Harley Davidson 2009 Dyna Models. Service manual — page 24
Table 7-13. Handlebar Switch Assembly Fasteners
TORQUE
FASTENER
60-80 in-lbs (6.8-9.0 Nm)
Handlebar switch clamp
screws
35-45 in-lbs (4.0-5.1 Nm)
Switch housing screws
12. Remove the cardboard insert between the brake lever and
lever bracket.
13. Adjust throttle cables. See
14. Install main fuse. See
Be sure that all lights and switches operate properly before
operating motorcycle. Low visibility of rider can result in
death or serious injury. (00316a)
15. Test the switches for proper operation.
16. Secure wire harness to handlebar as necessary.
4
3
2
1
sm01086
1.
Switch housing assembly
2.
Tab
3.
Groove
4.
Brake lever bracket
Figure 7-89. Switch Housing Alignment (typical)
1
2
sm02633
1.
Upper screw
2.
Lower screw and flat washer
Figure 7-90. Handlebar Switch Clamp Screws
DISASSEMBLY
Do not remove or install the master cylinder assembly
without first positioning a 5/32-inch (4 mm) thick insert
between the brake lever and lever bracket. Removing or
installing the master cylinder assembly without the insert
in place may result in damage to the rubber boot and
plunger on the front stoplight switch. (00324a)
1.
Place the cardboard insert between the brake lever and
lever bracket.
2.
Using a T25 TORX drive head, remove the upper and
lower switch housing screws.
3.
If replacing lower housing switches, perform steps 4
through 7 before continuing to repair section. If replacing
upper housing switches, proceed directly to repair section.
4.
See
. Using a T27 TORX drive head, loosen
the upper screw (1) securing the handlebar switch clamp
to the master cylinder housing. Remove the lower clamp
screw with flat washer (2).
5.
Remove the brass ferrules from the notches on the inboard
side of the throttle control grip. Remove the ferrules from
the cable end fittings.
6.
Remove the friction shoe from the end of the tension
adjuster screw.
NOTE
The friction shoe is a loose fit and may fall out or become dis-
lodged if the lower switch housing is turned upside down or
shaken.
7.
Remove the throttle control grip from the end of the
handlebar.
7-68 2009 Dyna Service: Electrical
SWITCH REPAIR/REPLACEMENT
Upper Housing Repair
NOTE
Replace the engine stop and engine start switches as a single
assembly even if only one switch is determined to be faulty.
1.
. From inside the switch housing, remove
the screw with lockwasher (4) to release the bracket (5).
Remove the bracket and switch assembly from the
housing.
2.
Move cable conduit (3) from beneath wing of bracket. Cut
wires 0.25 in. (6.4 mm) from old switches (1, 2). Discard
old switch and bracket assembly.
3.
Slide conduit forward over cut ends of switch wires and
cut off 0.5 in. (12.7 mm) of conduit (3) material. Push
conduit back to access switch wires.
4.
. Separate new engine stop switch (2)
and engine start switch (1) wires into two bundles.
NOTE
Replacement stop switch and start switch wires are cut to
length, 2.5 in. (63.5 mm) and 2.0 in. (50.8 mm) respectively,
and partially stripped.
5.
See
7.32 HANDLEBAR SWITCH ASSEMBLIES
for
information on splicing and general repair practices.
6.
Loop switch wires so that spliced lengths are positioned
as shown in
. Route wires downstream of
splices beneath wing on engine stop switch side of bracket
as shown in
.
7.
See
. Install a new7.0 in. (177.8 mm) cable
strap (5) beneath wing on engine start switch side (1) of
bracket and capture wire splices (4).
8.
Place switch assembly into upper housing aligning hole
in bracket with threaded hole in boss. Be sure that bracket
is fully seated. The step at the edge of the boss captures
the bottom edge of the bracket, while tabs on each side
of the bracket fit in slots cast into the housing.
9.
