Harley Davidson FLSTFI Fat Boy 2002 Service Repair Manual

2002 Softail: TSM & TSSM 3-1 HOME TSM/TSSM OVERVIEW 3.1 GENERAL See Figure 3-1. The turn signal module (TSM) has two major functions: ● Control turn signals. ● Serve as bank angle sensor. The optional, factory-installed, security system (turn signal security module or TSSM) provides the same functionality as the TSM, but also includes: ● Security and immobilization functions. See 3.2 TSM/TSSM FEATURES for complete details. TROUBLESHOOTING Problems fall into at least one of four categories: ● Turn signal malfunction. ● Bank angle (engine disable). ● Security lamp problem (TSSM only). ● Security system malfunction (TSSM only). To resolve TSM/TSSM problems, five basic steps are involved. In order of occurrence, they are: 1. Check for trouble codes by observing the turn signals. See 3.8 CHECKING FOR TROUBLE CODES: TSM/ TSSM. 2. Retrieve trouble codes using SCANALYZER (Part No. HD-41325) or TSM/TSSM diagnostics. See 3.11 SCAN- ALYZER: EFI MODELS ONLY or 3.8 CHECKING FOR TROUBLE CODES: TSM/TSSM. 3. Diagnose system problems. This involves using special tools and the diagnostic flow charts in this section. 4. Correct problems through the replacement and/or repair of the affected components. 5. After repairs are performed, the work must be validated. This involves clearing the trouble codes and confirming proper vehicle operation as indicated by the behavior of the turn signals. Figure 3-1. TSM/TSSM Figure 3-2. Key Fob 7844 s0457xtm

3-2 2002 Softail: TSM & TSSM HOME Figure 3-3. Simpliﬁed TSM/TSSM Wiring: See Diagrams For Wire Colors – + 11 9 5 6 12 3 4 12 7 8 2 1 – + 11 10 9 5 6 4 3 7 8 2 1 s0476x9x Battery backed siren (optional) Start switch Run/stop switch Starter relay Starter Left turn lamps Right turn lamps ECM GND Right turn switch Left turn switch Ignition switch Fuse block Security fuse IGN fuse ACC fuse Main circuit breaker Battery TSM/ TSSM Fuel Injected Models Carbureted Models Left turn lamps Right turn lamps Speedometer security lamp Speedometer GND Vehicle speed sensor Right turn switch Left turn switch ACC fuse IGN fuse Security fuse Ignition switch Main circuit breaker Fuse block Battery Battery backed siren (optional) Ignition module Start switch Run/stop switch Starter relay Starter TSM/ TSSM NOTES ● Pin 10 not connected on fuel injected models. ● Pin 4 (security lamp) and Pin 11 (siren) not used on TSM. NOTE Pin 4 (security lamp) and Pin 11 (siren) not used on TSM. Speedometer security lamp ECM IGN IGN BATT IGN IGN BATT

2002 Softail: TSM & TSSM 3-3 HOME TSM/TSSM FEATURES 3.2 GENERAL The TSM/TSSM provides the following capabilities. Note that some hardware options and software settings are dependent upon vehicle market specifications. TURN SIGNAL FUNCTIONS TSM/TSSM Features See 3.4 TSM/TSSM TURN SIGNAL FUNCTIONS for complete details. ● Manual turn signal control: Manual activation/deactiva- tion of left and right turn signal flashing sequences. ● Automatic turn signal cancellation: Automatic cancellation of left and right turn signal flashing sequences based on either vehicle speed, vehicle acceleration or turn completion. ● Emergency flashers: Four-way left and right turn signal flashing capability. ● Turn signal lamp diagnostics: Self-diagnostics for short circuit and open lamp conditions on both left and right turn signal systems. BANK ANGLE FUNCTIONS TSM/TSSM Features See 3.5 TSM/TSSM BANK ANGLE FUNCTION for complete details. ● Emergency engine shutdown: Monitors vehicle lean and will provide engine shutdown when lean exceeds 45° from vertical for more than one second. ● Emergency outputs disable: Monitors vehicle lean and will disable turn signal lamps and starter motor when lean exceeds 45° from vertical for more than one second. SECURITY ALARM AND IMMOBILIZATION FUNCTIONS TSSM Only Feature The following information applies only to vehicles with the security option (TSSM). See 3.6 SECURITY SYSTEM (TSSM) FUNCTIONS for more information. ● Remote arming/disarming: See Figure 3-4. Owners may enable and disable security alarm and immobilization functions with a remote, personally carried transmitter. This transmitter is referred to as a key fob within this document. ● Security status lamp: See Figure 3-5. A lamp within the speedometer face tells the rider if the system is armed or disarmed. ● Personal code disarming: If a key fob is not available, the TSSM allows the rider to disable the security alarm and immobilization functions if the rider knows the previously entered personal code. ● Security command confirmation: When the system is armed or disarmed, the system provides visual feedback to the rider by flashing the turn signals and sounding the optional siren. Figure 3-4. Key Fob Figure 3-5. TSSM Lamp s0457xtm 0 10 30 20 50 40 110 120 60 70 80 90 100 MPH H A R L E Y-D A VID S O N C E R TIFIE D s0520xtm

