Harley Davidson 2013 Sportster Models. Electrical Diagnostics Manual — page 12

HOME

DTC P1653,

P1654

6.19

DESCRIPTION AND OPERATION

Table 6-56. Code Description

DTCs P1653 and P1654 are associated with terminal 3 from

DTC

DESCRIPTION

the ECM. This terminal supports a tachometer output that is

not used from the factory. If either of these codes appear when

P1653

Tachometer low

checking for DTCs, inspect for any aftermarket components

P1654

Tachometer high

or systems wired into terminal 3 of the ECM.

An issue with the wiring or component using this terminal could

cause the codes to set. If no wiring is present in this terminal,

clear the codes and perform a road test. If the codes return,

replace the ECM.

6-56 2013 Sportster Diagnostics: Engine Management

HOME

ENGINE CRANKS,

BUT WILL NOT START

6.20

DESCRIPTION AND OPERATION

ed02013

If the starter will not crank the engine, the problem is not EFI

related. See

3.2 STARTING SYSTEM or 5.9 SECURITY

SYSTEM.

With the IGN ON and the engine stop switch at RUN, the ECM

will energize the system relay to complete the circuit to the

intank fuel pump. It will remain on as long as the engine is

cranking or running and the ECM is receiving ignition reference

pulses from the CKP sensor. If there are no reference pulses,

the ECM will de-energize the system relay within 2 seconds

after ignition is turned on or the engine has stalled, or immedi-

ately after the ignition is shut off.

The fuel pump delivers fuel to the injectors. The pressure reg-

ulator controls system pressure.

See Figure 6-38. When the engine is stopped, the pump can

be turned on by applying battery voltage to the terminal B and

ground to the terminal D wire of the fuel pump connector [86A].

Improper fuel system pressure may contribute to the following

symptoms:

•

Engine cranks, but will not run.

•

Engine cuts out (may feel like ignition problems).

Figure 6-36. Ignition Coil Circuit Test

•

Hesitation, loss of power.

There may be DTCs associated with this problem. Check for

DTCs and resolve them before proceeding with this test.

ed02859

NOTE

After turning ignition off, wait 10 seconds before turning the

ignition back on to get the fuel pump

to reprime. This time-out

period is necessary for the fuel pump and IAC to reset. To set

a CKP DTC, a start attempt must last at least five seconds.

ed02012

1. Pin A: coil primary battery (+)

2. Pin B: coil primary battery (+)

3. Pin C: coil B primary

4. Pin D: coil A primary

Figure 6-37. Ignition Coil

Connector Information

Figure 6-35. Spark Tester

For additional information about the connectors in the following

diagram(s) and diagnostic procedure(s), including the color of

the harness test kit terminal probes, see B.1 CONNECTORS.

2013 Sportster Diagnostics: Engine Management 6-57

HOME

em00648

[78A] [78B]

Y/GN

ECM

BE/GY

System

Relay

System Relay

GN/O

W/BK

[61B]

[61A]

Fuse Block

Y/GN

Fuel

Front Injector

Y/GN

O/GY

Pump

Y/GN

Front Injector

W/Y

[84B] [84A]

[141A] [141B]

Rear Injector

Y/GN

GND 1

Rear Injector

GN/GY

[85B] [85A]

[145A] [145B]

Ignition

Coil

Y/GN

Power

Y/GN

Power

Spark Plugs

Rear Coil

Y/BE

Rear Coil

Front Coil

BE/O

Front Coil

Ground

[83B] [83A]

Ground

GND 1

ECM Fuse

Main Fuse

15A

30A

Battery

BE/GY

Switch Power

W/BK

B+

OFF

IGN Fuse

ACC

Battery

Engine Stop

W/BK

15A

Switch

R/BK

IGN

Ignition

[22A] [22B]

Switch

Figure 6-38. Ignition Circuit

6-58 2013 Sportster Diagnostics: Engine Management

HOME

2. Using SPARK TESTER (Part No. HD-26792), check spark

ENGINE CRANKS BUT WILL NOT START

at both plugs while cranking engine.

PART NUMBER

TOOL NAME

3. Is spark present?

HD-26792

SPARK TESTER

a. Yes. Go to Test 4.

