Harley Davidson 2013 Sportster Models. Electrical Diagnostics Manual — page 4
HOME
1. Battery Test
STARTER SOLENOID CLICKS
1. Perform a battery test. See 3.1 BATTERY TESTING.
Table 3-9. Starter Solenoid Clicks Diagnostic Faults
2. Did battery pass test?
POSSIBLE CAUSES
a. Yes. Go to Test 2.
Low battery
b. No. Replace battery.
Starter malfunction
2. Starter Solenoid Control Coil Voltage Test
Starter solenoid malfunction
1. With IGN OFF, disconnect starter solenoid [128].
Open battery cable
2. Turn IGN ON.
Open starter cable
3. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
Mechanical binding
41404), test battery voltage on [128B] terminal 1 (GN)
wire.
1. Battery Test
1. Perform a battery test. See 3.1 BATTERY TESTING.
4. Is battery voltage present when start switch is pressed?
a. Yes. Replace starter solenoid assembly. (5845)
2. Did battery pass test?
a. Yes. Go to Test 2.
b. No. Go to Test 3.
b. No. Replace battery. Attempt to start engine. If starter
3. Starter Solenoid Control Coil Continuity
solenoid continues to click and starter does not
Test
engage, then continue with tests. Go to Test 2.
1. Turn IGN OFF and remove start relay.
2. Starter Voltage Test
2. Test continuity between [128B] terminal 1 and fuse block
1. With IGN ON, test battery voltage at starter solenoid ter-
[61B] socket terminal C (GN) wire.
minal 2 (BK) wire.
3. Is continuity present?
2. Is battery voltage present when start switch is pressed?
a. Yes.
See
1.3
DIAGNOSTICS
AND
a. Yes. Go to Test 3.
TROUBLESHOOTING, Relay Diagnostics. If relay
tests good, then continue with tests. Go to Test 4.
b. No. Go to Test 4.
b. No. Repair open between [128B] terminal 1 and [61B]
3. Starter Ground Test
socket terminal C (GN) wire. (5041)
1. Remove starter attaching bolts.
4. Start Solenoid Wiring Inspection Test
2. Clean bolts and starter base, install starter bolts.
1. Inspect for corrosion or damage to the wiring from [128A]
3. Does engine crank?
to starter solenoid.
a. Yes, engine cranks at normal speed. Repair com-
2. Are there any problems?
plete.
a. Yes. Repair damage or replace starter solenoid
b. Yes, engine cranks, but at a slower speed. See
assembly.
3.3 TESTING STARTER ON MOTORCYCLE, Starter
b. No. Go to Test 5.
Current Draw Test.
c. No. Replace starter. (5817)
5. Starter Solenoid Test
1. With IGN ON, press the start switch.
4. Starter Solenoid Voltage Drop Starter Side
2. Does starter solenoid click?
Test
a. Yes. See 3.2 STARTING SYSTEM, Starter Solenoid
1. Perform voltage drop test from battery (+) terminal to
Clicks.
starter solenoid terminal 2 (BK) wire.
b. No. Repair open in [61B] socket terminal J (R/BK)
2. Is voltage drop greater than 1.0V?
wire. (5041)
a. Yes. Go to Test 5.
b. No. Go to Test 6.
5. Starter Solenoid Battery Side Voltage
Drop Test
1. Perform voltage drop test from battery (+) terminal to
starter solenoid terminal 1 (BK) wire.
3-10 2013 Sportster Diagnostics: Starting and Charging
HOME
2. Is voltage drop greater than 1.0V?
STARTER STALLS OR SPINS TOO SLOWLY
a. Yes. Repair or replace (BK) wire from starter solenoid
terminal 1 to battery (+) terminal. (5041)
Table 3-11. Starter Stalls or Spins Too Slowly Diagnostic
b. No. Replace starter solenoid assembly. (5845)
Faults
POSSIBLE CAUSES
6. Starter Ground Circuit Voltage Drop Test
Low battery
1. Perform voltage drop test from battery (-) terminal to starter
Starter malfunction
attaching bolts.
Starter solenoid malfunction
2. Is voltage drop greater than 1.0V?
Poor connections at starter ground
a. Yes. Repair or replace (BK) wire from battery (-) ter-
minal or clean ground connections. (5041)
Open battery cable
b. No. Go to Test 7.
Open starter cable
ACR malfunction (if equipped)
7. Starter Draw Test
1. Battery Test
1. Perform Starter Current Draw Test on motorcycle. See
3.3 TESTING STARTER ON MOTORCYCLE, Starter
1. Perform a battery test. See 3.1 BATTERY TESTING.
Current Draw Test.
2. Did battery pass test?
2. Perform Starter Motor Free Running Current Draw Test
a. Yes. Go to Test 2.
(on bench). See 3.4 TESTING STARTER ON BENCH,
Free Running Current Draw Test.
b. No. Replace battery. If symptom continues, then
continue with tests. Go to Test 2.
