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    2008 Later Touring, TT418

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    The document provides information about diagnosing and repairing DTC codes P2135 and P2101 on 2008 and later Touring, Police, and Trike models. P2135 typically sets due to a voltage difference outside the allowed range between the two throttle position sensors. Fretting corrosion at connections in the throttle control actuator is a common cause. P2101 may set if the ECM does not detect throttle position sensor voltage changes when commanding the throttle motor. Poor ECM connections are a likely root cause for P2101. The repair procedure involves inspecting and cleaning connectors and replacing terminals if issues are found.

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    2008 Later Touring, TT418

    Uploaded by

    Investor Protection
    14K views4 pages
    The document provides information about diagnosing and repairing DTC codes P2135 and P2101 on 2008 and later Touring, Police, and Trike models. P2135 typically sets due to a voltage difference outside the allowed range between the two throttle position sensors. Fretting corrosion at connections in the throttle control actuator is a common cause. P2101 may set if the ECM does not detect throttle position sensor voltage changes when commanding the throttle motor. Poor ECM connections are a likely root cause for P2101. The repair procedure involves inspecting and cleaning connectors and replacing terminals if issues are found.

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    2008 Later Touring,TT418[1]

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    The document provides information about diagnosing and repairing DTC codes P2135 and P2101 on 2008 and later Touring, Police, and Trike models. P2135 typically sets due to a voltage difference outside the allowed range between the two throttle position sensors. Fretting corrosion at connections in the throttle control actuator is a common cause. P2101 may set if the ECM does not detect throttle position sensor voltage changes when commanding the throttle motor. Poor ECM connections are a likely root cause for P2101. The repair procedure involves inspecting and cleaning connectors and replacing terminals if issues are found.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    14K views4 pages

    2008 Later Touring, TT418

    Uploaded by

    Investor Protection
    The document provides information about diagnosing and repairing DTC codes P2135 and P2101 on 2008 and later Touring, Police, and Trike models. P2135 typically sets due to a voltage difference outside the allowed range between the two throttle position sensors. Fretting corrosion at connections in the throttle control actuator is a common cause. P2101 may set if the ECM does not detect throttle position sensor voltage changes when commanding the throttle motor. Poor ECM connections are a likely root cause for P2101. The repair procedure involves inspecting and cleaning connectors and replacing terminals if issues are found.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 4
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    The document discusses DTC codes P2135 and P2101 which could indicate issues with the throttle position sensors or throttle control actuator. Fretting corrosion and poor electrical connections are identified as potential root causes. Diagnostic and repair procedures include inspecting connectors and replacing pins/terminals.

    Driveability or performance concerns, abnormal or erratic mechanical operation, and intermittent or erratic electrical operation are listed as potential symptoms.

    Fretting corrosion at connections and poor electrical connections at the throttle control actuator or ECM are identified as potential causes for the codes.

    TT418: DTCs P2135 and P2101 Theory and

    Diagnostics
    November 3, 2009
    Electrical

    APPLIES TO SYMPTOMS
    2008-Later Touring, Police and Trike Models • Driveability or Performance Concerns
    • Abnormal or Erratic Mechanical Operation
    • Intermittent or Erratic Electrical Operation

    DTC P2135
    General Information
    Read this general information to better understand what can set code P2135 in the ECM. After
    the general information, you will find information about possible root causes and tips for diagnosing
    and repairing affected vehicles.
    NOTE
    Throttle Position Sensor circuit codes such as P0120, P0220, P0122, P0123, P0222 or P0223,
    should take diagnostic priority over a P2135 code. If any of these TP sensor codes exist concur-
    rently with the P2135, they should be investigated first using the Electrical Diagnostic Manual.
    The two TP sensors work opposite of each other. As the throttle plate opens, TPS1 voltage ranges
    from 0.0-5.0V, while TPS2 voltage ranges from 5.0-0.0V. The sum of the two TPS voltages should
    always measure approximately 5.0V. These wires are: TPS1, BN/V pin 37 of the ECM, and TPS
    BN/R pin 36 of the ECM.
    The TP sensors 1 and 2 should never add to more than 5.13 VDC or less than 4.87 VDC. A sum
    of voltages out of this range should register a current P2135 code.

