2008 Harley Davidson VRSC Models Electrical Diagnostics Manual – PDF DOWNLOAD
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2008 Harley Davidson VRSC Models Electrical Diagnostics Manual – PDF DOWNLOAD
ABOUT THIS MANUAL
GENERAL:
- This electrical diagnostic service manual has been prepared with two purposes in mind. First, it will acquaint the user with the construction of the Harley-Davidson product and assist in the performance of repair.
- Secondly, it will introduce to the professional Harley-Davidson Technician the latest field-tested and factory-approved diagnostic methods.We sincerely believe that this manual will make your association with Harley-Davidson products more pleasant and profitable.
HOW TO USE YOUR SERVICE MANUAL :
Refer to the table below for the content layout of this manual.
NO. CHAPTER
1 Starting / Charging
2 Instruments
3 TSM/HFSM
4 Engine Management
5 ABS
A Appendix A Connector Repair
B Appendix B Wiring
C Appendix C Conversions
D Appendix D Glossary
E Appendix E TSM/TSSM (Japan/Korea)
- Use the TABLE OF CONTENTS (which follows this FOREWORD) 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.
- For example, a cross-reference shown as 2.1 SPECIFICATIONS refers to chapter 2 CHASSIS, heading 2.1 SPECIFICATIONS.
- For quick and easy reference, all pages contain a section number followed by a page number. For example, page 3-5 refers to page 5 in section 3.
- A number of acronyms and abbreviations are used in this document. See the D.1 GLOSSARY for a list of acronyms, abbreviations and definitions.
TABLE OF CONTENTS:
2008 Harley Davidson VRSC Models Electrical Diagnostics Manual – PDF DOWNLOAD
COVER................................................................................................ 1 FOREWORD............................................................................................. 2 TABLE OF CONTENTS.................................................................................... 4 1. STARTING / CHARGING............................................................................... 14 1.1 STARTER TROUBLESHOOTING...................................................................... 16 General...................................................................................... 16 Starter Troubleshooting...................................................................... 16 1.2 STARTING SYSTEM DIAGNOSIS.................................................................... 18 Diagnostics.................................................................................. 18 1.3 DIAGNOSTICS/TROUBLESHOOTING.................................................................. 27 Voltage Drop................................................................................. 27 1.4 STARTER ACTIVATION CIRCUITS.................................................................. 28 Starter Activation Circuits.................................................................. 28 1.5 TESTING STARTER ON MOTORCYCLE................................................................ 29 Start Relay Test............................................................................. 29 Starter Current Draw Test.................................................................... 29 1.6 TESTING STARTER ON BENCH..................................................................... 30 Free Running Current Draw Test............................................................... 30 1.7 CHARGING SYSTEM.............................................................................. 31 General...................................................................................... 31 Troubleshooting.............................................................................. 31 Testing...................................................................................... 35 1.8 BATTERY TESTING.............................................................................. 38 General...................................................................................... 38 Voltmeter Test............................................................................... 38 Conductance Test............................................................................. 38 Load Test.................................................................................... 38 2. INSTRUMENTS....................................................................................... 40 2.1 CHECKING FOR TROUBLE CODES................................................................... 42 Check Engine Lamp............................................................................ 42 Code Types................................................................................... 43 Security Lamp................................................................................ 43 Retrieving Trouble Codes..................................................................... 43 Multiple Trouble Codes....................................................................... 43 2.2 INSTRUMENT MODULE (IM) SELF DIAGNOSTICS...................................................... 44 General...................................................................................... 44 Diagnostics.................................................................................. 44 2.3 BREAKOUT BOX: IM............................................................................. 46 General...................................................................................... 46 Installation................................................................................. 46 Removal...................................................................................... 46 2.4 INITIAL DIAGNOSTIC CHECK: IM................................................................. 47 General...................................................................................... 47 Initial Diagnostics.......................................................................... 47 2.5 INSTRUMENT MODULE............................................................................ 50 General...................................................................................... 50 Speedometer Theory of Operation.............................................................. 50 Tachometer Theory of Operation............................................................... 51 2.6 NO IM POWER.................................................................................. 52 General...................................................................................... 52 2.7 INDICATOR LAMPS.............................................................................. 55 General...................................................................................... 55 Diagnostics.................................................................................. 55 2.8 DTC B1003.................................................................................... 58 General...................................................................................... 58 2.9 FUEL GAUGE OPERATION......................................................................... 59 General...................................................................................... 59 2.10 DTC B1004, B1005............................................................................ 60 General...................................................................................... 60 Diagnostics.................................................................................. 60 2.11 DTC B1006, B1007............................................................................ 64 General...................................................................................... 64 2.12 DTC B1008................................................................................... 66 General...................................................................................... 66 2.13 DTC U1016................................................................................... 