3. Are test results within range?
a. Yes. Go to Test 8.
2. Starter Stud Voltage Drop Test
b. No. Replace starter. (5817)
1. Perform voltage drop test from battery (+) terminal to
starter solenoid terminal
2 (BK) wire. See
1.3 DIA-
8. Mechanical Binding Test
GNOSTICS AND TROUBLESHOOTING, Voltage Drop.
1. Remove spark plugs and place transmission in 5th gear.
2. Is voltage drop greater than 1.0V?
2. Raise vehicle.
a. Yes. Go to
Test 5.
3. Rotate rear wheel.
b. No. Go to Test 3.
4. Check for engine binding in the primary and/or crankshaft
3. Starter Ground Circuit Voltage Drop Test
or starter clutch.
1. Perform voltage drop test between battery (-) terminal and
5. Is engine binding?
starter attaching bolts.
a. Yes. Repair as needed. (Use appropriate code).
2. Is voltage drop greater than 1.0V?
b. No. Replace starter solenoid assembly. (5845)
a. Yes. Clean ground connections. (5041)
b. No. Go to Test 4.
STARTER SPINS BUT DOES NOT ENGAGE
4. Starter Draw Test
Table 3-10. Starter Spins But Does Not Engage Diagnostic
Faults
1. Perform Starter Current Draw Test on motorcycle. See
3.3 TESTING STARTER ON MOTORCYCLE, Starter
POSSIBLE CAUSES
Current Draw Test.
Pinion gear
2. Perform Starter Motor Free Running Current Draw Test
Starter clutch
(on bench). See 3.4 TESTING STARTER ON BENCH,
Free Running Current Draw Test.
Clutch shell and sprocket
3. Are test results within range?
1. Pinion Gear and Clutch Shell Test
a. Yes. With the spark plugs removed and the transmis-
1. Remove primary cover.
sion in 5th gear, rotate rear wheel. Check for engine,
primary and/or crankshaft bind. (Use appropriate
2. Inspect for damage to starter pinion gear and clutch shell
code.)
and sprocket.
b. No. Replace starter. (5817)
3. Is damage present?
a. Yes. Replace the clutch assembly or clutch shell and
sprocket. (5825)
b. No. Replace the starter clutch assembly. (5837)
2013 Sportster Diagnostics: Starting and Charging 3-11
HOME
2. Is voltage drop greater than 1.0V?
5. Starter Solenoid Voltage Drop Starter Side
a. Yes. Repair or replace connection between battery
Test
(+) terminal and starter solenoid terminal 1 (R) wire.
1. Perform voltage drop test between battery (+) terminal to
(5041)
starter solenoid terminal 1.
b. No. Replace starter solenoid assembly. (5845)
3-12 2013 Sportster Diagnostics: Starting and Charging
HOME
TESTING STARTER ON MOTORCYCLE
3.3
4. Clamp induction ammeter over positive starter cable to
STARTER CURRENT DRAW TEST
starter solenoid.
PART NUMBER
TOOL NAME
NOTE
In next step with engine stop switch in OFF position and purple
HD-41404
HARNESS CONNECTOR TEST KIT
male probes connected to the [61B] terminals C and J in place
of the start relay, starter will turn but engine will not start. This
NOTES
configuration also prevents diagnostic trouble codes from being
•
Engine temperature should be stable and at room temper-
set.
ature.
5. With IGN ON, read the ammeter. Disregard initial high
•
Battery should be fully charged.
current reading which is normal when engine is first turned
Check starter current draw with an induction ammeter before
over.
disconnecting battery. Proceed as follows:
a. Typical starter current draw will range between 160-
200A.
1. Verify that transmission is in neutral and engine stop switch
is in OFF position.
b. If starter current draw exceeds
250A, then the
problem may be in the starter or starter drive. See
2. Remove start relay.
3.4 TESTING STARTER ON BENCH, Free Running
3. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
Current Draw Test.
41404), connect patch cord to fuse block [61B] socket
terminals C and J.
2013 Sportster Diagnostics: Starting and Charging 3-13
HOME
TESTING STARTER ON BENCH
3.4
FREE RUNNING CURRENT DRAW TEST
STARTER SOLENOID
1. Place starter in vise, using a clean shop towel to prevent
Do not disassemble solenoid. Before testing, disconnect field
scratches or other damage.
wire from solenoid motor terminal as shown in Figure 3-6.
2. See Figure 3-5. Attach one heavy jumper cable (6 gauge
Perform each test for only 3-5 seconds to prevent damage to
minimum).
solenoid.
a. Connect one end to the starter mounting flange.
Perform the solenoid Pull-in, Hold-in and Return tests together
in one continuous operation. Conduct all three tests one after
b. Connect the other end to the battery (-) terminal of a
the other in the sequence given without interruption.
fully charged battery.
