B2112
POSSIBLE CAUSES
Short to battery in the accessory power circuit
1. Accessory Power Circuit Short to Voltage
Test
41404), test for voltage between DLC[91A] terminal 5 and
ground.
a. Yes. Repair short to voltage on (R/Y) wire.
2. BCM Test
1. Clear the DTC. See 7.14 INITIAL DIAGNOSTICS, Odo-
2. Turn the engine stop switch ON-OFF.
3. Check for DTCs.
4. Did the DTC return?
b. No. Concern is intermittent. Accessory devices may
have caused DTC to set. Inspect and repair as
needed.
DTC B2113, B2114
Table 7-39. DTC B2113, B2114 Diagnostic Faults
POSSIBLE CAUSES
Excessive current draw in accessory power circuit
Short to ground in the accessory power circuit
1. Accessory Power Circuit Short to Ground
Test
[242B] leaving BCM [242A] disconnected. See 7.13 DIA-
GNOSTIC TOOLS.
3. Measure resistance between breakout box terminal M2
and ground.
b. No. Concern is intermittent. See the electrical dia-
gnostic manual for performing a wiggle test procedure.
2. Accessory Circuit Test
1. Inspect for any accessories connected to the accessory
circuit.
2. Disconnect any accessories on the circuit.
3. Measure resistance between breakout box terminal M2
and ground.
a. Yes. Repair short to ground in (R/Y) wire.
3. BCM Test
1. Leave all aftermarket accessories disconnected.
2. Connect BCM [242A].
b. No. Accessory devices may have caused DTCto set.
Inspect and repair as needed.
HOME
7.25 DTCB2151, B2153, B2154, B2156, B2158, B2159
The rear turn signals are controlled by the BCM. The BCM
supplies power to the rear turn signals and controls the flash
rate of the turn signals through the power circuit.
DESCRIPTION DTC
Left rear turn signal output open B2151
Left rear turn signal output shorted low B2153
Left rear turn signal output overloaded B2154
Right rear turn signal output open B2156
Right rear turn signal output shorted low B2158
Right rear turn signal output overloaded B2159
After clearing the DTCs, operate the inoperative turn signal to
verify if the DTC has returned.
DTC B2151 or B2156 will set if the corresponding rear turn
signal circuit draws less than 120 milliamps. DTC B2154 or
B2159 will set if the corresponding rear turn signal circuit draws
more than 3 Amps.
2
3
5
6
7
8
9
10
11
4
1
ed03415
HOME
B
K
/
G
N
BE/BN
BE/PK
BK/GN
BK/GN
BE/PK
BE/BN
BE/V
W/BK
R/O
R/O
R/O
BK/GN
R/O
W/R
W/BK
W/R
W/BK
W/R
[39A] [39B]
[19A]
GND 1 GND 2
Speedometer
Battery
Fuse
Left Turn
Indicator
Lamps Right Turn
Power
BCM
RHCM LHCM
Hazard
Switch
Right Turn
Switch
Left Turn
Switch
BK
BE
BE
BK
BK
B
K
2
8
12
10
2
5 5
7 7
D2 D2
E2 E2
K2 K2
K4
CAN High
P
o
w
e
r
P
o
w
e
r
G
r
o
u
n
d
G
r
o
u
n
d
C
A
N
H
i
g
h
C
A
N
H
i
g
h
C
A
N
L
o
w
C
A
N
L
o
w
CAN Low
Right Rear Turn Signal
Left Rear Turn Signal K4
CAN High
Power
Ground
CAN Low
Left Turn Indicator
8
12
10
W/BK
W/R
BK/GN
R/O
W/BK
W/R
R/O
W/BK
W/R
BK
R/O
W/BK
W/R
B
K
B
K
B
K
R
/
O
R
/
O
R
/
O
W
/
B
K
W
/
B
K
W
/
R
W
/
R
BE/O
BE/O
4
3
2
1
4
3
2
1
4
3
2
1
4
3
1
3
1
3
2
6
2
6
2
1
[24A] [24B] [22B-1] [22A-1]
[20B] [20A]
BK
BE/V
BK
Rear Right
Turn Lamp
HDI HDI
DOM/
Canada
DOM/
Canada
Rear Left
Turn Lamp
1
2
1
2
BK
W 1
2
1
2
BK
W 1
2
1
2
[18A]
[19B]
[19B]
[18B]
[18B]
V
B
K
V
Front Left
Turn Lamp
Front Right
Turn Lamp
em01467
Figure 7-57. Turn Signal Circuit
HOME
DTC B2151
POSSIBLE CAUSES
Open in left rear turn signal ground circuit
Open in left rear turn signal power circuit
Short to voltage in left rear turn signal power circuit
Bulb malfunction
1. Bulb Test
1. Turn IGN OFF.
2. Remove left rear turn signal bulb.
3. Inspect bulb.
4. Is bulb good?
b. No. Replace bulb.
2. Ground Circuit Open Test
41404), test continuity between bulb socket ground and
ground.
3. Power Circuit Open Test
1. Turn IGN OFF.
2. Connect BREAKOUT BOX (Part No. HD-50390-1) and
[242B], leaving [242A] disconnected.
position on BOB.
41404), test continuity between BOB terminal K4 and left
rear turn signal bulb power circuit socket terminal.
a. Yes. Replace BCM.
b. No. Repair open in left rear turn signal power circuit
(BE/V).
DTC B2153, B2154
POSSIBLE CAUSES
Left rear turn signal bulb current too high
Accessory lighting overloading circuit
Short to ground in left rear turn signal power circuit
1. Bulb Test
1. Turn IGN OFF.
2. Remove left rear turn signal bulb.
3. Clear DTCs.
4. Activate left turn signal.
5. Did DTC return?
2. Power Circuit Short to Ground Test
1. Turn IGN OFF.
[242B], leaving [242A] disconnected. See 7.13 DIA-
GNOSTIC TOOLS.
position on BOB.
41404), test continuity between BOB terminal K4 and
ground.
a. Yes. Repair short to ground in left rear turn signal
power circuit (BE/V) wire.
b. No. Replace BCM.
HOME
DTC B2156
POSSIBLE CAUSES
Open in right rear turn signal ground circuit
Open in right rear turn signal power circuit
Short to voltage in right rear turn signal power circuit
Bulb malfunction
1. Bulb Test
1. Turn IGN OFF.
2. Remove right rear turn signal bulb.
3. Inspect bulb.
4. Is bulb good?
1. Turn IGN OFF.
41404), test continuity between bulb socket ground and
ground.
[242B], leaving [242A] disconnected.
position on BOB.
41404), test continuity between BOB terminal K2 and right
rear turn signal bulb power circuit socket terminal.
b. No. Repair open in right rear turn signal power circuit
(BE/BN).
DTC B2158, B2159
POSSIBLE CAUSES
Right rear turn signal bulb current too high
Short to ground in right rear turn signal power circuit
1. Bulb Test
1. Turn IGN OFF.
2. Remove right rear turn signal bulb.
3. Clear DTCs.
4. Activate right turn signal.
5. Did DTC return?
1. Turn IGN OFF.
GNOSTIC TOOLS.
position on BOB.
41404), test for continuity between BOB terminal K2 and
ground.
a. Yes. Repair short to ground in right rear turn signal
power circuit (BE/BN) wire.
b. No. Replace BCM.
HOME
7.26 STOPLAMPS, DTCB2161, B2163, B2164, B2223
See Figure 7-58. The BCM controls the stop lamp based off
inputs from the front and rear stop lamp switches. The front
stop lamp switch is a mechanical switch. When the front brake
lever is applied, the lever presses a mechanical switch and
closes the contacts on the switch. The front stop lamp switch
is part of the RHCM. When the switch is pressed, the RHCM
sends a message to the BCM over the CAN bus and the BCM
supplies power to the stop lamp.
The rear stop lamp switch is a pressure switch. When the rear
brake is applied, it generates pressure in the brake fluid. This
pressure in the fluid closes the contacts for the rear stop lamp
switch. The BCM supplies power to the rear stop lamp switch.
When the rear stop lamp switch is closed, it grounds the circuit
from the BCM. This signals the BCM to supply power to the
stop lamp.
Only Canada has a center brake lamp. The other regions turn
signals are used for stop, turn and tail lamp functions. If DTCs
B2161, B2163, B2164 set for these regions, it means the
vehicle is improperly configured. Use DIGITAL TECHNICIAN
II (Part No. HD-48650) to configure properly.
DESCRIPTION DTC
Brake lamp output open B2161
Brake lamp output shorted low B2163
Brake lamp output overloaded B2164
Rear brake switch shorted low B2223
2
1
ed03307
1. Rear stop lamp switch [121]
2. Exhaust pipe
Figure 7-58. Rear Stop Lamp Switch [121]
The brake lamp circuit needs to see activation to set DTCs.
Apply the front and rear brakes to verify brake lamp DTCs do
not return. DTCB2161 is set when the stop lamp circuit current
draw is less than 120 milliamps. DTC B2164 is set when the
stop lamp circuit current draw is above 4 Amps.
The brake switch is normally open and supplies a path to
ground when closed. In order to set a shorted brake switch
code, the vehicle needs to be operated over 30 mph (48 km/h)
for at least two minutes. DTCB2161 will only set when all loads
on the circuit are inoperable.
HOME
BE/GN
B
E
/
G
N
[242A]
[242B]
[19A] [40A] [18A]
[18B] [18B] [19B] [19B] [40B]
1
1
1
K3 F3 E2 D2
K3
B
r
a
k
e
L
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B
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a
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S
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F3 E2 D2
1
3
4
3
4
W/R
[121A-1] [121B-1]
[121A-2] [121B-2]
B
E
/
R
B
E
/
R
B
E
/
R
B
E
/
R
B
E
/
R
B
E
/
R
B
E
/
R
B
E
/
R
W/BK
W/R
W/BK
W/R
W
/
R
R
/
Y
R
/
Y
W/BK
W
/
B
K
Rear
Stop
Lamp
Switch
Front
Stop
Lamp
Switch
Pressure
Switch
(HDI) (DOM) (Canada)
BCM
BK
B
K
B
K
B
K
B
K
B
K
3 4
4 1 3
3 2
3 2
3 4
3 4 1
GND 2
LP
Stop/Tail
(Canada Only)
B
K
B
K
Left
Stop/Tail
W
W
R
R
B
K
B
K
Right
Stop/Tail
W
W
R
R
4 3 3 4
B
K
B
K
Left
Stop/Tail
B
K
B
K
Right
Stop/Tail
[22B-1] [22A-1]
em01468
Figure 7-59. Tail/Stop Lamps
HOME
STOP LAMP ALWAYS ON, DTC B2223
0.6 MM TERMINAL EXTRACTOR
TOOL
HD-50423
Table 7-46. Stop Lamp Always On, DTCB2223 Diagnostic
Faults
POSSIBLE CAUSES
Brake switch malfunction
Short to voltage on brake lamp output circuit
1. Brake Switch Test
1. Turn IGN OFF.
2. Disconnect rear brake switch [121-1] (BE/GN) wire.
3. Turn IGN ON.
4. Does stop lamp go out?
a. Yes. Replace rear brake switch.
2. Brake Switch Input Test
1. Turn IGN OFF.
GNOSTIC TOOLS.
position on BOB.
41404), test continuity between BOB terminal F3 and
ground.
a. Yes. Repair short to ground between [242B] and
[121B-1] (BE/GN) wire.
3. Brake Light Power Test
1. Using 0.6 MM TERMINAL EXTRACTOR TOOL (Part
No. HD-50423), remove terminal K3 from [242B] (BE/R)
wire.
2. Connect [242A].
3. Turn IGN ON.
4. Is brake lamp on?
a. Yes. Repair short to voltage on brake lamp power
circuit. (5041)
4. DTC Test
1. Remove BOB.
2. Insert terminal K3 into [242B] (BE/R) wire.
3. Connect [242].
4. Clear DTCs.
5. Operate system in the conditions for setting the DTCs.
6. Check DTCs.
7. Did DTC reset?
gnostic manual for wiggle test procedure.
DTC B2161
POSSIBLE CAUSES
Open in brake lamp ground circuit
Open in brake lamp power circuit
Bulb malfunction
1. Stop Lamp Test
1. Turn IGN OFF.
2. Inspect the stop lamp bulb.
3. Is bulb good?
41404), test continuity between stop lamp socket ground
and ground.
b. No. Repair open in (BK) ground circuit.
[242B] and [242A]. See 7.13 DIAGNOSTIC TOOLS.
position on BOB.
3. Install stop lamp bulb.
HOME
4. Jumper BOB terminals (M2) and (K3).
5. Turn IGN ON.
6. Does stop lamp illuminate?
b. No. Repair open in stop lamp power circuit.
DTC B2163, B2164
POSSIBLE CAUSES
Accessory tail lamp overloading circuit
Short to ground in stop lamp power circuit
Bulb malfunction
1. Bulb Test
1. Turn IGN OFF.
2. Inspect bulb.
3. Is bulb good?
2. Stop Lamp Power Circuit Short to Ground
Test
GNOSTIC TOOLS.
position on BOB.
41404), test continuity between BOB terminal (K3) and
ground.
a. Yes. Repair short to ground in stop lamp power circuit.
b. No. Replace BCM.
DTC B2223
POSSIBLE CAUSES
Short to ground in stop lamp switch power circuit (stop lamp
always illuminated)
Brake switch malfunction
1. Stop Lamp Switch Test
1. Turn IGN ON.
2. Disconnect rear stop lamp switch.
3. Does the stop lamp go out?
a. Yes. Replace the rear brake switch.
2. Brake Switch Short to Ground Test
1. Disconnect rear stop lamp switch [121-1].
GNOSTIC TOOLS.
4. Test for continuity to ground between breakout box ter-
minal (F3) and ground.
a. Yes. Repair short to ground on brake switch power
circuit.
3. DTC Test
1. Connect [242].
2. Clear the DTCs. See 7.14 INITIAL DIAGNOSTICS, Odo-
3. Operate the systemin the conditions for setting the DTCs.
4. Check DTCs. See 7.14 INITIAL DIAGNOSTICS, Odometer
Self-Diagnostics.
5. Did the DTC reset?
a. Yes. Replace the BCM.
gnostic manual for wiggle test procedure.
HOME
7.27
RUNNING LAMPS, DTC B2107, B2108, B2109,
B2166, B2168, B2169
The running lamps consist of the front position lamp (HDI),
located in the headlamp housing, the front running lamps, the
license plate lamp and the tail lamp. The running lamps are
powered by the BCMthrough terminal J3 and L4 (if equipped).
1
3
2
ed03194
DESCRIPTION DTC
Front position/running power output
shorted high
B2107
shorted low
B2108
overloaded
B2109
Running lights output open B2166
Running lights output shorted low B2168
Running lights output overloaded B2169
HOME
2
3
5
6
7
8
9
10
11
4
1
ed03415
The running lamps circuit powers up when the engine stop
switch is turned on. Any running lamp related DTCs will set
shortly after the engine stop switch is turned on.
DTC B2166 will only set if all lights are open on the circuit.
DTC B2166 will set if the running lights circuit is below 120
milliamps. DTC B2169 will set if the running lights circuit is
above 3 Amps. DTCB2109 will set if the switched power output
circuit is above 10 Amps.
HOME
[242A]
[242B]
[24B]
[24A]
[22B-1]
[22A-1]
[38B] [38A]
BE/BK
B
E
/
B
K
O/W
GND 2
BCM
D2 E2 J3 L4
D2 E2
[40A]
[40B]
1 3
1 3
J3 L4
C
A
N
H
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R
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F
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R
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/
F
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P
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M2
M2
A
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c
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s
s
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y
P
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C
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C
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C
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W
/
B
K
W
/
R
W
/
B
K
W
/
R
W
/
B
K
W
/
R
W
/
B
K
W
/
R
Front Right
Running Light
Front Left
Running Light
RHCM LHCM
Right Turn
Signal
Switch
Left Turn
Signal
Switch
B
K
B
E
B
K
B
E
B
E
B
E
B
E
B
K
B
E
B
K
B
K
B
K
BK
BK BK
BE
BK
B
K
Position
Lamp
(HDI)
Resistor
Assembly
DLC
Stop/Tail/
LP Lamp
(Canada)
[18A]
[18B] [18B]
1 4 [19A] 1 4
1 1
1 1 1 1
4
3 4
3 4
W
/
B
K
W
/
R
R
/
Y
R/Y
R
/
Y
W
/
B
K
W
/
R
W
/
B
K
W
/
R
3 4
3 4
4
Rear Right
STT
HDI DOM
B
K
W
1 4
B
E
B
K
1 4 [19B] [19B]
Rear Left
STT
HDI DOM
B
K
W
1 4
B
E
B
K
1 4
em01469
Figure 7-62. Running Lamps
HOME
FRONT RUNNING LAMPS INOPERATIVE
Table 7-51. Front Running Lamps Inoperative Diagnostic
Faults
POSSIBLE CAUSES
Open running lights circuit
Lamp malfunction
Open ground circuit
NOTE
This test refers to domestic running lamps integrated with the
front turn signals.
1. Domestic Running Lamp Configuration
Test
1. Inspect front running lamps.
2. Are running lamps wired directly to the LHCMand RHCM?
2. Bulb Test
1. Inspect inoperative bulb and socket.
2. Is bulb and socket good?
a. Yes. Replace LHCM or RHCM for the inoperative
lamp. (6165) or (6166)
b. No. Replace bulb. (6796)
3. Running Lamp Test
1. Inspect inoperative bulb.
2. Is bulb good?
1. Turn IGN OFF.
41404), test continuity between running lamp bulb socket
ground and ground.
a. Yes. Repair open in running lamp power circuit (BE)
wire. (5041)
b. No. Repair open in (BK) ground circuit. (5041)
REAR RUNNING LAMPS INOPERATIVE
Table 7-52. Rear Running Lamps Inoperative Diagnostic
Faults
POSSIBLE CAUSES
Open running lights circuit
Lamp malfunction
Open ground circuit
1. Bulb Test
2. Is bulb good?
1. Turn IGN OFF.
41404), test continuity between tail lamp bulb socket ter-
minal ground and ground.
a. Yes. Repair open in running lamp power circuit.
(5041)
b. No. Repair open in ground circuit (BK) wire. (5041)
DTC B2107
TOOL
HD-50424
POSSIBLE CAUSES
Short to power in front position/running circuit
1. Position Lamp Circuit Test
1. Turn IGN OFF.
2. Disconnect BCM [242].
No. HD-50424), remove terminal L4 from [242B].
[242B] and [242A]. See 7.13 DIAGNOSTIC TOOLS.
HOME
position on BOB.
6. Turn IGN ON.
7. Test voltage between extracted terminal L4 and ground.
a. Yes. Repair short to voltage in the front position/run-
ning circuit.
2. DTC Test
1. Connect [242].
2. Clear DTC.
3. Turn IGN ON.
4. Check DTCs.
5. Did DTC reset?
b. No. Concern is not currently present.
DTC B2108, B2109
POSSIBLE CAUSES
Short to ground in front position/running circuit
High current in front position/running circuit
1. Position Lamp Circuit Short to Ground
Test
1. Disconnect the position lamp.
GNOSTIC TOOLS.
ground.
a. Yes. Repair short to ground in (BE/BK) wire.
2. Excessive Draw Test
1. Remove accessory lighting (if equipped). Unplug one lamp
at a time on the circuit and cycle the engine stop switch
OFF-ON.
2. Check DTCs after each lamp is removed.
3. Does code clear?
a. Yes. Replace lamp that was causing issue.
3. DTC Test
1. Connect [242].
4. Check DTCs. See 7.14 INITIAL DIAGNOSTICS, Odometer
Self-Diagnostics.
gnostic manual for performing a wiggle test procedure.
DTC B2166 (DOMESTIC ONLY)
Table 7-55. DTCB2166 Diagnostic Faults (Domestic Only)
POSSIBLE CAUSES
Open in running lights ground circuit
Open in runnings lights power circuit
Incorrect configuration (HDI only)
1. Running Lamp Operation Test
1. Verify tail lamp/license plate lamp, fuel gauge and fork
mounted front running lamps are operational.
2. Are all lights on?
b. No, some of the lights are on. Go to Test 3.
c. No, all lights are inoperative. Go to Test 4.
2. Running Lamps Circuit Test
1. Turn IGN OFF.
2. Disconnect rear lighting harness [7].
3. Turn IGN ON.
41404), test voltage between [7A] terminal 7 and ground.
HOME
b. No. Repair open in (BE) wire.
3. Bulb Test
2. Is bulb good and the correct bulb?
a. Yes.
4. Running Lamp Open Circuit Test
1. Turn IGN OFF.
[242B], leaving [242A] disconnected. See 7.14 INITIAL
DIAGNOSTICS, Odometer Self-Diagnostics.
position on BOB.
5. Test continuity between BOB terminal J3 and inoperative
running lamp power circuit.
a. Yes. Replace bulb and socket.
b. No. Repair open in running lamp circuit between
inoperative lamp and BCM.
DTC B2168, B2169: FXS AND FLS
POSSIBLE CAUSES
Running lights circuit resistance too low
Short to ground in running lights power circuit
1. Right Rear Turn Lamp Circuit Test
1. Turn IGN OFF.
2. Disconnect right rear turn lamp [18].
3. Clear DTC.
4. Cycle IGN OFF-ON.
5. Did DTC return?
b. No. Repair short to ground or high current draw in
right rear turn signal harness in the running lamp
power circuits.
2. Left Rear Turn Lamp Circuit Test
1. Turn IGN OFF.
2. Disconnect left rear turn lamp [19].
3. Clear DTC.
5. Did DTC return?
b. No. Repair short to ground or high current drawin left
rear turn signal harness in the running lamp power
circuits.
3. Tail Lamp Circuit Test
1. Turn IGN OFF.
2. Disconnect tail lamp [40].
3. Clear DTC.
5. Did DTC return?
b. No. Repair short to ground or high current draw in tail
lamp harness in the running lamp power circuits.
1. Turn IGN OFF.
2. Disconnect the resistor assembly [200].
3. Clear DTC.
5. Did DTC return?
b. No. Replace the resistor assembly.
5. BCM Test
1. Turn IGN OFF.
GNOSTIC TOOLS.
position on BOB.
41404), test continuity between BOB terminal J3 and
ground.
HOME
a. Yes. Repair short to ground in (BE) wire.
b. No. Replace BCM.
LED CONSOLE INOPERATIVE
Table 7-57. LED Console Inoperative Diagnostic Faults
POSSIBLE CAUSES
Open in power circuit
LED console malfunction
1. DTC Test
2. Are any DTCs present?
2. LED Console Test
46601) to [39]. Attach connectors from BREAKOUT BOX
(Part No. HD-42682) to harness adapters leaving [39A]
disconnected.
3. Turn IGN ON.
4. Measure voltage between BOB terminal 5 and ground.
a. Yes. Replace the LED console. (6086)
HOME
7.28 SECURITY SYSTEM
SECURITY LAMP
See Figure 7-63. The security lamp indicates system status.
Refer to Table 7-58.
ABS
E
F
4
3
2
1
5
6
7
8
9
ed03408
2. Low fuel lamp
4. Tachometer
5. Security lamp
6. Low fuel lamp
7. ABS lamp
8. Battery lamp
9. Gear indicator
Table 7-58. Security Lamp Status
MODE LAMP
Security system not armed. Does not flash.
Two minute timeout after failed PINentry
attempt or a battery reconnect has
occurred while armed.
Flashes every
second.
Security system armed. Flashes every 2.5
seconds.
PIN entry mode. Flashes 4 times a
second.
Arming is starting up. You have five
seconds before system is armed.
Stays on solid with
the engine stop
switch OFF.
If solid for more than four seconds after
turning the engine stop switch ON, a
current DTC is present.
Stays on solid with
the engine stop
switch ON.
SECURITY IMMOBILIZATION
The BCMwill disable the starter and ignition system. Additional
functions include the ability to alternately flash the left and right
turn signals and sound a siren if a theft attempt is detected.
NOTE
The siren must be in the chirp mode for the siren to chirp on
arming or disarming. See the electrical diagnostic manual.
Conditions that trigger a security event when system is armed
include:
Detecting tampering of the ignition circuit: Turn signals
flash three times, siren chirps once and then turns off. If
the tampering continues, a second warning will activate
after four seconds. Continued tampering will cause the
alarm to activate for 30 seconds and then turn off. The
two warnings/alarm cycle is repeated for each tampering
incident. The system will remain armed and the vehicle
will be immobilized.
Detecting vehicle movement: Turn signals flash three
times, siren chirps once and then turns off. If the vehicle
is not returned to its original position, a second warning
will activate after four seconds. If the vehicle is not returned
to its original position, the alarm activates for 30 seconds
then turns off. The two warnings/alarm cycle may repeat
a maximum of 10 times with a 10 second pause between
cycles.
Detecting that a battery or ground disconnect has
occurred while armed: The optional siren activates its
self-alarm mode. Turn signals will not flash.
NOTE
Always disarm the vehicle by turning the engine stop switch
ON with the fob present before removing or disconnecting the
battery to prevent the siren (if installed) from activating.
SECURITY SYSTEM FEATURES
The following information applies only to vehicles equipped
with the security.
Personal code disarming: If the fob is not available or
inoperative, the BCM allows the rider to disable the
security alarm and immobilization functions with a five-
digit personal code.
Arming confirmation: When the security systemis armed,
the system provides visual feedback (confirmation) to the
rider by flashing the turn signals and an audible "chirp" if
chirp mode is enabled.
Disarming confirmation: When the security system is
disarmed, the systemprovides an audible "chirp" (confirm-
ation) if chirp mode is enabled.
Transport mode: It is possible to armthe security system
without enabling the motion detector for one ignition cycle.
HOME
This allows the vehicle to be moved in an immobilized
state.
Starter/ignition disable: When armed the starter and
ignition system are disabled.
Security system alarm: See the electrical diagnostic
manual. The system will alternately flash the left and right
turn signals and sound an optional Smart Siren if a vehicle
security condition is detected while the system is armed.
Dealer service mode: This mode allows the dealer to
disable security systemvia DIGITAL TECHNICIANII (Part
No. HD-48650). Dealer service mode is exited when the
engine stop switch is turned ON with the assigned fob in
range.
WARNINGS
A warning consists of three alternate flashes of the turn signals
and chirp from the optional smart siren. Warnings are issued
from an armed security system in the following order:
1. First Warning: A warning is issued whenever a person
without a fob present or with the system armed attempts
to move the vehicle or turns the engine stop switch ON.
2. Second Warning: If the motion continues or the engine
stop switch is not turned back to OFF, a second warning
is issued within four seconds of the first.
3. Alarm: If the motion continues or the engine stop switch
is not turned to OFF past the second warning, the smart
security system will go into full alarm.
ARMING
The H-DSSS automatically arms within five seconds when the
vehicle is parked and the engine stop switch is turned to OFF
and motion is not detected.
On arming, the turn signals flash twice and the smart siren will
"chirp" twice if chirp function is activated. While armed, the
security lamp will flash once every 2.5 seconds. Refer to
Table 7-58.
DISARMING
There are two ways to disarm the H-DSSS:
Automatic Disarming.
Using the PIN.
Automatic Disarming
Always have the fob present when riding, loading, fueling,
moving, parking or servicing the vehicle. Carry the fob in a
convenient pocket. The vehicle can be moved in an armed
state with the fob present without triggering the alarm. The H-
DSSS disarms automatically when the engine stop switch is
turned to ON.
On disarming, the smart siren will chirp once (if chirp function
is activated) and the security lamp will turn ON solid for four
seconds then go out. Refer to Table 7-58.
Disarming with a PIN
See 7.29 SERVICE AND EMERGENCY FUNCTIONS AND
CONFIGURATIONS to enter an initial PIN to enable the
system.
If you make an error while disarming the security systemusing
the PIN, the alarm will activate for 30 seconds after the last
digit is entered. After a failed attempt, the security lamp will
flash once every second for two minutes. During this time,
the vehicle will not accept any attempt to enter a PIN. Refer
to Table 7-59.
Table 7-59. Entering a PIN to Disarm Harley-Davidson Smart Security System
NOTES WAIT FOR CONFIRMATION ACTION STEP
NO.
Should be recorded on wallet card. If necessary, verify the current 5-digit
PIN.
1
The odometer window display will
show ENTER PIN.
Push the OFF/RUN switch to RUN. 2
In the odometer window, a flashing 1
will appear.
Press and release the left turn signal
switch.
3
The first digit in the odometer will be
the first digit in the PIN.
Increment the digit by tapping the left
turn signal until the odometer window
displays the first digit of the PIN.
4
Serves as enter key. The first digit is stored and the next
digit will flash.
Press right turn switch 1 time. 5
The second digit in the odometer will
be the second digit in the PIN.
Increment the second digit using the
left turn switch until the digit reaches
the second digit of the PIN.
6
Serves as enter key. The second digit is stored and the
next digit will flash.
The third digit in the odometer will be
the third digit in the PIN.
Increment the third digit using the left
turn switch until it reaches the third
digit of the PIN.
8
HOME
Table 7-59. Entering a PIN to Disarm Harley-Davidson Smart Security System
NOTES WAIT FOR CONFIRMATION ACTION STEP
NO.
Serves as enter key. The third digit is stored and the next
digit will flash.
The fourth digit in the odometer will
be the fourth digit in the PIN.
Increment the fourth digit using the
left turn switch until it reaches the
fourth digit of the PIN.
10
Serves as enter key. The fourth digit is stored and the next
digit will flash.
The fifth digit in the odometer will be
the fifth digit in the PIN.
Increment the fifth digit using the left
turn switch until it reaches the fifth
digit of the PIN.
12
Smart Security System is disarmed. The fifth digit is stored. The security
system indicator lamp stops blinking.
ALARM
Activation
In the full alarm state, the turn signals flash alternately and the
siren will sound.
After 30 seconds of alarm, if no further vehicle motion is
detected, the alarm will stop.
NOTE
Vehicle must be returned to original parked position with engine
stop switch turned to OFF.
If vehicle motion continues, the alarm will start again and con-
tinue for another 30 seconds.
The security system will repeat the alarm cycles 10 times for
a total of five minutes, with a 10-second pause between alarm
cycles.
During warnings and alarms, the starter motor and the ignition
remain disabled.
Deactivation of Alarm
The alarm cycles can be discontinued at any time by moving
an assigned fob to the vehicle. The presence of the fob will
terminate the alarm.
HOME
7.29
SERVICE AND EMERGENCY FUNCTIONS AND
CONFIGURATIONS
GENERAL
Setting up a vehicle's security requires a BCM that is security
equipped.
ACTUATION
Actuation consists of assigning two fobs to the system and
entering an initial PIN. The PIN can be changed by the rider
at any time.
1. Configure vehicles by assigning both fobs to the vehicle.
2. Configure vehicles by entering a PINpicked by the owner.
The personal code allows the owner to operate the system
if the fob is lost or inoperable. Record the PIN in the
owner's manual and instruct the customer to carry a copy
(use the wallet card found in the owner's manual).
Once the system has been activated, it will always arm within
five seconds of turning the engine stop switch to OFF and no
vehicle motion.
SELECTING A PIN
The PIN consists of five digits. Each digit can be any number
from 1-9. There can be no zeros (0) in the PIN. The PIN must
be used to disarmthe security systemin case the fob becomes
unavailable.
INITIAL PIN ENTRY
The initial PIN entry should be performed using DIGITAL
TECHNICIAN II (Part No. HD-48650) in conjunction with fob
assignment.
CHANGING THE PIN
To change a PIN, refer to Table 7-60.
If a PIN was previously entered, the odometer will display the
equivalent digit. To increment the digits, press the left turn
signal switch. The first press selects the same value and then
each additional press of the left turn signal switch will increment
the digit by one.
Examples:
To advance from 5 to 6, press and release the left turn
switch twice.
To advance from 8 to 2, press and release the left turn
switch four times.
Table 7-60. Changing the PIN
NOTES WAIT FOR CONFIRMATION ACTION NO.
Select a 5-digit (1 thru 9) PIN and
record on the wallet card fromOwner's
Manual.
1
With an assigned fob present, turn the
OFF/RUN switch to RUN.
2
Cycle the OFF/RUNswitch twice: OFF
- RUN - OFF - RUN.
3
ENTER PIN will scroll through the
odometer window.
Press left turn signal switch 2 times. 4
Turn signals will flash 3 times. Current
PIN will appear in odometer. The first
digit will be flashing.
Press right turn signal switch 1 time
and release.
5
Enter first digit of new PIN by pressing
and releasing the left turn signal switch
until the selected digit appears.
6
The new digit will replace the current
in odometer window.
and release.
7
Enter second digit of selected PIN by
pressing and releasing the left turn
signal switch until the selected digit is
present.
8
in odometer window.
and release.
9
HOME
Table 7-60. Changing the PIN
NOTES WAIT FOR CONFIRMATION ACTION NO.
Enter third digit of the selected PIN by
present.
10
in odometer window.
Press right turn switch 1 time and
release.
11
Enter fourth digit of new PIN by
present.
12
in odometer window.
release.
13
Enter fifth digit of the new PIN by
present.
14
in odometer window.
release.
15
Pushing the OFF/RUN switch to OFF
stores the new PIN in the module.
Push the OFF/RUN switch to the OFF
position.
16
TRANSPORT MODE
When transporting the motorcycle, place the system in the
transport mode. Otherwise, the alarm activated by motion
detection can discharge the battery.
In the transport mode, the security system is armed without
enabling the motion detector for one ignition cycle. This allows
the vehicle to be picked up and moved in an armed state,
however, any attempt to start the engine when the fob is not
within range will trigger the alarm.
To Enter Transport Mode
1. With an assigned fob within range, turn the engine stop
switch ON.
2. Before the security systemlamp goes out, turn the engine
stop switch OFF.
3. Within three seconds, simultaneously press both the left
and the right turn signal switches.
4. After the turn signals flash once, the system enters the
transport mode. With the fob removed, the motorcycle can
be moved without setting off the alarm.
To Exit Transport Mode
With the fob present, turn the engine stop switch ON to disarm
the system.
SERVICE MODE
With a fob present, the security system can be configured for
service by disabling the security system with DIGITAL TECH-
NICIAN II (Part No. HD-48650).
Once disabled, the vehicle can be operated without an assigned
fob present. To maintain the Service Mode, the assigned fobs
must be kept out of range. If the fob appears in range, the
Service Mode will be exited.
FOUR-WAY FLASHING
To Armthe Security Systemwith the Hazard
Warning Flashers ON
If it is necessary to leave a vehicle parked along side the road,
the hazard warning four-way flashers can be turned ON with
the smart security system armed.
2. Press the hazard warning switch. The four-way flashers
will continue for two hours.
3. Turn the engine stop switch OFF to armthe smart security
system.
To Disarm the Security System and Turn
the Hazard Warning Flashers OFF
1. With a fob present, turn the engine stop switch to ON.
2. Press the hazard warning switch.
HOME
NOTES
TABLE OF CONTENTS
SUBJECT............................................................................................................................PAGE NO.
