7

HOME

SPECIFICATIONS

4.1

Table 4-1. Spark Specifications

Table 4-3. Charging Specifications

DATA

IGNITION
Ignition timing range

TDC - 50 BTDC

Spark plug size

12 mm

Battery

28 amp hour/300 CCA

Alternator AC voltage output

0.038-0.043 in
Spark plug gap
0.97-1.09 mm
Harley-Davidson
No. 6R12 (no substitute)

Spark plug type

DATA

ITEM

FLHR, FLHR-I, FLHRC-I,

FLHT, FLHTC, FLTR
(38 Amp)

16-20 VAC per 1000 RPM

FLHT-I, FLTR-I, FLHTC-I,

FLHTCU-I (45 Amp)

19-26 VAC per 1000 RPM

Ignition coil primary

resistance at room temperature

0.3-0.5 ohms

Alternator stator coil

resistance

0.1-0.3 ohms

Ignition coil secondary

resistance at room temperature

2750-3250 ohms

Regulator voltage
output @ 3000 RPM

14.4-14.6 volts

Regulator amperes @ 3000 RPM

Table 4-2. Circuit Breaker/Fuses

FLHR, FLHR-I, FLHRC-I,

FLHT, FLHTC, FLTR
(38 Amp)

34-40 Amps

Color

Terminal
Type

40

Threaded
Posts

FLHT-I, FLTR-I, FLHTC-I,

FLHTCU-I (45 Amp)

41-48 Amps

Radio Power

10

Red

Blade

Brakes/Cruise

15

Blue

Blade

P&A

10

Red

Blade

Circuit

Main

Rating
(Amperes)

System Fuses

Radio Memory

15

Blue

Blade

Security System
(Hazard 4-Way Flasher)

15

Blue

Blade

Accessory

15

Blue

Blade

Instruments

15

Blue

Blade

Ignition

15

Blue

Blade

Lighting

15

Blue

Blade

Headlamp

15

Blue

Blade

Radio
Radio Memory
Power

Instruments
Security
System

Brake Light
Relay

4-Way Flasher

Spare
Fuses

Brakes/
Cruise

Headlamp
P&A
Accessory

NOTE
See Figure 4-1. The fuse labeled Security provides basic turn
signal functionality on vehicles without a factory-installed
security system. Do not remove this fuse or use it as a
replacement fuse for other systems.

f2023x9x

Lighting

Ignition

Figure 4-1. Fuse Locations (FLTR, FLHT/C)

2003 Touring: Engine Management (Carbureted)

4-1

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DIAGNOSTIC INTRODUCTION

4.2

SYSTEM PROBLEMS
s0520xtm

All system problems fall into at least one of three general categories.

40
30
20
10
0

No Start
The engine cranks over freely, but will not start. This does not
include situations where the engine will not crank, such as a
bad starter, dead battery, etc., and assumes that all obvious
checks are made- there is sufficient fuel in the tank, etc.

50 60 70
MPH

80
90
100
110
120

C
LE Y - D A V I D S O N

H AR ER T I F I E D

Poor Performance
The engine starts but there are performance problems, such
as poor fuel economy, rough idle, engine misfire, engine hesitation, severe spark knock, etc.

Check Engine Lamp

Figure 4-2. Check Engine Lamp (FLHR)

d0543x8x

The lamp indicates the existance of a fault condition. There

may also be starting or performance problems. See Figure 42.

RESOLVING PROBLEMS
To resolve system problems, five basic steps are involved. In
order of occurrence, they are:
1.

Check for trouble codes through observation of the

check engine lamp. See Section 4.3 CHECKING FOR
TROUBLE CODES.

2.

Retrieve trouble codes with the SCANALYZER (Part No.

HD-41325) or the check engine lamp diagnostics. See
Section 4.4 SCANALYZER: CARB, Section 4.5 CHECK
ENGINE LAMP DIAGNOSTICS: CARB and Figure 4-3.

3.

Diagnose problems relating to current trouble codes

using the diagnostic flow charts, Scanalyzer and other
special tools.

4.

Correct problems through replacement and/or repair of

faulty components.

5.

Validate repairs. Clear trouble codes and confirm proper

vehicle operation without recurrence of the fault condition, as indicated by the behavior of the check engine
lamp.

4-2

2003 Touring: Engine Management (Carbureted)

Figure 4-3. Scanalyzer

HOME

CHECKING FOR TROUBLE CODES

4.3

CHECK ENGINE LAMP

To diagnose system problems, start by observing the behavior of the Check Engine Lamp. See Figure 4-5.
1.

At Key On, the Check Engine Lamp will illuminate for

approximately four seconds and then turn off.
NOTES

References to Key ON or Ignition Switch ON in this

document means that the Ignition/Light Key Switch is
turned to IGNITION and the handlebar Engine Stop/Run
Switch is in the RUN position (although the engine is not
running). See Figure 4-4.

If the Check Engine Lamp is not illuminated at Key ON or

if it fails to go OFF after the initial four second ON period,
then a problem exists in the lamp circuit. See Section 4.9
NO CHECK ENGINE LAMP AT KEY ON or Section 4.10
CHECK ENGINE LAMP ON CONTINUOUSLY.

2.

When the lamp turns off after being illuminated for the
first four second period, it will:
a.

Remain off if there are no fault conditions or trouble

codes currently detected by the ignition module. See
A of Figure 4-5.

b.

Come back on for an 8 second period if only historic

codes exist. See B of Figure 4-5.

c.

Come back on, and remain on, if a current trouble

code exists. See C of Figure 4-5.

ON

f1240x2x

Figure 4-4. Ignition Switch (FLTR, FLHT/C/U)

3.

See CODE TYPES which follows for a complete description of trouble code formats.

NOTE
Trouble codes relating to the ignition coil can only be fully
diagnosed during actuation. For example, a problem with an
ignition coil will be considered a current fault even after the
problem is corrected, since the ignition module will not know
of its resolution until after the coil is exercised by a vehicle
start sequence. In this manner, there may sometimes be a
false indication of a current trouble code.

4 Sec.

Lamp OFF: No Current or Historic Trouble Codes

OFF
Key On
Lamp ON 8 Seconds:
Only Historic Trouble Codes Exist
ON

8 Sec.

4 Sec.

B
OFF

Lamp OFF

4 Sec.

Key On
Lamp Remains ON: Current Trouble Code *
ON

4 Sec.

C
OFF

4 Sec.

Key On

* Historic Trouble Codes May Also Exist

Figure 4-5. Check Engine Lamp Operation

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CODE TYPES

RETRIEVING TROUBLE CODES

There are three types of diagnostic trouble codes (DTCs),

current, historic and functional.

The system provides three levels of diagnostics.

The most sophisticated level uses a computer based

diagnostic package called the DIGITAL TECHNICIAN
(Part No. HD-44750).

At the second level, a portable Scan Tool called a Scanalyzer (HD-41325) plugs into the Data Link Connector
and facilitates the diagnosis of system problems through
a direct interface with the ignition module. Using a special programmable application cartridge, the Scanalyzer
offers data displays and menu selections that allow for
quick and easy retrieval of data and enables the user to
perform a variety of diagnostic tests while monitoring
inputs and outputs. See Section 4.4 SCANALYZER:
CARB.

