Harley Davidson 2013 Sportster Models. Electrical Diagnostics Manual — page 14
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DEUTSCH DT SEALED
TERMINAL REPAIR
A.14
NOTE
DEUTSCH DT SEALED TERMINAL CRIMPS
If the crimp tails are slightly out of alignment, the crimp tool
rotates the terminal to face the tails upward. When positioned,
PART NUMBER
TOOL NAME
the locking bar fits snugly in the space between the contact
HD-39965-A
DEUTSCH TERMINAL CRIMP TOOL
band and the core crimp tails.
5. Insert stripped wire core between crimp tails until ends
Preparing Wire Leads for Crimping
make contact with locking bar. Position wire that the wide
1. Use a shop gauge to determine gauge of wire lead.
pair of crimp tails squeeze bare wire strands, while the
narrow pair folds over the insulation material.
2. Strip 5/32 in (4.0 mm) of insulation from the wire lead.
6. Squeeze handle of crimp tool until tightly closed. Tool
Crimping Terminal to Lead
automatically opens after the terminal is crimped.
1. See Figure A-35. Squeeze the handles of the DEUTSCH
7. Raise locking bar up to remove wire lead and terminal.
TERMINAL CRIMP TOOL (Part No. HD-39965-A) to open
the jaws. Push the locking bar (1) up.
Inspecting Crimps
2. Match the wire gauge to the crimp tool die. Refer to
Inspect the wire core and insulation crimps. Distortion should
Table A-3.
be minimal.
NOTE
Table A-3. Deutsch DT Sealed Terminal Crimp:Wire Gauge
Rest the rounded side of the contact barrel in the nest (concave
To Die
split level area) with the crimp tails facing up.
WIRE GAUGE (AWG)
CRIMP TOOL DIE
3. Insert (2) terminal (socket/pin) through hole of the locking
bar.
20
Front
4. Release locking bar to lock terminal in die.
16-18
Middle
sm00021
5
2
1
6
4
3
1. Open jaws and raise locking bar
4. Insert stripped lead
2. Insert terminal in locking bar
5. Squeeze crimper
3. Release locking bar to lock terminal in die
6. Raise locking bar to remove terminal
Figure A-35. Crimping a Deutsch DT Sealed Terminal
A-24 2013 Sportster Diagnostics: Appendix A Connector Repair
HOME
DEUTSCH DTM SEALED MINI TERMINAL
REPAIR
A.15
DEUTSCH DTM SEALED MINI TERMINAL
Inspecting Crimps
CRIMPS
Inspect the core and insulation crimps. Distortion should be
minimal.
PART NUMBER
TOOL NAME
sm00022
HD-38125-7
PACKARD TERMINAL CRIMPER
Preparing Wire Leads for Crimping
1
Strip 5/32 in (4.0 mm) of insulation from the wire lead.
Crimping a Mini Terminal to Wire Lead
1. See Figure A-36. Compress the handles of PACKARD
TERMINAL CRIMPER (Part No. HD-38125-7) until the
ratchet (2) automatically opens.
NOTE
Always perform core crimp before insulation crimp.
2. Position the core crimp on die E (1) of the crimper. Verify
the core crimp tails are facing the forming jaws.
3. Gently apply pressure to handles of tool until crimpers just
secure the core crimp tails.
4. Insert stripped wire core stands between crimp tails. Pos-
2
ition wire that the short pair of crimp tails squeeze bare
wire strands, while long pair squeeze over the insulation.
5. Squeeze handle of crimper until
tightly closed. Tool auto-
matically opens when the crimping sequence is complete.
NOTE
If the crimper does not open, squeeze the ratchet trigger (2).
6. Position the insulation crimp on nest C of the crimper.
Verify the insulation crimp tails are facing the forming jaws.
7. Squeeze handle of crimp tool until tightly closed. Tool
1.
E die
automatically opens when the crimping sequence is com-
2.
Crimper ratchet trigger
plete.