See
. Install screw and lockwasher (4) to
secure bracket (5) inside housing. Verify that wing on
engine stop switch (2) side of bracket captures edge of
conduit (3) as shown.
10. Securely tighten cable strap to draw splices to bracket.
Remove any excess cable strap material.
11. Continue with
1
3
5
2
4
sm01087
1.
Start switch
2.
Stop switch
3.
Conduit
4.
Screw with lockwasher
5.
Bracket
Figure 7-91. Upper Housing Without Splices
1
3
5
2
4
sm01088
1.
Start switch
2.
Stop switch
3.
Conduit
4.
Splices
5.
Cable strap
Figure 7-92. Upper Housing With Splices
2009 Dyna Service: Electrical 7-69
Lower Housing Repair
1.
From inside the switch housing, carefully cut cable strap
to free conduit from the turn signal switch bracket.
2.
Remove the screw with lockwasher to release the turn
signal switch bracket. Remove the bracket and switch
assembly from the housing.
3.
Continue with TURN-RIGHT SIGNAL SWITCH or FRONT
STOPLIGHT SWITCH procedures which follow.
Turn-Right Signal Switch
1.
Perform steps in LOWER HOUSING REPAIR.
2.
Cut wire 1.5 in. (38.1 mm) from old switch. Discard old
switch assembly.
NOTE
Replacement turn-right signal switch wires are cut to length of
1.5 in. (38.1 mm) and partially stripped.
3.
See
7.32 HANDLEBAR SWITCH ASSEMBLIES
for
information on splicing and general repair practices.
4.
Continue with
Front Stoplight Switch
1.
Perform steps in LOWER HOUSING REPAIR.
2.
Carefully remove the wedge between the switch and switch
housing, if present. To remove the switch from the housing,
depress the plunger and slowly rotate switch upward while
rocking slightly.
3.
Cut wires 1.0 in. (25.4 mm) from old switch. Discard old
switch.
NOTE
Replacement stoplight switch wires are cut to length of 2.5 in.
(63.5 mm) and partially stripped.
4.
See
7.32 HANDLEBAR SWITCH ASSEMBLIES
for
information on splicing and general repair practices.
5.
Carefully depress plunger against inside wall of switch
housing. With thumb over plunger bore, move switch into
the installed position in the switch housing cavity. When
plunger is positioned against thumb, slowly rotate switch
downward while rocking slightly. Release the plunger only
after switch is properly positioned in the cavity.
6.
Verify that the plunger is square in the bore and that the
boot is not compressed, collapsed or torn. If necessary,
gently work the plunger in and out until boot is fully
extended.
7.
See
. Push down on switch (1) so that it bot-
toms against housing and wires (3) run in groove at base
of cavity. With the concave side facing outward, insert
wedge (2) between switch and outboard side of switch
housing.
8.
Push wedge down until it also bottoms against housing.
Verify that the plunger is still square in the bore and then
place a drop of RTV Silicone Sealant on upper corner of
wedge.
9.
Continue with
1
4
2
3
sm01089
1.
Stoplight switch
2.
Wedge
3.
Switch wires
4.
Lower switch housing
Figure 7-93. Install Stoplight Switch
ASSEMBLY
1.
See
. Insert tapered end of new7.0 in. (177.8
mm) cable strap (1) into round hole in turn signal switch
bracket (2) and then feed back through using the adjacent
hole. Reserve the oblong hole for the bracket screw.
NOTE
Be sure that all splices are positioned above the turn signal
switch bracket.
2.
Place the turn signal switch assembly into the housing,
aligning the oblong hole in the bracket with the threaded
hole in the boss. Be sure that the bracket is fully seated.
Tabs on each side of bracket are captured in slots cast
into switch housing.
3.
Start screw with lockwasher to secure bracket inside
housing.
If routed incorrectly, wires can be pinched by casting or
handlebar resulting in switch failure. (00542b)
4.
Loop switch wires so that spliced lengths are positioned
across bracket.
5.