HD-41404

HARNESS CONNECTOR TEST KIT

b. No. The spark plugs will not spark if there is low or

no compression. If spark is not present, test compres-

sion before troubleshooting ignition circuit. Once good

Table 6-57. Engine Cranks But Will Not Start Diagnostic

compression is confirmed, check condition of ignition

Faults

coils, coil primary wiring and spark plug boots. See

6.10 DTC P0373, P0374 or 3.1 BATTERY TESTING.

POSSIBLE CAUSES

Battery voltage too low

4. Compression Test

Ignition system issues

1. Perform compression test.

Fuel system issues

2. Does engine pass compression test?

Electrical system issues

a. Yes. Go to Test 5.

No or low compression

b. No. Repair engine loss of compression.

Open ground circuit

5. Fuel Pump Voltage Test

1. Preliminary Engine Tests

1. Disconnect fuel pump connector [141].

1. Verify battery connections are in good condition.

2. Using HARNESS CONNECTOR TEST KIT (Part No. HD-

2. Verify there are no blown fuses.

41404), test voltage between [141A] terminals 1 and 4

during the first 2-3 seconds after IGN ON.

3. Verify fuel in the tank is fresh and not contaminated.

3. Is battery voltage present?

4. Verify spark plug wires are firmly connected the coil and

plugs.

a. Yes. Go to Test 6.

5. Verify fuel injectors are not clogged.

b. No. Go to Test 7.

6. Check for DTCs. See 2.1 INITIAL DIAGNOSTICS, Odo-

6. Fuel System Test

meter Self-Diagnostics. If DTCs are present, see the

appropriate DTC procedure.

1. Check fuel system and perform fuel pressure test.

7. Perform battery test. See 6.21 NO ECM POWER.

2. Does fuel pressure meet specification?

a. Yes. Inspect and clean throttle body and repair as

8. Did battery pass tests?

needed.

a. Yes. Go to Test 2.

b. No. Inspect fuel inlet sock and fuel filter for obstruc-

b. No. Replace battery.

tion. Inspect internal fuel hose for leaks. If no issues

are found, replace fuel pump assembly.

2. Check Engine Lamp Test

1. Turn IGN ON and engine stop switch to RUN.

7. Fuel Pump Open Circuit Test

2. Does check engine lamp illuminate for 4 seconds immedi-

1. Turn IGN OFF.

ately after key ON?

2. Remove system relay [61A].

a. Yes. Go to Test 3.

3. Using HARNESS CONNECTOR TEST KIT (Part No. HD-

b. No. See 6.12 DTC P0505.

41404) , test for continuity between [141A] terminal 1 and

[61B] terminal E.

3. Spark Present Test

4. Is continuity present?

1. Check spark plug condition and replace if fouled.

a. Yes. Repair open on (BK) wire to ground.

b. No. Repair open (Y/GN) wire.

2013 Sportster Diagnostics: Engine Management 6-59

HOME

NO ECM POWER

6.21

DESCRIPTION AND OPERATION

ed03052

Constant power is supplied to the ECM through terminal 31.

The ECM turns on when power is applied to terminal 13 of

connector

[78]. The ECM goes through an initialization

sequence every time power is removed and re-applied to ter-

minal 13. The only visible part of this sequence is the check

engine lamp. Upon starting, the check engine lamp will illu-

minate for 4 seconds and then (if parameters are normal) go

out.

If battery power is absent at ECM terminal 31:

•

DTCs cannot be cleared. Tool will show them as cleared

but will be present next time ignition key is cycled.

•

ECM cannot be re-flashed.

•

Vehicle will start but IAC pintle will not reset at key OFF.

1. ECM [78]

Eventually pintle will be out of position causing perform-

2. Security antenna [209]

ance problems.

3. P&A battery [160]

4. Fuel sender resistor assembly [200]

NOTE

5. Battery

The IGN ON sequence also activates the idle air control motor.

6. Engine sensor harness [145]

If power from terminal 31 is disrupted (open fuse, etc.) always

Figure 6-40. ECM: XR

turn IGN OFF wait 10 seconds then turn IGN ON to reset the

motor to the default position.

Connector Information

ed03051

For additional information about the connectors in the following

diagram(s) and diagnostic procedure(s), including the color of

the harness test kit terminal probes, see B.1 CONNECTORS.