    TT418 1 / 4
    em00412 Twist Grip Sensor

    Throttle
    Control Actuator

    [224A] 6 5 4 3 2 1

    [224B] 6 5 4 3 2 1

    GY
    BN
    BE
    BK
    R
    V
    [211A] 6 5 4 3 2 1
    [211B] 6 5 4 3 2 1

    [204A] 6 5 4 3 2 1

    BN/O
    BN/R
    BK/O
    BN/V

    BK/W
    BK/PK
    [204B] 6 5 4 3 2 1
    ECM [78A] [78B]

    BN/O

    R/W
    BK/W
    BE/GN

    BK/GY
    V/Y
    Throttle By Wires HI 29 29 BK/O
    Throttle By Wires LO 30 30 BK/PK
    Throttle Pos. Sensor-2 36 36 BN/R
    Throttle Pos. Sensor-1 37 37 BN/V

    Twist Grip Sensor-2 39 39 V/Y

    5V Sensor Power-1 50 50 BN/O


    Twist Grip Sensor-1 59 59 BE/GN
    5V Sensor Ground-1 61 61 BK/W
    5V Sensor Ground-2 62 62 BK/GY

    5V Sensor Gower-2 68 68 R/W

    Figure 1. Schematic

    Current Root Cause Investigation


    It is believed that fretting corrosion is a major contributor to this code. A poor connection at the
    TCA can affect the sensor voltages reported to the ECM and set the DTC. As you can see from
    the General Information section, the sensor voltage only needs 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 8000 miles or
    those vehicles with 103ci and larger engines. The vibration that these connections are exposed
    to is believed to contribute to the fretting condition.
    Repair Procedure
    1. While monitoring the TPS 1 and TPS 2 voltage on the DT II, wiggle the TCA and the ECM
    connectors.
    2. If you the voltage changes while moving the ECM connector, inspect/replace the affected
    ECM terminals (Part No. 72605-08). These wires are: TPS1, BN/V pin 37 of the ECM, and
    TPS 2, BN/R pin 36 of the ECM.
    3. If no voltage change is noted while moving the ECM connector, the connection issue could
    be in the TCA. Replace pins 1, 4, 5 and 6 at the TCA connector 211B (Part No. 72168-07).
    4. Before connecting the TCA connector, clean the male TCA pins with a swab and alcohol,
    then assemble with dielectric grease (Part No. 99861-02 - Nyogel 760G).

    2 / 4 TT418
    Figure 2. View of Fretting on Pins

    Figure 3. View of Fretting on Pins

    DTC P2101
    General Information
    The TCA contains two potentiometers (designated as TPS1 and TPS2) and an electric DC motor
    for controlling the actuation of the throttle. TPS1 and TPS2 are mounted in the TCA. They are
    connected to the keyed shaft for the throttle plate and used to communicate the position of the
    throttle plate.
    Each TPS supplies input to the ECM in response to the positioning of the throttle plate. The ECM
    activates the motor in the TCA to move the throttle plate, based on signals from the TGS. When
    the ECM sends voltage modulations to pins 2 and 3 of the TCA to move the throttle motor, it
    checks for subsequent TP1 and TP2 voltage changes. If it does not sense TP sensor changes,
    it can set this code.

    TT418 3 / 4
    Current Root Cause Investigation
    First verify that the throttle plate moves freely while the engine is not running. If it does not, the
    TCA should be replaced.
    Poor ECM connections seem to be the most likely cause. Be aware that issues with 2008 models
    may be aggravated by seat pan-to-ECM connector contact.
    A poor connection at pins 29 and 30 could cause an interruption in voltage to the throttle motor
    and cause the code. Similarly the ECM uses voltage from pin 52 YEL/GN to supply power used
    at pins 29 and 30 and could cause the same symptoms.
    Repair Procedure
    Identifying connection issues at this location may be difficult.
    1. Test the listed wires from the ECM to the TCA for opens and shorts before replacing any
    parts.
    2. If the wires pass a resistance test and wiggle test, and the terminal pass visual inspections,
    the ECM socket terminals should be replaced. These are pins 29, 30, and 52 at the ECM.
    3. After the repair, cycle the ignition switch three times waiting about 10 seconds at each position.
    Each time the key is turned on, the throttle plate will open slightly, then close again. This is
    a normal IAC learn function.

    4 / 4 TT418

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