Harley Davidson Softail Delux FLSTN BIKE 2011-2015. Service Manual — page 40
8
1
2
3
4
5
6
7
sm00068a
1. First gear
2. Second gear
3. Third gear
4. Fourth gear
5. Fifth gear
6. Sixth gear
7. Mainshaft
8. Countershaft
Figure 6-1. Transmission Power Flow
2013 Softail Service: Transmission 6-5
6.4
SHIFTER
ADJUSTMENT
If operating problems exist, check the shift linkage for wear,
interference or adjustment. Adjust if necessary.
SHIFTER ROD ADJUSTMENT
TORQUE VALUE
FASTENER
7.9-10.2 Nm
70-90
in-lbs
Shifter rod to lever locknut
9.0-13.6 Nm
80-120
in-lbs
Shifter rod jam nut
The shifter rod length is set at the factory and should not require
adjustment under normal circumstances. However, if full
engagement or full lever travel is not achieved, adjust the shifter
rod.
NOTE
Do not allow shift levers to contact footboard when shifting.
This prevents proper gear engagement. Contact may also
damage the transmission.
1.
See
. Remove locknut, lockwasher and flat
washer (3) to free front end of shifter rod from inner shift
arm.
2.
Loosen jamnuts (1) and adjust rod (2) as necessary.
3.
Install flat washer, lockwasher and locknut to fasten shifter
rod to inner shift arm.
4.
Tighten locknut (3) with lockwasher and flat washer to
70-90
in-lbs
(7.9-10.2 Nm).
5.
Tighten jamnuts (1) to 80-120
in-lbs
(9.0-13.6 Nm).
2
1
3
1
sm02581
1. Jamnut (2)
2. Shifter rod
3. Locknut, lockwasher, flat washer
Figure 6-2. Shifter Rod
SHIFT LEVER REPLACEMENT
TORQUE VALUE
FASTENER
24.4-29.9 Nm
18-22 ft-lbs
Shift lever pinch bolts: all but
FXS
17.6-21.7 Nm
13-16 ft-lbs
Shift lever pinch bolt: FXS
10.9-16.3 Nm
96-144
in-lbs
Shifter peg
NOTE
After placing shift lever on pivot lever, make sure footboard
does not interfere with shift lever range of motion.
•
See
. Position shift levers for comfort.
•
All but FXS/B/T:
tighten pinch bolts to 18-22 ft-lbs (24.4-
29.9 Nm).
•
FXS/B/T Only:
tighten pinch bolt to 13-16 ft-lbs (17.6-21.7
Nm).
•
Tighten shifter peg to 96-144
in-lbs
(10.9-16.3 Nm).
6-6 2013 Softail Service: Transmission
1
2
3
4
5
6
7
8
9
10
11
13
14
12
sm02280a
8.
1.
Washer (FXS/B)
Pinch bolt, front (all but FXS/B)
2.
9.
Shifter peg, rear (all but FXS/B)
Shift lever (FXS/B)
10.
3.
Shifter peg (FXS/B)
Shift lever, rear (all but FXS/B)
4.
11.
Pinch bolt, rear (all but FXS/B)
Spacer
12.
5.
Bushing (2)
Shifter peg, front (all but FXS/B)
6.
13.
Shift lever, front (all but FXS/B)
O-ring (2)
14.
7.
Pivot lever
Pinch bolt (FXS/B)
Figure 6-3. Shift Lever Assembly
2013 Softail Service: Transmission 6-7
6.5
CLUTCH RELEASE COVER
REMOVAL AND DISASSEMBLY
1.
Remove main fuse.
2.
Remove exhaust system if needed. See
3.
Drain transmission. See
RICANT, Changing Transmission Lubricant
.
NOTE
Actuating the clutch hand lever after removing the six screws
will help break the cover free.
4.
See
. Remove the six screws that hold the clutch
release cover in place. Remove the clutch release cover
and discard the gasket.
5.
Add freeplay to clutch cable. See
.
