Harley Davidson 2013 Sportster Models. Service Manual — page 31

6.37

H-DSSS ACTUATION

GENERAL

Setting up a vehicle TSM/HFSM depends on whether the
vehicle has a TSM or the optional HFSM security system
installed.

SIDECAR CONFIGURATION

Only Touring Harley-Davidson Motorcycles are suitable
for sidecar use. Consult a Harley-Davidson dealer. Use of
motorcycles other than Touring models with sidecars
could result in death or serious injury. (00040a)

All motorcycles ship with the H-DSSS set for use

without

sidecar installed. If a motorcycle is equipped with a TSM, no
further actuation is required.

ACTUATION

Actuation consists of assigning two fobs to the system, and
entering an initial PIN. The PIN can be changed by the rider
at any time.

Configure vehicles by assigning

both

fobs to the vehicle.

Configure vehicles by entering a PIN picked by the owner.
The personal code allows the owner to operate the system
if the fob is lost or inoperable. Record the PIN in the
owner's manual. Instruct the customer to carry a copy (use
the wallet card found in the owner's manual). See

6.36 PERSONAL IDENTIFICATION NUMBER (PIN)

Once the system has been activated, it will always "arm" within
5 seconds of turning the ignition switch to

OFF

ACC

and no

motorcycle motion.

FOB ASSIGNMENT

TOOL NAME

PART NUMBER

DIGITAL TECHNICIAN II

HD-48650

Use DIGITAL TECHNICIAN II (Part No. HD-48650) to assign
both fobs to the H-DSSS. Follow the menu prompts to scan

the fob serial number with the bar code reader. Alternatively,
enter the number using the keyboard. The initial PIN entry
should be performed using DIGITAL TECHNICIAN II (Part
No. HD-48650) in conjunction with fob assignment.

NOTE

Each fob has a unique serial number. Attach fob label to a
blank NOTES page in the owner's manual for reference.

POWER DISRUPTION AND CONFIGURING

The following actions may result in a removal of battery voltage
from the TSM/HFSM:

•

Battery disconnect

•

Power drain

•

Battery fuse removal

•

Connecting a breakout box to the TSM/HFSM connector

After battery voltage has been removed from terminal 1 of the
TSM/HFSM, the module will not enter the PIN entry mode on
the first attempt. Initialize the PIN entry configuration sequence
twice before entering the PIN:

Set engine OFF/RUN switch to

OFF

Cycle the ignition switch:

IGNITION

OFF

IGNITION

OFF

IGNITION

Press the left turn signal switch

twice

Repeat the previous steps.

Continue with the PIN entry sequence.

HOME

2013 Sportster Service: Electrical 6-103

6.38

TSM/HFSM: PASSWORD LEARN

GENERAL

If the ECM or TSM/HFSM is faulty, replace the unit. See

6.6 ELECTRONIC CONTROL MODULE (ECM)

6.7 TURN

SIGNAL AND SECURITY MODULE (TSM/TSSM/HFSM)

. Then,

to determine if password learn is necessary, refer to

Table 6-13

Table 6-13. Password Learn

IS PASSWORD LEARN

NECESSARY?

DEVICE REPLACED

Yes

ECM

No *

TSM

Yes

TSM/HFSM

* If a TSM has been replaced by a HFSM, or a HFSM has
been replaced by a TSM, password learn is necessary.

PASSWORD LEARN

TOOL NAME

PART NUMBER

DIGITAL TECHNICIAN II

HD-48650

To perform the password learn procedure, refer to

Table 6-14

When finished, continue with all instructions under

6.37 H-

DSSS ACTUATION

TSM/HFSM:

Always perform all appropriate instructions under

6.37 H-DSSS ACTUATION

after TSM/HFSM replacement or

removal.

TSM/TSSM (Japan/Korea markets):

Always perform all

appropriate instructions under VEHICLE DELIVERY in the
electrical diagnostic manual after TSM/TSSM replacement or
removal.

