1. | Remove grab strap. See service manual. | |
2. | Remove seat. See service manual. | |
3. | Remove saddlebag. See service manual. |
1. | Tour-Pak® models: Open Tour-Pak lid. Lift front pad to access seat mounting. | |
2. | See Figure 11. Remove phillips-head screw with lockwasher (A) from rear of currently installed seat. Pull seat rearward to remove seat. Retain screw. | |
3. | Fender Strips: If equipped, remove fender trim strips: a. Cover tip of a regular screwdriver with a piece of tape to protect chrome and painted surfaces. b. See Figure 1. Insert tip of screwdriver between chrome bezel and rubber trim strip. c. Pry up the bezel. Pull it up and away from rubber trim strip. d. Starting at either end, peel rubber trim strip away from fender. e. Clean with a mixture of 50 percent isopropyl alcohol and 50 percent distilled water. |
1. | Figure 2 Remove Bumpers. a. Remove bolts (1). Retain. b. Remove bumpers (2). Discard. c. Install spacers (3). d. Install Original Equipment (OE) bolts (1). Tighten. Torque: 43.4–49 N·m (32–36 ft-lbs) |
1 | Bolt (2) |
2 | Bumper (2) |
3 | Spacer (2) |
1 | Screw |
2 | Seat |
3 | Adapter bracket |
4 | Seat tab |
1. | Install new grab strap. See service manual. | |||||||||||||||||||
WARNING To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) | ||||||||||||||||||||
2. | Follow the instructions in the owner's manual to remove the negative battery cable from the battery. | |||||||||||||||||||
3. | Figure 4 Identify and remove plug from accessory circuit connector (6). |
Figure 4. 2014-2016: Left Side Cover | ||||||||||||||||||
4. | Locate heated and cooled seat connector on underside of new seat. | |||||||||||||||||||
5. | Connect heated and cooled seat connector to accessory circuit connector (6). | |||||||||||||||||||
6. | See owner's manual. Connect negative (-) battery cable. | |||||||||||||||||||
7. | Guide wiring into space beneath seat so that wiring will not be pinched when seat is installed. | |||||||||||||||||||
8. | Verify harness fuse holder cap is fully seated and secured to clear seat base. | |||||||||||||||||||
9. | See Figure 5. If already installed, slide rear of seat through grab strap, from the front, until slot (2) on front underside of seat is behind seat mounting tongue (1) on fuel tank rear bracket. |
Figure 5. Seat Front Mounting (Typical) | ||||||||||||||||||
10. | Press seat down onto frame backbone. | |||||||||||||||||||
11. | Slide seat toward front of vehicle until fuel tank bracket tongue fully engages into the slot under seat. | |||||||||||||||||||
12. | Secure seat onto rear fender using a phillips-head screw (with lockwasher) removed in Seat Removal. Tighten. Torque: 5.4–8.1 N·m (4–6 ft-lbs) | |||||||||||||||||||
13. | Install seat. After installing seat, pull up on the seat to verify that it is secure. See service manual. | |||||||||||||||||||
14. | Install grab strap. See service manual. | |||||||||||||||||||
15. | If removed, install saddlebags to vehicle. See service manual. Secure with OE bail head studs and flat washers. NOTE The molded rubber insert at the bottom of the saddlebags must fit snugly on the lower saddlebag support rails. | |||||||||||||||||||
16. | Tighten forward saddlebag mounting bolts. Tighten. Torque: 7–11 N·m (62.0–97.4 in-lbs) |
1. | Figure 6 Rotary switches (1,3): a. Controls the individual level setting of rider and passenger zones. b. Level controls are independent. c. Detents on switches allow operator to quickly return to preferred setting. d. Rider control (1) is located closest to rider's seating position. e. Passenger control (3) is located closest to passenger's seating position. f. Lowest setting, first detent, turns seating position OFF regardless of setting on the other control or heat/cool switch (2). g. Additional four detents increase strength of the heating or cooling function set. | |
2. | Figure 6 Heat/cool switch (2): a. Press "H" for heating. b. Press "C" for cooling. | |
3. | Fans: a. Both remain OFF whenever heating is pressed. b. Both remain ON whenever either rider or passenger is set to a level other than OFF and "C" is pressed. c. Fans are always both OFF or both ON. d. Fans exhaust the waste heat from underside of heating/cooling element when in cooling mode. Path of air is not through the seating surface. e. Fans do not blow air on rider or passenger. f. Seat Remote Input / Output - Electronic Seat Controller (RIO-ESC) operates fans at the same speed regardless of level setting. g. Seat draws large currents which changes fan speed slightly. h. Slight fan speed changes may be audible under low ambient noise conditions. This is normal. | |