Wear safety glasses or goggles when removing or
installing retaining rings. Retaining rings can slip from the
pliers and could be propelled with enough force to cause
serious eye injury. (00312a)
6.
See
. Remove retaining ring (4). Lift inner ramp
(5) and ramp coupling (3) out of clutch release cover.
Disconnect clutch cable end (2) from the ball and ramp
coupling.
7.
See
. Remove balls (4) and outer ramp (2).
8.
Unscrew clutch cable fitting from clutch release cover.
2
4
1
3
5
6
sm03675
Figure 6-4. Cover Screws
1
4
5
6
3
2
sm03008
1. Cable fitting
2. Clutch cable end
3. Ramp coupling
4. Retaining ring
5. Inner ramp
6. Retaining ring opening
Figure 6-5. Clutch Cable Connection
2
4
3
1
5
sm03009
1. Inner ramp
2. Outer ramp
3. Outer ramp tab
4. Balls (3)
5. Ramp coupling
Figure 6-6. Coupling and Ramp Assembly
CLEANING AND INSPECTION
1.
See
. Wash the ball and ramp mechanism
components in cleaning solvent.
6-8 2013 Softail Service: Transmission
2.
Inspect the three balls (2) and ball socket surfaces on
ramps (1, 3) for wear, pitting, surface breakdown and other
damage. Replace as necessary.
3.
Check fit of the ramp coupling (4) on inner ramp (1).
Replace both parts if there is excessive wear.
4.
Inspect the retaining ring (6) for damage or distortion.
5.
Check clutch cable end for frayed or worn ends. Replace
cable if damaged or worn. Check cable fitting O-ring for
damage.
6.
Check the bore in the clutch release cover (5) where the
ramps (1, 3) are retained. There should be no wear that
would cause the ramps to tilt, causing improper clutch
adjustment.
1
6
7
4
8
5
2
3
sm03010
1. Inner ramp
2. Balls (3)
3. Outer ramp
4. Ramp coupling
5. Clutch release cover
6. Retaining ring
7. Gasket
8. Tab
Figure 6-7. Release Mechanism Assembly
ASSEMBLY AND INSTALLATION
TORQUE VALUE
FASTENER
14.9-17.6 Nm
132-156
in-lbs
Clutch release cover screws
10.2-13.6 Nm
90-120
in-lbs
Clutch cable fitting
NOTE
Replace cable fitting O-ring if damaged or deformed.
1.
See
. Apply a drop of LOCTITE 243 MEDIUM
STRENGTH THREADLOCKER AND SEALANT (blue) to
clutch cable fitting (1) and screw fitting into clutch release
cover. Do not tighten at this time.
2.
See
. Place outer ramp (3) with ball socket side
up in clutch release cover. Be sure tab (8) is in clutch
release cover slot.
3.
Apply a multi-purpose grease to the balls (2) and outer
ramp sockets. Place a ball in each of the outer ramp
sockets.
4.
Connect cable end to ramp coupling (4). Install coupling
on inner ramp (1) and place inner ramp and coupling in
position in clutch release cover (5).
Wear safety glasses or goggles when removing or
installing retaining rings. Retaining rings can slip from the
pliers and could be propelled with enough force to cause
serious eye injury. (00312a)
NOTE
See
. Center retaining ring opening above the break
in the ribbing at bottom of the clutch release cover.
5.
. Install retaining ring (6).
6.
Verify that two dowel pins are in place on transmission
bearing housing flange. Place a
new
gasket (7) on dowel
pins.
NOTE
See
. Clutch release cover screws in positions (1)
and (6) are shorter than the others.
7.
See
. Install clutch release cover. Tighten all six
screws to 132-156
in-lbs
(14.9-17.6 Nm) in sequence
shown.
8.
Tighten clutch cable fitting to 90-120
in-lbs
(10.2-13.6
Nm).
9.
Fill transmission to proper level with fresh transmission
fluid. See
10. Adjust clutch cable. See
.
11. Install exhaust system if removed. See
.
