Differences

This shows you the differences between two versions of the page.

Link to this comparison view

Both sides previous revision Previous revision
Next revision
Previous revision
techtalk:evo:elec03 [2020/05/05 16:05]
ixl2relax [Speedometer Connectors]
techtalk:evo:elec03 [2024/02/04 11:10] (current)
ixl2relax [Tail Light, Brake Light and License Light]
Line 3: Line 3:
  
 The REFERENCE section has a listing of - [[http://​sportsterpedia.com/​doku.php/​techtalk:​ref:​elec04#​device_connector_pinouts_ecm_icm_tsm_tssm_speedo_tach_etc|Device Connector Pinouts]]: The REFERENCE section has a listing of - [[http://​sportsterpedia.com/​doku.php/​techtalk:​ref:​elec04#​device_connector_pinouts_ecm_icm_tsm_tssm_speedo_tach_etc|Device Connector Pinouts]]:
 +
  
 ===== Sub-Documents ===== ===== Sub-Documents =====
Line 14: Line 15:
  
 ===== Key Switch ===== ===== Key Switch =====
- 
 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.
  
-Before 1994, there was a RUN position & a LIGHTS position, which harkened back to a time when the lights could be off for starting but then on or off as required. But sometime in the late 70's, the MoCo began putting a shorting wire across both output connections of the Key Switch. This means all the circuit breakers are powered whenever the Key Switch is ON, so that the lights are guaranteed to be on.+{{ :​techtalk:​evo:​elec:​ignitionswitch-3pos-old.jpg?​300|}} 
 +Before 1994, there was a RUN position & a LIGHTS position, which harkened back to a time when the lights could be off for kick starting but then on or off as required. But sometime in the late 70's, the MoCo began putting a shorting wire across both output connections of the Key Switch. This meant that all the circuit breakers are powered whenever the Key Switch is ON, so that the lights are guaranteed to be on (basically making the keyswitch simply an ON/OFF switch). The keyswitch labels were likely to be B - IG - L for Battery, Ignition & Lights.
  
-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.+{{ :​techtalk:​evo:​elec:​ignitionswitch-3pos-new.jpg?​300|}} 
 +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 be removed from the keyswitch on the HDI models.
  
 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.
  
 +{{ :​techtalk:​evo:​elec:​ignitionswitch-2014-canbusstock.jpg?​300|}}
 With the 2014 models, the older power switching key switch was replaced when the CANbus control was implemented using the Body Control Module (BCM). Most switches were now simply inputs to the BCM. This is true of the key switch. With the 2014 models, the older power switching key switch was replaced when the CANbus control was implemented using the Body Control Module (BCM). Most switches were now simply inputs to the BCM. This is true of the key switch.
  
 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.
- 
  
 ==== Testing the Key Switch ==== ==== Testing the Key Switch ====
- 
 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.
  
Line 40: Line 41:
 If the power is intermittent to the Fuses/CBs, in addition to checking the fuse panel and the wiring to it, you'll need to closely examine the Key Switch itself for damaged connections or loose/​broken internal parts. If the power is intermittent to the Fuses/CBs, in addition to checking the fuse panel and the wiring to it, you'll need to closely examine the Key Switch itself for damaged connections or loose/​broken internal parts.
  
-For 2014-later, you can remove the key switch connector (33A/B) and test the resistance (ohms) between the two wires of the key switch connector. When in the OFF position, there should be no conductivity. When the key switch is in ACC Mode then 800 ohms or in IGN Mode then 200 ohms should be read across the two wires of the connector. (See the Reference Section for an example of >>>>​ [[techtalk:​ref:​elec15|using the older style key switch]] <<<<​ with the new BCM, perhaps for relocation purposes.)+For 2014-later, you can remove the key switch connector (33A/B) and test the resistance (ohms) between the two wires of the key switch connector. When in the OFF position, there should be no conductivity. When the key switch is in ACC Mode then 800 ohms or in IGN Mode then 200 ohms should be read across the two wires of the connector. (See the Reference Section for an example of >>>>​ [[techtalk:​ref:​elec17|using the older style key switch]] <<<<​ with the new BCM, perhaps for relocation purposes.)
  
 For all key switches, there are no repairable parts so replacement is the only fix. For all key switches, there are no repairable parts so replacement is the only fix.
  
 ==== 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,​usb,​etc) but the bike is drawing current, you should track down the location of that current draw.
  
 Starting in 2004, the TSM/​TSSM/​HFSM will continue to draw 16-25 mA for 30 seconds after ignition is turned off. Any disruption and reconnection of battery power, such as disconnecting the battery to place a meter in series, will cause TSM/​TSSM/​HFSM to draw 16-25 mA for 30 seconds. Starting in 2004, the TSM/​TSSM/​HFSM will continue to draw 16-25 mA for 30 seconds after ignition is turned off. Any disruption and reconnection of battery power, such as disconnecting the battery to place a meter in series, will cause TSM/​TSSM/​HFSM to draw 16-25 mA for 30 seconds.
Line 72: Line 82:
  
 \\ \\
- 
  
 ===== Horn Switch ===== ===== Horn Switch =====
Line 82: Line 91:
  
 ===== Brake Switch - Front & Rear ===== ===== Brake Switch - Front & Rear =====
- 
 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:
  
-| Do not remove or install the master cylinder assembly and do not remove the switch housing assembly without first placing a 5/32in (4mm) thick cardboard insert between the brake lever and lever bracket. ​Removing ​the assembly without the insert in place may result in damage ​to the rubber boot and plunger of the front stoplight switch. |+|**IMPORTANT NOTE:​**\\ ​Do not remove or install the master cylinder assembly and do not remove the switch housing assembly\\ without first placing a 5/32in (4mm) thick cardboard insert between the brake lever and lever bracket.\\ If you remove ​the assembly without the insert in place you may damage the rubber boot and plunger\\ of the front stoplight switch. See the FSM.|
  
-{{:​techtalk:​evo:​elec:​brakelight-taillight-wiring-1.jpg?​800|}} ((Illustration created by IXL2Relax at the XLForum))+{{:​techtalk:​evo:​elec:​brakelight-taillight-wiring-1.jpg?​550|}} ((Illustration created by IXL2Relax at the XLForum)) ​|
  
-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://​xlforum.net/​forums/showthread.php?t=49330))+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/​forum/sportster-motorcycle-forum/​sportster-motorcycle-era-specific-and-model-specific/​rubber-mount-sportster-motorcycle-talk-2004-2006/​29595-rear-brake-light-switch-bad?t=49330))
  
 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.
  
-The front & rear brake switches are fed power on the ORANGE/​White (ORANGE*) wire from the accessory power circuit (circuit breaker or fuse). When activated, either or both switches will supply power on the RED/Yellow (RED*) wire to the rear brake light (*1986-1993 models used solid color wires).+The front & rear brake switches are fed power on the ORANGE/​White (ORANGE*) wire from the accessory power circuit (circuit breaker or fuse). When activated, either or both switches will supply power on the RED/Yellow (RED*) wire to the rear brake light
 + 
 +*Note: 1986-1993 models used solid-color wires without a stripe and had no ground wiring. They Tail Light Housing was grounded thru the frame to complete the electrical circuit for Tail & Brake Light.
  
 **Beginning in 2014**, the electrical function of the front brake switch is incorporated into the CANbus circuit board for the right switch housing (eliminating a separate brake switch there) and the rear brake switch closes an electrical circuit into the Body Control Module (BCM). **Beginning in 2014**, the electrical function of the front brake switch is incorporated into the CANbus circuit board for the right switch housing (eliminating a separate brake switch there) and the rear brake switch closes an electrical circuit into the Body Control Module (BCM).
Line 109: Line 119:
 Check the VSS Sensor section regarding signals to the Speedometer. Check the VSS Sensor section regarding signals to the Speedometer.
 [[techtalk:​evo:​engctl03#​vss_-_vehicle_speed_sensor]] [[techtalk:​evo:​engctl03#​vss_-_vehicle_speed_sensor]]
 +
 +If replacing ECM/​TSM/​TSSM/​HFSM/​Speedometer,​ [[techtalk:​evo:​trouble01#​ecm_password_learn_procedure|The Password Learn Procedure is HERE.]]
  
