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techtalk:evo:elec03 [2022/05/19 15:41] – [Speedometers] ixl2relax | techtalk:evo:elec03 [2025/01/06 16:20] (current) – [TURN SIGNALS] ixl2relax | ||
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===== Key Switch ===== | ===== Key Switch ===== | ||
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The Key Switch is fed from the main Circuit Breaker, later, the MaxiFuse. Typically, this feed wire is RED. The Key Switch has two positions (besides OFF), but their function changed in 1994. | The Key Switch is fed from the main Circuit Breaker, later, the MaxiFuse. Typically, this feed wire is RED. The Key Switch has two positions (besides OFF), but their function changed in 1994. | ||
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{{ : | {{ : | ||
- | In 1994, the MoCo rearranged the circuit breaker connections and removed the Key Switch jumper on the output connections. Now, the Key Switch had an ACCESSORY position and a RUN position. This allowed the 4-way flashers to function on the Accessories Circuit without the rest of the circuits being powered. The key could be removed in the Acc Position of the keyswtich so you could walk for help while leaving the 4-way flashers on, without leaving the key in the ignition switch. The keyswitch labels were now B - A - IG for Battery, Accessory & Ignition. The instrument lights, brake light & horn also operate off the ACC circuit. On HDI models, the Taillight & the Position Light (in the headlight) are also ON when in ACC position and the key may not be removed from the keyswitch. | + | In 1994, the MoCo rearranged the circuit breaker connections and removed the Key Switch jumper on the output connections. Now, the Key Switch had an ACCESSORY position and a RUN position. This allowed the 4-way flashers to function on the Accessories Circuit without the rest of the circuits being powered. The key could be removed in the Acc Position of the keyswtich so you could walk for help while leaving the 4-way flashers on, without leaving the key in the ignition switch. The keyswitch labels were now B - A - IG for Battery, Accessory & Ignition. The instrument lights, brake light & horn also operate off the ACC circuit. On HDI models, the Taillight & the Position Light (in the headlight) are also ON when in ACC position and the key cannot |
In 1995, the location of the keyswitch was moved from the side engine mount (between the two cylinders) to a location next to the ignition coil, under the front right side of the fuel tank. The switch function did not change, but it was implemented with a new switch housing, new coil bracket & the physical switch design was different. | In 1995, the location of the keyswitch was moved from the side engine mount (between the two cylinders) to a location next to the ignition coil, under the front right side of the fuel tank. The switch function did not change, but it was implemented with a new switch housing, new coil bracket & the physical switch design was different. | ||
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The CANbus Key Switch has three positions - OFF, ACC & IGN - There are only two wires used for the three functions. When OFF, the two wires have no connection. When in ACC Mode, the two wires are connected by an 800 ohm resistor, which provides a HI signal to the BCM. When in IGN Mode, the two wires are connected by a 200 ohm resistor, which provides a LO signal to the BCM. In this way, the BCM can determine the switch mode and implement the appropriate control of the various circuits. | The CANbus Key Switch has three positions - OFF, ACC & IGN - There are only two wires used for the three functions. When OFF, the two wires have no connection. When in ACC Mode, the two wires are connected by an 800 ohm resistor, which provides a HI signal to the BCM. When in IGN Mode, the two wires are connected by a 200 ohm resistor, which provides a LO signal to the BCM. In this way, the BCM can determine the switch mode and implement the appropriate control of the various circuits. | ||
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==== Testing the Key Switch ==== | ==== Testing the Key Switch ==== | ||
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Key Switches can fail and become intermittent. The internal contacts can be severely strained if you have a keyring with too many extra keys or other heavy items, or items that flap in the wind. | Key Switches can fail and become intermittent. The internal contacts can be severely strained if you have a keyring with too many extra keys or other heavy items, or items that flap in the wind. | ||
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==== Current Draw with Key Switch Off ==== | ==== Current Draw with Key Switch Off ==== | ||
+ | Here is a test to see if the bike is drawing electrical power from the battery when the keyswitch is off. This can happen if the key switch has an internal short due to damage or heavy corrosion. A sustained power drain from the battery, if large enough over enough time, will damage your battery. | ||
+ | |||
+ | With the KEY OFF - Remove the Negative Battery Cable (ground). Set your meter to the 20v scale. Put the RED lead on the negative battery cable & the BLACK lead on the Negative Battey Terminal. Is there any voltage reading? Record that. | ||
+ | |||
+ | If so, change your meter setting to current (amps). You should use the 10 amp setting just to be careful. Apply the leads again in the same way. What amount of current is being pulled? Record that. If the reading is very small, try reducing the meter setting to 2 amps or (carefully) to 1 amp. Then, check the amount of current draw again. Record that. | ||
