Harley Davidson 2013 Sportster Models. Service Manual - page 34

2013 Sportster Service: Appendix B Wiring B-1

Table B-1. Sportster Connector Locations

LOCATION

TERMINAL

PROBE
COLOR

TYPE

DESCRIPTION

NO.

Behind starter

Gray

3-place Delphi 150.2 Sealed
(BK)

VSS

[65]

Left side frame, in front of oil filter

Green

2-place Dekko (BK)

Voltage regulator

[77]

Behind rear cylinder

Breakout Box

36-place Delphi 100W Sealed
(GY)

ECM (XL)

[78]

Under seat

Breakout Box

36-place Delphi 100W Sealed
(GY)

ECM (XR)

[78]

Left side frame under oil filter

Brown

2-place Deutsch DTM Sealed
(BK)

CKP sensor

[79]

Top of intake manifold

Purple

4-place Bosch 1.1M sealed
(BK)

TMAP sensor

[80]

Under fuel tank

Gray

4-place Delphi GT 150 Sealed
(BK)

Ignition coil

[83]

Top of induction manifold

Purple

2-place Molex BPT Sealed (BK)

Front fuel injector

[84]

Top of induction manifold

Purple

2-place Molex BPT Sealed (BK)

Rear fuel injector

[85]

Top of induction manifold

Gray

4-place Delphi 150.2 sealed
(BK)

IAC

[87]

Behind air cleaner mounting plate

Gray

3-place Delphi 150.2 Sealed
(BK)

TPS

[88]

On right side ECM caddy: XL models

Gray

2-place Tyco Superseal 1.5
Sealed (BK)

ET sensor

[90]

On right side H-bracket: XR 1200X

Under left side cover

Black

4-place Deutsch DT Sealed
(GY)

DLC

[91]

Inside tail lamp lens

Gray

4-place Tyco 070 Multilock
Unsealed (BK)

Tail/stop lamp

[93]

Inside tail lamp lens

Gray

6-place Tyco 070 Multilock
Unsealed (BK)

Rear turn signal lamp

[94]

Back of tachometer

Breakout Box

12-place Delphi Micro 64
Sealed (GY)

Tachometer (XR)

[108]

Under oil filter mount

Right Angle Push On terminal
(BK)

Oil pressure switch

[120]

Left side under battery (XL)

Red

Tyco Insulated Spade terminals
(BK)

Rear stop lamp switch

[121]

Under rear fork (XR)

Between front frame tubes or on the
left side of engine

Red

Flag terminals (BK)

Horn

[122]

Right side bottom of starter

Gray

1-place Delphi 56 Spade ter-
minal (W)

Starter solenoid

[128]

Right side under sprocket cover
behind transmission sprocket

Black

Right Angle Push On Molded
terminals (BK)

Neutral switch

[131]

Left side frame down tube

Gray

3-place Molex MX 150 Sealed
(BK)

JSS (HDI)

[133]

Right side frame, beneath gearcase
cover

1-place bullet (BK)

Neutral switch jumper

[136]

On left side ECM caddy: XL models

Gray

2-place Tyco 070 Multilock
Unsealed (BK)

Rear O2 sensor

[137]

On left side H-bracket: XR 1200X

Left side frame in front of oil filter

Gray

2-place Tyco 070 Multilock
Unsealed (BK)

Front O2 sensor

[138]

B-2 2013 Sportster Service: Appendix B Wiring

Table B-1. Sportster Connector Locations

LOCATION

TERMINAL

PROBE
COLOR

TYPE

DESCRIPTION

NO.

On left side of ECM caddy: XL
models

Gray

4-place Molex MX 150 Sealed
(BK)

Fuel pump and low fuel switch

[141]

On left side of H-bracket: XR 1200X

Under frame

Gray

3-place Delphi 150.2 Sealed
(BK)

Security siren

[142]

Under seat

Gray

16-place Molex MX 150 Sealed
(BK)

Engine sensor harness

[145]

Under seat

Purple

1-place Delphi 800 Metripack
Sealed (GY)

P&A battery

[160]

Right side behind air box: XR 1200X

Gray

2-place Tyco Superseal 1.5
Sealed (BK)

Active intake solenoid

[178]

Under seat

Gray

3-place Molex MX 150 Sealed
(BK)