1. Fuse block [61]

2. ECM [78]

Figure 6-39. ECM: XL

6-60 2013 Sportster Diagnostics: Engine Management

HOME

em00648

[78A] [78B]

Y/GN

ECM

BE/GY

System

Relay

System Relay

GN/O

W/BK

[61B]

[61A]

Fuse Block

Y/GN

Fuel

Front Injector

Y/GN

O/GY

Pump

Y/GN

Front Injector

W/Y

[84B] [84A]

[141A] [141B]

Rear Injector

Y/GN

GND 1

Rear Injector

GN/GY

[85B] [85A]

[145A] [145B]

Ignition

Coil

Y/GN

Power

Y/GN

Power

Spark Plugs

Rear Coil

Y/BE

Rear Coil

Front Coil

BE/O

Front Coil

Ground

[83B] [83A]

Ground

GND 1

ECM Fuse

Main Fuse

15A

30A

Battery

BE/GY

Switch Power

W/BK

B+

OFF

IGN Fuse

ACC

Battery

Engine Stop

W/BK

15A

Switch

R/BK

IGN

Ignition

[22A] [22B]

Switch

Figure 6-41. Ignition Circuit

2013 Sportster Diagnostics: Engine Management 6-61

HOME

2. Using HARNESS CONNECTOR TEST KIT (Part No. HD-

NO ECM POWER

41404) and a multimeter, test for battery voltage between

breakout box terminal 31 and ground.

PART NUMBER

TOOL NAME

3. Is battery voltage present?

HD-41404

HARNESS CONNECTOR TEST KIT

a. Yes. Go to Test 5.

HD-43876

BREAKOUT BOX

b. No. Repair open in (BE/GY) wire. (5041)

Table 6-58. No ECM Power Diagnostic Faults

5. ECM Switched Voltage Test

POSSIBLE CAUSES

1. Turn IGN ON and engine stop switch in RUN.

Short to ground in ECM power circuit

2. Measure voltage between breakout box terminal 13 and

Open in ECM switched power circuit

ground.

Open ECM ground circuit

3. Is battery voltage present?

Engine stop switch malfunction

a. Yes. Go to Test 6.

b. No. Repair open (W/BK) wire. If wire is okay, then

1. ECM Fuse Test

continue with tests. Go to Test 7.

1. Check ECM fuse.

6. ECM Ground Wires Test

2. Is fuse good?

1. Measure voltage between positive battery terminal and

a. Yes. Go to Test 2.

breakout box terminals 10 and 28.

b. No. Repair short to ground on (BE/GY) wire and

2. Is battery voltage present?

replace fuse.

a. Yes. Replace ECM.

2. IGN Fuse Test

b. No. Repair open in (BK) wire.

1. Check IGN fuse.

7. Engine Stop Switch Battery Voltage Test

2. Is fuse good?

1. Disconnect right hand controls [22].

a. Yes. Go to Test 3.

2. Turn IGN ON.

b. No. Repair short to ground

on (GY) or (W/BK) wire

and replace IGN fuse.

3. Measure voltage on [22B] terminal 3 (GY) and ground.

3. ECM Connector Test

4. Is battery voltage present?

a. Yes. Go to Test 8.

1. With IGN OFF, disconnect ECM [78].

b. No. Repair open wire (GY).

2. Check for backed out, damaged and corroded terminals.

Repair terminal damage as required.

8. Engine Stop Switch Test

3. Connect ECM [78].

1. Turn IGN OFF and engine stop switch in RUN.

4. Turn IGN ON.

2. Measure the resistance between [22A] terminals 3 and 4.

5. Does ECM have power?

3. Is resistance less than 1.0 Ohm?

a. Yes. Problem solved.

a. Yes. Repair open in (W/BK) wire from terminal 4 of

b. No. Go to Test 4.

[22B] and ECM (78B).

b. No. Repair or replace engine stop switch.

4. ECM Battery Wire Test

1. Connect BREAKOUT BOX (Part No. HD-43876) between

wire harness [78B] and ECM [78A]. See 1.2 DIAGNOSTIC

TOOLS.

6-62 2013 Sportster Diagnostics: Engine Management

HOME

STARTS, THEN STALLS

6.22

DESCRIPTION AND OPERATION

STARTS, THEN STALLS

The starts, then stalls condition may be created by the fuel

system, the idle air control system or an ECM failure. When

Table 6-59. Starts, Then Stalls Diagnostic Faults

this condition exists, see 2.4 DTC U1300, U1301 OR BUS ER.

