Harley Davidson 2013 Sportster Models. Service Manual — page 33
A.18
MOLEX CMC SEALED CONNECTOR
MOLEX CMC SEALED CONNECTORS
TOOL NAME
PART NUMBER
0.6 MM TERMINAL EXTRACTOR
TOOL
HD-50423
1.5 MM TERMINAL EXTRACTOR
TOOL
HD-50424
Separating the Connector
Release:
See
. Press the catch and rotate the lever
arm down.
Connect:
Press on the front guard to release the latch and
rotate the lever arm up until the catch clicks in place.
sm06931
Figure A-41. Release
Removing Terminals
1.
With the lever arm open, cut the cable strap around the
wire bundle.
2.
See
. Open a wire cap latch (1) with a small
screwdriver.
3.
Maintain pressure on the cap and open the opposite latch
(2) with the screwdriver.
4.
Slide the cap off (3).
5.
See
. Use the screwdriver to open the sec-
ondary lock. Pull the locking bar all the way out.
6.
See
. Locate the wire lead cavity by the alpha-
numeric coordinates.
7.
Identify the size of the terminal and select either the CMC
extractor 0.6 MM TERMINAL EXTRACTOR TOOL (Part
No. HD-50423) or the 1.5 MM TERMINAL EXTRACTOR
TOOL (Part No. HD-50424).
8.
See
. Insert the pins of the CMC extractor tool
(1) into the access slots (2) of the terminal cavity and
retract the lead and terminal.
Installing Terminals
1.
Orient the terminal to the housing cavity. Snap the terminal
in place.
2.
Slide the cap over the lead bundle. Snap the cap in place.
3.
Install a cable strap through the guide and around the lead
bundle.
2
1
3
sm06936
1. Press latch
2. Press cap and latch
3. Remove cap
Figure A-42. Remove the Wire Lead Cap
sm06928
Figure A-43. Molex CMC Sealed Connector Secondary
Lock
2013 Sportster Service: Appendix A Connector Repair A-29
2
2
1
1
2
2
sm06927
1. Alpha
2. Numeric
Figure A-44. Alpha-Numeric Coordinates
1
2
sm06935
1. Extractor tool
2. Access slots
Figure A-45. Terminal Removal
CRIMPING TERMINALS
TOOL NAME
PART NUMBER
UNIVERSAL CRIMPER SET
HD-50120
HAND CRIMP FRAME
HD-50120-2
JAE DIE
HD-50120-3
JAE DIE
HD-50120-4
1.
Select the crimper die according to the terminal part
number from the UNIVERSAL CRIMPER SET (Part
No. HD-50120).
2.
Strip the wire insulation to specification. Refer to
or
3.
Install the JAE DIE (Part No. HD-50120-3) or JAE DIE
(Part No. HD-50120-4) in the handle of the HAND CRIMP
FRAME (Part No. HD-50120-2).
4.
Place the
new
terminal in the specified nest.
5.
Insert the wire to the wire stop. Crimp the terminal.
6.
Inspect the crimped terminal.
Table A-5. Molex CMC Sealed Crimper Die (Part No.
HD-50120-3)
NEST
STRIP LENGTH
TERMINAL:
WIRE GAUGE
PART
NO.
mm
in
B
4.5
0.177
Socket: 16 AWG
72226-11
A
4.5
0.177
Socket: 18 AWG
72227-11
Table A-6. Molex CMC Sealed Crimper Die (Part No.
HD-50120-4)
NEST
STRIP LENGTH
TERMINAL:
WIRE GAUGE
PART NO.
mm
in
B
3.5
0.138
Socket: 18 AWG
72222-11
A
3.5
0.138
Socket: 20 AWG
72222-11
A-30 2013 Sportster Service: Appendix A Connector Repair
A.19
MOLEX MX 150 SEALED CONNECTOR
MOLEX MX 150 SEALED CONNECTOR
REPAIR
TOOL NAME
PART NUMBER
TERMINAL REMOVER
HD-48114
Separating Pin and Socket Housings
See
. Press the latch while pulling the pin and
socket housings apart.
Mating Pin and Socket Housings
1.
Orient the latch on the pin housing to the latch pocket on
the socket housing so the rails on the outside of the pin
housings lines up with the tunnels on the socket housing.
2.
Press the housings together until the latch clicks.
Removing Terminals
1.
Pull the secondary lock up, approximately 3/16 in (4.8
mm), until it stops.
a.
