Harley Davidson Softail Delux FLSTN BIKE 2011-2015. Service Manual — page 42
sm06094a
Figure A-27. Remove Ground Secondary Lock
sm06095a
Figure A-28. Remove ECM Ground Terminal
2013 Softail Service: Appendix A Connector Repair A-19
A.13
DEUTSCH DT SEALED CONNECTORS
DEUTSCH DT SEALED CONNECTOR
REPAIR
TOOL NAME
PART NUMBER
DEUTSCH TERMINAL REPAIR KIT
HD-41475
FLAT BLADE L-HOOK
HD-41475-100
General
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
.
NOTES
•
A DEUTSCH TERMINAL REPAIR KIT (Part No. HD-
41475) contains a selection of seals and seal plugs,
locking wedges, attachment clips and terminals.
•
Also included is a FLAT BLADE L-HOOK (Part No. HD-
41475-100) used to remove locking wedges, compart-
mented storage box and carrying case.
Separating Pin and Socket Housings
See
. To separate the connector halves, Press the
external latch(es) (1) on the socket housing (2) while rocking
the pin (3) and socket housings.
NOTES
•
Generally, the socket housing is found on the accessory
side, while the pin housing is attached to the wiring har-
ness.
•
Six-place and smaller Deutsch connectors have one latch
on the connector.
•
Eight- and twelve-place connectors have a latch on each
side. Simultaneously press both latches to separate the
connector.
Mating Pin and Socket Housings
1.
Align the connectors to match the wire lead colors.
a.
For One External Latch:
Six-place and smaller
Deutsch connectors have one external latch on the
socket housing. To join the housings, align the latch
on the socket side with the latch cover on the pin side.
b.
For Two External Latches:
Align the tabs on the
socket housing with the grooves on the pin housing.
2.
Insert socket housing into pin housing until it snaps or
clicks into place.
NOTE
For Two External Latches: If latches do not click (latch), press
on one side of the connector until that latch engages then press
on the opposite side to engage the other latch.
3.
If necessary, fit the attachment clip to the pin housing.
4.
Place large end of slot on attachment clip over T-stud on
frame. Push assembly forward to engage small end of
slot.
2
3
1
1
sm00017a
1. External latch
2. Socket housing
3. Pin housing
Figure A-29. Deutsch DT Sealed Connector
Removing Socket Terminals
1.
See
. Insert a small screwdriver between the
socket housing and locking wedge in-line with the groove
(in-line with the pin holes if the groove is absent). Turn the
screwdriver 90 degrees to pop the wedge up and remove
the secondary locking wedge.
2.
See
. Use a pick or small screwdriver to press
terminal latches inside socket housing and back out
sockets through holes in rear wire seal.
NOTE
If wire leads require new terminals, see the instructions for
crimping terminals.
Installing Socket Terminals
1.
Match wire lead color to connector cavity.
2.
See
. Fit rear wire seal (1) into back of socket
housing (2), if removed.
3.
Grasp wire lead (3) approximately 1.0 in (25.4 mm) behind
the socket terminal. Gently push socket through hole in
wire seal into its chambers until it clicks in place.
4.
A tug on the wire will confirm that it is properly locked in
place.
NOTE
Install seal plugs (6) into unused chambers. If removed, seal
plugs must be replaced to seal the connector.
5.
Install internal seal (4) on lip of socket housing, if removed.
6.
Insert tapered end of secondary locking wedge (5) into
socket housing and press down until it snaps in place. The
A-20 2013 Softail Service: Appendix A Connector Repair
wedge fits into the center groove within the socket housing
and holds the terminal latches tightly closed.
NOTES
•
See
. 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.
sm00009a
Figure A-30. Deutsch DT Sealed Connector: Remove
Secondary Locking Wedge
2
1
sm00018
1. Arrow on socket locking wedge
2. Arrow on pin locking wedge
Figure A-31. Deutsch DT Sealed Connector: 3-Place
Locking Wedges
2013 Softail Service: Appendix A Connector Repair A-21
DEUTSCH
6
1
2
3
4
5
sm00010
1. Wire seal
2. Socket housing
3. Wire lead
4. Internal seal
5. Secondary locking wedge
6. Seal plug
Figure A-32. Deutsch DT Sealed Connector: 2, 3, 4 and
12-Place Socket Housings
Removing Pin Terminals
1.
Use the hooked end of a stiff piece of mechanics wire, a
needle nose pliers or the FLAT BLADE L-HOOK (Part
No. HD-41475-100) to remove the secondary locking
wedge.
2.
