M1458: 2009 – 2018 Harley-Davidson Trike – Service Manual Supplement Update

SEOCONTENT-STARTM1458 2017-10-11
M1458: 2009 – 2018 TRIKE – SERVICE MANUAL SUPPLEMENT UPDATE
Reason for Revision
Refer to Table 1.
Table 1. Document History
Date Revision Description
2017-07-11 Initial release
2018-10-02 Updated Section Purpose for Service Bulletin
Purpose for Service Bulletin
The purpose of this bulletin is to communicate updates to the
reverse motor inoperative diagnostic procedure in the service
manual supplement. Refer to Section Updated Diagnostic
Procedure.
The procedure used in 2016 – 2018 Trike service manual
supplements has been updated, however the procedure applies
to all 2009 – 2018 Trike models.
This bulletin also provides additional information which should
be provided to Trike customers. This information is also in 2018
Trike owner’s manuals. Refer to Section Important Information
for Customer.
Cause
A high percentage of reverse motors that have been returned
are in good condition. The belief is that the 150 A circuit breaker
is tripped, and not fully reset. This is causing the technician to
replace good parts that they believe are faulty.
Vehicles Affected
All 2009 – 2018 Trike models.
Markets Affected
All markets are affected.
Required Dealer Action
When diagnosing the reverse system, verify the 150 A circuit
breaker is working properly by doing the following:
1. Verify battery voltage is greater than 12.5 V when the
ignition is OFF.
2. Refer to Figure 1. Push manual trip push button (2).
3. Push reset lever fully in until a audible click is heard and
felt (1).
NOTE
If the lever is lightly pushed in, a click may be detected but the
circuit breaker may not be reset.
4. Trip and reset again if unsure.
5. Refer to Figure 2. Test voltage between circuit breaker (2)
[252B] and ground.
6. Is battery voltage present?
a. Yes. Circuit breaker is reset.
b. No. Repeat circuit breaker reset procedure. After second
attempt with no battery voltage present, replace circuit
breaker.
1 2
pd00596
1. Reset lever (push in direction of arrow to reset)
2. Manual trip pushbutton
Figure 1. Reverse Motor Circuit Breaker (Typical)
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NOTE
In the interest of preserving customer safety and satisfaction, always check for outstanding recalls whenever any motorcycle is brought into your dealership for either maintenance or service.
LEADTECHNICIAN TECHNICIAN NO. 1 TECHNICIAN NO. 2 TECHNICIAN NO. 3 RETURN THIS TO
WARRANTY
PROCESS
MANAGER
SERVICE SALES MANAGER PARTS MANAGER
ROUTING MANAGER
INITIAL HERE
2
5 3
4
1
6
1133426
1. Reverse Motor Solenoid
2. 150 A Circuit Breaker
3. Starter
4. Red Band
5. Battery
6. Reverse Motor
Figure 2. 150 A Circuit Breaker
Important Information for Customer
• Reverse is not intended for extended operation. Usage
should be limited to 20–30 s with a few minutes allowed for
cool down.
• Reverse is not intended to be activated and deactivated in
rapid bursts. The button should be pushed and held, not
bumped in repeatedly in rapid succession.
• The customer should be shown the location of the 150 A
circuit breaker at delivery of the vehicle.
Updated Diagnostic Procedure
REVERSE MOTOR INOPERATIVE
Table 2. Reverse Motor Inoperative Diagnostic Faults
POSSIBLE CAUSES
Reverse motor solenoid malfunction
Short to voltage in ground circuit
Reverse motor malfunction
Circuit breaker is tripped
1. Circuit Breaker Reset Test
1. Reset 150 A reverse motor circuit breaker.
2. Verify reverse function.
3. Is reverse motor working?
a. Yes. Circuit breaker was reset.
b. No. Go to Test 2.
2. Reverse Switch Function Test
1. Verify conditions are correct to enable reverse. See
REVERSE MOTOR SYSTEM DIAGNOSTICS (Page 7-32).
2. Start engine.
3. Activate reverse button on LHCM.
4. Does reverse indicator illuminate?
a. Yes. Solid “R”. Go to Test 3.
b. Yes. Flashing “R”. Go to Test 16.
c. No. See INDICATOR LAMP DIAGNOSTICS (Page
7-46).
3. RCM Circuit Test
1. With reverse drive button pressed and using TEST
CONNECTOR KIT (PART NUMBER: HD-41404), test
voltage between reverse motor solenoid [248] and ground.
2. Is voltage greater than 10 V?
a. Yes. Go to Test 4.
b. No. Go to Test 7.
4. Reverse Motor High Current Circuit Test
1. With reverse button pressed, test voltage between reverse
motor solenoid [249B] and ground.
2. Is voltage greater than 10 V?
a. Yes. Go to Test 5.
b. No. Go to Test 13.
5. Ground Circuit Test
1. Turn IGN OFF.
2. Test resistance between reverse motor mounting bolt [253]
and ground.
3. Is resistance less than 0.5 Ω?
a. Yes. Go to Test 6.
b. No. Clean/repair mounting bolts and mounting surface.
6. Reverse Motor Solenoid Test
1. Perform reverse motor solenoid test. See REVERSE
MOTOR TESTING (Page 7-43).
2. Did reverse motor solenoid pass test?
a. Yes. Replace reverse motor.
b. No. Replace reverse motor solenoid.