Fuel sender resistor assembly

[200]

Under battery

Black

4-place Deutsch DT Sealed
(GY)

HFSM antenna harness

[208]

Under seat

Gray

2-place Molex MX 64 Unsealed
(BK)

HFSM antenna

[209]

Under fuel tank cover

1-place molded (BK)

Fuel Tank Ground (XR)

[210]

Under frame

Gray

4-place Delphi GT 150 Sealed
(BK)

Anti-theft tracking module

[266]

Under battery

Black

3-place Deutsch DT Sealed
(BK)

Anti-theft harness to main har-
ness

[267]

Top of transmission case

Ring terminal (BK)

Battery ground

[Battery
ground]

Left side behind starter

Ring terminal (BK)

Harness ground

[GND 1]

2013 Sportster Service: Appendix B Wiring B-3

B.2

WIRING DIAGRAMS

WIRING DIAGRAM INFORMATION

Wire Color Codes

Wire traces on wiring diagrams are labeled with alpha codes.
Refer to

Table B-2

For Solid Color Wires:

See

Figure B-1

. The alpha code

identifies wire color.

For Striped Wires:

The code is written with a slash (/) between

the solid color code and the stripe code. For example, a trace
labeled GN/Y is a green wire with a yellow stripe.

Wiring Diagram Symbols

See

Figure B-1

. On wiring diagrams and in service/repair

instructions, connectors are identified by a number in brackets
[ ]. The letter inside the brackets identifies whether the housing
is a socket or pin housing.

A=Pin:

The letter A and the pin symbol after a connector

number identifies the pin side of the terminal connectors.

B=Socket:

The letter B and the socket symbol after a connector

number identifies the socket side of the terminal connectors.
Other symbols found on the wiring diagrams include the fol-
lowing:

Diode:

The diode allows current flow in one direction only in

a circuit.

Wire break:

The wire breaks are used to show option variances

or page breaks.

No Connection:

Two wires crossing over each other in a wiring

diagram that are shown with no splice indicating they are not
connected together.

Circuit to/from:

This symbol indicates a more complete circuit

diagram on another page. The symbol is also identifying the
direction of current flow.

Splice:

Splices are where two or more wires are connected

together along a wiring diagram. The indication of a splice only
indicates that wires are spliced to that circuit. It is not the true
location of the splice in the wiring harness.

Ground:

Grounds can be classified as either clean or dirty

grounds. Clean grounds are identified by a (BK/GN) wire and
are normally used for sensors or modules.

NOTE

Clean grounds usually do not have electric motors, coils or
anything that may cause electrical interference on the ground
circuit.

Dirty grounds are identified by a (BK) wire and are used for
components that are not as sensitive to electrical interference.

Twisted pair:

This symbol indicates the two wires are twisted

together in the harness. This minimizes the circuit's electromag-
netic interference from external sources. If repairs are neces-
sary to these wires they should remain as twisted wires.

GN/Y

[21A]

[21B]

ed03175

1. Connector number
2. Terminal code (A=pin, B=socket)
3. Solid wire color
4. Striped wire color
5. Socket symbol
6. Pin symbol
7. Diode
8. Wire break
9. No connection
10. Circuit to/from
11. Splice
12. Ground
13. Twisted pair

Figure B-1. Connector/Wiring Diagram Symbols

B-4 2013 Sportster Service: Appendix B Wiring

sm06836

1. Housing, oil pump
2. Exhaust camshaft, rear cylinder
3. Intake camshaft, front cylinder
4. Feed rotor set
5. Scavenge rotor set

Figure 3-9. Oil Pump: XR 1200X

See

Figure 3-10

. As the crankshaft rotates, the cavity volume

increases between the gerotors on the inlet side of the pump.
This creates a vacuum causing oil to be drawn in. The volume
continues to increase until it is equivalent to that of the missing
lobe on the inner gerotor.

See

Figure 3-11

. Continuous rotation moves the pocket of oil

to the outlet side of the pump. As the oil moves to the outlet
side of the pump, the cavity decreases in volume. This forces
pressurized oil out the discharge port. In operation, the gerotors
provide a continuous flow of oil.

sm02317

1. Oil in
2. Seal
3. Outer gerotor
4. Inner gerotor

Figure 3-10. Inlet Side Oil Flow

sm02319

1. Seal
2. Oil out
3. Continuous flow

Figure 3-11. Outlet Side Oil Flow

2013 Sportster Service: Engine 3-17

OIL FLOW: XL MODELS

NOTE

See

Figure 3-12

.The paragraph numbers correspond with the

callouts.

