Harley Davidson Sportster Models 2009. Service Repair Manual — page 70

A.7

DEUTSCH SOLID BARREL MINI TERMINAL
REPAIR

DEUTSCH SOLID BARREL TERMINAL
CRIMPS

TOOL NAME

PART NUMBER

ELECTRICAL CRIMPER TOOL

HD-42879

Preparing Wire Leads For Crimping

For size 20, 16 and 12 contacts, wire ranges 26-12 AWG.

Strip wire lead removing 1/4 in. (6.4 mm) of insulation.

Adjusting Crimper Tool

1.

See

Figure A-22

. 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).

3.

Raise selector knob and rotate 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-23

. 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 depression in indentor cover.
Tighten knurled locknut.

3.

Slowly squeeze handles of crimp tool until contact is
centered 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
closed. Tool automatically opens when the crimping
sequence is complete.

5.

Remove wire lead with crimped contact from indentor.

NOTE

Tool must be readjusted when changing contact size/type.

6.

Install pin to lock selector knob.

Inspecting Crimps

Inspect the crimp. All core wire strands are to be crimped in
the barrel.

This

HAND

tool

m

ust

not

be

used

in

an

y

po

w

ered

"PRESS''

as

defined

b

y

OSHA

CFR

1910.211

(46)

2

4

5

1

3

sm00023

1.

Locking pin

2.

Selector knob

3.

SEL. NO. arrow

4.

Knurled locknut

5.

Adjusting screw

Figure A-22. Electrical Crimper Tool (HD-42879)

HOME

2009 Sportster Service: Appendix A Connector Repair A-15

HDT

- 48

- 00

JDG360-1

HEMET

RYAN

AIRPOR

T, P

.O

. BO

X 878

HEMET

, CA.

92343-0161

(714)

929-1200

INDUSTRIAL

PR

ODUCTS

DIVISION

HDT

- 48

- 00

JDG360-1

HEMET

RYAN

AIRPOR

T, P

.O

. BO

X 878

HEMET

, CA.

92343-0161

(714)

929-1200

INDUSTRIAL

PR

ODUCTS

DIVISION

2

1

3

4

3

sm00024

1.

Contact barrel

2.

Indentor cover

3.

Indentor point

4.

Stripped wire lead

Figure A-23. Deutsch Solid Barrel

HOME

A-16 2009 Sportster Service: Appendix A Connector Repair

A.8

DEUTSCH MINI TERMINAL REPAIR

DEUTSCH MINI TERMINAL CRIMPS

TOOL NAME

PART NUMBER

PACKARD TERMINAL CRIMPER

HD-38125-7

Preparing Wire Leads for Crimping

Strip wire lead removing 5/32 in. (4.0 mm) of insulation.

Crimping a Mini Terminal to Wire Lead

1.

See

Figure A-24

. 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. Be
sure 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-
ition wire so that 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, it can be opened by squeezing
the ratchet trigger (2).

6.

Position the insulation crimp on nest C of the crimper. Be
sure the insulation crimp tails are facing the forming jaws.

7.

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

Inspecting Crimps

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

2

1

sm00022

1.

E die

2.

Crimper ratchet trigger

Figure A-24. Packard Terminal Crimper (HD-38125-7)

HOME

2009 Sportster Service: Appendix A Connector Repair A-17

A.9

MOLEX CONNECTORS

MOLEX CONNECTOR REPAIR

TOOL NAME

PART NUMBER

MOLEX ELECTRICAL CONNECTOR
TERMINAL REMOVER

HD-48114

Separating Pin and Socket Housings

See

Figure A-25

. Depress 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-26

. Use a small

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

b.

Pin Housing: See

Figure A-27

. Use needle nose

pliers to engage the D-holes in the center of the sec-
ondary lock.

NOTE

Do not remove the secondary lock from the connector housing.

2.

See

Figure A-28

. Insert MOLEX ELECTRICAL CON-

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

a.

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

b.

Pin Housing: The pin holes are outside the pins.

3.

Pressing the terminal remover to the bottom of the pin
hole, gently pull on the wire to remove wire terminal from
its cavity.

Installing Terminals

1.

See

Figure A-29

. 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.

2.

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

3.

Push the terminal into the cavity.

4.

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

5.

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

sm00040

Figure A-25. Molex Connector: Latch

sm03332

Figure A-26. Secondary Lock Pry Slot (Socket Housing)

HOME

A-18 2009 Sportster Service: Appendix A Connector Repair

sm02851

Figure A-27. Pull Up Secondary Lock (Pin Housing)

sm00043

Figure A-28. Molex Connector: Terminal Remover

(HD-48114)

1

3

2

sm00044

1.

Cavity number

2.

Tang

3.

Cavity slot

Figure A-29. Molex Connector: Pin Cavities and Wire

Terminal

CRIMP TERMINAL TO LEAD

TOOL NAME

PART NUMBER

ELECTRICAL CRIMP TOOL

HD-48119

Prepare Lead

1.

