Harley Davidson 2013 Sportster Models. Electrical Diagnostics Manual — page 6
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HORN
5.2
DESCRIPTION AND OPERATION
SYMPTOMS
The horn is powered through the horn switch from the
The horn circuit does not set DTCs when there is a malfunction.
accessories fuse. The horn is grounded through GND 1. When
Refer to Table 5-1 for troubleshooting.
the horn switch is pressed, battery voltage is applied to [122]
terminal A, causing the horn to sound.
Table 5-1. Horn Symptoms
COMPONENTS
SYMPTOM
COMMON CAUSE
Horn Switch
Horn always on
Short to voltage or a stuck
switch
The horn switch is a push button switch on the left handlebar
Horn inoperative
Open circuit, faulty horn or
controls.
horn switch
Horn
Diagnostic Tips
See Figure 5-3. The horn is located between the front frame
tubes or on the left side of engine.
If the fuse is open, check the circuit between the horn switch
and the horn for a short to ground. This would cause the fuse
ed01993
to open only when the horn switch is pressed. A short between
1
the brake lamp switches and the tail/stop lamp causes this fuse
to open when the brakes are applied.
The (O/W) wire from the fuse supplies battery voltage to several
components. A short anywhere in the (O/W) wire causes the
fuse to open immediately.
Connector Information
2
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. Horn [122]
2. Front O2 sensor
Figure 5-3. Horn (Typical)
5-2 2013 Sportster Diagnostics: Accessories, Horn, Lighting and Security
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em00542
Left
Accessory
Hand Controls
Power
Left Turn Switch
O/W
M
Horn Switch
O/W
Accessory
15A
O
[61B]
Accessory
6
1
[24A]
Power
6
1
[24B]
GND 1
BK
BK
Y/BK
B
A
[122B]
B
A
[122A]
Chassis
Grounds
Horn
Figure 5-4. Horn
HORN ALWAYS ON
HORN INOPERATIVE
Table 5-2. Horn Always On Diagnostic Faults
PART NUMBER
TOOL NAME
HD-41404
HARNESS CONNECTOR TEST KIT
POSSIBLE CAUSES
Short to voltage in horn power circuit
Table 5-3. Horn Inoperative Diagnostic Faults
Horn switch malfunction
POSSIBLE CAUSES
1. Horn Switch Test
Open accessory circuit
1. Disconnect left hand controls [24].
Shorted accessory circuit
2. Does the horn turn off?
Horn malfunction
a. Yes. Replace the horn switch. (5171)
Open ground circuit
b. No. Repair short to voltage in the (Y/BK) wire between
Horn switch malfunction
horn and left hand controls. (5041)
Open horn power circuit
1. Accessory Circuit Open or Shorted Test
1. With the IGN ON, activate the front and rear brakes.
2. Does the tail/stop lamp illuminate?
a. Yes. Go to Test 2.
b. No. Inspect the fuse. If fuse is good locate and repair
open in (O/W) wire. If fuse is open repair short to
ground in circuits that may affect the fuse. See dia-
gnostic tips. (5043)
2013 Sportster Diagnostics: Accessories, Horn, Lighting and Security 5-3
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2. Horn Test
4. Horn Switch Malfunction Test
1. Disconnect the horn [122].
1. Connect the horn [122].
2. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
2. Disconnect left hand controls [24].
41404), test for voltage at [122B] between terminals A and
3. With IGN ON, using the HARNESS CONNECTOR TEST
B.
KIT (Part No. HD-41404) jumper [24B] terminals 1 and 6.
3. Press the horn switch.
4. Does the horn sound?
4. Is battery voltage present?
a. Yes. Replace the horn switch. (5171)
a. Yes. Replace the horn. (5765)
b. No. Go to Test 5.
b. No. Go to Test 3.
5. Horn Power Circuit Open Test
3. Ground Circuit Open Test
1. Test for voltage from [24B] terminal 1 (O/W) to ground.
1. Test for continuity between [122B] terminal B and ground.
2. Is battery voltage present?
2. Is continuity present?
a. Yes. Repair open in (Y/BK) wire between [24B] and
a. Yes. Go to Test 4.
horn. (5041)
b. No. Repair open in the ground circuit. (5041)
b. No. Repair open (O/W) wire between [24B] and fuse
block. (5043)
5-4 2013 Sportster Diagnostics: Accessories, Horn, Lighting and Security
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TURN SIGNALS
5.3
mph (11 km/h) the directional will always cancel after 20
DESCRIPTION AND OPERATION
flashes if the system does not recognize any other input.
TSM, TSSM or HFSM receives battery power through the
•
If the vehicle speed drops to 7 mph (11 km/h) or less,
ignition. The operation functions the same way whether you
including stopped, the directionals will continue to flash.
have a TSM, a TSSM or a HFSM. The TSM communicates
Counting will resume when vehicle speed reaches 8 mph
with the other modules on the vehicle through the serial data
(12.9 km/h) and will automatically cancel when the count
line. The turn signal switches are inputs to the TSM. When the
total equals 20 as stated above.
turn signal switch is pressed the switch closes and power flows
to TSM. This signals the TSM to supply voltage and control
•
See Figure 5-5. The turn signals will cancel within two
the flash rate to the turn signals and the turn signal indicator.
seconds upon turn completion. A sensor inside the TSM,
If the turn signal switches are pressed at the same time and
TSSM or HFSM cancels the signal after the vehicle has
held down the TSM initiates the four-way flashers.
been returned to an upright position.
The TSM also monitors the position of the clutch and neutral
NOTE
switches to determine if it is safe to start the vehicle. The BAS
is internal to the TSM and allows the TSM to determine if the
The bank angle cancellation function has an automatic calibra-
vehicle is tipped over. If a tip over event occurs, the TSM sends
tion feature. Ride the vehicle for 0.25 mile (0.4 km) at steady
a signal to the ECM to turn off the engine.
speeds (upright) to calibrate the system. Performance of bank
angle function may not be optimal until this calibration is per-
The TSM has three major functions:
formed. This self-calibration is performed automatically every
•
Controls the turn signals.
time the vehicle is started and ridden.
