2008 Harley-Davidson Softail Models Service & Repair Manual

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-Dav- idson products more pleasant and profitable. HOW TO USE YOUR SERVICE MANUAL Refer to the table below for the content layout of this manual. CHAPTER NO. Starting / Charging 1 Instruments 2 TSM/HFSM 3 Engine Management 4 Appendix A Connector Repair A Appendix B Wiring B Appendix C Conversions C Appendix D Glossary D Appendix E TSM/TSSM (Japan/Korea) E 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. For example, a cross-reference shown as 2.1 SPECIFICA- TIONS refers to chapter 2 CHASSIS, heading 2.1 SPECIFIC- ATIONS. 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 GLOSSAR Y for a list of acronyms, abbreviations and definitions. PREPARATION FOR SERVICE 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. A clean work area at the start of each job will allow you to perform the repair as easily and quickly as possible, and will reduce the incidence of misplaced tools and parts. A motorcycle that is excessively dirty should be cleaned before work starts. Cleaning will occasionally uncover sources of trouble. Tools, instruments and any parts needed for the job should be gathered before work is started. Interrupting a job to locate tools or parts is a distraction and causes needless delay. NOTES • To avoid unnecessary disassembly, carefully read all rel- ative service information before repair work is started. • 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), you must first disarm the security system. Either keep the fob in close proximity to the vehicle, or use Digital Technician to disable the security system while the vehicle is being serviced and re-enable the system after service is completed. SERVICE BULLETINS In addition to the information presented in this Service Manual, Harley-Davidson 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 Do not use aftermarket parts and custom made front forks which can adversely affect performance and handling. Removing or altering factory installed parts can adversely affect performance and could result in death or serious injury. (00001a) To ensure 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 experience.This is your assurance that the parts you are using will fit right, operate properly and last longer. WARNINGS AND CAUTIONS Statements in this service 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) CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. (00139a) CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage. (00140a) I FOREWORD

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 service 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 service manual. However, please remember that these warnings are not all-inclusive. Inadequate safety precau- tions 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 SPX Kent-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 Loctite product usage or retailer/wholesaler locations, please contact Loctite Corp. at www.loctite.com. PRODUCT REGISTERED MARKS Allen, Amp Multilock, Bluetooth, Brembo, Delphi, Deutsch, Dunlop, Dynojet, Fluke, G.E. Versilube, Gunk, Hydroseal, Hylomar, Kevlar, Lexan, Loctite, Lubriplate, Keps, K&N, Mag- naflux, Marson Thread-Setter Tool Kit, MAXI fuse, Molex, MPZ, Mulitilock, Novus, Packard, Pirelli, Permatex, Philips, PJ1, Pozidriv, Robinair, S100, Sems, Snap-on, Teflon, Threadlocker, Torca, Torco, TORX, Tufoil, Tyco, Ultratorch, Velcro, X-Acto, and XM Satellite Radio are among the trademarks of their respective owners. H-D MICHIGAN, INC. TRADEMARK INFORMATION Harley, Harley-Davidson, H-D, Bar & Shield, Digital Tech, Digital Technician, Destroyer, Deuce, Dyna, Electra Glide, Evolution, Fat Boy, Glaze, Gloss, H-D, H-Dnet.com, HD, Harley, Heritage Softail, Heritage Springer, Low Rider, Night Rod, Night Train, Profile, Revolution, Road Glide, Road King, Rocker, Softail, Sportster, Sun Ray, Sunwash, Tech Link, Twin Cam 88, Twin Cam 88B, Twin Cam 96, Twin Cam 96B, Twin Cam 103, Twin Cam 103B, Twin Cam 110, Twin Cam 110B, Tour- Pak, Screamin' Eagle, Softail, Super Guide, Super Premium, SYN3, Ultra Glide, V-Rod, VRSC, V-Rod, VRSC, Wide Glide, 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. 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. II FOREWORD

STARTING / CHARGING 1.1 STARTER TROUBLESHOOTING General...............................................................................1-1 Starter Troubleshooting......................................................1-1 1.2 STARTING SYSTEM DIAGNOSIS Diagnostics.........................................................................1-3 Diagnostic Notes.........................................................1-3 Job/Time Code Values................................................1-3 1.3 DIAGNOSTICS/TROUBLESHOOTING Voltage Drop.....................................................................1-13 1.4 STARTER ACTIVATION CIRCUITS Starter Activation Circuits.................................................1-14 1.5 TESTING STARTER ON MOTORCYCLE Start Relay Test................................................................1-15 Starter Current Draw Test.................................................1-16 1.6 TESTING STARTER ON BENCH Free Running Current Draw Test......................................1-17 Starter Solenoid................................................................1-17 Solenoid Pull-In Test.........................................................1-17 Solenoid Hold-In Test........................................................1-17 Solenoid Return Test........................................................1-18 1.7 CHARGING SYSTEM General.............................................................................1-19 Alternator...................................................................1-19 Voltage Regulator......................................................1-19 Troubleshooting................................................................1-19 Battery.......................................................................1-19 Wiring........................................................................1-19 Job/Time Code Values..............................................1-19 Testing..............................................................................1-23 Milliampere Draw Test...............................................1-23 Total Current Draw Test.............................................1-23 Current and Voltage Output Test: Using HD-48053....1-24 Current and Voltage Output Test: Using Load