8.1 EFI SYSTEM..............................................................................................................................8-1
8.2 ELECTRONIC CONTROL MODULE.........................................................................................8-3
8.3 SENSORS AND DRIVERS........................................................................................................8-5
8.4 DTC B2102, B2103, B2104.......................................................................................................8-8
8.5 DTC B2116, B2117, B2118, B2119..........................................................................................8-12
8.6 DTC P0107, P0108, P0112, P0113.........................................................................................8-15
8.7 DTC P0117, P0118..................................................................................................................8-20
8.8 DTC P0120, P0122, P0123, P0220, P0222, P0223................................................................8-23
8.9 DTC P0031, P0032, P0131, P0132, P0134, P0151, P0152, P0154.......................................8-30
8.10 DTC P0261, P0262, P0264, P0265.......................................................................................8-37
8.11 DTC P0371, P0372, P0374....................................................................................................8-41
8.12 DTC P0444, P0445................................................................................................................8-43
8.13 DTC P0502, P0503................................................................................................................8-46
8.14 DTC P0505............................................................................................................................8-50
8.15 CRUISE CONTROL...............................................................................................................8-52
8.16 DTC P0577............................................................................................................................8-55
8.17 DTC P0603, P0605................................................................................................................8-56
8.18 DTC P0641, P0651................................................................................................................8-57
8.19 DTC P1009............................................................................................................................8-60
8.20 DTC P1270............................................................................................................................8-61
8.21 DTC P1353, P1356, P1357, P1358.......................................................................................8-64
8.22 DTC P1501, P1502................................................................................................................8-68
8.23 DTC P1510, P1511, P1512....................................................................................................8-71
8.24 DTC P1514............................................................................................................................8-72
8.25 DTC P1600............................................................................................................................8-73
8.26 DTC P1632............................................................................................................................8-74
8.27 DTC P1655, P1656................................................................................................................8-75
8.28 DTC P2100, P2101, P2102, P2103.......................................................................................8-79
8.29 DTC P2105, P2107................................................................................................................8-82
8.30 DTC P2119.............................................................................................................................8-85
8.31 DTC P2122, P2123, P2127, P2128.......................................................................................8-86
8.32 DTC P2135, P2138................................................................................................................8-91
8.33 DTC P2176............................................................................................................................8-94
8.34 DTC P2300, P2301, P2303, P2304.......................................................................................8-95
8.35 ENGINE CRANKS, BUT WILL NOT START..........................................................................8-99
8.36 STARTS, THEN STALLS.....................................................................................................8-101
8.37 MISFIRE AT IDLE OR UNDER LOAD.................................................................................8-102
E
N
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E
M
A
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A
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NOTES
8.1 EFI SYSTEM
GENERAL
See Figure 8-1. The engine management system consists of
the following components:
ECM
CKP sensor
TMAP sensor
ET sensor
TGS
TCA
VSS
Oxygen sensors
Ignition coil
Fuel pump
Fuel injector
Purge solenoid (if equipped)
The ECM is a solid state device mounted under the seat and
sealed to prevent contamination from dust/dirt, water and oil.
The ECM controls engine performance based upon input sup-
plied to the ECM from the ET, CKP, TMAP, TGS, the VSS and
oxygen sensors and other additional low-voltage circuits.
The ECM controls the dwell time for the ignition coil,
providing optimum ignition circuit performance for all
engine speeds/load conditions. Optimizing the ignition
system allows the ECM to control/vary engine timing (as
needed) from 0-50 degrees BTDC.
The ECM also has built-in protection against transient
voltages, continuous reverse voltages and inadvertent
damage resulting from jump starts. The ECM is a non-
repairable item and must be replaced when it fails.
EFI Operation
The EFI system operates as an open or closed loop system,
allowing it to adjust for all possible operating conditions. During
open loop operation, the system uses programmed fuel and
spark maps in the ECM providing easy cold starting and max-
imum power at Wide Open Throttle (WOT). The adaptive fuel
value, learned during closed loop operation, is applied to open
loop operation to adjust fuel and spark maps for optimal per-
formance. During closed loop operation, the O2 sensors provide
input for an optimal air/fuel mixture resulting in reduced emis-
sions, good fuel economy and smooth power. O2 sensors must
be at the normal operating temperature of the engine. By using
both open and closed loop systems, engine performance is
continuously tuned to compensate for changing conditions and
providing maximum performance. A simplified signal flow dia-
gram for the EFI system is shown in Figure 8-1.
Heat Management System
To improve rider comfort, an optional heat management system
may be enabled. After being enabled, the heat management
system improves rider comfort by turning off the rear cylinder
fuel injector when all of the following conditions exist:
High engine temperature
Engine at idle speed
Low or no vehicle speed
Clutch lever pulled in or transmission in neutral
As the engine maintains idle speed, the rear cylinder functions
as an "air pump," helping to cool the engine. This continues
until one of the above listed conditions is no longer met, then
the rear cylinder fires normally again.
NOTE
When the engine is in heat management mode, a noticeable
difference in idle may be accompanied by a unique exhaust
odor. While these conditions are normal, a rider or technician
unaware of the heat management system may incorrectly
assume an idle problem is present.
Enable/Disable Engine Idle Temperature
Management System (EITMS)
1. Turn the engine stop switch ONwith the motorcycle at idle
and not moving (the motorcycle may be running or not
running).
2. Push the throttle to roll-off position and hold.
3. After approximately three seconds, the cruise indicator
will flash either red (disabled) or green (enabled).
4. Repeat step two to change.
HOME
2013 FXSBSE Service Supplement: Engine Management 8-1
BK/Y
G
N
/
W
B
K
/
WB
K
/
W
R
B
K
/
G
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B
K
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R
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A
A
B
A
B
A
B
A
B
B
C
D
A Power
Ion Sense
Coil Rear
Coil Front
B
C
D
CKP
Sensor
ET
Sensor
TCA
TMAP
Sensor
Ignition Coil
VSS
JSS
Rear Fuel
Injector
Front Fuel
Injector
L3 L3 BCM
6 5 4 3 2 1
1 2
1 2
6 5 4 3 2 1
1
A
B
C
A
B
C
2
A B
A B
3 4
1 2
Front ACR
(If Equipped)
2 1
2 1
3 4
6 5 4 3 2 1
GY/BN
BK/BN
BK/BN
GN/BN
Right
GND 2
R
/
G
N
R
/
G
N
R
/
G
N
Purge Solenoid
(Optional)
A
B
A
B
[79A]
[79B]
[204B]
[90A]
[90B]
[203AF]
[203BF]
Rear ACR
(If Equipped)
2 1
2 1
[211A]
[211B]
[80A]
[80B]
[65A] [65B]
B
K
B
K
/
W
G
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[84B] [84A]
[85B] [85A]
[95B] [95A]
[83B] [83A]
[203AR]
[203BR]
[242B] [242A]
R/GN
R/GN
GN/Y
GY/Y
R/GN
R/GN
R/GN
R/GN
R/GN
LGN/BN
GY/BE
GN/BE
LGN/BK
G
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L
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R
R/W
LGN/Y
Battery
Fuse
ECM
[78B]
[78A]
19 20 23 24 28 29 30 33 36 37 39 40 43 46 48 49 50 51 52 53 54 59 61 62 63 64 66 68 71 72 73
19 20 23 24 28 29 30 33 36 37 39 40 43 46 48 49 50 51 52 53 54 59 61 62 63 64 66 68 71 72 73
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Rear
HO2S
Front
HO2S
1
2
3
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1
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3
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[138A]
[137A]
em01458
Figure 8-1. EFI Simplified Schematic
HOME
8-2 2013 FXSBSE Service Supplement: Engine Management
8.2 ELECTRONIC CONTROL MODULE
GENERAL
See Figure 8-2. The ECMreceives and processes signals from
the sensors and applies output signals to the drivers to start,
idle and run the engine. This section describes the configuration
of the ECM for this vehicle.
2
3
5
6
7
8
9
10
11
4
1
ed03415
ECM
The ECM is mounted under the seat. It computes the spark
advance for proper ignition timing and fuel control based on
sensor inputs (from ET, CKP, TMAP, TGS, VSS and oxygen
sensors) and controls the low-voltage circuits for the ignition
coils and injectors.
The ECM contains all of the components used in the ignition
system. The dwell time for the ignition coil is also calculated
in the microprocessor and is dependent upon battery voltage.
The programmed dwell is an added feature to give adequate
spark at all speeds. (The ECM has added protection against
transient voltages, continuous reverse voltage protection and
damage due to jump starts.) The ECM is fully enclosed to
protect it from vibration, dust, water or oil. This unit is a non-
repairable item. If it fails, it must be replaced.
32-2 Flywheel
The left flywheel has 32 teeth evenly spaced around its circum-
ference with two consecutive teeth missing (sync gap). In this
configuration, the ECM determines engine position, engine
phase and engine speed from the CKP sensor input. Phase
(TDC compression) is determined by the ECM during startup
and, when necessary, while running. No engine ignition events
HOME
can occur until the ECM determines the relationship of piston
position to crankshaft position. The following paragraphs in
this section describe synchronization and phasing by the ECM
to provide smooth operation of the engine at all speeds.
Crank Position Signal Synchronization
In the 32-2 crank configuration, crankshaft position is determ-
ined by the ECM finding the two-tooth (sync gap) in the CKP
sensor signal. This is usually accomplished the first time the
sync gap is encountered. The ECM monitors the CKP signal
status every engine revolution. If the ECMdetermines synchron-
ization is lost, it immediately terminates ignition events and
synchronizes on the next occurrence of the sync gap.
Engine Phase
Phasing is accomplished by the ECM identifying a widening in
the CKP signal caused by the deceleration of the crankshaft,
as a piston approaches TDC on its compression stroke. Since
the rear cylinder approaches TDCearlier than the front cylinder,
engine phase can be readily discriminated. Phasing is normally
accomplished on the first TDC cycle after engine synchroniza-
tion. Once phased, the ECM can begin normal ignition events.
If the ECM experiences a system reset or loss of synchroniza-
tion while the engine is running it also loses phase.
When phase is lost one of the following occurs:
If an engine-not-running (Crank Mode) rpm is detected,
the ECM executes the normal start-up phasing process.
If Engine Run Mode is detected, the ECM executes a
running re-phase sequence.
The front cylinder is fired every engine revolution. The ECM
monitors the power stroke after the fire event to determine if
sufficient acceleration occurred to indicate the ECM fired on
the compression stroke. When two valid power strokes are
detected, the ECM locks phase and resumes normal ignition
events.
Engine Run Mode
Many functions of the EFI system require an engine run mode
determination. Engine run is determined by the level of engine
rpm. Generally, the engine is considered to be running when
engine rpm exceeds a minimum of 750 rpm.
Removal
1. Remove seat. See 2.21 SEAT.
2. See Figure 8-3. Free ECM (1) from top caddy (2).
3. Disconnect ECM connector (3). See DELPHI GT 280
SEALED73-TERMINAL ECMCONNECTORin the service
manual.
NOTE
Internal latches are not fully disengaged until locking bar is in
the fully released position. Forcing socket housing with latches
partially engaged will result in connector damage.
Installation
1. Connect ECM connector. See DELPHI GT 280 SEALED
73-TERMINAL ECMCONNECTORin the service manual.
NOTE
Pin and socket housings must be fully engaged before locking
bar is rotated to the latched position. Forcing locking bar without
full engagement will result in connector damage.
2. See Figure 8-3. Secure ECM (1) in top caddy (2). Verify
holes engage two index pins on the bottom of the top
caddy.
3. Install seat. See 2.21 SEAT.
NOTE
After installing ECM, the password learn procedure must be
performed.
4. Perform password learn procedure using DIGITAL
TECHNICIAN II (Part No. HD-48650).
1
2 4 3
5
6
7
10 9
8
ed03414
1. ECM
2. ECM [78]
4. Security siren
5. BCM
8. Rear WSS [168]
9. ABS [166]
10. ABS ECU
HOME
8.3 SENSORS AND DRIVERS
Sensors and drivers play an important part in the ECM's ability
to regulate engine efficiency, emissions control and fuel eco-
nomy. When a failure occurs, a DTC is generated by the ECM.
These codes help the technician diagnose engine trouble to
the proper sensor or driver. See 7.14 INITIAL DIAGNOSTICS.
SENSORS
Not all sensor problems cause an engine shutdown, but sensor
failure can seriously degrade overall engine performance. A
notable exception is the CKP sensor, which if faulty, completely
disables engine operation. The following are brief explanations
of sensor types and their functions within the EFI system.
Crank Position (CKP) Sensor
The CKP sensor, located on the left front of the lower crankcase
half, is a variable reluctance sensor that generates AC voltage
as the teeth on the flywheel pass by the sensor. The signal is
routed to the ECM where it is used to determine crankshaft
position, engine speed (rpm) and engine phase (TDCcompres-
sion). Without the presence of the CKP signal, the ECM will
not allow the ignition and fuel injection drivers to operate, and
thus the engine will not run. The ECM uses crankshaft com-
pression slow down events to determine engine phase.
Therefore, the spark plugs must be installed when checking
for spark.
Twist Grip Sensor (TGS)
The TGS, mounted on the right hand side of the handlebar,
houses two internal (opposing) Hall-effect sensors for operator
control of the engine's throttle. The opposing operation of the
sensors ensures that repositioning of the throttle twist grip,
forward and/or back, is accurately reported to the ECM. As the
throttle is operated, position changes are reported to the ECM
that controls the corresponding movement of the throttle plate
by the TCA.
Throttle Control Actuator (TCA)
The TCA, mounted to the intake manifold, operates the throttle
plate internal to the induction module on the engine. Two cor-
responding TP sensors provide input to the ECM, so the ECM
may verify that plate position corresponds to TGS input (rider
desired position of the plate) and to adjust the position of the
throttle plate, accordingly.
Jiffy Stand Sensor (JSS)
The JSS (if equipped) uses a Hall-effect device to monitor jiffy
stand position. When the jiffy stand is fully retracted, the sensor
picks up the presence of a metal tab mounted to the jiffy stand.
When extended, the engine only starts and runs if the ECM
receives a signal from the neutral switch indicating the trans-
mission is in neutral, or a signal fromthe clutch switch indicating
the clutch is engaged. Otherwise, the engine stalls as the clutch
is released with the transmission in gear.
Accelerometer
The accelerometer is internal to the BCM. The BCM will shut
the engine down if the vehicle is tipped over. Once the sensor
is tripped, the motorcycle must be righted, the engine stop
switch turned off and then on again before the engine can be
restarted. This is communicated across the CAN bus circuit.
Clutch Switch
The clutch switch connects to the LHCM. When the clutch is
engaged (pulled in) the LHCMsends a message over the CAN
bus circuit to the ECM and BCM. The engine will not crank
unless the clutch is engaged or the transmission is in neutral.
Neutral Switch
The BCM provides voltage to the neutral switch, which is open
when the transmission is in gear. With the transmission in
neutral, the switch is closed, allowing current flow to ground.
The BCM will not allow the engine to start unless the transmis-
sion is in neutral or the clutch is engaged.
Engine Temperature (ET) Sensor
The ET sensor is a thermistor device, which means that at a
specific temperature it has a specific resistance across its ter-
minals. As this resistance varies, so does the voltage.
At high temperatures, the resistance of the sensor is very
low, which effectively lowers the signal voltage on ECM
[78] terminal 51.
At low temperatures, the resistance is very high, allowing
the voltage to rise close to 5V. The ECM monitors this
voltage to compensate for various operating conditions.
Temperature Manifold Absolute Pressure
(TMAP) Sensor
The TMAP sensor combines the MAP and IAT in a single
component. Each functions as described in the paragraphs
following, and are tested as separate units.
Manifold Absolute Pressure (MAP) Sensor
The MAP sensor is supplied 5V from the ECM and sends a
signal back to ECM. This signal varies in accordance with
engine vacuum, intake air temperature and atmospheric baro-
metric pressure. The MAP sensor monitors the intake manifold
pressure (vacuum) and sends the information to the ECM. The
ECM then adjusts the spark and fuel timing advance curves
for optimum performance. The output of the sensor can also
be used to determine if the engine is rotating when a fault with
the CKP sensor is present.
Intake Air Temperature (IAT) Sensor
The IAT sensor is a thermistor device. As such, it will have a
specific resistance across its terminals at a specific temper-
HOME
ature. As the temperature varies, the thermistor resistance
varies, and so does the voltage on ECM [78] terminal 49.
low, which effectively lowers the signal voltage on ECM
[78] terminal 49.
Vehicle Speed Sensor (VSS)
The VSS is a Hall-effect device mounted close to the teeth of
the 5th gear in the transmission. The output signal frequency
varies with vehicle speed. The ECM processes the vehicle
speed signal and transmits it via the CAN bus circuit to the
speedometer to indicate vehicle speed.
HO2S: Front and Rear
The HO2S sensor detects unburned oxygen in the engine
exhaust. The output of the sensor is a voltage having a range
of about 0-1.0V. The normal output is 0.5V, which represents
a balance between a lean (not enough fuel) and rich (too much
fuel) air/fuel mixture. An output less than 0.5V represents a
lean mixture; greater than 0.5V represents a rich mixture. The
change in output level signals the ECM to modify the air/fuel
ratio. This voltage is what is seen across the sensor. If the
voltage is measured from the sensor to ground or is displayed
on DIGITAL TECHNICIAN II (Part No. HD-48650), it will range
from 0.7-1.7V. This will cause the midpoint between rich and
lean to be 1.2V. It is important to note the HO2S do not operate
efficiently until it is at operating temperature. Therefore, before
any troubleshooting takes place, bring the sensor to operating
temperature. Leaks in the exhaust system, leaky exhaust
valves, misfires or any engine problem allowing unburned
oxygen into the exhaust stream could create a DTC indicating
a bad sensor. Look for problems related to an improper air/fuel
mixture before replacing the sensor.
DRIVERS
The ECM drivers are the output devices or system outputs of
the EFI system. Drivers are provided ground by the ECM to
pump, inject and ignite the air/fuel mixture in the engine.
Fuel Pump
The fuel pump, located inside the fuel tank, is provided battery
voltage by the BCM.
Ignition Coil and Spark Plugs
The ignition coil creates the energy to fire the spark plugs and
ignite the air/fuel mixture in the cylinders. Advancing or
retarding the spark is controlled by the ECM to suit load and
speed conditions of the engine.
The ignition coil is provided power by the BCM.
Fuel Injectors
The BCMprovides battery power to the fuel injectors. The ECM
provides the path to ground to trigger the injectors. The fuel
injectors are pulse-width modulated solenoids for metering fuel
into the intake tract. The pulse-width of the ground path to the
injectors is varied by the ECM in response to inputs from the
various sensors, thus varying the length of time the injector is
open.
Purge Solenoid (If Equipped)
The purge solenoid allows vapors from the charcoal canister
to flow to the throttle body. The timing and amount of solenoid
opening depends on engine speed, vehicle speed, engine
temperature and throttle position.
Table 8-1. Engine Starts Hard
SOLUTION CAUSE
Repair the circuit. If DTC P0117 or P0118 is present, diagnose and correct DTCs. Engine temperature circuit
Perform misfire diagnostics. Fuel or Ignition system fault
Charge and test the battery. Performcharging systemdiagnosis if problemcontinues. Battery discharged
Repair the circuit. If DTC P0371, P0372 or P0374 is present, diagnose and correct
DTC.
Crank position sensor circuit
Perform intake leak test. See the service manual. Manifold leak
Repair the circuit. If DTC P2300, P2301, P2303 or P2304 is present, diagnose and
correct DTCs.
Ignition coil circuit/spark plugs
Check for mechanical failures of the fuel injectors. If DTC P0261, P0262, P0264 or
P0265 is present, diagnose and correct them.
Leaky injectors
Clean or replace fuel injectors. See the service manual. Clogged fuel injectors
Perform compression test. See 3.4 TROUBLESHOOTING. Valve sticking
Table 8-2. Engine Performance Problems
SOLUTION CAUSE
Repair the circuit. If DTC P0117 or P0118 are present, diagnose and correct DTCs. Engine temperature circuit
Repair the circuit. If DTCP0371, P0372 and P0374 are present, diagnose and correct
DTC.
Crank position sensor circuit
HOME
Table 8-2. Engine Performance Problems
SOLUTION CAUSE
Perform misfire diagnostics. Fuel or Ignition system fault
Connect. EVAP hose disconnected from induction
module (if equipped)
Drain and refill with fresh fuel. Fuel system contaminated
Table 8-3. Engine Emits Black Exhaust or Fouls Plugs
SOLUTION CAUSE
Repair the circuit. If DTC P0117 or P0118 are present, diagnose and correct DTCs. Engine temperature circuit
Replace air filter. Clogged air filter
Repair the circuit. If DTC P0261, P0262, P0264 or P0265 are present, diagnose and
correct DTCs.
Leaky injectors
HOME
8.4 DTC B2102, B2103, B2104
The BCM supplies and monitors the 12V system power circuit
from terminal L3 of the BCM to the following components:
Ignition coil
Front fuel injector
Rear fuel injector
Purge solenoid
ECM
Front HO2 sensor
Rear HO2 sensor
Front ACR
Rear ACR
DESCRIPTION DTC
System power output shorted high B2102
System power output shorted low B2103
System power output overloaded B2104
DTC B2104 will set if the system power circuit draws more
than 10 Amps.
1
2 4 3
5
6
7
10 9
8
ed03414
1. ECM
2. ECM [78]
4. Security siren
5. BCM
8. Rear WSS [168]
9. ABS [166]
10. ABS ECU
Diagnostic Tips
Since the system power circuit normally has ignition voltage
with the vehicle ON, the short to voltage will have to be present
with the vehicle turned off in order to set DTC B2102.
HOME
B
K
/
G
N
B
K
/
B
N
A
A
B
A
B
L3
L3
A
B
A
B
B
C
D
A Power
Ion Sense
Coil Rear
Coil Front
B
C
D
Ignition Coil
Rear Fuel
Injector
Front Fuel
Injector
BCM
Battery Fuse
Rear
HO2S
Front
HO2S
GY/BN
BK/BN
BK/BN
GN/BN
Right
GND 2
Purge Solenoid
(Optional)
A
B
A
B
1
2
3
4
1
2
3
4
[84B] [84A]
[85B] [85A]
[95B] [95A]
[83B] [83A]
[138A]
[137A]
[242A]
[242B]
LGN/BN
GY/BE
GN/BE
R/GN
R/GN
R/GN
R/GN
R
/
G
N
R
/
G
N
R
/
G
N
GN/Y
G
N
/
Y
B
K
/
O
BK/O
BK/O
R/GR
R/GR
GY/Y
G
Y
/
Y
LGN/BK
L
G
N
/
B
K
L
G
N
/
B
N
G
N
/
B
E
G
Y
/
B
E
G
Y
/
B
N
G
N
/
B
N
R
/
O
20 23 28 33 46 48 52 53 54 66 71 72 73
20 23 28 33 46 48 52 53 54 66 71 72 73
P
u
r
g
e
S
o
l
e
n
o
i
d
F
r
o
n
t
F
u
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l
I
n
j
e
c
t
o
r
I
o
n
S
e
n
s
e
31
31
5
V
S
e
n
s
o
r
G
r
o
u
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d
R
e
a
r
O
2
S
e
n
s
o
r
O
2
R
e
t
u
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n
S
y
s
t
e
m
P
o
w
e
r
R
e
a
r
I
n
j
e
c
t
o
r
C
o
i
l
F
r
o
n
t
I
n
j
e
c
t
o
r
C
o
i
l
F
r
o
n
t
O
2
S
e
n
s
o
r
1
2
V
B
a
t
t
e
r
y
S
y
s
t
e
m
P
o
w
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G
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o
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R
e
a
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F
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I
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j
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c
t
o
r
ECM
[78B]
[78A]
R
/
O
em01402
HOME
DTC B2102
TOOL
HD-50424
POSSIBLE CAUSES
Short to battery in the system power circuit
1. System Power Circuit Short to Voltage
Test
No. HD-50424), remove terminal L3 from [242B].
3. Connect BCM [242].
extracted terminal L3 and ground.
a. Yes. Repair short to voltage in (R/GN) wire.
DTC B2103, B2104
POSSIBLE CAUSES
Short to ground in the system power circuit
Ignition coil resistance too low
Active intake resistance too low
Active exhaust resistance too low
Front fuel injector resistance too low
Rear fuel injector resistance too low
Purge solenoid resistance too low
Front HO2 resistance too low
Rear HO2 resistance too low
ACR resistance too low
1. System Power Circuit Short to Ground
Test
[242B] and BCM [242A]. See the electrical diagnostic
manual.
3. Clear the DTCs. See 7.14 INITIAL DIAGNOSTICS, Odo-
4. Is the DTC still present?
gnostic manual.
2. Ignition Coil Test
1. Disconnect the ignition coil [83].
2. Clear the DTCs.
b. No. Replace the ignition coil. See the service manual.
3. Rear Fuel Injector Test
1. Disconnect the rear fuel injector [85].
2. Clear the DTCs.
b. No. Replace the rear fuel injector. See the service
manual.
4. Front Fuel Injector Test
1. Disconnect the front fuel injector [84].
2. Clear the DTCs.
b. No. Replace the front fuel injector. See the service
manual.
5. Purge Solenoid Test
1. Disconnect the purge solenoid [95] (if equipped).
2. Clear the DTCs.
b. No. Replace the purge solenoid. See the service
manual.
6. Exhaust Actuator Test
1. Disconnect the exhaust actuator [179] (if equipped).
2. Clear the DTCs.
b. No. Replace the exhaust actuator. See the service
manual.
HOME
7. Rear ACR Test
1. Disconnect the rear ACR [203R].
2. Clear the DTCs.
b. No. Replace the rear ACR. See 3.6 CYLINDER
HEAD.
8. Front ACR Test
1. Disconnect the front ACR [203F].
2. Clear the DTCs.
b. No. Replace the front ACR. See 3.6 CYLINDER
HEAD.
9. Front HO2 Test
1. Disconnect the front HO2 sensor.
2. Clear the DTCs.
b. No. Replace the front HO2 sensor. See the service
manual.
10. Rear HO2 Test
1. Disconnect the rear HO2 sensor.
2. Clear the DTCs.
b. No. Replace the rear HO2 sensor. See the service
manual.
11. ECM Test
2. Clear the DTCs.
TROL MODULE.
12. BCM Test
1. Disconnect the BCM [242A] from the breakout box.
ground.
a. Yes. Repair short to ground in (R/GN) wire.
HOME
8.5 DTC B2116, B2117, B2118, B2119
The BCM supplies and monitors the 12V power circuit from
terminal F4 of the BCM to the fuel pump. The fuel pump is
constantly grounded. The BCM controls the fuel pump by
turning on and off the power to the pump on the (R/BN) wire.
1
2
ed03413
2. Console
DESCRIPTION DTC
Fuel pump output open B2116
Fuel pump output shorted high B2117
Fuel pump output shorted low B2118
Fuel pump output overloaded B2119
DTC B2116 will set if the fuel pump circuit draws less than 600
milliamps. DTC B2119 will set if the fuel pump circuit draws
more than 6 Amps.
Diagnostic Tips
DTC B2119 can set if the BCM sees an excessive load on the
fuel pump circuit. This could be caused by a fuel pump being
run dry. If the fuel pump was replaced or the vehicle was run
out of gas, prime the pump and clear the code. Start the vehicle
and check DTCs to see if the code returns. Any circuit that is
powered up continually with the engine stop switch ON could
cause DTC B2117 or B2119 to set if shorted to the fuel pump
circuit. If a short to voltage or overload conditon is found, test
for continuity between fuel pump circuit and the other power
circuits from the BCM.
HOME
[141A]
[141B]
[20A]
[20B]
[242B] [242A]
[200B] [200A]
[39B] [39A]
Fuel
Pump
R/O Battery Fuse
Ground
Fuel Level
Speedometer
5
7
9
5
7
9
6 4 2
6 4 2
BE
BE
BE
B
K
B
K
B
K
BK/GN
W/Y
R
/
O
B
K
/
G
N
B
K
/
G
N
B
K
/
G
N
W
/
Y
R
/
O
B
K
/
G
N
B
K
/
G
N
BK/GN
W
/
Y
W/Y
W
/
Y
W
/
Y
Battery
15A
Main
Harness
R
/
O
1
2 [64B]
R
R
A
F
u
e
l
P
u
m
p
P
o
w
e
r
A
B
F
u
e
l
L
e
v
e
l
S
e
n
s
o
r
B
C
S
e
n
d
e
r
G
r
o
u
n
d
C
D
P
u
m
p
G
r
o
u
n
d
D
[13A]
[13B]
1
1
2
2
3
3
4
4
R
/
B
N
R
/
B
N
R/BN
J3
1
2
3
1
2
3
F4 Fuel Pump Power
Running Light Power
BCM
Main
Harness
GND 1 GND 2
J3
F4
36
36 200
3
6
em01461
Figure 8-7. Fuel Sensor Circuit
DTC B2116
POSSIBLE CAUSES
Open in the fuel pump power circuit
Fuel pump fault or malfunction
1. Fuel Pump Circuit Test
1. Disconnect the fuel pump [141B].
2. Connect a voltmeter between the fuel pump [141B] ter-
minals A and D.
4. Was battery voltage displayed for a short time?
a. Yes. Replace the fuel pump. See the service manual.
2. Fuel Pump Ground Circuit Open Test
1. Test for continuity between [141B] terminal D and ground.
b. No. Repair open in (BK) ground wire.
3. Fuel Pump Power Circuit Open Test
GNOSTIC TOOLS.
3. Test for continuity between the breakout box terminal F4
and [141B] terminal A.
b. No. Repair open in (R/BN) wire.
HOME
DTC B2117
POSSIBLE CAUSES
Short to voltage in the fuel pump power circuit
1. Fuel Pump Power Circuit Short to Voltage
Test
2. Does the fuel pump continue to run after the initial two
second start up?
a. Yes. Repair short to voltage in (R/BN) wire. See dia-
gnostic tips. If no source of short is found, replace the
BCM. See the service manual.
2. Code Verification Test
gnostic manual.
DTC B2118, B2119
POSSIBLE CAUSES
Short to ground in the fuel pump power circuit
Fuel pump malfunction
1. Fuel Test
1. Verify there is fuel in the fuel tank.
2. Is fuel present in the tank?
b. No. Fill tank with fuel and clear DTCs. See 7.14 INI-
TIAL DIAGNOSTICS, Odometer Self-Diagnostics. If
the DTC returned, then continue with tests. Go to
Test 2.
2. Fuel Pump Test
1. Disconnect the fuel pump [141B].
5. Did DTC B2118 or B2119 reset?
b. No. Replace the fuel pump. See the service manual.
3. Fuel Pump Power Circuit Short to Ground
Test
1. With the engine stop switch OFF, disconnect the BCM
[242B].
2. Test for continuity between [141B] terminal A and ground.
a. Yes. Repair short to ground on (R/BN) wire.
b. No. See diagnostic tips. If problemnot found, replace
the BCM. See the service manual.
HOME
8.6 DTC P0107, P0108, P0112, P0113
VACUUM PUMP HD-23738
See Figure 8-8. The TMAP sensor provides the functions of
both an IAT sensor and a MAP sensor in one unit. The TMAP
sensor is supplied 5V from ECM terminal 68 and sends MAP
and IAT signals back to ECMterminals 24 and 49 respectively.
DESCRIPTION DTC
MAP sensor open/low P0107
MAP sensor high P0108
IAT sensor voltage low P0112
IAT sensor open/high P0113
TMAP: MAP Signal
The MAP signal varies in accordance with engine vacuumand
atmospheric pressure. Changes in atmospheric pressure are
influenced by weather and altitude.
TMAP: IAT Signal
The IAT portion of the TMAP sensor is a thermistor device,
meaning that at a specific temperature, it will have a specific
resistance across its terminals. As this resistance varies, so
does the voltage on terminal 49 of the ECM.
At high temperatures, the resistance of the IAT sensor is
very low, which effectively lowers the signal voltage on
terminal 49.
DTCs P0107 or P0108 will set if the MAP sensor signal is out
of range. DTC P0108 can only be detected with the engine
running.
Diagnostic Tips: MAP Portion of TMAP
Sensor
MAP sensor output check. Using the VACUUM PUMP
(Part No. HD-23738), apply a vacuumto the pressure port
of the TMAP sensor. The MAP signal voltage should
decrease as the vacuum is applied.
The TMAP and TGS are connected to the same reference
line (+5V Vref). If the reference line goes to ground or
open, multiple codes will be set (DTCs P0107, P0108,
P0122, P0123, P1501 and P1502).
Diagnostic Tips: IAT Portion of TMAP
Sensor
Check the following conditions:
Poor connection: Inspect ECM and harness connector
[78] for backed out terminals, improper mating, inoperative
locks, improperly formed or damaged terminals, poor ter-
minal- to-wire connection and damaged harness.
Intermittents: If connections and harness check out OK,
use a multimeter to check the IAT sensor voltage reading
while moving related connectors and wiring harnesses. If
the failure is induced, then the IAT sensor voltage reading
will change.
Shifted sensor resistance value: Compare the temper-
atures of the ET and IAT sensors with the engine at
ambient temperature in order to evaluate the possibility
of a shifted (out of calibration) sensor which may result in
driveability problems. The sensor temperatures should be
within 10 degrees of each other.
A faulty sensor can negatively affect the signal voltage of
the other sensors sharing the same 5V reference. If the
wiring passes the following tests, disconnect one sensor
at a time on the 5V reference and verify the DTC is still
present. Additional DTCs will be set as each sensor is
disconnected, clear DTCs after this test. Be sure to per-
form this test before replacing a component.
5
6
1
2
3
4
ed03192
HOME
Throttle Actuator Control HI
Throttle Actuator Control LO
TPS-2
TPS-1
TGS-2
TGS-1
5V Sensor Power-1
5V Sensor Ground-2
5V Sensor Power-2
29
30
36
37
39
50
59
62
68
29
30
36
37
39
50
ET Sensor 51 51
59
62
5V Sensor Ground-1 61 61
68
ECM
6 5 4 3 2 1
TCA
6 5 4 3 2 1
6 5 4 3 2 1
Vehicle Speed Input
JSS
Vehicle Speed Ground
Ground
40
56
64
73
40
56
64
73
JSS (HDI only)
1 2 3
VSS
A
B
C
A
B
C
B
K
/
G
Y
B
K
/
W
G
N
/
O
G
N
/
W
G
Y
/
W
G
Y
/
O
G
N
/
V
GN/V
R
/
G
Y
R
/
G
Y
G
Y
/
V
GY/V
BK/GY
BK/GN
B
K
/
G
N
B
K
/
G
N
BK/W
BK/W
BK/Y
Right GND 2
[204B]
[211A]
[211B]
[65A] [65B]
ET Sensor
A
B
A
B
[90A] [90B]
[78B] [78A]
[133B]
TMAP Sensor
TMAP Sensor Input
IAT
1 2 3 4
1 2 3 4 [80A]
[80B]
B
K
/
G
Y
G
N
/
G
Y
24
49
24
49
R
/
W
R
/
W
G
Y
GN
R/W
LGN/Y
L
G
N
/
G
Y
R
/
W
GY
GN/O
GY/O
LGN/Y
GN/GY
R/W
GN
LGN/GY
GN/W
GY/W
R/GY
BK/Y
B
K
/
W
B
K
RW
B
K
RW
B
K
RW
B
K
RW
1
Y BK
2 3 4 5 6
G
r
o
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n
d
T
G
S
2
T
G
S
1
P
o
w
e
r
5
V
S
e
n
s
o
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G
r
o
u
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d
1
5
V
S
e
n
s
o
r
P
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w
e
r
1
TGS
[204A]
em00903
Figure 8-9. Throttle Control Actuator Circuit
DTC P0107
POSSIBLE CAUSES
TMAP sensor malfunction
Open or shorted to ground signal wire
Open or shorted to ground 5V reference circuit
1. MAP Sensor Test
1. Disconnect the TMAP sensor [80].
No. HD-41404), connect a jumper between [80B] terminals
3 and 4.
4. Turn the engine stop switch OFF and ON.
5. Does DTC P0107 reset?
b. No. Replace the TMAP sensor. See 4.3 INDUCTION
MODULE.
2. MAP Sensor Signal Voltage Test
1. Remove the jumper wire.
2. With the engine stop switch ON, test for voltage from[80B]
terminal 3 to ground.
3. Is voltage approximately 5V?
3. MAP Sensor Signal Wire Continuity Test
1. Connect BREAKOUT BOX (Part No. HD-48637) to wire
2. Test for continuity between [80B] terminal 4 and breakout
box terminal 24.
HOME
b. No. Repair open in (GY) wire.
4. MAP Sensor Signal Wire Shorted to
Ground Test
ground.
a. Yes. Repair short to ground in (GY) wire.
5. MAP Sensor Signal Wire Shorted to
Sensor Ground Test
2. Test for continuity between breakout box terminals 24 and
62.
a. Yes. Repair short between (GY) and (BK/GY) wires.
b. No. See diagnostic tips before replacement. Replace
the ECM. See 8.2 ELECTRONIC CONTROL
MODULE.
6. MAPSensor 5VReference Wire Open Test
box terminal 68.
b. No. Repair open in (R/GY) wire.
7. MAP Sensor 5V Reference Shorted to
Signal Ground Test
62.
a. Yes. Repair short between the (R/GY) and (BK/GY)
wires.
b. No. See diagnostic tips before replacement. Replace
the ECM. See 8.2 ELECTRONIC CONTROL
MODULE.
DTC P0108
POSSIBLE CAUSES
MAP sensor malfunction
Short to voltage
1. MAP Sensor Test
1. Disconnect the TMAP sensor [80].
2. Clear DTCs using odometer self-diagnostics. 7.14 INITIAL
DIAGNOSTICS, Odometer Self-Diagnostics.