•
Serves as the BAS.
ed01792
•
Monitors the clutch and neutral switches to prevent starter
engagement.
BAS Operation
The TSM, TSSM or HFSM uses an
internal BAS to monitor
vehicle position. Under normal driving conditions the TSM,
TSSM or HFSM uses the BAS along with speed input provided
1
2
from the ECM to know when to automatically cancel the turn
signals after a turn. The TSM, TSSM or HFSM will disable turn
signal lamps and starter activation and will send a message
to the ECM to shut down the ignition and the fuel pump if the
vehicle is tipped over. The odometer will display "tIP" when a
tip-over condition is present.
BAS Restart
1. Left 45 degrees
To restart the vehicle after shutdown has occurred:
2. Right 45 degrees
1. Return the vehicle to an upright position.
Figure 5-5. Tilting: TSM, TSSM or HFSM
2. Cycle the IGN OFF-ON before restarting the vehicle.
FOUR-WAY FLASHING
MANUAL CANCELLATION
Use the following method to activate the four-way flashers:
If you want to stop the turn signals from flashing, briefly press
the turn signal switch a second time.
1. With the ignition switch ON and the security system dis-
armed (models with security only), press the left and right
If you are signalling to turn in one direction and you press the
turn signal switches at the same time.
switch for the opposite turn signal, the first signal is cancelled
and the opposite side begins flashing.
2. Turn the ignition switch OFF and arm the security system
if present and desired. The four-way flashers will continue
AUTOMATIC CANCELLATION
for two hours.
Press the left or right turn switch to activate automatic turn
3. To cancel four-way flashing, disarm the security system
signal cancellation. There is no need to hold the turn switch in
if necessary, turn the ignition switch ON and press the left
when approaching the turn. The TSM, TSSM or HFSM will not
and right turn signal switches at the same time.
cancel the signal before the turn is actually completed.
This system allows a stranded vehicle to be left in the four-way
•
When the directional switch is released, the system starts
flashing mode and secured until help is found.
a 20 count. As long as the vehicle is traveling above 7
If the security system is disarmed while the four-way flashers
are active, the lights will flash as follows:
2013 Sportster Diagnostics: Accessories, Horn, Lighting and Security 5-5
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1. TSSM or HFSM stops four-way flashing mode. Vehicle
Diagnostic Tips
sits for 1 second with turn signals off.
•
TSM or TSSM Only: DTC B1121 and B1122 will illuminate
2. TSSM or HFSM performs disarming confirmation (1 flash).
the security lamp. DTC B1141 will not illuminate the
security lamp.
3. Vehicle sits for 1 second with turn signals off.
•
HFSM Only: DTC B1121, B1122, B1123, B1124, B1125
4. Vehicle restarts four-way flashing mode.
and B1126 will illuminate the security lamp.
•
TSM, TSSM or HFSM: When an over current or short-to-
ground condition is detected, it will turn off the turn lamp
outputs.
•
If battery fuse is open and DTC B1123 or B1124 are set
in history check for an intermittent short to ground in turn
signal circuits (BN) or (V).
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.
5-6 2013 Sportster Diagnostics: Accessories, Horn, Lighting and Security
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em01443
Accessory
Power
Front Stop
TSM, TSSM,
[30A] [30B]
Lamp Switch
HFSM
Left Turn Switch Input
8
8
W/V
W/BN
W/BN
M
W/V
W/V
Right Turn Switch Input
7
7
W/BN
Accessory
W/BN
W/BN
A
A
W/BN
15A
Right Turn Feed
6
6
BN
W/V
W/V
B
B
W/V
Left Turn Feed
5
5
V
O
[61B]
[267A] [267B]
[24B] [24A]
A B
[266A]
O/W
1
1
O/W
O/W
Left
A B
[266B]
Turn
W/V
5
5
W/V
W/V
Switch
Anti-Theft
Tracking
[22B] [22A]
Module
(If Equipped)
O/W
1
1
O/W
O/W
Right
Turn
W/BN
5
5
W/BN
W/BN
Switch
V
[20A] [20B]
BK
6
6
BK
BK
Left
Left
Front
Turn
Turn
Indicator
BK
V
5
5
V
V
5
5
V
V
Signal
BN
BN
3
3
BN
BN
2
2
BN
BN
Right
Right
Front
Turn
Turn
Indicator
BK
BK
12
12
BK
BK
1
1
BK
BK
Signal
[31A] [31B]
Except XR,
XR
XL1200C/CP/CA/CB
XL1200C/CP/CA/CB
5
2
6
[7A]
5
2
6
[7A]
5
2
6
[7B]
5
2
6
[7B]
[94B]
5
2
6
5
2
6
[94B]
Right Rear
Turn
[94A]
[18B]
6 5 4 3
2
1
Signal
V
V
1
1
[18A]
1 2
[19A]
2 1
BK
2
2
[18A]
BK
[18B]
1 2
[19B]
2 1
[19B]
V
V
1
1
BK
2
2
[19A]
BK
4
Left Rear
1
3
Right Rear
Left Rear
2
2
Turn
Turn
Turn
3
1
Signal
Signal
Signal
Figure 5-6. Single Stop Lamp Turn Signal Circuit
2013 Sportster Diagnostics: Accessories, Horn, Lighting and Security 5-7
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em00945
Accessory
Power
Front Stop
TSM, TSSM,
[30A] [30B]
Lamp Switch
HFSM
Left Turn Switch Input
8
8
W/V
W/BN
W/BN
M
W/V
W/V
Right Turn Switch Input
7
7
W/BN
Accessory
W/BN
W/BN
A
A
W/BN
15A
Right Turn Feed
6
6
BN
W/V
W/V
B
B
W/V
Left Turn Feed
5
5
V
O
[61B]
[267A] [267B]
[24B] [24A]
A B
[266A]
O/W
1
1
O/W
O/W
Left
A B
[266B]
Turn
W/V
5
5
W/V
W/V
Switch
Anti-Theft
Tracking
[22B] [22A]
Module
(If Equipped)
O/W
1
1
O/W
O/W
Right
Turn
W/BN
5
5
W/BN
W/BN
Switch
V
[20A] [20B]
BK
6
6
BK
BK
Left
Left
Front
Turn
Turn
Indicator
BK
V
5
5
V
V
5
5
V
V
Signal
BN
BN
3
3
BN
BN
2
2
BN
BN
Right
Right
Front
Turn
Turn
Indicator
BK
BK
12
12
BK
BK
1
1
BK
BK
Signal
[31A] [31B]
5
2
6
[7A]
5
2
6
[7B]
(DOM)
(Except DOM)
Right Rear
Turn
Signal
[18B] [18A]
BK
1
1
BK
V
2
2
V/BN
[18A]
1 2
[19A]
2 1
[19B] [19A]
[18B]
1 2
[19B]