Figure A-36. Packard Terminal Crimper (HD-38125-7)
2013 Sportster Diagnostics: Appendix A Connector Repair A-25
HOME
DEUTSCH DTM SEALED SOLID BARREL MINI
TERMINAL REPAIR
A.16
DEUTSCH DTM SEALED SOLID BARREL
sm00023
TERMINAL CRIMPS
5
PART NUMBER
TOOL NAME
4
HD-42879
ELECTRICAL CRIMPER TOOL
Preparing Wire Leads For Crimping
For size 20, 16 and 12 contacts, wire ranges 26-12 AWG.
Strip 1/4 in (6.4 mm) of insulation from the wire lead.
1
Adjusting Crimper Tool
3
1. See Figure A-37. Squeeze the ELECTRICAL CRIMPER
TOOL (Part No. HD-42879) handles to cycle the crimp
tool to open.
2. Remove locking pin (1) from selector knob (2).
2
3. Raise selector knob. Roate knob until selected wire size
stamped on wheel is aligned with "SEL. NO." arrow (3).
4. Loosen knurled locknut (4) and turn adjusting screw (5)
clockwise (in) until it stops.
Crimping a Barrel Contact To Wire Lead
1. See Figure A-38. Turn tool over
and drop contact barrel
(1) into indentor cover (2) hole with the wire end out.
2. Turn adjusting screw counterclockwise (out) until contact
is flush with bottom of recess in indentor cover. Tighten
knurled locknut.
3. Slowly squeeze handles of crimp tool until contact centers
between the four indentor points (3).
4. Insert bare wire core strands of stripped wire lead (4) into
contact barrel. Squeeze handle of crimp tool until tightly
1.
Locking pin
closed. Tool automatically opens when the crimping
2.
Selector knob
sequence is complete.
3.
SEL. NO. arrow
4.
Knurled locknut
5. Remove wire lead with crimped contact from indentor.
5.
Adjusting screw
NOTE
Figure A-37. Electrical Crimper Tool (HD-42879)
Adjust the crimper tool for each contact/wire size.
6. Install pin to lock selector knob.
Inspecting Crimps
Inspect the crimp. All core wire strands are to be crimped in
the barrel.
A-26 2013 Sportster Diagnostics: Appendix A Connector Repair
HOME
sm00024
2
1
3
3
4
1. Contact barrel
2. Indentor cover
3. Indentor point
4. Stripped wire lead
Figure A-38. Deutsch Solid Barrel
2013 Sportster Diagnostics: Appendix A Connector Repair A-27
HOME
JAE MX19 SEALED CONNECTORS
A.17
JAE MX19 SEALED CONNECTORS
sm06926
2
PART NUMBER
TOOL NAME
B-50085
TERMINAL EXTRACTOR
Connector Housings
Separate Housings: See Figure A-39. Press the two release
buttons on each side of the housing to separate the connector.
1
2
1
Connect Housings: Align housings. Press together until the
locking tabs click.
sm06925
1. Extractor
2. Plastic molding
Figure A-40. JAE MX19 Terminal Removal
CRIMPING TERMINALS
PART NUMBER
TOOL NAME
HD-50120
UNIVERSAL CRIMPER SET
HD-50120-2
HAND CRIMP FRAME
HD-50120-6
JAE DIE
Figure A-39. Release Buttons: JAE MX19 Sealed Connector
1. Strip the wire insulation to specification. Refer to Table A-4.
Removing Terminals
2. Install the JAE DIE (Part No. HD-50120-6) in the handle
1. Modify a TERMINAL EXTRACTOR (Part No. B-50085)
of the HAND CRIMP FRAME (Part No. HD-50120-2) of
by filing the front edge to 45 degrees.
the UNIVERSAL CRIMPER SET (Part No. HD-50120).
2. See Figure A-40. Insert the extractor (1) into the opening
3. Place the new terminal in the specified nest.
above the terminal and press the plastic molding (2) up
4. Insert the wire to the wire stop. Crimp the terminal.
and out of the way.
5. Inspect the crimped terminal.
3. Pull the wire lead and terminal out of the back of the
housing.