 \\ \\
  
  
-<font 18px/Arial, , ;;#​000000;;#​ffffd0>​1986-1994 Speedometers</​font>​+<font 18px/Arial, , ;;#​000000;;#​ffffd0>​1986-1994 Speedometers ​- Wheel Driven Cable</​font>​
  
 These years used a mechanical speedometer operated by cable from a speedometer pickup attached to the front wheel. The rotation of the wheel was converted to a rotation of the speedometer cable using a worm gear in the pickup. These years used a mechanical speedometer operated by cable from a speedometer pickup attached to the front wheel. The rotation of the wheel was converted to a rotation of the speedometer cable using a worm gear in the pickup.
Line 119: Line 131:
 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,​ but they also used 2:1 ratio speedometers.((http://​xlforum.net/​forums/showthread.php?​threadid=1545261))+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,​ but they also used 2:1 ratio speedometers.((https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-era-specific-and-model-specific/​ironhead-sportster-motorcycle-talk-1957-1985/​142593-speedo-ratio-help?​threadid=1545261))
  
 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://​xlforum.net/​forums/showthread.php?t=41323))+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/​forum/sportster-motorcycle-forum/​sportster-motorcycle-general-discussion-and-problems/​24962-speedometer-ratio-questions?t=41323))
  
 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.
Line 168: Line 180:
 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 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.
  
-The Speedometer '​marries'​ to the ECM (when new after 30+ miles) and thereby may prevent the speedometer from being moved to another bike or another already-used speedometer being placed on this bike. This is related to preventing turn-back of the mileage reported on the odometer. The odometer information is stored in the speedometer. ((Speedo-barrygreen ​http://​xlforum.net/​forums/showthread.php?​t=1434026))((ECM-HandOverFist ​http://​xlforum.net/​forums/showthread.php?t=1526835 Post#222))+The Speedometer '​marries'​ to the ECM (when new after 30+ miles) and thereby may prevent the speedometer from being moved to another bike or another already-used speedometer being placed on this bike. This is related to preventing turn-back of the mileage reported on the odometer. The odometer information is stored in the speedometer. ((Speedo-barrygreen ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-electrical/​sportster-motorcycle-electrical-and-ignition/​133506-what-records-the-milage-the-speedo-or-the-ecm?​t=1434026))((ECM-HandOverFist ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-electrical/​sportster-motorcycle-electrical-and-ignition/​140830-new-h-d-combined-speedo-tach?t=1526835 Post#222))
  
-See also http://​xlforum.net/​forums/showpost.php?​p=5342448+XLForum Discussion: https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-era-specific-and-model-specific/​efi-sportster-motorcycle-talk-2007-and-up/​181738-dtcs-u1255-u1016-any-known-causes-ecm-dying/​page2#​post3887377
  
 \\ \\
Line 185: Line 197:
  
 If instrument module fails "​WOW"​ test, check for battery, ground, ignition, trip odometer reset switch and accessory wiring to speedometer. If instrument module fails "​WOW"​ test, check for battery, ground, ignition, trip odometer reset switch and accessory wiring to speedometer.
 +
 +**Tech Notes:**\\
 +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),​ which is shaped like a '​key',​ is illuminated by the TSM/​TSSM/​HFSM using positive voltage on the BROWN/​Violet wire.
 +
 +^  Power Sources at Connector 20 of the Main Harness (to Instruments) ​ ||||
 +|  Pin 2          |  Pin 6             ​| ​ Pin 1               ​| ​ Pin 12    |
 +|  Battery Fuse   ​| ​ Instrument Fuse   ​| ​ Accessory Fuse      |  Ground ​   |
 +|  Constant ​      ​| ​ When Ignition ON  |  When ACC or Ign ON  |  Constant ​ |
 +^  The results of these connections failing ​ ||||
 +| * 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 |
  
 \\ \\
Line 211: Line 235:
   * The minutes display will stop blinking, indicating that the clock has been set.   * The minutes display will stop blinking, indicating that the clock has been set.
   * Turn off the ignition & the OFF/RUN switch to OFF.   * Turn off the ignition & the OFF/RUN switch to OFF.
 +
 +\\
 +
 +**2007-later Low-Fuel & Fuel-Level Sensors**\\
 +Speedometers for the 2007-later models have a low-fuel indicator (added with the EFI system) and optional instruments have a multi-level fuel-level display. The information about how these systems work is disucssed in the [[techtalk:​ref:​elec18#​fuel_level_sensors_explained|REFerence section HERE]].
  
 \\ \\
Line 220: Line 249:
  
 {{ :​techtalk:​evo:​elec:​16-later1200cx-speedotach-fuellevel.jpg?​200|}} {{ :​techtalk:​evo:​elec:​16-later1200cx-speedotach-fuellevel.jpg?​200|}}
-The Speedometer '​marries'​ to the ECM (when new after 30+ miles) and may prevent the speedometer from being moved to another bike or another already-used speedometer being placed on this bike. This is related to preventing turn-back of the mileage reported on the odometer. The odometer information is stored in the ECM and updates the speedometer information if another speedometer unit is installed. ((Modphiss ​http://​xlforum.net/​forums/showthread.php?​t=1434026))+The Speedometer '​marries'​ to the ECM (when new after 30+ miles) and may prevent the speedometer from being moved to another bike or another already-used speedometer being placed on this bike. This is related to preventing turn-back of the mileage reported on the odometer. The odometer information is stored in the ECM and updates the speedometer information if another speedometer unit is installed. ((Modphiss ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-electrical/​sportster-motorcycle-electrical-and-ignition/​133506-what-records-the-milage-the-speedo-or-the-ecm?​t=1434026))
  
 \\ \\
  
-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://​xlforum.net/​forums/showthread.php?​t=2031561)) demonstrated that installing the 61200008A Fuel Level Sensor kit with this speedometer will indeed activate the fuel level gauge. ([[techtalk:​ref:​elec18#​hd_61200008a_xl_fuel_level_sensor_kit|See the REF electrical section on speedometers]])+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/​forum/sportster-motorcycle-forum/​sportster-motorcycle-electrical/​sportster-motorcycle-electrical-and-ignition/​190600-fitting-fuel-level-sensor-after-speedo-tach-on-2014-1200c?​t=2031561)) demonstrated that installing the 61200008A Fuel Level Sensor kit with this speedometer will indeed activate the fuel level gauge. ([[techtalk:​ref:​elec18#​hd_61200008a_xl_fuel_level_sensor_kit|See the REF electrical section on speedometers]])
  
 \\ \\
Line 259: Line 288:
   * 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.
- 
- 
  
 \\ \\
- 
  
 **VSS/​Speedometer Pulse-to-MPH Converter** **VSS/​Speedometer Pulse-to-MPH Converter**
Line 331: Line 357:
 {{techtalk:​evo:​elec:​l98-03-speedo-connector.jpg|}}((Annotated by IXL2Relax at the XLForum))\\ {{techtalk:​evo:​elec:​l98-03-speedo-connector.jpg|}}((Annotated by IXL2Relax at the XLForum))\\
  