3-4 2002 Softail: TSM & TSSM HOME ● Auto-arming: Automatically enables the security alarm and immobilization functions when the ignition key is switched OFF. NOTE Default auto-arming behavior depends upon vehicle market. All HDI vehicles have auto-arming by default. Motorcycles sold in other markets have auto-arming disabled, but it may be activated. See 3.3 TSM/TSSM VEHICLE DELIVERY. ● Transport mode: It is possible to arm the security system without enabling the motion detector for one ignition cycle. This allows the vehicle to be moved in an immobi- lized state. ● Starter/ignition disable: Should the security alarm and immobilization functions be triggered by a vehicle security condition, the starter and ignition system will be disabled. ● Security system alarm: See Figure 3-6. The system will alternately ﬂash the left and right turn signals and sound an optional siren if a vehicle security condition is detected while the system is armed. Figure 3-6. Siren o0236xox

2002 Softail: TSM & TSSM 3-5 HOME TSM/TSSM VEHICLE DELIVERY 3.3 GENERAL 1WARNING 1WARNING ONLY FLT Harley-Davidson Motorcycles are suitable for sidecar use. Consult your Harley-Davidson Dealer. Use of vehicles other than FLT models for this purpose could result in death or serious injury. Setting up a vehicle TSM/TSSM depends on two factors: ● Does the vehicle have a sidecar attached? ● Does the vehicle have a turn signal module (TSM) or the optional security system (TSSM) installed? All motorcycles ship with the TSM/TSSM set for use without a sidecar installed. If a motorcycle is equipped with a TSM, no further configuration is required. However, if a motorcycle has a sidecar or an optional security system (TSSM) installed, perform the following steps as necessary. CAUTION If the vehicle is being operated with a sidecar, the setting MUST be switched from solo vehicle operation to sidecar operation or the TSM/TSSM will not function properly. 1. Configure the TSM/TSSM for sidecar or solo configuration. If no sidecar is installed, skip this step. 2. Configure TSSM motorcycles by assigning both key fobs to the vehicle. 3. Configure TSSM motorcycles by entering a personal code picked by the owner. The personal code allows the owner to operate the system if the key fob is lost or inop- erable. Record this code in the owner’s manual and instruct the customer to carry a copy. IMPORTANT NOTE Do not forget to enter a personal code for TSSM vehicles. If a code is not assigned and the key fob is lost or damaged while the vehicle is armed, the TSSM must be replaced. Changes to TSM/TSSM settings are made by a series of programming operations involving the ignition key, left/right turn signal switches and key fob (security systems). At certain steps in the programming sequence, the motorcycle may provide confirmation of settings by flashing the turn signals, turn signal indicators and/or security lamp. All programming operations are listed in table format. Follow the numbered steps to configure the system. If a confirmation response is listed, wait for the confirmation before continuing to the next step. Important information pertaining to certain actions will be found in the NOTES column. USING SCANALYZER ON EFI MODELS The SCANALYZER CARTRIDGE (Part No. HD-41325-95C) has TSM/TSSM configuration capability on fuel injected Sof- tails. SIDECAR CONFIGURATION 1WARNING 1WARNING ONLY FLT Harley-Davidson Motorcycles are suitable for sidecar use. Consult your Harley-Davidson Dealer. Use of vehicles other than FLT models for this purpose could result in death or serious injury. On motorcycles with a sidecar, the TSM/TSSM must be switched from the factory solo vehicle setting to the sidecar setting. See Table 3-1. If a sidecar is removed from the motorcycle, the TSM/TSSM must be reconfigured. See Table 3-2. POWER DISRUPTION AND CONFIGURING The TSM/TSSM will not enter configuration mode on the first attempt after battery voltage has been removed from Pin 1. This will occur after any of the following situations: ● Battery disconnect or power drain. ● Security fuse removal. ● Connecting Breakout Box to TSM/TSSM connector. Therefore, after all battery reconnects, the configuration sequence must be modified as follows. 1. Set run switch to OFF , cycle ignition key ON-OFF-ON- OFF-ON and press left turn signal switch twice. 2. Repeat step listed above. 3. Continue with configuration sequence listed.