Table A-4. JAE MX19 Crimper Die (Part No. HD-50120-6)
Installing Terminals
TERMINAL
PART NO.
STRIP LENGTH
NEST
1. Inspect the plastic molding and replace the connector
in
mm
housing if necessary.
Socket
72910-11
0.051-0.098
2.0-2.5
B
2. Orient the terminal to the housing. Push terminal into
housing until it clicks into place.
Pin
72909-11
0.051-0.098
2.0-2.5
A
A-28 2013 Sportster Diagnostics: Appendix A Connector Repair
HOME
MOLEX CMC SEALED CONNECTORS
A.18
MOLEX CMC SEALED CONNECTORS
Installing Terminals
1. Orient the terminal to the housing cavity. Snap the terminal
PART NUMBER
TOOL NAME
in place.
HD-50423
0.6 MM TERMINAL EXTRACTOR
2. Slide the cap over the lead bundle. Snap the cap in place.
TOOL
3. Install a cable strap through the guide and around the lead
HD-50424
1.5 MM TERMINAL EXTRACTOR
bundle.
TOOL
sm06936
Separating the Connector
Release: See Figure A-41. Press the catch and rotate the lever
arm down.
Connect: Press on the front guard to release the latch and
2
rotate the lever arm up until the catch clicks in place.
sm06931
1
3
Figure A-41. Release
1. Press latch
2. Press cap and latch
3. Remove cap
Removing Terminals
Figure A-42. Remove the Wire Lead Cap
1. With the lever arm open, cut the cable strap around the
wire bundle.
2. See Figure A-42. Open a wire cap latch (1) with a small
sm06928
screwdriver.
3. Maintain pressure on the cap and open the opposite latch
(2) with the screwdriver.
4. Slide the cap off (3).
5. See Figure A-43. Use the screwdriver to open the sec-
ondary lock. Pull the locking bar all the way out.
6. See Figure A-44. 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).
Figure A-43. Molex CMC Sealed Connector Secondary
8. See Figure A-45. Insert the pins of the CMC extractor tool
Lock
(1) into the access slots (2) of the terminal cavity and
retract the lead and terminal.
2013 Sportster Diagnostics: Appendix A Connector Repair A-29
HOME
CRIMPING TERMINALS
sm06927
PART NUMBER
TOOL NAME
1
2
HD-50120
UNIVERSAL CRIMPER SET
2
HD-50120-2
HAND CRIMP FRAME
HD-50120-3
JAE DIE
2
HD-50120-4
JAE DIE
1. Select the crimper die according to the terminal part
1
number from the UNIVERSAL CRIMPER SET (Part
2
No. HD-50120).
2. Strip the wire insulation to specification. Refer to Table A-5
1. Alpha
or Table A-6.
2. Numeric
3. Install the JAE DIE (Part No. HD-50120-3) or JAE DIE
Figure A-44. Alpha-Numeric Coordinates
(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.
sm06935
5. Insert the wire to the wire stop. Crimp the terminal.
6. Inspect the crimped terminal.
1
Table A-5. Molex CMC Sealed Crimper Die (Part No.
HD-50120-3)
PART
TERMINAL:
STRIP LENGTH
NEST
NO.
WIRE GAUGE
in
mm
72226-11
Socket:
16 AWG
0.177
4.5
B
72227-11
Socket:
18 AWG
0.177
4.5
A
Table A-6. Molex CMC Sealed Crimper Die (Part No.
HD-50120-4)
PART NO.
TERMINAL:
STRIP LENGTH
NEST
2
WIRE GAUGE
in
mm
72222-11
Socket:
18 AWG
0.138
3.5
B
72222-11
Socket:
20 AWG
0.138
3.5
A
1. Extractor tool
2. Access slots
Figure A-45. Terminal Removal
A-30 2013 Sportster Diagnostics: Appendix A Connector Repair
HOME
MOLEX MX 150 SEALED CONNECTORS
A.19
5. With all terminals installed, push the secondary lock into
MOLEX MX 150 SEALED CONNECTOR
the socket housing to lock the wire terminals into the
REPAIR
housing.
