Harley Davidson 2013 Sportster Models. Electrical Diagnostics Manual — page 2
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1
1
2
5
3
4
1. Harness ground [GND1]
2. Starter
3. Battery to starter
4. VSS [65]
2
5. Battery ground
Figure 1-18. Grounds
1. Starter
2. Starter solenoid [128]
Figure 1-19. Starter Solenoid [128]
1-6 2013 Sportster Diagnostics: General Information
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DIAGNOSTIC
TOOLS
1.2
HOW TO USE DIAGNOSTIC TOOLS
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PART NUMBER
TOOL NAME
GRX-3110 HD
BATTERY DIAGNOSTIC STATION
HD-26792
SPARK TESTER
HD-34730-2E
FUEL INJECTOR TEST LIGHT
HD-39978
DIGITAL MULTIMETER (FLUKE 78)
HD-41199-3
IAC TEST LIGHT
HD-41404
HARNESS CONNECTOR TEST KIT
HD-42682
BREAKOUT BOX
HD-43876
BREAKOUT BOX
HD-44687
IGNITION COIL CIRCUIT TEST
ADAPTER
Figure 1-21. Spark Tester
HD-46601
BREAKOUT BOX ADAPTERS
HD-48650
DIGITAL TECHNICIAN II
HD-34730-2E Fuel Injector Test Light
The FUEL INJECTOR TEST LIGHT (Part No. HD-34730-2E)
GRX-3110 HD Battery Diagnostic Station
and IGNITION COIL CIRCUIT TEST ADAPTER (Part No. HD-
44687) are used to test the fuel injector drivers as well as the
Follow the instructions in the BATTERY DIAGNOSTIC STA-
ignition coil drivers in the ECM.
TION (Part No. GRX-3110 HD) instruction manual to perform
a battery test. The test results include a decision on the battery
1. Connect the BREAKOUT BOX (Part No. HD-43876).
condition.
2. Disconnect the fuel injector connectors.
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3. See Figure 1-22 for typical setup. Connect one side of the
fuel injector test
light to power and the other to the terminal
on the ECM for the circuit you are testing.
4. Crank the engine.
5. If the test light flashes, the circuit is working properly.
Figure 1-20. Advanced Battery Conductance and Electrical
System Analyzer Kit
HD-26792 Spark Tester
See Figure 1-21. The SPARK TESTER (Part No. HD-26792)
is used to verify adequate spark at the spark plug. Attach the
tester to the coil or spark plug cable and to ground. While
cranking the engine, a spark should jump across the gap on
the tester leads.
NOTE
The ignition system will not spark with both spark plugs
removed. When checking for spark, use SPARK TESTER (Part
No. HD-26792) with both plugs installed.
2013 Sportster Diagnostics: General Information 1-7
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2. Turn IGN ON for 2 seconds, then turn IGN OFF for 10
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seconds. Test light behavior may follow two patterns. The
2
color of the lights is not relevant to IAC operation.
1
a. Normal behavior: At IGN ON, test lights will altern-
ately flash and then remain on to confirm ECM sig-
nals. At IGN OFF, lights alternately flash and go out
after 10 second reset procedure.
b. Problem indicated: One or more lights fail to illu-
minate during IGN ON/IGN OFF cycle.
NOTE
There is a remote possibility that one of the circuits is
shorted to voltage which would have been indicated by a
steady light. Disconnect ECM and turn ignition ON. Probe
terminals to check for this condition.
3. Disconnect test light and connect IAC [87B].
3
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1
1. Fuel injector test light
2. Ignition coil circuit test adapter
3. Breakout box
Figure 1-22. Fuel Injector Test Light
HD-39978 Digital Multimeter (Fluke 78)
2
The DIGITAL MULTIMETER (FLUKE 78) (Part No. HD-39978)
is used for various tests throughout this manual.
1. IAC test light HD-41199-3
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2. IAC [87]
Figure 1-24. IAC Test Light (Part No. HD-41199-3)
HD-41404 Harness Connector Test Kit
The HARNESS CONNECTOR TEST KIT (Part No. HD-41404)
contains pin and socket terminals, and stackable banana jack
patch cords used to test circuits. The pin and socket terminals
are used to connect to various connectors used on the vehicle.
See the tool instruction sheet for specific terminal usage.
NOTE
To prevent terminal damage while using the probe tips, insert
the probe tip straight into the cavity and keep it stable during
the test. Do not wiggle or move the probe tip once it has been
Figure 1-23. Digital Multimeter (Fluke 78)
inserted into the terminal. Do not use more than one probe per
terminal or cavity at any one time.
HD-41199-3 IAC Test Light
HD-42682 Breakout Box
The IAC TEST LIGHT (Part No. HD-41199-3) is used to verify
The BREAKOUT BOX (Part No. HD-42682) and BREAKOUT
that the electrical circuit from the ECM to the IAC is operating
BOX ADAPTERS (Part No. HD-46601) connect to the
correctly.
speedometer [39] (XR) and tachometer [108] (XL). Used in
1. See Figure 1-24. Disconnect IAC [87B] and connect test
conjunction with a multimeter, it allows circuit diagnosis of
light.
wiring harness and connections without having to probe with
sharp objects. Install breakout box in series using the black
connectors as follows:
1. Access the speedometer [39] (XR) and tachometer [108]
(XL).
1-8 2013 Sportster Diagnostics: General Information
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2. See Figure 1-25. Press latch and disconnect speedometer
4. For HFSM: Mate antenna [208B] to HFSM.
[39B] (XR) or tachometer [108B] (XL).