Gently press terminal latches inside pin housing and back
out pins through holes in wire seal.
NOTES
•
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
Figure A-33. Deutsch DT Sealed Connector: Press Terminal
Latch and Back Out Pin
Installing Pin Terminals
1.
See
. Fit wire seal (1) into back of pin housing
(2).
2.
Grasp wire lead approximately 1.0 in (25.4 mm) behind
the pin terminal (3). Gently push pin through holes in wire
seal into its respective numbered chamber until it "clicks"
in place.
NOTE
A tug on the wire lead will confirm that a pin is locked in place.
3.
Insert tapered end of secondary locking wedge (4) into
pin housing. Press down until it snaps in place.
NOTES
•
The wedge fits in the center groove of the pin housing and
holds the terminal latches tightly closed.
•
See
. 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 Softail Service: Appendix A Connector Repair
DEUTSCH
1
2
3
4
sm00020
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
Crimping Terminals
Identify which of the types of Deutsch terminals are used with
the connector. Follow the corresponding crimping instructions.
Refer to
.
Table A-2. Deutsch Connector: Terminal Crimping Instructions
CRIMPING INSTRUCTIONS
TYPE
A.14 DEUTSCH DT SEALED TERMINAL REPAIR
DT Sealed (with crimp tails)
A.16 DEUTSCH DTM SEALED SOLID BARREL MINI TERMINAL REPAIR
DTM Mini Sealed Terminal (solid
barrel)
A.15 DEUTSCH DTM SEALED MINI TERMINAL REPAIR
DTM Mini Sealed Terminal (with crimp
tails)
2013 Softail Service: Appendix A Connector Repair A-23
A.14
DEUTSCH DT SEALED TERMINAL REPAIR
DEUTSCH DT SEALED TERMINAL CRIMPS
TOOL NAME
PART NUMBER
DEUTSCH TERMINAL CRIMP TOOL
HD-39965-A
Preparing Wire Leads for Crimping
1.
Use a shop gauge to determine gauge of wire lead.
2.
Strip 5/32 in (4.0 mm) of insulation from the wire lead.
Crimping Terminal to Lead
1.
See
. Squeeze the handles of the DEUTSCH
TERMINAL CRIMP TOOL (Part No. HD-39965-A) to open
the jaws. Push the locking bar (1) up.
2.
Match the wire gauge to the crimp tool die. Refer to
.
NOTE
Rest the rounded side of the contact barrel in the nest (concave
split level area) with the crimp tails facing up.
3.
Insert (2) terminal (socket/pin) through hole of the locking
bar.
4.
Release locking bar to lock terminal in die.
NOTE
If the crimp tails are slightly out of alignment, the crimp tool
rotates the terminal to face the tails upward. When positioned,
the locking bar fits snugly in the space between the contact
band and the core crimp tails.
5.
Insert stripped wire core 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.
6.
Squeeze handle of crimp tool until tightly closed. Tool
automatically opens after the terminal is crimped.
7.
Raise locking bar up to remove wire lead and terminal.
Inspecting Crimps
Inspect the wire core and insulation crimps. Distortion should
be minimal.
Table A-3. Deutsch DT Sealed Terminal Crimp: Wire Gauge
To Die
CRIMP TOOL DIE
WIRE GAUGE (AWG)
Front
20
Middle
16-18
2
5
4
6
1
3
sm00021
4.
1.
Insert stripped lead
Open jaws and raise locking bar
2.
5.
Insert terminal in locking bar
Squeeze crimper
6.
3.
Raise locking bar to remove terminal
Release locking bar to lock terminal in die
Figure A-35. Crimping a Deutsch DT Sealed Terminal
A-24 2013 Softail Service: Appendix A Connector Repair
A.15
DEUTSCH DTM SEALED MINI TERMINAL
REPAIR
DEUTSCH DTM SEALED MINI TERMINAL
CRIMPS
TOOL NAME
PART NUMBER
PACKARD TERMINAL CRIMPER
HD-38125-7
Preparing Wire Leads for Crimping
Strip 5/32 in (4.0 mm) of insulation from the wire lead.
Crimping a Mini Terminal to Wire Lead
1.
See
. 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-
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
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-36. Packard Terminal Crimper (HD-38125-7)
2013 Softail Service: Appendix A Connector Repair A-25
A.16
DEUTSCH DTM SEALED SOLID BARREL MINI
TERMINAL REPAIR
DEUTSCH DTM SEALED 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 1/4 in (6.4 mm) of insulation from the wire lead.
Adjusting Crimper Tool
1.