NOTES

•

HFSM: Fob assignment must be performed at an author-
ized Harley-Davidson dealer using DIGITAL TECHNICIAN
II (Part No. HD-48650).

•

TSSM: Do not forget to enter a Personal Identification
Number (PIN) for TSSM vehicles. If a code is not assigned
and the key fob is lost or damaged while the vehicle is
armed, the TSSM must be replaced.

Table 6-14. Setting TSM/TSSM/HFSM and ECM Password

NOTES

CONFIRMATION

ACTION

NO.

With Ignition Switch turned off,
Check Engine lamp and
Security lamp will be off.

Ignition must be turned off for at least 15 seconds.

Install

new

TSM/TSSM/HFSM or ECM.

Set Engine Stop Switch to

RUN.

TSM/HFSM enables start
relay.

Verify Check Engine lamp and
Security lamp illuminate and
then turn off.

Turn Ignition Switch

ON.

Password has not been
learned. ECM sets DTC
P1009.

Engine starts and stalls.
Check Engine lamp illuminates
and stays on.

Attempt normal start one time.

ECM enters Password
Learning mode for ten
minutes. Do not cycle Ignition
Switch or interrupt vehicle
power or Password Learn will
be unsuccessful.

Security lamp illuminates.

Wait ten seconds. Security lamp will illuminate and stay
on.

This takes ten minutes.

Wait until Security lamp turns off.

ECM must not be allowed to
shutdown.

Quickly (within two seconds) turn Ignition Switch
OFF-

ON.

This takes ten minutes.

Wait until Security lamp turns off.

ECM must not be allowed to
shutdown.

Quickly (within two seconds) turn Ignition Switch
OFF-

ON.

This takes ten minutes.

Wait until Security lamp turns off.

ECM must not be allowed to
shutdown.

Quickly (within two seconds) turn Ignition Switch
OFF-

ON.

HOME

6-104 2013 Sportster Service: Electrical

Table 6-14. Setting TSM/TSSM/HFSM and ECM Password

NOTES

CONFIRMATION

ACTION

NO.

Turn Ignition Switch

OFF

. Wait 15 seconds before

turning Ignition Switch on. Turn Ignition Switch

and

start engine to confirm successful Password Learn
procedure. Clear DTCs.

TSM/HFSM:

Perform all steps under

6.37 H-DSSS

ACTUATION

TSM/TSSM (Japan/Korea markets):

Perform all steps

under VEHICLE DELIVERY in electrical diagnostic
manual.

HOME

2013 Sportster Service: Electrical 6-105

TABLE OF CONTENTS

SUBJECT

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PAGE NO.

APPENDIX

CONNECT

REP

AIR

A.1

AUTOFUSE UNSEALED ELECTRICAL
CONNECTOR

AUTOFUSE UNSEALED CONNECTOR
REPAIR

TOOL NAME

PART NUMBER

SNAP-ON TERMINAL PICK

GA500A

General

Autofuse Unsealed connector terminals are found in ignition
switches and some fuse blocks.

Disassembly

See

Figure A-1

Figure A-2

. Insert smallest pair of pins

on the SNAP-ON TERMINAL PICK (Part No. GA500A)
into chamber on mating end of socket housing to press
tangs on each side of terminal simultaneously.

Gently pull on wire to remove terminal from wire end of
socket housing.

If necessary, crimp

new

terminals on wires.

Assembly

Carefully bend tang on each side of terminal outward away
from terminal body. Use the thin flat blade from a hobby
knife.

With the open side of the terminal facing rib on wire end
of socket housing, insert terminal into chamber until it locks
in place.

sm02849a

Figure A-1. Removing Autofuse Unsealed Terminal from

Ignition Switch

sm03480a

Figure A-2. Removing Autofuse Unsealed Terminal from

Fuse Block

HOME

2013 Sportster Service: Appendix A Connector Repair A-1

A.2

BOSCH COMPACT 1.1M CONNECTOR

TOOL NAME

PART NUMBER

SNAP-ON TERMINAL PICK

GA500A

General

See

Figure A-3

. The Bosch Compact 1.1M connector is found

on MAP and TMAP sensors on all models.