3-6 2002 Softail: TSM & TSSM HOME KEY FOB ASSIGNMENT The key fob on TSSM motorcycles must be set so it will operate the alarm system on the vehicle. This assignment must be completed with no pauses between steps greater than 10 seconds. Turn the ignition OFF after all key fobs have been assigned. The programming mode will also exit after 60 seconds has elapsed without detecting any fob signup messages or turn signal switch activity. Two key fobs may be assigned to the TSSM. The first suc- cessful attempt to program a fob will disable all previously assigned fobs. If a second fob is to be programmed, it must be done in the same programming sequence as the initial fob. To assign a key fob to a motorcycle, see Table 3-3. PERSONAL CODE ENTRY First Time Code Entry: TSSM Only IMPORTANT NOTE Do not forget to enter a personal code for TSSM vehicles. If a code is not assigned and the key fob is lost or damaged while the vehicle is armed, the TSSM must be replaced. The TSSM personal code consists of five digits. Each digit can be any number from 1-9. The personal code must be used to disarm the security system in case the key fob becomes unavailable. To set a personal code on a motorcycle with no code previously installed, see Table 3-4. The procedure listed uses 3-1- 3-1-3 as the desired personal code. NOTE For better security, do not use 3-1-3-1-3 as a personal code. It is shown as an example only. Decide what five digit code the owner would like to use. The code will be programmed using the turn signal switches and key fob. Keep a record of the code in a secure place such as your wallet or the owner’s manual. ● When programming the personal code, the security lamp flashes to provide feedback when entering each digit. ● The number of security lamp flashes corresponds to the number currently selected for a given digit. Therefore, the lamp may flash 1-9 times depending on the number entered. ● Press the left turn switch one time to increment each digit of the code. ● Quickly press the key fob button twice to advance to the next digit of the code. NOTE The programming mode exits upon turning the key switch to OFF or if no turn signal switch/key fob button activity occurs for 60 seconds. No data is saved for partial configuration attempts. Modifying Existing Codes: TSSM Only If a code was previously entered, the lamp will flash the equivalent digit. Each additional press of the left turn switch will increment the digit. ● To advance from 5 to 6, press and release the left turn switch 1 time. ● To advance from 8 to 2, press and release the left turn switch 3 times (9-1-2). Table 3-1. Configuring TSM/TSSM for Sidecar Use NO. ACTION WAIT FOR CONFIRMATION NOTES 1 Set RUN/OFF switch to OFF Verify that security lamp is not blinking (vehicle is disarmed) 2 Turn IGN key ON-OFF-ON-OFF-ON 3 Press left turn switch 2 times and release 1-3 flashes turn signals & indicators depending on vehicle configuration (See section under 3.3 TSM/TSSM VEHICLE DELIVERY regarding battery disconnects.) 1 flash-Worldwide TSM, no security 2 flashes-North American/ Domestic configuration TSSM 3 flashes-European/HDI configuration TSSM 4 Press right turn switch 1 time and release 1 flash turn signals & indicators 5 Press right turn switch 1 time and release 2 flashes turn signals & indicators 6 Press left turn switch 1 time and release 1 flash turn signals & indicators 7 Press left turn switch 1 time and release 2 flashes turn signals & indicators 8 Turn IGN key OFF

