Harley Davidson Sportster Models 2009. Service Repair Manual — page 85

sm00030

Pry rubber seal from connector

Insert safety pin to depress tang

Push on lead to remove terminal

Raise tang with X-Acto knife

Pull on lead to draw terminal into chamber

Figure A-26. 280 Metri-Pack Connector: Remove/Install

Socket Terminal

HOME

2009 Sportster Diagnostics: Appendix A Connector Repair A-21

A.11

480 METRI-PACK CONNECTORS

480 METRI-PACK CONNECTOR REPAIR

General

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

Referred to as Packard connectors, Metri-Pack connectors are
embossed with the initials P.E.D.

See

Figure A-27

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

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

Separating Pin and Socket Housings

NOTE

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

See

Figure A-27

. Using small flat blade screwdriver, press

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

Mating Pin and Socket Housings

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

Removing Socket Terminals

See

Figure A-27

. Bend back the latch (2) slightly and free

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

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

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

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

If necessary, crimp new terminals on wires. See

A.14 METRI-PACK TERMINALS

Installing Socket Terminals

Carefully bend the tang outward away from the terminal
body.

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

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

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

NOTE

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

sm00031a

Button on pin housing

Secondary lock latch

Opening between tang and chamber wall

Secondary Lock (shown open)

AFL housing

Figure A-27. 480 Metri-Pack Connector: Remove Socket

Terminal

HOME

A-22 2009 Sportster Diagnostics: Appendix A Connector Repair

A.12

630 METRI-PACK CONNECTORS

630 METRI-PACK CONNECTOR REPAIR

TOOL NAME

PART NUMBER

SNAP-ON PICK

SNAP-ON TT600-3

General

Referred to as Packard connectors, Metri-Pack 630 series
connectors are embossed with the initials P.E.D.

Separating Pin and Socket Housings

NOTE

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

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

Mating Pin and Socket Housings

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

NOTE

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

Removing Socket Terminal

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

Rotate the secondary lock outward on hinge to view the
terminals in the chambers of the connector housing. The
locking tang is on the side opposite the crimp tails and

engages a rib in the chamber wall to lock the terminal in
place.

Moving to the mating end of the connector, take note of
the small opening on the chamber wall side of each ter-
minal.

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

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

If necessary, crimp new terminals on wires. Refer to

A.14 METRI-PACK TERMINALS

Installing Socket Terminal

NOTE

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

Using a thin flat blade, like that of a hobby knife, carefully
bend the tang outward away from the terminal body.

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

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

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

HOME

2009 Sportster Diagnostics: Appendix A Connector Repair A-23

A.13

800 METRI-PACK CONNECTORS

DELPHI MAIN FUSE HOUSING REPAIR

General

A Delphi Main fuse connector completes the circuit through
the main fuse.

Removing Main Fuse

See

Figure A-28

. Depress latches on main fuse cover (1)

and then slide cover off of connector (2).

Holding the connector (fuse holder), pull the main fuse out
of the connector.

Installing Main Fuse

Insert the blade terminals of the main fuse into the sockets
of the connector and press the main fuse into the con-
nector.

Slide the cover over the fuse until the cover clicks into
place.

NOTE

If removed from an OE attachment such as a grooved fuse
block cover, engage cover and slide into place.

Removing Socket Terminals

See

Figure A-29

. Gently pull socket housing to disengage

slots (1) on secondary lock (2) from tabs (3) on socket
housing. Free secondary lock from cables and set aside.

Take note of the opening on one side of the socket ter-
minal. Gently insert flat blade of pick (Snap-On TT600-5)
or small screwdriver into opening (4) until it stops. Pivot
the pick toward the terminal body and hold in position.

Tug on cable to pull socket from wire end of socket
housing. A firm tug is necessary to overcome the resist-
ance of the rubber seal.

Repeat to remove remaining socket terminal.

Installing Socket Terminals

See

Figure A-30

. Carefully bend tang outward away from

the terminal body.