68 General...................................................................................... 68 Diagnostics.................................................................................. 68 2.14 DTC U1064................................................................................... 71 General...................................................................................... 71 Diagnostics.................................................................................. 71 2.15 DTC U1300, U1301 OR BUS ER.................................................................. 74 Diagnostics.................................................................................. 74 3. TSM/HFSM.......................................................................................... 76 3.1 TURN SIGNAL OVERVIEW......................................................................... 78 General...................................................................................... 78 Security System: Japan/Korea................................................................. 78 Turn Signal Functions........................................................................ 78 Manual Cancellation.......................................................................... 78 Automatic Cancellation....................................................................... 78 Bank Angle Functions......................................................................... 78 Bank Angle Restart........................................................................... 78 Clutch/Neutral Interlock..................................................................... 78 Security System H-DSSS....................................................................... 78 3.2 HARLEY-DAVIDSON SMART SECURITY SYSTEM........................................................ 79 Components................................................................................... 79 Security Immobilization...................................................................... 79 HFSM Features................................................................................ 80 3.3 H-DSSS ACTUATION............................................................................. 82 General...................................................................................... 82 Sidecar Configuration........................................................................ 82 Actuation.................................................................................... 82 Fob Assignment............................................................................... 82 Power Disruption and Configuring............................................................. 82 3.4 PERSONAL IDENTIFICATION NUMBER (PIN)......................................................... 83 General...................................................................................... 83 Initial Pin Entry............................................................................ 83 Changing the Pin............................................................................. 83 3.5 ARMING/DISARMING SECURITY SYSTEM............................................................. 85 Hands-Free Fob............................................................................... 85 Security Lamp (Key Icon)..................................................................... 85 Arming....................................................................................... 85 Disarming.................................................................................... 86 3.6 WARNINGS AND ALARMS.......................................................................... 87 Warnings..................................................................................... 87 Alarm........................................................................................ 87 Siren Chirp Mode (Confirmation).............................................................. 87 3.7 SERVICE/EMERGENCY FUNCTIONS.................................................................. 88 Transport Mode............................................................................... 88 Service Mode................................................................................. 88 Four-Way Flashing............................................................................ 88 3.8 TROUBLESHOOTING.............................................................................. 89 Turn Signals (TSM/HFSM)...................................................................... 89 Security System (HFSM)....................................................................... 89 Diagnostics Mode............................................................................. 89 Troubleshooting.............................................................................. 89 3.9 CHECKING FOR DIAGNOSTIC TROUBLE CODES........................................................ 90 General...................................................................................... 90 Security Lamp Diagnostics.................................................................... 90 Code Types................................................................................... 91 Retrieving DTCs.............................................................................. 91 Multiple DTCs/Priority Order................................................................. 92 3.10 INITIAL DIAGNOSTIC CHECK.................................................................... 93 General...................................................................................... 93 Initial Diagnostics.......................................................................... 93 3.11 INSTRUMENT MODULE (IM) SELF DIAGNOSTICS..................................................... 96 General...................................................................................... 96 Diagnostics.................................................................................. 96 3.12 BREAKOUT BOX: TSM/HFSM...................................................................... 98 General...................................................................................... 98 Installation................................................................................. 98 Removal...................................................................................... 98 3.13 FAILS TO DISARM (HFSM ONLY).................................................................100 General......................................................................................100 Job/Time Codes...............................................................................100 Diagnostics..................................................................................100 3.14 DTC B0563...................................................................................103 General......................................................................................103 Diagnostics..................................................................................103 3.15 TSM/HFSM: TURN SIGNAL ERRORS AND DTCS.......................................................104 General......................................................................................104 Diagnostics..................................................................................105 3.16 DTC B1131, B1132 (HFSM ONLY)................................................................118 General......................................................................................118 Diagnostics..................................................................................118 3.17 DTC B1134 STARTER OUTPUT HIGH...............................................................121 General......................................................................................121 Diagnostics..................................................................................121 3.18 DTC B1135...................................................................................124 