2002 Softail: TSM & TSSM 3-7 HOME Table 3-2. Configuring TSM/TSSM for Solo Vehicle Use NO. ACTION WAIT FOR CONFIRMATION NOTES 1 Set RUN/OFF switch to OFF Verify that security lamp is not blinking (vehicle is disarmed) 2 Turn IGN key ON-OFF-ON-OFF-ON 3 Press left turn switch 2 times and release 1-3 flashes turn signals & indicators depending on vehicle configuration (See section under 3.3 TSM/TSSM VEHICLE DELIVERY regarding battery disconnects.) 1 flash-Worldwide TSM, no security 2 flashes-North American/ Domestic configuration TSSM 3 flashes-European/HDI configuration TSSM 4 Press right turn switch 1 time and release 1 flash turn signals & indicators 5 Press right turn switch 1 time and release 2 flashes turn signals & indicators 6 Press left turn switch 1 time and release 2 flashes turn signals & indicators 7 Press left turn switch 1 time and release 1 flash turn signals & indicators 8 Turn IGN key OFF Table 3-3. TSSM Key Fob Assignment NO. ACTION WAIT FOR CONFIRMATION NOTES 1 Set RUN/OFF switch to OFF Verify that security lamp is not blinking (vehicle is disarmed) This assignment procedure must be completed with no pauses between steps greater than 10 seconds 2 Turn IGN key ON-OFF-ON-OFF-ON 3 Press left turn switch 2 times and release 1-3 flashes turn signals & indicators depending on vehicle configuration (See section under 3.3 TSM/TSSM VEHICLE DELIVERY regarding battery disconnects.) 1 flash-Worldwide TSM, no security 2 flashes-North American/ Domestic configuration TSSM 3 flashes-European/HDI configuration TSSM 4 Press right turn switch 1 time and release 1 flash turn signals & indicators 5 Press left turn switch 1 time and release 2 flashes turn signals & indicators 6 Press and hold key fob button until confirmation is received 2 flashes turn signals & indicators This may take 10-25 seconds 7 If you have two key fobs, press and hold button on second key fob until confirmation is received 2 flashes turn signals & indicators optional step 8 Turn IGN key OFF

3-8 2002 Softail: TSM & TSSM HOME Table 3-4. Programming A TSSM Personal Code (Example: 3-1-3-1-3) With No Code Previously Installed NO. ACTION WAIT FOR CONFIRMATION NOTES 1 Set RUN/OFF switch to OFF Verify that security lamp is not blinking (vehicle is disarmed) 2 Turn IGN key ON-OFF-ON-OFF-ON 3 Press left turn switch 2 times and release 1-3 flashes turn signals & indicators depending on vehicle configuration (See section under 3.3 TSM/TSSM VEHICLE DELIVERY regarding battery disconnects) 1 flash-Worldwide TSM, no security 2 flashes-North American/ Domestic configuration TSSM 3 flashes-European/HDI configuration TSSM 4 Quickly press key fob button 2 times and release 1 flash turn signals & indicators Vehicle is in personal code entry mode 5 Press left turn switch 1 time and release None if no code entered A lack of confirmation flashes indicates no digit is entered 1 - 9 flashes if code previously entered 6 Press and release left turn switch to advance through the digits In this example, you will press and release three times security lamp flashes to indicate each digit selected In this example, the lamp will flash 3 times You’ve selected 3 as a number for the first digit 7 Quickly press key fob button 2 times and release 2 flashes turn signals & indicators You’ve confirmed 3 as a number for the first digit and have advanced to entering the second digit 8 Press left turn switch 1 time and release none A lack of confirmation flashes indicates no digit is entered 9 Press and release left turn switch to advance through the digits In this example, you will perform this step one time security lamp flashes to indicate each digit selected In this example, the lamp will flash 1 time You’ve selected 1 as a number for the second digit 10 Quickly press key fob button 2 times and release 3 flashes turn signals & indicators You’ve confirmed 1 as a number for the second digit and have advanced to entering the third digit 11 Press left turn switch 1 time and release none A lack of confirmation flashes indicates no digit is entered 12 Press and release left turn switch to advance through the digits In this example, you will repeat this step three times security lamp flashes to indicate each digit selected In this example, the lamp will flash 3 times You’ve selected 3 as a number for the third digit 13 Quickly press key fob button 2 times and release 4 flashes turn signals & indicators You’ve confirmed 3 as a number for the third digit and have advanced to entering the fourth digit 14 Press left turn switch 1 time and release none A lack of confirmation flashes indicates no digit is entered 15 Press and release left turn switch to advance through the digits In this example, you will perform this step one time security lamp flashes to indicate each digit selected In this example, the lamp will flash 1 time You’ve selected 1 as a number for the fourth digit