2 1
V
2
2
V
BK
1
1
BK
Tail
Right Rear
Left Rear
Left Rear
Lamp
Turn
Turn
Turn
Converter
Signal
Signal
Signal
Module
Figure 5-7. Dual Stop Lamp Turn Signal Circuit
5-8 2013 Sportster Diagnostics: Accessories, Horn, Lighting and Security
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WILL NOT CANCEL UPON TURN
5. Speedometer Test
COMPLETION, NO DTCS
1. Does speedometer register vehicle speed?
a. Yes. Replace TSM, TSSM or HFSM. (6791)
Table 5-4. Will Not Cancel Upon Turn Completion, No
b. No. See 2.1 INITIAL DIAGNOSTICS.
DTCs Diagnostic Faults
POSSIBLE CAUSES
FLASH AT DOUBLE NORMAL RATE, NO
Improper configuration
DTCS
1. TSM, TSSM or HFSM Mounting Test
PART NUMBER
TOOL NAME
1. Verify TSM, TSSM or HFSM is mounted correctly.
99861-02
ELECTRICAL CONTACT LUBRICANT
2. Is TSM, TSSM or HFSM mounted properly?
a. Yes. Go to Test 2.
Table 5-5. Flash at Double Normal Rate, No DTCs
Diagnostic Faults
b. No. Mount correctly.
POSSIBLE CAUSES
2. Correct Configuration Test
Incorrect lamps
1. Check if TSM, TSSM or HFSM is configured correctly.
Lamp malfunction
See 5.12 SERVICE AND EMERGENCY FUNCTIONS
AND CONFIGURATIONS.
NOTE
2. Proper configuration?
Before troubleshooting this issue you should verify that the
a. Yes. Go to Test 3.
lamp loads have been learned by:
b. No. Select proper vehicle configuration.
•
Disconnect the negative battery cable for
1 minute.
Reconnect negative battery cable.
3. 4-Way Cancellation Test
•
Turn IGN OFF-ON.
1. Gain access to the vehicle's TSM, TSSM or HFSM.
•
Activate left turn lamps for 4 or more flashes.
2. See Figure 5-5. Position TSM, TSSM or HFSM in the same
•
Activate right turn lamps for 4 or more flashes.
orientation it is mounted on the vehicle.
3. With IGN ON, turn on 4-way flashers by depressing both
1. Lamp Verification Test
left and right turn signal switches at the same time.
1. Determine correct part number for all installed turn signal
bulbs.
4. Turn IGN OFF. The 4-way flashers should continue to
flash.
2. Verify correct parts are installed on vehicle.
5. Tilt the module greater than 45 degrees to the left.
3. Are the correct parts installed?
6. Repeat steps 2-4 then tilt the module greater than 45
a. Yes. Go to Test 2.
degrees to the right.
b. No. Replace with correct bulbs. (6820)
7. Do 4-way flashers cancel in both directions?
NOTE
a. Yes. Go to Test 4.
Depending on the model and destination, the rear turn signal
b. No. Replace TSM, TSSM or HFSM. (6773)
lamps may use LEDs or conventional bulbs. If conventional
bulbs are present inspect the bulbs and replace as needed.
4. Turn Signals Cancel Test
Replace the entire lamp if the LED fails.
1. Operate vehicle at a speed greater than 7 mph (11.2 km/h)
2. Bulb Corrosion Test
in a straight line.
1. Check for corrosion on bulbs and/or sockets.
2. Activate either turn signal.
2. Is corrosion present?
3. Turn signals should cancel after 20 flashes.
a. Yes. Go to Test 5.
4. Do turn signals cancel?
b. No. Go to Test 3.
a. Yes. System operating properly.
b. No. Go to Test 5.
3. Lamp Connection Terminal Corrosion
Test
1. Check for corrosion on all lamp connection terminals.
2013 Sportster Diagnostics: Accessories, Horn, Lighting and Security 5-9
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2. Is corrosion present?
3. While pressing the right turn signal switch, using HAR-
NESS CONNECTOR TEST KIT (Part No. HD-41404) and
a. Yes. Go to Test 4.
a multimeter, test for voltage on breakout box (gray) ter-
b. No. Replace TSM, TSSM or HFSM. (6791)
minal 7.
4. Is battery voltage present when switch is pressed?
4. Verification Test
a. Yes. Go to Test 8.
1. Clean corrosion from wires and terminals.
b. No. Go to Test 3.
2. Do lamps flash at normal rate?
a. Yes. System OK. (6822)
3. Right Turn Signal Switch Test
b. No. Replace TSM, TSSM or HFSM. (6791)
1. Disconnect right hand controls [22].
2. Test for voltage between [22B] terminal 1 and ground.
5. Lamp Operation Test
1. Remove corrosion with a wire brush.
3. Is battery voltage present?
a. Yes. Go to Test 4.
2. Install ELECTRICAL CONTACT LUBRICANT
(Part
No. 99861-02) in bulb sockets.
b. No. Repair open in (O/W) wire. (5041)
3. Do lamps flash at normal rate?
4. Right Turn Signal Circuit Continuity Test
a. Yes. System OK. (6822)
1. Turn IGN OFF.
b. No. Go to Test 6.
2. Test for continuity between [22B] terminal 5 and breakout
box (gray) terminal 7.