+ | |||
+ | Always in this order - check voltage first - then check for high current - then check for low current. | ||
+ | |||
+ | On pre-2004 bikes, if you have no ALWAYS_ON accessories (clock, | ||
Starting in 2004, the TSM/ | Starting in 2004, the TSM/ | ||
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===== Horn Switch ===== | ===== Horn Switch ===== | ||
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===== Brake Switch - Front & Rear ===== | ===== Brake Switch - Front & Rear ===== | ||
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The Front Brake Switch is installed between the brake lever & the master cylinder assembly. It is a normally closed switch, but the contacts are actually held open when the lever is not being pulled. When the lever is pulled to activate the front brake master cylinder, the brake switch is no longer pressed by the lever, the contacts now close and power is sent to the rear brake light. This switch is often damaged (causing the brake light to stay ON) by not paying close attention to the following caution from the manual regarding disassembly & assembly of the master cylinder or brake lever or right switch housing: | The Front Brake Switch is installed between the brake lever & the master cylinder assembly. It is a normally closed switch, but the contacts are actually held open when the lever is not being pulled. When the lever is pulled to activate the front brake master cylinder, the brake switch is no longer pressed by the lever, the contacts now close and power is sent to the rear brake light. This switch is often damaged (causing the brake light to stay ON) by not paying close attention to the following caution from the manual regarding disassembly & assembly of the master cylinder or brake lever or right switch housing: | ||
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| {{: | | {{: | ||
- | The Rear Brake Switch is installed in the rear brake hydraulic line from the master cylinder to the caliper, typically on the left side ahead of the caliper. It is a hydraulically activated switch, meaning that at a certain level of hydraulic pressure in the brake line, the switch closes to conduct power thru it to the rear brake light. (1986-2019 used the same rear brake switch, P/N 72023-51E. It's possible to also use a NAPA P/N ECH SL147.)((http:// | + | The Rear Brake Switch is installed in the rear brake hydraulic line from the master cylinder to the caliper, typically on the left side ahead of the caliper. It is a hydraulically activated switch, meaning that at a certain level of hydraulic pressure in the brake line, the switch closes to conduct power thru it to the rear brake light. (1986-2019 used the same rear brake switch, P/N 72023-51E. It's possible to also use a NAPA P/N ECH SL147.)((https://www.xlforum.net/ |
The front & rear brake switches are electrically connected in parallel. This means that either switch, when activated, will send power to the brake light (bright) element. | The front & rear brake switches are electrically connected in parallel. This means that either switch, when activated, will send power to the brake light (bright) element. | ||
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The odometer readings are stored mechanically in the speedometer. | The odometer readings are stored mechanically in the speedometer. | ||
- | The speedometers were rated as 2:1 ratio, meaning that for 2000 RPMs of the cable, the speedometer would register 60 MPH. All Sportster model speedometers from 1973-1994 were front wheel driven and used a 2:1 ratio. From 1957-1972, the Sportster speedometers were cable driven from the transmission, | + | The speedometers were rated as 2:1 ratio, meaning that for 2000 RPMs of the cable, the speedometer would register 60 MPH. All Sportster model speedometers from 1973-1994 were front wheel driven and used a 2:1 ratio. From 1957-1972, the Sportster speedometers were cable driven from the transmission, |
From 1973-later, the 19" front wheel meant that the wheel driven unit for driving the 2:1 ratio speedometers all used nearly identical ratios for converting wheel rotation into cable rotation, approximately 1 wheel rotation = 2.625 cable rotations. | From 1973-later, the 19" front wheel meant that the wheel driven unit for driving the 2:1 ratio speedometers all used nearly identical ratios for converting wheel rotation into cable rotation, approximately 1 wheel rotation = 2.625 cable rotations. | ||
- | Normally, for 1984-1994, the wheel driven unit will be a match to the speedometer - that is, a driven unit intended for 2:1 (67127-84A - which creates a 1:2.625 ratio of wheel-to-cable rotations) is used with a 2:1 speedometer (likewise, the drive unit and speedometer would be matched for 1:1 or 2240:60 on the BT). However, if you use a 21" wheel/tire on a model that original had a 19" wheel/tire and used a 2:1 ratio speedometer (as stock on all pre-95 XLs), then you need to use a wheel driven unit (FXLR - 67132-85A - that creates a 1:3 wheel-to-cable ratio) which was originally intended for a 2240:60 ratio speedometer. This makes the 2:1 ratio speedometer read close to the right speed. ((http:// | + | Normally, for 1984-1994, the wheel driven unit will be a match to the speedometer - that is, a driven unit intended for 2:1 (67127-84A - which creates a 1:2.625 ratio of wheel-to-cable rotations) is used with a 2:1 speedometer (likewise, the drive unit and speedometer would be matched for 1:1 or 2240:60 on the BT). However, if you use a 21" wheel/tire on a model that original had a 19" wheel/tire and used a 2:1 ratio speedometer (as stock on all pre-95 XLs), then you need to use a wheel driven unit (FXLR - 67132-85A - that creates a 1:3 wheel-to-cable ratio) which was originally intended for a 2240:60 ratio speedometer. This makes the 2:1 ratio speedometer read close to the right speed. ((https://www.xlforum.net/ |
