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2013 Sportster Electrical Diagnostic Manual .pdf


Original filename: 2013 Sportster Electrical Diagnostic Manual.pdf
Title: 99495-13
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2013 Harley-Davidson Sportster Models
Electrical Diagnostic Manual
99495-13
©2012 H-D.

IMPORTANT NOTICE

Harley-Davidson motorcycles conform to all applicable U.S.A. Federal Motor Vehicle Safety Standards
and U.S.A. Environmental Protection Agency regulations effective on the date of manufacture.
To maintain the safety, dependability, and emission and noise control performance, it is essential that
the procedures, specifications and service instructions in this manual are followed.
Any substitution, alteration or adjustment of emission system and noise control components outside of
factory specifications may be prohibited by law.

Harley-Davidson Motor Company

2013 Harley-Davidson
Sportster Models Electrical
Diagnostic Manual
©2012 H-D.
ALL RIGHTS RESERVED
99495-13
Printed in the U.S.A.

VISIT THE HARLEY-DAVIDSON WEB SITE
http://www.harley-davidson.com

Blank Text Here

READER COMMENTS
Blank Text Here
The Harley-Davidson Service Communications Department maintains a continuous effort to improve the quality
and usefulness of its publications. To do this effectively, we need user feedback - your critical evaluation of
this manual.

Please comment on the completeness, accuracy, organization, usability, and readability of this manual.

Please list the page, item, and part number(s) of any errors you find in this manual.

Please tell us how we can improve this manual.

Occupation:

Name:

Dealership:

Street:

Department:

City:

State:

2013 Harley-Davidson Sportster Models Electrical Diagnostic Manual (99495-13)

Please clip out and mail to:
Service Communications Department
Harley-Davidson Motor Company
P.O. Box 653
Milwaukee, WI USA 53201

Zip:

NOTES

ABOUT THIS MANUAL
GENERAL
This electrical diagnostic service manual has been prepared
with two purposes in mind. First, it will acquaint the user with
the construction of the Harley-Davidson product and assist in
the performance of repair. Secondly, it will introduce to the
professional Harley-Davidson Technician the latest field-tested
and factory-approved diagnostic methods. We sincerely believe
that this manual will make your association with Harley-Davidson products more pleasant and profitable.

HOW TO USE YOUR SERVICE MANUAL
Refer to the table below for the content layout of this manual.
CHAPTER

1

General Information

2

Initial Diagnostics and Serial Data

3

Starting and Charging

4

Instruments

5

Accessories, Horn, Lighting and Security

6

Engine Management

A

Appendix A Connector Repair

B

Appendix B Wiring

C

Appendix C Conversions

D

Appendix D Glossary

For example, a cross-reference shown as 2.2
SPECIFICATIONS refers to chapter 2 CHASSIS, heading 2.2
SPECIFICATIONS.
For quick and easy reference, all pages contain a chapter
number followed by a page number. For example, page 3-5
refers to page 5 in Chapter 3.
A number of acronyms and abbreviations are used in this
document. See the D.1 GLOSSARY for a list of acronyms,
abbreviations and definitions.

PREPARATION FOR SERVICE

HD-48650



To avoid unnecessary disassembly, carefully read all
related service information before repair work begins.



In figure legends, the number which follows the name of
a part indicates the quantity necessary for one complete
assembly.



When servicing a vehicle equipped with the Harley-Davidson Smart Security System (H-DSSS), it must first be
disarmed. Keep the fob close to the vehicle or use
DIGITAL TECHNICIAN II (Part No. HD-48650) to disable
the system. Activate the system after service is completed.

SERVICE BULLETINS
In addition to the information presented in this manual, HarleyDavidson Motor Company will periodically issue service bulletins to Harley-Davidson dealers. Service bulletins cover
interim engineering changes and supplementary information.
Consult the service bulletins to keep your product knowledge
current and complete.

USE GENUINE REPLACEMENT PARTS

Use the TABLE OF CONTENTS (which follows this FOREWORD) and the INDEX (at the back of this manual) to quickly
locate subjects. Chapters and topics in this manual are
sequentially numbered for easy navigation.