Oil is gravity-fed from the oil tank to the gerotor-style oil
pump through a

feed hose.

Oil enters the

feed section

and fills a cavity located under the feed pump. See

3.20 OIL PUMP: XL MODELS

The feed pump transfers oil from the inlet cavity through
the

feed hose

to the oil filter mount.

Oil flows through the

filter mount cavity

to the oil filter.

Oil enters the peripheral cavity of the

oil filter,

passes

through the filtering medium into the central cavity of the
oil filter, and flows into the filter adapter (fitting which
connects filter to filter mount).

Adequate oil pressure in the filter mount cavity activates
the

oil pressure indicator lamp switch

and shuts off the

oil pressure indicator lamp.

Oil flowing from the filter adapter opens the

check ball.

The check ball opens at 10-13 psi (69-90 kPa) oil pressure.

With the check ball open, oil flows into the

crankcase

feed galley.

Oil flows through the feed galley in the crankcase to the
tappet

blocks

and

hydraulic

lifters.

Cross-drilled

passages

intersect the main feed galley and carry oil to

each hydraulic lifter. From this cavity, oil is also fed to the
piston jets.

Oil also enters an

intersecting passage

in the gearcase

cover. Oil flow is then routed to the crankshaft area.

10. Oil enters a hole in the end of the

pinion gear shaft

and

travels to the right flywheel where it is routed through the
flywheel to the

crank pin.

Oil is forced through the crank

pin to properly lubricate the rod bearing assembly.

11. Oil flows up passages in the

pushrods

to the rocker arm

shafts and bushings.

12. The valve stems are lubricated by oil supplied through

drilled oil holes in the

rocker arms

13. Collected in the cylinder heads, oil flows down the

pushrod covers

and into the

tappet blocks

. From the

tappet block drain holes, oil flows into the gearcase. After
lubricating the gearcase the oil flows to the return side of
the oil pump.

14. Feed oil to the rocker area is returned to the gearcase

through a

passage

in the head, cylinder, and crankcase.

15. Oil collected in the

sump

is splash-fed to the pistons, cyl-

inder walls and flywheel components.

16. Oil in the sump returns to the scavenge pump through an

internal

passage

located in the rear of the sump housing.

The downward stroke of the pistons and the scavenge
pump feed oil to the oil pump.

17. Return oil fills a

cavity

above the pump's return gears.

The return gears pump oil back to the oil tank.

18. A small amount of oil flows from the feed galley in the right

crankcase through a

restricted orifice.

This sprays the

oil onto the rear intake cam gear in the gearcase. Oil is
transferred to the teeth of all the cam gears through the
gear meshing action.

OIL FLOW: XR 1200X

NOTE

See

Figure 3-13

. The paragraph numbers correspond with the

callouts.

Oil is gravity-fed from the oil tank to the gerotor-style oil
pump through a

feed hose and internal passages.

Oil

enters the inlet cavity of the

feed pump

. See

3.21 OIL

PUMP: XR 1200X

The feed pump transfers oil through a

passage

in the

pump housing to a point where it splits direction. The pump
is capable of delivering more oil than can flow through the
engine. When oil pressure exceeds 50 psi (345 kPa), the

bypass valve

opens. Oil circulates into the inlet side of

the feed pump.

Part of the oil passes through an

internal passage

toward

the oil filter and part heads toward the oil cooler line.

Oil exits the oil pump housing through a

line

connected

with quick connect fittings and enters the lower end of the
oil cooler. Oil flows up through the oil cooler and exits the
upper end where it flows back to the oil pump housing.

thermostat

is located where the oil cooler return line

connects to the oil pump housing. The thermostat begins
to open when the oil reaches 190 °F (88 °C). As it opens,
oil from the cooler flows past while oil flow from the feed
pump is restricted. This provides cooled oil for engine
lubrication. When the

thermostat

is full open, oil flow is

sealed off from the pump. All oil then passes through the
oil cooler, past the

thermostat

, and towards the oil filter.