Both the tire size and the intended speedometer ratio are relevant to selecting the required wheel driven unit to create the right number of cable revolutions for each wheel revolution so that the speedometer accurately displays the speed information. | Both the tire size and the intended speedometer ratio are relevant to selecting the required wheel driven unit to create the right number of cable revolutions for each wheel revolution so that the speedometer accurately displays the speed information. | ||
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<font 18px/Arial, , ;;# | <font 18px/Arial, , ;;# | ||
- | Beginning in 2004, the Vehicle Speed Sensor (VSS) feeds its pulses to the ECM (not directly to the speedometer). The ECM interprets the pulses and sends a digital stream of data, using the Serial Data Bus, to the speedometer & the TSM/TSSM related to the operating speed. The speedometer takes the SDB data and converts it to the necessary impulses to operate the dial needle to show the current speed. The TSM/TSSM uses the data in evaluating when to cancel the turn signal function. | + | Beginning in 2004, the Vehicle Speed Sensor (VSS) feeds its pulses to the ICM/ECM (not directly to the speedometer). The ICM/ECM interprets the pulses and sends a digital stream of data, using the Serial Data Bus, to the speedometer & the TSM/TSSM related to the operating speed. The speedometer takes the SDB data and converts it to the necessary impulses to operate the dial needle to show the current speed. The TSM/TSSM uses the data in evaluating when to cancel the turn signal function. |
- | The Speedometer ' | + | The Speedometer ' |
- | XLForum Discussion: | + | XLForum Discussion: |
- | + | ||
- | \\ | + | |
- | + | ||
- | **2004-later - Speedometer WOW Test** ((From the Electrical Diagnostic Manual))\\ | + | |
- | + | ||
- | Typically, when power is applied | + | |
- | + | ||
- | The visible part of this sequence is the check engine lamp, security lamp, backlighting and odometer display. Upon key ON (Run/Off switch set to RUN), the check engine lamp and security lamp will illuminate for four seconds and then (if parameters are normal) will turn off. | + | |
- | + | ||
- | As an additional quick check of speedometer function, a " | + | |
- | + | ||
- | Release trip odometer reset switch. Background lighting should illuminate, gauge needle should sweep its full range of motion, and indicator lamps (check engine, low fuel, battery and security) should illuminate. | + | |
- | + | ||
- | If instrument module fails " | + | |
- | + | ||
- | Tech Note: | + | |
- | Constant power is supplied to the speedometer through Pin2 (Battery) of connector [20]. The speedometer turns on when power is applied to Pin6 (Ignition | + | |
- | + | ||
- | The Security Lamp (Security Indicator in the speedometer), | + | |
\\ | \\ | ||
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{{ : | {{ : | ||
- | The Speedometer ' | + | The Speedometer ' |
\\ | \\ | ||
- | On the 2016-later 1200CX Roadster, the stock speedometer is P/N 70900549. It has a fuel level gauge that is not implemented with the stock low fuel sensor. However, testing by b0fh on the XLForum ((Pic from XLForum Thread - http:// | + | On the 2016-later 1200CX Roadster, the stock speedometer is P/N 70900549. It has a fuel level gauge that is not implemented with the stock low fuel sensor. However, testing by b0fh on the XLForum ((Pic from XLForum Thread - https://www.xlforum.net/ |
\\ | \\ | ||
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* When the preferred setting is displayed, Press/Hold the switch for five seconds to finalize the time settings | * When the preferred setting is displayed, Press/Hold the switch for five seconds to finalize the time settings | ||
* Turn off the ignition & the OFF/RUN switch to OFF. | * Turn off the ignition & the OFF/RUN switch to OFF. | ||
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\\ | \\ | ||
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**VSS/ | **VSS/ | ||
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\\ | \\ | ||
+ | |||
+ | ==== 2004-later Speedo WOW Test ==== | ||
+ | ((From the Electrical Diagnostic Manual))\\ | ||
+ | |||
+ | Typically, when power is applied and the speedometer turns on, it proceeds through an initialization sequence. It does this every time power is removed and re-applied. | ||
+ | |||
+ | The visible part of this sequence is the check engine lamp, security lamp, backlighting and odometer display. Upon key ON (Run/Off switch set to RUN), the check engine lamp and security lamp will illuminate for four seconds and then (if parameters are normal) will turn off. | ||
+ | |||
+ | As an additional quick check of speedometer function, a " | ||
+ | |||
+ | Release trip odometer reset switch. Background lighting should illuminate, gauge needle should sweep its full range of motion, and indicator lamps (check engine, low fuel, battery and security) should illuminate. | ||
+ | |||
+ | If instrument module fails " | ||
+ | |||
+ | **Tech Notes - 2004-2013**\\ | ||
+ | If instrument module fails " | ||
+ | |||