Feed socket into wire end of socket housing until it clicks
in place. Verify that socket will not back out of chamber.
A slight tug on the cable will confirm that it is locked.

Push rubber seal into wire end of socket housing.

Repeat to install remaining socket terminal.

Install secondary lock onto cables and then push onto wire
end of socket housing until slots engage tabs on sides of
socket housing.

sm00032

Main fuse cover

Delphi main fuse housing

Figure A-28. Delphi Connector Housing: Main Fuse

HOME

A-24 2009 Sportster Diagnostics: Appendix A Connector Repair

sm00033

Secondary lock slot

Secondary lock

Tab

Insert flat blade into opening

Figure A-29. Delphi Main Fuse Housing: Remove Socket

Terminals

sm00034

Figure A-30. Delphi Main Fuse Housing: Bend Tang

HOME

2009 Sportster Diagnostics: Appendix A Connector Repair A-25

A.14

METRI-PACK TERMINALS

METRI-PACK TERMINAL CRIMPS

TOOL NAME

PART NUMBER

PACKARD TERMINAL CRIMP TOOL

HD-38125-6

PACKARD TERMINAL CRIMPER

HD-38125-7

PACKARD CRIMPING TOOL

HD-38125-8

Matching Terminal To Crimper

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

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

See

Figure A-31

. A completed crimp may require two different

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

NOTE

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

Preparing Wire Lead

Use a wire striper to strip off the insulation and expose 5/32
in. (4.0 mm) of wire core.

Crimping Wire Core

NOTE

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

Squeeze and release handles until ratchet automatically
opens.

Identify the corresponding sized nest for the core crimp.

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

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

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

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

sm00035

HD-38125-6 sealed terminals

HD-38125-7 non-sealed terminals

HD-38125-8 non-sealed terminals

Figure A-31. Metri-Pack Terminal Crimp Tools

Crimping Insulation/Seal

NOTE

Always perform Crimping Wire Core before Crimping Insu-
lation/Seal.

HOME

A-26 2009 Sportster Diagnostics: Appendix A Connector Repair

See

Figure A-32

. Identify the correct die for the insula-

tion/seal crimp (2).

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

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

Inspecting Crimps

See

Figure A-32

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

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

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

sm00036

Wire core crimp

Insulation crimp

Seal crimp

Figure A-32. Metri-Pack Connector: Inspect Core and

Insulation/Seal Crimps

HOME

2009 Sportster Diagnostics: Appendix A Connector Repair A-27

A.15

MOLEX CONNECTORS

MOLEX CONNECTOR REPAIR

TOOL NAME

PART NUMBER

MOLEX ELECTRICAL CONNECTOR
TERMINAL REMOVER

HD-48114

Separating Pin and Socket Housings

See

Figure A-33

. Depress the latch while pulling the pin and

socket housings apart.

Mating Pin and Socket Housings

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.

Press the housings together until the latch clicks.

Removing Terminals

Pull the secondary lock up, approximately 3/16 in. (4.8
mm), until it stops.

Socket Housing: See

Figure A-34

. Use a small

screwdriver in the pry slot. The slot next to the
external latch provides a pivot point.

Pin Housing: See

Figure A-35

. 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.

See

Figure A-36

. Insert MOLEX ELECTRICAL CON-

NECTOR TERMINAL REMOVER (Part No. HD-48114)
into the pin hole next to the terminal until the tool bottoms.

Socket Housing: The pin holes are inside the ter-
minal openings.

Pin Housing: The pin holes are outside the pins.

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

See

Figure A-37

. 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. The cavity number can be determined by
counting the cavities up or down along the row from each
stamped number.

Orient the terminal so that the tang (2) opposite the open
crimp engages the slot (3) in the cavity.

Push the terminal into the cavity.

Gently tug on wire to verify that the terminal is captured
by the secondary lock.

