Throttle position sensor wiring failure prone.
#12
Just got mine early this year. Bought mine from a geezer who never rode the bike. Had 351 miles when I purchased it early this year. Has 1850 miles now and my trip with my wife to Big Bend National Park in two weeks should add some mileage. Waiting for my Love Jugs to arrive so I can keep it cool on the trip.
#13
#14
#16
#17
I inadvertently stumbled on the following while researching a similar problem I recently experienced with my '14 Ultra. The issue relates to the "throttle by wire [TBW]" system. I'm not sure if this at all related to the condition mentioned by the OP. My understanding of the cause is vibration. The condition created is "corrosion fretting". The permanent cure, evidently, is changing the steel connectors to gold. Having been stranded, it's something I'm going to have service consider the next time my bike is in for routine service.
> "This is some must read info for everyone that has had issues with the
> TBW.
> This is a service bulletin issued by HD on 1/7/2011 it is bulletin #
> TT418A:
> DTC's P2135 & P2101 Theory & Diagnostics. I am going to condense this
> some but I also believe from my past experiences with my TBW that this
> also would include the P1510 code.
>
>
> TT418A service bulletin applies to 2008-Later Touring, Police & Trike
> Models
>
> Symptoms: Driveability or Performance Concerns; Abnormal or Erratic
> Mechanical Operation; Intermittent or Erratic Electrical Operation.
>
> Note: Throttle Position Sensor (TPS) circuit DTC's P0120, P0220,
> P0122, P0123, P0222 and P223 should take diagnostic priority over a
> P2135 code. If any of these TPS codes exist concurrently with the
> P2135, they should be investigated first using the diagnostic manual.
>
> The TCA has two potentiometers (designated as TPS1 & TPS2) and a
> electric DC motor for controlling the actuation of the throttle. The
> two TPS sensors work opposite of each other. As the throttle plate
> opens , TPS1 voltage ranges from 0.0-5.0 Volts, while TPS2 voltage
> ranges from 5.0-0.0 volts. The sum of the two TPS voltages should
> always measure approximately 5.0 volts.
> These wire are: TPS1, pin # 37 (BN/V wire) of the ECM, and TPS2 pin
> #36 (BN/R wire) of the ECM
>
> The TPS1 and TPS2 sensors should never add to more than 5.13 Volts
> Direct Current (VDC) or less than 4.87 VDC . A sum of voltages out of
> this range should register a current P2135 code.
>
> Troubleshooting:
> It is believed that FRETTING CORROSION is a major contributor of this
> code.
> A poor connection at the Throttle Control Actuator (TCA) can affect
> the sensor voltages reported to the ECM and this will set this DTC. As
> you can see from the General Information section, the sensor voltage
> only need to be altered by 0.13 VDC to possibly set the code.
>
> The most common vehicles to have these symptoms are those with more
> than
> 8,000 miles (12875 Kilometers) or 103 cubic inch and larger engines.
> Vibration is believed to contribute to the FRETTING CONDITION.
>
> Repair Procedure:
> 1. While monitoring the TPS1 and TPS2 voltages on Digital Technician 2
> (DT 2), wiggle the TCA [211] and the ECM [78] connectors.
> 2. If the voltage changes while wiggling the ECM connector , replace
> the affected ECM terminals (part # 72605-08). These wires are: TPS1,
> pin
> #37
> brown/violet wire of the ECM, and TPS2, pin #36 brown/red wire of the
> ECM.
> 3. If no voltage change is noted while moving the ECM connector , the
> connection issue could be in the TCA. Replace all socket terminals
> with NEW terminals (part # 72663-11, used in current production) at
> the TCA connector[211B].
> 4. BEFORE CONNECTING the TCA CONNECTOR, clean the male TCA pin
> terminals with a swab and alcohol, and ASSEMBLE WITH DIELECTRIC
> GREASE.
>
> DTC P2101
>
> General Information: The TCA contains two potentiometers (designated
> as
> TPS1
> & TPS2) and a electric DC motor for controlling a actuation of the
> throttle.
> TPS1 & TPS2 are mounted in the TCA. They are connected to the keyed
> shaft of the throttle plate and used to communicate the throttle plate
> position.
> Each TPS supplies input to the ECM in response to the position of the
> throttle plate. The ECM activates the motor in the TCA to move the
> throttle plate, based on signals from the Twist Grip Sensor (TGS).
> When the ECM send voltage modulations to pins 2 & 3 0f the TCA to move
> the throttle motor, it checks fo subsequent TPS1 and TPS2 voltage
> changes. If it does not sense TPS changes it will set this code.
>
> Troubleshooting: First verify that the throttle plate moves freely
> when engine is not running. If it does not the TCA needs to be replaced.
> Poor ECM connections seem to be the most likely cause. Be aware that
> this issue may be aggravated by the seat pan making contact with the
> ECM connector. In most cases, this is caused by the installation of an
> aftermarket seat.
> A poor connection at ECM pins #29 & 30 could cause an interruption in
> voltage to the throttle motor and set this code. Similarly the ECM
> uses voltage from pin #52 yellow/green wire to supply power used at
> pins #29 & 30 and could cause the same symptoms.