+ | Constant power is supplied to the speedometer through Pin2 (Battery) of Connector #20 on the Main Harness. The speedometer turns on when power is applied to Pin6 (Ignition - Conn20). The speedometer proceeds through an initialization sequence every time power is removed (key switch off) and re-applied to Pin1 (Accessory - Conn20). The visible part of this sequence is the check engine lamp, security lamp, backlighting and odometer display. Upon key ON (Run/Off switch set to RUN), the check engine lamp and security lamp will illuminate for four seconds and then (if parameters are normal) will turn off. | ||
+ | |||
+ | The Security Lamp (Security Indicator in the speedometer), | ||
+ | |||
+ | ^ Power Sources to Speedometer | ||
+ | | Source | ||
+ | | Conn# | ||
+ | | At Speedo | ||
+ | | When | ||
+ | ^ The results of these connections failing | ||
+ | | | * Speedo non-functional\\ * Security lamp\\ .. glows dimly\\ .. during\\ .. 4-second\\ .. bulb check | * Will not do WOW\\ * Speed shows 0\\ * Tach unaffected\\ * Security lamp works\\ * Check Engine lamp\\ .. & battery lamp\\ .. non-functional\\ * No diagnostics | * Speedo non-functional\\ * Security lamp\\ .. will still do\\ .. 4-sec display | * Speedo non-functional\\ * No diagnostics | | ||
+ | |||
+ | |||
\\ | \\ | ||
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\\ | \\ | ||
\\ | \\ | ||
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===== Tachometers ===== | ===== Tachometers ===== | ||
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Pre-2004 HD Tachs used a pulse signal input and were designed for use with dual-fire ignition systems. The non-SPORT models used the trigger signal for the ignition coil (typically, PINK wire) to also trigger the tach. The SPORT models, which have a single-fire ignition system, used a tach trigger signal generated by the ICM (separate from the coil triggers) that is intended to drive a tachometer that is dual-fire ignition compatible. The same OEM tachometer was used on the dual-fire 1200 models and the single-fire 1200S models. | Pre-2004 HD Tachs used a pulse signal input and were designed for use with dual-fire ignition systems. The non-SPORT models used the trigger signal for the ignition coil (typically, PINK wire) to also trigger the tach. The SPORT models, which have a single-fire ignition system, used a tach trigger signal generated by the ICM (separate from the coil triggers) that is intended to drive a tachometer that is dual-fire ignition compatible. The same OEM tachometer was used on the dual-fire 1200 models and the single-fire 1200S models. | ||
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Quote: | Quote: | ||
- | http:// | + | https://www.xlforum.net/ |
| | ||
VBDiver on his 2007 Sportster 883L | VBDiver on his 2007 Sportster 883L | ||
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- | Pin #3 on OEM Speedo is Tach Signal Out. You need to supply the needed wire & connector for this Pin #3 - P/N for needed female socket in connector [39B] is 74196-04 ((http:// | + | Pin #3 on OEM Speedo is Tach Signal Out. You need to supply the needed wire & connector for this Pin #3 - P/N for needed female socket in connector [39B] is 74196-04 ((https://www.xlforum.net/ |
Rather than buying your own female connector and crimp tool, you might want to go to your local HD shop and ask them to create a short wire for you (about 6") and use their crimping tool to afix the proper female connector onto the end. | Rather than buying your own female connector and crimp tool, you might want to go to your local HD shop and ask them to create a short wire for you (about 6") and use their crimping tool to afix the proper female connector onto the end. | ||
Then, when you get home, release the Blue Locking Bar on connector 39B (at the Speedometer) and slide the short wire into the socket at location #3 and relock the bar in place. This will then give you a short pigtail onto which you can connect your Tachometer signal wire.\\ | Then, when you get home, release the Blue Locking Bar on connector 39B (at the Speedometer) and slide the short wire into the socket at location #3 and relock the bar in place. This will then give you a short pigtail onto which you can connect your Tachometer signal wire.\\ | ||
- | ((http:// | + | ((https://www.xlforum.net/ |
\\ | \\ | ||
==== Single-fire Ignition To Dual-fire Tachometer Adapter ==== | ==== Single-fire Ignition To Dual-fire Tachometer Adapter ==== | ||
- | + | If you are **NOT** using the OEM Digital Speedometer on your 04+ Sportster, and still want to implement a dual-fire tachometer, you will need an adapter to combine the firing signals from both coils into a single signal to the tach. You can buy such an adapter or make your own:((https://www.xlforum.net/ | |
- | If you are **NOT** using the OEM Digital Speedometer on your 04+ Sportster, and still want to implement a dual-fire tachometer, you will need an adapter to combine the firing signals from both coils into a single signal to the tach. You can buy such an adapter or make your own:((http:// | + | |
| \\ **NOTE: | | \\ **NOTE: | ||
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===== Indicator Lights - Idiot Lights ===== | ===== Indicator Lights - Idiot Lights ===== | ||
- | **1992-1994** models used Indicator Units without replaceable individual bulbs - The entire unit (cylindrical housing with pig tail wires) needs to be replaced:\\ | + | **Indicator Lights - Circuit Activation** |
+ | |||
+ | | YEAR | Indicator | Activated By | | ||
+ | | 86-91 | HiBeam | ||
+ | | ::: | Turn | Single Lamp - Powered when either TS Switch Active | | ||
+ | | ::: | HiBeam & TS Indicators Are Always Grounded || | ||
+ | | ::: | Neutral | ||
+ | | ::: | Oil | Grounded when Oil Pressure Switch has ' | ||
+ | | ::: | Neutral & Oil Indicators Always Get Power from Acc Circuit || | ||