3. Start engine.
4. Does DTC P0108 reset?
2. MAP Sensor Signal Wire Short to 5V Test
68.
a. Yes. Repair short between (R/GY) and (GY) wires.
3. MAP Sensor Signal Wire Short to Voltage
Test
1. With the engine stop switch ON, test for voltage on
breakout box terminal 24.
a. Yes. Repair short to voltage in (GY) wire.
4. MAP Sensor 5V Reference Shorted to
Battery Voltage Test
breakout box terminal 68 and ground.
2. Is voltage greater than 5.25V?
a. Yes. Repair short to voltage in (R/GY) wire.
5. MAP Sensor Ground Wire Open Test
box terminal 62.
HOME
a. Yes. Replace the TMAP sensor. See 4.3 INDUCTION
MODULE.
b. No. Repair open in (BK/GY) wire.
DTC P0112
POSSIBLE CAUSES
IAT sensor malfunction
Short to ground in 5V reference circuit
1. IAT Sensor Test
1. Disconnect TMAP sensor [80].
41404) and a multimeter, measure resistance between
terminals 1 and 2 of [80A].
3. Is the resistance reading between 500-5000 Ohms with
the vehicle and sensor at ambient room temperature?
b. No. Replace TMAP sensor. See 4.3 INDUCTION
MODULE.
2. IAT Sensor Signal Wire Shorted to Ground
Test
1. Measure resistance between [80B] terminal 2 (GN/GY)
and ground.
2. Is resistance reading less than 1 Ohm?
a. Yes. Repair short to ground on (GN/GY) wire.
3. IAT Sensor Signal Wire Shorted to Sensor
Ground Test
2. Test continuity between breakout box terminals 49 and
62.
a. Yes. Repair short between terminals 1 and 2 of [80B]
(GN/GY) and (BK/GY) wires.
b. No. Replace ECM. See 8.2 ELECTRONICCONTROL
MODULE.
DTC P0113
POSSIBLE CAUSES
IAT sensor malfunction
ECM malfunction
Open or short to voltage in 5V reference circuit
Open in signal circuit
1. IAT Sensor Test
1. Disconnect TMAP sensor [80].
41404) and a multimeter, measure voltage between [80B]
terminal 2 (GN/GY) and ground.
3. Is the voltage reading greater than 6V?
a. Yes. Repair short to voltage on (GN/GY) wire.
2. IAT Sensor Signal Wire Open Test
3. Test for continuity between [80B] terminal 2 (GN/GY) and
b. No. Repair open circuit in (GN/GY) wire.
3. IAT Sensor Open Ground Wire Test
[80B] terminal 1 (BK/GY).
4. IAT Sensor Signal Wire Shorted to Sensor
Power Test
68.
HOME
a. Yes. Repair short between (GN/GY) and (R/GY)
wires. Verify IAT sensor resistance value and if
incorrect replace TMAPsensor. See 4.3 INDUCTION
MODULE.
MODULE.
HOME
8.7 DTC P0117, P0118
The ECM supplies and monitors a voltage signal terminal 51
to one side of the ET sensor. The other side of the ET sensor
is connected to a common sensor ground, which is also con-
nected to the ECM terminal 61.
The ET sensor is a thermistor device, which means that at a
specific temperature it will have a specific resistance across
its terminals. As this resistance varies, so does the voltage on
terminal 51.
low, which effectively lowers the signal voltage on terminal
51.
the voltage to rise close to 5V.
The ECM monitors this voltage to compensate for various
operating conditions.
DESCRIPTION DTC
ET sensor voltage low P0117
ET sensor open/high P0118
Diagnostic Tips
Once the engine is started, the temperature should rise steadily.
An intermittent may be caused by a poor connection, rubbed
through wire insulation or an inoperative wire inside the insula-
tion.
Check the following conditions:
Poor connection: Inspect ECM harness connector [78]
for backed out terminals, improper mating, inoperative
minal-to-wire connection, loose sensor and damaged
harness.
use a multimeter to check the engine temperature reading
while moving related connectors and wiring harness. If
the failure is induced, the engine temperature display will
change.
Shifted sensor resistance value: Compare the temper-
atures of the ET and IAT sensors with the engine at
ambient temperature in order to evaluate the possibility
of a shifted (out of calibration) sensor which may result in
driveability problems. The sensor temperatures should be
within 10 F (5.6 C) of each other.
1
2
ed03337
1. ET sensor [90]
2. Horn [122]
Figure 8-10. Horn and ET Sensor
HOME
BK/GN
B
K
/
G
N
B
K
BK
B
K
R
ECM
CKP Sensor
43
51
61
63
73
Crank Position Sensor
C
K
P
S
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C
K
P
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Engine Temperature
5V Sensor Ground 1
Crank Pos Sensor (+)
Ground
43
51
61
63
73
ET
Sensor
1 2
1 2
A
B
A
B
GND 1
[79A]
[79B]
[90A] [90B]
[78B] [78A]
BK/W BK/W
R
GN GN
em01462
Figure 8-11. ET Sensor, CKP Sensor and Active Exhaust Circuit
DTC P0117
POSSIBLE CAUSES
ET sensor malfunction
Short to ground in 5V reference circuit
1. ET Sensor Test
1. Disconnect ET sensor [90].
41404) and a multimeter, measure the resistance between
[90A] terminals A and B.
3. Is the resistance reading between 900-10,000 Ohms with
the vehicle and sensor at ambient room temperature?
b. No. Replace ET sensor. See the service manual.
2. ET Sensor Signal Wire Shorted to Ground
Test
1. Measure resistance between ET sensor [90B] terminal A
(GN) and ground.
2. Is resistance reading less than 1 Ohm?
a. Yes. Repair short to ground in (GN) wire.
3. ET Sensor Signal Wire Shorted to Sensor
Ground Test
2. Test continuity between to breakout box terminals 51 and
61.
a. Yes. Repair short between terminal A (GN) and B
(BK/W) of [90B] wires.
MODULE.
DTC P0118
POSSIBLE CAUSES
ET sensor malfunction
Open or short to voltage
1. ET Sensor Test
1. Disconnect ET sensor [90].
41404) and a multimeter, measure the voltage between
ET sensor [90B] terminal A (GN) and ground.
HOME
3. Is the voltage reading greater than 6V?
a. Yes. Repair short to voltage on (GN) wire.
b. No. Voltage is less than 4V. Go to Test 2.
2. ET Sensor Signal Wire Open Test
41404) and a multimeter, test for continuity between ET
sensor [90B] terminal A (GN) and breakout box terminal
51.
b. No. Repair open circuit in the (GN) wire.
3. ET Sensor Open Ground Wire Test
1. Test for continuity between ET sensor [90B] terminal B
(BK/W) and breakout box terminal 61.
b. No. Repair open in (BK/W) wire.
4. ET Sensor Signal Wire Shorted to Power
Test
1. Test for continuity voltage between breakout box terminals
51 and 73.
a. Yes. Repair short to voltage in the (GN) wire. Verify
ET sensor resistance value and if incorrect replace
ET sensor. See the service manual.
5. ET Sensor Resistance Test
1. Measure the resistance of the ET sensor at ambient room
temperature.
2. Is resistance reading between 900-10,000 Ohms?
a. Yes. Replace the ECM. See 8.2 ELECTRONIC
CONTROL MODULE.
b. No. Replace the ET sensor. See the service manual.
HOME
8.8 DTC P0120, P0122, P0123, P0220, P0222, P0223
See Figure 8-12. A dual TPS is integrated into the TCA,
mounted to the induction module.
Within the TCA, a set of potentiometers are designated as TPS
(TPS1 and TPS2). The ECM drives the motor in the TCA to
open and close the throttle plate based on the signals fromthe
twist grip sensor. The TPS (TPS1 and TPS2) send signals
back to the ECM based on throttle plate position to verify the
throttle plate movement.
The ECM supplies a 5.0V signal from terminal 50 of [78] to
TPS1 and TPS2. The signals from TPS1 and TPS2 are sent
back to the ECM [78] terminals 37 and 36 and vary in voltage
according to actual throttle plate position.
The two TP sensors work opposite each other. When one
sensor reads high, the other reads low. The sum of TPS1 and
TPS2 signals should measure around 5.0V.
See Figure 8-13 for TCA (TPS1 and TPS2) circuitry diagram.
Refer to Table 8-19 for DTCs associated with TPS1 and TPS2
of the TCA.
DESCRIPTION DTC
TPS1 range error P0120
TPS1 low/open P0122
TPS1 high P0123
TPS2 range error P0220
TPS2 low/open P0222
TPS2 high P0223
5
6
1
2
3
4
ed03192
NOTE
The TMAP and TGS are both connected to the same reference
line (+5V REF). If the line goes to ground or open, multiple
trouble codes will be set (DTCs P0107, P0108 and P0122,
P0123, P1501 or P1502). Start with the highest priority DTC.
Refer to Table 7-3.
Check for the following conditions:
Poor connection: Inspect ECM harness connector [78B]
for backed out terminals, improper mating, inoperative
minal-to-wire connection and damaged harness.
monitor TPS voltage using a multimeter while moving
related connectors and wiring harness. If the failure is
induced, the TPS voltage will change.
An intermittent may be caused by poor connection, rubbed
through wire insulation or an inoperative wire within the
wire insulation.
HOME
TPS-2
TPS-1
TGS-2
TGS-1
5V Sensor Power-1
5V Sensor Ground-2
5V Sensor Power-2
29
30
36
37
39
50
59
62
68
29
30
36
37
39
50
ET Sensor 51 51
59
62
68
ECM
6 5 4 3 2 1
TCA
6 5 4 3 2 1
6 5 4 3 2 1
Vehicle Speed Input
JSS
Ground
40
56
64
73
40
56
64
73
JSS (HDI only)
1 2 3
VSS
A
B
C
A
B
C
B
K
/
G
Y
B
K
/
W
G
N
/
O
G
N
/
W
G
Y
/
W
G
Y
/
O
G
N
/
V
GN/V
R
/
G
Y
R
/
G
Y
G
Y
/
V
GY/V
BK/GY
BK/GN
B
K
/
G
N
B
K
/
G
N
BK/W
BK/W
BK/Y
Right GND 2
[204B]
[211A]
[211B]
[65A] [65B]
ET Sensor
A
B
A
B
[90A] [90B]
[78B] [78A]
[133B]
TMAP Sensor
TMAP Sensor Input
IAT
1 2 3 4
1 2 3 4 [80A]
[80B]
B
K
/
G
Y
G
N
/
G
Y
24
49
24
49
R
/
W
R
/
W
G
Y
GN
R/W
LGN/Y
L
G
N
/
G
Y
R
/
W
GY
GN/O
GY/O
LGN/Y
GN/GY
R/W
GN
LGN/GY
GN/W
GY/W
R/GY
BK/Y
B
K
/
W
B
K
RW
B
K
RW
B
K
RW
B
K
RW
1
Y BK
2 3 4 5 6
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TGS
[204A]
em00903
DTC P0120
POSSIBLE CAUSES
Open in sensor power circuit
Short to voltage in TPS-1 circuit
Open in TPS-1 circuit
Short to ground in TPS-1 circuit
Open sensor ground circuit
1. Sensor Power-1 Circuit Test
1. Connect BREAKOUT BOX (Part No. HD-48637) between
wire harness [78B] and ECM [78A], leaving [78A] discon-
2. Disconnect TCA [211].
41404) and a multimeter, test for continuity between
breakout box terminal 50 and TCA [211] terminal 5.
b. No. Repair open in (R/W) wire.
2. TPS-1 Circuit Shorted Test
1. Test continuity between breakout box terminal 50 and
terminal 37.
a. Yes. Repair short between (GN/V) and (R/W) wires.
3. TPS-1 Circuit Continuity Test
1. Test continuity between breakout box terminal 37 and TCA
[211B] terminal 6.
b. No. Repair open in (GN/V) wire.
HOME
4. TPS-1 Circuit Short to Ground Test
ground.
a. Yes. Repair short to ground on (GN/V) wire.
5. TPS-1 Circuit Short to Voltage Test
ground.
a. Yes. Repair short to voltage on (GN/V) wire.
6. Sensor Ground Continuity Test
[211B] terminal 1.
7. TCA Test
2. Connect ECM [78A] to breakout box.
3. Connect TCA [211].
5. Measure voltage between breakout box terminals 37 and
61.
6. Is voltage between 0.4-4.8V?
CONTROL MODULE.
b. No. Replace the TCA. See 4.3 INDUCTIONMODULE.
DTC P0122
POSSIBLE CAUSES
Short to ground in TPS-1 Circuit
1. TCA Sensor-1 Circuit Test
wire harness [78B] and ECM [78A]. See 7.13 DIA-
GNOSTIC TOOLS.
2. Turn the engine stop switch ON and engine stop switch
to run.
3. Test for voltage at breakout box between terminal 37 and
terminal 61.
2. TCA Sensor-1 Circuit Short to Ground
Test
2. Disconnect ECM [78A] from breakout box.
ground.
a. Yes. Repair short to ground in (GN/V) wire.
3. TCA Power-1 Circuit Open Test
a. Yes. Replace the TCA. See 4.3 INDUCTION
MODULE.
4. TCA Sensor Test
ground.
MODULE.
5. ECM Test
2. Test for continuity at breakout box between terminals 37
and ground.
TROL MODULE.
HOME
DTC P0123
POSSIBLE CAUSES
Short to voltage in sensor power circuit
Open in sensor ground circuit
1. TPS-1 Voltage Test
GNOSTIC TOOLS.
3. Using a multimeter, measure voltage between breakout
box terminals 37 and 61.
4. Is voltage less than 4.8V?
2. TPS-1 Circuit Test
41404) and a multimeter, measure voltage between TCA
[211B] terminal 6 and ground.
3. Is voltage between 4-5.25V?
b. No. Less than 4V. Repair open in (GN/V) wire.
c. No. Greater than 5.25V. Repair short to voltage in
(GN/V) wire.
3. Sensor Power Circuit Test
1. Measure voltage between TCA [211B] terminal 5 and
ground.
b. No. Repair short to voltage in (R/W) wire.
4. TCA Test
1. Jumper TCA [211B] terminals 6 and 1.
61.
5. Sensor Ground Test
2. Measure resistance between TCA [211B] terminal 1 and
ground.
6. Sensor Ground Circuit Shorted Test
1. Test for continuity between TCA [211B] terminals 5 and
6.
TROL MODULE.
7. Sensor Ground Circuit Test
1. Disconnect the ECM [78A].
2. Test for continuity between TCA [211B] terminal 1 and
CONTROL MODULE.
8. TPS-1 Circuit Function Test
3. Is voltage between 2-5.25V?
b. No. Less than 2V. Repair open in (GN/V) wire.
c. No. Greater than 5.25V. Repair short to voltage on
(GN/V) wire.
ground.
b. No. Repair short to voltage on (R/W) wire.
HOME
11. TPS-1 Continuity Test
MODULE.
DTC P0220
POSSIBLE CAUSES
2. Sensor Power-2 Short to Voltage Test
ground.
a. Yes. Repair short to voltage (R/W) wire.
3. TPS-2 Circuit Shorted Test
36.
a. Yes. Repair short between (GY/V) and (R/W) wires.
4. TPS-2 Circuit Continuity Test
TCA [211B] terminal 4.
b. No. Repair open in (GY/V) wire.
5. TPS-1 Circuit Short to Ground Test
ground.
a. Yes. Repair short to ground on (GY/V) wire.
6. TPS-1 Circuit Short to Voltage Test
ground.
a. Yes. Repair short to voltage on (GY/V) wire.
[211B] terminal 1.
8. TCA Test
61.
4. Is voltage between 0.4-4.8V?
CONTROL MODULE.
HOME
DTC P0222
POSSIBLE CAUSES
1. TCA Sensor-2 Circuit Test
GNOSTIC TOOLS.
2. Turn the engine stop switch ON and engine stop switch
to run.
3. Test for voltage at breakout box between terminal 36 and
terminal 61.
2. TCA Sensor-2 Circuit Short to Ground
Test
ground.
a. Yes. Repair short to ground in (GY/V) wire.
3. TCA Power-1 Circuit Open Test
MODULE.
4. TCA 5V Ref Circuit Short to Ground Test
ground.
MODULE.
5. ECM Test
2. Test for continuity at breakout box between terminal 36
and ground.
TROL MODULE.
DTC P0223
POSSIBLE CAUSES
GNOSTIC TOOLS.
61.
41404) and a multimeter, measure voltage between TCA
[211B] terminal 4 and ground.
HOME
ground.
b. No. Repair short to voltage in (R/W) wire.
ground.
a. Yes. Replace TCA. See 4.3 INDUCTION MODULE.
5. Shorted 5V Circuit Test
1. Test for continuity between TCA [211B] terminals 4 and
5.
b. No. Repair short to voltage on (GY/V) wire.
box terminal 61.
CONTROL MODULE.
ground.
b. No. Repair short to voltage on (GY/V) wire.
ground.
MODULE.
HOME
8.9
DTCP0031, P0032, P0131, P0132, P0134, P0151,
P0152, P0154
See Figure 8-14. The HO2S provides a signal to the ECM
which indicates whether the engine is running rich or lean.
A P0131 (front) or P0151 (rear) is set when the ECM
detects an excessively lean condition for a specified length
of time. This can be caused by mechanical issues such
as exhaust leaks. DTCs may also set if HO2S sensor fails.
A P0132 (front) or P0152 (rear) is set when the ECM
detects an excessively rich condition for a specified length
of time. This can be caused by oil contamination or fuel
injector malfunctions. DTCs may also set if HO2S sensor
fails.
A P0134 is set when the front O2 sensor circuit is open
or sensor is too cold to respond. A P0154 is set when the
rear O2 sensor circuit is open or sensor is too cold to
respond. Excessive oil usage may also cause these codes
to set.
When the air/fuel mixture is ideal, approximately 14.6 parts air
to 1 part fuel, the voltage will be approximately 0.45V when
measuring across the sensor. If the voltage is measured from
the sensor (terminals 46 or 66) to ground, the voltage will read
approximately 1.2V. This difference is due to an internal bias
in the ECM. When using DIGITAL TECHNICIAN II (Part
No. HD-48650), the O2 voltage reading is displayed in the
higher range 0.7-1.7V.
DESCRIPTION DTC
Heater open/low P0031
Heater shorted/high P0032
Front O2 sensor low or engine running lean P0131
Engine front O2 running rich P0132
Front O2 sensor open/not responding/high P0134
Rear O2 sensor low or engine running lean P0151
Engine rear O2 running rich P0152
Rear O2 sensor open/not responding/high P0154
ed02856
Figure 8-14. HO2 Sensor
Diagnostic Tips
The multimeter displays the signal fromthe HO2S in volts. This
voltage will have an average value tending towards lean, rich
or ideal value depending on operating temperature of the
engine, engine speed and throttle position. An open/short to
voltage or short to ground in the (PK/O) wire (front) and
(PK/GN) wire (rear) will cause the engine to run rich (short to
ground) or lean (short to voltage) until fault is detected. Once
fault is detected, vehicle will run in open loop.
Check for the following conditions:
Poor connection: Inspect the ECM [78], fuel injector [84,
85] and HO2S [137, 138] connectors for backed out ter-
minals, improper mating, inoperative locks, improperly
formed or damaged terminals, poor terminal-to-wire con-
nection and damaged harnesses.
Dirty/stuck open injectors: The vehicle may run lean
(dirty/clogged injectors) or rich (stuck open injectors) if
there are injector problems. This could also cause poor
fuel economy and performance.
Loose HO2S: If an HO2S is loose, engine performance
may be affected. This could also show up as a slow
changing HO2S voltage.
Loose/leaking exhaust: This can cause a poor ground
connection for the sensor or allowfresh air into the exhaust
system. If fresh air enters exhaust system, the HO2S will
read a lean condition, causing the system to go rich.
Engine misfire: See 8.37 MISFIRE AT IDLE OR UNDER
LOAD.
Leaking injectors: This causes fuel imbalance and poor
idle quality due to different air/fuel ratios in each cylinder.
To check for leaky injectors, first remove the air box and
air filter. See the service manual. Then, with the throttle
wide open, turn the engine stop switch ONfor two seconds
and then OFF for two seconds five consecutive times.
HOME
Replace the fuel injector if there is any evidence of raw
fuel in the bores. See Fuel Injectors in the service manual.
Intake leaks: See the service manual.
High oil usage: (all HO2 sensor codes).
HOME
B
K
/
G
N
B
K
/
B
N
A
A
B
A
B
L3
L3
A
B
A
B
B
C
D
A Power
Ion Sense
Coil Rear
Coil Front
B
C
D
Ignition Coil
Rear Fuel
Injector
Front Fuel
Injector
BCM
Battery Fuse
Rear
HO2S
Front
HO2S
GY/BN
BK/BN
BK/BN
GN/BN
Right
GND 2
Purge Solenoid
(Optional)
A
B
A
B
1
2
3
4
1
2
3
4
[84B] [84A]
[85B] [85A]
[95B] [95A]
[83B] [83A]
[138A]
[137A]
[242A]
[242B]
LGN/BN
GY/BE
GN/BE
R/GN
R/GN
R/GN
R/GN
R
/
G
N
R
/
G
N
R
/
G
N
GN/Y
G
N
/
Y
B
K
/
O
BK/O
BK/O
R/GR
R/GR
GY/Y
G
Y
/
Y
LGN/BK
L
G
N
/
B
K
L
G
N
/
B
N
G
N
/
B
E
G
Y
/
B
E
G
Y
/
B
N
G
N
/
B
N
R
/
O
20 23 28 33 46 48 52 53 54 66 71 72 73
20 23 28 33 46 48 52 53 54 66 71 72 73
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31
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2
V
B
a
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ECM
[78B]
[78A]
R
/
O
em01402
HOME
DTC P0031
POSSIBLE CAUSES
HO2 malfunction
1. HO2S Voltage Test
1. Disconnect front HO2S [138].
2. Turn IGN ON using HARNESS CONNECTOR TEST KIT
(Part No. HD-41404) and a multimeter, test for battery
voltage between front HO2S[138A] terminal 1 and ground.
b. No. Repair open in (Y/GN).
2. HO2S Ground Test
1. With IGN OFF, connect BREAKOUT BOX (Part No. HD-
48637) between wire harness [78B] and ECM [78A]. See
41404) and a multimeter, test for continuity between ECM
[78A] terminal 31 and front HO2S [138A] terminal 2.
b. No. Repair open in (GN/W).
3. HO2S Resistance Test
1. Measure resistance between front HO2S [138B] terminal
1 and terminal 2.
2. Is resistance between 13.5-23.5 Ohms?
a. Yes. Replace ECM.
b. No. Replace both HO2S.
DTC P0032
POSSIBLE CAUSES
HO2 malfunction
Short to voltage in sensor ground circuit
1. Rear HO2S Resistance Test
1. Disconnect rear HO2S [137].
2. Turn IGN ON, using HARNESS CONNECTOR TEST KIT
(Part No. HD-41404) and a multimeter, measure resistance
between rear HO2S [137B] terminal 1 and terminal 2.
b. No. Replace rear HO2S.
2. Front HO2S Resistance Test
1. With IGN OFF, disconnect front HO2S [138].
2. Measure resistance between front HO2S [138B] terminal
1 and terminal 2.
b. No. Replace front HO2S.
3. HO2S Short to Voltage Test
1. With IGN ON, test for voltage between front HO2S [138A]
a. Yes. Repair short to voltage in (GN/W) wire.
b. No. Replace ECM.
DTC P0131
POSSIBLE CAUSES
Front HO2S malfunction
Short to ground in signal circuit
Fuel system malfunction
Leak in exhaust system
1. Front HO2S Test
1. Disconnect front HO2S [138].
2. Turn IGN ON.
3. Measure voltage between front HO2S [138A] terminal 3
(PK/O), to chassis ground.
2. Front HO2S Signal Wire Shorted to
Sensor Ground Test
1. Turn IGN OFF.
2. Disconnect ECM [78].
3. Test for continuity between front HO2S [138A] terminals
3 (PK/O) and 4 (BK/BN).
HOME
a. Yes. Repair short between (PK/O) and (BK/BN) wires.
3. Front HO2S Signal Wire Shorted to
Ground Test
1. Test for continuity between front HO2S [138A] terminal 3
(PK/O) and vehicle ground.
a. Yes. Repair short between (PK/O) wire and ground.
b. No. If ECM [78] connections are good, replace ECM.
4. Front HO2S Operation Test
GNOSTIC TOOLS.
2. Turn IGN ON.
4. Turn the engine stop switch to RUN.
5. Start the engine and allow it to reach operating temper-
ature.
6. With engine speed at a steady rpm, measure voltage
between breakout box terminals 66 and 73.
7. Is voltage approximately 1.2V?
b. No, constant 0.7-1.1V. Perform fuel pressure test.
Look for incorrect ECMcalibration, low fuel pressure,
air leaks and dirty injectors. If no issues are found,
replace HO2S.
DTC P0132
POSSIBLE CAUSES
Oil contamination on sensor
1. Front HO2S Operation Test
1. Turn IGN OFF.
GNOSTIC TOOLS.
ature.
a. Yes. Replace the ECM.
Look for incorrect ECMcalibration, high fuel pressure,
stuck open or leaking injectors. If no issues are found,
replace the HO2S.
DTC P0134
POSSIBLE CAUSES
Open or short to voltage in signal circuit
Open sensor ground
Heavy oil contamination
1. Front HO2S Signal Wire Short Circuit
Voltage Test
1. Disconnect front O2 sensor [138].
2. Turn IGN ON.
41404) and a multimeter, measure voltage between front
HO2S [138A] terminal 3 to chassis ground.
a. Yes. Repair short to voltage on (PK/O) wire.
b. No, voltage greater than 4V. Go to Test 2.
c. No, voltage less than 4V. Go to Test 3.
2. Front HO2S Open Sensor Ground Test
1. Turn IGN OFF.
(BK/BN) and breakout box terminal 48.
a. Yes. Replace the front HO2S.
b. No. Repair open on (BK/BN) wire.
3. Front HO2S Signal Wire Open Test
(PK/O) and breakout box terminal 66.
b. No. Repair open (PK/O) wire.
HOME
DTC P0151
POSSIBLE CAUSES
Rear HO2S malfunction
Leak in exhaust system
1. Rear HO2S Test
2. Turn IGN ON.
41404) and a multimeter, measure voltage between rear
HO2S [137A] terminal 3 (PK/GN) to ground.
2. Rear HO2SSignal Wire Shorted to Sensor
Ground Test
1. Turn IGN OFF.
3. Test for continuity between rear HO2S [137A] terminals
3 (PK/GN) and 4 (BK/BN).
a. Yes. Repair short between (PK/GN) and (BK/BN)
wires.
3. Rear HO2SSignal Wire Shorted to Ground
Test
1. Test for continuity between rear HO2S [137A] terminal 3
(PK/GN) and ground.
a. Yes. Repair short between (PK/GN) wire and ground.
b. No. If ECM [78] connections are good, replace ECM.
4. Rear HO2S Operation Test
GNOSTIC TOOLS.
2. Turn IGN ON.
4. Turn the engine stop switch to RUN.
ature.
between ECM breakout box terminals 46 and 73.
Look for incorrect ECMcalibration, low fuel pressure,
air leaks and dirty injectors. If no issues are found,
replace HO2S.
DTC P0152
POSSIBLE CAUSES
Oil contamination on sensor
1. Rear HO2S Operation Test
1. Turn IGN OFF.
GNOSTIC TOOLS.
ature.
a. Yes. Replace the ECM.
Look for incorrect ECMcalibration, high fuel pressure,
stuck open or leaking injectors. If no issues are found,
replace the HO2S.
DTC P0154
POSSIBLE CAUSES
Open or short voltage in signal circuit
Open sensor ground
Heavy oil contamination
HOME
1. Rear HO2S Signal Wire Short Circuit
Voltage Test
2. Turn IGN ON.
48637) and a multimeter, measure voltage between rear
HO2S [137A] terminal 3 to chassis ground.
a. Yes. Repair short to voltage on (PK/GN) wire.
b. No, voltage greater than 4V. Go to Test 2.
c. No, voltage less than 4V. Go to Test 3.
2. Rear HO2S Open Sensor Ground Test
1. Turn IGN OFF.
(BK/BN) and breakout box terminal 48.
a. Yes. Replace the rear HO2S.
b. No. Repair open on (BK/BN) wire.
3. Rear HO2S Signal Wire Open Test
(PK/GN) and breakout box terminal 46.
b. No. Repair open in (PK/GN) wire.
HOME
8.10 DTC P0261, P0262, P0264, P0265
The fuel injectors are solenoids that allow pressurized fuel into
the intake tract. The injectors are timed to the engine cycle and
triggered sequentially. The power for the injectors comes from
the BCM. The BCM also provides power for the fuel pump and
the ignition coil. The ECMprovides the path to ground to trigger
the injectors.
NOTE
The BCM supplies power to both injectors, ignition coils and
fuel pump.
DESCRIPTION DTC
Front injector open/low P0261
Front injector high P0262
Rear injector open/low P0264
Rear injector high P0265
5
6
1
2
3
4
ed03192
HOME
BK/Y
G
N
/
W
B
K
/
WB
K
/
W
R
B
K
/
G
Y
B
K
/
G
Y
R
/
W
A
A
B
A
B
A
B
A
B
B
C
D
A Power
Ion Sense
Coil Rear
Coil Front
B
C
D
CKP
Sensor
ET
Sensor
TCA
TMAP
Sensor
Ignition Coil
VSS
JSS
Rear Fuel
Injector
Front Fuel
Injector
L3 L3 BCM
6 5 4 3 2 1
1 2
1 2
6 5 4 3 2 1
1
A
B
C
A
B
C
2
A B
A B
3 4
1 2
Front ACR
(If Equipped)
2 1
2 1
3 4
6 5 4 3 2 1
GY/BN
BK/BN
BK/BN
GN/BN
Right
GND 2
R
/
G
N
R
/
G
N
R
/
G
N
Purge Solenoid
(Optional)
A
B
A
B
[79A]
[79B]
[204B]
[90A]
[90B]
[203AF]
[203BF]
Rear ACR
(If Equipped)
2 1
2 1
[211A]
[211B]
[80A]
[80B]
[65A] [65B]
B
K
B
K
/
W
G
N
/
O
G
Y
/
V
G
N
/
V
[84B] [84A]
[85B] [85A]
[95B] [95A]
[83B] [83A]
[203AR]
[203BR]
[242B] [242A]
R/GN
R/GN
GN/Y
GY/Y
R/GN
R/GN
R/GN
R/GN
R/GN
LGN/BN
GY/BE
GN/BE
LGN/BK
G
Y
/
O
R
/
W
G
Y
/
W
G
N
G
N
/
G
Y
R
/
G
Y
R
/
G
Y
G
Y
L
G
N
/
R
L
G
N
/
R
L
G
N
/
R
R/W
LGN/Y
Battery
Fuse
ECM
[78B]
[78A]
19 20 23 24 28 29 30 33 36 37 39 40 43 46 48 49 50 51 52 53 54 59 61 62 63 64 66 68 71 72 73
19 20 23 24 28 29 30 33 36 37 39 40 43 46 48 49 50 51 52 53 54 59 61 62 63 64 66 68 71 72 73
P
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A
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B
K
RW
B
K
RW
B
K
RW
B
K
RW
1
Y BK
2 3 4 5 6
G
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G
S
2
T
G
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1
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1
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P
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1
TGS
[204A]
T
M
A
P
S
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T
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H
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S
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31
31
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T
C
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-
T
P
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2
T
C
A
-
T
P
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1
T
G
S
2
V
S
S
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P
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(
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1
5
V
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2
C
K
P
S
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(
+
)
V
S
S
G
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F
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2
S
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5
V
S
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P
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2
1
2
V
B
a
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S
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P
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L
G
N
/
B
K
L
G
N
/
B
N
G
Y
G
N
+
R
L
G
N
/
Y
L
G
N
/
R
R
/
O
R
/
W
+
B
K
G
Y
/
B
N
G
N
/
G
Y
G
Y
/
B
E
G
N
/
B
E
G
N
/
B
N
B
K
/
B
N
B
K
/
G
N
B
K
/
G
N
B
K
/
G
Y
G
Y
/
Y
G
N
/
Y
G
N
/
O
G
Y
/
O
B
K
/
O
BK/O
BK/O
G
Y
/
V
G
Y
/
W
G
N
/
W
B
K
/
W
B
K
/
Y
R
/
G
Y
R
/
G
N
R
/
G
N
G
N
/
V
B
K
B
K
B
K
B
K
Rear
HO2S
Front
HO2S
1
2
3
4
1
2
3
4
[138A]
[137A]
em01458
HOME
DTC P0261
POSSIBLE CAUSES
Front fuel injector malfunction
Open signal circuit
Open power circuit
1. Front Fuel Injector Test
1. Disconnect front fuel injector [84].
2. Connect FUEL INJECTOR TEST LIGHT (Part No. HD-
34730-2D) to [84B].
3. Crank engine.
4. Does light flash when engine is cranking (or running)?
b. No, lamp does not illuminate. Go to Test 2.
c. No, lamp is on steady. Go to Test 5.
2. Front Fuel Injector Power Wire Open
Circuit Test
1. Turn engine stop switch ON.
2. Remove fuel injector test light.
3. Connect BREAKOUT BOX (Part No. HD-43876) to ECM
fuel injector [84B] terminal B (GN/Y).
b. No. Repair open on (GN/Y) wire.
3. Front Fuel Injector Power Wire Shorted
to Ground Test
ground.
a. Yes. Repair short to ground in (GN/Y).
4. Injector Resistance Test
1. Test resistance between terminal A and B of injector [84A].
2. Is resistance value between 10-20 Ohms?
TROL MODULE.
b. No. Replace injector. See the service manual.
5. Driver Short to Ground Test
BOX (Part No. HD-43876) to wire harness [78B], leaving
ECM[78A] disconnected. See 7.13 DIAGNOSTICTOOLS.
ground.
a. Yes. Repair short to ground on (GN/Y) wire.
MODULE.
DTC P0262
POSSIBLE CAUSES
Front fuel injector malfunction
1. Front Fuel Injector Control Wire Shorted
to Voltage Test
1. With the engine stop switch ON, disconnect front injector
[84].
2. Measure the voltage between front injector [84B] terminal
B (GN/Y) and ground.
b. No. Repair short to voltage on (GN/Y) wire.
TROL MODULE.
b. No. Replace front injector. See the service manual.
DTC P0264
POSSIBLE CAUSES
Rear fuel injector malfunction
Open signal circuit
Open power circuit
1. Rear Fuel Injector Test
1. Disconnect rear fuel injector [85].
HOME
34730-2D) to [85B].
3. Crank engine.
4. Does lamp flash when engine is cranking (or running)?
b. No, lamp does not illuminate. Go to Test 2.
c. No, lamp is on steady. Go to Test 5.
2. Rear Fuel Injector Power Wire Open
Circuit Test
2. Remove fuel injector test light.
3. Connect BREAKOUT BOX (Part No. HD-43876) to ECM
fuel injector [85B] terminal B (GY/Y).
b. No. Repair open on (GY/Y) wire.
3. Rear Fuel Injector Power Wire Shorted to
Ground Test
ground.
a. Yes. Repair short to ground in (GY/Y).
TROL MODULE.
b. No. Replace rear fuel injector. See the service
manual.
5. Driver Short to Ground Test
ground.
a. Yes. Repair short to ground on (GY/Y) wire.
MODULE.
DTC P0265
POSSIBLE CAUSES
Rear fuel injector malfunction
1. Rear Fuel Injector Control Wire Shorted
to Voltage Test
1. With the engine stop switch ON, disconnect rear injector
[85].
2. Measure the voltage between rear injector [85B] terminal
B (GY/Y) and ground.
b. No. Repair short to voltage on (GY/Y) wire.
TROL MODULE.
b. No. Replace rear injector. See the service manual.
HOME
8.11 DTC P0371, P0372, P0374
If the CKP sensor signal is weak or absent, DTCs P0371,
P0372 or P0374 will be set. DTCs P0371, P0372 is usually set
when several attempts to crank the engine have failed.
NOTE
If signal is not detected or cannot synchronize (DTC P0374),
engine will not start.
DESCRIPTION DTC
CKP sensor intermittent P0373
CKP not detected/cannot synchronize P0374
Diagnostic Tips
Engine must be cranked for more than five seconds without
CKP signal to set P0374 code. Intermittent MAP or IAT wiring
or sensor issues may cause these codes to set prior to setting
MAP or IAT codes. Verify MAP or IAT wiring and sensor prior
to replacing the ECM.