With all terminals installed, push the secondary lock into
the socket housing to lock the wire terminals into the
housing.

sm00040

Figure A-33. Molex Connector: Latch

sm00041

Figure A-34. Molex Connector: Secondary Lock Pry Slot

(Socket Housing)

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A-28 2009 Sportster Diagnostics: Appendix A Connector Repair

sm00042

Figure A-35. Molex Connector: Secondary Lock D-Holes

(Pin Housing)

sm00043

Figure A-36. Molex Connector: Terminal Remover

(HD-48114)

sm00044

Cavity number

Tang

Cavity slot

Figure A-37. Molex Connector: Pin Cavities and Wire

Terminal

HOME

2009 Sportster Diagnostics: Appendix A Connector Repair A-29

A.16

PACKARD ECM CONNECTOR

PACKARD 100W CONNECTOR REPAIR

General

A Packard 100W connector connects the electronic control
module (ECM) to the main harness.

NOTE

For vehicles with 73-pin connectors, see

A.17 PACKARD

MICRO-64 CONNECTORS

and

A.14 METRI-PACK TER-

MINALS

Separating Socket Housing From ECM

See

Figure A-38

. While pressing the connector into the ECM,

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

Mating Socket Housing To ECM

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

Removing Socket Terminal

See

Figure A-39

. Gently press latch (1) on each side of

the clear plastic secondary lock (2) and remove. For best
results, release one side at a time.

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

See

Figure A-40

. Using a thin blade, gently pry at seam

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

Push on wire lead to free terminal from chamber.

Installing Socket Terminal

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

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

Install new cable strap in groove of strain relief collar
capturing cable conduit.

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

Crimping Terminals

If necessary, crimp new terminals on wire leads. See

A.14 METRI-PACK TERMINALS

sm00037

Thumb lever

Latch

Catch (ECM)

Figure A-38. Packard 100W to ECM (Typical)

HOME

A-30 2009 Sportster Diagnostics: Appendix A Connector Repair

sm00038

Latch

Secondary lock

Cable strap

Strain relief collar

Conduit

Figure A-39. Packard 100W Connector

sm00039

Pins

Socket terminal

Figure A-40. Packard 100W Connector: Separate Halves

of Socket Housing

HOME

2009 Sportster Diagnostics: Appendix A Connector Repair A-31

A.17

PACKARD MICRO-64 CONNECTORS

PACKARD MICRO-64 CONNECTOR REPAIR

TOOL NAME

PART NUMBER

PACKARD MICRO-64 TERMINAL
REMOVER

HD-45928

PACKARD MICRO-64 TERMINAL
CRIMPER

HD-45929

General

Packard Micro-64 connectors are frequently found on
speedometers, tachometers and the ECM of Touring Models.
For pin 73 of these ECMs, see

A.9 150 METRI-PACK CON-

NECTORS

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 and push the pin and socket hous-
ings of the connector together until the latches click.

Removing Terminal

See

Figure A-43

. Locate the head of the secondary lock

(1) on one side of the connector housing.

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.

Locate pin hole (2) between terminals on mating end of
connector.

See

Figure A-44

. Obtain the PACKARD MICRO-64 TER-

MINAL REMOVER (Part No. HD-45928).

See

Figure A-42

. Push the adjacent terminals all the way

into the connector housing and then insert tool into hole
until it bottoms.

Leaving the tool installed, gently tug on wires to pull either
one or both terminals from wire end of connector. Remove
tool.

sm00046

Figure A-41. Packard Micro 64 Terminal Remover

(HD-45928)

sm00048

Figure A-42. Packard Micro 64 Connector: Insert Tool and

Remove Terminal

HOME

A-32 2009 Sportster Diagnostics: Appendix A Connector Repair

Installing Terminal

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-43

. 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.

Bottom the terminal in the chamber and then gently tug
on the wire to verify that it is locked in place.

NOTE

Once the terminal is removed it may not lock in place when
first reinstalled. Until the lock engages, move the terminal back
and forth slightly while wiggling the lead.