See
. 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. 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
. 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
closed. Tool automatically opens when the crimping
sequence is complete.
5.
Remove wire lead with crimped contact from indentor.
NOTE
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.
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-37. Electrical Crimper Tool (HD-42879)
A-26 2013 Softail Service: Appendix A Connector Repair
HDT
- 48
- 00
JDG360-1
HEMET
RYAN
AIRPOR
T, P
.O
. BO
X 878
HEMET
, CA.
92343-0161
(714)
929-1200
INDUSTRIAL
PRODUCTS
DIVISION
HDT
- 48
- 00
JDG360-1
HEMET
RYAN
AIRPOR
T, P
.O
. BO
X 878
HEMET
, CA.
92343-0161
(714)
929-1200
INDUSTRIAL
PRODUCTS
DIVISION
2
1
3
4
3
sm00024
1. Contact barrel
2. Indentor cover
3. Indentor point
4. Stripped wire lead
Figure A-38. Deutsch Solid Barrel
2013 Softail Service: Appendix A Connector Repair A-27
A.17
JAE MX19 SEALED CONNECTORS
JAE MX19 SEALED CONNECTORS
TOOL NAME
PART NUMBER
TERMINAL EXTRACTOR
B-50085
Connector Housings
Separate Housings:
See
. Press the two release
buttons on each side of the housing to separate the connector.
Connect Housings:
Align housings. Press together until the
locking tabs click.
sm06925
Figure A-39. Release Buttons: JAE MX19 Sealed Connector
Removing Terminals
1.
Modify a TERMINAL EXTRACTOR (Part No. B-50085) by
filing the front edge to 45 degrees.
2.
See
. Insert the extractor (1) into the opening
above the terminal and press the plastic molding (2) up
and out of the way.
3.
Pull the wire lead and terminal out of the back of the
housing.
Installing Terminals
1.
Inspect the plastic molding and replace the connector
housing if necessary.
2.
Orient the terminal to the housing. Push terminal into
housing until it clicks into place.
1
2
2
1
sm06926
1. Extractor
2. Plastic molding
Figure A-40. JAE MX19 Terminal Removal
CRIMPING TERMINALS
TOOL NAME
PART NUMBER
UNIVERSAL CRIMPER SET
HD-50120
HAND CRIMP FRAME
HD-50120-2
JAE DIE
HD-50120-6
1.
Strip the wire insulation to specification. Refer to
2.
Install the JAE DIE (Part No. HD-50120-6) in the handle
of 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.
4.
Insert the wire to the wire stop. Crimp the terminal.
5.
Inspect the crimped terminal.
Table A-4. JAE MX19 Crimper Die (Part No. HD-50120-6)
NEST
STRIP LENGTH
PART NO.
TERMINAL
mm
in
B
2.0-2.5
0.051-0.098
72910-11
Socket
A
2.0-2.5
0.051-0.098
72909-11
Pin
A-28 2013 Softail Service: Appendix A Connector Repair
A.18
MOLEX CMC SEALED CONNECTORS
MOLEX CMC SEALED CONNECTORS
TOOL NAME
PART NUMBER
0.6 MM TERMINAL EXTRACTOR
TOOL
HD-50423
1.5 MM TERMINAL EXTRACTOR
TOOL
HD-50424
Separating the Connector
Release:
See
. Press the catch and rotate the lever
arm down.
Connect:
Press on the front guard to release the latch and
rotate the lever arm up until the catch clicks in place.
sm06931
Figure A-41. Release
Removing Terminals
1.
With the lever arm open, cut the cable strap around the
wire bundle.
2.
See
. Open a wire cap latch (1) with a small
screwdriver.
3.
Maintain pressure on the cap and open the opposite latch
(2) with the screwdriver.
4.
Slide the cap off (3).
5.
See
. Use the screwdriver to open the sec-
ondary lock. Pull the locking bar all the way out.
6.
See
. 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).
8.
See
. Insert the pins of the CMC extractor tool
(1) into the access slots (2) of the terminal cavity and
retract the lead and terminal.
Installing Terminals
1.
Orient the terminal to the housing cavity. Snap the terminal
in place.
2.
Slide the cap over the lead bundle. Snap the cap in place.
3.
Install a cable strap through the guide and around the lead
bundle.