Socket Housing:
See
. Use a small
screwdriver in the pry slot. The slot next to the
external latch provides a pivot point.
b.
Pin Housing:
See
. Use needle nose
pliers to engage the D-holes in the center of the sec-
ondary lock.
NOTE
Do not remove the secondary lock from the connector housing.
2.
See
. Insert TERMINAL REMOVER (Part
No. HD-48114) into the pin hole next to the terminal until
the tool bottoms.
a.
Socket Housing:
The pin holes are inside the ter-
minal openings.
b.
Pin Housing:
The pin holes are outside the pins.
3.
Pressing the terminal remover to the bottom of the pin
hole, gently pull on the wire to remove wire terminal from
its cavity.
Installing Terminals
1.
See
. From the wiring diagram, match the wire
color to its numbered terminal cavity.
NOTE
Cavity numbers (1) are stamped on the housing at the ends
of the cavity rows. Determine the cavity number by counting
the cavities up or down along the row from each stamped
number.
2.
Orient the terminal that the tang (2) opposite the open
crimp engages the slot (3) in the cavity.
3.
Push the terminal into the cavity.
4.
Gently tug on wire to verify that the terminal is captured
by the secondary lock.
5.
With all terminals installed, push the secondary lock into
the socket housing to lock the wire terminals into the
housing.
sm00040a
Figure A-46. Molex MX 150 Sealed Connector: Latch
sm03332a
Figure A-47. Secondary Lock Pry Slot (Socket Housing)
2013 Sportster Service: Appendix A Connector Repair A-31
sm02851a
Figure A-48. Pull Up Secondary Lock
sm00043a
Figure A-49. Molex MX 150 Sealed Connector: Terminal
Remover (HD-48114)
1
3
2
sm00044
1. Cavity number
2. Tang
3. Cavity slot
Figure A-50. Molex MX 150 Sealed Connector: Pin Cavities
and Wire Terminal
CRIMP TERMINAL TO LEAD
TOOL NAME
PART NUMBER
TERMINAL CRIMPER
HD-48119
Prepare Lead
1.
Cut the damaged terminal close to the back of the terminal
to leave as much wire length as possible.
2.
Strip wire lead removing 3/16 in (4.70-5.60 mm) of insula-
tion.
NOTE
The strip length is the same for both pin and socket terminals
and for wire gauges from 22 to 14.
Prepare Tool
1.
Identify the punch/die in the jaws of the TERMINAL
CRIMPER (Part No. HD-48119) for the wire gauge. Refer
to
2.
Squeeze and release the handles to open the tool.
NOTE
The crimp tool automatically opens when the handles are
released.
3.
See
. Hold fully open tool at approximately 45
degrees.
NOTE
Do NOT tighten the locknut holding the locator bars. The bars
must float to accommodate the different terminal gauges.
Table A-7. Crimp Tool Wire Gauge Punch/Die
PUNCH/DIE
AWG (WIRE GAUGE)
Left
22
Middle
18-20
Right
14-16*
* Crimp 16 AWG
pin
terminals in the 18-20 middle die.
A-32 2013 Sportster Service: Appendix A Connector Repair
sm02853a
Figure A-51. Open Terminal Crimper (HD-48119) at 45
Degrees
1
2
sm02854a
1. Socket locator bar
2. Pin locator bar
Figure A-52. Terminal Locator Bars
Position Terminal in the Punch/Die
1.
See
. With the crimp tails up, place the terminal
through the punch/die into the square opening in the
socket locator bar.
a.
Socket Terminal:
See
. A socket terminal
stops against the back face of the socket locator bar
(1).
b.
Pin Terminal:
See
. The tip of a pin ter-
minal passes through the socket locator bar and stops
in the notch in the face of the pin locator bar.
2.
See
. Ratchet the handles together until the
crimp tails are held in vertical alignment between the punch
and the die.
sm02855a
Figure A-53. Square Openings in Socket Locator Bar
Insert Stripped Lead
See
. Insert the stripped end (wire core) between
the crimp tails at an up angle until the wire core touches the
face of the socket locator bar above the square opening.
NOTES
•
The insulation must extend through the insulation crimp
tails.
•
Insert the wire with little or no pressure. Pressing on the
lead will bend the wire core.
sm02856a
Figure A-54. Pin Terminal against Pin Locator Bar
2013 Sportster Service: Appendix A Connector Repair A-33
sm02857a
Figure A-55. Crimp Tails in Vertical Alignment between
Punch and Die
Crimp Terminal to Lead
1.