PART NUMBER

NOTES

Harley-Davidson parts and accessories are designed for
Harley-Davidson motorcycles. Using non-Harley-Davidson
parts or accessories can adversely affect performance,
stability or handling, which could result in death or serious
injury. (00001b)
To achieve satisfactory and lasting repairs, carefully follow the
service manual instructions and use only genuine HarleyDavidson replacement parts. Behind the emblem bearing the
words GENUINE HARLEY-DAVIDSON stand more than 100
years of design, research, manufacturing, testing and inspecting
experience.This is your assurance that the parts you are using
will fit right, operate properly and last longer.

WARNINGS AND CAUTIONS
Statements in this manual preceded by the following words
are of special significance.

TOOL NAME
DIGITAL TECHNICIAN II

Stop the engine when refueling or servicing the fuel
system. Do not smoke or allow open flame or sparks near
gasoline. Gasoline is extremely flammable and highly
explosive, which could result in death or serious injury.
(00002a)
Good preparation is very important for efficient service work.
Start each job with a clean work area. This will allow the repair
to proceed as smoothly as possible. It will also reduce the
incidence of misplaced tools and parts. Clean a motorcycle
that is excessively dirty before work starts. Cleaning will occasionally uncover sources of trouble. Gather any tools, instru-

WARNING indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury. (00119a)

CAUTION indicates a potentially hazardous situation
which, if not avoided, may result in minor or moderate
injury. (00139a)

NOTICE indicates a potentially hazardous situation which,
if not avoided, may result in property damage. (00140b)

I

FOREWORD

NO.

ments and any parts needed for the job before work begins.
Interrupting a job to locate tools or parts is a distraction and
causes needless delay.

NOTE
Refers to important information, and is placed in italic type. It
is recommended that you take special notice of these items.
Proper service and repair is important for the safe, reliable
operation of all mechanical products. The service procedures
recommended and described in this manual are effective
methods for performing service operations.

Always wear proper eye protection when using hammers,
arbor or hydraulic presses, gear pullers, spring compressors, slide hammers and similar tools. Flying parts
could result in death or serious injury. (00496b)
Some of these service operations require the use of tools
specially designed for the purpose. These special tools should
be used when and as recommended. It is important to note
that some warnings against the use of specific service methods,
which could damage the motorcycle or render it unsafe, are
stated in this manual. However, remember that these warnings
are not all-inclusive. Inadequate safety precautions could result
in death or serious injury.
Since Harley-Davidson could not possibly know, evaluate or
advise the service trade of all possible ways in which service
might be performed, or of the possible hazardous consequences of each method, we have not undertaken any such
broad evaluation. Accordingly, anyone who uses a service
procedure or tool which is not recommended by Harley-Davidson must first thoroughly satisfy himself that neither his nor
the operator's safety will be jeopardized as a result. Failure to
do so could result in death or serious injury.

PRODUCT REFERENCES

Read and follow warnings and directions on all products.
Failure to follow warnings and directions can result in
death or serious injury. (00470b)
When reference is made in this manual to a specific brand
name product, tool or instrument, an equivalent product, tool
or instrument may be substituted.

Kent-Moore Products
All tools mentioned in this manual with an "HD", "J" or "B"
preface must be ordered through SPX Kent-Moore. For ordering
information or product returns, warranty or otherwise, visit
www.spx.com.

II FOREWORD

LOCTITE Sealing and THREADLOCKING
Products
Some procedures in this manual call for the use of LOCTITE
products. If you have any questions regarding LOCTITE product
usage or retailer/wholesaler locations, contact Loctite Corp. at
www.loctite.com.

