Harley Davidson 2011 Touring Models. Electrical Diagnostic Manual — page 24
A.15
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 wire lead removing 1/4 in. (6.4 mm) of insulation.
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 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.
. 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-34. Electrical Crimper Tool (HD-42879)
A-26 2011 Touring Diagnostics: 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
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-35. Deutsch Solid Barrel
2011 Touring Diagnostics: Appendix A Connector Repair A-27
A.16
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 and press the housings together
until the locking tabs click.
sm06925
Figure A-36. 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 and push terminal into
the housing until it snaps into place.
1
2
2
1
sm06926
1.
Extractor tool
2.
Molding
Figure A-37. JAE MX19 Terminal Removal
A-28 2011 Touring Diagnostics: Appendix A Connector Repair
A.17
MOLEX CMC SEALED CONNECTORS
MOLEX CMC SEALED CONNECTORS
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-38. Release
Removing Terminals
1.
With the lever arm open, cut the cable strap around the
wire bundle.
2.
. Open a wire cap latch with a small
screwdriver (1).
3.
Maintain pressure on the cap and open the opposite latch
with the screw driver (2).
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.
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 and snap the
terminal in place.
2.
Slide the cap over the lead bundle and 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-39. Remove the Wire Lead Cap
sm06928
Figure A-40. Molex CMC Sealed Connector Secondary
Lock
2011 Touring Diagnostics: Appendix A Connector Repair A-29
2
2
1
1
2
2
sm06927
1.
Alpha
2.
Numeric
Figure A-41. Alpha - Numeric Coordinates
1
2
sm06935
1.
Extractor tool
2.
Access slots
Figure A-42. Terminal Removal
A-30 2011 Touring Diagnostics: Appendix A Connector Repair
A.18
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. 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-43. Molex MX 150 Sealed Connector: Latch
sm03332
Figure A-44. Secondary Lock Pry Slot (Socket Housing)
2011 Touring Diagnostics: Appendix A Connector Repair A-31
sm02851
Figure A-45. Pull Up Secondary Lock (Pin Housing)
sm00043
Figure A-46. Molex MX 150 Sealed Connector: Terminal
Remover (HD-48114)
1
3
2
sm00044
1.
Cavity number
2.
Tang
3.
Cavity slot
Figure A-47. 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 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 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.
. 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.
A-32 2011 Touring Diagnostics: Appendix A Connector Repair
Table A-3. 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-48. Open Terminal Crimper (HD-48119) at 45
Degrees
1
2
sm02854
1.
Socket locator bar
2.
Pin locator bar
Figure A-49. Terminal Locator Bars
Position Terminal in the Punch/Die
1.
. 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.
sm02855
Figure A-50. 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.
2011 Touring Diagnostics: Appendix A Connector Repair A-33
sm02856
Figure A-51. Pin Terminal against Pin Locator Bar
sm02857
Figure A-52. 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-53. 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 and pull the lead.
1
3
2
sm02859
1.
Core crimp
2.
Wire strands
3.
Insulation crimp
Figure A-54. Terminal Crimp
A-34 2011 Touring Diagnostics: Appendix A Connector Repair
A.19
TYCO 070 MULTILOCK UNSEALED CONNECTOR
TYCO 070 MULTILOCK UNSEALED
CONNECTOR REPAIR
TOOL NAME
PART NUMBER
AMP MULTI-LOCK CRIMPER
HD-41609
SNAP-ON PICK
SNAP-ON TT600-3
General
Tyco 070 Multilock Unsealed connectors are found between
wire harnesses and component wiring and may be either
floating or anchored to the frame with attachment clips.
See
. Attachment clips (1) on the pin housings are
fitted to T-studs on the motorcycle frame. The T-studs identify
OE connector locations. To maintain serviceability, always
return connectors to OE locations after service.
Obtain the necessary tools to repair the connector and ter-
minals.
NOTE
For terminal crimping use the AMP MULTI-LOCK
CRIMPER (Part No. HD-41609).
Separating Pin and Socket Housings
1.
If necessary, slide connector attachment clip T-stud to the
large end of the opening.