Housings

Separate:

Snap back the secondary lock. Press on the latch

while pulling the socket connector from the sensor.

Join:

Align the sockets and press the housings together until

the latch snaps. Snap in the secondary lock.

sm07374

Figure A-3. Bosch Compact 1.1M Connector

Removing Socket Terminal

See

Figure A-4

. Slide the locking bar off the terminal

housing.

Insert the smallest pins of the SNAP-ON TERMINAL PICK
(Part No. GA500A) into the gaps on each side of the
socket to compress the tangs on each side of the terminal.

Gently pull on the wire to remove the terminal.

sm07337

Figure A-4. Terminal Removal: Bosch Compact 1.1M

Connector

Installing Socket Terminal

See

Figure A-5

. Use a hobby knife to bend the tangs on

each side of the terminal outward.

Align terminal to socket housing. Press terminal into
housing until it snaps.

NOTE

The teeth on the locking bar face down.

Slide the locking bar onto the connector.

sm07352

Figure A-5. Tangs: Bosch Compact 1.1M Socket Terminal

HOME

A-2 2013 Sportster Service: Appendix A Connector Repair

A.3

DELPHI 100W MICRO-PACK SEALED
CONNECTOR

DELPHI 100W MICRO-PACK SEALED
CONNECTOR REPAIR

General

A Delphi 100W Micro-Pack Sealed connector connects the
electronic control module (ECM) to the main harness.

Separating Socket Housing From ECM

See

Figure A-6

. While pressing the connector into the ECM,

press the thumb lever (1) against the connector until the latch
(2) pops out of the catch (3) on the ECM.

sm00037a

1. Thumb lever
2. Latch
3. Catch (ECM)

Figure A-6. Delphi 100W Micro-Pack Sealed Connector to

ECM

Mating Socket Housing To ECM

Push the connector into the ECM until the latch is captured by
the catch on the ECM.

sm00038a

1. Latch
2. Secondary lock
3. Cable strap
4. Strain relief collar
5. Conduit

Figure A-7. Delphi 100W Micro-Pack Sealed Connector

Removing Socket Terminal

See

Figure A-7

. To remove, gently press latch (1) on each

side of the clear plastic secondary lock (2). For best res-
ults, release one side at a time.

Carefully cut cable strap (3) to free strain relief collar (4)
from conduit (5).

See

Figure A-8

. Using a thin blade, gently pry at seam at

back of socket housing to release three plastic pins (1)
from slots in housing. Separate and spread halves of
socket housing.

Push on wire lead to free terminal from chamber.

Installing Socket Terminal

From inside socket housing, gently pull on wire to draw
terminal into chamber.

Exercising caution to avoid pinching wires, press halves
of socket housing together until three plastic pins fully
engage slots in housing.

Install

new

cable strap in groove of strain relief collar

capturing cable conduit.

With the two ribs on the secondary lock on the same side
as the external latch, install over terminals until latches
lock in place.

HOME

2013 Sportster Service: Appendix A Connector Repair A-3

sm00039a

1. Pins
2. Socket terminal

Figure A-8. Delphi 100W Micro-Pack Sealed Connector:

Separate Halves of Socket Housing

CRIMPING TERMINALS

TOOL NAME

PART NUMBER

UNIVERSAL CRIMPER SET

HD-50120

HAND CRIMP FRAME

HD-50120-2

DELPHI 100W MICRO-PACK SEALED
DIE

HD-50120-7

Strip the wire insulation to specification. Refer to

Table A-1

Install the DELPHI 100W MICRO-PACK SEALED DIE
(Part No. HD-50120-7) in the handle of the HAND CRIMP
FRAME (Part No. HD-50120-2) of the UNIVERSAL
CRIMPER SET (Part No. HD-50120).