12. Install main fuse.
2013 Softail Service: Transmission 6-9
6.6
TRANSMISSION ASSEMBLY
REMOVAL
NOTE
Leave the transmission case in the frame unless the case itself
requires replacement. For illustration purposes, some photo-
graphs may show the case removed. For information on case
removal see
.
1.
Remove exhaust system. See
.
2.
Remove oil tank. See
.
3.
Relieve drive belt tension. See
4.
Remove primary chaincase cover, clutch assembly,
primary chain, compensating sprocket assembly and
primary chaincase. See
.
5.
Remove the bearing inner race from the transmission
mainshaft. See
5.5 PRIMARY CHAINCASE HOUSING,
6.
Remove the clutch release cover from the transmission
bearing housing. See
.
7.
See
. Remove oil slinger assembly from main-
shaft. Remove pushrod.
8.
Remove transmission top cover, leaving the cover gasket
in place.
9.
See
. Place shifter cam pawl on top cover
gasket.
4
1
3
5
6
2
sm03013
1. Retaining ring
2. Thrust washer (2)
3. Throw out bearing
4. Oil slinger
5. Pushrod
6. Pushrod end, left side
Figure 6-8. Pushrod Assembly: Cable Clutch
2
1
sm03011
1. Shifter pawl
2. Top cover gasket surface
Figure 6-9. Set Shifter Pawl on Gasket
NOTE
Remove and install sprocket nut only while transmission is in
vehicle frame. Trying to remove and install sprocket nut with
transmission in transmission stand may cause damage to
transmission or stand.
10. If main drive gear is to be removed, see
.
NOTES
•
Replace the main drive gear bearing and retainer if the
main drive gear is removed. The bearing will be damaged
during the removal procedure.
•
Never attempt to remove bearing housing by tapping on
shafts from opposite side. Tapping them with a hammer
will damage the bearing housing bearings. If the bearing
housing sticks or binds on the ring dowels, pry loose using
indents at each side of bearing housing.
11. Cover mainshaft clutch hub splines with tape to prevent
the splines from damaging the main drive gear bearings.
12. See
. Remove the transmission bearing
housing:
a.
Remove the transmission bearing housing mounting
hardware.
b.
Remove exhaust bracket, if equipped.
c.
Pry the bearing housing loose.
d.
Remove bearing housing, mainshaft, countershaft
and shifter cam from transmission case as an
assembly.
e.
Discard gasket.
6-10 2013 Softail Service: Transmission
8
7
6
5
4
3
2
1
sm02582
1. Locknut (2)
2. Retaining ring (2)
3. Bearing (2)
4. Bearing housing
5. Bearing housing gasket
6. O-ring
7. Transmission dipstick
8. Transmission case
Figure 6-10. Bearing Housing Bearings
2
1
1
1
1
1
sm02595
1. Bolt (8)
2. Bearing housing
Figure 6-11. Bearing Housing Hardware
DISASSEMBLY
TOOL NAME
PART NUMBER
TRANSMISSION SHAFT RETAINING
RING PLIERS
J-5586A
Shifter Cam/Shifter Forks
1.
See
. Disassemble bearing housing assembly:
a.
Place bearing housing on end (shafts pointing
upward).
b.
Remove shift fork shafts using easy-out screw
extractor (14) (non-flute design) or vise grips. Shafts
have slight interference fit. Shafts can be reused; do
not damage end of shaft.
c.
Mark end of shaft to aid during assembly.
2.
Remove shift forks from dog rings.
3.
See
. Remove lock plate fasteners (3) from
lock plate (2). Discard fasteners.
4.
See
. Insert screwdriver and gently pry back
detent arm (4) to remove detent spring (3) tension from
shift cam (5). Remove shift cam.
5.
If servicing detent assembly, remove detent screw (2),
detent arm (4), sleeve and detent spring (3). Discard detent
screw.
NOTE
Many transmission parts can be installed in either direction.
To prolong usable life, install used parts in same direction as
when removed.
6.
See
. Using dog rings, lock two gears in place.
Temporarily place transmission assembly into transmission
case.