Tester.........................................................................1-24 Stator Check..............................................................1-25 AC Output Check......................................................1-25 1.8 BATTERY TESTING General.............................................................................1-27 Voltmeter Test...................................................................1-27 Conductance Test.............................................................1-27 Load Test..........................................................................1-27 INSTRUMENTS 2.1 CHECKING FOR DIAGNOSTIC TROUBLE CODES Check Engine Lamp...........................................................2-1 Security Lamp....................................................................2-2 Turn Signal Module (TSM)..........................................2-2 Turn Signal Security Module (TSSM) or Hands-Free Security Module (HFSM).............................................2-2 Code Types.........................................................................2-2 Current........................................................................2-3 Historic........................................................................2-3 Retrieving Diagnostic Trouble Codes..................................2-3 Multiple Diagnostic Trouble Codes.....................................2-3 2.2 INITIAL DIAGNOSTIC CHECK: SPEEDOMETER General...............................................................................2-4 Diagnostic Notes.........................................................2-4 Circuit Diagram/Wire Harness Connector Table..........2-4 Job/Time Code Values................................................2-4 Reprogramming ECM..................................................2-4 Initial Diagnostics...............................................................2-4 Diagnostic Tips............................................................2-4 Diagnostic Notes.........................................................2-5 Other Diagnostic Trouble Codes..................................2-5 2.3 SPEEDOMETER SELF DIAGNOSTICS General.............................................................................2-10 Diagnostics.......................................................................2-10 Diagnostic Tips..........................................................2-10 Diagnostic Notes.......................................................2-10 2.4 SPEEDOMETER General.............................................................................2-12 Trip Odometer Reset Switch.....................................2-12 Speedometer Theory of Operation...................................2-12 Odometer Theory of Operation.........................................2-12 2.5 BREAKOUT BOX: SPEEDOMETER General.............................................................................2-13 Installation........................................................................2-13 Removal...........................................................................2-13 2.6 FUEL GAUGE Theory of Operation.........................................................2-14 Fuel Gauge and Sender Test............................................2-14 2.7 INDICATOR LAMPS General.............................................................................2-15 Job/Time Code Values..............................................2-15 Diagnostics.......................................................................2-16 Diagnostic Notes.......................................................2-16 2.8 DTC B1004, B1005 General.............................................................................2-19 Diagnostics.......................................................................2-19 Diagnostic Tips..........................................................2-19 Diagnostic Notes.......................................................2-19 2.9 DTC B1006, B1007 General.............................................................................2-23 Accessory or Ignition Line Overvoltage.....................2-23 2.10 DTC B1008 General.............................................................................2-25 Trip Odometer Reset Switch Closed.........................2-25 Diagnostics.......................................................................2-25 Diagnostic Notes.......................................................2-25 2.11 DTC U1016, U1255 General.............................................................................2-28 Loss of ECM Serial Data...........................................2-28 Diagnostics.......................................................................2-28 Diagnostic Notes.......................................................2-28 2.12 DTC U1064, U1255 General.............................................................................2-31 III TABLE OF CONTENTS

Loss of TSM/TSSM/HFSM Serial Data.....................2-31 Diagnostics.......................................................................2-31 Diagnostic Notes.......................................................2-31 2.13 DTC U1300, U1301 OR BUS ER General.............................................................................2-34 Serial Data Low or Serial Data Open/High................2-34 Diagnostics.......................................................................2-34 Diagnostic Tips..........................................................2-34 Diagnostic Notes.......................................................2-34 TSM/HFSM 3.1 TURN SIGNAL OVERVIEW General...............................................................................3-1 Security System: Japan/Korea...........................................3-1 Turn Signal Functions.........................................................3-1 Manual Cancellation...........................................................3-1 Automatic Cancellation.......................................................3-1 Bank Angle Functions........................................................3-1 Bank Angle Restart............................................................3-1 Clutch/Neutral Interlock......................................................3-1 Security System H-DSSS...................................................3-1 3.2 HARLEY-DAVIDSON SMART SECURITY SYSTEM Components.......................................................................3-2 Security Immobilization......................................................3-2 HFSM