Diagnostics..................................................................................124 3.19 DTC B1136, B1142 (HFSM ONLY)................................................................125 Diagnostics..................................................................................125 3.20 DTC B1141 (HFSM ONLY).......................................................................126 Diagnostics..................................................................................126 3.21 DTC B1143, B1144, B1145 (HFSM ONLY).........................................................131 General......................................................................................131 Diagnostics..................................................................................131 3.22 DTC B1154, B1155............................................................................136 Diagnostics..................................................................................136 3.23 DTC U1016, U1255............................................................................140 General......................................................................................140 Diagnostics..................................................................................140 3.24 DTC U1300, U1301 OR BUS ER..................................................................143 Diagnostics..................................................................................143 3.25 TSM/HFSM: PASSWORD LEARN....................................................................144 General......................................................................................144 Password Learning............................................................................144 3.26 HFSM MAINTENANCE............................................................................145 General......................................................................................145 Hands-Free Fob...............................................................................145 Siren (If Installed).........................................................................145 4. ENGINE MANAGEMENT.................................................................................148 4.1 SPECIFICATIONS...............................................................................150 Specifications...............................................................................150 4.2 EFI SYSTEM...................................................................................151 General......................................................................................151 Troubleshooting..............................................................................151 4.3 DIAGNOSTIC INTRODUCTION......................................................................153 System Problems..............................................................................153 Resolving Problems...........................................................................153 4.4 CHECKING FOR TROUBLE CODES...................................................................154 Check Engine Lamp............................................................................154 Code Types...................................................................................155 Retrieving Diagnostic Trouble Codes..........................................................155 Multiple Diagnostic Trouble Codes............................................................155 4.5 INSTRUMENT MODULE (IM) SELF DIAGNOSTICS......................................................156 General......................................................................................156 Diagnostics..................................................................................156 4.6 BREAKOUT BOX: ECM............................................................................158 General......................................................................................158 Installation.................................................................................158 Removal......................................................................................158 4.7 WIGGLE TEST..................................................................................159 General......................................................................................159 Procedure....................................................................................159 4.8 INITIAL DIAGNOSTIC CHECK.....................................................................160 General......................................................................................160 Initial Diagnostics..........................................................................160 4.9 ENGINE CRANKS, BUT WILL NOT START............................................................169 General......................................................................................169 Diagnostics..................................................................................169 4.10 NO ECM POWER................................................................................177 General......................................................................................177 Diagnostics..................................................................................177 4.11 STARTS, THEN STALLS.........................................................................182 General......................................................................................182 Diagnostics..................................................................................182 4.12 FUEL SYSTEM ELECTRICAL TEST.................................................................186 General......................................................................................186 Diagnostics..................................................................................186 4.13 SYSTEM RELAY FAULT..........................................................................192 General......................................................................................192 Diagnostics..................................................................................192 4.14 FAN OPERATION CHECK.........................................................................197 General......................................................................................197 Diagnostics..................................................................................197 4.15 FUEL PRESSURE TEST..........................................................................201 General......................................................................................201 Testing......................................................................................201 Diagnostics..................................................................................202 4.16 IDLE AIR CONTROL............................................................................204 General......................................................................................204 Diagnostics..................................................................................204 4.17 MISFIRE AT IDLE OR UNDER LOAD...............................................................209 General......................................................................................209 Diagnostics..................................................................................209 4.18 COMBUSTION ABSENT/INTERMITTENT..............................................................215 General......................................................................................215 Diagnostics..................................................................................215 4.19 DTC P0107, P0108............................................................................219 General......................................................................................219 Diagnostics..................................................................................219 