SOLENOID PULL-IN TEST
3. Connect a second heavy jumper cable (6 gauge minimum).
1. See Figure 3-6. Using a 12V battery, connect three sep-
a. Connect one end to the battery (+) terminal of the
arate test leads as follows:
battery.
a. Solenoid housing to negative battery post.
b. Connect the other end to the battery terminal on the
starter. Place an induction ammeter over cable.
b. Solenoid motor terminal to negative battery post.
c. Solenoid relay terminal to positive battery post.
2. Observe starter shaft.
Keep fingers and clothing away from starter gear to pre-
a. If starter shaft extends strongly, solenoid is working
vent personal injury. (00613b)
properly.
4. Connect a smaller jumper cable (14 gauge minimum).
b. If starter shaft does not extend strongly, replace
a. Connect one end to the positive (+) terminal of the
solenoid assembly.
battery.
b. Connect the other end to the solenoid relay terminal.
ed02866
5. Check ammeter reading.
a. Ammeter should show 90A max.
b. If reading is higher, replace
starter.
1
c. If starter current draw on vehicle was over 200A and
this test was within specification, there may be a
problem with engine or primary drive.
ed02865
4
2
2
3
1. Battery
1
4
2. Solenoid housing
3. Solenoid relay terminal
4. Solenoid motor terminal
Figure 3-6. Pull-In Test
3
SOLENOID HOLD-IN TEST
5
1. See Figure 3-7. With test leads still connected in the
manner specified in the previous 3.4 TESTING STARTER
1. Mounting flange
ON BENCH, Solenoid Pull-In Test, disconnect solenoid
2. Battery
motor terminal/battery negative test lead at negative bat-
3. Induction ammeter
tery post only; reconnect loose end of this test lead to
4. Battery terminal
positive battery post instead.
5. Relay terminal
Figure 3-5. Free Running Current Draw Test
3-14 2013 Sportster Diagnostics: Starting and Charging
HOME
2. Observe starter shaft.
ON BENCH, Solenoid Hold-In Test, disconnect solenoid
relay terminal/positive battery post test lead at either end.
a. If starter shaft remains extended, solenoid is working
properly.
2. Observe starter pinion.
b. If starter shaft retracts, replace solenoid assembly.
a. If starter shaft retracts, solenoid is working properly.
b. If starter shaft does not retract, replace solenoid
ed02867
assembly.
ed02868
1
1
4
2
3
4
1. Battery
2
2. Solenoid housing
3
3. Solenoid relay terminal
1. Battery
4. Solenoid motor terminal
2. Solenoid housing
Figure 3-7. Hold-In Test
3. Solenoid relay terminal
4. Solenoid motor terminal
SOLENOID RETURN TEST
Figure 3-8. Return Test
1. See Figure 3-8. With test leads still connected
in the
manner specified at the end of 3.4 TESTING STARTER
2013 Sportster Diagnostics: Starting and Charging 3-15
HOME
CHARGING SYSTEM
3.5
lator will resume normal operation. This sequence will repeat
DESCRIPTION AND OPERATION
if the excessive temperatures are again detected.
The charging system is the source of electric current that sup-
plies power to run the ignition, lights, accessories, and charge
TROUBLESHOOTING
the battery. AC voltage is generated by an alternator assembly
Battery
driven by the crankshaft. A rotor supplied with a magnetic field
spins around a stator. A rectifier (located in the regulator)
Test for a weak or dead battery. Battery must be fully charged
converts the voltage from AC to DC. A regulator ensures that
in order to perform a conductance test, load test or starting or
the output voltage is properly matched to the battery voltage
charging tests. See 3.1 BATTERY TESTING.
as engine speed varies. Even though the alternator provides
additional voltage at all engine speeds, it is not recommended
Wiring
to idle the vehicle for long periods of time.
The stator connections must be clean and tight.
Alternator
Check for corroded or loose connections in the charging system
circuit.
The alternator consists of two main components:
•
The rotor which mounts to the primary side of the crank-
Voltage Regulator Inspection
shaft.
The voltage regulator must have clean, tight connections for
proper operation. Verify both AC and DC connectors are fully
•
The stator which is attached to the crankcase half.
inserted and locked with the regulator latch.
Voltage Regulator
Job/Time Code Values
See Figure 3-9. The voltage regulator is a series regulator.
Dealership Technicians filing warranty claims should use the
The circuit combines the functions of rectifying and regulating.
job/time code values printed in bold text next to the appropriate
The voltage regulator has a high temperature protection shut-
repair.
down circuit that will turn off the charging system if the regulator
reaches an over temperature condition. If this occurs, the
Connector Information
charging system will turn off until the regulator temperature
For additional information about the connectors in the following
cools to a safe operating temperature, at which time the regu-
diagram(s) and diagnostic procedure(s), including the color of
the harness test kit terminal probes, see B.1 CONNECTORS.
em00657
BK
BK
Stator
[47B]
1 2
[47A]
1 2
Main Fuse
30A
Voltage
Regulator
-
+
[77A]
[5B]
-
+
[77B]
B
A
R
BK
Battery
To Ignition
Battery
GND 1
Switch
Ground
Figure 3-9. Charging System Circuit
3-16 2013 Sportster Diagnostics: Starting and Charging
HOME
4. Is rotor in good condition?
LOW OR NO CHARGING
a. Yes. Go to Test 6.