7. Reverse Motor Control Circuit Test
1. Start engine.
2. With reverse button pressed, test voltage between reverse
control solenoid [251A & B] and ground.
3. Is voltage greater than 10 V at both terminals?
a. Yes. Repair open between [251B] and [248] (BK) wire.
b. No, only terminal [251A]. Go to Test 8.
c. No, neither terminal. Go to Test 12.
8. RCM Solenoid Control Circuit Test
1. Turn IGN OFF.
2. Disconnect [246].
3. Start engine.
4. With reverse switch pressed, test voltage between [246B]
terminal 1 (TN/R) wire and ground.
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5. Is voltage greater than 10 V?
a. Yes. Go to Test 9.
b. No. Go to Test 11.
9. RCM Solenoid Ground Circuit Test
1. Turn IGN OFF.
2. Test resistance between [246B] terminal 2 and ground.
3. Is resistance less than 1 Ω?
a. Yes. Replace RCM solenoid.
b. No. Go to Test 10.
10. RCM Ground Circuit Test
1. Disconnect [245].
2. Test resistance between [245B] terminal 8 and [246B]
terminal 2 (TN/GY).
3. Is resistance less than 0.5 Ω?
a. Yes. Replace RCM.
b. No. Repair open in (TN/GY) wire.
11. RCM Solenoid Control Circuit Open Test
1. Turn IGN OFF.
2. Disconnect RCM [245].
3. Test resistance between [246B] terminal 1 and [245B]
terminal 7 (TN/R).
4. Is resistance less than 0.5 Ω?
a. Yes. Replace RCM.
b. No. Repair open in (TN/R) wire.
12. Circuit Breaker Supply Voltage Test
1. Test voltage between circuit breaker [252A] and ground.
2. Is voltage greater than 10 V?
a. Yes. Repair open between [251A] and [252A] (BK) wire.
b. No. Repair open between [252A] and starter (BK) wire.
13. Reverse Motor Solenoid Test
1. Start engine.
2. With reverse button pressed, test voltage between reverse
motor solenoid [249A] and ground.
3. Is voltage greater than 10 V?
a. Yes. Replace reverse motor solenoid.
b. No. Go to Test 14.
14. Reverse Motor Circuit Solenoid Test
1. With reverse button pressed, test voltage between circuit
breaker [252B] and ground.
2. Is voltage greater than 10 V?
a. Yes. Repair open between [249A] and [252B] (BK) wire.
b. No. Go to Test 15.
15. Circuit Breaker Test
1. With reverse button pressed, test voltage between circuit
breaker [252A] and ground.
2. Is voltage greater than 10 V?
a. Yes. Replace circuit breaker.
b. No. Repair open in (BK) wire between [252A] and
starter.
16. Neutral Circuit Test
1. Verify transmission is in neutral.
2. Is neutral lamp functional?
a. Yes. Go to Test 17.
b. No. See neutral lamp diagnostics.
17. Accessory Circuit Open Test
1. Turn IGN OFF.
2. Disconnect RCM [245].
3. Turn IGN ON.
4. Test voltage between [245B] terminal 2 (R/Y) wire and
ground.
5. Is voltage greater than 10 V?
a. Yes. Go to Test 18.
b. No. Repair open in (R/Y) wire.
18. Ground Circuit Open Test
1. Turn IGN OFF.
2. Using TEST CONNECTOR KIT (PART NUMBER:
HD-41404), test resistance between RCM [245B] terminal
5 and ground (BK) wire.
3. Is resistance less than 0.5 Ω?
a. Yes. Go to Test 19.
b. No. Repair open in (BK) wire.
19. Backup Light Power Test
1. Connect [245].
2. Connect BREAKOUT BOX (PART NUMBER: HD-50390-1)
and BCM CABLE (PART NUMBER: HD-50390-2) to wire
harness [242B], leaving [242A] disconnected.
3. Verify BCM OVERLAY (PART NUMBER: HD-50390-2-P)
is in position on BOB.
4. Start engine.
5. With reverse button pressed, test voltage between BOB
terminal G2 and ground.
6. Is voltage greater than 10 V?
a. Yes. Go to Test 20.
b. No. Replace BCM.
20. Reverse Enable Feedback Test
1. Turn IGN OFF.
2. Remove BCM BOB, and connect [242].
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3. Connect BREAKOUT BOX (PART NUMBER: HD-50390-1)
and BCM CABLE (PART NUMBER: HD-50390-2) between
wire harness [78B-1], [78B-2], [78B-3] and ECM [78A-1],
[78A-2], [78A-3].
4. Verify BCM OVERLAY (PART NUMBER: HD-50390-2-P)
is in position on BOB.
5. Start engine.
6. With reverse button pressed, test voltage between BOB
[78-3] terminal 4 and [78-2] terminal 18.
7. Is voltage greater than 10 V?
a. Yes. Go to Test 21.
b. No. Replace RCM.
21. Reverse Activate Test
1. Press reverse button two times, test voltage between BOB
[78-3] terminal 16 and ground.
2. Is voltage between 4–6 V?
a. Yes. Go to Test 22.
b. No. Replace ECM.
22. Reverse Activate Input Open Test
1. Turn IGN OFF.
2. Disconnect RCM [245].
3. Test resistance between BOB [78-3] terminal 16 and [245B]
terminal 4.
4. Is resistance less than 0.5 Ω?
a. Yes. Replace RCM.
b. No. Repair open in (TN) wire.
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