PART NUMBER
TOOL NAME
sm00040a
HD-48114
TERMINAL REMOVER
Separating Pin and Socket Housings
See Figure A-46. 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 Figure A-47. Use a small
screwdriver in the pry slot. The slot next to the
Figure A-46. Molex MX 150 Sealed Connector: Latch
external latch provides a pivot point.
b. Pin Housing: See Figure A-48. Use needle nose
sm03332a
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 Figure A-49. 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.
Figure A-47. Secondary Lock Pry Slot (Socket Housing)
Installing Terminals
1. See Figure A-50. 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.
2013 Sportster Diagnostics: Appendix A Connector Repair A-31
HOME
CRIMP TERMINAL TO LEAD
sm02851a
PART NUMBER
TOOL NAME
HD-48119
TERMINAL CRIMPER
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.
Figure A-48. Pull Up Secondary Lock
Prepare Tool
1. Identify the punch/die in the jaws of the TERMINAL
sm00043a
CRIMPER (Part No. HD-48119) for the wire gauge. Refer
to Table A-7.
2. Squeeze and release the handles to open the tool.
NOTE
The crimp tool automatically opens when the handles are
released.
3. See Figure A-51. 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.
Figure A-49. Molex MX 150 Sealed Connector: Terminal
Table A-7. Crimp Tool Wire Gauge Punch/Die
Remover (HD-48114)
AWG (WIRE GAUGE)
PUNCH/DIE
22
Left
sm00044
18-20
Middle
3
14-16*
Right
1
* Crimp 16 AWG pin terminals in the 18-20 middle die.
2
1. Cavity number
2. Tang
3. Cavity slot
Figure A-50. Molex MX 150 Sealed Connector: Pin Cavities
and Wire Terminal
A-32 2013 Sportster Diagnostics: Appendix A Connector Repair
HOME
2. See Figure A-55. Ratchet the handles together until the
sm02853a
crimp tails are held in vertical alignment between the punch
and the die.
sm02855a
Figure A-51. Open Terminal Crimper (HD-48119) at 45
Degrees
Figure A-53. Square Openings in Socket Locator Bar
sm02854a
Insert Stripped Lead
See Figure A-56. 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.
1
NOTES
2
•
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
1. Socket locator bar
2. Pin locator bar
Figure A-52. Terminal Locator Bars
Position Terminal in the Punch/Die
1. See Figure A-53. With the crimp tails up, place the terminal
through the punch/die into the square opening in the
Figure A-54. Pin Terminal against Pin Locator Bar
socket locator bar.
a. Socket Terminal: See Figure A-52. A socket terminal
stops against the back face of the socket locator bar
(1).
b. Pin Terminal: See Figure A-54. 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.
2013 Sportster Diagnostics: Appendix A Connector Repair A-33
HOME
Inspect Crimp
sm02857a
1. Inspect Crimp: Inspect the core and insulation crimp.
a. See Figure A-57. 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.
sm02859
3
1
2
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
1. Core crimp
Open a stuck or jammed tool by pressing the ratchet release
2. Wire strands
lever found between the handles. Do not force the handles
3. Insulation crimp
open or closed.
Figure A-57. Terminal Crimp
sm02858a
Figure A-56. Stripped Lead at Up Angle
A-34 2013 Sportster Diagnostics: Appendix A Connector Repair
HOME
TYCO
070 MULTILOCK UNSEALED CONNECTOR
A.20
TYCO 070 MULTILOCK UNSEALED
sm00002a
CONNECTOR REPAIR
2
3
PART NUMBER
TOOL NAME
4
HD-41609
AMP MULTI-LOCK CRIMPER
SNAP-ON
TT600-3
SNAP-ON PICK
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 Figure A-58. 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.
1
NOTE
For terminal crimping use the AMP MULTI-LOCK CRIMPER
1. Attachment clip
(Part No. HD-41609).
2. Release button
3. Socket housing
Separating Pin and Socket Housings
4. Pin housing
1. If necessary, slide connector attachment clip T-stud to the
Figure A-58. Tyco 070 Multilock Unsealed Connector
large end of the opening.
