Electrical Diagnostic Manual 2009 Harley-Davidson VRSC Models | 99499-09

Electrical Diagnostic Manual 2009 Harley-Davidson VRSC Models 99499-09 (Preview)

FOREWORD
TABLE OF CONTENTS
1. STARTING / CHARGING
1.1 STARTER TROUBLESHOOTING
General
Starter Troubleshooting
1.2 STARTING SYSTEM DIAGNOSIS
Diagnostics
1.3 DIAGNOSTICS/TROUBLESHOOTING
Voltage Drop
1.4 STARTER ACTIVATION CIRCUITS
Starter Activation Circuits
1.5 TESTING STARTER ON MOTORCYCLE
Start Relay Test
Starter Current Draw Test
1.6 TESTING STARTER ON BENCH
Free Running Current Draw Test
1.7 CHARGING SYSTEM
General
Troubleshooting
Testing
1.8 BATTERY TESTING
General
Voltmeter Test
Conductance Test
Load Test
2. INSTRUMENTS
2.1 CHECKING FOR TROUBLE CODES
Check Engine Lamp
Code Types
Security Lamp
Retrieving Trouble Codes
Multiple Trouble Codes
2.2 INSTRUMENT MODULE (IM) SELF-DIAGNOSTICS
General
Diagnostics
2.3 BREAKOUT BOX: IM
General
Installation
Removal
2.4 INITIAL DIAGNOSTIC CHECK: IM
General
Initial Diagnostics
2.5 INSTRUMENT MODULE
General
Speedometer Theory of Operation
Tachometer Theory of Operation
2.6 NO IM POWER
General
2.7 INDICATOR LAMPS
General
Diagnostics
2.8 DTC B1003
General
2.9 FUEL GAUGE OPERATION
General
2.10 DTC B1004, B1005
General
Diagnostics
2.11 DTC B1006, B1007
General
2.12 DTC B1008
General
2.13 DTC U1016
General
Diagnostics
2.14 DTC U1064
General
Diagnostics
2.15 DTC U1300, U1301 OR BUS ER
Diagnostics
3. TSM/HFSM
3.1 TURN SIGNAL OVERVIEW
General
Security System: Japan/Korea
Turn Signal Functions
Manual Cancellation
Automatic Cancellation
Bank Angle Functions
Bank Angle Restart
Clutch/Neutral Interlock
Security System H-DSSS
3.2 HARLEY-DAVIDSON SMART SECURITY SYSTEM
Components
Security Immobilization
HFSM Features
3.3 H-DSSS ACTUATION
General
Sidecar Configuration
Actuation
Fob Assignment
Power Disruption and Configuring
3.4 PERSONAL IDENTIFICATION NUMBER (PIN)
General
Initial Pin Entry
Changing the Pin
3.5 ARMING/DISARMING SECURITY SYSTEM
Hands-Free Fob
Security Lamp (Key Icon)
Arming
Disarming
3.6 WARNINGS AND ALARMS
Warnings
Alarm
Siren Chirp Mode (Confirmation)
3.7 SERVICE/EMERGENCY FUNCTIONS
Transport Mode
Service Mode
Four-Way Flashing
3.8 TROUBLESHOOTING
Turn Signals (TSM/HFSM)
Security System (HFSM)
Diagnostics Mode
Troubleshooting
3.9 CHECKING FOR DIAGNOSTIC TROUBLE CODES
General
Security Lamp Diagnostics
Code Types
Retrieving DTCs
Multiple DTCs/Priority Order
3.10 INITIAL DIAGNOSTIC CHECK
General
Initial Diagnostics
3.11 INSTRUMENT MODULE (IM) SELF-DIAGNOSTICS
General
Diagnostics
3.12 BREAKOUT BOX: TSM/HFSM
General
Installation
Removal
3.13 FAILS TO DISARM (HFSM ONLY)
General
Job/Time Codes
Diagnostics
3.14 DTC B0563
General
Diagnostics
3.15 TSM/HFSM: TURN SIGNAL ERRORS AND DTCS
General
Diagnostics
3.16 DTC B1131, B1132 (HFSM ONLY)
General
Diagnostics
3.17 DTC B1134 STARTER OUTPUT HIGH
General
Diagnostics
3.18 DTC B1135
Diagnostics
3.19 DTC B1136, B1142 (HFSM ONLY)
Diagnostics
3.20 DTC B1141 (HFSM ONLY)
Diagnostics
3.21 DTC B1143, B1144, B1145 (HFSM ONLY)
General
Diagnostics
3.22 DTC B1154, B1155
Diagnostics
3.23 DTC U1016, U1255
General
Diagnostics
3.24 DTC U1300, U1301 OR BUS ER
Diagnostics
3.25 TSM/HFSM: PASSWORD LEARN
General
Password Learning
3.26 HFSM MAINTENANCE
General