6. Lamp Assembly Test
1. Clean or replace bulb.
3. Is continuity present?
a. Yes. Replace the right turn signal switch. (6811)
2. Do lamps flash at normal rate?
a. Yes. System OK. (6822)
b. No. Repair open in (W/BN) wire. (5041)
b. No. Replace lamp assembly. (6823)
5. Left Turn Signal Circuit Test
1. With IGN OFF, connect BREAKOUT BOX (Part No. HD-
BOTH TURN SIGNAL LAMPS ON ONE SIDE
42682) between wire harness connector [30B] and TSM,
INOPERATIVE, NO DTCS
TSSM or HFSM [30A]. See 1.2 DIAGNOSTIC TOOLS.
2. Turn IGN ON.
PART NUMBER
TOOL NAME
HD-41404
HARNESS CONNECTOR TEST KIT
3. While pressing the left turn signal switch, using HARNESS
CONNECTOR TEST KIT (Part No. HD-41404) and a
HD-42682
BREAKOUT BOX
multimeter, test for voltage on breakout box (gray) terminal
8.
Table 5-6. Both Turn Signal Lamps on One Side
4. Is battery voltage present when switch is pressed?
Inoperative, No DTCs Diagnostic Faults
a. Yes. Go to Test 9.
POSSIBLE CAUSES
b. No. Go to Test 6.
Open on turn signal inputs
6. Left Turn Signal Switch Test
Open accessory circuit
1. Disconnect left hand controls [24].
Left turn signal switch malfunction
Right turn signal switch malfunction
2. Test for voltage between [24B] terminal 1 and ground.
3. Is battery voltage present?
1. Left or Right Turn Signal Malfunction Test
a. Yes. Go to Test 7.
1. With IGN ON, operate the left and right turn signals.
b. No. Repair open in (O/W) wire. (5043)
2. Are the right turn signals inoperative?
a. Yes. Go to Test 2.
7. Left Turn Signal Circuit Continuity Test
b. No. Go to Test 5.
1. Turn IGN OFF.
2. Test for continuity between [24B] terminal 5 and breakout
2. Right Turn Signal Circuit Test
box (gray) terminal 8.
1. With IGN OFF, connect BREAKOUT BOX (Part No. HD-
3. Is continuity present?
42682) between wire harness connector [30B] and TSM,
a. Yes. Replace the right turn signal switch. (6811)
TSSM or HFSM [30A]. See 1.2 DIAGNOSTIC TOOLS.
b. No. Repair open in (W/V) wire. (5041)
2. Turn IGN ON.
5-10 2013 Sportster Diagnostics: Accessories, Horn, Lighting and Security
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2. Do all the turn signals operate on both sides?
8. Right Turn Signal Short to Voltage Test
a. Yes. System operating properly.
1. Release the right turn signal switch.
b. No, right front turn signal inoperative. Go to Test
2. Test for voltage on breakout box (gray) terminal 7.
2.
3. Is battery voltage present?
c. No, left front turn signal inoperative. Go to Test 5.
a. Yes. Repair short to voltage on (W/BN) wire.
d. No, right rear turn signal inoperative, except
b. No, without anti-theft tracking module. Replace
XL1200C/CP/CA/CB. Go to Test 8.
the TSM, TSSM or HFSM. (6791)
e. No, right rear turn signal inoperative,
c. No, with anti-theft tracking module. Go to Test 10.
XL200C/CP/CA/CB. Go to Test 20.
9. Left Turn Signal Short to Voltage Test
f.
No, left rear turn signal inoperative, except
XL200C/CP/CA/CB. Go to Test 11.
1. Release the left turn signal switch.
g. No, left rear turn signal inoperative,
2. Test for voltage on breakout box (gray) terminal 8.
XL200C/CP/CA/CB. Go to Test 25.
3. Is battery voltage present?
2. Right Front Turn Signal Bulb Test
a. Yes. Repair short to voltage on (W/V) wire.
1. Remove the right front turn signal bulb.
b. No, without anti-theft tracking module. Replace
the TSM, TSSM or HFSM. (6791)
2. Inspect the bulb.
c. No, with anti-theft tracking module. Go to Test 10.
3. Is the bulb good?
a. Yes. Go to Test 3.
10. Anti-Theft Tracking Module Test
b. No. Replace the bulb. (6820)
1. Disconnect anti-theft tracking module.
2. Press the inoperative turn signal switch.
3. Right Front Turn Signal Circuit Test
3. Do the turn signals function properly?
1. Disconnect front turn signals [31].
a. Yes. Replace the anti-theft tracking module. (6791)
2. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
41404), connect the
FUEL INJECTOR TEST LIGHT (Part
b. No. Replace the TSM, TSSM or HFSM. (6791)
No. HD-34730-2E) to [31A] between terminals 1 and 2.
ONE TURN SIGNAL LAMP INOPERATIVE,
3. Press the right turn
signal switch.
NO DTCS
4. Does the test light flash?
a. Yes. Replace the right front turn signal. (6823)
PART NUMBER
TOOL NAME
b. No. Go to Test 4.
HD-34730-2E
FUEL INJECTOR TEST LIGHT
HD-41404
HARNESS CONNECTOR TEST KIT
4. Right Front Turn Signal Ground Circuit
Test
Table 5-7. One Turn Signal Lamp Inoperative, No DTCs
1. Test for voltage between [31A] terminal 2 and ground.
Diagnostic Faults
2. Does the test light flash?
POSSIBLE CAUSES
a. Yes. Repair open in (BK) wire between [31A] terminal
1 and ground. (5041)
Open turn signal circuit
Open turn signal ground circuit
b. No. Repair open in (BN) wire between [31A] terminal
2 and TSM, TSSM or HFSM. (5041)
Inoperative turn signal
5. Left Front Turn Signal Bulb Test
1. Inoperative Signal Location Test
1. Remove the left front turn signal bulb.
1. With IGN ON, operate the left and right turn signals.
2. Inspect the bulb.
3. Is the bulb good?
a. Yes. Go to Test 6.
b. No. Replace the bulb. (6820)
6. Left Front Turn Signal Circuit Test
1. Disconnect front turn signals [31].
2013 Sportster Diagnostics: Accessories, Horn, Lighting and Security 5-11
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2. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
3. Is the bulb good?
41404), connect a test light to [31A] between terminals 5
a. Yes. Go to Test 12.
and 6.
b. No. Replace the bulb. (6820)
3. Press the left turn signal switch.
4. Does the test light flash?
12. Left Rear Turn Signal Circuit Test
a. Yes. Replace the left front turn signal. (6823)
1. Disconnect circuit board [94].
b. No. Go to Test 7.
2. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
41404), connect a test light to [94A] or [7A] between ter-
7. Left Front Turn Signal Ground Circuit Test
minals 5 and 6.
1. Test for voltage between [31A] terminal 5 and ground.
3. Press the left turn signal switch.
2. Does the test light flash?
4. Does the test light flash?
a. Yes. Repair open in (BK) wire between [31A] terminal
a. Yes. Go to Test 15.
6 and ground. (5041)
b. No. Go to Test 13.
b. No. Repair open in (V) wire between [31A] terminal
5 and TSM, TSSM or HFSM. (5041)
13. Left Rear Turn Signal Ground Circuit
Test
8. Right Rear Turn Signal Bulb Test
1. Test for voltage between [94B] (single stop lamp) or [7A]
1. Remove the right rear turn signal bulb.
(dual stop lamps) terminal 5 and ground.
2. Inspect the bulb.
2. Does the test light flash?
3. Is the bulb good?
a. Yes. Repair open in (BK) wire between terminal 6
and ground. (5041)
a. Yes. Go to Test 9.
b. No. Repair open in (V) wire between terminal 5 and
b. No. Replace the bulb. (6820)
TSM, TSSM or HFSM. (5041)
9. Right Rear Turn Signal Circuit Test
14. Right Rear Turn Signal Test: Single Stop
1. Disconnect rear lighting [94] (single stop lamp) or [7] dual
Lamp
stop lamps.
1. Connect [94].
2. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
41404), connect a test light to [94B] or [7A] between ter-
2. Disconnect right rear turn signal [18].
minals 2 and 6.
3. Turn on the right turn signal.
3. Press the right turn signal switch.
4. Test for voltage at [18A] between terminals 1 and 2.
4. Does the test light flash?
5. Is voltage fluctuating on and off?
a. Yes, single stop lamp. Go to Test 14.
a. Yes. Replace the right rear turn signal. (6823)
b. Yes, dual stop lamps. Go to Test 16.
b. No. Replace the circuit board. (5215)
c. No. Go to Test 10.
15. Left Rear Turn Signal Test: Single Stop
10. Right Rear Turn Signal Ground Circuit
Lamp
Test
1. Connect [94].
1. Test for voltage between [94B] (single stop lamp) or [7A]
2. Disconnect left rear turn signal [19].
(dual stop lamps) terminal 2 and ground.
3. Turn on the left turn signal.
2. Does the test light flash?
a. Yes. Repair open in (BK) wire between terminal 6
4. Test for voltage at [19A] between terminals 1 and 2.
and ground. (5041)
5. Is voltage fluctuating on and off?
b. No. Repair open in (BN) wire between terminal 2 and
a. Yes. Replace the left rear turn signal. (6823)
TSM, TSSM or HFSM. (5041)
b. No. Replace the circuit board. (5215)
11. Left Rear Turn Signal Bulb Test
16. Right Rear Turn Signal Test: Dual Stop
1. Remove the left rear turn signal bulb.
Lamp
2. Inspect the bulb.
1. Connect [7].
2. Disconnect left rear turn signal [18].
5-12 2013 Sportster Diagnostics: Accessories, Horn, Lighting and Security
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3. Turn on the right turn signal.
4. Is voltage fluctuating?
a. Yes. Go to Test 22.
4. Test for voltage at [18B] between terminals 1 and 2.
b. No. Repair open in (BN) wire. (5041)
5. Is voltage fluctuating on and off?
a. Yes. Replace the right rear turn signal. (6823)
22. Right Rear Turn Signal [7] Ground Test
b. No. (DOM). Replace the tail lamp converter module.
1. Turn IGN OFF.
(6809)
2. Test for continuity between [18B] terminal 6 (BK) wire and
c. No. (Except DOM). Go to Test 17.
ground.
17. Right Rear Turn Signal Ground Test:
3. Is continuity present?
Dual Stop Lamp
a. Yes. Go to Test 23.
1. Test for voltage at [18B] between terminal 2 and ground.
b. No. Repair open in (BK) wire. (5041)
2. Is voltage fluctuating on and off?
23. Right Rear Turn Signal [18] Ground Test
a. Yes. Repair open in (BK) wire. (5041)
1. Connect [7].
b. No. Repair open in (BN) wire. (5041)
2. Disconnect right rear turn signal [18].
18. Left Rear Turn Signal Test: Dual Stop
3. Test for continuity between [18A] terminal 1 (BK) wire and
Lamp
ground.
1. Connect [7].
4. Is continuity present?
a. Yes. Go to Test 24.
2. Disconnect right rear turn signal [19].
b. No. Repair open in (BK) wire. (5041)
3. Turn on the left turn signal.
4. Test for voltage at [19B] between terminals 1 and 2.
24. Right Rear Turn Signal Power [18]
5. Is voltage fluctuating on and off?
Circuit Test
a. Yes. Replace the left rear turn signal. (6823)
1. Test for voltage at [18A] terminal 2 (BN) wire.
b. No. (DOM). Replace the tail lamp converter module.
2. Turn IGN ON and press the right turn signal switch.
(6809)
3. Is voltage fluctuating?
c. No. (Except DOM). Go to Test 19.
a. Yes. Repair right rear turn signal socket assembly.
19. Left Rear Turn Signal Ground Test: Dual
b. No. Repair open in (BN) wire. (5041)
Stop Lamp
25. Left Rear Turn Signal Bulb Test
1. Test for voltage at [19B] between terminal 2 and ground.
1. Turn IGN OFF.
2. Is voltage fluctuating on and off?
2. Remove the left rear turn signal bulb.
a. Yes. Repair open in (BK) wire. (5041)
3. Inspect the bulb.
b. No. Repair open in (V) wire. (5041)
4. Is the bulb good?
20. Right Rear Turn Signal Bulb Test
a. Yes. Go to Test 26.
