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Harley Davidson 2013 Sportster Models. Electrical Diagnostics Manual - page 9

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em01321

Neutral

Indicator

Lamp

[20A]

[20B]

Clutch Switch

BK/R

Chassis

Grounds

[24A]

[24B]

[136B]

Ignition

[136A]

Power

[30B]

10 12

[131B]

GND 1

[30A]

10 12

[131A]

Neutral

Switch

TSM, TSSM, HFSM

Figure 5-30. Starting Circuit

DTC B1154

3. Is continuity present?

a. Yes. Go to Test 2.

PART NUMBER

TOOL NAME

b. No. Replace TSM, TSSM or HFSM.

HD-41404

HARNESS CONNECTOR TEST KIT

2. Clutch Switch Circuit Test

HD-42682

BREAKOUT BOX

1. Disconnect left hand controls [24].

2. Test for continuity between breakout box (Gray) terminal

Table 5-42. DTC B1154 Diagnostic Faults

10 and terminal 12.

POSSIBLE CAUSES

3. Is continuity present?

Switch malfunction

a. Yes. Repair short to ground on (BK/R) wire in main

Short to ground in clutch switch circuit

wiring harness between [30B] and [24B].

b. No. Go to Test 3.

NOTE

This DTC may occur if the vehicle is ridden with clutch disen-

3. Clutch Switch Test

gaged (pulled in) at speeds greater than 10 mph (16 km/h) for

1. Inspect left handlebar switch wiring for a short to ground.

more than 60 seconds (coasting down a long mountain road).

2. Was a short to ground present?

1. Clutch Circuit Short to Ground Test

a. Yes. Repair short to ground in left handlebar switch

1. With IGN OFF, connect BREAKOUT BOX (Part No. HD-

wiring.

42682) to wire harness [30B], leaving TSM, TSSM or

HFSM [30A] disconnected. See 1.2 DIAGNOSTIC TOOLS.

b. No. Replace clutch switch.

2. Using HARNESS CONNECTOR TEST KIT (Part No. HD-

41404) and a multimeter, test for continuity between

breakout box (Gray) terminal 10 and terminal 12.

5-62 2013 Sportster Diagnostics: Accessories, Horn, Lighting and Security

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2. With IGN OFF, connect BREAKOUT BOX (Part No. HD-

DTC B1155

42682) to wire harness [30B], leaving TSM, TSSM or

HFSM [30A] disconnected. See 1.2 DIAGNOSTIC TOOLS.

PART NUMBER

TOOL NAME

3. Using HARNESS CONNECTOR TEST KIT (Part No. HD-

HD-41404

HARNESS CONNECTOR TEST KIT

41404) and a multimeter, measure resistance between

HD-42682

BREAKOUT BOX

breakout box (Gray) terminal 4 and terminal 12.

4. Is resistance less than 10 Ohms?

Table 5-43. DTC B1155 Diagnostic Faults

a. Yes. Go to Test 2.

POSSIBLE CAUSES

b. No. Replace TSM, TSSM or HFSM.

Short to ground in neutral circuit

2. Neutral Switch Short to Ground Test

Neutral switch malfunction

1. Disconnect neutral switch [131].

NOTE

2. Measure resistance between breakout box (Gray) terminal

This DTC may occur if the vehicle is ridden in neutral at speeds

4 and terminal 12.

greater than 10 mph (16 km/h) for more than 60 seconds

3. Is resistance less than 10 Ohms?

(coasting down a long mountain road).

a. Yes. Repair short to ground on (TN) wire.

1. Neutral Circuit Short to Ground Test

b. No. Replace neutral switch.

1. Shift the transmission into 1st or 2nd gear.

2013 Sportster Diagnostics: Accessories, Horn, Lighting and Security 5-63

NOTES

5-64 2013 Sportster Diagnostics: Accessories, Horn, Lighting and Security

TABLE OF CONTENTS

SUBJECT

PAGE NO.

6.1 EFI SYSTEM

6-1

6.2 ELECTRONIC CONTROL MODULE

6-3

6.3 SENSORS AND DRIVERS

6-4

6.4 DTC P0107, P0108

6-7

6.5 DTC P0112, P0113

6-11

6.6 DTC P0117, P0118

6-14

6.7 DTC P0122, P0123

6-17

6.8 DTC P0131, P0132, P0134, P0151, P0152, P0154

6-21

6.9 DTC P0261, P0262, P0263, P0264

6-26

6.10 DTC P0373, P0374

6-30

6.11 DTC P0501, P0502

6-33

6.12 DTC P0505

6-37

6.13 DTC P0603, P0605

6-40

6.14 DTC P0661, P0662

6-41

6.15 DTC P1009, P1010

6-43

6.16 DTC P1001, P1002, P1003, P1004

6-44

6.17 DTC P1351, P1352, P1354, P1355

6-48

6.18 DTC P1501, P1502

6-52

6.19 DTC P1653, P1654

6-56

6.20 ENGINE CRANKS, BUT WILL NOT START

6-57

6.21 NO ECM POWER

6-60

6.22 STARTS, THEN STALLS

6-63

6.23 HESITATION, LOSS OF POWER

6-64

6.24 MISFIRE AT IDLE OR UNDER LOAD

6-67

NOTES

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EFI SYSTEM

6.1

Hands-Free Security Module (HFSM). This includes an

GENERAL

integrated Bank Angle Sensor (BAS).