Cut the damaged terminal close to the back of the terminal
to leave as much wire length as possible.

2.

Strip approximately 3/16 in. (4.70-5.60 mm) of insulation
from the end of the wire lead.

NOTE

The strip length is the same for both pin and socket terminals
and for wire gauges from 22 to 14.

Prepare Tool

1.

Identify the punch/die in the jaws of the ELECTRICAL
CRIMP TOOL (Part No. HD-48119) for the wire gauge.
Refer to

Table A-4

.

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-30

. 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.

HOME

2009 Sportster Service: Appendix A Connector Repair A-19

Table A-4. Crimp Tool Wire Gauge Punch/Die

PUNCH/DIE

AWG (WIRE GAUGE)

Left

22

Middle

18-20

Right

14-16*

* Crimp 16 AWG pin terminals in the 18-20 middle die.

sm02853

Figure A-30. Open Electrical Crimp Tool (HD-48119) at 45

Degrees

1

2

sm02854

1.

Socket locator bar

2.

Pin locator bar

Figure A-31. Terminal Locator Bars

Position Terminal in the Punch/Die

1.

See

Figure A-32

. With the crimp tails up, place the terminal

through the punch/die into the square opening in the
socket locator bar.

a.

Socket Terminal: See

Figure A-31

. A socket terminal

stops against the back face of the socket locator bar
(1).

b.

Pin Terminal: See

Figure A-33

. The tip of a pin ter-

minal passes through the socket locator bar and stops
in the notch in the face of the pin locator bar.

2.

See

Figure A-34

. Ratchet the handles together until the

crimp tails are held in vertical alignment between the punch
and the die.

sm02855

Figure A-32. Square Openings in Socket Locator Bar

Insert Stripped Lead

See

Figure A-35

. Insert the stripped end (wire core) between

the crimp tails at an up angle until the wire core touches the
face of the socket locator bar above the square opening.

NOTES

•

The insulation must extend through the insulation crimp
tails.

•

Insert the wire with little or no pressure. Pressing on the
lead will bend the wire core.

HOME

A-20 2009 Sportster Service: Appendix A Connector Repair

sm02856

Figure A-33. Pin Terminal against Pin Locator Bar

sm02857

Figure A-34. 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

A stuck or jammed tool can be opened by pressing the ratchet
release lever found between the handles. Do not force the
handles open or closed.

sm02858

Figure A-35. Stripped Lead at Up Angle

Inspect Crimp

1.

Inspect Crimp: Inspect the core and insulation crimp.

a.

See

Figure A-36

. 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 and pull the lead.

1

3

2

sm02859

1.

Core crimp

2.

Wire strands

3.

Insulation crimp

Figure A-36. Terminal Crimp

HOME

2009 Sportster Service: Appendix A Connector Repair A-21

A.10

PACKARD 150 METRI-PACK CONNECTORS

150 METRI-PACK CONNECTOR REPAIR

General

Metri-Pack connectors are embossed with the initials (P.E.D.).

There are two types of connectors in this series:

•

Pull-to-Seat

•

Push-to-Seat

Separating Pin and Socket Housings

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

Mating Pin and Socket Housings

Align the wire colors and push the pin and socket halves of the
connector together.

Removing Socket Terminal

1.

See

Figure A-37

for pull-to-seat connector or

Figure A-38

for push to seat connector. Remove wire lock (1) from wire
end of socket housing on push-to-seat type connectors.

NOTE

For best results, free one side of wire lock first and then release
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
and are on the same side as the external latch.

3.

Gently insert a safety 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 than it had previously. This is an indica-
tion that the tang has been depressed.

NOTE

On those terminals that have been extracted on multiple
occasions, the click may not be heard, but pivot the pin as if
the click was heard at least 3 times.

6.

Remove the pin.

a.

For pull-to-seat: Push on the lead to extract the ter-
minal from the mating end of the connector.

b.

For push-to-seat: Pull on the lead to draw the ter-
minal out the wire end.

Inserting Socket Terminal

NOTE

For wire location purposes, alpha characters are stamped into
the socket housings.

1.

See

Figure A-37

for pull-to-seat connector or

Figure A-38

for push to seat connector. Using a thin flat blade, like that
on a hobby knife, carefully bend the tang outward away
from the terminal body.

2.

Gently pull or push on the lead to install the terminal back
into the chamber. A click is heard when the terminal is
properly seated.

3.

Gently pull or push on the lead to verify that the terminal
is locked in place.

For push-to-seat: See

Figure A-38

. 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.

HOME

A-22 2009 Sportster Service: Appendix A Connector Repair

4

2

3

1

sm00027

1.

Locate tang in chamber

2.

Pivot pin to depress tang

3.

Push to remove

4.

Raise tang to install

Figure A-37. 150 Metri-Pack Connector: Pull-to-Seat

3

4

2

1

sm00028

1.

Remove wire lock

2.

Pivot pin to depress tang

3.