4. | Performance Characteristics: a. Optimal heating takes 2-5 minutes. b. RIO-ESC drives heat to a set temperature based on control switch level setting. c. Maximum temperatures may not be achievable in extreme cold conditions due to a maximum power limitation within seat. d. Optimal cooling conditions take between 10 and 20 minutes. e. RIO-ESC drives cooling as a percentage of full power based on control switch level setting to maximize benefit to rider and passenger under varying ambient temperature. f. Maximum performance depends on a healthy charging system since power is limited by system voltage. g. Performance will be degraded or shut down at unusually low system voltage. Such as with key turned to accessory mode and battery not at full charge. h. Heat is transferred to and removed from occupant through conduction. Choice of clothing will affect performance. i. Heating/cooling elements are only located under a portion of seating surface where buttocks make contact. Thigh areas will not be heated or cooled. | |
5. | Diagnostics: a. RIO-ESC contains three LED's exposed on backside: these are most easily visible by unclipping RIO-ESC from seat base. Cable strap on RIO-ESC harness must be replaced if cut. b. Event codes are displayed in sequential order and continue to sequence so long as power remains applied to the seat. To verify all event codes are identified, monitor LED's until the same event code is reported a second time. c. All event codes will clear with a power cycle. d. If the cause of event code is still present after cycling power, the RIO-ESC will set the appropriate code again. e. Troubleshooting may require rider to physically detach seat from vehicle frame and gain access to RIO-ESC without removing power. f. Seat automatically attempts to clear event when cause of event is corrected. Process takes between 5-30 seconds. g. Codes remain displayed until power cycling even if seat is able to self-recover and operate normally. h. See Table 1 for event code definition. |
1 | Rider control switch |
2 | Heat/cool control switch |
3 | Passenger control switch |
1 | LED1 |
2 | LED2 |
3 | LED3 |
LED | Flashes | Code | Detection | Possible Causes | Troubleshooting Actions |
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1 | 1 | Internal Controller Switch A | Monitored internal chip fault signal |
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1 | 2 | Internal Controller Switch B | Monitored internal chip fault signal |
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1 | 3 | Internal Controller Switch C | Monitored internal chip fault signal |
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1 | 4 | Internal Controller Switch D | Monitored internal chip fault signal |
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1 | 5 | Over-current A | Measure heating/cooling element current draw |
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1 | 6 | Under-current A | Measure heating/cooling element current draw |
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1 | 7 | Over-current C | Measure heating/cooling element current draw |
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1 | 8 | Under-current C | Measure heating/cooling element current draw |
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1 | 9 | Over-current D | Measure heating/cooling element current draw |
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1 | 10 | Under-current D | Measure heating/cooling element current draw |
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2 | 1 | Fan 1 Low Speed | Measured fan feedback signal |
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2 | 2 | Fan 2 Low Speed | Measured fan feedback signal |
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2 | 3 | Fan 1 High Speed | Measured fan feedback signal |
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2 | 4 | Fan 2 High Speed | Measured fan feedback signal |
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2 | 5 | Fan 1 Stall | Measured fan feedback signal |