2. See Figure A-58. Press the release button (2) on the
Removing Terminals from Housing
socket terminal side of the connector and pull the
socket
housing (3) out of the pin housing (4).
1. See Figure A-59. Bend back the latch (1) to free one end
of secondary lock (2) then repeat on the opposite end.
Mating Pin and Socket Housings
Hinge the secondary lock outward.
1. Hold the housings to match wire color to wire color.
2. Look in the terminal side of the connector (opposite the
2. Insert the socket housing into the pin housing until it clicks
secondary lock) and note the cavity next to each terminal.
in place.
3. Insert a pick or pin into the terminal cavity until it stops.
3. If OE location is a T-stud, fit large opening end of attach-
NOTE
ment clip over T-stud and slide connector to engage T-
If socket/pin terminal tool is not available, use a push pin/safety
stud to small end of opening.
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 Diagnostics: Appendix A Connector Repair A-35
HOME
NOTES
sm00013
•
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.
5
7
2. Gently tug on wire end to verify that the terminal is locked
in place.
2
3. Rotate the hinged secondary lock inward until tabs fully
engage latches on both sides of connector.
3
sm00005
1
1
2
4
- AMP
1
2
3
1
6
2
- AMP
8
1
2
3
4
5
6
1. Latch
2. Secondary lock open
3. Pin housing
3
4. Socket housing
5. Pin terminal
6. Socket terminal
7. Tang (pin)
8. Tang (socket)
5
6
7
8
9
10
Figure A-59. Tyco 070 Multilock Unsealed Connector:
Socket and Pin Housings
1.
3-place housing
2.
6-place housing
Inserting Terminals into Housing
3.
10-place housing
NOTE
Figure A-60. Tyco 070 Multilock Unsealed Connector:
Cavity Numbers on Secondary Locks (socket housings
See Figure A-60. Cavity numbers are stamped into the sec-
shown)
ondary locks of both the socket and pin housings. Match the
wire color to the cavity number found on the wiring diagram.
Preparing Wire Leads for Crimping
1. Hold the terminal so the catch faces the tang in the
chamber. Insert the terminal into its numbered cavity until
1. Strip wire lead removing 5/32 in (4.0 mm) of insulation.
it snaps in place.
A-36 2013 Sportster Diagnostics: Appendix A Connector Repair
HOME
2. See Figure A-59 and Figure A-62. Select the pin/socket
Crimping Terminals to Leads
terminals from the parts catalog and identify the insulation
crimp tails (1) and the wire crimp tails (2) and the groove
NOTE
for the crimp tool locking bar (3).
Crimping with the AMP Multi-lock Crimper is a one step opera-
tion. One squeeze crimps both the wire core and the insulation
3. Identify the wire lead gauge and the corresponding crimper
tails.
tool and nesting die. Refer to Table A-8.
1. See Figure A-63. Squeeze the handles to cycle the AMP
MULTI-LOCK CRIMPER (Part No. HD-41609) to the fully
Table A-8. AMP Multilock Connector: Crimp Tool Wire
open position (1).
Gauge/Nest
2. Raise locking bar by pushing up on bottom flange (2).
WIRE GAUGE
NEST
20
Front
NOTE
See Figure A-59 and Figure A-62. Hold the terminal with the
16
Middle
insulation crimp tail (1) facing up. The tool will hold the terminal
18
Rear
by the locking bar groove (3) and simultaneously crimp around
the stripped lead and the insulation.
3. See Figure A-63. With the insulation crimp tail facing
sm00004
upward, insert terminal (pin or socket) (3) through the
1
locking bar, so that the closed side of the terminal rests
on the nest of the crimp tool.
3
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.
2
6. Position wire that the wide pair of crimp tails squeeze bare
wire strands, while the narrow pair folds over the insulation
material.
1. Insulation crimp tail
7. Squeeze handle of
crimp tool until tightly closed. Tool
2. Wire crimp tail
automatically opens when the crimping sequence is com-
3. Locking bar groove
plete.