-**Late98-03 Sportster Electronic Speedometer Connector ​Pin Layout** +Late98-03 Sportster Electronic Speedometer Connector ​(160A/B) ||| ^ 99-03 Tachometer Connector (136A/B) ||| 
-^ Pin# ^ Color ^ Function ^ +^ Pin# ^ Color ^ Function ​|                                        :::Pin# ^ Color ^ Function | 
-|  1 |  BK  | Trip Function / Reset (to Pin#6) | +|  1 |  BK  | Trip Function / Reset (to Pin#​6) ​|                   :::​| ​ 1 |  O   | Power To Tach 
-|  2 | | Not Used | +|  2 | | Not Used |                                                :::|  2 |  BK  | Ground ​
-|  3 | | Not Used | +|  3 | | Not Used |                                                :::|  3 |  PK  | Tach Trigger ​
-|  4 | BK/Y | Ck Eng Lt - Used Only by 1999-2003 1200S | +|  4 |  BK/Y   Ck Eng Lt - Used Only by 1999-2003 1200S |        :::|  4 |  Not Used  |
-|  5 | | Not Used | +|  5 | | Not Used |                                                :::|  5 |  Not Used  |
-|  6 |  BK  | Trip Function / Reset (to Pin#1) | +|  6 |  BK  | Trip Function / Reset (to Pin#​1) ​|                   :::​| ​ 6 |  Not Used  |
-| ||| +| ||||||| 
-|  7 |  W/GN  | Speed Signal Output for TSM Cancel | +|  7 |  W/GN  | Speed Signal Output for TSM Cancel ​| | \\ The P/N for the Tachometer itself\\ is 67042-99 - used on Sportsters,​\\ FX & FLHP Models ||
-|  8 |  BK  | Ground | +|  8 |  BK  | Ground ​| :::| :::||
-|  9 |  W  | Vehicle Speed Sensor (VSS) Input | +|  9 |  W  | Vehicle Speed Sensor (VSS) Input | :::|:::||
-|  10 |  BK  | Ground to VSS | +|  10 |  BK  | Ground to VSS | :::|:::||
-|  11 |  R  | 12v Power to VSS | +|  11 |  R  | 12v Power to VSS | :::|:::||
-|  12 |  O/W  | 12v Power for Speedo (Accy Circ) |+|  12 |  O/W  | 12v Power for Speedo (Accy Circ) | :::​|:::​||| 
 + 
 +^ Speedo Connector (160A/B)(at Speedo) ||| :::^ Tach Connector (136A/B)(at Tach) ||| 
 +^ Years/Model ^ Shell P/N ^ Pin P/N | :::^ Years ^ Shell P/N ^ Pin P/N | 
 +| 1995-1998 All (Exc)| ​ Wired Direct (No Connector) ​ || :::| Upthru-1998 | Wired Direct (No Connector) || 
 +| Late-1998 883 Model connectorized as below ||| :::|||| 
 +| 1999-2003 |  72453-00\\ + 72454-00 ​ |  72455-00 ​ | :::| 1999-2003 | 72451-00 | 72452-00 ​|
 \\ \\
 \\ \\
Line 365: Line 397:
 | 6 accessory o/w |  | 7 ground bk |  | 6 accessory o/w |  | 7 ground bk | 
 | 5 battery bn/gy |  | 8 blank |  | 5 battery bn/gy |  | 8 blank | 
-| 4 security ​bn/v '​04-'​06 ('​07-13 blank) |  | 9 blank | +| 4 security ​bnn/v '​04-'​06 ('​07-13 blank) |  | 9 blank | 
 | 3 blank (Analog RPM Signal) |  | 10 blank |  | 3 blank (Analog RPM Signal) |  | 10 blank | 
 | 2 data lg/v |  | 11 blank |  | 2 data lg/v |  | 11 blank | 
Line 373: Line 405:
 \\ \\
 \\ \\
- 
  
 ===== Tachometers ===== ===== Tachometers =====
 +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.
  
- +Up thru 1998, the tachometers ​were wired direct - they had no connector on the tach. From 1999-2003, the tach used a 6-pin connector on the tach.
-Pre-2004 HD Tachs were pulse input from the ignition coil and designed for use with dual-fire ignitions.+
  
 2004-2013 HD Tachs were designed to communicate with the ECM & Speedometer using the Serial Data Bus. 2004-2013 HD Tachs were designed to communicate with the ECM & Speedometer using the Serial Data Bus.
  
-2014-later HD Speedo/​Tachs use the CAN-bus ​communications ​to the ECM BCM.+2014-later HD Speedo/​Tachs use the CAN-bus ​to communicate ​to the ECM and BCM.
  
 \\ \\
  
-==== Analog ​Dual-fire Tach on 2004-2007 Sportster with OEM Digital Speedometer ​====+==== Getting A Trigger Signal for Dual-fire Tach on 2004-2013 Sportsters ​====
  
-Here is the info needed to get an RPM signal for most Analog Dual-fire Tachometers on +The 2004-later stock instruments communicate with the ECM using the serial data bus or CANbus. Their ignition systems use single-fire modules & coils. However, aftermarket & HD-offered accessory tachometers are designed to operate with dual-fire ignition systems.
-the 2004-2007 Sportsters from your OEM Digital-input Speedometer:​+
  
-(Only the 2007 model wiring diagram shows Pin#3 as the Tach Output.)\\ +In order to use a dual-fire tachometer on those models you must obtain an appropriate dual-fire trigger signal. This became available on the 2007 model Sportster speedometers (4"). It is unknown ​if the 2004-06 speedometers ​have this undocumented signal, but the '​07-later ​speedometers ​are backward compatible to 2004.
-(**It is unknown ​whether 2008-2013 models ​have speedometers with the needed signal.**)\\ +
-(The Speedo model# also changed in 2014 and those speedometers ​may not provide this signal.)+
  
-**Summary: ​The OEM Speedo provides a valid Tach Signal OUTPUT on the #3 pin of the\\ +The 2007 model wiring diagram shows Pin#3 as the Tach Output from the speedometer, ​but that is not shown on later diagrams. (**It is believed that 2008-2013 models also have speedometers ​with this needed signal.**) The Speedometer model# changed in 2014 and those speedometers may or may not provide this signal.
-Speedometer Connector ​but does not come stock with a wire connected there.**((Finally indicated on the '07 wiring diagram even though it was functionally there from 2004+))+
  
-**This is Pin #3 of the OEM Speedometer.**\\+**Summary: The OEM Speedometer can provide a valid dual-fire Tach Signal OUTPUT on Pin #3 of the Speedometer,​ but there is no wire in that position on the stock Speedometer Connector.** 
 + 
 +**The reference here is to Pin #3 of the OEM Speedometer.**\\
  -- It is NOT part of the Serial Data Bus which is on Pin2.\\  -- It is NOT part of the Serial Data Bus which is on Pin2.\\
  -- It is NOT using the VSS signal to drive the tachometer.\\  -- It is NOT using the VSS signal to drive the tachometer.\\
  
-  ​Quote: +Quote: 
-  http://​xlforum.net/​forums/showpost.php?p=4380106&​postcount=7+ https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-era-specific-and-model-specific/​efi-sportster-motorcycle-talk-2007-and-up/​148975-after-market-tach?​postcount=7#​post3185865
   ​   ​
   VBDiver on his 2007 Sportster 883L   VBDiver on his 2007 Sportster 883L
Line 421: Line 450:
   ​   ​
   PINK LEAD CONNECTION TO TACHOMETER SIGNAL SOURCE For ALL OTHER models   PINK LEAD CONNECTION TO TACHOMETER SIGNAL SOURCE For ALL OTHER models
-  (This means 2004-later for Sportsters)+  (This means 2007-later for Sportster Speedometers)
   The tachometer signal source is the #3 cavity in the connector [39B] on   The tachometer signal source is the #3 cavity in the connector [39B] on
   the back of the speedometer. Insert the socket terminal on the pink (PK)   the back of the speedometer. Insert the socket terminal on the pink (PK)
Line 427: Line 456:
  
  
-Pin #3 on OEM Speedo is Tach Signal Out. P/N for needed female socket in connector [39B] is 74196-04 ((http://​xlforum.net/​forums/showpost.php?p=4500234&​postcount=17))+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/​forum/sportster-motorcycle-forum/​sportster-motorcycle-electrical/​sportster-motorcycle-electrical-and-ignition/​153933-where-to-pick-up-tach-signal/​page2?​postcount=17#​post3284016))
  
 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 +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.\\ 
-(at the Speedometer) and slide the short wire into the socket at location #3 +((https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-electrical/​sportster-motorcycle-electrical-and-ignition/​181523-analog-tach-on-2004-2013-sportster-with-oem-digital-speedometer?​t=1954653))
-and relock the bar in place. This will then give you a short pigtail onto which +
-you can connect your Tachometer signal wire.\\ +
-((http://​xlforum.net/​forums/showthread.php?​t=1954653))+
  