At the third level, the Check Engine Lamp is observed by

the user after being placed in the diagnostic mode. The
lamp blinks a code which correlates to a particular problem area. See Section 4.5 CHECK ENGINE LAMP
DIAGNOSTICS: CARB.

Current
Current trouble codes are those which presently disrupt
motorcycle operation. When current trouble codes are stored,
they can be read using either the Scanalyzer or the Check
Engine Lamp Diagnostics. A current trouble code resides in
the memory of the ignition module until the problem is corrected, at which point it becomes a historic, rather than a
current fault.

Historic
If a particular problem happens to resolve itself, the active or
current status is dropped and it also becomes a historic code.
Historic trouble codes are stored for a length of time to assist
in the diagnosis of intermittent faults. While historic trouble
codes are stored, they can be read using the Scanalyzer only.
The Check Engine Lamp will not indicate the existence of
historic trouble codes.
A historic trouble code resides in the memory of the ignition
module until the code is cleared by use of the Scanalyzer or a
total of 50 trips has elapsed. A trip consists of a start and
run cycle, the run cycle lasting at least 30 seconds. After the
50 trip retention period, the trouble code is automatically
erased from memory (that is, assuming no subsequent faults
of the same type are detected in that period).
It is important to note that historic trouble codes may also be
present whenever the system indicates the existence of a
current code. See MULTIPLE TROUBLE CODES for more
information.

Functional
A functional trouble code indicates an internal problem that
requires replacement of the ignition module (trouble codes 52
through 55).

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2003 Touring: Engine Management (Carbureted)

MULTIPLE TROUBLE CODES

While it is possible for more than one fault to occur and set
more than one trouble code, there are several conditions
which may result in one fault setting multiple trouble codes:

If one of the primary side coil lines becomes grounded it

will also ground the Bank Angle Sensor resulting in multiple trouble codes being set (DTC 24 and/or 25 and 44).

Always start with the trouble code having the lowest numerical value. In the case of multiple trouble codes, the second
code should be resolved when the first code is corrected. For
a priority ranking, see list of fault conditions in Table 4-8.

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SCANALYZER: CARB

4.4

SCANALYZER DIAGNOSTICS
Ignition
Module

Data Link
Connector [91A]

f1968x9x

Scanalyzer Cartridge
See Figure 4-7. Through a special programmable application
cartridge, the Scanalyzer offers data displays and menu
selections that allow for quick and easy retrieval of data. The
device enables the user to perform a variety of diagnostic
tests while monitoring inputs and outputs. For Scanalyzer
menu selections see Figure 4-8.

INSTALLATION
SPECIALTY TOOL

PART NO.
HD-41325

Scanalyzer

HD-41325-95C

Scanalyzer Cartridge

HD-42921A

Cable

Figure 4-6. Right Side Cover Removed

d0279x8x

The behavior of the check engine lamp as described under

Section 4.3 CHECKING FOR TROUBLE CODES indicates
the existence of a trouble code. Proceed as follows:
1.

Turn the Ignition/Light Key Switch to OFF.

2.

Remove right saddlebag and side cover to access data

link connector. See Figure 4-6.

3.

Remove rubber protective plug from data link connector.

Plug the Scanalyzer into the data link connector.

4.

Turn the Ignition/Light Key Switch to IGNITION. Turn the

handlebar mounted Engine Stop/Run Switch to RUN (but
do not start the engine).

5.

6.

Insert the diagnostic application cartridge into the Scanalyzer. During the next few seconds, the Scanalyzer
sequences through a series of screens that reflect a
power-on self test, the system copyright, and then an
attempt at communications with the ignition module.
Once communications is established, the Diagnostic
Menu appears. See Figure 4-8.

Cartridge
(Part No. HD-41325-95C)

Figure 4-7. Scanalyzer (Part No. HD-41325)

Continue with the instructions under USAGE which follows.

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DIAGNOSTIC MENU

f1657x8x

1- System ID
2- Trouble Codes
3- Data Monitor
4- Active Diagnostic
5- Special Tests
6- Tool Setup

Main Menu

TOOL SETUP MENU

1- General Setup
2- Save Setup
3- Restore Setup
SPECIAL TEST MENU
1- Wiggle Test
2- Data Capture
3- File Manager

ACTIVE TEST MENU

1- Front Coil
2- Rear Coil
3- Tachometer

MODE

Secondary
Menus
DATA MONITOR MENU
RPM
MAP
MAP
ADVANCE
B+
Dwell
BAS Mode
BAS
Check Eng

=1000
=14.8 in. Hg
=2.10 V
=20.0 DEG
=13.20 V
=1800 uSec
=Run Mode
=0.62 V
=Lamp ON

MODE

TROUBLE CODE MENU

1- Display Current
2- Display Historic
3- Clear Historic

MODE

SYSTEM ID
P/N 32479-99
CAL ID
HD32ER0K0

MODE

Figure 4-8. Scanalyzer Menus

4-6

2003 Touring: Engine Management (Carbureted)

MODE

MODE

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USAGE

d0543x8x

See Figure 4-8. The Diagnostic Menu, which consists of six

items, is the primary system menu (main menu) through
which all other secondary menus and displays are accessed.
Since the screen may not be large enough to display all line
items at any given time, use the up and down arrow keys to
scroll through the list.

Checking/Clearing Trouble Codes

1.
2.

3.

See Figure 4-9. From the diagnostic menu, press the

number 2 to access the Trouble Codes Menu.
At this point, the operator may:
a.

Press number 1 to display current trouble codes.

b.

Press number 2 to display historic trouble codes.

c.

Press number 3 to clear trouble codes. Note that

the Scanalyzer is the only method by which the
operator can display and manually clear historic
trouble codes.

After reading trouble codes, simply press the Mode key

to return to the Trouble Codes Menu. Press the Mode key
again to return to the Diagnostic Menu. In this manner,
regardless of where the operator is in the program, the
Mode key need only be pressed once or twice to return
to the Main Menu.

Figure 4-9. Scanalyzer Diagnostic Menu

NOTE
For more detailed instructions, refer to the literature provided
with the Scanalyzer.

REMOVAL

4.

1.

Turn the Ignition/Light Key Switch to OFF. Set the Engine

Stop/Run Switch to STOP.

2.

Unplug the Scanalyzer from the Data Link Connector.

Install protective plug.

3.

Install right side cover and saddlebag.

4.

Road test the vehicle and observe the check engine

lamp to confirm proper operation without the reoccurrence of trouble codes. See Section 4.3 CHECKING
FOR TROUBLE CODES.

5.

Write down all trouble codes on a piece of paper. If a current trouble code exists, place it at the top of the list.
a.

If current trouble codes are present, see Table 4-8.

to identify the source of the fault condition and then
see the applicable flow chart.

b.

If only historic trouble codes are present, then a fault

condition does not currently exist. If you wish, look
for an intermittent in the appropriate circuit.

c.

If trouble codes are NOT present, but starting or

driveability problems are evident, see symptoms
charts under Section 4.8 INITIAL DIAGNOSTIC
CHECK.