Features..................................................................3-3 3.3 H-DSSS ACTUATION General...............................................................................3-5 Sidecar Configuration.........................................................3-5 Actuation............................................................................3-5 Fob Assignment..................................................................3-5 Power Disruption and Configuring......................................3-5 3.4 PERSONAL IDENTIFICATION NUMBER (PIN) General...............................................................................3-6 Initial Pin Entry...................................................................3-6 Changing the Pin................................................................3-6 Modifying an Existing Pin............................................3-6 3.5 ARMING/DISARMING SECURITY SYSTEM Hands-Free Fob..................................................................3-8 Security Lamp (Key Icon)...................................................3-8 Arming................................................................................3-8 Disarming...........................................................................3-9 Disarming with a Personal Identification Number (PIN).....3-9 3.6 WARNINGS AND ALARMS Warnings..........................................................................3-10 Alarm................................................................................3-10 Activation...................................................................3-10 Deactivation...............................................................3-10 Siren Chirp Mode (Confirmation)......................................3-10 Chirpless Mode.........................................................3-10 Chirp Mode................................................................3-10 Switching Modes.......................................................3-10 3.7 SERVICE/EMERGENCY FUNCTIONS Transport Mode................................................................3-11 To Enter Transport Mode...........................................3-11 To Exit Transport Mode..............................................3-11 Service Mode...................................................................3-11 Four-Way Flashing...........................................................3-11 To Arm the HFSM with the Hazard Warning Flashers ON.............................................................................3-11 To Disarm the HFSM and Turn the Hazard Warning Flashers OFF............................................................3-11 3.8 TROUBLESHOOTING Turn Signals (TSM/HFSM)...............................................3-12 Security System (HFSM)..................................................3-12 Diagnostics Mode.............................................................3-12 Troubleshooting................................................................3-12 3.9 CHECKING FOR DIAGNOSTIC TROUBLE CODES General.............................................................................3-13 Security/Lamp Diagnostics...............................................3-13 Code Types.......................................................................3-14 Current......................................................................3-14 Historic......................................................................3-14 Retrieving DTCs...............................................................3-14 Multiple DTCs/Priority Order............................................3-15 3.10 INITIAL DIAGNOSTIC CHECK: TSM/HFSM General.............................................................................3-16 Diagnostic Notes.......................................................3-16 Circuit Diagram/Wire Harness Connector Table........3-16 Job/Time Codes........................................................3-16 Reprogramming ECM................................................3-16 Initial Diagnostics.............................................................3-16 Diagnostic Tips..........................................................3-16 Diagnostic Notes.......................................................3-16 Other Diagnostic Trouble Codes (DTCs)...................3-17 3.11 SPEEDOMETER SELF DIAGNOSTICS General.............................................................................3-21 Diagnostics.......................................................................3-21 Diagnostic Tips..........................................................3-21 Diagnostic Notes.......................................................3-21 3.12 BREAKOUT BOX:TSM/HFSM General.............................................................................3-23 Installation........................................................................3-23 Removal...........................................................................3-23 3.13 FAILS TO DISARM (HFSM ONLY) General.............................................................................3-24 Job/Time Codes...............................................................3-24 Diagnostics.......................................................................3-24 Diagnostic Tips..........................................................3-24 Diagnostic Notes.......................................................3-24 IV TABLE OF CONTENTS TABLE OF CONTENTS

3.14 DTC B0563 General.............................................................................3-27 Diagnostics.......................................................................3-27 Diagnostic Tips..........................................................3-27 Diagnostic Notes.......................................................3-27 3.15 TSM/HFSM: TURN SIGNAL ERRORS AND DTCS General.............................................................................3-28 Diagnostics.......................................................................3-28 Job/Time Codes........................................................3-28 Diagnostic Tips..........................................................3-28 Diagnostic Notes: All Turn Signal Flow Charts..........3-31 3.16 DTC B1131, B1132 (HFSM ONLY) General.............................................................................3-42 Diagnostics.......................................................................3-42 Diagnostic Tips..........................................................3-42 Diagnostic Notes.......................................................3-42 3.17 DTC