+ | | 92-13 | HiBeam | ||
+ | | ::: | L. Turn | Power from Left TS output circuit of TSM | | ||
+ | | ::: | R. Turn | Power from Right TS output circuit of TSM | | ||
+ | | ::: | HiBeam & TS Indicators Are Always Grounded || | ||
+ | | ::: | Neutral | ||
+ | | ::: | Oil | Grounded when Oil Pressure Switch has ' | ||
+ | | ::: | Neutral & Oil Indicators Are Always Powered from Acc Circuit || | ||
+ | | 14-22 | HiBeam | ||
+ | | ::: | L. Turn | ::: | | ||
+ | | ::: | R. Turn | ::: | | ||
+ | | ::: | Neutral | ||
+ | | ::: | Oil | ::: | | ||
+ | | ::: | All Indicators are Powered from Always-On Battery Fuse || | ||
+ | | Note: TS means Turn Signal / TSM means Turn Signal Module ||| | ||
+ | |||
+ | **Bulbs** | ||
+ | |||
+ | **1986-1991** models used individual Indicator bulbs.\\ | ||
+ | |||
+ | **1992-1994** models used Indicator Units without replaceable individual bulbs - The entire unit (cylindrical housing with pig tail wires) needs to be replaced.\\ | ||
**1995-2006** models used replaceable Indicator Bulbs - P/N 68024-94\\ | **1995-2006** models used replaceable Indicator Bulbs - P/N 68024-94\\ | ||
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Here's a thread regarding the bulbs used in the indicator lights:\\ | Here's a thread regarding the bulbs used in the indicator lights:\\ | ||
- | http:// | + | https://www.xlforum.net/ |
**2014-later** | **2014-later** | ||
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The indicator lights are LEDs that are soldered onto a circuit board strip (SMDs). These individual LEDs are activated by the Speedometer, | The indicator lights are LEDs that are soldered onto a circuit board strip (SMDs). These individual LEDs are activated by the Speedometer, | ||
- | Here is DIY info regarding the repair of faulty indicator lights | + | Here is DIY info regarding the repair of faulty indicator lights.\\ |
- | * [[techtalk: | + | * [[techtalk: |
+ | |||
+ | An interesting repair in this [[https:// | ||
**INDICATOR LIGHTS PARTS LIST** | **INDICATOR LIGHTS PARTS LIST** | ||
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^ 2007 Custom Models - LEDs || | ^ 2007 Custom Models - LEDs || | ||
| | LEDs & Housing part of Harness (68814-07)\\ 68382-07B Trim Plate & Bezel Assy (Symbols/ | | | LEDs & Housing part of Harness (68814-07)\\ 68382-07B Trim Plate & Bezel Assy (Symbols/ | ||
- | |||
- | An interesting repair in this [[http:// | ||
\\ | \\ | ||
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**Tail Light & Brake Light** | **Tail Light & Brake Light** | ||
- | **1986-2003E** - The standard | + | **1986-1998** - The stock tail light / brake light bulb for these models was a bayonet type bulb (P/N 68168-89A). Generically, |
+ | |||
+ | **1999-2003E** - A new distribution circuit board was added to the tail light assembly. The turn signals & tail light all connect here. The main wiring harness uses the under-fender sub-harness to provide power & control signals to the distribution circuit board (See Diagram for detailed connections). The connector on the (2-pin) right rear TS cable is BLACK while the LEFT is WHITE. Tail light / brake light uses a (4-pin) BLACK connector. | ||
+ | |||
+ | **NOTE:** There have been a number of situations where the Taillight Circuit Board becomes corroded and any/all contacts become intermittent or low-grade shorts. Because there is an opening from the fender to the circuit board area, it allows moisture (if not road debri) to cause oxidation. This is especially problematic if the bike is left outside or operated in the rain. It's a good idea to check & thoroughly clean this board and each connector with circuit cleaner at least once per year, using dielectric grease on the contacts. | ||
+ | |||
+ | The stock tail light / brake light bulb for these models was a bayonet type bulb (P/N 68168-89A) on a cable that plugged into the distribution circuit board. Generically, | ||
{{ : | {{ : | ||
**2003L-later** - Mid-year of 2003 there was a change to a wedge type bulb (P/N 68167-88). Generically, | **2003L-later** - Mid-year of 2003 there was a change to a wedge type bulb (P/N 68167-88). Generically, | ||
- | **2011 - Later** - All Custom model Sportsters received a new, self-contained, | + | **2011-later** - All Custom model Sportsters received a new, self-contained, |
+ | |||
+ | **2014-2020** - The under-fender wiring was changed when the CANbus controllers were implemented. Two wiring colors changed and causes some confusion because the wire that is RED/Yellow color is used differently in those years. The other four wiring colors & functions remained the same (into the same version distribution circuit board). | ||
+ | |||
+ | | Under-fender Wiring | ||
+ | | 1999-2013 | ||
+ | | ::: | Pin4 | RED/ | ||
+ | | 2014-2020 | ||
+ | | ::: | ||
\\ | \\ | ||
{{: | {{: | ||
- | |||
- | **NOTE:** There have been a number of situations where the Taillight Circuit Board becomes corroded and any/all contacts become intermittent or low-grade shorts. Because there is an opening from the fender to the circuit board area, it allows moisture (if not road debri) to cause oxidation. This is especially problematic if the bike is left outside or operated in the rain. It's a good idea to check & thoroughly clean this board and each connector with circuit cleaner at least once per year, using dielectric grease on the contacts. | ||
\\ | \\ | ||
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\\ | \\ | ||
+ | |||
+ | **( [[techtalk: | ||
**( [[techtalk: | **( [[techtalk: | ||
- | **( [[http:// | + | **( [[https://www.xlforum.net/ |