1. Turn IGN OFF.
b. No. Replace the bulb. (6820)
2. Remove the right rear turn signal bulb.
26. Left Rear Turn Signal Power [7] Circuit
3. Inspect the bulb.
Test
4. Is the bulb good?
1. Disconnect rear lighting [7].
a. Yes. Go to Test 21.
2. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
b. No. Replace the bulb. (6820)
41404), test for voltage at [7A] terminal 5 (V) wire.
3. Turn IGN ON and press the left turn signal switch.
21. Right Rear Turn Signal Power [7] Circuit
Test
4. Is voltage fluctuating?
a. Yes. Go to Test 27.
1. Disconnect rear lighting [7].
b. No. Repair open in (V) wire. (5041)
2. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
41404), test for voltage at [7A] terminal 2 (BN) wire.
3. Turn IGN ON and press the right turn signal switch.
2013 Sportster Diagnostics: Accessories, Horn, Lighting and Security 5-13
HOME
4. Is continuity present?
27. Left Rear Turn Signal [7] Ground Test
a. Yes. Go to Test 29.
1. Turn IGN OFF.
b. No. Repair open in (BK) wire. (5041)
2. Test for continuity between [18B] terminal 6 (BK) wire and
ground.
29. Left Rear Turn Signal Power [18] Circuit
3. Is continuity present?
Test
a. Yes. Go to Test 28.
1. Test for voltage at [19A] terminal 2 (V) wire.
b. No. Repair open in (BK) wire. (5041)
2. Turn IGN ON and press the left turn signal switch.
28. Left Rear Turn Signal [18] Ground Test
3. Is voltage fluctuating?
1. Connect [7].
a. Yes. Repair left rear turn signal socket assembly.
2. Disconnect right rear turn signal [19].
b. No. Repair open in (V) wire. (5041)
3. Test for continuity between [19A] terminal 1 (BK) wire and
ground.
5-14 2013 Sportster Diagnostics: Accessories, Horn, Lighting and Security
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HEADLAMPS
5.4
DESCRIPTION AND OPERATION
Diagnostic Tips
Use the headlamp switch to select either the high beam or the
If the lights fuse is open,
low beam headlamps. When the ignition is turned ON the
•
Test for short to ground on (BE) wire from the fuse to the
headlamp switch receives power through the lights fuse.
headlamp switch.
•
In the low position, the headlamp switch directs voltage
•
Check for a short to ground on the (W) wire from the
to illuminate the low beam headlamp.
headlamp switch. If this circuit is grounded, it will open the
•
In the high position, voltage is directed to the high beam
fuse when the headlamp switch is in the high position.
headlamp and the high beam indicator.
Connector Information
For additional information about the connectors in the following
ed01997
2
diagram(s) and diagnostic procedure(s), including the color of
9
1
the harness test kit terminal probes, see B.1 CONNECTORS.
3
4
5
8
7
6
1. Front turn signals [31]
2. Instruments [20]
3. Right hand controls [22]
4. IAC [87]
5. TMAP [80]
6. Rear fuel injector [85]
7. Front fuel injector [84]
8. Left hand controls [24]
9. Headlamp [38]
Figure 5-8. Under Fuel Tank Left Side
2013 Sportster Diagnostics: Accessories, Horn, Lighting and Security 5-15
HOME
em00957
Ignition
Power
G
Lights
15A
H
[61B]
BE
[38A] [38B]
[24A] [24B]
High
W
2
2
W
High
High
Low
Low
Y
2
2
Y
Y
3
3
Y
Low
Low
Headlamp
BE
3
3
BE
BK
4
4
BK
GND
GND
W
4
4
W
High
Headlamp
Hi/Lo
Switch
Chassis
[20B]
4
12
Ground
[20A]
4
12
GND 1
High Beam
Indicator
Figure 5-9. Headlamp and Running Lamps
HEADLAMP INOPERATIVE, NO DTCS
1. Operational Test
1. Turn IGN ON.
PART NUMBER
TOOL NAME
2. Move the headlamp switch to the high and low positions.
HD-41404
HARNESS CONNECTOR TEST KIT
3. Do the headlamps work in both positions?
a. Yes. Concern is intermittent perform wiggle test. See
Table 5-8. Headlamp Inoperative, No DTCs Diagnostic
1.3 DIAGNOSTICS AND TROUBLESHOOTING,
Faults
Wiggle Test.
POSSIBLE CAUSES
b. No, high beam headlamp inoperative. Go to Test
Open fuse
2.
Open power to switch circuit
c. No, low beam headlamp inoperative. Go to Test 5.
Headlamp Hi/Lo switch malfunction
d. No, both headlamps inoperative. Go to Test 7.
Open ground circuit
2. High Beam Indicator Test
Open high beam power circuit
1. With the headlamp Hi/Lo switch in the high position,
Open low beam power circuit
observe the high beam indicator lamp.
Headlamp malfunction
5-16 2013 Sportster Diagnostics: Accessories, Horn, Lighting and Security
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2. Does the high beam indicator illuminate?
8. Headlamp Test
a. Yes. Go to Test 4.
1. Disconnect the headlamp.
b. No. Go to Test 3.
2. With the IGN ON and the headlamp Hi/Lo switch in the
high position, test for voltage between [38A] terminals 2
3. Headlamp Hi/Lo Switch Test
and 4.
1. With IGN OFF, disconnect left hand controls [24].
3. Is battery voltage present?
2. Using a HARNESS CONNECTOR TEST KIT (Part No. HD-
a. Yes. Replace the headlamp. (5185)
41404), jumper [24B] terminals 3 and 4 together.
b. No. Repair open in (BK) wire between headlamp and
3. Turn IGN ON.
ground. (5041)
4. Does the high beam headlamp operate?
9. Ignition Power Circuit Test
a. Yes. Replace the left switch assembly. (5171)
1. With IGN ON, observe the tail lamp.
b. No. Repair open in (W) wire between [24B] and
indicator. (5041)
2. Is the tail lamp illuminated?
a. Yes. Go to Test 10.