5. When testing is completed remove the breakout box and
3. Connect BREAKOUT BOX ADAPTERS (Part No. HD-
restore connections.
46601) to [39A] and [39B] (XR) or [108A] and [108B] (XL).
NOTE
4. Attach black connectors from BREAKOUT BOX (Part
Vehicle will not start with TSM, TSSM or HFSM disconnected
No. HD-42682) to BREAKOUT BOX ADAPTERS (Part
or incorrectly mounted.
No. HD-46601). All tests will be performed using the black
side of the breakout box.
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5. When testing is completed, remove the breakout box and
jumper harness, and restore connections.
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1
1
2
2
3
3
1. Breakout box to harness connection
2.
Breakout box to TSM, TSSM, HFSM connection
3.
Breakout box
Figure 1-26. Breakout Box Connection Point at TSM,TSSM,
1. Tachometer [108]
HFSM (Typical)
2. Breakout box HD-42682
3. Breakout box adapter HD-46601
HD-43876 Breakout Box (ECM)
Figure 1-25. Breakout Box Connection (XR)
The BREAKOUT BOX (Part No. HD-43876) splices into the
main harness. Used in conjunction with a multimeter, it allows
HD-42682 Breakout Box (TSM, TSSM or
circuit diagnosis of wiring harness and connections without
HFSM)
having to probe with sharp objects. Install breakout box in
series as follows:
The BREAKOUT BOX (Part No. HD-42682) splices into the
main harness. Used in conjunction with a multimeter, it allows
NOTE
circuit diagnosis of wiring harness and connections without
See wiring diagrams for ECM terminal functions. ECM is loc-
having to probe with sharp objects. Install breakout box in
ated under passenger seat.
series as follows:
1. Access the ECM.
NOTE
2. Press latch and disconnect ECM [78B].
For HFSM: Disarm security system, then remove main fuse
while the system remains disarmed.
3. See Figure 1-27. Connect BREAKOUT BOX (Part No. HD-
43876) to connectors.
1. Access TSM, TSSM or HFSM.
4. When testing is completed, remove the breakout box and
2. Disconnect HFSM antenna jumper [208B] and [30B] from
restore connections.
TSM, TSSM or HFSM:
a. For HFSM: Press latches and disconnect [208B].
b. Press latches and disconnect [30B].
3. See Figure 1-26. Connect BREAKOUT BOX (Part No. HD-
42682) to connectors.
2013 Sportster Diagnostics: General Information 1-9
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HD-44687 Ignition Coil Circuit Test Adapter
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1
The IGNITION COIL CIRCUIT TEST ADAPTER (Part No. HD-
44687) and FUEL INJECTOR TEST LIGHT (Part No. HD-
34730-2E) are used to test the fuel injector drivers as well as
the ignition coil drivers in the ECM.
1. Connect the BREAKOUT BOX (Part No. HD-43876).
2. Disconnect the fuel injector connectors.
3. See Figure 1-22 for typical setup. Connect one side of the
fuel injector test light to power and the other to the terminal
on the ECM for the circuit you are testing.
2
4. Crank the engine.
3
5. If the test light flashes, the circuit is working properly.
1. Breakout box
HD-48650 Digital Technician II
2. ECM connector
3. Wiring harness connector
DIGITAL TECHNICIAN II (Part No. HD-48650) is a computer
based diagnostic device used to communicate/diagnose and
Figure 1-27. Breakout Box
program systems/modules.
Diagnostics in this manual are developed under the assumption
that DTII is not available.
1-10 2013 Sportster Diagnostics: General Information
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DIAGNOSTICS AND
TROUBLESHOOTING
1.3
starter side post of the starter solenoid and observe the
VOLTAGE DROP
meter reading. Crank the starter and observe the meter
Voltage Drop Test
reading. The difference in the voltage is the voltage drop.
The voltage drop test:
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•
Helps locate poor connections or components with
excessive voltage drops.
•
Measures the difference in potential or the actual voltage
dropped between the source and destination.
•
Checks the integrity of the wiring, switches, fuses, con-
nectors and contacts between the source and destination.
1
•
Identifies poor grounds.
2
A voltage drop test measures the difference in voltage between
two points in a circuit. The amount of voltage dropped over
any part of a circuit is directly related to the amount of resist-
3
ance in that part of the circuit. A poor connection may cause
an ohmmeter to give a good reading, but voltage drop test will
locate the problem.
1. Battery
Components such as wires, switches and connectors are
2. Starter solenoid
designed to have very little resistance and therefore very little
3. Starter motor
voltage drop. A possible fault is indicated when a voltage drop
Figure 1-28. To Starter Solenoid Starter Terminal
is greater than 1.0V across components. This could indicate
a high resistance in that circuit.
3. See Figure 1-29. Move the black meter lead to the battery
The benefits of testing this way are:
side post on the starter solenoid. Crank the starter.
•
Readings are not as sensitive to
real battery voltage.
•
Readings show the actual voltage dropped not just the
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presence of voltage.
•
The system is tested as it is actually being used.
2
•
Testing is more accurate and displays hard-to-find poor
connections.
•
Starting circuits, lighting circuits or ignition circuits can be
1
tested with this approach. (Start from the most positive
and go to the most negative destination or component.)
When testing a typical power circuit, place the positive (red)
meter lead on the most positive part of the circuit (or the pos-
3
itive battery post). Remember, there is nothing more positive
than the positive post of the battery. Place the negative (black)
meter lead at the positive side of the connector in question.