Place the

new

terminal in the specified nest.

Insert the wire to the wire stop. Crimp the terminal.

Inspect the crimped terminal.

Table A-1. Delphi 100W Micro-Pack Crimper Die (Part No.

HD-50120-7)

NEST

STRIP LENGTH

PART NO.

TERMINAL

5.1

0.200

72076-00

Socket:
18 AWG

5.1

0.200

72568-08

Socket:
20-22 AWG

HOME

A-4 2013 Sportster Service: Appendix A Connector Repair

A.4

DELPHI 150 METRI-PACK SEALED CONNECTOR

DELPHI 150 METRI-PACK SEALED
CONNECTOR REPAIR

General

Delphi 150 Metri-Pack Sealed connectors are embossed with
the initials (P.E.D.).

There are two types of connectors in this series:

•

Pull-to-Seat

•

Push-to-Seat

Separating Pin and Socket Housings

Bend back the external latch slightly and separate the pin and
socket halves of the connector.

Mating Pin and Socket Housings

Align the wire colors. Push the pin and socket halves of the
connector together.

Removing Socket Terminal

See

Figure A-9

for pull-to-seat connector or

Figure A-10

for push to seat connector. Remove wire lock (1) from wire
end of socket housing on push-to-seat type connectors.

NOTE

For best results, free one side of wire lock first and then release
the other side.

Find the locking tang in the mating end of the connector.

NOTE

The tangs are always positioned in the middle of the chamber.
The tangs are on the same side as the external latch.

Gently insert a small diameter straight pin into the chamber
about 1/8 in (3.2 mm).

For pull-to-seat:

Stay between the terminal and the

chamber wall and pivot the end of the pin toward the
terminal body.

For push-to-seat:

There is a small opening for the

pin.

When a click is heard, remove the pin and repeat the
procedure.

NOTE

The click is the sound of the tang returning to the locked posi-
tion as it slips from the point of the pin.

Pick at the tang until the clicking stops and the pin seems
to slide in deeper. This indicates the tang is pressed in.

NOTE

After repeated terminal extractions, the click may not be heard,
but pivot the pin as if the click was heard at least three times.

Remove the pin.

For pull-to-seat:

Push on the lead to extract the ter-

minal from the mating end of the connector.

For push-to-seat:

Pull on the lead to draw the ter-

minal out the wire end.

Inserting Socket Terminal

NOTE

For wire location purposes, alpha characters are stamped into
the socket housings.

See

Figure A-9

for pull-to-seat connector or

Figure A-10

for push to seat connector. Carefully bend tang on each
side of terminal outward away from terminal body. Use
the thin flat blade from a hobby knife.

Gently pull or push on the lead to install the terminal back
into the chamber. A click is heard when the terminal is
properly seated.

Gently pull or push on the lead to verify that the terminal
is locked in place.

For push-to-seat:

See

Figure A-10

. Seat wires in separate

channels of wire lock and then push channels

inside

chambers at wire end of socket housing. Fully installed,
slot on each side of wire lock engages ear on socket
housing.

HOME

2013 Sportster Service: Appendix A Connector Repair A-5

sm00027a

1. Locate tang in chamber
2. Pivot pin to release tang
3. Push to remove
4. Raise tang to install

Figure A-9. Delphi 150 Metri-Pack Sealed Connector:

Pull-to-Seat

sm00028a

1. Remove wire lock
2. Pivot pin to release tang
3. Pull to remove
4. Raise tang to install

Figure A-10. Delphi 150 Metri-Pack Sealed Connector:

Push-to-Seat

HOME

A-6 2013 Sportster Service: Appendix A Connector Repair

A.5

DELPHI 280 METRI-PACK UNSEALED
CONNECTOR

FUSE BLOCK REPAIR

Removing Socket Terminals

See

Figure A-11

. To remove secondary locks, insert end

of small flat blade screwdriver (1) under lip of locking
wedge (2) and gently pry up secondary lock.