4.20 DTC P0112, P0113............................................................................223 General......................................................................................223 Diagnostics..................................................................................223 4.21 DTC P0117, P0118............................................................................227 General......................................................................................227 Diagnostics..................................................................................227 4.22 DTC P0122, P0123............................................................................231 General......................................................................................231 Diagnostics..................................................................................231 4.23 DTC P0131, P0132, P0134, P0151, P0152, P0154................................................235 General......................................................................................235 Diagnostics..................................................................................235 4.24 DTC P0261, P0262, P0263, P0264..............................................................240 General......................................................................................240 Diagnostics..................................................................................240 4.25 DTC P0373, P0374............................................................................245 General......................................................................................245 Diagnostics..................................................................................245 4.26 DTC P0444, P0445............................................................................248 General......................................................................................248 Diagnostics..................................................................................248 4.27 DTC P0501, P0502............................................................................253 General......................................................................................253 Diagnostics..................................................................................253 4.28 DTC P0562, P0563............................................................................257 General......................................................................................257 Diagnostics..................................................................................257 4.29 DTC P0603, P0605............................................................................261 General......................................................................................261 Diagnostics..................................................................................261 4.30 DTC P1009, P1010............................................................................262 General......................................................................................262 Diagnostics..................................................................................262 4.31 DTC P1351, P1352, P1354, P1355..............................................................265 General......................................................................................265 Diagnostics..................................................................................265 4.32 DTC P1501, P1502............................................................................269 General......................................................................................269 Diagnostics..................................................................................269 4.33 DTC U1064, U1255............................................................................274 General......................................................................................274 Diagnostics..................................................................................274 4.34 DTC U1096, U1255............................................................................277 General......................................................................................277 Diagnostics..................................................................................277 5. ABS...............................................................................................280 5.1 ANTILOCK BRAKE SYSTEM (ABS) GENERAL INFORMATION..............................................282 Antilock Brake System (ABS) Description......................................................282 Code Types...................................................................................284 Retrieving Diagnostic Trouble Codes..........................................................284 Multiple Trouble Codes.......................................................................284 5.2 INSTRUMENT MODULE (IM) SELF DIAGNOSTICS......................................................285 General......................................................................................285 Diagnostics..................................................................................285 5.3 BREAKOUT BOX: ABS............................................................................287 General......................................................................................287 Installation.................................................................................287 Removal......................................................................................287 5.4 INITIAL DIAGNOSTIC CHECK: ABS................................................................288 General......................................................................................288 Initial Diagnostics..........................................................................288 5.5 ABS INDICATOR DIAGNOSTICS....................................................................292 ABS Indicator Always On Or Inoperative.......................................................292 5.6 DTC C0562....................................................................................296 DTC C0562: Device Voltage Low................................................................296 5.7 DTC C0563....................................................................................299 DTC C0563: Device Voltage High...............................................................299 5.8 DTC C1017....................................................................................302 DTC C1017: Pump Motor Power Circuit Open Fault...............................................302 5.9 DTC C1018....................................................................................305 DTC C1018: Pump Motor Ground High Resistance Fault...........................................305 5.10 DTC C1021, C1023............................................................................308 DTC C1021, C1023: Wheel Speed Sensor Equals Zero (Front or Rear).............................308 5.11 DTC C1025, C1027, C1206, C1208..............................................................311 DTC C1025, C1027, C1206, C1208: Wheel Speed Signal Intermittent or Frequency Out Of Range....311 5.12 DTC C1032, C1034............................................................................314 DTC C1032, C1034: Wheel Speed Sensor Circuit Open Or Shorted (Front or Rear).................314 5.13 DTC C1042...................................................................................320 DTC C1042: Pump Motor Open...................................................................320 5.14 DTC C1043...................................................................................321 DTC C1043: Pump Motor Stalled................................................................321 5.15 DTC C1094...................................................................................322 DTC C1094: Front Brake Switch Always On......................................................322 5.16 DTC C1095...................................................................................325 DTC C1095: Front Brake Switch Open...........................................................325 5.17 DTC C1151...................................................................................328 DTC C1151: Front Wheel Release Too Long......................................................328 5.18 DTC C1153...................................................................................331 DTC C1153: Rear Wheel Release Too Long.......................................................331 5.19 DTC C1158...................................................................................334 DTC C1158: Calibration Programming Required..................................................334 5.20 DTC C1212...................................................................................338 DTC C1212: Front or Rear Brake Not Applied with Decel........................................338 5.21 DTC C1214...................................................................................341 DTC C1214: Rear Brake Switch Always On.......................................................341 5.22 DTC C1216...................................................................................344 DTC C1216: Rear Brake Switch Open............................................................344 5.23 DTC C1014, C1055-C1066, C1118, C1121........................................................347 DTC C1014, C1055-C1066, C1118, C1121: ECU Internal Fault.....................................347 5.24 DTC U1300, U1301 OR BUS ER..................................................................351 Diagnostics..................................................................................351 A. APPENDIX A CONNECTOR REPAIR.......................................................................352 A.1 AMP 1-PLACE CONNECTORS.......................................................................354 AMP 1-Place Connector Repair.................................................................354 A.2 AMP MULTILOCK CONNECTORS.....................................................................356 AMP Multilock Connector Repair...............................................................356 A.3 DELPHI CONNECTORS............................................................................361 Delphi Connector Repair......................................................................361 A.4 DEUTSCH 1-PLACE ELECTRICAL CONNECTORS........................................................363 Deutsch 1-Place Connector Repair.............................................................363 A.5 DEUSCH ELECTRICAL CONNECTORS.................................................................364 Deutsch Connector Repair.....................................................................364 A.6 DEUTSCH STANDARD TERMINALS...................................................................368 Deutsch Standard Terminal Crimps.............................................................368 A.7 DEUTSCH MINI-TERMINAL CRIMPS.................................................................369 Deutsch Mini Terminal Crimps.................................................................369 A.8 DEUTSCH SOLID BARREL TERMINALS...............................................................370 Deutsch Solid Barrel Terminal Crimps.........................................................370 A.9 RELAY AND FUSE BLOCKS........................................................................372 Fuse Block Repair............................................................................372 A.10 150 METRI-PACK CONNECTORS...................................................................373 150 Metri-Pack Connector Repair..............................................................373 A.11 280 METRI-PACK CONNECTORS...................................................................375 280 Metri-Pack Connector Repair..............................................................375 A.12 480 METRI-PACK CONNECTORS...................................................................377 480 Metri-Pack Connector Repair..............................................................377 A.13 630 METRI-PACK CONNECTORS...................................................................378 630 Metri-Pack Connector Repair..............................................................378 A.14 800 METRI-PACK CONNECTORS...................................................................379 Delphi Maxi-Fuse Housing Repair..............................................................379 A.15 METRI-PACK TERMINALS........................................................................381 Metri-Pack Terminal Crimps...................................................................381 A.16 MOLEX CONNECTORS............................................................................383 Molex Connector Repair.......................................................................383 A.17 PACKARD ECM CONNECTOR.......................................................................385 Packard 100W Connector Repair................................................................385 A.18 PACKARD MICRO-64 CONNECTORS.................................................................387 Packard Micro-64 Connector Repair............................................................387 A.19 SEALED SPLICE CONNECTORS....................................................................390 Sealed Splice Connector Repair...............................................................390 B. APPENDIX B WIRING.................................................................................392 B.1 CONNECTORS...................................................................................394 Connector Locations..........................................................................394 B.2 WIRING DIAGRAMS..............................................................................396 Wiring Diagram Information...................................................................396 2008 VRSC Wiring Diagrams....................................................................397 C. APPENDIX C CONVERSIONS............................................................................422 C.1 METRIC CONVERSION............................................................................424 Conversion Table.............................................................................424 C.2 FLUID CONVERSIONS............................................................................425 United States System.........................................................................425 Metric System................................................................................425 British Imperial System......................................................................425 C.3 TORQUE CONVERSIONS...........................................................................426 United States System.........................................................................426 Metric System................................................................................426 D. APPENDIX D GLOSSARY...............................................................................428 D.1 GLOSSARY.....................................................................................430 Acronyms and Abbreviations...................................................................430 E. APPENDIX E TSM/TSSM (JAPAN/KOREA).................................................................432 E.1 TSM/TSSM (JAPAN/KOREA) OVERVIEW..............................................................434 General......................................................................................434 Troubleshooting..............................................................................434 E.2 TSM/TSSM FEATURES............................................................................436 