 \\ \\
  
 ==== 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/​forum/sportster-motorcycle-forum/​sportster-motorcycle-electrical/​sportster-motorcycle-electrical-and-ignition/​125187-how-to-wire-a-tachometer-on-a-carbed-rubbermount?​t=1255454))
-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://​xlforum.net/​forums/showthread.php?​t=1255454))+
  
 |  \\  **NOTE:​** ​ |  Connect to the INPUT side of the Coil - The Primary Trigger connections.\\ __**DO NOT USE THE HIGH-VOLTAGE SPARK PLUG WIRES!**__\\ Be sure you have the diode orientation as shown in the diagram.\\ You can use 1N4004/3/2 for diodes if they are more available. ​ | |  \\  **NOTE:​** ​ |  Connect to the INPUT side of the Coil - The Primary Trigger connections.\\ __**DO NOT USE THE HIGH-VOLTAGE SPARK PLUG WIRES!**__\\ Be sure you have the diode orientation as shown in the diagram.\\ You can use 1N4004/3/2 for diodes if they are more available. ​ |
Line 458: Line 483:
 ===== Indicator Lights - Idiot Lights ===== ===== Indicator Lights - Idiot Lights =====
  
-**1992-1994** models used Indicator Units without replaceable individual bulbs - The entire unit (incandescent bulb in individual ​cylindrical housing with pig tail wires) needs to be replaced:\\ +**1992-1994** models used Indicator Units without replaceable individual bulbs - The entire unit (cylindrical housing with pig tail wires) needs to be replaced:\\
-  * 68020-92A - INDICATOR LAMP, OIL PRESSURE (RED)\\ +
-  * 68021-92A - INDICATOR LAMP, TURN SIGNAL (GREEN) (2 needed)\\ +
-  * 68023-92A - INDICATOR LAMP, HIGH BEAM (BLUE)\\ +
-  * 68024-92A - INDICATOR LAMP, NEUTRAL (GREEN)\\+
  
-**1995-2007** models used replaceable Indicator Bulbs - P/N 68024-94\\+**1995-2006** models used replaceable Indicator Bulbs - P/N 68024-94\\
   * Generically known as #70 or #2721 bulbs - Replaceable with equivalent LED bulbs.   * Generically known as #70 or #2721 bulbs - Replaceable with equivalent LED bulbs.
  
 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://​xlforum.net/​forums/showthread.php?t=2045738+https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-electrical/​sportster-motorcycle-lighting/​191749-2003-1200c-indicator-bulb-size?t=2045738
  
 **2014-later** **2014-later**
  
-Here is info regarding the repair of faulty indicator lights (2014-later) ​that use Speedometer activation thru the CANbus.+The indicator lights are LEDs that are soldered onto a circuit board strip (SMDs). These individual LEDs are activated by the Speedometer,​ which communicates with the ECM/BCM via the CANbus. 
 + 
 +Here is DIY info regarding the repair of faulty indicator lights (2014-later).
   * [[techtalk:​evo:​elec03b|Subdoc - Indicator / Warning Lights Not Working - Repair]]   * [[techtalk:​evo:​elec03b|Subdoc - Indicator / Warning Lights Not Working - Repair]]
  
 +**INDICATOR LIGHTS PARTS LIST**
 +
 +^ 1986-1990 ^ Unit Lamps with pigtails |
 +| | Lamps mount individually on Speedo/Tach Bracket |
 +| ::: | 68489-86 Indicator Lamp for Oil Pressure (Red)\\ 68468-86 Indicator Lamp for Turn Signal (Green) (x2)\\ 68597-86 Indicator Lamp for High Beam (Blue)\\ 68574-86 Indicator Lamp for Neutral Trans (Green) |
 +^ 1991 ^ Unit Lamps with pigtails |
 +| | Lamps mount individually on Speedo/Tach Bracket |
 +| ::: | 68022-92A Indicator Lamp for Oil Pressure (Red)\\ 68740-91A Indicator Lamp for Turn Signal (Green) (x2)\\ 68023-92A Indicator Lamp for High Beam (Blue)\\ 68024-92A Indicator Lamp for Neutral Trans (Green)\\ 68513-92 Bezel Housing for Lamps\\ 68516-92 Trim Plate (Symbols/​Clear Lense) |
 +^ 1992-1994 ^ Unit Lamps with pigtails |
 +| | Bezel Housing Mounts on Speedo/Tach Bracket |
 +| ::: | 68020-92A Indicator Lamp - Red for Oil Pressure\\ 68021-92A Indicator Lamp - Green for Turn Signal (x2)\\ 68023-92A Indicator Lamp - Blue for High Beam\\ 68024-92A Indicator Lamp - Green for Neutral Trans\\ 68513-92 Bezel Housing for Lamps\\ 68516-92 Trim Plate (Symbols/​Clear Lense) |
 +^ 1995-2006 All (exc Custom) - Incandescent Bulbs||
 +| | 67184-94 Socket for bulb (x5)\\ 68024-94 Bulb - Incandescent (x5)\\ 68516-95 Housing Strip for sockets\\ 68513-95 Trim Plate (holds lense)\\ 68551-95 Bezel Lense ONLY (Symbols/​Color Lense)\\ 68513-95A Trim Plate & Bezel (Symbols/​Color Lense) |
 +^ 1995-2006 Custom Models - Incandescent Bulbs ||
 +| | 67184-94 Socket for bulb (x5)\\ 68024-94 Bulb - Incandescent (x5)\\ 68792-96 Housing Strip for sockets\\ 68382-96 Trim Plate & Bezel Assy (Symbols/​Color Lense) |
 +^ 2007 All (exc Custom) - LEDs ||
 +| | LEDs & Housing part of Harness (68813-07 - All exc R Model)\\ LEDs & Housing part of Harness (68811-07 - R Model)\\ 68513-07B Trim Plate & Bezel (Symbols/​Clear Lense for Color LEDs)(repl 68551-07)\\ 68513-95 Trim Plate (holds lense)\\ 68551-07 Bezel Lense ONLY (Symbols/​Clear Lense) |
 +^ 2007 Custom Models - LEDs ||
 +| | LEDs & Housing part of Harness (68814-07)\\ 68382-07B Trim Plate & Bezel Assy (Symbols/​Clear Lense) |
 +
 +An interesting repair in this [[https://​www.xlforum.net/​forum/​sportster-motorcycle-forum/​sportster-motorcycle-era-specific-and-model-specific/​rubber-mount-sportster-motorcycle-talk-2004-2006/​202706-repair-of-trim-plate-indicator-lamps-68513-95a?​t=2079909|XLForum Thread]] by Krono.
  
 \\ \\
Line 481: Line 525:
 ===== Headlight ===== ===== Headlight =====
  
-Early model Sportsters (1990-older) used a sealed-beam,​ 5-3/4" headlamp. In 1991, they were supplied with a headlamp lens (bulb housing) which uses a replaceable bulb known as an H4 version. The supplied bulbs were rated at 55w for low beam and 60w for high beam. Modern bulb model 9003 is also physically equivalent and may have the H4 designation as well. Various brands and types of bulbs are available in the H4/9003 base fitting including new LED versions. However, not all LED units are sized & positioned correctly for the H4/9003 lens, so some testing of the physical depth (both inside the lens and behind the lens) is necessary to proper fitting. It is important to obtain LED bulbs that are compatible with the headlight housing lens design - It is important in order to produce an appropriate light beam pattern similar to the original motorcycle style projection.+**Sub-Documents** 
 +  * [[techtalk:​evo:​elec03c|1986-1993 Wiring of the Headlight Housing Connector]] 
 + 
 +Early model Sportsters (1990-older) used a sealed-beam,​ 5-3/4" headlamp. 
 + 
 +In 1991, they were supplied with a headlamp lens (bulb housing) which uses a replaceable bulb known as an H4 version. The supplied bulbs were rated at 55w for low beam and 60w for high beam. Modern bulb model 9003 is also physically equivalent and may have the H4 designation as well. Various brands and types of bulbs are available in the H4/9003 base fitting including new LED versions. However, not all LED units are sized & positioned correctly for the H4/9003 lens, so some testing of the physical depth (both inside the lens and behind the lens) is necessary to proper fitting. It is important to obtain LED bulbs that are compatible with the headlight housing lens design - It is important in order to produce an appropriate light beam pattern similar to the original motorcycle style projection.
  