POSSIBLE CAUSES

There may be DTCs set causing this condition. Solve the

Fuel system malfunction

problems with the DTCs before performing the tests in this

Idle air control system malfunction

section. The DTCs that may be involved with starts, then stalls

are:

Open serial data circuit

•

Fuel injectors: DTCs P0261, P0262, P0263 and P0264

Neutral switch malfunction

•

Ignition coils: DTCs P1351, P1352, P1354 and P1355

1. Throttle Test

•

IAC actuator: DTC P0505

1. Will engine start with the throttle partially opened and then

•

Password problem: DTCs P1009 and P1010

stall when closed?

a. Yes. Check IAC for proper operation. If necessary,

•

TPS: DTCs P0122 and P0123

perform IAC test. See 6.12 DTC P0505.

•

JSS: DTCs P1501, P1502 and P1503

b. No, SidE StAnd displayed on odometer. Go to Test

•

Neutral switch: DTC P1155

•

All modes: DTCs P0603 and P0605

c. No. Go to Test 4.

Diagnostic Tips

2. Jiffy Stand Test

•

The vehicle will stall on HDI models if the jiffy stand is

1. Turn IGN OFF.

extended when the transmission is in gear and the clutch

is released.

2. Raise jiffy stand.

•

If serial data is shorted, U1300 and U1301 will automatic-

3. Turn IGN ON and engine stop switch to RUN.

ally set the check engine light.

4. Does odometer display SidE StAnd?

•

DTCs P1009 and P1010 may accompany DTCs U1300

a. Yes. Inspect JSS for correct mounting and clearance

and U1301.

to jiffy stand tab

(0.18 in

(4.5 mm). If sensor is

•

If this condition is fuel related, perform Fuel Pressure Test.

mounted correctly, replace sensor.

•

If the fuel system passes the pressure test, perform the

b. No. Go to Test 3.

Fuel System Electrical Test. See 6.23 HESITATION, LOSS

OF POWER.

3. Neutral Switch Test

Connector Information

1. Verify neutral switch circuit operation.

For additional information about the connectors in the following

2. Is neutral switch circuit operating normally?

diagram(s) and diagnostic procedure(s), including the color of

a. Yes. Replace TSM, TSSM or HFSM.

the harness test kit terminal probes, see B.1 CONNECTORS.

b. No. Replace neutral switch.

4. Fuel System Test

1. Perform Fuel Pressure test.

2. Is fuel pressure normal?

a. Yes. If fuel injectors are okay, replace ECM.

b. No. Repair fuel pressure problem.

2013 Sportster Diagnostics: Engine Management 6-63

HOME

HESITATION, LOSS OF POWER

6.23

DESCRIPTION AND OPERATION

ed03050

Improper fuel system pressure may contribute to hesitation,

loss of power.

ed01999

1. Fuse block [61]

2. Positive battery cable

3. Battery

4. P&A battery [160]

1. Fuse block [61]

5. Fuel sender resistor assembly [200]

2. Positive battery cable

6. DLC [91]

3. Battery

7. Main fuse [5]

4. Main fuse [5]

8. Rear O2 sensor [137]

5. DLC [91]

9. Fuel pump and low fuel switch [141]

6. Rear stop lamp switch (XL models) [121]

10. Rear O2 sensor

7. Fuel pump and low fuel switch [141]

Figure 6-43. Under Left Side Cover: XR

8. Rear O2 sensor [137]

9. Starter

10. Rear O2 sensor

Connector Information

11. ECM

For additional information about the connectors in the following

Figure 6-42. Under Left Side Cover: XL

diagram(s) and diagnostic procedure(s), including the color of

the harness test kit terminal probes, see B.1 CONNECTORS.

6-64 2013 Sportster Diagnostics: Engine Management

HOME

em00648

[78A] [78B]

Y/GN

ECM

BE/GY

System

Relay

System Relay

GN/O

W/BK

[61B]

[61A]

Fuse Block

Y/GN

Fuel

Front Injector

Y/GN

O/GY

Pump

Y/GN

Front Injector

W/Y

[84B] [84A]

[141A] [141B]

Rear Injector

Y/GN

GND 1

Rear Injector

GN/GY

[85B] [85A]

[145A] [145B]

Ignition

Coil

Y/GN

Power

Y/GN

Power

Spark Plugs

Rear Coil

Y/BE

Rear Coil

Front Coil

BE/O

Front Coil

Ground

[83B] [83A]