Table 3-12. Low or No Charging Diagnostic Faults
b. No. Replace rotor. (5319)
POSSIBLE CAUSES
6. Voltage Regulator Power Circuit Test
Low battery
1. With IGN OFF, disconnect voltage regulator [77].
Stator malfunction
2. Test continuity between [77B] terminal + and main fuse
Rotor malfunction
[5B].
Voltage regulator malfunction
3. Is continuity present?
Open voltage regulator circuit
a. Yes. Go to Test 7.
Stator shorted to ground
b. No. Repair or replace wire between [77B] terminal +
AC wire shorted to ground
and [5B]. (5041)
1. Battery Test
7. Voltage Regulator Ground Circuit Test
1. Perform a battery test. See 3.1 BATTERY TESTING.
NOTE
2. Did battery pass test?
The voltage regulator ground must have a clean, tight connec-
tion for proper grounding.
a. Yes. Go to Test 2.
1. Test resistance between voltage regulator [77B] terminal
b. No. Replace battery. Verify repair.
- and ground.
NOTE
2. Is resistance less than 0.5 Ohms?
A discharged battery may show a reading under 13V even
a. Yes. Replace voltage regulator. (5316)
though the charging system is working properly.
b. No. Repair or replace wire between [77B] terminal -
2. Off Idle Voltage Test
and GND 1 (BK) wire. (5041)
1. With vehicle in neutral, start engine and run at 3000 rpm.
OVERCHARGING
2. Test battery voltage.
3. Is voltage above 13V?
Table 3-13. Overcharging Diagnostic Faults
a. Yes. Charging system working properly.
POSSIBLE CAUSES
b. No. Go to Test 3.
Voltage regulator malfunction
Open in GND 1 circuit
3. AC Output Test
1. Battery Voltage Test
1. Perform an AC output test. See 3.5 CHARGING SYSTEM,
Battery Charging Tests.
1. With the vehicle in neutral, start engine and run at 3000
rpm, test battery voltage.
2. Did the output test pass?
a. Yes. Go to Test 6.
2. Is voltage above 15.5V?
a. Yes. Go to Test 2.
b. No. Go to Test 4.
b. No. Charging system working properly.
4. Stator Test
1. Perform stator test. See 3.5 CHARGING SYSTEM, Battery
2. Voltage Regulator Ground Circuit Test
Charging Tests.
NOTE
2. Is the stator good?
The voltage regulator ground must have a clean, tight connec-
a. Yes. Go to Test 5.
tion for proper grounding.
b. No. Replace stator. (5309)
1. With IGN OFF, disconnect voltage regulator [77].
2. Test resistance between voltage regulator [77B] terminal
5. Rotor Inspection Test
- and ground.
1. Inspect rotor for damage.
3. Is resistance less than 0.5 Ohms?
2. Inspect for loose rotor fastener and worn splines.
a. Yes. Replace voltage regulator. (5316)
3. Verify that stator bolts have not backed out and contacted
b. No. Repair open wire between voltage regulator [77B]
the rotor.
terminal - and GND 1 (BK) wire. (5041)
2013 Sportster Diagnostics: Starting and Charging 3-17
HOME
LOW BATTERY AFTER EXTENDED IGN OFF
BATTERY CHARGING TESTS
Table 3-14. Low Battery After Extended IGN OFF
PART NUMBER
TOOL NAME
Diagnostic Faults
HD-41404
HARNESS CONNECTOR TEST KIT
POSSIBLE CAUSES
Milliampere Draw Test
Battery
NOTE
Accessories improperly wired to stay on at all times
Be sure accessories are not wired so they stay on at all times.
Excessive draw from electrical component with IGN OFF
This condition could drain battery completely if vehicle is parked
Battery self-discharge and/or component draw because
for a long time. Test for this by connecting ammeter between
motorcycle was not operated for a long period
negative battery terminal and battery.
1. Battery Test
1. If vehicle is equipped with HFSM, enable service mode
before performing test.
1. Verify battery condition. See 3.1 BATTERY TESTING.
2. Disconnect the security siren (if equipped).
2. Is battery condition good?
3. Remove main fuse.
a. Yes. Go to Test 2.
NOTE
b. No. Replace battery.
With IGN OFF, an initial current draw of up to 200 mA will occur
directly after connecting meter. This should drop to the values
2. Amp Draw Test
shown in Table 3-16 in less than one minute.
1. Perform milliampere draw test. See
3.5 CHARGING
4. See Figure 3-10. Using HARNESS CONNECTOR TEST
SYSTEM, Battery Charging Tests.