 The low beam usually throws a more narrow light, a relatively shorter distance. The front-most element in the bulb has a small reflector built into the bulb to throw the produced light upwards against the lens reflector in order that the light will be projected downward onto the road surface. The high beam (produced by a second element closer to the connector that throws light in a 360° pattern) produces a broader beam and is redirected (by the entire reflector) to throw light farther and wider down the roadway. The low beam usually throws a more narrow light, a relatively shorter distance. The front-most element in the bulb has a small reflector built into the bulb to throw the produced light upwards against the lens reflector in order that the light will be projected downward onto the road surface. The high beam (produced by a second element closer to the connector that throws light in a 360° pattern) produces a broader beam and is redirected (by the entire reflector) to throw light farther and wider down the roadway.
Line 487: Line 536:
 Typical (recent) HD wiring practice is to supply the low-beam power on a Yellow Wire and the high-beam power on a White Wire. These wires come from the Left Handlebar, Hi/Lo Headlight Switch. With the introduction of the BCM in 2014, the handlebar switches are digital and communicate their status to the BCM over the CANbus. The BCM uses BLUE/Yellow & BLUE/White Wires to supply power to the Lo & Hi headlight filaments. Typical (recent) HD wiring practice is to supply the low-beam power on a Yellow Wire and the high-beam power on a White Wire. These wires come from the Left Handlebar, Hi/Lo Headlight Switch. With the introduction of the BCM in 2014, the handlebar switches are digital and communicate their status to the BCM over the CANbus. The BCM uses BLUE/Yellow & BLUE/White Wires to supply power to the Lo & Hi headlight filaments.
  
-See this [[http://candlepowerinc.com/pdfs/H4_9003.pdf|PDF file at the Candlepower brand website]] for some additional information about H4 & 9003(HB2) specifications. Also an interesting read that shows reflection diagrams is [[https://​ratwell.com/​technical/​BoschH4.html|THIS WEB PAGE LINK]] regarding H4 vs 9003 bulbs.+See this [[https://docs.google.com/file/d/​0B-KrKk_YXL4TLVozd09LcU9DSEU/​edit?​resourcekey=0-c1WiLSVLjue0AxppKckpuQ|PDF file from Candlepower brand lighting]] for some additional information about H4 & 9003(HB2) specifications. Also an interesting read that shows reflection diagrams is [[https://​ratwell.com/​technical/​BoschH4.html|THIS WEB PAGE LINK]] regarding H4 vs 9003 bulbs.
  
 {{techtalk:​evo:​elec:​h4-bulb-conn.jpg}}((Illustration created by IXL2Relax at the XLForum)) {{techtalk:​evo:​elec:​h4-bulb-conn.jpg}}((Illustration created by IXL2Relax at the XLForum))
Line 497: Line 546:
 **Tail Light & Brake Light** **Tail Light & Brake Light**
  
-**1986-2003E** - The standard ​tail light / brake light bulb for these models was a bayonet type bulb (P/N 68168-89A). Generically,​ it is known as a #1157 bulb. See the description of the dual-element Run/​TurnSignal bulbs [[techtalk:​evo:​elec03#​turn_signal_bulbs_sockets|BELOW]] as the bulbs are the same and the socket similar.+**1986-1998** - The stock tail light / brake light bulb for these models was a bayonet type bulb (P/N 68168-89A). Generically,​ it is known as a #1157 bulb. See the description of the dual-element Run/​TurnSignal bulbs [[techtalk:​evo:​elec03#​turn_signal_bulbs_sockets|BELOW]] as the bulbs are the same and the socket similar
 + 
 +**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,​ the bulb is known as a #1157 bulb. See the description of the dual-element Run/​TurnSignal bulbs [[techtalk:​evo:​elec03#​turn_signal_bulbs_sockets|BELOW]] as the bulbs are the same and the socket similar. However, after the mid-2003 change to the wedge-based bulbs, the new model lens, bulb (#3157) & cable (available as a set) was a valid retrofit for the 1999-2003 models.
  
 {{  :​techtalk:​evo:​elec:​99-13-taillightcircuitboard.jpg?​450|}} {{  :​techtalk:​evo:​elec:​99-13-taillightcircuitboard.jpg?​450|}}
 **2003L-later** - Mid-year of 2003 there was a change to a wedge type bulb (P/N 68167-88). Generically,​ it is know as a #3157 bulb. Later, the HD bulb P/N was changed (P/N 68167-04), but the same generic #3157 bulb is compatible. The physical mounting socket is a twist-lock type that mounts on the lens with a short cable (P/N 68370-03A) that plugs into the distribution circuit board. **2003L-later** - Mid-year of 2003 there was a change to a wedge type bulb (P/N 68167-88). Generically,​ it is know as a #3157 bulb. Later, the HD bulb P/N was changed (P/N 68167-04), but the same generic #3157 bulb is compatible. The physical mounting socket is a twist-lock type that mounts on the lens with a short cable (P/N 68370-03A) that plugs into the distribution circuit board.
  
-**2011 - Later** - All Custom model Sportsters received a new, self-contained,​ LED Tail Light assembly (P/N 69352-11A). The LEDs are integrated into the lens assembly and cannot be replaced separately. ​The other Sportster models (with a center tail light) continued to use the #3157 type bulb.+**2011 - later** - All Custom model Sportsters received a new, self-contained,​ LED Tail Light assembly (P/N 69352-11A). The LEDs are integrated into the lens assembly and cannot be replaced separately. ​Non-Custom ​Sportster models ​thru 2020 (with a center tail light) continued to use the distribution circuit board & the #3157 type bulb. Other Sportster models implemented brake lighting using the LED Turn Signals and had no center tail light.
  
 \\ \\
Line 527: Line 582:
 \\ \\
  
-====== ​Turn Signals ​======+====== ​TURN SIGNALS ​======
  
 \\ \\
  
 +**( [[techtalk:​evo:​elec03g|SUBdoc - BASIC TESTING of Turn Signal Wiring]] )**
  
 +**( [[https://​www.xlforum.net/​forum/​sportster-motorcycle-forum/​sportster-motorcycle-era-specific-and-model-specific/​efi-sportster-motorcycle-talk-2007-and-up/​202690-left-turn-signal-issue-no-led-s-bulbs-ok-what-to-check-next?​t=2079891|See this XLForum Thread regarding troubleshooting Turn Signal failure.]] )**
 +
 +
 +\\
  
 ===== Turn Signal Basic Functions ===== ===== Turn Signal Basic Functions =====
Line 564: Line 624:
  
 ^  Example: 1998 Turn Signal Cancellation ​ - Calculation & Signal ​ ^^^^| ^  Example: 1998 Turn Signal Cancellation ​ - Calculation & Signal ​ ^^^^|
-| 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. |{{:​techtalk:​evo:​elec:​95-03-speedo-tsm-cancel-oscope-decman.jpg?​200|}}((Decman at http://​xlforum.net/​forums/showthread.php?​t=1883180))| ​+| 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. |{{:​techtalk:​evo:​elec:​95-03-speedo-tsm-cancel-oscope-decman.jpg?​200|}}((Decman at https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-electrical/​sportster-motorcycle-lighting/​175521-self-cancelling-indicator-wiring?​t=1883180))| ​
 | ::: |  0-34  |  221ft  | ::: | ::: | | ::: |  0-34  |  221ft  | ::: | ::: |
 | ::: |  35-44  |  339ft  | ::: | ::: | | ::: |  35-44  |  339ft  | ::: | ::: |
Line 576: Line 636:
     * (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: ​http://​xlforum.net/​forums/showthread.php?t=2069154 )+( Here's a discussion about low-watt TS bulbs: ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-electrical/​sportster-motorcycle-lighting/​193171-turn-signal-won-t-blink-when-motor-s-on?t=2069154 )
 \\ \\
  
Line 582: Line 642:
 2004-06 Self-Cancelling Turn Signal Function</​font>​ ((Diagram created by IXL2Relax of the XLForum)) 2004-06 Self-Cancelling Turn Signal Function</​font>​ ((Diagram created by IXL2Relax of the XLForum))
  
-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/​Security Module). Either one of these (TSM or TSSM) is located under the battery ​(same as in the picture for 2007).+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/​Security Module). Either one of these (TSM or TSSM) are located under the battery.
  