2.
. Press the release button (2) on the
socket terminal side of the connector and pull the socket
housing (3) out of the pin housing (4).
Mating Pin and Socket Housings
1.
Hold the housings to match wire color to wire color.
2.
Insert the socket housing into the pin housing until it snaps
in place.
3.
If OE location is a T-stud, fit large opening end of attach-
ment clip over T-stud and slide connector to engage T-
stud to small end of opening.
2
3
1
4
sm00002
1.
Attachment clip
2.
Release button
3.
Socket housing
4.
Pin housing
Figure A-55. Tyco 070 Multilock Unsealed Connector
Removing Terminals from Housing
1.
. Bend back the latch (1) to free one end
of secondary lock (2) then repeat on the opposite end.
Hinge the secondary lock outward.
2.
Look in the terminal side of the connector (opposite the
secondary lock) and note the cavity next to each terminal.
3.
Insert a pick or pin into the terminal cavity until it stops.
NOTE
If socket/pin terminal tool is not available, a push pin/safety pin
or a SNAP-ON PICK (Part No. SNAP-ON TT600-3) may be
used.
4.
Press the tang in the housing to release the terminal.
a.
Socket: Lift the socket tang (8) up.
b.
Pin: Press the pin tang (7) down.
NOTE
A "click" is heard if the tang is released.
5.
Gently tug on wire to pull wire and terminal from cavity.
2011 Touring Diagnostics: Appendix A Connector Repair A-35
5
2
7
1
3
6
1
2
4
8
sm00013
1.
Latch
2.
Secondary lock open
3.
Pin housing
4.
Socket housing
5.
Pin terminal
6.
Socket terminal
7.
Tang (pin)
8.
Tang (socket)
Figure A-56. Tyco 070 Multilock Unsealed Connector:
Socket and Pin Housings
Inserting Terminals into Housing
NOTE
. Cavity numbers are stamped into the sec-
ondary locks of both the socket and pin housings. Match the
wire color to the cavity number found on the wiring diagram.
1.
Hold the terminal so the catch faces the tang in the
chamber. Insert the terminal into its numbered cavity until
it snaps in place.
NOTES
•
Up and down can be determined by the position of the
release button, the button is the top of the connector.
•
On the pin side of the connector, tangs are positioned at
the bottom of each cavity, so the slot in the pin terminal
(on the side opposite the crimp tails) must face downward.
•
On the socket side, tangs are at the top of each cavity, so
the socket terminal slot (on the same side as the crimp
tails) must face upward.
2.
Gently tug on wire end to verify that the terminal is locked
in place.
3.
Rotate the hinged secondary lock inward until tabs fully
engage latches on both sides of connector.
– AMP
1
2
3
– AMP
1
2
3
4
5
6
5
6
7
8
9
10
4
3
2
1
1
2
3
sm00005
1.
3-place housing
2.
6-place housing
3.
10-place housing
Figure A-57. Tyco 070 Multilock Unsealed Connector:
Cavity Numbers on Secondary Locks (socket housings
shown)
Preparing Wire Leads for Crimping
1.
Strip 5/32 in. (4.0 mm) of insulation from the wire lead.
A-36 2011 Touring Diagnostics: Appendix A Connector Repair
2.
. Select the pin/socket
terminals from the parts catalog and identify the insulation
crimp tails (1) and the wire crimp tails (2) and the groove
for the crimp tool locking bar (3).
3.
Identify the wire lead gauge and the corresponding crimper
tool and nesting die. Refer to
.
Table A-4. AMP Multilock Connector: Crimp Tool Wire
Gauge/Nest
NEST
WIRE GAUGE
Front
20
Middle
16
Rear
18
2
3
1
sm00004
1.
Insulation crimp tail
2.
Wire crimp tail
3.
Locking bar groove
Figure A-58. Tyco 070 Multilock Unsealed Connector: Pin
Terminal
2
3
1
sm00001
1.
Insulation crimp tail
2.
Wire crimp tail
3.
