2013 Harley-Davidson Sportster Models Electrical Diagnostic Manual – PDF DOWNLOAD
DESCRIPTION:
2013 Harley-Davidson Sportster Models Electrical Diagnostic Manual – PDF DOWNLOAD
ABOUT THIS MANUAL GENERAL:
This electrical diagnostic service manual has been prepared with two purposes in mind. First, it will acquaint the user with the construction of the Harley-Davidson product and assist in the performance of repair.
Secondly, it will introduce to the professional Harley-Davidson Technician the latest field-tested and factory-approved diagnostic methods.We sincerely believe that this manual will make your association with Harley-Davidson products more pleasant and profitable.
HOW TO USE YOUR SERVICE MANUAL
Refer to the table below for the content layout of this manual.
NO. CHAPTER
1 General Information
2 Initial Diagnostics and Serial Data
3 Starting and Charging
4 Instruments
5 Accessories, Horn, Lighting and Security
6 Engine Management
A Appendix A Connector Repair
B Appendix B Wiring
C Appendix C Conversions
D Appendix D Glossary
Use the TABLE OF CONTENTS (which follows this FOREWORD) and the INDEX (at the back of this manual) to quickly locate subjects. Chapters and topics in this manual are sequentially numbered for easy navigation. For example, a cross-reference shown as 2.2 SPECIFICATIONS refers to chapter 2 CHASSIS, heading 2.2 SPECIFICATIONS.
For quick and easy reference, all pages contain a chapter number followed by a page number. For example, page 3-5 refers to page 5 in Chapter 3. A number of acronyms and abbreviations are used in this document. See the D.1 GLOSSARY for a list of acronyms, abbreviations and definitions.
TABLE OF CONTENTS:
2013 Harley-Davidson Sportster Models Electrical Diagnostic Manual – PDF DOWNLOAD
FOREWORD........................................................... 7
TABLE OF CONTENTS.................................................. 9
1. GENERAL INFORMATION............................................. 21
1.1 SPECIFICATIONS AND COMPONENT LOCATIONS..................... 23
Specifications............................................. 23
Component Locations........................................ 23
1.2 DIAGNOSTIC TOOLS........................................... 29
How To Use Diagnostic Tools................................ 29
1.3 DIAGNOSTICS AND TROUBLESHOOTING............................ 33
Voltage Drop............................................... 33
Wiggle Test................................................ 34
Relay Diagnostics.......................................... 34
Job/Time Codes Values...................................... 35
2. INITIAL DIAGNOSTICS AND SERIAL DATA............................. 37
2.1 INITIAL DIAGNOSTICS........................................ 39
Description and Operation.................................. 39
Retrieving Trouble Codes................................... 39
Odometer Self-Diagnostics.................................. 39
Initial Diagnostics........................................ 39
Diagnostics................................................ 40
Code Types................................................. 42
Multiple Trouble Codes..................................... 43
Clearing DTCs.............................................. 43
Security Lamp.............................................. 43
Check Engine Lamp.......................................... 43
Symptoms................................................... 44
2.2 SERIAL DATA COMMUNICATION.................................. 50
Description and Operation.................................. 50
Components................................................. 50
Communication DTCs and "Bus Er"............................ 51
2.3 DTC U1016, U1064, U1097, U1098, U1255...................... 52
Description and Operation.................................. 52
DTC U1016.................................................. 53
DTC U1064, U1255........................................... 54
DTC U1097, U1255........................................... 55
DTC U1098, U1255........................................... 56
2.4 DTC U1300, U1301 OR BUS ER................................. 57
Description and Operation.................................. 57
DTC U1300.................................................. 58
DTC U1301.................................................. 59
3. STARTING AND CHARGING........................................... 61
3.1 BATTERY TESTING............................................ 63
General.................................................... 63
Voltmeter Test............................................. 63
Battery Diagnostic Test.................................... 63
Load Test.................................................. 63
3.2 STARTING SYSTEM............................................ 65
Description and Operation.................................. 65
Components................................................. 65
Starter Troubleshooting.................................... 68
Starter Testing............................................ 69
Nothing Clicks............................................. 70
Start Relay Clicks......................................... 71
Starter Solenoid Clicks.................................... 72
Starter Spins But Does Not Engage.......................... 73
Starter Stalls or Spins Too Slowly......................... 73
3.3 TESTING STARTER ON MOTORCYCLE.............................. 75
Starter Current Draw Test.................................. 75
3.4 TESTING STARTER ON BENCH................................... 76
Free Running Current Draw Test............................. 76
Starter Solenoid........................................... 76
Solenoid Pull-In Test...................................... 76
Solenoid Hold-In Test...................................... 76
Solenoid Return Test....................................... 77
3.5 CHARGING SYSTEM............................................ 78
Description and Operation.................................. 78
Troubleshooting............................................ 78
Low or No Charging......................................... 79
Overcharging............................................... 79
Low Battery After Extended IGN OFF......................... 80
Battery Runs Down During Use............................... 80
Battery Charging Tests..................................... 80
3.6 DTC B0563, P0562, P0563.................................... 83
Description and Operation.................................. 83
