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
VIDEO PREVIEW OF THE MANUAL:
IMAGES PREVIEW OF THE MANUAL:
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