Locking bar groove
Figure A-59. Tyco 070 Multilock Unsealed Connector:
Socket Terminal
Crimping Terminals to Leads
NOTE
Crimping with the AMP Multi-lock Crimper is a one step opera-
tion. One squeeze crimps both the wire core and the insulation
tails.
1.
See
. Squeeze the handles to cycle the AMP
MULTI-LOCK CRIMPER (Part No. HD-41609) to the fully
open position (1).
2.
Raise locking bar by pushing up on bottom flange (2).
NOTE
and
. Hold the terminal with the
insulation crimp tail (1) facing up. The tool will hold the terminal
by the locking bar groove (3) and crimp the wire crimp tail (2)
around the bare wire of the stripped lead and the insulation
crimp tail around the insulation.
3.
See
. With the insulation crimp tail facing
upward, insert terminal (pin or socket) (3) through the
locking bar, so that the closed side of the terminal rests
on the nest of the crimp tool.
4.
Release locking bar to lock position of contact (4). When
correctly positioned, the locking bar fits snugly in the space
at the front of the core crimp tails.
5.
Insert stripped end of lead (5) until ends make contact with
locking bar.
6.
Verify that wire is positioned so that wire crimp tails
squeeze bare wire strands, while insulation crimp tails fold
over the wire lead insulation.
7.
Squeeze handle of crimp tool until tightly closed. Tool
automatically opens when the crimping sequence is com-
plete.
8.
Raise up locking bar (7) and remove crimped terminal.
2011 Touring Diagnostics: Appendix A Connector Repair A-37
4
6
7
3
1
2
5
8
sm00007
1.
Open position
2.
Locking bar flange
3.
Insert contact
4.
Release locking bar
5.
Insert lead
6.
Squeeze
7.
Raise locking bar
8.
Remove crimped terminal
Figure A-60. Tyco 070 Multilock Unsealed Connector:
Terminal Crimping Procedure
Inspecting Crimped Terminals
See
. Inspect the wire core crimp (2) and insulation
crimp (1). Distortion should be minimal.
1
2
sm00008
1.
Insulation crimp
2.
Wire core crimp
Figure A-61. Tydo 070 Multilock Unsealed Connector:
Terminal Crimp
A-38 2011 Touring Diagnostics: Appendix A Connector Repair
A.20
SEALED SPLICE CONNECTORS
SEALED SPLICE CONNECTOR REPAIR
TOOL NAME
PART NUMBER
HEAT GUN
HD-25070
PACKARD CRIMPING TOOL
HD-38125-8
ULTRA TORCH
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.
1.
Using a shop gauge, identify the gauge of the wire.
2.
Match the wire gauge to a sealed splice connector by color
and part number. Refer to
3.
Using a wire stripper, cut and strip a length of insulation
off the wire ends. Refer to
for the strip length.
Table A-5. 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
. The connector is crimped twice - one side
and then the other.
1.
See
. Open the PACKARD CRIMPING
TOOL (Part No. HD-38125-8) ratchet by squeezing the
handles closed.
2.
Match the connector color to the wire gauge crimp die in
the jaws and insert one end of the sealed connector.
3.
Gently squeeze the handles until the connector is held in
the jaws.
4.
. Feed the stripped end of a wire into the
connector until the wire stops inside the metal insert (1).
5.
Squeeze the handles tightly closed to crimp the lead in
the insert (2). The tool automatically opens when the
crimping is complete.
6.
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.
7.
Use an ULTRA TORCH (Part No. HD-39969), or a 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
. 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.
2011 Touring Diagnostics: Appendix A Connector Repair A-39
1
2
3
sm00050
1.
Red connector die
2.
Blue connector die
3.
Yellow connector die
Figure A-62. Packard Crimping Tool (HD-38125-8)
1
1
4
2
2
4
3
sm00051
1.
Wire lead in metal insert
2.
Crimp metal insert
3.
Center of crimp
4.
Melted sealant
Figure A-63. Sealed Splice Connector
A-40 2011 Touring Diagnostics: Appendix A Connector Repair
SUBJECT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE NO.
APPENDIX B
WIRING
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