Harley Davidson 2013 Sportster Models. Electrical Diagnostics Manual — page 13
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CRIMPING TERMINALS
sm00039a
1
PART NUMBER
TOOL NAME
HD-50120
UNIVERSAL CRIMPER SET
HD-50120-2
HAND CRIMP FRAME
HD-50120-7
DELPHI 100W MICRO-PACK SEALED
DIE
1
1. Strip the wire insulation to specification. Refer to Table A-1.
2. 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
1
CRIMPER SET (Part No. HD-50120).
3. Place the new terminal in the specified nest.
4. Insert the wire to the wire stop. Crimp the terminal.
5. Inspect the crimped terminal.
Table A-1. Delphi 100W Micro-Pack Crimper Die (Part No.
HD-50120-7)
TERMINAL
PART NO.
STRIP LENGTH
NEST
in
mm
Socket:
72076-00
0.200
5.1
B
18 AWG
Socket:
72568-08
0.200
5.1
C
2
20-22 AWG
1. Pins
2. Socket terminal
Figure A-8. Delphi 100W Micro-Pack Sealed Connector:
Separate Halves of Socket Housing
A-4 2013 Sportster Diagnostics: Appendix A Connector Repair
HOME
DELPHI 150 METRI-PACK SEALED
CONNECTORS
A.4
DELPHI 150 METRI-PACK SEALED
6.
Remove the pin.
a. For pull-to-seat: Push on the lead to extract the ter-
CONNECTOR REPAIR
minal from the mating end of the connector.
General
b. For push-to-seat: Pull on the lead to draw the ter-
Delphi 150 Metri-Pack Sealed connectors are embossed with
minal out the wire end.
the initials (P.E.D.).
Inserting Socket Terminal
There are two types of connectors in this series:
•
Pull-to-Seat
NOTE
For wire location purposes, alpha characters are stamped into
•
Push-to-Seat
the socket housings.
Separating Pin and Socket Housings
1.
See Figure A-9 for pull-to-seat connector or Figure A-10
Bend back the external latch slightly and separate the pin and
for push to seat connector. Carefully bend tang on each
socket halves of the connector.
side of terminal outward away from terminal body. Use
the thin flat blade from a hobby knife.
Mating Pin and Socket Housings
2.
Gently pull or push on the lead to install the terminal back
Align the wire colors. Push the pin and socket halves of the
into the chamber. A click is heard when the terminal is
connector together.
properly seated.
Removing Socket Terminal
3.
Gently pull or push on the lead to verify that the terminal
is locked in place.
1. See Figure A-9 for pull-to-seat connector or Figure A-10
for push to seat connector. Remove wire lock (1) from wire
For push-to-seat: See Figure A-10. Seat wires in separate
end of socket housing on push-to-seat type connectors.
channels of wire lock and then push channels inside
chambers at wire end of socket housing. Fully installed,
NOTE
slot on each side of wire lock engages ear on socket
For best results, free one side of wire lock first and then release
housing.
the other side.
2. 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.
3. Gently insert a small diameter straight pin into the chamber
about 1/8 in (3.2 mm).
a. For pull-to-seat: Stay between the terminal and the
chamber wall and pivot the end of the pin toward the
terminal body.
b. For push-to-seat: There is a small opening for the
pin.
4. 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.
5. 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.
2013 Sportster Diagnostics: Appendix A Connector Repair A-5
HOME
sm00027a
sm00028a
1
1
2
2
3
3
4
4
1. Remove wire lock
1. Locate tang in chamber
2. Pivot pin to release tang
2. Pivot pin to release tang
3. Pull to remove
3. Push to remove
4. Raise tang to install
4. Raise tang to install
Figure A-10. Delphi 150 Metri-Pack Sealed Connector:
Figure A-9. Delphi 150 Metri-Pack Sealed Connector:
Push-to-Seat
Pull-to-Seat
A-6 2013 Sportster Diagnostics: Appendix A Connector Repair
HOME
DELPHI 280 METRI-PACK UNSEALED
CONNECTORS
A.5
FUSE BLOCK REPAIR
NOTE
The wiring diagram indicates when one socket terminal is be
Removing Socket Terminals
crimped to two wire leads.