Ground

GND 1

ECM Fuse

Main Fuse

15A

30A

Battery

BE/GY

Switch Power

W/BK

B+

OFF

IGN Fuse

ACC

Battery

Engine Stop

W/BK

15A

Switch

R/BK

IGN

Ignition

[22A] [22B]

Switch

Figure 6-44. Ignition Circuit

HESITATION, LOSS OF POWER TEST

1. Preliminary Engine Tests

1. Verify battery connections are in good condition.

PART NUMBER

TOOL NAME

2. Verify there are no blown fuses.

HD-26792

SPARK TESTER

3. Verify fuel in the tank is fresh and not contaminated.

4. Verify spark plug wires are firmly connected the coil and

Table 6-60. Hesitation, Loss of Power Test Diagnostic

plugs.

Faults

5. Verify fuel injectors are not clogged.

POSSIBLE CAUSES

6. Check for DTCs. See 2.1 INITIAL DIAGNOSTICS, Odo-

Loss of engine compression

meter Self-Diagnostics. If DTCs are present, see the

Fuel system issues

appropriate DTC procedure.

2013 Sportster Diagnostics: Engine Management 6-65

HOME

7. Perform battery test. See 3.1 BATTERY TESTING.

3. Is spark present?

a. Yes. Go to Test 4.

8. Did battery pass tests?

a. Yes. Go to Test 2.

b. No. The spark plugs will not spark if there is low or

no compression. If spark is not present, test compres-

b. No. Replace battery.

sion before troubleshooting ignition circuit. Once good

compression is confirmed, check condition of ignition

2. Vacuum Leak Test

coils, coil primary wiring and spark plug boots. See

1. Start the motorcycle and check for vacuum leaks.

6.10 DTC P0373, P0374 or 6.17 DTC P1351, P1352,

P1354, P1355.

2. Were any leaks found?

a. Yes. Repair the vacuum leak.

4. Compression Test

b. No. Go to Test 3.

1. Perform compression test.

2. Does engine pass compression test?

3. Spark Present Test

a. Yes. Go to Test 5.

1. Check spark plug condition and replace if fouled.

b. No. Repair engine loss of compression.

2. Using SPARK TESTER (Part No. HD-26792), check spark

at both plugs while cranking engine.

5. Fuel System Test

1. Check fuel system and perform fuel pressure test.

2. Does fuel pressure meet specification?

a. Yes. Inspect and clean throttle body. Repair as

needed.

b. No. Inspect fuel inlet sock and fuel filter for obstruc-

tion. Inspect internal fuel hose for leaks. If no issues

are found, replace fuel pump assembly.

6-66 2013 Sportster Diagnostics: Engine Management

HOME

MISFIRE AT IDLE OR UNDER LOAD

6.24

whether a problem exists in the ignition or fuel systems. If the

DESCRIPTION AND OPERATION

test light flashes without interruption on both cylinders during

Misfire conditions may be caused by:

the misfire event, verify spark plug condition and gap, and

inspect the fuel system for proper operation. If the test light

•

Battery condition and connections.

does not flash, or the flash is interrupted during the misfire

•

Fuel system problems. Refer to Table 6-1, Table 6-2 and

event, the problem is ignition related.

Table 6-3.

1. Turn IGN OFF.

•

Ignition system faults.

2. Remove front spark plug cable and install SNAP-ON IN-

Diagnostic Tips

LINE SPARK TESTER (Part No. YA840) between spark

plug cable and spark plug.

3. Start engine and inspect tester light. The light will flash on

each spark event if power is transmitted to the plug.

Wipe up spilled fuel and dispose of rags in a suitable

manner. An open spark around gasoline could cause a

4. Install and repeat procedure on rear cylinder.

fire or explosion, resulting in death or serious injury.

(00518b)

NOTE

A SNAP-ON IN-LINE SPARK TESTER (Part No. YA840) can

When performing the steps in the diagnostic tests, a known

also be used in conjunction with a dynamometer capable of

good part can be used to verify whether a suspected part is

loaded testing to diagnose misfire under load.

faulty. The ignition coil does not require full installation to be

functional. Verify faulty ignition coil by performing resistance

ed01780

test. See 6.17 DTC P1351, P1352, P1354, P1355.

ed02012

Figure 6-46. In-line Spark Tester

Figure 6-45. Spark Tester

Connector Information

For additional information about the connectors in the following

IN-LINE SPARK TESTER

diagram(s) and diagnostic procedure(s), including the color of

the harness test kit terminal probes, see B.1 CONNECTORS.