7.
Remove mainshaft and countershaft locknuts.
8.
Remove transmission assembly from transmission case.
2013 Softail Service: Transmission 6-11
3
4
5
6
7
1
2
13
14
12
11
10
9
8
sm05070a
1. Mainshaft
2. Countershaft
3. Mainshaft 1st gear
4. Mainshaft 2nd gear
5. Mainshaft 3rd gear
6. Mainshaft 4th gear
7. Mainshaft 5th gear
8. Countershaft 1st gear
9. Countershaft 2nd gear
10. Countershaft 3rd gear
11. Countershaft 4th gear
12. Countershaft 5th gear
13. Countershaft 6th gear
14. Screw extractor
Figure 6-12. Gear Set
1
3
3
2
4
sm03600a
1. Bearing housing
2. Lock plate
3. Lock plate fastener (2)
4. Shift cam
Figure 6-13. Shift Drum
6-12 2013 Softail Service: Transmission
7.36
RIGHT HANDLEBAR CONTROL MODULE
REMOVAL
To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before pro-
ceeding. (00251b)
1.
Remove main fuse.
NOTE
Fuel tank crossover hose does not need to be disconnected.
Once all other connections to fuel tank have been removed,
fuel tank can be slid back enough to reveal handlebar switch
assembly connectors.
2.
Remove fuel tank. See
.
3.
See
. Disconnect right hand control con-
nectors (1, 2).
4.
Loosen the upper handlebar clamp-to-master cylinder
housing screw. Remove the lower handlebar clamp-to-
master cylinder housing screw.
5.
Remove the upper and lower switch housing screws.
6.
Remove the friction shoe from the end of the tension
adjuster screw.
NOTE
The friction shoe is a loose fit and may fall out or become dis-
lodged if the lower switch housing is turned upside down or
shaken.
7.
Loosen cable adjusters. See
8.
See
. Remove the brass ferrules (4) from the
notches on the inboard side of the throttle control grip.
Remove the ferrules from the cable end fittings.
9.
Remove the throttle control grip from the end of the
handlebar.
10. See
. If replacing lower switch housing, pull
inserts (1, 2) from lower switch housing. Use a rocking
motion while pulling. Place a drop of light oil on the
retaining rings, if necessary. Remove the cables from the
switch housing.
11. See
. Remove screws (3) and retainer (1).
NOTE
Record wire routing before removal.
12. Carefully remove brake switch (2) and switch assembly
from lower switch housing. Remove switch assembly.
1
2
3
sm07233
1. Right hand controls [22-1]
2. Right hand controls [22-2]
3. Front turn signals [31]
Figure 7-108. Under Fuel Tank Right Side
5
4
3
2
1
sm01084a
1. Throttle cable (silver insert, front hole)
2. Groove in throttle grip
3. Notch
4. Brass ferrule
5. Idle cable (gold insert, rear hole)
Figure 7-109. Throttle Cable Attachment
7-76 2013 Softail Service: Electrical
1
3
2
sm02636a
1. Idle cable insert (gold insert, rear hole)
2. Throttle cable insert (silver insert, front hole)
3. Tension adjuster screw
Figure 7-110. Right Lower Module Housing
2
1
3
sm07031
1. Retainer
2. Brake switch
3. Screw (2)
Figure 7-111. Right Control Module and Brake Switch
Retainer
INSTALLATION
TORQUE VALUE
FASTENER
0.9-1.1 Nm
8-10
in-lbs
Handlebar switch assembly
retainer screws
6.8-9.0 Nm
60-80
in-lbs
Handlebar clamp to master
cylinder screws
4.0-5.1 Nm
35-45
in-lbs
Handlebar switch housing
screws
NOTE
When installing switch assembly and retainer, make sure wires
do not get pinched and that the rubber grommet on the wire
harness is properly placed on the switch housing.
1.
See
. Place switch assembly into position on
lower switch housing and carefully install brake switch (2).
2.
Install retainer (1) with screws (3). Tighten screws to 8-10
in-lbs
(0.9-1.1 Nm).