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2 | 6 | Fan 2 Stall | Measured fan feedback signal |
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2 | 7 | Fan 1 Over-current | Measured fan current draw |
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2 | 8 | Fan 1 Under-current | Measured fan current draw |
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2 | 9 | Fan 2 Over-current | Measured fan current draw |
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2 | 10 | Fan 2 Under-current | Measured fan current draw |
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2 | 11 | Rider Temp High 3 | Measured heating/cooling element temperature |
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2 | 12 | Passenger Temp High 3 | Measured heating/cooling element temperature |
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3 | 1 | Rider Temp High 1 | Measured heating/cooling element temperature |
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3 | 2 | Under Voltage 1 | Measured input connector voltage |
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3 | 3 | Over Voltage | Measured input connector voltage |
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3 | 4 | Rider Low Temp 1 | Measured heating/cooling element temperature |
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3 | 5 | Passenger High Temp 1 | Measured heating/cooling element temperature |
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3 | 6 | Passenger Low Temp 1 | Measured heating/cooling element temperature |
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3 | 8 | Passenger Switch Level High | Passenger knob voltage |
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3 | 10 | Rider Switch Level High | Rider knob voltage |
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3 | 11 | Passenger Temp High 2 | Measured heating/cooling element temperature |
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3 | 12 | Rider Temp High 2 | Measured heating/cooling element temperature |
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3 | 13 | Under Voltage 2 | Measured input connector voltage |
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1. | Toggle heat/cool control switch, wait two seconds before returning to heat or cool mode. | |
2. | If not traveling with a passenger, turn passenger control switch to OFF. |
1. | Check seat's harness fuse. a. If fuse is open, replace fuse with service part listed in Table 2. Do not replace this fuse with a higher rating. b. If fuse continues to open, see dealer. | |
2. | Operate seat. a. Maintain power to seat plug while accessing RIO-ESC to view event code history from controller. b. Because seat operates rider and passenger heating/cooling elements individually and in series, identifying the issue may require operating rider only, passenger only, or combination of both to verify the concern. | |
3. | Record event codes on RIO-ESC. | |
4. | Visually inspect fans for operation and blockage. a. Do not touch fan blade. Fan blade may cause bodily injury if operating or operation suddenly begins. b. Do not insert objects into fan. This can damage the fan and cause bodily injury if operation suddenly begins. c. Both fans operate when either control knob is set to a cooling mode above off. Some events will turn fans off. d. Unplug fans before clearing a blockage. Fans rotate with little resistance when not powered. | |
5. | If fans are damaged, see REPAIR section. Install fans and verify connector grommets are in place before connecting plugs. | |
6. | Set both seat sections to OFF. Cycle power to seat plug. | |
7. | Set seat to mode of concern and note events. a. This will verify only persistent events are reported. b. See Figure 1 for further troubleshooting actions. |
1. | Passenger fan replacement. NOTE Before replacing fan, remove seat. Power seat in cooling mode to visually inspect function of fans to verify which fan is malfunctioning. a. Remove grab strap and rear seat tab screw (6). b. Remove seat. Careful not to pull on wiring connection between seat and vehicle. c. Disconnect seat wiring harness from vehicle. d. Remove screws (5). Retain. NOTE Note routing of wiring with respect to seat base. Disconnect fan from seat wiring harness. e. Install replacement fan (3) in seat base. f. Install screws (5). Tighten. Torque: 0.564–0.79 N·m (5–7 in-lbs) NOTE