This chapter describes the operation of the Harley-Davidson

•

Clutch switch

EFI System. It is essential to have a working knowledge of the

many components surrounding the engine to accurately

•

Neutral switch

troubleshoot and correct problems that may occur. 6.2 ELEC-

•

Engine Temperature (ET)

TRONIC CONTROL MODULE and 6.3 SENSORS AND

DRIVERS briefly explain the operation of the ECM and function

•

Vehicle Speed Sensor (VSS)

of the various sensors and drivers. See 1.2 DIAGNOSTIC

•

Oxygen (O2) Sensor

TOOLS for instructions on using the test equipment called out

in the diagnostic test procedures in this chapter.

•

Temperature Manifold Absolute Pressure (TMAP) (includes

IAT)

The EFI System provides microprocessor-based electronic

engine management for the 883 and 1200 engines. The EFI

EFI Operation

system has the following features:

The EFI system operates as an open or closed loop system,

•

Independently mapped spark and fuel control

allowing it to adjust for all possible operating conditions.

•

Compensated fuel delivery through engine temperature,

•

During open loop operation, the system uses programmed

intake air temperature and manifold air pressure

fuel and spark maps in the ECM providing easy cold

•

Engine load measurement via throttle position sensing

starting and maximum power at Wide Open Throttle

(WOT). The adaptive fuel value, learned during closed

•

Single point spark delivery

loop operation, is applied to open loop operation to adjust

•

Sequential port indirect (manifold) fuel injection

fuel and spark maps for optimal performance.

•

Open/closed loop air/fuel control

•

During closed loop operation, the O2 sensors provide input

for an optimal air/fuel mixture resulting in reduced emis-

•

Automatic enrichment at start-up

sions, good fuel economy and smooth power. O2 sensors

•

Engine speed and position determined by using a single

must be at the normal operating temperature of the engine.

CKP sensor

By using both open and closed loop systems, engine perform-

•

Engine idle speed electronically managed with an IAC

ance is continuously tuned to compensate for changing condi-

system

tions and providing maximum performance. A simplified signal

flow diagram for the EFI

system is shown in Figure 6-1.

The EFI System performance is monitored by an ECM using

sensors and switches to regulate engine operation. The ECM

Symptom Diagnostics

makes decisions for enabling ignition, starting, spark and fuel

For symptoms of engine malfunctions not specifically covered

delivery. Sensors include:

by DTCs, refer to Table 6-1, Table 6-2 and Table 6-3. For other

•

Crank Position (CKP)

symptoms, refer to Table 2-3.

•

Throttle Position Sensor (TPS)

•

Jiffy Stand Sensor (JSS) (HDI)

•

Turn Signal Module (TSM) or optional, factory-installed

Turn Signal Security Module (TSSM: Japan/Korea) or

2013 Sportster Diagnostics: Engine Management 6-1

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em01325

CKP Sensor

Y/GN

[78A] [78B]

BE/GY

ECM

[79B] [79A]

GN/O

W/BK

CKP (+)

CKP (-)

[61B]

[61A]

System Relay

GN/O

Fuse Block

Ignition Coil

Y/GN

Power

Y/GN

Power

Spark Plugs

Rear Coil

Y/BE

Rear

Front Coil

BE/O

Front

Battery

BE/GY

ECM Fuse

15A

[83B] [83A]

Y/GN

GY/O

BE/GY

[178B]

Main Fuse

B+

OFF

30A

Ignition Fuse

ACC

15A

[178A]

R/BK

IGN

Ignition

Y/GN

Switch

W/Y

AIS

(XR)

Front

Battery

[84B] [84A]

Injector

Engine Case

Ground Point

Active Intake

GY/O

Y/GN

[244B] [244A]

Fuel Pump

Front Injector

W/Y

GN/GY

Rear

Rear Injector

GN/GY

Y/GN

[85B] [85A]

Injector

O/GN

IAC (A) Low

BE/GN

IAC (B) High

BN/R

IAC

IAC (B) Low

BK/PK

[141A] [141B]

IAC (A) High

BK/O

GND 1

Switch Power

W/BK

[87B] [87A]

Front O2

BK/W

Sensor

IAT

LGN/Y

TMAP

R/W

Sensor

MAP Sensor Input

V/W

[80B] [80A]

Rear O2

[138A]

Sensor

BK/W

[138B]

5V Sensor Power

R/W

TPS

TPS Input

GY/V

[145A] [145B]

[88B] [88A]

Engine Temp

PK/Y

[137A]

BK/W

Sensor

[137B]

[90B] [90A]

O2 Sensor A

PK/O

5V Sensor Ground

BK/W

O2 Sensor B

PK/GN

Serial Data Link

LGN/V

Speedometer

And

Tachometer

Engine

Stop

W/BK

[20B] [20A]

Switch

BK/R

VSS Input

BK/BE

[22B] [22A]

Ground

JSS (HDI)

GN/BN

VSS

LGN/V

DLC

[65B] [65A]

Ground

R/W

[91A]

JSS

GN/BN

(HDI)

[30B]

GND 1

[30A]

GND 1

TSM, TSSM, HFSM

Figure 6-1. EFI Simplified Schematic

6-2 2013 Sportster Diagnostics: Engine Management

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ELECTRONIC CONTROL MODULE

6.2

The ECM contains all of the components used in the ignition

GENERAL

system. The dwell time for the ignition coil is also calculated

See Figure 6-2 or Figure 6-3 depending upon vehicle variant.

in the microprocessor and is dependent upon battery voltage.