2
1
3
sm06936
1. Press latch
2. Press cap and latch
3. Remove cap
Figure A-42. Remove the Wire Lead Cap
sm06928
Figure A-43. Molex CMC Sealed Connector Secondary
Lock
2013 Softail Service: Appendix A Connector Repair A-29
2
2
1
1
2
2
sm06927
1. Alpha
2. Numeric
Figure A-44. Alpha-Numeric Coordinates
1
2
sm06935
1. Extractor tool
2. Access slots
Figure A-45. Terminal Removal
CRIMPING TERMINALS
TOOL NAME
PART NUMBER
UNIVERSAL CRIMPER SET
HD-50120
HAND CRIMP FRAME
HD-50120-2
JAE DIE
HD-50120-3
JAE DIE
HD-50120-4
1.
Select the crimper die according to the terminal part
number from the UNIVERSAL CRIMPER SET (Part
No. HD-50120).
2.
Strip the wire insulation to specification. Refer to
or
3.
Install the JAE DIE (Part No. HD-50120-3) or JAE DIE
(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.
5.
Insert the wire to the wire stop. Crimp the terminal.
6.
Inspect the crimped terminal.
Table A-5. Molex CMC Sealed Crimper Die (Part No.
HD-50120-3)
NEST
STRIP LENGTH
TERMINAL:
WIRE GAUGE
PART
NO.
mm
in
B
4.5
0.177
Socket: 16 AWG
72226-11
A
4.5
0.177
Socket: 18 AWG
72227-11
Table A-6. Molex CMC Sealed Crimper Die (Part No.
HD-50120-4)
NEST
STRIP LENGTH
TERMINAL:
WIRE GAUGE
PART NO.
mm
in
B
3.5
0.138
Socket: 18 AWG
72222-11
A
3.5
0.138
Socket: 20 AWG
72222-11
A-30 2013 Softail Service: Appendix A Connector Repair
A.19
MOLEX MX 150 SEALED CONNECTORS
MOLEX MX 150 SEALED CONNECTOR
REPAIR
TOOL NAME
PART NUMBER
TERMINAL REMOVER
HD-48114
Separating Pin and Socket Housings
See
. 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
. Use a small
screwdriver in the pry slot. The slot next to the
external latch provides a pivot point.
b.
Pin Housing:
See
. 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
. 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.
Installing Terminals
1.
See
. 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.
5.
With all terminals installed, push the secondary lock into
the socket housing to lock the wire terminals into the
housing.
sm00040a
Figure A-46. Molex MX 150 Sealed Connector: Latch
sm03332a
Figure A-47. Secondary Lock Pry Slot (Socket Housing)
2013 Softail Service: Appendix A Connector Repair A-31
sm02851a
Figure A-48. Pull Up Secondary Lock
sm00043a
Figure A-49. Molex MX 150 Sealed Connector: Terminal
Remover (HD-48114)
1
3
2
sm00044
1. Cavity number
2. Tang
3. Cavity slot
Figure A-50. Molex MX 150 Sealed Connector: Pin Cavities
and Wire Terminal
CRIMP TERMINAL TO LEAD
TOOL NAME
PART NUMBER
TERMINAL CRIMPER
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 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.
Prepare Tool
1.
Identify the punch/die in the jaws of the TERMINAL
CRIMPER (Part No. HD-48119) for the wire gauge. Refer
to
2.
Squeeze and release the handles to open the tool.
NOTE
The crimp tool automatically opens when the handles are
released.
3.
See
. 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.
Table A-7. 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.
A-32 2013 Softail Service: Appendix A Connector Repair
sm02853a
Figure A-51. Open Terminal Crimper (HD-48119) at 45
Degrees
1
2
sm02854a
1. Socket locator bar
2. Pin locator bar
Figure A-52. Terminal Locator Bars
Position Terminal in the Punch/Die
1.
See
. 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
. A socket terminal
stops against the back face of the socket locator bar
(1).
b.
Pin Terminal:
See
. 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
. Ratchet the handles together until the
crimp tails are held in vertical alignment between the punch
and the die.
sm02855a
Figure A-53. Square Openings in Socket Locator Bar
Insert Stripped Lead
See
. 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.
sm02856a
Figure A-54. Pin Terminal against Pin Locator Bar
2013 Softail Service: Appendix A Connector Repair A-33
sm02857a
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
Open a stuck or jammed tool by pressing the ratchet release
lever found between the handles. Do not force the handles
open or closed.
sm02858a
Figure A-56. Stripped Lead at Up Angle
Inspect Crimp
1.
Inspect Crimp:
Inspect the core and insulation crimp.
a.
See
. 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.
1
3
2
sm02859
1. Core crimp
2. Wire strands
3. Insulation crimp
Figure A-57. Terminal Crimp
A-34 2013 Softail Service: Appendix A Connector Repair
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