Capturing conduit about 0.25 in. (6.4 mm) from end,
securely tighten cable strap to draw conduit to bracket.
Remove any excess cable strap material.
6.
Install second 7.0 in. (177.8 mm) cable strap capturing
conduit and wire splices. Securely tighten cable strap to
7-70 2009 Dyna Service: Electrical
draw splices to conduit. Remove any excess cable strap
material.
7.
Tighten screw to secure bracket inside housing.
8.
Route wire bundle to upper switch housing by gently
pressing conduit into channel next to angular arm of
bracket. Secure bundle to arm using third cable strap. Cut
any excess cable strap material. If necessary, bend
angular arm of bracket downward to firmly secure front
stoplight switch in position.
9.
7.33 RIGHT HANDLEBAR SWITCH, Installation
a.
If lower housing switches were replaced, perform the
entire procedure.
b.
If upper housing switches were replaced, begin with
step 11.
3
2
1
sm01090
1.
Cable strap
2.
Bracket
3.
Right turn signal switch
Figure 7-94. Insert Cable Strap in Switch Bracket
2009 Dyna Service: Electrical 7-71
7.34
LEFT HANDLEBAR SWITCH
REMOVAL
NOTE
The removal and installation steps listed apply when replacing
the entire switch assembly, switch housing or handlebars.
To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before pro-
ceeding. (00251b)
1.
Remove main fuse. See
.
2.
Using a T25 TORX drive head, loosen but do not remove
the upper and lower switch housing screws.
3.
Using a T27 TORX drive head, remove the two screws
with flat washers securing the handlebar clamp to the
clutch lever bracket. Remove the clutch hand lever
assembly and clamp from the handlebar.
4.
Remove the upper and lower switch housing screws.
5.
Remove the grip sleeve from the end of the handlebar if
damaged.
INSTALLATION
1.
If the grip sleeve was removed, thoroughly clean handlebar
to remove all adhesive residue. Pour adhesive into new
grip. Roll grip to evenly distribute adhesive on inside sur-
faces. Install grip on handlebar with a twisting motion.
2.
. Install upper and lower switch housings
on handlebar. Be sure that ribs (2) on outboard side of
switch housings fit in grooves (3) molded into grip.
3.
Verify that the wire harness conduit runs in the groove at
the bottom of the handlebar. Be sure that the upper switch
housing harness will not be pinched under the handlebar
when the switch housing screws are tightened.
4.
Start the upper and lower switch housing screws, but do
not tighten.
5.
. Position the clutch hand lever assembly
inboard of the switch housing assembly, engaging the tab
(3) on the lower switch housing in the groove (2) at the
bottom of the clutch lever bracket.
6.
Align the holes in the handlebar switch clamp with those
in the clutch lever bracket and start the two screws (with
flat washers). Position for rider comfort. Beginning with
the top screw, tighten screws to specification with a T27
TORX drive head. Refer to
7.
Using a T25 TORX drive head, tighten lower and upper
switch housing screws to specification. Refer to
.
NOTE
Always tighten the lower switch housing screw first so that any
gap between the upper and lower housings is at the front of
the switch.
Table 7-14. Handlebar Switch Assembly Fasteners
TORQUE
FASTENER
60-80 in-lbs (6.8-9.0 Nm)
Handlebar switch clamp
screws
35-45 in-lbs (4.0-5.1 Nm)
Switch housing screws
8.
Install main fuse. See
.
Be sure that all lights and switches operate properly before
operating motorcycle. Low visibility of rider can result in
death or serious injury. (00316a)
9.
Test the switches for proper operation.
10. Secure wire harness to handlebar as necessary.
1
2
3
sm02632
1.
Grip sleeve
2.
Ribs
3.
Grooves
Figure 7-95. Left Handlebar Switch Housings
7-72 2009 Dyna Service: Electrical
4
2
3
1
sm02631
1.
Clutch lever bracket
2.
Groove
3.
Tab
4.