The ECM receives and processes signals from the sensors

The programmed dwell is an added feature to give adequate

and applies output signals to the drivers to start, idle and run

spark at all speeds. (The ECM has added protection against

the engine. This section describes the configuration of the ECM

transient voltages, continuous reverse voltage protection and

for this vehicle.

damage due to jump starts.) The ECM is fully enclosed to

protect it from vibration, dust, water or oil. This unit is a non-

ed03051

repairable item. If it fails, it must be replaced.

32-2 Flywheel

The left flywheel has 32 teeth evenly spaced around its circum-

ference with two consecutive teeth missing (sync gap). In this

configuration, the ECM determines engine position, engine

phase and engine speed from the CKP sensor input. Phase

(TDC compression) is determined by the ECM during startup

and, when necessary, while running. No engine ignition events

can occur until the ECM determines the relationship of piston

position to crankshaft position. The following paragraphs in

this section describe synchronization and phasing by the ECM

to provide smooth operation of the engine at all speeds.

Crank Position Signal Synchronization

1. Fuse block [61]

In the 32-2 crank configuration, crankshaft position is determ-

2. ECM [78]

ined by the ECM finding the two-tooth (sync gap) in the CKP

sensor signal. This is usually accomplished the first time the

Figure 6-2. ECM: XL

sync gap is encountered. The ECM monitors the CKP signal

status every engine revolution. If the ECM determines synchron-

ization is lost, it immediately terminates ignition events and

ed03052

synchronizes on the next occurrence of the sync gap.

Engine Phase

Phasing is accomplished by the ECM identifying a widening in

the CKP signal caused by the deceleration of the crankshaft,

as a piston approaches TDC on its compression stroke. Since

the rear cylinder approaches TDC earlier than the front cylinder,

engine phase can be readily discriminated. Phasing is normally

accomplished on the first TDC cycle after engine synchroniza-

tion. Once phased, the ECM can begin normal ignition events.

If the ECM experiences a system reset or loss of synchroniza-

tion while the engine is running it also loses phase.

When phase is lost one of the following occurs:

•

If an engine-not-running (Crank Mode) rpm is detected,

1. ECM [78]

the ECM executes the normal start-up phasing process.

2. Security antenna [209]

•

If Engine Run Mode is detected, the ECM executes a

3. P&A battery [160]

running re-phase sequence.

4. Fuel sender resistor assembly [200]

5. Battery

The front cylinder is fired every engine revolution. The ECM

6. Engine sensor harness [145]

monitors the power stroke after the fire event to determine if

sufficient acceleration occurred to indicate the ECM fired on

Figure 6-3. ECM: XR

the compression stroke. When two valid power strokes are

detected, the ECM locks phase and resumes normal ignition

ECM

events.

The ECM is mounted behind the rear cylinder (XL) or under

Engine Run Mode

the passenger seat (XR). It computes the spark advance for

proper ignition timing and fuel control based on sensor inputs

Many functions of the EFI system require an engine run mode

(from CKP, TMAP and TPS sensors) and controls the low-

determination. Engine run is determined by the level of engine

voltage circuits for the ignition coils and injectors.

rpm. Generally, the engine is considered to be running when

engine rpm exceeds a minimum of 750 rpm.

2013 Sportster Diagnostics: Engine Management 6-3

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SENSORS AND DRIVERS

6.3

DESCRIPTION AND OPERATION

Neutral Switch

Sensors and drivers play an important part in the ECM's ability

The speedometer (XL) or tachometer (XR) provides voltage

to regulate engine efficiency, emissions control and fuel eco-

to the neutral switch, which is open when the transmission is

nomy. When a failure occurs, a DTC is generated by the ECM.

in gear. With the transmission in neutral, the switch is closed,

These codes help the technician diagnose engine trouble to

allowing current flow to ground. The TSM, TSSM or HFSM will

the proper sensor or driver. See 2.1 INITIAL DIAGNOSTICS.

not allow the engine to start unless the transmission is in neutral

or the clutch is engaged.

SENSORS

Engine Temperature (ET) Sensor

Not all sensor problems cause an engine shutdown, but sensor

The ET sensor is a thermistor device, which means that at a

failure can seriously degrade overall engine performance. A

specific temperature it has a specific resistance across its ter-

notable exception is the CKP sensor, which if faulty, completely

minals. As this resistance varies, so does the voltage.

disables engine operation. The following are brief explanations

of sensor types and their functions within the EFI system.

•

At high temperatures, the resistance of the sensor is very

low, which effectively lowers the signal voltage on ECM

Crank Position (CKP) Sensor

[78] terminal 6.

The CKP sensor, located on the left front of the lower crankcase

•

At low temperatures, the resistance is very high, allowing

half, is a variable reluctance device that generates AC voltage

the voltage to rise close to 5V. The ECM monitors this

as the teeth on the flywheel pass by the sensor. The signal is

voltage to compensate for various operating conditions.

routed to the ECM where it is used to determine crankshaft

The ECM also uses the sensor input as a reference for

position, engine speed (rpm) and engine phase (TDC compres-

determining Idle Air Control (IAC) pintle position.

sion). Without the presence of the CKP signal, the ECM will

not allow the ignition and fuel injection drivers to operate, and

Temperature Manifold Absolute Pressure

thus the engine will not run. The ECM uses crankshaft com-

(TMAP) Sensor

pression slow down events to determine engine phase.

Therefore, the spark plugs must be installed when checking

The TMAP sensor combines the MAP and IAT in a single

for spark.

component. Each functions as described in the paragraphs

following, and are tested as separate units.