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^ Example: 1998 Turn Signal Cancellation | ^ Example: 1998 Turn Signal Cancellation | ||
- | | The turn signal cancellation function is\\ not a linear calculation of speed.\\ \\ Instead, it uses an internal table as\\ shown here. | Speed (mph) | Distance | Here is the speedo\\ generated signal to\\ the tsm. |{{: | + | | The turn signal cancellation function is\\ not a linear calculation of speed.\\ \\ Instead, it uses an internal table as\\ shown here. | Speed (mph) | Distance | Here is the speedo\\ generated signal to\\ the tsm. |{{: |
| ::: | 0-34 | 221ft | ::: | ::: | | | ::: | 0-34 | 221ft | ::: | ::: | | ||
| ::: | 35-44 | 339ft | ::: | ::: | | | ::: | 35-44 | 339ft | ::: | ::: | | ||
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* (Converting to LEDs) - To use the stock TSM setup with LED turn signal bulbs, you will need load equalizer resistors on each turn signal circuit to simulate (to the TSM) the normal load of the incandescent bulbs. A 6-ohm, 50-watt Resistor is necessary for each bulb that you replaced with an LED bulb on the Left & Right circuits. Simply connect the resistors in parallel of the bulb circuit. One side of the resistor(s) is connected on the turn signal power wire to the bulb (typically, Violet wire on Left circuit, Brown wire on the Right circuit) and the other side of each resistor is connected to ground. The load resistors are needed to satisfy the TSM and make it function normally. | * (Converting to LEDs) - To use the stock TSM setup with LED turn signal bulbs, you will need load equalizer resistors on each turn signal circuit to simulate (to the TSM) the normal load of the incandescent bulbs. A 6-ohm, 50-watt Resistor is necessary for each bulb that you replaced with an LED bulb on the Left & Right circuits. Simply connect the resistors in parallel of the bulb circuit. One side of the resistor(s) is connected on the turn signal power wire to the bulb (typically, Violet wire on Left circuit, Brown wire on the Right circuit) and the other side of each resistor is connected to ground. The load resistors are needed to satisfy the TSM and make it function normally. | ||
- | ( Here's a discussion about low-watt TS bulbs: | + | ( Here's a discussion about low-watt TS bulbs: |
\\ | \\ | ||
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2004-06 Self-Cancelling Turn Signal Function</ | 2004-06 Self-Cancelling Turn Signal Function</ | ||
- | In 2004, HD implemented on the Sportster models a TSM which was also used on the BT models. This TSM includes all the functions of the previous versions plus added the Bank Angle Sensor (BAS) function which allows cancelling the turn signals based on lean angle. This TSM implemented control over the Starter Relay in communications with the Ignition Control Module. There is a variation of the TSM which adds security features (known as a TSSM - Turn Signal/ | + | In 2004, HD implemented on the Sportster models a TSM which was also used on the BT models. This TSM includes all the functions of the previous versions plus added the Bank Angle Sensor (BAS) function which allows cancelling the turn signals based on lean angle. |
+ | |||
+ | This TSM implemented control over the Starter Relay in communications with the Ignition Control Module. There is a variation of the TSM which adds security features (known as a TSSM - Turn Signal/ | ||
{{ : | {{ : | ||
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The TSM now monitors the current used when the turn signals flash. (This fact, and some anedotal evidence, seems to indicate that these modules are capable of properly handling variations in the current load of the bulbs that are used.) | The TSM now monitors the current used when the turn signals flash. (This fact, and some anedotal evidence, seems to indicate that these modules are capable of properly handling variations in the current load of the bulbs that are used.) | ||
- | This module receives a positive signal from the left or right handlebar switch when pressed (these are momentary action switches). This begins the turn signal flashing function. The function continues as long as the switch is held down. When the switch is released, the module, in communications with the speedometer, | + | This module receives a positive signal from the left or right handlebar switch when pressed (these are momentary action switches). This begins the turn signal flashing function. The function continues as long as the switch is held down. When the switch is released, the module, in communications with the speedometer, |
+ | |||
+ | If the right turn signal switch is pressed while the left turn signal is flashing, the left will stop and the right side will begin a flashing sequence (same if right is flashing & left TS switch is pressed). Any time during the flashing sequence, if the same switch is pressed again, the flashing will stop. | ||
The 4-way flasher function is activated by momentarily pressing both the left and right turn signal buttons at the same time and cancelled in the same way. | The 4-way flasher function is activated by momentarily pressing both the left and right turn signal buttons at the same time and cancelled in the same way. | ||
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The above models use a Tail Lamp Converter Module (P/N 68278-07) to create Run/ | The above models use a Tail Lamp Converter Module (P/N 68278-07) to create Run/ | ||
- | * (Converting to LEDs) - There is some evidence that some of the TSM/TSSM modules are capable of sensing and properly controlling LED turn signals. According to a post from Screw Loose Dan((http:// | + | * (Converting to LEDs) - There is some evidence that some of the TSM/TSSM modules are capable of sensing and properly controlling LED turn signals. According to a post from Screw Loose Dan((https://www.xlforum.net/ |