4. High Beam Headlamp Test
b. No. Go to Test 11.
1. Disconnect the headlamp.
10. Headlamp Hi/Lo Switch Test
2. With the IGN ON and the headlamp Hi/Lo switch in the
high position using HARNESS CONNECTOR TEST KIT
1. With the IGN OFF, disconnect left hand controls [24].
(Part No. HD-41404) and a multimeter, test for voltage
2. Using a HARNESS CONNECTOR TEST KIT (Part No. HD-
between [38A] terminals 2 and 4.
41404), jumper [24B] terminals 2 and 3 together.
3. Is battery voltage present?
3. Turn IGN ON.
a. Yes. Replace the headlamp. (5185)
4. Does the low beam headlamp operate?
b. No. Repair open in (W) wire to headlamp. (5041)
a. Yes. Replace the left switch assembly. (5171)
5. Headlamp Hi/Lo Switch
Test
b. No. Repair open in (BE) wire to [24B]. (5039)
1. With the IGN OFF, disconnect left hand controls [24].
11. Lights Fuse Test
2. Using a HARNESS CONNECTOR TEST KIT (Part No. HD-
1. Inspect the lights fuse.
41404), jumper [24B] terminals 2 and 3 together.
2. Is the fuse good?
3. Turn IGN ON.
a. Yes. Go to Test 12.
4. Does the low beam headlamp operate?
b. No. Go to Test 13.
a. Yes. Replace the left switch assembly. (5171)
b. No. Go to Test 6.
12. Power Circuit Test
1. Test for voltage on [61B] socket terminal G of the lights
6. Low Beam Headlamp Test
fuse.
1. Connect [24].
2. Is battery voltage present?
2. Disconnect the headlamp.
a. Yes. Repair open in (BE) wire between fuse block
3. With the headlamp Hi/Lo switch in the low position using
and headlamp Hi/Lo switch. (5039)
HARNESS CONNECTOR TEST KIT (Part No. HD-41404)
b. No. Repair open in (R/BK) wire. (5041)
and a multimeter, test for voltage between terminals 3 and
4 of [38A].
13. Power Circuit Short to Ground Test
4. Is battery voltage present?
1. With IGN OFF, remove the lights fuse.
a. Yes. Replace the headlamp. (5185)
2. Disconnect left hand controls [24].
b. No. Repair open in (Y) wire to headlamp. (5041)
3. Measure resistance between [24B] terminal 3 and ground.
7. High Beam Indicator Test
4. Is resistance less than 10 Ohms?
1. With the headlamp Hi/Lo switch in the high position,
a. Yes. Go to Test 14.
observe the high beam indicator lamp.
b. No. Go to Test 17.
2. Does the high beam indicator illuminate?
14. Tail Lamp Test
a. Yes. Go to Test 8.
1. Disconnect rear lighting [94] or [7].
b. No. Go to Test 9.
2013 Sportster Diagnostics: Accessories, Horn, Lighting and Security 5-17
HOME
2. Measure resistance between [24B] terminal 3 and ground.
17. Low Beam Circuit Short to Ground Test
3. Is resistance less than 10 Ohms?
1. Measure resistance between [24B] terminal 2 and ground.
a. Yes. Go to Test 15.
2. Is resistance less than 10 Ohms?
b. No. Go to Test 16.
a. Yes. Repair short to ground in (Y) low beam circuit.
(5041)
15. Front Turn Signal Test
b. No. Go to Test 18.
1. Disconnect front turn signals [31].
18. High Beam Circuit Short to Ground Test
2. Measure resistance between [24B] terminal 3 and ground.
1. Measure resistance between [24B] terminal 4 and ground.
3. Is resistance less than 10 Ohms?
a. Yes. Repair short to ground in (BE) wire between
2. Is resistance less than 10 Ohms?
[24B] and fuse block. (5039)
a. Yes. Go to Test 19.
b. No. Repair short to ground in front turn signal. (5041)
b. No. Intermittent short perform wiggle test. See
1.3 DIAGNOSTICS AND TROUBLESHOOTING,
16. Rear Turn Signal Test
Wiggle Test. Replace lights fuse and verify repair.
(6822)
1. Connect [94] or [7].
2. Disconnect rear lighting [93] (single tail lamp) or [18] and
19. Indicator Short to Ground Test
[19] dual tail lamp.
1. Disconnect the [20].
3. Measure resistance between [93A] terminal 1 and ground
2. Using HARNESS CONNECTOR TEST KIT (Part No. HD-
(single tail lamp) or [18A] and [19A] terminal 3 (dual tail
41404) and a multimeter, measure resistance between
lamp).
[24B] terminal 4 and ground.
4. Is resistance less than 10 Ohms?
3. Is resistance less than 10 Ohms?
a. Yes, single stop lamp. Replace the circuit board.
a. Yes. Repair short to ground in (W) high beam circuit.
(5215)
(5041)
b. Yes, dual tail lamps DOM. Replace the converter
b. No. Repair or replace the indicator harness. (5191)
module. (6809)
c. Yes, dual tail lamps HDI. Repair short to ground in
(O/W) wire between [7B] and tail lamps. (5039)
d. No. Replace tail/stop lamp assembly. (5215)
5-18 2013 Sportster Diagnostics: Accessories, Horn, Lighting and Security
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STOP LAMPS
5.5
DESCRIPTION AND OPERATION
ed01999
2
3
See Figure 5-10. The front and rear stop lamp switches control
the stop lamp portion of the tail/stop lamp. The front stop lamp
11
switch is a mechanical switch. When the front stop lamp lever
1
is applied, the lever presses a mechanical switch and closes
10
4
the contacts on the switch.
The rear stop lamp switch is a pressure switch. When the rear
5
9
stop lamp switch is applied, it generates pressure in the brake
fluid. This pressure in the fluid causes the contacts for the rear
8
stop lamp switch to close. The fuse supplies power to the stop
lamp switches.