1. See Figure A-11. To remove secondary locks, insert end
of small flat blade screwdriver (1) under lip of locking
sm00025
wedge (2) and gently pry up secondary lock.
NOTE
1
For best results, start with locking wedge on outboard side of
2
secondary lock.
2. Looking into chamber at top of fuse block, note the tang
next to each socket terminal.
3. 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
1. Match the wire lead color to the fuse block terminal cavity.
NOTES
•
Refer to the main harness wiring diagram for wire lead
1. Pry up secondary lock
color codes.
2. Lip of locking wedge
•
See Figure A-12. Alpha (1) and numeric (2) coordinates
Figure A-11. Fuse Block: Remove Secondary Locks
identify the main fuse block terminal cavity. Refer
to the
main harness wiring diagram.
2. With the open side of the socket
terminal facing the tang,
sm00026
push lead into chamber at the wire end of the fuse block.
1
A click is heard when the terminal is properly engaged.
3. Gently tug on the wire to verify that the terminal is locked
in place.
A
C
E
G
J
2
1
4. Install the secondary locks. With the locking wedges
positioned above the tangs in each chamber, slide flat
2
side of secondary lock into slot between rows. Push down
3
until it bottoms.
4
Crimping Terminals
B
D
F
H
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.
1. Alpha
2. Numeric
Figure A-12. Fuse Block: Coordinates (typical)
2013 Sportster Diagnostics: Appendix A Connector Repair A-7
HOME
DELPHI 480 METRI-PACK UNSEALED
CONNECTORS
A.6
DELPHI 480 METRI-PACK UNSEALED
3. Verify that terminal will not back out of the chamber. A
slight tug on the cable will confirm that it is locked.
CONNECTOR REPAIR
4. Rotate the hinged secondary lock inward until latches fully
General
engage tabs on both sides of connector housing.
A 480 Metri-Pack connector is frequently used for the B+
NOTE
(battery voltage) connector to power P&A accessories.
If removed, install new anchored cable strap in original equip-
See Figure A-13. An AFL housing (5) is used on many igni-
ment location. Tighten cable strap to capture conduit of both
tion/light switches. The secondary lock (4) must be opened
accessory connector and B+ connector approximately 1.0 in
before removing the terminal from the housing.
(25.4 mm) from housings.
Separating Pin and Socket Housings
sm00031a
1
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.
2
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
1. 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
3
to access terminal in chamber of connector housing.
2. 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.
4
3. Pivot the end of the pin toward the terminal body to press
the tang.
5
4. Remove the pin and then pull terminal out of the wire end
of connector housing.
5. If necessary, crimp new terminals on wires. See
A.9 DELPHI METRI-PACK TERMINAL REPAIR.
1.
Button on pin housing
2.
Secondary lock latch
Installing Socket Terminals
3.
Opening between tang and chamber wall
1. Carefully bend the tang outward away from the terminal
4.
Secondary lock (shown open)
body.
5.
AFL housing
2. With the tang on the same side as the square shaped
Figure A-13. Delphi 480 Metri-Pack Unsealed Connector:
opening in the mating end of the connector housing, feed
Remove Socket Terminal
terminal into wire end of connector housing until it clicks
in place.
A-8 2013 Sportster Diagnostics: Appendix A Connector Repair
HOME
DELPHI 630 METRI-PACK UNSEALED
CONNECTORS
A.7
DELPHI 630 METRI-PACK UNSEALED
3. Moving to the mating end of the connector, find the small
opening on the chamber wall side of each terminal.
CONNECTOR REPAIR
4. Insert SNAP-ON PICK (Part No. SNAP-ON TT600-3) into
PART NUMBER
TOOL NAME
opening until it stops. Pivot the end of the pick toward the
terminal to press the locking tang.