Activate the circuit. Move the negative meter lead through the
1. Battery
circuit until the high voltage drop is found.
2. Starter solenoid
3. Starter motor
When testing a typical ground circuit, place the negative lead
on the most negative part of the circuit (or the negative battery
Figure 1-29. To Starter Solenoid Battery Terminal
post). Remember, there is nothing more negative than the
negative post of the battery. Place the positive meter lead at
4.
See Figure 1-30. Finally move the black meter lead to the
the negative side of the connector in question. Activate the
negative battery post and the red meter lead to the starter
circuit. Move the positive meter lead through the circuit until
case. Crank the starter.
the high voltage drop is found.
The following steps demonstrate a typical starter circuit voltage
drop test:
1. Disconnect the fuel pump connector [86] to prevent the
engine from starting.
2. See Figure 1-28. Connect the red meter lead to the pos-
itive battery post. Connect the black meter lead to the
2013 Sportster Diagnostics: General Information 1-11
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RELAY DIAGNOSTICS
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Relay Variation
See Figure 1-32. Relays normally have four or five terminals.
The circuitry inside the relays are very similar with the exception
of the normally closed contact being eliminated in the four ter-
minal relay. Some relays have five terminals at the base, even
though internally 4 or 87A are not connected. See this topic
1
whenever a relay terminal is referenced in this manual to make
2
sure the proper terminal is being accessed.
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3
5
87
5
87
1. Battery
4
87A
2. Starter solenoid
3
30
3
30
3. Starter motor
1
86
1
86
2
85
2
85
Figure 1-30. Starter Ground Circuit
WIGGLE TEST
1
2
PART NUMBER
TOOL NAME
HD-39978
DIGITAL MULTIMETER (FLUKE 78)
HD-48637
BREAKOUT BOX
1. Standard 5 terminal relay
2. Standard 4 terminal relay
HD-48650
DIGITAL TECHNICIAN II
Figure 1-32. Standard Relays
The wiggle test checks for the presence of intermittents in a
wiring harness. The DIGITAL TECHNICIAN II (Part No. HD-
Relay Test
48650) can be used to perform the wiggle test.
A relay can be tested using the motorcycle's 12V battery and
1. See Figure 1-31. Connect DIGITAL MULTIMETER (FLUKE
a multimeter.
78) (Part No. HD-39978) to wiring harness between the
suspect connections. When diagnosing ECM connections,
1. Unplug the relay from relay block.
use BREAKOUT BOX (Part No. HD-48637) to simplify the
2. See Figure 1-33 and Figure 1-34 to energize the relay.
procedure. See 1.2 DIAGNOSTIC TOOLS.
Connect relay terminal 85 to the negative battery terminal
2. Set the multimeter to read voltage changes.
and relay terminal 86 to the positive battery terminal.
3. Start the motorcycle engine and run at idle.
NOTE
Some relays contain internal diodes. If the applied voltage is
4. Shake or wiggle the harness to detect intermittents. If
not the correct polarity, the diode could be damaged.
intermittents are present, radical voltage changes register
on the multimeter.
3. Test for continuity between terminals 30 and 87.
a. A good relay shows continuity (continuity tester lamp
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on or a zero Ohm reading on the ohmmeter).
b. A malfunctioning relay will not show continuity and
must be replaced.
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1
2
-
+
30
(3)
86
(1)
85
(2)
87
(5)
1. Ohmmeter
2. Battery
3. Start relay
Figure 1-31. Digital Multimeter (Fluke 78)
Figure 1-33. Four Terminal Relay Test
1-12 2013 Sportster Diagnostics: General Information
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JOB/TIME CODES VALUES
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3
2
PART NUMBER
TOOL NAME
1
HD-48650
DIGITAL TECHNICIAN II
Dealership technicians filing warranty claims should use the
job/time code values printed in bold text at the end of the
appropriate repair. When using DIGITAL TECHNICIAN II (Part
No. HD-48650), dealership technicians filling out warranty
claims should use the job/time code given by the computer.
1. Battery
2. Start relay
3. Ohmmeter
Figure 1-34. Five Terminal Relay Test
2013 Sportster Diagnostics: General Information 1-13
TABLE OF CONTENTS
SUBJECT
PAGE NO.
2.1 INITIAL DIAGNOSTICS
2-1
2.2 SERIAL DATA COMMUNICATION
2-12
2.3 DTC U1016, U1064, U1097, U1098, U1255
2-14
2.4 DTC U1300, U1301 OR BUS ER
2-19
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INITIAL DIAGNOSTICS
2.1
5. Quickly press and release the trip odometer reset switch
DESCRIPTION AND OPERATION
to cycle through the letters. The letters will flash as they
Use initial diagnostics as a starting point to efficiently
are selected.
troubleshoot concerns. A basic understanding of electronics
6. Once the corresponding letter is flashing to the desired
and a general knowledge of the vehicle are necessary to
module press and hold the trip odometer reset switch.
effectively use this manual.
7. If no DTCs are present, "none" will appear on display.
NOTE
Certain diagnostic procedures require part removal. See the
8. If any DTCs are stored in the module, either current or
service manual for details.
historic, they will appear on the odometer. Quickly pressing
and releasing the trip odometer reset switch will cycle
Before diagnosing a concern, perform a general functional test
through the stored DTCs.
of the vehicle to verify the concern. This will also identify any
other issues that may affect diagnostics. Use the procedures
NOTE
in this chapter for initial diagnostics.