1
2
3
4
5
ed03292
1. Voltage regulator to stator [47]
2. Front HO2 sensor [138]
3. Voltage regulator [77]
4. JSS [133]
5. CKP sensor [79]
Figure 8-18. Under Voltage Regulator
BK/GN
B
K
/
G
N
B
K
BK
B
K
R
ECM
CKP Sensor
43
51
61
63
73
Crank Position Sensor
C
K
P
S
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n
s
o
r
L
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w
C
K
P
S
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s
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r
H
i
g
h
Engine Temperature
5V Sensor Ground 1
Crank Pos Sensor (+)
Ground
43
51
61
63
73
ET
Sensor
1 2
1 2
A
B
A
B
GND 1
[79A]
[79B]
[90A] [90B]
[78B] [78A]
BK/W BK/W
R
GN GN
em01462
Figure 8-19. ET Sensor, CKP Sensor and Active Exhaust Circuit
HOME
DTC P0371, P0372, P0374
Table 8-41. DTC P0371, P0372, P0374 Diagnostic Faults
POSSIBLE CAUSES
CKP sensor malfunction
ECM malfunction
Open or short to ground in signal circuit
1. CKP Sensor Connections Test
1. With the engine stop switch OFF, disconnect ECM [78].
2. Inspect the connection for corrosion or backed out ter-
minals.
3. Are terminal problems present?
a. Yes. Repair terminals as required.
2. CKP Sensor Signal Wire Continuity Test
1. Disconnect CKP sensor [79].
3. Test for continuity between breakout box terminal 63 to
CKP sensor [79B] terminal 1 (R).
4. Is resistance less than 0.5 Ohm?
b. No. Repair open wire (R).
3. CKP Sensor Ground Wire Continuity Test
1. Test continuity from breakout box terminal 43 to CKP
sensor [79B] terminal 2 (BK).
2. Is resistance less than 0.5 Ohm?
b. No. Repair open on (BK) wire.
4. CKP Sensor Signal Wire Shorted to CKP
Ground Wire Test
43.
a. Yes. Repair short between CKP [79B] terminals 1 (R)
and 2 (BK).
5. CKP Sensor LowShorted to Ground Test
73.
a. Yes. Repair short to sensor ground on (BK) wire.
6. CKP Sensor Output Test
1. Connect CKP sensor [79].
2. Test for AC voltage at breakout box terminals 63 and 43.
3. Place transmission in neutral and the engine stop switch
ON.
4. Crank engine for five seconds while observing multimeter.
5. Is AC voltage present?
TROL MODULE.
7. CKP Sensor Signal Wire Shorted to
Ground Test
1. Disconnect CKP sensor [79].
73.
a. Yes. Repair shorted (R) wire to ground.
b. No. Replace the CKPsensor. See the service manual.
HOME
8.12 DTC P0444, P0445
Purge Solenoid (CA and Select Foreign
Market Models Only)
See Figure 8-20. To comply with emission laws in certain
markets, a purge solenoid is mounted in front of the rear tire
above the BCM, connecting to the vent line in the top of the
fuel tank and to a vent canister mounted on the vehicle chassis.
A return line from the canister reconnects to the air intake
manifold allowing vented fumes to be recirculated, for emission
efficiency. The purge solenoid is timed to the throttle position
and is disabled during startup, low engine temperature, low
engine speed or low vehicle speed.
Power for the purge solenoid is supplied by the BCM. The BCM
also provides power for the VSS, fuel injectors, active exhaust,
active intake, ECM and the ignition coil.
The ECM provides a path to ground to trigger the purge
solenoid.
NOTES
BCM or wiring harness problems will cause 12V power to
be lost to the VSS, fuel injectors, active exhaust, active
intake, ECM, ignition coil and purge solenoid.
Purge solenoid is not installed on non-emission vehicles
and DTCs P0444 and P0445 are not available. If these
DTCs appear, the ECM is improperly programmed and
should be reprogrammed.
DESCRIPTION DTC
Purge solenoid low/open P0444
Purge solenoid shorted/high P0445
1
2
3
ed03308
1. Purge valve [95]
2. BCM
3. Rear tire
Figure 8-20. Purge Valve [95]
HOME
B
K
/
G
N
B
K
/
B
N
A
A
B
A
B
L3
L3
A
B
A
B
B
C
D
A Power
Ion Sense
Coil Rear
Coil Front
B
C
D
Ignition Coil
Rear Fuel
Injector
Front Fuel
Injector
BCM
Battery Fuse
Rear
HO2S
Front
HO2S
GY/BN
BK/BN
BK/BN
GN/BN
Right
GND 2
Purge Solenoid
(Optional)
A
B
A
B
1
2
3
4
1
2
3
4
[84B] [84A]
[85B] [85A]
[95B] [95A]
[83B] [83A]
[138A]
[137A]
[242A]
[242B]
LGN/BN
GY/BE
GN/BE
R/GN
R/GN
R/GN
R/GN
R
/
G
N
R
/
G
N
R
/
G
N
GN/Y
G
N
/
Y
B
K
/
O
BK/O
BK/O
R/GR
R/GR
GY/Y
G
Y
/
Y
LGN/BK
L
G
N
/
B
K
L
G
N
/
B
N
G
N
/
B
E
G
Y
/
B
E
G
Y
/
B
N
G
N
/
B
N
R
/
O
20 23 28 33 46 48 52 53 54 66 71 72 73
20 23 28 33 46 48 52 53 54 66 71 72 73
P
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31
31
5
V
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2
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2
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2
S
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1
2
V
B
a
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S
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R
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F
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r
ECM
[78B]
[78A]
R
/
O
em01402
HOME
DTC P0444
POSSIBLE CAUSES
Purge solenoid malfunction
1. With the engine stop switch OFF, disconnect purge
solenoid [95].
purge solenoid [95A] terminals A and B.
3. Is resistance between 4-21 Ohms?
b. No. Replace purge solenoid. See the service manual.
2. Purge Solenoid Voltage Test
1. Connect a multimeter to purge solenoid [95B] terminal A
and ground.
2. With the engine stop switch in RUN and while observing
the multimeter, turn the engine stop switch ON.
3. Is battery voltage present on multimeter for approximately
two seconds after the engine stop switch is ON?
3. Purge Solenoid Control Wire Shorted to
Ground Test
1. Turn the engine stop switch OFF and leave engine stop
switch in RUN.
3. Test for continuity between purge solenoid [95B] terminal
B (LGN/BK) and ground.
a. Yes. Repair short to ground on (LGN/BK) wire.
4. Purge Solenoid Control Wire Open Test
GNOSTIC TOOLS.
3. Test continuity between purge solenoid [95B] terminal B
(LGN/BK) and breakout box terminal 20.
a. Yes. If ECMconnections are good, replace BCM. See
the service manual.
b. No. Repair open in (LGN/BK) wire.
5. Purge Solenoid Power Wire Open Test
GNOSTIC TOOLS.
3. Test continuity between purge solenoid [95B] terminal A
(R/GN) and breakout box terminal L3.
a. Yes. If BCMconnections are good, replace BCM. See
the service manual.
DTC P0445
POSSIBLE CAUSES
Purge solenoid malfunction
Short to voltage in signal circuit
1. Disconnect purge solenoid [95].
purge solenoid [95A] terminals A and B.
3. Is resistance between 4-21 Ohms?
b. No. Replace purge solenoid. See the service manual.
2. Purge Solenoid Short to Voltage Test
1. Place transmission in neutral and turn the engine stop
switch to ON.
2. Measure voltage between purge solenoid [95B] terminal
B (LGN/BK) and ground.
3. Is battery voltage present on multimeter?
a. Yes. Repair short to voltage on (LGN/BK) wire.
b. No. If ECM connections are good, replace ECM. See
8.2 ELECTRONIC CONTROL MODULE.
HOME
8.13 DTC P0502, P0503
See Figure 8-22. The VSS is powered and monitored by the
ECM. The ECM processes the vehicle speed signal and
transmits this signal to the BCM and the speedometer through
the CAN bus circuit.
NOTES
The ECM uses VSS input to calculate idle air control
position. Therefore problems with the vehicle speed signal
can lead to improper operation of the idle air control.
The TCA, JSS, TGS and VSS sensors are connected to
the same reference line (+5V REF). If the reference line
goes to ground or open, multiple codes will be set. Start
with the trouble code having the lowest ranking value.
DESCRIPTION DTC
VSS failed low P0501
VSS failed high P0502
2
3
1
ed03304
1. Vehicle speed sensor
2. Oil tank
3. Starter
Figure 8-22. Vehicle Speed Sensor
HOME
BK/Y
G
N
/
W
B
K
/
WB
K
/
W
R
B
K
/
G
Y
B
K
/
G
Y
R
/
W
A
A
B
A
B
A
B
A
B
B
C
D
A Power
Ion Sense
Coil Rear
Coil Front
B
C
D
CKP
Sensor
ET
Sensor
TCA
TMAP
Sensor
Ignition Coil
VSS
JSS
Rear Fuel
Injector
Front Fuel
Injector
L3 L3 BCM
6 5 4 3 2 1
1 2
1 2
6 5 4 3 2 1
1
A
B
C
A
B
C
2
A B
A B
3 4
1 2
Front ACR
(If Equipped)
2 1
2 1
3 4
6 5 4 3 2 1
GY/BN
BK/BN
BK/BN
GN/BN
Right
GND 2
R
/
G
N
R
/
G
N
R
/
G
N
Purge Solenoid
(Optional)
A
B
A
B
[79A]
[79B]
[204B]
[90A]
[90B]
[203AF]
[203BF]
Rear ACR
(If Equipped)
2 1
2 1
[211A]
[211B]
[80A]
[80B]
[65A] [65B]
B
K
B
K
/
W
G
N
/
O
G
Y
/
V
G
N
/
V
[84B] [84A]
[85B] [85A]
[95B] [95A]
[83B] [83A]
[203AR]
[203BR]
[242B] [242A]
R/GN
R/GN
GN/Y
GY/Y
R/GN
R/GN
R/GN
R/GN
R/GN
LGN/BN
GY/BE
GN/BE
LGN/BK
G
Y
/
O
R
/
W
G
Y
/
W
G
N
G
N
/
G
Y
R
/
G
Y
R
/
G
Y
G
Y
L
G
N
/
R
L
G
N
/
R
L
G
N
/
R
R/W
LGN/Y
Battery
Fuse
ECM
[78B]
[78A]
19 20 23 24 28 29 30 33 36 37 39 40 43 46 48 49 50 51 52 53 54 59 61 62 63 64 66 68 71 72 73
19 20 23 24 28 29 30 33 36 37 39 40 43 46 48 49 50 51 52 53 54 59 61 62 63 64 66 68 71 72 73
P
u
r
g
e
S
o
l
e
n
o
i
d
A
C
R
G
r
o
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d
B
K
RW
B
K
RW
B
K
RW
B
K
RW
1
Y BK
2 3 4 5 6
G
r
o
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d
T
G
S
2
T
G
S
1
P
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5
V
S
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1
5
V
S
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P
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1
TGS
[204A]
T
M
A
P
S
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n
s
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I
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p
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F
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F
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T
G
S
H
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T
G
S
L
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31
31
5
V
S
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s
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G
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d
I
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n
S
e
n
s
e
T
C
A
-
T
P
S
2
T
C
A
-
T
P
S
1
T
G
S
2
V
S
S
I
n
p
u
t
C
K
P
S
e
n
s
o
r
(
-
)
R
e
a
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O
2
S
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2
R
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t
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T
M
A
P
-
I
A
T
5
V
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1
E
T
S
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S
1
5
V
S
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1
5
V
S
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2
C
K
P
S
e
n
s
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r
(
+
)
V
S
S
G
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F
r
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t
O
2
S
e
n
s
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5
V
S
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P
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2
1
2
V
B
a
t
t
e
r
y
S
y
s
t
e
m
P
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G
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R
e
a
r
F
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j
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c
t
o
r
L
G
N
/
B
K
L
G
N
/
B
N
G
Y
G
N
+
R
L
G
N
/
Y
L
G
N
/
R
R
/
O
R
/
W
+
B
K
G
Y
/
B
N
G
N
/
G
Y
G
Y
/
B
E
G
N
/
B
E
G
N
/
B
N
B
K
/
B
N
B
K
/
G
N
B
K
/
G
N
B
K
/
G
Y
G
Y
/
Y
G
N
/
Y
G
N
/
O
G
Y
/
O
B
K
/
O
BK/O
BK/O
G
Y
/
V
G
Y
/
W
G
N
/
W
B
K
/
W
B
K
/
Y
R
/
G
Y
R
/
G
N
R
/
G
N
G
N
/
V
B
K
B
K
B
K
B
K
Rear
HO2S
Front
HO2S
1
2
3
4
1
2
3
4
[138A]
[137A]
em01458
HOME
DTC P0502
POSSIBLE CAUSES
VSS malfunction
ECM malfunction
Open or short to ground in 5V reference circuit
1. VSS Connections Test
1. With the engine stop switch OFF, disconnect VSS [65].
minals.
3. Place transmission in neutral, turn the engine stop switch
to RUN.
41404) and a multimeter, measure voltage between VSS
[65B] terminal A and ground.
5. Is voltage reading approximately 5.0V?
2. VSS Sensor Power Short to Ground Test
2. Disconnect ECM.
3. Test continuity between [65B] terminal A and ground.
a. Yes. Repair short to ground on (R/W) wire.
b. No. Repair open on (R/W) wire.
3. VSS Signal Wire Short to Ground Test
73.
a. Yes. Repair short to ground on (LGN/Y) wire.
4. VSS Signal Wire Open Test
[65B] terminal B.
b. No. Repair open on (LGN/Y) wire.
5. VSS Dirty or Damaged Test
1. Remove VSS.
2. Check for debris on the sensor tip.
3. Is debris present?
a. Yes. Clean debris from VSS and install.
b. No. If VSS connections are good, replace VSS. See
the service manual.
DTC P0503
POSSIBLE CAUSES
VSS malfunction
ECM malfunction
Open ground
5V reference shorted to battery voltage
1. VSS Sensor Power Shorted to Voltage
Test
1. With the engine stop switch OFF, disconnect VSS [65].
minals.
3. Place transmission in neutral and turn the engine stop
switch ON.
41404) and a multimeter, measure voltage between VSS
[65B] terminals A (R/W) and C (BK/Y).
a. Yes. Repair short to voltage on (R/W) wire.
2. VSS Signal Wire Short to Voltage Test
1. Measure voltage between [65B] terminal B (LGN/Y) and
ground.
2. Is voltage above 6.0V?
a. Yes. Repair short to voltage on (LGN/Y) wire.
3. VSS Ground Wire Open Test
[65B] terminal C (BK/Y).
HOME
b. No. Repair open on (BK/Y) wire.
4. VSSSignal Wire Shorted to Sensor Power
Test
50.
a. Yes. Repair short between (LGN/Y) and (R/W) wires.
5. VSS Test
2. Verify the VSS [65] is disconnected.
4. Did the DTC P0503 return?
CONTROL MODULE.
b. No. Replace the VSS. See the service manual.
HOME
8.14 DTC P0505
LOSS OF IDLE SPEED CONTROL
The throttle control actuator uses a two wire DCmotor to move
the throttle plate from the spring loaded off-idle detent. The
ECM supplies a pulse width modulated voltage signal through
[78B] terminals 29 and 30. The ECM monitors throttle position
through the dual position sensors (TPS1 and TPS2). This code
will set if the idle speed becomes unstable. This can be caused
by a fuel or ignition related issue, throttle actuator friction or
an intermittent air leak.
NOTE
Although the ECM monitors terminals 29 and 30, faults on
these terminals will not cause this DTC. Faults on these ter-
minals will be higher priority DTCs, address them first.
5
6
1
2
3
4
ed03192
HOME
TPS-2
TPS-1
TGS-2
TGS-1
5V Sensor Power-1
5V Sensor Ground-2
5V Sensor Power-2
29
30
36
37
39
50
59
62
68
29
30
36
37
39
50
ET Sensor 51 51
59
62
68
ECM
6 5 4 3 2 1
TCA
6 5 4 3 2 1
6 5 4 3 2 1
Vehicle Speed Input
JSS
Ground
40
56
64
73
40
56
64
73
JSS (HDI only)
1 2 3
VSS
A
B
C
A
B
C
B
K
/
G
Y
B
K
/
W
G
N
/
O
G
N
/
W
G
Y
/
W
G
Y
/
O
G
N
/
V
GN/V
R
/
G
Y
R
/
G
Y
G
Y
/
V
GY/V
BK/GY
BK/GN
B
K
/
G
N
B
K
/
G
N
BK/W
BK/W
BK/Y
Right GND 2
[204B]
[211A]
[211B]
[65A] [65B]
ET Sensor
A
B
A
B
[90A] [90B]
[78B] [78A]
[133B]
TMAP Sensor
TMAP Sensor Input
IAT
1 2 3 4
1 2 3 4 [80A]
[80B]
B
K
/
G
Y
G
N
/
G
Y
24
49
24
49
R
/
W
R
/
W
G
Y
GN
R/W
LGN/Y
L
G
N
/
G
Y
R
/
W
GY
GN/O
GY/O
LGN/Y
GN/GY
R/W
GN
LGN/GY
GN/W
GY/W
R/GY
BK/Y
B
K
/
W
B
K
RW
B
K
RW
B
K
RW
B
K
RW
1
Y BK
2 3 4 5 6
G
r
o
u
n
d
T
G
S
2
T
G
S
1
P
o
w
e
r
5
V
S
e
n
s
o
r
G
r
o
u
n
d
1
5
V
S
e
n
s
o
r
P
o
w
e
r
1
TGS
[204A]
em00903
DTC P0505
POSSIBLE CAUSES
Vacuum/air leaks
Fuel system problems
Ignition system problems
Loss of engine compression
1. Fuel Quality Test
1. Verify there is sufficient supply of fresh fuel in the fuel tank.
2. Is fuel quality and level acceptable?
b. No. Flush the fuel system and fill fuel tank.
2. Vacuum Leak Test
1. Start the motorcycle and check for vacuum leaks.
2. Were any leaks found?
a. Yes. Repair the vacuum leak.
HOME
8.15 CRUISE CONTROL
The ECM controls and monitors the operation of the vehicle
cruise control. The cruise switch allows the control circuit to
be enabled or disabled and, when enabled, the lamp in the
switch illuminates.
Actual engagement of the vehicle cruise control is provided by
the cruise SET/RESUME switch, located on the operator right
hand controls. This switch is a three position momentary switch,
spring loaded to the center position.
Switch-Right Position (SET/COAST)
When the switch is toggled to the right position and
released, the cruise control is engaged and set to current
vehicle speed.
If the switch is toggled right and held momentarily, then
the cruise control enters the COAST mode.
Switch-Left Position (RESUME/ACCELERATE)
After brakes are applied or throttle is forced towards the
stop or the clutch is disengaged, the cruise control is dis-
engaged. When the switch is toggled to the left position
then released, the cruise control is engaged and will
resume the previously set speed/condition.
If the switch is toggled left and held momentarily while the
cruise control is engaged, acceleration is provided,
increasing the vehicle rpm/speed. If the switch is toggled
left and held, it continues to increase the vehicle speed
until the switch is released and allowed to return to the
neutral position.
DESCRIPTION DTC
Cruise Control Input Error P0577
SYSTEM OPERATION
To engage and disengage the cruise control system, proceed
as follows:
1. While riding in fourth, fifth or sixth gear, press straight in
on the the SET/RESUME switch to turn the cruise ON.
The cruise enabled/engaged lamp in the instrument turns
orange to indicate the system is activated.
2. With the motorcycle traveling at the desired cruise speed,
30-90 mph (48-145 km/h), momentarily push the cruise
SET/RESUME switch to SET.
3. The ECMmonitors the VSSto establish the desired vehicle
speed. The ECM then modulates the throttle control
actuator to maintain vehicle speed. The cruise
enabled/engaged lamp in the instrument turns fromorange
to green to indicate the cruising speed is locked in.
4. The ECM monitors both the engine rpm and the VSS
output speed signal. The ECM signals the throttle control
actuator to open or close the throttle to keep the speedo-
meter output speed signal constant. The engine rpm is
monitored to detect engine overspeed, a condition which
automatically causes cruise disengagement.
5. The ECMautomatically disengages cruise mode whenever
the ECM receives one of the following inputs:
a. Front or rear brake is applied.
b. Throttle is "rolled forward" past closed, thereby actu-
ating throttle roll off (disengage) command.
c. Motorcycle clutch is engaged or wheel slip detected.
(ECM senses too great an increase in rpm).
d. Cruise on/off switch placed in the off position. This is
done by pressing straight in on the SET/RESUME
switch. The cruise enabled/engaged lamp in the
instrument turns off to indicate the system is not
activated.
e. Handlebar-mounted engine stop switch placed in the
off position.
f. Handlebar-mounted cruise SET/RESUME switch is
pushed to SET and held in that position until vehicle
speed drops below 30 mph (48 km/h) or pushed to
RES until vehicle speed exceeds 93 mph (150 km/h).
NOTE
If the vehicle speed is above 30 mph (48 km/h) when the cruise
SET/RESUME switch is released, then the cruise system
automatically re-engages.
ABS
E
F
4
3
2
1
5
6
7
8
9
ed03408
2. Low fuel lamp
4. Tachometer
5. Security lamp
6. Low fuel lamp
7. ABS lamp
8. Battery lamp
9. Gear indicator
HOME
TROUBLESHOOTING
The ECM provides on-board diagnostics to help isolate any
problems that occur with the cruise system.
If the cruise is inoperative or fails to set, begin troubleshooting.
Refer to Table 8-50. If the cruise seems to disengage or drop
out for no apparent reason, see 8.16 DTC P0577.
In the diagnostic mode, the cruise enabled/engaged lamp in
the instrument is employed as a test indicator.
Diagnostic Tips
An intermittent may be caused by poor connection, rubbed
through wire insulation or an inoperative wire inside the
insulation.
Poor connection: Inspect component and harness con-
nectors for backed out terminals, improper mating, inoper-
ative locks, improperly formed or damaged terminals, poor
terminal-to-wire connection and damaged harnesses.
CRUISE INOPERATIVE DIAGNOSTICS
All diagnostics steps are listed in table format. Follow the
numbered steps to test the system. Compare the system
behavior CORRECT FUNCTION to INCORRECT FUNCTION
columns and advance to the next step listed. Refer to
Table 8-50.
Table 8-50. Cruise Inoperative Diagnostics
INCORRECT FUNCTION CORRECT FUNCTION ACTION NO.
If the green cruise lamp remains illumin-
ated after the switch is released then
one of the switches is stuck.
The green cruise lamp illuminates and
remains on as long as the cruise
SET/RESUME switch is held in the
SET position.
Enable cruise control so that the
orange cruise lamp illuminates and
then turn the engine stop switch OFF.
Enter the diagnostic mode: With the
engine stop switch off, hold the
SET/RESUME switch at SET while
turning the engine stop switch ON.
1
Continue to next step.
If the green cruise lamp does not illu-
minate at all, then the resume switch
may be stuck open.
remains on as long as the
SET/RESUME switch is held in the
RES(UME) position.
Push the SET/RESUME switch to
RES(UME) and hold in this position.
2
minate, see 8.32 DTC P2135, P2138.
The green cruise lamp illuminates
when the grip is closed (roll-off posi-
tion), and extinguishes when the
throttle grip returns to its free position.
Turn the throttle grip tightly closed to
check the throttle roll-off command.
3
minate, check for one or more of the
following conditions:
Front brake switch not wired cor-
rectly.
Open or shorted wire to front
brake switch.
Front brake switch not working
properly.
The green cruise lamp will illuminate
and remain on until the brake lever is
released.
Apply the front brake lever. 4
minate, check for one or more of the
following conditions:
Rear brake switch not wired cor-
rectly.
Inoperative or pinched wire to rear
brake switch.
Rear brake switch not working
properly.
Check for brake switch related DTCs.
remains on until the brake pedal is
released.
Apply the rear brake pedal. 5
To restart or repeat the diagnostic
sequence, return to Step 1.
6
HOME
CRUISE CONTROL INOPERATIVE
CONDITIONS
The cruise control will become inoperative under the following
conditions:
Engine stop switch is off
Cruise control switch is off (open)
Ignition voltage
Throttle position faults P0120 and P0220
VSS faults P0501 and P0502
Cruise control switch or brake switch failure P0577
TPS correlation error P2135
Flash checksum error P0605
Brake switch fault
TBW limited performance mode P1510
Cruise control set speed is too low
Cruise control set speed is too high
Vehicle cannot increase to cruise control set speed (up
hill)
Vehicle cannot decrease to cruise control set speed (down
hill)
Brake is applied
Twist grip roll-off
ECM seeing both the SET/RESUME switches pressed at
the same time
Engine has not been running long enough
Clutch lever is pulled in
Vehicle acceleration rate is too high
Vehicle deceleration rate is too high
Vehicle speed is too high
Vehicle speed is too low
Engine rpm is too high
Engine rpm is too low
Engine rpm acceleration is too high
Transmission is in too low of a gear or in neutral
HOME
8.16 DTC P0577
CRUISE CONTROL
The cruise control system in monitored and controlled through
the ECM. The set/coast and resume/accelerate switches send
signals from the RHCM to the ECM. If the ECM sees the same
signal with no interruptions for more than two minutes, DTC
P0577 will set.
DESCRIPTION DTC
Cruise control message fault P0577
If any of the switches are held or stuck for over two minutes
with the engine stop switch ON, the stuck switch code will set
for that switch.
Diagnostic Tips
Pressing any of these switches for an extended period of time
can set the stuck switch DTCs. These codes should be cleared
and operate the vehicle to see if they return. Stuck switch codes
will take over two minutes to set.
DTC P0577
POSSIBLE CAUSES
RHCM malfunction
1. Switch Test
2. Turn the engine stop switch ON and wait three minutes.
3. Operate the vehicle to meet the conditions for setting the
DTC.
b. No. Concern is intermittent. Switch may have been
pressed for an extended period of time.
HOME
8.17 DTC P0603, P0605
See Figure 8-27. The DTCs listed indicate a failure which
requires replacement of the ECM. See 8.2 ELECTRONIC
CONTROL MODULE for replacement information. Refer to
Table 8-53.
NOTE
After replacing ECM, perform password learning procedure
and clear DTCs using odometer self-diagnostics. See
2
3
5
6
7
8
9
10
11
4
1
ed03415
DESCRIPTION DTC
ECM EEPROM error P0603
ECM flash error P0605
DTC P0603 Test
2. Replace ECM if DTCs reappear. See 8.2 ELECTRONIC
CONTROL MODULE.
DTC P0605 Test
2. Attempt to program ECM using correct calibration.
3. Restart vehicle. If DTC reappears, replace ECM. See
HOME
8.18 DTC P0641, P0651
See Figure 8-28. The ECM controls 5V power from terminal
50 for sensor power-1 and terminal 68 for sensor power-2. The
ECMprovides a common ground point for components through
terminal 61 for sensor power-1 and terminal 62 for sensor
power-2. The ECM monitors voltage on the 5V reference cir-
cuits and sets the DTCs belowif the voltage goes out of range.
DTC P0641 is displayed when sensor voltage 1 is out of
range. The 5V sensor power-1 circuit supplies the TCA,
VSS, jiffy stand sensor and sensor 2 of the TGS with a 5V
reference signal.
DTC P0651 is displayed when sensor power-2 is out of
range. The 5V sensor power-2 circuit supplies the TMAP
sensor and sensor 1 of the TGSwith a 5V reference signal.
DESCRIPTION DTC
5V reference-1 out of range P0641
5V reference-2 out of range P0651
TPS-2
TPS-1
TGS-2
TGS-1
5V Sensor Power-1
5V Sensor Ground-2
5V Sensor Power-2
29
30
36
37
39
50
59
62
68
29
30
36
37
39
50
ET Sensor 51 51
59
62
68
ECM
6 5 4 3 2 1
TCA
6 5 4 3 2 1
6 5 4 3 2 1
Vehicle Speed Input
JSS
Ground
40
56
64
73
40
56
64
73
JSS (HDI only)
1 2 3
VSS
A
B
C
A
B
C
B
K
/
G
Y
B
K
/
W
G
N
/
O
G
N
/
W
G
Y
/
W
G
Y
/
O
G
N
/
V
GN/V
R
/
G
Y
R
/
G
Y
G
Y
/
V
GY/V
BK/GY
BK/GN
B
K
/
G
N
B
K
/
G
N
BK/W
BK/W
BK/Y
Right GND 2
[204B]
[211A]
[211B]
[65A] [65B]
ET Sensor
A
B
A
B
[90A] [90B]
[78B] [78A]
[133B]
TMAP Sensor
TMAP Sensor Input
IAT
1 2 3 4
1 2 3 4 [80A]
[80B]
B
K
/
G
Y
G
N
/
G
Y
24
49
24
49
R
/
W
R
/
W
G
Y
GN
R/W
LGN/Y
L
G
N
/
G
Y
R
/
W
GY
GN/O
GY/O
LGN/Y
GN/GY
R/W
GN
LGN/GY
GN/W
GY/W
R/GY
BK/Y
B
K
/
W
B
K
RW
B
K
RW
B
K
RW
B
K
RW
1
Y BK
2 3 4 5 6
G
r
o
u
n
d
T
G
S
2
T
G
S
1
P
o
w
e
r
5
V
S
e
n
s
o
r
G
r
o
u
n
d
1
5
V
S
e
n
s
o
r
P
o
w
e
r
1
TGS
[204A]
em00903
HOME
DTC P0641
POSSIBLE CAUSES
Short to voltage in sensor power-1 circuit
Short to ground in sensor power-1 circuit
JSS malfunction
TGS malfunction
VSS malfunction
BOX (Part No. HD-48637) between wire harness [78B]
and ECM [78A]. See 7.13 DIAGNOSTIC TOOLS.
3. Using a multimeter, test for voltage between breakout box
terminal 50 and terminal 61.
4. Is voltage between 4-6V?
b. No. Greater than 6V. Repair short to voltage in (R/W)
wire.
c. No. Less than 4V. Repair short to ground in (R/W)
wire.
2. Sensor Power-1 Circuit Resistance Test
1. Measure resistance between breakout box terminal 50
and terminal 61.
CONTROL MODULE.
3. TCA Test
1. Disconnect the TCA [211].
and terminal 61.
MODULE.
4. JSS Test
1. Disconnect the JSS [133].
and terminal 61.
a. Yes. Replace the JSS. See the service manual.
5. TGS Test
1. Disconnect the TGS [204].
and terminal 61.
a. Yes. Replace the TGS. See 2.11 HANDGRIPS AND
HAND CONTROLS.
6. VSS Test
1. Disconnect the VSS [65].
and terminal 61.
a. Yes. Replace the VSS. See the service manual.
b. No. Repair short to ground in (R/W) wire.
DTC P0651
POSSIBLE CAUSES
Short to voltage in sensor power-2
Short to ground in sensor power-2
TMAP malfunction
TGS malfunction
terminal 68 and terminal 62.
4. Is voltage between 4-6V?
b. No. Greater than 6V. Repair short to voltage in
(R/GY) wire.
c. No. Less than 4V. Repair short to ground in (R/GY)
wire.
2. Sensor Power-2 Circuit Resistance Test
and terminal 62.
HOME
CONTROL MODULE.
3. TMAP Test
1. Disconnect the TMAP [80].
and terminal 62.
a. Yes. Replace the TMAP. See 4.3 INDUCTION
MODULE.
4. TGS Test
1. Disconnect the TGS [204].
2. Measure resistance between breakout box terminals 68
and 62.
HAND CONTROLS.
b. No. Repair short to ground in (R/GY) wire.
HOME
8.19 DTC P1009
GENERAL
Password Problem
The ECMand BCMexchange passwords during operation. An
incorrect password or missing password will set a DTC. If any
U-codes exist, troubleshoot the higher priority codes prior to
performing the tests in this section. Refer to Table 7-3.
NOTE
If the BCM is not connected to the wiring harness, the vehicle
will not start.
DESCRIPTION DTC
Incorrect password P1009
1
2 4 3
5
6
7
10 9
8
ed03414
1. ECM
2. ECM [78]
4. Security siren
5. BCM
8. Rear WSS [168]
9. ABS [166]
10. ABS ECU
DTC P1009
POSSIBLE CAUSES
ECM malfunction
BCM malfunction
1. Incorrect Password Test
1. Program password. See the service manual.
2. Does DTC P1009 set?
b. No. System okay.
2. BCM Replacement Test
1. Replace BCM. See the service manual.
2. Program password. See the service manual.
3. Does DTC P1009 set?
a. Yes. Install original BCM and replace ECM. See
b. No. System okay.
HOME
8.20 DTC P1270
TGS2 Validation
Within the ECM, there are two independent Analog/Digital (A/D)
converter modules used to validate the input of Twist Grip
Sensor 2 (TGS2). TGS2 inputs are sent into both converter
modules and if the output of the two readings are not within
the designated value of each other, for a specified time, then
DTC P1270 fault is initiated.
Unless the ECM has a poor or intermittent connection, DTC
P1270 indicates the ECM is defective and requires replace-
ment. See 8.2 ELECTRONIC CONTROL MODULE for
replacement information.
NOTE
After replacing the ECM, performpassword learning procedure
and clear codes.
DESCRIPTION DTC
TGS2 validation error P1270
HOME
B
K
/
G
N
B
K
/
B
N
A
A
B
A
B
L3
L3
A
B
A
B
B
C
D
A Power
Ion Sense
Coil Rear
Coil Front
B
C
D
Ignition Coil
Rear Fuel
Injector
Front Fuel
Injector
BCM
Battery Fuse
Rear
HO2S
Front
HO2S
GY/BN
BK/BN
BK/BN
GN/BN
Right
GND 2
Purge Solenoid
(Optional)
A
B
A
B
1
2
3
4
1
2
3
4
[84B] [84A]
[85B] [85A]
[95B] [95A]
[83B] [83A]
[138A]
[137A]
[242A]
[242B]
LGN/BN
GY/BE
GN/BE
R/GN
R/GN
R/GN
R/GN
R
/
G
N
R
/
G
N
R
/
G
N
GN/Y
G
N
/
Y
B
K
/
O
BK/O
BK/O
R/GR
R/GR
GY/Y
G
Y
/
Y
LGN/BK
L
G
N
/
B
K
L
G
N
/
B
N
G
N
/
B
E
G
Y
/
B
E
G
Y
/
B
N
G
N
/
B
N
R
/
O
20 23 28 33 46 48 52 53 54 66 71 72 73
20 23 28 33 46 48 52 53 54 66 71 72 73
P
u
r
g
e
S
o
l
e
n
o
i
d
F
r
o
n
t
F
u
e
l
I
n
j
e
c
t
o
r
I
o
n
S
e
n
s
e
31
31
5
V
S
e
n
s
o
r
G
r
o
u
n
d
R
e
a
r
O
2
S
e
n
s
o
r
O
2
R
e
t
u
r
n
S
y
s
t
e
m
P
o
w
e
r
R
e
a
r
I
n
j
e
c
t
o
r
C
o
i
l
F
r
o
n
t
I
n
j
e
c
t
o
r
C
o
i
l
F
r
o
n
t
O
2
S
e
n
s
o
r
1
2
V
B
a
t
t
e
r
y
S
y
s
t
e
m
P
o
w
e
r
G
r
o
u
n
d
R
e
a
r
F
u
e
l
I
n
j
e
c
t
o
r
ECM
[78B]
[78A]
R
/
O
em01402
HOME
DTC P1270
POSSIBLE CAUSES
ECM malfunction
Open in system power circuit
1. ECM Connector Test
1. With the engine stop switch OFF, disconnect ECM [78]
and inspect for damaged, corroded or pushed out ter-
minals.
2. ECM Circuit Test
GNOSTIC TOOLS.
breakout box terminal 52 and ground and terminal 72 and
ground.
CONTROL MODULE.
HOME
8.21 DTC P1353, P1356, P1357, P1358
See Figure 8-31. A feedback voltage signal in the secondary
ignition circuit (terminal B) detects the presence of combustion
each time a cylinder fires on ECM terminal 33. For diagnostic
purposes, this signal is only analyzed at high speed and load
conditions where it may be easily measured. Failure to detect
combustion at high speed and load means one of following
conditions is true:
Cylinder is truly misfiring.