Holding the wire lead in position touching the locator face
at an angle, quickly and smoothly squeeze the crimp tool
closed.
2.
Final squeeze the handles to open the tool and release
the terminal.
NOTE
Open a stuck or jammed tool by pressing the ratchet release
lever found between the handles. Do not force the handles
open or closed.
sm02858a
Figure A-56. Stripped Lead at Up Angle
Inspect Crimp
1.
Inspect Crimp:
Inspect the core and insulation crimp.
a.
See
. The core tails should be creased
into the wire strands at the core crimp (1).
b.
Strands (2) of wire should be visible beyond the core
crimp but not forward into the terminal shell.
c.
The insulation tails should be folded into the insulation
(3) without piercing or cutting the insulation.
d.
Distortion should be minimal.
2.
Test Crimp:
Hold the terminal. Pull the lead.
1
3
2
sm02859
1. Core crimp
2. Wire strands
3. Insulation crimp
Figure A-57. Terminal Crimp
A-34 2013 Sportster Service: Appendix A Connector Repair
A.20
TYCO 070 MULTILOCK UNSEALED CONNECTOR
TYCO 070 MULTILOCK UNSEALED
CONNECTOR REPAIR
TOOL NAME
PART NUMBER
AMP MULTI-LOCK CRIMPER
HD-41609
SNAP-ON PICK
SNAP-ON TT600-3
General
Tyco 070 Multilock Unsealed connectors are found between
wire harnesses and component wiring and may be either
floating or anchored to the frame with attachment clips.
See
. Attachment clips (1) on the pin housings are
fitted to T-studs on the motorcycle frame. The T-studs identify
OE connector locations. To maintain serviceability, always
return connectors to OE locations after service.
Obtain the necessary tools to repair the connector and ter-
minals.
NOTE
For terminal crimping use the AMP MULTI-LOCK CRIMPER
(Part No. HD-41609).
Separating Pin and Socket Housings
1.
If necessary, slide connector attachment clip T-stud to the
large end of the opening.
2.
See
. Press the release button (2) on the
socket terminal side of the connector and pull the socket
housing (3) out of the pin housing (4).
Mating Pin and Socket Housings
1.
Hold the housings to match wire color to wire color.
2.
Insert the socket housing into the pin housing until it clicks
in place.
3.
If OE location is a T-stud, fit large opening end of attach-
ment clip over T-stud and slide connector to engage T-
stud to small end of opening.
2
3
1
4
sm00002a
1. Attachment clip
2. Release button
3. Socket housing
4. Pin housing
Figure A-58. Tyco 070 Multilock Unsealed Connector
Removing Terminals from Housing
1.
See
. Bend back the latch (1) to free one end
of secondary lock (2) then repeat on the opposite end.
Hinge the secondary lock outward.
2.
Look in the terminal side of the connector (opposite the
secondary lock) and note the cavity next to each terminal.
3.
Insert a pick or pin into the terminal cavity until it stops.
NOTE
If socket/pin terminal tool is not available, use a push pin/safety
pin or a SNAP-ON PICK (Part No. SNAP-ON TT600-3).
4.
Press the tang in the housing to release the terminal.
a.
Socket:
Lift the socket tang (8) up.
b.
Pin:
Press the pin tang (7) down.
NOTE
A click is heard if the tang is released.
5.
Gently tug on wire to pull wire and terminal from cavity.
2013 Sportster Service: Appendix A Connector Repair A-35
5
2
7
1
3
6
1
2
4
8
sm00013
1. Latch
2. Secondary lock open
3. Pin housing
4. Socket housing
5. Pin terminal
6. Socket terminal
7. Tang (pin)
8. Tang (socket)
Figure A-59. Tyco 070 Multilock Unsealed Connector:
Socket and Pin Housings
Inserting Terminals into Housing
NOTE
See
. Cavity numbers are stamped into the sec-
ondary locks of both the socket and pin housings. Match the
wire color to the cavity number found on the wiring diagram.
1.
Hold the terminal so the catch faces the tang in the
chamber. Insert the terminal into its numbered cavity until
it snaps in place.
NOTES
•
The release button is always on the top of the connector.
•
On the pin side of the connector, tangs are positioned at
the bottom of each cavity, so the slot in the pin terminal
(on the side opposite the crimp tails) must face downward.
•
On the socket side, tangs are at the top of each cavity, so
the socket terminal slot (on the same side as the crimp
tails) must face upward.