PRODUCT REGISTERED MARKS
Apple, Alcantara S.p.A., Allen, Amp Multilock, Bluetooth,
Brembo, Delphi, Deutsch, Dunlop, Dynojet, Fluke, G.E.
Versilube, Garmin, Gunk, Hydroseal, Hylomar, iPhone, iPod,
Kevlar, Lexan, Loctite, Lubriplate, Keps, K&N, Magnaflux,
Marson Thread-Setter Tool Kit, MAXI fuse, Molex, Michelin,
MPZ, Mulitilock, nano, NGK, Novus, Packard, Pirelli, Permatex,
Philips, PJ1, Pozidriv, Robinair, S100, Sems, Snap-on, Teflon,
Threadlocker, Torca, Torco, TORX, Tufoil, Tyco, Ultratorch,
Velcro, X-Acto, XM Satellite Radio, and zumo are among the
trademarks of their respective owners.

H-D MICHIGAN, INC. TRADEMARK
INFORMATION
Bar & Shield, Cross Bones, Digital Tech, Digital Technician,
Digital Technician II, Dyna, Electra Glide, Evolution, Fat Bob,
Fat Boy, Forty-Eight, Glaze, Gloss, H-D, H-Dnet.com, Harley,
Harley-Davidson, HD, Heritage Softail, Iron 883, Low Rider,
Night Rod, Nightster, Night Train, Profile, Revolution, Road
Glide, Road King, Road Tech, Rocker, Screamin' Eagle, Seventy-Two, Softail, Sportster, Street Glide, Street Rod, Sun Ray,
Sunwash, Super Glide, SuperLow, Switchback, SYN3, TechLink, TechLink II, Tour-Pak, Twin Cam 88, Twin Cam 88B,
Twin Cam 96, Twin Cam 96B, Twin Cam 103, Twin Cam 103B,
Twin Cam 110, Twin Cam 110B, Ultra Classic, V-Rod, VRSC,
XR1200X and Harley-Davidson Genuine Motor Parts and
Genuine Motor Accessories are among the trademarks of HD Michigan, Inc.

CONTENTS
All photographs, illustrations and procedures may not necessarily depict the most current model or component, but are
based on the latest production information available at the time
of publication.
Since product improvement is our continual goal, Harley-Davidson reserves the right to change specifications, equipment
or designs at any time without notice and without incurring
obligation.

1.1 SPECIFICATIONS AND COMPONENT
LOCATIONS
Specifications.....................................................................1-1
Component Locations........................................................1-1

1.2 DIAGNOSTIC TOOLS
How To Use Diagnostic Tools.............................................1-7
GRX-3110 HD Battery Diagnostic Station...................1-7
HD-26792 Spark Tester...............................................1-7
HD-34730-2E Fuel Injector Test Light.........................1-7
HD-39978 Digital Multimeter (Fluke 78)......................1-8
HD-41199-3 IAC Test Light..........................................1-8
HD-41404 Harness Connector Test Kit.......................1-8
HD-42682 Breakout Box.............................................1-8
HD-42682 Breakout Box (TSM, TSSM or HFSM).......1-9
HD-43876 Breakout Box (ECM)..................................1-9
HD-44687 Ignition Coil Circuit Test Adapter..............1-10
HD-48650 Digital Technician II..................................1-10

1.3 DIAGNOSTICS AND
TROUBLESHOOTING
Voltage Drop.....................................................................1-11
Voltage Drop Test......................................................1-11
Wiggle Test.......................................................................1-12
Relay Diagnostics.............................................................1-12
Relay Variation..........................................................1-12
Relay Test..................................................................1-12
Job/Time Codes Values....................................................1-13

INITIAL DIAGNOSTICS AND SERIAL
DATA
2.1 INITIAL DIAGNOSTICS
Description and Operation..................................................2-1
Retrieving Trouble Codes...................................................2-1
Odometer Self-Diagnostics.................................................2-1
Diagnostic Mode..........................................................2-1
Initial Diagnostics...............................................................2-1
1. Verifying Current DTC Test......................................2-1
2. Battery Power Test...................................................2-1
3. Ignition Power Test...................................................2-1
4. Engine Stop Switch Circuit Test...............................2-2
5. Security System Test...............................................2-2
6. Starter System Test.................................................2-2
7. Engine Running Test................................................2-2
8. Verification Test........................................................2-2
Diagnostics.........................................................................2-2
Diagnostic Tips............................................................2-2
Code Types.........................................................................2-4
Current........................................................................2-4
Historic........................................................................2-4
Multiple Trouble Codes.......................................................2-5
Clearing DTCs....................................................................2-5
Security Lamp....................................................................2-5
Check Engine Lamp...........................................................2-5
Symptoms..........................................................................2-6
Connector Information.................................................2-7