The ECM will show "no rsp" if the engine stop switch is not in
the RUN position. Verify the engine stop switch is in the RUN
NOTE
position.
When working through a diagnostic procedure follow the steps
in the order instructed. Never jump to a test in another pro-
9. If odometer displays "no rsp" then the motorcycle may not
cedure. All "Go to test" statements refer to a test in that pro-
be equipped with the module. If the motorcycle is equipped
cedure.
with the selected module then go to other modules and
look for applicable communication codes.
RETRIEVING TROUBLE CODES
10. When all the DTCs have been cycled the odometer will
display "end".
PART NUMBER
TOOL NAME
11. To clear all the DTCs in that module press and hold the
HD-48650
DIGITAL TECHNICIAN II
trip odometer reset switch. If DTCs are not to be cleared
quickly press and release the trip odometer reset switch.
There are two levels of diagnostics.
The part number of
the module will be displayed.
•
The most sophisticated mode uses a computer-based
12. Press and release the trip odometer reset switch again to
diagnostic package called DIGITAL TECHNICIAN II (Part
continue to the
next
module.
No. HD-48650).
13. Turn the IGN OFF to exit diagnostic mode.
•
The second mode requires using the odometer self-dia-
gnostics. Speedometer, tachometer, TSM, TSSM or
INITIAL DIAGNOSTICS
HFSM, ECM and ABS (if equipped) codes can be
accessed and cleared.
1. Verifying Current DTC Test
ODOMETER SELF-DIAGNOSTICS
1. Check for DTCs. See 2.1 INITIAL DIAGNOSTICS, Odo-
meter Self-Diagnostics.
Diagnostic Mode
NOTE
1. To enter diagnostic mode press and hold the trip odometer
Historic DTCs are not to be diagnosed unless the condition is
reset switch while turning the IGN ON.
reoccurring and intermittent.
2. Release the trip odometer reset switch. "diag" will appear
2. Are current DTCs present?
on the odometer display.
a. Yes. Refer to Table 2-2.
3. Press and release the trip odometer reset switch. "PSSPtb"
b. No. Go to Test 2.
will appear on the odometer display.
4. PSSPtb indicates the different modules that could display
2. Battery Power Test
codes if equipped.
1. Verify battery is charged. See 3.1 BATTERY TESTING.
2. Does vehicle have battery power?
Table 2-1. Modules That Set DTCs
a. Yes. Go to Test 4.
DESIGNATOR
MODULE
b. No. Go to Test 3.
P
ECM codes
S
TSM, TSSM or HFSM codes
3. Ignition Power Test
SP
Speedometer codes
1. With the engine stop switch in the off position, turn IGN
ON.
t
Tachometer codes
b
ABS codes
2013 Sportster Diagnostics: Initial Diagnostics and Serial Data 2-1
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2. Do the headlamps and instruments illuminate?
7. Engine Running Test
a. Yes. Go to Test 4.
1. Start the engine.
b. No. Refer to Table 2-3.
2. Does the engine start and run correctly?
a. Yes. Go to Test 8.
4. Engine Stop Switch Circuit Test
b. No. See 6.1 EFI SYSTEM.
1. Turn the engine stop switch to the RUN position.
2. Does the check engine lamp illuminate for a few seconds,
8. Verification Test
then turn off?
1. Operate the systems of the vehicle to verify the concern.
a. Yes. Go to Test 5.
2. Was the concern duplicated?
b. No. See 6.21 NO ECM POWER.
a. Yes. See appropriate diagnostic. Refer to Table 2-3.
5. Security System Test
b. No. Concern is intermittent. See 1.3 DIAGNOSTICS
AND TROUBLESHOOTING, Wiggle Test.
1. Turn the IGN OFF-ON.
2. Observe the security lamp.
DIAGNOSTICS
3. Does the security lamp illuminate for a few seconds and
Diagnostic Tips
then turn off?
•
For a quick check of instrument function, a "WOW" test
a. Yes. Go to Test 6.
can be performed by entering odometer self-diagnostics.
b. No. See 5.9 SECURITY SYSTEM.
Background lighting should illuminate, gauge needles
should sweep their full range of motion, and indicator
6. Starter System Test
lamps controlled by the serial data circuit (battery, security
and check engine) should illuminate.
1.
Press the start button.
•
If the instrument fails "WOW" test, check for battery,
2.
Does the starter spin and crank the engine?
ground and ignition voltage to the instrument. If any feature
a. Yes. Go to Test 7.
in the speedometer or tachometer is non-functional, see
b. No. See 3.2 STARTING SYSTEM.