KIT (Part No. HD-41404), connect ammeter to main fuse
2. Did the test exceed maximum draw?
socket terminals. With this arrangement, you will pick up
a. Yes. Repair excessive draw and run test again. (5308)
any drain.
b. No. System is working properly.
5. With IGN OFF and all lights and accessories off, observe
current reading.
BATTERY RUNS DOWN DURING USE
a. Add voltage regulator draw to appropriate value for
TSM, TSSM or HFSM and ECM. If observed ammeter
reading is less than listed in table, draw is within limits.
Table 3-15. Battery Runs Down During Use Diagnostic
Refer to Table 3-16.
Faults
b. A higher reading indicates excessive current draw.
POSSIBLE CAUSES
Check all accessories for excessive drain.
Low battery
Excessive accessory draw
Table 3-16. Milliampere Draw Test
Accessories on when idling or low rpm riding for extended
period
ITEM
MAXIMUM DRAW IN MILLI-
AMPERES
1. Total Current Draw Test
Speedometer
1.0
1. Perform Total Current Draw and Output Test. See
T
achometer (if equipped)
1.0
3.5 CHARGING SYSTEM, Battery Charging Tests.
Regulator
1.0
2. Does charging system exceed current draw by 3.5A?
TSM (non security models)
1.0
a. Yes. Go to Test 2.
TSSM (disarmed)
3.0
b. No. System accessory power requirements exceed
TSSM (armed)
3.0
charging system capability.
TSSM
or HFSM-Storage mode
1.0
(armed or disarmed)
2. Battery Test
HFSM
1.0
1. Perform a battery test. See 3.1 BATTERY TESTING.
ECM
1.0
2. Did battery pass test?
Security siren (optional)
20.0*
a. Yes. System is working properly.
* Siren will draw for 2-24 hours from time motorcycle battery
b. No. Replace battery.
is connected and 0.05 mA once siren battery is charged.
Disconnect siren during milliampere draw test.
3-18 2013 Sportster Diagnostics: Starting and Charging
HOME
em00656
ed02802
1
[47A]
1
2
1
3
-
+
[77A]
-
+
[77B]
2
3
[5B]
2
B
A
1. Load tester
2. Induction pickup
GND 1
3. Battery
Figure 3-11. Check Current Draw (Ignition Switch On)
R
1. See Figure 3-11. Connect load tester.
a. Connect negative and positive leads to battery ter-
1. Ammeter
minals.
2. Main fuse socket
3. Voltage regulator
b. Place load tester induction pickup over battery neg-
ative cable.
Figure 3-10. Milliampere Draw Test (Ignition Turned to
OFF)
2. With IGN OFF, disconnect voltage regulator [77].
3. Start engine.
Total Current Draw and Output Test
4. Turn all continuously running lights and accessories ON
If battery runs down during use, the current draw
of the
(headlamp on high beam).
motorcycle components and accessories may exceed
output
of the charging system.
5. Run engine at 3000 rpm and make note of the current
draw.
NOTE
If a load tester is unavailable, use an ammeter with current
6. Turn engine OFF.
probe.
7. With IGN OFF, connect voltage regulator [77].
8. Remove the induction pickup from the battery negative
cable.
Turn battery load tester OFF before connecting tester
9. Place induction pickup over positive regulator cable.
cables to battery terminals. Connecting tester cables with
load tester ON can cause a spark and battery explosion,
10. Start engine and run at 3000 rpm.
which could result in death or serious injury. (00252a)
NOTE
Do not leave any load switch turned on for more than 20
seconds or overheating and tester damage are possible.
11. Increase the load as required to obtain a constant 13.0V.
12. Current output should be 24-30A. Make note of current
output.
NOTE
Rider's habits may require output test at lower rpm.
13. Compare both of these readings.
a. The current output should exceed current draw by
3.5A minimum.
b. If output does not meet specifications, there may be
too many accessories for the charging system to
handle.
2013 Sportster Diagnostics: Starting and Charging 3-19
HOME
multimeter user's manual to either zero the display or manually
Stator Test
subtract the test lead resistance from the measured circuit's
value.
ed03182
ed03245
0
Figure 3-13. Check for Stator Resistance (Typical)
AC Output Test
1. See Figure 3-14. Test AC output.
Figure 3-12. Test for Grounded Stator (Typical)
a. Disconnect voltage regulator
[47] from alternator
stator wiring.
1.
Turn IGN OFF.
b. Test for VAC across stator [47B] terminals 1 to 2.
2.
See Figure 3-12. Connect an ohmmeter.
c. Run the engine at 2000 rpm. The VAC output should
a. Disconnect voltage regulator [47] from stator wiring.
be 40-56 VAC (approximately 20-28 per 1000 ).
b. Insert one ohmmeter lead
into a stator connector
2. Compare test results to specifications.
socket.
a. If the output is below specifications, charging problem
c. Attach the other lead to a suitable ground.
could be a faulty rotor or stator.