 +{{  :​techtalk:​evo:​elec:​07-tsm-location.jpg?​300|Image from HandOverFist at XLForum threadid=1318832}}
 This TSM still utilizes a current/​heat load design to operate the internal flashing function. It expects a nominal 2-amp load from each bulb (front & rear) as did the 1991-2003 TSM. This TSM still utilizes a current/​heat load design to operate the internal flashing function. It expects a nominal 2-amp load from each bulb (front & rear) as did the 1991-2003 TSM.
  
Line 594: Line 655:
     * (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.
  
-If the module is replaced for any reason, see [[techtalk:​evo:​trouble01#​ecm_password_learn_procedure|the Learn Procedure HERE.]]+If the module is replaced for any reason, see [[techtalk:​evo:​trouble01#​ecm_password_learn_procedure|the ​Password ​Learn Procedure HERE.]]
  
 \\ \\
Line 601: Line 662:
 2007-13 Self-Cancelling Turn Signal Function</​font>​ 2007-13 Self-Cancelling Turn Signal Function</​font>​
  
-{{  :​techtalk:​evo:​elec:​07-tsm-location.jpg?​200|Image from HandOverFist at XLForum threadid=1318832}}{{  :​techtalk:​evo:​elec:​07-tsm-tssm-compare.jpg?​200|Image from HandOverFist at XLForum threadid=1318832}}+{{  :​techtalk:​evo:​elec:​07-tsm-tssm-compare.jpg?​400|Image from HandOverFist at XLForum threadid=1318832}}
 In 2007, HD implemented a new version of the TSM. This TSM includes all the functions of the 2004 version plus adds interlock inputs from the Clutch Switch and Neutral Switch to assist in controlling the Starter Relay. There is also a variation of the TSM which adds security features (known as a TSSM - Turn Signal / Security Module) and an optional module called the Hands Free Security Module (HFSM). These (TSM or TSSM or HFSM) are located under the battery. (see the picture) In 2007, HD implemented a new version of the TSM. This TSM includes all the functions of the 2004 version plus adds interlock inputs from the Clutch Switch and Neutral Switch to assist in controlling the Starter Relay. There is also a variation of the TSM which adds security features (known as a TSSM - Turn Signal / Security Module) and an optional module called the Hands Free Security Module (HFSM). These (TSM or TSSM or HFSM) are located under the battery. (see the picture)
  
Line 622: Line 683:
 The above models use a Tail Lamp Converter Module (P/N 68278-07) to create Run/​Turn/​Brake functions using only the Rear Right & Left Turn Signal units. These models have no center Tail Light. The rear turn signal bulbs are dual-element bulbs (P/N 68168-89A - #1157). The Dim Element is used as the Running Tail Light while the Bright Element is used for both the Turn Signal & Stop Light Function. The above models use a Tail Lamp Converter Module (P/N 68278-07) to create Run/​Turn/​Brake functions using only the Rear Right & Left Turn Signal units. These models have no center Tail Light. The rear turn signal bulbs are dual-element bulbs (P/N 68168-89A - #1157). The Dim Element is used as the Running Tail Light while the Bright Element is used for both the Turn Signal & Stop Light Function.
  
-    * (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://​xlforum.net/​forums/showpost.php?​p=1760797)), the following procedure may allow the LED upgrade to function without the need for load equalizer resistors:+    * (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/​forum/sportster-motorcycle-forum/​sportster-motorcycle-era-specific-and-model-specific/​rubber-mount-sportster-motorcycle-talk-2004-2006/​66713-duel-element-rear-turn-signal-install-on-an-06-lots-o-pics/​page3#​post1409852)), the following procedure may allow the LED upgrade to function without the need for load equalizer resistors:
       * 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
Line 631: Line 692:
       * 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'​ and whether it will '​eventually'​ learn to deal with the LEDs.)((xElvis at xlforum.net/​forums/showthread.php?​t=2074413))+    * (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'​ and whether it will '​eventually'​ learn to deal with the LEDs.)((xElvis at https://​www.xlforum.net/​forum/sportster-motorcycle-buell-motorcycle-forum-general-discussion/​product-reviews/​197731-movotor-smoked-tail-light-and-turn-signal?​t=2074413))
     * 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.
  
-If the module is replaced for any reason, see [[techtalk:​evo:​trouble01#​ecm_password_learn_procedure|the Learn Procedure HERE.]]+If the module is replaced for any reason, see [[techtalk:​evo:​trouble01#​ecm_password_learn_procedure|the ​Password ​Learn Procedure HERE.]]
  
 \\ \\
Line 643: Line 704:
 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/​Lo/​Flash,​ Horn/Trip Button and the Left Turn Signal Button. Right controls include Start/​Hazard,​ OFF/Run and Right Turn Signal Button.
  
-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. 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 temporarily ​pressing the upper portion of the Start Button, which has a Hazard Triangle Symbol. The Ignition & RUN switch must be ON. Once activated, the ignition can be turned off and the hazard flashing will continue operating for two hours or until turned off. To turn off the flashing, the Ignition & RUN switch must be ON, then the Hazard Button is pressed again.
  
 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) 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:**\\ 
-2014-2018 883 Iron +2014-2018 883 Iron\\ 
-2014-2018 Forty Eight +2014-2018 Forty Eight\\ 
-2014-2016 Seventy Two +2014-2016 Seventy Two\\ 
-2016-2018 1200 Roadster +2016-2018 1200 Roadster\\ 
-2018-later 1200 Iron+2018-later 1200 Iron\\
 The above models have no center Tail Light. The BCM creates Run/​Stop/​Turn functions with the Rear Right & Left Turn Signal units. The rear turn signal bulbs are dual-element bulbs (P/N 68168-89A - #1157). The Dim Element is used as the Running Tail Light while the Bright Element is used for both the Turn Signal & Stop Light Function. ​ The above models have no center Tail Light. The BCM creates Run/​Stop/​Turn functions with the Rear Right & Left Turn Signal units. The rear turn signal bulbs are dual-element bulbs (P/N 68168-89A - #1157). The Dim Element is used as the Running Tail Light while the Bright Element is used for both the Turn Signal & Stop Light Function. ​
  
Line 667: Line 728:
 \\ \\
  
 +===== Turn Signal/​Security Module (TSSM) and Siren =====
  
-**( [[http://​xlforum.net/​forums/​showpost.php?​p=5466769&​postcount=32|Reference ​for Turn Signal ​Switches - Part Numbers for all years]] ​)**\\+There are several options available ​for replacing the Turn Signal ​Module (TSMin order to extend the functionality to include security features.
  