Hands-Free Fob
Siren (If Installed)
4. ENGINE MANAGEMENT
4.1 SPECIFICATIONS
Specifications
4.2 EFI SYSTEM
General
Troubleshooting
4.3 DIAGNOSTIC INTRODUCTION
System Problems
Resolving Problems
4.4 CHECKING FOR TROUBLE CODES
Check Engine Lamp
Code Types
Retrieving Diagnostic Trouble Codes
Multiple Diagnostic Trouble Codes
4.5 INSTRUMENT MODULE (IM) SELF-DIAGNOSTICS
General
Diagnostics
4.6 BREAKOUT BOX: ECM
General
Installation
Removal
4.7 WIGGLE TEST
General
Procedure
4.8 INITIAL DIAGNOSTIC CHECK
General
Initial Diagnostics
4.9 ENGINE CRANKS, BUT WILL NOT START
General
Diagnostics
4.10 NO ECM POWER
General
Diagnostics
4.11 STARTS, THEN STALLS
General
Diagnostics
4.12 FUEL SYSTEM ELECTRICAL TEST
General
Diagnostics
4.13 SYSTEM RELAY FAULT
General
Diagnostics
4.14 FAN OPERATION CHECK
General
Diagnostics
4.15 IDLE AIR CONTROL
General
Diagnostics
4.16 MISFIRE AT IDLE OR UNDER LOAD
General
Diagnostics
4.17 COMBUSTION ABSENT/INTERMITTENT
General
Diagnostics
4.18 DTC P0107, P0108
General
Diagnostics
4.19 DTC P0112, P0113
General
Diagnostics
4.20 DTC P0117, P0118
General
Diagnostics
4.21 DTC P0122, P0123
General
Diagnostics
4.22 DTC P0131, P0132, P0134, P0151, P0152, P0154
General
Diagnostics
4.23 DTC P0261, P0262, P0263, P0264
General
Diagnostics
4.24 DTC P0373, P0374
General
Diagnostics
4.25 DTC P0444, P0445
General
Diagnostics
4.26 DTC P0501, P0502
General
Diagnostics
4.27 DTC P0562, P0563
General
Diagnostics
4.28 DTC P0603, P0605
General
Diagnostics
4.29 DTC P1009, P1010
General
Diagnostics
4.30 DTC P1351, P1352, P1354, P1355
General
Diagnostics
4.31 DTC P1501, P1502
General
Diagnostics
4.32 DTC U1064, U1255
General
Diagnostics
4.33 DTC U1096, U1255
General
Diagnostics
4.34 FUEL PRESSURE TEST
General
Diagnostics
5. ABS
5.1 ANTILOCK BRAKE SYSTEM (ABS) GENERAL INFORMATION
Antilock Brake System (ABS) Description
Code Types
Retrieving Diagnostic Trouble Codes
Multiple Trouble Codes
5.2 INSTRUMENT MODULE (IM) SELF-DIAGNOSTICS
General
Diagnostics
5.3 BREAKOUT BOX: ABS
General
Installation
Removal
5.4 INITIAL DIAGNOSTIC CHECK: ABS
General
Initial Diagnostics
5.5 ABS INDICATOR DIAGNOSTICS
ABS Indicator Always On Or Inoperative
5.6 DTC C0562
DTC C0562: Device Voltage Low
5.7 DTC C0563
DTC C0563: Device Voltage High
5.8 DTC C1017
DTC C1017: Pump Motor Power Circuit Open Fault
5.9 DTC C1018
DTC C1018: Pump Motor Ground High Resistance Fault
5.10 DTC C1021, C1023
DTC C1021, C1023: Wheel Speed Sensor Equals Zero (Front or Rear)
5.11 DTC C1025, C1027, C1206, C1208
DTC C1025, C1027, C1206, C1208: Wheel Speed Signal Intermittent or Frequency Out Of Range
5.12 DTC C1032, C1034
DTC C1032, C1034: Wheel Speed Sensor Circuit Open Or Shorted (Front or Rear)
5.13 DTC C1042
DTC C1042: Pump Motor Open
5.14 DTC C1043
DTC C1043: Pump Motor Stalled
5.15 DTC C1094
DTC C1094: Front Brake Switch Always On
5.16 DTC C1095
DTC C1095: Front Brake Switch Open
5.17 DTC C1151
DTC C1151: Front Wheel Release Too Long
5.18 DTC C1153
DTC C1153: Rear Wheel Release Too Long
5.19 DTC C1158
DTC C1158: Calibration Programming Required
5.20 DTC C1212
DTC C1212: Front or Rear Brake Not Applied with Decel
5.21 DTC C1214
DTC C1214: Rear Brake Switch Always On
5.22 DTC C1216
DTC C1216: Rear Brake Switch Open