3.
See
. If previously removed from lower switch
housing, push the throttle and idle control cables into the
lower switch housing until they snap in place. Note the
different diameter inserts crimped into the end of the
throttle and idle cable housings.
a.
Push the silver insert (2) of throttle cable housing into
the hole in front of tension adjuster screw (3).
b.
Push the gold insert (1) of idle cable housing into the
hole at the rear of tension adjuster screw (3).
NOTE
To aid assembly, place a drop of light oil on the retaining rings
of the crimped inserts. Always replace the retaining rings if
damaged or distorted.
4.
Slide the throttle control grip over the end of the right
handlebar until it bottoms against the closed end. Rotate
the grip so that the ferrule notches are at the top. To pre-
vent binding, pull the grip back about 1/8 in (3.2 mm).
5.
With the concave side facing upward, install the friction
shoe so that the pin hole is over the point of the adjuster
screw.
NOTE
The friction shoe is a loose fit and may fall out or become dis-
lodged if the lower switch housing is turned upside down or
shaken.
6.
See
. Position lower switch housing beneath
the throttle control grip. Install the brass ferrules (4) onto
the cable so that the end fittings seat in the ferrule recess.
Seat the ferrules in their respective notches (3) on the
throttle control grip. Verify that the cables are captured in
the grooves (2) molded into the grip.
2013 Softail Service: Electrical 7-77
1
2
2
sm04496a
1. Clamping surface
2. Range marks
Figure 7-112. Right Hand Control Assembly to Handlebar
Alignment
NOTE
See
. When installing right handlebar switch
assembly for motorcycles with internally wired handlebars,
make sure the clamping surface (1) stays within the range
marks (2) or damage to the wires will occur.
7.
Position the upper switch housing over the handlebar and
lower switch housing.
8.
Start the upper and lower switch housing screws, but do
not tighten.
9.
See
. Position the brake lever/master cylinder
assembly inboard of the switch housing assembly, enga-
ging the tab (2) on the lower switch housing in the groove
(3) at the top of the brake lever bracket.
10. Install the lower handlebar clamp-to-master cylinder
housing screw (with flat washer). Position for rider comfort.
Beginning with the top screw, tighten to 60-80
in-lbs
(6.8-
9.0 Nm).
11. Tighten lower and upper switch housing screws to 35-45
in-lbs
(4.0-5.1 Nm).
NOTE
Always tighten the lower switch housing screw first so that any
gap between the upper and lower housings is at the front of
the switch.
12. Adjust throttle cables. See
.
13. See
. Connect right hand control connectors
(1, 2).
14. Secure harness with clamps and cable strap as noted
during removal.
15. Install fuel tank. See
.
16. Install main fuse. See
.
Be sure that all lights and switches operate properly before
operating motorcycle. Low visibility of rider can result in
death or serious injury. (00316a)
17. Test the switches for proper operation.
4
3
2
1
sm07068
1. Module housing assembly
2. Tab
3. Groove
4. Brake lever bracket
Figure 7-113. Module Housing Alignment
FRONT BRAKE SWITCH REPLACEMENT
TORQUE VALUE
FASTENER
0.9-1.1 Nm
8-10
in-lbs
Handlebar switch assembly
retainer screws
1.
Remove upper switch housing cover. See
HANDLEBAR CONTROL MODULE, Removal
.
2.
See
. From inside the switch housing, remove
screws (3) and retainer (1). Remove brake switch (2) from
housing.
3.
Cut wires flush at inoperative brake switch.
4.
If
new
brake switch wires have terminals installed, cut
wires at terminal end.
5.
Remove 0.25-0.3125 in. (6.4-7.9 mm) of insulation from
each wire end.
6.
Cut two pieces of dual wall heat-shrink tubing to a length
of 0.5 in. (12.7 mm).
7.
Solder wires together and cover with heat-shrink tubing.
See
7.35 HANDLEBAR CONTROL MODULES, Repair
8.
See
. Install brake switch (2) into housing.