3.
Test for continuity.
3. Check the output again as previously described under
Total Current Draw and Output Test.
a. A good stator will show no continuity (open circuit)
between all stator sockets and ground.
ed03246
b. Any other reading indicates a grounded stator which
must be replaced.
0
4.
See Figure 3-13. Remove ground lead. Measure resist-
ance across stator [47B] terminals 1-2.
a. Resistance across all the stator terminals should be
0.1-0.3 Ohm.
b. If the resistance is higher, the stator is damaged and
must be replaced.
c. If resistance is lower, the stator may have a turn-to-
turn short and should be replaced.
NOTE
When measuring resistance (Ohms), compensate for test lead
resistance before performing the measurement. Select the
Figure 3-14. Check Stator AC Voltage Output (Typical)
Ohms position and touch the test leads together. Refer to the
3-20 2013 Sportster Diagnostics: Starting and Charging
HOME
DTC B0563,
P0562, P0563
3.6
DESCRIPTION AND OPERATION
DIAGNOSTICS
Battery voltage is monitored by several modules. The modules
Diagnostic Tips
set DTCs if the battery voltage fails to meet the parameters.
Any of the following conditions could cause these DTCs to set:
DTC B0563
•
The vehicle is placed on a battery charger, on fast charge,
Battery voltage is monitored by the TSM, TSSM or HFSM on
for a long period of time.
terminal 1. DTC B0563 is displayed when the TSM, TSSM or
•
The charging system is malfunctioning.
HFSM exceeds 16.0V for more than 5.0 ±0.5 seconds.
•
There is excessive battery draw and/or extended idling in
DTC P0562 and P0563
heavy traffic.
Battery voltage is monitored by the ECM on terminal 72.
•
A faulty system ground is present.
•
DTC P0562 is displayed when battery voltage is less than
Low voltage generally indicates a loose wire, corroded connec-
12.2V at idle and voltage does not increase when engine
tions, battery and/or a charging system problem.
speed is greater than 2000 rpm.
High voltage DTC may set when the vehicle is placed on a
•
DTC P0563 is displayed when battery voltage is greater
battery charger, for a long period of time.
than 15.0V for more than 4 seconds.
Connector Information
Table 3-17. Code Description
For additional information about the connectors in the following
diagram(s) and diagnostic procedure(s), including the color of
DTC
DESCRIPTION
the harness test kit terminal probes, see B.1 CONNECTORS.
B0563
TSM, TSSM or HFSM voltage high
P0562
ECM voltage low
P0563
ECM voltage high
2013 Sportster Diagnostics: Starting and Charging 3-21
HOME
Main Fuse
Ignition Switch
em01326
30A
IGN
ACC
BK
R
OFF
[5B]
B+
ACC
IGN
A
B
Battery
Ground
Ignition
15A
GY
B
A
R/BK
[77B]
-
+
Battery
[77A]
-
+
15A
GND 1
BN/GY
R
P
R
ACCY
15A
O/W
O
M
R/GY
Voltage
Regulator
System
Relay
E
5
87
L
3
30
K
1
86
W/BK
F
2
85
[61B]
TSM, TSSM, HFSM
Battery
1
1
BN/GY
W/BK
4
4
W/BK
Engine
Tachometer
Stop Switch
O/W
6
6
Ground
12
12
BK
GY
3
3
GY
XR
O
1
1
[20B] [20A]
[30A] [30B]
[22B] [22A]
BK
7
7
ECM
O/W
1
1
O/W
[108B] [108A]
GY
6
6
O
Switch Power
13
13
W/BK
Speedometer
BK
BK
12
12
BK
Ground
10
10
O/W
6
6
Ground
28
28
BK
O
1
1
XL
BK
7
7
[78A] [78B]
GND 1
[39B] [39A]
Figure 3-15. High and Low Voltage Sensors
DTC P0562
2. Did battery pass test?
a. Yes. Go to Test 2.
PART NUMBER
TOOL NAME
b. No. Replace battery. Verify repair.
HD-41404
HARNESS CONNECTOR TEST KIT
2. Charging System Test
HD-43876
BREAKOUT BOX
1. Perform charging system test. See
3.5 CHARGING
SYSTEM, Low or No Charging.
Table 3-18. DTC P0562 Diagnostic Faults
2. Is charging system working properly?
POSSIBLE CAUSES
a. Yes. Go to Test 3.
Low battery
b. No. Repair charging system.
Ignition switch malfunction
Engine stop switch malfunction
3. ECM Switched Voltage Test
Open ECM ground circuit
1. Turn IGN OFF.
Open ECM switched power circuit
2. Disconnect ECM [78].
Open ignition circuit
3. Connect BREAKOUT BOX (Part No. HD-43876) between
wire harness [78A] and [78B]. See 1.2 DIAGNOSTIC
1. Battery Test
TOOLS.