B1134 General.............................................................................3-45 Diagnostics.......................................................................3-45 Diagnostic Notes.......................................................3-45 3.18 DTC B1135 Diagnostics.......................................................................3-48 DTC B1135 Accelerometer Fault..............................3-48 3.19 DTC B1136, B1142 (HFSM ONLY) Diagnostics.......................................................................3-49 DTC B1136 Accelerometer Tip-Over Self-Test Fault..........................................................................3-49 DTC B1142 Internal Fault..........................................3-49 3.20 DTC B1141 (HFSM ONLY) Diagnostics.......................................................................3-50 Diagnostic Tips..........................................................3-50 Diagnostic Notes.......................................................3-50 3.21 DTC B1143, B1144, B1145 (HFSM ONLY) General.............................................................................3-54 Diagnostics.......................................................................3-54 Diagnostic Notes.......................................................3-54 3.22 DTC B1154, B1155 Diagnostics.......................................................................3-59 Diagnostic Tips..........................................................3-59 Diagnostic Notes.......................................................3-59 3.23 DTC U1016, U1255 General.............................................................................3-63 Diagnostics.......................................................................3-63 Diagnostic Notes.......................................................3-63 3.24 DTC U1300, U1301 OR BUS ER Diagnostics.......................................................................3-66 Diagnostic Tips..........................................................3-66 Diagnostic Notes.......................................................3-66 3.25 TSM/HFSM: PASSWORD LEARN General.............................................................................3-67 Password Learning...........................................................3-67 3.26 HFSM MAINTENANCE General.............................................................................3-68 Hands-Free Fob................................................................3-68 Schedule...................................................................3-68 Battery Replacement.................................................3-68 Siren (If Installed).............................................................3-68 Schedule...................................................................3-68 Battery Replacement: Early Style Siren....................3-68 Battery Replacement: Late Style Siren.....................3-68 ENGINE MANAGEMENT 4.1 SPECIFICATIONS Specifications.....................................................................4-1 4.2 EFI SYSTEM General...............................................................................4-2 Troubleshooting..................................................................4-2 4.3 EFI DIAGNOSTIC INTRODUCTION System Problems...............................................................4-5 No Start.......................................................................4-5 Poor Performance.......................................................4-5 Check Engine Lamp....................................................4-5 Resolving Problems............................................................4-5 4.4 CHECKING FOR DIAGNOSTIC TROUBLE CODES: EFI Check Engine Lamp...........................................................4-6 Code Types.........................................................................4-7 Current........................................................................4-7 Historic........................................................................4-7 Retrieving Diagnostic Trouble Codes..................................4-7 Multiple Diagnostic Trouble Codes.....................................4-7 4.5 INITIAL DIAGNOSTIC CHECK General...............................................................................4-8 Diagnostic Notes.........................................................4-8 Circuit Diagram/Wire Harness Connector Table..........4-8 Reprogramming ECM..................................................4-8 Initial Diagnostics...............................................................4-8 General Information.....................................................4-8 Diagnostic Tips............................................................4-8 Diagnostic Notes.........................................................4-8 Other Diagnostic Trouble Codes (DTCs).....................4-8 4.6 SPEEDOMETER SELF DIAGNOSTICS General.............................................................................4-16 Diagnostics.......................................................................4-16 Diagnostic Tips..........................................................4-16 Diagnostic Notes.......................................................4-16 4.7 BREAKOUT BOX: EFI General.............................................................................4-18 TABLE OF CONTENTS V TABLE OF CONTENTS

Installation........................................................................4-18 Removal...........................................................................4-18 4.8 WIGGLE TEST General.............................................................................4-20 Procedure.........................................................................4-20 4.9 INTAKE LEAK TEST General.............................................................................4-21 Leak Tester.......................................................................4-21 Parts List...................................................................4-21 Tester Assembly........................................................4-21 Tester Adjustment......................................................4-21 Procedure.........................................................................4-21 4.10 ENGINE CRANKS, BUT WILL NOT START General.............................................................................4-23 Diagnostics.......................................................................4-23 Diagnostic Notes.......................................................4-23 