4.1 INSTRUMENTS.
Table 2-2. Diagnostic Trouble Codes (DTCs) and Fault Conditions
DTC
PRIORITY
FAULT CONDITION
SOLUTION
ORDER
B0563
66
TSM,
TSSM or HFSM voltage
3.6 DTC B0563, P0562, P0563
high
B1004
70
Fuel sender low
4.2 DTC B1004, B1005
B1005
71
Fuel sender open/high
4.2 DTC B1004, B1005
B1006
72
Speedometer accessory
3.7 DTC B1006, B1007
voltage high
B1007
73
Speedometer ignition voltage
3.7 DTC B1006, B1007
high
B1008
74
T
rip odometer rest switch
4.3 DTC B1008
closed
B1121
57
Left turn output fault
5.7 DTC B1121, B1122, B1123, B1124, B1125, B1126
B1122
58
Right turn output fault
5.7 DTC B1121, B1122, B1123, B1124, B1125, B1126
B1123
59
Left turn signal short-to-
5.7 DTC B1121, B1122, B1123, B1124, B1125, B1126
ground
B1124
60
Right turn signal short-to-
5.7 DTC B1121, B1122, B1123, B1124, B1125, B1126
ground
B1125
61
Left turn signal short-to-
5.7 DTC B1121, B1122, B1123, B1124, B1125, B1126
voltage
B1126
62
Right turn signal short-to-
5.7 DTC B1121, B1122, B1123, B1124, B1125, B1126
voltage
B1131
67
Alarm output low
5.14 DTC B1131, B1132
B1132
68
Alarm output high
5.14 DTC B1131, B1132
2-2 2013 Sportster Diagnostics: Initial Diagnostics and Serial Data
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Table 2-2. Diagnostic Trouble Codes (DTCs) and Fault Conditions
DTC
PRIORITY
FAULT CONDITION
SOLUTION
ORDER
B1134
56
Start relay output high
5.15 DTC B1134
B1135
19
Accelerometer fault
5.8 DTC B1135, B1136, B1141, B1142
B1136
20
Accelerometer tip-over self-
5.8 DTC B1135, B1136, B1141, B1142
test fault
B1141
69
Ignition switch open/low
5.8 DTC B1135, B1136, B1141, B1142
B1142
18
Internal fault
5.8 DTC B1135, B1136, B1141, B1142
B1143
63
Security antenna short-to-
5.16 DTC B1143, B1144, B1145
ground
B1144
64
Security
antenna short-to-bat-
5.16 DTC B1143, B1144, B1145
tery
B1145
65
Security antenna open
5.16 DTC B1143, B1144, B1145
B1154
21
Clutch swith short-to-ground
5.17 DTC B1154, B1155
B1155
22
Neutral
switch short-to-ground
5.17 DTC B1154, B1155
P0107
35
MAP sensor open/low
6.4 DTC P0107, P0108
P0108
36
MAP sensor high
6.4 DTC P0107, P0108
P0112
39
IA
T sensor voltage low
6.5 DTC P0112, P0113
P0113
40
IA
T sensor open/high
6.5 DTC P0112, P0113
P0117
37
ET sensor voltage low
6.6 DTC P0117, P0118
P0118
38
ET sensor open/high
6.6 DTC P0117, P0118
P0122
23
TP sensor open/low
6.7 DTC P0122, P0123
P0123
24
TP sensor high
6.7 DTC P0122, P0123
P0131
50
Front
O2 sensor low or engine
6.8 DTC P0131, P0132, P0134,
P0151, P0152, P0154
running lean
P0132
52
Engine front O2 running rich
6.8 DTC P0131, P0132, P0134, P0151, P0152, P0154
P0134
54
Front O2 sensor open/not
6.8 DTC P0131, P0132, P0134, P0151, P0152, P0154
responding/high
P0151
51
Rear
O2 sensor low or engine
6.8 DTC P0131, P0132, P0134, P0151, P0152, P0154
running lean
P0152
53
Engine rear O2 running rich
6.8 DTC P0131, P0132, P0134, P0151, P0152, P0154
P0154
55
Rear O2 sensor open/not
6.8 DTC P0131, P0132, P0134, P0151, P0152, P0154
responding/high
P0261
31
Front injector open/low
6.9 DTC P0261, P0262, P0263, P0264
P0262
33
Front injector high
6.9 DTC P0261, P0262, P0263, P0264
P0263
32
Rear injector open/low
6.9 DTC P0261, P0262, P0263, P0264
P0264
34
Rear injector high
6.9 DTC P0261, P0262, P0263, P0264
P0373
17
CKP sensor intermittent
6.10 DTC P0373, P0374
P0374
16
CKP not detected/cannot
6.10 DTC P0373, P0374
synchronize
P0501
43
VSS low
6.11 DTC P0501, P0502
P0502
44
VSS high
6.11 DTC P0501, P0502
P0505
47
Loss of idle speed control
6.12 DTC P0505
P0562
41
ECM voltage low
3.6 DTC B0563, P0562, P0563
P0563
42
ECM voltage high
3.6 DTC B0563, P0562, P0563
P0603
2
ECM EEPROM error
6.13 DTC P0603, P0605
P0605
1
ECM flash error
6.13 DTC P0603, P0605
2013 Sportster Diagnostics: Initial Diagnostics and Serial Data 2-3
HOME
Table 2-2. Diagnostic Trouble Codes (DTCs) and Fault Conditions
DTC
PRIORITY
FAULT CONDITION
SOLUTION
ORDER
P0661
48
Intake solenoid low/open
6.14 DTC P0661, P0662
P0662
49
Intake solenoid high/shorted
6.14 DTC P0661, P0662
P1001
12
System relay coil open/low
6.16 DTC P1001, P1002, P1003, P1004
P1002
11
System
relay coil high/shorted
6.16 DTC P1001, P1002, P1003, P1004
P1003
10
System relay contacts open
6.16 DTC P1001, P1002, P1003, P1004
P1004
13
System relay contacts closed
6.16 DTC P1001, P1002, P1003, P1004
P1009
14
Incorrect password
6.15 DTC P1009, P1010
P1010
15
Missing password
6.15 DTC P1009, P1010
P1351
27
Front ignition coil open/low
6.17 DTC P1351, P1352, P1354, P1355
P1352
29
Front
ignition coil high/shorted
6.17 DTC P1351, P1352, P1354, P1355
P1354
28
Rear ignition coil open/low
6.17 DTC P1351, P1352, P1354, P1355
P1355
30
Rear
ignition coil high/shorted
6.17 DTC P1351, P1352, P1354, P1355
P1501
25
JSS low
6.18 DTC P1501, P1502
P1502
26
JSS high
6.18 DTC P1501, P1502
P1653
75
T
achometer low
6.19 DTC P1653, P1654
P1654
76
T
achometer high
6.19 DTC P1653, P1654
U1016
6
Loss of ECM serial data
2.3 DTC U1016, U1064, U1097, U1098, U1255
U1064
5
Loss
of TSM, TSSM or HFSM
2.3 DTC U1016, U1064, U1097, U1098, U1255
serial data
U1097
7
Loss of speedometer serial
2.3 DTC U1016, U1064, U1097, U1098, U1255
data
U1098
8
Loss
of tachometer serial data
2.3 DTC U1016, U1064, U1097, U1098, U1255
U1255
9
Missing response at module
2.3 DTC U1016, U1064, U1097, U1098, U1255
U1300
3
Serial data low
2.4 DTC U1300, U1301 OR BUS ER
U1301
4
Serial data open/high
2.4 DTC U1300, U1301 OR BUS ER
CODE TYPES
tion period, the DTC is automatically erased from memory
providing that no subsequent faults of the same type are
detected in that period.