Throttle Position Sensor (TPS)

Manifold Absolute Pressure (MAP) Sensor

The TPS is a variable resistor (potentiometer) having a linear

resistance range, mounted on the throttle plate shaft. The

The MAP sensor is supplied 5V from the ECM and sends a

output of the sensor is a voltage, dependent on the position of

signal back to ECM. This signal varies in accordance with

the throttle plate, and used by the ECM to determine ignition

engine vacuum, intake air temperature and atmospheric baro-

timing and fuel required at any given rpm and engine load.

metric pressure. The MAP sensor monitors the intake manifold

pressure (vacuum) and sends the information to the ECM. The

Jiffy Stand Sensor (JSS): HDI Only

ECM then adjusts the spark and fuel timing advance curves

The JSS uses a Hall-effect device to monitor jiffy stand position.

for optimum performance. The output of the sensor can also

When the jiffy stand is fully retracted, the sensor picks up the

be used to determine if the engine is rotating when a fault with

presence of a metal tab mounted to the jiffy stand. When

CKP sensor is present.

extended, the engine only starts and runs if the ECM receives

Intake Air Temperature (IAT) Sensor

a signal from the neutral switch indicating the transmission is

in neutral, or a signal from the clutch switch indicating the clutch

The IAT sensor is a thermistor device. As such, it will have a

is engaged. Otherwise, the engine stalls as the clutch is

specific resistance across its terminals at a specific temper-

released with the transmission in gear.

ature. As the temperature varies, the thermistor resistance

varies, and so does the voltage on ECM [78] terminal 7.

Bank Angle Sensor (BAS)

•

At high temperatures, the resistance of the sensor is very

The BAS is within the TSM, TSSM or HFSM. The TSM, TSSM

low, which effectively lowers the signal voltage on ECM

or HFSM will shut the engine down if the vehicle is tipped over.

[78] terminal 7.

Once the sensor is tripped, the motorcycle must be righted,

the ignition turned off and then on again before the engine can

•

At low temperatures, the resistance is very high, allowing

be restarted. This is communicated across the serial data cir-

the voltage to rise close to 5V. The ECM monitors this

cuit.

voltage to compensate for various operating conditions.

Clutch Switch

Vehicle Speed Sensor (VSS)

The TSM, TSSM or HFSM provides voltage to the clutch switch,

The VSS is a Hall-effect device mounted close to the teeth of

which is open when the clutch is disengaged (released). With

the 5th gear in the transmission. The output signal frequency

the clutch engaged (pulled in), the switch closes, allowing

varies with vehicle speed. The ECM processes the vehicle

current flow to ground. The ECM will not allow the engine to

speed signal and transmits it via the serial data circuit to the

start unless the transmission is in neutral or the clutch is

speedometer to indicate vehicle speed.

engaged.

6-4 2013 Sportster Diagnostics: Engine Management

HOME

See Figure 6-1. Each cylinder has its own ignition coil which

O2 Sensor (Front and Rear)

is provided power by the system relay. Each coil is controlled

The O2 sensor detects unburned oxygen in the engine exhaust.

independently by the ECM.

The output of the sensor is a voltage having a range of about

0-1.0V.

Fuel Injectors

•

Output above 0.5V represents a rich mixture.

The system relay provides battery power to the fuel injectors.

The ECM provides the path to ground to trigger the injectors.

•

Output of 0.5V represents a proper balance between lean

The fuel injectors are pulse-width modulated solenoids for

and rich.

metering fuel into the intake tract. The pulse-width of the ground

•

Output below 0.5V represents a lean mixture.

path to the injectors is varied by the ECM in response to inputs

from the various sensors, thus varying the length of time the

The change in output level signals the ECM to modify the

injector is open.

air/fuel ratio.

Idle Air Control (IAC)

It is important to note the O2 sensor does not operate efficiently

until it is at vehicle operating temperature. Therefore, before

The IAC motor is a stepper-motor used to regulate the amount

any troubleshooting takes place, bring the sensor to operating

of air entering the intake manifold during idle. The ECM controls

temperature. Leaks in the exhaust system, leaky exhaust

engine idle speed by moving the IAC pintle to open or close a

valves, misfires or any engine problem allowing unburned

passage around the throttle plate. It does this by sending

oxygen into the exhaust stream could create a DTC indicating

voltage pulses to the proper motor winding of the IAC. This

a bad sensor. Look for problems related to an improper air/fuel

causes the pintle to move in or out of the IAC a given distance

mixture before replacing the sensor.

for each pulse received.

DRIVERS

•

To increase idle speed, the ECM retracts the pintle,

allowing more air to flow through the throttle body.

The ECM drivers are the output devices or system outputs of

the EFI system. Drivers are provided ground by the ECM to

•

To decrease idle speed, the ECM extends the pintle,

pump, inject and ignite the air/fuel mixture in the engine, and

allowing less air to flow through the throttle body.

to activate relays.

Start Relay

Fuel Pump

Pressing the start switch activates the start relay, sending

The fuel pump, located inside the fuel tank, is provided battery

battery voltage to the starter solenoid. The TSM, TSSM or

voltage when the system relay is activated.

HFSM controls the ground to the start relay, disabling it during

security and tip over conditions.

Ignition Coils and Spark Plugs

Active Intake Solenoid (AIS): XR England,

The ignition coils create the energy to fire the spark plugs and

Japan

ignite the air/fuel mixture in the cylinders. Advancing or

retarding the spark is controlled by the ECM to suit load and

The AIS regulates the amount of air entering the air cleaner.

speed conditions of the engine.