Diagnostic Tips..........................................................4-23 4.11 NO ECM POWER General.............................................................................4-30 No Spark/No Check Engine Lamp at Key On............4-30 Diagnostics.......................................................................4-30 Diagnostic Notes.......................................................4-30 4.12 STARTS,THEN STALLS General.............................................................................4-34 Diagnostic Trouble Codes U1300, U1301, or BUS ER.............................................................................4-34 Diagnostics.......................................................................4-34 Diagnostic Tips..........................................................4-34 Diagnostic Notes.......................................................4-34 4.13 FUEL SYSTEM ELECTRICAL TEST General.............................................................................4-39 Diagnostics.......................................................................4-39 Diagnostic Notes.......................................................4-39 4.14 SYSTEM RELAY CHECK General.............................................................................4-47 System Relay............................................................4-47 Diagnostics.......................................................................4-47 Diagnostic Notes.......................................................4-47 4.15 FUEL PRESSURE TEST General.............................................................................4-53 Testing..............................................................................4-53 Diagnostics.......................................................................4-55 Diagnostic Notes.......................................................4-55 4.16 IDLE AIR CONTROL General.............................................................................4-57 IAC Operation............................................................4-57 Diagnostic Trouble Code P0505: Loss of Idle Speed Control.......................................................................4-57 Diagnostics.......................................................................4-57 Diagnostic Tips..........................................................4-57 Diagnostic Notes.......................................................4-57 4.17 MISFIRE AT IDLE OR UNDER LOAD General.............................................................................4-62 Misfire at Idle or Under Load.....................................4-62 Diagnostics.......................................................................4-62 Diagnostic Notes.......................................................4-62 4.18 COMBUSTION ABSENT/INTERMITTENT General.............................................................................4-68 Diagnostic Trouble Codes P1353, P1356, P1357, P1358: No Combustion..........................................................4-68 Diagnostics.......................................................................4-68 Diagnostic Notes.......................................................4-68 4.19 DTC P0107, P0108 General.............................................................................4-73 MAP Sensor..............................................................4-73 Diagnostics.......................................................................4-73 Diagnostic Tips..........................................................4-73 Diagnostic Notes.......................................................4-73 4.20 DTC P0112, P0113 General.............................................................................4-77 IAT Sensor.................................................................4-77 Diagnostics.......................................................................4-77 Diagnostic Tips..........................................................4-77 Diagnostic Notes.......................................................4-77 4.21 DTC P0117, P0118 General.............................................................................4-81 ET Sensor.................................................................4-81 Diagnostics.......................................................................4-81 Diagnostic Tips..........................................................4-81 Diagnostic Notes.......................................................4-81 4.22 DTC P0122, P0123 General.............................................................................4-85 TP Sensor.................................................................4-85 Diagnostics.......................................................................4-85 Diagnostic Tips..........................................................4-85 Diagnostic Notes.......................................................4-85 4.23 DTC P0131, P0132, P0134, P0151, P0152, P0154 General.............................................................................4-89 Oxygen Sensor.........................................................4-89 Diagnostics.......................................................................4-89 Diagnostic Tips..........................................................4-89 Diagnostic Notes.......................................................4-89 4.24 DTC P0261, P0262, P0263, P0264 General.............................................................................4-94 Fuel Injectors.............................................................4-94 Diagnostics.......................................................................4-94 Diagnostic Notes.......................................................4-94 4.25 DTC P0373, P0374 General...........................................................................4-100 CKP Sensor............................................................4-100 VI TABLE OF CONTENTS TABLE OF CONTENTS