After correcting system problems, clear trouble codes

using the Trouble Codes Menu of the Scanalyzer.

NOTE
Trouble codes cannot be cleared while the engine is running.
Turn the engine off, but leave the Ignition/Light Key Switch in
the IGNITION position and return the handlebar Engine Stop/
Run Switch to RUN.

2003 Touring: Engine Management (Carbureted)

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CHECK ENGINE LAMP DIAGNOSTICS: CARB

ACTIVATION

d0278x8x

Use of check engine lamp diagnostics assumes that the

SCANALYZER (Part No. HD-41325) is not available.
1.

Access the data link connector [91] under the right side
cover.

2.

Activate the diagnostic feature of the check engine lamp

as follows:
a.

b.

c.

3.

This intermission is followed by a 2 second pause

in which the lamp is off.

b.

The lamp will then flash one or more times to indicate the first digit of the trouble code. The length of
time the lamp is illuminated and the length of time in
which it is off are each about 1 second in duration.

2003 Touring: Engine Management (Carbureted)

1.
2.
3.
4.
5.

Terminal 1: receive data line (Lt GN/R)

Terminal 2: ground (BK)
Terminal 3: transmit data line (V/R)
Terminal 4: power (W/BK)
Protective cap
Figure 4-11. Installing Diagnostic Test Wire

The lamp will then flash one or more times to indicate the second digit of the trouble code. Count the
number of times the lamp flashes to retrieve the second digit.

Following transmission of the second digit of the first

code, there is a third 2 second pause in which the
lamp is off.

Following transmission of the first digit, there is

another 2 second pause in which the lamp is off.

If more than one trouble code is sent:

a.

4-8

The second digit follows:

a.

5.

6924

Turn the Ignition/Light Key Switch to IGNITION and

wait approximately eight seconds for the check
engine lamp to start flashing.

b.

Figure 4-10. Diagnostic Test Wire

See Figure 4-11. Install diagnostic test wire across

Terminal 1 and Terminal 2 on the data link connector
[91A].

The transmission of a trouble code is always preceded by six rapid flashes (about 3 per second).

Part number 72191-94 (2)

2.0 inch (51 mm) 18 gauge wire

See Figure 4-12. All trouble codes are sent out as a

series of flashes. To retrieve the first digit of the trouble
code simply observe the number of times the lamp
flashes.

c.

4.

1.
2.

See Figure 4-10. Create diagnostic test wire from

parts shown.

a.

4.5

6.

b.

After the pause comes the intermission, which is followed by transmission of the next recorded trouble
code.

c.

All subsequent codes are sent in the same manner,

each separated from the next by the intermission.

Once all codes have been sent, the data string is

repeated. When you have recorded the same trouble
code twice, it is an indication that the transmission has
been restarted and that all trouble codes have been
retrieved.

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Intermission

1st Digit

ON

2nd Digit

1
Sec.

OFF
3 Flashes
per Second

1
Sec.

2 Sec.

2 Sec.

Pause Before
1st Digit

Pause Before
2nd Digit

Start of
Intermission

1
Sec.
1
Sec.

2 Sec.

Pause After
2nd Digit

NOTE
Looking at the above transmission, we can see that the trouble code is 12.
Now reference Table 4-8. The source of the fault condition is identified as the
Manifold Absolute Pressure (MAP) Sensor.

Figure 4-12. Check Engine Lamp Diagnostics

NOTE
If the lamp flashes at a rate faster than normal, then you are
observing the Intermission only, which means that no trouble codes are present.
7.

When examining trouble codes, write down all codes on

a piece of paper. If a current trouble code exists, place it
at the top of the list.
a.

If trouble codes are present, see Table 4-8. Follow

the applicable flow charts for each code.

b.

If trouble codes are NOT present, but starting or

driveability problems are evident, see symptoms
charts under Section 4.8 INITIAL DIAGNOSTIC
CHECK.

8.

Turn the Ignition/Light Key Switch to OFF.

9.

Remove diagnostic test wire from connector. Install protective plug in data link connector.

IMPORTANT NOTE
If diagnostic test wire is installed across Pins 1 and 2 on
connector [91A] in lieu of a Scanalyzer, the ignition module is placed in a diagnostic test mode and the engine
will start. The test wire must be removed from the data
link connector and the ignition switch turned OFF or the
check engine lamp will continue to flash codes.

10. Install right side cover and saddlebag.

2003 Touring: Engine Management (Carbureted)

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BREAKOUT BOX: CARB

4.6

GENERAL
See Figure 4-13. The BREAKOUT BOX (Part No. HD-42682),
used in conjunction with a DVOM, allows circuit diagnosis
without having to probe connectors with sharp objects.

INSTALLATION
1.

Remove the right saddlebag and side cover.

2.

Remove connector [10] and connector [11] to release

ignition harness from ignition module. See Figure 4-14.

3.

Install Breakout Box connectors to ignition module and

ignition harness connectors of the same color.

f2001x8x

f1998x9x

Figure 4-13. Breakout Box (Part No. HD-42682)

REMOVAL
f1876xtm

1.

Separate connectors to remove Breakout Box between

ignition module and ignition harness.

2.

To connect ignition harness, install connector [10] and

connector [11] to ignition module connectors of the same
color. See Figure 4-14.

3.

Install the right side cover and saddlebag.

Connector [10]
(Black)

Connector [11]
(Gray)
Figure 4-14. Ignition Module

4-10

2003 Touring: Engine Management (Carbureted)

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WIGGLE TEST

4.7

GENERAL

d0544x8x

The wiggle test indicates the presence of intermittents in a

wiring harness. Depending upon the availability of diagnostic
tools, either version of this test may be used.

PROCEDURE
Using Scanalyzer (Part No. HD-41325)
1.

Connect Scanalyzer to vehicle. See Section 4.4 SCANALYZER: CARB.

2.

Start motorcycle and allow to idle.

3.

Enter wiggle test mode.

4.

a.

Press 5 from the Diagnostic Menu to enter the

Special Tests menu.

b.

Press 1 from the Special Tests menu to enter the

Wiggle Test.

1.
2.

Minus sign
Corner LED (4)
Figure 4-15. Wiggle Test Indicators

hd39978

Shake or wiggle harness to detect intermittents. If intermittents are present the Scanalyzer will beep, light the
four corner LEDs and display a minus sign when a current trouble code is detected. See Figure 4-15.
NOTE

If a current trouble code is present when the wiggle test is

entered, the Scanalyzer will respond as described immediately upon entering the wiggle test mode. With key ON and
engine off, clear trouble codes and then perform wiggle test
with vehicle running.
Figure 4-16. Fluke 78 Multimeter (DVOM)
(Part No. HD-39978)

Using DVOM (Part No. HD-39978)

1.

2.

See Figure 4-16. Connect DVOM to wiring harness

between the suspect connections. When diagnosing ignition module connections, a BREAKOUT BOX (Part No.
HD-42682) may be used to simplify the procedure. See
Section 4.6 BREAKOUT BOX: CARB.

3.

Start motorcycle and allow to idle.

4.

Shake or wiggle harness to detect intermittents. If intermittents are present, radical voltage changes will register
on the DVOM.

Set DVOM to read voltage changes.