PART NUMBER
TOOL NAME
HD-48650
DIGITAL TECHNICIAN II
Current
Current DTCs are those which presently disrupt motorcycle
There are two types of DTCs: current and historic. If a DTC is
operation and are set during the current ignition cycle. See the
stored, it can be read using either a computer-based diagnostic
appropriate diagnostic procedures for solutions.
package called DIGITAL TECHNICIAN II (Part No. HD-48650)
or odometer self-diagnostics.
Historic
NOTES
If a particular problem happens to resolve itself, the active
status problem is dropped and it becomes a historic DTC rather
•
Odometer self-diagnostics will display both current and
than a current DTC. DTCs will also lose their current status
historic DTCs. To differentiate between current and historic
when the ignition is turned off. If the problem still exists when
DTCs, a computer-based diagnostic package called
the ignition is turned on the code will show as current.
DIGITAL TECHNICIAN II (Part No. HD-48650) must be
employed.
Historic DTCs are stored for 50 ignition cycles after any DTC
was last set as current to assist in the diagnosis of intermittent
•
Current DTCs reside in the memory of the ECM, TSM,
faults. On the 50th cycle, the DTC will clear itself. The security
TSSM or HFSM, speedometer or tachometer until the DTC
lamp or check engine lamp will only indicate the existence of
is resolved.
historic DTCs for two ignition cycles.
•
A historic DTC can be cleared by use of the odometer self-
It is important to note that historic DTCs will exist whenever
diagnostics or after a total of 50 ignition cycles (start and
the system indicates the existence of a current fault. See
run cycle) have elapsed. After the 50 ignition cycle reten-
2-4 2013 Sportster Diagnostics: Initial Diagnostics and Serial Data
HOME
2.1 INITIAL DIAGNOSTICS, Multiple Trouble Codes if multiple
CHECK ENGINE LAMP
DTCs are found.
To diagnose ECM system problems, start by observing the
Diagnostic procedures are designed for use with current DTCs.
behavior of the check engine lamp.
As a result, they frequently suggest part replacement. When
diagnosing a historic DTC, the procedures can be helpful but
NOTES
should not lead to part replacement without verification that
•
"IGN ON" means that the ignition switch is turned to IGN
the part is faulty.
and the engine stop switch is set to RUN (although the
engine is not running).
MULTIPLE TROUBLE CODES
•
When the IGN is turned ON, the check engine lamp will
All DTCs are assigned a priority number to determine the order
illuminate for approximately four seconds and then turn
in which they should be diagnosed. In the event there are
off.
multiple DTCs present always diagnose the highest priority
first. Refer to Table 2-2.
•
If the check engine lamp is not illuminated at IGN ON or
if it fails to turn off after the initial four-second period, then
After each DTC is repaired, restore connections, clear DTCs
see 6.21 NO ECM POWER.
and start vehicle. Perform self-diagnostics test and verify repair,
verify if DTCs are present, and if DTCs are still present. Refer
1.
See Figure 2-1. After the check engine lamp turns off fol-
to Table 2-2.
lowing the first four second illumination period, one of three
events may occur.
CLEARING DTCS
a. The lamp remains off. This indicates there are no
DTCs should be cleared after any diagnostic or repair pro-
current fault conditions or stored DTCs currently
cedure is performed. The odometer is capable of displaying
detected by the ECM.
and clearing ECM, TSM, TSSM or HFSM, speedometer,
b. The lamp stays off for only four seconds and then
tachometer and ABS DTCs. Once the DTCs are cleared per-
comes back on for an eight second period. This
form a road test to verify DTCs do not return. It is important to
indicates a DTC is stored, but no current DTC exists.
perform a road test and not simply start the motorcycle since
some DTCs may require vehicle speed or other inputs in order
c. If the lamp remains on beyond the eight-second
to validate repair.
period, a current DTC exists.
SECURITY LAMP
2.
See 2.1 INITIAL DIAGNOSTICS, Code Types for a com-
plete description of DTC formats.
The security lamp functions in the same manner as the check
engine lamp, except that it is controlled by the TSSM or HFSM.