7
•
When the front stop lamp switch closes (front brake lever
pulled in), power flows through the switch to the tail/stop
lamp.
6
•
When the rear stop lamp switch is applied (rear brake
1. Fuse block [61]
pedal pressed), power flows through the switch to the
2. Positive battery cable
tail/stop lamp.
3. Battery
4. Main fuse [5]
5. DLC [91]
6. Rear stop lamp switch (XL models) [121]
7. Fuel pump and low fuel switch [141]
8. Rear O2 sensor [137]
9. Starter
10. Rear O2 sensor
11. ECM
Figure 5-10. Under Left Side Cover: XL
Diagnostic Tips
When testing for a short to ground due to an open fuse, check
the (R/Y) wire between the brake switches and the stop lamp.
A short to ground on these wires causes the fuse to open only
when the brake switches are closed. A short to ground in the
(Y/BK) wire between the horn switch and the horn causes this
fuse to open when the horn switch is pressed and needs to be
checked for a short to ground as well.
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: Accessories, Horn, Lighting and Security 5-19
HOME
em01444
Accessory
Power
M
Accessory
15A
O
[61B]
[22B] [22A]
O/W
1
1
O/W
Front
Stop
Lamp
R/Y
2
2
R/Y
Switch
Chassis
BK
R/Y
1
Rear
Ground
Pressure
Stop
Switch
Lamp
O/W
1
Switch
[121B] [121A]
GND 1
Single Stop Lamp
(Except XL 1200C/CP/CA/CB)
Dual Stop Lamps
XL 1200C/CP/CA/CB
6
4
[7A]
6
4
[7A]
6
4
[7A]
6
4
[7B]
6
4
[7B]
6
4
[7B]
[94B]
6
4
6
4
[94B]
3
2
[40A]
(DOM)
(Except DOM)
3
2
[40B]
XR
Except XR
6
4
[94A]
Tail Lamp
R/Y
Circuit
Converter
Board
Module
Stop
Lamp
4
3
[93A]
4
3
[93B]
[19B]
2
1
2
1
[18B]
[18A]
1
4
1
4
[19A]
[19A]
2
1
2
1
[18A]
[18B]
1
4
1
4
[19B]
Stop
Lamp
Left Turn
Right Turn
Right Turn
Left Turn
Signal
Signal
Signal
Signal
Figure 5-11. Tail/Stop and Turn Signal Lamps
5-20 2013 Sportster Diagnostics: Accessories, Horn, Lighting and Security
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multimeter, measure resistance between [61B] socket
STOP LAMP INOPERATIVE
terminal O and ground.
PART NUMBER
TOOL NAME
2. Is resistance less than 10 Ohms?
HD-41404
HARNESS CONNECTOR TEST KIT
a. Yes. Go to Test 6.
b. No. See diagnostic tips. Replace accessories fuse
and verify repair. (6822)
Table 5-9. Stop Lamp Inoperative Diagnostic Faults
POSSIBLE CAUSES
6. Speedometer Test
Open fuse
1. Disconnect the speedometer [39].
Short in stop lamp circuit
2. Measure resistance between [61B] socket terminal O and
Open power to switch circuit
ground.
Open ground circuit
3. Is resistance less than 10 Ohms?
Open stop lamp circuit
a. Yes, without tachometer. Repair short to ground in
accessory circuit (O/W) wire. (5043)
Stop lamp malfunction
Rear stop lamp switch malfunction
b. Yes, with tachometer. Go to Test 7.
Front stop lamp switch malfunction
c. No. Replace the speedometer. (6765)
1. Accessory Circuit Test
7. Tachometer Test
1. Turn IGN to ACC.
1. Disconnect the tachometer [108].
2. Do the instruments illuminate?
2. Measure resistance between [61B] socket terminal O and
ground.
a. Yes. Go to Test 8.
3. Is resistance less than 10 Ohms?
b. No. Go to Test 2.
a. Yes. Repair short to ground in accessory circuit (O/W)
2. Accessories Fuse Test
wire. (5043)
1. Inspect the ACCY fuse.
b. No. Replace the tachometer. (6772)
2. Is the fuse good?
8. Stop
Lamp Switch Test
a. Yes. Go to Test 3.
1. Apply the front stop lamp switch while observing the stop
b. No. Go to Test 5.
lamp.
2. Apply the rear stop lamp switch while observing the stop
3. Accessory Circuit from Ignition Switch
lamp.
Test
3. Does the stop lamp illuminate?
1. With IGN in ACC, using HARNESS CONNECTOR TEST
a. Yes, stop lamp illuminates only with front stop
KIT (Part No. HD-41404) and a multimeter, test for voltage
lamp switch applied. Go to Test 11.
between [61B] socket terminal M and ground.
b. Yes, stop lamp illuminates only with rear stop
2. Is battery voltage present?
lamp switch applied. Go to Test 13.
a. Yes. Repair open in (O/W) wire from ACCY fuse.
(5043)
c. No. Go to Test 9.
b. No. Go to Test 4.
9. Tail Stop Lamp Test
4. Ignition Switch Test
1. Disconnect rear lighting [94] (single stop lamp) or [7] (dual
stop lamps).
1. Inspect for open or damaged wires between the ignition
switch and the accessory fuse.
2. With one of the stop lamp switches applied test for voltage
between [94B] (single stop lamp) or [7A] (dual stop lamps)
2. Was any damage to the wiring found?
terminals 4 and 6.
a. Yes. Repair open between [61B] socket terminal M
and ignition switch. (5041)
3. Is battery voltage present?
a. Yes, single stop lamp, except XL1200C, CP, CA,
b. No. Replace the ignition switch. (7287)
CB. Go to Test 15.
5. Accessory Circuit Resistance Test
b. Yes, single stop lamp, XL1200C, CP, CA, CB. Go
to Test 20.
1. With the accessories fuse removed, using HARNESS
CONNECTOR TEST KIT (Part No. HD-41404) and a
c. Yes, dual stop lamps. Go to Test 17.
d. No. Go to Test 10.
2013 Sportster Diagnostics: Accessories, Horn, Lighting and Security 5-21
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