Diagnostics................................................ 83
DTC P0562.................................................. 84
DTC B0563, P0563........................................... 86
3.7 DTC B1006, B1007........................................... 87
Description and Operation.................................. 87
DTC B1006, B1007........................................... 87
4. INSTRUMENTS..................................................... 89
4.1 INSTRUMENTS................................................ 91
Description and Operation.................................. 91
Speedometer Theory of Operation............................ 91
Tachometer Theory of Operation............................. 92
Instrument Diagnostics..................................... 92
4.2 DTC B1004, B1005........................................... 93
Description and Operation.................................. 93
DTC B1004.................................................. 94
DTC B1005.................................................. 95
4.3 DTC B1008.................................................. 96
Description and Operation.................................. 96
DTC B1008.................................................. 96
4.4 NO INSTRUMENT POWER........................................ 97
Description and Operation.................................. 97
Speedometer (XL) or Tachometer (XR) Inoperative............ 98
Speedometer Inoperative: XR................................100
4.5 INDICATOR LAMPS............................................101
Description and Operation..................................101
Low Fuel Lamp Always On....................................105
Low Fuel Lamp Inoperative..................................105
Oil Pressure Lamp Always On................................106
Oil Pressure Lamp Inoperative..............................106
Neutral Lamp Always On.....................................107
Neutral Lamp Inoperative...................................107
High Beam Indicator Lamp Inoperative.......................108
Turn Signal Indicator Inoperative..........................108
5. ACCESSORIES, HORN, LIGHTING AND SECURITY........................109
5.1 ACCESSORIES................................................111
Description and Operation..................................111
Components.................................................111
5.2 HORN.......................................................112
Description and Operation..................................112
Components.................................................112
Symptoms...................................................112
Horn Always On.............................................113
Horn Inoperative...........................................113
5.3 TURN SIGNALS...............................................115
Description and Operation..................................115
Manual Cancellation........................................115
Automatic Cancellation.....................................115
Four-Way Flashing..........................................115
Will Not Cancel Upon Turn Completion, No DTCs..............119
Flash at Double Normal Rate, No DTCs.......................119
Both Turn Signal Lamps on One Side Inoperative, No DTCs....120
One Turn Signal Lamp Inoperative, No DTCs..................121
5.4 HEADLAMPS..................................................125
Description and Operation..................................125
Headlamp Inoperative, No DTCs..............................126
5.5 STOP LAMPS.................................................129
Description and Operation..................................129
Stop Lamp Inoperative......................................131
5.6 RUNNING LAMPS..............................................134
Description and Operation..................................134
Position Lamp Inoperative: HDI.............................136
Running Lamps Inoperative..................................136
5.7 DTC B1121, B1122, B1123, B1124, B1125, B1126...............138
Description and Operation..................................138
DTC B1121: HFSM............................................141
DTC B1121: TSM or TSSM.....................................141
DTC B1122: HFSM............................................142
DTC B1122: TSM or TSSM.....................................142
DTC B1123..................................................143
DTC B1124..................................................143
DTC B1125..................................................144
DTC B1126..................................................144
5.8 DTC B1135, B1136, B1141, B1142.............................145
Diagnostics................................................145
DTC B1141..................................................145
5.9 SECURITY SYSTEM............................................146
Security Lamp..............................................146
Security Immobilization....................................146
TSSM or HFSM Features......................................146
Warnings...................................................147
Arming: HFSM...............................................147
Arming: TSSM...............................................147
Disarming: HFSM............................................148
Disarming: TSSM............................................148
Alarm......................................................149
Alarm Sensitivity: TSSM....................................149
5.10 KEY FOB...................................................150
HFSM Fob...................................................150
TSSM Fob...................................................150
Fob Assignment: HFSM.......................................150
Fob Assignment: TSSM.......................................150
5.11 SIREN.....................................................152
Description and Operation..................................152
Siren Chirp Mode Confirmation: HFSM........................152
5.12 SERVICE AND EMERGENCY FUNCTIONS AND CONFIGURATIONS........153
General....................................................153
Actuation: HFSM............................................153
Configuring a TSSM.........................................153
Selecting a PIN............................................153
Initial Pin Entry: HFSM....................................153
Initial Pin Entry: TSSM....................................154
Changing the Pin...........................................156
Transport Mode.............................................157