1. Perform a battery test. See 3.1 BATTERY TESTING.
3-22 2013 Sportster Diagnostics: Starting and Charging
HOME
4. With engine stop switch in the RUN position and transmis-
2. Is resistance greater than 1 Ohm?
sion in neutral, turn the IGN ON.
a. Yes. Repair (GY) wire between [61B] socket terminal
B and [22B] terminal 3.
5. Test voltage between terminals BOB 13 and 28.
b. No. Go to Test 9.
6. Is battery voltage present?
a. Yes. System is working properly.
9. Engine Stop Switch Test
b. No. Go to Test 4.
1. Test resistance between [22A] terminals 4 (GY) wire and
3 (W/BK) wire.
4. ECM Switched Voltage Drop Test
2. Is resistance greater than 1 Ohm?
1. Perform a voltage drop test between battery (+) terminal
a. Yes. Replace the engine stop switch assembly.
and BOB terminal 13. See 1.3 DIAGNOSTICS AND
TROUBLESHOOTING, Voltage Drop.
b. No. Go to Test 10.
2. Is voltage drop greater than 0.5V?
10. Ignition Circuit Voltage Drop Test
a. Yes. Go to Test 6.
1. With IGN ON, perform a voltage drop test between battery
b. No. Go to Test 5.
(+) terminal and [61B] terminal A. See 1.3 DIAGNOSTICS
AND TROUBLESHOOTING, Voltage Drop.
5. ECM Ground Circuit Voltage Drop Test
2. Is voltage drop greater than 0.5V?
1. Perform a voltage drop test between BOB terminals 10
a. Yes. Go to Test 11.
and 28 and battery (-) terminal.
b. No. Go to Test 13.
2. Is voltage drop greater than 0.5V?
a. Yes. Repair wiring between ECM [78B] terminals 10
11. Ignition Circuit Resistance Test
and 28 and battery negative.
1. With IGN OFF, remove main fuse [5].
b. No. Problem may be intermittent. Locate and repair
bad connection. Perform 1.3 DIAGNOSTICS AND
2. Turn IGN ON.
TROUBLESHOOTING, Wiggle Test.
3. Test resistance between main fuse [5B] terminal B and
[61B] socket terminal A.
6. ECM Switched Power Circuit Resistance
4. Is resistance greater than 1 Ohm?
Test
a. Yes. Replace ignition switch or repair wire between
1. With IGN OFF, remove system relay.
main fuse [5B]
terminal B and [61B] socket terminal
2. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
A.
41404), test resistance between BOB terminal 13 and fuse
b. No. Go to Test 12.
block [61B] socket terminal F (W/BK) wire.
3. Is resistance greater than 1 Ohm?
12. Ignition Switch Battery Circuit Voltage
a. Yes. Repair (W/BK) wire between ECM [78B] terminal
Drop Test
13 and [61B] socket terminal F.
1. Perform a voltage drop test between battery (+) terminal
b. No. Go to Test 7.
and [5B] terminal A (R) wire.
2. Is voltage drop greater than 0.5V?
7. Switched Power Circuit Resistance Test
a. Yes. Replace main fuse. Go to Test 13.
1. Disconnect right hand controls [22].
b. No. Repair wire between battery terminal (+) and main
2. Test resistance between [22B] terminal 4 and [61B] socket
fuse [5B] terminal A.
terminal F (W/BK) wire.
3. Is resistance greater than 1 Ohm?
13. Repair Validation Test
a. Yes. Repair (W/BK) wire between [22B] terminal 4
1. Clear DTCs. See 2.1 INITIAL DIAGNOSTICS, Odometer
and [61B] socket terminal F.
Self-Diagnostics.
b. No. Go to Test 8.
2. Start vehicle.
3. Run at 3000 rpm for 5 seconds.
8. Ignition Circuit Resistance Test
4. Does code set?
1. Test resistance between ignition fuse [61B] socket terminal
B and [22B] terminal 3 (GY) wire.
a. Yes. Replace ECM.
b. No. System working properly.
2013 Sportster Diagnostics: Starting and Charging 3-23
HOME
DTC B0563, P0563
2. Repair Validation Test
1. Clear DTCs using odometer self-diagnostics. See
Table 3-19. DTC B0563, P0563 Diagnostic Faults
2.1 INITIAL DIAGNOSTICS, Odometer Self-Diagnostics.
POSSIBLE CAUSES
2. Start vehicle.
Charging system malfunction
3. Run at 3000 rpm for 5 seconds.
4. Does code set?
1. Charging System Test
a. Yes, DTC B0563. Replace TSM, TSSM or HFSM.
1. Perform charging system tests. See
3.5 CHARGING
SYSTEM.
b. Yes, DTC P0563. Replace ECM.
2. Is charging system good?
c. No. System working properly.
a. Yes. Go to Test 2.
b. No. Repair charging system.