NOTE
Codes in the TSM or HFSM illuminate the security lamp. If the
Some DTCs can only be fully diagnosed during actuation. For
speedometer sets codes B1004 or B1005, the low fuel lamp
example, a problem with the ignition coil will be considered a
on the speedometer or tachometer also illuminates.
current fault even after the problem is corrected, since the ECM
will not know of its resolution until after the coil is exercised by
the vehicle start sequence. In this manner, there may some-
times be a false indication of the current DTC.
2013 Sportster Diagnostics: Initial Diagnostics and Serial Data 2-5
HOME
ed01887
ON
4 Sec.
A
Lamp OFF: No Current or Historic DTCs
OFF
Ignition ON
Lamp ON 8 Seconds:
Only Historic DTCs Exist
ON
4 Sec.
8 Sec.
B
Lamp OFF
OFF
4 Sec.
Ignition ON
Lamp Remains ON: Current DTC*
ON
4 Sec.
C
OFF
4 Sec.
Ignition ON
* Historic DTCs May Also Exist
Figure 2-1. Check Engine Lamp and Security Lamp Operation
is not a normal characteristic of the system. Refer to Table 2-3
SYMPTOMS
for a list of symptoms.
If no DTCs are present but there is a symptom or concern
indicating a malfunction, address and repair the symptom if it
Table 2-3. Symptom Table
SYMPTOM
DIAGNOSTIC PROCEDURE
Battery runs down during use
3.5 CHARGING SYSTEM
Both turn signals on one side inoperative,
5.3 TURN SIGNALS
no DTCs
Bus Er displayed
2.2 SERIAL DATA COMMUNICATION
Charging system inoperative
3.5 CHARGING SYSTEM
Check engine lamp inoperative
6.21 NO ECM POWER
Engine cranks, but will not start
6.20 ENGINE CRANKS, BUT WILL NOT START
Fuel gauge inoperative
4.1 INSTRUMENTS
Headlamp inoperative
5.4 HEADLAMPS
Hesitation, loss of power
6.23 HESITATION, LOSS OF POWER
High beam indicator inoperative
4.5 INDICATOR LAMPS
Horn always on
5.2 HORN
Horn inoperative
5.2 HORN
Low battery after extended IGN OFF
3.5 CHARGING SYSTEM
Low fuel lamp always on
4.5 INDICATOR LAMPS
Low fuel lamp inoperative
4.5 INDICATOR LAMPS
Low or no charging
3.5 CHARGING SYSTEM
Neutral lamp always on
4.5 INDICATOR LAMPS
Neutral lamp inoperative
4.5 INDICATOR LAMPS
No ECM power
6.21 NO ECM POWER
Misfire at idle or under load
6.24 MISFIRE AT IDLE OR UNDER LOAD
Oil pressure lamp always on
4.5 INDICATOR LAMPS
2-6 2013 Sportster Diagnostics: Initial Diagnostics and Serial Data
HOME
Table 2-3. Symptom Table
SYMPTOM
DIAGNOSTIC PROCEDURE
Oil pressure lamp inoperative
4.5 INDICATOR LAMPS
One
turn signal lamp inoperative, no DTCs
5.3 TURN SIGNALS
Overcharging
3.5 CHARGING SYSTEM
P&A battery power inoperative
5.1 ACCESSORIES
Position lamp inoperative (HDI)
5.6 RUNNING LAMPS
Running lamps inoperative
5.6 RUNNING LAMPS
Security lamp inoperative
5.9 SECURITY SYSTEM
Speedometer inoperative
4.1 INSTRUMENTS
Starter does not spin
3.2 STARTING SYSTEM
Starter inoperative
3.2 STARTING SYSTEM
Starter solenoid clicks
3.2 STARTING SYSTEM
Starter spins, but does not engage
3.2 STARTING SYSTEM
Starter stalls or spins too slowly
3.2 STARTING SYSTEM
Starts, then stalls
6.22 STARTS, THEN STALLS
Stop lamp inoperative
5.5 STOP LAMPS
T
achometer inoperative
4.1 INSTRUMENTS
T
urn signal indicator inoperative
4.5 INDICATOR LAMPS
T
urn signal inoperative
5.3 TURN SIGNALS
T
urn signals flash at double normal rate
5.3 TURN SIGNALS
T
urn signals will not cancel on turn comple-
5.3 TURN SIGNALS
tion
Connector Information
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: Initial Diagnostics and Serial Data 2-7
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em00958
Main Fuse
30A
[5]
Ignition Switch
IGN
OFF
ACC
A B
[5B]
B+
ACC
IGN
Red
Band
BK
R
Starter
Battery
R
R
R
1
[160B]