Service Mode...............................................157
Four-Way Flashing..........................................157
Storage Mode: TSSM.........................................157
Power Disruption and Configuring: HFSM.....................158
Power Disruption and Configuring: TSSM.....................159
5.13 FAILS TO DISARM...........................................160
Description and Operation..................................160
Fails to Disarm: HFSM......................................163
Fails to Disarm: TSSM......................................163
5.14 DTC B1131, B1132..........................................164
Description and Operation..................................164
DTC B1131..................................................165
DTC B1132..................................................166
5.15 DTC B1134.................................................167
Description and Operation..................................167
DTC B1134..................................................168
5.16 DTC B1143, B1144, B1145...................................169
Description and Operation..................................169
DTC B1143..................................................169
DTC B1144..................................................170
DTC B1145..................................................170
5.17 DTC B1154, B1155..........................................171
Description and Operation..................................171
DTC B1154..................................................172
DTC B1155..................................................173
6. ENGINE MANAGEMENT...............................................175
6.1 EFI SYSTEM.................................................177
General....................................................177
6.2 ELECTRONIC CONTROL MODULE..................................179
General....................................................179
6.3 SENSORS AND DRIVERS........................................180
Description and Operation..................................180
Sensors....................................................180
Drivers....................................................181
6.4 DTC P0107, P0108...........................................183
Description and Operation..................................183
DTC P0107..................................................185
DTC P0108..................................................185
6.5 DTC P0112, P0113...........................................187
Description and Operation..................................187
DTC P0112..................................................188
DTC P0113..................................................189
6.6 DTC P0117, P0118...........................................190
Description and Operation..................................190
DTC P0117..................................................191
DTC P0118..................................................192
6.7 DTC P0122, P0123...........................................193
Description and Operation..................................193
DTC P0122..................................................195
DTC P0123..................................................195
6.8 DTC P0131, P0132, P0134, P0151, P0152, P0154...............197
Description and Operation..................................197
DTC P0131..................................................199
DTC P0132..................................................199
DTC P0134..................................................199
DTC P0151..................................................200
DTC P0152..................................................200
DTC P0154..................................................201
6.9 DTC P0261, P0262, P0263, P0264.............................202
Description and Operation..................................202
DTC P0261..................................................204
DTC P0262..................................................204
DTC P0263..................................................205
DTC P0264..................................................205
6.10 DTC P0373, P0374..........................................206
Description and Operation..................................206
DTC P0373..................................................207
DTC P0374..................................................208
6.11 DTC P0501, P0502..........................................209
Description and Operation..................................209
DTC P0501..................................................211
DTC P0502..................................................211
6.12 DTC P0505.................................................213
Description and Operation..................................213
DTC P0505..................................................215
6.13 DTC P0603, P0605..........................................216
Description and Operation..................................216
6.14 DTC P0661, P0662..........................................217
Description and Operation..................................217
DTC P0661, P0662...........................................218
6.15 DTC P1009, P1010..........................................219
Description and Operation..................................219
DTC P1009, P1010...........................................219
6.16 DTC P1001, P1002, P1003, P1004............................220
Description and Operation..................................220
DTC P1001..................................................222
DTC P1002..................................................222
DTC P1003..................................................222
DTC P1004..................................................223
6.17 DTC P1351, P1352, P1354, P1355............................224
Description and Operation..................................224
DTC P1351..................................................226
DTC P1352..................................................226
DTC P1354..................................................226
DTC P1355..................................................227
6.18 DTC P1501, P1502..........................................228
Description and Operation..................................228
DTC P1501..................................................230
DTC P1502..................................................230
Side Stand Displayed on Odometer...........................230
6.19 DTC P1653, P1654..........................................232
Description and Operation..................................232