Figure A-61. Tyco 070 Multilock Unsealed Connector: Pin
8. Raise up locking bar (7) to remove crimped terminal.
Terminal
sm00001
1
3
2
1. Insulation crimp tail
2. Wire crimp tail
3. Locking bar groove
Figure A-62. Tyco 070 Multilock Unsealed Connector:
Socket Terminal
2013 Sportster Diagnostics: Appendix A Connector Repair A-37
HOME
Inspecting Crimped Terminals
sm00007
See Figure A-64. Inspect the wire core crimp (2) and insulation
1
crimp (1). Distortion should be minimal.
sm00008
3
1
2
2
4
1. Insulation crimp
2. Wire core crimp
5
Figure A-64. Tydo 070 Multilock Unsealed Connector:
Terminal Crimp
6
7
8
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
A-38 2013 Sportster Diagnostics: Appendix A Connector Repair
HOME
TYCO GET 64 SEALED CONNECTOR
A.21
TYCO GET 64 SEALED CONNECTOR
sm07311
PART NUMBER
TOOL NAME
B-50085
TERMINAL EXTRACTOR
General
See Figure A-65. 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-66. Tyco GET 64 Secondary Lock
sm07293
1
2
Figure A-65. Tyco GET 64 Sealed Connector Latch
Removing Socket Terminals
1
1. Remove the black wrap to access the back of the con-
2
nector.
2. See Figure A-66. Use needle nose pliers to pull the sec-
ondary lock out of the housing.
3. See Figure A-67. 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
1. Terminal extractor
the terminal.
2. Retention beam
4. Rotate the extractor to release the retention beam and
Figure A-67. Removing Terminals: Tyco GET 64 Sealed
simultaneously pull on the wire lead to remove the ter-
Connector
minal.
Installing Socket Terminals
1. See Figure A-68. Locate the wire lead cavity by number.
2. See Figure A-69. 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 Diagnostics: Appendix A Connector Repair A-39
HOME
CRIMPING TERMINALS
sm07340
PART NUMBER
TOOL NAME
HD-50120
UNIVERSAL CRIMPER SET
HD-50120-2
HAND CRIMP FRAME
HD-50120-7
TYCO GET 64 DIE
1. Strip the wire insulation. Refer to Table A-9.
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
Table A-9.
4. Insert the wire to the wire stop. Crimp the terminal.
5. Inspect the crimped terminal and wire lead.
Figure A-68. Cavity Numbers
Table A-9. Tyco GET 64 Sealed Crimper Die (Part No.
HD-50120-7)
sm07314
TERMINAL
PART NO.
STRIP LENGTH
NEST
in
mm
Socket:
72666-12
0.170
4.4
A
18-20
AWG
Figure A-69. Socket Terminal Orientation: Crimp Open
Side
A-40 2013 Sportster Diagnostics: Appendix A Connector Repair
HOME
TYCO MCP SEALED CONNECTOR
A.22
TYCO MCP SEALED CONNECTOR
sm07369b
PART NUMBER
TOOL NAME
B-0085
TERMINAL EXTRACTOR
GA500A
SNAP-ON TERMINAL PICK
General
The Tyco MCP sealed connector is used on certain ABS
modules.
Housing
Separate: See Figure A-70. 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-71. Tyco MCP Connector Secondary Lock
sm07354
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
Figure A-72. Removing Large Socket Terminals:Tyco MCP
NOTE
Connector
Insert a thin flat bladed screwdriver all the way to the bottom
behind the tab of the secondary lock.
Removing the Small Terminals
2. See Figure A-71. Gently slide the secondary lock out of
1. Snap the wire harness cover off of the back of the con-
the connector with a screw driver.
nector
3. See Figure A-72. Insert the smallest pins of the SNAP-ON
NOTE
TERMINAL PICK (Part No. GA500A) into the gaps on
Insert a thin flat bladed screwdriver all the way to the bottom
each side of the socket to compress the tangs on each
behind the tab of the secondary lock.
side of the terminal.