2.2 SERIAL DATA COMMUNICATION
Description and Operation................................................2-12
Components.....................................................................2-12
Electronic Control Module (ECM)..............................2-12

Speedometer and Tachometer..................................2-12
TSM, TSSM or HFSM...............................................2-12
Data Link Connector (DLC).......................................2-12
Communication DTCs and "Bus Er".................................2-13
Diagnostic Tips..........................................................2-13

2.3 DTC U1016, U1064, U1097, U1098, U1255
Description and Operation................................................2-14
Diagnostic Tips..........................................................2-14
Connector Information...............................................2-14
DTC U1016......................................................................2-15
1. Open Ground Test.................................................2-15
2. Switched Power Circuit Open Test.........................2-15
3. TSM, TSSM or HFSM Serial Data Circuit Continuity
Test............................................................................2-15
4. Speedometer Serial Data Circuit Continuity Test....2-16
5. Tachometer Serial Data Circuit Continuity Test......2-16
DTC U1064, U1255..........................................................2-16
1. Fuse Test...............................................................2-16
2. Loss of Battery Power Test....................................2-16
3. Loss of Ignition Power Test....................................2-16
4. Loss of Ground Test...............................................2-16
5. Speedometer Serial Data Circuit Continuity Test....2-16
6. Power Circuit Short to Ground Test.......................2-16
7. ECM Serial Data Circuit Continuity Test................2-17
8. Tachometer Serial Data Circuit Continuity Test......2-17
DTC U1097, U1255..........................................................2-17
1. Fuse Test...............................................................2-17
2. Loss of Power Test.................................................2-17
3. Loss of Ground Test...............................................2-17
4. Speedometer Serial Data Circuit Continuity Test....2-17
5. Power Circuit Short to Ground Test.......................2-17
6. ECM Serial Data Circuit Continuity Test................2-17
DTC U1098, U1255..........................................................2-18
1. Fuse Test...............................................................2-18
2. Loss of Power Test.................................................2-18
3. Loss of Ground Test...............................................2-18
4. Tachometer Serial Data Circuit Continuity Test......2-18
5. Power Circuit Short to Ground Test.......................2-18
6. ECM Serial Data Circuit Continuity Test................2-18

2.4 DTC U1300, U1301 OR BUS ER
Description and Operation................................................2-19
Diagnostic Tips..........................................................2-19
Connector Information...............................................2-19
DTC U1300......................................................................2-20
1. Serial Data Short to Ground Test...........................2-20
2. ECM Test...............................................................2-20
3. TSM, TSSM or HFSM Test.....................................2-20
4. Tachometer Test: XL (If Vehicle is not Equipped with
Tachometer, Go to Test 5.)........................................2-20
5. Serial Data Short to Ground Test: XL....................2-20
6. Speedometer Test: XR...........................................2-20
7. Serial Data Short to Ground Test: XR....................2-20
8. Serial Data Circuit Open Test................................2-20
9. Intermittent Test.....................................................2-20
DTC U1301......................................................................2-21
1. Serial Data Short to Voltage Test...........................2-21
2. ECM Test...............................................................2-21
3. TSM, TSSM or HFSM Test.....................................2-21
4. Tachometer Test: XL (If Vehicle is not Equipped with
Tachometer, Go to Test 5.)........................................2-21
5. Serial Data Short to Voltage Test: XL.....................2-21
6. Speedometer Test: XR...........................................2-21
7. Serial Data Short to Ground Test: XR....................2-21
8. Serial Data Circuit Open Test................................2-21
9. Intermittent Test.....................................................2-21
III

TABLE OF CONTENTS

GENERAL INFORMATION


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