Switch housing assembly
Figure 7-96. Clutch Lever Bracket
DISASSEMBLY
1.
Using a T25 TORX drive head, remove the upper and
lower switch housing screws.
2.
If replacing lower housing switches, perform next step
before continuing to repair section. If replacing upper
housing switches, proceed directly to repair section.
3.
Using a T27 TORX drive head, loosen the upper screw
securing the handlebar clamp to the clutch lever bracket.
Remove the lower clamp screw with flat washer.
SWITCH REPAIR/REPLACEMENT
Upper Housing Repair
NOTE
Replace the horn switch and high/low beam switch as a single
assembly even if only one switch is determined to be faulty.
1.
. From inside the switch housing, remove
the screw with lockwasher (4) to release the bracket (5).
Remove bracket and switch assembly from the housing.
2.
Move cable conduit (3) from beneath wing of bracket. Cut
wires 0.25 in. (6.4 mm) from old switches (1, 2). Discard
old switch and bracket assembly.
3.
Slide conduit forward over cut ends of switch wires and
cut off 0.5 in. (12.7 mm) of conduit (3) material. Push
conduit back to access switch wires.
4.
Separate the new horn switch (1) and high/low beam
switch (2) wires into two bundles.
NOTE
Replacement high/low beam switch and horn switch wires are
cut to length of 2.5 in. (63.5 mm) and 2.0 in. (50.8 mm)
respectively, and partially stripped.
5.
See
7.32 HANDLEBAR SWITCH ASSEMBLIES
for
information on splicing and general repair practices.
6.
Loop switch wires so that spliced lengths are positioned
as shown in
. Route wires downstream of
splices beneath wing on high/low beam switch side of
bracket as shown in
7.
See
. Install a new7.0 in. (177.8 mm) cable
strap (5) beneath wing on horn switch side (1) of bracket
and capture wire splices (4).
8.
Place switch assembly into upper housing aligning hole
in bracket with threaded hole in boss. Be sure that bracket
is fully seated. The step at the edge of the boss captures
the bottom edge of the bracket, while tabs on each side
of the bracket fit in slots cast into the housing.
9.
. Install screw and lockwasher (4) to
secure bracket (5) inside housing. Verify that wing on
high/low switch (2) side of bracket captures edge of conduit
(3) as shown.
10. Securely tighten cable strap to draw splices to bracket.
Remove any excess cable strap material.
11. Continue with
.
1
3
5
2
4
sm01091
1.
Horn switch
2.
High/low beam switch
3.
Conduit
4.
Screw with lockwasher
5.
Bracket
Figure 7-97. Upper Housing Without Splices
2009 Dyna Service: Electrical 7-73
1
3
5
2
4
sm01092
1.
Horn switch
2.
High/low beam switch
3.
Conduit
4.
Splices
5.
Cable strap
Figure 7-98. Upper Housing With Splices
Lower Housing Repair
1.
From inside the switch housing, carefully cut cable strap
to free conduit from the turn signal switch bracket.
2.
Remove screw with lockwasher to release the turn signal
switch bracket. Remove the bracket and switch assembly
from the housing.
3.
Continue with TURN-LEFT SIGNAL SWITCH or CLUTCH
INTERLOCK SWITCH procedures.
Turn-Left Signal Switch
1.
Perform steps in LOWER HOUSING REPAIR.
2.
Cut wires 1.5 in. (38.1 mm) from old switch (Turn-L(eft)
Signal Switch). Discard switch assembly.
NOTE
Replacement turn-right signal switch wires are cut to length of
1.5 in. (38.1 mm) and partially stripped.
3.
See
7.32 HANDLEBAR SWITCH ASSEMBLIES
for
information on splicing and general repair practices.
4.
Continue with
Clutch Interlock Switch
1.
Perform steps in LOWER HOUSING REPAIR.
2.
. Cut wires 0.25 in. (6.4 mm) from old
switch. Discard switch assembly.
NOTE
Replacement turn-right signal switch wires are cut to length
and partially stripped.