g. Connect fan to seat wiring harness. h. Connect seat wiring harness (1) to vehicle. i. Start vehicle or turn to accessory mode. j. Figure 6 Power seat in cooling mode to verify that the fan is working. k. Install seat. Pull up on seat to verify that it is secure. See service manual. NOTE Turn OFF vehicle before completing installation on vehicle. l. Install rear seat tab screw (6). m. Install grab strap. | |
2. | Rider duct assembly replacement. NOTE Before replacing duct, remove seat from vehicle and visually inspect duct for damage. If duct is cracked or broken such that airflow can leak directly to fan (bypassing cooling circuits), or fan is malfunctioning, then replace duct/fan assembly. a. Remove grab strap and rear seat tab screw. b. Remove seat. Careful not to pull on wiring connection between seat and vehicle. c. Disconnect seat wiring harness (1) from vehicle. d. Remove screws (2). Retain. NOTE Note routing of wiring with respect to seat base. Disconnect fan from seat wiring harness. e. Remove duct assembly (4) from seat. f. Connect new duct assembly fan connector to wiring harness. g. Install new duct assembly (4) to seat base. h. Install screws (2). Tighten. Torque: 0.564–0.79 N·m (5–7 in-lbs) NOTE
i. Connect seat wiring harness (1) to vehicle. j. Start vehicle or turn to accessory mode. k. Figure 6 Power seat in cooling mode (2) to verify that the fan is working. l. Install seat. After installing seat, pull up on the seat to verify that it is secure. See service manual. NOTE Turn OFF vehicle before completing installation on vehicle. m. Install rear seat tab screw (6). n. Install grab strap. | |
3. | See Figure 10 and Figure 8. RIO-ESC replacement. a. Remove grab strap and rear seat tab screw (6). b. Remove seat. Careful not to pull on wiring connection between seat and vehicle. c. Disconnect seat wiring harness (1) from vehicle. d. Remove cable strap (7) adjacent to RIO-ESC (10). Discard. e. Using a flat head screwdriver, gently pry back on RIO-ESC retention tab (9) on seat base while pulling RIO-ESC (10) out of its slot in seat base. f. Move lock on wiring harness connector (8) to unlocked position. g. Firmly press plug retention tab in to enable wiring harness to be disconnected from RIO-ESC (10). h. Figure 9 Using a 50:50 mixture of isopropyl/water clean back surface of RIO-ESC and allow surface to dry completely before attaching foam block. i. Figure 9 Remove backing from foam block (13) and apply to back side of RIO-ESC (10) under LED lights. j. Connect newRIO-ESC (10) to wiring harness (8). k. Move lock on wiring harness (8) to locked position. l. Insert RIO-ESC (10) into slot in seat base until RIO-ESC retention tab (9) on seat base locks RIO-ESC into place. m. Attach new cable strap (7) between wiring harness (8) and seat base adjacent to RIO-ESC (10). n. Connect seat wiring harness (1) to vehicle. o. Start vehicle or turn to accessory mode. p. Figure 6 Power seat in cooling mode to verify that the fan is working. q. Install seat. After installing seat, pull up on seat to verify that it is secure. See service manual. NOTE Turn OFF vehicle before completing installation on vehicle. r. Install rear seat tab screw. s. Install grab strap. |
1 | Seat harness |
2 | Duct screw (3) |
3 | Fan (2) |
4 | Duct |
5 | Fan screw (4) |
6 | Seat tab |
7 | Cable strap (3) |
8 | RIO-ESC harness |
9 | RIO-ESC retention tab |
10 | RIO-ESC |
11 | Fuse, seat harness |
12 | Retainer Clip (3) |
10 | RIO |
13 | Foam block |
1 | Locked |
2 | Unlocked |
Item | Description (Quantity) | Part Number |
---|---|---|
1 | Seat (plain pattern shown) | Not sold separately |
2 | Grab strap | 52400296 |
3 | Spacer (2) | 10300256 |
See Figure 8 for the following items: | ||
2 | Screw, duct (3) | 10200557 |
3 | Fan (2) | 26800204 |
4 | Duct assembly | 52000488 |
7 | Cable tie (3) | 10006 |
5 | Screw, fan (4) | 10201028 |
10 | 41000740 | |
11 | Fuse, seat harness | 69200293 |
12 | Retainer clip (3) | 10177 |
13 | Foam block (See Figure 9 ) | 52000635 |
Items mentioned in text, but not included in kit: | ||
A | Original equipment (OE) Phillips-head screw | 2952A |
B | OE Grab strap screw (2) | 2952A |
C | OE Grab strap washer (2) | 6703 |
D | 2014 and later model configuration |