2003 Touring: Engine Management (Carbureted)

4-11

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INITIAL DIAGNOSTIC CHECK

4.8

GENERAL

Diagnostic Tips

To locate faulty circuits or other system problems, follow the

diagnostic flow charts in this chapter. Read the general information and then work your way through the flow chart box by
box. For a systematic approach, always begin with INITIAL
DIAGNOSTICS below.

If the Scanalyzer is not working properly, check operation

on another vehicle.

If proper Scanalyzer function is verified, check data link

connector [91A] for 12 volts (Terminal 4) and proper
ground (Terminal 2). See Figure 4-17.

Diagnostic Notes

If a numbered circle appears adjacent to a box of the flow

chart, then more information is offered in the Diagnostic
Notes. Many diagnostic notes contain supplemental information, descriptions of various diagnostic tools or references to
other parts of the manual.

See Figure 4-11. If Scanalyzer reads No Response

with the ignition switch turned to IGNITION (engine stop
switch at RUN with the engine off), check serial receive
data wire for an open or short to ground between data
link Terminal 1 and ignition module.

Check for an open diagnostic test terminal between data

link Terminal 3 and ignition module. With ignition switch
turned to IGNITION, transmit data line and receive data
line should have 5 volts.

Scanalyzer Icon
The Scanalyzer icon appears at those points in the flow chart
where the Scanalyzer may be used.

Circuit Diagram/Connector Location Table

When working through a flow chart, refer to the illustrations,
the associated Circuit Diagram and the Wire Harness Connector Table as necessary. The wire harness connector table
opposite each flow chart identifies the connector number,
description, type and general location.
In order to perform most diagnostic routines, a Breakout Box
and a DVOM are required. See Section 4.6 BREAKOUT BOX:
CARB. To perform the circuit checks with any degree of efficiency, a familiarity with the various wire connectors is also
necessary.

IMPORTANT NOTE
If diagnostic test wire is installed across Pins 1 and 2 on
connector [91A] in lieu of a Scanalyzer, the ignition module is placed in a diagnostic test mode and the engine
will start. The test wire must be removed from the data
link connector and the ignition switch turned OFF or the
check engine lamp will continue to flash codes.

Diagnostic Notes
The reference numbers below correlate with the circled numbers on the diagnostic check flow charts. See page 4-15.
1.

Job/Time Code Values

When filing warranty claims, dealer technicians should use
the numeric job/time codes printed below the appropriate box
of the flow chart.

INITIAL DIAGNOSTICS
General
The diagnostic check is an organized approach to identifying
a system problem. If no problems are found after completion
of the diagnostic check, a comparison of Scanalyzer parameters may be used to help locate intermittents and out-of-specification sensors. See Table 4-4.

4-12

2003 Touring: Engine Management (Carbureted)

Compare engine behavior to symptoms tables.

a.

Starts hard. See Table 4-5.

b.

Hesitates, stumbles, surges, misfires and/or sluggish performance. See Table 4-6.

c.

Engine exhaust emits black smoke or fouls plugs.

See Table 4-7.

2.

Use HARNESS CONNECTOR TEST KIT (Part No. HD41404), black socket probes and patch cord.

3.

Connect BREAKOUT BOX (Part No. HD-42682) to ignition module. See Section 4.6 BREAKOUT BOX: CARB.

HOME

Table 4-4. Typical Scan Values

ITEM

MAP sensor

MIN.
VALUE

MAX.
VALUE

HOT
IDLE

0.1 V
(high
vacuum)

4.96 V
(atmospheric
pressure)

1.5-3.0 V

Table 4-6. Engine Performance Problems

SYMPTOM

SOLUTION
Spray water around induction module seals with
engine idling. If RPM
changes, change seals.

Manifold leak

10-15

MAP sensor plugged or not

operating properly

Section 4.14 DTC 12.

5600

1000

Water or dirt in fuel system

Drain and refill with fresh

fuel.

Run mode
0.45-1.1 V

Disable
1.8-3.2 V

Run mode
0.45-1.1 V

960 uSec

8100 uSec

1600-2400
uSec

Spark advance
while running

50

RPM

Bank angle
sensor
Dwell

Table 4-5. Engine Starts Hard

Section 4.13 MISFIRE.

EVAP hose disconnected

from induction module (CA)

Connect.

Throttle plates not opening

fully

See throttle cable adjustment in 2003 FLT Service

Manual (Part Number
99483-03),

SOLUTION

SYMPTOM
Battery discharged

Spark plugs

See charging system troubleshooting in this section.

Spark plugs

Section 4.13 MISFIRE.

Spark plug wires

Section 4.13 MISFIRE

Ignition coil

Section 4.13 MISFIRE.

Valve sticking

See Section 3 in 2003 FLT

Service Manual (Part Number
99483-03).

Water or dirt in fuel system

Drain and refill with fresh fuel.

Table 4-7. Engine Exhaust Emits

Black Smoke or Fouls Plugs
SYMPTOM

SOLUTION
See Section 1 in 2003 FLT
Service Manual (Part Number 99483-03).

Clogged air filter

MAP sensor plugged or not
operating properly

Section 4.14 DTC 12.

Table 4-8. Diagnostic Trouble Codes (DTC) and Fault Conditions

FAULT CONDITION

DTC

RELEVANT SECTION

12

Map Sensor

4.14 DTC 12

16

Battery Voltage

4.15 DTC 16

24

Front Ignition Coil

4.16 DTC 24, 25

25

Rear Ignition Coil

4.16 DTC 24, 25

35

Tachometer

4.17 DTC 35

41

Crank Sensor

4.18 DTC 41

44

Bank Angle Sensor (Within TSM/TSSM) Detects Possible Theft Attempt

4.19 DTC 44

52

RAM Failure

4.20 DTC 52, 53, 54, 55

53

ROM Failure

4.20 DTC 52, 53, 54, 55

54

EEPROM Failure

4.20 DTC 52, 53, 54, 55

55

Ignition Module Failure

4.20 DTC 52, 53, 54, 55

2003 Touring: Engine Management (Carbureted)

4-13

HOME

f1973t9s

Data
Link

Power Wire

V/R

Lt GN/R

W/BK

BK

V/R

Lt GN/R

[91A]

[10B]
[10A]

[11B]
[11A]

Ignition Module

Figure 4-17. Diagnostic Check

Table 4-9. Wire Harness Connectors in Figure 4-17.

NO.

4-14

DESCRIPTION

TYPE

LOCATION

[10]

Ignition Module (Black)

12-Place Deutsch

Under Right Side Cover

[11]

Ignition Module (Gray)

12-Place Deutsch

Under Right Side Cover

[91]

Data Link

4-Place Deutsch

Under Right Side Cover

2003 Touring: Engine Management (Carbureted)

HOME

Diagnostic Check (Part 1 of 2)

Turn Ignition Switch to IGNITION. Set

Engine Stop Switch to RUN. Do not start engine.
Does check engine lamp illuminate?

YES

NO

Does light go off after

four seconds?

See Section 4.9 NO CHECK

ENGINE LAMP AT KEY ON.

YES

NO

Does engine
start?

See Section 4.10

CHECK ENGINE LAMP
ON CONTINUOUSLY.