There is a lack of continuity in the ignition coil secondary
circuit.
NOTE
Make sure vehicle is running properly before performing the
tests in this section. Perform fuel pressure tests if required.
DESCRIPTION DTC
Front cylinder no combustion P1353
Rear cylinder no combustion P1356
Front cylinder combustion intermittent P1357
Rear cylinder combustion intermittent P1358
4
3
2
1
ed02980
1. Terminal A: power
2. Terminal B: ion sense
3. Terminal C: rear coil
4. Terminal D: front coil
HOME
B
K
/
G
N
B
K
/
B
N
A
A
B
A
B
L3
L3
A
B
A
B
B
C
D
A Power
Ion Sense
Coil Rear
Coil Front
B
C
D
Ignition Coil
Rear Fuel
Injector
Front Fuel
Injector
BCM
Battery Fuse
Rear
HO2S
Front
HO2S
GY/BN
BK/BN
BK/BN
GN/BN
Right
GND 2
Purge Solenoid
(Optional)
A
B
A
B
1
2
3
4
1
2
3
4
[84B] [84A]
[85B] [85A]
[95B] [95A]
[83B] [83A]
[138A]
[137A]
[242A]
[242B]
LGN/BN
GY/BE
GN/BE
R/GN
R/GN
R/GN
R/GN
R
/
G
N
R
/
G
N
R
/
G
N
GN/Y
G
N
/
Y
B
K
/
O
BK/O
BK/O
R/GR
R/GR
GY/Y
G
Y
/
Y
LGN/BK
L
G
N
/
B
K
L
G
N
/
B
N
G
N
/
B
E
G
Y
/
B
E
G
Y
/
B
N
G
N
/
B
N
R
/
O
20 23 28 33 46 48 52 53 54 66 71 72 73
20 23 28 33 46 48 52 53 54 66 71 72 73
P
u
r
g
e
S
o
l
e
n
o
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d
F
r
o
n
t
F
u
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l
I
n
j
e
c
t
o
r
I
o
n
S
e
n
s
e
31
31
5
V
S
e
n
s
o
r
G
r
o
u
n
d
R
e
a
r
O
2
S
e
n
s
o
r
O
2
R
e
t
u
r
n
S
y
s
t
e
m
P
o
w
e
r
R
e
a
r
I
n
j
e
c
t
o
r
C
o
i
l
F
r
o
n
t
I
n
j
e
c
t
o
r
C
o
i
l
F
r
o
n
t
O
2
S
e
n
s
o
r
1
2
V
B
a
t
t
e
r
y
S
y
s
t
e
m
P
o
w
e
r
G
r
o
u
n
d
R
e
a
r
F
u
e
l
I
n
j
e
c
t
o
r
ECM
[78B]
[78A]
R
/
O
em01402
HOME
DTC P1353, P1356
Table 8-62. DTC P1353, P1356 Diagnostic Faults
POSSIBLE CAUSES
Ignition coil malfunction
ECM malfunction
Spark plug wire connections faulty
1. Absence of Fuel Test
1. Verify vehicle has fuel.
2. Has vehicle run out of fuel recently?
a. Yes. Clear DTCs using odometer self-diagnostics.
See 7.14 INITIAL DIAGNOSTICS, Odometer Self-
Diagnostics. Fill with fresh fuel and restart. If code
returns, then continue with tests. Go to Test 2.
2. Ignition Coil Primary Resistance Test
1. Disconnect ignition coil [83].
ignition coil [83A] terminals A and C, and then from ter-
minals A and D.
3. Is resistance 0.3-0.5 Ohms?
Table 8-63. Spark Plug Cable Specifications
REAR FRONT SPECIFICATION
6.50-6.75 18.75-19.50 Length in.
165.1-171.5 476.3-495.3 Length mm
1625-4502 4688-13,007 Resistance-ohms
3. Spark Plug Wire Test
1. Disconnect the spark plug wires.
2. Measure the resistance of the spark plug wires.
3. Is the front and rear spark plug wire resistance within the
specified range? Refer to Table 8-63.
b. No. Replace the out of range spark plug wire. See
the service manual.
4. Ignition Coil Secondary Resistance Test
1. Measure resistance between ignition coil [83A] terminal
A to the front coil secondary. Repeat measurement for the
rear coil secondary.
2. Is resistance 3500-4500 Ohms?
a. Yes. Replace spark plug. See the service manual.
DTC P1357, P1358
Table 8-64. DTC P1357, P1358 Diagnostic Faults
POSSIBLE CAUSES
Spark plug wire connections faulty
1. Ion Sense Continuity Test
41404) and a multimeter, test for continuity between the
ignition coil [83B] terminal B and breakout box terminal
33.
a. Yes. Replace spark plug. See the service manual. If
condition persists, then continue with tests. Go to
Test 2.
b. No. Repair open in (LGN/BN) wire.
2. Ion Sense Resistance Test
1. Measure resistance between ignition coil [83A] terminals
A and B.
2. Is resistance greater than 100,000 Ohms?
TROL MODULE.
3. Ion Sense Short to Voltage Test
GNOSTIC TOOLS.
ignition coil [83B] terminal B and breakout box terminal
73.
HOME
a. Yes. Repair short to voltage on (LGN/BN) wire.
No. Replace ignition coil. See the service manual. b.
HOME
8.22 DTC P1501, P1502
See Figure 8-33. The Jiffy Stand Sensor (JSS) uses a Hall-
effect sensor to monitor jiffy stand position. When the jiffy stand
is fully retracted the sensor picks up the presence of the metal
tab mounted to the jiffy stand. The metal tab is moved away
from the sensor as the jiffy stand is extended. When the jiffy
stand is extended the engine will only start and run if the BCM
determines the transmission is in neutral. Otherwise the engine
will stall as the clutch is released. This is done by monitoring
the neutral switch input to the BCM and communicating that
input over the CAN bus circuit to the ECM.
The JSS is powered and monitored by the ECM. The ECM
supplies the 5V reference to the JSS. The JSS sends a signal
back to the ECM. This signal is used by the ECM to determine
when the jiffy stand is retracted or extended. The JSS is
grounded through the ECM.
The JSS also has a Fail Enable Mode. This mode allows the
engine to start and run if the systemrecognizes a problemwith
the JSS circuit. When a problem exists or if the transmission
is put in gear with the jiffy stand extended, the odometer will
display "SIdE Stand". DTC P1501 or P1502 will set if the JSS
circuits are out of range.
DESCRIPTION DTC
JSS low P1501
JSS high P1502
NOTE
The ECM supplies 5V reference voltage to the VSS, TPS and
MAP sensors, in addition to the JSS. Problems on the 5V ref-
erence will cause other DTCs.
1
2
3
4
5
ed03292
1. Voltage regulator to stator [47]
2. Front HO2 sensor [138]
3. Voltage regulator [77]
4. JSS [133]
5. CKP sensor [79]
Figure 8-33. Under Voltage Regulator
HOME
TPS-2
TPS-1
TGS-2
TGS-1
5V Sensor Power-1
5V Sensor Ground-2
5V Sensor Power-2
29
30
36
37
39
50
59
62
68
29
30
36
37
39
50
ET Sensor 51 51
59
62
68
ECM
6 5 4 3 2 1
TCA
6 5 4 3 2 1
6 5 4 3 2 1
Vehicle Speed Input
JSS
Ground
40
56
64
73
40
56
64
73
JSS (HDI only)
1 2 3
VSS
A
B
C
A
B
C
B
K
/
G
Y
B
K
/
W
G
N
/
O
G
N
/
W
G
Y
/
W
G
Y
/
O
G
N
/
V
GN/V
R
/
G
Y
R
/
G
Y
G
Y
/
V
GY/V
BK/GY
BK/GN
B
K
/
G
N
B
K
/
G
N
BK/W
BK/W
BK/Y
Right GND 2
[204B]
[211A]
[211B]
[65A] [65B]
ET Sensor
A
B
A
B
[90A] [90B]
[78B] [78A]
[133B]
TMAP Sensor
TMAP Sensor Input
IAT
1 2 3 4
1 2 3 4 [80A]
[80B]
B
K
/
G
Y
G
N
/
G
Y
24
49
24
49
R
/
W
R
/
W
G
Y
GN
R/W
LGN/Y
L
G
N
/
G
Y
R
/
W
GY
GN/O
GY/O
LGN/Y
GN/GY
R/W
GN
LGN/GY
GN/W
GY/W
R/GY
BK/Y
B
K
/
W
B
K
RW
B
K
RW
B
K
RW
B
K
RW
1
Y BK
2 3 4 5 6
G
r
o
u
n
d
T
G
S
2
T
G
S
1
P
o
w
e
r
5
V
S
e
n
s
o
r
G
r
o
u
n
d
1
5
V
S
e
n
s
o
r
P
o
w
e
r
1
TGS
[204A]
em00903
DTC P1501
POSSIBLE CAUSES
JSS malfunction
1. JSS 5V Reference Open Circuit Test
minals. Repair as required.
between breakout box terminal 50 and JSS[133B] terminal
1 (R/W).
b. No. Repair open on (R/W) wire.
2. JSS5VReference Shorted to Ground Test
1. Test for continuity between JSS [133B] terminal 1 (R/W)
to ground.
a. Yes. Repair short to ground on (R/W) wire.
3. JSS Signal Wire Shorted to Ground Test
ground.
a. Yes. Repair short to ground on (LGN/GY) wire.
4. JSS Signal Wire Open Circuit Test
JSS [133B] terminal 2 (LGN/GY).
HOME
a. Yes. Replace JSS. See the service manual.
b. No. Repair open on (LGN/GY) wire.
DTC P1502
POSSIBLE CAUSES
JSS malfunction
Open ground
Short between 5V reference circuit and signal circuit
Open in signal circuit
1. JSS Ground Wire Test
between terminal 3 of [133B] and ground.
2. JSS 5V Reference Wire Short to Voltage
Test
1. Test for voltage at jiffy stand sensor [133B] terminal 1
(R/W) wire.
a. Yes. Repair short to battery voltage on (R/W).
3. JSS Signal Wire Short to Voltage Test
1. Test for voltage on [133B] terminal 2.
a. Yes. Repair short to battery voltage in (LGN/GY) wire.
4. JSS 5V Reference and Signal Shorted
Together Test
1. With the engine stop switch OFF, disconnect the ECM
[78].
2. Test for continuity between terminals 1 and 2 of [133B].
a. Yes. Repair short between (R/W) and (LGN/GY)
wires.
b. No. Replace JSS. See the service manual.
SIDE STAND DISPLAYED ON ODOMETER
Table 8-68. Side Stand Displayed on Odometer Diagnostic
Faults
POSSIBLE CAUSES
Jiffy stand is down
Jiffy stand out of adjustment
1. Starts, Then Stalls Test
1. Check for DTCs and diagnose them first.
2. Does the engine start and stall?
a. Yes. See 8.36 STARTS, THEN STALLS.
2. Neutral Test
2. Is the neutral indicator on?
b. No. See 7.23 INDICATOR LAMPS.
3. JSS Clearance Test
1. Inspect the JSS and the jiffy stand for correct mounting
and clearance to the jiffy stand tab.
2. Is the clearance less than 0.18 in (4.5 mm)?
a. Yes. Replace the JSS.
b. No. Install the JSS and jiffy stand correctly.
HOME
8.23 DTC P1510, P1511, P1512
Throttle Actuation Control Management
The ECM constantly monitors throttle actuation and throttle
component positioning. Several safety features are pro-
grammed into the ECM to limit performance when an error or
fault in throttle actuation is detected. These DTCs always
accompany another code. Refer to Table 8-69.
DESCRIPTION DTC
Throttle actuator control limited perform-
ance mode
P1510
Throttle actuator control power manage-
ment mode
P1511
Throttle actuator control forced idle mode P1512
Performance limitations are identified by code, as follows:
P1510 Limited Performance: Enables near normal
operation of the vehicle, guarding against inadvertent wide
open throttle conditions. Typically this code is the result if
one of the TGS or TP sensors, or one of each, has failed.
P1511 Power Management: Provides more limitation on
driveability, due to failure of the TCA, without a TGS, MAP
or airflow faults. The TCA is de-energized and the throttle
plate returns to its idle detent position. The ECM monitors
the operation of the TGS and adjusts the spark advance
and cylinder shutoff/rev limiting, allowing the vehicle to
reach traffic speeds (limp-home).
P1512 Forced Idle Mode: Provides extreme limitation of
driveability, due to a failure of both TGS, TGS validation
error or failure of one TGS and the brake switch. The TCA
is de-energized and the throttle plate is forced to a fast
idle position providing enough torque to operate at a high
idle speed.
DTC P1510, P1511, P1512
Table 8-70. DTC P1510, P1511, P1512 Diagnostic Faults
POSSIBLE CAUSES
Other DTCs set
1. DTC Verification Test
2. Start and run the engine for a few seconds.
3. Cycle the engine on and off, for a few seconds each time
a total of three times.
4. Did DTCP1510, P1511 or P1512 set with no other DTCs?
CONTROL MODULE.
b. No. Other DTCs set. Refer to Table 7-3.
c. No. No DTCs set. DTC was properly cleared.
HOME
8.24 DTC P1514
Air Flow Fault
The ECM uses the TMAP sensor to monitor air flow past the
throttle plate. This ensures proper throttle plate positioning,
when the throttle is released and allowed to return to the
unpowered position. The unpowered position is typically 7%
of throttle plate range.
In order to avoid inconsistent readings at low rpm (or at idle),
testing air flow is only performed at engine speeds above
normal idle (10% of throttle plate range or approximately 1300
rpm).
The ECM compares the intake manifold pressure value from
the TMAP to the throttle plate position value from the TPS.
DTC 1514 sets if the manifold pressure is higher than it should
be for that given throttle plate position for three consecutive
ignition cycles. If a TMAP sensor error is present, then the
ECM does not check P1514 parameters and instead P2105
(forced shutdown mode) is initiated, shutting down the fuel
pump and fuel injectors. See 8.29 DTC P2105, P2107. The
ECM only checks for DTC P1514 if power management mode
(DTC P1511) is present.
DESCRIPTION DTC
Air flow fault P1514
DTC P1514
POSSIBLE CAUSES
Other DTCs set
4. Did DTC P1514 set with no other DTCs?
CONTROL MODULE.
HOME
8.25 DTC P1600
The ECM uses a main microprocessor and a monitoring
microcontroller, to communicate with the throttle actuation
control system.
The microcontroller monitors the main microprocessor of the
ECM, and when a communication failure is identified, the
microcontroller shuts down the TCA and fuel injectors.
An internal ignition delay timer monitors when the ignition circuit
is energized. The microcontroller issues DTC P1600 if no
communication is established between the main microprocessor
or if a monitoring failure occurs within three consecutive ignition
cycles.
DESCRIPTION DTC
TCA module processor - internal fault P1600
DTC P1600
POSSIBLE CAUSES
Other DTCs set
CONTROL MODULE.
HOME
8.26 DTC P1632
If the speedometer mileage is higher than the mileage in the
ECM, the ECM will set a DTC P1632 and increase its mileage
to match the speedometer. This will normally occur when the
ECM is replaced, or if continuous battery is not present on
terminal 71 of the ECM. If this code is set, verify the speedo-
meter or ECM have not been replaced with a used part from
another vehicle. Clear the DTC. See 7.14 INITIAL DIA-
GNOSTICS, Odometer Self-Diagnostics. If the code returns,
the ECM may not be powering down properly. Verify that 12V
is continually present on terminal 71.
DESCRIPTION DTC
Odometer learned up P1632
2
3
5
6
7
8
9
10
11
4
1
ed03415
HOME
8.27 DTC P1655, P1656
See Figure 8-37. When open, compressed gases are released
through the exhaust port.
See Figure 8-36. The Automatic Compression Release (ACR)
is opened and closed by the ECM to assist starting.
DESCRIPTION DTC
ACR solenoid low/open P1655
ACR solenoid high P1656
5
6
1
2
3
4
ed03192
ed03356
Figure 8-37. ACR in Head
HOME
BK/Y
G
N
/
W
B
K
/
WB
K
/
W
R
B
K
/
G
Y
B
K
/
G
Y
R
/
W
A
A
B
A
B
A
B
A
B
B
C
D
A Power
Ion Sense
Coil Rear
Coil Front
B
C
D
CKP
Sensor
ET
Sensor
TCA
TMAP
Sensor
Ignition Coil
VSS
JSS
Rear Fuel
Injector
Front Fuel
Injector
L3 L3 BCM
6 5 4 3 2 1
1 2
1 2
6 5 4 3 2 1
1
A
B
C
A
B
C
2
A B
A B
3 4
1 2
Front ACR
(If Equipped)
2 1
2 1
3 4
6 5 4 3 2 1
GY/BN
BK/BN
BK/BN
GN/BN
Right
GND 2
R
/
G
N
R
/
G
N
R
/
G
N
Purge Solenoid
(Optional)
A
B
A
B
[79A]
[79B]
[204B]
[90A]
[90B]
[203AF]
[203BF]
Rear ACR
(If Equipped)
2 1
2 1
[211A]
[211B]
[80A]
[80B]
[65A] [65B]
B
K
B
K
/
W
G
N
/
O
G
Y
/
V
G
N
/
V
[84B] [84A]
[85B] [85A]
[95B] [95A]
[83B] [83A]
[203AR]
[203BR]
[242B] [242A]
R/GN
R/GN
GN/Y
GY/Y
R/GN
R/GN
R/GN
R/GN
R/GN
LGN/BN
GY/BE
GN/BE
LGN/BK
G
Y
/
O
R
/
W
G
Y
/
W
G
N
G
N
/
G
Y
R
/
G
Y
R
/
G
Y
G
Y
L
G
N
/
R
L
G
N
/
R
L
G
N
/
R
R/W
LGN/Y
Battery
Fuse
ECM
[78B]
[78A]
19 20 23 24 28 29 30 33 36 37 39 40 43 46 48 49 50 51 52 53 54 59 61 62 63 64 66 68 71 72 73
19 20 23 24 28 29 30 33 36 37 39 40 43 46 48 49 50 51 52 53 54 59 61 62 63 64 66 68 71 72 73
P
u
r
g
e
S
o
l
e
n
o
i
d
A
C
R
G
r
o
u
n
d
B
K
RW
B
K
RW
B
K
RW
B
K
RW
1
Y BK
2 3 4 5 6
G
r
o
u
n
d
T
G
S
2
T
G
S
1
P
o
w
e
r
5
V
S
e
n
s
o
r
G
r
o
u
n
d
1
5
V
S
e
n
s
o
r
P
o
w
e
r
1
TGS
[204A]
T
M
A
P
S
e
n
s
o
r
I
n
p
u
t
F
r
o
n
t
F
u
e
l
I
n
j
e
c
t
o
r
T
G
S
H
i
g
h
T
G
S
L
o
w
31
31
5
V
S
e
n
s
o
r
G
r
o
u
n
d
I
o
n
S
e
n
s
e
T
C
A
-
T
P
S
2
T
C
A
-
T
P
S
1
T
G
S
2
V
S
S
I
n
p
u
t
C
K
P
S
e
n
s
o
r
(
-
)
R
e
a
r
O
2
S
e
n
s
o
r
O
2
R
e
t
u
r
n
T
M
A
P
-
I
A
T
5
V
S
e
n
s
o
r
P
o
w
e
r
1
E
T
S
e
n
s
o
r
S
y
s
t
e
m
P
o
w
e
r
R
e
a
r
I
n
j
e
c
t
o
r
C
o
i
l
F
r
o
n
t
I
n
j
e
c
t
o
r
C
o
i
l
T
G
S
1
5
V
S
e
n
s
o
r
G
r
o
u
n
d
1
5
V
S
e
n
s
o
r
G
r
o
u
n
d
2
C
K
P
S
e
n
s
o
r
(
+
)
V
S
S
G
r
o
u
n
d
F
r
o
n
t
O
2
S
e
n
s
o
r
5
V
S
e
n
s
o
r
P
o
w
e
r
2
1
2
V
B
a
t
t
e
r
y
S
y
s
t
e
m
P
o
w
e
r
G
r
o
u
n
d
R
e
a
r
F
u
e
l
I
n
j
e
c
t
o
r
L
G
N
/
B
K
L
G
N
/
B
N
G
Y
G
N
+
R
L
G
N
/
Y
L
G
N
/
R
R
/
O
R
/
W
+
B
K
G
Y
/
B
N
G
N
/
G
Y
G
Y
/
B
E
G
N
/
B
E
G
N
/
B
N
B
K
/
B
N
B
K
/
G
N
B
K
/
G
N
B
K
/
G
Y
G
Y
/
Y
G
N
/
Y
G
N
/
O
G
Y
/
O
B
K
/
O
BK/O
BK/O
G
Y
/
V
G
Y
/
W
G
N
/
W
B
K
/
W
B
K
/
Y
R
/
G
Y
R
/
G
N
R
/
G
N
G
N
/
V
B
K
B
K
B
K
B
K
Rear
HO2S
Front
HO2S
1
2
3
4
1
2
3
4
[138A]
[137A]
em01458
HOME
DTC P1655
POSSIBLE CAUSES
ACR solenoid malfunction
Open in ACR control circuit
ECM malfunction
Short to ground in ACR control circuit
1. Front ACR Test
1. Disconnect front ACR [203F].
34730-2D).
3. Crank engine for five seconds.
4. Does the test light flash on and off?
b. No, test light stays on steady. Go to Test 4.
c. No, did not stay on steady. Go to Test 6.
2. Rear ACR Test
1. Disconnect rear ACR [203R].
34730-2D).
a. Yes. Replace front and rear ACR solenoids. See
3.6 CYLINDER HEAD.
3. Rear ACR Control Circuit Test
1. While cranking the engine, test for voltage between
[203RB] terminal 1 and ground.
a. Yes. Repair open between [203RB] and [78] (LGN/R)
wire.
4. Front ACR Control Circuit Short to
Ground Test
3. Test for continuity between [203FB] terminal 2 and ground.
TROL MODULE.
5. Rear ACRControl Circuit Short to Ground
Test
1. Disconnect rear ACR [203RB].
2. Test for continuity between [203FB] terminal 2 and ground.
a. Yes. Repair short to ground in (LGN/R) wire.
b. No. Replace front and rear ACR solenoids. See
3.6 CYLINDER HEAD.
6. Shorted ACR Test
1. Disconnect rear ACR [203RB].
3.6 CYLINDER HEAD.
7. ACR Supply Circuit Open Test
1. Disconnect the test light.
2. While cranking the engine, test for voltage between
[203FB] terminal 1 and ground.
8. ACR Control Circuit Continuity Test
and ECM [78A] leaving [78A] disconnected. See
breakout box terminal 19 and [203FB] terminal 2.
CONTROL MODULE.
b. No. Repair open in (LGN/R) wire.
HOME
DTC P1656
POSSIBLE CAUSES
Short to voltage in ACR control circuit
ACR solenoid malfunction
1. Front ACR Test
1. Disconnect front ACR [203F].
34730-2D).
2. Rear ACR Control Circuit Test
2. While cranking the engine, using HARNESS CON-
NECTOR TEST KIT (Part No. HD-41404) and a multi-
meter, measure voltage between [203FB] terminal 2 and
ground.
a. Yes. Repair short to voltage between [203FB] terminal
2 and [78B] terminal 19.
b. No. Replace front and rear ACR solenoids. See
3.6 CYLINDER HEAD.
3. Rear ACR Test
3.6 CYLINDER HEAD.
4. Front ACR Control Circuit Test
1. Disconnect fuel injector test light.
2. While cranking the engine, using HARNESS CON-
NECTOR TEST KIT (Part No. HD-41404) and a multi-
meter, measure voltage between [203FB] terminal 2 and
ground.
a. Yes. Repair short to voltage between [203FB] terminal
2 and ECM [78B] terminal 19.
TROL MODULE.
HOME
8.28 DTC P2100, P2101, P2102, P2103
The TCA contains two potentiometers (designated as TPS1
and TPS2) and an electric DC motor for controlling the actu-
ation of the throttle. TPS1 and TPS2 are mounted in the TCA.
They are connected to the keyed shaft of the throttle plate and
used to communicate the position of the throttle plate.
Each TPS supplies input to the ECM in response to the posi-
tioning of the throttle plate. The ECMactivates the motor in the
TCA to move the throttle plate, based on signals fromthe TGS.
See Figure 8-39. The TCA motor receives input (position data)
from the ECM connector [78] terminal 29 for electronic throttle
control - HI and terminal 30 for electronic throttle control - LOW.
The TCA motor drives a series of gears to rotate the position
of the throttle plate. Refer to Table 8-79 for DTCs associated
with TCA drive motor.
DESCRIPTION DTC
TCA motor open P2100
TCA motor circuit range/performance
(actuation error)
P2101
TCA motor control circuit shorted low P2102
TCA motor control circuit shorted high P2103
TPS-2
TPS-1
TGS-2
TGS-1
5V Sensor Power-1
5V Sensor Ground-2
5V Sensor Power-2
29
30
36
37
39
50
59
62
68
29
30
36
37
39
50
ET Sensor 51 51
59
62
68
ECM
6 5 4 3 2 1
TCA
6 5 4 3 2 1
6 5 4 3 2 1
Vehicle Speed Input
JSS
Ground
40
56
64
73
40
56
64
73
JSS (HDI only)
1 2 3
VSS
A
B
C
A
B
C
B
K
/
G
Y
B
K
/
W
G
N
/
O
G
N
/
W
G
Y
/
W
G
Y
/
O
G
N
/
V
GN/V
R
/
G
Y
R
/
G
Y
G
Y
/
V
GY/V
BK/GY
BK/GN
B
K
/
G
N
B
K
/
G
N
BK/W
BK/W
BK/Y
Right GND 2
[204B]
[211A]
[211B]
[65A] [65B]
ET Sensor
A
B
A
B
[90A] [90B]
[78B] [78A]
[133B]
TMAP Sensor
TMAP Sensor Input
IAT
1 2 3 4
1 2 3 4 [80A]
[80B]
B
K
/
G
Y
G
N
/
G
Y
24
49
24
49
R
/
W
R
/
W
G
Y
GN
R/W
LGN/Y
L
G
N
/
G
Y
R
/
W
GY
GN/O
GY/O
LGN/Y
GN/GY
R/W
GN
LGN/GY
GN/W
GY/W
R/GY
BK/Y
B
K
/
W
B
K
RW
B
K
RW
B
K
RW
B
K
RW
1
Y BK
2 3 4 5 6
G
r
o
u
n
d
T
G
S
2
T
G
S
1
P
o
w
e
r
5
V
S
e
n
s
o
r
G
r
o
u
n
d
1
5
V
S
e
n
s
o
r
P
o
w
e
r
1
TGS
[204A]
em00903
HOME
DTC P2100
POSSIBLE CAUSES
Open in throttle actuator control circuit high
Open in throttle actuator control circuit low
1. TCA Test
and ECM [78A], leaving [78A] disconnected. See
2. Using a multimeter, measure resistance between breakout
box terminal 29 and terminal 30.
b. No. Performwiggle test. See the electrical diagnostic
manual. If resistance below 10 Ohms, replace the
ECM. See 8.2 ELECTRONIC CONTROL MODULE.
2. TCA High Circuit Test
breakout box terminal 29 and TCA [211B] terminal 3.
b. No. Repair open in (GN/O) wire.
3. TCA Low Circuit Test
MODULE.
b. No. Repair open in (GY/O) wire.
DTC P2101
POSSIBLE CAUSES
Short between throttle actuator control circuits
Open in throttle actuator control circuit high
Open in throttle actuator control circuit low
1. TCA Circuit Resistance Test
2. Using a multimeter, measure resistance between breakout
2. TCA Test
and terminal 30.
a. Yes. Repair short between the (GN/O) and (GY/O)
wires.
breakout box terminal 29 and TCA [211B] terminal 3.
b. No. Repair open in (GN/O) wire.
CONTROL MODULE.
b. No. Repair open in (GY/O) wire.
HOME
DTC P2102
POSSIBLE CAUSES
Short to ground in throttle actuator control circuit low
Short to ground in throttle actuator control circuit high
41404) and a multimeter test for measure resistance
between [211B] terminal 3 and ground.
b. No. Repair short to ground in (GN/O) wire.
2. TCA Test
ground.
a. Yes. Repair short to ground in (GY/O) wire.
DTC P2103
POSSIBLE CAUSES
Short to ground in throttle actuator control circuit low
Short to ground in throttle actuator control circuit high
3. Using a multimeter, test for continuity between breakout
a. Yes. Repair short between (GN/O) and (BK/GN)
wires.
terminal 30.
a. Yes. Repair short between (GY/O) and (BK/GN) wires.
b. No. Replace the ECM. See 8.2 ELECTRONIC
CONTROL MODULE.
HOME
8.29 DTC P2105, P2107
The ECM sets DTC P2105 and provides a forced shut down
of the engine when the performance of the TCA cannot be
verified. Refer to Table 8-84.
Initially, the ECM commands the fuel pump and fuel injectors
to be disabled until the actual fault is cleared.
The ECM sets DTC P2107 to identify an internal over-temper-
ature shutdown or a power supply failure. Refer to Table 8-84.
DESCRIPTION DTC
TCA system forced engine shutdown P2105
TCA systemmodule processor - internal
fault
P2107
HOME
BK/Y
G
N
/
W
B
K
/
WB
K
/
W
R
B
K
/
G
Y
B
K
/
G
Y
R
/
W
A
A
B
A
B
A
B
A
B
B
C
D
A Power
Ion Sense
Coil Rear
Coil Front
B
C
D
CKP
Sensor
ET
Sensor
TCA
TMAP
Sensor
Ignition Coil
VSS
JSS
Rear Fuel
Injector
Front Fuel
Injector
L3 L3 BCM
6 5 4 3 2 1
1 2
1 2
6 5 4 3 2 1
1
A
B
C
A
B
C
2
A B
A B
3 4
1 2
Front ACR
(If Equipped)
2 1
2 1
3 4
6 5 4 3 2 1
GY/BN
BK/BN
BK/BN
GN/BN
Right
GND 2
R
/
G
N
R
/
G
N
R
/
G
N
Purge Solenoid
(Optional)
A
B
A
B
[79A]
[79B]
[204B]
[90A]
[90B]
[203AF]
[203BF]
Rear ACR
(If Equipped)
2 1
2 1
[211A]
[211B]
[80A]
[80B]
[65A] [65B]
B
K
B
K
/
W
G
N
/
O
G
Y
/
V
G
N
/
V
[84B] [84A]
[85B] [85A]
[95B] [95A]
[83B] [83A]
[203AR]
[203BR]
[242B] [242A]
R/GN
R/GN
GN/Y
GY/Y
R/GN
R/GN
R/GN
R/GN
R/GN
LGN/BN
GY/BE
GN/BE
LGN/BK
G
Y
/
O
R
/
W
G
Y
/
W
G
N
G
N
/
G
Y
R
/
G
Y
R
/
G
Y
G
Y
L
G
N
/
R
L
G
N
/
R
L
G
N
/
R
R/W
LGN/Y
Battery
Fuse
ECM
[78B]
[78A]
19 20 23 24 28 29 30 33 36 37 39 40 43 46 48 49 50 51 52 53 54 59 61 62 63 64 66 68 71 72 73
19 20 23 24 28 29 30 33 36 37 39 40 43 46 48 49 50 51 52 53 54 59 61 62 63 64 66 68 71 72 73
P
u
r
g
e
S
o
l
e
n
o
i
d
A
C
R
G
r
o
u
n
d
B
K
RW
B
K
RW
B
K
RW
B
K
RW
1
Y BK
2 3 4 5 6
G
r
o
u
n
d
T
G
S
2
T
G
S
1
P
o
w
e
r
5
V
S
e
n
s
o
r
G
r
o
u
n
d
1
5
V
S
e
n
s
o
r
P
o
w
e
r
1
TGS
[204A]
T
M
A
P
S
e
n
s
o
r
I
n
p
u
t
F
r
o
n
t
F
u
e
l
I
n
j
e
c
t
o
r
T
G
S
H
i
g
h
T
G
S
L
o
w
31
31
5
V
S
e
n
s
o
r
G
r
o
u
n
d
I
o
n
S
e
n
s
e
T
C
A
-
T
P
S
2
T
C
A
-
T
P
S
1
T
G
S
2
V
S
S
I
n
p
u
t
C
K
P
S
e
n
s
o
r
(
-
)
R
e
a
r
O
2
S
e
n
s
o
r
O
2
R
e
t
u
r
n
T
M
A
P
-
I
A
T
5
V
S
e
n
s
o
r
P
o
w
e
r
1
E
T
S
e
n
s
o
r
S
y
s
t
e
m
P
o
w
e
r
R
e
a
r
I
n
j
e
c
t
o
r
C
o
i
l
F
r
o
n
t
I
n
j
e
c
t
o
r
C
o
i
l
T
G
S
1
5
V
S
e
n
s
o
r
G
r
o
u
n
d
1
5
V
S
e
n
s
o
r
G
r
o
u
n
d
2
C
K
P
S
e
n
s
o
r
(
+
)
V
S
S
G
r
o
u
n
d
F
r
o
n
t
O
2
S
e
n
s
o
r
5
V
S
e
n
s
o
r
P
o
w
e
r
2
1
2
V
B
a
t
t
e
r
y
S
y
s
t
e
m
P
o
w
e
r
G
r
o
u
n
d
R
e
a
r
F
u
e
l
I
n
j
e
c
t
o
r
L
G
N
/
B
K
L
G
N
/
B
N
G
Y
G
N
+
R
L
G
N
/
Y
L
G
N
/
R
R
/
O
R
/
W
+
B
K
G
Y
/
B
N
G
N
/
G
Y
G
Y
/
B
E
G
N
/
B
E
G
N
/
B
N
B
K
/
B
N
B
K
/
G
N
B
K
/
G
N
B
K
/
G
Y
G
Y
/
Y
G
N
/
Y
G
N
/
O
G
Y
/
O
B
K
/
O
BK/O
BK/O
G
Y
/
V
G
Y
/
W
G
N
/
W
B
K
/
W
B
K
/
Y
R
/
G
Y
R
/
G
N
R
/
G
N
G
N
/
V
B
K
B
K
B
K
B
K
Rear
HO2S
Front
HO2S
1
2
3
4
1
2
3
4
[138A]
[137A]
em01458
HOME
DTC P2105
POSSIBLE CAUSES
Other DTCs set
CONTROL MODULE.
DTC P2107
POSSIBLE CAUSES
ECM malfunction
1. ECM Connector Test
1. With the engine stop switch OFF, disconnect ECM [78]
and inspect for damaged, corroded or pushed out ter-
minals.
2. ECM Circuit Test
terminal 52 and ground and between terminal 72 and
ground.
CONTROL MODULE.
b. No. Repair open or high resistance in (R/GN) wire.
HOME
8.30 DTC P2119
The ECMsets DTCP2119 when it determines the throttle plate
does not return to the correct de-energized position. This error
primarily indicates there may be non-electrical conditions which
affect the throttle body range/performance. Refer to Table 8-87.
DESCRIPTION DTC
TCAsystemthrottle body range/perform-
ance
P2119
This DTC may have the following conditions:
Something may be physically interfering with the throttle
plate operation (such as foreign material, debris, physical
obstruction or loosely/improperly mounted throttle plate).
Damaged or inoperative throttle plate return spring.
Defective mechanical component(s) internal to the TCA.
DTC P2119
POSSIBLE CAUSES
Mechanical interference
1. Air Inlet Interference Test
1. Inspect the air inlet and check for foreign debris and/or
mechanical interference to the throttle plate.
2. Were any issues found?
b. No. Replace the induction module. See 4.3 INDUC-
TION MODULE.
2. Validation Test
1. Remove obstructions and foreign debris from inlet and
check throttle plate movement.
3. Start the engine and operate the throttle.
5. Did DTC P2119 set?
a. Yes. Replace the induction module. See 4.3 INDUC-
TION MODULE.
b. No. Repair complete.
HOME
8.31 DTC P2122, P2123, P2127, P2128
The TGS is an electronic assembly that replaces the conven-
tional throttle cable. Two opposing Hall-effect sensors transmit
signals to the ECM. The ECM uses these signals to determine
the desired throttle plate position. The ECM controls the motor
in the TCA to move the throttle plate to the desired position.