Oil flowing to the filter passes through an

internal passage

to the oil filter mount.

Oil flows through the

filter mount cavity

to the oil filter.

Oil enters the peripheral cavity of the

oil filter,

passes

through the filtering medium into the central cavity of the
oil filter, and flows into the filter adapter (fitting which
attaches the filter to filter mount).

Adequate oil pressure in the filter supply passage activates
the

oil pressure indicator lamp switch

and shuts off the

oil pressure indicator lamp.

10. Oil flowing from the filter adapter opens the

check ball.

The check ball opens at 5-7 psi (34-48 kPa) oil pressure.

11. With the check ball open, oil flows into the

crankcase

feed galley.

12. Oil flows through the feed galley in the crankcase to the

tappet

blocks

and

hydraulic

lifters.

Cross-drilled

passages

intersect the main feed galley and carry oil to

each hydraulic lifter. From this cavity, oil is also fed to the
piston jets.

13. Also from the feed galley in the crankcase, oil flows

through a cross drilled passage to the

check valve

assembly

. Then to the cylinder heads through

flexible

3-18 2013 Sportster Service: Engine

lines

. Oil flows across the cylinder heads and through

passages that surround the exhaust ports. Oil exits each
cylinder head near the exhaust port.

14.

Oil exiting

the heads flows to the

return oil manifold

where it is mixed with the scavenge oil from the scavenge
pump and is pushed back to the tank.

15. Oil flows from the feed galley through an

intersecting

passage

in the oil pump body and cam support. Oil flow

is then routed to the

outer bearing

of the rear intake

camshaft. A cast-in passage allows oil into a cavity that
surrounds the end of the pinion gear shaft.

16. From the

cavity

at the pinion shaft end, oil enters the

center hole in the

oil pump rotor cover

. The center hole

intersects a passage that carries oil to the outer bearings
of the front intake camshaft and rear exhaust camshaft.

17. The outer bearing of the front exhaust camshaft is lubric-

ated through a

drilled passage

that intersects with the

feed galley.

18. Crankcase end of bearings of the cams are fed through

holes in the camshaft.

19. A small amount of oil flows from the feed galley in the right

crankcase through a

restricted orifice.

This sprays the

oil onto the rear intake cam gear in the gearcase. Oil is
transferred to the teeth of all the cam gears through the
gear meshing action.

20. Oil enters a hole in the end of the

pinion gear shaft

and

travels to the right flywheel where it is routed through the
flywheel to the

crank pin.

Oil is forced through the crank

pin to properly lubricate the rod bearing assembly.

21. Oil flows up passages in the

pushrods

to the rocker arm

shafts and bushings.

22. The valve stems are lubricated by oil supplied through

drilled oil holes in the

rocker arms

23. Oil collected in the pushrod areas of the cylinder heads

flows down the

pushrod covers

to the

tappet blocks

. It

drains through holes in the tappet blocks and provides
lubrication to the gearcase components. Oil then settles
to the bottom of the gearcase and is collected by the
scavenge pump.

24. Feed oil to the rocker area is returned to the gearcase

through a

passage

in the cylinder head, cylinder, and

crankcase.

25. Oil collected in the

sump

is splash-fed to the pistons, cyl-

inder walls and flywheel components.

26. Oil in the sump returns to the scavenge pump through an

internal passage

located in the rear of the sump housing.

The downward stroke of the pistons and the scavenge
pump feed oil to the oil pump.

27. Oil collected in the gearcase passes through a

passage

in the oil pump body and cam support and is also collected
by the scavenge pump.

28. The

scavenge pump

pushes the collected oil back to the

oil tank.

29. Crankcase vents to oil tank.

3.8 TOP END SERVICE, Engine in Chassis

2013 Sportster Service: Engine 3-19

sm04243

Figure 3-12. Lubrication Diagram: XL Models (Red=Feed Oil, Blue=Return Oil)

Figure 3-12.

Lubrication Diagram: XL Models (Red=Feed Oil, Blue=Return

Oil)

Lubrication Diagram: XL Models (Red=Feed Oil, Blue=Return

Oil)

sm05338

Figure 3-13. Lubrication Diagram: XR 1200X (Red=Feed Oil, Blue=Return Oil)

Figure 3-13.