6.20 ENGINE CRANKS, BUT WILL NOT START.........................233
Description and Operation..................................233
Engine Cranks but Will Not Start...........................235
6.21 NO ECM POWER..............................................236
Description and Operation..................................236
No ECM Power...............................................238
6.22 STARTS, THEN STALLS.......................................239
Description and Operation..................................239
Starts, Then Stalls........................................239
6.23 HESITATION, LOSS OF POWER.................................240
Description and Operation..................................240
Hesitation, Loss of Power Test.............................241
6.24 MISFIRE AT IDLE OR UNDER LOAD.............................243
Description and Operation..................................243
In-line Spark Tester.......................................243
Misfire At Idle or Under Load..............................245
A. APPENDIX A CONNECTOR REPAIR.....................................247
A.1 AUTOFUSE UNSEALED ELECTRICAL CONNECTORS....................249
Autofuse Unsealed Connector Repair.........................249
A.2 BOSCH COMPACT 1.1M CONNECTOR...............................250
Bosch Compact 1.1M Connector...............................250
A.3 DELPHI 100W MICRO-PACK SEALED CONNECTOR....................251
Delphi 100W Micro-Pack Sealed Connector Repair.............251
Crimping Terminals.........................................252
A.4 DELPHI 150 METRI-PACK SEALED CONNECTORS....................253
Delphi 150 Metri-Pack Sealed Connector Repair..............253
A.5 DELPHI 280 METRI-PACK UNSEALED CONNECTORS..................255
Fuse Block Repair..........................................255
A.6 DELPHI 480 METRI-PACK UNSEALED CONNECTORS..................256
Delphi 480 Metri-Pack Unsealed Connector Repair............256
A.7 DELPHI 630 METRI-PACK UNSEALED CONNECTORS..................257
Delphi 630 Metri-Pack Unsealed Connector Repair............257
A.8 DELPHI 800 METRI-PACK SEALED MAIN FUSE HOUSING.............258
Delphi 800 Metri-Pack Sealed Main Fuse Housing Repair......258
A.9 DELPHI METRI-PACK TERMINAL REPAIR..........................259
Metri-Pack Terminal Crimps.................................259
A.10 DELPHI MICRO 64 SEALED CONNECTORS.........................261
Delphi Micro 64 Sealed Connector Repair....................261
A.11 DELPHI GT 150 SEALED CONNECTORS...........................264
Delphi GT 150 Sealed Connector Repair......................264
A.12 DELPHI GT 280 SEALED 73-TERMINAL ECM CONNECTOR............266
Delphi GT 280 Sealed 73-Terminal ECM Connector.............266
A.13 DEUTSCH DT SEALED CONNECTORS..............................268
Deutsch DT Sealed Connector Repair.........................268
A.14 DEUTSCH DT SEALED TERMINAL REPAIR.........................272
Deutsch DT Sealed Terminal Crimps..........................272
A.15 DEUTSCH DTM SEALED MINI TERMINAL REPAIR...................273
Deutsch DTM Sealed Mini Terminal Crimps....................273
A.16 DEUTSCH DTM SEALED SOLID BARREL MINI TERMINAL REPAIR......274
Deutsch DTM Sealed Solid Barrel Terminal Crimps............274
A.17 JAE MX19 SEALED CONNECTORS................................276
JAE MX19 Sealed Connectors.................................276
Crimping Terminals.........................................276
A.18 MOLEX CMC SEALED CONNECTORS...............................277
Molex CMC Sealed Connectors................................277
Crimping Terminals.........................................278
A.19 MOLEX MX 150 SEALED CONNECTORS............................279
Molex MX 150 Sealed Connector Repair.......................279
Crimp Terminal to Lead.....................................280
A.20 TYCO 070 MULTILOCK UNSEALED CONNECTOR.....................283
Tyco 070 Multilock Unsealed Connector Repair...............283
A.21 TYCO GET 64 SEALED CONNECTOR..............................287
Tyco GET 64 Sealed Connector...............................287
Crimping Terminals.........................................288
A.22 TYCO MCP SEALED CONNECTOR.................................289
Tyco MCP Sealed Connector..................................289
Crimping Terminals.........................................290
A.23 SEALED SPLICE CONNECTORS..................................291
Sealed Splice Connector Repair.............................291
B. APPENDIX B WIRING...............................................293
B.1 CONNECTORS.................................................295
Connector Locations........................................295
B.2 WIRING DIAGRAMS............................................298
Wiring Diagram Information.................................298
2013 Sportster Wiring Diagrams.............................300
C. APPENDIX C CONVERSIONS..........................................321
C.1 METRIC CONVERSION..........................................323
Conversion Table...........................................323
C.2 FLUID CONVERSIONS..........................................324
United States System.......................................324
Metric System..............................................324
British Imperial System....................................324
C.3 TORQUE CONVERSIONS.........................................325
United States System.......................................325
Metric System..............................................325
D. APPENDIX D GLOSSARY.............................................327
D.1 GLOSSARY...................................................329
Acronyms and Abbreviations.................................329
TOOLS..............................................................333
TORQUE VALUES......................................................341
INDEX..............................................................343
2013 HARLEY-DAVIDSON SPORTSTER MODELS ELECTRICAL DIAGNOSTIC MANUAL – PDF DOWNLOAD:
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2013 Harley-Davidson Sportster Models Electrical Diagnostic Manual – PDF DOWNLOAD2013 Harley-Davidson Sportster Models Electrical Diagnostic Manual – PDF DOWNLOAD
PLEASE NOTE:
This is the SAME exact manual used by your dealers to fix your vehicle.
The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
Any queries / doubts regarding your purchase, please feel free to contact [email protected]
S.V
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