Install retainer (1) and screws (3). Tighten screws to 8-10
in-lbs
(0.9-1.1 Nm).
9.
Assemble right handlebar switch housing. See
HANDLEBAR CONTROL MODULE, Installation
.
7-78 2013 Softail Service: Electrical
7.37
LEFT HANDLEBAR CONTROL MODULE
REMOVAL
To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before pro-
ceeding. (00251b)
1.
Remove main fuse.
NOTE
Fuel tank crossover hose does not need to be disconnected.
Once all other connections to fuel tank have been removed,
fuel tank can be slid back enough to reveal handlebar switch
assembly connectors.
2.
Remove fuel tank. See
.
3.
See
. Disconnect left hand control connector
(2).
4.
Loosen the upper handlebar clamp-to-clutch lever screw.
Remove the lower handlebar clamp-to-clutch lever screw.
5.
Remove the upper and lower switch housing screws.
Remove upper switch housing.
6.
See
. Remove screws (3) and retainer (1).
7.
Carefully remove clutch switch (2) and switch assembly
from lower switch housing.
NOTE
Make note of wire routing along with clamp and cable strap
locations before removal.
8.
Remove switch assembly from motorcycle.
5
4
1
2
3
6
sm07179a
1. Instruments [20]
2. Left hand control [24]
3. Fuel gauge [117]
4. Front wheel speed sensor [167]
5. Headlamp [38]
6. Front fender tip lamp [32]: FLSTC
Figure 7-114. Under Fuel Tank Left Side
2
1
3
sm07034
a
1. Retainer
2. Clutch switch
3. Screw (2)
Figure 7-115. Left Handlebar Control Module and Clutch
Switch Retainer
INSTALLATION
TORQUE VALUE
FASTENER
0.9-1.1 Nm
8-10
in-lbs
Handlebar switch assembly
retainer screws
6.8-9.0 Nm
60-80
in-lbs
Handlebar clamp to clutch
lever bracket screws
4.0-5.1 Nm
35-45
in-lbs
Handlebar switch housing
screws
NOTE
When installing switch assembly and retainer, make sure wires
do not get pinched and that the rubber grommet on the wire
harness is properly placed on the switch housing.
1.
See
. Place switch assembly into position on
lower switch housing and carefully install clutch switch (2).
2013 Softail Service: Electrical 7-79
2
2
1
sm03982b
1. Clamping surface
2. Range marks
Figure 7-116. Left Hand Control Assembly to Handlebar
Alignment
NOTE
See
. When installing left handlebar switch
assembly for motorcycles with internally wired handlebars,
make sure the clamping surface (1) stays within the range
marks (2) or damage to the wires will occur.
2.
Install retainer (1) with screws (3). Tighten to 8-10
in-lbs
(0.9-1.1 Nm).
3.
Position the upper switch housing over the handlebar and
lower switch housing.
4.
Start the upper and lower switch housing screws, but do
not tighten.
5.
See
. Position the clutch hand lever assembly
inboard of the switch housing assembly, engaging the tab
(3) on the lower switch housing in the groove (2) at the
bottom of the clutch lever bracket.
6.
Secure the handlebar switch clamp to the clutch lever
bracket with two screws (with flat washers). Position for
rider comfort. Beginning with the top screw, tighten to
60-80
in-lbs
(6.8-9.0 Nm).
7.
Tighten switch housing screws to 35-45
in-lbs
(4.0-5.1
Nm).
NOTE
Always tighten the lower switch housing screw first so that any
gap between the upper and lower housings is at the front of
the switch.
8.
See
. Connect left hand control connector
(2).
9.
Secure harness with clamps and cable strap as noted
during removal.
10. Install fuel tank. See
.
11. Install main fuse. See
.
Be sure that all lights and switches operate properly before
operating motorcycle. Low visibility of rider can result in
death or serious injury. (00316a)
12. Test the switches for proper operation.
4
2
3
1
sm02631
1. Clutch lever bracket
2. Groove
3. Tab
4. Switch housing assembly
Figure 7-117. Clutch Lever Bracket
CLUTCH SWITCH REPLACEMENT
TORQUE VALUE
FASTENER
0.9-1.1 Nm
8-10
in-lbs
Handlebar switch assembly
retainer screws
1.