3.
See
7.32 HANDLEBAR SWITCH ASSEMBLIES
for
information on splicing and general repair practices.
4.
Continue with
.
sm02644
Figure 7-99. Clutch Interlock Switch
ASSEMBLY
1.
See
. Insert tapered end of new 7.0 in. (177.8
mm) cable strap (1) into round hole in turn signal switch
bracket (2) and then feed back through using the adjacent
hole. Reserve the oblong hole for the bracket screw.
NOTE
Be sure that all splices are positioned above the turn signal
switch bracket.
2.
Place the turn signal switch assembly (3) into the housing,
aligning the oblong hole in the bracket with the threaded
hole in the boss. Be sure that the bracket is fully seated.
Tabs on each side of bracket are captured in slots cast
into switch housing.
3.
Start screw with lockwasher to secure bracket inside
housing.
If routed incorrectly, wires can be pinched by casting or
handlebar resulting in switch failure. (00542b)
4.
Loop switch wires so that spliced lengths are positioned
across bracket.
5.
Capturing conduit about 0.25 in. (6.4 mm) from end,
securely tighten cable strap to draw conduit to bracket.
Remove any excess cable strap material.
6.
Tighten screw to secure bracket inside housing.
7.
Route wire bundle to upper switch housing below and then
forward of the main wire harness, positioning conduit in
channel next to angular arm of bracket. Secure bundle to
7-74 2009 Dyna Service: Electrical
arm using new cable strap. Cut any excess cable strap
material.
8.
7.34 LEFT HANDLEBAR SWITCH, Installation
a.
If lower housing switches were replaced, perform the
whole procedure.
b.
If upper housing switches were replaced, begin with
step 7.
9.
Verify the operation of the clutch interlock switch. See the
ELECTRICAL DIAGNOSTIC MANUAL.
3
2
1
sm01094
1.
Cable strap
2.
Bracket
3.
Left turn signal switch
Figure 7-100. Insert Cable Strap in Switch Bracket
2009 Dyna Service: Electrical 7-75
SUBJECT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE NO.
APPENDIX A CONNECT
OR REP
AIR
A.1
AMP MULTILOCK CONNECTORS
AMP MULTILOCK CONNECTOR REPAIR
TOOL NAME
PART NUMBER
AMP MULTILOCK CRIMPER
HD-41609
General
AMP Multilock 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 MULTILOCK
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.
. Depress 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 snaps
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
sm00002
1.
Attachment clip
2.
Release button
3.
Socket housing
4.
Pin housing
Figure A-1. AMP Multilock Connector
Removing Terminals from Housing
1.
. 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, a push pin/safety pin
or a Snap-on pick (Part No. TT600-3) may be used.
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.
2009 Dyna Service: Appendix A Connector Repair A-1
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-2. AMP Multilock Connector: Socket and Pin
Housings
Inserting Terminals into Housing
NOTE
. 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
•
Up and down can be determined by the position of the
release button, the button is 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-3. AMP Multilock Connector: Cavity Numbers on
Secondary Locks (Socket Housings Shown)
Preparing Wire Leads for Crimping
1.
Strip 5/32 in. (4.0 mm) of insulation from the wire lead.
A-2 2009 Dyna Service: Appendix A Connector Repair
2.
and
. Select the pin/socket ter-
minals 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-1. 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-4. AMP Multilock Connector: Pin Terminal
2
3
1
sm00001
1.
Insulation crimp tail
2.
Wire crimp tail
3.
Locking bar groove
Figure A-5. AMP Multilock Connector: Socket Terminal
Crimping Terminals to Leads
NOTE
Crimping with an Amp Multilock tool is a one step operation.
One squeeze crimps both the wire core and the insulation tails.
1.
See
. Squeeze the handles to cycle the AMP
MULTILOCK CRIMPER (Part No. HD-41609) to the fully
open position (1).
2.
Raise locking bar by pushing up on bottom flange (2).