The AIS opens when vehicle speed exceeds 45 mph (70 km/h)

with 50% or greater throttle opening. Once open, active intake

will close when vehicle speed falls below 40 mph (65 km/h).

Table 6-1. Engine Starts Hard

CAUSE

SOLUTION

Engine temperature circuit

Repair the circuit. If DTC P0117 or P0118 is present, diagnose and correct DTCs.

Fuel or Ignition system fault

Perform misfire diagnostics.

Battery discharged

Charge and test the battery. Perform charging system diagnosis if problem continues.

Crank position sensor circuit

Repair the circuit. If DTC P0373 or P0374 is present, diagnose and correct DTC.

Manifold leak

Perform intake leak test.

Ignition coil circuit/spark plugs

Repair the circuit. If DTC P1351, P1352, P1354 or P1355 is present, diagnose and

correct DTCs.

Leaky injectors

Check for mechanical failures of the fuel injectors. If DTC P0261, P0262, P0263 or

P0264 is present, diagnose and correct them.

Clogged fuel injectors

Clean or replace fuel injectors.

Valve sticking

Perform compression test.

2013 Sportster Diagnostics: Engine Management 6-5

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Table 6-2. Engine Performance Problems

CAUSE

SOLUTION

Engine temperature circuit

Repair the circuit. If DTC P0117 or P0118 are present, diagnose and correct DTCs.

Crank position sensor circuit

Repair the circuit. If DTC P0373 and P0374 are present, diagnose and correct DTC.

Fuel or Ignition system fault

Perform misfire diagnostics.

Manifold Leak

Perform intake leak test.

Note: If manifold leak is large enough, the

IAC closes and DTC P0505 sets.

Throttle plates not opening fully

Perform Throttle Cable Adjustment.

Clogged fuel injector

Clean or replace injectors.

EVAP hose disconnected from induction

Connect.

module

Fuel system contaminated

Drain and refill with fresh fuel.

Table 6-3. Engine Emits Black Exhaust or Fouls Plugs

CAUSE

SOLUTION

Engine temperature circuit

Repair the circuit. If DTC P0117 or P0118 are present, diagnose and correct DTCs.

Clogged air filter

Replace air filter.

Leaky injectors

Repair the circuit. If DTC P0261, P0262, P0263 or P0264 are present, diagnose and

correct DTCs.

TMAP sensor circuit

Repair the circuit. If DTC P0107, P0108, P0112 or P0113 are present, diagnose and

correct DTCs.

6-6 2013 Sportster Diagnostics: Engine Management

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DTC P0107,

P0108

6.4

present. Additional DTCs will be set as each sensor is

DESCRIPTION AND OPERATION

disconnected, clear DTCs after this test. Be sure to per-

form this test before replacing a component.

PART NUMBER

TOOL NAME

HD-23738

VACUUM PUMP

NOTE

Intermittent TPS malfunctions may cause the TMAP to set a

See Figure 6-4. The MAP portion of the TMAP sensor is sup-

code prior to the TPS codes setting. Verify smooth and con-

plied 5V from the ECM terminal 14 and sends a signal back to

sistent TPS operation before replacing the ECM.

the ECM terminal 25. This signal varies in accordance with

engine vacuum and atmospheric barometric pressure. Changes

See Figure 6-5 for common 5V sensor power and ground

in barometric pressure are influenced by weather and altitude.

interconnections.

Connector Information

Table 6-4. Code Description

For additional information about the connectors in the following

DTC

DESCRIPTION

diagram(s) and diagnostic procedure(s), including the color of

the harness test kit terminal probes, see B.1 CONNECTORS.

P0107

MAP sensor open/low

P0108

MAP sensor high

ed03059

Diagnostic Tips

These codes will set if the MAP sensor signal is out of range.

Code P0108 can only be detected with the engine running.

NOTE

Do not over-pump vacuum pump during MAP sensor output

check as sensor damage may result.

•

MAP sensor output check. Using the VACUUM PUMP

(Part No. HD-23738), apply a vacuum to the pressure port

of the TMAP sensor. The signal

voltage should lower as

the vacuum is applied.

•

The TMAP, JSS, TPS and VSS are connected to the same

5V reference line. If the reference line shorts to ground or

1. ET sensor

opens, multiple codes will be set (DTC P0107, P0108,

2. Rear fuel injector [85]

P0122, P0123, P1501, P1502).

3. IAC [87]

•

A faulty sensor can negatively affect the signal voltage of

4. Front fuel injector [84]

the other sensors sharing the same 5V reference. If the

5. TPS [88]

wiring passes the following tests, disconnect one sensor

6. TMAP sensor [80]

at a time on the 5V reference and verify the DTC is still

Figure 6-4. Between Cylinders Right Side

2013 Sportster Diagnostics: Engine Management 6-7

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em00647

[90B] [90A]

PK/Y

BK/W

Sensor

[78A] [78B]

ECM

[145A] [145B]

[80B] [80A]

PK/Y

BK/W

LGN/Y

TMAP

5V Sensor Power

R/W

Sensor

MAP

V/W

[88B] [88A]

BK/W

R/W

TPS

GY/V

5V Sensor GND

BK/W

CKP

[79B] [79A]

Sensor

CKP Sensor(+)

CKP Sensor(-)

[138B] [138A]

Front O2

Sensor

Front O2 Sensor Input

PK/O

BK/W

GY/BK

[137B] [137A]

Rear O2

Sensor

Rear O2 Sensor Input

PK/GN

BK/W

GY/BK

[65B] [65A]

BK/R

VSS Input

BK/BE

VSS

JSS (HDI)

GN/BN

[133B] [133A]

Power GND

R/W

Power GND

JSS

GN/BN

(HDI)

GND 1

Figure 6-5. Sensor Circuit

6-8 2013 Sportster Diagnostics: Engine Management

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DTC P0107

5. MAP Sensor Signal Wire Shorted to

Sensor Ground Test

PART NUMBER

TOOL NAME

1. Turn IGN OFF.

HD-41404

HARNESS CONNECTOR TEST KIT

2. Test for continuity between breakout box terminals 25 and

HD-43876

BREAKOUT BOX

26.