* After removing or replacing your selected turn signals with LED versions: | * After removing or replacing your selected turn signals with LED versions: | ||
* Reset the TSM by briefly pulling the MaxiFuse - then replace it | * Reset the TSM by briefly pulling the MaxiFuse - then replace it | ||
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* Now, start the bike and check the turn signal functions | * Now, start the bike and check the turn signal functions | ||
* (Note: a variation is to use the 4-way flashers for 15 flashes after the individual turn signals) | * (Note: a variation is to use the 4-way flashers for 15 flashes after the individual turn signals) | ||
- | * (If your particular module for these years does not respond correctly after doing the above procedure, you may need to install load equalizer resistors as detailed for earlier models. BUT, you may also want to wait for a week, putting up with the hyperflash to see if your TSM is just a 'slow learner' | + | * (If your particular module for these years does not respond correctly after doing the above procedure, you may need to install load equalizer resistors as detailed for earlier models. BUT, you may also want to wait for a week, putting up with the hyperflash to see if your TSM is just a 'slow learner' |
* Service Bulletin M-1115 relates to earlier version TSM/TSSM for BT models (using a similar procedure with 5-blinks required), but might apply to later XL versions. | * Service Bulletin M-1115 relates to earlier version TSM/TSSM for BT models (using a similar procedure with 5-blinks required), but might apply to later XL versions. | ||
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In 2014, the Turn Signal Module (TSM) function was integrated into the Body Control Module (BCM), which controls many of the power functions and is located between the battery & the ECM. This change, in association with implementing the CANbus communications system between the intelligent modules, means that all the functions previously handled by the TSM are incorporated into the BCM along with many other functions. There is also a variation of the BCM which adds security features (similar to the TSM/TSSM modules previously). | In 2014, the Turn Signal Module (TSM) function was integrated into the Body Control Module (BCM), which controls many of the power functions and is located between the battery & the ECM. This change, in association with implementing the CANbus communications system between the intelligent modules, means that all the functions previously handled by the TSM are incorporated into the BCM along with many other functions. There is also a variation of the BCM which adds security features (similar to the TSM/TSSM modules previously). | ||
- | In 2014, the handlebar switch housings were changed again (matching the FX-style models). The switch sets (both left & right) are now implemented with intelligent components. They no longer send their individual switch functions on separate wires, but instead communicate with the BCM/ECM using the CANbus to send the status of the individual switches. | + | In 2014, the handlebar switch housings were changed again (matching the FX-style models). The switch sets (both left & right) are now implemented with intelligent components. They no longer send their individual switch functions on separate wires, but instead communicate with the BCM/ECM using the CANbus to send the status of the individual switches. Left controls include Headlight Hi/ |
- | The BCM receives a signal on the CANbus from the left or right handlebar switch when pressed (these are momentary action switches). This begins the turn signal flashing function. The function continues as long as the switch is held down. When the switch is released, the module, in communications with the Electronic Control Module (ECM), calculates the amount of distance travelled. Once the predefined distance is travelled, the unit turns off the flashing function. It will also turn off the flashing function within 2 seconds after determining (using the BAS) that a turn has been completed. If the right turn signal switch is pressed while the left turn signal is flashing, the left will stop and the right side will begin a flashing sequence (same if right is flashing & left TS switch is pressed). Any time during the flashing sequence, if the same switch is pressed again, the flashing will stop. | + | The BCM receives a signal on the CANbus from the left or right handlebar switch when pressed (these are momentary action switches). This begins the turn signal flashing function. The function continues as long as the switch is held down. When the switch is released, the module, in communications with the Electronic Control Module (ECM), calculates the speed and amount of distance travelled. Once the predefined distance is travelled, the unit turns off the flashing function. It will also turn off the flashing function within 2 seconds after determining (using the BAS) that a turn has been completed. The TSM must be mounted upright for the BAS to operate properly. If the right turn signal switch is pressed while the left turn signal is flashing, the left will stop and the right side will begin a flashing sequence (same if right is flashing & left TS switch is pressed). Any time during the flashing sequence, if the same switch is pressed again, the flashing will stop. |
- | The 4-way flasher function is activated by momentarily | + | The 4-way flasher function is activated by temporarily |