YES

NO

Does Scanalyzer or check engine

lamp display ignition module
data? See Section 4.3 CHECKING FOR TROUBLE CODES.

See Section 4.11

ENGINE CRANKS, BUT
WILL NOT START.

YES

NO

Are any trouble

codes displayed?

STOP

YES

NO

Refer to applicable trouble code flow

chart. Start with lowest trouble code. All
diagnostic codes are listed in Table 4-8.

Compare scan data with

Table 4-4. Are values normal
or within typical ranges?

Go to Diagnostic
Check (Part 2 of 2).

YES

NO

See Section 4.7 WIGGLE

TEST. If Wiggle Test does
not recreate condition,
refer to symptoms tables.

Refer to diagnostic
tips in related trouble
code chart (even if
no code is set).

7110

2003 Touring: Engine Management (Carbureted)

4-15

HOME

Diagnostic Check (Part 2 of 2)

Continued from Diagnostic Check (Part 1 of 2).

Remove ignition module connectors [10B]

(BK) and [11B] (GY). Check for continuity to
ground at Pins 1 and 3 of Connector [91A].
Continuity to ground?

YES

NO

Locate and repair

short to ground.
7115

Test the four data link connector terminals against

their ignition module connector pins for continuity.

DATA LINK TERMINAL

IGNITION MODULE
TERMINAL

Pin

Wire Color

Pin

Connector

Lt. GN/R

11

[11B]

BK

11

[10B]

V/R

12

[11B]

W/BK

[10B]

Continuity present in all four circumstances?

YES

NO

Check Scanalyzer on
another vehicle.
Scanalyzer OK?

Inspect terminals
for damage or repair
opens as necessary.
7120

YES

NO

Replace ignition
module.

Scanalyzer
malfunction.

7125

4-16

2003 Touring: Engine Management (Carbureted)

HOME

NO CHECK ENGINE LAMP AT KEY ON

4.9

GENERAL
s0520xtm

If the Ignition/Light Key Switch is turned to IGNITION and the

Engine Stop/Run Switch is set to RUN (with the engine off),
the check engine lamp should illuminate for four seconds.
See Figure 4-18.

40
30
20
10
0

Battery voltage is supplied to the lamp bulb. The lamp bulb is

grounded by the ignition module through the BK/Y wire. A
lack of power to the ignition module will cause the check
engine lamp to be inoperative and also create a no start situation.

50 60 70
MPH

80
90
100
110
120

C
LE Y - D A V I D S O N

H AR ER T I F I E D

DIAGNOSTICS
Figure 4-18. Check Engine Lamp (FLHR)

Diagnostic Tips

f2023x9x

Check for the following conditions:

Check for open in BK/Y wire.

Check for blown accessory fuse. See Figure 4-19.

Diagnostic Notes
Accessory
Fuse

The reference numbers below correlate with the circled numbers on the Test 4.9 flow chart.
1.

Connect BREAKOUT BOX (Part No. HD-42682). See

Section 4.6 BREAKOUT BOX: CARB.

2.

Remove instrument console on FLHR models, outer fairing on FLHT/C, or instrument bezel on FLTR. See the
2003 FLT Service Manual (Part Number 99483-03).

3.

Leaving speedometer connector [39] connected, insert

probe into wire end of connector [39B] until contact is
made with backside of terminal. If necessary, use a fine
paper clip to avoid damage.

4.

5.

Use HARNESS CONNECTOR TEST KIT (Part No. HD41404), purple pin probe and patch cord between Breakout Box and ground. Align blade with slot in terminal of
Breakout Box.

Figure 4-19. Left Side Cover Removed

(FLTR, FLHT/C)

6.

Assumes speedometer is functioning. If speedometer is

not functioning, see Section 2.2 SPEEDOMETER.

7.

Use HARNESS CONNECTOR TEST KIT (Part No. HD41404), black pin or socket probe and patch cord.

8.

Check continuity.
a.

If continuity is present, most likely short to voltage;

b.

If no continuity present, then open.

LED failure requires speedometer replacement.

2003 Touring: Engine Management (Carbureted)

4-17

HOME

Ignition Module

[10B] [10A]

BK \ Y

[8B]

[8A]

Check Engine Lamp Ground Circuit

3 4 5 6 7 8 9 10 11 12

Ignition Module
Connector

Check Engine Lamp (LED)

1
2
3
4
5
6

BK \ Y

O\ W

+12V From Instruments

7
8
9
10
11
12

[39B] [39A]

Figure 4-20. Check Engine Lamp Circuit

Table 4-10. Wire Harness Connectors in Figure 4-20.

NO.

DESCRIPTION

MODEL

TYPE

LOCATION

[8]

Ignition Harness

All

12-Place Deutsch

Under Right Side Cover

[10]

Ignition Module

All

12-Place Deutsch (Black)

Under Right Side Cover

FLHT/C

12-Place Packard

Inner Fairing (Back of Speedometer)

[39]

Speedometer

FLTR

12-Place Packard

Under Bezel (Back of Speedometer)

FLHR/C

12-Place Mini-Deutsch

Under Console (Back of Speedometer)

4-18

2003 Touring: Engine Management (Carbureted)

HOME

Test 4.9
NO CHECK ENGINE LAMP AT KEY ON

Turn Ignition Switch to

IGNITION. Turn Engine Stop
Switch to RUN. Does the
Engine Start?

YES

NO

Turn Ignition Switch OFF. Disconnect Connector [10] (BK)

and Connect Breakout Box.

Did No Check Engine

Lamp and No Start
Conditions Occur
Simultaneously?

Check Continuity Between

Socket 4 of Connector [39B]
and Terminal 4 of Connector
[10] (BK) on Breakout Box.
Continuity Present?

2
3

NO

YES
4

2
7

NO

YES

Replace
Ignition
Module.

Replace
Speedometer.
7143

7130

NO

No Ignition Module
power. See Section
4.12 NO IGNITION
MODULE POWER.

See Section 4.11

ENGINE CRANKS, BUT
WILL NOT START for No
Start Condition and then
Return to Section 4.9 NO
CHECK ENGINE LAMP
AT KEY ON to Resolve
No Check Engine Lamp.

Disconnect Connector
[8]. Check Continuity of
BK/Y Wire Between Connectors [8A] and [39B].
Continuity Present?

Place Jumper Between

Terminal 4 of Connector
[10] (BK) on Breakout Box
to Ground. Check Engine
Lamp Should Be On.
Is It?

YES

YES

NO

Locate and Repair

Open on BK/Y Wire
Between Connectors [8B] and [10B].

Locate and Repair

Open on BK/Y Wire
Between Connectors [8A] and [39B].

7135

7145

2003 Touring: Engine Management (Carbureted)

4-19

HOME

CHECK ENGINE LAMP ON CONTINUOUSLY

4.10

GENERAL
s0520xtm

If the Ignition/Light Key Switch is turned to IGNITION and the

Engine Stop/Run Switch is set to RUN (with the engine off),
the check engine lamp should illuminate for four seconds.
See Figure 4-21.

40
30
20
10
0

Following the initial period of illumination, the lamp should go

off for four seconds. It may then come back on for an eight
second period or remain on continuously.