2002 Softail: TSM & TSSM 3-9 HOME 16 Quickly press key fob button 2 times and release 5 flashes turn signals & indicators You’ve confirmed 1 as a number for the fourth digit and have advanced to entering the fifth digit 17 Press left turn switch 1 time and release none A lack of confirmation flashes indicates no digit is entered 18 Press and release left turn switch to advance through the digits In this example, you will repeat this step three times security lamp flashes to indicate each digit selected In this example, the lamp will flash 3 times You’ve selected 3 as a number for the fifth digit 19 Quickly press key fob button 2 times and release 1 flash turn signals & indicators You’ve confirmed 3 as a number for the fifth digit and have gone back to the first digit 20 Turn IGN key OFF 21 Write down code in owner’s manual 22 Arm the security system and attempt to disarm using personal code entry. See Table 3-10. Table 3-4. Programming A TSSM Personal Code (Example: 3-1-3-1-3) With No Code Previously Installed NO. ACTION WAIT FOR CONFIRMATION NOTES

3-10 2002 Softail: TSM & TSSM HOME TSM/TSSM TURN SIGNAL FUNCTIONS 3.4 GENERAL The TSM/TSSM’s turn signal feature has several modes: ● Automatic cancellation. ● Manual cancellation. ● Four-way flashing. ● Diagnostics mode. Turn signals cannot be activated or deactivated when the ignition key is in the ACC position. The turn signals can only be activated or deactivated with the ignition key in the IGN position. CAUTION If the vehicle is being operated with a sidecar, the setting MUST be switched from solo vehicle operation to sidecar operation or the TSM/TSSM will not function properly. If a sidecar is installed, reconfigure the TSM/TSSM using the method under 3.3 TSM/TSSM VEHICLE DELIVERY. AUTOMATIC CANCELLATION Press the left or right turn switch to activate automatic turn signal cancellation. There is no need to hold the turn switch in when approaching the turn. The TSM/TSSM will not cancel the signal before the turn is actually completed. ● When the directional switch is released, the system starts a 20 count. As long as the vehicle is traveling above 7 MPH the directional will always cancel after 20 flashes if the system does not recognize any other input. ● If the vehicle speed drops to 7 MPH or less, including stopped, the directionals will continue to flash. Counting will resume when vehicle speed reaches 8 MPH and will automatically cancel when the count total equals 20 as stated above. ● The turn signals will cancel within two seconds upon turn completion if the turn is greater than 45 degrees. A sensor inside the TSM/TSSM cancels the signal after the vehicle has been returned to an upright position. NOTE The bank angle cancellation function has a calibration feature. Ride the motorcycle for 1/4 mile (0.4 KM) at steady speeds (upright) to calibrate the system. MANUAL CANCELLATION If you want to stop the turn signals from flashing, briefly depress the turn signal switch a second time. If you are signalling to turn in one direction and you depress the switch for the opposite turn signal, the first signal is can- celled and the opposite side begins flashing. FOUR-WAY FLASHING Use the following method to activate the four-way flashers. 1. With the ignition key ON and security system disarmed (models with security only), press the left and right turn signal switches at the same time. 2. Turn the ignition key OFF and arm the security system if present and desired. The four-way flashers will continue for two hours. 3. To cancel four-way flashing, disarm the security system if necessary, turn the ignition key ON and press the left and right turn signal switches at the same time. NOTE Auto-arming (always active on HDI bikes, user selectable on other vehicles) requires that the four-way flashers be activated within 30 seconds of key OFF or after the vehicle has been disarmed. This system allows a stranded vehicle to be left in the four- way flashing mode and secured until help is found. If the security system is disarmed while the four-way flashers are active, the lights will flash as follows: 1. TSSM stops four-way flashing mode. Motorcycle sits for 1 second with turn signals off. 2. TSSM performs disarming confirmation (1 flash). 3. Motorcycle sits for 1 second with turn signals off. 4. Motorcycle restarts four-way flashing mode. DIAGNOSTICS MODE The TSM/TSSM measures the current when the turn signals are used. If there is a burned out light bulb on one side, the remaining light and the corresponding turn signal indicator flash at double the normal rate starting with the fifth flash. Other diagnostic conditions monitored include: ● Short circuit in the turn signal wiring. ● Open circuit in the turn signal wiring. ● Stuck turn signal switch. NOTE ● A stuck turn signal switch will disable the automatic turn signal cancellation feature. ● If a stuck switch is detected, you must hold the left and right turn signal switches in for more than one second to activate the four-way flashers. See 3.8 CHECKING FOR TROUBLE CODES: TSM/TSSM for more information.

Harley Davidson FLSTFI Fat Boy 2002 Service Repair Manual

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