Diagnostics.....................................................................4-100 Diagnostic Tips........................................................4-100 Diagnostic Notes.....................................................4-100 4.26 DTC P0501, P0502 General...........................................................................4-103 Vehicle Speed Sensor (VSS)..................................4-103 Diagnostics.....................................................................4-103 Diagnostic Notes.....................................................4-103 4.27 DTC P0562, P0563 General...........................................................................4-107 Battery Voltage........................................................4-107 Diagnostics.....................................................................4-107 Diagnostic Tips........................................................4-107 Diagnostic Notes.....................................................4-107 4.28 DTC P0603, P0605 General...........................................................................4-111 ECM Failure............................................................4-111 Diagnostics.....................................................................4-111 DTC P0603.............................................................4-111 DTC P0605.............................................................4-111 4.29 DTC P0661, P0662 General...........................................................................4-112 Active Intake Solenoid (HDI Models Only)..............4-112 Diagnostics.....................................................................4-112 Diagnostic Notes.....................................................4-112 4.30 DTC P1009, P1010 General...........................................................................4-116 Password Problem..................................................4-116 Diagnostics.....................................................................4-116 Diagnostic Notes.....................................................4-116 4.31 DTC P1351, P1352, P1354, P1355 General...........................................................................4-120 Ignition Coil.............................................................4-120 Diagnostics.....................................................................4-120 Diagnostic Notes.....................................................4-120 4.32 DTC P1475, P1477, P1478 General...........................................................................4-125 Active Exhaust Actuator (HDI Models Only)............4-125 Diagnostics.....................................................................4-125 Diagnostic Notes.....................................................4-125 4.33 DTC P1501, P1502 General...........................................................................4-131 Jiffy Stand Sensor (HDI Models Only).....................4-131 Diagnostics.....................................................................4-131 Diagnostic Notes.....................................................4-131 4.34 DTC U1064, U1255 General...........................................................................4-136 Loss of TSM/TSSM/HFSM Serial Data...................4-136 Diagnostics.....................................................................4-136 Diagnostic Notes.....................................................4-136 4.35 DTC U1097, U1255 General...........................................................................4-139 Loss of Speedometer Serial Data...........................4-139 Diagnostics.....................................................................4-139 Diagnostic Notes.....................................................4-139 APPENDIX A CONNECTOR REPAIR A.1 AMP 1-PLACE CONNECTORS AMP 1-Place Connector Repair.........................................A-1 General.......................................................................A-1 Separating Pin and Socket Housings.........................A-1 Mating Pin and Socket Housings................................A-1 Removing Socket Terminals........................................A-1 Installing Socket Terminal...........................................A-1 Removing Pin Terminal...............................................A-1 Installing Pin Terminal.................................................A-2 A.2 AMP MULTILOCK CONNECTORS AMP Multilock Connector Repair.......................................A-3 General.......................................................................A-3 Separating Pin and Socket Housings.........................A-3 Mating Pin and Socket Housings................................A-3 Removing Terminals from Housing.............................A-3 Inserting Terminals into Housing.................................A-4 Preparing Wire Leads for Crimping.............................A-4 Crimping Terminals to Leads......................................A-6 Inspecting Crimped Terminals.....................................A-6 A.3 DELPHI CONNECTORS Delphi Connector Repair....................................................A-8 General.......................................................................A-8 Separating Pin and Socket Housings.........................A-8 Mating Pin and Socket Housings................................A-8 Removing Socket Terminals........................................A-8 Installing Socket Terminals..........................................A-8 A.4 DEUTSCH 1-PLACE ELECTRICAL CONNECTORS Deutsch 1-Place Connector Repair..................................A-10 Separating Pin and Socket Housings.......................A-10 Mating Pin and Socket Housings..............................A-10 Removing Socket Terminals......................................A-10 Installing Socket Terminals........................................A-10 A.5 DEUSCH ELECTRICAL CONNECTORS Deutsch Connector Repair...............................................A-11 General.....................................................................A-11 Separating Pin and Socket Housings.......................A-11 Mating Pin and Socket Housings..............................A-11 Removing Socket Terminals......................................A-11 Installing Socket Terminals........................................A-11 Removing Pin Terminals...........................................A-13 Installing Pin Terminals.............................................A-13 Crimping Terminals...................................................A-14 A.6 DEUTSCH STANDARD TERMINALS Deutsch Standard Terminal Crimps.................................A-15 Preparing Wire Leads for Crimping...........................A-15 Crimping Terminal to Lead........................................A-15 TABLE OF CONTENTS VII TABLE OF CONTENTS