5.23 DTC C1014, C1055-C1066, C1118, C1121
DTC C1014, C1055-C1066, C1118, C1121: ECU Internal Fault
5.24 DTC U1300, U1301 OR BUS ER
Diagnostics
A. APPENDIX A CONNECTOR REPAIR
A.1 AMP MULTILOCK CONNECTORS
AMP Multilock Connector Repair
A.2 DELPHI CONNECTORS
Delphi Connector Repair
A.3 DEUTSCH 1-PLACE ELECTRICAL CONNECTORS
Deutsch 1-Place Connector Repair
A.4 DEUSCH ELECTRICAL CONNECTORS
Deutsch Connector Repair
A.5 DEUTSCH STANDARD TERMINALS
Deutsch Standard Terminal Crimps
A.6 DEUTSCH MINI-TERMINAL CRIMPS
Deutsch Mini Terminal Crimps
A.7 DEUTSCH SOLID BARREL TERMINALS
Deutsch Solid Barrel Terminal Crimps
A.8 RELAY AND FUSE BLOCKS
Fuse Block Repair
A.9 150 METRI-PACK CONNECTORS
150 Metri-Pack Connector Repair
A.10 280 METRI-PACK CONNECTORS
280 Metri-Pack Connector Repair
A.11 480 METRI-PACK CONNECTORS
480 Metri-Pack Connector Repair
A.12 630 METRI-PACK CONNECTORS
630 Metri-Pack Connector Repair
A.13 800 METRI-PACK CONNECTORS
Delphi Main Fuse Housing Repair
A.14 METRI-PACK TERMINALS
Metri-Pack Terminal Crimps
A.15 MOLEX CONNECTORS
Molex Connector Repair
A.16 PACKARD ECM CONNECTOR
Packard 100W Connector Repair
A.17 PACKARD MICRO-64 CONNECTORS
Packard Micro-64 Connector Repair
A.18 SEALED SPLICE CONNECTORS
Sealed Splice Connector Repair
B. APPENDIX B WIRING
B.1 CONNECTORS
Connector Locations
B.2 WIRING DIAGRAMS
Wiring Diagram Information
2009 VRSC Wiring Diagrams
C. APPENDIX C CONVERSIONS
C.1 METRIC CONVERSION
Conversion Table
C.2 FLUID CONVERSIONS
United States System
Metric System
British Imperial System
C.3 TORQUE CONVERSIONS
United States System
Metric System
D. APPENDIX D GLOSSARY
D.1 GLOSSARY
Acronyms and Abbreviations
E. APPENDIX E TSM/TSSM (JAPAN/KOREA)
E.1 TSM/TSSM (JAPAN/KOREA) OVERVIEW
General
Troubleshooting
E.2 TSM/TSSM FEATURES
Turn Signal Functions
Bank Angle Function
Clutch/Neutral Interlock Functions
Security Alarm and Immobilization Functions
E.3 TSM/TSSM VEHICLE DELIVERY
General
Configuring A TSSM
Power Disruption and Configuring
Key FOB Assignment: TSSM
Pin Entry: TSSM
Changing the Pin: TSSM
E.4 TSM/TSSM TURN SIGNAL FUNCTIONS
General
Automatic Cancellation
Manual Cancellation
Four-Way Flashing
Diagnostics Mode
E.5 TSM/TSSM BANK ANGLE FUNCTION
General
Operation
E.6 SECURITY SYSTEM FUNCTIONS: TSSM
General
Alarm Sensitivity: TSSM
Auto-Arming Function: TSSM
Storage Mode: TSSM
E.7 ARMING/DISARMING: TSSM
General
Security Lamp
Using Key FOB: TSSM
Using the Pin
E.8 DIAGNOSTIC TROUBLE CODES (DTCS)
TSM/TSSM
Code Types
Retrieving Diagnostic Trouble Codes
Multiple Diagnostic Trouble Codes
E.9 INITIAL DIAGNOSTIC CHECK: TSM/TSSM
General
Initial Diagnostics
E.10 INSTRUMENT MODULE (IM) SELF-DIAGNOSTICS
General
Diagnostics
E.11 BREAKOUT BOX: TSM/TSSM
General
Installation
Removal
E.12 FAILS TO DISARM
General
Diagnostics
E.13 TURN SIGNAL ERRORS: B1121, B1122, B1141
General
Diagnostics
E.14 DTC B0563
General
Diagnostics
E.15 DTC B1131, B1132
General
Diagnostics
E.16 DTC B1134
General
Diagnostics
E.17 DTC B1135
General
E.18 DTC B1154, B1155
General
Diagnostic Notes
E.19 DTC U1016
General
Diagnostics
E.20 DTC U1300, U1301 OR BUS ER
General
Diagnostics
E.21 PASSWORD LEARN
General
Password Learning
E.22 TSSM MAINTENANCE
General
Key FOB
Siren (If Installed)
TOOLS
TORQUE VALUES
INDEX