Pull to remove

4.

Raise tang to install

Figure A-38. 150 Metri-Pack Connector: Push-to-Seat

HOME

2009 Sportster Service: Appendix A Connector Repair A-23

A.11

PACKARD 280 METRI-PACK RELAY AND FUSE
BLOCK CONNECTORS

FUSE BLOCK REPAIR

Removing Socket Terminals

1.

See

Figure A-39

. To remove secondary locks, insert end

of small flat blade screwdriver (1) under lip of locking
wedge (2) and gently pry up secondary lock.

NOTE

For best results, start with locking wedge on outboard side of
secondary lock.

2.

Looking into chamber at top of fuse block, note the tang
next to each socket terminal.

3.

Using a thin flat blade, like that on a hobby knife, gently
push tang away from terminal, and then 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
color codes.

•

See

Figure A-40

. The main fuse block terminal cavity is

identified as alpha (1) and numeric (2) coordinates. Refer
to the main harness wiring diagram for fuse block terminal
cavity coordinates.

2.

With the open side of the socket terminal facing the tang,
push lead into chamber at the wire end of the fuse block.
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 and will not back out of the chamber.

4.

Install the secondary locks. With the locking wedges
positioned above the tangs in each chamber, slide flat
side of secondary lock into slot (between rows), and push
down until it bottoms.

Crimping Terminals

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.

NOTE

The wiring diagram indicates when one socket terminal is be
crimped to two wire leads.

1

2

sm00025

1.

Pry up secondary lock

2.

Lip of locking wedge

Figure A-39. Fuse Block: Remove Secondary Locks

3

A

C

D

E

F

G

H

J

1

2

4

B

1

2

sm00026

1.

Alpha

2.

Numeric

Figure A-40. Fuse Block: Coordinates (typical)

HOME

A-24 2009 Sportster Service: Appendix A Connector Repair

A.12

PACKARD 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-41

. 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-41

. 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-41

. 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.

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.

3.

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

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.14 PACKARD METRI-PACK TERMINALS

.

Installing Socket Terminals

1.

Carefully bend the tang outward away from the terminal
body.

2.

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.

3.

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

4.

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.

1

2

4

3

5

sm00031a

1.

Button on pin housing

2.

Secondary lock latch

3.

Opening between tang and chamber wall

4.

Secondary Lock (shown open)

5.

AFL housing

Figure A-41. 480 Metri-Pack Connector: Remove Socket

Terminal

HOME

2009 Sportster Service: Appendix A Connector Repair A-25

A.13

PACKARD 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

1.

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

2.

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.

3.

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

4.

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.

5.

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.

6.

If necessary, crimp new terminals on wires. Refer to

A.14 PACKARD 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.

1.

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

2.

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.

3.

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

4.

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

HOME

A-26 2009 Sportster Service: Appendix A Connector Repair

A.14

PACKARD 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-42

. 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.

1.

Squeeze and release handles until ratchet automatically
opens.

2.

Identify the corresponding sized nest for the core crimp.

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
will automatically open.

1

2

3

sm00035

1.

HD-38125-6 sealed terminals

2.

HD-38125-7 non-sealed terminals

3.

HD-38125-8 non-sealed terminals

Figure A-42. Metri-Pack Terminal Crimp Tools

Crimping Insulation/Seal

NOTE

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

HOME

2009 Sportster Service: Appendix A Connector Repair A-27

1.

See

Figure A-43

. Identify the correct die for the insula-

tion/seal crimp (2).

2.

Position the insulation/seal crimp in the nest. Be sure the
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-43

. 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

2

1

sm00036

1.

Wire core crimp

2.

Insulation crimp

3.

Seal crimp

Figure A-43. Metri-Pack Connector: Inspect Core and

Insulation/Seal Crimps

HOME

A-28 2009 Sportster Service: Appendix A Connector Repair

A.15

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.16 PACKARD

MICRO-64 CONNECTORS

and

A.14 PACKARD METRI-PACK

TERMINALS

.

Separating Socket Housing From ECM

See

Figure A-44

. 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

1.

See

Figure A-45

. 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.

2.

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

3.

See

Figure A-46

. 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.

4.

Push on wire lead to free terminal from chamber.

Installing Socket Terminal

1.

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

2.

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

3.

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

4.

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 PACKARD METRI-PACK TERMINALS

.

2

3

1

sm00037

1.

Thumb lever

2.

Latch

3.

Catch (ECM)

Figure A-44. Packard 100W to ECM (Typical)

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2009 Sportster Service: Appendix A Connector Repair A-29

1

3

5

1

4

2

sm00038

1.

Latch

2.

Secondary lock

3.

Cable strap

4.

Strain relief collar

5.

Conduit

Figure A-45. Packard 100W Connector

2

1

1

1

sm00039

1.

Pins

2.

Socket terminal

Figure A-46. Packard 100W Connector: Separate Halves

of Socket Housing

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A-30 2009 Sportster Service: Appendix A Connector Repair