2008 Softail Models Electrical
Diagnostics Manual
©2007 H-D.
ALL RIGHTS RESERVED
99498-08
Printed in the U.S.A.
VISIT THE HARLEY-DAVIDSON WEB SITE
http://www.harley-davidson.com
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
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2008 Harley-Davidson FXSTC Softail Custom Service & Repair Manual
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Description
This workshop service manual for the Harley Davidson FXSTC Softail Custom 2008 provides comprehensive data, instructions, and methodology for performing repair interventions on the vehicle and its components. It includes special notes, important points, service data, precautions, and detailed, comprehensive step-by-step procedures, explanations, and pictorial diagrams from bumper to bumper. This manual is intended as a handy, easy-to-read reference book for both professional mechanics and DIY enthusiasts.
The manual covers adjustment and repair operations, including reference to service tool numbers and associated illustrations depicting the tools for the Harley Davidson FXSTC Softail Custom 2008. It can be viewed on any computer, zoomed, and printed. The explanation is simple and suitable for comparatively new personnel to give satisfactory after-services to customers, as well as disassemble and maintain the vehicle.
It provides general descriptions for accomplishing service and repair work with tested, effective techniques, ensuring reliability. The manual also includes information on construction, function, troubleshooting, servicing specifications, tightening torque, checking and adjusting, disassembling and assembling, and servicing procedures.
The manual is designed primarily for use by trained technicians in a properly equipped workshop, but it contains enough detail and basic information to make it useful to the owner who desires to perform basic maintenance and repair work. It outlines procedures for servicing and repairing vehicles using safe, effective methods, and contains many notes, cautions, and warnings to be followed along with standard safety procedures to eliminate the possibility of personal injury or improper service that could damage the vehicle or compromise its safety.
To maximize the life of your Harley Davidson FXSTC Softail Custom 2008, it is recommended to accurately follow the maintenance requirements, investigate unusual noises and changes in riding characteristics, use only genuine parts, follow the procedures in the manual carefully, keep complete records of all maintenance and repairs, and use approved lubricants as specified in the manual.
This manual has been issued to provide technical information regarding the design, function, disassembly, adjusting work, and troubleshooting on the components and model of the Harley Davidson FXSTC Softail Custom 2008. It is supported by photographs, notes, drawings, schematics, exploded and sectional drawings, and contains valuable reference data for adjustment values.
All maintenance and repair work must strictly observe accident prevention guidelines, and a complete set of standard tools, as well as the special tools and fixtures shown and listed, are necessary to perform all repairs listed in this manual. Safety measures are described for dangerous work, and special remarks are indicated for danger, caution, or note.
This Harley Davidson FXSTC Softail Custom 2008 workshop service manual for repair is 100% complete and intact, with no missing or corrupt pages/sections. It is known by various names, including service manual, repair manual, workshop manual, and shop manual.
For a complete repair work, it is recommended to peruse and utilize this manual fully. The information, illustrations, and specifications contained in this manual are based on the latest product information available at the time of publication approval.
Finally, the manual contains a wide range of specifications for the Harley Davidson FXSTC Softail Custom 2008, including the vehicle identification number, wheels, tires, brakes, steering, suspension, engine, fuel system, ignition system, charging system, lighting, and wiring diagrams, among others.