2. See Figure A-71. Gently slide the secondary lock out of
4. Gently pull on the wire to remove the terminal.
the connector with a screw driver.
3. See Figure A-73. 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 Diagnostics: Appendix A Connector Repair A-41
HOME
2. Install the TYCO MCP DIE (Part No. HD-50120-8) in the
sm07355a
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)
TERMINAL
PART NO.
STRIP LENGTH
NEST
in
mm
Large socket:
72579-12
0.165-0.189
4.2-4.8
A
14 AWG
Large socket:
72579-12
0.165-0.189
4.2-4.8
B
16 AWG
Figure A-73. Removing Small Socket Terminal: Tyco MCP
Small socket:
72580-12
0.130-0.153
3.3-3.9
C
Connector
20 AWG
Installing Terminals
sm07290
1. See Figure A-74. 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.
1
sm07361
2
3
1. Locking tang
Figure A-74. Tyco MCP Sealed Connector Cavity Numbers
2. Lead crimp
3. Seal crimp
CRIMPING TERMINALS
Figure A-75. Tyco MCP Socket Terminal Crimp
PART NUMBER
TOOL NAME
HD-50120
UNIVERSAL CRIMPER SET
HD-50120-8
TYCO MCP DIE
1. Strip the wire insulation to specification. Refer to
Table A-10.
A-42 2013 Sportster Diagnostics: Appendix A Connector Repair
HOME
SEALED SPLICE CONNECTORS
A.23
6. Slide the connector to the other half of the metal insert.
SEALED SPLICE CONNECTOR REPAIR
Insert the stripped wire lead (1) until it stops. Crimp the
lead in the insert (2).
PART NUMBER
TOOL NAME
HD-25070
HEAT GUN
HD-38125-8
PACKARD CRIMPING TOOL
Be sure to follow manufacturer's instructions when using
HD-39969
ULTRA TORCH
the UltraTorch UT-100 or any other radiant heating device.
HD-41183
HEAT SHIELD ATTACHMENT
Failure to follow manufacturer's instructions can cause a
fire, which could result in death or serious injury. (00335a)
General
•
Avoid directing heat toward any electrical system com-
ponent that is not being serviced.
Splice connectors and several OE ring terminal connectors
use heat shrink covering to seal the connection.
•
Always keep hands away from tool tip area and heat shrink
attachment.
Preparing Wire Leads
7. Use an ULTRA TORCH (Part No. HD-39969), or a HEAT
NOTE
GUN (Part No. HD-25070) with a HEAT SHIELD
When splicing adjacent wires, stagger the splices that the
ATTACHMENT (Part No. HD-41183), to heat the connector
sealed splice connectors will not touch each other.
from the center of the crimp (3) out to each end.
1. Using a shop gauge, identify the gauge of the wire.
NOTE
2. Match the wire gauge to a sealed splice connector by color
It is acceptable for the splice to rest against the heat shrink
and part number. Refer to Table A-11.
tool attachment.
3. Strip insulation off the the wire lead. Refer to Table A-11.
Inspecting Seals
See Figure A-77. Allow the splice to cool and inspect the seal.
Table A-11. Sealed Splice Connectors
The insulation should appear smooth and cylindrical. Melted
WIRE GAUGE
COLOR
PART NO.
STRIP LENGTH
sealant will have extruded out the ends (4) of the insulation.
in
mm
sm00050
18-20 (0.5-0.8 mm)
Red
70585-93
3/8
9.5
1
14-16 (1.0-2.0 mm)
Blue
70586-93
3/8
9.5
10-12 (3.0-5.0 mm)
Y
ellow
70587-93
3/8
9.5
3
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 Figure A-77. The connector is crimped on one side and
then the other.
2
1. See Figure A-76. 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.
1. Red connector die
3. Gently squeeze the handles until the connector is held in
2. Blue connector die
the jaws.
3. Yellow connector die
4. See Figure A-77. Feed the stripped end of a wire into the
Figure A-76. Packard Crimping Tool (HD-38125-8)
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.
2013 Sportster Diagnostics: Appendix A Connector Repair A-43
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