- | On all of these 2014-2018 models, the front TS units have dual-element bulbs (P/N 68168-89A - #1157) that provide Running & Turn Signal functions. On models with a center tail light, the rear TS units have single-element bulbs (P/N 68163-84 - #7506 generic) that provide Turn Signal functions only. | + | On all of these 2014-2018 models, the front TS units have dual-element bulbs (P/N 68168-89A - #1157 generic) that provide Running & Turn Signal functions. On models with a center tail light, the rear TS units have single-element bulbs (P/N 68163-84 - #7506 generic) that provide Turn Signal functions only. |
**Rear Turn Signals - Exceptions: | **Rear Turn Signals - Exceptions: | ||
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* Security Pager Receiver II | * Security Pager Receiver II | ||
- | **NOTE:** All devices that use Radio Frequency (RF) signals to function have susceptibility to signal overload from unintended RF sources of signals from other electronic or electrical devices in close proximity to them. The security functions may not work or have difficulty responding to the FOB in locations with high RF signals from other sources. Moving the bike to a different location may allow proper functioning, | + | **NOTE:** All devices that use Radio Frequency (RF) signals to function have susceptibility to signal overload from unintended RF sources of signals from other electronic or electrical devices in close proximity to them. The security functions may not work or have difficulty responding to the FOB in locations with high RF signals from other sources. Moving the bike to a different location may allow proper functioning, |
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**Password Learn Procedure: | **Password Learn Procedure: | ||
- | |||
\\ | \\ | ||
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Most late models use a similar mounting style. However, there are variations as specific models were implemented with alternative lighting styles. You should refer to the parts & service manual for your specific model year, especially for 2007-later models. | Most late models use a similar mounting style. However, there are variations as specific models were implemented with alternative lighting styles. You should refer to the parts & service manual for your specific model year, especially for 2007-later models. | ||
- | ^ Part Numbers for Rear TS Lamps & Mounts ||| {{techtalk: | + | ^ Part Numbers for Rear TS Lamps & Mounts ||| {{techtalk: |
| 1986-89 | 68480-73 | Rear Oblong TS Support |:::| | | 1986-89 | 68480-73 | Rear Oblong TS Support |:::| | ||
| | 4724 | 3/8-24 x 1-1/2" Hex Bolt - Inside Fender to Support |:::| | | | 4724 | 3/8-24 x 1-1/2" Hex Bolt - Inside Fender to Support |:::| | ||
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| 2014-later see the parts catalog for specific year |||:::| | | 2014-later see the parts catalog for specific year |||:::| | ||
- | {{techtalk: | + | {{techtalk: |
\\ | \\ | ||
- | |||
- | |||
===== Turn Signal Bulbs & Sockets ===== | ===== Turn Signal Bulbs & Sockets ===== | ||
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**NOTES: | **NOTES: | ||
**On 1157 socket, Bright contact is CW from deepest locking pin**\\ | **On 1157 socket, Bright contact is CW from deepest locking pin**\\ | ||
- | **You can also find a chart of alternative 1157 bulbs in the [[techtalk: | + | **You can also find a chart of alternative 1157 bulbs in the [[techtalk: |
\\ | \\ | ||
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|2014 |69992-12A (Std BCM) |69994-12A (BCM/SM)| | |2014 |69992-12A (Std BCM) |69994-12A (BCM/SM)| | ||
|2015-2016 |69992-12B (Std BCM) |69994-12B (BCM/SM)| | |2015-2016 |69992-12B (Std BCM) |69994-12B (BCM/SM)| | ||
+ | |||
+ | **Testing Signals TO/FROM the TS Module (2000 Model)**\\ | ||
+ | |||
+ | For 1997-2003 the TS Module is part number 68540-96. | ||
+ | |||
+ | The TS Connector has these wires/ | ||
+ | 1 - BLACK wire - Ground\\ | ||
+ | 2 - ORANGE/ | ||
+ | 3 - BROWN - Right TS Flash Out\\ | ||
+ | 4 - VIOLET - Left TS Flash Out\\ | ||
+ | 5 - WHITE/Green - Speedo Cancel In\\ | ||
+ | 6 - no wire\\ | ||
+ | 7 - WHITE/Brown - Rt TS Switch IN\\ | ||
+ | 8 - WHITE/ | ||
+ | |||
+ | DISCONNECT THE CONNECTOR TO THE TS MODULE. | ||
+ | Then test the signals on the harness connector. | ||
+ | |||
+ | With a multimeter, BLACK PROBE on Pin1, you can use the RED PROBE to check for power on Pin2,\\ | ||
+ | check Pin 7 to see if it gets power from the Rt TS Switch (when pressed),\\ | ||
+ | check Pin 8 to see if it gets power from the Lt TS Switch (when pressed).\\ | ||
+ | |||
+ | With a jumper wire from Pin2 (if it has power)\\ | ||
+ | jumper it to Pin3 to see if both Right TS lights are ON,\\ | ||
+ | jumper it to Pin4 to see if both Left TS lights are ON.\\ | ||
+ | |||
+ | THOSE TESTS do not check the TS Module - they check everything connected to the TS Module\\ | ||
+ | to see whether they DO OR DO NOT WORK. If all that works, then the TS Module is suspect.\\ | ||
+ | |||
+ | Use the correct pinouts for other year TS Modules to do the same type testing. | ||
+ | |||
{{techtalk: | {{techtalk: | ||
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(Body Control Module) ---- The BCM (on 2014-later models) is used to supply power to most controlled circuits. | (Body Control Module) ---- The BCM (on 2014-later models) is used to supply power to most controlled circuits. | ||
(Turn Signal Switch condition is input thru the CANbus.) | (Turn Signal Switch condition is input thru the CANbus.) | ||
+ | |||
{{techtalk: | {{techtalk: |