SNAP-ON
TT600-3
SNAP-ON PICK
5. Remove the pick and gently tug on the wire to pull the
terminal from the wire end of the connector. Repeat steps
Separating Pin and Socket Housings
if the terminal is still locked in place.
NOTE
6. If necessary, crimp new terminals on wires. Refer to
If necessary, remove connector from barbed anchor or other
A.9 DELPHI METRI-PACK TERMINAL REPAIR.
retaining device.
Installing Socket Terminal
Bend back the external latch slightly and separate pin and
socket halves of the connector.
NOTE
Mating Pin and Socket Housings
Refer to the wiring diagrams to match wire lead colors to alpha
characters molded into the secondary locks of each connector
Orient the latch to the catch. Push the pin and socket halves
housing.
of the connector together until the latch "clicks".
1. Carefully bend tang on each side of terminal outward away
NOTE
from terminal body. Use the thin flat blade from a hobby
If removed, install connector on barbed anchor or other OE
knife.
retaining device.
2. With the tang facing the chamber wall, push the lead into
Removing Socket Terminal
the chamber at the wire end of the connector. A click is
heard when the terminal is properly seated.
1. Bend back the latch slightly and
free one side of the sec-
ondary lock. Repeat the step to unlatch the other side.
3. Gently tug on the wire end to verify that the terminal is
locked in place
and
will not back out of the chamber.
2. Rotate the secondary lock outward on hinge to view the
terminals in the chambers of the connector housing. The
4. Rotate the hinged secondary lock inward until tabs fully
locking tang is on the side opposite the crimp tails and
engage latches on both sides of connector.
engages a rib in the chamber wall to lock the terminal in
place.
2013 Sportster Diagnostics: Appendix A Connector Repair A-9
HOME
DELPHI 800 METRI-PACK SEALED MAIN FUSE
HOUSING
A.8
DELPHI 800 METRI-PACK SEALED MAIN
sm00033
FUSE HOUSING REPAIR
3
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)
1
2
1. Disconnect battery.
2. See Figure A-14. Disengage slots (1) on secondary lock
(2) from tabs (3) and remove secondary lock.
3. Insert flat blade of pick or small screwdriver into opening
(4) until it stops.
4. Tug on cable to pull socket from connector housing. Pivot
the pick toward the terminal body to release the latch if
necessary.
4
5. 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
1. See Figure A-15. Carefully bend
tang outward away from
1. Secondary lock slot
the terminal body.
2. Secondary lock
2. Properly orient terminal to the cavity in the housing. Push
3. Tab
terminal into connector housing until it clicks in place.
4. Insert flat blade into opening
Verify that socket will not back out of chamber.
Figure A-14. Delphi 800 Metri-Pack Sealed Main Fuse
3. Push rubber seal into connector housing.
Housing: Remove Socket Terminals
4. Repeat to install remaining socket terminal.
5. Install secondary lock onto connector housing. Verify slots
sm00034
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)
6. Connect battery cables.
Figure A-15. Delphi 800 Metri-Pack Sealed Main Fuse
Housing: Bend Tang
A-10 2013 Sportster Diagnostics: Appendix A Connector Repair
HOME
DELPHI METRI-PACK TERMINAL REPAIR
A.9
METRI-PACK TERMINAL CRIMPS
sm00035a
PART NUMBER
TOOL NAME
HD-38125-6
PACKARD TERMINAL CRIMP TOOL
HD-38125-7
PACKARD TERMINAL CRIMPER
HD-38125-8
PACKARD CRIMPING TOOL
Matching Terminal To Crimper
Metri-Pack connectors embossed with the initials P.E.D. require
Packard crimp tools to crimp terminals to wire leads.
1
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.
2
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.
1. Squeeze and release handles until ratchet automatically
opens.
2. Identify the corresponding sized nest for the core crimp.
3
3. Position the core crimp in the die. Be Sure the core crimp
tails are facing the forming jaws.
4. Gently squeeze the handles until crimpers just secure the
core crimp tails.
5. 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.
6. Squeeze handles tightly closed. Release grip and the tool
1.