+
[77B]
[61B]
+
[77A]
P
S
P&A
Battery
Battery
ECM
System
Fuse
Fuse
87
30
85
86
Relay
15A
15A
5
3
1
2
R
U
E L F K
Voltage
Regulator
BN/GY
BN/GY
BE/GY
2
[20B]
2
[20A]
XR
XL
1
[30B]
A
[142B]
31
[78B]
1
[30A]
A
[142A]
31
[78A]
TSM, TSSM
Security
ECM
Siren
(Optional)
[39A]
B
5
[108A]
5
[39A]
[39B]
B
5
[108B]
5
[39B]
Speedometer Tachometer
Speedometer
Figure 2-2. Battery Power
2-8 2013 Sportster Diagnostics: Initial Diagnostics and Serial Data
HOME
em01323
Ignition Switch
IGN
OFF
ACC
B+
ACC
IGN
Battery
R
Power
[61B]
G
A
Lights
IGN
Start
Fuse
Fuse
87
30
85
86
Relay
15A
15A
5
3
1
2
H
B
C J D I
4
3
[31A]
3
[24B]
4
[91A]
2
[30B]
3
[22B]
4
3
[31B]
3
[24A]
2
[30A]
3
[22A]
DLC
6
[20B]
Headlamp
Left
Right
[20A]
Hi/Lo
6
Turn
Turn
Low
TSM,
High
Switch
Lamp
Lamp
TSSM,
HFSM
Engine
Stop
Single Stop Lamp
Dual Stop Lamps
Switch
XR
Except
XR
XL
XR
3
[7A]
3
[7A]
3
[7B]
3
[7B]
Tail
Lamp
[108B]
1
[39B]
1
Converter
Module
[108A]
1
[39A]
1
3
[94B]
Indicators
Indicators
3
[94A]
[18A]
3
3
[19A]
Circuit
Board
[18B]
3
3
[19B]
Tachometer
Speedometer
1
[93A]
1
[93B]
Right
Left
Turn/
Turn/
Tail
Tail
Lamp
Lamp
Tail
Lamp
(DOM)
Figure 2-3. Ignition Power
2013 Sportster Diagnostics: Initial Diagnostics and Serial Data 2-9
HOME
em01446
Ignition Switch
IGN
OFF
ACC
B+
ACC
IGN
Battery
R
Power
[61B]
M
ACC
Fuse
15A
O
1
[121B-B]
1
[24B]
1
[22B]
1
[20B]
1
[38A]
1
[121B-A]
1
[24A]
1
[22A]
1
[20A]
1
[38B]
Rear
Stop
Left
Right
Position
Lamp
Turn
Turn
Lamp
Switch
Switch
Switch
(HDI)
XR
XL
Single Stop Lamp
Dual Stop Lamps
XR
Except
XR
1
[7A]
1
[7A]
[94B]
1
[94A]
1
1
[7B]
1
[7B]
[108B]
6
[39B]
A
[39B]
6
Circuit
[108A]
6
[39A]
A
[39A]
6
Board
Except
XL1200C/CP/
XL1200C/CP/
[93A]
2
CA/CB
CA/CB
DOM
HDI
[93B]
2
T
achometer
Speedometer Speedometer
[94B]
1
1
[40A]
Tail
Lamp
[94A]
1
1
[40B]
Tail
(HDI)
Lamp
Circuit
Converter
Board
Module
[93A]
2
3
[19B]
1
[40B]
3
[18B]
[93B]
2
Tail
3
[19A]
1
[40A]
3
[18A]
Lamp
Tail
Left
License
Right
Lamp
Tail
Plate
Tail
(HDI)
Lamp
Lamp
Lamp
Figure 2-4. Accessory Power
2-10 2013 Sportster Diagnostics: Initial Diagnostics and Serial Data
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Fuel Pump
em01447
Security Siren
Fuel Tank
And Sender
Horn
(Optional)
ECM
(XR Only)
Assembly
Fuel Sender
Resistor
Assembly
3
[133A]
1
[200A]
B
[122A]
C
[142A]
10
28
[78A]
1
[210A]
4
[141B]
DLC
3
[133B]
1
[200B]
B
[122B]
C
[142B]
10
28
[78B]
1
[210B]
4
[141A]
2
[91A]
Speedometer
Tachometer
Speedometer
Position Lamp
BK
(HDI)
Indicators
Indicators
BK
4
4
BK
BK
Headlamp
[38A] [38B]
[39A]
D
[108A]
7
7
[39A]
[39B]
D
[108B]
7
7
[39B]
BK
1
1
BK
4
4
Right Turn Signal
BK
6
6
BK
4
4
Left Turn Signal
[31A] [31B]
[65A] [65B]
VSS
C
C
BK
XR
XL
[30B] [30A]
BK
12
12
BK
TSM, TSSM,
BK
12
12
[20A] [20B]
HFSM
BK
8
8
BK
Clutch
Switch
[24B] [24A]
Voltage
BK
-
-
BK
Regulator
Left
High
Right
Turn
Beam
Turn
[77B] [77A]
Indicator
Indicator
Indicator
BK
Single Stop Lamp
Dual Stop Lamps
XR
Except
XR
GND 1
Battery
6
[7A]
6
[7A]
6
[7B]
6
[7B]
Battery
Ground
Except
XL1200C/
XL1200C/CP/CA/CB
CP/CA/CB
HDI
DOM
Tail Lamp
Converter
6
[94B]
6
[94B]
Module
[19B] [19A]
[19B] [19A]
6
[94A]
6
[94A]
Left
Left
3
[40A]
Turn
2
2
Turn
2
2
Circuit
Circuit
Signal
Signal
3
[40B]
Right
Board
Right
Board
2
2
2
2
Turn
Turn
1
[19B]
2
[40B]
1
[18B]
Signal
4
[93A]
Signal
4
[93A]
1
[19A]
2
[40A]
1
[18A]
[18B] [18A]
[18B] [18A]
4
[93B]
4
[93B]
Tail
Lamp
Left
License
Right
Tail
Tail
Turn/Stop
Plate
Turn/Stop
Lamp
Lamp
Tail Lamp
Lamp
Tail Lamp
Figure 2-5. Chassis Grounds
2013 Sportster Diagnostics: Initial Diagnostics and Serial Data 2-11
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