NOTE

For best results, start with locking wedge on outboard side of
secondary lock.

Looking into chamber at top of fuse block, note the tang
next to each socket terminal.

Use the thin flat blade from a hobby knife. Gently push
tang away from terminal and tug on wire to back terminal
out.

Installing Socket Terminals

Match the wire lead color to the fuse block terminal cavity.

NOTES

•

Refer to the main harness wiring diagram for wire lead
color codes.

•

See

Figure A-12

. Alpha (1) and numeric (2) coordinates

identify the main fuse block terminal cavity. Refer to the
main harness wiring diagram.

With the open side of the socket terminal facing the tang,
push lead into chamber at the wire end of the fuse block.
A click is heard when the terminal is properly engaged.

Gently tug on the wire to verify that the terminal is locked
in place.

Install the secondary locks. With the locking wedges
positioned above the tangs in each chamber, slide flat
side of secondary lock into slot between rows. Push down
until it bottoms.

Crimping Terminals

Terminals are crimped twice: once over the wire core and a
second time over the insulation/seal.

A correctly crimped terminal may require different crimping
dies found on separate crimpers.

NOTE

The wiring diagram indicates when one socket terminal is be
crimped to two wire leads.

sm00025

1. Pry up secondary lock
2. Lip of locking wedge

Figure A-11. Fuse Block: Remove Secondary Locks

sm00026

1. Alpha
2. Numeric

Figure A-12. Fuse Block: Coordinates (typical)

HOME

2013 Sportster Service: Appendix A Connector Repair A-7

A.6

DELPHI 480 METRI-PACK UNSEALED
CONNECTORS

DELPHI 480 METRI-PACK UNSEALED
CONNECTOR REPAIR

General

A 480 Metri-Pack connector is frequently used for the B+
(battery voltage) connector to power P&A accessories.

See

Figure A-13

. An AFL housing (5) is used on many igni-

tion/light switches. The secondary lock (4) must be opened
before removing the terminal from the housing.

Separating Pin and Socket Housings

NOTES

•

Record position of cable straps anchoring wire conduits
of the pin and socket housing before removing them.

•

Cut any cable strap anchoring the wire conduits of the pin
(accessory connector housing) and the socket (B+)
housing.

See

Figure A-13

. Using small flat blade screwdriver, press

button (1) on pin housing (red wire) side of the connector and
pull apart the pin and socket housings.

Mating Pin and Socket Housings

Orient the latch on the socket housing to the button catch on
the pin housing and press the housings together.

Removing Socket Terminals

See

Figure A-13

. Bend back the latch (2) slightly and free

one side of secondary lock, then repeat to release the
opposite side. Rotate the secondary lock outward on hinge
to access terminal in chamber of connector housing.

On the mating end of the connector, note the tang in the
square shaped opening centered next to the terminal.
Gently insert the point of a stick pin or large safety pin into
the opening (3) between the tang and the chamber wall
until it stops.

Pivot the end of the pin toward the terminal body to press
the tang.

Remove the pin and then pull terminal out of the wire end
of connector housing.

If necessary, crimp

new

terminals on wires. See

A.9 DELPHI METRI-PACK TERMINAL REPAIR

Installing Socket Terminals

Carefully bend the tang outward away from the terminal
body.

With the tang on the same side as the square shaped
opening in the mating end of the connector housing, feed
terminal into wire end of connector housing until it clicks
in place.

Verify that terminal will not back out of the chamber. A
slight tug on the cable will confirm that it is locked.

Rotate the hinged secondary lock inward until latches fully
engage tabs on both sides of connector housing.