HD-38125-6 sealed terminals
will automatically open.
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.
2013 Sportster Diagnostics: Appendix A Connector Repair A-11
HOME
1. See Figure A-17. Identify the correct die for the insula-
sm00036
tion/seal crimp (2).
2
2. Position the insulation/seal crimp in the nest. Be sure the
1
insulation/seal crimp tails are facing the forming jaws.
3. Squeeze handle of crimp tool until tightly closed. Tool
automatically opens when the crimp is complete.
Inspecting Crimps
1. 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.
2. Inspect the insulation (2) or seal (3) crimp. The tails of the
terminal should be wrapped around the insulation without
distortion.
3
1. Wire core crimp
2. Insulation crimp
3. Seal crimp
Figure A-17. Metri-Pack Connector: Inspect Core and
Insulation/Seal Crimps
A-12 2013 Sportster Diagnostics: Appendix A Connector Repair
HOME
DELPHI MICRO 64 SEALED CONNECTORS
A.10
6. Leaving the tool installed, gently tug on wires to pull either
DELPHI MICRO 64 SEALED CONNECTOR
one or both terminals from wire end of connector. Remove
REPAIR
tool.
PART NUMBER
TOOL NAME
sm00046
HD-45928
TERMINAL REMOVER
HD-45929
TERMINAL CRIMPER
General
Delphi Micro 64 Sealed connectors are frequently found on
speedometers, tachometers and the ECM of Touring Models.
Separating Pin and Socket Housings
Bend back the external latches slightly and separate the pin
and socket housings.
Mating Pin and Socket Housings
Orient the wire lead colors. Align pin and socket housings.
Figure A-19. Terminal Remover (HD-45928)
Push the pin and socket housings of the connector together
until the latches click.
Removing Terminal
sm00048
1. See Figure A-18. Locate the head of the secondary lock
(1) on one side of the connector housing.
2. Insert the blade of a small screwdriver between the
center
ear of the lock and the connector housing and gently pry
out lock. When partially removed, pull lock from connector
housing.
3. Locate pin hole (2) between terminals on mating
end of
connector.
sm00047
3
2
1
6
1
1
2
3
4
5
6
7
8
9 10
11 12
7
12
1. Secondary lock
2. Pin hole
3. Stamped number
Figure A-18. Delphi Micro-64 Sealed Connector: Housing
4. See Figure A-19. Obtain the TERMINAL REMOVER (Part
No. HD-45928).
Figure A-20. Delphi Micro-64 Sealed Connector: Insert Tool
and Remove Terminal
5. See Figure A-20. Push the adjacent terminals all the way
into the connector housing and then insert tool into hole
until it bottoms.
2013 Sportster Diagnostics: Appendix A Connector Repair A-13
HOME
Installing Terminal
sm00045
1. Insert terminal into its respective numbered chamber on
wire end of connector. No special orientation of the ter-
minal is necessary.
NOTE
See Figure A-18. For wire location purposes, the corners of
the socket housing are stamped (3) with the numbers 1, 6, 7
and 12, representing terminals 1-6 on one side, and 7-12 on
the other.
2. Bottom the terminal in the chamber and then gently tug
on the wire to verify that it is locked in place.
NOTE
Once removed, the terminal may not lock in place when first
installed. Until the lock engages, move the terminal back and
forth slightly while wiggling the lead.
3. Since the terminal remover tool releases two terminals
Figure A-21. Terminal Crimper (HD-45929)
simultaneously, repeat step 2 on the adjacent terminal
even if it was not pulled from the connector housing.
4. With the center ear on the head of the secondary lockpin
facing the mating end of the connector, push secondary
lock in until head is flush with the connector housing.
Preparing Wire Leads for Crimping
Strip 1/8 in (3.0 mm) of insulation from the wire lead.
Crimping Terminals
1. Inspect new socket terminal for bent or deformed contact
and crimp tails. Replace as necessary.
2. See Figure A-22. Squeeze the handles of the TERMINAL
CRIMPER (Part No. HD-45929) to cycle the tool
to the
fully open position (1).