NOTE
See
. Hold the terminal with the
insulation crimp tail (1) facing up. The tool will hold the terminal
by the locking bar groove (3) and crimp the wire crimp tail (2)
around the bare wire of the stripped lead and the insulation
crimp tail around 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.
Verify that wire is positioned so that wire crimp tails
squeeze bare wire strands, while insulation crimp tails fold
over the wire lead insulation.
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) and remove crimped terminal.
2009 Dyna Service: Appendix A Connector Repair A-3
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-6. AMP Multilock Connector: Terminal Crimping
Procedure
Inspecting Crimped Terminals
. 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-7. AMP Multilock Connector: Terminal Crimp
A-4 2009 Dyna Service: Appendix A Connector Repair
A.2
AUTOFUSE ELECTRICAL CONNECTORS
AUTOFUSE CONNECTOR REPAIR
TOOL NAME
PART NUMBER
SNAP-ON TERMINAL PICK
GA500A
General
Autofuse electrical connector terminals are found in ignition
switches and some fuse blocks.
Disassembly
1.
Obtain SNAP-ON TERMINAL PICK (Part No. GA500A).
2.
or
. Insert smallest pair of pins
into chamber on mating end of socket housing to depress
tangs on each side of terminal simultaneously.
3.
Gently pull on wire to remove terminal from wire end of
socket housing.
4.
If necessary, crimp new terminals on wires.
Assembly
1.
Using a thin flat blade, like that on a hobby knife, carefully
bend tang on each side of terminal outward away from
terminal body.
2.
With the open side of the terminal facing rib on wire end
of socket housing, insert terminal into chamber until it locks
in place.
sm02849
Figure A-8. Removing Autofuse Terminal from Ignition
Switch
sm03480
Figure A-9. Removing Autofuse Terminal from Fuse Block
2009 Dyna Service: Appendix A Connector Repair A-5
A.3
DELPHI CONNECTORS
DELPHI CONNECTOR REPAIR
General
Delphi connectors are embossed with the brand name, Delphi,
on the housing latch.
Separating Pin and Socket Housings
See
. Bend back the external latch(es) slightly and
separate pin and socket halves of connector.
Mating Pin and Socket Housings
Push pin and socket halves of connector together until external
latch(es) engage.
Removing Socket Terminals
NOTE
Although the parts of the different Delphi connectors vary in
appearance, the instructions which follow will work for all. The
only exception is the oil pressure sender connector [139B], the
terminals of which are removed like the Packard push-to-seat
connectors. Therefore, see
to remove/install terminals in this connector.
1.
. If present, free one side of wire lock (1)
from ear on wire end of socket housing, then release the
other side. Release wires from channels in wire lock and
remove from socket housing.
2.
Use a fingernail to pry colored terminal lock (2) loose and
then remove from mating end of socket housing.
3.
Using a thin flat blade, like the unsharpened edge of a
hobby knife, gently pry tang (3) outward away from ter-
minal, and then tug on wire to back terminal out wire end
of chamber. Do not pull on wire until tang is released or
terminal will be difficult to remove.
Installing Socket Terminals
NOTE
For wire location purposes, alpha or numeric characters are
stamped into the wire end of each socket housing.
1.
Gently push tang on socket housing inward toward
chamber. With the open side of the terminal facing the
tang, push terminal into chamber at wire end of socket
housing.
2.
Gently tug on wire to verify that terminal is locked and will
not back out of chamber. If necessary, use fingernail to
push tang into engagement with terminal.
3.
Install colored terminal lock onto mating end of socket
housing.
4.
If present, 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.
sm00014
Figure A-10. Delphi Connector: Socket Housing Latch
A-6 2009 Dyna Service: Appendix A Connector Repair
2
3
1
sm00015
1.
Remove wire lock
2.
Remove terminal lock
3.
Pry tang outward
Figure A-11. Delphi Connector: Removing Socket
Terminals
2009 Dyna Service: Appendix A Connector Repair A-7
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