-===== Turn Signal/Security Module (TSSM) and Siren =====+The second version is the Turn Signal Security Module (TSSM) ​which incorporates a Radio Frequency (RF) receiver. This module replaces the TSM and provides a FOB with a button that can be pressed to activate or disable the security features. The system also allows selecting auto arming or to enter a PIN number should the FOB not be available. The security function can disable the starting circuit, flash the turn signals and sound an optional alarm if someone tampers with the ignition or moves the motorcycle. 
 + 
 +The third version is the Hands Free Security Module (HFSM) with an RF receiver. This module replaces the TSM and provides a button-less FOB.  When in proximity of the bike, the FOB allows automatic arming and disarming of the security features. The system also allows use of a PIN number should the FOB not be available. 
 + 
 +Be sure to replace the battery (CR2032 3 Volt Lithium Coin Cell) in the FOB to keep it working.  
 + 
 +There are additional add-on options with variations of the HD Smart Security System (H-DSSS) which enhances some functions:​ 
 +  * Smart Siren 
 +  * Security Pager 
 +  * Smart Siren 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,​ but distance may vary from 10-100 feet depending on the source of interference. Like many other devices, the FOB uses 433.92Mhz for communications.((SwissXL at https://​www.xlforum.net/​forum/​sportster-motorcycle-forum/​sportster-motorcycle-electrical/​sportster-motorcycle-electrical-and-ignition/​199909-hfsm-refusing-to-disarm-urban-spot-one-solution?​t=2076848))
  
  
 **Flashing Alarm**\\ **Flashing Alarm**\\
-From the 2013 Elec Diag Manual, page 5-37:\\+From the 2013 Elec Diag Manual, page 5-37 (See [[http://​sportsterpedia.com/​lib/​exe/​fetch.php/​pdf-bulletin:​tt0251.pdf|TT#​251]] for information.):\\
 Quote: WARNINGS: A warning consists of three alternate flashes of the turn signals and chirp from the optional smart siren. Warnings are issued from an armed TSSM or HFSM in the following order: Quote: WARNINGS: A warning consists of three alternate flashes of the turn signals and chirp from the optional smart siren. Warnings are issued from an armed TSSM or HFSM in the following order:
  
Line 681: Line 755:
  
 2. Second Warning: If the motion continues or the ignition switch is not turned back to OFF,\\ 2. Second Warning: If the motion continues or the ignition switch is not turned back to OFF,\\
-a second warning is issued within four seconds ​of the first.+a second warning is issued within four seconds ​(from alert).
  
-3. Alarm: If the motion continues or the ignition switch is not turned to OFF past the\\ +3. Alarm: If the motion continues or the ignition switch is not turned to OFF after the\\ 
-second warning, the smart security system will go into full alarm. ​+second warning, the smart security system will go into full alarm
 + 
 + 
 +**Key FOB Assignment**\\ 
 +Only the TSSM FOB is user assignable. The procedure for assigning the FOB(s) is [[https://​serviceinfo.harley-davidson.com/​sip/​service/​procedure/​58666/​PDF/​276d870a-3d79-4641-b72c-8242addd47cb/​en_US|HERE]] and may also be in your manual. Once started, the process will erase the setting of previous FOBs. It will allow two FOBs to be assigned for use, but both must be assigned during the same procedure. 
 + 
 +The procedure for entering a PIN (Personal Entry Code) should be in your manual. 
 + 
 +The HFSM FOB has no button on it and requires that it be assigned using with the Digital Technician software at a dealer. To have them assigned, in addition to having the FOB(s), you will need to supply a chosen PIN and the FOB S/N(s) which should have been attached to the FOB(s) when new. 
 + 
 +**Caution Related To FOB Location**\\ 
 +When parked or refueling the motorcycle, if the FOB is on/near the bike (as in a jacket stored on the bike), the alarm system will not auto-arm. On the other hand, if the rider takes the FOB away from the bike (to pay for fuel, use the restroom, etc.), the bike will auto-arm and the passenger will be at risk of triggering the alarm if they disturb the bike. Also be sure to always have your PIN available to deal with the security system in case the FOB is lost. 
 + 
 + 
 +**Transportation Mode**\\ 
 +The security system can be placed into Transportation Mode to prevent the motorcycle from alarming while you move it around, transport it or wash it. See [[http://​sportsterpedia.com/​lib/​exe/​fetch.php/​pdf-bulletin:​tt0251.pdf|TT#​251]] for the procedure.
  
  
 **Security Siren**\\ **Security Siren**\\
 The security siren is a self-contained unit. It has its own power supply, a 9-V rechargeable battery. It is mounted near the rear brake master cylinder under the bike. The security siren is a self-contained unit. It has its own power supply, a 9-V rechargeable battery. It is mounted near the rear brake master cylinder under the bike.
- 
-Not needing frequent replacement,​ the battery life, under normal conditions, is approximately three to six years. The siren battery may not charge if the vehicle’s battery is less than 12.5 volts. Only a nickel metal hydride (Ni-MH) nine-volt battery should be used in the siren. The current stock part number is 69309-10 (about $16 - supercedes previous P/N). It is a VARTA brand, P/N V7/8H (Type 5622) battery with these specs: 8.4v, 150mah, charging rate of 15h @ 15ma. These batteries will discharge relatively quickly ​ when the bike is parked, being mostly depleted within a few months of storage at room temperature. 
  
 If the siren does not chirp on a valid arming command from the TSSM, the siren is either not connected, not working, or the siren wiring was opened or shorted while the siren was disarmed. If the siren does not chirp on a valid arming command from the TSSM, the siren is either not connected, not working, or the siren wiring was opened or shorted while the siren was disarmed.
Line 698: Line 785:
 When the TSSM has been armed and a security event occurs, the alarm cycle is activated, causing the siren to sound and the turn signal lamps to flash. When the TSSM has been armed and a security event occurs, the alarm cycle is activated, causing the siren to sound and the turn signal lamps to flash.
  
-In this >​[[https://​serviceinfo.harley-davidson.com/​sip/​service/​document/​118167?​locale=en_US|Siren Install Guide]], there are two different extension cables mentioned. These cables reach from the stock harness connector by the electrical panel and battery (the connector is located in the same place on all 2004-later models) to below the bike where the siren will be mounted. These cables are not represented on the electrical schematics.+Not needing frequent replacement,​ the battery life, under normal conditions, is approximately three to six years. The siren battery may not charge if the vehicle’s battery is less than 12.5 volts. Only a nickel metal hydride (Ni-MH) nine-volt battery should be used in the siren. The current stock part number is 69309-10 (about $16 - supercedes previous P/N). It is a VARTA brand, P/N V7/8H (Type 5622) battery with these specs: 8.4v, 150mah, charging rate of 15h @ 15ma. These batteries will discharge relatively quickly ​ when the bike is parked, being mostly depleted within a few months of storage at room temperature. 
 + 
 +**Siren Intallation Note:​** ​In this >​[[https://​serviceinfo.harley-davidson.com/​sip/​service/​document/​118167?​locale=en_US|Siren Install Guide]], there are two different extension cables mentioned. These cables reach from the stock harness connector by the electrical panel and battery (the connector is located in the same place on all 2004-later models) to below the bike where the siren will be mounted. ​**These cables are not represented on the electrical schematics.**
  
 For 2004-05 models, use a conversion/​extension cable, 91702-04. On these models, the stock electrical harness connector for the siren is a 3-pin Deutsch connector, triangular in shape. This extension cable has the 3-pin triangular harness connector on one end and connects to the siren which uses an oval, 3-pin, Delphi Packard connector. For 2004-05 models, use a conversion/​extension cable, 91702-04. On these models, the stock electrical harness connector for the siren is a 3-pin Deutsch connector, triangular in shape. This extension cable has the 3-pin triangular harness connector on one end and connects to the siren which uses an oval, 3-pin, Delphi Packard connector.
Line 704: Line 793:
 For 2006-later models, use the extension cable, 91734-06. On these models, the stock electrical harness connector for the siren is an oval, 3-pin, Delphi Packard connector that matches with the connector on the siren. So this cable is a simple, true extension cable, with mating siren connectors on the ends. For 2006-later models, use the extension cable, 91734-06. On these models, the stock electrical harness connector for the siren is an oval, 3-pin, Delphi Packard connector that matches with the connector on the siren. So this cable is a simple, true extension cable, with mating siren connectors on the ends.
  
 +**Password Learn Procedure:​** If the ECM or TSM/​TSSM/​HFSM are replaced, you may need to follow the Password Learn Procedure before the bike will operate correctly. If the procedure is not followed, the engine will start and run for a few seconds, and then stall. This will typically throw a P1009 diagnostic code. See this section of the Sportsterpedia for the [[techtalk:​evo:​trouble01#​ecm_password_learn_procedure|Password Learn Procedure]].
  