3. Raise locking bar and barrel holder by pushing up on
bottom tab with index finger (2).
4. With the crimp tails facing upward, insert terminal through
locking bar into front hole in barrel holder (20-22 gauge
wire) (3).
5. Release locking bar to lock position of contact. When
correctly positioned, the locking bar fits snugly in the space
at the front of the core crimp tails and the closed side of
the terminal rests on the outer nest of the crimp tool.
6. Insert wires between crimp tails until ends make contact
with locking bar. 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 (4). Tool
automatically opens when the crimping sequence is com-
plete.
8. Raise locking bar and barrel holder to remove contact.
Inspecting Crimps
Inspect the quality of the core and insulation crimps. Distortion
should be minimal.
A-14 2013 Sportster Diagnostics: Appendix A Connector Repair
HOME
sm00049
1
2
3
4
1. Open position
2. Raising locking bar
3. Insert terminal
4. Crimp terminal
Figure A-22. Delphi Micro-64 Sealed Connector: Terminal
in Crimper
2013 Sportster Diagnostics: Appendix A Connector Repair A-15
HOME
DELPHI GT 150 SEALED CONNECTORS
A.11
DELPHI GT 150 SEALED CONNECTOR
sm00014a
REPAIR
General
Delphi connectors are embossed with the brand name, Delphi,
on the housing latch or terminal block.
Separating Pin and Socket Housings
See Figure A-23. 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.
1. See Figure A-24. If present, free one side of wire lock (1)
from ear on wire end of socket housing. Release the other
Figure A-23. Delphi GT 150 Sealed Connector: Socket
side if necessary. Release wires from channels in wire
Housing Latch
lock. Remove from socket housing.
2. Use a fingernail to pry colored terminal lock (2) loose.
Remove from mating end of socket housing.
3. Use the thin flat blade from a hobby knife. Gently pry tang
(3) outward away from terminal.
Tug on wire to back ter-
minal 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, pre-
venting it from backing 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.
A-16 2013 Sportster Diagnostics: Appendix A Connector Repair
HOME
sm00015a
1
2
3
1. Remove wire lock
2. Remove terminal lock
3. Pry tang outward
Figure A-24. Delphi GT 150 Sealed Connector: Removing
Socket Terminals
2013 Sportster Diagnostics: Appendix A Connector Repair A-17
HOME
DELPHI GT 280 SEALED 73-TERMINAL ECM
CONNECTOR
A.12
DELPHI GT 280 SEALED 73-TERMINAL ECM
sm06098a
CONNECTOR
NOTE
Do not operate latch lever when connector is not mated to
3
ECU. Damage will occur.
Separating Socket Housing From ECM
See Figure A-25. Remove strap (1). Press the latch (2). Rotate
2
lock lever to the released position (3).
Mating Socket Housing To ECM
1
Push the connector into the ECM. Rotate the lock lever to the
locked position.
1. Strap
Socket Terminal
2. Latch
1. Cut cable strap to release harness from strain relief collar
3. Lock lever released
of connector housing.
Figure A-25. Unlatch ECM Connector
2. See Figure A-26. Release latches (4) that retain cover (3)
to housing (2) and remove cover.
3. Remove and service the Micro-64 terminals. See
sm06093
A.10 DELPHI MICRO 64 SEALED CONNECTORS.
3
4. Install connector housing cover. Verify all wires are within
the confines of the cover and that the cover latches are
engaged.
2
5. Install new cable strap cable to the strain relief
of the
connector.
ECM Ground Terminal
4
1. See Figure A-26. Remove secondary lock (1).
1
5
2. See Figure A-27. Using a thin blade screwdriver, gently
pry ground terminal retainer from connector housing.
3. See Figure A-28. Using a thin blade screwdriver, release
latch and pull ground wire, wire seal and terminal from
cover side of housing.
1. Secondary lock
4. Follow instructions in A.9 DELPHI METRI-PACK TER-
2. Terminal housing
MINAL REPAIR to replace the terminal or wire seal.