3. Is continuity present?

Table 6-5. DTC P0107 Diagnostic Faults

a. Yes. Repair short between (V/W) and (BK/W) wires.

POSSIBLE CAUSES

b. No. See diagnostic tips before replacement. Replace

the ECM.

TMAP sensor malfunction

Open or shorted to ground signal wire

6. MAP Sensor 5V Reference Wire Open Test

Open or shorted to ground 5V reference circuit

1. Connect BREAKOUT BOX (Part No. HD-43876) to wire

harness [78B], leaving ECM [78A] disconnected. See

1. MAP Sensor Test

1.2 DIAGNOSTIC TOOLS.

1. Disconnect the TMAP sensor [80].

2. Test for continuity between [80B] terminal 3 and breakout

2. Using the HARNESS CONNECTOR TEST KIT (Part

box terminal 14.

No. HD-41404), connect a test wire between [80B] ter-

3. Is continuity present?

minals 3 and 4.

a. Yes. Go to Test 7.

3. Clear DTC P0107. See 2.1 INITIAL DIAGNOSTICS,

Odometer Self-Diagnostics.

b. No. Repair open in (R/W) wire.

4. Turn IGN OFF and ON.

7. MAP Sensor 5V Reference Shorted to

5. Does the DTC P0107 reset?

Signal Ground Test

a. Yes. Go to Test 2.

1. Test for continuity between breakout box terminals 14 and

26.

b. No. Replace the TMAP sensor.

2. Is continuity present?

2. MAP Sensor Signal Voltage Test

a. Yes. Repair

short between the (R/W) and (BK/W)

1. Remove the test wire.

wires.

2. With IGN ON, test for voltage from [80B] terminal 3 to

b. No. See diagnostic tips before replacement. Replace

ground.

the ECM.

3. Is voltage approximately 5V?

DTC P0108

a. Yes. Go to Test 3.

b. No. Go to Test 6.

PART NUMBER

TOOL NAME

HD-43876

BREAKOUT BOX

3. MAP Sensor Signal Wire Continuity Test

1. Connect BREAKOUT BOX (Part No. HD-43876) to wire

harness [78B], leaving ECM [78A] disconnected. See

Table 6-6. DTC P0108 Diagnostic Faults

1.2 DIAGNOSTIC TOOLS.

POSSIBLE CAUSES

2. Test for continuity between [80B] terminal 4 and breakout

TMAP sensor malfunction

box terminal 25.

Short to voltage

3. Is continuity present?

a. Yes. Go to Test 4.

1. MAP Sensor Test

1. Disconnect the TMAP sensor [80].

b. No. Repair open in (V/W) wire.

2. Clear DTC P0108. See 2.1 INITIAL DIAGNOSTICS,

4. MAP Sensor Signal Wire Shorted to

Odometer Self-Diagnostics.

Ground Test

3. Start engine.

1. Test for continuity between breakout box terminal 25 and

4. Does the DTC P0108 reset?

ground.

a. Yes. Go to Test 2.

2. Is continuity present?

b. No. Go to Test 4.

a. Yes. Repair short to ground in (V/W) wire.

b. No. Go to Test 5.

2013 Sportster Diagnostics: Engine Management 6-9

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2. MAP Sensor Signal Wire Short to 5V Test

4. MAP Sensor 5V Reference Shorted to

1. Connect BREAKOUT BOX (Part No. HD-43876) to wire

Battery Voltage Test

harness [78B], leaving ECM [78A] disconnected. See

1. With IGN ON, test for voltage between breakout box ter-

1.2 DIAGNOSTIC TOOLS.

minal 14 and ground.

2. Test for continuity between breakout box terminals 14 and

2. Is voltage greater than 5.25V?

25.

a. Yes. Repair short to voltage in (R/W) wire.

3. Is continuity present?

b. No. Go to Test 5.

a. Yes. Repair short between (R/W) and (V/W) wires.

b. No. Go to Test 3.

5. MAP Sensor Ground Wire Open Test

1. Test for continuity between [80B] terminal 1 and breakout

3. MAP Sensor Signal Wire Short to Voltage

box terminal 26.

Test

2. Is continuity present?

1. With IGN ON, test for voltage on breakout box terminal

a. Yes. Replace the TMAP sensor.

25.

b. No. Repair open in (BK/W) wire.

2. Is voltage present?

a. Yes. Repair short to voltage in (V/W) wire.

b. No. Go to Test 4.