The TGS receives a 5V reference signal from the ECM. As the
throttle plate is opened the TGS1 signal voltage increases and
TGS2 signal voltage decreases. By design, the sum of the
voltages when measured for both TGS1 and TGS2 should
equal approximately 5.0V. If the sum of these voltages is not
5.0V, then DTCs are initiated for TGS1 and/or TGS2.
The ECMmonitors and controls the TACsystemand generates
DTCs when errors are reported by the ECM. Refer to
Table 8-89.
DESCRIPTION DTC
TGS1 low/open P2122
TGS1 high P2123
TGS2 low/open P2127
TGS2 high P2128
TPS-2
TPS-1
TGS-2
TGS-1
5V Sensor Power-1
5V Sensor Ground-2
5V Sensor Power-2
29
30
36
37
39
50
59
62
68
29
30
36
37
39
50
ET Sensor 51 51
59
62
68
ECM
6 5 4 3 2 1
TCA
6 5 4 3 2 1
6 5 4 3 2 1
Vehicle Speed Input
JSS
Ground
40
56
64
73
40
56
64
73
JSS (HDI only)
1 2 3
VSS
A
B
C
A
B
C
B
K
/
G
Y
B
K
/
W
G
N
/
O
G
N
/
W
G
Y
/
W
G
Y
/
O
G
N
/
V
GN/V
R
/
G
Y
R
/
G
Y
G
Y
/
V
GY/V
BK/GY
BK/GN
B
K
/
G
N
B
K
/
G
N
BK/W
BK/W
BK/Y
Right GND 2
[204B]
[211A]
[211B]
[65A] [65B]
ET Sensor
A
B
A
B
[90A] [90B]
[78B] [78A]
[133B]
TMAP Sensor
TMAP Sensor Input
IAT
1 2 3 4
1 2 3 4 [80A]
[80B]
B
K
/
G
Y
G
N
/
G
Y
24
49
24
49
R
/
W
R
/
W
G
Y
GN
R/W
LGN/Y
L
G
N
/
G
Y
R
/
W
GY
GN/O
GY/O
LGN/Y
GN/GY
R/W
GN
LGN/GY
GN/W
GY/W
R/GY
BK/Y
B
K
/
W
B
K
RW
B
K
RW
B
K
RW
B
K
RW
1
Y BK
2 3 4 5 6
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[204A]
em00903
HOME
DTC P2122
POSSIBLE CAUSES
Open in TGS-1 circuit
Short to ground in TGS-1 circuit
TGS malfunction
JSS malfunction
VSS malfunction
1. TGS-1 Voltage Test
GNOSTIC TOOLS.
2. TGS-1 Circuit Open Test
1. Disconnect TGS [204].
41404) and a multimeter, test for continuity between [204B]
terminal 5 and breakout box terminal 59.
b. No. Repair open in (GN/W) wire.
3. TGS-1 Short to Ground Test
ground.
a. Yes. Repair short to ground on (GN/W) wire.
4. Twist Grip Sensor Test
[204B] terminal 6.
HAND CONTROLS.
5. TGS-1 Test
1. Measure voltage between breakout box terminal 59 and
61.
2. While watching the voltage slowly turn the throttle to the
wide open position.
3. Does the voltage steadily increase to greater than 4.6V?
CONTROL MODULE.
6. TGS-1 Open Test
[204B] terminal 5.
7. Sensor Power-1 Continuity Test
[204B] terminal 6.
8. Sensor Power Resistance Test
and 61.
2. Is the resistance greater than 100 Ohms?
HAND CONTROLS.
9. TCA Test
1. Disconnect the TCA [211].
and 61.
MODULE.
10. JSS Test
HOME
and 61.
a. Yes. Replace the JSS. See the service manual.
11. VSS Test
1. Disconnect the VSS [65].
and 61.
a. Yes. Replace the VSS. See the service manual.
DTC P2123
POSSIBLE CAUSES
Short to voltage in TGS-1 circuit
TGS malfunction
GNOSTIC TOOLS.
2. TGS-1 Short to Voltage Test
b. No. Repair short to voltage in (GN/W) wire.
1. Measure voltage between [204B] terminal 6 and ground.
4. TGS Test
[204B] terminal 4.
HAND CONTROLS.
5. TGS-1 Test
61.
6. TGS-1 Open Test
2. Disconnect ECM [78A].
terminals 5 and [204B] terminal 6.
a. Yes. Repair short between (R/W) and (GN/W) wires.
b. No. Repair short to voltage in (GN/W) wire.
41404) and a multimeter, measure voltage [204B] terminal
6 and ground.
2. Measure resistance between [204B] terminal 4 and ground.
3. Is the resistance less than 2 Ohms?
HAND CONTROLS.
9. TCA Test
2. Test continuity between [204B] terminal 4 and breakout
box terminal 61.
HOME
CONTROL MODULE.
DTC P2127
POSSIBLE CAUSES
TGS malfunction
TMAP malfunction
Short to ground in sensor power circuit
GNOSTIC TOOLS.
2. TGS-2 Open Test
terminal 2 and breakout box terminal 39.
b. No. Repair open in (GY/W) wire.
ground.
a. Yes. Repair short to ground on (GY/W) wire.
4. TGS Test
[204B] terminal 3.
HAND CONTROLS.
5. TGS-2 Test
61.
2. While watching the voltage slowly turn the throttle to the
wide open position.
3. Does the voltage steadily increase to greater than 4.6V?
CONTROL MODULE.
6. TGS-2 Open Test
[204B] terminal 2.
b. No. Repair open in (GY/W) wire.
[204B] terminal 3.
b. No. Repair open in (R/GY) wire.
and 62.
HAND CONTROLS.
9. TMAP Test
1. Disconnect the TMAP [80].
and 61.
a. Yes. Replace the TMAP. See 4.3 INDUCTION
MODULE.
HOME
DTC P2128
POSSIBLE CAUSES
TGS malfunction
GNOSTIC TOOLS.
2. TGS-1 Short to Voltage Test
b. No. Repair short to voltage in (GY/W) wire.
1. Measure voltage between [204B] terminal 3 and ground.
b. No. Repair short to voltage on (R/GY) wire.
4. TGS Test
[204B] terminal 1.
HAND CONTROLS.
5. TGS-1 Test
62.
6. TGS-1 Open Test
3. Test continuity between TGS [204B] terminals 2 and 3.
a. Yes. Repair short between (R/GY) and (GY/W) wires.
b. No. Repair short to voltage in (GY/W) wire.
1. Measure voltage TGS [204B] terminal 3 and ground.
a. Yes. Repair short to voltage on (R/GY) wire.
1. Turn the engine stop switch OFF
2. Measure resistance between [204B] terminal 1 and ground.
3. Is the resistance less than 2 Ohms?
HAND CONTROLS.
9. TCA Test
2. Test continuity between [204B] terminal 1 and breakout
box terminal 62.
CONTROL MODULE.
HOME
8.32 DTC P2135, P2138
The TCA system uses DTCs when the ECM determines that
a correlation error exists for either the TP sensor or the TGS.
The two TP sensors work opposite of each other. As the throttle
plate opens, TPS1 voltage ranges from 0.0-5.0V, while TPS2
voltage ranges from5.0-0.0V. The sumof the two TPS voltages
should always measure approximately 5.0V.
The two TGSs work the same way. As the throttle plate is
opened, TGS1 voltage increases and TGS2 voltage decreases.
The sum of these two voltages should always measure
approximately 5.0V. If either component fails to correlate the
proper voltage or has out-of-range voltage conditions, then the
ECM will initiate a DTC. Refer to Table 8-94.
DESCRIPTION DTC
TPS correlation error P2135
TGS correlation error P2138
TPS-2
TPS-1
TGS-2
TGS-1
5V Sensor Power-1
5V Sensor Ground-2
5V Sensor Power-2
29
30
36
37
39
50
59
62
68
29
30
36
37
39
50
ET Sensor 51 51
59
62
68
ECM
6 5 4 3 2 1
TCA
6 5 4 3 2 1
6 5 4 3 2 1
Vehicle Speed Input
JSS
Ground
40
56
64
73
40
56
64
73
JSS (HDI only)
1 2 3
VSS
A
B
C
A
B
C
B
K
/
G
Y
B
K
/
W
G
N
/
O
G
N
/
W
G
Y
/
W
G
Y
/
O
G
N
/
V
GN/V
R
/
G
Y
R
/
G
Y
G
Y
/
V
GY/V
BK/GY
BK/GN
B
K
/
G
N
B
K
/
G
N
BK/W
BK/W
BK/Y
Right GND 2
[204B]
[211A]
[211B]
[65A] [65B]
ET Sensor
A
B
A
B
[90A] [90B]
[78B] [78A]
[133B]
TMAP Sensor
TMAP Sensor Input
IAT
1 2 3 4
1 2 3 4 [80A]
[80B]
B
K
/
G
Y
G
N
/
G
Y
24
49
24
49
R
/
W
R
/
W
G
Y
GN
R/W
LGN/Y
L
G
N
/
G
Y
R
/
W
GY
GN/O
GY/O
LGN/Y
GN/GY
R/W
GN
LGN/GY
GN/W
GY/W
R/GY
BK/Y
B
K
/
W
B
K
RW
B
K
RW
B
K
RW
B
K
RW
1
Y BK
2 3 4 5 6
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TGS
[204A]
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HOME
DTC P2135
POSSIBLE CAUSES
breakout box terminal 37 and TCA [211B] terminals 6.
61.
50.
b. No. Repair open in (GY/V) wire.
61.
50.
61.
a. Yes. Repair short to voltage on (GY/V) wire.
61.
3. Start the vehicle and operate the throttle.
MODULE.
b. No. Operation normal.
HOME
DTC P2138
POSSIBLE CAUSES
TCA malfunction
wire harness [78B] and ECM [78A] leaving [78A] discon-
nected. See 7.13 DIAGNOSTIC TOOLS
breakout box terminal 59 and [204B] terminal 5.
2. TGS-2 Circuit Test
61.
a. Yes. Repair short to ground in (GN/W) wire.
50.
a. Yes. Repair short between (GN/W) and (R/W) wires.
breakout box terminal 61 and TGS [204B] terminal 4.
61.
a. Yes. Repair short to ground in (GY/W) wire.
50.
a. Yes. Repair short between (GY/W) and (R/W) wires.
7. Sensor Ground-2 Open Circuit Test
[204B] terminal 1.
8. TGS-2 Circuit Test
61.
a. Yes. Repair short to voltage on (GY/W) wire.
61.
a. Yes. Repair short to voltage on (GN/W) wire.
1. Connect [204].
3. Start the vehicle and operate the throttle.
MODULE.
b. No. Operation normal.
HOME
8.33 DTC P2176
The ECMsets DTCP2176 when it determines the zero position
of the throttle plate has not been successfully learned.
At power up, the ECM adjusts the throttle plate to the limp-
home position, then begins to move the throttle plate closed.
The ECM monitors and verifies the amount of movement that
occurred. The throttle plate minimum position is held briefly
then verified against the expected minimum and maximum
range of throttle. If the zero position is found within range, then
the position is stored.
If the ECM is not able to learn the minimum position or if the
learning fails four consecutive ignition cycles, the ECM sets
DTC P2176. Refer to Table 8-97.
DESCRIPTION DTC
TCA close position not learned P2176
DTC P2176
POSSIBLE CAUSES
Induction module malfunction
Mechanical interference
1. Air Inlet Interference Test
1. Inspect the air inlet and check for foreign debris and/or
mechanical interference to the throttle plate.
2. Were any issues found?
b. No. Replace the induction module. See 4.3 INDUC-
TION MODULE.
2. Validation Test
1. Remove obstructions and foreign debris from inlet and
check throttle plate movement.
3. Start the engine and operate the throttle.
5. Did DTC P2176 set?
a. Yes. Replace the induction module. See 4.3 INDUC-
TION MODULE.
b. No. Repair complete.
HOME
8.34 DTC P2300, P2301, P2303, P2304
Ignition coil DTCs will set if the ignition coil primary voltage is
out of range. This could occur if there is an open coil or loss
of power to the coil. If front and rear DTCs are set simultan-
eously, it is likely a coil power failure or a coil failure. The coil
receives power from the BCM at the same time the purge
solenoid, active exhaust actuator, active intake solenoid, ECM
and injectors are activated.
DESCRIPTION DTC
Ignition coil driver low/open (front) P2300
Ignition coil driver high/shorted (front) P2301
Ignition coil driver low/open (rear) P2303
Ignition coil driver high/shorted (rear) P2304
1 2
3
ed03195
1. Ignition coil connector [83]
2. Rear spark plug cable
3. Front spark plug cable
4
3
2
1
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3. Terminal C: rear coil
4. Terminal D: front coil
Diagnostic Tips
When disconnecting any connectors always inspect connector
for corrosion or backed out terminals and repair as required.
HOME
B
K
/
G
N
B
K
/
B
N
A
A
B
A
B
L3
L3
A
B
A
B
B
C
D
A Power
Ion Sense
Coil Rear
Coil Front
B
C
D
Ignition Coil
Rear Fuel
Injector
Front Fuel
Injector
BCM
Battery Fuse
Rear
HO2S
Front
HO2S
GY/BN
BK/BN
BK/BN
GN/BN
Right
GND 2
Purge Solenoid
(Optional)
A
B
A
B
1
2
3
4
1
2
3
4
[84B] [84A]
[85B] [85A]
[95B] [95A]
[83B] [83A]
[138A]
[137A]
[242A]
[242B]
LGN/BN
GY/BE
GN/BE
R/GN
R/GN
R/GN
R/GN
R
/
G
N
R
/
G
N
R
/
G
N
GN/Y
G
N
/
Y
B
K
/
O
BK/O
BK/O
R/GR
R/GR
GY/Y
G
Y
/
Y
LGN/BK
L
G
N
/
B
K
L
G
N
/
B
N
G
N
/
B
E
G
Y
/
B
E
G
Y
/
B
N
G
N
/
B
N
R
/
O
20 23 28 33 46 48 52 53 54 66 71 72 73
20 23 28 33 46 48 52 53 54 66 71 72 73
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[78B]
[78A]
R
/
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HOME
DTC P2300
POSSIBLE CAUSES
Open power circuit
41404), measure resistance between [83A] terminals A
and D.
a. Yes. Replace the ignition coil. See the service manual.
2. Ignition Coil Input Voltage Test
1. Disconnect ignition coil [83]. Inspect the connection for
corrosion or backed out terminals.
2. With the engine stop switch ON, test for battery voltage
between ignition coil [83B] terminal A and ground.
b. No. Repair open on (R/GN) wire.
3. Ignition Coil Control Wire Continuity Test
ignition coil [83B] terminal D (GN/BE).
b. No. Repair open in (GN/BE) wire.
4. Ignition Coil Control Wire Shorted to
Ground Test
ground.
a. Yes. Repair short to ground in (GN/BE) wire.
TROL MODULE.
DTC P2301
POSSIBLE CAUSES
1. Ignition Coil Shorted to Voltage Test
1. Disconnect ignition coil [83].
41404), measure voltage between ignition coil [83B] ter-
minal D and ground.
4. Is voltage more than 1.0V?
a. Yes. Repair short to voltage in (GN/BE) wire.
2. Ignition Coil Open Test
1. Test resistance between ignition coil [83A] terminals A
and D.
2. Is resistance greater than 0.4 Ohms?
a. Yes. If ECMconnections are good, replace ECM. See
b. No. Replace ignition coil. See the service manual.
DTC P2303
POSSIBLE CAUSES
Open power circuit
41404), measure resistance between [83A] terminals A
and C.
a. Yes. Replace the ignition coil. See the service manual.
HOME
2. Ignition Coil Input Voltage Test
1. Disconnect ignition coil [83]. Inspect the connection for
corrosion or backed out terminals.
2. With the engine stop switch ON, test for battery voltage
between ignition coil [83B] terminal A and ground.
3. Ignition Coil Control Wire Continuity Test
ignition coil [83B] terminal C (GY/BE).
b. No. Repair open in (GY/BE) wire.
4. Ignition Coil Control Wire Shorted to
Ground Test
ground.
a. Yes. Repair short to ground in (GY/BE) wire.
DTC P2304
POSSIBLE CAUSES
1. Ignition Coil Shorted to Voltage Test
1. Disconnect ignition coil harness [83].
41404), measure voltage between ignition coil [83B] ter-
minal C and ground.
4. Is voltage more than 1.0V?
a. Yes. Repair short to voltage in (GY/BE) wire.
2. Ignition Coil Open Test
1. Measure resistance between ignition coil [83A] terminals
A and C.
2. Is resistance greater than 0.4 Ohms?
a. Yes. If ECMconnections are good, replace ECM. See
HOME
8.35 ENGINE CRANKS, BUT WILL NOT START
If the starter will not crank the engine, the problem is not EFI
related. See the electrical diagnostic manual.
There may be DTCs associated with this problem. Check for
DTCs and clear them before proceeding with this test.
NOTE
To set a CKP DTC, a start attempt must last at least five
seconds.
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3. Terminal C: coil rear
4. Terminal D: coil front
Figure 8-47. Ignition Coil Connector Terminals
ENGINE CRANKS BUT WILL NOT START
Table 8-104. Engine Cranks But Will Not Start Diagnostic
Faults
POSSIBLE CAUSES
Battery voltage too low
Ignition system issues
Fuel system issues
No or low compression
Electrical system issues
Open ground circuit
1. Preliminary Engine Tests
1. Make sure there is fresh fuel in tank, spark plug wires
firmly connected to coil terminals, fuel injectors are not
clogged and battery connections are in good condition.
meter Self-Diagnostics. If DTCs are present, see the
appropriate DTC procedure.
manual.
4. Does battery pass tests?
b. No. Charge or replace battery.
2. Check Engine Lamp Test
2. Does check engine lamp illuminate for four seconds
immediately after key ON?
b. No. See 8.14 DTC P0505.
3. Spark Present Test
1. Check spark plug condition and replace if fouled.
2. Using SPARK TESTER(Part No. HD-26792), check spark
at both plugs while cranking engine.
HOME
3. Is spark present?
a. Yes. Perform compression test, check fuel system
and perform fuel pressure test. See the service
manual.
b. No. The spark plugs will not spark if there is low or
no compression. If spark is not present, test compres-
sion before troubleshooting ignition circuit. Once good
compression is confirmed, check condition of ignition
coils, coil primary wiring and spark plug boots. See
8.11 DTC P0371, P0372, P0374 or 8.34 DTC P2300,
P2301, P2303, P2304.
HOME
8.36 STARTS, THEN STALLS
The starts, then stalls condition may be created by the fuel
system, the idle air control system or an ECM failure.
There may be DTCs set causing this condition. Solve the
problems with the DTCs before performing the tests in this
section. The DTCs that may be involved with starts, then stalls
are:
Fuel injectors: DTCs P0261, P0262, P0264 and P0265
Lost idle: DTC P0505
TPS: DTCs P0122 and P0123
Password Problem: DTCs P1009
ECM errors: DTCs P0603 and P0605
Diagnostic Tips
The vehicle will stall on HDI models if the jiffy stand is
extended when the transmission is in gear and the clutch
is released.
If this condition is fuel related, performFuel Pressure Test.
STARTS, THEN STALLS
Table 8-105. Starts, Then Stalls Diagnostic Faults
POSSIBLE CAUSES
Idle air control system malfunction
ECM malfunction
1. Throttle Test
2. Will engine start with the throttle partially opened and then
stall when closed?
a. Yes. See 8.14 DTC P0505.
2. Fuel System Test
1. Perform Fuel Pressure test. See the service manual.
2. Is fuel pressure normal?
a. Yes. If fuel injectors are okay, then continue with tests.
Go to Test 3.
b. No. Repair fuel pressure problem. See the service
manual.
3. System Power Test
breakout box terminal 52 and ground.
a. Yes. Inspect connections at ECM. If connections are
good, replace the ECM. See 8.2 ELECTRONIC
CONTROL MODULE.
HOME
8.37 MISFIRE AT IDLE OR UNDER LOAD
Misfire conditions may be caused by:
Battery condition and connections.
Fuel system problems. Refer to Table 8-1, Table 8-2 and
Table 8-3.
Ignition system faults.
Diagnostic Tips
Wipe up spilled fuel and dispose of rags in a suitable
manner. An open spark around gasoline could cause a
fire or explosion, resulting in death or serious injury.
(00518b)
When performing the steps in the diagnostic tests, a known
good part can be used to verify whether a suspected part is
faulty. The ignition coil does not require full installation to be
functional. Verify faulty ignition coil by performing resistance
test. See 8.34 DTC P2300, P2301, P2303, P2304.
ed02012
IN-LINE SPARK TESTER
SNAP-ON IN-LINE SPARK TESTER YA840
See Figure 8-49. The use of a SNAP-ON IN-LINE SPARK
TESTER (Part No. YA840) or equivalent can help determine
whether a problem exists in the ignition or fuel systems. If the
test light flashes without interruption on both cylinders during
the misfire event, verify spark plug condition and gap and
inspect the fuel system for proper operation. If the test light
does not flash, or the flash is interrupted during the misfire
event, the problem is ignition related.
2. Remove front spark plug wire and install SNAP-ON IN-
LINE SPARK TESTER (Part No. YA840) between spark
plug wire and spark plug.
3. Start engine and inspect tester light. The light will flash on
each spark event if power is transmitted to the plug.
4. Install and repeat procedure on rear cylinder.
NOTE
A SNAP-ON IN-LINE SPARK TESTER (Part No. YA840) can
also be used in conjunction with a load applying dynamometer
to diagnose misfire under load.
ed01780
Figure 8-49. In-line Spark Tester
HOME
BK/Y
G
N
/
W
B
K
/
WB
K
/
W
R
B
K
/
G
Y
B
K
/
G
Y
R
/
W
A
A
B
A
B
A
B
A
B
B
C
D
A Power
Ion Sense
Coil Rear
Coil Front
B
C
D
CKP
Sensor
ET
Sensor
TCA
TMAP
Sensor
Ignition Coil
VSS
JSS
Rear Fuel
Injector
Front Fuel
Injector
L3 L3 BCM
6 5 4 3 2 1
1 2
1 2
6 5 4 3 2 1
1
A
B
C
A
B
C
2
A B
A B
3 4
1 2
Front ACR
(If Equipped)
2 1
2 1
3 4
6 5 4 3 2 1
GY/BN
BK/BN
BK/BN
GN/BN
Right
GND 2
R
/
G
N
R
/
G
N
R
/
G
N
Purge Solenoid
(Optional)
A
B
A
B
[79A]
[79B]
[204B]
[90A]
[90B]
[203AF]
[203BF]
Rear ACR
(If Equipped)
2 1
2 1
[211A]
[211B]
[80A]
[80B]
[65A] [65B]
B
K
B
K
/
W
G
N
/
O
G
Y
/
V
G
N
/
V
[84B] [84A]
[85B] [85A]
[95B] [95A]
[83B] [83A]
[203AR]
[203BR]
[242B] [242A]
R/GN
R/GN
GN/Y
GY/Y
R/GN
R/GN
R/GN
R/GN
R/GN
LGN/BN
GY/BE
GN/BE
LGN/BK
G
Y
/
O
R
/
W
G
Y
/
W
G
N
G
N
/
G
Y
R
/
G
Y
R
/
G
Y
G
Y
L
G
N
/
R
L
G
N
/
R
L
G
N
/
R
R/W
LGN/Y
Battery
Fuse
ECM
[78B]
[78A]
19 20 23 24 28 29 30 33 36 37 39 40 43 46 48 49 50 51 52 53 54 59 61 62 63 64 66 68 71 72 73
19 20 23 24 28 29 30 33 36 37 39 40 43 46 48 49 50 51 52 53 54 59 61 62 63 64 66 68 71 72 73
P
u
r
g
e
S
o
l
e
n
o
i
d
A
C
R
G
r
o
u
n
d
B
K
RW
B
K
RW
B
K
RW
B
K
RW
1
Y BK
2 3 4 5 6
G
r
o
u
n
d
T
G
S
2
T
G
S
1
P
o
w
e
r
5
V
S
e
n
s
o
r
G
r
o
u
n
d
1
5
V
S
e
n
s
o
r
P
o
w
e
r
1
TGS
[204A]
T
M
A
P
S
e
n
s
o
r
I
n
p
u
t
F
r
o
n
t
F
u
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l
I
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j
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c
t
o
r
T
G
S
H
i
g
h
T
G
S
L
o
w
31
31
5
V
S
e
n
s
o
r
G
r
o
u
n
d
I
o
n
S
e
n
s
e
T
C
A
-
T
P
S
2
T
C
A
-
T
P
S
1
T
G
S
2
V
S
S
I
n
p
u
t
C
K
P
S
e
n
s
o
r
(
-
)
R
e
a
r
O
2
S
e
n
s
o
r
O
2
R
e
t
u
r
n
T
M
A
P
-
I
A
T
5
V
S
e
n
s
o
r
P
o
w
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r
1
E
T
S
e
n
s
o
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S
y
s
t
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m
P
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w
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r
R
e
a
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I
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j
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c
t
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C
o
i
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F
r
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I
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j
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c
t
o
r
C
o
i
l
T
G
S
1
5
V
S
e
n
s
o
r
G
r
o
u
n
d
1
5
V
S
e
n
s
o
r
G
r
o
u
n
d
2
C
K
P
S
e
n
s
o
r
(
+
)
V
S
S
G
r
o
u
n
d
F
r
o
n
t
O
2
S
e
n
s
o
r
5
V
S
e
n
s
o
r
P
o
w
e
r
2
1
2
V
B
a
t
t
e
r
y
S
y
s
t
e
m
P
o
w
e
r
G
r
o
u
n
d
R
e
a
r
F
u
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l
I
n
j
e
c
t
o
r
L
G
N
/
B
K
L
G
N
/
B
N
G
Y
G
N
+
R
L
G
N
/
Y
L
G
N
/
R
R
/
O
R
/
W
+
B
K
G
Y
/
B
N
G
N
/
G
Y
G
Y
/
B
E
G
N
/
B
E
G
N
/
B
N
B
K
/
B
N
B
K
/
G
N
B
K
/
G
N
B
K
/
G
Y
G
Y
/
Y
G
N
/
Y
G
N
/
O
G
Y
/
O
B
K
/
O
BK/O
BK/O
G
Y
/
V
G
Y
/
W
G
N
/
W
B
K
/
W
B
K
/
Y
R
/
G
Y
R
/
G
N
R
/
G
N
G
N
/
V
B
K
B
K
B
K
B
K
Rear
HO2S
Front
HO2S
1
2
3
4
1
2
3
4
[138A]
[137A]
em01458
HOME
MISFIRE AT IDLE OR UNDER LOAD
Table 8-106. Misfire At Idle or Under Load Diagnostic
Faults
POSSIBLE CAUSES
Ignition system issues
Fuel system issues
Electrical system issues
1. Power Ground Continuity Test
GNOSTIC TOOLS.
41404) and a multimeter, check for continuity between
breakout box terminal 73 to ground.
b. No. Repair poor ground on (BK/GN) wire.
2. Spark Test
1. Connect SNAP-ON IN-LINE SPARK TESTER (Part
No. YA840) between front spark plug cable and ground.
See 7.13 DIAGNOSTIC TOOLS.
2. Crank engine for a few seconds.
3. Remove tester from front spark plug cable and connect
rear spark plug cable and ground.
4. Did spark jump gap on both cables?
a. Yes. Check for faulty, worn or cracked spark plugs,
plug fouling due to mechanical problems or faulty
connection at plug or coils. See the service manual
and repair as required.
3. Spark Plug Wire Test
1. Disconnect the spark plug wires.
2. Measure the resistance of the spark plug wires.
3. Is the front and rear spark plug wire resistance within the
specified range? Refer to Table 8-63.
b. No. Replace the out of range spark plug wire. See
the service manual.
4. Carbon Tracking Inspection Test
1. Inspect top of ignition coils for carbon tracking.
2. Is carbon tracking present?
a. Yes. Switch ignition coil with known good unit and
perform Test 2. If spark jumps gap, replace ignition
coil. See the service manual. If not, then continue with
tests. Go to Test 5.
5. Ignition Coil Primary Wire Continuity Test
GNOSTIC TOOLS.
4. Measure resistance between breakout box terminal L3
and [83B] terminal A. Wiggle connectors while measuring.
5. Is resistance continuously less than 0.5 Ohms?
b. No. Repair intermittent open on (R/GN) wire.
6. Battery to Main Fuse Block Voltage Drop
1. With engine running, measure voltage drop between bat-
tery (+) and main fuse [64B] terminal A.
2. Is voltage drop more than 1.0V?
a. Yes. Repair (R) wire between terminal A of [64B] and
connection at battery including connections at starter.
b. No. Check for corrosion or damage at the BCM[259].
HOME
TABLE OF CONTENTS
SUBJECT............................................................................................................................PAGE NO.
A.1 CONNECTORS.........................................................................................................................A-1
A.2 WIRING DIAGRAMS.................................................................................................................A-4
A
P
P
E
N
D
I
X
A
W
I
R
I
N
G
NOTES
A.1 CONNECTORS
CONNECTOR LOCATIONS
Function/Location
All vehicle connectors are identified by their function and loca-
tion. Refer to Table A-1.
Place and Color
The place (number of wire cavities of a connector housing)
and color of the connector can also aid identification.
Connector Number
On wiring diagrams and in service/repair instructions, con-
nectors are identified by a number in brackets.
Repair Instructions
The repair instructions in Appendix A are by connector type.
Refer to Table A-1.
Table A-1. Connector Locations
LOCATION TERMINAL
PROBE
COLOR
TYPE DESCRIPTION NO.
Under seat Gray 4-place Tyco 070 Multilock
Unsealed (Gray)
Right rear lighting [18]
Inside tail lamp lens Gray 2-place Tyco 070 Multilock
Unsealed (BK)
Right rear turn signal [18C/D]
Unsealed (Gray)
Left rear lighting [19]
Inside tail lamp lens Gray 12-place Tyco 070 Multilock
Unsealed (BK)
Left rear turn signal [19C/D]
Under fuel tank, left side Gray 8-place Molex MX 150 Sealed
(BK)
Console harness [20]
Under fuel tank, right side Yellow 4-place JAEMX19 Sealed (BK) Right hand controls [22-1]
Under fuel tank, right side Yellow 2-place JAEMX19 Sealed (BK) Right hand controls [22-2]
Under fuel tank, left side Yellow 4-place JAEMX19 Sealed (BK) Left hand controls [24]
Headlamp shell assembly Gray 2-place Running/position lamp [29]
Inside top frame tube Gray 3-place Tyco 070 Multilock
Unsealed (BK)
Right directional and DOMrun-
ning lamps
[31L]
Inside top frame tube Gray 3-place Tyco 070 Multilock
Unsealed (BK)
Right directional and DOMrun-
ning lamps
[31R]
Under fuel tank, left side Gray 4-place Tyco 070 Multilock
Unsealed (BK)
Headlamp [38]
Headlamp shell assembly Gray 3-place Tyco Unsealed Spade
(BK)
Headlamp [38-2]
Under console Breakout Box 12-place Delphi Micro 64
Sealed (GY)
Speedometer [39]
Unsealed (BK)
Tail lamp [40]
Back of voltage regulator 3-place Dekko (BK) Voltage regulator to stator [47]
Under seat Gray/Red Delphi 280 Metripack Sealed Fuse block [64]
Delphi 800 Metripack Sealed
(main fuse)
Top of transmission case Gray 3-place Delphi GT 150 Sealed
(BK)
VSS [65]
Back of voltage regulator 2-place Dekko (BK) Voltage regulator [77]
Under seat Breakout Box 73-place Delphi Micro 64
Sealed (BK)
ECM [78]
Back of voltage regulator bracket Brown 2-place Deutsch DTM Sealed
(BK)
CKP sensor [79]
HOME
2013 FXSBSE Service Supplement: Appendix A Wiring A-1
LOCATION TERMINAL
PROBE
COLOR
Top of induction module Orange 4-place Bosch Compact 1.1
Sealed (BK)
TMAP sensor [80]
Back of coil Gray 4-place Delphi GT 150 Sealed
(BK)
Ignition coil [83]
Beneath fuel tank Purple 2-place Molex BPT Sealed
(GY)
Front fuel injector [84]
Beneath fuel tank Purple 2-place Molex BPT Sealed
(GY)
Rear fuel injector [85]
Back of front cylinder, left side Gray 2-place Delphi GT 150 Sealed
(BK)
ET sensor [90]
Under seat Black 6-place Deutsch DT Sealed
(GY)
DLC [91]
Circuit board under tail lamp
assembly
Gray 6-place Tyco 070 Multilock
Unsealed (BK)
Rear fender lights harness in
circuit board
[94]
Electrical panel behind fender
extension
Purple 2-place Delphi 150 Metripack
Sealed (BK)
Purge solenoid [95]
Left front side of fuel tank Gray 4-place Tyco 040 Unsealed
(BK)
Fuel gauge [117]
Front right crankcase Right Angle Push On Molded
(BK)
Oil pressure switch [120]
Right side of transmission Red Tyco Insulated Spade terminal
(BK)
Rear stop lamp switch [121]
Between cylinders, left side Red Flag terminals (BK) Horn [122]
Top of starter Red Tyco Insulated Spade terminal
(W)
Starter solenoid [128]
Top of transmission Right Angle Push On Molded
(BK)
Neutral switch [131]
Back of voltage regulator bracket Gray 3-place Molex MX 150 Sealed
(BK)
JSS [133]
Under oil tank Gray 4-place Molex MX 150 Sealed
(BK)
Rear HO2 sensor [137]
Behind voltage regulator Gray 4-place Molex MX 150 Sealed
(BK)
Front HO2 sensor [138]
Top of fuel tank Gray 4-place Delphi GT 150 Sealed
(BK)
Fuel pump and sender [141]
extension
Gray 3-place Delphi GT 150 Sealed
(BK)
Security siren [142]
Under seat Breakout Box 20-place Molex MX 150 Sealed
(BK)
ECU [166]
Under fuel tank, left side Gray 2-place Delphi 150 Metripack
Sealed (BK)
Front WSS [167]
extension
Gray 2-place Delphi 150 Metripack
Sealed (BK)
Rear WSS [168]
Bracket attached to the induction
module
Gray 2-place Tyco Superseal 1.5
Sealed
ACR (front) [203F]
Bracket attached to the induction
module
Gray 2-place Tyco Superseal 1.5
Sealed
ACR (rear) [203R]
Under fuel tank, right side Gray 6-place Molex MX 150 Sealed
(BK)
TGS [204]
HOME
A-2 2013 FXSBSE Service Supplement: Appendix A Wiring
LOCATION TERMINAL
PROBE
COLOR
Under seat Gray 2-place Molex MX 64 Unsealed
(BK)
Security antenna [209]
Right side of engine (induction
module)
Gray 6-place Molex MX 150 Sealed
(BK)
TCA [211]
extension
Breakout Box 48-place Molex CMC Sealed
(BK)
BCM [242]
Right front fork brackets Gray 4-place Delphi GT 150 Sealed
(BK)
Front HCU [254]
Below electrical panel behind fender
extension
Gray 4-place Delphi GT 150 Sealed
(BK)
Rear HCU [255]
extension
Breakout Box 1-place Delphi 800 Metripack
Sealed (BK)
BCM battery power [259]
Handle bars Gray 2-place Deutsch DTM Sealed LED console [277]
Under seat Ring terminals Left side ground stud [GND1]
Right side transmission housing Ring terminal Right side ground stud [GND2]
Anti-theft tracking module
ground
[GND3]
HOME
A.2 WIRING DIAGRAMS
WIRING DIAGRAM INFORMATION
Wire Color Codes
Wire traces on wiring diagrams are labeled with alpha codes.
Refer to Table A-2.
For Solid Color Wires: See Figure A-1. The alpha code
identifies wire color.
For Striped Wires: The code is written with a slash (/) between
the solid color code and the stripe code. For example, a trace
labeled GN/Y is a green wire with a yellow stripe.
Wiring Diagram Symbols
See Figure A-1. On wiring diagrams and in service/repair
instructions, connectors are identified by a number in brackets
[ ]. The letter inside the brackets identifies whether the housing
is a socket or pin housing.
A=Pin: The letter A and the pin symbol after a connector
number identifies the pin side of the terminal connectors.
B=Socket: The letter Band the socket symbol after a connector
number identifies the socket side of the terminal connectors.
Other symbols found on the wiring diagrams include the fol-
lowing:
Diode: The diode allows current flow in one direction only in
a circuit.
Wire break: The wire breaks are used to showoption variances
or page breaks.