Since the terminal remover tool releases two terminals
simultaneously, repeat step 2 on the adjacent terminal
even if it was not pulled from the connector housing.

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 lead removing 1/8 in. (3.0 mm) of insulation.

Crimping Terminals

Inspect new socket terminal for bent or deformed contact
and crimp tails. Replace as necessary.

See

Figure A-45

. Squeeze the handles of the PACKARD

MICRO-64 TERMINAL CRIMPER (Part No. HD-45929)
to cycle the tool to the fully open position (1).

Raise locking bar and barrel holder by pushing up on
bottom tab with index finger (2).

With the crimp tails facing upward, insert terminal through
locking bar into front hole in barrel holder (20-22 gauge
wire) (3).

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.

Insert wires between crimp tails until ends make contact
with locking bar. Verify that wire is positioned so that wide
pair of crimp tails squeeze bare wire strands, while the
narrow pair folds over the insulation material.

Squeeze handle of crimp tool until tightly closed (4). Tool
automatically opens when the crimping sequence is com-
plete.

Raise locking bar and barrel holder to remove contact.

Inspecting Crimps

Inspect the quality of the core and insulation crimps. Distortion
should be minimal.

9 10

11 12

sm00047

Secondary lock

Pin hole

Stamped number

Figure A-43. Packard Micro 64 Connector: Housing

sm00045

Figure A-44. Packard Micro 64 Terminal Crimper (HD-45929)

HOME

2009 Sportster Diagnostics: Appendix A Connector Repair A-33

sm00049

Open position

Raising locking bar

Insert terminal

Crimp terminal

Figure A-45. Packard Micro 64 Connector: Terminal in

Crimper

HOME

A-34 2009 Sportster Diagnostics: Appendix A Connector Repair

A.18

SEALED SPLICE CONNECTORS

SEALED SPLICE CONNECTOR REPAIR

TOOL NAME

PART NUMBER

ROBINAIR HEAT GUN

HD-25070

PACKARD CRIMPING TOOL

HD-38125-8

ULTRA TORCH UT-100

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

If adjacent wires are to be spliced, stagger the splices so that
the sealed splice connectors will not touch each other but are
located at different positions along the length of the wires.

Using a shop gauge, identify the gauge of the wire.

Match the wire gauge to a sealed splice connector by color
and part number. Refer to

Table A-4

Using a wire stripper, cut and strip a length of insulation
off the wire ends. Refer to

Table A-4

for the strip length.

Table A-4. Sealed Splice Connectors

STRIP LENGTH

PART NO.

COLOR

WIRE GAUGE

3/8 in. (9.5 mm)

70585-93

Red

18-20

(0.5-0.8 mm)

3/8 in. (9.5 mm)

70586-93

Blue

14-16

(1.0-2.0 mm)

3/8 in. (9.5 mm)

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

Figure A-47

. The connector is crimped twice - one side

and then the other.

See

Figure A-46

. Open the PACKARD CRIMPING

TOOL (Part No. HD-38125-8) ratchet by squeezing the
handles closed.

Match the connector color to the wire gauge crimp die in
the jaws and insert one end of the sealed connector.

Gently squeeze the handles until the connector is held in
the jaws.

See

Figure A-47

. Feed the stripped end of a wire into the

connector until the wire stops inside the metal insert (1).

Squeeze the handles tightly closed to crimp the lead in
the insert (2). The tool automatically opens when the
crimping is complete.

Slide the connector to the other half of the metal insert.
Insert the stripped wire lead (1) until it stops, and 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 fuel system component.
Extreme heat can cause fuel ignition/explosion resulting
in death or serious injury.

•

Avoid directing heat toward any electrical system com-
ponent other than the connectors on which heat shrink
work is being performed.

•

Always keep hands away from tool tip area and heat shrink
attachment.

Use an ULTRA TORCH UT-100 (Part No. HD-39969), or
a ROBINAIR 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

Figure A-47

. 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.

HOME

2009 Sportster Diagnostics: Appendix A Connector Repair A-35