2.
Gently tug on wire end to verify that the terminal is locked
in place.
3.
Rotate the hinged secondary lock inward until tabs fully
engage latches on both sides of connector.
– AMP
1
2
3
– AMP
1
2
3
4
5
6
5
6
7
8
9
10
4
3
2
1
1
2
3
sm00005
1. 3-place housing
2. 6-place housing
3. 10-place housing
Figure A-60. Tyco 070 Multilock Unsealed Connector:
Cavity Numbers on Secondary Locks (socket housings
shown)
Preparing Wire Leads for Crimping
1.
Strip wire lead removing 5/32 in (4.0 mm) of insulation.
A-36 2013 Sportster Service: Appendix A Connector Repair
2.
See
and
. Select the pin/socket
terminals from the parts catalog and identify the insulation
crimp tails (1) and the wire crimp tails (2) and the groove
for the crimp tool locking bar (3).
3.
Identify the wire lead gauge and the corresponding crimper
tool and nesting die. Refer to
Table A-8. AMP Multilock Connector: Crimp Tool Wire
Gauge/Nest
NEST
WIRE GAUGE
Front
20
Middle
16
Rear
18
2
3
1
sm00004
1. Insulation crimp tail
2. Wire crimp tail
3. Locking bar groove
Figure A-61. Tyco 070 Multilock Unsealed Connector: Pin
Terminal
2
3
1
sm00001
1. Insulation crimp tail
2. Wire crimp tail
3. Locking bar groove
Figure A-62. Tyco 070 Multilock Unsealed Connector:
Socket Terminal
Crimping Terminals to Leads
NOTE
Crimping with the AMP Multi-lock Crimper is a one step opera-
tion. One squeeze crimps both the wire core and the insulation
tails.
1.
See
. Squeeze the handles to cycle the AMP
MULTI-LOCK CRIMPER (Part No. HD-41609) to the fully
open position (1).
2.
Raise locking bar by pushing up on bottom flange (2).
NOTE
See
and
. Hold the terminal with the
insulation crimp tail (1) facing up. The tool will hold the terminal
by the locking bar groove (3) and simultaneously crimp around
the stripped lead and the insulation.
3.
See
. With the insulation crimp tail facing
upward, insert terminal (pin or socket) (3) through the
locking bar, so that the closed side of the terminal rests
on the nest of the crimp tool.
4.
Release locking bar to lock position of contact (4). When
correctly positioned, the locking bar fits snugly in the space
at the front of the core crimp tails.
5.
Insert stripped end of lead (5) until ends make contact with
locking bar.
6.
Position wire that the wide pair of crimp tails squeeze bare
wire strands, while the narrow pair folds over the insulation
material.
7.
Squeeze handle of crimp tool until tightly closed. Tool
automatically opens when the crimping sequence is com-
plete.
8.
Raise up locking bar (7) to remove crimped terminal.
2013 Sportster Service: Appendix A Connector Repair A-37
4
6
7
3
1
2
5
8
sm00007
1. Open position
2. Locking bar flange
3. Insert contact
4. Release locking bar
5. Insert lead
6. Squeeze
7. Raise locking bar
8. Remove crimped terminal
Figure A-63. Tyco 070 Multilock Unsealed Connector:
Terminal Crimping Procedure
Inspecting Crimped Terminals
See
. Inspect the wire core crimp (2) and insulation
crimp (1). Distortion should be minimal.
1
2
sm00008
1. Insulation crimp
2. Wire core crimp
Figure A-64. Tydo 070 Multilock Unsealed Connector:
Terminal Crimp
A-38 2013 Sportster Service: Appendix A Connector Repair
A.21
TYCO GET 64 SEALED CONNECTOR
TYCO GET 64 SEALED CONNECTOR
TOOL NAME
PART NUMBER
TERMINAL EXTRACTOR
B-50085
General
See
. The Tyco GET 64 Sealed connector is found
on the ECM of Dyna and Softail Models.
Housings
Separate:
Press on the latch. Pull the socket housings off of
the ECM.
Join:
Align the socket housing latch with the catch on the ECM.
Press housing onto ECM.
sm07294
Figure A-65. Tyco GET 64 Sealed Connector Latch
Removing Socket Terminals
1.
Remove the black wrap to access the back of the con-
nector.
2.
See
. Use needle nose pliers to pull the sec-
ondary lock out of the housing.
3.