No Connection: Two wires crossing over each other in a wiring
diagram that are shown with no splice indicating they are not
connected together.
Circuit to/from: This symbol indicates a more complete circuit
diagram on another page. The symbol is also identifying the
direction of current flow.
Splice: Splices are where two or more wires are connected
together along a wiring diagram. The indication of a splice only
indicates that wires are spliced to that circuit. It is not the true
location of the splice in the wiring harness.
Ground: Grounds can be classified as either clean or dirty
grounds. Clean grounds are identified by a (BK/GN) wire and
are normally used for sensors or modules.
NOTE
Clean grounds usually do not have electric motors, coils or
anything that may cause electrical interference on the ground
circuit.
Dirty grounds are identified by a (BK) wire and are used for
components that are not as sensitive to electrical interference.
Twisted pair: This symbol indicates the two wires are twisted
together in the harness. This minimizes the circuit's electromag-
netic interference from external sources. If repairs are neces-
sary to these wires they should remain as twisted wires.
9
12
13
1 2
1 2
8
11
10
7
6
5
3 4
W
W
G
N
/
Y
G
N
/
Y
1 2
1 2
[21A]
[21B]
ed03175
1. Connector number
2. Terminal code (A=pin, B=socket)
3. Solid wire color
4. Striped wire color
5. Socket symbol
6. Pin symbol
7. Diode
8. Wire break
9. No connection
10. Circuit to/from
11. Splice
12. Ground
13. Twisted pair
Figure A-1. Connector/Wiring Diagram Symbols
1
A B
2 3 4
4
3
1 2
ed03169
1. Battery
2. P&A
3. Main
4. Fuse block [64]
Figure A-2. Fuse Block and Socket Terminals
HOME
Table A-2. Wire Color Codes
WIRE COLOR ALPHA CODE
Blue BE
Black BK
Brown BN
Green GN
Gray GY
Light Green LGN
Orange O
Pink PK
Red R
Tan TN
Violet V
White W
Yellow Y
HOME
WIRING DIAGRAMS
Wiring Diagram List
LOCATION DIAGRAM
Figure A-3 Battery Power Distribution
Figure A-4 Ignition and Accessory Power Distribution
Figure A-5 Sensor Grounds
Figure A-6 Ground Circuit
Figure A-7 Main Wiring Harness (1 of 2): 2013 FXSBSE
Figure A-8 Main Wiring Harness (2 of 2): 2013 FXSBSE
Figure A-9 Lighting: 2013 FXSBSE
HOME
Fuse
Block
ECU
(ABS Only)
GND 1
Battery
DLC
ECM
Voltage
Regulator
BCM
Starter
Stud
Left
Hand
Controls
11
6
1 1
20
11 20
R
/
B
E
R/O
R/O
R
/
O
BK R R
R
R
R
R
R
RRR
Right
Hand
Controls
1 1
5 5
R/O
[77A]
[77B]
[91A]
[24A] [24B]
71 71
[78A] [78B]
R
/
O
R/O R/O
1
P
P
1
[22A-1] [22B-1]
R/O
R/O
R/O
Security
Siren
1
1
A
B
[259B] [259A]
[20B] [20A] [39B] [39A]
Speedometer 5 5
R/O
Indicator
Lamps
[64B]
Main
40A
1
2
Battery
15A
3
4
P&A
15A
[142B]
[142A]
em01463
Figure A-3. Battery Power Distribution
HOME
R
R
W
W
W
[120B] [120A]
E3 J3 L3 M2 F4
O
i
l
P
r
e
s
s
u
r
e
S
w
i
t
c
h
I
n
p
u
t
F
u
e
l
P
u
m
p
P
o
w
e
r
R
u
n
n
i
n
g
L
i
g
h
t
P
o
w
e
r
S
y
s
t
e
m
P
o
w
e
r
F
r
o
n
t
R
u
n
n
i
n
g
/
F
o
g
L
i
g
h
t
P
o
w
e
r
A
c
c
e
s
s
o
r
y
P
o
w
e
r
B
a
t
t
e
r
y
P
o
w
e
r
BCM
Battery
Power
Distribution
1
E3 J3 L3
L4
L4 M2 F4 1
B
E
B
E
/
B
K
BE/BK
R
/
B
N
R
/
G
N
R
/
G
N
R/GN
R/GN
R/GN
R/GN
R/GN
R/GN
R
/
Y
R/Y R/Y
R/Y
O/W O/W
W
/
O
R/BN R/BN
W/O
[259A]
[259B]
[242A]
[242B]
1 1
Oil
Pressure
Switch
[141B] [141A]
1 1
Fuel
Pump
[200B] [200A]
1 1
Resistor
Assembly
[84B] [84A]
[38B] [38A]
[91A]
A A
Front Fuel
Injector
[85B] [85A]
A
A
A
A
Rear Fuel
Injector
R/GN
R/GN
1 1
Front HO2S
1 1
Rear HO2S
Ignition
Coil
DOM
Canada
HDI
BE
BE
BE
[83B]
[83A]
[95A] [95B]
[18A]
A A
Purge
Solenoid
1 1
Position
Lamp
DLC
[78A] [78B]
R/GN 52 52
72 72
ECM
[203AF] [203BF]
1 1
Front
ACR
[203AR] [203BR]
[138A] [138B]
[137A] [137B]
1 1
Rear
ACR
1 1
[20B] [20A]
6 6
5
[19A]
1
1
[19A]
1
Left
Tail
Lamp
Right
Tail
Lamp
LP
Lamp
BK
B
K
B
K
BK
B
E
B
E
BE
BE
[19B]
1
[40B]
1
[18B]
1
Left
Tail
Lamp
Right
Tail
Lamp
LP/
Stop/Tail
B
E
B
E
B
E
BE
BE
BE
[19B]
1
[40B]
1
[18B]
1
Left
Tail
Lamp
Right
Tail
Lamp
LP
Lamp
B
E
[19B]
1
[40B]
1
[18B]
1
BK
BK
em01465
Figure A-4. Ignition and Accessory Power Distribution
HOME
B
K
/
G
N
B
K
/
G
N
B
K
/
G
N
BK/GN BK/GN
BK/GN
BK/GN BK/GN
[65B] [65A]
[78B] [78A]
GND 1 Battery
BK
BK
Speedometer
Resister
Assembly
[39A]
[39B]
[200A]
[200B]
BK/GN
BK/GN
BK/GN
BK/GN
Fuel
Pump
C
C
C C
[22A-1] [22B-1]
JSS 3 3
BCM G4 G4
RHCM 2 2
BK/GN BK/GN
[24A] [24B]
[13A] [13B] [141A] [141B]
[242A] [242B]
[133A] [133B]
LHCM 2 2
VSS C C
ECM
73 73
[20B] [20A]
2 2 3 3
7
7
BK/GN
em01464
Figure A-5. Sensor Grounds
HOME
[166B] [166A]
[91A]
Canada DOM/HDI
DLC
B
K
B
K
B
K
B
K
B
K
BK
BK
BK BK BK
D
D
[141A]
[141B]
2
Rear HCU
[255A]
[255B]
Fuel
Pump
D
D
[13A]
[13B] 1
1
[18A]
[18A]
[40A] 4
4
4 3
[77A] [77B]
Headlamp
1 1
BK
B
K
B
K
B
K
B
K
Position Lamp
1 1
Horn
1 1
[122A-2] [122B-2]
[121A-2] [121B-2]
Rear Brake
Switch
1 1 BK BK
[142A] [142B]
Security Siren
3 3 BK
[131B-2] [131A-2]
BK
Neutral
Switch
1 1
ABS
ECU
6 6
[38B] [38A]
4 4
GND 2
BK
Voltage
Regulator
N N
Right
Rear
Turn
Signal
[18A]
4
B
K
Right
Rear
Turn
Signal
[40A]
3
B
K
LP
Lamp
[40A]
3
B
K
LP/
Stop/Tail
4
B
K
Left
Rear
Turn
Signal
[19A]
[19A]
4
B
K
Left
Rear
Turn
Signal
[19A]
em01466
Figure A-6. Ground Circuit
HOME
CAN Low
CAN High
High Beam Indicator
Battery Fuse
Neutral Indicator
Ground
Fuel Level
Left Turn Indicator
Left Turn Indicator
High Beam Indicator
Neutral Indicator
Battery Fuse
Speedometer
Indicator
Lamps
B
K
/G
N
BK/GN
BK/GN
L
G
N
/R
L
G
N
/R
L
G
N
/R
G
Y
/B
N
GY/BN
G
Y
/B
E
G
Y
/B
E
G
N
/B
E
BE/BK
G
N
/B
N
GN/BN
BK/BN
BK/GN
B
K
/G
N
B
K
/B
N
B
K
/G
Y
B
K
/G
Y
B
K
/G
Y
G
N
/G
Y
G
N
/G
Y
L
G
N
/Y
LGN/Y
L
G
N
/B
K
LGN/BK
L
G
N
/G
Y
LGN/GY
L
G
N
/B
N
L
G
N
/B
N
G
Y
/Y G
Y
/Y
G
N
/Y
B
K
/O
BK/O
O/BK
O/BE
O/BK
O/BE
W
/B
K
BE/W
BE/Y
BE/R
W/BK
W/GY
W
/G
Y
R/BN
B
K
/W B
K
/W
B
K
/W
B
K
/W
B
K
/Y
BK/Y
G
N
/O
G
N
/O
G
N
/V
G
N
/W
G
N
/W
G
N
/R
G
N
/R
G
N
/R
GN/R
G
N
/R
G
N
/R
R
/G
Y
R
/G
Y
R
/G
Y
R
/G
N
G
Y
/O
G
Y
/O
G
Y
/V
G
N
/V
G
Y
/V
G
Y
/W
G
Y
/W
B
K
B
K
B
K
G
Y
G
Y
B
K
BK
BK
B
K
B
K
BE
G
N
G
N
/B
E
G
N
B
K
W
/R
R
/W
R
/W
R
/W
R/W
R/V
R
/V
R/Y
B
E
/R
B
E
/R
R
/B
E
R
/Y
W/R
W
/B
K
W
/R
W
/B
K
W
/R
R/O
R
/O
R
/O
R
/O
R
BK/GN
BK/GN
B
K
/G
N
B
K
/G
N
B
K
/G
N
BK/GN
BE/PK
BE/PK
BE/BK
GN/Y
W/BK
BE/W
BE/Y
BE/W
BE/W
BE/O
BE/O
R/GN
BK
B
K
B
K
B
K
B
K
BK
BK
W/R
W/BK
W
/B
K
W
/B
K
W/R
W
/R
W
/R
W/Y
W
/Y
W
/Y
W
/Y
W/O
W/Y
W/O
R/O
R/O
R
/O
R
/O
R/O
R
R R
R
R
W
W
WB
K
R W
B
K
R WB
K
R W
R
R
R
R
[91A]
[20A]
[20B]
[13A]
[13B]
[204A]
[204B]
[203A]
[203B]
[80A]
[80B]
[211A]
[211B]
[203AR]
[203BR]
[141A]
[141B]
[24A]
[38A]
4
3
2
1
B
A
[78B]
[78A]
[122B-1]
[122A-1]
[90B]
[90A]
[85B]
[85A]
[83B]
[83A]
[122B-2]
[122A-2]
[22A-1] [22A-2]
[200B] [200A]
[167B] [167A]
[84B] [84A]
[39B] [39A]
8
2
4
5
6
7
1
9
10
12
8
2
4
5
6
7
1
9
10
12
A B C D
A B C D
F
u
e
l
P
u
m
p
P
o
w
e
r
F
u
e
l
L
e
v
e
l
S
e
n
d
e
r
S
e
n
d
e
r
G
ro
u
n
d
P
u
m
p
G
ro
u
n
d
Fuel
Pump
RHCM
TGS
G
ro
u
n
d
T
G
S
2
T
G
S
1
P
o
w
e
r
5
V
S
e
n
s
o
r
G
ro
u
n
d
1
5
V
S
e
n
s
o
r
P
o
w
e
r
1
Y BK
2 3 4 1 5 6
2 3 4 1 5 6
4 2 6 3 1
4 2 6 3 1
1 2 3 4
1 2 3 4
1 2 3 4 1
Front ACR
G
ro
u
n
d
P
o
w
e
r
2 1
2 1
G
ro
u
n
d
P
o
w
e
r
IA
T
S
e
n
s
o
r
O
u
tp
u
t
2 4 3 1
2 4 3 1
2 3 4 1 5 6
2 3 4 1 5 6
G
ro
u
n
d
T
P
S
L
o
w
T
P
S
H
ig
h
T
P
S
2
T
P
S
1
P
o
w
e
r
TMAP Sensor TCA Rear ACR
2 1
2 1
G
ro
u
n
d
P
o
w
e
r
36
36 200
3
6
1
2
3
1
2
3
Resistor
Assembly
GND 1
A
B
A
B
Front WSS High
Front WSS Low
Front
WSS
LHCM
1
2
3
4
4
3
2
1
See Front
Lighting
A
B
A
B Front Fuel Injector
System Power
Front Fuel
Injector
P
u
rg
e
S
o
le
n
o
id
A
C
R
G
ro
u
n
d
C
P
A
T
e
th
e
r
T
M
A
P
S
e
n
s
o
r
In
p
u
t
F
ro
n
t
F
u
e
l
In
je
c
to
r
T
C
A
H
ig
h
T
C
A
L
o
w
5
V
S
e
n
s
o
r
G
ro
u
n
d
Io
n
S
e
n
s
e
T
C
A
-T
P
S
2
T
C
A
-T
P
S
1
T
G
S
2
V
S
S
In
p
u
t
C
A
N
H
ig
h
C
A
N
L
o
w
C
K
P
S
e
n
s
o
r
(-)
R
e
a
r
H
O
2
S
e
n
s
o
r
H
O
2
R
e
tu
r
n
T
M
A
P
-IA
T
5
V
S
e
n
s
o
r
P
o
w
e
r
1
E
T
S
e
n
s
o
r
S
y
s
te
m
P
o
w
e
r
R
e
a
r
Ig
n
itio
n
C
o
il
F
ro
n
t
Ig
n
itio
n
C
o
il
J
S
S
C
P
A
T
e
th
e
r
T
G
S
1
5
V
S
e
n
s
o
r
G
ro
u
n
d
1
5
V
S
e
n
s
o
r
G
ro
u
n
d
2
C
K
P
S
e
n
s
o
r
(+
)
V
S
S
G
ro
u
n
d
F
ro
n
t
H
O
2
S
e
n
s
o
r
5
V
S
e
n
s
o
r
P
o
w
e
r
2
1
2
V
B
a
tte
r
y
S
y
s
te
m
P
o
w
e
r
G
ro
u
n
d
R
e
a
r
F
u
e
l
In
je
c
to
r
18 19 20 23 24 28 29 30 33 36 37 39 40 41 42 43 46 48 49 50 51 52 53 54 56 57 59 61 62 63 64 66 68 71 72 73 31
18 19 20 23 24 28 29 30 33 36 37 39 40 41 42 43 46 48 49 50 51 52 53 54 56 57 59 61 62 63 64 66 68 71 72 73 31
ECM DLC
1 2 3 4 5 6
Fuse
Block
[64B]
P&A
15A
Battery
15A
Main
40A
A B C D
A B C D
R
e
a
r
Ig
n
itio
n
C
o
il
S
y
s
te
m
P
o
w
e
r
IO
N
S
e
n
s
e
F
ro
n
t
Ig
n
itio
n
C
o
il
Ignition
Coil
Horn Rear
Fuel Injector
ET
Sensor
E
T
S
e
n
s
o
r
G
ro
u
n
d
H
o
r
n
P
o
w
e
r
S
y
s
te
m
P
o
w
e
r
R
e
a
r
F
u
e
l
In
je
c
to
r
5
V
S
e
n
s
o
r
G
ro
u
n
d
A B
A B
A B
A B
1
1
1
1
S
e
e
M
a
in
H
a
r
n
e
s
s
(
2
o
f
2
)
et00561
Figure A-7. Main Wiring Harness (1 of 2): 2013 FXSBSE
Figure A-7. Figure A-7.
Main Wiring Harness (1 of 2): 2013 FXSBSE Main Wiring Harness (1 of 2): 2013 FXSBSE
CKP Sensor
Low
CKP Sensor
High
B
K
B
K
B
K
W R
/B
K
L
G
N
/Y
R
/W
R
/G
N
B
K
/Y
L
G
N
/B
K
B
K
R
O
/B
N
O
/P
K
B
K
O
/Y
O
/V
O
/W
R
R
R
O
/G
N
O
/G
Y
B
K
O
/R
O
/G
N
O
/B
N
O
/G
Y
O
/B
K
O
/P
K
O
/B
E
W
/B
K
B
K
O
/R
O
/W
W
/R
O
/Y
O
/V
R R
BE/Y
BE/GN
BK
GY
BK
BK
W/O
LGN/GY
R/W
BK
R/GN
BK
GN/BN
BK/BN
BK/GN
R
R
W
W
V
BK/O
G
Y
/B
N
B
K
/B
N
B
E
B
E
B
E
/R
B
E
/R
B
E
/R
B
E
/V
B
E
/B
N
VW
R
/G
N
B
E
B
K
B
K
/O
W/R
W/BK
W/GY
R/Y
R/O
R
/O
R/W
R/V
O/BE
BE/W
O/BK
BE/R
R/BN
BK/O
LGN/BK
LGN/Y
LGN/GY
GY/BN
GN/BN
BE/BK
BK/BN
BK/GN
R
R
R
R
BK
BE
BK
R/GN
BK/Y
B
K
B
K
B
K
B
K
B
K
B
K
B
K
B
K
B
K
B
K
B
K
B
K
BK
B
E
/R
B
E
B
E
/G
N
B
E
/V
B
E
/B
N
B
E
/B
K
B
K
/G
N
R
/B
N
R
/G
N
R
/B
K
W
/G
Y
R
/V
W
/B
K
B
E
/W
B
E
/Y
W
/G
N
W
/G
N
W
/R
R
/Y
R
/Y
W
/O R
R
R W
2 1
2 1 1 3 2 4
1 3 2 4
S
e
c
u
r
ity
A
n
te
n
n
a
L
o
w
S
e
c
u
r
ity
A
n
te
n
n
a
H
ig
h
Security
Antenna
Rear O2
Sensor
S
y
s
te
m
P
o
w
e
r
O
2
R
e
tu
r
n
G
ro
u
n
d
R
e
a
r
O
2
S
e
n
o
r
O
2
R
e
tu
r
n
System
Power
See Rear Lighting
S
ta
r
t
E
n
a
b
le
S
e
c
u
r
ity
R
F
A
n
te
n
n
a
S
e
c
u
r
ity
A
n
te
n
n
a
L
o
w
E
n
g
in
e
S
to
p
S
w
itc
h
In
p
u
t
C
A
N
H
ig
h
N
e
u
tra
l
S
w
itc
h
In
p
u
t
C
A
N
L
o
w
O
il
P
re
s
s
u
re
S
w
itc
h
In
p
u
t
H
o
r
n
P
o
w
e
r
B
ra
k
e
S
w
itc
h
In
p
u
t
F
u
e
l
P
u
m
p
P
o
w
e
r
G
ro
u
n
d
S
e
c
u
r
ity
S
ire
n
R
u
n
n
in
g
L
ig
h
t
P
o
w
e
r
R
ig
h
t
R
e
a
r
T
u
r
n
S
ig
n
a
l
B
ra
k
e
L
ig
h
t
P
o
w
e
r
L
e
ft
R
e
a
r
T
u
r
n
S
ig
n
a
l
S
ta
r
te
r
S
o
le
n
o
id
P
o
w
e
r
S
y
s
te
m
P
o
w
e
r
F
ro
n
t
R
u
n
n
in
g
/F
o
g
L
ig
h
t
P
W
R
A
c
c
e
s
s
o
r
y
P
o
w
e
r
H
ig
h
B
e
a
m
P
o
w
e
r
L
o
w
B
e
a
m
P
o
w
e
r
B
a
tte
r
y
P
o
w
e
r
S
e
c
u
r
ity
A
n
te
n
n
a
H
ig
h
R
ig
h
t
F
ro
n
t
T
u
r
n
S
ig
n
a
l
L
e
ft
F
ro
n
t
T
u
r
n
S
ig
n
a
l
A3 A4 B2 C4 D2 D3 E2 E3 E4 F3 G4 H2 J3 K2 K3 K4 L2 L3 M2 M3 M4 F4 1 A2 J2 J4 L4
A3 A4 B2 C4 D2 D3 E2 E3 E4 F3 G4 H2 J3 K2 K3 K4 L2 L3 M2 M3 M4 F4 1 A2 J2 J4 L4
1 2 3 4 1 2 3 1 2 3 4
BCM
Rear WSS Rear HCU
G
ro
u
n
d
R
e
a
r
H
C
U
R
e
le
a
s
e
R
e
a
r
H
C
U
A
p
p
ly
R
e
a
r
H
C
U
P
o
w
e
r
R
e
a
r
W
S
S
L
o
w
R
e
a
r
W
S
S
H
ig
h
A B C D
A B C D A B
A B
1
1
1
1 Rear
Brake
Switch
1
2
3
4
1
2
3
4
[242A]
[242B] [168A]
[168B]
[209A]
[209B]
[77A]
[77B]
[259A]
[259B]
[255A]
[255B]
[121A-2] [121B-2]
[79A] [79B]
[120A] [120B]
[133A] [133B]
[121A-1] [121B-1]
[131B-1]
[131A-1]
[166B]
[166A]
[95B]
[95A]
[65B]
[65A]
[128B]
[128A]
[254B]
[254A]
[131B-2]
[131A-2]
[142B]
[142A]
[47B]
[47A]
[19A] [40A]
[137B]
[137A]
[18A]
[138B] [138A]
2
1
2
1
Front
O2 Sensor
CKP
Sensor
Oil
Pressure
Switch
Rear O2
Heater Ground
Front O2
Sensor
5V Sensor
Ground
5V Sensor
Power
Sensor
Ground
Oil Pressure Switch
Input
1 1
1
2
3
1
2
3
JSS JSS Signal
A B C D
A B C D
F
ro
n
t
H
C
U
P
o
w
e
r
F
ro
n
t
H
C
U
A
p
p
ly
F
ro
n
t
H
C
U
R
e
le
a
s
e
F
ro
n
t
W
S
S
L
o
w
G
ro
u
n
d
R
e
a
r
H
C
U
R
e
le
a
s
e
R
e
a
r
H
C
U
A
p
p
ly
R
e
a
r
H
C
U
P
o
w
e
r
B
a
tte
r
y
P
o
w
e
r
R
e
a
r
W
S
S
L
o
w
R
e
a
r
W
S
S
H
ig
h
F
ro
n
t
W
S
S
H
ig
h
C
A
N
H
ig
h
C
A
N
L
o
w
B
a
tte
r
y
P
o
w
e
r
1 2 4 5 6 7 9 10 11 12 13 15 18 19 20
1 2 4 5 6 7 9 10 11 12 13 15 18 19 20
ECU
(ABS Only)
1 3 2
1 3 2
P N
P N
F
ro
n
t
H
C
U
P
o
w
e
r
F
ro
n
t
H
C
U
A
p
p
ly
F
ro
n
t
H
C
U
R
e
le
a
s
e
G
ro
u
n
d
Front HCU
Stator
Voltage
Regulator
P
o
w
e
r
S
e
c
u
r
ity
S
ire
n
G
ro
u
n
d
Security Siren
1 2 3
1 2 3
GND 2
S
e
e
M
a
in
H
a
r
n
e
s
s
(
1
o
f
2
)
1
1
1
1
Neutral
Switch
GND 1
Battery
VSS
Starter
Solenoid
Starter
Stud Purge
Solenoid
S
ta
r
te
r
S
o
le
n
o
id
P
o
w
e
r
S
y
s
te
m
P
o
w
e
r
5
V
S
e
n
s
o
r
P
o
w
e
r
V
S
S
In
p
u
t
G
ro
u
n
d
P
u
rg
e
S
o
le
n
o
id
A B C
A B C
A B
A B
1
1
et00562
Figure A-8. Main Wiring Harness (2 of 2): 2013 FXSBSE
Main Wiring Harness (2 of 2): 2013 FXSBSE Main Wiring Harness (2 of 2): 2013 FXSBSE
4
3
2
1
Front Lighting
Position Lamp
(HDI Only)
Headlamp
See
Main
Harness
[38B]
BK
BK
O/W
O/W
W
W
Y
BK
BK
B
K
B
K
B
K
BE
R/W
BK
R/W
O/R
O/R
V
BK
BE
V
BK
BK
BK
BK
BK BK
BK
BK
BK
BK
BK
BK
BK
BK BK
BK BK
GN GN
GN GN
BK
BK
BK
BE
BE
BE BE
V
BK
BE
V
BE
BE
BE
V
BE
V
V
V
R R
R R
W
W
W
W
V
BK
BE
V
B
K
B
K
B
K
B
E
V
B
E V
Y
[38B-2]
Right Hand
Control Module
With Turn Signal
and DOM
Running Lamp
Left Hand
Control Module
With Turn Signal
and DOM
Running Lamp
See Main
Harness
(1 of 2)
Right Front
Turn Signal
Running DOM
Only
Running DOM
Only
Clutch
Switch
Left Front
Turn Signal
Front Brake
Switch
Engine Stop
Switch
Battery Fuse
Ground
CAN High
CAN Low
1
2
3
4
1
CAN High
Ground
Battery Fuse
CAN Low
4
3
2
1
W/BK
BK
R/W
O/R
R/Y
R/Y
W/BK
BK
R/W
O/R
W/BK
W/GY
W/GY
W/BK
[24B]
[22B-1]
[22B-2]
[18B]
[18B]
[18B]
[19B]
[19B]
[40B]
[40B]
[40B]
[19B]
1
2
3
1
3
1
2
3
4
1
3
1
2
3
4
1
2
4
1
2
4
1
2
4
1
2
4
Rear Lighting
Right Rear
Stop/Tail/Turn
Right Rear LED
Stop/Tail/Turn
Right Rear LED
Stop/Tail/Turn
Left Rear LED
Stop/Tail/Turn
Left Rear LED
Stop/Tail/Turn
Left Rear
Stop/Tail/Turn
LP
LP
LP
Stop/Tail
Canada
DOM
HDI
et00563
Figure A-9. Lighting: 2013 FXSBSE
Lighting: 2013 FXSBSE Lighting: 2013 FXSBSE
TABLE OF CONTENTS
SUBJECT............................................................................................................................PAGE NO.
B.1 GLOSSARY...............................................................................................................................B-1
A
P
P
E
N
D
I
X
B
G
L
O
S
S
A
R
Y
NOTES
B.1 GLOSSARY
ACRONYMS AND ABBREVIATIONS
Table B-1. Acronyms and Abbreviations
DESCRIPTION ACRONYM OR ABBREVIATION
Amperes A
Ambient air temperature AAT
Anti-lock braking system ABS
Alternating current AC
Accessory position on ignition switch ACC
Automatic compression release ACR
Absorbed glass mat (battery) AGM
Ampere-hour Ah
Active Intake Solenoid AIS
American wire gauge AWG
Battery voltage B+
Bar bar
Bank angle sensor BAS
Body control module BCM
Breakout box BOB
Before top dead center BTDC
Celsius (Centigrade) C
California CA
Calibration CAL
Controller area network CAN
Cubic centimeters cc
Cold cranking amps CCA
Counterclockwise CCW
Crankshaft position CKP
Centimeters cm
Cubic centimeters cm
3
Clockwise CW
Direct current DC
Data link connector DLC
Domestic DOM
Department of Transportation DOT
Diagnostic trouble code DTC
Digital volt ohm meter DVOM
Electronic control module ECM
Engine coolant temperature ECT
Electronic Control Unit ECU
Electrically erasable programmable read only memory EEPROM
Electronic fuel injection EFI
Electro Hydraulic Control Unit EHCU
Engine temperature ET
HOME
2013 FXSBSE Service Supplement: Appendix B Glossary B-1
Evaporative emissions control system EVAP
Fahrenheit F
Fuel pressure sensor FPS
Feet ft
Foot pounds ft-lbs
Fluid ounce fl oz
Gram g
Gallon gal
Gross axle weight rating GAWR
Ground (electrical) GND
Global positioning system GPS
Gross vehicle weight rating GVWR
Hydraulic control unit HCU
Harley-Davidson International HDI
Harley-Davidson smart security system H-DSSS
Hands-free security module HFSM
Mercury Hg
Heated oxygen sensor H02S
Horsepower hp
Hour hr
Idle air control IAC
Intake air temperature IAT
Instrument cluster IC
Inside diameter ID
Ignition light/key switch position IGN
inch in
Cubic inch in
3
Injector pulse width INJ PW
Inch pounds in-lbs
Jiffy stand sensor JSS
Kilogram kg
Kilometer km
Kilometers per hour km/h
Kilopascal kPa
Kilowatt kW
Liter L
Pounds lb
Liquid crystal display LCD
Light emitting diode LED
Left hand LH
Left hand control module LHCM
License plate LP
Left LT
HOME
B-2 2013 FXSBSE Service Supplement: Appendix B Glossary
Milliampere mA
Manifold absolute pressure MAP
Maximum max
Mile mi
Minimum min
Milliliter mL
Millimeter mm
Miles per hour mph
Millisecond ms
Newton-meter Nm
Navigation interface module NIM
Nickel metal hydride NiMH
Not applicable N/A
Oxygen O2
Outside diameter OD
Original equipment manufacturer OEM
Ounce oz
Parts and Accessories P&A
Part number Part No.