NOTE

If removed, install new anchored cable strap in original equip-
ment location. Tighten cable strap to capture conduit of both
accessory connector and B+ connector approximately 1.0 in
(25.4 mm) from housings.

sm00031a

1. Button on pin housing
2. Secondary lock latch
3. Opening between tang and chamber wall
4. Secondary lock (shown open)
5. AFL housing

Figure A-13. Delphi 480 Metri-Pack Unsealed Connector:

Remove Socket Terminal

HOME

A-8 2013 Sportster Service: Appendix A Connector Repair

A.7

DELPHI 630 METRI-PACK UNSEALED
CONNECTOR

DELPHI 630 METRI-PACK UNSEALED
CONNECTOR REPAIR

TOOL NAME

PART NUMBER

SNAP-ON PICK

SNAP-ON TT600-3

Separating Pin and Socket Housings

NOTE

If necessary, remove connector from barbed anchor or other
retaining device.

Bend back the external latch slightly and separate pin and
socket halves of the connector.

Mating Pin and Socket Housings

Orient the latch to the catch. Push the pin and socket halves
of the connector together until the latch "clicks".

NOTE

If removed, install connector on barbed anchor or other OE
retaining device.

Removing Socket Terminal

Bend back the latch slightly and free one side of the sec-
ondary lock. Repeat the step to unlatch the other side.

Rotate the secondary lock outward on hinge to view the
terminals in the chambers of the connector housing. The
locking tang is on the side opposite the crimp tails and
engages a rib in the chamber wall to lock the terminal in
place.

Moving to the mating end of the connector, find the small
opening on the chamber wall side of each terminal.

Insert SNAP-ON PICK (Part No. SNAP-ON TT600-3) into
opening until it stops. Pivot the end of the pick toward the
terminal to press the locking tang.

Remove the pick and gently tug on the wire to pull the
terminal from the wire end of the connector. Repeat steps
if the terminal is still locked in place.

If necessary, crimp

new

terminals on wires. Refer to

A.9 DELPHI METRI-PACK TERMINAL REPAIR

Installing Socket Terminal

NOTE

Refer to the wiring diagrams to match wire lead colors to alpha
characters molded into the secondary locks of each connector
housing.

Carefully bend tang on each side of terminal outward away
from terminal body. Use the thin flat blade from a hobby
knife.

With the tang facing the chamber wall, push the lead into
the chamber at the wire end of the connector. A click is
heard when the terminal is properly seated.

Gently tug on the wire end to verify that the terminal is
locked in place and will not back out of the chamber.

Rotate the hinged secondary lock inward until tabs fully
engage latches on both sides of connector.

HOME

2013 Sportster Service: Appendix A Connector Repair A-9

A.8

DELPHI 800 METRI-PACK SEALED MAIN FUSE
HOUSING

DELPHI 800 METRI-PACK SEALED MAIN
FUSE HOUSING REPAIR

Removing Socket Terminals

Disconnect negative (-) battery cable first. If positive (+)
cable should contact ground with negative (-) cable con-
nected, the resulting sparks can cause a battery explosion,
which could result in death or serious injury. (00049a)

Disconnect battery.

See

Figure A-14

. Disengage slots (1) on secondary lock

(2) from tabs (3) and remove secondary lock.

Insert flat blade of pick or small screwdriver into opening
(4) until it stops.

Tug on cable to pull socket from connector housing. Pivot
the pick toward the terminal body to release the latch if
necessary.

Repeat to remove remaining socket terminal.

NOTE

The battery positive cable and power wire for the main fuse
are crimped together at the starter ring terminal. Replace both
as an assembly if either requires replacement.

Installing Socket Terminals

See

Figure A-15

. Carefully bend tang outward away from

the terminal body.

Properly orient terminal to the cavity in the housing. Push
terminal into connector housing until it clicks in place.
Verify that socket will not back out of chamber.

Push rubber seal into connector housing.

Repeat to install remaining socket terminal.