50 60 70
MPH

80
90
100
110
120

C
LE Y - D A V I D S O N

H AR ER T I F I E D

Battery voltage is supplied to the lamp bulb. The lamp bulb is

grounded by the ignition module through the BK/Y wire. A
steady light may indicate a short to ground on the black wire.

DIAGNOSTICS
Diagnostic Notes

Figure 4-21. Check Engine Lamp (FLHR)

3.

Remove instrument console on FLHR models, outer fairing on FLHT/C, or instrument bezel on FLTR. See the
2003 FLT Service Manual (Part Number 99483-03).

4.

Use HARNESS CONNECTOR TEST KIT (Part No. HD41404), black pin probe and patch cord.

The reference numbers below correlate with the circled numbers on the Test 4.10 flow chart.
1.

If the lamp goes OFF when ignition module connector is

unplugged, BK/Y wire is shorted to ground.

2.

Check for trouble codes. See RETRIEVING TROUBLE

CODES under Section 4.3 CHECKING FOR TROUBLE
CODES.

4-20

2003 Touring: Engine Management (Carbureted)

HOME

Ignition Module

[10B] [10A]

BK \ Y

[8B]

[8A]

Check Engine Lamp Ground Circuit

3 4 5 6 7 8 9 10 11 12

Ignition Module
Connector

Check Engine Lamp (LED)

1
2
3
4
5
6

BK \ Y

O\ W

+12V From Instruments

7
8
9
10
11
12

[39B] [39A]

Figure 4-22. Check Engine Lamp Circuit

Table 4-11. Wire Harness Connectors in Figure 4-22.

NO.

DESCRIPTION

MODEL

TYPE

LOCATION

[8]

Ignition Harness

All

12-Place Deutsch

Under Right Side Cover

[10]

Ignition Module

All

12-Place Deutsch (Black)

Under Right Side Cover

FLHT/C

12-Place Packard

Inner Fairing (Back of Speedometer)

FLTR

12-Place Packard

Under Bezel (Back of Speedometer)

FLHR/C

12-Place Mini-Deutsch

Under Console (Back of Speedometer)

[39]

Speedometer

2003 Touring: Engine Management (Carbureted)

4-21

HOME

Test 4.10
CHECK ENGINE LAMP ON CONTINUOUSLY

Turn Ignition/Light Key Switch to IGNITION and Engine

Stop/Run Switch to RUN. Verify that there is NOT a 4
second lamp OFF period. Is there a lamp OFF period?

YES

NO

Check engine lamp function

OK. Check for trouble codes.

Turn ignition switch OFF. Disconnect

ignition module connector [10] (black).
Turn ignition switch to IGNITION.
Is the check engine lamp OFF?

YES

NO

Replace
ignition module.

7150

Disconnect connector [39].

Check for continuity to
ground on Pin 4 (BK/Y wire)
of connector [10] (black).
Continuity present?

YES

NO

Disconnect connector [8].

Does check engine
light illuminate?

Replace
speedometer.
7148

YES

NO

Locate and repair short

to ground on BK/Y wire
between Connectors
[8A] and [39B].

Locate and repair short

to ground on BK/Y wire
between Connectors
[8B] and [10B].

7160

4-22

2003 Touring: Engine Management (Carbureted)

7165

HOME

ENGINE CRANKS, BUT WILL NOT START

4.11

GENERAL
d0273x8x

If starter will not crank engine, the problem is not ignition

related. Refer to Starting/Charging in Section 1 of this manual.
Engine can be started with diagnostic test wire installed or if
the receive data line is grounded. The ignition switch must be
turned OFF after test wire is removed or check engine lamp
will continue to flash stored codes.

DIAGNOSTICS

Figure 4-23. Spark Tester

Diagnostic Notes

d0275x8x

The reference numbers below correlate with the circled numbers on the Test 4.11 flow charts.
1.

Check for trouble codes. See RETRIEVING TROUBLE

CODES under Section 4.3 CHECKING FOR TROUBLE
CODES.

2.

Check the condition of the battery. Perform a voltage test

and recharge if below 12.60V. Check battery connections
and perform load test. Replace the battery if necessary.

3.

Remove spark plug cable from spark plug.

a.

Visually check condition of plug.

b.

Attach cable to SPARK TESTER (Part No. HD26792). Clip tester to cylinder head bolt. See Figure
4-23.

c.

C B

Battery

While cranking engine, look for spark. Repeat procedure on other spark plug cables.
Figure 4-24. Ignition Coil Test

NOTE
Engine will not spark with both spark plugs removed.
When checking for spark, use SPARK TESTER with both
spark plugs installed.
4.

Use HARNESS CONNECTOR TEST KIT (Part No. HD41404) gray pin probes and patch cords.

5.

Gently use test lamp as shown in Figure 4-24. Inserting

the test lamp forcefully into the connector will damage
the terminal and require its replacement.

6.

Connect BREAKOUT BOX (Part No. HD-42682). See

Section 4.6 BREAKOUT BOX: CARB.

7.

Use HARNESS CONNECTOR TEST KIT (Part No. HD41404), gray pin probe and patch cord.

8.

Use HARNESS CONNECTOR TEST KIT (Part No. HD41404), brown socket probe and patch cord.

2003 Touring: Engine Management (Carbureted)

4-23

HOME

[79A] [79B]

Crank
Position
Sensor
(CKP)

R
BK

[11B] [11A] GY

1
2

BK

Ignition Module
Connectors

[83B]

A
B
C

Y \ BE

BE \ O

1
2
3
1

To
Data Link

[10B] [10A] BK

9
10
11
12

6-Place on FLHR
3 4 5 6 7 8 9 10 11 12

Key ON Power

7
8

Engine Stop Switch

4
5
6

3 4 5 6 7 8 9 10 11 12

FLHT/C
and FLTR Only

Rear Coil

W
\
B
K

Ignition
Coil

[1B]
[1A]

Front Coil

[22B]
[22A]

[8B] [8A]
To TSM/TSSM
GY

15 Amp
Ignition Fuse

R/BK To Ignition Switch

Figure 4-25. Ignition Circuit Diagram

Table 4-12. Wire Harness Connectors in Figure 4-25.

NO.

DESCRIPTION

MODEL

TYPE

LOCATION

[1]

Main to Interconnect Harness

FLHT/C

12-Place Deutsch

Inner Fairing- Right Fairing Bracket

FLTR

12-Place Deutsch

Inner Fairing- Below Radio (Right Side)

[8]

Ignition Harness

All

12-Place Deutsch

Under Right Side Cover

[10]

Ignition Module

All

12-Place Deutsch (Black)

Under Right Side Cover

[11]

Ignition module

All

12-Place Deutsch (Gray)

Under Right Side Cover

[79]

CKP Sensor

All

2-Place Mini-Deutsch

Under Right Side Cover

(Behind Electrical Bracket)

[83]

Ignition Coil

All

3-Place Packard

Below Fuel Tank (Left Side)

4-24

2003 Touring: Engine Management (Carbureted)

HOME

Test 4.11 (Part 1 of 3)

ENGINE CRANKS, BUT WILL NOT START

Is Fresh Gasoline in Tank?