 \\ \\
Line 716: Line 806:
 \\ \\
 {{techtalk:​evo:​elec:​91-13-stockturnsignaldesign.jpg?​600|}}((Illustration created by IXL2Relax at the XLForum)) {{techtalk:​evo:​elec:​91-13-stockturnsignaldesign.jpg?​600|}}((Illustration created by IXL2Relax at the XLForum))
 +
 +\\
 +
 +===== Turn Signal - Rear Housing Mounting & Wiring =====
 +
 +The rear turn signals are mounted on the frame struts. Over the years, the exact style of mounting them varied.
 +
 +The 1986-1993 strut covers were quite rigid and the turn signals were mounted to & thru them to the curved frame struts. For 1986-1989, the mounts were bolted to the TS housing, then bolted to the struts. For 1990-1993, the mounting posts were round, hollow bolts, which were first mounted to the TS housing, then bolted to the struts (see pics).
 +
 +In 1994, the frame struts became straight and the covers changed to thin metal. This required a slightly different method of mounting. It used a double-ended,​ threaded stud with a mid-placed, non-moveable nut. First, while the strut cover is off the strut, the long side of the stud is placed thru the cover (inside to outside), then passed thru the TS mount (standoff) and into the TS housing, thus affixing the housing to the strut cover (see pics). The wiring is routed thru the mount and to the inside of the strut cover. Then the strut cover is placed over the strut with the short end of the threaded stud passing thru the frame strut into the fender. The TS wiring passes thru a separate hole in the strut & fender. Finally, the strut cover is affixed in place by a nut on the double-threaded stud (inside the fender) and by other strut mounting screws.
 +
 +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:​evo:​elec:​TS-RrMount-Wire-1992.jpg?​280| }}((Pics by Erik at https://​www.xlforum.net/​forum/​sportster-motorcycle-forum/​sportster-motorcycle-electrical/​sportster-motorcycle-lighting/​67506-rear-turn-signals-loose?​t=445519)) |
 +| 1986-89 | 68480-73 | Rear Oblong TS Support |:::|
 +| | 4724 | 3/8-24 x 1-1/2" Hex Bolt - Inside Fender to Support |:::|
 +| | 2698 | 5/16-18 x 9/16" Socket Head Bolt - Support to Housing |:::|
 +| | 68407-86 | Rear 2.5" TS Lamp Housing |:::|
 +^ |||:::|
 +| 1990 | 68501-90 | Rear Round Threaded Hollow TS Support |:::|
 +| | 68410-87B | Rear 2.5" TS Lamp Housing |:::|
 +^ |||:::|
 +| 1991-93 | 68493-90 | Rear Round Threaded Hollow TS Support |:::|
 +| | 68410-87B | Rear 2.5" TS Lamp Housing |:::|
 +^ |||:::|
 +| 1994-01 | 68480-93A | Rear Oblong TS Support |:::|
 +| | 56104-94A | Mounting Stud - Mid-Nut |:::|
 +| | 68760-94 | Rear 2.5" TS Lamp Housing |:::|
 +^ |||:::|
 +| 2002-10 | 68480-02 | Rear Oblong TS Support |:::|
 +| | 56104-02 ​ | Mounting Stud - Mid-Nut |:::|
 +| | 68977-00 | Rear 2" Bullet TS Lamp Assembly |:::|
 +^ |||:::|
 +| 2011-13 | 68480-02 | Rear Oblong TS Support |:::|
 +| | 56104-02 ​ | Mounting Stud - Mid-Nut |:::|
 +| | 69978-00 | Rear 2" Bullet TS Lamp Assembly |:::|
 +^ |||:::|
 +| 2014-later see the parts catalog for specific year |||:::|
 +
 +{{techtalk:​evo:​elec:​TS-RrMount-Wire-2009.jpg|}}((Pics by nleco at https://​www.xlforum.net/​forum/​sportster-motorcycle-forum/​sportster-motorcycle-electrical/​sportster-motorcycle-lighting/​67506-rear-turn-signals-loose?​t=445519))
 +
  
 \\ \\
Line 725: Line 856:
 **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:​ref:​elec03#​turn_signals|Reference Section HERE]].**\\+**You can also find a chart of alternative 1157 bulbs in the [[techtalk:​ref:​elec06#​turn_signals|Reference Section HERE]].**\\
  
 \\ \\
Line 734: Line 865:
  
 \\ \\
 +
 +
 +===== Turn Signal Switches =====
 +
 +^ Model Year ^ Left P/N ^ Right P/N ^  Description ​ |
 +| xxxx-1981 | 71484-72A | 71484-72A | Square Housing - Small Pushbutton Switch - Both Sides |
 +| 1982-1985 | 71570-82A | 71572-82A | New Housing Style - Upper/Lower Shell - Sq Edge Buttons|
 +| 1986 only | 71570-86A | 71572-86A |  |
 +| 1987-1992 | 71570-82A | 71572-82A |  |
 +| 1993-1995 | 71598-92 | 71591-92 |  |
 +| 1996-1999 | 71598-96 | 71591-96 | New Housing Style - Upper/Lower Shell - Rnd Edge Buttons|
 +| 2000-2008 | 71598-00 | 71591-00 |  |
 +| 2009-2013 | 71685-06A | 71683-06A |  |
 +| 2014-2015 | 72949-12A | 72948-12 | CANbus SWITCH MODULE Assembly in new housing |
 +| 2016-2021 | 71500292 | 71500297 | CANbus SWITCH MODULE Assembly |
 +| Part Numbers are for the TS switch itself (Not The TS Housings) ||||
 +
 +In the Pre-1991 version, the actual TS flashing voltage was sent to the lamps through these momentary-contact handlebar switches... Therefore, you have to hold the button down (except 1986) to keep the flasher operating.
 +
 +In 1986, for one year only, the TS switches were PressOn/​Lock - PressOff/​Unlock - therefore, you could keep the flashing going without a constant thumb on the switch. In 1987-1992, the switches were reverted back to the pre-'​86 momentary-contact style.
 +
 +From 1991 on, the Turn Signal Module (TSM) only needed to see a momentary positive signal input (Press&​Release) from these switches in order to activate the TS function from within the TSM. Press again to turn the function off.
  
  
Line 739: Line 892:
  
 \\ \\
-|Year |TSM - No Security|TSM w/Sec Module ​|+|Year |TSM - No Security|TSM w/Security Functions ​|
 |1973-1990 |68543-64B - Simple Bi-Metallic Flasher Unit|| |1973-1990 |68543-64B - Simple Bi-Metallic Flasher Unit||
 |1991-1992 |68537-89C (TSM)|| |1991-1992 |68537-89C (TSM)||
Line 749: Line 902:
 |2006 |68920-01D (Std TSM) |68922-00D (TSSM)| |2006 |68920-01D (Std TSM) |68922-00D (TSSM)|
 |2007-2013 |68920-07 (Std TSM) |68924-07 (TSSM)| |2007-2013 |68920-07 (Std TSM) |68924-07 (TSSM)|
 +| According to [[http://​sportsterpedia.com/​lib/​exe/​fetch.php/​pdf-bulletin:​tt0224.pdf|TT#​224]] the 68922-00D TSSM module will retrofit to 2004-05 models. |||
 +|   |||
 | TS Functions incorporated into BCM - Body Control Module ||| | TS Functions incorporated into BCM - Body Control Module |||
 |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/​signals:​\\
 +1 - BLACK wire - Ground\\
 +2 - ORANGE/​White - Acc Power In\\
 +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/​VIOLET - Lt TS Switch IN\\
 +
 +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:​evo:​elec:​turn_signal_module_connections.jpg?​direct|}}\\ {{techtalk:​evo:​elec:​turn_signal_module_connections.jpg?​direct|}}\\
  
 **2014 - later BCM**\\ **2014 - later BCM**\\
 (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.)
 +
  
 {{techtalk:​evo:​elec:​2014sportster-bcm-connections.jpg|}}\\ {{techtalk:​evo:​elec:​2014sportster-bcm-connections.jpg|}}\\