Lubrication Diagram: XR 1200X (Red=Feed Oil, Blue=Return

Oil)

Lubrication Diagram: XR 1200X (Red=Feed Oil, Blue=Return

Oil)

3.7

HOW TO USE THIS SECTION

TYPICAL SYMPTOMS

Always use all available symptoms to begin a diagnosis.
Symptoms indicating a need for engine repair are often mis-
leading. If more than one symptom is present, possible causes
can be narrowed down to make a partial diagnosis. An above
normal consumption of oil, for example, could be caused by
several mechanical faults. However, when accompanied by
blue-gray exhaust smoke and low engine compression, it
indicates worn piston rings. Low compression by itself however,
may indicate leaking valves, in addition to worn piston rings.
See

1.28 TROUBLESHOOTING

Certain knocking noises may be caused by loose bearings,
others by piston slap, a condition where piston or cylinder or
both out of tolerance, allowing the piston to slap from front to
rear of the cylinder as it moves up and down.

Frequently, valves, rings, pins, bushings and bearings need
attention at the same time. If any one of the above components
is worn, inspect all of these components. Repair or replace as
necessary.

TOP END REPAIR

NOTE

During top end disassembly, the engine may be left in the
chassis for service.

Two options are available depending upon engine status.

•

•

3.8 TOP END SERVICE, Engine Removed from Chassis

BOTTOM END REPAIR

NOTE

Servicing components in the cam compartment requires only
partial disassembly. This can be done with the engine left in
the chassis.

After disassembling as far as the cylinder heads you may find
that bottom end repair is necessary. Bottom end service may
require either partial or complete disassembly of the engine.

•

The cam compartment can be serviced with the engine in
the chassis. See

3.9 BOTTOM END SERVICE, Engine in

Chassis

•

To service components in the flywheel compartment, the
engine must be removed and the crankcase halves split.
See

3.9 BOTTOM END SERVICE, Engine Removed From

Chassis

3.13 TOP END OVERHAUL: DISASSEMBLY, Stripping Motorcycle for Top End
Repair

2013 Sportster Service: Engine 3-25

3.8

TOP END SERVICE

ENGINE IN CHASSIS

Table 3-24. Engine in Chassis

COMPONENT REPAIR
PROCEDURES

SERVICE PROCEDURE

Remove parts necessary to gain access to all components above cylinder deck. See

Continue with

3.13 TOP END OVERHAUL: DISASSEMBLY

. Remove/repair sub-

assembly components only if necessary.

Inspect and repair as necessary. See

3.4 CRANKCASE BREATHING SYSTEM,
XL Models

3.4 CRANKCASE

BREATHING SYSTEM, XR 1200X

Remove rocker arm outer covers. Remove crankcase breathers. See

3.13 TOP END

OVERHAUL: DISASSEMBLY, Cylinder Heads

Inspect and repair as necessary. See

3.14 CYLINDER HEAD

Remove cylinder heads. See

3.13 TOP END OVERHAUL: DISASSEMBLY, Cylinder

Heads

Inspect and repair as necessary. See

3.22 BOTTOM END OVERHAUL:
ASSEMBLY, Tappets

Remove pushrods, pushrod covers and tappet covers. See

3.13 TOP END OVER-

HAUL: DISASSEMBLY, Cylinder Heads

. Remove tappets. See

OVERHAUL: DISASSEMBLY, Tappets

Inspect and repair as necessary. See

3.15 CYLINDER AND PISTON

Remove cylinders and pistons. See

3.13 TOP END OVERHAUL: DISASSEMBLY,

Cylinder and Piston

Inspect upper connecting rod and repair
as necessary. See

3.15 CYLINDER AND

PISTON, Connecting Rod Bushings

Complete all appropriate steps under

3.16 TOP END OVERHAUL: ASSEMBLY,

Complete motorcycle assembly. See

Assembling Motorcycle After Top End Repair

When this step is completed during top end service, advance to

if no other work is

to be done.

3.10 REMOVING ENGINE FROM CHASSIS

3-26 2013 Sportster Service: Engine

ENGINE REMOVED FROM CHASSIS

Table 3-25. Engine Removed from Chassis

COMPONENT REPAIR
PROCEDURES

SERVICE PROCEDURE

Remove engine from chassis. See

Start

3.13 TOP END OVERHAUL: DISASSEMBLY

. Remove and repair subassembly

components as necessary.