Install secondary lock onto connector housing. Verify slots
engage tabs on sides of connector housing.

Connect positive (+) battery cable first. If positive (+) cable
should contact ground with negative (-) cable connected,
the resulting sparks can cause a battery explosion, which
could result in death or serious injury. (00068a)

Connect battery cables.

sm00033

1. Secondary lock slot
2. Secondary lock
3. Tab
4. Insert flat blade into opening

Figure A-14. Delphi 800 Metri-Pack Sealed Main Fuse

Housing: Remove Socket Terminals

sm00034

Figure A-15. Delphi 800 Metri-Pack Sealed Main Fuse

Housing: Bend Tang

HOME

A-10 2013 Sportster Service: Appendix A Connector Repair

A.9

DELPHI METRI-PACK TERMINAL REPAIR

METRI-PACK TERMINAL CRIMPS

TOOL NAME

PART NUMBER

PACKARD TERMINAL CRIMP TOOL

HD-38125-6

PACKARD TERMINAL CRIMPER

HD-38125-7

PACKARD CRIMPING TOOL

HD-38125-8

Matching Terminal To Crimper

Metri-Pack connectors embossed with the initials P.E.D. require
Packard crimp tools to crimp terminals to wire leads.

Terminals are crimped twice to a wire lead, once over the wire
core and a second time over the insulation/seal.

See

Figure A-16

. A crimp can require two crimping dies. The

dies are found on the PACKARD TERMINAL CRIMP TOOL
(Part No. HD-38125-6) and the PACKARD TERMINAL
CRIMPER (Part No. HD-38125-7). The terminal and the wire
gauge determine the core crimp die and the insulator/seal die.

NOTE

The PACKARD CRIMPING TOOL (Part No. HD-38125-8) will
also crimp sealed splice connectors in wire gauge sizes 18-20,
14-16 and 10-12.

Preparing Wire Lead

Strip 5/32 in (4.0 mm) of insulation from the wire lead.

Crimping Wire Core

NOTE

Metri-Pack terminal crimps require two steps. Always perform
Crimping Wire Core before Crimping Insulation/Seal.

Squeeze and release handles until ratchet automatically
opens.

Identify the corresponding sized nest for the core crimp.

Position the core crimp in the die. Be Sure the core crimp
tails are facing the forming jaws.

Gently squeeze the handles until crimpers just secure the
core crimp tails.

Insert stripped wire between crimp tails. Verify that wire
is positioned so that short pair of crimp tails squeeze core
wire strands, while long pair is positioned over the insula-
tion or seal material.

Squeeze handles tightly closed. Release grip and the tool
will automatically open.

sm00035a

1. HD-38125-6 sealed terminals
2. HD-38125-7 non-sealed terminals
3. HD-38125-8 non-sealed terminals

Figure A-16. Metri-Pack Terminal Crimp Tools

Crimping Insulation/Seal

NOTE

Always perform Crimping Wire Core before Crimping
Insulation/Seal.

HOME

2013 Sportster Service: Appendix A Connector Repair A-11

See

Figure A-17

. Identify the correct die for the insula-

tion/seal crimp (2).

Position the insulation/seal crimp in the nest. Be sure the
insulation/seal crimp tails are facing the forming jaws.

Squeeze handle of crimp tool until tightly closed. Tool
automatically opens when the crimp is complete.

Inspecting Crimps

See

Figure A-17

. Inspect the wire core crimp (1). The tails

should be folded in on the wire core without any distortion
or excess wire strands.

Inspect the insulation (2) or seal (3) crimp. The tails of the
terminal should be wrapped around the insulation without
distortion.

sm00036

1. Wire core crimp
2. Insulation crimp
3. Seal crimp

Figure A-17. Metri-Pack Connector: Inspect Core and

Insulation/Seal Crimps

HOME

A-12 2013 Sportster Service: Appendix A Connector Repair

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