Personal identification number PIN
Pounds per square inch psi
Pulse width modulated signal PWM signal
Quart qt
Reverse control module RCM
Reserve mark on fuel supply valve RES
Right hand RH
Right hand control module RHCM
Revolutions per minute rpm
Right RT
Seconds s
Cubic feet per hour at standard conditions SCFH
Satellite digital audio radio service SDARS
Speedometer SPDO
Speaker SPKR
Stop/tail/turn STT
Throttle control actuator TCA
Top dead center TDC
Twist grip sensor TGS
Throttle position sensor TPS
Turn signal module TSM
Turn signal/security module TSSM
Volt V
Volts of alternating current VAC
HOME
2013 FXSBSE Service Supplement: Appendix B Glossary B-3
Volts of direct current VDC
Vehicle identification number VIN
Voice recognition VR
Vehicle speed sensor VSS
Watt W
Wheel speed sensor WSS
HOME
B-4 2013 FXSBSE Service Supplement: Appendix B Glossary
Tools Used in This Manual
NOTES TOOL NAME PART NUMBER
1.10 SUSPENSION ADJUSTMENTS, Shock Absorbers SHOCK ADJUSTMENT SPANNER 94448-82B
2.18 BLEEDING CLUTCH FLUID LINE, Drain and Fill SNAP-ON BASIC VACUUM BRAKE
BLEEDER
BB200A
7.13 DIAGNOSTIC TOOLS, How To Use Diagnostic
Tools
BATTERY DIAGNOSTIC STATION GRX-3110 HD
8.6 DTC P0107, P0108, P0112, P0113, Description and
Operation
VACUUM PUMP HD-23738
Tools
8.35 ENGINE CRANKS, BUT WILL NOT START, Engine
Cranks But Will Not Start
3.4 TROUBLESHOOTING, Compression Test CYLINDER COMPRESSION GAUGE HD-33223-1
3.6 CYLINDER HEAD, Inspection VALVE GUIDE HONE HD-34723
3.6 CYLINDER HEAD, Replacing Valve Guides 8 MM VALVE GUIDE FLEX HONE HD-34723
Tools
Tools
8.10 DTC P0261, P0262, P0264, P0265, DTC P0261 FUEL INJECTOR TEST LIGHT HD-34730-2D
8.10 DTC P0261, P0262, P0264, P0265, DTC P0264 FUEL INJECTOR TEST LIGHT HD-34730-2D
8.27 DTC P1655, P1656, DTC P1655 FUEL INJECTOR TEST LIGHT HD-34730-2D
8.27 DTC P1655, P1656, DTC P1656 FUEL INJECTOR TEST LIGHT HD-34730-2D
3.6 CYLINDER HEAD, Disassembly VALVE SPRING COMPRESSOR HD-34736-B
3.6 CYLINDER HEAD, Assembly VALVE SPRING COMPRESSOR HD-34736-B
3.6 CYLINDER HEAD, Replacing Valve Guides VALVE GUIDE AND VALVE GUIDE SEAL
HANDLE
HD-34740
3.6 CYLINDER HEAD, Replacing Valve Guides VALVE GUIDE AND VALVE GUIDE SEAL
HANDLE
HD-34740
3.6 CYLINDER HEAD, Assembly VALVE GUIDE AND VALVE GUIDE SEAL
HANDLE
HD-34740
3.6 CYLINDER HEAD, Inspection VALVE GUIDE CLEANING BRUSH HD-34751
3.6 CYLINDER HEAD, Replacing Valve Guides VALVE GUIDE CLEANING BRUSH HD-34751
3.6 CYLINDER HEAD, Replacing Valve Guides VALVE GUIDE CLEANING BRUSH HD-34751
3.6 CYLINDER HEAD, Assembly VALVE GUIDE CLEANING BRUSH HD-34751
1.8 DRIVE BELT AND SPROCKETS, Checking Belt
Deflection
BELT TENSION GAUGE HD-35381-A
3.4 TROUBLESHOOTING, Cylinder Leakdown Test CYLINDER LEAKDOWN TESTER HD-35667-A
3.9 CRANKCASE ASSEMBLY, Assembly SPROCKET SHAFT OIL SEAL INSTALLER HD-39361-B
3.6 CYLINDER HEAD, Replacing Valve Guides CYLINDER HEAD SUPPORT STAND HD-39782-A
3.6 CYLINDER HEAD, Replacing Valve Guides CYLINDER HEAD SUPPORT STAND HD-39782-A
3.6 CYLINDER HEAD, Disassembly CYLINDER HEAD HOLDING FIXTURE HD-39786
3.6 CYLINDER HEAD, Replacing Valve Guides CYLINDER HEAD HOLDING FIXTURE HD-39786
3.6 CYLINDER HEAD, Assembly CYLINDER HEAD HOLDING FIXTURE HD-39786
3.6 CYLINDER HEAD, Replacing Valve Guides RATCHETING TAP HANDLE HD-39847
3.6 CYLINDER HEAD, Replacing Valve Guides RATCHETING TAP HANDLE HD-39847
3.6 CYLINDER HEAD, Replacing Valve Guides VALVE GUIDE REAMER HD-39932
3.6 CYLINDER HEAD, Replacing Valve Guides REAMER LUBRICANT HD-39964
3.6 CYLINDER HEAD, Replacing Valve Guides REAMER LUBRICANT HD-39964
I
T
O
O
L
S
Tools
DIGITAL MULTIMETER (FLUKE 78) HD-39978
Tools
7.17 NOVEHICLEPOWER, DTCU0100, U0121, U0140,
U0141, U0142, U0156, No Vehicle Power, DTC U0140
7.18 STARTING SYSTEM DIAGNOSTICS, Nothing
Clicks
7.20 DTC B1210, B1211, DTC B1211 HARNESS CONNECTOR TEST KIT HD-41404
7.21 TRIP ODOMETER FUNCTIONS INOPERATIVE,
DTC B2255, Trip Odometer Functions Inoperative, DTC
B2255
7.22 NO INSTRUMENT POWER, DTC B1200, No
Instrument Power
7.23 INDICATORLAMPS, Oil Pressure Lamp Inoperative HARNESS CONNECTOR TEST KIT HD-41404
7.23 INDICATOR LAMPS, Neutral Lamp Inoperative HARNESS CONNECTOR TEST KIT HD-41404
7.25 DTC B2151, B2153, B2154, B2156, B2158,
B2159, DTC B2151
7.25 DTC B2151, B2153, B2154, B2156, B2158,
B2159, DTC B2151
7.25 DTC B2151, B2153, B2154, B2156, B2158,
B2159, DTC B2153, B2154
7.25 DTC B2151, B2153, B2154, B2156, B2158,
B2159, DTC B2156
7.25 DTC B2151, B2153, B2154, B2156, B2158,
B2159, DTC B2158, B2159
7.26 STOP LAMPS, DTC B2161, B2163, B2164,
B2223, Stop Lamp Always On, DTC B2223
B2223, DTC B2161
B2223, DTC B2163, B2164
7.27 RUNNING LAMPS, DTC B2107, B2108, B2109,
B2166, B2168, B2169, Front Running Lamps Inoperative
B2166, B2168, B2169, DTC B2166 (Domestic Only)
B2166, B2168, B2169, DTC B2168, B2169: FXS and
FLS
8.6 DTC P0107, P0108, P0112, P0113, DTC P0107 HARNESS CONNECTOR TEST KIT HD-41404
8.7 DTC P0117, P0118, DTC P0117 HARNESS CONNECTOR TEST KIT HD-41404
8.8 DTC P0120, P0122, P0123, P0220, P0222,
P0223, DTC P0120
II TOOLS
8.8 DTC P0120, P0122, P0123, P0220, P0222,
P0223, DTC P0122
8.8 DTC P0120, P0122, P0123, P0220, P0222,
P0223, DTC P0123
8.8 DTC P0120, P0122, P0123, P0220, P0222,
P0223, DTC P0220
8.8 DTC P0120, P0122, P0123, P0220, P0222,
P0223, DTC P0222
8.8 DTC P0120, P0122, P0123, P0220, P0222,
P0223, DTC P0223
8.9 DTC P0031, P0032, P0131, P0132, P0134, P0151,
P0152, P0154, DTC P0031
8.9 DTC P0031, P0032, P0131, P0132, P0134, P0151,
P0152, P0154, DTC P0031
8.9 DTC P0031, P0032, P0131, P0132, P0134, P0151,
P0152, P0154, DTC P0134
8.9 DTC P0031, P0032, P0131, P0132, P0134, P0151,
P0152, P0154, DTC P0151
8.21 DTC P1353, P1356, P1357, P1358, DTC P1353,
P1356
8.21 DTC P1353, P1356, P1357, P1358, DTC P1357,
P1358
8.37 MISFIRE AT IDLE OR UNDER LOAD, Misfire At
Idle or Under Load
3.9 CRANKCASE ASSEMBLY, Assembly CRANKSHAFT GUIDE HD-42326-B
Tools
Tools
7.16 ODOMETERSELF-DIAGNOSTICSINOPERATIVE,
DTC U0001, U0011, B2274, Odometer Self-Diagnostic
Inoperative, DTC U0001, U0011, B2274
TOOLS III
U0141, U0142, U0156, DTC U0156
7.20 DTC B1210, B1211, DTC B1210 BREAKOUT BOX HD-42682
7.20 DTC B1210, B1211, DTC B1211 BREAKOUT BOX HD-42682
Instrument Power
Instrument Power
7.23 INDICATOR LAMPS, Oil Pressure Lamp Always
On
B2166, B2168, B2169, LED Console Inoperative
Tools
7.19 DTC P0562, DTC P0562 BREAKOUT BOX HD-43876
8.10 DTC P0261, P0262, P0264, P0265, DTC P0261 BREAKOUT BOX HD-43876
8.13 DTC P0502, P0503, DTC P0502 BREAKOUT BOX HD-43876
3.10 OIL TANK, Removal and Disassembly OIL LINE REMOVING TOOL HD-44455
Tools
IGNITION COIL CIRCUIT TEST ADAPTER HD-44687
Tools
IGNITION COIL CIRCUIT TEST ADAPTER HD-44687
2.8 FRONT FORKS, Assembly FORK SEAL DRIVER HD-45305
3.6 CYLINDER HEAD, Replacing Valve Guides VALVE GUIDE INSTALLER HD-46583
Tools
Tools
U0141, U0142, U0156, DTC U0156
7.20 DTC B1210, B1211, DTC B1210 BREAKOUT BOX ADAPTERS HD-46601
7.20 DTC B1210, B1211, DTC B1211 BREAKOUT BOX ADAPTERS HD-46601
Instrument Power
Instrument Power
On
IV TOOLS
B2166, B2168, B2169, LED Console Inoperative
4.3 INDUCTION MODULE, Removal INTAKE MANIFOLD WRENCH HD-47250
3.6 CYLINDER HEAD, Disassembly ACR SOLENOID SOCKET HD-48498-A
3.6 CYLINDER HEAD, Inspection CYLINDER TORQUE PLATES HD-48627
3.8 BORING AND HONING CYLINDERS, Inspection CYLINDER TORQUE PLATES HD-48627
Tools
U0141, U0142, U0156, DTC U0100
8.8 DTC P0120, P0122, P0123, P0220, P0222,
P0223, DTC P0120
8.8 DTC P0120, P0122, P0123, P0220, P0222,
P0223, DTC P0122
8.8 DTC P0120, P0122, P0123, P0220, P0222,
P0223, DTC P0123
8.8 DTC P0120, P0122, P0123, P0220, P0222,
P0223, DTC P0220
8.8 DTC P0120, P0122, P0123, P0220, P0222,
P0223, DTC P0222
8.8 DTC P0120, P0122, P0123, P0220, P0222,
P0223, DTC P0223
8.9 DTC P0031, P0032, P0131, P0132, P0134, P0151,
P0152, P0154, DTC P0031
8.9 DTC P0031, P0032, P0131, P0132, P0134, P0151,
P0152, P0154, DTC P0131
8.9 DTC P0031, P0032, P0131, P0132, P0134, P0151,
P0152, P0154, DTC P0134
8.9 DTC P0031, P0032, P0131, P0132, P0134, P0151,
P0152, P0154, DTC P0151
8.21 DTC P1353, P1356, P1357, P1358, DTC P1357,
P1358
8.21 DTC P1353, P1356, P1357, P1358, DTC P1357,
P1358
TOOLS V
8.36 STARTS, THEN STALLS, Starts, Then Stalls BREAKOUT BOX HD-48637
Idle or Under Load
Tools
U0141, U0142, U0156, DTC U0121
3.6 CYLINDER HEAD, Assembly VALVE GUIDE SEAL INSTALLER HD-48644
2.14 ABS HYDRAULIC CONTROL UNIT (HCU), Front
HCU
Tools
7.14 INITIAL DIAGNOSTICS, Retrieving Trouble Codes DIGITAL TECHNICIAN II HD-48650
U0141, U0142, U0156, Description and Operation
7.21 TRIP ODOMETER FUNCTIONS INOPERATIVE,
DTC B2255, Description and Operation
B2223, Description and Operation
7.28 SECURITY SYSTEM, Security System Features DIGITAL TECHNICIAN II HD-48650
8.9 DTC P0031, P0032, P0131, P0132, P0134, P0151,
P0152, P0154, Description and Operation
Tools
Tools
Clicks
7.19 DTC P0562, DTC P0562 BREAKOUT BOX HD-50390-1
On
7.23 INDICATOR LAMPS, Neutral Lamp Inoperative BREAKOUT BOX HD-50390-1
7.24 ACCESSORIES, DTC B2112, B2113, B2114, DTC
B2113, B2114
7.25 DTC B2151, B2153, B2154, B2156, B2158,
B2159, DTC B2151
7.25 DTC B2151, B2153, B2154, B2156, B2158,
B2159, DTC B2153, B2154
7.25 DTC B2151, B2153, B2154, B2156, B2158,
B2159, DTC B2156
7.25 DTC B2151, B2153, B2154, B2156, B2158,
B2159, DTC B2158, B2159
VI TOOLS
B2223, DTC B2161
B2223, DTC B2163, B2164
B2223, DTC B2223
B2166, B2168, B2169, DTC B2107
B2166, B2168, B2169, DTC B2108, B2109
B2166, B2168, B2169, DTC B2168, B2169: FXS and
FLS
8.4 DTC B2102, B2103, B2104, DTC B2103, B2104 BREAKOUT BOX HD-50390-1
8.5 DTC B2116, B2117, B2118, B2119, DTC B2116 BREAKOUT BOX HD-50390-1
8.12 DTC P0444, P0445, DTC P0444 BREAKOUT BOX HD-50390-1
8.12 DTC P0444, P0445, DTC P0444 BREAKOUT BOX HD-50390-1
Idle or Under Load
Tools
Tools
Clicks
7.19 DTC P0562, DTC P0562 BCM CABLE HD-50390-2
On
7.23 INDICATOR LAMPS, Neutral Lamp Inoperative BCM CABLE HD-50390-2
B2113, B2114
7.25 DTC B2151, B2153, B2154, B2156, B2158,
B2159, DTC B2151
7.25 DTC B2151, B2153, B2154, B2156, B2158,
B2159, DTC B2153, B2154
7.25 DTC B2151, B2153, B2154, B2156, B2158,
B2159, DTC B2156
7.25 DTC B2151, B2153, B2154, B2156, B2158,
B2159, DTC B2158, B2159
TOOLS VII
B2223, DTC B2161
B2223, DTC B2163, B2164
B2223, DTC B2223
B2166, B2168, B2169, DTC B2107
B2166, B2168, B2169, DTC B2108, B2109
B2166, B2168, B2169, DTC B2168, B2169: FXS and
FLS
8.4 DTC B2102, B2103, B2104, DTC B2103, B2104 BCM CABLE HD-50390-2
8.5 DTC B2116, B2117, B2118, B2119, DTC B2116 BCM CABLE HD-50390-2
8.12 DTC P0444, P0445, DTC P0444 BCM CABLE HD-50390-2
8.12 DTC P0444, P0445, DTC P0444 BCM CABLE HD-50390-2
Idle or Under Load
Tools
Clicks
7.19 DTC P0562, DTC P0562 BCM OVERLAY HD-50390-2-P
On
7.23 INDICATOR LAMPS, Neutral Lamp Inoperative BCM OVERLAY HD-50390-2-P
B2113, B2114
7.25 DTC B2151, B2153, B2154, B2156, B2158,
B2159, DTC B2151
7.25 DTC B2151, B2153, B2154, B2156, B2158,
B2159, DTC B2153, B2154
7.25 DTC B2151, B2153, B2154, B2156, B2158,
B2159, DTC B2156
7.25 DTC B2151, B2153, B2154, B2156, B2158,
B2159, DTC B2158, B2159
B2223, DTC B2161
B2223, DTC B2163, B2164
VIII TOOLS
B2223, DTC B2223
B2166, B2168, B2169, DTC B2107
B2166, B2168, B2169, DTC B2108, B2109
B2166, B2168, B2169, DTC B2168, B2169: FXS and
FLS
8.4 DTC B2102, B2103, B2104, DTC B2103, B2104 BCM OVERLAY HD-50390-2-P
8.5 DTC B2116, B2117, B2118, B2119, DTC B2116 BCM OVERLAY HD-50390-2-P
8.12 DTC P0444, P0445, DTC P0444 BCM OVERLAY HD-50390-2-P
8.12 DTC P0444, P0445, DTC P0444 BCM OVERLAY HD-50390-2-P
Idle or Under Load
0.6 MM TERMINAL EXTRACTOR TOOL HD-50423
B2166, B2168, B2169, DTC B2107
1.5 MM TERMINAL EXTRACTOR TOOL HD-50424
8.4 DTC B2102, B2103, B2104, DTC B2102 1.5 MM TERMINAL EXTRACTOR TOOL HD-50424
3.6 CYLINDER HEAD, Inspection VALVE SPRING TESTER HD-96796-47
On
OIL PRESSURE GAUGE SET HD-96921-52D
3.10 OIL TANK, Installation HOSE CLAMP PLIERS HD-97087-65B
3.9 CRANKCASE ASSEMBLY, Assembly SPROCKET SHAFT BEARINGINSTALLER HD-97225-55C
3.8 BORING AND HONING CYLINDERS, Inspection SNAP-ON TORQUE ANGLE GAUGE TA360
8.37 MISFIRE AT IDLE OR UNDER LOAD, In-line Spark
Tester
Idle or Under Load
TOOLS IX
X TOOLS
NOTES
2013 Harley-Davidson FXSBSEModel Service Manual
Supplement
4.1 AIR CLEANER BACKPLATE
ASSEMBLY, Repair
6.2-6.8 Nm 55-60 in-lbs Air cleaner backplate screws
3.6 CYLINDER HEAD, Assembly/Apply three
equally spaced dots of LOCTITE 243 MEDIUM
STRENGTH THREADLOCKER AND SEALANT
(blue) around lower third of threads
14.9-20.3 Nm 131-180 in-lbs Automatic compression release (ACR)
2.4 FRONT AXLE COVERS, Replacement 1.7-2.5 Nm 15-22 in-lbs Axle cover set screw, front
2.5 FRONT WHEEL, Installation 1.7-2.5 Nm 15-22 in-lbs Axle cover set screw, front
2.6 REAR WHEEL, Assembly 81.4 Nm 60 ft-lbs Belt sprocket screws, 1st torque
2.6 REAR WHEEL, Assembly 104.5-112.6 Nm 77-83 ft-lbs Belt sprocket screws, final torque
7.5 WHEEL SPEED SENSOR (WSS), Front WSS 38-52 Nm 28-38 ft-lbs Brake caliper/WSS bracket mounting
bolts
2.5 FRONT WHEEL, Installation 38.0-51.5 Nm 28-38 ft-lbs Brake caliper mounting bolt, front
2.5 FRONT WHEEL, Assembly 21.7-32.5 Nm 16-24 ft-lbs Brake disc screws, front
2.6 REAR WHEEL, Assembly 40.7-61.0 Nm 30-45 ft-lbs Brake disc screws, rear
2.7 BRAKE PEDAL PAD, Installation 3.4-4.5 Nm 30-40 in-lbs Brake pedal pad
ASSEMBLY, Repair
29.8-32.5 Nm 22-24 ft-lbs Breather bolts
5.5 CLUTCH, Clutch Pack Only 7.9-11.3 Nm 70-100 in-lbs Clutch diaphragm spring retainer bolts
2.17 CLUTCH FLUID LINE, Replacement 6.8-10.8 Nm 60-96 in-lbs Clutch fluid line clamp fastener
2.17 CLUTCH FLUID LINE, Replacement 10.9-16.3 Nm 96-144 in-lbs Clutch fluid line flare nut
2.17 CLUTCH FLUID LINE, Replacement 3.4-4.5 Nm 30-40 in-lbs Clutch fluid line P-clamp screw
5.4 CLUTCH RELEASE BEARING AND PUSH
ROD, Installation
23.0-29.8 Nm 17-22 ft-lbs Clutch master cylinder banjo bolt
2.17 CLUTCH FLUID LINE, Replacement 23.0-29.8 Nm 17.0-22.0 ft-lbs Clutch master cylinder banjo bolt
8.1-12.2 Nm 72-108 in-lbs Clutch master cylinder clamp fastener
1.5 HYDRAULICCLUTCHFLUID, Fluid Inspection 1.4-1.7 Nm 12-15 in-lbs Clutch reservoir cover screws
3.9 CRANKCASE ASSEMBLY, Assembly 13.6 Nm 120 in-lbs Crankcase bolts, 1st torque
3.9 CRANKCASE ASSEMBLY, Assembly 20.3-25.8 Nm 15-19 ft-lbs Crankcase bolts, final torque
tion
13.6-16.3 Nm 120-144 in-lbs Cylinder bolts, 1st torque
tion/See procedure for properly marking bolts
before turning 90 degrees.
20.3-23.1 Nm
plus 90 degrees
15-17 ft-lbs plus
90 degrees
3.5 INSTALLINGENGINEINCHASSIS, Procedure 47.5-54.2 Nm 35-40 ft-lbs Cylinder head bracket bolts
3.10 OIL TANK, Installation 4.1-6.8 Nm 36-60 in-lbs Electrical panel fastener
3.5 INSTALLINGENGINEINCHASSIS, Procedure 40.7-47.5 Nm 30-35 ft-lbs Engine/transmission bracket bolts
3.5 INSTALLINGENGINEINCHASSIS, Procedure 61.0-67.8 Nm 45-50 ft-lbs Engine mount bolt, top
3.5 INSTALLINGENGINEINCHASSIS, Procedure 27.1-33.9 Nm 20-25 ft-lbs Engine mount bracket nuts, top
XI
T
O
R
Q
U
E
V
A
L
U
E
S
Supplement
3.5 INSTALLINGENGINEINCHASSIS, Procedure 94.9-108.5 Nm 70-80 ft-lbs Engine mounting bolts, front
4.4 EXHAUST SYSTEM, System 20.4-27.1 Nm 15-19 ft-lbs Exhaust interconnect clamp
4.4 EXHAUST SYSTEM, System 1.0-2.0 Nm 9-18 in-lbs Exhaust manifold clamp lower nut, 1st
torque
4.4 EXHAUST SYSTEM, System 11.3-13.6 Nm 100-120 in-lbs Exhaust manifold clamp lower nut final
torque
4.4 EXHAUST SYSTEM, System 11.3-13.6 Nm 100-120 in-lbs Exhaust manifold clamp upper nut
4.4 EXHAUST SYSTEM, System 2.3-4.5 Nm 20-40 in-lbs Exhaust shield clamps
4.4 EXHAUST SYSTEM, System 27.1-33.9 Nm 20-25 ft-lbs Exhaust system interconnect tube
fasteners
sion
2.9 FOOTRESTS, Assembly 19-25.7 Nm 14-19 ft-lbs Footpegs
2.5 FRONT WHEEL, Installation 95.0-101.8 Nm 70-75 ft-lbs Front axle nut
2.5 FRONT WHEEL, Installation 14.9-20.3 Nm 132-180 in-lbs Front axle slider cap nuts
2.8 FRONT FORKS, Assembly 40-50 Nm 29.5-36.8 ft-lbs Front fork damper tube screw
2.8 FRONT FORKS, Assembly 50-60 Nm 36.8-44.2 ft-lbs Front fork slider tube plug
4.2 CONSOLE, Installation 4.5-6.8 Nm 40-60 in-lbs Fuel tank console fasteners
4.2 CONSOLE, Installation 0.6-1.1 Nm 5-10 in-lbs Fuel tank console rear fastener
2.12 HANDLEBARS AND RISERS, Installation 16.3-21.7 Nm 12-16 ft-lbs Handlebar clamp front fasteners
2.12 HANDLEBARS AND RISERS, Installation 16.3-21.7 Nm 12-16 ft-lbs Handlebar clamp rear fasteners
4.0-5.1 Nm 35-45 in-lbs Handlebar switch housing screw
(HCU), Front HCU
13.6-16.3 Nm 120-144 in-lbs HCU banjo bolts
(HCU), Front HCU
(HCU), Front HCU
(HCU), Front HCU
1.4 AIR FILTER, Installation 5.1-6.2 Nm 45-55 in-lbs Hose clamp (air filter)
2.12 HANDLEBARS AND RISERS, Installation 2.3-3.4 Nm 20-30 in-lbs Indicator lamp fasteners
7.4 INDICATOR LAMPS, Installation 2.3-3.4 Nm 20-30 in-lbs Indicator lamp fasteners
4.3 INDUCTION MODULE, Installation/metric 10.9-16.3 Nm 96-144 in-lbs Induction module flange adapter screws
4.3 INDUCTION MODULE, Installation/metric 10.9-16.3 Nm 96-144 in-lbs Induction module flange adapter screws
ASSEMBLY, Repair
6.2-6.8 Nm 55-60 in-lbs Intake tube screws
2.8 FRONT FORKS, Installation 40.7-47.5 Nm 30-35 ft-lbs Lower fork stem pinch bolts
2.12 HANDLEBARS AND RISERS, Installation 40.7-54.3 Nm 30-40 ft-lbs Lower handlebar clamp fasteners
XII TORQUE VALUES
Supplement
4.4 EXHAUST SYSTEM, Mufflers 51.6-58.4 Nm 38-43 ft-lbs Muffler clamps
4.4 EXHAUST SYSTEM, Mufflers 10.9-13.6 Nm 96-120 in-lbs Muffler fasteners
4.4 EXHAUST SYSTEM, Mufflers 2.3-4.5 Nm 20-40 in-lbs Muffler shield clamps
2.22 HEADLAMP NACELLE, Installation 9.0-11.3 Nm 80-100 in-lbs Nacelle bracket fasteners
2.22 HEADLAMP NACELLE, Installation 10.9-13.6 Nm 96-120 in-lbs Nacelle fasteners
3.10 OIL TANK, Installation 16.3-20.3 Nm 12-15 ft-lbs Oil tank bolts
11.2-13.6 Nm 100-120 in-lbs Outer transmission cover screws
3.5 INSTALLINGENGINEINCHASSIS, Procedure 122-149.1 Nm 90-110 ft-lbs Pivot shaft nut
2.6 REAR WHEEL, Installation/LOCTITE 243
MEDIUM STRENGTH THREADLOCKER AND
SEALANT (blue)
2.6 REAR WHEEL, Installation 128.8-142.5 Nm 95-105 ft-lbs Rear axle nut
7.7 ELECTRICAL PANEL, Installation 4.1-6.8 Nm 36-60 in-lbs Rear electrical panel fasteners
2.13 REAR FENDER, Installation 28.5-36.6 Nm 21-27 ft-lbs Rear fender support to fender
1st torque
final torque
2.20 REARFORK PIVOT COVERS, Replacement 6.8-9.5 Nm 60-84 in-lbs Rear fork pivot cover set screws
7.6 TURN SIGNALS, Rear Lamp Replacement 16.3-21.7 Nm 12-16 ft-lbs Rear turn signal housing fastener
2.11 HANDGRIPS AND HAND CONTROLS, Turn
Signals and Mirrors
6.4 SECONDARYCLUTCHACTUATOR, Replace-
ment
3.5-4.6 Nm 31-41 in-lbs Secondary clutch actuator bleeder valve
2.19 SHIFTER PEG, Assembly 16.3-19.0 Nm 12-14 ft-lbs Shifter peg screw
7.3 SPEEDOMETER, Installation 1.4-1.9 Nm 12-17 in-lbs Speedometer fasteners
3.10 OIL TANK, Installation 4.1-6.8 Nm 36-60 in-lbs Splash guard fasteners
4.3 INDUCTION MODULE, Temperature Manifold
Absolute Pressure (TMAP)/metric
9.5-12.2 Nm 84-108 in-lbs TMAP hex screw
sion
6.3 TRANSMISSON SIDE COVERS, Installation 11.2-13.6 Nm 100-120 in-lbs Transmission inner side cover screw
3.5 INSTALLINGENGINEINCHASSIS, Procedure 20.3 Nm 15 ft-lbs Transmission mounting bolts, 1st torque
3.5 INSTALLINGENGINEINCHASSIS, Procedure 46.1-52.9 Nm 34-39 ft-lbs Transmission mounting bolts, final torque
6.3 TRANSMISSON SIDE COVERS, Installation 11.2-13.6 Nm 100-120 in-lbs Transmission outer side cover screw
7.4 INDICATOR LAMPS, Installation 16.3-21.7 Nm 12-16 ft-lbs Upper handlebar clamp fasteners
TORQUE VALUES XIII
XIV TORQUE VALUES
NOTES
A
ABS
Front HCU. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
Front WSS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Acronyms and Abbreviations. . . . . . . . . . . . . . . . . . . . . . B-1
Active Exhaust. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Air Cleaner Assembly
Component Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Air Filter
Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Alarm
Activation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-93
Deactivation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-93
Alternator Rotor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Amplifier and Control Assembly Location. . . . . . . . . . . . 7-15
Automatic Compression Release (ACR)
Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-75
B
BAS Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Battery Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-46
BCM
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
BCM Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33
Boring and Honing Cylinders
Cylinder Bore Finished Size. . . . . . . . . . . . . . . . . . . 3-23
Piston Orientation. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Brake Pedal Pad
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Bulb Chart (Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Bulb Replacement
Headlamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Bulb Requirements
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
C
CAN Bus
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33
CAN Bus Communication. . . . . . . . . . . . . . . . . . . . . . . . 7-33
Carrying Capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Changing the PIN
Modifying an Existing PIN. . . . . . . . . . . . . . . . . . . . 7-94
Check Engine Lamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30
CKP Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
CKP Sensor Description. . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
CKP Synchronization. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Clearing DTCs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30
Clutch
Clutch Pack Only. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Clutch Fluid Line
Bleed Fluid Line and Secondary Clutch Actuator. . . 2-37
Clutch Fluid System
Bleed Master Cylinder. . . . . . . . . . . . . . . . . . . . . . . 2-36
Drain, Fill and Bleed. . . . . . . . . . . . . . . . . . . . . . . . . 2-35
Drain, Fill and Bleed. . . . . . . . . . . . . . . . . . . . . . . . . 2-36
Clutch Hand Lever
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
Clutch Master Cylinder
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . 2-30
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
Clutch Master Cylinder/Reservoir
Clutch Fluid Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
Clutch Release Bearing
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Clutch Release Bearing and push rod
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Clutch Release Bearing and Push Rod
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Clutch Release Cover
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Clutch Switch Description. . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Connectors
Connector Number. . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Location Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Repair Instruction. . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Console
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Console: FXS
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Console Harness Location. . . . . . . . . . . . . . . . . . . . . . . 7-15
Control Lever Brackets. . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Crankcase Assembly
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Cruise Control
Description and Operation. . . . . . . . . . . . . . . . . . . . 8-52
Cruise Control Diagnostics. . . . . . . . . . . . . . . . . . . . . . . 8-53
Current DTCs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30
Cylinder
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Cylinder Heads
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Determining Service. . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Replacing Valve Guides. . . . . . . . . . . . . . . . . . . . . . 3-14
D
Data Link Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33
Diagnostic Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
DLC Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
Drive
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Drive Belt and Sprockets
Checking Belt Deflection. . . . . . . . . . . . . . . . . . . . . 1-10
Drive Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
DTC Priority Order. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
DTC Priority Table
DTC B1200. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-63
DTC B1210. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-57
DTC B1211. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-57
DTC B2102. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
DTC B2103. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
DTC B2104. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
DTC B2107. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-84
DTC B2108. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-84
DTC B2109. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-84
DTC B2112. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-72
DTC B2113. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-72
DTC B2114. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-72
XV
I
N
D
E
X
DTC B2116. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
DTC B2117. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
DTC B2118. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
DTC B2119. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
DTC B2151. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-76
DTC B2153. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-76
DTC B2154. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-76
DTC B2156. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-76
DTC B2158. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-76
DTC B2159. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-76
DTC B2161. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-80
DTC B2163. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-80
DTC B2164. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-80
DTC B2166. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-84
DTC B2168. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-84
DTC B2169. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-84
DTC B2223. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-80
DTC B2255. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-60
DTC P0031. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-30
DTC P0032. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-30
DTC P0117. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
DTC P0118. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
DTC P0120. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
DTC P0122. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
DTC P0123. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
DTC P0131. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-30
DTC P0132. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-30
DTC P0134. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-30
DTC P0151. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-30
DTC P0152. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-30
DTC P0154. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-30
DTC P0220. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
DTC P0222. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
DTC P0223. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
DTC P0261. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-37
DTC P0262. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-37
DTC P0264. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-37
DTC P0265. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-37
DTC P0371. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-41
DTC P0372. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-41
DTC P0374. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-41
DTC P0444. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-43
DTC P0445. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-43
DTC P0502. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-46
DTC P0503. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-46
DTC P0505. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-50
DTC P0562. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-53
DTC P0577. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-55
DTC P0603. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-56
DTC P0605. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-56
DTC P0641. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-57
DTC P0651. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-57
DTC P1009. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-60
DTC P1270. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-61
DTC P1353. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-64
DTC P1356. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-64
DTC P1357. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-64
DTC P1358. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-64
DTC P1501. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-68
DTC P1502. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-68
DTC P1510. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-71
DTC P1511. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-71
DTC P1512. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-71
DTC P1514. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-72
DTC P1600. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-73
DTC P1655. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-75
DTC P1656. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-75
DTC P2100. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-79
DTC P2101. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-79
DTC P2102. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-79
DTC P2103. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-79
DTC P2105. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-82
DTC P2107. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-82
DTC P2119. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-85
DTC P2122. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-86
DTC P2123. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-86
DTC P2127. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-86
DTC P2128. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-86
DTC P2135. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-91
DTC P2138. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-91
DTC P2176. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-94
DTC P2300. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-95
DTC P2301. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-95
DTC P2303. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-95
DTC P2304. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-95
DTC U0001. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34
DTC U0011. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34
DTC U0100. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40
DTC U0121. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40
DTC U0140. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40
DTC U0141. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40
DTC U0142. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40
DTC U0156. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40
E
ECM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
ECM Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
ECM Drivers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Fuel Injectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Fuel Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Ignition Coils. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Purge Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
ECM Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
ECU
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
EFI System Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Engine
Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Engine Phase. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Engine Run Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Engine Stop Switch Description. . . . . . . . . . . . . . . . . . . 7-45
Engine Symptoms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
ET Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
ET Sensor Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Exhaust System
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Mufflers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
XVI INDEX
F
Fluids and Lubricants
Disposal and Recycling. . . . . . . . . . . . . . . . . . . . . . . 1-3
Footpegs
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Foreword
Important General Information. . . . . . . . . . . . . . . . . . . i-I
Front ACR Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
Front Axle Covers
Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Front Forks
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . 2-13
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Front Fuel Injector Location. . . . . . . . . . . . . . . . . . . . . . . 7-16
Front HCU Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
Front Spark Plug Location. . . . . . . . . . . . . . . . . . . . . . . . 7-16
Front Wheel
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . 2-8
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Front WSS Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
Fuel Injectors Description. . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Fuel Pump Description. . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Fuel Pump Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
Fuse Block Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
G
Glossary
Acronyms and Abbreviations. . . . . . . . . . . . . . . . . . . B-1
GND 1 Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
GND 2 Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
GRX-3110 HD Battery Diagnostic Station. . . . . . . . . . . . 7-18
H
Handgrips
Left Handgrip. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Throttle Twist Grip. . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Handlebars
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Lower Clamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Handlebar Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
HCU, front
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
HD-26792 Spark Tester. . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
HD-34730-2D Fuel Injector Test Light. . . . . . . . . . . . . . . 7-18
HD-39978 Digital Multimeter (Fluke 78). . . . . . . . . . . . . 7-19
HD-41404 Harness Connector Test Kit. . . . . . . . . . . . . . 7-19
HD-42682 Breakout Box. . . . . . . . . . . . . . . . . . . . . . . . . 7-19
HD-44687 Ignition Coil Circuit Test Adapter. . . . . . . . . . 7-19
HD-48637 Breakout Box (ECM). . . . . . . . . . . . . . . . . . . 7-20
HD-48642 Breakout Box (ABS). . . . . . . . . . . . . . . . . . . . 7-20
HD-48650 Digital Technician II. . . . . . . . . . . . . . . . . . . . 7-20
HD-50390-1 Breakout Box (BCM). . . . . . . . . . . . . . . . . . 7-20
Headlamp
Assembly Removal and Installlation. . . . . . . . . . . . . . 7-2
Bulb Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Head Lamp Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
Heat Management System. . . . . . . . . . . . . . . . . . . . . . . . 8-1
High Beam Indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-68
History DTCs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30
HO2S Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Hydraulic Clutch Fluid
Clutch Fluid Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
I
Ignition Coil Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
Ignition Coils. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Indicator Lamp
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Indicator Lamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-66
Induction Module
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Initial Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
Diagnostic Procedure. . . . . . . . . . . . . . . . . . . . . . . . 7-22
Installing engine in chassis
Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
J
Jiffy Stand
Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
JSS Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
L
LED Console Location. . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
LHCM Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
Light Bulbs
Replacement (Table). . . . . . . . . . . . . . . . . . . . . . . . . 1-2
LOCTITE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-II
Low Battery Lamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-66
Low Fuel Indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-66
M
Maintenance
Headlamp Bulb Replacement. . . . . . . . . . . . . . . . . . . 7-2
Maintenance Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Mirrors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Multiple DTCs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30
N
Nacelle
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
Neutral Indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-67
Neutral Lamp Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . 7-70
Neutral Switch Description. . . . . . . . . . . . . . . . . . . . . . . . 8-5
O
O2 Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Odometer Self-Diagnostics. . . . . . . . . . . . . . . . . . . . . . . 7-22
Oil Pressure Indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . 7-67
Oil Pressure Lamp Diagnostics. . . . . . . . . . . . . . . . . . . . 7-69
Oil Tank
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
Removal and Disassembly. . . . . . . . . . . . . . . . . . . . 3-28
INDEX XVII
P
Passenger Grabstrap. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
PIN Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-94
Changing the PIN. . . . . . . . . . . . . . . . . . . . . . . . . . . 7-94
Initial PIN Entry. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-94
Pistons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Purge Solenoid Description. . . . . . . . . . . . . . . . . . . . . . . . 8-6
R
Rear ACR Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
Rear Electrical Panel
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Rear Fender
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
Rear Fork Pivot Covers
Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39
Rear Fuel Injector Location. . . . . . . . . . . . . . . . . . . . . . . 7-16
Rear Spark Plug Location. . . . . . . . . . . . . . . . . . . . . . . . 7-16
Rear Wheel
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Maintenance and Cleaning. . . . . . . . . . . . . . . . . . . . . 2-9
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Retrieving Trouble Codes. . . . . . . . . . . . . . . . . . . . . . . . 7-22
RHCM Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
Running Lamps Description. . . . . . . . . . . . . . . . . . . . . . 7-84
Running Lamps Diagnostics. . . . . . . . . . . . . . . . . . . . . . 7-87
S
Seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
Secondary Clutch Actuator
Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Security Antenna Location. . . . . . . . . . . . . . . . . . . . . . . . 7-16
Security Immobilization. . . . . . . . . . . . . . . . . . . . . . . . . . 7-91
Security Lamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30
Security Lamp Description. . . . . . . . . . . . . . . . . . . . . . . . 7-91
Security Siren
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Security System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-91
Arming. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-92
Disarming. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-92
Security System Features
Arming Confirmation. . . . . . . . . . . . . . . . . . . . . . . . . 7-91
Dealer Service Mode. . . . . . . . . . . . . . . . . . . . . . . . 7-92
Disarming Confirmation. . . . . . . . . . . . . . . . . . . . . . 7-91
Personal Code Disarming. . . . . . . . . . . . . . . . . . . . 7-91
Security System Alarm. . . . . . . . . . . . . . . . . . . . . . . 7-92
Starter/Ignition Disable. . . . . . . . . . . . . . . . . . . . . . . 7-92
Transport Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-91
Security System Warnings. . . . . . . . . . . . . . . . . . . . . . . . 7-92
Sensors and Drivers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
BAS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
CKP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Clutch Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
ET. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
IAT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
JSS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
MAP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Neutral Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
O2 Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
VSS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Service and Emergency Functions. . . . . . . . . . . . . . . . . 7-94
Actuation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-94
Service Bulletins. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-I
Service Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-95
Service Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-I
Shifter Peg
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
Shock Absorbers
Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Shop Practices
Disposal and Recycling. . . . . . . . . . . . . . . . . . . . . . . . i-II
Sixth Gear Indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-68
Specifications
Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Engine Tolerances. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Specifications: Chassis
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Specifications: Drive
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Specifications: Transmission
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Speedometer
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Speedometer Location. . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
SPX Kent-Moore. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-II
Starter Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-45
Starter Solenoid Description. . . . . . . . . . . . . . . . . . . . . . 7-45
Starter Symptoms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-48
Starter Testing Diagnostics. . . . . . . . . . . . . . . . . . . . . . . 7-49
Starter Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . 7-48
Starting System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-45
Start Switch Description. . . . . . . . . . . . . . . . . . . . . . . . . 7-45
Steer Head Bearings
Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Stop Lamp Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . 7-82
Stop Lamps Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . 7-80
Switch Housings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Symptoms
Symptom Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31
T
TCA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
TCA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
TCA Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
Temperature/Manifold Absolute Pressure Sensor (TMAP)
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
TGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
TGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
TGS Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
Throttle Control Actuator (TCA). . . . . . . . . . . . . . . . . . . . . 4-5
Throttle Grip Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
TMAP Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
TMAP Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
TMAP Sensor Description. . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Trademarks
Harley-Davidson. . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-II
Referenced Products. . . . . . . . . . . . . . . . . . . . . . . . . . i-II
XVIII INDEX
Transmission Side Covers
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Transport Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-95
Troubleshooting
Compression Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Cylinder Leakdown Test. . . . . . . . . . . . . . . . . . . . . . . 3-6
Turn Signal
Bulb Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Turn Signal Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . 7-67
Turn Signal Indicators Diagnostics. . . . . . . . . . . . . . . . . 7-71
Turn Signals
Front. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Turn Signals/Running Lights
Rear Lamp Replacement. . . . . . . . . . . . . . . . . . . . . . 7-9
V
VIN
Vehicle Identification Number. . . . . . . . . . . . . . . . . . . 2-4
VSS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
VSS Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
W
Wiring
Color Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
Diagram Symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
WOW Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
WSS
Installation, front. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Removal, front. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
INDEX XIX
XX INDEX
NOTES

2013 HD Softail FXSBSE Supplement

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