>
> Repair Procedure:
>
> Identifying the connection issues at this location may be difficult.
> 1. Replace all socket terminals with NEW terminals (part #72663-11
> used in current production) at the TCA connector [211B].
> 2. BEFORE CONNECTING the TCA CONNECTOR, clean the male TCA pin
> terminals with a swab and alcohol, and ASSEMBLE WITH DIELECTRIC
> GREASE"
> "This is some must read info for everyone that has had issues with the
> TBW.
> This is a service bulletin issued by HD on 1/7/2011 it is bulletin #
> TT418A:
> DTC's P2135 & P2101 Theory & Diagnostics. I am going to condense this
> some but I also believe from my past experiences with my TBW that this
> also would include the P1510 code.
>
>
> TT418A service bulletin applies to 2008-Later Touring, Police & Trike
> Models
>
> Symptoms: Driveability or Performance Concerns; Abnormal or Erratic
> Mechanical Operation; Intermittent or Erratic Electrical Operation.
>
> Note: Throttle Position Sensor (TPS) circuit DTC's P0120, P0220,
> P0122, P0123, P0222 and P223 should take diagnostic priority over a
> P2135 code. If any of these TPS codes exist concurrently with the
> P2135, they should be investigated first using the diagnostic manual.
>
> The TCA has two potentiometers (designated as TPS1 & TPS2) and a
> electric DC motor for controlling the actuation of the throttle. The
> two TPS sensors work opposite of each other. As the throttle plate
> opens , TPS1 voltage ranges from 0.0-5.0 Volts, while TPS2 voltage
> ranges from 5.0-0.0 volts. The sum of the two TPS voltages should
> always measure approximately 5.0 volts.
> These wire are: TPS1, pin # 37 (BN/V wire) of the ECM, and TPS2 pin
> #36 (BN/R wire) of the ECM
>
> The TPS1 and TPS2 sensors should never add to more than 5.13 Volts
> Direct Current (VDC) or less than 4.87 VDC . A sum of voltages out of
> this range should register a current P2135 code.
>
> Troubleshooting:
> It is believed that FRETTING CORROSION is a major contributor of this
> code.
> A poor connection at the Throttle Control Actuator (TCA) can affect
> the sensor voltages reported to the ECM and this will set this DTC. As
> you can see from the General Information section, the sensor voltage
> only need to be altered by 0.13 VDC to possibly set the code.
>
> The most common vehicles to have these symptoms are those with more
> than
> 8,000 miles (12875 Kilometers) or 103 cubic inch and larger engines.
> Vibration is believed to contribute to the FRETTING CONDITION.
>
> Repair Procedure:
> 1. While monitoring the TPS1 and TPS2 voltages on Digital Technician 2
> (DT 2), wiggle the TCA [211] and the ECM [78] connectors.
> 2. If the voltage changes while wiggling the ECM connector , replace
> the affected ECM terminals (part # 72605-08). These wires are: TPS1,
> pin
> #37
> brown/violet wire of the ECM, and TPS2, pin #36 brown/red wire of the
> ECM.
> 3. If no voltage change is noted while moving the ECM connector , the
> connection issue could be in the TCA. Replace all socket terminals
> with NEW terminals (part # 72663-11, used in current production) at
> the TCA connector[211B].
> 4. BEFORE CONNECTING the TCA CONNECTOR, clean the male TCA pin
> terminals with a swab and alcohol, and ASSEMBLE WITH DIELECTRIC
> GREASE.
>
> DTC P2101
>
> General Information: The TCA contains two potentiometers (designated
> as
> TPS1
> & TPS2) and a electric DC motor for controlling a actuation of the
> throttle.
> TPS1 & TPS2 are mounted in the TCA. They are connected to the keyed
> shaft of the throttle plate and used to communicate the throttle plate
> position.
> Each TPS supplies input to the ECM in response to the position of the
> throttle plate. The ECM activates the motor in the TCA to move the
> throttle plate, based on signals from the Twist Grip Sensor (TGS).
> When the ECM send voltage modulations to pins 2 & 3 0f the TCA to move
> the throttle motor, it checks fo subsequent TPS1 and TPS2 voltage
> changes. If it does not sense TPS changes it will set this code.
>
> Troubleshooting: First verify that the throttle plate moves freely
> when engine is not running. If it does not the TCA needs to be replaced.
> Poor ECM connections seem to be the most likely cause. Be aware that
> this issue may be aggravated by the seat pan making contact with the
> ECM connector. In most cases, this is caused by the installation of an
> aftermarket seat.
> A poor connection at ECM pins #29 & 30 could cause an interruption in
> voltage to the throttle motor and set this code. Similarly the ECM
> uses voltage from pin #52 yellow/green wire to supply power used at
> pins #29 & 30 and could cause the same symptoms.
>
> Repair Procedure:
>
> Identifying the connection issues at this location may be difficult.
> 1. Replace all socket terminals with NEW terminals (part #72663-11
> used in current production) at the TCA connector [211B].
> 2. BEFORE CONNECTING the TCA CONNECTOR, clean the male TCA pin
> terminals with a swab and alcohol, and ASSEMBLE WITH DIELECTRIC
> GREASE"
#19
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