3-24 2013 Sportster Diagnostics: Starting and Charging
HOME
DTC B1006,
B1007
3.7
DESCRIPTION AND OPERATION
Table 3-20. Code Description
Battery voltage is constantly monitored by the speedometer
DTC
DESCRIPTION
(XL) and tachometer (XR). If the battery voltage fails to meet
normal operating parameters, a DTC is set.
B1006
Accessory line overvoltage
DTC B1006 and B1007
B1007
Ignition line overvoltage
The speedometer (XL) and tachometer (XR) monitors terminal
Diagnostic Tips
1 for ignition power, and terminal 6 for accessory power.
Voltage high DTC may set when the vehicle is placed on a
•
DTC B1006 is displayed when accessory line voltage is
battery charger, on fast charge, for a long period of time.
greater than 16.0V for longer than 5 seconds.
DTC B1006, B1007
•
DTC B1007 is displayed when ignition line voltage is
greater than 16.0V for longer than 5 seconds.
Table 3-21. DTC B1006, B1007 Diagnostic Faults
NOTE
POSSIBLE CAUSES
ECM, ECU, and/or TSM, TSSM or HFSM may also set a battery
Charging system malfunction
voltage DTC.
1. Charging System Test
ed01991
1. Perform charging system tests. See
3.5 CHARGING
SYSTEM.
2. Is charging system good?
a. Yes. Go to Test 2.
b. No. Repair charging system.
2. Repair Validation Test
1. Clear
DTCs using odometer self-diagnostics. See
2.1 INITIAL DIAGNOSTICS, Odometer Self-Diagnostics.
2. Start vehicle.
3. Run at 3000 rpm for 5 seconds.
4. Does code reset?
Figure 3-16. Speedometer [39]: XL
a. Yes, XL. Replace speedometer.
b. Yes, XR. Replace tachometer.
ed01992
c. No. System working properly.
1
2
3
1. Tachometer [108]
2. Speedometer [39]
3. Trip odometer reset switch
Figure 3-17. Instruments: XR
2013 Sportster Diagnostics: Starting and Charging 3-25
NOTES
3-26 2013 Sportster Diagnostics: Starting and Charging
TABLE OF CONTENTS
SUBJECT
PAGE NO.
4.1 INSTRUMENTS
4-1
4.2 DTC B1004, B1005
4-3
4.3 DTC B1008
4-6
4.4 NO INSTRUMENT POWER
4-7
4.5 INDICATOR LAMPS
4-11
NOTES
HOME
INSTRUMENTS
4.1
DESCRIPTION AND OPERATION
Trip Odometer Reset Switch Operation
The instruments on the XL and XR look significantly different
Pressing the trip odometer reset switch provides the following
but do many of the same functions:
capabilities:
•
The XL has only a speedometer, which contains the check
•
Change the odometer display between mileage, trip and
engine lamp, low fuel lamp, battery lamp, security lamp
fuel range values (press and immediately release).
and the sixth gear indicator, which is not used.
•
Reset the trip odometer (press and hold 2-3 seconds).
•
The XR has a speedometer that displays vehicle speed
•
Gain access to self-diagnostic mode and clear diagnostic
in a digital output, and a tachometer. All the functions,
codes. See 2.1 INITIAL DIAGNOSTICS, Odometer Self-
including the indicators, the odometer and the trip odo-
Diagnostics.
meter reset switch, are located in the tachometer.
The odometer mileage is permanently stored and will not be
lost when electrical power is turned off or disconnected. The
trip odometer reset switch allows switching between the odo-
meter, trip odometer and fuel range displays.
To zero the trip odometer, have the odometer display visible,
press and keep the trip odometer reset switch depressed. The
trip odometer mileage will be displayed for 2-3 seconds and
then the trip mileage will return to zero miles.
ed03198
6
7
3
4
7
8
3
10
8
9
6
9
5
5
2
1
1. Instruments:
XL models
6. Check engine lamp
2. Instruments:
XR 1200X
7.
Low fuel lamp
3. Speedometer
8.
Battery lamp
4. Tachometer: XR 1200X
9.
Security system lamp
5. Odometer
10. Temperature lamp
Figure 4-1. Instruments
Selecting Instrument Units: XR Models
3. Press and hold the trip odometer reset switch until the
units change (miles/kilometers).
The instrument units can be displayed in miles or kilometers.
4. To change the units again, release trip odometer reset
1. Turn the ignition switch to the ACC or ON position.
switch, then press and hold until units change again.
2. Press the trip odometer reset switch to select the odometer
SPEEDOMETER THEORY OF OPERATION
display screen.
The speed sensor is mounted on the right side of transmission
case. The sensor circuitry is a Hall-Effect sensor that is
2013 Sportster Diagnostics: Instruments 4-1
Большое спасибо!
Ваше мнение очень важно для нас.
Нет комментариевНе стесняйтесь поделиться с нами вашим ценным мнением.
Текст