General......................................................................................436 Turn Signal Functions........................................................................436 Bank Angle Function..........................................................................436 Clutch/Neutral Interlock Functions...........................................................436 Security Alarm and Immobilization Functions..................................................436 E.3 TSM/TSSM VEHICLE DELIVERY....................................................................438 General......................................................................................438 Configuring A TSSM...........................................................................438 Power Disruption and Configuring.............................................................438 Key FOB Assignment: TSSM.....................................................................438 Pin Entry: TSSM..............................................................................439 Changing the Pin: TSSM.......................................................................441 E.4 TSM/TSSM TURN SIGNAL FUNCTIONS...............................................................442 General......................................................................................442 Automatic Cancellation.......................................................................442 Manual Cancellation..........................................................................442 Four-Way Flashing............................................................................442 Diagnostics Mode.............................................................................442 E.5 TSM/TSSM BANK ANGLE FUNCTION.................................................................443 General......................................................................................443 Operation....................................................................................443 E.6 SECURITY SYSTEM FUNCTIONS: TSSM..............................................................444 General......................................................................................444 Alarm Sensitivity: TSSM......................................................................444 Auto-Arming Function: TSSM...................................................................445 Storage Mode: TSSM...........................................................................446 E.7 ARMING/DISARMING: TSSM.......................................................................447 General......................................................................................447 Security Lamp................................................................................447 Using Key FOB: TSSM..........................................................................447 Using the Pin................................................................................447 E.8 DIAGNOSTIC TROUBLE CODES (DTC)...............................................................449 TSM/TSSM.....................................................................................449 Code Types...................................................................................450 Retrieving Diagnostic Trouble Codes..........................................................450 Multiple Diagnostic Trouble Codes............................................................451 E.9 INITIAL DIAGNOSTIC CHECK: TSM/TSSM...........................................................452 General......................................................................................452 Initial Diagnostics..........................................................................452 E.10 INSTRUMENT MODULE (IM) SELF DIAGNOSTICS.....................................................455 General......................................................................................455 Diagnostics..................................................................................455 E.11 BREAKOUT BOX: TSM/TSSM......................................................................457 General......................................................................................457 Installation.................................................................................457 Removal......................................................................................457 E.12 FAILS TO DISARM.............................................................................458 General......................................................................................458 Diagnostics..................................................................................458 E.13 TURN SIGNAL ERRORS: B1121, B1122, B1141.....................................................461 General......................................................................................461 Diagnostics..................................................................................461 E.14 DTC B0563...................................................................................472 General......................................................................................472 Diagnostics..................................................................................472 E.15 DTC B1131, B1132............................................................................473 General......................................................................................473 Diagnostics..................................................................................473 E.16 DTC B1134...................................................................................476 General......................................................................................476 Diagnostics..................................................................................476 E.17 DTC B1135...................................................................................479 General......................................................................................479 E.18 DTC B1154, B1155............................................................................480 General......................................................................................480 Diagnostic Notes.............................................................................480 E.19 DTC U1016...................................................................................483 General......................................................................................483 Diagnostics..................................................................................483 E.20 DTC U1300, U1301 OR BUS ER..................................................................486 General......................................................................................486 Diagnostics..................................................................................486 E.21 PASSWORD LEARN..............................................................................487 General......................................................................................487 Password Learning............................................................................487 E.22 TSSM MAINTENANCE............................................................................488 General......................................................................................488 Key FOB......................................................................................488 Siren (If Installed).........................................................................488 TOOLS................................................................................................490 TORQUE VALUES........................................................................................494 INDEX................................................................................................496
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