See
. Orient the bevel of the TERMINAL
EXTRACTOR (Part No. B-50085) (1) to the upper or lower
terminal row. Insert the extractor into the slot adjacent to
the terminal.
4.
Rotate the extractor to release the retention beam and
simultaneously pull on the wire lead to remove the ter-
minal.
sm07311
Figure A-66. Tyco GET 64 Secondary Lock
2
1
2
1
sm07293
1. Terminal extractor
2. Retention beam
Figure A-67. Removing Terminals: Tyco GET 64 Sealed
Connector
Installing Socket Terminals
1.
See
. Locate the wire lead cavity by number.
2.
See
. Orient the open side of the crimp to the
lower or the upper terminal row.
3.
Press the terminal in through the rear cover and the seal
until it clicks.
4.
Press the secondary lock into the locked position.
5.
Black wrap the wire lead bundle.
2013 Sportster Service: Appendix A Connector Repair A-39
sm07340
Figure A-68. Cavity Numbers
sm07314
Figure A-69. Socket Terminal Orientation: Crimp Open
Side
CRIMPING TERMINALS
TOOL NAME
PART NUMBER
UNIVERSAL CRIMPER SET
HD-50120
HAND CRIMP FRAME
HD-50120-2
TYCO GET 64 DIE
HD-50120-7
1.
Strip the wire insulation. Refer to
.
2.
Install the TYCO GET 64 DIE (Part No. HD-50120-7) in
the HAND CRIMP FRAME (Part No. HD-50120-2) of the
UNIVERSAL CRIMPER SET (Part No. HD-50120).
3.
Place the
new
terminal in the specified nest. Refer to
4.
Insert the wire to the wire stop. Crimp the terminal.
5.
Inspect the crimped terminal and wire lead.
Table A-9. Tyco GET 64 Sealed Crimper Die (Part No.
HD-50120-7)
NEST
STRIP LENGTH
PART NO.
TERMINAL
mm
in
A
4.4
0.170
72666-12
Socket:
18-20 AWG
A-40 2013 Sportster Service: Appendix A Connector Repair
A.22
TYCO MCP SEALED CONNECTOR
TYCO MCP SEALED CONNECTOR
TOOL NAME
PART NUMBER
TERMINAL EXTRACTOR
B-0085
SNAP-ON TERMINAL PICK
GA500A
General
The Tyco MCP sealed connector is used on certain ABS
modules.
Housing
Separate:
See
. Press and hold the lock tab. Pulling
on both ends of the lever, open the lever.
Join:
Gently mate the pins to the socket. Press and hold the
lock tab. Pressing on both ends of the lever, close the lever.
sm07296
Figure A-70. Tyco MCP Connector Release Bar
Removing the Large Terminals
1.
Snap the wire harness cover off of the back of the con-
nector
NOTE
Insert a thin flat bladed screwdriver all the way to the bottom
behind the tab of the secondary lock.
2.
See
. Gently slide the secondary lock out of
the connector with a screw driver.
3.
See
. 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.
4.
Gently pull on the wire to remove the terminal.
sm07369b
Figure A-71. Tyco MCP Connector Secondary Lock
sm07354
Figure A-72. Removing Large Socket Terminals: Tyco MCP
Connector
Removing the Small Terminals
1.
Snap the wire harness cover off of the back of the con-
nector
NOTE
Insert a thin flat bladed screwdriver all the way to the bottom
behind the tab of the secondary lock.
2.
See
. Gently slide the secondary lock out of
the connector with a screw driver.
3.
See
. Insert the TERMINAL EXTRACTOR
(Part No. B-0085) into the cavity on the outside of the ter-
minal.
4.
Tilt the extractor to lift the molding latch and release the
terminal.
5.
Gently pull on the wire to remove the terminal.
2013 Sportster Service: Appendix A Connector Repair A-41
sm07355a
Figure A-73. Removing Small Socket Terminal: Tyco MCP
Connector
Installing Terminals
1.
See
. Locate the wire lead cavity by number.
2.
Use a hobby knife to bend the tangs on each side of the
terminal outward.
3.
Align the socket.
4.
Push the socket in until it clicks.
5.
Press the secondary lock back into the connector.
6.
Snap the wire cover in place.
sm07361
Figure A-74. Tyco MCP Sealed Connector Cavity Numbers
CRIMPING TERMINALS
TOOL NAME
PART NUMBER
UNIVERSAL CRIMPER SET
HD-50120
TYCO MCP DIE
HD-50120-8
1.