Are Spark Plug Wires in
Correct Coil Towers?

YES

NO

Check for
Trouble Codes.
Codes Found?

Fill Tank With Fresh

Gasoline or Route Spark
Plug Wires Correctly.

YES

NO

Refer to Applicable Trouble

Code Chart.
Start With
Lowest Code.

Place Scanalyzer
in Data Monitor
Mode. Does
BAS MODE=RUN?

YES

NO

Check Battery
Connections. Perform
a Voltage Test. Is
Voltage Above 12.60?

Go to Section
4.19 DTC 44.

YES

NO

Does Battery
Pass Load
Test?

Recharge
Battery.

YES

NO

Check Spark Plug

Condition. Replace,
If Fouled. Check
Spark at Both Plugs
While Cranking.
Spark Present?

Replace
Battery.

7180

7185

YES

NO

Check Compression.
If Compression is
Good, Check Fuel
System.

Turn Ignition/Light Key

Switch to IGNITION and
Engine Stop Switch to
RUN. Check Engine
Lamp Should Illuminate
for 4 Seconds. Does it?

7210

YES

NO

Using DVOM, Check for

Battery Voltage at Socket
B of Connector [83B].
Battery Voltage Present?

See Section 4.12 NO

IGNITION MODULE
POWER.

YES

NO

STOP

Locate and
Repair Open
in W/BK Wire
to Coil.

Go to Test 4.11
(Part 2 of 3).

7215

2003 Touring: Engine Management (Carbureted)

4-25

HOME

Test 4.11 (Part 2 of 3)

ENGINE CRANKS, BUT WILL NOT START

Continued From Test 4.11 (Part 1 of 3).

Disconnect Connector [83]. Gently Connect Test Lamp to Sockets C (Front Cylinder) or A (Rear Cylinder) of Connector
[83B]. Crank Engine. Does Light Flash?

NO

YES
Check Coil Connections. Are
Connections OK?

6
7

YES

NO

Test Spark Plug

Cable Resistance.
See Section 4.13
MISFIRE.
Resistance OK?

Repair.

Connect Breakout Box. Check Continuity Between Socket A of Connector

[83B] and Terminal 7 of Connector
[10] (BK) on Breakout Box. Measure
Resistance Between Socket C of
Connector [83B] and Terminal 6 of
Connector [10] (BK) on Breakout Box.
Resistance Should be Less than 1.0
Ohm. Is it?

7226

YES

NO

Connect DVOM to Terminals 5 and 6

of Connector [11] (GY) on Breakout
Box and Set It for AC Volts. Crank
Engine. Meter Should Read 1 VAC
Minimum. Does it?

YES

NO

Plug Wires in
Correct Coil
Towers?

Replace
Spark Plug
Cables.

Locate and Repair

Poor Connection
at Connector [10B]
(BK) or Open in
Harness Between
Coil and Ignition
Module.
7225

7227

YES

YES

NO
8

NO

STOP
Replace
Coil.
7228

Route
Correctly.

Disconnect Connector [79].

Check Connector for Moisture
and Corrosion. Check Wires for
Chafing.
Connect DVOM to Pins 1 and 2
of Connector [79A]. Crank
engine. Meter Should Read 1
VAC Minimum. Does it?

Go to Test 4.11
(Part 3 of 3).

YES

NO

Check for Continuity

Between Socket 1 of
Connector [79B] and Terminal 5 of Connector [11]
(GY) on Breakout Box.
Continuity Present?

With Meter Still Connected, Check for

Resistance. Should
be Between 600-1200
Ohms. Is it?

YES

NO

Locate and Repair

Open on BK Wire
Between Socket 2 of
Connector [79B] and
Socket 6 of Connector [11B] (GY).

Locate and Repair

Open on R wire
Between Socket 1
of Connector [79B]
and Socket 5 of
Connector [11B]
(GY).

7231
7231

4-26

2003 Touring: Engine Management (Carbureted)

YES

NO

Loose Sensor
at Crankcase.
Tighten Sensor.

Replace
Crank
Position
Sensor.

7235
7230

HOME

Test 4.11 (Part 3 of 3)

ENGINE CRANKS, BUT WILL NOT START

Continued from Test 4.11 (Part 2 of 3).

Replace Ignition Module. Does Vehicle Start?

YES

NO

System OK.

Check For Improper Cam

Timing, Sprocket Failure,
Failed Timing Chain or Other
Mechanical Problem.

7250

7255

2003 Touring: Engine Management (Carbureted)

4-27

HOME

NO IGNITION MODULE POWER

4.12

GENERAL

DIAGNOSTICS

No Spark/No Check Engine

Lamp At Key ON

Diagnostic Notes
The reference numbers below correlate with the circled numbers on the Test 4.12 flow chart.

The ignition module turns on when power is applied to Pin 1

of Connector [10], black. The ignition module goes through an
initialization sequence every time power is removed and reapplied to Pin 1. The only visible part of this sequence is the
check engine lamp. Upon starting, the check engine lamp will
illuminate for 4 seconds and then (if parameters are normal)
go out.

1.

See Section 4.1 SPECIFICATIONS.

2.

Connect BREAKOUT BOX (Part No. HD-42682). See

Section 4.6 BREAKOUT BOX: CARB.

3.

Use HARNESS CONNECTOR TEST KIT (Part No. HD4104), black pin probe and patch cord.

4.

Remove headlamp assembly on FLHR models or outer

fairing on FLHT/C and FLTR. See the 2003 FLT Service
Manual (Part Number 99483-03).

R/BK To Ignition Switch

[83B]

11

A
B
C
15 Amp
Ignition Fuse
GY

Y \ BE

BE \ O

W
\
B
K

Ignition
Coil

[1B]
[1A]

4
5
6

3 4 5 6 7 8 9 10 11 12
FLHT/C
and FLTR Only

To
Data Link

7
8

Engine Stop Switch

9
10
11
12

6-Place on FLHR
[22B]
[22A]

3 4 5 6 7 8 9 10 11 12
[8B] [8A]

Ground Stud

Figure 4-26. Ignition Coil Circuit Diagram

4-28

Rear Coil

BK

1
2
3
To TSM/TSSM

Front Coil

2003 Touring: Engine Management (Carbureted)

[10B] [10A] BK

Ground
Key ON Power

HOME

Test 4.12
NO IGNITION MODULE POWER
1

Check Ignition
Fuse. Is Fuse
OK?

YES

NO
Replace Fuse
and Find
Source of Fault.

2
3

7270

Connect Breakout Box. With Ignition

ON, Place Multimeter Red Wire to
Terminal 1 of Connector [10] (BK)
on Breakout Box, Multimeter Black
Wire to Terminals 2 and 11 on Connector [10] (BK) on Breakout Box.
Is Voltage 12V 1.0V.?

NO

YES
Replace
Ignition
Module.

7305

Using a Breakout Box, Check Continuity Between Terminals on Breakout Box and Ground and Terminal 11
of Connector [10] (BK) on Breakout
Box and Ground. Continuity Present
in Both Places?

NO

YES
3

Repair Open in BK
Wire (Pin 2 or Pin
11) to Ground.