PART NUMBER

TOOL NAME

YA840

SNAP-ON IN-LINE SPARK TESTER

See Figure 6-45. The use of a SNAP-ON IN-LINE SPARK

TESTER (Part No. YA840) or equivalent can help determine

2013 Sportster Diagnostics: Engine Management 6-67

HOME

em00648

[78A] [78B]

Y/GN

ECM

BE/GY

System

Relay

System Relay

GN/O

W/BK

[61B]

[61A]

Fuse Block

Y/GN

Fuel

Front Injector

Y/GN

O/GY

Pump

Y/GN

Front Injector

W/Y

[84B] [84A]

[141A] [141B]

Rear Injector

Y/GN

GND 1

Rear Injector

GN/GY

[85B] [85A]

[145A] [145B]

Ignition

Coil

Y/GN

Power

Y/GN

Power

Spark Plugs

Rear Coil

Y/BE

Rear Coil

Front Coil

BE/O

Front Coil

Ground

[83B] [83A]

Ground

GND 1

ECM Fuse

Main Fuse

15A

30A

Battery

BE/GY

Switch Power

W/BK

B+

OFF

IGN Fuse

ACC

Battery

Engine Stop

W/BK

15A

Switch

R/BK

IGN

Ignition

[22A] [22B]

Switch

Figure 6-47. Ignition Circuit

6-68 2013 Sportster Diagnostics: Engine Management

HOME

2. Is carbon tracking present?

MISFIRE AT IDLE OR UNDER LOAD

a. Yes. Replace ignition coil.

PART NUMBER

TOOL NAME

b. No. Switch ignition coil with known good unit and

HD-26792

SPARK TESTER

perform Test 2. If spark jumps gap, replace ignition

coil. If not, then continue with tests. Go to Test 5.

HD-41404

HARNESS CONNECTOR TEST KIT

HD-43876

BREAKOUT BOX

5. Ignition Coil Primary Wire Continuity Test

1. Turn IGN OFF.

Table 6-61. Misfire At Idle or Under Load Diagnostic Faults

2. Remove system relay and disconnect ignition coil [83].

POSSIBLE CAUSES

3. Measure resistance between fuse block [61B] socket ter-

Ignition system malfunction

minal E and [83B] terminal A, and then between [61B]

socket terminal E and [83B] terminal B. Wiggle connectors

Fuel system malfunction

while measuring.

IAC malfunction

4. Is resistance continuously less than 0.5 Ohms?

Electrical system malfunction

a. Yes. Go to Test 6.

1. Power Ground Continuity Test

b. No. Repair intermittent on (Y/GN) wire.

1. Connect BREAKOUT BOX (Part No. HD-43876) between

6. Battery to System Relay Voltage Drop

wire harness [78B] and ECM [78A]. See 1.2 DIAGNOSTIC

TOOLS.

Test

2. Using HARNESS CONNECTOR TEST KIT (Part No. HD-

1. Reconnect ignition coil and install system relay.

41404) and a multimeter, check for continuity between

2. Turn IGN ON, start engine.

breakout box terminals 10 and then 28, to ground.

3. With engine running, measure voltage drop between bat-

3. Is continuity present?

tery (+) and system relay [61B] socket terminal E (under-

a. Yes. Go to Test 2.

side of fuse/relay block). See 1.3 DIAGNOSTICS AND

TROUBLESHOOTING, Voltage Drop.

b. No. Repair poor ground on (BK) wire.

4. Is voltage drop less

than 1.0V?

2. Spark Test

a. Yes. Problem is fuel related. Recheck symptoms.

1. Connect SPARK TESTER (Part No. HD-26792) between

b. No. Go to Test 7.

front spark plug cable and ground. See 1.2 DIAGNOSTIC

TOOLS.

7. Battery to System Relay Contact Voltage

2. Crank engine for a few seconds.

Drop Test

3. Remove tester from front spark plug cable and connect

1. With engine running, measure voltage drop between bat-

rear spark plug cable and ground.

tery (+) and system relay [61B] socket terminal L (under-

side of fuse/relay block).

4. Did spark jump gap on both cables?

a. Yes. Check for faulty, worn, or cracked spark plugs,

2. Is voltage drop less than 1.0V?

plug fouling due to mechanical problems, or faulty

a. Yes. Replace system relay.

connection at plug or coils. Repair as required.

b. No. Go to Test 8.

b. No. Go to Test 3.