Inspect and repair as necessary. See

3.4 CRANKCASE BREATHING SYSTEM,
XL Models

3.4 CRANKCASE

BREATHING SYSTEM, XR 1200X

Remove rocker arm outer covers. Remove crankcase breathers. See

3.13 TOP END

OVERHAUL: DISASSEMBLY, Cylinder Heads

Inspect and repair as necessary. See

3.14 CYLINDER HEAD

Remove cylinder heads. See

3.13 TOP END OVERHAUL: DISASSEMBLY, Cylinder

Heads

Inspect and repair as necessary. See

3.22 BOTTOM END OVERHAUL:
ASSEMBLY, Tappets

Remove pushrods, pushrod covers and tappet covers. See

3.13 TOP END OVER-

HAUL: DISASSEMBLY, Cylinder Heads

. Remove tappets. See

OVERHAUL: DISASSEMBLY, Tappets

Inspect and repair as necessary. See

3.15 CYLINDER AND PISTON

Remove cylinders and pistons. See

3.13 TOP END OVERHAUL: DISASSEMBLY,

Cylinder and Piston

Inspect upper connecting rod and repair
as necessary. See

3.15 CYLINDER AND

PISTON, Connecting Rod Bushings

Complete all appropriate steps under

3.16 TOP END OVERHAUL: ASSEMBLY,

Install engine in motorcycle. Complete all appropriate steps under

3.11 INSTALLING

ENGINE IN CHASSIS

Complete motorcycle assembly. See

Assembling Motorcycle After Top End Repair

When this step is completed during top end service, advance to

if no other work is

to be done.

3.13 TOP END OVERHAUL: DISASSEMBLY, Stripping Motorcycle for Top End
Repair

2013 Sportster Service: Engine 3-27

3.9

BOTTOM END SERVICE

ENGINE IN CHASSIS

Table 3-26. Engine in Chassis: Cam Compartment Service

COMPONENT REPAIR
PROCEDURES

SERVICE PROCEDURE

Remove parts necessary to gain access to all components above cylinder deck. See

Continue with

3.13 TOP END OVERHAUL: DISASSEMBLY

. Remove/repair sub-

assembly components only if necessary.

Inspect and repair as necessary. See

3.4 CRANKCASE BREATHING SYSTEM,
XL Models

3.4 CRANKCASE

BREATHING SYSTEM, XR 1200X

Remove rocker arm outer covers. Remove crankcase breathers. See

3.13 TOP END

OVERHAUL: DISASSEMBLY, Cylinder Heads

Inspect and repair as necessary. See

3.22 BOTTOM END OVERHAUL:
ASSEMBLY, Tappets

Remove pushrods, pushrod covers and tappet covers. See

3.13 TOP END OVER-

HAUL: DISASSEMBLY, Cylinder Heads

. Remove tappets. See

OVERHAUL: DISASSEMBLY, Tappets

Continue with

3.17 BOTTOM END OVERHAUL: DISASSEMBLY

Inspect and repair as necessary. See

3.17 BOTTOM END OVERHAUL: DISAS-
SEMBLY, Gearcase Cover and Cam
Gears: XL Models

OVERHAUL: DISASSEMBLY, Oil Pump
Housing/Gearcase Cover and Cam Gears:
XR 1200X

Remove gear case cover and cam gears. See

3.17 BOTTOM END OVERHAUL:

DISASSEMBLY, Gearcase Cover and Cam Gears: XL Models

OVERHAUL: DISASSEMBLY, Oil Pump Housing/Gearcase Cover and Cam Gears:
XR 1200X

Inspect and repair as necessary. See

3.20 OIL PUMP: XL MODELS

3.21 OIL

PUMP: XR 1200X

Remove oil pump components. See

3.20 OIL PUMP: XL MODELS

3.21 OIL PUMP:

XR 1200X

Complete all appropriate steps under

3.22 BOTTOM END OVERHAUL: ASSEMBLY

Complete motorcycle assembly. See

3.16 TOP END OVERHAUL: ASSEMBLY,

Assembling Motorcycle After Top End Repair

When this step is completed during bottom end service, advance to

3.22 BOTTOM END OVERHAUL: ASSEMBLY

if no other

work is to be done.