Check Continuity Between Pin

4 (W/BK) of Connector [22A]
and Terminal 1 of Connector
[10] (BK) on Breakout Box.
Is Continuity Present?

7310

YES

NO

Check Continuity
Between Sockets 4
(W/BK) and 3 (GY) of
Connector [22B]. With
Engine Stop Switch
ON, Is Continuity
Present?

Locate and Repair

Open in W/BK Wire
Between Connectors
[22] and [10].
7285

YES

NO

Locate and Repair

Open in GY Wire
Between Connector
[22A] and Fuse Block.

Replace
Engine Stop
Switch.
7295

7291

Table 4-13. Wire Harness Connectors in Figure 4-26.

NO.

DESCRIPTION

[1]

Main to Interconnect Harness

MODEL

TYPE

LOCATION

FLHT/C

12-Place Deutsch

Inner Fairing- Right Fairing Bracket

FLTR

12-Place Deutsch

Inner Fairing- Below Radio (Right Side)

[8]

Ignition Harness

All

12-Place Deutsch

Under Right Side Cover

[10]

Ignition Module

All

12-Place Deutsch (Black)

Under Right Side Cover

FLHT/C

12-Place Deutsch

Inner FairingRight Fairing Support Brace

FLTR

12-Place Deutsch

Inner Fairing Right Side of Radio Bracket

FLHR

6-Place Deutsch

Inside Headlamp Nacelle

[22]

Interconnect to Right
Handlebar Switch Controls

2003 Touring: Engine Management (Carbureted)

4-29

HOME

MISFIRE

4.13

GENERAL
d0273x8x

Misfire at Idle or Under Load

Battery condition and connections may also cause misfires.

Fuel system problems may also cause misfires. See

Table 4-6.

DIAGNOSTICS
Figure 4-27. Spark Tester

Diagnostic Notes
The reference numbers below correlate with the circled numbers on the Test 4.13 flow chart.

c.

1WARNING
Any open spark around gasoline or other combustibles
may result in fire or explosion. Thoroughly wipe up any
spilt fuel and dispose of rags in a suitable manner. Inadequate safety precautions could result in death or serious
injury.
1.

See Figure 4-27. Use the SPARK TESTER (Part No. HD26792) to verify adequate secondary voltage (25,000
volts) at the spark plug.
a.

Turn Ignition/Light Key Switch to IGNITION.

b.

Remove spark plug cable from spark plug. Visually

check plug condition.

c.

Attach cable to SPARK TESTER. Clip tester to cylinder head bolt.

d.

e.
2.

Reinstall and repeat procedure on other spark plug

cable.

Perform spark plug cable resistance test.

a.

Remove spark plug cable from spark plug and ignition coil. For best results, use a needle nose pliers
for removal/installation on coil. Gently grasp cable
as close to terminals as possible.

b.

Using an ohmmeter, touch probes to terminals on

each end plug wire.

4-30

Table 4-14. Spark Plug Cables

LOCATION
Front/Rear

2003 Touring: Engine Management (Carbureted)

LENGTH

RESISTANCE

20 inch

5,000-11,666

3.

If carbon tracking is evident, replace ignition coil and

inspect spark plug wires. Wires must be clean and tight.
Excessive wire resistance or faulty connections can
cause coil damage.

4.

This test can also be performed by substituting a known

good coil for one causing the no spark condition. The coil
does not require full installation to be functional. Verify
faulty coil by performing resistance test.

5.

Use HARNESS CONNECTOR TEST KIT (Part No. HD41404), gray pin probe and patch cord to the coil connector [83B].

6.

Inspect for corrosion at battery terminals, main circuit

breaker, ignition fuse terminals GY and R/BK, right handlebar switch controls connector [22], and ignition coil
connector [83].

While cranking engine, watch for spark to jump

tester gap on leads.

IMPORTANT NOTE
Engine will not spark with both spark plugs removed.
When checking for spark, use SPARK TESTER with both
spark plugs installed.

Compare resistance values to Table 4-14. Replace

cables not meeting specifications. Reinstall and
repeat procedure on other spark plug cable.

HOME

[83B]
R/BK To
Ignition Switch

15 Amp
Ignition Fuse

A
B
C

Y \ BE

BE \ O

1
2
3

GY

Key ON Power

[1B]

[1A]

3 4 5 6 7 8 9 10 11 12

FLHT/C
and FLTR Only

To
Data Link

7
8
9
10
11
12

6-Place on FLHR
2

[10B] [10A] BK

Engine Stop Switch

Front Coil

W
\
B
K

Ignition
Coil

[22B]
[22A]

Rear Coil

3 4 5 6 7 8 9 10 11 12
[8B] [8A]

Figure 4-28. Ignition Coil Circuit Diagram

Table 4-15. Wire Harness Connectors in Figure 4-28.

NO.
[10]

[22]

[83]

DESCRIPTION
Ignition Module

Interconnect to Right
Handlebar Switch Controls

Ignition Coil

MODEL

TYPE

LOCATION

All

12-Place Deutsch (Black)

Under Right Side Cover

FLHT/C

12-Place Deutsch

Inner FairingRight Fairing Support Brace

FLTR

12-Place Deutsch

Inner Fairing Right Side of Radio Bracket

FLHR

6-Place Deutsch

Inside Headlamp Nacelle

All

3-Place Packard

Below Fuel Tank (Left Side)

2003 Touring: Engine Management (Carbureted)

4-31

HOME

Test 4.13
MISFIRE AT IDLE OR UNDER LOAD

Is Fuel
Contaminated?

NO

YES
Drain and
Flush Tank.
Refill With
Fresh Fuel.

Turn Ignition Switch OFF.

Disconnect One Spark Plug Lead
at a Time and Install Spark Tester
(HD-26792). See Figure 4-27.
Crank Engine to Induce Spark.
Observe Spark Tester During Test.
Spark Should Jump Tester Gap on
Both Leads During Test. Did It?

NO

YES
2

Check For:

Faulty, Worn or Cracked

Spark Plug(s).

Plug Fouling Due to

Engine Mechanical Fault.
See ENGINE TROUBLESHOOTING.

Faulty or Poor Connection at Plug.

Check the Resistance of Each Spark

Plug Cable That Did Not Fire the Spark
Tester. Also Check for Faulty Plug Wire
Connections and Wire Boots for Carbon Tracking. Are Wires OK?

YES

NO

Coil Should Be
Free of Carbon
Tracking. Is It?

Replace Faulty
Wire(s).

YES

NO

Switch Coil With Unit

Known to be Good.

Replace
Ignition Coil.

3
7520

7525

Spark Should Jump Tester

Gap While Cranking.
Did It?

7535

NO

YES
Original Ignition
Coil is Faulty.
Finish Installing
New Coil.
7535

Remove Test Coil. Disconnect

Negative (-) Battery Cable. Measure Resistance Between Battery
Positive and Socket B (W/BK) of
Connector [83B]. Wiggle Harness.
Resistance Should Be Less Than
1.0 Ohm Continuously. Is It?

YES

NO

Replace
Ignition
Module.

Find Source
of Intermittent
and Repair.

7541

4-32

2003 Touring: Engine Management (Carbureted)

7540