8. Battery to ECM Fuse Voltage Drop Test

3. Spark Plug Cable Test

1. With engine running, measure voltage drop between bat-

1. Disconnect the spark plug cable.

tery (+) and [61B] socket terminal U.

2. Measure the resistance of the spark plug cable.

2. Is voltage drop less than 1.0V?

3. Is the front and rear spark plug cable resistance within the

a. Yes. Repair (BE/GY) wire or connections.

specified range? Refer to Table 1-5.

b. No. Go to Test 9.

a. Yes. Go to Test 4.

9. Battery to Fuse Block Voltage Drop Test

b. No. Replace the out of range spark plug cable.

1. With engine running, measure voltage drop between bat-

4. Carbon Tracking Inspection Test

tery (+) and [61B] socket terminal S.

1. Inspect top of ignition coils for carbon tracking.

2013 Sportster Diagnostics: Engine Management 6-69

HOME

2. Is voltage drop less than 1.0V?

11. Battery to Main Fuse Block Voltage Drop

a. Yes. Repair ECM fuse connections or replace ECM

Test

fuse.

1. With engine running, measure voltage drop between bat-

b. No. Go to Test 10.

tery (+) and main fuse [5B] terminal B.

2. Is voltage drop less than 1.0V?

10. Battery to Fuse Block Voltage Drop Test

a. Yes. Repair main fuse connections or replace main

1. With engine running, measure voltage drop between bat-

fuse.

tery (+) and main fuse [5B] terminal A.

b. No. Repair (R) wire between battery and main fuse

2. Is voltage drop less than 1.0V?

[5B] terminal B, including connections at starter.

a. Yes. Repair (R) wire.

b. No. Go to Test 11.

6-70 2013 Sportster Diagnostics: Engine Management

TABLE OF CONTENTS

SUBJECT

PAGE NO.

A.1 AUTOFUSE UNSEALED ELECTRICAL CONNECTORS

A-1

A.2 BOSCH COMPACT 1.1M CONNECTOR

A-2

A.3 DELPHI 100W MICRO-PACK SEALED CONNECTOR

A-3

A.4 DELPHI 150 METRI-PACK SEALED CONNECTORS

A-5

A.5 DELPHI 280 METRI-PACK UNSEALED CONNECTORS

A-7

A.6 DELPHI 480 METRI-PACK UNSEALED CONNECTORS

A-8

A.7 DELPHI 630 METRI-PACK UNSEALED CONNECTORS

A-9

A.8 DELPHI 800 METRI-PACK SEALED MAIN FUSE HOUSING

A-10

A.9 DELPHI METRI-PACK TERMINAL REPAIR

A-11

A.10 DELPHI MICRO 64 SEALED CONNECTORS

A-13

A.11 DELPHI GT 150 SEALED CONNECTORS

A-16

A.12 DELPHI GT 280 SEALED 73-TERMINAL ECM CONNECTOR

A-18

A.13 DEUTSCH DT SEALED CONNECTORS

A-20

A.14 DEUTSCH DT SEALED TERMINAL REPAIR

A-24

A.15 DEUTSCH DTM SEALED MINI TERMINAL REPAIR

A-25

A.16 DEUTSCH DTM SEALED SOLID BARREL MINI TERMINAL REPAIR

A-26

A.17 JAE MX19 SEALED CONNECTORS

A-28

A.18 MOLEX CMC SEALED CONNECTORS

A-29

A.19 MOLEX MX 150 SEALED CONNECTORS

A-31

A.20 TYCO 070 MULTILOCK UNSEALED CONNECTOR

A-35

A.21 TYCO GET 64 SEALED CONNECTOR

A-39

A.22 TYCO MCP SEALED CONNECTOR

A-41

A.23 SEALED SPLICE CONNECTORS

A-43

NOTES

HOME

AUTOFUSE UNSEALED ELECTRICAL

CONNECTORS

A.1

AUTOFUSE UNSEALED CONNECTOR

sm02849a

REPAIR

PART NUMBER

TOOL NAME

GA500A

SNAP-ON TERMINAL PICK

General

Autofuse Unsealed connector terminals are found in ignition

switches and some fuse blocks.

Disassembly

1. See Figure A-1 or Figure A-2. Insert smallest pair of pins

on the SNAP-ON TERMINAL PICK (Part No. GA500A)

into chamber on mating end of socket housing to press

tangs on each side of terminal simultaneously.