Remove upper switch housing cover. See
HANDLEBAR CONTROL MODULE, Removal
.
2.
See
. From inside the switch housing, remove
screws (3) and retainer (1). Remove clutch switch (2) from
housing.
3.
Cut wires flush at inoperative clutch switch.
4.
If
new
clutch switch wires have terminals installed, cut
wires at terminal end.
5.
Remove 0.25-0.3125 in. (6.4-7.9 mm) of insulation from
each wire end.
6.
Cut two pieces of dual wall heat-shrink tubing to a length
of 0.5 in. (12.7 mm).
7.
Solder wires together and cover with heat-shrink tubing.
See
7.35 HANDLEBAR CONTROL MODULES, Repair
8.
See
. Install clutch switch (2) into housing.
Install retainer (1) and screws (3). Tighten screws to 8-10
in-lbs
(0.9-1.1 Nm).
9.
Assemble left handlebar switch housing. See
HANDLEBAR CONTROL MODULE, Installation
.
7-80 2013 Softail Service: Electrical
SUBJECT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE NO.
APPENDIX
A
CONNECT
OR
REP
AIR
A.1
AUTOFUSE UNSEALED ELECTRICAL
CONNECTORS
AUTOFUSE UNSEALED CONNECTOR
REPAIR
TOOL NAME
PART NUMBER
SNAP-ON TERMINAL PICK
GA500A
General
Autofuse Unsealed connector terminals are found in ignition
switches and some fuse blocks.
Disassembly
1.
See
or
. Insert smallest pair of pins
on the SNAP-ON TERMINAL PICK (Part No. GA500A)
into chamber on mating end of socket housing to press
tangs on each side of terminal simultaneously.
2.
Gently pull on wire to remove terminal from wire end of
socket housing.
3.
If necessary, crimp
new
terminals on wires.
Assembly
1.
Carefully bend tang on each side of terminal outward away
from terminal body. Use the thin flat blade from a hobby
knife.
2.
With the open side of the terminal facing rib on wire end
of socket housing, insert terminal into chamber until it locks
in place.
sm02849a
Figure A-1. Removing Autofuse Unsealed Terminal from
Ignition Switch
sm03480a
Figure A-2. Removing Autofuse Unsealed Terminal from
Fuse Block
2013 Softail Service: Appendix A Connector Repair A-1
A.2
BOSCH COMPACT 1.1M CONNECTOR
BOSCH COMPACT 1.1M CONNECTOR
TOOL NAME
PART NUMBER
SNAP-ON TERMINAL PICK
GA500A
General
See
. The Bosch Compact 1.1M connector is found
on MAP and TMAP sensors.
Housings
Separate:
Snap back the secondary lock. Press on the latch
while pulling the socket connector from the sensor.
Join:
Align the sockets and press the housings together until
the latch snaps. Snap in the secondary lock.
sm07374
Figure A-3. Bosch Compact 1.1M Connector
Removing Socket Terminal
1.
See
. Slide the locking bar off the terminal
housing.
2.
Insert the smallest pins of the SNAP-ON TERMINAL PICK
(Part No. GA500A) into the gaps on each side of the
socket to compress the tangs on each side of the terminal.
3.
Gently pull on the wire to remove the terminal.
sm07337
Figure A-4. Terminal Removal: Bosch Compact 1.1M
Connector
Installing Socket Terminal
1.
See
. Use a hobby knife to bend the tangs on
each side of the terminal outward.
2.
Align terminal to socket housing. Press terminal into
housing until it snaps.
NOTE
The teeth on the locking bar face down.
3.
Slide the locking bar onto the connector.
sm07352
Figure A-5. Tangs: Bosch Compact 1.1M Socket Terminal
A-2 2013 Softail Service: Appendix A Connector Repair
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