Inspecting Crimps.....................................................A-15 A.7 DEUTSCH MINI-TERMINAL CRIMPS Deutsch Mini Terminal Crimps.........................................A-16 Preparing Wire Leads for Crimping...........................A-16 Crimping a Mini Terminal to Wire Lead.....................A-16 Inspecting Crimps.....................................................A-16 A.8 DEUTSCH SOLID BARREL TERMINALS Deutsch Solid Barrel Terminal Crimps.............................A-17 Preparing Wire Leads For Crimping.........................A-17 Adjusting Crimper Tool..............................................A-17 Crimping a Barrel Contact To Wire Lead...................A-17 Inspecting Crimps.....................................................A-17 A.9 RELAY AND FUSE BLOCKS Fuse Block Repair............................................................A-19 Removing Socket Terminals......................................A-19 Installing Socket Terminals........................................A-19 Crimping Terminals...................................................A-19 A.10 150 METRI-PACK CONNECTORS 150 Metri-Pack Connector Repair....................................A-20 General.....................................................................A-20 Separating Pin and Socket Housings.......................A-20 Mating Pin and Socket Housings..............................A-20 Removing Socket Terminal.......................................A-20 Inserting Socket Terminal..........................................A-20 A.11 280 METRI-PACK CONNECTORS 280 Metri-Pack Connector Repair....................................A-22 General.....................................................................A-22 Separating Pin and Socket Housings.......................A-22 Mating Pin and Socket Housings..............................A-22 Removing Socket Terminals......................................A-22 Installing Socket Terminals........................................A-22 Crimping Terminals...................................................A-22 A.12 480 METRI-PACK CONNECTORS 480 Metri-Pack Connector Repair....................................A-24 General.....................................................................A-24 Separating Pin and Socket Housings.......................A-24 Mating Pin and Socket Housings..............................A-24 Removing Socket Terminals......................................A-24 Installing Socket Terminals........................................A-24 A.13 630 METRI-PACK CONNECTORS 630 Metri-Pack Connector Repair....................................A-25 General.....................................................................A-25 Separating Pin and Socket Housings.......................A-25 Mating Pin and Socket Housings..............................A-25 Removing Socket Terminal.......................................A-25 Installing Socket Terminal.........................................A-25 A.14 800 METRI-PACK CONNECTORS Delphi Maxi-Fuse Housing Repair...................................A-26 General.....................................................................A-26 Removing Maxi-Fuse................................................A-26 Installing Maxi-Fuse..................................................A-26 Removing Socket Terminals......................................A-26 Installing Socket Terminals........................................A-26 A.15 METRI-PACK TERMINALS Metri-Pack Terminal Crimps.............................................A-28 Matching Terminal To Crimper..................................A-28 Preparing Wire Lead.................................................A-28 Crimping Wire Core..................................................A-28 Crimping Insulation/Seal...........................................A-28 Inspecting Crimps.....................................................A-29 A.16 MOLEX CONNECTORS Molex Connector Repair..................................................A-30 Separating Pin and Socket Housings.......................A-30 Mating Pin and Socket Housings..............................A-30 Removing Terminals.................................................A-30 Installing Terminals...................................................A-30 A.17 PACKARD ECM CONNECTOR Packard 100W Connector Repair.....................................A-32 General.....................................................................A-32 Separating Socket Housing From ECM....................A-32 Mating Socket Housing To ECM...............................A-32 Removing Socket Terminal.......................................A-32 Installing Socket Terminal.........................................A-32 Crimping Terminals...................................................A-32 A.18 PACKARD MICRO-64 CONNECTORS Packard Micro-64 Connector Repair................................A-34 General.....................................................................A-34 Separating Pin and Socket Housings.......................A-34 Mating Pin and Socket Housings..............................A-34 Removing Terminal...................................................A-34 Installing Terminal.....................................................A-34 Preparing Wire Leads for Crimping...........................A-35 Crimping Terminals...................................................A-35 Inspecting Crimps.....................................................A-35 A.19 SEALED SPLICE CONNECTORS Sealed Splice Connector Repair......................................A-37 General.....................................................................A-37 Preparing Wire Leads...............................................A-37 Splicing Wire Leads..................................................A-37 Inspecting Seals.......................................................A-37 APPENDIX B WIRING B.1 CONNECTORS Connector Locations..........................................................B-1 Function/Location.......................................................B-1 Place and Color..........................................................B-1 Connector Number......................................................B-1 Repair Instructions......................................................B-1 B.2 WIRING DIAGRAMS Wiring Diagram Information...............................................B-3 Wire Color Codes........................................................B-3 Wiring Diagram Symbols............................................B-3 2008 Softail Wiring Diagrams.............................................B-4 VIII TABLE OF CONTENTS TABLE OF CONTENTS