6-10 2013 Sportster Diagnostics: Engine Management

HOME

DTC P0112,

P0113

6.5

ambient temperature in order to evaluate the possibility

DESCRIPTION AND OPERATION

of a shifted (out of calibration) sensor which may result in

The ECM supplies and monitors a voltage signal on terminal

driveability problems. The sensor temperatures should be

7 to one side of the IAT portion of the TMAP sensor. The other

within 10 degrees of each other.

side of the IAT sensor is connected to a common sensor

•

A faulty sensor can negatively affect the signal voltage of

ground, which is also connected to the ECM terminal 26.

the other sensors sharing the same 5V reference. If the

The IAT sensor is a thermistor device, meaning that at a spe-

wiring passes the following tests, disconnect one sensor

cific temperature, it will have a specific resistance across its

at a time on the 5V reference and verify the DTC is still

terminals. As this resistance varies, so does the voltage at

present. Additional DTCs will be set as each sensor is

terminal 7.

disconnected. Clear DTCs after this test. Be sure to per-

•

At high temperatures, the resistance of the sensor is very

form this test before replacing a component.

low, which effectively lowers the signal voltage on terminal

ed03059

•

At low temperatures, the resistance is very high, allowing

the voltage to rise close to 5V.

The ECM monitors this voltage to compensate for various

operating conditions.

Table 6-7. Code Description

DTC

DESCRIPTION

P0112

IAT sensor voltage low

P0113

IAT sensor open/high

Diagnostic Tips

An intermittent may be caused by a poor connection, rubbed

1. ET sensor

through wire insulation or an open wire inside the insulation.

Rear fuel injector [85]

Check the following conditions:

IAC [87]

Front fuel injector [84]

•

Poor connection: Inspect ECM and harness connector

TPS [88]

[78] for backed out terminals, improper mating, inoperative

TMAP sensor [80]

locks, improperly formed or damaged terminals, poor ter-

minal- to-wire connection and damaged harness.

Figure 6-6. Between Cylinders Right Side

•

Perform 1.3 DIAGNOSTICS AND TROUBLESHOOTING,

Wiggle Test to locate intermittents: If connections and

Connector Information

harness check out OK, use a multimeter to check the IAT

For additional information about the connectors in the following

sensor voltage while moving related connectors and wiring

diagram(s) and diagnostic procedure(s), including the color of

harness. If the failure is induced, the IAT voltage will

the harness test kit terminal probes, see B.1 CONNECTORS.

change.

•

Shifted sensor resistance value: Compare the temper-

atures of the ET and IAT sensors with the engine at

2013 Sportster Diagnostics: Engine Management 6-11

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em00647

[90B] [90A]

PK/Y

BK/W

Sensor

[78A] [78B]

ECM

[145A] [145B]

[80B] [80A]

PK/Y

BK/W

LGN/Y

TMAP

5V Sensor Power

R/W

Sensor

MAP

V/W

[88B] [88A]

BK/W

R/W

TPS

GY/V

5V Sensor GND

BK/W

CKP

[79B] [79A]

Sensor

CKP Sensor(+)

CKP Sensor(-)

[138B] [138A]

Front O2

Sensor

Front O2 Sensor Input

PK/O

BK/W

GY/BK

[137B] [137A]

Rear O2

Sensor

Rear O2 Sensor Input

PK/GN

BK/W

GY/BK

[65B] [65A]

BK/R

VSS Input

BK/BE

VSS

JSS (HDI)

GN/BN

[133B] [133A]

Power GND

R/W

Power GND

JSS

GN/BN

(HDI)

GND 1

Figure 6-7. Sensor Circuit

DTC P0112

1. IAT Sensor Test

1. Disconnect TMAP sensor [80].

PART NUMBER

TOOL NAME

2. Using HARNESS CONNECTOR TEST KIT (Part No. HD-

HD-41404

HARNESS CONNECTOR TEST KIT

41404) and a multimeter, measure resistance between

HD-43876

BREAKOUT BOX

terminals 1 and 2 of [80A].

3. Is the resistance reading between 500-5000 Ohms with

the vehicle and sensor at ambient room temperature?

Table 6-8. DTC P0112 Diagnostic Faults

a. Yes. Go to Test 2.

POSSIBLE CAUSES

b. No. Replace TMAP sensor.

TMAP sensor malfunction

Short to ground in 5V reference circuit

6-12 2013 Sportster Diagnostics: Engine Management

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2. IAT Sensor Signal Wire Shorted to

1. IAT Sensor Test

Ground Test

1. Disconnect TMAP sensor [80].

1. Measure resistance between [80B] terminal 2 (LGN/Y)

2. Using HARNESS CONNECTOR TEST KIT (Part No. HD-

and ground.

41404) and a multimeter, measure voltage between [80B]

terminal 2 (LGN/Y) and ground.

2. Is resistance reading less than 1 Ohm?

a. Yes. Repair short to ground on (LGN/Y) wire.

3. With the IGN ON, the voltage reading greater than 6V?

a. Yes. Repair short to voltage on (LGN/Y) wire.

b. No. Go to Test 3.

b. No. Voltage is less than 4V. Go to Test 2.

3. IAT Sensor Signal Voltage High Test

2. IAT Sensor Signal Wire Open Test

1. Connect BREAKOUT BOX (Part No. HD-43876) to wire

harness [78B], leaving ECM [78A] disconnected. See

1. Turn IGN OFF.

1.2 DIAGNOSTIC TOOLS.

2. Connect BREAKOUT BOX (Part No. HD-43876) to wiring

2. Test continuity between breakout box terminals 7 and 10.

harness [78B], leaving ECM [78A] disconnected. See

1.2 DIAGNOSTIC TOOLS.

3. Is continuity present?

a. Yes. Go to Test 4.

3. Test for continuity between [80B] terminal 2 (LGN/Y) and

breakout box terminal 7.

b. No. Repair short to ground on (LGN/Y) wire.