3. Cover
4. Cover latch
5. Push the terminal into place from the cover side of the
5. Ground secondary lock
connector housing until the latch engages. Pull on wire to
verify terminal is secure.
Figure A-26. Delphi 73-Terminal ECM Connector
NOTE
See Figure A-26. Secondary lock has one short leg and one
long leg. Install as shown.
6. See Figure A-26. Install ground secondary lock (5) and
install secondary lock (1) as shown.
A-18 2013 Sportster Diagnostics: Appendix A Connector Repair
HOME
sm06094a
sm06095a
Figure A-27. Remove Ground Secondary Lock
Figure A-28. Remove ECM Ground Terminal
2013 Sportster Diagnostics: Appendix A Connector Repair A-19
HOME
DEUTSCH DT SEALED CONNECTORS
A.13
DEUTSCH DT SEALED CONNECTOR
sm00017a
REPAIR
PART NUMBER
TOOL NAME
3
HD-41475
DEUTSCH TERMINAL REPAIR KIT
HD-41475-100
FLAT BLADE L-HOOK
General
1
Deutsch DT sealed connectors are colored coded for location
purposes. DT connectors associated with left side accessories,
such as the front and rear left turn signals, are gray. All other
DT connectors are black.
NOTE
2
A DEUTSCH TERMINAL REPAIR KIT (Part No. HD-41475)
contains a selection of seals and seal plugs, locking wedges,
1
attachment clips and terminals.
Also included is a FLAT BLADE L-HOOK (Part No. HD-41475-
100) used to remove locking wedges, compartmented storage
1. External latch
box and carrying case.
2. Socket housing
3. Pin housing
Separating Pin and Socket Housings
Figure A-29. Deutsch DT Sealed Connector
See Figure A-29. To separate the connector halves, Press the
external latch(es) (1) on the socket housing (2) while rocking
the pin (3) and socket housings.
Removing Socket Terminals
NOTES
1. See Figure A-30. Insert a small screwdriver between the
socket housing
and
locking wedge in-line with the groove
•
Generally, the socket housing is
found on the accessory
(in-line with the pin holes if the groove is absent). Turn the
side, while the pin housing is attached to the wiring har-
screwdriver 90 degrees to pop the wedge up and remove
ness.
the secondary locking wedge.
•
Six-place and smaller Deutsch connectors have one latch
2. See Figure A-33. Use a pick or small screwdriver to press
on the connector.
terminal latches inside socket housing and back out
•
Eight- and twelve-place connectors have a latch on each
sockets through holes in rear wire seal.
side. Simultaneously press both latches to separate the
connector.
NOTE
If wire leads require new terminals, see the instructions for
Mating Pin and Socket Housings
crimping terminals.
1. Align the connectors to match the wire lead colors.
Installing Socket Terminals
a. For One External Latch: Six-place and smaller
Deutsch connectors have one external latch on the
1. Match wire lead color to connector cavity.
socket housing. To join the housings, align the latch
2. See Figure A-32. Fit rear wire seal (1) into back of socket
on the socket side with the latch cover on the pin side.
housing (2), if removed.
b. For Two External Latches: Align the tabs on the
3. Grasp wire lead (3) approximately 1.0 in (25.4 mm) behind
socket housing with the grooves on the pin housing.
the socket terminal. Gently push socket through hole in
2. Insert socket housing into pin housing until it snaps or
wire seal into its chambers until it clicks in place.
clicks into place.
4. A tug on the wire will confirm that it is properly locked in
NOTE
place.
For Two External Latches: If latches do not click (latch), press
NOTE
on one side of the connector until that latch engages then press
Install seal plugs (6) into unused chambers. If removed, seal
on the opposite side to engage the other latch.
plugs must be replaced to seal the connector.
3. If necessary, fit the attachment clip to the pin housing.
5. Install internal seal (4) on lip of socket housing, if removed.
4. Place large end of slot on attachment clip over T-stud on
6. Insert tapered end of secondary locking wedge (5) into
frame. Push assembly forward to engage small end of
socket housing and press down until it snaps in place. The
slot.