APPENDIX C CONVERSIONS C.1 METRIC CONVERSION Conversion Table................................................................C-1 C.2 FLUID CONVERSIONS United States System........................................................C-2 Metric System....................................................................C-2 British Imperial System......................................................C-2 C.3 TORQUE CONVERSIONS United States System........................................................C-3 Metric System....................................................................C-3 APPENDIX D GLOSSARY D.1 GLOSSARY Acronyms and Abbreviations.............................................D-1 APPENDIX E TSM/TSSM (JAPAN/KOREA) E.1 TSM/TSSM (JAPAN/KOREA) OVERVIEW General..............................................................................E-1 TSM............................................................................E-1 TSSM..........................................................................E-1 Troubleshooting..................................................................E-1 E.2 TSM/TSSM FEATURES General..............................................................................E-3 Turn Signal Functions........................................................E-3 TSSM/TSSM Features................................................E-3 Bank Angle Function..........................................................E-3 Clutch/Neutral Interlock Functions.....................................E-3 TSM/TSSM Features..................................................E-3 Security Alarm and Immobilization Functions....................E-3 TSSM Feature.............................................................E-3 E.3 VEHICLE DELIVERY General..............................................................................E-5 Configuring A TSSM..........................................................E-5 Sidecar Configuration.........................................................E-5 Power Disruption and Configuring.....................................E-5 Key Fob Assignment: TSSM...............................................E-5 Pin Entry: TSSM.................................................................E-6 Changing the Pin: TSSM....................................................E-8 E.4 TURN SIGNAL FUNCTIONS General..............................................................................E-9 Automatic Cancellation......................................................E-9 Manual Cancellation...........................................................E-9 Four-Way Flashing.............................................................E-9 Diagnostics Mode..............................................................E-9 E.5 BANK ANGLE FUNCTION General............................................................................E-10 Operation.........................................................................E-10 E.6 SECURITY SYSTEM FUNCTIONS (TSSM ONLY) General............................................................................E-11 Security System Operation.......................................E-11 Security System Options: TSSM...............................E-11 Alarm Sensitivity: TSSM...................................................E-11 Sensitivity..................................................................E-11 Transport Mode.........................................................E-12 Auto-Arming Function: TSSM...........................................E-12 Storage Mode: TSSM.......................................................E-13 E.7 ARMING/DISARMING (TSSM ONLY) General............................................................................E-14 Security Lamp..................................................................E-14 Using Key FOB: TSSM.....................................................E-14 General.....................................................................E-14 Arming the System...................................................E-14 Disarming the System...............................................E-14 Troubleshooting.........................................................E-14 Using the Pin....................................................................E-14 General.....................................................................E-14 Disarming the System...............................................E-14 E.8 DIAGNOSTIC TROUBLE CODES (DTC) TSM/TSSM......................................................................E-16 Code Types......................................................................E-17 Current......................................................................E-17 Historic......................................................................E-17 Retrieving Diagnostic Trouble Codes...............................E-17 Multiple Diagnostic Trouble Codes...................................E-17 E.9 INITIAL DIAGNOSTIC CHECK: TSM/TSSM General............................................................................E-19 Diagnostic Notes.......................................................E-19 Circuit Diagram/Wire Harness Connector Table.......E-19 Job/Time Code Values..............................................E-19 Reprogramming ECM...............................................E-19 Initial Diagnostics.............................................................E-19 Diagnostic Tips.........................................................E-19 Diagnostic Notes.......................................................E-19 Other Diagnostic Trouble Codes (DTCs)...................E-19 E.10 SPEEDOMETER SELF DIAGNOSTICS General............................................................................E-24 Diagnostics......................................................................E-24 Diagnostic Tips.........................................................E-24 Diagnostic Notes.......................................................E-24 E.11 BREAKOUT BOX:TSM/TSSM General............................................................................E-26 Installation........................................................................E-26 Removal...........................................................................E-26 E.12 FAILS TO DISARM (TSSM ONLY) General............................................................................E-27 Security Equipped Vehicles Only..............................E-27 Job/Time Code Values..............................................E-27 Diagnostics......................................................................E-27 Diagnostic Tips.........................................................E-27 TABLE OF CONTENTS IX TABLE OF CONTENTS

2008 Harley-Davidson Softail Models Service & Repair Manual

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