Figure A-1. Removing Autofuse Unsealed Terminal from

2. Gently pull on wire to remove terminal from wire end of

Ignition Switch

socket housing.

3. If necessary, crimp new terminals on wires.

sm03480a

Assembly

1. Carefully bend tang on each side of terminal outward away

from terminal body. Use the thin flat blade from a

hobby

knife.

2. With the open side of the terminal facing rib on wire end

of socket housing, insert terminal

into chamber until

it locks

in place.

Figure A-2. Removing Autofuse Unsealed Terminal from

Fuse Block

2013 Sportster Diagnostics: Appendix A Connector Repair A-1

HOME

BOSCH COMPACT 1.1M CONNECTOR

A.2

BOSCH COMPACT 1.1M CONNECTOR

sm07337

PART NUMBER

TOOL NAME

GA500A

SNAP-ON TERMINAL PICK

General

See Figure A-3. The Bosch Compact 1.1M connector is found

on MAP sensors on Sportster and Touring Models.

Housings

Separate: Snap back the secondary lock. Press on the latch

while pulling the socket connector from the MAP sensor.

Join: Align the sockets with the MAP connect and press the

housings together until the latch snaps. Snap in the secondary

lock.

sm07374

Figure A-4. Terminal Removal: Bosch Compact 1.1M

Connector

Installing Socket Terminal

1. See Figure A-5. Use a hobby knife to bend the tangs on

each side of the terminal outward.

2. Align terminal to socket housing. Press terminal into

housing until it snaps.

NOTE

The teeth on the locking

bar face down.

3. Slide the locking bar onto the connector.

Figure A-3. Bosch Compact 1.1M Connector

sm07352

Removing Socket Terminal

1. See Figure A-4. Slide the locking bar off the terminal

housing.

2. Insert the smallest pins of the SNAP-ON TERMINAL PICK

(Part No. GA500A) into the gaps on each side of the

socket to compress the tangs on each side of the terminal.

3. Gently pull on the wire to remove the terminal.

Figure A-5. Tangs: Bosch Compact 1.1M Socket Terminal

A-2 2013 Sportster Diagnostics: Appendix A Connector Repair

HOME

DELPHI 100W MICRO-PACK SEALED

CONNECTOR

A.3

DELPHI 100W MICRO-PACK SEALED

sm00038a

CONNECTOR REPAIR

General

A Delphi 100W Micro-Pack Sealed connector connects the

electronic control module (ECM) to the main harness.

Separating Socket Housing From ECM

See Figure A-6. While pressing the connector into the ECM,

press the thumb lever (1) against the connector until the latch

(2) pops out of the catch (3) on the ECM.

sm00037a

Latch

2. Secondary lock

3. Cable strap

Strain relief collar

Conduit

Figure A-7. Delphi 100W Micro-Pack Sealed Connector

Removing Socket Terminal

1. See Figure A-7. To remove, gently press latch (1) on each

side of the clear plastic secondary lock (2). For best res-

ults, release one side at a time.

1. Thumb lever

2. Latch

2. Carefully cut cable strap (3) to free strain relief collar (4)

3. Catch (ECM)

from conduit (5).

Figure A-6. Delphi 100W Micro-Pack Sealed Connector to

3. See Figure A-8. Using a thin blade, gently pry at seam at

ECM

back of socket housing to release three plastic pins (1)

from slots in housing. Separate and spread halves of

socket housing.

Mating Socket Housing To ECM

4. Push on wire lead to free terminal from chamber.

Push the connector into the ECM until the latch is captured by

the catch on the ECM.

Installing Socket Terminal

1. From inside socket housing, gently pull on wire to draw

terminal into chamber.

2. Exercising caution to avoid pinching wires, press halves

of socket housing together until three plastic pins fully

engage slots in housing.

3. Install new cable strap in groove of strain relief collar

capturing cable conduit.

4. With the two ribs on the secondary lock on the same side

as the external latch, install over terminals until latches

lock in place.

2013 Sportster Diagnostics: Appendix A Connector Repair A-3

Была ли эта страница вам полезна?

Да!Нет

9 посетителей считают эту страницу полезной.

Harley Davidson 2013 Sportster Models. Electrical Diagnostics Manual — page 12

Нет комментариевНе стесняйтесь поделиться с нами вашим ценным мнением.