A-20 2013 Sportster Diagnostics: Appendix A Connector Repair
HOME
wedge fits into the center groove within the socket housing
sm00018
and holds the terminal latches tightly closed.
NOTES
•
See Figure A-31. While rectangular wedges do not require
2
a special orientation, align arrow (1) on conical secondary
locking wedge towards external latch for three-place con-
nectors.
•
If the secondary locking wedge does not slide into position
easily, check the installation of all the terminals. Unseated
terminals prevent the locking wedge from proper installa-
tion.
1
sm00009a
1. Arrow on socket locking wedge
2. Arrow on pin locking wedge
Figure A-31. Deutsch DT Sealed Connector: 3-Place
Locking Wedges
Figure A-30. Deutsch DT Sealed
Connector: Remove
Secondary Locking Wedge
2013 Sportster Diagnostics: Appendix A Connector Repair A-21
HOME
NOTES
sm00010
•
If wire leads require new terminals, see the instructions
for crimping terminals.
•
The 8-place and 12-place gray and black connectors are
not interchangeable. If replacing both the socket and pin
housings, the black may be substituted for the gray.
•
The socket and pin housings of all other connectors are
interchangeable. Black may be mated with the gray since
the alignment tabs are absent and the orientation of the
external latch is the same.
sm00019
5
6
4
2
1
Figure A-33. Deutsch DT Sealed Connector: Press Terminal
Latch and Back Out Pin
3
1. Wire seal
Installing Pin Terminals
2. Socket housing
1.
See Figure A-34. Fit wire seal (1) into back of pin housing
3. Wire lead
(2).
4. Internal seal
5. Secondary locking wedge
2.
Grasp wire lead approximately 1.0 in (25.4 mm) behind
6. Seal plug
the pin terminal (3). Gently push pin through holes in wire
seal into its respective numbered chamber until it "clicks"
Figure A-32. Deutsch DT Sealed Connector: 2, 3, 4 and
in place.
12-Place Socket Housings
NOTE
A tug on the wire lead will confirm that a pin is locked in place.
Removing Pin Terminals
3.
Insert tapered end of secondary locking wedge (4) into
1. Use the hooked end of a stiff piece of mechanics wire, a
pin housing. Press down until it snaps in place.
needle nose pliers or the FLAT BLADE L-HOOK (Part
No. HD-41475-100) to remove the secondary locking
NOTES
wedge.
•
The wedge fits in the center groove of the pin housing and
2. Gently Press terminal latches inside pin housing and back
holds the terminal latches tightly closed.
out pins through holes in wire seal.
•
See Figure A-31. While rectangular wedges do not require
a special orientation, align arrow (1) on conical secondary
locking wedge towards external latch for three-place con-
nectors.
•
If the secondary locking wedge does not slide into position
easily, check the installation of all the terminals. Unseated
terminals prevent the locking wedge from proper installa-
tion.
A-22 2013 Sportster Diagnostics: Appendix A Connector Repair
HOME
Crimping Terminals
sm00020
3
Identify which of the types of Deutsch terminals are used with
the connector. Follow the corresponding crimping instructions.
1
Refer to Table A-2.
2
4
1. Wire seal
2. Pin housing
3. Pin terminal
4. Locking wedge
Figure A-34. Deutsch DT Sealed Connector: 2, 3, 4 and
12-Place Pin Housings
Table A-2. Deutsch Connector: Terminal Crimping Instructions
TYPE
CRIMPING INSTRUCTIONS
DT Sealed (with crimp tails)
A.14 DEUTSCH DT SEALED TERMINAL REPAIR
DTM Mini Sealed
Terminal (solid
A.16 DEUTSCH DTM SEALED SOLID BARREL MINI TERMINAL REPAIR
barrel)
DTM
Mini Sealed Terminal (with crimp
A.15 DEUTSCH DTM SEALED MINI TERMINAL REPAIR
tails)
2013 Sportster Diagnostics: Appendix A Connector Repair A-23
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