Strip the wire insulation to specification. Refer to
2.
Install the TYCO MCP DIE (Part No. HD-50120-8) in the
handle of the UNIVERSAL CRIMPER SET (Part No. HD-
50120).
3.
Place the
new
terminal in the specified nest.
4.
Insert the wire to the wire stop.
5.
Crimp the terminal.
6.
Inspect the crimped terminal.
Table A-10. Tyco MCP Crimper Die (Part No. HD-50120-8)
NEST
STRIP LENGTH
PART NO.
TERMINAL
mm
in
A
4.2-4.8
0.165-0.189
72579-12
Large socket:
14 AWG
B
4.2-4.8
0.165-0.189
72579-12
Large socket:
16 AWG
C
3.3-3.9
0.130-0.153
72580-12
Small socket:
20 AWG
1
3
2
sm07290
1. Locking tang
2. Lead crimp
3. Seal crimp
Figure A-75. Tyco MCP Socket Terminal Crimp
A-42 2013 Sportster Service: Appendix A Connector Repair
A.23
SEALED SPLICE CONNECTOR
SEALED SPLICE CONNECTOR REPAIR
TOOL NAME
PART NUMBER
HEAT GUN
HD-25070
PACKARD CRIMPING TOOL
HD-38125-8
ULTRA TORCH
HD-39969
HEAT SHIELD ATTACHMENT
HD-41183
General
Splice connectors and several OE ring terminal connectors
use heat shrink covering to seal the connection.
Preparing Wire Leads
NOTE
When splicing adjacent wires, stagger the splices that the
sealed splice connectors will not touch each other.
1.
Using a shop gauge, identify the gauge of the wire.
2.
Match the wire gauge to a sealed splice connector by color
and part number. Refer to
.
3.
Strip insulation off the the wire lead. Refer to
Table A-11. Sealed Splice Connectors
STRIP LENGTH
PART NO.
COLOR
WIRE GAUGE
mm
in
9.5
3/8
70585-93
Red
18-20 (0.5-0.8 mm)
9.5
3/8
70586-93
Blue
14-16 (1.0-2.0 mm)
9.5
3/8
70587-93
Yellow
10-12 (3.0-5.0 mm)
NOTE
If any copper wire strands are cut off of the wire core, trim the
end and strip the wire again in a larger gauge stripper.
Splicing Wire Leads
NOTE
See
. The connector is crimped on one side and
then the other.
1.
See
. Open the PACKARD CRIMPING TOOL
(Part No. HD-38125-8) ratchet by squeezing the handles
closed.
2.
Match the connector color to the wire gauge crimp die in
the jaws. Insert one end of the sealed connector.
3.
Gently squeeze the handles until the connector is held in
the jaws.
4.
See
. Feed the stripped end of a wire into the
connector until the wire stops inside the metal insert (1).
5.
Squeeze the handles tightly closed to crimp the lead in
the insert (2). The tool automatically opens when the
crimping is complete.
6.
Slide the connector to the other half of the metal insert.
Insert the stripped wire lead (1) until it stops. Crimp the
lead in the insert (2).
Be sure to follow manufacturer's instructions when using
the UltraTorch UT-100 or any other radiant heating device.
Failure to follow manufacturer's instructions can cause a
fire, which could result in death or serious injury. (00335a)
•
Avoid directing heat toward any electrical system com-
ponent that is not being serviced.
•
Always keep hands away from tool tip area and heat shrink
attachment.
7.
Use an ULTRA TORCH (Part No. HD-39969), or a HEAT
GUN (Part No. HD-25070) with a HEAT SHIELD
ATTACHMENT (Part No. HD-41183), to heat the connector
from the center of the crimp (3) out to each end.
NOTE
It is acceptable for the splice to rest against the heat shrink
tool attachment.
Inspecting Seals
See
. Allow the splice to cool and inspect the seal.
The insulation should appear smooth and cylindrical. Melted
sealant will have extruded out the ends (4) of the insulation.
1
2
3
sm00050
1. Red connector die
2. Blue connector die
3. Yellow connector die
Figure A-76. Packard Crimping Tool (HD-38125-8)
2013 Sportster Service: Appendix A Connector Repair A-43
1
1
4
2
2
4
3
sm00051
1. Wire lead in metal insert
2. Crimp metal insert
3. Center of crimp
4. Melted SEALANT
Figure A-77. Sealed Splice Connector
A-44 2013 Sportster Service: Appendix A Connector Repair
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