4. Is continuity present?

4. IAT Sensor Signal Wire Shorted to Sensor

a. Yes. Go to Test 3.

Ground Test

b. No. Repair open circuit in (LGN/Y) wire.

1. Test continuity between breakout box terminals 7 and 26.

3. IAT Sensor Open Ground Wire Test

2. Is continuity present?

1. Test for continuity between breakout box terminal 26 and

a. Yes. Repair short between terminals 1 and 2 of [80B]

[80B] terminal 1 (BK/W).

(LGN/Y and BK/W) wires.

2. Is continuity present?

b. No. Replace ECM.

a. Yes. Go to Test 4.

DTC P0113

b. No. Repair open in (BK/W) wire.

PART NUMBER

TOOL NAME

4. IAT Sensor Signal Wire Shorted to Sensor

HD-41404

HARNESS CONNECTOR TEST KIT

Power Test

HD-43876

BREAKOUT BOX

1. Test for continuity between breakout box terminals 7 and

14.

Table 6-9. DTC P0113 Diagnostic Faults

2. Is continuity present?

a. Yes. Repair short between (LGN/Y) and (R/W) wires.

POSSIBLE CAUSES

Verify IAT sensor resistance value and if incorrect

TMAP sensor malfunction

replace TMAP sensor.

Open or short to voltage in 5V reference circuit

b. No. Replace ECM.

2013 Sportster Diagnostics: Engine Management 6-13

HOME

DTC P0117,

P0118

6.6

harness check out OK, use a multimeter to check the

DESCRIPTION AND OPERATION

engine temperature reading while moving related con-

The ECM supplies and monitors a voltage signal from terminal

nectors and wiring harness. If the failure is induced, the

6 to one side of the ET sensor. The other side of the ET sensor

engine temperature display will change.

is connected to a common sensor ground, which is also con-

•

Shifted sensor resistance value: Compare the temper-

nected to the ECM terminal 26.

atures of the ET and IAT sensors with the engine at

The ET sensor is a thermistor device, which means that at a

ambient temperature in order to evaluate the possibility

specific temperature it will have a specific resistance across

of a shifted (out of calibration) sensor which may result in

its terminals. As this resistance varies, so does the voltage on

driveability problems. The sensor temperatures should be

terminal 6.

within 10 °F (5.6 °C) of each other.

•

At high temperatures, the resistance of the sensor is very

low, which effectively lowers the signal voltage on terminal

ed03059

•

At low temperatures, the resistance is very high, allowing

the voltage to rise close to 5V.

The ECM monitors this voltage to compensate for various

operating conditions. The ECM also uses the sensor input as

a reference for determining IAC pintle position.

Table 6-10. Code Description

DTC

DESCRIPTION

P0117

ET sensor voltage low

P0118

ET sensor open/high

Diagnostic Tips

1. ET sensor

2. Rear fuel injector [85]

Once the engine is started, the temperature should rise steadily.

IAC [87]

An intermittent may be caused by a poor connection, rubbed

Front fuel injector [84]

through wire insulation or an inoperative wire inside the insula-

TPS [88]

tion.

TMAP sensor [80]

Check the following conditions:

Figure 6-8. Between Cylinders Right Side

•

Poor connection: Inspect ECM harness connector [78]

for backed out terminals, improper mating, inoperative

Connector Information

locks, improperly formed or damaged terminals, poor ter-

For additional information about the connectors in the following

minal-to-wire connection and damaged harness.

diagram(s) and diagnostic procedure(s), including the color of

•

Perform 1.3 DIAGNOSTICS AND TROUBLESHOOTING,

the harness test kit terminal probes, see B.1 CONNECTORS.

Wiggle Test to locate intermittents: If connections and

6-14 2013 Sportster Diagnostics: Engine Management

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em00647

[90B] [90A]

PK/Y

BK/W

Sensor

[78A] [78B]

ECM

[145A] [145B]

[80B] [80A]

PK/Y

BK/W

LGN/Y

TMAP

5V Sensor Power

R/W

Sensor

MAP

V/W

[88B] [88A]

BK/W

R/W

TPS

GY/V

5V Sensor GND

BK/W

CKP

[79B] [79A]

Sensor

CKP Sensor(+)

CKP Sensor(-)

[138B] [138A]

Front O2

Sensor

Front O2 Sensor Input

PK/O

BK/W

GY/BK

[137B] [137A]

Rear O2

Sensor

Rear O2 Sensor Input

PK/GN

BK/W

GY/BK

[65B] [65A]

BK/R

VSS Input

BK/BE

VSS

JSS (HDI)

GN/BN

[133B] [133A]

Power GND

R/W

Power GND

JSS

GN/BN

(HDI)

GND 1

Figure 6-9. Sensor Circuit

DTC P0117

1. ET Sensor Test

1. Disconnect ET sensor [90].

PART NUMBER

TOOL NAME

2. Using HARNESS CONNECTOR TEST KIT (Part No. HD-

HD-41404

HARNESS CONNECTOR TEST KIT

41404) and a multimeter, measure the resistance between

HD-43876

BREAKOUT BOX

[90A] terminals 1 and 2.

3. Is the resistance reading between 900-10,000 Ohms with

the vehicle and sensor at ambient room temperature?

Table 6-11. DTC P0117 Diagnostic Faults

a. Yes. Go to Test 2.

POSSIBLE CAUSES

b. No. Replace ET sensor.

ET sensor malfunction

Short to ground in 5V reference circuit

2013 Sportster Diagnostics: Engine Management 6-15

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